Page 1
SERVICE MANUAL
COMMERCIAL GENERATOR
PPXX1122000000ee
\
0914-0506 REV 11/06
Page 2
CONTENTS
Section Title Page
1. SPECIFICATIONS
2. PERFORMANCE CURVES
3. GENERAL DESCRIPTION OF GENERATOR
4. CONSTRUCTION AND FUNCTION
4-1 CONSTRUCTION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 6
4-2 FUNCTION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 6
4-3 DESCRIPTION of GENERATOR OPERATION ・・・・・・・・・・・・・・・・ 17
5. SAFETY PRECAUTIONS
6. RANGE OF APPLICATIONS
7. MEASURING PROCEDURES
7-1 MEASURING INSTRUMENTS ・・・・・・・・・・・・・・・・・・・・・・・ 23
7-2 AC OUTPUT MEASURING ・・・・・・・・・・・・・・・・・・・・・・・・・ 24
7-3 MEASURING INSULATION RESISTANCE ・・・・・・・・・・・・・・・・・・ 25
8. CHECKING FUNCTIONAL MEMBERS
8-1 PILOT LAMP and VOLTMETER ・・・・・・・・・・・・・・・・・・・・・・・ 27
8-2 AC RECEPTACLES ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 27
8-3 AC SWITCH (NO-FUSE BREAKER) ・・・・・・・・・・・・・・・・・・・・・ 28
8-4 STATOR ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 28
8-5 ROTOR ASSEMBLY ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 29
8-6 EXCITING COIL・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 29
8-7 BRUSH ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 30
8-8 A.V.R (AUTOMATIC VOLTAGE REGULATOR) ・・・・・・・・・・・・・・・・ 30
8-9 CURRENT TRANSFORMER (RGV13100T only) ・・・・・・・・・・・・・・・ 31
8-10 ECU (ELECTRONIC CONTROL UNIT) ・・・・・・・・・・・・・・・・・・・ 31
8-11 IDLE CONTROL UNIT (PX12000 only) ・・・・・・・・・・・・・・・・・・ 32
8-12 DIODE UNIT (RGV13100T only) ・・・・・・・・・・・・・・・・・・・・・・ 33
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1
2
3
6
19
20
23
27
9. DISASSEMBLY and REASSEMBLY
9-1 PREPARATION and PRECAUTIONS ・・・・・・・・・・・・・・・・・・・・ 34
9-2 DISASSEMBLY PROCEDURES・・・・・・・・・・・・・・・・・・・・・・・ 34
9-3 COMPONENT PARTS ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 35
9-4 GENERATOR ASSEMBLING PROCEDURES・・・・・・・・・・・・・・・・・ 40
10. TROUBLESHOOTING
10-1 NO AC OUTPUT ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44
10-2 AC VOLTAGE IS TOO HIGH OR TOO LOW ・・・・・・・・・・・・・・・・・ 44
10-3 AC VOLTAGE IS NOMINAL AT NO-LOAD, BUT LOAD CANNOT BE APPLIED・・ 44
10-4 ENGINE DOSE NOT RUN・・・・・・・・・・・・・・・・・・・・・・・・・ 45
11. WIRING DIAGRAM
NOTE
This Service Manual excludes information for engine.
As for the total servicing information as a generator set, please refer in conjunction with the
EH63-65 OHV Engine Service Manual.
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34
44
46
Page 3
1. SPECIFICATIONS
Type
Model PX12000
Brush, Self-exciting,
2-pole, Single phase
RGV13100T
Brush, Self-exciting,
2-pole, 3-phase
Rated frequency 60Hz
Rated voltage
Maximum output 12000VA
120V / 240V
120V / 208V
13000VA
Alternator
Rated output 9500VA
Power factor 1.0
Voltage regulator
A.V.R type
Model EH65D
10000VA
0.8
C.T. type
EH63D
Type V-Twin cylinder, Air-cooled, 4-stroke, Overhead valve engine
Displacement 653 cm
3
Maximum output 22 HP/ 3600 rpm
18 HP/ 3600 rpm
Engine
Fuel Unleaded automobile gasoline (RON87 or higher)
Oil capacity 1.55 liters
Starting system Electric starter
Fuel tank capacity 44 liters
Rated continuous
3/4 Rated Approx. 9.0 hours
Approx. 9.7 hours
operation per a
tankful of fuel
Noise level
Length
Width
Dimensions
Height
Dry weight 141 kg (149 kg
Rated Approx. 8.2 hours
Rated (dB-7m)
77.0 dB
611 mm (752 mm *1)
771 mm (845 mm *1)
*
Approx. 8.9 hours
826
mm
2
)
143 kg (151 kg
77.0 dB
2
)
*
*1: ( ) shows dimensions with castors.
*2: ( ) shows dry weight with castors installed.
−−1−−
Page 4
2. PERFORMANCE CURVES
PX12000
(Hz)
63
62
61
60
(V)
250
(
)
125
240
(
)
120
230
(
)
115
220
(
)
110
Hz
240V/120V
PX
RGV13100T
(Hz)
63
62
61
60
(V)
230
220
210
0 1/2 4/4
Load Rated
Hz
208V
200
0 1/2 4/4
Load Rated
−−2−−
Page 5
3. GENERAL DESCRIPTION OF GENERATOR
FUEL TANK
CONTROL
PANEL
BATTERY
OIL FILLER CAP
TANK CAP
AIR CLEANER
COOLING AIR
INLET PORT
FUEL COCK
OIL FILTER
SPARK PLUG CAP
SPARK PLUG
CAP
OIL GAUGE
MUFFLER
OIL DRAIN PLUG
CHOKE KNOB
(RGV13100T only)
CONNECTOR
FOR REMOTE
CONTROL
(PX12000 only)
END COVER
(RGV13100T only)
ELECTRIC STARTER
−−3−−
Page 6
CONTROL PANEL
(PX12000)
VOLTMETER
OIL PURESSURE
WARNING LAMP
PILOT LAMP HOUR METERNO-FUSE BREAKER
TERMINAL
(RGV13100T)
110
0
2
120
2
0
2
4
0
CONNECTOR
FOR REMOTE CONTROL
VOLTMETER
PILOT LAMP HOUR METERNO-FUSE BREAKER
KEY SWITCH
IDLE CONTROL
SWITCH
AC RECEPTACLEEARTH (GROUND)
OIL PURESSURE
WARNING LAMP
EARTH (GROUND)
TERMINAL
110
0
2
120
2
0
2
4
0
AC RECEPTACLE
AC (THREE PHASE
and SINGLE PHASE
RECEPTACLE
−−4−−
KEY SWITCH
)
Page 7
SERIAL NUMBER
Serial number is stamped on the label stuck on the end cover.
