Subaru Robin Power Products RGV12100 manual

SERVICE MANUAL RGV12100 / 13100T Models PUB-GS1328 Rev . 09/01 GENERA TORS[...]

CONTENTS Section Title Page 1. SPECIFICA TIONS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 1 2. PERFORMANCE CURVES ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・[...]

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− − 1 − − 1. SPECIFICA TIONS Model RGV12100 Alternator T ype Rated voltage Brush, Self-exciting, 2-pole, Single phase 61 1 mm (752 mm * 1 ) Rated frequency 60Hz 771 mm (845 mm * 1 ) 120V / 240V Maximum output 12000V A Rated output 9500V A Length Power factor 1.0 Width V oltage regulator Height A.V .R type Engine Model EH65D T ype V -T win c[...]

− − 2 − − 2. PERFORMANCE CUR VES Hz ( Hz ) ( V ) ( 125 ) 63 250 ( 120 ) 240 ( 115 ) 230 ( 110 ) 220 62 61 60 0 1/2 4/4 Load Rated 240V/120V RGV12100 RGV13100T Hz ( Hz ) ( V ) 63 230 220 210 200 62 61 60 0 1/2 4/4 Load Rated 208V[...]

− − 3 − − 3. GENERAL DESCRIPTION OF GENERA T OR SPARK PLUG CAP FUEL COCK BATTERY TANK CAP SPARK PLUG CAP OIL FILLER CAP MUFFLER CONNECTOR FOR REMOTE CONTROL (RGV12100 only) END COVER (RGV13100T only) FUEL TANK CONTROL PANEL AIR CLEANER COOLING AIR INLET PORT OIL FILTER CHOKE KNOB (RGV13100T only) OIL GAUGE ELECTRIC STARTER OIL DRAIN PLUG[...]

− − 4 − − CONTROL P ANEL (RGV12100) KEY SWITCH OIL PURESSURE WARNING LAMP 0 2 4 0 110 120 2 2 0 IDLE CONTROL SWITCH VOLTMETER PILOT LAMP HOUR METER NO-FUSE BREAKER AC RECEPTACLE EARTH (GROUND) TERMINAL CONNECTOR FOR REMOTE CONTROL (RGV13100T) KEY SWITCH OIL PURESSURE WARNING LAMP 0 2 4 0 110 120 2 2 0 VOLTMETER PILOT LAMP HOUR METER NO-FUSE[...]

SERIAL NUMBER stamped label − − 5 − − SERIAL NUMBER Serial number is stamped on the label stuck on the end cover . NOTE : Always specify serial number when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service. (RGV13100T) (RGV12100)[...]

− − 6 − − 4. CONSTRUCTION AND FUNCTION 4-1 CONSTRUCTION MOUNT RUBBER BALL BEARING TROUGH BOLT FRONT COVER REAR COVER ROTOR COMPLETE STATOR COMPLETE STATOR BOLT END COVER (RGV13100T only) BRUSH HOLDER SLIP RING 4-2 FUNCTION 4-2-1 ST A T OR The stator consists of a laminated silicon steel sheet core, a main coil which is wound in the core slo[...]

− − 7 − − 4-2-2 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core. DC current in the field coil magnetizes the steel sheet core. T wo permanent magnets are provided for the primary exciting action (RGV13100T). Slip rings are provided on the rotor shaft to receive DC exciting curre[...]

− − 8 − − 4-2-5 A.V .R ( AUTOMA TIC VOL T AGE REGULA TOR ) (RGV12100 only) The automatic voltage regulator employs an electronic circuit to automatically regulate voltage. 4-2-6 ECU (ELECTRONIC CONTROL UNIT) ECU controls the start/stop of an engine enabling the fuel cut while stop. It also automatically stops the engine if an abnormal oil p[...]

− − 9 − − 4-2-7 IDLE CONTROL UNIT (RGV12100 only) The idle control unit 1 1 releases throttle valve when the applied load current exceeds 0.04A. The two output wires 2 2 from the main coils must go through the ZCT 3 3 in the same direction. NOTE : It is normal that the engine speed goes up for a moment when you turn the key switch to "[...]

− − 10 − − Model Specification No-fuse Breaker Object of Protection RGV12100 60Hz-120V/240V 39A T otal output amperage RGV13100T 60Hz-120V/208V 24A T otal output amperage 4-2-8 OIL PRESSURE SWITCH The oil pressure switch sends a signal to ECU to stop the engine when the engine oil pressure drops to 1.0 kg/cm 2 4-2-9 RELIEF V AL VE The relie[...]

