RGV2800, RGV4100, RGV6100 GENERATOR SERVICE MANUAL
Contents
1. yueung powy 5900041 yes ssejusnig si 6 18 8 n 081 sqi e 069 089 819 8 X 892 x MX Jeugis 212 qeuondo 5 Bues _ sien 2 S N ZEO Ayoeded _sinoy 04 peieu 2 siew 6 12 n 195 B uidi 0096 ndino 5 uy 02 866 jueweoedsiq 9 VOZ VOP 00 0 00 m ____ Peru 2 Lino poet 2 M 0084 ndino winwixeyy ZH 09 Aouenbel4 ejog z 00 9 2 PERFOMANCE CURVES Hz 63 62 61 60 v 250 125 240 120 230 S N 220 110 230V 115V 0 1 2 4 4 Load Rated DC OUTPUT DC Voltage 12V DC Ampere 8 34 DC output 100 W The voltage curve shown in the left indicates the characteristic of DC output when charging a battery The voltage may be decreased by 202. Condenser Specification Windi MODEL eng White Red Black Blue Yellow Yelow Raveno NOTE If the circuit tester is not sufficiently accurate it may not show the values given give erroneous readings Erroneous readings will also occur when there is a wide variation of resis tance among coil windings or when measurement is performed at ambient temperatures differ ent from 20 C 68 F mee 9 5 ROTOR ASSEMBLY 1 Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals Q MODEL RGV2800 RGV4100 RGV6100 Table 9 2 NOTE 1 Because a diode is soldered to the coil ends at the terminals resistance may be measured only when tester probes touche the terminals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity NOTE 2 If the circuit tester is not sufficiently accurate it may not show the values given and may give er roneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 20 C 68 F 9 6 CONDENSER Use a Dr Robin in capacitance meter mode to check the capacity of condensers y CONDENSER CONDENSER i Fig 6A RGV2800 Fig 9 6B RGV4100 RGV6100 NOTE Be sure to discharge
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4. 4 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 3 Attach the bushing over the lead wire drawn out from the rear cover Press the smaller end of the bushing into the window of the rear cover Fig 10 25 zo 10 3 5 END COVER RGV4100 only Attach the end cover to the rear cover Fig 10 26 10 3 6 FRAME 1 Attach the mount rubbers to the frame Insert UPPER the setting tongue of mount rubber into the hole gt on the frame and tighten the nut from the bot tom of the frame 8 flange 4 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 8 ft lb Fig 10 27 NOTE The mount rubbers are selected to reduce vibration most effectively by model Be sure to use the correct mount rubber for your generator Although mount rubbers have the same appear ance their characteristics are different 2 Attach the 5 mm terminal of the grounding wires green yellow to the unpainted thread hole of the frame base plate using a 5 mm brass screw 3 Install the engine and alternator assembly into the frame Put the engine and alternator as sembly into the frame from the side of it Tighten the nuts over the mount rubber bolts to fix Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 8 ft lb M8 nuts 4 pcs NOTE Remove the air cleaner cover for easier installation NOTE When tightening the nuts slightly lift the engine and
5. Delay circuit This his prevents the sensor from making an unnecessary stop of the engine by momentary lowering of the oil level due to the engine being slanted or affected by vibration in spite of sufficient oil in the crankcase 4 Stopping circuit This automatically stops the engine running 5 4 5 CAUTIONS TO BE TAKEN ON HANDLING THE SENSOR 1 Oil sensor unit T Be sure not to damage each wire Broken or short circuited power supply wires and or a ground ing wire in particular may lead to malfunction or breakdown 2 The sensor is not interchangeable from engine to engine because the sensor is to be exclusively installed individually in each engine employed 2 Mounting and wiring of oil sensor unit D Although this has been designed to have enough antinoise properties in practical use do not route the sensor wirings in the vicinity of noise generating sources such as ignition plugs or high voltage cords This may cause malfunction or breakdown Since capacity of power source is limited current flown in the electronic circuit of the sensor is kept as low as possible Be sure to use terminals with a high contact reliability of more than that of tinned terminals 3 Operation of oil sensor If operating with the engine kept tilted oil surface inside of the engine varies and the correct oil level can not to be detected which in turn obstructs the preventing function of engine seizure Operate the engine b
6. Wipe off split fuel 2 Disconnect rubber pipe from the strainer Loosen the hose clamp on the top of the Strainer and pull out the rubber pipe from the strainer 3 Take off the four bolts and rubber fuel tank and then remove the fuel tank See Fig 10 6 10 mm spanner or box wrench Yes N 39 Part to remove Description Muffler and 1 Remove the two bolts which fix the Muffler cover muffler to the alternator Loosen the two nuts the muffler flange and remove 12 mm spanner box wrench the muffler from the engine 8 x 20 mm bolt and washer Ass y 2 pcs 8 mm stainless nut 2 pcs 8 mm spring washer 2 pcs j for RGV4100 and RGV6100 Muffler gasket 1 pce 2 Remove the muffler cover 1 and the i 10 mm spanner or muffler cover 2 from the muffler box wrench 6 10 mm bolt and washer Ass y 8 pcs See Fig 10 8 3 Remove the muffler bracket from the rear cover 8 20 mm bolt and washer 5 2 pcs 12 mm spanner or box wrench MUFFLER COVER 1 KET for RGV2800 RGV6100 Fig 10 8 Step Part to remove Description Remarks 4 lPipe Frame 10 mm spanner 2 Remove the nuts which are fixing engine and alternator to the mount rubbers See Fig 10 9 3 Using a chain blo
