RGV12100 RGV13100T - Subaru Industrial Power
Contents
1. EARTH GROUND CONNECTOR AC RECEPTACLE TERMINAL FOR REMOTE CONTROL RGV13100T OIL PURESSURE VOLTMETER WARNING LAMP NO FUSE BREAKER PILOT LAMP HOUR METER KEY SWITCH AC RECEPTACLE EARTH GROUND AC THREE PHASE TERMINAL and SINGLE PHASE RECEPTACLE SERIAL NUMBER Serial number is stamped on the label stuck on the end cover NOTE Always specify serial number when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service RGV13100T RGV12100 SERIAL NUMBER stamped label SERIAL NUMBER stamped label 4 CONSTRUCTION AND FUNCTION 4 1 CONSTRUCTION BRUSH HOLDER RGV13100T only STATOR COMPLETE STATOR BOLT REAR COVER ROTOR COMPLETE FRONT COVER MOUNT RUBBER BALL BEARING TROUGH BOLT SLIP RING 4 2 FUNCTION 4 2 1 STATOR The stator consists of a laminated silicon steel sheet core a main coil which is wound in the core slots 4 2 2 rotor consists 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 RGV2. RGV12100 RGV13100T 8 4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a circuit tester referring to the following specification table NOTE the circuit tester is not sufficiently accu rate 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 measure ment is performed at ambient tempera tures different from 20 C 68 Hz Voltage White Red White Black Blue Black Red Light green Black White RGV12100 60 120 240 0 110 0 110 0 370 37 RGV13100T 60 120 208 0 230 0 230 0 230 28 8 5 ASSEMBLY 1 Field Remove the brush holder and measure resistance between the slip rings RGV12100 4110 RGV13100T 69 60 NOTE the circuit tester sufficiently rate may show the values given may give erroneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measure ment is performed at ambient tempera tures different from from 20 C 68 F 2 Cleaning Slip rings The slip ring surfaces must be uniformly SLIP RING bright Slip rings showing black spots excessive wear or uneven we
3. e CURRENT TRANSFORMER RGV13100T Measure the insulation resistance between each terminal and the core If itis less than 1 replace the current transformer Any part where the insulation resistance is less than 1 has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 26 8 CHECKING FUNCTIONAL MEMBERS 8 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 PILOT LAMP too large 8 2 AC RECEPTACLES Using 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 continu ity 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 recep tacles are also normal 27 8 3 SWITCH NO FUSE BREAKER Check continuity between each of 2 terminals at the back side of AC switch no fuse breaker while it is mounted on the control panel Normally there is continuity between each of the 2 terminals when the breaker is ON while no continuity when the breaker is OFF
4. tester Light green 0 350 125 14 8 9 CURRENT TRANSFORMER RGV13100T only Disconnect the connectors and couplers of current transformer Check the inter terminal resistance of current transformer with a circuit tester RGV13100T 2000 2000 0 0090 If current transformer is found to faulty replace with new 8 10 ECU ELECTRONIC CONTROL UNIT Check the resistance between 13 terminals of ECU with circuit tester oo 9 Q 9 9 9 0 9 Terminal number of the ELECTRONIC CON UNIT 31 Tester ONE 5 Co eme iowa e o o Tester 0 pom ER ee E RIIE GR PH a Erpa 8 11 IDLE CONTROL UNIT RGV12100 only Check the
5. RevisiT 3100T 2 pole Single phase 2 pole 3 Fuel tank capacity 44 liters Rated continuous 3 4 Rated Approx 9 0 hours Approx 9 7 hours operation per a tankful of fuel Approx 8 2 hours Approx 8 9 hours Rated dB 7m 77 0 dB 77 0 dB lt 826 mm 611 mm 752 mm Dimensions 771 845 mm Dry weight 141 kg 149 kg 143 kg 151 kg shows dimensions with castors 2 shows dry weight with castors installed 2 PERFORMANCE CURVES eRGV12100 eRGV13100T Hz 63 Hz 62 61 a E E V 250 125 240 240V 120V 120 230 115 220 110 Load Rated Hz 63 62 61 60 230 220 210 200 Load Rated 3 GENERAL DESCRIPTION GENERATOR FUEL TANK TANK CAP AIR CLEANER COOLING AIR INLET PORT FUEL COCK OIL FILTER SPARK PLUG CAP CHOKE KNOB RGV13100T only FOR REMOTE CONTROL RGV12100 only MUFFLER SPARK PLUG CAP END COVER RGV13100T only OIL GAUGE OIL DRAIN PLUG ELECTRIC STARTER CONTROL PANEL RGV12100 OIL PURESSURE VOLTMETER WARNING LAMP NO FUSE BREAKER PILOT LAMP HOUR METER a ME 2 KEY SWITCH 322 T CP C D SWITCH 6 6
