1. Manuals
  2. Brands
  3. Subaru Manuals
  4. Inverter
  5. ROBIN RGD3300H
  6. Service manual

Subaru RGD3300H Service Manual

Generators subaru
Hide thumbs Also See for RGD3300H:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Instructions for Use Manual
SERVICE
MANUAL
Models
RGD3300H
RGD5000H
GENERATORS
PUB-GS2380
Rev. 06/08

Advertisement

Table of Contents
loading

Related Manuals for Subaru RGD3300H

Summary of Contents for Subaru RGD3300H

  • Page 1 SERVICE MANUAL Models RGD3300H RGD5000H GENERATORS PUB-GS2380 Rev. 06/08...

  • Page 3: Table Of Contents

    CONTENTS Section Title Page 1. SPECIFICATIONS ................. 2. PERFORMANCE CURVES ..............3. GENERAL DESCRIPTION External View................... Control Panel ................... Serial Number and Specification Number........4. CONSTRUCTION AND FUNCTION Construction ..................Function ................... Generator Operation................ 5. SAFETY PRECAUTIONS ..............6. RANGE OF APPLICATIONS ...............

  • Page 4: Specifications

    1. SPECIFICATIONS Model RGD3300H RGD5000H Type Brushless, self-exciting, 2-poles, single phase Voltage regulator Condenser type Frequency (Hz) Rated voltage 120, 120/240 AC output Rated output (VA) 3000 4500 Maximum output (VA) 3300 5000 DC output (V-A) 12-8.3 Power factor Over current protector...

  • Page 5: Performance Curves

    2. PERFORMANCE CURVES 2-1 MODEL RGD3300H RGD3300H Output Max ......3300 W Rated ......3000 W Frequency .........60 Hz Voltage ........110 V 2-2 MODEL RGD5000H RGD5000H Output Max ......5000 W Rated ......4500 W Frequency .........60 Hz Voltage ........110 V 2-3 DC OUTPUT (RGD3300H, RGD5000H) DC Voltage ........12 V...

  • Page 6: General Description

    3. GENERAL DESCRIPTION 3-1 EXTERNAL VIEW FUEL GAUGE TANK CAP AIR CLEANER FUEL TANK FUEL COCK OIL GAUGE (OIL FILLER) SPEED ADJUSTER CONTROL PANEL OIL FILTER FUEL FILTER OIL DRAIN PLUG MUFFLER RECOIL STARTER HANDLE RECOIL STARTER ELECTRIC STARTER – 3 –...

  • Page 7: Control Panel

    3-2 CONTROL PANEL ● RGD3300H/5000H: 60 Hz-120 V, 240 V TYPE RGD3300H DC FUSE VOLTMETER AC CIRCUIT FULL POWER BREAKER SWITCH AC RECEPTACLES (20 A) AC CIRCUIT BREAKER HOUR METER KEY SWITCH AC RECEPTACLES (30 A) GROUND TERMINAL DC TERMINALS 3-3 SERIAL NUMBER AND SPECIFICATION NUMBER Serial number and Production number are indicated on the labels stuck on the rear cover.

  • Page 8: Construction And Function

    4. CONSTRUCTION AND FUNCTION 4-1 CONSTRUCTION SUPPORT RING BALL BEARING ROTOR COMPLETE STARTOR COMPLETE END COVER MOUNT RUBBER REAR COVER FRONT COVER STARTOR BOLT THROUGH BOLT GENERATOR BASE 4-2 FUNCTION 4-2-1 STATOR The stator consists of a laminated silicon steel sheet core, a main coil and a condenser coil which are wound in the core slots.
  • Page 9 4-2-2 CONDENSER 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. 4-2-3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core.
  • Page 10 The table below shows the capacity of no-fuse breaker by each spec. and their object of pro- tection. MODEL SPECIFICATION NO-FUSE BREAKER OBJECT of PROTECTION RGD3300H 120/240 V 14 A × 2 Total output amperage 20 A × 2 Total output amperage...
  • Page 11 4-2-6 RECEPTACLE AND AC PLUG (STD. SPEC.) These are used for taking AC output power from the generator. A total of three kinds of receptacles, each varying in rated voltage and current from another, are used to deliver the rated generator output. As many AC plugs as the receptacles, each matching the corresponding receptacle, are provided.

