Page 1
SERVICE
MANUAL
Models
RGX2900
RGX3600
RGX4800
GENERATORS
PUB-GS2102
Rev. 05/06
Page 2
Page 3
CONTENTS
Section Title Page
1. SPECIFICATIONS
1-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2 PERFOMANCE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. GENERAL DESCRIPTION
2-1 EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-3 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2-4 LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER . . . . . . . . . . . .12
3. RANGE OF APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4. MEASURING AND CHECKING PROCEDURES
4-1 MEASURING INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4-2 AC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4-3 DC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4-4 MEASURING INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4-5 CHECKING FUNCTIONAL MEMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
5. DISASSEMBLY AND ASSEMBLY
5-1 PREPARATION AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5-2 DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5-3 REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
This manual covers only alternator and control unit portion of the generator.
As to the servicing information of engine portion, please refer to the “EX series” service manual.
The specifications and information included in this manual were in effect at the time of printing.
FUJI HEAVY INDUSTRIES LTD. reserve the right to change the specifications and to make modifications in the course of
technical progress, at anytime without notice.
No parts of this manual may be reproduced without written permission.
Page 4
– 1 –
1. SPECIFICATIONS
1-1 SPECIFICATIONS
MODEL
Type
Voltage regulating system
AC Output
Rated voltage-Frequency
VA (W)Rated output
Maximum output
Rated power factor
Safety device type
DC Output
Rated voltage
Rated current
Safety device type
Model
VA (W)
V-Hz
V
A
50Hz
60Hz
50Hz
60Hz
RGX2900
Brush-less, self-exciting, 2-poles, single phase
220-50, 240-50, 230-50, 120/240-60
2000
2400
2400
2900
Fuse-less circuit breaker
Fuse-less circuit breaker
EX17D
RGX3600 RGX4800
Condenser type
2400
2900
3000
3600
1.0
12
8.3
EX21D
3500
4100
4100
4800
EX27D
Type
Displacement
Fuel
Fuel tank capacity
Rated continuous operation
Engine Generator
Engine oil capacity
Spark plug
Starting system
Length
Width
Height
Dimension
Dry weight
Specifications are subject to change without notice.
mL
L
H
L
mm
mm
mm
kg
50Hz
60Hz
ROBIN, Air-cooled, 4-stroke, OHC
211
Automotive Unleaded Gasoline
16.6
12
0.6
BR-6HS (NGK) (Champion; RL86C)
9.5
8.4
Recoil starter
605
450
500
54
265169
7
610.5
1.0
650580
510420
540480
7048
Page 5
– 2 –
1-2 PERFOMANCE CURVES
RGX2900
(50Hz-220, 230V)
230
220
210
52
50
48
FREQUENCY (Hz) VOLTAGE (V)
5010
CURRENT (A)
3.0
2.0
1.0
0
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
OUTPUT (kVA)
(50Hz-240V)
250
240
230
52
50
48
FREQUENCY (Hz) VOLTAGE (V)
3.0
2.0
OUTPUT (kVA)
1.0
5010
0
CURRENT (A)
Maximum output 2,400 VA
Rated output 2,000 VA
Frequency 50 Hz
Rated voltage 240 V
Rated amperage 8.3 A
Page 6
– 3 –
RGX2900
(60Hz-120/240V)
●
60Hz-240V output
250
240
230
62
60
58
FREQUENCY (Hz) VOLTAGE (V)
3.0
2.0
OUTPUT (kVA)
1.0
515010
0
CURRENT (A)
Maximum output 2,900 VA
Rated output 2,400 VA
Frequency 60 Hz
Rated voltage 240 V
Rated amperage 10 A
●
60Hz-120V output
130
120
110
62
60
58
FREQUENCY (Hz) VOLTAGE (V)
3.0
2.0
OUTPUT (kVA)
1.0
10020
0
CURRENT (A)
Maximum output 2,900 VA
Rated output 2,400 VA
Frequency 60 Hz
Rated voltage 120 V
Rated amperage 20 A
Page 7
– 4 –
RGX3600
(50Hz-220, 230V)
230
220
210
52
50
48
FREQUENCY (Hz) VOLTAGE (V)
