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SERVICE
MANUAL
Models
RGV2800, RGV4100,
RGV6100
Generators
PUB-GS1277
Rev. 1/04
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Section
Title
Page
9-4 STATOR .............................................................................................................. 33
9-5 ROTOR ASSEMBLY ........................................................................................... 34
9-6 CONDENSER ..................................................................................................... 34
9-7 DIODE RECTIFIER ............................................................................................. 35
9-8 OIL SENSOR ...................................................................................................... 36
10.DISASSEMBLY AND ASSEMBLY ........................................................................... 37
10-1PREPARATION and PRECAUTIONS ................................................................ 37
10-2 DISASSEMBLY PROCEDURES....................................................................... 37
10-3 ASSEMBLY PROCEDURES ............................................................................. 38
10-4 CHECKING, DISASSEMBLY and REASSEMBLY of the FRONT PANEL ........ 46
11. TROUBLESHOOTING ............................................................................................ 51
11-1 NO AC OUTPUT................................................................................................ 53
11-2 AC VOLTAGE IS TOO HIGH OR TOO LOW ..................................................... 55
11-3 AC VOLTAGE IS NORMAL AT NO-LOAD,
BUT THE LOAD CANNOT BE APPLIED..................................... 56
11-4 NO DC OUTPUT ............................................................................................... 57
11-5 IDLE CONTROL(OPTIONAL EQUIPMENT) ..................................................... 58
12. WIRING DIAGRAM ................................................................................................. 61
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 high or too low........................................................................ 67
2-3 AC voltage is normal at No-load, but the load cannot be applied....................... 68
2-4 No DC output...................................................................................................... 69
2-5 Idle control (Optional equipment)........................................................................ 71
3. RANGE OF APPLICATIONS................................................................................... 74
4. WIRING DIAGRAM................................................................................................... 77
NOTE : As for the servicing information on engine protion, please refer to the EH17-2,
EH25-2 and EH34 engine service manual.
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1. SPECIFICATIONS
E N G I N E
R O T
T E A R L N A
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R O T
T E A R L N A
E N G I N E
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2. PERFOMANCE CURVES
(
Hz
)
63
Hz
62
61
60
( )
V
250
125
(
(
(
(
)
)
)
)
240
120
230V/115V
230
115
220
110
0
1/2
4/4
Load
Rated
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3
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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.
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3. FEATURES
3-1 BRUSHLESS ALTERNATOR
Newly developed brushless alternator eliminates troublesome brush maintenance.
3-2 CONDENSER TYPE VOLTAGE REGULATOR
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 level falls down below the lower limit to
protect the engine from seizure.
3-4 QUIET OPERATION
Robin RGV series 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 refueling.
3-7 RUGGED TUBULAR FRAME
Full cradle type rugged tubuler frame protects the generator all around.
3-8 COMPACT AND LIGHT WEIGHT
Newly developed brushless alternator enabled the RGV generators to be very compact in size and light
in weight.
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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 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-iron cylinder liner.
* A forged aluminum connecting rod.
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4. GENERAL DESCRIPTION
4-1 EXTERNAL VIEW
FUEL GAUGE
TANK CAP
VOLTMETER
ENGINE SWITCH
FULL POWER
SWITCH
CHOKE KNOB
AIR CLEANER
AC
RECEPTACLE
EARTH
TERMINAL
DC OUTPUT
TERMINAL
RECOIL STARTER
IDEL CONTROL
SWITCH
DC CIRCUIT
BREAKER
NO-FUSE
BREAKER
OIL SENSOR
SPARK PLUG
ENGINE
EMISSION LABEL
MUFFLER
OIL DRAIN PLUG
OILGAUGE (OIL FILLER)
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4-2 CONTROL PANEL
* RGV2800 : U.S.A., 60Hz-120V [NEMA RECEPTACLE]
AC OUTPUT
V METER
ENGINE SWITCH
ON
AC MAX 20A
ON
OFF
DC 12V-8.3A
BATTERY CHARGE ONLY
OFF
DC OUTPUT
DC BREAKER
AC BREAKER
* RGV4100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE]
AC 120V
FULL POWER SWITCH
AC 120V / 240V
V METER
ENGINE SWITCH
ON
120V
120V
240V
OFF
RESET
TEST
R E S E T
IDEL CONTROL
ON
T E S T
ON
30A
125V
20A
AC MAX 20A
AC MAX 30A
AC MAX 20A
OFF
ON
OFF
OFF
DC 12V-8.3A
BATTERY CHARGE ONLY
DC OUTPUT
DC BREAKER
AC BREAKER
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* RGV6100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE]
AC 120V
FULL POWER SWITCH
AC 120V / 240V
V METER
ENGINE SWITCH
ON
120V
120V
/240V
RESET
R E S E T
T E S T
OFF
TEST
30A
150V
20A
ON
IDEL CONTROL
AC MAX 30A
AC MAX 20A
AC MAX 20A
ON
OFF
ON
OFF
DC 12V-8.3A
BATTERY CHARGE ONLY
OFF
DC OUTPUT
DC BREAKER
AC BREAKER
4-3 LOCATION of SERIAL NUMBER and SPECIFICATION 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 correct parts and accurate service.
LABEL,
MODEL NAME
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5. CONSTRUCTION AND FUNCTION
5-1 CONSTRUCTION
END COVER
BALL BEARING
STATOR COMPLETE
ROTOR COMPLETE
REAR COVER
STATOR COVER
CRANKSHAFT
MOUNT RUBBER
THROUGH BOLT
Fig. 5-1
COVER BOLT
FRONT COVER
5-2 FUNCTION
5-2-1 STATOR
The stator consists of a laminated silicon steel
sheet core, a main coil and a condenser coil which
are wound in the core slots.
The condenser coil excites the rotor field coil which
generates AC voltage in the main coil.
Fig. 5-2
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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.
Fig. 5-3
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.
Fig. 5-4
A diode rectifier and surge absorber is mounted inside of the insulator.
Fig. 5-5A
Fig. 5-5B
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5-2-4 NO-FUSE BREAKER
The no-fuse breaker protects the generator from getting damage by overloading or short circuit in the
appliance. Table 5-1 shows the capacity of no-fuse breaker by each spec. and their object of protection.
MODEL
SPECIFICATION
NO-FUSE BREAKER
OBJECT or PROTECTION
RGV2800
60 Hz-120V
20 A
Total output amperage
RGV4100
RGV6100
60 Hz-120 V/ 240V
60 Hz-120 V/ 240V
15 A (2-Pole, 2-Element)
Total output amperage
20 A (2-Pole, 2-Element)
30 A
Total output amperage
Output from 30A receptacle
Table. 5-1
5-2-5 DC CIRCUIT BREAKER
The 10 ampere DC circuit breaker mounted on
the control panel protects whole DC circuit from
getting damage by overload or short circuit.
Fig. 5-6
5-2-6 RECEPTACLE and AC PLUG (STD. SPEC.)
These are used for taking AC output power from the generator. A total of six kinds of receptacles, each
varying in rated voltage and current from another, are used. Each model has at least one receptacle to
deliver the rated generator output. As many AC plugs as the receptacles, each matching the 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.
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Style
Ampere
Receptacle
AC plug
Description
GFCI (Ground Fault
Circuit Interrupter)
Receptacle, duplex
(REC1)
up to 20A
NEMA 5-20A
NEMA 5-20P
Locking Receptacle
(REC2)
up to 20A
up to 30A
NEMA L14-20R
NEMA L14-20P
NEMA L5-30P
Locking Receptacle
(REC3)
NEMA L5-30R
Table. 5-2
NOTE : If your generator has receptacles pecu-
liar to your country, Table 5-2 does not
apply.
TWIST
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 other receptacles are not pro-
tected by GFCI.
Caution : To connect the appliance to locking
receptacle, insert the plug into the re-
ceptacle and turn it clockwise to lock.
Fig. 5-8
5-2-7 GFCI RECEPTACLE
After starting the engine, check the GFCI for proper functioning by the following test procedure.
Push yellow 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 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.
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5-2-8 CONNECTING TO DOMESTIC CIRCUITS (HOUSE WIRING)
WARNING :
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, personal injury, damage to generator, damage to appli-
ances, damage to the building's wiring or fire.
