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Robin America RGV2800, Service Manual

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Robin America RGV2800 Service Manual Download Page 7

- 4 -

DC OUTPUT

DC Voltage ................. 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 simultaneously up to the rated output in total.

Summary of Contents for RGV2800

Page 1: ...PUB GS1277 Rev 1 04 SERVICE MANUAL RGV2800 RGV4100 RGV6100 Models Generators ...

Page 2: ...BILITY 6 4 GENERAL DESCRIPTION 7 4 1 EXTERNAL VIEW 7 4 2 CONTROL PANEL 8 4 3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER 9 5 CONSTRUCTION AND FUNCTION 10 5 1CONSTRUCTION 10 5 2 FUNCTION 10 5 3 GENERATOR OPERATION 16 5 4 OIL SENSOR 19 6 SAFETY PRECAUTIONS 22 7 RANGE OF APPLICATIONS 23 8 MEASURING PROCEDURES 26 8 1 MEASURING INSTRUMENTS 26 8 2 AC OUTPUT MEASURING 29 8 3 DC OUTPUT MEASURING 29...

Page 3: ...VOLTAGE IS NORMAL AT NO LOAD BUT THE LOAD CANNOT BE APPLIED 56 11 4 NO DC OUTPUT 57 11 5 IDLE CONTROL OPTIONAL EQUIPMENT 58 12 WIRING DIAGRAM 61 NOTE As for the servicing information on engine protion please refer to the EH17 2 EH25 2 and EH34 engine service manual Troubleshooting Manual RGV4101 RGV6101 64 1 SPECIFCATIONS 64 2 GENERATOR TROUBLE SHOOTING 65 2 1 No AC output 65 2 2 AC voltage is too...

Page 4: ...d e l o o C r i A l e d o M D 2 7 1 H E D 2 5 2 H E t n e m e c a l p s i D m c 2 7 1 3 n i u c 0 5 0 1 m c 1 5 2 3 n i u c 2 3 5 1 t u p t u O d e t a R m p r 0 0 6 3 P H 0 4 m p r 0 0 6 3 P H 4 6 l e u F e n i l o s a G e l i b o m o t u A y t i c a p a C k n a T l e u F s r e t i l 2 1 l a g S U 7 1 3 s r e t i l 6 6 1 l a g S U 8 3 4 n o i t a r e p O s u o u n i t u o C d e t a R s r u o h 0 ...

Page 5: ... i g n E e n i l o s a G e v l a V d a e h r e v O e l c y C 4 d e l o o C r i A l e d o M D 4 3 H E t n e m e c a l p s i D m c 8 3 3 3 n i u c 3 6 0 2 t u p t u O d e t a R m p r 0 0 6 3 P H 0 8 l e u F e n i l o s a G e l i b o m o t u A y t i c a p a C k n a T l e u F s r e t i l 5 1 2 l a g S U 7 6 5 n o i t a r e p O s u o u n i t u o C d e t a R s r u o h 0 7 y t i c a p a C l i O s r e t i...

Page 6: ... 3 2 PERFOMANCE CURVES Hz Hz V 125 63 250 120 240 115 230 110 220 62 61 60 0 1 2 4 4 Load Rated 230V 115V ...

Page 7: ... voltage curve shown in the left indicates the characteristic of DC output when charging a battery The voltage may be decreased by 20 when the resistance load is applied NOTE It is possible to use both DC and AC outputs simultaneously up to the rated output in total ...

Page 8: ...generator delivers a quiet operation with A large super silent muffler A quiet 4 stroke Robin Rro OHV 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 which is sufficient for a half day or one day work without ...

Page 9: ... A dust proof cyclone air cleaner 3 10 LONG LIFE DURABILITY The heavy duty 4 stroke Robin Rro OHV engine and virtually maintenance free brushless alternator ensure greater durability with A brushless alternator with a condenser voltage regulator Full rubber mount in a sturdy tubular frame A forged steel crankshaft supported by two main ball bearings A pointless electronic ignition system A cast ir...

Page 10: ...C 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 ...

Page 11: ... 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 DC OUTPUT DC BREAKER ON OFF DC 12V 8 3A BATTERY CHARGE ONLY AC BREAKER ON OFF AC MAX 20A AC MAX 20A AC MAX 30A IDEL CONTROL ON OFF ON OFF 20A 30A 125V TEST TEST RESET RESET ...

