PARTS MANUAL. RGD5000 Generator. Model. PUB-GP1204 Rev. 7/98

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1 PARTS MANUAL Model RGD5000 Generator PUB-GP1204 Rev. 7/98

2

3 GROUP INDEX Group Name Page GENERATOR GROUP... 4 FRAME and FUEL TANK GROUP... 6 CONTROL BOX GROUP... 8 CRANKCASE GROUP CYLINDER and CYLINDER HEAD GROUP CRANKSHAFT and PISTON GROUP CAMSHAFT and VALVE GROUP MUFFLER and AIR CLEANER GROUP GOVERNOR OPERATION GROUP BLOWER HOUSING GROUP RECOIL STARTER GROUP FUEL INJECTION PUMPand NOZZLE GROUP FUEL FILTER GROUP STARTING MOTOR GROUP Lively Blvd. Wood Dale, IL Phone: Fax: sales@robinamerica.com Copyright 1998 Robin America, Inc. RGD '98-7

4 FIG. 1 GENERATOR GROUP RGD '98-7

5 FIG. 1 GENERATOR GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * ROTOR, compl. 1 Includes item BALL BEARING (6205-2RS) STATOR, compl SUPPORT RING REAR COVER, compl BOLT WASHER SPRING WASHER THROUGH BOLT WASHER SPRING WASHER BOLT and WASHER ASS Y BUSHING STARTING PULLEY, compl KEY CLAMP SPACER 1 RGD '98-7

6 FIG. 2 FRAME AND FUEL TANK RGD '98-7

7 FIG. 2 FRAME AND FUEL TANK REF PART NUMBER DESCRIPTION QTY REMARKS PIPE FRAME, compl. 1 * SIDE PLATE, compl. 1 Includes item LABEL (RGD5000) BOLT and WASHER ASS Y FLANGE BOLT ENGINE BASE, compl VIBRATION ISOLATOR NUT STOPPER BOLT and WASHER ASS Y BOLT FLANGE NUT GENERATOR BASE, compl RUBBER MOUNT BOLT and WASHER ASS Y WASHER EARTH CORD FUEL TANK, compl FUEL FILTER LABEL, caution LABEL, fuel only LABEL, caution FUEL TANK CAP, compl FUEL GAUGE, compl SCREW, counter head RUBBER VIBRATION ISOLATOR BATTERY BASE FLANGE BOLT BATTERY BOLT NUT SPRING WASHER BATTERY ANGLE BATTERY CORD (+) BATTERY CORD BATTERY SUPPORT SCREW and WASHER ASS Y CLAMP 1 RGD '98-7

8 FIG. 3 CONTROL BOX GROUP RGD '98-7

9 FIG. 3 CONTROL BOX GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * CONTROL BOX ASS Y 1 Includes items I thru CONTROL BOX 1 * CONTROL PANEL A ASS Y 1 Includes items 2 thru CONTROL PANEL A NO-FUSE BREAKER (20A) NO-FUSE BREAKER (30A) SCREW and WASHER ASS Y (M3 x 6mm) V-METER (AC 200V) NUT (M3) B AC RECEPTACLE (1 25V-20A GFCI) SCREW and WASHER ASS Y WASHER NUT AC RECEPTACLE (125V-30A, TWIST LOCK) AC RECEPTACLE (125V/25OV-20A) 1 For 4P TWIST LOCK SCREW SWITCH, full power STARTER SWITCH 1 Includes item 16A 16A KEY SET LED SCREW (M5 x 15mm) SPRING WASHER WASHER SPRING WASHER NUT (M5) WING NUT (M5) FUSE HOLDER (DC) (250V-10A) FUSE (10A) TERMINAL BOLT (COLOR: RED) I TERMINAL BOLT (COLOR: BLACK) CONDENSER (30 µ F x 2) CONDENSER BRACKET SCREW and WASHER ASS Y SCREW and WASHER ASS Y (M4 x 15mm) NUT (M4) DIODE STACK ASS Y SCREW and WASHER ASS Y (M4 x 18mm) OIL SENSOR, compl BOLT and WASHER ASS Y CONNECTOR GROMMET CLAMP FLANGE BOLT (M6 x 12mm) EGULATOR, compl BOLT and WASHER ASS Y FUSE HOLDER 1 RGD '98-7

