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Robin America RGX7100 Service Manual

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SERVICE
MANUAL
Models
RGX7100, 7800
GENERATORS
PUB-GS6828
Rev. 07/09

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Summary of Contents for Robin America RGX7100

  • Page 1 SERVICE MANUAL Models RGX7100, 7800 GENERATORS PUB-GS6828 Rev. 07/09...
  • Page 2 Robin America, Inc. 905 Telser Road • Lake Zurich, IL 60047 • Phone: 847-540-7300• Fax: 847-438-5012 © Copyright 2009 Robin America, Inc. e-mail: sales@robinamerica.com • www.subarupower.com...

  • Page 3: Table Of Contents

    CONTENTS Section Title Page 1. SPECIFICATIONS............1 2..PERFORMANCE.CURVES ..

  • Page 5: Specifications

    1. SPECIFICATIONS MODEL RGX7100 RGX7800 Type Brush, self-exciting, 2-poles, single phase Voltage regulating system AVR type AC Output Rated voltage 50Hz 220, 240 60Hz 120 / 240 Rated current 50Hz 20 .9, 19 .2 25, 22 .9 60Hz 41 .7 / 20 .8...

  • Page 6: Performance.curves

    2..PERFORMANCE.CURVES •RGX7100 50Hz-220V N / A 50Hz-240V N / A - 2 -...
  • Page 7 60Hz-120/240V 8000 62.5 7000 6000 57.5 5000 4000 3000 [125] 2000 [120] 1000 Voltage (V) [115] Frequency (Hz) Output (VA) Current (A) - 3 -...
  • Page 8 •RGX7800 50Hz-220V N / A 50Hz-240V N / A - 4 -...
  • Page 9 60Hz-120/240V 9000 8000 62.5 7000 6000 57.5 5000 4000 3000 [125] 2000 [120] Voltage (V) 1000 [115] Frequency (Hz) Output (VA) Current (A) - 5 -...

  • Page 10: General.description

    3..GENERAL.DESCRIPTION RGX7100,.RGX7800 Tank cap Engine switch Control panel Fuel strainer (Fuel valve) Recoil starter handle Oil gauge (oil filler) Recoil starter Oil drain plug Fuel gauge Fuel tank Choke lever Spark plug cap Air cleaner Muffler Muffler cover - 6 -...
  • Page 11 CONTROL.PANEL (50Hz-220V, 240V) AC circuit receptacle breaker Voltmeter [Electric starter model] Key switch DC circuit Engine switch breaker Earth ( ground ) DC receptacle terminal (60Hz-120/240V) AC receptacle 30A AC receptacle 30A Idle Control Switch AC receptacle 20A Pilot lamp [Electric starter model] AC circuit breaker...
  • Page 12 SERIAL.NUMBER Serial number is stamped on the label stuck on the control box . NOTE : A lways 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 ) CONSTRUCTION •RGX7100./.RGX7800 STATOR CORE END COVER EARTH TERMINAL FLANGE BOLT BRUTH BRUSH HOLDER DIODE STACK...

  • Page 13: Range.of.applications

    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) .
  • Page 14 570 W by 1 .2 to 3 as explained in the ltem (3) . 570 (W) × 1 .2 to 3 = 684 (W) to 1710 (W) Applicable.Wattage(approx..W) Applications 50Hz 60Hz RGX7100 RGX7800 RGX7100 RGX7800 Incandescent.lamp,.Heater 4600...
  • Page 15 NOTES : Wiring between generator and electrical appliances 1. A llowable 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. C able 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.. Allowable. No.of.strands. cross.. A.W.G.. Resistance Current.Amp. current /.strands.dia. section No . No ./mm Ω/100m 0 .75 30/0 .18 2 .477 2 .5V 7 .5V 12 .5V 1 .25 50/0 .16 1 .486...

  • Page 16: Measuring.procedures

    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...
  • Page 17 (4) CIRCUIT TESTER Used for measuring resistance, etc . (5) MEGGER TESTER Used for measuring generator insulation resistance . Select one with testing voltage range of 500V . (6) TACHOMETER Use the contactless type tacho meter . - 13 -...

  • Page 18: Ac Output Measuring

    . Adjust the load and rpm . 219 - 228 239 - 248 and check that the voltage range is as specified RGX7100 118 - 127 219 - 228 239 - 248 in the following table at the rated amperage and...
  • Page 19 An insulation resistance of 1 megohm or more is normal . (The original insulation resistance at the time of shipment from the factory is 10 megohm or more .) If it is less than 1 megohm, disassemble the generator and measure the insulation resistance of the stator, rotor and control panel individually .

  • Page 20: Checking.functional.members

    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 .

  • Page 21: Circuit Breaker

    . Type Type •AC.CIRCUIT.BREAKER Model Frequency Rated.output Rated.voltage Rated.fault.current Type 220V 50Hz 4600VA RGX7100 240V N / A 60Hz 5000VA 120/240V 220V N / A 50Hz 5500VA RGX7800 240V N / A 60Hz...

