rgd2500 / rgd3300 generator service manual
Contents
1. 2 3 DC OUTPUT VOLTAGE V CURRENT OUTPUT W RGD3300 Output Max 3300 Rated 3000 60Hz 120V 240V DC Voltage 12V DC Ampere 8 3 Output 100W The voltage curve shown in the left indicates the characteristic of DC output when charging a battery The voltage may be decreased by 20 when the re sistance load is applied NOTE It is possible to use both DC and AC out puts simultaneously up to the rated output in total 3 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 FEATURES BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance EASY STARTING Light pull recoil starter accompanied with automatic decompression system makes the new RGD series generators even easier in starting than gasoline engine generators QUIET OPERATION The new RGD series generator provides quiet operation by means of The superb design of intake exhaust system e Direct injection combustion system A large super silent muffler An efficient low noise air cleaner ECONOMICAL PERFORMANCE On top of well known diesel economy the air cooled Robin diesel engine features direct fuel injection and special design refinements for extra fuel efficiency OIL SENSOR The OIL SENSOR automatically shuts the2. 600W 650W 800W 900 Table 7 1 2 94 NOTES Wiring between generator and electrical appliances 1 Allowable current of cable Use a cable with an allowable current that is larger than the rated input current of the load electrical appliance If the input current is larger than the allowable current of the cable used the cable will be come excessively heated and deteriorate the insulation possibly burning it out Table 7 2 shows cables and their allowable currents for your reference 2 Voltage drop in long electric extension cords When a long wire is used to connect an appliance with the generator a certain amount of voltage drop occurs in the wire which lessens effective voltage available to the appliance The table below has been prepared to illustrate the approximate voltage loss when an extension cord of 300 feet approx 100 meters is used to connect an appliance or tool to the generator No of strands strand Resistance Current Amp dia No mm 100 1 3A 5A 10A 12 15A 2 7 Ea Nominal cross A W G Allowable section Gauge No current 1 30 0 18 2 477 25 125V 50 0 18 1 486 1 5 SV 75V 12V 15V 18V Voltage drop 37 0 26 i 0 952 i 1 3 5V 8v 10V 12V 45 032 C 517 15v 25v lav 5V 6 5 7 5 70 0 32 0 232 v 2 25 3 5 l Voltage drop indicates Vie x R gt Jh ag p indicates as 100 means resista
3. 5 A Starting System Recoil Starter and Optional Electric Starter Dimensions Recoil start 536 x 400 x 458 m mm 21 1 x 15 8 x 18 0 in PE LxWxH Electric start 709 x 400 x 458 mm 27 9 x 15 8 x 18 0 in Recoil start 55 kg 121 Ibs 58 5 kg 129 Ibs Dry Weight Elit ba pe lt Electric start 58 5 kg 129 lbs 62 kg 137 Ibs Specifications are subject to change without notice SNOI1VOIdIO93dS L 2 PERFORMANCE CURVES MODEL RGD2500 d FREQUENCY Hz VOLTAGE V FREQUENCY Hz VOLTAGE V FREQUENCY Hz gt VOLTAGE V 8 12 16 CURRENT A i VOLTAGE Movi VOLTAGE 220V OUTPUT W OUTPUT W gt OUTPUT W RGD2500 Output Max 2200W Rated 2 za ca ees 2000W Frequency 50Hz 220V RGD2500 Output 2200W Rated 2000W Frequency 50Hz 0 899 240V RGD2500 Output Max 2200W 86161 519 2000W 50Hz Voltages oA 110V 220V FREQUENCY Hz P gt gt VOLTAGE V FREQUENCY gt VOLTAGE V 8 12 16 20 CURRENT 2 2 MODEL RGD3300 FREQUENCY Hz
4. VOLTAGE V CURRENT OUTPUT W 9 OUTPUT W gt OUTPUT W RGD2500 Output Max 2500W Rated 2300W Frequency 60Hz Voltage 110V 220V RGD2500 Output 2500W Rated 2300W Frequency 60Hz Voltage 4 nig ak uwa asik 120V RGD3300 Output 3000W Rated 2700W 50Hz Voltages ERE 220V FREQUENCY Hz gt VOLTAGE FREQUENCY Hz VOLTAGE V FREQUENCY Hz m VOLTAGE V 230 220 CURRENT A VOLTAGE 110Vj VOLTAGE 220V 12 16 20 CURRENT A 7 220 FREQUENCY 12 16 20 CURRENT A 2 OUTPUT OUTPUT W gt OUTPUT W RGD3300 Output Max 3000W Rated us us ava a wes 2700W Frequency 50Hz Voltage uw 240V RGD3300 Output Max 3000W Rated 2700W Frequency 50Hz Voltage 110V 220V RGD3300 Output Max 3300W Rated 3000W Frequency 60Hz 110V 220V FREQUENCY Hz VOLTAGE V 0 4 8 12 16 20 24 CURRENT
5. 6 Do not connect the generator to the commercial power lines This cause short circuit or damage to the generator Use a transfer switch for connecting with in door wiring NOTE The parts numbers of the transfer switches and of the plastic box to store them are as shown in Table 6 1 Part No Part iName Phase Allowable Current 365 45604 08 Transfer Switch 1 15A 367 45605 08 Transfer Switch i 1 30A 340 45606 08 Transfer Switch 60A 367 43008 08 Plastic Box 30A 348 43009 08 Plastic Box Table 6 1 7 Use a fuse of the correct capacity DC output If the generator rpm is increased excessively in the overload condition by using an over rated fuse the generator may be burnt CAUTION If the fuse is burnt out or the circuit breaker tripped off as a result of using an electrical appliance the cause can be an overload a short circuit In such a case stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring 22 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 a
6. NO FUSE BREAKER 220V RECEPTACLE VOLTMETER DC OUTPUT TERMINAL DC FUSE EARTH IGROUNDI TERMINAL RGD2500 RGD3300 SWITZERLAND 50Hz 220V START SWITCH Option NO FUSE BREAKER 220V RECEPTACLE VOLTMETER DC OUTPUT TERMINAL DC FUSE EARTH GROUND TERMINAL e RGD2500 RGD3300 FRANCE 50Hz 220V NO FUSE BREAKER 220V RECEPTACLE VOLTMETER DC OUTPUT TERMINAL DC FUSE EARTH GROUND TERMINAL sa AD RGD2500 RGD3300 AUSTRALIA 50Hz 240V Q START Sve 7 NO FUSE AREAKES START SWITCH Option NO FUSE BREAKER 240V RECEPTACLE VOLTMETER DC OUTPUT TERMINAL DC FUSE EARTH GROUND TERMINAL is 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number stamped on the LABEL MODEL NAME stuck on the end cover Always specify these numbers when inquiring about the generator or ordering spare parts in order NOTE to get correct parts and accurate service 00000 SERIAL NUMBER 14 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION STATOR BOLT END COVER REAR COVER STATOR CONPLETE ROTOR COMPLETE GENERATOR BASE MOUNT RUBBER BALL BEARING THROUGH BOLT SUPPORT RING FRONT COVER Fig 5 1 5 2 FUNCTION 5 2 1 STATOR The stator consists of a laminated silicon steel sheet core a main coil and a condenser coil which are wound in the core slots The condenser coil excites the rotor field
