Generator Model RGX305,305D RGX405,405D RGX505,505 D Technical Data& OverhaulInstructions
CONTENTS Title Section Page 1. SPECIFICATIONS .......................................... 1 2. PERFORMANCE 2-1 Model 2-2 Model 2-3 Model 2-4 Model 2-5 Model 2-6 Model ........................................... RGX305 ...................................... RGX305D ..................................... RGX405 ...................................... RGX405D ..................................... RGX505 ...................................... RGX505D ..................................... 3 3 4 5 6 7 8 9 .
Model .- - _- Type _--.. .- .T Frequency RGX305 _-.. --- -. 60Hr _.-. 3400w 2900w _-. Self-Exciting, .- _ __ 50Hz .__ _ - P-pole, .-- 50Hr ._ ._- 3ooow 2500W - -.. RGX405 -- _- --__. Revolving-Field, -.. -_... _- 50Hz .-__ __ 3ooow 2500W RGX305D ._ _ .-.... - __.-. __-- Single Phase -- - _-.-. .- .._ -,- Model - -__-, Factor -. - -. .- - . _-- _._-_,. ..- _ - _ ._-. - -- - - .-_ - - ._ -...- -. - . _. Air-Cooled, -_. _- ____. 16 Liters --..
Model . RGX505D RGXSOB -- I I Type Revolving-Field, ,._._- - -_ _ -_ Max. Rated ___,_ Self Exciting, .--_ 50Hz 6OHZ 5ooOW 4400w 5500w 4800W 2-pole, Single Phase _-- 1oov 5 t 2 5 c) / 220v -120 -_-----. --_._. _--.----_ / 240V .. I Power Factor DC Output - .-.__---...-- I h) I - -- Voltage Regulator Voltage Regulation -.- 1 .o I -. -_-_ - _.- .-__- -~. - .---- - .---- Type -. - _ Model -. - ; zw - -- - - - -._ Iimensions -. Dry Weight - ._ Air-Cooled, .
2. PERFORMANCE 2-l OUTPUT MODEL Type RGX305. . . . . . . . . . . . . . . . Self Exciting, 2-Pole, Single Phase Power Factor . . . . . . . . . . 1.O Engine . . . . . . . . . . . . . . EY25-2D(EY25WI* Output t 63 ‘; 1;;62 60 2 59 3400W Rated 2900W Frequency ,t z 61 2 Max. ............... .............. ................. Voltage ................... 60Hz 11ov 3 -- 2500 5 7 e $20 ;;llO 0’ .- 2000 %O 5 -.1500 : 12 16 20 CURRENT(A) 24 - 28 32 Output Max. ...............
MODEL Type RGX305D ............... Self Exciting, Power Factor .......... 1.O Engine EY25-2D .............. OUTPUT(240V). t 2-Pole, Single Phase (EY25W)” OUTPUT (12OV1 Output I Max. ............... 3400W Rated 2900W .............. 3000 Frequency ................. 6OHZ Voltage ................ t2500 2230 t iii !T I k 1‘15002 ti hO0 12OVl24OV 1: 2000 I 250 240 d630 > 120 -c 500 110 0 5 10 15 20 25 30 CURRENT(A)- I ---I= ‘n, A,, :rr&n\;\ I (11OV) Output Max.
MODEL Type RGX405 ............... Self Exciting, 2-Pole, Single Phase Power Factor .......... 1.0 Engine EY35D(Wl-340)* .............. Output ?4500 Max. ............... Rated .............. 44OOW 3700W I Frequency ................. 60Hz iNo”4 Voltage ................... 11ov +4000 Output I 120 ZllO $00 2 G CURRENT(A) - Max. ............... Rated 13500 Frequency .............. ................. Voltage ...................
MODEL Type RGX405D ............... Self Exciting, 2-Pole, Single Phase Power Factor .......... 1.0 Engine .............. EY35D (Wl-340)’ Output -62 Max. . .............. 4400W Rated 3700w Frequency. 61 .............. . . .............. Voltage . . . . . ........... 60 6OHZ 12OV/24OV 59 s i--i f 240 250 3000 5 e 5: z 230 0 2000 s I 2 zJ 130 1000 t 120 i : 0 5 10 15 j 20 25 30 35 40 CURRENT(A)- Output Max. . . . . . . . . . . . . . . .
