Subaru RGV12100 User Manual

SERVICE MANUAL

Models

RGV12100 / 13100T

GENERATORS

PUB-GS1328 Rev. 09/01

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 (RGV12100 only) ・・・・・・・・・・・・・・・・・・ 32 8-12 DIODE UNIT (RGV13100T only) ・・・・・・・・・・・・・・・・・・・・・・ 33

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

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NOTE This Service Manual excludes information for engine. As for the total servicing information as a generator set, please refer in conjunction with the Robin EH63-65 OHV Engine Service Manual.

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−−1−−

1. SPECIFICATIONS

Model RGV12100

Alternator

Type

Rated voltage

Brush, Self-exciting,

2-pole, Single phase

611 mm (752 mm *1)

Rated frequency 60Hz

771 mm (845 mm *1)

120V / 240V Maximum output 12000VA Rated output 9500VA

Length

Power factor 1.0

Width

Voltage regulator

Height

A.V.R type

Engine

Model EH65D Type V-Twin cylinder, Air-cooled, 4-stroke, Overhead valve engine Displacement 653 cm

Maximum output 22 HP/ 3600 rpm Fuel Unleaded automobile gasoline (RON87 or higher) Oil capacity 1.55 liters Starting system Electric starter

Fuel tank capacity 44 liters Rated continuous

operation per a tankful of fuel

3/4 Rated Approx. 9.0 hours Rated Approx. 8.2 hours

Noise level

Rated (dB-7m)

77.0 dB

Dimensions

826

Dry weight 141 kg (149 kg

)

RGV13100T

120V / 208V

13000VA 10000VA

0.8

Approx. 9.7 hours Approx. 8.9 hours

77.0 dB

18 HP/ 3600 rpm

*1: ( ) shows dimensions with castors. *2: ( ) shows dry weight with castors installed.

C.T. type

EH63D

143 kg (151 kg

)

Brush, Self-exciting,

2-pole, 3-phase

−−2−−

2. PERFORMANCE CURVES

(Hz)

(V)

(

125

)

250

(

120

)

240

(

115

)

230

(

110

)

220

0 1/2 4/4

Load Rated

240V/120V

RGV12100

RGV13100T

(Hz)

(V)

230

220

210

200

0 1/2 4/4

Load Rated

208V

−−3−−

3. GENERAL DESCRIPTION OF GENERATOR

SPARK PLUG CAP

FUEL COCK

BATTERY

TANK CAP

SPARK PLUG CAP

OIL FILLER CAP

MUFFLER

CONNECTOR

FOR REMOTE

CONTROL

(RGV12100 only)

END COVER

(RGV13100T only)

FUEL TANK

CONTROL PANEL

AIR CLEANER

COOLING AIR

INLET PORT

OIL FILTER

CHOKE KNOB

(RGV13100T only)

OIL GAUGE

ELECTRIC STARTER

OIL DRAIN PLUG

−−4−−

CONTROL PANEL

(RGV12100)

KEY SWITCH

OIL PURESSURE

WARNING LAMP

110

120

IDLE CONTROL

SWITCH

VOLTMETER

PILOT LAMP HOUR METERNO-FUSE BREAKER

AC RECEPTACLEEARTH (GROUND)

TERMINAL

CONNECTOR FOR REMOTE CONTROL

(RGV13100T)

KEY SWITCH

OIL PURESSURE

WARNING LAMP

110

120

VOLTMETER

PILOT LAMP HOUR METERNO-FUSE BREAKER

AC RECEPTACLE

AC (THREE PHASE and SINGLE PHASE

)

RECEPTACLE

EARTH (GROUND) TERMINAL

SERIAL NUMBER stamped label

−−5−−

SERIAL NUMBER

Serial number is stamped on the label stuck on the end cover.

NOTE : Always specify serial number when inquiring about the generator or ordering spare parts in order

to get correct parts and accurate service.

(RGV13100T)

(RGV12100)

−−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.

−−7−−

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 (RGV12100) and diode unit (RGV13100T).

