Robin RG2800DX, RG4300DX, RG3200DX Service Manual

TechnicaI Data & Overhaul Instructions

CONTENTS

Section Title Page

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. GENERAL DESCRIPTION

2-1 EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2-2 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-3 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-4 LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER . . . . . . . . . . . . 7

3. RANGE OF APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4. MEASURING AND CHECKING PROCEDURES

4-1 MEASURING INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4-2 AC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4-3 DC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4-4 MEASURING INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4-5 CHECKING FUNCTIONAL MEMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

5. DISASSEMBLY AND ASSEMBLY

5-1 PREPARATION AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5-3 DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

5-4 REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

5-5 RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

6. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

7. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

This manual covers only alternator and control unit portion of the generator.

As to the servicing information of engine portion, please refer to the “EX13, E17, EX21 and EX27” service manual.

The specifications and information included in this manual were in effect at the time of printing.

FUJI HEAVY INDUSTRIES LTD. reserve the right to change the specifications and to make modifications in the

course of technical progress, at anytime without notice.

No parts of this manual may be reproduced without written permission.

– 1 –

1. SPECIFICATIONS

1-1) SPECIFICATIONS

MODEL

Type

Voltage regulator AVR type

AC Output

Frequency Hz

Rated voltage V

Rated current A

Rated output k

Maximum output kVA

AlternatorEngineDimension

Over current protector

DC Output

Rated voltage V

Rated current A

Over current protector

Model

Type Forced air-cooled,4-cycle,single cylinder OHC type gasoline engine

VA

RG2800DX RG3200DX RG4300DX

2-Pole, Revolving Field type Self Exciting, Single Phase

60

120

EX17 EX27

120/240 120/240

30.8/15.420.0 22.5/11.3

3.72.4 2.7

3.2 4.32.8

1.0Rated power factor

No fuse breaker

12

8.3

100Rated output W

Circuit breaker

EX21

Displacement mL (cu.in.)

Fuel Automotive unleaded gasoline

Fuel tank capacity
L (U.S. gal)

Rated continuous operation
[Approx.] hours

Starting system Recoil starter

Length mm (in.)

Width mm (in.)

Height mm (in.)

Dry weight kg (lb)

Ground system Neutral ground

Valve Clearance
(Intake & Exhaust) mm(in.)

Emissions Durability Period
(California only) hours

Specifications are subject to change without notice.

169 (10.31) 265 (16.17)

10.8 (2.9) 12.8 (3.4)

7.5 6.4

537 (21.1)

432 (17.0)

475 (18.7)

43 (94.8)

0.1±0.03 (0.0039±0.0012)

Note : Adjust the valve clearance while the engine is cold.

211 (12.87)

10.8 (2.9)

6.7

48 (105.8)

500

Recoil / Electric

580 (22.8)

477 (18.8)

508 (20.0)

55 (121.3)

– 2 –

1-2) PERFOMANCE CURVES

RG2800DX [60Hz - 120/240V]

RG3200DX [60Hz - 120/240V]

64

63

(Hz) 62 Rated output 2,400 VA

61 

60 2 Frequency 60 Hz

59 Rated voltage 120 V

130 1 (kVA)

(V)

120

110

3

Maximum output 2,800 VA

Rated amperage 20.0 A

0

0 4 8 12 16 20 24

64

63

(Hz) 62 Rated output 2,700 VA

61 

60 2 Frequency 60 Hz

59 Rated voltage 120/240 V

130/260 1 (kVA)

(V)

120/240

(A)

3

Maximum output 3,200 VA

Rated amperage 22.5/11.3 A

110/220

0 4 8 12 16 20 24 28

0

(A)

– 3 –

RG4300DX [60Hz - 120/240V]

64
63

(Hz) 62 3

61
60
59

130/260

125/250

(V) 1

120/240

115/230

Maximum output 4,300 VA

Rated output 3,700 VA



Frequency 60 Hz

Rated voltage 120/240 V

Rated amperage 30.8/15.4 A

2

(kVA)

0 4 8 12 16 20 24 28 32 36

0

(A)

– 4 –

2. GENERAL DESCRIPTION

2-1) EXTERNAL VIEW OF GENERATOR

FUEL LEVEL GAUGE

FUEL TANK

CONTROL PANEL

SPECIFICATIONS LABEL

MUFFLER
(EXHAUST OUTLET)

RECOIL STARTER HANDLE

TANK CAP

OIL LEVEL GAUGE

DRAIN PLUG

SPARK PLUG

AIR CLEANER

2-2) CONTROL PANEL

– 5 –

(1) ENGINE SWITCH

The engine switch is designed for easy operation with the interlocking

mechanism between the fuel cock and the choke furnished.

(2) PILOT LAMP (Standard model）

The lamp is turned ON (Green) while generating properly.
The lamp will be turned OFF at the same time when the
AC circuit breaker is turned OFF.

CHOKE

To start the engine, turn the knob to the position.
(Choke valve is closed.)

OPEN

Keep the knob in this position after the engine
starts. (The engine can be started with the knob at
this position when the engine is warm.)

CLOSE

To stop the engine, return the knob to the position.
(The fuel cock is closed as well.)

MULTI MONITOR

ENGINE SWITCH

AC CIRCUIT
BREAKER

MULTI MONITOR

AUTO
P-SAVE

Hours
V
Hz

FULL POWER SWITCH

KEY SWITCH
[Electric starter model]

AC RECEPTACLES

DC CIRCUIT
BREAKER

(20A)

DC
TERMINALS

AC RECEPTACLES

(30A)

GROUND
TERMINAL

CLOSE

ENGINE SWITCH

OPEN

CHOKE

PILOT LAMP

– 6 –

(3) MULTI MONITOR

■■

LE display

Operation hour, voltage and frequency are

indicated in turns by means of depressing the

LE display changeover switch. In addition,

"O_Lod" (overload) will be indicated when the

generator is in the overload condition or

appliance(s) will be out of order.

■■

Operation hour lamp

Lamp (red) is turned on when changing over into operation hour indication in the LE display.

■■

Voltage lamp

Lamp (red) is turned on when changing over into voltage indication in the LE display.

■■

Frequency lamp

Lamp (red) is turned on when changing over into frequency indication in the LE display.

■■

LE display changeover switch

When depressing this switch, indication in LE display is changed over in turns;
operation hour → voltage → frequency → operation hour.

When starting the engine, operation hour is indicated in LE display at first.

■■

Idle switch

When depressing this switch, Idle function is activated.

■■

Idle lamp

Lamp (green) is turned on while Idle function is activated.

■■

Engine oil level warning lamp

When the engine oil level is lower than the specified level, the lamp is turned on.

Then engine will be stopped.

