Subaru Robin Power Products RGX2400, RGX3500, RGX5500, RGXI 800 User Manual

MANUAL

Models

RGXI 800,*. RGX2400, RGX3500, RGX5500

Generators

PUB-GS0597B Rev. 8198

.

i

Model

TY Pe

Frequency Maximum Output Rated Output

Power Factor

Voltage Regulator Voltage Regulation Within 10%

Type Model

Displacement 183cc

-

11OV

Rated 220V

240V

Current

".

.

-,

.

". -.

50Hz 16ow 1300W

I

I I

RGX1800

11.8A

5.9A

5.4A

~~~~ ~~ ~

Brushless, Revolving Field, Self-Exciting,-2-Pole, Single Phase

I I

~~ 1800W

I

1

11OV

I

120V

I

220V

60Hz

~

1500W

I

13.6A

1

12.5A

I

6.8A 240V

Robin Air-Cooled 4-Cycle Gasoline Engine

___~

~

I

"I

I

220V

1 1 OV122OV

.o

1

12V-8.3A (1 OOW) DC Output

Condenser Type

EY20D

(11.17

cu. in.)

11OV

-

50Hz

2000w

1700W

I

I I

15.5AR.7A

RGX2400

~~~ ~

7

15.5A

7.7A

7.1A

-

I I

I

11OV

I

120V

I

220V 1 1 OVl22OV 12OVl24OV

60Hz 2400W 2000w

I

I I

18.2Al9.1 A

16.7Al8.3A

18.2A

16.7A

9.1A

Rated Output Fuel Fuel Tank Capacity 10 liters (2.64

Fuel Consumption Ratio

(at Rated Output)

Oil Capacity Starting System

-.

.

Dimensions

Dry

Weight 45 kg (97 Ibs.)

L

x

_""

W X H

..

50Hz:

1

.O

liters/hour

60Hz: 1.3 literslhour

3.5 HP13600 rpm

Automobile Gasoline

Recoil Starter

552

X

(21.7

US.

gal.)

600 cc

377 X 482 mm

14.8 X 19.0 in.)

I

50Hz: 1.1 liters/hour 60Hz: 1.4 liters/hour

45.5 kg (100 Ibs.)

I

-

Model

TY Pe

Frequency

Rated Output

Rated

Voltage

Current

,

. . .

..

-.

I

L

I

~

RGX3500

~ ~ ~ ~~~

Brushless, Revolving Field, Self-Exciting, 2-Pole, Single Phase

50Hz

"".

-

.

3000W Maximum Output

2500W 110v 220v

22.7A

11.4A

120v

60Hz 3500W 3000W

240V

1 1 OV1220V

26.4Al13.2A

24.2N12.1A 120V1240V

-.

. , .

"

1 1 OV1220V

-

..

22.7AIl1.4A

"

-

.

""

-

Power Factor

I

1 1 OV1220V

.o

1

-

50HZ 5000W 4400W

RGX5500

40Al20A

-

5500W

4800W

1 1 OV1220V

i

~

60Hz

43.6A 110v 40A 110v 26.4A 110v 40A 120v 20A 220v 24.2A

21.8A 220v 18.3A 240V 13.2A 220v 10.4A

43.6AI21.8A 40AI20A 120V1240V

DC Output

Voltage Regulator

"-

"

.

Voltage Regulation

I

Iu

I

TY Pe

Model

I

Displacement

I

Rated Output

I I

~ ~~

273 cc (16.66

5.5 HP/3600 rpm

Robin Air-Cooled 4-Cycle Gasoline Engine

cu.

in.)

12V-8.3A (1 OOW)

Condenser Type

Within 10%

I I

,

"

EY40D EY28D

388 cc (23.68

cu.

in.)

8.0 HP13600 rpm

Automobile Gasoline

"

-

W

.

Fuel Consumption Ratio (at Rated Output)

Oil Capacity Starting System

Dimensions

Dry

Weight

L

X W

X

-.

-

13 liters (3.43

50Hz: 1.8 literdhour 60Hz:'2.1 literslhour

-

."

I I

X 413

H

552

(21.7

X

56 kg (123.5 Ibs.)

U.S.

" "

gal.)

850 cc

Recoil Starter and Optional Electric Starter

x

520 mm

16.3 x 20.5 in.)

15.5 liters (4.10

I

50Hz:

2.7 literslhour

U.S.

ghl.)

60Hz: 3.1 literdhour

I

1200

cc

X 448

X

635

(25.0

76

X

kg

596 mm

17.6 X 23.5 in.) (167.6 Ibs.)

c

2.

PERFOMANCE

2-1

MODEL

I

RGX1800

CURVES

+

3

6

CURRENT

9

{A)&

12

15

-3-

u

U

t

I

>

-

W

U

a

5

0

>

1.5k

3

-

-1k

5

n

t-

3

-0.5k

0

-0

bk

c1.5k

0.5k

2

rz

3

I-

2

-0.5k

o

-0

CURRENT

(A)

+

-4-

2k

1.5k

lk

0.5k

0

-

t

iz

3

n

I-

3

o

>

CURRENT

0

3

CURRENT

(A)-

2k

1.5k

t

lk

I-

3

n

I-

3

0.5k

0

6

9

(A)+

12 15

2-2

+

5

0

>

MODEL

RGX2400

CURRENT

(A)-

-5-

4

CURRENT

0

4

CURRENT

a

(A)+

12

(A\+

16

20

4

CURRENT

(A)”--.)

-2

k

-t

1

3

-1k

I-

2

I-

-3

0

-0

-6-

t

62

61

c

>.

L:

60

z

w

3

59

z

K

U

240

1

220

>

200

-

w

u

a

5

00

>

_."

