Robin RGV2800 Service manual

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Robin RGV2800 Service manual | Manualzz
SERVICE
MANUALModels
RGV2800,RGV4100,
RGV6100
Generators
PUB-GSI 277
Rev. 4/99
.
CONTENTS
Section
Title
.
Page
.......................................................................................................
...........................................................................................
1 SPECIFICATIONS
2 PERFOMANCE CURVES
3 FEATURES..................................................................................................................
1
3
5
................................................................................
3-2 CONDENSER TYPE VOLTAGE REGULATOR ....................................................
3-3 OIL SENSOR ........................................................................................................
5
5
3-4 QUIET OPERATION .............................................................................................
5
................................................................................................
3-6 LARGEFUELTANK ..............................................................................................
3-7 RUGGED TUBULAR FRAME ...............................................................................
3-8 COMPACT AND LIGHT WEIGHT.........................................................................
5
3-9 MINIMAL MAINTENANCE....................................................................................
6
3-10 LONG-LIFE DURABILITY...................................................................................
6
7
7
.
.
3-1 BRUSHLESS ALTERNATOR
3-5 NO RADIO NOISE
"
..........................................................................................
.
4 GENERAL DESCRIPTION
4-1 EXTERNAL VIEW .................................................................................................
................................................................................................
4-3 LOCATION of SERIAL NUMBERand SPECIFICATION NUMBER ......................
4-2 CONTROL PANEL
5
5
5
5
8
9
.........................................................................
10
5-1CONSTRUCTION ................................................................................................
10
5-2 FUNCTION ..........................................................................................................
10
5-3 GENERATOR OPERATION ................................................................................
16
.
5 CONSTRUCTION AND FUNCTION
5-4 OIL SENSOR
......................................................................................................
.........................................................................................
....................................................................................
..................................................................................
6.SAFETY PRECAUTIONS
7. RANGE OF APPLICATIONS
8. MEASURING PROCEDURES
8-1 MEASURING INSTRUMENTS ...........................................................................
19
22
23
26
26
8-2AC OUTPUT MEASURING................................................................................. 29
8-3 DC OUTPUT MEASURING.................................................................................
29
8-4 MEASURING INSULATION RESISTANCE ........................................................ 30
.
9 CHECKING FUNCTIONALMEMBERS
.
....................................................................
32
9-1 VOLTMETER ....................................................................................................... 32
9-2 AC RECEPTACLES ............................................................................................
32
9-3 NO-FUSE BREAKER
...........................................................................................
32
Section
Title
..............................................................................................................
33
34
9-5 ROTOR ASSEMBLY...........................................................................................
9-6 CONDENSER .....................................................................................................
34
9-7 DIODE RECTIFIER............................................................................................. 35
36
9-8 OIL SENSOR ......................................................................................................
9-4 STATOR
10.DISASSEMBLY AND ASSEMBLY ...........................................................................
10-1PREPARATION and PRECAUTIONS ................................................................
37
37
10-2 DISASSEMBLY PROCEDURES
.......................................................................
37
10-3 ASSEMBLY PROCEDURES.............................................................................
38
10-4 CHECKING, DISASSEMBLY and REASSEMBLY of the FRONT PANEL ........ 46
11 TROUBLESHOOTING
51
11-1 NO AC OUTPUT................................................................................................
53
11-2 AC VOLTAGE IS TOO HIGH OR TOO LOW .....................................................
55
11-3 AC VOLTAGE IS NORMAL AT NO.LOAD,
.
............................................................................................
BUT THE LOAD
CANNOT BE APPLIED .....................................
11-4 NO DC OUTPUT...............................................................................................
56
57
11-5IDLE CONTROL(OPTI0NAL EQUIPMENT) .....................................................
58
.
61
12 WIRING DIAGRAM
.................................................................................................
NOTE :As for the servicing information on engine protion. please referto the €HI 7.2.
EH25-2 and EH34 engine service manual
.
w
1 SPECIFICATIONS
I
0
a
3NI9N3
-
1-
I
Iu
I
Gasoline
A
Automobile
(100
V-8.3
60
,,
Model
....".
".
..
~~~~
I
I
,
~
~~
.....
_"
8.0rpm
HP / 3600
.
liters)
0.32(1.2
U S . gal.
7.0 hours
5.67 U.S.gal. (21.5 liters)
.
....
-.
.
."
x 470 x 630mm)
...
,
."
. . . ,. . .
172 Ibs.(180 Ibs.)* / 78 kg (81.5 kg)"
26.8 x 18.5 x 24.8in.(680
."
....
....
EH34D
40N20A
W)
....
338 cm3 (20.63 cu. in.)
_"
.
Type Condenser
4800 W
W
Hz
RGV6100
RecoilStarterandOptionalElectricStarter
~
_. .-
.
120V/240V
* Electric starter motoris available as option.
-
Starting System
. . . _...Dimensions (L x W x H)
~
Capacity
Oil
-
I
I
_"
"
',....
--
Rated Coutinuous Operation
Fuel Tank Capacity
"
"
Fuel
Output
Rated
Displacement
Model
."
Air-Cooled
Type
4-Cycle,
Overhead
Gasoline
Valve
Engine
Voltage Regulator
~
I
Voltage
tn: : : !
Power Factor
1
..............
Rated Output
Output Maximum
Frequency
Brushless,
Exciting,
TY2-Pole,
Phase
Single
Pe
Self
.
"
12 Output DC
5800
I
.
. .
_
1
I
I
I
2. PERFOMANCE CURVES
(120)
"""""""""""~""
(115)
220
(110)
1
c
I
I
I
I
1
0
-
3-
I
I
I
I
I
I
I
112
4/4
Load
Rated
DC OUTPUT
DC Voltage ................. 12 V
DC Ampere ................ 8.3 A
DC output ................... 100 W
The voltage curve shown in the left indicates the characteristicof DC output when charging a battery.
The voltagemay be decreased by 20% when the resistance load is applied.
NOTE :I f is possible fo use bothDC and AC outputs simultaneouslyup to the rafedoutput in total.
-
4-
-
3. FEATURES
3-1 BRUSHLESS ALTERNATOR
Newly developed brushless alternator eliminates troublesome brush maintenance.
3-2 CONDENSER TYPE VOLTAGE REGULATOR
A trouble free condensertype voltage regulator ensuresa stable voltage underall working conditions.
3-3 OIL SENSOR
Oil sensor automatically shuts
off the engine wheneverthe oil levelfalls down below the lower limit
to
protect the engine from seizure.
3-4QUIET OPERATION
Robin RGV series generator delivers a quiet operation with
:
A large super silent muffler.
A quiet 4-stroke Robin RroOHV engine.
A silent cyclone air cleaner.
3-5 NO RADIO NOISE
Noise suppressor spark plug
is equipped standard to prevent radio frequency interference.
3-6 LARGE FUEL TANK
The large fuel tank allows more than
7 to 10 hours of continuous operation whichis 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 RGV
the generators to be very compact
in size and light
in weight.
-
5-
3-9 MINIMAL MAINTENANCE
* A brushless
alternator release the operator
from periodical brush maintenance.
A trouble free condensertype 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 durabilitywith :
A brushless alternatorwith 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.
A cast-iron cylinder liner.
A forged aluminum connecting rod.
- 6-
4. GENERAL DESCRIPTION
4-1 EXTERNAL VIEW
FUEL
GAUGE
TANK
CAP
VOLTMETER
ENGINE
SWITCH
i
\
\
/
/
FULL POWER
CHOKE KNOB
RECEPTACLE
AIR CLEANER
EARTH
TERMINA
RECOIL STARTER
MUFFLER
L
/
OIL
DRAIN
PLUG
OILGAUGE
(OIL FILLER)
- 7-
4-2 CONTROL PANEL
RGV2800 :U.S.A., 60Hz-120V [NEMA RECEPTACLE]
- 8-
RGV6100 :U.S.A., 60Ht-l20V/240V [NEMA RECEPTACLE]
/-
V METER
0
4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER
Serial number andspecification number are stamped on theLABEL (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.
