RGV6100 - Subaru Industrial Power
Contents
1. 38 10 4 CHECKING DISASSEMBLY and REASSEMBLY of the FRONT PANEL 46 TROUBEESHOO TING 51 TST NOAG OUTPUT aote rip Eats ERE 53 11 2 AC VOLTAGE IS TOO HIGH OR TOO 55 11 3 AC VOLTAGE IS NORMAL NO LOAD BUT THE LOAD CANNOT BE APPLIED 56 NO DG OUTPUT tem mo Ope 57 CONTROL OP TIONAL EQUIPMENT 08 WIRING DIAGRAM 61 NOTE As for the servicing information on engine protion please refer to the EH1 7 2 EH25 2 and 4 engine service manual 1 SPECIFICATIONS uondo SE SI JOJOW 194615 0140914 9 9 67 09 OL 541 1 gp 541 901 Aig 266 X X 029 Ut 2 LZ X 69LX p vc 667 X SLp 099 Ul p 6L X EOL 022 X M X 7 Jeuels Jeuondo pue Jeuels 10994 Hues 1911 071 S 92 0 69 0 126 5 ZEO 991 5 86 ZL S N LFE Ayoede yueL 9n ejiqouioiny 2641 62 0601 221 ENE e o 9 y2. 19509002 00L V 5 8 1 indino VO SL VO OE V9 6 Vc 6l juano voog NOZ L NOZ L M 009 M 0052 jindino OV M 001 M 0082 jndingo oseug 04 2 Buniox3 ssejusnug 00LUVASH 0086A9H uondo SB s 1911615 0140814 9718 87 581 081 841 2 1 WBM 069 X 027 X 089 UI amp vZ X 981 X 8 92 H X M X 1 suorsueuuiq 211 99 3 pue ueis s sje en Zeo Ayoede 6 12 Sn 29 9 Ayoede yueL any ejiqouioiny n ND 29 02 BEE eur osec 9 o 29 p 22000000 ed VOZ VOY AOvZ AOZ oseug 04 2 Guniox3 ssejusnug ______ m JJ JJ 1 SPECIFICATIONS PUE LOLVADH JOJOW 193215 0110913 x eonou 1 64 9718 sal 7 671 SZ Sal 0 221 29 sqi 0071 09 Sal 069 X 0 7 X 08
3. 19 6 SAFETY PRECAUTIONS an EUR CV 22 OF APPLICATIONS Doux bran us ROS 23 8 MEASURING PROCEDURES 26 8 1 MEASURING INSTRUMENTS testet qiue eee up rd aie te 26 92 AC OUTPUT MEASURING ee edema 29 8 3 DG OUTPUT eae haben tasses 29 8 4 MEASURING INSULATION RESISTANCE 47 1 30 9 CHECKING FUNCTIONAL 65 32 19 TER __ ___ EE 32 JZ ACGREGEPTACLE 32 CONTENTS BREAKER e T T EE 32 Section Title Page P Mele e Tm 33 9 5 ROTOR ASSEMBLY E 34 8 34 9 7 DIODE REGTIF IE M 35 FOEGEN SOP eer ren err re ee ree nent en ere eet ne tere 36 10 DISASSEMBLY AND ASSEMBLY see rere 37 10 1 PREPARATION and 37 10 2 DISASSEMBLY PROCEDURE RR SEE 37 10S ASSEMBLY PROCEDURES sat
4. 2 086 29 lt 8 Pleo 120 240V 285 005 5 gt 9 29025 5 lt or np 2 8 D O gt 5 cz S 2 080 1 we 694 5 5 5 Sos 5 pog 522 cs 5 Voltmeter 854 9 lt ny 9T 55 Winding lt Diode 0 75BIk 0 75Grn Y Condenser Condenser DC Winding Assy 250 Circuit breaker DC output 1 25Brn terminal 1 25Br W Magnetiec Electric switch starter IL IJ 7 Earth Ons Ground terminal 68 RGV6101 CONTROL BOX GENERATOR nee Fu No fuse breaker oT O 2 0BIk VU 5 5 Full power m 5 gt I switch 52 5 5365 120 240V ses 3 Ses 2 5 lt Or 5 2 0 2 0Blu 1 oS 2 3 REC3 32 Voltmeter OR 55 883 o Auxiliary 82 2 E Winding 5 120 240 condenser 0 9 5 5 120V 3 i 2 0W 225 ota 2 0W 25 2 08m 2 2 ____ 8 220 0 75Grn a Engin switch 5 lt 1 25 Diode stack Assy Ek Circuit breaker DC output A lt 1 1 25 terminal 1 25Bm W 2 Jl 1 a gt gt gt Earth CU
5. Blu Light blue Org Orange Brn Brown Gry Gray E 4 WIRING DIAGRAM RGV4101 GENERATOR CONTROL BOX ENGINE Idle control switch 0 75W 0 o 0 7504 0 75Blu 0 75LBlu in coloni Solenoid No fuse breaker Full power o 2 0BIk switch 120 240V Sarge absorber tacle AC output recep 120V MMV Field Winding AC Winding 1 Ignition coil cl 1 258 Diode stack gt 5Brn 7 Assy 3 0 0 1 250 e Circuit breaker DC output 1 25 terminal 1 25Brm W EM Earth Ground terminal ec a 2 0Blu 1 5 9 5 E Volmer i Es BEC 5 oltmeter 555 o gt x 2 0R 998 99 2 o Q Sen c 2 985 5 condenser 0 75BIk 2 c 1 1 25Y 9 Oil sensor l 2 2 n 0 75Blk 0 75Gm Y c c 1 25 2 0Grn MM 7 RGV4101 Electric starter model GENERATOR CONTROL BOX ENGINE Idle control switch 0 75W Q 75W 0 75W gt 0 75LBlu Solenoid oo for condenser VAV 5 No fuse breaker Full power ow e 0 75Blu
6. x SURGE ABSORBER 5 2 4 NO FUSE BREAKER The no fuse breaker protects 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 _ or PROTECTION RGV2800 60 Hz 120V 7 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 60 Hz 120 V 240V Output from 30A receptacle Table 5 1 5 2 5 DC CIRCUIT BREAKER The 10 ampere DC circuit breaker mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit 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 E 13 TL n GFCI Ground Fault Circuit Interrupter o e up to 20A NEMA 5 20A NEMA 5 20P Receptacle duplex REC1 up to 20A NEMA L14 20R NEMA L
7. Magnetiec switch ENGINE 0 75Blu 0 75Blu 0 75Grn W ZEN Fuel cut solenoid Charge coil Ignition coil Spark plug Oil sensor 0 75Gm Y ENGINE 0 75Blu 0 75Blu 0 75Grn W Fuel cut solenoid Charge coil Ignition coil Spark plug 0 75Gm Y 9 Battery Electric starter Robin America Inc 940 Lively Blvd Wood Dale IL 60191 Phone 630 350 8200 Fax 630 350 8212 e mail sales robinamerica com www robinamerica com PRINTED IN THE USA
