Subaru Robin Power Products RGX3510 User's Manual
Contents
1. 43 8 4 Measuring Insulation Resistance 44 CHECKING FUNCTIONAL MEMBERS 46 9 1 Volt Meter 46 9 2 AC Receptacles 46 9 3 No Fuse Breaker 47 9 4 Stator 47 9 5 Rotor Assembly 48 9 6 Condenser 48 9 7 Diode Rectifier2. 49 9 8 Oil Sensor Option 50 Disassembly AND AssEMBLY 5l 1o 1 10 2 10 3 10 4 Preparation and Precautions 51 Disassembly Procedures 52 Assembly Procedures 59 Checking Disassembly and Reassembly of the Control Box 65 Section Title Page 11 TROUBLESHOOTlNG 11 1 No AC Output 11 2 ACvoltage istoo high ortoo low 66 66 68 11 3 AC voltage is normal at no load but the load cannot be applied 69 69 71 74 11 4 No DC Output 11 5 Idle Control Option for60 Hz only
3. 1800W 1500W 60Hz 220v CURRENT A 12 l k 1 5k t n 3 0 5k 2 Y t 3 0 o 5 CURRENT A RGXl810 Output M a Rated Frequency Voltage 1500W 1300W 50Hz 240V t t 2k 1 5k t 0 5k to RGXl810 Output Max Rated Frequency Voltage 1500W 1300W 50Hz 1 1 OV 220V CURRENT A 4 t2k t 3 1 5k 5 5 0 1k 0 5k 0 RGX1810 Output Max 1800W Rated Frequency 60Hz Voltage 1 1 OV 220V 1500W CURRENT A1 2 2 MODEL RGX2410 1 5k 1 CURRENT A C z 61 3 60 s 59 L h gt V 3 t 120 E 110 Y 100 s e 0 4 8 12 16 20 1 5k 0 5k 0 LO CURRENT A1 5 0 CURRENT A 2k 1 5k z RGX2410 Output M a Rated Frequency Voltage 2400W 2000w 60Hz 220v 0 0 2 4 6 8 10 12 CURRENT A 6 t 53 52 z 51 5 50 E Y 0 x s 49 240 E 220 s 120 g 200 110 100 0 4 8 12 16 20 RGX2410 Output Max rk t 2000w Rated 1700W
4. 12 WIRING DIAGRAM 1 SPECIFICATIONS T I I T i i 0 0 r r N N 5 5 I n m E Q 0 O W Q a I Ln m I 01 07 m P CI CI 3 a CI tlOlVNtl3llV 3NIDN3 1 gt j c 6 si 0 d i N g ln N g W 3 0 0 0 In 3 0 0 m m l I i i i I x 0 cd Q u s I I X 3 X J a c m Y 8 w U L L L i _ klOlVNkl3llV 3NIE N3 i I 2 2 PERFOMANCE CURVES 2 1 MODEL RGX1810 2k 1 5k t l k z W I 0 5k 2 0 0 s RGXl810 Output M a Rated Frequency Voltage 1500W 1300W 50Hz 110v 5 CURRENT A RGXl810 Output Max 1800W 1500W 1 1 ov 120v 2k t Rated Frequency 60Hz Voltage 1 5k CURRENT A F l k 5 n D 5k RGX1810 Output M a 1500W 2k Rated 1300W 50Hz Frequency Voltage 220v 5 CURRENT A 3 t t h 3 1k 5 n 0 5k I RGXl810 Output M a Rated Frequency Voltage
5. 5500W Rated 4aoow Frequency Voltage 60Hz 1 1 OV 120V z RGX5510 Output M a 5000W 4400W 5k t Rated Frequency 50Hz 4k Voltage 220v CURRENT A 10 6k 5k t 4k z 3k 2k l k 0 0 2k 5 1k 0 RGX5510 Output M a Rated Frequency 5500W 4800W 60Hz Voltage 220v CURRENT A 2k 1k 0 CURRENT A 11 RGX5510 Output M a 5500W 4800W 1 t Rated Frequency 60Hz Voltage 1 1 OV 220V 12OV 24OV 5k s I 4k g 3 3 0 t 3k 2k 1k 0 CURRENT A1 2 5 DC OUTPUT Option DC Voltage DCAmpere DC output 12v 8 3A 1 oow The voltage curve shown in the left indicates the characteristic of DC output when charging a battery The voltage ma be decreased by 20 when the resistance load is applied NOTE It is possible to use both DC and AC outputs simultaneously up to the rated output in total 12 3 FEATURES 3 1 BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance 3 2 CONDENSER TYPE V
6. 120 140 kg cm i 8 7 10 1 ft lb Fig 10 24 NOTE When tightening the nuts slightly lift the engine and alternator assembly so that the weight is not applied to the mount rubbers 3 Attach the side plate frame M6 x 10 mm bolt 2 pcs Attach fuel tank mount rubbers to side plates The nuts for mount rubbers are welded to side plates 3 9 5 9 Nom 2 9 4 3 ft4b Fig 10 25 10 3 6 CONTROL BOX Mount the control box assembly to the frame Refer to Section 10 5 for disassembly checking and reassembly procedures of the control box 2 Connect the wires drawn out from the stator to the wires from the control box Connect the oil sensor u ires at the same time NOTE Connect the wires of the same color 62 3 Press the upper end of the bushing into the bottom window of the control box Attach the grommet for the oil sensor wires to the rear panel of the control box 4 Mount the control box to the frame 346 X12 mm flange bolt 3 pcs I Tightening torque I 3 9 5 9 Nom 40 60 kg cm 2 9 4 3 ftolb 5 Fasten the one earth cable with 86 terminal drawn out from the control box to the rear cover leg M8 nut 1 pce 5 8 7 2 fblb I Fig 10 26 Fig 70 27 Fasten the other earth cable with 5 terminal to the unpainted bolt hole on the frame See Fig 10 36 5 0 TERMINAL FRAME 6 TE
7. Generator Model RGXl810 RGX2410 RGX3510 RGX5510 CONTENTS Section Title Page 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS O O O O C O O 00 0 0 O O O O 1 PERFORMANCE CURVES 3 FEATURES 13 GENERAL DESCRIPTION 14 4 1 External View 14 4 2 Control Panel 15 4 3 Location of Serial Number and Specification Number 23 Construction AND FUNCTION 24 5 1 Construction 24 5 2 Fu
8. 7 RANGE OF APPLICATIONS Generally the power rating of an electrical appliance indicates the amount of work that can be done by it The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance The electrical appliances generally have a label showing their rated voltage frequency and power consumption input wattage The power consumption of an electrical appliance is the power necessary for using it When using a generator for operating an electrical appliance the power factor and starting wattage must be taken into consideration In order to determine the right size generator it is necessary to add the total wattage of all appliances to be connected to the unit Refer to the followings to calculate the power consumption of each appliance or equipment by its type 1 Incandescent lamp heater etc with a power factor of 1 O Total power consumption must be equal to or less than the rated output of the generator Example A rated 3OOOW generator can turn thirty lOOW 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 Gemrally 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 requi
9. 74 3 RGXl810 RGX2410 1 1 OV 22OV 1 20V 240V GENERATOR CONTROL BOX 7 F 1 DC OUTPUT Available as option 4 RGX3510 1 lOV 120V GENERATOR 1 I CONTROL BOX DC OUT DC OUTPUT Available as option 75 5 RGX3510 220V 240V DC OUTPUT Available as option 6 RGX3510 1 1 OV 22OV 120V 240V GENERATOR CONTROLBOX I I I I I I NFB DC OUT E DC OUTPUT Available as option 76 7 RGX5510 1 1 OV 120V GENERATOR CONTROL BOX 1 I A K I DC OUTPUT Available as option 8 RGX5510 220V 240V GENERATOR CONTROL BOX 77 9 RGX5510 1 1 OV 220V 1 20V 240V GENERATOR CONTROLBOX 1 I I NFBl lc ORAN YELLOW YELLOW T DC OUT 0 BROWN BROWN WHITE 1 I DC OUTPUT Available as option 78 ENGINE WIRING DIAGRAM RECOIL STATER TYPE _ r m 4 I J r 0 I _ J ENGINE 79 0 ENGINE WIRING DIAGRAM ELECTRIC STATER Optional Equipment TYPE for RGX3510 7 I 0 ENGINE WIRING DIAGRAM ELECTRIC STATER Optional Equipment TYPE for RGX5510 I GREENiWHITE Ir h The battery cords have a cross sectional area of 22 mm 0 75 mm2 1 25 mm2 81 Symbols I Part Name M c AC Winding SC 1 Auxiliary Winding DC DC Outpgt Terminal T Diodes Stack Assy D C I Condenser Field Winding FC DC Winding F
