Subaru Robin Power Products RGX3500 manual

MANUAL Models RGXI 800,*. RGX2400, RGX3500, RGX5500 Generators PUB-GS0597B Rev. 8198[...]

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i RGX1800 RGX2400 Model - - TY Pe Frequency Maximum Output Rated Output ~~~~ ~~ ~ ___~ ~ Brushless, Revolving Field, Self-Exciting,-2-Pole, Single Phase ~~~ ~ 50Hz I 60Hz I 50Hz I 60Hz 16ow I ~~ 1800W "I 2000w 7 2400W ~ 1300W I 1500W I 1700W I 2000w 11OV I 11.8A 1 11OV I 13.6A 11OV I 15.5A I 11OV I 18.2A Rated 220V I 5.9A I 120V 1 12.5A 220V I[...]

I I Iu Model I RGX3500 I RGX5500 I I i - ~ ~ TY Pe ~ ~ ~ ~~~ Brushless, Revolving Field, Self-Exciting, 2-Pole, Single Phase Frequency 4800W 4400W 3000W 2500W Rated Output 5500W 5000W 3500W 3000W Maximum Output 60Hz 50HZ 60Hz 50Hz "". - . . I Voltage , . . . .. 110v 43.6A 110v 40A 110v 26.4A 110v 22.7A Rated 40A 120v 20A 220v 24.2A 120v 1[...]

2. PERFOMANCE CURVES 2-1 MODEL RGX1800 I 3 6 9 12 15 CURRENT {A)& + -3-[...]

u U t I > U - W a 5 0 > 1.5k - 3 -1k 5 n t- -0.5k 0 3 -0 bk c1.5k rz 0.5k 2 3 I- -0.5k o 2 -0 CURRENT (A) + -4-[...]

> CURRENT (A)- 0 3 6 9 12 15 CURRENT (A)+ 2-2 MODEL RGX2400 + 5 0 > 2k 1.5k - t iz lk n 3 I- 0.5k o 3 0 2k 1.5k t lk I- n 3 I- 3 0.5k 0 CURRENT (A)- -5-[...]

4 4 CURRENT (A)+ 0 4 a 12 16 20 CURRENT (A+ -2 k -t 1 -1k 3 I- 2 I- -3 0 -0 CURRENT (A)”--.) -6-[...]

_." t 62 1 220 c 61 >. L: 60 z 3 59 w z K U 240 - > 200 a 00 5 2 4 6 a 10 12 w u > CURRENT (A)+ CURRENT iAl+ t IZt 1 -1k t- I- -3 0 2 -c -2k -t I is -1k E n I- 3 0 d -0 r 0 4 8 12 16 20 CURRENT (A) - -7-[...]

4 8 12 16 20 CURRENT (A) - 2-3 MODEL RGX3500 t L 52 51 50 49 120 110 100 0 10 20 30 CURRENT (A!- 63 62 61 60 59 120 110 100 0 10 20 30 - 4k -3k t 3 -2k 2 k -1k 6 -0 CURRENT (A)- -a-[...]

>- V z w 3 z a U /- z t CURRENT (A)+ -3k -2 t 3 - I- 3 0 3 -1k -0 U t - 4k - 3k -2k :- 1k 4 > 8 12 CURRENT [A)- t - > 0 I- d 0 > G a 14k CURRENT (A)- -9-[...]

N I - % i, W z 3 U a W Y > W CY I- -I 3 > - a W 3 El LL CT 50 10 20 30 CURRENT [A!- LL W U i- -1 a C > 0 CURRENT [A)- -1 - 10-[...]

2-4 MODEL RGX5500 - 4k -3k - t s -2k 3 a. t -1k 0 3 -0 t > 0 z 3 u 0 K U -3k 3 -2k 2 I- 3 -1k 0 I- -0 CURRENT (A)- CURRENT (AI+ - 11 -[...]

62 61 60 59 130 120 110 0 10 20 30 40 50 - t 52 51 5 50 z - Ej 49 3, L= U 240 t 220 - 2 200 a w 13 t -1 20 5 10 15 20 25 ~ CURRENT (A)- N 61 I 60 - z cl a 5 53 IL U 240 f 220 I - > 200 (3 < t -1 0 0 5 10 15 > 20 25 LLI CURRENT [A)- LO LO - 6k :-t 4k - -3k 3 -2k 3 -1k 0 LO - 12-[...]

U a CURRENT (A)- t > a - W a 0 -1 > CURRENT (AI - t a U - 5k I- z t- -2k 3 0 ~ lk -0 r 6k i - 13-[...]