2

CURRENT

4

6

(A)+

a

10 12

IZt

1

-1k

t-

2

I-

-3

0

-c

-2k

-t

I

is

-1k

E

d

n

I-

3

0

-0

t

0

4

CURRENT

8

iAl+

12 16 20

(A)

-

r

-7-

2-3

t

L

120 110

100

MODEL

52

51

50

49

4

8

CURRENT

RGX3500

12

(A)

-

16

20

63 62

61 60

59

120

110

100

0

10

CURRENT

10

CURRENT

(A)-

(A!-

20

30

-

4k

-3k

-2k

-1k

-0

-a-

t

3

2

k

6

>-

V

z

w

3

z

a

U

-

-2k

:-

4k

3k

1k

z

t

>

CURRENT

4

CURRENT

(A)+

8

[A)-

12

-3k

-2

-1k

-0

t

3

-

I-

3

0

t

14k

U

t

>

-

/-

G

0

a

I-

d

0

>

CURRENT

(A)-

-9-

N

I

-

%

i,

z

W

3

U

W

a

Y

>

-

W

CY

a

I-

-I

3

>

W

3

El

CT

LL

50

LL

W

U

a

i-

-1

C

>

10

CURRENT

[A!-

[A)-

20

0

30

-1

-

10-

2-4

MODEL

RGX5500

-

4k

-3k

-2k

-1k

-0

-

t

s

3

a.

t

3

0

t

>

0

z

u

3

0

K

U

CURRENT

(A)-

-3k

-2k

-1k

-0

3

I-

2

I-

3

0

CURRENT

(AI+

-

11

-

62

61 60

59

130 120

110

LO

0

-

t

52

51

-

5

50

z

Ej

49

3,

L=

U

240

t

220

-

2

200

w

13

a

t

-1

20

~

10

5 10

CURRENT

20 30 40

15

(A)-

20

50

LO

25

N

I

-

z

5

cl

IL

a

U

f

I

>

-

LLI

(3

<

t

-1

0

>

61

60

53

240 220

200

0

5

CURRENT

10

[A)-

15

20 25

-

6k

:-t

4k

-

-3k

3

-2k

3

-1k

0

LO

-

12-

a

U

t

>

-

W

a

-1

0

>

CURRENT

(A)-

(AI

-

5k

-2k

~

lk

-0

I-

z

t-

3

0

t

a

U

-

r

6k

i

13-

6k

I:,

c

5

-3k

3

a

I-

3

-2k

o

r

lk

i

2-5

DC

OUTPUT

CURRENT

[A)-

The voltage curve shown in the left indicates the characteristic The voltage resistance load

NOTE:

of

DC

output when charging a battery.

may

be decreased by

is

applied.

It

is

possible

puts simultaneously

in

total.

to

use

both

DC

up

to the rated

20%

and

when the

AC

out-

output

-

14-

FEATURES

3.

BRUSHLESS ALTERNATOR

3-1

Newly developed brushless alternator eliminates troublesome brush maintenance.

CONDENSER TYPE VOLTAGE REGULATOR

3-2

A

trouble free condenser type voltage regulator ensures a stable voltage under all working

conditions.

OIL SENSOR

3-3

Oil sensor automatically

shuts

off

the engine whenever the oil level

to protect the engine from seizure.

34

QUIET OPERATION

Robin

0 0 0

NO RADIO NOISE

3-5

RGX

series generator delivers a quiet operation with

A

large super silent muffler.

A

quiet 4-stroke Robin engine.

A

silent cyclone air cleaner.

:

Noise suppressor spark plug and spark plug cap are equipped standard interference.

3-6

LARGE FUEL TANK

The large fuel tank allows more than 5 to

10

hours of continuous operation which

half day or one day work without refueling.

3-7

RUGGED TUBULAR FRAME

Full cradle type rugged tubuler frame protects the generator all around.

COMPACT AND LIGHT WEIGHT

3-8

Newly developed brushless alternator enabled the

RGX

generators to be very compact in sue and

light in weight.

falls

down below the lower limit

to

prevent radio frequency

is

sufficient for a

3-9

MINIMAL MAINTENANCE

0

A

brushless alternator release the operator from periodical brush maintenance.

0

A

trouble free condenser type voltage regulator.

0

A

drip-proof alternator design.

0

No-fuse circuit breakers.

0

An

electronic pointless ignition system.

0

A

dust-proof cyclone air cleaner.

3-10

LONG-LIFE DURABILITY

The heav-duty 4 stroke Robin engine and virtually maintenance-free brushless alternator ensure greater durability with

0

A

brushless alternator with a condenser voltage regulator.

0

Full rubber mount in a sturdy tubular frame.

0

A

forged steel crankshaft supported by two main ball bearings.

0

A

pointless electronic ignition system.

0

A

cast iron cylinder liner.

0

A

forged aluminum connecting rod.

:

-

15-

4.

GENERAL DESCRIPTION

4-1

EXTERNAL VIEW

FULL POWER SWITCH (DUAL VOLTAGE TYPE)

Of

GENERATOR

OF

THE GENERATOR

VOLTMETER

(PILOT LAMP)

NO FUSE BREAKER (RGX1800.2400: CIRCUIT BREAKER)

e

EARTH (GROUND) TERMINAL FUEL COCK

PLUG COVER (SPARK PLUG, INSIDE)

7NK

CAP

-1

GAUGE

OIL DRAINING PLUG (RGX3500 ONLY)

/

-

16-

DC OUTPUT TERMINAL

4-2

CONTROL

0

RGXl800

DC

PANEL

:

50HZ-11

VOLTMETER CIRCUIT BREAKER

OV, 60Hz-120V

TYPE

RGX2400 : 50HZ-11 OV, 60Hz-12OV

VOLTMETER

\

DC

FUSE

\

0

TYPE

CIRCUIT BREAKER

P-T

0

AC RECEPTACLE

DC

OUTPUT

TERMINAL

-

17-

EARTH

(GROUND)

TERMINAL

RGX1800,

DC FUSE

RGX2400

VOLTMETER

\

:

50Hz-220VY 240V, 60HZ-220V

TVPE

DC

OUTPUT

RGX1800,

FULL POWER SWITCH

220V RECEPTACLE

TERMINAL

RGX2400

:

5OHZ,

\

60H~-llOV/220V

TYPE

-

EARTH (GROUND1 TERMINAL

CIRCUIT BREAKER

AC RECEPTACLE

VOLTMETER

\

DC OUTPUT TERMINAL

-

18

110V

RECEPTACLE

EARTH

-

(GROUND)

TERMINAL

RGXl800,2400

"

VOLTAGE CHANGEOVER SWITCH

220V RECEPTACLE

:

U.K.,

50H~-llOV/12OV

\

[BS

RECEPTACLE]

CIRCUIT BREAKER

VOLTMETER

"-----

DC

FUSE\

DC OUTPUT TERMINAL

RGX2400 : U.S.A., 60Hz-120V [NEMA RECEPTACLE]

PILOT LAMP

\

IDLE CONTRC

(Option)

A

llOV RECEPTACLE

i

EARTH (GROUND) TERMINAL

CIRCUIT

/

BREAKER

120V RECEPTACLE

-

19-

\

EARTH (GROUND) TERMINAL

RGXl800,2400 GERMANY, 50HZ-220V

CIRCUIT BREAKER

DC

OUTPUT TERMINAL.

