RGD3700 / RGD5000 GENERATOR SERVICE MANUAL
Contents
1. NO FUSE BREAKER ON START SWITCH 220V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL 12 e RGD3700 OCEANIA 50Hz 240V VOLTMETER DC FUSE NO FUSE BREAKER NO FUSE BREAKER ON AC 240 x START SWITCH 240V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL 80 e RGD5000 50Hz 110V 60Hz 110V 120V TYPE VOLTMETER DC FUSE NO FUSE BREAKER O AC 110 m O OUT 12V START SWITCH 110V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGD5000 50Hz 220V 240V 60Hz 220V TYPE VOLTMETER DC FUSE NO FUSE BREAKER NO FLSE BREA START SWITCH 1STCP 57 i START SWITCH 220V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL _ 14 e RGD5000 50Hz 110V 220V 60Hz 110V 220V TYPE VOLTMETER FULL POWER SWITCH DC FUSE NO FUSE BREAKER 220V RECEPTACLE O FUSE BREAKER ON START SWITCH 110v RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGD5000 U K 50Hz 110V 220V BS RECEPTACLE 110V RECEPTACLE VOLTMETER VOLTAGE CHANGEOVER SWITCH NO FUSE BREAKER DC FUSE 220V RECEPTACLE WARNING LAMP START SWITCH EARTH GROUND DC OUTPUT OIL SENSOR TERMINAL TERMINAL 15 e RGD5000 U S A 60Hz 120V 240V NEMA RECEPTACLE PILOT LAMP FULL POWER SWITCH NO FUSE BREAKER 240V RECEPTACLE AC 120 240 WER SWITCH NO FUSE BREAKER O AS Y 122 li N 82. SWITCH 110 RECEPTACLE GROUND TERMINAL DC OUTPUT TERMINAL RGD3700 50Hz 220V 240V 60Hz 220V TYPE VOLTMETER DC FUSE NO FUSE BREAKER 22cv G TOTAL 15 e SCOUT if START 54 TCH 12V 83A START SWITCH AC RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL 10 e RGD3700 50Hz 110V 220V 60Hz 110V 220V TYPE VOLTMETER FULL POWER SWITCH DC FUSE NO FUSE BREAKER 220V RECEPTACLE O FUSE 8REAKER EE gt ON AC novJO pcouT 3 Q A 12v 83A 15 MAX START SWITCH 110V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL RGD3700 U K 50Hz 110V 220V BS RECEPTACLE 110V RECEPTACLE VOLTMETER VOLTAGE CHANGEOVER SWITCH NO FUSE BREAKER DC FUSE i MAX C O x NO FUSE BREAKER A Qi 110 C 220 a ANA E os vil LE O O i NI A Ex 220V RECEPTACLE WARNING LAMP START SWITCH EARTH GROUND DC OUTPUT OIL SENSOR TERMINAL TERMINAL sit e RGD3700 GERMANY 50Hz 220V VOLTMETER DC FUSE NO FUSE BREAKER 220 NO FUSE BREAKER PN 0 PON 220 RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL WARNING LAMP OIL SENSOR O 220v START SWITCH e RGD3700 50Hz 220V WITH SPECIAL RECEPTACLE VOLTMETER DC FUSE NO FUSE BREAKER
3. 110V or Rated output No output can be taken 120V 110 220 Half of rated or output Rated output 120 240V 120V 110V m Table 5 4 Fig 5 12 24 Inside the generator are two sets of main coils Each main coil outputs half the rated power at the lower volt age 110V or 120V These main coils are wound to be in the same phase The full power switch reconnects these main coils in parallel or in series Fig 5 10 shows a circuit diagram When the full power switch is set for single lower voltage indication 110V or 120V the switch position is as indicated by the lower solid line in the diagram Fig 5 11 is a simplified representation of this circuit showing the two main coils connected in parallel In this case the higher volt age 220V or 240V at Rec 3 cannot be taken out Rec 2 for the lower voltage can output up to the rated power up to if the rated current is over 30A and Rec 1 can output up to a total of 15A When the full power switch is set for double voltage indication 110V 220V or 120V 240V the switch position is as indicated by the upper dotted line in Fig 5 10 Fig 5 12 is a simplified representation of this circuit showing the two main coils connected in series In this case power can be taken simultaneously from the receptacles for the both voltages Rec 3 for the higher voltage can output up to the rated power but Rec 1 and 2 for the lower voltage can output only u
4. 60 11 1 3 CHECKING OF ROTOR 1 CHECKING FIELD COIL m Remove rear cover and stator W Unsolder the coil ends from the terminals on the rotor See Fig 11 3 m Measure the resistance of field coil with a circuit tester See Fig 11 4 m NORMAL RESISTANCE MODEL RGD3700 RGD5000 Resistance 2 12 Table 11 2 Fig 11 4 Remedy If the resistance is not normal replace rotor with a new one 2 CHECKING OF DIODES AND RESISTORS ON THE ROTOR m Unsolder and take out the diodes and a resistor from rotor m Measure the resistance of diodes POLARITY OF CIRCUIT TESTER Continuity exists Fig 11 5 Each rotor has three diodes Check the resistance of each diode 61 m Measure the resistance of surge absorber connected to the diode holder NORMAL RESISTANCE 0 m Check the magnetic force of permanent magnets molded in the rotor Remedy 1 If the magnetic force of rotor magnets is weak or if the surge absorber is not good replace the rotor with a new one 2 If the diode is not good replace it with a new one CAUTION In case the diode troubles are frequent check the surge absorber because it might be brok en even if its resistance is normal 22 In such a case replace the rotor with a new one Reassembling SURGE ABSORBER 1 As shown in Fig 11 6 place the white mark on the magnet to the left and solder the diodes so that cathode mark is to be placed at the bott
5. the insulation is faulty and may cause electric leakage Replace the faulty part Fig 11 8 63 11 4 NO DC OUTPUT 11 4 1 CHECK THE AC OUTPUT Check the generator by following Step 11 1 1 through Step 11 1 3 11 4 2 CHECK THE DC FUSE Check the fuse in the fuse holder If the fuse is blown check for the cause of fuse blowing and then replace with a new one FUSE 10A NOTE If the DC output is used to charge a large capacity battery or an over discharged bat tery an excessive current may flow causing fuse blow 11 4 3 CHECK THE WIRING Check all the wires to be connected correctly 11 4 4 CHECK THE DIODE RECTIFIER pA Remove the control panel and check the diode recti fier with a circuit tester DIODE RECTIFIER Refer to Section 9 7 DIODE RECTIFIER for the checking procedure Fig 11 10 11 4 5 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester SPECIFICATION RESISTANCE 110V 220V 240V 110V 220V 120V 110V 220V 120V 240V 110V 220V 240V 110V 220V 120V 110V 220V 120V 240V 5OHz 60Hz 50Hz RGD5000 60Hz Table 11 3 If the resistance reading is much larger or smaller than the specified value the DC coil of the stator is faulty Replace stator with a new one 64 12 WIRING DIAGRAM RGD3700 50Hz 110V 60Hz 110V 120V TYPE GENERATOR CONTROL BOX BLACK e o T
6. ose a ustusqa 3000W 50Hz 110 220 FREQUENCY Hz VOLTAGE V FREQUENCY Hz VOLTAGE V RGD3700 Output Max 3700W Rated 3300W 60Hz Voltage 110V 220V aa 2 AA A gi 2 A ase HHH RGD3700 Output Max 3700W Rated 3300W Frequency 60Hz Voltage 120V 240V A z 2k 2 gt 1k O CURRENT A 2 2 MODEL RGD5000 FREQUENCY Hz VOLTAGE V 0 10 20 30 40 FREQUENCY Hz 2 Lp SE VOLTAGE V RE 1 1 21 Tr ZI TI SENE Ede FREQUENCY Hz w VOLTAGE V 8 Esp 51222 1 1 SE REM 2 3 Na 2 2 15 CURRENT A HR DEN 2147 1101 OUTPUT W Sk 4k 3k 2k m x A e N OUTPUT W OUTPUT W RGD5000 Output Max 4800W Rated 4300W 50Hz Moltage uu occ ens 110V RGD5000 Output Max 5000W Rated 4500W Frequency 60Hz Voltage Cur 120V RGD5000 Output Max 4800W Rated 2 sies
