RGD2500 & RGD3300 GENERATOR SERVICE MANUAL
Contents
1. 0 6 to The smaller the motor the Fluorescent lamp 0 7 to 0 8 lower the efficiency 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 72 57W As explained in Item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get the figure of the neces sary capacity of a generator In other words a generator with a rated output of 1000Wcapacity can light nine to fourteen 40 W fluorescent lamps Example 2 Generally speaking a 400 W motor means that its work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570 W When this motor is used for a motor driven tool the capacity of the generator should be multiple of 570 W by 1 2 to 3 as explained in the Item 3 570 W x 1 2 to 3 2 684 W to 1710 W MODEL RGD2500 RGD3300 heater etc Fluorescent lamp Motor approx approx driven tool general porpose 1500 W 2100 W approx approx Mercury lamp etc 1300 W 1800 W approx approx Table 7 1 16 ww NOTES Wiring between generator and electrical appliances 1 Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load electrical appliance If the input current is higher than the allowable current of the cable used the cable will becom2. 2 Remove front protector from front cover See Fig 10 22 8 mm spanner or screw driver 6 O addi K IAS N X 2222222280 Y OF zz Fig 10 22 87 10 4 ASSEMBLY PROCEDURES 10 4 1 FRONT PROTECTOR amd FRONT COVER 1 Attach the front protector to front cover The louvers of the front protector project into the inside of front cover as shown in Fig 10 23 5 x 10 mm Tapping screw 4 pcs Tightening torque 3 4 5 4 N m 35 55 kg cm 2 5 4 0 ft lb ww Fig 10 23 ww 2 Install front cover to the engine See Fig 10 24 5 x 20 mm bolt and washer assy NOTE The size of faucet joint and pitch of mount ing holes of front cover is different by models RGD2500 and RGD3300 Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft lb Fig 10 24 10 4 2 ROTOR 1 Clean the tapered portion of driving shaft and the matching tapered hole of rotor shaft of oil and dirt using a waste cloth 2 Attach rotor to the driving shaft See Fig 10 25 Tighten through bolt with washer and spring washer Tightening torque RGD2500 RGD3300 11 3 13 2 N m 22 6 34 5 N m 115 135 kg cm 230 250 kg cm 8 3 9 7 ft Ib 16 6 18 0 ft lb Fig 10 25 Hooking holes for removing support ring 10 4 3 STATOR and REAR COVER 1 Set the stator on the jig Match the grooves of the stator
3. 1 Attach the 6 terminal of the grounding wires to the bottom of the control box See Fig 10 42 6 nut brass 1 pce Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 45 2 In the case of generator models equipped with oil sensor connect the wires to oil pressure switch and solenoid Screw the black yellow wire to the center of the oil pressure switch Connect the two blue wires to the solenoid and clamp the connectors to the side of speed control unit 3 Connect the wires drawn out from the stator to the wires from the control box NOTE 1 Connect the wires of the same color NOTE 2 On 220V and 240V models connect one blue stator lead with a white con trol box lead NOTE 3 Engage the connectors securely 4 Push the wires into the control box and attach the bushing over the wires Press the upper end of the bushing into the control box See Fig 10 43 5 Install the contro box to the frame 6 x16 mm flange bolt 2 pcs 6 12 mm flange bolt 2 pcs 1 Tighten the above three bolts tentatively 2 Tighten the two black bolts which join the side plate to the frame 3 Tighten the above three bolts adjusting the po sition of the control box See Fig 10 44 Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb lt Electric start mode gt 6 Connect the light green and the pink leads of the control bo
4. Robin Power Equipment SERVICE MANUAL RGD2500 RGD3300 Generator PUB GS1186 Rev 8 98 Robin SUBARU CONTENTS Section Title Pa Section Title Page 1 SPECIFICATIONS Brushless Self Exciting 2 Pole Single Phase 5 Voltage BL mm 6 5 E sd _ Starting System Recoil Starter and Optional Electric Starter 21 1 x 15 8 x 18 0 in 27 9 x 15 8 x 18 0 in 536 x 400 x 458 mm 709 x 400 x 458 mm 55 kg 58 5 121 Ibs 58 5 kg 62 kg 128 7 5 129 Ibs 137 Ibs Dimensions L x W H i Dry Weight Electric starter motor is available as option 2 PERFOMANCE CURVES 2 1 MODEL RGD2500 VOLTAGE V FREQUENCY Hz gt 8 12 16 CURRENT 2 2 MODEL RGD3300 VOLTAGE V FREQUENCY Hz 8 12 16 20 CURRENT 2 3 DC OUTPUT 6 8 4 CURRENT 2k 1k OUTPUT W 3k 1k Output Max 2500 W Output Rated 2300 W 60 Hz Voltage 120V Output Max 3300 W Output Rated 3000 W Frequency 60 Hz Voltage 120 V 240V 5 a o DC Voltage 12V DC
