RGV Series-Generator - Jacks Small Engines
Contents
1. Eo di DISJONCTEUR CA L PRISES CC E RCHE ARRE tjere n 1 l 1 CCL2Y 8 3A JL CHARGE DE BATTERIE SEULEMENT H IDISJONCTEUR CC 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL MODEL NAME stuck on the end cover NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correci parts and accurate service LABEL MODEL NAME 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION END COVER REAR COVER ROTOR COMPLETE STATOR COMPLETE NZZ LL AT CH je TI FT A ri CE AV Mi AV AV EE Ze MOUNT RUBBER STATOR BOLT BALL BEARING THROUGH BOLT SUPPORT RING 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 vvound 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 control 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 field2. 1 set Dimensions L x W Xx H 285 mmx200 mmx110 mm 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 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 Oto 150V Type with an output voltage of 110 or 120V Oto 300V Type vvith an output voltage of 220 230 or 240V 0 to 150V 0 to 330V Dual voltage type FOR AC Fig 8 2 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 FOR AC Fig 8 3 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range 4 CIRCUIT TESTER 5 6 Used for measuring resistance etc MEGGER TESTER Used for measuring generator insulation resistance Select one with testing voltage range of 500V ENGINE TACHOMETER There are various types of tachometers such as contactless type contact type and strobe type The contact type can be used only when the generator and engine have been dis assembl
3. 4 Measure the insulation resistance between BROWN lead and the core Fig 8 10 e ROTOR Measure the insulation across one of the soldered terminals of the rotor and the core Fig 8 11 e CONTROL PANEL Measure the insulatlon resistances between the live parts and the grounded parts Fig 8 12 Any part where the insulation resistance is less than IMS2 has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 9 CHECKING FUNCTIONAL MEMBERS 9 1 PILOT LAMP and VOLTMETER Check the pilot lamp and the voltmeter if it is turned on by applying specific voltage Pilot lamp and voltmeter cannot be checked with circuit tester because its resistance is too large See Fig 9 1 PILOT LAMP Pilot lamp should be turned on at 70 to 120V 9 2 AC RECEPTACLES Using a Dr Robin or a circuit tester check continuity between the two terminals at the rear of the 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 WIRE Fig 9 2A enen pel Check continuity between each of two terminals at y the rear of the circuit breaker while it is mounted on the control panel Normally there is continu
4. 120V or 110V Fig 5 9 120V 110V Fig 5 10 Switch LOWER VOLTAGE HIGHER VOLTAGE Position i RECEPTACLE RECEPTACLE Rated output i No output can be taken 110 220V or aW O laje Rated output 120 240V GON Table 5 4 Fig 5 11 Two main coils are vvound over stator core Each main coil outputs half the rated power at the lower voltage 110V or 120V These main coils are vvound to be in the same phase The full povver svvitch reconnects these main coils in parallel or in series Fig 5 9 shows a circuit diagram When the full power switch is set for single lower voltage indication 110V or 120V the switch position is as indicated by the lower solid line in the diagram Fig 5 10 is a simplified representation of this circuit showing the two main coils connected in parallel In this case the higher voltage 220V or 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 110V 220V or 120V 240V the switch position is as indicated by the upper dotted line in Fig 5 9 Fig 5 11 is a simplified representation of this circuit showing the two main coils connectea in series n 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 p
5. 50 7 gt 250 Me 240V 120V 240 120 1 Ee 230 115 230V 115V 220 110 210 105 DC OUTPUT VOLTAGE V gt CURRENT Aj 3 DC Voltage E ee e i rere 12V DC Ampere sara eee ee se seua s ca 6 5 0 2 8 3A DC output Ba et ww lt lt en 1 DON 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 out puts simultaneously up to the rated output in total 3 FEATURES 3 1 3 2 3 4 3 8 3 9 BRUSHLESS ALTERNATOR Nevviy developed brushless alternator eliminates troublesome brush maintenance CONDENSER TYPE VOLTAGE REGULATOR A trouble free condenser type voltage regulator ensures a stable voltage under all working conditions 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 QUIET OPERATION Robin RGV series generator delivers a quiet operation with e A large super silent muffler e A quiet 4 stroke Robin Rro OHV engine e A silent cyclone air cleaner NO RADIO NOISE Noise suppressor spark plug and spark plug cap are equipped standard to prevent radio frequency interference LARGE FUEL TANK The large fuel tank allows more than 5 to 11 hours o
6. RGV2600 RGV4000 RGV6000 Table 10 1 T Be 60 WASHER RENTE 69 BOLT Fig 10 25 3 Apply the support ring between the rear cover and 65 mm 2 56 inch 85 mm 3 35 inch 95 mm 3 74 inch 115 mm 4 53 inch 15 mm 0 59 inch 20 mm 0 79 inch 20 mm 0 79 inch 40 mm 1 57 inch 60 SPRING VVASHER 4 4 pcs M6 X 1 0 M6 X 1 0 M6 X 1 0 10 4 4 REAR COVER 1 Attach the bushing over the lead vvire dravvn out from the rear cover Press the smaller end of the bushing into the window of the rear cover See Fig 10 27 Fig 10 27 2 Put the rear cover vvith stator over the rotor Tap on the rear cover evenly vvith a plastic hammer to press the rotor bearing into the rear Cover Di A x up DT JA TAS Fig 10 28 3 Fix the rear cover to the adaptor with four bolts spring washers and washers Re an M6 X 25 mm bolt e 4 pcs M6 spring washer rr been e A pcs a M6 washer CEUTA 4 pcs E Tightening torque 50 60 kgecm 49 59 Nem 3 6 4 3 ftelbs 10 4 5 END COVER Attach the end cover to the rear cover M6 x 8mm flange bolt 4 pcs Tightening torque 40 60 kg cm 3 9 5 9 Nem 29 43 ft lbs Fig 10 30 10 4 6 FRAME w 1 Attach the mount rubbers to the frame FRAME UPPER Insert the setting tongue of mount rubber into Nili the hole on the frame and tighten the nut from the bottom of
