Subaru Robin Power Products RGV4100 manual

PUB-GS1277 Re v . 1 / 04 SERVICE MANUAL RGV2800, RGV4100, RGV6100 Models Generators[...]

CONTENTS Section Title Page 1. SPECIFICA TIONS ....................................................................................................... 1 2. PERFOMANCE CURVES ........................................................................................... 3 3. FEA TURES .....................................................................[...]

Section Title Page 9-4 ST A T OR .............................................................................................................. 33 9-5 ROTOR ASSEMBL Y ........................................................................................... 34 9-6 CONDENSER ..........................................................................[...]

- 1 - 1. SPECIFICA TIONS * Electric starter motor is available as option. ENGINE AL TERNA TOR l e d o M0 0 8 2 V G R0 0 1 4 V G R e p y T e s a h P e l g n i S , e l o P - 2 , g n i t i c x E f l e S , s s e l h s u r B C A y c n e u q e r F z H 0 6 t u p t u O m u m i x a MW 0 0 8 2W 0 0 1 4 t u p t u O d e t a RW 0 0 3 2W 0 0 6 3 e g a t l o V d [...]

- 2 - * Electric starter motor is available as option. ENGINE AL TERNA TOR l e d o M0 0 1 6 V G R e p y T e s a h P e l g n i S , e l o P - 2 , g n i t i c x E f l e S , s s e l h s u r B C A y c n e u q e r Fz H 0 6 t u p t u O m u m i x a MW 0 0 8 5 t u p t u O d e t a RW 0 0 8 4 e g a t l o V d e t a R t n e r r u C V 0 4 2 / V 0 2 1A 0 2 / A 0 [...]

- 3 - 2. PERFOMANCE CUR VES Hz ( Hz ) ( V ) ( 125 ) 63 250 ( 120 ) 240 ( 115 ) 230 ( 110 ) 220 62 61 60 0 1/2 4/4 Load Rated 230V/115V[...]

- 4 - DC OUTPUT DC V oltage ................. 12 V DC Ampere ................ 8.3 A 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 s[...]

- 5 - 3. FEA TURES 3-1 BRUSHLESS AL TERNA T OR Newly developed brushless alternator eliminates troublesome brush maintenance. 3-2 CONDENSER TYPE VOL T AGE REGULA T OR 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 le[...]

- 6 - 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 st[...]

- 7 - 4. GENERAL DESCRIPTION 4-1 EXTERNAL VIEW FUEL GAUGE VOLTMETER AC RECEPTACLE EARTH TERMINAL SPARK PLUG NO-FUSE BREAKER OIL DRAIN PLUG OILGAUGE (OIL FILLER) ENGINE SWITCH CHOKE KNOB AIR CLEANER RECOIL STARTER OIL SENSOR TANK CAP MUFFLER FULL POWER SWITCH DC CIRCUIT BREAKER DC OUTPUT TERMINAL IDEL CONTROL SWITCH ENGINE EMISSION LABEL[...]

- 8 - 4-2 CONTROL P ANEL * RGV2800 : U.S.A., 60Hz-120V [NEMA RECEPT ACLE] * RGV4100 : U.S.A., 60Hz-120V/240V [NEMA RECEPT ACLE] ENGINE SWITCH AC OUTPUT AC MAX 20A V METER DC OUTPUT AC BREAKER DC BREAKER ON OFF ON OFF DC 12V-8.3A BATTERY CHARGE ONLY TEST TEST RESET RESET FULL POWER SWITCH AC 120V AC 120V / 240V ENGINE SWITCH 120V 120V 240V V METER D[...]

- 9 - * RGV6100 : U.S.A., 60Hz-120V/240V [NEMA RECEPT ACLE] 4-3 LOCA TION of SERIAL NUMBER and SPECIFICA TION 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 correc[...]

- 10 - 5. CONSTRUCTION AND FUNCTION 5-1 CONSTRUCTION 5-2 FUNCTION 5-2-1 ST A TOR 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 Fig. 5 -1 END COVER STATOR COVER STAT[...]