7. LE Robin Generator Model RGD3 700 RGD5000 Technical Data amp Overhaul Instructions VICE MANUZ CONTENTS Section Title Page Section 1 Title RGD3700 R GD5000 Brushless Revolving Field Se exciting 2 pole Single Phase Frequency 60Hz 50Hz Maximum Output 3700W 4800W Rated Output 3300W AS00W 30 0A 410V 39 1A 27 5A 220V 19 5A Rated yo Voltage 15 0 240 17 9 Current 110 220 30 0A 15 0A 110v 220v 39 1A 19 5A 120 240 27 5A 13 8A ALTERNATOR Power Factor DC Output 12 8 10040 Voltage Regulator Condenser Type Voltage Regulation Within 1096 Type Air Cooled 4 Cycle le Diesel Engine Model Robin DY30D Robin DY41D Displacement 299 cc c 18 25 cu in 412 cc 25 14 cu in Maximum Output 6 0 PS 3000 r rpm 6 5 PS 3600 rpm 8 0 PS 3000 rpm E 5 PS 3600 r rpm Automotive type Diesel Fuel Fuel Tank Capacity 14 liters 3 6 U S gal yo 16 liters 4 2 9 5 gal ENGINE 2 1 2 liters hour 50Hz 1 7 liters hour Fuel Consumption Ratio 60Hz 1 5 liters hour 60Hz 2 0 liters hour Oil Capacity 1 0 liter 2 1 U S pints 1 1 liters e 3 S pint Starting System Recoil starter and Electric starter Dimensions LxWxH 673 x 500 x 514 mm 673 x 500 x 542 mm ARNA 26 5 x 19 7 x 20 2 in 26 5 x 19 7 x 21 3 in Dry Weight 85 kg 186 Ibs i 99 kg 218 Ibs SNOIJVOIHIO3dS L 2 PERFORMANCE CURV
8. O O 26 qao 8 WARNING LAMP OIL SENSOR START SWITCH 120V RECEPTACLE EARTH GROUND TERMINAL e RGD5000 GERMANY 50Hz 220V VOLTMETER DC FUSE NO FUSE BREAKER 22CV A WARNING LAMP OIL SENSOR AC 220v FN START SWITCH 220V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL 16 e RGD5000 50Hz 220V WITH SPECIAL RECEPTACLE VOLTMETER DC FUSE NO FUSE BREAKER O 220v NO FUSE BREAKER a x o CB i f START SA CH START SWITCH 220V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGD5000 OCEANIA 50Hz 240V VOLTMETER DC FUSE NO FUSE BREAKER O NO FUSE BREAKER ON START SWITCH 240V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL 17 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number is stamped on the LABEL MODEL NAME stuck on the rear cover Specification number is stamped on the stator cover NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service SERIAL NUMBER 18 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION RECOIL STARTER STATOR COMPLETE FLYWHEEL ROTOR COMPLETE SUPPORT RING THROUGH BOLT MOUNT RUBBER STARTER PULLEY DRIVING SHAFT GENERATOR BASE STATOR BOLT BALL BEARING ADAPTER Fig 5 1 5 2 FUNCTION 5 2 1 STATOR The stator c
9. ENGINE CONTROL BOX 0 75 mm u 20mm 1 25 mm 3 mm ELECTRIC STARTER TYPE WITH OIL SENSOR Optional Equipment 1 Z r lt br gt o lt WHITE BLACK YELLOW M LIGHT GREEN O P SW ME DEP KEY SW WHITE po PINK CONTROL BOX The battery cords have a cross sectional area of 22 mm 0 75 mm 20mm 125mm 3 5mm ey Symbol sc Auxiliary Winding ETT 20 HE IUE MC SC i DC Fe C Condenser Output Terminal Fuse 1 NFB1 No Fuse Breaker NFB2 No Fuse Breaker FPSw Full Power Switch Regulator Oil Sensor OS Starting Motor SOL Solenoid BAT E KEY SW KEY Switch O P SW Oil Pressure Switch VC SW Voltage Changeover Switch AC Output Receptacle Total 15A MAX AC Output Receptacle 220V 240V AC Output Receptacle 110V 120V AC Output Receptacle 120V 240V REC5 AC Output Receptacle Total 20A MAX Battery Earth Terminal Ground Terminal 722 MEMO FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS DIV OVERSEAS SALES DEPT Subaru Bldg 1 7 2 Nishi Shinjuku Shinjuku ku Tokyo 160 Japan TEL TOKYO 03 347 2414 5 TELEX 232 2401 FUJI J CABLE ADDRESS FUJIHEAVY TOK
10. 3 Attach battery cords to the battery Attach the positive cord first and then the negative cord Fasten the other end of the negative cord to the engine base using the engine mount nut NUT 2 pcs 8 SPRING WASHER Loh Raa Wea 2 pcs 4 BATTERY SPACER WIN TIED 2 pcs A s BATTERY CABLE BATTERY ANGLE p BATTERY n 22 gt bL d E 6 BOLT 2065 lt 23 ANE BATTERY BASE 2 B BATTERY BOLT i J PIPE FRAME Fig 10 45 56 10 4 9 FUEL TANK 1 Connect fuel pipe 29 complete and rubber pipe 6 mm inside diameter 12 mm outside diameter 170 mm long to the fuel tank a Connect the rubber pipe and fasten it with the hose clamp 10 5 mm inside diameter b Connect fuel pipe 29 complete to both ends of the banjo and tighten it with banjo bolt using two pieces of GASKET ALUMINUM Tightening 80 100 kg cm FUEL TANK 1 HOSE CLAMP INSIDE DIA 7 8 2 HOSE CLAMP INSIDE DIA 10 5 GASKET ALUMINUM BANJO BOLT FUEL PIPE 29 COMPLET To NOZZLE 5 E PURSE LOCK RUBBER PIPE x 126 x 170 mm BANJO To INJECTION PUMP RUBBER x 120 x 250 mm FUEL FILTER ASSY Fig 10 46 57 2 Mount the fuel tank on the mount rubbers attached to the side plates SONU ii ae kn dre Y xo pus Aeg 4 pcs 89 spring washer 4 pcs Tightening to
11. Grooves of stator Grooves of jig Fig 10 29 49 e The dimensions of the stator bolts are shown in Table 10 2 inch Table 10 2 10 4 4 REAR COVER 1 Attach the bush over the lead wires drawn out from the rear cover Press the bush end into the window of the rear cover See Fig 10 30 Fig 10 30 2 Put the rear cover with stator over the rotor Tap on the rear cover evenly with a plastic ham mer to press the rotor bearing into the rear cover See Fig 10 31 Fig 10 31 50 3 Fix the rear cover to the adaptor with four bolts spring washers and washers See Fig 10 32 66 x 25 mm bolt 4 pcs 69 spring washer 4 pcs 69 washer 4 pcs Tightening torque 50 60 kg cm 10 4 5 RECOIL STARTER 1 Remove the through bolt which has been tenta tively attached to the rotor 2 Insert the key into the keyway of the rotor shaft See Fig 10 33 Then insert the spacer Tapping the starter pulley with a plastic ham mer attach the starter pulley to the rotor shaft Fig 10 33 3 Apply a washer and a spring washer to the through bolt and insert it into the rotor shaft Through bolt zu i oa ees ect Dey Sn eS 1 pce 106 spring 1 LOO wash r ua Suara Qs amas T Sa DR AN pce 220 mm 50 mm 10 mm 8 66 inch 1 97 inch 0 39 inch Table 10 3 51 4
12. Tighten the through bolt with a box wrench or a spanner If an impact wrench is available use it Tightening torque 240 300 kg cm 5 Attach the RECOIL STARTER to REAR COVER 66 8 mm flange bolt 4 pcs OA RECOIL STARTER Tightening torque 40 60 kg cm BOLT Fig 10 35 10 4 6 FRAME 1 Attach two engine mount rubbers and one alternator mount rubber to the frame See Fig 10 36 Omm NUE ees bodes M t de MN E 2 pes Tightening 240 300 kg cm RUBBER V I 2pcs 100 NUT Fig 10 36 2 Attach the engine base to the bottom of the engine See Fig 10 37 8 x50mm bolt 4 pcs OO NUE coe EN a ds 4 pes Tighteningtorque 120 140 kg cm NOTE Insert the bolts from the bottom side of the engine base ENGINE MOUNT RUBBERS ENGINE MOUNT HOLES ENGINE MOUNT HOLES for RGD3700 for RGD5000 Fig 10 37 3 Mount the generator base on the alternator mount rubber and fix with the nut SO ibus etr thapa ph pce Tightening torque 120 140 kg cm NOTE Set the generator base so that the column of the frame is placed in the center of the pipe on the bottom of the generator base ki an r Make this gap even Fig 10 38 4 Install the engine and alternator assembly into the frame a Lift the engine and alternator