6. Fig 4 2 RATED VOLTAGE lt WITH AVR 17 4 3 3 CURRENT TRANSFORMER CONTROL RGV13100T When the engine starts a permanent magnet implanted in the rotor rotates creating voltage in the main coil MC When a load makes contact with the coil the load current passing through the primary coil of current transformer causes a magnetizing current to flow in ratio to the load current flowing through the current transformer primary coil This magnetizing current passing through a diode to field coil creates a strong magnetic field in the rotor which falls with the amount of the load increasing the voltage GENERATOR CONTROLBOX output receptacle 120V Single phase 208V Three phase REC5 7 quee trm Winding 1 4 bd i T transformer AC output receptacle 120V REC2 Brush Brn Feld Winding Brush L1 Key switch M Earth Ground terminal Grn Y AC output receptacle 120V REC1 4 3 4 THE ADVANTAGES OF CURRENT TRANSFORMER CONTROL RGV13100T With AVR control control is effected according to variations in output voltage When an inductive load is applied a large starting current is required current variations are greater than voltage variation precise control becomes difficult
7. feed current the generator field 3 See Fig 4 1 The rotor is turned an electromagnet by that __ __ current and rotates so that voltage are gener ENGINE MAGNETO ated in the stator coils main coil and sub coil The voltage generated in the sub coils Fig 4 1 is operated by the AVR to feed a current to increase the field coil current See Fig 4 2 As a result the rotor magnetism increases This operation is repeated to generate the rated voltage at 50 Hz or 60 Hz in the main coil and DC coil 4 3 2 VOLTAGE REGULATING MECHANISM RGV12100 Y 8 d Connect a load to the AC output terminal and increase current Output voltage varies as shown in Fig 4 3 depending on whether an automatic voltage regulator is used or not The operation of the AVR is explained below When an AC output is taken the engine is loaded and its rpm falls Also the AC voltage fails due to the voltage drop caused by the internal resistance of the coils The AVR WITHOUT AVR detects this voltage drop and its built in SCR automatically increase the current flows to the field coil As a result the rotor magnetism increase the voltage fallen by the load cur rent is raised and the output voltage is kept constant If the AC output is reduced the SCR operates in the opposite way to similarly keep the output voltage constant AVR
8. TO AC RECEPTACLE Use a circuit above 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 speci fied in the following table at the rated amperage and rated rpm 24 Rated voltage 120 V 208 V 240 V RGV12100 112V 128V peg 224V 256V 7 3 MEASURING INSULATION RESISTANCE 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 resis tance An insulation resistance 1 or more is normal If it is less than 1MQ disassemble the gen erator and measure the insulation resistance of the stator rotor and control panel individu ally Voltage range e STATOR 1 Measure the insulation resistance between BLUE RGV12100 GREEN RGV13100T lead and the core 2 Measure the insulation resistance between WHITE lead and the core 3 Measure the insulation resistance between BLACK lead and the core 4 Measure the insulation resistance between RED lead and the core id d 4 25 Measure the resistance between the slip ring and the core e CONTROL PANEL Measure the insulation resistance between the live parts and the grounded parts
9. 20 20 mE T20V 240 30A or less 20A or less 30A or less 50A or less 30A or less 20A or less 30A or less Total 50A or less Total 30A or less RGV12100 RGV13100T CAUTION AS F TWIST To connect the appliance to the locking type receptacle insert the plug in to the receptacle and then turn it clockwise to lock 2 gt mg Check the amperage of the receptacles used referring to TABLE 1 be sure not to take current exceeding the specified amperage Be sure that the total wattage of all appliances dose not exceed the rated output of the gen erator NEMA NEMA GFCI Ground Fault Circuit D up to 20A 5 208 5 20P REC eceptacle duplex NEMA NEMA Locking Receptacle up towne L5 30R L5 30P REC2 NEMA NEMA Locking Receptacle UP TOSS L14 30R L14 30P REC3 Locking Receptacle up to 50A Locking Receptacle URIO 508 121 308 L21 30P RECS TABLE 1 NOTE When the no fuse breaker turns off during operation the generator is over loaded or the appli ance is defective Stop the generator immediately check the appliance and or generator for overloading or detect and have repaired as necessary by Robin dealer or service shop CAUTION The duplex 120V receptacle is protected by a GFCI Ground Fault Circuit Interrupter shuts off the output current from