7. 1 7 2 Nishi Shinjuku Shinjuku ku Tokyo 160 Japan TEL Tokyo 03 3347 2414 5 TELEX 232 2401 FUJI J CABLE ADDRESS FUJIHEAVY TOKYO FACSIMILE TOKYO 03 3347 2418 PRINTED IN JAPAN June 1993
8. Fluorescent lamp mercury lamp etc Electric tool eic Pump compressor etc approx 700W approx 400W approx 300W 60Hz approx 900W approx 400W approx 400W 50Hz approx 1000W approx 800W approx 400W Table 7 1 60Hz approx 1100W approx 800W approx 400W approx 1500W approx 1600W approx 750W approx 1800W approx 1600W approx 750W 5OHZ approx 2000W approx 1800W approx 800W 60Hz approx 2350W approx 2000W approx 800W NOTES Wiring between generator and electrical appliances 1 Allovvable current of cable Use a cable vvith an allovvable current that is higher than the rated input current of the load electrical appliance If the input current is higher than the allovvable current of the cable used the cable vvill become excessively heated and deteriorate the insulation possibly burning it out Table 7 2 shovys cables and their allovvable currents for your reference 2 Gable length If a long cable is used a voltage drop occurs due to the increased resistance in the conductors decreasing the input voltage to the load electrical product As a result the load can be damaged Table 7 2 shows voltage drops pet 100 meters of cable No of stra nds strands A W G Allowable Gauge No current Nominal cross section Flowing Current Resistan
9. 1000 0 o Condenser Type 0 RE an ve Air Cooled 4 Cycle Overhead Valve Gasoline Engine o ED o we gt 472 cc 10 50 cu in AN _ 3 5 HP 3600 rpm Co 50Hz 8 9 liters hour 60Hz 8 0 liters hour 47 kg 104 Ibs SNOILVOI4193dS Maximum Output Rated Output Rated Voltage Current ALTERNATOR Power Factor DC Output Voltage Regulator Voltage Regulation Type Displacement Il Rated Output Fuel Fuel Tank Capacity Fuel Consumption Ratio at Rated E Oil Capacity Starting System Dimensions L X W XH Dry Weight RGV4000 RGV6000 Brushless Self Exciting 2 Pole Single Phase 60Hz 4 20V 240V 12V 8 3A 100W MU Condenser Tye _ E Sin adro Within ae MM Air Cooled 4 Cycle Overhcad Valve Gasoline Engine me Eugen EH34D ME 251 cc 15 32 cu in n i o EE cc 20 63 CU in a o 5 5 HP 3600 rpm o SBOHPSEOMm nn Automobile Gasoline 8 166 liters 4 38 U S gal ve MH 50Hz 8 3 liters hour 50Hz 5 7 liters hour 60Hz 6 9 liters hour 60Hz 5 1 liters hour onne elemi y oa mane NND os Recoil Starter and Optional Electric Starter D 577 X 430 X 540 mm 660 X 470 X 585 mm 2 PERFOMANCE CURVES 60Hz 60 ee BOHZ V Hz 63 62 61 V 250 125 240 230V 115V 120 230 ett 00000000 220 110 0 1 2 4 4 Load Rated HZ 53 52 Hz 51
10. 30A Table 5 1 I 3 I OBJECT of PROTECTION Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Total output amperage Output from 30A receptacle Total output amperage Total output amperage Total output amperage Output from 30A receptacle 5 2 6 RECEPTACLE and AC PLUG STD SPEC These are used for taking AC output povver from the generator A total of five 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 corresponding 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 up to total 15 amperes from tvvo receptacles Up to 15 amperes up to 20 amperes Up to 30 amperes See Caution Table 5 2 Caution To connect the appliance to locking receptacle insert the plug into the receptacie and turn it clockwise to
11. 60HZ 120V TYPE e RGV2200 RGV2600 50Hz 220V 240V 60Hz 220V TYPE e RGV2200 RGV2600 50Hz 60Hz 110V 220V DUAL VOLTAGE TYPE DE mA e RGV2600 U S A 60Hz 120V NEMA RECEPTACLE e RGV2200 RGV2600 RGV4000 SOUTH AFRICA 50Hz 220V e RGV2200 RGV2600 RGV4000 AUSTRALIA 50Hz 240V e Se O TL el DC EFEAKEN JIAC EREARES e RGV4000 50Hz 60HZ 110V 60HZ 120V TYPE 220V TYPE e RGV4000 50Hz 220V 240V 60Hz e RGV4000 50Hz 60Hz 110V 220V TYPE e RGV4000 U S A 60Hz 120V 240V NEMA RECEPTACLE TOTAL 20A PRISES CA OO CHARGE DE BATTERIE SEULEMENT PRI SES CC e RGV6000 50Hz 60Hz 110V 60HZ 120V TYPE e RGV6000 50Hz 220V 240V 60Hz 220V TYPE L e RGV6000 50Hz 60Hz 110V 220V DUAL VOLTAGE TYPE O e RGV6000 U K 50Hz 110V 220V BS RECEPTACLE e RGV6000 U S A 60Hz 120V 240V NEMA RECEPTACLE e RGV6000 GERMANY 50Hz 220V d e DC 2V 8 SA BATTERY CHARGE ONLY ad ft O e RGV6000 SOUTH AFRICA 50Hz 220V O e RGV6000 SWITZERLAND 50Hz 220V e RGV6000 AUSTRALIA 50Hz 240V e RGV6000 FRANCE 50HZ 220V O o O C PRISES CA VOLTMETRE ARRET gt y 2 I MARCHE U CC12V 8 3A ur Ai fi els ill CHARGE DE BATTERIE SEULEMENT Jji M Fi ff ts PRISES CC DISJONCTEUR CC DISJONCTEUR CAJ O SO ai O PRISES CA gt p H z E
12. ENGINE CONT BOX o CS I bol E OS STOP SW Zk gt gt l A ET Green Green AAA sl Yellow i Yellow GENERATOR pa Black o lam a Zil I It I IL 3 E prot G 2 Blue IE Wo FC Li i H e E Red IE ei act you REC 1 E I I i gt iv White _ Yellow La Yellow C i SS SS le Sr ae i iii 0 75mm 2 00mm 1 25mm e RGV4000 50Hz 110V 60HZ 110V 60HZ 120V TYPE ENGINE _ CONT BOX LL ERR i i I I l E E BC E E E HAMM e ddr AA 2 a Green Oo Green OE ee Yellow Yellon CB T S AO Orange e ea zm e RGV4000 50Hz 220V 240V 60Hz 220V TYPE ENGINE CONT BOX ST MM Sa I i Lol I pra IG os STOP SW ZH ack is e RE O ET aa e a a SE GENERATOR I E pa EE les Yellow pe IS Br Brown D Seos Li Brown I AA EE NN De 1 25mm 2 00mm SS 0 75mm e RGV4000 50Hz 60Hz 110V 220V TYPE ENGINE CONT BOX i ISP i te os sio rack EQ ac A e reen Ni heal Green GENERATOR gt E _ Black STOP SN RH O x p REC White Le ea na _ r de dd te D ET e RGV4000 U K 50Hz 110V 220V BS RECEPTACLE ENGINE 0 CONT BOX __ o Si D I I SP I l H os Black STOP SW r Pia e l Fe a DI pagg ee a Green Green GENERATOR