(a) When contnecting a Robin generator to 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 fuse or
AC breaker box.
Caution : If the neutral wire of house wiring is grounded, be sure to ground the ground terminal of the
generator. Otherwise an electric shock may occur to the operator.
UTILITY HIGH LINE
CONNECTING BOX
MAIN POWER LINE
240V
RECEPTACLE
TRANSFER SWITCH
Fig. 5-9
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Utility high line
House circuit breaker
Meter box
X W Y
120V
appliance
240V
appliance
120V
appliance
X W Y
Transfer
switch
Generator
( )
W
( )
X
( )
Y
( )
G
240V
4P- Receptacle
Fig. 5-10
(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.
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5-3 GENERATOR OPERATION
Fig. 5-11
5-3-1 GENERATION of NO-LOAD VOLTAGE
(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 generates a minute current awhich flows through the condenser coil. At this time, a small flux is
produced with which the magnetic force at the rotor’s magnetic pole is intensified. When this mag-
netic force is intensified, the respective voltages in the main coil and condenser coil rise up. As the
current aincreases, the magnetic flux at the rotor’s magnetic pole increases further. Thus the volt-
ages at the main coil and condenser coil keep rising by repeating this process.
(3) As AC current flows through 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 current in the condenser coil and field coil
increases rapidly. This acts to stabilize the output voltage of each coils. If generator speed further
increases to the rated value, the generator output voltage will reach to the rated value.
5-3-2 VOLTAGE FLUCTUATIONS UNDER LOAD
When the output current cflows through the main coil to the appliance, a magnetic flux is produced and
serves to increase current ain the condenser coil. When current aincreases, the density of magnetic
flux across the rotor core rises. As a result, the current flowing in the field coil increases and the genera-
tor output voltage is prevented from decreasing.
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5-3-3 FULL POWER SWITCH (Dual Voltage Type)
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. 5-12
Fig. 5-13
Switch
Position
LOWER VOLTAGE HIGHER VOLTAGE
RECEPTACLE
RECEPTACLE
120/240 V Half of rated output
Rated output
Table. 5-3
Fig. 5-14
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Two 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 indication
(120V), the switch position is as indicated by the lower solid line in the diagram. Fig. 5-13 is a simplified
representation of this circuit, showing the two main coils connected in parallel. In this case, the higher
voltage (240V) at Rec. 3 cannot be taken out. Rec. 2 for the lower voltage can output up to the rated
power (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 series. In this case, power can be taken simultaneously from
the receptacles for the both voltages. Rec. 3 for the higher voltage can output up to the rated power, but
Rec. 1 and Rec. 2 for the lower voltage can output only up to half the rated power each.
Table 5-4 is a summary of the above explanation. Select the proper output voltage by full power switch in
accordance with the appliance to be used.
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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 oil in the crankcase.
OIL SENSOR
* Since the sensor has been designed to consume
a part of power supplied to the igniter to ener-
gize its electronics circuit, any other external
power supply is not necessary so that it can be
mounted at the oil filler port.
Fig. 5-15
Introduction of newly developed sensing principle features super durability and no change with the
passage of time as it does not use any moving part.
Merits due to introduction of electrical conductivity detection are as follows ;
1 It has resistance to mechanical shocks and property of no change with the passage of time as
sensing element consists simply of electrodes having no moving parts.
2 At the same time, it is capable of detecting the oil level stably as it is not influenced by engine
vibrations.
3 No error occurs due to foam and flow of the oil.
4 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
absolute value of the current is very small. The sensor detects this current difference and make use of it.
The sensor judges the oil quantity, by comparing a current flowing across a pair of electrodes (inner and
outer) with the reference, in such a way that if a current flows between the electrodes more than the
reference, sufficient oil is in the crankcase, on the other hand, if a current flows less than the reference,
oil is not sufficient. Since an electric current is flown to detect oil quantity, this is called the “electrical
conductivity detection” type of sensor. The oil level to be detected is determined by the length of elec-
trodes and their mounting positions with the engine.
5-4-3 HOW IT OPERATES
[Power supply]
The sensor makes use of a part of primary power source for ignition of the engine (igniter) to drive the
sensor circuit. Power to the sensor can usually be derived from the “stop button” by branching wires out.
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[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 sufficient. When
oil level goes down and the inner electrode is exposed to the air due to consumption of oil, no current flow
between the electrodes as air is considered to be electrically nonconductive. The sensor in this case
judges that oil is insufficient.
[Decision of oil shortage]
Oil level at the electrodes may go down momentarily probably due to the engine being slanted or affected
by vibration even if a sufficient oil is in the crankcase. For that reason, the sensor has an electronic timer
circuit to prevent it from interpreting as short of oil when amount of oil is sufficient. The sensor 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”.
[Automatic stop of engine]
When the sensor decides as oil-shortage, it makes the engine to stop running automatically for protec-
tion of engine. Once the stopping circuit is activated, it keeps functioning until it confirms that the engine
has made a complete stop, then the circuit stops functioning automatically.
5-4-4 BLOCK DIAGRAM OF THE CIRCUIT
Igniter
Power circuit
Detection
circuit
Stopping
circuit
Inner pole
Oil
Deley circuit
Outer pole
Engine ground
Fig. 5-16
1 Power circuit ..........This rectifies a part of power to the igniter and regulates it to supply the stabi-
lized power to necessary circuits.
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2 Detection circuit ..... This detects quantity of oil, sufficient or not, according to difference 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 by vibration in spite of sufficient oil in the crankcase.
4 Stopping circuit ...... This automatically stops the engine running.
5-4-5 CAUTIONS TO BE TAKEN ON HANDLING THE SENSOR
(1) Oil sensor unit
1 Be sure not to damage each wire. Broken or short-circuited power supply wires and/or a ground-
ing wire in particular may lead to malfunction or breakdown.
2 The sensor is not interchangeable from engine to engine because the sensor is to be exclusively
installed individually in each engine employed.
(2) Mounting and wiring of oil sensor unit
1 Although this has 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 reliability of more than that of
tinned terminals.
(3) Operation of oil sensor
1 If operating with the engine kept tilted, oil surface inside of the engine varies and the correct oil
level can not to be detected which in turn obstructs the preventing function of engine seizure.
Operate the engine by keeping it level.
2 When starting the engine with an insufficient oil in the crankcase, engine starts once then it stops
automatically after it runs for 5 seconds.
3 When the engine has been stopped by the oil sensor, voltage remained in the electronic circuit
prevents the sensor from being restarted for 3 seconds after the engine stop. Try to restart the
engine after 3 seconds or more.
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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 materials near the generator.
Be careful not to put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the
generator.
3. Do not operate the generator in a room, cave or tunnel. Always operate in a well-ventilated
area.
Otherwise the engine may overheat and also, the poisonous carbon monoxide contained in the ex-
haust gases will endanger human lives. Keep the generator at least 1 m (4 feet) away from structures
or facilities during use.
4. Operate 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 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 (Optional parts) for
connecting with indoor wiring.
NOTE : The parts numbers of the transfer switches and of the plastic box to store them are as shown in
Table 6-1.
Part No.
Part Name
Transfer Switch
Transfer Switch
Transfer Switch
Plastic Box
Q'ty
Phase Allowable Current
365-45604-08
367-45605-08
340-45606-08
367-43008-08
348-43009-08
1
1
1
1
1
1
15 A
30 A
60 A
30 A
60 A
1
1
1
1
Plastic Box
Table. 6-1
7. Be sure to check and remedy the cause of circuit breaker tripping before resetting it on.
CAUTION : If the circuit breaker tripped off as a result of using an electrical appliance, the cause
can be an overload or a short-circuit. In such a case, stop operation immediately and carefully
check the electrical appliance and AC plugs for faulty wiring.
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7. RANGE OF APPLICATIONS
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, fre-
quency, and power consumption (input wattage). The power consumption of an electrical appliance is
the power necessary for using it. When using a generator for operating an electrical appliance, the power
factor and starting wattage must be taken into consideration.
In order to determine the right size generator, it is necessary to add the total wattage of all appliances to
be connected to the unit.
Refer to the followings to calculate the power consumption of each appliance or equipment by its type.