LE display Operation hour lamp

MULTI MONITOR

Engine oil level
warning lamp

IDLE

Auto-power
saving lamp

Auto-power
saving switch

Voltage lamp

Hours
V
Hz

LE display
changeover switch

Frequency

lamp

– 7 –

2-4) LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER

Generator serial number and production number are stamped on the label stuck on the side of fuel tank.

For soundproof type models, remove the side cover (R) to check these numbers.

NOTE : When inquiring about your generator or ordering spare parts, always give us the Model, Serial

Number and Production Number.

2-3) ALTERNATOR

AVR AY

Diode stack

End cover

Brush CP

Ball bearing

Rotor bolt

Slip ring

Rear cover

Stator cover

Rotor CP

Rotor shaft

Stator CP

PROD No. / SER No. (Label)

– 8 –

3. RANGE OF APPLICATIONS

Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it.

The electric power required for operating an electrical appliance is not always equal to the output wattage

of the appliance. The electrical appliances generally have a label showing their rated voltage, frequency,

and power consumption (input wattage). The power consumption of an electrical appliance is the power

necessary for using it. When using a generator for operating an electrical appliance, the power factor and

starting wattage must be taken into consideration.

In order to determine the right size generator, it is necessary to add the total wattage of all appliances to

be connected to the unit.

Refer to the followings to calculate the power consumption of each appliance or equipment by its type.

(1) Incandescent lamp, heater, etc. with a power factor of 1.0

Total power consumption must be equal to or less than the rated output of the generator.

Example : A rated 3000W generator can turn thirty 100W incandescent lamps on.

(2)

Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power factor

Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the

load. Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3

times lager than their running wattage.

Example : A rated 250 W electric drill requires a 400 W generator to start it.

NOTE 1: If a power factor correction capacitor is not applied to the fluorescent lamp, the more power

shall be required to drive the lamps.

NOTE 2: Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp.

Therefore, if the fluorescent lamp has no special indication as to the power consumption,
efficiency should be taken into account as explained in ltem (5) on the following page.

(3) Mercury lamps with a smaller power factor

Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.

Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on. A rated

3000 W generator can power two or three 400 W mercury lamps.

(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.

These appliances require large starting wattage which is 3 to 5 times of running wattage.

Example : A rated 900 W compressor requires a 4500 W generator to drive it.

NOTE 1: Motor-driven appliances require the aforementioned generator output only at the starting.

Once their motors are started, the appliances consume about 1.2 to 2 times their rated power
consumption so that the excess power generated by the generator can be used for other
electrical appliances.

NOTE 2: Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting

power depending on the kind of motor and start-up load. If it is difficult to determine the
optimum generator capacity, select a generator with a larger capacity.

– 9 –

(5) Appliances without any indication as to power consumption

Some appliances have no indication as to power consumption; but instead the work load (output) is

indicated. In such a case, power consumption is to be worked out according to the numerical formula

mentioned below.

Efficiencies of some electrical appliances are as follows :

Single-phase motor . . . . . .0.6 to 0.75 (The smaller the motor, the lower the efficiency)

Fluorescent lamp . . . . . . . .0.7 to 0.8

Example 1: A 40W fluorescent lamp means that its luminous output is 40W. Its efficiency is 0.7 and

accordingly, power consumption will be 40÷0.7= 57W. As explained in Item (2), multiply this

power consumption value of 57W by 1.2 to 2 and you will get the figure of the necessary

capacity of a generator. In other words, a generator with a rated output of 1000W capacity

can light nine to fourteen 40W fluorescent lamps.

Example 2

: Generally speaking, a 400W motor means that its work load is 400W. Efficiency of this motor

is 0.7 and power consumption will be 400÷0.7= 570W. When this motor is used for a

motor-driven tool, the capacity of the generator should be multipled by 1.2 to 3 and 570W as

explained in the ltem (3). 570 (W) x 1.2 to 3 = 684 (W) to 1710 (W)

(Output of electrical appliance)

(Efficiency)

= (Power consumption)

Applications

Applicable Wattage (approx. W)

RG4300DX

3300 / 3700

1700 / 1900

RG2800DX RG3200DX

1600 / 1600

50Hz / 60Hz

700 / 800

Incandescent lamp, Heater, etc 2100 / 2400 2400 / 2700

Fluorescent lamp, Electric tool, etc 1100 / 1200 1200 / 1400

Mercury lamp, etc 800 / 800 1000 / 1000

Pump, Compressor, etc 450 / 500 500 / 550

– 10 –

NOTES : Wiring between generator and electrical appliances

1. Allowable current of cable

Use a cable with an allowable current that is higher than the rated input current of the load (electrical

appliance). If the input current is higher than the allowable current of the cable used, the cable will

become excessively heated and deteriorate the insulation, possibly burning it out. The table below

shows cables and their allowable currents for your reference.

2. Cable length

If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors

decreasing the input voltage to the load (electrical product). As a result, the load can be damaged.

The table below shows voltage drops per 30 meters of cable.

2

Allowable

Current

Cable

Resistance

Ω/100m

1.486

0.952

0.517

0.332

1

100

Voltage drops per 30 meters of cable

R : Resistance (Ω/100m)

Cross

sectional

Voltage drop indicates as V= x R x I x L

I : Electric current (A)

L : Length (m)

The length of wire (L) indicates round length, which is the length from the generator

to the electrical tools and back.

<Example> R : Resistance 1.25mm

2

=1.48Ω/100m
I : Electric current 10A
L : Length 30m

The voltage drop of the case described above is

30A25A20A15A10A5AAmm

＊＊＊＊8.9V4.5V121.25

＊＊＊8.6V5.7V2.8V172.0

＊＊6.2V4.7V3.1V1.6V233.5

6.0V5.0V4.0V3.0V2.0V1.0V355.5

1.48Ωx 10A x (30m x 2)

V=

100

≒ 8.9 (V)

– 11 –

4. MEASURING AND CHECKING PROCEDURES

4-1) MEASURING 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 150 V : Type with an output voltage of 110 or

120 V

0 to 300 V : Type with an output voltage of 220,

230 or 240 V

0 to 150 V, 0 to 330 V : Dual voltage type

(2) AMMETER

AC ammeter is necessary.

An AC ammeter with a range that can be changed

according to the current rating of a given generator

is most desirable. (About 10 A, 20 A, 100 A)

(3) FREQUENCY METER

Frequency range : To cover 45 to 65Hz

NOTE : Be careful of the frequency meter's input voltage

range.

For AC

For AC

For DC

For DC

– 12 –

(5) MEAGER TESTER

Used for measuring generator insulation resistance.

Select the one with testing voltage range of 500V.

(4) CIRCUIT TESTER

For measuring resistance, etc.

