Subaru Robin Power Products RGV6100 User's Manual
Contents
1. GRNERATOR CONTROL BOX _ i 2 0Blk No fuse breaker z 1 2 0 output receptacle 120 5 E 5 tur 5 lt 5 5 5 2 0Blu REC1 W 8 5 78 o sZ 9 5 5 T S 208 8 2 1 5 E Y Voltmeter 07586 8 5 i Auxiliary lt 1 2 0W Winding L fg 1 257 5 Engine switch Ls 0 75 Oil sensor Te a 6 1 25Y 1 258 Diode stack E Assy gt lt 7 1 250 5 Circuit breaker output 1 25Brn terminal e 1 25Brn W O 1 25Grn AM 1 25 E Earth on Ground terminal RGV4100 U S A 60Hz 120V 240V TYPE NEMA RECEPTACLE GENERATOR CONTROL BOX ms as a 0 75W Idle 5 5 0 75W CS 0 75W i control E 5 oido Sach 9079 see unt 0 75LBlu 55 Solenoid re No fuse breaker 8 lt oTo 2 0Blk Fullpower 38 0 758 8 2 1 120 240 2 5 2 1 t Z T 5 5 120V3 REC1 W y gt 5 8 52. Key switch ENGINE NS 0 75Blu RGV4100 Ss 33 u 1 og 8 5 821 5 m ao o 5 0 WW N N NN S S I A gt 1 1 a re S 0 75Blkw TIT TIT Oil sensor gt 0 75Grn Y 14 14 e Q Battery Magnetiec Electric starter switch Ground terminal Wiring color cord Blk W Blu LBlu Brn Black Blue Brown Black White Light blue Brn W Grn Grn W Org Gry Brown White Green Green White Orange Gray _ 63 W Y Red White Yellow 1 SPECIFICATIONS LOL9ADH PUL 0 L JOJOW 1891645 94199 x eonou 9718 54 2 624 64 SZ 541 07271 9 29 sq 0707 09 541 069 X 027 X 089 Ul X 981 X 8792 299 X X 029 Ul 212 691 X H X M suorsueuiiq UPS 0140914 aes 01545 jeu 221 s 9220 1941 071 Ayoeded uoneJedo 5 S N 29 9 S1 9 12 Ces S N 86
3. 35 9 8 OQIL SENSOR 0 36 10 DISASSEMBLY AND ASSEMBLY 37 10 1 PREPARATION and PRECAUTIONS 37 10 2 DISASSEMBLY PROCEDURES 37 10 3 ASSEMBLY PROCEDURES EU 38 10 4 CHECKING DISASSEMBLY REASSEMBLY of the FRONT PANEL 46 11 TROUBLESHOOTING gt 51 NS AC OUTPUT us 53 11 2 AC VOLTAGE IS TOO HIGH OR TOO 55 11 3 AC VOLTAGE IS NORMALAT NO LOAD BUT THE LOAD CANNOT BE 56 11 4 NO Aa 57 11 5 IDLE CONTROL OPTIONAL EQUIPMENT 58 12 WIRING DIAGRAM m 61 Troubleshooting Manual RGV4101 RGV6101 64 1 SPECIPG da lcs 64 2 GENERATOR TROUBLE SHOOTINGQ 65 2 1 NO PG GUN DUM u SUR S asa 65 2 2 voltage is too high or 100 LOW succ rcr exhi RE EK 67 2 3 AC voltage is normal at No load but the load cannot be
4. 10 ONS TRIG TON aei c ir PIS nea n S RM 10 B2 FUNCTION bo a ashes ete 10 5 3 GENERATOR 22 200 2020 0 000000000000000000000000 16 Sod OU SENSOR a 19 6 SAFETY PRECAUTIONS ana 22 7 RANGE OF APPLICATIONS 23 8 MEASURING PROCEDURES annua anna uasa asas assa assa aa 26 8 1 MEASURING INSTRUMENTS 26 8 2 AG OUTPUT MEASURING 29 8 3 DC OUTPUT MEASURING ix 29 8 4 MEASURING INSULATION RESISTANCE 30 9 CHECKING FUNCTIONAL MEMBERS 32 COLE TN TE Se bet acd 32 9 2 32 9 3 No F SE BREAKER Pes rl aur 32 Section Title Page 9 4 STATOR Me tI PRU 33 9 5 ROTOR ASSEMBLY eda a du eee 34 9 6 CONDENSER L 34 9 7 DIODE
5. 68 2 4 No DO 69 2 5 Idle control Optional 14 188 71 3 RANGE OF APPLICATIONS J J 74 4 WIRING DIAGRANM U J J J 77 NOTE As for the servicing information on engine protion please refer to the EH17 2 EH25 2 and EH34 engine service manual se si 5 2u129 3 1 SPECIFICATIONS 9 29 09 OVE 501 ZEL 501 901 299 X 067 X 029 Ul 212 X BOL X v vc X SL X 099 Ul 61 X 69 6 H x M X 7 suorsueuiiq Jeyejs jeuondo pue 1 JOURS I099H uj 1s S Bues 071 1 6 en 980 seu 690 eb S N ZEO sinou 0 51109 6 saei 9791 1 6 S N 86 ZL S N jen iqoujo nv u 0096 9 0096 dH 0 indino gt Ul 2641 62 Ul 0601 sW 1 jueujeoe dsiq 9
6. 2v 2 M 0089 zH 09 ou nb 1uj Buniox3 Jes ssejusnug d l 0019A9H 2 PERFOMANCE CURVES Hz 63 62 Hz 61 60 V 250 125 240 230V 115V 120 230 115 220 110 0 1 2 4 4 Load Rated DC DC Voltage 12V DC Ampere 8 3A DC output 100 W The voltage curve shown in the left indicates the characteristic of DC output when charging a battery The voltage may be decreased by 20 when the resistance load is applied NOTE It is possible to use both DC and AC outputs simultaneously up to the rated output in total 3 5 3 1 BRUSHLESS ALTERNATOR Newly developed brushless alternator eliminates troublesome brush maintenance 3 2 CONDENSER TYPE VOLTAGE REGULATOR A trouble free condenser type voltage regulator ensures a stable voltage under all working conditions 3 3 OIL SENSOR Oil sensor automatically shuts off the engine whenever the oil level falls down below the lower limit to protect the engine from seizure 3 4 QUIET OPERATION Robin RGV series generator delivers a quiet operation with Alarge super silent muffler Aquiet 4 stroke Robin Rro OHV engine Asilent cyclone air cleaner 3 5 NO RADIO NOISE Noise suppressor spark plug is equipped standard to prevent radio frequency interference 3 6 LARGE FUEL TANK The la
7. 30A 1 150V 2 E gt IDEL CONTROL AC MAX ZOK AC MAX 30A AC MAX 20A o ON ADIO Qop 2 0 215 ONLY DC OUTPUT DC BREAKER AC BREAKER e e 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL MODEL NAME stuck on the side wall of control box NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service I LABEL MODEL NAME 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION END COVER BALL BEARING STATOR COMPLETE ROTOR COMPLETE REAR COVER STATOR COVER CRANKSHAFT mw MOUNT RUBBER THROUGH BOLT COVER BOLT FRONT COVER Fig 5 1 5 2 FUNCTION 5 2 1 STATOR The stator consists of a laminated silicon steel sheet core a main coil and a condenser coil which are wound in the core slots The condenser coil excites the rotor field coil which generates AC voltage in the main coil Fig 5 2 10 5 2 2 CONDENSER One or two condensers are installed in the trol box and are connected to the condenser coil of the stator These con
8. Q2 LLH3 0 9 2 ed d 99090002 M 001 V 8 ZL indino 0L 10804 JOMOd VO SL VO OE 96 2 2 021 wenno Seyon m VO OE 61 pary 5 M 0096 M 0082 indino OV M 0017 0082 2 09 KouenboJJ eseug Bunioxg ssejusnug d 00 0082A9H I POIN se e qejreAe SI 2911615 201293 618 8 081 541 221 1uBieM 089 X 0 7 X 089 Ul 9 76 X 981 X 892 H X M 1 Suoisuauuiq 1911819 pue 015456 Ayoede sinou Q7 snonunnoo papy seu 6712 S N 9 9 Kyoedeo jen4 2 0096 0 8 indino ul 29 02 BEE jueujeoejdsiq 0 9 000 d L d 195090002 M 001 V 8 A ZL 01 10084 J9MOd 0 1 HM m 2 M 0087 indino
9. NOTE For easy tank assembly glue the rubber a HOSE CLAMP washers over the mounting holes of the i RUBBER PIPE 3 Connect the rubber pipe First fit the hose clamps on the rubber pipe and connect it to the strainer and the carburetor Then ve fasten it with the hose clamps For RGV6100 connect the rubber pipe to the strainer and the fuel tank in the same way 2 NOTE Apply 8 drop o oil the rubber pipe for easier connection Fig 10 30 50 10 3 9 FRONT PANEL Mount the front panel assembly to the frame Refer to Section 10 4 for disassembly checking and reassembly procedures the front panel 1 Connect the wires from the front panel and the engine 2 Connect the wires drawn out from the stator to the wires from the front panel NOTE wires of the same color 3 Press the upper end of the bushing into the bottom window the front panel 4 Mount the front panel to the frame M5 12 mm bolt and washer 2 pcs M5 25 mm bolt and washer Ass y 2 pcs Fig 10 31 10 4 CHECKING DISASSEMBLY and REASSEMBLY of the FRONT PANEL 10 4 1 CHECKING OF THE FRONT PANEL Dismount the front panel from frame Remove the control panel and check each components and wiring Refer to Section 9
10. gt 0 75LBlu 1 No fuse breaker 8 200 120 240V 55 5 sl 5 e 37 BK 2365 ur 4 6 5 RECT W 5 A T lt 1 W E 6 2 0Blu r YH 2 B 1 P 55 lt s Voltmeter 2 0R 252 Diode 1 W 255 ooo PA stack Auxiliary lt 95 lt 55 5 Winding 120 240 H for 5 L condenser I gi 120V 2 0W 1 i LH L 1 25Y x 3 2 2 0Grn 5 5 1 o o 5 5 lt 1 257 1 1 1 25Brn i 1 Diode stack Assy 1 250 3 lt D Circuit breaker pc output 1 25 terminal 1 1 25Bm W Key switch 1 1 Magnetiec I 5 5 Solenoid 1 EM 55 0 75Blu 5 8 tim 5 SEM 2 Spark plug Oil sensor 0 75BIk 4 1 0 75Grm Y 1 Electric starter E Earth QU Ground terminal RGV6101 GENERATOR CONTROL BOX Sarge absorber Diode No fuse breaker Idle control unit and Fuel cut unit Idle control switch 0 75W o o 0 75W 1 25Bm W 0 75 2 0 S3 l Full power 224 I switch 25 53465 I 120 240V sis g 5 zas l ooo 55906 v
11. 3 Measure the insulation across one of the sol dered terminals of the rotor and the core Fig 2 6 If insulation is bad replace rotor with a new one Fig 2 6 2 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 2 2 1 CHECKING ENGINE SPEED If the engine speed is too high or too low adjust it to the rated r p m How to adjust engine r p m Loosen the lock nut on the adjusting screw Turn the adjusting screw clockwise to decrease engine speed or counterclockwise to increase speed ADJUSTING SCREW RGV4101 Normal engine speed at no load 3700 to 3750 rpm 2 2 2 CHECKING CONDENSER Check condenser referring to Step 2 1 1 2 2 3 CHECKING STATOR Check stator referring to Step 2 1 2 2 2 4 CHECKING ROTOR Check rotor referring to Step 2 1 3 67 2 3 VOLTAGE IS NORMAL NO LOAD THE LOAD APPLIED 2 3 1 CHECK THE ENGINE SPEED If the engine speed is low adjust it to the rated r p m Refer to Step 2 2 1 for engine speed adjustment 2 3 2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR Refer to Section 3 RANGE OF APPLICATIONS for the wattage of the appliances If the generator is overloaded reduce the load to the rated output of the generator 2 3 3 CHECK THE APPLIANCE FOR TROUBLE If the appliance is faulty repair it 2 3 4 CHECK IF THE ENGINE IS OVERHEATED If the cooling