− − 11 − − 4-2-1 1 AC Receptacle AC receptacles are used for taking AC output power from the generator . A total of 4 kinds of receptacle, each varying in rated voltage and current from another , are used. As many AC plugs as the receptacles, each matching the corresponding receptacle, are provided. The rated current for each receptacle is [...]

− − 12 − − ■ Check the amperage of the receptacles used referring to T ABLE 1 , and be sure not to take a current exceeding the specified amperage. ■ Be sure that the total wattage of all appliances dose not exceed the rated output of the gen- erator . T ABLE 1 NOTE : When the no-fuse breaker turns off during operation, the generator is[...]

− − 13 − − GFCI RECEPT ACLE After starting the engine, check the GFCI for proper functioning by the following test procedure. ■ Push blue TEST button, The red RESET button will pop out exposing the word TRIP . Power is now off at the outlets protected by the GFCI, indicating that the device is functioning prop- erly . ■ If TRIP dose not[...]

− − 14 − − MAIN POWER LINE TRANSFER SWITCH UTILITY HIGH LINE CONNECTING BOX 240V RECEPTACLE Utility high line Meter box Generator House circuit breaker XW Y X ( X )( Y ) ( G ) ( W ) WY XW Y Transfer switch 240V 4P- Receptacle 120V appliance 120V appliance 240V appliance OR Generator ( X ) ( Y ) ( G ) ( W ) 240V 4P- Receptacle W X Y[...]

− − 15 − − (c) Operating the generator . ■ T urn the house AC breaker off before starting the generator . ■ Start the generator and warm it up. ■ T urn the house AC breaker on. Do not start the generator with electrical appliance (s) connected and with their switch- es on. Otherwise the appliance (s) may be damaged by the surge voltag[...]

− − 16 − − SINGLE-PHASE OUTPUT W G Y X Z ■ Three phase application (208V) Insert the plug into the receptacle X, Y and Z. Generator rated output : 10000V A AC (THREE PHASE) RECEPT ACLE (RGV13100T only) RGV13100T has a receptacle for three plase (208V) and single phase (120V) as follows : ■ Single phase lower application (120V) Insert th[...]

− − 17 − − 4-3 DESCRIPTION of GENERA TOR OPERA TION 4-3-1 PRIMAR Y EXCITING ACTION (RGV12100) When the generator is started, the perma- nent magnet on the engine rotates to genera- tor a voltage in the exciting coil. This voltage is regulated by a diode in the A VR to feed a current to the generator field coil. (FC). (See Fig. 4-1) The roto[...]

− − 18 − − 4-3-4 THE ADV ANT AGES OF CURRENT TRANSFORMER CONTROL (RGV13100T) With A VR control, control is effected according to variations in output voltage. When an inductive load is applied, a large starting current is required (current variations are greater than voltage variation), precise control becomes difficult. Current transformer[...]

− − 19 − − 5. 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 inf[...]

− − 20 − − 6. 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 wattage of the appliance. The electrical appliances generally have a label show- ing their rated[...]

− − 21 − − NOTE 2 : Motor -driven appliances mentioned in lets (3) and (4) vary in their required motor starting power depending on the kind of motor and start-up load. If it is difficult to determine the optimum generator capacity , select a generator with a larger capacity . (5) Appliances without any indication as to power consumption So[...]

− − 22 − − NOTES : W iring 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 d[...]

− − 23 − − FOR AC 7. MEASURING PROCEDURES (2) AMMETER AC ammeter is necessary . An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable. (About 10 A, 20 A, 100 A) (3) FREQUENCY METER Frequency range : About 45 to 65Hz NOTE : Be careful of the frequency meter's input voltage [...]

− − 24 − − (4) CIRCUIT TESTER Used for measuring resistance, etc. (5) MEAGER TESTER Used for measuring generator insulation resistance. Select one with testing voltage range of 500V . 7-2 AC OUTPUT MEASURING SWITCH LOAD TO AC RECEPTACLE F A ~ V ~ Use a circuit above for measuring AC output. A hot plate or lamp with a power factor of 1.0 may[...]

− − 25 − − 7-3 MEASURING INSULA TION RESIST ANCE Use a megger tester to check the insulation resistance. Connect a megger tester to one of receptacle output terminals and the ground terminal, then measure the insulation resis- tance. An insulation resistance of 1M Ω or more is normal. If it is less than 1M Ω , disassemble the gen- erator [...]

