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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

it on .

NOTE : If the DC output is used to charge

a large capacity battery or an over-

discharged battery, an excessive

current may flow causing.

8-4-3.CHECK.THE.WIRING.

Check all the wires to be connected correctly .

8-4-5.CHECK.THE.DC.COIL

Check the resistance between two Brown leads from stator with a circuit tester .

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 .

8-4-4.CHECK.THE.DIODE.STACK.

Remove the end cover and check the diode

stack with a circuit tester .
Refer to Section 6-7 “DIODE STACK” for the

checking procedure .

DIODE STACK

White

Black

Brown

White

Black

Brown

CIRCUIT TESTER

(Continuity test)

(Ω)

FREQUENCY

50Hz

60Hz

RATED.VOLTAGE

220V

240V

120/240V

RGX7100

49 .0

RGX7800

55 .0

Summary of Contents for RGX7100

Page 1: ...SERVICE MANUAL RGX7100 7800 GENERATORS Models PUB GS6828 Rev 07 09 ...

Page 3: ...2 6 8 OIL SENSOR 23 6 9 IDLE CONTROL OPTIONAL EQUIPMENT 24 7 DISASSEMBLY AND ASSEMBLY 27 7 1 PREPARATION and PRECAUTIONS 27 7 2 DISASSEMBLY PROCEDURES 27 7 3 COMPONENT PARTS 33 7 4 ASSEMBLY PROCEDURES 37 7 5 CHECKING DISASSEMBLY and REASSEMBLY of the CONTROL PANEL 48 8 TROUBLESHOOTING 49 8 1 NO AC OUTPUT 49 8 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 50 8 3 AC VOLTAGE IS NORMAL AT NO LOAD BUT THE LOAD C...

Page 4: ......

Page 5: ...8 3 Safety device type Fuse less circuit breaker Engine Model EX35D EX40D Type ROBIN Air cooled 4 stroke OHC Gasoline Engine Displacement mL 404 Fuel Automotive Unleaded Gasoline Fuel tank capacity L 22 0 27 5 1 Engine oil capacity L 1 2 Spark plug BR 6HS NGK Starting system Electric starter Recoil Direction of rotation Counter clockwise Dimension Length mm 725 975 2 Width mm 530 Height mm 580 Dry...

Page 6: ... 2 2 PERFORMANCE CURVES RGX7100 50Hz 220V 50Hz 240V N A N A ...

Page 7: ... 3 4000 5000 6000 7000 8000 62 5 60 57 5 55 0 1000 2000 3000 115 120 125 230 250 240 Voltage V Frequency Hz Output VA Current A Voltage V Frequency Hz Output VA 0 10 20 30 40 50 60 70 60Hz 120 240V ...

Page 8: ... 4 RGX7800 50Hz 220V 50Hz 240V N A N A ...

Page 9: ... 4000 5000 6000 7000 8000 9000 57 5 0 1000 2000 3000 230 115 62 5 65 60 55 250 125 240 120 Voltage V Frequency Hz Output VA Current A Voltage V Frequency Hz Output VA 0 10 20 30 40 50 60 70 60Hz 120 240V ...

Page 10: ...7100 RGX7800 Control panel Fuel tank Fuel gauge Engine switch Recoil starter handle Choke lever Oil gauge oil filler Spark plug cap Air cleaner Muffler Tank cap Recoil starter Muffler cover Oil drain plug Fuel strainer Fuel valve ...

Page 11: ...nal AC receptacle DC receptacle Engine switch Electric starter model Key switch AC circuit breaker DC circuit breaker AC receptacle 20A Engine switch Electric starter model Key switch AC receptacle 30A Pilot lamp Full power switch AC receptacle 30A Earth ground terminal Hour meter DC receptacle Idle Control Switch ...

Page 12: ...ways specify serial number when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service CONSTRUCTION AVR UNIT EARTH TERMINAL BRUTH STATOR CORE ROTOR BOLT END COVER REAR COVER FRONT COVER FLANGE BOLT BRUSH HOLDER N BRACKET STATOR BOLT DIODE STACK RGX7100 RGX7800 ...

Page 13: ...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 th...

