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Robin America RG2800iS Service Manual

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SERVICE
MANUAL
Models
RG2800iS,
RG3200iS,
RG4300iS,
RG2800i,
RG3200i, RG4300i
GENERATORS
PUB-GS1981
Rev. 09/04

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Summary of Contents for Robin America RG2800iS

  • Page 1 SERVICE MANUAL Models RG2800iS, RG3200iS, RG4300iS, RG2800i, RG3200i, RG4300i GENERATORS PUB-GS1981 Rev. 09/04...

  • Page 3: Table Of Contents

    CONTENTS Section Title Page 1. SPECIFICATIONS ........... . . 1 2.

  • Page 4: Specifications

    1. SPECIFICATIONS RG2800i RG3200i RG4300i Model Type Multi-Pole, Rotating Field Inverter Generator Frequency 50 / 60 Rated Output Voltage 50Hz Rated Current 22.7 11.4 10.9 25.5 12.7 12.2 34.5 17.3 16.5 Voltage 60Hz Rated Current 20.8 10.4 23.3 11.7 31.7 15.8 Power Factor Rated Output...
  • Page 5 RG2800iS RG3200iS RG4300iS Model Multi-Pole, Rotating Field Inverter Generator Type Frequency 50 / 60 Rated Output Voltage 50Hz Rated Current 22.7 11.4 10.9 25.5 12.7 12.2 34.5 17.3 16.5 Voltage 60Hz Rated Current 20.8 10.4 23.3 11.7 31.7 15.8 Power Factor Rated Output Voltage Current...

  • Page 6: General Description

    2. GENERAL DESCRIPTION 2-1-1) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE RG2800i / RG3200i FUEL LEVEL GAUGE AC RECEPTACLES FUEL TANK MULTI MONITOR ENGINE SWITCH RECOIL STARTER HANDLE DC CIRCUIT BREAKER GROUND TERMINAL DC TERMINALS TANK CAP SPECIFICATIONS LABEL FRAME MUFFLER (EXHAUST OUTLET)
  • Page 7 2-1-2) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE WITH ELECTRIC STARTER RG4300i FUEL LEVEL GAUGE AC RECEPTACLES FUEL TANK MULTI MONITOR ENGINE SWITCH KEY SWITCH RECOIL STARTER HANDLE DC CIRCUIT BREAKER DC TERMINALS GROUND TERMINAL TANK CAP SPECIFICATIONS LABEL FRAME AIR CLEANER MUFFLER...
  • Page 8 2-1-3) EXTERNAL VIEW OF GENERATOR : SOUND PROOF TYPE RG2800iS FUEL LEVEL GAUGE AC RECEPTACLES FUEL TANK MULTI MONITOR SIDE COVER (R) RECOIL STARTER HANDLE INSIDE OF SIDE COVER (R) ENGINE SWITCH DC CIRCUIT BREAKER DC TERMINALS DRAIN PLUG GROUND TERMINAL MUFFLER (EXHAUST OUTLET) TANK CAP...
  • Page 9 2-1-4) EXTERNAL VIEW OF GENERATOR : SOUND PROOF TYPE WITH ELECTRIC STARTER RG3200iS / RG4300iS FUEL LEVEL GAUGE AC RECEPTACLES FUEL TANK MULTI MONITOR SIDE COVER (R) ENGINE SWITCH RECOIL STARTER HANDLE KEY SWITCH INSIDE OF SIDE COVER (R) DC CIRCUIT BREAKER DC TERMINALS GROUND TERMINAL DRAIN PLUG...

  • Page 10: Control Panel

    2-2) CONTROL PANEL 50Hz-230V MULTI MONITOR AC RECEPTACLES MULTI MONITOR Hours DC CIRCUIT BREAKER AUTO P-SAVE ENGINE SWITCH KEY SWITCH DC TERMINALS GROUND TERMINAL (G4300I / G3200IS /G4300IS) 60Hz-120V MULTI MONITOR AC RECEPTACLES MULTI MONITOR Hours DC CIRCUIT BREAKER AUTO P-SAVE ENGINE SWITCH KEY SWITCH...
  • Page 11 (1) ENGINE SWITCH RG2800i / RG3200i / RG2800iS The engine switch is designed for easy operation with the interlocking STOP ENGINE SWITCH mechanism between the fuel cock and the choke furnished. To start the engine, turn the knob to the position. CHOKE (Choke valve is closed.) CHOKE...

  • Page 12: Location Of Serial Number And Production Number

    2-3) LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER Generator serial number and production number are stamped on the label stuck on the side of fuel tank. For soundproof type models, remove the side cover (R) to check these numbers. RG2800i / RG3200i / RG4300i PROD No.

