Robin America RGX305, RGX305D, RGX405, RGX40 Service Manual Download Page 1

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Summary of Contents for RGX305, RGX305D, RGX405, RGX40

Page 1: ...Generator Model RGX305 305D RGX405 405D RGX505 505 D TechnicalData OverhaulInstructions ...

Page 2: ......

Page 3: ...ATOR 29 8 MEASURING PROCEDURE 32 8 1 Meters 32 8 2 AC Output Measuring 34 8 3 DC Output Measuring 34 8 4 Insulation Resistance Measuring 34 9 CHECKING FUNCTIONAL MEMBERS 36 9 1 Stator Assembly 36 9 2 Rotor Assembly 37 9 3 Brushes 38 9 4 AVR Automatic Voltage Regulator 38 9 5 No Fuse Breaker and Fuse Holder 40 9 6 Receptacle and AC Plug 41 9 7 Voltmeters 41 9 8 Diode Stack Assembly 41 9 9 Primary E...

Page 4: ...ions min _ _ lgntition System _ Starting System _____ _ _ _ Fuel Consumption Ratio _ Irry Weight _ _ _ _ _ _ _ _ __ _ Robin Air Cooled 4 Cycle Gasoline Engine _ _ _ _ _ EY25 2D EY26 WI _ _ ____ __ 252 cc 15 40 cu in _ _ _ 7HPl4000 rpm _ _ _ ___ 7 _ _ EY35DIWl 340 _ _ __ ___ __ _ 334 cc 20 39 cu in _ _ 8 5HP13600 rpm _ _ _ _ _ _ ___ Automobile Gasoline _ _ _ _ _ ___ _ 16 Liters 4 2 U S gall __ _ I ...

Page 5: ... Wl 350 EY40D _ _ _____ Displacement 388 cc 23 68 cu in _ Max Output lO OHPl3600 rpm _ _ _ Fuel Automobile Gasoline _ Fuel Tank Capacity 16 liters 4 2 U S gal __ _ ___ Oil Capacity 1 2 liters 2 6 pints __ _____ __ _ _ _ _ Revolutionlmin 50Hz 3000 rpm 60Hz 3600 rpm ___ __ _ _ __ _ _ __ Ignition System Robein Solid State Ignition System Starting System Recoil Starter Electric Starter Optional _ _ Fu...

Page 6: ...RRENT A 3 2500 5 e 0 2000 1500 T 1500 t 1000 3000 Output Max 3400W Rated 2900W Frequency 60Hz Voltage 11ov Output Max 3000W Rated 2500W Frequency 5OHZ Voltage 220v Output Max 3000W Rated 2500W Frequency 5OHZ Voltage 240V 0 bOo NOTE These diagmms show the RGX305 characteristics at I the main line frequencies and voltages The characteristics 1000 are similar to 6OHz 12OV 5OHz 1lOV and 5OHz 230V For ...

Page 7: ...OV CURRENT A I3000 t2500 1 t 2000 iii I T I k 1 1500 2 hO0 c 500 Output Max 3400W Rated 2900W Frequency 6OHZ Voltage 12OVl24OV I I 3000 Output Max 3000W Rated 2500W Frequency 5OHZ 2500 t Voltage 11OV 22OV E 2000 2 5 1 0 1500 NOTE These diagrams show the RGX305D characteristics at the main line frequencies and voltages The characteristics are similar ro 6OHz 1IOVB OV 6OHz 12OVR4OV For U S A and Can...

Page 8: ... 8 10 12 14 16 18 4500 Output Max 44OOW Rated 3700W I iNo 4 Frequency 60Hz Voltage 11ov 4000 13500 I 3OOoj Output Max 4000W Rated 3300W Frequency 50Hz 220v Voltage i 2 i 1500 44000 Output Max 4000W Rated 3300W Frequency 50Hz Voltage 240V t 2000 NOTE mesa diagrams show tie RGX405 characteristics at 1500 tie main line frequencies and voltages The characteristics are similar to 6OHz 12OV 5OHz 1lOV an...