6k I:, c 5 -3k 3 a I- -2k o 3 r lk i CURRENT [A)- 2-5 DC OUTPUT The voltage curve shown in the left indicates the characteristic of DC output when charging a battery. The voltage may be decreased by 20% when the resistance load is applied. NOTE: It is possible to use both DC and AC out- puts simultaneously up to the rated output in total. - 14-[...]

3. FEATURES 3-1 3-2 3-3 34 3-5 3-6 3-7 3-8 3-9 BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance. CONDENSER TYPE VOLTAGE REGULATOR A trouble free condenser type voltage regulator ensures a stable voltage under all working conditions. OIL SENSOR Oil sensor automatically shuts off the engine whenever t[...]

4. GENERAL DESCRIPTION OF THE GENERATOR 4-1 EXTERNAL VIEW Of GENERATOR FULL POWER SWITCH (DUAL VOLTAGE TYPE) VOLTMETER (PILOT LAMP) e NO FUSE BREAKER (RGX1800.2400: CIRCUIT BREAKER) EARTH (GROUND) TERMINAL FUEL COCK PLUG COVER (SPARK PLUG, INSIDE) 7NK CAP GAUGE / DC OUTPUT TERMINAL OIL DRAINING PLUG (RGX3500 ONLY) -1 - 16-[...]

4-2 CONTROL PANEL 0 RGXl800 : 50HZ-11 OV, 60Hz-120V TYPE VOLTMETER CIRCUIT BREAKER DC RGX2400 : 50HZ-11 OV, 60Hz-12OV TYPE VOLTMETER DC FUSE 0 P-T 0 CIRCUIT BREAKER AC RECEPTACLE DC OUTPUT TERMINAL EARTH (GROUND) TERMINAL - 17-[...]

RGX1800, RGX2400 : 50Hz-220VY 240V, 60HZ-220V TVPE VOLTMETER DC FUSE DC OUTPUT TERMINAL RGX1800, RGX2400 : 5OHZ, 60H~-llOV/220V TYPE FULL POWER SWITCH 220V RECEPTACLE - AC RECEPTACLE EARTH (GROUND1 TERMINAL CIRCUIT BREAKER VOLTMETER 110V RECEPTACLE DC OUTPUT TERMINAL EARTH (GROUND) TERMINAL - 18 -[...]

RGXl800,2400 : U.K., 50H~-llOV/12OV [BS RECEPTACLE] VOLTAGE CHANGEOVER SWITCH " CIRCUIT BREAKER VOLTMETER 220V RECEPTACLE "----- i A llOV RECEPTACLE DC FUSE DC OUTPUT TERMINAL EARTH (GROUND) TERMINAL RGX2400 : U.S.A., 60Hz-120V [NEMA RECEPTACLE] PILOT LAMP IDLE CONTRC (Option) RGX2400 : U.S.A., 60Hz-120V [NEMA RECEPTACLE] PILOT LAMP [...]

RGXl800,2400 GERMANY, 50HZ-220V CIRCUIT BREAKER DC OUTPUT TERMINAL. t I AC 22OVl RGX1800,2400 : 50Hz-220V [WITH SPECIAL RECEPTACLE] DC FUSE 1 A 220V RECEPTACLE EARTH (GROUND) TERMINAL TJJJ 0 0 CIRCUIT BREAKER / VOLTMETER + 220V RECEPTACLE EARTH (GROUND) TERMINAL DC OUTPUT TERMINAL - 20 -[...]

RGXI800,2400 : SWITZERLAND, 50Hz-220V DC FUSE DC OUTPUT TERMINAL OFF -n- c I AC 220V I 3 i vo CIRCUIT BREAKER ILTMETER L 22QV RECEPTACLE EARTH (GROUND) TERMINAL RGXl800,2400 : AUSTRALIA, 5OHZ-240V CIRCUIT BREAKER DC FUSE / ---. VOLTMETER - 24QV RECEPTACLE DC OUTPUT TERMINAL EARTH [GROUND) TERMINAL - 21 -[...]

RGX3500 : 50HZ-11 OV, 60Hz-120V TYPE START SWITCH (Option) AC RECEPTACLE F VOLTMETER I EARTH (GROUND) TERMINAL RGX3500 : 50H~-220V, 240V, 60Hz-220V TYPE START SWITCH (Option) AC RECEPTACLE VOLTMETER C / C NO-FUSE BREAKER / DC F’ DC OUTPUT TERMINAL NO-FUSE BREAKER 0 SE DC FUSE / EARTH (GROUND) TERMINAL - 22 - DC OUTPUT TERMINAL[...]