NOTE : Always specify serial number when inquiring about the generator or ordering spare parts in order
to get correct parts and accurate service.
(RGV13100T)
(PX12000)
SERIAL NUMBER
stamped label
SERIAL NUMBER
stamped label
−−5−−
Page 8
−−6−−
4. CONSTRUCTION AND FUNCTION
4-1 CONSTRUCTION
MOUNT RUBBER BALL BEARING TROUGH BOLT
FRONT COVER
REAR COVER ROTOR COMPLETE
STATOR COMPLETE
STATOR BOLT
END COVER
(RGV13100T only)
BRUSH HOLDER
SLIP RING
4-2 FUNCTION
4-2-1 STATOR
The stator consists of a laminated silicon
steel sheet core, a main coil which is wound
in the core slots.
Page 9
4-2-2 ROTOR
The rotor consists of a laminated silicon steel
sheet core and a field coil which is wound
over the core.
DC current in the field coil magnetizes the
steel sheet core.
Two permanent magnets are provided for the
primary exciting action (RGV13100T).
Slip rings are provided on the rotor shaft to
receive DC exciting current from AVR
(PX12000) and diode unit (RGV13100T).
4-2-3 BRUSH / BRUSH HOLDER
An exciting current is supplied from the A.V.R
to the rotor. The brushes are made of carbon
and the brush-holder of plastic.
It is necessary to keep the contact pressure
between the brushes and slip rings within
specific limits. Thus, care must be taken of
brush length.
4-2-4 CURRENT TRANSFORMER
/ DIODE UNIT (RGV13100T only)
The current transformer and diode unit will perform a role to step up the voltage lowered by the
load and stabilize the output voltage.
1 2 31 2 31 2 3
CURRENT TRANSFORMER
DIODE UNIT
−−7−−
Page 10
4-2-5 A.V.R
AUTOMATIC VOLTAGE REGULATOR
(
(PX12000 only)
The automatic voltage regulator employs an
electronic circuit to automatically regulate
voltage.
4-2-6 ECU (ELECTRONIC CONTROL UNIT)
ECU controls the start/stop of an engine
enabling the fuel cut while stop.
It also automatically stops the engine if an
abnormal oil pressure occurs.
)
Function Description of Operation
Warning lamp
Starter motor control
When the lubrication oil pressure drops below the safety limit (Oil pressure
becomes less than 1kg/cm
limit (Engine speed increases higher than 4,500 r/min for 7 seconds), the
warning lamp repeats turning on and off, and the engine stops automatically. The warning lamp turns off after 3 minutes.
When the engine starts and reaches 1,050 r/min, the starter motor is
automatically stopped.
When the engine is operating, the starter motor cannot start.
2
) and/or the engine speed ups above the safety
−−8−−
Page 11
1
2
3
Function Description of Operation
Fail-safe function
When the key switch or the remote control switch is turned to "START", the
fuel cut-off valve of the carburetor opens. When the key switch or the
remote control switch is turned to "STOP", the fuel cut-off valve closes.
If the starter motor is locked by any reason, the starter motor is shut off
automatically after 3 seconds.
When the remote controller is connected, the electric starter dose not run
when the switch of remote controller is turned "OFF" even if the key switch
on the generator is turned to "START".
When the engine speed increases higher than 4,500 r/min for 7 seconds,
the engine is shut down automatically and the warning lamp repeats turning on and off for 3 minutes.
Self checking function for
warning lamp bulb
When the key switch or remote control switch is turned to "START", the
warning lamp lights up for a moment to indicate that the bulb for the warning lamp is normal.
When the engine does not start (engine speed does not reach 1,050
r/min), the starter motor is stopped after 21 seconds.
4-2-7 IDLE CONTROL UNIT
(PX12000 only)
The idle control unit
releases throttle
11
valve when the applied load current exceeds
0.04A.
The two output wires
must go through the ZCT
from the main coils
22
in the same
33
direction.
NOTE :
It is normal that the engine speed goes up for
a moment when you turn the key switch to
"STOP" while the Idle Control Switch is in
"ON" position.
−−9−−
Page 12
−−10−−
Model Specification No-fuse Breaker Object of Protection
60Hz-120V/240V 39A Total output amperage
RGV13100T 60Hz-120V/208V 24A Total output amperage
4-2-8 OIL PRESSURE SWITCH
The oil pressure switch sends a signal to ECU to stop the engine when the engine oil pressure
drops to 1.0 kg/cm
2
4-2-9 RELIEF VALVE
The relief valve begins to open when the engine's oil pressure increases above 3.0 kg/cm
OIL FILTER
CAMSHAFT
OIL PRESSURE SWITCH
CRANKSHAFT
RELIEF VALVE
OIL PUMP
2
OIL PUMP FILTER
4-2-10 AC SWITCH (NO-FUSE BREAKER)
The AC switch (no-fuse breaker) protects the generator from getting damaged from overloading or
a short circuit in the appliance. The capacity of AC switch (no-fuse breaker) is as follows ;
PX12000
Page 13
4-2-11 AC Receptacle
AC receptacles are used for taking AC output power from the generator.
A total of 4 kinds of receptacle, each varying in rated voltage and current from another, are
used. As many AC plugs as the receptacles, each matching the corresponding receptacle, are
provided.
The rated current for each receptacle is shown as follows;
CAUTION
Be careful not to use the receptacles
beyond the specified amperage limits to
prevent burning.
