Download rgd2500 / rgd3300 generator service manual
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Robin Model G RGD25 ator OlRGD3300 1 ISSUE EMD-GO604 1 Section Title 1. SPECIFICATIONS 2. PERFORMANCE 2-1 2-2 2-3 Page 1 ............................................. 2 .............................................. 2 3 5 Model RGD2500 ......................................... ......................................... Model RGD3300 DC Output. ............................................. 3. FEATURES .................................................. 6 4. GENERAL DESCRIPTION OF GENERATOR ....................... 7 4- 1 4-2 4-3 5. External View of Generator ................................. Control Panel ............................................ Location of Serial Number and Specification Number CONSTRUCTION 5-1 5-2 5-3 AND FUNCTION ....................................... SAFETY PRECAUTIONS 7. RANGE OF APPLICATIONS 8. MEASURING 9. 10. 10- 1 1 0-2 1 0-3 1 0-4 10-5 15 15 19 22 23 PROCEDURES .................................... 26 FUNCTIONAL MEMBERS ............................ Voltmeter and Pilot Lamp .................................. AC Receptacles .......................................... Circuit Breaker ........................................... Stator .................................................. Rotor Assembly .......................................... Condenser .............................................. Diode Rectifier ........................................... DISASSEMBLY 15 .................................... Measuring Instruments ..................................... AC Output Measuring ...................................... Measuring Insulation Resistance .............................. CHECKING 9- 1 9-2 9-3 9-4 9-5 9-6 9-7 .............................. ............................................ Construction Function ............................................... Description of Generator Operation ........................... 6. 8-1 8-2 8-3 ............. 7 8 14 AND ASSEMBLY ................................ Preparation and Precautions ................................. Special Tools for Disassembly and Assembly .................... Disassembly Procedures .................................... Assembly Procedures ...................................... Checking, Disassembly and Reassembly of the Control Box . . . . . . . . . 26 28 28 30 30 30 31 31 32 32 33 34 34 34 35 43 55 11. TROUBLE 11-1 11-2 11-3 11-4 11-5 Page Title Section SHOOTING .. ........ No AC Output ...... ...... AC voltage is too high or too low AC voltage is normal at no-load, No DC Output . . . . . . . . . . . . Oil sensor trouble shooting . . . 12. WIRING DIAGRAM .... .... .. but .... .... ... ... .. . the ... ... ......... ......... ......... load cannot ......... ......... ......... ......... ......... be applied ......... ......... ... .. ..... ..... .... ..... ..... . . . . . . 56 56 57 58 59 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Model --.. -_- Type - _- ,.- -._ -.-. _ ___ .-- Withrn -. Air-cooled, _- ___ 4 cycle, rpm 50 Hr: 60 H7: 4.8 PS/3600 .-- rpm 5.0 PS/3000 Oil rpm l- .- 5.5 PS/3600 .- rpm -_ Starter -_ 0.9 liters _ .-__ and Optional .._ .50 H7: 1.18 liters/hour 60 Hz: 1.30 liters/hour - ----_. - Recoil .-.-.._ ._ 7.8 liters (2.1 U.S. gal.) .._ 0.93 liters/hour 1 .lO liters/hour - -_- LxWxH -.__ 265cc (16.17 cuin.) _._----_ --.. Dimensions _ DY27D ._ ___.-- -. . 230 cc (I 4.04 cuin.) _. -_. ., Diesel engine --__- Diesel Light Ratio .- 10% bY23D . 4.3 PS/3000 - .-__ - ..- (IOOW) -_-_ Condenser Type . .- __. .-- Phase 1.0 -_ . 2-Pole, Single 12V-8.3A ..-- ._-- Field, Self-Exciting, RGD3300 . .-_. -__- --_ -.. Fuel Consumption (at Ratc!tl Ol.rtpllt) Revolving .-_. - --_ I Type .- ___ -- Voltage Regulator ..Voltage Regulation -- j u - ..~. Brushless, Power Factor -_. DC Output u c RGD2500 -_- -.-- . -. - .-. Electric ___ Starter _. - 536 x 400 x 458 mm (21 .I x 15.8 x 18.0 in.) . .-.709 x 400 x 458 mm (27.9 x 15.8 x 18.0 in.) Specifications -._ are subject _ ._-- to change without notice. PERFORMANCE CURVES MODEL RGD2500 RGD2500 Output 53 Max. Rated 52 51 Frequency 50 Voltage. 49 ............... .............. ................. .................. 2200W 2000W 50Hz 220v 230 4 2 220 s 2 210 0 2 6 8 4 CURRENT (A)---+ 10 RGD2500 Output Max. Rated i 2k Frequency Voltage. 4 0 t 2 4 6 8 CURRENT (A) + 51 4 49 50 ................. .................. 2000W 50Hz 240V RGD2500 Output 1 230 Frequency A Voltage Y 220 0 4 8 12 16 CURRENT (A)---) Max. Rated I 4 2k i E .............. 2200W 10 52 53 z ............... 20 -2- ............... .............. ................. ................ 2200W 2000W 50Hz 11 OV!22OV RGD2500 Output Max. Rated Frequency Voltage O 4 8 CURRENT 12 IA)--, 16 20 ............... .............. ................. ................ 2500W 2300W 60Hz 11 OV!22OV 24 RGD2500 63 Output 62 Rated 61 60 Frequency 59 A Max. Voltage ............... .............. ................. ................... 2500W 2300W 60Hz 120v 130 120 110 I 0 4 8 12 16 CURRENT IA) ---) 20 2-2 MODEL RGD3300 RGD3300 Output Max. Rated Frequency. -2k A Voltage 230 t > 220 0 2 4 6 CURRENT 8 IA) + 10 12 14 -3- ............... .............. ................ ................... 3000W 2700W 50Hz 220v t N I RGD3300 53 s ze 52 5 UJ r LL 50 1 51 49 - 2k 250 4 5 g ;r -I 0 > Output ‘3k I -I lk 240 Max. Rated Frequency .............. ................. Voltage. t ............... .................. 3000W 2700W 50Hz 240V 2 c 2 E 5 0 230 0 2 4 6 CURRENT 8 10 (A) --) 12 14 RGD3300 52 I 51 Output -r3k 50 Max. Rated 49 Frequency. - 2k 230 220 Voltage ............... .............. ................ ................ 3000W 2700W 50Hz 11 OVi22OV t z i 3 k = 0 210 -1k 120 110 I 100 0 4 8 12 CURREhlT 16 (At + 20 24 28 JO RGD3300 Output i , /’ Rated Frequency 2 0 w z Voltage. 230 220 t 210 2 g 120 2 110 g > 100 0 4 8 12 CURRENT Max. 16 (Ai+ 20 24 8 1 28 32 0 -4- ............... .............. ................. ............... 3300W 3000W 60Hz 1 lOV:22OV A 63. RGD3300 1 Output ............... Max. Rated Frequency Voltage. .............. ................. ............... 3300 3000 60Hz 12OVi24OV ‘i CURRENT (A) + 2-3 DC OUTPUT t 20 18 5 16 g 14 2 12 DC Voltage ................ 12v DC Ampere ................ 6.3A DC Output ................ 1oow The voltage curve shown in the left indicates the characteristic of DC output when charging a batter?. The voltage may be decreased b!- 20% when the resistance load is applied. NOTE: 0 2 4 CURRENT 6 IA) - 8 10 -5- It is possible to use both DC and AC outputs simultaneously up to the rated output in to tat. 3. FEATURES 3-1 BRUSHLESS ALTERNATOR Netvly developed brushless alternator sliminates troublesome brush maintenance. 3-2 EASY STARTING Light pull recoil starter accompanied Lvith automatic decompression system makes the new RGD series gensrators ev2n easier in starting than gasoline engine generators. 3-3 QUIET OPERATION The new RGD seriss generator provides qui2t operation by means of: 0 The superb design of intake-eshaust system. Direct injection combustion sl-stem. 0 .A large super silent muffler. 0 An efficient 10~~noise air cleansr. l 3-4 ECONOMICAL PERFORMANCE On top of ~~211known diesel economy. the air-cooled Robin dies21engine f2aturss dirzct fu2! injection and spscial dssign refinements for extra fu21 efficiens>-. 3-5 OIL SENSOR Ths OIL SESSOR automaticall)- shuts the 2ngin2 off whenever th2 oil level falls down below a safe 12v21 prsv2nting engine seizur2. 3-6 COMPACT, LIGHT WEIGHT The combination of ne\vl>- devslop2d brushless alternator and air-cool2d sing12 cl-linder Robin di2sel engine enables the n2w RGD ssrirs generators to be \-er>-compact in size and light in weight. 3-7 RELIABLE PERFORMANCE WITH MINIMAL MAINTENANCE 0 A brushlsss alternator eliminates troublesome brush maintsnancs. 