RGX1800,2400

:

50Hz-220V

t

[WITH SPECIAL RECEPTACLE]

I

AC

22OVl

0

A

\

EARTH (GROUND) TERMINAL

CIRCUIT BREAKER

/

220V RECEPTACLE

VOLTMETER

DC FUSE

DC

1

OUTPUT TERMINAL

TJJJ

0

-

20

-

+

\

EARTH

(GROUND)

220V RECEPTACLE

TERMINAL

RGXI800,2400 : SWITZERLAND,

DC FUSE

\

50Hz-220V

c

CIRCUIT BREAKER

OFF

-n-

i

vo

ILTMETER

I

AC

220V

I

L

3

22QV

RECEPTACLE

DC OUTPUT TERMINAL

RGXl800,2400 : AUSTRALIA,

DC FUSE

5OHZ-240V

\

EARTH (GROUND) TERMINAL

CIRCUIT BREAKER

/

---.

-

VOLTMETER

24QV

RECEPTACLE

DC OUTPUT TERMINAL EARTH [GROUND) TERMINAL

-

21

-

RGX3500 : 50HZ-11 OV, 60Hz-120V

TYPE

START SWITCH

(Option)

\

AC RECEPTACLE

EARTH (GROUND) TERMINAL

F

VOLTMETER

I

NO-FUSE BREAKER

DC

OUTPUT TERMINAL

/

DC

SE

F’

RGX3500 : 50H~-220V, 240V, 60Hz-220V

START SWITCH

(Option)

\

AC RECEPTACLE

VOLTMETER

\

/

TYPE

NO-FUSE BREAKER

DC FUSE

/

0

\

C

EARTH

(GROUND)

TERMINAL

-

22

DC OUTPUT TERMINAL

-

0

RGX3500

:

5OHZ, 60H~-llOV/220V TYPE

START SWITCH

(Option’

\

VOLTMETER

AC RECEPTACLE

-

EARTH

k

3

AC

(GROUND)

TERM~NAL

FULL POWER SWITCH

7

0

/

NO-FUSE BREAKER

/

DC OUTPUT TERMINAL

Dc

FUSE

RGX3500

START SWITCH VOLTAGE CHANGEOVER SWITCH NO-FUSE BREAKER

(Option)

VOLTMETER

220V RECEPl

\

:

U.K.,

50H~-llOV/22OV

Lo

,/

[BS

RECEPTACLE]

/

J

:DC

FUSE

llOV RECEPTACLE

EARTH

-

(GROUND)

23

-

TERMINAL

DC

OUTPUT TERMINAL

RGX3500

START SWITCH FULL POWER SWITCH NO-FUSE BREAKER (Option)

:

U.S.A.,

60H~-120V/24OV

[NEMA RECEPTACLE]

IDLE CONTROL

(Option)

240V

RGX3500 : GERMANY,

START SWITCH VOLTMETER

(Option’

\

50Hz-220V

I

\

EARTH (GROUND)

NO-FUSE

VOLTMETER

120V RECEPTACLE

TERMINAL

BREAKER

220v RECEPTACLE

I

EARTH(GROUND)

TERMINAL

0

-

/

24

-

/Dc

DC OUTPUT TERMINAL

FUSE

RGX3500 : 50HZ-220V [WITH

SPECIAL

RECEPTACLE]

START SWITCH

'Option'

220V RECEPTACLE

\

EARTH

0

(GROUND)

VOLTMETER

I

0

~ERMINAL

NO-FUSE BREAKER

DC

OUTPUT

TERMINAL

RGX3500 : SWITZERLAND, 50HZ-22OV

START SWITCH

(Option'

220v RECEPTACLE

\

3

VOLTMETER

I

~ ~~

,F

NO-FUSE BREAKER

/

Jl

0

EARTH

(GROUND)

TERMINAL

-

25

-

DC

OUTPUT TERMINAL

RGX3500

:

AUSTRALIA,

50HZ-24OV

START SWITCH VOLTMETER

(Option)

240V RECEPTACLE

\

0

*

EARTH (GROUND) TERMINAL

NO-FUSE BREAKER

/

0

DC

OUTPUT

TERMINAL

DC FUSE

RGX5500

:

50Hz-11

OV,

60Hz-120V

I I

TYPE

VOLTMETER

DC FUSE

NO-FUSE BREAKER

/

START SWITCH

AC RECEPTACLF

EARTH (GROUND) TERMINAL

-

26

-

DC OUTPUT TERMINAL

RGX5500

:

50H~-22OV, 240V, 60Hz-220V

VOLTMETER DC FUSE NO-FUSE BREAKER

TYPE

AC RECEPTACLE EARTH (GROUND) TERMINAL DC OUTPUT TERMINAL

RGX5500

220V RECEPTACLE

:

SOHZ,

\

60Hz-1 10V/220V

TYPE

/

START

/

llQV RECEPTACLE

EARTH

(GROUND)

-

27

TERMINAL

-

DC OUTPUT TERMINAL

0

RGX5500

llOV RECEPTACLE

:

U.K.,

220v

RECEPTACLE

RGX5500

240V

RECEPTACLE

:

U.S.A.,

\

START

60H~-120V/240V

PILOT LAMP FULL POWER SWITCH

[NEMA

SWITCH

RECEPTACLE]

I

!GO31

DC OUTPUT

TERMINAL

NO-FUSE BREAKER

0

/

EARTH

(GROUND)

TERMINAL

IDLE CONTROL

(Option)

START SWITCH

120V RECEPTACLE

i

/

1

EARTH (GROUND) TERMINAL

-

28

-

RGX5500 : GERMANY,

50Hz-220V

VOLTMETER DC FUSE

AC

220V

220v RECEPTACLE EARTH (GROUND) TERMINAL DC OUTPUT TERMINAL

NO-FUSE BREAKER

-

START SWITCH

RGX5500

:

50Hz-220V

WITH

VOLTMETER

SPECIAL RECEPTACLE]

kc

220v

*

Io

DC

FUSE NO-FUSE BREAKER

/

START

220v RECEPTACLE EARTH

(GROUN'D)

-

29

-

TERMINAL

DC

OUTPUT

TERMINAL

0

RGX5500

:

SWITZERLAND,

5OHZ-220V

220v

RECEP~ACLE

VOLTMETER DC FUSE

EARTH

(GROUND)

TERMINAL

NO-FUSE BREAKER

/

/START

DC

OUTPUT TERMINAL

RGX5500

:

AUSTRALIA,

50Hz-240V

VOLTMETER

r

0

AC

@

0

DC

FUSE NO-FUSE BREAKER

/

START SWITCH

/

24QV RECEPTACLE

EARTH

/

(GROUND)

TERMINAL

-

30

DC OUTPUT TERMINAL

-

4-3

LOCATION

of

SERIAL NUMBER

and

SPECIFICATION NUMBER

Serial number and specification number are stamped cover.