- 11 - 5-2-2 CONDENSER One or two condensers are installed in the con- trol box and are connected to the condenser coil of the stator . These condensers and condenser coil regulate the output voltage. 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 ma[...]

- 12 - 5-2-4 NO-FUSE BREAKER The no-fuse breaker protects the generator from getting damage by overloading or short circuit in the appliance. T able 5-1 shows the capacity of no-fuse breaker by each spec. and their object of protection. 5-2-5 DC CIRCUIT BREAKER The 10 ampere DC circuit breaker mounted on the control panel protects whole DC circuit [...]

- 13 - NOTE : If your generator has receptacles pecu- liar to your country , T able 5-2 does not apply . 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 othe[...]

- 14 - 5-2-8 CONNECTING TO DOMESTIC CIRCUITS (HOUSE WIRING) W ARNING : All 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,[...]

- 15 - Utility high line Meter box Generator House circuit breaker XW Y X ( X )( Y ) ( G ) ( W ) WY Transfer switch 240V 4P- Receptacle 120V appliance 120V appliance 240V appliance Fig. 5 -1 0 (c) Operating the generator . Set the full power switch to 120V/ 240V side. T urn the house AC breaker off before starting the generator . Start the generato[...]

- 16 - 5-3 GENERA T OR OPERA TION 5-3-1 GENERA TION of NO-LOAD VOL T AGE (1) When the generator starts running, the permanent magnet built-in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator . (2) As one or two condensers are connected to the condenser coil, the small voltage at the condenser coil[...]

- 17 - 5-3-3 FULL POWER SWITCH (Dual V oltage T ype) The full power switch is provided for the dual voltage type to take out the full rated power from one receptacle in each voltage. Fig. 5 -1 2 Fig. 5 -1 3 Fig. 5 -1 4 T able. 5-3 h c t i w S n o i t i s o P E G A T L O V R E W O L E L C A T P E C E R E G A T L O V R E H G I H E L C A T P E C E R V[...]

- 18 - T wo 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 indi[...]

- 19 - 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 oi[...]

- 20 - [Judgement of oil level] When sufficient oil is in the crankcase, both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes. The sensor judges that oil in the crankcase is suf ficient. When oil level goes down and the inner electrode is exposed to the air due to consumption of oil, no curren[...]

- 21 - 2 Detection circuit ..... This detects quantity of oil, sufficient or not, according to dif ference 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[...]

- 22 - 6. SAFETY PRECAUTIONS 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 not to spill fuel when refueling. If spilt, wipe it and let dry before starting the engine. 2. Do not place inflammable mat[...]

- 23 - 7. RANGE OF APPLICA TIONS 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, fr[...]

- 24 - (5) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a case, power consumption is to be worked out according to the numerical formula mentioned below . Efficiencies of some electrical appliances are as follows : Singl[...]

- 25 - 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 th[...]

- 26 - 8. MEASURING PROCEDURES 8-1 MEASURING INSTRUMENTS 8-1-1 “Dr . ROBIN” GENERA TOR 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 [...]

- 27 - 8-1-2 INSTRUMENTS (1) VOL TMETER AC voltmeter is necessary . The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows: 0 to 150V : T ype with an output voltage of 1 10 or 120V 0 to 300V : T ype with an output voltage of 220, 230 or 240V 0 to 150V , 0 to 330V : Dual voltage type (2) AMMETER[...]

- 28 - (4) CIRCUIT TESTER Used for measuring resistance, etc. (5) MEGGER TESTER Used for measuring generator insulation re- sistance. Select one with testing voltage range of 500V . (6) T ACHOMETER Use the contactless type tacho meter . Fig. 8 -5 Fig. 8 -6 Fig. 8 -7[...]

