Red-D-Arc RDA60T3S User manual

SERVICE MANUAL
WARNING
This equipment is designed and built with safety in mind. However, your overall
safety can be increased by your full understand followed by the content in this
manual.
Read this manual and familiarize yourself with its contents for your safety.
This equipment should only be operated and maintained by trained and qualified
personnel.
This equipment is designed for generating power source of electric tools, home
appliances and lights.
Do not install, operate or service this equipment without reading this manual and
unless you clearly understand this manual.
Specifications sub ect to change without notice.
File№ DGO-251_RDA60T3s

This service manual is edited for authorized person to perform repair,
maintenance, and trouble-shooting to Diesel Engine Generator Welder,
Model Designation RDA60T3s.
It is inevitably necessary to maintain and ad ust Red-D-Arc products
periodically in order to use fully and safely for long time. Therefore,
understand this service manual fully enough before use and proper
maintenance.
The information contained in this service manual describes equipment
available at the time of publication. While every attempt has been made to
give you the very latest information about your product, there may be some
differences between your equipment and the equipment described in this
manual. We reserve the right to make changes to equipments without prior
notice, and without obligation to make alterations to equipments previously
manufactured.
For service of the engine, refer to Workshop (Service) Manual provided by
the engine manufacturer described below.
MANUFACTURER
MODEL
KUBOTA V3800D -T

Table of Contents
1. Attention Statements ··············································································· 1
2. General Safety Instructions ···································································· 2
3. Specifications ····························································································· 4
4. General ········································································································ 5
4-1 Appearance ······················································································ 5
4-2 Dimension ························································································ 5
5. General Par ts Description ······························································ 7
5.1 Equipment ························································································ 7
5.2 Main Parts and Feature ········································································ 10
5.3 Main omponent ················································································ 10
6. Ser vice Data ······························································································· 14
6.1 Technical Specification ········································································ 14
6.2 Generator ························································································· 15
7. ightening orque ······················································································ 17
8. Periodical Check for Engine ··························································· 18
9. rouble Shooting ························································································ 19
10. Wiring Diagram ············································································· 22

1
1. Attention Statements
・Technicians only who own enough knowledge and experience should work for
maintenance and operational check after maintenance.
・Before maintenance, always read this service manual as well as owner’s manual and
familiarize contents thoroughly before starting the service and maintenance of the
equipment for understanding of the equipment, safety instructions and cautions.
・ Throughout this manual are special attention statements.
A statement preceded by the triangular attention symbol and the word “WARNING”
contains information that should be acted upon to prevent serious bodily in ury.
A statement preceded by the triangular attention symbol and the word “CAUTION”
contains information that should be acted upon to prevent mechanical damage.
WARNING
CAU ION

2
2. General Safety Instructions
ELECTRIC SHOCK
NEVER touch the output terminals
during operation
NEVER touch the output terminal during
operation even though the breaker on the
load is being set at “OFF” position.
ALWAYS stop engine and make sure it
stopped before you will connect the loads to
the output terminals.
Suffocation by exhaust gas
NEVER run the engine indoors! Make
sure there is always good ventilation.
Fu es fro engine exhaust cause
serious injury.
ALWAYS operate the equipment in the
ventilated area.
When the equipment is used in a tunnel, hall
or any other indoor, the equipment for
ventilation must be used to prevent serious
accident caused by suffocation.
NEVER direct the exhaust fume to
houses nearby while considering the wind
flow direction.
Exhaust gas contains many harmful
elements that would cause affect to human.
Be free from suffocation when the
equipment is used in poorly ventilated area
such as inside of the building.
Entangled Injuries under
By Moving Componen t
NEVER reach and touch the moving
component during operation!
ALWAYS stop the engine during inspection
to prevent serious bodily in ury by entangled
accident under moving component.
Electric shock/Injuries/Burns
Never inspect equipment during
use .
Never serve and inspect when equipment is
being operated.
It may cause electric shock, in uries or
burns.
WARNING-Use good judgment
① NEVER run the engine when
transporting the equipment.
② ALWAYS stop the equipment
immediately if it suddenly begins to
violate or abnormal noise. Inspect for
broken, missing or improperly installed
parts.
③ ALWAYS keep the equipment as clean
as practical. Keep it free of loose
vegetation, mud, etc.
DO NOT make unauthorized
modifications or alterations to this equipment
of any of its components. YAMABIKO must
authorize alterations and modifications in
writing. Unauthorized modifications or
alterations may alter the equipment
operation and could eopardize personal
safety during operation.
WARNING