5. 11 8 NORMAL RESISTANCE Fig 11 8 If the resistance is larger or smaller than the above limits solenoid is defective Replace it with a new one 4 Checking the oil sensor unit a Disconnect the connector on the Black Yellow lead of the oil sensor unit which is connected to the pressure switch b Start the engine and ground the Black Yellow lead of the oil sensor unit to engine body c If the solenoid actuated to shut the engine down the oil sensor unit is operating properly 5 Checking the pressure switch a Disconnect the Black Yellow lead of the pressure switch from the control unit b Check the resistance between the Black Yellow lead and ground Resistance should be infinite when engine is stopped c Start the engine The resistance should be O when engine is running The pressure switch actuates at 0 3 kg cm oil pressure d If the pressure switch does not work properly replace it with a new one 57 12 WIRING DIAGRAM GENERATOR _ CONTROL BOX GENERATOR Resistor gt Be Se Se 2 i 1 1 1 1 1 Only for RGD3300 58 Robin America Inc 940 Lively Blvd Wood Dale IL 60191 Phone 630 350 8200 Fox 630 350 8212 e mail sales robinamerica com www robinamerica com PRINTED IN THE USA Robin America Inc
6. If the generator is wet with water the insulations will be adversely affected and may cause current leakage and electric shock 6 Do not connect the generator to the commercial power lines ww This may cause a short circuit or damage to the generator Use a transfer switch Optional parts for connecting with indoor wiring NOTE The parts numbers of the transfer switches and of the plastic box to store them are as shown in Table 6 1 Allowable Current 367 45605 08 Transfer Switch 1 1 367 43008 08 1 348 43009 08 7 Be sure to check and remedy the cause of circuit breaker tripping before re setting it on CAUTION If 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 a case stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring w 14 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 watt age of the appliance The electrical appliances generally have a label showing their rated voltage fre quency and power consumption input wattage The power consumption of an electrical appliance is the power necessary for using it When using a generator for operating an electrical appliance the power fac
7. A market is equipped with NEMA standard recep tacles shown in table 5 2 Use the proper plug for connecting ap pliance to the generator Caution connect the appliance to locking receptacle insert the plug into the re ceptacle and turn it clockwise to lock Fig 5 8 p 125V NEMA NEMA 20A 5 20R 5 20P n 125V 250 20A L14 20R L14 20P Locking Receptacle 5 GFCI Ground Fault Circuit Interrupter Receptacle duplex Locking Receptacle Table 5 2 10 5 3 GENERATOR OPERATION PERMANENT MAGNET FOR INITIAL EXCITATION STATOR MAIN COIL FIELD COIL RECEPTACLE RESISTOR APPLIANCE DIODE CONDENSER COIL CONDENSER 5 3 1GENERATION of NO LOAD VOLTAGE 1 When the generator starts running the permanent magnet built in to the rotor generates 3 to 6V of AC voltage inthe main coil and condenser coil wound on the stator 2 As one or two condensers are connected to the condenser coil the small voltage at the condenser coil generates a minute current 8 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 mag netic force is intensified the respective voltages in the main coil and condenser coil rise up As the current increases the magnetic flux at the rotor s magnetic pole increases further Thus the volt
8. Ampere 8 3A DC output 100W The voltage curve shown in the left indicates the char acteristic of DC output when charging a battery The voltage may be decreased by 20 when the resis tance load is applied NOTE It is possible to use both DC and AC outputs simultaneously up to the rated output in total 3 FEATURES 3 1 3 2 3 3 3 4 3 5 3 7 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 A large super silent muffler An efficient low noise air cieaner ECONOMICAL PERFORMANCE On top of well known diesel economy the air cooled Robin diesel engine features direct fuel injection and special design refinemen s 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 cooled single cylinder Robin diesel engine enables the new RGD series generators to be very compact in
9. ages at the main coil and condenser coil keep rising by repeating this process 8 As AC current flows through the condenser coil the density of magnetic flux in the rotor changes 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 magne tizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 3000 to 3300 rpm the current in the condenser coil and field coil increases rapidly This acts to stabilize the output voltage of each coils 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 8 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 genera tor output voltage is prevented from decreasing dici 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 receptacle in each voltage 120V 1 110V Fig 5 12 120 110V 120 240V r or 110 220V Fig 5
10. follows Yellow Gray Red Red Yellow Yellow Fig 9 7 Checking table for analogue circuit tester Apply minus needle of the circuit tester me wem 99 selon een Goin pomme Table 9 4 1 Analogue circuit tester Apply red plus needle of the circuit tester 27 Checking table for digital circuit tester Apply red plus needle of the circuit tester me vm 9 pesas Recor _ ome Table 9 4 2 Digital circuit tester Apply black minus needle of the circuit tester NOTE 1 Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester polarity of tester needles should be reversed 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 NOTE 3 Simpson brand analogue testers have the characteristics as same as the digital circuit tester 28 10 DISASSEMBLY AND ASSEMBLY 10 1PREPARATION and PRECAUTIONS 1 Be sure to memorize the location