Page 14: ...ower consumption will be 400 0 7 570 W When this motor is used for a motor driven tool the capacity of the generator should be multiple of 570 W by 1 2 to 3 as explained in the ltem 3 570 W 1 2 to 3 684 W to 1710 W 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...

Page 15: ...he load electrical product As a result the load can be damaged Table 4 2 shows voltage drops per 100 meters of cable Voltage drop indicates as R means resistance Ω 100 m on the above table I means electric current through the wire A L means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools Table 4 2 Nominal cross section...

Page 16: ...Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range FOR AC 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 0 to 150 V ...

Page 17: ...RCUIT 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 ...

Page 18: ... 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 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 10V the voltage output is normal NOTE If a battery is connected as a load to the gener...

Page 19: ...leakage and electric shock Replace the faulty part MEGGER TESTER SLIP RING ROTOR MEGGER TESTER 1 STATOR Measure the insulation resistance between each lead wire and the core MEGGER TESTER 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 me...

Page 20: ...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 When the wire is removed and no continuity is found between these terminals the receptacles are also normal CIRCUIT TESTER Continuity test CIRCUIT TESTER Continuity test WIRE ...

Page 21: ...ty between each of the two when the circuit breaker is on while there is no continuity when the circuit breaker is off AC CIRCUIT BREAKER DC CIRCUIT BREAKER Model Frequency Rated output Rated voltage Rated fault current Type RGX7100 50Hz 4600VA 220V 20 1 240V N A 1 60Hz 5000VA 120 240V 23 3 RGX7800 50Hz 5500VA 220V N A 1 240V N A 1 60Hz 6000VA 120 240V 28 3 Model Rated current Rated voltage Rated ...

Page 22: ...NG 1 RED GRAY 0 59 0 64 0 41 AC WINDING 2 ORANGE BLUE 0 59 0 64 0 41 SUB COIL BLUE BLUE 1 80 1 76 1 35 DC WINDING BROWN BROWN 0 13 0 10 0 09 AC WINDING 1 GREEN WHITE 0 10 0 11 0 07 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 s...

Page 23: ...ratures different from from 20 C 68 F SLIP RING ROTOR CIRCUIT TESTER Resistance Ω Rotor Slip ring 50Hz 60Hz 220V 240V 120 240V RGX7100 49 0 49 0 49 0 RGX7800 55 0 55 0 55 0 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 s...

Page 24: ...aintain the output voltage for the AC current which generated by the magnetic flux by the field coil 2 A V R trouble may be identified by simply looking at the A V R or by the inter lead resistance with a tester or actually mounting it in the generator and operating it CIRCUIT TESTER Resistance a A V R TROUBLE IDENTIFICATION by APPEARANCE If an A V R electronic part is burnt dark or the surface ep...

Page 25: ...ulty A V R in a normal generator or mount a mormal A V R in a generator which fails to generate voltage Checking table for analogue circuit tester RGX7100 RGX7800 Ω R 20 Apply black needle of the circuit tester White ⓐ Red ⓑ Green White Blue Blue Apply red needle of the circuit tester White ⓐ 2 1M 5 0M 5 1M 4 6M 4 2M Red ⓑ 1 8M 2 1M 2 1M 1 9M 1 6M Green 4 4M 2 0M 4 9M 4 4M 4 1M White 4 6M 2 1M 5 1...

Page 26: ...circuit tester Apply red needle of the circuit tester Brown Brown White Black Apply black needle of the circuit tester Brown No continuity Continuity No continuity Brown No continuity Continuity No continuity White No continuity No continuity No continuity Black Continuity Continuity Continuity Checking table for analogue circuit tester Checking table for digital circuit tester NOTE 1 In checking ...

Page 27: ...ter the wirings have checked the sensor is wrong Replace the sensor with new one 6 8 1 SPECIFICATIONS Type Float type with lead switch incorporated Resistance at FULL oil level 100 M ohms or over Operating Temperature 30 to 180 degree Celsius 6 8 2 CONSTRUCTION AND OPERATION Disconnect wires comming from the sensor The oil sensor is composed of the float permanent magnet incorporated into the floa...

