rgd351/351d/500/500d generator service manual
Contents
1. 4 pcs 109 spring 4 pcs Tighteningtorque 550 to 700 kg cm 2 Install the adaptor in the blower housing making sure that its flat side is down and its fuel filter mounting boss on the alr cleaner side 8 x 25 mmbolt e 4 pcs SO sping WASHED RS 4 pcs Tightening torque 200 to 230 kg cm FUEL FILTER MOUNTING BOSS 5 LA FLAT SIDE Fig 10 24 10 3 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 Install the rotor and tighten the through bolt See Fig 10 25 Tighten the through bolt by striking the box spanner or socket wrench hard with a hammer clockwise NOTE If you have an impact wrench use it NOTE The rotor outside diameter and layer thickness are shown in 2 2 ROTOR The RGD Series has no fan for the rotor Fig 10 25 53 NOTE The shape of the through bolt is shown below 10 3 3 STATOR Install the stator in such a way that it matches the faucet joint of the front cover If it is difficult to install in place gently strike the stator core with a plastic hammer as shown in Fig 10 26 NOTE Never strike the coils NOTE Make sure that the control box leads are up the brush leads are out from the control box side and the leads to the diode out to2. 4 pcs UC 2 2 Connect the coupler the of the control box wr Push in the coupler all the way until it is locked See 52 i x Fig 10 40 1 3 Fasten the exciter with the on the back of the control box See Fig 10 41 Fig 10 39 1 5 No o7 Fig 10 40 Fig 10 41 64 10 3 8 FUEL TANK 1 Connect fuel pipe 5 complete and rubber pipe 6 mm inside diameter 12 mm outside diameter 160 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 5 complete to both ends of the banjo and tighten it with gaskets aluminum and banjo bolts FUEL TANK 1 HOSE CLAMP INSIDE DIA 7 8 GASKET ALUMINIUM 2 HOSE CLAMP INSIDE DIA 610 5 BANJO BOLT I 222223 we To NOZZLE FUEL PIPE 5 COMPLETE ol os BLOWER HOUSING a E di PURSE LOCK CLAMP Lo Ax N BRACKET N D EN 22 RUBBER 12 160 CRANKCASE 2 L WAN BANJO s N 2522224 e b 02227 w SS OR 2 2 S NG To INJE N PUMP CTION PU FUEL FILTER ASSY RUBBER 120 x 240 mm Fig 10 42 2 Install the fuel tank on the side plates with rubber washers between them 80K 15 mm bolt le sss is S ers 4 pcs 86
3. ENGINE ___ Lx YELLOW __ 2 sak WA EC NG YELLOW i MGI 77 for the U S A Canada is of the snape yn FOR ELECTRIC START CONTROL BOX ENGINE ERN Tug d U EC N jS M cct BROWN i s Choc y Cp KS m 2 PINK i 4 SM GRAY I KAN Sad ees The battery cords have a cross sectional area of 22 mm SYMBOLS Symbols M 5 Auxiliary Winding DC DC Winding FC Name of Parts AC Winding D Diode Stack Assy F Fuse Output Receptacle Total 15 Max AC Output Receptacle 110 120V AC Output Receptacle 220 230 240V REC REC 78 T DC Output Terminal M KS Name of Parts 5 Starting Motor Key Switch The wire symbols in the circuit diagrams signify as follows Use the wire sizes specified 0 75 1 25 mm 2 0 3 5 5 0 mm FUJI HEAVY INDUSTRIES LTD Engine amp Machinery Sales Dept 39th 55 Shinjuku Mitsui Bidg 2 1 1 Nishi Shinjuku Shinjuku ku Tokyo Japan TEL Tokyo 347 2414 6 TELEX 232 2401 CABLE A DRESS FUJIHEAVY TOKYO PRINTED IN JAPAN November 1986 CE I
4. 4800W Rated 4300W 50Hz Voltage P PE 240V NOTE These characteristics are typical Those of 60 Hz 120V and 50Hz 110V or 230V are similar to the above MODEL RGD500D Power 1 0 ENGINE y RR DY41D FREQUENCY Hz VOLTAGE V FREQUENCY Hz L VOLTAGE V 15 20 25 30 CURRENT 5 20 25 30 CURRENT 35 40 45 OUTPUT W OUTPUT W Output 5000W Rated 4500W Frequency 60Hz 120V 240V Output 4800W Rated 26 uqu kayaq aa 4300W u zu tale 50Hz 110V 220V NOTE These characteristics are typical Those of 60Hz 110 220V and 50Hz 120 240V are similar to the above 2 2 DC OUTPUT DC Voltage 12V DC Ampere 8 3A DC Output 100W VOLTAGE V w CURRENT While charging a battery the voltage sometimes shows about 20 higher than the characteristic measured by the resistance load because of the battery capacity value of charging electric current etc The above characteristic shows battery charging value and in case of resistance load it shows 20 lower than this characteristic NOTE It is possible
5. Check and correct load AC plug LM Correct wrong wiring No Fuse Breaker defective e Change No Fuse Braker Load defective Check and correct load Stator short or broken Stator replace Slip ring defective e Clean Replace Brush defective Check Replace Generator insulation e Replace defective Fan faulty cooling air passage blocked Check Correct Replace AVR defective e Replace 12 OPTIONS An electric starter castors etc are available as options for the RGD Series The procedures for adding options changing parts disassembly and reassembly are described below 12 1 ELECTRIC STARTER Robin generators with an electric starter are maker options because the crankcase must be specially modified to suit it The engine parts to be changed to meet the electric starter specifications include the crankcase ring gear and starter motor For these main engine parts refer to the SERVICE MANUAL for the Robin Diesel Engines DY30D and DY35D The parts peculiar to the RGD351 and the generator parts are explained below 12 1 1 FRAME The frame has a battery base for installing the battery and is partially changed to fasten it See Figs 12 1 and 12 2 a RGD351 RGD351D RGD500 RGD500D Nut is welded to the pipe frame for battery Nut is welded to the pipe frame Fig 12 1 Fig 12 2 73 12 1 2 CONTROL BOX The control box is additionally fitted with a key switch
6. 2 ELECTRIC STARTER TYPE 220V 230V 240V VOLTMETER NO FUSE BREAKER RECEPTACLE DC FUSE 10 STARTING SWITCH GROUND TERMINAL DC OUTPUT TERMINAL 11 3 HAND STARTER 110 120V VOLTMETER NO FUSE BREAKER NO FUSE BREAKER y AC RECEPTACLE 1 DC FUSE 10A AC RECEPTACLE 2 EARTH GROUND TERMINAL DC OUTPUT TERMINAL 4 ELECTRIC STARTER 110 120 VOLTMETER NO FUSE BREAKER AC RECEPTACLE 1 DC FUSE 10A AC RECEPTACLE 2 STARTING SWITCH EARTH GROUNDI TERMINAL DC OUTPUT TERMINAL 12 4 2 2 RGD351D 1 HAND STARTER TYPE dual voltage type FULL POWER SWITCH NO FUSE BREAKER AC RECEPTACLE 3 POWER SWITCH LZ D E DC FUSE 10A AC RECEPTACLE 2 AC RECEPTACLE 1 EARTH GROUND TERMINAL DC OUTPUT TERMINAL 2 ELECTRIC STARTER TYPE dual voltage type FULL POWER SWITCH VOLTMETER NO FUSE BREAKER AC RECEPTACLE 3 DC FUSE 10A AC RECEPTACLE 2 STARTING SWITCH AC RECEPTABLE 1 EARTH GROUND TERMINAL DC OUTPUT TERMINAL 13 3 HAND STARTER 110 120V VOLTMETER NO FUSE BREAKER RECEPTACLE 1 DC FUSE 10A RECEPTACLE 2 EARTH GROUND TERMINAL DC OUTPUT TERMINAL 4 ELECTRIC STARTER 110 120V VOLTMETER NO FUSE BREAKER RECEPTACLE 1 RECEPTACLE 2 DC FUSE 10 STARTING SWITCH EARTH GROUND TERMINAL DC OUTPU
7. 5 4 3 FUEL PIPING A fuel filter is attached to the adaptor hose to which the fuel pipe air vent pipe and return pipes are also connected RETURN PIPE GASKET FUEL PIPE FUEL FILTER ASSY 5 4 4 HANDLE BRACKET The handle bracket is secured to the crankcase and blower housing boss so that the starting handle can be stored The elec tric starter type is also provided with the starting handle and bracket and therefore can be started both electrically and by cranking BRACKET BUSH STARTING HANDLE lt DL 228 5 Fig 5 21 27 5 4 5 SPEED CONTROL Generator speed can be easily changed by means of the speed control GASKET muffler CONTROL PANEL COMPLETE lt AIR CLEANER MOUNTED SPEED CONTROL 2 COMPLETE CONTROL SPRING 2 1 WASHER KNOB LINK PIVOT lt N Can To SPEED CONTROL LINK COMPLETE 224 SPEED CONTROL 1 Fig 5 22 28 SAFETY PRECAUTIONS Use extreme caution near fuel A 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 Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oil cloth straw trash and any other inflammables near the gene
8. Sub coil broken broken 69 Remedy Replace Wire correctly Replace exciting coil Replace AVR Clean replace Check replace Replace Replace stator Replace stator Replace AVR 2 No DC output voltage Set generator to normal rpm 3 AC voltage Fuse checked Wiring checked Diode checked Check coil resistance Voltage too high Generator rpm checked OK Wiring checked Check No voltaqe Wrong wiring or some leads unconnected Characteristics faulty Resistance too high Resistance too low Resistivity value of DC coil is the value the middle of Blue Blue leads for which refer to Lthe Paragraph 9 1 1 Rpm too high Wrong wiring 70 Cause Remedy See 1 Voltmeter does not work Wrong wiring Diode broken DC coil broken DC coil short Rpm unadjusted Wrong wiring AVR broken e Check for cause and replace Wire correctly Replace e Replace stator Replace stator e Adjust Wire correctly Replace In case voltage is less than 10V voltmeter needle should not deflect Rpm unadjusted e Adjust Generator rpm checked Wiring checked Wire correct Wrong wiring Wrong wiring loose wire joints e Adjust OK Inter brush resistance check
