1. Manuals
  2. Brands
  3. Robin Manuals
  4. Portable Generator
  5. RG2800DX
  6. Service manual

Robin RG2800DX Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
TechnicaI Data & Overhaul Instructions

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the RG2800DX and is the answer not in the manual?

Questions and answers

Related Manuals for Robin RG2800DX

Summary of Contents for Robin RG2800DX

  • Page 1 TechnicaI Data & Overhaul Instructions...

  • Page 2: Table Of Contents

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

  • Page 3: Specifications

    1. SPECIFICATIONS 1-1) SPECIFICATIONS MODEL RG2800DX RG3200DX RG4300DX Type 2-Pole, Revolving Field type Self Exciting, Single Phase Voltage regulator AVR type AC Output Frequency Rated voltage V 120/240 120/240 Rated current 20.0 22.5/11.3 30.8/15.4 Rated output Maximum output kVA Rated power factor...

  • Page 4: Frequency Hz

    1-2) PERFOMANCE CURVES RG2800DX [60Hz - 120/240V] Maximum output 2,800 VA Rated output 2,400 VA (Hz) Frequency 60 Hz Rated voltage 120 V Rated amperage 20.0 A 1 (kVA) RG3200DX [60Hz - 120/240V] Maximum output 3,200 VA Rated output 2,700 VA...

  • Page 5: Rated Voltage

    RG4300DX [60Hz - 120/240V] Maximum output 4,300 VA Rated output 3,700 VA (Hz) Frequency 60 Hz Rated voltage 120/240 V Rated amperage 30.8/15.4 A 130/260 (kVA) 125/250 120/240 115/230 36(A) – 3 –...

  • Page 6: General Description

    2. GENERAL DESCRIPTION 2-1) EXTERNAL VIEW OF GENERATOR FUEL LEVEL GAUGE FUEL TANK CONTROL PANEL RECOIL STARTER HANDLE TANK CAP SPECIFICATIONS LABEL MUFFLER (EXHAUST OUTLET) OIL LEVEL GAUGE AIR CLEANER SPARK PLUG DRAIN PLUG – 4 –...

  • Page 7: Control Panel

    2-2) CONTROL PANEL AC CIRCUIT AC RECEPTACLES AC RECEPTACLES MULTI MONITOR BREAKER (20A) (30A) MULTI MONITOR Hours AUTO P-SAVE ENGINE SWITCH FULL POWER SWITCH GROUND TERMINALS TERMINAL KEY SWITCH DC CIRCUIT [Electric starter model] BREAKER (1) ENGINE SWITCH CLOSE ENGINE SWITCH The engine switch is designed for easy operation with the interlocking OPEN mechanism between the fuel cock and the choke furnished.

  • Page 8: [Approx.] Hours

    (3) MULTI MONITOR LE display Operation hour lamp Voltage lamp LE display MULTI MONITOR Hours Operation hour, voltage and frequency are Frequency indicated in turns by means of depressing the lamp LE display changeover switch. In addition, "O_Lod" (overload) will be indicated when the IDLE Engine oil level warning lamp...

  • Page 9: Alternator

    2-3) ALTERNATOR Slip ring End cover Rear cover AVR AY Brush CP Rotor CP Ball bearing Rotor shaft Rotor bolt Stator CP Stator cover Diode stack 2-4) 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.

  • Page 10: 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 11 1.2 to 3 and 570W as explained in the ltem (3). 570 (W) x 1.2 to 3 = 684 (W) to 1710 (W) Applicable Wattage (approx. W) Applications RG2800DX RG3200DX RG4300DX 50Hz / 60Hz...
  • Page 12 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 13: 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 14 (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 15 The "Dr.Robin" generator tester can be ordered from Robin generator distributors by the following part number. Dr.Robin_Part_Number_:_388-47565-08 If you do not have a "Dr.Robin" generator tester, use the instruments described in the following section for checking generator parts. – 13 –...

  • Page 16: Ac Output Measuring

    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. Specification Model 60Hz-120V 60Hz-120/240V RG2800DX 119 - 133 RG3200DX 240 - 269 RG4300DX 237 - 265...