NOTE : The ordinary circuit tester may cause erroneous

readings due to their measuring method.
Use a high-grade, precise circuit tester to check
the generator components.

(6) TACHOMETER

Use the contactless type tacho meter for checking

engine speed.

– 13 –

(7) "Dr.Robin" GENERATOR TESTER

The "Dr.Robin" generator tester is exclusively
designed for fast, easy diagnosis and repair of
Robin generators.
The "Dr.Robin" has the following features :

1) Functions of voltmeter, frequency meter, megger
tester, capacitance meter and circuit tester are
combined in one unit.

2) Fast and easy readout by digital indicator.

3) Built-in automatic battery checker indicates the
time to change batteries.

4) Tester and accessories are installed in a handy,
sturdy case for easy carrying.

•

SPECIFICATIONS

MODEL Dr.Robin

Part Number 388-47565-08

Measuring
Range

0 to 500 V AC

25 to 70 Hz

0.1 to 1,999 Ω

10 to 100 μF

3MΩ

Circuit Protector Fuse

Power Source 2 x 6F44P (006P) Dry Cell Battery

Accessories

Test leads with needle probes ... 1 set

Test leads with jack plugs ... 1 set

Dimensions (L x W x H) 285 mm x 200 mm x 110 mm

Weight 1.6 kg

Voltage

Frequency

Resistance

Condenser Capacity

Insulation Resistance

The "Dr.Robin" generator tester can be ordered from Robin generator distributors by the following part number.

Dr.Robin_Part_Number_:_388-47565-08

If you do not have a "Dr.Robin" generator tester, use the instruments described in the following section for
checking generator parts.

– 14 –

4-2) AC OUTPUT MEASURING

Use a circuit above 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 the following table at the

rated amperage and rated rpm.

4-3) DC OUTPUT MEASURING

Measurement of DC output is executed with the switch turned ON while the current is regulated at 8.3A by

adjusting the load to the generator. If the voltage is within the range from 6V to 14V, the voltage output is

normal.

NOTE : If a battery is connected as a load to the generator, the DC output voltage will increase by

approximately 1 to 2 V.

Therefore, carefully observe the electrolyte level and do not overcharge the battery.

TO AC RECEPTACLE

SWITCH

A
~

F

V
~

LOAD

Specification

Model

60Hz-120V

60Hz-120/240V

RG2800DX

RG3200DX

119 - 133

240 - 269

RG4300DX

237 - 265

SW

To DC Terminal

Load

– 15 –

4-4) MEASURING INSULATION RESISTANCE

Use a “Dr. Robin” generator tester in megger tester

mode or use a megger tester to check the insulation

resistance. Connect a megger tester to one of

receptacle output terminals and the ground terminal,

then measure the insulation resistance. An insulation

resistance of 1 megohm or more is normal. (The original

insulation resistance at the time of shipment from the

factory is 10 megohm or more.) If it is less than 1

megohm, disassemble the generator and measure the

insulation resistance of the stator, rotor and control

panel individually.

●

STATOR

Measure insulation resistance between each terminal

from the stator and the stator core.

Measured insulation resistance of 1M ohm or

more is normal.

If it is less than 1M ohm, leakage current and

electric shock might occur due to faulty insulation.

Replace with new one.

●

CONTROL PANEL

With AC circuit breaker turned on, measure insulation

resistance between each portion of electrical parts

and earth (grounding) terminal or control panel itself.

Measured insulation resistance of 1M ohm or

more is normal.

If it is less than 1M ohm, leakage current and electric

shock might occur due to faulty insulation.

Replace with new one.

Any part where the insulation resistance is less than
1MΩ has faulty insulation, and may cause electric

leakage and electric shock.

Replace the faulty part.

Wire

– 16 –

4-5) CHECKING FUNCTIONAL MEMBERS

(1) STATOR

Disengage connectors on the wires from stator and check

the resistance between the wires using a circuit tester

referring to the table below.

NOTE :

If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings.

Erroneous readings will also occur when there is a wide variation of resistance among coil windings or

when measurement is performed at ambient temperature different from 20°C (68°F).

(2) ROTOR ASSEMBLY

1) Field coil

Measure resistance between the slip rings.

2) Cleaning Slip rings

The slip ring surfaces must be uniformly bright.

Slip rings showing black spots, excessive wear, or

uneven wear must be repaired.

A stained slip ring lowers generator efficiency and

output voltage.

Polish the slip rings with fine sandpaper while turning

the rotor until rough spots disappear.

NOTE :

When measuring, tolerance should be considered

because of the tester inaccuracy, winding number

variation, ambient temperature etc.

NOTE : Care should be taken not to touch the rotor

coils with the sandpaper.

Coil resistance (Ω)

Main coil

Exciter coil

DC coil

Sub coil

Wire color

Black−Yellow

Green−Red

Blue−Blue

Brown−Brown

Yellow−Yellow

Black−Black

RG2800DX RG4300DXRG3200DX

0.7

-

1.3

0.6

0.4 0.4

0.3 0.3 0.3

Coil resistance (Ω)

RG2800DX RG4300DXRG3200DX

Field coil

(Between two Slip rings)

41 4744

0.9

0.9 0.5

1.2

0.5

0.5

1.1

0.4

0.3

Rotor

Slip ring

Slip ring

Rotor

Sandpaper

– 17 –

（3）BRUSH

The brushes must be smooth where they contact the slip

rings. If not, polish smooth the brushes with sandpaper.

A brush that is not smooth produces arcs between the

brush and slip ring leading to possible damage.

A brush shorter than 5 mm must be replaced because

decreased contact pressure between the brush and slip

ring lowers generator efficiency and output voltage.

（4）AC CIRCUIT BREAKER

Check continuity between each of two terminals at the

rear of the AC circuit breaker while it is mounted on the

control panel.

(5) DC CIRCUIT BREAKER

Check that there is continuity between the two terminals

of DC circuit breaker when its push button is pressed.

AC circuit breaker

OFF

：No continuity

BRUSH HOLDER

5 mm

BRUSH

ON ：Continuity

– 18 –

(6) A.V.R (AUTOMATIC VOLTAGE REGULATOR)

1) Features

This AVR operates to control the field current in

order to maintain the output voltage for the AC

current, which generated by the magnetic flux by

the field coil.

2) A.V.R. trouble may be identified by simply looking

at the A.V.R., or by the inter-lead resistance with

a tester, or actually mounting it in the generator

and operating it.

(a) A.V.R. TROUBLE IDENTIFICATION by APPEARANCE

If an A.V.R. electronic part is burnt dark, or the surface epoxy resin melted, it often indicates A.V.R.

trouble.

(b) IDENTIFYING A.V.R. TROUBLE by CHECKING INTER-LEAD RESISTANCE

Check the inter-lead resistance of the A.V.R. with a tester, referring to the following table.

