Subaru RGX5100E Generator Service Manual
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SERVICE
MANUAL
Models
RGX3000, 3800, 5100
GENERATORS
PUB-GS6679
Rev. 07/09
Robin America, Inc.
905 Telser Road • Lake Zurich, IL 60047 • Phone: 847-540-7300• Fax: 847-438-5012 e-mail: [email protected] • www.subarupower.com
© Copyright 2009 Robin America, Inc.
CONTENTS
Section Title Page
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. PERFORMANCE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4. RANGE OF APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5. MEASURING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5-1 MEASURING INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5-2 AC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5-3 DC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5-4 MEASURING INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6. CHECKING FUNCTIONAL MEMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6-1 RECEPTACLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6-2 CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6-3 STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6-4 ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6-5 BRUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6-6 A .V .R . (AUTOMATIC VOLTAGE REGULATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6-7 DIODE STACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6-8 OIL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
7. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7-1 PREPARATION and PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7-2 DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7-3 COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7-4 ASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7-5 CHECKING, DISASSEMBLY and REASSEMBLY of the CONTROL PANEL . . . . . . . . . .47
8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
8-1 NO AC OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
8-2 AC VOLTAGE IS TOO HIGH OR TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED . . . .50
9. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
NOTE
This Service Manual excludes information for engine.
As for the total servicing information as a generator set, please refer in conjunction with the
Robin EX13/17/21/27 and EX30 OHC Engine Service Manual.
1. SPECIFICATIONS
MODEL
Type
Voltage regulating system
AC Output
Rated voltage
V
Rated current
50 Hz
60 Hz
50 Hz
A
Rated output
VA (W)
Rated power factor
Safety device type
DC Output
Rated voltage
Rated current
V
A
60 Hz
50 Hz
60 Hz
RGX3000 RGX3800
Brush, self-exciting, 2-poles, single phase
AVR type
110, 220, 110/220, 230, 240
110,120, 220, 110/220, 120/240
18.2, 9.1, 18.2/9.1, 8.7, 8.3
21.8, 20, 10.9, 21.8/10.9, 20/10
2000
2400
110, 220, 110/220, 230, 240
110,120, 220, 110/220, 120/240
21.8, 10.9, 21.8/10.9, 10.4, 10
26.4, 24.2, 13.2, 26.4/13.2, 24.2/12.1
2400
2900
1.0
Fuse-less circuit breaker
RGX5100
110, 220, 110/220, 230, 240
110,120, 220, 110/220, 120/240
32.7, 16.4, 32,7/16.4, 15.7, 15
38.2, 35, 19.1, 38.2/19.2, 35/17.5
3600
4200
Safety device type
Model
Type
Displacement
Fuel
Fuel tank capacity
Engine oil capacity
Spark plug
Starting system
Direction of rotation
Length
Width
Height
Dry weight mL
L
L mm mm mm kg
12
8.3
EX17D
Fuse-less circuit breaker
EX21D
169
ROBIN, Air-cooled, 4-stroke, OHC, Gasoline Engine
211
Automotive Unleaded Gasoline
12.8
(16.6)*1
0.6
BR-6HS (NGK)
Recoil starter
Electric starter / Recoil
EX30D
287
17.8
(21.5)*1
1.0
600
420
500
47
Counter - clockwise
620
(870)*2
450
500
52
(57.5)*3
675
(925)*2
510
570
69
(79)*3
Specifications are subject to change without notice.
*1: ( ) shows the filled amount up to the "LEVEL" position.
*2: ( ) shows dimensions with Battery frame.
*3: ( ) shows dry weight with Electric starter.
- 1 -
2. PERFORMANCE CURVES
•RGX3000
50Hz-220V
50Hz-230V
53
52
51
50
49
48
47
235
230
225
220
215
210
0 2 4 6
Current (A)
8 10
1600
1200
800
400
2800
2400
2000
50
49
48
52
51
235
230
225
0 2 4 6
Current (A)
8 10 12
0
1200
800
400
3200
2800
2400
2000
1600
- 2 -
Voltage (V)
Frequency (Hz)
Output (VA)
Voltage (V)
Frequency (Hz)
Output (VA)
50Hz-240V
60Hz-120V
52
51
50
49
48
245
1200
800
240
0 2
400
4 6
Current (A)
8 10 12
0
2800
2400
2000
1600
62.5
60
57.5
55
130
125
120
115
110
0 4 8 12 16 20 24 28
0
Current (A)
1600
1200
800
400
3200
2800
2400
2000
- 3 -
Voltage (V)
Frequency (Hz)
Output (VA)
Voltage (V)
Frequency (Hz)
Output (VA)
•RGX3800
50Hz-220V
50Hz-230V
47
230
50
49
48
52
51
225
220
0 2 4 6 8 10
Current (A)
12 14 16
0
800
400
4000
3600
3200
2800
2400
2000
1600
1200
52 3200
2800
51
50
49
2400
2000
1600
48
235
1200
230
800
225
0 2
400
4 6 8
Current (A)
10 12 14
0
- 4 -
Voltage (V)
Frequency (Hz)
Output (VA)
Voltage (V)
Frequency (Hz)
Output (VA)
50Hz-240V
60Hz-120/240V
65
62.5
60
57.5
55
250
[125]
240
[120]
230
[115]
220
[110]
0
50
49
48
47
52
51
250
245
240
235
0 2 4 6 8
Current (A)
10 12 14
0
2000
1600
1200
800
400
3600
3200
2800
2400
8 16
Current (A)
24 32
0
1000
500
4000
3500
3000
2500
2000
1500
- 5 -
Voltage (V)
Frequency (Hz)
Output (VA)
Voltage (V)
Frequency (Hz)
Output (VA)
•RGX5100
50Hz-220V
N / A
50Hz-230V
52
49
235
51
50
230
225
0 4 8 12
Current (A)
16
2400
1800
1200
600
20
0
4800
4200
3600
3000
- 6 -
Voltage (V)
Frequency (Hz)
Output (VA)
50Hz-240V
N / A
60Hz-120/240V
62.5
60
57.5
55
250
[125]
240
[120]
230
[115]
220
[110]
0 10 20 30
Current (A)
40 50
0
3750
3000
2250
1500
750
6000
5250
4500
- 7 -
Voltage (V)
Frequency (Hz)
Output (VA)
3. GENERAL DESCRIPTION
Engine switch
Fuel strainer
(Fuel cock)
Recoil starter handle
Recoil starter
Oil drain plug
Oil gauge (oil filler)
Control panel
Fuel tank
Fuel gauge Tank cap
Spark plug cap
Choke lever
Air cleaner
Muffler
- 8 -
CONTROL PANEL
•RGX3000
(50Hz-220V, 240V)
Engine switch
AC receptacle
AC circuit breaker
Voltmeter
V
(50Hz-230V)
Engine switch
Earth (ground) terminal
DC circuit breaker
DC receptacle
AC receptacle
AC circuit breaker
Voltmeter
(60Hz-120V)
AC receptacle 20A
DC circuit breaker
Earth (ground) terminal
DC receptacle
AC circuit breaker
Pilot lamp
Engine switch
Earth (ground) terminal
- 9 -
Hour meter
DC circuit breaker
DC receptacle
•RGX3800
(50Hz-220V, 240V)
(50Hz-230V)
Engine switch
AC receptacle
AC circuit breaker
V
Voltmeter
Engine switch
Earth (ground) terminal
DC circuit breaker
DC receptacle
AC receptacle
AC circuit breaker
Voltmeter
DC circuit breaker
Earth (ground) terminal
(60Hz-120/240V)
AC receptacle 20A
[Electric starter model]
AC receptacle 30A AC circuit breaker
DC receptacle
Pilot lamp
Key switch
Engine switch
Earth (ground) terminal
Hour meter
Idel control switch
Full power switch
DC circuit breaker
DC receptacle
- 10 -
•RGX5100
(50Hz-220V, 240V)
Engine switch
AC receptacle
AC circuit breaker
V
Voltmeter
(50Hz-230V)
Engine switch
DC circuit breaker
DC receptacle
Earth (ground) terminal
AC receptacle
AC circuit breaker
Voltmeter
DC circuit breaker
(60Hz-120/240V)
Earth (ground) terminal
DC receptacle
AC receptacle 30A
Idle Control Switch AC receptacle 20A
AC receptacle 30A
Pilot lamp
[Electric starter model]
Key switch
AC circuit breaker
Engine switch DC circuit breaker
Full power switch
Earth (ground) terminal
Hour meter DC receptacle
- 11 -
SERIAL NUMBER
Serial number is stamped on the label stuck on the control box .