12. IDEL CONTROL UNIT 7 OUTPUT WIRE 2 Fig 11 15 Fig 11 16B black minus needle of the circuit tester Apply red plus needle of the circuit tester Table 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 59 11 5 2 ENGINE SPEED IS REDUCED WHEN LOAD IS OFF 1 Check the distortion of the SOLENOID BRACKET as shown in step 11 5 1 1 2 Check the wiring of SOLENOID Check two leads from SOLENOID securely connected 3 Check the wiring of IDLE CONTROL UNIT Check all leads from IDLE CONTROL UNIT are securely and correctly connected 4 Checking the SOLENOID Measure the resistance between two leads from SOLENOID Normal Resistance 25 310 If the resistance is larger smaller than this range SOLENOID is defective SOLENOID Replace with a new one 60 Fig 11 17 12 WIRING DIAGRAM RGV2800 U S A 60Hz 120V TYPE NEMA RECEPTACLE
13. Press the smaller end of the bushing into the window of the rear cover 47 STATOR STATOR COVER Fig 10 24 e he l 4 xi Fig 10 25 10 3 5 END COVER RGV4100 only TT EET Attach the end cover to the rear cover pe E Ur w EN EL Ta 1 K A eI I 1 ur Ir 52 r M J4L L L x 00 18 r ar 1 1 u r4 ar ar CNI p ne s ih Py Xo NC PM La T k y n 73 T 6 l omar GE re ETE TR as Fig 10 26 10 3 6 FRAME 1 Attach the mount rubbers to the frame Insert the setting tongue of mount rubber into the hole on the frame and tighten the nut from the bot tom of the frame FRAME UPPER M8 flange nut 4 pcs Tightening torque 11 8 13 7 N m 120 140 kg cm 8 7 10 8 ft lb Fig 10 27 NOTE The mount rubbers are selected to reduce vibration most effectively by model Be sure to use the correct mount rubber for your generator Although mount rubbers have the same appear ance their characteristics are different 2 Attach the 5 mm terminal of the ground
14. To prevent bolts and nuts from being misplaced or installed incorrectly replace them temporarily to their original position 4 Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools properly and use the proper tool for each specific job _ 37 10 2 DISASSEMBLY PROCEDURES Step Part to remove Description Remarks Tool 1 Control box 1 Take off the bushing from the bottom of the control box See Fig 10 1 2 Disconnect the connectors on the wiring Press the upper end of from the control box to the alternator the bushing and pull See Fig 10 1 out 3 Disconnect the connectors on the wiring between from the control box and the engine See Fig 10 2 Fig 10 1 Fig 10 2 4 Take off the four bolts and remove the control box the frame See Fig 10 3 5 x 12 mm bolt and washer Ass y black 2 pcs 5 x 25 mm bolt and washer Ass y black 2 pcs 8 mm Spanner Description Remarks Tool 2 Fuel Tank 1 Discharge fuel from the tnak 1 Shut the fuel strainer 2 Remove the strainer cup 3 Put a vessel to receive fuel under the strainer and open the fuel cock to discharge fuel See Fig 10 4 4 Attach
15. Turn on the no fuse breaker before mea surement STATOR 1 Measure the insulation resistance between BLUE lead and the core 2 Measure the insulation resistance between WHITE lead and the core 3 Measure the insulation resistance between YELLOW lead and the core 4 Measure the insulation resistance between BROWN lead and the core ROTOR Measure the insulation across one of the soldered terminals of the rotor and the core Fig 8 12 30 CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Fig 8 13 Any part where the insulation resistance is less than 1 has faulty insulation and may cause electric leakage and electric shock Replace the faulty part _ 31 9 CHECKING FUNCTIONAL MEMBERS 9 1 VOLTMETER Check the voltmeter if it is turned on by applying specific voltage Voltmeter cannot be checked with circuit tester because its resistance is too large D Check that no disconnection nor short circuit occurs with a tester and the internal resistance is around 00k ohms normally 2 Turn on the commercial power supply input and check the indication VOLTMETER 9 2 AC RECEPTACLES Using 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
16. 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 72 6 Checking the IDLE CONTROL UNIT RGV6101 Check the resistance between five leads of IDLE CONTROL UNIT with circuit tester EOS Eos Terminal number of the IDEL CONTROL UNIT Fig 2 19 Circuit tester with battery Apply black of the circuit breaker e e e Je uad o soq neq e o 0 e o s se e e pood oo sreunbreaker 6 gt 0 megma se e mods e oad se S sadsad e e e od Table 2 7 2 5 2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF 1 Check the distortion of the SOLENOID BRACKET as shown in step 2 5 1 1 2 Check the wiring of SOLENOID Check two leads from SOLENOID are securely connected 3 Check the wiring of IDLE CONTROL UNIT Check all leads from IDLE CONTROL UNIT are securely and correctly connected 4 Checking the SOLENOID Measure the resistance between t
17. 6 4 lt 2207 1 258 Diode stack 2 x Assy 5 bg 79 1 250 lt breaker DC output a 1 25Brn terminal Key switch 1 25Brn W io 5 Py S 5 0 75Y 0 75BIk W 0 75Grn W C 0 75Grn W 4 0 75BIKW 1 0 75W Solenoid 0 75Blu 0 75Blu Fuel cut solenoid Ignition D gt lt lt Spark plug TIT Oil sensor 0 75Grn Y Magnetiec switch Q Earth Ground terminal _ 78 Robin America Inc 940 Lively Blvd Wood Dale IL 60191 Phone 630 350 8200 Fax 630 350 8212 e mail sales robinamerica com www robinamerica com PRINTED IN THE USA
18. Brown T Brower White Orange Orange Brewn Brown Brown White CIRCUIT TESTER Fig 9 7 Fig 9 8 Circuit inside of the diode rectifiers is as shown in Fig 9 7 Check continuity between each terminal by using a circuit tester as shown in Fig 9 8 The rectifier is normal when condtinuity is as follows Checking table for analogue circuit tester Apply black minus needle of the circuit tester Analogue circuit tester sown om No continuity No continuity No continuity the circuit tester Continuity Continuity Brown White No continuity No continuity No continuity Table 9 4 1 Apply red plus needle of 35 Checking table for digital circuit tester Apply red plus needle of the circuit tester Digital circuit tester No continuity No continuity Continuity Apply black minus needle No continuity No continuity Continuity of the circuit tester Continuity Continuity Continuity Brown White No continuity No continuity No continuity 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 exte
19. C 0 75Blu I breakor di lt 0 75 1 i 0 UV 0 75Gr W Fuel cut solenoid E HGE Fullpower 52 5 5 1 switcl 5 57 5 EER 120 240 525 5 5 EA SSES o 09 af AT IO 1120V REC1 W ES whe 5 1 i 1 amp 83 8 5 a gt D gt 00 o UNE RECANTE Voltmeter IS 88 503 56 555 5 a L lt 208 H Auxiliar 95 Winding 5 a i 120 240V 7 28 E 1 1 25 p Zl pow Su 5 9 Lozs w f 55 2 0W m 5 TT Cxr 2 0Y 4 2 0Gm Oil sensor 2 s 4 5 5 0 75 1 5 5 1 CZ 2 0Y 1 9 4 0 75Gm TE switch LHT xI 1 25Bm Diode stack Assy sf lt D o 7o 1 2501 Y Circuit breaker pc output rA x1 1 25Brn terminal 1 N 1 25Br W 2 4 i i Earth Ground terminal _ 62 RGV4100 6100 CONTROL BOX ELECTRIC STARTER TYPE 1 25Grn 0 75Blu RGV4100 0 75GrnW RGV6100 mm ENS ge 88 20 oc gt gt 22 Sas amt x aco ena low 1010 SN MN 1 25Grn Y RGV4100 6100 for BS 1 25Gm
20. I means electric current through the wire A L means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools _ 76 4 WIRING DIAGRAM RGV4101 GENERATOR CONTROL BOX ENGINE Sarge absorber Field Winding Auxiliary Winding for condenser AC Winding 1 AC Winding 2 No fuse breaker Voltmeter Idle control switch Idle 0 75W control unit 0 75Blu 0 75LBlu lt 0 75 CSF0 75WA Solenoid Full 52 120 240V aS 120 240V 0 75BIk AC output receptacle 120 240 Engin switch DC Winding KG condenser b 2 Condenser Diode stack T lt 1 25Brn 4 lt 770 1 25 lt Circuit breaker DC output 1 25Brn terminal 1 25Bm W 2 0Grn 0 75Gm Y 0 75BIk 0 75LBlu Charge coil Ignition coil Spark plug 1 0 75BIk 4 Oil sensor 0 75 t t 0 75G8m Y i RGV4101 Electric starter model Earth Ground terminal ENGINE GENERATOR ES CONTROL BOX __ __ __ control switch 0 75W 0 75W 1 i 0 75Blu gt
21. continuity No continuity Table 2 4 2 Apply black minus needle No continuity 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 70 NOTE 2 Continuity means forward direction characteristics of the diode different from short circuit condition in which a pointer of the tester goes out of its normal scale shows resis tance to some extent When results of the checking indicates failure even in one section replace with a new one NOTE 3 Simpson brand analogue testers have the characteristics as same as the digital circuit tester 2 4 6 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester MODEL SPECIFICATION RGV4101 120V 240V RGV6101 120V 240V Table 2 5 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 2 5 IDLE CONTROL OPTIONAL EQUIPMENT 4 ms 2 5 1 ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS APPLIED 13 1 i 1 Inspect the solenoid bracket Check the bend EET JE MUG angle of solenoid bracket If the bracket is dis x torted correct the angle with proper tool 2 Check the wattage of load applied to the gen erator If the generator is loaded over the rated 7 wattage the engine
