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Robin
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RGX1800

Robin RGX1800, RGX2400, RGX3500, RGX5500 Service Manual

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Page 1
MANUAL
Models
RGXI 800,*. RGX2400, RGX3500, RGX5500
Generators
PUB-GS0597B Rev. 8198
Page 2
Page 3
Page 4
i
RGX1800
RGX2400
Model
-
-
TY Pe
Frequency Maximum Output Rated Output
~~~~ ~~ ~
___~
~
Brushless, Revolving Field, Self-Exciting,-2-Pole, Single Phase
~~~ ~
50Hz
I
60Hz
I
50Hz
I
60Hz
16ow
I
~~ 1800W
"I
2000w
7
2400W
~
1300W
I
1500W
I
1700W
I
2000w
11OV
I
11.8A
1
11OV
I
13.6A
11OV
I
15.5A
I
11OV
I
18.2A
Rated 220V
I
5.9A
I
120V
1
12.5A
220V
I
7.7A
I
120V
I
16.7A
240V
I
5.4A
I
220V
I
6.8A 240V
I
7.1A
I
220V
I
9.1A
Current
".
.
-,
.
1 1 OV122OV
16.7Al8.3A
12OVl24OV
-
-
18.2Al9.1 A
1 1 OVl22OV
15.5AR.7A
". -.
Power Factor
1
.o
12V-8.3A (1 OOW) DC Output
Voltage Regulator
Condenser Type
Voltage Regulation Within 10%
Robin Air-Cooled 4-Cycle Gasoline Engine
EY20D
Type Model Displacement 183cc
(11.17
cu. in.)
Rated Output
3.5 HP13600 rpm
Fuel
Automobile Gasoline
Fuel Tank Capacity 10 liters (2.64
US.
gal.)
Fuel Consumption Ratio (at Rated Output)
50Hz:
1
.O
liters/hour
60Hz: 1.3 literslhour
50Hz: 1.1 liters/hour 60Hz: 1.4 liters/hour
Oil Capacity Starting System
-.
.
_""
..
600 cc
Recoil Starter
552
X
377 X 482 mm
(21.7
X
14.8 X 19.0 in.)
Dimensions
L
x
W X H
Dry
Weight 45 kg (97 Ibs.)
I
45.5 kg (100 Ibs.)
Page 5
I
I
Iu
Model
I
RGX3500
I
RGX5500
I
I
i
-
~
~
TY Pe
~ ~ ~ ~~~
Brushless, Revolving Field, Self-Exciting, 2-Pole, Single Phase
Frequency
4800W
4400W
3000W
2500W
Rated Output
5500W
5000W
3500W
3000W Maximum Output
60Hz
50HZ
60Hz
50Hz
"".
-
.
.
I
Voltage
,
. . .
..
110v
43.6A 110v 40A 110v 26.4A 110v
22.7A
Rated
40A 120v 20A 220v 24.2A
120v
11.4A
220v 240V
21.8A 220v 18.3A 240V 13.2A 220v 10.4A
Current
43.6AI21.8A
1 1 OV1220V
40Al20A
1 1 OV1220V
26.4Al13.2A
1 1 OV1220V
22.7AIl1.4A
1 1 OV1220V
"
-
40AI20A 120V1240V
-
-
24.2N12.1A 120V1240V
-
-.
-.
. , .
"
..
""
-
.
L
Power Factor
1
.o
DC Output Voltage Regulator
12V-8.3A (1 OOW)
,
TY Pe
Within 10%
Voltage Regulation
"
"
Condenser Type
"-
.
"
Robin Air-Cooled 4-Cycle Gasoline Engine
Model
EY40D EY28D
I
Displacement
I
~ ~~
273 cc (16.66
cu.
in.)
I
388 cc (23.68
cu.
in.)
I
Rated Output
I
5.5 HP/3600 rpm
I
8.0 HP13600 rpm
Automobile Gasoline
13 liters (3.43
U.S.
gal.)
I
15.5 liters (4.10
U.S.
ghl.)
W
"
-
.
-.
-
" "
Fuel Consumption Ratio
(at Rated Output)
50Hz: 1.8 literdhour 60Hz:'2.1 literslhour
50Hz:
2.7 literslhour
60Hz: 3.1 literdhour
I
Oil Capacity Starting System
Recoil Starter and Optional Electric Starter
-
."
850 cc
1200
cc
I I
Dimensions
L
X W
X
H
552
X 413
x
520 mm
(21.7
X
16.3 x 20.5 in.)
635
X 448
X
596 mm
(25.0
X
17.6 X 23.5 in.)
Dry
Weight
76
kg
(167.6 Ibs.)
56 kg (123.5 Ibs.)
c
Page 6
2.
PERFOMANCE
CURVES
2-1
MODEL
RGX1800
I
3
6
9
12
15
CURRENT
{A)&
+
-3-
Page 7
u
U
t
I
>
U
-
W
a
5
0
>
1.5k
-
3
-1k
5
n
t-
-0.5k
0
3
-0
bk
c1.5k
rz
0.5k
2
3
I-
-0.5k
o
2
-0
CURRENT
(A)
+
-4-
Page 8
>
CURRENT
(A)-
0
3
6
9
12 15
CURRENT
(A)+
2-2
MODEL
RGX2400
+
5
0
>
2k
1.5k
-
t
iz
lk
n
3
I-
0.5k
o
3
0
2k
1.5k
t
lk
I-
n
3
I-
3
0.5k
0
CURRENT
(A)-
-5-
Page 9
4
4
CURRENT
(A)+
0
4
a
12
16
20
CURRENT
(A\+
-2
k
-t
1
-1k
3
I-
2
I-
-3
0
-0
CURRENT
(A)”--.)
-6-
Page 10
_."
t
62
1
220
c
61
>.
L:
60
z
3
59
w
z
K
U
240
-
>
200
a
00
5
2
4
6
a
10 12
w
u
>
CURRENT
(A)+
CURRENT
iAl+
t
IZt
1
-1k
t-
I-
-3
0
2
-c
-2k
-t
I
is
-1k
E
n
I-
3
0
d
-0
r
0
4
8
12 16 20
CURRENT
(A)
-
-7-
Page 11
4
8
12
16
20
CURRENT
(A)
-
2-3
MODEL
RGX3500
t
L
52
51
50
49
120 110
100
0
10
20
30
CURRENT
(A!-
63 62
61 60
59
120
110
100
0
10
20
30
-
4k
-3k
t
3
-2k
2
k
-1k
6
-0
CURRENT
(A)-
-a-
Page 12
>-
V
z
w
3
z
a
U
/-
z
t
CURRENT
(A)+
-3k
-2
t
3
-
I-
3
0
3
-1k
-0
U
t
-
4k
-
3k
-2k
:-
1k
4
>
8
12
CURRENT
[A)-
t
-
>
0
I-
d
0
>
G
a
14k
CURRENT
(A)-
-9-
Page 13
N
I
-
%
i,
W
z
3
U
a
W Y
>
W
CY
I-
-I
3
>
-
a
W
3
El
LL
CT
50
10
20
30
CURRENT
[A!-
LL
W
U
i-
-1
a
C
>
0
CURRENT
[A)-
-1
-
10-
Page 14
2-4
MODEL
RGX5500
-
4k
-3k
-
t
s
-2k
3
a.