Page 9: ... 2 49 2 1230 I 220 Output Max Rated Frequency i i Voltage s I 3000 5 e 2000 s t 1000 4400W 3700w 6OHZ 12OV 24OV Output Max 4000W Rated 3300W Frequency 5OHZ I Voltage 11OVl22OV 0 7 2 t 5 0 2m NOTE These diagrams show the RGX405D characteristi at the main line frequencies and voltages The characterisri CURRENT A ara similar to 6OHz I lOVR2OV 5OHz 12OVR4OV For U S A and Canadian markets 6 ...

Page 10: ...51 2 0 50 g 49 u 1 250 5240 3 13 230 2 0 5 10 15 20 25 I t 5000 Output Max 5500W Rated 4800W I I z 3000 5 k Frequency 60Hz Voltage 1lOV 5000 I s 3000 5 e e 2000 2 Output Max 5000W Rated 4400W Frequency 5OHZ Voltage _ 220v 1000 t Output Max 5000W Rated 4400W Frequency 5OHZ Voltage 240V 1000 I NOTE These diagmms show the RGX505 characteristics at the main line frequencies and voltages me characteris...

Page 11: ...ijII i i 0 10 20 30 40 50 CURRENT A 1 5000 I f4000 bo00 2000 looo t 5000 t i I 2 3000 5 c 2000 0 Output Max 5500W Rated 48OOw Frequency 60Hz Voltage 12OVl24OV Output Max 5000W Rated 4400W Frequency 5OHZ Voltage 11OVl22OV t 1000 NOTE These diagmms show tie RGX505D characteristics at tie main line frequencies and voltages The characteristics are similar to 6OHz 1lOVL22OV 5OHz 12OVR4OV For U S A and ...

Page 12: ...Automatic Voltage Regulator The automatic voltage regulator automatically adjusts the exciting current to hold voltage regulation down to lessthan 3 This helps prolong product life without damaging the electric devices DC Output for Battery Charging The generator can generate a DC output 12V 1OOW while generating an AC output so that batteries can be charged during AC operation In this case make s...

Page 13: ...ox type frame is so ruggedly built that two or more generators can be stacked Another convenient feature for the Robin generators 15 Wide Range of Options The elctric starter type wheels and econo throttle are availabe asoptions 10 ...

Page 14: ... CAP SPARK PLUG CAP SPEED CONTROL CHOKE LEVER STOP BUTTON I P L s1 2 5 E ii z 3 G s am 4 si I FUEL STRAINER I AIR CLEANER I RECOIL STARTER I CONTROL BOX FUEL COCK MUFFLER RECOIL STARTER HANDLE P t s E r u m t 7 1 G i i2 0 2 z i 3 si ...

Page 15: ... FUSE I REAKER AC RECEPTACLE 2 A ECEPTACLE 1 NO FUSE BREAKER AC RECEPTACLE 2 FULL POWER SWITCH 0 OAC V J E I 0 OJ AC RECEPTACLE 1 VOLTMETER NO FUSE BREAKER AC RECEPTACLE 2 MODEL RGX305 22ov 23ov 240v RGX405 22ov 23ov 240v MODEL RGX505 MODEL RGX305 RGX405 RGX505 MODEL RGX305D RGX405D RGX505D 22OV 23OV 240V llOV 12Ov llOV 120v llOV 120v 12 ...

Page 16: ...3 PANEL B DC FUS DC OUTPUT TERMINAL J DC EARTH GROUND TERMINAL FUSE IOA EARTH GROUND TERMINAL AC RECEPTACLE 3 MODEL RGX305 RGX405 RGX505 RGX305D RGX405D RGX505D EAR iH GROUND TERMINAL AC R ECEPTACLE 3 13 ...

Page 17: ...THROUGH BOLT SLIP RING COVER BOLT FRONT COVER SHAFT I I RUBBER MOUNT ROTOR COMPL I ENGINE P 1 O I I I REAR COVER STAi OR COMPL COOLI NG FAN H 8 q z 1 E I p 5 z SHAFT BkUSH HOLDER ...

Page 18: ...iver the power The copper wire is wound into the main coil sub auxiliary coil and DC coil AC output power is taken from the main coil and DC output power from the DC coil The outside diameters and laminated core thicknesses of various models are asshown below Fig 5 1 Fig 5 2 MODEL RGX305 RGX405 1 RGX505 RGX305D RGX405D 1 RGX505D yg j Table 5 1 15 ...

