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ISSUE EMD-GS2025

2005.08

TechnicaI Data & Overhaul Instructions

Содержание RG2800DX

Страница 1: ...TechnicaI Data Overhaul Instructions ...

Страница 2: ...20 5 2 SPECIAL TOOLS 20 5 3 DISASSEMBLY PROCEDURES 21 5 4 REASSEMBLY PROCEDURES 34 5 5 RECOIL STARTER 46 6 TROUBLE SHOOTING 51 7 WIRING DIAGRAM 55 This manual covers only alternator and control unit portion of the generator As to the servicing information of engine portion please refer to the EX13 E17 EX21 and EX27 service manual The specifications and information included in this manual were in e...

Страница 3: ...ne Displacement mL cu in 211 12 87 43 94 8 48 105 8 10 8 2 9 12 8 3 4 10 8 2 9 7 5 6 4 6 7 Length mm in Width mm in Height mm in 537 21 1 432 17 0 477 18 8 475 18 7 Dry weight kg lb 580 22 8 508 20 0 55 121 3 Fuel tank capacity L U S gal Valve Clearance Intake Exhaust mm in 0 1 0 03 0 0039 0 0012 Note Adjust the valve clearance while the engine is cold Emissions Durability Period California only h...

Страница 4: ... voltage 120 V Rated amperage 20 0 A 130 1 kVA V 120 110 0 0 4 8 12 16 20 24 A RG2800DX 60Hz 120 240V 3 64 63 Maximum output 3 200 VA Hz 62 Rated output 2 700 VA 61 60 2 Frequency 60 Hz 59 Rated voltage 120 240 V Rated amperage 22 5 11 3 A 130 260 1 kVA V 120 240 110 220 0 0 4 8 12 16 20 24 28 A RG3200DX 60Hz 120 240V ...

Страница 5: ...tput 4 300 VA 63 Rated output 3 700 VA Hz 62 3 61 Frequency 60 Hz 60 Rated voltage 120 240 V 59 Rated amperage 30 8 15 4 A 2 130 260 kVA 125 250 V 1 120 240 115 230 0 0 4 8 12 16 20 24 28 32 36 A RG4300DX 60Hz 120 240V ...

Страница 6: ...AL DESCRIPTION 2 1 EXTERNAL VIEW OF GENERATOR DRAIN PLUG FUEL TANK OIL LEVEL GAUGE FUEL LEVEL GAUGE CONTROL PANEL SPARK PLUG SPECIFICATIONS LABEL AIR CLEANER MUFFLER EXHAUST OUTLET TANK CAP RECOIL STARTER HANDLE ...

Страница 7: ...th the interlocking mechanism between the fuel cock and the choke furnished 2 PILOT LAMP Standard model The lamp is turned ON Green while generating properly The lamp will be turned OFF at the same time when the AC circuit breaker is turned OFF CHOKE To start the engine turn the knob to the position Choke valve is closed OPEN Keep the knob in this position after the engine starts The engine can be...

Страница 8: ...o frequency indication in the LE display LE display changeover switch When depressing this switch indication in LE display is changed over in turns operation hour voltage frequency operation hour When starting the engine operation hour is indicated in LE display at first Idle switch When depressing this switch Idle function is activated Idle lamp Lamp green is turned on while Idle function is acti...

Страница 9: ...r soundproof type models remove the side cover R to check these numbers NOTE When inquiring about your generator or ordering spare parts always give us the Model Serial Number and Production Number PROD No SER No Label 2 3 ALTERNATOR Rear cover Rotor CP Stator CP End cover AVR AY Slip ring Rotor shaft Stator cover Diode stack Brush CP Ball bearing Rotor bolt ...

Страница 10: ...their running wattage Example A rated 250 W electric drill requires a 400 W generator to start it NOTE 1 If a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps NOTE 2 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 th...

Страница 11: ... and you will get the figure of the necessary capacity of a generator In other words a generator with a rated output of 1000W capacity can light nine to fourteen 40W fluorescent lamps Example 2 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 th...