t
-1k
0
3
-0
t
>
0
z
3
u
0
K
U
-3k
3
-2k
2
I-
3
-1k
0
I-
-0
CURRENT
(A)-
CURRENT
(AI+
-
11
-
Page 15
62
61 60
59
130 120
110
0
10
20 30 40
50
-
t
52
51
5
50
z
-
Ej
49
3,
L=
U
240
t
220
-
2
200
a
w
13
t
-1
20
5 10
15
20
25
~
CURRENT
(A)-
N
61
I
60
-
z
cl
a
5
53
IL
U
240
f
220
I
-
>
200
(3
<
t
-1
0
0
5
10
15
>
20 25
LLI
CURRENT
[A)-
LO
LO
-
6k
:-t
4k
-
-3k
3
-2k
3
-1k
0
LO
-
12-
Page 16
U
a
CURRENT
(A)-
t
>
a
-
W
a
0
-1
>
CURRENT
(AI
-
t
a
U
-
5k
I-
z
t-
-2k
3
0
~
lk
-0
r
6k
i
-
13-
Page 17
6k
I:,
c
5
-3k
3
a
I-
-2k
o
3
r
lk
i
CURRENT
[A)-
2-5
DC
OUTPUT
The voltage curve shown in the left indicates the
characteristic
of
DC
output when charging a battery.
The voltage
may
be decreased by
20%
when the
resistance load
is
applied.
NOTE:
It
is
possible
to
use
both
DC
and
AC
out-
puts simultaneously
up
to the rated
output
in
total.
-
14-
Page 18
Page 19
Page 20
4-2
CONTROL
PANEL
0
RGXl800
:
50HZ-11
OV, 60Hz-120V
TYPE
VOLTMETER CIRCUIT BREAKER
DC
RGX2400 : 50HZ-11 OV, 60Hz-12OV
TYPE
VOLTMETER
\
DC
FUSE
\
0
P-T
0
CIRCUIT BREAKER
AC RECEPTACLE
DC
OUTPUT
TERMINAL
EARTH
(GROUND)
TERMINAL
-
17-
Page 21
Page 22
Page 23
Page 24
RGXI800,2400 : SWITZERLAND,
50Hz-220V
DC FUSE
\
DC OUTPUT TERMINAL
OFF
-n-
c
I
AC
220V
I
3
i
vo
CIRCUIT BREAKER
ILTMETER
L
22QV
RECEPTACLE
EARTH (GROUND) TERMINAL
\
RGXl800,2400 : AUSTRALIA,
5OHZ-240V
CIRCUIT BREAKER
DC FUSE
/
---.
VOLTMETER
-
24QV
RECEPTACLE
DC OUTPUT TERMINAL EARTH [GROUND) TERMINAL
-
21
-
Page 25
Page 26
0
RGX3500
:
5OHZ, 60H~-llOV/220V TYPE
NO-FUSE BREAKER
START SWITCH
(Option’
\
FULL POWER SWITCH
/
\
/
Dc
FUSE
VOLTMETER
-
k
3
AC
AC RECEPTACLE
7
0
EARTH
(GROUND)
TERM~NAL
DC OUTPUT TERMINAL
RGX3500
:
U.K.,
50H~-llOV/22OV
[BS
RECEPTACLE]
START SWITCH VOLTAGE CHANGEOVER SWITCH NO-FUSE BREAKER
(Option)
\
/
:DC
FUSE
VOLTMETER
220V RECEPl
Lo
,/
J
llOV RECEPTACLE
EARTH
(GROUND)
TERMINAL
-
23
-
DC
OUTPUT TERMINAL
Page 27
Page 28
RGX3500 : 50HZ-220V [WITH
SPECIAL
RECEPTACLE]
'Option'
\
START SWITCH
220V RECEPTACLE
VOLTMETER
I
0
0
EARTH
(GROUND)
~ERMINAL
RGX3500 : SWITZERLAND, 50HZ-22OV
(Option'
\
START SWITCH
220v RECEPTACLE
VOLTMETER
I
Jl
3
,F
0
~ ~~
EARTH
(GROUND)
TERMINAL
-
25
-
NO-FUSE BREAKER
DC
OUTPUT
TERMINAL
NO-FUSE BREAKER
/
DC
OUTPUT TERMINAL
Page 29
Page 30
Page 31
Page 32
Page 33
Page 34
Page 35
Page 36
5-2-2
CONDENSER
One or
two
condensers are installed in the control box and are connected to the condenser coil of the stator. These condensers and condenser coil regulate the output voltage.
5-2-3
ROTOR
The rotor consists of a laminated silicon steel
sheet core and a field coil which
is
wound over the core. DC
current
in
the field coil magnetizes the steel
sheet core.
Two
permanent magnets are provided
for the primary exciting action.
fig.
5-3
Fig.
5-4
A
diode rectifier and surge absorber is mounted inside
of
the insulator.
I
11
I
I
Fig.
5-5A
Fig.
5-58
-
33
-
Page 37
Page 38
Page 39
Page 40
Page 41
Page 42
6. SAFETY PRECAUTIONS
●
1.
2.
3.
4.
5.
e
6.
7.
Use extreme caution near fuel. A constant danger of explosion or fire exists.
Do not fill the fuel tank while the engine is running. Do not smoke or use opem flame near the fuel tank. Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before starting the engine.
Do not place inflammable materials near the generator.
Be careful not to put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the generator.
Do not operate the generator in
a roorn,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.
Operate the generator on a level surface.
If the generator is tilted or moved during use, there is a danger of fuel spillage and a chance that the generator may tip over.
Do not operate with wet hands or in the rain.
Severe electric shock may occur. If the generator is wet by rain or snow, wipe 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 leakage and electric shock.
Do not connect the generator to the commercial power lines.
it and thoroughly dry it
and may cause current
This may cause a short-circuit or damage to the generator.Use a transfer switch for connecting with indoor wiring.
NOTE: The patts numbers of the transfer switches and of tie plastic box to store them are as
shown in Table 6-1.
7
Part No. Part Name
Q’ty
Phase Allowable Current
365-45604-08
Transfer Switch 1 1 15A
367-45605-08
Transfer Switch
1
1
30A
340-45606-08
Transfer Switch 1 1 60A
367-43008-08
Plastic Box 1
1 30A
348-43009-08
Plastic Box 1
1
60A
Table 6-1
Use a fuse of the correct capacity. (DC output)
If the generator rpm is increased excessively in the overload condition by using an over rated fuse, the generator may be burnt.
CAUTION :
If the fuse is burnt or the circuit breaker tripped off as a result of using an
electrical appliance,the cause can be an overload or a short-oircuit. In such a case, stop operation immediately and carefully check the electricalappliance and AC plugs for faulty wiring.
–39–
Page 43
7. RANGE OF APPLICATIONS
Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it.The electric power required for operating an electrical appliance is not always equal to the output
wattage of the appliance. The electrical appliances generally have a label showing their rated voltage,
frequency, and 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 1OOW incandescent lamps on.
(2) Fluorescent lamps,mercury lamps, 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.
Example:
A 400W mercury lamp requires 600W to 700W power source to be turned on. A rated 3000W generator can power four or five 400W mercury lamps.
NOTEI: If a power factor correction capacitor is not applied to the mercury lamp or fluorescent
lamp, the more power shall be required to drive those lamps.
A rated 3000 W generator can drive one or two 400 W mercury lamps without power factor
correction capacitors.
.-
NOTEZ: 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 Item (5) on the following page.
(3) Motor driven tools and light electrical appliances
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 250W electric drill requires a 400W generator to start it.
(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 9OOW compressor requires a 4500W generator to drive it.