NOTE:

Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service.

on

the LABEL (MODEL NAME) stuck

LABEL,

/

on

MODEL

the end

NAME

-

31

-

5.

CONSTRUCTION AND FUNCTION

5-1

CONSTRUCTION

END COVER REAR COVER ROTOR COMPLETE STATOR COMPLETE

MOUNT RUBBER STATOR BOLT BALL BEARING THROUGH BOLT SUPPORT

5-2

FUNCTION

5-2-1

The stator consists sheet core, a main coil and

STATOR

of

a laminated silicon steel

a

condenser coil which are wound in the core slots. The condenser coil excites the rotor field coil which generates

AC

voltage in the main coil.

Fig.

5-2

RING

FRONT

COVER

i

I

*

-

32

-

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

sheet core.

in

the field coil magnetizes the steel

Two

permanent magnets are provided

for the primary exciting action.

fig.

5-3

A

diode rectifier and surge absorber is mounted inside

I

Fig.

5-5A

-

33

of

the insulator.

11

I

-

Fig.

5-4

5-58

5-24

(1)

The

FUSE.

10

ampere

DC

control panel protects whole getting damage by overload

fuse mounted on the

DC

circuit from

or

short circuit.

Fig.

5-6

5-26

NO-FUSE

BREAKER

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

appliance.Table

MODEL

I

RGX1800

I

RGX2400

RGX3500

RGX5500

5-1

shows the capacity of no-fuse breaker by each spec. and their object of protection.

SPECIFICATION

1

ov,

1

20v

1

1 1 ov/22ov, 1 2OVl24OV

60HZ-11 OV/22OV, 120V/240V

220v 6.3A 240V

~

~.

11

ov,

120v

50HZ-220V, 240V

50HZ-11 OV/22OV

50HZ-11 OV

50HZ-220V 60Hz-220V 50HZ-240V

5OHZ-11 OV/22OV

11

ov,

120v

50HZ-220V 60Hz-220V

50HZ-240V

50Hz-11 OV/22OV

1

60HZ-

OV/220V, Total output amperage

120V/240V

NO-FUSE

I

12A (2-Pole, 2-Element)

I

14A (BPole, 2-Element) Total output amperage

1

20A

I

22A (2-Pole, 2-Element)

Table

1%

15A

1 OA 60HZ-220V

1OA (2 pcs.) 22A 25A 60HZ-11 OV, 120V 12A 14A

1

40A

22A

18A

(2-Pole,

30A

5-1

BREAKER

5A

6.3A (2 pcs.)

8A

(2 pcs.)

OA

2-Element)

OBJECT

!

i

I

i

Output from 30A receptacle 30A

Output from 30A receptacle

Output from 30A receptacle 30A

of

PROTECTION

Total output amperage Total output amperage

Total outDut amDeraae Total output amperage

Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage

Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage

Total output amperage

Total output amperage 20A Total output amperage Total output amperage Total output amperage

.-

-

34

-

5-2-6

RECEPTACLE

and

AC

PLUG

(STD.SPEC.)

These are used for taking varying in rated voltage and current from another, are used. Each model has at least one receptacle to deliver the rated generator output. corresponding receptacle, are provided. Table not to use the receptacles and AC plugs beyond the specified amperage limits to prevent burning.

up to total

from

I

@)

,ei

+y

1

up to 15 amperes

up

(See

Table

AC

two

receptacles

to

30 amperes

Caution.)

5-2

output power from the generator. A total of five kinds of receptacles, each

As

15

amperes

many

AC

plugs as the receptacles, each matching the

5-2

shows the rated current for each receptacle. Be careful

I

Caution:

To

connect the appliance

Insert the plug into the receptacle

clockwise

to

lock.

to

locking receptacle,

and

turn

It

NOTE: NOTE: The generator for

If

your generator has receptacles peculiar to your country, Table

5-3.

Use the proper plug for connecting appliance to the generator.

I

Style

0

U.S.A.

I

Ampere

125v

20A

1 25Vl25OV

20A

Fig.

5-7

5-2

does not apply.

market is equipped with NEMA standard receptacles shown in table

Receptacle

NEME 5-20R

NEME

L14-20R

AC plug

NEME

5-20P

NEME

L14-20P

Description

GFCI (Ground Fault Circuit Interrupter) Receptacle, duplex

Locking Receptacle

@

125v

30A

NEME

L5-30

-

35

Table

-

5-3

NEME

L5-30P

Locking Receptacle

5-3

DESCRIPTION

of

GENERATOR OPERATION

PERMANENT

FOR

INITIAL

MAGNET

EXCITATION

STATOR

Fig.

5-8

MAIN

COIL

5-3-1

GENERATION

Of

NO-LOAD VOLTAGE

When the generator starts running, the permanent magnet built-in to the rotor generates 3 to

AC

voltage in the main coil and condenser coil wound

As

one or two condensers are connected to the condenser coil, the small voltage at the condenser

coil generates a minute current

@I

which flows through the condenser coil. At this time, a small flux is produced with which the magnetic force at the rotor’s magnetic pole magnetic force

As

the current @ increases, the magnetic flux at the rotor’s magnetic pole increases further. Thus the

is

intensified, the respective voltages

on

the stator.

is

intensified.When this

in

the main coil and condenser coil rise up.

voltages at the main coil and condenser coil keep rising by repeating this process.

As

AC

current flows through the condenser coil, the density of magnetic flux in the rotor changes. This change of magnetic flux induces coil circuit rectifies this

AC

voltage into

AC

voltage in the field coil, and the diode rectifier

DC.

Thus a

DC

current @ flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil. When generator speed reaches

2700

to

2800

rpm

(50Hz

type) or

3000

to

3300

rpm

current in the condenser coil and field coil increases rapidly. This acts

to

stabilize the output voltage of each coils. If generator speed further increases

value, the generator output voltage will reach to the rated value.

5-3-2

When the output current @ flows through the main serves to increase current flux across the rotor core rises.

VOLTAGE FLUCTUATIONS UNDER LOAD

@I

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

As

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

coil

to the appliance, a magnetic flux is produced and

generator output voltage is prevented from decreasing.

(60Hz

to

6V

in

the field

type), the

the rated

of

-1

-

36

-

5-34

"

The full power switch receptacle

FULL

in

each voltage.