Page 12: ...box NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service ENGINE SWITCH V METER DC OUTPUT AC BREAKER DC BREAKER ON OFF ON OFF DC 12V 8 3A BATTERY CHARGE ONLY AC 120V AC 120V 240V FULL POWER SWITCH 120V 120V 240V IDEL CONTROL ON OFF ON OFF 20A 30A 150V AC MAX 20A AC MAX 30A AC MAX 20A TEST TEST RESET RESET LAB...

Page 13: ... 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 STATOR COMPLETE REAR COVER BALL BEARING CRANKSHAFT ROTOR COMPLETE THROUGH BOLT COVER BOLT FRONT COVER MOUNT RUBBER ...

Page 14: ...ate the output voltage 5 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action A diode rectifier and surge absorber is mounted inside of the insulator Fig 5 3 Fig 5 4 Fig 5 5B Fig 5 5A ...

Page 15: ...d Each model has at least one receptacle to deliver the rated generator output As many AC plugs as the receptacles each matching the correspond ing receptacle are provided Table 5 2 shows the rated current for each receptacle Be careful not to use the receptacles and AC plugs beyond the specified amperage limits to prevent burning Fig 5 6 Table 5 1 L E D O M N O I T A C I F I C E P S R E K A E R B...

Page 16: ...ioning 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 pops out during operation stop the generator immediately and call a qualified electrician for checking generator and the appliances Caution To connect the appliance to locking receptacle insert the plug into the re ceptacle and tu...

Page 17: ...o a house wiring generator output power must be taken from the 240V 4P receptacle b Install a transfer switch A transfer switch must be installed to transfer the load from the commercial power source to the generator This switch is necessary to prevent accidents caused by the recovery from power outage Use a transfer switch of the correct capacity Install transfer switch between the meter and the ...

Page 18: ... 10 c Operating the generator Set the full power switch to 120V 240V side Turn the house AC breaker off before starting the generator Start the generator and warm it up Turn the house AC breaker on Caution Do not start the generator with electrical appliance s connected and with their switches on Otherwise the appliance s may be damaged by the surge voltage at starting ...

Page 19: ... the condenser coil the density of magnetic flux in the rotor changes This change of magnetic flux induces AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies this AC voltage into DC Thus a DC current b flows through the field coil and magne tizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 3000 to 3300 rpm the c...

Page 20: ...e type to take out the full rated power from one receptacle in each voltage Fig 5 12 Fig 5 13 Fig 5 14 Table 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 0 4 2 0 2 1 t u p t u o d e t a r f o f l a H t u p t u o d e t a R ...

Page 21: ...en out Rec 2 for the lower voltage can output up to the rated power up to 30A if the rated current is over 30A and Rec 1 can output up to a total of 15A When the full power switch is set for double voltage indication 120V 240V the switch position is as indicated by the upper dotted line in Fig 5 12 Fig 5 14 is a simplified representation of this circuit showing the two main coils connected in seri...

Page 22: ... Influence against the ignition system or the electronics units can be neglected because an electric current supplied to the sensor can be decreased 5 4 2 PRINCIPLE OF SENSING OIL LEVEL There is a great difference between electric resistance of air and that of oil Since the resistance of air is far higher than that of oil more electric current passes through the oil than through the air although a...

Page 23: ...ensor has been designed so that the engine is to be stopped only when oil shortage is detected for 5 seconds uninter rupted The timer employs an integration circuit and it is to be reset when the inner electrode is soaked in the oil again before the sensor decides it as oil shortage The oil level where the sensor decides as oil shortage when oil level goes down gradually is called threshold level ...

Page 24: ...been designed to have enough antinoise properties in practical use do not route the sensor wirings in the vicinity of noise generating sources such as ignition plugs or high voltage cords This may cause malfunction or breakdown 2 Since capacity of power source is limited current flown in the electronic circuit of the sensor is kept as low as possible Be sure to use terminals with a high contact re...

Page 25: ... rain or snow wipe it and thoroughly dry it before starting Don t pour water over the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leakage and electric shock 6 Do not connect the generator to the commercial power lines This may cause a short circuit or damage to the generator Use a transfer switch Opti...

Page 26: ...an their running wattage Example A rated 250 W electric drill requires a 400 W generator to start it NOTE1 If a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps NOTE2 Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to t...

