RGX3000
RGX3800
RGX5100
RGX7100
RGX7800
Original
3ZZ9990434
Download from Www.Somanuals.com. All Manuals Search And Download.
(California Proposition 65)
DANGER
WARNING:
Using a generator indoors CAN KILL YOU IN MINUTES.
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects or other reproductive
harm.
Generator exhaust contains carbon monoxide. This is
a poison you cannot see or smell.
NEVER use inside a home Only use OUTSIDE and
or garage, EVEN IF doors
and windows are open.
far away from windows,
doors, and vents.
Download from Www.Somanuals.com. All Manuals Search And Download.
FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY
EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE – This emission warranty is applicable in all States, except the state
of California.
Fuji Heavy Industries Ltd. and Robin America Inc., Lake Zurich Illinois, (herein “ROBIN AMERICA”) warrant(s) to the initial retail purchaser and
each subsequent owner, that this Nonroad engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale
to all applicable regulations of the U.S.
Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to
fail to conform with EPA regulations during its warranty period.
For the components listed under PARTS COVERED, the service dealer authorized by ROBIN AMERICA will, at no cost to you, make the
necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations.
EMISSION COMPONENT DEFECT WARRANTY PERIOD
OWNER’S WARRANTY RESPONSIBILITIES
The warranty period for this engine begins on the date of sale to the
initial purchaser and continues for a period of two years.
As the engine owner, you are responsible for the performance of the
required maintenance listed in your owner’s manual. ROBIN
AMERICA recommends that you retain all receipts covering
maintenance on your engine, but ROBIN AMERICA cannot deny
warranty solely for the lack of receipts or for your failure to ensure
the performance of all scheduled maintenance.
PARTS COVERED
Listed below are the parts covered by the Emission Components
Defect Warranty. Some of the parts listed below may require
scheduled maintenance and are warranted up to the first scheduled
replacement point for that part.
As the engine owner, you should however be aware that ROBIN
AMERICA may deny warranty coverage if your engine or a part has
failed due to abuse, neglect, improper maintenance or unapproved
modifications.
EXHAUST EMISSIONS
(1) Fuel Metering System
(i) Carburetor and internal parts (and/or pressure regulator or
fuel injection system).
You are responsible for presenting your engine to the nearest service
dealer authorized by ROBIN AMERICA when a problem exists.
(ii) Air/fuel ratio feedback and control system, if applicable.
(iii) Cold start enrichment system, if applicable.
(iv) Regulator assy (gaseous fuel, if applicable)
(2) Air Induction System
If you have any questions regarding your warranty rights and
responsibilities, you should contact the Robin America customer
service department at 1-800-277-6246 for the information.
(i) Intake manifold, if applicable
THINGS YOU SHOULD KNOW ABOUT THE EMISSION
CONTROL SYSTEM WARRANTY MAINTENANCE AND
REPAIRS
(ii) Air filter.
(3) Ignition System
(i) Spark plugs.
(ii) Magneto or electronic ignition system.
(iii) Spark advance/retard system, if applicable.
(4) Exhaust manifold, if applicable
(5) Miscellaneous Items Used in Above Systems
(i) Electronic controls, if applicable
(ii) Hoses, belts, connectors, and assemblies.
(iii) Filter lock assy (gaseous fuel, if applicable)
You are responsible for the proper maintenance of the engine.
You should keep all receipts and maintenance records covering the
performance of regular maintenance in the event questions arise.
These receipts and maintenance records should be transferred to
each subsequent owner of the engine. ROBIN AMERICA reserves
the right to deny warranty coverage if the engine has not been properly
maintained. Warranty claims will not be denied, however, solely
because of the lack of required maintenance or failure to keep
maintenance records.
*EVAPORATIVE EMISSIONS
(1) Fuel Line
(2) Fuel Line Fittings
(3) Clamps
MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION
CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY
ANY REPAIR ESTABLISHMENT OR INDIVIDUAL;
*Fuji is not liable for the warranty on these parts if these parts are
installed on the engine by the equipment manufacture. Please refer
to the equipment manufactures warranty.
HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A
SERVICE DEALER AUTHORIZED BY ROBIN AMERICA. THE USE
OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND
DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE
EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY
HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM.
OBTAINING WARRANTY SERVICE
To obtain warranty service, take your engine to the nearest authorized
Robin America service dealer . Bring your sales receipts indicating date
of purchase for this engine. The service dealer authorized by ROBIN
AMERICA will perform the necessary repairs or adjustments within a
reasonable amount of time and furnish you with a copy of the repair
order. All parts and accessories replaced under this warranty become
the property of ROBIN AMERICA.
If other than the parts authorized by ROBIN AMERICA are used for
maintenance replacements or for the repair of components affecting
emission control, you should assure yourself that such parts are
warranted by their manufacturer to be equivalent to the parts
authorized by ROBIN AMERICA in their performance and durability.
WHAT IS NOT COVERED
*Conditions resulting from tampering, misuse, improper adjustment
(unless they were made by the service dealer authorized by ROBIN
AMERICA during a warranty repair), alteration, accident, failure to
use the recommended fuel and oil, or not performing required
maintenance services.
HOW TO MAKE A CLAIM
All repair qualifying under this limited warranty must be performed by a
service dealer authorized by ROBIN AMERICA. In the event that any
emission-related part is found to be defective during the warranty period,
you shall notify Robin America customer service department at 1-800-
277-6246 and you will be advised of the appropriate warranty service
*The replacement parts used for required maintenance services.
*Consequential damages such as loss of time, inconvenience, loss of
use of the engine or equipment, etc.
dealer or service providers where the warranty repair can be performed.
*Diagnosis and inspection charges that do not result in warranty-
eligible service being performed.
*Any non-authorized replacement part, or malfunction of authorized
parts due to use of non-authorized parts.
WS6645
Download from Www.Somanuals.com. All Manuals Search And Download.
FOREWORD
Thank you for purchasing a Robin generator.
This manual covers operation and maintenance of the Robin generators.
All information in this publication is based on the latest production
information available at the time of approval for printing.