POWER

SWITCH

is

provided for the dual voltage type to take out the full rated power from

f

(Dual

Voltage

Type)

1

Fig.

5-9

120124ov

-

i

(or

120124ov

110122Ov)

240V

-

(or

220V)

r

-

r

-

one

Ret.

i

MC,

1

-

Rec.

3

220V)

Fig.

5-10

Switch

Position

1 lOl220V 120/24ov

LOWER VOLTAGE

RECEPTACLE

Rated

output

Half

of

rated

output

Table

5-4

HIGHER VOLTAGE

RECEPTACLE

No

output

can

be

Rated

output

taken.

I

A

Fig.

5-1

1

-

37

-

Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower

in

voltage (llOV or 120V). These main coils are wound to be

the same phase. The full power switch reconnects these main coils in parallel or in series. Fig.

5-9

shows a circuit diagram-When the full power switch

is

set for single lower voltage indication

(llOV or 120V), the switch position is as indicated by the lower solid line in the diagram. Fig. 5-10 is a simplified representation of this circuit, showing the two main coils connected in para1lel.h this case, the higher voltage (220V or 240V) at Rec. to the rated power (up to

30A

if the rated current is over

cannot be taken out. Rec. 2 for the lower voltage

30A),

and Rec. 1 can output up to a total of 15A.

can

output up

3

When the full power switch is set for double voltage indication (llOV/220V or 120V/240V), the switch position is as indicated by the upper dotted line in Fig.

Fig. 5-11 is a simplified representation

of

this

5-9.

circuit, showing the two main coils connected in series. In this case, power can be taken simultaneously from the receptacles for the both voltages. Rec.

for the higher voltage can output

up

to the rated power,

3

but Rec. 1 and Rec. 2 for the lower voltage can output only up to half the rated power each.

Table 5-4 is

a

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

accordance with the appliance to be used.

5-34

The generator of 50Hz llOV/220V dual voltage type for

VOLTAGE

CHANGEOVER

SWITCH

U.K.

is provided with voltage changeover

switch instead of full power switch.

The output voltage is selected from llOV and 220V by turning this switch and both voltages cannot be taken out simultaneously.

VOLTAGE CHANGEOVER SWITCH

NFB

11ov

RECEPTACLE

Fig.

5-

J

12

-

38

-

●

6. SAFETY PRECAUTIONS

1.

Use extreme caution near fuel. A constant danger of explosion or fire exists.

Do not fill the fuel tank while the engine is running. Do not smoke or use opem flame near the fuel tank. Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before starting the engine.

2.

Do not place inflammable materials near the generator.

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

e

Do not operate the generator in

3.

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.

4.

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.

5.

Severe electric shock may occur. If the generator is wet by rain or snow, wipe

it and thoroughly dry it

before starting. Don’t pour water over the generator directly nor wash it with water. If the generator is wet with water, the insulations will be adversely affected

and may cause current

leakage and electric shock.

Do not connect the generator to the commercial power lines.

6.

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

367-45605-08

340-45606-08

367-43008-08

348-43009-08

Use a fuse of the correct capacity. (DC output)

7.

Transfer Switch 1 1 15A

Transfer Switch

Transfer Switch 1 1 60A

Plastic Box 1

1

Table 6-1

1

1 30A

1

30A

60A

If the generator rpm is increased excessively in the overload condition by using an over rated fuse, the generator may be burnt.

CAUTION :

electrical appliance,the cause can be an overload or a short-oircuit. In such a case, stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring.

If the fuse is burnt or the circuit breaker tripped off as a result of using an

–39–

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:

(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:

NOTEI: If a power factor correction capacitor is not applied to the mercury lamp or fluorescent

NOTEZ: Nominal wattage of the fluorscent lamp generally indicates the output wattage of the

A rated 3000W generator can turn thirty 1OOW incandescent lamps on.

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.

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.

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:

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

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

These appliances require large starting wattage which is 3 to 5 times of running wattage.

Example:

NOTEI: .Motor-driven appliances require the aforementioned generator output only at the starting.

NOTEZ: Motor-driven appliances mentioned in Items (3) and (4) vary in their required motor

A rated 9OOW compressor requires a 4500W generator to drive it.

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.

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 -

:.

: (

_ ~. 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

II-

Three-phase motor * * - . * - - * * - - - - - - - 0.65 - 0.9

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 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

MODEL RGX1800

Frequency 50Hz lncandesent lamp,

heater, etc.

Item(3).

60Hz

item(2),

4400w

multiply

4800W

Fluorescent lamp, mercury lamp, etc.

Motor-driven tool, general-purpose motor, etc.

Water pump, compressor, etc.

approx.

9oow

I I

approx. approx.

800W 9oow

I I

approx.

4oow 450w

I I

approx.

1 OOOW

approx.

1lOOW

approx.

1 ooow

approx.

5oow

Tab/e 7-1

- 41 -

approx.

13oow

approx.

12oow

approx.

600W

approx.

17oow

approx.

15Oow

approx.

750w

approx.

2ooow

approx.

18OOW

approx.

9oow.

approx.

2800w

approx.

2600W

approx.

13oow

approx. 3200W

approx. 2900w

approx.

14oow

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.

Current Amp.

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

5.5 10-8 25 70 I 0.32 0.332 - 1U

45 IO.32

0.517

I

Table 7-2

- 1.5u

I I

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 -

.

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.

l

SPEClFlCATlONS

Fig. 8-l

Model

Part Number

Voltage

i%

Frequency

s

nr

P Resistance

‘Z

3

Condenser Capacity

3

I

Insulation Resistance

Circuit Protector

Power Source

Accessories

Dimensions (L X W X H) Weight

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

Table 8-1

Dr. Robin

388-47565-08

0-500V AC

25-70Hz

0.1-l ,999 Q lo-100 ,zF

3MQ Fuse

1.6kg

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 -

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)

FOR AC

Fig. 8-2

(3) FREQUENCY METER

Frequency range : About 45 to 65Hz

NOTE: Be careful of the frequency meter’s

input voltage range.

FOR AC

Fig. 8-3

1:

j:. /i

b--j;.

: /-.--.

II

!j

r-

I i

F

i

Fig. 8-4

ii!

II

- 44 -

(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

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

I

Fig. 8-6

CONTACT TYPE

STnOdE TYPE

Fig. 8-7

- 45 -

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 Voltage range

1lOV

107-119v 117-130v 215-238U 235-20OU

120v

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.

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.