- 9-
5. CONSTRUCTION AND FUNCTION
5-1 CONSTRUCTION
BALL BEARING
END COVER
\
\
!
\\\
ROTOR COMPLETE
STATOR
COMPLETE
REAR COVER
',\
'\
jl
I
I
\\
\,\
i
/
STATORCOVER
CRANKSHAFT
1
'
i
:! /i
i
I
I
I
I
I
i
//
THROUGH BOLT
I
COVER BOLT
I
I
MOUNT RUBBER
1
\
\
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.
coilwhich
The condensercoil excites the rotor field
coil.
generates AC voltage in the main
Fig. 5-2
-
10-
w
5-2-2 CONDENSER
One or two condensers are installedin the control box and are connected to the condenser coil
of the stator.
These condensers and condensercoil regulate
the output voltage.
Fig. 5-3
5-2-3 ROTOR
The rotor consists
of a laminated silicon steel sheet
core and a
field coilwhich is wound over the core.
DC current in the field coil magnetizes the steel
sheet core.Two permanent magnets are provided
for the primary exciting action.
Fig. 5-4
A diode rectifier and surge absorber
is mounted inside of the insulator.
DIODE
\ RECTIFIER
b
w
&
I
Fig
Fig. 5-58
5-5A
-
11 -
5-2-4 NO-FUSE BREAKER
The no-fuse breaker protects
the generator from getting damage by overloading or short circuit
in the
appliance. Table5-1 shows the capacity of no-fuse breaker by each spec. and their object
of protection.
IpMO~~~"l
SPECIFICATION
NO-FUSE BREAKER
OBJECT or PROTECTION
RGV2800
60 Hz-120V
20 A
Total output amperage
RGV4100
60 HZ-120 V/ 240V
RGV6100
60 HZ-120V/ 240V
15 A (2-Pole, 2-Element) Total
w
output amperage
20 A (PPole, 2-Element) Total output amperage
30 A
I
Output from 30A receptacle
I
Table. 5-7
52-5 DC CIRCUIT BREAKER
The 10 ampere DC circuit breaker mounted on
the control panel protects wholeDC circuit from
getting damageby overload or short circuit.
I
j
j
Fig. 5-6
5-2-6RECEPTACLE and AC PLUG (STD. SPEC.)
These are used for taking
AC output power from the generator.
A total of six kinds
of receptacles, each
varying in rated voltage and current from another, are used. Each model has at least one receptacle to
deliver the rated generator output.
As many AC plugs as the receptacles, each matching the corresponding receptacle, are provided. Table
5-2 shows the rated current for each receptacle.
Be careful not to use
the receptacles andAC plugs beyondthe specified amperage limits to prevent burning.
-
12 -
Style
Description Ampere
b5q
@
Receptacle
AC plug
up to 20A
NEMA 5-20A
NEMA 5-20p
UPt020A
NEMA L14-20R
NEMA L14-20P
GFCl (Ground Fault
Circuit Interrupter)
Receptacle, duplex
(RECi)
Locking Receptacle
Locking Receptacle
NEMA L5-30P NEMA L5-30R
(REC3)
up to 30A
Table. 5-2
NOTE :If your generatorhas receptacles peculiar io your countv, Table 5-2 does not
apply.
Caution :
The duplex 120V receptacle is protected by a
GFCl (Ground Fault Circuit Interrupter).
GFCl shuts off the output current from the
duplex 120V receptacle when a ground fault
occurs in the generator or theappliance.
Please note thatother receptacles arenot protected by GFCI.
t o locking
Caution :To connect the appliance
receptacle, insert the plug
into thereceptacle and turnit clockwise to lock
Fig. 5-8
5-2-7 GFCl RECEPTACLE
After starting the engine, check theGFCl for proper functioning by the following test procedure.
TRIP. Power is now off
Push yellowTEST button, The red RESET buttonwill pop out exposing the word
at the outlets protected by the
GFCI, indicating thatthe device is functioning properly..
If TRIP dose not appear when testing, do not use the generator.
Call a qualified electrician.
To restore power, push RESET button.
WARNING :
If the RESET button popsout during operation, stop the generatorimmediately and call a
qualified electricianfor checkinggenerator and the appliances.
-
13-
5-2-8 CONNECTING TO DOMESTIC CIRCUITS (HOUSE WIRING)
e
WARNING :
All Robin generatorsare a neutral ungrounded type.
If a generator is to be
connected t o residential or commercial powerlines, 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, damageto generator, damageto appliances, damage to thebuilding's wiring orfire.
When contnectinga Robin generatorto a house wiring, generator output power must
be taken from
the 24OV-4P receptacle.
Install a transfer switch.
A transfer switch mustbe installed to transfer the load from the commercial power source
to the
is necessary to prevent accidentscaused by the recovery from power outage.
generator. This switch
or the fuse
Use a transfer switch of the correct capacity. Install transfer switch between the meter and
AC breaker box.
Caution : If the neutral wireof house wiringis grounded, be sureto ground the ground terminalof the
generator. Otherwise an electric shock may occur
to the operator.
Fig. 5-9
-
14-
Fig. 5-10
(c) Operating the generator.
Set the full power switchto 120V/ 240V side.
Turn the houseAC breaker off before startingthe generator.
it up.
Start the generator and warm
Turn the houseAC breaker on.
Caution : Do not start the generator with electrical appliance
(s) connected andwith their switches on.
at starting.
Otherwise the appliance(s)may be damaged by the surge voltage
-
15-
e output
5-3 GENERATOR OPERATION
PERMANENT MAGNET
STATOR
I
L"
"
"
"
I
Fig. 5- 11
5-3-1 GENERATION Of NO-LOAD VOLTAGE
(I) When the generator starts running, the permanent magnet built-in
to the rotor generates
3 to 6V of AC
voltage
stator.
condenser
and
the
wound
coil
in
main
on
coil
the
w
(2) As one ortwo condensers are connectedto the condenser coil, the small voltage at the condenser
coil generates a minute current
@which flows through the condenser coil. At this time, a small flux is
produced with which the magnetic force
at the rotor's magnetic poleis intensified. When this magnetic forceis intensified, the respective voltages
in the main coil and condenser coil riseup. As the
current (3
increases, the magnetic flux
at the rotor's magnetic pole increases further. Thus
the voltages atthe main coil and condenser
coil keep risingby repeating this process.
(3)As AC current flows through the condenser coil, the density
of magnetic fluxin the rotor changes. This
change of magnetic flux inducesAC voltage in the field coil, and the diode rectifierin the field coil
AC voltage intoDC. Thus a DC current 8 flows through the field coil and magnecircuit rectifies this
tizes the rotor core
to generate an output voltage
in the main coil.
(4) When generator speed reaches3000 to 3300 rpm, the current in the condenser coil and field coil
increases rapidly. This acts
to stabilize the output voltageof each coils. If generator speed further
increases to the rated value, the generator output voltage will reach to the rated value.
5-3-2VOLTAGE FLUCTUATIONS UNDER LOAD
When the output current flows through the main coilto the appliance, a magnetic fluxis produced and
selves to increase current in the condenser coil. When current increases, the density of magnetic
As a result, the current flowing in the field coil increases and the generaflux across the rotor core rises.
tor
4
tzl
!@
-
16-
5-3-3FULL POWER SWITCH (Dual Voltage Type)
The full power switch is provided for the dual voltage type
to take out thefull rated power from one
receptacle in each voltage.
-T
I
120f240V
r""
I
I
I I
6
REC.3
-
$-.
I
I 12ov
1
Fig. 5-12
"
MC2
Fig. 5-13
REC.1
Switch
RECEPTACLE
120/240 V
REC.3
Half of rated output
240V
Table. 5-3
Fig. 5-14
-
17-
HIGHER VOLTAGE LOWER V
Position
RECEPTACLE
Rated output
main
Two main coils are wound over stator core. Each main
coil outputs half the rated power at the lower
voltage (1 20V).These main coils are wound
to be in the same phase.The full power switch reconnects
these
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.