3.0
2.0
OUTPUT (kVA)
1.0
515010
0
CURRENT (A)
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
(50Hz-240V)
250
240
230
52
50
48
FREQUENCY (Hz) VOLTAGE (V)
3.0
2.0
OUTPUT (kVA)
1.0
515010
0
CURRENT (A)
Maximum output 3,000 VA
Rated output 2,400 VA
Frequency 50 Hz
Rated voltage 240 V
Rated amperage 10 A
Page 8
– 5 –
RGX3600
(60Hz-120/240V)
●
60Hz-240V output
250
240
230
62
60
58
FREQUENCY (Hz) VOLTAGE (V)
3.0
2.0
OUTPUT (kVA)
1.0
515010
0
CURRENT (A)
Maximum output 3,600 VA
Rated output 2,900 VA
Frequency 60 Hz
Rated voltage 240 V
Rated amperage 12.1 A
●
60Hz-120V output
130
120
110
62
60
58
FREQUENCY (Hz) VOLTAGE (V)
3.0
2.0
OUTPUT (kVA)
1.0
10 30020
0
CURRENT (A)
Maximum output 3,600 VA
Rated output 2,900 VA
Frequency 60 Hz
Rated voltage 120 V
Rated amperage 24.2 A
Page 9
– 6 –
RGX4800
(50Hz-220V,230V)
230
220
210
52
50
48
FREQUENCY (Hz) VOLTAGE (V)
(50Hz-240V)
5.0
Maximum output 4,100 VA
Rated output 3,500 VA
4.0
Frequency 50 Hz
Rated voltage 220V, 230 V
3.0
2.0
1.0
0
481216 200
CURRENT (A)
Rated amperage 15.9 A, 15.2 A
OUTPUT (kVA)
250
240
230
52
50
48
FREQUENCY (Hz) VOLTAGE (V)
5.0
Maximum output 4,100 VA
Rated output 3,500 VA
4.0
Frequency 50 Hz
3.0
2.0
1.0
0
481216 200
CURRENT (A)
Rated voltage 240 V
Rated amperage 14.6 A
OUTPUT (kVA)
Page 10
– 7 –
RGX4800
(60Hz-120/240V)
●
60Hz-240V output
250
240
230
62
60
58
FREQUENCY (Hz) VOLTAGE (V)
●
60Hz-120V output
5.0
4.0
Maximum output 4,800 VA
Rated output 4,100 VA
Frequency 60 Hz
Rated voltage 240 V
3.0
2.0
1.0
0
481216 200
CURRENT (A)
Rated amperage 17.1 A
OUTPUT (kVA)
130
120
110
62
60
58
FREQUENCY (Hz) VOLTAGE (V)
5.0
Maximum output 4,800 VA
Rated output 4,100 VA
4.0
Frequency 60 Hz
Rated voltage 120 V
3.0
2.0
1.0
0
8162432 400
CURRENT (A)
Rated amperage 34.2 A
OUTPUT (kVA)
Page 11
– 8 –
2. GENERAL DESCRIPTION
2-1 EXTERNAL VIEW
Fuel tank
Fuel strainer
(
Fuel cock
Recoil starter
handle
)
Engine switch
Control panel
Recoil starter
Fuel gauge
Oil gauge (oil filler)
Oil drain plug
Tank cap
Spark plug cap
Choke lever
Air cleaner
Muffler cover
Exhaust outlet
Page 12
– 9 –
2-2 CONTROL PANEL
RGX2900
(50Hz-220V, 240V)
DC output
terminal
DC circuit
breaker
RGX3600
(50Hz-220V, 240V)
AC receptacle
Earth (ground
terminal
AC receptacle
Voltmeter
AC circuit
breaker
)
Voltmeter
RGX2900
(60Hz-120/240V)
DC output
terminal
DC circuit
breaker
RGX3600
(60Hz-120/240V)
AC receptacle
Earth (ground
terminal
AC receptacle
Voltmeter
AC circuit
breaker
)
Voltmeter
DC output
terminal
DC circuit
breaker
RGX4800
(50Hz-220V, 240V)
DC output
terminal
DC circuit
breaker
Earth (ground
terminal
AC receptacle
Earth (ground
terminal
AC circuit
breaker
Voltmeter
AC circuit
breaker
)
AC circuit
breaker
)
DC output
terminal
DC circuit
breaker
Earth (ground
terminal
)
RGX4800
(60Hz-120/240V)
Full power
switch
Voltmeter
AC circuit
breaker
Earth (ground
terminal
)
DC output
terminal
AC receptacle
DC circuit
breaker
Page 13
– 10 –
RGX2900
(50Hz-230V)
AC receptacle
Voltmeter
AC circuit
breaker
DC output
terminal
RGX3600
(50Hz-230V)
DC output
terminal
DC circuit
breaker
AC receptacle
DC circuit
breaker
Earth (ground
terminal
Voltmeter
AC circuit
breaker
Earth (ground
terminal
)
)
RGX4800
(50Hz-230V)
DC output
terminal
AC receptacle
DC circuit
breaker
Voltmeter
AC circuit
breaker
Earth (ground
terminal
)
Page 14
– 11 –
2-3 ALTERNATOR
RGX2900/3600
RGX4800
Mount rubber
Ball bearing
Rotor bolt
Rotor CP Cover bolt Stator CP
Rear cover
Stator cover
Crank shaft
Front cover
Ball bearing
Rear coverMount rubber
Stator cover
Rotor CPCover bolt Stator CP
Crank shaftRotor bolt
Front cover
Page 15
– 12 –
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.