9. NUT 86 4 pcs SPRING WASHER 4 pcs WASHER 4 pcs WASHER 16 pcs SPRING WASHER 16 pcs BOLT 89 16 pcs RUBBER V I 4 pes Fig 10 17 l cover Brush Holder 1 Remove the brush cover from the rear driver 2 Disconnect the terminal wires from the If rear cover is removed driver brush holder and remove the brush from the generator with 56 screw 2 pcs holder the brush will break Be sure to remove the brush holder holder See Fig 10 18 out removing the brush 50 Item 6 Rear Cover Fig 10 18 Procedure Loosen and remove the cover bolts 80 bolt 4 pcs 2 Turn up stator cover edge and up remove the stator cover 3 Remove the rear cover See Fig 10 19 Remove the rear cover by evenly and lightly tapping it with a plastic hammer 1 Remove the stator from the adaptor Lightly strike the outside of the stator core with a plastic hammer See Fig 10 20 2 Separate the stator and rear cover Disengage the connector and wire Remove the terminal catch in the connector by pushing it with some thing pointed like a needle and pull out the terminal See Fig 10 21 Fig 10 21 3 Pull out the wire from the grommet and rear cover 2 51 2 Fig 10 19 13 mm spanner box spanner Screwdriver Plast
10. and diode stack 12 2 CASTORS All the RGD351 and RGD351D models have holes drilled in their frame for installing castors in place of rubber mounts on the underside of the frame It is also necessary to change the rubber mounts because vibration varies due to the castors Therefore the castors are maker options Models RGD500 and RGD500D are all originally furnished with casters 13 CIRCUIT DIAGRAM RGD351 110V 120V GENERATOR CONTROL BOX 21 BROWN E FC B AVR LGREEN r p ORANGE BROWN WHITE nA YELLOW 75 RGD351D 110 220V 120 240V GENERATOR CONTROL BOX BLACK 5 L 8 YELLOW RGD500 110V 120V GENERATOR CONTROL BOX BLACK MC 3 YELLOW WHITE BROWN B SC E 2 P B Im L GREEN BLUE AND ORANGEF DC lt p p as ccr ccm BROWN WHITE _ ENGINE M YELLOW EC S gt N YELLOW 708 XD E KN ee i C D aces ae ee 76 RGD500 220V 230V 240V GENERATOR CONTROL BOX ____ _ RED NEB YELLOW Ti YELLOW RGD500 110 220V 120 240V GENERATOR CONTROL BOX _ BLACK FPSw gt x h gt YELLOW SERES is BROWN E sc C po Bi REC L GREEN l
11. banjo to the injection pump A gas ket must be placed on each side of the banjo Use hose clamps 10 5 mm in inside diameter Finally clamp the pipe to the crankcase 4 Fasten the handle bracket to the crankcase 10 4 CONTROL BOX CHECK DISASSEMBLY and REASSEMBLY 10 4 1 CHECK Check the wiring after removing the control box from the pipe frame and box panel B from the back of the control box 10 4 2 DISASSEMBLY 1 Remove box panel B from the back of the control box See Fig 10 43 2 Disconnect the connector and automatic voltage regulator AVR from box panel B 66 Fig 10 43 3 Disconnect the wires Pull out the 4P connector by pushing the lock as shown in Fig 10 44 Disconnect the primary exciting wires two yellow ones by pushing the terminal catches inside the connector with 7 PULL WIRE DEI PUSH gun something pointed like a needle until the terminals come off See Figs 10 44 and 10 45 NOTE White wire 19 has not been used since March 1983 when it was replaced by body grounding BROWN 220 230 240V YELLOW YELLOW BROWN GREEN pre ORANGE WHITE RED BROWN _ D type 110 120 YELLOW YELLOW BROWN GREEN mg ORANGE WHITE RED YELLOW BROWN GREEN ORANGE WHITE BROWN GREEN ORANGE WHITE RED WHITE 220 230 240V Start D type 110 120V Electric 220 230 240 YELLOW YEELOW PINK GREY D type 1
12. if for continuity If the fuse carries current the fuse holder is faulty If the fuse carries no current replace it with a fuse of the correct capacity and check the fuse holder again for continuity Fuse capacity is 10A NO FUSE BREAKER TESTER 41 Fig 9 6 9 6 RECEPTACLE and PLUG Check the current carrying parts of the receptacles and AC plugs and their leads and plastic parts for burns 9 7 VOLTMETERS Apply AC voltage to a terminal and check if the voltmeter AC reads normal VOLTMETER Fig 9 8 9 8 DIODE STACK ASSEMBLY Fig 9 9 The internal circuitry of the diode stack assembly is as shown in Fig 9 9 Check inter terminal continuity with tester as shown in Fig 9 10 to see that the results are as shown in Table 9 8 TERMINAL CURRENT TERMINAL NOTE B Current flows from to B C D Current does not flow from to D Check both terminals Table 9 8 42 9 9 PRIMARY EXCITING CIRCUIT As described in 5 3 DESCRIPTION of GENERATOR OP the primary exciting coil is in the magneto mounted on the engine and the AVR has a circuit for it 9 9 1 EXCITING COIL The normal inter terminal resistance of the exciting coil is about 2 to 3 ohms Its voltage at the rated rpm is about AC 10 to 20V Check the resistance and voltage with a tester to see if they meet these requirements 9 9 2 OTHERS Fi
13. pcs used box spanner 2 Remove the nuts and bolts that fasten the generator and frame together RGD351 RGD351D i 1 Remove the nuts that fasten the Bolts are welded to 13 mm spanner or bottom of engine to mount brack mount bracket box spanner et A See Fig 10 15 Remove the earth wire from 80 nut 4 pcs i 2 Remove the bolts that fasten the Nuts are welded to 13 mm spanner or bottom of generator to the gen the generator base box spanner erator base l 80 nut 2 pcs RGD500 RGD500D Remove the bolts that fasten the Nuts are welded to 13 mm spanner or engine generator to base the bottom of base spanner 89 6 pes 3 Lift the generator with a chain block Be careful to keep the and remove it from the frame belt in place and gen See Fig 10 16 4 Remove the rubber mounts and castors from the frame mRGD351 RGD351D MOUNT BRACKET A 2 pcs s VN BOLT pos RUBBER 4 ps SPRING WASHER 4 pcs WASHER 4 pcs MOUNT BRACKET 2 5 EARTH WIRE WASHER SPRING WASHER 86 14 pcs NUT 86 14 pcs 4 WASHER 80 14 pcs SPACER RUBBER MOUNT 49 Order Item Procedure 460500 RGD500D EARTH WIRE Nut is welded to the pipe frame
14. point shown in Fig 10 36 Use a brass screw for this purpose SOK IU mim iuo ss us EE EATEN Sa usis 1 pce Sospringwasher 1 pce 3 4 5 6 Install the rubber vibration isolators Fasten four rubber vibration isolators to the pipe frame The pipe frame has nuts welded to it so turn the rubber vibra tion isolators in Install the engine base a Tighten four bolts in the tapped holes in the engine base where the engine is to be installed BOSOM eee we 4 pcs b Install the engine base the rubber vibration isolators attached the pipe frame and tighten it with flange nuts LT TUE 4 pcs Install the engine and generator assembly in the pipe frame a Lift the engine and generator assembly with a chain block and lower it making sure that the bolts fasten in Step 4 a and fit to the engine base mounting holes NOTE Be careful of maintaining balance b Place two spacers under each side of the generator so that it is level with the engine ped x Fig 10 37 c Align the holes in the generator base and spacers with those in the engine base and lightly tighten the bolts from above Then lower the chain block all the way and remove the belt from the chain block Tighten the generator base bolts Nuts are welded to the bottom of the engine base SoxoUmmDolt xxl Ebert E eb 2 pcs qno ae dco RUE dp pti
15. spring washer 4 pcs 4 pcs 8 15 mm bolt and washer assembly 4 sets 3 Connect the fuel pipe a Install the fuel filter assembly on the boss on the side of the adaptor generator 8 x 65 mm bolt l 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 correct point Then secure the pipe with the purse lock NOTE Connect the shorter pipe of fuel pipe 5 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 5 complete is 7 8 mm in inside diameter Connect the longer pipe of fuel pipe 5 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 240 mm long and clamp it Connect the other end of the pipe to the fuel filter and clamp it Connect the