10. I i STATOR COVER STAT I I Fig 10 12 55 Step Tool Remarks Description Part to remove 5 Stator I i j I 6 STATOR COVER CLAMP Fig 70 73 1 j Take off the through bolt i Apply a box wench on the head of j through bolt Hit the wrench hzndle with I a hammer cocnter clockwise to loosen I Fig 10 14 2 Put the engine on the working table recoil starter side down Box wrench Plastic hammer 56 Step Part to remove Description Remarks i i 6 Rotor 3j Use a bolt and oil as a tool for pulling j I out rotor in the following procedures 1 1 Pour engine oil into the center hole of i rotor shaft Fill Lvith oil to the shaft end See Fig 10 15 thread size 1 2 Prepare a bolt with the following i I I i i RGX1810 2410 3510 h IlOXP1 25 RGX5510 M12XP1 50 3 Apply a few turns of seal tape around the tip of the bolt i I SeeFig 10 16 I Tool Fig 10 15 Fig 10 16 4 Screw the bolt into the thread of the rotor shaft j 5 Torque the bolt using a socket wrench until the rotor comes off loose The hydraulic pressure inside the rotor i shaft takes apart the rotor from the engine shaft i 4 U ipe off oii thoroughly from rotor shaft i I and engine PTO shaft I Fig 10 1 7 Socket wrench 57 step I Part to remove Description Remarks i To
11. I Frequency i 25 70HZ K I Resistance m L i 0 1 1 999 0 i Condenser Capacity I 10 1 00 Q F i Insulation Resistance I 314 0 Circuit Proiector Power Sosrce 2 x 6F44P 006P Dry Cell Battery I Fuse i Tesi leads with needie probes 1 sei 1 Test leads with jack plugs 1 set Accessories I Dimensions L x W X H 285 mmx200 rnmxl10 mrn Weight 1 6kg Table 8 1 The Dr Robin generator tester can be ordered from Robin generator distributors by the following part number I Dr Robin Part Sumber 388 37565 08 I If you do not have a Dr Robin generator tester use the instruments described in the following section for checking generator parts 40 8 1 2 INSTRUMENTS j 1 VOLTMETER AC voltmeter is necessary The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as G i I e 0 to 15OV Type with an output voltage of i a follows G 5 I 110 or 120V 4 3 0 to 3OOV Type with an output voltage of 220 230 or 240V 0 to EOV 0 to 33OV Dual voltage type FOR AC Fig 8 2 2 AMMETERS AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10AJ 20AJ 100A 3 FREQUEXCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltag
12. resistance may be measured only when tester probes touch the terminals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity Remedy If the resistance is not normal replace rotor with a new one I Fig 11 5 67 3 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 VOLTGE 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 1 w Loosen the lock nut on the adjusting screw w Turn the adjusting screw clockwise to de crease engine speed or counter clockwise to increase engine speed Normal engine speed at no load 31 00 31 50 r p m for 50HZ ype 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 Fig 11 6 HIGH SPEED rf Q LOW SPEED i i i i I I RGX5510 Fig 11 7 11 2 4 CHECKING ROTOR Check rotor referring to Step 11 1 3 68 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 CH
13. to one of receptacle output terminals and the ground terminal then measure the insulation resistance An insulation resistance of 1 megohm or more is normal The original insulation resistance at the time of shipment from the factory is 10 megohm or more If it is less than 1 megohm disassemble the generator and measure the insulation resistance of the stator rotor and control panel individually 0 STATOR 1 Measure the insulation resistance between 2 Measure the insulation resistance between 3 Measure the insulation resistance between 4 Measure the insulation resistance between BLUE lead and the core WHITE lead and the core YELLOW lead and the core BROWS lead and the core 0 ROTOR Measure the insulation across one of the soldered terminals of the rotor and the core Fig 8 IO Fig 8 1 1 Fig 8 12 44 Measure the insulation resistances between the live parts and the grounded parts 0 CONTROL PANEL i Fig 8 13 Any part where the insulation resistance is less than l M Q has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 45 9 CHECKING FUNCTIONAL MEMBERS 9 1 VOLTMETER Check the voltmeter if it is turned on by applying specific voltage i Voltmeter cannot be checked with circuit tester AC because its resistance is too large I i i Voltmeter I Fig 9 1 9 2 AC RECEPT
14. Fuse NFB j No Fuse Breaker NFB 1 No Fuse Breaker FP SW I Fdll Power Switch S SW i Engine Stop Switcn I os Spark Plug SP Oil Sensor M G j Magneto IG j Ignition Coil MG SW Magnetic Swiich E Earth Terminal Ground Terminal ST M Starting Motor KEY SW Battery BAT Key Switch V Voltmeter RECl RECz AC Output Receptacle 22OV 240V AC OGipUt Receptacle 1 10V320V REC3 AC Output Receptacle Total 15A MAX 220 240V REC4 AC 0s put Receptacle Total 15A M A X 11 0 120V AC Output Receptacle 1 1 OV 120V total 30A RECe AC Output Receptacle Total 20A MAX RECs 82 I ISSUE EMD GS1001 I FUJI HEAVY INDUSTRIES LTD
15. a e This his prevents the sensor from making an unnecessary stop of the engine by momentary lowering of the oil level due to the engine being slanted or affected by vibration in spite of sufficient oil in the crankcase n amp Stopping circuit This automatically stops the engine running Also the LED indicator for warning can be lit amp hile the engine is being stopped We have the wires to be connected to LED available 5 5 5 CAUTIONS TO BE TAKEN ON HANDLING THE SENSOR 1 Oil sensor unit a Be sure not to damage each wire Broken or short circuited power supply wires andior a grounding wire in particular may lead to malfunction or breakdown i amp The sensor is not interchangeable from engine to engine because the sensor is to be exclusively A installed individually in each engine employed 2 Mounting and wiring of oil sensor unit A amp Although this has been designed to have enough anti noise properties in practical use do not route the sensor wirings in the vicinity of noise generating sources such as ignition plugs or high voltage cords This may cause malfunction or breakdown Since capacity of power source is limited current flown in the electronic circuit of the sensor is kept as low as possible Be sure to use terminals with a high contact reliability of more than that of tinned terminals n 3 Operation of oil sensor n amp If operating with the engine kept tilted oil surface insid
