Subaru Robin Power Products RG3200IS, RG2800IS, RG4300IS service manual Contents

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CONTENTS

Section

Title

Page

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2-1 EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2-2 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2-3 LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER . . . . . . . . . . . . 9 2-4 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3. RANGE OF APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4. MEASURING AND CHECKING PROCEDURES

14

4-1 MEASURING INSTRUMENTS

14

4-2 AC OUTPUT MEASURING

17

4-3 DC OUTPUT MEASURING

17

4-4 MEASURING INSULATION RESISTANCE

18

4-5 CHECKING FUNCTIONAL MEMBERS

19

5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 5-1 PREPARATION AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 5-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 5-3 DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 5-4 REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 5-5 RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

6. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

7. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

This manual covers only alternator and control unit portion of the generator.

As to the servicing information of engine portion, please refer to the “EX13, E17, EX21 and EX27” service manual.

The specifications and information included in this manual were in effect at the time of printing.

FUJI HEAVY INDUSTRIES LTD. reserve the right to change the specifications and to make modifications in the course of technical progress, at anytime without notice.

No parts of this manual may be reproduced without written permission.

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Contents Generators Page Contents STD SpecificationsModel RG2800i RG3200i RG4300i NGK BR6HSModel RG2800iS RG3200iS RG4300iS External View of Generator Open Frame Type General DescriptionRG4300i RG2800iS External View of Generator Sound Proof TypeRG3200iS / RG4300iS 50Hz-240V Control Panel50Hz-230V 60Hz-120VMulti Monitor Engine SwitchLocation of Serial Number and Production Number Alternator Incandescent lamp, heater, etc. with a power factor Mercury lamps with a smaller power factorRange of Applications Appliances without any indication as to power consumption Cross Allowable Cable Voltage drops per 30 meters of cable Ammeter Measuring and Checking ProceduresMeasuring Instruments VoltmeterCircuit Tester Meager TesterTachometer Specifications ModelDr.RobinPartNumber388-47565-08 DC Output Measuring AC Output MeasuringMeasuring Insulation Resistance StatorControl Panel RG2800i RG3200i RG4300i RG2800iS RG3200iS RG4300iS Output Wires4P Connector Checking Functional MembersAC Receptacles Diode RectifierChecking table for analogue circuit tester Checking table for degital circuit testerFloat Type OIL Sensor DC Circuit BreakerPart Number Part Name Shape Usage Disassembly and AssemblyPreparation and Precautions Special ToolsStarter Handle Disassembly ProceduresFuel PIPES, Fuel Strainer and Battery Cables Side Cover L and RControl Panel and Inverter Unit Grounding WireChoke Wire For electric start modelsRear Cover Wire BandFuel Tank and Fuel System Parts Fuel TankAutothrottle Coupler Wire HarnessControl BOX and Inverter Unit Components and Control BOX ComponentsInverter Unit Components Control Panel Control BOX Components RG2800i / RG3200i / RG2800iSControl BOX Components RG4300i / RG3200iS / RG4300iS Foam Rubber Insulators Muffler CoverMuffler AIR Cleaner and Carburetor Engine Block Open Frame TypeSoundproof Type Through Bolt and Rotor Alternator Components Blower Housing Recoil StarterBottom Extension Plate Flywheel Drive Shaft and FANFor SOUND-PROOF Models Reassembly ProceduresMount Rubbers Sound InsulatorTightening torque 40-60 Kgf ・cm 4.4 Ft ・lbs Blower HousingFlywheel FAN and Drive Shaft Tightening torque 8.0-10.0 N・m 80-100 kgf・cm 5.9-7.4 ft・lbsThrough Bolt thread in reverse direction Recoil StarterTightening torque 6.5-8.5 N・m 65-85 kgf・cm 6.3 ft・lbs Rear CoverInstallation of Engine Alternator Assembly Onto Frame Tightening torque 6.0-8.0 N・m 60-80 kgf・cm 5.9 ft・lbs AIR Cleaner BaseAIR Cleaner Element CarburetorMuffler Cover MufflerGrounding Wires Connection of Wiring HarnessControl BOX and Inverter Unit Tightening torque 4.0-6.0 N・m 40-60 kgf・cm 4.4 ft・lbs Clamping of the Choke Cable and Ground WiresAuto Throttle Fuel TankMuffler Cover Rear Rear Cover UpperGround Wire Side Cover Recoil Starter HandleRecoil Starter Disassembly proceduresDisassembly is completed Assembly procedure Five turns in counter-clockwise When Checking items after assemblyNo output power or Low output Trouble ShootingImproper revolutions Electronic throttle Engine does not start Start failure RG2800i / RG3200i / RG2800iS 50Hz-230V Recoil starter model Wiring DiagramRelay AC receptacle Earth ground terminal RG2800i / RG3200i / RG2800iS 50Hz-240V Recoil starter modelEngine 240V Switch Fuse10A RG2800i / RG3200i / RG2800iS 60Hz-120V Recoil starter model Engine 120V SwitchDiode DC output Terminal Rectifier Coil Page Lively Blvd. Wood Dale, IL 60191 Phone 630-350-8200 Fax
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