  • Page 17: Measuring Insulation Resistance

    4-4) MEASURING INSULATION RESISTANCE 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. An insulation resistance of 1 megohm or more is normal.

  • Page 18: 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. Coil resistance ( ) Wire color RG2800DX RG3200DX RG4300DX Black Yellow Main coil Green Red...
  • Page 19 3 BRUSH The brushes must be smooth where they contact the slip BRUSH HOLDER rings. If not, polish smooth the brushes with sandpaper. A brush that is not smooth produces arcs between the brush and slip ring leading to possible damage. A brush shorter than 5 mm must be replaced because decreased contact pressure between the brush and slip 5 mm...
  • Page 20 (6) A.V.R (AUTOMATIC VOLTAGE REGULATOR) 1) Features This AVR operates to control the field current in order to maintain the output voltage for the AC current, which generated by the magnetic flux by the field coil. 2) A.V.R. trouble may be identified by simply looking at the A.V.R., or by the inter-lead resistance with a tester, or actually mounting it in the generator and operating it.
  • Page 21 (7) DIODE RECTIFIER Brown Orange Brown 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 (minus) needle of the circuit tester Analogue circuit tester No continuity...

  • Page 22: Disassembly And Assembly

    (8) Bind the wires and fuel pipes using wire bands as they have been done in original configuration. NOTE : As to detailed information for servicing procedures on engine portion, please refer to Robin engine service manual for models EX13/17/21/27.

  • Page 23: Disassembly Procedures

    5-3) DISASSEMBLY PROCEDURES 5-3-1 FUEL PIPES, FUEL STRAINER and BATTERY CABLES (1) Turn the engine switch to “STOP” position to close fuel cock. (2) Disconnect fuel pipes from fuel strainer. (3) Remove fuel strainer. Fuel strainer 5-3-2 REAR COVER Muffler cover (Rear) (1) Remove muffler cover.
  • Page 24 5-3-3 AUTOTHROTTLE COUPLER [Deluxe model] Auto-throttle Disengage the coupler from the auto-throttle unit of carburetor. coupler 5-3-4 CHOKE WIRE [Deluxe model] Loosen screw fixing choke wire to carburetor choke lever. Turn the engine switch to “CHOKE” position to disconnect choke wire from choke lever. Tools : Screw driver Choke wire 5-3-5 GROUNDING WIRE...
  • Page 25 5-3-6 END COVER End cover Remove end cover. M5 x 10mm bolt : 2pcs. Tools : Screw driver 5-3-7 FRONT COVER (UPPER) BRACKET (COVER) Remove front cover (upper). For disassembling the front cover (upper), see illustrations on the following page. Disconnect alternator couplers.
  • Page 26 FRONT COVER (UPPER) and CONTROL PANEL Front cover (Upper) Gromet Engine switch Micro switch CONTROL PANEL AC receptacles AC receptacles DC circuit breaker Ground AC circuit terminal breaker Multi monitor terminals 4.0 - 6.0 N･m 40 - 60 kgf･cm (3.0 - 4.4 ft･lbs) M6 Screw –...
  • Page 27 5-3-8 BRUSH HOLDER (1) Remove brush holder. M5 x 18mm Screw : 1pce. Tools : Screw driver Brush holder 5-3-9 WIRE BAND Cut the wire band binding wires behind control panel. For electric starter model, cut the wire band binding battery cables also.
  • Page 28 FUEL TANK and FUEL LINE Fuel tank cap Fuel gauge Fuel filter 4.0 - 6.0 N･m 40 - 60 kgf･cm (3.0 - 4.4 ft･lbs) Fuel tank M6 Flange reamer bolt Rubber pipe Rubber Rubber pipe (Tank) Fuel strainer Screw Filter O-ring –...
  • Page 29 5-3-11 FOAM RUBBER INSULATORS Remove foam rubber insulators from the gaps between frame and fuel tank. 5-3-12 MUFFLER COVER Loosen bolts and remove muffler cover (L) by pushing it inward. M6 x 12mm Flange bolt : 4pcs. Tools :10mm Box wrench 5-3-13 MUFFLER (1) Loosen nuts and remove muffler.
  • Page 30 5-3-14 GOVERNOR ROD [Standard model only] Throttle shaft Take out governor rod from carburetor throttle shaft. Governor rod 5-3-15 ROD SPRING [Standard model only] Rod spring Take out rod spring from carburetor throttle shaft. Throttle shaft Tools : Long-nose pliers 5-3-16 GOVERNOR LEVER [Standard model only] Remove governor lever.
  • Page 31 5-3-17 AIR CLEANER and CARBURETOR Element Cleaner cover (1) Remove air cleaner cover and element from the air cleaner. (2) Loosen nuts and a bolt, and remove air cleaner body. Air cleaner base M6 Flange nut : 2pcs. M6 x 20mm Flange bolt : 1pce. Tools : 10mm Box wrench Carburetor (3) Be sure not to break the gasket, carefully remove...
  • Page 32 5-3-18 ENGINE BLOCK (1) Loosen nuts fixing the engine to mount rubbers, and remove the engine. M8 Flange nut : 4pcs. Tools : 12mm Box wrench (2) Remove mount rubbers from frame as necessary. M8 Flange nut : 4pcs. Tools : 12mm Box wrench 5-3-19 CRANKSHAFT COVER Loosen bolts and remove crankshaft cover.
  • Page 33 5-3-21 ROTOR BOLT and ROTOR (1) Remove rotor bolt. Rotor bolt : 1pce. Tools : Socket wrench NOTE : Since the thread of the through bolt is in reverse direction, turn it clockwise to loosen. Remove rotor by using the Rotor Puller. Special tools : Rotor Puller (33B9990801) Rotor Puller ALTERNATOR...
  • Page 34 5-3-22 RECOIL STARTER Loosen bolts and remove recoil starter. M6 x 18mm Flange bolt : 3pcs. Recoil starter Tools : 10mm Box wrench NOTE : Refer to section 5-5 for further instruction for disassembly/reassembly procedures of recoil starter. 5-3-23 BOTTOM EXTENSION PLATE Bottom extension plate Loosen bolts and remove bottom extension plate.
  • Page 35 5-3-25 DRIVE SHAFT and FAN Using the special tool “DRIVE SHAFT HOLDER” to hold drive shaft, loosen bolts to remove 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 5-3-26 FLYWHEEL...