Page 19: ...on nected to the slip rings and direct current DC to the field coil turns the rotor and magnet The tooling fans cool the generator by drawing cooling air from the slip rings and dis charging it through the fans FAN SLIP RING BEARING Fig 5 3 Fig 5 4 MODEL I RGX305 RGX405 RGX505 RGX305D RGX405D RGX505D d mm 99 6 118 118 inch 3 92 j 4 65 4 65 I bnml 100 80 loo inch 3 94 3 15 3 94 Table 5 2 16 ...

Page 20: ... an electronic cir cuit to automatically regulate voltage 5 2 5 VOLTMETER The voltmeter comes in two types a 150V maximum type and a 300V maximum type Type voltmeter indicates generator output voltages The generators with a generated voltage of 1lOV 120V type and dual voltage type use the 15OV maximum type voltmeter and those of 22OV 23OV and 240V type specifications use the 300V maximum type volt...

Page 21: ...nd protecting objects 1 Model eciiications N F B Protecting Object N F B Protecting Object 11ov 30A Maximum current RGX305 I 220V 23OV 240V I 15A 2P2E Maximum current RGX305D 110 22OV 120 24OV 15A 2P2E Maximum current 50Hz 1 lOV 60Hz 120V 30A 1 Maximum current I RGX405 60Hz 11ov 35A Maximum current I I 22OV 230V 20A 2P2E j Maximum current I I 240v 15A 2P2E Maximum current I 110 22OV 6OHz 120 240V ...

Page 22: ...ble 5 4 shows the rated current for each receptacle Be careful not to use the receptacles and AC plugs beyond the specified limits to prevent burn ing I tz up to total i 5 amperes from two receptacles w j up to 15 amperes I a aI up to 20 amperes I up to 30 amperes See Caution Table 5 4 5 2 9 TERMINALS The terminals are for producing DC output power and come in two colors red and black The red one ...

Page 23: ...gned that human fingers will not go in RGX305 RGX305C RGX405 RGX405D RGX505 RGX505D Fig 5 12 5 2 12 RUBBER MOUNTS RUBBER VIBRATION ISOLATORS Rubber pads for controlling generator vibration and disloca tion These are made of the most suitable rubber material to optimum shape and hardness 5 2 13 PIPE FRAME Fig 5 73 The pipe frame consits of a pipe frame skeleton side plates A and B box stay and air ...

Page 24: ...OLDER SLIP RING REAR COVER RfIl T SOCKETPLUG FRONT COVER YOKE I FNClhlF POLE ASSY FIELD COIL SHAFT ARMATURE ASSY FIELD COIL RMATURE ASSY RUBBER VIBRATION ISOLATOR COOLll G FAN Fig 5 75 ROTOR COMPL I SLIP RING COVER BOLT FRONT COVER STATOR COMPL SHA FT r r II 4 II BRUSH HOLDER ROTOR COMPL REAR COVER SHAFT Fig 5 16 21 ...

Page 25: ...ill The revolving field type falls in this latter category The pole serving as an electromagnet rotattes and armature which consists of a conductor remains still The features of the revolving field type are asfollows a b 4 onlytwosliprings As generator applications diversified it became necessaryfor generators to meet increasingly varied conditions involv ing AC output DC output dual voltage three...

Page 26: ...ed in the stator coils main coil sub coil and DC coil The voltage generated in the sub coils is operated by the AVR to feed a current to in crease the field coil current See Fig 5 17 B As a result the rotor magnetism increases This operation is repeated to generate the rated voltage at 5OHz or 6OHz in the main coil and DC coil 5 3 3 VOLTAGE REGULATING MECHANISM Connect a load to the AC output term...

Page 27: ... the rated output can be outputted by combining the outputs of the two 12OV receptacles The RGX Seriesshown in Fig 5 19 changesthe connection of MC1 and MC2 to seriesor parallel with the full power switch When the full power switch is shifted to the 12OV 24OV postion the switch is up asindicated by the solid line in Fig 5 19 and connects MC 1 and MC2 in seriesasshown in Fig 5 l 8 In this case volt...