8. 24 200 2 28u 2 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 White Orange Orange Co Enna Brewn Brown Brown White CIRCUIT TESTER Fig 9 7 Fig 9 8 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 Brown No continuity No continuity Continuity Analogue circuit tester Apply red plus needle of Brown No continuity Oo No continuity Continuity the circuit tester Continuity Continuity Continuity Brown White No continuity No continuity No continuity Table 9 4 1 66 Checking table for digital circuit tester Apply red plus needle of the circuit tester Digital circuit tester Brown Brown White Brown No continuity No continuity Continuity Apply black minus needle No continuity Continuity of the circuit tester Continuity Continuity Continuity Brown White No continuity No continuity Table 9 4 2 NOTE 1 Because of the difference of measuri
9. 250 kg cm 13 7 18 0 ft Ib 10 3 8 FUEL TANK 1 For RGV2600 and RGV4100 only FUEL GAUGE Attach the fuel strainer to the bottom of the x FUELTANK fuel tank Screw in the fuel strainer all the way v and return one to two turns and then lock it with the lock nut us FUEL FILTER For RGV6000 only 1 Attach the fuel strainer to the frame Tightening torque E e 4 9 6 9 N m did 50 70 kg cm m ae 3 6 5 0 ft lb s BENE e y oum M T 2 Mount the fuel tank on the frame with rubber il washers between the tank flange and the frame did 2 FUEL STRAINER M6 x 20 mm bolt 4 pcs m Rubber washer 4 pcs NOTE For easy tank assembly glue the rubber ed x HOSE CLAMP gt washers over the mounting holes of the RUBBER PIPE a HOSE CLAMP 3 Connect the rubber pipe First fit the hose clamps on the rubber pipe and 0 connect it to the strainer and the carburetor Then ve fasten it with the hose clamps For RGV6100 connect the rubber pipe to the strainer and the fuel tank in the same NOTE Apply a drop of oil to the rubber pipe for easier connection Fig 10 30 51 10 3 9 FRONT PANEL Mount the front panel assembly to the frame Hefer to Section 10 4 for disassembly checking and reassembly procedures of the front panel 1 Connect the wires from t
10. Continuity Continuity Continuity 0o Continuity Brown White No continuity No continuity No continuity Table 2 4 1 Checking table for digital circuit tester Apply red plus needle of the circuit tester Digital circuit tester Bow No continuity No continuity Continuity Apply black minus needle Brown No continuity No continuity Continuity of the circuit tester Continuity Continuity Continuity Brown White No continuity No continuity No continuity Table 2 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 60 11 4 6 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester MODEL SPECIFICATION RESISTANCE RGV2800 120 V 120V 240 5 RGV4100 0 18 RGV4101 99 Hz 8 0 14 RGV6100 50 Hz 120 V 120V 240 3 0 13 RGV6101 0 11 Table 11 3 If the resistance reading is much larger or smaller than the specified value the DC coil of the stator is faulty Replace stator with a new one 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 i
11. Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption 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 ariven 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 and 4 vary in their required motor starting power depending on the kind of motor and start up load If it is difficult to determine the optimum generator capacity select a generator with a larger capacity 24 5 Appliances without any indication as to power consumption Some appliances
12. 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 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 oil again before the sensor decides it as oil shortage The oil level where the sensor decides as oil 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 Power circuit Igniter Detection TE Stopping nner pore circuit Deley circuit circuit Oil Outer pole Engine ground Fig 5 16 1 Power circuit T
13. faulty replace it with a new one Fig 11 2 54 2 GENERATOR TROUBLESHOOTING 2 1 NO AC OUTPUT 2 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 NORMAL CAPACITY OF CONDENSER RGV4101 RGV6101 200 Fx2 30u Fx2 Table 2 1 2 If such an instrument is unavailable the con denser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect CONDENSER in original condenser Fig 2 1 2 1 2 CHECKING STATOR 1 Remove control panel and disconnect stator wires at the connectors COUPLER STATOR 2 Measure the resistance between terminals on stator leads See Fig 2 2 Refer to Table 2 2 for normal resistance If stator is faulty replace it with a new one Fig 2 2 Specification AC Winding MODEL inding Voltage White Red Black Blue Yellow Yellow Table 2 2 55 3 Check the insulation resistance between sta tor core and each 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 2