5-13 is
Fig.
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 (upto 30A if the rated currentis over 30A), and Rec. 1 can output up toa total of 15A.
When the full power switch is set for double voltage indication
(120V/240V), the switch positionis as
indicated by the upper dotted line in Fig. 5-12. Fig. 5-14 is a simplified representationof this circuit,
showing the two maincoils connected in series. in this case, power can be taken simultaneously from
3 for the higher voltage can output toup
the rated power, but
the receptacles for the both voltages. Rec.
uphalf the rated power each.
Rec. 1 and Rec. 2 for the lower voltage can output only to
by full power switch in
Table 5-4 is a summaryof the above explanation. Select the proper output voltage
accordance with the applianceto be used.
-
18-
e
5-4 OIL SENSOR
5-4-1 DESCRIPTION
* The oil sensor mainly functionsto detect posi-
tion of the surface of engine
oil in the crankcase
of engines for general use andto stop the engine automatically when the oil level goes down
below the lower limit specified. This prevents seizure of engine from occurring due
to insufficient
amount of oil in the crankcase.
Since the sensor has been designed to consume
a partof power suppliedto the igniterto energize its electronics circuit, any other external
so that it can be
power supply is not necessary
mounted atthe oil filler port.
Fig. 5-15
Introduction of newly developed sensing principle features super durability and
no change with the
passage of time asit does not use any moving part.
Merits dueto introduction of electrical conductivity detection are as follows
;
%, It has resistance to mechanical shocks
and property of no change with the passage of time as
sensing element consists simply of electrodes having no moving parts.
3.At the same time, it is capable of detecting the oil level stably asit is not influenced by engine
vibrations.
n
No error occurs due to foam and flow of the oil.
!zInfluence against the ignition system or the electronics unitsbecanneglected 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 ofis air
far higher than that of oil, more electric current passes through the
oil than throughthe air, although
the current is very small. The sensor detects this current difference and make use of it.
absolute value of
oil quantity, by comparing a current flowing across
a pair of electrodes (inner and
The sensor judges the
outer) withthe reference, in such a way thatif 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 detectoil quantity, thisis called the ”electrical
conductivity detection” type of sensor. The oil level
to be detected is determined by the length
of electrodes and their mounting positions with the engine.
5-4-3HOW IT OPERATES
[Power supply]
The sensor makes useof a partof primary power source for ignition
of the engine (igniter) to drive the
by button”
branching wires out.
sensor circuit. Power to the sensor can usually be derived from the %top
-
19-
[Judgement of oil level]
and outer electrodes are immersed
in the oil through
When sufficientoil is in the crankcase, both of inner
4
which currentflows across the electrodes. The sensor judges that oil in the crankcase is sufficient. When
to the air due to consumption of oil, no current flow
oil level goes down and the inner electrode is exposed
between the electrodes as air
is considered to be electrically nonconductive. The sensor
in this case
judges thatoil is insufficient.
[Decision of oil shortage]
Oil level at the electrodes go
may
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
of oil is sufficient. The sensor has been
circuit to prevent it from interpreting as short of oil when amount
is detected for5 seconds uninterdesigned so that the engineis to be stopped only when oil-shortage
rupted. Thetimer employs an integration circuit and
it is to be reset when the inner electrode is soaked
in
the oil again beforethe sensor decidesit as oil-shortage. The oil level where the sensor decides as oilshortage, whenoil level goes down gradually,is called "threshold level".
[Automatic stop of engine]
When the sensor decidesas oil-shortage, it makes the engine to stop running automatically for protecis activated, it keeps functioning until
it confirms that the engine
tion of engine. Once the stopping circuit
has made a complete stop, then the circuit stops functioning automatically.
5-44 BLOCK DIAGRAM OF THE CIRCUIT
Power circuit
I
Inner pole
oil
Outer pole
-
Detection
circuit
-
Deley circuit
ground
Igniter
Stopping
circuit
Engine
Fig. 5-16
a Power circuit ..........This rectifies a part of power to the igniter and regulatesit to supply the stabilized power to necessary circuits.
-
20-
,
1
3
Detection circuit..... This detects quantityof oil, sufficient or not, according to difference of electric
resistance across inner and outer electrodes.
n
of the
stopengine
Delay circuit_..........This his prevents the sensor from making an unnecessary
by momentary lowering of the oil level due tothe engine being slanted or
affected by vibration in spite
of sufficient oilin the crankcase.
:x.Stopping circuit...... This automatically stops the engine running.
5-4-5 CAUTIONS TOBE TAKEN ON HANDLING THE
SENSOR
(1) Oil sensor unit
Be sure not
to damage each wire. Broken or short-circuited power supply wires and/or a grounding wire in particular may leadto malfunction or breakdown.
@ The sensoris not interchangeable from engine
to engine because the sensor
is to be exclusively
installed individuallyin each engine employed.
(2) Mounting and wiringof oil sensor unit
@ Although this has been designed to have enough antinoise propertiesin practical use, do not
route theSensor wirings in the vicinityof noise-generating sources suchas ignition plugsor high
voltage cords. This may cause malfunction or breakdown.
a Since capacityof power sourceis limited, current flownin the electronic circuit of the sensoris
kept as low as possible. Be sure
to use terminals with a high contact reliability of more than
of that
tinned terminals.
(3) Operation of oil sensor
1
3
If operating with the engine kept tilted,
oil surface insideof the engine varies and the correct
oil
of engine seizure.
level cannot to be detected which in turn obstructs the preventing function
Operate the engine by keeping
it level.
-38When
starting the engine with an insufficient
oil in the crankcase, engine starts once then it stops
automatically afterit runs for5 seconds.
.z,When the engine has been stopped by the oil sensor, voltage remained in the electronic circuit
3 seconds after the engine stop.
Try to restart the
prevents the sensor from being restarted for
engine after3 seconds or more.
-
21
-
1. Use extreme caution near fuel. A constant danger of explosion or fire
exists.
Do not fill the fuel tank while the engine is running.
Do not smoke or use open flame near the fuel tank.
Be careful notto spill fuelwhen 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 thegenerator in aroom, cave or tunnel.Always operate in a well-ventilated
area.
Otherwise the engine may overheat and also,
the poisonous carbon monoxide contained in the exhaust gases will endanger human lives. Keep the generator
at least 1 m (4 feet) away from structures
or facilities duringuse.
4. Operate the generatoron alevel surface.
If the generatoris tilted or moved during use, there
is a danger of fuel spillage and
a chance that the
generator maytip over.
5. Do not operate with wet hands or in the rain.
Severe electric shock may occur.
If the generatoris wet by rain or snow, wipe
it and thoroughlydry it
before starting. Don’ t pour water over the generator directly norit with
washwater. If the generator
is
wet with water, the insulations willbe adversely affected and may cause current leakage and electric
shock.
-4
6. Do not connect thegenerator to thecommercial powerlines.
transfer switch (Optional parts) for
This may cause a short-circuit or damage to the generator.aUse
connecting with indoor wiring.
NOTE I The parts numbers of the transfer switches
and of the plasticbox to store themare as shown in
Table 6-7.
Table. 6-1
7. Be sure to check
and remedythe cause of circuitbreaker tripping before resettingit on.
CAUTION :If the circuit
breaker tripped off as a resultof using an electrical appliance, the cause
can be an overload or a short-circuit. In suchcase,
a stop operationimmediately and carefully
check
electrical
the
appliance and faulty
ACfor
plugs
wiring.
- 22-
.
1
7. RANGE OF APPLICATIONS
Generally, the power rating of an electrical appliance indicates the amount of work that
be can
doneby it.
The electric power required for operating an electrical appliance is not alwaystoequal
the output wattage of the appliance. The electrical appliances generally have a label showing their rated voltage, frequency, and power consumption (input wattage). The power consumption of an
electrical applianceis
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 necessaryto add the total wattage
of all appliances to
be connected to the unit.
type.