7. 5 Checking the IDLE CONTROL UNIT Check the resistance between five leads of IDLE CONTROL UNIT with circuit tester Terminal number of the IDEL CONTROL UNIT Fig 11 16A Fig 11 16B Apply black minus needle of the circuit tester gt ep mw 7 s ewe Table 11 4 Circuit tester with battery power source 1 5 V Apply red pius needie of the circuit tester 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 ordinary analogue circuit tester with 1 5 volt battery power source It is advisable for you to check the resistance readings using your standard circuit tester and revise the checking table 50 11 5 2 ENGINE SPEED IS REDUCED WHEN LOAD IS OFF 1 Check the distortion of the SOLENOID BRACKET as shown in step 11 5 1 1 2 Check the wiring of SOLENOID Check two leads from SOLENOID are securely connected 3 Check the wiring of IDLE CONTROL UNIT Check all leads from IDLE CONTROL UNIT are securely and correctly connected 4 Checking the SOLENOID Measure the resistance between two leads from SOLENOID Normal Resistance 25 310 If the resistance is larger or smaller than this range SOLENOID is defective
8. the house AC breaker on Caution Do not start the generator with electrical appliance s connected and with their switches on Otherwise the appliance s be damaged by the surge voltage at starting 15 5 3 GENERATOR OPERATION PERMANENT MAGNET FOR INITIAL EXCITATION STATOR FIELD COIL MAIN COIL RECEPTACLE APPLIANCE ABSORBER DIODE CONDENSER COIL 5 3 1 GENERATION of NO LOAD VOLTAGE 1 When the generator starts running the permanent magnet built in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator 2 As one or two condensers are connected to the condenser coil the small voltage at the condenser coil generates a minute current which flows through the condenser coil At this time a small flux is produced with which the magnetic force at the rotor s magnetic pole is intensified When this mag netic force is intensified the respective voltages in the main coil and condenser coil rise up As the current increases the magnetic flux at the rotor s magnetic pole increases further Thus the volt ages at the main coil and condenser coil keep rising by repeating this process 3 As AC current flows through the condenser coil the density of magnetic flux in the rotor changes This change of magnetic flux induces AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies this AC voltage into DC Thus a DC current
9. 1 Take off the through bolt Apply a box wrench on the head of through bolt Hit the wrench handle with a hammer counter clockwise to loosen Box wrench Plastic hammer Fig 10 16 2 Put the engine on the working table recoil starter side down i 3 Use bolt and 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 See Fig 10 17 2 Prepare a bolt with the following thread size RGV2800 M10xP 1 5 RGV4100 6100 MI2x 1 5 i 3 Apply a few tums of seal tape around the tip of the bolt See Fig 10 18 SEAL TAPE Fig 10 18 Step Description Remarks Tool 7 Rotor 4 Screw the bolt into the thread of the rotor Do not stick out your shaft face over the rotor 5 Torque the bolt using a socket wrench It may jump up on Socket wrench until the rotor comes off loose separation The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft 4 Wipe off thoroughly from rotor shaft and enaine PTO shaft Fig 10 19 8 Front Cover 1 Remove the front cover 12 mm socket Loosen the four bolts and remove the wrench front cover M8 x 20mm bolt and washer Ass y 4 pcs 10 3 ASSEMBLY PROCEDURES 10 3 1 FRONT COVER Attach the front cover to the engine main bea
10. REC3 up to 30A NEMA L5 30R NEMA L5 30P Table 5 2 NOTE If your generator has receptacles pecu liar to your country Table 5 2 does not apply Caution The duplex 120V receptacle is protected by a 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 pro i tected Caution To connect the appliance to locking receptacle insert the plug into the re ceptacle and turn it clockwise to lock Fig 5 8 5 2 7 RECEPTACLE After starting the engine check the for proper functioning by the following test procedure Push yellow 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 2 4 5 2 8 CONNECTING DOMESTIC CIRCUITS HOUSE WIRING WARNING All Robin generators are a neutral ungrounded type If a generator is to be connected to residential or commercial power lines such as a stand by power sour
11. flows through the field coil and magne tizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 3000 to 3300 rpm the current in the condenser coil and field coil increases rapidly This acts to stabilize the output voltage of each coils If generator speed further increases to the rated value the generator output voltage will reach to the rated value 5 3 2 VOLTAGE FLUCTUATIONS UNDER LOAD When the output current flows through the main coil to the appliance a magnetic flux is produced and serves to increase current 8 in the condenser coil When current 8 increases the density of magnetic flux across the rotor core rises As a result the current flowing in the field coil increases and the genera tor output voltage is prevented from decreasing 5 3 3 FULL POWER SWITCH Dual Voltage The full power switch is provided for the dual voltage type to take out the full rated power from one receptacle in each voltage 120 240V 2 IREC 1 120V 1 L gt 3 REC2 MC2 120V Fig 5 12 Fig 5 13 120 240 V Half of rated output Rated output Table 5 3 Fig 5 14 17 Two main coils are wound over stator core Each main coil outputs half the rated power at the lower voltage 120V These main coils are wound to be in the same phase The full power switch reconnects t
12. 9 CHECKING FUNCTIONAL MEMBERS 9 1 VOLTMETER Check the voltmeter if it is turned on by applying AC e specific voltage Voltmeter cannot be checked with circuit tester because its resistance is too large XD Check that no disconnection nor short circuit occurs with a tester and the internal resistance is around 00k ohms normally D on the commercial power supply input i and check the indication VOLTMETER 9 2 AC RECEPTACLES Using a Dr Robin or a circuit tester check continuity between the two terminals at the rear of AC receptacles while the 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 AC receptacle is normal When the wire is removed and no continuity is found between these terminals the receptacles are also normal AC RECEPTACLE Fig 9 2 9 3 No FUSE BREAKER Check continuity between each of two terminals at the rear of the no fuse breaker while it is mounted on the control panel Normally there is continuity between each of the two when the no fuse breaker is on while there is no continuity when the no fuse breaker is off NO FUSE BREAKER Fig 9 3 32 9 4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a Dr Robin or a circuit tester referring to the fol lowing table