0 RGX3500 : 5OHZ, 60H~-llOV/220V TYPE NO-FUSE BREAKER START SWITCH (Option’ FULL POWER SWITCH / / Dc FUSE VOLTMETER - k 3 AC AC RECEPTACLE 7 0 EARTH (GROUND) TERM~NAL DC OUTPUT TERMINAL RGX3500 : U.K., 50H~-llOV/22OV [BS RECEPTACLE] START SWITCH VOLTAGE CHANGEOVER SWITCH NO-FUSE BREAKER (Option) / :DC FUSE VOLTMETER 220V RECEPl Lo ,/ J llOV[...]

RGX3500 : U.S.A., 60H~-120V/24OV [NEMA RECEPTACLE] START SWITCH FULL POWER SWITCH NO-FUSE BREAKER (Option) IDLE CONTROL (Option) 240V RGX3500 : GERMANY, 50Hz-220V (Option’ START SWITCH VOLTMETER I 220v RECEPTACLE I 0 EARTH (GROUND) TERMINAL / 120V RECEPTACLE NO-FUSE BREAKER VOLTMETER /Dc FUSE EARTH(GROUND) TERMINAL - 24 - DC OUTPUT TERMINAL[...]

RGX3500 : 50HZ-220V [WITH SPECIAL RECEPTACLE] 'Option' START SWITCH 220V RECEPTACLE VOLTMETER I 0 0 EARTH (GROUND) ~ERMINAL RGX3500 : SWITZERLAND, 50HZ-22OV (Option' START SWITCH 220v RECEPTACLE VOLTMETER I Jl 3 ,F 0 ~ ~~ EARTH (GROUND) TERMINAL - 25 - NO-FUSE BREAKER DC OUTPUT TERMINAL NO-FUSE BREAKER / DC OUTPUT TERMINAL[...]

RGX3500 : AUSTRALIA, 50HZ-24OV START SWITCH VOLTMETER (Option) 240V RECEPTACLE * 0 0 0 EARTH (GROUND) TERMINAL RGX5500 : 50Hz-11 OV, 60Hz-120V TYPE VOLTMETER AC RECEPTACLF NO-FUSE BREAKER / DC FUSE / DC FUSE DC OUTPUT TERMINAL NO-FUSE BREAKER I I / START SWITCH EARTH (GROUND) TERMINAL - 26 - DC OUTPUT TERMINAL[...]

RGX5500 : 50H~-22OV, 240V, 60Hz-220V TYPE VOLTMETER DC FUSE NO-FUSE BREAKER / START / AC RECEPTACLE EARTH (GROUND) TERMINAL DC OUTPUT TERMINAL RGX5500 : SOHZ, 60Hz-1 10V/220V TYPE 220V RECEPTACLE llQV RECEPTACLE EARTH (GROUND) TERMINAL - 27 - DC OUTPUT TERMINAL[...]

0 RGX5500 : U.K., llOV RECEPTACLE 220v RECEPTACLE START SWITCH I RGX5500 : U.S.A., 60H~-120V/240V [NEMA RECEPTACLE] PILOT LAMP FULL POWER SWITCH 240V RECEPTACLE 120V RECEPTACLE / DC OUTPUT EARTH (GROUND) TERMINAL TERMINAL NO-FUSE BREAKER i 0 !GO31 1 EARTH (GROUND) TERMINAL IDLE CONTROL / (Option) START SWITCH - 28 -[...]

RGX5500 : GERMANY, 50Hz-220V VOLTMETER DC FUSE AC 220V NO-FUSE BREAKER - START SWITCH 220v RECEPTACLE EARTH (GROUND) TERMINAL DC OUTPUT TERMINAL RGX5500 : 50Hz-220V WITH SPECIAL RECEPTACLE] VOLTMETER DC FUSE NO-FUSE BREAKER * Io kc 220v / START 220v RECEPTACLE EARTH (GROUN'D) TERMINAL DC OUTPUT TERMINAL - 29 -[...]

0 RGX5500 : SWITZERLAND, 5OHZ-220V VOLTMETER DC FUSE NO-FUSE BREAKER / /START 220v RECEP~ACLE EARTH (GROUND) TERMINAL DC OUTPUT TERMINAL RGX5500 : AUSTRALIA, 50Hz-240V VOLTMETER DC FUSE NO-FUSE BREAKER / 24QV RECEPTACLE r AC 0 @ 0 0 / START SWITCH / EARTH (GROUND) TERMINAL DC OUTPUT TERMINAL - 30 -[...]

