Robin RGD2500, RGD330 Service Manual

SERVICE

--

MAIUUAL -

Model

RGD2500, RGD3300

Generator

PUB-GS1186 Rev. 8198

CONTENTS

.

Section

Tile

Page

1

.

SPEClFlCATlONS

.......................................................................................................

1

2

.

PERFOMANCE CURVES

...........................................................................................

2

2-1 MODEL RGD2500

.................................................................................................

2

2-2

MODEL RGD3300

.................................................................................................

2

2-3

DC OUTPUT

.........................................................................................................

2

3

.

FEATURES

..................................................................................................................

3

4

.

GENERAL DESCRIPTION

..........................................................................................

4

4-1 EXTERNAL VIEW

.................................................................................................

4

4-2

CONTROL PANEL

................................................................................................

5

4-3 LOCATION

of

SERIAL NUMBER

and

SPECIFICATION NUMBER

......................

6

5

.

CONSTRUCTION AND FUNCTION

...........................................................................

7

5-1

CONSTRUCTION

.................................................................................................

7

5-2 FUNCTION

............................................................................................................

7

5-3

GENERATOR OPERATION

................................................................................

11

6

.

SAFETY PRECAUTIONS

.........................................................................................

14

7

.

RANGE

OF

APPLICATIONS

....................................................................................

15

8

.

MEASURING PROCEDURES

..................................................................................

18

8-1 MEASURING INSTRUMENTS

...........................................................................

18

8-2 AC OUTPUT MEASURING

.................................................................................

21

8-3

DC OUTPUT MEASURING

.................................................................................

21

8-4 MEASURING INSULATION RESISTANCE

........................................................

22

9

.

CHECKING FUNCTIONAL MEMBERS

....................................................................

24

9-1 VOLTMETER

.......................................................................................................

24

9-2 AC RECEPTACLES

............................................................................................

24

9-3 NO-FUSE BREAKER

...........................................................................................

24

9-4 STATOR

..............................................................................................................

25

9-5 ROTOR ASSEMBLY

...........................................................................................

26

9-6 CONDENSER

.....................................................................................................

26

9-7 DIODE RECTIFIER

.............................................................................................

27

10

.

DISASSEMBLY AND ASSEMBLY

..........................................................................

29

10-1

PREPARATION

and

PRECAUTIONS

...............................................................

29

Section

Title

Page

10-2

SPECIAL TOOLS

for

DISASSEMBLY

and

ASSEMBLY

....................................

29

10-3

DISASSEMBLY PROCEDURES

.......................................................................

30

10-4

ASSEMBLY PROCEDURES

.............................................................................

38

10-5

CHECKING. DISASSEMBLY

and

REASSEMBLY

of

the

CONTROL

BOX

.......

51

t

1

.

TROUBLESHOOTING

............................................................................................

53

11-1

NO AC OUTPUT

................................................................................................

53

11-2

AC VOLTAGE

IS

TOO THIGH

OR

TOO

LOW

...................................................

54

11-3

AC

VOLTAGE

IS

NORMAL AT NO.LOAD. BUTTHE LOAD CANNOT

BE

APPLIED

.....

55

11

-4

NO

DC OUTPUT

...............................................................................................

56

11

-5

OIL SENSOR TROUBLE SHOOTING

.......................

.......................................

57

12

.

WIRING DIAGRAM

.................................................................................................

58

r

I

U

0

z

W

s

a

5

a

I

-

Model

RGD2500

RGD3300

I

Brushless, Self Exciting, 2-Pole, Single Phase

I

Frequency

60

Hz

60

Hz

I

Maximum Output Rated Output

AC

3300

W

2500 W

3000

W

2200

W

Rated

Current

25.0N 12.5A 120Vl240V 18.3N

9.2A

120V/240V

120

v

25.0

A

120

v

18.3

A

Voltage

Power Factor

1

.o

DC Output Voltage Regulator

12 V-8.3

A

(1

00

W)

Condenser Type

Type

Air-Cooled CCycle, Diesel Engine

Model DY23-2D

I

i

DY27-2D

~

Displacement

I

230 cm3 (14.04 cu. in.)

I

265

cm3 (16.17 cu. in.)

I

Rated

Output

4.8

HP

/

3600 rpm

2.06

U.S.

gal. (7.8 liters)

Fuel Tank Capacity

Diesel light oil Fuel

5.5

HP

/

3600

rpm

I

~ ~~ ~~~ ~

Rated

Coutinuous

Operation

I

1.10

hours

I

1.30 hours

Oil Capacity

Recoil Starter and Optional Electric Starter

Starting System

0.9

liters

I

Dimensions

(L

x

W

x

H)

21.1

~15.8~18.0in(27.9~15.8~18.0in)’/536~400~458

mm (709

x

400

x.458 mm)*

I

Dry Weight

!

I

55

kg (58.5 kg.)’

/

121

Ibs.

58.5 kg (62 kg.)’ / 128.7

Ibs.

I

(129

Ibs.)’

(1

37

I&.)*

Electric

starter motor

is

available as

option.

-

1-

2.

PERFOMANCE

CURVES

2-1

MODEL RGD2500

-

2k

t

A

s

a

n

I-

O

3

-

lk

-0

CURRENT(A)

-

2-2

MODEL

RGD3300

CURRENT

(A)

+

2-3

DC

OUTPUT

16 14

v

5

12

g

10

0246810

CURRENT(A)

"+

3k

2k

t

3

CI

Y

Output

Max.

.................

2500

W

Output Rated

...............

2300

W

Frequency

....................

60

Hz

Voltage

.........................

120

V

Output

Max.

..............

3300

W

Output Rated

............

3000

W

Frequency

.................

60 Hz

Voltage

120

V/240V

e

......................

0

DC

Voltage

..................

12

V

DC

Ampere

.................

8.3

A

DC

output

....................

100

W

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 resis-

tance load

is

applied.

NOTE

:

It

is possible

to

use both

DC

and

AC

outputs

simultaneously up

to

the rated output

in

total.

-

2-

3-1

BRUSHLESS ALTERNATOR

Newly developed brushless alternator eliminates troublesome brush maintenance.

3-2

EASY STARTING

Light pull recoil starter accompanied with automatic decompression system makes the new

RGD

series

generators even easier in starting than gasoline engine generators.

3-3

QUIET

OPERATION

The new

KGD

series generator provides quiet operation by means

of:

The

superb

design

of

intake-exhausr system.

Direct injection combustion system.

A

large super silent muffler.

An efficient

low

noise air cleaner.

3-4

ECONOMICAL PERFORMANCE

On

top

of

well

known diesel economy. the air-coolea Robin diesel engine features direct fuel injection

and special design refinemem for extra fuel efficiency.

3-5

OIL

SENSOR

The

OIL

SENSOR

automatically shuts the engine off whenever the oil level

falls

down below a safe level

preventing engine seizure.

3-6

COMPACT, LIGHT WEIGHT

The combination of newiy developed brushless alternator and air-cooled single cylinder Robin diesel engine enables the new

RGD

series generators to be very compact in size and light in weight.

3-7

RELIABLE PERFORMANCE WITH MINIMAL MAINTENANCE

A

brushless alternator eliminates troublesome brush maintenance.

A

drip-proof alternator design.

A

trouble free condenser voltage regulator.

A

fuseless circuit breaker.

A

dust-proof dual element air cleaner.

The

OIL

SESSOR

automatically shuts the engine off whenever the

oil

level falls down below a safe

level preventing engine seizure.

3-8

LONG-LIFE DURABILITY

C'onlpact

and

smooth

running

air-cooled Robin diesel engine lasts much longer than the gasoline

engine

of

the same size.

Trouble-free brushless alternator with condenser type voltage regulator works all the year round

without any maintenace work.