If the tester readings very greatly from the values specified in the table, the A.V.R. is faulty.

(c) IDENTIFYING A.V.R. TROUBLE by MOUNTING and OPERATING in THE GENERATOR

SCR or transistor damage cannot be detected by simply looking at the A.V.R. or checking the lead

resistance. Check it by mounting the suspectedly faulty A.V.R. in a normal generator, or mount a normal

A.V.R. in a generator which fails to generate voltage.

Apply black (minus) needle

Apply red (plus)
needle of the
circuit tester

Orange/Green

of the circuit tester

Orange/Green

−

ContinuityOrange

Orange

No continuity

−

4P Connector

Red-White

Blue

：No continuity

-

Blue：No continuity

– 19 –

(9) FLOAT TYPE OIL SENSOR

Check the oil sensor when it is installed on the engine.

Check that sufficient engine oil is filled in the crankcase.

Check that there is continuity between the lead wire of

oil sensor and the ground (engine crankcase) when the

oil level is above the minimum level mark of oil gauge.

Check that there is no continuity as above when the oil

level is below the minimum level mark of oil gauge.

(8) AC RECEPTACLES

Check that no live part or wire or plastic part is burnt.

(7) DIODE RECTIFIER

The circuit inside the diode rectifiers is as shown in the chart

above.

Check continuity between each terminal by using a circuit

tester.

The rectifier is normal when continuity is as follows:

Brown

Brown

1
2

3

Orange

Checking table for analogue circuit tester

Analogue circuit tester

Apply black (minus) needle of the circuit tester

123

2

1

3

Apply red (plus)
of the circuit tester

needle

1

-

No continuity2

Continuity3

Checking table for digital circuit tester

Digital circuit tester

Apply black (minus) needle
of the circuit tester

Apply red (plus)

1

No continuity2

Continuity3

123

-

No continuity

-

Continuity

needle of the circuit tester

No continuity

-

Continuity

No continuity

No continuity

-

No continuity

No continuity

-

Oil sensor

– 20 –

5. DISASSEMBLY AND ASSEMBLY

5-1) PREPARATION AND PRECAUTIONS

(1) Be sure to memorize the location of individual parts when disassembling the generator so that the generator

can be reassembled correctly. Tag the disassembled part with the necessary information to facilitate easier and

smoother reassembly.

(2) For more convenience, divide the parts into several groups and store them in boxes.

(3) To prevent bolts and nuts from being misplaced or installed incorrectly, replace them temporarily to their

original position.

(4) Handle disassembled parts with care; clean them before reassembly using a neutral cleaning fluid.

(5) Remove the battery before disassembling the generator. (Electric start models)

(6) Use all disassembly/assembly tools properly, and use the proper tool for each specific job.

(7) Be sure to attach the foam rubber linings inside the covers on their original position when reassembling the

generator. When deformation or damage or falling-off of foam rubber lining is found, replace it with new part.

Failure to do so will result in poor performance and durability of the generator.

(8) Bind the wires and fuel pipes using wire bands as they have been done in original configuration.

NOTE : As to detailed information for servicing procedures on engine portion, please refer to Robin engine service

manual for models EX13/17/21/27.

5-2) SPECIAL TOOLS

Use correct tools to prevent unnecessary effort and giving damages to the parts.

Part Number

33B9990801

Part Name Shape Usage

FLYWHELL HOLDER33B9990101

DRIVESHAFT HOLDER33B9990201

ROTOR PULLER

– 21 –

(3) Remove fuel strainer.

5-3) DISASSEMBLY PROCEDURES

5-3-1

FUEL PIPES, FUEL STRAINER and BATTERY CABLES

(1) Turn the engine switch to “STOP” position to close

fuel cock.

(2) Disconnect fuel pipes from fuel strainer.

5-3-2 REAR COVER

(1) Remove muffler cover.

M6 x 18mm Flange bolt :6pcs.

Tools : 10mm Box wrench

(2) Remove upper rear cover.

Fuel strainer

Muffler cover

(Rear)

Rear cover
(Upper )

– 22 –

5-3-3 AUTOTHROTTLE COUPLER [Deluxe model]

Disengage the coupler from the auto-throttle unit of carburetor.

5-3-4 CHOKE WIRE [Deluxe model]

Loosen screw fixing choke wire to carburetor choke lever.
Turn the engine switch to “CHOKE” position to disconnect
choke wire from choke lever.

Tools : Screw driver

5-3-5 GROUNDING WIRE

Remove grounding wire at the right bottom side of control

panel.

M6 Nut :1pce.

Auto-throttle
coupler

Choke wire

Grounding wire

– 23 –

5-3-6 END COVER

Remove end cover.

M5 x 10mm bolt : 2pcs.

Tools : Screw driver

5-3-7 FRONT COVER (UPPER)

BRACKET (COVER)

Remove front cover (upper).

For disassembling the front cover (upper), see
illustrations on the following page.

Disconnect alternator couplers.

End cover

– 24 –

FRONT COVER (UPPER) and CONTROL PANEL

Gromet

Front cover (Upper)

Multi
monitor

Micro
switch

AC circuit

breaker

AC receptacles

DC circuit

breaker

Engine switch

CONTROL PANEL

AC receptacles

Ground
terminal

DC
terminals

4.0 - 6.0 N･m
40 - 60 kgf･cm
(3.0 - 4.4 ft･lbs)

M6 Screw

– 25 –

5-3-9 WIRE BAND

Cut the wire band binding wires behind control panel.

For electric starter model, cut the wire band binding battery
cables also.

Tools : Nipper

5-3-8 BRUSH HOLDER

(1) Remove brush holder.

M5 x 18mm Screw : 1pce.

Tools : Screw driver

5-3-10 FUEL TANK

Loosen bolts and remove fuel tank from frame.

M6 x 20mm Flange reamer bolt :4pcs.
Rubber :4pcs.

Tools : 10mm Box wrench

NOTE1 : Be sure to drain fuel from the tank before

removing the tank.

NOTE2 : Take care not to get lost the four mounting

rubbers of the tank.

Brush holder

Wire band

Fuel tank

– 26 –

FUEL TANK and FUEL LINE

Fuel gauge

Fuel tank cap

Fuel filter

4.0 - 6.0 N･m
40 - 60 kgf･cm
(3.0 - 4.4 ft･lbs)

Fuel tank

M6 Flange
reamer bolt

Rubber pipe

Fuel strainer

Screw

Filter

O-ring

Cup

Rubber pipe

Rubber
(Tank)

– 27 –

5-3-13 MUFFLER

(1) Loosen nuts and remove muffler.

M8 Flange nut : 2 pcs.

Tools : 12mm Box wrench

(2) Loosen bolts and remove muffler bracket.