Page 27: ...urteen 40 W fluorescent lamps Example 2 Generally speaking a 400 W motor means that its work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570 W When this motor is used for a motor driven tool the capacity of the generator should be multiple of 570 W by 1 2 to 3 as explained in the ltem 3 570 W x 1 2 to 3 684 W to 1710 W Power consumpition Output of electrical...

Page 28: ...n be damaged Table 7 2 shows voltage drops per 100 meters of cable Voltage drop indicates as V x R x I x L R means resistance Ω 100 m on the above table I means electric current through the wire A L means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools l a n o i t c e S m m a e r a 3 e l b a w o l l A A t n e r r u c a...

Page 29: ...following part number Dr Robin Part Number 388 47565 08 If you do not have a Dr Robin generator tester use the instruments described in the following section for checking generator parts SPECIFICATIONS Fig 8 1 L E D O M n i b o R r D r e b m u N t r a P 8 0 5 6 5 7 4 8 8 3 g n i r u s a e M e g n a R e g a t l o V C A V 0 0 5 o t 0 y c n e u q e r F z H 0 7 o t 5 2 e c n a t s i s e R 9 9 9 1 o t ...

Page 30: ...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 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10A 20A 100A 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range Fig 8 2 Fi...

Page 31: ... Used for measuring resistance etc 5 MEGGER TESTER Used for measuring generator insulation re sistance Select one with testing voltage range of 500V 6 TACHOMETER Use the contactless type tacho meter Fig 8 5 Fig 8 6 Fig 8 7 ...

Page 32: ...C output is executed with the switch turned ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal NOTE If 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 and do not overcharge the ...

Page 33: ... 10 megohm or more If it is less than 1 megohm disassemble the generator and measure the insulation resis tance of the stator rotor and control panel indi vidually NOTE Turn on the no fuse breaker before mea surement STATOR 1 Measure the insulation resistance between BLUE lead and the core 2 Measure the insulation resistance between WHITE lead and the core 3 Measure the insulation resistance betwe...

Page 34: ...insulation resistances between the live parts and the grounded parts 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 Fig 8 13 ...

Page 35: ...t the rear of the AC receptacles while the receptacle is mounted on the control panel When continuity is found between the output terminals of the receptacle with a wire connected across these terminals the AC receptacle is normal When the wire is removed and no continuity is found between these terminals the receptacles are also normal 9 3 No FUSE BREAKER Check continuity between each of two term...

Page 36: ...lso occur when there is a wide variation of resis tance among coil windings or when measurement is performed at ambient temperatures differ ent from 20 C 68 F Fig 9 4 Table 9 1 L E D O M n o i t a c i f i c e p S g n i d n i W C A r e s n e d n o C g n i d n i W z H e g a t l o V d e R e t i h W e u l B k c a l B w o l l e Y w o l l e Y 0 0 8 2 V G R 0 6 V 0 4 2 V 0 2 1 V 0 2 1 8 5 0 8 5 0 7 6 1 0...

Page 37: ... the values given and may give er roneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 20 C 68 F 9 6 CONDENSER Use a Dr Robin in capacitance meter mode to check the capacity of condensers NOTE Be sure to discharge condensers by shorting condenser leads each other b...

Page 38: ...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 e h t f o e l d e e n s u n i m k c a l b y l p p A n w o r B n w o r B e g n a r O e t i h W n w o r B f o e l d e e n s u l p d e r y l p p A r e t s e t t i u c r i c e h t n w o r B y t i u n i t n o c o N y t i u n i t n o c o N y t i u n i t n o C n w o r B y t i u n i t n o c o N y t i u n i t n o c o N y t i u n i t n o C e g n a r O ...

Page 39: ... Connect the removed wires again with the oil sensor 5 Start the engine with the oil sensor removed and confirm if a Engine stops after 5 seconds which is normal or b Engine does not stop after more than 10 seconds which is unusual NOTE The sensor will not operate properly when wire is broken or poorly connected Check the wires for correct connection If it fails to stop within 5 seconds after the ...

Page 40: ...ormation to facilitate easier and smoother reassembly 2 For more convenience divide the parts into several groups and store them in 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 p...