-

3-

4.GENERAL

DESCRIPTION

4-1

EXTERNAL

VIEW

No-fuse

bmakei

Speed

control lever Rocker cover

Full mwer switch

I-

/

Air cleaner

(DU~

voltage

type

o

Key

switch

(Only

for RGD3300)

\

/

Fuel injection pump

\

DC

output

terminal

Stop

lever

.

Earth

terminal

Fuel fi&r Oil

filter

Fuel cock

/

Muffler

Electric starter (only for

RGDSOO)

/

\

Oil

gauge

-

4-

4-2

CONTROL

PANEL

_-

RGD2500, RGD3300 : 60HZ-l20V, 60H~-120V/240V

TYPE

Full

power

switch

Key switch (Only

for

RGD3300)

Vottmeter

i,

I((

DC

output

terminal

7

DC

fuse

@

1111

/

No-fuse

breaker

/Ac

receptacle

/

Earth

terminal

-

5-

4-3

LOCATION

of

SERIAL NUMBER

and

SPECIFICATION NUMBER

Serial number and specification number are stamped

on

the

LABEL

(MODEL

NAME)

stuck on the side

wall

of

control

box.

w

NOTE

:

Always specify these numbers when inquiring about the generator or ordering spare

parfs

in

order to get correct

parts

and accurate service.

Specifications

label

-

6-

5.CONSTRUCTION

AND

FUNCTION

Generator base Mount rubber

Ball bearing Through

bolt

Support

ring

Front cover

Fig-

5-7

5-2

FUNCTION

5-2-1

STATOR

The stator consists

of

a

laminated silicon steel

sheet

core,

a

main

coil

and

a condenser coil which

are wound in the core

slots.

The condenser coil excites the rotor field

coil

which

generates

AC

voltage in the main

coil.

Fig.

5-2

-

7-

5-2-2

CONDENSER

One or

two

condensers are

installed

in

the

con-

trol

box

and are connected

to

the condenser coil

of

the stator.

These condensers and condenser coil regulate the

output

voltage.

5-24

ROTOR

The rotor consists

of

a laminated silicon steel sheet

core and a field coil which

is

wound over the core.

DC

current

in

the field coil magnetizes

the

steel

sheet

core. Two permanent magnets are

provided

for

the primary exciting action.

A

diode rectifier and surge absorber

is

mounted

inside

of

the

insulator.

I

Fig.

53

Fig.

5-4

Diode

rectifier and

Surge

absorber

Fig.

5-5

-

a-

5-2-4

DC

FUSE

(1)

The

10

ampere DC fuse mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit.

(2)

The

15

ampere DC fuse

in

the control box protects the diode rectifier from getting damage by reverse connection to the battery.

(Electric

start

model)

I

Fig.

5-6

5-2-5

NO-FUSE

BREAKER

The no-fuse breaker protects the generator from getting damage by overloading or short circuit

in

the

appliance.Table

5-1

shows

the capacrty of no-fuse breaker by each spec.

and

their object of protection.

MODEL

OBJECT

or

PROTECTION

NO-FUSE

BREAKER

SPECIFICATION

60

HZ-120

V

RGD2500

20

A

10Ax2

60

HZ-1

20

V,

240V

Total output amperage Total

output

amperage

RGD3300

60 HZ-120

V

Total output amperage

14Ax2

60

HZ-1 20 V, 240V

Total output amperage

27

A

Table.

5-1

1

Fig.

5-7

-

9-

5-2-6 RECEPTACLE

and

AC PLUG

(STD.SPEC.)

These are used for taking AC output power from the generator. A total

of

six kinds

of

receptacles, each varying in rated voltage and current from another, are used. Each model has at least one receptacle to deliver the rated generator output.

As

many AC plugs

as

the receptacles, each matching the correspond-

ing receptacle, are provided. Table

5-2

shows the rated current for each receptacle. Be careful not to use

the receptacles and AC plugs beyond the specified amperage limits to prevent burning.

w

NOTE

7

:

If

your generator has receptacles pecu-

liar

to

your

county,

Table

5-2

does not

apply.

NOTE

2

:The generator for

U.S.A.

market is equipped with NEMA standard receptacles shown

in

table

5-2.

Use the proper plug for connecting appliance to the generator.

Caution

:

To

connect the appliance

to

locking

receptacle, insert

the

plug into the

re-

ceptacle and

turn

it

clockwise to

lock.

Fig.

5-8

Style

Description

AC plug

Receptacle

Ampere

~1

20A

GFCl

125V

(Ground Fault

NEMA NEMA

5-20R

Circuit interrupter)

5-20P

Receptacle, duplex

@

125VI 250V NEMA NEMA

20A

L14-2OP L14-20R

Locking Receptacle

1

25V

L5-30P

L5-30

30A

NEMA

Locking Receptacle

Table.

5-2

-

10-

5-3

GENERATOR OPERATION

PERMANENT MAGNET

FOR

INITIAL EXCITATION

FIELD

COIL

\

STATOR

r---

1

MAIN

COIL

I

"""1

I

"""""I

Fig.

5-9

5-3-1

GENERATION

Of

NO-LOAD VOLTAGE

(1)

When the generator starts running,

the

permanent magnet built-in to the rotor generates 3 to

6V

of AC

voltage inthe main coil and condenser coil wound on the stator.

(2)

As

one or

two

condensers are connected to the condensercoil, the small voltage at the condenser

coil generates a minute current

8)

which flows through the condenser coil.

At

this time, a small flux is produced with which the magnetic force at the rotor's magnetic pole is intensified.When this magnetic force is intensified, the respective voltages in the main coil and condenser coil rise up.

As

the

current

3

increases, the magnetic flux at the rotor's magnetic pole increases further. Thus the volt-

ages at the main coil and condenser coil keep rising

by

repeating this process.

(3)

As

AC

current flows through the condenser coil, the density of magnetic flux in the rotor changes. This

change of magnetic flux induces

AC

voltage in the field coil, and the diode rectifier in the field coil

circuit rectifies this

AC

voltage into DC. Thus a DC current

13

flows through the field coil and magne-

tizes the rotor core to generate an output voltage in the main coil.

(4)

When generator speed reaches

3000

to

3300

rpm, the current in the condenser coil and field coil

increases rapidly. This acts to stabilize the output voltage

of

each coils.

If

generator speed further

increases to the rated value, the generator output voltage

will

reach to the rated value.

5-3-2

VOLTAGE FLUCTUATIONS UNDER LOAD

When the

output

current @ flows through the main coil to the appliance, a magnetic flux is produced and

serves to increase current

@

in the condenser coil. When current @ increases, the density

of

magnetic

flux across

the

rotor core rises.

As

a result, the current flowing in the field coil increases and the genera-

tor output voltage is prevented from decreasing.

-

11

-

5-3-3 FULL

POWER

SWITCH

(Dual

Voltage

Type)

The full power switch

is

provided for the dual voltage type to take

out

the full rated power from one

receptacle in each voltage.

1"

REc21&

$""

/

-

I

,

IREC1

Fig. 5-

11

-1

1

OV)

1 1

RECEPTACLE

I

RECEPTACLE

LOWER

VOLTAGE

HIGHER

VOLTAGE

110

v

I

,orv

I

Rated

output

I

No

output

can

be

taken.

I

110/220

v

120/240

V

or

Tale.

5-4

Rated output

Half

of

rated

output

Fig. 5-12

-

12-

Two main coils are wound over stator core. Each main coil outputs

half

the rated power at the lower

voltage

(11OV

or

12OV).

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.

5-1

0

shows a circuit diagram. When the full power switch is set for single lower voltage indication

(11OV

or

12OV),

the switch position is as indicated by the lower solid line in the diagram. Fig.

5-11

is

a

simplified representation of this circuit, showing the

two

main coils connected

in

parallel.ln this case, the

higher voltage

(22OV

or

240v)

at Rec. 3 cannot be taken out. Rec. 2 for the lower voltage can output up

to the rated power (up to

30A

if

the rated current

is

over

30A),

and Rec. 1 can

output

up to a total of

15A.