- 29 - 8-2 AC OUTPUT MEASURING Use a circuit like the shown in Fig.8-8 for measuring AC output. A hot plate or lamp with a power factor of 1.0 may be used as a load. Adjust the load and rpm. and check that the voltage range is as specified in T able 8-2 at the rated amperage and rated rpm. 8-3 DC OUTPUT MEASURING Measurement of DC output is execute[...]

- 30 - 8-4 MEASURING INSULA TION RESIST ANCE Use a “Dr . Robin” generator tester in megger tester mode or use a megger tester to check the insula- tion resistance. Connect a megger tester to one of receptacle output terminals and the ground ter- minal, then measure the insulation resistance. An insulation resistance of 1 megohm or more is nor- [...]

- 31 - * CONTROL P ANEL Measure the insulation resistances between the live parts and the grounded parts. Any part where the insulation resistance is less than 1M Ω has faulty insulation, and may cause electric leakage and electric shock. Replace the faulty part. Fig. 8 -1 3[...]

- 32 - 9. CHECKING FUNCTIONAL MEMBERS 9-1 VOL TMETER Check the voltmeter if it is turned on by applying specific voltage. V oltmeter cannot be checked with circuit tester because its resistance is too large. 1 Check that no disconnection nor short-circuit occurs with a tester , and the internal resistance is around 00k ohms normally . 2 T urn on th[...]

- 33 - 9-4 ST A T OR Disengage connectors on the wires from stator and check the resistance between wires with a “Dr . Robin” or a circuit tester referring to the fol- lowing table. NOTE : If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings. Erroneous readings will also occur when[...]

- 34 - 9-5 ROTOR ASSEMBL Y (1) Using a “Dr . Robin” or a circuit tester , measure the resistance of the field coil at the terminals. NOTE 1 : Because a diode is soldered to the coil ends at the terminals, resistance may be measured only when tester probes touche the terminals in one combination of polarity . Therefore, if no resistance reading [...]

- 35 - * If such an instrument is unavailable, the condenser can be checked by replacing with a new one. If the generator performs good with new condenser , the cause of trouble is defect in original condenser . 9-7 DIODE RECTIFIER Circuit inside of the diode rectifiers is as shown in Fig. 9-7. Check continuity between each terminal by using a circ[...]

- 36 - * Checking table for digital circuit tester . 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[...]

- 37 - 10. DISASSEMBL Y AND ASSEMBL Y 10-1 PREP ARA TION and PRECAUTIONS 1) Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly . T ag the disassembled part with the necessary information to facilitate easier and smoother reassembly . 2) For more convenience, divid[...]

- 38 - p e t Se v o m e r o t t r a Pn o i t p i r c s e Ds k r a m e Rl o o T 1x o b l o r t n o Cf o m o t t o b e h t m o r f g n i h s u b e h t f f o e k a T ) 1 ( ) . 1 - 0 1 . g i F e e S ( . x o b l o r t n o c e h t g n i r i w e h t n o s r o t c e n n o c e h t t c e n n o c s i D ) 2 ( . r o t a n r e t l a e h t o t x o b l o r t n o c[...]

- 39 - p e t Se v o m e r o t t r a Pn o i t p i r c s e Ds k r a m e Rl o o T 2k n a T l e u F. k a n t e h t m o r f l e u f e g r a h c s i D ) 1 ( . r e n i a r t s l e u f e h t t u h S . 1 . p u c r e n i a r t s e h t e v o m e R . 2 e h t r e d n u l e u f e v i e c e r o t l e s s e v a t u P . 3 o t k c o c l e u f e h t n e p o d n a r e[...]

- 40 - p e t Se v o m e r o t t r a Pn o i t p i r c s e Ds k r a m e Rl o o T 3d n a r e l f f u M r e v o c r e l f f u M e h t x i f h c i h w s t l o b o w t e h t e v o m e R ) 1 ( o w t e h t n e s o o L . r o t a n r e t l a e h t o t r e l f f u m e v o m e r d n a e g n a l f r e l f f u m e h t n o s t u n . e n i g n e e h t m o r f r e [...]

