Robin America RGX2410 Service Manual Download Page 1

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Summary of Contents for RGX2410

Page 1: ... Generator Model RGXl810 RGX2410 RGX3510 RGX5510 ...

Page 2: ... 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 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 Rectifier 49 9 8 Oil Sensor Option 50...

Page 3: ...UBLESHOOTlNG 11 1 NoACOutput 11 2ACvoltage 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 DCOutput 11 5 Idle Control Option for60 Hz only 12 WIRING DIAGRAM ...

Page 4: ...1 SPECIFICATIONS T I IT 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 ...

Page 5: ... j c 6 si 0 d i N g l n N g W 3 0 0 0 I n 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 ...

Page 6: ...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 ...

Page 7: ...y Voltage 1800W 1500W 60Hz 220v CURRENT A 12 l k 1 5k tn 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 11OV 220V CURRENT A 4 ...

Page 8: ... 0 1k 0 5k 0 RGX1810 Output Max 1800W Rated Frequency 60Hz Voltage 11OV 220V 1500W CURRENT A1 2 2 MODEL RGX2410 1 5k 1 CURRENT A C z 61 3 60 s 59 L h 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 ...

Page 9: ...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 ...

Page 10: ... 200 110 100 0 4 8 12 16 20 RGX2410 Output Max rkt 2000w Rated 1700W 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 ...

Page 11: ...ENT 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 11ov 120v RGX3510 4k Output M a 3500W a ...

Page 12: ...NT 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 OutputMax Rated Frequency Voltage 3000W 2500W 50Hz 240V RGX3510 Output M a Rated Frequency Voltage 3500W 3000W 60Hz 11OV 220V 120V 240V ...

Page 13: ...LRGX5510 t 5k 4k 3k 2k 1k 0 6k 5k 4k 3k 2k lk 0 RGX5510 Output Max t 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 ...

Page 14: ...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 ...

Page 15: ...DC OUTPUT Option DCVoltage DCAmpere DC output 12v 8 3A 1oow The voltage curve shown in the left indicates the characteristicof 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 ...

Page 16: ... 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 MINIMALMAINTENANCE 0 A brushless alternator release the operator from periodical brush maintena...

Page 17: ...E TYPE ONLY IDLE CONTROLSWITCH DC 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 F U E L G A U G E Option RGX 3510 ONLY OIL DRAIN PLUG DC OUTPUT TERMINAL OIL FILLER CAP Option RGX 3510 ONLY 14 ...

Page 18: ... 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 ...

Page 19: ...0V 240V TYPE VOLTMETER NO FUSE BREAKER 220V RECEPTACLE DC FUSE Option 11O V RECEPTACLE DC OUTPUT TERMINAL Option EARTH GROUND TERMINAL RGXl810 2410 50Hz 220V WITH SPECIALRECEPTACLE DC FUSE Option 220VRECEPTACLE DC OUTPUT TERMINAL Option 1 6 ...

Page 20: ...0V VOLTMETER DC OUTPUT TERMINAL Option RGX3510 50Hz 60Hz 1lOV 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 ...

Page 21: ...C RECEPTACLE E A R H GROUND TERMINAL RGX3510 5OHZ 60Hz 110V 22OVy120V 240V TYPE START SWITCH Option VOLTMETER I AC RECEPTACLE c No FUSE BREAKER EARTH GROUND TERMINAL 1 8 DC FUSE Option DC OUTPUT TERMINAL Option NO FUSEBREAKER DCFUSE Option DC OUTPUT TERMINAL Option ...

Page 22: ...on 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 ...

Page 23: ...TMETER AC RECEPTACLE AC RECEPTACLE f NO FUSEBREAKER START SWITCH Option EARTH GROUND TERMINAL DC OUTPUTTERMINAL Option 0 RGX5510 60H 220V 240V TYPE DC FUSE Option I J NO FUSEBREAKER START SWITCH Option EARTH GROUND TERMINAL DC OUTPUT TERMINAL Option 20 ...

Page 24: ...NO FUSE BREAKER DC FUSE Option START SWITCH Option I 11OV RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL Option RGX5510 50Hz 220V WITH SPECIAL RECEPTACLE I VOLTMETER DC FUSE Option 220VRECEPTACLE NO FUSE BREAKER START SWITCH Option EARTH GROUND TERMINAL DC OUTPUTTERMINAL Option 21 ...

Page 25: ...RGX5510 AUSTRALIA 50Hz 240V VOLTMETER DC FUSE Option NO FUSEBREAKER I START SWITCH Option 240V RECEPTACLE EARTH GROUND TERMINAL DC OUTPUT TERMINAL Option 22 ...

