Robin RGV2200, RGV2600, RGV6000, RGV4000 Service Manual

IISSUE EM D-GS08591

6

mEab

E

HRdi!!!I!@MGASOLINEENGINEGENERATQ

SERVICE MANUAL

@FUJl HEAVYINDUSTRIESLTD.

CONTENTS

Section

Title Page

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

SPECIFICATIONS ..........." ....". """.......".. "". . ..... . .. . . ........ ...." ...."" . ... . . . .. 1

PERFORMANCE CURVES .. ..." .. ... . ....."... "....".. "... "...... ......... .... ........" 3

FEATURES .. . . .......... ......" ......" ...."... "". "....... . . ......... . ..... .... .." ......... . . 5

GENERAL DESCRIPTION OF THE GENERATOR ...-”” .”... -. ...”. o........”...... 6

4-1

External View of Generator

.. . ...... . . . . . .... . . . . . . . . . . . . ..... . ... . ... . .... . .... . . . ...

6

4-2 Control Panel

.... . .... . . ... . ... . .... ....... . . . ..... . . . . . . . . ...... . ... . .... ... . .... . . ...

7

4-3 Location of Serial Number and Specification Number . . . . . . . ...”...............”.. 20

Construction AND FUNCTION .. . . . . .."... ".- ... . . . . . . .....-. -C.---... -"--------- 21

5-1

Construction

... .. . ...." .. ..."... ".... . . .." .. ..". . ....." .. . . . . . ...." .. . . ... . ... . . .... . 21

5-2 Function . ... . . . ...... . .... . ..." .. . ... . . . ..... . . .." ...."" . . . . . . ...." ... . ... . ... . . ... . . . 21

5-3 Description of Generator Operation

..... .... . . . . . . . . . . . ..... . . . ... . ....... .... . . . .. 25

SAFETY PRECAUTIONS ................" ..... ..." . ............. . . ............. ..... . . . 28

RANGE OF APPLICATIONS .. ... . .... . ....... . . . . . .......... . .." . . ... . .... . ... . .... ..- 29

MEASURING PROCEDURES ..".. ".. .." . . . ... . . . . . . .. . . . . .... . . . . ... . .... .... . .... . . . 32

8-1

Measuring Instruments ..... . ... . .... . . . . .... . . . ..... ..... . ....... C.. . . ..... . . .... ..- 32

8-2 AC Output Measuring

.. . ...... . .." . ....... ....... . . . . . . . . ....... ....... ..". "........ 35

8-3 Measuring Insulation Resistance .. ....... .... ... . . . ....... . . . . . ... .... . ... . .... ...- 35

CHECKING FUNCTIONAL MEMBERS ..... . .. . ............ . .................... .... 37

9-1

Pilot LamP .. . . . . ..... . .... . ... . ... ... . . . . . .... . . . . . ..... ..... ..... . .... . .... .... . . .... 37

9-2 AC Receptacles

.... . ... ... . . ... . ... . . . . . ... . . . . . ... . . . . . . . . .. ....... ... .... .... . . ....

9-3 Circuit Breaker

37

.. . . . ... . ... . ... . . ... . ...... . . ... ... . . . . . . . ....... . . ... . ... . ... .... . . . . 38

9-4 Stator . .... . . . ....... . .... . . ... .... . ... . . . . .. .. ....... . . . . . . . . . ... .. C... . .... .... . . .... 38

9-5 Rotor . ...... . . . . . .... . . ....... .... . .... . . . . .... . . . . . ........ . . . . . ... . ... . . .. C. . . ... . .. 39

9-6 Condenser .... . . . . .... . . ... . ... . ....... ... . .... . . . . . .. . . . .... . . . . ... . ....... .... . . ... 39

9-7 Diode Rectifier

.... . ... . .... . ... . .... . .. ..... . . . .... . . . . . . . ....... .... . . ... .... .... . . .

40

Disassembly AND ASSEMBLY ... . .. ..... . . . . . .... . .... ........ C... . . ... . .... . . ... 41

10-1 Preparation and Precautions . . ... . . ....."... ".. ".. "... .... . . . . . .. . .... ... . .... . . ... 41

10-2 Special Tools for Disassembly and Assembly

.... . . . . . ...... . . .... . .... ... . . ..... . 41

10-3 Disassembly Procedures . . ... . ....... . . . . . .... .. . .......... . . . . ... . ....... .... . . .... 42

10-4 Assembly Procedures .." . . ... ... . .... . . . . .... . . . . . . . . . . .... . . . . ... . .... . ... . .... . . . . 51

10-5 Checking, Disassembly and Reassembly of the Control Box . ... . . ... . ... ....--.. 58

Troubleshooting .. . ...." .. . ....." . . . . . .... . . . . . ... . . . . . . . . ...... .... . .... .... ... . . . 59

11-1 No AC Output . . . . . ... . . .... . ... . ... ....... . . ....... . . . . . . . . ...... ... . .... .... . . .... . . 59

11-2 AC voltage is too high or too low

... . . . .... . . . . . .... . .. . . . ...... .... . .... .... .... . . .

’61 11-3 AC voltage is normal at no-load, but the load cannot be applied ..-. ---... ”...-”. 62

11-4 No DC Output ..... . .... . . .... ........ . . . . . ... . . . . . . ... .. .... . .. .... .... . ... . .... . . ... 63

11-5 idle Control . .. ..... . .... . . .... .... . .... . . . .... . . . . . .......... . . . . ...... . . .. . ..... . . ..- 64

WIRING DIAGRAM

.. . . .... ..... . . .... . . .... . . . .... . . . .... . . . ....... . . .... . ... . . ... .... . .

67

NOTE: As for the servicing information on engine portion, please refer to the

EHI 7, EH25 and EH34 engine service manual.

1.

SPECIFICATIONS

-

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II

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c

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.-

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m

U

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3V

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3NIDN3

UOlVNU3llV

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-1-

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I

0

co

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0 0 0

>

(D

0

PC

0

9

0

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7

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:d

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0

m

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a,

n

C

a,

U

S

s

i:

j:

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d

m

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0

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d

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b

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b

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..

,:

..

s

I

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:j:

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-

.-

c

0

n3

U

-I

tlOlVNtl3llV

3N13N3

I

-2-

2.

PERFOMANCE CURVES

63T

\

250

(1 25)

23ov/115v

220

0

1 /2

414

Load Rated

50Hz

(Hz)

Hz

51

00

250

(1 25) 24ov/12ov

230V/115V

220

21

0

(1

05)

0

1 12

414

Load Rated

-3-

DC

OUTPUT

DC Voltage

........................

DCAmpere

........................

DC output

........................

12v

8.3A

1

oow

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

out-

puts simultaneously up to the rated output

in total.

CURRENT

(AI&

-4-

3.

3-1

3-2

3-3

3-4

3-5

3-6

3-7

3-8

3-9

FEATURES

BRUSHLESS ALTERNATOR

Newly developed brushless alternator eliminates troublesome brush maintenance.

CONDENSER TYPE VOLTAGE REGULATOR

A

trouble free condenser type voltage regulator ensures a stable voltage under all working

conditions.

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.

QUIET OPERATION

Robin RGV series generator delivers a quiet operation with

:

0

A large super silent muffler.

0

A quiet 4-stroke Robin Rro OHV engine.

0

A

silent cyclone air cleaner.

NO RADIO NOISE

Noise suppressor spark plug and spark plug cap are equipped standard to prevent radio frequency

interfe.rence.

LARGE FUEL TANK

The large fuel tank allows more than 5 to

11

hours

of

continuous operation which

is

sufficient for a

half day or one day work without refueling.

RUGGED TUBULAR FRAME

Full cradle type rugged tubuler frame protects the generator all around.

COMPACT AND LIGHT WEIGHT

Newly developed brushless alternator enabled the

RGV

generators to be very compact

in

size and

light

in

weight.

MINIMAL MAINTENANCE

0

A brushless alternator release the operator from periodical brush maintenance.

0

A trouble free condenser type voltage regulator.

0

A drip-proof alternator design.

0

No-fuse circuit breakers.