3
Work Safely
Generators and welders operate at very high
speeds and can do serious damage or
in ury if they are misused or abused. Never
allow a person without training or instruction
to operate and serve this equipment!
Attention to CAUTION LABEL！
Caution labels are placed on this equipment
and it would request special attention for
operation. Make sure to locate the labels
and understand the content of the caution.
・Check the caution labels is legible. Always
keep the labels clean or replace them when
worn or damaged
・Clean the labels by cloth, water or
detergent and never use organic solvent or
gasoline which may cause label peel off due
to adhesive solvent.
・Make sure to replace the labels when
damaged and illegible.
Before replacing the label(s), make sure to
place the new label(s) in the same position.
STOP the equipment immediately when
abnormal circumstances are noticed!
STSTOP the equipment immediately whenever
abnormal circumstances are noticed such
as unusual noise, smell, vibration and etc.
It may lead serious accident or fatal damage
of the equipment or properties.
Inflammables！
Keep the equipment far away from fire such
as cigarettes when refueling fuel, oil or
battery fluid.
NEVER operate or service the equipment
nearby fire as the equipment may catch
fire.
No Modification！
NEVER modify the equipment without
manufacturer’s advanced approval. .
It may lead serious safety issue and damage
the equipment.
Inspect the equipment before engine
start for operation and periodical inspection
without fail！
Make sure to serve initial check before start
engine and periodical inspection for safety
and longer life of the equipment.
CAUTION

3. Specifications
Model Unit RDA60T3s
Alternator
Generator Type -
Revolving Field Brushless A
Simultaneous 3-Phase-120V/240V,
Single Phase
Rated Frequency Hz 60
Rated Output
3-phase kVA
60
kW
48
Single phase kVA
36/ [18] *1
kW
36/ [18] *1
Rated Voltage 3-phase V 208/240/ [480] *1
Single phase V 120/139/240/[277] *1
Rated urrent
3-phase-208V A 144
3-phase-240V A 144
3-phase-480V A 72
Single phase-120V
A 150×2 [75 x 2]*1
Single phase-240V
A 150 [75]*1
Power Factor - 3-phase 0.8, Single phase 1.0
Insulation class - F
Excitation - Self Excitation (brushless)
No. of Poles - 4
Engine
Type - Vertical Water- ooled 4- ycle Diesel
Model(Manufacturer) - Kubota V3800DI-TI
No. of ylinders
(bore × stroke) (in./mm) 4 (3.94×4.72/100×120)
ontinuous Rated
Output hp 77
Rated Speed rpm 1800
Displacement
c
u.in.
/liters
230
/3.769
ombustion System - Direct Injection (Turbo-charged)
ooling Method - Radiator
Lubricating Method - Forced Lubrication
Starting Method - Electric
Fuel - No. 2-D EPA regulation
Lubricating Oil - F class or higher
Fuel Tank apacity
gal.
/liters
111
/420
Lubricant Volume
gal.
/liters
3.5
/13.2 (including filter
0.1
/0.4)
ooling Water Volume
gal.
/liters
3.3
/12.5 (including sub-tank
0.4
/1.6)
Starting Motor apacity
V-kW 12-3.0
harging Alternator
apacity V-W 12-960
Battery apacity - 12V-92AH
Unit
Length
in.
/mm
78
/1970
Width
in.
/mm
35
/880
Height
in.
/mm
64
/1630
Dry Weight
lbs.
/kg
2843
/1290
Installed Weight
lbs.
/kg
3703
/1680
*Outputs shown in above *1 are when the voltage selector switch is set at 240V.
**Specifications subject to change without notice.
4

