RGX3000 3800 5100 Service GS.indd
Contents
1. NOTE With regards to the wiring diagram please refer to the section 9 page52 MAGNETIC FORCE E 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 FLANGE FUEL TANK BOLT RUBBER TANK 2 Disconnect rubber pipe from the strainer 3 Remove the fuel tank 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 4 flange 4 pcs 2 Disconnect the connectors on the wiring from the control panel to the alternator 3 Remove the control box2. WR 2 Grn LE lt Blu Sub coi Blu Blu Gm B Ei w Blu Blu IO 9 AVR unit 8 Bik Brn RGX5100 Q 50Hz 220V 50Hz 230V 50Hz 240V 60 2 110 220 60Hz 120 240V AC WINDING 1 RED GRAY 0 390 0 367 0 429 0 329 0 317 AC WINDING 2 ORANGE BLUE 0 390 0 367 0 429 0 329 0 317 SUB COIL BLUE BLUE 1 748 1 613 1 746 1 610 1 496 DC WINDING BROWN BROWN 0 147 0 169 0 147 0 133 0 133 AC WINDING 1 GREEN WHITE N A 0 074 N A N A 0 060 6 4 ROTOR ASSEMBLY 1 Field coil Remove the brush holder and measure resistance between the slip rings CIRCUIT TESTER Resistance Q 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 trom 20 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 SANDPAPER 6 5 BRUSH
3. lt M4 M6 29 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 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 x 165mm 3 pcs RGX5100 M6 x 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 END COVER FLANGE BOLT Disconnect the connectors REAR MOUNT COVER RUBBER 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 ro tor shaft Fill with oil to the shaft end 2 Prepare a bolt with the following thread size M10 x 1 5 RGX3000 RGX3800 M12 x 1 75 RGX5100 3 Apply a few turns of seal tape around the tip of the bolt SEAL TAPE 4 Screw the bolt into the thr
4. 25 6 7 DIODE STACK Seed AN W Male e s Ren ede io CR da 27 6 6 OIE SENSOR d 28 7 DISASSEMBLY AND ASSEMBLY 29 7 1 PREPARATION and PRECAUTIONS 29 7 2 DISASSEMBLY PROCEDURES 29 7 3 COMPONENT PARTS 32 1 4 ASSEMBLY PROCEDURE uu wozy 4 amar Ee a d 27 7 5 CHECKING DISASSEMBLY and REASSEMBLY of the CONTROL PANEL 47 8 48 8 1 NO AG OUTPUT uires atre ey Means 8S oo awe bbe Rd pa WR 48 8 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 49 8 3 AC VOLTAGE IS NORMAL NO LOAD BUT THE LOAD BE APPLIED 50 9 WIRING DIAGRAM hh hh hh hh hinh hh sh nnn nns 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 RGX3000 RGX3800 RGX5100 Brush self exciting 2 poles single phase Type Voltage regulating system AVR type AC Output Rated voltage 50 Hz 110 220 110 220 230 240 110 220 110 220 230 240 110 220
5. RGX3800 M6 x 165 flange 3 pcs RGX5100 M6 165 flange bolt 4 pcs Tightening torque 6 5 8 5 Nem 65 85 kgfecm 4 8 6 3 165 4 Set the mount rubber bolts into the rear cover holes Do not tighten the nut at this moment 40 FLANGE NUT 5 Install the brush holder AVR unit and diode stack in the rear cover M5 x 16 bolt 2 pcs AVR unit Tightening torque 4 0 4 5 Nem 40 45 kgfecm 3 0 3 3 165 M5 x 16 bolt 2 pcs brush holder M4 x 18 bolt 1 pc diode stack Tightening torque 1 5 2 0 Nem Wiring color 15 20 kgfecm Plus amp Minus 1 1 1 ft lbs A V R type A Blue Yellow A V R type B Red 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 x 12 1 pc On rear cover side 8mm nut commonly tighten the mount rubber bolt EARTH GROUND WIRE 41 9 Tighten the nuts over the mount rubber bolts to fix FLANGE NUT N NOTE When tightening the nuts slightly lift the alternator assembly so that the weight