  • Page 22: Stator

    Disengage connectors on the wires from stator and check the resistance between wires with a circuit tester referring to the following table . NOTE : I f 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). CIRCUIT TESTER (Resistance) Sub coil Bridge diode AVR unit •RGX7100 (Ω) FREQUENCY 50Hz 60Hz RATED.VOLTAGE 220V 240V 120/240V AC.WINDING.1 RED.-.GRAY 0 .56 0 .69...

  • Page 23: Rotor Assembly

    1) Field coil (Resistance) Remove the brush holder and measure SLIP RING resistance between the slip rings . (Ω) 50Hz 60Hz Rotor. (Slip.ring) 220V 240V 120/240V RGX7100 49.0 49.0 49.0 RGX7800 55.0 55.0 55.0 ROTOR NOTE : I f the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings. Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from from 20°C (68°F).

  • Page 24: Brush

    6-5.BRUSH 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 "...
  • Page 25 AVR unit White A .V .R . in a normal generator, or mount a mormal A .V .R . in a generator which fails to Blue generate voltage . Blue *.Checking.table.for.analogue.circuit.tester. ..RGX7100./.RGX7800 (Ω) (R±20%) Apply.black.⊖.needle.of.the.circuit.tester ⓐ ⓑ ① ② ③...

  • Page 26: Diode Stack

    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.

  • Page 27: Oil Sensor

    6-8.OIL.SENSOR (1) Disconnect wires comming from the sensor at the connection . (2) Loosen the sensor to remove it from the engine . (3) Plug the opening of oil filler hole (created after sensor is removed) with suitable means such as oil gauge .

  • Page 28: Idle Control (Optional Equipment)

    The normal idling speed by the IDLE CONTROL is as follows : RGX7100/7800 (USA model) . . . 2100 to 2500 r .p .m . The above speed setting is for cold engine condition . If the engine speed is out of adjusting range, move the solenoid backward .
  • Page 29 3) Check the wiring through ZCT on the IDLE IDEL CONTROL UNIT CONTROL UNIT . Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT . OUTPUT WIRE 4) Checking the IDLE CONTROL UNIT Check CIRCUIT TESTER the resistance between five leads of IDLE (Resistance)
  • Page 30 (2).. E NGINE.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) Checking the SOLENOID .

  • Page 31: Disassembly.and.assembly

    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 reassembly . (2) For more convenience, divide the parts into several groups and store them in boxes .
  • Page 32 7-2-2.CONTROL.PANEL.and.CONTROL.BOX CONTROL BOX (1) Remove the control panel . M6 flange bolt . . . 4 pcs . M4 flange bolt . . . 4 pcs . (2) Disconnect the connectors on the wiring from the control panel to the alternator .
  • Page 33 (3) Remove the Muffler Bracket 2 from Muffler Bracket 1 . M8 flange bolt . . . 2 pcs . (4) Loosen Nut and Washer for Exhaust Pipe . Remove the Muffler from Cylinder Head . MUFFLER M8 nut and washer .
  • Page 34 7-2-4.ALTERNATOR Disconnect the (1) Remove the end cover . connectors M6 flange bolt . . . 2 pcs . END COVER FLANGE BOLT (2) Disconnect the connectors on the wiring from the alternator . EARTH (GROUND) WIRE DIODE (3) Remove the AVR unit, brush holder and STACK...
  • Page 35 (6) Remove the rear cover . RGX7100 M6 × 180mm . . . 4 pcs . RGX7800 M6 × 195mm . . . 4 pcs . (7) Take out stator cover with crows (2 pcs) raised up by using screw driver .
  • Page 36 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 .

  • Page 37: Component Parts

    7-3.COMPONENT.PARTS (1)Generator.assembly RGX7100./.RGX7800 24.0-26.0 N-m 16.5-20.5 N-m 240-260 kgf-cm 165-205 kgf-cm 17.7-19.2 ft-lbs 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 BEARING STATOR REAR COVER DIODE STACK BRUSH HOLDER FLANGE NUT SPONGE (FILTER) 24.0-30.0 N-m...
  • Page 38 (2) Control.Box.Assy CONTROL BOX CONTROL PANEL ENGINE SWITCH AC RECEPTACLE KEY SWITCH AC CIRCUIT BREAKER FULL POWER SWITCH EARTH ( GROUND ) EARTH ( GROUND ) DC CIRCUIT TERMINAL TERMINAL BREAKER IDEL CONTROL UNIT HOUR METER DC RECEPTACLE - 34 -...
  • Page 39 (3) Fuel.Tank FUEL TANK CAP FUEL GAUGE FUEL FILTER FUEL STRAINER FUEL TANK FILTER PACKING BRACKET(TANK-A) RUBBER PIPE M6 × 16 BOLT - 35 -...
  • Page 40 (4) Muffler M6 × 12 flange bolt M8 flange bolt 6.5-8.5 N-m MUFFLER 12.0-15.0 N-m 65-85 kgf-cm BRACKET 120-150 kgf-cm DUCT (CASE) 4.8-6.3 ft-lbs 8.9-11.1 ft-lbs M8 flange nuts M8 flange bolt EX. PIPE M8 flange nuts 18.0-22.0 N-m 18.0-22.0 N-m 180-220 kgf-cm 180-220 kgf-cm 23.0-30.0 N-m...