  • Page 13: Alternator

    2-4) ALTERNATOR 8P Connector for battery charging and others. 4P Connector for output wires Diode Rectifier Ball Bearing Pipe Cover Rotor CP Rear Cover Stator CP. – 10 –...

  • Page 14: Range Of Applications

    3. 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 15 (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.
  • Page 16 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). If the input current is higher than the allowable current of the cable used, the cable will become excessively heated and deteriorate the insulation, possibly burning it out.

  • Page 17: Measuring And Checking Procedures

    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 generators are as follows : 0 to 150 V : Type with an output voltage of 110 or 120 V 0 to 300 V : Type with an output voltage of 220, 230 or 240 V...
  • Page 18 (4) CIRCUIT TESTER For measuring resistance, etc. NOTE : The ordinary circuit tester may cause erroneous readings due to their measuring method. Use a high-grade, precise circuit tester to check the generator components. (5) MEAGER TESTER Used for measuring generator insulation resistance. Select the one with testing voltage range of 500V.
  • Page 19 (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.

  • Page 20: Ac Output Measuring

    4-2) AC OUTPUT MEASURING SWITCH LOAD TO AC RECEPTACLE 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.

  • Page 21: Measuring Insulation Resistance

    4-4) MEASURING INSULATION RESISTANCE Use a “Dr. Robin” generator tester in megger tester Wire 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. An insulation resistance of 1 megohm or more is normal.

  • Page 22: Checking Functional Members

    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.
  • Page 23 (3) DIODE RECTIFIER Yellow Gray Orange Diode rectifier Orange Yellow Yellow Yellow Gray Circuit tester The circuit inside the diode rectifiers is as shown in the chart above. Check continuity between each terminal by using a circuit tester. The rectifier is normal when continuity is as follows: Checking table for analogue circuit tester Apply black needle of the circuit tester...
  • Page 24 (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. Check that there is continuity between the lead wire of Oil sensor oil sensor and the ground (engine crankcase) when the...

  • Page 25: Disassembly And Assembly

    5. DISASSEMBLY AND ASSEMBLY 5-1) PREPARATION 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.

  • Page 26: Disassembly Procedures

    5-3) DISASSEMBLY 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. 20mm Cover Bolt 4 pcs. Tools : Screw driver 5-3-2 STARTER HANDLE Make a knot on the recoil starter rope inside the side cover in order to prevent the rope from being fully rewound into the starter.
  • Page 27 (3) Remove the fuel strainer. Fuel strainer [ For electric start models ] (4) Remove the battery cover and disconnect battery cables. 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.
  • Page 28 (3) Loosen the five bolts and remove the cover bracket from the inverter unit. M6 x 12mm Flange bolt 2pcs. M6 x 18mm Flange bolt 2pcs. M6 x 25mm AY Bolt 1pce. NOTE : At this step, electric wires are still connected to the control panel.
  • Page 29 5-3-9 FUEL TANK Loosen the four bolts and remove the fuel tank from frame. Fuel tank 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.
  • Page 30 5-3-10 AUTOTHROTTLE COUPLER Auto-throttle Disengage the coupler from the auto-throttle unit of coupler carburetor. 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.
  • Page 31 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. For further taking apart, refer to "INVERTER UNIT COMPONENTS"...
  • Page 32 CONTROL BOX COMPONENTS (RG2800i / RG3200i / RG2800iS) Control box Gromet Micro switch Engine switch CONTROL PANEL AC receptacles AC receptacles DC circuit breaker Ground terminal Multi monitor terminals 4.0 - 6.0 N･m 40 - 60 kgf･cm (3.0 - 4.4 ft･lbs) M6 Screw –...
  • Page 33 CONTROL BOX COMPONENTS (RG4300i / RG3200iS / RG4300iS) Control box Gromet Regulator ATTACHED TO THE BATTERY BASE Micro switch Engine switch CONTROL PANEL AC receptacles AC receptacles DC circuit breaker Ground terminal Multi monitor terminals 4.0 - 6.0 N･m 40 - 60 kgf･cm (3.0 - 4.4 ft･lbs) Key switch M6 Screw...
  • Page 34 5-3-14 FOAM RUBBER INSULATORS Remove the foam rubber insulators from the gaps between frame and fuel tank. 5-3-15 MUFFLER COVER Loosen the four bolts and remove the muffler cover (L) pushing it inward. M6 x 12mm Flange bolt : 4pcs. Tools :10mm Box wrench 5-3-16 MUFFLER (1) Loosen the two M8 nuts and remove the muffler.
  • Page 35 5-3-17 AIR CLEANER and CARBURETOR Element Cleaner cover (1) Remove the air cleaner cover and element from the air cleaner. (2) Loosen the two M6 nuts and one M6 bolt, and Air cleaner remove the air cleaner body. M6 Flange nut : 2pcs. M6 x 20mm Flange bolt : 1pce.
  • Page 36 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.
  • Page 37 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. M10 x 55mm Bolt : 1pce. Tools : Socket wrench NOTE : Since the thread of the through bolt is in reverse direction, turn it clockwise to loosen.
  • Page 38 (2) Using a special tool, Rotor Puller, remove the rear cover together with rotor and stator. Special tools : Rotor Puller (33B9990501) Rotor puller 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.
  • Page 39 5-3-22 RECOIL STARTER Loosen the three M6 bolts and remove the recoil starter. 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.
  • Page 40 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. M8 x 27mm Flange bolt : 4pcs. Tools : 12mm Box wrench Drive shaft holder (33B9990201) Drive shaft Drive shaft holder...