4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL (MODEL NAME) stuck on the end cover. NOTE: Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service. LABEL, / MODEL NAME - 31 -[...]

5. CONSTRUCTION AND FUNCTION 5-1 CONSTRUCTION END COVER REAR COVER ROTOR COMPLETE STATOR COMPLETE MOUNT RUBBER STATOR BOLT BALL BEARING THROUGH BOLT SUPPORT RING FRONT COVER 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 ex[...]

5-2-2 CONDENSER One or two condensers are installed in the control box and are connected to the condenser coil of the stator. These condensers and condenser coil regulate the output voltage. 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 t[...]

5-24 FUSE. (1) The 10 ampere DC fuse mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit. Fig. 5-6 5-26 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 [...]

5-2-6 RECEPTACLE and AC PLUG (STD.SPEC.) These are used for taking AC output power from the generator. A total of five kinds of receptacles, each varying in rated voltage and current from another, are used. Each model has at least one receptacle to deliver the rated generator output. As many AC plugs as the receptacles, each matching the correspond[...]

5-3 DESCRIPTION of GENERATOR OPERATION PERMANENT MAGNET FOR INITIAL EXCITATION STATOR MAIN COIL Fig. 5-8 5-3-1 GENERATION Of NO-LOAD VOLTAGE When the generator starts running, the permanent magnet built-in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator. As one or two condensers are connected to [...]

" 5-34 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. 120124ov r - - - i (or 110122Ov) 240V (or 220V) f - - 120124ov r - - - i (or 110122Ov) 1 240V (or 220V) Fig. 5-9 i MC, Fig. 5-10 Ret. 1 Switch LOWER VOLTAGE Position RECE[...]

Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower voltage (llOV 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. 5-9 shows a circuit diagram-When the full power switch is set for single lower voltage indica[...]

6. SAFETY PRECAUTIONS ● 1. 2. 3. 4. 5. e 6. 7. 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 opem 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 i[...]

7. RANGE OF APPLICATIONS Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it.The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance. The electrical appliances generally have a label showing their rated voltage, frequency, and[...]

:. : ( _ ~. I .-.. .- (5) Appliances without any indication & t& -&&ver 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) = [...]

NOTES: 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 insula[...]

. 8. MEASURING PROCEDURES 8-l MEASURING INSTRUMENTS 8-1-l “Dr. ROBIN” GENERATOR TESTER The “Dr. RobirPgenerator tester is exclusively designed for fast, easy diagnosis and repair of Robin generators. The “Dr. Robin” has the following features: (1) Functions of voltmeter, frequency meter, meggertester, capacitance meter and circuit tester [...]

8-l-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 15OV: Type with an output voltage of 110 or 120V 0 to 300V: Type with an output voltage of 220,230 or 240V 0 to 15OV, 0 to 330V: Dual voltage type (2) AMMETERS AC ammeter is ne[...]

(4) CIRCUIT TESTER Used for measuring resistance, etc. (5) MEGGER TESTER Used for measuring generator insulation resistance. Select one with testing voltage range of 5oov. I I Fig. 8-5 I I Fig. 8-6 There are various types of tachometers, such as contactless type, contact type, and strobe type. The contact type can be used only when the generator an[...]

8-2 AC OUTPUT MEASURING TO AC RECEPTACLE Fig. 8-8 Use a circuit like the shown in Fig.88 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 1lOV 120v 22OV 240v Voltag[...]

l ROTOR Measure the insulation across one of the soldered l terminals of the rotor and the core. l CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts. Fig. 8-l 1 Fig. 8-12 Any part where the insulation resistance is less than 1MQ has faulty insulation, and may cause electric leakage and electric shock. Re[...]

9. CHECKING FUNCTIONAL MEMBERS 9-l PILOT LAMP and VOLTMETER Check the pilot lamp and the voltmeter if it is turned on by applying specific voltage. Pilot lamp and voltmeter cannot be checked with circuit tester because its resistance is too large. (See Fig.9-1.) n. Fig. 9-1 Pilot lamp should be turned on at 70 to 120V. 9-2 AC RECEPTACLES Using a ?[...]