(1) Incandescent lamp, heater, etc. with a power factor of 1.0
Total power consumption must be equal to or less than the rated output of the generator.
Example : A rated 3000W generator can turn thirty 100W incandescent lamps on.
(2) Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power
factor
Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the
load. Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3
times lager than 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 the power consumption, effi-
ciency should be taken into account as explained in ltem (5) on the following page.
(3) Mercury lamps with a smaller power factor
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.
Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on. A rated
3000 W generator can power two or three 400 W mercury lamps.
(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.
These appliances require large starting wattage which is 3 to 5 times of running wattage.
Example : A rated 900 W compressor requires a 4500 W generator to drive it.
NOTE1 : Motor-driven appliances require the aforementioned generator output only at the starting. Once
their motors are started, the appliances consume about 1.2 to 2 times their rated power con-
sumption so that the excess power generated by the generator can be used for other electrical
appliances.
NOTE2 : Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting
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.
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(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.
(Output of electrical appliance)
= (Power consumpition)
(Efficiency)
Efficiencies of some electrical appliances are as follows :
Single-phase motor................................ 0.6 to 0.75
Fluorescent lamp ................................... 0.7 to 0.8
The smaller the motor, the
lower the efficiency.
(
)
Example 1: A 40W fluorescent lamp means that its luminous output is 40W. Its efficiency is 0.7 and
accordingly, power consumption will be 40 ÷ 0.7= 57W. As explained in Item (2), multiply
this power consumption value of 57 W by 1.2 to 2 and you will get the figure of the neces-
sary capacity of a generator. In other words, a generator with a rated output 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 (W)
MODEL
RGV2800
RGV4100
RGV6100
Frequency
60 H
Incandesent lamp,
heater, etc.
2300 W
3600 W
4800 W
Fluorescent lamp, Motor-
driven tool, general-porpose
approx.
1200 W
approx.
1800 W
approx.
2400 W
approx.
800 W
approx.
1400 W
approx.
1600 W
Mercury lamp, etc.
approx.
550 W
approx.
850 W
approx.
1100 W
Pump, compressor, etc.
Table. 7-1
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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 the insulation, possibly burning it out. Table 7-2 shows
cables and their allowable currents for your reference.
2. Cable length
If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors de-
creasing the input voltage to the load (electrical product). As a result, the load can be damaged. Table
7-2 shows voltage drops per 100 meters of cable.
Gauge No./
wire element
No./ mm
Voltage drop per 100 m
Sectional
Allowable
Resistance
Ohm / 100 m
area / mm3 current / A
1 A
3 A
5 A
8 A
10 A
12 A
15 A
0.75
1.25
2.0
7
30 / 0.18
50 / 0.18
37 / 0.26
45 / 0.32
70 / 0.32
2.477
1.486
0.952
0.517
0.332
2.5 V
1.5 V
1.0 V
8 V 12.5 V
12
17
23
35
5 V
3 V
7.5 V 12 V
15 V
10 V
5 V
18 V
12 V
5.0 V
8 V
4 V
15 V
3.5
1.5 V 2.5 V
1 V 2 V
6.5 V 7.5 V
4 V 5 V
5.5
2.5 V 3.5 V
Table. 7-2
1
Voltage drop indicates as V=
x R x I x L
100
R
I
means resistance ( Ω / 100 m) on the above table.
means electric current through the wire (A).
means the length of the wire (m).
L
The length of wire indicates round length, it means twice the length from generator to electrical tools.
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8. MEASURING PROCEDURES
8-1 MEASURING INSTRUMENTS
8-1-1 “Dr. ROBIN” GENERATOR TESTER
The “Dr. Robin” generator tester is exclusively
designed for fast, easy diagnosis and repair of
Robin generators. The “Dr. Robin” has the follow-
ing features :
(1) Functions of voltmeter, frequency meter,
megger tester, capacitance meter and circuit
tester are combined in one unit.
(2) Fast and easy readout by digital indicator.
(3) Built-in automatic battery checker indicates the
time to change batteries.
Fig. 8-1
(4) Tester and accessories are installed in a handy,
sturdy case for easy carrying.
* SPECIFICATIONS
MODEL
Dr. Robin
Part Number
Voltage
388-47565-08
0 to 500 V AC
25 to 70 Hz
Frequency
Measuring
Resistance
Range
0.1 to 1.999 Ω
10 to 100 μF
Condenser Capacity
Insulation Resistance
Circuit Protector
3MΩ
Fuse
Power Source
Accessories
2 x 6F44P (006P) Dry Cell Battery
Test leads with needle probes . . . 1 set
Test leads with jack plugs . . . 1 set
Dimensions (L x W x H)
Weight
285 mm x 200 mm x 110 mm
1.6 kg
Table. 8-1
The “Dr. Robin” generator tester can be ordered from Robin generator distributors by the 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.
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8-1-2 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 150V : Type with an output voltage of 110
or 120V
0 to 300V : Type with an output voltage of 220,
230 or 240V
0 to 150V, 0 to 330V : Dual voltage type
Fig. 8-2
(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)
Fig. 8-3
(3) FREQUENCY METER
Frequency range : About 45 to 65Hz
NOTE : Be careful of the frequency meter’s input
voltage range.
Fig. 8-4
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(4) CIRCUIT TESTER
Used for measuring resistance, etc.
Fig. 8-5
(5) MEGGER TESTER
Used for measuring generator insulation re-
sistance. Select one with testing voltage range
of 500V.
Fig. 8-6
(6) TACHOMETER
Use the contactless type tacho meter.
Fig. 8-7
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8-2 AC OUTPUT MEASURING
Fig. 8-8
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
Table 8-2 at the rated amperage and rated rpm.
Rated voltage
120 V
240 V
Voltage range
108 -132 V
216 - 264 V
Table. 8-2
8-3 DC OUTPUT MEASURING
Fig. 8-9
Measurement of DC 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 battery.
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8-4 MEASURING INSULATION RESISTANCE
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-
mal. (The original insulation resistance at the time
of shipment from the factory is 10 megohm or
more.) If it is less than 1 megohm, disassemble
the generator and measure the insulation resis-
tance of the stator, rotor and control panel indi-
vidually.
Fig. 8-10
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 between
YELLOW lead and the core.
(4) Measure the insulation resistance between
BROWN lead and the core.
Fig. 8-11
* ROTOR
Measure the insulation across one of the soldered
terminals of the rotor and the core.
Fig. 8-12
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* CONTROL PANEL
Measure the insulation resistances between the
live parts and the grounded parts.
Fig. 8-13
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.
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9. CHECKING FUNCTIONAL MEMBERS
9-1 VOLTMETER
Check the voltmeter if it is turned on by applying
specific voltage. Voltmeter 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 Turn on the commercial power supply input
and check the indication.
Fig. 9-1
9-2 AC RECEPTACLES
Using a “Dr. Robin” or a circuit tester, check continuity between the two terminals at the rear of the AC
receptacles while the receptacle is mounted on the control panel. When continuity is found between the
output 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.
WIRE
AC RECEPTACLE
Fig. 9-2B
Fig. 9-2A
9-3 No-FUSE BREAKER
Check continuity between each of two terminals
at the rear of the no-fuse breaker while it is
mounted on the control panel. Normally, there is
continuity between each of the two when the no-
fuse breaker is on while there is no continuity when
the no-fuse breaker is off.
NO-FUSE BREAKER
Fig. 9-3
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9-4 STATOR
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.
Fig. 9-4
Condenser
Winding
Specification
MODEL
AC Winding
Hz
Voltage
White / Red
0.58
Black / Blue
0.58
Yellow / Yellow
RGV2800
RGV4100
RGV6100
60
120 V, 120 V / 240 V
1.67
60
60
120 V, 120 V / 240 V
120 V, 120 V / 240 V
0.52
0.25
0.52
0.25
0.99
0.58
Table. 9-1
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 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).
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9-5 ROTOR ASSEMBLY
(1) Using a “Dr. Robin” or a circuit tester, measure the resistance of the field coil at the terminals.
( Ω )
MODEL
RGV2800
RGV4100
RGV6100
RESISTANCE
1.75 Ω
1.77 Ω
1.60 Ω
Table. 9-2
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 appears, try checking in reverse polarity.