Page 26: ...mber 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 ...

Page 27: ... BOLT BALL BEARING THROUGH BOLT FRONT COVER 5 2 FUNCTION 5 2 1 STATOR The stator sts of a laminated silicon steel j I sheet core a main coil and 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 II II Fig 5 2 24 ...

Page 28: ...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 thefieldcoilmagnetizesthesteel sheetcore Twopermanentmagnetsareprovided 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 insideof the insulator DIODE RECTIFIER SURGE ABSORBER Fig 5 5A Fig 5 58 25 ...

Page 29: ...v 8 A I RGX2410 i 11ovi220v j 8A 2 Pole 2 Element 12OV 240V 7A 2 Pole 2 Elexent llnv 17nv I 1RA 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 11ovj220v 12A 2 Pole 2 Element i 120V 240V 1O A 2 Pole 2 Element 1 1 ov 120v 27 A RGX55 0 r Total output amperage 60HZ 220V 240V I 14A 11OVi22OV 120Vi240V...

Page 30: ...tacles 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 v J from two receptacles Caution To connect the appliance to locking receptacle Insert the plugintothereceptacleand turnIt clockwise to lock Fig 5 ...

Page 31: ...his process As AC current flows through the condenser coil the density of magnetic flux in the rotor changes This change of magnetic flux inducesAC 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 s...

Page 32: ...fullratedpower from one receptacle in each voltage 0 Dual voltage type RGX1810 2410 3510 N F B k Q j _ I I Q REC 11O V 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 ...

Page 33: ...Vl 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 iNo output can be taken 110 220v Half of rated output Rated output i 120 24OV Table 5 4 Fig 5 12 30 ...

Page 34: ...for the lower voltage can output up to the rated power up to 30A if the rated current is over 30A and Rec 1can 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...

Page 35: ...h 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 ...

Page 36: ...owof the oil 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 SENSINGOILLEVEL There is a great differencebetween electric resistanceof 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 a...

Page 37: ... 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 circuitand it is to be reset when the inner electrode is soaked in the oil again before the sensor decidesit as oil shortage The oil levelwherethesensordecidesasoil shortage whenoillevelgoesdowngradually iscalled threshold level Automatic...

Page 38: ...ing of oil sensor unit A 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 su...

Page 39: ...ain Severe electric shockmay occur If the generator is wet by rain or snon wipeit and thoroughly dry it before starting Don t pour water over the generator directly nor wash it with water If the generator is wetwithwater theinsulationswillbeadverselyaffectedandmay cause current leakage and electric shock Do not connect the generator to the commercial power lines This may cause a short circuit or d...

Page 40: ...n their running wattage Example A rated 250W electric drill requires a 400W generator to start it NOTEI If a power factor correction capacitor is not applied to the fluorescent lamp themore power shall berequired 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 po...

Page 41: ...ty of a generator In other words a generator with a rated output of1OOOWcapacity can light nine to fourteen 40W fluorescent lamps Generallyspeaking a400Wmotormeansthatitsworkloadis 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 ...

Page 42: ...ctrical product As a result the load can be damaged Table 7 2 shows voltage drops per 100meters ofcable 2 Cable length Table 7 2 8A 8A 10A 12A I Sectional I Gauge No Resistance Voltage drop per 100 m area mm2 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 0 517 2Vi l V b 5 5 0 332 j 2 5V I 1 5...

Page 43: ...dy case for easy carring 0 SPECIFICATIONS I Model Dr Robin I Pari Number 388 37565 08 Voltage I a I O 0 500V AC 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 3140 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...

Page 44: ... or 120V 4 3 0 to 3OOV Type withanoutputvoltage of 220 230 or 240V 0 to EOV 0 to 33OV Dual voltage type FOR AC Fig 8 2 2 AMMETERS ACammeter isnecessary An ACammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10AJ 20AJ 100A 3 FREQUEXCYMETER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range...

Page 45: ...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 iI Fig 8 6 J Fig 8 7 42 ...

Page 46: ...26QV 107 119V Voltage range 120V I 220V I 240V 11ov 8 3 DC OUTPUT MEASURING d 0 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 adjustingtheload to thegenerator If thevoltageiswithintherangefrom 6V to 14V thevoltage output is normal Note If a battery is connected as a load to the generator the DC output volta...

Page 47: ...hefactory 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...

Page 48: ...es 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 ...

Page 49: ...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 outputterminals of thereceptaclewithawireconnectedacrosstheseterminals the AC receptacle is normal Whenthewire is removedandnocontinuity is foundbetweentheseterminals thereceptacles are also norma...

