Subaru RGX2900 Service Manual
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Subaru RGX2900 Service Manual

Subaru RGX2900 Service Manual

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SERVICE
MANUAL
Models
RGX2900
RGX3600
RGX4800
GENERATORS
PUB-GS2102
Rev. 05/06

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Summary of Contents for Subaru RGX2900

  • Page 1 SERVICE MANUAL Models RGX2900 RGX3600 RGX4800 GENERATORS PUB-GS2102 Rev. 05/06...

  • Page 3: Table Of Contents

    CONTENTS Section Title Page 1. SPECIFICATIONS 1-1 SPECIFICATIONS ..........1 1-2 PERFOMANCE CURVES .

  • Page 4: Specifications

    1. SPECIFICATIONS 1-1 SPECIFICATIONS MODEL RGX2900 RGX3600 RGX4800 Type Brush-less, self-exciting, 2-poles, single phase Voltage regulating system Condenser type AC Output Rated voltage-Frequency V-Hz 220-50, 240-50, 230-50, 120/240-60 Rated output VA (W) 50Hz 2000 2400 3500 60Hz 2400 2900 4100...

  • Page 5: Perfomance Curves

    1-2 PERFOMANCE CURVES RGX2900 (50Hz-220, 230V) Maximum output 2,400 VA Rated output 2,000 VA Frequency 50 Hz Rated voltage 220V, 230 V Rated amperage 9.1 A, 8.7 A CURRENT (A) (50Hz-240V) Maximum output 2,400 VA Rated output 2,000 VA Frequency...
  • Page 6 RGX2900 (60Hz-120/240V) 60Hz-240V output Maximum output 2,900 VA Rated output 2,400 VA Frequency 60 Hz Rated voltage 240 V Rated amperage 10 A CURRENT (A) 60Hz-120V output Maximum output 2,900 VA Rated output 2,400 VA Frequency 60 Hz Rated voltage...
  • Page 7 RGX3600 (50Hz-220, 230V) Maximum output 3,000 VA Rated output 2,400 VA Frequency 50 Hz Rated voltage 220V, 230 V Rated amperage 10.9 A, 10.4 A CURRENT (A) (50Hz-240V) Maximum output 3,000 VA Rated output 2,400 VA Frequency 50 Hz Rated voltage 240 V Rated amperage 10 A...
  • Page 8 RGX3600 (60Hz-120/240V) 60Hz-240V output Maximum output 3,600 VA Rated output 2,900 VA Frequency 60 Hz Rated voltage 240 V Rated amperage 12.1 A CURRENT (A) 60Hz-120V output Maximum output 3,600 VA Rated output 2,900 VA Frequency 60 Hz Rated voltage 120 V Rated amperage 24.2 A...
  • Page 9 RGX4800 (50Hz-220V,230V) Maximum output 4,100 VA Rated output 3,500 VA Frequency 50 Hz Rated voltage 220V, 230 V Rated amperage 15.9 A, 15.2 A CURRENT (A) (50Hz-240V) Maximum output 4,100 VA Rated output 3,500 VA Frequency 50 Hz Rated voltage 240 V Rated amperage 14.6 A...
  • Page 10 RGX4800 (60Hz-120/240V) 60Hz-240V output Maximum output 4,800 VA Rated output 4,100 VA Frequency 60 Hz Rated voltage 240 V Rated amperage 17.1 A CURRENT (A) 60Hz-120V output Maximum output 4,800 VA Rated output 4,100 VA Frequency 60 Hz Rated voltage 120 V Rated amperage 34.2 A...

  • Page 11: General Description

    2. GENERAL DESCRIPTION 2-1 EXTERNAL VIEW Engine switch Fuel tank Fuel strainer ( Fuel cock ) Control panel Recoil starter handle Recoil starter Oil gauge (oil filler) Oil drain plug Fuel gauge Tank cap Spark plug cap Choke lever Air cleaner Muffler cover Exhaust outlet –...