M6 x 23mm Flange bolt : 2pcs.

Tools : 10mm Box wrench

5-3-11 FOAM RUBBER INSULATORS

Remove foam rubber insulators from the gaps between
frame and fuel tank.

5-3-12 MUFFLER COVER

Loosen bolts and remove muffler cover (L) by pushing it
inward.

M6 x 12mm Flange bolt : 4pcs.

Tools :10mm Box wrench

– 28 –

5-3-14 GOVERNOR ROD [Standard model only]

Take out governor rod from carburetor throttle shaft.

5-3-15 ROD SPRING [Standard model only]

Take out rod spring from carburetor throttle shaft.

Tools : Long-nose pliers

5-3-16 GOVERNOR LEVER [Standard model only]

Remove governor lever.

M6 x 25mm Bolt and Washer : 1pce.

Tools : 10mm Box wrench

Plier

Throttle shaft

Rod spring

Throttle shaft

Governor rod

Governor lever

– 29 –

5-3-17 AIR CLEANER and CARBURETOR

(1) Remove air cleaner cover and element from the air

cleaner.

(2) Loosen nuts and a bolt, and remove air cleaner body.

M6 Flange nut : 2pcs.

M6 x 20mm Flange bolt : 1pce.

Tools : 10mm Box wrench

(3) Be sure not to break the gasket, carefully remove

carburetor from insulator.

Element

Cleaner cover

Air cleaner base

Carburetor

– 30 –

5-3-18 ENGINE BLOCK

(1) Loosen nuts fixing the engine to mount rubbers, and

remove the engine.

M8 Flange nut : 4pcs.

Tools : 12mm Box wrench

(2) Remove mount rubbers from frame as necessary.

M8 Flange nut : 4pcs.

Tools : 12mm Box wrench

5-3-19 CRANKSHAFT COVER

Loosen bolts and remove crankshaft cover.

M8 x 12 Flange bolt : 2pcs.

Tools : 12mm Box wrench

5-3-20 REAR COVER

Remove rear cover along with stator.

Cover
(Crankshaft)

– 31 –

ALTERNATOR

Rotor Puller

Remove rotor by using the Rotor Puller.

Special tools : Rotor Puller (33B9990801)

5-3-21 ROTOR BOLT and ROTOR

(1) Remove rotor bolt.

Rotor bolt : 1pce.

Tools : Socket wrench

NOTE : Since the thread of the through bolt is in

reverse direction, turn it clockwise to

loosen.

End cover

Grommet

AVR unit

M5 Bolt

2.0 - 3.4 N･m
20 - 34 kgf･cm
(1.4 - 2.5 ft･lbs)

Brush holder

6.5 - 8.5 N･m
65 - 85 kgf･cm
(4.7 - 6.1 ft･lbs)

Rotor Bolt

Rear cover

Bearing

Washer

19.0 - 21.0 N･m
190 - 210 kgf･cm
(13.7 - 15.2 ft･lbs)

Rotor

Stator cover

Stator
Bolt
(M6)

Stator

M5 Bolt

8.0 - 10.0 N･m
80 - 100 kgf･cm
(5.8 - 7.2 ft･lbs)

– 32 –

5-3-22 RECOIL STARTER

Loosen bolts and remove recoil starter.

M6 x 18mm Flange bolt : 3pcs.

Tools : 10mm Box wrench

NOTE : Refer to section 5-5 for further instruction for

disassembly/reassembly procedures of recoil

starter.

5-3-23 BOTTOM EXTENSION PLATE

Loosen bolts and remove bottom extension plate.

M8 x 33mm Flange bolt for crankcase side : 2 pcs.

M8 x 12mm Flange bolt for blower housing side : 2 pcs.

Tools : 12mm Box wrench

5-3-24 BLOWER HOUSING

Loosen bolts and remove blower housing.

M6 x 35mm Bolt : 1pce.

M6 x 45mm Bolt : 3pcs.

Tools : 10mm Box wrench

Recoil starter

Bottom extension plate

Blower housing

M6x35mm Bolt

M6x45mm
Bolt

– 33 –

5-3-25 DRIVE SHAFT and FAN

Using the special tool “DRIVE SHAFT HOLDER” to hold
drive shaft, loosen bolts to remove drive shaft and fan
from the flywheel.

M8 x 27mm Flange bolt : 4pcs.

Tools : 12mm Box wrench

Drive shaft holder (33B9990201)

5-3-26 FLYWHEEL

Using the special tool “FLYWHEEL HOLDER” to hold
flywheel, loosen flywheel nut.
Remove flywheel using an ordinary flywheel puller.

M19 Nut : 1pce.

Tools : Socket wrench

Flywheel Holder (33B9990101)

Flywheel puller (Available on market)

Drive shaft

Drive shaft holder

Flywheel holder

– 34 –

5-4) REASSEMBLY PROCEDURES

NOTE : The mount rubbers are designed to isolate the

vibration most effectively by their original stiffness

and shape of rubber. Be sure to use the correct

mount rubbers attaching them to the correct position.

5-4-1 MOUNT RUBBERS

Attach the four Mount Rubbers to the frame. Insert the

locating tab of mount rubber into the locating hole of the

frame and fix it by tightening M8 flange nut.

M8 Flange nut : 4pcs.

5-4-2 FLYWHEEL

NOTE : Be sure to wipe off oil from the tapered portion

of the crankshaft and the hole of flywheel
before assembly.

Install the Flywheel onto the crankshaft and tighten the
Flywheel Nut using the special tool “FLYWHEEL
HOLDER” to hold the flywheel.

M19 Nut : 1pce. (EX17, 21)

Tightening torque : 59.0-64.0 N・m

590

-

640 kgf

・

cm

(43.5

-

47.2 ft・lbs)

Tightening torque : 10.0

-

12.0 N

・

m

100

-

120 kgf・cm

(7.4

-

8.7 ft・lbs)

5-4-3 FLYWHEEL FAN and DRIVE SHAFT

(1) Install the Flywheel Fan to the flywheel so as that the

three alignment tabs on the back of flywheel fan to

mate with the holes of the flywheel.

(2) Assemble the Drive Shaft onto the flywheel.

Tighten the four M8 bolts while holding the drive shaft

using the special tool “Drive Shaft Holder”.

M8 x 27mm Flange bolt : 4pcs.

Tightening torque : 25.0-27.0 N・m

250

-

270 kgf・cm

(18.4

-

19.9 ft・lbs)

Top side of frame

Drive shaft

Drive shaft holder

– 35 –

5-4-4 BLOWER HOUSING

(1) Assemble the Blower Housing onto the crankcase.

M6 x 35mm Bolt : 1 pce.

M6 x 45mm Bolt : 3 pcs.

