Subaru Robin Power Products RG3200I, RG4300I, RG4300IS, RG3200IS, RG2800IS User Manual
...
SERVICE
MANUAL
Models
RG2800iS,
RG3200iS,
RG4300iS,
RG2800i,
RG3200i, RG4300i
GENERATORS
PUB-GS1981
Rev. 09/04
CONTENTS
Section Title Page
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1 EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3 LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER . . . . . . . . . . . . 9
2-4 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3. RANGE OF APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4. MEASURING AND CHECKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4-1 MEASURING INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4-2 AC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4-3 DC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4-4 MEASURING INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4-5 CHECKING FUNCTIONAL MEMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5-1 PREPARATION AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5-3 DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5-4 REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5-5 RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
6. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
This manual covers only alternator and control unit portion of the generator.
As to the servicing information of engine portion, please refer to the “EX13, E17, EX21 and EX27” service manual.
The specifications and information included in this manual were in effect at the time of printing.
FUJI HEAVY INDUSTRIES LTD. reserve the right to change the specifications and to make modifications in the
course of technical progress, at anytime without notice.
No parts of this manual may be reproduced without written permission.
– 1 –
1. SPECIFICATIONS
Model
Type
Frequency
50Hz
AC
60Hz
Power Factor
Rated Output
DC
Voltage Regulator
Voltage Regulation
Model
Type
Displacement
Fuel
Voltage V
Rated Current
Voltage V
Rated Current
Hz
kVARated Output
A
A
W
VVoltage
ACurrent
mL(cc)
RG2800i RG3200i RG4300i
Multi-Pole, Rotating Field Inverter Generator
50 / 60
2.5 2.8 3.8
110 110 110
22.7 25.5 34.5
120 120 120
20.8 23.3 31.7
220 220 220
11.4 12.7 17.3
240 240 240
10.4 11.7 15.8
EX17 EX21
169 211 265
230 230 230
10.9 12.2 16.5
---
---
1.0
100
12
8.3
PWM Controlling
Within 10%
Air-Cooled 4-stroke OHC Gasoline engine
Unleaded Automobile Gasoline
EX27
Fuel Tank Capacity
Continuous Operating
Engine Alternator
Hours at Rated Output
Lubrication Oil Capacity
Ignition System
Spark Plug NGK BR6HS
Starting System
Over-current Protection
For AC Output
For DC Output
Oil Sensor
Equipment
Multi Monitor
Dimensions L×W×H
Dry Weight
Specifications are subject to change without notice.
L
h
L
mm
kg
10.0 10.8
7.0 6.0 4.5
0.6 1.0
Solid-state flywheel magneto
Recoil Starter
Electronic Circuit Breaker
Circuit Breaker
487×432×475
37 52.5
Electric Starter / Recoil
STD
STD
523×477×508
38
– 2 –
Type
Model
RG2800iS RG3200iS RG4300iS
Multi-Pole, Rotating Field Inverter Generator
Frequency
50Hz
AC
60Hz
Alternator
Power Factor
Rated Output
DC
Voltage Regulator
Voltage Regulation
Model
Type
Displacement
Fuel
Fuel Tank Capacity
Continuous Operating
Engine
Hours at Rated Output
Voltage V
Rated Current
Voltage V
Rated Current
Hz
kVARated Output
A
A
W
VVoltage
ACurrent
mL(cc)
L
h
50 / 60
2.5 2.8
110 110 110
22.7 25.5 34.5
120 120 120
20.8 23.3 31.7
220 220 220
11.4 12.7 17.3
240 240 240
10.4 11.715.8
EX17 EX21 EX27
169 211 265
230 230 230
10.9 12.2 16.5
---
---
1.0
100
12
8.3
PWM Controlling
Within 10%
Air-Cooled 4-stroke OHC Gasoline engine
Unleaded Automobile Gasoline
10.8 12.8
7.6 6.5 5.3
3.8
Lubrication Oil Capacity
Ignition System
Spark Plug NGK BR6HS
Starting System
Over-current Protection
For AC Output
For DC Output
Oil Sensor
Equipment
Multi Monitor
Dimensions L×W×H
Dry Weight
Specifications are subject to change without notice.
