SERVICE MANUAL Models RGX7100, 7800 GENERATORS PUB-GS6828 Rev.
Robin America, Inc. 905 Telser Road • Lake Zurich, IL 60047 • Phone: 847-540-7300• Fax: 847-438-5012 e-mail: sales@robinamerica.com • www.subarupower.com © Copyright 2009 Robin America, Inc.
CONTENTS Section Title Page 1. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. PERFORMANCE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3. GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4. RANGE OF APPLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. SPECIFICATIONS MODEL RGX7100 Type RGX7800 Brush, self-exciting, 2-poles, single phase Voltage regulating system AVR type AC Output Rated voltage Generator Rated current Rated output V A VA (W) 50Hz 220, 240 60Hz 120 / 240 50Hz 20.9, 19.2 25, 22.9 60Hz 41.7 / 20.8 50 / 25 50Hz 4600 5500 60Hz 5000 6000 Rated power factor 1.0 Safety device type Fuse-less circuit breaker DC Output Rated voltage V 12 Rated current A 8.
2.
60Hz-120/240V Voltage (V) 62.5 7000 60 6000 57.
•RGX7800 50Hz-220V N/A 50Hz-240V N/A -4-
60Hz-120/240V Voltage (V) 65 8000 62.5 7000 60 6000 57.
3.
CONTROL PANEL (50Hz-220V, 240V) AC receptacle AC circuit breaker Voltmeter [Electric starter model] V Key switch DC circuit breaker Engine switch Earth (ground) terminal DC receptacle (60Hz-120/240V) AC receptacle 30A AC receptacle 30A Idle Control Switch AC receptacle 20A Pilot lamp [Electric starter model] AC circuit breaker Key switch DC circuit breaker Engine switch Full power switch Hour meter Earth (ground) terminal -7- DC receptacle
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.
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.
(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) = (Power consumption) (Efficiency) Efficiencies of some electrical appliances are as follows : Single-phase motor . . . 0.6 to 0.75 Fluorescent lamp . . . . . 0.7 to 0.
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.
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 FOR AC (2) A MMETER AC ammeter is necessary.
(4) C IRCUIT TESTER Used for measuring resistance, etc. (5) M EGGER TESTER Used for measuring generator insulation resistance. Select one with testing voltage range of 500V. (6) T ACHOMETER Use the contactless type tacho meter.
5-2 AC OUTPUT MEASURING SWITCH LOAD A ~ F V ~ 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.
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.
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.
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. PUSH type REVER type A A 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.
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).
6-4 ROTOR ASSEMBLY 1) Field coil Remove the brush holder and measure resistance between the slip rings. CIRCUIT TESTER (Resistance) SLIP RING (Ω) 50Hz Rotor. (Slip ring) 220V 240V 60Hz 120/240V RGX7100 49.0 49.0 49.0 RGX7800 55.0 55.0 55.0 ROTOR NOTE : If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings.
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. BRUSH HOLDER BRUSH 6-6 A.V.R. .
(c) I DENTIFYING 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. ① ② ③ ④ ⓐ White ⓑ Red ① Green AVR unit ② White ③ Blue ④ Blue * Checking table for analogue circuit tester.
6-7 DIODE STACK CIRCUIT TESTER (Continuity test) Brown Black White White Brown DIODE STACK Black Brown 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.
6-8 OIL SENSOR (1) D isconnect wires comming from the sensor at the connection. (2) L oosen the sensor to remove it from the engine. (3) P lug the opening of oil filler hole (created after sensor is removed) with suitable means such as oil gauge. (4) C onnect the removed wires again with the oil sensor. (5) S tart 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.
6-9 IDLE CONTROL (OPTIONAL EQUIPMENT) (1) ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS APPLIED 1) Check the wattage of load applied to the generator. If the generator is loaded over the rated wattage, the engine speed can not be increased. Most induction loads such as electric motor or electric tools or welding machine require three to five times large wattage of their ratings at starting. This starting wattage must not exceed the rated output of the generator. 2) Check the slow set r.p.m.