6. 10 14 Output VA Voltage V Frequency Hz Output VA Output VA Voltage V Frequency Hz Output VA 50Hz 240V 3600 52 F 3200 gt 51 z 2800 9 50 o 2 49 2400 LL N s 48 s Y 2000 amp 2 47 o 1600 _ 250 1200 2 245 8 S PORA 800 3 240 400 77 Voltage V 235 Frequency Hz Output VA 0 0 2 4 6 8 10 12 14 Current A 60Hz 120 240V 65 4000 I 62 5 3500 gt c 5 2 60 3000 2 E lt 57 5 2500 gt 5 55 2000 250 125 1500 240 21120 1000 15 500 Voltage V Frequency Hz 220 e Output VA 8 16 24 32 Current A RGX5100 50Hz 220V 50Hz 230V Frequency Hz Voltage V Voltage V Frequency Hz Output VA N A 4800 s U 4200 N M N 3600 lt E X 3000 Z s N 2 5 4 N 124009 235 1800 230 1200 225 600 0 0 4 8 12 16 20 Current A 50Hz 240V 60Hz 120 240V Frequency Hz Voltage V N A 6000 gus 5250 Se 4500 57 5 3 30 K 3000 250 250 2250 240 240 1500 230 115 id 220 0 110 0 10 20 30 40 50 Current A gt 5 2 T Frequency H
7. os I Blu lt 4 Sub coil d Y T w Bik ircui as E Bridge W lt gt receptacle Earth diode Ground M 2 terminal 4 AVR unit 8 Bik BIK Brn E 2 z 5 E i E E 5 _ Gm Y 55 RGX3800 60Hz 120 240V Electric starter model ENGINE _ _ CONTROLBOXAY 5 1 R Wiring color code Idle control switch Black 2 4 Bik gt 15 Org BIK W Black White pue 5 Blk 5 Blu Blue o e 5 Or S LBlu Light blue 2 2 ew J Bm Brown 1 1 o eg T EM 221 2B 518218 Brn W Brown White Y O o 59 e 2 4 8 12011 8 i
8. ENGINE CONTROL BOX AY Wiring color code Blk Blk o 75 Grn Dik Black m Engine switch BIK W Black White _ 5 Bik S rw Blu Blue 8 LBlu Light bl gl Ze 5 u Light blue gl 55 5 Bm Brown 1 G zm Brn W Brown White 9 o seule bb Y Grn Green YRC Grn W Green White 1 5 1 GENERATOR l 25 r a S Gry Gray ROTOR STATOR circuit breaker 5 R R R R Red W White 1 11 5 Yellow ring l Gry Blu WIBIk White Black Grn Y Green Yellow VII 1 Org Hour mater Pilot lamp Pur Purple 5 nil Brn Blu lt Blu la i Sub coil i ni 4 1 Grn Li i circuit breaker DC Output ZE ZE W receptacle ron d roun i Brn BluY e 7 pc12v terminal LI AVR unit Bk Bik 1 RGX3800 60Hz 120 240V ENGINE I _ CONTROL BOX AY _ _ _ Bik Bik Grn 2 0 T T AW 5 gt oc w w Engine switch E Blk 5 w Idle control 5 8 org 5 Switch EL i 5 2 ass Ei 10 6 o 4189 1 Lo 521 211821 E 1 1 H 2 2011 Y e 488 9 YRI t 4 4 8 GENERATOR _ _ 2 LI a 1 C ROTOR STATOR circuit breaker 28 yi R R R 25551 I 5515 22 d g Z gl i 2 1 Slip ring T 25 i a ba 1 I 1 ESI sed Y Bu oi Gry
9. Sub EF i INTE _1Gm i em E o circuit DC Output m Bridge W W receptacle Ts d diode roun Y 5 i 201 DC12V terminal AVR unit 8 Bk Jamy I 259 RGX5100 50Hz 220 240 ENGINE CONTROL BOX AY T E Wiring color code Blk 3 Bik Gm Blk Black Engine switch BIk W Black White I _ 5 S Blu Blue 18 sre 5 LBlu Light blue ja 16 5 5 Bm Brown 1 I a s LES Brn W Brown White o 7 2H ele Grn Green O Grn W Green White 1 1 GENERATOR Org Orange T a 1 AC Gry Gray i ROTOR STATOR circuit breaker i R R R R Red T 6 AC 1 H AC Output W White n winding 1 recepiacie Y Yellow ring WIBIk White Black IGry AC Output Grn Y Green Yellow Or Voltmeter receptacle Pur Purple Y Blu AC 9 Blu Blu Blu Sub coil li Y ly L Gm Gm 1 pm pem E DC 4 o Bm 1 circuit breaker DC Output i amp Bridge 5 receptacle d diode roun W i DC12V
10. 5 4066 7 pc12v terminal AVR unit 8 Em Bk Bik 1 z e E 2 2 2 2 _ Gm Y RGX5100 50Hz 230V ENGINE _ _ CONTROL BOX _ _ _ Blk 1 Gm a Engine switch 8 Blk 5 E 5 S 5 Ze 2 19 2 gt m Y nu EG Kei VIRL GENERATOR 2 ROTOR IISTATOR circuit breaker s 8 R B AC Output AC Output 5 receptacle receptacle T 11 2 de Gry i U A N Org Org WIR E CC Voltmeter gt DE 1 lt Blu Blu DC circuit breaker DC Output W receptacle Earth ZP Ground DC12V terminal AVR unit 54 RGX3000 60Hz 120V