NOTE 2 :
If the circuit tester is not sufficiently accurate, it
may not show 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).
Fig. 9-5
9-6 CONDENSER
Use a “Dr. Robin” in capacitance meter mode to check the capacity of condensers.
Fig. 9-6A
Type RGV2800
Fig. 9-6B Type RGV4100, RGV6100
NOTE : Be sure to discharge condensers by shorting condenser leads each other before checking their
capacitance, or the accurate reading cannot be obtained.
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NORMAL CAPACITY OF CONDENSER
RGV2800
24μF
RGV4100
RGV6100
28μF x 2
20μF x 2
Table. 9-3
* 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
Fig. 9-7
Fig. 9-8
Circuit inside of the diode rectifiers is as shown in Fig. 9-7. Check continuity between each terminal by
using a circuit tester as shown in Fig. 9-8. The rectifier is normal when condtinuity is as follows:
* Checking table for analogue circuit tester.
Apply black (minus) needle of the circuit tester
Analogue circuit tester
Brown
Brown
Orange
Brown / White
Continuity
Continuity
Continuity
---------
Brown
Brown
---------
No continuity No continuity
No continuity
Continuity
---------
No continuity
---------
Apply red (plus) needle of
the circuit tester
Orange
Continuity
Brown / White
No continuity No continuity No continuity
Table. 9-4-1
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* Checking table for digital circuit tester.
Apply red (plus) needle of the circuit tester
Digital circuit tester
Brown
Brown
---------
Brown
Orange
Brown / White
Continuity
Continuity
Continuity
---------
No continuity No continuity
Brown
No continuity
Continuity
---------
No continuity
---------
Apply black (minus) needle
of the circuit tester
Orange
Continuity
Brown / White
No continuity No continuity No continuity
Table. 9-4-2
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 which a pointer of the tester goes out of its normal scale), shows resistance
to some extent. When results of the checking indicates failure even in one section, replace
with a new one.
NOTE 3 : Simpson brand analogue testers have the characteristics as same as the digital circuit tester.
9-8 OIL SENSOR
(1) Disconnect two (2) wires comming from the
sensor at the connection.
(2) Loosen the sensor to remove it from the en-
gine.
(3) Plug the opening of oil filler hole (created after
sensor is removed) with suitable means such
as oil gauge.
(4) Connect the removed wires again with the oil
sensor.
Fig. 9-9
(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 wirings have checked, the
sensor is wrong. Replace the sensor with new one.
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10. DISASSEMBLY AND ASSEMBLY
10-1 PREPARATION and PRECAUTIONS
1) Be sure to memorize the location of individual parts when disassembling the generator so that the
generator can be reassembled correctly. Tag the disassembled part with the necessary information 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 properly, and use the proper tool for each specific job.
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10-2 DISASSEMBLY PROCEDURES
Step Part to remove
Control box
Description
Remarks
Tool
1
(1) Take off the bushing from the bottom of
the control box. (See Fig. 10-1.)
(2) Disconnect the connectors on the wiring Press the upper end of
from the control box to the alternator.
(See Fig. 10-1.)
the bushing and pull
out.
(3) Disconnect the connectors on the wiring
between from the control box and the
engine. (See Fig. 10-2.)
Fig. 10-1
Fig. 10-2
(4) Take off the four bolts and remove the
control box the frame. (See Fig. 10-3.)
5 x 12 mm bolt and
8 mm Spanner
washer Ass'y (black) . . . 2 pcs.
5 x 25 mm bolt and
washer Ass'y (black) . . . 2 pcs.
Fig. 10-3
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Step Part to remove
Fuel Tank
Description
Remarks
Tool
2
(1) Discharge fuel from the tnak.
1. Shut the fuel strainer.
Use utmost care about
fire hazard.
2. Remove the strainer cup.
3. Put a vessel to receive fuel under the
strainer and open the fuel cock to
discharge fuel. (See Fig. 10-4.)
4. Attach the strainer cup to the strainer
body.
Wipe off split fuel
thoroughly.
Do not lose the filter
screen.
Fig. 10-4
(2) Disconnect rubber pipe from the strainer.
Loosen the hose clamp on the top of the
strainer and pull out the rubber pipe from
the strainer.
Pliers
(3) Take off the four bolts and rubber (fuel
tank) and then remove the fuel tank.
(See Fig. 10-6.)
10 mm spanner or
box wrench
RUBBER PIPE
HOSE CLAMP
Fig. 10-5
Fig. 10-6
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Step Part to remove
Description
Remarks
Tool
3
Muffler and
Muffler cover
(1) Remove the two bolts which fix the
muffler to the alternator. Loosen the two
nuts on the muffler flange and remove
the muffler from the engine.
12 mm spanner or
box wrench
8 x 20 mm bolt and washer Ass'y . . . 2 pcs.
8 mm stainless nut . . . 2 pcs.
8 mm spring washer . . . 2 pcs.
for RGV4100 and RGV6100
Muffler gasket . . . 1 pce.
(2) Remove the muffler cover 1 and the
muffler cover 2 from the muffler.
10 mm spanner or
box wrench
6 x 10 mm bolt and washer Ass'y . . . 8 pcs.
(See Fig. 10-8.)
(3) Remove the muffler bracket from the
rear cover.
12 mm spanner or
box wrench
8 x 20 mm bolt and washer Ass'y . . . 2 pcs.
Fig. 10-8
Fig. 10-7
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Step Part to remove
Pipe Frame
Description
(1) For RGV6100
Remarks
Tool
4
10 mm spanner
Remove the fuel strainer from the frame.
(2) Remove the nuts which are fixing engine
and alternator to the mount rubbers.
(See Fig. 10-9.)
12 mm spanner
(3) Using a chain-block, sling up the engine Remove the air
and alternator and dismount from the
frame.
cleaner cover for
dismounting.
MOUNT
RUBBER
(ALTERNATOR
SIDE : 2 pcs)
MOUNT RUBBER
(ENGINE SIDE : 2 pcs)
Fig. 10-9
(4) Remove the mount rubbers from the
frame. Loosen the nuts on the bottom
side of the frame. (See Fig. 10-10.)
12 mm spanner or
socket wrench
M8 flange nut . . . 4 pcs.
STOPPER PLATE
SPACER : 1 pce.
MOUNT RUBBER : 2 pcs.
MOUNT RUBBER : 2 pcs.
FRAME
M5 SCREW : 1 pce.
EARTH
CORD
M8 FLANGE
NUT : 2 pcs.
M8 FLANGE
NUT : 2 pcs.
Fig. 10-10
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Step Part to remove
Rear cover
Description
Remarks
Tool
5
(1) Remove the end cover.(See Fig. 10-11.)
(Except RGV6100)
10 mm spanner or
box wrench
6φbolt . . . 3 pcs.
(2) Remove the four bolts which fasten the
rear cover to the front cover. (See Fig.
10-12.)
10 mm spanner or
box wrench
6φbolt . . . 4 pcs.
Fig. 10-11
Fig. 10-12
(3) Remove the rear cover by hitting on the Do not give a strong hit Plastic hammer
legs of rear cover with a plastic hammer on the boss or legs.
to loosen.
Fig. 10-13
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Step Part to remove
Stator
Description
Remarks
Tool
6
(1) Remove the stator cover.
VER
STATOR
Fig. 10-14
STATOR COVER
REAR COVER
STATOR
BRUSHING
SPRING
WASHER : 4 pcs.
GROMMET
COVER BOLT : 4 pcs.
Fig. 10-15
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Step Part to remove
Rotor
Description
Remarks
Tool
7
(1) Take off the through bolt.
Box wrench
Apply a box wrench on the head of
through bolt. Hit the wrench handle with
a hammer counter-clockwise to loosen.
Plastic hammer
Fig. 10-16
(2) Put the engine on the working table
recoil starter side down.
(3) Use a bolt and oil as a tool for pulling out
rotor in the following procedures :
1. Pour engine oil into the center hole of
rotor shaft. Fill with oil to the shaft end.
(See Fig. 10-17.)
2. Prepare a bolt with the following thread
size :
RGV2800 . . . M10 x P 1.5
RGV4100, 6100 . . . M12 x P 1.5
3. Apply a few turns of seal tape around the
tip of the bolt. (See Fig. 10-18.)
