Robin America RGV12100 Service Manual Download

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(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

CONNECTOR
for REMOTE
CONTROL

WIRE

RELAY

Summary of Contents for RGV12100

Page 1: ...SERVICE MANUAL RGV12100 13100T Models PUB GS1328 Rev 09 01 GENERATORS ...

Page 2: ...29 8 7 BRUSH 30 8 8 A V R AUTOMATIC VOLTAGE REGULATOR 30 8 9 CURRENT TRANSFORMER RGV13100T only 31 8 10 ECU ELECTRONIC CONTROL UNIT 31 8 11 IDLE CONTROL UNIT RGV12100 only 32 8 12 DIODE UNIT RGV13100T only 33 9 DISASSEMBLY and REASSEMBLY 34 9 1 PREPARATION and PRECAUTIONS 34 9 2 DISASSEMBLY PROCEDURES 34 9 3 COMPONENT PARTS 35 9 4 GENERATOR ASSEMBLING PROCEDURES 40 10 TROUBLESHOOTING 44 10 1 NO AC...

Page 3: ... 04 ...

Page 4: ... Maximum output 22 HP 3600 rpm Fuel Unleaded automobile gasoline RON87 or higher Oil capacity 1 55 liters Starting system Electric starter Fuel tank capacity 44 liters Rated continuous operation per a tankful of fuel 3 4 Rated Approx 9 0 hours Rated Approx 8 2 hours Noise level Rated dB 7m 77 0 dB Dimensions 826 mm Dry weight 141 kg 149 kg 2 RGV13100T 120V 208V 13000VA 10000VA 0 8 Approx 9 7 hours...

Page 5: ... 2 2 PERFORMANCE CURVES 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 ...

Page 6: ...K 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 ...

Page 7: ...OLTMETER PILOT LAMP HOUR METER NO FUSE BREAKER AC RECEPTACLE EARTH GROUND TERMINAL CONNECTOR FOR REMOTE CONTROL RGV13100T KEY SWITCH OIL PURESSURE WARNING LAMP 0 24 0 110 120 220 VOLTMETER PILOT LAMP HOUR METER NO FUSE BREAKER AC RECEPTACLE AC THREE PHASE and SINGLE PHASE RECEPTACLE EARTH GROUND TERMINAL ...

Page 8: ...ed 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 ...

Page 9: ...L 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 STATOR The stator consists of a laminated silicon steel sheet core a main coil which is wound in the core slots ...

Page 10: ...00 and diode unit RGV13100T 4 2 3 BRUSH BRUSH HOLDER An exciting current is supplied from the A V R to the rotor The brushes are made of carbon and the brush holder of plastic It is necessary to keep the contact pressure between the brushes and slip rings withing specific limits Thus care must be taken of brush length 4 2 4 CURRENT TRANSFORMER DIODE UNIT RGV13100T only The current transformer and ...

Page 11: ...escription of Operation Warning lamp When the lubrication oil pressure drops below the safety limit Oil pressure becomes less than 1kg cm2 and or the engine speed ups above the safety limit Engine speed increases higher than 4 500 r min for 7 seconds the warning lamp repeats turning on and off and the engine stops automati cally The warning lamp turns off after 3 minutes Starter motor control When...

Page 12: ...OP the fuel cut off valve closes If the starter motor is locked by any reason the starter motor is shut off automatically after 3 seconds When the engine dose not start engine speed does not reach 1 050 r min the starter motor is stopped after 21 seconds When the remote controller is connected the electric starter dose not run when the switch of remote controller is turned OFF even if the key swit...

Page 13: ...hen the engine oil pressure drops to 1 0 kg cm2 4 2 9 RELIEF VALVE The relief valve begins to open when the engine s oil pressure increases above 3 0 kg cm2 4 2 10 AC SWITCH NO FUSE BREAKER The AC switch no fuse breaker protects the generator from getting damage by overloading or short circuit in the appliance The capacity of AC switch no fuse breaker is as follows OIL PUMP OIL PUMP FILTER CRANKSH...