22. 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 con sumption so that the excess power generated by the generator can be used for other electrical appliances NOTE Motor driven appliances mentioned in items 3 and 4 vary in their required motor starting power depending on the kind of motor and start up load If it is difficult to determine the optimum generator capacity select a generator with a larger capacity 5 Appliances without indication as to power consumption Some appliances have no indication as to power consumption but instead the work load output is indicated In such a case power consumption is to be worked out according to the numerical formula mentioned below Output of electrical appliance Power consumpition Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 6 0 75 The smaller the motor the Fluorescent lamp 0 7 to 0 8 lower the efficiency Example 1 A 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 72 57W As explained in Item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get
23. 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 H 4 CONDENSER 1 ZCONDENSER Fig 11 1A RGV2800 Fig 11 1 Type RGV4100 RGV6100 NORMAL CAPACITY OF CONDENSER RGV2800 RGV4100 RGV6100 24u 20 F x 2 28 F 2 Table 11 1 2 If such an instrument is unavailable the condenser can be checked by replacing with a new one the generator performs good with new condenser the cause of trouble is defect in original condenser 11 1 2 CHECKING STATOR COUPLER STATOR 1 Remove control panel and disconnect stator wires at the connectors 2 Measure the resistance between terminals on stator leads See Fig 11 2 Refer to Table 9 1 for normal resistance If stator is faulty replace it with a new one Fig 11 2 _ 53 3 Check the insulation resistance between 518 tor core and each stator lead using a Dr Robin generator tester in megger tester mode or a megger tester Fig 11 3 If insulation is bad replace stator with a new one 11 1 3 CHECKING ROTOR 1 Remove rear cover and stator 2 Using a Dr Robin or a circuit tester measure the resistance of the field coil at the terminals 0 MODEL RGV2800 RGV4100 RGV6100 RESISTANCE 1750 1770 1 600 Table 11 2 NOTE Because a dio
24. lt e 20V i I L 2 0Blu 1 m 1 REC3 525 Voltmeter 888 I 2965 Auxiliary 2 Winding 5 120 240 i4 condenser 9 I 20Y 0 75Grn Engin switch c 1 25Brn Diode stack Assy 1 250r Circuit breaker DC output 1 25Brn terminal 0 75 0 75Y ENGINE lt 1 0 75W 9 02 i Solenoid 5 5 oc 0 75Blu 0 75Blu i 0 75Grn W Fuel cut solenoid 0 75BIK W 0 75Grn W 0 75Blkw Charge coil Ignition coil Spark plug Oil sensor RGV6101 Electric starter model GENERATOR CONTROL BOX Ground terminal ENGINE Sarge absorber No fuse breaker posh TT v 2 0Blk Full power 0 75W 0 75W Idle control switch 9 0 75 0 75Blu 0 75Blu 0 75BIk W 0 75Grn W 0 75Grn W 0 75 0 75Grn I 3 2 switch 52 85305 120 240 88 Z 285 4 25 5 i lt 7 tS 2 0Blu A pi 85 38 Voltmeter 1 sas st ro HeH w 5925 Auxiliary 1 lt Winding S 1 120 240V for condenser 85 ge lt 28 25 2 0 5 5 ial 8
25. motor is 0 7 and power consumption will be 400 0 72 570 W When this motor is used for a motor driven tool the capacity of the generator should be multiple of 570 W by 1 2 to 3 as explained in the Item 3 570 W x 1 2 to 3 684 W to 1710 W RGV4101 RGV6101 Incandesent lamp heater etc 3600 W 4800 W Fluorescent lamp Motor driven tool approx approx general porpose 1800 W 2400 W approx approx Mercury lamp etc 1400 W 1600 W approx approx Pump compressor etc 850 W 1100 W Table 3 1 75 NOTES Wiring between generator and electrical appliances 1 Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load electrical appliance If the input current is higher than the allowable current of the cable used the cable will become excessively heated and deteriorate the insulation possibly burning it out Table 7 2 shows cables and their allowable currents for your reference 2 Cable length If a long cable is used a voltage drop occurs due to the increased resistance in the conductors de creasing the input voltage to the load electrical product As a result the load can be damaged Table 7 2 shows voltage drops per 100 meters of cable Sectional Allowable Resistance Voltage drop per 100 m wire element Table 3 2 xRxIxL Voltage drop indicates as V R means resistance Q 100 m on the above table
26. output is used to charge a large m capacity battery or an over discharged battery excessive current flow causing as Fig 11 10 11 4 3 CHECK THE DC FUSE Check the fuse in the fuse holder If the fuse is blown check for the cause of fuse PUSE blowing and then replace with a new one FUSE 10A NOTE If the DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing fuse blow Fig 11 11 11 4 4 CHECK THE WIRING Check all the wires to be connected correctly 11 4 5 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode rectifier with a circuit tester Refer to Section 9 7 DIODE RECTIFIER for the checking procedure Fig 11 12 57 11 4 6 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester MODEL SPECIFICATION RGV2800 120V 120V 240V RGV4100 120V 120V 240V RGV6100 120V 120V 240V Table 11 3 the resistance reading is much larger or smaller than the specified value the DC coil of the stator is faulty Replace stator with a new one 11 5 IDLE CONTROL 11 5 1 ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS APPLIED 1 Inspect the solenoid bracket Check the bend angle of solenoid bracket If the bracket is dis Paks torted correct the angle with proper tool 2 Check the wattage of lo
27. 0 280 kg cm 15 8 20 2 ft lb 2 Tighten the bolts to fix the muffler to the rear cover M8 x 20 mm bolt and washer Ass y 2 pcs for RGV4100 Tightening torque 18 6 24 5 N m 190 250 kg cm 13 7 18 0 ft Ib EARTH CABLE Fig 10 28 MUFFLER COVER 1 GASKET MUFFLER MUFFLER COVER 2 MUFFLER BRACKET for RV ZEDD 1 00 Fig 10 29 49 3 2800 6100 Tighten the two bolts fix the muffler bracket to the front cover cover and then the two bolts for the muffler to the muffler bracket 8 x 20 mm bolt and washer Ass y 4 pcs for RGV2800 and 6100 Tightening torque 18 6 24 5 N m 190 250 kg cm 13 7 18 0 ft lb 10 3 8 FUEL TANK 1 For RGV2600 and RGV4100 only FUEL GAUGE Attach the fuel strainer to the bottom of the 2 FUELTANK fuel tank Screw the fuel strainer all the way B and return one to two turns and then lock it with the lock nut m FUEL FILTER For RGV6000 only Attach the fuel strainer to the frame 7 4 9 6 9 50 70 kg cm uS dl 3 6 5 0 ft Ib is 7 p in 2 Mount the fuel tank on the frame with rubber washers between the tank and the frame aci FUEL STRAINER M6 20 mm bolt black 4 pcs pu Rubber washer 4 pcs E
28. 2 times of the power consumption of the load Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times lager than their running wattage Example rated 250 W electric drill requires 400 W generator to start it NOTE1 a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps NOTE2 Nominal wattage of the fluorscent lamp generally indicates the wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption effi ciency should be taken into account as explained 5 on the following page 9 Mercury lamps with a smaller power factor Loads for mercury lamps require 2 to 3 times the indicated wattage during start up Example 400 W mercury lamp requires 800 W to 1200 W power source to be turned on rated 3000 W generator can power two or three 400 W mercury lamps 4 Initially loaded motor driven appliances such as water pumps compressors etc These appliances require large starting wattage which is 3 to 5 times of running wattage Example A rated 900 W compressor requires a 4500 W generator to drive it 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 con sumption so that the excess power
29. 519 9791 jen u 009 dH 8 0096 dH 9 indino uo no ZEGE 62 5 29 02 Ul Saz seH3 2 ed 0 9 d 959090002 M 001 V 8 ZL indino 01 140804 VO SLA O OE AOvZ AOZ I VO SL VO O I wenn 2 0096 jndino 2 M 0017 indino zH 09 ou nb 1ug eseug oq z Bunioxg Jes ssejusnig ed L0L9ADH LOLEAOH I9polN 64 2 GENERATOR TROUBLESHOOTING 2 1 NO AC OUTPUT 2 1 1 CHECKING CONDENSER 1 Check the capacity of condensers using a Dr Robin generator tester in capacitance meter mode NOTE Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance or the accurate reading cannot be obtained NORMAL CAPACITY OF CONDENSER RGV4101 RGV6101 20 Fx2 F x2 Table 2 1 Y 2 If such an instrument is unavailable the denser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect original con
30. 8 13 7 N m 120 140 kg cm 8 7 10 1 ft Ib 10 3 2 ROTOR 1 Wipe off oil grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft 2 Mount the rotor to the engine shaft Tighten the through bolt Apply a wrench on the through bolt and hit wrench handle clockwise with a hammer to tighten If an impact wrench is available use it Tightening torque Tightening torque 11 3 13 2 N m RGV2800 115 135 kg cm 8 7 10 8 ft Ib Fig 10 22 22 5 24 5 N m 230 250 kg cm 16 6 19 5 ft lb RGV4100 RGV6100 46 10 3 3 STATOR 1 Put the stator in the cover setting the four grooves on the side of stator with thread holes of the rear cover 2 Attach the stator cover around the stator 10 3 4 REAR COVER 1 Put the rear cover with stator over the rotor Tap on the rear cover evenly with a plastic hammer tto press the rotor bearing into the rear cover 2 Fix the rear cover to the adaptor with four bolts spring washers and washers RGV6100 M6 160 mm 4 pcs M6 spring washer 4 pcs M6 washer 4 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb RGV2800 and 4100 M6 x 110 mm bolt 4 pcs M6 spring washer 4 pcs Tightening torque 4 5 5 9 N m 50 60 kg cm 3 6 4 3 ft lb 3 Attach the bushing over the lead wire drawn out from the rear cover