13. Use hose clamps 10 5 mm in inside diameter Finally clamp the pipe to the crankcase 58 10 5 CHECKING DISASSEMBLY and REASSEMBLY of the CONTROL BOX 10 5 1 CHECKING OF THE CONTROL BOX Dismount the control box from frame Remove the control panel and check each components and wiring Refer to Section 9 for the detail of checking the components in the control box 10 5 2 DISASSEMBLY 1 Remove the control panel from the control box 4 lt 8 pcs REGULATOR 2 Disconnect the connectors on the wires to de tach the control panel and box 3 Remove the regulator oil sensor unit condens ers and diode rectifier from the control box When removing the regulator push the hook on the coupler and pull out to disengage the cou plers See Fig 10 47 Fig 10 47 4 After disconnecting individual wires remove the control panel components NOTE DC fuse full power switch pilot lamp and warning lamp have their wires soldered Unsolder them to remove those parts if necessary 10 5 3 REASSEMBLY 1 Install the receptacles no fuse breaker fuse terminals switches etc on the control panel and wire them NOTE Circuit diagrams are shown in Section 12 Colored wires are used for easy identification and are of the correct capacity and size Use heat resistant type wires permissible temperature range 75 or over in the specified gauge shown in the circuit diagrams 2 Install regulator
14. ru 4300W 50Hz Voltage uel ures ARES 220V FREQUENCY Hz VOLTAGE V FREQUENCY Hz ao ah gt i aF VOLTAGE V FREQUENCY Hz VOLTAGE 10 15 20 25 15 20 25 39 CURRENT Sk 4k 3k 2k 5k 4k 3k 2k 1k OUTPUT W OUTPUT W OUTPUT W RGD5000 Output Max 5000W Rated 22 25 4500W 60Hz Voltage v ovem eR ES 220V RGD5000 Output Max 4800W Rated 2 3s 2408s DVRs 4300W Frequency ule e RISE 50Hz Volt ge e Ne gus 240V RDG5000 Output Max 4800W Rated see 4300W 50Hz Voltage ise eR 110V 220V VOLTAGE V FREQUENCY Hz FREQUENCY Hz L VOLTAGE V VOLTAGE V 20 18 16 14 12 10 2 e oon VOLTAGE 1 100 111 Rees 10 45 CURRENT 10 15 202 25 30 35 40 45 CURRENT 3 DC OUTPUT RGD3700 RGD5000 4 6 8 10 CURRENT A RGD5000 Output Max 5000W 5k Rated 22222525222 4500W 4k 60Hz Voltage 110V 120V 3k t a 5 2k o 1k 0 RGD5000 Output Max 5000W Rated 4500W 5k 60Hz Voltage i
15. the frame m Refer to Section 10 5 for disassembly checking and reassembly procedures of the control box 1 Mount the control box to the frame See Fig 10 42 10 mm flange bolt 3 pcs Washer 3 pcs Tightening torque 40 60 kg cm 2 Connect the wires drawn out from the stator to the wires from the control box Connect the oil sensor wires at the same time NOTE Connect the wires of the same color 3 Press the upper end of the bushing into the bottom window of the control box See Fig 10 43 Attach the grommet for the oil sensor wires to the rear panel of the control box 4 Fasten the one earth cable with 80 terminal drawn out from the control box to the rear cover leg SOX 25 mn voee za aee d eb pce Tightening torque 120 240 kg cm Fasten the other earth cable with 69 terminal to the unpainted bolt hole on the frame See Fig 10 44 CONTROL BOX 60 TERMINAL 80 TERMINAL Fig 10 44 55 10 4 8 BATTERY 1 Attach the battery base to the frame 6 x 10mm bolt 2 pes Tighteningtorque 40 60 kg cm 2 Mount the battery on the battery base and fix it with two battery bolts and a battery angle See Fig 10 45 GO nutre cR Re E e ts 2 pcs spring washer 2 pcs Tighteningtorque 40 60 kg cm
16. tool the capacity of the generator should be multipled by 1 2 to 3 and 570W as explained in the Item 3 MODEL RGD3700 RGD5000 Frequency i 50 Hz 60 Hz 50 Hz 60 Hz Incandesent lamp heater etc 3 000W 3 300W 4 300W 4 500W approx approx approx approx Fluorescent lamp mercury lamp etc 2 000W 2 200W 2 800W 3 000W approx approx approx approx Motor driven tool general purpose motor etc 1 800W 1 900W 2 600W 2 700W approx approx approx approx 900W 950W 1 250W 1 300W Water pump compressor etc Table 7 1 28 NOTES Wiring between generator and electrical appliances 1 Allowable current of cable Use a cable with an allowable current that is larger than the rated input current of the load electrical appliance If the input current is larger than the allowable current of the cable used the cable will be come excessively heated and deteriorate the insulation possibly burning it out Table 7 2 shows cables and their allowable currents for your reference 2 Voltage drop in long electric extension cords When a long wire is used to connect an appliance with the generator a certain amount of voltage drop occurs in the wire which lessens effective voltage available to the appliance The table below has been prepared to illustrate the approximate voltage loss when an extension cord of 300 feet approx 100 meters is used to connect an appliance or tool to the generator No of strands s
17. EBA 1 E ome FLAT SIDE LEP Z ZA lt we a e Fig 10 25 10 4 2 ROTOR 1 Clean the tapered part of the driving shaft and the matching tapered part of the rotor shaft of oil and dirt with a waste cloth 2 Attach the rotor to the engine shaft Tighten the through bolt tentatively See Fig 10 26 Apply a wrench on the head of through bolt and hit it clockwise with a hammer to tighten THROUGH BOLT Fig 10 26 48 10 4 3 STATOR 1 Set the stator on the jig so that the grooves on the stator side match with the grooves of the jig At the same time be sure to set the stator on the jig so that the lead wires direct to the window of rear cover Attach the support ring around the stator Check that the hooking holes are placed at the flat sides of the stator See Fig 10 27 2 Insert 4 guide bolts in the rear cover and let them match with the grooves in the stator and set the rear cover over the stator 3 Take the stator leads out from the window of the rear cover 4 Tap lightlv and evenly the upper surface of the rear cover with plastic hammer and press the rear cover over the stator See Fig 10 28 5 Fix the stator to the rear cover with four bolts washers and spring washers See Fig 10 29 oz cr 4 pcs 4 pcs G spring washer 4 pcs Tightening torque 50 60 kg cm Hooking holes for removing support ring
18. ES 2 1 MODEL RGD3700 FREQUENCY Hz VOLTAGE V 0 5 10 15 20 25 30 CURRENT A FREQUENCY Hz VOLTAGE V 0 5 10 15 20 25 30 CURRENT A VOLTAGE V FREQUENCY Hz 10 CURRENT 111 oe 35 35 3k 2k 1k 15 OUTPUT W OUTPUT W OUTPUT W RGD3700 Output Max 3500W Rated 3000W Frequency 50Hz 110 RGD3700 Output Max 3700W Rated 3300W 60Hz Voltage roa 120V RGD3700 Output Max 3500W delude 3000W 50Hz 220V VOLTAGE V FREQUENCY Hz n VOLTAGE V FREQUENCY Hz FREQUENCY Hz VOLTAGE V 10 15 20 CURRENT 4k 3k 2k 25 OUTPUT W 30 ET OUTPUT W N x OUTPUT W RGD3700 Output Max 3700W Rated 2 rev 3300W 60Hz Voltages uya 220V RGD3700 Output Max 3500W Rated ossi S 3000W Frequency 50Hz Voltage 240V RGD3700 Output Max 3500W Rated
