RGD5000 GENERATOR SERVICE MANUAL
Contents
1. Tightening torque 53 9 68 6 N m 550 700 kg cm 39 8 50 6 ft lb 2 Install the adapter in the blower housing making sure that its flat side is down and its fuel filter mounting boss on the air cleaner side 8 25 mm bolt 4 pes 8 spring washer 4 pcs Tightening torque 19 6 22 6 N m 200 230 kg cm 14 4 16 6 ft lb Fuel filter mounting boss Fig 10 25 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 the rotor to the engine shaft Tighten the through bolt tentatively See Fig 10 26 Apply a wrench on the head of through bolt and hit it clockwise with a hammer to tighten Through bolt Fig 10 26 39 10 4 3 STATOR and REAR COVER Hooking holes 1 Set the stator on the jig so that grooves on the for removing stator side match with the grooves of the jig support ring At the same time be sure to set the stator on the jig so that the lead wires direct to the win dow of rear cover Attach the support ring around the stator Check that the hooking holes are placed at the PORTE flat sides of the stator See Fig 10 27 of stator Stator Support ring Grooves of jig Jig 2 Insert four guide bolts in the rear cover and let them match with the grooves in the stator and set the rear cover over the stator 3 Take the stator leads out fro2. Set the generator base so that the column of the frame is placed in the center of the pipe on the bottom of the generator base Tightening torque 11 8 1 m 120 140 kg cm 8 7 10 1 ft lb 4 Install the engine and alternator assembly into the frame a Lift the engine and alternator assembly with a chain block and down it into the frame mak ing sure that the boits of the mount rubbers are correctly inserted into the engine base b Fix the engine and a altemator assembly to the mount rubbers Tighten the two nuts at engine base and two bolts at generator base 10 nut 2 pcs Tightening torque 23 5 29 4 N m 240 300 kg cm 17 4 21 7 ft lb 8 x 25 mm bolt 2 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft lb NOTE When tightening the nuts and bolts slightly lift the engine and alternator assembly so that the weight is not applied to the mount rubbers 5 Attach the stoppers to the frame NOTE 1 Set the stoppers so that the engine base is placed in the center of the upper and the lower rubbers See Fig 10 40 NOTE2 If the engine mount rubbers are replaced with new ones set the stoppers so that i the upper rubber touches the engine base The new mount rubber shall be dis torted by approx 3mm in one month Make this gap even Engine base Fig 10 40 8 x12 mm bolt 4 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7
3. ww 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 consumpiion is to be worked out according to the numerical formula mentioned below Output of electrical appliance 0 Power consumpition Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 6 to The smaller the motor the Three phase motor 0 65 to 0 9 lower the efficiency Fluorescent lamp 0 7 to 0 8 Example 1 A 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 gt 0 7 57W As explained in Item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get the figure of the neces sary capacity of a generator In other words a generator with a rated output of 1000Wcapacity can light nine to fourteen 40 W fluorescent lamps Example 2 Generally speaking a 400 W motor means that its work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 4000 72 570 W When this motor is used for a motor driven tool the capacity of the generator should be multiple of 570 W by 1 2 to 3 as explained in the 3 570 x 1 2 to 684 to 1710 W MODEL RGD5000 R
4. 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 11 2 3 CHECKING ROTOR Check rotor referring to Step 11 1 3 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 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 TROUBLE If the appliance is faulty repair it 11 3 4 CHECK IF THE ENGINE IS OVERHEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re move it 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 1M Q 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 the insulation is faulty and may cause electric leakage Replace the faulty part Fig 11 8 11 4 NO DC OUTPUT 11 4 1 CHECK TH