MAX 20A MAX 20A
AC120V
20A or less
MAX 30A MAX 30A
30A or less 50A or less
30A or less
Total 50A or less
MAX 50A
AC 120V / 240V
(PX12000)
CAUTION
To connect the appliance to the locking
type receptacle, insert the plug into the
receptacle and then turn it clockwise to
lock.
30A or less
30A or less
Total 30A or less
(RGV13100T)
MAX 20A
20A or less
TWIST
−−11−−
Page 14
■
Check the amperage of the receptacles used referring to TABLE 1, and be sure not to take a
current exceeding the specified amperage.
■
Be sure that the total wattage of all appliances does not exceed the rated output of the generator.
Style Ampere Receptacle AC plug Description
GFCI (Ground Fault Circuit
Interrupter) Receptacle, duplex
(REC1)
Locking Receptacle
(REC2)
Locking Receptacle
(REC3)
Locking Receptacle
(REC5)
up to 20A
up to 30A
up to 30A
up to 50A
up to 30A
NEMA
5-20R
NEMA
L5-30R
NEMA
L14-30R
NEMA
L21-30R
NEMA
5-20P
NEMA
L5-30P
NEMA
L14-30P
Locking Receptacle
(REC4)
NEMA
L21-30P
TABLE 1
NOTE :
When the no-fuse breaker turns off during operation, the generator is overloaded or the appliance is defective. Stop the generator immediately, check the appliance and / or generator for
overloading or detect and have repaired as necessary by CUMMINS ONAN dealer or service shop.
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 protected by GFCI.
−−12−−
Page 15
GFCI RECEPTACLE
After starting the engine, check the GFCI for proper functioning by the following test procedure.
■
Push blue TEST button, The red RESET button will pop out exposing the word TRIP. Power
is now off at the outlets protected by the GFCI, indicating that the device is functioning properly.
■
If TRIP does 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.
CONNECTING TO DOMESTIC CIRCUIT (HOUSE WIRING)
WARNING
This generator is neutral grounded type.
If a generator is to be connected to residential or commercial power lines, such as a
standby 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 appliances, damage to the building's wiring or fire.
(a) When connecting a CUMMINS ONAN 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.
−−13−−
Page 16
−−14−−
MAIN POWER LINE
TRANSFER SWITCH
UTILITY HIGH LINE
CONNECTING BOX
240V
RECEPTACLE
Utility high line
Meter box
Generator
House circuit breaker
XWY
X
(X)(
Y
)
(G)
(W)
WY
XWY
Transfer
switch
240V
4P- Receptacle
120V
appliance
120V
appliance
240V
appliance
OR
Generator
(X)(Y)
(G)
(W)
240V
4P- Receptacle
W
X
Y
Page 17
−−15−−
(c) Operating the generator.
■
Turn the house AC breaker off before starting the generator.
■
Start the generator and warm it up.
■
Turn the house AC breaker on.
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.
［
CAUTION
］
4-2-12 3-PHASE APPLICATION (RGV13100T only)
Connection of Power Cables
■
Do not touch output terminals while the generator is running or the operator may suffer severe electric shock resulting in death.
■
Be sure to shut down the generator before connecting or changing connection of
power cables to the generator.
WARNING
This generator has four output terminals of three phase, four wire system.
Connect power cables to the generator output terminals according to the type of application.
Page 18
−−16−−
SINGLE-PHASE OUTPUT
W
G
Y
X
Z
■
Three phase application (208V)
Insert the plug into the receptacle X, Y and
Z.
Generator rated output : 10000VA
AC (THREE PHASE) RECEPTACLE
(RGV13100T only)
RGV13100T has a receptacle for three plase
(208V) and single phase (120V) as follows :
■
Single phase lower application (120V)
Insert the plug into the receptacle W and X,
W and Y, W and Z.
Maximum one-third (1/3) of generator output
can be utilized from each phase.
W
G
Y
X
Z
3-PHASE OUTPUT
Generator rated output :
3324VA (120V x 27.7A)
SINGLE PHASE AC120V
THREE PHASE AC208V
W
Y
X
Z
Page 19
4-3 DESCRIPTION of GENERATOR OPERATION
FC
EC
a
AVR
ENGINE MAGNETO
AVR
MC
FC
SC
b
Fig. 4-1
Fig. 4-2
WITH AVR
A
RATED VOLTAGE
WITHOUT AVR
V
Fig. 4-3
4-3-1 PRIMARY EXCITING ACTION
(PX12000)
When the generator is started, the permanent magnet on the engine rotates to generator a voltage in the exciting coil.
This voltage is regulated by a diode in the
AVR to feed a current to the generator field
coil. (FC). (See Fig. 4-1)
The rotor is turned an electromagnet by that
current and rotates so that voltage are generated in the stator coils (main coil and sub
coil). The voltage generated in the sub coils
is operated by the AVR to feed a current to
increase the field coil current. (See Fig. 4-2)
As a result, the rotor magnetism increases.
This operation is repeated to generate the
rated voltage at 50 Hz or 60 Hz in the main
coil and DC coil.
4-3-2
VOLTAGE REGULATING MECHANISM
(PX12000)
Connect a load to the AC output terminal and
increase current. Output voltage varies as
shown in Fig. 4-3 depending on whether an
automatic voltage regulator is used or not.
The operation of the AVR is explained below.
When an AC output is taken, the engine is
loaded and its rpm falls. Also the AC voltage
fails due to the voltage drop caused by the
internal resistance of the coils. The AVR
detects this voltage drop and its built-in SCR
automatically increases the current flows to
the field coil. As a result, the rotor magnetism
increase, the voltage fallen by the load current is raised, and the output voltage is kept
constant. If the AC output is reduced, the
SCR operates in the opposite way to similarly
keep the output voltage constant.
−−17−−
Page 20
−−18−−
4-3-4 THE ADVANTAGES OF CURRENT TRANSFORMER CONTROL (RGV13100T)
With AVR control, control is effected according to variations in output voltage.
When an inductive load is applied, a large starting current is required (current variations are
greater than voltage variation), precise control becomes difficult.
Current transformer control, on the other hand, controls the output voltage according to the
load current, which is better for using inductive load.