13. Table 7 1 24 ww 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 7 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 de creasing the input voltage to the load electrical product As a result the load can be damaged Table 7 2 shows voltage drops per 100 meters of cable Allowable Gauge NoJ Resistance Voltage drop per 100 m current A re Ohm 100 m 124 pepe vee pese pre pe p sev ov sov ov wv v 59 as pom pee sm sv ev sv Table 7 2 Sectional area Voltage drop indicates as l 100 xRxIxL means resistance Q 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 leng
14. alternator assembly so that the weight is not applied to the mount rubbers 48 4 Fasten the other earth cable with 5 mm termi nal to the unpainted bolt hole on the frame See Fig 10 28 10 3 7 MUFFLER and MUFFLER COVER 1 Temporarily fix the muffler bracket to either the rear or front covers for RGV6100 or RGV2800 M8 x 20 mm and washer Ass y 2 pcs 2 Attach the muffler cover 1 and the muffler cover Fig 10 28 2 to the muffler M6 x 10 mm bolt and washer 5 8 pcs Tightening torque 7 9 9 8 N m 80 100 kg cm 5 8 7 2 ft lb MUFFLER COVER 1 3 Put the muffler gasket to the engine 4 Attach the muffler with muffler cover to the engine and the rear cover XD Tighten the two nuts for the muffler first Use the spring washers for RGV4100 and RGV6100 MUFFLER 8 mm stainless nut 2 pcs 2 8 mm spring washer 2 pcs for RGV4100 and RGV6100 only Tightening torque 21 6 27 4 MUFFLER COVER 2 220 280 kg cm PEE 15 8 20 2 ft lb i Tighten the bolts to fix the muffler to the rear TZ i 8 x 20 mm bolt and washer Ass y 2 pcs 4 1 for RGV4100 3 Tightening torque eX MUFFLER BRACKET e for RGV2800 RGV6100 13 7 18 0 ft Ib 49 3 For RGV2800 and 6100 Tighten the two bolts to fix the muffler bracket to the front cover rear cover and then the two bolts for the muffler to t
15. be worked out according to the numerical formula mentioned below Output of eres appliance Power consumpltion Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 6 0 75 f The smaller the motor the Fluorescent lamp 0 7 to 0 8 lower the efficiency 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 Item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get the figure of the neces sary 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 4000 72 570 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 Item 3 570 W x 1 2 to 3 684 W to 1710 W MODEL RGV2800 RGV4100 RGV6100 Incandesent lamp 2300 W 3600 W 4800 W heater etc Fluorescent lamp Motor approx approx approx driven tool general porpose 1200 W 1800 W 2400 W Pump compressor etc 550 W 850 W 1100 W
16. make use of it The sensor judges the oil quantity by comparing a current flowing across a pair of electrodes inner and outer with the reference in such a way that if a current flows between the electrodes more than the reference sufficient oil is in the crankcase on the other hand if a current flows less than the reference oil is not sufficient Since an electric current is flown to detect oil quantity this is called the electrical conductivity detection type of sensor The level to be detected is determined by the length of elec trodes and their mounting positions with the engine 5 4 3 HOW IT OPERATES Power supply The sensor makes use of a part of primary power source for ignition of the engine igniter to drive the sensor circuit Power to the sensor can usually be derived from the stop button by branching wires out 19 Judgement of level When sufficient oil is in the crankcase both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes The sensor judges that oil in the crankcase is sufficient When oil level goes down and the inner electrode is exposed to the air due to consumption of oil no current flow between the electrodes as air is considered to be electrically nonconductive The sensor in this case judges that oil is insufficient Decision of oil shortage Oil level at the electrodes may go down momentarily probably due to the engine being slanted
17. or affected by vibration even if a sufficient oil is in the crankcase For that reason the sensor has an electronic timer circuit to prevent it from interpreting as short of oil when amount of oil is sufficient The sensor has been designed so that the engine is to be stopped only when oil shortage is detected for 5 seconds uninter rupted The timer employs an integration circuit and it is to be reset when the inner electrode is soaked in the again before the sensor decides it as oil shortage The oil level where the sensor decides as shortage when oil level goes down gradually is called threshold level Automatic stop of engine When the sensor decides as oil shortage it makes the engine to stop running automatically for protec tion of engine Once the stopping circuit is activated it keeps functioning until it confirms that the engine has made a complete stop then the circuit stops functioning automatically 5 4 4 BLOCK DIAGRAM OF THE CIRCUIT igniter Power circuit Detection circuit Stopping circuit inner pole Deley circuit Oil Outer pole Engine ground Fig 5 16 Power circuit This rectifies a part of power to the igniter and regulates it to supply the stabi lized power to necessary circuits 20 ww Detection circuit This detects quantity of oil sufficient or not according to difference of electric resistance across inner and outer electrodes