11. 8 2 2000 _ 5 2 1600 amp 5 o 1200 gt 800 5 9 S 400 Voltage V Frequency Hz Output VA 0 Current A 50 2 230 52 3200 F 51 2800 gt 5 50 2400 49 2000 lt 5 amp 48 1600 8 235 1200 230 5 555 400 Voltage V Frequency Hz Output VA 0 0 2 4 6 8 10 12 Current A 50Hz 240V 52 2800 Z 51 2400 gt o z 50 2000 5 5 5 49 1600 8 2 48 1200 gt 245 800 o p 5 240 400 Voltage V Frequency Hz Output VA 0 0 2 4 6 8 10 12 Current A 60Hz 120V 62 5 3200 N 5 60 2800 5 o g 57 5 2400 T 2000 gt 5 2 2 130 1600 O 125 1200 gt 120 800 S 9 400 Voltage V Frequency Hz Output VA 0 0 4 8 12 16 20 24 28 Current A 800 50Hz 220V 50Hz 230V Frequency Hz Voltage V Frequency Hz Voltage V 52 51 50 49 48 47 230 225 220 0 2 4 6 8 10 Current A 12 4000 3600 3200 2800 2400 2000 1600 1200 800 400 16 3200 2800 2400 2000 1600 1200 800 400 0 2 4 6 8 Current A
12. The brushes must be smooth where they BRUSH contact the slip rings If not polish smooth the HOLDER 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 k 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 itin the generator and operating it 425 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
13. 1 Put the cover onto the frame temporary CONTROL Box x2 NOTE Don t set bolt for the control 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 Nem A 22 A nel 15 20 kgfecm 1 1 1 5 165 5 Mount the control panel together with the control box Control box Assembly onto the frame 12 mm Screw 4 pcs Tightening torque 5 0 6 0 Nem 50 60 kgfecm 3 7 4 8 165 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 Insta
14. BOLT AVR UNIT REAR COVER N BRACKET FRONT COVER RGX5100 STATOR CORE END COVER EARTH TERMINAL FLANGE BOLT BRUSH HOLDER Q DIODE STACK Q Im d l Ed sj dec AE I n 5 9 C s C 3 I Loo STATOR BOLT ROTOR BOLT FRONT COVER AVR UNIT REAR COVER N BRACKET RE 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 dr
15. 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 INLET ALTERNATOR AIR INLET ENGINE AIR OUTLET ALTERNATOR 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 1 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 MEGGER TESTER Any part where the insulation resistance is less than 1 the insulation is faulty and may cause electric leakage Replace the faulty part 50 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 I
16. 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 A V R TYPE B A V R TYPE A Checking table for analogue circuit tester Apply black needle of the circuit tester O A V R TYPE A Yellow 8 Blue 5 Blue D Brown 2 Yellow 3 Yellow 4 Apply red needle of the circuit tester Yellow 8 1 5M 3 8M 4 3 Blue 6 3 9M 2 0M 2 1M Blue D Brown 2 Yellow 3 Yellow 4 Checking table for analogue circuit tester A V R B Apply black needle of the circuit tester White Red b Green D White 2 Blue 3 Apply red needle of the circuit tester White 8 2 1M 5 0M 5 1M 4 6M Red b 1 8M 2 1M 2 1M 1 9M Green D 4 4M 2 0M 4 9M 4 4M White 2 4 6M 2 1M 5 1M 4 6M Blue 3 4 0M 1 7M 4 5M 4 5M Blue 4 4 2M 1 8M 26 4 7M 4 7M 4 2M 6 7 DIODE STACK CIRCUIT TESTER Continuity test Brown OUER Black White White Brown DIODE STACK Brown Brown Black Fig 6 8a Fig 6 8b Circuit inside of the diode st
17. blue E 16 5 8 Bm Brown 1 a G 51 zu Brn W Brown White E KJ e Grn Green 9 YRC Grn W Green White 1 4 4 GENERATOR PC NUR Exi AC Gry Gray ROTOR STATOR e 1 R Red 577 utput S e 1 receptacle w White d 5 Y Yellow d Lob Slip ring l Qs Gry Gry rn Y Green Yellow 1 2 gt Voltmeter Pur Purple i Brn og Blu lt Blu Sub coil mE 1 4 Grn o Bm circuit breaker DC Output Bridge 1 W receptacle Earth msu Bj diode 1 Ground sl ER l 7 pc12v terminal AVR unit 8 Em Bik 1 z e E 3 2 2 _ Gm Y RGX3800 50Hz 220 240V ENGINE _ CONTROL BOX _ _ _ _ Blk Gm a Engine switch 5 Blk S S e 3 8 2 S 5 5 TE ER 5 2 x 9 TRE 2 B GENERATOR _ _ I Ra ROTOR IISTATOR ir 1 circuit breaker 5 i AC Output receptacle 79 1 b 1 Slip 2 Gry Gry al AC Output 9 ie Voltmeter receptacle 5 1 1 lt Blu Blu