Page 41: ... e S f o d n e r e p p u e h t s s e r P l l u p d n a g n i h s u b e h t t u o 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 3 e h t d n a x o b l o r t n o c e h t m o r f n e e w t e b 2 0 1 g i F e e S e n i g n e e h t e v o m e r d n a s t l o b r u o f e h t f f o e k a T 4 3 0 1 g i F e e S e m a r f e h t x o b l o r t n o c d n a t l o b m m 2 1 x 5 s c p 2 k c a l...

Page 42: ...h c a t t A 4 y d o b t u o b a e r a c t s o m t u e s U d r a z a h e r i f l e u f t i l p s f f o e p i W y l h g u o r o h t r e t l i f e h t e s o l t o n o D n e e r c s 2 r e n i a r t s e h t m o r f e p i p r e b b u r t c e n n o c s i D e h t f o p o t e h t n o p m a l c e s o h e h t n e s o o L m o r f e p i p r e b b u r e h t t u o l l u p d n a r e n i a r t s r e n i a r t s e ...

Page 43: ... c p 2 t u n s s e l n i a t s m m 8 s c p 2 r e h s a w g n i r p s m m 8 0 0 1 6 V G R d n a 0 0 1 4 V G R r o f e c p 1 t e k s a g r e l f f u M r o r e n n a p s m m 2 1 h c n e r w x o b e h t d n a 1 r e v o c r e l f f u m e h t e v o m e R 2 r e l f f u m e h t m o r f 2 r e v o c r e l f f u m s c p 8 y s s A r e h s a w d n a t l o b m m 0 1 x 6 8 0 1 g i F e e S r o r e n n a p s m m 0...

Page 44: ... 3 e h t m o r f t n u o m s i d d n a r o t a n r e t l a d n a e m a r f r i a e h t e v o m e R r o f r e v o c r e n a e l c g n i t n u o m s i d e h t m o r f s r e b b u r t n u o m e h t e v o m e R 4 m o t t o b e h t n o s t u n e h t n e s o o L e m a r f 0 1 0 1 g i F e e S e m a r f e h t f o e d i s s c p 4 t u n e g n a l f 8 M r o r e n n a p s m m 2 1 h c n e r w t e k c o s Fig 1...

Page 45: ...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 e e S r e v o c t n o r f e h t o t r e v o c r a e r 2 1 0 1 6φ s c p 4 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 o g n i t t i h y b r e v o c r a e r e h t e v o m e R 3 r e m m a h c i t s a l p a h t i w r e v o c r a e r f o s g e l n e s o o l o t t i h g n o r t s a e v i g t o n o D s g e l r o s s o b e h t n o r e...

Page 46: ... r a P n o i t p i r c s e D s k r a m e R l o o T 6 r 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 10 14 Fig 10 15 SPRING WASHER 4 pcs REAR COVER COVER BOLT 4 pcs STATOR STATOR COVER BRUSHING GROMMET STATOR COVER STATOR ...

Page 47: ...2 n w o d e d i s r e t r a t s l i o c e r t u o g n i l l u p r o f l o o t a s a l i o d n a t l o b a e s U 3 s e r u d e c o r p g n i w o l l o f e h t n i r o t o r f o e l o h r e t n e c e h t o t n i l i o e n i g n e r u o P 1 d n e t f a h s e h t o t l i o h t i w l l i F t f a h s r o t o r 7 1 0 1 g i F e e S d a e r h t g n i w o l l o f e h t h t i w t l o b a e r a p e r P 2 e z ...

Page 48: ...r e h t t r a p a s e k a t t f a h s r o t o r t f a h s e n i g n e e h t r u o y t u o k c i t s t o n o D r o t o r e h t r e v o e c a f n o p u p m u j y a m t I n o i t a r a p e s h c n e r w t e k c o S t f a h s r o t o r m o r f y l h g u o r o h t l i o f f o e p i W 4 t f a h s O T P e n i g n e d n a 8 r e v o C t n o r F r e v o c t n o r f e h t e v o m e R 1 e h t e v o m e r d n ...

Page 49: ...tor shaft 2 Mount the rotor to the engine shaft Tighten the through bolt Apply a wrench on the through bolt and hit wrench handle clockwise with a hammer to tighten If an impact wrench is available use it Tightening torque Fig 10 21 Fig 10 22 e u q r o t g n i n e t h g i T m N 7 3 1 8 1 1 m c g k 0 4 1 0 2 1 b l t f 1 0 1 7 8 e u q r o t g n i n e t h g i T 0 0 8 2 V G R m N 2 3 1 3 1 1 m c g k 5...