  • Page 41: Assembly Procedures

    7-4.ASSEMBLY.PROCEDURES 7-4-1.ENGINE.and.FRAME (1) Attach the mount rubbers to the frame . FRAME UPPER Insert the setting tongue of mount rubber into the hole on the frame and tighten the nut from the bottom of the frame . M8 flange nut . . . 4 pcs . Tightening.torque.:..
  • Page 42 (3) Install 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.:..
  • Page 43 (2) Mount the rotor to the engine shaft . Tighten the through bolt . THROUGH BOLT M10 × 285 flange bolt . . . 1 pc .(RGX7100) M10 × 300 flange bolt . . . 1 pc .(RGX7800) BEARING Tightening.torque.:..
  • Page 44 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 : B e 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 .
  • Page 45 (6) Set the Mount Rubber bolts into the Mount REAR COVER Base holes . MOUNT RUBBER Don’t tighten the nut at this moment . FLANGE NUT (7) Install the brush holder, AVR unit and diode stack in the rear cover . BRUSH HOLDER M5 ×...
  • Page 46 (11) Tighten the nuts over the mount rubber bolts to fix . NOTE : W hen tightening the nuts, slightly lift the alternator assembly so that the MOUNT BASE weight is not applied to the mount rubbers. M10 flange nut . . . 2 pcs . Tightening.torque.:.. . 24.0-30.0. N•m. .240-300. kgf•cm. .(17.8-22.2.ft•lbs) NOTE : D o not tighten the nut and the bolt for Muffler Bracket 1.
  • Page 47 (13) Set the Sponge(Filter) to inside of End END COVER Cover . NOTE : H old 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.:..
  • Page 48 (2) Temporally attach the Muffler Cover (F) to the flame . M6 × 10 flange bolt . . . 4 pcs . MUFFLER COVER (F) (3) Temporally attach the muffler and gasket to the cylinder head . Temporally attach the muffler bracket 2 to Muffler bracket 1 .
  • Page 49 (4) Tightening the Muffler Cover (F) . M6 × 40 flange bolt . . . 2 pcs . Tightening.torque.:.. . 6.5-8.5. N•m. .65-85. kgf•cm. (4.8-6.3. ft•lbs) MUFFLER COVER (F) (5) Tightening the Muffler Bracket 1 . MUFFLER BRACKET1 M10 nut and M10 ×...
  • Page 50 7-4-7.FUEL.TANK (1) Hand tighten the strainer screw as far as FUEL TANK CAP it will go, loosen it again by one or two FUEL GAUGE rotations (fuel outlet faces down), then tighten the lock nut . FUEL FILTER (2) Mount the fuel tank on the frame with rubber washers between the tank flange and the frame .
  • Page 51 7-4-8.CONTROL.BOX.ASSY Refer to Section 7-5 for disassembly, checking and reassembly procedures of the control panel . (1) Put the cover onto the frame temporary . CONTROL BOX NOTE : Don't set bolt for the control box. (2) Pass wires drawn out generator and engine to the control box . (3) Connect the wires coming from the control panel with wires coming from generator and engine .

  • Page 52: Checking, Disassembly And Reassembly Of The Control Panel

    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 .

  • Page 53: Troubleshooting

    8. TROUBLESHOOTING 8-1.NO.AC.OUTPUT 8-1-1.CHECKING.STATOR (1) Remove control panel and disconnect stator wires at the connectors . (2) Measure the resistance between terminals CIRCUIT TESTER on stator leads . (Resistance) Refer to Table of Section 6-3 STATOR for normal resistance . If stator is faulty, replace it with a new one .

  • Page 54: Ac Voltage Is Too High Or Too Low

    2) Cleaning Slip rings The slip ring surfaces must be uniformly bright . Slip rings showing black spots, excessive wear, or uneven wear must be SLIP RING 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 .

  • Page 55: Ac Voltage Is Normal At No-Load, But The Load Cannot Be Applied

    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 .

  • Page 56: No Dc Output

    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 . (Ω) FREQUENCY 50Hz 60Hz RATED.VOLTAGE 220V 240V 120/240V RGX7100 49 .0 49 .0 49 .0 RGX7800 55 .0 55 .0 55 .0 - 52 -...

  • Page 57: Wiring.diagram

    9. WIRING.DIAGRAM RGX7100./.RGX7800.(50Hz-220V,240V).[Recoil.Starter.Model] ENGINE CONTROL BOX Wiring color code : Black Blk/W : Black/White Engine switch : Blue LBlu : Light blue : Brown Brn/W : Brown/White : Green Grn/W : Green/White : Orange GENERATOR : Gray circuit breaker ROTOR...
  • Page 58 RGX7100./.RGX7800.(60Hz-120/240V).[Recoil.Starter.Model] ENGINE CONTROL BOX Wiring color code : Black Engine switch Blk/W : Black/White Idle Control Switch : Blue LBlu : Light blue : Brown Brn/W : Brown/White : Green Grn/W : Green/White GENERATOR AC circuit : Orange breaker : Gray...
  • Page 60 PRINTED IN THE USA...

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