When the full power switch is set for double voltage indication

(11OV/22OV

or

120V/240V),

the switch

position is as indicated by the upper dotted line in Fig.

5-10.

Fig.

5-12

is a simplified representation

of

this

circuit, showing the

two

main coils connected in series. In this case, power

can

be taken simultaneously

from the receptacles for the both voltages. Rec.

3

for the higher voltage can output up to the rated power,

but Rec.

1

and Rec. 2 for the lower voltage can output only up to half the rated power each.

Table

5-4

is a summary

of

the above explanation. Select the proper output voltage by full power switch

in

accordance with the appliance to be used.

"

-

13-

6.:

SAFETY

PRECAUTIONS

1.

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.

2. Do

not place inflammable materials near the generator.

Be careful not to put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the generator.

3.

Do

not operate the generator in a room,cave or tunnel. Always operate in a well-ventilated area.

Otherwise the engine may overheat and also, the poisonous carbon monoxide contained in the exhaust gases will endanger human lives. Keep the generator at least

1 m (4

feet) away from structures

or facilities during use.

4.Operate the generator on a level surface.

5.

6.

If

the generator

is

tilted or moved during use, there is a danger

of

fuel spillage and a chance that the

generator may tip over.

Do

not operate with wet hands or

in

the rain.

Severe electric shock may occur.

If

the generator is wet by rain or snow, wipe

it

and thoroughly

dry

it

before starting.

Don't

pour water over the generator directly nor wash it with water. If the generator is

wet with water, the insulations

will

be adversely affected and may cause current leakage and electric

shock.

Do

not connect the generator to the commercial power

lines.

w

This may cause a short-circuit or damage to the generator. Use a transfer switch (Optional parts) for connecting with indoor wiring.

NOTE

:

The parts numbers

of

the transfer swifches and

of

the

plastic box to store them are as

shown

in

Table

6-

1.

Part

No.

Part Name

Q'ty

Phase

Allowable

Current

Table.

6-1

365-45604-08 Transfer

Switch

1 1

15

A

367-45605-08 Transfer

Switch

1 1

30

A

340-45606-08

Transfer Switch

1

60

A

367-43008-08

Plastic

Box

1 1

30

A

348-43009-08

Plastic

Box

1 1 60

A

Table.

6-1

7.

Be sure to check and remedy the cause of circuit breaker tripping

before

resetting

it

on.

CAUTION

:

If

the circuit breaker tripped

off

as a result of using an electrical appliance,the cause

can

be

an overload or a short-circuit.

In

such a case, stop operation immediately and carefully

check the electrical appliance and AC

plugs

for faulty wiring.

-

14-

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

.O

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

Example : A

rated 3000W generator can turn thirty

lOOW

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

7

:

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

shall be required to drive the lamps.

NOTE2

:

Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp.

Therefore,

if

the fluorescent lamp has no special indication as to the power consumption, efi-

ciency should be taken into account as explained in item

(5)

on the following page.

(3)

Mercury lamps with a smaller power factor

Loads for mercury lamps require 2 to 3 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

7

:

Motor-driven appliances require the aforementioned generator output only at the shdng. Once their motors are started, the appliances consume about

7.2

to 2 times their rated power con-

sumption

so

that the excess power generated by the generator can

be

used forother electrical

appliances.

NOTE2

:

Motor-driven appliances mentioned in Items(3) and

(4)

vary

in their required motor sbrting

power depending on the kind of motor and start-up load.

if

it

is

dficult to determine the

optimum

generator capacw, select a generator with a larger capaciw.

-

15-

(5) Appliances without

any

indication as to power consumption

Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a case, power consumption is to be worked out according to the numerical formula mentioned below.

(Output

of

electrical appliance)

(Efficiency)

=

(Power consumpition)

Efficiencies of some electrical appliances are as follows

:

Single-phase motor

................................

Fluorescent lamp

...................................

0.7

to

0.8

lower the efficiency.

Oe6

to

0-753(

The smaller the motor, the

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

t

0.7=

57W.

As

explained in Item (2), multiply

this power consumption value of 57

W

by

1.2

to 2 and you

will

get the figure of the neces-

sary

capacity

of

a generator.

In

other words, a generator with a rated output

of

1 OOOWcapacity

can

light nine to fourteen

40

W fluorescent lamps.

Example 2 :

Generally speaking, a

400

W

motor means that its work load is

400

W.

Efficiency

of

this

motor is

0.7

and power consumption will be

400+0.7=

570

W.

When this motor is used for

a motor-driven tool, the capacity of the generator should

be

multiple of 570 W by 1.2 to 3 as

explained in the Item

(3).

570

(W)

x

1.2

to

3

=

684

(W)

to 1710

(W)

MODEL RGD3300 RGD2500

Frequency

I I I

60

Hz

60

Hz

lncandesent

lamp,

heater, etc.