31. ER SPARK PLUG ENGINE EMISSION LABEL MUFFLER OIL DRAIN PLUG OILGAUGE FILLER 4 2 CONTROL PANEL RGV2800 U S A 60Hz 120V NEMA RECEPTACLE AC OUTPUT 204 ENGINE rS 65 0 4 ONLY DC OUTPUT ON c OFF DC BREAKER BREAKER RGV4100 U S A 60 2 120 240 NEMA RECEPTACLE 120 eS 30A FULL POWER SWITCH 120 240V 120V Oz 540 cA E AC MAX 20A V METER ENGINE EM M ON orr 2 CONTROL OFF 2 9 9 0 OFF BATTERY CHARGE ONLY DC OUTPUT DC BREAKER AC BREAKER e e RGV6100 U S A 60 2 120 240 NEMA RECEPTACLE e 120V FULL POWER SWITCH 1207 240V V METER ENGINE SWITCH 120V 120V 240V 1353 Ca
32. SERVICE MANUAL Models RGV2800 RGV4100 RGV6100 Generators PUB GS1277 5 Section Title Page 1 SPECIFICATIONS 00 1 2 5 J 3 0 5 3 1 BRUSHLESS ALTERNATOR 2 8 5 3 2 CONDENSER TYPE VOLTAGE REGULATOR 5 SOLI SENSOR es I A ED 5 3 4 QUIET OPERATION aan ayak 5 3 5 NOWBADIQUNOILSE d ta te is 5 9 5 LARGE PUBL TANK te E eects 5 3 7 RUGGED TUBULAR FRAME vo stades 5 3 8 COMPACT AND LIGHT WEIGHT cp exa 5 3 9 MINIMAL 6 3 10 LONG LIFE T 6 4 GENERAL DESCRIPTION U 7 4 1 EXTERNAL VIEW kee ncn e Bs b lo ra PC aa 7 4 2 CONTROL PANED e tus 8 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER 9 5 CONSTRUCTION AND FUNCTION
33. ad applied to the gen erator If the generator is loaded over the rated wattage the engine speed can not be in Do ES creased Most induction loads such as elec motor electric tools or welding machine require three to five times large wattage of their ratings at starting This starting wattage must not exceed the rated output of the generator Fig 11 13 SPEED CONTROL LEVER_ 3 Check the slow set r p m The normal idling speed by the IDLE CON TROL is as follows RGV2800 1900 to 2100 r p m RGV4100 6100 2000 to 2200 r p m The above speed setting is for cold engine con dition If the engine speed is out of adjusting range of the adjusting screw move the sole noid backward ADJUSTING SCREW Fig 11 14 58 4 Check the wiring through 207 on the IDLE CONTROL UNIT Single Voltage Type Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT Dual Voltage Type 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 b Checking the IDLE CONTROL UNIT Check the resistance between five leads of IDLE CONTROL UNIT with circuit tester Terminal number of the IDEL CONTROL UNIT Fig 11 16A Circuit tester with battery power source 1 5 V
34. air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re move it I AIR OUTLET ENGINE AIR INLET ENGINE AIR OUTLET ALTERNATOR AIR INLET ALTERNATOR Fig 2 8 2 3 5 CHECK THE INSULATION OF THE GENERATOR Stop the engine Measure the insulation resistance between the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1 dis assemble the generator and check the insulation resistance of the stator rotor and the live parts in the control box Any part where the insulation resistance is less than 1 the insulation is faulty and may cause electric leakage Replace the faulty part Fig 2 9 _ 68 2 4 DC OUTPUT 2 4 1 CHECK THE AC OUTPUT Check the generator by following Step 2 1 1 through Step 2 1 3 2 4 2 CHECK THE DC BREAKER If the DC breaker turned off while charging a bat tery check the cables for short circuit or connec tion in reverse polarity before resetting it on NOTE If the DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing Fig 2 10 2 4 3 CHECK THE DC FUSE Check the fuse in the fuse holder If the fuse is blown check for the cause of fuse blowing then replace with new FUSE 10 NOTE If th
35. anner or box wrench MUFFLER BRACKET Tor Fig 10 8 40 Description Remarks Tool Pipe Frame 1 For RGV6100 Remove the fuel strainer from the frame 2 Remove the nuts which are fixing engine and alternator to the mount rubbers See Fig 10 9 10 mm spanner 12 mm spanner frame 3 Using a chain block sling up the engine and alternator and dismount from the Remove air cleaner cover for dismounting ALTERNATOR F3 SIDE 2pcs FUEL STRAINER For RGV6100 MOUNT RUBBER ENGINE SIDE 2 pcs Fig 10 9 4 Remove the mount rubbers from the frame Loosen the nuts on the bottom side of the frame See Fig 10 10 M8 flange nut 4 pcs N SPACER 1 lt gt 5 SCREW 1 Ro EARTH a gt CORD 55 M8 FLANGE NUT 2pcs 41 Fig 10 10 M8 FLANGE NUT 2 pcs 12 mm spanner or Socket wrench RUBBER 2 pcs Description Remarks Tool 5 Rear cover 1 Remove the end cover See Fig 10 11 10 mm spanner or Except RGV6100 box wrench bolt 3 pcs 2 Remove the four bolts which fasten the 10 mm spanner or rear cover to the front cover See Fig bo
36. ar may lead to malfunction or breakdown 2 The sensor is not interchangeable from engine to engine because the sensor is to be exclusively installed individually in each engine employed 2 Mounting and wiring of oil sensor unit CD Although this has been designed to have enough antinoise properties in practical use do not route the sensor wirings in the vicinity of noise generating sources such as ignition plugs or high voltage cords This may cause malfunction or breakdown 2 Since capacity of power source is limited current flown in the electronic circuit of the sensor is kept as low as possible Be sure to use terminals with a high contact reliability of more than that of tinned terminals 3 Operation of oil sensor CD If operating with the engine kept tilted oil surface inside of the engine varies and the correct oil level can not to be detected which in turn obstructs the preventing function of engine seizure Operate the engine by keeping it level 2 When starting the engine with an insufficient oil in the crankcase engine starts once then it stops automatically after it runs for 5 seconds 8 When the engine has been stopped by the oil sensor voltage remained in the electronic circuit prevents the sensor from being restarted for 3 seconds after the engine stop Try to restart the engine after 3 seconds or more 21 6 SAFETY PRECAUTIONS Use extreme caution near fuel A constant danger of explosion or fire exist
37. 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 of e 5 RECEPTACLE Fig 9 2 Fig 9 2B 9 3 No FUSE BREAKER Check continuity between each of two terminals at the rear of the no fuse breaker while it is mounted on the control panel Normally there is continuity between each of the two when the no fuse breaker is on while there is no continuity when the no fuse breaker is off NO FUSE BREAKER Fig 9 3 32 9 4 STATOR Disengage connectors on the wires from stator gt check the resistance between wires with Dr Robin or a circuit tester referring to the fol Ee lowing table Fig 9 4 Specification AC Winding 4 MODEL inding White Red Black Blue Yellow Yellow RGV2800 120 V 120 V 240 V Table 9 1 NOTE If the circuit tester is not sufficiently accurate it not show the values given may give erroneous readings Erroneous readings will also occur when there is a wide variation of resis tance among coil windings or when measurement is performed at ambient temperatures differ ent from 20 C 68 F 33 9 5 ASSEMBLY 1 Using a Dr Rob
38. by the GFCI indicating that the device is functioning properly 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 qualified electrician for checking generator and the appliances 5 2 8 CONNECTING DOMESTIC CIRCUITS HOUSE WIRING WARNING Robin generators are a neutral ungrounded type If a generator is to be connected to residential or commercial power lines such as a stand by power source during power outage all connections must be made by a licensed electrician Failure in connection may result in death personal injury damage to generator damage to appli ances damage to the building s wiring or fire a When contnecting a Robin generator to a house wiring generator output power must be taken from the 240V 4P receptacle b Install a transfer switch A transfer switch must be installed to transfer the load from the commercial power source to the generator This switch is necessary to prevent accidents caused by the recovery from power outage Use a transfer switch of the correct capacity Install transfer switch between the meter and the fuse or AC breaker box Caution If the neutral wire of house wiring is grounded be sure to ground the ground terminal of the generator Otherwise an electric shock may occur to the op
39. de is soldered to the coil ends at the terminals resistance may be mea sured only when tester probes touch the termi nals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity Remedy If the resistance is not normal replace rotor with a new one 54 3 Measure the insulation across one of the sol dered terminals of the rotor and the core Fig 11 6 If insulation is bad replace rotor with a new one u 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW SBEEDGONTRGLAEVER 11 2 1 CHECKING ENGINE SPEED 2 If the engine speed is too high or too low adjust it to the rated r p m How to adjust engine r p m Loosen the lock nut on the adjusting screw Turn the adjusting screw clockwise to decrease engine speed or counterclockwise to increase ERE engine speed gt ADJUSTING SCREW _ i RGV2800 4100 Normal engine speed at no load 3700 to 3750 rpm 11 2 2 CHECKING CONDENSER Check condenser referring to Step 11 1 1 RGV6100 11 2 3 CHECKING STATOR Check stator referring to Step 11 1 2 Fig 11 7 11 2 4 CHECKING ROTOR Check rotor referring to Step 11 1 3 55 11 3 VOLTAGE IS NORMAL NO LOAD BUT THE LOAD CANNOT BE APPLIED 11 3 1 CHECK THE ENGINE SPEED If the engine speed is low adjust it to the rated r p m Refer to Step 11 2 1 for engine speed adjustmen