  • Page 12: Control Panel

    2-2 CONTROL PANEL RGX2900 RGX2900 (50Hz-220V, 240V) (60Hz-120/240V) AC receptacle AC receptacle Voltmeter Voltmeter AC circuit breaker AC circuit breaker Earth ( ground ) Earth ( ground ) terminal terminal DC output DC circuit DC output DC circuit terminal breaker...
  • Page 13 RGX2900 (50Hz-230V) AC receptacle Voltmeter AC circuit breaker Earth ( ground ) terminal DC output DC circuit terminal breaker RGX3600 (50Hz-230V) AC receptacle Voltmeter AC circuit breaker Earth ( ground ) terminal DC output DC circuit terminal breaker RGX4800 (50Hz-230V)

  • Page 14: Alternator

    2-3 ALTERNATOR RGX2900/3600 Rotor CP Cover bolt Stator CP Ball bearing Crank shaft Rotor bolt Rear cover Mount rubber Stator cover Front cover RGX4800 Ball bearing Cover bolt Rotor CP Stator CP Rotor bolt Crank shaft Mount rubber Rear cover...

  • Page 15: Location Of Serial Number And Production Number

    2-4 LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER Generator serial number and production number are stamped on the label stuck on the side of fuel tank. PROD No. / SER No. (Label) NOTE : When inquiring about your generator or ordering spare parts, always give us the Model, Serial Number and Production Number.

  • Page 16: Range Of Applications

    3. 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.
  • Page 17 1.2 to 3 and 570W as explained in the ltem (3). 570 (W) x 1.2 to 3 = 684 (W) to 1710 (W) Applicable Wattage (approx. W) Applications RGX2900 RGX3600 RGX4800 50Hz...
  • Page 18 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.

  • Page 19: Measuring And Checking Procedures

    4. MEASURING AND CHECKING PROCEDURES 4-1 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 20 (4) CIRCUIT TESTER For measuring resistance, etc. NOTE : The ordinary circuit tester may cause erroneous readings due to their measuring method. Use a high-grade, precise circuit tester to check the generator components. (5) MEAGER TESTER Used for measuring generator insulation resistance. Select the one with testing voltage range of 500V.
  • Page 21 (7) "Dr.Robin" GENERATOR TESTER The "Dr.Robin" generator tester is exclusively designed for fast, easy diagnosis and repair of Robin generators. The "Dr.Robin" has the following features : 1) Functions of voltmeter, frequency meter, megger tester, capacitance meter and circuit tester are combined in one unit.

  • Page 22: Ac Output Measuring

    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. Specification Model 50Hz-220V,230V 50Hz-240V 60Hz-120/240V RGX2900 226-259 207-238 226-259 RGX3600 113-130 RGX4800 4-3 DC OUTPUT MEASURING...

  • Page 23: Measuring Insulation Resistance

    4-4 MEASURING INSULATION RESISTANCE Use a “Dr. Robin” generator tester in megger tester mode or use a megger tester to check the insulation resistance. Connect a megger tester to one of receptacle output terminals and the ground terminal, then measure the insulation resistance. An insulation resistance of 1 megohm or more is normal.

  • Page 24: Checking Functional Members

    4-5 CHECKING FUNCTIONAL MEMBERS (1) STATOR Disengage connectors on the wires from stator and check the resistance between the wires using a circuit tester referring to the table below. Coil resistance (Ω) Coils RGX2900 RGX3600 RGX4800 (Wire color) 50Hz-220V 50Hz-220V 50Hz-220V...
  • Page 25 The diode rectifier and surge absorber are located as RGX2900/3600 shown in the following illustrations. DIODE SURGE ABSORBER RECTIFIER RGX4800 SURGE ABSORBER DIODE RECTIFIER (3) SURGE ABSORBER Measure the surge absorber resistance. Resistance (Ω) – 22 –...
  • Page 26 4 AC CIRCUIT BREAKER RGX2900 RGX3600/4800 Check continuity between each of two terminals at the rear of the AC circuit breaker while it is mounted on the control panel. AC circuit breaker OFF No continuity Continuity (5) DC CIRCUIT BREAKER...
  • Page 27 If such instrument is unavailable, the condenser can be checked by replacing with new one. If the generator performs good with new condenser, the cause of trouble is defect in original condenser. MODEL RGX2900 RGX3600 RGX4800 CAPACITY(μF) 20 and 30 (8) AC RECEPTACLES Make sure that no live part wire or plastic part is burnt out.