22OV

MEGGER TESTER

\

240v

n

Fig. 8-9

- 46 -

Fig. 8-10

l

ROTOR

Measure the insulation across one of the soldered

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 -

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.)

Pilot lamp should be turned on at 70 to 120V.

n.

Fig. 9-1

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.

AC RECEPTACLE

Fig. 9-2A

Fig. 9-2B

-4848

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.

Fig. 9-3

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.

MODEL

RGXl800

RGX2400

RGX3500

RGX5500

Hz 1 Voltage White/Red 50

60

50

60

50

60

50

60

Specification AC Winding 1 Condenser Winging

110v,220v,110v/220v 1.85 1.85 5.56

240V 2.10 2.10 5.56 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

240V 1.42 1.42 3.37 220v,110v/220v 0.84 0.84 2.51 12OV,12OVl24OV 0.84 0.84 2.51

110v,220v,110v/220v 0.73 0.73 1.81

240V 0.83 0.83 1.83 220v,110v/220v 0.69 0.69 12OV,12OVl24OV 0.69 0.69 1.52

110v,220v,11

22ov, 11

12OV,12OVl24OV 0.26 0.26 0.58

OVl22OV

240V 0.41 0.41 0.78

OVl22OV

TOR

Fig. 9-4

Black/ Blue

I

0.34 0.34

0.26 0.26 0.58

Yellow / Yellow

I

1.52

0.81

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 -

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

RESISTANCE

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 nation 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 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).

RGX1800 RGX2400

2.5 Q

2.7 $2 Table 9-2

combi-

erroneous

RgEy Rgzy

2.1 R 2.2 R 1.6 R

Fig. 9-5

RGXSOO

n.

,-I

9-5 CONDENSER

Use a “Dr. Robin” in capacitance meter mode to check the capacity of condensers. (See Fig.9-6).

RGXl800, RGX2400

Fig. 9-6

RGX3!500

NOTE: Be sure to discharge condensers by shorting condenser leads each other before checking their

capacitance,or the accurate reading cannot be obtained.

RGX5!500

n

- 50 -

n

NORMAL CAPACITY OF CONDENSER

MODEL RGXl BOO

0

14,xF 20,~F

RGX2400

RGX3500

17fiFX2 28,~FX2

RGX5500

Resistance

0

14,~F 20,~F

Table 9-3

17pFX2 28fiFX2

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

Brown

Fig. 9-9 Fig. 9-10

0 II

rl

Brown

II

Brown/White

CIRCUIT TESTER

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

I

Apply red @ needle

of the circuit tester

Brown Brown

Orange

Brown

I I. I I

No continuity

Continuity

Apply black @needle of the circuit tester

Brown Orange BrownMlhite

No continuity No continuity Continuity

Brown/White

No continuity

Table 9-4-l

- 51 -

n

Checking table for digital circuit tester.

Apply red @ needle of the circuit tester

No continuity 1 No continuity Continuity

.I

No continuity

Apply black 0 needle

of the circuit tester

NOTE I:

Because of the difference of measuring method between the analogue circuit tester and the

Digital circuit tester

Brown Brown

drange

Brown/White

Brown Brown Orange Brown/White

No continuity Continuity

Continuity Continuity

I I

No continuity No continuity

Table 9-4-2

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.

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

n

- 52 -

104 DISASSEMBLY PROCEDURES

Step Part to remove

Fuel Tank

1.

Description Remarks

(1) Discharge fuel from the tank.

1. Shut the fuel strainer.

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.)

4. Attach the strainer cup to the strainer body.

Tool

Use utmost care about fire hazard.

Wipe off sprit fuel

thoroughly. Do not lose the filter

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.)

(3) Take off the four nuts and remove the

fuel tank. (See Fig. 10-3.)

Pliers

13 mm spanner or

box wrench

Fig. 10-2

Fig. 10-3

- 53 -

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.)

(5) Take off the bushing from the bottom of

the control box. (See Fig. 10-7.)

Fig. 10-5

Press the upper end of the bushing and pull out.

10 mm spanner

box wrench

Oi

Fig. IO-6

Fig. 10-7

. . :

Step Part to remove

Description Remarks

Tool

3.

Pipe Frame

(1) Remove SIDE PLATE from frame.

(See Fig. 10-8.)

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.

10 mm spanner 0:

box wrench

12 mm spanner 0:

box wrench

Take out the engine and alternator assy from the side of the frame. (See Fig. 10-9.)

Fig. 10-8

MOUNT RUBBER..

Fig. 10-9

MOUNT RUBBER

WBOLT

BoNUT . . . 2pcs.

. . . . . . 21~s.

itep Part to remove

4.

Rear Cover

Description Remarks Tool

(1) Remove the end cover. (See Fig. 10-l 1.)

66

bolt . . . . . _ . . . . . _ _ . . _ 4 pcs.

(2) Take off the rear cover.

1. Remove the four bolts which fasten the rear cover to the front cover.

6@f,c,lt . . . . . . . . . . . .._.. dpcs.

2. Use a special tool “REAR COVER

I

PULLER” to remove the rear cover. a) Insert the two screws of the special

tool into the thread holes of the

rear cover.

b) Apply the center bolt of the special

tool on the head of the through bolt.

c) Tighten the center bolt to pull out

the rear cover.

10 mm spanner 01

box wrench

10 mm spanner 01

box wrench

Insert the two screws sufficiently and evenly, or the thread hole may be damaged at removing.

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.

Fig. lo-13

Box wrench Plastic hammer

- 56 -

Step Part to remove

5.

Staitor (1) Remove the four bolts which fasten the

Description : Remarks

stator to the rear cover. (See Fig. 10-14.)

(2) Rut a piece of lumber on the floor in

upright position. (See Fig. 10-E)

Tool

10 mm socket

wrench

&BOLT . . . . . .4pcs.

60 SPRING WASHER

Fig. 10-14

(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 -

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.

6.

Rotor

i

(1) Take off the through bolt.

Apply a box wrench on the head of through bolt. Hit the wrench handle with

a hammer counter-clockwise to loosen.

Fig. IO-18

Fig. 10-17

Box wrench Plastic hammer

(2) Put the engine on the working table recoil starter side down.

- 58 -

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

until the rotor comes off loose.

lit pressure inside the rotor

apart the rotor from the

Fig. 10-20

Socket wrench

Fig. 10-21

Step Part to remove

Description

Remarks

Tool

7. Front Cover

(1) Remove the front cover.

Loosen the four bolts and remove the front cover.

84 bolt.. . . . . . . . . . . . . . .4pa.

Fig. 10-22

12 mm Socket

wrench

- 60 -

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

- 10.1 ftlbs.