NOTE : Always specify serial number when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service.
PROD No. / SER No. (Label)
- 12 -
CONSTRUCTION
•RGX3000 / RGX3800
EARTH TERMINAL
BRUSH HOLDER
DIODE STACK
END COVER
BRUSH
FLANGE BOLT
•RGX5100
AVR UNIT
ROTOR BOLT
STATOR BOLT
REAR COVER
N-BRACKET
FRONT COVER
EARTH TERMINAL
BRUSH HOLDER
DIODE STACK
END COVER
BRUTH
STATOR CORE
FLANGE BOLT
AVR UNIT
ROTOR BOLT
STATOR BOLT
REAR COVER
- 13 -
N-BRACKET
FRONT COVER
4. 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 . The electrical appliances generally have a label showing their rated voltage, frequency, and power consumption (input wattage) . The power consumption of an electrical appliance is the power necessary for using it . When using a generator for operating an electrical appliance, the power factor and starting wattage must be taken into consideration .
In order to determine the right size generator, it is necessary to add the total wattage of all appliances to be connected to the unit .
Refer to the followings to calculate the power consumption of each appliance or equipment by its type .
(1) Incandescent lamp, heater, etc. with a power factor of 1.0
Total power consumption must be equal to or less than the rated output of the generator .
Example : A rated 3000W generator can turn thirty 100W incandescent lamps on .
(2) Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power factor
Select a generator with a rated output equivalent to 1 .2 to 2 times of the power consumption of the load . Generally the starting wattage of motor driven tools and light electrical appliances are
1 .2 to 3 times lager than their running wattage .
Example: A rated 250 W electric drill requires a 400 W generator to start it .
NOTE 1: If a power factor correction capacitor is not applied to the fluorescent lamp, the more power shall be required to drive the lamps.
NOTE 2: Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp.
Therefore, if the fluorescent lamp has no special indication as to the power consumption, efficiency should be taken into account as explained in ltem (5) on the following page.
(3) Mercury lamps with a smaller power factor
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up .
Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on . A rated 3000 W generator can power two or three 400 W mercury lamps .
(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.
These appliances require large starting wattage which is 3 to 5 times of running wattage .
Example : A rated 900 W compressor requires a 4500 W generator to drive it .
NOTE 1: Motor-driven appliances require the aforementioned generator output only at the starting. Once their motors are started, the appliances consume about 1.2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances.
NOTE 2 : Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting power depending on the kind of motor and start-up load. If it is difficult to determine the optimum generator capacity, select a generator with a larger capacity.
- 14 -
(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 .
(Output of electrical appliance)
(Efficiency)
= (Power consumption)
Efficiencies of some electrical appliances are as follows :
Single-phase motor . . . . 0 .6 to 0 .75
Fluorescent lamp . . . . . . 0 .7 to 0 .8
(
The smaller the motor, the lower the efficiency .
)
Example 1 : A 40W fluorescent lamp means that its luminous output is 40W . Its efficiency is 0 .7 and accordingly, power consumption will be 40÷0 .7= 57W . As explained in Item (2), multiply this power consumption value of 57 W by 1 .2 to 2 and you will get the figure of the necessary capacity of a generator . In other words, a generator with a rated output of 1000W capacity can light nine to fourteen 40 W fluorescent lamps .
Example 2 : Generally speaking, a 400 W motor means that its work load is 400 W . Efficiency of this motor is 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 multiple of 570
W by 1 .2 to 3 as explained in the ltem (3) . 570 (W) × 1 .2 to 3 = 684 (W) to 1710 (W)
Applications
Incandescent lamp, Heater
Fluorescent lamp, Electric tool
Mercury lamp
Pump, Compressor
Applicable Wattage(approx. W)
50Hz 60Hz
RGX3000 RGX3800 RGX5100 RGX3000 RGX3800 RGX5100
2000 2400 3500 2400 2700 3700
1100 1200 1800 1200 1400 1900
800
500
900
550
Table. 4-1
1300
800
900
550
1000
600
1400
850
- 15 -
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. Table 4-2 shows cables and their allowable currents for your reference.
2. Cable length
If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors decreasing the input voltage to the load (electrical product). As a result, the load can be damaged. Table 4-2 shows voltage drops per 100 meters of cable.
Nominal cross section
mm
2
0 .75
1 .25
2 .0
3 .5
5 .5
No .
18
16
14
12 to 10
10 to 8
12
17
23
35
A
7
No.of strands
/ strands dia. Resistance
No ./mm
30/0 .18
50/0 .16
37/0 .26
45/0 .32
70/0 .32
Ω/100m
2 .477
1 .486
0 .952
0 .517
0 .332
Table. 4-2
Current Amp.
1A 3A 5A 8A 10A 12A 15A
2 .5V 7 .5V 12 .5V
-
1 .5V 4 .5V 7 .5V 12V 15V 18V -
1V 3V 5V 8V 10V 12V 15V
1 .5V 2 .5V
4V 5V 6 .5V 7 .5V
1V 2V 2 .5V 3 .5V
4V 5V
Voltage drop indicates as
R means resistance (Ω/100 m) on the above table.
I means electric current through the wire (A) .
L means the length of the wire (m) .
The length of wire indicates round length, it means twice the length from generator to electrical tools .
- 16 -
5. MEASURING PROCEDURES
5-1 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
0 to 150 V, 0 to 330 V : Dual voltage type
(2) AMMETER
AC ammeter is necessary .
An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable .
(About 10 A, 20 A, 100 A)
FOR AC
FOR AC
(3) FREQUENCY METER
Frequency range : About 45 to 65Hz
NOTE : Be careful of the frequency meter's input voltage range.
- 17 -
(4) CIRCUIT TESTER
Used for measuring resistance, etc .
(5) MEGGER TESTER
Used for measuring generator insulation resistance .
Select one with testing voltage range of
500V .
(6) TACHOMETER
Use the contactless type tacho meter .
- 18 -
5-2 AC OUTPUT MEASURING
SWITCH
LOAD
TO AC RECEPTACLE
F
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 .
Model
RGX3000
RGX3800
RGX5100
Hz
50
60
50
60
50
60
110V
107-115
107-115
107-115
107-115
107-115
107-115
120V
-
118-127
-
118-127
-
118-127
Rated voltage
220V
219-228
219-228
219-228
219-228
219-228
219-228
230V
229-238
-
229-238
-
229-238
-
240V
239-248
239-248
239-248
239-248
239-248
239-248
5-3 DC OUTPUT MEASURING
Measurement of DC output is executed with the switch turned ON while the current is regulated at 8 .3A by adjusting the load to the generator .
If the voltage is within the range from 10V, the voltage output is normal .