  • Page 41: Reassembly Procedures

    5-4) REASSEMBLY PROCEDURES 5-4-1 MOUNT RUBBERS Attach the four Mount Rubbers to the frame. Insert the Top side of frame locating tab of mount rubber into the locating hole of the frame and fix it by tightening M8 flange nut. M8 Flange nut : 4pcs.
  • Page 42 5-4-4 FLYWHEEL FAN and DRIVE SHAFT (1) Install the Flywheel Fan to the flywheel so as that the Drive shaft three alignment tabs on the back of flywheel fan to mate with the holes of the flywheel. (2) Assemble the Drive Shaft onto the flywheel. Tighten the four M8 bolts while holding the drive shaft using the special tool “Drive Shaft Holder”.
  • Page 43 5-4-7 RECOIL STARTER Assemble the Recoil Starter to blower housing. M6 x 18mm Bolt : 3pcs. Recoil starter Tightening torque : 6.5-8.5 65-85 kgf cm (4.8-6.3 ft lbs) NOTE : Refer to section 5-5 for further instruction for disassembly/reassembly procedures of recoil starter.
  • Page 44 5-4-10 COVER (CRANKSHAFT) for the frame type FAN (SILENT) for the soundproof type Cover (Crankshaft ) For the frame type generator: Assemble the Cover (Crankshaft) to the main bearing cover. M8 x 12mm Flange bolt : 2 pcs. Open frame type For the soundproof type generator: Assemble the Fan (Silent) to the crankshaft.
  • Page 45 5-4-12 CARBURETOR Sponge insulator (1) Install the Sponge Insulator around the intake flange. (2) Install the Carburetor to the intake flange. NOTE: Be sure to attach the gasket between the carburetor and the intake flange. 5-4-13 AIR CLEANER BASE Air cleaner Attach the Air Cleaner Base to the carburetor and fix with two M6 bolts and one M6 Flange bolt.
  • Page 46 5-4-15 MUFFLER Install the muffler to the engine. M8 Flange nut : 2 pcs. Tightening torque : 17.0-19.0 N m 170-190 kgf cm (12.5-14.0 ft lbs) M6 x 23mm Flange bolt : 2 pcs. Tightening torque : 4.0-6.0 40-60 kgf cm (3.0-4.4 ft lbs) 5-4-16 MUFFLER COVER...
  • Page 47 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. 5-4-19 GROUNDING WIRES Fasten the ground wire from the alternator and the one from the inverter unit together to the rear cover with a screw.
  • Page 48 (4) Install the regulator to the battery box. M6 x 8mm Flange bolt : 1 pce. Regulator 5-4-21 AUTO THROTTLE Auto-throttle (1) Connect the wires to Auto Throttle Unit of the coupler carburetor. (2) Temporarily connect the choke cable to the carburetor choke lever.
  • Page 49 5-4-24 REAR COVER (UPPER) and MUFFLER COVER (REAR) (1) Attach the Rear Cover (Upper) first to the frame. Rear cover (Upper ) (2) Install the Muffler Cover (Rear) onto the Rear Cover Muffler cover (Upper) and the frame. (Rear) M6 x 18mm Flange bolt : 6pcs. Tightening torque : 4.0-6.0 40-60 kgf cm...
  • Page 50 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. NOTE : Be sure to install the return spring. Choke wire 5-4-27 GROUND WIRE Fasten the ground wire to the frame.
  • Page 51 5-4-29 RECOIL STARTER 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.

