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Robin RGD500, Service Manual

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Summary of Contents for RGD500

Page 1: ...MAN UAL Model RGD5000 Generator PUB GS1187 Rev 8198 ...

Page 2: ...GENERATOR OPERATION 11 6 SAFETY PRECAUTIONS 14 7 RANGE OF APPLICATIONS 15 8 MEASURING PROCEDURES 18 8 1 MEASURING INSTRUMENTS 18 8 2AC OUTPUT MEASURING 21 8 3 DC OUTPUT MEASURING 21 8 4 MEASURING INSULATION RESISTANCE 22 9 CHECKING FUNCTIONAL MEMBERS 24 9 1 VOLTMETER 24 9 2 AC RECEPTACLES 24 9 3 NO FUSEBREAKER 24 9 4 STATOR 25 9 5 ROTORASSEMBLY 26 9 6 CONDENSER 27 9 7 DIODE RECTIFIER 27 10 DISASSE...

Page 3: ...ROCEDURES 39 10 5 CHECKING DISASSEMBLYand REASSEMBLYo fthe CONTROL BOX 50 11 TROUBLESHOOTING 52 11 1 NOAC OUTPUT 52 11 2AC VOLTAGE I STOO THIGH OR TOO LOW 54 11 3AC VOLTAGE I SNORMALAT NO LOAD BUTTHELOAD CANNOTBEAPPLIED 55 11 4 NO DC OUTPUT 56 12 WIRING DIAGRAM 57 ...

Page 4: ...r Cooled 4 Cycle Diesel Engine a 5 g 5 1 a 1 I W 1 t c 1 Dimensions Lx W x H Dry Weight 95 kg 209Ibs I 26 5 x 19 7 x 21 3 in 675 x 500 x 542 mm Electric starter motoris available as option Model 8 5 HP 3600rpm Rated O u t p u t 412 cm3 25 14 cu in Displacement DY41 D Fuel Diesel lightoil Fuel TankCapacity 4 2 U S gal 16 0 liters RatedCoutinuousOperation 11 2 0 hours I Oil Capacity Starting System ...

Page 5: ...ted 4500 W Frequency 60 Hz Voltage 120V Output Max 5000 W Output Rated 4500 W Frequency 60 Hz Voltage 120 Vl24OV DCVoltage 12V DCAmpere 8 3A DC output 100 W The voltage cuwe shown in the left indicates the char acteristic o f DC output when charging a battery The voltage may be decreased by 20 when the resis tance loadis applied NOTE It i spossible to use both DC andAC outputs simultaneouslyup to ...

Page 6: ...sthe engine off wheneverthe oil level f down below a safe level preventingengine seizure 3 6 COMPACT LIGHT WEIGHT The combination of newly developed brushless alternator and air cooledsingle cylinder Robin diesel engine enables the new RGD series generators to bevery compact in size and light in weight 3 7 RELIABLE PERFORMANCEWITH MINIMAL MAINTENANCE A brushless alternator eliminates troublesome b...

Page 7: ...4 GENERAL DESCRIPTION 4 1 EXTERNALVIEW Rocketcover Air cleaner ACreceptack Fuelgauge Tank cap Muffler 4 ...

Page 8: ...4 2 CONTROL PANEL RGD5000 60HZ l20V 60Hz l2OV 240VTYPE Voltmeter Full power switch AC Earthterminal DC outputterminal 5 ...

Page 9: ...umber and specification number are stamped on the LABEL MODELNAME stuck on the side wall o fcontrol box e NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order toget correct parts and accurate service Serial number 6 ...

Page 10: ...ase Statorbolt Ball bearing Adapter Fig 5 1 5 2 FUNCTION 5 2 1 STATOR Thestatorconsists of alaminatedsiliconsteel I sheet core a main coil and a condenser coil which are woundin the core slots The condenser coil excites the rotor field coil which generatesAC voltage inthe main coil Fig 5 2 7 ...