Page 28: ...mploy a solid state ignition system For the RGX305 RGX305D refer to the section on EY25 CD1 in the Electrical Ignition Service Manual For the RGX405 RGX405D and RGX505 RGX505D refer to the section on Robin Solid State Ignition in the EY35 and EY40 Service Manuals All models use a primary exciting coil or lighting coil of special performance and lead length NOTE Be careful not to use an exciting co...

Page 29: ... inside the blower housing WIRE BLOWER HOUSING Fig 5 20 21 5 4 3 FUEL SYSTEM The large sized 164ter fuel tank is mounted in the frame The fuel piping was changed asa result asshown in Fig 5 21 FUEL GAUGE FUEL TANK RUBBER to CARBURETOR HOSE CLAMP RUBBER PIPE 2 HOSE CLAMP Fig 5 27 FUEL STRAINER 26 ...

Page 30: ... C CAP RUBBER HEAD COVER TO MUFF TO CARBURETOR CYLINDER BAFFLE 3 RGX305 RGX305D LEA BAFFLE CARBURETOR RGX405 RGX405D RGX505 RGX505D SIDE Fig 5 22 5 4 5 OTHERS The RGX405 RGX405D and RGX505 RGX505D are fitted with an iron plate under the engine to reduce vibration The oil dram parts shown in Fig 5 23 are newly employed for these models to solve the problem of inconvenience in oil change CRANKCASE l...

Page 31: ...ry it before starting Don t pour water over the generator directly or wash it with water If the generator is wet with water the insulations wilI be adversely affected and may causecurrent leakage and electric shock 6 Do not connect the generator to the commercial power lines This may causea short circuit or destroy the generator Use a transfer switch for connecting with indoor wiring NOTE The part...

Page 32: ...scent lamp generally does not indicate the power consumption but indicates the ou ut of the lamp Therefore if the fluorescent lamp has no s oecial indication as to the power conwmption or input power efficiency should be taken into accounts as explained in Item 5 on the folio wingpage Electric tools etc that are driven by a motor Power 1 2 to 3 times the power consumption of a motor driven tool is...

Page 33: ...erator with a rated output of 1000 W capacity can light 9 14 40 W fluorescent lamps Example 2 Generally speaking a 400 W motor means that its work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570 W When this motor is used for a motor driven tool the capa city of the generator should be multipled by 1 2 to 3 and 570 W as explained in the item 3 Moreover in cas...

Page 34: ...he load electrical product decreases As a result the load can be damaged table 7 2 shows voltage drops per 100 meters of cable Nominal cross section Currant Amp I mm1 I A i NoJmm SWlOOm 1 1A 1 3A 1 5A 1 8A 1 10A 1 12A 1 15A 1 1 0 75 1 7 1 3010 18 2 477 1 2 5V 8V 1 12 5V 1 1 1 1 I 1 25 12 1 5010 18 1 486 i 1 5v 5v 7 5v 1 12v 15V 1 18V 1 1 2 0 17 j 3710 26 0 952 1v 1 3v 1 5v j 8V 1 1OV 12v I 15v 3 5...

Page 35: ... 0 to 150 V 0 to 300 V Dual voltage type The DC voltmeter range is approximately from 0 to 30V FOR AC FOR DC Fig 8 1 8 l 2 AMMETERS AC and DC ar meters are 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 The DC ammeter range is approximately from 0 to 15 A FOR AC FOR DC Fig 8 2 8 l 3 FREQUENCY MET...

Page 36: ...e with testing voltage range of 5OOV 8 1 6 TACHOMETER There are various types of tachometers such ascontact less type contact type and strobe type The contact type can be used only when the generator and engine have been dis assembled The contact less type is recommended Fig 8 4 Fig 8 5 CONTACT LESS TYPE STRbBE TYPE Fig 8 6 33 ...

Page 37: ...ad check that the voltage is within the range of 13 to 11V NOTE If a battery is connected as the load the output voltage increases by about I to ZV possibly causing battery over charge Control battery liquid level during charging to prevent overcharging 84 MEASURING INSULATION RESISTANCE Connect ameggertester to one of the two receptable output terminals and the ground terminal then measurethe ins...