16. box 3 Remove the condensers and diode rectifier from the control box 4 After disconnecting individual wires remove the control panel components NOTE DC fuse full power switch and pilot lamp have their wires soldered Unsolder them to remove those parts if necessary 10 4 3 REASSEMBLY 1 Install the receptacles no fuse breaker fuse terminals switches etc on the control panel and wire 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 them 3 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 30 Attach the control panel to the control box 4 ScreLV 6 pcs RGX1810 RGX2410 RGX3510 M4 scre v 8 pcs RGX5510 1 2 1 5 Nom REAR COVER CLAMP M4 NUT WELDING NUT EARTH WIRES To EARTH TERMINAL CONDENSER BRACKET I I I I I I Fig 10 30 65 11 TROUBLESHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING CONDENSER 1 Check the capacity of condensers using a Dr R0bin generator tester in capacitance meter mode N
17. of a transistor incorporated ignition coil and a permanent magneto built in flywheel which is press fitted on the rotor shaft of the generator IGNITION TIMING I i IGNITION COIL I FLYWHEEL COOLING FAN PLUG 1 When the permanent magneto built in flywheel starts rotating power is generated in the primary coil of the ignition coil and current flows to the resistor 13 From the resistor current flows to the power transistor With this current the power transistor turns on releasing current B This stage corresponds to the closing of contact points 2 As the flywheel comes to the point of ignition the ignition timing detecting circuit is activated while the current is flowing through the circuit hen the ignition timing detecting circuit is activated the signal transmitter transistor actuates with current flowing When current a starts flowing current 3 flowing through the power transistor is cut quickly As a result high voltage is produced in the secondary coil and this voltage is applied simultaneously to the spark plug n hich ignites for ignition This stage corresponds to the opening of contact points 32 5 5 OIL SENSOR 5 5 1 DESCRIPTION 0 The oil sensor mainly functions to detect position of the surface of engine oil in the crankcase of engines for general use and to stop the engine automatically when the oil level goes down below the lower limit specified This prevents seizure of engin
18. of the circuit tester Analogue circuit tester Brown Brown Orange I BrownWhite Brown i NO continuity I NO continuity cmtinuity I Brown I No continuity j I NO continuity Continuity I Orange I Continuity Continuity Continuity 1 Brown White No continuity No continuity j No continuity i i i Apply red needle of the circuit tester I i Table 9 4 1 49 W Checking table for digital circuit tester Apply red needle of the circuit tester Digital circuit tester I Brown j Brown I Orange Brown White I Brown Brown I NO contir uity 1 1 NO continuity i NO continuity I Ccntinuity Orange i Continuity i Continuity No coniinuiiy Continuity Continuity Apply black 0 needle of the circuit tester i I Brown White I No continuity I No ccntinuity No continuity Table 9 4 2 NOTE 1 NOTE 2 NOTE 3 Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester polarity of tester needles should be reversed Continuity means forward direction characteristics of the diode and different from short circuit condition in which a pointer of the tester goes out of its normal scale shows resistance to some extent When results of the checking indicates failure even in one section replace with a new one Simpson brand analogue testers have the characteristics as same as the digital ci
19. 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 voltage in the field coil and the diode rectifier in the field coil circuit rectifies this AC voltage into DC Thus a DC current s flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil When generator speed reaches 2700 to 2800 rpm 50Hz type or 3000 to 3300 rpm 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 in the condenser coil When current i increases the density of magnetic flux across the rotor core rises As a result the current flowing in the field coil increases and the Eenerator output voltage is prevented from decreasing 28 5 3 3 FULL POWER SWITCH The full power switch is provided for the dual voltage type to take out the full rated power from one receptacle in each voltage 0 Dual voltage type RGX
20. 0 I I Frequency 50Hz 60HZ i 50HZ 60Hz 50Hz 60Hz 50Hz 60Hz i lncandesent lamp I heater etc I 1300W 1500W I 1700W 2000W I 2500W I 3000W i 4400W 4800W i Fluorescent l a q Pvlo3r driven r w 1 geserai purpose IYCtOi etc I I I I i I I Mercury lamp etc approx approx approx approx approx approx approx approx I 400W I 400W I 400W I 800W 1 800W I 1600W I 1600W I 16OOW I Wate pump Tzble 7 1 350W I 400W I 500W 600W I 700W I lOOOw I 1100W 300W coqressor etc approx approx I approx approx I approx approx approx approx 38 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 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 2 Cable length Table 7 2 8A 8A 10A 12A I Sectional I Gauge No Resistance Voltage drop per 100 m area mm2
21. 10 I 1 1 ov 120v 14 A 60Hz 220V 240V I 7 A 1 1 OVj220V 120Vi 240V 7A 2 Pole 2 Element I 11ov 18A 120v 15 A 240V 7 A I 1 50Hz 220v 8 A I RGX2410 i 1 1 ovi220v j 8A 2 Pole 2 Element 12OV 240V 7A 2 Pole 2 Elexent llnv 17nv I 1 RA i _ I I 60Hz 1 220v 2cov 9A 1 j 1 1 OVi220V 120V 240V I 9A 2 Pole 2 Element I I l l 0 V 120v 25 A 22 A At I 1 I50Hz I zzuv I 1 Z H 240V 10A RGX3510 I 1 1 ovj220v 12A 2 Pole 2 Element i 120V 240V 1 OA 2 Pole 2 Element 1 1 ov 120v 27 A RGX55 0 r Total output amperage 60HZ 220V 240V I 14 A 11 OVi22OV 120Vi240V I 14A PPole 2 Element I 11 ov 120v Total output amperage 40 A 30 A Output from 30A receptacle 50HZ 220V 240V 20 A Output from 30A receptacle 30 A i Total output amperage 20A PPole 2 Element i 1 1 OV 22OV 120Vi240V Total output amperage 11 ov 120v 40 A I Total output amperage i 30 A I Output from 30A receptacle i 60Hz 220V 240V I 30 A j OutDut from 30A receDtacle 22 A Total output amperage 1 1 OVi220V 1 20V 240V 22A 2 Pole 2 Element I Total output amperage T2S e 5 7 26 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 anothe