Page 50: ...rear cover to the adaptor with four bolts spring washers and washers RGV6100 M6 x 160 mm bolt 4 pcs M6 spring washer 4 pcs M6 washer 4 pcs RGV2800 and 4100 M6 x 110 mm bolt 4 pcs M6 spring washer 4 pcs 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 23 Fig 10 24 Fig 10 25 e u q r o t g n i n e t h g...

Page 51: ...inal of the grounding wires green yellow to the unpainted thread hole of the frame base plate using a 5 mm brass screw 3 Install the engine and alternator assembly into the frame Put the engine and alternator as sembly into the frame from the side of it Tighten the nuts over the mount rubber bolts to fix M8 nuts 4 pcs NOTE Remove the air cleaner cover for easier installation NOTE When tightening t...

Page 52: ...ch the muffler with muffler cover to the engine and the rear cover 1 Tighten the two nuts for the muffler first Use the spring washers for RGV4100 and RGV6100 8 mm stainless nut 2 pcs 8 mm spring washer 2 pcs for RGV4100 and RGV6100 only 2 Tighten the bolts to fix the muffler to the rear cover M8 x 20 mm bolt and washer Ass y 2 pcs for RGV4100 Fig 10 28 e u q r o t g n i n e t h g i T m N 8 9 9 7 ...

Page 53: ... 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 over the mounting holes of the frame 3 Connect the rubber pipe First fit the hose clamps on the rubber pipe and connect it to the strainer and the carburetor Then fasten it with the hose clamps For RGV6100 connect the ...

Page 54: ...G DISASSEMBLY and REASSEMBLY of the FRONT PANEL 10 4 1 CHECKING OF THE FRONT PANEL Dismount the front panel from frame Remove the control panel and check each components and wiring Refer to Section 9 for the detail of checking procedure for the components in the front panel 10 4 2 DISASSEMBLY 1 Remove the control panel from the front panel M4 screw 6 pcs RGV2800 RGV4100 M4 screw 7 pcs RGV6100 2 Di...

Page 55: ...city and size Use heat resistant type wires permissible temperature range 75 C or over in the specified gauge shown in the circuit diagrams 2 Install condensers and diode rectifier into the front panel 3 Connect the wires of control panel components and front panel 4 Attach the control panel to the front panel M4 screw 6 pcs RGV2800 RGV4100 M4 screw 7 pcs RGV6100 e u q r o t g n i n e t h g i T m ...

Page 56: ...eplacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 11 1 2 CHECKING STATOR 1 Remove control panel and disconnect stator wires at the connectors 2 Measure the resistance between terminals on stator leads See Fig 11 2 Refer to Table 9 1 for normal resistance If stator is faulty replace it with a new one Fig 11 1B Type RGV4100...

Page 57: ...measure the resistance of the field coil at the terminals NOTE Because a diode is soldered to the coil ends at the terminals resistance may be mea sured only when tester probes touch the termi nals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity Remedy If the resistance is not normal replace rotor with a new one Fig 11 3 Fig 11 4 Fig 11 5 ...

Page 58: ...just engine r p m Loosen the lock nut on the adjusting screw Turn the adjusting screw clockwise to decrease engine speed or counterclockwise to increase engine speed 11 2 2 CHECKING CONDENSER Check condenser referring to Step 11 1 1 11 2 3 CHECKING STATOR Check stator referring to Step 11 1 2 11 2 4 CHECKING ROTOR Check rotor referring to Step 11 1 3 Fig 11 6 Fig 11 7 SPEED CONTROL LEVER ADJUSTING...

Page 59: ...CK IF THE ENGINE IS OVERHEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re move it 11 3 5 CHECK THE INSULATION OF THE GENERATOR Stop the engine Measure the insulation resistance between the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1MΩ dis assemble the generator and check the insulati...

Page 60: ...rrent may flow causing 11 4 3 CHECK THE DC FUSE Check the fuse in the fuse holder If the fuse is blown check for the cause of fuse blowing and then replace with a new one FUSE 10 A NOTE If the DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing fuse blow 11 4 4 CHECK THE WIRING Check all the wires to be connected correctly 11 4 5...