14. is available use it Tightening torque Tightening torque 11 3 13 2 N m RGV2800 115 135 kg cm 8 7 10 8 ft lb Fig 10 22 22 5 24 5 N m 230 250 kg cm 16 6 19 5 ft Ib RGV4100 RGV6100 47 10 3 3 STATOR 1 Put the stator in the rear cover setting the four grooves on the side of stator with thread holes of the rear cover 2 Attach the stator cover around the stator 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 2 Fix the rear cover to the adaptor with four bolts spring washers and washers RGV6100 160 mm 4 pcs au TU COVER M6 spring washer 4 pcs 6 washer 4 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft Ib RGV2800 and 4100 M6 x 110 mm bolt 4 pcs M6 spring washer 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 A 10 3 5 END COVER RGV4100 only Attach the end cover to the rear cover m 1 U Da aa l 1 J M n L 1 r T
15. m 1 Dr Tra I LL p Fig 10 26 10 3 6 FRAME 1 Attach the mount rubbers to the frame Insert FRAME UPPER the setting tongue of mount rubber into the hole on the frame and tighten the nut from the bot tom of the frame M8 flange nut 4 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 8 ft Ib 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 Tightening torque the frame Put the engine and alternator as sembly into the frame from the side of it 11 8 13 7 N m Tighten the nuts over the mount rubber bolts to fix 120 140 kg cm 8 7 10 8 ft Ib 8 nuts 4 pcs NOTE Remove the air cleaner cover for easier installation NOTE When tightening the nuts slightly lift the engine and alternator assembly so that the weight is not applied to the mount rubbers 49 4 Fasten the other earth cable with 5 mm termi nal to the unpainted bolt hole on the f
16. voltage Voltmeter cannot be checked with circuit tester because its resistance is too large 1 Check that no disconnection nor short circuit occurs with a tester and the internal resistance is around OOk ohms normally 2 on the commercial power supply input 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 the 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 2A Fig 9 2B 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 by 3 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 Fig 9 4 LO MODEL 25 120 V 120V 240 RGV2800 1 67 58 120 V 120V 240 RGV6100 NOTE If the circuit tester
17. 00 2 0Blu Engin switch lt DOSE X Diode stack Assy ETAT 250r 3 Circuit breaker DC output 1 25Brn terminal 1 25Brn W 2 DC Winding 0 1 O 6 gt Voltmeter 59 5 2 08 gt 2 gt 120 240V 7 Eze de pt za 120 9 33 5 lt 2 0W 55 2 2 0W mec c 2 0Grn r o o c c 2 2 o CZ 2 0Y e o 0 75Grn CN Earth ON Ground terminal d e ENGINE 5 x e 10 N 1 0 750 Oil sensor Charge coil Ignition coil Spark plug RGV4100 6100 ELECTRIC STARTER TYPE CONTROL BOX ENGINE Oil sensor gt 0 75Blu RGV4100 gt 0 75Grn W RGV6100 5 5 Oc L S SG 58 m ge Ox TS es gt 2e io 5 gt 9 Or 5 Or gt gt cS Bw f OO gt oo call 3 SS E a P 5 x LO 0 LO LO o S 58 5 1 25Grn x D N 0 75BIK W lt 7 1 25Gm Y RGV4100 6100 for BS 1 25Grn Magnetiec Electric switch starter Earth OWS Ground terminal Wiring color cord BIk Black Brn W Brown White R Red BIKW Black White Grn Green W White Blu Blue Grn W Green White Y Yellow
18. 14 20P Locking Receptacle REC2 _ Locking Receptacle up to 30A NEMA L5 30R NEMA L5 30P REC3 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 tected by GFCI 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 GFCI RECEPTACLE After starting the engine check the GFCI 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 a J 5 2 8 CONNECTING TO 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 lin
19. 7 2 Prepare a bolt with the following thread size 0 2800 10 1 5 0 4100 6100 2 P 1 5 3 Apply a few turns of seal tape around the ip of the bolt See Fig 10 18 M SEAL TAPE 45 Seem Oreos 7 4 Screw the bolt into the thread of the roto Do not stick out your shaft face over the rotor 5 Torque the bolt using a socket wrench _ It may jump up 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 oil thoroughly from rotor shaft 3 line PTO shaft 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 46 10 3 ASSEMBLY PROCEDURES 10 3 1 FRONT COVER Attach the front cover to the engine main bearing cover Match the faucet joint and tighten the bolts 20 mm bolt 4 pcs M8 spring washer 4 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 1 ft Ib Fig 10 21 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