4-3-3 CURRENT TRANSFORMER CONTROL (RGV13100T)
When the engine starts, a permanent magnet implanted in the rotor rotates, creating voltage in
the main coil (MC). When a load makes contact with the coil, the load current passing through
the primary coil of current transformer causes a magnetizing current to flow in ratio to the load
current flowing through the current transformer primary coil. This magnetizing current passing
through a diode to field coil creates a strong magnetic field in the rotor which falls with the
amount of the load, increasing the voltage.
R
Grn
W
Blk
R
W
Blk
Brn
Grn/W
Y
R
Y
W
Y
Blk
GENERATOR CONTROL BOX
V
PL
Hr
AC Winding
Feld Winding
Brush
Brush
Diode
unit
AC output
receptacle
(
120V
)
REC1
AC output receptacle
(120V : Single phase)
(208V : Three phase) REC5
AC output receptacle
(
120V)REC2
W
X
W
W
H
G
GGY
Z
Grn/Y
Grn/Y
Voltmeter
No-fuse
breaker
Earth
(Ground)
terminal
Pilot
lamp
Hour
meter
Grn
Key switch (-M
)
Current
transformer
1
23
1
23
1
23
Page 21
5. SAFETY PRECAUTIONS
1. Use extreme caution near fuel. A constant danger of explosion or fire exists.
Do not fill the fuel tank while the engine is running. Do not smoke or use open flame near the
fuel tank. Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before starting
the engine.
2. Do not place 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-venti-
lated area.
Otherwise the engine may overheat and also, the poisonous carbon monoxide contained in
the exhaust gases will endanger human lives. Keep the generator at least 1 m (3 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 insulation's 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.
7. Be sure to check and remedy the cause of circuit breaker tripping before resetting it
to 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.
−−19−−
Page 22
6. 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 wattage of the appliance. The electrical appliances generally have a label showing their rated voltage, frequency, 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 following 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 generator.
Example : A rated 3000 W generator can turn thirty 100W incandescent lamps on.
(2) Fluorescent lamps, mercury lamps, 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.
Example : A 400 W mercury lamp requires 600 W to 700 W power source to be turned on.
A rated 3000 W generator can power four or five 400 W mercury lamps.
NOTE 1 : If a power factor correction capacitor is not applied to the mercury lamp or fluorescent
lamp, the more power shall be required to drive those lamps.
A rated 3000 W generator can drive one or two 400 W mercury lamps without power factor correction capacitors.
NOTE 2 : Nominal wattage of the fluorescent lamp generally indicates the output wattage of the
lamp.
Therefore, if the fluorescent lamp has no special indication as to the power consumption,
efficiency should be taken into account as explained in item (5) on the following page.
(3) Motor driven tools and light electrical appliances
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.
(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.
NOTE 1 : 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 consumption so that the excess power generated by the generator can be used for
other electrical appliances.
−−20−−
Page 23
NOTE 2 : Motor-driven appliances mentioned in lets (3) and (4) vary in their required motor starting
power depending on the kind of motor and start-up load. If it is difficult to determine the
optimum generator capacity, select a generator with a larger capacity.
(5) Appliances without any indication as to power consumption
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 consumption)
＝
(Efficiency)
Efficiencies of some electrical appliances are as follows:
Single-phase motor ・・・・・・・・・ 0.6 to 0.75 The smaller the motor, the lower
Three-phase motor・・・・・・・・・・ 0.65 to 0.9
the efficiency.
Fluorescent lamp・・・・・・・・・・・ 0.7 to 0.8
Example 1 : A 40 W fluorescent lamp means that its luminous output is 40W. Its efficiency is
0.7 and accordingly, power consumption will be 40÷0.7=57W. As explained in
Item(2), multiply this power consumption value of 57 W by 1.2 to 2 and you will
get the figure of the necessary capacity of a generator. In other words, a generator with a rated output of 1000 W capacity can light nine to fourteen 40W 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 570W by 1.2 to 3 as explained in the Item (3).
570 (W)×1.2 to 3=684 (W) to1710 (W)
Applications
Incandescent Lamp, Heater 10000
Fluorescent Lamp, Electric Tool 4950
Pump, Compressor 2500
Applicable Wattage (W)
PX12000 (60 Hz)
−−21−−
Page 24
−−22−−
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 decreasing 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.
1
Voltage drop indicates as V=
100
×R×I×
R means resistance (Ω/ 100 m) on the above table.
I
means electric current through the wire (A).
means the length of the wire (m).
The length of wire indicates round length, it means twice the length from generator to
electrical tools.
Nominal
cross
section
A.W.G.
Gauge
No.
Allowable
current
No.of strands
/ strands dia.
Resistance
Current Amp.
No./mm
Ω/100m
mm
2
No. A 1A 3A 5A 8A 10A 12A 15A
0.75 18 7 30/0.18 2.477 2.5V 8V
12.5V
─ ─ ─ ─
Voltage drop
1.27 16 12 50/0.16 1.486 1.5V 5V 7.5V 12V 15V 18V
─
2.0 14 17 37/0.26 0.952 1V 3V 5V 8V 10V 12V 15V
3.5 12 to 10 23 45/0.32 0.517
─
1.5V 2.5V 4V 5V 6.5V 7.5V
5.5 10 to 8 35 70/0.32 0.332
─
1V 2V 2.5V 3.5V 4V 5V
Page 25
−−23−−
FOR AC
7. MEASURING PROCEDURES
(2) AMMETER
AC ammeter is necessary.
An AC ammeter with a range that can be
changed according to the current rating
of a given generator is most desirable.
(About 10 A, 20 A, 100 A)
(3) FREQUENCY METER
Frequency range : About 45 to 65Hz
NOTE : Be careful of the frequency meter's input
voltage range.
7-1 MEASURING INSTRUMENTS
(1) VOLTMETER
AC voltmeter is necessary.
The approximate AC voltage ranges of
the voltmeters to be used for various
types of generators are as follows :
0 to 150 V : Type with an output voltage
of 110 or 120 V
0 to 300 V : Type with an output voltage
of 220, 230 or 240 V
0 to 150 V, 0 to 330 V : Dual voltage type
FOR AC
Page 26
−−24−−
(4) CIRCUIT TESTER
Used for measuring resistance, etc.