40. denser CONDENSER Fig 2 1 2 1 2 CHECKING STATOR 1 Remove control panel and disconnect stator wires at the connectors COUPLER STATOR 2 Measure the resistance between terminals on stator leads See Fig 2 2 Refer to Table 2 2 for normal resistance If stator is faulty replace it with a new one Specification AC Winding MODEL inging Voltage White Red Black Blue Yellow Yellow E 20 Table 2 2 65 3 Check the insulation resistance between 518 tor core and each stator lead using a Dr Robin generator tester in megger tester mode or a megger tester Fig 2 3 If insulation is bad replace stator with a new one TSS Fig 2 3 2 1 3 CHECKING ROTOR 1 Remove rear cover and stator SURGE ABSORBER V NN NN 2 Using a Dr Robin or a circuit tester measure NSS MO QU NN the resistance of the field coil at the terminals Fig 2 4 0 MODEL RGV4101 RGV6101 RESISTANCE 4 85 Q Table 2 3 NOTE Because a diode is soldered to the coil ends at the terminals resistance may be mea sured only when tester probes touch the termi nals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity Remedy If the resistance is not normal replace rotor with a new one 66
41. densers and condenser coil regulate the output voltage 5 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action Fig 5 3 Fig 5 4 A diode rectifier and surge absorber is mounted inside of the insulator DIODE RECTIFIER SURGE ABSORBER 5 2 4 NO FUSE BREAKER The no fuse breaker protects the generator from getting damage by overloading or short circuit in the appliance Table 5 1 shows the capacity of no fuse breaker by each spec and their object of protection MODEL SPECIFICATION NO FUSE BREAKER OBJECT or PROTECTION RGV2800 60 Hz 120V Total output amperage 5 2 5 E RGV4100 60 Hz 120 V 240V 15 A 2 Pole 2 Element Total output amperage 20 A 2 Pole 2 Element Total output amperage RGV6100 60 Hz 120 V 240V 30A Output from 30A receptacle Table 5 1 5 2 5 DC CIRCUIT BREAKER The 10 ampere DC circuit breaker mounted on EN the control panel protects whole DC circuit from E getting damage by overload or short circuit j x i EY Fig 5 6 5 2 6 RECEPTACLE and AC PLUG STD SPEC These are used for taking AC output power from the generator A total of six kinds of receptacles each varying in rated voltage and current f
42. e DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing fuse blow Fig 2 11 2 4 4 CHECK THE WIRING Check all the wires to be connected correctly 2 4 5 CHECK THE DIODE RECTIFIER Remove the control panel and check the diode rectifier with a circuit tester Fig 2 12 69 DIODE RECTIFIER Brown Brown White Orange Orange Brown Brown Brown Brown White CIRCUIT TESTER Fig 2 18 Fig e 14 Circuit inside of the diode rectifiers is as shown in Fig 2 13 Check continuity between each terminal by using a circuit tester as shown in Fig 2 14 The rectifier is normal when condtinuity is as follows Checking table for analogue circuit tester Apply black minus needle of the circuit tester Analogue circuit tester Bon No continuity No continuity Continuity Apply red plus needle of Brown No continuity No continuity Continuity the circuit tester Continuity Continuity ERE Continuity Brown White No continuity No continuity No continuity Table 2 4 1 Checking table for digital circuit tester Apply red plus needle of the circuit tester Digital circuit tester continuity continuity Continuity No continuity Continuity of the circuit tester Continuity Continuity Brown White No continuity No
43. e 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 Rated voltage 120 V 240 V Voltage range 108 132 V 216 264 V Table 8 2 8 3 DC OUTPUT MEASURING DC Terminal Fig 8 9 Measurement of DC output is executed with the switch turned ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal NOTE battery is connected as a load to the generator the DC output voltage will increase by approximately 1 to 2 V Therefore carefully observe the electrolyte level and do not overcharge the battery 29 8 4 MEASURING INSULATION RESISTANCE Use a Dr Robin generator tester megger tester mode or use a megger tester to check the insula tion resistance Connect a megger tester to one of receptacle output terminals and the ground ter minal then measure the insulation resistance An insulation resistance of 1 megohm or more is nor mal The original insulation resistance at the time of shipment from the factory is 10 megohm or more If it is less than 1 megohm disassemble the generator and measure the insulation resis tance of the stator rotor and control panel indi vidually NOTE
44. e condenser coil the small voltage at the condenser coil generates a minute current which flows through the condenser coil At this time a small flux is produced with which the magnetic force at the rotor s magnetic pole is intensified When this mag netic force is intensified the respective voltages in the main coil and condenser coil rise up As the current increases the magnetic flux at the rotor s magnetic pole increases further Thus the volt ages at the main coil and condenser coil keep rising by repeating this process 3 As AC current flows through the condenser coil the density of magnetic flux in the rotor changes This change of magnetic flux induces AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies this AC voltage into DC Thus a DC current b flows through the field coil and magne tizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 3000 to 3300 rpm the current in the condenser coil and field coil increases rapidly This acts to stabilize the output voltage of each coils If generator speed further increases to the rated value the generator output voltage will reach to the rated value 5 3 2 VOLTAGE FLUCTUATIONS UNDER LOAD When the output current flows through the main coil to the appliance a magnetic flux is produced and serves to increase current in the condenser coil When current increases the density of mag
45. e input voltage to the load electrical product As a result the load can be damaged Table 7 2 shows voltage drops per 100 meters of cable Sectional Allowable No Resistance Voltage drop per 100 m wire element Table 7 2 Voltage drop indicates as R means resistance Q 100 m on the above table I means electric current through the wire A L means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools 25 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 Dr ROBIN GENERATOR TESTER The Dr Robin generator tester is exclusively designed for fast easy diagnosis and repair of Robin generators The Dr Robin has the follow ing features 1 Functions of voltmeter frequency meter megger tester capacitance meter and circuit tester are combined in one unit 2 Fast and easy readout by digital indicator 3 Built in automatic battery checker indicates the time to change batteries 4 Tester and accessories are installed in a handy sturdy case for easy carrying SPECIFICATIONS Range e Range Condenser Capacity 10 to 100 u F 2 x 6F44P 006P Dry Cell Battery Test leads with needle probes 1 set Test leads with jack plugs 1 set Table 8 1 The Dr Robin generator tester can be ordered from Robin generator distributors by the following
46. ensor The oil level to be detected is determined by the length of elec trodes and their mounting positions with the engine 5 4 3 HOW IT OPERATES Power supply The sensor makes use of a part of primary power source for ignition of the engine igniter to drive the sensor circuit Power to the sensor can usually be derived from the stop button by branching wires out 19 Judgement of oil level When sufficient oil is in the crankcase both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes The sensor judges that oil in the crankcase is sufficient When oil level goes down and the inner electrode is exposed to the air due to consumption of oil no current flow between the electrodes as air is considered to be electrically nonconductive The sensor in this case judges that oil is insufficient Decision of oil shortage Oil level at the electrodes may go down momentarily probably due to the engine being slanted or affected by vibration even if a sufficient oil is in the crankcase For that reason the sensor has an electronic timer circuit to prevent it from interpreting as short of oil when amount of oil is sufficient The sensor has been designed so that the engine is to be stopped only when oil shortage is detected for 5 seconds uninter rupted The timer employs an integration circuit and it is to be reset when the inner electrode is soaked in the oil again before the sensor decid