11. fuel tank fuel cock fuel filter and fuel injection pump See Fig 10 47 Attach the 10 mm flange nut to the fuel cock before connect the fuel pipe to it Use the correct clamps for each fuel pipe 2 raters omm 70mm ree vmm emm zm Table 10 3 5 Attach fuel cock and fuel filter to the control box The fuel cock can be installed on the bracket by turning it 90 degrees with fue pipes connected Fuel cock 10 flange 1 pce Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb Fuel filter 6 x 16 mm flange nut 2 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft Ib 49 15 4 8 BATTERY FRAME and BATTERY 1 Attach BATTERY FRAMEs to the frame See Fig 10 49 Clamp the upper end of the battery frames to the side member of the frame Tighten two bolt amp washers tentatively 86 x 20 mm bolt and washer assy 2 pcs Join the lower end of the battery frames to the base plate of the frame Tighten two bolt amp washers tentatively 86 x 20 mm bolt and washer assy 2 pcs 2 Mount the BATTERY BASE on the battery frame Insert the four bolts from the bottom of the frame and tighten the flange nuts 66 x 40 mm bolt and washer assy 4 pcs 6 flange nut 4 pcs 3 Tighten the four bolt amp washers attached at step 1 4 Mount the battery on the battery base Insert the battery bolts into the
12. hooking holes of the battery base then apply the battery stay to the battery and tighten two nuts 6 spring washer 2 pcs 6 nut 2 pcs 50 Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft Ib Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 5 Connect battery cables to the battery Connect the positive cable first and then the negative cable Battery cable Bolt and Washer Battery 8 x 20 mm 2 pes Battery stay Pipe frame Bolt and Washer 8 x 20 mm 2 pcs Battery base Flange nut Battery flame 69 4 pcs Bolt and Washer 8 x 20 4 pes Fig 10 49 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 screw 6 pcs 2 Disconnect the connectors on the wires to detach the contro 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 couplers See Fig 10 50 Fig 10 50 51 4 After disconnecting
13. of individual parts when disassembling the generator so that the generator can be reassembled correctly Tag the disassembled part with the necessary information to facilitate easier and smoother reassembly 2 For more convenience divide the parts into several groups and store them in boxes 3 To prevent bolts and nuts from being misplaced or installed incorrectly replace them temporarily to their original position 4 Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools properly and use the proper tool for each specific job 10 2 SPECIAL TOOLS for DISASSEMBLY and ASSEMBLY D ROTOR PULLER REAR COVER PULLER JIG 10 3 DISASSEMBLY PROCEDURES S 1 Fuel Tank 1 Close fuel cock Draining tank of fuel before disassembly is un necessary 2 Loosen the nut and remove fuel cock 14 mm spanner from the bracket Turn the fuel cock body by 90 degrees to remove Fig 10 1 3 Remove the two bolts which join the 10 mm spanner fuel filter to the control box See Fig 10 2 4 Remove the fuel pipe which connects Plier fuel filter and fuel injection pump Loosen the clamp using pliers and pull out the fuel pipe from the fuel filter See Fig 10 3 aN KW 1874 oema TM 1 Fuel Tank 5 Remove fuel return pipe which connects Take care of spilt fuel Plier the fuel injection nozzle and the b
14. with the grooves of the jig 2 Attach the support ring around the stator set ting the open ends of the ring to the position of stator leads Check that the hooking holes are placed at the flat sides of the stator See Fig 10 26 3 Insert four guide bolts into the bolt holes of the rear cover and mount it on the stator match ing the guide bolts with the grooves of the sta tor Tighten the guide bolts tentatively 4 Take the stator leads out from the window of the rear cover 5 Put a board on the rear cover and press it us ing a pressing machine If a pressing machine is unavailable tap around the board on the rear cover evenly with a plastic hammer to press fit the rear cover over the stator See Fig 10 27 CAUTION Take care of the rear cover to be pressed in upright position Fig 10 27 39 6 Join the stator to rear cover with four bolts washers and spring washers See Fig 10 28 6 bolt 4 pcs 6 washer 4 pcs 6 spring washer 4 pcs NOTE Tighten four bolts evenly taking several steps Tightening torque 7 9 9 8 N m 80 100 kg cm 5 8 7 2 ft lb Fig 10 28 The dimensions of the stator bolts are shown in Table 10 1 ver va fo 8 Table 10 1 7 Attach the boot over the lead wires drawn out from the rear cover Press the smaller end of boot into the rear cover See Fig 10 29 8 Put the rear cover and st
