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. SPECIFICATIONS

				Model			RG2800i					RG3200i					RG4300i
	Type							Multi-Pole, Rotating Field Inverter Generator
	Frequency				Hz							50 / 60
		Rated Output			kVA		2.5					2.8					3.8
		50Hz		Voltage	V	110		220		230	110		220		230	110		220		230
	AC
Alternator				Rated Current	A	22.7		11.4		10.9	25.5		12.7		12.2	34.5		17.3		16.5
		60Hz		Voltage	V	120		240		-	120		240		-	120		240		-
				Rated Current	A	20.8		10.4		-	23.3		11.7		-	31.7		15.8		-
	Power Factor											1.0
		Rated Output			W							100
	DC
		Voltage			V							12
		Current			A							8.3
	Voltage Regulator										PWM Controlling
	Voltage Regulation										Within 10%
	Model							EX17					EX21					EX27
	Type							Air-Cooled 4-stroke OHC Gasoline engine
	Displacement				mL(cc)		169					211					265
	Fuel									Unleaded Automobile Gasoline
Engine	Fuel Tank Capacity				L					10.0							10.8
	Continuous Operating						7.0					6.0					4.5
	Hours at Rated Output				h
	Lubrication Oil Capacity				L					0.6							1.0
	Ignition System									Solid-state flywheel magneto
	Spark Plug										NGK BR6HS
	Starting System								Recoil Starter							Electric Starter / Recoil
Equipment	Over-current Protection
		For AC Output								Electronic Circuit Breaker
		For DC Output									Circuit Breaker
	Oil Sensor												STD
	Multi Monitor												STD
Dimensions				L×W×H	mm		487×432×475									523×477×508
Dry Weight					kg		37					38					52.5

Specifications are subject to change without notice.

– 1 –

				Model		RG2800iS				RG3200iS			RG4300iS
	Type						Multi-Pole, Rotating Field Inverter Generator
	Frequency				Hz						50 / 60
		Rated Output			kVA		2.5				2.8			3.8
		50Hz		Voltage	V	110	220		230	110	220	230	110	220	230
	AC
Alternator				Rated Current	A	22.7	11.4		10.9	25.5	12.7	12.2	34.5	17.3	16.5
		60Hz		Voltage	V	120	240		-	120	240	-	120	240	-
				Rated Current	A	20.8	10.4		-	23.3	11.7	-	31.7	15.8	-
	Power Factor										1.0
		Rated Output			W						100
	DC
		Voltage			V						12
		Current			A						8.3
	Voltage Regulator									PWM Controlling
	Voltage Regulation									Within 10%
	Model						EX17				EX21			EX27
	Type						Air-Cooled 4-stroke OHC Gasoline engine
	Displacement				mL(cc)		169				211			265
	Fuel								Unleaded Automobile Gasoline
Engine	Fuel Tank Capacity				L			10.8						12.8
	Continuous Operating						7.6				6.5			5.3
	Hours at Rated Output				h
	Lubrication Oil Capacity				L			0.6						1.0
	Ignition System								Solid-state flywheel magneto
	Spark Plug									NGK BR6HS
	Starting System					Recoil Starter					Electric Starter / Recoil
Equipment	Over-current Protection
		For AC Output							Electronic Circuit Breaker
		For DC Output								Circuit Breaker
	Oil Sensor										STD
	Multi Monitor										STD
Dimensions				L×W×H	mm			537×482×583					580×527×618
Dry Weight					kg		54				59			74

Specifications are subject to change without notice.

– 2 –

2. GENERAL DESCRIPTION

2-1-1) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE

RG2800i / RG3200i	FUEL LEVEL GAUGE
FUEL TANK	AC RECEPTACLES
MULTI MONITOR

ENGINE SWITCH

RECOIL STARTER HANDLE

DC CIRCUIT BREAKER

DC TERMINALS

GROUND TERMINAL

SPECIFICATIONS LABEL	TANK CAP
FRAME

MUFFLER (EXHAUST OUTLET)

OIL LEVEL GAUGE	SPARK PLUG	AIR CLEANER
	DRAIN PLUG

– 3 –

2-1-2) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE WITH ELECTRIC STARTER