19. ROTECTION 110V 120V 27A Total output amperage 220V I Total output amperage RGD3700 1 x 1 240V Total output amperage 110 220V 120 240V Total output amperage Total output amperage 110V Output from 30A receptacle Total output amperage 120V Output from 30A receptacle RGD5000 E i gt 220V Total output amperage 240V I Total output amperage Total output amperage 110 220V 120 240V Output from 30A receptacle Table 5 1 Fig 5 7 5 2 6 RECEPTACLE and AC PLUG STD SPEC These are used for taking AC output power from the generator total of five kinds of receptacles each varying in rated voltage and current from another are used Each model has at least one receptacle to deliver the rated generator output As many AC plugs as the receptacles each matching the corresponding receptacle are provided Table 5 2 shows the rated current for each receptacle Be careful not to use the receptacles and AC plugs beyond the specified limits to prevent burning up to total 15 amperes from two receptacles up to 15 amperes up to 20 amperes up to 30 amperes See Caution Table 5 2 Caution To connect the appliance to locking receptacle insert the plug into the receptacle and turn it clockwise to lock Fig 5 8 NOTE If your generator has receptacles peculiar to your country Table 5 2 does not apply NOTE The generator for U
20. S A market is equipped with NEMA standard receptacles shown in table 5 3 Use the proper plug for connecting appliance to the generator Ampere Receptacle AC plug Description GFCI Ground Fault Circuit Interrupter Receptacle duplex NEMA NEMA L14 20R L14 20P Locking Receptacle Locking Receptacle Table 5 3 22 5 3 DESCRIPTION of GENERATOR OPERATION SURGE ABSORBER PERMANENT MAGNET FOR INITIAL EXCITATION FIELD COIL MAIN COIL RECEPTACLE APPLIANCE DIODE m CONDENSER COIL CONDENSER Fig 5 9 5 3 1 GENERATION of NO LOAD VOLTAGE 1 2 3 4 When the generator starts running the permanent magnet built in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator As two condensers are connected to the condenser coil the small voltage at the condenser coil generates a minute current a which flows through the condenser coil At this time a small flux is produced with which the magnetic force at the rotor s magnetic pole is intensified When this magnetic force is intensified the respective voltages in the main coil and condenser coil rise up As the current a in creases the magnetic flux at the rotor s magnetic pole increases further Thus the voltages at the main coil and condenser coil keep rising by repeating this process As AC current flows through the condenser coil the density of magnetic flux in the rotor ch
21. YO PRINTED IN JAPA FACSIMILE TOKYO 03 347 2418 AUGUST 198
22. a case stop operation immediately and carefully check the electrica appliance and AC plugs for faulty wiring 26 7 RANGE OF APPLICATIONS Generally the power rating of an electrical appliance indicates the amount of work that can be done by it The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance The electrical appliances generally have a label showing their rated voltage frequency and power consumption input wattage The power consumption of an electrical appliance is the power neces sary for using it When using a generator for operating an electrical appliance the power factor and starting wattage must be taken into consideration In order to determine the right size generator it is necessary to add the total wattage of all appliances to be connected to the unit Refer to the followings to calcurate the power consumption of each appliance or equipment by its type 1 2 3 4 Incandescent lamp heater etc with a power factor of 1 0 Total power consumption must be equal to or less than the rated output of the generator Example A rated 3000W generator can turn thirty 100W incandescent lamps on Fluorescent lamps mercury lamps etc with a smaller power factor Select a generator with a rated output equivalent to 1 2 to 2 times of the power consumption of the load Example A 400W mercury lamp requires 600W to 700W power source to
23. anges This change of magnetic flux induces AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies this AC voltage into DC Thus a DC current flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil When generator speed reaches 2700 to 2800 rpm 50Hz type or 3000 to 3300 rpm 60Hz type the current in the condenser coil and field coil increases rapidly This acts to stabilize the output voltage of each coils If generator speed further increases to the rated value the generator output voltage will reach to the rated value 5 3 2 VOLTAGE FLUCTUATIONS UNDER LOAD When the output current c flows through the main coil to the appliance a magnetic flux is produced and serves to increase current a in the condenser coil When current increases the density of magnetic flux across the rotor core rises As a result the current flowing in the field coil increases and the generator output voltage is prevented from decreasing y 5 3 3 FULL POWER SWITCH Dual Voltage Type The full power switch is provided for the dual voltage type to take out the full rated power from one recepta cle in each voltage 120 240V m 1 110 220 120V 140V I Mc 120v or 110V 240V or 220V 120V or 110V Fig 5 10 120v 110V Fig 5 11 Switch LOWER VOLTAGE HIGHER VOLTAGE Position RECEPTACLE RECEPTACLE
24. assembly with a chain block and down it into the frame making sure that the bolts of the mount rubbers are correctly inserted into the engine base b Fix the engine and a alternator assembly to the mount rubbers lighten the two nuts at engine base and two bolts at generator base TOONUD 2 pcs Tightening torque 240 300 kg cm 86 x25 mm bolt 2 pes Tightening torque 120 140 kg cm Fig 10 39 NOTE When tightening the nuts and bolts slightly lift the engine and alternator assembly so that the weight is not applied to the mount rubbers 53 5 Attach the stoppers to the frame NOTE 1 Set the stoppers so that the engine base is placed the center of the up per and the lower rubbers See Fig Make this gap even 10 40 NOTE 2 If the engine mount rubbers are re placed with new ones set the stop pers so that the upper rubber touches the engine base The new mount rub ber shall be distorted by approx mm in one month ENGINE BASE 8 x12mmbolt 4 pcs Tightening torque 120 140 kg cm Fig 10 40 6 Attach side plate A to frame 10 mm bolt 2 pcs Attach fuel tank mount rubbers to side plates The nuts for mount rubbers are welded to side plates Tightening torque 40 60 kg cm RUBBER V I 4 pes SIDE PLATE A Fig 10 41 54 10 4 7 CONTROL BOX Mount the control box assembly to
