Subaru RGX3000 User manual

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

© Copyright 2009 Robin America, Inc.
Robin America, Inc.
905 Telser Road • Lake Zurich, IL 60047 • Phone: [phone]• Fax: [phone]
e-mail: [email protected] • www.subarupower.com

CONTENTS
Section Title Page
1. SPECIFICATIONS...........................................................1
2.PERFORMANCECURVES ....................................................2
3. GENERALDESCRIPTION.....................................................8
4.RANGEOFAPPLICATIONS..................................................14
5.MEASURINGPROCEDURES.................................................17
5-1MEASURINGINSTRUMENTS..............................................17
5-2ACOUTPUTMEASURING.................................................19
5-3DCOUTPUTMEASURING ................................................19
5-4 MEASURING INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.CHECKINGFUNCTIONALMEMBERS..........................................21
6-1RECEPTACLES.........................................................21
6-2CIRCUITBREAKER......................................................22
6-3STATOR...............................................................23
6-4ROTORASSEMBLY......................................................24
6-5BRUSH................................................................25
6-6 A.V.R. (AUTOMATIC VOLTAGE REGULATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6-7DIODESTACK..........................................................27
6-8OILSENSOR ...........................................................28
7.DISASSEMBLYANDASSEMBLY .............................................29
7-1PREPARATIONandPRECAUTIONS ........................................29
7-2DISASSEMBLYPROCEDURES ............................................29
7-3COMPONENTPARTS....................................................32
7-4ASSEMBLYPROCEDURES ...............................................37
7-5 CHECKING, DISASSEMBLY and REASSEMBLY of the CONTROL PANEL . . . . . . . . . .47
8.TROUBLESHOOTING.......................................................48
8-1NOACOUTPUT.........................................................48
8-2ACVOLTAGEISTOOHIGHORTOOLOW...................................49
8-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED. . . .50
9. WIRINGDIAGRAM .........................................................52
NOTE
This Service Manual excludes information for engine.
As for the total servicing information as a generator set, please refer in conjunction with the
Robin EX13/17/21/27 and EX30 OHC Engine Service Manual.

- 1 -
1. SPECIFICATIONS
MODEL
Type
Starting system
L
mm
mm
mm
mL
L
kg
Model
Type
Voltage regulating system
VA (W)
Rated output
Rated current
AC Output
Rated voltage
Fuel tank capacity
Engine oil capacity
Spark plug
Dry weight
Specifications are subject to change without notice.
*1: ( ) shows the filled amount up to the "LEVEL" position.
*2: ( ) shows dimensions with Battery frame.
*3: ( ) shows dry weight with Electric starter.
Displacement
ROBIN, Air-cooled, 4-stroke, OHC, Gasoline Engine
211
Length
Width
Height
Recoil
starter Electric starter / Recoil
17.8
(21.5)*1
BR-6HS (NGK)
0.6
12.8
(16.6)*1
Fuel Automotive Unleaded Gasoline
Fuse-less circuit breaker
V
Rated current
12
A
Safety device type
8.3
DC Output
Rated power factor 1.0
AVR type
RGX3800 RGX5100RGX3000
EX30DEX17D
287169
Brush, self-exciting, 2-poles, single phase
2900
110,120, 220, 110/220, 120/240110,120, 220, 110/220, 120/240110,120, 220, 110/220, 120/240
110, 220, 110/220, 230, 240110, 220, 110/220, 230, 240110, 220, 110/220, 230, 240
V 60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
Rated voltage
Safety device type Fuse-less circuit breaker
2400 4200
EX21D
675
(925)*2
600 620
(870)*2
510420 450
570500 500
69
(79)*3
47 52
(57.5)*3
Direction of rotation Counter - clockwise
1.0
A
26.4, 24.2, 13.2, 26.4/13.2, 24.2/12.1 21.8, 20, 10.9, 21.8/10.9, 20/10 38.2, 35, 19.1, 38.2/19.2, 35/17.5
24002000 3600
21.8, 10.9, 21.8/10.9, 10.4, 10 18.2, 9.1, 18.2/9.1, 8.7, 8.3 32.7, 16.4, 32,7/16.4, 15.7, 15
Engine Generator
Dimension

- 2 -
2. PERFORMANCE CURVES
1600
2000
2400
2800
50
51
52
53
0
400
800
1200
210
215
220
225
230
235
48
47
49
0 2 4 6 8 10 12
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
Voltage (V)
Frequency (Hz)
Output (VA)
•RGX3000
50Hz-220V
2000
2400
2800
3200
50
51
52
49
0
400
800
1200
1600
225
230
235
02 4 6 8 10 12
48
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
Voltage (V)
Frequency (Hz)
Output (VA)
50Hz-230V

- 3 -
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
1600
2000
2400
2800
51
50
49
52
0
400
800
1200
240
245
0 2 4 6 8 10 12
48
Voltage (V)
Frequency (Hz)
Output (VA)
50Hz-240V
Voltage (V)
Frequency (Hz)
Output (VA)
2000
2400
2800
3200
62.5
60
57.5
0
400
800
1200
1600
110
115
120
125
130
04812 16 20 24 28
55
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
60Hz-120V

- 4 -
2400
2800
3200
3600
4000
50
49
48
47
51
52
0
400
800
1200
1600
2000
220
225
230
02 4 6 8 10 12 14 16
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
Voltage (V)
Frequency (Hz)
Output (VA)
•RGX3800
50Hz-220V
14
2000
2400
2800
3200
50
51
52
49
0
400
800
1200
1600
225
230
235
0 2 4 6 8 10 12
48
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
Voltage (V)
Frequency (Hz)
Output (VA)
50Hz-230V