(5) MEAGER TESTER
Used for measuring generator insulation
resistance.
Select one with testing voltage range of
500V.
7-2 AC OUTPUT MEASURING
SWITCH
LOAD
TO AC RECEPTACLE
F
A
~
V
~
Use a circuit above for measuring AC output. A hot plate or lamp with a power factor of 1.0
may be used as a load. Adjust the load and rpm. and check that the voltage range is as specified in the following table at the rated amperage and rated rpm.
Page 27
120 V 208 V 240 V
PX12000 112V-128V -------------- 224V-256V
RGV13100T -------------- 218V-249V --------------
Voltage range
Model
Rated voltage
7-3
MEASURING INSULATION RESISTANCE
Use a megger tester to check the insulation
resistance. Connect a megger tester to one
of receptacle output terminals and the ground
terminal, then measure the insulation resistance.
An insulation resistance of 1MΩor more is
normal.
If it is less than 1MΩ, disassemble the generator and measure the insulation resistance
of the stator, rotor and control panel individually.
●
STATOR
(1) Measure the insulation resistance
between BLUE (PX12000),
GREEN (RGV13100T) lead and the core.
(2) Measure the insulation resistance
between WHITE lead and the core.
(3) Measure the insulation resistance
between BLACK lead and the core.
(4) Measure the insulation resistance
between RED lead and the core.
−−25−−
Page 28
−−26−−
●
ROTOR
Measure the resistance between the slip ring
and the core.
●
CONTROL PANEL
Measure the insulation resistance between
the live parts and the grounded parts.
●
CURRENT TRANSFORMER (RGV13100T)
Measure the insulation resistance between
each terminal and the core.
If it is less than 1MΩ, replace the current
transformer.
Any part where the insulation resistance is
less than 1MΩhas faulty insulation, and may
cause electric leakage and electric shock.
Replace the faulty part.
Page 29
−−27−−
8. CHECKING FUNCTIONAL MEMBERS
PILOT LAMP
8-2 AC RECEPTACLES
Using a circuit tester, check continuity
between the two terminals at the rear of the
AC receptacles while the receptacle is
mounted on the control panel. When 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.
8-1 PILOT LAMP and VOLTMETER
Check the pilot lamp and the voltmeter if it is
turned on by applying specific voltage.
Pilot lamp and voltmeter cannot be checked
with circuit tester because its resistance is
too large.
Page 30
−−28−−
Model Hz/Voltage
Stator coil
Red-White Black-Blue Black-Red
White
-
Light green
Black-White
RGV13100 60/120/240
0.11Ω 0.11Ω
------------
0.37Ω
------------
RGV13100T 60/120/208
0.23Ω
------------
0.23Ω
------------
0.23Ω
8-3 AC SWITCH (NO-FUSE BREAKER)
Check continuity between each of 2 terminals at the back side of AC switch (no-fuse breaker)
while it is mounted on the control panel.
Normally, there is continuity between each of the 2 terminals when the breaker is ON, while no
continuity when the breaker is OFF.
PX12000 RGV13100
8-4 STATOR
Disengage connectors on the wires from stator and check the resistance between wires with a
circuit tester, referring to the following specification table.
NOTE : If the circuit tester is not sufficiently accu-
rate, it may not show the values given and
may give erroneous readings.
Erroneous readings will also occur when
there is a wide variation of resistance
among coil windings or when measurement is performed at ambient temperatures different from 20
(68°F).
℃
Page 31
8-5 ROTOR ASSEMBLY
1) Field coil
Remove the brush holder and measure resistance between the slip rings.
Rotor (Slip ring) Resistance
PX1200
RGV13100T
4.11Ω
69.6Ω
NOTE : If the circuit tester is not sufficiently accu-
rate, it may not show the values given and
may give erroneous readings.
Erroneous reading will also occur when
there is a wide variation of resistance
among coil windings or when measurement is performed at ambient temperatures different from from 20
℃
(68°F).
2) Cleaning Slip Rings
The slip ring surfaces must be uniformly
bright. Slip rings showing black spots,
excessive wear, or uneven wear must be
repaired. A stained slip ring lowers generator efficiency and output voltage. Polish
the slip rings with fine sandpaper while
turning the rotor until rough spots disappear. Care should be taken not to touch
the rotor coils with the sandpaper.
ROTOR
SLIP RING
SANDPAPER
8-6 EXCITING COIL (PX12000 only)
1) Disconnect the two yellow wires which
come out from the exciting coil through the
hole of the crankcase and connected with
A.V.R. in the control box.
2) Check the resistance between two yellow
wires with a circuit tester.
Exciting coil for A.V.R. Resistance
PX02100
3) Check the AC voltage between these two
yellow wires when the engine speed at no
-
load ; 3600
3800 rpm with a circuit tester.
2.35Ω
−−29−−
Ignition coil
AC voltage
35 to 45 V
Exciting
coil
Yellow
Yellow
Charge
coil
Page 32
−−30−−
8-7 BRUSH
The brushes must be smooth where they
contact the slip rings. If not, polish smooth
the brushes with sandpaper. A brush that is
not smooth produces arcs between the brush
and slip ring leading to possible damage.
Usable brush lengths are from 5 mm to 15
mm (0.2 " to 0.6").
A brush shorter than 5 mm must be replaced
because decreased contact pressure
between the brush and slip ring lowers generator efficiency and output voltage.
15 to 5 mm
(0.6" to 0.2")
BRUSH
BRUSH
HOLDER
8-8 A.V.R
(AUTOMATIC VOLTAGE REGULATOR)
1) Features
This AVR operates to control the field current
in order to maintain the output voltage for the
AC current, which generated by the magnetic
flux by the field coil.
2) A.V.R. trouble may be identified by simply
looking at the A.V.R., or by the inter-lead
resistance with a tester, or actually mounting it in the generator and operating it.
2 4
1 3
Terminal number
of the A.V.R.
Yellow
(a) A.V.R. TROUBLE IDENTIFICATION by APPEARANCE
If an A.V.R. electronic part is burnt dark, or the surface epoxy resin melted, it often indicates A.V.R. trouble.
