RGX1800/2400/3500/5500 GENERATOR SERVICE MANUAL
Contents
1. HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS DIV Subaru Bldg 1 7 2 Nishi Shinjuku Shinjuku ku Tokyo 160 Japan TEL Tokyo 03 3347 2414 5 TELEX 232 2401 FUJI J CABLE ADDRESS FUJIHEAVY TOKYO PRINTED IN JAPAN FACSIMILE TOKYO 03 3347 2418 SEPTEMBER 19902. PE WE 50Hz Voltage 5 5555 55 59 240 FREQUENCY Hz 3 FREQUENCY Hz VOLTAGE V VOLTAGE V VOLTAGE V FREQUENCY I N 1 5k 49 OUTPUT 2207 NA a a L 220 a BE VOLTAGE 220 vi 20 JA vd XL VOLTAGE 110y 110 I ee re mo 0 2 4 6 8 W 12 14 CURRENT A m FREQUENCY 12207 62 F F i 5 187 5 OUTPUT W 3 2 a j S dit L 7 110vJ 0 3 6 9 12 15 CURRENT A1 2 MODEL RGX2400 OUTPUT W 39 0 4 8 12 16 20 CURRENT A L RGX1800 Output 1500 Rated 999999999999 1300 Frequency 50Hz Voltage Pale 11 0 220 RGX1800 Output Max 1800W Rated H8 1500W Frequency 60Hz Voltage 11 0 220 RGX2400 Output 2000 Rated 959 1700W Frequency EE NE NE SES 50Hz Voltage mw ee suae nie s W 110V FREQUENCY H2 VOLTAGE V VOLTAGE V J FREQUENCY He gt VOLTAGE V FREQUENCY Hz TT Set p 2 NEC AD ptet itil gt VOLTAGE 0 4 8 12 15 20 CURRENT A
3. C YELLOW du I ft LT Co snows ORANGE ft LE L cn i D A 1 OUT BROWN DES Peo s ra ROWNTWHITE 0 75 mm 20mm 1 25 mm 3 5 mm e RGX3500 50Hz 60Hz 110V 220V TYPE CONTROL BOX s gt o 7 n gt n FL F psw 110 220 M REC3 GREEN YELLOW YELLOW E lt YELLOW aii 1 1 1 o J w 2 lt gt gt B BROWN WHITE e RGX3500 U K 50Hz 110V 220V BS RECEPTACLE GENERATOR CONTROL BOX MEE BLACK GREEN YELLOW YELLOW ze YELLOW 5 ORANGE F Y BROWN 0 40 4 ALL j u i DC OUT m BROWN Pe us SOWRWAITE ee 075mm 20mm ss mm 35 mm e RGX3500 U S A 60Hz 120V 240V NEMA RECEPTACLE with IDLE CONTROL ENGINE CONTROL BOX L2 O QO 5 E Eg GREEN YELLOW YELLOW _U L C re YELLOW_ e RGX5500 50Hz 110V 60Hz 120V GENERATOR CONTROL BOX GREEN YELLOW YELLOW E ae YELLOW E 1 e L1 l an BROWN 2 E 2 BROWN TWHITE 0 75 mm SP Nay ee 2 0 mm e RGX5500 50Hz 220V 240V 60Hz 220V TYPE GENERATOR CONTROL BOX GREEN YELLOW YEL
4. 2 pcs Remove the mount rubbers from SIDE PLATE 10 mm spanner or box wrench 3 Pipe Frame 2 Remove the nuts which fix the engine and alternator on the mount rubbers 12 mm spanner or box wrench Take out the engine and alternator assv from the 3 Dismount the engine and altemator from side of the frame the frame See Fig 10 9 Fig 10 8 4 Remove the mount rubbers from frame 12 mm spanner Loosen the nuts on the bottom side of box wrench the frame MOUNT RUBBER 2pcs SIDE PLATE 2pcs Step 4 Rear Cover k assum oo Part to remove Description Remarks 1 Remove the end cover Fig 10 11 10 mm spanner or 66 bolt 4 pcs box wrench 2 Take off the rear cover 1 Remove the four bolts which fasten 10 mm spanner or the rear cover to the front cover box wrench bolt e reese 4 pcs 2 Use a special tool REAR COVER x PULLER to remove the rear cover a Insert the two screws of the special Insert the two screws tool into the thread holes of the sufficiently and evenly rear cover or the thread hole may be b Apply the center bolt of the special damaged at removing tool on the head of the through bolt Tighten the center bolt to pull out x the rear cover 8 n s REAR COVER PULLER
5. 1 E M H Pe I l OC OUT i START SWITCH a 12V 83A X START SWITCH 9 A 110V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL RGX5500 U K 50Hz 110V 220V BS RECEPTACLE 110V RECEPTACLE VOLTMETER VOLTAGE CHANGEOVER SWITCH NO FUSE BREAKER DC FUSE acro i MAXI MERE 272 NO FUSE BREAKER oA Gi 1 ON Oi DC OUTPUT EARTH GROUND 220V RECEPTACLE START SWITCH TERMINAL TERMINAL e RGX5500 U S A 60Hz 120V 240V NEMA RECEPTACLE PILOT LAMP FULL POWER SWITCH NO FUSE BREAKER 240V RECEPTACLE IDLE CONTROL Option l 3 LI 4 Z 5 i gt 2 1 START SWITCH TOTAL 20 4 1 2 h 120V RECEPTACLE EARTH GROUND TERMINAL 28 RGX5500 GERMANY 50Hz 220V VOLTMETER FUSE NO FUSE BREAKER 229V NO FUSE BREAKER ON a START SWITCH 220V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX5500 50Hz 220V WITH SPECIAL RECEPTACLE VOLTMETER DC FUSE NO FUSE BREAKER O NO FUSE BREAXER ON 5 SWITCH 220 RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX5500 SWITZERLAND 50Hz 220V VOLTMETER DC FUSE NO FUSE BREAKER Y MC F SE BREAKER ON i s A START SWITCH 220V RECEPTACLE EART
6. 110V 120V 30A Output from receptacle 50Hz 220V 20A i Total output amperage 60Hz 220V 22A Total output amperage I RGX5500 50Hz 240V 18A Total output 20 2 Pole 2 Element Total output amperage 50Hz 110V 220V p perag 30A i Output from receptacie 110V 220V 22 2 2 Element Total output amperage Z 120V 240V 30A Output from 30A receptacle Table 5 1 5 2 6 RECEPTACLE and PLUG STD SPEC These are used for taking AC output power from the generator A total of five kinds of receptacles each varying in rated voltage and current from another are used Each model has at least one receptacle to deliver the rated generator output As many AC 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 amperage limits to prevent burning up to total 15 amperes from two receptacles up to 15 amperes up to 20 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 7 NOTE If 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
7. 110V 220V FRE QUENCY Hz VOL TAGE V VOLTAGE V 3 FREQUENCY H4 3 VOLTAGE V FREQUENCY H7 y 61 4 1 i VOLTAGE 1220 122 ge ae VOLTAGE JA ET T0v 100 0 4 8 12 15 20 CURRENT Ai 3 MODEL RGX3500 CURRENT At lt Lo OUTPUT W 35 OUTPUT W 3 OUTPUT W gt RGX2400 Output Max 2400W Rated 6 6068 2000W Frequency 60Hz Voltage 110V 220V RGX3500 Output Max 3000W Rated 2500 Frequency 50Hz Voltage 110V RGX3500 Output 3500W Rated TIPP 3000W Frequency d a hA S d 60Hz Voltage seis e seh ave 110V VOLTAGE V FREQUENCY Hz VOLTAGE V FREQUENCY Hz 39 VOLTAGE V FREQUENCY Hz a 61 ere 3k ue eu E I d 130 21 12 EE L VOLTAGE B 3 L CURRENT A 3 25 2 LETT 50 2k gt Lm EE EE 4 1 4 1 1 1 1 12 8 L ri SEE CURRENT A 63 1 4 5 TH EDERSEN 1 2 m 60 pm eoe AT I TA
8. YELLOW ORANGE F T BROWN Eno TI ne ws BROWN 2 ay BROWN WHITE Se 0 75 mm 20 mm 3 5 mm RGX1800 2400 50Hz 220V 240V 60Hz 220V GENERATOR CONTROL BOX YELLOW ORANGE F2 o BROWN ON Orel Kasa OUT 1 A BROWN_ 1 lt 05 e RGX1800 2400 50Hz 60Hz 110V 220V GENERATOR CONTROL BOX C B BLACK C D O GREEN YELLOW ___ E mi i N 2 T BROWN ORANGE A 0 4 G s an BROWN po L ge BROWN WHITE oe gt 0 75 mm HT 20 m J OD Thi 3 5 mm e RGX1800 2400 U K 50Hz 110V 220V BS RECEPTACLE GENERATOR CONTROL BOX GREEN YELLOW YELLOW YELLOW 2 BROWNIWHITE e RGX2400 U S A 60Hz 120V NEMA RECEPTACLE with IDLE CONTROL ENGINE CONTROL BOX 6 ICSW LIGHT BLUE GENERATOR ne 1 25 mm n 2 5 mm e RGX3500 50Hz 110V 60Hz 120V GENERATOR CONTROL BOX GREEN YELLOW YELLOW E h ORANGE 51 BROWN oui j V _ BROWN _ s WWE e RGX3500 50Hz 220V 240V 60Hz 220V GENERATOR CONTROL BOX GREEN YELLOW YELLOW