3) C heck the wiring through ZCT on the IDLE CONTROL UNIT. IDEL CONTROL UNIT Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT. OUTPUT WIRE ZCT 4) C hecking the IDLE CONTROL UNIT Check the resistance between five leads of IDLE CONTROL UNIT with circuit tester. 5 1 CIRCUIT TESTER (Resistance) 4 2 3 Terminal number of the IDEL CONTROL UNIT Apply black ⊖ needle of the circuit tester Circuit tester . (with battery power source 1.
(2) ENGINE SPEED IS NOT REDUCED . WHEN LOAD IS OFF 1) Check the wiring of SOLENOID. Check two leads from SOLENOID are securely connected. 2) Check the wiring of IDLE CONTROL UNIT. Check all leads from IDLE CONTROL UNIT are securely and correctly connected. 3) C hecking the SOLENOID. Measure the resistance between two leads from SOLENOID. Normal Resistance (Ω) SOLENOID 25 - 31 If the resistance is larger or smaller than this range, SOLENOID is defective, Replace with a new one.
7. DISASSEMBLY AND ASSEMBLY 7-1 PREPARATION and PRECAUTIONS (1) B e 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 reassembly. (2) F or more convenience, divide the parts into several groups and store them in boxes.
7-2-2 CONTROL PANEL and CONTROL BOX (1) R emove the control panel. M6 flange bolt . . . 4 pcs. M4 flange bolt . . . 4 pcs. CONTROL BOX (2) D isconnect the connectors on the wiring from the control panel to the alternator. (3) R emove the control box. CONTROL PANEL CONTROL PANEL M4 M6 7-2-3 MUFFLER (1) R emove the Muffler Cover (R). M6 flange bolt . . . 11 pcs. MUFFLER COVER (R) (2) L oose the bolt for Muffler Cover (F). M6 flange bolt . . . 2 pcs.
(3) R emove the Muffler Bracket 2 from Muffler Bracket 1. M8 flange bolt . . . 2 pcs. (4) L oosen Nut and Washer for Exhaust Pipe. Remove the Muffler from Cylinder Head. MUFFLER M8 nut and washer . . . 2 pcs. (Exhaust Pipe) (5) R emove the Muffler Cover (F). M6 flange bolt . . . 2 pcs. MUFFLER COVER (F) (6) R emove the Muffler Bracket 1 from Rear Cover. M8 flange bolt . . . 1 pc. (Bracket) M10 flange nut . . . 1 pc.
7-2-4 ALTERNATOR (1) R emove the end cover. M6 flange bolt . . . 2 pcs. Disconnect the connectors END COVER FLANGE BOLT (2) D isconnect the connectors on the wiring from the alternator. EARTH (GROUND) WIRE DIODE STACK (3) R emove the AVR unit, brush holder and diode stack. BRUSH HOLDER EARTH (GROUND) WIRE (4) S et the generator set with the rear cover upwards. REAR COVER AVR UNIT MOUNT RUBBER NOTE : Before starting this work, make sure engine oil has been discharged.
(6) R emove the rear cover. RGX7100 M6 × 180mm . . . 4 pcs. RGX7800 M6 × 195mm . . . 4 pcs. (7) T ake out stator cover with crows (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. 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.
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.
7-3 COMPONENT PARTS (1)Generator assembly RGX7100 / RGX7800 24.0-26.0 N-m 240-260 kgf-cm 17.7-19.2 ft-lbs 16.5-20.5 N-m 165-205 kgf-cm 12.2-15.2 ft-lbs 43.0-47.0 N-m 430-470 kgf-cm 31.7-34.7 ft-lbs THROUGH BOLT BOLT BOLT ROTOR FRONT COVER STATOR COVER N-BRACKET FAN BEARING STATOR REAR COVER DIODE STACK BRUSH HOLDER FLANGE NUT SPONGE (FILTER) 24.0-30.0 N-m 240-300 kgf-cm 17.8-22.2 ft-lbs COVER BOLT END COVER 6.5-8.5 N-m 65-85 kgf-cm 4.8-6.