NOTE : If a battery is connected as a load to the generator, the DC output voltage will increase by approximately 1 to 2 V. Therefore, carefully observe the electrolyte level and do not overcharge the battery.
5-4 MEASURING INSULATION RESISTANCE
Use a megger tester to check the insulation resistance . Remove the control panel, and disconnect the connector of GREEN lead for ground . Connect a megger tester to one of receptacle output terminals and the ground terminal, then measure the insulation resistance .
MEGGER TESTER
- 19 -
An insulation resistance of 1 megohm or more is normal .
(The original insulation resistance at the time of shipment from the factory is 10 megohm or more .)
If it is less than 1 megohm, disassemble the generator and measure the insulation resistance of the stator, rotor and control panel individually .
(1) STATOR
Measure the insulation resistance between each lead wire and the core .
MEGGER TESTER
(2) ROTOR
Measure the insulation resistance between the slip ring and the core .
SLIP RING
ROTOR
MEGGER TESTER
(3) CONTROL PANEL
Measure the insulation resistance between the live parts and the grounded parts .
MEGGER TESTER
Any part where the insulation resistance is less than 1MΩ has faulty insulation, and may cause electric leakage and electric shock .
Replace the faulty part .
- 20 -
6. CHECKING FUNCTIONAL MEMBERS
6-1 RECEPTACLES
Using a circuit tester, check continuity between the two terminals at the rear of the 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 receptacle is normal .
When the wire is removed and no continuity is found between these terminals, the receptacles are also normal .
CIRCUIT TESTER
(Continuity test)
CIRCUIT TESTER
(Continuity test)
WIRE
- 21 -
6-2 CIRCUIT BREAKER
Check continuity between each of two terminals at the rear of the circuit breaker while it is mounted on the control panel .
Normally, there is continuity between each of the two when the circuit breaker is on while there is no continuity when the circuit breaker is off .
PUSH type
A
REVER type
A A A
CIRCUIT TESTER
(Continuity test)
Type
1
B
Type
2
B
Type
3
B
Type
4
B
•AC CIRCUIT BREAKER
Model
RGX3000
RGX3800
RGX5100
Frequency Rated output Rated voltage Rated fault current
50Hz
60Hz
50Hz
60Hz
50Hz
60Hz
2000VA
2400VA
2400VA
2900VA
3600VA
4200VA
220V
230V
240V
120V
110V / 220V
220V
230V
240V
110V / 220V
120V / 240V
220V
230V
240V
110V / 220V
120V / 240V
15A
15A
20A
20A
15A
20A
20A
12A
12A
12A
10A
10A
10A
10A
23A
•DC CIRCUIT BREAKER
Model
RGX3000
RGX3800
RGX5100
Rated current
8 .3A
Rated voltage Rated fault current
12V 10A
Type
1
Type
1
3
3
1
1
3
3
1
1
3
1
1
2
1
1
- 22 -
6-3 STATOR
Disengage connectors on the wires from stator and check the resistance between wires with a circuit tester referring to the following table .
NOTE : If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings. Erroneous readings will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 20 °C (68 °F).
1) RGX3000 / RGX3800
R
AC winding
Y
Blu
Brn
Blu
Sub coil
Y Y
AC winding
Brn
Blu Y Y
Brn
Bridge diode
AVR unit
Brn
Gry
Org
Blu
Grn
W
Blk
CIRCUIT TESTER
(Resistance)
•RGX3000
AC WINDING 1
AC WINDING 2
SUB COIL
DC WINDING
AC WINDING 1
RED - GRAY
ORANGE - BLUE
YELLOW - YELLOW
BROWN - BROWN
BROWN - BLUE
50Hz-220V
0 .980
0 .980
3 .682
0 .193
N / A
50Hz-230V
1 .042
1 .042
3 .530
0 .238
0 .185
50Hz-240V
1 .234
1 .234
3 .570
0 .215
N / A
(Ω)
60Hz-120V 60Hz-110/220V
0 .851
0 .851
0 .749
0 .749
2 .390
0 .189
0 .137
2 .370
0 .191
N / A
•RGX3800
AC WINDING 1
AC WINDING 2
SUB COIL
DC WINDING
AC WINDING 1
RED - GRAY
ORANGE - BLUE
YELLOW - YELLOW
BROWN - BROWN
BROWN - BLUE
50Hz-220V
0 .772
0 .772
3 .100
0 .186
N / A
50Hz-230V
0 .753
0 .753
3 .030
0 .172
0 .137
(Ω)
50Hz-240V 60Hz-110/220V 60Hz-120/240V
0 .902 0 .605 0 .615
0 .902
3 .121
0 .183
N / A
0 .605
2 .080
0 .187
N / A
0 .615
2 .060
0 .163
0 .103
- 23 -
2) RGX5100
AC winding
W R
Grn
W
Sub coil
Blu Blu
AC winding
Grn W Blu Blu
Brn
Bridge diode
AVR unit
Brn
R
Gry
Org
Blu
Grn
W
Blk
•RGX5100
AC WINDING 1
AC WINDING 2
SUB COIL
DC WINDING
AC WINDING 1
RED - GRAY
ORANGE - BLUE
BLUE - BLUE
BROWN - BROWN
GREEN - WHITE
50Hz-220V
0 .390
0 .390
1 .748
0 .147
N / A
50Hz-230V
0 .367
0 .367
1 .613
0 .169
0 .074
(Ω)
50Hz-240V 60Hz-110/220V 60Hz-120/240V
0 .429 0 .329 0 .317
0 .429
1 .746
0 .147
N / A
0 .329
1 .610
0 .133
N / A
0 .317
1 .496
0 .133
0 .060
6-4 ROTOR ASSEMBLY
1) Field coil
Remove the brush holder and measure resistance between the slip rings .
Rotor
(Slip ring)
50Hz 60Hz
220V 230V 240V 120V 240V
RGX3000 45 .0 45 .0 45 .0 45 .0
45 .0
RGX3800 49 .3 49 .3 49 .3 49 .3
RGX5100 47 .0 47 .0 47 .0 47 .0
220V
-
49 .3
47 .0
(Ω)
SLIP RING
ROTOR
CIRCUIT TESTER
(Resistance)
NOTE : If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings.
Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from from
20°C (68°F).
- 24 -
2) Cleaning Slip rings
The slip ring surfaces must be uniformly bright . Slip rings showing black spots, excessive wear, or uneven wear must be repaired . A stained slip ring lowers generator efficiency and output voltage . Polish the slip rings with fine sandpaper while turning the rotor until rough spots disappear . Care should be taken not to touch the rotor coils with the sandpaper .
6-5 BRUSH
The brushes must be smooth where they contact the slip 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 . Usable brush lengths are from 5 mm to 11 mm (0 .20 " to 0 .43") .
A brush shorter than 5 mm must be replaced because decreased contact pressure between the brush and slip ring lowers generator efficiency and output voltage .
6-6 A.V.R.
(AUTOMATIC VOLTAGE REGULATOR)
1) Features
This A .V .R . 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 .
SLIP RING
BRUSH
SANDPAPER
ROTOR
BRUSH
HOLDER
5 mm
CIRCUIT TESTER
(Resistance)
- 25 -
(a) A .V .R . TROUBLE IDENTIFICATION by APPEARANCE
If an A .V .R . electronic part is burnt dark, or the surface epoxy resin melted, it often indicates
A .V .R . trouble .
(b) IDENTIFYING A .V .R . TROUBLE by CHECKING INTER-LEAD RESISTANCE
Check the inter-lead resistance of the A .V .R . with a tester, referring to the following table .
If the tester readings very greatly from the values specified in the table on next page, the
A .V .R . is faulty .