9. Fig 10 11 Fig 10 12 In the case that REAR COVER PULLER is unavailable remove the rear cover by the following instructions Do not give a strong hit Box wrench on the boss or legs Plastic hammer 2 Hit on the boss and legs of rear cover with a plastic hammer to loosen 1 SSS Zon Z ee EX eS ne x 48 io 7mm TS zcaQ Fig 10 13 ee ee Description Tool Startor 1 Remove the four bolts which fasten the 10 mm socket stator to the rear cover i wrench See Fig 10 14 SPRING WASHER Fig 10 14 2 Put a piece of lumber on the floor in upright position See Fig 10 15 3 Hold the rearcover and stator upside down with both hands 4 Down the cover and stator over 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 Step Part to remove Description Remarks 5 Take apart the support ring and stator from rear cover STATOR REAR COVER
10. DC TERMINAL EARTH GROUND TERMINAL RGX2400 50Hz 110V 60Hz 120V VOLTMETER CIRCUIT BREAKER DC FUSE AC RECEPTACLE DC OUTPUT TERMINAL EARTH GROUND TERMINAL e RGX1800 RGX2400 50Hz 220V 240V 60Hz 220V VOLTMETER CIRCUIT BREAKER DC FUSE AC RECEPTACLE DC OUTPUT TERMINAL EARTH GROUND TERMINAL e RGX1800 RGX2400 50Hz 60Hz 110V 220V FULL POWER SWITCH CIRCUIT BREAKER 220V RECEPTACLE VOLTMETER DC FUSE 110V RECEPTACLE DC OUTPUT TERMINAL EARTH GROUND TERMINAL RGX1800 2400 U K 50Hz 110V 120V BS RECEPTACLE VOLTAGE CHANGEOVER SWITCH CIRCUIT BREAKER CIRCLIT C n VOLTMETER 220V RECEPTACLE 110V RECEPTACLE DC FUSE DC Batte F SE 152 A DC OUTPUT TERMINAL EARTH GROUND TERMINAL e RGX2400 U S A 60Hz 120V NEMA RECEPTACLE PILOT LAMP CIRCUIT BREAKER IDLE CONTROL BREAKER Option DLE CONTASE 120V RECEPTACLE EARTH GROUND TERMINAL e RGX1800 2400 GERMANY 50Hz 220V CIRCUIT BREAKER CIRCLIT EI SE VOLTMETER DC FUSE 220V RECEPTACLE DC OUTPUT TERMINAL EARTH GROUND TERMINAL e RGX1800 2400 50Hz 220V WITH SPECIAL RECEPTACLE CIRCUIT BREAKER C RCUIT VOLTMETER DC FUSE 220V RECEPTACLE eltg narge DI FOSE 19 2
11. BOLT SPRING WASHER Fig 10 17 1 Take off the through bolt Box wrench Apply a box wrench on the head of Plastic hammer through bolt Hit the wrench handle with i a hammer counter clockwise to loosen Fig 10 18 2 Put the engine on the working table recoil starter side down Step Part to remove Description I Remarks 6 Rotor 3 Use bolt and oil as a tool for pulling out rotor in the following procedures I Pour engine oil into the center hole rotor shaft Fill with oil to the shaft end See Fig 10 19 2 a bolt with the following thread size RGX1800 2400 3500 10 1 25 12 1 50 3 Apply few turns of seal around the tip of the bolt See Fig 10 20 SEAL TAPE Fig 10 20 4 Screw the bolt into the thread of the rotor shaft 5 Torque the bolt using a socket wrench Socket wrench until the rotor comes off loose The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft 4 Wipe off oil thoroughly from rotor shaft and engine PTO shaft ewe aM TE Fig 10 21 Step Part to remove Description Remarks 1 Remove the front cover 12 mm Socket Loosen the four bolts and remove the wrench front cover 80 DOlpe seus sss q 10 22 10 4 ASSEMBLY PROCEDURES 10 4 1 FRONT COVER Attach the front cover to the engine main bearing cover
12. Do not lose the filter Screen Fig 10 1 x x R RY n h osys o 3 2 Disconnect fuel hose from the strainer Loosen the top of the Pliers strainer and pull out the fuel hose from the strainer See Fig 10 2 3 Take off the four nuts and remove the 13 mm spanner or fuel tank See Fig 10 3 box wrench Step Part to remove Description Remarks 2 Control Box 1 off the grommet from the rear pannel of control box See Fig 10 4 2 Disconnect the connectors 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 5 a Masel AN 1 i Q yo j N vo J gt N SA ee 97 8 SS NAN VA YO NN O A mp 2 EE Y D a Fig 10 4 Fig 10 5 4 Take off the three bolts and remove the 10 mm spanner or control box from the frame box wrench See Fig 10 6 5 Take off the bushing from the bottom of Press the upper end of the control box the bushing and pull See Flg 10 7 PULL OUT 11 Fig 10 7 Step Part to remove Description Remarks Tool 1 Remove SIDE PLATE from frame See Fig 10 8 6
13. 37 0 26 45 032 0517 15 25 av sv 65 75 70 02 0 332 1v wv 1 3 5Vi 4V 5 Voltage drop Table 7 2 d Voltage drop indicatesas V Gog X R X IX R mens resistance Q 100 m on the above table I means electric current through the wire A means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 Dr ROBIN GENERATOR TESTER The Dr Robin generator tester is exclusively designed for fast easy diagnosis and repair of Robin generators The Dr Robin has the following features 1 Functions of voltmeter frequency meter 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 Fig 8 1 4 Tester and accessories are installed in a handy sturdy case for easy carring e SPECIFICATIONS Model Dr Robin Part Number 388 47565 08 Voltage 0 500V AC Frequency 25 70Hz Resistance 0 1 1 999 0 Condenser Capacity 10 100 Measuring Range Circuit Protector Power Source 2 x 6F44P 006P Dry Cell Battery Test leads with needle probes 1 set Accessories Test leads with jack plugs Dimensions L x W Table 8 1 The
14. 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 not Dr Robin generator tester use the instruments described following section for checking generator patts 8 1 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 Oto 150 Type with an output voltage of 110 or 120V Oto 300V Type with an output voltage of 220 230 or 240V 0 to 150 0 to 330V Dual voltage type FOR AC Fig 8 2 2 AMMETERS ammeter is necessary ammeter with range that changed according to the current rating of a given generator 15 most desirable About 10 20 100 FOR AC Fig 8 3 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range Fig 8 4 4 CIRCUIT TESTER 5 6 Used for measuring resistance etc MEGGER TESTER Used for measuring generator insulation resistance Select one with testing voltage range of 500 There 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 dis assembled
