Subaru RGX3000 Service Manual
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Subaru RGX3000 Service Manual

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SERVICE
MANUAL
Models
RGX3000, 3800, 5100
GENERATORS
PUB-GS6679
Rev. 07/09

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  • Page 1 SERVICE MANUAL Models RGX3000, 3800, 5100 GENERATORS PUB-GS6679 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.

  • Page 5: Specifications

    1. SPECIFICATIONS MODEL RGX3000 RGX3800 RGX5100 Type Brush, self-exciting, 2-poles, single phase Voltage regulating system AVR type AC Output 110, 220, 110/220, 230, 240 110, 220, 110/220, 230, 240 110, 220, 110/220, 230, 240 Rated voltage 50 Hz 110,120, 220, 110/220, 120/240...

  • Page 6: Performance Curves

    2. PERFORMANCE CURVES •RGX3000 50Hz-220V 2800 2400 2000 1600 1200 Voltage (V) Frequency (Hz) Output (VA) Current (A) 50Hz-230V 3200 2800 2400 2000 1600 1200 Voltage (V) Frequency (Hz) Output (VA) Current (A) - 2 -...
  • Page 7 50Hz-240V 2800 2400 2000 1600 1200 Voltage (V) Frequency (Hz) Output (VA) Current (A) 60Hz-120V 62.5 3200 2800 57.5 2400 2000 1600 1200 Voltage (V) Frequency (Hz) Output (VA) Current (A) - 3 -...
  • Page 8 •RGX3800 50Hz-220V 4000 3600 3200 2800 2400 2000 1600 1200 Voltage (V) Frequency (Hz) Output (VA) Current (A) 50Hz-230V 3200 2800 2400 2000 1600 1200 Voltage (V) Frequency (Hz) Output (VA) Current (A) - 4 -...
  • Page 9 50Hz-240V 3600 3200 2800 2400 2000 1600 1200 Voltage (V) Frequency (Hz) Output (VA) Current (A) 60Hz-120/240V 4000 62.5 3500 3000 57.5 2500 2000 1500 [125] 1000 [120] Voltage (V) [115] Frequency (Hz) Output (VA) [110] Current (A) - 5 -...
  • Page 10 •RGX5100 50Hz-220V N / A 50Hz-230V 4800 4200 3600 3000 2400 1800 1200 Voltage (V) Frequency (Hz) Output (VA) Current (A) - 6 -...
  • Page 11 50Hz-240V N / A 60Hz-120/240V 6000 5250 62.5 4500 3750 57.5 3000 2250 [125] 1500 [120] Voltage (V) [115] Frequency (Hz) Output (VA) [110] Current (A) - 7 -...

  • Page 12: General Description

    3. GENERAL DESCRIPTION Engine switch Fuel strainer Control panel ( Fuel cock ) Recoil starter handle Recoil starter Oil gauge (oil filler) Oil drain plug Fuel gauge Tank cap Fuel tank Spark plug cap Choke lever Air cleaner Muffler - 8 -...
  • Page 13 CONTROL PANEL •RGX3000 (50Hz-220V, 240V) AC circuit Engine switch receptacle breaker Voltmeter DC circuit breaker Earth ( ground ) DC receptacle terminal (50Hz-230V) AC circuit Engine switch receptacle breaker Voltmeter DC circuit breaker Earth ( ground ) DC receptacle terminal...
  • Page 14 •RGX3800 (50Hz-220V, 240V) AC circuit Engine switch receptacle breaker Voltmeter DC circuit breaker Earth ( ground ) DC receptacle terminal (50Hz-230V) AC circuit Engine switch receptacle breaker Voltmeter DC circuit breaker Earth ( ground ) DC receptacle terminal (60Hz-120/240V) AC receptacle 30A AC circuit Pilot lamp breaker...
  • Page 15 •RGX5100 (50Hz-220V, 240V) AC circuit Engine switch breaker receptacle Voltmeter DC circuit breaker Earth ( ground ) DC receptacle terminal (50Hz-230V) AC circuit Engine switch receptacle breaker Voltmeter DC circuit breaker Earth ( ground ) DC receptacle terminal (60Hz-120/240V) AC receptacle 30A AC receptacle 30A Idle Control Switch AC receptacle 20A...
  • Page 16 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. ( Label ) - 12 -...
  • Page 17 CONSTRUCTION •RGX3000 / RGX3800 END COVER BRUSH HOLDER FLANGE BOLT EARTH TERMINAL DIODE STACK BRUSH STATOR BOLT ROTOR BOLT AVR UNIT REAR COVER FRONT COVER N-BRACKET •RGX5100 STATOR CORE END COVER EARTH TERMINAL FLANGE BOLT BRUTH BRUSH HOLDER DIODE STACK...