7. position of the control box See Fig 10 44 Tightening torque 50 60 kg cm Fig 10 42 Fig 10 43 Fig 10 44 lt Electric start model gt 6 Connect the light green and the pink leads of the control box to the starting motor Connect the pink lead to the terminal of the motor and attach the light green lead together with the BATTERY CABLE to the 6 mm bolt of the motor 7 Clamp the wires of starting motor and oil sensor at the rear panel of contro box main bearing cover and front cover See Fig 10 45 NOTE Take a enough margin in the length of wires between control box and alter nator to allow the move of rubber mounted alternator Clamp the BATTERY CABLE to the left side leg of the rear cover Fig 10 45 51 10 4 7 FUEL TANK 1 Attach the BRACKET TANK to the frame See Fig 10 46 66 x 16 mm flange bolt 2 pes Tightening torque 50 60 kg cm 2 Connect fuel pipes to the bottom of the fuel tank Be careful of the direction of the BANJO See Fig 10 47 GASKET Aluminium B Aluminium DVE 7 6 so m gt z lt q m e or Yoo t a z 4 e 8 FUEL FILTER Fig 10 47 Inner Dia Length I FUEL PIPE 12mm 6mm i 350 mm Part Name Outer Dia FUEL PIPE 9 mm 4 5 mm FUEL PIPE 9 mm 45mm
8. 11 2 3 CHECKING ROTOR Check rotor referring to Step 11 1 3 57 11 3 AC VOLTAGE IS NORMAL AT NO LOAD BUT THE LOAD CANNOT BE APPLIED 11 3 1 CHECK THE ENGINE SPEED If the engine speed is low adjust it to the rated r p m 11 3 2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR Refer to Section 7 RANGE OF APPLICATIONS for the wattage of the appliances If the generator is over loaded reduce the load to the rated output of the generator 11 3 3 CHECK THE APPLIANCE FOR TROUBLE If the appliance is faulty repair it AIR INLET 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 re move 11 AIR OUTLET Fig 11 4 11 3 5 CHECK THE INSULATION OF THE GENERATOR Stop the engine Measure the insulation resistance between the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1 MQ disas semble 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 the insulation is faulty and may cause electric leakage Replace the faulty part Fig 11 5 58 11 4 NO DC OUTPUT 11 4 1 CHECK THE AC OUTPUT Check the generator by following Step 11 1 1 through Step 11 1 3 11 4 2 CHECK THE DC FUSE
9. 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 be tween each of the two when the circuit breaker is on while there is no continuity when the circuit breaker is off 9 4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a circuit tester referring to the following table COUPLER Fig 9 4 R x 10 210 Model Specifications Brown White Blue Skyblue Yellow Yellow Black Orange 50Hz 110V 0 860 _ 0 862 0 162 210 50Hz 220V 0 850 0860 0 160 210 50Hz 240V J 0 910 0 912 0 160 2 10 50 110 220 0 862 0 862 0 162 2 10 60Hz 110V 0 662 0 662 0 120 1 92 60Hz 120V 0 662 0 662 0120 190 60Hz 110V 220V 0 662 0 662 0 120 1 90 RGD2500 60Hz 120V 240V 0 660 0 662 0 129 1 99 50Hz 110V 0 642 0 642 0 142 1 92 50Hz 220V 0 642 0 640 0 142 1 90 50Hz 240V 0 772 0 779 0 140 190 50Hz 110V 220V 069 0 640 0 140 1 90 RGD3300 r 60Hz 110V 0 44Q 0 442 0 112 1 62 60Hz 220V 0 442 0 442 0 112 1 62 60Hz 110V 220V 0 442 0 442 0 112 1 62 60Hz 120V 240V 0 440 0 442 0 112 1 62 Table 9 1 NOTE If the circuit tester is not sufficientily accurate it may not show the values given and may give er roneous readings Erroneous readings will also occur when there is a wide variation of resistance among coil
10. Fig 10 25 Ados 10 4 3 STATOR and REAR COVER 1 Set the stator on the jig Match the grooves of the stator with the grooves of the jig 2 Attach the support ring around the stator set ting the open ends of the ring to the position of stator leads Check that the hooking holes are placed at the flat sides of the stator See Fig 10 26 3 Insert four guide bolts into the bolt holes of the rear cover and mount it on the stator matching the guide bolts with the grooves of the stator Tighten the guide bolts tentatively 4 Take the stator leads out from the window of the rear cover 5 Put a board on the rear cover and press it using a pressing machine If a pressing machine is unavailable tap around the board on the rear cover evenlv with a plas tic hammer to press fit the rear cover over the stator See Fig 10 27 CAUTION Take care of the rear cover to be pressed in upright position 6 Join the stator to rear cover with four bolts washers and spring washers See Fig 10 28 GO bolt sau ex Sd 4 pcs 4 pcs 60 springwasher 4 pcs Tightening torque 80 100 kg cm NOTE Tighten four bolts evenly taking several steps Hooking holes for removing support ring Grooves of stator STATOR SUPPORT RING Grooves of jig JIG Fig 10 26 Fig 10 27 44 The dimensions of the stator bolts are shown in Table 1
11. TERMINAL of the frame base plate using a 5 mm brass CONTROL BOX REAR COVER screw See Fig 10 33 Fig 10 33 46 3 Attach the alternator mount rubber to the frame See Fig 10 34 NOTE The mount rubbers are selected to reduce vibration most effectively by model and its fre quency Be sure to use the correct mount rubber for your generator 80 MOUNT RUBBER 2pcs GENERATOR BASE a a Fig 10 54 4 Mount the GENERATOR BASE on the mount rubber attached to the frame at step 3 See Fig 10 35 86 flange nut 1 pce Tightening torque 120 140 kg cm GENERATOR BASE RUBBER MOUNT RUBBER MOUNT Fig 10 35 47 5 6 7 8 Attach SHAFT STOPPER to the bottom of engine crankcase Tighten nuts tentatively NOTE Pay attention to the position of the SHAFT STOPPER The flange nuts shall be tightened after fine adjustment Cover the both ends of SHAFT STOPPER with RUBBERs Push RUBBERs until they touch the crankcase See Fig 10 36 RUBBER Lift engine and alternator assembly with a chain block and mount it to the frame Down the alternator first then the engine into the frame Lift the engine by approx 25 mm so as not to apply weight to the engine mount rubbers See Fig 10 37 Fix the legs of rear cover to the generator base Attach the 86 terminal of the grounding wires and the clamp to the right
12. Total 20 MAX 69 FUJI HEAVY INDUSTRIES LTD Engine amp Machinery Export Sales b i gou Floor Shinjuku Mitsui Bldg 2 1 1 Nishi Shinjuku Shinjuku ku Tokyo Japan TEL LA 347 2414 6 TELEX 232 2401 CAB E ADDRESS FUJIHEAVY TOKYO PRINTED IN JA IM ET MAY