10. Current transformer control on the other hand controls the output voltage according to the load current which is better for using inductive load 18 5 PRECAUTIONS 1 Use extreme caution near fuel constant danger of explosion or fire exists Do not fill the fuel tank while the engine is running Do not smoke or use open flame near the fuel tank Be careful not to spill fuel when refueling If spilt wipe it and let dry before starting the engine 2 Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oily cloth straw and any other inflammables near the generator 3 Do not operate the generator in a room cave or tunnel Always operate in a well venti lated 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 3 feet away from structures or facilities during use 4 Operate the generator on a level surface If the generator is tilted or moved during use there is a danger of fuel spillage and a chance that the generator may tip over 5 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 thor oughly 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 insulation s will be adversely a
11. 00000 00000 28 8 5 ROTOR 0 00 0 29 8 6 EXCITING 0000 000 00000 0 00 0 0 0 000 0 0 00000 29 8 7 BRUSH 000000000000000000000000000000000 30 8 8 A V R AUTOMATIC VOLTAGE REGULATOR 30 8 9 CURRENT TRANSFORMER RGV13100T only 31 8 10 ECU ELECTRONIC CONTROL UNIT 31 8 11 IDLE CONTROL UNIT RGV12100 only 000000000000000000 32 8 12 DIODE UNIT RGV13100T only 0000000000000000000000 ss 9 DISASSEMBLY and REASSEMBLY 34 9 1 PREPARATION and PRECAUTIONS 00000000000000000000 4 9 2 DISASSEMBLY PROCEDURES 0000000000000000000000 34 9 3 COMPONENT PARTS 000000000000000000000000 35 9 4 GENERATOR ASSEMBLING PROCEDURES 0 00 00000 00000000 40 10 TROUBLESHOOTING 0000000000000000000000 4 10 1 OUTPUT 000000000000000000000000000 4 10 2 VOLTAGE IS HIGH OR TOO Q 0000000000000000 4 10 3 AC VOLTAGE IS NOMINAL AT NO LOAD BUT LOAD CANNOT BE APPLIED 4 10 4 ENGINE DOSE NOT RUND 0000000000000000000000 45 11 WIRING DIAGRAM 00000 000 0000 000 0 0 0 0 000 46 This Service Manual excludes information for engine As for the total servicing information as a generator set please refer in conjunction with the Robin EH63 65 OHV Engine Service Manual 04 1 SPECIFICATIONS
12. 13121110 9 8 7 Electric starter Magnetic switch to terminal 92251 Oil pressure switch AC output receptacle 120V AC output output receptacle 120 240V receptacle 120 240V Connector Remote control CONTROL BOX Field Winding Auxiliary Winding r 1 2 AC Winding 2 Pilot lamp Voltmeter 0 Exciting Wiring color cord Black Brn W Black White Grn Blu Blue Grn W LBlu Light blue Org Brn Brown Gry 46 Brown White R Green w Green White Y Orange Pik Gray Grn Y Earth Ground terminal Red BIKR White R W Yellow LGrn Pink Green Yellow Black Red Red White Light green RGV13100T CONTROL BOX LGrn Fuel cut Ignition coil Charge coil R gt HRW lt J Bikw Blk i om Magnetic Electronic control unit 13121110 9 8 7 Oil pressure warning lamp starter switch pel Regulator Gry D Oil pressure Switch GENERATOR CONTROL BOX to earth terminal AC output receptacle 120V Single phase 208V Three phase REC5 7 Winding B
13. Nominal W G Allowable No of strands cross T strands dia Resistance Current Amp section EN BI Lem m 7 mese zer fs DL Voltage drop Voltage drop indicates as V vm x Rx Ix 0 R means resistance 100 on the above table I means electric current through the wire 0 means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools 22 7 MEASURING PROCEDURES 7 1 MEASURING 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 to 150 V Type with an output voltage of 110 or 120 V 0 to 300 V Type with an output voltage of 220 230 or 240 V 0 to 150 V 0 to 330 V Dual voltage type 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10 A 20 A 100 A 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range 23 4 CIRCUIT TESTER Used for measuring resistance etc 5 MEAGER TESTER Used for measuring generator insulation resistance Select one with testing voltage range of 500V 7 2 AC OUTPUT MEASURING