I

22OOw

I

30OOW

Fluorescent lamp, Motor-

2100

w

15OO W

driven

tool,

general-porpose

approx.

~~~~~

Mercury

lamp,

etc.

approx.

1

13OOW

I

18WW

Pump, compressor, etc.

approx.

1

650

W

Table.

7-1

-

16-

NOTES

:

Wring between generator and electrical appliances

I.

Allowable current of cable.

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

appliance). If the input current is higher than the allowable current

of

the cable used, the cable will

become excessively heated and deteriorate the insulation, possibly burning it out. Table

7-2

shows

cables and their allowable 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 de-

creasing the input voltage to the load (electrical product). As a result, the load

can

be damaged. Tabe

7-2

shows voltage drops per

I00

meters

of

cable.

"

Sectional

area

/

mm3

0.75

1.25

2.0

3.5

5.5

Gauge

No'

wire

dement

Resistance

Voltage

A"owab'e

current

/

A

mm

Ohm/100m

1~

3~

5~

7

I

3010.18

I

2.477 I 2.5

V

I

8 V 112.5

V

12

50

10.18

1.486

1.5V 5V 7.5V

17

37 10.26

0.952

1.0

V

3V 5.0

V

23

I

45/0.32

I

0.517

I

1.5V

I

2.5

V

Table.

7-2

Voltage drop indicates as

V=

-

x

R

x

I

x

L

1

100

drop

per

100

m

4V

I

5V

16.5V

2.5v

I

35-v

I

4

v

7.5

v

I

5v

I

R

means resistance

(

hz

/

100

m) on the above table.

I

means electric current through the wire

(A).

L

means the length

of

the wire

(m).

The length

of

wire indicaters round length, it means twice the length from generator to electrical tools.

-

17-

8-1

MEASURING INSTRUMENTS

8-1

-1

“Dr. ROBIN” GENERATOR TESTER

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

:

(1)

Functions of voltmeter, frequency meter,

meggertester, 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 carring.

SPECIFICATIONS

r

Fig.

8-1

MODEL

I

Dr.

Robin

Part Number

25

to

70

Hz

Frequency

0

to

500

V

AC

Voltage

388-47565-08

Measuring

Range

Resistance 0.1 to 1.999

Q

Condenser Capacity

3M

Q

insulation Resistance

10 to 100 pF

Circuit Protector

2 x 6F44P

(006P)

Dry Cell Battery Power Source

Fuse

Accessories

I

Test

Leads with needle probes

. . .

1 set

Test leads with jack plugs

. . .

1

set

I

Dimensions

(L

x W x

H)

1.6 kg

Weight

285

mrn

x

200

mm x 110 mrn

Table.

8-1

The

“Dr. Robinngenerator 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. Robinngenerator tester,use the instruments described in the following section for

checking generator parts.

-

18-

8-14

INSTRUMENTS

(1)

VOLTMETER

AC

voltmeter is necessary. The approximate

AC

voltage ranges of the voltmeters to be

used

for various types

of

generators are as follows:

0

to 150V : Type with an output voltage

of

11

0

to

3OOV

:

Type with

an

output

voltage

of

220,

0

to

150V, 0 to 330V : Dual voltage type

or 120V

230 or 240V

(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

1

OA,

20A,

1

OOA)

(3) FREQUENCY METER

Frequency range

:

About

45

to

65Hz

NOTE

:

Be careful

of

the frequency meter's input

voltage range.

FOR

AC

Fig.

8-2

FOR

AC

Fig.

8-3

I

Fig.

84

-

19-

(4)

CIRCUIT TESTER

Used for measuring resistance, etc.

(5)

MEGGER TESTER Used for measuring generator insulation re-

sistance. Select one with testing voltage range

of

500V.

(6)

TACHOMETER

Use the contactless type tacho meter.

Fig.

8-5

I

Fig.

8-6

Fig.

8-7

-

20-

8-2

AC OUTPUT MEASURING

TO

AC

Fig.

8-8

Use a circuit like the shown in Fig.8-8 for measuring

AC

output. A hot plate or lamp with a power factor of

1

.O

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

235 - 260

V

117

-130

V

Voltage range

240

v

120

v

Table.

8-2

8-3

DC

OUTPUT MEASURING

d

To

DC

Terminal

Q

??

i.

"I

fig.

8-9

Measurement of

DC

output

is executed

with

the switch turned

ON

while the current is regulated at

8.3A

by adjusting the load to the generator.

If

the voltage is within the range from

6V

to

14V,

the voltage

output

is

normal.

NOTE

:

If a battery

is

connected as a load to the generator, the

DC

output voltage

will

increase

by approximately 1 to 2 K Therefore, carefully observe the electrolyte level and do not overcharge the battery.

-

21

-

WMEASURING INSULATION RESISTANCE

Use a "Dr. Robinngenerator 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 ter-

minal, 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

I

megohm, disassemble the generator and measure the insulation resistance

of

the stator, rotor and control panel indi-

vidually.

STATOR

(1)

Measure the insulation resistance between

BLUE

lead and the core.

(2)

Measure the insulation resistance between

WHITE lead and the core.

(3)

Measure the insulation resistance between

YELLOW

lead and the core.

(4)

Measure the insulation resistance between

BROWN

lead and the core.

ROTOR

Measure the insulation across one

a

terminals of the rotor andthe core.

If

the solderec

Fig.

8-10

1

Fig.

8-11

-

22-

.-

CONTROL

PANEL

Measure the insulation resistances between the live parts and the grounded parts.

I

Fig.

8-13

Any part where

the

insulation resistance is

less

than

1

MQ

has faulty insulation, and may cause electric

leakage and electric shock.

Replace the faulty part.

-

23-

9.CHECKING

FUNCTIONAL

MEMBERS

9-1

VOLTMETER

w

Check the the voltmeter if

it

is

tumed on by apply-

ing specific voltage. Voltmeter cannot be checked with circuit tester

because its resistance is too large.

9-2

AC RECEPTACLES

Using a "Dr. Robinnor a circuit tester, check conti-

nuity between the two terminals at the rear of the

AC

receptacles while the receptacle is mounted

VOLTMETER

on the control panel.

Fig.

9-1

When continuity

is

found between the output terminals

of

the receptacle with a wire connected across

these terminals, the

AC

receptacle is normal. When the wire

is

removed and no continuity is found

between these terminals, the receptacles are also normal.

..

Fig.

9-24

Fig.

9-28

9-3

NolFUSE BREAKER

Check continuity between each of

two

terminals

at the rear

of

the no-fuse breaker while

it

is

mounted on the control panel. Normally, there is

continuity between each of the

two

when the no-

fuse breaker is on while there is no continutty when

the

no-fuse breaker

is

off.

Fig.

9-3

-

24-

9-4

STATOR

Disengage connectors on the wires from stator and check the resistance between wires with

a

"Dr. Robin" or a circuit tester refering to the fol-

lowing table.

Stator

Fig.

9-4

Specification

Black / Orange

Yellow

/

Yellow

Blue

/

Sky-blue

Brown

/

White

Voltage

Hz

Condenser Winding

AC

Winding

MODEL

120

v

1.6 0.1

1

0.44

120

v

1.9

0.12

0.66

0.66 120V/240V

1.9 0.1 2 0.66

0.66

RGD2500

I

60

RGD3300

60

I

1.6

0.1 1

0.44

120v/240v

Thle.

9-1

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 temperatures different from

20

OC

(68

OF).

-

25-

9-5

ROTOR

ASSEMBLY

(1)

Using a "Dr. Robin" or a circuit tester, measure the resistance of the field coil at the terminals.

(0)

I

MODEL RGD2500 RGD3300

RESlSTANCE

Table.

9-2

3.3

Q

3.7

n

I

NOTE

1

:

Because a diode is soldered to the coil ends at

the terminals, resistance may be measured only when tester probes touche the teminais in one

combination

of

polariw Therefore,

if

no

resistance

reading appears,

try

checking in reverse poladty

NOTE

2

:

If

the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings. Erroneous reading will also occur when there

is

a

wide

variation

of

resistance

among coil windings or when measurement is

performed at embient temperatures different from

20

"C

(68

OF).

9-6

CONDENSER

Use

a

"Dr.

Robin" in capacitance meter mode to

check the capacity of condensers.

NOTE : Be sure to discharge condensers by shorting condenser leads each otber before checking their capacitance,or the accurate reading cannot be obtained.

I

NORMAL CAPACITY

OF

I

CONDENSER

1

I

10pFx2

I

10pFx2

1

Fig.

9-5

Fig.

9-6

1

*

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 condenser.

w

-

26-

9-7

DIODE

RECTIFIER

Circuit inside

of

the diode rectifiers is as shown in

Fig.

9-7.

Check continutty between each terminal by

using a circuit tester

as

shown in Fig.

9-8.

The rectifier is normal when condtinuity is as follows:

Yellow

Diode

rectifier

Fig.

9-7

Fig.

9-8

Circuit

tester

Checkina table for analoaue circuit tester.

~~

Analogue

circuit

tester

~ ~~~ ~~~~ ~ ~ ~ ~~ ~ ~

Apply black

(minus)

needle

of

the circuit tester

Yellow Yellow

Red

I

Gray

Yellow

-

No

continuity

No

continuity

Apply

red

(plus)

needle

of

the

circuit

tester

Yellow

Continuity

-

Continuity Continuity

Red

Continuity

No

continuity

-

No

continuity

I

Gray

No

continuity

Table.

9-4-

1

No

continuity

-

No

continuity

1

-

27-

Checkina table

for

diaital circuit

tester.

~~~ ~ ~ ~~~~ ~~~ ~ ~~ ~ ~ ~~ ~~~

Apply red (plus) needle

of

the circuit tester

Yellow

I

Yellow Red

I

Gray

Digital circuit tester

Yellow

Continuity

No

continuity

-

No

continuity

Yellow

Continuity

No

continuity

No

continuity

-

Apply black (minus) needle

of

the circuit tester

Red

Continuity

-

Continuity

Gray

-

No

continuity

No

continuity

No

continuity

NOTE 1 :

Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester, polarity

of

tester needles should be reversed.

NOTE

2

:

"Continuity" means forward direction characteristics

of

the diode, and different from short

circuit condition (in which

a

pointer of the tester

goes

out

of

its normal scale), shows resistance

to

some extent. When results

of

the checking indicates failure even in one section,replace with

a

new one.

NOTE 3 :

Simpson

brand

analogue testers

have

the

characteristics

as

same

as

the

digital

circuit

tester.

-

28-

10-1

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)

Use

all disassembly/assembly tools properly, and

use

the proper tool for each specific job.