5. 10 1 ft lb 45 6 Attach side piate A to frame 6 x 10 mm bolt 2 pcs Attach fuel tank mount rubbers to side plates The nuts for mount rubbers are welded to side plates Tightening torque 3 9 5 9 N m 40 60 kg cm 2 9 4 3 ft Ib Rubber V I 4 pcs y Side plate A 6 Bolt 2 pcs Fig 10 41 10 4 7 CONTROL BOX Mount the control box assembly to the frame Refer to Section 10 5 for disassembly checking and reassembly procedures of the control box 1 Mount the control box to the frame See Fig 10 42 6 x 10 mm flange bolt 3 pcs 6 washer 3 pcs Tightening torque 3 9 5 9 N m 40 60 kg cm 2 9 4 3 ft Ib Fig 10 42 2 Connect the wires drawn out from the stator to the wires from the control box Connect the oil Fig 10 43 sensor wires at the same time NOTE Connect the wires of the same color 3 Press the upper end of the bushing into the bottom window of the control box See Fig 10 43 Attach the grommet for the oil sensor wires to the rear panel of the control box 4 Fasten the one earth cable with 8 terminal drawn out from the control box to the rear cover leg 8 x25 mm bolt 1 pce Fasten the other earth cable with 6 terminal to the unpainted bolt hole on the frame 47 See Fig 10 44 Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft Ib Control box 69 Te
6. 20 2 30 35 40 45 CURRENT A 2 2 DC OUTPUT DC Voltage 12 V DC Ampere 8 3A DC output 100W The voltage curve shown in the left indicates the char acteristic of DC output when charging a battery The voltage may be decreased by 2096 when the resis tance load is applied NOTE It is possible to use both DC and AC outputs simultaneously up to the rated output in total 4 6 CURRENT 3 FEATURES 3 1 BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance 3 2 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 3 3 QUIET OPERATION The new RGD series generator provides quiet operation by means of The superb design of intake exhaust system Direct injection combustion system A large super silent muffler An efficient low noise air cleaner 3 4 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 3 5 OIL SENSOR The OIL SENSOR automatically shuts the engine off whenever the oil level falls down below a safe level preventing engine seizure 3 6 COMPACT LIGHT WEIGHT The combination of newly developed brushless alternator and air cooled s
7. SS Soe 2 ETA B NSIT QUUM 0 WI h Le KAS NN NN NU I Hh ili Fig 5 5A Fig 5 5B 5 2 4 DC FUSE 1 The 10 ampere DC fuse mounted on the con trol panel protects whole DC circuit from get FUSE 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 appliance Table 5 1 shows the capacity of no fuse breaker by each spec and their object of protection MODEL SPECIFICATION NO FUSEBREAKER OBJECT or PROTECTION 37 5A Total output amperage Hz t20 V Output from 30A receptacie S 20Ax2 Total output amperage x ouput amperage __ 60 Hz 120 V 240V a Output from 30A receptacle Table 5 1 Fig 5 7 5 2 6 RECEPTACLE and AC PLUG STD SPEC These are used for taking AC output power from the generator A total of six 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 correspond ing receptacle are provided Table 5 2 shows the rated cur
8. starter pulley to the rotor shaft 8 Apply a washer and a spring washer to the through bolt and insert it into the rotor shaft Through bolt 1 pce 10 washer 1 pce 10 spring washer 1 pce The dimension of the through bolt is shown in Table 10 2 ow TT T ss a 6 Table 10 2 42 4 Tighten the through bolt with a box wrench or a spanner If an impact wrench is avail able use it Tightening torque 23 5 29 4 N m 240 300 kg cm 17 4 21 7 ft lb 5 Attach the RECOIL STARTER to REAR 2 COVER YOR 69 Bolt 4 pcs 6 x 8 mm flange bolt 4 pcs Tightening torque 3 9 5 9 N m 40 60 kg cm 2 9 4 3 ft Ib Recoil satrter Fig 10 35 10 4 6 FRAME 1 Attach two engine mount rubbers and one alternator mount rubber to the frame See Fig 10 36 10 mm nut 2 pcs Rubber V I 2 pe Rubber V I 1 pce Tightening torque 23 5 29 4 N m 240 300 kg cm 17 4 21 7 ft Ib Fig 10 36 43 2 Attach the engine base to the bottom of the engine See Fig 10 37 8 x 50 mm flange bolt 4 pcs 8 0 nut 4pcs NOTE Insert the bolts from the bottom side of the engine base Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft lb Engine mount rubbers Engine mount holes Fig 10 37 3 Mount the generator base on the alternator mount rubber and fix with the nut 8 nut 1 pce NOTE
9. support ring 1 Remove the four bolts which fasten 10 mm socket the stator to the rear cover 2 Insert a small hook into the hole inside of the support ring and pull it out SUPPORT RING Dou Ib Fig 10 20 2 Take apart the stator from the rear cover NOTE Use utmost care not to give dam age to the stator insulation and stator leads REAR COVER STATOR SUPPORT RING 6 WASHER 66 SPRING WASHER 4 Fig 10 21 37 DICTU RN 1 Insert the rotor puller shaft into the IOtor and tighten the rotor puller bolt until the rotor comes loose If the special tool is unavailable take the following instructions to remove the rotor Lightly strike the rotor core with plastic Never strike on the coil hammer and pull out the rotor from the tapered shaft of the engine If the rotor cannot be taken off strike it at different angles See Fig 10 23 ROTOR PULLER Fig 10 22 Adaptor and 1 Remove the four adaptor mounting Driving Shaft bolts and the adaptor j 8 bolt 2 Remove the four driving shaft mount ing bolts and the driving shaft 106 bolt ADAPTER 106 BOLT DRIVING SHAFT 106 SPRING WASHER Fig 10 24 10 4 ASSEMBLY PROCEDURES 10 4 1 FRONT PROTECTOR amd FRONT COVER 1 Aligh the driving shaft with the faucet joint of the flywheel and install it 10 x 30 mm bolt 4 pcs 10 spring washer 4 pcs