13. side leg of the rear cover at the same time In the case of electric starting model attach the 89 terminal of the grounding wires a clamp and the BATTERY CABLE to the right side leg and a clamp to the left side leg of the rear cover at the same time See Fig 10 38 NOTE Two nuts are welded to the bottom side of the GENERATOR BASE 86 x 25 mm bolt amp washer assy 2 pes Tightening torque 120 140 kg cm BOLT and WASHER ASSY CLAMP NM S WIRE CLAMP Electric start model BATTERY CABLE I Electric start model Fig 10 38 48 9 Fix the engine mount rubbers to the crankcase base 86 flange nut 2 pes Tightening torque 120 140 kg cm CAUTION Pay attention to the position of the mount rubbers Lift down the engine and alternator assembly and remove the chain block belt 10 Attach two STOPPERs to the frame covering the both ends of the SHAFT STOPPER See Fig 10 39 x 166 flange bolt 4 pcs Fig 10 39 Tightening torque 50 60 kg cm 11 Adjust the position of SHAFT STOPPER so as its both ends are placed in the center of the STOPPERs then tighten the flange nuts to fix the SHAFT STOPPER See Fig 10 40 Tightening torque 120 140 kg cm Fig 10 40 12 Attach the SIDE PLATE to the frame See Fig 10 41 Tighten the two black flange bolts tentatively 60 x 8 mm flange bolt black 2 pes NOTE The flan
14. starts running the permanent magnet built in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator As two condensers are connected to the condenser coil the small voltage at the condenser coil generates a minute current which flows through the condenser coil At this time a small flux is produced with which the magnetic force at the rotor s magnetic pole is intensified When this magnetic force is intensified the respective voltages in the main coil and condenser coil rise up As the current a in creases the magnetic flux at the rotors magnetic pole increases further Thus the 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 AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies this AC voltage into DC Thus a DC current 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 S0Hz type or 3000 to 3300 rpm 60Hz type the current in the condenser coil and field coil increases rapidly This acts to stabilize the output voltage of each coils If generator speed further increases to the rated value the generator output voltage will reach to the rated value 5 3 2 VOLTAGE FLUCTUATIONS UNDER L
15. the wires to de tach the control panel and box Remove the regulator oil sensor unit condens ers and diode rectifier from the control box When removing the regulator push the hook on the coupler and pull out to disengage the cou plers See Fig 10 30 Fig 10 50 After disconnecting individual wires remove the control panel components NOTE DC fuse full power switch pilot lamp and warning lamp have their wires soldered Unsolder them to remove those parts if necessary 10 5 3 REASSEMBLY 1 2 3 4 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 identification and are of the correct capacity and size Use heat resistant type wires permissible temperature range 75 C or over in the specified gauge shown in the circuit diagrams Install regulator oil sensor unit condensers and diode rectifier into the control box Connect the wires of control panel components and control box Fasten the earth wires to the rear of the control box using a 66 nut to the bolt which fixes the condens er bracket to the inside of the control box See Fig 10 51 Attach the control panel to the control box AO SCTE Wik scl E edd en 6 pes Tightening torque 12 15 kg cm Je CONTROL BOX CONDENSER BRACKET 2 TE
16. windings or when measurement is performed at ambient temperatures different from 20 C 68 F 21 9 5 ROTOR ASSEMBLY R x 19 10 1 Using the circuit tester measure the resistance of the field coil MODEL RGD2500 RGD3300 Resistance 3 72 3 32 Table 9 2 NOTE 7 Measure the resistance of each coil wind ing while the diode and each resistor are disconnected with their solder removed NOTE 2 If the circuit tester is not sufficiently ac curate it may not show the values given and may give erroneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measure ment is performed at ambient tempera tures different from 20 C 68 F 9 6 CONDENSER m If an instrument QC meter or C meter for mea CONDENSER suring capacity of condender is available check the capacity of condenser See Fig 9 6 Fig 9 6 m NORMAL CAPACITY OF CONDENSER NODEL RGD2500 RGD3300 A CAPACITY IC 18 ee E E e al 10uF 10uF Table 9 3 m Ifsuch an instrument is unavailable the condenser be checked by replacing with a new one If the gen erator performs good with new condenser the cause of trouble is defect in original condenser 32 9 7 DIODE RECTIFI Yellow Grey Yellow ER DIODE RECTIFIER ca Red Red Yellow Yellow Grey Fig 9 7 CIRCUIT TESTER Fig 9 8 Circuit inside of the di
17. 0 1 95 RGD3300 inch 3 74 1 57 Table 10 1 7 Attach the boot over the lead wires drawn out from the rear cover Press the smaller end of boot into the rear cover See Fig 10 29 Fig 10 29 8 Put the rear cover and stator assembly over the rotor Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover See Fig 10 30 Fig 10 30 45 9 Tighten the four bolts washers and spring CLAMP washers to join the rear cover to the front Electric x 25 mm bolt 4 pes 66 washer 4 pes spring washer 4 pcs Tightening torque 50 60 ke cm In the case of models with oil sensor or electric starter attach the clamp at the same time See Fig 10 31 10 4 4 END COVER Attach end cover to the rear cover The air inlets of the end cover have to face down ward See Fig 10 32 66 x 8 mm flange bolt 4 pcs Tightening torque 40 60 kg cm Fig 10 32 10 4 5 FRAME 1 Attach two mount rubbers to the engine base of the frame Tighten the nuts from the bot tom side of the frame See Fig 10 34 8 flange nut 2 pes Tightening torque 120 140 kg cm 50 TERMINAL FRAME 2 Attach the 5 terminal of grounding wires green yellow to the unpainted arean hole 66 TERMINAL 86
18. 260 Table 10 2 Use the correct clamps for each fuel pipe 52 3 Mount the fuel tank on the frame Apply RUBBER TANK s between side plate and tank and bracket tank and tank See Fig 10 48 Use black flange bolts to join them 6 x 18 mm flange bolt black 4 pes Tightening torque 30 40 kg cm Fig 10 48 4 Connect fuel pipes between fuel tank fuel cock fuel filter and fuel injection pump See Fig 10 47 Attach the 10 mm flange nut to the fuel cock before connect the fuel pipe to it Use the correct clamps for each fuel pipe Ref No Part Name Outer Dia Inner Dia Length FUEL PIPE FUEL PIPE Table 10 3 S Attach fuel cock and fuel filter to the control box The fuel cock can be installed on the bracket by turning it 90 degrees with fuel pipes connected Fuel cock 106 flange nut pce Tightening torque 50 60 kg cm Fuel filter x 16 mm flange nut pcs Tightening torque 50 60 kg cm 53 10 4 8 BATTERY FRAME and BATTERY 1 Attach BATTERY FRAMEs to the frame See Fig 10 49 Clamp the upper end of the battery frames to the side member of the frame Tighten two bolt amp washers tentatively 80 x 20 mm bolt amp washer assy 2 pcs Join the lower end of the battery frames to the base plate of the frame Tighten two bolt amp washers tentatively 86 x 20 mm bolt amp washer assy 2 pes 2 Mount the BATTERY