0 A drip-proof alternator design. l A trouble free condsnser voltags regulator. l .A fus212sscircuit breaksr. l A dust-proof dual element air cleaner. The OIL SESSOR automaticall!- shuts ths rsngine off wh2n2ver the oil level prsv2nting sngine szizurs. l 3-8 LONG-LIFE l l level falls down belokv a safe DURABILITY Compact and smooth running air-cool2d Robin dirssl 2ngin2 lasts much longr than th2 gasoline 2ngin2 of th2 Sam2 sizs. Trouble-fr22 brushless altsrnator 1%.ith2ondzns2r t)-ps voltags regulator Lvorks all the year round without any maintenace work. -6- 4. GENERAL DESCRIPTION OF TH E GENERATOR 4-l EXTERNAL VIEW of GENERATOR NO-FUSE ROCKER BREAKER COVER AC VOLTMETER KEY SWITCH (Electric starter as option) type FUEL INJECTION -STOP I EARTH (GROUND) TERMINAL \ I FUEL Ltvtn FILTER o\IL FILTER FUEL FUEL TANK COCK & TANK CAP MUFFLER FUEL STARTING IFlcvrrlc __.._F OIL CiAUbf= MOTOR starter type as OptIOn) -7- GAUGE -, . . . -. (Electric sti wtef type as optiol 4-2 CONTROL PANEL l RGD2500, RGD3300: START luptlonl 50Hz-220V, 24OV. 60Hz-220V TYPE SWITCH NO-FUSE BREAKER AAC RECEP DC OUTPUT TERMINAL EARTH !GROUNDl TERMINAL DC FUSE . RGD2500, RGD3300: START IOPtionl 50Hz-11OV. 60Hz-llOV, 120V TYPE SWITCH DC OUTPUT TERMINAL NO-FUSE \ II,- 9 m’ AC RECEPTA EARTH DC FUSE/ -8- BREAKER (GROUNDI TERMINAL . RGD2500, RGD3300: FULL START (Option) POWER SWITCH 50Hz-llOV/220V, 60Hz-llOV/220V, 12OV/24OV TYPE - NO-FUSE SWITCH BREAKER AC RECEPTACLE VOLTMETER/ DC OUTPUT ;:d TERMINAL \ ‘EARTH DC FUSE! . RGD2500, RGD3300: VOLTAGE START (ODtion CHANGEOVER U.K., 50Hz-llOV/220V SWITCH :GROUNDl TERMlhAL [BS RECEPTACLE] z NO-FUSE SWITCH I BREAKER VOLTMETER/ 1lOV 22OV RECEPTACLE- DC OUTPUT RECEPTACLE > TERMINAL \ ? ’ DC FUSE! -9- EARTH IGROUND) TERMINAL . RGD2500: U.S.A., 60Hz-120V [NEMA RECEPTACLE] NO-FUSE PILOT BREAKER LAMP 12OV RECEP RTH . RGD3300: FULL START (Option) POWER U.S.A., 60Hz-120V/240V [NEMA TERMINAL RECEPTACLE] SWITCH SWITCH -NO-FUSE -.,a ~ PILOT IGROUND! BREAKER I 0 0, 120V RECEPTACLE LAMP EARTH - 10- IGROUNDi TERMINAL . RGD2500, RGD3300: START (Option) GERMANY, 50Hz-220V NO-FUSE SWITCH 220V VOLTMETER DC OUTPUT BREAKER RECEPTACLE / TERMINAL \ EARTH DC FUSE/ . RGD2500, RGD3300: START (OptIonI TERMINAL 50Hz-220V [WITH SPECIAL RECEPTACLE] NO-FUSE SWITCH T VOLTMETER/ DC OUTPUT (GROUND) 220V BREAKER RECEPTACLE TERMINAL \ EARTH DC FUSE ------ - 11- IGROUND) TERMINAL . RGD2500, RGD3300: START (OptIoni SWITZERLAND, 50Hz-220V NO-FUSE SWITCH 220v VOLTMETER BREAKER RECEPTACLE y DC OUTPUT TERMINAL \ DC FUSE l EARTH ! RGD2500, RGD3300: !GROUND! TERMINAL FRANCE, 50Hz-220V NO-FUSE VOLTMETER BREAKER 220V RECEPTACLE iGROUND TERMlnAL y DC OUTPUT TERMI’UAL \ DC FUSE y ’ - 12- EARTH 8 RGD2500, RGD3300: START IOptbon) AUSTRALIA, 50Hz240V SWITCH NO-FUSE 240V BREAKER RECEPTACLE VOLTMETER DC OUTPUT TERMINAL RTH DC FUSE - 13- (GROUNDI TERMINAL 4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number arc stamped on the L-ABEL (MODEL T.UlE) stuck on the end cover. NOTE: Always specify these numbers when inquiring to get correct parts and accurate service. about the generator or ordering spare parts in order SERIAL - 14- NUMBER 5. CONSTRUCTION AND FUNCTION 5- 1 CONSTRUCTION STATOR GENERATOR BASE MOUNT BOLT END RUBBER BALL COVER REAR BEARING STATOR COVER THROUGH BOLT COMPLETE SUPPORT RING Fig. 5- 1 5-2 FUNCTION 5-2- 1 STATOR The stator consists of a laminated silicon steel sheet core. a main coil and a condenser coil Lvhich are wound in the core slots. The condenser coil excites the rotor field coil \vhich gensrates XC voltage in the main coil. Fig. 5-2 - 15- ROTOR FRONT COMPLE COVER TE 5-2-Z CUNDENSEK Two condensers are installed in the control box and are connected to the condenser coil of the stator. These condensers and condenser coil regulate the output voltage. Fig. 5-3 5-2-3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core. DC current in the field coil magnetizes the steel sheet core. Two permanent magnets are provided for the primary exciting action. Fig. 5-4 A diode rectifier and a resistor are mounted inside of the insulator. I DIODE RECTIFIER & SURGE Fig. 5-5 - 16- ABSORBER 5-2-4 (1) FUSE The 10 ampere DC fuse mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit. (2) 0 Q The 15 ampere DC fuse in the control box protects the diode rectifier from getting damage by reverse connection to the battery. (Electric start model) Fig. 5-6 5-2-5 NO-FUSE BREAKER The no-fuse breaker protects the generator from gettmg damage by overloading or short circuit in the appliancc. RATING GENERATOR SPECIFICATION 50Hz-IlOV 50Hz-220V 50Hz-240V - 50Hz-1 lOVf22OV RGD3300 20A 25A IOA 12A 10A 12A 12Ax2 27A 20A 60Hz-120V - 60Hz-1 lOV!22OV - 20A I 27A 14Ax lOAx lOAx I BREAKER RGD2500 lOAx 60Hz-1 IOV 60Hz-120V/240V OF NO-FUSE I 2 14Ax2 Table 5- 7 Fig. 5-7 - 17- 7 5-2-6 RECEPTACLE and AC PLUG (STD. SPEC.) These are used for taking AC output po\ver from the generator. X total of four kinds of receptacles, each varying in rated voltage and current from another. are used. Each model has at least one receptacle to deliver the rated generator output. As many AC plugs as the receptacles. each matching the corresponding receptacle, r 2 sho\vs the rated current for each receptacle. Be careful not to use the receptacles and are provided. Table 3AC plugs beyond the specified limits to prcvsnt burning. 1 from -u -q ,a.3 * +$ w’ I ! ! two receptacles up to 15 amperes up to 30 amperes (See Caution.) Table 5- 2 Caution: To connect the appliance to locking receptacle, insert the plug into the receptacle and turn it clockwise to lock. Fig. 5-8 NOTE: If your generator has receptacles peculiar to your country, Table 5-2 does not apply. NOTE: The generator for U.S. A. market is equipped with NEMA standard receptacles shown in table 5-3. Use the proper plug for connecting appliance to the generator. I Style ’ Ampere 125V 20A Receptacle Description AC plug NEMA NEMA 5-20R 5-2OP , GFCI ’ (Ground Fault Circuit Interrupter I Receptacle, NEMA NEMA 20A Ll4-20R L14-20P 125V NEMA 30A L5-30 125V 250V / NEMA L5-3OP Table 5 - 3 - 18- duplex Locking Receptacle Locking Receptacle 5-3 DESCRIPTION of GENERATOR PERMANENT FOR INITIAL MAGNET EXCITATION FIELD STATOR 1% ‘d 7 1 NI I s i’ t F RESISTOR ------J i@k ------I I / / MAIN r----7 COIL COIL ROTOR r------ L- OPERATION / II I’ I’ I’ i’ I I I I APPLIANCE I I I i DIODE CONDENSER COIL CONDENSER Fig. 5-9 5-3- 1 GENERATION of NO-LOAD VOLTAGE (1, When the generator starts running. the permanent magnet built-in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator. (2) As two condensers are connected to the condenser coil. the small voltage at the condenser coil generates a minute current @ which flows through th-e condenser coil. At this time, a small flux is produced with which the magnetic force at the rotor’s magnetic pole is intensified. When this magnetic force is intensified. the respective voltages in the main coil and condenser coil rise up. As the current @ increases, the magnetic flux at the rotor’s magnetic pole increases further. Thus the voltages at the main coil and condenser coil keep rising by repeating this process. (3) As AC current flows through the condenser coil. the density of magnetic flux in the rotor changes. This change of magnetic flux induces AC voltage in the field coil. and the diode rectifier in the field coil circuit rectifies this AC voltage into DC. Thus a DC current flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil. (4) \-C‘hengenerator speed reaches 2700 to 1800 rpm (5OHz type) or 3000 to 3300 rpm (60Hz type), the current in the condenser coil and field coil increases rapidly. This acts to stabilize the output voltage of each coils. If generator speed further increases to the rated value. the generator output voltage uill reach to the rated value. 