15. 10 REC 2 120V 11 ov Fig 5 11 Switch LOWER VOLTAGE HIGHER VOLTAGE Position RECEPTACLE RECEPTACLE 1 V Rated output No be 120 1 aues V Half of rated output Rated output 120 240 V Table 5 4 12 Two main coils are wound over stator core Each main coil outputs half the rated power at the lower voltage 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 isa simplified representation of this circuit showing the two main coils connected in parallel In this case the higher voltage 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 30A 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 an
16. If the appliance is faulty repair it 11 3 4 CHECK IF THE ENGINE IS OVERHEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re move it Air outlet Fig 11 4 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 1M dis assemble 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 1M C the insulation is faulty and may cause electric leakage LT clu Replace the faulty part Fig 11 5 55 13 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 FUSE 10A 0 f NOTE If the DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing fuse blow 11 4 3 CHECK THE WIRING Check ali the wires to be connected correctly Fig 11 6 11 4 4 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode rectifier with a circuit tester Refer to Se
17. ator assembly over the rotor Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover See Fig 10 30 9 Tighten the four bolts washers and spring washers to join the rear cover to the front cover 6 x25 mm bolt 4 pcs 6 washer 4 pcs 6 spring washer 4 pcs In the case of models with oil sensor or elec tric starter attach the clamp at the same time See Fig 10 31 Clam Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 10 4 4 END COVER Attach end cover to the rear cover The air inlets of the end cover have to face down ward See Fig 10 32 6 x 8mm flange bolt 4 pcs Tightening torque 3 9 5 4 N m 40 55 kg cm 2 9 4 0 ft lb 41 15 4 5 FRAME 5 Terminal 1 Attach two mount rubbers to the engine base Frame of the frame Tighten the nuts from the bottom side of the frame See Fig 10 34 8 flange nut 2 pcs 2 Attach the 5 terminal of grounding wires green yellow to the unpainted thread hole of the frame base plate using a 5 mm brass 6 Terminal 8 Terminal screw See Fig 10 33 Control box Rear cover Fig 10 33 Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft Ib 3 Attach the alternator mount rubber to the frame See Fig 10 34 NOTE The mount rubbers are selected to reduce vibration most effectively by model and its frequency Be su
18. ce with a new one Fig 11 1 11 1 2 CHECKING CONDENSER If an instrument QC meter or C meter for mea suring capacity of condenser is available check the capacity of condenser See Fig 11 2 NORMAL CAPACITY OF CONDENSER RGD2500 RGD3300 Table 11 1 If such an instrument is unavailable the condenser can be checked by replacing with a new If the generator performs good with new condenser the cause of trouble is defect in original condenser 53 1 1 3 CHECKING OF ROTOR 1 CHECKING FIELD COIL Measure the resistance of field coil with a circuit tester See Fig 11 3 Fig 11 3 Q MODEL RGD2500 RGD3300 Table 11 2 Remedy If the resistance is not normal replace rotor with a new one 11 2 AC VOLTAGE IS TOO THIGH 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 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 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
19. ck and dismount it from frame Fig 10 10 Fig 10 70 7 Remove generator base from frame 12 mm spanner B nut 1 pce 8 Remove mount rubbers from frame 12 mm spanner See Fig 10 11 MOUNT RUBBER 2pcs GENERATOR BASE PIPE FRAME MOUNT RUBBER Fig 10 11 33 Step Part to remove 4 Rear Cover Description 1 Remove end cover from rear cover See Fig 10 12 2 Remove through bolt from rotor shaft Apply a socket wrench on the head of through boit and hit the wrench handle with a hammer counterclockwise to loosen See Fig 10 13 3 Remove the four bolts which join the rear cover to the front cover 4 Take off the rear cover Use the special too REAR COVER PULLER to remove the rear cover See Fig 10 14 8 Insert the two bolts of the special tool into the thread holes of the rear cover b Apply the center bolt of the special tool to the center hole of the rotor shaft Tighten the center bolt to pull out the rear cover See Fig 10 15 Fig 10 14 Remarks 10 mm spanner or box wrench RGD2500 12 mm RGD3300 14 mm Box wrench Insert the two bolts suf ficiently and evenly or the thread holes may be damaged at removing Fig 10 15 Insert the through bolt into the rotor Do not give a strong hit shaft and tighten lightly on the rear cover boss or Hit on the boss at the top of the rear legs co