NOTE : Take tester inaccuracy into account in reading the tester.
(c) IDENTIFYING A .V .R . TROUBLE by
MOUNTING and OPERATING in THE
GENERATOR
SCR or transistor damage cannot be detected by simply looking at the A .V .R . or checking the lead resistance . Check it by mounting the suspectedly faulty A .V .R . in a normal generator, or mount a mormal A .V .R . in a generator which fails to generate voltage .
ⓐ ⓑ
②
①
④
③
AVR unit
ⓐ ⓑ
①
②
③
④
Yellow
Blue
Blue
Brown
Yellow
Yellow
ⓐ ⓑ
①
②
③
④
White
Red
Green
White
Blue
Blue
* Checking table for analogue circuit tester.
A.V.R. TYPE (A)
Apply red ⊕ needle
of the circuit tester
Yellow
ⓐ
Blue
ⓑ
Blue
①
Brown
②
Yellow
③
Yellow
④
Yellow
ⓐ
-
3 .9M
∞
∞
8 .5M
8 .5M
(R±20%)
Apply black ⊖ needle of the circuit tester (Ω)
Blue
ⓑ
Blue
①
Brown
②
Yellow
③
Yellow
④
1 .5M
∞ ∞
3 .8M
4 .3M
-
∞
∞ ∞ 2 .0M
∞
2 .1M
∞
∞
1 .7M
-
3 .4M
∞
4 .1M
-
∞
∞
-
∞
4 .3M
1 .6M
∞ ∞
4 .2M
-
* Checking table for analogue circuit tester.
A.V.R. TYPE (B)
Apply red ⊕ needle
of the circuit tester
White
ⓐ
Red
ⓑ
Green
①
White
②
Blue
③
Blue
④
White
ⓐ
-
1 .8M
4 .4M
4 .6M
4 .0M
4 .2M
Apply black ⊖ needle of the circuit tester
Red
ⓑ
Green
①
White
②
Blue
③
2 .1M
5 .0M
5 .1M
4 .6M
2 .1M
2 .1M
1 .9M
2 .0M
2 .1M
1 .7M
1 .8M
-
5 .1M
4 .5M
4 .7M
4 .9M
-
4 .5M
4 .7M
4 .4M
4 .6M
-
4 .2M
- 26 -
(R±20%)
Blue
④
4 .2M
1 .6M
4 .1M
4 .2M
3 .8M
-
6-7 DIODE STACK
CIRCUIT TESTER
(Continuity test)
Brown
Black White
White
Brown
Brown
Black
DIODE STACK
Brown
Fig.6-8a Fig.6-8b
Circuit inside of the diode stack is as shown in Fig .6-8a .
Check continuity between each terminal by using a circuit tester as shown in Fig .6-8b .
The diode stack is normal when continuity is as follows:
* Checking table for analogue circuit tester.
Analogue circuit tester
Apply red ⊕ needle
of the circuit tester
Brown
Brown
White
Black
Brown
-
No continuity
No continuity
Continuity
Apply black ⊖ needle of the circuit tester
Brown
No continuity
White
Continuity
Black
No continuity
-
No continuity
Continuity
Continuity
-
Continuity
No continuity
No continuity
-
* Checking table for digital circuit tester.
Digital circuit tester
Apply black ⊖ needle
of the circuit tester
Brown
Brown
White
Black
Brown
-
No continuity
Apply red ⊕ needle of the circuit tester
Brown White
No continuity Continuity
Black
No continuity
Continuity No continuity
No continuity
Continuity
No continuity
Continuity
-
Continuity
No continuity
-
NOTE 1 : In checking the diode , direction of connection is contrary to the ordinary case because of characteristics of the diode and battery incorporated in the tester.
NOTE 2 : "Continuity" means forward direction characteristics of the diode, and different from short circuit condition (In which a pointer of the tester goes out of its normal scale), shows resistance to some extent. When results of the checking indicates failure even in one section, replace with a new one.
- 27 -
6-8 OIL SENSOR
(1) Disconnect wires comming from the sensor at the connection .
(2) Loosen the sensor to remove it from the engine .
(3) Plug the opening of oil filler hole (created after sensor is removed) with suitable means such as oil gauge .
(4) Connect the removed wires again with the oil sensor .
(5) Start the engine with the oil sensor removed and confirm if ; a . Engine stops after 5 seconds which is normal, or b . Engine does not stop after more than 10 seconds which is unusual .
NOTE : The sensor will not operate properly when wire is broken or poorly connected.
Check the wires for correct connection. If it fails to stop within 5 seconds after the wirings have checked, the sensor is wrong. Replace the sensor with new one.
6-8-1 SPECIFICATIONS
Type
Float type
(with lead switch incorporated)
Resistance
(at FULL oil level)
100 M ohms or over
Operating Temperature -30 to +180 degree Celsius
OIL SENSOR
6-8-2 CONSTRUCTION AND OPERATION
Disconnect wires comming from the sensor The oil sensor is composed of the float, permanent magnet incorporated into the float and the oil sensor .
In accordance with the oil level, the float moves up and down .
When the oil level is upper level, the float moves up .
When the oil level is lower level, the float moves down .
The permanent magnet is close to the lead switch, and the lead switch is activated by the magnetic force .
NOTE : With regards to the wiring diagram, please refer to the section 9 (page52).
- 28 -
PERMANENT MAGNET
LEAD SWITCH
MAGNETIC FORCE
FLOAT
7. DISASSEMBLY AND ASSEMBLY
7-1 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 reassemble .
2) For more convenience, divide the parts into several groups and store them in boxes .
3) To prevent bolts and nuts from being misplaced or installed incorrectly, replace them temporarily to their original position .
4) Handle disassembled parts with care; clean them before reassemble using a neutral cleaning fluid .
5) Use all disassembly / assembly tools properly, and use the proper tool for each specific job .
7-2 DISASSEMBLY PROCEDURES
7-2-1 FUEL TANK
(1) Shut the fuel strainer and discharge fuel from caburetor .
(2) Disconnect rubber pipe from the strainer .
(3) Remove the fuel tank .
M6 flange bolt . . . 4 pcs .
Rubber(tank) . . . 4 pcs .
7-2-2 CONTROL PANEL and CONTROL BOX
(1) Remove the control panel .
M6 flange bolt . . . 4 pcs .
M4 flange bolt . . . 4 pcs .
(2) Disconnect the connectors on the wiring from the control panel to the alternator .
(3) Remove the control box .
FUEL TANK
CONTROL BOX
CONTROL PANEL
CONTROL PANEL
M4
M6
- 29 -
7-2-3 ALTERNATOR
(1) Remove the end cover .
M6 flange bolt . . . 2 pcs .
(2) Disconnect the connectors on the wiring from the alternator .
(3) Remove the AVR unit, brush holder and diode stack .
END COVER
FLANGE
BOLT
Disconnect the connectors
EARTH (GROUND) WIRE
BRUSH
HOLDER
DIODE
STACK
(4) Set the generator set with the rear cover upwards .
NOTE) Before starting this work, make sure engine oil has been discharged.
(5) Remove the two flange nuts fixing rear cover onto the mount rubbers .
M8 flange nut . . . 2 pcs .
(6) Remove the rear cover .
RGX3000 M6 × 140mm . . . 3 pcs .
RGX3800 M6 × 165mm . . . 3 pcs .
RGX5100 M6 × 165mm . . . 4 pcs .
(7) Take out stator cover with claws (2 pcs) raised up by using screw driver .
(8) Remove the stator .
NOTE : The stator is heavy. Be careful do not hit the coil of the stator to the rotor.