MODEL Type RGX505 ............... Self Exciting, 2-Pole, Single Phase Power Factor .......... 1.0 Engine EY40D(Wl-390)” .............. I ;; E > Output I 5000 t 62 6’ Max. ............... 5500W Rated 4800W Frequency +3 -~I p a ..3000 .............. . . . . . . . . . . . . . . . . . 60Hz Voltage . . . . . . . . . . . . . . . . . . . 1lOV Iz 5 L k t 110 120 F ;;;lOO ;;;loo 0 2 i I 1 ] 0 11 10 ! 20 i 30 CURRENT(A) 40 50 - Output -5000 Max. . . . . . . . . . . . . . .
MODEL Type RGX505D ............... Self Exciting, 2-Pole, Single Phase Power Factor .......... 1.0 Engine EY40D (Wl-390)* .............. Output t sak,l~rl?rv%!-kUT-I 11 i Rated ............... 5500W .............. 48OOw Frequency ................. 15000 I VI> Max. Voltage ................ 60Hz 12OVl24OV f4000 bo00 .-240 -*2000 z 230 ; 2 130 g 120 -~looo 110 10 0 20 30 CURRENT(A) 40 - Output Max. Rated Frequency t z 220 .............. 4400W .................
3. 1. FEATURES Lightweight, Compact The Robin engine and revolving field generator designs provide added output power per weight and economical operation. 2. Centralized Control The switches, meters, and receptacles are located together on a large-sized control box, and all operating controls are located on top of the engine for easy generator operation. 3. Large 16-Liter Gas Tank * 16-liter (4.2-gallon) fuel tank is provided for ten hours of operation for Model RGX305 or seven hours for Model RGX405.
14. Ruggedly Built Frame The box type frame is so ruggedly built that two or more generators can be stacked. Another convenient feature for the Robin generators. 15. Wide Range of Options The elctric starter type, wheels, and econo-throttle are availabe as options.
P L FUEL GAU/GE and TANK CAP SPARK CHOKE LEVER PLUG \ CAP SPEED STOP CONTROL BUTTON I s1 2 5) E < ii z 3, G) s am 4; si P t) ?s E r u m t? 7[1 G i i2 0 2 z” i 3 si OIL GAUGE CONTROL I FUEL BOX STRAINER AIR FUEL I COCK CLEANER RECOIL I MUFFLER STARTER RECOIL I STARTER HANDLE
4-2 PANEL A ‘0 f AC RECEPTACLE CAC V 1 VOLTMETER NO-FUSE MODEL RGX305 RGX405 22ov, 23ov, 240v 22ov, 23ov, 240v MODEL ,RGX505 22OV, 23OV, 240V MODEL RGX305 RGX405 RGX505 llOV, llOV, llOV, BREAKER 0 OAC V -n Iv-l- -I “3C JREAKER I ON 0 0 -4 OFF 0 AC RECEPTACLE A 1 ECEPTACLE / AC RECEPTACLE POWER 2 1 SWITCH No FUSE NO-FUSE AC RECEPTACLE FULL VOLTMETER I~REAKER ‘BREAKER 2 \ 0 OAC V\ MODEL RGX305D RGX405D RGX505D ” , J) E 0 I \ OJ / / AC RECEPTACLE VOLTMETER
4-3 PANEL B DC FUS MODEL RGX305 RGX405 RGX505 DC OUTPUT TERMINAL J EARTH FUSE (GROUND) TERMINAL IOA RGX305D RGX405D DC EARTH (GROUND) TERMINAL AC RECEPTACLE 3 RGX505D EAR-iH (GROUND) TERMINAL AC R‘ECEPTACLE - 13- 3
THROUGH BOLT SLIP RING COVER BOLT FRONT SHAFT COVER I II BkUSH HOLDER REAR ‘COVER RUBBER MOUNT / ROTOR I STAi’OR COMPL. -..-.. I ENGINE I COMPL. COOLI’NG FAN P.1 ‘.O.
5-2 FUNCTIONS 5-2-l STATOR -l-he stator consists of a laminated silicon steel sheet core, copper wire which winds the core, and lead wires which deliver the power. The copper wire is wound into the main coil, sub (auxiliary) coil, and DC coil. AC output power is taken from the main coil, and DC output power from the DC coil. The outside diameters and laminated core thicknesses of various models are as shown below. Fig. 5-1 Fig.