Page 28: ...s such as electric motor or electric tools or welding machine require three to five times large wattage of their ratings at starting This starting wattage must not exceed the rated output of the generator 2 Check the slow set r p m The normal idling speed by the IDLE CONTROL is as follows RGX7100 7800 USA model 2100 to 2500 r p m The above speed setting is for cold engine condition If the engine s...

Page 29: ...f the IDEL CONTROL UNIT Circuit tester with battery power source 1 5 V Apply black needle of the circuit tester Apply red needle of the circuit tester 250kΩ 250kΩ 75kΩ 250kΩ 250kΩ 75kΩ 250kΩ 250kΩ 75kΩ 8 5kΩ 7 8kΩ 7 8kΩ 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 ordina y analogue circuit tes...

Page 30: ...ted 2 Check the wiring of IDLE CONTROL UNIT Check all leads from IDLE CONTROL UNIT are securely and correctly connected 3 Checking the SOLENOID Measure the resistance between two leads from SOLENOID If the resistance is larger or smaller than this range SOLENOID is defective Replace with a new one SOLENOID Normal Resistance Ω 25 31 ...

Page 31: ...c 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 gen...

Page 32: ... M4 flange bolt 4 pcs 2 Disconnect the connectors on the wiring from the control panel to the alternator 3 Remove the control box 7 2 3 MUFFLER 1 Remove the Muffler Cover R M6 flange bolt 11 pcs 2 Loose the bolt for Muffler Cover F M6 flange bolt 2 pcs NOTE Do not remove the flange bolt at this process MUFFLER COVER R MUFFLER COVER F ...

Page 33: ...he Guide plate and the Bracket Tank A from frame M6 flange bolt 4 pcs Guide plate M6 flange bolt 4 pcs Bracket Tank A MUFFLER COVER F BRACKET TANK A GUIDE PLATE MUFFLER BRACKET 1 3 Remove the Muffler Bracket 2 from Muffler Bracket 1 M8 flange bolt 2 pcs 4 Loosen Nut and Washer for Exhaust Pipe Remove the Muffler from Cylinder Head M8 nut and washer 2 pcs Exhaust Pipe MUFFLER ...

Page 34: ... pcs 2 Disconnect the connectors on the wiring from the alternator 3 Remove the AVR unit brush holder and diode stack 4 Set the generator set with the rear cover upwards NOTE Before starting this work make sure engine oil has been discharged 5 Remove the flange nut fixing rear cover onto the mount base with mount rubber M10 flange nut 1 pc Opposite side flange nut has been removed at muffler disas...

Page 35: ...e stator NOTE The stator is heavy Be careful do not hit the coil of the stator to the rotor 9 Take off the through bolt of the rotor 10 Use a bolt and oil as a tool for pulling out rotor in the following procedures 1 Pour engine oil into the center hole of rotor shaft Fill with oil to the shaft end 2 Prepare a bolt with the following thread size M12 1 75 RGX7100 RGX7800 ...

Page 36: ...11 Remove the front cover M8 20 bolt countersunk head 4 pcs FRONT COVER 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 ...

Page 37: ...OVER REAR COVER COVER BOLT BRUSH HOLDER AVR UNIT DIODE STACK FAN BEARING MOUNT RUBBER FLANGE NUT 24 0 30 0 N m 240 300 kgf cm 17 8 22 2 ft lbs N BRACKET BOLT 43 0 47 0 N m 430 470 kgf cm 31 7 34 7 ft lbs 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 7 3 COMPONENT PARTS RGX7100 RGX7800 ...

Page 38: ...Box Assy CONTROL BOX ENGINE SWITCH EARTH GROUND TERMINAL DC CIRCUIT BREAKER DC RECEPTACLE AC RECEPTACLE CONTROL PANEL KEY SWITCH FULL POWER SWITCH HOUR METER EARTH GROUND TERMINAL IDEL CONTROL UNIT AC CIRCUIT BREAKER ...

Page 39: ... 35 3 Fuel Tank FUEL TANK CAP FUEL FILTER FUEL TANK BRACKET TANK A RUBBER PIPE FILTER PACKING CUP FUEL GAUGE FUEL STRAINER M6 16 BOLT ...