- 30 -
EARTH (GROUND) WIRE
AVR UNIT
REAR
COVER
MOUNT
RUBBER
FLANGE NUT
STATOR COVER
(9) Take off the through bolt of the rotor .
(10) 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 . Prepare a bolt with the following thread size : M10 × 1 .5 (RGX3000 / RGX3800)
M12 × 1 .75 (RGX5100)
3 . Apply a few turns of seal tape around the tip of the bolt .
SEAL TAPE
SEAL TAPE
4 . Screw the bolt into the thread of the rotor shaft .
5 . Torque the bolt using a socket wrench until the rotor comes off loose .
* The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft .
(11) Remove the front cover .
M8 × 20 bolt(countersunk head) . . . 4 pcs .
- 31 -
FRONT COVER
7-3 COMPONENT PARTS
(1)Generator assembly
RGX3000 / RGX3800
24.0-26.0 N-m
17.7-19.2 ft-lbs
6.5-8.5 N-m
4.8-6.3 ft-lbs
BOLT
ROTOR
BOLT
FRONT COVER
N-BRACKET
FAN
BEARING
STATOR
220-240 kgf-cm
16.2-17.7 ft-lbs
THROUGH BOLT
STATOR COVER
REAR COVER
FLANGE NUT
16.0-20.0 N-m
11.8-14.8 ft-lbs
MOUNT RUBBER
AVR UNIT
COVER
BOLT
6.5-8.5 N-m
4.8-6.3 ft-lbs
DIODE STACK
BRUSH
SPONGE (FILTER)
HOLDER
END COVER
- 32 -
RGX5100
24.0-26.0 N-m
17.7-19.2 ft-lbs
BOLT
165-205 kgf-cm
12.2-15.2 ft-lbs
N-BRACKET
ROTOR
FAN
BOLT
FRONT COVER
THROUGH BOLT
STATOR
SPONGE (FILTER)
END COVER
BEARING
43-47 N-m
31.7-34.7 ft-lbs
STATOR COVER
REAR COVER
BRUSH
HOLDER
FLANGE NUT
DIODE STACK
240-300 kgf-cm
17.8-22.2 ft-lbs
A.V.R.
COVER BOLT
6.5-8.5 N-m
4.8-6.3 ft-lbs
MOUNT RUBBER
- 33 -
(2) Control Box Assy
50Hz - 220V
240V
CONTROL BOX
DC CIRCUIT
BREAKER
PILOT LAMP
ENGINE SWITCH
EARTH (GROUND)
TERMINAL
VOLTMETER
DC RECEPTACLE
AC RECEPTACLE
60Hz - 120V / 240V
CONTROL PANEL
N / A
- 34 -
(3) Fuel Tank
FUEL GAUGE
FUEL TANK CAP
FUEL FILTER
FUEL TANK
FUEL
STRAINER
FILTER
PACKING
CUP
RUBBER PIPE
- 35 -
(4) Muffler
6.5-8.5 N-m
4.8-6.3 ft-lbs
M6 × 8 flange bolt
65-85 kgf-cm
4.8-6.3 ft-lbs
M6 × 8 flange bolt
MUFFLER COVER
RGX5100
M8 flange nuts
180-220 kgf-cm
13.3-16.2 ft-lbs
M8 × 12 flange bolt
165-205 kgf-cm
12.2-15.2 ft-lbs
MUFFLER
BRACKET
MUFFLER
EX. PIPE
DUCT (CASE)
M8 flange nuts
18.0-22.0 N-m
13.3-16.2 ft-lbs
MUFFLER
BRACKET 1
MUFFLER
BRACKET 2
RGX3000
RGX3800
M6 × 12 flange bolt
65-85 kgf-cm
4.8-6.3 ft-lbs
- 36 -
7-4 ASSEMBLY PROCEDURES
7-4-1 ENGINE and FRAME
(1) Attach the mount rubbers to the frame . Insert the setting tongue of mount rubber into the hole on the frame and tighten the nut from the bottom of the frame .
RGX3000/RGX3800
M8 flange nut . . . 4 pcs .
FRAME UPPER
Tightening torque : 20.0-24.0 N•m
200-240 kgf•cm
(14.8-17.8 ft•lbs)
RGX5100
M10 flange nut . . . 4 pcs .
Tightening torque : 24.0-30.0 N•m
240-300 kgf•cm
(17.8-22.2 ft•lbs)
NOTE : The mount rubbers are selected to reduce vibration most effectively by model.
Be sure to use the correct mount rubber for your generator.
Although mount rubbers have the same appearance, their characteristics are different.
(2) Install the engine into the frame from the side of it .
Tighten the nuts over the mount rubber bolts to fix .
NOTE : Tighten nut together with air cleaner bracket in air cleaner side.
RGX3000/RGX3800
M8 flange nut . . . 2 pcs .
Tightening torque : 16.0-20.0 N•m
160-200 kgf•cm
(11.8-14.8 ft•lbs)
RGX5100
M10 flange nut . . . 2 pcs .
Tightening torque : 24.0-30.0 N•m
240-300 kgf•cm
(17.8-22.2 ft•lbs)
AIR CLEANER
BRACKET
MOUNT RUBBER
NOTE : Remove the air cleaner cover for easier installation.
NOTE : When tightening the nuts, slightly lift the engine so that the weight is not applied to the mount rubbers.
- 37 -
7-4-2 MUFFLER BRACKET
(1) Assemble the muffler bracket to engine .
RGX3000/RGX3800
Assemble muffler bracket 1 to cylinder head .
Temporally attach the muffler bracket 2 to the muffler bracket 1 .
M6 × 12 flange bolt . . . 4 pcs .
Tightening torque : 6.5-8.5 N•m
65-85 kgf•cm
(4.8-6.3 ft•lbs)
RGX5100
Assemble muffler bracket to main bearing cover .
M8 × 12 flange bolt . . . 2 pcs .
Tightening torque : 16.5-20.5 N•m
165-205 kgf•cm
(12.2-15.2 ft•lbs)
7-4-3 FRONT COVER
(1) Attach the N-bracket onto the front cover .
NOTE : Match the rib direction on the N-bracket with the top mark on the front cover surface.
RGX3000/RGX3800
M6 × 20 flange bolt . . . 4 pcs .
Tightening torque : 6.5-8.5 N•m
65-85 kgf•cm
(4.8-6.3 ft•lbs)
RGX5100
M8 × 20 flange bolt . . . 4 pcs .
Tightening torque : 16.5-20.5 N•m
165-205 kgf•cm
(12.2-15.2 ft•lbs)
MUFFLER
BRACKET
RGX5100
BOLT
N-BRACKET
A
BOLT
TOP mark
- 38 -
MUFFLER
BRACKET 1
MUFFLER
BRACKET 2
RGX3000
RGX3800
RIB
FRONT
COVER
View A
(2) Attach the front cover to the engine main bearing cover .
NOTE : Match the top mark on the front cover surface with upside direction.
M8 × 20 bolt(countersunk head) . . . 4 pcs .
Tightening torque : 24.0-26.0 N•m
240-260 kgf•cm
(17.8-19.2 ft•lbs)
7-4-4 ROTOR
(1) Wipe off oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft .
(2) Mount the rotor to the engine shaft .
Tighten the through bolt .
RGX3000 : M8 × 222 flange bolt . . . 1 pc .
RGX3800 : M8 × 235 flange bolt . . . 1 pc .
Tightening torque : 22.0-24.0 N•m
220-240 kgf•cm
(16.3-17.8 ft•lbs)
RGX5100 : M10 × 260 flange bolt . . . 1 pc .