NOTEI: .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.
NOTEZ: 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 diti’icult to determine the optimum generator capacity, select a generator with a larger capacity.
- 40 -
Page 44
:.
: (
_ ~. I .-.. .-
(5) Appliances without any indication & t& -&&ver consumption
Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a case, power consumption is to be worked out according to the numerical formula mentioned below.
(Output of electrical appliance) = tPower consumption~
(Efficiency)
Efficiencies of
some
electrical appliances are as follows:
Single-phase motor * - * * . * * - - - * * . . * - * 0.6 - 0.75 The smaller the motor, the Three-phase motor * * - . * - - * * - - - - - - - 0.65 - 0.9
II-
lower the efficiency.
Fluorescent lamp * . - . . * * * * - . * * . * * . * - 0.7 - 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 - 2 and you will get the figure of the necessary capacity of a generator. In other words, a generator with a rated output of 1OOOWcapacity 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 f 0.7= 57OW. When this motor is used for a motor-driven tool, the capacity of the generator should be multipled by 1.2 to 3 and 570W as explained in the
Item(3).
MODEL RGX1800
Frequency 50Hz
60Hz
lncandesent lamp, heater, etc.
Fluorescent lamp, mercury lamp, etc.
I I
approx.
approx.
9oow
1 OOOW
Motor-driven tool,
general-purpose motor,
I I
approx. approx.
etc.
800W 9oow
Water pump, compressor, etc.
approx.
I I
approx.
4oow 450w
approx.
1lOOW
approx.
1 ooow
approx.
5oow
approx.
13oow
approx.
12oow
approx.
600W
approx.
17oow
approx.
15Oow
approx.
750w
approx. 2ooow
approx.
18OOW
approx.
9oow.
4400w
4800W
approx.
2800w
approx. 3200W
approx.
2600W
approx. 2900w
approx.
13oow
approx.
14oow
Tab/e 7-1
- 41 -
Page 45
NOTES: Wiring between generator and electrical appliances
7. Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load (electrical appliance). If the input current is higher than the allowable current of the cable used, the cable will become excessively heated and deteriorate the 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 decreasing the input voltage to the load (electrical product). As a result, the load can be damaged. Table 7-2 shows voltage drops per 100 meters of cable.
mm’ No. A No. I mm QllOOm 1A 3A
0.75 18 7 30 IO.18 2.477 2.5U 8U
1.27 16 12 5010.18 1.486 1.5u 5u
2.0 14 17 37 IO.26 0.952 1u 3u
3.5 112-101 23 1
45 IO.32
I
0.517
I I
- 1.5u
5.5 10-8 25 70 I 0.32 0.332 - 1U
Table 7-2
Current Amp.
XJyJ-yA
2u 2.5U I3.5U 4U 5U
Voltage drop indicates as V =
R mens resistance ( Q /lo0 m) on the above table.
I means electric current through the wire (A).
f2 means the length of the wire (m).
The length of wire indicates round length,it means twice the length from generator to electrical tools.
- 42 -
Page 46
.
8. MEASURING PROCEDURES
8-l MEASURING INSTRUMENTS 8-1-l “Dr. ROBIN” GENERATOR TESTER
The “Dr. RobirPgenerator tester is exclusively designed for fast, easy diagnosis and repair of
Robin generators.
The “Dr. Robin” has the following features: (1) Functions of voltmeter, frequency meter,
meggertester, capacitance meter and circuit
tester 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 car-ring.
Fig. 8-l
l
SPEClFlCATlONS
Model
Part Number
i%
Voltage
s
nr
Frequency
P Resistance
‘Z
3 3
Condenser Capacity
I
Insulation Resistance Circuit Protector Power Source
Accessories
Dimensions (L X W X H) Weight
Dr. Robin
388-47565-08
0-500V AC
25-70Hz
0.1-l ,999 Q lo-100 ,zF
3MQ Fuse
2 x 6F44P (006P) Dry Cell Battery
Test leads with needle probes . . . 1 set
Test leads with jack plclgs . . . . . . 1 set
285 mmx200 mmxll0 mm
1.6kg
Table 8-1
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.
- 43 -
Page 47
8-l-2 INSTRUMENTS
(1) VOLTMETER
AC voltmeter is necessary-The approximate
AC voltage ranges of the voltmeters to be
used for various types of generators are as follows: 0 to 15OV: Type with an output voltage of
110 or 120V
0 to 300V: Type with an output voltage of
220,230 or 240V
0 to 15OV, 0 to 330V: Dual voltage type
(2) AMMETERS
AC ammeter is necessary. An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable. (About lOA, 20A, 100A)
(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
1:
ii!
j:. /i
II
b--j;.
: /-.--.
F
II
!j
r-
I i
i
Fig. 8-4
- 44 -
Page 48
(4) CIRCUIT TESTER
Used for measuring resistance, etc.
(5) MEGGER TESTER
Used for measuring generator insulation resistance. Select one with testing voltage range of 5oov.
I I
Fig. 8-5
I
I
Fig. 8-6
There are various types of tachometers, such as contactless type, contact type, and strobe type. The contact type can be used only when the generator and engine have been dis­assembled. The contactless type is recom­mended.
I
CONTACTLESS TYPE
CONTACT TYPE
STnOdE TYPE
Fig. 8-7
- 45 -
Page 49
8-2 AC OUTPUT MEASURING
TO AC RECEPTACLE
Fig. 8-8
Use a circuit like the shown in Fig.88 for measuring AC output. A hot plate or lamp with a power factor of 1.0 may be used as a load. Adjust the load and rpm. and check that the voltage range is as specified in Table 8-2.at the rated amperage and rated rpm.
-
Rated voltage
1lOV
120v
22OV
240v
Voltage range
107-119v 117-130v 215-238U 235-20OU
Table 8-2
8-3 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.
MEGGER TESTER
\
Fig. 8-9
l
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.
n
Fig. 8-10
- 46 -
Page 50
l
ROTOR
Measure the insulation across one of the soldered
l
terminals of the rotor and the core.
l
CONTROL PANEL
Measure the insulation resistances between the live parts and the grounded parts.
Fig. 8-l 1
Fig. 8-12
Any part where the insulation resistance is less than 1MQ has faulty insulation, and may cause electric leakage and electric shock. Replace the faulty part.
- 47 -
Page 51
9. CHECKING FUNCTIONAL MEMBERS
9-l PILOT LAMP and VOLTMETER
Check the pilot lamp and the voltmeter if it is turned on by applying specific voltage. Pilot lamp and voltmeter cannot be checked with circuit tester because its resistance is too large. (See Fig.9-1.)
n.
Fig. 9-1
Pilot lamp should be turned on at 70 to 120V.
9-2 AC RECEPTACLES
Using a “Dr. Robin”or a circuit tester, check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel. 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. 9-2A
AC RECEPTACLE
Fig. 9-2B
-4848
Page 52
9-3 CIRCUIT BREAKER
Check continuity between each of two terminals at the rear of the circuit breaker while it is mounted on the control panel. Normally, there is continuity between each of the two when the circuit breaker
is on while there is no continuity when the circuit breaker is off.
9-4 STATOR
Disengage connectors on the wires from stator and check the resistance between wires with a “Dr.
Robin” or a circuit tester refering to the following table.