18. is not applied to the mount MOUNT RUBBER rubbers RGX3000 RGX3800 M8 flange nut 2 pcs Tightening torque 16 0 20 0 N m 160 200 kgfecm 11 8 14 8 ftelbs RGX5100 M10 flange 2 pcs Tightening torque 24 0 30 0 N m 240 300 17 8 22 2 ftelbs 10 Set stator cover with the crow inserted into slit and bent 2 pcs 42 11 Set the Sponge Filter to inside of End Cover NOTE Hold the Sponge by tab of End Cover 12 Attach the end cover to the rear cover M5 x 16 bolt 2 pcs Tightening torque 4 0 4 5 Nem 40 45 kgfecm 3 0 3 3 165 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 Nem 180 220 kgfecm 13 3 16 2 ftelbs 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 END COVER SPONGE FILTER cus gt 7 ZA 4 END COVER EXHAUST PIPE gt MUFFLER It has two faces 8 NUT 2 pcs 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
19. terminal AVR unit 8 Bik Brn gt Grn y SBa RGX3000 3800 50Hz 230V ENGINE CONTROL BOX AY Wiring color code Blk 5 Gm 1 Blk Black p Engine switch BIK W Black White _ 5 Bik 5 Blu Blue 5 8 SmO 5 LBlu Light bl gi 2 8 1 u Light blue 16 5 8 Bm Brown S zu Brn W Brown White 9 E Y 2 Green o YIR c Grn W Green White 4 4 4 GENERATOR 1 M 5 AC Gry Gray ROTOR STATOR e 1 R Red o AC Output AC Output w White 1 11 1 5 AA receptacle receptacle _ Y Yellow ring Qs Gry Gry WIBIk White Black 1 Grn Y Green Yellow VIENT 2 Org Cry Voltmeter 5 e Pur Purple WI og Blu lt Blu Sub coil mE 1 Y Grn B o Brn circuit breaker DC Output 5 Bridge 1 W P receptacle ami d diod roun i
20. 110 220 230 240 V 60 Hz 110 120 220 110 220 120 240 110 120 220 110 220 120 240 110 120 220 110 220 120 240 Rated current 50 Hz 18 2 9 1 18 2 9 1 8 7 8 3 21 8 10 9 21 8 10 9 10 4 10 32 7 16 4 32 7 16 4 15 7 15 A 60 Hz Rated output 50 Hz 21 8 20 10 9 21 8 10 9 20 10 26 4 24 2 13 2 26 4 13 2 24 2 12 1 2400 38 2 35 19 1 38 2 19 2 35 17 5 VA W 60Hz 2900 Rated power factor 1 0 Safety device type Fuse less circuit breaker DC Output Rated voltage V 12 Rated current A 8 3 Safety device type Model EX17D Fuse less circuit breaker EX21D Type ROBIN Air cooled 4 stroke OHC Gasoline Engine Displacement 169 211 Fuel Automotive Unleaded Gasoline Fuel tank capacity 12 8 16 6 1 Engine oil capacity 0 6 Spark plug BR 6HS NGK o CH c o o Starting system Electric starter Recoil Direction of rotation Counter clockwise mm mm mm Dry weight kg 47 Specifications are subject to change without notice 1 2 3 shows the filled amount up to the LEVEL position shows dimensions with Battery frame shows dry weight with Electric starter 2 PERFORMANCE CURVES 000 50Hz 220V 2800 2400 N
21. 68 F 48 CIRCUIT TESTER Resistance 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 SANDPAPER 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 m cm to increase engine speed Normal engine speed at 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 ADJUST SCREW 8 2 3 CHECKING ROTOR Check rotor referring to Step 8 1 2 49 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