10. 50 mm long and clamp it Connect the other end of the pipe to the fuel filter and clamp it Connect the banjo to the injection pump gasket must be placed on each side of the banjo Use hose clamps 10 5 mm in inside diameter Finally clamp the pipe to the crankcase 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 Remove the control panel from the control box 4 screw 8pcs 2 Disconnect the connectors on the wires to de tach the control panel and box 3 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 couplers See Fig 10 47 4 After disconnecting individual wires remove the control panel components Fig 10 47 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 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 r
11. E 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 in the fuse holder If the fuse is blown check for the cause of fuse blowing and then replace with a new one FUSE 10A NOTE If the DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing fuse blow 11 4 3 CHECK THE WIRING Check all the wires to be connected correctly Fig 11 9 11 4 4 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode rectifier with a circuit tester Refer to Section 9 7 DIODE RECTIFIER for the checking procedure 11 4 5 CHECK THE DC COIL Fig 11 10 Check the resistance between two brown leads from stator with a circuit tester RGD5000 60 Hz 120 V 120 V 240 V 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 12 WIRING DIAGRAM GENERATOR Resistor Flokd Winding ENGINE 57 Robin America Inc 940 Lively Blvd Wood Dale IL 60191 Phone 630 350 8200 Fox 630 350 8212 e mail sales robinamerica com www robinamerica com PRINTED IN THE USA Robin America Inc
12. EE d 2 Take out the grommet from the bottom face of the control box Fig 10 7 3 Pull out the wires for the oil sensor and electric starter and remove them from the connectors MES S M 32 Control Box 4 Remove the control box from the frame 10 mm spanner or box spanner Fig 10 9 1 Remove side plate A 6 bolt Remove the mount rubbers from side plate 2 Remove the nuts and bolts that fasten the generator and frame together 1 Remove the two bolts which fix the Nuts are welded to alternator to the generator base the generator base 2 Remove the four bolts and flange nuts which fix the engine to the engine base RUBBER V I 4pcs GENERATOR ENGINE BASE SIDE PLATE A 4 Pipe Frame 3 Lift the generator with a chain block Be careful to keep and dismount from the frame the belt in place See Fig 10 11 Fig 10 11 4 Remove engine base generator base and mount rubbers from frame Q4 86 FLANGE NUT 1pce GENERATOR 8 russer v 1pce 1 22 221 gt N Uf Recoil Starter 1 Remove recoil starter from rear cover 10 mm spanner or 3 box spanner Fig 10 13 Rear Cover Be careful not to lose 1 Take off the through bolt and remo
13. N Incandesent lamp heater etc Fluorescent lamp Motor approx driven tool general porpose 3000 Mercury lamp etc 2700 W approx 1 Table 7 16 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 de creasing 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 Voltage drop per 100 m Gauge NoJ Resistance Sectional wire element area mm wm pem pepe Lom o peres rm pev re ev Lm po peres s ev ev pov v pe pom pee ser C pe ar p v ov er rev Le os pese sm pv E pepe ov Table 7 2 Allowable current A Voltage drop indicates as 1 xRxIxL 100 resistance 100 m on the above table I means electric current through the wire A L means the length of the wire m The length of w
14. Robin Power Equipment SERVICE MANUAL RGD5000 Generator PUB GS1187 Rev 8 98 Robin SUBARU CONTENTS Title Title Section 1 SPECIFICATIONS Frequency 60 Hz Wemmoma 37 5 37 5A 18 8A AC ALTERNATOR DC Output 12 V 8 3 A 100 W Voltage Regulator Condenser Type Type Air Cooled 4 Cycle Diesel Engine Model DY41D Displacement 412 cm 25 14 cu in Rated Output 8 5 HP 3600 rpm ENGINE Fuel Diesel light oil Fuel Tank Capacity 4 2 U S gal 16 0 liters Rated Coutinuous Operation 2 0 hours Oil Capacity 2 3 U S gal 1 1 liters Starting System i Recoil Starter and Electric Starter Dimensions L x W x H 26 5 x 19 7 x 21 3 in 675 500 x 542 mm Dry Weight 95 kg 209 Ibs Electric starter motor is available as option 2 PERFOMANCE CURVES 2 1 MODEL RGD5000 3 5 Output Max 5000 W 5 ai Output Rated 4500 W Frequency 60 Hz 120 V u E 2k 2 E 1k 5 5 0 5 9 0 10 20 30 40 50 CURRENT Output Max 5000 W Output Rated 4500 W Frequency 60 Hz B OSEE EE Tiber Fat Voltage 120 V 240V Ir gir LL A VOLTAGE 240V ZEE AV di ER FREQUENCY Hz VOLTAGE V 0 5 10 15