4. General
4.1 Appearance
4.2 Dimension
Unit in the drawings below is shows by mm.
5

6
EHHAUST GAS OUTLET
AIR OUTLET
WATER OUTLET

. General Parts Description
5.1 Equipment
7

8

9

5.2 Main Parts and Feature
(1) Unit Serial Number
(2) Engine Serial Number
5.3 Main omponent
1
0
Provide both serial number of unit and engine to your
local service shop for update parts and warranty
information.
M
onitor Lamp
Feature: Light a monitor
lamp when equipment is
malfunctioned.
Voltage Meter
Feature: Display
the output voltage
from the generator.
Voltage Selector Switch
Feature: Switch to change
voltage.
Voltage Adjust Dial
Feature: A dial to adjust
voltage.
Serial Number Plate
3
-
Phase
Circuit reaker
Feature: rotect an electrical
circuit from damage by
overload or short circuit.
Ampere Meter
Feature: Display
the output current
from the generator.
Frequency Meter
Feature: Display
frequency of the
generator.
1
-
Phase Circuit reaker
Feature: rotect an electrical
circuit from damage by
overload or short circuit.
Ampere Meter Selector
Switch
Feature: A switch to select
the output current.
reaker Trip Selector
Switch
Feature: A switch to select
the tripping order due to
short
-
circuit or overload.

Right Side Door
Fuel Inlet
Feature: Inlet to refuel from
external fuel tank.
Fuel Return
Feature: Outlet to return
fuel to external fuel tank.
1
1

Left Side Door
1
2
Terminal
Rest
Feature: Relay terminal block of
the power output from the
alternator.
3
-
Way Valve
Feature: Valve to change fuel supply from a
built
-
in or external tank.
Oil Drain lug
Feature: Drain the old oil
from the oil tank.
Coolant
Drain lug
Feature: Drain coolant
from the radiator.

Standard Accessory
① Owners Manual 1 copy
② Engine Warranty Manual 1 copy
③ Starter Key 1 set (2 pcs)
3
-
Way Valve
Position A (to use a built-in fuel tank)
Position a 3-way valve lever to UPWARD to use fuel
from the external fuel tank.
Position B (to use an external fuel tank)
Position a 3-way valve lever to DOWNWARD to use
fuel from a built-in fuel tank.
Note: The 3-way valve lever is set at position A at
delivery from a factory.
Position A
Position B
3-Way Valve
Lever
1
3

6. Service Data
ELECTRIC SHOCK
WARNING
Never touch the output terminal during operation to avoid electric
shock. Always stop the engine and remove the starter key during a
service maintenance.
Stop the engine before you will start any maintenance!
6-1 Technical Specification
tems Reference Value Note
nsulation
Armature
winding 3MΩ or more DC500V
Megger Tester
Exciter field
Preheat time
Approx. 15 sec. with coolant temperature
-15℃(5 °F) and approx. 0.5 sec. with
coolant temperature 30℃(86 °F)
Automatic
preheating system
Min. rpm at no load 1100 min
-1
Max. rpm at no load 60Hz: 1800 min
-1
Lubricant oil pressure 0.1~0.49MPa{1~5kgf/cm²}
Coolant temperature 70~100℃ (158~212
°F)
Frame temperature limit
within 80℃ (212 °F)
Sealed bearing temperature limit
Speed regulation Momentary within 10%
Steady-state
deviation within 5%
Voltage regulation
Momentary within 25%
Steady-state
deviation within 1.0%
Frequency Rated: 60 Hz
Variable voltage 193~255V
Protective device
1
Low oil pressure Working Pressure 0.049MPa{0.52kgf/cm²} Engine Stop
2
High water temp. Working Temperature 110℃ (230
°F) Engine Stop
3
Current Leakage
Rated 30mA, 0.1 sec.
4
Insufficient Battery
Charge
- Battery voltage: below 8V Engine Stop
5
Over Speed
- above 2070 min
-1
Engine Stop
14