18. when the resistance load is applied NOTE It is possible to use both DC and AC outputs simultaneously up to the rated output in total 3 FEATURES 3 1 BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance 3 2 CONDENSER TYPE VOLTAGE REGULATOR A trouble free condenser type voltage regulator ensures a stable voltage under all working conditions 3 3 SENSOR Oil sensor automatically shuts off the engine whenever the oil level falls down below the lower limit to protect the engine from seizure 3 4 QUIET OPERATION Robin RGV series generator delivers a quiet operation with A large super silent muffler A quiet 4 stroke Robin Rro OHV engine Asilent cyclone air cleaner 3 5 NO RADIO NOISE Noise suppressor spark plug is equipped standard to prevent radio frequency interference 3 6 LARGE FUEL TANK The large fuel tank allows more than 7 to 10 hours of continuous operation which is sufficient for half day or one day work without refueling 3 7 RUGGED TUBULAR FRAME Full cradle type rugged tubuler frame protects the generator all around 3 8 COMPACT AND LIGHT WEIGHT Newly developed brushless alternator enabied the RGV generators to be very compact in size and light in weight 3 9 Abrushless alternator release the operator from periodical brush maintenance A trouble free condenser type voltage regulator A dri
19. 0 to 330V Dual voltage type 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10A 20A 100A 3 FREQUENCY METER Frequency range About 45 to 65 2 NOTE Be careful of the frequency meter s input voltage range Fig 8 4 2 97 4 CIRCUIT TESTER Used for measuring resistance etc Fig 8 5 5 MEGGER TESTER Used for measuring generator insulation re sistance Select one with testing voltage range of 500V 6 TACHOMETER Use the contactless type tacho meter 28 8 2 OUTPUT MEASURING SWITCH LOAD TO AC RECEPTACLE Fig 8 8 Use a circuit like the shown Fig 8 8 for measuring AC output hot plate or lamp with a power factor of 1 0 may be used as a load Adjust the load and rpm and check that the voltage range is as specified in Table 8 2 at the rated amperage and rated rpm Rated voltage 120 V 240 V Voltage range 108 132 V 216 264 V Table 8 2 8 3 DC OUTPUT MEASURING To DC Terminal Fig 8 9 Measurement of DC output is executed with the Switch tumed ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal NOTE If a battery is connected as a load to the generator the DC output voltage will increase by approximately 1 to
20. 1 2 3 CHECKING STATOR Check stator referring to Step 11 1 2 11 2 4 CHECKING ROTOR Check rotor referring to Step 11 1 3 55 11 3 VOLTAGE IS NORMAL AT NO LOAD BUT THE LOAD CANNOT BE APPLIED 11 3 1 CHECK THE ENGINE SPEED If the engine speed is low adjust it to the rated r p m Refer to Step 11 2 1 for engine speed adjustment 11 3 2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR Refer to Section 7 RANGE OF APPLICATIONS for the wattage of the appliances If the generator is overloaded reduce the load to the rated output of the generator 11 3 3 CHECK THE APPLIANCE FOR TROUBLE If the appliance is faulty repair it 11 3 4 CHECK IF THE ENGINE IS OVERHEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re a move it AIR INLET 7 AIR OUTLET CORE ENGINE 22 150 AIR OUTLET ALTERNATOR ALTERNATOR Fig 11 8 11 3 5 CHECK THE INSULATION OF THE GENERATOR Stop the engine Measure the insulation resistance between the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1 dis assemble the generator and check the insulation resistance of the stator rotor and the live parts in the control box Refer to Section 8 3 Any part where the insulation resistance is less than 1MQ the insulation is faulty and may cause electric lea
21. 2 V Therefore carefully observe the electrolyte level and do not overcharge the battery 29 8 4 MEASURING INSULATION RESISTANCE Use a Dr Robin generator tester in megger tester mode or use a megger tester to check the insula tion resistance Connect a megger tester to one of receptacle output terminals and the ground ter minal then measure the insulation resistance An insulation resistance of 1 megohm or more is nor mal The original insulation resistance at the time of shipment from the factory is 10 megohm or more If itis less than 1 megohm disassemble the generator and measure the insulation resis tance of the stator rotor and control panel indi vidually Fig 8 10 NOTE on the no fuse breaker before mea surement STATOR 1 Measure the insulation resistance between BLUE lead and the core 2 Measure the insulation resistance between WHITE lead and the core 3 Measure the insulation resistance between YELLOW lead and the core 4 Measure the insulation resistance between BROWN lead and the core ROTOR Measure the insulation across one of the soldered terminals of the rotor and the core 30 CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Any part where the insulation resistance is less than 1MQ has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 31
22. Replace with a new one SOLENOID 60 12 WIRING DIAGRAM RGV2800 U S A 60Hz 120V TYPE NEMA RECEPTACLE CONTROLBOX 2 i 7 8 i li gt e 8 E lt E d H M AC Winding 2 RGV4100 U S A 60Hz 120V 240V TYPE NEMA RECEPTACLE GENERATOR CONTROL BOX ENGINE Sarga absorber 8 EN Winding 2 0 75 y 8 Condensor Engin switch 0 75BIk ER ned 1 25Bm Diode stack 1 Assy d gt 1 250 lt Circuit breaker ER 5 lt sermina 2 1 25Bm W DC Winding Ground terminal 61 lt 2 Spark plug U S A 50 2 120 240 NEMA RECEPTACLE RGV6100 ENGINE 002 0 jndjno ov 012812090 _ 103 0 0 2 0 4 CONTROL BOX n piora iQ 8 2940 qe 62 RGV4100 6100 ELECTRIC STARTER CONTROL BOX ENGINE ENGINE 758 4100 _ 6 600 55 i 5 gt 35 58 5 pen
23. Robin Power Equipment SERVICE MANUAL RGV2800 RGV4100 RGV6100 Generators PUB GS1277 Section CONTENTS Section Title Page 1 3 AC VOLTAGE IS NORMAL AT NO LOAD BUT THE LOAD CANNOT BE APPLIED 56 NOTE As for the servicing information on engine protion please refer to the EH17 2 EH25 2 and EH34 engine service manual SPECIFICATIONS 1 uondo se 1 91499 901 wbem 517 X 090 X 9L X O22 H X M X 7 suoisueuiq JOVIS 191546 s494 590 166512120 Ayoedeg IO saa 21 186 0176 669 09 sdi 261 299 029 216 X GOL X vc JOURS 91149913 pue sew 0 Te 671960 9 9 86 Ayoedeo pay jueweoe dsiq 0096 dH 0 06 01 2 1 0096 dH 9 ul 2661 LSZ YOLVNYSLIV eujoset 0 000 1 90 eBeyoA M 001 V 2 8 21 jndino 104084 0