(2) Control Box Assy CONTROL BOX CONTROL PANEL ENGINE SWITCH AC RECEPTACLE KEY SWITCH AC CIRCUIT BREAKER FULL POWER SWITCH EARTH (GROUND) TERMINAL HOUR METER DC CIRCUIT BREAKER DC RECEPTACLE - 34 - IDEL CONTROL UNIT
(3) Fuel Tank FUEL TANK CAP FUEL GAUGE FUEL FILTER FUEL STRAINER FUEL TANK FILTER PACKING CUP BRACKET(TANK-A) RUBBER PIPE M6 × 16 BOLT - 35 -
(4) Muffler M6 × 12 flange bolt M8 flange bolt MUFFLER BRACKET 12.0-15.0 N-m 120-150 kgf-cm 8.9-11.1 ft-lbs M8 flange nuts DUCT (CASE) M8 flange bolt A 18.0-22.0 N-m 180-220 kgf-cm 13.3-16.2 ft-lbs 23.0-30.0 N-m 230-300 kgf-cm 17.0-22.2 ft-lbs M8 flange nuts 12.0-15.0 N-m 120-150 kgf-cm 8.9-11.1 ft-lbs 6.5-8.5 N-m 65-85 kgf-cm 4.8-6.3 ft-lbs M8 flange nuts EX. PIPE 18.0-22.0 N-m 180-220 kgf-cm 13.3-16.2 ft-lbs EX. PIPE 12.0-15.0 N-m 120-150 kgf-cm 8.9-11.
7-4 ASSEMBLY PROCEDURES 7-4-1 ENGINE and FRAME (1) A ttach 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. FRAME UPPER M8 flange nut . . . 4 pcs. Tightening torque : 20.0-24.0 N•m. 200-240 kgf•cm. (14.8-17.8 ft•lbs) NOTE : There are two type of mount rubber. Before attaching the mount rubbers, make sure the position.
(3) I nstall the engine into the frame from the side of it. Insert the bolt of mount rubbers into the hole on the mount base. Tighten the nuts over the mount rubber bolts to fix. M10 flange nut . . . 2 pcs. ENGINE Tightening torque : 24.0-30.0 N•m. 240-300 kgf•cm. (17.8-22.2 ft•lbs) Tighten the temporally fixed bolt and nut for mount base. M10 flange nut & M10 × 40 flange bolt . . . 1 pc. Tightening torque : 24.0-30.0 N•m. 240-300 kgf•cm. (17.8-22.
(2) A ttach the front cover to the engine main bearing cover. TOP mark 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) 7-4-3 ROTOR (1) Wipe off oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft. FAN ROTOR (2) Mount the rotor to the engine shaft. Tighten the through bolt.
7-4-5 REAR COVER (1) Put the rear cover over the rotor. Pull out the stator wirings through the opening of the rear cover. REAR COVER NOTE : Be careful not to give cuts to wires when pulling them out from the rear cover. PLASTIC HAMMER (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. M6 × 180 flange bolt . . . 4 pcs. Tightening torque : 6.5-8.5 65-85 (4.8-6.3 N•m.
(6) S et the Mount Rubber bolts into the Mount Base holes. Don’t tighten the nut at this moment. REAR COVER MOUNT RUBBER FLANGE NUT (7) 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 40-45 (3.0-3.3 N•m. kgf•cm. ft•lbs) BRUSH HOLDER AVR UNIT DIODE STACK M5 × 16 bolt . . . 2 pcs. (brush holder) M4 × 18 bolt . . . 1 pc. (diode stack) Tightening torque : 1.5-2.0 15-20 (1.1-1.5 N•m. kgf•cm.
(11) 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. MOUNT BASE M10 flange nut . . . 2 pcs. Tightening torque : 24.0-30.0 N•m. 240-300 kgf•cm. (17.8-22.2 ft•lbs) NOTE : Do not tighten the nut and the bolt for Muffler Bracket 1. After attaching Muffler to the Engine, the nut and the bolt are fixed. (12) Set stator cover with the claw inserted into slit and bent (2 pcs).