6-2 Generator
(1) Exciting Amperage
Amperage fluctuates based upon the winding temperature. Following is for reference only.
Frequency/Rated Output Load Exciting Amperage (Measured)
3- hase 60Hz: 48 kW No load 0.39A
Full load( power factor=1.0) 0.63A
(2) Resistance Value
Nominal resistance of the winding is tolerated within ± 10% at 20℃ of the ambient temperature.
The resistance must be measured by low resistance tester. It can not be measured by
multi-purpose tester cause of index error.
Generator Exciter (Measured)
Stator Rotor Stator Rotor
Armature Exciter Winding Exciter
Field J (Gray)－K ( urple) Armature
Between
1-10, 11-N
2-20, 21-N
3-30, 31-N
A (Br) – B (Y)
B (Y) – C (Or)
C (Or) – A (Br)
-
U-V
V-W
W-U
0.048 Ω 1.06 Ω 6.14 Ω 26.9 Ω 0.66 Ω
[ olor ode]
(B) (W) (R) (G) (Y) (Br) (L) (Or) (Gr)
Black
White
Red Green
Yellow
Brown
Blue
Orange
Gray
(3) Technical Specifications
Items
Article Method Condition to verify Criterion
Check before operation
Shape, Dent, Blot
Visual
Inspection
No dent, blot and deformation
Coating No looseness
Joint Meet the criteria
Oil, Coolant Meet the required level
Wiring
Lead wires to be securely fastened
against
abrasion and damage to bring by
vibration
Grounding
Continuity Tester
“GROUNDING” in
terminal rest is connected;
-with Engine (bolt)
-with Bed (bolt)
-with Receptacle
Continuity is to be confirmed
I
nsulation Check
Insulation Resistance
DC500V
Mega
Tester
Main Breaker (1- & 3-phase) ON
1-phase breaker (30A) ON
1-phase breaker (20A) OFF
Disconnect coupler (AVR & rinted
Circuit)
Voltage Selector: 240V (3-phase)
“N” in terminal rest is connected;
-with Engine
-with initial excitation winding
*Insulate all terminals after removal
Over 3MΩ
Dielectric Voltage Tester AC2400V (1 sec)
15