Pay special attention to statements preceded by the following words:
DANGER
Indicates a possibility of death or serious injury if instructions are not
followed.
WARNING
Indicates a strong possibility of severe personal injury, loss of life and
equipment damage if instructions are not followed.
［CAUTION］
Indicates a possibility of personal injury or equipment damage if instructions
are not followed.
NOTE:
Gives helpful information.
If a problem should arise, or if you have any questions about the generator,
consult an authorized dealer or service shop
WARNING
■
The generator is designed to give safe and dependable service if
operated according to instructions.
■
Do not operate the generator before you have read and
understood the instructions. Failure to do so could result in death,
personal injury or equipment damage.
Download from Www.Somanuals.com. All Manuals Search And Download.
CONTENTS
1. SAFETY PRECAUTIONS ・・・・・・・・・・・・・・・・ 1
2. SPECIFICATIONS・・・・・・・・・・・・・・・・・・・ 3
3. COMPONENTS ・・・・・・・・・・・・・・・・・・・・ 4
4. PRE-OPERATION CHECKS・・・・・・・・・・・・・・・ 7
5. OPERATING PROCEDURES ・・・・・・・・・・・・・・11
6. WATTAGE INFORMATION ・・・・・・・・・・・・・・・22
7. SPARK ARRESTER ・・・・・・・・・・・・・・・・・・24
8. MAINTENANCE SCHEDULE ・・・・・・・・・・・・・・25
9. "HOW-TO" MAINTENANCE・・・・・・・・・・・・・・・27
10. PREPARATION FOR STORAGE ・・・・・・・・・・・・・31
11. TROUBLESHOOTING ・・・・・・・・・・・・・・・・・32
12. WIRING DIAGRAM ・・・・・・・・・・・・・・・・・・33
Download from Www.Somanuals.com. All Manuals Search And Download.
1. SAFETY PRECAUTIONS
Please make sure you review each precaution carefully.
WARNING
Do not operate the generator near gasoline or gaseous fuel because of the
potential danger of explosion or fire.
Do not fill the fuel tank with fuel while the engine is running. Do not smoke or
use open flame near the fuel tank. Be careful not to spill fuel during refueling.
If fuel is spilt, wipe it off and let dry before starting the engine.
WARNING
Do not place in flammables near the generator.
Be careful not to place fuel, matches, gunpowder, oily cloths, straw, trash, or any other in flammables
near the generator.
WARNING
Do not operate the generator inside a room, cave, tunnel, or other
insufficiently ventilated area.
Always operate it in a well-ventilated area, otherwise the engine may
1m
become overheated, and the poisonous carbon monoxide gas, an
odorless, colorless, poison gas, contained in the exhaust gas will
endanger human lives.
1m
Operate generator only outdoors and far from open windows, doors,
ventilation intakes and other openings.
Keep the generator at least 1 meter (3 feet) away , including overhead,
from any structure or building use.
WARNING
Do not enclose the generator nor cover it with a box.
The generator has a built-in forced air cooling system, and may become overheated if it is enclosed.
If generator has been covered to protect it from the weather during non use, be sure to remove it and
keep it well away from the area during generator use.
WARNING
Operate the generator on a level surface.
It is not necessary to prepare a special foundation for the generator.
However, the generator will vibrate on an irregular surface, so choose a level place without surface
irregularities.
If the generator is tilted or moved during operation, fuel may spill and / or the generator may tip over,
causing a hazardous situation.
Proper lubrication cannot be expected if the generator is operated on a steep incline or slope. In such
a case, piston seizure may occur even if the oil is above the upper level.
WARNING
Pay attention to the wiring or extension cords from the generator to the connected device.
If the wire is under the generator or in contact with a vibrating part, it may break and
possibly cause a fire, generator burnout, or electric shock hazard.
Replace damaged or worn cords immediately.
Download from Www.Somanuals.co－m. 1Al－l Manuals Search And Download.
WARNING
Do not operate in rain, in wet or damp conditions, or with wet hands.
The operator may suffer severe electric shock if the generator is wet due to rain or snow.
WARNING
If wet, wipe and dry it well before starting. Do not pour water directly over the generator, nor wash it
with water.
WARNING
Be extremely careful that all necessary electrical grounding procedures are followed during each and
every use. Failure to do so can be fatal.
WARNING
Do not contact the generator to a commercial power line. Connection to a commercial
power line may short circuit the generator and ruin it or cause electric shock hazard.
Use the transfer switch for connecting to domestic circuit.
WARNING
No smoking while handling the battery. The battery emits flammable hydrogen gas,
which can explode if exposed to electric arcing or open flame.
Keep the area well-ventilated and keep open flames/sparks away when handling the battery.
WARNING
Engine becomes extremely hot during and for some time after operation.
Keep combustible materials well away from generator area.
Be very careful not to touch any parts of the hot engine especially the muffler area
or serious burns may result.
WARNING
Keep children and all bystanders at a safe distance from work areas.
WARNING
It is absolutely essential that you know the safe and proper use of the power tool or appliance that
you intend to use. All operators must read, understand and follow the tool/appliance owners manual.
Tool and appliance applications and limitations must be understood. Follow all directions given on
labels and warnings. Keep all instruction manuals and literature in a safe place for future reference.
WARNING
Use only "LISTED" extension cords.
When a tool or appliance is used outdoors, use only extension cords marked "For Outdoor Use".
Extension cords, when not in use should be stored in a dry and well ventilated area.
WARNING
Always switch off generator's AC circuit breaker and disconnect tools or appliances when not in use,
before servicing, adjusting, or installing accessories and attachments.
CAUTION
Make sure the engine is stopped before starting any maintenance, servicing or repair.
Make sure maintenance and repair of the generator set are performed by properly trained personnel only.
－2－
Download from Www.Somanuals.com. All Manuals Search And Download.