Tightening torque : 8.0

-

10.0 N

・

m

80

-

100 kgf

・

cm

(5.9

-

7.4 ft

・

lbs)

Tightening torque : 18.0-22.0 N・m

180

-

220 kgf・cm

(13.3

-

16.2 ft・lbs)

5-4-5 BOTTOM EXTENSION PLATE

Assemble the Bottom Extension Plate to the engine.

M8 x 33mm Flange bolt for crankcase side : 2 pcs.

M8 x 12mm Flange bolt for blower housing side : 2 pcs.

Tightening torque : 6.5-8.5 N・m

65

-

85 kgf・cm

(4.8

-

6.3 ft・lbs)

5-4-6 RECOIL STARTER

Assemble the Recoil Starter to blower housing.

M6 x 18mm Bolt : 3pcs.

NOTE : Refer to section 5-5 for further instruction for

disassembly/reassembly procedures of recoil

starter.

Blower housing

M6x35mm Bolt

M6x45mm
Bolt

Bottom extension plate

Recoil starter

– 36 –

5-4-8 REAR COVER

Assemble the Rear Cover to the blower housing.

M6 x 90mm Stator Bolt : 4pcs.

Tightening torque : 6.5

-

8.5 N

・

m

65

-

85 kgf

・

cm

(4.8

-

6.3 ft

・

lbs)

5-4-7

THROUGH BOLT (thread in reverse direction)

Insert the Rotor bolt into the center of rotor shaft and

tighten it.

Rotor bolt : 1 pce.

Tightening torque : 19.0

-

21.0 N

・

m

190

-

210 kgf

・

cm

(14.0

-

15.5 ft

・

lbs)

NOTE1 : Wipe off oil, grease and dust from the tapered

portion of engine shaft and matching tapered
hole of rotor shaft.

NOTE2 : The thread of the Through Bolt is in reverse

direction.
Therefore, torque it counter-clockwise to
tighten it.

5-4-9 COVER (CRANKSHAFT)

Assemble the Cover (Crankshaft) to the main bearing

cover.

M8 x 12mm Flange bolt : 2 pcs.

Tightening torque : 18.0-22.0 N・m

180

-

220 kgf・cm

(13.3

-

16.2 ft・lbs)

Cover
(Crankshaft)

– 37 –

NOTE : The nut on the LH-side rear cover commonly

fixes grounding wire.

5-4-10 Installation of ENGINE and ALTERNATOR

ASSEMBLY onto FRAME

Install the engine and alternator assembly onto frame

carefully aligning the bolts of mounting rubbers into the

engine/alternator base.

Then tighten flange nuts.

M8 Flange nut : 4pcs.

5-4-11 CARBURETOR

Install the Carburetor to the intake flange.

NOTE: Be sure to attach the gasket between the

carburetor and the intake flange.

5-4-12 AIR CLEANER BASE

Attach the Air Cleaner Base to the carburetor and fix with

two M6 bolts and one M6 Flange bolt.

M6 Flange nut : 2 pcs.

M6 x 20mm Flange bolt : 1 pce.

Tightening torque : 6.0

-

8.0 N

・

m

60

-

80 kgf

・

cm

(4.4

-

5.9 ft

・

lbs)

Tightening torque : 10.0-12.0 N・m

100

-

120 kgf・cm

(7.4

-

8.7 ft・lbs)

Air cleaner base

Carburetor

– 38 –

5-4-13 AIR CLEANER ELEMENT

Assemble the Air Cleaner Element and the Air Cleaner

Cover to the air cleaner base.

Wash the cleaner element if it is dirty before reassembly.

5-4-15 ROD SPRING [Standard model only]

Fit Rod Spring onto Carburetor Throttle Shaft.

5-4-14 GOVERNOR LEVER [Standard model only]

Fix Governor Lever with the Governor Shaft fully turned
clockwise.

M6 x 25mm Bolt and Washer : 1pce.

Element

Cleaner cover

Governor lever

Rod spring

Throttle shaft

– 39 –

5-4-17 MUFFLER

Install Muffler to the engine.

M8 Flange nut : 2 pcs.

M6 x 23mm Flange bolt : 2 pcs.

Tightening torque : 4.0-6.0 N・m

40

-

60 kgf・cm

(3.0

-

4.4 ft・lbs)

Tightening torque : 17.0-19.0 N・m

170

-

190 kgf・cm

(12.5

-

14.0 ft・lbs)

5-4-16 GOVERNOR ROD

[Standard model only]

Install Governor Rod onto Carburetor Throttle Shaft.

Throttle shaft

Governor rod

– 40 –

Tightening torque : 4.0-6.0 N・m

40

-

60 kgf・cm

(3.0

-

4.4 ft・lbs)

5-4-18 MUFFLER COVER

Attach the Muffler Cover to the muffler.

M6 x 12mm Flange bolt : 4 pcs.

5-4-19 SPONGE

Install the Sponges between the fuel tank and the frame

as shown in the figure righrt.

5-4-20 FRONT COVER (UPPER)

Temporarily fit Front Cover (upper) in position.

Connect alternator couplers.

5-4-21 BRUSH HOLDER

Install the brush holders in the rear cover.

M5 x 18mm Screw : 1pce.

Brush holder

– 41 –

5-4-22 GROUNDING WIRES

Fasten the grounding wire from the alternator.

Tools : Screw driver

5-4-23 Connection of WIRING HARNESS

Connect engine wire harness couples.

Connect main coil wiring to the terminal; Red wiring to
the upper terminal, while White to the lower one.

Connect couples of wiring harness between control
panel and alternator.

Main coil wiring

– 42 –

5-4-25 FUEL TANK

(1) Install the Fuel Tank onto the frame. Be sure to insert

the mount rubbers between the tank and the frame.

M6 x 20mm Flange bolt : 4 pcs.

Mount Rubbers : 4 pcs.

5-4-26 Clamping of CHOKE CABLE and

GROUNDING WIRES

Clamp the choke cable and grounding wires using a wire

band.

(2) Attach two pieces of Rubber Seal (Tank).

(3) Attach the Sponge Seal (Muffler).

Tightening torque : 4.0

-

6.0 N

・

m

40

-

60 kgf・cm

(3.0

-

4.4 ft・lbs)

5-4-24 AUTO THROTTLE

(1) Connect the wires to Auto Throttle Unit of the

carburetor.

(2) Temporarily connect the choke cable to the

carburetor choke lever.

Auto-throttle
coupler

Fuel tank

Wire band

– 43 –

5-4-27 REAR COVER (UPPER) and

MUFFLER COVER (REAR)

(1) Attach the Rear Cover (Upper) first to the frame.

(2) Install the Muffler Cover (Rear) onto the Rear Cover

(Upper) and the frame.