Refer to the followingsto calculate the power consumption of each appliance or equipmentitsby
(1) Incandescent lamp, heater, etc. with a power factor 1.0
of
Total power consumption mustbe equalto or less than the rated output of the generator.
Example :A rated 3000W generator can turn thirtyOOW
1 incandescent lamps on.
(2) Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power
factor
Select a generator witha rated output equivalent to
1.2 to 2 times of the power consumption of the
1.2are
to 3
load. Generally the starting wattage of motor driven tools and light electrical appliances
times lager than their running wattage.
Example : A rated 250W electric drill requires 400
a W generator tostart it.
NOTEl :If a power factor correction capacitor is not applied to the fluorescent lamp, the more power
shall be required to drive the lamps.
the lamp.
of
NOTE2 :Nominal wattage of the fluorscent lamp generally indicates the output wattage
as to the power consumption,
efiTherefore, if the fluorescent lamp has no special indication
ciency should be taken into account as explained in(5)Item
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 requires800 W to 1200W power source to be turned on.
A rated
3000 W generator can powertwo or three400 W mercury lamps.
(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.
These appliances require large starting wattage which
is 3 to5 times of running wattage.
Example :A rated 900 W compressor requires a4500 W generator to drive it.
NOTEl :Motor-driven appliances require the aforementioned generator outputatonly
the starting. Once
their motors are started, the appliances consume about
1.2 to 2 times their rated power consumption so that the excess power generated
by the generator can be used for other electrical
appliances.
NOTE2 :Motor-driven appliances mentioned in items
(3) and (4) vary in their required motor starting
If it load.
is difficult to determine the optimum
power depending on the kind of motor and start-up
generator capacw, select a generator with
a larger capacity
-
23-
(5)Appliances without anyindication asto power consumption
Some appliances have no indication asto power consumption; but instead the work load (output) is
indicated. In such a case, power consumptionis to be worked out accordingto the numerical formula
mentioned below.
1
(Output of electrical appliance)
= (Power consumpition)
(Efficiency)
Efficiencies of some electrical appliances are as follows
:
Single-phase motor ................................ 0.6 to 0.75 The smaller
Fluorescentlamp
...................................
0.7to
0.8
the motor, the
( lowerthe efficiency-
)
Example 1: A 40W fluorescent lamp means that its luminous output is
40W. Its efficiency is 0.7 and
accordingly, power consumption will be 40 0.7= 57W. As explained in Item (2),multiply
this power consumption value of
57 W by 1.2 to 2 and you will getthe figureof the necessary capacity of a generator.In other words, a generator with a rated outputof lOOOW
capacity can light nine to fourteen
40 W fluorescent lamps.
+
Example 2 :Generally speaking, a 400W motor means that its work loadis 400 W. Efficiency of this
570 W. When this motoris used for
motor is 0.7 and power consumption will be 400+0.7=
of the generator should be multiple
of 570 W by 1.2 to 3 as
a motor-driven tool, the capacity
explained in the Item(3).570 (W) x 1.2 to 3 = 684 (W) to 1710 (W)
MODEL
RGV4lOO RGV2800
I
Fluorescent lamp, Motor-
I
I
2300 W
I
approx.
driven tool, general-porpose
Mercury lamp, etc.
Pump, compressor, etc.
d
60 H
Frequency
lncandesent lamp,
heater, etc.
RGV6100
1
approx.
3600 W
approx.
1800W
approx.
800W
approx.
approx.
850 W
550 W
Table. 7-7
-
24-
1
I
I
1
48oow
approx.
2400W
approx.
1600W
approx.
1100 w
I
I
NOTES :Wring between generatorand electrical appliances
7. Allowable current of cable
Use a cablewith an allowable current that is higher than the rated inputofcurrent
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 your
for reference.
2. Cable length
*
If a long cableis used, a voltage drop occurs due
to the increased resistance in the conductors decreasing the input voltage to the load (electrical product). As a result, the
canload
be damaged. Table
7-2 shows voltage drops per
700 meters of cable.
Gauge NoJ Resistance
wire element
area / mm3 current / A
NoJ mm
Sectional
7
30 I 0.1 8
12
50 I 0.18
17
37 I 0.26
Voltage drop per 100 m
3A
SA
8A
10A
12A
8V
12.5 V
5V
7.5V
12V
15V
18V
3v
5.o~
av
10v
1 2 ~15v
45 I 0.32
0.517
1.5 V
I 2.5V I
4V
70 I 0.32
0.332
1v
2v
2.5v
15A
I 5 V I 6.5V 1 7.5V
3.5v
4v
5V
Table. 7-2
Voltage drop indicates asV=
xRxIxL
100
R
means resistance ( Q / 100 rn) on the above table.
I
meanselectriccurrentthroughthewire (A).
L
meansthelengthofthewire
(m).
The lengthof 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 repairof
Robin generators. The “Dr. Robin” has the following 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 ahandy,
sturdy case for easy carrying.
SPECIFICATIONS
I
MODEL
IiNumber
I
I
Dr. Robin
I
388-47565-08
1
0 to 500 V AC
Voltage
d
25 to 70Hz
Frequency
Measuring
Resistance
Range
Condenser Capacty
0.1 to 1.999
n
10 to 100 p F
3M Q
Insulation Resistance
Fuse
Circuit Protector
Power Source
2 x 6F44P (006P) Dry Cell Battery
Test leads with needle probes. . . 1 set
Test leads with jack plugs . . . 1 set
Accessories
Dimensions (L x W x H)
285 mm x 2 0 0 mm x 110 mm
1.6 kg
Weight
Table. 8-7
The “Dr. Robin” generator tester can be ordered from Robin generator distributors
the following
by
part
number.
Dr. Robin Part Number :38847565-08
If you do not have a “Dr. Robin” generator tester, use the instruments described in the following section
-1
for checking generator parts.
- 26-
8-1-2 INSTRUMENTS
(1) VOLTMETER
AC voltmeter is necessary. The approximate
AC voltage rangesof the voltmeters to be used
for various typesof generators areas follows:
0 to 15OV :Type with an output voltage
of 110
or 120V
0 to 300V:Type with an output voltage
of 220,
230 or 240V
0 to 150V, 0 to 330V: Dual voltage type
FOR AC
(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 1OA, 20A, 1OOA)
FOR AC
Fig. 8-3
(3)FREQUENCY METER
Frequency range:About 45 to 65Hz
NOTE :Be careful of the frequency meter'sinput
voltage range.
Fig- 8-4
- 27-
(4) CIRCUIT TESTER
Used for measuring resistance, etc.
Fig. 8-5
I
(5)MEGGER TESTER
Used for measuring generator insulationresistance. Select one with testing vottage range
of 500V.
Fig. 8-6
(6)TACHOMETER
Use the contactlesstype tacho meter.
Fig. 8-7
-
28-
8-2 AC OUTPUT MEASURING
Fig. 8-8
Use a circuit like the shown
in Fig.8-8 for measuring AC output. A hot plateor lamp witha power factor of
1.O may be used as a load. Adjust the load and
rpm. and check that the voltage range
is as specifiedin
Table 8-2 at the rated amperage and rated
rpm.
I
I
Rated voltage
range
Voltage
I
I
120 v
108-132V
240 V
I
216 - 2 6 4 V
I
Table. 8-2
8-3DC OUTPUT MEASURING
I
I
1
Measurement of DC output is executed with the switch turned
ON while the currentis regulated at8.3A
by adjusting the load to the generator.
If the voltageis within the rangefrom 6V to 14V, the voltageoutput
is normal.
a battery is connected as a load to the generator, the DC output voltage will increase by
approximately 1 to 2 V. Therefore, carefully observe the electrolyte level do
and
not overcharge
the battery.