19. 591 e 3 4 2 1 4 Lcr L J Lo iO YELLOW YELLOW __ GREEN YELLOW E 1 O P SW e RGD2500 RGD3300 ELECTRIC STARTER SYSTEM Optional Equipment ALTERNATOR CONTROL BOX e a AG aiaa A gt to 4 ZON N DC bou YELLOW eae gt prin eee erer NO e N Z ig us Y Lr L2 YELLOW ENGINE LIGHT GREEN E A m m 2 T gt cop BAT 12V 24A4 Use t e battery cabies v th a cross sectioral area large thar 22 mm e RGD2500 RGD3300 ELECTRIC STARTER AND OIL SENSOR SYSTEM Optional Equipment VALTERNATOR CONTROL BOX pee 1 e A BLACK aug a L am PINK LIGHT GREEN SC Auxiliary Winding FC Field Winding V Voltmeter PL Pilot Lamp 1 DC Output Terminal No Fuse Breaker FPSW Full Power Switch R EG Regulator OS Oil Sensor KEY SW KEY Switch O P SW Oil Pressure Switch Voltage Changeover Switch AC Output Receptacle Total 15 MAX AC Output Receptacle 220V 240V REC AC Output Receptacle 110V 120V REC AC Output Receptacle 120V 240V Output Receptacle
20. BASE on the battery frame Insert the four bolts from the bottom of the frame and tighten the flange nuts 66 x 40 mm bolt amp washer assy 4 pcs 66 flange nut 4 pcs Tightening torque 50 60 kg cm 3 Tighten the four bolt amp washers attached at step 1 Tightening torque 120 140 kg cm 4 Mount the battery on the battery base Insert the battery bolts into the hooking holes of the battery base then apply the battery stay to the battery and tighten two nuts 66 spirng 2 pcs 60 nut dave eR 2 pcs Tightening torque 50 60 kg cm 5 Connect battery cables to the battery Connect the positive cable first and then the negative cable BOLT and WASHER BATTERY BATTERY CABLE x 20 2 pcs BATTERY STAY N CATCHER 2 PIPE FRAME l BOLT and WASHER 80 x 20 mm 2 pcs BATTERY FRAME BATTERY BASE FLANGE NUT Bo 4 pcs BOLT and WASHER 8o x 20 mm 4 pcs Fig 10 49 54 10 5 CHECKING DISASSEMBLY and REASSEMBLY of the CONTROL BOX 10 5 1 CHECKING OF THE CONTROL BOX Dismount the control box from frame Remove the control panel and check each components and wiring Refer to Section 9 for the detail of checking the components in the control box 10 5 2 DISASSEMBLY 1 2 3 4 REGULATOR Remove the control panel from the control box 46 SCreW 6 5 Disconnect the connectors on
21. Check the fuse in the fuse holder If the fuse is blown check for the cause of fuse blowing and then replace with a new one FUSE 10 NOTE If the DC output is used to charge a large capacity battery or an over discharged bat tery an excessive current may flow causing fuse blow 11 4 3 CHECK THE WIRING Check all the wires to be connected correctly 11 4 4 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode recti fier with a circuit tester Refer to Section 9 7 DIODE RECTIFIER for the checking procedure 11 4 5 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester SPECIFICATION RESISTANCE 50Hz 7 110V 220V 240V 110V 220V 120V 0 162 RGD2500 60Hz 0 122 50Hz RGD3300 60Hz 110 220 120V 240V 110V 220V 240V 0 149 110 220V 120V 110V 220 120V 240 0 1122 Table 11 3 If the resistance reading is much larger or smaller than the specified value the DC coil of the stator is faulty Replace stator with a new one 59 11 5 OIL SENSOR TROUBLE SHOOTING 11 5 1 PRINCIPLE OF OPERATION The sensor for diesel engine consists of a pressure switch as a sensor section and controller section The pressure switch detects the drop of oil pressure the crankcase When the oil pressure falls down below the predetermined value 0 3 kg cm turns on the generate a signal to the cont
22. OAD When the output current flows through the main to the appliance a magnetic flux is produced serves to increase current in the condenser coil When current increases the density of magnetic flux across the rotor core rises As a result the current flowing in the field coil increases and the generator output voltage is prevented from decreasing 19 5 3 3 FULL POWER SWITCH Dual Voltage Type The full power switch is provided for the dual voltage type to take out the full rated power from one recepta cle in each voltage 120 240V lor 110 220V 120 for 110 1 1 120V LI 110V 240V 220V 120 110V Fig 5 10 120V 110 Fig 5 11 Switch LOWER VOLTAGE HIGHER VOLTAGE Position RECEPTACLE RECEPTACLE 110V or Rated output No output can be taken 240V 120V 220 1 ki a Half of rated 190 output Rated output Table 5 4 Fig 5 12 20 Inside the generator are two sets of main coils Each main coil outputs half the rated power at the lower volt age 110 120V These main coils are wound to be in the same phase The full power switch reconnects these main coils in parallel or in series Fig 5 10 shows a circuit diagram When the full power switch is set for single lower voltage indication 110V or 120V the switch position is as indicat
23. RMINAL WIRES WELDING 60 NUT Fig 10 51 11 TROUBLE SHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING STATOR m Remove control panel and disconnect black blue red and white wires at the connectors m Measure the resistance between terminals on sta tor leads See Fig 11 1 Refer to Table 11 1 for normal resistance If sta tor is faulty replace with a new one Fig 11 1 11 1 2 CHECKING CONDENSER If an instrument QC meter or C meter for mea suring capacity of condender is available check the capacity of condenser See Fig 11 2 Fig 17 2 NORMAL CAPACITY OF CONDENSER NODEL RGD2500 RGD3300 T G 10uF 10uF CAPACITY r 4 coy 10uF 10uF Table 11 1 m Ifsuch an instrument is unavailable the condenser can be checked by replacing with a new one If the gen erator performs good with new condenser the cause of trouble is defect in original condenser 56 11 1 3 CHECKING OF ROTOR 1 CHECKING FIELD COIL m Measure the resistance ot field coil with a circuit tester See Fig 11 3 m NORMAL RESISTANCE R x 12 10 MODEL RGD2500 RGD3300 Resistance 370 Fig 11 3 Table 11 2 Remedy If the resistance is not normal replace rotor with a new one 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11 2 1 CHECKING STATOR Check stator referring to Step 11 1 1 11 2 2 CHECKING CONDENSER Check condenser referring to Step 11 1 2