  • Page 28: Disassembly And Assembly

    NOTE : As to detailed information for servicing procedures on engine portion, please refer to Robin engine service manual for "EX series". NOTE : Illustrations adopted for the following procedures are ones for RGX4800 model. Also illustrations for RGX2900/3600 are adopted as necessary. – 25 –...

  • Page 29: Disassembly Procedures

    5-2 DISASSEMBLY PROCEDURES 5-2-1 Fuel Draining (1) Make sure fuel strainer cock is closed. Disconnect fuel pipe from carburetor. Turn fuel cock lever to the OPEN position, and the drain fuel from fuel tank. Tool : Pliers (2) Remove drain screw from carburetor, and drain fuel from carburetor.

  • Page 30: Fuel Tank

    5-2-2 Fuel Tank Cussion rubber Remove bolts and take out fuek tank. Fastener : M6 -12 mm Flange reamer bolts (2 pcs) Tool : Box wrench (10 mm) CAUTION : Before removing fuel tank, make sure to drain fuel from fuel tank and pipings. NOTE : Don't forget to keep rubbers (2 pcs) commonly Control panel...
  • Page 31 5-2-3 Electric Connectors Remove bushing from control panel on back side, pull out wiring harness connectors, and then disconnect electric wirings. Disconnect electric wirings from engine switch terminals. 5-2-4 Control Panel Remove screws and take out control panel from frame. Fastener : M6 - 12 mm Screws (4 pcs) Tool : Box wrench (10 mm)
  • Page 32 Fastener : M8 - 20 mm Bolt & washers (2 pcs-RGX 4800) M8 Flange nuts (2 pcs) M8 - 20 mm Bolt & washers (4 pcs-RGX 2900/3600) Tool : Socket wrench (12 mm) RGX2900/3600 Frange nut Bolt and washer AY Muffler bracket B Bolt and washer AY Muffler bracket A –...
  • Page 33 5-2-6 Rear Cover Arms and Grounding Terminal Remove nuts fixing rear cover onto mounting rubbers. Fastener : M8 Flange nuts (2 pcs) Tool : Box wrench (12 mm) Grounding Terminal 5-2-7 Stator Cover Take out stator cover with crows (2 pcs) raised up by using screw driver.
  • Page 34 (RGX2900/3600). Fastener : M6 - 150 mm Stator bolts (4 pcs - RGX4800) M6 -130 mm Cover bolts (3 pcs - RGX3600) M6 -110 mm Cover bolts (3 pcs - RGX2900) Tool : Box wrench (12 mm) NOTE: For easy operation, set wooden pieces under the alternator.
  • Page 35 Remove through bolt, by tapping the wrench with plastic hammer. Fastener : M10x1.5 - 240 mm Through bolt (RGX4800) M8x1.25 - 260 mm Through bolt (RGX3600) M8x1.25 - 240 mm Through bolt (RGX2900) Tool : Box-end wrench (14 mm) and Plastic hammer 5-2-13 Rotor (1) Set the engine in the condition of recoil starter side downward.
  • Page 36 Model Bolt Seal tape RGX4800 M12 1.5 RGX2900 M10 1.5 RGX3600 c. Apply a few turns of seal tape around the tip of the bolt. d. Screw the bolt into the thread of the rotor shaft. e. Torque up the bolt by using socket wrench until rotor comes off loose.

