Subaru ROBIN RGD3300H Service Manual Download Page 54

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PRINTED IN THE USA

940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212

e-mail: [email protected] • www.robinamerica.com

Summary of Contents for ROBIN RGD3300H

Page 1: ...SERVICE MANUAL RGD3300H RGD5000H GENERATORS Models PUB GS2380 Rev 06 08 ...

Page 2: ......

Page 3: ...easuring 17 7 3 Measuring Insulation Resistance 18 8 CHECKING FUNCTIONAL MEMBERS 8 1 AC Receptacles 19 8 2 Circuit Breaker 19 8 3 Stator 20 8 4 Rotor Assembly 20 8 5 Condenser 21 8 6 Diode Rectifier 22 9 DISASSEMBLY AND ASSEMBLY 9 1 Preparation and Precautions 23 9 2 Special Tools for Disassembly and Assembly 23 9 3 Disassembly Procedures 24 9 4 Assembly Procedures 33 9 5 Control Box 42 10 TROUBLE...

Page 4: ... DC output V A 12 8 3 Power factor 1 0 Over current protector No fuse Breaker Noise level at rated output dB 7 m 77 5 79 7 ENGINE Model 1B30 1B40 Type Air cooled 4 cycle single cylinder diesel engine Displacement ml cu in 347 21 17 462 28 19 Fuel Automobile diesel light oil Fuel tank capacity L US gal 12 0 3 17 Continuous operating hours at rated output h 8 5 5 9 Starting system Electric and Recoi...

Page 5: ...quency 60 Hz Voltage 110 V 2 3 DC OUTPUT RGD3300H RGD5000H DC Voltage 12 V DC Ampere 8 3 A DC Output 100 W The voltage curve shown in the left indi cates the characteristic of DC output when charging a battery The voltage may be decreased by 20 when the resistance load is applied NOTE It is possible to use both DC and AC outputs simultaneously up to the rated output in total ...

Page 6: ...ION 3 1 EXTERNAL VIEW FUEL COCK AIR CLEANER RECOIL STARTER RECOIL STARTER HANDLE FUEL GAUGE TANK CAP FUEL TANK CONTROL PANEL OIL GAUGE OIL FILLER SPEED ADJUSTER OIL FILTER OIL DRAIN PLUG FUEL FILTER ELECTRIC STARTER MUFFLER ...

Page 7: ...ver Specification label is attached on the frame NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service RGD3300H AC RECEPTACLES 20 A VOLTMETER FULL POWER SWITCH AC CIRCUIT BREAKER DC FUSE HOUR METER KEY SWITCH GROUND TERMINAL DC TERMINALS AC CIRCUIT BREAKER AC RECEPTACLES 30 A PROD No SER No Label ...

Page 8: ...teel sheet core a main coil and a condenser coil which are wound in the core slots The condenser coil excites the rotor field coil which generates AC voltage in the main coil GENERATOR BASE MOUNT RUBBER STARTOR BOLT REAR COVER THROUGH BOLT FRONT COVER END COVER BALL BEARING STARTOR COMPLETE SUPPORT RING ROTOR COMPLETE ...

Page 9: ... the output voltage 4 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action A diode rectifier and surge absorber is mounted inside of the insulator DIODE RECTIFIER SURGE ABSORBER ...

Page 10: ...ker protects the generator from getting damage by overloading or short circuit in the appliance The table below shows the capacity of no fuse breaker by each spec and their object of pro tection MODEL SPECIFICATION NO FUSE BREAKER OBJECT of PROTECTION RGD3300H 120 240 V 14 A 2 Total output amperage RGD5000H 120 240 V 20 A 2 Total output amperage 30 A Output from 30 A receptacle ...

Page 11: ...d the specified limits to prevent burning CAUTION To connect the appliance to locking receptacle insert the plug into the receptacle and turn it clockwise to lock NOTE The generator for U S A market is equipped with NEMA standard receptacles Use the proper plug for connecting appliance to the generator NOTE If your generator has receptacles peculiar to your country the table above does not apply S...

Page 12: ...ange 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 flows through the field coil and mag netizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 3000 to 3300 rpm 60 Hz type the current in the condenser coil and field coil increases rapidly This a...

Page 13: ...one recep tacle in each voltage Fig 1 Fig 2 Switch Position LOWERVOLTAGE RECEPTACLE HIGHER VOLTAGE RECEPTACLE 120 V Rated output No output can be taken 120 240 V Half of rated output Rated output Table A MC1 MC2 Rec 1 Rec 2 120 V 120 V Rec 3 120 V 120 240 V 240 V MC1 MC2 Rec 1 Rec 2 120 V 120 V MC1 MC2 Rec 1 Rec 2 120 V 120 V Rec 3 240 V Fig 3 ...