Page 14: ...urrent for each receptacle is shown as follows Be careful not to use the receptacles beyond the specified amperage limits to prevent burning CAUTION CAUTION To connect the appliance to the locking type receptacle insert the plug in to the receptacle and then turn it clockwise to lock TWIST Total 50A or less 20A or less 30A or less 50A or less 30A or less AC120V MAX 20A MAX 20A MAX 30A MAX 30A MAX ...

Page 15: ... as necessary by Robin dealer or service shop The duplex 120V receptacle is protected by a GFCI Ground Fault Circuit Interrupter GFCI shuts off the output current from the duplex 120V receptacle when a ground fault occurs in the generator or the appliance Please note that other receptacles are not protected by GFCI CAUTION up to 30A up to 30A up to 20A NEMA 5 20R NEMA L5 30R NEMA L14 30R NEMA 5 20...

Page 16: ...dential or commercial power lines such as a stand by power source during power outage all connections must be made by a licensed electrician Failure in connection may result in death personal injury damage to generator dam age to appliances damage to the building s wiring or fire WARNING a When connecting a Robin generator to a house wiring generator output power must be taken from the 240V 4P rec...

Page 17: ...H LINE CONNECTING BOX 240V RECEPTACLE Utility high line Meter box Generator House circuit breaker X W Y X X Y G W W Y X W Y Transfer switch 240V 4P Receptacle 120V appliance 120V appliance 240V appliance OR Generator X Y G W 240V 4P Receptacle W X Y ...

Page 18: ...tage at starting CAUTION 4 2 12 3 PHASE APPLICATION RGV13100T only Connection of Power Cables Do not touch output terminals while the generator is running or the operator may suf fer severe electric shock resulting in death Be sure to shut down the generator before connecting or changing connection of power cables to the generator WARNING This generator has four output terminals of three phase fou...

Page 19: ...00T only RGV13100T has a receptacle for three plase 208V and single phase 120V as follows Single phase lower application 120V Insert the plug into the receptacle W and X W and Y W and Z Maximum one third 1 3 of generator output can be utilized from each phase W G Y X Z 3 PHASE OUTPUT Generator rated output 3324VA 120V x 27 7A SINGLE PHASE AC120V THREE PHASE AC208V W Y X Z ...

Page 20: ...ain coil and DC coil 4 3 2 VOLTAGE REGULATING MECHANISM RGV12100 Connect a load to the AC output terminal and increase current Output voltage varies as shown in Fig 4 3 depending on whether an automatic voltage regulator is used or not The operation of the AVR is explained below When an AC output is taken the engine is loaded and its rpm falls Also the AC voltage fails due to the voltage drop caus...

Page 21: ... When a load makes contact with the coil the load current passing through the primary coil of current transformer causes a magnetizing current to flow in ratio to the load current flowing through the current transformer primary coil This magnetizing current passing through a diode to field coil creates a strong magnetic field in the rotor which falls with the amount of the load increasing the volt...

Page 22: ...ate the generator on a level surface If the generator is tilted or moved during use there is a danger of fuel spillage and a chance that the generator may tip over 5 Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is wet by rain or snow wipe it and thor oughly dry it before starting Don t pour water over the generator directly nor wash it with water If...

Page 23: ...requires 600 W to 700 W power source to be turned on A rated 3000 W generator can power four or five 400 W mercury lamps NOTE 1 If a power factor correction capacitor is not applied to the mercury lamp or fluorescent lamp the more power shall be required to drive those lamps A rated 3000W generator can drive one or two 400W mercury lamps without power fac tor correction capacitors NOTE 2 Nominal w...

Page 24: ...to 0 9 Fluorescent lamp 0 7 to 0 8 Example 1 A 40 W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 7 57W As explained in Item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get the figure of the necessary capacity of a generator In other words a genera tor with a rated output of 1000 W capacity c...

Page 25: ...e to the load electrical product As a result the load can be damaged Table 7 2 shows voltage drops per 100 meters of cable 1 Voltage drop indicates as V 100 R I R means resistance Ω 100 m on the above table I means electric current through the wire A means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools Nominal cross s...