16. to take out both AC and DC output simultaneously up to the rated output in total 3 FEATURES 1 10 11 Compact Lightweight Robin air cooled diesel engine and revolving field generator designs provide added output per weight and economical operation Good Fuel Economy Direct injection combustion provides marvelous fuel saving Long Life and Safe Operation Compact and smooth running diesel engine lasts much longer than same size gasoline engine Volatility of diesel fuel is far lower than that of gasoline which makes it safer to handle store and use Centralized Control A large sized control box is employed and the switches voltmeter and receptacles are located together on the front panel for easy operation Large 16 Liter Fuel Tank 16 liter 4 2 gal capacity fuel tank is provided for 13 hours of operation for Model RGD351 or 9 hours for Model RGD500 at the 50Hz rated output Fuel gauge is located on the tank cap for easy monitoring of the fuel level Simple and Easy Operation Easy engine starting by automatic decompressor Controls and switches are within easy reach from the front operator s position Quiet Operation Quiet operation with Robin s newly designed air cooled diesel engine Low noise and less vibration for quiet and smooth operation Small Voltage Fluctuations by AVR Automatic Voltage Regulator The automatic voltage regulator automatically adjusts the exciting current to ho
17. 0D use a special engine and special engine parts These parts can be classified into generator drive parts exciting and charging parts fuel piping parts handle bracket parts and speed control parts Each of these categories is explained below 5 4 1 GENERATOR DRIVE The flywheel has a driving shaft to transmits power from the engine to the generator The driving shaft is tapered to be coupled to the generator rotor shaft The adaptor is fixed to the blower housing for mounting the generator stator BOLT 10o x 30 mm DRIVING SHAFT OLT x 25 mm i i SPRING WASHER 10 ADAPTER SPRING WASHER 80 j Fig 5 18 5 4 2 EXCITING and CHARGING The exciting coil for primary excitation and the charging coil for charging the starter battery for the electric starter type are installed in the bearing holder Magnets for power generation are installed on the flywheel There are a total of four leads two yellow leads for exciting and the other two for charging The hand starter type uses only the two yellow leads for excita tion not the other two for charging The electric starter type uses all the four leads NOTE This coil exciting and charging feature is peculiar to the Robin generators Be careful not to attach different parts because the automatic voltage regulator may break down as a result GENERATOR COMPLETE PES N 2774 Ww 5 k A M Y SAN AS N te NN
18. 1 5 ASSEMBLY 9 1 1 MEASURING WINDING RESISTANCE Check the resistance of the leads from the stator with a tester See Fig 9 1 Check all the leads which are shown by type in the tables below Any lead which is inactive is faulty NOTE Testers are not so accurate that some margin of er ror must be taken into account when reading the tester against the values shown in the Tables It is measured by wheatstone bridge in regularly In this STATOR ASSY TESTER time please care enough not to exist the contact registance RGD351 RGD351D e 50Hz 220V 230V 240V Wire color RED GREEN Wire color BLUE WHITE 149 27 9 BLUE 020 50Hz 110V 50Hz 110V 220V 50Hz 120V 240V WHITE 072 270 BLACK e60Hz 110V 60Hz 120V 60Hz 110V 220V 60Hz 120V 240V WHITE 050 2 2 2 BLACK 050 e 60Hz 220V Wire color RED GREEN Wire color BLUE WHITE 10 Q 22 Q 37 Fig 9 1 Wire color BLUE BLUE 0 2 2 xRGD500 RGD500D e 50Hz 220V 230V 240V Wire color RED GREEN WHITE 079 e 50Hz 110V 50Hz 110V 220V 50Hz 120V 240V Wire color RED GREEN WHITE 0 35 Q BLUE 0140 BLACK 0 35 Q BLUE 0 14 Q e60Hz 110V 60Hz 120V 60 2 110 220 60Hz 120V 240V e 60Hz 220V WHITE 40 139 9 1 2 MEASURING INSULATION RESISTANCE Refer to 8 4 MEASURING INSULATION RESISTANCE 9 2 ROTOR ASSEMBLY 9 2 1 WINDING RESISTANC
19. 10 120 YELLOW YELLOW PINK GREY Table 10 4 4 Install the connector which was wired to control panel B in Step 3 b If your Robin generator has an electric starter install the diode and wire it Install the exciter coil wire clamp on the side opposite to control panel B 5 Install control panel B on the control box AO x TO qn Socios qao Mere td 6 pcs 68 11 TROUBLE SHOOTING When the generator is in trouble check carefully the trouble part and remedy it 1 Voltmeter does not work Normal voltage at receptacie NO Wire checked OK Primary exciting circuit checked YES See 9 9 Primary Exciting circuit OK Inter brush resistance checked OK Main coil resistance checked OK Sub resistance checked OK Check AVR See the description of winding resistance in 9 1 See the description of winding resistance in 9 1 Cause Voltmeter defectiva Wrong wiring Wrong wiring some leads unconnected Exciting coil defective Primary exciting circuit in AVR defective Resistance outside range of 5 10 52 Slip ring checked Slip ring defective Inter slip ring OK resistance checked Brush defective Check winding resistance Resistance outside range of 5 10 50 Field coil short or broken Main coil broken
20. 1000W can light ten 100W lamps Fluorescent lamps mercury lamps etc with a smaller power factor Select a generator with a rated output equivalent to 1 2 to 2 times the power consumption of the load Example generator with a capacity of 100W to 160W is necessary for lighting a 80W fluorescent lamp generator with a rated output of 1000W can light 6 to 10 fluorescent lamps of 40W NOTE Wattage of the fluorescent lamp generally does not indicate the power consumption but indicates the output of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption or input power effi should be taken into accounts as explained in 5 on the following page Electric tools etc that are driven by a motor Power 1 2 to 3 times the power consumption of a motor driven tool is required for starting so select a generator with a maximum output 1 2 to 3 times the power sonsumption of the load Example 300W motor driven drill requires a generator with a maximum output of 400 to 900W or more Water pumps compressors etc that are driven by a motor which is loaded at starting 3 to 5 times the power consumption of the load is necessary for starting so select a generator with a maximum output 3 to 5 times its power consumption Example A water pump with a power consumption of 40W requires a generator with a maximum output of 1200 to 2000W or more NOTE 1 Motor driven products mentioned in Ite
21. 2 pcs 89 washer special size 2 pcs d Tighten flange nuts on the bolts under the engine 86 flange nut Install side plate A and B and box stay a Attach the nameplate that shows the product name Robin Generator and its model name to the front control side and the blank plate to the rear Use black bolts for this purpose The pipe frame has nuts welded to it 66x 13 mm bolt black 8 pes b Fasten the box stay to the side plates The stay for mounting the control box should be up front See Fig 10 36 The side plates have nuts welded to them 6 x 12 mm flange nut 2 pcs 62 10 3 7 CONTROL BOX Install the control box as subassembly in the frame The subassembly procedure is described in 10 4 CONTROL BOX CHECK DISASSEMBLY and REASSEMBLY The RGD351 and RGD351D differ in the way of installing the control box depending on whether they are fitted with optional castors m Standard without castors 1 Lift the pipe frame with a chain block fasten only one rubber mount to the front right hole in the control box and tighten the other three points with bolts spacer and washer must be placed between the rubber mount and pipe frame The box base has nuts welded to it See Fig 10 38 80 520 mm bolt 2 v ye ee um 2 pcs 80 spring washer 2 pcs 80 WASHER ie tossing Bek 2 p
22. 25 Robin Generator Model RGD351 RGD351D RGD500 RGD500D ISSUE EMD GS0054 Technical Data amp Overhaul Instructions CONTENTS Section Title Page SPECIFICATIONS Section 10 Title RGD351D RGD500 RGD500D Type Revolving Field Self Exciting 2 Single Phase Frequency 50Hz Output 110 39 1A _ 220v 19 5 Rated dl 120 35 8A _ Voltage 240V 1 7 GENERATOR Power Factor DC Output 12 8 100W Voltage Regulator gt AVR Automatic Voltage Regulator Voltage Regulation i Within 3 Type Robin Air Cooled 4 Diesel Engine Mode 0 DY41D Displacement 299 18 27 412 25 14 cu in Output 6 0 Ps 3000 rpm 6 5 Ps 3600 rpm 8 0 Ps 3000 rpm 8 5 Ps 3600 rpm Fuel Automotive type Diesel Fuel Fuel Tank Capacity 16 Liters 4 2 U S gal 1 2 liters hour 2 5 U S pints 50Hz 1 7 liters hour 3 6 U S pints Fuel Consumption Ratio 1 5 liters hour 3 2 U S pints 60Hz 2 0 liters hour 4 2 U S pints 60Hz ENGINE Oil Capacity 1 0 liter 2 1 U S pints 1 1 liter 2 3 U S pints Revolution 50Hz 3000 rpm 60Hz 3600 rpm Starting System Hand Crank Electric Starter Optional Length 661 mm 26 in 747 mm 29 4 in 661 mm 26 0 in 747 mm 29 4 in Dimensions Width 486 mm 19 1 in Generator with Electric Star