47. erator UTILITY HIGH LINE s EX mm I 4 I 22 240V AIR RECEPTACLE m x dE a pem 51 TRANSFER SWITCH aa Lss 1 neq Fig 5 9 14 Utility high line House circuit breaker 120V appliance 240V 120V appliance appliance Meter box Transfer switch 240V 4P Receptacle Fig 5 10 c Operating the generator Set the full power switch to 120V 240V side Turn the house AC breaker off before starting the generator Start the generator and warm it up Turn the house AC breaker on Caution Do not start the generator with electrical appliance s connected and with their switches on Otherwise the appliance s may be damaged by the surge voltage at starting 15 5 3 GENERATOR FEHMAHENT FQR INMAL FIELD TEIL I ROTOR 5 MAIN COIL RECEFTACLE EIC EN APPLIANCE i gt CE CONDENSER COIL ho SURGE ABSORBER i DIODE CONDENSER 5 3 1 GENERATION of NO LOAD VOLTAGE 1 When the generator starts running the permanent magnet built in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator 2 As one or two condensers are connected to th
48. es it as oil shortage The oil level where the sensor decides as oil shortage when oil level goes down gradually is called threshold level Automatic stop of engine When the sensor decides as oil shortage it makes the engine to stop running automatically for protec tion of engine Once the stopping circuit is activated it keeps functioning until it confirms that the engine has made a complete stop then the circuit stops functioning automatically 5 4 4 BLOCK DIAGRAM OF THE CIRCUIT Igniter Power circuit Detection AE Stopping Inner pole circuit Deley circuit circuit Cil Outer pole Engine ground Fig 5 16 D Power circuit This rectifies a part of power to the igniter and regulates it to supply the stabi lized power to necessary circuits 20 2 Detection circuit This detects quantity of oil sufficient or not according to difference of electric resistance across inner and outer electrodes 3 Delay circuit This his prevents the sensor from making an unnecessary stop of the engine by momentary lowering of the oil level due to the engine being slanted or affected by vibration in spite of sufficient oil in the crankcase 4 Stopping circuit This automatically stops the engine running 5 4 5 CAUTIONS TO BE TAKEN ON HANDLING THE SENSOR 1 Oil sensor unit CD Be sure not to damage each wire Broken or short circuited power supply wires and or a ground ing wire in particul
49. for the detail of checking procedure for the components in the front panel 10 4 2 DISASSEMBLY 1 Remove the control panel from the front panel screw 6 pcs RGV2800 4100 screw 7 pcs RGV6100 2 Disconnect the connectors on the wires to detach the control panel and front panel 3 Remove the condensers and diode rectifier from the front panel 4 After disconnecting individual wires remove the control panel components NOTE Full power switch and pilot lamp have their wires soldered Unsolder them to remove those parts if necessary 51 10 4 3 REASSEMBLY 1 Install the receptacles no fuse breaker terminals switches etc on the control panel and wire them NOTE Circuit diagrams are shown in Section 12 Colored wires are used for easy identification and are of the correct capacity and size Use heat resistant type wires permissible temperature range 75 or over in the specified gauge shown in the circuit diagrams 2 Install condensers and diode rectifier into the front panel 3 Connect the wires of control panel components and front panel 4 Attach the control panel to the front panel M4 screw 6 pcs RGV2800 RGV4100 M4 screw 7 pcs RGV6100 Tightening torque 1 2 1 5 N m 12 15 kg cm 8 7 10 9 ft Ib 52 11 TROUBLESHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING CONDENSER 1 Check the capacity of condensers using a Dr Robin generator tester
50. generated by the generator can be used for other electrical appliances NOTE Motor driven appliances mentioned in items 3 4 vary in their required motor starting power depending on the kind of motor and start up load If it is difficult to determine the optimum generator capacity select a generator with a larger capacity _ 74 5 Appliances without indication as to power consumption Some appliances have no indication as to power consumption but instead the work load output is indicated In such a case power consumption is to be worked out according to the numerical formula mentioned below Output of electrical li Power consumpition Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 6 to 0 75 The smaller the motor the Fluorescent lamp 0 7 to 0 8 lower the efficiency Example 1 A 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 72 57W As explained in Item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get the figure of the neces sary capacity of a generator In other words a generator with a rated output of 1000W capacity can light nine to fourteen 40 W fluorescent lamps Example 2 Generally speaking a 400 W motor means that its work load is 400 W Efficiency of this
51. iL o 1 2 080 i w 1H 654 52 5 Du 85 s SRN 8 5 555 output Sos x r voltmeter PB 588 receptacle AMEN de i 120 240 8 Winding o 120 240V 7 4 S 1 0758 5 condenser 9 5 29 5 2 0W 1200 o o 1 25 Oil sensor 1 13 8 CZ 0 75BIk 4 5 0 75Grn Y 1 s 1 257 9 e 2 0Grn 2 1 25Brn Diode stack 5 i A Assy 5 3 7 9 1 250 lt Circuit breaker i S 1 Y DC output T C 1 25Brn terminal o 25Brn W n Earth Ground terminal _ 61 RGV6100 U S A 50Hz 120V 240V NEMA RECEPTACLE GENERATOR CONTROL BOX P 0 ENGINE ___ 0 Auto idle switch 1 2754 6 079 m contro 1 HI 0 75Blu LXL 075W unit 9 0 75Blu Solenoid x BB P rn Fuel _ 0 75Grn W 59 cut unit 7 0 75Blk 4 4L 0 75Grn
52. in or a circuit tester measure the resistance of the field coil at the terminals MODEL RGV2800 RGV4100 RGV6100 RESISTANCE 1750 1770 Table 9 2 NOTE 1 Because a diode is soldered to the coil ends at terminals resistance be measured only when tester probes touche the terminals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity NOTE 2 If the circuit tester is not sufficiently accurate it may not show the values given and may give er roneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 20 C 68 F 9 6 CONDENSER Use a Dr Robin in capacitance meter mode to check the capacity of condensers 7 4 CONDENSER 1 CONDENSER Fig 9 6A RGV2800 Fig 9 6B Type RGV4100 RGV6100 NOTE Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance or the accurate reading cannot be obtained _ 34 NORMAL CONDENSER 00 0 0 Table 3 If such an instrument is unavailable the condenser be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 9 7 DIODE RECTIFIER DIODE RECTIFIER
53. ing wires green yellow to the unpainted thread hole of the frame base plate using a 5 mm brass screw 3 Install the engine and alternator assembly into Tightening torque the frame Put the engine and alternator as sembly into the frame from the side of it 11 8 13 7 Tighten the nuts over the mount rubber bolts 120 140 8 7 10 8 ft lb to fix M8 nuts 4 pcs NOTE Remove the air cleaner cover for easier installation NOTE When tightening the nuts slightly lift the engine and alternator assembly so that the weight is not applied to the mount rubbers 48 4 Fasten the other earth cable with 5 mm termi nal to the unpainted bolt hole on the frame See Fig 10 28 10 3 7 MUFFLER and MUFFLER COVER 1 Temporarily fix the muffler bracket to either the rear or front covers for RGV6100 or RGV2800 8 x 20 mm bolt and washer Assy 2 pcs 2 Attach the muffler cover 1 and the muffler cover 2 to the muffler M6 x 10 mm bolt and washer Ass y 8 pcs Tightening torque 7 9 9 8 N m 80 100 kg cm 5 8 7 2 ft Ib 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 for the muffler first Use the spring washers for RGV4100 and RGV6100 8 mm stainless nut 2 pcs 8 mm spring washer 2 pcs for RGV4100 and RGV6100 only Tightening torque 21 6 27 4 N m 22
54. mbers of the transfer switches and of the plastic box to store them are as shown in 7 Table 6 1 Table 6 1 Be sure to check and remedy the cause circuit breaker tripping before resetting it on CAUTION If the circuit breaker tripped off as a result of using an electrical appliance the cause can be an overload or a short circuit In such a case stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring _ 22 _ 7 RANGE APPLICATIONS Generally the power rating of an electrical appliance indicates the amount of work that can be done by it The electric power required for operating an electrical appliance is not always equal to the output watt age of the appliance The electrical appliances generally have a label showing their rated voltage fre quency and power consumption input wattage The power consumption of an electrical appliance is the power necessary for using it When using a generator for operating an electrical appliance the power factor and starting wattage must be taken into consideration In order to determine the right size generator it is necessary to add the total wattage of all appliances to be connected to the unit Refer to the followings to calculate the power consumption of each appliance or equipment by its type 1 Incandescent lamp heater etc with a power factor of 1 0 Total power consumption must be equal to or less than the rated output of