Page 11: ...late the output voltage 5 2 3 ROTOR The rotor consists of a laminated silicon s t e e l sheet core and afield coil which iswound over the core DC current in the field coil magnetizes the steel sheet core Twopermanent magnets are provided for the primary exciting action Fig 5 4 A diode rectifier and surge absorber is mounted insideof the insulator Fig 5 5A 8 Fig 5 5B ...

Page 12: ... start model 5 2 5 NO FUSEBREAKER L Fig 5 6 The no fuse breaker protects the generator from getting damage by overloading or short circuit in the appliance Table 5 1 shows the capacityo f no fuse breaker by each spec and their object o f protection MODEL OBJECTor PROTECTION NO FUSEBREAKER SPECIFICATION 60HZ 120V 37 5 A Total output amperage RGD5000 30A Outputfrom 30A receptacle 2 0 A x 2 Total out...

Page 13: ...pecified amperage limits to prevent burning w NOTE 1 If your generator has receptacles pecu liar to your country Table 5 2does not apply NOTE 2 The generator for U S A market is equipped with NEMA standard recep tacles shown in table 5 2 Usetheproperplug for connectingap pliance to the generafoE I W Caution To connect the appliance to locking receptacle insertthe plugintothe r e ceptacleandturn it...

Page 14: ... 3 AsAC current flows through the condenser coil the density of magnetic flux in the rotor changes T change o f magnetic flux inducesAC voltage in the field coil and the diode rectifier inthe field coil circuit rectifies this AC voltage intoDC Thus aDCcurrent flows through the field coil and magne tizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 30...

Page 15: ...al voltage type to take out thefull rated power from one receptacle in eachvoltage I Fig 5 10 L 3MCz Fig 5 11 w Switch RECEPTACLE RECEPTACLE HIGHER VOLTAGE LOWER VOLTAGE 110v 1 lgvI Rated output No outputcan be taken 11o m 0 v 120 240v or Rated output Half of ratedoutput Table 5 4 12 ...

Page 16: ...t be taken out Rec 2for the lower voltage canoutput up to the rated power up to 30A if the rated current is over 30A and Rec 1 canoutput upto a total of 15A When the full power switch is set for double voltage indication 11OV 22OV or 120V 240V the switch positionisas indicated by the upper dotted line in Fig 5 10 Fig 5 12isa simplified representation of this circuit showing the two main coils conn...

Page 17: ...in Severe electric shock may occur If the generatori swet by rain or snow wipe it and thoroughly dry it before starting Don t pour water over the generator directly nor wash itwith water If the generatoris wet with water the insulations will be adversely affected and may cause current leakage and electric shock 6 Do not connect the generator to the commercial power lines 4 This may cause a short c...

Page 18: ... 2 Fluorescent lamps motor driven tools light electrical appliances etc with a smaller power NOTE7 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...

Page 19: ...gly power consumptionwill be 40 f 0 7 57W As explained in Item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get the figure of the neces sary capacity of agenerator Inother words a generator witha rated outputof 1OOOWcapacity can light nine to fourteen 40 W fluorescent lamps Example2 Generally speaking a400 W motor means thatits work load is400 W Efficiency of this motor...

Page 20: ... cable i s used a voltage drop occursdue to the increased resistance in the conductors de creasing the input voltage to the load electrical product As a result the load can be damaged Table 7 2shows voltage drops per 100meters of cable Sectional areaI mm3 I I 5 5 Allowable current I A 7 12 17 23 35 No w i r eelement NoJmm Resistance 30 10 18 50 I 0 18 1 486 37 I 0 26 0 517 70 I 0 32 0 332 Table 7 ...

Page 21: ...ring 4 Tester and accessories are installed ina handy SPECIFICATIONS w Fig 8 1 MODEL Dr Robin Part Number 388 47565 08 Voltage Oto500VAC 1 25 to 70 Hz Measuring Range Resistance 0 1 to 1 999 Q ICondenser Capacity I 10to100 p F Power Source 2 x 6F44P 006P Dry C e l l Battery Accessories Dimensions Lx W x H 285mm x 200mm x 110 mm Weight 1 6 kg Test leadswith needle probes 1 set Test leadswith jack p...