22. 1810 2410 3510 N F B k Qj _ I I Q REC 11 OV or 120V RECr 220V or 240V Fig 5 9 I I I Lower Voltage Receptacle Higher Voltage REC 2 REC 1 Receptacle Harf of rated at each Receptacle out put Rated output Table 5 3 29 0 Dual voltage type RGX5510 120 24ov r i or 110 22OVl 240V or 22OVl I 120V or llOV1 Fig 5 10 Ret 1 Rec 2 Ret 1 r i I MC Fig 5 1 1 Switch i LOWER VOLTAGE HIGHER VOLTAGE Position I RECEPTACLE RECEPTACLE 11ov 120v I or I Rated output i No output can be taken 110 220v Half of rated output Rated output i 120 24OV Table 5 4 Fig 5 12 30 Two main coils are wound over stator core Each main coil outputs half the rated power at the lower voltage llOV 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 llOV or 120V the switch position is as indicated by the lower solid line in the diagram Fig 5 10 is a simplified representation of this circuit showing the two main coils connected in paralle1 h 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 i
23. 220V 240V TYPE DC FUSE Option I J NO FUSEBREAKER START SWITCH Option EARTH GROUND TERMINAL DC OUTPUT TERMINAL Option 20 RGX5510 OHZ 60H lIOV 220V 120V 240V TYPE 220V RECEPTACLE VOLTMETER FULL POWER SWITCH NO FUSE BREAKER DC FUSE Option START SWITCH Option I 1 1 OV RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL Option RGX5510 50Hz 220V WITH SPECIAL RECEPTACLE I VOLTMETER DC FUSE Option 220V RECEPTACLE NO FUSE BREAKER START SWITCH Option EARTH GROUND TERMINAL DC OUTPUT TERMINAL Option 21 RGX5510 AUSTRALIA 50Hz 240V VOLTMETER DC FUSE Option NO FUSEBREAKER I START SWITCH Option 240V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL Option 22 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 control box NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service PEL MODEL NAME 23 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION REAR COVER ROTOR COMPLETE STATOR COMPLETE MOUNT RIBBER STATOR BOLT BALL BEARING THROUGH BOLT FRONT COVER 5 2 FUNCTION 5 2 1 STATOR The stator consists of a laminated silicon steel j I sheet core a main coil a
24. 6 2 92 1 38 1 38 120V 240V 1 20Vi240V 2 92 1 16 1 16 60 1 1 ov 220v 1 1 OV 22OV 1 1 ov 220v 1 1 ovi 220v j 0 38 0 38 1 0 96 1 1 ov 220v 11 ov1220v 1 0 78 1 2 1 8 0 78 120V 240V 12OVi24OV j 0 78 I 0 60 1 1 22 I 120V 240V 12OVi24OV I 0 60 1 22 0 58 0 58 0 78 1 2 1 8 50 60 1 20Vz 240V 120V 240V 0 38 0 38 1 0 96 11 OV 220V 1 1 OVi22OV 0 32 0 24 0 24 0 58 120V 240V 1 20V 240V 0 58 0 24 0 24 1 1 ov 220v 1 1 OV 220V 0 76 0 39 I 0 39 120V 240V 120V 240V 0 32 1 0 76 50 60 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 2OoC 68 F 47 9 5 1 ROTOR ASSEMBLY Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals 0 MODEL I RGXl810 I RGX2410 i RGX3510 i RGX5510 I I RESISTANCE 1 62 R 2 0 R 1 88 R 1 74 R 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 1 touche the terminals in one combi j nation of polarity Therefore if no re sistance reading appears try checking in reverse polarity NOTE 2 If the circu
25. ACLES Using a Dr Robin or a circuit tester check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel When continuity is found between the output terminals of the receptacle with a wire connected across these terminals the AC receptacle is normal When the wire is removed and no continuity is found between these terminals the receptacles are also normal AC RECEPTACLE F c 9 2A 46 Fig 9 26 9 3 NO FUSE BREAKER Check continuity between each of two terminals 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 30 Fuse breaker is on while there is no continuity when the No Fuse breaker is off 9 4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a Dr Robin or a circuit tester refering to the following table MODEL RGX1810 RGX2410 RGX3510 RGX5510 NO FUSEBREAKER I Fig 9 3 Fig 9 4 Resistance 0 Specification i AC Winding I Condenser Winging Hz I Voltage 50 i 12OV 240V 12OVi24OV White i Red Black Blue 1 Yellow 1 Yellow 60 j 50 I 1 1 ov 220v 1 1 ovj220v i 11 ov 220v 11 OV 220V I 1 58 1 58 1 3 82 1 oo I 1 oo 2 76 1 I 1 72 1 72 3 82 12OV 24dV 12OVl24OV i 1 oo 1 11 OV 220V 1 1 OVi22OV 1 oo 1 2 7
26. C SE 10A 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 Section 9 7 DIODE RECTIFIER for the checking procedure Fig 11 70 Fig 1 1 1 1 11 4 5 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester MODEL SPECIFICATION I RESISTANCE 1 1 ov 220v 1 1 OVl22OV RGXl810 120V 240V 12OVi24OV I 50HZ i I 0 30 I 60HZ I 11 OV 120V 220V 240V 11 OVi22OV 12OVi24OV I 0 2952 I 1 1 ov 220v 1 1 OV 220V 120V 240V 120Vj240V RGX2400 50Hz 0 280 I 60Hz I 11 OV 120V 220V 240V 11 OV 22OV 120V 240V I 0 2R 1 1 ov 220v 1 1 OV 220V 120v 210v 120v 240v I I 0 230 I I I 60Hz I 11 OV 120V 220V 240V 11 OV 22OV 120Vi240V I 0 2R I RGX5510 I 50Hz I 11 ov 220v 11 ovi 220v 120V 240V 120Vi240V I 0 140 I I I I I i 60Hz I 11 OVt 120V 220V 240V 1 1 OV 22OV 120V 240V 0 1 3 0 Tabie 1 1 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 70 11 5 IDLE CONTROL Option for 60Hz only 11 5 1 ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS APPLIED 1 Inspect the solenoid bracket Check the bend angle of solenoid bracket i If the bracket is distorted correct the angle w
27. ECK 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 andlor cooling air outlet is clogged with dirt grass chaff or other debris remove 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 1 MO 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 Fig 11 8 I q 11 4 NO DC OUTPUT 11 4 1 CHECK THE AC OUTPUT Check the generator by following Step 11 1 1 through Step 11 1 3 69 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 NOTE If the DC output is used to charge a large capacity battery or an over dis charged battery an excessive current may flow causing fuse blow F
28. ERMINAL Option 1 6 RGX1810 2410 AUSTRALIA 50HZ 240V VOLTMETER DC OUTPUT TERMINAL Option RGX3510 50Hz 60Hz 1 lOV 120V TYPE START SWITCH VOLTMETER Option I NO FUSE BREAKER 240V RECEPTACLE NO FUSEBREAKER AC RECEPTACLE EARTH GROUND TERMINAL 1 7 DC FUSE Option DC OUTPUT TERMINAL Option RGX3510 50Hz 60Hz 220VY 240V TYPE START SWITCH Option VOLTMETER AC RECEPTACLE E A R H GROUND TERMINAL RGX3510 5OHZ 60Hz 1 10V 22OVy 120V 240V TYPE START SWITCH Option VOLTMETER I AC RECEPTACLE c No FUSE BREAKER EARTH GROUND TERMINAL 18 DC FUSE Option DC OUTPUT TERMINAL Option NO FUSEBREAKER DCFUSE Option DC OUTPUT TERMINAL Option RGX3510 50Hz 220V WITH SPECIAL RECEPTACLE START SWITCH VOLTMETER Option I 220v RECEPTACLE EARTH GROUND TERMINAL RGX3510 AUSTRALIA 50HZ 240V START SWITCH VOLTMETER Option d I i C 0 0 1 No FUSEBREAKER Dc FUSE Option DC OUTPUT TERMINAL Option 240V RECEPTACLE EARTH GROUND TERMINAL 19 NO FUSE BREAKER Dc FUSE Option DC OUTPUT TERMINAL Option RGX5510 50Hz 60Hz 1 lOV 120V TYPE DC FUSE Option VOLTMETER AC RECEPTACLE AC RECEPTACLE f NO FUSEBREAKER START SWITCH Option EARTH GROUND TERMINAL DC OUTPUT TERMINAL Option 0 RGX5510 60H