4-2-3 BRUSH / BRUSH HOLDER

An exciting current is supplied from the A.V.R to the rotor. The brushes are made of carbon and the brush-holder of plastic. It is necessary to keep the contact pressure between the brushes and slip rings withing specific limits. Thus, care must be taken of brush length.

4-2-4 CURRENT TRANSFORMER

/ DIODE UNIT (RGV13100T only)

The current transformer and 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

−−8−−

4-2-5 A.V.R

(

AUTOMATIC VOLTAGE REGULATOR

)

(RGV12100 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

When the lubrication oil pressure drops below the safety limit (Oil pressure becomes less than 1kg/cm

) and/or the engine speed ups above the safety limit (Engine speed increases higher than 4,500 r/min for 7 seconds), the warning lamp repeats turning on and off, and the engine stops automatically. The warning lamp turns off after 3 minutes.

Starter motor control

When the engine started and reaches 1,050 r/min, the starter motor is automatically stopped.

When the engine is operating, the starter motor can not start.

−−9−−

4-2-7 IDLE CONTROL UNIT

(RGV12100 only)

The idle control unit

releases throttle

valve when the applied load current exceeds

0.04A. The two output wires

from the main coils

must go through the ZCT

in the same

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.

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 engine dose not start (engine speed does not reach 1,050 r/min), the starter motor is stopped after 21 seconds.

When the remote controller is connected, the electric starter dose not run when the switch of remote controller is turned "OFF" even if the key 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.

−−10−−

Model Specification No-fuse Breaker Object of Protection

RGV12100 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

4-2-9 RELIEF VALVE

The relief valve begins to open when the engine's oil pressure increases above 3.0 kg/cm

4-2-10 AC SWITCH (NO-FUSE BREAKER)

The AC switch (no-fuse breaker) protects the generator from getting damage by overloading or short circuit in the appliance. The capacity of AC switch (no-fuse breaker) is as follows ;

OIL PUMP

OIL PUMP FILTER

CRANKSHAFT

OIL FILTER

RELIEF VALVE

CAMSHAFT

OIL PRESSURE SWITCH

−−11−−

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;

Be careful not to use the receptacles beyond the specified amperage limits to prevent burning.

CAUTION

To connect the appliance to the locking type receptacle, insert the plug in to the receptacle and then turn it clockwise to lock.

(RGV12100)

(RGV13100T)

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

30A or less

Total 30A or less

MAX 20A

20A or less

TWIST

−−12−−

■

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 dose not exceed the rated output of the generator.

TABLE 1

NOTE :

When the no-fuse breaker turns off during operation, the generator is over loaded 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 Robin dealer or service shop.

The duplex 120V receptacle is protected by a GFCI (Ground Fault Circuit Interrupter). GFCI shuts off the output current from the duplex 120V receptacle when a ground fault occurs in the generator or the appliance. Please note that other receptacles are not protected by GFCI.

［

CAUTION

］

up to 30A

up to 20A

NEMA

5-20R

NEMA

L5-30R

NEMA

L14-30R

NEMA

5-20P

NEMA

L5-30P

NEMA

L14-30P

GFCI (Ground Fault Circuit Interrupter) Receptacle, duplex

(REC1)

Locking Receptacle (REC2)

Locking Receptacle (REC3)

Style Ampere Receptacle AC plug Description

up to 30A

NEMA

L21-30R

NEMA

L21-30P

up to 50A

Locking Receptacle (REC4)

Locking Receptacle (REC5)

−−13−−

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 dose not appear when testing, do not use the generator. Call a qualified electrician.

■

To restore power, push RESET button.

If the RESET button pops out during operation, stop the generator immediately and call a qualified electrician for checking generator and the appliances.

WARNING

CONNECTING TO DOMESTIC CIRCUIT (HOUSE WIRING)

This generator is neutral grounded type. If a generator is to be connected to residential or commercial power lines, such as a stand-by power source during power outage, all connections must be made by a licensed electrician. Failure in connection may result in death, personal injury, damage to generator, damage to appliances, damage to the building's wiring or fire.

WARNING

(a) When connecting a Robin generator to a house wiring, generator output power must be taken

from the 240V-4P 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.

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.

［

CAUTION

］

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