0

An electronic pointless ignition system.

0

A

dust-proof cyclone air cleaner.

3-10 LONG-LIFE DURABILITY

The heavy-dut! 4 stroke Robin Rro

OHV

engine and virtually maintenance-free brushless alternator

ensure greater durability with

:

0

A brushless alternator with a condenser voltage regulator.

Full

rubber mount

in

a sturdy tubular frame.

0

A

forged ste.el crankshaft supported by two main ball bearings.

A

pointless electronic ignition system.

0

A

cast-iron cylinder liner.

0

A

forged aluminum connecting rod.

-5-

4.

4-1

GENERAL DESCRIPTION

OF

THE GENERATOR

EXTERNAL VIEW

of

GENERATOR

VOLT?JETER FUEL LEVEL GAUGE TANK CAP

STOP

BUTON

CHOKE KNOB

kC

AIR CLEANER

..

DC

RECOIL STARTER

,

DC CIRCUIT BREAKEFi AC CIRCUIT BREAKER

OIL SENSOR

SPARK PLUG MUFFLER

31L DRAIN PLUG OIL LEVEL GAUGE

-6-

4-2 CONTROL PANEL

RGV2200, RGV2600 : SOHz, 60HZ-1 lOV, 60Hz-120V TYPE

RGV2200, RGV2600 : 50H~-220V, 240V, 60HZ-220V TYPE

-7-

RGV2200, RGV2600 : SOHZ, 60H~-lIOV/220V DUAL VOLTAGE TYPE

RGV2200, RGV2600, RGV4000

:

U.K.,

50H~-110V/120V

[BS

RECEPTACLE]

-8-

RGV2600 : U.S.A., 60Hz-120V [NEMA RECEPTACLE]

RGV2200, RGV2600, RGV4000

:

GERMANY, 50Hz-220V

-9-

RGV2200, RGV2600, RGV4000 : SOUTH

AFRICA,

50HZ-220V

I

RGV2200, RGV2600, RGV4000 SWITZERLAND, 50HZ-22OV

-

10

-

RGV2200, RGV2600, RGV4000

:

AUSTRALIA,

50HZ-240V

RGV4000 : 5OHZ, 60Hz-11 OV, 60HZ-120V

TYPE

-

11

-

RGV4000 : 50H~-220V, 240V, 60HZ-220V

TYPE

0

RGV4000 : SOHZ, 6OHZ-l10V/220V

TYPE

-

12

-

RGV4000 : U.S.A., 60H~-120V/240V [NEMA RECEPTACLE]

@I

.

RGV2200, RGV2600, RGV4000 : FRANCE, 50Hz-220V

L

PRISES

CA

CHARGE

DE

BATTERIE

SEULEMENT

-

13-

0

RGV6000 : 50Hz, 60Hz-1 lOV, 60Hz-IiOV TYPE

I

!

L

!

@

1

0

I

U

VMEIER

1

RGV6000 : 50H~-220V, 240V, 60Hz-220V TYPE

f0

0 0

o\

\O

~

0

0)

-

14-

RGV6000 : 50Hz, 60H~-llOV/220V DUAL VOLTAGE

TYPE

..

-

15

-

RGV6000 : U.S.A., 60H~-120V/240V [NEMA RECEPTACLE]

RGV6000

:

GERMANY,

50Hz-220V

f0 0 0

I

\O

0

-

16

-

RGV6000 : SOUTH

AFRICA,

50Hz-220V

h

A

J

U

kEm

,

VMEtER

I

63

0

RGV6000 : SWITZERLAND,

50Hz-220V

f0

0

o\

ON

0

E

-

17

-

RGV6000

:

AUSTRALIA,

50HZ-240V

0

RGV4000, RGV6000 : (With optional electric starter and idle control)

-

la

-

RGV6000

:

FRANCE,

50H~220V

VOLTMETRE

0

RGV4000, RGV6000 : (With optional electric starter and idle control)

/@

PRlSES

CA

-

19

-

4-3

LOCATION

of

SERIAL NUMBER

and

SPECIFICATION NUMBER

Serial number and specification number are stamped

on

the

LABEL

(MODEL

NAME)

stuck on the end

cover.

NOTE:

Always specify these numbers when inquiring about the generator or ordering spare parts in order

to

get correct parts and accurate service.

MODEL

NAME

-

20

-

5.

CONSTRUCTION AND FUNCTION

5-1

CONSTRUCTION

END

COVER

REAR

COVER

ROTOR

COMPLETE

STATOR

COMPLETE

MOUNT

RUBBER

STATOR

BOLT

BALL

BEARING

THROUGH

BOLT SUPPORT

RING

FRONT

COVER

Fig.

5-7

5-2 FUNCTION

5-2-1 STATOR

I

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

i

-I

which generates

AC

voltage

in

the

main

coil.

i

1

I

Fig.

5-2

-

21

-

5-2-2 CONDENSER

One

or

two condensers are installed

in

the control

box and are connected to the condenser coil

of

the stator. These condensers and condenser coil regulate the

:

output voltage.

5-2-3

ROTOR

The rotor consists

of

a laminated silicon steel sheet core and a field coil which is xound over the core.

DC

current in the fie.ld coil magnetizes the steel

sheet core.

Tw~o

permanent magnets are provided

for the primary exciting action.

Fig.

5-4

A

diode rectifier and surge absorber is mounted inside

of

the insulator.

1

!

!.

-

22

-

5-2-4

DC CIRCUIT

BREAKER

(1)

The

10

ampere

DC

circuit breaker mounted

on

the control panel protects whole

DC

circuit from getting damage by overload or short circuit.

j

Fig.

5-6

5-2-5

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.

I

MODEL

1

SPECIFICATION

I

NO-FUSE

BREAKER

j

OBJECT

of

PROTECTION

I

50HZ-11 OV

Total output amperage

6.5A 50HZ-220V, 240V

Total output amperage

15A

60Hz-11 OV, 120v

Total output amperage

12A

60HZ-220V

8A

Total output amperage

RGV2200

'

I

50HZ-11 OVI22OV

'

Total output amperage

6.5A (2-Pole, 2-Element)

60HZ-120VI240V

'

I

8A (2-Pole. 2-Element)

Total output amperage

.

50HZ-11 OV.

I

18A

Total output amperage

9A 50Hz-220V

Total output amperage

..

20A 60HZ-11 OV. 12Ov

Total output amperage

RGV2600

1 OA

.i

Total output amperage 60HZ-220V

!

60HZ-240V

50HZ-11 OVl220V

.

9A (2-Pole. 2-Element) Total output amperage

. .

aA

I

Total output amperage

I

~

60Hz-11 OVi22OV, 12OVi24OV

i

1

OA (2-Pole. 2-Element)

1

Total output amperage

50HZ-11 OV

!

27A Total output amperage

I

60142-1

lov,

120v

.

j

30A Total output amperage

.

50Hz-220V

I

14A

Total output amperage

I

RGV4000

60HZ-220V 15A

!

Total output amperage

.12A Total output amperage

..

-5OHZ-240V

I

50HZ-11 OVi220V

I

14A (2-Pole, 2-Element)

i

Total output amperaqe

I

.60Hz-11 OV!22OV. 120V!240V

[

15A (2-Pole, 2-Element) Total output amperage

Total output amperage

50HZ-11 OV

40A

1

60HZ-11 OV. 120V

50HZ-220V. 60Hz-220V

50HZ-240V

50HZ- 1

1

OV/22OV.

.I

!

.

30A

Output from 30A receptacle

RGV6000

I

20A

20A (2-Pole. 2-Element) Total output amperage

18A

I

Total output amperage

I

60HZ- 1 1 OVi22OV.

.

60Hz-120Vi240V 30A

i

Output from 30A receptacle

Table

5-

1

-

23

-

5-2-6

RECEPTACLE

and

AC PLUG (STD.SPEC.)

These are used for taking

AC

output power from the generator. A total

of

five 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

corresponding 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.

I

up

to

30

amperes

(See Caution.)

I

Table

5-2

Caution:

To

connect the appliance to locking receptacle, insert the plug into the receptacle and turn it clockwise to lock.