- 41 - p e t Se v o m e r o t t r a Pn o i t p i r c s e Ds k r a m e Rl o o T 4e m a r F e p i P0 0 1 6 V G R r o F ) 1 ( . e m a r f e h t m o r f r e n i a r t s l e u f e h t e v o m e R r e n n a p s m m 0 1 e n i g n e g n i x i f e r a h c i h w s t u n e h t e v o m e R ) 2 ( . s r e b b u r t n u o m e h t o t r o t a n r e t l a d n a ) .[...]

- 42 - p e t Se v o m e r o t t r a Pn o i t p i r c s e Ds k r a m e Rl o o T 5r e v o c r a e R) . 1 1 - 0 1 . g i F e e S ( . r e v o c d n e e h t e v o m e R ) 1 ( ) 0 0 1 6 V G R t p e c x E ( 6 φ . s c p 3 . . . t l o b r o r e n n a p s m m 0 1 h c n e r w x o b e h t n e t s a f h c i h w s t l o b r u o f e h t e v o m e R ) 2 ( . g i F [...]

- 43 - p e t Se v o m e r o t t r a Pn o i t p i r c s e Ds k r a m e Rl o o T 6r o t a t S. r e v o c r o t a t s e h t e v o m e R ) 1 ( Fig. 1 0 -1 4 Fig. 1 0 -1 5 SPRING WASHER : 4 pcs. REAR COVER COVER BOLT : 4 pcs. STATOR STATOR COVER BRUSHING GROMMET STATOR COVER STATOR[...]

- 44 - p e t Se v o m e r o t t r a Pn o i t p i r c s e Ds k r a m e Rl o o T 7r o t o R. t l o b h g u o r h t e h t f f o e k a T ) 1 ( f o d a e h e h t n o h c n e r w x o b a y l p p A h t i w e l d n a h h c n e r w e h t t i H . t l o b h g u o r h t . n e s o o l o t e s i w k c o l c - r e t n u o c r e m m a h a h c n e r w x o B r e m m[...]

- 45 - p e t Se v o m e r o t t r a Pn o i t p i r c s e Ds k r a m e Rl o o T 7r o t o Rr o t o r e h t f o d a e r h t e h t o t n i t l o b e h t w e r c S . 4 . t f a h s h c n e r w t e k c o s a g n i s u t l o b e h t e u q r o T . 5 . e s o o l f f o s e m o c r o t o r e h t l i t n u e h t e d i s n i e r u s s e r p c i l u a r d y h e h[...]

- 46 - 10-3 ASSEMBL Y 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 x 20 mm bolt . . . 4 pcs. M8 spring washer . . . 4 pcs. 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) M[...]

- 47 - 10-3-3 ST A TOR (1) Put the stator in the rear cover setting the four grooves on the side of stator with thread holes of the rear cover . (2) Attach the stator cover around the stator . 10-3-4 REAR COVER (1) Put the rear cover with stator over the rotor . T ap on the rear cover evenly with a plastic hammer to press the rotor bearing into the[...]

- 48 - 10-3-5 END COVER (RGV4100 only) Attach the end cover to the rear cover . 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. M8 flange nut . . . 4 pcs. NOTE : The mount rubbers are selected to reduce vibration most eff[...]

- 49 - (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) T emporarily fix the muffler bracket to either the rear or front covers for RGV6100 or RGV2800. M8 x 20 mm bolt and washer Ass’y . . . 2 pcs. (2) Attach the muffler cover 1 and the muf fler co[...]

- 50 - 3 For RGV2800 and 6100 : T ighten the two bolts to fix the muf fler bracket to the front cover , rear cover , and then the two bolts for the muffler to the muf fler bracket. M8 x 20 mm bolt and washer Ass’y . . . 4 pcs. (for RGV2800 and 6100) 10-3-8 FUEL T ANK (1) For RGV2600 and RGV4100 only : Attach the fuel strainer to the bottom of the[...]