5-3-2 VOLTAGE FLUCTUATIONS UNDER LOAD When the output current @ flows through the main coil to the appliance, a magnetic flux is produced and serves to increase current @ in the condenser coil. When current 3 increases, the density of magnetic flux across the rotor core rises. As a result. the current flowing in the field coil increases and the generator output voltage is prevented from decreasing. - 19- 5-3-3 FULL POWER SWITCH (Dual Voltage Type) The full power switch is provided for the dual voltage type to take out the full rated po\ver from one receptacle in each voltage. 120124OV r---l~or11o/22ov) - MC, 240V lor 22OV) Fig. 5- 10 MC: Fig. 5-l 1 1 Rec. 1 I Switch Position i LOWER VOLTAGE RECEPTACLE HIGHER VOLTAGE RECEPTACLE 11ov i I 1 Rated output No output can be taken. I& 240V (22OV) 110.22ov 120°~40v I MC, ’ Half of rated output I Table 5- 4 Fig. 5-12 - 20 - Rated output Inside the generator are t\vo sets of main coils. Each main coil outputs half the rated power at the lower voltage (1 1OV or 1ZOVI. These main coils are wound to be in the Sam2phase. The full power s\vit& reconnects these main coils in parallel or in s2ries. Fig. 5-10 sho\vs a circuit diagram. 1Vh2n the full power switch is set for single lower voltage indication (1 1OV or 1ZOV). the switch position is as indicated by th2 lower solid line in the diagram. Fig. 5-l 1 is a simplified representation of this circuit. show-ing the two main coils connected in parallel. In this case. the higher voltage i7ZO\- or Z4OVi at Rec. 3 cannot be taken out. Rec. 2 tor - the lower voltage can output up to the rated power (up to 30.1 if the rated current is over 30-A). and Rec. 1 can output up to a total of 15A. \Vhen the full poiver s\vitch is set for double voltage indication ( 1 1OV 3201’ or 12OV ‘24OV), the switch position is as indicated by the upper dotted line in Fig. 5-l 0. Fig. 5- 12 is a simplified representation of this circuit. showing the two main coils connected in series. In this case. power can be taken simultaneously from the receptacles for the both voltages. Rec. 3 for th? higher voltage can output up to the rated power. but Rec. 1 and Rec. 3 for the lower voltage can output only up to half the rated power each. Table 5-4 is a summary of the above ssplanation. Select the propsr output I-oltags by full power witch in accordance with the appliance to be used. 5-3-4 VOLTAGE CHANGEOVER SWITCH The gensrator of 50Hz 1101’ L3OV dual voltage type for U.K. is provided with voltage changeover switch instead of full pow2r switch. The output voltage is sel2cted from 11OV and ‘1OV bx turning this switch and both voltages cannot be taken out simultaneously. The middle point of the main coil shall be grounded \vhen the changeol-er sn-itch is turned to 11OV side. 11OV RECEPTACLE RECEPTACLE Fig. 5-73 -21- 6. SAFETY PRECAUTIONS 1. Use extreme caution near fuel. A constant danger of explosion or fire exists. Do not fill the fuel tank while the engins is running. Do not smoke or use open flame near the fuel tank. Be careful not to spill fuel when refueling. If spilt. wipe it and let dry before starting the engine. 2. Do not place inflammable materials near the generator. Be careful not to put fuel. matchss. gunpoa-dsr. oily cloth. straw. and an)- other intlammables near the generator. 3. Do not operate the generator in a room, cave or tunnel. Always operate in a well-ventilated area. Otherwise the engine may overheat and also. the poisonous carbon monoxide contained in th2 exhaust gases will endanger human li\-2s. K2ep thz gen2rator at 12ast 1 m (4 f2et) a\va)- from structures or facilities during use. 4. Operate the generator on a level surface. If the gsnerator is tilt2d or movzd during us2. thers is a danger of fuel spillage and a chance that the generator may tip over. 5. Do not operate with wet hands or in the rain. Severe electric shock ma?- occur. If ths gsnerator is wet b!- rain or snow. wipe it and thoroughly dry it before starting. Don’t pour water o\-2r the gensrator dir2ctll- nor leash it with wat2r. If the generator is xv-etwith water. th2 insulations ii-ill b2 adv2rsely affectsd 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 gsn2rator. Us2 a transf2r s\vitch for connecting with indoor wiring. NOTE: The parts numbers Table 6- 1. of the transfer switches and of the plastic box to store them are as shown in Part Name Part No. 365-45604-08 Transfer Switch 367-45605-08 Transfer Switch Transfer Switch 340-45606-08 ’ 367-43008-08 348-43009-08 Plastic Box ’ 8 O’ty 1 i ’ I I 1 1 1 1 Plastic Box ’ 1 1 a Phase Allowable 15A ’ 30A 1 60A 1 30A 1 Current ’ I 60A Table 6- 7 7. Use a fuse of the correct capacity. (DC output) If the generator rpm is incr2as2d excessiv2lq- in th2 overload condition bk- using an over rated fuse. th2 generator may be burnt. CAUTION: If the fuse is burnt out or the circuit breaker tripped off as a result of using an electrical appliance, the cause can be an overload or a short-circuit. In such a case, stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring. - 22 - 7. RANGE OF APPLICATIONS Generally. the power rating of an electrical appliance indicates the amount of Lvork that can be done by it. The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance. The electrical appliances generall)- have a lab4 showing their rated voltage. frequency. and power consumption (input wattage). The po\ver consumption of an electrical appliance is the power necessary for using it. \Vhen using a generator for operating an electrical appliance. the power factor and starting wattage must be taken into consideration. In order to determine the right sizs generator. it is nxessary to add the total kvattage of all appliances to be connected to the unit. Refer to the followings to calcurate the po\ver consumption! of each appliance or equipment by its t!‘pe. (1) Incandescent lamp, heater, etc. with a power factor of 1.0 Total power consumption must be equal to or less than the rated output of the generator. Example: X rated 3OOO\Vgsnsrator can turn thirt). lOON’ incandescent lamps on. (2) Fluorescent lamps, mercury lamps, etc. with a smaller power factor Select a generator kvith a rated output equivalent to 1.2 to 2 times of the power consumption of the load. Example: A 4OON’mercury lamp requires 6OOL to -0OK power source to be turned on. A rated 3OOO\Vgensrator can power four or fivs 4OOK mercur)- lamps. NOTE 1: If a power factor correction capacitor is not applied to the mercury lamp or fluorescent the more power shall be required to drive those lamps. A rated 3000W generator can drive one or two 400W mercury lamps without power correction capacitors. lamp, factor NOTE 2: Nominal wattage of the fluorescent lamp generally indicates the output wattage of the lamp. Therefore, if the fluorescent lamp has no special indication as to the power consumption, efficiency should be taken into account as explained in ltem (51 on the following page. (3) Motor driven tools and light electrical appliances Generally- the starting Lvattage of motor driven tools and light electrical appliances are 1.2 to 2 times larger than their running Lvattagc. Example: A ratsd 2501V electric drill requires a -tOO\Vgenerator to start it. (4) Initially loaded motor driven appliances such as water pumps, compressors, etc. Thsss appliances require the large starting wattage kvhish is 3 to 5 times of running lvattage. Example: .A rated 900\V compressor requires a 45OON’generator to drive it. NOTE 1: Motor-driven appliances require the aforementioned generator output only at the starting. Once their motors are started, the appliances consume about 1.2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrica / appliances. NOTE 2: Motor-driven appliances mentioned in ltems (3) and (4) vary in their required motor starting power depending on the kind of motor and start-up load. lf it is difficult to determine the optimum generator capacity, select a generator with a larger capacity. - 23 - (5) Appliances without any indication as to power consumption Some appliances have no indication as to poH-er consumption: but instead the work load ioutput) is indicated. In such a case. po\ver consumption is to be worked out according to the numerical formula mentioned below. (Output of electrical appliance) = (Poner consumption 1 iEfficienq) Efficiencies of some electrical appliances are as follo~vs: The smaller the motor. the lower Sin&.