Fig. 5-7

NOTE: If your generator has receptacles peculiar to your country, Table

5-2

does not apply.

NOTE: The generator for

U.S.A.

market is equipped with

NEMA

standard receptacles shown in table

5-3.

Use the proper plug for connecting appliance to the generator.

Style

Ampere

125V

20A

Receptacle

NEMA

5-20R

NEMA

L14-20R

AC plug

NEMA

5-20P

NEMA

L14-20P

Description

GFCl (Ground Fault Circuit Interrupter) Receptacle, duplex

Locking Receptacle

NEMA

Locking Receptacle

L5-30P

Table

5-3

-

24

-

5-3

DESCRIPTION

Of

GENERATOR OPERATION

PERMANENT MAGNET

FOR

INITIAL EXCITATION

STATOR MAIN COIL

.

RECEPTACLE

SURGE

ABSORBER

'""""_I

Fig.

5-8

5-3-1

GENERATION

Of

NO-LOAD VOLTAGE

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.

As

one

or

two condensers are connected

to

the condenser coil, the small voltage at the condenser

coil generates a minute current

!z

which

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

magnetic force

is

intensified, the respective voltages

in

the main coil and condenser coil rise up.

As

the current

:s

increases, the magnetic

flux

at the

rotor's

magnetic pole increases further. Thus the

voltages at the main coil and condmser coil keep rising

by

repeating this process.

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

(8

flows

through the field coil and

magnetizes the rotor core

to

generate

an

output voltage

in

the main coil.

When generator speed reaches

2700

to

2800

rpm (50Hz type)

or

3000

to

3300

rpm (60Hz type), the

current

in

the condenser coil and field coil increases rapidly.

This acts to stabilize the output voltage of each coils.

If

gene.rator 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

:g

flows through the

main

coil to the appliance, a magnetic

flux

is

produced and

serves to increase current

;zn

in

the condenser coil. When current

83

increases, the density

of

magnetic

flux

across the rotor core rises.

As

a

result, the current flowing

in

the field -coil increases and the

-

generator output voltage is prevented from decreasing.

-

25

-

i

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.

1201240V

r

"-:(or

11OI220V)

I

43l

240V

(or

220V)

Fig.

5-9

MC,

I

Rec.

1

Fig.

5-

10

-

I

"

-

Switch

:

LOWER VOLTAGE

HIGHER VOLTAGE

Position

I

RECEPTACLE

1

RECEPTACLE

ll0V

I

or

:

Rated output

No

output can

be

:aken.

120v

:

1 10:'220v

120i240V

or

I

Half

of

rated

output

Rated output

I

1

Table

5-4

-

26

-

Two main coils

are

wound over stator core. Each main coil outputs half the rated power at the 1owe.r voltage (llOV or 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.

5-9

shows a circuit diagram.When the full power switch is set for single lower voltage indication

(11OV or

12OV),

the switch position is as indicated by the lower solid line in the diagram. Fig.

5-10

is

a

simplified representation of this circuit, showing the two main coils connected in parallel.In this case, the higher voltage -(220V or 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 (110V/220V or 120V/240V), the switch

position is as indicated

by

the upper dotted line in Fig.

5-9.

Fig.

5-11

is a simplified representation of this

circuit, showing the two main coils connectea 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.

5-3-4

VOLTAGE CHANGEOVER SWITCH

The generator of

50Hz

110V/220V dual voltage type for

U.K.

is provided with voltage changeover

switch instead

of

full power switch.

The output voltage

is

selected from llOV and 220V by turning this switch and both voltages cannot be

taken out simultaneously.

CHANGEOVER

VOLTAGE

11ov

SWITCH

RECEPTACLE

PTACLE

-

Fig.

5-

12

-

27

-

6.

SAFETY PRECAUTIONS

1.

2.

3.

4.

5.

6.

7.

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 opern flame near the fuel

tank. Be careful not to spill fuel when refueling.

If

spilt, wipe it and let dry before starting the engine.

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.

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 exhaust

gases will endanger human lives. Keep the generator at least

1

m

(4

feet) away from structures or

facilities during use.

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.

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.

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 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.

j

Part Name

'

Q'ty

'

Phase

Allowable Current

!

365-45604-08

1j1j

60A

340-45606-08

j

Transfer Switch

30A

1

I

367-45605-08

,

Transfer Switch

I

1

15A

1

Transfer Switch

!

367-43008-08

I

Plastic

Box

30A

1

i

348-43009-08

j

Plastic

Box

I

1'1

i

60A

Table

6-

7

Be

sure to check and remedy

the

cause

of

circuit breaker tripping before re-setting

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.

-

28

-

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 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 followings to calculate the power consumption of each appliance or equipment by

its

type.

Incandescent lamp, heater, etc. with a power factor

of

1

.O

Total power consumption must be equal to or less than. the rated output of the generator.

Example:

A

rated 3000W generator can turn thirty lOOW incandescent lamps

on.

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

400W mercury lamp requires 600W to 700W power source to be turned

on.

A

rated 3000W generator can power four or five 400W mercury lamps.

NOTE1: 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.

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,

efficiency should be taken into account

as

explained in Item

(5)

on

the following page.

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 250W electric drill requires a 400W generator to start it.

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

900W

compressor requires a 4500W generator to drive it.

NOTEi: 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.

NOTE2

Motor-driven appliances mentioned

in

ltems

(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.

-

29

-

(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)

(Efficiency)

=

(Power consumption)

Example

1

:

Example

2:

Efficiencies of some electrical appliances are as follows:

Single-phase motor

- - - - - -

.

- -

-

0.6

-

0.75

The smaller the motor, the

Three-phase motor

- - -

- -

- - - -

- -

-

0.65

-

0.9

lower the efficiency.

Fluorescent lamp

.

. . . . . .

. . . .

.

. . . .

. .

.

0.7

-

0.8

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

57W by

1.2

-

2 and you will get the figure

of

the necessary

capacity of a generator. In other words, a generator with a rated output

of

1000Wcapacity can light nine to fourteen 40W fluorescent lamps. Generally speaking, a

400W

motor means that its work load

is

400W. Efficiency of this

motor is

0.7

and power consumption will be

400

+

0.7= 570W. 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

Itern(3).

570(W) X 1.2-3=684(W)-1710(W)

MODEL

1

I

RGV2200

Frequency 50Hz

i

60Hz

i

lncandesent lamp, heater, etc.

1

14OOW I 1800W

Fluorescent lamp, mercury lamp, etc.

Electric tool etc.

approx.

I

approx.

1

700W

1

9OOW

approx.

I

approx.

400W

'

400W

RGV2600 RGV4000 RGV6000

I

-

I

50Hz 60HZ

1

50Hz

!

60Hz

1

50Hz

'

i

60Hz

I

2000w

2200w

3000W j 3500W

1

4400W I 4800W

I

i

I

I I I

I

approx. approx.

I

approx.

I

approx.

I

approx.

lOOOW

j

1100W

1

1500W

1

1800W

\

2000W

I

2350W

!

I

i

approx. 1 approx.

1600W

!

16OOW 18OOW

I

2000W

800W

i

800W

approx.

1

approx. 1 approx. j approx.

approx.

I

approx. approx. approx. approx. approx. approx. app:ox.

Pump. compressor, etc.

I

300W

i

400W

I

400W

I

400W

:

750W

I

750W 800W

1

800W

i

Table

7-1

-

30

-

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.

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.

2.

Cable length

Nominal

cross

dia.

mm2

I

No.

1

A

I

No.

lmm

I

0.75

2.0

8

13

i

17

i

3710.26

50

/

0.18

12 16 1.27

18 7

1

3010.18

3.5

1

12-10

I

23

45 10.32

5.5

70 10.32

25 10-8

T

I

Resistance Flowing Current

Qil00m

1

1A

1

3A

I

5A

I

8A

1

10A

1.486 1.5V 5V

1

7.5V 12V 15V

2.477 2.5V 8V 12.5V

,

-

0.952

I

1 V 1 3V

8V

1

1OV 5V

I

0.517

j

-

!

