SERVICE MANUAL. This equipment is designed for generating power source of electric tools, home appliances and lights.

Transcription

1 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 subject to change without notice. File DGO-261_RDA150T3

2 This service manual is edited for authorized person to perform repair, maintenance, and trouble-shooting to Diesel Engine Generator Welder, Model Designation RDA150T3. It is inevitably necessary to maintain and adjust 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 KUBOTA MODEL V3800DI-TI

3 Table of Contents 1. Attention Statements 1 2. General Safety Instructions 2 3. Specifications 4 4. General Appearance Dimension 5 5. General Parts Description Equipment Main Parts and Feature Main Component Service Data Service Data Generator Tightening Torque Periodical Check for Engine Trouble Shooting Wiring Diagram 22

4 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. WARNING A statement preceded by the triangular attention symbol and the word WARNING contains information that should be acted upon to prevent serious bodily injury. CAUTION A statement preceded by the triangular attention symbol and the word CAUTION contains information that should be acted upon to prevent mechanical damage. 1

5 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. WARNING By Entangled Injuries under Moving Component NEVER reach and touch the moving component during operation! ALWAYS stop the engine during inspection to prevent serious bodily injury by entangled accident under moving component. Electric shock/injuries/burns Suffocation by exhaust gas NEVER run the engine indoors! Make sure there is always good ventilation. Fumes from 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. 2 Never inspect equipment during use. Never serve and inspect when equipment is being operated. It may cause electric shock, injuries 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 jeopardize personal safety during operation.

6 CAUTION Work Safely Generators and welders operate at very high speeds and can do serious damage or injury 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. 3

7 3. Specifications Alternator Engine Unit Model Unit RDA150T3 Generating Type - Rotating Filed, Brushless 3-Phase Synchronous Alternator Rated Output kva 150 kw 120 Voltage Three phase V 208 / 480 Voltage Single phase V 120 / 240 / 277 Three phase 480V A 180 Amps Three phase 208V A 416 Single phase 240V A 361 (zigzag) Single phase 120V A 361 x 2 (zigzag) Rated Frequency Hz 60 Winding - 3-phase, 4-wire Star with neutral / Zig-zig Power factor % 80 Insulation class - F Excitation - Self-Excitation(Brushless) No. of poles - 4 Types - Vertical Water-cooled 4-cycle Diesel Engine Model (Manufacturer) - 6HK1 (ISUZU) No. of Cylinders (bore x stroke) (in. / mm) 6 ( 4.53x4.92 / 115x125 ) Continuous rated output kw 142 HP 190 Rated speed rpm 1800 Displacement cu.in. / liters / Combustion system - Direct Fuel Injection with Turbo Charger Cooling method - Radiator Lubricating method - Forced lubrication Starting method - Electric start Fuel - Diesel Lubricant oil - CD class Fuel tank capacity gal. / liters 74 / 280 Lubricant volume (Full) gal. / liters 10 / 38 Cooling water volume gal. / liters 6.3 / 23.8 Starting motor capacity V-kW Charging dynamo capacity V-A Battery - 105E41R x 2 Battery capacity V-AH 12(V) 100AH Length in. / mm / 3450 Width in. / mm 48.8 / 1240 Height in. / mm 72.8 / 1850 Dry Weight lbs. / kg 6504 / 2950 Installed Weight lbs. / kg 7187 / 3260 **Specifications subject to change without notice. 4

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

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10 5. General Parts Description 5.1 Equipment 7

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13 5.2 Main Parts and Feature (1) Unit Serial Number (2) Engine Serial Number Provide both serial number of unit and engine to your local service shop for update parts and warranty information. 5.3 Main Component Ampere Meter Selector Dial Feature: Dial to select the output current. Volt Meter Selector Dial Feature: Dial to change voltage. Monitor Lamp Feature: Light a monitor lamp when equipment is malfunctioned. Circuit Breaker Feature: Protect electrical circuit from damage by overload or short circuit. Water Temp. Meter Feature: Display water temp. in the radiator. Oil Pressure Meter Feature: Display oil pressure. Fuel Meter Feature: Display volume of the fuel left in the fuel tank. Voltage Adjusting Dial Feature: A dial to adjust a voltage. Emergency Stop Button Feature: Engine stops when emergency by pressing it. Turn it to clockwise to release the button. 10