24. Robin Generator Model RGD2500 RGD3300 Technical Data amp Overhaul Instructions MANUAL Section Title Section 1 Title ALTERNATOR ENGINE Model RGD2500 RGD3300 B RE oo e z L Type Brushless Revolving Field Self Exciting 2 Pole Single Phase Frequency 50Hz I 60Hz 50Hz 60Hz Maximum n 2300W 2500W 3000W 3300W Rated Output 2000W 22008 2700W 3000W iwi TUE 5 ei 4 7 IE oo 110V 18 2A 110V 20 0A 110V 24 6 110V 27 3A lt Rated 220V 9 1A 120V 18 3A 220V 12 3A 120V 25 0A Voltage 240V 8 3A 220V 9 2A 240V 11 3 220V 12 3 Current 110 220 18 2 9 1 110 220 20 0 10 0 110 220 24 6 12 3 110 220 27 3 13 6 120V 240V 18 3A 9 2A 120V 240V 25 0A 12 5A Power Factor 1 0 DC Output 12V 8 3A 100W 9 P Voltage Regulator Condenser Voltage Regulation Within 10 _Type Air cooled 4 cycle Diesel engine Model DY23D DY27D Displacement 230 cc 14 04 cu in 265 16 17 cu in L ES W Rated Output 4 3 PS 3000 rpm 48 PS 3600 rpm 5 0 PS 3000 rpm 5 5 5 3600 L Fuel Diesel Light Oil Fuel Tank Capacity 7 8 liters 2 1 U S gal Fuel Consumption Ratio 50 Hz 0 93 liters hour 50 Hz 1 18 liters hour at Rated Output 60 Hz 1 10 liters hour 60 Hz 1 30 liters hour Oil Capacity 0 9 liters
25. STROBE TYPE Fig 8 6 EST 8 2 AC OUTPUT MEASURING TO AC RECEPTACLE Fig 8 7 Use a circuit like the one shown in Fig 8 for measuring AC output A hot plate or lamp with a power fac tor 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 1 at the rated amperage and rated rpm Rated voltage 110V 120V 220V 240V Voltage range 107 119V 117 130V 215 238 235 260 Table 8 1 8 3 MEASURING INSULATION RESISTANCE MEGGER TESTER Connect a megger tester to one of receptacle output terminals and the ground terminal then measure the insulation resistance An insulation resistance of l megohm or more is normal The original insulation resistance at the time of shipment from the factorv is 10 megohms or more If it is less than 1 megohm disassemble the gen erator and measure the insulation resistance of the stator rotor and control panel individually Fig 8 8 e 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 BLACK lead and the core 2 980 e ROTOR Measure the insulation across one of the soldered terminals of the rotor and the core Fig 8 10 e CONTROL PANEL Measure the insulation resistances between the l
26. TYPE ALTERNATOR CONTROL BOX ORANGE 1 a L ORANGE c Ler ADE 4 lt gt 7 i BLACK _ BLACK 2 GE F YELLOW 1 RED DC OUT 75 1 2 20 RGD3300 50Hz 110V 220V 60Hz 110V 220V 120V 240V ALTERNATOR CONTROL BOX ORANGE _ ORANGE c 71 CUP 1 L of Weg BES e YELLOW e RGD3300 U K 50Hz 110V 220V BS RECEPTACLE ALTERNATOR CONTROL BOX ORANGE c ORANGE BLACK Lp BLACK ag __ F YELLOW 0 75 mm2 1 25 mm 20 mm RGD3300 U S A 60Hz 120V 240V NEMA RECEPTACLE ALTERNATOR_ CONTROL BOX BROWN GREEN YEL LOW ENGINE JM SOU 91 q BLUE 2 O P SW D BLACK YELLOW _ t BLACK YELLOW _ 1 LIGHT GREEN 4 A a d Q LI2V 28AH Use the cattery cables w th a crass sectional area larger than 22 mmz Ur 0 75 mm V 1 25 20 mm 66 RGD3300 50Hz 220V FOR EUROPEAN COUNTRIES ALTERNATOR CONTROL e RGD2500 RGD3300 OIL SENSOR SYSTEM Optional Equipment ALTERNATOR CONTROL BOX lt gt L gt A AS gt 7
27. VOLTAGE CHANGEOVER SWITCH MAIN COIL 220V RECEPTACLE MAIN COIL Fig 5 13 fa 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 open flame near the fuel tank Be careful not to spill fuel when refueling If spilt wipe it and let dry before starting the engine 2 Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oily cloth straw and any other inflammables near the generator 3 Do not operate the generator in a room cave or tunnel Always operate in a well ventilated area Otherwise the engine may overheat and also the poisonous carbon monoxide contained in the exhaust gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facil ities 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 gen erator may tip over 5 Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is wet by rain or snow wipe it and thoroughly dry it before starting Don t pour water over the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leak age and electric shock
28. appliance Power consumption Efficiency D P Efficiencies of some electrical appliances as follows Single phase motor 0 6 0 5 The smaller the motor the lower Three phase motor 0 65 0 9 the efficiency Fluorescent lamp 0 7 0 8 Example 1 A 40 fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 accordingly power consumption will be 40 0 7 57 As explained in Item 2 multi ply this power consumption value of 57W by 1 2 2 and vou 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 40 fluorescent lamps Example 2 Generally speaking 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 Item 3 MODEL RGD2500 RGD3300 Frequency 50 Hz 60 Hz 50 Hz Incandesent lamp etc 2000W 2200W 2700W 3000W approx approx approx approx Fluorescent lamp mercury lamp etc 1400W 1500W 1800W 2100W approx approx approx approx dri Motor driven tool general purpose motor etc 1200W 1300W 1600W 1800W approx approx approx approx t pub
29. coil which generates AC voltage in the main coil Fig 5 2 15 5 2 2 CONDENSER 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 laminated silicon steel sheet core and a field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided tor the primary exciting action Fig 5 4 A diode rectifier and a resistor are mounted inside of the insulator DIODE RECTIFIER amp SURGE ABSORBER el o8 5 2 4 FUSE 1 The 10 ampere DC fuse mounted on the con trol panel protects whole DC circuit from get ting damage by overload or short circuit 2 The 15 ampere DC fuse in the control box pro tects the diode rectifier from getting damage by reverse connection to the battery Electric start model Fig 5 6 5 2 5 NO FUSE BREAKER The no fuse breaker protects the generator from getting damage by overloading or short circuit in the appli ance GENERATOR RATING OF NO FUSE BREAKER SPECIFICATION RGD2500 RGD3300 50Hz 110V 25A 50Hz 220V 50Hz 240V 50Hz 110V 220V 60Hz 110V 60Hz 120V 60Hz 110V 220V 60 2 120 240 Table 5 1 Fig 5 7 7 5 2 6 RECEPTACLE and AC PLUG STD SPEC These are used for taking AC output power from the ge