15. n 0 4 8 12 16 20 CURRENT A V CURRENT A OUTPUT W gt OUTPUT W gt OUTPUT W RGX2400 Output Max e RMMHHeHe ee fy 2400W Rated e 99 2000W Freq uency 60Hz Voltage 4 44 110 RGX2400 Output e m 44H 2400W Rated eee 2000W Frequency EoeseveseteseetcecenCnns 60Hz Voltage 4 44 120 2400 Output Max lt lt 2400W Rated 2000W Frequency 50Hz Voltage 220 VOLTAGE V VOLTAGE V FREQUENCY H7 FREQUENCY Hz gt VOLTAGE V 120 110 HA M VOLTAGE 220V 4 1211 VOLTA 7 q RARER 0 4 8 12 16 20 CURRENT A OUTPUT W 3 OUTPUT W OUTPUT W gt RGX2400 Output 5 2400 Rated eee 2000W Frequency Fs WS NON Sas 60Hz Voltage vA ew Use Sista V Vive ve 220V RGX2400 Output Max eteseeeseseoeouescoone 2000W Rated 1700 Frequency 50Hz Voltage 4 240V RGX2400 Output Max ee MIR 2000W Rated 55 56 1700W Freq sem Voltage vale ews ce
16. L ALTERNATOR Oil Capacity Frequency Rated Output Voltage Current Power Factor DC utput Regulator Voltage Regulation Displacement Rated Output Fuel Tank Capacity Fuel Consumption Ratio at Rated Output Starting System Dimensions L x W x H Dry Weight RGX3500 Brushless Revolving Field Self Exciting 2 Pole Single Phase 60Hz 5500W 4800W MOV 436A 20A 120V 40A 183A 220 21 8A 40A 20A 110V 220V 43 6A 21 8A 120V 240V 40A 20A 110V 220V 110V 220V 12V 8 3A 100W Condenser Type Within 1096 EE Robin Air Cooled 4 Cycle Gasoline Engine 20 EY28D __ 2 273 16 66 55 HP 3600 388 23 68 8 0 3600 Automobile Gasoline 15 5 liters 4 10 U S gal 13 liters 3 43 U S gal 50Hz 1 8 liters hour 60Hz 2 1 liters hour 50Hz 2 7 liters hour 60Hz 3 1 liters hour 850 Starter and Optional Electric Starter 552 413 520 mm 21 7 x 16 3 x 20 5 in 635 x 448 x 596 mm 25 0 x 17 6 x 23 5 in 756 kg 123 5 Ibs 76 kg 167 6 lbs N N VOLTAGE V FREQUENCY Hz VOLTAGE w FREQUENCY Hz VOLTAGE 3 FREQUENCY Hz m PERFOMANCE CURVES MODEL RGX1800 CURRENT gt OUTPUT W OUTPUT W OUTPUT W RGX1800 Output Max MR
17. Match the faucet joint and tighten the bolts M8 x 18 bolt 4 pcs 8 spring washer 4 pcs Tightening torque 120 140 kg cm 8 7 10 1 ft lbs Fig 10 23 10 4 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 ft lbs to _ RGX3500 5500 230 250 Fig 10 24 16 6 19 5 ft lbs 10 4 3 5 1 Put the stator in the rear cover setting the four grooves on the side of stator with thread holes of the cover Tighten the four bolts tentatively to check if the grooves and thread holes are aligned WASHER 4 pcs correctly See Fig 10 25 CV 2 Remove the four bolts 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 10 26 CAUTION Be careful of the position of hook ing holes of the support ring ALUMINUM 4 Join the stator to rear cover with four bolts washers and spring washers See Fig 10 25 M6 bolt a 418 5 5 8 478 4 8 8 415
18. Rated output Half of rated Switch LOWER VOLTAGE HIGHER VOLTAGE Position RECEPTACLE RECEPTACLE No output can be taken output Rated output Table 5 4 Two coils wound over stator core Each main coil outputs half the rated power at the lower voltage 110V or 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 9 shows a circuit diagram When the full power switch is set for single lower voltage indication 110V 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 parallel In this case the higher voltage 220V or 240V at Rec 3 cannot be taken out Rec 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 9 Fig 5 11 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 2 for the lower voltage can output only up to half the rated power
19. The contactless type is recom mended Fig 8 5 Fig 8 7 STROBE TYPE 8 2 AC OUTPUT MEASURING SWITCH TO AC RECEPTACLE Fig 8 8 Use a circuit like the shown in Fig 8 8 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 Voltage range 107 119V 117 130V 215 238V 235 280V Table 8 2 3 MEASURING INSULATION RESISTANCE A 5 LM MEGGER TESTER lol ROQ as Use 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 1s 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 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 BROWN lead and the core Fig 8 10 a Measure
20. 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 resistance load is applied NOTE It is possible to use both DC and AC out puts simultaneously up to the rated output in total 3 FEATURES 3 1 3 3 3 4 3 6 3 8 BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance CONDENSER TYPE VOLTAGE REGULATOR A trouble free condenser type voltage regulator ensures a stable voltage under all working conditions OIL SENSOR Oil sensor automatically shuts off the engine whenever the oil level falls down below the lower limit to protect the engine from seizure QUIET OPERATION Robin RGX series generator delivers a quiet operation with e A large super silent muffler A quiet 4 stroke Robin engine A silent cyclone air cleaner NO RADIO NOISE Noise suppressor spark plug and spark plug cap are equipped standard to prevent radio frequency interference LARGE FUEL TANK The large fuel tank allows more than 5 to 10 hours of continuous operation which is sufficient for a half day or one day work without refueling RUGGED TUBULAR FRAME Full cradle type rugged tubuler frame protects the generator all around COMPACT AND LIGHT WEIGHT Newly developed brushless alternator enabled the RGX generators to be very compact in size and light in weight MINIMAL MAINTENANCE
21. 1500W Rated 1300W Frequency 50Hz Voltage 110V RGX1800 Output Max mH 1800W Rated veeeeeeseeceocoseooo 1500W Frequency H8 60Hz Voltage 110V RGX1800 Output Max 5555 55 55 5 55 1800W Rated veseeeseseoseeooosese 1500W Frequency 555 55 59 60Hz Voltage sn 120 VOLTAGE V 3 FREQUENCY Hz m FREQUENCY Hz gt gt VOLTAGE V FREQUENCY Hz VOLTAGE 7 tn OUTPUT W X 2 3 4 5 6 7 CURRENT A rs 1 62 d old pr en S ee i la LA Hik E VOL _ Te ME E HN 0 3 6 9 CURRENT iA gt r 4 2 Pt m aga ia 50 m gt ram 49i m 5 I o dE 260 1 W 2 1 1 VOLTAGE os 240 j i vm Lp s ai A 7 1 i 0 1 2 3 4 5 6 7 CURRENT RGX1800 Output Max 1500W Rated 1300W Frequency Voltage c gt esassas 220V RGX1800 Output Max MH 1800W Rated 8e 1500W Freq s MIS 60Hz Voltage ME a e 220V RGX1800 Output Max ee HR 1500W Rated 1300W Frequency