  • Page 36: 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 37: Recoil Starter

    5-4-4 BLOWER HOUSING Blower housing M6x35mm Bolt (1) Assemble the Blower Housing onto the crankcase. M6 x 35mm Bolt : 1 pce. M6 x 45mm Bolt : 3 pcs. Tightening torque : 8.0-10.0 M6x45mm 80-100 kgf cm Bolt (5.9-7.4 ft lbs) 5-4-5 BOTTOM EXTENSION PLATE Bottom extension plate Assemble the Bottom Extension Plate to the engine.
  • Page 38 5-4-7 THROUGH BOLT (thread in reverse direction) Insert the Rotor bolt into the center of rotor shaft and tighten it. Rotor bolt : 1 pce. Tightening torque : 19.0-21.0 N m 190-210 kgf cm (14.0-15.5 ft lbs) NOTE1 : Wipe off oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft.
  • Page 39 5-4-10 Installation of ENGINE and ALTERNATOR ASSEMBLY onto FRAME Install the engine and alternator assembly onto frame carefully aligning the bolts of mounting rubbers into the engine/alternator base. Then tighten flange nuts. M8 Flange nut : 4pcs. Tightening torque : 10.0-12.0 N m 100-120 kgf cm (7.4-8.7...
  • Page 40 5-4-13 AIR CLEANER ELEMENT Element Cleaner cover Assemble the Air Cleaner Element and the Air Cleaner Cover to the air cleaner base. Wash the cleaner element if it is dirty before reassembly. 5-4-14 GOVERNOR LEVER [Standard model only] Fix Governor Lever with the Governor Shaft fully turned clockwise.
  • Page 41 5-4-16 GOVERNOR ROD [Standard model only] Throttle shaft Governor rod Install Governor Rod onto Carburetor Throttle Shaft. 5-4-17 MUFFLER Install 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.
  • Page 42 5-4-18 MUFFLER COVER Attach the Muffler Cover to the muffler. M6 x 12mm Flange bolt : 4 pcs. Tightening torque : 4.0-6.0 40-60 kgf cm (3.0-4.4 ft lbs) 5-4-19 SPONGE Install the Sponges between the fuel tank and the frame as shown in the figure righrt.
  • Page 43 5-4-22 GROUNDING WIRES Fasten the grounding wire from the alternator. Tools : Screw driver 5-4-23 Connection of WIRING HARNESS Connect engine wire harness couples. Connect main coil wiring to the terminal; Red wiring to Main coil wiring the upper terminal, while White to the lower one. Connect couples of wiring harness between control panel and alternator.
  • Page 44 5-4-24 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. 5-4-25 FUEL TANK (1) Install the Fuel Tank onto the frame. Be sure to insert Fuel tank the mount rubbers between the tank and the frame.
  • Page 45 5-4-27 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 (Rear) (Upper) and the frame. M6 x 18mm Flange bolt : 6pcs. Tightening torque : 4.0-6.0 40-60 kgf cm...
  • Page 46 5-4-29 FRONT COVER (UPPER) Front Cover (Upper) Securely fix Front Cover (upper). M6 x 12mm Flange bolt : 4 pcs. Tightening torque : 4.0-6.0 40-60 kgf cm (3.0-4.4 ft lbs) 5-4-30 CHOKE WIRE Fix the Choke Wire to the carburetor choke lever making sure that the choke valve is fully closed when engine switch is turned to “CHOKE”...
  • Page 47 5-4-32 FUEL STRAINER and FUEL PIPE Fuel strainer (1) Align the shaft of engine switch to the Fuel Strainer Cock when the engine switch is in “STOP” position and the fuel cock closed. (2) Connect the fuel pipe from carburetor to the Fuel Strainer.