30. e the rotor core with permanent magnets Plastic a plastic hammer many directions and pull out the rotor from engine shaft See Fig 10 21 Fig 10 20 Fig 10 21 41 7 Front cover 1 Remove the four bolts which join the 12 mm spanner Front front cover to the engine Protector 86 bolt 2 Remove front protector from front 8 mm spanner or cover See Fig 10 22 screw driver 2 10 4 ASSEMBLY PROCEDURES 10 4 1 FRONT PROTECTOR and FRONT COVER 1 Attach the front protector to front cover The louvers of the front protector project into the inside of front cover as shown in Fig 10 23 5 x 10mm Tapping screw 4 pes Tightening torque 35 55 kg cm Fig 10 23 2 Install front cover to the engine See Fig 10 24 86 x 20 mm bolt and washer assy Qux ex ded DA eee E eb 4 pcs Tightening torque 120 140 kg cm NOTE The size of faucet joint and pitch of mounting holes of front cover is dif ferent by models RGD2500 and RGD 3300 Fig 10 24 10 4 2 ROTOR 1 Clean the tapered portion of driving shaft and the matching tapered hole of rotor shaft of oil and dirt using a waste cloth 2 Attach rotor to the driving shaft See Fig 10 25 Tighten through bolt with washer and spring washer Tightening torque 2500 115 135 kg cm RGD3300 230 250 kg cm
31. ed by the lower solid line in the diagram Fig 5 11 is a simplified representation of this circuit showing the two main coils connected in parallel In this case the higher volt age 220V or 240V at Rec 3 cannot be taken out 2 for the lower voltage can output up to the rated power up to 30A if the rated current is over 30A and Rec 1 can output up to a total of 15A When the full power switch is set for double voltage indication 110V 220V or 120V 240V the switch position is as indicated by the upper dotted line in Fig 5 10 Fig 5 12 is a simplified representation of this circuit showing the two main coils connected in series In this case power can be taken simultaneously from the receptacles for the both voltages Rec 3 for the higher voltage can output up to the rated power but Rec 1 and Rec 2 for the lower voltage can output only up to half the rated power each Table 5 4 is a summary of the above explanation Select the proper output voltage by full power switch in accordance with the appliance to be used 5 3 4 VOLTAGE CHANGEOVER SWITCH The generator of 50Hz 110V 220 dual voltage type for U K is provided with voltage changeover switch instead of full power switch The output voltage is selected from 110V and 220V by turning this switch and both voltages cannot be taken out simultaneously The middle point of the main coil shall be grounded when the changeover switch is turned to 110V side 110V RECEPTACLE
32. engine off whenever the oil level falls down below a safe level preventing engine seizure COMPACT LIGHT WEIGHT The combination of newly developed brushless alternator and air cooled single cylinder Robin diesel engine enables the new RGD series generators to be very compact in size and light in weight RELIABLE PERFORMANCE WITH MINIMAL MAINTENANCE A brushless alternator eliminates troublesome brush maintenance drip proot alternator design A trouble free condenser voltage regulator A fuseless circuit breaker A dust proof dual element air cleaner The OIL SENSOR automatically shuts the engine off whenever the oil level falls down below a safe level preventing engine seizure LONG LIFE DURABILITY e Compact and smooth running air cooled Robin diesel engine lasts much longer than the gasoline engine of the same size Trouble free brushless alternator with condenser type voltage regulator works all the year round without any maintenace work 4 GENERAL DESCRIPTION OF THE GENERATOR 4 1 EXTERNAL VIEW of GENERATOR NO FUSE BREAKER SPEED CONTROL LEVER ROCKER COVER AC VOLTMETER AIR CLEANER KEY SWITCH Electric starter type as option RECOIL STARTER FUEL INJECTION PUMP STOP LEVER DC TERMINALS EARTH GROUND TERMINAL FUEL FILTER OIL FILTER FUEL COCK FUEL TANK amp TANK CAP MUFFLER FUEL GAUGE STARTING MOTOR OIL GAUGE BATTERY Electric starter type as option Electric starter type as opti
33. er See Fig 10 11 MOUNT RUBBER 2pcs GENERATOR BASE MOUNT RUBBER Fig 10 11 Step Part to remove Description Remarks Tool 4 Rear Cover 1 Remove end cover from rear cover 10 mm spanner or See Fig 10 12 box wrench 60 bolt 4 pcs I Remove through bolt from rotor shaft RGD2500 12 mm Apply socket wrench on the head of 1 RGD3300 14 mm through bolt and hit the wrench handle Box wrench with a hammer counterclockwise to i loosen See Fig 10 13 3 Remove the four bolts which join the rear cover to the front cover Insert the two bolts suf ficiently and evenly or the thread holes may be damaged at removing 4 Take off the rear cover Use the special tool REAR COVER PULLER to remove the rear cover See Fig 10 14 a Insert the two bolts of the special tool into the thread holes of the rear cover b Apply the center bolt of the special tool to the center hole of the rotor shaft c Tighten the center bolt to pull out the rear cover See Fig 10 15 Fig 10 12 REAR COVER PULLER Fig 10 14 Fig 10 15 _ 39 Rear Cover In case that REAR COVER PULLER is unavailable remove the rear cover by the following instructions a Insert the through bolt into the rotor Do not give a strong hit Plastic hammer shaft and tighten lightly I on the rear cover boss or b Hit on t
34. ge bolts shall be tightened after the installation of the control box Fig 10 47 49 10 4 6 CONTROL BOX Mount the control box assembly to the frame Refer to Section 10 5 for disassembly checking and reassembly procedures of the control box 1 Attach the 6 terminal of the grounding wires to the bottom of the control box See Fig 10 42 6 nut brass 1 Tightening torque 50 60 kg cm 2 In the case of generator models equipped with oil sensor connect the wires to oil pressure switch and solenoid e Screw the black yellow wire to the center of the oil pressure switch Connect the two blue wires to the solenoid and clamp the connectors to the side of speed control unit 3 Connect the wires drawn out from the stator to the wires from the control box NOTE 1 Connect the wires of the same color NOTE 2 On 220V and 240V models connect one blue stator lead with a white control box lead NOTE 3 Engage the connectors securely 4 Push the wires into the control box and attach the bushing over the wires Press the upper end of the bushing into the contro box See Fig 10 43 5 Install the control box to the frame 6 x 16 mm flange bolt 2 pes x 12 mm flange bolt pce Tighten the above three bolts tentatively to Tighten the two black bolts which join the side plate to the frame 3 Tighten the above three bolts adjusting the