24. TE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service LABEL MODEL NAME 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION END COVER BALL BEARING STATOR ROTOR COMPLETE REAR COVER STATOR COVER CRANKSHAFT V 2 22 lt lt lt lt lt lt hu i 4 40 MOUNT RUBBER THROUGH BOLT COVER BOLT FRONT COVER Fig 5 1 5 2 FUNCTION 5 2 1 STATOR The stator consists of a laminated silicon steel sheet core a main coil and a condenser coil which are wound in the core slots The condenser coil excites the rotor field coil which generates AC voltage in the main coil Fig 5 2 10 5 2 2 CONDENSER One or two condensers are installed in the con trol box and are connected to the condenser coil of the stator These condensers and condenser coil regulate the output voltage Fig 5 3 5 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action Fig 5 4 A diode rectifier and surge absorber is mounted inside of the insulator DIODE RECTIFIER SURGE ABSORBER Fig 5 5A Fig 8 11 5 2 4 NO FUSE BREAKER The no fuse breaker protects
25. To prevent bolts and nuts from being misplaced or installed incorrectly replace them temporarily to their original position 4 Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools properly and use the proper tool for each specific job 37 10 2 DISASSEMBLY PROCEDURES Step Part to remove Description Remarks 1 Take off the bushing from the bottom of the control box See Fig 10 1 1 Contro box 2 Disconnect the connectors on the wiring i Press the upper end of from the control box to the alternator i the bushing and pull See Fig 10 1 out 3 Disconnect the connectors on the wiring between from the control box and the engine See Fig 10 2 4 Take off the four bolts and remove the control box the frame See Fig 10 3 5 12 mm bolt and washer Ass y black 2 pcs 5x25 mm boit and washer Ass y black 2 pcs Fig 10 1 Fig 10 2 2 Fuel Tank 1 Discharge fuel from the tnak 1 Shut the fuel strainer 2 Remove the strainer cup 3 Put a vessel to receive fuel under the strainer and open the fuel cock to discharge fuel See Fig 10 4 4 Attach the strainer cup to the strainer body 4 sa Use utmost care about fire hazard thoroughly Do not lose the filter screen
26. aulty Replace stator with a new one 11 5 IDLE CONTROL 11 5 1 ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS APPLIED 1 Inspect the solenoid bracket Check the bend angle of solenoid bracket If the bracket is dis torted correct the angle with proper tool 2 Check the wattage of load applied to the gen erator If the generator is loaded over the rated wattage the engine speed can not be in creased Most induction loads such as elec tric 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 3 Check the slow set r p m LEVER Fig 11 13 The normal idling speed by the IDLE CON TROL is as follows RGV2800 1900 to 2100 r p m RGV4100 6100 2000 to 2200 r p m The above speed setting is for cold engine con dition If the engine speed is out of adjusting range of the adjusting screw move the sole noid backward U 1 apuusiine screw w Fig 11 14 58 4 Check the wiring through 2 the IDLE CONTROL UNIT IDEL CONTROL UNIT Single Voltage Type Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT Dual Voltage Type Check that two output wires black wire and red wire from main coils are passing through the ZCT on the IDLE CONTROL UNIT in the same direction
27. cale shows resistance to some extent When results of the checking indicates failure even in one section replace with a new one NOTE 3 Simpson brand analogue testers have the characteristics as same as the digital circuit tester 9 8 OIL SENSOR 1 Disconnect two 2 wires comming from the i sensor at the connection 2 Loosen the sensor to remove it from the en gine OIL SENSOR sensor is removed with suitable means such 3 Plug the opening of oil filler hole created after as oil gauge 4 Connect the removed wires again with the oil sensor i 5 Start the engine with the oil sensor removed Fig 9 9 and confirm if a Engine stops after 5 seconds which is normal or b Engine does not stop after more than 10 seconds which is unusual NOTE The sensor will not operate properly when wire is broken or poorly connected Check the wires for correct connection If it fails to stop within 5 seconds after the wirings have checked the sensor is wrong Replace the sensor with new one 36 10 DISASSEMBLY ASSEMBLY 10 1 PREPARATION and PRECAUTIONS 1 Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly Tag the disassembled part with the necessary information to facilitate easier and smoother reassembly 2 For more convenience divide the parts into several groups and store them in boxes 3
28. ce during power outage all connections must be made by a licensed electrician Failure in connection may result in death personal injury damage to generator damage to appli ances damage to the building s wiring or fire a When contnecting a Robin generator to a house wiring generator output power must be taken from the 240V 4P receptacle b install a transfer switch A transfer switch must be installed to transfer the load from the commercial power source to the generator This switch is necessary to prevent accidents caused by the recovery from power outage Use a transfer switch of the correct capacity Install transfer switch between the meter and the fuse or AC breaker box Caution If the neutral wire of house wiring is grounded be sure to ground the ground terminal of the generator Otherwise an electric shock may occur to the operator 050559 UTILITY HIGH LINE MAIN POWER 2223 ws gt CONNECTING BOX 240 RECEPTACLE ANNAN RK 0 0000 JJ gt o D 3 0 gt Utility high line House circuit breaker 120V appliance 120V appliance Meter box 240V appliance 4P Receptacle Fig 5 10 c Operating the generator Set the full power switch to 120V 240V side Tum the house AC breaker off before starting the generator Start the generator and warm it up
29. cial indication as to the power consumption effi ciency should be taken into account as explained in 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 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 con sumption so that the excess power generated by the generator can be used for other electrical appliances NOTE Motor driven appliances mentioned in items 3 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 23 5 Appliances without 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