14. Total power consumption must be equal to or less than the rated output of generator Example A rated 3000 W 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 consump tion of the load Example A 400W mercury lamp requires 600 W to 700 W power source to be turned on A rated 3000 W generator can power four or five 400 W mercury lamps NOTE 1 If a power factor correction capacitor is not applied to the mercury lamp or fluorescent lamp the more power shall be required to drive those lamps A rated 3000W generator can drive one or two 400W mercury lamps without power fac tor correction capacitors NOTE 2 Nominal wattage of the fluorescent lamp generally indicates the output wattage of the lamp Therefore 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 wattage Example A rated 250 W electric drill requires a 400 W generator to start it 4 Initially loaded motor driven appliances such as water pumps compressors etc These appliances require large starting wattage which is 3 to 5 tim
15. direction NOTE It is normal that the engine speed goes up for a moment when you turn the key switch to STOP while the Idle Control Switch is in ON position 4 2 8 OIL PRESSURE SWITCH The oil pressure switch sends a signal to ECU to stop the engine when the engine oil pressure drops to 1 0 kg cm 4 2 9 RELIEF VALVE The relief valve begins to open when the engine s oil pressure increases above 3 0 kg cm OIL FILTER OIL PUMP FILTER 4 2 10 AC SWITCH NO FUSE BREAKER The AC switch no fuse breaker protects the generator from getting damage by overloading or short circuit in the appliance The capacity of AC switch no fuse breaker is as follows Modi Specification No fuse Breaker Object of Protection RGV12100 60Hz 120V 240V Total output amperage RGV13100T 60Hz 120V 208V 10 4 2 11 receptacles used for taking AC output power from the generator A total of 4 kinds of receptacle each varying in rated voltage and current from another are used As many AC plugs as the receptacles each matching the corresponding receptacle are provided The rated current for each receptacle is shown as follows CAUTION Be careful not to use the receptacles beyond the specified amperage limits to prevent burning 30A 30A MAX 20A 50A 9
16. 13100T Slip rings are provided on the rotor shaft to receive DC exciting current from AVR RGV12100 and diode unit RGV13100T 4 2 3 BRUSH BRUSH HOLDER An exciting current is supplied from the A V R to the rotor The brushes are made of carbon and the brush holder of plastic It is necessary to keep the contact pressure between the brushes and slip rings withing specific limits Thus care must be taken of brush length 4 2 4 CURRENT TRANSFORMER DIODE UNIT RGV13100T only The current transformer and diode unit will perform a role to step up the voltage lowered by the load and stabilize the output voltage DIODE UNIT 4 2 5 VOLTAGE REGULATOR RGV12100 only The automatic voltage regulator employs an electronic circuit to automatically regulate voltage 4 2 6 ECU ELECTRONIC CONTROL UNIT ECU controls the start stop of an engine enabling the fuel cut while stop It also automatically stops the engine if an abnormal oil pressure occurs Function Description of Operation When the lubrication oil pressure drops below the safety limit Oil pressure becomes less than 1kg cm and or the engine speed ups above the safety Warning lamp limit Engine speed increases higher than 4 500 r min for 7 seconds the warning lamp repeats turning on and off and the engine stops automati cally The warning lamp turns off after 3 minutes When the engine started and reaches 1 050 r
17. 40 kg cm 11 8 13 7 N m 8 7 10 1 ft lbs 4 Install the brush holders in the rear cover Pass the mounting screws through the brush holders push the brush holders so that the brushes will be perpendicular to the slip rings and tighten the screws NOTE There are two kinds of brush holders a brush is installed oblique to the slip ring the brush holder can break when the screw is tightened or the brush may break when the generator of started After installing the brush holders measure the resistances across the brushes and terminals with a tester if they are from 5 ohms to 7 5 ohms If so the brush holders are correctly mounted 42 Fig 9 10 BRUSH HOLDER FLANGE BOLT Attach the connectors to the brush holders Connector the green wire to the stator end WIRE GREEN and the brown wire to the bearing end Coil side Install the brush cover 5 RGV13100T only Attach the end cover to the rear cover 6 Tighten the nuts over the mount rubber WIRE BROWN bolts to fix End cover side Fig 9 12 Tightening torque 120 140 kg cm 11 8 18 7 N m 8 7 10 1 ft Ibs NOTE When tightening the nuts slightly lift the alternator assembly so that the weight is not applied to the mount rubbers 7 Fasten the earth cable to the unpainted bolt hole on the frame Fig 9 13 43 10 TROUBLESHOOTING 10 1 No AC output Checking the exciting coil for resistanc