35. gine The resistance should be 0 when engine is running The pressure switch actuates at 0 3 kg cm oil pressure d If the pressure switch does not work properly replace it with a new one 60 12 WIRING DIAGRAM e RGD2500 50Hz 220V 240V 60Hz 220V ALTERNATOR CONTROL BOX e RGD2500 50Hz 110V 60Hz 110V 120V TYPE ALTERNATOR CONTROL B0X OT RED DC OUT pe X 44 20 mm e RGD2500 50Hz 110V 220V 60Hz 110V 220V 120V 240V TYPE ALTERNATOR CONTROL BOX Oia 2 m BLACK e RGD2500 U K 50Hz 110V 220V BS RECEPTACLE ALTERNATOR CONTROL BOX riske mon 0 75 mm 125mm E mn e RGD2500 U S A 60Hz 120V NEMA RECEPTACLE ALTERNATOR CONTROL BOX ORANGE ORANGE atc 1 V CDU j BEACK C GREEN YELLO 4 EEN Low BLACK T RGD2500 50Hz 220V FOR EUROPEAN COUNTRIES ALTERNATOR CONTROL BOX 4 1 E 1 M ORANGE 1 _ a 3 ORANGE E rapia i lo 075mm 1 25 mm 2 0 mm RGD3300 50Hz 220V 240V 60Hz 220V ALTERNATOR CONTROL B0X ORANGE pro ORANGE Ze J r BLACK CCI T Lge BLACK 4d YELLOW RGD3300 50Hz 110V 60Hz 110V 120
36. he boss at the top of the rear legs cover and two legs evenly with a plastic hammer to remove Fig 10 16 Stator 1 Remove the four bolts which join the 10 mm box wrench stator to rear cover See Fig 10 17 Insert a small hook into the hole inside of the support ring and pull it out See Fig 10 18 e fa small hook is unavailable remove careful not to give the stator by the following procedure damage to the stator a Hold the rear cover and stator assem winding bly open side down b Place a cushion under the stator to protect it when dropped c Hit on the bearing housing of rear cover with a wooden block 6o BOLT 4pcs SUPPORT RING SPRING WASHER 66 WASHER 4pcs x x Fig 10 17 5 Stator 3 Pull out the wires from rear cover See Fig 10 19 SUPPORT RING STATOR REAR COVER 6oBOLT 4 pcs Rotor puller RGD2500 14 mm RGD3300 17 mm See Fig 10 20 Spanner If the special tool rotor puller is un Take utmost not to 1 Insert the rotor puller shaft into the I I available take the following instructions strike on the rotor wind rotor and tighten the rotor puller bolt until the rotor comes loose to remove the rotor ing or plastic insulator or Lightly strik
37. ive parts and the grounded parts Fig 8 11 Any part where the insulation resistance is less than 1 MQ has faulty insulation and may cause electric leak age and electric shock Replace the faulty part 28 9 CHECKING FUNCTIONAL MEMBERS 9 1 VOLTMETER and PILOT LAMP Models RGD2500 and RGD3300 have a voltmeter that comes in two types 150V maximum type and 300 V maximum type The voltmeter indicates generator output voltages The generators with a generated voltage of 110V or 120V and dual voltage type use the 150V maximum type voltmeter and those of 220V 230V and 240V specifications use the 300V maximum type voltmeter Generator for U S A employs a pilot lamp The lamp lights when a voltage is generated The pilot lamp also comes in two types 125V type and 240V type These types are selected to suit generator output voltage 300V MAX 150V MAX 220V 230V 240 1 110 120V Fig 9 1A Fig 9 18 9 2 AC RECEPTACLES Using 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 re moved and no continuity is found between these terminals the receptacles are also normal i AC RECEPTACLE Fig 9 2A Fig 9 2B 30 9 3 CIRCUIT BREAKER
38. nce Q 100 the above table I means electric current through the wire A means the length of the wire um The length of the wire indicates round length it means twice the length from generator to electrical tools 25 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 VOLTMETER AC voltmeter is necessary The approximate AC volt age ranges of the voltmeters to be used for various types of generators are as follows Oto 150V Type with an output voltage of 110 or 120V 0 300V Type with an output voltage of 220 230 or 240V Oto 150V 0 300V Dual voltage type Fig 8 1 8 1 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 10A 20A 100A Fig 8 2 8 1 3 FREQUENCY METER Frequency range About 43 to 65Hz NOTE Be careful of the frequency meter s input voltage range Fig 8 3 26 8 1 4 TESTER Used for measuring resistance etc Fig 8 4 8 1 5 MEGGER TESTER Used for measuring generator insulation resistance Select one with testing voltage range of 500V 8 1 6 TACHOMETER There are various types of tachometers such as con tactless 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 CONTACT
39. nerator total of four kinds of receptacles each varying in rated voltage and current from another used Each model has at least receptacle to deliver the rated generator output As many plugs as the receptacles each matching the corresponding receptacle are provided Table 5 2 shows the rated current for each receptacle Be careful not to use the receptacles and AC plugs beyond the specified limits to prevent burning up to total 15 amperes from two receptacles up to 15 amperes up to 30 amperes See Caution Table 5 2 Caution To connect the appliance to locking receptacle insert the plug into the receptacle and turn it clockwise to lock Fig 5 8 NOTE your generator has receptacles peculiar to your country Table 5 2 does not apply NOTE The generator for U S A market is equipped with NEMA standard receptacles shown in table 5 3 Use the proper plug for connecting appliance to the generator Ampere Receptacle Description Ground Fault Circuit Interrupter Receptacle duplex 125V 250V NEMA NEMA ki 20A L14 20R L14 20P Locking Receptacle Locking Receptacle Table 5 3 IB 5 3 DESCRIPTION of GENERATOR OPERATION RESISTOR PERMANENT MAGNET FOR INITIAL EXCITATION MAIN COIL FIELD COIL RECEPTACLE APPLIANCE CONDENSER COIL CONDENSER Fig 5 9 5 3 1 GENERATION of NO LOAD VOLTAGE 1 2 3 4 When the generator
40. ode rectifiers is as shown in Fig 9 7 Check continuity between each terminal by using a circuit tester as shown in Fig 9 8 rectifier is normal when continuity is as follows Apply black needle of the circuit tester Yellow Apply red of the circuit tester No continuity Yellow No continuity No continuity Continuity No continuity Continuity Continuity Continuity a A Continuity No continuity Table 9 4 No continuity NOTE 7 checking the diode direction of connection is contrary to the ordinary case because of charac teristics of the diode and battery incorporated the tester 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 E 10 DISASSEMBLY AND ASSEMBLY 10 1 PREPARATION and PRECAUTIONS 1 Be sure to memorize the location of individual parts when disassembling the generator so that the genera tor can be reassembed correctly Tie tags noted 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 tempo