15. 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 watt age of the appliance The electrical appliances generally have a label showing their rated voltage fre quency and power consumption input wattage The power consumption of an electrical appliance is the power necessary for using it When using a generator for operating an electrical appliance the power factor and starting wattage must be taken into consideration In order to determine the right size generator it is necessary to add the total wattage of all appliances to be connected to the unit Refer to the followings to calculate the power consumption of each appliance or equipment by its type 1 Incandescent lamp heater etc with a power factor of 1 0 Total power consumption must be equal to or less than the rated output of the generator Example A rated 3000W generator can tum thirty 100W incandescent lamps on 2 Fluorescent lamps motor driven tools light electrical appliances etc with a smaller power factor Select a generator with a rated output equivalent to 1 2 to 2 times of the power consumption of the load Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times lager than their running wattage Example A rated 250 W electric drill requires a 400 W generator to start it NOTE1 power factor correction capacitor is not ap
16. and different from short circuit condition in which a pointer of the tester goes out of its normal scale shows resistance to some extent When results of the checking indicates failure even in one section replace with a new one NOTE 3 Simpson brand analogue testers have the characteristics as same as the digital circuit tester 28 10 DISASSEMBLY AND ASSEMBLY 10 1PREPARATION 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 replace them temporarily to 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 D ROTOR PULLER REAR COVER PULLER JIG 10 3 DISASSEMBLY PROCEDURES nenn 1 Fuel Tank 1 Discharge fuel from the tank 1 Turn the fuel cock to close S 2 Disconnect the rubber pipe from the injection pump See Fig 10 1 3 Tum the fuel cock to OPEN O to discharge the fuel Do
17. c voltage Voltmeter cannot be checked with circuit tester Pilot lamp because its resistance is too large 9 2 AC RECEPTACLES Using a Dr Robin or a circuit tester check conti nuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel Fig 9 1 When continuity is found between the output terminals of the receptacle with a wire connected across these terminals the AC receptacle is normal When the wire is removed and no continuity is found between these terminals the receptacles are also normal AC receptacle Fig 9 2A Fig 9 2B 9 3 No FUSE BREAKER Circuit breaker Check continuity between each of two terminals NO at the rear of the no fuse breaker while it is mounted on the control panel Normally there is continuity between each of the two when the no fuse breaker is on while there is no continuity when the no fuse breaker is off 1 24 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 fol lowing table AY om CE PARAL 4 r Fig 9 4 MODEL Hz Voltage White Red Black Blue Yellow Yellow 120 240 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 th
18. dicated 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 13 6 SAFETY PRECAUTIONS 1 Use extreme caution near fuel A constant danger of explosion or fire exists ww 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 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 ex haust gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facilities during use 4 Operate the generator on a level surface If the generator is tilted or moved during use
19. e the condenser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 9 7 DIODE RECTIFIER Brown Brown ite Brown 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 a Checking table for analogue circuit tester Apply black minus needle of the circuit tester som oem we sers mem esee nena sem wenn eme omm Gem Table 9 4 1 Analogue circuit tester Apply red pius needle of the circuit tester Checking table for digital circuit tester Apply red plus needle of the circuit tester mel sem m pem nana comma sem Reser nenas cen omes oma oem sese eei Table 9 4 2 Digital circuit tester Apply black minus needie of the circuit tester NOTE 1 Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester polarity of tester needles should be reversed NOTE 2 Continuity means forward direction characteristics of the diode