2. SPECIFICATIONS
RGX3000 RGX3800 RGX5100 RGX7100 RGX7800
MODEL
Brush, self-exciting, 2-poles, single phase
AVR type
Type
Voltage regulating system
AC Output
Rated voltage-Frequency V-Hz
120-60
20
120/240-60
24.2 / 12.1 35 / 17.5 41.7 / 20.8
50 / 25
6000
Rated current
A
2400
2900
4200
1.0
5000
Rated output
VA (W)
Rated power factor
Safety device type
Fuse-less circuit breaker
DC Output
Rated voltage
V
A
12
8.3
Rated current
Safety device type
Fuse-less circuit breaker
EX17D
EX21D
EX30D
EX35D
EX40D
Model
Type
ROBIN, Air-cooled, 4-stroke, OHC, Gasoline Engine
169
287
404
Displacement
Fuel
mL
211
Automotive Unleaded Gasoline
17.8
22.0
(27.5)*1
12.8
Fuel tank capacity
L
L
(16.6)*1
(21.5)*1
1.0
1.2
Engine oil capacity
Spark plug
0.6
BR-6HS (NGK)
Recoil
starter
Starting system
Direction of rotation
Length
Electric starter / Recoil
Counter - clockwise
620
675
725
(975)*2
600
mm
(870)*2
(925)*2
420
500
450
510
570
530
Width
mm
mm
500
580
Height
52
(57.5)*3
69
(79)*3
88
(98)*3
91
(101)*3
47
Dry weight
kg
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.
Download from Www.Somanuals.co－m. 3Al－l Manuals Search And Download.
3. COMPONENTS
RGX3000, 3800, 5100
Engine switch
Fuel tank
Control panel
Fuel strainer
(
)
Fuel valve
Recoil starter
handle
Recoil starter
Fuel gauge
Oil gauge (oil filler)
Oil drain plug
Tank cap
Spark plug cap
Choke lever
Air cleaner
Muffler cover
Exhaust outlet
－4－
Download from Www.Somanuals.com. All Manuals Search And Download.
RGX7100, 7800
Tank cap
Engine switch
Control panel
Recoil starter
handle
Oil gauge (oil filler)
Oil drain plug
Recoil starter
Fuel gauge
Fuel tank
Choke lever
Spark plug cap
Air cleaner
Muffler
Muffler cover
Download from Www.Somanuals.co－m. 5Al－l Manuals Search And Download.
CONTROL PANEL
(RGX3000)
Pilot lamp
AC circuit
breaker
AC receptacle 20A
Engine switch
DC circuit
breaker
(
)
Earth ground
Hour meter
DC receptacle
Pilot lamp
terminal
(RGX3800)
AC receptacle 30A
AC circuit
breaker
AC receptacle 20A
[Electric starter model]
Key switch
Idle Control
Switch
Full power
switch
Engine switch
DC circuit
breaker
ï
(
)
AC circuit
breaker
Earth ground
Hour meter
DC receptacle
terminal
(RGX5100, 7100, 7800)
AC receptacle 30A
AC receptacle 20A
AC receptacle 30A
Idle Control Switch
Pilot lamp
[Electric starter model]
AC circuit
breaker
Key switch
Engine switch
DC circuit
breaker
AC circuit
breaker
Full power
switch
Hour meter
DC receptacle
(
)
Earth ground terminal
－6－
Download from Www.Somanuals.com. All Manuals Search And Download.
4. PRE-OPERATION CHECKS
CHECK ENGINE OIL
Before checking or refilling oil, be sure
Oil filler cap
(Oil gauge)
generator is located on stable and level
surface with engine stopped.
■
Remove oil filler cap and check the
engine oil level.
Upper level
Lower level
■
If oil level is below the lower level line,
refill with suitable oil (see table) to
upper level line. Do not screw in the
oil filler cap when checking oil level.
■
Change oil if contaminated.
(See "How-To" Maintenance.)
Oil capacity (Upper level) : L (U.S. gal)
RGX3000 . . . . . . . . . . . . . . 0.6 (0.15)
RGX3800 . . . . . . . . . . . . . . 0.6 (0.15)
RGX5100 . . . . . . . . . . . . . . 1.0 (0.26)
RGX7100 . . . . . . . . . . . . . . 1.2 (0.32)
RGX7800 . . . . . . . . . . . . . . 1.2 (0.32)
Recommended engine oil:
Use 4-stroke automotive detergent oil
of API service class SE or higher grade
5W
10W
20W
#20
Single grade
(SG, SH or SJ is recommended). SAE
10W-30 or 10W-40 is recommended
for general, all-temperature use. If
single viscosity oil is used, select the
appropriate viscosity for the average
temperature in your area.
#30
#40
10W
-30
Multigrade
10W
-
40
Ambient
temperature
Download from Www.Somanuals.co－m. 7Al－l Manuals Search And Download.
CHECK ENGINE FUEL.
WARNING
Do not refuel while smoking or near open flame or other such
potential fire hazards. Otherwise fire accident may occur.
NOTE :
THIS ENGINE IS CERTIFIED TO OPERATE
ON AUTOMOTIVE UNLEADED GASOLINE.
LEVEL
■
■
Check fuel level at fuel level gauge.
If fuel level is low, refill with
unleaded automotive gasoline.
■
Be sure to use the fuel filter screen
on the fuel filter neck.
Fuel tank cap
Fuel filter screen
RGX3000
RGX3800
RGX5100
RGX7100
RGX7800
Fuel Amount
up to "LEVEL" position :
(L)
RGX3000 . . . . . . . . . . . . . . . . . 12.8
RGX3800 . . . . . . . . . . . . . . . . . 12.8
RGX5100 . . . . . . . . . . . . . . . . . 12.8
RGX7100 . . . . . . . . . . . . . . . . . 22.0
RGX7800 . . . . . . . . . . . . . . . . . 22.0
FULL
E
F
EMPTY
EMPTY
FULL
WARNING
Make sure you review each warning in order to prevent fire hazard.
■
Do not refill tank while engine is running or hot.
■
Close fuel valve before refueling with fuel.
■
Be careful not to admit dust, dirt, water or other foreign objects Into
fuel.
■
■
Wipe off spilt fuel thoroughly before starting engine.
Keep open flames away.
－8－
Download from Www.Somanuals.com. All Manuals Search And Download.