10-2

SPECIAL TOOLS

for

DISASSEMBLY

and

ASSEMBLY

ROTOR

PULLER

REAR

COVER

PULLER

JIG

-

29-

10-3

DISASSEMBLY

PROCEDURES

I

i

I

i

Part

to

remove

Fuel

Tank

Description

Remarks

I

(1)

Close

fuel cock.

I

Draining

tank

of fuel

before disassembly

is

un-

necessary.

(2)

Loosen

the nut

and

remove fuel cock

from

the

bracket.

Turn the fuel cock body by

90

degrees

to remove.

(Fig.

10-1)

(3)

Remove the two bolts

which

join

the

fuel filter

to

the control box.

(See

Fig.

10-2.)

(4)

Remove the fuel pipe

which

connects

he1 fdxer

and

fuel injection pump.

Loosen

the

clamp

using

pliers

and

pull out the fuel pipe from the fuel fdter. (See

Fig.

10-3)

~~~ ~ ~~~~

I

Fig.

707

Tod

14

mm

spanner

10

mm

spanner

Fig.

102

Fig.

703

-

30-

ep

I

Part

to

remove

L

Fuel Tank

I

Description

Remarks

I

Tool

(5)

Remove fuel return pipe which connects the fuel injection nozzle and the bottom of fuel

tank.

Loosen the clamp and pull out the fuel return pipe from the fuel injection nozzle. (Fig.

10-4)

(6)

Loosen the four bolts and remove fuel tank from frame. (See Fig.

10-5.)

Take care of spilt fuel from the fuel pipe.

~~ ~ ~~ ~

Plier

I

'

10

mm

spanner or

box spanner

-

2

Control Box

Fig.

70-4

Fig.

10-5

(1)

Remove control box from frame

by

re-

moving

the

thee

bolts

joining

the

con-

trol

box

to frame and side plate.

(See Fig.

10-6.)

Wire

harness

is

stdl

con-

10

mm

spanner

or

nected.

box

spanner

(2)

Put the control box with control panel

down.

(3)

Remove the ground wire (greenjyellow) from the bottom of control box.

(4)

Pull

the bushing out from the control

box. (See Fig.

10-7.)

Fig.

706

Put a waste cloth under

I

10

mm

spanner

the control panel to pro-

b

I

Fig.

107

-

31

-

Part

to

remove Description Remarks

Control Box

(5)

Pull

the wire hamess out

from

the control box. Disengage the connectors

to

separate

the control box. (See

Fig.

10-8.)

'I

ij

:

I

Fig.

lQ8

Tod

~.

Pipe Frame

'

(1)

Remove side plate from frame.

~ ~ ~ ~~~~~

!

69

bolt

.........

.2

PCS.

I

69

bolt

.2

pcs.

I

i

(2)

Remove

tank

bracket from frame.

.........

I

(3)

Remove stoppers from engine base

of

i

frame.

6@

bolt

.........

.4

PCS.

1

10

mm

spanner

i

(4)

Remove the four

nuts

which

join

the

'

mount rubbers to

the

engine.

!

1

(5)

Remove the two bolts which

join

the

rear cover to the generator

base.

(See

Fig.

10-9.)

89

bolt

.........

.2

pcs.

I

12mmspanner

12

mm

spanner

I

6u2

BOLT

.....

.4

pes.

80NUT

2pcs.

.......

/

-

32-

Pipe Frame

Remarks

bly

using

a

chain-block,

and

dismount

it

from frame.

(Fig.

10-10)

Fig.

1010

I

!

L

I

t

(7)

Remove generator

base

from frame.

89

nut

. . .

.

. .

.

1

pce.

(8)

Remove mount rubbers from frame.

I

~~~ ~~~

(See

Fig.

10-1

1.)

Tod

12

mm

spanner

Fig.

IQI

I

-

33-

Part

to

remove

Rear Cover

i

(1)

Remove end cover from rear cover.

Description

I

(See Fig. 10-12.)

I

i

69

bolt

.

. . . . .

. . .

.4

pcs.

I

(2)

Remove throqh bolt from

rotor

shaft.

Apply

a socket wrench on the head of

through

bolt and

hit

the wrench handle

with a hammer counterclockwise

to

(3)

Remove the four bolts

which

joir,

the

rear cover to the front cover.

i

use the special tool

'REAR

COVER

I

PULLER"

to remove the rear cover.

;

(See

Fig.

10-14.)

i

2.

Insert the two bolts of the special tool into the thread holes of the rear cover.

5.

Apply

the center bolt

of

the special

tool to

the

center hole

of

the rotor

shaft.

c. Tighten the center bolt to

pull

out

the rear cover. (See Fig. 10-15.)

Fig.

10-

74

Remarks

Tod

10

mm

spanner or

box wrench

RGD2500: 12

mm

RGD3300:

14

mm

Box

wrench

Insert the

two

bolts suf-

I

ficiently

and

evenly, or the thread holes may be damaged

at

removing.

Fig.

70-

13

I

Fig.

70-15

-

34-

#

Part

to

remove

Step

4

Rear Cover

Description

Remarks

In case that "REAR COVER

PULLER"

is

unavailable, remove the rear

cover by the following instructions: a. Insert the through bolt into

the

rotor

Do

not give a strong

hit

b.

Hit on the boss at the top of the rear

legs.

shaft and tighten lightly.

hammer to remove.

(Fig.

10-

16)

I

cover and two legs evenly with a plastic

on the rear cover boss or

5

1

Stator

(1)

Remove the four bolts which

join

the

stator

to

rear cover. (See Fig.

10-17.)

i

(2)

Insert a small

hook into the hole insjde

of the

support

ring and pull it out.

(See

Fig.

10-1

8.)

If

a small

hook

is

unavailable, remove

the stator by the following procedure:

a. Hold the rear cover and stator assem-

bly open side down.

b.

Place a cushion under the stator to

protect it when dropped.

c.

Hit

on the bearing housing

of

rear

cover with

a

wooden block.

!

I

&BOLT

......

4

pa.

I

4pcs.

I

!

60

SPRING

WASHER

I

..........

I

F~.

10.77

Be careful not to give a damage to

the

stator

winding.

Tool

Plastic hammer

10

mm

box wrench

SUPPORT

RING

\

Step

Tod

Remarks

Description

Part

to

remove

I

Stator

(3)

Pull

out the wires from rear cover.

(See

Fig.

10-19.)

SUPPORT

RIN

STATOR

..

4

pa.

I

Fig.

7019

6

Rotor

(1)

Insert

the rotor-puller shaft into the

rotor

and

tighten the rotor-puller bolt

until the rotor comes

loose.

(See Fig.

10-20.)

If the

special

tool (rotor-puller)

is

un-

available, take the following instructions to remove the rotor:

Lightly strike the rotor core with

a

plastic hammer in

many

directions

and pull out the rotor from engine

shaft

(See Fig.

10-21

.)

Take utmost care not to strike on the rotor

wind-

ing

or plastic insulator or

permanent magnets.

Rotor puller

RGD2500:

14

mm

RGD3300:

17

mm

Spanner

Plastichammer

I

Fig.

1Q20

Fig.

1021

I

-

36-

7

and Front. Protector

Part

to

remove

Description

Remarks

Front cover

(1)

Remove the four

bolts

which join the

I

.

i

I

front cover to the engine.

84

bolt

. . . . . . .

. .

.4

PCS.

(2)

Remove front protector from front cover. (See

Fig.

10-22.)

Fig.

10-22

Tod

12

mm

spanner

8

mm

spanner

or

screw driver

(+)

~~ ~

-

37-

I

G4

ASSEMBLY PROCEDURES

10-4-1

FRONT PROTECTOR

amd

FRONT COVER

(1) Attach the front protector

to

front cover.The louvers of the front protector project into the inside of front

cover

as

shown

in

Fig.10-23.