Page 38: ...en the core and one of the slip rings of the rotor Fig 8 11 CONTROL BOX Measure the insulation between the live parts and the casing or grounded part Close the no fuse breaker first then measure it Any part which has an insulation resistance of less than 1 megohm has a faulty insulation which can cause electric shock or leakage Replace such parts Fig 8 12 35 ...

Page 39: ...gin of er ror must be taken into account when reading the tester agains the values shown in the Tables lt is measured by wheatstone bridge in regularly ln this time please care enough not to exist the contact registance STATOR ASS Y RGX305 RGX305D Fig 9 1 l 50Hz 220V 23QV 24QV l 50Hz 11OV 11OVf22QV 12OVf24QV l 60Hz 1lOV 12OV 1lOV 22OV 12OVI24OV RGX405 RGX405D l 50Hz 22OV 23QV 24QV 50Hz 1IQV 1lQVf2...

Page 40: ...e resistance is normal if it is anywhere from 5 ohms to 7 5 ohms TESTER Fig 9 2 9 2 2 MEASURING INSULATION RESISTANCE Refer to 8 4 MEASURING INSULATION RESISTANCE 9 2 3 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 ri...

Page 41: ... AUTOMATIC VOLTAGE REGULATOR AVR trouble may be identified by simply looking at the AVR or by checking the inter lead resistance with a tester or actu ally mounting it ln the generator and operating it 9 4 l AVR TROUBLE IDENTIFICATION by APPEARANCE If an AVR electronic part is burnt dark or the surface epoxy resin melted it often indicates indicates AVR trouble 9 4 2 IDENTIFYING AVR TROUBLE by CHE...

Page 42: ...Another existence 150K 25OKfi lOKR 70KR 1 One wire OR lead resistance 00 Another 00 existence 00 j 220K 25OKR 3OOKR 00 llOK 125KS2 m 15OKa 00 220K 250Ka 1 00 lead resistance 1 00 llOK 125Kn I 00 existence 00 i 330K 500KSZ I 10K 70Ka f lead resistance 00 j 150K 256KS2 j IOK 7OKQ 8 existence 00 300K 5OOKS2 i 10K 40KS2 m 00 150K 25OKR 10K 40KQ 00 Upper rows are for the 220 230 240V specifications low...

Page 43: ... type the two pairs of terminals must carry current Fig 9 6 9 5 2 NO FUSE BREAKER Check that a fuse is in the fuse holder and check its conti nuity with a tester See Fig 9 7 If it carries current it is normal FUSE HOLDER If there is no current take the fuse out and check it for continuity If the fuse carries current the fuse holder is faulty If the fuse carries no current replace it with a fuse of...

Page 44: ...rmal 9 8 DIODE STACK ASSEMBLY e I Fig 9 9 VOLTMETER Fig 9 8 Fig 9 10 The internal circuitry of the diode stack assembly is as shown in Fig 9 9 Check inter terminal continuity with a tester as shown in Fig 9 10 to see that the results are as shown in Table 9 8 I TERMINAL CURRENT TERMINAL NOTE A 4 c B Current flows from A I to B 1 J 1 1 C D Current does not flow from C PI to D l 1 I Check both termi...

Page 45: ...ry exciting circuit asfollows A Disconnect the control box and operate the generator at the rated rpm Disconnect the two yellow wires from the excit B ing coil to the AVR and momentarily connect the positive and negative leads of a 12V battery in their place If no output voltage is generated reconnect the battery leads the other way If output voltage is generated the exciting coil is defective If ...

Page 46: ...d suspend the wiling i control box front panel with a wire I 4 screw 6 PCS I 2 Remove the strainer bracket SeeFig I i 8 mm spanner I 10 2 Remove the strainer bracket bolts on the bottom of the control box 54 bolt _ 2 PCS I 3 Temporarily f ten the front panel 1 Be careful not to pinch screwdriver Temporarily fasten it with two or the wiring three screws removed in Step 1 4 Remove the rubber pipe i ...