20. ere is a wide variation of resis tance among coil windings or when measurement is performed at ambient temperatures differ ent from 20 C 68 F 25 9 5 ROTOR ASSEMBLY 1 Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals 0 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 combination of polarity Therefore if no resistance reading appears try checking in reverse polarity NOTE 2 If the circuit tester is not sufficiently accurate it may not show the values given and may give er roneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is Fig 9 5 performed at embient temperatures different from 20 C 68 F 2 Check if the surge absorber is bumt Check the resistance of surge adsorber Normal resistance is 62 8 Measure the resistance of the diode Fig 9 6 Polarity of circuit tester 9 6 CONDENSER Use a Dr Robin in capacitance meter mode to check the capacity of condensers NOTE Be sure to discharge condensers by short ing condenser leads each other before checking their capacitance or the accurate reading cannot be obtained NORMAL CAPACITY OF CONDENSER Table 9 3 If such an instrument is unavailabl
21. esistant type wires permissible temperature range 75 C or over in the specified gauge shown in the circuit diagrams 2 Install regulator oil sensor unit 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 6 nut to the bolt which fixes the condenser bracket to the inside of the control box See Fig 10 48 4 Attach the control panel to the control box 4 screw 8 pcs To Earth terminal Condenser bracket 11 TROUBLESHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING STATOR Remove control panel and disconnect black blue red and white wires at the connectors Measure the resistance between terminals on R HZ stator leads See Fig 11 1 Re aise Refer to Table 11 1 for normal resistance sta tor is faulty replace with a new one Fig 11 1 11 1 2 CHECKING CONDENSER instrument QC meter or C meter for mea suring capacity of condenser is available check the capacity of condenser See Fig 11 2 NORMAL CAPACITY OF CONDENSER Table 11 1 Fig 11 2 If such an instrument is unavailable the condenser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 52 11 1 3 CHECKING OF ROTOR 1 CHECKING FIELD COIL Remove rera co
22. ingle cylinder Robin diesel engine enables the new RGD series generators to be very compact in size and light in weight 3 7 RELIABLE PERFORMANCE WITH MINIMAL MAINTENANCE A brushless alternator eliminates troublesome brush maintenance A drip proof alternator design A trouble free condenser voltage regulator A fuseless circuit breaker A dust proof oil bath air cleaner The OIL SENSOR automatically shuts the engine off whenever the oil level falls down below a safe level preventing engine seizure 3 8 LONG LIFE DURABILITY 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 4 1 EXTERNAL VIEW Rocker cover Air cleaner Full power switch Dual voltage type only Speed control lever No fuse breaker Solenoid for Oil sensor Oil gauge filler DC fuse Key switch Electric starter as option a dm Saye DC output terminal Electric starter Fuel filter Earth terminal Electric starter as option Fuel tank Recoil starter Electric starter as option 4 2 CONTROL PANEL RGD5000 60Hz 120V 60Hz 120V 240V TYPE Voltmeter Full power switch No fuse breaker DC fuse AC Pilot lamp receptacle Key switch Ea
23. ire indicaters round length it means twice the length from generator to electrical tools 17 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 follow ing 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 Fig 8 1 time to change batteries 4 Tester and accessories are installed in a handy sturdy case for easy carring Test leads with needle probes 1 set Test leads with jack plugs 1 set ___________ Table 8 1 SPECIFICATIONS The Dr Robin generator tester can be ordered from Robin generator distributors by the following part number Dr Robin Part Number 388 47565 08 If you do not have a Dr Robin generator tester use the instruments described in the following section for checking generator parts 18 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 010 150 Type with an output voltage of 110 or 120V 0 to 300 Type with an output voltage of 220 230 or 240V to 150V t