20. 9 Ul X 981 X 8 92 ZSS X X 029 212 X 691 X v vc H X M X 7 19215 ueis s S N jeu S 920 Jeu 0 Ayoedey 29 9 6712 S ee v 9 94 ejiqouioiny 29 02 BEE Ul ND ZEGE 6 queweoeidsiq e o 9 p ed oseug Buniox3 ssajusmg o HOIVNHZAILTIV 2 PERFOMANCE CURVES Hz 63 62 Hz 61 60 V 250 125 240 230V 115V 120 S 115 220 110 Load Rated DC OUTPUT DC Voltage 12V DC Ampere 8 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 20 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
21. A trouble free condenser type voltage regulator ensures a stable voltage under all working conditions 3 3 OIL 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 Alarge super silent muffler Aquiet 4 stroke Robin Pro 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 a 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 enabled the RGV generators to be very compact in size and light in weight 3 9 MINIMAL MAINTENANCE A brushless alternator release the operator from periodical brush maintenance Atrouble free condenser type voltage regulator A drip 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 Pro OHV engine and virtually maintenance free brushless alternator ensure greater durability with A brushless alternator with
22. 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 SOLENOID 25 3102 If the resistance is larger smaller than this range SOLENOID is defective with a new one Fig 11 17 64 12 WIRING DIAGRAM RGV2800 U S A 60Hz 120V TYPE NEMA RECEPTACLE GRNERATOR LL Sarge absorber 0000 Auxiliary Winding for condenser RGV4100 U S A 60Hz 120V 240V TYPE NEMA RECEPTACLE GENERATOR LL Sarge absorber DC Winding AC Winding 2 0000 CONTROL BOX ENGINE p A No fuse breaker pec TU SUB AC output receptacle E 5 120V gt lt GP lt 1 2 0Blu 1 W gt 2 0R N 5 5 Voltmeter A 2 lt 5 E lt 2 0W 1 lt 1 1 25 Engine switch D 0 0 75 5 5 gt lt 1 25Y lt 1 25 5 1 2501 5 E O Circuit breaker DC output N gt 1 25Brn term
23. 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 MODEL r Robi Range Condenser Capacity 10 to 100 2 x GFA4P 006P Dry Cell Battery Test leads with needle probes 1 set Test leads with jack plugs 1 set Table 8 1 The Dr Robin generator tester can be ordered from Robin generator distributors by the following part number Dr Robin Part Number 388 47565 08 If you do not have a Dr Robin generator tester use the instruments described in the following section for checking generator parts 27 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 150 Type with an output voltage of 110 or 120V 0 to 300 Type with an output voltage of 220 230 or 240V 0 to 150V 0 to 330 Dual voltage type 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating o
24. Fig 5 13 Switch LOWER VOLTAGE HIGHER VOLTAGE Position RECEPTACLE RECEPTACLE 120 240 V Half of rattad outpu t Rated outpu Table 5 3 Em 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 these 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 Hec 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 S
25. N Ground terminal RGV6101 Electric starter model GENERATOR CONTROL BOX cut unit No fuse breaker 2 0BIk control unit and cut unit unit 1 Idle control and Fu 1 0 751 8 0 75W 0 75Blu 9 0 75Blu 0 75BIK W el 0 75Gm W 6 0 75Gm W 0 75Blk 0 75Grn 0 75W 8 0 75W 0 75Blu 9 0 75Blu 0 75BIk W 0 75Grn W 0 75Grn W 0 75BIk 0 75Grn Key switch 5 VV 19 Full power 15 5 2 switch 55 E 8 120 240V_ 585 5 ooo ei 5 v o np iL 2 0Blu 1 g 55 REC3 T5 2 gt Voltmeter 85 89 lt 2 0R o 5 265 0 0 0 0 oq ona Auxiliary Q9 Winding 120 240 n for s N condenser ie 9 5 2 0W 59 Za 2 0W M 2 0 2 0Grn 19 e e T F c c 8 8 j 2 0Y 1 25Gry d lt gt 1 25 Diode stack E y Assy gt 1 250 1 25 2 Circuit breaker DC output a lt 1 25 terminal 125R 1 25Brn W EA Earth CUN Ground terminal 2169 Idle control switch 0 0 75W 0 75Blk Idle control switch 0 0 75W lt lt lt lt OO LO LO SN oo Diode stack Assy lt lt 0 75Blk MAMMA MMV
26. NCIPLE 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 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 oil 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 20 Judgement of oil 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
27. SERVICE MANUAL Models RGV2800 RGV4100 RGV6100 Generators PUB GS1277 Section Title Page 1 2 PERFOMANGE CURVES 3 3 FEATURE ee M N 5 3 1 BRUSHLESS ALTERNATOR _ _________ 6 5 3 2 CONDENSER TYPE VOLTAGE REGULATOR rte t d E aha QU itd 5 E NS aestu dtr scant E ___ 5 SAQUET OPERATION epe enne iesus 5 RADIO e 5 MID c 5 3 7 RUGGED TUBULAR FRAME d 5 3 8 COMPACT AND EIGHT WEIGHT oe ees 5 3 9 MINIMAL MAINTENANCE 1 66 nnn 6 6 4 GENERAL 7 EXTERNAE bm 7 8 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER 9 5 CONSTRUCTION AND FUNCTION 10 10 SZ FUNCTION 10 5 3 GENERATOR 16