(b) IDENTIFYING A.V.R. TROUBLE by CHECKING INTER-LEAD RESISTANCE
Check the inter-lead resistance of the A.V.R. with a tester, referring to the following table.
If the tester readings very greatly from the values specified in the table on next page, the
A.V.R. is faulty.
NOTE : Take teater inaccuracy into account in reading the tester.
(c) IDENTIFYING A.V.R. TROUBLE by MOUNTING and OPERATING in THE GENERATOR
SCR or transistor damage cannot be detected by simply looking at the A.V.R. or checking
the lead resistance. Check it by mounting the suspectedly faulty A.V.R. in a normal generator, or mount a mormal A.V.R. in a generator which fails to generate voltage.
Page 33
−−31−−
* Checking table for analogue circuit tester.
Analogue circuit tester
Apply black
-
needle of the circuit tester
Yellow
Black
11
White
22
Light green 33Brown
44
orYellow
Apply red +
needle of
the circuit
tester
Yellow ---------------
∞ ∞ ∞ ∞
Black
11
∞
---------------
200 kΩ
∞
300 kΩ
White
22
∞
60 kΩ
---------------
∞
100 kΩ
Light green
33
16 kΩ 350 kΩ 125 kΩ
---------------
14 kΩ
Brown
44
orYellow
∞
250 kΩ 100 kΩ
∞
---------------
8-9 CURRENT TRANSFORMER
(RGV13100T only)
Disconnect the connectors and couplers of
current transformer.
Check the inter-terminal resistance of current
transformer with a circuit tester.
If current transformer is found to be faulty, replace with new one.
8-10 ECU (ELECTRONIC CONTROL UNIT)
Check the resistance between 13 terminals
of ECU with circuit tester.
Terminal number of the ELECTRONIC CONTROL UNIT
1013
7
1
11
3 6
8
12
2 5
9
4
Terminal number
1 and 2 1 and 3
RGV13100T
2.00Ω 2.00Ω 0.009Ω
2 and 3
Page 34
−−32−−
Tester (-)
Tester
( )
Pin No.
11 22 33 44 55 66 77 88 99 !!00 !!11 !!22 !!33
11
-------
∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞
22
∞
-------
∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞
33
∞
18.4M
-------
10M 10.2M
∞
10.4M 11M 14.4M 5.3M
∞ ∞ ∞
44
∞ ∞ ∞
-------
0.1
∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞
55
∞ ∞ ∞
0.1
-------
∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞
66
∞ ∞ ∞ ∞ ∞
-------
∞ ∞ ∞ ∞ ∞ ∞ ∞
77
∞ ∞ ∞ ∞ ∞ ∞
-------
∞
2675
k
∞ ∞ ∞ ∞
88
∞ ∞ ∞ ∞ ∞ ∞ ∞
-------
2590
k
∞ ∞ ∞ ∞
99
∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞
-------
∞ ∞ ∞ ∞
!!00
∞
5.3M
∞
2392k2389
k
∞
2438k2664
k
4
M
-------
∞ ∞ ∞
!!11
∞
18M
∞
10.3M 10.2M
∞
10.3M 11M 14M 5.3M
-------
∞ ∞
!!22
∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞
-------
∞
!!33
∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞
-------
*Tester measuring range : 1000 k
45 3
1 2
NOTE : The resistance readings vary depending on the types of circuit testers.
The above table shows an example of the resistance readings measured by an 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.
Terminal number of the IDLE CONTROL
UNIT
Circuit tester (with battery
power source 1.5 V)
Apply black
〇
-
needle of the circuit breaker
Apply red 〇+
needle of the cir-
cuit breaker
11 22 33 44 55
11
-------
∞
65 65 30
22
∞
-------
∞ ∞ ∞
33
65
∞
-------
65 30
44
65
∞
65
-------
30
55
6.5
∞
6.5 6.5
-------
8-11 IDLE CONTROL UNIT
(PX12000 only)
Check the resistance between five terminals
of IDLE CONTROL UNIT with circuit tester.
Page 35
−−33−−
8-12 DIODE UNIT (RGV13100T only)
Check the resistance between five wires of
DIODE UNIT with circuit tester.
Diode unit
Apply black
〇
-
needle of the circuit breaker
Apply red 〇+
needle of the cir-
cuit breaker
Brown Yellow 1 Yellow 2 Yellow 3 Light green
Brown -------
∞ ∞ ∞ ∞
Yellow 1
16
-------
∞ ∞ ∞
Yellow 2
16
∞
-------
∞ ∞
Yellow 3
16
∞ ∞
-------
∞
Light green
30 16 16 16
-------
Page 36
−−34−−
9. DISASSEMBLY AND ASSEMBLY
9-1 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 reassemble.
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 reassemble using a neutral cleaning fluid.
5) Use all disassembly / assembly tools properly, and use the proper tool for each specific job.
9-2 DISASSEMBLY PROCEDURES
9-2-1 CONTROL PANEL
(1) Remove the front panel.
(2) Disconnect the connectors on the wiring
from the front panel to the alternator.
9-2-2 ALTERNATOR
(1) Remove the end cover.
(2) Remove the brush cover and the brush
holder.
(3) Take off the two flange-nuts and lift the
front cover with a piece of lumber.
(See Fig. 9-1)
NOTE : Lift the front cover until completely
the rear cover removes from the
mount rubber. (See Fig. 9-2)
(4) Remove the rear cover.
(5) Remove the bushing.
(6) Remove the stator cover.
REAR COVER
MOUNT RUBBER
Fig. 9-1
Fig. 9-2
Page 37
−−35−−
9-3 COMPONENT PARTS
For disassembling and assembling, the following illustrations show the major component parts
and their configuration for (1) Generator assembly, (2) Control Box and (3) Fuel Tank and sys-
tem.
The specified tightening torque is indicated in the illustration.
(8) Loosen the through bolt of the rotor.
(9) Remove the rotor with the soft hammer.
(See Fig. 9-4)
NOTE : Temporarily tighten the through bolt
of the rotor when hit the rotor.
(See Fig. 9-4)
(10) Remove the front cover.