29. Frequency 50Hz 1 5k E n I 3 c 3 l k CURRENT A1 CURRENT A1 2 3 MODEL RGX3510 B CURRENT A1 l k 0 RGX3510 Output Max 3k 3000W 2500W 2k t Rated Frequency 50Hz Voltage 110v s lk 5 0 0 7 B CURRENT A t t 63 62 61 60 59 240 220 200 0 4 8 12 16 CURRENT A 4k 3k 2k t z lk 5 o s n c 3k 2k t l k c 3 n 0 0 5 RGX3510 Output M a Rated Frequency 60Hz 3500W 3000W Voltage 1 1 ov 120v RGX3510 4k Output M a 3500W a 0 10 20 30 CURRENT A 9 3k t 2k 3 E l k 0 0 4k 3k t z 2k 2 0 s lk D 3k t 2k z 5 n l k g 0 0 RGX3510 Output Max Rated Frequency Voltage 3000W 2500W 50Hz 240V RGX3510 Output M a Rated Frequency Voltage 3500W 3000W 60Hz 1 1 OV 220V 120V 240V 2 4 MODEL RGX5510 t 5k 4k 3k 2k 1k 0 6k 5k 4k 3k 2k lk 0 RGX5510 Output Max t
30. I i No i mm Ohm 100 m 1 1 A i 3 A 5 A I 0 75 5 0V 3V 1 OV 2 0 17 37 0 26 7 5V 5V 1 5V 1 25 I 12 50i0 18 1 486 12 5V 8V 2 5V 2 477 3010 18 7 23 I 45 0 32 0 51 7 2Vi l V b 5 5 0 332 j 2 5V I 1 5V I I 12V 8V 4V 2 5V 12V 15V 18V 8Vi 1OV 12V 5V 6 5V 10A j 12A 15V 18V 10V 12V 5V 6 5V 3 5 q 4V 15A 15V 7 5V 5V Voltage drop indicates as V 100 X R X I X l R mens resistance 0 lo0 m on the above table I means electric current through the wire A i means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools 39 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 Dr ROBIN GENERATOR TESTER The Dr Robin generator tester is exclusively designe d for fast easy diagnosis and repair of I Robin generators I 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 4 Tester and accessories are installed in a the time to change batteries Fig 8 1 handy sturdy case for easy carring 0 SPECIFICATIONS I Model Dr Robin I Pari Number 388 37565 08 Voltage I a I O 0 500V AC
31. OLTAGE REGULATOR A trouble free condenser type voltage regulator ensures a stable voltage under all working conditions 3 3 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 3 4 QUIET OPERATION Robin RGX series generator delivers a quiet operation with 0 A large super silent muffler 0 A quiet 4 stroke Robin engine 0 A silent cyclone air cleaner 3 5 NO RADIO NOISE Soise suppressor spark plug and spark plug cap are equipped standard to prevent radio frequency interference 3 6 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 3 7 RUGGED TUBULAR FRAME Full cradle type rugged tubuler frame protects the generator all around 3 8 COMPACT AND LIGHT WEIGHT Newly developed brushless alternator enabled the RGX generators to be very compact in size and light in weight 3 9 MINIMAL MAINTENANCE 0 A brushless alternator release the operator from periodical brush maintenance 0 A trouble free condenser type voltage regulator 0 A drip proof alternator design 0 No fuse circuit breakers 0 An electronic pointless ignition system 0 A dust proof cyclone air cleaner 3 10 LONG LIFE DURABILITY The heav duty 4 stroke Robin engine and virtually maintenance free brushless alternator ensure 0 A brushless alternator wit
32. OTE Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance or the accurate reading cannot be obtained RGX1810 RGX2410 RGX3510 RGX5510 Fig 11 1 I NORMAL CAPACITY OF CONDENSER I RGXl810 RGX2410 RGX3510 RGX5510 17yF 1 20yF 17 cF 20yF 28 zFX2 i I Tzble 11 1 2 If such an instrument is unavailable the condenser can be checked by replacing with a new one If the v generator performs good with new condenser the cause of trouble is defect in original condenser 11 1 2 CHECKING STATOR 1 Remove control panel and disconnect stator wires at the connectors 2 Measure the resistance between terminals on 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 1 1 2 66 3 Check the insulation resistance between stator core and each stator lead using a Dr Robin generator tester in megger tester mode or a megger tester Fig 11 3 If insulation is bad replace stator with a new j one I I Fig 1 1 3 11 1 3 CHECKING ROTOR 1 Remove rear cover and stator Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals I i i MODEL 1 RGXl810 RGX2410 1 RGX3510 RGX5510 I RESISTANCE I 2 0 R 1 88 R 1 74R I 1 62 R Table 9 2 NOTE 1 Because a diode is soldered to the coil ends at the terminals
33. Q 2 16kQ Tzble 1 1 4 NOTE Take 5 10 tolerance on above resistance value If the measurement differs largely from mormal value the IDLE CONTROL UNIT is defective Replace with a new one 72 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 COKTROL UNIT If fuse is blown replace with a new one FUSE 0 2A 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 COKTROL USIT Check all leads from IDLE COXTROL UXIT are securely and correctly connected 5 Checking the SOLENOID SOLENOID Measure the resistance between two leads from SOLENOID If the resistance is larger or smaller than this range SOLENOID is defective Replace with a new one Fig 11 17 73 12 WIRING DIAGRAM 1 RGX1810 RGX2410 llOV 120V I 1 EhlC I I I NFB GENERATOR CONTROLBOX I I I 1 3 1 YELLOW I I I DC OUTPUT Available as option DC OUT 2 RGX1810 RGX2410 220V 240v GENERATOR CONTROL BOX L I r iii I I NFB A K n I I GREENBELLOW YELLOW P I E YELLOW BROWN DC OUT BROWN I BROWN WHITE DC OUTPUT Available as option
34. RMINAL 8 d TERMINAL CONTROL BOX REAR COVER I I Fig 10 28 63 10 3 7 FUEL TANK 1 Connect the rubber pipe to the engine carburetor and fasten it with a hose clamp Attach the banjo to the opposite end of the rubber pipe tighten it with a hose clamp and fasten the pipe to the fuel strainer with the banjo bolt 2 Fasten the strainer to the strainer bracket with the joint nuts 3 Mount the fuel tank on the side plates with rubber fuel tank between them NOTE For easy tank assembly glue the rubber fuel tank 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 FUEL GAUGE RUBBER PIPE GASKET FUEL TANK Fig 10 29 64 10 4 CHECKING DISASSEMBLY and REASSEMBLY of the CONTROL BOX 10 4 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 4 2 DISASSEMBLY 1 Remove the control panel from the control box screw 6 pcs RGX1810 RGX2410 RGX3510 M4 screw 8 pcs RGX5510 2 Disconnect the connectors on the wires to detach the control panel and