M6 x 18mm Flange bolt : 6pcs.

Tightening torque : 4.0-6.0 N・m

40

-

60 kgf・cm

(3.0

-

4.4 ft・lbs)

5-4-28 END COVER

Attach the End Cover to the rear cover.

M5 x 10mm bolt : 2pcs.

Rear cover
(Upper )

Muffler cover

(Rear)

End cover

– 44 –

Tightening torque : 4.0-6.0 N・m

40

-

60 kgf・cm

(3.0

-

4.4 ft・lbs)

5-4-29 FRONT COVER (UPPER)

Securely fix Front Cover (upper).

M6 x 12mm Flange bolt : 4 pcs.

5-4-30 CHOKE WIRE

Fix the Choke Wire to the carburetor choke lever making

sure that the choke valve is fully closed when engine

switch is turned to “CHOKE” position.

NOTE : Be sure to install the return spring.

5-4-31 GROUNDING WIRE

Fasten the grounding wire to the frame.

M6 Screw : 1pce.

Front Cover (Upper)

Choke wire

Grounding wire

– 45 –

(2) Connect the fuel pipe from carburetor to the Fuel

Strainer. Clamp the fuel pipe with a hose clamp.

5-4-32 FUEL STRAINER and FUEL PIPE

(1) Align the shaft of engine switch to the Fuel Strainer

Cock when the engine switch is in “STOP” position

and the fuel cock closed.

Fuel strainer

– 46 –

5-5) RECOIL STARTER

Tools used : Long-nose pliers, retaining-ring pliers, protective goggles

The recoil starter of this device is located between the alternator assembly and the engine, so remove the recoil

starter after removing the alternator assembly.

Caution :

Please wear protective goggles before starting disassembly

Caution :

The pull of the spring is maximized while the rope is fully pulled out.

Please do not release it suddenly, or relax your grip.

1) Disassembly procedures

(1) Unhook the spring.

-1 Hold the starter handle, and pull out the starter

rope.

-2 Pull out all of the rope, and align the rope guide

and the knot of the rope inside the reel.

-3 Be sure to hold the reel with both thumbs

so your fingers do not become be entangled.

-4 Pull the knot of the rope out from the reel, loosen

the knot, then pull it up from the starter handle

side (this should be done by two people).

-5 Slowly rewind the rope until the reel stops while

controlling the reel with both thumbs.

Starter rope

Starter handle

– 47 –

Caution :

The reel is disassembled with the spring still

assembled, so place it on a flat table without

dropping, or shaking.

(2) Remove the small parts.

-1 Hold the case, and remove the retaining-ring C

with the ring pliers.

-2 Beginning at the top, remove the retaining-ring,

friction plate, and ratchet.

Disassembly is completed.

(3) Remove the reel.

-1 Move the reel to left and right at a 1/4 turns

several times until it moves smoothly, gently

holding it down.

-2 Slowly lift the reel, removing it from the case.

-3 Repeat (3) 1 and (3) 2 if the spring assembled in

the reel sticks out.

Retaining-ring
pliers

Retaining-ring C

Retaining-ring C

Ratchet

Friction
spring

Reel

Friction plate

Starter handle

Spiral spring

Starter case

– 48 –

(2) Install the ratchet and friction spring.

Install the ratchet and friction spring into the reel.

(3)Installation of friction plate and retaining ring C.

Install by putting the Tab of friction plate into the

hole of the ratchet.

Fasten with the retaining ring C.

Be sure that the retaining ring is fitted into the

grooves.

Caution:

Please wear protective goggles before starting assembly.

2) Assembly procedure

(1) Assemble the reel into the case.

-1 Apply grease to the case.

-2 Properly orient the inner end of the spring installed

in the reel.

-3 Hold the reel so that the shaft and hook part can

be caught on the inner end of the spring, and

softly drop into the case from the top.

-4 Move the reel gently in the counter-clockwise

direction, making sure that the spring catches.

Hooking
position

Inner end of

the spring

Grease

Reel

Spiral
spring

Starter case

Retaining-ring C

Friction plate

Ratchet

Friction
spring

Friction plate

Retaining-ring C

– 49 –

(4) Wind the spiral spring.

-1 Holding the case, turn the reel five turns in

counter-clockwise.

-2 Fix the reel in the position that the rope hole of

reel aligns with the rope guide.

(5) Inserting the rope.

(this should be done by two people)

-1 Thread the rope end through the rope guide and

the rope hole of the reel, and pull 20cm out from

the reel.

-2 Tight the end of the rope.

-3 Fix the rope end to the reel.

-4 Hold the rope at the distance 50cm from the rope

guide. Hold securely.

-5 Gently release the reel and have it wind the rope

on the reel until the knot reaches the rope guide.

Caution:

Do not release the pressure to hold the reel
while winding the spiral spring.
The spring force is strong and cause sudden
rewinding if you release the pressure.

Assembly is completed.

※These are the disassembly and assembly procedures, please be sure to review the following item checklist to

insure that the parts securely installed.

Five turns in counter-clockwise

About 20cm

About 10mm

– 50 –

3) Checking items after assembly

(1) Try to pull the starter handle for 2 to 3 times.

(a)When the starter handle is difficult to pull, please make sure the parts, etc., are installed in the right direction.

(b)When the ratchet does not operate, please re-check if there are any missing parts such as the spring.

(2) Pull the starter handle and try to pull the starter rope out to the limit.

(a)When the starter rope does not return smoothly, or the starter handle is hangs down loosely, please add

grease or mobile oil in the rotating and friction parts.

If it still does not work, rewind 1~2 times.

(In that case, confirm that the spring is not under pressure by following the previous procedure.)

(b)Please re-assemble from the beginning if there was the sound when the spring was removed and the starter

rope does not re-winded into the reel.

4) When . . .

(1)The spring pops out

(a)Hook the end hook of the spring to the notched

part of the reel, and attach the spring, applying

pressure with your fingers so that it isn’t released

from the groove. (Please wear gloves)

(b)Hook the inside hook of the spring to the claw of

the starter case while turning.

※ Please refer to assembly procedures.

(2) Oil refill

At the end of the season or when disassembling, add

grease (preferably one that is heat resistant, if

possible) or mobile oil to rotation parts, friction parts,

and the spring.

ReelSpiral spring

– 51 –

6.TROUBLE SHOOTING

Check if engine speed is normal.

50Hz : 3,000rpm

60Hz : 3,600rpm

OK

Check if brush is weared.

Check if the total length of
brush is 5mm or over.

OK

Check if stator coil is normal.

Main coil

Exciter coil

NG

NG

NG

Refer to
"Engine dose not start (Start failure )"

Check and replace brush.

Replace

OK

Check if rotor coil is normal.

OK

Check if AVR is normal.