13. 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 vvipe it and thoroughly dry it before starting Don t pour water over the generator directly nor vvash 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 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 Part Name i Allowable Current 365 45604 08 Transfer Switch 367 45605 08 Transfer Switch 340 45606 08 Transfer Switch 367 43008 08 Plastic Box 348 43009 08 Piastic Box Table 6 1 Be sure to check and remedy the cause of circuit breaker tripping before re setting 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 7 RANGE OF APPLICATIONS Generally the power rating of an electrical a
14. 3 I 200 7 CC I TE E E e ke 187 J Orange LI py Brown _ 8 toi Ci em Brown White AN letres A A Si 0 75mm 2 00mm 1 25m a Fon em en _ I eee UN emm e ET e RGV4000 U S A 60Hz 120V 240V NEMA RECEPTACLE with IDLE CONTROL ENGINE CONT BOX LL ES oi gt l Na SP E d I La REA STOP SW El e zH oHa Aj MR 5 ET 4 NE Green Green E Yellow Yellow P I II A SOL S Tra white q 4 White I It i SW an Gd l CHG SS Blue A ap Light ENERATOR La blue Black GO Blue ES FC Red e RGV6000 50Hz 110V 60Hz 110V 60HZ 120V TYPE ENGINE _ CONT BOX LL de bol I ISP Pal i os STOP SW Black L OT gt A ET AA a Green Green GENERATOR A ellow gt A D Black pen Eq O C0 OS REC 4 REC2 i a ui el I 1 Yellow Yellow C m CB T eres range ro rown White E SSS 0 75mm 2 00mm2 1 25m 3 50mm2 e RGV6000 50Hz 220V 240V 60Hz 220V TYPE ENGINE CONT BOX lr 77 Green o Green i Yellow Yellow i Black NEB CE A ET e RGV6000 50Hz 60Hz 110V 220V TYPE ENGINE CONT BOX E E i I E i SP E a BIEL STOP SW SC Se H Green Yellon lt ET Le ui 7 Green E Yellow Green Yellow Yellow rC en 22
15. 9 1 for normal resistance a ASS AH ASS SN If stator is faulty replace it with a new one Fig 11 2 mM Check the insulation resistance between stator core and cach 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 CHECKING FIELD COIL mM Remove rear cover and Stator Fig 11 4 m Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals RX10 110 RGV2200 RGV2600 RGV4000 RGV6000 RESISTANCE Table 11 2 NOTE 1 Because a diode is soldered to the coil ends at the terminals resistance may be measured only when tester probes touch the terminals 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 ee m Measure the insulation across one of the soldered 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 LOVY 11 2 1 CHECRING ENGINE SPEED sy FE Fri If the engine speed is too high or too low adjust it ti GC d i to the rated r p m 4 ii a How to adjust engine r p m E Loosen the lock nut on the adjusting screw mM Turn the adjusting screw clockwise to de crease engine spe
16. continuity between each terminal by using a Circuit tester as shown in Fig 9 10 The rectifier is normal when condtinuity is as follows m Checking table for analogue circuit tester Apply black Oneedle of the circuit tester Orange Brown White Apply red needle a of the circuit tester Brown White No continuity No continuity No continuity Table 9 4 1 m Checking table for digital circuit tester Apply red needle of the circuit tester Digital circuit tester Brown White No continuity No continuity Brown White No continuity No continuity No continuity lea 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 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 Some analogue testers like Simpson brand operate as same as digital testers 10 DISASSEMBLY AND 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 faci
17. is defective Replace with a new one SOLENOID Fig 11 17 12 VVIRING DIAGRAM e RGV2200 2600 50Hz 110V 60Hz 110V 60Hz 120V TYPE b ss ur mu STOP SW HOT S Green Yellow SS IS Black i Green Yellow CONT BOX SRE d E SP HZH Ka ENGINE GENERATOR Yellow Tr AS 0 75mm 1 25mm e RGV2200 2600 50Hz 220V 240V 60Hz 220V TYPE x NO Em o n C gt OM uo 8 O O ne Lou M h z v l s em X O D 7 O o Vo T ile gt ro 3 A BI IM M A I SO ta iO DI D 4 bi ES m Li OD Z ch Ee wy ol jel o C I de Brown White Yellow Yellow rel a aa A 0 75mm 1 25mm e RGV2200 2600 50Hz 60Hz 110V 220V TYPE ENGINE CONT BOX e ee a I I ISP 1 1 os STOP SN qu Black gt OH ES DI cz Green Green Yellow Yellow Yellow Yellow 5 Brown BE zgj P Q O d range ii Lis Brown _ Brown White 0 75mm 1 25mm tt sr ds il e RGV2200 2600 U K 50Hz 110V 220V BS RECEPTACLEJ ENGINE CONT BOX ISP lol 1 os EE ey Ser a loan lt h LD gt A ET W ai Green GENERATOR a TIDY ye Yellow IL Yellow 70 e RGV2600 U S A 60Hz 120V NEMA RECEPTACLE
18. remove the rear cover by the following Instructions 3 Hit on the boss and legs of rear cover with a plastic hammer to loosen Fig 10 12 Do not give a strong hit Box wrench on the boss or legs Plastic hammer Fig 10 13 Step Part to remove Description Remarks 6 Startor 1 Remove the four bolts which fasten the i 10 mm socket stator to the rear cover i s wrench See Fig 10 14 Fig 10 14 2 Put a piece of lumber on the focs in upright position See Fig 10 15 i 3 Hold the rear cover and stator upside down with both hands 4 Down the rear cover and stator over a lumber lightiv hitting the bottom of rear cover to the top end of lumber to pui out the stator See FIg 10 16 NOTES I Apply fingers to stator coil to keep the stator from dropping on the floor 2 Gently hit the bottom of rear cov er to the top end of lumber several times until the stator comes out loose Fig 10 15 Fig 10 16 Step Part to remove Desen geg te 6 Stator 5 Take apar the support r ng and stator from rear cover 1 SUPPORT RING STATOR REAR COVER Fig 10 17 Rotor 1 Take off the through bolt Box wrench Apply a box wrench on the head of Plastic hammer through bolt Hit the wrench handle with I a hammer counter clockwise to loosen i I Fig 10 18 2 Put the engine on the working table recol star
