Subaru Robin Power Products 13100T, RGV12100 User Manual

SERVICE
MANUAL

Models

RGV12100 / 13100T

GENERATORS

PUB-GS1328
Rev. 09/01

CONTENTS

Section Title Page

1. SPECIFICATIONS

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

1

2. PERFORMANCE CURVES

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

2

3. GENERAL DESCRIPTION OF GENERATOR

・・・・・・・・・・・・・・・・・・・・・・・・・・・・

3

4. CONSTRUCTION AND FUNCTION

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

6

4-1 CONSTRUCTION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 6
4-2 FUNCTION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 6
4-3 DESCRIPTION of GENERATOR OPERATION ・・・・・・・・・・・・・・・・ 17

5. SAFETY PRECAUTIONS

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

19

6. RANGE OF APPLICATIONS

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

20

7. MEASURING PROCEDURES

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

23

7-1 MEASURING INSTRUMENTS ・・・・・・・・・・・・・・・・・・・・・・・ 23
7-2 AC OUTPUT MEASURING ・・・・・・・・・・・・・・・・・・・・・・・・・ 24
7-3 MEASURING INSULATION RESISTANCE ・・・・・・・・・・・・・・・・・・ 25

8. CHECKING FUNCTIONAL MEMBERS

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

27

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

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

34

9-1 PREPARATION and PRECAUTIONS ・・・・・・・・・・・・・・・・・・・・ 34
9-2 DISASSEMBLY PROCEDURES・・・・・・・・・・・・・・・・・・・・・・・ 34
9-3 COMPONENT PARTS ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 35
9-4 GENERATOR ASSEMBLING PROCEDURES・・・・・・・・・・・・・・・・・ 40

10. TROUBLESHOOTING

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

44

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

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

46

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.

−−04−−

−−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

3

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

mm

Dry weight 141 kg (149 kg

*

2

)

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

*

2

)

Brush, Self-exciting,

2-pole, 3-phase

−−2−−

2. PERFORMANCE CURVES

Hz

(Hz)

(V)

(

125

)

63

250

(

120

)

240

(

115

)

230

(

110

)

220

62

61

60

0 1/2 4/4

Load Rated

240V/120V

RGV12100

RGV13100T

Hz

(Hz)

(V)

63

230

220

210

200

62

61

60

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

0

2

4

0

110

120

2

2

0

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

0

2

4

0

110

120

2

2

0

VOLTMETER

PILOT LAMP HOUR METERNO-FUSE BREAKER

AC RECEPTACLE

AC (THREE PHASE
and SINGLE PHASE

)

RECEPTACLE

EARTH (GROUND)
TERMINAL

SERIAL NUMBER
stamped label

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

2

) 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

11

releases throttle

valve when the applied load current exceeds

0.04A.
The two output wires

22

from the main coils

must go through the ZCT

33

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.

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 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

2

4-2-9 RELIEF VALVE

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

2

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

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

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 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

］

−−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

−−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.

−−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

−−17−−

4-3 DESCRIPTION of GENERATOR OPERATION

4-3-1 PRIMARY EXCITING ACTION

(RGV12100)

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
(

RGV12100

)

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 increase 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.

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

−−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

−−19−−

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-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 (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 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.

−−20−−

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

(1) Incandescent lamp, heater, etc. with a power factor of 1.0

Total power consumption must be equal to or less than the rated output of 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 400W 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 3000W generator can drive one or two 400W 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.

−−21−−

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)

(Efficiency)

Efficiencies of some electrical appliances are as follows:

Single-phase motor ・・・・・・・・・ 0.6 to 0.75 The smaller the motor, the lower

the efficiency.

Three-phase motor・・・・・・・・・・ 0.65 to 0.9
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)

＝

(Power consumption)

Applications

Applicable Wattage (W)

Incandescent Lamp, Heater 10000
Fluorescent Lamp, Electric Tool 4950
Pump, Compressor 2500

RGV12100 (60 Hz)

−−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

−−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

−−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.

−−25−−

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 (RGV12100),
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.

120 V 208 V 240 V

RGV12100 112V-128V -------------- 224V-256V

RGV13100T -------------- 218V-249V --------------

Voltage range

Model

Rated voltage

−−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.

−−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.

−−28−−

Model Hz/Voltage

Stator coil

Red-White Black-Blue Black-Red

White

-

Light green

Black-White

RGV12100 60/120/240

0.11Ω 0.11Ω

------------

0.37Ω

------------

RGV13100T 60/120/208

0.23Ω

------------

0.23Ω

------------

0.23Ω

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).

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.

RGV13100TRGV12100

−−29−−

8-5 ROTOR ASSEMBLY

1) Field coil
Remove the brush holder and measure resistance between the slip rings.

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) Resistance

RGV12100

4.11Ω

RGV13100T

69.6Ω

SLIP RING

ROTOR

SANDPAPER

8-6 EXCITING COIL (RGV12100 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.

Ignition coil

Charge
coil

Exciting
coil

Yellow
Yellow

Exciting coil for A.V.R. Resistance

RGV12100

2.35Ω

3) Check the AC voltage between these two
yellow wires when the engine speed at no
load ; 3600

-

3800 rpm with a circuit tester.