Fig. 9-3
TOR
Fig. 9-4
MODEL
Specification AC Winding 1 Condenser Winging
Hz 1 Voltage White/Red
I
Black/ Blue
I
Yellow / Yellow
RGXl800
RGX2400
50
110v,220v,110v/220v 1.85 1.85 5.56
240V 2.10 2.10 5.56
60
220v,110v/220v 1.10 1.10 3.80 12OV,12OV/24OV 1.10 1.10 3.80
11ov,22ov,11ovi22ov 1.18 1.18 3.34
50
240V 1.42 1.42 3.37
220v,110v/220v 0.84 0.84 2.51
60
12OV,12OVl24OV 0.84 0.84 2.51
50
110v,220v,110v/220v 0.73 0.73 1.81
RGX3500
240V 0.83 0.83 1.83
220v,110v/220v 0.69 0.69
60
1.52
12OV,12OVl24OV 0.69 0.69 1.52
0.34 0.34
50
110v,220v,11
OVl22OV
0.81
RGX5500
240V 0.41 0.41 0.78
60
22ov, 11
OVl22OV
0.26 0.26 0.58
12OV,12OVl24OV 0.26 0.26 0.58
Table 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°C(68”F).
- 49 -
Page 53
9-5 ROTOR ASSEMBLY
(1) Using a “Dr. Robin” or a circuit tester, measure the resistance of the field coil at the terminals.
(RXlQ &lo%)
MODEL
RGX1800 RGX2400
RgEy Rgzy
RGXSOO
RESISTANCE
2.5 Q
2.7 $2
2.1 R 2.2 R 1.6 R
Table 9-2
NOTE 1: Because a diode is soldered to the coil
ends at the terminals, resistance may be measured only when tester probes touche the terminals in one
combi­nation of polarity. Therefore, if no re­sistance reading appears, try checking in reverse polarity.
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 tem-
peratures ditferent from 20°C(68”F).
Fig. 9-5
9-5 CONDENSER
Use a “Dr. Robin” in capacitance meter mode to check the capacity of condensers. (See Fig.9-6).
RGXl800, RGX2400
RGX3!500
Fig. 9-6
n.
RGX5!500
,-I
n
NOTE: Be sure to discharge condensers by shorting condenser leads each other before checking their
capacitance,or the accurate reading cannot be obtained.
- 50 -
Page 54
n
NORMAL CAPACITY OF CONDENSER
MODEL RGXl BOO
RGX2400
RGX3500
RGX5500
0
14,xF 20,~F
17fiFX2 28,~FX2
Resistance
0
14,~F 20,~F
17pFX2 28fiFX2
Table 9-3
H If such an instrument is unavailable, the condenser can be checked by replacing with a new one.
If the generator performs good with new condenser, the cause of trouble is defect in original condenser.
9-7 DIODE RECTIFIER
DIODE RECTIFIER
Brown/ White
Orange
Orange 0
II
rl
Brown
Brown
0 II
Brown/White
CIRCUIT TESTER
Fig. 9-9 Fig. 9-10
Circuit inside of the diode rectifiers is as shown in Fig. 9-9. Check continuity between each terminal by using a circuit tester as shown in Fig. 9-10. The rectifier is normal when condtinuity is as follows:
H Checking table for analogue circuit tester.
Analogue circuit tester
Apply black @needle of the circuit tester
Brown
Brown Orange BrownMlhite
I
Brown
No continuity No continuity Continuity
I I. I I
Apply red @ needle
of the circuit tester
Brown
No continuity
Orange
Continuity
Brown/White
No continuity
Table 9-4-l
- 51 -
Page 55
n
Checking table for digital circuit tester.
Apply red @ needle of the circuit tester
Digital circuit tester
Brown Brown Orange Brown/White
Brown
No continuity 1 No continuity Continuity
Apply black 0 needle
of the circuit tester
Brown
drange
No continuity Continuity
Continuity Continuity
I I
.I
Brown/White
No continuity No continuity
No continuity
NOTE I:
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 are digital.
Table 9-4-2
IO. DISASSEMBLY AND ASSEMBLY
10-I 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, place them temporarily back at 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
REAR COVER PULLER
- 52 -
n
Page 56
104 DISASSEMBLY PROCEDURES
Step Part to remove
Description Remarks
Tool
1.
Fuel Tank
(1) Discharge fuel from the tank.
Use utmost care about
1. Shut the fuel strainer.
fire hazard.
2. Remove the strainer cup.
3. Put a vessel to receive fuel under the strainer and open the fuel cock to discharge fuel. (See Fig. 10-l.)
Wipe off sprit fuel thoroughly.
4. Attach the strainer cup to the strainer
Do not lose the filter
body.
screen.
Fig. 10-l
(2) Disconnect fuel hose from the strainer.
Loosen the hose clamp on top of the strainer and pull out the fuel hose from the strainer. (See Fig. 10-2.)
Pliers
(3) Take off the four nuts and remove the
13 mm spanner or
fuel tank. (See Fig. 10-3.)
box wrench
Fig. 10-2
Fig. 10-3
- 53 -
Page 57
tep Part to remove
Description
Remarks
Tool
2.
Control Box
(1) Take off the grommet from the rear
pannel of control box.
(See Fig. 10-4.)
(2) Disconnect the connector on the wiring
from the control box to the alternator.
(3) Remove the fuel strainer.
Remove the nut on top of the fuel strainer located beside the control box. (See Fig. 10-S.)
Fig. IO-4
(4) Take off the three bolts and remove the
control box from the frame. (See Fig. 10-6.)
Fig. 10-5
10 mm spanner
Oi
box wrench
(5) Take off the bushing from the bottom of
Press the upper end of
the control box.
the bushing and pull
(See Fig. 10-7.)
out.
Fig. IO-6
Fig. 10-7
Page 58
. . :
Step Part to remove
Description Remarks
Tool
3.
Pipe Frame
(1) Remove SIDE PLATE from frame.
10 mm spanner 0:
(See Fig. 10-8.)
box wrench
64
bolt. . . . _ . . . . . . . . . . . 2 pcs.
Remove the mount rubbers from SIDE PLATE.
(2) Remove the nuts which fix the engine
and alternator on the mount rubbers.
(3) Dismount the engine and alternator from
the frame.
Take out the engine and alternator assy from the side of the frame. (See Fig. 10-9.)
12 mm spanner 0:
box wrench
Fig. 10-8
Fig. 10-9
MOUNT RUBBER..
MOUNT RUBBER
WBOLT
. . . . . . 21~s.
BoNUT . . . 2pcs.
Page 59
itep Part to remove
Description Remarks Tool
4.
Rear Cover
(1) Remove the end cover. (See Fig. 10-l 1.)
10 mm spanner 01
66
bolt . . . . . _ . . . . . _ _ . . _ 4 pcs.
box wrench
(2) Take off the rear cover.
1. Remove the four bolts which fasten
10 mm spanner 01
the rear cover to the front cover.
box wrench
6@f,c,lt . . . . . . . . . . . .._.. dpcs.
I
2. Use a special tool “REAR COVER PULLER” to remove the rear cover. a) Insert the two screws of the special
Insert the two screws
tool into the thread holes of the
sufficiently and evenly,
rear cover.
or the thread hole may be
b) Apply the center bolt of the special
damaged at removing.
tool on the head of the through bolt.
c) Tighten the center bolt to pull out
the rear cover.
Fig. lo-11 Fig. lo-12
In the case that REAR COVER PULLER” is unavailable, remove the rear cover by the following instructions.
2’. Hit on the boss and legs -of rear Do not give a strong hit
cover with a plastic hammer to on the boss or legs.
loosen.