10 FIG. 3 CONTROL BOX GROUP RGD '98-7

11 FIG. 3 CONTROL BOX GROUP, cont. REF PART NUMBER DESCRIPTION QTY REMARKS FUSE (1 5A) SCREW LABEL, model 1 RGD '98-7

12 FIG. 4 CRANKCASE GROUP RGD '98-7

13 FIG. 4 CRANKCASE GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * CRANKCASE, compl. 1 Includes items 2 thru 8, MAIN BEARING, STD MAIN BEARING, under size 0.25mm MAIN BEARING, under size 0.5mm TENSION BOLT TENSION BOLT PIPE KNOCK DOWEL PIN SPRING PIN SWITCH ASS Y, oil pressure THRUST BEARING 1 * BEARING HOUSING 1 Includes item OIL SEAL (40 x 58 x 8) GASKET, t= GASKET, t= GASKET, t= O-RING, bearing housing 1 * GEAR CASE COVER, compl. 1 Includes items -14 thru BALL BEARING (BB-6007C3) I STUD STUD BLIND PLATE GASKET, case cover (T=0.5) OIL PAN, GASKET, oil pan (t=1.5) BOLT and WASHER ASS Y BOLT and WASHER ASS Y BOLT and WASHER ASS Y BOLT and WASHER ASS Y BALANCER COVER GASKET, balancer cover BOLT and WASHER ASS Y ADJUSTING SCREW BLIND PLUG PLUG NUT GASKET, aluminum OIL FILTER ASS Y RING OIL GAUGE, compl ;PLUG GASKET I BOLT and WASHER ASS Y CLAMP BOLT and WASHER ASS Y WIRE 11, compl STUD 2 RGD '98-7

14 FIG. 5 CYLINDER and CYLINDER HEAD GROUP RGD '98-7

15 FIG. 5 CYLINDER and CYLINDER HEAD GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * CYLINDER HEAD, compl. 1 Includes items 2 thru VALVE GUIDE STUD STUD STUD CYLINDER UNIT ROCKER COVER BREATHER PLATE, compl GASKET, breather (t=2) GASKET, rocker cover RING, cylinder SPACER, cylinder (t=0.1) SPACER, cylinder (t=0.2) BOLT and WASHER ASS Y BOLT and WASHER ASS Y RING I FLANGE NUT WASHER 4 RGD '98-7

16 FIG. 6 CRANKSHAFT and PISTON GROUP RGD '98-7

17 FIG. 6 CRANKSHAFT and PISTON GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * CRANKSHAFT, compl. 1 Includes item BALL BEARING (BB-6308C3) 1 * CONNECTING ROD ASSY 1 Includes items 4 and SMALL END BUSH CONNECTING ROD BOLT LARGE END BEARING, STD LARGE END BEARING, under size 0.25mm LARGE END BEARING, under size 0.50mm PISTON, STD PISTON, over size 0.25mm PISTON, over size 0.50mm PISTON PIN PISTON RING SET, STD PISTON RING SET, over size 0.25mm PISTON RING SET, over size 0.50mm CLIP FLYWHEEL LOCK NUT KEY LOCK WASHER DRIVING SHAFT BOLT SPRING WASHER ADAPTER, generator BOLT and WASHER ASS Y RING GEAR PI E KNOCK SCREW 4 RGD '98-7

18 FIG. 7 CAMSHAFT and VALVE GROUP RGD '98-7

19 FIG. 7 CAMSHAFT and VALVE GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * CAMSHAFT ASS Y 1 Includes items 1 thru CAMSHAFT, compl WOODRUFF KEY CAMSHAFT GEAR, compl RELEASE LEVER 1 * EXHAUST ROCKER ARM, compl. Includes items 6 and ADJUSTING SCREW NUT 2 * INTAKE ROCKER ARM, compl. Includes items 6 and SPACER (t=0.8) SPACER (t=1.0) SPACER (t=1.2) INTAKE VALVE EXHAUST VALVE VALVE SPRING SPRING RETAINER RETAINER LOCK VALVE STEM SEAL ROCKER SHAFT TAPPET PUSH ROD TAPPET GUIDE PUSH ROD SLEEVE PLATE, push rod O-RING GASKET, tappet guide NUT SPRING WASHER 4 RGD '98-7

20 FIG. 8 MUFFLER and AIR CLEANER GROUP RGD '98-7

21 FIG. 8 MUFFLER and AIR CLEANER GROUP REF PART NUMBER DESCRIPTION QTY REMARKS MUFFLER, compl MUFFLER COVER, compl FLANGE BOLT 4 * AIR CLEANER ASS Y 1 Includes items 5 and PACKING OIL PAN LABEL,air cleaner ELEMENT, compl ELEMENT CAP (air cleaner) LABEL,air cleaner BOLT and WASHER ASS Y WASHER GASKET, muffler NUT NUT SPRING WASHER 4 RGD '98-7