Page 47: ...e the connector and coupler ing are so designed asto I that are connect to the rear of the I lock so push and pull control box out asshown in Fig lo 5 I I I I 1 Fig 10 5 2 Remove the control box bolts and 1Be careful not to drop the 10 mm spanner the control box the control box Remove the bolts from the frame and box stay I Fig 10 6 44 ...

Page 48: ... RGX405 RGX405D RGX505 RGX The bolts are welded to 505D Remove the nuts that fasten the engine base the engine to the engine base and the nuts that fasten the rubber mount the generator SeeFig 1O 7 I ag nut 6 PCS I I 4 Remove the generator Be careful of the genera 1 See Fig 10 8 tor balance Lift the generator with a chain block j and remove the frame I 5 Remove the rubber mount I Rubber mount is f...

Page 49: ... i 1 Loosen the cover bolts and remove them I I RGX305 RGX305D 10 mm spanner or 6 bolt 3 PCS i box spanner RGX405 RGX405D RGX505 RGX505D i 13 mm spanner or a box spanner 89 bolt 4 PCS I 2 Remove the stator cover Turn up the stator cover edge and 1 screwdriver remove the stator cover I 3 Remove the rear cover The type that usesa con I See Fig lo 10 nectar does not permit Lightly tap the rear cover ...

Page 50: ...Fig I 10 12 i 2 Separate the stator and rear cover Separate the connector and wire Rush the terminal locks in the con nector with a pm having a needle like sharp point and remove the terminals See Fig lo 13 f 1 L I t sever hammer the wind ings and leads Be careful not to peel the stator steel sheets It is not necessaryto separatethe stator and rear cover except when re placing the stator rear cove...

Page 51: ...t wrench hard counterclockwise with a ham 14mm mer to loosen and remove the through bolt See Fig 10 14 1Ogbolt 1pee 2 Remove the rotor Never strike the slip rings Strike the rotor by the core with a plas or windings tic hammer and remove the rotor from the engine taper shaft If the rotor does not come out change its angle and strike it again See Fig lo 15 Fig 10 14 Fig lo 15 48 ...

Page 52: ...G50 31 0 79 i 0 47 0 06 RGX405 1 235mm 33mm f lOmm mm 20mm 12mm 1 5mm RGX405D 9 3 1 3 j 40 39 bO 31 0 79 0 47 0 06 RGX505 266mm 33mm RGX505D i 10 5 1 3 1 lOmm 8mm 20mm i 12mm 1 5mm i qlo 39 0 31 0 79 0 47 I 0 06 Table 1O 1 Parts numbers of the rotor puller are as follows I Parts No Parts Name 1 Description I I 367 543308 i SHAFT i RGX305 RGX305 I I 1 RGX405 RGX405D I RGX505 RGX505D 367 543308 BOLT...

Page 53: ... the P T 0 shaft on the side of engine 3 As shown in Fig lo 16 screw up the bolt pushing the rotor puller shaft and remove the rotor Fig lo 16 1 Order Item I Procedure I Remarks I TOOI 1 8 Front cover 1 Remove the front cover I 13mm box spanner Remove the bolts that fasten the en I gine s main bearing cover to the front cover I 8 bolt 4pcs 1 50 ...

Page 54: ... shaft and the female tapered shaft of the rotor shaft of oil and other foreign matter with waste cloth Install the rotor and tighten the through bolt See Fig 10 18 Tighten the through bolt by striking a box spanner or socket wrench hard clockwise NOTE The outside diameter and lamination thick ness of tie rotor is shown in Item 12 Rotor Para graph 5 2 Functions NOTE The tiro rgh bolt is shaped as ...

Page 55: ...oBRUSH HO GREEN AND FRONT COVER o DIODE STACK 0 BLUE WIRES ATOR COVER Fig lo 19 10 3 4 REAR COVER 1 2 3 Install the diode stack in the rear cover See Fig lo 21 40 x 18 mm screw 1 pc Wire the stator to the diode stack The diodes are marked asshown in Fig 10 22 Connect the two blue wires to the two points marked 0 Connect the orange wire to the point marked 0 Connect the brown wire to the point mark...