8.7

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.

Fig. 10-23

Fig. lo-24

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.

- 61 -

@BOLT . . . . . .4pcs.

60SPRlNG WASHER

. . . . . . . . . . 4 pa.

60 WASHER . . . . 4 PCS.

Fig. 10-25

(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

M6 washer . . . . ...-.....-..-... 4~~s.

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

4 pa.

M6 spring washer **-.**--..* 4 PCS. Tightening torque : 80 - 100 kg-cm

5.8 - 7.2

NOTE: Tighten four bolts evenly taking several

steps.

ft. lbs.

Fig. lo-26

l

The dimensions of the stator bolts are shown in Table 10-l.

Table 10-l

MODEL

RGX1800

RGX2400

RGX3500

(50Hz)

RGX5500

1

65mm

25.6 inch 25.6 inch

75

mm

29.5 inch 0.59 inch

85mm

3.35 inch 3.35 inch

115

mm

4.53 inch

s

65

mm

15mm

85

mm

40

mm

1.57 inch

d

M8X1.25

M8 x 1.25

Ml0 x 1.5

- 62 -

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 Tightening torque :

. . . . . . . . . . . . . . . . . . . . . 4 pcsm

50 - 60 kg-cm

3.6 - 4.3 ftlbs.

- 63 -

I I

Fig. lo-28

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.

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. lo-30

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.

- 64 -

;n

(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

-

(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 Tightening torque : 80 - 100 kg-cm

Fasten the other earth cable with 54 terminal to the unpainted bolt hole on the frame. (See Fig.lO-36.)

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

5.8 - 7.2 ftlbs.

59 TERMINAL

(FRAME)

0

A

6$ TERMINAL

(CONTROL 80X) (REAR COVER)

89 TERMINAL

1 pee.

0

Fig. lo-36

- 66 -

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 M6 washers

“.~..““..““....................... 4 pcs.

M6 spring washers

NOTE : For easy tank assembly, glue the rubber washers over the holes on the side plates.

. . . . . . . . . . . . . . . . . . . . . . . 4 pcs.

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

4 pcs.

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

TANK

FUEL

\

FUEL GAUGE

NUT (JOINT)

v~ HOSE CLAMP

FUEL STRAINER -

/

BANJO

Fig. 1037

- 67 -

STRAINER BRACKET

/

ARBURETOR

cc,

HOSE CLAMP

pu

BANJO BOLT

t

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

REAR COVER

---- 12 - 15 kg-cm

CLAMP M4

EARTH WIRES

NUT

WELDING NUT

To EARTH TERMINAL

,CONDENSER BRACKET

Fig. 10-38

- 68 -

0

11. TROUBLESHOOTING

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

CAPACIlY

n

If such an instrument is unavailable,the condenser can be checked by replacing with a new one-If the

14pF

RGX2400

2fJfiF

Table 1 l-l

RGX3500 RGXSSOO

17,uFx2

28,uFX2

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

-

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

Remove rear cover and stator.

n

Fig. 11-4

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

n

(RxlQ flO%)

MODEL RGX1800 RGX2400

RESISTANCE

2.5 C-2

2.7 Q

RGXSOO

Table 11-2

6ow

2.1 n

RgEy

2.2 a

RGX!iSOO

1.6Q

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 -

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.

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.

Fig. 11-6

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.

i ADJUSTING BOLT

- RtSX1800,2400,3!500 1

‘\

~RGX5500 1

Fig. 11-7

a

L

1 l-2-4 CHECKING ROTOR

Check rotor referring to Step 11-1-3.

- 71 -

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 -

0

11-4 NO DC OUTPUT 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

FUS

blowing, and then replace with a new one.

FUSE : 10A

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.

0

11-4-5 CHECK THE DC COIL

Fig. 11-11

Check the resistance between two brown leads from stator with a circuit tester.

MODEL

RGXl800

RGX2400 -

I

RGX3!500

RGX5!500

50Hz 60Hz 12OV, tiOV, 11 OVl22OV, 12OV/24OV 0.3552 50Hz 60Hz 50Hz 60Hz 12OV, 22OV, 11 OVl22OV, 12OVl24OV 0.2251 50Hz 60Hz 12OV, 22OV, 11 OVl22OV, 12OVl24OV 0.1452

SPECIFICATION RESISTANCE

11 OV, 22OV, 24OV, 11 OVl22OV

12OV, 22OV, 11 OV/22OV, 12OVl24OV 0.278

11 OV, 22OV, 24OV, 11 OVl22OV 0.26R

11 OV, 22OV,

24OV,

Table 1 l-3

11 OVl22OV 0.1552

0.41 !a

0.298

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 -

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

SOLENOID

p-g&+$

RGX2400,3!500

SOLENOID f&KET

I

Fig. 17-12

RGX5500

(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.

f

-.

- 74 -

Fig. 11-13

A

(4) Check the wiring through ZCT on the IDLE

CONTROL UNIT BOARD.

ZCT

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.

UNIT

Fig. 11-14

(5) Checking the IDLE CONTROL UNIT

Check the resistance between six leads of IDLE CONTROL UNIT with circuit tester.

OUTPUT WIRE

J

\

IDLE CONTROL UNIT

TES-

Fig. 11-15

Tester Polarity

LIGHT BLUE (FUSE)

LIGHT BLUE

RED

20-50kQ 20-50kQ

UGHT BLUE (FUSE)

Langer than 190kQ

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.

UGHT BLUE

Langer than 85kQ Langer than 85kQ

RED

03

- 75 -

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.

SOLENOID

Measure the resistance between two leads from 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 -

0

12. WIRING DIAGRAM

l

RGX1800 : 50Hz-1 lOV, 6OHz-120V TYPE

GENERATOR

CONTROL BOX

--1 r-------

Ii

--

C. B.

II

l

RGX2400 : 50Hz-11 OV, 60Hz-120V TYPE

GENERATOR

CONTROL BOX

r------1 ---

GREEN YELLOW

l!

.-.

I

-E

--

1

c

---------

---

- 77 -

0.75 ,,2

1.25

mm2

2.0

3.5

mm2 mm2

0 RGX180~,2400:50Hz-220V,240V,60Hz-220V TYPE

GENERATOR CONTROL BOX

r--1

7-i. 8. [NFBI

BROWN

RROWN

_ _ . _

I

l

RGXI 800,240O : 50Hz, 6OHz-11 OV/22OV TYPE

- -

--

ORANGE f’,

+,T

-

JTE

GENERATOR

CONTROL BOX

C. B.

-

SW

02=----l!