CHECKING COMPONENT PARTS
Check following items before starting engine:
■
Fuel leakage from fuel hose, etc.
■
Bolts and nuts for looseness.
■
Components for damage or breakage.
■
Generator not resting on or against any adjacent wiring.
CHECK GENERATOR SURROUNDINGS
WARNING
Make sure you review each warning in order to prevent fire hazard.
■
Keep area clear of in flammables or other hazardous materials.
■
Keep generator at least 3 feet (1 meter) away from buildings or other
structures.
■
Only operate generator in a dry, well ventilated area.
■
Keep exhaust pipe clear of foreign objects.
■
Keep generator away from open flame. No smoking!
■
Keep generator on a stable and level surface.
■
Do not block generator air vents with paper or other material.
BATTERY INSTALLATION (Electric Starter Model)
Recommended Battery
Type
Capacity (Ah/5hr) ; 12V-21AH or more
Size ; Less than 185(L) x 125(W) x 160(H) mm
; Lead-acid battery
Setting Plate
Nut
Earth Cable(BLACK)
Bolt Protection Plate
Bolt
Battery Frame #1
Bolt
Starter Cable(RED)
Nut
Setting Bolt
Bolt
Battery Frame #2
Download from Www.Somanuals.co－m. 9Al－l Manuals Search And Download.
Nut
Bolt
Battery Plate
WARNING
Death, personal injury and/or property damage may occur unless
instructions are followed carefully.
■
Use battery of recommended capacity.
■
Turn the starter switch to the "STOP" position when mounting or
dismounting battery. When mounting battery, connect the positive (+)
cable first and then the negative (-) cable to the battery. Be careful not to
short battery cables. When dismounting battery, disconnect negative (
-)
cable first.
RED CABLE
: To positive (+) terminal
: To negative ( ) terminal
BLACK CABLE
-
■
■
■
Should the connection be made in incorrect manner, the generator will
be broken.
Tighten bolts and nuts on terminals securely so they will not be
loosened by vibration.
Disconnect battery cables when charging battery.
GROUNDING THE
GENERATOR
■
To ground the generator to the earth,
connect the grounding lug of the
generator to the grounding spike
driven into the earth or to the
conductor which has been already
grounded to the earth.
Grounding spike
■
If such grounding conductor or
grounding electrode is unavailable,
connect the grounding lug of the
generator to the grounding terminal of
the using electric tool or appliance.
Download from Www.Somanu－als.1co0m－. All Manuals Search And Download.
5. OPERATING PROCEDURES
STARTING THE GENERATOR
CAUTION
［
］
Check the oil level before each operations as outlined by the article
"CHECK ENGINE OIL"
(a) Turn the Engine switch to the position
ON
"ON".
OFF
(b) Turn the AC circuit breaker to the
position "OFF".
ON
OFF
OFF
(c) Open the fuel valve.
CLOSE
CLOSE
OPEN
(d) Set choke lever to close if the engine
Choke lever
is cold.
CLOSE
OPEN
－11－
Download from Www.Somanuals.com. All Manuals Search And Download.
(e) [Recoil starter model]
Pull the starter handle slowly until
passing the compression point
(resistance will be felt), then return
the handle to its original position
and pull briskly.
■
If the engine fails to start after several
attempts, repeat above procedures
with choke lever returned to "OPEN"
position.
■
Do not fully pull out the rope.
■
After starting, allow the starter handle
to return to its original position while
still holding the handle.
(f) [Electric starter model]
STOP
Insert the key into the key switch and
turn it clockwise to the "RUN" position
to start the engine.
RUN
RUN
STOP
START
START
Then turn the key further to the
"START" position. The engine will be
started by starting motor.
CAUTION
［
］
■
Do not run the starting motor over 5 seconds continuously.
If the engine fails to start, return the key to the "RUN" position and wait
about 10 seconds then start again.
■
■
Do not turn the key switch to "START" position when the engine is
running to prevent damage of starting motor.
When starting the engine by recoil starter, set the key switch at the "ON"
position and pull the starter handle.
Download from Www.Somanu－als.1co2m－. All Manuals Search And Download.
(g) After the engine started, return the
choke lever gradually to "OPEN"
position.
Choke lever
CLOSE
OPEN
(h) Warm up the engine without a load for
a few minutes.
－13－
Download from Www.Somanuals.com. All Manuals Search And Download.
USING ELECTRIC POWER
WARNING
■
Make sure that the appliance is switched OFF before connecting it to
the generator.
■
Do not move the generator while it is running.
■
Be sure to ground the generator if the connected appliance is
grounded. Failure to ground unit may lead to electrical shock.
(1) AC APPLICATION
(a) Make sure the pilot lamp is turned on.
(b) Turn off the switch (es) of the electrical
appliance (s) before connecting to the
generator.
(c) Insert the plug (s) of the electrical
appliance(s) into the receptacle.
■
Check the amperage of the receptacles used referring to TABLE 1, and be
sure not to take a current exceeding the specified amperage.
■
Be sure that the total wattage of all appliances dose not exceed the rated
output of the generator.
Download from Www.Somanu－als.1co4m－. All Manuals Search And Download.
Style
Ampere
Receptacle
AC plug
Description
GFCI (Ground Fault
Circuit Interrupter)
Receptacle, duplex
(REC1)
NEMA
5-20R
NEMA
5-20P
up to 20A
NEMA
L5-30R
NEMA
L5-30P
Locking Receptacle
(REC3)
up to 30A
up to 30A
NEMA
L14-30R
NEMA
L14-30P
Locking Receptacle
(REC4)
TABLE 1
WARNING
TWIST
■
To take power out from the TWIST
LOCK RECEPTACLE, insert the
plug into the receptacle, and turn
it clockwise to the lock position.
■
Be sure to ground the generator if
the connected electrical device Is
grounded.
NOTE :
When the AC circuit breaker turns off during operation, the generator is over
loaded or the appliance is defective. Stop the generator immediately, check the
appliance and / or generator for overloading or detect and have repaired as
necessary by Robin dealer or service shop.
