Instruction/ maintenance manual of the product RG2800IS Subaru Robin Power Products
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SERVICE MANU AL RG2800iS, RG3200iS, RG4300iS, RG2800i, RG3200i, RG4300i Models PUB-GS1981 Rev . 09/04 GENERA TORS.
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CONTENTS Section Title Page 1. SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– 1 – 1. SPECIFICA TIONS Model T ype Starting System Hz W L mm mL(cc) L kg Model T ype Frequency kV A Rated Output AC Rated Output Fuel T ank Capacity h Lubrication Oil Capacity Ignition System Dry Weight Specifications are subject to change without notice.
– 2 – Model T ype Starting System Hz W L mm mL(cc) L kg Model T ype Frequency Rated Output Fuel T ank Capacity h Lubrication Oil Capacity Ignition System Dry Weight Dimensions L × W × H Displace.
– 3 – 2. GENERAL DESCRIPTION 2-1-1) EXTERNAL VIEW OF GENERA TOR : OPEN FRAME TYPE DC TERMINALS DRAIN PLUG GROUND TERMINAL AC RECEPT ACLES DC CIRCUIT BREAKER FUEL T ANK OIL LEVEL GAUGE FUEL LEVEL G.
– 4 – 2-1-2) EXTERNAL VIEW OF GENERA TOR : OPEN FRAME TYPE WITH ELECTRIC ST ARTER DC TERMINALS DRAIN PLUG GROUND TERMINAL AC RECEPT ACLES DC CIRCUIT BREAKER FUEL T ANK OIL LEVEL GAUGE FUEL LEVEL G.
– 5 – DC TERMINALS GROUND TERMINAL AC RECEPT ACLES DC CIRCUIT BREAKER FUEL T ANK FUEL LEVEL GAUGE MUL TI MONITOR FRAME SPECIFICA TIONS LABEL MUFFLER (EXHAUST OUTLET) ENGINE SWITCH T ANK CAP RECOIL.
– 6 – DC TERMINALS GROUND TERMINAL AC RECEPT ACLES DC CIRCUIT BREAKER FUEL T ANK FUEL LEVEL GAUGE MUL TI MONITOR FRAME SPECIFICA TIONS LABEL T ANK CAP SIDE COVER (R) INSIDE OF SIDE COVER (R) RECOI.
– 7 – 2-2) CONTROL P ANEL Hours MUL TI MONITOR V Hz AUTO P-SA VE Hours MUL TI MONITOR V Hz AUTO P-SA VE Hours MUL TI MONITOR V Hz AUTO P-SA VE DC TERMINALS GROUND TERMINAL AC RECEPT ACLES DC CIRCU.
(3) MUL TI MONITOR ■ ■ LE D display Operation hour, voltage and frequency are indicated in turns by means of depressing the LE D display changeover switch. In addition, "O_Lod" (overload) will be indicated when the generator is in the overload condition or appliance(s) is out of order.
– 9 – 2-3) LOCA TION OF SERIAL NUMBER AND PRODUCTION NUMBER Generator serial number and production number are stamped on the label stuck on the side of fuel tank.
– 10 – 2-4) AL TERNA TOR Rear Cover 8P Connector for battery charging and others. 4P Connector for output wires Rotor CP Stator CP. Ball B e aring Pipe Cover Diode Rectifier.
– 11 – Generally, the power rating of an electrical appliance indicates the amount of work 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.
– 12 – (5) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a case, power consumption is to be worked out according to the numerical formula mentioned below.
– 13 – NOTES : Wiring between generator and electrical appliances 1. Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load (electrical appliance).
– 14 – 4. MEASURING AND CHECKING PROCEDURES 4-1) MEASURING INSTRUMENTS (1) VOLTMETER AC voltmeter is necessary. The approximate AC voltage ranges of the voltmeters to be used for various types of .
– 15 – (5) MEAGER TESTER Used for measuring generator insulation resistance. Select the one with testing voltage range of 500V. (4) CIRCUIT TESTER For measuring resistance, etc. NOTE : The ordinary circuit tester may cause erroneous readings due to their measuring method.
(7) "Dr.Robin" GENERATOR TESTER The "Dr.Robin" generator tester is exclusively designed for fast, easy diagnosis and repair of Robin generators. The "Dr.Robin" has the following features : 1) Functions of voltmeter, frequency meter, megger tester, capacitance meter and circuit tester are combined in one unit.