Fig. 10-17
Fig. 10-18
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Step Part to remove
Description
Remarks
Tool
7
Rotor
4. Screw the bolt into the thread of the rotor Do not stick out your
shaft.
face over the rotor.
It may jump up on
separation.
5. Torque the bolt using a socket wrench
until the rotor comes off loose.
Socket wrench
* The hydraulic pressure inside the
rotor shaft takes apart the rotor from
the engine shaft.
(4) Wipe off oil thoroughly from rotor shaft
and engine PTO shaft.
Fig. 10-19
8
Front Cover
(1) Remove the front cover.
Loosen the four bolts and remove the
front cover.
12 mm socket
wrench
M8 x 20mm bolt and washer Ass'y . . . 4 pcs.
Fig. 10-20
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10-3 ASSEMBLY 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.
Tightening torque
11.8 - 13.7 N-m
120 - 140 kg-cm
8.7 - 10.1 ft-lb
Fig. 10-21
10-3-2 ROTOR
(1) Wipe off oil, grease and dust from the tapered
portion of engine shaft and matching tapered
hole of rotor shaft.
(2) Mount the 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. 10-22
Tightening torque
11.3 - 13.2 N-m
RGV2800
115 - 135 kg-cm
8.7 - 10.8 ft-lb
22.5 - 24.5 N-m
230 - 250 kg-cm
16.6 - 19.5 ft-lb
RGV4100
RGV6100
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10-3-3 STATOR
(1) Put the stator in the rear cover setting the four
grooves on the side of stator with thread holes
of the rear cover.
VER
(2) Attach the stator cover around the stator.
STATOR
10-3-4 REAR COVER
(1) Put the rear cover with stator over the rotor.
Tap on the rear cover evenly with a plastic
hammer to press the rotor bearing into the rear
cover.
(2) Fix the rear cover to the adaptor with four bolts,
spring washers, and washers.
Fig. 10-23
RGV6100
M6 x 160 mm bolt . . . 4 pcs.
M6 spring washer . . . 4 pcs.
M6 washer . . . 4 pcs.
Tightening torque
4.5 - 5.9 N-m
50 - 60 kg-cm
3.6 - 4.3 ft-lb
RGV2800 and 4100
M6 x 110 mm bolt . . . 4 pcs.
Fig. 10-24
M6 spring washer . . . 4 pcs.
Tightening torque
4.5 - 5.9 N-m
50 - 60 kg-cm
3.6 - 4.3 ft-lb
(3) Attach the bushing over the lead wire drawn
out from the rear cover. Press the smaller end
of the bushing into the window of the rear
cover.
Fig. 10-25
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10-3-5 END COVER (RGV4100 only)
Attach the end cover to the rear cover.
Fig. 10-26
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.
Tightening torque
11.8 - 13.7 N-m
120 - 140 kg-cm
8.7 - 10.8 ft-lb
Fig. 10-27
NOTE : The mount rubbers are selected to reduce vibration most effectively by model. Be sure to use
the correct mount rubber for your generator. Although mount rubbers have the same appear-
ance, their characteristics are different.
(2) Attach the 5 mm terminal 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
Tightening torque
the frame. Put the engine and alternator as-
11.8 - 13.7 N-m
120 - 140 kg-cm
sembly into the frame from the side of it.
Tighten the nuts over the mount rubber bolts
to fix.
8.7 - 10.8 ft-lb
M8 nuts . . . 4 pcs.
NOTE : Remove the air cleaner cover for easier installation.
NOTE : When tightening the nuts, slightly lift the engine and alternator assembly so that the weight is not
applied to the mount rubbers.
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(4) Fasten the other earth cable with 5 mm termi-
nal to the unpainted bolt hole on the frame.
(See Fig.10-28.)
EARTH CABLE
10-3-7 MUFFLER and MUFFLER COVER
(1) Temporarily fix the muffler bracket to either the
rear or front covers for RGV6100 or RGV2800.
M8 x 20 mm bolt and washer Ass’y . . . 2 pcs.
Fig. 10-28
(2)Attach the muffler cover 1 and the muffler cover
2 to the muffler.
M6 x 10 mm bolt and washer Ass’y . . . 8 pcs.
Tightening torque
7.9 - 9.8 N-m
80 - 100 kg-cm
5.8 - 7.2 ft-lb
(3) Put the muffler gasket to the engine.
(4) Attach the muffler with muffler cover to the
engine and the rear cover .
1Tighten 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)
Tightening torque
21.6 - 27.4 N-m
220 - 280 kg-cm
15.8 - 20.2 ft-lb
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)
Tightening torque
18.6 - 24.5 N-m
190 - 250 kg-cm
13.7 - 18.0 ft-lb
Fig. 10-29
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3 For RGV2800 and 6100 : Tighten the two bolts to fix the muffler bracket to the front cover, rear cover,
and then the two bolts for the muffler to the muffler bracket.
M8 x 20 mm bolt and washer Ass’y . . . 4 pcs. (for RGV2800 and 6100)
Tightening torque
18.6 - 24.5 N-m
190 - 250 kg-cm
13.7 - 18.0 ft-lb
10-3-8 FUEL TANK
(1) For RGV2600 and RGV4100 only :
Attach the fuel strainer to the bottom of the
fuel tank. Screw in the fuel strainer all the way
and return one to two turns, and then lock it
with the lock nut.
For RGV6000 only :
Attach the fuel strainer to the frame.
Tightening torque
4.9 - 6.9 N-m
50 - 70 kg-cm
3.6 - 5.0 ft-lb
(2) Mount the 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 rubber pipe to the
strainer and the fuel tank in the same way.
NOTE : Apply a drop of oil to the rubber pipe for
easier connection.
Fig. 10-30
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10-3-9 FRONT PANEL
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 color.
(3) Press the upper end of the bushing into the
bottom window of the front panel.
(4) Mount the front panel to the frame.
M5 x 12 mm bolt and washer Ass’y . . . 2 pcs.
M5 x 25 mm bolt and washer Ass’y . . . 2 pcs.
Fig. 10-31
10-4 CHECKING, 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) Disconnect the connectors on the wires to detach the control panel and front panel.
(3) Remove the condensers and diode rectifier from the front panel.
(4) After disconnecting individual wires, remove the control panel components.
NOTE : Full power switch and pilot lamp have their wires soldered. Unsolder them to remove those parts
if necessary.
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10-4-3 REASSEMBLY
(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) 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)
Tightening torque
1.2 - 1.5 N-m
12 - 15 kg-cm
8.7 - 10.9 ft-lb
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11. TROUBLESHOOTING
11-1 NO AC OUTPUT
11-1-1 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.
Fig. 11-1A Type RGV2800
Fig. 11-1B Type RGV4100, RGV6100
NORMAL CAPACITY OF CONDENSER
RGV2800
RGV4100
RGV6100
28μF x 2
24μF
20μF x 2
Table. 11-1
(2) If such an instrument is unavailable, the condenser can be checked by replacing with a new one. If
the generator performs good with new condenser, the cause of trouble is defect in original condenser.
11-1-2 CHECKING STATOR
COUPLER
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. 11-2
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(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. 11-3)
If insulation is bad, replace stator with a new
one.
Fig. 11-3
11-1-3 CHECKING ROTOR
(1) Remove rear cover and stator.
(2) Using a Dr. Robin or a circuit tester, measure
the resistance of the field coil at the terminals.
Fig. 11-4
( Ω )
RGV6100
1.60 Ω
MODEL
RGV2800
RGV4100
RESISTANCE
1.75 Ω
1.77 Ω
Table. 11-2
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. 11-5
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(3) Measure the insulation across one of the sol-
dered terminals of the rotor and the core.
(Fig.11-6)
If insulation is bad, replace rotor with a new
one.
Fig. 11-6
11-2 AC VOLTAGE IS TOO HIGH OR TOO LOW
11-2-1 CHECKING ENGINE SPEED
SPEED CONTROL LEVER
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 lock nut on the adjusting screw.
* Turn the adjusting screw clockwise to decrease
engine speed or counterclockwise to increase
engine speed.