22. BER PIPE e 9 l ug Lo PACKING a o 35 4 Muffler 6 5 8 5 65 85 kgf cm 6 5 8 5 4 8 6 3 ftlbs 65 85 kgf cm 4 8 6 3 ft lbs M6 8 flange bolt M6 8 flange bo a CASE M8 flange nuts 9 18 0 22 0 N m 180 220 kgf cm 13 3 16 2 ftlbs M8 flange nuts 18 0 22 0 N m 180 220 kgf cm 13 3 16 2 ft lbs MUFFLER BRACKET 1 RGX5100 MUFFLER 27 BRACKET 2 M8 12 flange bolt M6 x 12 flange bolt 16 5 20 5 N m 6 5 8 5 N m 165 205 MUFFLER 2 65 85 12 2 15 2 ft lbs BRACKET RGX3000 4 8 6 3 ftlbs RGX3800 MUFFLER 1 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 kgfecm 14 8 17 8 ftelbs RGX5100 M10 flange nut 4 pcs Tightening torque 24 0 30 0 N m 240 300 17 8 22 2 ftelbs 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 si
23. 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 REVER type CIRCUIT BREAKER Frequency Rated output Rated voltage Rated fault current RGX3000 50Hz 2000VA 220V 10A 230V 10A 240V 10A 2400VA 120V 23A 110V 220V 12A RGX3800 2400VA 220V 12A 230V 12A 240V 10A 2900VA 110V 220V 15A 120V 240V 15A RGX5100 3600VA 220V 20A 230V 20A 240V 15A 4200VA CIRCUIT BREAKER Model Rated current Rated voltage 110V 220V 120V 240V 20A Rated fault current RGX3000 RGX3800 RGX5100 8 3A 12V 10A 3200 VD ulo e OO 41 41 CIRCUIT TESTER Continuity test 6 3 5 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 varia
24. ENSOR 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 Float type with lead switch incorporated Type OIL SENSOR D Resistance at FULL oil level 100 M ohms or over Operating Temperature 30 to 180 degree Celsius 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
25. Grn Green 5 25 g 29918 m Grn W Green White 4 YR Ju CAN 8 R Org Orange GENERATOR AC circuit 5 breaker 5 c Gry Gray ROTOR i STATOR el 5 LR 25 R Red TS gt Bric Te 22 W White Z 1 Y Yellow H 4 1 p Slip ring 8 9 ev lle 81 1 5 t WIBIk White Black y ry Eig i a 1 T 1 1 T 2 Grn Y Green Yellow le w Org Org Gry Pur Purple Y Blu JE i Brn LE E Blu Blu lt Blu Blu i T Org 4 Sub Blu ly PE w BIk DC circuit i lt circui jo breaker DC Output i receptacle Earth 79 9 o B Bridge Ground mBiuY dioda ew Blk DC12V terminal AVR unit 8 1 Brn 1 1 1 1 1 1 1 1 1 1 1 E RGX5100 60Hz 120 240V ENGINE _ _ _ __ CONTROLBOXAY _ I _ Bik Bik o 3 Grn Se Wc Engine switch ls 5 org 5 Idle Control Switch 5 rt E 18 JR a 15 5 ri 18 TEE 1 56 Ke 5 5 e S ll 011284 2 YR w s gt i kier poz r Dx 0 25 GENERATOR u AC circuit E ES 1 L ROTOR TATOR ERA breaker TRE Z oT 5 Bat Tapu 581 2 WEEN indi l s sure al EI PSE MP I jp t 1 1 g
26. SERVICE MANUAL Models RGX3000 3800 5100 GENERATORS Robin America Inc 905 Telser Road e Lake Zurich IL 60047 Phone 847 540 7300 e Fax 847 438 5012 e mail sales robinamerica com www subarupower com Copyright 2009 Robin America Inc CONTENTS Section Title Page 1 SPECIFICATIONS W fe Se ral len AA Sieger A te 1 2 PERFORMANCE CURVES 2 3 GENERAL 8 4 RANGE OF APPLICATIONS 0 0 0 0 00 0 0 0 14 5 MEASURING PROCEDURES 17 5 1 MEASURING INSTRUMENTS 17 5 2 AC OUTPUT MEASURING anre Sewer eee ee Be 19 5 3 DC OUTPUT MEASURING 19 5 4 MEASURING INSULATION RESISTANCE 19 6 CHECKING FUNCTIONAL MEMBERS 21 De 1 2 2060 den E 21 6 2 CIRCUIT BREAKER a marah ed meee ooo RUIN seeded 22 STATOR ede a Se 23 64 ASSEMBLY Z Saa a Da dtes 24 6 5 BRUSKI EN 25 6 6 A V R AUTOMATIC VOLTAGE
27. ack 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 Apply black needle of the circuit tester Analogue circuit tester Brown Brown White Black Brown No continuity Continuity No continuity Apply red needle Brown No continuity Continuity No continuity of the circuit tester White No continuity No continuity No continuity Black Continuity Continuity Continuity Checking table for digital circuit tester Apply red needle of the circuit tester Digital circuit tester Brown White Black No continuity Continuity No continuity No continuity Continuity No continuity Apply black O needle of the circuit tester No continuity No continuity No continuity Continuity Continuity 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 S