ROTOR
SOFT
HAMMER
THROUGH
BOLT
Fig. 9-4
Fig. 9-3
(7) Remove the stator. (See Fig. 9-3)
NOTE : The stator is heavy. Be careful do not
hit the coil of the stator to the rotor.
Page 38
−−36−−
(1) Generator assembly
11.8-13.7Nm
120-140Kg-cm
11.8-13.7Nm
120-140Kg-cm
22.5-24.5Nm
230-250Kg-cm
ROTOR
STATOR
BEARING
THROUGH BOLT
REAR COVER
GENERATOR
BASE
BRUSH
COVER
BRUSH
HOLDER
COVER BOLT
FRONT COVER
STATOR COVER
BUSHING
MOUNT RUBBER
FLANGE NUT
BOLT
11.8-13.7Nm
120-140Kg-cm
END COVER
RGV13100T only
Page 39
(2-1) Control Box (PX12000)
PLATE
CONTROL BOX
GROMMET
WIRE
CONNECTOR
EARTH
(
GROUND
TERMINAL
AC RECEPTACLE
CAP
)
AC RECEPTACLE
NO-FUSE
BREAKER
CONNECTOR
for REMOTE
CONTROL
IDLE CONTROL
SWITCH
GROMMET
RELAY
CLAMP
IDLE CONTROL
ECU (P4)
CONTROL
PANEL
UNIT
A.V.R.
(
AUTOMATIC
VOLTAGE
REGULATOR
STARTER SWITCH
)
HOUR METER
PILOT LAMP
OIL PRESSURE
WARNING LAMP
VOLTMETER
−−37−−
Page 40
(2-2) Control Box (RGV13100T)
−−38−−
PLATE
GROMMET
EARTH
(
GROUND
TERMINAL
)
CURRENT TRANSFORMER
CONTROL BOX
DIODE UNIT
05
WIRE
AC RECEPTACLE
NO-FUSE BREAKER
AC RECEPTACLE
GROMMET
PILOT LAMP
CONTROL PANEL
CLAMP
RELAY
VOLTMETER
ECU (P4
)
OIL PRESSURE
WARNING LAMP
STARTER SWITCH
HOUR METER
Page 41
−−39−−
(3) Fuel Tank
FUEL GAUGE
FUEL TANK CAP
FUEL TANK
FILTER
PACKING
CUP
HOSE CLAMP
HOSE
CLAMP
RUBBER
PIPE (120 mm
)
RUBBER
PIPE (630 mm
)
PURSE
LOCK
FUEL FILTER
FRANGE BOLT
(
M6 x 14 mm
)
RUBBER
WASHER
FUEL PUMP
FLANGE BOLT
(
M6 x 14 mm
)
FUEL STRAINER
A
DETAIL A
Page 42
−−40−−
9-4-1 FRONT COVER
Attach the front cover to the engine main
bearing cover. Match the faucet joint and
tighten the bolts.
FRONT COVER
BOLT
SPRING WASHER
WASHER
9-4-2 ROTOR
(1) Wipe off oil, grease and dust from the
tapered portion of engine shaft and
matching tapered hole of rotor shaft.
(2) Mount the rotor to the engine shaft.
Tighten the through bolt.
ROTOR
SPRING WASHER
WASHER
THROUGH BOLT
BEARING
9-4 GENERATOR ASSEMBLING PROCEDURES
Fig. 9-5
Fig. 9-6
Tightening torque
230-250 kg cm
22.5-24.5 N m
16.6-19.5 ft lbs
Tightening torque
120-140 kg cm
11.8-13.7 N m
8.7-10.1 ft lbs
Page 43
−−41−−
Fig. 9-8
9-4-3 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.
Tighten the four bolts tentatively to check
if the grooves and thread holes are
aligned correctly. (See Fig.9-8)
(2) Remove the four bolts.
STATOR COVER
STATOR
Fig. 9-7
Page 44
9-5 REAR COVER
BRUSH
COVER
BRUSH
HOLDER
FLANGE
BOLT
SCREW
Fig. 9-9
Fig. 9-10
Fig. 9-11
(1) Put the rear cover with stator and stator
cover over the rotor.
Pull wires out from the rear cover.
NOTE : Be careful not to give cuts to wires when
pulling them out from the rear cover.
Attach the bushing over the lead wire
drawn out from the rear cover.
Press the smaller end of the bushing into
the window of the rear cover.
(2) Tap on the rear cover evenly with a plastic
hammer to press the rotor bearing into
the rear cover.
(3) Fix the rear cover with four bolts, spring
washers, and washers.
Tightening torque
120-140 kg cm
11.8-13.7 N m
8.7-10.1 ft lbs
(4) Install the brush holders in the rear cover.
Pass the mounting screws through the
brush holders, push the brush holders so
that the brushes will be perpendicular to
the slip rings, and tighten the screws.
NOTE : There are two kinds of brush holders.
If a brush is installed oblique to the
slip ring, the brush holder can break
when the screw is tightened; or the
brush may break when the generator
is started. After installing the brush
holders, measure the resistances
across the brushes and terminals
with a tester. If they are from 5 ohms
to 7.5 ohms the brush holders are
correctly mounted.
−−42−−
Page 45
−−43−−
NOTE : When tightening the nuts, slightly lift the
alternator assembly so that the weight is
not applied to the mount rubbers.
(7) Fasten the earth cable to the unpainted
bolt hole on the frame.
EARTH CABLE
Attach the connectors to the brush holders.
Fig. 9-12
Fig. 9-13
Tightening torque
120-140 kg cm
11.8-13.7 N m
8.7-10.1 ft lbs
Connect the green wire to the stator end
and the brown wire to the bearing end.
Install the brush cover.
(5) (RGV13100T only)
Attach the end cover to the rear cover.
(6) Tighten the nuts over the mount rubber
bolts to fix.
Page 46
10. TROUBLESHOOTING
10-1 No AC output
* Check the exciting coil for resistance. (PX12000) (Refer to 8-6.)
If insulation is NG, replace exciting coil with new one.
* Check the brush and slip ring of rotor for resistance. (Refer to 8-5 and 8-7.)
If insulation is NG, replace brush and slip ring with new one.
* Check stator for winding resistance between terminals. (Refer to 8-4.)