55. netic flux across the rotor core rises As a result the current flowing in the field coil increases and the genera tor output voltage is prevented from decreasing _ 16 5 3 3 FULL POWER SWITCH Dual Voltage Type The full power switch is provided for the dual voltage type to take out the full rated power from one receptacle in each voltage 120 24Dv SUM REG 7 1 3 E I la204 T 2407 7 7 Ala Vp We u x 120 Fig 5 12 ED rs lt QU 5 c bn 120 MC S T ee Fig 5 13 Switch LOWER VOLTAGE HIGHER VOLTAGE Position RECEPTACLE RECEPTACLE 120 240 V Half of rated output Rated output Table 5 3 17 Two main coils are wound over stator core Each main coil outputs half the rated power at the lower voltage 120V These main coils are wound to be in the same phase The full power switch reconnects these main coils in parallel or in series Fig 5 12 shows a circuit diagram When the full power switch is set for single lower voltage indication 120V the switch position is as indicated by the lower solid line in the diagram Fig 5 13 is a simplified representation of this circuit showing the two main coils connected in parallel In this case the higher voltage 240V at Rec 3 cannot be taken out Rec 2 for the lower voltage can output up to the rated power up to 30A if
56. no change with the passage time it does not use any moving part Merits due to introduction of electrical conductivity detection are as follows D It has resistance to mechanical shocks and property of no change with the passage of time as sensing element consists simply of electrodes having no moving parts 2 At the same time it is capable of detecting the oil level stably as it is not influenced by engine vibrations 3 No error occurs due to foam and flow of the oil 4 Influence against the ignition system or the electronics units can be neglected because an electric current supplied to the sensor can be decreased 5 4 2 PRINCIPLE OF SENSING OIL LEVEL There is a great difference between electric resistance of air and that of oil Since the resistance of air is far higher than that of oil more electric current passes through the oil than through the air although absolute value of the current is very small The sensor detects this current difference and make use of it The sensor judges the oil quantity by comparing a current flowing across a pair of electrodes inner and outer with the reference in such a way that if a current flows between the electrodes more than the reference sufficient oil is in the crankcase on the other hand if a current flows less than the reference oil is not sufficient Since an electric current is flown to detect oil quantity this is called the electrical conductivity detection type of s
57. nt When results of the checking indicates failure even in one section replace with a new one NOTE 3 Simpson brand analogue testers have the characteristics as same as the digital circuit tester 9 8 OIL SENSOR 1 Disconnect two 2 wires comming from the sensor at the connection i 2 Loosen the sensor to remove it from the gine OIL SENSOR Pe 3 Plug the opening of oil filler hole created after sensor is removed with suitable means such E as oil gauge i 4 Connect the removed wires again with the oil 2 sensor 5 Start the engine with the oil sensor removed Fig 9 9 and confirm if a Engine stops after 5 seconds which is normal or b Engine does not stop after more than 10 seconds which is unusual NOTE The sensor will not operate properly when wire is broken or poorly connected Check the wires for correct connection If it fails to stop within 5 seconds after the wirings have checked the sensor is wrong Replace the sensor with new one 36 10 DISASSEMBLY AND ASSEMBLY 10 1 PREPARATION PRECAUTIONS 1 Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly Tag the disassembled part with the necessary information to facilitate easier and smoother reassembly 2 For more convenience divide the parts into several groups and store them in boxes 3
58. 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 _ 26 8 1 2 INSTRUMENTS 1 VOLTMETER voltmeter is necessary approximate voltage ranges of the voltmeters to used for various types of generators are as follows 150V Type with an output voltage of 110 or 120V 0 to 300V Type with an output voltage of 220 230 or 240V 010 150V 0 to 330V Dual voltage type 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10A 20A 100A 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range 27 4 CIRCUIT TESTER Used for measuring resistance etc 5 MEGGER TESTER Used for measuring generator insulation re sistance Select one with testing voltage range of 500V 6 TACHOMETER Use the contactless type tacho meter Fig 8 7 28 8 2 OUTPUT MEASURING SWITCH gt LOAD i Y VL 2 CO RE 1 i oir puc v m ME vx AC RECEPTACLE x F Wa uf soy OX a Fig 8 8 Us
59. rge fuel tank allows more than 7 to 10 hours of continuous operation which is sufficient for a half day or one day work without refueling 3 7 RUGGED TUBULAR FRAME Full cradle type rugged tubuler frame protects the generator all around 3 8 COMPACT AND LIGHT WEIGHT Newly developed brushless alternator enabled the RGV generators to be very compact in size and light in weight 3 9 MINIMAL MAINTENANCE A brushless alternator release the operator from periodical brush maintenance A trouble free condenser type voltage regulator A drip proof alternator design No fuse circuit breakers An electronic pointless ignition system A dust proof cyclone air cleaner 3 10 LONG LIFE DURABILITY The heavy duty 4 stroke Robin Rro OHV engine and virtually maintenance free brushless alternator ensure greater durability with A brushless alternator with a condenser voltage regulator Full rubber mount in a sturdy tubular frame A forged steel crankshaft supported by two main ball bearings A pointless electronic ignition system cast iron cylinder liner Aforged aluminum connecting rod 4 GENERAL DESCRIPTION 4 1 EXTERNAL VIEW FUEL GAUGE TANK CAP VOLTMETER ENGINE SWITCH FULL POWER SWITCH CHOKE KNOB AC H RECEPTACLE 12 2 AIR CLEANER EARTH TERMINAL DC OUTPUT TERMINAL RECOIL STARTER IDEL CONTROL DC CIRCUIT SWITCH BREAKER OIL SENSOR BREAK
60. rom another are used Each model has at least one receptacle to deliver the rated generator output As many AC plugs as the receptacles each matching the correspond ing receptacle are provided Table 5 2 shows the rated current for each receptacle Be careful not to use the receptacles and AC plugs beyond the specified limits to prevent burning 12 L T Ground Fault _ Circuit Interrupter D up to 204 NEMA 5 20A NEMA 5 20P Receptacle duplex REC1 I 4 Locking Receptacle up to 20A NEMA L14 20R NEMA L14 20P REC2 _ Locking Receptacle up to 30A NEMA L5 30R NEMA L5 30P REC3 Table 5 2 NOTE your generator has receptacles pecu liar to your country Table 5 2 does not ARBIY TWIST Caution The duplex 120V receptacle is protected by a GFCI Ground Fault Circuit Interrupter GFCI shuts off the output current from the duplex 120V receptacle when a ground fault occurs in the generator or the appliance Please note that other receptacles are not pro tected by GFCI Caution To connect the appliance to locking receptacle insert the plug into the re ceptacle and turn it clockwise to lock Fig 5 8 5 2 7 GFCI RECEPTACLE After starting the engine check the GFCI for proper functioning by the following test procedure Push yellow TEST button The red RESET button will pop out exposing the word TRIP Power is now off at the outlets protected
61. s Do not fill the fuel tank while the engine is running Do not smoke or use open flame near the fuel tank Be careful not to spill fuel when refueling If spilt wipe it and let dry before starting the engine 2 Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oily cloth straw and any other inflammables near the generator 3 Do not operate the generator in a room cave or tunnel Always operate in a well ventilated area Otherwise the engine may overheat and also the poisonous carbon monoxide contained in the ex haust gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facilities during use 4 Operate the generator on a level surface If the generator is tilted or moved during use there is a danger of 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 thoroughly dry it before starting Don t pour water over the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leakage and electric shock 6 Do not connect the generator to the commercial power lines This may cause a short circuit or damage to the generator Use a transfer switch Optional parts for connecting with indoor wiring NOTE The parts nu
62. speed 5 creased Most induction loads such elec tric motor or electric tools or welding machine require three to five times large wattage of their ratings at starting This starting wattage must not exceed the rated output of the generator 3 Check the slow set r p m The normal idling speed by the IDLE CON 15 as follows 2000 to 2200 The above speed setting is for cold engine con dition If the engine speed is out of adjusting range of the adjusting screw move the sole noid backward ADJUSTING SCREW Fig 2 16 4 Check the wiring through 207 the IDLE CONTROL UNIT IDEL CONTROL UNIT Single Voltage Type Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT Dual Voltage Type Check that two output wires black wire and red wire from main coils are passing through the 2 on the IDLE CONTROL UNIT in the same direction 5 Checking the IDLE CONTROL UNIT RGV4101 Check the resistance between five leads of IDLE CONTROL UNIT with circuit tester Terminal number of the IDEL CONTROL UNIT Fig 2 18A Fig 2 18B Circuit tester with minus needle of the circuit tester Apply red plus ES Table 2 6 NOTE The resistance readings vary depending on the types of circuit testers The above table shows