CAUTION
［
］
The duplex 120V receptacle is protected by a GFCI (Ground Fault Circuit
Interrupter). GFCI shuts off the output current from the duplex 120V
receptacle when a ground fault occurs in the generator or the appliance.
Please note that other receptacles are not protected by GFCI.
－15－
Download from Www.Somanuals.com. All Manuals Search And Download.
(d) Turn the AC circuit breaker to the
position "ON".
ON
(e) Turn on the switch of the appliance.
OFF
ON
GFCI RECEPTACLE
After starting the engine, check the GFCI for proper functioning by the following
test procedure.
■
Push blue TEST button, The red RESET button will pop out exposing the word
TRIP. Power is now off at the outlets protected by the GFCI, indicating that the
device is functioning properly.
■
If TRIP dose not appear when testing, do not use the generator. Call a
qualified electrician.
■
To restore power, push RESET button.
WARNING
If the RESET button pops out during operation, stop the generator
immediately and call a qualified electrician for checking generator and
the appliances.
Download from Www.Somanu－als.1co6m－. All Manuals Search And Download.
FULL POWER SWITCH (Except RGX3000)
Select the voltage using the FULL
POWER SWITCH in accordance with the
electrical appliance.
120V
240V
Refer to TABLE 2.
120V
CAUTION
［
］
Change the FULL POWER SWITCH
after turning the AC circuit breaker
to "OFF".
Switch position
120V
Lower Voltage Receptacle
Activated full rated output
Activated half of rated output
TABLE 2
Higher Voltage Receptacle
N.A
120/240V
Activated full rated output
－17－
Download from Www.Somanuals.com. All Manuals Search And Download.
IDLE CONTROL SWITCH (Except RGX3000)
IDLE CONTROL SWITCH automatically reduces engine speed when load is OFF,
and automatically increases engine speed to rated r.p.m. when load is ON.
IDLE CONTROL SWITCH provides fuel economy and low noise operation at no-
load running.
(1) HOW TO USE IDLE CONTROL SWITCH
■
Start the engine with IDLE CONTROL
OFF
SWITCH off.
ON
NOTE :
Warm up the engine without a load for a
few minutes.
■
Turn IDLE CONTROL SWITCH on.
(2) CHECKING THE OPERATION
When IDLE CONTROL SWITCH does not operate normally, please check following :
■
Overloaded ?
Please make it sure that the generator is not overload.
NOTE :
Most induction loads such as electric motors require three to five times more
wattage than their ratings during starting.
This starting wattage should not exceed the rated output of the generator for proper
operation of IDLE CONTROL SWITCH.
■
Turn IDLE CONTROL SWITCH off when the IDLE CONTROL SWITCH does not
work normally under the rated output.
NOTE :
The IDLE CONTROL SWITCH may not operate when the applied load is under 40W.
In such cases turn the IDLE CONTROL SWITCH off.
(3) STOPPING THE ENGINE
■
Turn off the switch of load.
■
Switch off generator's AC breaker.
■
Disconnect tool or appliance.
■
Turn the IDLE CONTROL SWITCH off.
■
Turn the STOP SWITCH to the position "O" (OFF).
NOTE :
Allow the engine about 3 minutes to cool down at no-load before stopping.
Download from Www.Somanu－als.1co8m－. All Manuals Search And Download.
(2) DC APPLICATION
(Only for charging 12 volt battery)
BLACK
CABLE
DC receptacle (Only for charging 12 volt
battery)
RED
CABLE
-
+
For charging 12 voltage battery, 12V-8.3A
(100W) of maximum AC power can be
taken out from the DC receptacle by
means of the exclusive DC cable.
DC receptacle
The exclusive DC cable is come with your
generator set (included in the package).
DC Circuit Breaker
DC circuit breaker is turned off to shut down the DC power, when the DC is over
the usage range or the battery is defective.
Check the generator and/or battery for overloading or defect, and turn on the DC
circuit breaker after no problem and defect are found out.
Connection of exclusive DC cable :
■
Connect positive (red) clip of DC cable to positive (+) terminal on battery.
■
Connect negative (black) clip of DC cable to negative (-) terminal on battery.
－19－
Download from Www.Somanuals.com. All Manuals Search And Download.
Battery Charging Procedures :
1) Stop engine.
2) Remove all connections from battery.
3) Insert the plug of exclusive DC cable into DC receptacle.
4) Connect positive (red) clip of DC cable to positive (+) terminal on battery, and
then connect negative (black) clip of DC cable to negative (-) terminal on
battery.
5) Take out all plugs at the battery electrolyte fluid filler ports.
6) Check the electrolyte fluid level, and refill the distilled water as necessary.
7) Start engine.
8) Make sure that the pilot lamp is turned on.
9) Make sure that the DC circuit breaker is in the ON position.
10) Battery charging will be started.
CAUTION
［
］
■
Do not use both AC and DC output at the same time.
■
Install correct positive (red) or negative (black) cable to the correct
polarity on the battery.
■
■
Connect and disconnect DC cable with engine stopped.
An explosive hydrogen gas is discharged through vent holes in the
battery during the charging process.
Do not allow spark or open flame around the generator or battery during
the charging process.
■
Electrolyte fluid contains sulphuric acid, and so the fluid can burn eyes
and clothing. Be extremely careful to avoid contact.
If injured, wash the affected area immediately with large quantities of
water and consult a doctor for treatment.
■
Charging time is varied according to the kind of battery and discharged
level of battery.
Measure the specific gravity of electrolyte fluid by means of hydrometer
every one hour during battery charging.
Make sure if the DC circuit breaker is not turned off.
Battery charging is completed when the specific gravity is in the range of
1.26 to 1.28.
Download from Www.Somanu－als.2co0m－. All Manuals Search And Download.
ON
STOPPING THE GENERATOR
(a) Turn off the power switch of the
electric equipment and unplug the cord
from receptacle of the generator.
OFF
OFF
(b) Turn the AC circuit breaker to the
"OFF" position.
ON
(c) Allow the engine about 3 minutes to
cool down at no-load before stopping.