-phase motor . . . . . . . . . . . . _ . 0.6 - 0.75 1. Three-phase motor . . . . . _ . . . . . . . 0.65 - 0.9 z the efficienq-. Fluorescent lamp . . . _ . . . _ . . . . . 0.7 - 0.8 Example 1: A -IO%-tluorsscent lamp means that its luminous output is 4OR’. Its efficiency is 0.7 and accordin&-. power consumption will be 40 + 0.7 = 57iV. A%explained in Item (2). multiply this power consumption value of 5-W by 1.2 - 3 and you will pet the figure of the necessaq- capacit), of a generator. In other words. a generator with a rated output of 1OOOK capacit>- can light nine to fourteen 40X fluorescent lamps. Example 2: Generally- speaking. a 400X motor means that its Lvork load is 4001V. Efficiency of this motor is 0.7 and power consumption n-ill be 400 + 0.7 = 5’0\5‘. N-hen this motor is used for a motor-driven tool. the capacity of the generator should be multipled by 1.1 to 3 and 57OW as explained in the Item (3). r MODEL I Frequency lncandesent lamp, heater, Fluorescent lamp, mercury Motor-driven tool, Water pump, compressor, 60 Hz 50 Hz 60 Hz 2ooow 22OOW 2700W 3000121 approx. 1400w approx. approx. 15OOW 18OOW approx. 12oow approx. approx. approx. approx. 50Hz etc. lamp, etc. general-purpose etc. motor, etc. i RGD3300 RGD2500 600W Table 7- 1 - 24 - ’ 13oow 650W approx. 21 oow 16OOW approx. 18OOW approx. approx. 800W 9oow I NOTES: Wiring between generator and electrical appliances 1. Allowable current of cable Use a cable with an allowable current that is larger than the rated input current of the load (electrical appliance). If the input current is larger than the allowable current of the cable used, the cable will become excessively heated and deteriorate the insulation, possibly burning it out. Table 7-2 shows cables and their allowable currents for your reference. 2. Voltage drop in long electric extension cords When a long wire is used to connect an appliance with the generator, a certain amount of voltage drop occurs in the wire which lessens effective voltage available to the appliance. The 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. ! I Nominal cross section A.W.G. Gauge No. Allowable current : No. of strandshtrand Reststance dia. I A No. mm mm’ ! UO. 0.75 ’ 18 7 16 12 50 0.18 14 17 37026 i 23 45 0 32 ’ 35 70 032 1 1.27 2.0 3.5 5.5 / 12 - 10 110-d I I Current Amp. I -0. 100 T 2.477 1 486 30018 0952 c.517 0332 1 1 I 1A 3A 5A 25 8V 12.5V 1 5v 5v 11; 3v - j 15v I - :’ 1L’ ! 8A!lOA - - 12A 15A - - 7.5v , 12v 15v j18V 5V 8V iov i 12v I 15v 5v 6.5V 7.5v 2 5v 2v 1 4v 2.5V ! ’ 3.5V 1 4V 0” G . B r s 5V Table 7-2 1-oltage drop indicates as \’ = - 1 100 ‘- R b. 1 ‘\ i R means resistance ( S2 100 m I on the above table. I Illt!dIlS eltxtri< iurrent through the \i iI-2 ( A 1. I; means the length of the v, ire ( ITI 1. The length of the \\iire indicate> round length. it means t\vi<e the length from generator to electrical tools. - 25 - 8. MEASURING PROCEDURES 8-l MEASURING 8-l-l INSTRUMENTS VOLTMETER AC voltmeter is necessary. The approximate .4C voltage ranges of the voltmeters to be used for various types of generators are as follows: 0 to 15OV: Type with an output \-oltag of 1 10 or 13ov 0 to 300V: Type with an output voltage of “0. 230. or Z4OV 0 to 15OV. 0 to 300\-: Dual voltage type I FOR AC I Fig. 8- 1 8-1-2 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. (.\bout 1OA. 30‘4. 100-A\) FOR AC Fig. 8-2 8-l-3 r FREQUENCY METER Frequency range: About 35 to 65Hz NOTE: Be careful of the frequency voltage range. meter’s input Fig. 8-3 - 26 - 8-l-4 TESTER Used for measuring resistance. etc. Fig. 8-4 8-l-5 MEGGER TESTER Used for measuring generator insulation resistance. Select one lvith testing x-oltage rang of 5001-. I I Fig. 8-5 8-1-6 TACHOMETER There are various types of tashometsrs. ~~1~ as contactless type. contact tl.ps. and strobe tk-ps. The contxt t!-pe can be ussd onl>- n-hen the generator and engine ha\e been disassembled. The contactless type is recommended. CCN’J~ACTLESS TYPE , I STROBE Fig. 8-6 -27 - TYPE 8-2 AC OUTPUT MEASURING LJ Fig. 8-7 Use a cirsurt like the one shown in Fip. 8-- for msasurinp XC output. A hot plate or lamp with a power factor of 1.O may be used as a load. Adjust the load and rpm. and check that the vo1tas-eranpe is as specified in Table 8- 1 at the rated amperage and rated rpm. Rated voltage ’ Voltagerange 11ov 107- I 120v 220v 117 - 130v 119v 215-238 I 240V 235 - 260 Table 8.; 1 8-3 MEASURING INSULATION RESISTANCE VEGGER TESTER Connect a megger tester to one of recsptacls output terminals and th2 ground terminal. then measure the insulation resistance. An insulation rtzsistance of 1 me_gohm or more is normal. (Th2 original insulation resistance at the time oi shipment from the factory is 10 megohms or mars.) If it is 12~s than 1 megohm. disassemble the 92nerator and measure th2 insulation resistanx of the stator. rotor and control panel individuall!.. I I 1 Fig. 8-8 . STATOR (1) Measure th2 insulation resistanc2 BLUE lead and the core. (2 j Measure the insulation resistance WHITE lead and the corz. (3) Measure the insulation resistanc2 YELLOW lead and the core. (4) Measure the insulation resistaxe BL-KK lead and ths core. I between b2tw2en betwe2n b2t\\-een J 1 Fig. k-9 - 28 - . ROTOR Measure the insulation across one of the soldered terminals of the rotor and the core. Fig. 8-70 . CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts. Fig. 8- 11 Any part where the insulation resistance is less than 1MS1 has faulty insulation. and may cause electric leakage and electric shock. Replace the faulty part. - 29 - 9. CHECKING FUNCTIONAL MEMBERS 9-1 VOLTMETER and PILOT LAMP Models RGD2500 and RGD3300 have a voltmeter that comes in two types: 15OV maximum type and 300V maximum type. The voltmeter indicates generator output voltages. The generators with a generated voltage of 11OV or 1ZOV and dual voltage type use the 15OV maximum type voltmeter; and those of 31OV. 2301! and 24O\r specifications use the 300V maximum type voltmeter. Generator for U.S.A. employs a pilot lamp. The lamp lights when a voltage is generated. The pilot lamp also comes in two t>-pes: 135\’ t)-pe and 34OV type. These types are selected to suit generator output voltage. 300V (22OV. WAX. 23OV. 15OV MAX. 240V1 (1 lOV, 12OV) Fig. 9-7A Fig. 9- 78 9-2 AC RECEPTACLES Usins 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. &-hen continuity is found between the output terminals of the receptacle with a wire connected across these terminals. the AC receptacle is normal. \Yhen the wire is removed and no continuity is found between these terminals. the receptacles are also normal. AC RECEPTACLE - Fig. 9-2A Fig. 9-2B - 30 - 9-3 CIRCUIT BREAKER 1 CIRCUIT Check continuity between each of two terminals at the rear of the circuit breaker Lvhile it is mounted on the control panel. ?;ormall]-. there is continuity between each of the two when the circuit breaker is on while there is no continuity when the circuit breaker is off. Fig. 9-3 9-4 STATOR Disengage connectors on the wires from stator and check the resistance between Lvires with a circuit tester referring to the following table. Fig. 9-4 (R x In +10x) Brown-White Blue-Skyblue 50Hz-11 OV 0.86E 0.86G 0.16_0, 0.86fi 0.16Q 2.IL? 0.91,0, 0.16,0, 2.lQ Specifications Model 50Hz-220V 0.869 , 50Hz-240V 0.9IQ : 50Hz-IlOV/220V RGD2500 ’ 0.86R ! 0.16.0, 0.66C 0.66Q 0.12R 60Hz-120V 0.669 0.66,0, 0.129 , Black-Orange 1 ! 