22. 25a 220 tso Table 9 2 NOTE 1 Because a diode is soldered to the coil ends at the terminals resistance may be measured only when tester probes touche the terminals in one combi nation of polarity Therefore if no re sistance reading appears try checking in reverse polarity NOTE 2 If the circuit tester is not sufficiently accurate it may not show the values given and may give erroneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when meas urement is performed at embient tem peratures different from 20 68 9 6 CONDENSER Use a Dr Robin in capacitance meter mode to check the capacity of condensers See Fig 9 6 RGX1800 RGX2400 RGX3500 RGX5500 Fig 9 6 NOTE Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance or the accurate reading cannot be obtained NORMAL CAPACITY CONDENSER MODEL RGX1800 RGX2400 RGX3500 RGX5500 1 uF 20uF 174 2 28 2 Resistance MF 204 17 2 28 2 Table 9 3 instrument is unavailable the condenser can be checked by replacing with a new one the generator performs good with new condenser the cause of trouble is defect in original condenser 9 7 DIODE RECTIFIER DIODE RECTIFIER Brown Brown White range Orange Brown Brown Brown l 1
23. A brushless alternator release the operator from periodical brush maintenance A trouble free condenser type voltage regulator drip proof alternator design No fuse circuit breakers e An electronic pointless ignition system 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 A brushless alternator with a condenser voltage regulator Full rubber mount in a sturdy tubular frame A forged steel crankshaft supported by two main ball bearings e A pointless electronic ignition system e A cast iron cylinder liner A forged aluminum connecting rod 4 GENERAL DESCRIPTION THE GENERATOR 4 1 EXTERNAL VIEW of GENERATOR FULL POWER SWITCH VOLTMETER NO FUSE BREAKER DUAL VOLTAGE TYPE PILOT LAMP RGX1800 2400 CIRCUIT BREAKER IDLE CONTROL SWITCH Option CHOKE LEVER AIR CLEANER AC RECEPTACLE DC FUSE HOLDER 2 RECOIL STARTER DC OUTPUT TERMINAL MUFFLER EARTH GROUND TERMINAL FUEL COCK TANK CAP FUEL GAUGE PLUG COVER SPARK PLUG INSIDE FUEL TANK STOP BUTTON OIL SENSOR UNIT Option DC FUSE HOLDER RGX3500 ONLY OIL FILLER DC OUTPUT TERMINAL OIL DRAINING PLUG RGX3500 ONLY 4 2 CONTROL PANEL e RGX1800 50Hz 110V 60Hz 120V VOLTMETER CIRCUIT BREAKER 2 80 7 BREAKER FUSE RECEPTACLE
24. Brown White CIRCUIT TESTER Fig 9 9 Fig 9 10 Circuit inside of the diode rectifiers is as shown in Fig 9 9 Check continuity between each terminal by using a circuit tester as shown in Fig 9 10 The rectifier is normal when condtinuity is as follows m Checking table for analogue circuit tester Apply black needle of the circuit tester Analogue circuit tester Brown Brown Brown White Brown No continuity No continuity Continuity Brown No continuity No continuity Continuity Of tha CHOU tostar Orange Continuity Continuity Continuity Brown White continuity continuity No continuity RE Apply red needle Table 9 4 1 m Checking table digital circuit tester Apply red needle of the circuit tester Digital circuit tester Brown Brown Orange Brown White Brown No continuity No continuity Continuity Brown No continuity No continuity Continuity Apply black needle of the circuit tester Orange Continuity Continuity Continuity Brown White continuity No continuity continuity 550 Table 9 4 2 NOTE 1 Because of difference of measuring method between the analogue circuit tester 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 Cond
25. NOTE DC fuse full power switch and pilot lamp have their wires soidered 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 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 2 Install condensers and diode rectifier into the control box 3 Connect the wires of control panel components and control box Fasten the earth wires 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 10 38 4 Attach the control panel to the control box MA screw 55555555555 6 pcs 1800 RGX2400 500 screw c6 8 pcs RGX5500 Tightening torque 12 15 kg cm REAR COVER CLAMP M4 NUT WELDING NUT EARTH WIRES TERMINAL e BE 3 SIER A 7 x X CONDENSER BRACKET IN CONTROL BOX Fig 10 38 11 TROUBLESHOOTING 11 1 AC OUTPUT 11 1 1 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 o
26. 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 AIR INLET AIR OUTLET Fig 11 8 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 dis assemble 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 11 4 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 Check the fuse the fuse holder If the fuse is blown check for the cause of fuse blowing and then replace with a new one FUSE 10A If the DC output is used to charge a large capacity batiery or an over dis charged battery an excessive current may flow causing fuse blow NOTE 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 rectifier with a circuit tester Refer to Sec
27. 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 220V 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 VOLTAGE CHANGEOVER 110V SWITCH RECEPTACLE MAIN COIL 220V RECEPTACLE MAIN COIL Fig 5 12 6 5 PRECAUTIONS Use extreme caution near fuel constant danger of fire exists Do not fill the fuel tank while the engine is running Do not smoke or use opern flame near the fuel tank Be careful not to spill fuel when refueling If spilt wipe it and let dry before starting the engine Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oily cloth straw and any other inflammables near the generator Do not operate the generator in a 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 facilities during use Operate the generator on a level surface If the generator is tilted or moved during
28. gt Robin Robin Generator Model HGX1800 HGX2400 RGX3500 RGX5500 Revised Technical Data amp Overhaul Instructions SERVICE MANUAL 5 Section Title Page Section Title RGX1 800 RGX2400 a nn Brushless Revolving Field Self Exciting 2 Pole Single Phase Frequency Maximum Output Rated Output MOV 1 110 220 5 120 12 5A Voltage 2 240v Al 220V Current 110 220 11 8 5 9 110V 220V 13 6A 6 8A 182A 9 1A mann t IT T b 120V 240V 12 5A 6 3A 16 7A 8 3A ALTERNATOR Power Factor u 1 0 DC Output 85 12V 8 3A 100W _ Voltage Regulator Condenser Type n Voltage Regulation Within 10 1 Typ Robin Air Cooled 4 Cycle Gasoline Engine 25 200 183 11 17 cu in 3 5 3600 Automobile Gasoline Fuel Tank Capacity 10 liters 2 64 U S gal ees 8 Pow YY ov m a a Fuel Consumption Ratio 50Hz 1 0 liters hour 50Hz 1 1 liters hour at Rated Output 60Hz 1 3 liters hour 60Hz 1 4 liters hour Capacity 00 Starting System Recoil Starter 552 x 377 x 482 mm Dimensions L x W x H 21 7 x 14 8 19 0 in Dry Weight 000 45 kg 97 Ibs 455kg 100 Ibs SNOILVOIJIO3dS