14 Right Side Door Fuel Drain Plug Feature: Drain the old fuel from the fuel tank. Oil Drain Plug Feature: Drain the old oil from the oil tank. Left Side Door Terminal Rest Feature: Relay terminal block of the power output from the alternator. External Fuel Inlet Feature: Inlet to refuel from the external tank. External Fuel Return Feature: Outlet to return fuel from external tank. 11

15 3-Way Valve Feature: Valve to change fuel supply from a built-in or external tank. Note: Do not remove the plugs when fuel is supplied from a built-in tank. (when the 3-way valve positions at position A.) Position A 3-Way Valve Position A (to use a built-in fuel tank) Position the 3-way valve lever to UPWARD to use fuel from the external fuel tank. Position B 3-Way Valve Lever Position B (to use an external fuel tank) Position the 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. Standard Accessory 1 Owners Manual 2 Engine Instruction Manual 3 Engine Warranty Manual 4 Starter Key 1 copy 1 copy 1 copy 1 set (2 pcs) 12

16 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 Insulation Preheat time Items Reference Value Note Armature winding Exciter field 3MΩ or more Approx. 20 sec. with coolant temperature -15 (5 F) and approx. 1 sec. with coolant temperature 30 (86 F) Min. rpm at no load 1000±25 min -1 Max. rpm at no load 60Hz: 1800±25 min -1 Lubricant oil pressure 0.2~0.6MPa{2.0~6.1kgf/cm²} DC500V Megger Tester Automatic preheating system Coolant temperature 75~90 (167~194 F) Frame temperature limit within 115 (239 F) Sealed bearing temperature limit within 70 (158 F) Speed regulation Momentary within 10% Steady-state deviation within 5% Momentary within 20% Voltage regulation Steady-state deviation within 1.0% Frequency Idle: 33.3 Hz, Rated: 60 Hz Variable voltage (60Hz) 400~505V at 60±0.1Hz Protective device 1 Low oil pressure Working Pressure 0.1MPa{1.02kgf/cm²} Engine Stop 2 High water temp. Working Temperature 105 (221 F) Engine Stop 3 Diagnosis Engine Malfunction - - Insufficient Battery 4 Charge - Battery voltage: below 8V - 5 Over Speed - above 2070 min -1 Engine Stop 6 Boost Intake Temperature 85 (185 F) - 13

17 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-Phase 60Hz: 120 kw No load 0.57A Full load( power factor=1.0) 1.04A (2) Resistance Value Nominal resistance of the winding is tolerated within ± 10% at 32 F( 220 ) 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 J-K Armature Between T1-T4, T7-T10 T2-T5, T8-T11 T3-T6, T9-T Ω 1.574Ω 14.96Ω 0.185Ω [Color Code] (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 Coating Joint Oil, Coolant Wiring Visual Inspection No dent, blot and deformation No looseness Meet the criteria Meet the required level Lead wires to be securely fastened against abrasion and damage to bring by vibration Grounding Continuity Tester GROUNDING is connected; -with Engine (bolt for grounding) -with Bed (bolt for grounding) -with grounding for Receptacle Continuity is to be confirmed Insulation Check Insulation Resistance Dielectric Voltage DC500V Mega Tester Tester Main Breaker ON. 1-phase breaker (50A) ON 1-phase breaker (20A) OFF Disconnect one coupler from the stator. Voltage Selector: 480V (3-phase) - Remove all output lines connecting to T10 & T11 in terminal rest. - Remove the output line T12 from the terminal rest. -Open a pc terminal in the output line U2 from the stator. *Insulate all terminals after removal Over 3MΩ AC2400V (1 sec) Electric Current: 10mA 14