23. 51D and RGD500 RGD500D have an exciting coil for primary exciting action to eliminate such a phenomenon The primary exciting action of the new type is explained below When the generator is started the permanent magnet on the engine rotates to generate a voltage in the exciting coil This voltage is regulated by a diode in the AVR to feed a current to the generator field coil FC See Fig 5 13 The rotor is turned an electromagnet by that current and rotates so that voltages are generated in the stator coils main coil sub coil and DC coil The voltage generated in the sub coils is operated by the AVR to feed a current to increase the field coil current See Fig 5 14 As a result the rotor mugnetism increases This operation is repeated to generate the rated voltage at SOHz or 60Hz in the main coil and DC coil 5 3 2 VOLTAGE REGULATING MECHANISM Connect a load to the AC output terminal and increase cur rent Output voltage varies as shown in Fig 5 15 depending on whether an automatic voltage regulator is used or not The operation of the AVR is explained below When an AC output is taken the engine is loaded and its rpm falls Also the AC voltage falls due to the voltage drop caused by the internal resistance of the coils The AVR de tects this voltage drop and its built in SCR automatically increases the current flows to the field coil As a result the rotor magnetism increases the voltage fallen by the load current is ra
24. DC OUTPUT MEASURING DC TERMINAL Fig 8 8 Switch the power on when 1 45Q resistance attached as a load check that the voltage is within the range of 13 to 11V NOTE a battery is connected as the load the output voltage increases by about 1 to 2V possibly causing battery over charge Control battery liquid level during charging to prevent overcharging 8 4 MEASURING INSULATION RESISTANCE Connect a megger tester to one of the two receptacle out put terminals and the ground terminal then measure the insulation resistance An insulation resistance of 1 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 generator and measure the insulation resistance of the stator rotor and control box individually 35 eSTATOR Measure the insulation resistance between the red or white coupler from the stator and the core Fig 8 10 eROTOR Measure the insulation resistance between the core and one of the slip rings of the rotor Fig 8 11 eCONTROL BOX Measure the insulation between the live parts and the cas ing or grounded part Close the no fuse breaker first then measure it Any part which has an insulation resistance of less than 1 megohm has a faulty insulation which can cause electric shock or leakage Replace such parts 36 9 CHECKING FUNCTIONAL MEMBERS 9
25. E MEASURING Check the resistance between the two slip rings with a test er See Fig 9 2 The resistance is normal if it is anywhere from 5 ohms to 10 5 ohms 9 2 2 MEASURING INSULATION RESISTANCE Refer to 8 4 MEASURING INSULATION RESISTANCE 9 2 3 CLEANING SLIP RINGS The slip ring surfaces must be uniformly bright Slip rings showing black spots excessive wear or uneven wear must be repaired stained slip ring lowers generator efficiency and output voltage Polish the slip rings with fine sandpaper while turning the rotor until rough spots disappear Care should be taken not to touch the rotor coils with the sand paper See Fig 9 3 38 Wire color YELLOW BLACK 0292 Wire color BLUE BLUE 0 129 BLUE 0 12 Q ROTOR SLIP RING TESTER Fig 9 2 SLIP RING SANDPAPER Fig 9 3 9 3 BRUSHES The brushes must be smooth where they contact the slip rings If not polish smooth the brushes with sandpaper brush that is not smooth produces arcs between the brush and slip ring leading to possible damage Usable brush lengths are from 5 mm to 15 mm as shown in Fig 9 4 A brush shorter than 5 mm must be replaced because decreas ed contact pressure between the brush and slip ring lowers generator efficiency and output voltage 9 4 AVR AUTOMATIC VOLTAGE REGULATOR AVR trouble may be identified by simply looking at the AVR or by checking the inter lead resistance with a test
26. N WIRE Fig 10 32 NOTE If the brush is placed aslant the brush holder may break under screw pressure or the brush may break when the engine is started After installing the brush holder measure the brush terminal resistance with a tester The brush is properly installed if the terminal resistance is anywhere about 5 to 10 5 ohms 2 Connect the wires to the brush holder Connect the green wire to the stator side and the brown wire to the bearing side of the brush holder See Fig 10 32 3 Install the brush cover SOK 10 mm screw 2 pcs 57 10 3 6 860351 RGD351D RUBBER BOLT 5 x 13 mm SPECIAL SIZE WASHER CASTOR ee WASHER 8 3 SPRING WASHER 60 Fig 10 33 58 MOUNT ns RUBBER V I BOLT 8 20 2 SPRING WASHER 8 LWASHER 8 BOLT 80 25 mm 4 SPRING WASHER 89 Speci al size PIPE FRAME 1 2 3 4 Attach two mount brackets Bs to the pipe frame See Fig 10 33 Tighten the earth wire together with the mount bracket bolt that is farthest from the control box SOc 20 mm bolt aise ssh yu te sam uH 4 pcs 86 spring washer 4 pes Bo washer a A 4 pcs SO TUD cess rou pupas C QUSE 4 pcs 8 springwasher 4 pcs SO was
27. T TERMINAL 14 4 2 3 RDG500 1 HAND STARTER TYPE 220V 230V 240 VOLTMETER RECEPTACLE 2 NO FUSE BREAKER DC FUSE 10A RECEPTACLE 1 i EARTH GROUND TERMINAL DC OUTPUT TERMIANL 2 ELECTRIC STARTER TYPE 220V 230V 240V VOLTMETER RECEPTACLE 2 NO FUSE BREAKER DC FUSE 10A RECEPTACLE 1 STARTING SWITCH EARTH GROUND TERMINAL DC OUTPUT TERMINAL 15 4 2 4 RGD500D 1 HAND STARTER FULL POWER SWITCH VOLTMETER RECEPTACLE 3 NO FUSE BREAKER FULN POWER SWITCH DC FUSE 10A RECEPTACLE 2 RECEPTACLE 1 GROUND TERMINAL DC OUTPUT TERMINAL 2 ELECTRIC STARTER TYPE FULL SWITCH VOLTMETER NG FUSE RECEPTACLE 3 NO FUSE BREAKER DC FUSE 10A RECEPTACLE 2 STARTING SWITCH RECEPTACLE 1 EARTH GROUND TERMINAL DC OUTPUT TERMINAL STATOR COMPLETE BRUSH HOLDER REAR COVER SHAFT STATOR COVER FLYWHEEL COVER BOLT SLIP RING STATOR COMPLETE ROTOR COMPLETE 46 lt 2 lt a 27 ons So M n O SS L ES HMA NI gt WAAAY NS 2722 DRY 1 COMPLETE BALL BEARING ADAPTER THROUGH BOLT RUBBER MOUNT DRIVING SHAFT NOILONYLSNOD 1 6 NOILONN4A Pue NOILONYLSNOD S 5 2 FUNCTIONS 5 2 1 STATOR The stator consists of lam
28. ammeters are 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 and 100A The DC ammeter range is approximately from 0 to 15A 8 1 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter input voltage range 33 EOR ar EI Fig 8 1 Fig 8 2 Fig 8 3 8 1 4 TESTER Used for measuring resistance etc 8 1 5 MEGGER TESTER Used for measuring generator insulation resistance Select one with testing voltage range of 500V 8 1 6 TACHOMETER There are various types of tachometers such as contact less contact type and strobe type The contact type can be used only when the generator and engine have been dis assembled The contract less type is recommended 34 Fig 8 4 ie CONTACT TYPE STROBE TYPE Fig 8 6 8 2 AC OUTPUT MEASURING SWITCH O To AC RECEPTACLE CR e Fig 8 7 r gt 0006 Use circuit like the shown Fig 8 7 for measuring output hot plate or lamp with power factor of 1 0 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 amper age and rated rpm Rated voltage 110V 120V 220V 230V 240V Voltage range 108 115V 118 125V 218 225V 228 235V 238 245V Table 8 1 8 3
29. ank 1 Discharge fuel from the tank 1 Turn the fuel cock to OFF S 2 Disconnect the rubber pipe from Do not lose the gasket 17 mm spanner the injection pump See Fig 10 1 3 Turm the fuel cock to OPEN O Wipe off spilt fuel to discharge the fuel Disconnect the fuel pipe and return pipe from the tank bottom See Fig 10 2 1 Remove the fuel pipe clamp and Phers pull the fuel pipe off the tank 2 Remove the banjo bolt that fastens i Do not lose the gasket 12 mm spanner the return pipe Remove the fuel tank 13 mm spanner or After removing the bolts remove the box spanner fuel tank See Fig 10 3 8 bolt 4 pcs Remove the fuel filter Pliers 1 Remove the air vent pipe clamp and pull out the pipe See Fig 10 4 2 Remove the fuel filter bolts and 12 mm spanner or and the fuel filter or box spanner 44 EM Tia 2 Battery 1 the battery cord First dis careful not to short Only electric connect the negative end of the battery starter type i cord and then the positive end of it 2 Remove the battery 10 mm spanner or Remove the two nuts that fasten the box spanner I battery and take off the battery battery bolts and battery 6 nut 2 pcs 3 Remove the battery frame from the It is not necessary to pipe frame remove the battery base from the battery frame 10 mm sp