Page 26: ...Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range 7 1 MEASURING INSTRUMENTS 1 VOLTMETER AC voltmeter is necessary The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows 0 to 150 V Type with an output voltage of 110 or 120 V 0 to 300 V Type with an output voltage of 220 230 or 240 V 0 to 150 V 0 to 33...

Page 27: ...th 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 be used as a load Adjust the load and rpm and check that the voltage range is as speci fied in the following table at the rated amperage and rated rpm ...

Page 28: ... the gen erator and measure the insulation resistance of the stator rotor and control panel individu ally STATOR 1 Measure the insulation resistance between BLUE RGV12100 GREEN RGV13100T lead and the core 2 Measure the insulation resistance between WHITE lead and the core 3 Measure the insulation resistance between BLACK lead and the core 4 Measure the insulation resistance between RED lead and th...

Page 29: ...arts and the grounded parts CURRENT TRANSFORMER RGV13100T Measure the insulation resistance between each terminal and the core If it is less than 1MΩ replace the current transformer Any part where the insulation resistance is less than 1MΩ has faulty insulation and may cause electric leakage and electric shock Replace the faulty part ...

Page 30: ... between the output terminals of the receptacle with a wire connected across these terminals the AC receptacle is normal When the wire is removed and no continuity is found between these terminals the recep tacles are also normal 8 1 PILOT LAMP and VOLTMETER Check the pilot lamp and the voltmeter if it is turned on by applying specific voltage Pilot lamp and voltmeter cannot be checked with circui...

Page 31: ...ficiently accu rate it may not show the values given and may give erroneous readings Erroneous readings will also occur when there is a wide variation of resistance among coil windings or when measure ment is performed at ambient tempera tures different from 20 68 F 8 3 AC SWITCH NO FUSE BREAKER Check continuity between each of 2 terminals at the back side of AC switch no fuse breaker while it is ...

Page 32: ... gener ator efficiency and output voltage Polish the slip rings with fine sandpaper while turning the rotor until rough spots disap pear Care should be taken not to touch the rotor coils with the sandpaper Rotor Slip ring Resistance RGV12100 4 11Ω RGV13100T 69 6Ω SLIP RING ROTOR SANDPAPER 8 6 EXCITING COIL RGV12100 only 1 Disconnect the two yellow wires which come out from the exciting coil throug...

Page 33: ...R or by the inter lead resistance with a tester or actually mount ing it in the generator and operating it 2 4 1 3 Terminal number of the A V R Yellow a A V R TROUBLE IDENTIFICATION by APPEARANCE If an A V R electronic part is burnt dark or the surface epoxy resin melted it often indi cates A V R trouble b IDENTIFYING A V R TROUBLE by CHECKING INTER LEAD RESISTANCE Check the inter lead resistance ...

Page 34: ... orYellow 250 kΩ 100 kΩ 8 9 CURRENT TRANSFORMER RGV13100T only Disconnect the connectors and couplers of current transformer Check the inter terminal resistance of current transformer with a circuit tester If current transformer is found to be faulty replace with new one 8 10 ECU ELECTRONIC CONTROL UNIT Check the resistance between 13 terminals of ECU with circuit tester Terminal number of the ELE...

Page 35: ... 3 1 2 NOTE The resistance readings vary depending on the types of circuit testers The above table shows an example of the resistance readings measured by an ordi nary analogue circuit tester with 1 5 volt battery power source It is advisable for you to check the resistance readings using your standard circuit tester and revise the checking table Terminal number of the IDLE CONTROL UNIT Circuit te...

Page 36: ...tween 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 Yellow 1 Yellow 2 Yellow 3 Light green Brown Yellow 1 16 Yellow 2 16 Yellow 3 16 Light green 30 16 16 16 ...

Page 37: ...e disassembled parts with care clean them before reassemble using a neutral clean ing fluid 5 Use all disassembly assembly tools properly and use the proper tool for each specific job 9 2 DISASSEMBLY PROCEDURES 9 2 1 CONTROL PANEL 1 Remove the front panel 2 Disconnect the connectors on the wiring from the front panel to the alternator 9 2 2 ALTERNATOR 1 Remove the end cover 2 Remove the brush cove...