ADJUSTING SCREW
RGV2800,4100
Normal engine speed at no load
3700 to 3750 rpm
11-2-2 CHECKING CONDENSER
Check condenser referring to Step 11-1-1.
RGV6100
11-2-3 CHECKING STATOR
Fig. 11-7
Check stator referring to Step 11-1-2.
11-2-4 CHECKING ROTOR
Check rotor referring to Step 11-1-3.
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11-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED.
11-3-1 CHECK THE ENGINE SPEED.
If the engine speed is low, adjust it to the rated r.p.m.
*Refer to Step 11-2-1 for engine speed adjustment.
11-3-2 CHECK THE TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR.
Refer to Section 7 “RANGE OF APPLICATIONS” for the wattage of the appliances.
If the generator is overloaded, reduce the load to the rated output of the generator.
11-3-3 CHECK THE APPLIANCE FOR TROUBLE.
If the appliance is faulty, repair it.
11-3-4 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.
AIR INLET
ENGINE
IR OUTLET
(
)
)
ENGINE
AIR OUTLET
ALTERNATOR
(
)
AIR INLET
ALTERNATOR
(
)
Fig. 11-8
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 insulation
resistance of the stator, rotor and the live parts in
the control box. (Refer to Section 8-3.)
Any part where the insulation resistance is less
than 1MΩ, the insulation is faulty and may cause
electric leakage.
Replace the faulty part.
Fig. 11-9
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11-4 NO DC OUTPUT
11-4-1 CHECK THE AC OUTPUT.
Check the generator by following Step 11-1-1 through Step 11-1-3.
11-4-2 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
capacity battery or an over-discharged
battery, an excessive current may flow
causing.
Fig. 11-10
11-4-3 CHECK THE DC FUSE.
Check the fuse in the fuse holder.
FUSE
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.
Fig. 11-11
11-4-4 CHECK THE WIRING.
Check all the wires to be connected correctly.
11-4-5 CHECK THE DIODE RECTIFIER.
Remove the control panel and check the diode
rectifier with a circuit tester.
Refer to Section 9-7 “DIODE RECTIFIER” for the
checking procedure.
Fig. 11-12
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11-4-6 CHECK THE DC COIL
Check the resistance between two brown leads from stator with a circuit tester.
MODEL
SPECIFICATION
RESISTANCE
RGV2800
60 Hz
60 Hz
60 Hz
120V, 120V/240V
0.25 Ω
RGV4100
RGV6100
120V, 120V/240V
0.18 Ω
120V, 120V/240V
0.13 Ω
Table. 11-3
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.
11-5 IDLE CONTROL
11-5-1 ENGINE SPEED IS NOT INCREASED
WHEN A LOAD IS APPLIED
(1) Inspect the solenoid bracket. Check the bend
angle of solenoid bracket. If the bracket is dis-
torted, correct the angle with proper tool.
(2) Check the wattage of load applied to the gen-
erator. If the generator is loaded over the rated
wattage, the engine speed can not be in-
creased. 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
Fig. 11-13
not exceed the rated output of the generator.
SPEED CONTROL LEVER
(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 for cold engine con-
dition. If the engine speed is out of adjusting
range of the adjusting screw, move the sole-
noid backward.
ADJUSTING SCREW
Fig. 11-14
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(4) Check the wiring through ZCT on the IDLE
CONTROL UNIT.
IDEL CONTROL UNIT
* Single Voltage Type
Make sure that an output wire from main coil is
passing through the ZCT on the IDLE CONTROL
UNIT.
* Dual Voltage Type
OUTPUT WIRE
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
direction.
ZCT
Fig. 11-15
(5) Checking the IDLE CONTROL UNIT
Check the resistance between five leads of
IDLE CONTROL UNIT with circuit tester.
5
1
4
3
2
Terminal number of
the IDEL CONTROL UNIT
Fig. 11-16A
Fig. 11-16B
Apply black (minus) needle of the circuit tester
Circuit tester (with battery
power source 1.5 V)
1
2
∞
3
4
5
1
2
3
4
5
-----------
∞
250 kΩ
∞
250 kΩ
∞
75 kΩ
∞
-----------
∞
Apply red (plus) needle
of the circuit tester
250 kΩ
250 kΩ
8.5 kΩ
-----------
250 kΩ
7.8 kΩ
250 kΩ
-----------
7.8 kΩ
75 kΩ
75 kΩ
-----------
∞
∞
Table. 11-4
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 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.
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11-5-2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF.
(1) Check the distortion of the SOLENOID BRACKET as shown in step 11-5-1-(1).
(2) Check the wiring of SOLENOID.
Check two leads from SOLENOID are securely connected.
(3) Check the wiring of IDLE CONTROL UNIT.
Check all leads from IDLE CONTROL UNIT are securely and correctly connected.
(4) Checking the SOLENOID.
SOLENOID
Measure the resistance between two leads
from SOLENOID.
Normal Resistance
25 - 31 Ω
If the resistance is larger or smaller than this range,
SOLENOID is defective,
Replace with a new one.
Fig. 11-17
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12. WIRING DIAGRAM
* RGV2800 : U.S.A., 60Hz-120V TYPE [NEMA RECEPTACLE]
GRNERATOR
CONTROL BOX
ENGINE
No-fuse breaker
2.0Blk
2.0Blk
AC output
receptacle
(120V)
W
REC1
2.0Blu
2.0R
V
0.75Blk
Voltmeter
2.0W
Auxiliary
Winding
for
1.25Y
condenser
Engine switch
0.75Blk
0.75Blk
Oil sensor
1.25Y
0.75Grn/Y
1.25Brn
Diode stack
Assy
1.25Or
+
Circuit breaker
DC output
terminal
1.25Brn
1.25Grn
1.25Brn/W
-
Earth
(Ground) terminal
* RGV4100 : U.S.A., 60Hz-120V/240V TYPE [NEMA RECEPTACLE]
GENERATOR
CONTROL BOX
ENGINE
0.75W
0.75W
0.75Blu
1
5
3
4
2
1
5
3
4
2
0.75W
0.75W
Idle
control
unit
Auto idle switch
Solenoid
0.75LBlu
No-fuse breaker
2.0Blk
Full power
switch
120/240V
2
0.75Blu
1
3
REC3
W
REC1 W
120V
2.0Blu
2.0R
4
5
V
AC output
receptacle
(120/240V)
6
Voltmeter
W
Auxiliary
Winding
for
120/240V
7
9
0.75Blk
condenser
8
120V
REC2
2.0W
Oil sensor
1.25Y
0.75Blk
0.75Grn/Y
1.25Y
2.0Grn
Diode stack
Assy
1.25Brn
1.25Or
+
Circuit breaker
DC output
terminal
1.25Brn
1.25Brn/W
-
Earth
(Ground) terminal
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*RGV6100 : U.S.A., 50Hz-120V/240V TYPE [NEMA RECEPTACLE
GENERATOR
CONTROL BOX
ENGINE
Auto idle switch
0.75W
0.75W
2
8
1
9
5
3
6
7
4
2
8
1
9
5
3
6
7
4
0.75W
0.75W
0.75W
Idle
0.75Blu
control
unit
0.75Blu
Solenoid
0.75Blk/W
0.75Grn/W
0.75Grn/W
0.75Blk
and
Fuel
cut unit
0.75Grn
0.75Blu
0.75Blu
No-fuse breaker 1
2.0Blk
0.75Grn/W
Fuel cut solenoid
Full power
switch
120/240V
2
1
3
120V
REC1
W
W
2.0Blu
2.0R
4
5
REC4
REC3
V
6
Voltmeter
W
Auxiliary
Winding
for
120/240V
7
9
8
condenser
120V
REC2
2.0W
0.75Blk/W
2.0W
Oil sensor
2.0Y
2.0Grn
0.75Grn/Y
0.75Grn
2.0Y
Engin switch
Diode stack
Assy
1.25Brn
1.25Or
+
Circuit breaker
DC output
terminal
1.25Brn
1.25Brn/W
-
Earth
(Ground) terminal
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*RGV4100, 6100 : ELECTRIC STARTER TYPE
CONTROL BOX
ENGINE
(
)
0.75Blu RGV4100
(
)
0.75Grn/W RGV6100
1.25Grn
Diode
stack
Assy
0.75Blk/W
0.75Gry
Oil sensor
0.75Grn/Y
IG
+M
B
14Blk
14Blk
-M
1.25Or
1.25Grn
+
-
ST
1.25R
Battery
Key switch
Magnetiec
switch
Electric
starter
Earth
(Ground) terminal
Wiring color cord
Blk : Black
Blk/W : Black/White
Brn/W
Grn
Grn/W
Org
: Brown/White
: Green
: Green/White
: Orange
R
W
Y
: Red
: White
: Yellow
Blu
: Blue
LBlu
: Light blue
Brn
: Brown
Gry
: Gray
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1. SPECIFICATIONS
E N G I N E
O T R
T E A R L N A
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2. GENERATOR 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.