30. anner or i box spanner 13 mm spanner sRGD351 RGD351D A 4 6 4 WASHER 4 pcs SPRING WASHER 4 pcs BOLT 8 2 pcs SPRING WASHER 2 pcs WASHER 2 pcs Nuts are welded to the bottom of frame Fig 10 5 _ 45 Order Item Procedure 500 RGD500D Remarks 10 mm spanner box spanner 13 mm spanner lt Control Box RGD351 RGD351D 1 Disengage all connectors from the rear of the control box PULL OUT 2 Remove the guide that binds the control box top to side frame See Fig 10 8 S 2 pcs 46 BOLT 60 4 pes ON SPRING WASHER 4 pes WASHER 4 pcs Nut is welded to the frame The connectors are a lock type so push and pull out as shown in Fig 10 7 8 mm spanner or box spanner 3 Remove the control box from the frame 1 Place spacer under the con trol box end of the frame and raise the frame aslant See Fig 10 9 Remove the three bolts and Rubber mounts can be 13 mm spanner rubber mounts from the removed by turning frame under the control If castors are provided box remove the four castor 8 3 pcs mounting bolts Pull out the control box and remove the clamp that fastens the exciting coil leads on the back panel Fig 10 10 If
31. ations lower lines for the 110 120V specifications and the dual voltage type Table 9 1 MODEL RGD500 RGD500D Tester polarity 1 Yellow One wire 002 lead resistance 300K 7 Another existence Yellow One wire 00 lead resistance 150K 250KQ 10K 70KQ Another existence 220K 250KQ 300K22 110 125 150KQ2 ar 220K 250KQ i co lead resistance 721 10K 125KQ2 existence 330K 500KX2 10 70 lead resistance 150 250 10 70 existence 150 250KQ 10K 40KQ Upper lines the 220 230 240V specifications lower lines the 110 120 specifications and the dual voltage type Lead resistance existence does not change so big in the amplitude degree of the hand when change the range of the tester Table 9 2 40 9 5 FUSE HOLDER NO FUSE HOLDER 9 5 1 NO FUSE BREAKER Turn the power switch off and check continuity If no cur rent flows it is normal Then turn the power switch on and check continuity again If current flows it is normal If the breaker is a two pole type the two pairs of terminals must carry current 9 5 2 FUSE HOLDER Check that fuse is in the fuse holder and check its conti nuity with tester See Fig 9 7 If it carries current it is normal If there is no current take the fuse out and check
32. castors are provided remove 13 mm spanner or all castors by lifting the frame box or placing a spacer under the 2 pcs frame Completely pull out the control box CONTROL BOX BOX GUIDE Fig 10 9 47 Order Item Procedure Remarks 3 Control RGD500 RGD500D i 1 Disengage all connectors from the The connectors a lock i of the control box Fig 10 11 type so push and pullas shown in Fig 10 11 lt PUSH R PULL OUT 2 Remove the control box from the frame 1 Remove the bolts from the con 10 mm or trol box side See Fig 10 13 box spanner bolt 4 pcs Pull out the control box and re move the clamp that fastens the exciting leads on the back panel See Fig 10 12 Fig 10 11 Fig 10 12 Completely pull out the control box On page 45 and in the Order 2 it is mentioned that the bat tery be removed However in case of the control box being faulty and or in the case of only checking the brush it is un necessary to remove the battery in advance for taking out the control box a APARRA A iro a 212 48 Order Item Procedure 4 Pipe Frame 1 side plates and Black coated bolts are 10 mm spanner or 6 boli 8
33. ded the rated output can be outputted by combining the outputs of the two 120 receptacles RGD351 RGD351D and RGD500 RGDSOOD shown Fig 5 17 change the connection of MC and MC to series or parallel with the full power switch When the full power switch is shifted to the 120V 240V position the switch is up as indi cated by the solid line in Fig 5 17 and connects MC and in series as shown in Fig 5 16 In this case voltages up to the rated level can be outputted from Receptacle 3 and voltages up to one half 120V of the rated voltage from Receptacle I and Receptacle 2 If the rated current is over 30A at 120V up to 15 can be outputted from Receptacle 1 as the com bined output of the two When the full power switch is shifted to the 120V position the switch is down as indicated by the broken line in Fig 5 17 and connects MC and MC parallel to each other In this case no 240V can be outputted and Receptacle 3 cannot be used Receptacle 2 which outputs 120V can generate up to the rated power and Receptacle 1 can output up to 15A in total or up to 30A if the rated current is over 30A at 120V The above is summarized in Table 5 6 Use the full power switch as suitable to the voltage and input ratings of the electric devices 25 5 4 ENGINE PARTS CHANGED For a detailed description of the engine refer to the Service Manual for Robin Diesel Engines DY30 and DY41 Models RGD351 RGD351D and RGD500 RGD50
34. e and a 300V maximum type The voltmeter indicates genera tor output voltages The generators with a generated voltage of 110V 120V type and dual voltage type use the 150V maximum type voltmeter and those of 220V 230V and 240V type specifications use the 300V maximum type volt meter Fig 5 5 RGD351 RGD351D 20 gt RGD500 RGD500D Fig 5 6 300 V MAX 20 v 230 V 240 v A MAAA Na ASA Fig 5 7 50 V MAX 1119 V 120 Vv 5 2 6 NO FUSE BREAKER The no fuse breaker prevents AC output overcurrent and shortcircuit overcurrent Some models have one no fuse breaker and the other have two The single no fuse breaker protects the generator from maximum current and the double no fuse breakers protect the generator from maximum current and its receptacles If the generator is operated for long above the maximum current the internal temperature of the generator abnormal ly rises to cause insulation deterioration burning electric NO FUSE BREAKER USE HOLDER shock and electric leakage The no fuse breaker protects S the generator from such troubles The receptacles and AC Fig 5 8 plug have their own rated capacities Refer to 5 2 8 RECEPTACLES and PLUG STD SPEC If they are used above the rated current insulation deterioration buring electric shock or leakage can occur These troubles are prevented by the no fuse breaker Table 5 3 show
35. e drop occurs due to the increased resistance in the conductors so that the input voltage to the load electrical product decreases As a result the load can be damaged table 7 2 shaws voltage drops per 100 meters of cable Nominal cross Allowable of strands TD section current arand diaii Resistance j Current Amp No mm 2 100m 1A 3A 5A 8A 10 12 15A 30 0 18 2477 25V 8 125 50 0 18 1 486 1 6 7 54 12V 1 15V 18V I 37 0 26 0952 1V 3V 5V 8v 10V 12V 15V Voltage drop 45 0 32 0517 1 5V 2 5V i 4V 6 5 7 5V 70 0 32 0 332 2v 25 35 av Table 7 2 1 Voltage decrese indicates as V 300 xRxIx means resistance 12 100 on the above table I means electric current through the wire A means the length of the wire m The length of the wire indicates round length it means two times of the length from generator to electrical tools 32 8 MEASURING PROCEDURE 8 1 5 8 1 1 VOLTMETERS and DC voltmeters are necessary The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows 150 Type with an output voltage of 110 or 120V 0 10 300 Type with an output voltage of 220 230 240V 0 150 0 10 300 Dual voltage type The DC voltmeter range is approximately from 0 to 30 8 1 2 AMMETERS AC and DC
36. e similar to the above MODEL RGD351D oak Po ea Ceres Self Exciting 2 Pole Single Phase Power Factor 1 0 Engine DY30D Output 3700W 5 Rated 3300W gt 60Hz Volje Z u lt a eal eels 120V 240V c al 2k 1 2 O 1k lt gt Output Max 3500W Rated o va uu 3000W gt 50Hz a 110V 220V amp tc 3k 2k gt 22 lt TE gt NOTE These characteristics typical Those of 60Hz 110 220V and 50Hz 120 240V are similar 25 to the above 10 CURRENT MODEL RGD500 TYPE Self Exciting 2 Pole Single Phase Power Factor 1 0 Engin DY41D VOLTAGE V FREQUENCY Hz 10 2 30 40 gt FREQUENCY Hz 0 5 10 15 20 CURRENT FREQUENCY Hz VOLTAGE V VOLTAGE 10 15 CURRENT A OUTPUT W OUTPUT W OUTPUT W 5000W Rated 4500W 60Hz Voltage ce 110V Output 4800W Rated 4300W 50Hz Voltage Eod 220V Output Max
37. ed Resistance less than 40 Field coil shorted e Rotor replace Resistance more than 11 NG Slip rings checked OK Slip ring defective e Clean replace OK Brush defective e Check replace Main coil resistance Main shorted e Stator replace checked 5 Sub coil resistance checked Sub coil shorted e Stator replace OK Check AVR AVR broken e Replace 5 Off load voltage is normal but load cannot be operated Generator rpm checked OK Overload checked OK Load s inter terminal resistance checked OK Stator resistance checked OK Inter brush resistance checked OK Generator insulation checked OK Generator overheat checked OK AVR checked Engine output power insufficient Rpm too low Operates if load is decreased Resistance nearly zero AC plug checked for shortcircuit OK Resistance infinite AC plug checked for wrong wiring No Fuse Breaker check the resistance Resistance outside Range of 5 10 52 Slip rings checked OK Cooling air not circulating well Not checked properly Or opera tion returns to normal when AVR is replaced with another one See Engine Trouble shooting cs Cause Remedy Rpm unadjusted e Adjust Overload e Change load AC plug shorted Correct Load shorted