18 Items Article Method Condition to verify Criterion Insulation Check Monitor Dielectric Voltage Glow & Monitor Lamp (OIL PRESS, WATER TEMP, ENGINE, AIR FILTER & FUEL) Tester Connect grounding terminal - with output terminal L1. - with output terminal L2 - with output terminal L3. - with initial excitation winding. (Coupler marked with J or K.) Starter Switch RUN position Engine is running. Coolant Temp:-15~50 (5~122 F ) ditto Glow Lamp & Charge Lamp ON. DIAG (diagnosis) lamp OFF after it turns on for a while. Hour Meter is activated. All monitor lamp OFF. Pilot lamp ON. Hour meter is activated. Protection Circuit Operational Check Emergency Stop Water Temp. Thermal Relay Terminal Cover Safety Feature Phase rotation AVR Adjustment 3-Phase Output (Comprehensive Voltage Regulation) 3-Phase Output (Transient Load Change Excursions) Visual Inspection Phase Rotation Indicator AC Volt Meter Load Tester Frequency Meter Wattmeter Stop Watch Engine is running Engine Stop Engine is running Output selector switch is set at 2080V (3-phase) No Load Voltage Adj. Dial: Max Emergency stop switch ON and engine stops. Short-circuit red/black and black/yellow lines connecting to a water temp. sensor. Overheat lamp ON and engine stops. Thermal relay is set at 3.6A. Breaker ON and thermal relay RESET. Turn test trip lever to TRIP. Main breaker lever trips between ON and OFF position. Open 3-Phase output terminal cover. Main breaker lever trips between ON and OFF position. Engine Speed 1800 min -1, Engine Control Switch Setting: - Load Advance: OFF - Regulation Mode: OFF: Output selector switch is set at 480V. (3-phase) Output: 120±1.2kW Voltage: 480+/-1V Frequency: 60±0.1Hz Power Factor: 1.0 Throttle Switch: RUN Output selector switch is set at 280V. (3-phase) Output: 120±1.2kW Voltage: 240+/-1V Power Factor: 1.0 Throttle Switch: RUN Frequency (Hz) 60±0.1 Rotate as arrow shows Output (V) 253±1 *Adjust the Volt Adjusting Volume in AVR. (#1) % kw V A Hz / ±1 (1.04) 60± /-0.9 (0.88) /-0.6 (0.72) / ±6 (0.60) 60±0.2 0 no load (0.57) Refer to #2 1-Phase Output 3-Phase Output Voltage Adjustment AC Volt Meter Output selector switch is set at 240/120V. (3-phase) Voltage: 240+/-1V Frequency: 60±0.1Hz Output selector switch is set at 480V. (3-Phase) No Load Voltage Max. (V) Receptacle Voltage (50A) X-Y GFCI Receptacle Output 240±3V 120±2V Voltage Min. (V) over 504 below 408 Engine Speed Adjustment Digital Tachometer Adjust the engine control switch at no load. Idle Speed (min-1) Engine Speed Adjustment (Hz) 1000±25 below 50~above

19 #1: VRE VOLT.ADJ Use screw locking glue (recommended ThreeBond 1401C) over the VRD and VRE after adjusted. #2: Mode Output Voltage (V) Setting Time Frequency (Hz) Setting Time Loaded No Load (Transient Max.) below 288 below 2 sec. below 66 below 8 sec. No Load 240+/-3-60+/ No Load Loaded (Transient Min.) over 192 below 2 sec. over 54 below 8 Loaded 240+/-3-60+/