Box wrench Plastic hammer
Fig. lo-13
- 56 -
Page 60
Step Part to remove
Description : Remarks
Tool
5.
Staitor (1) Remove the four bolts which fasten the
10 mm socket
stator to the rear cover.
wrench
(See Fig. 10-14.)
&BOLT . . . . . .4pcs.
60 SPRING WASHER
Fig. 10-14
(2) Rut a piece of lumber on the floor in
upright position. (See Fig. 10-E)
(3) Hold the rearcover and stator upside
down with both hands.
(4) Down the rear cover and stator over the
lumber lightly hitting the bottom of rear cover to the top end of lumber to pull out the stator.
(See Fig. 10-16.)
+NOTES]
1. Apply fingers to stator coil to keep the stator from dropping on the floor.
2. Gently hit the bottom of rear cover to the top end of lumber several times until the stator comes out loose.
Fig. 10-15
Fig. 10-16
- 57 -
Page 61
Zep Part to remove
Description
Remarks
Tool
5.
Stator
(5). Take apart the support ring and
stator from rear cover.
SUPPORT RING
@BOLT . . . _ _ .4pcs.
w SPRING WASHER
. . . . . . . . . . 4 PCS.
@WASHER
. . . . 4~~s.
Fig. 10-17
6.
Rotor
(1) Take off the through bolt.
Box wrench
Apply a box wrench on the head of
Plastic hammer
through bolt. Hit the wrench handle with a hammer counter-clockwise to loosen.
i
Fig. IO-18
(2) Put the engine on the working table recoil starter side down.
- 58 -
Page 62
tep Part to remove
Description
Remarks
Tool
6. Rotor
(3) Use a bolt and oil as a tool for pulling
out rotor in the following procedures :
1. Pour engine oil into the center hole of rotor shaft.
Fill with oil to the shaft end.
(See Fig. 10-19.)
2. Prepare a bolt with the following thread size: RGX1800,2400,3500. . MlOXP1.25
RGX5500........... M12XP1.50
3. Apply a few turns of seal tape around the tip of the bolt.
(See Fig. 10-20.)
I I
! I
Fig. 10-19
Fig. 10-20
until the rotor comes off loose.
lit pressure inside the rotor
apart the rotor from the
Socket wrench
Fig. 10-21
Page 63
Step Part to remove
Description
Remarks
Tool
7. Front Cover
(1) Remove the front cover.
12 mm Socket
Loosen the four bolts and remove the
wrench
front cover.
84 bolt.. . . . . . . . . . . . . . .4pa.
Fig. 10-22
- 60 -
Page 64
104 ASSEMBLY PROCEDURES
104-l FRONT COVER
Attach the front cover to the engine main bearing cover. Match the faucet joint and tighten the bolts.
M8 X 18mm bolt . . . . . .4 pcs.
M8 spring washer . . _ . -4 pcs. Tightening torque : 120 - 140 kg-cm
8.7
- 10.1 ftlbs.
104-2 ROTOR
(1) Wipe off oil, grease and dust from the tapered
portion of engine shaft and matching tapered hole of rotor shaft.
(2) Mount the rotor to the engine shaft.
Tighten the through bolt. Apply a wrench on the through bolt and hit wrench handle clockwise with a hammer to tighten. If an impact wrench is available, use it.
Tightening torque :
RGX1800,2400 : 115 - 135 kg-cm
8.7
- 10.8 ftlbs.
RGX3500,5500 : 230 - 250 kg-cm
16.6 - 19.5 ftlbs.
104-3 STATOR
(1) Put the stator in the rear cover setting the four
grooves on the side of stator with thread holes of the rear cover. Tighten the four bolts tentatively to check if the grooves and thread holes are aligned correctly. (See Fig-lo-25.)
(2) Remove the four bolts.
Fig. 10-23
Fig. lo-24
@BOLT . . . . . .4pcs.
60SPRlNG WASHER
. . . . . . . . . . 4 pa.
60 WASHER . . . . 4 PCS.
Fig. 10-25
- 61 -
Page 65
(3) Apply the support ring between the rear cover
and the stator. Tap on the support ring evenly using an aluminum bar and a hammer to press into the rear cover. (See Fig-lo-26.)
CAUTION: Be careful of the position of hook-
ing holes of the support ring.
(4) Join the stator to rear cover with four bolts,
washers and spring washers. (See Fig. 10-25.)
M6 bolt
. . . . . . . . . . . . . . . . . . . . . . .
4 pa.
M6 washer . . . . ...-.....-..-... 4~~s.
M6 spring washer **-.**--..* 4 PCS. Tightening torque : 80 - 100 kg-cm
5.8 - 7.2
ft. lbs.
NOTE: Tighten four bolts evenly taking several
steps.
l
The dimensions of the stator bolts are shown in Table 10-l.
Fig. lo-26
MODEL
1
s
d
RGX1800
65mm
65
mm
25.6 inch 25.6 inch
M8X1.25
RGX2400
75
mm
15mm
29.5 inch 0.59 inch
M8X1.25
RGX3500
85mm
85
mm
(50Hz)
3.35 inch 3.35 inch
M8 x 1.25
RGX5500
115
mm
4.53 inch
40
mm
1.57 inch
Ml0 x 1.5
Table 10-l
- 62 -
Page 66
1044 REAR COVER
(1) Attach the bushing over the lead wire drawn out from the rear cover.
Press the smaller end of the bushing into the window of the rear cover. (See Fig.lO-27.)
Fig. 10-27
(2) Put the rear cover with stator over the rotor.
Tap on the rear cover evenly with a plastic
hammer to press the rotor bearing into the rear cover.
(3) Fix the rear cover to the adaptor with four
bolts, spring washers, and washers.
M6 X 25 mm bolt *.***----..*.. 4 pcs.
M6 spring washer *.-*---*.*.** 4 PCS.
M6 washer
. . . . . . . . . . . . . . . . . . . . . 4 pcsm
Tightening torque :
50 - 60 kg-cm
3.6 - 4.3 ftlbs.
I I
Fig. lo-28
- 63 -
Page 67
104-S END COVER
Attach the end cover to the rear cover.
M6 X 8mm flange bolt *.--.-.-*-. 4 PCS. Tightening torque : 40 - 60 kg-cm
2.9 - 4.3 ftlbs.
Fig. lo-30
104-6 FRAME
(1) Attach the mount rubbers to the frame.
Insert the setting tongue of mount rubber into the hole on the frame and tighten the nut from the bottom of the frame. M8 flange nut
. . . . . . . . . . . . . . . . . . . . . .
4 pa*
Tightening torque : 120 : 140 kg-cm
8.7 - 10.8 ft-lbs
Fig. 10-31
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.
Although mount rubbers have the same appearance, their characteristics are different.
(2) Attach the 5~$ terminal of the grounding wires (green/yellow) to the unpainted thread hole of the
frame base plate using a 5 mm brass screw.
;n
- 64 -
Page 68
(3) Install the engine and alternator assembly into.
the frame. Put the engine and alternator assembly into the frame from the side of it. Tighten the nuts over the mount rubber bolts to fix.
M8 nuts
Tightening torque : 120 - 140 kg-cm
8.7 - 10.1 ftlbs.
Fig. IO-32
NOTE : When tightening the nuts, slightly lift the engine and‘altemator assembly so that the weight is
not applied
to
the mount rubbers.
(4) Attach the side plate frame.
M6 X10 mm bolt *.-.***.*--*** 2 pcs. Attach fuel tank mount rubbers to side plates. The nuts for mount rubbers are welded to side
plates.