Page 40: ...R BRACKET 1 M8 flange nuts 12 0 15 0 N m 120 150 kgf cm 8 9 11 1 ft lbs M8 flange bolt 18 0 22 0 N m 180 220 kgf cm 13 3 16 2 ft lbs M8 flange bolt 18 0 22 0 N m 180 220 kgf cm 13 3 16 2 ft lbs M8 flange nuts 12 0 15 0 N m 120 150 kgf cm 8 9 11 1 ft lbs M8 flange nuts 18 0 22 0 N m 180 220 kgf cm 13 3 16 2 ft lbs A MUFFLER COVER R M8 flange bolt 12 0 15 0 N m 120 150 kgf cm 8 9 11 1 ft lbs M8 flan...

Page 41: ...rnator side ENGINE MOUNT BASE 7 4 ASSEMBLY PROCEDURES NOTE There are two type of mount rubber Before attaching the mount rubbers make sure the position 2 Temporally attach the Mount Base to the engine by inserting flange bolt into middle hole on mount base and engine base Temporally fix the bolt by nut NOTE Meet other side hole on the mount base with hole of engine base Refer to right side picture...

Page 42: ...ighten the temporally fixed bolt and nut for mount base M10 flange nut M10 40 flange bolt 1 pc Tightening torque 24 0 30 0 N m 240 300 kgf cm 17 8 22 2 ft lbs Tightening torque 24 0 30 0 N m 240 300 kgf cm 17 8 22 2 ft lbs 7 4 2 FRONT COVER 1 Attach the N bracket onto the front cover NOTE Match the rib direction on the N bracket with the top mark on the front cover surface FRONT COVER BOLT A View ...

Page 43: ... 300 flange bolt 1 pc RGX7800 ROTOR THROUGH BOLT FAN BEARING Tightening torque 43 0 47 0 N m 430 470 kgf cm 31 8 34 8 ft lbs 2 Attach the front cover to the engine main bearing cover NOTE Match the top mark on the front cover surface with upside direction TOP mark M8 20 bolt countersunk head 4 pcs Tightening torque 24 0 26 0 N m 240 260 kgf cm 17 8 19 2 ft lbs 7 4 4 STATOR 1 Put the stator in the ...

Page 44: ...y and in turns M6 180 flange bolt 4 pcs REAR COVER PLASTIC HAMMER MOUNT BASE REAR COVER MUFFLER BRACKET 1 5 Temporally assemble the Mount Base to the Rear Cover by inserting flange bolt into middle hole on Mount Base Rear Cover hole and Muffler Bracket 1 hole Temporally fix the bolt by nut NOTE Meet other side hole on the Mount Base with hole of Rear Cover Refer to right side picture M10 flange nu...

Page 45: ...lt 1 pc diode stack 7 Install the brush holder AVR unit and diode stack in the rear cover M5 16 bolt 2 pcs AVR unit NOTE If the brush is installed oblique to the slip ring there is possibility that the brush holder can break when the screw is tightened or the brush may break when generator of started Make this process carefully BRUSH HOLDER DIODE STACK AVR UNIT AVR UNIT BRUSH HOLDER DIODE STACK EA...

Page 46: ...NOTE When tightening the nuts slightly lift the alternator assembly so that the weight is not applied to the mount rubbers NOTE Do not tighten the nut and the bolt for Muffler Bracket 1 After attaching Muffler to the Engine the nut and the bolt are fixed M10 flange nut 2 pcs Tightening torque 24 0 30 0 N m 240 300 kgf cm 17 8 22 2 ft lbs ...

Page 47: ...rester to the Muffler M8 nut and Washer 2pcs exhaust pipe with gasket M8 nut 4pcs muffler bracket 2 Tightening torque 12 0 15 0 N m 120 150 kgf cm 8 9 11 1 ft lbs Tightening torque 12 0 15 0 N m 120 150 kgf cm 8 9 11 1 ft lbs SPONGE FILTER END COVER 13 Set the Sponge Filter to inside of End Cover NOTE Hold the Sponge by tab of End Cover M5 16 bolt 2 pcs Tightening torque 4 0 4 5 N m 40 45 kgf cm 3...