38. elps improve generator effi ciency and prolong generator life Full Frame Protection The fuel tank engine and generator are fully protected by the frame The box type frame is very convenient in stack ing one generator upon another Wide Range of Options A wide range of options including an electric starter castors only for RGD351 etc are available FUEL and TANK CAP DECOMPRESSION LEVER AIR CLEANER NOZZLE MUFFLER ROCKER COVER SPEED CONTROL LEVER OIL GAUGE OIL INLET STARTING HANDLE EARTH GROUND WIRE OIL FILTER DRAIN PLUG FUEL INJECTION PUMP FUEL FILTER Rob in Generator MODEL RGD351 FUEL CONTROL BOX 01846094 p lejsnji H31HVlS 1 1 YOLVYANAD IO 1VNH31X3 tiOLVH3N39 NOILdIHOS3Q TVH3N39 Y FUEL TANK CAP MUFFLER OIL GAUGE EARTH GROUND WIRE ROCKER COVER OIL INLET OIL FILTER DRAIN PLUG DECOMPRESSION LEVER AIR CLEANER SPEED CONTROL LEVER Robin G 1 STARTING MOTOR FUEL FILTER FUEL INJECTIONPUMP STARTING HANDLE rato lt lt NOZZLE FUEL COCK CONTROL BOX BATTERY 12V 35AH Standard GLSEGOH 3dAL YSLYVLS 19313 C Vv 4 2 FRONT PANEL 4 2 1 RGD351 1 HAND STARTER TYPE 220 230V 240V VOLTMETER NO FUSE BREAKER RECEPTACLE DC FUSE 10A EARTH GROUND TERMINAL DC OUTPUT TERMINAL
39. eptacles 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 4 shows the rated current for each receptacle Be careful not to use the receptacles and AC plugs beyond the specified limits to prevent burn ing up to total 15 amperes from two receptacles up to 15 amperes CR 2227 4 up to 20 amperes up to 5 See Caution Caution Taking out power from TWIST LOCK RECEPTACLE put the plug into outlet and turn clockwise to lock it Fig 5 9 Table 5 4 NOTE If your generator has receptacles peculiar to your contry Table 5 4 does not apply NOTE The generator for U S A and Canadian markets has receptacles to satisfy NEMA Standards Use the plug matching the corresponding receptacle referring to the NEMA Standards shown in Table 5 5 Receptacle AC Plug NEMA Voltage NEMA and Amp Standard No Standard No 125V 2 receptacles totalling 15A Table 5 5 22 5 2 9 TERMINALS The terminals are for providing DC output power and RED BLACK come in two colors red and black The red one is positive and the black one negative 5 2 10 REAR COVER The terminals are for providing DC output power and joint to hold the sta
40. er or actually mounting it in the generator and operating it 9 4 1 AVR TROUBLE IDENTIFICATION by APPEARANCE If an AVR electronic part is burnt dark or the surface epoxy resin melted it often indicates AVR trouble 9 4 2 IDENTIFYING AVR TROUBLE by CHECKING INTER LEAD RESISTANCE Check the inter lead resistance of the AVR with a tester See Fig 9 5 If the tester readings vary greatly from the values specified in the table on next page the AVR is faulty NOTE Take tester inaccuracy into account in reading the tester Fig 9 4 TESTER Fig 9 5 9 4 3 IDENTIFYING AVR TROUBLE by MOUNTING and OPERATING in THE GENERATOR SCR or transistor damage cannot be detected by simply looking at the AVR or checking the lead resistances Check it by mounting the suspectedly faulty AVR in a normal generator or mount a normal AVR in a generator which fails to generate voltage 39 MODEL RGD351 RGD351D One wire 00 700K 1MQ 72K 120KQ22 65K 10KQ Another One wire 09 400K 500KQ 72K 120KQ 65K 10KQ Another 130K 140KQ 220K 250KQ2 250K 300K2 45K 50KQ White 130K 140KQ 45 50 Yellow G 600K 1MQ2 70K 110KQ2 7K 9 5KQ 400K 500KQ 70K 110KQ 6 5 8 5 9 Brown Upper lines are for the 220 230 240V specific
41. es 86 washer special size 1 pce 2 Fasten rubber mounts to the remaining three points of the pipe frame A spacer and washer must be placed between the pipe frame and each rubber mount See Fig 10 33 89 washer special size b uU De 3 pes BO TU Eo nt aoe See oa 3 pes So spring washer 3 pes SO Washer he MCN eges 3 pes 3 Lower the generator remove the chain block and fasten the box guide to the side of the control box and side plate A Nuts are welded to the inside of the control box and the side plate 5 15 mm bolt tee pat 2 pcs SO spring WaSher Sear 2 pcs S0 WASHEE CELER de ae ee CR 2 pcs 4 Connect the coupler on the rear of the control box Push in the coupler all the way until it is locked See Fig 10 40 5 Fasten the exciter coil wire with the clamp on the back of the control box See Fig 10 41 N CONTROL BOX To SIDE PLATE A BOX GUIDE BOLT x 15 2 pcs SPRING WASHER 50 2 pcs WASHER 50 2 pcs CASTOR WASHER Special size SPACER a 04 gt RUBBER MOUNT 89SPRING 0 0 bw 8o SPRING amp WASHER WASHER Z 80 x 20 mm BOLT 80 20 Fig 10 38 63 Model with castors 1 Lift the pipe frame with a chain block ins
42. g 9 11 No output voltage from the generator If the trouble cannot be detected by Step 9 9 1 above check the primary exciting circuit as follows A Disconnect the control box and operate the generator at the rated rpm Disconnect the two yellow wires from the excit ing coil to the and momentarily connect the positive and negative leads of a 12V battery in their place If no output voltage is generated reconnect the battery leads the other way If output voltage is generated the exciting coil is defective B no output voltage is generated by the test conducted as described in Step A operate the generator at the rated rpm and momentarily connect a 12V battery to the brushes The green lead is positive and the black or brown lead nega tive See Fig 9 12 If output voltage is generated the primary exciting circuit in the AVR is defective Replace the AVR 43 10 DISASSEMBLY and REASSEMBLY 10 1 PREPARATIONS and SUGGESTIONS 1 When disassembling the engine remember well the locations of individual parts so that they can be reassembled correct ly If you are uncertain of identifying some parts it is suggested that tags be attached to them 2 Have boxes ready to keep disassembled parts by group 3 To prevent missing and misplacing temporarily assemble each group of disassembed parts 4 Use the correct tools in the correct way 10 2 HOW TO DISASSEMBLE Item I Procedure Remarks Fuel T
43. her 2 pcs Lg washer special size 2 pcs After tightening the assembly lower the chain block all the way and remove the belt After removing the belt check the bolts and nuts again that they are securely tightened NOTE Be careful of maintaining engine balance when lifting the assembly with the chain block 6 Fasten side plates A and B to the pipe frame Attach the nameplate that shows the product name Robin Generator and its model name to the front the control box side of the pipe frame and the blank plate to the rear Use the black bolts box 13 mm bolt black 8 pcs 6 spring washer 8 pcs GO washer 8 pcs 5d Hit o u du c atta 8 pcs 60 mRGD500 RGD500D FLANGE BOLT 86 x 50 SPRING WASHER ee WASHER BOX STAY BOLT 8 x 50 mm SIDE PLATE B BOLT 13 mm SCREW BRASS 10mm a 5 4 7 WIRE CASTOR SIDE PLATE A BOLT amp WASHER ASSY 80 20 mm Fig 10 36 1 Install the castors under the pipe frame The castors are of rubber measuring 100 mm in diameter None of the four castors swivel The pipe frame has nuts welded to it Use bolts with spring washer and washer 89 20 mm bolt and washer assembly 16 sets 2 Fasten the earth wire Fasten the earth wire to the pipe frame at the
44. her a aee A ee et 4 pcs BO DUE kumu e Ap T 4 pcs Bo spring washer 4 pcs BO Washer a eoque d EN CH S ERR 4 oio 4 pcs Attach two rubber vibration isolators to the bottom of the pipe frame under the generator and install the generator base on it The pipe frame has nuts welded to it so turn the rubber vibration isolators into them The direction of mounting the generator base is shown in Fig 10 34 SO DUE Vu l suwa a ace NIS 2 pcs 86 spring washer 2 pcs 80 washer 2 pcs GENERATOR MOUNTING HOLES RUBBER VIBRATION ISOLATOR ENGINE MOUNTING DIRECTION 471 MOUNTING HOLES GENERATOR BASE Fig 10 34 59 5 Install the engine and generator assembly in the pipe frame a Lift the engine and generator assembly with a chain block and lower it making sure that it is in line with the bolts welded to mount bracket A b After lowering the assembly to position tighten the engine end with four nuts and the generator end with two bolts In this case tighten one of the earth wires together with the bolt welded farthest from the generator under the engine muffler op posite to the fuel filter lll puss emia eee ee 4 pes Engine ND 8 springwasher 4 pcs i NO WAaSh r uu Ede ee 4 pcs 8 x25mmbolt 2 pcs Generator side 8 spring was