  • Page 48: 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 Starter rope (1) Unhook the spring.
  • Page 49 (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 Friction plate -1 Move the reel to left and right at a 1/4 turns several times until it moves smoothly, gently...
  • Page 50 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. Hooking -2 Properly orient the inner end of the spring installed Spiral position spring in the reel. Inner end of -3 Hold the reel so that the shaft and hook part can the spring...
  • Page 51 (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 52 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 53: Trouble Shooting

    6.TROUBLE SHOOTING Check if engine speed is normal. Refer to 50Hz : 3,000rpm "Engine dose not start (Start failure )" 60Hz : 3,600rpm Check if brush is weared. Check and replace brush. Check if the total length of brush is 5mm or over. Check if stator coil is normal.
  • Page 54 No DC current Check if DC coil of stator is normal. Replace Check if diode rectifier is normal. Replace Check if DC circuit breaker is normal. Replace Replace when wiring is break or damage. Check if wiring is break or improper connection.
  • Page 55 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 56 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 Fuel cock is in Open...

  • Page 57: Wiring Diagram

    7. WIRING DIAGRAM RG2800DX (60Hz-120V) [Recoil starter model] CONTROL PANEL GENERATOR Grn/Y Grn/Y AC Circuit breaker Main coil 120V winding DC Circuit DC output breaker terminal Sub coil 1 Sub coil 2 Grn/Y MONITOR C/U Grn/Y Stepping motor Grn/Y Ignition...
  • Page 58 RG3200DX/4300DX (60Hz-120/240V) [Recoil starter model] CONTROL PANEL GENERATOR Grn/Y Grn/Y AC Circuit AC Circuit breaker breaker Main coil 2 120V 120/240V 120/240V 120V 120V Main coil 1 winding DC Circuit DC output breaker terminal Sub coil 1 Sub coil 2 Grn/Y MONITOR C/U Grn/Y...
  • Page 59 RG3200DX/4300DX (60Hz-120 / 240V) [Electric starter model] GENERATOR CONTROL PANEL Grn/Y Grn/Y AC Circuit AC Circuit breaker breaker Main coil 2 120V 120/240V 120/240V 120V Main 120V coil 1 AC Circuit winding breaker DC Circuit DC output breaker terminal Grn/Y Sub coil 1 Regulator Sub coil 2...
  • Page 60 ISSUE EMD-GS2025 2 0 0 5 .0 8...

This manual is also suitable for:

Rg4300dxRg3200dx

Table of Contents