9-3 CIRCUIT BREAKER Check continuity between each of two terminals at the rear of the circuit breaker while it is mounted on the control panel. Normally, there is continuity between each of the two when the circuit breaker is on while there is no continuity when the circuit breaker is off. 9-4 STATOR Disengage connectors on the wires from stator an[...]

9-5 ROTOR ASSEMBLY (1) Using a “Dr. Robin” or a circuit tester, measure the resistance of the field coil at the terminals. (RXlQ &lo%) MODEL RGX1800 RGX2400 RgEy Rgzy RGXSOO RESISTANCE 2.5 Q 2.7 $2 2.1 R 2.2 R 1.6 R Table 9-2 NOTE 1: Because a diode is soldered to the coil ends at the terminals, resistance may be measured only when tester p[...]

n NORMAL CAPACITY OF CONDENSER MODEL RGXl BOO RGX2400 RGX3500 RGX5500 0 14,xF 20,~F 17fiFX2 28,~FX2 Resistance 0 14,~F 20,~F 17pFX2 28fiFX2 Table 9-3 H If such an instrument is unavailable, the condenser can be checked by replacing with a new one. If the generator performs good with new condenser, the cause of trouble is defect in original condense[...]

n Checking table for digital circuit tester. Apply red @ needle of the circuit tester Digital circuit tester Brown Brown Orange Brown/White Brown No continuity 1 No continuity Continuity Apply black 0 needle of the circuit tester Brown drange No continuity Continuity Continuity Continuity I I .I Brown/White No continuity No continuity No continuity[...]

104 DISASSEMBLY PROCEDURES Step Part to remove Description Remarks Tool 1. Fuel Tank (1) Discharge fuel from the tank. Use utmost care about 1. Shut the fuel strainer. fire hazard. 2. Remove the strainer cup. 3. Put a vessel to receive fuel under the strainer and open the fuel cock to discharge fuel. (See Fig. 10-l.) Wipe off sprit fuel thoroughly.[...]

tep Part to remove Description Remarks Tool 2. Control Box (1) Take off the grommet from the rear pannel of control box. (See Fig. 10-4.) (2) Disconnect the connector on the wiring from the control box to the alternator. (3) Remove the fuel strainer. Remove the nut on top of the fuel strainer located beside the control box. (See Fig. 10-S.) Fig. IO[...]

. . : Step Part to remove Description Remarks Tool 3. Pipe Frame (1) Remove SIDE PLATE from frame. 10 mm spanner 0: (See Fig. 10-8.) box wrench 64 bolt. . . . _ . . . . . . . . . . . 2 pcs. Remove the mount rubbers from SIDE PLATE. (2) Remove the nuts which fix the engine and alternator on the mount rubbers. (3) Dismount the engine and alternator f[...]

itep Part to remove Description Remarks Tool 4. Rear Cover (1) Remove the end cover. (See Fig. 10-l 1.) 10 mm spanner 01 66 bolt . . . . . _ . . . . . _ _ . . _ 4 pcs. box wrench (2) Take off the rear cover. 1. Remove the four bolts which fasten 10 mm spanner 01 the rear cover to the front cover. box wrench 6@f,c,lt . . . . . . . . . . . .._.. dpcs[...]

Step Part to remove Description : Remarks Tool 5. Staitor (1) Remove the four bolts which fasten the 10 mm socket stator to the rear cover. wrench (See Fig. 10-14.) &BOLT . . . . . .4pcs. 60 SPRING WASHER Fig. 10-14 (2) Rut a piece of lumber on the floor in upright position. (See Fig. 10-E) (3) Hold the rearcover and stator upside down with bot[...]

Zep Part to remove Description Remarks Tool 5. Stator (5). Take apart the support ring and stator from rear cover. SUPPORT RING @BOLT . . . _ _ .4pcs. w SPRING WASHER . . . . . . . . . . 4 PCS. @WASHER . . . . 4~~s. Fig. 10-17 6. Rotor (1) Take off the through bolt. Box wrench Apply a box wrench on the head of Plastic hammer through bolt. Hit the w[...]

tep Part to remove Description Remarks Tool 6. Rotor (3) Use a bolt and oil as a tool for pulling out rotor in the following procedures : 1. Pour engine oil into the center hole of rotor shaft. Fill with oil to the shaft end. (See Fig. 10-19.) 2. Prepare a bolt with the following thread size: RGX1800,2400,3500. . MlOXP1.25 RGX5500........... M12XP1[...]

Step Part to remove Description Remarks Tool 7. Front Cover (1) Remove the front cover. 12 mm Socket Loosen the four bolts and remove the wrench front cover. 84 bolt.. . . . . . . . . . . . . . .4pa. Fig. 10-22 - 60 -[...]