Tightening torque : 40 - 60 kg-cm
2.9 -
4.3
ftlbs.
Fig. lo-33
10-4-7 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 4t$ terminal of the grounding wires to the rear panel of the control box.
M4nut (brass)-..-..-...---... 1 pee.
(2) Connect the wires drawn out from the stator to the wires from the control box.
Connect the oil sensor wires at the same time.
NOTE : Connect the wires of the same color.
-
65
-
Page 69
(3) Press the upper end of the bushing into the
bottom window of the control box. Attach the grommet for the oil sensor wires to
the rear panel of the control box.
(4) Mount the control box to the frame.
M6 X12 mm fiange bolt ..-*..***. 3 pcs. Tightening torque : 40 - 60 kg-cm
2.9 - 4.3 ftlbs.
PUSH
Fig. lo-34
Fig. 10-35
(5) Fasten the one earth cable with 86 terminal drawn out from the control box to the rear cover leg.
M8 nut
. . . . . . . . . . . . . . . . . . . . . . . . . . .
1 pee.
Tightening torque : 80 - 100 kg-cm
5.8 - 7.2 ftlbs.
Fasten the other earth cable with 54 terminal to the unpainted bolt hole on the frame. (See Fig.lO-36.)
59 TERMINAL
(FRAME)
0
A
0
0
6$ TERMINAL
89 TERMINAL
(CONTROL 80X) (REAR COVER)
- 66 -
Fig. lo-36
Page 70
10-4-8 FUEL TANK
1) Connect the rubber pipe to the engine carburetor and fasten it with a hose clamp. Attach the banjo to the opposite end of the rubber pipe, tighten it with a hose clamp, and fasten the pipe to the fuel strainer with the banjo bolt.
2) Fasten the strainer to the strainer bracket with the joint nuts.
3) Mount the fuel tank on the side plates with rubber washers between them. M6 X20 mm black bolts
. . . . . . . . . . . . . . . . . . . . . . . 4 pcs.
M6 washers
“.~..““..““....................... 4 pcs.
M6 spring washers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 pcs.
NOTE : For easy tank assembly, glue the rubber washers over the holes on the side plates.
4) Connect the rubber pipe
First, fit the hose clamps on the rubber pipe, connect the strainer and fuel tank, then fasten the rubber pipe with the hose clamps.
NOTE : Apply a drop of oil to the rubber pipe so that it may easily be connected to the strainer and the
fuel tank.
PLUG
FUEL
TANK
\
v~ HOSE CLAMP
STRAINER BRACKET
/
FUEL GAUGE
ARBURETOR
NUT (JOINT)
FUEL STRAINER -
/
cc,
HOSE CLAMP
BANJO
pu
BANJO BOLT
Fig. 1037
- 67 -
t
Page 71
10-S CHECKING, DISASSEMBLY and REASSEMBLY of the CONTROL BOX
10-5-l CHECKING OF THE CONTROL BOX
Dismount the control box from frame. Remove the control panel and check each components and wiring. Refer to Section 9 for the detail of checking procedure for the components in the control box.
10-5-2 DISASSEMBLY
(1) Remove the control panel from the control box.
M4screw . . . . . . . . . . . . . .
6
PCS. (RGX1800, RGX2400, RGX3500)
M4 screw .-*-***.--..** 8pcs. (RGX5500) (2) Disconnect the connectors on the wires to detach the control panel and box. (3) Remove the condensers and diode rectifier from the control box. (4) After disconnecting individual wires, remove the control panel components.
NOTE: DC fuse, full power switch and pilot 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
them.
NOTE : Circuit diagrams are shown in Section 12. Colored wires are used for easy idenfification, 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.
(2) Install condensers, and diode rectifier into the control box. (3) Connect the wires of control panel components and control box.
Fasten the earth w’ires to the rear of the control box using a M4 nut to the bolt which fixes the condenser bracket to the inside of the control box. (See Fig.lO-38.)
(4) Attach the control panel to the control box.
M4 Screw . . . . . . . . . . . . . .
6
PCS. (RGX1800, RGX2400, RGX3500) M4 screw *--.--.*..-*-. 8pcs. (RGX5500) Tightening torque
---- 12 - 15 kg-cm
REAR COVER
CLAMP M4
NUT
WELDING NUT
EARTH WIRES
To EARTH TERMINAL
,CONDENSER BRACKET
Fig. 10-38
- 68 -
Page 72
11. TROUBLESHOOTING
0
11-l NO AC OUTPUT
11-1-l CHECKING CONDENSER
Check the capacity of condensers using a “Dr. Robin”generator tester in capacitance meter mode.
NOTE : Be sure to discharge condensers by shorting condenser leads each other before checking their
capacitance, or the accurate reading cannot be obtained.
Fig. 11-l
n
NORMAL CAPACITY OF CONDENSER
MODEL RGXl800
RGX2400
RGX3500 RGXSSOO
CAPACIlY
14pF
2fJfiF
17,uFx2
28,uFX2
Table 1 l-l
n
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.
11-l-2 CHECKING STATOR
W Remove control panel and disconnect stator
wires at the connectors.
W Measure the resistance between terminals on
stator leads. (See Fig. 11-2) Refer to Table 9-l for normal resistance. If stator is faulty, replace it with a new one.
Fig. 11-2
-
69
-
Page 73
n
Check the insulation resistance between stator core and each stator lead using a Dr. Robin generator tester in megger tester mode
or a megger tester. (Fig. 11-3)
If insulation is bad, replace stator with a new
one.
1 l-1 -3
CHECKING ROTOR
(1) CHECKING FIELD COIL
n
Remove rear cover and stator.
Fig. 11-4
n
Using a Dr. Robin or a circuit tester, measure the resistance of the field coil at the terminals.
(RxlQ flO%)
MODEL RGX1800 RGX2400
RGXSOO
6ow
RgEy
RGX!iSOO
RESISTANCE
2.5 C-2
2.7 Q
2.1 n
2.2 a
1.6Q
Table 11-2
NOTE I : Because a diode is soldered to the coil
ends at the terminals, resistance may be measured only when tester probes touch the terminals in one combination of polarity- Therefore, if no resistance reading appears, try checking in reverse polarity.
IRemedy
If the resistance is not normal, replace rotor with a new one.
Fig. 11-5
- 70 -
Page 74
W IMeasure the insulation across one of the
soldered terminals of the rotor and the core. = (FigAl-6)
If insulation is bad, replace rotor with a new one.
Fig. 11-6
11-2 AC VOLTAGE IS TOO HIGH OR TOO LOW
11-2-l CHECKING ENGINE SPEED
If the engine speed is too high or too low, adjust it to the rated r.p.m.
[How to adjust engine r.p.m.1
W Loosen the lock nut on the adjusting screw. W Turn the adjusting screw clockwise to de-
crease engine speed or counter-clockwise to increase engine speed. Normal engine speed at no load is :
3100 - 3150 r.p.m. for 5OHz type 3700 - 3750 r.p.m. for 60Hz type
11-2-2 CHECKING CONDENSER
Check condenser referring to Step 11-1-l.
11-2-3 CHECKING STATOR
Check stator referring to Step 11-1-2.
1 l-2-4 CHECKING ROTOR
a
Check rotor referring to Step 11-1-3.
- 71 -
‘\
- RtSX1800,2400,3!500 1
i ADJUSTING BOLT
~RGX5500 1
Fig. 11-7
L
Page 75
1 l-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED. 11-3-l CHECK THE ENGINE SPEED.