29. in table 5 3 Use the proper plug for connecting appliance to the generator Receptacle AC plug Description Ground Fault Circuit Interrupter Receptacle duplex 125V 250V NEME NEME 20 114 208 L14 20p Locking Receptacie Locking Table 5 3 5 3 DESCRIPTION of GENERATOR OPERATION PERMANENT MAGNET M FOR INITIAL EXCITATION STATOR FIELD COIL RECEPTACLE APPLIANCE SURGE ABSORBER DIODE CONDENSER COIL CONDENSER 5 3 1 GENERATION of NO LOAD VOLTAGE 1 2 3 4 When the generator 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 one or two condensers are connected to the condenser coil the small voltage at the condenser coil generates a minute current 20 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 increases the magnetic flux at the rotor s 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 vo
30. on the side plates with rubber washers between them M6 X20 mm black bolts 955995955555 5555252 4 pcs M6 washers Nip quie VS M RIS 4 pcs M6 spring washers s 4 pcs NOTE For easy tank assembly glue the rubber washers over the holes on the side plates 4 Connect the rubber pipe First fit the hose clamps on the rubber pipe connect the strainer and fuel tank then fasten the rubber pipe with the hose clamps NOTE Apply a drop of oil to the rubber pipe so that it may easily be connected to the strainer and the fuel tank PLUG COVER pr TANK CAP FUEL FILTER FUEL TANK FUEL GAUGE STRAINER BRACKET RUBBER PIPE to CARBURETOR NUT JOINT Da FUEL STHAINER HOSE CLAMP BANJO BANJO BOLT Fig 10 37 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 procedure for the components in the control box 10 5 2 DISASSEMBLY 1 Remove the control panel from the control box screw se 6 pcs RGX1800 2400 RGX3500 screw 8 pcs 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
31. the insulation across one of the soldered terminals of the rotor and the core Fig 8 11 e CONTROL PANEL i Measure the insulation resistances between the live parts and the grounded parts Any part where the insulation resistance is less than 1MO has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 9 FUNCTIONAL 5 9 1 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 9 2 AC RECEPTACLES PILOT LAMP Fig 9 1 Using Dr Robin or circuit tester check continuity between the two terminals at the rear of the 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 AC RECEPTACLE Fig 9 2B 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
32. use there is a danger of fuel spillage and a chance that the generator may tip over Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is wet by rain or snow wipe 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 This may cause a short circuit or damage to the generator Use a transfer switch for connecting with indoor 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 Name Qty 348 43009 08 Plastic Box Table 6 1 Use a fuse of the correct capacity DC output If the generator rpm is increased excessively in the overload condition by using an over rated fuse the generator may be burnt CAUTION If the fuse is burnt or the circuit breaker tripped off as a result of using an electrical appliance the cause can be an overload or a short circuit In such a case stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring 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 elec
33. x zz z 66 Pe N ag ON ON co oS N gt gt e ene o o gt a O E e ge al TR es ww GM xR Bi edi e 8 gt gt e gt x 95 90 05 S 29 Xa c S s S 5 G 5 G 5 TO gt L gt gt lt M 1Ndino 4 M 1 8 180 4 M Lnd x N ka 4 50 OV CURRENT 111 eee 40 CURRENT O lt o gt 30 NUIT i n a A A I 20 CURRENT A p 10 214 amp 3 A 39V LIOA 2H A9Nano3ud a JOVLT0A amp 2 AONaNDAYA 48 amp 39V110A E gt 2 44 LL c 220 VOLTAGE 12404 1 130 2 fi 120 2 EMO I gt 0 10 20 39 40 CURRENT A 3 2 5 DC OUTPUT VOLTAGE V 0 2 4 6 8 10 CURRENT A J3 OUTPUT W 2k VOLTAGE 120 1 La 50 5500 Output Max 55555 5555 5500W Rated 4800 Frequency Ses a EE RET RE T ET ETE 60Hz Voltage de e eu see 120V 240V DC Voltage PEDE 12V DC Ampere 4 4 44 4 8 DC output TEE
34. 1000W 1700W 2000W i 2800W 3200W Motor driven tool approx one motor 1800W 2600W 2900W approx 1100W approx 1300W approx 800W 900W 1000W 1200W approx 1500W approx approx approx approx 750W 900 1300W 1400W Water pump compressor etc approx 600W approx 400W approx 450W approx 500W Table 7 1 NOTES Wiring between generator and electrical appliances 1 Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load electrical appliance If the input current is higher than the allowable current of the cable used the cable will become excessively heated and deteriorate the insulation possibly burning it out 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 Nominal cross Allowable section current strands strands Resistance Current Amp 5 8A 10A 12A 154 30 0 18 2 5V 8V 12 5 50 018 t 5V 7 5V FIZE 18
35. 21 7 Ze 3 DC OUTPUT TERMINAL EARTH GROUND TERMINAL e RGX1800 2400 SWITZERLAND 50Hz 220V CIRCUIT BREAKER VOLTMETER DC FUSE 220V RECEPTACLE DC OUTPUT TERMINAL EARTH GROUND TERMINAL RGX1800 2400 AUSTRALIA 50Hz 240V CIRCUIT BREAKER VOLTMETER DC FUSE 240V RECEPTACLE DC OUTPUT TERMINAL EARTH GROUND TERMINAL e RGX3500 50Hz 110V 60Hz 120V TYPE START SWITCH VOLTMETER NO FUSE BREAKER Option DC FUSE AC RECEPTACLE CC cm age or EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX3500 50Hz 220V 240V 60Hz 220V TYPE START SWITCH VOLTMETER NO FUSE BREAKER Option DC FUSE AC RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL RGX3500 50Hz 60 2 110 220 FULL POWER SWITCH NO FUSE BREAKER START SWITCH Option DC FUSE VOLTMETER AC RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL RGX3500 U K 50Hz 110V 220V BS RECEPTACLE START SWITCH VOLTAGE CHANGEOVER SWITCH NO FUSE BREAKER Option NO FLSE BREAKEAYJ DC FUSE VOLTMETER Battery chp ge 220V RECEPTACLE 110v RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX3500 U S A 60Hz 120V 240V NEMA RECEPTACLE START SWITCH FULL POWER SWITCH NO FUSE BREAKER Option NI F SE O O 56 IDLE CONTROL Option VOLTMETER C x 120v 24