Страница 12: ...sing the input voltage to the load electrical product As a result the load can be damaged The table below shows voltage drops per 30 meters of cable Voltage drops per 30 meters of cable 30A 25A 20A 15A 10A 5A A mm2 8 9V 4 5V 12 1 25 8 6V 5 7V 2 8V 17 2 0 6 2V 4 7V 3 1V 1 6V 23 3 5 6 0V 5 0V 4 0V 3 0V 2 0V 1 0V 35 5 5 Allowable Current Cross sectional Ω 100m 1 486 0 952 0 517 0 332 Cable Resistance...

Страница 13: ...put voltage of 110 or 120 V 0 to 300 V Type with an output voltage of 220 230 or 240 V 0 to 150 V 0 to 330 V Dual voltage type 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10 A 20 A 100 A 3 FREQUENCY METER Frequency range To cover 45 to 65Hz NOTE Be careful of the frequency meter s inpu...

Страница 14: ...age range of 500V 4 CIRCUIT TESTER For measuring resistance etc NOTE The ordinary circuit tester may cause erroneous readings due to their measuring method Use a high grade precise circuit tester to check the generator components 6 TACHOMETER Use the contactless type tacho meter for checking engine speed ...

Страница 15: ...carrying SPECIFICATIONS MODEL Dr Robin Part Number 388 47565 08 Measuring Range 0 to 500 V AC 25 to 70 Hz 0 1 to 1 999 Ω 10 to 100 μF 3MΩ Circuit Protector Fuse Power Source 2 x 6F44P 006P Dry Cell Battery Accessories Test leads with needle probes 1 set Test leads with jack plugs 1 set Dimensions L x W x H 285 mm x 200 mm x 110 mm Weight 1 6 kg Voltage Frequency Resistance Condenser Capacity Insul...

Страница 16: ...C Terminal SW Load Measurement of DC output is executed with the switch turned ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal NOTE If a battery is connected as a load to the generator the DC output voltage will increase by approximately 1 to 2 V Therefore carefully observe the electroly...

Страница 17: ...OR Measure insulation resistance between each terminal from the stator and the stator core Measured insulation resistance of 1M ohm or more is normal If it is less than 1M ohm leakage current and electric shock might occur due to faulty insulation Replace with new one CONTROL PANEL With AC circuit breaker turned on measure insulation resistance between each portion of electrical parts and earth gr...

Страница 18: ... 6 0 9 1 2 0 5 0 5 Green Red 0 9 0 5 1 1 0 4 Yellow Yellow Sub coil 0 4 0 4 0 3 Black Black 0 3 0 3 0 3 2 ROTOR ASSEMBLY 1 Field coil Measure resistance between the slip rings Slip ring Rotor 2 Cleaning Slip rings The slip ring surfaces must be uniformly bright Slip rings showing black spots excessive wear or uneven wear must be repaired A stained slip ring lowers generator efficiency and output v...

Страница 19: ...ecause decreased contact pressure between the brush and slip ring lowers generator efficiency and output voltage BRUSH BRUSH HOLDER 5 mm 4 AC CIRCUIT BREAKER Check continuity between each of two terminals at the rear of the AC circuit breaker while it is mounted on the control panel 5 DC CIRCUIT BREAKER Check that there is continuity between the two terminals of DC circuit breaker when its push bu...

Страница 20: ...LE by CHECKING INTER LEAD RESISTANCE Check the inter lead resistance of the A V R with a tester referring to the following table If the tester readings very greatly from the values specified in the table the A V R is faulty c IDENTIFYING A V R TROUBLE by MOUNTING and OPERATING in THE GENERATOR SCR or transistor damage cannot be detected by simply looking at the A V R or checking the lead resistanc...

Страница 21: ...R The circuit inside the diode rectifiers is as shown in the chart above Check continuity between each terminal by using a circuit tester The rectifier is normal when continuity is as follows 1 2 3 1 2 3 Apply black minus needle of the circuit tester 1 Checking table for analogue circuit tester Analogue circuit tester No continuity 2 Apply red plus needle of the circuit tester Continuity 3 No cont...