19. rr e RGV6000 U K 50Hz 110V 220V BS RECEPTACLEJ ENGINE ____CONT BOX IN Y ii l ol l SP grace STOP SW Ea a HO Green Yellow d es Green fe GENERATOR E HA E Black sr 0900 FC Yellow tar Es i vellow e RGV6000 U S A 60Hz 120V 240V NEMA RECEPTACLE with IDLE CONTROL ENGINE CONT BOX PS T BE M blue A en Bc E NFB m Black m e TYPE VITH ELECTRIC STARTER Optional Equipment 15mm CONT BOX ENGINE t ET Green Yellow White 2 00mm a e es a 0 75m b Yy 2 1 25mm Key switch e TYPE VITH ELECTRIC STARTER AND IDLE CONTROL Optional Equipment 15mm CONTROL BOX ENGINE Green Yellow DSANN MAJ e 00mm 3 50mm SAFE O Sh ii 4 san Key switch e TYPE VITHIDLE CONTROL Optional Equipment ENGINE CONT BOX Yellon blue AE cd lu Li A 0 75mm 2 00mm 1 25m 3 50mm symbols Pam TT AC Winding Field VVinding o STOP Su O Oil Sensor Control Unit SP Spark Plug E ET Earth Terminal Ground Terminal KEY SW BAT i Battery C M CC DC FC C L T C NF VV RE AC Output Receptacle CONT BOX Control Box Front Panel FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS DIV Subaru Bldg
20. 120V 240V RGV2200 RGV2600 RGV4000 RGV6000 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 OPTIONAL EQUIPMENT 11 5 1 ENGINE SPEED IS NOT INCREASED VVHEN A LOAD IS APPLIED 1 Inspect the solenoid bracket Check the bend angle of solenoid bracket If the bracket is distorted correct the angle with proper tool 2 Check the vvattage of load appied to the generator If the generator is loaded over the rated wattage the engine speed can not be increased Most induction loads such as electric motor or electric tools or vvelding machine require three to five times large wattage of their ratings at starting This starting vvattage must not exceed the rated output of the generator 3 Check the slow set r p m p yA OP LL The normal idling speed by the IDLE ADJUSTING SCREW AAA CONTROL is as follows RGV2200 2600 1900 2100 r p m RGV4000 6000 2000 2200 r p m The above speed setting is for cold engine condition If the engine speed is out of adjusting range of the adjusting screw move the solenoid backward Fig 11 13 4 Check the vviring through ZCT on the IDLE CONTROL UNIT IDLE CONTROL UNIT A Single Voltage Type Make sure that an output wire from main coil is passing through
21. LER BRACKET r RGV6000 only Step Part to remove Description 4 Pipe Frame 1 For RGV6000 Remove 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 8 3 Using a chain block sling up the engine Remove the air cleaner and alternator and dismount from the cover for easier frame dismounting Fig 10 8 4 Remove the mount rubbers from the 12 mm spanner or frame box wrench i Loosen the nuts on the bottom side of the frame See Fig 10 9 Kr ci LEZ MOUNT RUBBER EARTH CABLE I amp Fig 10 9 CIT Gezen Sep EI TT 1 Remove the end cover See Fig 10 10 5 Rear Cover 2 Take off the rear cover l Remove the four bolts which fasten the rear cover to the front cover 6 boli 4 pcs 2 Use a special tool REAR COVER PULLER to remove the rear cover a Insert the two screws of the special tool into the thread holes of the rear cover b Apply the center bolt of the special tool on the head of the through bolt l c Tighten the center bolt to pull out the rear cover La Fig 10 10 10 mm spanner or box wrench 10 mm spanner or box wrench Insert the two screws sufficiently and evenly or the thread hole may be damaged at removing In the case that REAR COVER PULLER is unavallable
22. Q 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 1 MQ the insulation is faulty and may cause electric leakage 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 battery check the cables for short circuit or connection in reverse polarity before resetting it on NOTE If the DC output is used to charge a large capacity battery or an over dis charged battery an excessive current may flow causing 11 4 3 CHECK THE VVIRING Fig 11 10 Check all the wires to be connected correctly a 11 4 4 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode rectifier with a circuit tester Refer to Section 9 7 DIODE RECTIFIER forthe checking procedure ig 11 11 11 4 5 CHECK THE DC COIL Fig Check the resistance between two brown leads from stator with a Circuit tester MODEL SPECIFICATION RESISTANCE 110V 220V 240V 110V 220V 0 369 120V 220V 110V 220V 120V 240V 110V 220V 240V 110V 220V 120V 220V 110V 220V 120V 240V 50Hz 1 110V 220V 240V 110V 220V 60Hz 120V 220V 110V 220V 120V 240V 120V 220V 110V 220V
23. ce No mm 9 100 m 30 0 18 1 27 16 12 50 0 18 1 486 37 10 26 Voltage drop 3 5 12 10 23 45 0 32 O 0517 1 5Vi 25V av 5V 6 5vi7 5v 7010 32 iv av 2 5V 3 5V 4V 5V Table 7 2 Voltage drop indicates as V a XRXIX R means resistance 100 m on the above table I means electric current through the wire E means the length of the vvire m The length of wire indicates round length it means twice the length from generator to electrical tools 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 follovving features 1 Functions of voltmeter frequency meter meggertester 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 time to change batteries Fig 8 1 4 Tester and accessories are installed in a handy sturdy case for easy carring e SPECIFICATIONS Resistance 0 1 1 999 Q 10 100 LF Circuit Protector Fuse Povver Source 2 X 6F44P 006P Dry Cell Battery Test leads with needie probes 1 set Condenser Capacity Measuring Range Accessories Test leads with jack plugs