(d)［Recoil starter model］
Turn the engine switch to the position
"OFF".
OFF
RUN
STOP
RUN
STOP
ST
ART
［Electric starter model］
Turn the key switch to the STOP
position.
START
(e) Close the fuel valve.
OIL SENSOR
CLOSE
(a) The oil sensor detects the fall in oil
level in the crankcase and automati-
cally stops the engine when the oil
level falls below a predetermined level.
CLOSE
(b) When engine has stopped
automatically, switch off generator's
AC circuit breaker, and check the oil
level.
OPEN
Refill engine oil to the upper level as
instructed on page 7 and restart the
engine.
Oil sensor
(c) If the engine does not start by usual
starting procedures, check the oil level.
－21－
Download from Www.Somanuals.com. All Manuals Search And Download.
6. WATTAGE INFORMATION
Some appliances need a "surge" of energy when starting.
This means that the amount of electrical power needed to start the appliance may exceed
the amount needed to maintain its use.
Electrical appliances and tools normally come with a label indicating voltage, cycles / Hz,
amperage (amps) and electrical power needed to run the appliance or tool.
Check with your nearest dealer or service center with questions regarding power surge of
certain appliances or power tools.
■
Electrical loads such as incandescent lamps and hot plates require the same wattage
to start as is needed to maintain use.
■
Loads such as fluorescent lamps require 1.2 to 2 times the indicated wattage during
start-up.
■
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.
■
Electrical motors require a large starting current. Power requirements depend on the
type of motor and its use. Once enough "surge" is attained to start the motor,
the appliance will require only 50% to 30% of the wattage to continue running.
■
Most electrical tools require 1.2 to 3 times their wattage for running under load during
use. For example, a 5,000 watt generator can power a 1800 to 4000 watt electrical
tool.
■
Loads such as submersible pumps and air compressors require a very large force to
start. They need 3 to 5 times the normal running wattage in order to start.
For example, a 5,000 watt generator would only be able to drive a 1,000 to 1,700 watt
pump.
NOTE :
The following wattage chart is general guide only. Refer to your specific appliance for
correct wattage.
To determine the total wattage required to run a particular electrical appliance or tool,
multiply the voltage figure of the appliance/tool by the amperage (amps) figure of same.
The voltage and amperage (amps) information can be found on a name plate which is
normally attached to electrical appliances and tools.
Applicable Wattage(W)
Applications
RGX3000 RGX3800 RGX5100 RGX7100 RGX7800
Incandescent lamp, Heater
Fluorescent lamp, Electric tool
Mercury lamp
2400
1300
950
2900
1600
1150
700
4200
2300
1700
1050
5000
2750
2000
1250
6000
3300
2400
1500
Pump, Compressor
600
Download from Www.Somanu－als.2co2m－. All Manuals Search And Download.
VOLTAGE DROP IN ELECTRIC EXTENSION CORDS
When a long electric extension cord is used to connect an appliance or tool to the
generator, a certain amount of voltage drop or loss occurs in the extension cord
which reduces the effective voltage available for the appliance or tool.
The chart below has been prepared to illustrate the approximate voltage loss when
an extension cord of 300 feet (approx. 100 meters) is used to connect an
appliance or tool to the generator.
Nominal
cross
section
Allowable No.of strands
Resistance
A.W.G.
Current Amp.
current
/ strands dia.
mm2
0.75
1.27
2.0
No.
18
A
No./mm
30/0.18
50/0.16
37/0.26
45/0.32
70/0.32
1A 3A 5A 8A 10A 12A 15A
Ω/100m
7
2.477 2.5V 8V 12.5V
─
─
─
─
─
16
12
17
23
35
1.486 1.5V 5V 7.5V 12V 15V 18V
14
0.952
0.517
0.332
1V 3V 5V 8V 10V 12V 15V
3.5
12 to 10
10 to 8
1.5V 2.5V 4V 5V 6.5V 7.5V
1V 2V 2.5V 3.5V 4V 5V
─
─
5.5
－23－
Download from Www.Somanuals.com. All Manuals Search And Download.
7. SPARK ARRESTER
In a dry or wooded area, it is recommendable to use the product with a spark arrester.
Some areas require the use of a spark arrester. Please check your local laws and
regulations before operating your product
.
The spark arrester must be cleaned regularly to keep it functioning as designed.
A clogged spark arrester :
● Prevents the flow of exhaust gas
● Reduces engine output
● Increases fuel consumption
● Makes starting difficult
If the engine has been running, the muffler and the spark arrester will be very hot.
Allow the muffler to cool before cleaning the spark arrester.
How to remove the spark arrester
1. Remove the flange bolts from the muffler cover and remove the muffler cover.
2. Remove the special screw from the spark arrester and remove the spark arrester
from the muffler.
RGX3000, 3800, 5100
RGX7100, 7800
Muffler
cover
Spark
arrester
screen
Spark arrester screen
Muffler cover
Exhaust
outlet
Screw
Clean the spark arrester screen
Use a brush to remove carbon deposits from the spark arrester screen.
Be careful to avoid damaging the screen.
The spark arrester must be free of breaks and holes. Replace the spark arrester if it
is damaged.
Install the spark arrester, and muffler protector in the reverse order of disassembly.
RGX3000, 3800, 5100
RGX7100, 7800
Spark arrester screen
Spark arrester screen
Download from Www.Somanu－als.2co4m－. All Manuals Search And Download.
8. MAINTENANCE SCHEDULE
MAINTENANCE, REPLACEMENT, OR REPAIR OF THE EMISSION CONTROL DEVICES
AND SYSTEMS MAY BE PERFORMED BY ANY NONROAD ENGINE REPAIR
ESTABLISHMENT OR INDIVIDUAL.
DAILY INSPECTION
Before running the generator, check the following service items:
Enough gasoline
Excessive vibration,noise
Enough clean engine oil
Loose or broken bolts and nuts
Leakage of gasoline and engine oil
Safe surroundings
Clean air cleaner element
PERIODIC MAINTENANCE
Periodic maintenance is vital to safe and efficient operation of your generator.
Check the table below for periodic maintenance intervals.