---_--___ O-75 mm2

--- ---

1.25 mm2 1.25 mm2

- 78 - - 78 -

2.0 mm2 2.0 mm2

3.5 mm2 3.5 mm2

i

l

RGXI 800,240O : U.K., 50Hz-1 lOV/22OV [BS RECEPTACLE]

GENERATOR

CONTROL BOX

I I

BLACK

r-- i c-

C. B.

-

l

RGX2400 : U.S.A., 60Hz-120V [NEMA RECEPTACLE with IDLE CONTROL]

CONTROL BOX

p

F

---- -___

---

- 79 -

-

0.75mm2

1.25

mm2

2.0

3.5

i

mm2

l

RGX3500 : SOHz-11

OV,

5OHz-120V

TYPE

GENERATOR

--- 1

CONTROL BOX

--

l

RGX3500 : SOHz-220V, 24OV, 6OHz-220V

SENERATOR CONTROL BOX

---I y-&B,

FC

m

I I I

DC ! ii GREEN/YELL0

1

1 I

i

E I,

TYPE

II

--

YELLOW _

YELLOW 1 3

+*c

W

3

I I!

REC

em

--

-i

II --

E

+T

4

DC OUT

d

-_----___

---

0.75 ,,,&

1.25

- 80

mm2

-

2.0

3.5

mm2 mm2

i

l

RGX3500 : SOHz, 6OHz-1 lOW22OV TYPE

GENERATOR

--1 I

CONTROL BOX

me

--

1 SC ;

r-

1

l

RGX3500 : U.K.., SOHz-1 lOW22OV [BS RECEPTACLE]

GENERATOR

FC

II

I!

I I I 8 I 1

CONTROL BOX

GREEN/YELLOW YELLOW _

L-3

YELLOW TC Bc

--

1

m

_--- _____ 0.75mm2

---

-

81

1.25 mm2

-

2.0 mm2

3.5 mm2

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

I

GREEN/YELLOW YELLOW

BROWN

--

-

E

--_----__ 0.75 mm2 2.0

--- 1.25 mm2

- 82 -

3.5

mm2 mm2

i

l

RGX5500 : SOHz-220V, 24OV, 60Hz-220V TYPE

GENERATOR

---I I--

CONTROL BOX

GREENIYELLC

_

NFB

-

--

RECl

REC2

UT

l

RGX5500 : SOHz, 60Hz-11

GENERATOR

I

I-

II I

-- --

II c3 i i 1----. ,.,-. . ^._. Ii

II P‘ 1; LLEb

u “1

-_

OW22OV TYPE

CONTROL BOX

RI

ArU

Y--Y..

r

I I-

-_ I :

Ii

i

btlttN/YtLLUW

BROWN

-

--

1 ll

G:c

I!

-_

E

.o

I L

----_---- O-75 mm*

---

- 83 -

1.25 mm2 3.5 mm2

2.0 mm2

l

RGX5500 : U.K., SOHz-1 lOV/22OV [BS RECEPTACLE]

GENERATOR CONTROL BOX

II II II

:

RECa

00

0

I

P

l

RGX5500 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE with IDLE CONTROL]

ENGINE CONTROL BOX

r-1 I

I -L

I

FENERATOR 1 (

f

I

SOL.

FC

RI

.MC

I I

LIGHT BLUE

LIGHT BLUE n

__

F

-

REC, -

?-P

----__--- O-75 mm2

---

1.25

- 84 -

mm2

2.0

3.5

mm2

l

TYPE WITH OIL SENSOR (Optional Equipment)

eP-l

I I

I

I 1

---a

L

I I

I

i L

GENERATOR

I I

i L i - -----A------

I I

--

-a----------

t 1

I I

I

BLACK

r-------------------- ---I

L2

.-m

CONTROL BOB

EN&NE

I I

YELLOW

i

----- ---- 0.75 mm2

---

1.25 mm2

2.0 mm2

3.5

mm2

- 85 -

l

RGX3500 : ELECTRIC STARTER TYPE (Optional Equipment)

--

The battery cords have a cross sectional area of 22 mm’.

- 86 -

-------__

---

0.75

1.25

2.0

3.5

mm2 mm2

mm2

l

RGX5500 : ELECTRIC STARTER TYPE (Optional Equipment)

---

SP

GREEN/WHITE

1

I

-m-s------

=

GREEN/WHITE b

.-_--------

=

I I

ENGINE

The battery cords have a cross sectional area of 22 mm’.

- 87 -

__-------

---

0.75 mm2

1.25 mm2

2.0 mm2

3.5 mm2

l

RGX3500 : ELECTRIC STARTER TYPE WITH OIL SENSOR (Optional Equipment)

; e

\pn

I -‘)

I I

I

1’ i

I

losr

L .

--

--m--------w-

II II

I I

I

7h

!

I I

REEN/WHITE j

YELLOW/RED I

ORANGE

I

I I

I

i

, BLACK

RED

YELLOW

i

r

*J

----mm--

E

-.-i ;

I I

The battery cords have a cross sectional area of 22 mm’.

- 88 -

--

----m---w

--

0.75

1.25

2.0

3.5

mm2

l

RGX5500 : ELECTRIC STARTER TYPE WITH OIL SENSOR (Optional Equipment)

SP

YELLOW/RED

--

---

The battery cords have a cross sectional area of 22 mm’.

L

i

I

--

;

I

PINK 1;

YELLOW

I.L I ..a..

---

CONTROL

;YELLOV

I

i GREEN

------

J

+

I

I I

BOX

El

I

- 89 -

---------

---

0.75

1.25

2.0

3.5

mm2

mm2 mm2 mm2

Symbols 1 Part Name

I

1 C 1 Condenser

1 D

L, Lz

T

F

C.B.

NFB, ( No-Fuse Breaker

I

NFBp 1 No-Fuse Breaker

I

vc SW

I

FP SW Full Power Switch

ssw Engine Stop Switch

OS Oil Sensor

osc

SIU

SP

MG Magneto

I I I

IG ] Ignition Coil

MG, SW / Magnetic Switch

E

ST. M

KEY SW

1 Diodes Stack Assy

Pilot Lamp

Warning Lamp (Oil sensor)

DC Output Terminal Fuse Circuit Breaker

1 Voltage Changeover Switch

Oil Sensor Controller I Solid State Ignition Unit 1 Spark Plug

Earth Terminal (Ground Terminal)

Starting Motor

Key Switch

I I

I

BAT

I

I v

REC, REC, RECI REC. REC,

1 Battery i Voltmeter 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 -

I

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