Page 50: ... 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 11OV 220V 11OVi22OV 1 oo 1 2 76 2 92 1 38 1 38 120V 240V 120Vi240V 2 92 1 16 1 16 60 11ov 220v 11OV 22OV 1 1 ov 220v 1 1 ovi 220v j 0 38 0 38 1 0 96 11ov 220v 11 ov1220v 1 0 78 1 2 18 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 18 50 60 120Vz 240V 1...

Page 51: ... in reverse polarity NOTE 2 If the circuit tester is not sufficiently accurate it may not show the values given and may give erroneous readings Erroneous reading will also occur when 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 c...

Page 52: ... 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 testeras shown in Fig 9 10 The rectifier is normal when condtinuity is as follows W Checking table for analogue circuit tester I Apply black Oneedieof the circuit tester Analogue circuit tester Brown Brown Orange I BrownWhite Brown i NO continuity I NO continuity ...

Page 53: ...e 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 circuit tester 1 2 3 4 5 9 8 OIL SENSOR OPTION I Disconnect tn o 2 irescomming from the sensor at the connection Loosen the sensor to remove it from the engine Plug the opening of oil filler hole c...

Page 54: ... to facilitate easier and smoother reassembly 2 For more convenience divide the parts into several groups and store them in boxes 3 To prevent bolts and nuts from being misplaced or installed incorrectly place them temporarily back at their original position 4 Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools proper...

Page 55: ...e 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 boltsand rubber fuel j tank and then remove the fuel tank See Fig 10 ...

Page 56: ...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 the control box See FIg 10 6 I the bushing and pull I out Fig 10 5 I Fig 10 6 53 ...

Page 57: ...on the mount rubbers 1 3 Dismount the engine and alternator from I Take outthe engine and the frame i alternator assyfrom the 1 side of the frame See Fig lo 9 j I Fig 10 7 Fig 10 8 I I 1I I I i I i I I I i i 4 jRemove hemount rubbersfromframe Loosen the nuts on the bottom side of I the frame MOUNT RUBBER 8 r n m NUT 2 12 mm spanner or box wench I I MOUNT RUBBER 2 pcs 6 rnrn BOLT 2 pcs 8 mm NUT 2 p...

Page 58: ...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 coloosen i i i Fig 10 10 Fig 10 17 Startor 1 Remove the stator cover I 1 i I i STATOR COVER STAT I I Fig 10 12 55 ...

Page 59: ...R COVER CLAMP Fig 70 73 1j Take off the through bolt i Apply a box wench on the head of j throughbolt 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 ...

Page 60: ...ollowing 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 boltintothethreadof 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 ipeoffoii...

Page 61: ...step IPart to remove Description Remarks i Tool 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 ...

Page 62: ...omthetaperedportion of 2 Mount the rotor to the engine shaft engine shaft and matching tapered hole of rotor shaft Tighten the through bolt Applyawrench on thethroughboltand hit wrenchhandle clockwise with a hammerto 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 t t 8 7 10 8 ft4b i I 22 6 24 5 N rn RGX 3510...

Page 63: ... Fig 10 20 10 3 4 REAR COVER 1 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 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 3ft lb j Fig 10 21 60 ...

Page 64: ...nd tighten the nut from the bottom of the frame h18 flan nut 4 pcs r FRAME UPPER Fig 10 23 NOTE Themount rubbers areselected to reduce vibration most effectively by modeland its frequency Be sureto use the correct mount rubber foryour generator Although mountrubbers have the same appearance their characteristics are different 2 Attachthe 5 Q terminal of thegroundingwires greeniyellow to the unpain...

Page 65: ...ght is not applied to the mount rubbers 3 Attach the side plate frame M6 x 10mm 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 5for disassembly checking and reassembly proceduresof the control box 2 Connect the wires dr...

Page 66: ...mm flange bolt 3 pcs I Tightening torque I 3 9 5 9 Nom 40 60 kg cm 2 9 4 3 ftolb 5 Fastentheoneearthcablewith 86 terminal drawn out from the control box to the rear cover leg M8 nut 1pce 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 TERMINAL 8d TERMINAL CONTROL BOX REAR COVER I I Fig 10 28 ...

Page 67: ...joint nuts 3 Mount the fuel tank on the side plates withrubber fuel tank between them NOTE For easy tank assembly glue therubber 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 thehose clamps NOTE Apply a drop of oil to the rubber pipe so that it may easily be conn...

Page 68: ...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 Cor over in the specified gauge shown in the circuit ...

Page 69: ...PACITY 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 Measu...