Page 22: ...0V Type with an output voltage o f220 0to 15OV 0to 330V Dual voltage type or 120V 230 or 240V 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current ratingof a given generatori s most desirable About 10A 20A 1OOA 3 FREQUENCYMETER Frequency range About 45 to 65Hz NOTE Be careful ofthe frequency meter s input voltagerange FOR AC L Fig 8 2 FQR AC Fig...

Page 23: ... Usedfor measuring resistance etc 5 MEGGERTESTER Used for measuring generator insulationre sistance Select one with testing voltage range of 500V 6 TACHOMETER Use the contactless type tacho meter I Fig 8 6 I Fig 8 7 20 ...

Page 24: ...edvoltage 235 260 V 117 130 V Voltage range 240 v 120v Table 8 2 8 3DC OUTPUT MEASURING To DCTerminal Fig 8 9 Measurementof DCoutputis executed with the switch turned ON while the current is regulatedat 8 3A by adjusting the load to the generator Ifthe voltage iswithin the range from 6V to 14V the voltageoutput is normal NOTE If a batteryis connected as a load to the generator theDC output voltage...

Page 25: ... from the factory is 10 megohm or more If it is less than1 megohm disassemble the generator and measure the insulation resis tance of the stator rotor and control panel indi vidually STATOR 1 Measure the insulation resistance between BLUElead and the core 2 Measure the insulation resistance between WHITE lead and the core 3 Measure the insulation resistance between YELLOW lead and the core 4 Measu...

Page 26: ...lation resistances between the live parts and the grounded parts 4 I fig 8 13 Any part where the insulation resistanceis less than1MQ has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 23 ...

Page 27: ...ntinuityi sfound 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 I W I Wire AC receptacle Fig 9 2A Fig 9 26 9 3NO FUSEBREAKER I Circuit breake Check continuity between each of two terminals at the rear of the no fuse bre...

Page 28: ...ding MODEL Hz Yellow Yellow Black Blue White Red Voltage 120v RGD5000 120 V 240 V 6o 0 26 0 57 0 26 Tale 9 1 NOTE If the circuit tester is not sufficiently accurate it may not show the values given and maygive erroneous readings Erroneous readings will also occur when there is a wide variationofresis tance among coil windings or when measurement is performed at ambienf temperafures differ ent from...

Page 29: ... appears try cbecking in reverse polarity NOTE2 If the circuit tester is not sufficiently accurate it may not show the values given and may give er roneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurementis petformed at embient temperatures dfierent from 20 C 68 O F 2 Check if the surge absorberi s burnt Check the resis...

Page 30: ...9 3 I Fig 9 8 If such an instrument i s unavailable the condenser can be checked by replacing with a new one Ifthe generator performs good with new condenser the cause of trouble is defect in original condenser 9 7 DIODE RECTIFIER Diode rectifier Fig 9 9 Circuittester Fig 9 70 Circuit inside of the diode rectifiers isasshownin Fig 9 9 Check continuity between each terminal by using acircuit tester...

Page 31: ...it tester Brown Continuity Continuity Continuity Orange Continuity No continuity No continuity I I I I BrownMlhite No continuity No continuity No continuity Table 9 4 2 NOTE I Because o f the differenceo f measuring method between the analogue circuit tester and the digital circuit tester polarity o f tester needles should be reversed NOTE 2 Continuity means forward direction characteristics o f t...

Page 32: ...assembly 2 For more convenience dividethe parts into several groups and store them in boxes 3 To prevent bolts and nuts from being misplaced or installed incorrectly replace them temporarily to their original position 4 Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools properly and use the proper tool for each speci...