Tightening torque : 43.0-47.0 N•m
430-470 kgf•cm
(31.8-34.8 ft•lbs)
TOP mark
ROTOR
FAN
THROUGH BOLT
BEARING
- 39 -
7-4-5 STATOR
(1) Put the stator in the front cover .
STATOR
FRONT
COVER
7-4-6 REAR COVER
(1) Put the rear cover over the rotor .
Pull out the stator wirings through the opening of the rear cover .
NOTE : Be careful not to give cuts to wires when pulling them out from the rear cover.
(2) Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover .
(3) Fix the rear cover with bolts .
NOTE : Tighten the bolts evenly and in turns.
RGX3000 : M6 × 140 flange bolt . . . 3 pcs .
RGX3800 : M6 × 165 flange bolt . . . 3 pcs .
RGX5100 : M6 × 165 flange bolt . . . 4 pcs .
Tightening torque : 6.5-8.5 N•m
65-85 kgf•cm
(4.8-6.3 ft•lbs)
(4) Set the mount rubber bolts into the rear cover holes .
Do not tighten the nut at this moment .
- 40 -
REAR COVER
PLASTIC
HAMMER
REAR COVER
MOUNT RUBBER
FLANGE NUT
(5) Install the brush holder, AVR unit and diode stack in the rear cover .
M5 × 16 bolt . . . 2 pcs . (AVR unit)
Tightening torque : 4.0-4.5 N•m
40-45 kgf•cm
(3.0-3.3 ft•lbs)
M5 × 16 bolt . . . 2 pcs . (brush holder)
M4 × 18 bolt . . . 1 pc . (diode stack)
Tightening torque : 1.5-2.0 N•m
15-20 kgf•cm
(1.1-1.5 ft•lbs)
BRUSH
HOLDER
AVR UNIT
A.V.R. type (A)
A.V.R. type (B)
DIODE
STACK
Plus ⊕
Blue
Red
Wiring color
Minus ⊖
Yellow
White
NOTE : If the brush is installed oblique to the slip ring, there is possibility that the brush holder can break when the screw is tightened : or the brush may break when generator of started.
Make this process carefully.
(6) Attach the connectors to the brush holder,
AVR unit and diode stack .
(7) Connect the earth (ground) wire (green/ yellow) with the rear cover with screw .
(8) Connect earth (ground) wire between frame and rear cover .
On frame side: M6 × 12 bolt . . . 1 pc .
On rear cover side: 8mm nut
(commonly tighten the mount rubber bolt)
EARTH
(GROUND)
WIRE
SCREW
White
Brown
EARTH
(GROUND)
WIRE
Brown
Black
DIODE
STACK
EARTH (GROUND) WIRE
AVR UNIT
- 41 -
(9) Tighten the nuts over the mount rubber bolts to fix .
NOTE : When tightening the nuts, slightly lift the alternator assembly so that the weight is not applied to the mount rubbers.
RGX3000/RGX3800
M8 flange nut . . . 2 pcs .
Tightening torque : 16.0-20.0 N•m
160-200 kgf•cm
(11.8-14.8 ft•lbs)
RGX5100
M10 flange nut . . . 2 pcs .
Tightening torque : 24.0-30.0 N•m
240-300 kgf•cm
(17.8-22.2 ft•lbs)
(10) Set stator cover with the crow inserted into slit and bent (2 pcs) .
FLANGE NUT
MOUNT RUBBER
- 42 -
(11) Set the Sponge(Filter) to inside of End
Cover .
NOTE : Hold the Sponge by tab of End Cover.
END COVER
SPONGE
(FILTER)
(12) Attach the end cover to the rear cover .
M5 × 16 bolt . . . 2 pcs .
Tightening torque : 4.0-4.5 N•m
40-45 kgf•cm
(3.0-3.3 ft•lbs)
7-4-7 MUFFLER and MUFFLER COVER
(1) Mount the Exhaust pipe and the gasket on the cylinder head .
M8 flange nut (sus) . . . 2 pcs .
Tightening torque : 18.0-22.0 N•m
180-220 kgf•cm
(13.3-16.2 ft•lbs)
GASKET
(Attention to the wrong side and right side)
EXHAUST PIPE SIDE
(RIGHT SIDE)
CYLINDER SIDE
(WRONG SIDE)
Take utmost care not to cut your hand with the muffler gasket
- 43 -
EXHAUST PIPE
END COVER
M8 NUT : 2 pcs.
GASKET
(MUFFLER)
(It has two faces)
(2) Attach the muffler to the exhaust pipe and muffler bracket without tightening .
(3) Tightening the muffler to the exhaust pipe and bracket .
M8 flange nuts (sus) . . . 2 pcs . (exhaust pipe)
Tightening torque : 18.0-22.0 N•m
180-220 kgf•cm
(13.3-16.2 ft•lbs)
RGX3000/RGX3800
M6 × 12 flange bolt . . . 2 pcs . (bracket2)
Tightening torque : 6.5-8.5 N•m
65-85 kgf•cm
(4.8-6.3 ft•lbs)
RGX5100
M8 × 12 flange bolt . . . 1 pc . (bracket)
Tightening torque : 16.5-20.5 N•m
165-205 kgf•cm
(12.2-15.2 ft•lbs)
(4) Assemble the duct and the muffler cover .
M6 × 8 flange bolt . . . 7 pcs .
Tightening torque : 6.5-8.5 N•m
65-85 kgf•cm
(4.8-6.3 ft•lbs)
M6 x 12 BOLT : 3 pcs.
DUCT (CASE)
- 44 -
MUFFLER
COVER
MUFFLER
RGX3000
RGX3800
RGX5100
7-4-8 FUEL TANK
(1) Hand tighten the strainer screw as far as it will go, loosen it again by one or two rotations (fuel outlet faces down), then tighten the lock nut .
(2) Mount the fuel tank on the frame with rubber washers between the tank flange and the frame .
M6 x 20 mm bolt (black) . . . 4 pcs .
Rubber washer . . . 4 pcs .
NOTE : For easy tank assembly, glue the rubber washers over the mounting holes of the frame.
(3) Connect the rubber pipe .
First, fit the hose clamps on the rubber pipe and connect it to the strainer and the carburetor . Then fasten it with the hose clamps .
NOTE : Apply a drop of oil to the rubber pipe for easier connection.
FUEL GAUGE
FUEL TANK
FUEL
STRAINER
FILTER
PACKING
CUP
FUEL TANK CAP
FUEL FILTER
RUBBER
PIPE
- 45 -
7-4-9 CONTROL BOX ASSY
Refer to Section 7-5 for disassembly, checking and reassembly procedures of the control panel .
(1) Put the cover onto the frame temporary .
NOTE : Don't set bolt for the control box.
(2) Pass wires drawn out generator and engine to the control box .
(3) Connect the wires coming from the control panel with wires coming from generator and engine .
NOTE : Connect the wires of the same color.
(4) Install the control panel onto the control box .
M4 × 12 mm Screw . . . 4 pcs .
Tightening torque : 1.5-2.0 N•m
15-20 kgf•cm
(1.1-1.5 ft•lbs)
CONTROL BOX
CONTROL PANEL
M4
M6
(5) Mount the control panel together with the control box (Control box Assembly) onto the frame .
M6 × 12 mm Screw . . . 4 pcs .
Tightening torque : 5.0-6.0 N•m
50-60 kgf•cm
(3.7-4.8 ft•lbs)
- 46 -
7-5 CHECKING, DISASSEMBLY and REASSEMBLY of the CONTROL PANEL
7-5-1 CHECKING OF THE CONTROL PANEL
Dismount the control box assy from frame . Remove the control box from control panel and check each components and wiring . Refer to Section 6 for the detail of checking procedure for the components in the front panel .