18. ION RGV13100T only Connection of Power Cables WARNING Do not touch output terminals while the generator is running or the operator may suf fer severe electric shock resulting in death Be sure to shut down the generator before connecting or changing connection of power cables to the generator This generator has four output terminals of three phase four wire system Connect power cables to the generator output terminals according to the type of application 15 AC THREE PHASE RECEPTACLE RGV13100T only RGV13100T has a receptacle for three plase 208V and single phase 120V as follows W lt Ye SINGLE PHASE AC120V PHASE 208 m Three phase application 208V Insert the plug into the receptacle X Y and Z Generator rated output 10000VA 3 PHASE OUTPUT Single phase lower application 120V Insert the plug into the receptacle W and X W and Y W 2 Maximum one third 1 3 of generator output can be utilized from each phase Generator rated output 3324VA 120V x 27 74 SINGLE PHASE OUTPUT 16 4 3 DESCRIPTION GENERATOR 4 3 1 RGV12100 When the generator is started the perma FC 3 nent magnet on the engine rotates to genera tor a voltage in the exciting coil This voltage is regulated by a diode in the
19. SERVICE MANUAL Models RGV12100 13100T GENERATORS PUB GS1328 CONTENTS Section Title Page 1 SPECIFICATIONS 0000000000000000000000000 1 2 PERFORMANCE CURVES 0 00000000000000000000 2 3 GENERAL DESCRIPTION 3 4 CONSTRUCTION AND FUNCTION 0 0 0 0000 e 4 1 CONSTRUCTION 0 000000000000020000000000000000 6 4 2 0000000000000000000000000000000 6 4 3 DESCRIPTION of GENERATOR OPERATION 17 5 SAFETY PRECAUTIONS 0 00000000000000 19 6 RANGE OF APPLICATIONS 00000 20 7 MEASURING PROCEDURES 0 0 0 0 0 0 000000 23 7 1 MEASURING INSTRUMENTS 00000000000000000000000 23 7 2 OUTPUT MEASURING I 000000000000000000000000 24 7 3 MEASURING INSULATION RESISTANCE 25 8 CHECKING FUNCTIONAL MEMBERS 0000000000000000 27 8 1 PILOT LAMP VOLTMETER 27 8 2 AC RECEPTACLES 0000000000000000000000000000 27 8 3 AC SWITCH NO FUSE BREAKER FO 000 0000 0000 0 0 0 0 0 0 28 8 4 STATOR 00000 00000 00000 00000
20. ar must be repaired A stained slip ring lowers gener ator efficiency and output voltage Polish the slip rings with fine sandpaper while turning the rotor until rough spots disap pear Care should be taken not to touch the rotor coils with the sandpaper 8 6 EXCITING COIL RGV12100 only 1 Disconnect the two yellow wires which come out from the exciting coil through the hole of the crankcase and connected with Ignition coil A V R in the control box 2 Check the resistance between two yellow wires with a circuit tester Exciting coil for A V R Exciting Charge coil coil RGV12100 2 35Q 3 Check the AC voltage between these two AC voltage yellow wires when the engine speed at no load 3600 3800 rpm with a circuit tester 35 to 45 V 29 8 7 BRUSH brushes must smooth where they contact the slip rings If not polish smooth the brushes with sandpaper A brush that is not smooth produces arcs between the brush and slip ring leading to possible damage Usable brush lengths are from 5 mm to 15 15 to 5 mm mm 0 2 to 0 6 0 6 to 0 2 A brush shorter than 5 mm must be replaced because decreased contact pressure between the brush and slip ring lowers gen erator efficiency and output voltage 8 8 A V R AUTOMATIC VOLTAGE REGULATOR Sle 1 Features 9 This AVR operates to control the field current order to maintain the
21. ch the faucet joint and tighten the bolts Tightening torque 230 250 kg cm 22 5 24 5 N m 16 6 19 5 ft Ibs 9 4 2 ROTOR 1 Wipe off oil grease and dust from the tapered portion of engine shaft and matching tapered hole rotor shaft 2 Mount the rotor to the engine shaft Tighten the through bolt Tightening torque 120 140 kg cm 11 8 13 7 N m 8 7 10 1 ft lbs FRONT COVER WASHER SPRING WASHER BOLT Fig 9 5 BEARING THROUGH BOLT WASHER SPRING WASHER Fig 9 6 40 9 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 ZA 22 if the grooves and thread holes 77 aligned correctly See Fig 9 8 2 GE 7 gt NN 2 Remove the four bolts 41 9 5 1 Put the rear cover with stator stator cover over the rotor Pull wires out from the rear cover NOTE Be careful not to give cuts to wires when pulling them out from the rear cover 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 2 Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover 3 Fix the rear cover with four bolts spring washers and washers Tightening torque 120 1