63. t 11 3 2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR Refer to Section 7 RANGE OF APPLICATIONS for the wattage of the appliances If the generator is overloaded reduce the load to the rated output of the generator 11 3 3 CHECK THE APPLIANCE FOR TROUBLE If the appliance is faulty repair it 11 3 4 CHECK IF THE ENGINE IS OVERHEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re move it beat AIR OUTLET ALTERNATOR AIR INLET ALTERNATOR Fig 11 8 11 3 5 CHECK THE INSULATION OF THE GENERATOR Stop the engine Measure the insulation resistance between the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1 dis assemble the generator and check the insulation resistance of the stator rotor and the live parts in the control box Refer to Section 8 3 Any part where the insulation resistance is less than 1 the insulation is faulty and may cause electric leakage Replace the faulty part _ 56 11 4 NO DC 11 4 1 CHECK THE OUTPUT Check the generator by following Step 11 1 1 through Step 11 1 3 11 4 2 CHECK THE DC BREAKER If the DC breaker turned off while charging a bat tery check the cables for short circuit or connec tion reverse polarity before resetting it on NOTE If the DC
64. the figure of the neces sary capacity of a generator In other words a generator with a rated output of 1000W capacity can light nine to fourteen 40 W fluorescent lamps Example 2 Generally speaking a 400 W motor means that its work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 400 0 72 570 W When this motor is used for a motor driven tool the capacity of the generator should be multiple of 570 W by 1 2 to 3 as explained in the Item 3 570 W x 1 2 to 3 2 684 W to 1710 W MODEL RGV2800 RGV4100 RGV6100 Frequency Incandesent lamp 2300 W 3600 W 4800 W heater etc Fluorescent lamp Motor approx approx approx driven tool general porpose 1200 W 1800 W 2400 W approx approx approx 800 W 1400 W 1600 W Pump compressor etc 550 W 850 W 1100 W Table 7 1 24 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 insulation possibly burning it out Table 7 2 shows cables and their allowable currents for your reference 2 Cable length If a long cable is used a voltage drop occurs due to the increased resistance in the conductors de creasing th
65. the generator Example A rated 3000W generator can turn thirty 100W incandescent lamps on 2 Fluorescent lamps motor driven tools light electrical appliances etc with a smaller power factor Select a generator with a rated output equivalent to 1 2 to 2 times of the power consumption of the load Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times lager than their running wattage Example A rated 250 W electric drill requires a 400 W generator to start it NOTE If a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps NOTE Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption effi ciency should be taken into account as explained in Item 5 on the following page 3 Mercury lamps with a smaller power factor Loads for mercury lamps require 2 to 3 times the indicated wattage during start up Example A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on A rated 3000 W generator can power two or three 400 W mercury lamps 4 Initially loaded motor driven appliances such as water pumps compressors etc These appliances require large starting wattage which is 3 to 5 times of running wattage Example A rated 900 W compressor requires a 4500 W generator to
66. the rated current is over 30A and Rec 1 can output up to a total of 15A When the full power switch is set for double voltage indication 120V 240V the switch position is as indicated by the upper dotted line in Fig 5 12 Fig 5 14 is a simplified representation of this circuit showing the two main coils connected in series In this case power can be taken simultaneously from the receptacles for the both voltages Rec 3 for the higher voltage can output up to the rated power but Rec 1 and Rec 2 for the lower voltage can output only up to half the rated power each Table 5 4 is a summary of the above explanation Select the proper output voltage by full power switch in accordance with the appliance to be used _ 18 5 4 OIL SENSOR 5 4 1 DESCRIPTION The oil sensor mainly functions to detect posi tion of the surface of engine oil in the crankcase of engines for general use and to stop the en gine automatically when the oil level goes down below the lower limit specified This prevents sei zure of engine from occurring due to insufficient amount of oil in the crankcase lt lt OIL SENSOR Since the sensor has been designed to consume a part of power supplied to the igniter to ener gize its electronics circuit any other external power supply is not necessary so that it can be Fig 5 15 mounted at the oil filler port Introduction of newly developed sensing principle features super durability and
67. the strainer cup to the strainer body Use utmost care about fire hazard Wipe off split fuel thoroughly Do not the filter screen 2 Disconnect rubber pipe from the strainer Loosen the hose clamp on the top of the strainer and pull out the rubber pipe from the strainer Pliers 3 Take off the four bolts and rubber fuel tank and then remove the fuel tank See Fig 10 6 10 mm spanner or box wrench RUBBER PIPE HOSE CLAMP 39 4 RA i 0 5 EUN Sys 4 Fig 10 5 Fig 10 6 Description Remarks Tool 3 Muffler and Muffler cover MLIFFLEH MUFFLER EI MUFFLER COVER 2 1 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 8 20 mm bolt and washer Ass y 2 pcs 8 mm stainless nut 2 pcs 8 mm spring washer 2 pcs for RGV4100 and RGV6100 Muffler gasket 1 pce 12 mm spanner or box wrench 2 Remove the muffler cover 1 and the muffler cover 2 from the muffler 10 mm bolt and washer Ass y 8 pcs See Fig 10 8 10 mm spanner or box wrench 3 Remove the muffler bracket from the rear cover 8 x 20 mm bolt and washer Ass y 2 pcs GASKET 12 mm sp
68. wo leads from SOLENOID Normal Resistance SOLENOID 25 310 If the resistance is larger or smaller than this range SOLENOID is defective Replace with a new one Fig 2 20 _ 73 3 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 watt age of the appliance The electrical appliances generally have a label showing their rated voltage fre quency and power consumption input wattage The power consumption of an electrical appliance is the power necessary for using it When using a generator for operating an electrical appliance the power factor and starting wattage must be taken into consideration In order to determine the right size generator it is necessary to add the total wattage of all appliances to be connected to the unit Refer to the followings to calculate the power consumption of each appliance or equipment by its type 1 Incandescent lamp heater etc with a power factor of 1 0 Total power consumption must be equal to or less than the rated output of the generator Example A rated 3000W generator can turn thirty 100W incandescent lamps on 2 Fluorescent lamps motor driven tools light electrical appliances etc with a smaller power factor Select a generator with a rated output equivalent to 1 2 to
69. working table recoil starter side down 3 Use bolt and oil as a tool for pulling out rotor in the following procedures 1 Pour engine oil into the center hole of rotor shaft Fill with oil to the shaft end See Fig 10 17 2 Prepare a bolt with the following thread size RGV2800 M10 x P 1 5 3 4100 6100 MI2 x P 1 5 3 Apply a few turns of seal tape around the tip of the bolt See Fig 10 18 SEAL TAPE Fig 10 18 44 Part to remove Description Remarks Tool Rotor Front Cover 4 Screw the bolt into the thread of the rotor Do not stick out your shaft face over the rotor 5 Torque the bolt using a socket wrench may jump up on until the rotor comes off loose separation The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft Socket wrench 4 Wipe off oil thoroughly from rotor shaft and enaine PTO shaft Fig 10 19 1 Remove the front cover Loosen the four bolts and remove the front cover M8 x 20mm bolt and washer Ass y 4 pcs Fig 10 20 45 12 mm socket wrench 10 3 ASSEMBLY PROCEDURES 10 3 1 FRONT COVER Attach the front cover to the engine main bearing cover Match the faucet joint and tighten the bolts M8 20 mm bolt 4 pcs 8 spring washer 4 pcs Tightening torque 11
70. x wrench 10 12 bolt 4 pcs v LA r QUT 2 0 ees VU k u i i JP Jc r E gt 1 2 L m Isao UE m poc Ma 1 a ae Hos r JK 1 r UA T 72 E Aden are CHE IP i lt dE 1 5 2 LE Cuv K JE d soe IE 1r T up 5 meem Fig 10 11 Fig 10 12 3 Remove the cover by hitting on the Do not give strong hit Plastic hammer legs of rear cover with a plastic hammer on the boss or legs to loosen ie ili RH COVER Fig 10 13 42 Part to remove Description Remarks Tool Stator 1 Remove the stator cover STATOR STATOR COVER REAR COVER G WASHER 4 pcs Fig 10 14 STATOR COVER COVER BOLT 4 pcs 43 Fig 10 15 Description Remarks Tool Rotor 1 Take off the through bolt Apply a box wrench on the head of through bolt Hit the wrench handle with a hammer counter clockwise to loosen Fig 10 16 Box wrench Plastic hammer 2 Put the engine on the
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