NOTE : When inquiring about your generator or ordering spare parts, always give us the Model, Serial
Number and Production Number.
PROD No. / SER No. (Label)
Page 16
– 13 –
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. 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. When using a generator for operating an electrical appliance, the power factor and
starting wattage must be taken into consideration.
In order to determine the right size generator, it is necessary to add the total wattage of all appliances to
be connected to the unit.
Refer to the followings to calculate the power consumption of each appliance or equipment by its type.
(1) Incandescent lamp, heater, etc. with a power factor of 1.0
Total power consumption must be equal to or less than the rated output of the generator.
Example : A rated 3000W generator can turn thirty 100W incandescent lamps on.
(2)
Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power factor
Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the
load. Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3
times lager than their running wattage.
Example : A rated 250 W electric drill requires a 400 W generator to start it.
NOTE 1: If a power factor correction capacitor is not applied to the fluorescent lamp, the more power
shall be required to drive the lamps.
NOTE 2: Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp.
Therefore, if the fluorescent lamp has no special indication as to the power consumption,
efficiency should be taken into account as explained in ltem (5) on the following page.
(3) Mercury lamps with a smaller power factor
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.
Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on. A rated
3000 W generator can power two or three 400 W mercury lamps.
(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.
These appliances require large starting wattage which is 3 to 5 times of running wattage.
Example : A rated 900 W compressor requires a 4500 W generator to drive it.
NOTE 1: Motor-driven appliances require the aforementioned generator output only at the starting.
Once their motors are started, the appliances consume about 1.2 to 2 times their rated power
consumption so that the excess power generated by the generator can be used for other
electrical appliances.
NOTE 2: Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting
power depending on the kind of motor and start-up load. If it is difficult to determine the
optimum generator capacity, select a generator with a larger capacity.
Page 17
– 14 –
(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.
Efficiencies of some electrical appliances are as follows :
Single-phase motor . . . . . .0.6 to 0.75 (The smaller the motor, the lower the efficiency)
Fluorescent lamp . . . . . . . .0.7 to 0.8
Example 1: A 40W fluorescent lamp means that its luminous output is 40W. Its efficiency is 0.7 and
accordingly, power consumption will be 40÷0.7= 57W. As explained in Item (2), multiply this
power consumption value of 57W by 1.2 to 2 and you will get the figure of the necessary
capacity of a generator. In other words, a generator with a rated output of 1000W capacity
can light nine to fourteen 40W fluorescent lamps.
Example 2: Generally speaking, a 400W motor means that its work load is 400W. Efficiency of this motor
is 0.7 and power consumption will be 400÷0.7= 570W. When this motor is used for a
motor-driven tool, the capacity of the generator should be multipled by 1.2 to 3 and 570W as
explained in the ltem (3). 570 (W) x 1.2 to 3 = 684 (W) to 1710 (W)
(Output of electrical appliance)
(Efficiency)
= (Power consumption)
Applicable Wattage (approx. W)
Applications
RGX2900
RGX3600 RGX4800
Incandescent lamp, Heater, etc
Fluorescent lamp, Electric tool, etc
Mercury lamp, etc
Pump, Compressor, etc
2000
1100 1200
800 900
500 550
2400
2400 2900
1200 1500
900 1100
550 650
50Hz 60Hz50Hz 60Hz50Hz 60Hz
3500 4100
1800 2100
1300 1500
800 950
Page 18
– 15 –
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. The table below
shows cables and their allowable currents for your reference.