28. ction current strands dia No mm 100 30 0 18 2 477 50 0 16 1 486 14 37 0 26 Voltage drop 12 to 10 45 0 32 10 to 8 70 0 32 Table 4 2 Voltage drop indicates 100 xRxIxL R means resistance O 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 46 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 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 t
29. de 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 kgfecm 11 8 14 8 ftelbs RGX5100 M10 flange 2 pcs Tightening torque 24 0 30 0 N m 240 300 17 8 22 2 ftelbs 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 387 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 12 flange 4 pcs Tightening torque 6 5 8 5 Nem 65 85 kgfecm 4 8 6 3 165 RGX5100 Assemble muffler bracket to main bearing cover M8 12 flange bolt 2 pcs Tightening torque 16 5 20 5 Nem 165 205 12 2 15 2 ftelbs 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 4 pcs Tightening torque kgfecm ftelbs RGX5100 20 flange bolt 4 pcs Tightening torque 16 5 20 5 Nem 165 205 12 2 15 2 ftelbs MUFFLER BRACKET RGX5100
30. ead 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 7 3 COMPONENT PARTS 1 Generator assembly RGX3000 RGX3800 24 0 26 0 Nm 6 5 8 5 N m 240 260 kgf cm 65 85 kgf cm 17 7 19 2 ft lbs 4 8 6 3 165 22 0 24 0 N m 220 240 kgf cm 16 2 17 7 ftlbs THROUGH BOLT STATOR COVER BEARING STATOR FLANGE NUT BRUSH 2 HOLDER 16 0 20 0 9 MS 160 200 kgfcm 7 4 11 8 14 8 163 COVER BOLT 6 5 8 5 N m MOUNT RUBBER 65 85 4 8 6 3 ft lbs AVR UNIT 220 c RGX5100 24 0 26 0 N m 240 260 kgf cm 17 7 19 2 ft lbs 16 5 20 5 165 205 kgf cm 12 2 15 2 ft lbs THROUGH BOLT BEARING 43 47 N m 430 470 kgf cm 31 7 34 7 ft lbs STATOR COVER P d _ REAR COVER ge d SPONGE FILTER 24 0 30 0 N m END COVER 240 300 17 8 22 2 ftlbs MOUNT RUBBER 83 2 Control Box Assy 50Hz 220V 240V CONTROL BOX PILOT LANP NE DC CIRCUIT BREAKER EARTH GROUND CONTROL PANEL TERMINAL 60Hz 120V 240V ZY 3 Fuel Tank FUEL TANK CAP FUEL FILTER FUEL GAUGE CA 0 aby FUEL TANK RUB
31. eo 4 ryt 7 ls JPT T Blu 8 WIR E LLIOrg T r NEM Blu BI Grn winding 2 w Blu Blu i Dow Less Org i Sub coil 1 Blu ey Gm L Grn Bn wi DC circuit DC Output o breaker i 7 Bridge oo receptacle od Gmw Bu Biu dodeg 1 1 7 Y epci2v terminal AVR unit 8 Bik Bik Brn 16 56 RGX5100 60Hz 120 240V Electric starter model ENGINE CONTROL BOX AY r e ies IE dn 7 w Wiring color code Blk Blk c3 w Idle Control Switch Black I BIK W Black White 5 Bk 5 5 Blu Blue Esm 8 w Blu LBlu Light blue E fs 29 IE Bm Brown m 215 5 iss its Su 5 8 BP 152 MS Brn W Brown White dt ol 2 155115 Gm Green Li 8 On s Blu Grn W Green White ji 5 17 Org Orange GENERATOR _ 1 Gry Gray ROTOR STATOR R n W White d R Y Yellow Slip ring wind
32. f the DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing 8 4 3 CHECK THE WIRING Check all the wires to be connected correctly CIRCUIT TESTER Continuity test 8 4 4 CHECK THE DIODE STACK Remove the end cover and check the diode stack with a circuit tester Refer to Section 6 7 DIODE STACK for the checking procedure DIODE STACK 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 50Hz 220V 60Hz 220V 50Hz 230V 50Hz 240V 60Hz 120V 240V RGX3000 0 193 0 191 0 238 0 215 0 181 RGX3800 0 186 0 187 0 172 0 183 0 163 RGX5100 0 147 0 133 0 169 0 147 0 133 9 WIRING DIAGRAM RGX3000 50Hz 220 240V ENGINE CONTROL BOX AY Wiring color code Blk gt Gm 1 Blk Black p Engine switch BIK W Black White Eus Bik 5 Blu Blue 18 5 Org 5 LBlu Light