24. 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 SURGE ABSORBER Fig 5 5B 5 2 4 circuit DC CIRCUIT BREAKER 1 The 10 ampere DC circuit breaker mounted on the control panel protecis vvhole DC circuit from getting damage by overload or short 5 2 5 NO FUSE BREAKER The no fuse breaker protects the generator from getting damage by overloading or short circuit in the Fig 5 6 appliance Table 5 1 shows the capacity of no fuse breaker by each spec and their object of protection 60Hz 110V 120V RGV2200 SPECIFICATION 50Hz 110V 50Hz 220V 240V 60Hz 220V 50Hz 110V 220V _ NO FUSE BREAKER 12A 5A 6 5A BA 6 5A 2 Pole 2 Element i 60Hz 120V 240V 8A 2 Pole 2 Element 8 50Hz 110V 18A 60Hz 110V 120V 50Hz 220V RGV2600 RGV4000 RGV6000 60Hz 220V 60Hz 240V 50Hz 110V 220V 60Hz 110V 220V 120V 240V 50Hz 110V 60Hz 110V 120V 50Hz 220V 60Hz 220V 50HZ 240V 50Hz 110V 220V 60Hz 110V 220V 120V 240V 50Hz 110V 60Hz 110V 120V 50Hz 220V 60Hz 220V 50Hz 240V 50Hz 110V 220V 60Hz 110V 220V 60Hz 120V 240V 8 20A 9 10A BA 9A 2 Pole 2 Element 10A 2 Pole 2 Element 27A 30A 14A 15A 12A 14A 2 Pole 2 Element 15A 2 Pole 2 Element 40A 30A 20A 18A 20A 2 Pole 2 Element
25. e coil ends at the terminals resistance may be measured only when tester probes touche the terminals in one combi nation of polarity Therefore if no re sistance 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 erroneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when meas urement is performed at embient tem peratures different from 20 C 68 EL 9 6 CONDENSER m Usea Dr Robin in capacitance meter mode to check the capacity of condensers See Fig 9 6 ke cf if S RGV2200 RGV2600 RGV4000 RGV6000 Fig 9 6 NOTE Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance or the accurate reading cannot be obtained 39 m NORMAL CAPACITY OF CONDENSER MODEL soten RGV2600 Resistance 17uF E 204Fx2 284Fx2 M l 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 Table 9 3 9 7 DIODE RECTIFIER DIODE RECTIFIER Brown Brown White Brown White CIRCUIT TESTER Fig 9 9 Fig 9 10 Circuit inside of the diode rectifiers is as shown in Fig 9 9 Check
26. ed The contactless type is recom mended The PET 2100E engine tachometer is available from your Robin distributors Please inquire by the part number PET 2100E Fig 8 5 Fig 8 7 8 2 AC OUTPUT MEASURING SWITCH AN AT o LOAD a OO Q EF EN ge TO AC RECEPTACLE o M J Q 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 Voltage range 99 121V _ 108 132V 198 242V 216 264V Table 8 2 8 3 MEASURING INSULATION RESISTANCE Use a Dr Robin generator tester in megger tester mode or use a megger tester to check the insulation resistance Connect a megger tester to one of receptacle output terminals and the ground terminal then measure the insulation resistance An insulation resistance of 1 megohm or more is normal The original insulation resistance at the time of shipment from the factory is 10 megohm or more If it is less than 1 megohm disassemble the generator and measure the insulation resistance of the stator rotor and control panel individually e 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
27. ed or counter clockwise to increase engine speed Normal engine speed at no load is 3100 3150 r p m for 50Hz type 3700 3750 r p m for 60Hz type RE de I 11 2 2 CHECKING CONDENSER E SA A a Check condenser referring to Step 11 1 1 3 NA Ya condenser referring to Step 11 ai PRES ON Sousa 11 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 11 3 AC VOLTAGE IS NORMAL AT NO LOAD BUT THE LOAD CANNOT BE APPLIED 11 3 1 CHECR THE ENGINE SPEED If the engine speed is low adjust it to the ratedr 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 over loaded 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 OVER HEATED If the cooling air inlet and or cooling air outlet 1s clogged with dirt grass chaff or other debris remove it AIR INLET GENERATOR AIR OUTLET GENERATOR Fig 11 8 11 3 5 CHECK THE INSULATION OF THE GENERATOR es Stop the engine Measure the insulation resistance am betvveen the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1 M
28. em 2 9 4 3 ftelbs Fig 10 33 10 4 7 MUFFLER and MUFFLER COVER 1 For RGV6000 only Attach the muffler bracket to the rear cover Tighten the bolts temporarily 2 Attach the muffler cover 1 and the muffler cover 2 to the muffler M6 x 10mm bolt and washer Ass y 8 pcs Tightening torque 80 100 kg cm 7 9 9 8 Nem 5 8 7 2 ftelbs 3 Put the muffler gasket to the engine 4 Attach the muffler with muffler cover to the engine and the rear cover D Tighten the two nuts fou the muffler first Use the spring washers for RGV4000 and RGV6000 MUFFLER COVER 8mm stainless nuti 2 pcs 8mm spring vash n testise 2 pes for RGV4000 and RGV6000 only Tightening torque 220 280 kg cm 21 6 27 4 Nem 15 8 20 2 ftelbs Tighten the bolts to fix the muffler to the rear cover M8 x 20mm bolt and washer Ass y gt 2 pes for RGV2200 2600 4000 Tightening torque 190 250 kg cm 18 6 24 5 Nem 13 7 18 0 ftelbs 8 For RGV6000 only Tighten the two bolts to fix the muffler bracket to the rear cover and then the two bolts for the muffler to the muffler bracket M8 x 20mm bolt and washer Ass y ooo 4 pcs for RG V6000 only E Tightening torque L CAT o MUFFLER BRACKET 190 250 kg cm for RGV6000 onty 18 6 24 5 Nem 13 7 18 0 ftelbs Fig 10 35 5 For RGV2200 RGV2600 and RGV4000 only Attach the rear plate to the frame M6 X10mm bolt een 2 pcs Tightening t
29. essel to receive fuel under the Wipe off spilt fuel _ Strainer and open the fuel cock to thoroughly discharge fuel See Fig 10 4 i 4 Attach the strainer cup to the strainer Do not lose the filter body w screen 2 Disconnect fuel hose from the strainer Loosen the hose clamp on the top of the strainer and pull out the fuel hose from the strainer See Fig 10 5 3 Take off the four nuts and remove the Tn 10 mm spanner or fuel tank See Fig 10 6 o box wrench j 1 3 Muffler and 1 Remove the rear plate from the frame The rear plate is welded 10 mm spanner or Muffler Except for RGV6000 to the frame of the box wrench Cover 6X12mmflangeboli 2 pcs RGV6000 2 Remove the two bolts which fix the muffler to the alternator Loosen the two nuts on the muffler flange and remove the muffler from the engine 12 mm spanner or box wrench 8X20mm bolt and washer ass y 2 pcs 8mm stainless nut 2 pcs 8mm spring washer for RGV4000 and RGV6000 2 pcs 10 mm spanner or box wrench 3 Remove the muffler cover 1 and the muffler cover 2 from the muffler 6X 10mm bolt and washer ass y 8 pcs See Fig 10 8 4 For RGV6000 only 12 mm spanner or Remove the muffler bracket from the rear cover box wrench 8X20mm bolt and washer ass v 2 pcs Muffler gasket a YA e 1 pc l LA ul fo UFF