L
mm
kg
0.6 1.0
Solid-state flywheel magneto
Recoil Starter Electric Starter / Recoil
Electronic Circuit Breaker
Circuit Breaker
537×482×583
54 74
STD
STD
580×527×618
59
– 3 –
2. GENERAL DESCRIPTION
2-1-1) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE
RG2800i / RG3200i
MULTI MONITOR
ENGINE SWITCH
DC CIRCUIT BREAKER
FUEL TANK
FUEL LEVEL GAUGE
DC TERMINALS
AC RECEPTACLES
RECOIL STARTER HANDLE
GROUND TERMINAL
SPECIFICATIONS LABEL
FRAME
MUFFLER
(EXHAUST OUTLET)
OIL LEVEL GAUGE
DRAIN PLUG
TANK CAP
SPARK PLUG
AIR CLEANER
– 4 –
2-1-2) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE WITH ELECTRIC STARTER
RG4300i
MULTI MONITOR
ENGINE SWITCH
KEY SWITCH
DC CIRCUIT BREAKER
FUEL TANK
FUEL LEVEL GAUGE
DC TERMINALS
AC RECEPTACLES
RECOIL STARTER HANDLE
GROUND TERMINAL
SPECIFICATIONS LABEL
FRAME
MUFFLER
(EXHAUST OUTLET)
OIL LEVEL GAUGE
DRAIN PLUG
TANK CAP
AIR CLEANER
BATTERY
COVER
BATTERY
SPARK PLUG
– 5 –
RG2800iS
2-1-3) EXTERNAL VIEW OF GENERATOR : SOUND PROOF TYPE
FUEL LEVEL GAUGE
FUEL TANK
MULTI MONITOR
AC RECEPTACLES
SIDE COVER (R)
RECOIL STARTER HANDLE
ENGINE SWITCH
DC CIRCUIT BREAKER
DC TERMINALS
MUFFLER
(EXHAUST OUTLET)
SPECIFICATIONS
LABEL
GROUND TERMINAL
TANK CAP
FRAME
INSIDE OF SIDE COVER (L)
SPARK PLUG
INSIDE OF SIDE COVER (R)
DRAIN PLUG
AIR CLEANER
SIDE COVER (L)
BRAKE
OIL LEVEL
GAUGE
– 6 –
RG3200iS / RG4300iS
2-1-4) EXTERNAL VIEW OF GENERATOR : SOUND PROOF TYPE WITH ELECTRIC STARTER
FUEL LEVEL GAUGE
FUEL TANK
MULTI MONITOR
ENGINE SWITCH
AC RECEPTACLES
SIDE COVER (R)
RECOIL STARTER HANDLE
KEY SWITCH
DC CIRCUIT BREAKER
MUFFLER
(EXHAUST OUTLET)
SPECIFICATIONS
LABEL
DC TERMINALS
GROUND TERMINAL
TANK CAP
FRAME
INSIDE OF SIDE COVER (R)
DRAIN PLUG
INSIDE OF SIDE COVER (L)
AIR CLEANER
SPARK PLUG
BATTERY
COVER
SIDE COVER (L)
BRAKE
OIL LEVEL
GAUGE
BATTERY
– 7 –
2-2) CONTROL PANEL
50Hz-230V
MULTI MONITOR
AC RECEPTACLES
ENGINE SWITCH KEY SWITCH
60Hz-120V
MULTI MONITOR
MULTI MONITOR
AUTO
P-SAVE
Hours
V
Hz
(G4300I / G3200IS /G4300IS)
MULTI MONITOR
AUTO
P-SAVE
Hours
V
Hz
DC TERMINALS
AC RECEPTACLES
DC CIRCUIT
BREAKER
GROUND TERMINAL
DC CIRCUIT
BREAKER
ENGINE SWITCH KEY SWITCH
50Hz-240V
MULTI MONITOR
ENGINE SWITCH KEY SWITCH
(G4300I / G3200IS /G4300IS)
MULTI MONITOR
AUTO
P-SAVE
Hours
V
Hz
(G4300I / G3200IS /G4300IS)
DC TERMINALS
AC RECEPTACLES
DC TERMINALS
GROUND TERMINAL
DC CIRCUIT
BREAKER
GROUND TERMINAL
(3) MULTI MONITOR
■■
LED display
Operation hour, voltage and frequency are
indicated in turns by means of depressing the LED
display changeover switch. In addition, "O_Lod"
(overload) will be indicated when the generator is
in the overload condition or appliance(s) is out of
order.