36. 418 478 4 8 474 8 5 4 pcs M6 washer ee V ud EA Y 4 pes M6 spring washer 4 pcs Tightening torque 80 100 kg cm 5 8 7 2 ft Ibs Fig 10 26 NOTE Tighten four bolts evenly taking several steps The dimensions of the stator bolts are shown Table 10 1 65 65 RGX1800 25 6inch 25 6inch M8 1 25 7 RGX2400 295inch 0 59inch 8 1 25 RGX3500 85 mm 85 mm M8 x 1 25 50Hz 3 35 inch 3 35 Inch RGX3500 90mm 25mm 60Hz 3 54 inch 0 98 inch M10 1 5 115mm 40 mm RGX5500 4 53 inch 1 57 inch M10 x 1 5 Table 10 1 10 4 4 1 Attach the bushing over the lead wire drawn the rear cover Press the smaller end of the bushing into the window of the rear cover See Fig 10 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 Fig 10 28 3 Fix the rear cover to the adaptor with four bolts spring washers and washers M6 X25 mm bolt 4 pcs M6 spring washer 5099999 4 pcs M6 washer 4 4 pcs Tightening torque 50 60 kg cm 3 6 4 3 ft lbs Fig 10 29 10 4 5 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 ft Ibs Fig 10 30 10 4 6 FRAME 1 Attach the mount rubbers to th
37. 9v 240V RECEPTACLE 120V RECEPTACLE EARTH GROUND TERMINAL e RGX3500 GERMANY 50Hz 220V START SWITCH VOLTMETER NO FUSE BREAKER Option DC FUSE 220V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX3500 50Hz 220V WITH SPECIAL RECEPTACLE START SWITCH VOLTMETER NO FUSE BREAKER Option DC FUSE EC 14 o 220 EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX3500 SWITZERLAND 50Hz 220V START SWITCH VOLTMETER NO FUSE BREAKER Option NC JSE ON FUSE 220V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX3500 AUSTRALIA 50Hz 240V START SWITCH VOLTMETER NO FUSE BREAKER Option NC FLSE gaza e Y2 FUSE 240V RECEPTACLE 7 EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX5500 50Hz 110V 60Hz 120V TYPE VOLTMETER DC FUSE NO FUSE BREAKER amp l s 3A 21 C ME NA x A Ole 0 START SWITCH AC RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL RGX5500 50Hz 220V 240V 60Hz 220V TYPE VOLTMETER DC FUSE NO FUSE BREAKER START SWITCH AC RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL e RGX5500 50Hz 60Hz 110V 220V TYPE VOLTMETER FULL POWER SWITCH NO FUSE BREAKER AC RESWITCH NO FUSE BREAKER H 2 VO ON D 220V RECEPTACLE DC FUSE DC FUSE 10
38. H GROUND TERMINAL DC OUTPUT TERMINAL RGX5500 AUSTRALIA 50Hz 240V VOLTMETER DC FUSE NO FUSE BREAKER DC 2 SS START SWITCH 1 i a 23 240V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL MODEL NAMB stuck on the end cover NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service LABEL MODEL NAME 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION ROTOR COMPLETE STATOR COMPLETE MT SO ME AT ME AV W EE us 72277 22222 2 4 gt P4 w Z 59 24 J J CON 2 MOUNT RUBBER STATOR BOLT 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 coil which generates AC voltage in the main coil Fig 5 2 5 2 2 CONDENSER One 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
39. LOW E a an av ap gt zug vELLOWT T RCGNUM S GE dtum 2 ORANGE T BROWN SS 1 D BROWN ai a 2 SROWNIWHITE e RGX5500 50Hz 60Hz 110V 220V TYPE BLACK ae GENERATOR CONTROL BOX 1 110V 220V FPSW BLACK 9 GREEN YELLOW YELLOW 2 nac D 1 YELLOW re D 4 ORANGE fF BROWN n O O i D 1 DC OUT BROWN RO erie ate i l BROWN WHITE SS 0 75 mm ___ 20 mm 125mm 3 5 mm RGX5500 U K 50Hz 110V 220V BS RECEPTACLE GENERATOR CONTROL BOX BLACK GREEN YELLOW n m YELLOW a H YELLOW mm S ORANGE F T E BROWN E oS eas up OUT Lom FG _ BROWN _ a BR OWNIWHITE e 5500 U S A 60Hz 120V 240V NEMA RECEPTACLE with IDLE CONTROL ENGINE CONTROL BOX m ICSW LIGHT BLUE T L2 OO m 1 SOL LIGHT BLUE sp GENERATOR GREEN YELLOW a YELLOW 3 LCD _ 111 YELLOW 1 E IRSE 0 75 mm 2 0 mm 125mm 35mm e TYPE WITH OIL SENSOR Optional Equipment n n 2 YELLOW RED SIU HO OSC FrO FR yo YELLOW CONTROL BOX 2 0 mm 3 5 mm e RGX3500 ELECTRIC STARTER TYPE Optional Equipment
40. S La 1 I yen I 240 __ L PI 220 a A A pee REVO eee o CURRENT Ai 3 OUTPUT W 3 RGX3500 Output 3500W Rated eR 3000W Frequency 60Hz Voltage sn 120V RGX3500 Output Max em 3000W Rated 2500W Frequency Voltage 220 RGX3500 Output Max en 3500W Rated MI 3000W Frequency 60Hz Voltage t 220V VOL TAGE V gt FREQUENCY 92 FREQUENCY Hz VOLTAGE Vi FREQUENCY He VOLTAGE V RGX3500 52 12 dE Output 3000W 50 Rated 2500W 38 A Frequency 50Hz i i lt a 2 Voltage 240V Ter ae 260 Fik gt gt men AGE 5 240 2 220 0 b Q 2 4 6 8 10 12 CURRENT Al i FREOUENCY 220V x RGX3500 3k Output eee 3500W Rated 3000 1 50Hz Voltage 110 220 T gt VOLTAGE 220V j bik amp 0 I Ft 1 0 10 20 30 CURRENT A RGX3500 Output MM 3500 Rated 3000 Frequen
41. ces 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 i ov Power consumption Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 P dine smaller the motor the Three phase motor 5 mnm IS je 0 9 lower the efficiency Fluorescent lamp 0 7 0 8 Example 1 40W fluorescent lamp means that its luminous output 15 40W Its efficiency is 0 7 accordingly power consumption will be 40 0 7 57W As explained in Item 2 multiply this power consumption value of 57W by 1 2 2 and you will get the figure of the necessary capacity of a generator In other words a generator with a rated output of 1000Wcapacity can light nine to fourteen 40W fluorescent lamps Example 2 Generally speaking a 400W motor means that its work load is 400W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570W When this motor is used for a motor driven tool the capacity of the generator should be multipled by 1 2 to 3 and 570W as explained in the Item 3 Frequency 50 2 6082 50Hz 50 2 60Hz Incandesent lamp i heater etc 1300W 1500W 2500W 3000W 4400W 4800W Fluorescent lamp approx approx approx approx approx approx mercury lamp etc 900W
42. coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action Fig 5 4 A diode rectifier and surge absorber is mounted inside of the insulator DIODE RECTIFIER WEN a Nee Fig 5 SURGE ABSORBER 5 2 4 FUSE 1 10 ampere DC fuse mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit 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 appliance Table 5 1 shows the capacity of no fuse breaker by each spec and their object of protection SPECIFICATION NO FUSE BREAKER OBJECT of PROTECTION 1107 120V Total output amperage 220V Total output amperage RGX1800 240V Total output amperage 110V 220V 120V 240V 6 2 pes i Total output 110V 120V 15 Total output 50Hz 220V 240V 8 Total output amperage A RGX2400 50Hz 110V 220V 2 pcs 6 2 110 220 120V 240V 10A 2 pcs 50Hz 220V Total output amperage RGX3500 60Hz 220V 14A 50Hz 240V 10A i Total output amperage 50Hz 110V 220V 12 2 Pole 2 Element Total output amperage 60Hz 110V 220V 120V 240V 14A 2 Pole 2 Element Total output amperage 40A Total output