Страница 22: ... Electric start models 6 Use all disassembly assembly tools properly and use the proper tool for each specific job 7 Be sure to attach the foam rubber linings inside the covers on their original position when reassembling the generator When deformation or damage or falling off of foam rubber lining is found replace it with new part Failure to do so will result in poor performance and durability of...

Страница 23: ...FUEL STRAINER and BATTERY CABLES 1 Turn the engine switch to STOP position to close fuel cock 2 Disconnect fuel pipes from fuel strainer Muffler cover Rear 5 3 2 REAR COVER 1 Remove muffler cover M6 x 18mm Flange bolt 6pcs Tools 10mm Box wrench Rear cover Upper 2 Remove upper rear cover ...

Страница 24: ...e coupler 5 3 4 CHOKE WIRE Deluxe model Loosen screw fixing choke wire to carburetor choke lever Turn the engine switch to CHOKE position to disconnect choke wire from choke lever Tools Screw driver Choke wire 5 3 5 GROUNDING WIRE Remove grounding wire at the right bottom side of control panel M6 Nut 1pce Grounding wire ...

Страница 25: ...d cover M5 x 10mm bolt 2pcs Tools Screw driver End cover 5 3 7 FRONT COVER UPPER BRACKET COVER Remove front cover upper For disassembling the front cover upper see illustrations on the following page Disconnect alternator couplers ...

Страница 26: ...m 40 60 kgf cm 3 0 4 4 ft lbs CONTROL PANEL Gromet DC terminals Ground terminal AC receptacles AC receptacles DC circuit breaker AC circuit breaker M6 Screw Engine switch Micro switch Multi monitor FRONT COVER UPPER and CONTROL PANEL ...

Страница 27: ...Brush holder 5 3 8 BRUSH HOLDER 1 Remove brush holder M5 x 18mm Screw 1pce Tools Screw driver 5 3 10 FUEL TANK Loosen bolts and remove fuel tank from frame M6 x 20mm Flange reamer bolt 4pcs Rubber 4pcs Tools 10mm Box wrench NOTE1 Be sure to drain fuel from the tank before removing the tank NOTE2 Take care not to get lost the four mounting rubbers of the tank Fuel tank ...

Страница 28: ...M6 Flange reamer bolt Rubber pipe Rubber Tank Fuel tank Fuel tank cap Fuel filter Fuel gauge Rubber pipe 4 0 6 0 N m 40 60 kgf cm 3 0 4 4 ft lbs Fuel strainer Screw Filter O ring Cup FUEL TANK and FUEL LINE ...

Страница 29: ... and remove muffler bracket M6 x 23mm Flange bolt 2pcs Tools 10mm Box wrench 5 3 11 FOAM RUBBER INSULATORS Remove foam rubber insulators from the gaps between frame and fuel tank 5 3 12 MUFFLER COVER Loosen bolts and remove muffler cover L by pushing it inward M6 x 12mm Flange bolt 4pcs Tools 10mm Box wrench ...

Страница 30: ...rottle shaft Governor rod 5 3 15 ROD SPRING Standard model only Take out rod spring from carburetor throttle shaft Tools Long nose pliers Throttle shaft Rod spring 5 3 16 GOVERNOR LEVER Standard model only Remove governor lever M6 x 25mm Bolt and Washer 1pce Tools 10mm Box wrench Plier Governor lever ...

Страница 31: ...ment from the air cleaner 2 Loosen nuts and a bolt and remove air cleaner body M6 Flange nut 2pcs M6 x 20mm Flange bolt 1pce Tools 10mm Box wrench Cleaner cover Element Air cleaner base Carburetor 3 Be sure not to break the gasket carefully remove carburetor from insulator ...

Страница 32: ...ge nut 4pcs Tools 12mm Box wrench 2 Remove mount rubbers from frame as necessary M8 Flange nut 4pcs Tools 12mm Box wrench 5 3 19 CRANKSHAFT COVER Loosen bolts and remove crankshaft cover M8 x 12 Flange bolt 2pcs Tools 12mm Box wrench Cover Crankshaft 5 3 20 REAR COVER Remove rear cover along with stator ...