33. gt ONS MUFFLER BRACKET 1 MUFFLER BRACKET 2 RGX3000 RGX3800 38 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 17 8 19 2 ftelbs 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 THROUGH BOLT RGX3000 M8 222 flange 1 pc RGX3800 M8 x 235 flange bolt 1 pc BEARING Tightening torque 22 0 24 0 N m 220 240 16 3 17 8 ft lbs RGX5100 M10 x 260 flange bolt 1 pc Tightening torque 43 0 47 0 N m 430 470 kgfecm 31 8 34 8 ftelbs 39 7 4 5 STATOR 1 Put the stator in the 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 REAR COVER NOTE Tighten the bolts evenly and in turns HAMMER MOUNT RUBBER RGX3000 M6 x 140 flange bolt 3 pcs
34. ing aryl WIBIk White Black t T Grn Y Green Yellow W zi Org FH Pur Purple bres windin my i Blu i Biu Jr 1 1 1 Grn ll Grn 1 DC circuit W Blk breaker DC Output s o receptacle Earth diod Ground e 1 pc12v terminal 7 Blk 57 45 SUBARU PRINTED IN THE USA
35. iven 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 Item 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 star
36. l N di dh Engine switch MT Gm 2 LS Z breaker Earth ground meter DC receptacle terminal 10 RGX5100 50Hz 220V 240V AC AC circuit Engine switch receptacle breaker B ca o IN DC circuit UM a breaker o Earth ground DC receptacle terminal Engine switch breaker TEE Voltmeter AT DC circuit breaker Earth ground DC receptacle terminal 60Hz 120 240V AC receptacle 30A AC receptacle 30A Idle Control Switch AC receptacle 20A Pilot lamp VE O Electric starter model peni AC circuit breaker Key switch IO CO TE Engine switch BED e DC circuit J En breaker Full power 22 Hour meter DC receptacle Earth ground terminal 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 END COVER BRUSH HOLDER EARTH TERMINAL FLANGE BOLT DIODE STACK BRUSH O ALLAL ETT ZZ 1 G CD C dee y EN 11 ROTOR BOLT STATOR
37. ll 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 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 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
38. m 180 220 13 3 16 2 ftelbs RGX3000 RGX3800 M6 x 12 flange bolt 2 pcs bracket2 Tightening torque 6 5 8 5 Nem 65 85 kgfecm 4 8 6 3 165 RGX3000 RGX3800 RGX5100 M8 x 12 flange bolt 1 pc bracket Tightening torque 16 5 20 5 Nem 165 205 kgf cm 12 2 15 2 ftelbs RGX5100 4 Assemble the duct and the muffler cover M6 x 8 flange bolt 7 pcs Tightening torque 6 5 8 5 Nem 65 85 kgfecm 4 8 6 3 165 DUCT CASE M6 x 12 BOLT 3 pcs MUFFLER COVER 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 fitthe 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 45 FUEL GAUGE 23 FUEL TANK CAP Q FUEL FILTER FUEL TANK SA FUEL S STRAINER 227 FILTER 28 PACKING CUP 20 R BEER 7 4 9 CONTROL BOX ASSY Refer to Section 7 5 for disassembly checking and reassembly procedures of the control panel
39. tance 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 itis 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 2 ROTOR Measure the insulation resistance between the slip ring and the core 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 1MO has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 20 6 CHECKING FUNCTIONAL MEMBERS 6 1 RECEPTACLES CIRCUIT TESTER Using a circuit tester check continuity between Continuity test 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 5 6 2