30. f continuous Opera ni n which is sufficient for a half day or one day work without refueling RUGGED TUBULAR FRAME Full cradle type rugged tubuler frame protects the generator all around COMPACT AND LIGHT WEIGHT Newly developed brushless alternator enabled the RGV generators to be very compact in size and light in weight MINIMAL MAINTENANCE e A brushless alternator release the operator from periodical brush maintenance e A trouble free condenser type voltage regulator e 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 Rro OHV engine and virtually maintenance free brushless alternator ensure greater durability with e A brushless alternator with a condenser voltage regulator e Full rubber mount in a sturdy tubular frame e A forged steel crankshaft supported by two main ball bearings e A pointless electronic ignition system e A cast iron cylinder liner e A forged aluminum connecting rod 4 GENERAL DESCRIPTION OF THE GENERATOR 4 1 EXTERNAL VIEW of GENERATOR VOLTMETER FUEL LEVEL GAUGE TANK CAP STOP BUTTON CHOKE KNOB AC RECEPTACLE SS Pd AIR CLEANER DE j DC TERMINAL RECOIL STARTER i DC CIRCUIT BREAKER AC CIRCUIT BREAKER OIL SENSOR SPARK PLUG MUFFLER OIL DRAIN PLUG OIL LEVEL GAUGE 4 2 CONTROL PANEL e RGV2200 RGV2600 50Hz 60Hz 110V
31. it diagrams 2 Install condensers and diode rectifier into the front panel 3 Connect the vvires of control panel components and front panel 4 Attach the control panel to the front panel M4 screw ewo 6 pcs RGV2200 RGV2600 RGV4000 M4 screw sete 7 pcs RGV6000 Tightening torgue 12 15 kg cm 12 15 Nem 8 7 10 9 ftelbs 11 TROUBLESHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING CONDENSER 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 y eroi rh gt NN i SIS ENE SE ti MA i DS i E E P T li j a SE 3 i 13 RGV2200 RGV2600 RGV4000 RGV6000 Fig 11 1 m NORMAL CAPACITY OF CONDENSER MODEL RGV2200 RGV2600 RGV4000 i RGV6000 CAPACITY 17uF 204Fx2 284Fx2 Table 11 1 E 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 n Fia m Remove control panel and disconnect stator wires at the connectors M Measure the resistance between terminals on stator leads See Fig 11 2 c a A a s 8 SANN AL A 4 i i P n Refer to Table
32. ity between each of the two when the circuit breaker is on while there is no continuity when the circuit breaker is off 9 3 CIRCUIT BREAKER LE mes DE CIRCUIT BREAKER q 2227 1mkm D I nh gr 9 4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a Dr Robin or a circuit tester refering to the following table COUPLER Fig 9 4 RXI 10 a Specification Hz Voltage White Red Black Blue Yellow Yellow aT gg ov 220V 110V 220V RGV2200 n 220V 110V 220V 1 24 1 24 110V 220V 110V 220V 220V 110V 220V 120V 120V 240V 110V 220V 110V 220V RGV4000 120V 120V 240V 110V 220V 110V 220V 0 33 i 0 33 E 079 240V 0 39 RGV6000 pe ae i 120V 120V 240V E Table 9 1 NOTE If the circuit tester 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 resistance among coil windings or when measurement is performed at ambient temperatures different from 20 C 68 F 9 5 ROTOR ASSEMBLY 1 Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals RX1Q 1096 MODEL RGV2200 RGV2600 RGV4000 RGV6000 Table 9 2 NOTE 1 Because a diode is soldered to th
33. litate 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 10 2 SPECIAL TOOLS for DISASSEMBLY and ASSEMBLY Part Number 388 95001 07 Part Name REAR COVER PULLER REAR COVER PULLER 10 3 DISASSEMBLY PROCEDURES I gt Front Panel 1 Take off the four bolts and remove the 10 mm spanner or ne front panel from the frame gt Di box wrench ne See Fig 10 1 i o 2 Disconnect the connectors on the wiring ee Ro between the front panel and the engine si A Sul See Fig 10 2 SM Fig 10 1 i 3 Take off the bushing from the bottom of i the front panel i See Fig 10 2 4 Disconnect the connectors on the wiring Press the upper end of from the front panel to the alternator _ the bushing and pull See Fig 10 3 i d UL a Mn O ig 10 2 a A dels ria Fig 10 3 Step Part to remove Description Remarks 2 Fuel Tank 1 Discharge fuel from the tank Use utmost care about Ar 1 Shut the fuel strainer fire hazard 2 Remove the strainer cup EE i 3 Put a v
34. lock Fig 5 7 NOTE If your generator has receptacles peculiar to your country Table 5 2 does not apply NOTE The generator for U S A market is equipped vvith NEMA standard receptacles shovyn in table 5 3 Use the proper plug for connecting appliance to the generator GFCI Ground Fault Circuit interrupter Receptacle duplex NEMA L14 20P NEMA L14 20R 125V 250V 20A Locking Receptacle NEMA Locking Receptacle Table 5 3 5 3 DESCRIPTION of GENERATOR OPERATION PERMANENT MAGNET FOR INITIAL EXCITATION LATOR MAIN COIL FIELD COIL RECEPTACLE APPLIANCE SURGE ABSORBER DIODE CONDENSER COIL CONDENSER Fig 5 8 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 inthe main coil and condenser coil wound on the stator 2 As one or two condensers are 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 yara force at the rotor s magnetic pole is intensified When this magnetic 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 voltages at the main coil and condenser coil keep ri