Page 33: ...ipe from the tank bottom See Fig 10 2 1 Remove the hose clampand pull the 12 spanner Do not lose the gasket 2 Removethe banjo boltthat fastens Pliers 3 Remove the fuel t a n k 12mm spanneror After removing the nutand washer re i box spanner move the fuel tank See Fig 10 3 89 Flange Nut 4 pcs 89Washer 4 pcs fuel pipe off fromthe tank the return pipe I 4 Remove the fuel fiter Pliers 1 Remove the hos...

Page 34: ...ove battery from battery base battery bolts and battery battery and take offthe battery holder box spanner Remove the two nuts that fasten the i 10mm spanner or 69nut 2pcs i 3 Remove battery base from the pipe frame 69bolt 2pcs WNUT 2pcs SPRING WASHER 2pcs I 10mm spanner or box spanner BAlTERY SPACER 2 p a BATTERY ANGLE BAlTERYCABLE BATTERY BATTERY BOLT4 1 dl i PIPE FRAME I v Fig 10 5 ...

Page 35: ...I of the control box OUT Fig 10 6 1 2 Take outthegrommetfromthe bottom I face of the control box I c Fig 10 7 t I 3 Pull out the wiresforthe o i l Sensor and electricstarter and remove them from i the connectors Fig 10 8 32 Remarks Press the upperend and pull out the bushing ...

Page 36: ...lts that fasten the generatarand frame together 1 Remove the two bolts which f u r the alternator to the generator base 2 Remove the four bolts and flange nuts which f u cthe engine to the engine base 8 bolt 4 pcs 84 flangenut 4 p a Nuts are welded to the generator base Nexesarytwl 10mm spanneror box spanner 12mm spanner or box spanner 80 FLANGE NUT 4 pa RUBBER V I ENGINE BASE SIDE PLATE A 2p a 2 ...

Page 37: ...eep Description Necesrarytod Remarks 1 and dismount from the frame i the belti nplace See Fig 10 11 r L Fig 10 17 4 Remove enginebase generatorbase and mount rubbersfrom frame 1 0 0 NUT 4 pa I BASE RUBBERV I 2 p a Fig 10 12 FLANGE NUT GENERATOR e RUBBER V I 1 P c e BASE 1 P c e 34 ...

Page 38: ...f thethrough bolt and remove Be careful not to lose the starting pulleyand spacerfromrotorthekeyatremoving shaft Applya box wrenchonthehead startingpulley of through boltand hit the wrench handlewith ahammer counterclockwise I toloosen I f Fig 10 14 Necessaryt o o l 10mm spanneror box spanner Box spanneror socket wrench Hammer Fig 10 15 35 ...

Page 39: ... b Apply the center bolt of the BOLT 4pcs Remarks Necessary tool 10mm spanneror box spanner Insert the two bolts sufficentlyand evenly or the thread hole may be damagedat remov ing specialtool 17 mm spanner Driver BOLT 60 BOLT 2 p a Fig 10 16 Fig 10 I 7 I In c a e that REAR COVER PULLER is un available removethe rear coverby the follow ing instructions I Insert the through bolt into the rotor with...

Page 40: ... the hole the statorto therear cover inside of thesupport ring and pull it out I 10mm socket BOLT 4pa SPRING WASHER pes 60 WASHER 4 pa Fig 10 20 I I 2 Take apartthestatorfromtherearcover NOTE Use utmost care not to give dam I age to thestator insulationand stator I leads I SUPPORT SPRING WASHER 4 pes 60BOLT 4 pcs Fig 10 27 37 ...

Page 41: ...r and pull out therotor from the tapered shaft of theengine Ifthe rotor cannot be taken off strikeit at differentangles See Fig 10 23 9 I Adaptor and Driving Shaft I Fig 10 22 Never strike onthe c o i l Necetrarytool 17 mm spanner mtich a m m a Fig 10 23 1 Remove the four adaptor mounting 12 mm spanner bolts andthe adaptor 89bolt 4pcs 2 Remove the four driving shaft mount 14mm spanner ing bolts an...