24. l and do not overcharge the battery 21 8 4 MEASURING INSULATION RESISTANCE Use a Dr Robin generator tester in megger tester mode or use a megger tester to check the insula tion resistance Connect a megger tester to one of receptacle output terminals and the ground ter minal then measure the insulation resistance An insulation resistance of 1 megohm or more is nor mal 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 resis tance of the stator rotor and control panel indi vidually 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 ROTOR Measure the insulation across one of the soldered terminals of the rotor andthe core Fig 8 12 CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Fig 8 13 Any part where the insulation resistance is less than 1MQ has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 23 9 CHECKING FUNCTIONAL MEMBERS 9 1 VOLTMETER Check the the voltmeter if it is tumed on by apply ing specifi
25. m the window of the rear cover 4 Tap lightly and evenly the upper surface of the board on the rear cover with plastic hammer to press fit the rear cover over the stator See Fig 10 28 5 Fix the stator to the rear cover with four bolts washers and spring washers See Fig 10 29 6 bolt 4 pcs 6 washer 4 pcs 6 spring washer 4 pcs Tightening torque 4 9 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 40 The dimensions of the stator bolts are shown in Table 10 1 ww Ts 2 6 Table 10 1 10 4 4 REAR COVER 1 Attach the bush over the lead wires drawn out from the rear cover Press the bush and into the window of the rear cover See Fig 10 30 Fig 10 30 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 See Fig 10 31 Fig 10 31 41 3 Fix the rear cover to the adapter with four bolts spring washer and washer SP TREE 6 x25 mm bolt 4 pcs 6 washer 4 pcs 6 spring washer 4 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 10 4 5 RECOIL STARTER 1 Remove the through bolt which has been ten tatively attached to the rotor 2 Insert the key into the keyway of the rotor shaft See Fig 10 33 Then insert the spacer Tapping the starter pulley with a plastic ham mer attach the
26. not lose the gasket 17 mm spanner Wipe off spilt fuel Disconnect the fuel pipe and return pipe from the tank bottom See Fig 10 2 1 Remove the hose clamp and pull the fuel pipe off from the tank 2 Remove the banjo bolt that fastens the return pipe Pliers Do not lose the gasket 12 mm spanner i 3 Remove the fuel tank 12 mm spanner or After removing the nut and washer re box spanner move the fuel tank See Fig 10 3 8 FlangeNut Remove the fuel filter Pliers 1 Remove the hose clamp and pull out the air return pipe See Fig 10 4 2 Remove the fuel filter bolts and the 12 mm spanner or fuel filter FUEL TANK mem emm 2 Battery 1 Remove battery cable from battery Be careful not to short Only electric Remove the negative side cable first and starter type then the positive side 2 Remove battery from battery base Remove the two nuts that fasten the 10 mm spanner or box spanner battery and take off the battery holder battery bolts and battery 3 Remove battery base from the pipe 10 mm spanner or box spanner BATTERY CABLE BATTERY BASE BATTERY BOLT PIPE FRAME Fig 10 5 a ee T RN 3 Control Box 1 Take off the bushing from the bottom Press the upper end of the control box and pull out the bushing
27. o 330V Dual voltage type 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10A 20A 100A 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range 19 4 CIRCUIT TESTER Used for measuring resistance etc Fig 8 5 5 MEGGER TESTER Used for measuring generator insulation re sistance Select one with testing voltage range of 500V 6 TACHOMETER Use the contactless type tacho meter 20 8 2 AC OUTPUT MEASURING 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 Susie mv 3 Voltage range 117 130 V 235 260 V Table 8 2 8 3 DC OUTPUT MEASURING To DC Termina Fig 8 9 Measurement of DC output is executed with the switch turned ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal NOTE If a battery is connected as a load to the generator the DC output voltage will increase by approximately 1 to 2 V Therefore carefully observe the electrolyte leve
28. ondenser coil At this time a small flux is produced with which the magnetic force at the rotor s magnetic pole is intensified When this mag netic force is intensified the respective voltages in the main coil and condenser coil rise up As the current 8 increases the magnetic flux at the rotor s magnetic pole increases further Thus the volt ages at the main coil and condenser coil keep rising by repeating this process 3 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 b flows through the field coil and magne tizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 3000 to 3300 rpm 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 8 increases the density of magnetic flux across the rotor core rises As a result the current flowing in the field coil increases and the genera tor o