40. ted 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 P ti Efficiency Power consumption Efficiencies of some electrical appliances are as follows Single phase motor 0 6 to 0 75 The smaller the motor the Fluorescent lamp 0 7 to 0 8 lower the efficiency Example 1 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 4070 77 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 i
41. tion of resistance among coil windings or when measurement is performed at ambient temperatures different from 20 C 68 F 1 RGX3000 RGX3800 AC winding 1 AC winding 2 Blu Sub Brn Bridge AVR unit DC winding diode 000 50 2 220 50 2 230 50Hz 240V CIRCUIT TESTER Resistance 60Hz 120V Q 60Hz 110 220V AC WINDING 1 RED GRAY 0 980 1 042 1 234 0 851 0 749 AC WINDING 2 ORANGE BLUE 0 980 1 042 1 234 0 851 0 749 SUB COIL YELLOW YELLOW 3 682 3 530 3 570 2 390 2 370 DC WINDING AC WINDING 1 RGX3800 BROWN BROWN BROWN BLUE 0 193 50Hz 220V 0 238 50Hz 230V 0 215 50Hz 240V 0 189 60Hz 110 220V 0 191 Q 60Hz 120 240V AC WINDING 1 RED GRAY 0 772 0 753 0 902 0 605 0 615 AC WINDING 2 ORANGE BLUE 0 772 0 753 0 902 0 605 0 615 SUB COIL YELLOW YELLOW 3 100 3 030 3 121 2 080 2 060 DC WINDING BROWN BROWN 0 186 0 172 0 183 0 187 0 163 AC WINDING 1 BROWN BLUE N A 0 137 299 N A N A 0 103 2 RGX5100 R 4 1 lt
42. ts work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570 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 Item 3 570 W x 1 2 to 3 684 W to 1710 W Applicable Wattage approx W Applications 50Hz 60Hz RGX3000 RGX3800 RGX5100 RGX3000 RGX3800 RGX5100 Incandescent lamp Heater 2000 2400 3500 2400 2700 3700 Fluorescent lamp Electric tool 1100 1200 1800 1200 1400 1900 Mercury lamp 800 900 1300 900 1000 1400 Pump Compressor 500 800 550 600 850 Table 4 1 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 A W G Allowable No of strands Resistance Current Amp se
43. ype tacho meter 18 5 2 OUTPUT MEASURING SWITCH 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 Rated voltage 110V 220V 230V 240V 107 115 219 228 229 238 239 248 107 115 118 127 219 228 239 248 107 115 219 228 229 238 239 248 107 115 118 127 219 228 239 248 107 115 219 228 229 238 239 248 107 115 118 127 219 228 239 248 RGX3000 RGX3800 Voltage range RGX5100 5 3 DC OUTPUT MEASURING Measurement of DC output is executed with the switch turned ON while the current is regulated Load at 8 3A by adjusting the load to the generator If the voltage is within the range from 10V the To DC Terminal 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 resis
44. z Output VA 3 GENERAL DESCRIPTION Engine switch Fuel strainer Fuel cock Control panel Recoil starter handle Recoil starter Cil gauge oil filler Cil drain plug Fuel gauge Tank cap Spark plug cap Choke lever Air cleaner Muffler CONTROL PANEL RGX3000 50Hz 220V 240V Engine switch AC circuit e breaker 1454 ET Voltmeter 5 Eje el breaker Earth ground DC receptacle terminal 50Hz 230V AC AC circuit Engine switch receptacle breaker D er DC circuit wa breaker Earth ground DC receptacle terminal 60Hz 120V AC receptacle 20A AC circuit Pilot lamp breaker vr 00 v U AE er Engine switch gt rm J 2 21 p breaker Earth ground Hour meter DC receptacle terminal 800 50Hz 220V 240 Engine switch AC circuit breaker EF FEE DC circuit N 3l breaker mem DC receptacle terminal 50Hz 230V AC AC circuit Engine switch receptacle breaker DC circuit breaker Earth ground DC receptacle terminal 60Hz 120 240V AC receptacle 30A AC circuit Pilot lamp AC receptacle 20A Electric starter model UN 5 Idel control U i ER ep S Key switch 9 NW m ower HE o
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