43. cy 8 5 8 4 808 8 8 Siew Bee ee web ee 1 10V 220V F vOLTAGE 120 ki 120 A E Lo CURRENT VOLTAGE V FREQUENCY Hz gt VOLTAGE V 3 FREQUENCY Hz gt VOLTAGE V FREQUENCY H2 FREQUENCY 240V1 I TDI 61 FREQUE 12 2 TTS LIS A m OUTPUT 240V RF 9 3k 260 73 m 2k VOLTAGE A LT tk 130 TZ ILTAGE CN 0 10 20 30 CURRENT 4 MODEL RGX5500 52 a Ele 4 7 49 l 1 p 1 3k lt E I 9 120 110 gue Ld br i 100 Lo CURRENT s r 6 61 6k 0 27 59 T kan i i cele 2 r2k 110 p LAGE E 1k 100 i 18 1 I i I I I 0 10 20 30 40 50 CURRENT Ai OUTPUT W OUTPUT W OUTPUT W 9 RGX3500 Output HMM 3500W Rated HMM 3000W Frequency 60Hz Voltage e 120V 240V RGX5500 Output eeteteetesenssessooons 5000W Rated Me 4400W Frequency 4 4 06 50Hz Voltage seqessaaoss s 110 RGX5500 Output Max 5500W Rated e 4800W Frequenc
44. e frame Insert the setting tongue of mount rubber into the hole on the frame and tighten the nut from the bottom of the frame 8 flange nut 4 Tightening torque 120 140 kg cm 8 7 10 8 ft lbs FRAME UPPER 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 3 Install 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 ft lbs Fig 10 32 NOTE When tightening the nuts slightly lift the engine and alternator 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 nuts for mount rubbers welded to side plates Tightening torque 40 60 KI 2 9 4 3 ft lbs gt HA 1151 A Fig 10 33 10 4 7 CONTROL BOX Mount the control box assembly to the frame Refer t
45. erse polarity Remedy If the resistance is not normal replace rotor with a new one Measure the insulation across one of the soldered terminals of the rotor and the core Fig 11 6 If insulation is bad replace rotor with a new one 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11 2 1 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 Loosen the lock nut on the adjusting screw Turn the adjusting screw clockwise to de crease engine speed or counter clockwise to increase engine speed Normal engine speed at no load 18 3100 3150 r p m for 50Hz type 3700 3750 r p m for 60Hz type 11 2 2 CHECKING CONDENSER Check condenser referring to Step 11 1 1 11 2 3 CHECKING STATOR Check stator referring to Step 11 1 2 11 2 4 CHECKING ROTOR Check rotor referring to Step 11 1 3 Fig 11 6 HIGH SPEED yp LOW SPEED m 11 3 VOLTAGE IS NORMAL NO LOAD 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 Refer to Step 11 2 1 for engine speed adjustment 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
46. ition 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 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 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 10 3 DISASSEMBLY PROCEDURES Step Part to remove Description Remarks Tool 1 Fuel Tank 1 Discharge fuel from the tank Use utmost care about 1 Shut the fuel strainer fire hazard 2 Remove the strainer cup 3 Put a vessel to receive fuel under the strainer and open the fuel cock to discharge fuel See Fig 10 1 4 Attach the strainer cup to the strainer body Wipe off sprit fuel thoroughly
47. ltage 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 50 2 type 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 LOAD When the output current flows through the main coil to the appliance a magnetic flux is produced and serves to increase current 8 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 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 receptacle in each voltage 120 240V 110 220V 1 e 5 120 1 I 110 up 240 220 110 l 3 mi 3 120 110 5 9 Fig 5 10 110 120V 110 220V or 120 240V Fig 5 11
48. o Section 10 5 for disassembly checking and reassembly procedures of the control box 1 Attach the 4 terminal of the grounding wires to the rear panel of the control box MA4 nut brass TIT 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 3 Press 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 X12 mm flange bolt 3 pcs Tightening torque 40 60 kg cm 2 9 4 3 ft lbs Fig 10 35 5 Fasten the one earth cable with 8 terminal drawn out from the control box to the rear cover leg MS nut 1 Tightening torque 80 100 kg cm 5 8 7 2 ft lbs Fasten the other earth cable with 5 terminal to the unpainted bolt hole on the frame See Fig 10 36 50 TERMINAL FRAME Q 60 TERMINAL 89 TERMINAL CONTROL BOX COVER Fig 10 36 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
49. on 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 1 CON OS gt 2 RGX2400 3500 3150 3200 r p m RGX5500 esperes 2700 2800 r p m Adjust the idling speed monitoring the volt ST meter so that it indicates between 75 volt and a 5 Yi A 85 Vu ES a AN x ET UN LA Turn the adjusting screw to adjust the slow speed L M Fig 11 13 4 Check the wiring through ZCT on the IDLE CONTROL UNIT BOARD A Single Voltage Type Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT OUTPUT WIRE 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 Fig 11 14 5 Checking the IDLE CONTROL UNIT Check the resistance between six leads of IDLE CONTROL UNIT with circuit tester IDLE CONTROL UNIT TESTER Fig 11 15 Tester Polarity o LIGHT BLUE FUSE LIGHT BLUE Langerthan 190 Langer than 85 Langer than 85kQ LIGHT BLUE FUSE __ pe LIGHTBLUE 5255 1212 d Table 11 4 NOTE Take 10 tolerance on above re
50. power factor correction capacitors NOTE2 Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption efficiency should be taken into account as explained in 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 lager 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 large starting wattage which is 3 to 5 times of running wattage Example A rated 900W compressor requires a 4500W generator to drive it NOTE1 Motor driven appliances require the aforementioned generator output only at the starting Once their motors are started the appliances consume about 1 2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances NOTE2 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 5 Appliances without indication to power consumption Some applian