If stator is faulty, replace with new one.
* Check stator for insulation resistance. (Refer to 7-3.)
If insulation is NG, replace stator with new one.
* Check the A.V.R . (PX12000) (Refer to 8-8.)
If insulation is NG, replace A.V.R with new one.
* Check the diode unit and C.T . (RGV13100T) (Refer to 8-9 and 8-12.)
If insulation is NG, replace diode unit and C.T with new one.
10-2 AC Voltage is too high or too low
* Check engine speed.
Nominal engine speed at no load ; 3,700 to 3,750 rpm
If engine speed is too high or too low, adjust to the rated rpm.
* Check stator for winding resistance and insulation. (Refer to 8-4 and 7-3.)
* Check rotor for resistance and insulation. (Refer to 8-5 and 7-3.)
* Check the idle control unit. (PX12000) (Refer to 8-11.)
If insulation is NG, replace idle control unit with new one.
10-3 AC voltage is nominal at no-load, but load cannot be applied.
* Check engine speed.
If engine speed is low, adjust to the rated rpm.
* Check total wattage of appliances connected to generator.
If the generator is overloaded, reduce the load to the rated output of generator.
* Check appliance for trouble.
If the appliance is faulty, replace it.
* Check if engine is overheated.
If generator cooling air inlet and/or outlet is clogged with dirt, grass, chaff or other debris,
remove it.
* Check insulation of generator. (Refer to 7-3.)
−−44−−
Page 47
10-4 Engine does not run.
Remedy
Wait for more than 2 seconds and then turn the
key switch to "START" position.
The ECU is defective.
Replace with new one.
Supply fuel or open the fuel cocks.
Add or change engine oil.
Replace the bulb with a new one.
Symptom Possible causes
1) The key switch (or remote
switch) is turned to "START"
within 2 seconds the engine has
been stopped.
1. Electric starter
does not operate
2. Warning lamp
2) The remote controller is connected.
3) The above possible causes 1)
and 2) does not apply.
1) No fuel in the tank or the fuel
cock is closed.
turns on and off
when engine is
stopped
2) Oil level is low or oil is contaminated.
Both the key switch of the generator and the
switch of remote controller must be turned to
"ON" position.
3. Engine is automatically stopped
but the warning
lamp does not
light up
1) The bulb of warning lamp failed.
−−45−−
Page 48
−−46−−
LGrn
R/W
Blk/W Black/White Grn Green W White
Blu Blue Grn/W Green/White Y Yellow
LBlu Light blue Org Orange Pik Pink
Brn Brown Gry Gray Grn/Y Green/Yellow
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Light green
Red/White
11. WIRING DIAGRAM
(PX12000)
Auto choke
(
Bimetal
Ignition coil
Exciting
coil
(
)
AVR
)
Y
Y
-
Blk15
Battery 12V
Blk
Fuel cut
Charge
coil
Blk
+
Idle
solenoid
Electric
starter
Regulator
R15
CONTROL BOXGENERATOR
R
R
Blk/W
Blk
Grn
W
W
Org
R
Magnetic
switch
Gry
Oil pressure
switch
CONTROL BOX
LGrn
R/W
Blk/W
W
W
1
53
Idle
control
unit
Idle control
switch
to earth
terminal
AC output
receptacle(120V)
Blk
(AC output)
LBlu
2
4
Org
R
Grn/Y
Grn/Y
LBlu
ST Relay
AC output
receptacle(120/240V)
1
2133124115106
Electronic control unit
Y
Brn
LBlu
Org
OFF
ON
START
W
Grn
Oil pressure
Gry
warning lamp
W
-
M+MB
Grn/Y
Grn
987
LBlu
Gry W
L.IG
Org
Grn/Y
Grn/Y
Org
Grn
Gry
ST
Key
switch
Connector
(
Remote control
AC output
receptacle(120/240V)
(
Red
W
)
WW
W
)
Field
Winding
Brush
Auxiliary
Winding
Blk
AC WindingAC Winding
Blu
R
Blk
W W
LGrn
Brm
W
YY
VHr
Voltmeter
Hour meter
No-fuse breaker
Blk
W
LGrn
Brm
Y
Y
Exciting coil
(Engine)
Grn/Y
PL
REC1 REC2
Idle
unit
control
HH
R
Pilot lamp
Blk
GG
WW
G
GG
XX
WW
AC otuput
receptacle(120V)
REC3
W
Grn/Y
REC5
REC4
YY
Grn/Y
AVR
Key switch -M
Grn/Y
Idle control unit 3
Earth(Ground)
terminal
Wiring color cord
:
:
:
Blk/RBlk Black Brn/W Brown/White R Red
Black/Red
:
Page 49
−−47−−
(RGV13100T)
CONTROL BOX
1
Fuel cut
Ignition coil
Electric
starter
Oil pressure
switch
Regulator
Magnetic
switch
Oil pressure
warning lamp
(
Red
)
Charge
coil
Electronic control unit
-
+
Battery 12V
Blk15
R15
LGrn
Gry
Blk
Blk
Grn
2133124115106
987
R
W
W
W
W
Org
Grn/Y
Org
R
Org
Blk/WBlk/W
R/W
Gry
Grn
Blk
R
Blk
Key
switch
to earth
terminal
OFF
-
M+MB
L.IG
ST
ON
START
ST Relay
Gry
Grn
Org
Grn/Y
Grn/Y
Y
Brn
Org
LBlu
R
Grn
W
Blk
R
W
Blk
Brn
Grn/W
Y
R
Y
W
Y
Blk
GENERATOR CONTROL BOX
V
PL
Hr
AC Winding
Feld Winding
Brush
Brush
Diode
unit
AC output
receptacle
(
120V
)
REC1
AC output receptacle
(120V : Single phase)
(208V : Three phase) REC5
AC output receptacle
(
120V)REC2
W
X
W
W
H
G
GGY
Z
Grn/Y
Grn/Y
Voltmeter
No-fuse
breaker
Earth
(Ground)
terminal
Pilot
lamp
Hour
meter
Grn
Key switch (-M
)
Current
transformer
1
23
1
23
1
23
Page 50
Page 51
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