20 7. Tightening Torque No Nomenclature 1 Drain Plug~Socket Part to be tighten Drain Plug Size M24 (fine pitch) 2 Socket~Oil Pan Nipple ditto 1 3 Cushion~Bonnet Screw M4x Panel~Front Door Nut M5 8 5 Stay~Engine Bolt M10x Rotor~Engine (flywheel side) Qty Bolt M10x Stator~Engine Bolt M10x Bolt~Plate Nut M Terminal Cover~Bonnet Bolt M10x Radiator~Frame Bolt M12x Exhaust Pipe~Engine Flex. Tube~Exhaust Pipe Fuel Tank~Frame (bed) Nut M10 (fine pitch) Bolt M16x Torque Allowance Nm(kgf/cm) ( ) ( ) (11-14) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ) Bolt M8x Elbow~Valve Elbow Valve~Frame (bed) Pipe~Fuel Strainer Eye Bolt M16x ( ) Reference Put a lubricant to O-ring and align it into a groove. ditto Uniformly tighten the bolts. There should be no rattles in fuel tank. Attention to the direction for installation of the elbow. Attention to the direction for installation of the elbow. Attention to the direction for installation of the pipe. Insert the packing into both side of the pipe. Put a lubricant. 17 Fuel pomp~frame Put a lubricant. 18 Fuel Pomp~Frame Attention to the direction of the fuel pomp. 19 Joint~Oil Strainer Joint G3/ ( ) Attention to the direction of the joint. Put a lubricant. 17

21 No Nomenclature Part to be tighten Size 20 Joint~Engine Joint G3/ Hose,14~Joint Hose, 14 G3/ Air Cleaner Cleaner Band 23 Plug~Engine Plug M10 1 Qty Torque Allowance Nm(kgf/cm) ( ) ( ) ( ) Reference ditto Attention to piping for inlet & outlet. Attention to the direction of the air cleaner intake. 18

22 8. Periodical Check for Engine Consult Service Dealer User Check Description Engine Side Daily check Every 250hrs Every 500hrs Every 1000hrs Clean each parts / tightening Engine oil checks / add oil Engine oil and Oil Filter change PCV Filter change Coolant level check / add coolant (1 st time at 50 hrs) (1 st time at 50 hrs) Exhaust color check Coolant change / bleeding EGR Drain excess water and sediments in the fuel filter and water sedimenter Clean or 1 yr. Clean or replace fuel filter element and water sedimenter element Clean Replace Drain water from fuel tank Clean gauze filter in engine feed pump Change filter in the electromagnetic pump for air extraction in fuel line Clean Clean Clean inside fuel tank Leak check (fuel, oil, and coolant) Replacing fuel hose Clean or replace air cleaner element Clean Replace or 1yr. Battery fluid level check Battery hydrometer check Fan belt check Radiator Flush Cleaning Check and adjust engine valve clearance Compression check Alternator side Various meter and alarm lamps check 19

23 9. Trouble Shooting 9.1 Generator <Pre-check> Always check the volume of oil, coolant, and fuel before processing to trouble shooting. Problem Suspected Cause Action Starter motor does not drive or speed is low. 1. Battery output is weak 2. Battery is deteriorated 3. Battery terminal is OFF or loose 4. Battery terminal is corroded 5. Starter switch or relay is defective 6. Starter motor is defective 7. ECU(Engine Controller) is defective 1. Check/ battery liquid/ or Charge 2. Change battery 3. Fix/Tighten terminal 4. Clean terminal 5. Contact your distributor to repair 6. Contact your distributor to repair 7. Contact your distributor to repair Engine does not start Starter motor drives but engine does not start 1. Fuel is insufficient 2. Fuel filter is clogged 3. Gauze filter is clogged 4. Water is interfused in fuel line 5. Air is interfused in fuel line 6. Poor piping connection to external fuel tank 7. Fuel tank selector lever (3-way valve) position is wrong 8. Fuel cut solenoid (motor) does not work 9. Emergency operation/fault detection 1. Add fuel 2. Clean/Change fuel filter 3. Clean/Change gauze filter 4. Drain water in water sedimenter, fuel filter or fuel tank 5. Extract the air 6. Check piping connection 7. Check lever (3-way valve) 8-1. Check/Change fuse 8-2. Check/Change fuel cut solenoid 9. Contact your distributor to repair <Ambient temperature falls down below zero> 1. Fuel is frozen 2. Water in fuel line is frozen 3. Pre-heater is defective 1. Use winterized fuel 2. Drain water in fuel line 3. Contact your distributor to repair Engine starts but stalls immediately Engine oil pressure is low 1. Fuel filter is clogged 2. Gauze filter is clogged 3. Water is interfused in fuel line 4. Air is interfused in fuel line 5. Poor piping connection to external fuel tank 6. Air filter element is clogged 7. Lubricant oil is insufficient 8. Emergency operation/fault detection 1. Lubricant oil is insufficient 2. Oil filter is clogged 3. Oil Pressure switch is defective 4. Oil pressure meter is defective 5. Wrong oil is used 1. Clean/Change fuel filter 2. Clean/Change gauze filter 3. Drain water in water sedimenter, fuel filter or fuel tank 4. Extract the air 5. Check piping connection 6. Check/Change air filter element 7. Supply lubricant oil 8. Contact your distributor to repair 1. Supply lubricant oil 2. Change oil filter 3. Contact your distributor to repair 4. Contact your distributor to repair 5. Change to proper kind and viscosity oil Overheated 1. Engine thermostat is defective 2. Water temp sensor is defective 3. Water temp meter is defective 4. Fan belt tension is weak 5. Coolant is insufficient 6. Radiator core is clogged 1. Contact your distributor to repair 2. Contact your distributor to repair 3. Contact your distributor to repair 4. Check/Adjust fan belt 5. Check/Supply coolant 6. Clean radiator core 20