NORMAL CAPACITY OF
CONDENSER
RGV4101
RGV6101
20μF x 2
30μF x 2
Table. 2-1
(2) If such an instrument is unavailable, the con-
denser 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.
Fig. 2-1
2-1-2 CHECKING STATOR
COUPLER
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
Condenser
Winding
Specification
MODEL
AC Winding
Hz
60
60
Voltage
White / Red
0.54
Black / Blue
0.54
Yellow / Yellow
1.20
RGV4101
RGV6101
120 V, 120 V / 240 V
120 V, 120 V / 240 V
0.22
0.22
0.46
Table. 2-2
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(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.
Fig. 2-3
2-1-3 CHECKING ROTOR
(1) Remove rear cover and stator.
(2) Using a Dr. Robin or a circuit tester, measure
the resistance of the field coil at the terminals.
Fig. 2-4
( Ω )
RGV6101
5.3 Ω
MODEL
RGV4101
RESISTANCE
4.85 Ω
Table. 2-3
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. 2-5
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(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.
Fig. 2-6
2-2 AC VOLTAGE IS TOO HIGH OR TOO LOW
2-2-1 CHECKING ENGINE SPEED
SPEED CONTROL LEVER
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 lock nut on the adjusting screw.
* Turn the adjusting screw clockwise to decrease
engine speed or counterclockwise to increase
engine speed.
ADJUSTING SCREW
RGV4101
Normal engine speed at no load
3700 to 3750 rpm
2-2-2 CHECKING CONDENSER
Check condenser referring to Step 2-1-1.
RGV6101
2-2-3 CHECKING STATOR
Fig. 2-7
Check stator referring to Step 2-1-2.
2-2-4 CHECKING ROTOR
Check rotor referring to Step 2-1-3.
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2-3 AC VOLTAGE IS NORMAL AT 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 TOTAL WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR.
Refer to Section 3 “RANGE OF APPLICATIONS” for the wattage of the appliances.
If the generator is overloaded, reduce the load to the rated output of the generator.
2-3-3 CHECK THE APPLIANCE FOR TROUBLE.
If the appliance is faulty, repair it.
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.
AIR INLET
ENGINE
IR OUTLET
(
)
)
ENGINE
AIR OUTLET
ALTERNATOR
(
)
AIR INLET
ALTERNATOR
(
)
Fig. 2-8
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 insulation
resistance of the stator, rotor and the live parts in
the control box.
Any part where the insulation resistance is less
than 1MΩ, the insulation is faulty and may cause
electric leakage.
Replace the faulty part.
Fig. 2-9
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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
capacity battery or an over-discharged
battery, an excessive current may flow
causing.
Fig. 2-10
2-4-3 CHECK THE DC FUSE.
Check the fuse in the fuse holder.
FUSE
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.
Fig. 2-11
2-4-4 CHECK THE WIRING.
Check all the wires to be connected correctly.
2-4-5 CHECK THE DIODE RECTIFIER.
Remove the control panel and check the diode
rectifier with a circuit tester.
Fig. 2-12
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Fig. 2-13
Fig. 2-14
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.
Apply black (minus) needle of the circuit tester
Analogue circuit tester
Brown
Brown
Orange
Brown / White
Continuity
Continuity
Continuity
---------
Brown
Brown
---------
No continuity No continuity
No continuity
Continuity
---------
No continuity
---------
Apply red (plus) needle of
the circuit tester
Orange
Continuity
Brown / White
No continuity No continuity No continuity
Table. 2-4-1
* Checking table for digital circuit tester.
Apply red (plus) needle of the circuit tester
Digital circuit tester
Brown
Brown
---------
Brown
Orange
Brown / White
Continuity
Continuity
Continuity
---------
No continuity No continuity
Brown
No continuity
Continuity
---------
No continuity
---------
Apply black (minus) needle
of the circuit tester
Orange
Continuity
Brown / White
No continuity No continuity No continuity
Table. 2-4-2
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.
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NOTE 2 : ”Continuity” means forward direction characteristics of the diode, and different from short
circuit condition (in which a pointer of the tester goes out of its normal scale), shows resis-
tance to some extent. When results of the checking indicates failure even in one section,
replace with a new one.
NOTE 3 : Simpson brand analogue testers have the characteristics as same as the digital circuit tester.
2-4-6 CHECK THE DC COIL
Check the resistance between two brown leads from stator with a circuit tester.
MODEL
RGV4101
RGV6101
SPECIFICATION
120V/240V
RESISTANCE
0.14 Ω
60 Hz
60 Hz
120V/240V
0.11 Ω
Table. 2-5
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 APPLIED
(1) Inspect the solenoid bracket. Check the bend
angle of solenoid bracket. If the bracket is dis-
torted, correct the angle with proper tool.
(2) Check the wattage of load applied to the gen-
erator. If the generator is loaded over the rated
wattage, the engine speed can not be in-
creased. Most induction loads such as elec-
tric motor or electric tools or welding machine
require three to five times large wattage of their
Fig. 2-15
ratings at starting. This starting wattage must
not exceed the rated output of the generator.
SPEED CONTROL LEVER
(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.
ADJUSTING SCREW
Fig. 2-16
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(4) Check the wiring through ZCT on the IDLE
CONTROL UNIT.
* Single Voltage Type
Make sure that an output wire from main coil is
passing through the ZCT on the IDLE CONTROL
UNIT.
* Dual Voltage Type
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
direction.
Fig. 2-17
(5) Checking the IDLE CONTROL UNIT (RGV4101)
Check the resistance between five leads of
IDLE CONTROL UNIT with circuit tester.
Fig. 2-18A
Fig. 2-18B
Apply black (minus) needle of the circuit tester
Circuit tester (with battery
power source 1.5 V)
1
2
∞
3
4
5
1
-----------
∞
250 kΩ
∞
250 kΩ
∞
75 kΩ
∞
2
-----------
∞
Apply red (plus) needle
3
250 kΩ
250 kΩ
8.5 kΩ
-----------
250 kΩ
7.8 kΩ
250 kΩ
-----------
7.8 kΩ
75 kΩ
75 kΩ
-----------
of the circuit tester
∞
4
5
∞
Table. 2-6
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 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.
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(6) Checking the IDLE CONTROL UNIT (RGV6101)
Check the resistance between five leads of
IDLE CONTROL UNIT with circuit tester.
Fig. 2-19
-
〇
1
-------
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
110 kΩ
-------
110 kΩ
110 kΩ
∞
110 kΩ 50 kΩ 50 kΩ
∞
∞
∞
∞
∞
∞
-------
∞
∞
∞
∞
∞
∞
∞
∞
∞
-------
∞
∞
∞
110 kΩ
∞
110 kΩ 50 kΩ 50 kΩ
-------
∞
∞
∞
∞
∞
-------
110 kΩ 110 kΩ
110 kΩ 50 kΩ 50 kΩ
+
〇
350 kΩ
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
-------
110 kΩ 110 kΩ
85 kΩ 85 kΩ
85 kΩ 85 kΩ
110 kΩ
80 kΩ
80 kΩ
50 kΩ 50 kΩ
∞
-------
80 kΩ
80 kΩ
0 Ω
∞
-------
0 Ω
∞
Table. 2-7
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) Checking the SOLENOID.
SOLENOID
Measure the resistance between two leads
from SOLENOID.
Normal Resistance
25 - 31 Ω
If the resistance is larger or smaller than this range,
SOLENOID is defective,
Replace with a new one.