– 17 – 4-2) AC OUTPUT MEASURING SWITCH LOAD TO AC RECEPTACLE F A ~ V ~ Use a circuit 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 following table at the rated amperage and rated rpm.
– 18 – 4-4) MEASURING INSULA TION RESIST ANCE Use a “Dr. Robin” generator tester in megger tester mode or use a megger tester to check the insulation resistance. Connect a megger tester to one of receptacle output terminals and the ground terminal, then measure the insulation resistance.
– 19 – 4-5) CHECKING FUNCTIONAL MEMBERS (1) STATOR Disengage connectors on the wires from stator and check the resistance between the wires using a circuit tester referring to the table below. NOTE : If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings.
– 20 – (3) DIODE RECTIFIER The circuit inside the diode rectifiers is as shown in the chart above. Check continuity between each terminal by using a circuit tester.
– 21 – (5) DC CIRCUIT BREAKER Check that there is continuity between the two terminals of DC circuit breaker when its push button is pressed. (6) FLOAT TYPE OIL SENSOR Check the oil sensor when it is installed on the engine. Check that sufficient engine oil is filled in the crankcase.
– 22 – 5. DISASSEMBL Y AND ASSEMBL Y 5-1) PREP ARA TION AND PRECAUTIONS (1) Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly. Tag the disassembled part with the necessary information to facilitate easier and smoother reassembly.
– 23 – 5-3) DISASSEMBL Y PROCEDURES 5-3-1 SIDE COVER (L) and (R) Take off the four bolts and remove the side cover (L) and (R) from the frame. M6 x 20mm Cover Bolt : 4 pcs.
– 24 – Battery cables Fuel strainer (3) Remove the fuel strainer. [ For electric start models ] (4) Remove the battery cover and disconnect battery cables. (5) Remove the battery from frame. 5-3-4 GROUNDING WIRE Remove the grounding wire at the right bottom side of control panel.
5-3-8 WIRE BAND Cut the wire bands that are binding wires behind the control panel. For electric start models, cut the wire band that is binding battery cables also. Tools : Nipper Wire band (3) Loosen the five bolts and remove the cover bracket from the inverter unit.
– 26 – 5-3-9 FUEL TANK Loosen the four bolts and remove the 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 misplace the four mounting rubbers for the tank.
– 27 – 5-3-10 AUTOTHROTTLE COUPLER Disengage the coupler from the auto-throttle unit of carburetor. Auto-throttle coupler 5-3-11 WIRE HARNESS (1) Disengage the couplers of wire harness from the control panel and monitor unit. (2) Disengage the couplers of wire harness from the control panel, inverter unit and the alternator.
– 28 – 5-3-12 GROUNDING WIRE (2) Disconnect the two grounding wires from the alternator and the inverter unit. Tools : Screw driver 5-3-13 CONTROL BOX and INVERTER UNIT Removing the cover bracket from the bottom of the inverter unit, separate the control box and inverter unit.
– 29 – CONTROL P ANEL Control box Gromet 4.0 - 6.0 N ･ m 40 - 60 kgf ･ cm (3.0 - 4.4 ft ･ lbs) DC terminals Ground terminal AC receptacles AC receptacles DC circuit breaker Multi monitor M6 .
– 30 – Regulator AT T ACHED TO THE BA TTER Y BASE 4.0 - 6.0 N ･ m 40 - 60 kgf ･ cm (3.0 - 4.4 ft ･ lbs) CONTROL P ANEL Control box Gromet DC terminals Ground terminal AC receptacles AC recep.
5-3-16 MUFFLER (1) Loosen the two M8 nuts and remove the muffler. M8 Flange nut : 2 pcs. Tools : 12mm Box wrench (2) Loosen the two M6 bolts and remove the muffler bracket. M6 x 23mm Flange bolt : 2pcs. Tools : 10mm Box wrench – 31 – 5-3-14 FOAM RUBBER INSULATORS Remove the foam rubber insulators from the gaps between frame and fuel tank.
– 32 – 5-3-17 AIR CLEANER and CARBURETOR (1) Remove the air cleaner cover and element from the air cleaner. (2) Loosen the two M6 nuts and one M6 bolt, and remove the air cleaner body.
– 33 – 5-3-18 ENGINE BLOCK (1) Loosen the four M8 nuts that fasten the engine to the mount rubbers, and remove the engine. M8 Flange nut : 4pcs. Tools : 12mm Box wrench (2) Remove the mount rubbers from the frame as necessary. M8 Flange nut : 4pcs.