Page 42: ...ts flat side is down and its fuel filter mounting boss on the air cleaner side 8 x25mmbolt 4pcs 8 spring washer 4 pcs filter nting 200 230 kg 14 4 16 6ft lb boss 10 4 2 ROTOR 1 Clean the tapered portion of driving shaft and the matching tapered hole of rotor shaft of oil and dirt usinga waste cloth 2 Attach the rotor to the engine shaft Tighten the through bolt tentatively See Fig Apply a wrench o...

Page 43: ...e bolts inthe rear cover and let them match with the grooves in the stator and set the rear cover over the stator 3 Take the stator leads out from the window of the rear cover 4 Tap lightly and evenly the upper surface o fthe board on the rear cover with plastic hammer to pressfit the rear cover over the stator See Fig 10 28 5 Fixthe statorto the rear cover with four bolts washers and spring washe...

Page 44: ...the bush over the lead wires drawn out from the rear cover Press the bush and into the window of the rear cover See Fig 10 30 Fig 1030 2 Putthe rear cover with stator over the rotor Tapon therearcoverevenlywithaplastic hammer to press the rotor bearing into the rear cover SeeFig 10 31 Fig 1031 41 ...

Page 45: ...y attachedto therotor 2 Insert the key into the keyway o f the rotor shaft SeeFig 10 33 Then insert the spacer Tapping the starterpulley with a plastic ham mer attachthe starterpulleytothe rotorshaft Fig 70 33 3 Apply a washer anda spring washer to the through bolt and insert it intothe rotor shaft Through bolt 1pce 10 washer 1 pce 10 spring washer 1 pce Thedimension o f the through bolt isshown i...

Page 46: ...e use it 240 300 kgcm 17 4 21 7 ft lb 5 Attach the RECOIL STARTER to REAR COVER 6 x 8 mm flange bolt 4 pcs I Tightening torque I 3 9 5 9 N m 40 60 kg cm 2 9 4 3 ft lb Fig 70 35 1 Attach twoengine mount rubbers and one alternator mount rubber to the frame See Fig 10 36 10 mm nut 2pcs V I 1 pce ...

Page 47: ...s placed in the center of the pipe on the bottom of the generator base 11 8 13 7 N m 120 140kg m 8 7 10 1ft lb 4 Install the engine and alternator assembly into a Lift the engine and alternator assembly with a chain block and downit into the frame mak ing sure that the bolts of the mount rubbers are correctly inserted into the engine base b Fixtheengine and a alternator assembly tothe mount rubber...

Page 48: ...e frame NOTE 1 Set the stoppers so that the engine base is placed in the center of the upper and the lower rubbers See Fig 10 40 NOTE2 If the engine mount rubbers are replaced with new ones set the stoppers so that the upper rubber touchesthe engine base The new mount rubber shall be dis torted by approx 3mm in one month 8 x 12mm bolt 4 pcs I lighteningtoque I Makethis gap even Engine base I I I 1...

Page 49: ...ing toque I 3 9 5 9 N m 40 60 kgcm 2 9 4 3ft lb 1 I 10 4 7CONTROL BOX Mount the control box assembly to the frame Referto Section 10 5 for disassembly checking and reassembly procedures o fthe control box 1 Mount the control box to the frame See Fig 10 42 6 x 10mm flangebolt 3 pcs 6 washer 3pcs 40 60k g 2 9 4 3 ft lb 69 Bolt 2 p c s Fig 10 41 1 I Fig 10 42 46 ...

Page 50: ... controlbox See Fig 10 43 Attach the grommet for the oil sensor wires to the rear panel of the control box _ t I Fig 10 43 4 Fasten the one earth cable with 8 C I terminaldrawn out from the control box to the rear cover leg 8C Ix25mmbolt lpce Fasten the other earth cable with 6i terminal to the unpainted bolt hole on the frame See Fig 1044 11 8 13 7 N m 120 140 k g m 8 7 10 1 ft lb Controlbox 1 6 ...