104 ASSEMBLY PROCEDURES 104-l FRONT COVER Attach the front cover to the engine main bearing cover. Match the faucet joint and tighten the bolts. M8 X 18mm bolt . . . . . .4 pcs. M8 spring washer . . _ . -4 pcs. Tightening torque : 120 - 140 kg-cm 8.7 - 10.1 ftlbs. 104-2 ROTOR (1) Wipe off oil, grease and dust from the tapered portion of engine shaf[...]

(3) Apply the support ring between the rear cover and the stator. Tap on the support ring evenly using an aluminum bar and a hammer to press into the rear cover. (See Fig-lo-26.) CAUTION: Be careful of the position of hook- ing holes of the support ring. (4) Join the stator to rear cover with four bolts, washers and spring washers. (See Fig. 10-25.[...]

1044 REAR COVER (1) Attach the bushing over the lead wire drawn out from the rear cover. Press the smaller end of the bushing into the window of the rear cover. (See Fig.lO-27.) Fig. 10-27 (2) Put the rear cover with stator over the rotor. Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover. (3) Fix the[...]

104-S END COVER Attach the end cover to the rear cover. M6 X 8mm flange bolt *.--.-.-*-. 4 PCS. Tightening torque : 40 - 60 kg-cm 2.9 - 4.3 ftlbs. Fig. lo-30 104-6 FRAME (1) Attach the mount rubbers to the frame. Insert the setting tongue of mount rubber into the hole on the frame and tighten the nut from the bottom of the frame. M8 flange nut . . [...]

(3) Install the engine and alternator assembly into. the frame. Put the engine and alternator assembly into the frame from the side of it. Tighten the nuts over the mount rubber bolts to fix. M8 nuts Tightening torque : 120 - 140 kg-cm 8.7 - 10.1 ftlbs. Fig. IO-32 NOTE : When tightening the nuts, slightly lift the engine and‘altemator assembly so[...]

(3) Press the upper end of the bushing into the bottom window of the control box. Attach the grommet for the oil sensor wires to the rear panel of the control box. (4) Mount the control box to the frame. M6 X12 mm fiange bolt ..-*..***. 3 pcs. Tightening torque : 40 - 60 kg-cm 2.9 - 4.3 ftlbs. PUSH Fig. lo-34 Fig. 10-35 (5) Fasten the one earth cab[...]

10-4-8 FUEL TANK 1) Connect the rubber pipe to the engine carburetor and fasten it with a hose clamp. Attach the banjo to the opposite end of the rubber pipe, tighten it with a hose clamp, and fasten the pipe to the fuel strainer with the banjo bolt. 2) Fasten the strainer to the strainer bracket with the joint nuts. 3) Mount the fuel tank on the s[...]

10-S CHECKING, DISASSEMBLY and REASSEMBLY of the CONTROL BOX 10-5-l 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 procedure for the components in the control box. 10-5-2 DISASSEMBLY (1) Remove the control panel from the co[...]

11. TROUBLESHOOTING 0 11-l NO AC OUTPUT 11-1-l CHECKING CONDENSER Check the capacity of condensers using a “Dr. Robin”generator tester in capacitance meter mode. NOTE : Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance, or the accurate reading cannot be obtained. Fig. 11-l n NORMAL CAPACITY[...]

n Check the insulation resistance between stator core and each stator lead using a Dr. Robin generator tester in megger tester mode or a megger tester. (Fig. 11-3) If insulation is bad, replace stator with a new one. 1 l-1 -3 CHECKING ROTOR (1) CHECKING FIELD COIL n Remove rear cover and stator. Fig. 11-4 n Using a Dr. Robin or a circuit tester, me[...]

W IMeasure the insulation across one of the soldered terminals of the rotor and the core. = (FigAl-6) If insulation is bad, replace rotor with a new one. Fig. 11-6 11-2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11-2-l CHECKING ENGINE SPEED If the engine speed is too high or too low, adjust it to the rated r.p.m. [How to adjust engine r.p.m.1 W Loosen the l[...]

1 l-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED. 11-3-l CHECK THE ENGINE SPEED. If the engine speed is low, adjust it to the rated r.p.m. * Refer to Step 11-2-1 for engine speed adjustment. 11-3-2 CHECK THE TOTAL WAlTAGE OF APPLIANCES CONNECTED TO THE GENERATOR. Refer to Section 7 “RANGE OF APPLICATIONS” for the wattage of[...]