7-5-2 DISASSEMBLY
(1) Remove the control panel from the control box .
(2) Disconnect the connectors on the wires to detach the control panel .
(3) After disconnecting individual wires, remove the control panel components .
NOTE : Full power switch have their wires soldered. Unsolder them to remove those parts if necessary.
7-5-3 REASSEMBLY
(1) Install the receptacles, circuit breakers, terminals, switches, etc . on the control panel and wire them .
NOTE : Circuit diagrams are shown in Section 9. Colored wires are used for easy identification, and are of the correct capacity and size. Use heat-resistant type wires (permissible temperature range 75°C or over) in the specified gauge shown in the circuit diagrams.
(2) Connect the wires of control panel components .
(3) Attach the control panel and control box to the Frame .
(Refer to 7-4-9 for details .)
- 47 -
8. TROUBLESHOOTING
8-1 NO AC OUTPUT
8-1-1 CHECKING STATOR
(1) Remove control panel and disconnect stator wires at the connectors .
(2) Measure the resistance between terminals on stator leads .
Refer to Table of Section 6-4 STATOR for normal resistance .
If stator is faulty, replace it with a new one .
CIRCUIT TESTER
(Resistance)
(3) Check the insulation resistance between stator core and each stator lead using a megger tester .
If insulation is bad, replace stator with a new one .
8-1-2 CHECKING ROTOR
1) Field coil
Remove the brush holder and measure resistance between the slip rings . Refer to
Section 6-5 ROTOR ASSEMBLY for normal resistance .
NOTE : If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings.
Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from from 20°C
(68°F).
- 48 -
SLIP RING
ROTOR
MEGGER TESTER
CIRCUIT TESTER
(Resistance)
2) Cleaning Slip rings
The slip ring surfaces must be uniformly bright . Slip rings showing black spots, excessive wear, or uneven wear must be repaired . A stained slip ring lowers generator efficiency and output voltage . Polish the slip rings with fine sandpaper while turning the rotor until rough spots disappear . Care should be taken not to touch the rotor coils with the sandpaper .
SLIP RING
SANDPAPER
ROTOR
8-2 AC VOLTAGE IS TOO HIGH OR TOO LOW
8-2-1 CHECKING ENGINE SPEED
If the engine speed is too high or too low, adjust it to the rated r .p .m .
[How to adjust engine r.p.m.]
* Loosen the lock nut on the adjusting screw .
* Turn the adjusting screw clockwise to decrease engine speed or counterclockwise to increase engine speed .
Normal engine speed at no load :
3050 to 3250 rpm for 50Hz type
3650 to 3850 rpm for 60Hz type
8-2-2 CHECKING STATOR
Check stator referring to Step 8-1-1 .
8-2-3 CHECKING ROTOR
Check rotor referring to Step 8-1-2 .
- 49 -
LOW SPEED HIGH SPEED
ADJUST SCREW
8-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED.
8-3-1 CHECK THE ENGINE SPEED.
If the engine speed is low, adjust it to the rated r .p .m .
*Refer to Step 8-2-1 for engine speed adjustment .
8-3-2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR.
Refer to Section 4 “RANGE OF APPLICATIONS” for the wattage of the appliances .
If the generator is overloaded, reduce the load to the rated output of the generator .
8-3-3 CHECK THE APPLIANCE FOR TROUBLE.
If the appliance is faulty, repair it .
8-3-4 CHECK IF THE ENGINE IS OVERHEATED.
If the cooling air inlet and/or cooling air outlet is clogged with dirt, grass, chaff or other debris, remove it .
AIR OUTLET
(ENGINE)
AIR OUTLET
(ALTERNATOR)
AIR INLET
(ALTERNATOR)
AIR INLET
(ENGINE)
8-3-5 CHECK THE INSULATION OF THE GENERATOR.
(1) Stop the engine . Remove the control panel, and disconnect the connector of GREEN lead for ground .
(2) Measure the insulation resistance between the live terminal of the receptacle and the ground terminal .
If the insulation resistance is less than
1MΩ, disassemble the generator and check the insulation resistance of the stator, rotor and the live parts in the control box .
(Refer to Section 5-4 .)
Any part where the insulation resistance is less than 1MΩ, the insulation is faulty and may cause electric leakage .
Replace the faulty part .
- 50 -
MEGGER TESTER
8-4 NO DC OUTPUT
8-4-1 CHECK THE AC OUTPUT.
Check the generator by following Step 8-1-1 through Step 8-1-2 .
8-4-2 CHECK THE DC BREAKER.
If the DC breaker turned off while charging a battery, check the cables for short-circuit or connection in reverse polarity before resetting it on .
NOTE : If the DC output is used to charge a large capacity battery or an overdischarged battery, an excessive current may flow causing.
8-4-3 CHECK THE WIRING.
Check all the wires to be connected correctly .
Brown
8-4-4 CHECK THE DIODE STACK.
Remove the end cover and check the diode stack with a circuit tester .
White
Brown
Refer to Section 6-7 “DIODE STACK” for the checking procedure .
Brown
Black
DIODE STACK
CIRCUIT TESTER
(Continuity test)
8-4-5 CHECK THE DC COIL
Check the resistance between two Brown leads from stator with a circuit tester .
If the resistance reading is much larger or smaller than the specified value, the DC coil of the stator is faulty . Replace stator with a new one .
RGX3000
RGX3800
RGX5100
50Hz - 220V
0 .193
0 .186
0 .147
60Hz - 220V
0 .191
0 .187
0 .133
50Hz-230V
0 .238
0 .172
0 .169
50Hz-240V
0 .215
0 .183
0 .147
60Hz - 120V/240V
0 .181
0 .163
0 .133
- 51 -
9. WIRING DIAGRAM
RGX3000 (50Hz-220, 240V)
ENGINE
Blk
CONTROL BOX AY
Blk Grn
Engine switch
Org
Blk
GENERATOR
ROTOR STATOR
Y
Y/R
Slip ring
Y
Blu
Brn
Blu
Sub coil
Y Y
Brn
Blu
AVR unit
Y
Brn
Bridge diode
Y
Grn/Y
Brn
R R
AC circuit breaker
R
Gry
Org
Blu
Grn
W
Gry
Gry
V
Voltmeter
Blu
Grn
DC
W circuit breaker
W
Blk Blk
AC Output receptacle