  • Page 37: Reassembly Procedures

    (8.7-10.1 ft lbs) 5-3-2 Rotor Install rotor onto crankshaft. Fastener : M8x1.25 - 240 mm Through bolt with washer (RGX2900) M8x1.25 - 260 mm Through bolt with washer (RGX3600) M10x1.5 - 240 mm Through bolt with washer (RGX4800) RGX2900/3600 Tightening torque : 11.3-13.2 N m (115-135 kgf cm) (8.3-9.7...
  • Page 38 5-3-3 Stator Install stator into front cover. Adjust the stator grove position (4 places) so that stator bolt can be tightened later. (RGX4800) (Stator bolt) Stator bolt fixed hole(4 places) Grove (4 places) Roter Stator Front cover 5-3-4 Wire CP Fix wire CP at inside of rear cover in position.
  • Page 39 (RGX2900/3600). Fastener : M6 - 150 mm Stator bolts (4 pcs - RGX4800) M6 - 130 mm Cover bolts (3 pcs - RGX3600) M6 - 110 mm Cover bolts (3 pcs - RGX2900) Tool : Box wrench (12 mm) RGX2900/3600 Tightening torque : 4.5-5.9...
  • Page 40 5-3-7 Stator Cover Set stator cover with the crow inserted into slit and bent (2 pcs). Tool : Screwdriver 5-3-8 Rear Cover Arm and Grounding Terminal Fix rear cover arms with mount rubbers, along with grounding terminal. Fastener : M8 Flange nuts (2 pcs) Tool : Box wrench (12 mm) Tightening torque : 11.8-13.7 N m...
  • Page 41 (1) Install muffler bracket. Fastener : M8 - 20 mm Bolt & washers (2 pcs - RGX4800) M8 Flange nuts (2 pcs) M8 - 20 mm Bolt & washers (4 pcs - RGX2900/3600) Tool : Socket wrench (12 mm) Tightening torque : 11.8-13.7 N m (120-140 kgf cm) (8.7-10.1 ft lbs)
  • Page 42 (4) Attach exhaust pipe cover. Fastener : M6 - 12 mm Flange bolts (3 pcs) Tool : Box wrench (10 mm) Tightening torque : 4.5-5.9 (50-60 kgf cm) (3.6-4.3 ft lbs) 5-3-10 Control Panel Fix control panel into frame. Fastener : M6 - 12 mm Screws (4 pcs) Tool : Box wrench (10 mm) Tightening torque : 4.5-5.9...
  • Page 43 (2) Push into bushing into the hole on the back side of control panel. Also connect electric wirings with engine switch terminals. Either wiring can be connected with terminal. 5-3-12 Fuel Tank Cussion rubber (1) Set fuel tank with cushion rubber sliding into stay (2 places).
  • Page 44 5-3-13 Fuel piping Connect fuel pipe to carburetor with clam. Fuel pipe Tool : Pliers Clamp Carburetor – 41 –...

  • Page 45: Trouble Shooting

    6. TROUBLE SHOOTING Check if engine speed is normal. Refer to 50Hz : 3,000rpm "Engine dose not start (Start failure )" 60Hz : 3,600rpm Check if stator coil is normal. Replace Main coil Check if rotor coil is normal. Replace Check if condenser coil is normal.
  • Page 46 No DC current Check if DC coil of stator is normal. Replace Check if diode rectifier is normal. Replace Check if DC circuit breaker is normal. Replace Replace when wiring is break or damage. Check if wiring is break or improper connection.
  • Page 47 Engine does not start (Start failure) None Check the gasoline Add gasoline in the tank None Add oil (up to the Check the oil volume rated volume) Confirm of the oil SW Resistance value 0 Ω Change the Oil sensor unit Tester Fuel cock is in Open...

  • Page 48: Wiring Diagram

    7. WIRING DIAGRAM (50Hz-220V, 50Hz-240V) RGX2900/3600 ENGINE CONTROL BOX Wiring color code Ignition Oil sensor : Black coil control unit Blk/W : Black/White : Blue LBlu : Light blue Engine switch : Brown Brn/W : Brown/White : Green Grn/W : Green/White...
  • Page 49 (50Hz-230V) RGX2900 / 3600 ENGINE CONTROL BOX Wiring color code Ignition Oil sensor : Black coil control unit Blk/W : Black/White : Blue LBlu : Light blue Engine switch : Brown Brn/W : Brown/White : Green Grn/W : Green/White : Orange...
  • Page 50 (60Hz-120/240V) RGX2900 ENGINE CONTROL BOX Wiring color code Ignition Oil sensor : Black coil control unit Blk/W : Black/White : Blue Engine switch LBlu : Light blue : Brown Brn/W : Brown/White : Green Grn/W : Green/White : Orange GRNERATOR...
  • Page 51 (60Hz-120/240V) RGX4800 ENGINE CONTROL BOX Wiring color code Ignition Oil sensor coil : Black control unit Blk/W : Black/White : Blue Engine switch LBlu : Light blue : Brown Brn/W : Brown/White : Green Grn/W : Green/White : Orange GRNERATOR : Gray AC circuit breaker : Red...
  • Page 52 940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.com • www.robinamerica.com © Copyright 2006 Robin America, Inc. PRINTED IN THE USA...

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