  • Page 18: 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 19 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 RGX3000 RGX3800 RGX5100 RGX3000 RGX3800 RGX5100 Incandescent lamp, Heater 2000 2400 3500...
  • Page 20 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 21: 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 22 (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 . - 18 -...

  • Page 23: 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 . Rated voltage Model 110V 120V 220V 230V 240V 107-115 219-228 229-238 239-248 RGX3000 107-115 118-127 219-228 239-248 107-115 219-228 229-238 239-248 RGX3800 107-115 118-127 219-228...
  • Page 24 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 25: 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 26: Circuit Breaker

    Type Type Type Type •AC CIRCUIT BREAKER Model Frequency Rated output Rated voltage Rated fault current Type 220V 50Hz 2000VA 230V RGX3000 240V 120V 60Hz 2400VA 110V / 220V 220V 50Hz 2400VA 230V RGX3800 240V 110V / 220V 60Hz 2900VA...

  • Page 27: Stator

    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). 1) RGX3000 / RGX3800 Sub coil Bridge diode AVR unit •RGX3000...

  • Page 28: Rotor Assembly

    . (Ω) 50Hz 60Hz Rotor (Slip ring) 220V 230V 240V 120V 240V 220V RGX3000 45 .0 45 .0 45 .0 45 .0 45 .0 RGX3800 49 .3 49 .3 49 .3 49 .3 49 .3...

  • Page 29: Brush

    2) Cleaning Slip rings The slip ring surfaces must be uniformly bright . Slip rings showing black spots, SLIP RING 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 30 (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 .

  • Page 31: 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 32: 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 33: 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 reassemble . 2) For more convenience, divide the parts into several groups and store them in boxes .
  • Page 34 FLANGE NUT (6) Remove the rear cover . RGX3000 M6 × 140mm . . . 3 pcs . RGX3800 M6 × 165mm . . . 3 pcs . RGX5100 M6 × 165mm . . . 4 pcs .
  • Page 35 . Fill with oil to the shaft end . 2 . Prepare a bolt with the following thread size : M10 × 1 .5 (RGX3000 / RGX3800) M12 × 1 .75 (RGX5100) 3 . Apply a few turns of seal tape around the tip of the bolt .

  • Page 36: Component Parts

    7-3 COMPONENT PARTS (1)Generator assembly RGX3000 / RGX3800 24.0-26.0 N-m 6.5-8.5 N-m 240-260 kgf-cm 65-85 kgf-cm 17.7-19.2 ft-lbs 4.8-6.3 ft-lbs 22.0-24.0 N-m 220-240 kgf-cm 16.2-17.7 ft-lbs THROUGH BOLT BOLT BOLT ROTOR FRONT COVER STATOR COVER N-BRACKET BEARING STATOR REAR COVER...
  • Page 37 RGX5100 BOLT 24.0-26.0 N-m 240-260 kgf-cm 17.7-19.2 ft-lbs BOLT 16.5-20.5 N-m 165-205 kgf-cm 12.2-15.2 ft-lbs N-BRACKET ROTOR FRONT COVER THROUGH BOLT STATOR BEARING 43-47 N-m 430-470 kgf-cm STATOR COVER 31.7-34.7 ft-lbs REAR COVER BRUSH HOLDER FLANGE NUT SPONGE (FILTER) 24.0-30.0 N-m DIODE STACK END COVER 240-300 kgf-cm...
  • Page 38 (2) Control Box Assy 50Hz - 220V 240V CONTROL BOX PILOT LAMP DC CIRCUIT BREAKER VOLTMETER ENGINE SWITCH DC RECEPTACLE AC RECEPTACLE EARTH ( GROUND ) CONTROL PANEL TERMINAL 60Hz - 120V / 240V N / A - 34 -...
  • Page 39 (3) Fuel Tank FUEL TANK CAP FUEL FILTER FUEL GAUGE FUEL TANK FUEL RUBBER PIPE STRAINER FILTER PACKING - 35 -...
  • Page 40 180-220 kgf-cm 13.3-16.2 ft-lbs MUFFLER BRACKET 1 RGX5100 MUFFLER BRACKET 2 M8 × 12 flange bolt M6 × 12 flange bolt 16.5-20.5 N-m 6.5-8.5 N-m MUFFLER 165-205 kgf-cm 65-85 kgf-cm 12.2-15.2 ft-lbs BRACKET RGX3000 4.8-6.3 ft-lbs RGX3800 MUFFLER - 36 -...