5

@

x

10

mm

Tapping screw

. .

.4

pcs.

35

-

55

kg-

2.5

-

4.0

ft-lb

(2)

Install front cover

to

the engine.

(See

Fig.

10-24.)

5

@

x

20

mm

bolt

and washer

assy

. . . . . . .

. .

.

.4

pcs.

NOTE

:

The

ske

of

faucet joint and pitch

of

mount-

ing

holes

of

front cover

is

different

by

models

RGD25UU

and

RGD33OU.

1

1.8

-

13.7

N-m

120 - 140

kg-cm

8.7

-

10.1

ft-lb

1

Fig.

70-23

Tightening torque

I

-4

-

38-

10-4-2

ROTOR

(1)

Clean the tapered portion of driving shaft and the matching tapered hole of rotor shaft

of

oil

and dirt using a waste cloth.

(2)

Attach rotor to the driving shaft.

(See Fig.

10-25.)

Tighten through bolt with washer and spring washer.

__~

~~~ ~

Tightening torque

RGD2500

230

-

250

kg-cm

115

-

135

kg-cm

22.6

-

34.5

N-m

11.3

-

13.2 N-m

RGD3300

8.3

-

9.7

ft-lb

16.6

-

18.0

ft-lb

10-4-3

STATOR and

REAR

COVER

(1)

Set the stator on the jig.

Match the grooves of the stator with the grooves of the jig.

(2)

Attach the support ring around the stator

set-

ting the open ends of the ring to the position of stator leads. Check that the hooking holes are placed at the flat sides of the stator. (See Fig.

10-26.)

(3)

insert four guide

bolts

into the bolt holes of the

rear cover and mount

it

on the stator match-

ing the guide

bolts

with

the

grooves of the

sta-

tor. lighten the guide

bolts

tentatively.

(4)

Take the stator leads out from the window of

(5)

Put

a board on the rear cover and press it

us-

ing a pressing machine.

If

a

pressing machine is unavailable, tap

around the

board

on the rear cover evenly with a plastic hammer to press fit the rear cover over the stator. (See Fig.

10-27.)

the rear cover.

CAUTION : lake care

of

the rear cover to

be

pressed in upright position.

~~

Fig.

10-25

Direction

of

stator

leads

GrooveS

of

stator

,

Stator

Grooves

of

jig

Fig.

10-26

Board

\

Fig.

10-27

-

39-

(6)

Join the stator to rear cover with four bolts,

washers and spring washers.(See

Fig.

10-28.)

6

cp

bolt.

.

.4

pcs.

6

cp

washer.

.

.4

pcs.

6

cp

spring washer.

.

.4

pcs.

NOTE:

Tighten

four

bolts evenly taking several

steps.

7.9

-

9.8

N-m

80

-

100

kg-cm

5.8

-

7.2

ft-lb

69

Bolt.

. . .

.

. .

4

pcs.

69

Spring

washer.

.

4

pcs.

-60

Washer.

.

. . . . .

4

pcs-

The dimensions of the stator bolts are shown in Table

10-1.

1

i

LST

-1

(inch)

6

40

95

(mm)

0.24 1.57

3.74

RGD3300

Table.

10-

1

(7)

Attach the boot over the lead wires drawn out from the rear cover.

Press the smaller end of boot into the rear cover. (See Fig. 10-29.)

Fig.

10-29

-

40-

(8)

Put the rear cover and stator assembly over the rotor. Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover. (See Fig. 10-30.)

Fig.

10-30

(9)

Tighten the four bolts, washers and spring washers to join the rear cover to the front cover. 6#~25mmbolt

...

4pcs.

6

#

washer.

.

.4

pcs.

6

#

spring washer.

.

-4

pcs.

In the case

of

models with oil sensor or elec-

tric starter, attach the clamp at the same time.

(See

Fig.

10-31

.)

4.5

-

5.9

N-m

50

-

60

kg-cm

3.6

-

4.3

ft-lb

10-4-4

END

COVER

Attach end cover to the rear cover. The air-inlets of the end cover have to face

down-

ward. (See Fig. 10-32.)

6

#

x

8

mm

flange bolt.

.

.4

pcs.

3.9

-

5.4

N-m

40

-

55

kg-Cm

2.9

-

4.0

ft-lb

Fig.

10-31

Fig.

10-32

-

41

-

i545

FRAME

(1)

Attach

two

mount rubbers to the engine base of the frame. Tighten the nuts from the bottom side of the frame. (See

Fig.

10-34.)

8

@

flange nut.

.

.2

pcs.

(2)

Attach the

5

@

terminal of grounding wires (greenlyellow) to the unpainted thread hole of the frame base plate using a

5

mrn brass

screw. (See Fig.

10-33.)

11.8

-

13.7

N-m

120

-

140

kg-cm

8.7

-

10.1

ft-ib

6#

Terminal

89

Terminal

(Control

box)

(Rear cover)

Fig.

10-33

(3)

Attach the alternator mount rubber to the frame. (See Fig.

10-34.)

NOTE

:

The mount rubbers are selected to reduce vibration most effectively by model and

its

frequency

Be sure to use the correct mount rubber for your generator.

/

flame

*#

Nut

Generator

base

Mount

rubber

Mount

rubber

'

:

2pcs.

Fig.

10-34

-

42-

(4)

Mount the

GENERATOR

BASE

on the mount

rubber attached to the frame at step

(3).

(See Fig.

10-35.)

8

@

flange nut.

.

1

pce.

120

-

140

kgcm

8.7

-

10.1

ft-lb

*

Mount

rubber

VIEW

A

(5)

Attach SHAFT

(STOPPER)

to the bottom

of

engine crankcase.

Tighten nuts tentatively.

-

NOTE

:

Pay attention to the

position

of

the

SHAFT

(STOPPER).

The flange

nuts

shall

be

tightened after fine adjustment.

(6)

Cover the both ends

of

SHAFT

(STOPPER)

with

RUBBERS.

Push

RUBBERS

until they

touch the crankcase. (See Fig.

10-36.)

(7)

Lift

engine and alternator assembly

with a chain block and mount it to the frame. Down the alternator first then the engine into

the frame.

Lift

the engine by approx.

25

mm

so

as

not

to

apply

weight to the engine mount rubbers.

(See

Fig.

10-37.)

Fig.

10-35

*

/

\

Shaft

(Stopper)

Rubber

Fig.

10-36

I

Fig.

10-37

-

43-

(8)

Fix

the legs of rear cover to the generator base.

Attach the

8

@

terminal of the grounding wires and the clamp to the right side

leg

of the rear cover at

the same time. In the case of electric starting model, attach the

8

@

terminal

of

the grounding wires,

a clamp and the BATTERY CABLE

(-)

to the right side

leg

and a clamp to the left side

leg

of

the rear

w

cover at the same time. (See Fig.

10-38.)

NOTE : Two

nuts

are welded

to

the

bottom

side

of

the

GENERATOR

BASE.

8@

x

25

mm

bolt

and washer assy

.

.2

pcs.

/

BoR

and washer

Assy

Clamp

(Electric

start

model)

(Electric

start

model)

Fig.

10-38

(9)

Fix the engine mount rubbers to the crank-

case base.

8

@

flange nut

......

2

pcs.

11.8 - 13.7

N-m

120

-

140

kg-cm

8.7

-

10.1

ft-lb

CAUTION

:

Pay attention to the position

of

the

Lift

down the engine and alternator assembly and

remove the chain block belt.

mount rubbers.

(10)

Attach

two

STOPPERS to the frame cover-

ing the

both

ends of the SHAFT(ST0PPER).

(See

Fig.

10-39.)

6

@I

x

16

@I

flange bolt..

.2

pcs.

I

Fig.

10-39

4.5

-

5.9

Nm

50

-

60

kg-cm

3.6

-

4.3

ft-lb

-

44-

(1

1)

Adjust the position

of

SHAFT (STOPPER)

so

as its both ends are placed in the center of the

STOPPERS,

then tighten the flange

nuts

to fix the SHAR(ST0PPER). (See Fig.

10-40.)

I

Tightening torque

I

11.8 - 13.7