28. URING 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 NOTE Turn 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 CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Fig 8 13 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 32 9 CHECKING FUNCTIONAL MEMBERS 9 1 VOLTMETER Check the voltmeter if it is turned on by applying specific
29. Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals 0 MODEL RGV260 RGV410 RGV610 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 m I 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW SPEEDCONTROLLEVER 11 2 1 CHECKING ENGINE SPEED If the engine speed is too high 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 Normal engine speed at no load 3 00 to 3750 rpm 11 2 2 CHECKING CONDENSER Check condenser referring to Step 11 1 1 wo c RGV6100 6101 11 2 3 CHECKING STATOR Check stator referring to Step 11 1 2 Fig 11 7 11 2 4 CHECKING ROTOR Check rotor referring to Step 11 1 3 11 3 AC VOLTAGE IS NORMAL AT NO LOAD BUT THE LOAD CANNOT BE APPLIED 11 3 1 CHECK THE ENGINE SPEED If the engine spee
30. a condenser voltage regulator Full rubber mount in a sturdy tubular frame forged steel crankshaft supported by two main ball bearings A 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 gt TERMINAL DC OUTPUT TERMINAL RECOIL STARTER IDLE CONTROL DC CIRCUIT SWITCH BREAKER NO FUSE OIL SENSOR BREAKER SPARK PLUG ENGINE EMISSION LABEL MUFFLER OIL DRAIN PLUG OILGAUGE OIL FILLER 4 2 CONTROL PANEL RGV2800 U S A 60Hz 120V NEMA RECEPTACLE AC OUTPUT V METER ENGINE SWITCH AC BREAKER AC 120V FULL POWER SWITCH 120V 120V 240 30 20 69 gt L s BATTERY CHARGE ONLY DC OUTPUT DC BREAKER AC BREAKER RGV6100 6101 U S A 60 2 120 240 NEMA RECEPTACLE AC 120V FULL POWER SWITCH AC 120V 240V V METER 120V 120V 240V ON 69 a m AC eS 20A ENGINE SWITCH IDEL CONTROL AC CS 30A 9 0 DC 12V 8 3A BATTERY CHARGE ONLY n OFF DC OUTPUT DC BREAKER AC BREAKER 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 NOTE Always specify thes
31. d is low adjust it to the rated r p m RHefer to Step 11 2 1 for engine speed adjustment 11 3 2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR Hefer to Section 7 HANGE 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 Mr move it Ez OUTLET ENGINE xs i ENGINE AIR OUTLET ALTERNATOR AIR INLET 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 1Mo the insulation is faulty and may cause electric leakage Replace the faulty part 58 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 c
32. e numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service LABEL MODEL NAME 10 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION END COVER BALL BEARING STATOR COMPLETE ROTOR COMPLETE REAR COVER STATOR COVER CRANKSHAFT Bu ae Mh 222 ES S 4 N N Ia 7 S Y _ 2 A NAS A SS lt 8 ___________ Po SS pth 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 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 r Li o A DODE RECTIFIER
33. e 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 b 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 c flows through the main coil to the appliance a magnetic flux is produced and serves to increase current a in the condenser coil When current a 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 EE iL 5 3 3 FULL POWER SWITCH Dual Voltage Type 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 40 REG 1 1 1 ge 4 2 UE li20 __ 2400 G
34. elect the proper output voltage by full power switch in accordance with the appliance to be used 2 5 4 OIL 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 lower limit specified This prevents sei zure of engine from occurring due to insufficient amount of oil in the crankcase K 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 1 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 2 Atthe same time it is capable of detecting the oil level stably as it is not influenced by engine vibrations No error occurs due to foam and flow of the oil 4 Influence against the ignition system or the electronics units can be neglected because an electric current supplied to the sensor can be decreased 5 4 2 PRI
35. epending 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 m 6 Checking the IDLE CONTROL UNIT RGV6101 Check the resistance between five leads of IDLE CONTROL UNIT with circuit tester Terminal number of the IDEL CONTROL UNIT Fig 2 19 Circuit tester with battery power source 1 5 V e Apply red 99 so ko needle of the 350 9 9 66 zo sid e e one e 4 o 4 00 Table 2 7 2 5 2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF 1 Check the distortion of the SOLENOID BRACKET as shown in step 2 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 SOLENOID 25 310 If the resistance is larger or smaller than this range SOLENOID is defective Replace with a new one Fig 2 20 63 11 5 2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF 1