– 34 – 5-3-20 REAR COVER Loosen the four M6 bolts that fasten the rear cover to the blower housing. M6 x 25mm Bolt : 4pcs. Tools : 10mm Box wrench 5-3-21 THROUGH BOLT and ROTOR (1) Remove the through bolt.
– 35 – Hand-pressing machine (2) Using a special tool, Rotor Puller, remove the rear cover together with rotor and stator. Special tools : Rotor Puller (33B9990501) NOTE 1: Usually, you do not need to separate the rotor from the stator. However, should it be necessary, use a hand-pressing machine to press out the rotor shaft from the bearing.
– 36 – 5-3-22 RECOIL STARTER Loosen the three M6 bolts and remove the recoil starter. M6 x 18mm Flange bolt : 3pcs. Tools : 10mm Box wrench NOTE : Refer to section 5-5 for further instruction for disassembly/reassembly procedures of recoil starter.
– 37 – 5-3-25 DRIVE SHAFT and FAN Using a special tool “DRIVE SHAFT HOLDER” to hold the drive shaft, loosen the four M8 bolts to remove the Drive Shaft and Fan from the flywheel.
– 38 – T op side of frame Base plate (Lower) Sponge (Base) Brake Battery base Wheel Base plate (Upper) Shaft 5-4) REASSEMBL Y PROCEDURES 5-4-2 SOUND INSULA TOR for SOUND-PROOF MODELS (1) WHEELS Inset the Shafts to the Base Plate (Lower) and assemble the four Wheels to the Shafts.
– 39 – Blower housing M6x35mm Bolt M6x45mm Bolt Separator (SEL) Separator (A/C) Drive shaft holder Drive shaft 5-4-4 FL YWHEEL F AN and DRIVE SHAFT (1) Install the Flywheel Fan to the flywheel so as that the three alignment tabs on the back of flywheel fan to mate with the holes of the flywheel.
– 40 – Recoil starter T ightening torque : 6.5 - 8.5 N ・ m 65 - 85 kgf ・ cm (4.8 - 6.3 ft ・ lbs) 5-4-7 RECOIL ST ARTER Assemble the Recoil Starter to blower housing. M6 x 18mm Bolt : 3pcs. NOTE : Refer to section 5-5 for further instruction for disassembly/reassembly procedures of recoil starter.
– 41 – 5-4-10 COVER (CRANKSHAFT) for the frame type F AN (SILENT) for the soundproof type For the frame type generator: Assemble the Cover (Crankshaft) to the main bearing cover. M8 x 12mm Flange bolt : 2 pcs. For the soundproof type generator: Assemble the Fan (Silent) to the crankshaft.
– 42 – 5-4-12 CARBURETOR (1) Install the Sponge Insulator around the intake flange. 5-4-13 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.
– 43 – 5-4-15 MUFFLER Install the muffler to the engine. M8 Flange nut : 2 pcs. M6 x 23mm Flange bolt : 2 pcs. T ightening torque : 4.0 - 6.0 N ・ m 40 - 60 kgf ・ cm (3.0 - 4.4 ft ・ lbs) T ightening torque : 4.0 - 6.0 N ・ m 40 - 60 kgf ・ cm (3.
– 44 – 5-4-18 CONTROL BOX and INVERTER UNIT (1) Temporarily assemble the Control Box and Inverter Unit. (2) Connect the wire harness to the control box and inverter unit. 5-4-20 CONNECTION OF WIRING HARNESS (1) Engage the connectors of wiring harness between the control panel, inverter unit and the alternator.
– 45 – 5-4-21 AUTO THROTTLE (1) Connect the wires to Auto Throttle Unit of the carburetor. (2) Temporarily connect the choke cable to the carburetor choke lever. 5-4-22 FUEL T ANK (1) Install the fuel tank onto the frame. Be sure to insert the mount rubbers between the tank and the frame.
– 46 – 5-4-24 REAR COVER (UPPER) and MUFFLER COVER (REAR) (1) Attach the Rear Cover (Upper) first to the frame. (2) Install the Muffler Cover (Rear) onto the Rear Cover (Upper) and the frame. M6 x 18mm Flange bolt : 6pcs. (2) Assemble the Front Cover (Lower) below the Front Cover (Upper) M6 x 18mm Flange bolt : 2 pcs.