25. be turned on A rated 3000W generator can power four or five 400W mercury lamps NOTE 1 lf a power factor correction capacitor is not applied to the mercury lamp or fluorescent lamp the more power shall be required to drive those lamps A rated 3000W generator can drive one or two 400W mercury lamps without power factor correction capacitors NOTE 2 Nominal wattage of the fluorescent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption efficiency should be taken into account as explained in Item 5 on the following page Motor driven tools and light electrical appliances Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times larger than their running wattage Example A rated 250W electric drill requires a 400W generator to start it Initially loaded motor driven appliances such as water pumps compressors etc These appliances require the large starting wattage which is 3 to 5 times of running wattage Example A rated 900W compressor requires a 4500W generator to drive it NOTE 1 Motor driven appliances require the aforementioned generator output only at the starting Once their motors are started the appliances consume about 1 2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other elec trical appliances NOTE 2 Motor driven applia
26. ere is no continuity when the circuit breaker Is off 9 4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a circuit tester referring to the following table COUPLER Fig 9 4 R x 1Q 10 MODEL SPECIFICATION AC Winding Condenser Winding White Red Black Blue Yellow Yellow 110V ES 220V 0 68 0 68 1 35 110V 220V RGD3700 f 0 84 0 84 1 35 is 110V 220V 0 56 0 56 0 98 p 120V i 120V 240V 0 56 0 56 0 98 110V i 220V 0 34 0 34 0 80 50 110V 220V i pL 2 1 240V 0 41 0 41 0 80 RGD5000 220V 0 26 110V 220V 240V 120V 240V 0 26 Table 9 1 NOTE If the circuit tester is not sufficientlly accurate it may not show the values given and may give er roneous readings Erroneous readings will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 20 C 68 F 35 9 5 ROTOR ASSEMBLY R x 12 10 1 Using the circuit tester measure the resistance of the field coil MODEL RGD3700 RGD5000 Resistance 2 10 1 60 Table 9 2 NOTE 1 Measure the resistance of each coil wind ing while the diode and each resistor are disconnected with their solder removed NOTE 2 If the circuit tester is not sufficiently ac curate it may not show the values given and may give erroneous readings Err
27. i ds an kaa 2 r GREEN YELLOW YELLOW re YELLOW i BROWN e RGD3700 50Hz 220V 240V 60Hz 220V TYPE GENERATOR CONTROL BOX _ BLACK pe 272 ORANGE Pea ee 1 lt UT 0 75 mm2 20mm 1 25 mm warm 3 5 mm e RGD3700 50Hz 110V 220V 60Hz 110V 220V TYPE GENERATOR CONTROL BOX BLACK Rs BLUE e RGD3700 U K 50Hz 110V 220V BS RECEPTACLE GENERATOR CONTROL BOX iz CEN 2 e RGD5000 50Hz 110V 60Hz 110V 120V TYPE GENERATOR CONTROL BOX BLACK rz HITE ren E GREEN YELLOW YELLOW e RGD5000 50Hz 110V 220V 60Hz 110V 220V TYPE GENERATOR CONTROL BOX BROWN WHITE e RGD5000 U K 50Hz 110V 220V BS RECEPTACLE GENERATOR CONTROL BOX REC3 REC3 e RGD5000 U S A 60Hz 120V 240V NEMA RECEPTACLE GENERATOR CONTROL BOX ze E GREEN YELLOW eee YELLOW YELLOW BLACK YELLOW 1 D 1 LIGHT GREEN M sw lol KEY SW 4 WHITE pw jr PINK py N ENGINE The battery cords have a cross sectional area of 22 mm 0 75 mm 20mm 1 25 mm 35 mm 69 ELECTRIC STARTER TYPE Optional Equipment te 3 m M RES an 95 ENGINE CONTROL BOX The battery M have a cross sectional area of 22 mm e TYPE WITH OIL SENSOR Optional Equipment
28. ich fix the engine to the Nuts are welded to the generator base 12 mm spanner or box spanner engine base S Dot 4 pcs 8 flangenut 4 pcs 8 FLANGE NUT 4 pcs e m RUBBER V i 4pcs 1 GENERATOR SIDE PLATE A OBEE Fig 10 10 42 gonna ce in m someone 4 Pipe Frame 3 Lift the generator with a chain block Be careful to keep and dismount from the frame the belt in place See Fig 10 11 Fig 10 11 4 Remove engine base generator base and mount rubbers from frame lt 86 FLANGE NUT 1 pce kod e GENERATOR BASE 1pce RUBBER V I 2pcs Fig 10 12 43 1 Remove recoil starter from rear cover 6 bolt 4 pcs 10 mm spanner or box spanner Recoil Starter 5 Fig 10 13 Rear Cover 1 Take off the through bolt and remove Be careful not to lose Box spanner or the starting pulley and spacer from rotor the key at removing socket wrench shaft Apply a box wrench on the head starting pulley Hammer of through bolt and hit the wrench handle with a hammer counterclockwise to loosen STARTING PULLEY SPACER Fig 10 15 44 6 Rear Cover 2 Take off the rear cover 1 Remove the four bolts which fasten 10 mm spanner or the rear cover to the adapter of the box spanne
29. led single cylinder Robin diesel engine enables the new RGD series generators to be very compact in size and light in weight RELIABLE PERFORMANCE WITH MINIMAL MAINTENANCE A brushless alternator eliminates troublesome brush maintenance A drip proof alternator design A trouble free condenser voltage regulator A fuseless circuit breaker A dust proof oil bath air cleaner The OIL SENSOR automatically shuts the engine off whenever the oil level falls down below a safe level preventing engine seizure LONG LIFE DURABILITY Compact and smooth running air cooled Robin diesel engine lasts much longer than the gasoline engine of the same size Trouble free brushless alternator with condenser type voltage regulator works all the year round without any maintenace work 4 GENERAL DESCRIPTION OF THE GENERATOR 4 1 EXTERNAL VIEW of GENERATOR AC RECEPTACLE ROCKER COVER AIR CLEANER FULL POWER SWITCH DUAL VOLTAGE TYPE ONLY PILOT LAMP SPEED CONTROL NO FUSE BREAKER SOLENOID DC FUSE SENSOR OIL GAUGE KEY SWITCH DC TERMINAL FUEL INJECTION PUMP EARTH GROUND TERMINAL OIL FILTER STARTING MOTOR OPTION FUEL FILTER FUEL TANK amp TANK CAP MUFFLER FUEL GAUGE a Hue Ta A Dj 1 m j j RECOIL STARTER BATTERY Option 4 2 CONTROL PANEL RGD3700 50Hz 110V 60Hz 110V 120V TYPE VOLTMETER DC FUSE NO FUSE BREAKER NO FUSE BREAKER ON 0
30. m structures or facil ities during use 4 Operate the generator on a level surface If the generator is tilted or moved during use there is a danger of fuel spillage and a chance that the gen erator may tip over 5 Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is wet by rain or snow wipe it and thoroughly dry it before starting Don t pour water over the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leak age and electric shock 6 Do not connect the generator to the commercial power lines This may cause a short circuit or damage to the generator Use a transfer switch for connecting with in door wiring NOTE The parts numbers of the transfer switches and of the plastic box to store them are as shown in Table 6 1 Part Name Phase Allowable Current 365 45604 08 Transfer Switch 1 367 45605 08 Transfer Switch 340 45606 08 Transfer Switch 367 43008 08 Plastic Box 348 43009 08 Plastic Box Table 6 1 7 Use a fuse of the correct capacity DC output If the generator rpm is increased excessively in the overload condition by using an over rated fuse the generator may be burnt CAUTION If the fuse is burnt out or the circuit breaker tripped off as a result of using an electrical appliance the cause can be an overload or a short circuit In such