36. es such as a stand by power source 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 UTILITY HIGH LINE Tos CONNECTING a Fei a d 240 RECEPTACLE 0 3 TRANSFER SWITCH MM ua P _ 8 desee E Fig 5 9 5 Meter box Transfer switch bELIIIIlLLIIlLI LLL LLL Generator 00 Cs 120 appliance 240V Utility high line 240V zu House ci
37. f a given generator is most desirable About 10A 20A 100A 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range 28 4 CIRCUIT TESTER Used for measuring resistance etc 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 Fig 8 7 2 8 2 AC OUTPUT MEASURING SWITCH lLoAD PA le TO AC RECEPTACLE 5 E Jars ul Fig 8 8 Use a circuit like the shown in Fig 8 8 for measuring AC output A 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 V 108 132 V216 264 Table 8 2 8 3 DC OUTPUT MEASURING Lead amp Ta DC Terminal o E Fig 8 9 Measurement of DC output is executed with the switch turned ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal NOTE a battery is connected as a load to the generator the DC output voltage will increase by approximately 1 to 2 V Therefore carefully observe the electrolyte level and do not overcharge the battery zu 8 4 MEAS
38. have no indication as to power consumption but instead the work load output is indicated In such a case power consumption is to be worked out according to the numerical formula mentioned below Output of electrical appliance Power consumpition Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 6 to 0 75 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 accordingly power consumption will be 40 0 72 57W As explained in Item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get the figure of the 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 400 0 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 2 684 W to 1710 W MODEL RGV2800 RGV4100 RGV6100 Frequenoy 000000 Incandesent lamp 2300 W 3600W WA800 heater etc Fluorescent lamp Motor approx approx approx driven tool general porpo
39. he front panel 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 gt b 0 4 Mount the front panel to the frame EC 5 12 mm bolt and washer Ass y 2 pcs M5 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 M4 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 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 identif
40. heck 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 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 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 59 DIODE RECTIFIER Brown Brown White Orange Orange Brown Brown Brown Brown White CIRCUIT TESTER Fig 2 13 Circuit inside of the diode rectifiers is as shown in Fig 2 13 Check continuity between each terminal by using a circuit tester as shown in Fig 2 14 The rectifier is normal when condtinuity is as follows Checking table for analogue circuit tester Apply black minus needle of the circuit tester Analogue circuit tester Bom No continuity No continuity Continuity Apply red plus needle of Brown No continuity No continuity
41. his rectifies a part of power to the igniter and regulates it to supply the stabi lized power to necessary circuits 2 Detection circuit This detects quantity of oil sufficient or not according to difference of electric resistance across inner and outer electrodes 3 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 1 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 1 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 2 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 tha
42. ication 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 control 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 53 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 CONDENSER CONDENSER Fig 11 1A Type RGV2800 Fig 11 1B Type RGV4100 4101 RGV6100 6101 NORMAL CAPACITY OF CONDENSER RGV2800 RGY410 RGY610 24u F 20u 2 28 2 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 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