- 51 - 10-3-9 FRONT P ANEL Mount the front panel assembly to the frame. Refer to Section 10-4 for disassembly , checking and reassembly procedures of 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 : Connect the wires of the same colo[...]

- 52 - 10-4-3 REASSEMBL Y (1) Install the receptacles, no-fuse breaker , terminals, switches, etc. on the control panel and wire them. NOTE : Circuit diagrams are shown in Section 12. Colored wires are used for easy identification, and are of the correct capacity and size. Use heat-resistant type wires (permissible temperature range 75 ° C or over[...]

- 53 - 1 1. TROUBLESHOOTING 1 1-1 NO AC OUTPUT 1 1-1-1 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. (2) If such a[...]

- 54 - (3) Check the insulation resistance between sta- tor core and each stator lead using a Dr . Robin generator tester in megger tester mode or a megger tester . (Fig. 1 1-3) If insulation is bad, replace stator with a new one. 1 1-1-3 CHECKING ROTOR (1) Remove rear cover and stator . (2) Using a Dr . Robin or a circuit tester , measure the resi[...]

- 55 - (3) Measure the insulation across one of the sol- dered terminals of the rotor and the core. (Fig.1 1-6) If insulation is bad, replace rotor with a new one. 1 1-2 AC VOL T AGE IS T OO HIGH OR TOO LOW 1 1-2-1 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.] * Loos[...]

- 56 - 1 1-3 AC VOL T AGE IS NORMAL A T NO-LOAD, BUT THE LOAD CANNOT BE APPLIED. 1 1-3-1 CHECK THE ENGINE SPEED. If the engine speed is low , adjust it to the rated r .p.m. *Refer to Step 1 1-2-1 for engine speed adjustment. 1 1-3-2 CHECK THE TOT AL W A TT AGE OF APPLIANCES CONNECTED T O THE GENERA TOR. Refer to Section 7 “RANGE OF APPLICA TIONS?[...]

- 57 - 1 1-4 NO DC OUTPUT 1 1-4-1 CHECK THE AC OUTPUT . Check the generator by following Step 1 1-1-1 through Step 1 1-1-3. 1 1-4-2 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[...]

- 58 - 1 1-4-6 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester . 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. 1 1-5 IDLE CONTROL 1 1-5-1 ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS APPLIED (1) Inspe[...]

- 59 - (4) Check the wiring through ZCT on the IDLE CONTROL UNIT . * Single V oltage T ype Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT . * Dual V oltage T ype 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 dir[...]

- 60 - 1 1-5-2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF . (1) Check the distortion of the SOLENOID BRACKET as shown in step 1 1-5-1-(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. [...]

- 61 - 12. WIRING DIAGRAM * RGV2800 : U.S.A., 60Hz-120V TYPE [NEMA RECEPT ACLE] * RGV4100 : U.S.A., 60Hz-120V/240V TYPE [NEMA RECEPT ACLE] V + - REC1 Field Winding Diode Sarge absorber Auxiliary Winding for condenser AC Winding 1 AC Winding 2 1.25Grn 1.25Brn 1.25Brn 1.25Y 1.25Y 2.0W 2.0R 2.0Blu 2.0Blk 2.0Blk Voltmeter No-fuse breaker AC output rece[...]

- 62 - *RGV6100 : U.S.A., 50Hz-120V/240V TYPE [NEMA RECEPT ACLE V + - 120V 120V 120/240V 120/240V 8 1 9 5 3 6 7 4 2 8 9 1 5 3 6 7 4 REC1 GENERATOR CONTROL BOX Field Winding AC Winding 2 AC Winding 1 DC Winding Diode Sarge absorber 2 0.75W 0.75W 0.75Blu 0.75Blu 0.75Blk/W 0.75Grn/W 0.75Grn/W 0.75Blk 0.75Grn Auxiliary Winding for condenser 2.0Blu 2.0B[...]