1.5~ j 2.5V , 4~ 1 5~

I I

I

0.332

I

-

1V ! 2V I 2.5V

3.5V

I

Table

7-2

1

Voltage drop indicates as

V

=

100

XRXIXl

R

means resistance

( 0 !lo0

m)

on

the above table.

I

means electric current through the wire

(A).

8

means the length

of

the wire (m).

The length of wire indicates round length,it means twice the length from generator to electrical tools.

-

31

-

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 following features:

(1)

Functions of voltmeter, frequency meter, meggertester, 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

(4)

Tester and accessories are installed

in

a

the time to change batterie.s.

handy, sturdy case

for

easy carring.

0

SPECIFICATIONS

Fig.

8-1

Model

-I

Dr.

Robin

~

Part Number 388-47565-08

Voltage

0-5OOV AC

Q)

p!

,

Frequency

25-70HZ

[r

.G

Resistance

-

m

z

Condenser Capacity

m1

0.1 -1.999

Q

10-1

00

,E

F

L

3

m

a,

I

lnsuiation Resistance

3M

R

_____

Circuit Protector

1

Fuse

Power Source

I

2 x 6F44P (006P)

Dry

Cell Battery

I

Test leads with needie probes

.

‘1

set

Test leads with jack plugs

. .

.

1

set

Accessories

Dimensions

(L

X

W X H)

i

285 mrnx200 rnmxl10

rnrn

Weight

1.6kg

Table

8-

1

The

“Dr.

Robin”generator tester can be ordered from Robin generator distributors by the following part

number.

I

Dr. Robin

Part

Number

:

388-47565-08

I

If

you do not

have

a

”Dr.

Robin“generator tester,use the instruments described

in

the following section

for

checking generator

parts.

-

32

-

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 15OV: Type with an output voltage

of

110

or

120V

0

to 300V: Type with an output voltage

of

220,230 or 240V

0

to 15OV, 0 to 330V: Dual voltage type

(2)

AMMETER

AC ammeter

is

necessary. An AC ammeter with a range. that can be changed according to the current rating of a given generator

is

most

desirable. (About 10A, 20A, 100A)

FREQUENCY METER Frequency range

:

About

45

to

65Hz

NOTE:

Be careful of the frequency input voltage range.

meter’s

.-

””-

I

FOR

AC

Fig.

8-2

FOR

AC

Fig.

8-3

.,

r

I

!

Fig.

8-4

-

33

-

(4)

CIRCUIT TESTER Used for measuring resistance,

etc.

Fig.

8-5

(5)

MEGGER TESTER

!

Used for measuring generator insulation resistance. Select one with testing voltage range of

5OOV.

I

Fig.

8-6

(6)

ENGINE TACHOMETER

There are various types of tachometers,

such

as contactlzss type, contact type, and strobe type. The contact type can be used only when

the generator and engine have been dis-

assembled. The contactless type

is

recommended. The PET-2100E engine tachometer

is

available from your Robin distributors. Please inquire by the part number PET-2100E.

I I

!

I

Fig.

8-7

!

-

34

-

8-2

AC OUTPUT MEASURING

TO

AC

RECEPTACLE

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

21 6-264V 198-242V 108-1 32V 99-121V

Voltage range

240V

220v

1 20v 110v

Table

8-2

8-3

MEASURING INSULATION RESISTANCE

Use a "Dr. Robin"generator tester in megger tester mode

or

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

1

megohm

or

more is normal. (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 resistance of the stator, rotor and control panel individually.

0

STATOR

(1)

Measure the insulation resistance between

(2)

Measure the insulation resistance between

(3)

Measure the insulation resistance between

(4)

lMeasure the insulation resistance between

BLUE lead and the core.

WHITE lead and the core.

YELLOW lead and -the core.

BROWN lead and the core.

Fig.

8-10

-

35

-

0

ROTOR

.

..

Measure the insulation across one

of

the soldered

terminals

of

the rotor and the core.

0

CONTROL PANEL

Measure the insulation resistances between the live parts and the grounded parts.

I\

I

Fig.

8-

1

Any part where the insulation resistance is less than 1MQ has faulty insulation, and may cause electric leakage and electric shock.

Replace the faulty part.

-

36

-

9.

CHECKING FUNCTIONAL MEMBERS

9-1

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.

I

(See Fig.9-1.)

Fig.

9-1

Pilot lamp should be turned

on

at

70

to

12OV.

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 rece.ptacle 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.

&

.I:

AC RECEPTACLE

.:

I

Fig.

9-2A

Fig.

9-28

-

37

-

9-3

CIRCUIT BREAKER

Check continuity between each

of

two terminals at

the rear

of

the circuit breaker while it is mounted

on

the control panel. Normally, there is continuity

be.tween each

of

the two when the circuit breaker

is

on

while there

is

no

continuity when the circuit

breaker is off.

-

..

9-4

STATOR

Disengage connectors

on

the wires from stator and check the resistance between wires with a "Dr. Robin"

or

a

circuit tester refering

to

the following

table.

Fig.

9-3

Fig.

9-4

(Rxl!!

+lo%)

I

Specification

AC Winding

I

i

Hz

I

Condenser Winging

Voltaae

Black!

Blue

.

I

~ Yellow

iYellow

White / Red

...

I

11 ov, 220v, 1.1 OVl22OV

4.48

..

1.96

j

1.96

50

I

I.

.,

I

240V

1.24

!

220V,~ llOV/220V

.

1

.

1.24

4.48.

. .

2.33

RGV2200

'

.

60

3.46

..

-

1

~OV.

I~OV~~~OV

..I

1.24

.

3.46.

.

-,

1.24

I

11

ov.

220v, 11 OV/220V

2.64

:

1

.oo

1

.oo

i

50

RGV2600

240v 2.64 1.19

1.19

..

220v, 1 1 OV:'220V

i

0.75

.

.!

1

;99.

60

I

120V, 120Vi240V 0.75

.

0.75

.

:

..

-!

1.99

I

r;n

I

110V. 220V. 110Vj220V

.

0.70

I

.

0.70

1.

".

1 :44

I

j

4"

240V 0.83

I

0.83 1.44

RGV4000

.

'

-1

-

..

I

220v. 1 1 OV!220V

0.54

.

__

j

-

0.54

j.

1.03

I

-60

j

120V. 120V/240V 0.54 0.54

i

'

-1.03

I

11

ov.

220v. 11 ovi220v

i

!

0.33 0.33

0.39

.j

50.

0.79

240V

!

RGV6000

.

I

.

0.39

0.79

..

220v. 1 lOV/220V

.

I

0.24 0.56 0.24

::

60

,

. .-

.r

!.

!

120v. 120vi240v 0.24

.

-0.56

:.

.

-0.24

..

.

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

0-f

resistance among coil

windings or when measurement is performed

at

ambient temperatures different from

ZO"C(68"F).

..

-

38

-

9-5

ROTOR

ASSEMBLY

(1)

Using a "Dr.

Robin"

or a circuit tester, measure the resistance

of

the field coil

at

the terminals.

(RxlQ

&lo%)

MODEL

RGV6000

RGV4000 RGV2600

RGV2200

RESISTANCE

I

2.52

R

1.60

R

1.77

R

2.04

R

I

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 erroneous

readings.

Erroneous reading will also occur when

there is a wide variation of resistance

among coil windings or when meas-

urement is performed at embient temperatures different from

2OoC(68"F).

9-6

CONDENSER

W

Use a

"Dr.

Robin" in capacitance meter mode

to

check the capacity

of

condensers. (See Fig.9-6).

Fig.

9-6

3

RGV4000, RGV6000

I

NOTE:

Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance,or the accurate reading cannot be obtained.

-

39

-

I

W

NORMAL CAPACITY OF CONDENSER

MODEL

RGV6000 RGV4000

RGV2600

RGV2200

Resistance

282FX2

202FX2

.

24kF

17~F

Table

9-3

I

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

DIODE RECTIFIER

Brown

Brown/

White

..

Brown

Orange

Brown

CIRCUIT TESTER

~.

Fig.

9-9

Fig.

9-

10

..

Circuit -inside

of

the diode rectifiers is

as

shown

in

Fig.