20. ction 9 7 DIODE RECTIFIER for the checking procedure 11 4 5 CHECK THE DC COIL Fig 11 6 Check the resistance between two brown leads from stator with a circuit tester RGD2500 120 V 120 V 240 V 0420 RGD3300 60 Hz 120 V 120 V 240 V Table 11 3 If the resistance reading is much larger or smaller than the specified value the DC coil of the stator is wl faulty Replace stator with a new one 56 11 5 OIL SENSOR TROUBLE SHOOTING 11 5 1 PRINCIPLE OF OPERATION The oil sensor for diesel engine consists of a pressure switch as a sensor section and a controller section The pressure switch detects the drop of oil pressure in the crankcase When the oil pressure falls down below the predetermined value 0 3 9 turns on the generate a signal to the controller section The controller which is powered by the DC coil sets up a delay for a few seconds for detecting signals transmitted during the period If more signals than the predetermined number are generated the controller feeds power to the solenoid which actuated the latch on the control bracket to release the control lever to shut the engine down 11 5 2 TROUBLESHOOTING 1 Check oil level Fill it up to maximum level if necessary 2 Check all wires to be connected properly If they possibly have breaks in connection the sensor will also malfunction 8 Checking the solenoid Measure the resistance between two leads from solenoid See Fig
21. d Rec 2 for the lower voltage can output only up 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 43 6 SAFETY PRECAUTIONS 1 Use extreme caution near fuel A constant danger of explosion or fire exists ww Do not fill the fuel tank while the engine is running Do not smoke or use opern 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 ex haust gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facilities 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 generator 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
22. e excessively heated and deteriorate the insulation possibly burning it out Table 7 2 shows cables and their allowable currents for your reference 2 Cable length a long cable is used a voltage drop occurs due to the increased resistance in the conductors de creasing the input voltage to the load electrical product As a result the load can be damaged Table shows voltage drops per 100 meters of cable 7 2 Gauge Resistance Voltage drop per 100 m wire element Ohm 100 m Vm Toa wa Lem zem pepe oue peres pr pev om o peres sem uv sv env ov ov pev o eee ser per env av SNC ETE Table 7 2 Allowable current A Sectional area mm Voltage drop indicates as V 1_x 100 meansresistance Q 100 m on the above table I means electric current through the wire A L means the length of the wire m The length of wire indicaters round length it means twice the length from generator to electrical tools 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 Dr ROBIN GENERATOR TESTER The Dr Robin generator tester is exclusively designed for fast easy diagnosis and repair of Robin generators The Dr Robin has the follow ing features 1 Functions of voltmeter frequency meter meggerte
23. er measure the resistance of the field coil at the terminals Q MODEL RGD2500 RGD3300 Table 9 2 NOTE 1 Because a diode is soldered to the coil ends at the terminals resistance may be measured only when tester probes touche the terminals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity NOTE 2 the circuit tester is not sufficiently accurate it may not show the values given and may give er roneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at embient temperatures different from 20 C 68 F 9 6 CONDENSER Use a Dr Robin in capacitance meter mode to check the capacity of condensers NOTE Be sure to discharge condensers by short ing condenser leads each other before checking their capacitance or the accurate reading cannot be obtained NORMAL CAPACITY OF CONDENSER RGD2500 RGD3300 Table 9 3 Fig 9 6 lf such an instrument is unavailable the condenser can be checked by replacing with a new If the generator performs good with new condenser the cause of trouble is defect in original condenser ww 26 9 7 DIODE RECTIFIER Circuit inside of the diode rectifiers is as shown in Fig 9 7 Check continuity between each terminal by using a circuit tester as shown in Fig 9 8 The rectifier is normal when condtinuity is as
24. es the indicated wattage during start up Example A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on A rated 3000 W generator can power two or three 400 W mercury lamps 4 Initially loaded motor driven appliances such as water pumps compressors etc These appliances require large starting wattage which is 3 to 5 times of running wattage Example A rated 900 W compressor requires a 4500 W generator to drive it NOTE1 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 con sumption so that the excess power generated by the generator can be used forother electrical appliances NOTE Motor driven appliances mentioned in Items 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 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 Power consumpition Efficiency Efficiencies of some electrical appliances are as follows Single phase