  • Page 41: Assembly Procedures

    (1) Attach 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 . RGX3000/RGX3800 M8 flange nut . . . 4 pcs .
  • Page 42 7-4-2 MUFFLER BRACKET (1) Assemble the muffler bracket to engine . RGX3000/RGX3800 Assemble muffler bracket 1 to cylinder head . Temporally attach the muffler bracket 2 to the MUFFLER muffler bracket 1 . BRACKET M6 × 12 flange bolt . . . 4 pcs .
  • Page 43 Tighten the through bolt . THROUGH BOLT RGX3000 : M8 × 222 flange bolt . . . 1 pc . RGX3800 : M8 × 235 flange bolt . . . 1 pc . BEARING Tightening torque : 22.0-24.0 N•m...
  • Page 44 NOTE : Tighten the bolts evenly and in turns. RGX3000 : M6 × 140 flange bolt . . . 3 pcs . RGX3800 : M6 × 165 flange bolt . . . 3 pcs .
  • Page 45 (5) Install the brush holder, AVR unit and diode BRUSH stack in the rear cover . HOLDER M5 × 16 bolt . . . 2 pcs . (AVR unit) AVR UNIT DIODE STACK Tightening torque : 4.0-4.5 N•m 40-45 kgf•cm...
  • Page 46 NOTE : When tightening the nuts, slightly lift the alternator assembly so that the weight is not applied to the mount MOUNT RUBBER rubbers. RGX3000/RGX3800 M8 flange nut . . . 2 pcs . Tightening torque : 16.0-20.0 N•m 160-200 kgf•cm (11.8-14.8 ft•lbs)
  • Page 47 (11) Set the Sponge(Filter) to inside of End END COVER Cover . NOTE : Hold the Sponge by tab of End Cover. SPONGE (FILTER) (12) Attach the end cover to the rear cover . M5 × 16 bolt . . . 2 pcs . Tightening torque : 4.0-4.5 N•m 40-45...
  • Page 48 M8 flange nuts (sus) . . . 2 pcs . (exhaust pipe) Tightening torque : 18.0-22.0 N•m 180-220 kgf•cm (13.3-16.2 ft•lbs) RGX3000/RGX3800 M6 × 12 flange bolt . . . 2 pcs . (bracket2) Tightening torque : 6.5-8.5 N•m RGX3000 65-85 kgf•cm...
  • Page 49 7-4-8 FUEL TANK (1) Hand tighten the strainer screw as far as FUEL TANK CAP FUEL GAUGE it will go, loosen it again by one or two FUEL FILTER 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 50 7-4-9 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 .

  • Page 51: 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 .

  • Page 52: 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 6-4 STATOR for normal resistance .

  • Page 53: 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 54: 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.
  • Page 55 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 . 50Hz - 220V 60Hz - 220V 50Hz-230V 50Hz-240V 60Hz - 120V/240V RGX3000 0 .193 0 .191 0 .238 0 .215 0 .181 RGX3800 0 .186...

  • Page 56: Wiring Diagram

    9. WIRING DIAGRAM RGX3000 (50Hz-220, 240V) ENGINE CONTROL BOX AY Wiring color code : Black Engine switch Blk/W : Black/White : Blue LBlu : Light blue : Brown Brn/W : Brown/White : Green Grn/W : Green/White : Orange GENERATOR : Gray...
  • Page 57 RGX5100 (50Hz-220, 240V) ENGINE CONTROL BOX AY 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 STATOR : Red...
  • Page 58 RGX3000 / 3800 (50Hz-230V) ENGINE CONTROL BOX AY Wiring color code : Black Engine switch Blk/W : Black/White : Blue LBlu : Light blue : Brown Brn/W : Brown/White : Green Grn/W : Green/White : Orange GENERATOR : Gray circuit breaker...
  • Page 59 RGX3000 (60Hz-120V) ENGINE CONTROL BOX AY Wiring color code : Black Engine switch Blk/W : Black/White : Blue LBlu : Light blue : Brown Brn/W : Brown/White : Green Grn/W : Green/White : Orange GENERATOR : Gray circuit breaker ROTOR...
  • Page 60 RGX3800 (60Hz-120/240V) [Electric starter model] ENGINE CONTROL BOX AY Wiring color code Idle control switch : Black Fuse Blk/W : Black/White : Blue LBlu : Light blue : Brown Brn/W : Brown/White Key switch : Green Grn/W : Green/White : Orange GENERATOR AC circuit : Gray...
  • Page 61 RGX5100 (60Hz-120/240V) [Electric starter model] ENGINE CONTROL BOX AY Wiring color code : Black Idle Control Switch Fuse Blk/W : Black/White Battery : Blue LBlu : Light blue : Brown Brn/W : Brown/White Key switch : Green Grn/W : Green/White : Orange GENERATOR AC circuit...
  • Page 64 PRINTED IN THE USA...

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