9-9.

Check continuity between each terminal

b!

using a circuit tester as shown

in

Fig.

9-10.

The rectifier is normal when condtinuity

is

as

follows:

.

..

...

W

Checking table

..

for analogue c.ircuit tester.

I

Apply black Sneedle

of

the circuit tester

.

-

Analogue. circuit tester

i

I

Brown

i

Brown

i

Orange

i

Brown:White

i

I

!

:

Brown

I

No

continuity

No

continuity

j

Continuity

.. . .

..

I

r-"

I

..

I

Brown

Apply red

3

.needle

No

continuity

Orange

I

Continuity

I

Continuity

,

Continuity

-of

ttie circuit tester

I

NO

continuity Continuity

Brown;White

No

continuity

j

No

continuity

j

No

continuity

?"-..,

I

-

40

-

W

Checking table for digital circuit tester.

Apply red

@J

needle

of

the circuit tester

Digital circuit tester

Brown

1

Brown

BrownWhite

Orange

Brown

Continuity

No

continuity

No

continuity

-

Apply black @ needle

of

the circuit tester

Brown

Continuity Continuity Continuity

Orange

No

continuity Continuity

NO

continuity

1

!

I

Brown,White

No

continuity

No

continuity

No

continuity

NOTE

1:

NOTE

2:

NOTE

3:

Table

9-4-2

Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester, polarity

of

tester needles should be reversed.

“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.

Some analogue testers like “Simpson” brand operate as same as digital testers.

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

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.

their original position.

10-2

SPECIAL TOOLS

for

DISASSEMBLY

and

ASSEMBLY

Part Number

:

388-95001

-07

Part Name

:

REAR COVER PULLER

REAR

COVER

PULLER

-

41

-

Step

Description

I

Remarks

Part

to

remov

Front Panel

.-

'.

Tool

..

10

mm spanner

or

box wrench

(1)

Take off

the

four

bolts

and remove the

-

.

front panel

from

the frame.

~

-

(See Fig.

10-

1

.)

..-

.

..

t

i

.-

.

..

.

..

.

(2)

Disconnect the connectors on the wiring

.

~~

beween the-front panel and the engine.

. - .

-

(SeeFig.

10-2.)

.

..

-1

." .

.-

,

..

.-

.

..

i.

..

.

...

..

.

,.

Fig.

10-1

f

..

1.

."

(.3)

Take

off

the bushing from the bottom of

.-

the front panel.

.

(See

Fig.

10-2.:)

(4)

Disconnect the connectors on the wiring from

the front panel to'the alternator.

'(See

Fig.

10-1.)

..

-

..

.

:..

:

!

.

.-

Press the upper end of the bushing and pull out:

I

-.-

:.

i..

..

.

-.

...

..

FIG.

10-3

-

42

-

Step

2.

..

I

..

.

..

.

'art to remove

Fuel Tank

-

..

.

..

-

-Description

.

-1

..Remarks

(I)

Discharge fuel from the

tank:

-

.

Use utmost .care about

1:

Shut the fuel strainer. .fire hazard.

.

-

2.

Remove the-strainer cup.

3.

Put a vessel to receive fuel under the - Wipe off spilt fuel strainer and open the -fuel. cock to thoroughly. discharge fuel:(See Fig.

10-4.)

body.

screen.

4.

Attach the strainer cup

to

the strainer Do not lose the filter

..

I

:I

.

;;

.

1;

Fig.

10-4

-

I

(2)

Disconnect fuel hose from. the strainer.

'

Loosen the hose clamp on the top of the

i

strainer and

pull

out the fuel hose

from

the strainer. (See

Fig.

10-5.)

(3j

Take

off

the four

nuts

and remove the

fuel tank. (See Fig.

10-6.1

I

T

I

Tool

-.

Pliers

10

mm

spanner

or

box

wrench

Fig.

10-5

Fig.

10-6

-

43

-

Step

3.

Part

to remove

Muffler and l4uffler Cover

Description

!

Remarks

(1)

Remove the rear plate from the frame.

The rear plate

is

welded

(Except for

RGV6000)

to the frame of the

6X 12mm

flange bolt

.........

.2

pcs.

I

RGV6000.

(2)

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.

8X20mm

bolt and washer ass'y

.....

2

pcs.

8mm

stainless

nut

................

2

pcs.

8mm

spring washer

for

RGV4000

and

RGV6000

.......

2

pcs.

Muffler gasket

..................

1

PC.

(3)

Remove

the

muffler

cover 1 and the muffler cover 2 from the muffler.

6X lOmm

bolt and washer ass'y

-

.

8

pcs.

(See

Fig.

10-8.)

(3)

For

RGV6000

only:

Remove

the muffler bracket from the rear cover.

8X20mm

bolt and washer ass'y

...

2

pcs.

~cIUFFLER COVER

1

A

M.ilL!FFLER COVER

2

for

RGV6000

only

FAUFFLER BRACKET

Tool

10

mm

spanner

or

box wrench

12

mm

spanner

or

box

wrench

10

mm

spanner

or

box wrench

12

mm

spanner

or

box

wrench

FIG.

10-7

-

44

-

Dart to remove

Pipe Frame

Description

(1)

For RGV6000: Remove

the

fuel strainer from

the

frame.

(2)

Remove the

nuts

which are fixing engine

and alternator to

the

mount rubbers.

(See Fig.

10-8.)

(3)

Using a chain-block, sling up

the

engine

and alternator and dismount from

the

frame.

Remarks

Remove the

air

cleaner cover for easier dismounting.

Fig.

10-8

(3)

Remove the mount rubbers from the

’

frame. Loosen the

nuts

on

the bottom side

of

the frame. (See Fig.

10-9.)

Tool

12

rnm spanner

12

mm spanner

or

box wrench

MOUNT

RUBBER

,

0

Fig.

10-9

-

45

-

'art

to remove

Rear Cover

-

Description

(1)

Remove the end cover. (See Fig.

10-10.)

64

bolt.

..............

.4

pa.

(2)

Take off the rear cover.

1.

Remove the four bolts which fasten

the rear cover to the front cover.

64

bolt.

...............

.4

PC-,

2.

Use. a special tool "REAR COVER PULLER" to remove

the

rear cover.

a) Insert the two screws of the special

tool into the thread holes of

the

rear

cover.

b)Apply the center bolt of the special

tool on the head of the through bolt.

c)Tighten the center bolt to

pull

out

the rear cover.

Remarks

Insert the

two

screws

sufficiently and evenly,

or

the thread hole may be

damaged at removing.

Tool

10

mm

spanner

or

box wrench

10

mm spanner

or

box wrench

Fig.

10-10

Fig.

10-1

1

!

In

the case that

"RE.AR

COLER PULLER'' is unavailable, remove the

I

rear cover

by

the follow-ing instructions.

I

3.

Hit

on

the

boss

and legs of rear

Do

not give a

strong

hit

Box

Lvrench

cover with a plastic hammer to

;

on the boss

or

legs.

I

Plastic hammer

loosen.

i

Fig.

10-12

Fig.

10-13

-

46

-

Step

6.

'art

to

remove

Startor

.

. - .

.Description

~

.

Tool

. .~

-

Remarks

I

(1)

Remove

the

four bolts which fasten

the

stator

to

the

rear cover.