Страница 33: ... 4 2 5 ft lbs 6 5 8 5 N m 65 85 kgf cm 4 7 6 1 ft lbs 19 0 21 0 N m 190 210 kgf cm 13 7 15 2 ft lbs Stator Bolt M6 ALTERNATOR Rotor Puller Remove rotor by using the Rotor Puller Special tools Rotor Puller 33B9990801 5 3 21 ROTOR BOLT and ROTOR 1 Remove rotor bolt Rotor bolt 1pce Tools Socket wrench NOTE Since the thread of the through bolt is in reverse direction turn it clockwise to loosen ...

Страница 34: ...il starter Recoil starter 5 3 23 BOTTOM EXTENSION PLATE Loosen bolts and remove bottom extension plate M8 x 33mm Flange bolt for crankcase side 2 pcs M8 x 12mm Flange bolt for blower housing side 2 pcs Tools 12mm Box wrench Bottom extension plate 5 3 24 BLOWER HOUSING Loosen bolts and remove blower housing M6 x 35mm Bolt 1pce M6 x 45mm Bolt 3pcs Tools 10mm Box wrench Blower housing M6x35mm Bolt M6...

Страница 35: ... 27mm Flange bolt 4pcs Tools 12mm Box wrench Drive shaft holder 33B9990201 Drive shaft holder Drive shaft 5 3 26 FLYWHEEL Using the special tool FLYWHEEL HOLDER to hold flywheel loosen flywheel nut Remove flywheel using an ordinary flywheel puller M19 Nut 1pce Tools Socket wrench Flywheel Holder 33B9990101 Flywheel puller Available on market Flywheel holder ...

Страница 36: ... of flywheel before assembly Install the Flywheel onto the crankshaft and tighten the Flywheel Nut using the special tool FLYWHEEL HOLDER to hold the flywheel M19 Nut 1pce EX17 21 Tightening torque 59 0 64 0 N m 590 640 kgf cm 43 5 47 2 ft lbs Tightening torque 10 0 12 0 N m 100 120 kgf cm 7 4 8 7 ft lbs Drive shaft holder Drive shaft 5 4 3 FLYWHEEL FAN and DRIVE SHAFT 1 Install the Flywheel Fan t...

Страница 37: ... ft lbs Bottom extension plate 5 4 5 BOTTOM EXTENSION PLATE Assemble the Bottom Extension Plate to the engine M8 x 33mm Flange bolt for crankcase side 2 pcs M8 x 12mm Flange bolt for blower housing side 2 pcs Recoil starter Tightening torque 6 5 8 5 N m 65 85 kgf cm 4 8 6 3 ft lbs 5 4 6 RECOIL STARTER Assemble the Recoil Starter to blower housing M6 x 18mm Bolt 3pcs NOTE Refer to section 5 5 for f...

Страница 38: ...e Tightening torque 19 0 21 0 N m 190 210 kgf cm 14 0 15 5 ft lbs NOTE1 Wipe off oil grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft NOTE2 The thread of the Through Bolt is in reverse direction Therefore torque it counter clockwise to tighten it 5 4 9 COVER CRANKSHAFT Assemble the Cover Crankshaft to the main bearing cover M8 x 12mm Flange bolt 2 p...

Страница 39: ... flange nuts M8 Flange nut 4pcs 5 4 11 CARBURETOR Install the Carburetor to the intake flange NOTE Be sure to attach the gasket between the carburetor and the intake flange 5 4 12 AIR CLEANER BASE Attach the Air Cleaner Base to the carburetor and fix with two M6 bolts and one M6 Flange bolt M6 Flange nut 2 pcs M6 x 20mm Flange bolt 1 pce Air cleaner base Carburetor Tightening torque 6 0 8 0 N m 60...