2. Cable 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.
The table below shows voltage drops per 30 meters of cable.
2
Allowable
Current
Cable
Resistance
Ω/100m
1.486
0.952
0.517
0.332
1
100
Voltage drops per 30 meters of cable
R : Resistance (Ω/100m)
Cross
sectional
Voltage drop indicates as V= x R x I x L
I : Electric current (A)
L : Length (m)
The length of wire (L) indicates round length, which is the length from the generator
to the electrical tools and back.
2
<Example>
R : Resistance 1.25mm
= 1.48 Ω/100m
I : Electric current 10A
L : Length 30m
The voltage drop of the case described above is
30A25A20A15A10A5AAmm
＊＊＊＊8.9V4.5V121.25
＊＊＊8.6V5.7V2.8V172.0
＊＊6.2V4.7V3.1V1.6V233.5
6.0V5.0V4.0V3.0V2.0V1.0V355.5
1.48Ωx 10A x (30m x 2)
V =
100
≒ 8.9 (V)
Page 19
– 16 –
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
0 to 150 V, 0 to 330 V : Dual voltage type
(2) AMMETER
AC ammeter is necessary.
An AC ammeter with a range that can be changed
according to the current rating of a given generator
is most desirable. (About 10 A, 20 A, 100 A)
(3) FREQUENCY METER
Frequency range : To cover 45 to 65Hz
NOTE : Be careful of the frequency meter's input voltage
range.
For AC For DC
For AC For DC
Page 20
– 17 –
(5) MEAGER TESTER
Used for measuring generator insulation resistance.
Select the one with testing voltage range of 500V.
(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.
(6) TACHOMETER
Use the contactless type tacho meter for checking
engine speed.
Page 21
– 18 –
(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.
2) Fast and easy readout by digital indicator.
3) Built-in automatic battery checker indicates the
time to change batteries.
4) Tester and accessories are installed in a handy,
sturdy case for easy carrying.
The "Dr.Robin" generator tester can be ordered from Robin generator distributors by the following part number.
Dr.Robin_Part_Number_:_388-47565-08
If you do not have a "Dr.Robin" generator tester, use the instruments described in the following section for
checking generator parts.
●
SPECIFICATIONS
MODEL Dr.Robin
Part Number
Voltage
Frequency
Measuring
Range
Resistance
Condenser Capacity
Insulation Resistance
Circuit Protector
Power Source
Accessories
Dimensions (L x W x H)
2 x 6F44P (006P) Dry Cell Battery
Te st leads with needle probes ... 1 set
Te st leads with jack plugs ... 1 set
285 mm x 200 mm x 110 mm
Weight
388-47565-08
0 to 500 V AC
25 to 70 Hz
0.1 to 1,999 Ω
10 to 100μF
3MΩ
Fuse
1.6 kg
Page 22
– 19 –
4-2 AC OUTPUT MEASURING
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.
4-3 DC OUTPUT MEASURING
Measurement of DC output is executed with the switch turned ON while the current is regulated at 8.3A by
adjusting the load to the generator. If the voltage is within the range from 6V to 14V, the voltage output is
normal.
NOTE : If a battery is connected as a load to the generator, the DC output voltage will increase by
approximately 1 to 2 V.
Therefore, carefully observe the electrolyte level and do not overcharge the battery.
SWITCH
A
~
TO AC RECEPTACLE
Model
50Hz-220V,230V 60Hz-120/240V
F
Specification
50Hz-240V
RGX2900
RGX3600
207-238
226-259
V
~
226-259
113-130
LOAD
RGX4800
Voltage range
SW
To DC Terminal
Load
Page 23
– 20 –
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. (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.
●
STATOR
Measure insulation resistance between each terminal
from the stator and the stator core.
Measured insulation resistance of 1M ohm or
more is normal.
If it is less than 1M ohm, leakage current and
electric shock might occur due to faulty insulation.
Replace with new one.