45. ic hammer As the connector cannot be pulled out through rear cover or grommet stator and rear cover can not be completely sepa rated Simply disengage rear cover from rotor bearing 1 Never strike the Plastic hammer and leads Be careful not to screwdriver peel the stator steel plate It is not necessary to separate the stator and cover except when replacing the stator rear cover or diode stack Fig 10 20 Procedure Remarks Rotor 1 Remove the through bolt Hammer Hold the through bolt with box span box spanner or ner socket wrench strike it hard socket wrench with hammer counterclockwise to loosen and remove the bolt See Fig 10 22 pce Remove the rotor Never strike the slip ring Lightly strike the rotor core with plastic and coil hammer and pull out the rotor from the tapered shaft of the engine the rotor cannot be taken off strike it at different angles See Fig 10 23 Adaptor and 1 Remove the four adaptor mounting 12 mm spanner Driving Shaft bolts and the adaptor i 809 bolt 4 pcs Remove the four driving shaft mount 14 mm spanner ing bolts and the driving shaft 109 bolt 4 pcs Fig 10 22 Fig 10 23 52 10 3 HOW REASSEMBLE 10 3 1 DRIVING SHAFT and ADAPTOR 1 Align the driving shaft with the faucet joint of the flywheel and install it 100 30 mm bolt
46. inated silicon steel sheet copper wire which winds the core and lead wires which de liver the power The copper wire is wound into the main coil sub auxiliary coil and DC coil AC output power is taken from the main coil and DC output power from the DC coil The outside diameters and laminated core thick nesses of various models are as shown below 11111 Fig 5 2 RGD351 RGD500 MODEL RGD351D RGD500D mm 204 204 inch 8 03 8 03 mm 70 100 inch 2 76 3 94 Table 5 1 _ 18 5 2 2 ROTOR The field coil is wound over a laminated silicon steel sheet core and to the end of its shaft slip ring is fitted An end of the field coil lead is connected to the slip ring When DC cur rent is sent to the field coil through this connecting point it becomes an electromagnet Fig 5 3 Fig 5 4 RGD351 RGD500 RGD351D RGD500D Table 5 2 19 5 2 3 BRUSHES An exciting current is supplied from the AVR to the rotor The brushes are made of carbon and the brush holders of plastic It is necessary to keep the contact pressure between the brushes and slip rings within specified limits Thus care must be taken of brush length See 9 3 BRUSHES 5 2 4 AVR AUTOMATIC VOLTAGE REGULATOR The automatic voltage regulator employs an electronic cir cuit to automatically regulate voltage 5 2 5 VOLTMETER The voltmeter comes in two types a 150V maximum typ
47. ised and the output voltage is kept constant If the AC output is reduced the SCR operates in the opposite way to similarly keep the output voltage constant 24 ENGINE MAGNETO Fig 5 13 Fig 5 14 WITHOUT AVR RATED VOLTAGE WITH AVR Fig 5 15 5 3 3 FULL POWER SWITCH The dual voltage type has a full power switch to produce the rated output from a single 110V or 120V receptacle The full power switch operates as described below The full power switch for 120V 240V is described as the construction of both full power switches for 120V 240V and 110 220 is same Fig 5 16 Fig 5 17 A circuit diagram of the conventional dual voltage type without full power switch is shown in Fig 5 16 and a LOW VOLTAGE HIGH VOLTAGE circuit diagram of the RGD351 RGD351D and RGD500 Switch RECEPTACLE RECEPTACLE RGDSOOD which is fitted with a full power switch is shown in Fig 5 17 AC windings MC and MC generate a voltage Rated output Cannot use of 120V each 110 220V Fig 5 16 shows MC and connected in series In br Rated output outpu this case an output can be generated from either the 240V 120 240V or 120V receptacle The 240V receptacle outputs the rated Table 5 6 output or the maximum output in a short time operation but one 120V receptacle can output only one half of the rated output Since two 120V receptacles are provi
48. ld voltage regulation within 3 This helps prolong product life without damaging the electric devices DC Output for Battery Charging The generator can generate a DC output 12V 100W while generating AC output so that batteries can be charged during AC operation In this case make sure that the total of AC and DC outputs does not exceed the rated output Full Power Switch Provided The dual voltage type has a full power switch as a standard component The rated output can be generated at both 120V 110V and 240V 220V Small Sized Efficient Generator The engine and generator are cooled by a single fan This design makes the generator small in size and highly efficient with less space requirement and mechanical loss and constant delivery of output power for long hours 12 13 14 15 16 Resistant to Inductive Load Exciting power is obtained from the sub coil which is wound apart from the main coil This means less output voltage fluctuations against load variation and thus a steady level of power This feature is particularly effective in starting induction motors which are subject to sharp current variation Output Voltage Waveform Close to Sine Curve The output voltage waveform is close to a sine curve and is free of surges so that the electrical device connected to the generator will not be damaged 100 Copper Windings The windings are made only of copper having low internal resistance This feature also h
49. ms 3 and 4 required the aforementioned generator capacities only when starting their motors Once their motors are started the products consume only about 1 2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances NOTE 2 Motor driven products 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 acpacity select a generator with larger Capacity 30 5 Appliances without any indication as to power consumption Some appliances have indication as to power consumption but instead the work load output is indicated In such case power consumption is to be worked out according to the numerical formula mentioned below Output of electrical appliance Power consumption Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 6 0 75 The smaller the capacity the worse the efficiency Three phase motor 0 65 0 9 and vice versa Fluorescentlamp 0 7 08 Example 1 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly pow er consumption will be 40 0 7 57W As explained in Item 2 multiply this power consumption value of 57W by 1 2 2 and you will get the figure of the necessary capaci
50. p of the rear cover through the grommet and fit the grommet into the hole in the rear cover 8 Insert the wires into the connectors The connector positions and wire colors are shown in Table 10 3 BR 220 230 240 YELLOW YELLOW GREEN BROWN ORANGE PRON e RED WHITE b Hand WHITE I start BROWN 110 120 YELLOW YELLOW GREEN BROWN ORANGE RED WHITE BLACK BROWN 220 230 240v ORANGE RED WHITE A WHITE i Electric start BROWN 110 120 GREEN BROWN ORANGE RED WHITE BLACK I WHITE 220 230 240V D type 110 120 YELLOW 220 230 240V YELLOW YEELOW GRAY PINK WHITE Electric start D type 110 120V YELLOW YELLOW YELLOW GRAY PINK WHITE Table 10 3 NOTES 1 Wire sizes are as follows 2 White wire 2 has not been used since March 1983 1 9 9 0 75 when it was replaced body grounding 56 10 3 5 BRUSH HOLDER 1 Install the brush holder in the rear cover Pass the screws for tightening the brush holder push it so the brush will be perpendicular to the slip ring and tighten the screws See Fig 10 31 5 18mm screw 2 pes NOTE The direction of installing the brush holder is shown in Fig 19 32 AER Fig 10 31 STATOR SIDE GREEN WIRE BROW
51. rator Do not operate the generator in a room cave or tunnel Always operate in a well ventilated area Otherwise the engine may become overheated and also the poisonous carbon monoxide contained in the exhuast gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facilities during use 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 Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is moistened by rain or snow wipe it and fully dry it before starting Don t pour water over the generator directly or wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leakage and electric shock Do not connect the generator to the commercial power lines This may cause a short circuit or destroy the generator Use a transfer switch 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 Part No Part Name Q ty Phase Allowable Current 3654560408 Transfer Switch 1 367 45605 08 Transfer Switch 30A 3404560608 Transfer Switch 60 3404560808 Transfer Switch 72 11 348 4560908 348 43009 08 Plastic Box Table 6 1 Use fuses of the correct capaci