DC Output receptacle
DC12V
RGX3800 (50Hz-220, 240V)
ENGINE
Blk
CONTROL BOX AY
Blk Grn
Engine switch
Org
Blk
GENERATOR
ROTOR STATOR
Y
Y/R
Slip ring
Y Blu
Brn
Blu
Sub coil
Y Y
Brn Blu
AVR unit
Y Y
Brn
Bridge diode
Brn
Grn/Y
Blu
Grn
W
R
Gry
Org
Blk
Gry
Gry
R
AC circuit breaker
R
AC Output receptacle
V
Voltmeter
Blu
Grn
DC
W circuit breaker
W
DC Output receptacle
DC12V
Blk
AC Output receptacle
Earth
(Ground) terminal
Earth
(Ground) terminal
Wiring color code
Blk : Black
Blk/W : Black/White
Blu : Blue
LBlu : Light blue
Brn : Brown
Brn/W : Brown/White
Grn : Green
Grn/W : Green/White
Org : Orange
Gry : Gray
R : Red
W
Y
: White
: Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow
Pur : Purple
- 52 -
RGX5100 (50Hz-220, 240V)
ENGINE
Blk
CONTROL BOX AY
Blk Grn
Engine switch
Org
Blk
Y
Y/R
GENERATOR
ROTOR STATOR
Slip ring
AC winding 1
Y Blu
Brn
Blu
Sub coil
Y Y
AC winding 2
Brn Blu
Y Y
Brn
Bridge diode
AVR unit
Brn
Grn/Y
R R
AC circuit breaker
R
Gry
Org
Blu
Grn
W
Gry
Org
V
Voltmeter
Blu
Grn
W
DC circuit breaker
W
Blk Blk
AC Output receptacle
DC Output receptacle
DC12V
AC Output receptacle
Earth
(Ground) terminal
Wiring color code
Blk : Black
Blk/W : Black/White
Blu : Blue
LBlu : Light blue
Brn : Brown
Brn/W : Brown/White
Grn : Green
Grn/W : Green/White
Org : Orange
Gry : Gray
R : Red
W
Y
: White
: Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow
Pur : Purple
- 53 -
RGX3000 / 3800 (50Hz-230V)
ENGINE
Blk
CONTROL BOX AY
Blk Grn
Engine switch
Org
Blk
GENERATOR
ROTOR STATOR
Y
Y/R
Slip ring
Y
Blu
Brn
Blu
Sub coil
Y Y
Brn
Blu
AVR unit
Y
Brn
Bridge diode
Y
Grn/Y
Brn
R R
AC circuit breaker
R
Gry
Org
Blu
Grn
W
Gry
Gry
V
Voltmeter
Blu
Grn
DC
W circuit breaker
W
Blk Blk
AC Output receptacle
AC Output receptacle
DC Output receptacle
DC12V
RGX5100 (50Hz-230V)
ENGINE
Blk
Org
Blk
GENERATOR
ROTOR STATOR
Y
Y/R
Slip ring
W R
Grn
W
Sub coil
Blu Blu
Brn
Grn W Blu Blu
AVR unit
Grn/Y
Brn
Bridge diode
CONTROL BOX AY
Blk Grn
Engine switch
R R
AC circuit breaker
R
Gry
Org
Blu
Grn
W
Gry
Org
V
Voltmeter
Blu
Grn
DC
W circuit breaker
W
Blk
Blk
AC Output receptacle
AC Output receptacle
DC Output receptacle
DC12V
Earth
(Ground) terminal
Earth
(Ground) terminal
Wiring color code
Blk : Black
Blk/W : Black/White
Blu : Blue
LBlu : Light blue
Brn : Brown
Brn/W : Brown/White
Grn : Green
Grn/W : Green/White
Org : Orange
Gry : Gray
R : Red
W
Y
: White
: Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow
Pur : Purple
- 54 -
RGX3000 (60Hz-120V)
ENGINE
Blk
Org
Blk
GENERATOR
ROTOR STATOR
Y
Y/R
Slip ring
Y Blu
Brn
Blu
Sub coil
Y Y
Brn Blu
AVR unit
Y
Brn
Y
Grn/Y
Brn
Bridge diode
CONTROL BOX AY
Blk Grn
Engine switch
R R
AC circuit breaker
R
Blu
Gry
Org
Blu
Grn
W
Blk
Blu
R
Hr
Hour mater
PL
Pilot lamp
Blu
Grn
DC
W circuit breaker
W
DC Output receptacle
DC12V
Blk
Blu
Grn
Earth
(Ground) terminal
RGX3800 (60Hz-120/240V)
ENGINE
Blk
Org
Blk
W
W
GENERATOR
ROTOR STATOR
Y
Y/R
Slip ring
Y
Blu
Brn
Blu
Sub coil
Y Y
Brn Blu
AVR unit
Y Y
Brn
Bridge diode
Brn
Grn/Y
CONTROL BOX AY
W W
Idle control switch
Blk Grn
Engine switch
Slowdown Solenoid
R
R
Gry
Org
Gry
Org
Blu
Grn
W
Blu
Grn
W
Blu
Blk Blk
R
AC circuit breaker
R
Blu
120/240V
120V
Blu
Blu
W Blk DC circuit breaker
W
Org
Blu
DC Output receptacle
DC12V
Gry
Gry
Earth
(Ground) terminal
Wiring color code
Blk : Black
Blk/W : Black/White
Blu : Blue
LBlu : Light blue
Brn : Brown
Brn/W : Brown/White
Grn : Green
Grn/W : Green/White
Org : Orange
Gry : Gray
R : Red
W
Y
: White
: Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow
Pur : Purple
- 55 -
RGX3800 (60Hz-120/240V) [Electric starter model]
ENGINE
R
Blk
Blk
Blk
Org
Blk
Y/R
GENERATOR
ROTOR STATOR
Y
Slip ring
Y Blu
Brn
Blu
Sub coil
Y Y
Brn Blu
AVR unit
Y Y
Brn
Bridge diode
Brn
Grn/Y
W W
R
Gry
Org
Blu
Grn
W
Blk
Blu
Grn
W
Blk
R
Gry
Org
CONTROL BOX AY
W
W
W
Idle control switch
Blu
Gry
R
Blk
Grn
Blu
Org
Fuse
Org
Grn
Gry
Grn
Key switch
AC circuit breaker
R
Blu
120/240V
120V
Gry
R
Blu
Blu
Blu
W Blk
DC circuit breaker
W
Org
Blu
DC Output receptacle
DC12V
Gry
Earth
(Ground) terminal
RGX5100 (60Hz-120/240V)
ENGINE
Blk
Org
Blk
W W
Y
Y/R
GENERATOR
ROTOR STATOR
R
AC winding 1
Slip ring
Gry
W R
Grn
W
Sub coil
Blu Blu
AC winding 2
Grn W
Blu Blu
Brn
Bridge diode
Org
Blu
Grn
W
AVR unit
Brn
Blk
Grn/Y
CONTROL BOX AY
W W
Idle Control Switch
Blk Grn
Engine switch
R
Gry
Blu
Org
Blu
Grn
W
Blk
W
AC circuit breaker
R
Full Power Switch
Blu
Blu
W Blk
DC circuit breaker
W
Blu
120/240V
120V
Org
DC Output receptacle
DC12V
Gry
Grn
R
Gry
Earth
(Ground) terminal
Wiring color code
Blk : Black
Blk/W : Black/White
Blu : Blue
LBlu : Light blue
Brn : Brown
Brn/W : Brown/White
Grn : Green
Grn/W : Green/White
Org : Orange
Gry : Gray
R : Red
W
Y
: White
: Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow
Pur : Purple
- 56 -
RGX5100 (60Hz-120/240V) [Electric starter model]
ENGINE
R
Blk
Battery
Blk
Blk
Org
Blk
W W
Y
Y/R
GENERATOR
ROTOR STATOR
Slip ring
AC winding 1
R
Gry
W R
Grn
W
Sub coil
Blu Blu
AC winding 2
Grn
W Blu Blu
Brn
Bridge diode
Org
Blu
Grn
W
AVR unit
Brn
Blk
Grn/Y
Slowdown Solenoid
Blk
CONTROL BOX AY
W
W
W
Idle Control Switch
Blu
Gry
R
Blk
Grn
Blu
R
AC circuit breaker
R
Blu
Org
Blu
Grn
W
Gry
Full Power Switch
Blu
Blu
W Blk
DC circuit breaker
W
Org
Fuse
Org
Grn
Gry
Grn
Key switch
Blu
120/240V
120V
Org
DC Output receptacle
DC12V
R
Gry
Gry
Grn
Earth
(Ground) terminal
Wiring color code
Blk : Black
Blk/W : Black/White
Blu : Blue
LBlu : Light blue
Brn : Brown
Brn/W : Brown/White
Grn : Green
Grn/W : Green/White
Org : Orange
Gry : Gray
R : Red
W
Y
: White
: Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow
Pur : Purple
- 57 -
PRINTED IN THE USA
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