Fig. 2-20
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3. RANGE OF APPLICATIONS
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, fre-
quency, and power consumption (input wattage). The power consumption of an electrical appliance is
the power necessary for using it. When using a generator for operating an electrical appliance, the power
factor and starting wattage must be taken into consideration.
In order to determine the right size generator, it is necessary to add the total wattage of all appliances to
be connected to the unit.
Refer to the followings to calculate the power consumption of each appliance or equipment by its type.
(1) Incandescent lamp, heater, etc. with a power factor of 1.0
Total power consumption must be equal to or less than the rated output of the generator.
Example : A rated 3000W generator can turn thirty 100W incandescent lamps on.
(2) Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power
factor
Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the
load. Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3
times lager than 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 the power consumption, effi-
ciency should be taken into account as explained in ltem (5) on the following page.
(3) Mercury lamps with a smaller power factor
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.
Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on. A rated
3000 W generator can power two or three 400 W mercury lamps.
(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.
These appliances require large starting wattage which is 3 to 5 times of running wattage.
Example : A rated 900 W compressor requires a 4500 W generator to drive it.
NOTE1 : Motor-driven appliances require the aforementioned generator output only at the starting. Once
their motors are started, the appliances consume about 1.2 to 2 times their rated power con-
sumption so that the excess power generated by the generator can be used for other electrical
appliances.
NOTE2 : Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting
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.
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(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.
(Output of electrical appliance)
= (Power consumpition)
(Efficiency)
Efficiencies of some electrical appliances are as follows :
Single-phase motor................................ 0.6 to 0.75
Fluorescent lamp ................................... 0.7 to 0.8
The smaller the motor, the
lower the efficiency.
(
)
Example 1: A 40W fluorescent lamp means that its luminous output is 40W. Its efficiency is 0.7 and
accordingly, power consumption will be 40 ÷ 0.7= 57W. As explained in Item (2), multiply
this power consumption value of 57 W by 1.2 to 2 and you will get the figure of the neces-
sary capacity of a generator. In other words, a generator with a rated output 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 (W)
MODEL
RGV4101
RGV6101
Frequency
60 Hz
Incandesent lamp, heater, etc.
3600 W
4800 W
Fluorescent lamp, Motor-driven tool,
general-porpose
approx.
1800 W
approx.
2400 W
approx.
1400 W
approx.
1600 W
Mercury lamp, etc.
approx.
850 W
approx.
1100 W
Pump, compressor, etc.
Table. 3-1
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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 the insulation, possibly burning it out. Table 7-2 shows
cables and their allowable currents for your reference.
2. Cable length
If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors de-
creasing the input voltage to the load (electrical product). As a result, the load can be damaged. Table
7-2 shows voltage drops per 100 meters of cable.
Gauge No./
wire element
No./ mm
Voltage drop per 100 m
Sectional
Allowable
Resistance
Ohm / 100 m
area / mm3 current / A
1 A
3 A
5 A
8 A
10 A
12 A
15 A
0.75
1.25
2.0
7
30 / 0.18
50 / 0.18
37 / 0.26
45 / 0.32
70 / 0.32
2.477
1.486
0.952
0.517
0.332
2.5 V
1.5 V
1.0 V
8 V 12.5 V
12
17
23
35
5 V
3 V
7.5 V 12 V
15 V
10 V
5 V
18 V
12 V
5.0 V
8 V
4 V
15 V
3.5
1.5 V 2.5 V
1 V 2 V
6.5 V 7.5 V
4 V 5 V
5.5
2.5 V 3.5 V
Table. 3-2
1
Voltage drop indicates as V=
x R x I x L
100
R
I
means resistance ( Ω / 100 m) on the above table.
means electric current through the wire (A).
means the length of the wire (m).
L
The length of wire indicates round length, it means twice the length from generator to electrical tools.
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4. WIRING DIAGRAM
RGV4101
GENERATOR
CONTROL BOX
ENGINE
Idle control switch
1
5
3
4
2
1
5
3
4
2
0.75W
0.75W
0.75W
0.75W
Idle
control
unit
0.75Blu
0.75LBlu
Solenoid
No-fuse breaker
2.0Blk
Full power
switch
120/240V
0.75Blu
REC1
W
120V
W
2.0Blu
2.0R
V
REC3
Voltmeter
W
Auxiliary
Winding
for
120/240V
0.75Blk
condenser
120V
REC2
2.0W
Oil sensor
1.25Y
0.75Blk
0.75Grn/Y
1.25Y
2.0Grn
Diode stack
Assy
1.25Brn
1.25Or
+
Circuit breaker
DC output
terminal
1.25Brn
1.25Brn/W
-
Earth
(Ground) terminal
RGV4101 (Electric starter model)
GENERATOR
CONTROL BOX
ENGINE
Idle control switch
1
1
5
3
4
2
0.75W
0.75W
0.75W
0.75W
Idle
control
unit
5
3
4
2
0.75Blu
Solenoid
0.75LBlu
No-fuse breaker
2.0Blk
Full power
switch
120/240V
0.75Blu
REC1
W
120V
W
2.0Blu
2.0R
V
REC3
Voltmeter
Diode
W
stack
Assy
Auxiliary
Winding
for
120/240V
0.75Blk
condenser
120V
REC2
2.0W
Oil sensor
1.25Y
2.0Grn
0.75Blk
0.75Grn/Y
0.75Gry
0.75Blk
1.25Y
IG
1.25Brn
Diode stack
Assy
+M
B
14Blk
14Blk
-M
ST
Key switch
1.25Or
1.25R
1.25Or
Circuit breaker
+
1.25Grn
DC output
terminal
1.25Brn
Battery
1.25Brn/W
-
Magnetiec
switch
Electric
starter
Earth
(Ground) terminal
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RGV6101
GENERATOR
CONTROL BOX
ENGINE
Idle control switch
0.75W
0.75W
0.75W
2
8
1
9
5
3
6
7
4
2
8
1
9
5
3
6
7
4
0.75W
0.75W
Idle
control
unit
0.75Blu
0.75Blu
Solenoid
0.75Blk/W
0.75Grn/W
0.75Grn/W
0.75Blk
and
Fuel
cut unit
0.75Grn
0.75Blu
0.75Blu
No-fuse breaker
2.0Blk
Fuel cut solenoid
0.75Grn/W
Full power
switch
120/240V
120V
W
REC1
W
2.0Blu
2.0R
V
REC3
Voltmeter
W
Auxiliary
Winding
for
120/240V
120V
condenser
REC2
2.0W
0.75Blk/W
2.0W
Oil sensor
2.0Y
2.0Grn
0.75Grn/Y
0.75Grn
2.0Y
Engin switch
1.25Brn
Diode stack
Assy
1.25Or
Circuit breaker
+
DC output
terminal
1.25Brn
-
1.25Brn/W
Earth
(Ground) terminal
RGV6101 (Electric starter model)
GENERATOR
CONTROL BOX
ENGINE
Idle control switch
0.75W
0.75W
0.75W
2
8
1
9
5
3
6
7
4
2
8
1
9
5
3
6
7
4
0.75W
0.75W
Idle
control
unit
0.75Blu
0.75Blu
Solenoid
0.75Blk/W
0.75Grn/W
0.75Grn/W
0.75Blk
and
Fuel
cut unit
0.75Grn
0.75Blu
0.75Blu
No-fuse breaker
2.0Blk
Fuel cut solenoid
0.75Grn/W
Full power
switch
120/240V
120V
W
REC1
W
2.0Blu
2.0R
Diode
stack
Assy
V
REC3
Voltmeter
W
Auxiliary
Winding
for
120/240V
condenser
120V
REC2
2.0W
0.75Blk/W
2.0W
Oil sensor
2.0Y
2.0Grn
0.75Grn/Y
1.25Gry
2.0Y
IG
Diode stack
1.25Brn
Assy
+M
B
14Blk
14Blk
-M
1.25Or
1.25Or
+
1.25Grn
Circuit breaker
+
-
ST
DC output
terminal
1.25Brn
1.25R
Battery
Key switch
1.25Brn/W
-
Magnetiec
switch
Electric
starter
Earth
(Ground) terminal
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