(See Fig. 10-14.)

~~~ ~ ~ ~~~~~~~~~

6~

BOLT

. . . . .

.

4

pcs.

..

,60

SPRING

WASHER

. . . . .

.

.4

pcs.

-.

.

Fig.

10-14

(2)

Put a piece of .lumber

on

the floor

in.

I

upright position.

I.

-.

(See Fig.

10-15.)

I

(3)

Hold

the

rear cover and stator upside

down

with

both hands.

(4)

Down

the rear cover and stator over a

lumber lightly hitting

the

bottom of rear

I

cover to the top end of lumber to pull out

I

the

stator.

I

(See FIE. 10-16.)

i

I

~.

10

mm socket

wrench

I

"[NOTES]

1

1.

Apply

fingers- to stator coil to keep the stator from dr-opping

on

the floor.

2.

Gently

hit

the bottom of rear cover to-.the top end

of

lumber several times until the stator

comes out loose:'

I!

Fig.

10-15

Fig.

10-16

-

47

-

Step

6.

-

..

Part to remove

I

Description

Remarks

Tool

Stator

Rotor

..

(5)

Take apart the

support

ring

and

stator

from

rear

cover.

SUPPORT

RING

\

60

BOLT

......

4

pcs.

60

SPRING

WASHER

.........

.4

pcs.

Q

WASHER

....

4

pcs.

Fig.

10-1

7

i

1

i

Take

off

the through

Dolt.

.Apply

a

box

nrench

on

the

head

of

I

through bolt. Hit the Lvrench handle

with

1

a hammer counter-clockwise to loosen.

j

Fig.

10-18

Box

lvrench

Plastic hammer

-

48

-

Step

I.

-

I

Dart to remove

Rotor

Description

(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. 10-19.)

thread size:

2.

Prepare a bolt with the following RGV2200,2600.

......

MIOXP1.25

RGV4000,6000..

....

.M12XP1.50

3.

Apply a few turns of seal tape around the tip of the bolt.

Remarks

Tool

Fig.

10-19

4.

Screw~the bolt into the thread of the rotor shaft.

5.

Torque the bolt using a socket wrench

until

the rotor comes

off

loose.

*

The hydraulic pressure inside the rotor shaft takes apan the rotor from the engine shaft.

Fig.

10-20

Do

not stick out your

face over the rotor.

It

may

jump

up

on

separation.

Socket wrench

(4)

Wipe .off oil thoroughly from rotor shaft

and

engine-PTO shaft.

I

Fig.

10-21

-

49

-

Step

8.

-

Part

to

remove

Front Cover

Description Remarks

(1)

Remove the front cover. Loosen the four

bolts

and

remove the

front cover.

86

bolt

.

. . .

. . . . . . . . . . . .4

PC-.

Fig.

10-22

Tool

12

mm

Socket

wrench

-

50

-

10-4

ASSEMBLY PROCEDURES

10-4-1

FRONT

COVER

Attach the front cover to the engine main bearing cover. Match the faucet joint and tighten the bolts.

M8

X

18mm bolt.

. . . .

.

4

pcs.

M8 spring washer

. . . .

.

4

pcs.

Tightening torque

120-1

40

kg-crn

11.8-13.7

Nm

8.7-10.1

ft4bS

10-4-2

ROTOR

(1)

Wipe off oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor 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.

(2)

Mount the rotor

to

the engine shaft.

Tightening torque

:

I

Tightening torque

IRGV

I

115-135

kg-cm

2200.2600

1 1.3-1 3.2

Nom

I

8.7-10.8

ft4bs

230-250

kgwn

RGV

4000,6000

22.5-24.5

Nom

16.6-1 9.5

ft*lbs

Fig.

10-23

Fig.

10-24

-

51

-

10-4-3

STATOR

1

(1)

Put

the

stator

in

the

rear

cover

setting

the

four

i

grooves

on

the

side

of

stator

with

thread

holes

of

the

rear

cover.

i

......

e"----

60

BOLT

4

pcs.

60

SPRING

WASHER

/

..........

.4

pcs.

I

Tighten

the

four

bolts

tentatively

to

check

if

I

the

grooves

and thread

holes

are

aligned

I

correctly.

(See

Fig.10-25.)

!

pulling them out from the rear cover.

I

....

B-

60

WASHER

4

pcs.

NOTE : Be careful not to give cuts to wires when

(2) Remove

the

four

bolts.

i

a.

L

-

I

Fig.

10-25

(3)

Apply

the

support

ring

between

the

rear

cover

and

I

/

Tap on

the

support

ring

evenly

using

an

aluminum

bar

and a hammer

to

press

into

the

rear

cover.

(See

Fig.lO-26.)

(4)

Join

the

stator

to

rear

cover

with

four

bolts,

washers

and

spring

washers.

(See

Fig.

10-25.)

M6

bolt

.......................

M6

washer

....................

4

pcs.

4

pcs.

M6

spring

washer

...........

4

pcs.

80-1

00

kgwn

7.8-9.8

Nom

5.8L7.2

ft-lbs

NOTE: Tighten

four

bolts evenly taking several

steps.

The

dimensions

of

the

stator

bolts

are

shown

in

Table

10-1.

;

ALUMINUM

I

Fig.

10-26

MODEL

'

lI

S

id

!

65mm

1

15mm

RGV2200

,

2.56

inch i 0.59 inch

,

i

RGV2600

3.35

inch

'

85mm

!

20mm

j

M6x

,.o

'

2o

mm

I

M6

X

1.0

0.79 inch

I

95

mm

RGV4000

I

3.74 inch

;

0.79 inch

!

I

RGV6000

1

4.53 inch 1.57 irxh

:

115mm

I

40

mm

b.16

X

1.0

-1

Tab!e

70-

7

-

52

-

10-4-4

REAR

COVER

(1)

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. (See Fig.10-27.)

Fig.

10-27

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.

Fig.

10-28

Fix

the rear cover to the adaptor with

bolts,

spring

washers, and washers.

M6

x

25

mm

bolt

..............

4

pcs.

4

pcs.

M6

spring washer

.............

4

pcs.

346

washer

.....................

50-60

kg-cm

4.9-5.9

Nom

3.6-4.3

ft-lbs

four

Fig.

10-29

-

53

-

10-4-5

END

COVER

Attach the end cover

to

the rear cover.

M6

X

8mm flange bolt

-----.---..

4

pcs.

40-60 kg*cm

3.9-5.9 N-m

2.9-4.3

ft-lbs

10-4-6

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 bottom of the frame.

M8

flange nut

. . .

. . . . . . . . . . . . . . .

. .

.

4

pcs.

Tightening torque

120-1

40 kg-cm

1

1.8-1 3.7

Nom

8.7-1 0.8

ft*lbS

Fig.

10-30

r-

FRAME

UPPER

Fig.

10-31

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 appearance, their characteristics are different.

(2)

Attach the 5 mm terminal

of

the grounding wires (green.:pellow) to the unpainted thread hole of the

frame base plate using

a

5

mm brass

scrsLv.

-

54

-

(3)

Install the engine and alternator assembly into the frame. Put the engine and alternator assembly into the frame from the side of

it.

Tighten the nuts over the mount rubber bolts to fix.

Mgnuts

..........................

4

pcs.

I

Tightening torque

1

120-1

40

kgwn

11.8-1.3.7

Nom

8.7-1

0.1

ftolbs

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.

(4)

Fasten the other earth cable with 5 mm terminal to the unpainted bolt hole on the frame. (See Fig.10-32.)

(5)

Attach the rear plate frame.

(For

RGV2200,2600,4000 only)

"6 x 10

mm

bolt

..............

2 pcs.

Attach fuel tank mount rubbers to rear plates.

The nuts

€or

mount rubbers are welded

to

rear

plates.

I

Tightening torque

I

40-60

kg-cm

3.9-5.9

N-rn

2.9-4.3

f?*lbs

EARTH

CABLE

Fig.

10-32

REAR

PLATE

I

...

Fig.

10-33

-

55

-

104-7

MUFFLER

and

MUFFLER COVER

(1)

For RGV6000 only:

(2) Attach the muffler cover