Page 56: ...6mm 130 mm 25 mm I RGX305D i 0 24 inch j 5 12 inch 0 98 inch RGX405 1 8mm 135 mm 25 mm RGX405D 0 31 inch 5 31 inch 0 98 inch RGX505 8mm I 155mm 35 mm RGX505D I 0 31 inch i 6 10 inch i 1 38 inch 6 Install the stator cover RGX305 RGX305D Fit the stator cover between the stator and cover bolts until it covers all the cover bolts and fold back the edge RGX405 RGX405D and RGX505 RGX505D Fit the stator ...

Page 57: ...WHITE RED BROWN GREEN RGX505 220 230 24OV WHITE RED WHITE RED BROWN ORANGE WHITE RED BROWN GREEN I I RGX305D 405D I I RGX305 405 YELLOW BRACK I I WHITE RED BROWN ORANGE WHITE RED 1 BROWN GREEN 110 120v I I Table 10 5 10 3 5 BRUSH HOLDER 1 Install the brush holders in the rear cover Passthe mounting screws through the brush holders push the brush holders so that the brushes will be per pendicular t...

Page 58: ...rush holders Connect the green wire to the stator end and the brown wire to the bearing end See Fig 10 28 3 Install the brush cover RGX305 RGX305D 4tpx 8 mm screw 2 PCS RGX405 RGX405D RGX505 RGX505D 5 xlOmmscrew 2pcs 10 3 6 FRAME 1 Attach the rubber mounts to the frame Tighten the rubber mounts on the nuts welded to the bottom of the frame RGX305 RGX305D 4 PCS RGX405 RGX405D RGX505 RGX505D 6 pcs N...

Page 59: ... bolts for tightening them jt x 13 mm bolts _ 8 PCS 5 Attach the air guide to the box stay 5 xl5mmbolt 2pcs 6 Attach the box stay to the side plates 6r x15mmbolt 2pcs 10 3 7 CONTROL BOX 1 2 Fasten the control box to the frame and box stay See Fig 10 31 6 xl2mmbolt 4pcs Wire the primary exciting circuit Connect the two yellow wires of the automatic volt age regulator in the control box to the excit...

Page 60: ...ith rubber washers between the side plates and the fuel tank 84x 18mmbolt 4pcs 4 Connect the rubber pipes First fit the hose clamps on the rubber pipe connect the strainer and fuel tank fasten the rubber pipe with the hose clamps NOTE Keep the strainer in the off position until the pipe has been connected See F 10 33 FUEL TANK FUEL GAUGE RUBBER PIPE 1 II I I HOSE CLAMPS STRAINER u I gK q RUBBER PI...

Page 61: ... full po rswitch have their es soldered to them Unsolder their wires first and then remove them 10 4 3 REASSEMBLY Reversethe disassembly procedure NOTE The wires are colored for identification of capacity and gauge Be wre to use the same wires as disconnected Fig 70 34 9 PUSH Fig 1035 NOTES 1 RGX505 1lOV 1aV RGX505D Connectors are used for terminals 171 through 10 only 7rhe others are pin terminal...

Page 62: ...g or some leads unconnected 1 OK Resistance outside range of 5 7 5X2 Slip ring defective Resistance outside range of 5 7 5a Field coil short Main coil broken Sub coil broken resistance in 9 l I AVR broken Replace Wire correctly Replace exciting coil a Replace AVR Clean replace Check replace Replace Replace stator Replace stator Replace AVR 59 ...

Page 63: ......

Page 64: ...usted t loose wire joints Wrong wiring IOK 1 Resistance less than 4a Field coil shorted NG Slip ring defective OK Brush defective Remedy l Adjust l Wire correct l Adjust 0 Rotor replace 0 Clean replace l Check replace Main coil shorted 0 Stator replace OK Sub coil shorted l Stator replace OK AVR broken l Replace 61 ...

Page 65: ......

Page 66: ...in GasolineEngineService m ral Theenginepartsandgenerator partsexclusive to theRGX Seriesareexplainedbelow 12 l l EXCITING COIL The standardmodelshavetwo wires for primary exciting but oneswith anelectric starterhavetwo additionalwiresfor battery chargingfor atotal of four wires Fig 12 1 49 FOR PRIMARY EXCITATION RGX305 RGX305D BROWN WIRE RGXa5 RGX405D _ YELLOW RGX505 RGX505D WIRE FOR PRIMARY EXCI...