11-4 NO DC OUTPUT 0 11-4-l CHECK THE AC OUTPUT. Check the generator by following Step 11-1-l through Step 11-1-3. 1 l-4-2 CHECK THE DC FUSE. Check the fuse in the fuse holder. If the fuse is blown, check for the cause of fuse blowing, and then replace with a new one. FUSE : 10A FUS NOTE: If the DC output is used to charge a large capacity battery o[...]

11-5 IDLE CONTROL (OPTIONAL EQUIPMENT) 11-5-l ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS APPLIED (1) Inspect the solenoid bracket. Check the bend angle of solenoid bracket. If the bracket is distorted, correct the angle with proper tool. .EN SOLENOID BRA&ET RGX2400,3!500 SOLENOID p-g&+$ SOLENOID f&KET f I RGX5500 Fig. 17-12 (2) Check [...]

(4) Check the wiring through ZCT on the IDLE CONTROL UNIT BOARD. A) Single Voltage Type Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT. B) Dual Voltage Type Check that two output wires (black wire and red wire) from main coils are passing through the ZCT on the IDLE CONTROL UNIT in the same directio[...]

11-5-2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF. (1) Check the distortion of the SOLENOID BRACKET as shown in step 11-5-l-(1). - (2) Check the FUSE on wiring of IDLE CONTROL UNIT. l Remove the control panel from control box. l Check the FUSE in the fuse holder of IDLE CONTROL UNIT. If fuse is blown, replace with a new one. (FUSE : 0.3A) FUSE FU[...]

12. WIRING DIAGRAM Ii C. B. 0 l RGX1800 : 50Hz-1 lOV, 6OHz-120V TYPE GENERATOR CONTROL BOX --1 r------- -- l! I GREEN -- YELLOW E II .-. l RGX2400 : 50Hz-11 OV, 60Hz-120V TYPE GENERATOR CONTROL BOX r------1 --- -- 1 --------- 0.75 ,,2 2.0 mm2 --- 1.25 mm2 3.5 mm2 - 77 - c[...]

0 RGX180~,2400:50Hz-220V,240V,60Hz-220V TYPE GENERATOR CONTROL BOX r--1 7-i. 8. [NFBI -- ORANGE f’, +,T BROWN - - RROWN I _ _ . _ - JTE l RGXI 800,240O : 50Hz, 6OHz-11 OV/22OV TYPE GENERATOR CONTROL BOX C. B. - SW 02=----l! - ---_--___ O-75 mm2 ---_--___ O-75 mm2 2.0 mm2 2.0 mm2 --- --- 1.25 mm2 1.25 mm2 3.5 mm2 3.5 mm2 - 78 - - 78 - i[...]

l RGXI 800,240O : U.K., 50Hz-1 lOV/22OV [BS RECEPTACLE] GENERATOR CONTROL BOX I I BLACK C. B. - r-- i c- l RGX2400 : U.S.A., 60Hz-120V [NEMA RECEPTACLE with IDLE CONTROL] CONTROL BOX p F i ---- -___ - 0.75mm2 2.0 mm2 --- 1.25 mm2 3.5 mm2 - 79 -[...]

l RGX3500 : SOHz-11 OV, 5OHz-120V TYPE GENERATOR CONTROL BOX --- 1 -- -- l RGX3500 : SOHz-220V, 24OV, 6OHz-220V TYPE SENERATOR CONTROL BOX ---I y-&B, -- m REC em FC 3 -- -i I I I II I I! 1 I 1 i E I, DC ! ii GREEN/YELL0 W -- II -- E YELLOW _ +*c YELLOW 1 3 +T 4 DC OUT d -_----___ 0.75 ,,,& 2.0 mm2 --- 1.25 mm2 3.5 mm2 - 80 - i[...]

l RGX3500 : SOHz, 6OHz-1 lOW22OV TYPE GENERATOR CONTROL BOX --1 I me -- II 1 SC ; r- GREEN/YELLOW -- I! YELLOW _ I I L-3 1 I 8 I 1 YELLOW TC Bc l RGX3500 : U.K.., SOHz-1 lOW22OV [BS RECEPTACLE] GENERATOR CONTROL BOX 1 m FC _--- _____ 0.75mm2 2.0 mm2 --- 1.25 mm2 3.5 mm2 - 81 -[...]