- 5 -
2000
2400
2800
3200
3600
51
50
52
0
400
800
1200
1600
235
240
245
250
024 6 8 10 12 14
49
48
47
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
Voltage (V)
Frequency (Hz)
Output (VA)
50Hz-240V
Voltage (V)
Frequency (Hz)
Output (VA)
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
2500
3000
3500
4000
62.5
60
65
57.5
0
500
1000
1500
2000
220
[110]
230
[115]
240
[120]
250
[125]
0816 24 32
55
60Hz-120/240V

- 6 -
•RGX5100
50Hz-220V
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
3000
3600
4200
4800
0
600
1200
1800
2400
4 8 12 16 20
50
51
52
49
225
230
235
0
Voltage (V)
Frequency (Hz)
Output (VA)
50Hz-230V
N / A

- 7 -
50Hz-240V
Voltage (V)
Frequency (Hz)
Output (VA)
Voltage (V) Frequency (Hz)
Output (VA)
Current (A)
3750
4500
5250
6000
62.5
60
57.5
0
750
1500
2250
3000
010 20 30 40 50
230
[115]
55
250
[125]
240
[120]
220
[110]
60Hz-120/240V
N / A

- 8 -
3. GENERAL DESCRIPTION
Control panel
Fuel tank
Fuel gauge
Engine switch
Recoil starter
handle
Fuel strainer
(Fuel cock)
Choke lever
Oil drain plug
Oil gauge (oil filler)
Spark plug cap
Air cleaner
Muffler
Tank cap
Recoil starter

- 9 -
CONTROL PANEL
Engine switch
Pilot lamp
AC receptacle 20A
Earth (ground)
terminal
AC circuit
breaker
Hour meter DC
receptacle
DC circuit
breaker
Engine switch
Voltmeter
DC circuit
breaker
AC circuit
breaker
Earth (ground)
terminal
AC
receptacle
DC receptacle
Engine switch
V
Voltmeter
DC circuit
breaker
AC circuit
breaker
Earth (ground)
terminal
AC
receptacle
DC receptacle
(60Hz-120V)
(50Hz-230V)
(50Hz-220V, 240V)
•RGX3000

- 10 -
Engine switch
AC receptacle 30A Pilot lamp
Earth (ground)
terminal
AC circuit
breaker
Hour meter DC
receptacle
DC circuit
breaker
Engine switch
Full power
switch
Idel control
switch
[Electric starter model]
Key switch
AC receptacle 20A
Voltmeter
DC circuit
breaker
AC circuit
breaker
Earth (ground)
terminal
AC
receptacle
DC receptacle
Engine switch
V
(60Hz-120/240V)
(50Hz-230V)
(50Hz-220V, 240V)
Voltmeter
DC circuit
breaker
AC circuit
breaker
Earth (ground)
terminal
AC
receptacle
DC receptacle
•RGX3800

- 11 -
(60Hz-120/240V)
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
(50Hz-230V)
Voltmeter
DC circuit
breaker
AC circuit
breaker
Earth (ground)
terminal
AC
receptacle
DC receptacle
Engine switch
Engine switch
V
(50Hz-220V, 240V)
Voltmeter
DC circuit
breaker
AC circuit
breaker
Earth (ground)
terminal
AC
receptacle
DC receptacle
•RGX5100

- 12 -
PROD No. / SER No. (Label)
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.

- 13 -
CONSTRUCTION
DIODE STACK
AVR UNIT
EARTH TERMINAL
ROTOR BOLT
BRUSH
END COVER
REAR COVER FRONT COVER
FLANGE BOLT
STATOR BOLT
BRUSH HOLDER
N-BRACKET
•RGX3000 / RGX3800
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
•RGX5100

- 14 -
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). 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.

- 15 -
Efficiencies of some electrical appliances are as follows :
Single-phase motor . . . . 0.6 to 0.75
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 57 W 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 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 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 consumption is to be worked out according to the
numerical formula mentioned below.
(Output of electrical appliance)
(Efficiency) = (Power consumption)
The smaller the motor, the
lower the efficiency.
( )
Table. 4-1
Applications
Applicable Wattage(approx. W)
50Hz 60Hz
RGX3000 RGX3800 RGX5100 RGX3000 RGX3800 RGX5100
Incandescent lamp, Heater 2000 2400 3500 2400 2700 3700
Fluorescent lamp, Electric tool
1100 1200 1800 1200 1400 1900
Mercury lamp 800 900 1300 900 1000 1400
Pump, Compressor 500 550 800 550 600 850

- 16 -
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. Table 4-2 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. 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.
Imeans 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
A.W.G. Allowable
current
No.of strands
/ strands dia. Resistance Current Amp.
mm2No. A No./mm Ω/100m 1A 3A 5A 8A 10A 12A 15A
0.75 18 7 30/0.18 2.477 2.5V 7.5V 12.5V
----
Voltage drop
1.25 16 12 50/0.16 1.486 1.5V 4.5V 7.5V 12V 15V 18V -
2.0 14 17 37/0.26 0.952 1V 3V 5V 8V 10V 12V 15V
3.5 12 to 10 23 45/0.32 0.517
- 1.5V 2.5V 4V 5V 6.5V 7.5V
5.5 10 to 8 35 70/0.32 0.332
- 1V 2V 2.5V 3.5V 4V 5V
1
V= 100 × R × I× L