If the engine speed is low, adjust it to the rated r.p.m.
* Refer to Step 11-2-1 for engine speed adjustment.
11-3-2 CHECK THE TOTAL WAlTAGE OF APPLIANCES CONNECTED TO THE GENERATOR.
Refer to Section 7 “RANGE OF APPLICATIONS” for the wattage of the appliances. If the generator is over-loaded, reduce the load to the rated output of the generator.
11-3-3 CHECK THE APPLIANCE FOR TROUBLE.
If the appliance is faulty, repair it.
11-3-4 CHECK IF THE ENGINE IS OVER-
HEATED.
If the cooling air inlet and/or cooling air outlet is clogged with dirt, grass, chaff or other debris, remove it.
115-5 CHECK THE INSULATION OF THE
GENERATOR.
Stop the engine. Measure the insulation resistance
between the live terminal of the receptacle and
the ground terminal. If the insulation resistance is less than 1 MQ, 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 MQ, the insulation is faulty and may cause
electric leakage.
Replace the faulty part.
AIR OUTLET
Fig. 1 l-8
Fig. 17-9
- 72 -
Page 76
11-4 NO DC OUTPUT
0
11-4-l CHECK THE AC OUTPUT.
Check the generator by following Step 11-1-l through Step 11-1-3.
1 l-4-2 CHECK THE DC FUSE.
Check the fuse in the fuse holder. If the fuse is blown, check for the cause of fuse
blowing, and then replace with a new one.
FUSE : 10A
FUS
NOTE: If the DC output is used to charge a
large capacity battery or an overdis­charged battery, an excessive current may flow causing fuse blow.
1 l-4-3 CHECK THE WIRING.
Check all the wires to be connected correctly.
1 l-4-4 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.
11-4-5 CHECK THE DC COIL
Fig. 11-11
Check the resistance between two brown leads from stator with a circuit tester.
MODEL
SPECIFICATION RESISTANCE
50Hz
RGXl800
11 OV, 22OV, 24OV, 11 OVl22OV
0.41 !a
60Hz 12OV, tiOV, 11 OVl22OV, 12OV/24OV 0.3552
I
50Hz
RGX2400 -
11 OV, 22OV, 24OV, 11 OVl22OV
0.298
60Hz
12OV, 22OV, 11 OV/22OV, 12OVl24OV 0.278
50Hz
RGX3!500
11 OV, 22OV, 24OV, 11 OVl22OV 0.26R 60Hz 12OV, 22OV, 11 OVl22OV, 12OVl24OV 0.2251 50Hz
RGX5!500
11 OV, 22OV,
24OV,
11 OVl22OV 0.1552
60Hz 12OV, 22OV, 11 OVl22OV, 12OVl24OV 0.1452
0
Table 1 l-3
If the resistance reading is much larger or smaller than the specified value, the DC coil of the stator is
faulty. Replace stator with a new one.
- 73 -
Page 77
11-5 IDLE CONTROL (OPTIONAL EQUIPMENT) 11-5-l ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS APPLIED
(1) Inspect the solenoid bracket.
Check the bend angle of solenoid bracket. If the bracket is distorted, correct the angle with proper tool.
.EN
SOLENOID BRA&ET
RGX2400,3!500
SOLENOID
p-g&+$
SOLENOID f&KET
f
I
RGX5500
Fig. 17-12
(2) Check the wattage of load appied to the generator.
If the generator is loaded over the rated wattage, the engine speed can not be increased. Most induction loads such as electric motor or electric tools or welding machine require three to five times large wattage of their ratings at starting. This starting wattage must not exceed the rated output of the generator.
(3) Check the slow set r.p.m.
The normal idling speed by the IDLE CONTROL is as follows :
RGX2400,3500
-...‘* 3150 - 3200 r.p.m.
RGX5500 *..*.**.-**... 2700 - 2800 r.p.m.
Adjust the idling speed monitoring the volt-
meter so that it indicates between 75 volt and 85 volt.
l
Turn the adjusting screw to adjust the slow speed.
Fig. 11-13
-.
- 74 ­A
Page 78
(4) Check the wiring through ZCT on the IDLE
CONTROL UNIT BOARD.
A) Single Voltage Type
Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT.
B) Dual Voltage Type
Check that two output wires (black wire and red wire) from main coils are passing through the ZCT on the IDLE CONTROL UNIT in the same direction.
ZCT
UNIT
OUTPUT WIRE
J
Fig. 11-14
(5) Checking the IDLE CONTROL UNIT
Check the resistance between six leads of IDLE CONTROL UNIT with circuit tester.
\
IDLE CONTROL UNIT
TES-
Fig. 11-15
Tester Polarity
LIGHT BLUE (FUSE)
LIGHT BLUE
RED
20-50kQ 20-50kQ
UGHT BLUE (FUSE)
UGHT BLUE
RED
Langer than 190kQ
Langer than 85kQ Langer than 85kQ
03
2-16kQ
Table 11-4
NOTE : Take & 10% tolerance on above resistance value.
If the measurement differs largely from momral value, the IDLE CONTROL UNIT is defective. Replace with a new one.
- 75 -
Page 79
11-5-2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF.
(1) Check the distortion of the SOLENOID BRACKET as shown in step 11-5-l-(1).
-
(2) Check the FUSE on wiring of IDLE CONTROL UNIT.
l
Remove the control panel from control box.
l
Check the FUSE in the fuse holder of IDLE CONTROL UNIT. If fuse is blown, replace with a new one. (FUSE : 0.3A)
FUSE
FUSE HOLDER
Fig. 11-16
(3) Check the wiring of SOLENOID.
Check two leads from SOLENOID are securely connected.
(4) Check the wiring of IDLE CONTROL UNIT.
Check all leads from IDLE CONTROL UNIT are securely and correctly connected.
(5) Checking the SOLENOID.
Measure the resistance between two leads from SOLENOID.
SOLENOID
\
NORMAL RESISTANCE
235 - 290 8
If the resistance is larger or smaller than this
range, SOLENOID is defective,
Replace with a new one.
Fig. 11-17
- 76 -
Page 80
12. WIRING DIAGRAM
Ii
C. B.
0
l
RGX1800 : 50Hz-1 lOV, 6OHz-120V TYPE
GENERATOR
CONTROL BOX
--1 r-------
--
l!
I
GREEN
--
YELLOW
E
II
.-.
l
RGX2400 : 50Hz-11 OV, 60Hz-120V TYPE
GENERATOR
CONTROL BOX
r------1 ---
--
1
---------
0.75 ,,2
2.0
mm2
---
1.25
mm2
3.5
mm2
- 77 -
c
Page 81
0 RGX180~,2400:50Hz-220V,240V,60Hz-220V TYPE
GENERATOR CONTROL BOX
r--1
7-i. 8. [NFBI
--
ORANGE f’,
+,T
BROWN
- -
RROWN
I
_ _ . _
-
JTE
l
RGXI 800,240O : 50Hz, 6OHz-11 OV/22OV TYPE
GENERATOR
CONTROL BOX
C. B.
-
SW
02=----l!