RG4300i	FUEL LEVEL GAUGE
FUEL TANK	AC RECEPTACLES
MULTI MONITOR

ENGINE SWITCH

KEY SWITCH

RECOIL STARTER HANDLE

DC CIRCUIT BREAKER

DC TERMINALS

GROUND TERMINAL

SPECIFICATIONS LABEL	TANK CAP
FRAME

	AIR CLEANER
MUFFLER	BATTERY
(EXHAUST OUTLET)	COVER

BATTERY

OIL LEVEL GAUGE

SPARK PLUG

DRAIN PLUG

– 4 –

2-1-3) EXTERNAL VIEW OF GENERATOR : SOUND PROOF TYPE

RG2800iS

FUEL LEVEL GAUGE

FUEL TANK

AC RECEPTACLES

MULTI MONITOR

SIDE COVER (R)

	RECOIL STARTER HANDLE
ENGINE SWITCH	INSIDE OF SIDE COVER (R)

DC CIRCUIT BREAKER

DC TERMINALS

GROUND TERMINAL

DRAIN PLUG

MUFFLER
(EXHAUST OUTLET)	TANK CAP
	FRAME
SPECIFICATIONS
LABEL

INSIDE OF SIDE COVER (L)
SPARK PLUG	AIR CLEANER

SIDE COVER (L)	OIL LEVEL
	GAUGE

– 5 –

2-1-4) EXTERNAL VIEW OF GENERATOR : SOUND PROOF TYPE WITH ELECTRIC STARTER

RG3200iS / RG4300iS

FUEL LEVEL GAUGE

AC RECEPTACLES

FUEL TANK

MULTI MONITOR

SIDE COVER (R)

ENGINE SWITCH
		RECOIL STARTER HANDLE
KEY SWITCH		INSIDE OF SIDE COVER (R)
DC CIRCUIT BREAKER
DC TERMINALS
GROUND TERMINAL
		DRAIN PLUG
MUFFLER
(EXHAUST OUTLET)
TANK CAP	FRAME
SPECIFICATIONS
LABEL
		INSIDE OF SIDE COVER (L)
		AIR CLEANER	BATTERY
		SPARK PLUG	COVER

	SIDE COVER (L)	BATTERY
		OIL LEVEL
		GAUGE

– 6 –

2-2) CONTROL PANEL

50Hz-230V

MULTI MONITOR

AC RECEPTACLES

MULTI MONITOR

Hours

V

Hz

AUTO

P-SAVE

DC CIRCUIT BREAKER

ENGINE SWITCH	KEY SWITCH	DC TERMINALS	GROUND TERMINAL
	(G4300I / G3200IS /G4300IS)

60Hz-120V

MULTI MONITOR

AC RECEPTACLES

MULTI MONITOR

Hours

V

Hz

AUTO

P-SAVE

DC CIRCUIT BREAKER

ENGINE SWITCH	KEY SWITCH	DC TERMINALS	GROUND TERMINAL
	(G4300I / G3200IS /G4300IS)

50Hz-240V

MULTI MONITOR

AC RECEPTACLES

MULTI MONITOR

Hours

V

Hz

AUTO

P-SAVE

DC CIRCUIT BREAKER

ENGINE SWITCH	KEY SWITCH	DC TERMINALS	GROUND TERMINAL
	(G4300I / G3200IS /G4300IS)

– 7 –

	(1) ENGINE SWITCH		RG2800i / RG3200i / RG2800iS
	The engine switch is designed for easy operation with the interlocking		STOP	ENGINE SWITCH
	mechanism between the fuel cock and the choke furnished.			RUN
		To start the engine, turn the knob to the position.		CHOKE
		(Choke valve is closed.)
	CHOKE
		Keep the knob in this position after the engine	RG4300i / RG3200iS / RG4300iS
		starts. (The engine can be started with the knob at
			(With electric starter)
	RUN	this position when the engine is warm.)
				ENGINE SWITCH
		To stop the engine, return the knob to the position.		STOP
				RUN
	STOP	(The fuel cock is closed as well.)
				START

(2) KEY SWITCH for electric starting models.

To start the engine with electric starter.

(3) MULTI MONITOR	LED display		Operation hour lamp
■ LED display					Voltage lamp
Operation hour, voltage and frequency are		MULTI MONITOR		Hours
indicated in turns by means of depressing the LED
				V	Frequency
display changeover switch. In addition, "O_Lod"
				Hz	lamp
(overload) will be indicated when the generator is
in the overload condition or appliance(s) is out of		AUTO
order.	Engine oil level
		P-SAVE
In this case, stop the engine immediately and check	warning lamp
the appliance and/or generator for overloading.
After the check and remedy, restarting the engine	Auto-power		Auto-power		LED display
will resume displaying in the normal manner.	saving lamp		saving switch		changeover switch

■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 –

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.