●
CONTROL PANEL
With AC circuit breaker turned on, measure insulation
resistance between each portion of electrical parts
and earth (grounding) terminal or control panel itself.
Measured insulation resistance of 1M ohm or
more is normal.
If it is less than 1M ohm, leakage current and electric
shock might occur due to faulty insulation.
Replace with new one.
Any part where the insulation resistance is less than 1M
Ω has faulty insulation, and may cause electric leakage
and electric shock.
Replace the faulty part.
Page 24
– 21 –
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.
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 temperature different from 20°C (68°F).
(2) ROTOR
Measure resistance between the field coil.
NOTE1 :
When measuring the field coil resistance, be sure
to disconnect the soldering connection and take
out diode rectifier and surge absorber.
NOTE2 :
When measuring, tolerance should be considered
because of the tester inaccuracy, winding number
variation, ambient temperature etc.
Coils
(Wire color)
AC coil 1
(Black - Blue)
AC coil 2
(Red - White)
Condenser coil
(Yellow - Yellow)
DC coil
(Brown - Brown)
50Hz-220V
50Hz-230V
0.8 0.6 0.4
0.8 0.6 0.4
2.2 1.3 0.9
0.3 0.2 0.2
RGX2900 RGX4800RGX3600
50Hz-240V
0.9
0.9
2.2
0.3
60Hz-120/240V
0.6
0.6
1.7
0.2
Coil resistance (Ω)
50Hz-220V
50Hz-230V
50Hz-240V
0.7
0.7
1.3
0.2
60Hz-120/240V
0.4
0.4
1.0
0.2
50Hz-220V
50Hz-230V
50Hz-240V
0.4
0.4
0.9
0.2
60Hz-120/240V
0.3
0.3
0.6
0.1
Coil resistance (Ω)
RGX2900 RGX4800RGX3600
Field coil
1.8 1.61.6
Page 25
– 22 –
The diode rectifier and surge absorber are located as
shown in the following illustrations.
SURGE ABSORBER
DIODE
RECTIFIER
RGX4800
RGX2900/3600
(3) SURGE ABSORBER
Measure the surge absorber resistance.
Resistance (Ω)
∞Ω
SURGE ABSORBER
DIODE RECTIFIER
Page 26
– 23 –
（4）AC CIRCUIT BREAKER
Check continuity between each of two terminals at the
rear of the AC circuit breaker while it is mounted on
the control panel.
(5) DC CIRCUIT BREAKER
Make sure that there is continuity between the two
terminals of DC circuit breaker when its push button
is pressed.
AC circuit breaker
OFF
：No continuity
ON ：Continuity
RGX2900 RGX3600/4800
A
A
B
B
Page 27
– 24 –
(9) FLOAT TYPE OIL SENSOR
Check the oil sensor when it is installed on the engine.
Check that sufficient engine oil is filled in the crankcase.
Check that there is continuity between the lead wire of
oil sensor and the ground (engine crankcase) when the
oil level is above the minimum level mark of oil gauge.
Check that there is no continuity as above when the oil
level is below the minimum level mark of oil gauge.
(8) AC RECEPTACLES
Make sure that no live part wire or plastic part is burnt out.
(6) CONDENSER
Use "Dr. ROBIN" in capacitance mode to check the
capacity of condenser.
NOTE: Be sure to discharge by shorting condenser leads
each other before checking the capacitance, or the
accurate reading cannot be obtained.
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 RGX290024RGX360037RGX4800
CAPACITY(μF)
20 and 30
Oil sensor
Page 28
– 25 –
5. DISASSEMBLY AND ASSEMBLY
5-1 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.
(3) To prevent bolts and nuts from being misplaced or installed incorrectly, replace them temporarily to their
original position.
(4) Handle disassembled parts with care; clean them before reassembly using a neutral cleaning fluid.
(5) Remove the battery before disassembling the generator. (Electric start models)
(6) Use all disassembly/assembly tools properly, and use the proper tool for each specific job.
(7) Be sure to attach the foam rubber linings inside the covers on their original position when reassembling the
generator. When deformation or damage or falling-off of foam rubber lining is found, replace it with new part.
Failure to do so will result in poor performance and durability of the generator.
(8) Bind the wires and fuel pipes using wire bands as they have been done in original configuration.
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.