Page 67: ...o thecarburetor andamagnetic switchanddioderectifier areprovided Thecylinderheadis providedwith abracketandanignition coil xlOmm BOLT 1 PC SPRING WASHER LABEL 0 COVER COMPL SPRING WASHER I I i _ CONTROL BOX GROMMET MAGNETIC SWITCH SPRING WASHER BOLT 2 PCS 5 NUT 2 PCS TO STARTING MOTOR Fig 12 3 1 ERY I BRACKET Fig 12 3 21 64 ...

Page 68: ...r areinstalled DIODE RECTIFIER B xlZmrnd B x 12 SCREW 1 PC BOLT 2 PCS 12 l 4 STRAINER BRACKET MAGNETIC SWITCH B xBmm FLANGE BOLT 2 PCS SPRING WASHER GROMMET CONTROL BOX COMPL TO STARTING MOT0 Fig 12 4 TO KEY SWITCH 9 TO BAlTERY RED The strainerbrackethasbeenchanged andnowhasakey switch Thekey switch iswired to the control box on theengine side Fig 12 5 65 ...

Page 69: ...Be sure to ground the earth terminal on tie key switch to tie generator or engine body If the key switch is not correctly grounded the engine will not stop 12 l 5 CLAMP The wire connectingthe key switch to the control box is fastenedwith the clampboltedto themainbearingcover Fig 12 6 CLAMP Fig 12 6 66 ...

Page 70: ...r the RGX405 RGX405D RGX505 andRGX505Dremainunchanged RGX305 305D STANDARD ELECTRIC START Fig 12 7 12 l 7 CIRCUIT DIAGRAMS BLACK 1 A 3 r i SIU I I RFn KEY SWITCH or i CDI 1 I 1 orKTR i i I I I W 456 mm 18 0 inch W 486 mm 19 1 inch BATTERY STARTING MOTOR CONTROL BOX MAGNETIC BROWN YELLOW ENGINE SIDE SWITCH Fig 72 8 67 ...

Page 71: ...aseis boltedto the frame 2 Theframemustbedrilled to openholesfor mountingthecasterbase 3 TheRGX 305andRGX305Dhaveaframe30 mm widerthan thestandardframeasmentionedin 12 l 6 4 TheRGX405 RGX405D RGX505 andRGX505Dhavespacers placedbetweentheframeandcasterbase I CASTER BASE CASTER Fig 12 9 68 ...

Page 72: ...I I pc jb i jExc Kz 11 BLUE 1 I I J j I J GENERATOR CONTROL BOX ENGINE 0 11 RECEPTACLE is equipped only for RGX505 RGX305D 110 22OV 120 24OV RGX405D 110 22OV 120 24OV3 RGX505D 50Hz 120 240VI REC 11 p J pi SIU 1 IutiANGE i I i rr mr r nIII 1 I T c GREEN i III I A ji GENERATOR CONTROL BOX ENGINE 69 ...

Page 73: ... If I ___ j APT __ ENGINE REC pETa 0 REC c I I I I i I E 11 Y IGREEN I A T Im F IL o T tiLUE1 i u I GENERATOR CONTROL BOX RGX505D m v 240v BLACK I 1 I i I iL 7 7 r O m EPSw REC 11 1 i d G I I EXC EC Y I A GENERATOR CONTROL BOX ENGINE MG 70 ...

Page 74: ... Winding I DC DC Winding I I FC Field Winding I 1 D Diode Stack Assy I F Fuse I Symbols Name of Parts 4 RECs i AC Output Receptacle 22OV 230 24OV IT DC Output Terminal I I EC Exciting Coil Charge Coil I I ExC 1 Excitor Coil I I PC Pulser Coil I MG Magneto SB Stop Button I SIU Solid State Ignition Unit I E Earth Ground Terminal I 71 ...

Page 75: ...D GS0005 1 FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS DIV 2ND Subaru Bldg 1 1 Choume Miyahara cho Omiya shi Saitama 330 0038 Japan PHONE Omiya 48 653 5811 FACSIMILE Omiya 48 653 5691 PRINTED IN JAPAN B303 CE ...

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