43. inal 1 258 5Brn 1 25Grn Earth CONTROL BOX No fuse breaker 0 2 0 switch 2 0Blu i vermeren 2 0R enser Condenser Cond 1 25Y Diode stack SSy 1 25Brn VM Full power 120 240V 2 1 e Circuit breaker 1 25Brn 1 25Bm W Ground terminal 0 75W 0 75W 0 75Blu o Auto idle switch 0 75LBlu AC output receptacle 150 receptacle 120 240V AC one receptacie 150 2 0Gr 1 2501 DC output terminal Earth Ground terminal Quo 65 gt D 5 LO M c LLI Ignition coil Spark plug 3 0 75BIk Oil sensor 0 75Grn Y Ignition coil Spark plug 3 0 7 0 75Grn Y Oil sensor RGV6100 U S A 50Hz 120V 240V TYPE NEMA RECEPTACLE GENERATOR CONTROL BOX Auto idle switch 2 0 75W 0 0 75W control unt 0 75Blu d 5 0 75Blk W 0 75Grn W Fuel 6 0 75Grn W cut unit 0 75Blk 0 75Grn No fuse breaker 1 2 0B gu V Full power switch 2 20 240 Sarge absorber 1 Field Winding AC Winding 1 AC receptacle 19
44. is not sufficiently accurate it may not show the values given and may 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 ent from 20 C 68 F 53 B 1 Table 9 da 9 5 ROTOR ASSEMBLY 1 Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals MODEL RGV2800 RGV4100 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 Fig 9 6A Type RGV2800 Fig 9 68 RGV4100 4101 RGV6100 6101 NOTE Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance or the accurate reading cannot be obtained 35 NORMAL CAPACITY OF CONDENSER RGV2800 RGV4100 RGV6100
45. n that of tinned terminals 3 Operation of oil sensor 1 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 by keeping it level 2 When starting the engine with an insufficient oil in the crankcase engine starts once then it stops automatically after it runs for 5 seconds 3 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 22 6 SAFETY PRECAUTIONS 3 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 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 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 struct
46. ng 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 in which a pointer of the tester goes out of its normal scale 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 85 same as the digital circuit tester 9 8 OIL SENSOR 1 Disconnect two 2 wires comming from the sensor at the connection 2 Loosen the sensor to remove it from the en gine 3 Plug the opening of oil filler hole created after sensor is removed with suitable means such as oil gauge 4 Connect the removed wires again with the oil Sensor 5 Start the engine with the oil sensor removed 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 7 10 DISASSEMBLY AND ASSEMBLY 10 1 PREPARATION and PRECAUTIONS 1 Be sure to memorize the location of individual parts when disassembling the generator s
47. o 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 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 38 10 2 DISASSEMBLY PROCEDURES _ Control box Take off the bushing from the bottom of the control box See Fig 10 1 2 Disconnect the connectors on the wiring Press the upper end of from the control box to the alternator 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 8 mm Spanner control box the frame See Fig 10 3 5 x 12 mm bolt and washer Ass y black 2 pcs 5 x 25 mm bolt and washer Ass y black 2 pcs 39 _ Fuel Tank 1 Discharge fuel from the tnak Use utmost care about 1 Shut the fuel strainer fire hazard 2 Remove the strainer cup 3 Put a vessel to receive fuel under the Wipe off split fuel strainer and o
48. pen the fuel cock to thoroughly discharge fuel See Fig 10 4 4 Attach the strainer cup to the strainer Do not lose the filter body screen 2 Disconnect rubber pipe from the strainer Pliers 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 10 mm spanner or tank and then remove the fuel tank box wrench See Fig 10 6 RUBBER NN 1 40 LUI NN Muffler and 1 Remove the two bolts which fix the 12 mm spanner or Muffler cover muffler to the alternator Loosen the two box wrench nuts on the muffler flange and remove 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 for RGV4100 and RGV6100 Muffler gasket 1 pce 2 Remove the muffler cover 1 and the muffler cover 2 from the muffler 10 mm spanner or box wrench 6 x 10 mm bolt and washer Ass y 8 pcs See Fig 10 8 3 Remove the muffler bracket from the rear cover 8 x 20 mm bolt and washer Ass y 2 pcs 12 mm spanner or box wrench 41 _ 4 Pipe Frame FoARGV610 10 mm spanner the fuel strainer from the frame 2 Remove the nuts which are fixing engine 12 mm spanner and alternator to the mount rubbers See Fig 10 9 3 Using a chain block sling up the engine Remo
49. pliance is not always equal to the output watt age of the appliance The electrical appliances generally have a label showing their rated 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 A rated 250 W electric drill requires a 400 W generator to start it NOTE power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps NOTE 2