22. e RGV12100 Refer to 8 6 If insulation is NG replace exciting coil with new one Checking the brush and slip ring of rotor for resistance Refer to 8 5 and 8 7 If insulation is NG replace brush and slip ring with new one Check stator for winding resistance between terminals Refer to 8 4 If stator is faulty replace with new one Checking stator for insulation resistance Refer to 7 3 If insulation is NG replace stator with new one Checking the A V R RGV12100 Refer to 8 8 If insulation is NG replace A V R with new one Checking the diode unit and C T RGV13100T Refer to 8 9 and 8 12 If insulation is NG replace diode unit and C T with new one 10 2 AC Voltage is too high or too low Check engine speed Nominal engine speed at no load 3 700 to 3 750 rpm If engine speed is too high or too low adjust to the rated rpm Check stator for winding resistance and insulation Refer to 8 4 and 7 3 Check rotor for resistance and insulation Refer to 8 5 and 7 3 Checking the idle control unit RGV12100 Refer to 8 11 If insulation is NG replace idle control unit with new one 10 3 AC voltage is nominal at no load but load cannot be applied Check engine speed If engine speed is low adjust to the rated rpm Check total wattage of appliances connected to generator If the generator is overloaded reduce the load to the rated output of generator Check appliance for trouble I
23. es of running wattage Example A rated 900 W compressor requires a 4500 W generator to drive it NOTE 1 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 20 NOTE 2 Motor driven appliances mentioned in lets 3 4 vary in their required motor starting power depending on the kind of motor and start up load If it is difficult to determine the optimum generator capacity select a generator with a larger capacity 5 Appliances without any indication as to power consumption Some appliances have no indication as to power consumption but instead the work load output is indicated In such a case power consumption is to be worked out according to the numerical formula mentioned below Output of electrical appliance Power consumption Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 500000000 0 6 to 0 75 E The smaller the motor the lower Three phase motorp 000000000 0 65 to 0 9 the efficiency Fluorescent 00000000000 0 7 to 0 8 Example 1 40 W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 7 57 As explained in Item 2 multiply this power con
24. f the appliance is faulty replace it Check if engine is overheated If generator cooling air inlet and or outlet is clogged with dirt grass chaff or other debris remove it Check insulation of generator Refer to 7 3 44 10 4 Engine dose run 1 The key switch or remote Switch is turned to START Wait for more than 2 seconds and then turn the within 2 seconds the engine has key switch to START position been stopped Both the key switch of the generator and the switch of remote controller must be turns into ON position 1 Electric starter 2 The remote controller is con dose not operate nected 3 The above possible causes 1 The ECU is defective and 2 dose not apply Replace with new one 1 No fuel in the tank or the fuel Warning lamp cock is closed turns on and off when engine is Supply fuel or open the fuel cocks stopped 2 Oil level is low or oil is contami nated Add or change engine oil Engine is auto matically stopped but the warning 1 The bulb of warning lamp failed Replace the bulb with a new one lamp dose not light up 45 11 WIRING DIAGRAM RGV12100 CONTROL BOX ch Bimetal ge cut Ignition coil Exciting e coil 5 AVR Sy mm GENERATOR LGrn Charge coil Oil pressure warning lamp Electronic control unit
25. ffected and may cause current leakage and electric shock 6 Do not connect the generator to the commercial power lines This may cause a short circuit or damage to the generator 7 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 opera tion immediately and carefully check the electrical appliance and AC plugs for faulty wiring 19 6 RANGE APPLICATIONS Generally the power rating of an electrical appliance indicates the amount of work that 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 show ing their rated voltage frequency and power consumption input wattage The power con sumption 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