NOTE :I f
-
29-
8-4 MEASURING INSULATION RESISTANCE
Use a"Dr. Robin" generator tester in megger tester
mode or use a megger tester
to check the insulation resistance. Connect a megger
tester to one
of receptacle output terminals and the ground terminal, then measure the insulation resistance.
An
insulation resistanceof 1 megohm or more is normal. (The original insulation resistance at the time
of shipment from the factory is 10 megohm or
more.) If it is less than 1 megohm, disassemble
the generator and measurethe insulation resistance of the stator, rotor and control panel individually.
NOTE :Turn on the no-fuse breaker before
measurement.
* STATOR
(1) Measure the insulation resistance between
BLUE lead and the core.
(2) Measure the insulation resistance between
WHITE lead andthe core.
(3) Measure the insulation resistance between
YELLOW lead and the core.
(4) Measure the insulation resistance between
BROWN leadand the core.
Fig. 8-11
ROTOR
Measure the insulation across one of the soldered
the core.
terminals of the rotor and
Fig. 8-12
-
30-
I
CONTROL PANEL
Measure the insulation resistances between the
live parts and the grounded parts.
I
Fig. 8- 13
Any part where the insulation resistance is less than
1M SZ has faulty insulation, and may cause electric
leakage and electricshock.
Replacethefaulty
part.
.
.
- 31 -
9. CHECKING FUNCTIONAL MEMBERS
9-1 VOLTMETER
Check the voltmeterif it is turned on by applying
specific voltage. Voltmeter cannot
be checked with
circuit tester because its resistance
is too large.
3 Check thatno disconnection nor short-circuit
occurs witha tester, and the internal resistance
is around OOk ohms normally.
3
Turn on the commercial power supply-input
and check the indication.
VOLTMETER
Fig. 9-1
9-2 AC RECEPTACLES
Using a "Dr. Robin" or a circuit tester,
check continuity between
the two terminals at the rear of the
AC
receptacles while the receptacle
is mounted on the control panel. When continuity is found between the
output terminalsof the receptacle with a wire connected across these terminals,AC
thereceptacle is
normal. Whenthe wire is removed andno continuity is found between these terminals, the receptacles
are also normal.
I
t
WIRE
i
AC RECEPTACLE
Fig. 9-28
Fig. 9-2A
1
9-3NO-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 nois no continuity when
fuse breaker is on while there
the no-fuse breakeris off.
\
Ii
NO-FUSE BREAKER
\
Fig. 9-3
-
32-
9-4STATOR
4
Disengage connectors onthe wires from stator
and check the resistance between wires with a
"Dr. Robin" or a circuit tester referring to the following table.
Fig. 9-4
~~
MODEL
Condenser
Winding
AC Winding
Specification
Hz
Voltage
White I Red
/ Blue
Yellow I Yellow Black
RGV2800
60
120 V, 120 VI240 V
0.58
0.58
1.67
RGV4100
60
120 v, 120 v/240 v
0.52
0.52
0.99
RGV6100
60
120 V, 120 V/240 V
0.25
0.58 0.25
Table. 9-1
NOTE :If the circuit tester is not sufficiently accurate,
may
it not show the values given and may give
erroneous readings. Erroneous readingswill 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 "0.
-
33-
9-5 ROTOR ASSEMBLY
(1) Using a "Dr. Robin" or a circuit tester, measure the resistance
of the field coil at the terminals.
(Q)
MODEL
RGV2800
RESISTANCE
1.75 Q
RGV6100
1.77
a
1.60
RGV4100
Q
Table. 9-2
NOTE 7 :
Because a diodeis soldered to the coil endsat
the terminals, resistancemay 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 notsuff7ciently accurate,it
may not show the values given
and may give erroneous readings. Erroneous readingwill also
occur when thereis a wide variation
of resistance
among coil windings or when measurement is
performed at ambient temperatures different from
20 "C(68
Fig- 9-5
=F).
9-6 CONDENSER
Use a "Dr.Robin" in capacitance meter modeto check the capacityof condensers.
1
I
:
!
i
Ii
!
\
(I\
Fig. 4 6 A
!
CONDENSER
I
\
I
CONDENSER
Fig. 9-6B
Type RGV2800
Type RGV4700, 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 CAPACITYOF CONDENSER
RGV6100RGV4100RGV2800
2 8 p F x 22 0 p F x 2
Table. 9-3
If such an instrumentis unavailable, the condenser can
be checkedby replacing with a new one. If the
generator performs good with
new condenser, the cause of troubleis defectin original condenser.
9-7 DIODE RECTIFIER
DIODE RECTIFIER
Brown
Brown/
Whim
1
Brown
Brown/ White
CIRCUIT TESTER
fig. 9-7
Fig. 9-8
Circuit insideof the diode rectifiers is as shown
in Fig. 9-7. Check continuity between each terminal by
is as follows:
using a circuit tester as shown in 9-8.
Fig. The rectifier is normal when condtinuity
Checkina table for analogue circuit tester.
Apply black (minus) needleof the circuit tester
Analogue circuit tester
Brown Brown
I
Apply red (plus) needleof
the circuit tester
I
Brown
I - I
Brown
No continuity
continuity
-
I
NO
continuity
No continuity
Continuity Continuity
Orange
Brown /White
NO
No continuity
Table. 94-1
-
35-
No continuity
No continuity
I
Continuity
Continuity
Continuity
-
I
Checkina tablefor diaital circuit tester.
~~
~
~~~~
~
~
~
~~
~~
~~
w
Apply red (plus) needle
of the circuit tester
Digital circuit tester
Brown
I
Brown
-
~
Brown
No continuity
Apply black (minus) needle
of the circuit tester
Orange
Brown / White
~
No continuity
No continuity
Continuity
Brown
No continuity
Continuity
- OrangeContinuity
Continuity Continuity
Brown /White
No continuity
No continuity
No continuity
-
NOTE 1 :Because of the difference of measuring method between the analogue circuit tester and the
digital circuit tester, polar@ of tester needles should be reversed.
NOTE 2 :"Continuit)r means forward direction characteristicsof the diode,and different from short
circuit condition (in which a pointer of the tester
outgoes
of its normal scale), shows resistance
to some extent. When results of the checking indicates failure even in one section, replace
with a new one.
NOTE 3 :Simpson brand analogue testers have the characteristics as same as the digital circuit testeL
9-8 OIL SENSOR
p
i
~4
j
(1) Disconnect two (2) wires comming from the
sensor at the connection.
(2) Loosen
gine.
the
sensor
to
remove
it from
the
en-
i
(3) Plug the opening
of oil filler hole (created after
sensor is removed)withsuitablemeanssuch
as oil gauge.
(4) Connect the removed wires again with the oil
sensor.
(5)Start
engine
thewith
the
i
:i
I
OIL SENSOR
I
,
i
oil sensor
removed
Fig. 9-9
and confirmif ;
a. Engine stops after5 seconds which is normal, or
b. Engine does notstop after more than10 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 within5 seconds after the wirings have checked, the
sensor is wrong. Replace the sensor with new one.
4
- 36-
IO. DISASSEMBLY AND ASSEMBLY
10-1 PREPARATION and PRECAUTIONS
1) Be sure to memorize the location of individual parts when disassembling the generator
so that the
generator can be reassembled correctly. Tag the disassembled part with the necessary information
facilitate easier and smoother reassembly.
2) For more convenience, divide the parts into several groups and store in
them
boxes.
3) To prevent bolts and nuts from
being misplaced or installed incorrectly, replace them temporarily
to
their original position.
4) Handle disassembled parts with care; clean them before reassembly using a neutral cleaning fluid.
5 ) Use all disassembly/assembly tools properly, and use the proper tool for each specific job.
-
37-
10-2 DISASSEMBLY PROCEDURES
:
Step Part to remove
Description
I
Remarks
,
the bushing and pull
out.
I
I
~~
1
(1) Takeoff the bushing from the bottom
of
the control box.(See Fig. 10-1.)
Zontrol box
I
I
(2) Disconnect the connectors on the wiring Press the upper
of end
10-1
Fig.
from the control box to the alternator.