35. m 8 7 10 1 ft lbs 10 4 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 115 135 kgecm Fig 10 24 RGV 2200 2600 11 3 13 2 Nem 8 7 10 8 ftelbs 230 250 kg cm 22 5 24 5 Nem RGV 4000 6000 16 6 19 5 ftelbs 10 4 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 Tighten the four bolts tentatively to check if the grooves and thread holes are aligned correctly See Fig 10 25 NOTE Be careful not to give cuts to vvires vvhen pulling them out from the rear cover 2 Remove the four bolts Tap on the support ring evenly using an aluminum bar and a hammer to press into the rear cover See Fig 10 26 4 Join the stator to rear cover vvith four bolts ti kil washers and spring washers See Fig 10 25 M6 bolt det EE 4 pcs M6 washer aen ES pes M6 spring washer cce 4 pes a Tightening torque 80 100 kgecm 7 8 9 8 Nem 5 8 7 2 ftelbs K NOTE Tighten four bolts eveniy taking several FAT steps e The dimensions of the stator bolts are shown in Table 10 1 RGV2200
36. me 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 M6 X12 mm flange bolt 4 pcs Tightening torque 40 60 kg cm 3 9 5 9 Nem 2 9 4 3 ftelbs Fig 10 37 10 5 CHECKING DISASSEMBLY and REASSEMBLY of the FRONT PANEL 10 5 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 5 2 DISASSEMBLY 1 Remove the control panel from the front panel M4 Screw cre 6 pcs RGV2200 RGV2600 RGV4000 MA screw evessisekensee 7 pcs RGV 6000 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 paris if necessary 10 5 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 identification 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 circu
37. orque 40 60 kg cm 3 9 5 9 Nem 2 9 4 3 ftelbs 10 4 8 FUEL TANK 1 For RGV2200 RGV2600 and RGV4000 only Attach the fuel strainer to the bottom of the fuel tank Screw in the fuel strainer all the way and return one to two turns and then lock it with the lock nut For RGV6000 only Attach the fuel strainer to the frame 50 70 kg cm 4 9 6 9 Nem 3 6 5 0 ft lbs 2 Mount the fuel tank on the frame with rubber washers between the tank flange and the frame M6 X20mm bolt black e 4 pcs Rubber washer eene Ka 4 pcs NOTE For easy tank assembly glue the rubber FUEL GAUGE washers over the mounting holes of the frame 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 RGV6000 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 36 FUEL TANK CAP FUEL FILTER 2 H er HOSE CLAMP de RUBBER PIPE R HOSE CLAMP 10 4 9 FRONT PANEL Mount the front panel assembly to the frame Refer to Section 10 5 for disassembly checking and reassembly procedures of the front panel 1 Connect the vvires from the 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 sa
38. ower but Rec 1 and Rec 2 for the lower voltage can output only up to half the rated power each Table 5 4 isa summary of the above explanation Select the proper output voltage by full power switch in accordance with the appliance to be used 5 3 4 VOLTAGE CHANGEOVER SVVITCH The generator of 50Hz 110V 220V dual voltage type for U K is provided with voltage changeover switch instead of full power switch The output voltage is selected from 110V and 220V by turning this switch and both voltages cannot be taken out simultaneously VOLTAGE CHANGEOVER 110V SWITCH RECEPTACLE MAIN COIL 220V RECEPTACLE MAIN COIL Fig 5 12 6 k 7 SAFETY PRECAUTIONS se 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 opern 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 gunpovvder 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 vvell ventilated area Otherwise the engine may overheat and also the poisonous carbon monoxide contained in the exhaust gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facilities during use
39. ppliance indicates the amount of work that can be done by it The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance The electrical appliances generally have a label showing their rated voltage frequency and power consumption input wattage The power consumption of an electrical appliance is the power necessary for using it When using a generator for operating an electrical appliance the power factor and starting wattage must be taken into consideration In order to determine the right size generator it is necessary to add the total vvattage 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 mercury lamps 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 Example A 400W mercury lamp requires 600W to 700W power source to be turned on A rated 3000W generator can power four or five 400W mercury lamps NOTE Ifa power factor correction capacitor is not applied to the mercury lamp or fluorescent lamp the more power shall be required to dri
40. rger capacity 5 Appliances vvithout any indication as to povver consumption Some appliances have no indication as to power consumption but instead the work load output is indicated In such a case povver consumption is to be vvorked out according to the numerical formula mentioned below Output of electrical appliance Povver con tion Efficiency OE SIERO Efficiencies of some electrical appliances are as follows Single phase motor lt lt 0 6 0 75 The smaller the motor the Three phase motor teste tet 0 65 0 9 lower the efficiency Flugrcscent lamp ee moman kon mona ma a 0 7 0 8 Example 1 A 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 7 57W As explained in Item 2 multiply this power consumption value of 57W by 1 2 2 and you vvill get the figure of the necessary capacity of a generator In other words a generator with a rated output of 1000Wcapacity can light nine to fourteen 40W fluorescent lamps Example 2 Generally speaking a 400W motor means that its work load is 400W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570W When this motor is used for a motor driven tool the capacity of the generator should be multiple of 570W by 1 2 to 3 as explained in the item 3 570 W X 1 2 3 684 W 1710 W RGV2200 RGV2600 RGV4000 RGV6000 Frequency Incandesent lamp heater etc