31. nces mentioned in tems 3 and 4 vary in their required motor starting power depending on the kind of motor and start up load If it is difficult to determine the optimum generator capacity select a generator with a larger capacity 129752 5 Appliances without any indication as to power consumption Some appliances have no indication as to power consumption but instead the work load output is indicated In such a case power consumption is to be worked out according to the numerical formula mentioned below Output of electrical appliance Efficiency Efficiencies of some electrical appliances are as follows Power consumption Single phase motor 0 6 0 75 Vite smaller the motor the lower Three phase motor 0 65 0 9 the efficiency Fluorescent lamp 0 7 0 8 Example 1 A 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 7 57W As explained in Item 2 multi ply this power consumption value of 57W by 1 2 2 and you will get the figure of the necessary capacity of a generator In other words a generator with a rated output of 1000W capacity can light nine to fourteen 40W fluorescent lamps Example 2 Generally speaking a 400W motor means that its work load is 400W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570W When this motor is used for a motor driven
32. ntact type and strobe type The contact type can be used only when the generator and engine have been disassembled The contactless type is recommended CONTACTLESS TYPE A STROBE Fig 8 6 uud 8 2 AC OUTPUT MEASURING SWITCH TO AC RECEPTACLE Fig 8 7 Use a circuit like the one shown in Fig 8 7 for measuring AC output hot plate or lamp with a power fac tor of 1 0 may be used as a load Adjust the load and rpm and check that the voltage range is as specified in Table 8 1 at the rated amperage and rated rpm 107 119V 117 130V 215 238 235 260 Table 8 1 8 3 MEASURING INSULATION RESISTANCE Connect a megger tester to one of receptacle output terminals and the ground terminal then measure the insulation resistance An insulation resistance of megohm or more is normal The original insulation resistance at the time of shipment from the factory is 10 megohms or more If it is less than 1 megohm disassemble the gen erator and measure the insulation resistance of the stator rotor and control panel individually e STATOR 1 Measure the insulation resistance between BLUE lead and the core 2 Measure the insulation resistance between WHITE lead and the core 3 Measure the insulation resistance between YELLOW lead and the core 4 Measure the insulation resistance between BROWN lead and the core Rode e ROTOR Measure the insulation across one of
33. oil sensor unit condensers and diode rectifier into the control box 3 Connect the wires of control panel components and control box Fasten the earth wires to the rear of the control box using a 6 nut to the bolt which fixes the condens er bracket to the inside of the control box See Fig 10 48 4 Attach the control panel to the control box 46 screw ON 8 pcs Tighteningtorque 1 12 15 kg cm To EARTH TERMINAL CONTROL BOX WELDING NUT Fig 10 48 11 TROUBLE SHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING STATOR m Remove control panel and disconnect black blue red and white wires at the connectors m Measure the resistance between terminals on sta tor leads See Fig 11 1 Refer to Table 11 1 for normal resistance If sta tor is faulty replace with a new one 11 1 2 CHECKING CONDENSER m f an instrument QC meter or C meter for mea suring capacity of condender is available check the capacity of condenser See Fig 11 2 m NORMAL CAPACITY OF CONDENSER RGD3700 NODEL 50Hz 60Hz 20uF 20uF 20uF 20uF NO CAPACITY Table 11 1 Fig 11 1 Fig 11 2 RGD5000 i 50 Hz 60 Hz 30uF 30uF 30uF 30uF m If such an instrument is unavailable the condenser be checked by replacing with a new one If the gen erator performs good with new condenser the cause of trouble is defect in original condenser
34. om 2 Solder the coil ends to the terminal Fig 11 6 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11 2 1 CHECKING STATOR Check stator referring to Step 11 1 1 11 2 2 CHECKING CONDENSER Check condenser referring to Step 11 1 2 11 2 3 CHECKING ROTOR Check rotor referring to Step 11 1 3 62 11 3 AC VOLTAGE IS NORMAL AT NO LOAD BUT THE LOAD CANNOT BE APPLIED 11 3 1 CHECK THE ENGINE SPEED If the engine speed is low adjust it to the rated r p m x Refer to Step 11 2 1 for engine speed adjustment 11 3 2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR Refer to Section 7 RANGE OF APPLICATIONS for the wattage of the appliances If the generator is over loaded reduce the load to the rated output of the generator 11 3 3 CHECK THE APPLIANCE FOR TROUBLE If the appliance is faulty repair it AIR OUTLET 11 3 4 CHECK IF THE ENGINE IS OVER HEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re move it 11 3 5 CHECK THE INSULATION OF THE GENERATOR Stop the engine Measure the insulation resistance between the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1 disas semble the generator and check the insulation resistance of the stator rotor and the live parts in the control box Refer to Section 8 3 Any part where the insulation resistance is less than 1
35. oneous reading will also occur when there is a wide variation of resistance among coil windings or when measure ment s performed at ambient tempera tures different from 20 68 s 2 Check if the surge absorber is burnt Check the resistance of surge absorber Normal resistance is 262 3 Measure the resistance of the diode POLARITY OF CIRCUIT TESTER Continuity exists 9 6 CONDENSER m f an instrument QC meter or C meter for mea suring capacity of condender is available check the capacity of condenser See Fig 9 8 gt i i CONDENSER T NORMAL CAPACITY OF CONDENSER RGD3700 i RGD5000 50 Hz 60Hz 50Hz 60 Hz D 20uF 20uF 30uF 30uF CAPACITY 2 20uF 20uF 30uF 30uF Table 9 3 MODEL m If such an instrument is unavailable the condenser can be checked by replacing with a new one If the gen erator performs good with new condenser the cause of trouble is defect in original condenser 9 7 DIODE RECTIFIER DIODE RECTIFIER Brown Brown White range Orange Brown Brown Brown Brown White CIRCUIT TESTER Fig 9 9 Fig 9 10 Circuit inside of the diode rectifiers is as shown in Fig 9 9 Check continuity between each terminal by using a circuit tester as shown in Fig 9 10 The rectifier is normal when continuity is as follows 37 of the circuit tester Apply black needle of the circuit tester Brown Orange Bro