52. s breaker capacities and protecting objects Model Specifications N F B Protecting Object Protecting Object 110V 120V Maximum current 110 220V 120 240V RGD351 Maximum current RGD351D 15A 2P2E Maximum current 50 110 60Hz 120V 40A Maximum current 30A Receptacle 60Hz 110V Maximum current 30A 30A Receptacle RGD500 50Hz 220V 230V 240V 20A Maximum current 2 110 220 120 240 20A 2P2E Maximum current 15A 2P2E 30A Receptacle 60Hz 110 220V 25A 2P2E Maximum current 15A 2p2E 30A Receptacle RGD500D Table 5 3 2P2E means the bipolar double element type and if either of two pairs of currents running through the no fuse breaker exceeds the rated cur rent the no fuse breaker operates to turn power off The 220V 230V and 240V types use the two pairs connected in series and 110V 120V type have them connected in parallel 5 2 7 FUSE The fuse prevents DC output overcurrent and shortcircuit overcurrent If the generator is operated at a level exceeding the maximum current it can cause insulation deterioration burning electric shock and electric leakage The fuse protects the generator from these troubles Fuse capacity 10 21 5 2 8 RECEPTACLE and PLUG STD SPEC These used for taking AC output power from the generator A total of five kinds of rec
53. tall the control box on the frame and a castor on the underside of the frame and tighten them together with the bolts See Fig 10 38 SOX 20 mim blo os E A CEG 4 pcs 8 springwasher 4 pcs BO WaSDBT aun p asua nie 4 pcs 2 Install the remaining three castors on the underside of the pipe frame See Fig 10 38 SOX 20 mm belt S 12 pcs SOUL Loy AT bu 12 pcs 8 springwasher 12 pcs SO Washer oo aya ex y tupas y m 12 pcs 3 Lower the chain block remove the chain block and install the box guide on the control box side and side plate A Nuts are welded to the inside of the control box and the side plate bolt Sa ee EUR 2 pcs 56 spring washer 2 pcs SQ WASET a nues eee d RS due dE Vds a 2 pcs 4 Connect the coupler on the rear of the control box Push in the coupler all the way until it is locked See Fig 10 40 5 Fasten the exciting coil wire with the clamp on the back of the control box See Fig 10 41 RGD500 RGD500D 1 Fasten the control box to the frame and box stay Tone Nuts are welded to the inside of the control box See Fig 10 39 Rapip kesi Use lock washers 15mm bolt 4 5 53 6 lock
54. ter 486 mm 19 1 in 486 mm 19 1 Generator with Electric Starter 486 mm 19 1 in Height 556 mm 21 9 in 556 mm 21 9 670 mm 26 4 in 670 mm 26 4 in Dry Weight 87 kg 192 155 Generator with Electric Starter 95 kg 210 1558 122 kg 269 Ibs Geli rator with Electric Stier 130 kg 287 Ibs 1 Specifications are subject to change without notice 2 Optional electric starter does not include battery Use 12V 35AH or larger capacity battery 3 Casters are optional for Models RGD351 and RGD351D Models RGD500 and RGD500D have furnished with casters as standard parts L 5 011 91419348 2 PERFORMANCE 2 1 OUTPUT MODEL RGD351 Type VOLTAGE FREQUENCY Hz VOLTAGE V FREQUENCY Hz Self Exciting 2 Pole Single Phase 1 0 15 20 5 CURRENT OUTPUT W N gt x OUTPUT W x OUTPUT W Output Max 3700W Rated 3300W 60Hz Voltage sa bed Hk 110V Output 3500W Pateda NEA 3000W Frequency 50Hz Voltage 522 220V Output 3500W Rated 3000W 50Hz 240V NOTE These characteristics are typical Those of 60 Hz 120V and 50Hz 110V 230V ar
55. the opposite side as shown in Fig 10 27 Fig 10 26 To CONTROL BOX STATOR FRONT COVER To BRUSH HOLDER GREEN and BROWN WIRES To DIODE STACK TWO BLUE WIRES and ORANGE and BROWN STATOR COVER WHITE WIRES Fig 10 27 4 10 3 4 REAR COVER 1 Install the diode stack in the rear cover 40 mm SCIEW ouod E EA 1 pce 2 Connect the stator wires to diode stack 20 The diode has markings as shown in Fig 10 28 Connect the two blue wires to the points marked N Connect the brown wire to the point marked Connect the orange wire to the point marked Fig 10 28 3 Pass all the wires from the stator to the control box through hole in the top of the rear cover 4 Install the rear cover so that it matches the rotor bear ing Gently strike the edge of the rear cover evenly all around with a plastic hammer See Fig 10 29 T 3 NOTE Be careful not to let the wires get caught be tween the stator and rear cover Fig 10 29 5 Tighten the cover bolt NOTE The front cover and rear cover must be in the correct position to be installed The cover bolt is shaped as shown below RGD351D mm RGD500 mm Table 10 2 55 6 Install the stator cover Make sure that all the cover bolts are covered by the stator cover and fold back the stator cover edge 7 Pass the wires from the to
56. tor It has bosses inside for holding the brushes and slits for taking cooling air in The slits are so designed that human fingers will not go in Fig 5 11 5 2 11 RUBBER MOUNTS RUBBER VIBRATION ISOLATORS Rubber pads for controlling generator vibration and disloca tion These are made of the most suitable rubber material to optimum shape and hardness f Model RGD351 uses two types of rubber mounts one is used between the generator and frame the other under 2 the frame However those models with castors require rubber mounts under the frame The rubber mounts under the engine are diagonally supported by the mount bracket to reduce the vibration Fig 5 12 5 2 12 PIPE FRAME The frame consists of pipe frame skeleton side plates A and B To this frame a base stay etc for mounting will be fitted 5 3 DESCRIPTION of GENERATOR OPERATION 5 3 1 PRIMARY EXCITING ACTION RGD351 RGD351D RGD500 RGD500D employ an exciting coil in the engine magneto for raising the prima ry voltage This action is explained as follows The RGD551 RGD1101 and RG Series generate a voltage when the generator is started again because of the residual magnetism remaining in the yokes and poles If a generator of this type is disassembled and stored for a long period of time the residual magnetism may dissipate so that the gen erator may not generate a voltage when it is restarted The RGD351 RGD3
57. ty If the generator rpm is increased exorbitantly in the overload condition by using a fuse in excess of the rated capacity the generator could be burnt and the AVR be damaged 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 a case stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring 29 7 APPLICABLE RANGES of GENERATOR Generally the rated power of an electrical appliance often refers to the amount of work that can be done by it The electric power required for operating an electrical appliance is not necessarily equal to the amount of work that can be done by it Electrical products generally have a label showing their rated voltage frequency and power consumption input power The power consumption of an electrical product is the power necessary for using it When using a generator for operating an electrical product however the power factor and starting current must also be taken into consideration Determine the required capacity of your generator from the power required for operating electrical products that are classi fied as follows 1 Incandescent lamps hot plates 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 generator with a rated output power of
58. ty of a generator In other words a generator with a rated output of 1000W capacity can light 9 14 fluorescent lamps of 40W 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 7 570 When this motor is used for a motor driven tool the capacity of the generator should be multipled by 1 2 to 3 and 570W as explained in the Item 3 Moreover in case when used this motor for the pump in the water or compressor it is necessary 3 5 times power ful generator according to the Item 4 RGD351 RGDS00 RGD351D RGD500D Frequency Incandescent lamp hot plate etc 4300W Fluorescent lamp about about about mercury lamp etc 2000W 2200W 2850W Motor driven tool general purpose motor etc about about about 15009 1650W 2200W Water pump about about about compressor 750W 820W 1100W Table 7 1 94 NOTE Wiring between generator and electrical appliances 7 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 become excessively heated and deteriorate the insulation possibly burning it out Table 7 2 shows cables and their allowable current for your reference 2 Cable length If a long cable is used a voltag
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