In this case, stop the engine immediately and check
the appliance and/or generator for overloading.
After the check and remedy, restarting the engine
will resume displaying in the normal manner.
■■
Operation hour lamp
Lamp (red) is turned on when LED display is changed over into operation hour indication.
■■
Voltage lamp
Lamp (red) is turned on when LED display is changed over into voltage indication.
■■
Frequency lamp
Lamp (red) is turned on when LED display is changed over into frequency indication.
■■
LED display changeover switch
When depressing this switch, indication in LED display is changed over in turns;
operation hour → voltage → frequency → operation hour.
When starting the engine, operation hour is indicated in LED display at first.
■■
Auto-power saving switch
When depressing this switch, auto-power saving function is activated.
■■
Auto-power saving lamp
Lamp (green) is turned on while auto-power saving function is activated.
■■
Engine oil level warning lamp
When the engine oil level is lower than the specified level, the lamp is turned on.
Then engine will be stopped.
– 8 –
(1) ENGINE SWITCH
The engine switch is designed for easy operation with the interlocking
mechanism between the fuel cock and the choke furnished.
(2) KEY SWITCH for electric starting models.
To start the engine with electric starter.
CHOKE
To start the engine, turn the knob to the position.
(Choke valve is closed.)
RUN
Keep the knob in this position after the engine
starts. (The engine can be started with the knob at
this position when the engine is warm.)
STOP
To stop the engine, return the knob to the position.
(The fuel cock is closed as well.)
RG2800i / RG3200i / RG2800iS
STOP
ENGINE SWITCH
RUN
RG4300i / RG3200iS / RG4300iS
(With electric starter)
Engine oil level
warning lamp
LED display Operation hour lamp
MULTI MONITOR
AUTO
P-SAVE
Auto-power
saving lamp
Auto-power
saving switch
CHOKE
ENGINE SWITCH
Hours
V
Hz
LED display
changeover switch
STOP
RUN
START
Voltage lamp
Frequency
lamp
– 9 –
2-3) LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER
Generator serial number and production number are stamped on the label stuck on the side of fuel tank.
For soundproof type models, remove the side cover (R) to check these numbers.
NOTE : When inquiring about your generator or ordering spare parts, always give us the Model, Serial
Number and Production Number.
RG2800i / RG3200i / RG4300i
RG2800iS / RG3200iS / RG4300iS
PROD No. / SER No.
PROD No. / SER No.
– 10 –
2-4) ALTERNATOR
8P Connector for battery
charging and others.
4P Connector for output wires
Diode Rectifier
Rear Cover
Ball Bearing
Pipe Cover
Rotor CP
Stator CP.
– 11 –
Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it.
The electric power required for operating an electrical appliance is not always equal to the output wattage
of the appliance. The electrical appliances generally have a label showing their rated voltage, frequency,
and power consumption (input wattage). The power consumption of an electrical appliance is the power
necessary for using it. When using a generator for operating an electrical appliance, the power factor and
starting wattage must be taken into consideration.
In order to determine the right size generator, it is necessary to add the total wattage of all appliances to
be connected to the unit.
Refer to the followings to calculate the power consumption of each appliance or equipment by its type.
(1) Incandescent lamp, heater, etc. with a power factor of 1.0
Total power consumption must be equal to or less than the rated output of the generator.
Example : A rated 3000W generator can turn thirty 100W incandescent lamps on.
(2)
Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power factor
Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the
load. Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3
times lager than their running wattage.
Example : A rated 250 W electric drill requires a 400 W generator to start it.
NOTE 1: If a power factor correction capacitor is not applied to the fluorescent lamp, the more power
shall be required to drive the lamps.
NOTE 2: Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp.
Therefore, if the fluorescent lamp has no special indication as to the power consumption,
efficiency should be taken into account as explained in ltem (5) on the following page.
(3) Mercury lamps with a smaller power factor
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.
Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on. A rated
3000 W generator can power two or three 400 W mercury lamps.
(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.
These appliances require large starting wattage which is 3 to 5 times of running wattage.
Example : A rated 900 W compressor requires a 4500 W generator to drive it.
NOTE 1: Motor-driven appliances require the aforementioned generator output only at the starting.