Page 61: ...d Most induction loads such as elec tric motor or electric tools or welding machine require three to five times large wattage of their ratings at starting This starting wattage must not exceed the rated output of the generator 3 Check the slow set r p m The normal idling speed by the IDLE CON TROL is as follows RGV2800 1900 to 2100 r p m RGV4100 6100 2000 to 2200 r p m The above speed setting is f...

Page 62: ...e table shows an example of the resistance readings measured by an ordinary analogue circuit tester with 1 5 volt battery power source It is advisable for you to check the resistance readings using your standard circuit tester and revise the checking table Fig 11 16B Fig 11 15 Fig 11 16A y r e t t a b h t i w r e t s e t t i u c r i C V 5 1 e c r u o s r e w o p r e t s e t t i u c r i c e h t f o...

Page 63: ...LENOID are securely connected 3 Check the wiring of IDLE CONTROL UNIT Check all leads from IDLE CONTROL UNIT are securely and correctly connected 4 Checking the SOLENOID Measure the resistance between two leads from SOLENOID If the resistance is larger or smaller than this range SOLENOID is defective Replace with a new one Fig 11 17 e c n a t s i s e R l a m r o N 1 3 5 2 Ω SOLENOID ...

Page 64: ... DC Winding W 0 75 V 120V 120V 120 240V 120 240V W W 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 Circuit breaker Diode stack Assy Full power switch Idle control unit AC output receptacle 120 240V Auto idle sw...

Page 65: ... 25Brn 1 25Brn Condenser Condenser 2 0W 1 25Or 1 25Brn W DC output terminal Circuit breaker Diode stack Assy Full power switch Idle control unit and Fuel cut unit AC output receptacle 120V AC output receptacle 120V No fuse breaker 2 Auto idle switch 0 75Blk ENGINE 0 75W 0 75W Solenoid 0 75Blu 0 75Blu Fuel cut solenoid 0 75Grn W 0 75Blk 0 75Blk W Oil sensor 0 75Grn Y Charge coil Ignition coil 0 75Y...

Page 66: ...n Electric starter 0 75Blu RGV4100 0 75Grn W RGV6100 Charge coil Ignition coil Earth Ground terminal 0 75LBlu RGV4100 0 75Grn W RGV6100 0 75LBlu RGV4100 0 75Grn W RGV6100 0 75Blu RGV4100 0 75Grn W RGV6100 1 25Grn Y RGV4100 6100 for BS RGV4100 6100 ELECTRIC STARTER TYPE Wiring color cord Blk Black Brn W Brown White R Red Blk W Black White Grn Green W White Blu Blue Grn W Green White Y Yellow LBlu L...

Page 67: ... e v O e l c y C 4 d e l o o C r i A l e d o M S D 2 5 2 H E D 2 5 2 H E S D 4 3 H E D 4 3 H E t n e m e c a l p s i D m c 1 5 2 3 n i u c 2 3 5 1 m c 8 3 3 3 n i u c 3 6 0 2 t u p t u O d e t a R m p r 0 0 6 3 P H 4 6 m p r 0 0 6 3 P H 0 8 l e u F e n i l o s a G e l i b o m o t u A y t i c a p a C k n a T l e u F l a g S U 8 3 4 s r e t i l 6 6 1 l a g S U 7 6 5 s r e t i l 5 1 2 n o i t a r e p...

Page 68: ... original condenser 2 1 2 CHECKING STATOR 1 Remove control panel and disconnect stator wires at the connectors 2 Measure the resistance between terminals on stator leads See Fig 2 2 Refer to Table 2 2 for normal resistance If stator is faulty replace it with a new one Fig 2 2 COUPLER STATOR Table 2 1 Fig 2 1 F O Y T I C A P A C L A M R O N R E S N E D N O C 1 0 1 4 V G R 1 0 1 6 V G R 0 2 μ 2 x F ...

Page 69: ...rcuit tester measure the resistance of the field coil at the terminals NOTE Because a diode is soldered to the coil ends at the terminals resistance may be mea sured only when tester probes touch the termi nals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity Remedy If the resistance is not normal replace rotor with a new one Fig 2 3 Fig 2 ...

Page 70: ...to adjust engine r p m Loosen the lock nut on the adjusting screw Turn the adjusting screw clockwise to decrease engine speed or counterclockwise to increase engine speed 2 2 2 CHECKING CONDENSER Check condenser referring to Step 2 1 1 2 2 3 CHECKING STATOR Check stator referring to Step 2 1 2 2 2 4 CHECKING ROTOR Check rotor referring to Step 2 1 3 Fig 2 6 Fig 2 7 SPEED CONTROL LEVER ADJUSTING SC...