25. 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 7 amp Cor over in the specified gauge shown in the circuit diagrams 2 Install regulator 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 6E nut to the bolt which fixes the condenser bracket to the inside of the control box See Fig 10 51 4 Attach the control panel to the control box 4 screw 6 pes 1 2 1 5 N m 12 15 kg cm 0 9 1 1 ft lb Control box Condenser bracket Earth terminal Earth wires Fig 10 51 52 11 TROUBLE SHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING STATOR Remove control panel and disconnect black blue red and white wires at the connectors Measure the resistance between terminals on stator leads See Fig 11 1 Refer to Tabie 11 1 for normal resistance If sta tor is faulty repla
26. is mounted on the control panel Fig 9 1 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 removed and no continuity is found between these terminals the receptacles are also normal AC receptacle Fig 9 2B 9 3 No FUSE BREAKER No fuse breaker Check continuity between each of two terminals at the rear of the no fuse breaker while it is mounted on the control panel Normally there is continuity between each of the two when the no fuse breaker is on while there is no continuity when the no fuse breaker is off Fig 9 3 24 9 4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a Dr Robin or a circuit tester refering to the fol lowing table Fig 9 4 Specification Condenser Winding Blue Sky blue Yellow Yellow Black Orange om o RGD2500 35 RGD3300 Table 9 1 MODEL NOTE If the circuit tester is not sufficiently accurate it may not show the values given and may give erroneous readings Erroneous readings will also occur when there is a wide variation of resis tance among coil windings or when measurement is performed at ambient temperatures differ ent from 20 C 68 F 9 5 ROTOR ASSEMBLY 1 Using a Dr Robin or a circuit test
27. nd the ground ter minal then measure the insulation resistance An insulation resistance of 1 megohm or more is nor mal The original insulation resistance at the time of shipment from the factory is 10 megohm or more If itis less than 1 megohm disassemble the generator and measure the insulation resis tance of the stator rotor and control panel indi vidually STATOR 1 Measure the insulation resistance between BLUE lead and the core 2 Measure the insulation resistance between WHITE lead and the core 8 Measure the insulation resistance between YELLOW lead and the core 4 Measure the insulation resistance between BROWN lead and the core Fig 8 11 ROTOR Measure the insulation across one of the soldered terminals of the rotor andthe core CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Any part where the insulation resistance is less than 1MQ has fauity insulation and may cause electric leakage and electric shock Replace the faulty part 23 9 CHECKING FUNCTIONAL MEMBERS 9 1 VOLTMETER Check the the voltmeter if it is tumed on by apply ing specific voltage Voltmeter cannot be checked with circuit tester because its resistance is too large 9 2 AC RECEPTACLES Using a Dr a circuit tester check conti nuity between the two terminals at the rear of the VOLTMETER AC receptacles while the receptacle
28. o nuts are welded to the bottom side of the GENERATOR BASE 89 x 25 mm bolt and washer assy 2 pcs Bolt and washer Assy Clamp SN Clamp Battery cable Electric start model o Electric start model Fig 10 38 9 Fix the engine mount rubbers to the crank case base 8 flange nut 2 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft lb CAUTION Pay attention to the position of the mount rubbers Lift down the engine and alternator assembly and remove the chain block belt Fig 10 39 10 Attach two STOPPERs to the frame cover ing the both ends of the SHAFT STOPPER See Fig 10 39 6 x 16 flange bolt 2 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 11 Adjust the position of SHAFT STOPPER so as its both ends are placed in the center of the STOPPERs then tighten the flange nuts to fix the SHAFT STOPPER See Fig 10 40 Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft lb Fig 10 40 12 Attach the SIDE PLATE to the frame See Fig 10 41 Tighten the two black flange bolts tentatively 6 x 8 mm flange bolt black 2 pcs NOTE The flange bolts shall be tightened after the installation of the control box X 10 4 6 CONTROL BOX Mount the control box assembly to the frame Refer to Section 10 5 for disassembly checking and reassembly procedures of the control box
29. of the frequency meter s input voltage range Fig 8 4 19 4 CIRCUIT TESTER Used for measuring resistance etc Fig 8 5 5 MEGGER TESTER Used for measuring generator insulation re sistance Select one with testing voltage range of 500V 6 TACHOMETER Use the contactless type tacho meter 20 8 2 AC OUTPUT MEASURING LOAD TO AC RECEPTACLE Fig 8 8 Use a circuit like the shown in Fig 8 8 for measuring AC output A hot plate or lamp with a power factor 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 2 at the rated amperage and rated rpm Rated voltage 120 Voltage range 117 130 V 235 260V Table 8 2 8 3 DC OUTPUT MEASURING To DC Terminal Fig 8 9 Measurement of DC output is executed with the switch turned ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal NOTE If a battery is connected as a load to the generator the DC output voltage will increase by approximately 1 to 2 V Therefore carefully observe the electrolyte level and do not overcharge the battery 21 8 4 MEASURING INSULATION RESISTANCE Use a Dr Robin generator tester in megger tester mode or use a megger tester to check the insula tion resistance Connect a megger tester to one of receptacle output terminals a