-
---_--___ O-75 mm2
---_--___ O-75 mm2
2.0 mm2 2.0 mm2
--- ---
1.25 mm2 1.25 mm2
3.5 mm2 3.5 mm2
- 78 - - 78 -
i
Page 82
l
RGXI 800,240O : U.K., 50Hz-1 lOV/22OV [BS RECEPTACLE]
GENERATOR
CONTROL BOX
I I
BLACK
C. B.
-
r-- i c-
l
RGX2400 : U.S.A., 60Hz-120V [NEMA RECEPTACLE with IDLE CONTROL]
CONTROL BOX
p
F
i
---- -___
-
0.75mm2
2.0
mm2
---
1.25
mm2
3.5
mm2
- 79 -
Page 83
l
RGX3500 : SOHz-11
OV,
5OHz-120V
TYPE
GENERATOR
CONTROL BOX
--- 1
--
--
l
RGX3500 : SOHz-220V, 24OV, 6OHz-220V
TYPE
SENERATOR CONTROL BOX
---I y-&B,
--
m
REC
em
FC
3
--
-i
I I I
II
I I!
1 I
1
i
E I,
DC ! ii GREEN/YELL0
W
--
II --
E
YELLOW _
+*c
YELLOW 1 3
+T
4
DC OUT
d
-_----___
0.75 ,,,&
2.0
mm2
---
1.25
mm2
3.5
mm2
- 80
­i
Page 84
l
RGX3500 : SOHz, 6OHz-1 lOW22OV TYPE
GENERATOR
CONTROL BOX
--1 I
me
--
II
1 SC ;
r-
GREEN/YELLOW
--
I!
YELLOW _
I I
L-3
1
I 8 I 1
YELLOW TC Bc
l
RGX3500 : U.K.., SOHz-1 lOW22OV [BS RECEPTACLE]
GENERATOR
CONTROL BOX
1
m
FC
_--- _____ 0.75mm2
2.0 mm2
---
1.25 mm2
3.5 mm2
-
81
-
Page 85
8 RGX3500 : U.S.A., 60Hz-120W240V [NEMA RECEPTACLE with IDLE CONTROL]
ENGINE
CONTROL BOX
r--1 I--
_-
I I
ICSW
- --. -- BLUE 1-1
--
l
RGX5500 : SOHz-11 OV, 60Hz-120V TYPE
GENERATOR
CONTROLBOX
--1 I-------- --
1 1 1
GREEN/YELLOW YELLOW
I
BROWN
-
E
--_----__ 0.75 mm2 2.0
mm2
--- 1.25 mm2
3.5
mm2
- 82 -
i
Page 86
l
RGX5500 : SOHz-220V, 24OV, 60Hz-220V TYPE
GENERATOR
CONTROL BOX
---I I--
--
NFB
-
RECl
REC2
GREENIYELLC
_
UT
l
RGX5500 : SOHz, 60Hz-11
OW22OV TYPE
GENERATOR
CONTROL BOX
-- --
--
I
RI
ArU
I-
Y--Y..
r
I I-
II I
I!
II c3 i i 1----. ,.,-. . ^._. Ii
II P‘ 1; LLEb
btlttN/YtLLUW
1 ll
-
-_
-_
u “1
I :
G:c
-_ Ii
BROWN
i
BROWN
E
.o
2.0 mm2
----_---- O-75 mm*
---
1.25 mm2 3.5 mm2
- 83 -
I L
Page 87
l
RGX5500 : U.K., SOHz-1 lOV/22OV [BS RECEPTACLE]
GENERATOR CONTROL BOX
II II II
RECa
00
0
P
I
:
l
RGX5500 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE with IDLE CONTROL]
ENGINE CONTROL BOX
r-1 I
__
-
LIGHT BLUE
I -L
I
I
F
SOL.
I I
LIGHT BLUE n
FENERATOR 1 (
REC, -
?-P
f
RI
FC
.MC
I
----__--- O-75 mm2
2.0
mm2
---
1.25
mm2
3.5
mm2
- 84 -
Page 88
l
TYPE WITH OIL SENSOR (Optional Equipment)
I I
eP-l I
I
I
I
I
i
I
L
1 L
---a
I I
i
L i - -----A------
I I
-­t 1
-a----------
GENERATOR
I I
I
BLACK
r-------------------- ---­I
L2
I I
YELLOW
i
EN&NE
.-m
CONTROL BOB
----- ---- 0.75 mm2
---
1.25 mm2
2.0 mm2
3.5
mm2
- 85 -
Page 89
l
RGX3500 : ELECTRIC STARTER TYPE (Optional Equipment)
--
The battery cords have a cross sectional area of 22 mm’.
-------__
0.75
mm2
---
1.25
mm2
2.0
mm2
3.5
mm2
- 86 -
Page 90
l
RGX5500 : ELECTRIC STARTER TYPE (Optional Equipment)
1
---
SP
I
ENGINE
= =
GREEN/WHITE
-m-s------
GREEN/WHITE b
I
.-_--------
I
I I
The battery cords have a cross sectional area of 22 mm’.
__-------
0.75 mm2
---
1.25 mm2
2.0 mm2
3.5 mm2
- 87 -
Page 91
l
RGX3500 : ELECTRIC STARTER TYPE WITH OIL SENSOR (Optional Equipment)
; e
\pn
1’ i
I -‘)
I
7h
I
!
I
I
I
I
I
I
I
I
I
I
I
REEN/WHITE j
I
I
--m--------w-
I
L .
losr
i
I
, BLACK
I
--
i
YELLOW/RED I
r
*J
YELLOW
I
ORANGE
----mm--
II II
E
RED
-.-i ;
--
The battery cords have a cross sectional area of 22 mm’.
----m---w
0.75
mm2
--
1.25
mm2
2.0
mm2
3.5
mm2
- 88 -
Page 92
l
RGX5500 : ELECTRIC STARTER TYPE WITH OIL SENSOR (Optional Equipment)
SP
---
I
i
I
;
PINK 1;
I
;YELLOV
YELLOW/RED
YELLOW
--
+
I
I
I
I I
I.L I ..a..
J
i GREEN
-----­El
I
L
--
---
CONTROL
BOX
The battery cords have a cross sectional area of 22 mm’.
---------
0.75
mm2
---
1.25
mm2
2.0
mm2
3.5
mm2
- 89 -
Page 93
I
Symbols 1 Part Name
I
1 C 1 Condenser
I
1 D
1 Diodes Stack Assy
I L, Lz T
F
C.B.
Pilot Lamp Warning Lamp (Oil sensor) DC Output Terminal Fuse Circuit Breaker
I
NFB, ( No-Fuse Breaker
I
I
NFBp 1 No-Fuse Breaker
I
I
vc SW
1 Voltage Changeover Switch
I
FP SW Full Power Switch
ssw Engine Stop Switch
OS Oil Sensor
osc
Oil Sensor Controller
SIU
I Solid State Ignition Unit
SP
1 Spark Plug
I
MG Magneto
I
I
IG ] Ignition Coil
I
I
MG, SW / Magnetic Switch
I
E
ST. M
KEY SW
Earth Terminal (Ground Terminal) Starting Motor Key Switch
I
BAT
1 Battery
I
I v
i Voltmeter
I
REC, REC, RECI REC. REC,
1 AC Output Receptacle (Total 15A MAX.)
AC Output Receptacle (22OV/24OV)
, AC Output Receptacle (11 OV/12OV)
AC Output Receptacle (12OV/24OV) AC Output Receptacle (Total 20A MAX.)
- 90 -
Page 94
I\ America, Inc.
940 Lively Blvd. l Wood Dole, 1160191 l Phone: 630-350-8200 l Fax: 630-350-8212
e-mail: sales @robinamerica.com l www. robinamefkxcom
PRINTED IN THE USA
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