Page 14: ...tion is as indi cated by the upper dotted line in Fig 1 Fig 3 is a simplified representation of this circuit showing the two main coils connected in series ln 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 Ta...

Page 15: ...erator is wet by rain or snow wipe it and thoroughly dry it before starting Do not pour water over the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leakage and electric shock 6 Do not connect the generator to the commercial power lines This may cause a short circuit or damage to the generator Use a tra...

Page 16: ...a power factor correction capacitor is not applied to the mercury lamp or fluores cent lamp the more power shall be required to drive those lamps A rated 3000 W generator can drive one or two 400 W mercury lamps without power factor correction capacitors NOTE 2 Nominal wattage of the fluorescent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no specia...

Page 17: ...with a rated output of 1000 W capacity can light nine to fourteen 40 W fluorescent lamps Example 2 Generally speaking a 400 W motor means that its work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570 W When this motor is used for a motor driven tool the capacity of the generator should be multipled by 1 2 to 3 and 570 W as explained in the Item 3 Output of e...

Page 18: ... table below has been prepared to illustrate the approximate voltage loss when an extension cord of 300 feet approx 100 meters is used to connect an appliance or tool to the generator R means resistance Ω 100 m on the above table l means electric current through the wire A 2 means the length of the wire m The length of the wire indicates round length it means twice the length from generator to ele...

Page 19: ...120 V 0 to 300 V Type with an output voltage of 240 V 0 to 150 V 0 to 300 V Dual voltage type 7 1 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10 A 20 A 100 A 7 1 3 FREQUENCY METER Frequency range About 45 to 65 Hz NOTE Be careful of the frequency meter s input voltage range 7 1 4 TESTE...

Page 20: ...ngine have been disassembled The contact less type is recommended 7 2 AC OUTPUT MEASURING Use a circuit like the one shown in the figure above 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 the table below at the rated amperage and rated rpm Rated voltage 120 V 240 V Voltage ra...

Page 21: ...ulation resistance of the stator rotor and control panel individually STATOR 1 Measure the insulation resistance between BLUE lead and the core 2 Measure the insulation resistance between WHITE lead and the core 3 Measure the insulation resistance between YELLOW lead and the core 4 Measure the insulation resistance between BROWN lead and the core ROTOR Measure the insulation across one of the sold...

Page 22: ... 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 Front Rear 8 2 CIRCUIT BREAKER Check continuity between each of two terminals at the rear of the circuit breaker while it is mounted on the control panel Normally there is continuity between each of the two when the circuit breaker is on while the...

Page 23: ...f the field coil NOTE 1 Measure the resistance of each coil winding while the diode and each resistor are disconnected with their solder removed NOTE 2 If the circuit tester is not sufficiently accurate it may not show the values given and may give erroneous read ings Erroneous reading will also occur when there is a wide variation of resis tance among coil windings or when measurement is performe...

Page 24: ...he capacity of condenser 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 Normal resistance is Ω NORMAL CAPACITY OF CONDENSER MODEL RGD3300H RGD5000H 60 Hz 60 Hz CONDENSER 20 µF 30 µF 20 µF 30 µF Continuity exists POLARITY OF CIRCUIT TESTER POLARITY OF...

Page 25: ...haracteristics 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 Apply black needle of the circuit tester Brown Brown Orange Brown White Apply red needle of the circuit tester Brown No continuity No continuity ...

Page 26: ...sembly 2 For more convenience divide the parts into several groups and store them in boxes 3 To prevent bolts and nuts from being misplaced or installed incorrectly place them temporarily back at their original position 4 Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools properly and use the proper tool for each spe...

Page 27: ...nnecessary 2 Remove the fuel cock from the bracket 6 ø flange bolt 3 Remove the hose clamps three places Plier 4 Loosen the four nuts 8 ø and remove the fuel tank Take care of spilt fuel from the fuel tank 10 mm spanner or box spanner 5 Remove the fuel tank mount 4 places HOSE CLAMP FUEL TANK HOSE CLAMP 8 ø NUT 8 ø NUT FUEL COCK 6 ø FLANGE BOLT MOUNT ...

Page 28: ...e harness is still connected 10 mm spanner or box spanner 3 Put the control box with control panel down Put a waste cloth under the control panel to protect it 10 mm spanner 4 Loosen the nut 4 ø to remove the ground wire green yellow from the rear of control box 5 Pull the bushing out from the control box Step Part to remove Description Remarks Tool COUPLER FOR KEY SWITCH ...