2.lR i 1.9-c2 0.66fi 0.12, 1.9,c2 0.669 0.12,0, 1.9*0, 50Hz-11 OV 0.64,0_ 0.64R 0.14,0_ 1.9n 50Hz-220V 0.64fi 0.64Q 0.14_0_ I.99 0.77fi 0.14a 1.90 0.649 0.14n I .9fi 0.660 1 50Hz-240V i 0.77_0, 50Hz-1 IOV: 220V , 60Hz-IIOV I 0.649 ! ! 0.449- 0.440 0.44,nl 60Hz-ll0V~220V 0.44R 0.44_0, - 0.449 0.1 l,o, 60Hz-120V 0.449 0.44_0, 0.11~ 60Hz-220V ‘240V I I I ---z---l 0.66C 60Hz-110V/220V i 0.862 60Hz-1IOV 60Hz-120V!240V RGD3300 j I ! Yellow-Yellow 0.1 l,r! I.6C 0.1 IR 1.60 1.6R i I I I 1.6n Table 9- 1 NOTE: If the circuit tester is not sufficientlly accurate, it may not show the values given and may give erroneous readings. Erroneous readings will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 20°C (68”FJ. -31- 9-5 ROTOR ASSEMBLY 1) Using the circuit tester, measure the resistance of the field coil. Table 9- 2 NOTE I: 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 readings. Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 2O’C 168°F). i Fig. 9-5 9-6 CONDENSER H If an instrument (QC-meter or C-meter) for measuring capacity of condender is available. check the capacity of condenser. (Se? Fig. 9-6. I COUDEUSEil Fig. 9-6 n NORMAL CAPACITY OF CONDENSER I NODEL RGD2500 (g CAPACITY ig I : 1OpF IOpF RGD3300 1OpF I l&IF Table 9-3 n If such an instrument is unavailabl?. 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. - 32 - 9-7 DIODE RECTIFIER DIODE RECTIFIER Yellow Grey Red Red - Yellow Yellow 0 II Yellow I] Gw CIRCUIT Fig. 9-7 TESTER Fig. 9-8 Circuit inside of the diode rectifiers is as shown in Fig. 9- 7. Check continuity between each terminal by using a circuit tester as shown in Fig. 9-8. The rectifier is normal when continuity is as follows: Apply black 0 Yellow ! needle of the circuit tester Yellow 1 Yellow Apply red @ needle of the circuit tester ! Yellow 1 No continuity ’ Red ! Continuity 1 , Grey ’ I : Red No continuity , I ’ No continuity Grey Continuity Continuity Continuity I - F No continuity ’ I - No continuity 1 1 No continuity Table 9- 4 NOTE 1: In checking the diode, direction teristics of the diode and battery of connection is contrary to the ordinary incorporated in the tester. case because of charac- NOTE 2: “Continuity” means forward direction characteristics of the diode, and different from short circuit condition (in which a pointer of the tester goes out of its normal scale), shows resistance to some extent. When results of the checking indicates failure even in one section, replace with a new one. - 33 - 10. DISASSEMBLY AND ASSEMBLY 10-I PREPARATION and PRECAUTIONS 1) Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembed corrwtl!-. Tie tags noted with the necessar>-information to facilitate easier and smoother reassembly-. 3) 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 car?: clean them before reass?mbl>-using a neutral cleaning fluid. 5) Us2 all disassembly assembly tools properly. and use the proper tool for each specific job. 10-2 SPECIAL TOOLS for DISASSEMBLY and ASSEMBLY ROTOR PULLER REAR COVER PULLER - 34 - 10-3 DISASSEMBLY jtep 1 PROCEDURES ‘art to remove Fuel Tank Tool Remarks Description Draining tank of fuel before disassembly is unnecessary. (1) Close fuel cock. (2) Loosen the nut and remove fuel cock from the bracket. Turn the fuel cock body by 90 degrees to remove. (Fig. 10-l) 14 mm spanner I (3 j Remove the two bolts which join the fuel filter to the control box. (See Fig. 10-3.) 10 mm spanner (4) Remove the fuel pipe which connects Plier fuel filter and fuel injection pump. Loosen the clamp using pliers and pull out the fuel pipe from the fuel filter. (See Fig. 10-3:) Fig. lo- 1 Fig. 70-3 Fig. 10-2 - 35 - Step 1 Part to remove Fuel Tank (5) Remove fuel return pipe which connects the fuel injection nozzle and the bottom of fuel tank. Loosen the clamp and pull out the fuel return pipe from the fuel injection nozzle. (Fig. 10-4) Take care of spilt fuel from the fuel pipe. Fig. 70-4 Control Box Plier i 10 mm spanner or box spanner (6) Loosen the four bolts and remove fuel tank from frame. (See Fig. 10-j.) 2 Tool Remarks Description Fig. 10-5 (1) Remove control box from frame by removing the three bolts joining the control box to frame and side plate. (See Fig. 10-6.) (2) Put the control box with control panel d0Lv-n. Wire harness is still connected. Put a waste cloth under / 10 mm spanner : the control panel to protect it. (3) Remove the ground wire (green!yellow) from the bottom of control box. (4) Pull the bushing out from the control box. (See Fig. 10-Y.) Fig. IO-6 Fig. 10-7 - 36 - 10 mm spanner or box spanner Remarks tep Part to remove Description 2 Control Box (5) Pull the wire harnessout from the control box. Disengagethe connectorsto separate the control box. (SeeFig. 10-8.) Tool 1 ‘. I\ Fig. 108 I 3 Pipe Frame 10 mm spanneror box spanner (1) Removesideplate from frame. 66bolt.. . . . . . . . .2pcs. (2) Removetank bracket from frame. 6@bolt . . . . . . . . . .2pcs. B@BOLT (3) Removestoppersfrom enginebaseof frame. 6Obolt.. . . . . . . . .4pcs. 10 mm spanner (4) Removethe four nuts which join the mount rubbersto the engine. 12 mm spanner (5) Removethe two bolts which join the rear coverto the generatorbase. (SeeFig. 10-9.) 8Obolt . . . . . . . . . .2pcs. 12 mm spanner . . . . . . 4pcs. 80 NUT . . 2~s. 78 STOPPER. . . . Fig. 109 - 37 - I . Zpcs. Step 3 Part to remove Pipe Frame Description Remarks (6) Lift up the engine and alternator assembly using a chain-block. and dismount it from frame. (Fig. 10-10) Tool i Fig. 10-10 (7) Remove generator base from frame. 8~ nut . , . . . . . . . . 1 pee. (8) Remove mount rubbers from frame. (See Fig. 10-l l.j MOUNT i 12 mm spanner 12 mm spanner 2pcs. 8c NUT GENERATOR r BASE RUBBER 2pcs. Fig. 10-l 1 - 38 - Step ) Part to remove ! Description I (1) Remove end cover from rear cover. Rear 'Over ' . . (See Fig. lo-l'.) 1 I I I I 6obolt.. :. . . . _ . .4pcs. 1 (2) Remove through bolt from rotor shaft. Xppl>- a socket wrench on the head of through bolt and hit the wrench handle I with a hammer counterclockwise to loosen. (See Fig. 10-13.) Remarks I -1-- I ~~~ 10 mm spanner or I I I I 1 RGDZSOO: 12 mm 1 RGD3300: 14 mm Box wrench I i I (3) Remove the four bolts which join the rear cover to the front cover. I I I I I I i (1) Take off the rear cover. Use the special tool “REAR COVER PULLER” to remove the rear cover. (See Fig. 10-14.) 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. I c. Tighten the center bolt to pull out the rear cover. (See Fig. 10-15.) Tool I I r Insert the two bolts sufficiently and evenly-, or ! the thread holes may be 1 damaged at removing. I i Fig. lo- 72 Fig. lo- 13 6; Fig. 70-74 Fig. lo-15 BOLT . 2~s. Step Part to remove 4 Description Remarks In case that “REAR COVER PULLER” is unavailable. remove the rear cover by the following instructions: Rear Cover I a. Insert the through bolt into the rotor shaft and tighten lightly. b. Hit on the boss at the top of the rear cover and two legs evenI)- with a plastic hammer to remove. (Fig. lo- 16j I I 1 1 F/g. lo-16 I I ’ Stator (1) Remove the four bolts which join the stator to rear cover. (See Fig. 10-17.) I (2) Insert a small hook into the hole inside of the support ring and pull it out. (See Fig. 10-18.) l 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 block. 60 BOLT . . 69 SPRING WASHER / Ilk I Plastic hammer I 1 I 5 Tool . 4 PCS. 4pcs. 6r, WASHER 4 PCS. - 40 - I I ’ I I ’ Be careful not to give a damage to the staror l winding. ’ 10 mm box wrench ! Step Part to remove Description Stator 5 Remarks Tool (3) Pull out the wires from rear cover. (See Fig. 10-19.) I STATOR 60 BOLT . . 4 PCS. Fig. IO- 19 , 6 . Rotor I I I (1) Insert the rotor-puller shaft into the rotor and tighten the rotor-puller bolt until the rotor comes loose. (See Fig. 10-1-O.) If the special tool (rotor-puller) is unavailable, take the folloCng instructions to remove the rotor: Lightly strike the rotor core with a plastic hammer in many directions and pull out the rotor from engine shaft. (See Fig. 10-21.) 