N-rn

120

-

140

kgcm

8.7

-

10.1

ft-lb

Fig.

10-40

(12)

Attach the

SIDE

PLATE

to the frame.

(See Fig.

10-41

.)

lighten the

two

black fIange bolts tentatively.

6

0

x

8

mm flange bolt (black)

. .

.2

pcs.

NOTE

:

The flange bolts shall be tightened after

the installation

of

the Control box.

Fig.

10-41

10-4-6

CONTROL

BOX

Mount

the control box assembly to the frame.

Refer to Section

10-5

for disassembly, checking and reassembly procedures of the control box.

(1)

Attach the

6 @ terminal of the grounding wires

to the bottom

of

the control

box.

(See Fig.

10-

42.)

6

@

nut (brass)

.....

1

pce.

50 - 60

kg-crn

3.6

-

4.3

ft-lb

Fig.

10-42

-

45-

(2)

In the case of generator models equipped with oil sensor, connect thewires to

oil

pressure

switch and solenoid. Screw the blacklyellow wire to the center of

the oil pressure switch.

Connect the

two

blue wires to the solenoid and clamp the connectors to the side of speed control unit.

(3)

Connect the wires drawn out from the stator to

the wires from the control

box.

NOTE

I

:

Connect the wires

of

the same color.

NOTE

2

:

On

220V

and

240V

models, connect

one blue stator lead with a white con-

trol

box lead.

NOTE

3

:

Engage the connectors securely

(4)

Push the wires into the control

box

and attach

the bushing over the wires.

Press the upper end of the bushing into the

control box. (See Fig.

10-43.)

(5)

Install the control

box

to the frame.

6

@

x

16

mm

flange bolt.

.

-2

pcs.

6

@

x

12

mm

flange bolt.

.

-2

pcs.

1

lghten the above three bolts tentatively.

2

lighten the

two

black bolts which join the side

3

lighten the above three bolts adjusting the po-

plate to the frame.

sition of the control box. (See Fig.

1044.)

50

-

60

kgtm

3.6 - 4.3

ft-lb

Fig.

10-43

!

\i

I

Fig.

30-43

-

46-

<

Electric

start

model

>

(6)

Connect the light green and the pink leads

of

the control

box

to the starting motor.

Connect the pink lead to the terminal

of

the motor and attach the light green lead together with the

BAlTERY

CABLE

(+)

to the

6ao

bolt

of

motor.

(7)

Clamp the wires of starting motor and

oil

sen-

sor at the rear panel of control

box,

main bear-

ing

cover and front cover. (See

Fig.

10-45.)

NOTE

:

Take a enough margin in the length

of

wires between control box and alternator

to

allow the move

of

rubber mounted al-

ternator.

Clamp the

BAlTERY

CABLE

(+)

to the left side

leg

of the

rear cover.

Fig.

10-45

-

47-

104-7

FUEL

TANK

(1) Attach the BRACKET

(TANK)

to the frame.

(See Fig. 10-46.)

6

t$

x

16 mm flange bolt.

.

-2

pcs.

4.5 - 5.9

N-m

50

-

60

kg-cm

3.6 - 4.3

ft-lb

(2)

Connect fuel pipes to the

bottom

of the fuel

tank.

Be careful

of

the direction of the BANJO.

(See Fig. 10-47.)

Fig.

10-46

Banjo

bolt

Banjo

Gasket (Aluminium)

,.e!

Ei

Fuel

filter

Fig.

10-47

Ref.

No.

260 mm

4.5

mm

9

mm

Fuel pipe

5

350

mm

4.5

mm

9

mm

Fuel pipe

4

175 mm

6

mm

12

mm

Fuel pipe

1

Length

Inner Dia. Outer Dia. Part Name

Table.

10-2

-1

Use the correct clamps for each fuel pipe.

-

48-

(3)

Mount the fuel tank on the frame. Apply

RUBBER

(TANK)s between side plate and tank, and bracket (tank) and tank. (See Fig. 10-48.)

Use

black flange

bolts

to join them.

6

@

x

18 mm flange bolt (black)

.

. .

4 pcs.

2.9 - 3.9

N-m

30 - 40

kg-Cm

2.2

-

2.9

ft-lb

Fig.

10-48

(4) Connect fuel pipes between fuel tank, fuel cock, fuel filter and fuel injection pump. (See Fig.

10-47.)

Attach the

10

mm

flange nut to the fuel cock before connect the fuel pipe to it.

Use

the correct clamps for each fuel pipe.

I I

Part

Name

I

Outer

Dia. I inner Dia.

I

Length

1

I 2 I

FUELPIPE

I

12

mm

I

6

mm

I

70mm

I

I 3 I

FUELPIPE

I

12

rnm

I

6

mm

I

230

mm

I

~~

Tale.

10-3

(5)

Attach fuel cock and fuel filter to the control

box.

The fuel cock can be installed on the bracket

by

turning

it

90

degrees with fuel pipes connected. Fuel cock 10

@

flange nut

. . .

1 pce.

4.5 - 5.9

N-m

50

-

60

kg-

3.6 - 4.3

ft-lb

Fuel filter

6

t$

x

16

mm flange nut.

.

.2

pcs.

4.5 - 5.9

N-m

50

-

60

kgCm

3.6

-

4.3

ft-lb

-

49-

:348

BATTERY

FRAME

and

BATTERY

(1)

Attach BAlTERY FRAMES to the frame. (See Fig.

1049.)

Clamp the upper end of the battery frames to the side member of the frame. Tighten

two

bolt & washers tentatively.

8qj

x

20

mm bolt and washer assy

.

.2

pcs.

Join the lower end

of

the battery frames to the base plate of the frame.

Tighten

two

bolt & washers tentatively.

80

x

20

mm

bolt and washer assy

.

-2

pcs.

(2)

Mount the BATTERY

BASE

on

the battery

frame. Insert the four bolts from the

bottom

of

the frame and tighten the flange nuts.

4.5

-

5.9

N-m

50

-

60

kgcrn

60

x

40

mm

bolt and washer assy

. .

.4

pcs.

3.6

-

4.3

ft-lb

6

@

flange nut.

.

.4

pcs.

(3)

Tighten the four bolt & washers attached at step

(1).

(4)

Mount the battery on the battery base. Insert the battery bolts into the hooking holes of the

battery base, then apply the battery stay to

the battery and tighten

two

nuts.

6

@

spring washer.

.

.2

pcs.

6

@

nut.

.

.2

pcs.

I

Tightening

torque

r

~~ ~ ~~~~ ~

11.8

-

13.7

N-m

120

-

140

kgcm

8.7

-

10.1

ft-lb

4.5 - 5.9

N-m

50

-

60

kg-crn

3.6

-

4.3

ft-lb

-

50-

(5)

Connect battery cables to the battery.

Connect

the positive

(+)

cable

first

and then the negative

(-)

cable.

8-

Catcher

\\\-%a

Pipe

Bolt and Washer

"4-Y

\

89~20mm:2pcs.

Bolt and Washer 89~20mm:4pcs.

Fig.

10-49

frame

10-5

CHECKING, DISASSEMBLY

and

REASSEMBLY

of

the

CONTROL BOX

10-5-1

CHECKING

OF

THE CONTROL BOX

Dismount

the control

box

from frame. Remove the control panel and check each components and

wiring.

Refer to Section

9

for

the detail

of

checking the components

in

the control

box.

10-5-2

DISASSEMBLY

(1)

Remove

the

control

panel

from

the control box.

4

@

screw.

.

.6

pcs.

(2)

Disconnect the connectors on the wires

to

detach the control panel

and

box.

(3)

Remove

the

regulator, oil sensor

unit,

condens-

ers and diode rectifier from the control

box.

When removing

the

regulator,

push

the

hook

on

the

coupler and

pull

out

to

disengage the

couplers. (See

Fig.

10-50.)

Fig.

10-50

-

51

-

(4)

After disconnecting individual wires, remove the control panel components.

NOTE

:

DC

fuse, full power switch, pilot lamp and warning lamp have their wires soldered.

Unsolder them

to

remove those parts if necessary