30. ottom from the fuel pipe of fuel tank Loosen the clamp and pull out the fuel return pipe from the fuel injection nozzle Fig 10 4 6 Loosen the four 00115 and remove fuel tank fronr frame See Fig 10 5 10 mm spanner or box spanner Control Box 1 Remove control box from frame by re moving the three bolts joining the con trol box to frame and side plate See Fig 10 6 2 Put the control box with control panel Put a waste cloth under 10 mm spanner down the control panel to pro tect it 3 Remove the ground wire green yellow from the bottom of control box 4 Pull the bushing out from the control box See Fig 10 7 Wire harness is still con nected 10 mm spanner or box spanner z N Fig 10 7 31 Step Control Box 5 Pull the wire harness out from the con trol box Disengage the connectors to separate the control box See Fig 10 8 1 Remove side plate from frame i 2 Remove tank bracket from frame i 66 bolt 3 Remove stoppers from engine base of i 4 Remove the four nuts which join the i mount rubbers to the engine 5 Remove the two bolts which join the rear cover to the generator base See Fig 10 9 TANK BRACKET 86 BOLT 10 mm spanner or box spanner 12 mm spanner 12 mm spanner SIDE PLATE m 3 Pipe Frame 6 Lift up the engine and alternator assem bly using a chain blo
31. re to use the correct mount rubber for your generator Mount rubber 2pcs Generator E Mount rubber __ Pipe flame 2 Nut 2pcs Fig 10 34 42 4 Mount the GENERATOR BASE on the mount rubber attached to the frame at step 3 See Fi 8 13 9 10 35 11 8 13 7 8 flange nut 1 pce ibus l Generator base Mount rubber Mount rubber VIEW A Fig 10 35 5 Attach SHAFT STOPPER to the bottom of engine crankcase Tighten nuts tentatively NOTE Pay attention to the position of the SHAFT STOPPER The flange nuts shall be tightened after fine adjustment 6 Cover the both ends of SHAFT STOPPER with RUBBERs Push RUBBERS until they touch the crankcase See Fig 10 36 7 Lift engine and alternator assembly with a chain block and mount it to the frame Down the alternator first then the engine into the frame Lift the engine by approx 25 mm so as not to apply weight to the engine mount rubbers See Fig 10 37 Fig 10 37 8 Fix the legs of rear cover to the generator base Attach the 8 terminal of the grounding wires and the clamp to the right side leg of the rear cover at the same time In the case of electric starting model attach the 8 terminal of the grounding wires a clamp and the BATTERY CABLE to the right side leg and a clamp to the left side leg of the rear cover at the same time See Fig 10 38 NOTE Tw
32. 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 dual element 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 4 1 EXTERNAL VIEW No fuse breaker Speed control lever Rocker cover Full power switch Air cleaner Dual voltage type only Key switch Only for RGD3300 Recoil starter Fuel injection pump DC fuse DC output terminal Stop lever Earth terminal Fuel filter Oil filter Fuel cock Fuel gauge Electric starter Battery Only for RGD3300 Oil gauge Only for RGD3300 Eum 4 2 CONTROL PANEL RGD2500 RGD3300 60Hz 120V 60Hz 120V 240V TYPE Full power switch No fuse breaker Key switch Only for RGD3300 Voltmeter AC receptacle AC receptacle DC output terminal Earth terminal DC fuse 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and
33. specification number are stamped on the LABEL MODEL NAME stuck on the side wall of control box NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service Specifications label 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION Stator boit End cover Rear cover Stator complete Rotor complete SR ELLE uL Generator base Mount rubber Ball bearing Through boit Support ring Front cover Fig 5 1 5 2 FUNCTION 5 2 1 STATOR The stator consists 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 5 2 2 CONDENSER One or two condensers are installed in the con trol box and are connected to the condenser coil of the stator These condensers and condenser coil regulate the output voltage 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 Diode rectifier and Surge absorber inside of the insulator 5 2 4 DC FUSE 1 The 10 ampere DC fuse mo