35. all disassembly assembly tools properly and use the proper tool for each specific job 51 10 2 DISASSEMBLY PROCEDURES Step Part to remove I Description Remarks Tool I 1 Fuel Tank i 1 Discharge fuel from the tank 1 Shut the fuel strainer 2 Remove the strainer cup 3 Put a vessel LO receive fuel under the strainer and open the fuel cock to dischzrge fuel See Fig 10 1 1 Atrach he straicer cap to tine srrainer bo Use utmost care about fire hazard Wipe off sprit fuel thoroughly Do not lose the filter SCieeG Fig 10 1 i2j Disconnect fuel hose from the strainer Loosen the hose clamp on top of the strainer and pull out the fuei hose from 1 the strainer See Fig 10 2 I 3j Take off the four bolts and rubber fuel j tank and then remove the fuel tank See Fig 10 3 j I i t Pliers 10 mm spanner or box wench I T Fig 10 2 Fig 10 3 52 Step 2 Part to remove I Description I Remarks i Tool Control Box 1 Take off the grommet from the rear pannel of control box 2 Disconnect the connectors on the wiring from the control box to the alternator 3 Rerxove the fuel strainer Rerr o e the nut on top of the fuel strainer located beside the contro box See Fig 10 5 L Fig 10 4 4 Take off the three bolts and remove the control box from the frame I 10 mm spanner or box wrench t
36. by comparing a current flowing across a pair of electrodes inner and outer with the reference in such a way that if a current flows between the electrodes more than the reference sufficient oil is in the crankcase on the other hand if a current flows less than the reference oil is not sufficient Since an electric current is flown to detect oil quantity this is called the electrical conductivity detection type of sensor The oil level to be detected is determined by the length of electrodes and their mounting positions with the engine 5 5 3 HOW IT OPERATES Power supply The sensor makes use of a part of primary power source for ignition of the engine igniter to drive the sensor circuit Power to the sensor can usually be derived from the stop button by branching wires out 33 Judgement of oil level When sufficient oil is in the crankcase both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes The sensor judges that oil in the crankcase is sufficient hen oil level goes down and the inner electrode is exposed to the air due to consumption of oil no current flow between the electrodes as air is considered to be electrically non conductive The sensor in this case judges that oil is insufficient Decision of oil shortage Oil level at the electrodes may go down momentarily probably due to the engine being slanted or affected by vibration even if a sufficient o
37. e of the engine varies and the correct oil level can not to be detected which in turn obstructs the preventing function of engine seizure Operate the engine by keeping it level amp When starting the engine with an insufficient oil in the crankcase engine starts once then it stops n automatically after it runs for 5 seconds When the engine has been stopped by the oil sensor voltage remained in the electronic circuit prevents the sensor from being re started for 3 seconds after the engine stop Try to re start the engine after 3 seconds or more A 35 6 1 2 3 4 5 6 SAFETY PRECAUTIONS Use extreme caution near fuel A constant danger of explosion or fire exists Do not fill the fuel tank while the engine is running Do not smoke or use 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 Y generator Do not operate the generator in a roomycave 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 sur
38. e from occurring due to insufficient amount of oil in the crankcase 0 Since the sensor has been designed to consume a part of power supp1ie d to the igniter to energize its electronics circuit any other external power supply is not necessary so that it can be mounted at the oil filler port Introduction of newly developed sensing principle features super durability and no I OIL SENSOR Fig 5 14 change with the passage of time as it does not use any moving part Merits due to introduction of electrical conductivity detection are as follows z It has resistance to mechanical shocks and property of no change with the passage of time as sensing element consists simply of electrodes having no moving parts amp At the same time it is capable of detecting the oil level stably as it is not influenced by engine vibrations z No error occurs due to foam and flow of the oil amp Influence against the ignition system or the electronics units can be neglected because an electric current supplied to the sensor can be decreased A n 5 5 2 PRINCIPLE OF SENSING OIL LEVEL There is a great difference between electric resistance of air and that of oil Since the re sistance of air is far higher than that of oil more electric current passes through the oil than through the air although absolute value of the current is very small The sensor detects this current difference and make use of it The sensor judges the oil quantity
39. e range FOR AC Fig 8 3 Fig 8 4 41 4 CIRCUIT TESTER Used for measuring resistance etc MEGGER TESTER Used for measuring generator insulation resistance Select one Kith testing voltage range of 5oov 6 TACHOMETER Use the contactless type tacho meter Fig 8 5 1 i I Fig 8 6 J Fig 8 7 42 8 2 AC OUTPUT MEASURING 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 Rated voltage Table 8 2 117 13OV I 215 238V I 235 26QV 107 11 9V Voltage range 120V I 220V I 240V 11ov 8 3 DC OUTPUT MEASURING d0 sw Load 4 To DC Terminal Fig 8 9 Measurement of DC output is executed with the switch turned OK 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 2V Therefore carefully observe the electrolyte level and do not overcharge the battery 43 8 4 MEASURING INSULATION RESISTANCE Use a Dr Robin generator tester in megger tester mode or use a megger tester to check the insulation resistance Connect a megger tester
40. face If the generator is tilted or moved during use there is a danger of fuel spillage and a chance that the generator may tip over Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is wet by rain or snon 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 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 Part No Part Name I Q ty j Phase I Allowable Current I 367 43008 08 Pkstic Box l i d 30A 348 43009 08 I Plastic Bcx 60A 1 1 1 T amp le 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 36