1

and the muffler cover 2 to the muffler.

Attach the muffler bracket to the rear cover. Tighten the bolts temporarily.

M6

X

lOmm bolt and washer Ass'y

-.-----

8

pcs.

7.9-9.8 Nom

5.8-7.2

ft*lbs

(3)

Put the muffler gasket

to

the engine.

(4)

Attach the muffler with muffler cover to the engine and the rear cover.

:&

Tighten the two nuts fou the muffler first.

P

Use

the spring washers €or RGV4000 and

RGV6000.

8mm

stainless nut.

...................

8mm spring washer..

.................

2 pcs.

2

pcs.

(for RGV4000 and RGV6000 only)

220-280

kgwn

21.6-27.4 Nom

15.8-20.2

ft-lbs

:z

Tighten the bolts to fix the muffler to the

A

rear cover.

M8

X20mm bolt and washer

Ass')'

.-.-.

2 pcs. (for RGV2200, 2600,

4000)

190-250

kg-crn

18.6-24.5 Nom

13.7-1 8.0

ft*lbS

is

For RGV6000 only: Tighten the two bolts

to

fix

the muffler

bracket to.the 'rear cover: and .then the two

-..

bolts-for the muffler to the muffler bracket.

M8

X20mm

bolt and Lvasher

Ass'y

.....

-

.

3-pcs.

(for RGV6000 only)

190-250

kg-cm

18.6-24.5 Nom

13.7-1 8.0

ft*lbS

Fig.

10-35

-

56

-

(5)

For

RGV2200, RGV2600 and RGV4000 only

:

Attach the rear plate to the frame.

M6

X

1Omm bolt

...............

2 pcs.

I

Tightening torque

I

40-60 kg-cm

3.9-5.9 Nom

2.9-4.3

ft*lbs

10-4-8

FUEL

TANK

(1)

For

RGV2200, RGV2600 and RGV4000 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.

FUEL TAXK CAP

FUEL GAUGE

4.9-6.9 Nom

(2)

Mount the fuel tank

on

the frame with rubber

washers between the tank flange

and

the frame.

M6 X20mm bolt (black)

...........

Rubber \%-asher

........................

NOTE

:

For easy tank assembly, glue the rubber

/;.

washers over the mounting holes

of

the

Y'

frame.

(3)

Connect the rubber pipe. First,

€it

the hose clamps

on

the rubber pipe

and connect

it

to

the strainer and the

carburetor. Then fasten

it

with the hose

HOSE

CUMP

clamps.

For

RGV6000,

connect the rubber pipe

to

the

strainer and the fuel tank

in

the same wag.

easier connection.

-

57

-

Fig.

10-36

10-4-9 FRONT PANEL

-Mount the front panel assembly to the frame. Refer to Section

10-5

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.

M6

X

12

mm flange bolt

....................

4 pcs.

3.9-5.9

Nom

Fig.

10-37

10-5 CHECKING, DISASSEMBLY

and

REASSEMBLY

of

the

FRONT PANEL

10-5-1 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.

10-5-2

DISASSEMBLY

(1)

Remove the control panel from the front panel.

344scre~~

..............

6

pcs. (RGV2200, RGV2600, RGV4000)

344screLy

..............

7

pcs. (RGV6000)

(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.

10-5-3 REASSEMBLY

(1)

Install the receptacles, no-fuse breaker, terminals, switches, etc. on the control panel and wirz 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. (RGV2200, RGV2600, RGV4000)

M4 Screw

..............

7

pcs. (RGV6000)

1.2-1.5

Nom

-

58

-

11.

TROUBLESHOOTING

11-1 NO AC

OUTPUT

11 -1 -1 CHECKING CONDENSER

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.

11-1

NORMAL CAPACITY

OF

CONDENSER

I

MODEL

’

RGV2200

I

RGV2600

I

RGV4000

1

RGV6000

I

CAPACITY

j

17.2

F 20,2Fx2

i

28cFX2

24y

F

!

Table

11-1

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

~.

Remove control panel and disconnect stator wires at the connectors.

Measure the resistance between terminals

on

stator leads. (See Fig1 1-2)

Refer to Table

9-1

for

normal resistance.

If

stator

is

faulty: replace

it

\vith

a new one.

Fig.

1

1-2

-

59

-

Check the insulation resistance between

!

stator core and each stator lead using a

Dr.

Robin generator tester

in

msgger tester mode

or

a megger tester.

(Fig.

11-3)

If

insulation

is

bad, replace stator with a new

one.

Fig. 1 1-3

1

!

11 -1

-3

CHECKING

ROTOR

(1)

CHECKING FIELD COIL

W

Remove rear cover and stator.

Fig.

1

1-4

W

Using a Dr. Robin

or

a circuit tester, measure the resistance

of

the field coil at the terminals.

(RXlQ

*lo%)

t

MODEL

RGV6000 RGV2200 RGV2600

'

RGV4000

RESISTANCE

2.52

Q

I

2.01

ST

'

1.77

R

I

1.60

Q

..

T&de

1

1-2

NOTE

1

:

Because a diode is soldered to the coil ends at the terminals, resistance may be measured only when tester probes touch the terminals 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

I

new one.

Fig.

11

-5

-

60

-

Measure the insulation across one

of

the

soldered 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

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.1

Loosen the lock nut on the adjusting screw.

Turn the adjusting screw clockwise

to

de-

crease engine speed

or

counter-clockwise to increase engine speed. Normal engine speed at no load

is

:

3100 - 3150

r.p.m. for 50Hz type

3700

-

3750

r.p.m. for 6OHz type

11

-2-2 CHECKING CONDENSER

Check condenser referring to Step

11-1-1

11 -2-3 CHECKING STATOR

Check stator referring to Step

11-1-2.

11-2-4 CHECKING

ROTOR

Check

rotor

referring to Step

11-1-3.

.

..

.

..

;

;;

I

Fig.

1

-7

-

61

-

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

over-loaded, 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.

11-34 CHECK

IF

THE ENGINE

IS

OVER-

HEATED.

If the cooling air inlet and/or cooling air outlet is clogged with dirt, grass, chaff or other debris..

remove it.

11-3-5 CHECK THE INSULATION

OF

THE

GENERATOR.

Stop the engine. Measure the insulation resistance between- the live terminal of the receptacle and the ground terminal.

If

the insulation resistance is less than

1

MQ:

disassemble 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

1

ME,

the insulation is faulty

and

may cause

electric leakage.

Replace the faulty part.

AIR

OUTLET

(GENERATOR!

.

Fig.

11-8

..

Fig.

1

1-9

-

62

-

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.

114-2 CHECK THE DC BREAKER.

If

the DC breaker turned

off

while charging a battery, check the cables for short-circuit or connection 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.

11-4-3 CHECK THE

WIRING.

Check all the wires to be connected correctly.

11-44 CHECK THE DIODE RECTIFIER.

Remove the control panel and che-ck the diode rectifier with a circuit tester. Refer to Section

9-7

"DIODE RECTIFIER'' for the

checking procedure.

11-4-5 CHECK THE DC COIL

I

Fig.

17-10

Check the resistance between two brown leads from stator with a circuit tester.

I

MODEL SPECIFICATION

I

RESISTANCE

I

i

50Hz

!

11 OV. 220V. 240V, 11 OVl22OV

0.3652

i

60Hz i 120V, 220V, 11 OV/22OV, 12OVl24OV 0.32R

I

RGV2200

I

i

