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Fuji Bikes ROBIN RGX6500 Service Manual

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RGX6500
RGX7500
FUJI HEAVY INDUSTRIES LTD.
1

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Summary of Contents for Fuji Bikes ROBIN RGX6500

  • Page 1 RGX6500 RGX7500 FUJI HEAVY INDUSTRIES LTD.
  • Page 3 1. SPECIFICATIONS...

  • Page 4: Performance Curves

    2. PERFORMANCE CURVES RGX6500 60Hz 240V RGX7500 60Hz 240V...

  • Page 5: General Description

    3. GENERAL DESCRIPTION Canister??

  • Page 6: Control Panel

    CONTROL PANEL 50Hz-220V, 240V, 60Hz-220V, 240V, 60Hz-110/, 220V...
  • Page 7 SERIAL NUMBER CONSTRUCTION RGX6500 / RGX7500 Isolator Slip Ring Through Bolt...

  • Page 8: 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.
  • Page 9 (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.
  • Page 10 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 11: Measuring Procedures

    5. MEASURING PROCEDURES...
  • Page 13 Rated voltage Model 120V 220V 240V 219 - 228 239 - 248 RGX6500 118 - 127 219 - 228 239 - 248 219 - 228 239 - 248 RGX7500 118 - 127 219 - 228 239 - 248...
  • Page 14 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 15: Checking Functional Members

    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.

  • Page 16: Rotor Assembly

    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.

  • Page 17: Automatic Voltage Regulator)

    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.
  • Page 18 (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.
  • Page 19 6-7 DIODE STACK Table 6-7a Table 6-7b Circuit inside of the diode stack is as shown in Table 6-7a. Check continuity between each terminal by using a circuit tester as shown in Table 6-7b. The diode stack is normal when continuity is as follows: * Checking table for analogue circuit tester.

  • Page 20: Specifications

    section, replace with a new one. 6-8 OIL SENSORS (1) Disconnect wires coming 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 21: Control Unit

    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.
  • Page 22 NOTE: The resistance readings vary depending on the types of circuit testers. The above table shows an example of the resistance readings measured by an ordinary analogue circuit tester with 1.5 volt battery power source. It is advisable for you to check the resistance readings using your standard circuit tester and revise the checking table.

  • Page 23: 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 24 7-2-2 CONTROL PANEL and CONTROL BOX (1) Remove the control panel. M6 flange bolt . . . 4 pcs. M4 bolt & washer . . . 4 pcs. (2) Disconnect the connectors on the wiring from the control panel to the alternator. (3) Remove the control box.
  • Page 25 (3) Remove the two bolts which fix the muffler from the generator cover. Loosen the two bolts on the muffler flange and remove the muffler from the exhaust pipe. M8 bolt and washer . . . 2 pcs. M8 spring washer … 2 pcs. Muffler Gasket …...
  • Page 26 7-2-4 ALTERNATOR (1) Remove the brush holder. (2) Remove the four bolts which fasten the rear cover to the front cover. M6 flange bolt . . . 4 pcs. (3) Remove the rear cover by hitting on the legs of rear cover with a plastic hammer to loosen.
  • Page 27 (4) Remove the stator cover. Bushing...
  • Page 28 (5) Take off the through bolt of the rotor. Apply a box wrench on the head of through bolt. Hit the wrench handle with a hammer counter-clockwise to loosen. (6) Put the engine on the work table recoil starter side down. (7) Use a bolt and oil as a tool for pulling out the rotor in the following procedures: 1.
  • Page 29 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. (8) Wipe off oil thoroughly from rotor shaft and engine PTO shaft.
  • Page 30 7-3 ASSEMBLY PROCEDURES 7-3-1 ENGINE and FRAME (1) Attach the mount rubbers to the frame. Insert the setting tongue of Isolator into the hole on the frame and tighten the nut from the bottom of the frame. M8 flange nut . . . 4 pcs. NOTE: The Isolators are selected to reduce vibration most effectively by model.

  • Page 31: Front Cover

    7-3-2 FRONT COVER Attach the front cover to the engine main bearing cover. Match the faucet joint and tighten the bolts. M8 x 20 mm bolt . . . 4 pcs. M8 spring washer . . . 4 pcs. 7-3-3 ROTOR (1) Wipe off oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft.

  • Page 32: Rear Cover

    7-3-4 STATOR (1) Put the stator in the rear cover setting the four grooves on the side of stator with thread holes of the rear cover. (2) Attach the stator cover around the stator. 7-3-5 REAR COVER (1) Put the rear cover with stator over the rotor. Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover.
  • Page 33 (3) Attach the bushing over the lead wire drawn out from the rear cover. Press the smaller end of the bushing into the window of the rear cover. (4) Attach the 5 mm terminal of the grounding wires (green / yellow) to the unpainted thread hole of the frame base plate using a 5 mm brass screw.
  • Page 34 7-3-6 BRUSH / BRUSH HOLDER (1) Install the brush holders in the rear cover. Pass the mounting screws through the brush holders, push the brush holders so that the brushes will be perpendicular to the slip rings, and tighten the screws. NOTE: There are two kinds of brush holders.
  • Page 35 7-3-7 MUFFLER and MUFFLER COVER (1) Assemble the exhaust pipe to engine. M8 nuts . . . 2 pcs. (2) Assemble the muffler bracket to the muffler. M8 flange nuts . . . 4 pcs. (3) Assemble the muffler cover (Rear) to the frame. M6 flange bolt .
  • Page 36 (4) Attach the muffler to the exhaust pipe and generator rear cover without tightening. (5) Tighten the muffler to the exhaust pipe. M8 x 20 mm bolts . . . 2 pcs. (6) Tighten the muffler bracket to the generator cover. M8 x 20 mm bolt and washer AY .
  • Page 37 7-3-8 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.
  • Page 38 7-3-9 CONTROL PANEL Mount the control panel assembly to the control box. Refer to Section 8-4 for disassembly, checking and reassembly procedures of the control panel. (1) Connect the wires from the control panel and the engine. (2) Connect the wires drawn out from the stator to the wires from the control panel.

  • Page 39: Troubleshooting

    7-4-3 REASSEMBLY (1) Install the receptacles, AC circuit breaker, terminals, switches, etc. on the control panel and wire them. NOTE: Circuit diagrams are shown in Section 11. Colored wires are used for easy identification, and are of the correct capacity and size. Use heat-resistant type wires (permissible ...

  • Page 40: Checking Rotor

    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 on stator leads. Refer to Table of Section 6-3 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.
  • Page 41 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.
  • Page 42 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”...

  • Page 43: Wiring Diagram

    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 NOTE: If the DC output is used to charge a large capacity battery or an over...
  • Page 44 (50Hz-220V, 50Hz-240V, 60Hz-220V, 60Hz-240V) RGX6500, 7500 [Electric starter model]...
  • Page 45 (50Hz-220V, 50Hz-240V, 60Hz-220V, 60Hz-240V) RGX6500, 7500...
  • Page 46 (60Hz-110/220V) RGX6500, 7500 [Electric starter model]...
  • Page 47 (60Hz-110/220V) ISSUE EMD-GSxxxx Ver. 1...

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Robin rgx7500

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