41. h a condenser voltage regulator 0 Full rubber mount in a sturdy tubular frame 0 A forged steel crankshaft supported by two main ball bearings 0 A pointless electronic ignition system 0 A cast iron cylinder liner 0 A forged aluminum connecting rod u greater durability with 13 4 GENERAL DESCRIPTION 4 1 EXTERNAL VIEW FULL POWER SWITCH VOLTMETER NO FUSEBREAKER RGX5510 DUAL VOLTAGE TYPE ONLY IDLE CONTROL SWITCH DC FUSE HOLDER CHOKE LEVER Option AIR CLEANER AC RECEPTACLE DC OUTPUT TERMINAL Option EARTH GROUND TERMINAL FUEL COCK PLUG COVER SPARK PLUG INSIDE OIL SENSOR TAN CAP FUEL GAUGE Option RGX 351 0 ONLY OIL DRAIN PLUG DC OUTPUT TERMINAL OIL FILLER CAP Option RGX 351 0 ONLY 14 4 2 CONTROL PANEL RGX1810 RGX2410 50Hz 60H llOV 12OV TYPE VOLTMETER DC FUSE Option DC OUTPUT TERMINAL Option RGX1810 RGX2410 50Hz 60H 220V 240V TYPE VOLTMETER DC FUSE Optionj DC OUTPUT TERMINAL Optio No FUSEBREAKER AC RECEPTACLE EARTH GROUND TERMINAL NO FUSE BREAKER AC RECEPTACLE 15 RGXl810 RGX2410 50Hz 60Hz 11 OV 220V 120V 240V TYPE VOLTMETER NO FUSE BREAKER 220V RECEPTACLE DC FUSE Option 1 1 OV RECEPTACLE DC OUTPUT TERMINAL Option EARTH GROUND TERMINAL RGXl810 2410 50Hz 220V WITH SPECIAL RECEPTACLE DC FUSE Option 220V RECEPTACLE DC OUTPUT T
42. h a plastic hammer to press the rotor bearing into the rear cover Fix the rear cover to the adaptor with four bolts spring washers and washers M6 x 25 mm bolt 4 pcs 4 pcs M6 spring washer 4 pcs M6 LVasher I Tightening torque I 4 9 5 9 N m i 50 60 kg crn I z 3 6 4 3 ft lb j Fig 10 21 60 3 Attach the bushing over the lead wire drawn out from the rear cover Press the smaller end of the bushing into the window of the rear cover i I j Fig 10 22 10 3 5 FRAME 1 Attach the mount rubbers to the frame Insert the setting tongue of mount rubber into the hole on the frame and tighten the nut from the bottom of the frame h18 flan nut 4 pcs r FRAME UPPER Fig 10 23 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 Q terminal of the grounding wires greeniyellow to the unpainted thread hole of the frame base plate using a 5 mm brass s Lrew 61 Install the engine and alternator assembly into the frame Put the engine and alternator assembly into the frame from the side of it Tighten the nuts over the mount rubber bolts to fix Tightening torque 1 1 8 13 7 Nom
43. he control box See FIg 10 6 I the bushing and pull I out Fig 10 5 I Fig 10 6 53 I step Part to remove I Description Remarks Tool 1 See Fig 10 8 box wrench 3 I Pipe Frame 1 Remove SIDE PLATE from frame 10 mm spanner or I 6 mm bolt 2 PC i I 2 Remove the nuts Lvhich fix he engine 1 1 and alternator on the mount rubbers 1 3 Dismount the engine and alternator from I Take out the engine and the frame i alternator assy from the 1 side of the frame See Fig lo 9 j I Fig 10 7 Fig 10 8 I I 1 I I I i I i I I I i i 4j Remove he mount rubbers from frame Loosen the nuts on the bottom side of I the frame MOUNT RUBBER 8 rnm NUT 2 12 mm spanner or box wench I I MOUNT RUBBER 2 pcs 6 rnrn BOLT 2 pcs 8 mm NUT 2 pcs pcs Fig 10 9 54 I Description Step I Part to remove 1 Remarks Tool L 4 Rear Cover il j Remove the four bolts Lvhich f x e n the I 12 mm spanner or I I rear cover to the front cover i box wench 1 6 9 bolt 4 pes I I I i Do not give 2 strong hit 1 Plastic hammer 2 Rmove the rear cover by hitting on the I on the legs I i legs of rear cover Lvith a plastic hammer I co loosen i i i Fig 10 10 Fig 10 1 7 Startor 1 Remove the stator cover I 1 i
44. il is in the crankcase For that reason the sensor has an electronic timer circuit to prevent it from interpreting as short of oil when amount of oil is sufficient The sensor has been designed so that the engine is LO be stopped only when oil shortage is detected for 5 seconds uninterrupted The timer emplovs an integration circuit and it is to be reset when the inner electrode is soaked in the oil again before the sensor decides it as oil shortage The oil level where the sensor decides as oil shortage when oil level goes down gradually is called threshold level Automatic stop of engine When rhe sensor decides as oil shortage it makes the engine to stop running automatically for protection of engine Once the stopping circuit is activated it keeps functioning until it confirms that the engine has made a complete stop then the circuit stops functioning automatically 5 5 4 BLOCK DIAGRAM OF THE CIRCUIT Power circuit Igniter LED indicator Inner pole 1 Detection Deley circuit Stopping circuit circuit oil I Outer pole Engine ground Fig 5 15 1 Po er circuit u This rectifies a part of power to the igniter and regulates it to supply the stabilized power to necessary circuits 34 amp Detection circuit This detects quantity of oil sufficient or not according to difference of electric resistance across inner and outer electrodes n n amp Delay circuit
45. it tester is not sufficiently accurate it may not show the values given and may give erroneous readings Erroneous reading will also occur when j there is a wide variation of resistance among coil windings or when meas Fig 9 5 urement is performed at embient tem peratures different from 20 C 68 F i I 9 6 CONDENSER Use a Dr Robin in capacitance meter mode to check the capacity of condensers See Fig 9 6 RGXl810 RGX2410 RGX3510 I i I RGX5510 i 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 40 NORMAL CAPACITY OF CONDENSER I RGX1810 I RGX2410 I RGX3510 I RGX5510 I I 1 7 z F 2OcF i 17 zF 20 F I 28 zFX2 Table 9 3 W If such an instrument is unavailable the condenser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 9 7 DIODE RECTIFIER Brown Brown White Brown Orange Orange 0 IBrown Brown1 0 I Brown White Fig 9 7 DIODE RECTIFIER CIRCUIT TESTER Fig 9 8 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 W Checking table for analogue circuit tester I Apply black Oneedie
46. ith proper tool 1 I SOLENOID SOLENOID BRACKET RGX5510 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 induction loads such as electric motor or electric tools or welding machine require three to five times large wattage of their ratings at starting This starting wattage must not exceed the rated output of the generator 3 Check the slow set r p m The normal idling speed by the IDLE CONTROL is as follows RGX2410 3510 3150 3200 r p m 2700 2800 r p m Adjust the idling speed monitoring the volt meter so that it indicates between 75 volt and 85 volt Turn the adjusting screw to adjust the slow RGX5j10 speed 71 4 Check the wiring through ZCT on the IDLE CONTROL UNIT BOARD 0 Single Voltage Type Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT 0 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 I DL CONTROL UNIT 3 Fig 11 14 5 Checking the IDLE CONTROL UXIT Check the resistance between six leads of IDLE CONTROL UNIT with circuit tester IDLE CONTROL UNIT Fig 11 15 I Tester Polaritv I I I LIGHT BLUE FUSE LIGHT BLUE 20 50k