  • Page 12: Generator Operation

    4-3 GENERATOR OPERATION PERMANENT MAGNET MAIN COIL STATOR FOR INITIAL EXCITATION FIELD COIL ROTOR RECEPTACLE APPLIANCE SURGE ABSORBER DIODE CONDENSER COIL CONDENSER 4-3-1 GENERATION OF NO-LOAD VOLTAGE When the generator starts running, the permanent magnet built-in to the rotor generates 3 to 6 V of AC voltage in the main coil and condenser coil wound on the stator.
  • Page 13 4-3-3 FULL POWER SWITCH (DUAL VOLTAGE TYPE) The full power switch is provided for the dual voltage type to take out the full rated power from one recep- tacle in each voltage. 120/240 V 120 V Rec. 1 240 V 120 V Rec.
  • Page 14 lnside the generator are two sets of main coils. Each main coil outputs half the rated power at the lower voltage (120 V). These main coils are wound to be in the same phase. The full power switch reconnects these main coils in parallel or in series. Fig.

  • Page 15: Safety Precautions

    5. SAFETY PRECAUTIONS Use extreme caution near fuel. A constant danger of explosion or fire exists. Do not fill the fuel tank while the engine 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. Do not place inflammable materials near the generator.

  • Page 16: Range Of Applications

    6. RANGE OF APPLICATIONS 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.
  • Page 17 0.7 and power consumption will be 400 ÷ 0.7 = 570 W. When this motor is used for a motor-driven tool, the capacity of the generator should be multipled by 1.2 to 3 and 570 W as explained in the Item (3). MODEL RGD3300H RGD5000H Frequency 60 Hz 60 Hz Incandescent lamp, heater, etc.
  • Page 18 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.

  • Page 19: Measuring Procedures

    7. MEASURING PROCEDURES 7-1 MEASURING INSTRUMENTS 7-1-1 VOLTMETER AC voltmeter is necessary. The approximate AC voltage ranges of the voltmeters to be used for vari- ous types of generators are as follows: 0 to 150 V: Type with an output voltage of 120 V 0 to 300 V: Type with an output voltage of 240 V 0 to 150 V, 0 to 300 V: Dual voltage type FOR AC...

  • Page 20: Ac Output Measuring

    7-1-5 MEGGER TESTER Used for measuring generator insulation resis- tance. Select one with testing voltage range of 500 V. 7-1-6 TACHOMETER There are various types of tachometers, such as contactless type, contact type, and strobe type. The CONTACTLESS TYPE contact type can be used only when the generator and engine have been disassembled.

  • Page 21: Measuring Insulation Resistance

    7-3 MEASURING INSULATION RESISTANCE ● CONTROL PANEL Connect a megger tester to one of receptacle out- put terminals and the ground terminal, then mea- sure the insulation resistance. An insulation resistance of 1 megohm or more is normal. (The original insulation resistance at the time of shipment from the factory is 10 megohms or more.) If it is less than 1 megohm, disassemble the gener-...

  • Page 22: Checking Functional Members

    8. CHECKING FUNCTIONAL MEMBERS 8-1 AC RECEPTACLES Using 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. When continuity is found between the output terminals of the receptacle with a wire connected across these terminals, the AC receptacle is normal.

  • Page 23: Stator

    (R × 1 Ω ±10%) SPECIFICATION AC Winding Condenser Winding DC Winding MODEL Voltage White-Red Black-Blue Yellow-Yellow Brown-Brown 120 V RGD3300H 0.48 0.48 0.92 0.17 120 V/240 V 240 V RGD5000H 0.23 0.23 0.54 0.13 120 V/240 V NOTE: If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings.

  • Page 24: Condenser

    [Continuity exists.] 8-5 CONDENSER ■ If an instrument (QC-meter or C-meter) for mea- suring capacity of condenser is available, check CONDENSER the capacity of condenser. NORMAL CAPACITY OF CONDENSER RGD3300H RGD5000H MODEL 60 Hz 60 Hz 20 µF 30 µF CONDENSER 20 µF...

  • Page 25: Diode Rectifier

    8-6 DIODE RECTIFIER DIODE RECTIFIER Brown Brown/ Orange White Orange Brown Brown Brown Brown/White CIRCUIT TESTER Fig. 5 Fig. 6 Circuit inside of the diode rectifiers is as shown in Fig. 5. Check continuity between each terminal by using a circuit tester as shown in Fig. 6. The rectifier is normal when continuity is as follows: Apply black needle of the circuit tester Brown...