51. sistance value If the measurement differs largely from mormal value the IDLE CONTROL UNIT is defective Heplace with a new one 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 1 1 2 Check the FUSE on wiring of IDLE CONTROL UNIT Remove the control panel from control box Check the FUSE in the fuse holder of IDLE CONTROL UNIT If fuse is blown replace with a new one FUSE 0 3A IDLE CONTROL UNIT 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 If the resistance is larger or smaller than this range SOLENOID is defective Replace with a new one Fig 11 17 12 WIRING DIAGRAM RGX1800 50Hz 110V 60Hz 120V GENERATOR CONTROL BOX GREEN YELLOW YELLOW BROWN men f 0 1 222 ppt BROWN LM BR WRUWHITE 9 ORANGE F2 wa YAO e RGX2400 50Hz 110V 60Hz 120V TYPE GENERATOR CONTROL BOX p YELLOW ea awen n ape s
52. ther before checking their capacitance or the accurate reading cannot be obtained RGX1800 RGX2400 Fig 11 1 m NORMAL CAPACITY OF CONDENSER manam Table 11 1 Ifsuch an instrument is unavailable the condenser can be checked by replacing with a new the generator performs good with new condenser the cause of trouble is defect in original condenser 11 1 2 CHECKING STATOR Remove control panel and disconnect stator wires at the connectors Measure the resistance between terminals stator leads See Fig 11 2 Refer to Table 9 1 for normal resistance If stator is faulty replace it with a new one Fig 11 2 Check the insulation resistance between stator core and each stator lead using 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 11 1 3 CHECKING ROTOR 1 CHECKING FIELD COIL Remove rear cover and stator Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals RX1 10 MODEL RGX1800 Rex2400 RGX5500 RESISTANCE 250 270 210 220 160 Table 11 2 NOTE 1 Because diode is soldered to the 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 rev
53. tion 9 7 DIODE RECTIFIER for the checking procedure 11 4 5 CHECK THE DC COIL FUSE Fig 11 10 ene DIODE RECTIFIER Fig 11 11 Check the resistance between two brown leads from stator with a circuit tester MODEL 50 2 60Hz 50Hz RGX1800 SPECIFICATION 110V 220V 240V 110V 220V 120V 220V 110V 220V 120V 240V 110V 220V 240V 110V 220V RGX2400 50Hz 60Hz 50Hz eoHz RGX3500 RGX5500 60Hz 120V 220V 110V 220V 120V 240V 110V 220 240V 110V 220V 120V 220V 110V 220V 120V 240V 110V 220V 240V 110V 220V 120V 220V 110V 220V 120V 240V RESISTANCE 0 299 0 27 9 0 269 0 159 0 149 Table 11 3 If the resistance reading 15 much larger smaller than the specified value the DC coil of the stator is faulty Replace stator with a new one 11 5 IDLE CONTROL OPTIONAL EQUIPMENT 11 5 1 ENGINE SPEED 15 NOT INCREASED WHEN LOAD 15 APPLIED 1 Inspect the solenoid bracket Check the bend angle of solenoid bracket If the bracket is distorted correct the angle with proper tool RGX2400 110 5 RGX3500 SE SOLENOID y S CAE M REM SOLENOID RGX2400 3500 SOLENOID SOLENOID BRACKET RGX5500 Fig 11 12 2 Check the wattage of load appied to the generator If the generator is loaded over the rated wattage the engine speed can not be increased Most inducti
54. trical 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 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 A 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 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 f a power factor correction capacitor is not applied to the mercury lamp or fluorescent lamp the more power shall be required to drive those lamps A rated 3000W generator can drive one or two 400W mercury lamps without
55. when the circuit breaker is on while there is no continuity when the circuit breaker is off CIRCUIT BREAKER 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 COUPLER Fig 9 4 RX19 10 _ Specification _ AC Winding Condenser Winging White Red Black Blue Yellow Yellow 220 10122018 RGX1800 0 220V 110V 220V 1 42 3 37 0 84 2 51 6 120 120V 240V 410V 220V 110V 220V RGX2400 220V 110V 220V 120V 120V 240V 110V 220V 110V 220V i 240V 0 83 0 83 1 83 RGX3500 mi K 220V 110V 220V 0 69 0 69 1 52 120V 120V 240V 110V 220V 110V 220V 240V 0 41 0 41 i 0 78 RGX5500 220V 110V 220V 0 26 0 26 0 58 120V 120V 240V 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 9 5 ASSEMBLY 1 Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals 10 10 RGX3500 RGX3500 MODEL RGX1800 RGX2400 50Hz 60Hz RGX5500 RESISTANCE
56. x Le lt GREEN WHITE I YO 7 BLACK ORANGE E BAT CONTROL BOX The battery cords have a cross sectional area of 22 mm E AR 0 75 mm n 1 25 mm 2 0 mm 3 5 mm e RGX5500 ELECTRIC STARTER Optional Equipment GREEN WHITE 1 1 N ST M H ee N ENGINE CONTROL BOX The battery cords have a cross sectional area of 22 mm 9 1 i 1 25 mm 2 0 mm 3 5 mm e RGX3500 ELECTRIC STARTER WITH OIL SENSOR Optional Equipment SP D lt GREEN WHITE MG 1 10255 4 7 l YELLOW y E E eac YELLOW RED Se 18 i dU vT amp lt 001 9 CONTROL BOX The battery cords have a cross sectional area of 22 mm 0 75 mm2 125mm 2 0 mm2 3 5 mm2 e RGX5500 ELECTRIC STARTER WITH OIL SENSOR Optional Equipment NI ENGINE CONTROL BOX The battery cords have a cross sectional area of 22 mm 125mm 2 0 mm 3 5 mm 2 e Field Winding ST M Starting Motor AC Output Receptacle Total 15 MAX REC AC Output Receptacle 120V 240V AC Output Receptacle Total 20A MAX
57. y 60Hz Voltage PN 110V 9 FREQUENCY Hz VOLTAGE V gt FREQUENCY Hz VOLTAGE V FREQUENCY Hz 62 porem 212 i a 6k 60 5k d 59 E EE A L 1 w zi an E NET 130 A B EN t 2k i I i 110 0 i i I 0 10 20 30 40 50 CURRENT iA l 52 T 1 i 51 m QUE NC 5k l L 1 1 pA 20 U IE 1 2 LA 2 I l 3k ro 1 VOLT 220 Mc trm voL AGE 1k 1 I A Li ERTE 200 FA i 0 1 1 1 TEE 0 5 10 15 20 25 CURRENT A1 9 60 Mm NE Pat L5k 1 b i i A 59 A i 2215 1 lt k Bay 240 pp L 2k c VOLTAGE 220 p spe zu pik 200 Lo CURRENT IAi s OUTPUT W OUTPUT W OUTPUT W RGX5500 Output AA 5000W Rated ee ee eee 4800W Frequency MH 60Hz Voltage s e hors gr ee 120V RGX5500 Output Max ee n RR 5000W Rated e Me 4400W Frequency Tm 50Hz Voltage 1 4 4 44 4 220V RGX5500 Output Max HH 5500W Rated eee 4800W Frequency Mee 60Hz Voltage Wie Wise P RE T TR Pre 220V N N z Z
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