41. on a Ne 4 2 CONTROL PANEL e RGD2500 RGD3300 50Hz 220V 240V 60Hz 220V TYPE START SWITCH ER NO FLSE BREAKER o START SWITCH Option NO FUSE BREAKER AC RECEPTACLE VOLTMETER DC OUTPUT TERMINAL EARTH GROUND TERMINAL DC FUSE START SWITCH Option NO FUSE BREAKER VOLTMETER AC RECEPTACLE DC OUTPUT TERMINAL EARTH GROUND TERMINAL DC FUSE RGD2500 RGD3300 50Hz 110V 220V 60Hz 110V 220V 120V 240V TYPE FULL POWER SWITCH START SWITCH Option NO FUSE BREAKER AC RECEPTACLE VOLTMETER AC RECEPTACLE DC OUTPUT TERMINAL EARTH GROUND TERMINAL VOLTAGE CHANGEOVER SWITCH wo FUSE START SWITCH NO FUSE BREAKER Option VOLTMETER 220V RECEPTACLE 110V RECEPTACLE DC OUTPUT TERMINAL DC FUSE EARTH GROUND TERMINAL e RGD2500 U S A 60Hz 120V NEMA RECEPTACLE NO FUSE BREAKER PILOT LAMP 120V RECEPTACLE EARTH GROUND TERMINAL e RGD3300 U S A 60Hz 120V 240V NEMA RECEPTACLE FULL POWER SWITCH FL_i POSER Sw 72 4 2 8 B3EA lt ER START SWITCH NO FUSE BREAKER Option 120V RECEPTACLE PILOT LAMP 240V RECEPTACLE EARTH IGROUNDI TERMINAL 240 e RGD2500 RGD3300 GERMANY 50Hz 220V vu r gt s START SWITCH NO FUSE BREAKER Option 220V RECEPTACLE VOLTMETER DC OUTPUT TERMINAL DC FUSE EARTH GROUND TERMINAL START SWITCH Option
42. ppliance is the power neces sary 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 calcurate the power consumption of each appliance or equipment by its type a 2 3 4 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 rated 3000W generator can turn thirty 100W incandescent lamps on 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 400W mercury lamp requires 600W to OOW power source to be turned on A rated 3000W generator can power four five 400W mercury lamps NOTE 7 Ifa power factor correction capacitor is not applied to the mercury lamp or fluorescent lamp the more power shall be required to drive those lamps A rated 3000W generator can drive one or two 400W mercury lamps without power factor correction capacitors NOTE 2 Nominal wattage of the fluorescent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption efficiency
43. rame Wire harness is still con moving the three bolts joining the con nected trol box to frame and side plate See Fig 10 6 2 Put the control box with control panel Put a waste cloth under down the control panel to pro tect it 3 Remove the ground wire green yellow 10 mm spanner or box spanner 10 mm spanner from the bottom of control box 4 Pull the bushing out from the control box See Fig 10 7 rN Fig 10 6 Fig 10 7 36 3 Control 5 the wire harness out from the con trol box Disengage the connectors to separate the control box See Fig 10 8 Pipe Frame 1 Remove side plate from frame 10 mm spanner or ES box spanner 2 Remove tank bracket from frame 3 Remove stoppers from engine base of 10 mm spanner frame 4 Remove the four nuts which join the 12 mm spanner mount rubbers to the engine 5 Remove the two bolts which join the 12 mm spanner rear cover to the generator base See Fig 10 9 86 bolt TANK BRACKET 89 BOLT SIDE PLATE Fig 10 9 2 Step Part to remove Description Remarks 3 Frame 6 Lift up the engine and alternator assem j bly using a chain block and dismount it from frame Fig 10 10 7 Remove generator base from frame 12 mm spanner 8 Remove mount rubbers from frame 12 mm spann
44. rarily 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 ROTOR PULLER REAR COVER PULLER JIG 34 10 3 DISASSEMBLY PROCEDURES Part to remove Deerpdon 1 Fuel Tank 1 Close fuel cock Draining tank of fuel before disassembly is un necessary 2 Loosen the nut and remove fuel cock 14 mm spanner from the bracket Turn the fuel cock body by 90 degrees to remove Fig 10 1 Remove the two bolts which join the 10 mm spanner fuel filter to the control box See Fig 10 2 Remove the fuel pipe which connects fuel filter and fuel injection pump Loosen the clamp using pliers and pull out the fuel pipe from the fuel filter See Fig 10 3 35 1 Fuel Tank 5 Remove fuel return pipe which connects Take care of spilt fuel the fuel injection nozzle and the bottom from the fuel pipe of fuel tank Loosen the clamp and pull out the fuel return pipe from the fuel injection nozzle Fig 10 4 6 Loosen the four bolts and remove fuel tank from frame See Fig 10 5 Plier 10 mm spanner or box spanner Fig 10 4 Fig 10 5 2 Control 1 Remove control box from f
45. roller section The controller which is powered by the DC coil sets up a delay for a few seconds for detecting signals trans mitted during the period If more signals than the predetermined number are generated the controller feeds power to the solenoid which actuates the latch on the control bracket to release the control lever to shut the engine down 11 5 2 TROUBLE SHOOTING 1 2 3 4 Check oil level Fill it up to maximum level if necessary Check all wires to be connected properly If they possibly have breaks in connection the sensor will also malfunction Checking the solenoid Measure the resistance between two leads from solenoid See Fig 11 8 NORMAL RESISTANCE 235 290 Q If the resistance is larger or smaller than the above limits solenoid is defective Replace it with a new one Fig 11 8 Checking the oil sensor unit a Disconnect the connector on the Black Yellow lead of the oil sensor unit which is connected to the pressure switch b Start the engine and ground the Black Yellow lead of the oil sensor unit to engine body c If the solenoid actuates to shut the engine down the oil sensor unit is operating properly Checking the pressure switch a Disconnect the Black Yellow lead of the pressure switch from the control unit b Check the resistance between the Black Yellow lead and ground Resistance should be infinite when engine is stopped c Start the en
46. should be taken into account as explained in Item 5 on the following page 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 larger than their running wattage Example A rated 250W electric drill requires a 400W generator to start it Initially loaded motor driven appliances such as water pumps compressors etc These appliances require the large starting wattage which is 3 to 5 times of running wattage Example rated 900W compressor requires a 4500W 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 elec trical 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 23 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
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