26. installed incorrectly replace them tem porarily to their original position 4 Handle disassembled parts with care clean them before reassemble using a neutral clean ing fluid 5 Use all disassembly assembly tools properly and use the proper tool for each specific job 9 2 DISASSEMBLY PROCEDURES 9 2 1 CONTROL PANEL 1 Remove the front panel 2 Disconnect the connectors on the wiring from the front panel to the alternator 9 2 2 ALTERNATOR 1 Remove the end cover 2 Remove the brush cover and the brush holder 3 Take off the two flange nuts and lift the front cover with a piece of lumber See Fig 9 1 NOTE Lift the front cover until completely the rear cover removes from the mount rubber See Fig 9 2 4 Remove the rear cover b Remove the bushing 6 Remove the stator cover MOUNT RUBBER Fig 9 2 34 7 Remove the stator See Fig 9 3 NOTE The stator is heavy Be careful do not hit the coil of the stator to the rotor 8 Loosen the through bolt of the rotor 9 Remove the rotor with the soft hammer See Fig 9 4 NOTE Temporarily tighten the through bolt of the rotor when hit the rotor See Fig 9 4 10 Remove the front cover 9 3 COMPONENT PARTS For disassembling and assembling the following illustrations show the major component parts and their configuration for 1 Generator assembly 2 Control Box and 3 Fuel Tan
27. k and sys tem The specified tightening torque is indicated in the illustration 1 Generator assembly FRONT COVER 22 5 24 5Nm 230 250Kg cm ROTOR 9 STATOR N NS 11 8 13 7Nm STATOR COVER 120 140Kg cm BUSHING FLANGE NUT SE 11 8 13 7Nm id 1 120 140Kg cm 11 8 13 7 120 140Kg cm RGV13100T only 2 1 12100 w 7 IDLE CONTROL UNIT N A V R AUTOMATIC VOLTAGE REGULATOR CONNECTOR CAP EARTH CONNECTOR GSS GROUND for REMOTE TERMINAL CONTROL AC RECEPTACLE NO FUSE OIL PRESSURE WARNING LAMP VOLTMETER 37 2 2 Control Box RGV13100T CURRENT TRANSFORMER Po uw lt 9 GROMET GROUND TERMINAL OIL PRESSURE WARNING LAMP EM x STARTER SWITCH Ge A R HOUR METER DD VOLTMETER CONTROL PANEL 3 Fuel Tank FUEL GAUGE FRANGE BOLT M6 x 14 mm RUBBER WASHER I M X NN FUEL TANK CAP FUEL FILTER FUEL TANK cup DETAIL A HOSE CLAMP FUEL STRAINER gt OH aoe BOLT 2 6 14 UBBER PIPE 630 mm N SN ss mS ANS 9 4 GENERATOR ASSEMBLING PROCEDURES 9 4 1 FRONT COVER Attach the front cover to the engine main bearing cover Mat
28. l power source to the generator This switch is necessary to prevent accidents caused by the recovery from power outage Use 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 43 Wee 555 117 B09 d UTILITY HIGH LINE RS MAIN POWER LINE 1 125252524 T Eun WS 5 lt SS 5 5 QS CONNECTING W lt lt F o 240V RECEPTACLE P z poe gt ii 4 E gt 556 ee d ils d s gt gt House circuit Meter box 120V appliance 240V 120 appliance ransfer switch Generator OR 240V 4P Receptacle Operating the generator m Turn the house AC breaker off before starting the generator Start the generator and warm it up m Turn the house AC breaker on CAUTION Do not start the generator with electrical appliance 5 connected and with their switch es on Otherwise the appliance s may be damaged by the surge voltage at starting 4 2 12 3 PHASE APPLICAT
29. lk Voltmeter Current transformer Brn 120V REC2 Brush o pad 5 S 1 5 1 1 L1 AC output receptacle Key switch M Grn Y AC output receptacle 120V REC1 Earth Ground terminal 47 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 Copyright 2001 Robin America Inc PRINTED IN THE USA
30. min the starter motor is automatically stopped Starter motor control When the engine is operating the starter motor can not start Function _ Description Operation When the key switch the remote control switch is turned to START the fuel cut off valve of the carburetor opens When the key switch or the remote control switch is turned to STOP the fuel cut off valve closes If the starter motor is locked by any reason the starter motor is shut off automatically after 3 seconds When the engine dose not start engine speed does not reach 1 050 r min the starter motor is stopped after 21 seconds Fail safe function When the remote controller is connected the electric starter dose not run when the switch of remote