10-5-3

REASSEMBLY

(1)

Install

the receptacles, no-fuse breaker, fuse, terminals, switches, etc. on the control panel and wire

NOTE

:

Circuit diagrams are shown in Section

12.

Colored wires are used for easy identification, and are

of the correct capacity and size. Use heat-resistant type wires (permissible temperature range

75

C or over) in the specified gauge shown in the circuit diagrams.

them.

(2)

Install regulator, oil sensor unit, condensers, and diode rectifier into the control box.

(3)

Connect the wires

of

control panel components

and

control box.

Fasten the earth wires

to

the rear of the control box using

a

6l?

nut to the bolt which fixes the

condenser bracket to the inside of the control box. (See Fig.

10-51

.)

(4)

Attach the control panel to the control box.

4

@

screw

. .

.6 pcs.

12

-

15

kgcm

0.9 - 1.1

it-lb

Earth

wires

01

box

Condenser

bracket

To

Earth

terminal

Fig.

70-57

-

52-

11

TROUBLE

SHOOTING

11-1

NO

AC

OUTPUT

11-1

-1

CHECKING

STATOR

Remove control panel and disconnect black, blue, red, and white wires at the connectors.

Measure the resistance between terminals on stator leads. (See Fig.

11

-1

.)

Refer to Table

11

-1

for normal resistance.

If

sta-

tor is faulty, replace with a new one.

I

NORMAL

CAPACITY

OF

CONDENSER

I

Stator

I

Fig.

11-1

11-1-2 CHECKING CONDENSER

*

If

an instrument (QC-meter or C-meter) for mea-

suring capacity

of

condenser is available, check

the capacity of condenser.

(See

Fig.

11

-2.)

-

RGD2500

10pFx2

RGD3300

Table.

11-

1

Fig.

11-2

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 condenser.

-

53-

1-t-1-3 CHECKING

OF

ROTOR

(1)

CHECKING

FIELD

COIL

Measure

the

resistance of

field

coil

with

a

circuit

tester. (See

Fig.

11-3.)

I

Fig.

11-3

(Q)

MODEL

RGD3300

RGD2500

RESISTANCE

3.3

0

3.7

Q

Tale.

77-2

[

Remedy

]

If

the resistance

is

not normal, replace rotor

with

a new one.

11-2 AC VOLTAGE

IS

TOO THIGH

OR

TOO

LOW.

11-2-1 CHECKING STATOR

Check stator referring to Step

11

-1 -1.

11-2-2 CHECKING CONDENSER

Check condenser referring to Step

11

-1

-2.

11

-2-3

CHECKING ROTOR

Check rotor

referring

to Step

11

-1

-3.

-

54-

11-3 AC VOLTAGE

IS

NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED.

-

11-3-1 CHECK THE ENGINE SPEED.

If the engine speed

is

low,

adjust it to the rated r.p.m.

11-3-2 CHECK THE TOTAL WATTAGE

OF

APPLIANCES CONNECTED

TO

THE GENERATOR.

Refer to Section

7

"RANGE

OF

APPLICATIONS for the wattage of the appliances.

If

the generator

is

over-loaded, reduce

the

load to the rated

output

of the generator.

11-39 CHECK THE APPLIANCE

FOR

TROUBLE.

If the appliance is faulty, repair it.

11-3-4 CHECK

IF

THE ENGINE

IS

OVERHEATED.

11

-

If

the cooling air inlet and/or cooling air outlet is

clogged with dirt, grass, chaff or other debris, re-

move

it.

Air

outlet

Fig.

11-4

-3-5 CHECK THE INSULATION

OF

THE GENERATOR.

Stop the engine. Measure the insulation resistance

between the live terminal of the receptacle and

the ground terminal.

"

!

IIU

I

1

I

If the insulation resistance is less than 1 Mn, disassemble the generator and check the insulation resistance of the stator, rotor and the live parts in the control box. (Refer to Section

8-3.)

Any part where the insulation resistance is less than

1

Mn,

the insulation

is

faulty and may cause

electric leakage.

Replace the faulty part.

Fig.

11-5

-

55-

X-4

NO

DC OUTPUT

1141 CHECK THE

AC

OUTPUT.

Check the generator by following Step

11

-1

through Step

11

-1-3.

1142 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

:

1OA

NOTE

:

If

the

DC

output

is

used

to

charge a large

capacity battery or

an

over-discharged

batfew,

an

excessive current may

flow

causing

fuse

blow.

1143 CHECK THE WIRING.

Check all the wires to be connected correctly.

1144 CHECK THE DIODE RECTIFIER.

Remove the control panel and check the diode rectifier with a circuit tester. Refer to Section

9-7

"DIODE

RECTIFIER" for the

checking procedure.

1145 CHECK THE DC COIL

Fig.

11-6

Check the resistance between

two

brown leads

from stator with a circuit tester.

Fig.

11-6

I

MODEL

I

SPECIFICATION

1

RESISTANCE

I

RGD3300

I

60

Hz

I

120

V,

120

V/240

V

I

0.11

Q

I

If the resistance reading

is

much larger or smaller than the specified value, the DC

coil

of the stator is

e

faulty. Replace stator with a new one.

-

56-

11-5

OIL

SENSOR

TROUBLE

SHOOTING

11

-5-1

PRINCIPLE OF OPERATION

The oil sensor for diesel engine consists

of

a pressure switch as a sensor section and a controller section. The pressure switch detects the drop

of

oil pressure in the crankcase. When .the oil pressure falls down

below the predetermined value

(0.3Ei3,

tums on the generate a signal to the controller section.

The controller which is powered by the DC coil sets up a delay for a few seconds for detecting signals transmitted during the period.

If

more signals than the predetermined number are generated, the controller feeds power to the solenoid

which actuated the latch on the control bracket to release the control lever to shut the engine down.

11-54

TROUBLESHOOTING

(1)

Check oil level.

Fill

it up to maximum level

if

necessary.

(2)

Check all wires to be connected properly.

If

they possibly have breaks in connection, the

sensor will also malfunction.

(3)

Checking the solenoid.

Measure the resistance between

two

leads

from

solenoid. (See Fig.

11-8.)

NORMAL

RESISTANCE

235-290

62

1

Fig.

11-8

If

the resistance

is

larger

or

smaller than the above limits, solenoid is defective.

Replace it with a new one.

(4)

Checking the oil sensor unit

(a) Disconnect the connector on the BlacWellow lead

of

the oil sensor unit which is connected to the

(b) Start the engine and ground the BlackNellow lead of the oil sensor unit to engine body. (c)

If

the solenoid actuated to shut the engine down, the oil sensor unit

is

operating properly.

pressure switch.

(5)

Checking the pressure switch

(a) Disconnect the BlackNellow lead of the pressure switch from the control unit. (b) Check the resistance between the BlacWellow lead and ground.

Resistance should be

03

(infinite) when engine is stopped.

(c) Start the engine.

The resistance should be

0

when engine is running.

The pressure switch actuates

at

0.3

kg/cm2 oil pressure.

(d)

If

the pressure switch

does

not work properly, replace

it

with a new one.

-

57-

12.WIRING

DIAGRAM

GENERATOR

I"

E8m

*Only

for

RGD3300.

-

5a-