FAN 5-2-2 ROTOR The rotor consists of a laminated silicon steel sheet cover SLIP with a field coil wound arount it and cooling fans and slip rings at both ends of the shaft. The field coil leads are con. nected to the slip rings and direct current (DC) to the field coil turns the rotor and magnet. The tooling fans cool the generator by drawing cooling air from the slip rings and discharging it through the fans. BEARING Fig. 5-3 Fig.
5-2-3 - - - BRUSHES --------- An exciting current is supplied from the AVR to the rotor. The brushes are made of carbon; and the brush-holders of plastic. It is necessary to keep the contact pressure between the brushes and slip rings withing specific limits. Thus, care must be taken of brush length. (See 9-3 BRUSHES.) RGX305. RGX405. RGX505, RGX305D RGX405D RGX505D Fig.
5-2-6 NO-FUSE BREAKER The no-fuse breaker prevents AC output overcurrent and shortcircuit overcurrent. Some models have one no-fuse breaker, and the others have two. The single no-fuse breaker protects the generator from maximum current; and the double no-fuse breakers protect the generator from maximum current, and its receptacles.
5-2-7 FUSE The fuse prevents DC output overcurrent and shortcircuit overcurrent. If the generator is operated at a level exceeding the maximum current, it can cause insulation deterioration. burning, electric shock. and electric leakage. The fuse protects the Fuse capacity: 1OA generator from these troubles. 5-2-8 RECEPTACLE and AC PLUGS These are used for taking AC output power from the generator.
5-2-l 1 REAR COVER The rear cover is also an aluminum die casting, and has a faucet joint to hold the stator together with the front cover. It has bosses inside for holding the brushes, and slits for taking cooling air in. The slits are so designed that human fingers will not go in. RGX305 RGX305C RGX405, RGX405D RGX505, RGX505D Fig. 5-12 5-2-12 RUBBER MOUNTS (RUBBER VIBRATION ISOLATORS) Rubber pads for controlling generator vibration and dislocation.
5-3-l REVOLVING FIELD TYPE and REVOLVING ARMATURE AC VOLTMETER NO-FUSE I BREAKER BRUSH ASSY BRUSH HOLDER TYPE CONTROL BOX .\ SOCKETPLUG FRONT SLIP RING I ,YOKE REAR COVER FNClhlF COVER RfIl POLE ASSY FIELD COIL T SHAFT ARMATURE ASSY FIELD COIL RMATURE RUBBER VIBRATION ASSY ISOLATOR COOLll;G FAN Fig. 5- 75 ROTOR COMPL. \ SLIP \ I RING COVER BOLT /FRONT COVER / SHA ,FT STATOR COMPL. r-r> BRUSH II 4! II \ HOLDER ROTOR REAR COMPL. COVER SHAFT Fig.
The RG Series is the revolving armature type, and the RGX Series is now the revolving field type. The differences between these types and their features are described below. The construction of the revolving armature type is shown in Fig. 5- 15, and that of the revolving field type in Fig. S- 16. The basic operating principle of the generator is this. As a conductor moves in a magnetic flux (between poles N and S of a magnet), a voltage is generated in the conductor and can be taken out as electric power.
5-3-2 PRIMARY EXCITING ACTION The RGX Series employs an exciting coil in the engine magneto for raising the primary voltage. This action is explained. The RG Series generates a voltage when the generator is started again because of the residual magnetism remaining in the yokes and poles. If aienerator FC of this type is disas- sembled and stored for a long period of time, the residual magnetism may dissipate so that the generator may not generate a voltage when it is restarted.
5-3-4 FULL POWER SWITCH The dual voltage type has a full power switch to produce the rated output from a single 11OV or 120V receptacle. The full power switch operates as described below. (The full power switch for 12OV/24OV is described as the construction of both full power switches for 12OV/24OV and 1 lOV/22OVis same. 240V i-J?-; 7 I Fig. 5-18 i Fig. 5- 19 A circuit diagram of the conventional dual voltage type is shown in Fig.
54 CHANGE of ENGINE PARTS In detail of the engine, please refer to the service manual, RGX305, RGX305D are refer to EY25, RGX405, RGX405D, RGX505 and RGX505D are refer to EY35 and EY40. The RGX Series employs engine parts special to the RGX to suit the modified engine. The engine parts can be classified by ignition system, control system, fuel system, and cooling system. The engine parts for each of these systems are explained below.