IT IS ALSO NECESSARY FOR THE USER OF THIS GENERATOR TO
CONDUCT THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION-
RELATED PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL
SYSTEM EFFECTIVE.
The emission control system consists of the following parts :
(1) Carburetor and internal
parts
(4) Air cleaner elements
(5) Spark plug
(8) Exhaust manifold, if
applicable
(2) Cold start enrichment
system, if applicable
(9) Hoses, belts,
connectors, and
assemblies
(6) Magneto or electronic
ignition system
(3) Intake manifold, if
applicable
(7) Spark advance/retard
system, if applicable
The maintenance schedule indicated in the table is based on the normal generator
operation. Should the generator be operated in extremely dusty condition or in
heavier loading condition, the maintenance intervals must be shortened depending
on the contamination of oil, clogging of filter elements, wear of parts, and so on.
－25－
Download from Www.Somanuals.com. All Manuals Search And Download.
Periodic Maintenance Schedule table
Every
8 hours
(Daily)
Every
50 hours 200 hours
(Weekly) (Monthly)
Every
Every
500
hours
Every
1000
hours
Maintenance Items
(Daily)
Clean generator and check bolt and nuts
Check and refill engine oil
●
●
(Refill daily up to upper level)
Change engine oil (*Note1)
● (Initial
● (Every
20 hours) 100 hours)
(Every 100 hours)
Clean spark plug
Clean air cleaner
●
●
●
(Every 100 hours)
Clean spark arrester
Replace air cleaner element
Clean fuel filter
●
●
●
Clean and adjust spark plug and electrodes
Replace spark plug
●
●
●
●
●
Remove carbon from cylinder head (*Note 2)
Check and adjust valve clearance (*Note 2)
Clean and adjust carburetor (*Note 2)
Check and replace carbon brushes
Replace fuel lines
● (Yearly)
Overhaul engine (*Note 2)
●
● (Daily)
● (Daily)
● (Daily)
Check AC receptacles
Check DC termianl
Check engine switch
Check rotor
●
●
●
Check stator
Replace engine mount
*Note: 1. Initial oil change should be performed after first twenty (20) hours of operation.
Thereafter change oil every hundred (100) hours.
Before changing oil, check for a suitable way to dispose of old oil.
Do not pour it down into sewage drains, onto garden soil or into open streams. Your
local zoning or environmental regulations will give you more detailed instructions on
proper disposal.
*Note: 2. As to the procedures for these items, please refer to the SERVICE MANUAL or
consult your nearest service dealer.
Download from Www.Somanu－als.2co6m－. All Manuals Search And Download.
9. "HOW-TO" MAINTENANCE
ENGINE OIL CHANGE
■
Change engine oil every 100 hours.
(For new engine, change oil after 20
hours.)
(a) Drain oil by removing the drain plug
and the oil filler cap while the engine
is warm.
Oil drain plug
(b) Reinstall the drain plug and fill the engine with oil until it reaches the upper level
on the oil filler cap.
■
Use fresh and high quality lubricating oil to the specified level as directed on page 7.
If contaminated or deteriorated oil is used or the quantity of the engine oil is not
sufficient, the engine damage will result and its life will be greatly shortened.
SERVICING THE AIR CLEANER
Maintaining an air cleaner in proper condition is very important.
Dirt induced through improperly installed, improperly serviced or inadequate
elements damages and wears out engines. Keep the element always clean.
(a) Remove the bolt of air cleaner cover. (RGX7100, 7800)
Remove the air cleaner cover and cleaner element.
(b) Urethane form : Wash urethane form element in kerosene or diesel fuel. Then
saturate the element in a mixture of 3 parts kerosene or diesel fuel and 1 part
engine oil.
Squeeze the element to remove the mixture and install it in the air cleaner.
NOTE :
Instead of washing oil (kerosene), it is possible to wash the urethane foam element
in a solution of mild detergent and warm water.
Then rinse the element thoroughly in clean water.
Allow the element to dry thoroughly. Soak the element in clean engine oil and
squeeze out excess oil.
RGX3000, 3800
Element
RGX5100
RGX7100, 7800
Element
Element
Base
Bolt
Base
Base
Air cleaner
cover
Air cleaner
cover
Air cleaner
cover
－27－
Download from Www.Somanuals.com. All Manuals Search And Download.
CLEANING AND ADJUSTING
SPARK PLUG
(a) If the plug is contaminated with carbon,
remove it using a plug cleaner or wire
brush.
(b) Adjust the electrode gap to 0.6 to 0.7
mm (0.024 to 0.028 in.).
Gap 0.6 to 0.7 mm
(
)
0.024 to 0.028 in.
Spark plug : BR-6HS (NGK)
CLEANING FUEL STRAINER
Dirt and water in the fuel are removed by
the fuel strainer.
(a) Remove the strainer cup and throw
away water and dirt.
(b) Clean the screen and strainer cup
with gasoline.
(c) Tightly fasten the cup to main body,
making sure to avoid fuel leak.
Download from Www.Somanu－als.2co8m－. All Manuals Search And Download.
CHECKING CARBON BRUSH
Brush Maintenance Essentials (Effective Length)
The brush is the area which touches the slip ring, and its surface must be kept
smooth.
If it is not smooth then carbon and other substances will adhere between the brush
and slip ring.
This must be buffed with sandpaper or the like because it is hazardous.
The usable length of the brush is 5~11mm, so if the brush is 5mm long or less
replace it with a new one.
This is done because if the length of the
brush gets any shorter, its contact
pressure with the slip ring will decrease,
resulting in a drop in generator efficiency
and the output voltage.
Check the brush every 500 hours to
Length when new
confirm its length.
In addition, check the brush length if the
generator malfunctions, such as when it is
10~11mm
not generating power or its voltage is low.
Effective brush length
5 mm
－29－
Download from Www.Somanuals.com. All Manuals Search And Download.
Brush Maintenance Essentials (Disassembly and Assembly)
Disassembly
1. Remove the two flange bolts (M5 x 20),
then remove the bracket cover.
