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
1.48Ωx 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
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