.)
(See
(3) Disconnect the connectors on the wiring
between from the control box and the
engine. (See Fig. 10-2.)
!
!
i
Fig. 10-2
Fig. 10-1
control box the frame. (SeeFig. 10-3.)
5 x 12 mrn bolt and
washer Ass'y (black) . . . 2pcs.
5 x 25 mrn bolt and
washer Ass'y (black) . . . 2 pcs.
!
- -
i
Fig. 10-3
- 38-
.
Tool
Step Part to remove
-
Fuel Tank
2
Description
Remarks
(1) Discharge fuel from the tnak.
1. Shut the fuel strainer.
2. Remove the strainer cup.
Tool
fire hazard.
3. Put a vessel to receive fuel under theWipe off split fuel
strainer and open the fuel cock to
thoroughly.
discharge fuel. (See Fig. 104.)
4. Attach the strainer cup to the strainer Do not lose the filter
body.
screen.
-
I
I
(2) Disconnect
strainer.
/Pliers
the
from
rubber
pipe
strainer.
Loosen the hose clamp on the top of the
strainer and pull out the rubber pipe from
the
i
i
(3)Take off the four bolts and tubber (fuel
wrench
box
tank.
fuel
remove
then
the
and
tank)
(See Fig. 10-6.)
10 mrn spanner or
Fig. 10-6
Fig. 70-5
I
I
-
39-
Muffler and
Muffler cover
Remarks
Description
Part to remove
I
Tool
12 mm spanner or
box wrench
(1) Remove thetwo bolts which fix the
muffler to the alternator. Loosentwo
the
nuts on the muffler flange and remove
the muffler from the engine.
8 x 20 mm bolt and washer Ass'y . . . 2 pcs.
8 rnm stainless nut. . - 2 pcs.
8 mm spring washer.. .2pcs.
I
for RGV4100 and RGV6100
Muffler gasket. . . 1 pce.
(2) Remove the muffler cover 1 and the
muffler cover2 from the muffler.
6 x 10 mrn bolt and washerAss'y . . .8 pcs.
(See Fig. 10-8.)
t
IO mm spanner or
i tmx wrench
I
t
-i
112 mm spanner or
t)ox wrench
(3)Remove the muffler bracket from the
rear cover.
8 x 20 mm bolt and washer
Ass'y . ..2 pcs.
MUFFLERCOVER 1
A
I
d"
MUFFLER BRACKET
for RGV2800,RGV6100
Fig. 10-7
I
I
I
step Part to remove
! Pipe Frame
I
I
I
Remarks
Description
I
I
Tool
(1) For RGV6100
Remove thefuel strainer from the frame.
10 rnm spanner
(2)Remove thenuts which are fixing engine
and alternator to the mountrubbers.
(See Fig. 10-9.)
12 mm spanner
i
~~
(3) Using a chain-block, sling up the engine
Remove the air
and alternator and dismount from the cleaner cover for
frame.
dismounting.
I
I
I
I
I
i
1
I
!
-
[4) Remove the mount rubbers from the
frame. Loosen thenuts on the bottom
side of the frame. (See Fig. 10-10.)
12 mm spanner or
socket wrench
I
M8 flange nut. . . 4 pcs.
b.
SPACER :1 pce.-e
1
STOPPER PLATE
MOUNT RUBBER :2 pcs.
I
i
:2pcs.
NUT :2 p
c
s
7
.
Fig. 10-70
i
I
-
41
-
M8 FLANGE
vNUT:2pcs.
1
Step
Part to remove
Remarks
Description
~
5
Rear cover
10 mm spanner or
box wrench
(2) Remove the fourb o b which fasten the
rearcovertothefrontcover.
(See Fig.
10-12.)
16#boR...4pcs.
10 mrn spanner or
box wrench
I
I
I
~-
(1) Remove the end cover.(See Fig.
10-11.)
(Except RGV6100)
66bolt ... 3pcs.
ii
!
!
~~
j
Fig. 10-71
Fig. 10-12
I
Plastic hammer
legs of rear coverwith a plastic hammer on theboss or legs.
to loosen.
I
Ij
REAR COVER
I
Fig. 10-13
I
j
I
I
L
ii
I
-
42-
d
rStep Part to remove
-I
I
Description
!
"
6
Stator
Remarks
Tool
1
(1) Remove the stator cover.
I
STATORCOVER
~-j
c--------
4
STA,TOR
\
Fig. 1 0 7 4
STATOR COVER
W
COVER BOLT :4 PCS.
Fig. 10-75
I
-
43-
I
Step Part to remove
7
Remarks
Description
Rotor
(1) Take off through
the bolt.
Apply a box wrench on the head of
i
1
Tool
Box wrench
I
Plastic hammer
through bolt. Hit the wrench handle with
a hammer counter-clockwiseto loosen. i
I 1
1
i
i
i
i
i
1
Fig. 10-16
j
I
(2) Put the engine on the working table
recoilstartersidedown.
i (3) Use a bolt andasoil
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
RGV4100,6100.. . M12 x P.1.5
3. Apply a few turns
ofseal tape around the
. tip of the bolt. (See Filq. 10-18.)
i
j
i
!
I
i
I
;
[
!
!
I
Fig. 10-17
Fig. 10- 18
- 44-
i
i
Step
Part to remove
i
Description
Remarks
Tool
L
4. Screw the bolt into the thread of the rotor Do not stick out your
3otor
face over the rotor.
It may jump up on
shaft.
5. Torque the bolt using a socket wrench
Socket wrench
until the rotor comes off loose.
shaft.
The hydraulic pressure inside the
rotor shafttakes apart the rotor from
the
engine
I
(4) Wipe off oil thoroughly from rotor shaft
and enainePTO shaft.
!
I
I
I
Fig. 10- 19
!
Front Cover
1
[l) Remove the front cover.
Loosen the four bolts and remove the
front cover.
!
I IM8 x 20mm bolt and washerAss'y ..- 4pcs.
I
I
I
!
I
!
!
Fig. 10-20
-
45-
12 mm socket
wrench
10-3 ASSEMBLY PROCEDURES
10-3-1 FRONT COVER
Attach the front coverto the engine main bearing
cover. Match the faucet joint and tighten the bolts.
M8 x 20 mm bolt . . - 4 pcs.
M8 spring washer - . . 4 pcs.
120 - 140 kg-crn
8.7 - 10.1 fGlb
~~~
I
~
Fig. 1027
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 rotorto the engine shaft. Tighten
the throughbolt. 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:
Fig. 10-22
-
113 132 N-m
RGV2800
RGV4100
RGV6100
115 - 135 kgcrn
8.7 - 10.8 ft-lb
-
22.5 2 4 5 N-m
230 - 250 k g t m
16.6 - 19.5 ft-lb
-
46-
10-3-3 STATOR
(1) Put the statorin the rear cover setting the four
grooves onthe side of stator with thread holes
of the rear cover.
STATOR COVER
(2) Attach the stator cover around the stator.
10-3-4 REAR COVER
(1) Put the rear cover with stator over
the rotor.
Tap on the rear cover evenly with a plastic
hammer to press the rotor bearing into the rear
cover.
(2) Fix the rear cover to the adaptor
with four bolts,
spring washers, and washers.
"
Fig. 10-23
RGV6100
M6x160mmboIt... 4pcs.
M6 spring washer. . . 4 pcs.
M6 washer. . . 4 pcs.
-
4.5 5.9 N-m
50 - 60 kgcm
3.6 - 4.3 ft-lb
RGV2800 and 4100
M6 x110 mm bolt.. . 4 pcs.
Fig. 10-24
M6 spring washer. . . 4 pcs.
t
I
1
Tightening torque
-
4.5 5.9 N-rn
50 - 60 kg-cm
3.6 - 4.3 ft-lb
(3) Attach the bushing over the lead wire drawn
out from the rear cover. Press the smaller end
of the bushing into the window of the rear
cover.