50. rame See Fig 10 28 FARTH CABLE 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 bolt 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 Ass y 8 pcs Tightening torque 7 9 9 8 N m 80 100 kg cm MUFFLER COVER 1 5 8 7 2 ft lb 3 Put the muffler gasket to the engine 4 Attach the muffler with muffler cover to the A engine and the rear cover 1 Tighten the two nuts for the muffler first Use the spring washers for RGV4100 and E GASKET RGV6100 MUFFLER 8 mm stainless nut 2 pcs 8 mm spring washer 2 pcs for RGV4100 and RGV6100 only Tightening torque 21 6 27 4 N m MUFFLER COVER 2 220 280 kg cm 15 8 20 2 ft lb 2 Tighten the bolts to fix the muffler to the rear cover M8 x 20 mm bolt and washer Ass y 2 pcs for RGV4100 Tightening torque HE MUFFLER for RGY ZEDD 100 18 6 24 5 N m 190 250 kg cm 13 7 18 0 ft Ib Fig 10 29 50 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 the muffler bracket M8 20 mm bolt and washer Ass y 4 pcs for RGV2800 and 6100 Tightening torque 18 6 24 5 N m 190
51. rcuit breaker 120V appliance PA appliance 4P Receptacle Fig 5 10 c Operating the generator Set the full power switch to 120V 240V side Turn the house AC breaker off before starting the generator Start the generator and warm it up Turn 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 may be damaged by the surge voltage at starting Wee 5 3 GENERATOR OPERATION MACIHET INITIAL EXCITATIGIN FIELD COIL ROTOR ANE cc MAIN COIL RECEFTACLE T X M M APPLIANCE SURGE L DIODE Fig 5 11 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 a 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 a increases the magnetic flux at the rotor s magnetic pole increases further Thus th
52. s 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 x SPEED CONTROLLEVER The normal idling speed by the IDLE CON TROL is as follows RGV2800 1900 to 2100 r p m RGV4100 4101 epee 2000 to 2200 r p m RGV6100 6101 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 Fig 11 14 61 4 Check the wiring through ZCT on the IDLE CONTROL UNIT IDLE 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 OUTPUT WIRE 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 Fig 11 15 5 Checking the IDLE CONTROL UNIT Check the resistance between five leads of IDLE CONTROL UNIT with circuit tester Terminal number of the IDLE CONTROL UNIT Fig 11 16A Fig 11 16B Circuit tester with battery 1 4 black minus needle of the circuit tester Table 11 4 NOTE The resistance readings vary d
53. se 1200 W 1800 W 2400 W approx approx approx 800 W 1400 W 1600 W approx approx approx Pump compressor etc 550 W 850 W 1100 W Table 7 1 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 Gauge wire element No mm Resistance Voltage drop per 100 m Ohm 100 m Sectional Allowable area mm current 45 0 32 70 0 32 Table 7 2 Voltage drop indicates as xRxIxL R 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 length from generator to electrical tools 26 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 Dr ROBIN GENERATOR TESTER The
54. ures or facilities during use Operate the generator on a level surface If the generator is tilted or moved during use there is a danger of fuel spillage and a chance that the generator may tip over Do not operate with wet hands or in the rain Severe electric shock 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 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 T Table 6 1 Table 6 1 Be sure to check and remedy the cause of circuit breaker tripping before resetting it on CAUTION If 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 25 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 ap
55. ve the air and alternator and dismount from the cleaner cover for frame dismounting FUEL STRAINER For RGV6100 MOUNT RUBBER ENGINE SIDE 2 pcs 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 42 Hear cover 1 Reinove the end cover See Fig 10 11 Except RGV6100 10 mm spanner or box wrench 6 3 pcs 2 Remove the four bolts which fasten the rear cover to the front cover See Fig 10 12 6 bolt 4 pcs 10 mm spanner or box wrench 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 43 Step Part to remove to Part to remove m Descriptio s meo Remove the stator cover E COVER BN 44 27 _ Rotor Take off the through bolt Box wrench Apply a box wrench on the head of Plastic hammer through bolt Hit the wrench handle with a hammer counter clockwise to loosen Put the engine on the working table recoil starter side down 3 Use a bolt and oil as a tool for pulling out rotor in the following procedures 1 Pour engine oil into the center hole of rotor shaft Fill with oil to the shaft end See Fig 10 1
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