36. onsists of a laminated silicon steel sheet core a main coil and a condenser coil which are wound in the core slots The condenser coil excites the rotor field coil which generates AC voltage in the main coil Fig 5 2 19 5 2 2 CONDENSER Two condensers are installed in the control box and are connected to the condenser coil of the stator These condensers and condenser coil regulate the output voltage Fig 5 3 5 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action Fig 5 4 A diode rectifier and surge absorber is mounted inside of the insulator T DIODE RECTIFIER 7 Tu gt SURGE ABSORBER AN li 10 N 5 2 4 FUSE 1 The 10 ampere DC fuse mounted on the con trol panel protects whole DC circuit from get ting damage by overload or short circuit 2 The 15 ampere DC fuse in the control box pro tects the diode rectifier from getting damage by reverse connection to the battery Fig 5 6 5 2 5 NO FUSE BREAKER The no fuse breaker protects the generator from getting damage by overloading or short circuit in the appli ance Table 5 1 shows the capacity of no fuse breaker by each spec and their object of protection MODEL SPECIFICATION NO FUSE BREAKER OBJECT of P
37. p to half the rated power each Table 5 4 is a summary of the above explanation Select the proper output voltage by full power switch in accordance with the appliance to be used 5 3 4 VOLTAGE CHANGEOVER SWITCH The generator of 50Hz 110V 220V dual voltage type for U K is provided with voltage changeover switch instead of full power switch The output voltage is selected from 110V and 220V by turning this switch and both voltages cannot be taken out simultaneously The middle point of the main coil shall be grounded when the changeover switch is turned to 110V side VOLTAGE CHANGEOVER 110 SWITCH RECEPTACLE MAIN COIL 220V RECEPTACLE MAIN COIL Fig 5 13 25 6 SAFETY PRECAUTIONS 1 Use extreme caution near fuel constant danger of explosion or fire exists Do not fill the fuel tank while the engine is running Do not smoke or use open flame near the fuel tank Be careful not to spill fuel when refueling If spilt wipe it and let dry before starting the engine 2 Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oily cloth straw and any other inflammables near the generator 3 Do not operate the generator in a room cave or tunnel Always operate in a well ventilated area Otherwise the engine may overheat and also the poisonous carbon monoxide contained in the exhaust gases will endanger human lives Keep the generator at least 1 m 4 feet away fro
38. per tool for each specific job 10 2 SPECIAL TOOLS for DISASSEMBLY and ASSEMBLY ROTOR PULLER REAR COVER PULLER JIG 38 10 3 DISASSEMBLY PROCEDURES 1 Fuel Tank 1 Discharge fuel from the tank 1 Turn the fuel cock to close S 2 Disconnect the rubber pipe from the injection pump See Fig 10 1 3 Turn the fuel cock to OPEN O to discharge the fuel 2 Disconnect the fuel pipe and return pipe from the tank bottom See Fig 10 2 1 Remove the hose clamp and pull the i fuel pipe off from the tank 2 Remove the banjo bolt that fastens i the return pipe 3 Remove the fuel tank After removing the nut and washer re move the fuel tank See Fig 10 3 86 Flange Nut 4 pcs 8oWasher 4 Remove the fuel filter 1 Remove the hose clamp and pull out the air return pipe See Fig 10 4 Remove the fuel filter bolts and the to fuel filter Do not lose the gasket 17 mm spanner Wipe off spilt fuel Pliers Do not lose the gasket 12 mm spanner 12 mm spanner or box spanner Pliers 12 mm spanner or box spanner N 6 Nio A X dy ZY e raf s X A L y EL 724 CE NO FUEL INJECTION PUMP Fig 10 1 FUEL TANK 39 Battery 1 Remove battery cable from battery Be careful not to short Only electric Remove the negative side cable first and star
39. r engine 66bolt 4 pcs 2 Use a special tool REAR COVER Insert the two bolts Special tool PULLER to remove the rear cover sufficently and evenly 17 mm spanner a Insert the two bolts of the or the thread hole may Driver special tool into the thread hole be damaged at remov of the rear cover ing b Apply the center bolt of the special tool to the center hole of the rotor shaft c Tighten the center bolt to pull out the rear cover Fig 10 16 Fig 10 17 In case that REAR COVER PULLER isun available remove the rear cover by the follow ing instructions 1 Insert the through bolt into the rotor Do not give a strong Box spanner or shaft and tighten lightly hit on the rear cover socket wrench Hit on the boss and legs of rear cover boss or legs Plastic hammer with a plastic hammer Fig 10 18 45 Stator 1 Remove support ring 1 Remove the four bolts which fasten 10 mm socket the stator to the rear cover 2 Insert a small hook into the hole inside of the support ring and pull it out 7 SUPPORT RING Fig 10 19 Fig 10 20 2 Take apart the stator from the rear cover NOTE Use utmost care not to give dam age to the stator insulation and stator leads REAR COVER STATOR SUPPORT RING m 60 WASHER 4pcs SPRING WASHER DP PEE 4 pcs Fig 10 21 46 ROTOR 1 Insert the roto
40. r puller shaft into the rotor and tighten the rotor puller bolt until the rotor comes loose If the special tool is unavailable take the following instructions to remove the rotor Lightly strike the rotor core with plastic hammer and pull out the rotor from the tapered shaft of the engine If the rotor cannot be taken off strike it at different angles See Fig 10 23 8 17 mm spanner Never strike on the coil Platic hammer ROTOR PULLER Fig 10 23 Adaptor and 12 mm spanner Driving Shaft 1 Remove the four adaptor mounting bolts and the adaptor 86bolt 2 Remove the four driving shaft mount 14 mm spanner ing bolts and the driving shaft 106 bolt DRIVING SHAFT 100 SPRING WASHER Fig 10 24 47 10 4 ASSEMBLY PROCEDURES 10 4 1 DRIVING SHAFT and ADAPTOR 1 Align the driving shaft with the faucet joint of the flywheel and install it 100 x 30 mm bolt 4 pcs 10 spring washer 4 pcs Tighteningtorque 550 700 kg cm 2 Install the adaptor in the blower housing making sure that its flat side is down and its fuel filter mount ing boss on the air cleaner side 86 x 25mm bolt 4 pcs 80 spring washer 4 pcs Tighteningtorque 200 230 kg cm FUEL FILTER MOUNTING BOSS 24 D
41. rque 1 120 140 kg cm 3 Connect the fuel pipe a b c d Install the fuel filter assembly on the boss on the side of the adaptor generator SONGS mm bolt 1 pce Connect the other end of the pipe installed in Step 1 to the fuel filter Slide the hose clamp over the pipe connect the pipe to the fuel filter and clamp the pipe at the cor rect point Then secure the pipe with the purse lock NOTE Connect the shorter pipe of fuel pipe 29 complete to the fuel filter The hose clamp for the rubber pipe has an inside diameter of 10 5 mm and that for fuel pipe 29 complete is 7 8 mm in inside diameter Connect the longer pipe of fuel pipe 29 complete to the engine nozzle The nozzle must be pulled up from the cylinder head before connecting the pipe to it After pulling the nozzle up slide the hose clamp 7 8 mm in inside diameter over the pipe connect the pipe to the nozzle and fasten the pipe with the hose clamp at the correct point Then install the nozzle on the head Mount the bracket on the blower housing and secure the pipe with the clamp Connect the fuel filter and injection pump with pipe Fit the banjo to the rubber pipe 6 mm in inside diameter 12 mm in outside diameter 250 mm long and clamp it Connect the other end of the pipe to the fuel filter and clamp it Connect the banjo to the injection pump A gasket must be placed on each side of the banjo