29. pipe Fuel filter assy 6 x 129 x 250 mm Fig 10 46 49 2 Mount the fuel tank on the mount rubbers attached to the side plates Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft lb 8 0 nut 4pcs 8 spring washer 4 pcs 3 Connect the fuel pipe a Install the fuel filter assembly on the boss on the side of the adaptor generator 8 x65 mm bolt 1 b Connect the other end of the pipe installed in Step 1 to the fuel filter Slide the hose clamp over the pipe connect the pipe to the fuel filter and clamp the pipe at the cor rect point Then secure the pipe with the purse lock NOTE Connect the shorter pipe of fuel pipe 29 complete to the fue filter The hose clamp for the rubber pipe has an inside diameter of la5 mm and that for fue pipe 29 compiete is 7 8 mm in inside diameter c Connect the longer pipe of fuel pipe 29 complete to the engine nozzle The nozzle must be pulled up from the cylinder head before connecting the pipe to it After pulling the nozzle up slide the hose clamp 7 8 mm in inside diameter over the pipe connect the pipe to the nozzle and fasten the pipe with the hose clamp at the correct point Then install the nozzle on the head Mount the bracket on the blower housing and secure the pipe with the clamp d Connect the fuel filter and injection pump with pipe Fit the banjo to the rubber pipe 6 mm in inside diameter 12 mm in outside diameter 2
30. plied to the fluorescent lamp the more power Shall be required to drive the lamps 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 effi ciency should be taken into account as explained in ftem 5 on the following page 3 Mercury lamps with a smaller power factor Loads for mercury lamps require 2 to 3 times the indicated wattage during start up Example A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on A rated 3000 W generator can power two or three 400 W mercury lamps 4 Initially loaded motor driven appliances such as water pumps compressors etc These appliances require large starting wattage which is 3 to 5 times of running wattage Example A rated 900 W compressor requires a 4500 W generator to drive it 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 con sumption so that the excess power generated by the generator can be used forother electrical appliances NOTE 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 15
31. rent for each receptacle Be careful not to use the receptacies and AC plugs beyond the specified amperage limits to prevent burning NOTE 1 If your generator has pecu liar to your country Table 5 2 does not e apply TWIST NOTE 2 The generator for U S A market is equipped with NEMA standard recep tacles shown in table 5 2 Use the proper plug for connecting ap pliance to the generator rm Caution To connect the appliance to locking receptacle insert the plug into the re ceptacle and turn it clockwise to lock Fig 5 8 ELCHE SN D m r3 125V NEMA NEMA 20A 5 20R 5 20P CX 125V 250V NEMA NEMA 20A L14 20R L14 20P 125V NEMA NEMA 30A L5 30 L5 30P Table 5 2 GFCI Ground Fault Circuit Interrupter Receptacle duplex Locking Receptacle Locking Receptacle 10 5 3 GENERATOR OPERATION PERMANENT MAGNET FOR INITIAL EXCITATION FIELD COIL STATOR STATOR MAIN COIL RECEPTACLE APPLIANCE SURGE ABSORBER DIODE CONDENSER COIL CONDENSER Fig 5 9 5 3 1GENERATION of NO LOAD VOLTAGE 1 When the generator starts running the permanent magnet built in to the rotor generates 3 to 6V of AC voltage inthe main coil and condenser coil wound on the stator 2 As one or two condensers are connected to the condenser coil the small voltage at the condenser coil generates a minute current 8 which flows through the c
32. rminal 8 Terminal 10 4 8 BATTERY 1 Attach ttach the battery base to the frame Tightening torque 6 0 10 mm bolt 2 pcs 3 9 5 9 N m 40 60 kg cm 2 9 4 3 ft lb 2 Mount the battery on the battery base and fix it with two battery bolts and a battery angle See Fig 10 45 6 nut 2 pcs 6 spring washer 2 pcs Tightening torque 3 9 5 9 N m 40 60 kg cm 2 9 43 ft Ib 3 Attach battery cords to the battery Attach the positive cord first and then the negative cord Fasten the other end of the negative cord to the engine base using the engine mount nut 6 Nut 2 pcs 6 Spring washer 2 pcs Battery Battery spacer 2 pcs Battery angie Battery 6 2 pcs Battery bolt Pipe frame 10 4 9 FUEL TANK 1 Connect fuel pipe 29 complete and rubber pipe 6 mm inside diameter 12 mm outside diameter 170 mm long to the fuel tank a Connect the rubber pipe and fasten it with the hose clamp 10 5 mm inside diameter b Connect fuel pipe 29 complete to both ends of the banjo and tighten it with banjo bolt using two pieces of GASKET ALUMINUM Tightening torque 7 8 9 8 N m 80 100 kg cm 5 8 7 2 ft lb Fuel tank 1 Hose clamp inside DIA 7 8 2 Hose clamp inside DIA 10 5 Gasket Aluminum Banjo bolt Fuel pipe 29 complete Purse lock Rubber pipe 69 x 12 x 170 mm To Injection pump Rubber