Once their motors are started, the appliances consume about 1.2 to 2 times their rated power
consumption so that the excess power generated by the generator can be used for other
electrical appliances.
NOTE 2: Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting
power depending on the kind of motor and start-up load. If it is difficult to determine the
optimum generator capacity, select a generator with a larger capacity.
3. RANGE OF APPLICATIONS
– 12 –
(5) Appliances without any indication as to power consumption
Some appliances have no indication as to power consumption; but instead the work load (output) is
indicated. In such a case, power consumption is to be worked out according to the numerical formula
mentioned below.
Efficiencies of some electrical appliances are as follows :
Single-phase motor . . . . . .0.6 to 0.75 (The smaller the motor, the lower the efficiency)
Fluorescent lamp . . . . . . . .0.7 to 0.8
Example 1: A 40W fluorescent lamp means that its luminous output is 40W. Its efficiency is 0.7 and
accordingly, power consumption will be 40÷0.7= 57W. As explained in Item (2), multiply this
power consumption value of 57W by 1.2 to 2 and you will get the figure of the necessary
capacity of a generator. In other words, a generator with a rated output of 1000W capacity
can light nine to fourteen 40W fluorescent lamps.
Example 2
: Generally speaking, a 400W motor means that its work load is 400W. Efficiency of this motor
is 0.7 and power consumption will be 400÷0.7= 570W. When this motor is used for a
motor-driven tool, the capacity of the generator should be multipled by 1.2 to 3 and 570W as
explained in the ltem (3). 570 (W) x 1.2 to 3 = 684 (W) to 1710 (W)
(Output of electrical appliance)
(Efficiency)
= (Power consumption)
Applications
Applicable Wattage (W)
RG4300i
RG4300IS
approx. 3800
approx. 1900
RG2800i
RG2800iS
RG3200i
RG3200iS
approx. 1600
50Hz / 60Hz
approx. 800
Incandescent lamp, Heater, etc approx. 2500 approx. 2800
Fluorescent lamp, Electric tool, etc approx. 1300 approx. 1400
Mercury lamp, etc approx. 800 approx. 1000
Pump, Compressor, etc approx. 500 approx. 600
– 13 –
NOTES : Wiring between generator and electrical appliances
1. Allowable current of cable
Use a cable with an allowable current that is higher than the rated input current of the load (electrical
appliance). If the input current is higher than the allowable current of the cable used, the cable will
become excessively heated and deteriorate the insulation, possibly burning it out. The table below
shows cables and their allowable currents for your reference.
2. Cable length
If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors
decreasing the input voltage to the load (electrical product). As a result, the load can be damaged.
The table below shows voltage drops per 30 meters of cable.
2
Allowable
Current
Cable
Resistance
Ω/100m
1.486
0.952
0.517
0.332
1
100
Voltage drops per 30 meters of cable
R : Resistance (Ω/100m)
Cross
sectional
Voltage drop indicates as V= x R x I x L
I : Electric current (A)
L : Length (m)
The length of wire (L) indicates round length, which is the length from the generator
to the electrical tools and back.
<Example> R : Resistance 1.25mm
2
=1.48Ω/100m
I : Electric current 10A
L : Length 30m
The voltage drop of the case described above is
30A25A20A15A10A5AAmm
＊＊＊＊8.9V4.5V121.25
＊＊＊8.6V5.7V2.8V172.0
＊＊6.2V4.7V3.1V1.6V233.5
6.0V5.0V4.0V3.0V2.0V1.0V355.5
1.48Ωx 10A x (30m x 2)
V=
100
≒ 8.9 (V)
– 14 –
4. MEASURING AND CHECKING PROCEDURES
4-1) MEASURING INSTRUMENTS
(1) VOLTMETER
AC voltmeter is necessary.
The approximate AC voltage ranges of the
voltmeters to be used for various types of
generators are as follows :
0 to 150 V : Type with an output voltage of 110 or
120 V
0 to 300 V : Type with an output voltage of 220,
230 or 240 V
0 to 150 V, 0 to 330 V : Dual voltage type
(2) AMMETER
AC ammeter is necessary.