The blower housing has nuts for mounting the bracket, and a wire for the stop button which runs inside the blower housing. BLOWER WIRE HOUSING Fig. 5-20 (21 5-4-3 FUEL’SYSTEM The large-sized 164ter fuel tank is mounted in the frame. The fuel piping was changed as a result as shown in Fig. 5 -21. FUEL GAUGE FUEL /-+, ’ ’ RUBBER TANK ’ to CARBURETOR /, HOSE RUBBER HOSE \ Fig.
5-4-4 COOLING SYSTEM A baffle is provided to prevent engine cooling air from raising the temperature of other parts. Large sized rubber pipe 1 shown in Fig. 5 -21 prevents vapor lock even at high ambient temperature (up to about 45’C). CAP (RUBBER) HEAD TO MUFF LEA BAFFLE (CARBURETOR TO CARBURETOR ‘CYLINDER RGX305, BAFFLE COVER SIDE) 3 RGX405, RGX505, RGX305D RGX405D RGX505D Fig.
6. SAFETY PRECAUTIONS 1. Use extreme caution near gasoline. A constant danger of explosion or fw exists. Do not ffi the fuel tank with gasoline while the engine is running. Do not smoke or use open flame near the fuel tank. Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before starting the engine. 2. Do not place inflammable materials near the generator. Be careful not to put gasoline, matches, gunpowder, oil cloth, straw, trash and any other inflammables near the generator. 3.
7. RANGE of APPLICATIONS Generally, the rated power of an electrical appliance often refers to the amount of work that can be done by it. The electric power required for operating an electrical appliance is not necessarily equal to the amount of work that can be done by it. Electrical products generally have a label showing their rated voltage, frequency, and power consumption (input power). The power consumption of an electrical products is the power necessary for using it.
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 - 0.75 Three-phase motor . . . . . . . . . . 0.65 - 0.
NOTE: 1. Wiring between generator and electrical appliances Allowable current of cable Use a cable with a allowable current that is higher than the rated input current of the load lelectrical input current is higher than the allowable teriorate 2 the insulation, possibly appliance). If the current of the cable used, tie cable will become excessively heated and de boring it out Table 7-2 shows cables and their allowable currents for your reference.
8. MEASURING 8-1 PROCEDURE METERS 8- 1 - 1 VOLTMETERS AC and DC voltmeters are 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 FOR 0 to 150 V, 0 to 300 V: Dual voltage type AC DC FOR DC Fig. 8- 1 The DC voltmeter range is approximately from 0 to 30V. 8- l-2 FOR AMMETERS AC and DC ar:meters are necessary.
8-1-4 TESTER Used for measuring resistance, etc. Fig. 8-4 8-1-5 MEGGER TESTER Used for measuring generator insulation resistance. Select one with testing voltage range of 5OOV. Fig. 8-5 8-1-6 TACHOMETER There are various types of tachometers, such as contact-less type, contact type, and strobe type. The contact type can CONTACT-LESS TYPE be used only when the generator and engine have been disassembled. The contact-less type is recommended. STRbBE Fig.
8-2 AC OUTPUT MEASURING TO Use a circuit like the one shown in Fig. 8-7 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 Table 8-1 at the rated amperage and rated rpm. I I 11ov 1 Voltage range ! 108-115V 220 v 12OV I Rated voltage 218 - 225 V 118%125V 230v 1 228 - 235 V 240v 238 - 245 V Table 8- 1 8-3 DC OUTPUT MEASURING 00 SWITCH LOAD @ @ DC TERMINAL Fig.
. STATOR Measure the insulation resistance between the red or white coupler from the stator and the core. Fig. 8- 70 . ROTOR Measure the insulation resistance between the core and one of the slip rings of the rotor. Fig. 8- 11 . CONTROL BOX Measure the insulation between the live parts and the casing or grounded part. Close the no-fuse breaker first, then measure it. Any part which has an insulation resistance of less than 1 megohm has a faulty insulation, which can cause electric shock or leakage.
9. CHECKING 9-1 STATOR 9-l-l FUNCTIONAL MEMBERS STATOR ASSEMBLY MEASURING ASS’Y \ WINDING \ RESISTANCE Check the resistances of the leads from the stator with a tester. (See Fig. 9 - 1.) Check all the leads which are shown by type in the tables below. Any lead which is inactive is faulty. NOTE: Testers are not so accurate that some margin of er- ror must be taken into account when reading the tester agains the values shown in the Tables. lt is measured by wheatstone bridge in regularly.