Monitor
Glow & Monitor Lamp
(OIL RESS,
WATER TEM ,
ENGINE, AIR
FILTER & FUEL)
Visual
Inspection
Starter Switch “RUN”
position
Coolant Temp: 0~50℃ (32~122°F )
Glow Lamp ON. OIL RESS, WATER TEM
& ENGINE Lamp ON for approx. 1 sec. Hour
Meter is activated.
Operational Check
hase rotation
hase
Rotation
Indicator
Connect 3-phase output
and wires from phase
rotation indicator.
Rotate as arrow shows
AVR Adjustment Voltage-
Meter
Output selector switch is
set at 240V (3-phase)
No Load
Voltage Adj. Dial: Max
(Turn the VRD in AVR to
counter-clockwise to max.
position. #1)
Frequency (Hz)
Output (V)
60 ± 0.1
255 ± 2
*Adjust by VRE volume in
AVR. (#1)
3- hase Output
(Comprehensive
Voltage Regulation)
Load Tester
Frequency
Meter
Wattmeter
DC Amp.
Meter
Engine Speed 1800 min
-1
Output selector switch is
set at 480V. (3-phase)
Voltage: 480+/-1V
ower Factor: 1.0
Throttle Switch: RUN
% kW V A Water
Temp
100
48.0+/-0.5
480+/-
(0. 8)
32~212F
0~100℃
75 3 .0+/-0.4
-
50 24.0+/-0.3
-
25 12.0+/-0.2
-
0 no load (0.49)
1- hase, Three-Wire
Output
(Comprehensive
Voltage Regulation)
Output selector switch is
set at 280V. (3-phase)
Voltage: 240+/-1V (U-V)
ower Factor: 1.0
Throttle Switch: RUN
% kW V A Hz
100
3 .0+/-0.4
240+/-1
(0. 7)
60 ± 0.5
75 - -
50 - -
25 - -
0 no load 240
+12
~0
(0.49)
1- hase Output
Wattmeter
AC Amp.
Meter
Output selector switch is
set at 240V. (3-phase)
Voltage: 240+/-1V (U-V)
Throttle Switch: RUN
No
Load
Voltage U-N & W-N
120 ± 2V
Receptacle
Voltage (50A) X-Y
240 ± 3V
GFCI Receptacle Output
120±2V
3- hase Output
(Comprehensive
Voltage Regulation)
Load Tester
Frequency
Meter
Wattmeter
Output: 48.0±0.5kW
Voltage: 3- hase 240±1V
Throttle Switch: RUN
Refer to #2.
3- hase Output
Voltage Adjustment
AC Voltage
Meter
Adjust by “Voltage
Adjuster”
Voltage Max. (V) Voltage Min. (V)
over 252 below 228
#1:
VRD
#2:
Mode Output Voltage (V) Setting Time Frequency (Hz)
Setting Time
Loaded  No Load
(Transient Max.) below 295 below 2 sec. below 66 below 8 sec.
No Load 240+/-3 - 60+/-0.1 -
No Load  Loaded
(Transient Min.) over 185 below 2 sec. over 54 below 8
Loaded 240+/-3 - 60+/-0.1 -
1
6
Use screw locking glue (recommended ThreeBond 1401C) over the VRD
and VRE after adjusted.
VRF VRE VRE VRF VRE

7. Tightening Torque
No Nomenclature
Part to
be
tighten
Size Qty
Torque
Allowance
Nm(kgf/cm)
Reference
1 Nipple~Oil Pan Nipple M22x1.5 1 50.0-70.0
(510-713)
2 Panel~Front Door
Nut M5 2 2.0-2.9
(21-29)
3 Rotor~Engine Bolt M10x1.5x60 8 49.0-56.0
(500-571)
4 Stator~Engine Bolt M10x1.5x30 12
49.0-56.0
(500-571)
5 Stay~Engine Bolt M12x1.25x25
8 44-54
(449-550)
6 Stud Bolt~ nst.
Plate Nut M12 7 34.4-44.1 (351-449)
7 Drain Plug~Socket
Drain
Plug M12x1.25x13
1 39.3-49.0
(401-499) nstall packing.
8 Fuel Pump~Bonnet
Stay - - - -
Attention for the
direction of
installation.
9 Stopper~Control
Box Bolt M8x35 1 -
Use ThreeBond
1401C as screw
locking glue.
10 Drain Plug~Valve Drain
Plug - 1 13-15 (133-152)
Use LOCT TE
575 as screw
locking glue.
11 Valve~Guard Valve - 1 -
Use LOCKT TE
635 as screw
locking glue.
12 Drain Plug~Guard
Drain
Plug - 1 17.7-21.5 (181-219)
Use LOCT TE
575 as screw
locking glue.
13 Elbow ~Valve
#E237801-0200 Elbow - 2 -
Use LOCT TE
575 as screw
locking glue.
Attention for the
direction of the
elbow for
installation.
14 Elbow~Valve
#E237801-0800 Elbow - 2 -
Attention for the
direction of the
elbow for
installation.
15 Hose~Band - - 1 -
Remain 35±5mm
between the
band and clamp.
16 Valve~Socket Valve - 1 -
Put ThreeBond
1104 over sealed
tape. Handle
should position
upward.
17 Nipple~Valve Nipple - 1 -
Put ThreeBond
1104 as screw
locking glue over
sealed tape.
18 Drain Plug~Socket
Drain
Plug - 1 39.3-49.0 (401-499)
Slip the circular
gasket.
1
7