34. ster capacitance meter and circuit tester are combined in one unit 2 Fast and easy readout by digital indicator 3 Built in automatic battery checker indicates the Fig 8 1 time to change batteries 4 Tester and accessories are installed in a handy sturdy case for easy carring SPECIFICATIONS Voltage 0 to 500 V AC Range Condenser Capacity 10 to 100 uF Accessories Test leads with needle probes 1 set Test leads with jack plugs 1 set Dimensions L x W x H 285 mm x 200 mm x 110 mm Table 8 1 The Dr Robin generator tester can be ordered from Robin generator distributors by the following part number Dr Robin Part Number 388 47565 08 If you do not have a Dr Robin generator tester use the instruments described in the following section for checking generator parts 18 8 1 2 INSTRUMENTS 1 VOLTMETER AC voltmeter is necessary The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows 0 to 150V Type with an output voltage of 110 or 120V 0 to 300V Type with an output voltage of 220 230 or 240V 0 to 150V 0 to 330V Dual voltage type 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 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful
35. tor 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 calculate the power consumption of each appliance or equipment by its type 1 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 2 Fluorescent lamps motor driven tools light electrical appliances 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 Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times lager than their running wattage Example A rated 250 W electric drill requires a 400 W generator to start it NOTE1 If a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps NOTE2 Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption effi ciency should be taken into account as explained in Item 5 on the following page 3 Mercury lamps with a smaller power factor Loads for mercury lamps require 2 to 3 tim
36. unted 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 Electric start model 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 appliance Table 5 1 shows the capacity of no fuse breaker by each spec and their object of protection MODEL SPECIFICATION NO FUSEBREAKER OBJECT or PROTECTION 80 Hz120 V eee utput amperag 60 Hz 120 V 240V 10Ax2 Total output amperage 60 Hz 120 V Total output amperage RGD3300 60 Hz 120 V 240V 14Ax2 Total output amperage 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 A total of six 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 correspond ing 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 amperage limits to prevent burning NOTE 1 If your generator has receptacles pecu liar to your country Table 5 2 does not G2 appl TWIST NOTE 2 The generator for U S
37. ver and two legs evenly with a plastic hammer to remove Fig 10 16 1 Remove the four bolts which join the stator to rear cover See Fig 10 17 2 Insert a small hook into the hole inside of the support ring and pull it out See Fig 10 18 If a small hook is unavailable remove Be careful not to give a the stator by the following procedure damage to the stator a Hold the rear cover and stator assem winding bly open side down b Place a cushion under the stator to protect it when dropped Hit on the bearing housing of rear cover with a wooden block SUPPORT RING Fig 10 17 Fig 10 18 5 3 Pull out the wires from rear cover See Fig 10 19 Stator SUPPORT RING STATOR REAR COVER 1 Insert the rotor puller shaft into the rotor and tighten the rotor puller bolt until the rotor comes loose See Fig 10 20 If the special tool rotor puller is un available take the following instructions to remove the rotor Lightly strike the rotor core with a plastic hammer in many directions and pull out the rotor from engine shaft See Fig 10 21 Rotor puller RGD2500 14 mm RGD3300 17 mm Take utmost care not to strike on the rotor wind ing or plastic insulator or permanent magnets Fig 10 21 Front cover 1 Remove the four bolts which join the and Front front cover to the engine Protector 86 bolt 4 pes
38. x to the starting motor Connect the pink lead to the terminal of the motor and attach the light green lead together with the BATTERY CABLE to the 680 bolt of motor 7 Clamp the wires of starting motor and oil sen sor at the rear panel of control box main bear ing cover and front cover See Fig 10 45 NOTE Take a enough margin in the length of wires between control box and alternator to allow the move of rubber mounted al ternator Clamp the BATTERY CABLE to the left side leg of the rear cover SAT 10 4 7 FUEL TANK 1 Attach the BRACKET TANK to the frame See Fig 10 46 6 x 16 mm flange 2 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 2 Connect fuel pipes to the bottom of the fuel Fig 10 46 tank Be careful of the direction of the BANJO See Fig 10 47 Banjo bolt Banjo Gasket Aluminium _ 4 5 Banjo boit Fuel filter Fig 10 47 ner Patan verme anam Reise mm time tomm s Reise mm Table 10 2 Use the correct clamps for each fuel pipe 3 Mount the fuel tank on the frame Apply RUBBER TANK s between side plate and tank and bracket tank and tank See Fig 10 48 Use black flange bolts to join them 6 x 18 mm flange bolt black 4 pcs Tightening torque 2 9 3 9 N m 30 40 kg cm 2 2 2 9 ft lb Fig 10 48 4 Connect fuel pipes between
Download Pdf Manuals
Related Search