- 63 - + - CONTROL BOX 1.25Grn 1.25R 1.25Or 0.75Gry ST B -M +M IG Key switch 0.75Blk ( RGV4100 ) 1.25Blk ( RGV6100 ) Diode stack Assy ENGINE 0.75Blk 0.75Blk/W Oil sensor 0.75Grn/Y 0.75Grn/Y 0.75Blk/W Spark plug Battery Magnetiec switch 14Blk 14Blk 1.25Grn Electric starter 0.75Blu ( RGV4100 ) 0.75Grn/W ( RGV6100 ) Charge coil Ignition coil Earth (Gr[...]

- 64 - 1. SPECIFICA TIONS Specifications are subject to change without notice. * : Electric starter motor model : RGV4101 and RGV6101. ENGINE AL TERNA TOR l e d o M1 0 1 4 V G R1 0 1 6 V G R e p y T e s a h P e l g n i S , e l o P - 2 , g n i t i c x E f l e S , s s e l h s u r B C A y c n e u q e r F z H 0 6 t u p t u O m u m i x a MW 0 0 1 4W 0 0[...]

- 65 - 2. GENERA TOR 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. (2) If s[...]

- 66 - (3) Check the insulation resistance between sta- tor core and each stator lead using a Dr . Robin generator tester in megger tester mode or a megger tester . (Fig. 2-3) If insulation is bad, replace stator with a new one. 2-1-3 CHECKING ROTOR (1) Remove rear cover and stator . (2) Using a Dr . Robin or a circuit tester , measure the resistan[...]

- 67 - (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. 2-2 AC VOL T AGE IS TOO HIGH OR T OO 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[...]

- 68 - 2-3 AC VOL T AGE IS NORMAL A T NO-LOAD, BUT THE LOAD CANNOT BE 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 TOT AL W A TT AGE OF APPLIANCES CONNECTED T O THE GENERA TOR. Refer to Section 3 “ RANGE OF APPLICA TIONS ” for[...]

- 69 - 2-4 NO 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 cap[...]

- 70 - 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 . Fig. 2-13 Fig. 2-14 r e t s e t t i u c r i c e u g o l a n A r e t s e t t i u c r i c[...]

- 71 - 2-4-6 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester . 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) 2-5-1 ENGINE SPEED IS NOT INCREASED WHEN A LOAD IS AP[...]

- 72 - (4) Check the wiring through ZCT on the IDLE CONTROL UNIT . * Single V oltage T ype Make sure that an output wire from main coil is passing through the ZCT on the IDLE CONTROL UNIT . * Dual V oltage T ype 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 dir[...]

- 73 - 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) [...]

- 74 - 3. RANGE OF APPLICA TIONS 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, fr[...]

- 75 - (5) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a case, power consumption is to be worked out according to the numerical formula mentioned below . Efficiencies of some electrical appliances are as follows : Singl[...]

- 76 - 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 th[...]

- 77 - 4. WIRING DIAGRAM RGV4101 RGV4101 (Electric starter model) V + - 120V 120V 120/240V 120/240V REC1 W W REC3 GENERATOR CONTROL BOX Field Winding AC Winding 2 AC Winding 1 DC Winding Diode Sarge absorber Auxiliary Winding for condenser 2.0Blu 2.0Blk No-fuse breaker 2.0R Voltmeter 1.25Y 1.25Brn Condenser 2.0W 1.25Or 1.25Brn/W DC output terminal [...]

- 78 - RGV6101 RGV6101 (Electric starter model) V + - 120V 120V 120/240V 8 1 9 5 3 6 7 4 2 8 9 1 5 3 6 7 4 REC1 REC3 W W REC2 GENERATOR CONTROL BOX Field Winding AC Winding 2 AC Winding 1 DC Winding Diode Sarge absorber 2 0.75W 0.75W 0.75W 0.75Blu 0.75Blu 0.75Blk/W 0.75Grn/W 0.75Grn/W 0.75Blk 0.75Grn 2.0Grn Auxiliary Winding for condenser 2.0Blu 2.[...]

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