30. ck sling up the engine Remove the air and alternator and dismount from the cleaner cover for i dismounting FUEL STRAINER For RGV6100 ALTERNATOR 92 MOUNT RUBBER SIDE 2pcs 47 ENGINE SIDE 2 pcs Fig 10 9 1 4 Remove the mount rubbers from the frame Loosen the nuts on the bottom side of the frame See Fig 10 10 12 mm spanner or socket wrench 8 flange nut 4 pcs MOUNT RUBBER 2 pes 4 MOUNT RUBBER 2 pes 8 FLANGE NUT 2 pes e NUT 2 pcs Fig 10 10 5 Rear cover 1 Remove the end cover See Fig 10 11 10 mm spanner or Except RGV6100 box wrench 6 0 bolt 3 065 2 Remove the four bolts which fasten the rear cover to the front cover See Fig 10 12 10 mm spanner or box wrench Fig 10 11 Fig 10 12 3 Remove the rear cover by hitting on the Do not give a strong hit Plastic hammer legs of rear cover with a plastic hammer on the boss or legs to loosen REAR COVER Fig 10 13 42 STATOR BRUSHING Remarks STATOR COVER Fig 10 14 Description REAR COVER 1 Remove the stator cover Step Part to remove SPRING GROMMET WASHER 4 pcs COVER BOLT 4 pcs Fig 10 15 Remarks Step Part to remove 7 Rotor
31. condensers by shorting condenser leads each other before checking their capacitance or the accurate reading cannot be obtained NORMAL CAPACITY OF CONDENSER RGV2800 RGV4100 RGV6100 Table 9 3 If such an instrument is unavailable the condenser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 9 7 DIODE RECTIFIER DIODE RECTIFIER Brown Brown B White Orange Orange Brown Brown Brown 0 Brown White Fig 9 7 Circuit inside of the diode rectifiers is as shown in Fig 9 7 Check continuity between each terminal by using a circuit tester as shown in Fig 9 8 The rectifier is normal when condtinuity is as follows Checking table for analogue circuit tester Apply black minus needle of the circuit tester esi neni canis Analogue circuit tester Table 9 4 1 Checking table for digital circuit tester Apply red plus needle of the circuit tester Digital circuit tester mem Table 9 4 2 NOTE 1 Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester polarity of tester needles should be reversed NOTE 2 Continuity means forward direction characteristics of the diode and different from short circuit condition which a pointer of the tester goes out of its normal s
32. he front panel 1 Connect the wires from the front pane and the engine 2 Connect the wires drawn out from the stator to the wires from the front panel NOTE Connect the wires of the same color 3 Press the upper end of the bushing into the bottom window of the front panel 4 Mount the front panel to the frame M5 12 mm bolt and washer Ass y 2 pcs 5 x 25 mm bolt and washer Ass y 2 pcs Fig 10 31 10 4 CHECKING DISASSEMBLY and REASSEMBLY of the FRONT PANEL 10 4 1 CHECKING OF THE FRONT PANEL Dismount the front panel from frame Remove the control panel and check each components and wiring Refer to Section 9 for the detail of checking procedure for the components in the front panel 10 4 2 DISASSEMBLY 1 Remove the control panel from the front panel M4 screw 6 pcs RGV2800 RGV4100 4 screw 7 pcs RGV6100 2 Disconnect the connectors on the wires to detach the control panel and front panel 3 Remove the condensers and diode rectifier from the front panel 4 After disconnecting individual wires remove the control panel components NOTE Full power switch and pilot lamp have their wires soldered Unsolder them to remove those parts if necessary 51 10 4 3 REASSEMBLY 1 Install the receptacles no fuse breaker terminals switches etc on the control panel and wire them NOTE Circuit diagrams are shown in Section 12 Colored wires are used for easy ident
33. he muffler bracket 20 mm bolt and washer Ass y 4 pcs for RGV2800 and 6100 Tightening torque 18 6 24 5 N m 190 250 kg cm 13 7 18 0 ft Ib 10 3 8 FUEL TANK 1 For RGV2600 and RGV4100 only FUEL wins Attach the fuel strainer to the bottom of the FUELTANK fuel tank Screw in the fuel strainer all the way e A DV SZ and return one to two turns and then lock it with the lock nut FUEL FILTER For RGV6000 only Attach the fuel strainer to the frame Tightening torque 4 9 6 9 N m 50 70 kg cm 3 6 5 0 ft lb 2 Mount the fuel tank on the frame with rubber washers between the tank flange and the frame FUEL STRAINER 7 M6 20 mm boit 4 pcs Rubber washer 4 5 000 NOTE For easy tank assembly glue the rubber washers over the mounting holes of the pum frame RUBBER PIPE 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 clamps For RGV6100 connect the rubber pipe to the strainer and the fuel tank in the same way NOTE Apply a drop of oil to the rubber pipe for easier connection Fig 10 30 50 10 3 9 Mount the front panel assembly to the frame Refer to Section 10 4 for disassembly checking and reassembly procedures of t
34. hese main coils in parallel or in series Fig 5 12 shows a circuit diagram When the full power switch is set for single lower voltage indication 120V the switch position is as indicated by the lower solid line in the diagram Fig 5 13 is a simplified representation of this circuit showing the two main coils connected in parallel In this case the higher voltage 240V at Rec 3 cannot be taken out Rec 2 for the lower voltage can output up to the rated power up to 30A if the rated current is over 30A and Rec 1 can output up to a total of 15A When the full power switch is set for double voltage indication 120V 240V the switch position is as indicated by the upper dotted line in Fig 5 12 Fig 5 14 is a simplified representation of this circuit showing the two main coils connected in series In this case power can be taken simultaneously from the receptacles for the both voltages Rec 3 for the higher voltage can output up to the rated power but Rec 1 and Rec 2 for the lower voltage can output only up to half the rated power each Table 5 4 is a summary of the above explanation Select the proper output voltage by full power switch in accordance with the appliance to be used 18 5 4 SENSOR 5 4 1 DESCRIPTION The oil sensor mainly functions to detect posi tion of the surface of engine oil in the crankcase of engines for general use and to stop the en gine automatically when the oil level goes down below the lo