  • Page 26: Disassembly And Assembly

    9. DISASSEMBLY AND ASSEMBLY 9-1 PREPARATION AND PRECAUTIONS Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly. Tie tags noted with the necessary information to facilitate easier and smoother reassembly. For more convenience, divide the parts into several groups and store them in boxes.

  • Page 27: Disassembly Procedures

    9-3 DISASSEMBLY PROCEDURES Step Part to remove Description Remarks Tool Fuel Tank (1) Close fuel cock. Draining tank of fuel before disassembly is unnecessary. (2) Remove the fuel cock from the bracket (6 ø flange bolt). (3) Remove the hose clamps (three Plier places).
  • Page 28 Step Part to remove Description Remarks Tool Control Box (1) Disconnect the coupler for key switch. COUPLER FOR KEY SWITCH (2) Remove control box from frame by Wire harness is still 10 mm spanner or removing the three bolts (6 ø) joining connected.
  • Page 29 (6) Pull the wire harness out from the con- trol box. Disengage the connectors to separate the control box. Pipe Frame 2 pcs. RGD3300H: 8 ø NUT 2 pcs. RGD5000H: 10 ø NUT 2 pcs. 6 ø BOLT ENGINE BASE 2 pcs.
  • Page 30 Step Part to remove Description Remarks Tool Pipe Frame (1) Remove the fuel tank baffle plate. 6 ø bolts ......2 pcs. (2) Remove the stoppers. 10 mm spanner or 8 ø bolts ......4 pcs. box spanner (3) Remove the filter bracket from the Take care of spilt fuel frame.
  • Page 31 10 mm spanner or 6 ø bolt........ 4 pcs. box wrench (2) Remove through bolt from rotor shaft. RGD3300H: 14 mm Apply a socket wrench on the head of RGD5000H: 14 mm through bolt and hit the wrench handle Box wrench with a hammer counterclockwise to loosen.
  • Page 32 Step Part to remove Description Remarks Tool Rear Cover In case that “REAR COVER PULLER” is unavailable, remove the rear cover by the following instructions: a. Insert the through bolt into the rotor Do not give a strong Plastic hammer shaft and tighten lightly.
  • Page 33 Step Part to remove Description Remarks Tool Stator (3) Pull out the wires from rear cover. SUPPORT RING STATOR REAR COVER 4 pcs. 6 ø BOLT Rotor (1) Take off the through bolt. Box wrench Apply a box wrench on the head of Plastic hammer through bolt.
  • Page 34 Step Part to remove Description Remarks Tool Rotor (3) Use a bolt and oil as a tool for pulling out rotor in the following procedures: 1. Pour engine oil into the center hole of rotor shaft. Fill with oil to the shaft end. 2.
  • Page 35 Step Part to remove Description Remarks Tool Rotor 5. Torque the bolt using a socket wrench It may jump up on Socket wrench until the rotor comes off loose. separation. * The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft.

  • Page 36: Assembly Procedures

    NOTE 2: The size of faucet joint and pitch of mounting holes of front cover is different by models RGD3300H and RGD5000H. 9-4-2 ROTOR Clean the tapered portion of driving shaft and the matching tapered hole of rotor shaft of oil and dirt using a waste cloth.
  • Page 37 Tightening torque: 7.8 ~ 9.8 N-m (80 ~ 100 kg-cm, 5.8 ~ 7.2 ft-lb) NOTE: Tighten four bolts evenly taking several steps. ● The dimensions of the stator bolts are shown in the table below. Model (mm) RGD3300H (inch) 3.35 0.99 0.24 (mm) RGD5000H (inch) 4.53...
  • Page 38 Attach the boot over the lead wires drawn out from the rear cover. Press the smaller end of boot into the rear cover. 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.
  • Page 39 NOTE: The mount rubbers are selected to reduce vibration most effectively by model and its frequency. Be sure to use the correct mount rubber for your generator. 2 pcs. RGD3300H: 8 ø NUT 2 pcs. RGD5000H: 10 ø NUT 2 pcs.
  • Page 40 8 ø flange nut......1 pc. Tightening torque: 11.8 ~ 13.7 N-m (120 ~ 140 kg-cm, 8.68 ~ 10.1 ft-lb) Make this gap even. Attach the base plate to the engine. RGD3300H ........ 8 ø RGD5000H ........ 10 ø RGD3300H: 8 ø RGD5000H: 10 ø...
  • Page 41 CLAMP BATTERY CABLE (-) Fix the engine mount rubbers to the crankcase bracket. RGD3300H: 8 ø flange nut..2 pcs. RGD5000H: 10 ø flange nut..2 pcs. Tightening torque: 11.8 ~ 13.7 N-m (120 ~ 140 kg-cm, 8.68 ~ 10.1 ft-lb) CAUTION: Pay attention to the position of the mount rubbers.
  • Page 42 9-4-6 CONTROL BOX Mount the control box assembly to the frame. Refer to Section 9-5 for disassembly, checking and reassembly procedures of the control box. Attach the 6 ø terminal of the grounding wires to the rear of the control box. 4 ø...
  • Page 43 Connect the coupler for key switch. COUPLER FOR KEY SWITCH 9-4-7 FUEL TANK Install the fuel tank with four nuts (8 ø). Connect the hose clamps (three places). Install the fuel cock to the bracket (6 ø flange bolt). Open the fuel cock. 8 ø...
  • Page 44 9-4-8 BATTERY FRAME AND BATTERY Apply the battery stay to the battery and tighten two nuts with battery bolts installed in position. 6 ø nut........2 pcs. Tightening torque: 4.9 ~ 5.9 N-m (50 ~ 60 kg-cm, 3.6 ~ 4.3 ft-lb) Connect battery cables to the battery.