47. nction 24 5 3 Generator Operation 28 5 4 Electronic Ignition System 32 5 5 Oil Sensor 32 SAFETY PRECAUTIONS 36 RANGE OF APPLICATIONS 37 MEASURING PROCEDURES 40 8 1 Measuring Instruments C 40 8 2 AC Output Measuring 43 8 3 DC Output Measuring
48. nd a condenser coil which I are wound in the core slots The condenser coil excites the rotor field coil which generates AC voltage in the main coil I I I I Fig 5 2 24 5 2 2 CONDENSER One or two condensers are installed in the control box and are connected to the condenser coil of the stator These condensers and condenser coil regulate the output voltage 5 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action i I I i I I Fig 5 3 i 1 Fig 5 4 A diode rectifier and surge absorber is mounted inside of the insulator DIODE RECTIFIER SURGE ABSORBER Fig 5 5A Fig 5 58 25 5 2 4 DC FUSE OPTION I The 10 ampere DC fuse mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit 5 2 5 NO FUSE BREAKER The KO Fuse breaker protects the generator from getting damage by overloading or short circuit in Fig 5 6 the appliance Table 5 1 shows the capacity of No Fuse breaker by each spec and their object of protection i MODEL I SPECIFICATION NO FUSE BREAKER I OBJECT of PROTECTION 11ov 14A 120v 12A 50Hz I I 220v 6 5 A 240V 5 5 A i 1 1 1 OV122OV 120V 240V 6 5A 2 Pole 2 Element 1 RGX18
49. ol 1 Remo1 e rhe front cover I Loosen the four bois and remove the I front cover 30 bolt 4 pes 12 mm Socket vrench I I Fig 10 18 58 10 3 ASSEMBLY PROCEDURES 10 3 1 FRONT COVER Attach the front cover to the engine main bearing cover Match the faucet joint and tighten the bolts M8 X 18mm bolt 4 pcs 8 spring washer 4 pcs 120 140 kgocrn 1 8 7 10 1 ft lb 10 3 2 ROTOR 1 Wipe off oil grease and dust from the tapered portion of 2 Mount the rotor to the engine shaft engine shaft and matching tapered hole of rotor 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 I Tightening torque I I I 11 3 13 2 N m I RGX 1810 2410 j 115 135 kg cm tt 8 7 10 8 ft4b i I 22 6 24 5 N rn RGX 351 0 551 0 i 230 250 kgocrn 16 6 19 5 ft4b j I FRONT COVER BEARING 59 10 3 3 STATOR 1 Put the stator in the rear cover setting the four grooves on the side of stator with thread holes of the rear cover i 2 Attach the stator cover around the stator STATOR COVER I I I I I T I I Fig 10 20 10 3 4 REAR COVER 1 Put the rear cover with stator over the rotor Tap on the rear cover evenly wit
50. r 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 f e I up to total 15 amperes vJ from two receptacles 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 27 5 3 GENERATOR OPERATION PERMANENT MAGNET FOR INITIAL EXCITATION STATOR MAIN COIL ECEPTACLE APPLIANCE DIODE CONDENSER COIL CONDENSER Fig 5 8 5 3 1 GENERATION Of NO LOAD VOLTAGE IVhen 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 z 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
51. rcuit tester 1 2 3 4 5 9 8 OIL SENSOR OPTION I Disconnect tn o 2 ires comming from the sensor at the connection Loosen the sensor to remove it from the engine Plug the opening of oil filler hole created after sensor is removed with suitable means such as oil gauge Connect the removed wires again with the oil I sensor Start the engine with the oil sensor removed and confirm if a Engine stops after 5 seconds which is normal or b Engine does not stop after more than 10 seconds which is unusual Fig 9 9 NOTE The sensor will not operate properly when wire is broken or poorly connected Check the wires for correct connection If it fails to stop within 5 seconds after the wirings have checked the sensor is wrong Replace the sensor with new one 50 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 v 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
52. res a 400W generator to start it NOTEI If a power factor correction capacitor is not applied 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 efficiency should be taken into account as explained in Item 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 4OOW mercury lamp requires 800W to 1200W power source to be turned on A rated 30001 generator can power two or three 40014 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 9OOW compressor requires a 4500W generator to drive it NOTEI 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 dete
53. rmine the optimum generator capacity select a generator with a larger capacity 37 5 Appliances without any indication as to power consumption Some appliances have no indication as to power consumption but instead the work load output is indicated In such a case power consumption is to be worked out according to the numerical formula mentioned below Output of electrical appliance Efficiency Power consumption Efficiencies of some electrical appliances are as follows Single phase motor 0 6 to 0 75 The smaller the motor the i lower the efficiency i Fluorescent lamp 0 7 to 0 8 Example 1 Example 2 A 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 7 57W As explained in Item 2 multiply this power consumption value of 571 by 1 2 to 2 and you will get the figure of the necessary capacity of a generator In other words a generator with a rated output of 1OOOWcapacity can light nine to fourteen 40W fluorescent lamps 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 MODEL i RGX1810 RGX3510 RGX5510 RGX241
54. s over 30A and Rec 1 can output up to a total of 15A When the full power switch is set for double voltage indication llOV 220V or 120V 240V the switch position is as indicated by the upper dotted line in Fig 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 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 31 5 4 ELECTRONIC IGNITION SYSTEM The electronic ignition system features a power transistor as the current control element Therefore the ignition system is an electronic contact point free type that operates with the power transistor impulses controlling the current This system is also called TIC transistor igniter circuit and is virtually free of ignition failure n hich generally results from contamination of the contact points a typical problem with contact type ignition systems Because this ignition system has no contact points it is not affected by moisture oil dust or other contaminants As a result this electronic ignition system ensures sure and positive ignition with reduced maintenance The TIC mechanism consists
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