~
~~
Fig. 10-25
-
47-
10-3-5 END COVER (RGV4100 only)
Attach the end cover to the rear cover.
Fig. 70-26
10-3-6 FRAME
(1) Attach the mount rubbersto the frame. Insert
the setting tongue of mount rubber into the hole
on the frame and tighten
the nut from the bottom of the frame.
M8 flange nut. . . 4 pcs.
120 - 140 kgcm
8.7 - 10.8 ft-lb
Fig. 10-27
NOTE :The
mount rubbers are selected to reduce vibration most
effectivelyby model. Be sure to use
the correct mount rubberforyour generator. Although mount rubbers have same
the appearance, their characteristics aredifferent.
(2) Attach the5 mm terminal of the grounding wires (green
/yellow) to the unpainted thread hole of the
frame base plate using 5a mm brass screw.
(3) Install the engine and alternator assembly into
the frame. Put the engine and alternatorassembly into the frame from the side of it.
Tighten the nuts over the mount rubber bolts
to fix.
Tightening torque
-
11.8 13.7 N-m
120 - 140 kgcm
8.7 - 10.8 ft-lb
M8 nuts . . . 4 pcs.
NOTE I Remove theair 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 mrn terminal to the unpainted bolt hole on the frame.
(See Fig.10-28.)
10-3-7 MUFFLER and MUFFLERCOVER
(1) Temporarily fix the muffler bracket to either the
rear or front covers for RGV6100 or RGV2800.
M8 x 20 mm bolt and washer Ass'y. . . 2 pcs.
Fig. 70-28
(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.
-
7.9 9.8 N-m
80 - 100 kg-crn
5.8 - 7.2 ft-lb
MUFFLER COVER 1
A
(3) Put the muffler gasket to the engine.
(4) Attach the muffler with muffler coverto the
engine and the rear
cover.
3 Tighten
thetwo nuts for the muffler first. Use
the spring washers for RGV4100 and
RGV6100.
8 mm stainless nut. . - 2pcs.
8 m m spring washer. - - 2 pcs.
(for RGV4100 and RGV6100 only)
-
21.6 27.4 N-m
220 - 280 kg15.8 - 20.2 ft-lb
3
1
Tighten the bolts to fix the muffler to the rear
cover.
M8 x20 mm bolt and washer Ass'y. . .2pcs.
(for RGV4100)
MUFFLER BRACKET
for RGV2800,RGV6100
-
18.6 24.5 N-m
190 - 250 kg-crn
13.7 - 18.0 ft-lb
Fig. 10-29
-
49-
3 For
RGV2800 and
6100 :Tighten thetwo bolts to fix the muffler bracket
to the frontcover, rear cover,
and thenthe two bolts for the muffler to the muffler bracket.
M8 x 20 mm bolt and washer Ass’y
. . - 4 pcs. (for RGV2800 and 61
00)
-
190 250 kg-cm
13.7 18.0 ft-lb
-
10-3-8 FUEL TANK
(1) For RGV2600 andRGV4100 only :
FUEL GAUGE
Attach the fuel strainer to the bottom of the
fuel tank. Screwin the fuel strainerall the way
and return one to two turns, and then lock it
with the lock nut.
FUELTANK CAP
For RGV6000 only :
Attach thefuel strainer to the frame.
50 - 70 kg-crn
3.6 - 5.0 ft-lb
(2) Mountthe fuel tank on the frame with rubber
washers between the tank flange and the frame.
M6 x 20 mm bolt (black). . . 4 pcs.
Rubber washer - . . 4 pcs.
NOTE :For easy tank assembly, glue the rubber
washers overthe mountingholes of the
frame.
(3) Connect the rubber pipe.
First, fit the hose clampson the rubber pipeand
connect it to the strainer and the carburetor. Then
fasten it with the hose clamps.
For RGV6100, connect the rubber pipe to the
same way.
strainer and the fuel tank in the
NOTE :Apply a drop o f oil to the rubber pipe for
easier connection.
Fig. 10-30
-
50-
*
10-3-9 FRONT PANEL
I
Mount the front panel assemblyto the frame.
Refer to Section 10-4 for disassembIy, checking and reassembly procedures of the front panel.
(I) 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 :Connect the wires of the same color.
(3)Press the upper end of the bushing into the
bottom window of the front panel.
(4) Mount the front panel to the frame.
. . . 2 pcs.
M5 x 25 mm bolt and washerAss'y . . .2pcs.
M5 x 12 mm bolt and washer Ass'y
L
Fig. 10-31
-
104 CHECKING, DISASSEMBLY and REASSEMBLY of the FRONT PANEL
104-1 CHECKING OF THE FRONT PANEL
Dismount the front panel from frame. Remove
the control panel and check each components and wiring.
Referto Section 9 for thedetail of checking procedurefor the components in the front panel.
10-4-2 DISASSEMBLY
(1) Remove the control panel from the front
panel.
M4 screw. . - 6pcs. (RGV2800, RGV4100)
M4 screw . . .7 pcs. (RGV6100)
(2)Disconnect the connectors on the wires
to detach the control panel and front panel.
(3)Remove the condensers and
diode rectifier from the front panel.
(4) After disconnecting
individual wires, remove the control panel components.
-
51
-
10-4-3 REASSEMBLY
(1) Install the receptacles, no-fuse breaker, terminals, switches, etc.
on the control panel andwire them.
NOTE :Circuit diagrams are
shown in Section 12. Colored wiresare used for easy identification, andare
of the correct capacity andsize. Use heat-resistant type wires (permissible temperature range
75°C or over) in the specifiedgauge shown in the circuit diagrams.
(2) Install condensers, and diode rectifierinto the front panel.
(3)Connect the wires of control panel componentsand front panel.
(4) Attach the control panel tothe front panel.
M4 screw . . .6pcs. (RGV2800, RGV4100)
M4 screw. . .7 p a . (RGV6100)
-
12 1.5 N12- 15 kg-cm
-
8.7 10.9 fi-lb
- 52-
4
11. TROUBLESHOOTING
11-1 NO AC OUTPUT
11-1-1 CHECKING CONDENSER
(1) Check the capacity of condensers using
a “Dr. Robin” generator testerin capacitance meter mode.
NOTE :Be sure to discharge condensersby shorting condenser leads each other before checking their
capacitance, or the accurate reading cannot
be obtained.
cjL
yr
/-
\1
Y
CONDENSER
CONDENSER
I
1
Fig. 11-1A
I
;
Fig. 11-18
T y ~ RGV2800
e
T ~ p RGV4100,
e
RGV6100
NORMAL CAPACITY OF CONDENSER
RGV2800
I
RGV4100
24flF
RGV6100
28uFx2
20pFx2
Table. 11-1
(2) If such an instrument is unavailable,
the condenser can be checked
by replacing with a new one.If
the generator performs good with new condenser, the ofcause
trouble is defect in original condenser.
11-1-2 CHECKING STATOR
COUPLER
\
(1) Remove control panel and disconnect stator
wires at the connectors.
STATOR
/
!
i
I
(2) Measure the resistance between terminals on
stator leads. (See Fig.11-2) Refer
toTable 9-1
for normal resistance.
If statoris faulty, replace it with a new one.
I
I
Fig. 11-2
-
53-
(3)Check the insulation resistance betweenstator 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.
Fig. 11-3
r
11-1 -3CHECKING ROTOR
(1) Remove rear coverand stator.
(2) Using a Dr. Robin or a circuit tester, measure
the resistance of the field coil at the terminals.
J
Fig. 11-4
(0)
MODEL
RGV2800
RGV4100
RGV6100
RESISTANCE
1.75 hz
1.77 Q
1.60 Q
Table. 11-2
NOTE :Because a diodeis soldered to the coil
ends at the terminals, resistance may be measured only when tester probes touch the terminals in one combinationof polarity. Therefore, if
no resistance reading appears, try checkingin
reverse polarity
[Remedy]
If the resistance is not normal, replace rotor with
a new one.