− − 26 − − ● ROTOR Measure the resistance between the slip ring and the core. ● CONTROL P ANEL Measure the insulation resistance between the live parts and the grounded parts. ● CURRENT TRANSFORMER (RGV13100T) Measure the insulation resistance between each terminal and the core. If it is less than 1M Ω , replace the current transform[...]

− − 27 − − 8. CHECKING FUNCTIONAL MEMBERS PILOT LAMP 8-2 AC RECEPT ACLES Using a circuit tester , check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel. When continu- ity is found between the output terminals of the receptacle with a wire connected across these term[...]

− − 28 − − Model Hz/V oltage Stator coil Red - White Black - Blue Black - Red White - Light green Black - White RGV12100 60/120/240 0.1 1 Ω 0.1 1 Ω ------------ 0.37 Ω ------------ RGV13100T 60/120/208 0.23 Ω ------------ 0.23 Ω ------------ 0.23 Ω 8-4 ST A T OR Disengage connectors on the wires from stator and check the resistance be[...]

− − 29 − − 8-5 ROTOR ASSEMBL Y 1) Field coil Remove the brush holder and measure resistance between the slip rings. NOTE : If the circuit tester is not sufficiently accu- rate, it may not show the values given and may give erroneous readings. Erroneous reading will also occur when there is a wide variation of resistance among coil windings [...]

− − 30 − − 8-7 BRUSH The brushes must be smooth where they contact the slip rings. If not, polish smooth the brushes with sandpaper . A brush that is not smooth produces arcs between the brush and slip ring leading to possible damage. Usable brush lengths are from 5 mm to 15 mm (0.2 " to 0.6"). A brush shorter than 5 mm must be re[...]

− − 31 − − * Checking table for analogue circuit tester . Analogue circuit tester Apply black - needle of the circuit tester Y ellow Black 1 1 White 2 2 Light green 3 3 Brown 4 4 orY ellow Apply red + needle of the circuit tester Y ellow --------------- ∞ ∞ ∞ ∞ Black 1 1 ∞ --------------- 200 k Ω ∞ 300 k Ω White 2 2 ∞ 60 k ?[...]

− − 32 − − Tester ( - ) Tester ( ) Pin No. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 ! ! 0 0 ! ! 1 1 ! ! 2 2 ! ! 3 3 1 1 ------- ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ 2 2 ∞ ------- ∞∞∞∞∞∞∞∞∞∞∞ 3 3 ∞ 18.4M ------- 10M 10.2M ∞ 10.4M 11M 14.4M 5.3M ∞ ∞ ∞ 4 4 ∞ ∞ ∞ ------- 0.1 ∞ ∞ ∞ ∞ ∞ ∞ [...]

− − 33 − − 8-12 DIODE UNIT (RGV13100T only) Check the resistance between five wires of DIODE UNIT with circuit tester . Diode unit Apply black 〇 - needle of the circuit breaker Apply red 〇 + needle of the cir- cuit breaker Brown Y ellow 1 Y ellow 2 Y ellow 3 Light green Brown ------- ∞ ∞ ∞ ∞ Y ellow 1 16 ------- ∞ ∞ ∞ Y el[...]

− − 34 − − 9. DISASSEMBL Y AND ASSEMBL Y 9-1 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 neces- sary information to facilitate easier and smoother reassemble. 2) For more conveni[...]

− − 35 − − 9-3 COMPONENT P ARTS For disassembling and assembling, the following illustrations show the major component parts and their configuration for (1) Generator assembly , (2) Control Box and (3) Fuel T ank and sys- tem. The specified tightening torque is indicated in the illustration. (8) Loosen the through bolt of the rotor . (9) Re[...]

− − 36 − − (1) Generator assembly 11.8-13.7Nm 120-140Kg-cm 11.8-13.7Nm 120-140Kg-cm 22.5-24.5Nm 230-250Kg-cm ROTOR STATOR BEARING THROUGH BOLT REAR COVER GENERATOR BASE BRUSH COVER BRUSH HOLDER COVER BOLT FRONT COVER STATOR COVER BUSHING MOUNT RUBBER FLANGE NUT BOLT 11.8-13.7Nm 120-140Kg-cm END COVER RGV13100T only[...]