AC voltage

35 to 45 V

−−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.

−−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

−−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

8-11 IDLE CONTROL UNIT

(RGV12100 only)

Check the resistance between five terminals
of IDLE CONTROL UNIT with circuit tester.

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

-------

−−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

-------

−−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

−−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.

−−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

−−37−−

(2-1) Control Box (RGV12100)

PLATE

CONTROL BOX

GROMMET

WIRE

CONNECTOR

EARTH
(

GROUND

TERMINAL

AC RECEPTACLE

CAP

)

AC RECEPTACLE

NO-FUSE
BREAKER

CONNECTOR
for REMOTE
CONTROL

IDEL 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

(2-2) Control Box (RGV13100T)

−−38−−

PLATE

GROMET

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

−−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

−−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

−−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

−−42−−

9-5 REAR COVER

(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.

(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
of 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.If so, the brush holders
are correctly mounted.

BRUSH
COVER

BRUSH
HOLDER

FLANGE
BOLT

SCREW

Fig. 9-9

Fig. 9-10

Fig. 9-11

Tightening torque

120-140 kg cm

11.8-13.7 N m

8.7-10.1 ft lbs

−−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.
Connector 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.

Fig. 9-12

Fig. 9-13

Tightening torque

120-140 kg cm

11.8-13.7 N m

8.7-10.1 ft lbs

10. TROUBLESHOOTING

10-1 No AC output

* Checking the exciting coil for resistance. (RGV12100) (Refer to 8-6.)

If insulation is NG, replace exciting coil with new one.

* Checking 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.

* Checking stator for insulation resistance. (Refer to 7-3.)

If insulation is NG, replace stator with new one.

* Checking the A.V.R . (RGV12100) (Refer to 8-8.)

If insulation is NG, replace A.V.R with new one.

* Checking 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.)
* Checking the idle control unit. (RGV12100) (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−−

−−45−−

10-4 Engine dose not run.

Symptom Possible causes Remedy

1. Electric starter

dose not operate

1) The key switch (or remote
switch) is turned to "START"
within 2 seconds the engine has
been stopped.

Wait for more than 2 seconds and then turn the
key switch to "START" position.

1) No fuel in the tank or the fuel
cock is closed.

2) The remote controller is con­nected.

Both the key switch of the generator and the
switch of remote controller must be turns into
"ON" position.

3) The above possible causes 1)
and 2) dose not apply.

The ECU is defective.
Replace with new one.

2. Warning lamp
turns on and off
when engine is
stopped

Supply fuel or open the fuel cocks.

2) Oil level is low or oil is contami­nated.

Add or change engine oil.

3. Engine is auto­matically stopped
but the warning
lamp dose not
light up

1) The bulb of warning lamp failed. Replace the bulb with a new one.

53

2

4

(AC output)

(

AVR

)

1

CONTROL BOX

Fuel cut

Ignition coil

Auto choke
(

Bimetal

)

Electric
starter

Oil pressure
switch

Regulator

Magnetic
switch

Charge
coil

Exciting
coil

-

+

Battery 12V

Grn/Y

Grn

LBlu

Gry W

Key
switch

to earth
terminal

ST Relay

Connector
(

Remote control

)

Gry

R15

Blk15

Grn

WW
W

Blk/W

Gry

Gry

Blk

R

Blk/W
Blk

R

Grn/Y

Grn/Y

Grn

Grn

Org
R

Org

Org

LBlu

LBlu

LBlu

Brn

Y

Org

R

W

W

W

W
W

W
W

OFF

-

M+M B

L.IG

ST

ON

START

R/W

Idle
solenoid

1

Electronic control unit

2133124115106

987

Blk

Y
Y

Blk

Grn/Y

Grn/Y

Idle control
switch

Idle

control

unit

Oil pressure
warning lamp

(

Red

)

LGrn

Org

Blk

Blu

Blk

R

R

Blk

W W

W

LGrn

Grn/Y

Grn/Y

Grn/Y

Grn/Y

Brm

CONTROL BOXGENERATOR

No-fuse breaker

Voltmeter

Hour meter

Pilot lamp

VHr

PL

Earth(Ground)
terminal

Brush

Auxiliary
Winding

Field

Winding

AC WindingAC Winding

AVR

Exciting coil
(Engine)

Idle

control

unit

AC otuput
receptacle(120V)

AC output
receptacle(120V)

AC output
receptacle(120/240V)

AC output
receptacle(120/240V)

YY

REC1 REC2

REC3

REC4

REC5

WW

WW

XX

YY

HH

G

GG

GG

Key switch -M
Idle control unit 3

Blk

Y
Y

W

W

LGrn
Brm

−−46−−

Wiring color cord

LGrn

R/W

Blk/RBlk Black Brn/W Brown/White R Red
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

Black/Red

11. WIRING DIAGRAM

(RGV12100)

−−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+M B

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

940 Lively Blvd.  Wood Dale, IL 60191  Phone: [phone]  Fax: [phone]

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