*RGX505, l RGX505D 50Hz 22OV. 23OV, 240V yzJG-Jq ml l 50H.z 1 lOV, llOVI22OV. 12OVl24OV l 60Hz 11OV. 12OV, llOVi22OV. 9-l-2 MEASURING INSULATION Refer to 8-4 MEASURING 9-2 9-2-l i BLUE I ] 0.14 BLUE 12OVi24OV RESISTANCE INSULATION 1 Wire color ROTOR RESISTANCE. ROTOR ASSEMBLY WWDING RESISTANCE MEASURING Check the resistance between the two slip rings with a tester. (See Fig. 9-2.) The resistance is normal if it is anywhere from 5 ohms to 7.5 ohms. TESTER Fig.
9-3 BRUSHES 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 15 mm as shown in Fig. 9 -4. 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. !15mm-5mm 15mm-5m r Fig.
Tester polarity Yellow Red White Green j Brown ! I I m i7OOK-lMi2 One wire: 052 72K - - 120KQ Another: Yellow 00 White I Green i I Brown j I - - - - QO One wire: Ost 409K - 500KR 72K - 120KS2 Another: , Red ’ 65K - 1OKR 65K - 1OKR 00 / 250K - 300KS2 Do 400K - 500KC! 1 130K - 140KSI 00 220K - 250KR 1 45K-5OKR - ’ 250K-3OOKSZ ’ - m - i 130K- ; - m j - ! 6OOK-1Mfl i 70K-1lOKR - ! - 1 400K - 5OOKCZ 70K-1lOKn - - i 400K - 5OOKS1 40K - 46KR m ’ 6.
9-5 FUSE HOLDER 9-5-l and NO-FUSE HOLDER FUSE HOLDER Only the LG301 and LG301D have a no-fuse breaker. Push the power switch off and check continuity. If no cur- rent flows, it is normal. Then push the power switch on and check continuity again. If current flows, it is normal. If the breaker is a two-pole type, the two pairs of terminals must carry current. Fig. 9-6 9-5-2 NO-FUSE FUSE HOLDER BREAKER Check that a fuse is in the fuse holder and check its continuity with a tester. (See Fig.
9-6 RECEPTACLE and AC PLUG Check the current-carrying parts of the receptacles and AC plugs and their leads and plastic parts for bums. 9-7 VOLTMETERS Apply AC voltage to a terminal and check if the voltmeter reads normal. VOLTMETER 9-8 DIODE STACK Fig. 9-8 ASSEMBLY + -- eI- Fig. 9-9 The internal circuitry Fig. 9-10 of the diode stack assembly is as shown in Fig. 9-9. Check inter-terminal continuity with a tester as shown in Fig. 9-10 to see that the results are as shown in Table 9 -8.
9-9 PRIMARY EXCITING CIRCUIT As described in 5-3 DESCRIPTION ERATION, of GENERATOR OP- the primary exciting coil is in the magneto mounted 0~1the engine, and the AVR has a circuit for it. 9-9-l EXCITING COIL The normal inter-terminal resistance of the exciting coil is about 10 to 30 ohms. Its voltage at the rated rpm is about AC 10 to 30 V. Check the resistance and voltage with a tester to seeif they meet these requirements. 9-9-2 OTHERS Fig. 9- 10 No output voltage from the generator.
10. DISASSEMBLY and REASSEMBLY 10-I PREPARATIONS and SUGGESTIONS 1) Wren disassembling the engine, remember well the locations of individual parts so that they can be reassembled correctly. If you are uncertain of identifying some parts, it is suggested that tags be attached to them. 2) Have boxes ready to keep disassembled parts by group. 3) To prevent missing and misplacing, temporarily assemble each group of disassembled parts. 4) Use the correct tools in the correct way.
Fig. 10-3 Fig. 10-4 I Order 1 i 2 Item Procedure Control Box I Remarks (1) Remove the connector and coupler. Remove the connector and coupler that are connect to the rear of the control box. Tool The connector and bushing are so designed as to I lock, so push and pull I out as shown in Fig. lo- 5. I I I (1) Fig. 10-5 (2) Remove the control box bolts and the control box. Remove the bolts from the frame and box stay. Fig.