Page 29: ...the control box 3 Pipe Frame Step Part to remove Description Remarks Tool PIPE FRAME GENERATOR BASE MOUNT RUBBER MOUNT RUBBER 2 pcs RGD3300H 8 ø NUT RGD5000H 10 ø NUT 2 pcs 2 pcs 8 ø NUT 8 ø BOLT 2 pcs 6 ø BOLT 2 pcs FUEL TANK BUFFLE PLATE ENGINE BASE STOPPER RGD3300H 8 ø NUT RGD5000H 10 ø NUT 2 pcs 2 pcs ...

Page 30: ...hich join the mount rubbers to the engine 12 mm spanner 5 Remove the two bolts which join the rear cover to the generator base 8 ø bolt 2 pcs 12 mm spanner 6 Remove the bolts and nuts to fix the engine base 7 Lift up the engine and alternator assembly using a chain block and dis mount it from frame 8 Remove generator base from mount rubber 8 ø nut 1 pc 12 mm spanner 9 Remove mount rubbers from fra...

Page 31: ...h join the rear cover to the front cover 4 Take off the rear cover Use the special tool REAR COVER PULLER to remove the rear cover a Insert the two bolts of the special tool into the thread holes of the rear cover b Apply the center bolt of the special tool to the center hole of the rotor shaft c Tighten the center bolt to pull out the rear cover Insert the two bolts sufficiently and evenly or the...

Page 32: ...the four bolts which join the stator to rear cover 10 mm box wrench 2 Insert a small hook into the hole inside of the support ring and pull it out If a small hook is unavailable remove the stator by the following procedure a Hold the rear cover and stator assembly open side down b Place a cushion under the stator to protect it when dropped c Hit on the bearing housing of rear cover with a wooden b...

Page 33: ...pply a box wrench on the head of through bolt Hit the wrench handle with a hammer counter clockwise to loosen Box wrench Plastic hammer 2 Put the engine on the working table recoil starter side down Step Part to remove Description Remarks Tool SUPPORT RING STATOR REAR COVER 6 ø BOLT 4 pcs ...

Page 34: ...enter hole of rotor shaft Fill with oil to the shaft end 2 Prepare a bolt with the following thread size M12 P1 5 3 Apply a few turns of seal tape around the tip of the bolt 4 Screw the bolt into the thread of the rotor shaft Do not stick out your face over the rotor Step Part to remove Description Remarks Tool SEAL TAPE ...

Page 35: ...rotor shaft takes apart the rotor from the engine shaft 4 Wipe off oil thoroughly from rotor shaft and engine PTO shaft 7 Front cover and Front Protector 1 Remove the four bolts which join the front cover to the engine 8 ø bolt 4 pcs 12 mm spanner 2 Remove front protector from front cover 8 mm spanner or screw driver Step Part to remove Description Remarks Tool ...

Page 36: ...row without fail 8 ø 20 mm bolt and washer assy 4 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 68 10 1 ft lb NOTE 1 Insufficient thread locking agent application could cause oil leak age NOTE 2 The size of faucet joint and pitch of mounting holes of front cover is different by models RGD3300H and RGD5000H 9 4 2 ROTOR 1 Clean the tapered portion of driving shaft and the matching tapered hole...

Page 37: ...achine If a pressing machine is unavailable tap around the board on the rear cover evenly with a plastic hammer to press fit the rear cover over the stator CAUTION Take care of the rear cover to be pressed in upright position 6 Join the stator to rear cover with four bolts washers and spring washers 6 ø bolt 4 pcs 6 ø washer 4 pcs 6 ø spring washer 4 pcs Tightening torque 7 8 9 8 N m 80 100 kg cm ...

Page 38: ...s the rotor bearing into the rear cover 9 Tighten the four bolts washers and spring washers to join the rear cover to the front cover 6 ø 25 mm bolt 4 pcs 6 ø wash 4 pcs 6 ø spring washer 4 pcs Tightening torque 4 9 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 9 4 4 END COVER Attach end cover to the rear cover The air inlets of the end cover have to face down ward 6 ø 8 mm flange bolt 4 pcs Tightening torque...

Page 39: ...ing a 5 mm brass screw 3 Attach the generator mount rubber to the frame 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 5 ø TERMINAL FRAME 8 ø TERMINAL REAR COVER 6 ø TERMINAL CONTROL BOX PIPE FRAME GENERATOR BASE MOUNT RUBBER MOUNT RUBBER 2 pcs RGD3300H 8 ø NUT RGD5000H 10 ø NUT 2 pcs 2 ...

Page 40: ... 68 10 1 ft lb 5 Attach the base plate to the engine RGD3300H 8 ø RGD5000H 10 ø 6 Lift engine and alternator assembly with a chain block and mount it to the frame Down the alternator first then the engine into the frame Lift the engine by approx 25 mm so as not to apply weight to the engine mount rubbers Make this gap even RGD3300H 8 ø RGD5000H 10 ø ...