  • Page 45: Control Box

    9-5 CONTROL BOX 9-5-1 CHECKING OF THE CONTROL BOX Dismount the control box from frame. Remove the control panel and check each components and wiring. Refer to Section 8. for the detail of checking the components in the control box. 9-5-2 DISASSEMBLY Remove the control panel from the control box.

  • Page 46: Trouble Shooting

    10-1-2 CHECKING CONDENSER ■ If an instrument (QC-meter or C-meter) for mea- suring capacity of condenser is available, check CONDENSER the capacity of condenser. NORMAL CAPACITY OF CONDENSER RGD3300H RGD5000H MODEL 60 Hz 60 Hz 20 µF 30 µF CONDENSER 20 µF...
  • Page 47 ■ Measure the resistance of field coil with a circuit tester. ■ NORMAL RESISTANCE MODEL RGD3300H RGD5000H 2.1 Ω 1.6 Ω Resistance [Remedy] If the resistance is not normal, replace rotor with a new one. CHECKING OF DIODES AND RESISTORS ON THE ROTOR ■...

  • Page 48: Ac Voltage Is Too High Or Too Low

    [Reassembling] SURGE ABSORBER As shown in the figure, place the white mark on the magnet to the left and solder the diodes so that cathode mark is to be placed WHITE MARK at the bottom. Solder the coil ends to the terminal. DIODE 10-2 AC VOLTAGE IS TOO HIGH OR TOO LOW.

  • Page 49: Ac Voltage Is Normal At No-Load, But The Load Cannot Be Applied

    10-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED. 10-3-1 CHECK THE ENGINE SPEED. If the engine speed is low, adjust it to the rated r.p.m. * Refer to Step 10-2-1 for engine speed adjustment. 10-3-2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR. Refer to Section 6.

  • Page 50: No Dc Output

    DIODE RECTIFIER checking procedure. 10-4-5 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester. MODEL SPECIFICATION RESISTANCE 120 V RGD3300H 60 Hz 0.18 120 V/240 V 120 V RGD5000H 60 Hz 0.13...

  • Page 51: Wiring Diagram

    11. WIRING DIAGRAM ● RGD3300H: 60 Hz-120 V, 240 V TYPE Display panel G/~ G/~ 30 50 ENGINE switch BATTERY 50a 15 0 1 2 GENERATOR CONTROL BOX (120V/240V) AC circuit breaker (120V) Grn/Y EARTH TERMINAL FUSE DC output terminal...
  • Page 52 ● RGD5000H: 60 Hz-120 V/240 V TYPE Display panel G/~ G/~ 30 50 ENGINE switch BATTERY 50a 15 0 1 2 GENERATOR CONTROL BOX (120V/240V) AC circuit breaker (120V) AC circuit breaker Grn/Y EARTH TERMINAL FUSE DC output terminal (10A) Brn/W (PIPE FRAME) Wiring color cord...
  • Page 54 940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.com • www.robinamerica.com © Copyright 2008 Robin America, Inc. PRINTED IN THE USA...

This manual is also suitable for:

Rgd5000h

Table of Contents