RG2800i / RG3200i / RG4300i

PROD No. / SER No.

RG2800iS / RG3200iS / RG4300iS

PROD No. / SER No.

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

– 9 –

2-4) ALTERNATOR

8P Connector for battery charging and others.

4P Connector for output wires

Diode Rectifier

Ball Bearing

Pipe Cover

Rotor CP

Rear Cover

Stator CP.

– 10 –

3. RANGE OF APPLICATIONS

Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it. The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance. The electrical appliances generally have a label showing their rated voltage, frequency, and power consumption (input wattage). The power consumption of an electrical appliance is the power necessary for using it. When using a generator for operating an electrical appliance, the power factor and starting wattage must be taken into consideration.

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

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

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

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

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

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

Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the load. Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3 times lager than their running wattage.

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

NOTE 1: If a power factor correction capacitor is not applied to the fluorescent lamp, the more power shall be required to drive the lamps.

NOTE 2: Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp. Therefore, if the fluorescent lamp has no special indication as to the power consumption, efficiency should be taken into account as explained in ltem (5) on the following page.

(3)Mercury lamps with a smaller power factor

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

Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on. A rated 3000 W generator can power two or three 400 W mercury lamps.

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

These appliances require large starting wattage which is 3 to 5 times of running wattage. Example : A rated 900 W compressor requires a 4500 W generator to drive it.

NOTE 1: Motor-driven appliances require the aforementioned generator output only at the starting. Once their motors are started, the appliances consume about 1.2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances.

NOTE 2: Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting power depending on the kind of motor and start-up load. If it is difficult to determine the optimum generator capacity, select a generator with a larger capacity.

–11 –

= (Power consumption)

(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)

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)

			Applicable Wattage (W)
Applications		RG2800i		RG3200i		RG4300i
		RG2800iS		RG3200iS		RG4300IS
				50Hz / 60Hz
Incandescent lamp, Heater, etc		approx. 2500		approx. 2800		approx. 3800
Fluorescent lamp, Electric tool, etc		approx. 1300		approx. 1400		approx. 1900
Mercury lamp, etc		approx. 800		approx. 1000		approx. 1600
Pump, Compressor, etc		approx. 500		approx. 600		approx. 800

– 12 –

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.

Cross

Allowable

Cable

Voltage drops per 30 meters of cable

sectional

Current

Resistance

mm2

A

Ω/100m

5A

10A

15A

20A

25A

30A

1.25

12

1.486

4.5V

8.9V

2.0

17

0.952

2.8V

5.7V

8.6V

3.5

23

0.517

1.6V

3.1V

4.7V

6.2V

5.5

35

0.332

1.0V

2.0V

3.0V

4.0V

5.0V

6.0V

1

R : Resistance (Ω/100m)

Voltage drop indicates as V=

x R x I x L

100

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 1.25mm2=1.48Ω/100m

I : Electric current 10A

L : Length 30m

The voltage drop of the case described above is

V= 1.48Ω x 10A x (30m x 2) 8.9 (V) 100

– 13 –

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 DC

	For AC		For DC

– 14 –

(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.

(5)MEAGER TESTER

Used for measuring generator insulation resistance. Select the one with testing voltage range of 500V.

(6)TACHOMETER

Use the contactless type tacho meter for checking engine speed.

– 15 –

(7)"Dr.Robin" GENERATOR TESTER

The "Dr.Robin" generator tester is exclusively designed for fast, easy diagnosis and repair of Robin generators.

The "Dr.Robin" has the following features :

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

2)Fast and easy readout by digital indicator.

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

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

•SPECIFICATIONS
		MODEL	Dr.Robin
Part Number			388-47565-08
		Voltage	0 to 500 V AC
		Frequency	25 to 70 Hz
Measuring
		Resistance	0.1 to 1,999 Ω
Range
		Condenser Capacity	10 to 100 μF
		Insulation Resistance	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

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.

– 16 –

4-2) AC OUTPUT MEASURING

SWITCH

LOAD

A

~

TO AC RECEPTACLE	F	V
		~

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.

	Model		Specification
		120V / 60Hz	220V / 50Hz	230V / 50Hz	240V / 60Hz
	RG2800i					range
	RG3200i
	RG4300i	117-130	215-238	225-248	235-259
						Voltage
	RG2800iS
	RG3200iS
	RG4300iS

4-3) DC OUTPUT MEASURING

SW Load

To DC Terminal

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.

– 17 –

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.

Wire

(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.

Wire

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.

– 18 –