Page 29
– 26 –
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.
After draining, install drain screw in position.
Tool : Socket wrench (8 mm)
(3) Remove strainer and drain fuel from strainer cap.
After draining, install strainer in position.
Drain screw
Page 30
– 27 –
5-2-2 Fuel Tank
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
fixed with bolts.
Fuel tank
Cussion rubber
Control panel
side
Frange reamer bolt
Cussion rubber
Rubber
Page 31
– 28 –
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)
5-2-5 Muffler
(1) Remove screws and take out cover from engine.
Fastener : M6 - 12 mm Flange bolts (3 pcs)
Tool : Box wrench (10 mm)
Page 32
– 29 –
(3) Remove muffler and cover.
Fastener : M8 - 10 mm Flange bolts (6 pcs)
Tool : Box wrench (12 mm)
(4) Remove muffler bracket commonly fixed with alternator.
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)
(2) Remove nuts and take out exhaust pipe.
Fastener : M8 Flange nuts (2 pcs)
Tool : Box wrench (12 mm)
RGX2900/3600
Frange nut Bolt and washer AY
Muffler bracket B
Bolt and washer AY
Muffler bracket A
Page 33
– 30 –
5-2-8 Bushing
Take out bushing from rear cover, pinching with hand.
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)
5-2-7 Stator Cover
Take out stator cover with crows (2 pcs) raised up by using
screw driver.
Tool : Screwdriver
Grounding
Terminal
Page 34
– 31 –
5-2-9 Rear Cover
(1) Remove stator bolts (RGX4800) or cover bolts
(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.
5-2-10 Wire CP
Remove screw and disconnect wire CP from inside rear
cover.
Fastener : M4 -6 mm Screw
Tool : Philips (cross-head) screwdriver
(2) Take off rear cover from stator, by lightly hitting at boss
portions with plastic hammer.
Tool : Plastic hammer
Wire CP
Screw
Page 35
– 32 –
5-2-12 Through Bolts
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.
5-2-11 Stator
Take out stator, holding with hands.
Page 36
– 33 –
5-2-14 Front Cover
Remove bolts and washers and take out front cover.
Fastener : M8 - 20 mm Bolt & washers (4 pcs)
Tool : Box-end wrench (12 mm)
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.
NOTE: The hydraulic pressure inside the rotor shaft takes
apart the rotor from the engine PTO shaft.
f. Wipe off engine oil thoroughly from rotor, rotor shaft,
engine PTO shaft and front cover.
(2) Use engine oil and the bolt with seal tape as a tool for
pulling out rotor as follows;
a. Pour engine oil into the center (through bolt) hole of rotor
shaft.
b. prepare a bolt with the following thread size;
Model
RGX4800
RGX2900
RGX3600
Bolt
M12×1.5
M10×1.5
Seal tape
Page 37
– 34 –
5-3-1 Front Cover
Install front cover onto main bearing cover of the engine in
position.
Fastener :
M8 - 20 mm (4 pcs) Bolt with spring washer & washer
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
NOTE: Before installing, clean and wipe off oil and foreign
materials from taper portion of crankshaft.
RGX4800
5-3 REASSEMBLY PROCEDURES
Tightening torque : 11.3
-
13.2 N・m
(115
-
135 kgf・cm)
(8.3-9.7 ft・lbs)
Tightening torque : 22.5-24.5 N・m
(230-250 kgf・cm)
(16.6
-
18.1ft・lbs)
Tightening torque : 11.8
-
13.7 N・m
(120-140 kgf・cm)
(8.7-10.1 ft・lbs)
Page 38
– 35 –
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)
5-3-4 Wire CP
Fix wire CP at inside of rear cover in position.
Fastener : M4 -6 mm Screw
Tool : Philips (cross-head) screwdriver
(Stator bolt)
Stator bolt
fixed hole(4 places)
Grove
(4 places)
Roter
Stator
Front cover
Wire CP
Screw
Page 39
– 36 –
5-3-5 Rear Cover
(1) Install rear cover over stator, lightly hitting at the center
portion of rear cover with plastic hammer.
Tool : Plastic hammer
(2) Tighten stator bolts (RGX4800) or cover bolts
(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
5-3-6 Bushing
Insert wirings into bushing, and push bush (big grove side)
into rear cover hole.