41. sing 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 5 flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 2700 to 2800 rpm 50Hz type or 3000 to 3300 rpm 60Hz type the current in the condenser coil and field coil increases rapidly This acts to stabilize the output voltage of each coils H 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 2 in the condenser coil When current increases the density of magnetic flux across the rotor core rises AS a result the current nane in the field coil increases and the generator output voltage is prevented from decreasing 5 3 3 FULL POWER SVVITCH 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 240V I tor 110 220V gt cai a a m l a for 110V 420v 240V or 220V or 110V ps Lo A
42. ter side down 7 Rotor 3 Usea boltandoilasa 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 19 2 Prepare a bolt with the following thread size RGV2200 2600 MIOXPI 25 RGVA4000 6000 M12XP1 50 3 Apply a few turns of seal tape around the tip of the bolt See Fig 10 20 SEAL TAPE Fig 10 19 Fig 10 20 i 4 Screw the bolt into the thread of the Do not stick out your rotor 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 mi i ii eg E 4 Wi ipe off oil thoroughly from rotor shaft and engine PIU shaft E T 7 i RE re Wer Fig 10 21 Step Part to remove Description Pomare mag 8 Front Cover 1 Remove the front cover 12 mm Socket Loosen the four bolts and remove the vvrench front cover 80 bolt Fig 10 22 10 4 ASSEMBLY PROCEDURES 10 4 1 FRONT COVER Attach the front cover to the engine main bearing cover Match the faucet joint and tighten the bolts M8 X 18mm bolt 4 pcs M8 spring washer 4 pcs Tightening torque 120 140 kg cm 11 8 13 7 Ne
43. the ZCT on the IDLE CONTROL UNIT B 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 Fig 11 14 5 Checking the IDLE CONTROL UNIT 7 7 Check the resistance between six leads of M IDLE CONTROL UNIT with circuit tester IDEE T UNIT Terminal number of the IDLE CONTROL UNIT Circuit tester i with battery power source 1 5V Apply red needle of the circuit tester Tester measuring range 1000 k Tabie 11 4 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 11 5 2 ENGINE SPEED IS NOT REDUCED VVHEN LOAD IS OFF 1 Check the distortion of the SOLENOID BRACKET as shown in step 11 5 1 1 2 Check the vriring of SOLENOID Check two leads from SOLENO D 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 rom SOLENOID NORMAL RESISTANCE If the resistance is larger or smaller than this range SOLENOID
44. the frame M8 flange nut vt 4 pcs C 120 140 kg cm 11 8 13 7 Nem 1 Ni 8 7 10 8 ft lbs IN Fig 10 31 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 appearance their characteristics are different 2 Attach the Smm 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 assembly into the frame from the side ofit Tighten the nuts over the mount rubber bolts to fix M8 US 4 pcs Tightening torque 120 140 kg cm 11 8 13 7 Nem 8 7 10 1 ftelbs NOTE Remove the air cleaner cover for easier installation NOTE When tightening the nuts slightly lift the engine and alternator assembly so that the vveight is not applied to the mount rubbers 4 Fasten the other earth cable with 5 mm terminal i JE Po to the unpainted bolt hole on the frame Ue I T i See Fig 10 32 K A Sk n EE ni lang E EARTH CABLE Fig 10 32 S Attach the rear plate frame TJ For RGV2200 2600 4000 only REAR PLATE M6 X 10 mm bolt stese 2 pcs Attach fuel tank mount rubbers to rear plates The nuts for mount rubbers are welded to rear plates Tightening torque 40 60 kg cm 3 9 5 9 N
45. ve those lamps A rated 3000W generator can drive one or two 400W mercury lamps without power factor correction capacitors NOTE2 Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Theretore if the fluorescent lamp has no special indication as to the power consumption efficiency should be taken into account as explained in item 5 on the following page 3 Motor driven tools and light electrical appliances Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times lager than their running vvattage Example A rated 250W electric drill requires a 400W generator to start it 4 Initially loaded motor driven appliances such as water pumps compressors etc These appliances require large starting vvattage which is 3 to 5 times of running wattage Example A rated 900YY compressor reguires a 4500W generator to drive it NOTE1 Motor driven appliances require the aforementioned generator output only at the starting Once their motors are started the appliances consume about 1 2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances NOTE2 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 la
46. vs H yi Li ne 3 Y yw g SEN Y RARE Es Mw FU mn NER G GUN KT A N N DUSTRIES LTD E til sd Mar ASOLINE FUJI tun EE ER E der ish E wa R l D d WI V Wf Q L T A D Lu gt D n CONTENTS Section Title NOTE As for the servicing information on engine portion please refer to the EH17 EH25 and EH34 engine service manual ALTERNATOR Dry Weight bisi _ Type F requency Maximum Output _Rated Output AC Rated Voltage Current Power Factor DC DC Output Voltage Regulator o Voltage Regulation Model Displacement i io ve O Rated Output Fuel Tank Capacity Fuel Consumption Ratio at Rated Output Oil Capacity Starting System Dimensions L XVV XH 45 kg 99 lbs a RGV2200 Automobile Gasoline 12 liters 3 17 U S gal 50Hz 11 4 liters hour 60Hz 9 4 liters hour 0 65 iters o _ Recoil Starter Momo onm sa mesi ir em 546 X 394 X 480 mm Brushless Self 2l Exciting 2 Pole Single Phase RGV2600 a Cu A mon kn dna 60Hz SOU 60Hz 2 200W 2 300W 2600W 1800W _ 2000W 2200W 110V mov 18 24 220V 16 7A 240V 91A 110v 220v 110V 220V 15 5A 7 7A 182A 9 1A 120V 240V 12 5A 6 3A mwen 120V 240V 16 7A 8 3A Ms bem E SA AB SA
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