controller is turned OFF even if the key switch on the generator is turned to START When the engine speed increases higher than 4 500 r min for 7 seconds the engine is shut down automatically and the warning lamp repeats turn ing on and off for 3 minutes When the key switch or remote control switch is turned to START the warning lamp lights up for a moment to indicate that the bulb for the warn ing lamp is normal Self checking function for warning lamp bulb 4 2 7 IDLE CONTROL UNIT RGV12100 only The idle control unit releases throttle valve when the applied load current exceeds 0 04A The two output wires 2 from the main coils must go through the ZCT 3 in the same
31. output voltage for the ME AC current which generated by the magnetic flux by the field coil 2 A V R trouble may be identified by simply looking at the A V R or by the inter lead resistance with a tester or actually mount ing it in the generator and operating it a A V R TROUBLE IDENTIFICATION by APPEARANCE If an A V R electronic part is burnt dark or the surface epoxy resin melted it often indi cates A V R trouble b IDENTIFYING A V R TROUBLE by CHECKING INTER LEAD RESISTANCE Check the inter lead resistance of the A V R with a tester referring to the following table If the tester readings very greatly from the values specified in the table on next page the A V R is faulty NOTE Take teater inaccuracy into account in reading the tester c IDENTIFYING A V R TROUBLE by MOUNTING and OPERATING in THE GENERATOR SCR or transistor damage cannot be detected by simply looking at the A V R or checking the lead resistance Check it by mounting the suspectedly faulty A V R a normal gener ator or mount a mormal A V R in a generator which fails to generate voltage Checking table for analogue circuit tester Apply black needle of the circuit tester Analogue circuit tester Black White Light green 3 Brown orYellow gt 8889 lt 20080 needle tecreui White
32. resistance between five terminals of IDLE CONTROL UNIT with circuit tester Terminal number of the IDLE CONTROL UNIT Circuit tester with battery power source 1 5 V Apply red needle of the cir cuit breaker Tester measuring range 1000 k Q 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 ordi nary 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 32 8 12 DIODE UNIT RGV13100T only Check the resistance between five wires of DIODE UNIT with circuit tester Apply black needle of the circuit breaker Diode unit Apply black meedieofthecicuitbresker Brown Yellow 1 Yellow 2 Yellow 3 Ses green E snn ea sworn mke ke 9 DISASSEMBLY AND ASSEMBLY 9 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 neces sary information to facilitate easier and smoother reassemble 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
33. sumption value of 57 W by 1 2 to 2 and you will get the figure of the necessary capacity of a generator In other words a genera tor with a rated output of 1000 W capacity can light nine to fourteen 40W fluores cent 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 72570 W 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 to 32684 W to1710 W Applicable Wattage W Applications RGV12100 60 Hz Fluorescent Lamp Electric Tool 4950 Incandescent Lamp Heater 10000 Pump Compressor 2500 21 NOTES Wiring between generator 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 insula tion 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 conduc tors decreasing the input voltage to the load electrical product As a result the load can damaged Table 7 2 shows voltage drops per 100 meters of cable
34. the duplex 120 receptacle when a ground fault occurs in the generator or the appliance Please note that other receptacles are not protected by 12 GFCI RECEPTACLE After starting the engine check the GFCI for proper functioning by the following test procedure Push blue TEST button 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 prop erly 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 CONNECTING TO DOMESTIC CIRCUIT HOUSE WIRING This generator is neutral grounded type If a generator is to be connected to residential or commercial power lines such 5 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 dam age to appliances damage to the building s wiring or fire a When connecting 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 commercia
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