1 Rotor puller 1 RGDXOO: 14mm RGD3300: 17 mm Spanner 1 Take utmost care not to 1 strike on the rotor wind- j ing or plastic insulator or , 1 Plastic hammer permanent magnets. Fig. lo-21 Fig. 70-20 -41- Step ’ Part to remove I 7 1 Front cover and Front j Protector Description Remarks Tool I ’ (1) Remove the four bolts which join the front cover to the engine. gobolt.. . . . . . . . .4pcs. 12 mm spanner ( (2) Remove front protector from front Cover. (See Fig. 10-Z.) 8 mm spanner or I screw driver (+) I 1 1 / Fig. lo-22 - 42 - I 10-4 ASSEMBLY PROCEDURES 10-4-l (1) FRONT PROTECTOR and FRONT COVER Attach the front protector to front cover. The louvers of the front protector project into the inside of front cover as shown in Fig. 10-23. 5# x 10 mm Tapping screw . . . . . 4 PCS. Tightening torque: 35 - 55 kg-cm Fig. IO-23 (2) Install front cover to the engine. (See Fig. 10-24.) 8$ x 20 mm bolt and washer assy . . . . . . . . . . . . . . . . . . . . . . . . . 4 PCS. Tightening torque: 120 - 140 kg-cm NOTE: The size of faucet joint and pitch of mounting holes of front cover is different by models RGD2500 and RGD 3300. Fig. IO-24 10-4-2 ROTOR (1) Clean the tapered portion of driving shaft and the matching tapered hole of rotor shaft of oil and dirt using a waste cloth. (2) Attach rotor to the driving shaft. (See Fig. lo25.) Tighten through bolt with washer and spring washer. Tightening torque: RGDXOO.. . . . . . . 115 - 135 kg-cm RGD3300. . _ . . . . . 330 - 250 kg-cm Fig. lo-25 10-4-3 Hookmg holes for remown support -1ng STATOR and REAR COVER (1) Set the stator on the jig. Match the grooves of the stator with the grooves of the jig. (2) Attach the support ring around the stator setting the open ends of the ring to the position of stator leads. Check that the hooking holes are placed at the flat sides of the stator. (See Fig. 10-X.) D~mx~on Grooves of stator leads of stator STATOR SUPPORT (3) (4) (5) Insert four guide bolts into the bolt holes of the rear cover and mount it on the stator matching the guide bolts with the grooves of the stator. Tighten the guide bolts tentatively. Grooves RING JIG o‘ ,‘g Fig. lo-26 BOARD Take the stator leads out from the windo\\- of the rear cover. \ Put a board on the rear cover and press it using a pressing machine. If a pressing machine is unavailable. tap around the board on the rear cover even&- with a plastic hammer to press fit the rear cover over the stator. (See Fig. 10-Y.) CAUTION: Take care of the rear cover to be pressed in upright position. Fig. lo-27 (6) Join the stator to rear cover with four bolts. washers and spring washers. (See Fig. 10-28.) 60 bolt . . . . . . . _ . . . . . . . . . _ 4 PCS. 60 washer . . . . . . . . . . . . . . . . . _ . 4 pcs. 6Q spring washer . . . . . . . . . . . . . . 4 pcs. Tightening torque: 80 - 100 kg-cm NOTE: Tighten steps. 60 BOLT 4 DCS. II----6~ SPRlhG d// m oM- 60 WASHER four bolts evenly taking several I Fig. lo-28 - 44 - WASHER .4pcs. 4 PCS. l The dimensions of the stator bolts are shown in Table 1O-l. I I Model RGD2500 [(mm) 1 I i 85 I (inch) I RGD3300 I (mm) Ii (inch) I I 1.57 95 / 40 3.74 ] I 1.57 Attach the boot over the lead wires drawn out from the rear cover. Press the smaller end of boot into the rear cover. (See Fig. 1O-29.) Put the rear cover and stator assembly over the rotor. Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover. (See Fig. 10-30.) Fig. IQ30 - 45 - 40 ’ Fig. 70-29 @i I d s 3.35 Table 10-l (7) ( i 6 0.24 ’ 6 0.24 (9) Tighten the four bolts, washers and spring washers to join the rear cover to the front coyer. 69 x 25 mm bolt . . . . . . . . . . . . . 4 PCS. 6cJwasher . . . . . _ . _ . . . . . . . . . . . 4 PCS. 69 spring washer . . . . . . . . . . . . . _ 4 PCS. Tightening torque: 50 - 60 kg-cm In the case of models with oil sensor or electric starter. attach the clamp at the same time. (See Fig. 10-31.) Fig. 10-3 7 10-4-4 END COVER Attach end cover to the rear cover. The air-inlets of the end cover have to face downward. (See Fig. 10-32.) 69 x 8 mm flange bolt . . . . . . . . . . . .4 PCS. Tightening torque: 40 - 60 kg-cm Fig. 1O-32 10-4-5 FRAME 50 TERMINAL (1) Attach two mount rubbers to the engine base of the frame. Tighten the nuts from the bottom side of the frame. (See Fig. 10-34.) 8@flange nut . . . . . . . . . . _. . . . . 2 PCS. Tightening torque : 120 - 140 kg-cm (2) Attach the 50 terminal of grounding wires igreen:yellow) to the unpainted thread hole of the frame base plate using a 5 mm brass screw. (See Fig. 10-33.) 60 TERMINAL (CONTROL BOX) 80 TERMINAL {REAR COVER) Fig. lo-33 - 46 - (3) Attach the alternator mount rubber to the frame. (See Fig. 10-34. j NOTE: The mount rubbers are selected to reduce vibration most effectively quency. Be sure to use the correct mount rubber for your generator. by model and its fre- Fig. 10-34 (4) Mount the GENERATOR BASE on the mount rubber attached to the frame at step (3). (See Fig. 10-35.) 84 flange nut . _. . . . . . . . . . . . . . 1 pee. Tightening torque: 120 - 140 kg-cm _I RUBBER ENGINE BASE RUBBER MOUNT SIDE VIEW MOUNT Fig. 1035 -47 GENERATOR - A (5) Attach SHAFT (STOPPER) to the bottom of engine crankcase. Tighten nuts tentatively. NOTE: (6) Pay attention to the position of the SHAFT (STOPPER). The flange nuts shall be tightened a fier fine adjustment. Cover the both ends of SHAFT (STOPPER) with RUBBERS. Push RUBBERS until they touch the crankcase. (See Fig. lo- 36.j I SHAFT &JBBER (SThPPER) Fig. 10-36 (7) Lift engine and alternator assemblv 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 nor to apply weight to the engine mount rubbers. (See Fig. 10-37.) Fig. lo-37 (8;) Fix the legs of rear cover to the generator base. Attach the 8$ terminal of the grounding wires and the clamp to the right side leg of the rear cover at the same time. In the case of electric starting model, attach the 89 terminal of the grounding wires. a clamp and the BXTTERY CABLE (-j to the right side leg and a clamp to the left side leg of the rear cover at the same time. (See Fig. 10-38.) NOTE: Two nuts are welded to the bottom side of the GENERATOR BASE. 80 x 25 mm bolt 8r washer ass>- . . . . 2 PCS. Tightening torque: 120 - 140 kg-cm BOLT CLAMP iElectrIc and WASHER start model) BATTERY CABLE I-) (Electric start model) fig. IO-38 - 48 - ASSY (9) Fix the engine mount rubbers to the crankcase base. 89 flange nut . . . . . . . . . . . . . . . . 2 pcs. Tightening torque: 120 - 140 kg-cm CAUTION: Pay attention to the position of the mount rubbers. Lift down the engine and alternator assembly and remove the chain block belt. (10) (11) Attach two STOPPERS to the frame covering the both ends of the SHAFT (STOPPER!. (See Fig. 1O-39. j 6$x 169flangebolt . . . . . . . . . . . 4pcs. Tightening torque: 50 - 60 kg-cm fig. lo-39 Adjust the position of SHAFT (STOPPER) so as its both ends are placed in the center of the STOPPERS, then tighten the flange nuts to fix the SHAFT (STOPPER!. (See Fig. 10-40.) Tightening torque: 120 - 140 kg-cm Fig. 1040 (12) Attach the SIDE PLATE to the frame. (See Fig. lo-41 .) Tighten the two black flange bolts tentativel?. 69 x 8 mm flange bolt (black) _ . . . _ 2 PCS. NOTE: The flange bolts shall be tightened after the installation of the control box. Fig. lo-47 - 49 - 10-4-6 CONTROL BOX Mount the control box assembly to the frame. Refer to Section 10-S for disassembly-, checking and reassembly procedures of the control box. (1) Attach the 69 terminal of the grounding wires to the bottom of the control box. (See Fig. 10-41. j 64 nut (brass) _ . _. . . _ . . . . . . . . . 1 pee. Tightening torque: 50 - 60 kg-cm (2) In the case of generator models equipped Lvith oil sensor, connect the wires to oil pressure switch and solenoid. 