  • Page 52: Recoil Starter

    5-5) RECOIL STARTER Tools 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. Caution : Please wear protective goggles before starting disassembly 1) Disassembly procedures (1) Unhook the spring.
  • Page 53 (2) Remove the small parts. -1 Hold the case, and remove the retaining-ring C with the ring pliers. -2 Beginning at the top, remove the retaining-ring, friction plate, and ratchet. Retaining-ring pliers Retaining-ring C (3) Remove the reel. Retaining-ring C -1 Move the reel to left and right at a 1/4 turns Friction plate several times until it moves smoothly, gently...
  • Page 54 Caution: Please wear protective goggles before starting assembly. 2) Assembly procedure (1) Assemble the reel into the case. Reel -1 Apply grease to the case. -2 Properly orient the inner end of the spring installed Hooking Spiral position spring in the reel. Inner end of -3 Hold the reel so that the shaft and hook part can the spring...
  • Page 55 (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. Caution: Do not release the pressure to hold the reel while winding the spiral spring.
  • Page 56 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. (2) Pull the starter handle and try to pull the starter rope out to the limit.

  • Page 57: Trouble Shooting

    6.TROUBLE SHOOTING No output power or Low output Engine start Remove the electric Overload warning- "O_Load" is displayed equipment that is connected Stop the engine, and reset the overload warning Engine start Confirm the engine revolutions Voltage display is : Out of the (Turn of the APS switch) rated range...
  • Page 58 Improper revolutions (Electronic throttle) Engine starts but Go to the start malfunction section stops suddenly. Engine revolution Confirm connection of does not increase. electronic throttle coupler. Hunting Confirmed Does Pull the recoil starter lightly with the full throttle open. not run Change the carburetor Full throttle direction Throttle direction is from the air cleaner in front...
  • Page 59 Engine does not start (Start failure) None Check the gasoline Add gasoline in the tank warning lamp is on Oil warning lamp turns on Add oil (up to the Check the oil level when the recoil is pulled rated volume) Good Confirm of the oil sensor Fuel cock is in...

  • Page 60: Wiring Diagram

    7. WIRING DIAGRAM RG2800i / RG3200i / RG2800iS (50Hz-230V) [Recoil starter model] GENERATOR CONTROL PANEL DC circuit breaker DC output Diode terminal rectifier Coil (1) Brn/W Coil (2) Grn/Y Coil (3) Micro switch Main coil Blu W Blu W INV&E/G C/U MONITOR C/U Grn/Y Stepping motor...
  • Page 61 RG4300i / RG3200iS / RG4300iS (50Hz-230V) [Electric starter model] GENERATOR CONTROL PANEL DC circuit breaker DC output Diode terminal rectifier Coil (1) Diode rectifier Brn/W Coil (2) Grn/Y Grn/Y Key switch Coil (3) L.IG Main coil MONITOR C/U INV&E/G C/U Grn/Y Stepping motor Earth...
  • Page 62 RG2800i / RG3200i / RG2800iS (50Hz-240V) [Recoil starter model] GENERATOR CONTROL PANEL DC circuit breaker DC output Diode terminal rectifier Coil (1) Brn/W Coil (2) Grn/Y Coil (3) Micro switch Main coil Blu W Blu W INV&E/G C/U MONITOR C/U Grn/Y Stepping motor Earth...
  • Page 63 RG4300i / RG3200iS / RG4300iS (50Hz-240V) [Electric starter model] GENERATOR CONTROL PANEL DC circuit breaker DC output Diode terminal rectifier Coil (1) Diode rectifier Brn/W Coil (2) Grn/Y Grn/Y Key switch Coil (3) L.IG Main coil MONITOR C/U INV&E/G C/U Grn/Y Stepping motor Earth...
  • Page 64 RG2800i / RG3200i / RG2800iS (60Hz-120V) [Recoil starter model] GENERATOR CONTROL PANEL DC circuit breaker DC output Diode terminal rectifier Coil (1) Brn/W Coil (2) Grn/Y Coil (3) Micro switch Main coil Blu W Blu W INV&E/G C/U MONITOR C/U Grn/Y Stepping motor Earth...
  • Page 65 RG4300i / RG3200iS / RG4300iS (60Hz-120V) [Electric starter model] GENERATOR CONTROL PANEL DC circuit breaker DC output Diode terminal rectifier Coil (1) Diode rectifier Brn/W Coil (2) Grn/Y Grn/Y Key switch Coil (3) L.IG Main coil MONITOR C/U INV&E/G C/U Grn/Y Stepping motor Earth...
  • Page 67 940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.com • www.robinamerica.com © Copyright 2004 Robin America, Inc. PRINTED IN THE USA...

This manual is also suitable for:

Rg2800iRg3200isRg3200iRg4300iRg4300is

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