Order Item I Frame 3 I Procedure I Remarks (1) Remove the box stay. 69 bolt. . . 2 PCS. (2) Remove the side plates, front and rear. I , It is not necessary to remove the air guide. Black special bolts are used. 10 mm spanner 10 mm spanner or box spanner 13 mm spanner (3) Remove the generator mounting nuts. I I / I RGX305, RGX305D: Remove the \ nuts that fasten the engine and rubber ( mount and the nuts that fasten the generator and rubber mount. I I 89 nut . . .4 PCS.
Order 1 I 4 Item Procedure Brush holder (1) Remove the brush cover. Remove the brush cover in back of the I rear cover. 40 screw. . . 2 pcs. , (2) Remove the brush holders. I (See Fig. 10-9.) Disconnect the terminals wired to the I brushes before removing the brush holders. I 50 screw _ . . 2 pcs.
Order 6 T t I I I Item Stator I ! I Tool Procedure 1L I t ! (1) Remove the stator. Full out the stator from the front cover ! by lightly tapping the outside of the core with a plastic hammer. (See Fig. 10 11.) If the stator does not come out, insert a screwdrive between the front cover and stator, and twist it. (See Fig. 10-12.) I i (2) Separate the stator and rear cover. Separate the connector and wire.
Order 7 item Rotor , Procedure Remarks (1) Pull out the through-bolt. Fit a box spanner or socket wrench over the head of the through-bolt, strike it hard counterclockwise with a hammer to loosen, and remove the through-bolt. (See Fig. 10-14.) 1Og bolt . . . 1 pee. (2) Remove the rotor. Strike the rotor by the core with a plastic hammer, and remove the rotor from the engine taper shaft. If the rotor does not come out, change its angle and strike it again. (See Fig. lo- 15.) ! Fig.
NOTE: 1. In case the rotor cannot pull out, please do the following Prepare the tool in the dimensions of the following L, a ways. for pulling out the rotor. -i , T! -1 11) -I A’B ‘T jC1D ! Pitch MODEL 1 L RGX305 RGX305D / : 250mm 9.8” : 33mm 1.3” @lOmm I; $0.39” / @mm G50.31” 20mm , ( 0.79” i i 12mm 0.47” 1.5mm : 0.06” RGX405 RGX405D 1 235mm , 9.3” ’ 33mm : 1.3” f$lOmm j 40.39” / ’ @mm (bO.31” 20mm , ; 0.79” / 12mm 0.47” 1.5mm ! 0.06” RGX505 RGX505D ! 266mm i 10.
2. Remove a throughbolt and insert the shaft of rotor puller into the hole for throughbolt and push it up till the shaft reaches the screw hole of the P. T. 0. shaft on the side of engine. 3. As shown in Fig. lo- 16, screw up the bolt pushing the rotor puller shaft and remove the rotor. Fig. lo-16 1 Order 8 ] Item I ( Front cover ! I 1 Procedure I (1) Remove the front cover. Remove the bolts that fasten the engine’s main bearing cover to the front cover. 8@bolt...4pcs.
10-3 HOW TO REASSEMBLE 10-3-l FRONT COVER Attach the front cover to the engine main bearing cover. Match the faucet joint, and tighten the bolts. 8$xlSmmbolt...4pcs. Tightening torque 120 to 14Okg-m NOTE: Make sure that the slits for cooling air an? dew. NOTE: The RGX405, RGX405D and RGX505 RGX 505D use the same front cover. 10-3-2 1) ROTOR Clean the tapered part of the engine output shaft and Fig.
10-3-3 STATOR Install the stator to fit the faucet joint of the front cover. If it does fit properly, lightly strike the stator core with a plastic hammer as shown in Fig. 10-20. NOTE: Never strike the winding. NOTE: Make sure that the mares to tie control h toBRUSH (GREEN to CONTROL HO AND box are up and that the wires to the brushes are to the back. BOX FRONT COVER o DIODE 0 BLUE ATOR STACK WIRES) Fig. lo-20 COVER Fig.
4) Install the rear cover to fit the rotor bearing. Lightly strike the circumference of the rear cover evenly with a plastic hammer. (See Fig. 1O-23.) NOTE: Be careful not to pinch the wires between the stator and rear cover. Fig. lo-23 5) Tighten the cover bolt. NOTE: The bolt cannot be tightetied unless the front cover and rearcover are positioned correcdy. The shape of the cover bolt is shown below. d MODEL RGX305 I 6mm RGX305D i I 0.