Page 41: ...ut 2 pcs RGD5000H 10 ø flange nut 2 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 68 10 1 ft lb CAUTION Pay attention to the position of the mount rubbers Lift down the engine and alternator assembly and remove the chain block belt 9 Attach the stoppers to the frame 8 ø 12 mm bolt 4pcs 2 places Tightening torque 11 8 13 7 N m 120 140 kg cm 8 68 10 1 ft lb NOTE 1 Set the stoppers so that the ...

Page 42: ...onnectors to the side of speed control unit 3 Connect the wires drawn out from the stator to the wires from the control box NOTE 1 Connect the wires of the same color NOTE 2 On 240 V model connect one blue stator lead with a white con trol box lead NOTE 3 Engage the connectors securely 4 Push the wires into the control box and attach the bushing over the wires Press the upper end of the bushing in...

Page 43: ... Install the fuel tank with four nuts 8 ø 2 Connect the hose clamps three places 3 Install the fuel cock to the bracket 6 ø flange bolt 4 Open the fuel cock COUPLER FOR KEY SWITCH HOSE CLAMP FUEL TANK HOSE CLAMP 8 ø NUT 8 ø NUT FUEL COCK 6 ø FLANGE BOLT MOUNT ...

Page 44: ...en two nuts with battery bolts installed in position 6 ø nut 2 pcs Tightening torque 4 9 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 2 Connect battery cables to the battery Connect the positive cable first and then the negative cable PIPE FRAME A A BATTERY STAY BATTERY BATTERY CABLE BATTERY BOLT ...

Page 45: ...ir wires soldered Unsolder them to remove those parts if necessary 9 5 3 REASSEMBLY 1 Install the receptacles no fuse breaker fuse terminals switches etc on the control panel and wire them NOTE Circuit diagrams are shown in Section 11 Colored wires are used for easy identifica tion and are of the correct capacity and size Use heat resistant type wires permissible temperature range 75 C or over 2 I...

Page 46: ...QC meter or C meter for mea suring capacity of condenser is available check the capacity of condenser 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 10 1 3 CHECKING OF ROTOR 1 CHECKING FIELD COIL Remove rear cover and stator Unsolder the coil ends fr...

Page 47: ...onnected to the diode holder Check the magnetic force of permanent magnets molded in the rotor Remedy 1 If the magnetic force of rotor magnets is weak or if the surge absorber is not good replace the rotor with a new one 2 If the diode is not good replace it with a new one CAUTION In case the diode troubles are frequent check the surge absorber because it might be broken even if its resistance is ...

Page 48: ...ark is to be placed at the bottom 2 Solder the coil ends to the terminal 10 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 10 2 1 CHECKING STATOR Check stator referring to Step 10 1 1 10 2 2 CHECKING CONDENSER Check condenser referring to Step 10 1 2 10 2 3 CHECKING ROTOR Check rotor referring to Step 10 1 3 DIODE SURGE ABSORBER WHITE MARK ...

Page 49: ...If the appliance is faulty repair it 10 3 4 CHECK IF THE ENGINE IS OVERHEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris remove it 10 3 5 CHECK THE INSULATION OF THE GEN ERATOR 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 MΩ d...

Page 50: ...0 4 3 CHECK THE WIRING Check all the wires to be connected correctly 10 4 4 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode rec tifier with a circuit tester Refer to Section 8 6 DIODE RECTIFIER for the checking procedure 10 4 5 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester If the resistance reading is much larger or smaller ...

Page 51: ... 4 5 6 7 8 W G 9 EARTH TERMINAL DC output terminal Org FUSE 10A Org D Brn W Brn C Y Y Brn Brn Gry PIPE FRAME Grn Y DC W R Blu MC MC FC SC V Hr Blk CONTROL BOX GENERATOR ENGINE BATTERY Blk Black Wiring color cord R Red Blu Blue Org Orange Brn Brown Y Yellow W White Gry Gray Grn Y Green Yellow Brn W Brown White MC AC winding SC Auxiliary winding DC DC winding FC Field winding C Condenser D Diode sta...

Page 52: ... Grn Y Green Yellow Brn W Brown White X1 Display panel X1 X1 U C L W G G G G3 B 30 50 M M1 S8 S7 S6 Y4 7 0 0 1 2 50a 15 30 120V 240V 120V 1 2 3 Blu Blk H W Y W X G 4 5 6 7 8 W W Y G G 9 Org Org D Brn W C Y Y Brn Brn Gry PIPE FRAME Grn Y DC W R Blu MC MC FC SC V Hr Blk BATTERY Brn CONTROL BOX GENERATOR ENGINE MC AC winding SC Auxiliary winding DC DC winding FC Field winding C Condenser D Diode stac...

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