(13) Set the Sponge(Filter) to inside of End Cover. END COVER NOTE : Hold the Sponge by tab of End Cover. SPONGE (FILTER) (14) Attach the end cover to the rear cover. M5 × 16 bolt . . . 2 pcs. Tightening torque : 4.0-4.5 40-45 (3.0-3.3 N•m. kgf•cm. ft•lbs) END COVER 7-4-6 MUFFLER and MUFFLER COVER (1) A ttach the Exhaust Pipe (with gasket), Muffler Bracket 2 and Spark Arrester to the Muffler. M8 nut and Washer . . . 2 pcs.
(2) T emporally attach the Muffler Cover (F) to the flame. M6 × 10 flange bolt . . . 4 pcs. MUFFLER COVER (F) (3) T emporally attach the muffler and gasket to the cylinder head. Temporally attach the muffler bracket 2 to Muffler bracket 1. After that, tighten the nuts and flange bolts. M8 nut . . . 2 pcs. (cylinder head) Tightening torque : 18.0-22.0 N•m. 180-220 kgf•cm. (13.2-16.2 ft•lbs) MUFFLER M8 × 16 flange bolt . . . 2 pcs. (Muffler Bracket 1) Tightening torque : 12.0-15.0 N•m.
(4) T ightening the Muffler Cover (F). M6 × 40 flange bolt . . . 2 pcs. Tightening torque : 6.5-8.5 65-85 (4.8-6.3 N•m. kgf•cm. ft•lbs) MUFFLER COVER (F) (5) T ightening the Muffler Bracket 1. MUFFLER BRACKET1 M10 nut and M10 × 40 flange bolt . . . 1 pc. (with rear cover) Tightening torque : 24.0-30.0 N•m. 240-300 kgf•cm. (17.8-22.2 ft•lbs) M8 × 16 flange bolt . . . 1 pc. Tightening torque : 16.5-20.5 N•m. 165-205 kgf•cm. (12.2-15.2 ft•lbs) (6) A ttach the muffler cover to the flame.
7-4-7 FUEL TANK (1) H and 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. FUEL TANK CAP FUEL GAUGE FUEL FILTER (2) M ount 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. FUEL STRAINER FILTER NOTE : For easy tank assembly, glue the rubber washers over the mounting holes of the frame.
7-4-8 CONTROL BOX ASSY Refer to Section 7-5 for disassembly, checking and reassembly procedures of the control panel. (1) P ut the cover onto the frame temporary. CONTROL BOX NOTE : Don't set bolt for the control box. (2) P ass wires drawn out generator and engine to the control box. (3) C onnect the wires coming from the control panel with wires coming from generator and engine. NOTE : Connect the wires of the same color. CONTROL PANEL (4) I nstall the control panel onto the control box.
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.
8. TROUBLESHOOTING 8-1 NO AC OUTPUT 8-1-1 CHECKING STATOR (1) R emove control panel and disconnect stator wires at the connectors. (2) M easure the resistance between terminals on stator leads. Refer to Table of Section 6-3 STATOR for normal resistance. If stator is faulty, replace it with a new one. CIRCUIT TESTER (Resistance) (3) C heck the insulation resistance between stator core and each stator lead using a megger tester. If insulation is bad, replace stator with a new one.
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.
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.
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.
9.
RGX7100 / RGX7800 (60Hz-120/240V) [Recoil Starter Model] ENGINE CONTROL BOX Blk Slip ring R Grn AC winding 2 W Sub coil Blu Blu Grn W Blu Blu AVR unit DC winding W Brn Bridge diode Brn R Gry Gry Org Org Blu Blu Grn Grn W W R Full Power Switch R AC winding 1 AC circuit breaker R Hour Meter STATOR Idle Control Unit W Blu 120/240V Pilot L amp Y Y/R GENERATOR ROTOR Blk : Blk/W : Blu : LBlu : Brn : Brn/W : Grn : Grn/W : Org : Gry : R : W : Y : W/Blk : Grn/Y : Pur : W W Slowdow
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