8) Insert the wires into the connectors. The connector positions and wire colors are shown in Table 10-3. NOTES: 1. RGX505 - 1 lOV, 12OV, RGX505D: Connectors are used for terminals (7) through (101 only. The others are pin terminals 2. Terminals 111 through (61 are for a 2 mm’ terminals (71 through (10) for a 0, 75mm2 wire and wire. Fig. lo-25 MODEL RGX305,405 220,230,24OV ’ ! RGX505 220,230,24OV WHITE RGX305D. 405D. RGX305.
NOTE: The mounting isshown in Fig. lo- 28 dirmtion GREEN WIRE BROWN WIRE of the brush holders for Models RGX405, RGX405D, RGX505 and RGX 505D Fig. lo-28 NOTE: If a brush is installed oblique to the slip ring, the brush holder can break tien the screw is tightened; or the brush may break when the generator is started. After installing the brush holders, measure the resistances across the bnrshes and terminals with a tester if they am from 5 ohms to 7.5 ohms.
3) Install the generator in the frame. Lift the generator with a chain block, install it in the frame, and tighten the nuts. (See Fig. 10-30.) RGX305, RGX305D B@nuts...4pcs. RGX405, RGX405D, RGX505, RGX505D 89 nuts . . .6 PCS. 4) Attach the side plates to the frame. Mount the side plate that reads Robin Generator Model name to the front, and the blank side plate to the rear. NOTE: Use the black bolts for tightening them. Fig. lo-30 jt$ x 13 mm bolts _ . -8 PCS.
10-3-8 FUEL TANK 1) Attach the strainer, nut, and banjo to the strainer bracket. 2) Remove the front panel from the control box, and mount the strainer bracket. 5q5~12mmbolt...2pcs. Mount the front panel again. 3) Mount the fuel tank on the side plates with rubber washers between the side plates and the fuel tank. 84x 18mmbolt...4pcs. 4) Connect the rubber pipes. First, fit the hose clamps on the rubber pipe, connect the strainer and fuel tank, fasten the rubber pipe with the hose clamps.
10-4 CONTROL BOX CHECK, DISASSEMBLY, and REASSEMBLY lo-4- 1 CHECK Check the wiring by removing the control box from the frame and taking the top lid off. 10-4-2 DISASSEMBLY 1) Remove the control box top lid, and the front panel from the control box. (See Fig. 10-34.) 2) Remove the connectors from the control box, and the wires from the connectors. NOTE: Push the tenninal locks in #e connectors with a long, pointed pin to unclock the terminals, and remove them. (See Fig. 1O-35.
11. TROUBLE-SHOOTING When the generator is in trouble, check carefully the trouble part and remedy it. (I) (Cause) YES Replace. Wrong wiring or some leads unconnected. Win? checked? (Remedy) Wire correctly. 1 OK Replace a exciting Replace AVR. Resistance outside range of 5 -7.5X2 Slip ring defective Resistance outside range of 5 -7.5a resistance Clean, replace. Check, replace. Field coil short Replace. Main coil broken Replace stator. Sub coil broken Replace stator.
Voltage too low (Remedy) Kau!w) In case AC voltage is less than lOV, voltmeter needle should not deflect. Rpm unadjusted Rpm too low t l Adjust. l Wire correct. l Adjust. Field coil shorted 0 Rotor replace. Slip ring defective 0 Clean, replace. Wrong wiring loose wire joints I OK 1 Resistance less than 4a NG OK Brush defective l Check, replace. Main coil shorted 0 Stator replace. Sub coil shorted l Stator replace. OK OK AVR broken - 61 - l Replace.
12. OPTIONS An electric starter, casters,and other parts are availableas options for the RG.X Series.The use of optional parts may require addition or changeof parts. The assemblyand disassemblyproceduresto be followed in using optional parts are describedbelow. 12-l ELECTRIC STARTER All generatorswith an electric starter are maker options becausethe crankcaserequiresspecialadditional processing.
12-1-3 CONTROL BOX (on ENGINE SIDE) 1) RGX305,305D A control box such as shown in Fig. 12-3 (1) is installedon the crankcaseoppositeto the carburetor;anda magnetic switch and diode rectifier are provided.The cylinder headis providedwith a bracket and an ignition coil. &xlOmm BOLT: 1 PC. SPRING WASHER LABEL-0 I I’ i COVER COMPL. / CONTROL _ , SPRING WASHER BOX GROMMET MAGNETIC SWITCH SPRING WASHER BOLT: 2 PCS. 5@ NUT: 2 PCS. ‘ERY (+I TO STARTING MOTOR Fig. 12-3 (1) BRACKET Fig.