8 RGX3500 : U.S.A., 60Hz-120W240V [NEMA RECEPTACLE with IDLE CONTROL] ENGINE CONTROL BOX r--1 I-- _- I I ICSW - --. -- BLUE 1-1 -- l RGX5500 : SOHz-11 OV, 60Hz-120V TYPE GENERATOR CONTROLBOX --1 I-------- -- 1 1 1 GREEN/YELLOW YELLOW I BROWN - E --_----__ 0.75 mm2 2.0 mm2 --- 1.25 mm2 3.5 mm2 - 82 - i[...]

l RGX5500 : SOHz-220V, 24OV, 60Hz-220V TYPE GENERATOR CONTROL BOX ---I I-- -- NFB - RECl REC2 GREENIYELLC _ UT l RGX5500 : SOHz, 60Hz-11 OW22OV TYPE GENERATOR CONTROL BOX -- -- -- I RI ArU I- Y--Y.. r I I- II I I! II c3 i i 1----. ,.,-. . ^._. Ii II P‘ 1; LLEb btlttN/YtLLUW 1 ll - -_ -_ u “1 I : G:c -_ Ii BROWN i BROWN E .o 2.0 mm2 ----_---- O-[...]

l RGX5500 : U.K., SOHz-1 lOV/22OV [BS RECEPTACLE] GENERATOR CONTROL BOX II II II RECa 00 0 P I : l RGX5500 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE with IDLE CONTROL] ENGINE CONTROL BOX r-1 I __ - LIGHT BLUE I -L I I F SOL. I I LIGHT BLUE n FENERATOR 1 ( REC, - ?-P f RI FC .MC I ----__--- O-75 mm2 2.0 mm2 --- 1.25 mm2 3.5 mm2 - 84 -[...]

l TYPE WITH OIL SENSOR (Optional Equipment) I I eP-l I I I I I i I L 1 L ---a I I i L i - -----A------ I I -- t 1 -a---------- GENERATOR I I I BLACK r-------------------- ---- I L2 I I YELLOW i EN&NE .-m CONTROL BOB ----- ---- 0.75 mm2 --- 1.25 mm2 2.0 mm2 3.5 mm2 - 85 -[...]

l RGX3500 : ELECTRIC STARTER TYPE (Optional Equipment) -- The battery cords have a cross sectional area of 22 mm’. -------__ 0.75 mm2 --- 1.25 mm2 2.0 mm2 3.5 mm2 - 86 -[...]

l RGX5500 : ELECTRIC STARTER TYPE (Optional Equipment) 1 --- SP I ENGINE = = GREEN/WHITE -m-s------ GREEN/WHITE b I .-_-------- I I I The battery cords have a cross sectional area of 22 mm’. __------- 0.75 mm2 --- 1.25 mm2 2.0 mm2 3.5 mm2 - 87 -[...]

l RGX3500 : ELECTRIC STARTER TYPE WITH OIL SENSOR (Optional Equipment) ; e pn 1’ i I -‘) I 7h I ! I I I I I I I I I I I REEN/WHITE j I I --m--------w- I L . losr i I , BLACK I -- i YELLOW/RED I r *J YELLOW I ORANGE ----mm-- II II E RED -.-i ; -- The battery cords have a cross sectional area of 22 mm’. ----m---w 0.75 mm2 -- 1.25 mm2 2.0 mm2 3[...]

l RGX5500 : ELECTRIC STARTER TYPE WITH OIL SENSOR (Optional Equipment) SP --- I i I ; PINK 1; I ;YELLOV YELLOW/RED YELLOW -- + I I I I I I.L I ..a.. J i GREEN ------ El I L -- --- CONTROL BOX The battery cords have a cross sectional area of 22 mm’. --------- 0.75 mm2 --- 1.25 mm2 2.0 mm2 3.5 mm2 - 89 -[...]

I Symbols 1 Part Name I 1 C 1 Condenser I 1 D 1 Diodes Stack Assy I L, Lz T F C.B. Pilot Lamp Warning Lamp (Oil sensor) DC Output Terminal Fuse Circuit Breaker I NFB, ( No-Fuse Breaker I I NFBp 1 No-Fuse Breaker I I vc SW 1 Voltage Changeover Switch I FP SW Full Power Switch ssw Engine Stop Switch OS Oil Sensor osc Oil Sensor Controller SIU I Solid[...]

I America, Inc. 940 Lively Blvd. l Wood Dole, 1160191 l Phone: 630-350-8200 l Fax: 630-350-8212 e-mail: sales @robinamerica.com l www. robinamefkxcom PRINTED IN THE USA[...]