Tightening torque : 4.5
-
5.9 N・m
(50
-
60 kgf・cm)
(3.6-4.3 ft・lbs)
RGX4800
Tightening torque : 11.8-13.7 N・m
(120-140 kgf・cm)
(8.7-10.1 ft・lbs)
Page 40
– 37 –
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)
5-3-7 Stator Cover
Set stator cover with the crow inserted into slit and bent
(2 pcs).
Tool : Screwdriver
Tightening torque : 11.8-13.7 N・m
(120
-
140 kgf・cm)
(8.7
-
10.1 ft・lbs)
Grounding
Terminal
Page 41
– 38 –
(2) Install muffler and cover.
Fastener : M8 - 10 mm Flange bolts (6 pcs)
Tool : Box wrench (12 mm)
(3) Install exhaust pipe.
Fastener : M8 Flange nuts (2 pcs)
Tool : Box wrench (12 mm)
5-3-9 Muffler
(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)
Tightening torque : 11.8
-
13.7 N・m
(120
-
140 kgf・cm)
(8.7-10.1 ft・lbs)
Tightening torque : 11.8-13.7 N・m
(120-140 kgf・cm)
(8.7
-
10.1 ft・lbs)
Page 42
– 39 –
(4) Attach exhaust pipe cover.
Fastener : M6 - 12 mm Flange bolts (3 pcs)
Tool : Box wrench (10 mm)
5-3-11 Electric Connectors
(1) Connect all wirings of the same appearance each other
between control panel and alternator.
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 N・m
(50
-
60 kgf・cm)
(3.6-4.3 ft・lbs)
Tightening torque : 4.5-5.9 N・m
(50
-
60 kgf・cm)
(3.6
-
4.3 ft・lbs)
Page 43
– 40 –
5-3-12 Fuel Tank
(1) Set fuel tank with cushion rubber sliding into stay
(2 places).
(2) Fix with bolts.
Fastener : M6 -12 mm Flange reamer bolts (2 pcs)
Tool : Box wrench (10 mm)
(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.
Tightening torque : 4.5-5.9 N・m
(50
-
60 kgf・cm)
(3.6-4.3 ft・lbs)
Cussion rubber
Stay
Control panel
side
Page 44
– 41 –
5-3-13 Fuel piping
Connect fuel pipe to carburetor with clam.
Tool : Pliers
Fuel pipe
Clamp
Carburetor
Page 45
– 42 –
6. TROUBLE SHOOTING
Check if engine speed is normal.
50Hz : 3,000rpm
60Hz : 3,600rpm
OK
Check if stator coil is normal.
Main coil
OK
Check if rotor coil is normal.
NG
NG
NG
Refer to
"Engine dose not start (Start failure )"
Replace
Replace
OK
Check if condenser coil is normal.
OK
Check if wiring is break or
improper connection.
NG
NG
Replace
Replace when wiring is break or damage.
Connect properly.
Page 46
– 43 –
No DC current
Check if DC coil of stator is normal.
OK
Check if diode rectifier is normal.
OK
Check if DC circuit breaker is normal.
OK
NG
NG
NG
Replace
Replace
Replace
Check if wiring is break or
improper connection.
NG
Replace when wiring is break or damage.
Connect properly.
Page 47
– 44 –
Engine does not start (Start failure)
Check the gasoline
in the tank
Yes
Check the oil volume
Yes
Confirm of the oil SW
E/g
GND
Fuel cock is in
the ON position
Gasoline leaks when the
carburetor drain is loosened
Tester
Yes
Yes
None
None
Resistance
value≒0 Ω
NO
NO
Open
the cock
Clean,
change
the filter
Add gasoline
Add oil (up to the
rated volume)
Change the Oil sensor unit
Check for
gasoline corrosion
OK
Remove the spark plug
and check the electrode
Wet
Attach the plug to the plug
cap, and check for sparks
by grounding the electrode
Sparks
Check the valve clearance
of the compressed pressure
(compression)
Corrosion
Dry
No spark
NG
Change
gasoline
Blockage of the fuel tube
carburetor, such as noise, etc.