0 Screw the black/yellow wire to the center of the oil pressure switch. l Connect the two blue wires to the solenoid and clamp the connectors to the side of speed control unit. (3) Connect the wires drawn out from the stator to the wires from the control box. Fig. IQ42 NOTE I: Connect the wires of the same color. NOTE 2: On 220V and 240V models, connect one blue stator lead with a white control box lead. NOTE 3: Engage the connectors securely. Fig. IO-43 (4) Push the wires into the control box and attach the bushing over the wires. Press the upper end of the bushing into the control box. (See Fig. 1O-43. j (5) Install the control box to the frame. 64x 16mmflangebolt ._...... 60x 12mmflangebolt ........ 3pcs. 1 pc2. 1 Tighten the above three bolts tentatively. 2 Tighten the two black bolts which join the side plate to the frame. 3 Tighten the above three bolts adjusting the position of the control box. (See Fig. 10-44.) Tightening torque: 50 - 60 kg-cm fig. 70-44 < Electric start model > (6) Connect the light green and the pink leads of the control box to the starting motor. Connect the pink lead to the terminal of the motor and attach the light green lead together with the BATTERY CABLE (+) to the 6 mm bolt of the motor. (7) Clamp the wires of starting motor and oil sensor at the rear panel of control box, main bearing cover and front cover. (See Fig. 10-45.) NOTE: Take a enough margin in the length of wires between control box and alternator to allow the move of rubber mounted alternator. Clamp the BATTERY CABLE (+) to the left side leg of the rear cover. -51- Fig. lo-45 10-4-7 (1) FUEL TANK Attach the BRACKET (TANK) to the frame. (See Fig. 10-46.) 6r$x 16mmflangebolt . . . . . .._ 3pcs. Tightening torque: 50 - 60 kg-cm Fig. 10-46 (2) Connect fuel pipes to the bottom of the fuel tank. Be careful of the direction of the BANJO. (See Fig. 10-47.) ‘1 ‘,, -._ /r - ,BANJO BOLT 1 PBANJO IGASKET ;;gg , *.-0 63 \ Fig. 70-47 I Ref. No. ’ , I 1 (Aluminlum) \ FUEL FILTER I Part Name ’ Outer Dia. FUEL PIPE ’ 12mm Inner Dia. i Length 1 6mm ; 175mm j I 4 ’ FUEL PIPE , 9mm i 4.5 mm ’ 350 mm 1 I 5 i FUEL PIPE ; 9mm , 4.5mm i 260 mm 1 Table 1 O-2 Use the correct clamps for each fuel pipe. - 52 - (3) Mount the fuel tank on the frame. -4pply RUBBER (TXNK)s between side plate and tank. and bracket (tankj and tank. (See Fig. IO-48.j Use black flange bolts to join them. 69 x 18 mm flange bolt (black) . . . . 4 PCS. Tightening torque: 30 - 40 kg-cm Fig. 70-48 (4) Connect fuel pipes between fuel tank, fuel cock, fuel filter and fuel injection pump. (See Fig. 10-47.) Attach the 10 mm flange nut to the fuel cock before connect the fuel pipe to it. Use the correct clamps for each fuel pipe. Ref. No. I 2 , FUEL PIPE 3 - FUEL PIPE Part Name 1 Outer Dia. I : 12mm I ! 12mm Inner Dia. 6mm 6mm I 1 I I i Length 70 mm 230mm ‘ Table (Sj 10-3 Attach fuel cock and fuel filter to the control box. The fuel cock can be installed on the bracket by turning it 90 depress with fuel pipes connected. Fuel cock 100 flange nut . . . . . . _ . . _ . . . 1 pee. Tightenins torque: 50 - 60 kg-cm Fuel filter 66x 16mmflangenut . .._... 2pcs. Tightening torque: 50 - 60 kg-cm - 53 - 10-4-8 BATTERY FRAME and BATTERY (1 j Attach BATTERY FRAMEs to the frame. (See Fig. 10-49.) Clamp the upper end of the batter>- frames to the side member of the frame. Tighten two bolt 8i washers tentatively. 84 x 20 mm bolt & washer ass>- . _ . _ 2 PCS. Join the lower end of the battery frames to the base plate of the frame. Tighten two bolt & washers tentatively. 89 x 20 mm bolt 8r washer assy . . . . 2 PCS. (3) Mount the BATTERY BASE on the battery frame. Insert the four bolts from the bottom of the frame and tighten the flange nuts. 6Q x 40 mm bolt & washer assy . _ . . 4 pcs. 69 flange nut . . . . . . . . . . _ . . . . . . .4 PCS. Tightening torque: 50 - 60 kg-cm (3) Tighten the four bolt & washers attached at step (1 j. Tightening torque: 120 - 140 kg-cm (4) Mount the battery on the battery base. Insert the battery bolts into the hooking holes of the battery base, then apply the battery stay to the battery and tighten two nuts. 69 spirng washer . . _ . . . . . . . . . . . 2 PCS. 7pcs. 69nut . . . . .._.............. Tightening torque: 50 - 60 kg-cm (5) Connect battery cables to the battery. Connect the positive (+) cable first and then the negative (-1) cable. BOLT and WASHER 2 PCS. BATTERY BATTERY CABLE @--l BATTERY BAiTERY FRAME BOLT and WASHER 80 x 20 mm: 4 PCS. - 54 - BASE Fig. 70-49 PI-PE FRAME \ BOLT and WASHER 80 20 2 x mm: PCS. FLANGE NUT 60. 4 pcs lo-5 CHECKING, DISASSEMBLY and REASSEMBLY of the CONTROL BOX 10-5-l CHECKING OF THE CONTROL BOX Dismount the control box from frame. Remove the control panel and check each components and Lviring. Refer to Section 9 for the detail of checking the components in the control box. 10-5-2 DISASSEMBLY (1) Remove the control panel irom the control box. 49 screw. . . . . . . . . . : . . 6 pss. (2 j Disconnect the connectors on the wires to detach the control panel and box. (3) Remove the regulator. oil sensor unit. condensers and diode rectifier from the control box. \Vhen removing the regulator. push the hook on the coupler and pull out to disengage the couplers. (See Fig. 10-50.) Fig. 70-50 (4) After disconnecting individual wires. remow the control panel components. NOTE: 10-5-3 (1 j DC fuse, full power switch, pilot lamp and warning lamp have their wires soldered. them to remove those parts if necessary. Unsolder REASSEMBLY Install the receptacles. no-fuse breaksr. fuse. terminals. switches. etc. on the control panel and wire them. NOTE: Circuit diagrams are shown in Section 12. Colored wires are used for easy identification, and are of the correct capacity and size. Use heat-resistant type wires (permissible temperature range 75°C or over) in the specified gauge shown in the circuit diagrams. (2) Install regulator. oil sensor unit. condensers. and diode rectifier into the control box. (3) Connect the ivires of control panel components and control box. Fasten the earth Lvires to the rear of the control box using a 60 nut to the bolt which fixes the condenser bracket to the inside of the control box. (See Fig. 10-5 1.) (4) Attach the control panel to the control box. 40 screiv . . _ . . . . . _ . . . . . . . . . . _ . . . . . 6 pss. Tightening torque . . . . . . . . . . . . . . _ . . 13 - 15 kg-cm CONDENSER , To EARTH EARTH WIRES BRACKET TERMINAL JT - Fig. 70-57 - 55 - 11. TROUBLE SHOOTING 11-l NO AC OUTPUT 11-1-l CHECKING STATOR n Remove control panel and disconnect black. blue. red, and white wires at the connectors. n hleasure the resistance between terminals on stator leads. (.SeeFig. 1 1-l .I Refer to Table 1 l-l for normal resistance. If stator is fault!-. replace with a ne\v one. Fig. 77-7 11-l-2 n CHECKING CONDENSER If an instrument (QC-meter or C-mew) for meacapad!of condender is availabl?. check the capacity of condenser. (.SeeFig. 1 l-2. I CONDENSER suring Fig. ? 1-2 m NORW4L CAPACITY OF CONDENSER NODE L RGD2500 I CAPACITY 1s I ,~, IL I 1 RGD3300 I 10,uF 1OpF 1OpF I 1OpF Table 7 I- 1 H If such an instrument is unavailable. the condenser can be checked b>-replacing with a new one. If the generator performs good with new condenser. the cause of trouble is defect in original condenser. - 56 - 11-1-3 (1) CHECKING OF ROTOR CHECKING FIELD COIL w Measure the resistance of field coil lvith a circuit tester. (See Fig. 1 I - 3. ) n NORMAL RESISTANCE (R x l.o_~lO%~ Fig. 1 7-3 Table 7 l-2 [Remedy] If the resistance is not normal. replace rotor Lvith a new one. 11-2 AC VOLTAGE 11-2-l IS TOO HIGH OR TOO LOW. CHECKING STATOR Check stator referring to Step 1 l- 1- 1. 11-2-2 CHECKING CONDENSER Check condenser referring to Step 1 1- l-2. 