2) RGX405, RGX405D, RGX505, RGX505D A control box such as shown in Fig. 12-4 is installed on the crankcaseoppositeto the carburetor.A magneticswitch and diode rectifier areinstalled. / B@x 12 SCREW: 1 PC. B@xBmm FLANGE BOLT: 2 PCS. B@xlZmrnd : BOLT: 2 PCS. SPRING WASHER \ DIODE RECTIFIER )\ MAGNETIC SWITCH GROMMET TO KEY SWITCH CONTROL BOX COMPL. 9 TO BAlTERY TO STARTING (+) MOT0 RED Fig. 12-4 12-l -4 STRAINER BRACKET The strainer bracket hasbeenchanged,andnow hasa key switch.
KEY SWITCH NUT I CONTROL BOX (TO ENGINE SIDE) / TO CONTROL I STRAINER BOX STRAINER BRACKEi Fig. 12-5 AfOE: Be sure to ground the earth terminal on tie key switch to tie generator or engine body. If the key switch is not correctly grounded, the engine will not stop. 12-l -5 CLAMP The wire connectingthe key switch to the control box is fastenedwith the clampbolted to the main bearingcover.(Fig. 12-6) CLAMP Fig.
12-l-6 FRAME (RGX305and RGX305D ONLY) Only the RGX305 and RGX305D have a frame of different width from before. The framesfor the RGX405, RGX405D, RGX505, and RGX505D remainunchanged. RGX305,305D STANDARD ELECTRIC START W - 456 mm (18.0 inch) W - 486 mm (19.1 inch) Fig. 12-7 12-l-7 CIRCUIT DIAGRAMS BLACK 1-A” - or-3 r-? ii(CDISIU1; I I ; I RFn &KEY SWITCH 1 , orKTR)/ I I I i i BATTERY ! - BROWN -YELLOW STARTING CONTROL BOX (ENGINE SIDE) MAGNETIC SWITCH Fig.
12-2 CASTER 1) The casterbaseis fitted with rubber casters75 mm in diameter,and the casterbaseis bolted to the frame. 2) The framemust be drilled to openholesfor mounting the casterbase. 3) The RGX 305 and RGX305Dhavea frame 30 mm wider than the standardframeasmentionedin 12-l-6. 4) The RGX405, RGX405D, RGX505, and RGX505Dhavespacersplacedbetweenthe frame andcasterbase. I \ CASTER Fig.
13. CIRCUIT RGX305 RGX405 RGX505 DIAGRAM (220V-23OV-24OV) (22OV-23OV-24OV) (22OV-23OV-24OV) pf I TFC ‘y--$--p& I pc /,~~--$@jb -- ; i BLUE 1 ;Kz II I --- -- CONTROL GENERATOR ~jExc ‘-‘“J/[ -- BOX j -- J ENGINE 0 ‘11 RGX305D RGX405D RGX505D 11 “=& == RECEPTACLE is equipped only for RGX505. (110/22OV-120/24OV) (110/22OV-120/24OV3 (50Hz-120/240VI REC, 11 p$$J$~pi /GREEN I i”rr\! GENERATOR ,IutiANGE : mr)r..nIII.
RGX305 RGX405 (I IOV-I 2OVl (IlO-12OV) --j APT --___ 7 ---If-- -- I pETa REC, REC, ‘0’ I I 11 “I” ; i *Y - i u F o-T I -__ -- GENERATOR RGX505D E I IGREEN A+T ! Im ILtiLUE1 -- c\ I I CONTROL BOX ENGINE --- ;;~m&,v,240v --- BLACK/ --1 I-I ! i -O’m ;EPSw REC,; I iL 11 ( --7-7-r ] 1 ! -- i d ,G MG I --- ---- GENERATOR \EC !?!I -- -- CONTROL --A-- BOX - 70 - \ EXC Y ENGINE -- - I
RGX505 (lIOV-IZOV) Ly -- 1~ CONTROL GEN&ATOR I I iI -- __-.
1 ISSUE EMD-GS0005 1 @FUJIHEAVY INDUSTRIES LTD. INDUSTRIAL PRODUCTS DIV. 2ND Subaru Bldg.