・Check for dirty plugs, or gap
・Check the connection
(coupler, high tension cord)
Adjustment
Page 48
7. WIRING DIAGRAM
(60Hz-120V) RGX2900 [U.S.A. model]
ENGINE
Oil sensor
Ignition coil
Spark plug
GENERATOR
Rotor
Condenser
Winding
Field
Winding
AC
Winding 1
Winding 2
AC
DC
Winding
Blk
Blu
R
W
Brn
Brn
Y
Y
CONTROL BOX
Blk
Grn
Hour
meter
AC circuit
breaker
Hr
Diode stack
Assy
Pilot
lamp
Org
Brn/W
Condenser
PL
Engine switch
R
Rec
Circuit breaker
Grn
Wiring color code
Blk : Black
Blk/W : Black/White
Blu : Blue
LBlu : Light blue
Brn : Brown
Brn/W : Brown/White
Grn : Green
Grn/W : Green/White
Org : Orange
Gry : Gray
R : Red
W : White
Y : Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow
Pur : Purple
Grn
Gry
WH
DC output
terminal
Earth
(Ground)
terminal
(60Hz-120/240V) RGX3600 [U.S.A. model]
ENGINE
Oil sensor
Blk
Blu
R
W
Brn
Brn
Y
Y
Blk
LBlu
W
W
Hour
meter
Hr
Ignition coil
Spark plug
Solenoid
GENERATOR
Rotor
Condenser
Winding
Field
Winding
AC
Winding 1
AC
Winding 2
DC
Winding
Charge coil
CONTROL BOX
Grn
Blu
Idle control switch
AC circuit
breaker
Pilot
PL
lamp
Engine switch
Full power
switch
1
2
3
4
5
6
7
8
9
Diode stack
Assy
Condenser
3
2
1
5
Org
Brn/W
control
Idle
unit
Rec1
Circuit breaker
Rec2
Grn
G
X
W
G
Y
X
W
Rec3
DC output
terminal
G
WH
Gry
Earth
(Ground)
terminal
– 45 –
Page 49
(60Hz-120/240V) RGX4800 [U.S.A. model]
ENGINE
Oil sensor
Ignition coil
Spark plug
Solenoid
GENERATOR
Rotor
Condenser
Winding
Field
Winding
AC
Winding 1
AC
Winding 2
DC
Winding
Charge coil
Blk
Blu
R
W
Brn
Brn
Y
Y
Blk
Blu
LBlu
W
W
Hour
meter
CONTROL BOX
Grn
Idle control switch
AC circuit
breaker
Pilot
lamp
Hr
PL
Engine switch
Full power
switch
2
5
8
Diode stack
Assy
1
3
4
6
7
9
3
2
1
5
Org
Brn/W
control
CondenserCondenser
Idle
unit
Rec1
Circuit breaker
Wiring color code
Blk : Black
Blk/W : Black/White
Blu : Blue
LBlu : Light blue
Brn : Brown
Brn/W : Brown/White
Grn : Green
Grn/W : Green/White
Org : Orange
Gry : Gray
R : Red
W : White
Y : Yellow
W/Blk : White/Black
Grn/Y : Green/Yellow
y
Gr
Earth
(Ground)
terminal
Grn
Circuit
breaker
X
Y
W
Rec2
G
Rec3
G
W
X
DC output
terminal
G
WH
Pur : Purple
(60Hz-120/240V) RGX4800 w / Starter motor [U.S.A. model]
ENGINE
-
+
Battery
Oil sensor
Ignition coil
Spark plug
Solenoid
GENERATOR
Rotor
Condenser
Winding
Field
Winding
Electric
starter
Magnetiec switch
Charge coil
Blk
AC
Winding 1
Blu
R
AC
Winding 2
W
Brn
DC
Winding
Brn
Y
Y
Hour
meter
Blu
LBlu
W
W
CONTROL BOX
Idle control switch
AC circuit
breaker
Pilot
lamp
Hr
Fuse
Org
Blk
Diode stack
Assy
3
Idle
2
control
1
unit
5
Full power
switch
1
2
PL
3
4
5
6
7
8
9
Diode stack
Assy
Org
Brn/W
CondenserCondenser
Key switch
B
ST
+M
R
Grn
Rec1
G
WH
Circuit breaker
IG
-M
X
Circuit
breaker
Grn
Rec2
G
Y
W
Rec3
DC output
terminal
Grn
Gry
G
W
X
Earth
(Ground)
terminal
– 46 –
Page 50
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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