11-2-3 CHECKING ROTOR Check rotor referring to Step 11-l-3. - 57 - 11-3 AC VOLTAGE 11-3-1 IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED. CHECK THE ENGINE SPEED. If the engine speed is low. adjust it to the rated r.p.m. 11-3-2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR. Refer to Section 7 “RASGE OF APPLICXTIOSS” for the aattage of the appliances. If the generator is over-loaded. reduce the load to the rated output of ths generator. 11-3-3 CHECK THE APPLIANCE FOR TROUBLE. If the appliance is fault>-. repair it. 11-3-4 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. rcmove it. AIR OL’TLET Fig. 1 l-4 11-3-5 CHECK THE INSULATION GENERATOR. OF THE Stop the engine. Measure the insulation resistance between the live terminal of th? rezptacle and the ground terminal. If the insulation resistance is less than 1 M2. disassemble the generator and check the insulation resistance of the stator. rotor and the live parts in the control box. (Refer to Section 8-3.) Any part lvhere the insulation resistance is l+s than 1 M-151. the insulation is faulty and may causs clcctric leakage. Replace the faulty part. L Fig. 7 l-5 - 58 - 11-4 NO DC OUTPUT 11-4-1 CHECK THE AC OUTPUT. Check the generator by following Step 1 1- 1- 1 through Step 1 1- l-3. 11-4-2 CHECK THE DC FUSE. Check the fuse in the fuse holder. If the fuse is b1oLv-n.check for the cause of fuse blo\ving. and then replace with a new one. FUSE : 10-A NOTE: If the DC output is used to charge a large capacity battery or an over-discharged battery, an excessive current may fro w causing fuse b/o w. 11-4-3 Fig. 11-6 CHECK THE WIRING. Check all the wires to be connected correctly. E RECTIFIER 11-4-4 CHECK THE DIODE RECTIFIER. Remove fier with Refer to checking the control panel and check the diode rectia circuit tester. Section 9-Y “DIODE RECTIFIER” for the procedure. Fig. 11-7 11-4-5 CHECK THE DC COIL Check the resistance bet\veen two bro\vn leads from stator lvith a circuit tester. r RESISTANCE SPECIFICATION MODEL 50Hz 1 1OV. 22Oi. 11ov 220v 60Hz 120v I loV~22OV. 50Hz II OV, 220;. 1 1ov 220v RG D2500 240V I 0.16E 0.12,0_ 12OV 240V 240V I 12OV ‘240V 1 0.14Q RGD3300 ‘r-7 ‘OH’ 1 ::::: 220V. O.llR Table 1 l-3 If the resistance reading is much larger or smaller than the specifisd value. the DC coil of the stator is faulty. Replace stator Lvith a new one. - 59 - 11-5 OIL SENSOR TROUBLE SHOOTING 11-5-l PRINCIPLE OF OPERATION The oil sensor for diesel engine consists of a pressure switch as a sensor section and a controller section. The pressure switch detects the drop of oil pressure in the crankcase. When the oil pressure falls down below the predetermined value (0.3 kg’cm2 ), turns on the generate a signal to the controller section. The controller which is powered by the DC coil sets up a delay for a few seconds for detecting signals transmitted during the period. If more signals than the predetermined number are generated. the controller f2eds power to the solenoid which actuates the latch on the control bracket to release the control lever to shut the engine down. 11-5-2 TROUBLE SHOOTING (1 j Check oil level. Fill it up to maximum level if necessary. (2) Check all wires to be connected properly. If they possibly have breaks in connection, the sensor will also malfunction. (3 j Checking the solenoid. Measure the resistance between two leads from solenoid. (See Fig. 1 l-8.) If the resistance is larger or smaller than the above limits, solenoid is defective. Replace it Lvith a new one. Fig. 7 l-8 (4j Checking the oil sensor unit (a) Disconnect the connector on the Black:Yellow lead of the oil sensor unit \\-hich is connected to the pr2ssur2 switch. (b) Start the engine and ground the Black: Yellow lead of the oil sensor unit to engine body. (c) If the solenoid actuates to shut the engine down, the oil sensor unit is operating properly-. (5 j Checking the pressure switch (a) Disconnect the Black ‘Yellow lrad of the pressure switch from the control unit. ib:) Check the resistance betwesn th2 Black Yellow lead and ground. Resistance should be 00(infinite] when engine is stopp2d. (c) Start the engine. The resistance should b2 0 when engine is running. * The pressure switch actuates at 0.3 kg cm2 oil pressure. (d) If the pressure switch does not work properly, rsplac2 it with a new one. - 60 - 12. WIRING DIAGRAM . RGD2500 : 50Hz-220V, 24OV, 60Hz-220V TYPE CONTROL l RGD2500: BOX __ 50Hz-1 lOV, 60Hz-1 IOV, 12OV TYPE 4LTERNATOR -----1 CONTROL I-- BOX -- u CRANGE --+33--1 -------Oe75mm2 ---------1.25mm2 -61- 2.0 mm2 l RGD2500: 50Hz-1 lOV/22OV, 60Hz-llOV/220V, CONTROL LLTERNATOR -m--s 12OV/24OV TYPE BOX __ --1 F PSW NFB ------ l RGD2500: U.K., 50Hz-llOV/220V [BS RECEPTACLE] CONTROL .LTERNATOR__-_-- BOX __ S’” p --------- -- ______ i C:?EEN -_----- “ELLCM ---- 1 ORAYGE f-cc+---- -..--I 0.75 mm2 _- I-1.25 mm2 __----___ - 62 - 2.0 mm2 . RGD2500: U.S.A., 60Hz-120V [NEMA RECEPTACLE] ALTERNATOR --- CONTROL --- --1 BOX -- ---- 9 hF B n 0 --SRO’A’N G R E E ‘4 Y E L L O’<d i -E . RGD2500: 50Hz-220V [FOR EUROPEAN COUNTRIES] CONTROL ALTERNATOR ----- rI rI BOX __ REC: ---.-------~ GqEE’d _____. E “E LLCi*i L I /__ ------- --J i 0.75mm2 b I -----_--2V.._L.. -- I----_--__- - 63 - ~~25~~2 2.0 mm' . RGD3300: 50Hz-220V, 24OV, 60Hz-220V TYPE CONTROL ALTERNATOR 1 -L-l I tlKUWN J BOX I-- 1 I I I= -- IZFB\ 0 0 1 1 I ~XREEN YELLOW J ORAKGE r-m----a37 T 3UT T --------A --I --- . RGD3300: 50Hz-llOV, 1 4LTERNATOR ----- -- I 60Hz110V. GREEN, -- 120V TYPE :ONTROL BOX __ -- 1 GREEN;YELLOW ORANGE --a-1 r-u3-- -.-- ---__-_ - YELLOVi I ----__--_ ------- 0.75 mm2 ___------ 1.25mm2 - 64 - GREEN\ 2.0 mm2 . RGD3300: 50Hz-1 lOV/22OV, 60Hz-1 lOV/22OV. 12OV/24OV TYPE 4LTERNATOR , t ; GREEN .- ORANGE --*- o- =-T ? wcANGE -__r l RGD3300: U.K., 50Hz-llOV/220V ALTERNATOR YELLOW iiiZi??-A - 1 -C --W-1 BLACK 1 - [BS RECEPTACLE] CONTROL BOX vcs FC Jli..--’ ’ KC I R I : ----la 1; I 1 ! ! I I GREEN YELLOW I ORANGE I L _---- --_ YELLOL’v’ -----__----- -------_----___- t------__-- Om75mm2 ~~25~~2 - 65 - 2.0 mm2 . RGD3300: U.S.A., 60Hz-120V/240V LTERNATOR , [NEMA CONTROL RECEPTACLE] BOX -- -F F’S’;‘.’ _--31 PEC; 3 ,P il; 12 “’ ---------.------_---------- LlGilT Ph< -_-___- 0.75 mm2 G9EEN __________ - _____ - ________ Jli _ ---------1.25mm2 -66- 2.0 mm2 l RGD3300: 50Hz-220V [FOR EUROPEAN COUNTRIES] 4LTERNATOR ------ CONTROL DEE? BOX __ -- BLUE ‘,SHITE GREENYELLOW ORANGE --J --- l RGD2500, RGD3300: i -- OIL SENSOR SYSTEM (Optional Equipment) CONTROLBOX ALTERNATOR 1 i--J I----------------,,-, -----_I 1 YE LLOlzl :NGINE -y SOL 3LUE -- i OS BLUE -- f=T 0. P. SW --@ BLACK;Yf ----_- -------0.75mm2 r - GREEN _---_----_---_----_---- YELLOW I -.-i -- -_ ---------1.25mm2 - 67 - _2.0 mm2 l RGD2500, RGD3300: ELECTRIC JLTERNATOR SYSTEM (Optional Equipment) STARTER :ONTROL BOX YELLOW LIGHT LIGHT GREEY GREEh l PIXK KEY S’.:’ a RGD2500, RGD3300: ELECTRIC STARTER AND OIL SENSOR SYSTEM (Optional Equipment) 1ALTERNATOR CONTROL BOX L*-------*‘. f 1 1; , k-n .,E.L*!q 1i i c -r---- -----1 I 1YELLCi,, L-i--iTe I------- --------{I, _---- I__.-__L,re r-e Lx!?-\ ------- ) catz es ...I.- SACK -- YE;-LO;: _- I I -- l -- I a c-05s sect or51 are2 a-;er ?a- 2i r-l-l: 0.75mm2 1.25mm2 ____--__- - 68 - 2.0 mm2 Symbols Parts Name MC SC AC Winding DC i Auxiliary Winding I ( DC Winding FC ! Field Winding C 1 Condenser R i D ; Diode Stack Assy v ; Voltmeter PL i Pilot Lamp T 1 DC Output Resistor Terminal i Fuse -+---FPSW REG OS i No-Fuse Breaker I : Full Power Switch I : Regulator I Oil Sensor ST.M I Starting SOL I Solenoid Motor KEY.SW 1 KEY. Switch O.P.SW I Oil Pressure Switch BAT E vcs i Battery i Earth Terminal (Ground Terminal) ; Voltage Changeover Switch RECl ; AC Output Receptacle (Total REC2 , AC Output Receptacle (22OV/24OV) REC3 , AC Output Receptacle (11 OV/ 12OV) REC, , AC Output Receptacle (12OV/24OV) RECj / AC Output Receptacle (Total 20A MAX.) - 69 - 15A MAX.) FUJI HEAVY 1 USTWIES LTD.