35. ification and are of the correct capacity and size Use heat resistant type wires permissible temperature range 75 C or over in the specified gauge shown in the circuit diagrams 2 Install condensers and diode rectifier into the front panel 3 Connect the wires of control panel components and front panel 4 Attach the contro panel to the front panel M4 screw 6 pcs RGV2800 RGV4100 M4 screw 7 pcs RGV6100 Tightening torque 1 2 1 5 N m 12 15 kg cm 8 7 10 9 ft Ib 52 ww 11 TROUBLESHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING CONDENSER 1 Check the capacity of condensers using a Dr Robin generator tester in capacitance meter mode NOTE Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance or the accurate reading cannot be obtained RGV4100 20uFx2 Table 11 1 2 If such an instrument is unavailable the condenser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 11 1 2 CHECKING STATOR COUPLER STATOR 1 Remove control panel and disconnect stator wires at the connectors 2 Measure the resistance between terminals on stator leads See Fig 11 2 Refer to Table 9 1 for normal resistance If stator is faulty replace it with a new one 53 3 Check the insulation resistance between sta tor core and each
36. k may occur If the generator is wet by rain or snow wipe it and thoroughly dry it before starting Don t pour water over the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leakage and electric shock w 6 Do not connect the generator to the commercial power lines This may cause a short circuit or damage to the generator Use a transfer switch Optional parts for connecting with indoor wiring NOTE The parts numbers of the transfer switches and of the plastic box to store them are as shown in Table 6 1 3 A 367 43008 08 PlasicBox 1 1 30 Table 6 1 7 sure to check and remedy the cause of circuit breaker tripping before resetting it on CAUTION the circuit breaker tripped off as a result of using an electrical appliance the cause can be an overload or a short circuit In such a case stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring 22 7 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 watt age of the appliance The electrical appliances generally have a label showing their rated
37. kage Replace the faulty part Fig 11 9 11 4 NO DC OUTPUT 11 4 1 CHECK THE AC OUTPUT Check the generator by following Step 11 1 1 through Step 11 1 3 11 4 2 CHECK THE DC BREAKER If the DC breaker turned off while charging a bat tery check the cables for short circuit or connec tion 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 Fig 11 10 11 4 3 CHECK THE DC FUSE Check the fuse in the fuse holder If the fuse is blown check for the cause of fuse FUSE blowing and then replace with a new one FUSE 10A NOTE If the DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing fuse blow Fig 11 11 11 4 4 CHECK THE WIRING Check all the wires to be connected correctly 11 4 5 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode rectifier with a circuit tester Refer to Section 9 7 DIODE RECTIFIER for the checking procedure Fig 11 12 57 11 4 6 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester RGV2800 120V 120V 240V 0 25 Q RGV4100 120V 120V 240V RGV6100 120V 120V 240V Table 11 3 If the resistance reading is much larger or smaller than the specified value the DC coil of the stator is f
38. p proof alternator design No fuse circuit breakers An electronic pointless ignition system A dust proof cyclone air cleaner 3 10 LONG LIFE DURABILITY The heavy duty 4 stroke Robin Rro OHV engine and virtually maintenance free brushless alternator ensure greater durability with A brushless alternator with a condenser voltage regulator Full rubber mount in a sturdy tubular frame A forged steel crankshaft supported by two main ball bearings gt pointless electronic ignition system cast iron cylinder liner A forged aluminum connecting rod 4 GENERAL DESCRIPTION 4 1 EXTERNAL VIEW FUEL GAUGE TANK CAP VOLTMETER ENGINE SWITCH FULL POWER SWITCH AC RECEPTACLE EARTH TERMINAL DC OUTPUT TERMINAL RECOIL STARTER CIRCUIT REAKER wo FUSE OIL SENSOR BREAKER SPARK PLUG ENGINE EMISSION LABEL MUFFLER OIL DRAIN PLUG 4 2 CONTROL PANEL RGV2800 U S A 60 2 120 NEMA RECEPTACLE L MAX 204 LT 0 DC 12V 8 3A N BATTERY CHARGE ONLY 4 DC BREAKER DC OUTPUT AC BREAKER RGV4100 U S A 60 2 120 240 NEMA RECEPTACLE 120V RGV6100 U S A 60 2 120 240 NEMA RECEPTACLE FULL POWER SWITCH 120v 120V B DC OUTPUT 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL MODEL NAME stuck on the side wall of control box NO
39. ring cover Match the faucet joint and tighten the bolts M8 x 20 mm bolt 4 pcs 8 spring washer 4 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft lb 10 3 2 ROTOR 1 Wipe off oil grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft 2 Mount the rotor to the engine shaft Tighten the through bolt Apply a wrench on the through bolt and hit wrench handle clockwise with a hammer to tighten If an impact wrench is available use it Tightening torque Tightening torque 11 3 13 2 N m 115 135 kg cm 8 7 10 8 ft lb Fig 10 22 RGV2800 RGV4100 22 5 24 5 N m RGV6100 230 250 kg cm 16 6 19 5 ft Ib 46 10 3 3 STATOR 1 Put the stator in the rear cover setting the four STATOR COVER grooves on the side of stator with thread holes of the rear cover 2 Attach the stator cover around the stator 10 3 4 REAR COVER 1 Put the rear cover with stator over the rotor Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover 2 Fix the rear cover to the adaptor with four bolts spring washers and washers RGV6100 160 mm 4 pcs M6 spring washer 4 pcs washer 4 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb REAR COVER RGV2800 and 4100 M6 x 110 mm 4 pcs 6 spring washer
40. stator lead using a Dr Robin generator tester in megger tester mode or a megger tester Fig 11 3 If insulation is bad replace stator with a new one 11 1 3 CHECKING ROTOR 1 Remove rear cover and stator NA 2 Using a Dr Robin or a circuit tester measure DR sar the resistance of the field coil at the terminals Fig 11 4 Q MODEL RGV2800 RGV4100 RGV6100 res Table 11 2 NOTE Because a diode is soldered to the coil ends at the terminals resistance may be mea sured only when tester probes touch the termi nals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity Remedy If the resistance is not normal replace rotor with a new one 3 Measure the insulation across one of the sol dered terminals of the rotor and the core Fig 11 6 If insulation is bad replace rotor with a new one 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11 2 1 CHECKING ENGINE SPEED If the engine speed is too high or too low adjust it to the rated r p m How to adjust engine r p m Loosen the lock nut on the adjusting screw Turn the adjusting screw clockwise to decrease engine speed or counterclockwise to increase engine speed EN ADJUSTING SCREW i RGV2800 4100 Normal engine speed at no load 3700 to 3750 rpm 11 2 2 CHECKING CONDENSER Check condenser referring to Step 11 1 1 1