22 FIG. 9 GOVERNOR OPERATION GROUP RGD '98-7

23 FIG. 9 GOVERNOR OPERATION GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * GOVERNOR PLATE ASS Y 1 Includes items 2 thru GOVERNOR GEAR PUMP SHAFT OIL PUMP COVER OIL PUMP, inner RIVET LOCK PIN BOLT and WASHER ASS Y GOVERNOR SLEEVE GOVERNOR SHAFT GOVERNOR YOKE GOVERNOR LEVER GOVERNOR LEVER 2 UNIT GOVERNOR SPRING START SPRING SPEED CONTROL 1, compl SPACER FRICTION WASHER WASHER NUT STEEL BALL SCREW and WASHER ASS Y O-RING NUT CLIP WASHER WASHER SCREW NUT LOCK PLATE CONTROL PANEL, compl LABEL, operation SPEED CONTROL 2, compl KNOB LINK PIVOT CONTROL SPRING BOLT SCREW 1 * LINK, compl. 1 Includes item NYLON BUSH BRACKET, pivot LINK. PIVOT WASHER FRICTION WASHER 2 RGD '98-7

24 FIG. 9 GOVERNOR OPERATION GROUP RGD '98-7

25 FIG. 9 GOVERNOR OPERATION GROUP, cont. REF PART NUMBER DESCRIPTION QTY REMARKS NUT ROD COTTER PIN BRACKET BASE BRACKET, solenoid 1 RGD '98-7

26 FIG. 10 BLOWER HOUSING GROUP RGD '98-7

27 FIG. 10 BLOWER HOUSING GROUP REF PART NUMBER DESCRIPTION QTY REMARKS CYLINDER BAFFLE 1 UNIT CYLINDER BAFFLE 2 UNIT BLOWER HOUSING CYLINDER BAFFLE 3 UNIT FIN DAMPER RUBBER SCREW, pan head NUT FLANGE BOLT BOLT and WASHER ASS Y BOLT and WASHER ASS Y 2 RGD '98-7

28 FIG. 11 RECOIL STARTER GROUP RGD '98-7

29 FIG. 11 RECOIL STARTER GROUP REF PART NUMBER DESCRIPTION QTY REMARKS RECOIL STARTER ASS Y 1 Includes items 2 thru I I SPIRAL SPRING REEL, compl STARTER ROPE STARTER KNOB RATCHET FRICTION SPRING RETURN SPRING FRICTION PLATE THRUST WASHER CLIP FLANGE BOLT 4 RGD '98-7

30 FIG. 12 FUEL INJECTION PUMP and NOZZLE GROUP RGD '98-7

31 FIG. 12 FUEL INJECTION PUMP and NOZZLE GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * INJECTION PUMP ASS Y 1 Includes items 2 thru PLUNGER ASS Y DELIVERY VALVE SPRING, delivery valve GASKET O-RING 1 * EYE BOLT ASS Y 1 Includes items 18,20 and EYE BOLT GASKET, pump BOLT GASKET 1 * NOZZLE ASS Y 1 Includes items 23 thru NOZZLE GASKET, pump (t=0.1) GASKET, pump (t=0.2) GASKET, pump (t=0.3) GASKET, nozzle INJECTION PIPE, compl BRACKET, nozzle NUT SPRING WASHER FLANGE NUT GROMMET 1 RGD '98-7

32 FIG. 13 FUEL FILTER GROUP RGD '98-7

33 FIG. 13 FUEL FILTER GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * FUEL FILTER ASS Y 1 Includes items 1 thru O RING CUP RING NUT O RING ELEMENT BOLT and WASHER ASS Y RUBBER PIPE (ø 4.5 x ø 9 x 180mm) 1 * FUEL PIPE 11, compl. 1 Includes items 19 thru BANJO RUBBER PIPE (ø 6 x ø 12 x 250mm) HOSE CLAMP HOSE CLAMP RUBBER PIPE (ø6 x ø 12 x 150mm) CLAMP, compl PURSE LOCK HOSE CLAMP HOSE CLAMP 2 RGD '98-7

34 FIG. 14 STARTING MOTOR GROUP RGD '98-7

35 FIG. 14 STARTING MOTOR GROUP REF PART NUMBER DESCRIPTION QTY REMARKS * STARTING MOTOR ASS Y 1 Includes items I thru ARMATURE ASS Y THRUST WASHER KIT PINION STOPPER SET 1 * FIELD COIL ASS Y 1 Includes items 5 and POLE CORE SET SCREW BRUSH (+) 2 * REAR COVER ASS Y REAR COVER METAL 1 * BRUSH HOLDER ASS Y 1 Includes items 10 and I I BRUSH (-) BRUSH SPRING CENTER PLATE PINION ASS Y 1 * GEAR CASE ASS Y 1 Includes item GEAR CASE METAL SHIFT LEVER KIT DUST COVER KIT MAGNETIC SWITCH ASS Y THROUGH BOLT BLIND COVER NUT SPRING WASHER 2 RGD '98-7

36 PRINTED IN THE USA

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