33. rth terminal DC output terminal 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL MODEL NAME stuck on the side wall of contro box NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service Serial number 5 CONSTRUCTION AND FUNCTION 5 TCONSTRUCTION Recoil starter Stator complete Flywheel Rotor complete Support ring G7 A j SS HER through bolt Mount rubber Starter pulley Driving shaft Generator base Stator bolt Ball bearing Adapter 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 or two condensers are installed in the con trol box and are connected to the condenser coil of the stator These condensers and condenser coil regulate the output voltage 5 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action A diode rectifier and surge absorber is mounted inside of the insulator 7
34. there is a danger of fuel spillage and a chance that the generator 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 leakage and electric shock 6 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 Optional parts 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 7 rennen aw res Awa cure Tee a 0506 muerte 4 meses Pewee ma Table 6 1 7 Be sure to check and remedy the cause of circuit breaker tripping before re setting it on CAUTION If 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 usi zd 7 RANGE OF APPLICATIONS Generally the power rating of an electrical appliance indicates the
35. utput voltage is prevented from decreasing 11 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 r 4 or 110 220V 420V 110V 120 110V Fig 5 10 REC 2 330 120V 110V Fig 5 11 Switch LOWER VOLTAGE HIGHER VOLTAGE Position RECEPTACLE RECEPTACLE 1 pa V Rated output T 120 V 1 yn V Half of rated output Rated output 120 240 V Table 5 4 12 Two main coils are 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 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 indicated 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 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 in
36. ve Box spanner or the starting pulley and spacer from rotor the key at removing socket wrench shaft Apply a box wrench on the head starting pulley Hammer of through bolt and hit the wrench handle with a hammer counterclockwise to loosen STARTING PULLEY Fig 10 14 Fig 10 15 6 Rear Cover 2 Take off 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 1 Remove the four bolts which fasten 10 mm spanner or the rear cover to the adapter of the box spanner engine 66bolt 4 pcs 2 Use a special tool REAR COVER _ Insert the two bolts Special tool PULLER to remove the rear cover sufficently and evenly 17 mm spanner a Insert the two bolts of the or the thread hole may Driver special tool into the thread hole be damaged at remov of the rear cover ing Fig 10 16 Fig 10 17 In case that REAR COVER PULLER is un available remove the rear cover by the follow ing instructions 1 Insert the through bolt into the rotor Do not give a strong Box spanner or shaft and tighten lightly hit on the rear cover socket wrench Hit on the boss and legs of rear cover boss or legs Plastic hammer with a plastic hammer Fig 10 18 36 7 Stator 1 Remove
37. ver and startor Unsolder the coil from the terminal on the rotor See Fig 11 3 N N N VAN SN SN SS Measure the resistance of field coil with a circuit tester See Fig 11 4 Remedy MODEL RESISTANCE Table 11 2 If the resistance is not normal replace rotor with a new one 2 CHECKING OF DIODES AND RESISTOR ON THE ROTOR Unsolder and take out the diodes and a resistor from rotor Measure the resistance of diodes Polarity of circuit tester Continuity exists Fig 11 5 Each rotor has three diodes Check the resistance of each diode 53 Measure the resistance of surge absorber connected to the diode holder Normal resistance is Q Measure the resistance of surge absorber connected to the diode holder Remedy 1 If the magnetic force of rotor magnets is weak or if the surge absorber is not good replace the rotor with a new one 2 If the diode is not good replace it with a new one CAUTION in case the diode troubles are frequent check the surge absorber because it might be broken even if its resistance is normal Q In such a case replace the rotor with new one Reassembling Surge absorber 1 As shown in Fig 11 6 place the white mark on the magnet to left and solder the diodes so that cathode mark is to be placed at the bottom 2 Solder the coil ends to the terminal 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW
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