Страница 40: ...er element if it is dirty before reassembly Cleaner cover Element 5 4 15 ROD SPRING Standard model only Fit Rod Spring onto Carburetor Throttle Shaft Throttle shaft Rod spring 5 4 14 GOVERNOR LEVER Standard model only Fix Governor Lever with the Governor Shaft fully turned clockwise M6 x 25mm Bolt and Washer 1pce Governor lever ...

Страница 41: ... M6 x 23mm Flange bolt 2 pcs Tightening torque 4 0 6 0 N m 40 60 kgf cm 3 0 4 4 ft lbs Tightening torque 17 0 19 0 N m 170 190 kgf cm 12 5 14 0 ft lbs 5 4 16 GOVERNOR ROD Standard model only Install Governor Rod onto Carburetor Throttle Shaft Throttle shaft Governor rod ...

Страница 42: ...M6 x 12mm Flange bolt 4 pcs 5 4 19 SPONGE Install the Sponges between the fuel tank and the frame as shown in the figure righrt 5 4 20 FRONT COVER UPPER Temporarily fit Front Cover upper in position Connect alternator couplers Brush holder 5 4 21 BRUSH HOLDER Install the brush holders in the rear cover M5 x 18mm Screw 1pce ...

Страница 43: ...ls Screw driver 5 4 23 Connection of WIRING HARNESS Connect engine wire harness couples Main coil wiring Connect main coil wiring to the terminal Red wiring to the upper terminal while White to the lower one Connect couples of wiring harness between control panel and alternator ...

Страница 44: ...LE and GROUNDING WIRES Clamp the choke cable and grounding wires using a wire band 2 Attach two pieces of Rubber Seal Tank 3 Attach the Sponge Seal Muffler Wire band Tightening torque 4 0 6 0 N m 40 60 kgf cm 3 0 4 4 ft lbs Auto throttle coupler 5 4 24 AUTO THROTTLE 1 Connect the wires to Auto Throttle Unit of the carburetor 2 Temporarily connect the choke cable to the carburetor choke lever Fuel ...

Страница 45: ... the frame 2 Install the Muffler Cover Rear onto the Rear Cover Upper and the frame M6 x 18mm Flange bolt 6pcs Tightening torque 4 0 6 0 N m 40 60 kgf cm 3 0 4 4 ft lbs Muffler cover Rear Rear cover Upper End cover 5 4 28 END COVER Attach the End Cover to the rear cover M5 x 10mm bolt 2pcs ...

Страница 46: ...r M6 x 12mm Flange bolt 4 pcs Choke wire 5 4 30 CHOKE WIRE Fix the Choke Wire to the carburetor choke lever making sure that the choke valve is fully closed when engine switch is turned to CHOKE position NOTE Be sure to install the return spring Grounding wire 5 4 31 GROUNDING WIRE Fasten the grounding wire to the frame M6 Screw 1pce ...

Страница 47: ...etor to the Fuel Strainer Clamp the fuel pipe with a hose clamp Fuel strainer 5 4 32 FUEL STRAINER and FUEL PIPE 1 Align the shaft of engine switch to the Fuel Strainer Cock when the engine switch is in STOP position and the fuel cock closed ...

Страница 48: ...out Please do not release it suddenly or relax your grip 1 Disassembly procedures 1 Unhook the spring 1 Hold the starter handle and pull out the starter rope 2 Pull out all of the rope and align the rope guide and the knot of the rope inside the reel 3 Be sure to hold the reel with both thumbs so your fingers do not become be entangled 4 Pull the knot of the rope out from the reel loosen the knot ...

Страница 49: ...liers 2 Beginning at the top remove the retaining ring friction plate and ratchet Disassembly is completed 3 Remove the reel 1 Move the reel to left and right at a 1 4 turns several times until it moves smoothly gently holding it down 2 Slowly lift the reel removing it from the case 3 Repeat 3 1 and 3 2 if the spring assembled in the reel sticks out Starter handle Friction plate Starter case Reel ...