24 Problem Suspected cause Action White smoke comes out from muffler Indicator does not move in voltage meter Indicator does not goes up to the rated voltage Indicator exceeds the rated voltage The voltage drops drastically when connecting to load Cannot turn the breaker to ON position 1. Air filter element is clogged 2. Fuel injection nozzle is defective 3. Improper fuel is used 1. Too much or too little oil to cylinder 2. Water is interfused in fuel line 3. Fuel injection nozzle is defective 4. Coolant temperature is too low 5. Engine thermostat is defective 1. Voltage meter is defective 2. AVR is defective 3. Disconnected circuit, loose terminal or departed 4. Initial exciter is defective 5. Alternator is defective 1. Voltage meter is defective 2. AVR is defective 3. Voltage regulator dial is defective 4. Frequency is low 5. Improper load cable connection 6. Voltage selector switch set is wrong 1. Voltage meter is defective 2. AVR is defective 3. Voltage regulator dial is defective 4. Frequency is high 5. Improper load cable connection 6. Voltage selector switch set is wrong 1. AVR is defective 2. Unbalanced loads sharing to each terminal 3. Total loads exceeds the rated current 4. Frequency Speed Switch set is wrong 1. The breaker positions stays between ON and OFF 2. Short circuit on the load 3. Terminal cover opened 4. The thermal relay activates 1. Check/Change air filter element 2. Contact your distributor to repair 3. Change to clean fuel 1. Contact your distributor to repair 2. Drain water in water sedimenter, fuel filter or fuel tank 3. Contact your distributor to repair 4. Warm-up driving is needed 5. Contact your distributor to repair 1. Contact your distributor to repair 2. Contact your distributor to repair 3. Contact your distributor to repair 4. Contact your distributor to repair 5. Contact your distributor to repair 1. Contact your distributor to repair 2. Contact your distributor to repair 3. Contact your distributor to repair 4. Contact your distributor to repair 5. Correctly set the connection location to the output terminal 6. Set the Voltage selector switch correct 1. Contact your distributor to repair 2. Contact your distributor to repair 3. Contact your distributor to repair 4. Contact your distributor to repair 5. Correctly set the connection location to the output terminal 6. Set the Voltage selector switch correct 1. Contact your distributor to repair 2. Balance the loads sharing to each terminal 3. Decrease the loads with in the rated output 4. Set the Speed Switch correct 1. Turning the lever to OFF first then turn it to ON position 2. Check the load circuit 3. Close terminal cover 4. Reset the thermal relay 21

25 10. Wiring Diagram 22

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