Page 71: ...2 3 4 CHECK IF THE ENGINE IS OVERHEATED If the cooling air inlet and or cooling air outlet is clogged with dirt grass chaff or other debris re move it 2 3 5 CHECK THE INSULATION OF THE GENERATOR Stop the engine Measure the insulation resistance between the live terminal of the receptacle and the ground terminal If the insulation resistance is less than 1MΩ dis assemble the generator and check the ...

Page 72: ...scharged battery an excessive current may flow causing 2 4 3 CHECK THE DC FUSE Check the fuse in the fuse holder If the fuse is blown check for the cause of fuse blowing and then replace with a new one FUSE 10 A NOTE If the DC output is used to charge a large capacity battery or an over discharged battery an excessive current may flow causing fuse blow 2 4 4 CHECK THE WIRING Check all the wires to...

Page 73: ... t n o C y t i u n i t n o C e t i h W n w o r B y t i u n i t n o c o N y t i u n i t n o c o N y t i u n i t n o c o N Table 2 4 1 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 r e t s e t t i u c r i c l a t i g i D r e t s e t t i u c...

Page 74: ...ratings at starting This starting wattage must not exceed the rated output of the generator 3 Check the slow set r p m The normal idling speed by the IDLE CON TROL is as follows 2000 to 2200 r p m The above speed setting is for cold engine con dition If the engine speed is out of adjusting range of the adjusting screw move the sole noid backward Fig 2 16 Fig 2 15 Table 2 5 SPEED CONTROL LEVER ADJU...

Page 75: ...e above table shows an example of the resistance readings measured by an ordinary analogue circuit tester with 1 5 volt battery power source It is advisable for you to check the resistance readings using your standard circuit tester and revise the checking table Fig 2 18B Fig 2 17 Fig 2 18A Table 2 6 IDEL CONTROL UNIT OUTPUT WIRE ZCT 2 1 3 5 4 Terminal number of the IDEL CONTROL UNIT y r e t t a b...

Page 76: ...ENOID is defective Replace with a new one Fig 2 20 e c n a t s i s e R l a m r o N 1 3 5 2 Ω SOLENOID 6 Checking the IDLE CONTROL UNIT RGV6101 Check the resistance between five leads of IDLE CONTROL UNIT with circuit tester Fig 2 19 Table 2 7 2 1 8 9 3 4 5 6 7 Terminal number of the IDEL CONTROL UNIT Circuit tester with battery power source 1 5 V Apply black 〇 needle of the circuit breaker Apply r...

Page 77: ...an their running wattage Example A rated 250 W electric drill requires a 400 W generator to start it NOTE1 If a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps NOTE2 Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to t...

Page 78: ...put of 1000W capacity can light nine to fourteen 40 W fluorescent lamps Example 2 Generally speaking a 400 W motor means that its work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570 W When this motor is used for a motor driven tool the capacity of the generator should be multiple of 570 W by 1 2 to 3 as explained in the ltem 3 570 W x 1 2 to 3 684 W to 1710...

Page 79: ...n be damaged Table 7 2 shows voltage drops per 100 meters of cable Voltage drop indicates as V x R x I x L R means resistance Ω 100 m on the above table I means electric current through the wire A L means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools l a n o i t c e S m m a e r a 3 e l b a w o l l A A t n e r r u c a...

Page 80: ...75W 0 75Grn Y 0 75Blk 0 75LBlu 0 75Blk Oil sensor 0 75Grn Y 0 75Blk Earth Ground terminal 1 25Grn 1 25R 1 25Or ST B M M IG Key switch Battery Magnetiec switch 14Blk 14Blk Electric starter V 120V 120V 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 ...

Page 81: ... W 0 75Grn W Spark plug 0 75Grn 0 75Blk Engin switch W 2 0Grn 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 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 Auxiliary Winding for condenser 2 0Blu 2 0Blk No fuse breaker 2 0R 2 0W Voltmeter 2 0Y 2 0...

Page 82: ...PRINTED IN THE USA 940 Lively Blvd Wood Dale IL 60191 Phone 630 350 8200 Fax 630 350 8212 e mail sales robinamerica com www robinamerica com ...

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