Page 51: ...ry angle See Fig 10 45 6 Q nut 2pcs 6 spring washer 2pcs 3 9 5 9 N m 40 60kg cm 2 9 4 3 ft lb I Tighteningtorque I 3 9 5 9 N m 40 60kgcm 2 9 4 3 ft lb 3 Attach battery cordsto the battery Attach the positive cord first and then the negative cord Fasten the other end of the negative cord tothe engine base using the engine mount nut Batterycable frame Fig 10 45 48 ...

Page 52: ...Connect fuel pipe 29 complete to both ends o fthe banjo and tightenitwith banjo bolt using twopieces mm long to the fuel tank o f GASKET ALUMINUM Fueltank 80 100 kg cm 5 8 7 2ft lb 1 Hoseclamp inside DIA 7 8 2Hose clamp inside DIA 10 5 Gasket Aluminum Fuel pipe 29 complete To Nozzle Rubberpipe 69 x 129 x 170 mm Clamp 2 I To Injectionpump Rubber pipe Fuelfilter assy 6 x 12 x 250 mm Fig 10 46 49 ...

Page 53: ... up from the cylinder head before connecting the pipe to it After pulling the nozzle up slide the hose clamp 7 8 mm in inside diameter over the pipe connect the pipeto thenozzle and fasten the pipe with the hose clamp at the correct point Then install the nozzle 9 on the head Mount the bracket on the blower housing and secure the pipe with the clamp Fit the banjo to the rubber pipe 6 mm in inside ...

Page 54: ...EASSEMBLY 1 Install the receptacles no fuse breaker fuse terminals switches etc on the control panel and wire them NOTE Circuit diagrams are shown in Section 12 Colored wiresare usedforeasyidentification and are of the correct capacity and size Use heat resistant type wires permissible temperature range 75 C or over in the specified gauge shown in the circuit diagrams 2 Install regulator oil senso...

Page 55: ...ce If sta tor is faulty replace with a new one 11 1 2 CHECKING CONDENSER If an instrument QC meter or C meter for mea suring capacity of condenser is available check the capacity of condenser See Fig 11 2 NORMAL CAPACITYOF CONDENSER Table 11 1 Fig 11 1 Fig 11 2 If such an instrument is unavailable the condenser can be checkedby replacing with a new one Ifthe generator performs good with new conden...

Page 56: ... Fig 11 4 Remedy I MODEL I RGD5000 I I RESISTANCE I 1 6 Q I Table 11 2 Fig 11 3 If the resistance is not normal replace rotor with a new one Fig 1 1 4 2 CHECKING OF DIODES AND RESISTOR ON THE ROTOR Unsolder and take out the diodes and a resistor from rotor Measurethe resistanceo f diodes Polarityo f I ContinuityexistsJ I I Fig 11 5 Each rotor has three diodes Check the resistance of each diode 53 ...

Page 57: ... are frequent check the surge absorber because it mightbe broken evenif its resistanceis normal a S Z In such a case replace the rotor with a new one Reassembling 1 As shown in Fig 11 6 placethe whitemarkon the magnetto leftand solder the diodes sothat cathode markisto be placed at the bottom 2 Solder the coil endsto the terminal Surgeabsorber I Fig 11 6 11 2 AC VOLTAGEI STOO HIGH OR TOO LOW 11 2 ...

Page 58: ...pliance isfaulty repairit 11 3 4 CHECKIFTHE ENGINEI SOVERHEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re move it Fig 11 7 11 3 5 CHECK THE INSULATION OFTHE 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 1MQ dis asse...

Page 59: ...fuse blow 1 1 4 3 CHECK THEWIRING Check all the wires to be connected correctly 1 1 4 4 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode rectifierwith a circuit tester Referto Section 9 7 DIODERECTIFIER forthe checking procedure 1 1 4 5 CHECK THE DC COIL I Check the resistance between two brown leads from stator with a circuit tester Fig 11 70 MODEL RESISTANCE SPECIFICATION R...

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