Страница 50: ...he grooves Friction plate Retaining ring C Caution Please wear protective goggles before starting assembly 2 Assembly procedure 1 Assemble the reel into the case 1 Apply grease to the case 2 Properly orient the inner end of the spring installed in the reel 3 Hold the reel so that the shaft and hook part can be caught on the inner end of the spring and softly drop into the case from the top 4 Move ...

Страница 51: ...pe end to the reel 4 Hold the rope at the distance 50cm from the rope guide Hold securely 5 Gently release the reel and have it wind the rope on the reel until the knot reaches the rope guide Five turns in counter clockwise About 20cm About 10m m Caution Do not release the pressure to hold the reel while winding the spiral spring The spring force is strong and cause sudden rewinding if you release...

Страница 52: ...imes In that case confirm that the spring is not under pressure by following the previous procedure b Please re assemble from the beginning if there was the sound when the spring was removed and the starter rope does not re winded into the reel 4 When 1 The spring pops out a Hook the end hook of the spring to the notched part of the reel and attach the spring applying pressure with your fingers so...

Страница 53: ...rmal Check if wiring is break or improper connection Refer to Engine dose not start Start failure Check and replace brush Replace Replace when wiring is break or damage Connect properly Check if engine speed is normal 50Hz 3 000rpm 60Hz 3 600rpm OK OK OK OK OK Replace Replace Check if stator coil is normal Main coil Exciter coil NG NG NG NG NG NG ...

Страница 54: ...ifier is normal Check if DC circuit breaker is normal Check if wiring is break or improper connection OK OK OK Check if DC coil of stator is normal NG NG NG NG Replace Replace Replace Replace when wiring is break or damage Connect properly ...

Страница 55: ...n of electronic throttle coupler Confirmed Runs Pull the recoil starter lightly with the full throttle open Full throttle direction Throttle direction is from the air cleaner in front towards opposite direction towards the back Dirty or bad spark plug Poor return of the choke Air cleaner blockage Muffler blockage Bad carburetor water contamination blockage etc Lack of gasoline Gasoline deteriorati...

Страница 56: ... the spark plug and check the electrode Wet Dry Attach the plug to the plug cap and check for sparks by pulling the recoil starter Good Sparks Valve clearance adjustment Check the compression at the spark plug hole by pulling recoil starter Poor compression Resistance value 0Ω Engine does not start Start failure E g GND Tester Change gasoline Blockage of the fuel passage or jets of carburotor Chec...

Страница 57: ...ub coil 2 FC EXC DC winding Oil level sensor DC output terminal Grn Gry Gry Gry Pur Blk Black Wiring color code Blk W Black White Blu Blue LBlu Light blue Brn Brown Brn W Brown White Grn Green Grn W Green White Org Orange Gry Gray R Red W White Y Yellow Grn Y Green Yellow W Blk White Black Pur Purple Pin Pink Ignition coil Spark plug AC Circuit breaker DC Circuit breaker AVR Grn Y Grn Y Grn Y 120V...

Страница 58: ...2 FC EXC DC winding Oil level sensor DC output terminal Grn Gry Gry Gry Pur Blk Black Wiring color code Blk W Black White Blu Blue LBlu Light blue Brn Brown Brn W Brown White Grn Green Grn W Green White Org Orange Gry Gray R Red W White Y Yellow Grn Y Green Yellow W Blk White Black Pur Purple Pin Pink Ignition coil Spark plug AVR Grn Y Grn Y AC Circuit breaker AC Circuit breaker DC Circuit breaker...

Страница 59: ...OR C U CONTROL PANEL GENERATOR ENGINE Main coil 1 Sub coil 1 Regulator Sub coil 2 Main coil 2 FC EXC DC winding Oil level sensor DC output terminal Grn Gry Gry Gry Pur Blk Black Wiring color code Blk W Black White Blu Blue LBlu Light blue Brn Brown Brn W Brown White Grn Green Grn W Green White Org Orange Gry Gray R Red W White Y Yellow Grn Y Green Yellow W Blk White Black Pur Purple Pin Pink Ignit...

Страница 60: ...ISSUE EMD GS2025 2005 08 ...

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