50Hz

1

110V. 220V, 240V. 110V/220V

1

0.260

:

60Hz I 120V. 220V, 110V/220V. 120Vi240V

1

0.21

0

RGV2600

~

:

50Hz

;

1 1 OV. 220V, 240V. 11 OV!220V 0.24R

60Hz

i

120V. 220V, 11 OVi22OV, 12OVl24OV

5OHz

0.200

0.150

1 1 OV. 220V, 240V,

1

1 OVi22OV

8

60Hz I 120V. 220V. 11 OVl22OV. 120V/240V 0.13R

RGV4000

:

RGV6000

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.

-

63

-

11-5

IDLE CONTROL (OPTIONAL EQUIPMENT)

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 distorted, correct the angle

with proper tool.

.

(2)

Check the wattage

of

load appied

to

the

v

generator.

If

the generator is loaded over the rated wattage, the engine speed can not be increased. lMost induction loads such as electric motor

or

electric tools or welding machine require three to five times large wattage

of

their ratings at starting. This starting wattage must not exceed the rated output of the generator.

(3)

Check the slow set r.p.m. The normal idling speed by the

IDLE

CONTROL is as follows

:

RGV2200,

2600

-----.

1900

-

2100

r.p.m.

RGV4000,

6000

---.-.

2000

-

2200

r.p.m.

The above speed setting is for

cold

engine

condition.

If

the engine speed is out

of

adjusting range

of

the adjusting screw, move the solenoid backward.

Fig.

11-12

ADJUSTING

SCREW

Fig.

77-73

-

64

-

IDLE

CONTROL

UNIT

i

(4)

Check the wiring through ZCT on the IDLE CONTROL UNIT.

A)

Single Voltage Type

Make sure that an output wire from main coil

is

passing through the. ZCT on the IDLE

COKTROL UNIT.

B)

Dual Voltage Type Check that two output wires (black wire and red wire) from main coils are passing through the ZCT on the IDLE COKTROL UKIT in the same direction.

(5)

Checking the IDLE CONTROL UNIT Check the resistance between six leads

of

IDLE CONTROL UNIT with circuit tester.

11”-

I

Terminal number

of

the

IDLE

CONTROL UNIT

I

/

ZCT

\\\

Fig.

17-14

IDL

Fig.

11-15-

Circuit tester

(with battery power source

1

SV)

Apply black 3 needle

of

the circuit tester

1

I

:g

A

.a

n

L.

\I

I

250 kR

.

250 kR

i

75kQ

!

Q

1

00

22

I

00

Apply red

@

needle

!

I

of

the circuit tester

3

1

250 kR

1

250 kQ 75 kR

,”.

I

75 kR

I

:

I-

250 kR

-

.n

f

.&

I

8.5 kR

30-

!

7.8kR 7.8kQ

11

*

Teste:

measuring

range

:

1000

k

0

Tabi‘e

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.

-

65

-

11-5-2

ENGINE SPEED

IS

NOT REDUCED WHEN LOAD

IS

OFF.

(1) Check the distortion of the SOLEKOID 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

USIT.

Check all leads from IDLE CONTROL UNIT are securely and correctly connected.

(4)

Checking the SOLEKOID.

-

Measure the resistance between two leads from SOLENOID.

I

NORMAL

RESISTANCE

I

25-31

O

If

the resistance. is larger or smaller than th-is

range, SOLENOID

..

is

defective,

Replace \vith a new one.

SOLEXOID

\

Fig.

11-17

.-

.

..

-

66

-

12.

WIRING

DIAGRAM

0

RGV2200,2600 : 50Hz-11 OV, 60H~-11 OV, 60HZ-120V

TYPE

ENGINE CONT-BOX

r--------

~

r""""""--

1

ET

I

-

67

-

RGV2200,2600 : 50H~-220V, 240V, 60Hz-220V

TYPE

ENGINE

CONT-BOX

r""""~

r"""""""

1

..

.,

I,

?@

II

STOP

SW

I

b

i

,

i

L"

CB T

fix:

I

-

68

-

RGV2200,2600 : 50Hz, 60H~-llOV/22OV

TYPE

ENGINE CONT-BOX

r--------

~

r"""""-"""

1

ET

1.

25mm2

-

69

-

RGV2200,2600

:

U.K.,

50H~-llOV/22OV

[BS

RECEPTACLE]

ENGINE CONT-BOX

r””“”~

r”””””“””-

1

II

STOP

SW

“-3

Black

I

c

CB

.

T

I1

II

Brown/White

-

70

-

0

RGV2600 U.S.A., 60Hz-12OV [NEMA RECEPTACLE]

ENGINE

~

r""""""""-

CONT-BOX

1

I

ET

-

71

-

0

RGV4000 : 50H~-11 OV, 60Hz-11 OV, 60Hz-120V-TYPE

ENGINE CONT-BOX

r--------

1

r--

1

STOP

SW

I

ET

!I

Ii

Piii

I

-

72

-

RGV4000 50H~-220V, 240V, 60HZ-220V

TYPE

ENGINE

CONT-BOX

7

r--

1

II

I

II

-

Brown/White

L

1-L

-

I

J

I

i

I

i

I

ET

..

-

73

-

0

RGV4000

:

5OHZ,

6OHZ-l1OV/220V

TYPE

ENGINE

CONT-BOX

r--------

7

r--

1

ET

-

74

-

RGV4000

:

U.K..,

50H~-llOV/220V

[BS

RECEPTACLE]

ENGINE

CONT-BOX

r--------

1

r----------

-

- -

1

STOP

SW

Black

I

II

Ii

PI

i

I

J

-

75

-

0

RGV4000

:

U.S.A.,

60Hz-l20V/240V

[NEMA RECEPTACLE

with

IDLE CONTROL]

ENGINE

CONT-BOX

r--

~

r"""-"""""""""-

1

I I

STOP

SW

A

'I

ET

Green/

Yellow

!

L""""II""""-"""""""""""---l

I

-

76

-

RGV6000 : 5OHZ-1 lOV, 6OHZ-1 lOV, 60Hz-120V

TYPE

ENGINE-

CONT-BOX

r--

1

r---

1

I

STOP

SW

I

Brown/White

I

-

- - - - - -

-

0.75mm2 2.00mm2

ET

-

77

-

RGV6000 : 50H~-220V,

240V,

60HZ-22OV

TYPE

ENGINE

CONT-BOX

r""""7

r""""""""-

1

I

.

-1

I

:I

Brown/White

I

-

- - - - - - -

-

0.

75mm2

2.

Omm"

ET

1.25mm'

-

78

-

0

RGV6000 : 50Hz, 60HZ-11 OV/22OV

TYPE

ENGINE

CONT-BOX

r--

r""""""""""

1

I

STOP

SW

?

I

I I

L--J

Green/

II

-

Brown/White

I

1

ET

I

-

79

-

RGV6000

:

U.K.,

50H~-lIOV/220V

[BS

RECEPTACLE]

ENGINE

CONT-BOX

~

r""""""""""

1

L

- -

-

II

GENERATOR

II

r--------

I

II

I

II

Brown/White

I

STOP

SW

Green/Yellow

I

T

I

Trl

ET

-

80

-

0

RGV6000 : U.S.A., 60Hz-l20V/240V [NEMA RECEPTACLE

with

IDLE CONTROL]

ENGINE

CONT-BOX

r--

1

r--

1

I

II

I'

I

II

White

II

I I

J

-

81

-

a

TYPE

WITH

ELECTRIC STARTER (Optional Equipment)

15mm2

ENGINE

,~

CONT-BOX

-Black

1;

!

Green/Yellow

I

4

ET

!

Key

switch

-M

ST

IG

6

I

I I

I

OFF

ON

I

START

-

a2

-

TYPE

WITH ELECTRIC STARTER AND IDLE CONTROL (Optional Equipment)

+M

-M

B

IG

ST

I

ET

L

-

II""""""""""

blue

!

Key

switch

-

a3

-

0

TYPE

WITH

IDLE CONTROL (Optional Equipment)

ENGINE

CONT-BOX

r---

""-~

r"""""""""""""

1

,-

I,

I

"-

""

I

Green/

Yellow

I

SOL

.-

I

"I

I

CHG

-

84

-

Symbols

Part Name

MC

AC Winding

cc

Circuit Breaker

CB

DC Output Terminal T

Pilot Lamp

L

Diodes Stack Assy D

Condenser C

Field Winding

FC

DC Winding

DC

Condenser Winding

N FB No-Fuse Breaker

vc

sw

Voltage Changeover Switch sw1

Voltage Changeover Switch

STOP SW

Engine Stop Switch

0.s

Oil Sensor Control Unit

so

L

Solenoid

Idle Control Unit Spark Plug Charge Coil Ignition Coil

ET Earth Terminal (Ground Terminal)

ST. M Starting Motor

KEY

SW

BAT

:

Battery

Key Switch

V

Voltmeter

REC

Control Box (Front Panel) CONT.BOX

AC Output Receptacle

-

85

-

0

FUJI

HEAVY

-INDUSTRIES

LTD.

INDUSTRIAL

PRODUCTS

DIV.

Subaru

Bldg.

1-7-2, Nishi-Shinjuku, Shinjuku-ku, Tokyo 160, Japan

CABLE ADDRESS

:

FUJIHEAVY

TOKYO

TEL : (Tokyo 03) 3347-241 4,5 TELEX 232-2401 FUJI

J

FACSIMILE:

(TOKYO

03)

3347-2418

PRINTED

IN

JAPAN

June-1993