Fig. 11-5
-
54-
(3) Measure the insulation across one
of the soldered terminals of the rotor and the core.
(Fig.11-6)
If insulation is bad, replace rotor with a new
one.
Fig. 11-6
11-2 AC VOLTAGE IS TOO HIGH OR TOO LOW
SPEED CONTROL LEVER
\f=?
11-2-1 CHECKING ENGINE SPEED
If the enginespeed is too high ortoo low, adjustit
to the rated r.p.m.
[How to adjust engine r.p.m.1
Loosen the lock nut
on the adjusting screw.
Turn the adjusting screw clockwise
to decrease
engine speed or counterclockwiseto increase
engine speed.
Normal engine speed at no load
I
3700 to 3750 rpm
11-2-2 CHECKING CONDENSER
Check condenser referring
to Step 11-1-1.
L
11-2-3 CHECKING STATOR
Fig. 11-7
Check stator referring to Step
11-1-2.
11-2-4 CHECKING ROTOR
Check rotor referring to Step
11-1-3.
-
55-
11-3 AC VOLTAGE I
S NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED.
11-3-1 CHECK THE ENGINE SPEED.
If the engine speedis low, adjust it to the rated r.p.m.
*Refer to Step11-2-1 for engine speed adjustment.
11-3-2 CHECK THE TOTAL WATTAGEOF APPLIANCES CONNECTED TO THE GENERATOR.
Refer to Section 7 “RANGEOF APPLICATIONS” for the wattage of the appliances.
If the generatoris overloaded, reduce the load to the rated output of the generator.
11-3-3 CHECK THE APPLIANCE FOR TROUBLE.
If the applianceis faulty, repair it.
11-34 CHECK IF THE ENGINE IS OVERHEATED.
If the coolingair inlet andor cooling air outletis
clogged with dirt, grass, chaff or other debris,remove it.
(ALTERNATOR)
Fig. 11-8
11-3-5 CHECK THE INSULATIONOF THE GENERATOR.
Stop the engine. Measure
the insulation resistance
between the live terminal of the receptacle and
the ground terminal.
I
I
j
i!
U
If the insulation resistanceis less than 1MSZ, disassemble the generator and check the insulation
resistance ofthe stator, rotor and the live parts
in
the control box. (Refer to Section 8-3.)
Any part where the insulation resistanceis less
than 1MQ the insulation is faulty and
may cause
electric leakage.
I/
..
Replace the faulty part.
Fig. 11-9
- 56-
11-4 NO DC OUTPUT
11-4-1 CHECK THE AC OUTPUT.
Check the generatorby following Step11-1-1 through Step 11-1-3.
11-4-2 CHECK THE DCBREAKER.
If theDC breaker turnedoff while charging a battery, checkthe cables for short-circuit or connection in reverse polarity before resetting
it on.
NOTE :If the DC output is used to charge
a large
capacity batteryor an over-discharged
battery, an excessive currentmay flow
causing.
Fig. 11-10
11-4-3CHECK THE DCFUSE.
Check thefuse in the fuse holder.
_-
If the fuseis blown, check for the cause of fuse
blowing, and then replace with a new one.
FUSE: 10A
NOTE :If the DC output is usedto charge a large
capacity battery oran over-discharged
battery, an excessive currentmay flow
causing fuse blow.
Fig. 17-11
114-4 CHECK THEWIRING.
Check all the wires to be connected correctly.
11-4-5 CHECK THE DIODE RECTIFIER.
Remove the control panel and check the diode
rectifier witha circuit tester.
Refer to Section9-7 "DIODE RECTIFIER" for the
checking procedure.
- 57-
11-4-6 CHECK THE DC COIL
Check the resistance between
two brown leads from stator with a circuit tester.
MODEL
SPECIFICATION
RESISTANCE
RGV2800
60 Hz
120V,120V1240V
0.25 0
RGV4100
60 Hz
120V, 120Vl240V
0.18 0
RGV6100
60 Hz
120V, 120Vl240V
0.13 Q
Table. 11-3
If the resistance readingis much larger or smaller than the specified value, DC
thecoil of the stator is
faulty. Replace stator with a new one.
115 IDLE CONTROL
11-5-1 ENGINE SPEED IS NOT INCREASED
WHEN A LOADIS APPLIED
(1) Inspect the solenoid bracket. Check
the bend
angle of solenoid bracket.
If the bracketis distorted, correctthe angle with proper tool.
(2) Check the wattage of load applied
to the generator. If the generatoris loaded overthe rated
wattage, the engine speed can not be increased. Most induction loads such as electric 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.
Check the slow set
r.p.m.
The normal idling speed by the IDLE CONTROL is as follows:
Fig. 11-13
I
I
RGV2800 ..............._..1900 to 2100 r.p.m.
2000 to 2200 r.p.m.
RGV4100, 6100 ..___...
The above speed setting is cold
for engine condition. If the engine speedis out of adjusting
range of the adjusting screw, move the solenoid backward.
I
i
Fig. 11-14
- 58-
c
(4) Check the wiring through ZCT onthe IDLE
CONTROL UNIT.
I
I
IDEL CONTROL UNIT
* Single Voltage Type
Make sure that an output wire from main coil is
passing through the
ZCTon the IDLE CONTROL
UNIT.
* Dual Voltage Type
Check that two output
wires (black wire and red
wire) from main coils are passing throughthe
ZCT on the IDLE CONTROLUNIT in the same
direction.
I
i
Fig. 11-15
(5) Checking the IDLECONTROL UNIT
Check the resistance betweenfive leads of
IDLE CONTROLUNIT with circuit tester.
_-
Terminal number of
the IDEL CONTROL UNIT
Fig. 17-16A
Fig. 17-168
Apply red (plus) needle
of the circuit tester
~~
~
Table. 11-4
NOTE :The resistance readings vary dependingon the @pesof circuit testers. The above table shows
an ordinary analogue circuit tester witb
1.5
an exampleof the resistance readings measured by
volt battery power source. Itis advisable for you to check the resistance readings using your
standard circuit tester and revise the checking table.
- 59-
11-5-2 ENGINE SPEEDIS NOT REDUCED WHEN LOADI
S OFF.
(1) Check the distortion of the SOLENOID BRACKET
as shown in step 11-5-1-(1).
(2)Check the wiring of SOLENOID.
Check two leads from SOLENOID are securely connected.
(3)Check the wiring of IDLE CONTROL UNIT.
Check all leads from IDLE CONTROL UNIT are securely and correctly connected.
(4) Checking the SOLENOID.
Measure the resistance betweentwo leads
from SOLENOID.
SOLENOID
\
25-31 Q
If the resistance is larger or smaller than this range,
SOLENOID is defective,
Replace witha new one.
Fig- 11-17
-9
- 60-
12. WIRING DIAGRAM
L
-
RGV2800 :U.S.A., 60Hz-120V TYPE [NEMA RECEPTACLE]
CONTROL
BOX
__
I"
LRNERATOR
,
"
"
2
_""""
I
_"
_""
2
"
"
"2
"
RGV4100 :U.S.A., 60H~-120V/240VTYPE [NEMA RECEPTACLE]
GENERATOL CONTROL BOX
r
1
I-"-
__
"
"
"
ENGINE
"
1
I"-
!
__
Oil s e m r
‘RGV6100 : U.S.A., 50H~-120V/240V
TYPE [NEMA RECEPTACLE
GENERATW-
1
__-__-__
COllrmOLBOX
I
!
-
62-
j
r
*RGV4100,6100 : ELECTRIC STARTER TYPE
CONTROLBOX
"--"ENGINE
" "_
"
I
Wiring color cord
Blk
BlW
Blu
LBlu
Brn
: Black
: BlackWhite
: Blue
: Light blue
: Brown
BmNV
Gm
GmNV
Org
Gry
: BrowWhite
: Green
: GreedWhite
: Orange
: Gray
-
63-
R
W
Y
:Red
:White
: Yellow

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