OK

Check if wiring is break or
improper connection.

NG

NG

NG

Replace

Replace

Replace when wiring is break or damage.

Connect properly.

– 52 –

No DC current

Check if DC coil of stator is normal.

OK

Check if diode rectifier is normal.

OK

Check if DC circuit breaker is normal.

OK

NG

NG

NG

Replace

Replace

Replace

Check if wiring is break or
improper connection.

NG

Replace when wiring is break or damage.

Connect properly.

– 53 –

Improper revolutions (Electronic throttle)

Engine starts but
stops suddenly.

No

・Engine revolution
does not increase.

・Hunting

・Pull the recoil starter lightly with the full throttle open.

Full throttle direction ：Throttle direction is from the air cleaner in front

towards opposite direction (towards the back)

Go to the engine malfunction section.
engine check (refer to p. 00)

Yes

Yes

Go to the start malfunction section

Confirm connection of
electronic throttle coupler.

Confirmed

Does
not run

Change the carburetor

Runs

・Dirty or bad spark plug
・Poor return of the choke
・Air cleaner blockage
・Muffler blockage
・Bad carburetor (water contamination, blockage, etc.)
・Lack of gasoline
・Gasoline deterioration
・Blockage from the tank to the carburetor

– 54 –

Engine does not start (Start failure)

Check the gasoline
in the tank

Yes

Oil warning lamp turns on
when the recoil is pulled

Fuel cock is in
the ON position

Yes

Gasoline leaks when the
carburetor drain is loosened

Yes

Check for
gasoline deterioration

Good

Remove the spark plug
and check the electrode

Wet

Attach the plug to the plug
cap, and check for sparks
by pulling the recoil starter

None

warning
lamp is on

No

Open
the cock

No

Clean,
change
the filter

Deteriorated

Dry

Blockage of the fuel passage or
jets of carburotor

No or
poor sparks

Add gasoline

Check the oil level

Good

Confirm of the oil sensor

E/g

GND

Change
gasoline

・Check for dirty electrodes, or gap
・Check the connection of coupler,

high tension cord and spark plug cap

STANDARD MODEL
DELUXE MODEL : Change the Monitor unit

Low

Resistance
value≒0Ω

Tester

No continuity

: Change the Oil sensor unit

Add oil (up to the
rated volume)

Change Oil sensor

Good Sparks

Check the compression
at the spark plug hole
by pulling recoil starter

Poor compression

Valve clearance adjustment

– 55 –

7. WIRING DIAGRAM

RG2800DX (60Hz-120V) [Recoil starter model]

GENERATOR

FC

EXC

Main
coil

DC
winding

Sub coil 1

Sub coil 2

W

Org
Gry

Blk
Blk

Y
Y

AVR

AC Circuit

R

Grn

breaker

RR

Blu

Blu

DC Circuit
breaker

Org Org
Gry

W
Blu

DC output
terminal

Grn/Y

CONTROL PANEL

Grn/Y

Grn/Y

120V

Blu

Blu

R

Brn

Grn/Y

Stepping
motor

Oil level
sensor

ENGINE

Wiring color code

Blk : Black
Blk/W : Black/White
Blu : Blue

Spark
plug

Ignition
coil

Grn
Blu
Pur

Gry
Y

Org
Blk

LBlu : Light blue
Brn : Brown
Brn/W : Brown/White

MONITOR C/U

Grn : Green
Grn/W : Green/White
Org : Orange

Blk

W

Gry : Gray
R : Red
W : White

Engine
switch

Y : Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow

Grn/Y

Grn/Y

Earth (ground)
terminal

Pur : Purple
Pin : Pink

– 56 –

RG3200DX/4300DX (60Hz-120/240V) [Recoil starter model]

GENERATOR

FC

EXC

Main
coil 2

Main
coil 1

DC
winding

Sub coil 1

Sub coil 2

W

Org
Gry

Blk
Blk

Y
Y

AVR

R

AC Circuit

R

Grn

Y

Blk

breaker

RRR

Blu

W

Blk Blk

DC Circuit
breaker

Org Org
Gry

W
Blu

AC Circuit
breaker

120/240V

1

2

3

4

5

6

Blu

120V

W

Blk

Blk

DC output
terminal

Grn/Y

CONTROL PANEL

Grn/Y

Grn/Y

W

120V

Brn

R

Blu

120V

11

8

R

7

9

10

12

120/240V

Grn/Y

Blu

R

W

Blu

Blu

Stepping
motor

Oil level
sensor

ENGINE

Wiring color code

Blk : Black
Blk/W : Black/White
Blu : Blue

Spark
plug

Ignition
coil

Grn
Blu
Pur

Gry
Y

Org
Blk

LBlu : Light blue
Brn : Brown
Brn/W : Brown/White

MONITOR C/U

Grn : Green
Grn/W : Green/White
Org : Orange

Blk

W

Gry : Gray
R : Red
W : White

Grn/Y

Engine
switch

Y : Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow

Grn/Y

Earth (ground)
terminal

Pur : Purple
Pin : Pink

– 57 –

RG3200DX/4300DX (60Hz-120 / 240V) [Electric starter model]

GENERATOR

FC

EXC

Main
coil 2

Main
coil 1

DC
winding

Sub coil 1

Sub coil 2

W

Org
Gry

Blk
Blk

Y
Y

AVR

R

AC Circuit

R

Grn

Y

Blk

breaker

RRR

Blu

W

Blk Blk

DC Circuit
breaker

Org Org
Gry

Brn
Brn

AC Circuit
breaker

120/240V

1

2

3

4

5

6

Y
Y

Blu

120V

W

Blk

Blk

DC output
terminal

Regulator

W
Blu

Grn/Y

R

120V

Brn

Grn/Y

Grn/Y

AC Circuit
breaker

Grn/Y
R

CONTROL PANEL

R

7

8

9

10

11

W

Blu

120V

W

12

W

120/240V

Blu

Grn/Y

Blu

R

Blu

Stepping
motor

Oil level
sensor

Starting
motor

M

ENGINE

Wiring color code

Blk : Black
Blk/W : Black/White
Blu : Blue

Spark
plug

Battery

Ignition
coil

R

Blk

LBlu : Light blue
Brn : Brown
Brn/W : Brown/White

Grn
Blu
Pur

Gry
Y

Org
Blk

R

W

MONITOR C/U

Engine switch

Fuse10A

Relay

Grn : Green
Grn/W : Green/White
Org : Orange

Grn/Y

Blk

W

Gry : Gray
R : Red
W : White

M-

ST

L.IG

M+

B

Key
switch

Org

R

Grn/Y

Y : Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow

Grn/Y

Earth (ground)
terminal

Pur : Purple
Pin : Pink

ISSUE EMD-GS2025

2005.08