Page 70: ...ittester measure the resistance of the field coil at the terminals I i i MODEL 1 RGXl810 RGX2410 1 RGX3510 RGX5510 I RESISTANCE I 2 0R 1 88 R 1 74R I 1 62R 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 touch the terminals in one combination of polarity Therefore if no resistance reading appears try checking in reve...

Page 71: ...e r p m 1 w Loosen the lock nut on the adjusting screw w Turn the adjusting screw clockwise to de creaseenginespeed or counter clockwiseto increase engine speed Normal engine speedat no load 3100 3150 r p m for 50HZ ype 3700 3750 r p m for 60Hztype 11 2 2 CHECKING CONDENSER Check condenser referring to Step11 1 1 11 2 3 CHECKING STATOR Check stator referring to Step 11 1 2 Fig 11 6 HIGH SPEEDrf QL...

Page 72: ... 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 betweentheliveterminal of thereceptacleand the ground terminal If the insulation resistance is less than 1MO dis assemblethegeneratorandchecktheinsulation resistance of the ...

Page 73: ...ECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester MODEL SPECIFICATION I RESISTANCE 11ov 220v 11OVl22OV RGXl810 120V 240V 12OVi24OV I 50HZ iI 0 30 I 60HZ I 11OV 120V 220V 240V 11OVi22OV 12OVi24OV I 0 2952 I 11ov 220v 11OV 220V 120V 240V 120Vj240V RGX2400 50Hz 0 280 I 60Hz I 11OV 120V 220V 240V 11OV 22OV 120V 240V I 0 2R 11ov 220v 11OV 220V 120v 210v 120v...

Page 74: ...ver 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 mustnot exceed therated 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...

Page 75: ...g through the ZCT on the IDLE CONTROL UNIT in the same direction IDL CONTROL UNIT 3Fig 11 14 5 Checking the IDLE CONTROL UXIT Check the resistance between six leadsof IDLE CONTROLUNIT with circuit tester IDLE CONTROL UNIT Fig 11 15 I Tester Polaritv I I I LIGHT BLUE FUSE LIGHT BLUE 20 50kQ 2 16kQ Tzble 1 1 4 NOTE Take 510 tolerance on above resistance value If the measurement differs largely from ...

Page 76: ...IT If fuse is blown replace with a new one FUSE 0 2A FUSE HOLDER Fig 11 16 3 Check the wiringof SOLENOID Check two leads from SOLENOID are securely connected 4 Check the wiringof 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 theresistanceislargerorsmallerthanth...

Page 77: ... NFB GENERATOR CONTROLBOX 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 74 ...

Page 78: ...3 RGXl810 RGX2410 11OV 22OV 120V 240V GENERATOR CONTROL BOX 7 F 1 DC OUTPUT Available as option 4 RGX3510 1lOV 120V GENERATOR 1 I CONTROL BOX DC OUT DC OUTPUT Available as option 75 ...

Page 79: ...5 RGX3510 220V 240V DC OUTPUT Available as option 6 RGX3510 11OV 22OV 120V 240V GENERATOR CONTROLBOX I I I I I I NFB DC OUT E DC OUTPUT Available as option 76 ...

Page 80: ...7 RGX5510 11OV 120V GENERATOR CONTROL BOX 1 I A K I DC OUTPUT Available as option 8 RGX5510 220V 240V GENERATOR CONTROL BOX 77 ...

Page 81: ...9 RGX5510 11OV 220V 120V 240V GENERATOR CONTROLBOX 1 I I NFBl l c ORAN YELLOW YELLOW T DC OUT 0 BROWN BROWN WHITE 1 I DC OUTPUT Available as option 78 ...

Page 82: ...ENGINE WIRING DIAGRAM RECOIL STATER TYPE _ r m 4 I J r 0 I _ J ENGINE 79 ...

Page 83: ...0 ENGINE WIRING DIAGRAM ELECTRIC STATER Optional Equipment TYPE for RGX3510 7 I ...

Page 84: ...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 75mm2 1 25 mm2 81 ...

Page 85: ...witcn I os Spark Plug SP Oil Sensor MG j Magneto IG j Ignition Coil MG SW Magnetic Swiich E Earth Terminal GroundTerminal ST M Starting Motor KEY SW Battery BAT Key Switch V Voltmeter RECl RECz AC Output Receptacle 22OV 240V AC OGipUt Receptacle 110V320V REC3 AC Output Receptacle Total 15A MAX 220 240V REC4 AC 0s put Receptacle Total 15A MAX 110 120V AC Output Receptacle 11OV 120V total 30A RECe A...

Page 86: ...I ISSUEEMD GS1001 I F U J IHEAVY INDUSTRIESLTD ...

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