42. ter type then the positive side 2 2 Remove battery from battery base Remove the two nuts that fasten the battery and take off the battery holder battery bolts and battery 2 pes 10 mm spanner or box spanner 3 Remove battery base from the pipe 10 mm spanner or frame box spanner 2 pcs dere 2 pcs sj SPRING WASHER pd cd M eae 2 pcs 1 BATTERY CABLE BOLT Ld e ans e BATTERY BASE lt p BATTERY BOLT EM PIPE FRAME Fig 10 5 40 nan mua Control Box 1 Take off the bushing from the bottom Press the upper end of the control box and pull out the bushing 2 Take out the grommet from the bottom face of the control box 3 Pull out the wires for the oil sensor and electric starter and remove them from the connectors Enn 3 Control Box 4 Remove the control box from the frame 10 mm spanner or 66 Washer 3 pcs G bolt 3 pcs A a H l f j SSS j f 2 i box spanner 1 Remove side plate A 60bolt 2 pcs Remove the mount rubbers from side plate 2 Remove the nuts and bolts that fasten the generator and frame together 1 Remove the two bolts which fix the alternator to the generator base 2 Remove the four bolts and flange nuts wh
43. the soldered terminals of the rotor and the core Fig 8 10 e CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Fig 8 11 Any part where the insulation resistance is less than 1 MQ has faulty insulation and may cause electric leak age and electric shock Replace the faulty part 33 9 CHECKING FUNCTIONAL MEMBERS 9 1 PILOT LAMP Check the pilot lamp if it is turned on by applying specified voltage Pilot lamp cannot be checked with circuit tester be cause its resistance is too large See Fig 9 1 PILOT LAMP I Fig 9 1 eRGD3700 RGD5000 Pilot lamp should be turned on at 70 to 120V 9 2 AC RECEPTACLES Using a circuit tester check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel When continuity is found between the output terminals of the receptacle with a wire connected across these terminals the AC receptacle is normal When the wire is re moved and no continuity is found between these terminals the receptacles are also normal AC RECEPTACLE AC RECEPTACLE TESTER Fig 9 2A Front Fig 9 2B Rear 34 9 3 CIRCUIT BREAKER Check continuity between each of two terminals at the rear of the circuit breaker while it is mounted on the control panel Normally there is continuity be tween each of the two when the circuit breaker is on while th
44. trand Resistance Current Amp dia 25 8v 125v Nominal cross x Allowable section current 8 2 o o gt Table 7 2 Voltage drop indicatesas V is xR Ix amp R means resistance Q 100 on the above table I means electric current through the wire means the length of the wire m The length of the wire indicates round length it means twice the length from generator to electrical tools 29 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 VOLTMETER AC voltmeter is necessary The approximate AC volt age ranges of the voltmeters to be used for various types of generators are as follows Oto 150V Type with an output voltage of 110 or 120V Oto 300V Type with an output voltage of 220 230 or 240V Oto 150V 0 to 300V Dual voltage type Fig 8 1 8 1 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10A 20A 100A Fig 8 2 8 1 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range Fig 8 3 30 8 1 4 TESTER Used for measuring resistance etc Fig 8 4 8 1 5 MEGGER TESTER Used for measuring generator insulation resistance Select one with testing voltage range of 300V 8 1 6 TACHOMETER There are various types of tachometers such as con tactless type co
45. ul ON 120V 240V 4k z 2k amp 2 1k 0 DC Voltage 12V DC Ampere 8 3A DC Output 100W The voltage curve shown in the left indicates the characteristic of DC output when charging a battery The voltage may be decreased by 20 when the re sistance load is applied NOTE It is possible to use both DC and AC out puts simultaneously up to the rated output in total 3 1 3 2 3 3 3 4 3 5 3 7 3 8 FEATURES BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance EASY STARTING Light pull recoil starter accompanied with automatic decompression system makes the new RGD series generators even easier in starting than gasoline engine generators QUIET OPERATION The new RGD series generator provides quiet operation by means of The superb design of intake exhaust system Direct injection combustion system large super silent muffler An efficient low noise air cleaner ECONOMICAL PERFORMANCE On top of well known diesel economy the air cooled Robin diesel engine features direct fuel injection and special design refinements for extra fuel efficiency OIL SENSOR The OIL SENSOR automatically shuts the engine off whenever the oil level falls down below a safe level preventing engine seizure COMPACT LIGHT WEIGHT The combination of newly developed brushless alternator and air coo
46. wn White Brown No continuity continuity Continuity PF Apply red needle Brown Nocontinuity No continuity Continuity Orange Continuity Continuity Continuity Brown White No continuity No continuity No continuity Table 9 4 NOTE 1 In checking the diode direction of connection is contrary to the ordinary case because of charac teristics of the diode and battery incorporated in the tester NOTE 2 Continuity means forward direction characteristics of the diode and different from short circuit condition in which a pointer of the tester goes out of its normal scale shows resistance to some extent When results of the checking indicates failure even in one section replace with a new one 10 DISASSEMBLY AND ASSEMBLY 10 1 PREPARATION and PRECAUTIONS 1 Be sure to memorize the location of individual parts when disassembling the generator so that the genera 2 3 4 5 tor can be reassembed correctly Tie tags noted with the necessary information to facilitate easier and smoother reassembly For more convenience divide the parts into several groups and store them in boxes To prevent bolts and nuts from being misplaced or installed incorrectly place them temporarily back at their original position Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid Use all disassembly assembly tools properly and use the pro
Download Pdf Manuals
Related Search