An AC ammeter with a range that can be changed
according to the current rating of a given generator
is most desirable. (About 10 A, 20 A, 100 A)
(3) FREQUENCY METER
Frequency range : To cover 45 to 65Hz
NOTE : Be careful of the frequency meter's input voltage
range.
For AC
For AC
For DC
For DC
– 15 –
(5) MEAGER TESTER
Used for measuring generator insulation resistance.
Select the one with testing voltage range of 500V.
(4) CIRCUIT TESTER
For measuring resistance, etc.
NOTE : The ordinary circuit tester may cause erroneous
readings due to their measuring method.
Use a high-grade, precise circuit tester to check
the generator components.
(6) TACHOMETER
Use the contactless type tacho meter for checking
engine speed.
(7) "Dr.Robin" GENERATOR TESTER
The "Dr.Robin" generator tester is exclusively
designed for fast, easy diagnosis and repair of
Robin generators.
The "Dr.Robin" has the following features :
1) Functions of voltmeter, frequency meter, megger
tester, capacitance meter and circuit tester are
combined in one unit.
2) Fast and easy readout by digital indicator.
3) Built-in automatic battery checker indicates the
time to change batteries.
4) Tester and accessories are installed in a handy,
sturdy case for easy carrying.
•
SPECIFICATIONS
– 16 –
MODEL Dr.Robin
Part Number 388-47565-08
Measuring
Range
0 to 500 V AC
25 to 70 Hz
0.1 to 1,999 Ω
10 to 100 μF
3MΩ
Circuit Protector Fuse
Power Source 2 x 6F44P (006P) Dry Cell Battery
Accessories
Test leads with needle probes ... 1 set
Test leads with jack plugs ... 1 set
Dimensions (L x W x H) 285 mm x 200 mm x 110 mm
Weight 1.6 kg
Voltage
Frequency
Resistance
Condenser Capacity
Insulation Resistance
The "Dr.Robin" generator tester can be ordered from Robin generator distributors by the following part number.
Dr.Robin_Part_Number_:_388-47565-08
If you do not have a "Dr.Robin" generator tester, use the instruments described in the following section for
checking generator parts.
– 17 –
4-2) AC OUTPUT MEASURING
Use a circuit above for measuring AC output. A hot plate or lamp with a power factor of 1.0 may be used as a
load. Adjust the load and rpm, and check that the voltage range is as specified in the following table at the
rated amperage and rated rpm.
4-3) DC OUTPUT MEASURING
Measurement of DC output is executed with the switch turned ON while the current is regulated at 8.3A by
adjusting the load to the generator. If the voltage is within the range from 6V to 14V, the voltage output is
normal.
NOTE : If a battery is connected as a load to the generator, the DC output voltage will increase by
approximately 1 to 2 V.
Therefore, carefully observe the electrolyte level and do not overcharge the battery.
120V / 60Hz
215-238 235-259
RG2800i
RG3200i
RG4300i
RG2800iS
RG3200iS
RG4300iS
117-130
220V / 50Hz 240V / 60Hz
Voltage range
Model
Specification
225-248
230V / 50Hz
TO AC RECEPTACLE
SWITCH
A
~
F
V
~
LOAD
SW
To DC Terminal
Load
– 18 –
4-4) MEASURING INSULATION RESISTANCE
Use a “Dr. Robin” generator tester in megger tester
mode or use a megger tester to check the insulation
resistance. Connect a megger tester to one of
receptacle output terminals and the ground terminal,
then measure the insulation resistance. An insulation
resistance of 1 megohm or more is normal. (The original
insulation resistance at the time of shipment from the
factory is 10 megohm or more.) If it is less than 1
megohm, disassemble the generator and measure the
insulation resistance of the stator, rotor and control
panel individually.
NOTE : Connect across the two output terminals of a
receptacle using a wire as shown in the figure
right before checking.
(2) STATOR
Check the insulation resistance between red lead
and core, blue lead and core, and white lead and
core respectively. Should any reading is less than 1
megohm, the stator is faulty.
(3) CONTROL PANEL
Measure the insulation resistances between the live
parts and the grounded parts.
NOTE : Connect across the two output terminals of a
receptacle using a wire as shown in the figure
right should the inverter unit is still connected to
the control panel.
Any part where the insulation resistance is less than 1MΩ has faulty insulation, and may cause electric leakage
and electric shock.
Replace the faulty part.
Wire
Wire
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