Brush
2. Remove the two flange bolts (M5 x 16),
then remove the brush.
Slip ring
Assembly
1. While pressing the brush against the
slip ring, secure it (1.5~2N・m) by
tightening it with the two flange bolts
Brush holder
Flange bolts
(M5 x 16).
When doing so, confirm that the brush
is in the proper position relative to the
slip ring.
2. Secure the bracket cover (3~4N・m) by
tightening it with the two flange bolts
(M5 x 20).
Bracket cover
Flange bolts
Download from Www.Somanu－als.3co0m－. All Manuals Search And Download.
10. PREPARATION FOR STORAGE
The following procedures should be followed prior to storage of your generator for
periods of 6 months or longer.
■
Drain fuel from fuel tank carefully by
disconnecting the fuel line.
Gasoline left in the fuel tank will
eventually deteriorate making engine-
starting difficult.
Drain screw
■
Remove the carburetor float chamber
and also drain the carburetor.
■
Change engine oil.
■
Check for loose bolts and screws,
tighten them if necessary.
■
Clean generator thoroughly with oiled cloth. Spray with preservative if
available. NEVER USE WATER TO CLEAN GENERATOR !
■
Pull starter handle until resistance is felt, leaving handle in that position.
■
Store generator in a well ventilated, low humidity area.
－31－
Download from Www.Somanuals.com. All Manuals Search And Download.
11. TROUBLESHOOTING
When generator engine fails to start after several attempts, or if no electricity is
available at the output socket, check the following chart. If your generator still fails
to start or generate electricity, contact your nearest Robin dealer or service shop
for further information or corrective procedures.
When Engine Fails to Start :
Set the choke lever to "CLOSE"
position.
Check if choke lever is in its proper
position.
Check if fuel valve is open.
Check fuel level.
If closed, open fuel valve.
If empty, refill fuel tank making sure not
to overfill.
Check if engine switch is in OFF.
Turn engine switch to ON.
Check to make sure generator is not
connected to an appliance.
If connected, turn off the power switch
on the connected appliance and unplug.
Check spark plug for loose spark plug
cap.
If loose, push spark plug cap back into
place.
Check spark plug for contamination.
Remove spark plug and clean electrode.
When No Electricity Is Generated at Receptacle :
After making sure that the total wattage
of the electrical appliance is within
permissible limits and there are no
defects in the appliance, turn the AC
circuit breaker to the "ON" position.
If breakers continue to actuate, consult
your nearest servicing dealer.
Check to make sure AC circuit breaker
is in the "ON" position.
Check AC receptacle and DC terminals
for loose connection.
Secure connection if necessary.
Turn off switch on the appliance, and
disconnect cable from receptacle.
Reconnect after generator has been
started properly.
Check to see if engine starting was
attempted with appliances already
connected to generator.
Low power.
Carbon brushes are excessively worn
Download from Www.Somanu－als.3co2m－. All Manuals Search And Download.
12. WIRING DIAGRAM
P i l o t l a m p
H o u r m e t e r
O i l s e n s o r u n i t
D C w i n d i n g
Y
Y
O i l s e n s o r s w i t c h
I g n i t i o n c o i l
B l u
B r n
B l u
B r n
B l u
Y
S p a r k p l u g
－33－
Download from Www.Somanuals.com. All Manuals Search And Download.
G r n / Y
b r e a k e r
A C c i r c u i t
I d l e c o n t r o l u n i t
P i l o t l a m p
B l k
W
H o u r m e t e r
s o l e n o i d
S l o w d o w n
W
W
O i l s e n s o r u n i t
D C w i n d i n g
Y
Y
O i l s e n s o r s w i c h
I g n i t i o n c o i l
l u B
B r n
B l u
B r n
B l u
S p a r k p l u g
Y
Download from Www.Somanu－als.3co4m－. All Manuals Search And Download.
G r n / Y
b r e a k e r
A C c i r c u i t
I d l e c o n t r o l u n i t
P i l o t l a m p
B l k
W
H o u r m e t e r
C h a r g e c o i l
s o l e n o i d
S l o w d o w n
W
W
M a g n e t i c s w i t c h
E l e c t r i c s t a r t e r
O i l s e n s o r u n i t
D C w i n d i n g
Y
Y
O i l s e n s o r s w i t c h
B l u
B r n
B l u
B r n
I g n i t i o n c o i l
B l u
Y
S p a r k p l u g
－35－
Download from Www.Somanuals.com. All Manuals Search And Download.
G r n / Y
b r e a k e r
b r e a k e r
A C c i r c u i t
A C c i r c u i t
b r e a k e r
A C c i r c u i t
b r e a k e r
A C c i r c u i t
I d l e c o n t r o l u n i t
P i l o t l a m p
H o u r m e t e r
s o l e n o i d
S l o w d o w n
W
W
O i l s e n s o r u n i t
D C w i n d i n g
B l u
B l u
B l u
O i l s e n s o r s w i t c h
B l u
W
I g n i t i o n c o i l
W
G r n
G r n
R
W
S p a r k p l u g
Download from Www.Somanu－als.3co6m－. All Manuals Search And Download.
G r n / Y
b r e a k e r
A C c i r c u i t
b r e a k e r
A C c i r c u i t
b r e a k e r
A C c i r c u i t
b r e a k e r
A C c i r c u i t
I d l e c o n t r o l u n i t
P i l o t l a m p
H o u r m e t e r
C h a r g e c o i l
S l o w d o w n s o l e n o i d
W
W
M a g n e t i c s w i t c h
E l e c t r i c s t a r t e r
O i l s e n s o r u n i t
D C w i n d i n g
B l u
B l u
W
O i l s e n s o r s w i t c h
I g n i t i o n c o i l
W
G r n
G r n
R
W
S p a r k p l u g
－37－
Download from Www.Somanuals.com. All Manuals Search And Download.
Download from Www.Somanuals.com. All Manuals Search And Download.
ISSUE EMD-GU6809
PRINTED IN JAPAN
September 2009
IMPRESO EN JAPÓN
Septiembre 2009
Download from Www.Somanuals.com. All Manuals Search And Download.
|