41. th from generator to electrical tools Db 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 Dr ROBIN GENERATOR TESTER The Dr Robin generator tester is exclusively designed for fast easy diagnosis and repair of Robin generators The Dr Robin has the follow ing features 1 Functions of voltmeter frequency meter megger tester capacitance meter and circuit tester are combined in one unit 2 Fast and easy readout by digital indicator 3 Built in automatic battery checker indicates the Fig 8 1 time to change batteries 4 Tester and accessories are installed in a handy _ sturdy case for easy carrying SPECIFICATIONS Test leads with needle probes 1 set Test leads with jack plugs 1 set Table 8 1 Measuring Range The Dr Robin generator tester be ordered from Robin generator distributors by the following part number Dr Robin Part Number 388 47565 08 If you do not have Dr Robin generator tester use the instruments described in the following section for checking generator parts 26 w 8 1 2 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 150V Type with an output voltage of 110 120V 0 to 300V Type with an output voltage of 220 230 or 240V 0 to 150V
42. the generator from getting damage by overloading or short circuit in the appliance Table 5 1 shows the capacity of no fuse breaker by each spec and their object of protection MODEL SPECIFICATION NO FUSE BREAKER OBJECT or PROTECTION RGV2800 60 Hz 120V Total output amperage RGV4100 60 Hz 120 V 240V 15 A 2 Pole 2 Element Total output amperage 20 A 2 Pole 2 Element Total output amperage RGV6100 Output from 30A receptacle 5 2 5 DC CIRCUIT BREAKER Table 5 1 The 10 ampere DC circuit breaker mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit ww 60 Hz 120 240V Fig 5 6 5 2 6 RECEPTACLE and AC PLUG STD SPEC These are used for taking AC output power from the generator A total of six kinds of receptacles each varying in rated voltage and current from another are used Each model has at least one receptacle to deliver the rated generator output As many AC plugs as the receptacles each matching the correspond ing receptacle are provided Table 5 2 shows the rated current for each receptacle Be careful not to use the receptacles and AC plugs beyond the specified amperage limits to prevent burning 12 Ground Fault Circuit interrupter Receptacle duplex REC1 a to 20A NEMA 5 20A NEMA 5 20P Locking Receptacle REC2 up to 20A NEMA L14 20R NEMA L14 20P Locking Receptacle
43. voltage fre quency 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 Arated 250 W electric drill requires a 400 W generator to start it NOTE If a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps 2 Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no spe
44. wer limit specified This prevents sei zure of engine from occurring due to insufficient amount of oil in the crankcase OIL SENSOR Since the sensor has been designed to consume a part of power supplied to the igniter to ener gize its electronics circuit any other external power supply is not necessary so that it can be Fig 5 15 mounted at the oil filler port Introduction of newly developed sensing principle features super durability and no change with the passage of time as it does not use any moving part Merits due to introduction of electrical conductivity detection are as follows it has resistance to mechanical shocks and property of no change with the passage of time as sensing element consists simply of electrodes having no moving parts 69 At the same time it is capable of detecting the level stably as it is not influenced by engine vibrations No error occurs due to foam and flow of the oil Influence against the ignition system the electronics units be neglected because an electric current supplied to the sensor can be decreased 5 4 2 PRINCIPLE OF SENSING OIL LEVEL There is a great difference between electric resistance of air and that of oil Since the resistance of air is far higher than that of oil more electric current passes through the oil than through the air although absolute value of the current is very small The sensor detects this current difference and
45. y keeping it level When starting the engine with an insufficient oil in the crankcase engine starts once then it stops automatically after it runs for 5 seconds When the engine has been stopped by the oil sensor voltage remained in the electronic circuit prevents the sensor from being restarted for 3 seconds after the engine stop Try to restart the engine after 3 seconds or more 21 6 SAFETY PRECAUTIONS 1 Use extreme caution near fuel A constant danger of explosion or fire exists Do not fill the fuel tank while the engine is running Do not smoke or use open flame near the fuel tank Be careful not to spill fuel when refueling If spilt wipe it and let dry before starting the engine 2 Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oily cloth straw and any other inflammables near the generator 3 Do not operate the generator in a room cave or tunnel Always operate in a well ventilated area Otherwise the engine may overheat and also the poisonous carbon monoxide contained in the ex haust gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facilities during use 4 Operate the generator on a level surface If the generator is tilted or moved during use there is a danger of fue spies and a chance that the generator may tip over 5 Do not operate with wet hands or in the rain Severe electric shoc
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