− − 37 − − (2-1) Control Box (RGV12100) CONTROL BOX PLATE NO-FUSE BREAKER AC RECEPTACLE CONNECTOR CAP A.V.R. ( AUTOMATIC VOLTAGE REGULATOR ) IDLE CONTROL UNIT ECU (P4) EARTH ( GROUND ) TERMINAL VOLTMETER STARTER SWITCH CONTROL PANEL OIL PRESSURE WARNING LAMP GROMMET IDEL CONTROL SWITCH GROMMET CLAMP PILOT LAMP HOUR METER AC RECEPTACLE CONNE[...]

(2-2) Control Box (RGV13100T) CURRENT TRANSFORMER CONTROL BOX GROMET NO-FUSE BREAKER AC RECEPTACLE PILOT LAMP STARTER SWITCH OIL PRESSURE WARNING LAMP GROMMET CLAMP PLATE DIODE UNIT 05 EARTH ( GROUND ) TERMINAL AC RECEPTACLE WIRE VOLTMETER CONTROL PANEL HOUR METER ECU ( P4 ) RELAY − − 38 − −[...]

− − 39 − − (3) Fuel T ank FUEL GAUGE FUEL TANK CAP FUEL TANK FILTER PACKING CUP HOSE CLAMP HOSE CLAMP RUBBER PIPE ( 120 mm ) RUBBER PIPE ( 630 mm ) PURSE LOCK FUEL FILTER FRANGE BOLT ( M6 x 14 mm ) RUBBER WASHER FUEL PUMP FLANGE BOLT ( M6 x 14 mm ) FUEL STRAINER A DETAIL A[...]

− − 40 − − 9-4-1 FRONT COVER Attach the front cover to the engine main bearing cover . Match the faucet joint and tighten the bolts. FRONT COVER BOLT SPRING WASHER WASHER 9-4-2 ROTOR (1) Wipe off oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft. (2) Mount the rotor to the engine shaft. T[...]

− − 41 − − Fig. 9-8 9-4-3 ST A T OR (1) Put the stator in the rear cover setting the four grooves on the side of stator with thread holes of the rear cover . T ighten the four bolts tentatively to check if the grooves and thread holes are aligned correctly . (See Fig.9-8) (2) Remove the four bolts. STATOR COVER STATOR Fig. 9-7[...]

− − 42 − − 9-5 REAR COVER (1) Put the rear cover with stator and stator cover over the rotor . Pull wires out from the rear cover . NOTE : Be careful not to give cuts to wires when pulling them out from the rear cover . Attach the bushing over the lead wire drawn out from the rear cover . Press the smaller end of the bushing into the window[...]

− − 43 − − NOTE : When tightening the nuts, slightly lift the alternator assembly so that the weight is not applied to the mount rubbers. (7) Fasten the earth cable to the unpainted bolt hole on the frame. EARTH CABLE Attach the connectors to the brush holders. Connector the green wire to the stator end and the brown wire to the bearing end[...]

10. TROUBLESHOOTING 10-1 No AC output * Checking the exciting coil for resistance. (RGV12100) (Refer to 8-6.) If insulation is NG, replace exciting coil with new one. * Checking the brush and slip ring of rotor for resistance. (Refer to 8-5 and 8-7.) If insulation is NG, replace brush and slip ring with new one. * Check stator for winding resistanc[...]

− − 45 − − 10-4 Engine dose not run. Symptom Possible causes Remedy 1. Electric starter dose not operate 1) The key switch (or remote switch) is turned to "START" within 2 seconds the engine has been stopped. Wait for more than 2 seconds and then turn the key switch to "START" position. 1) No fuel in the tank or the fuel[...]

53 2 4 (AC output) ( AVR ) 1 CONTROL BOX Fuel cut Ignition coil Auto choke ( Bimetal ) Electric starter Oil pressure switch Regulator Magnetic switch Charge coil Exciting coil - + Battery 12V Grn/Y Grn LBlu Gry W Key switch to earth terminal ST Relay Connector ( Remote control ) Gry R15 Blk15 Grn W W W Blk/W Gry Gry Blk R Blk/W Blk R Grn/Y Grn/Y Gr[...]

− − 47 − − ( RGV13100T ) CONTROL BOX 1 Fuel cut Ignition coil Electric starter Oil pressure switch Regulator Magnetic switch Oil pressure warning lamp ( Red ) Charge coil Electronic control unit - + Battery 12V Blk15 R15 LGrn Gry Blk Blk Grn 2 13 3 12 4 11 5 10 6 987 R W W W W Org Grn/Y Org R Org Blk/W Blk/W R/W Gry Grn Blk R Blk Key switch[...]

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