Page 38: ...ied tightening torque is indicated in the illustration 8 Loosen the through bolt of the rotor 9 Remove the rotor with the soft hammer See Fig 9 4 NOTE Temporarily tighten the through bolt of the rotor when hit the rotor See Fig 9 4 10 Remove the front cover ROTOR SOFT HAMMER THROUGH BOLT Fig 9 4 Fig 9 3 7 Remove the stator See Fig 9 3 NOTE The stator is heavy Be careful do not hit the coil of the ...

Page 39: ...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 ...

Page 40: ... 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 CONNECTOR for REMOTE CONTROL WIRE RELAY ...

Page 41: ...RANSFORMER 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 ...

Page 42: ...UGE 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 ...

Page 43: ...l grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft 2 Mount the rotor to the engine shaft Tighten the through bolt ROTOR SPRING WASHER WASHER THROUGH BOLT BEARING 9 4 GENERATOR ASSEMBLING PROCEDURES Fig 9 5 Fig 9 6 Tightening torque 230 250 kg cm 22 5 24 5 N m 16 6 19 5 ft lbs Tightening torque 120 140 kg cm 11 8 13 7 N m 8 7 10 1 ft lbs ...

Page 44: ...ar cover setting the four grooves on the side of stator with thread holes of the rear cover Tighten 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 ...

Page 45: ...all the brush holders in the rear cover Pass the mounting screws through the brush holders push the brush holders so that the brushes will be perpendicular to the slip rings and tighten the screws NOTE There are two kinds of brush holders If a brush is installed oblique to the slip ring the brush holder can break when the screw is tightened or the brush may break when the generator of started Afte...

Page 46: ...olt 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 Install the brush cover 5 RGV13100T only Attach the end cover to the rear cover 6 Tighten the nuts over the mount rubber bolts to fix Fig 9 12 Fig 9 13 Tightening torque 120 140 kg cm 11 8 13 7 N m 8 7 10 1 ft lbs ...

Page 47: ... Voltage is too high or too low Check engine speed Nominal engine speed at no load 3 700 to 3 750 rpm If engine speed is too high or too low adjust to the rated rpm Check stator for winding resistance and insulation Refer to 8 4 and 7 3 Check rotor for resistance and insulation Refer to 8 5 and 7 3 Checking the idle control unit RGV12100 Refer to 8 11 If insulation is NG replace idle control unit ...

Page 48: ...remote controller is con nected Both the key switch of the generator and the switch of remote controller must be turns into ON position 3 The above possible causes 1 and 2 dose not apply The ECU is defective Replace with new one 2 Warning lamp turns on and off when engine is stopped Supply fuel or open the fuel cocks 2 Oil level is low or oil is contami nated Add or change engine oil 3 Engine is a...

Page 49: ...amp Red LGrn Org Blk Blu Blk R R Blk W W W LGrn Grn Y Grn Y Grn Y Grn Y Brm CONTROL BOX GENERATOR No fuse breaker Voltmeter Hour meter Pilot lamp V Hr PL Earth Ground terminal Brush Auxiliary Winding Field Winding AC Winding AC Winding AVR Exciting coil Engine Idle control unit AC otuput receptacle 120V AC output receptacle 120V AC output receptacle 120 240V AC output receptacle 120 240V Y Y REC1 ...

Page 50: ...R Blk Key switch to earth terminal OFF M M B L IG ST ON START ST Relay Gry Grn Org Grn Y Grn Y Y Brn Org LBlu R Grn W Blk R W Blk Brn Grn W Y R Y W Y Blk GENERATOR CONTROL BOX V PL Hr AC Winding Feld Winding Brush Brush Diode unit AC output receptacle 120V REC1 AC output receptacle 120V Single phase 208V Three phase REC5 AC output receptacle 120V REC2 W X W W H G G G Y Z Grn Y Grn Y Voltmeter No f...

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