Page 48: ... Muffler Cover F to the flame M6 10 flange bolt 4 pcs 3 Temporally attach the muffler and gasket to the cylinder head Temporally attach the muffler bracket 2 to Muffler bracket 1 After that tighten the nuts and flange bolts M8 nut 2 pcs cylinder head M8 16 flange bolt 2 pcs Muffler Bracket 1 Tightening torque 18 0 22 0 N m 180 220 kgf cm 13 2 16 2 ft lbs Tightening torque 12 0 15 0 N m 120 150 kgf...

Page 49: ...et 1 M10 nut and M10 40 flange bolt 1 pc with rear cover 6 Attach the muffler cover to the flame M6 10 flange bolt 11 pcs Tightening torque 6 5 8 5 N m 65 85 kgf cm 4 8 6 3 ft lbs Tightening torque 6 5 8 5 N m 65 85 kgf cm 4 8 6 3 ft lbs Tightening torque 16 5 20 5 N m 165 205 kgf cm 12 2 15 2 ft lbs Tightening torque 24 0 30 0 N m 240 300 kgf cm 17 8 22 2 ft lbs ...

Page 50: ...en the lock nut 2 Mount the fuel tank on the frame with rubber washers between the tank flange and the frame M6 x 20 mm bolt black 4 pcs Rubber washer 4 pcs NOTE For easy tank assembly glue the rubber washers over the mounting holes of the frame 3 Connect the rubber pipe First fit the hose clamps on the rubber pipe and connect it to the strainer and the carburetor Then fasten it with the hose clam...

Page 51: ...r and engine to the control box 3 Connect the wires coming from the control panel with wires coming from generator and engine NOTE Connect the wires of the same color 4 Install the control panel onto the control box 5 Mount the control panel together with the control box Control box Assembly onto the frame M4 12 mm Screw 4 pcs M6 12 mm Screw 4 pcs Tightening torque 5 0 6 0 N m 50 60 kgf cm 3 7 4 8...

Page 52: ...el components 3 Attach the control panel and control box to the Frame Refer to 7 4 8 for details 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 7 5 2 DISASSEMBLY 1 Remove the control panel from the...

Page 53: ...mal 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 If insulation is bad replace stator with a new one CIRCUIT TESTER Resistance MEGGER TESTER NOTE If the circuit tester is not sufficiently accurate it may not show the values given and may give erroneous readings Erroneous reading will also oc...

Page 54: ... CHECKING ROTOR Check rotor referring to Step 8 1 2 LOW SPEED HIGH SPEED ADJUST SCREW 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 Care ...

Page 55: ...ling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris remove it 8 3 5 CHECK THE INSULATION OF THE GENERATOR 1 Stop the engine Remove the control panel and disconnect the connector of GREEN lead for ground 2 Measure the insulation resistance between the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1MΩ disassemb...

Page 56: ...Check all the wires to be connected correctly 8 4 5 CHECK THE DC COIL Check the resistance between two Brown leads from stator with a circuit tester 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 8 4 4 CHECK THE DIODE STACK Remove the end cover and check the diode stack with a circuit tester Refer to Se...

Page 57: ... Ignition coil Oil sensor switch Sub coil Bridge diode AVR unit Blu Y R Blu Blu Blu W W Blk Grn Y Brn Brn Grn Grn Earth Ground terminal Spark plug Oil sensor unit ROTOR STATOR DC winding AC winding 2 AC winding 1 Slip ring DC Output receptacle AC Output receptacle AC Output receptacle DC12V Y W W W W R R R R Blu Blu Blk Grn Grn Blk Blk Voltmeter AC circuit breaker DC circuit breaker Org Org Gry Or...

Page 58: ...ition coil Oil sensor switch Key switch Sub coil Bridge diode AVR unit Y R Blk Grn Grn Y Brn Brn GENERATOR CONTROL BOX ENGINE Earth Ground terminal Spark plug Oil sensor unit ROTOR STATOR DC winding AC winding 2 AC winding 1 Slip ring DC12V Y W W W W R R R Blu Blu Blu Blk Grn Grn Blk Blk AC circuit breaker Org Org Gry Org Gry Blk Blu Blu Grn Gry Gry R Blu W W W Idle Control Switch Idle Control Uni...

Page 59: ......

Page 60: ...PRINTED IN THE USA ...

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