- 47 - 5-4-27 GROUND WIRE Fasten the ground wire to the frame. M6 Nut : 1pce. 5-4-26 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.
– 48 – 5-4-29 RECOIL ST ARTER HANDLE (1) Pass the starter rope through the side cover (R) and then the starter handle. Make a figure eight knot to hold the rope end in the starter handle. (2) Release the knot inside the side cover that has been made while disassembly procedure to keep the rope.
– 49 – 5-5) RECOIL ST ARTER T ools used : Long-nose pliers, retaining-ring pliers, protective goggles The recoil starter of this device is located between the alternator assembly and the engine, so remove the recoil starter after removing the alternator assembly.
– 50 – Caution : The reel is disassembled with the spring still assembled, so place it on a flat table without dropping, or shaking. Retaining-ring C Retaining-ring pliers (2) Remove the small parts. -1 Hold the case, and remove the retaining-ring C with the ring pliers.
– 51 – (2) Install the ratchet and friction spring. Install the ratchet and friction spring into the reel. Friction plate Retaining-ring C Ratchet Friction spring (3)Installation of friction plate and retaining ring C. Install by putting the Tab of friction plate into the hole of the ratchet.
– 52 – (4) Wind the spiral spring. -1 Holding the case, turn the reel five turns in counter-clockwise. -2 Fix the reel in the position that the rope hole of reel aligns with the rope guide.
– 53 – 3) Checking items after assembly (1) Try to pull the starter handle for 2 to 3 times. (a)When the starter handle is difficult to pull, please make sure the parts, etc., are installed in the right direction. (b)When the ratchet does not operate, please re-check if there are any missing parts such as the spring.
– 54 – 6.TROUBLE SHOOTING No output power or Low output Engine start Engine start Change INV C/U ＜ Resistance value of the stator windings for reference ＞ Surrounding temperature 20 ℃ Red Wh.
– 55 – Improper revolutions (Electronic throttle) Engine starts but stops suddenly . Go to the start malfunction section No Ye s Ye s Does not run ・ Engine revolution does not increase. ・ Hunting Confirm connection of electronic throttle coupler .
– 56 – Check the gasoline in the tank Add gasoline Check the oil level Confirm of the oil sensor Change Oil sensor Add oil (up to the rated volume) Open the cock Clean, change the filter Ye s None.
– 57 – 7. WIRING DIAGRAM Grn/Y Org Brn/W Brn Brn Blu R W Blk Grn Blu Y Blk R W Blu W W Blu W W Grn/Y Blk Earth (ground) terminal R Brn Grn/Y INV&E/G C/U Engine switch Micro switch Diode rectif.
– 58 – M RELA Y Key switch M- L.IG B M+ ST R Org R R R R R R W W W W W W W Org Org Org Blu Blu Blu Blu Blu Blu Y Blk Blk R W Blu Blk R Blk Blk Earth (ground) terminal Brn Brn Brn Brn Grn/Y Grn/Y G.
– 59 – Org Brn/W Brn Brn Blu R W Blk Grn Blu Y Blk R W Blu W W Blu W W Grn/Y Blk Earth (ground) terminal R Brn Grn/Y Grn/Y INV&E/G C/U Engine switch Micro switch Diode rectifier Stepping motor.
– 60 – M RELA Y Key switch M- L.IG B M+ ST R Org R R R R R R W W W W W W W Org Org Blu Blu Blu Blu Blu Blu Y Blk Blk R Blk Blk Earth (ground) terminal Brn Brn Grn/Y Grn/Y Grn/Y Grn/Y Grn/Y INV&.
– 61 – Org Brn/W Brn Brn Blu Blu R W Blk Grn Blu Y Blk R W W Blu W W Blu W W Grn/Y Blk Earth (ground) terminal R R Brn Grn/Y INV&E/G C/U Engine switch Micro switch Diode rectifier Stepping mot.
– 62 – M RELA Y Key switch M- L.IG B M+ ST R R Org R R R R R R W W W W W W W W Org Org Blu Blu Blu Blu Blu Blu Y Blk Blk R Blk Blk Earth (ground) terminal Brn Brn Grn/Y Grn/Y Grn/Y Grn/Y Grn/Y INV.
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PRINTED IN THE USA © Copyright 2004 Robin America, Inc. 940 Lively Blvd. • W ood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.
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