Subaru Robin Power Products RGV4100, RGV6100 User Manual

SERVICE MANUAL

Models

RGV2800, RGV4100,

RGV6100

Generators

PUB-GS1277

Rev. 1/04

	CONTENTS
Section	Title	Page
1. SPECIFICATIONS .......................................................................................................		1
2. PERFOMANCE CURVES ...........................................................................................		3
3. FEATURES ..................................................................................................................		5
3-1 BRUSHLESS ALTERNATOR ................................................................................		5
3-2 CONDENSER TYPE VOLTAGE REGULATOR ....................................................		5
3-3 OIL SENSOR ........................................................................................................		5
3-4 QUIET OPERATION .............................................................................................		5
3-5 NO RADIO NOISE ................................................................................................		5
3-6 LARGE FUEL TANK ..............................................................................................		5
3-7 RUGGED TUBULAR FRAME ...............................................................................		5
3-8 COMPACT AND LIGHT WEIGHT .........................................................................		5
3-9 MINIMAL MAINTENANCE ....................................................................................		6
3-10 LONG-LIFE DURABILITY ...................................................................................		6
4. GENERAL DESCRIPTION ..........................................................................................		7
4-1 EXTERNAL VIEW .................................................................................................		7
4-2 CONTROL PANEL ................................................................................................		8
4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER ......................		9
5. CONSTRUCTION AND FUNCTION .........................................................................		10
5-1CONSTRUCTION ................................................................................................		10
5-2 FUNCTION ..........................................................................................................		10
5-3 GENERATOR OPERATION ................................................................................		16
5-4 OIL SENSOR ......................................................................................................		19
6. SAFETY PRECAUTIONS .........................................................................................		22
7. RANGE OF APPLICATIONS ....................................................................................		23
8. MEASURING PROCEDURES ..................................................................................		26
8-1 MEASURING INSTRUMENTS ...........................................................................		26
8-2 AC OUTPUT MEASURING .................................................................................		29
8-3 DC OUTPUT MEASURING.................................................................................		29
8-4 MEASURING INSULATION RESISTANCE ........................................................		30
9. CHECKING FUNCTIONAL MEMBERS ....................................................................		32
9-1 VOLTMETER.......................................................................................................		32
9-2 AC RECEPTACLES ............................................................................................		32
9-3 No-FUSE BREAKER ...........................................................................................		32

Section

Title

Page

9-4 STATOR ..............................................................................................................	33
9-5 ROTOR ASSEMBLY ...........................................................................................	34
9-6 CONDENSER .....................................................................................................	34
9-7 DIODE RECTIFIER .............................................................................................	35
9-8 OIL SENSOR ......................................................................................................	36
10.DISASSEMBLY AND ASSEMBLY ...........................................................................	37
10-1PREPARATION and PRECAUTIONS ................................................................	37
10-2 DISASSEMBLY PROCEDURES .......................................................................	37
10-3 ASSEMBLY PROCEDURES .............................................................................	38
10-4 CHECKING, DISASSEMBLY and REASSEMBLY of the FRONT PANEL ........	46
11. TROUBLESHOOTING ............................................................................................	51
11-1 NO AC OUTPUT................................................................................................	53
11-2 AC VOLTAGE IS TOO HIGH OR TOO LOW .....................................................	55
11-3 AC VOLTAGE IS NORMAL AT NO-LOAD,
BUT THE LOAD CANNOT BE APPLIED. ....................................	56
11-4 NO DC OUTPUT ...............................................................................................	57
11-5 IDLE CONTROL(OPTIONAL EQUIPMENT) .....................................................	58
12. WIRING DIAGRAM .................................................................................................	61
Troubleshooting Manual RGV4101/RGV6101............................................................	64
1. SPECIFCATIONS.....................................................................................................	64
2. GENERATOR TROUBLE SHOOTING......................................................................	65
2-1 No AC output......................................................................................................	65
2-2 AC voltage is too high or too low........................................................................	67
2-3 AC voltage is normal at No-load, but the load cannot be applied.......................	68
2-4 No DC output......................................................................................................	69
2-5 Idle control (Optional equipment)........................................................................	71
3. RANGE OF APPLICATIONS...................................................................................	74
4. WIRING DIAGRAM...................................................................................................	77

NOTE : As for the servicing information on engine protion, please refer to the EH17-2,

EH25-2 and EH34 engine service manual.

- 1 -

		Model
	Type
		Frequency
ENGINE		Maximum Output
	AC	Voltage
		Rated Output
		Rated
		Current
	Power Factor
	DC Output
	Voltage Regulator
	Type
	Model
ALTERNATOR	Displacement

Rated Output

Fuel

Fuel Tank Capacity

Rated Coutinuous Operation

Oil Capacity

Starting System

Dimensions (L x W x H)

Dry Weight

	RGV2800	RGV4100
	Brushless, Self Exciting, 2-Pole, Single Phase
		60 Hz
	2800 W	4100 W
	2300 W	3600 W
120V	19.2A	120V	30.0A
120V/240V	19.2A/9.6A	120V/240V	30.0A/15.0A
		1.0
	12 V-8.3 A (100 W)
	Condenser Type
	Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine
	EH17-2D	EH25-2D
172 cm3 (10.50 cu. in.)		251 cm3 (15.32 cu. in.)
4.0 HP / 3600 rpm		6.4 HP / 3600 rpm
	Automobile Gasoline
3.17 U.S. gal. (12 liters)		4.38 U.S. gal. (16.6 liters)
	9.0 hours	7.0 hours
0.17 U.S. gal. (0.65 liters)		0.36 U.S. gal. (1.0 liters)
	Recoil Starter	Recoil Starter and Optional Electric Starter
22.0 x 16.3 x 19.4 in. (560 x 415 x 493 mm)		24.4 x 16.9 x 21.7 in. (620 x 430 x 552 mm)
	106 lbs. (48 kg)	132 lbs. (140 lbs.)* / 60 kg (63.5 kg)*

SPECIFICATIONS .1

* Electric starter motor is available as option.

- 2 -

			Model
		Type
			Frequency
	ENGINE		Maximum Output
		AC	Rated Output
			Rated
			Voltage
			Current

Power Factor

DC Output

Voltage Regulator

Type

Model

	ALTERNATOR	Displacement
		Rated Output
		Fuel
		Fuel Tank Capacity

Rated Coutinuous Operation

Oil Capacity

Starting System

Dimensions (L x W x H)

Dry Weight

RGV6100

Brushless, Self Exciting, 2-Pole, Single Phase

60 Hz

5800 W

4800 W

120V/240V

40A/20A

1.0

12 V-8.3 A (100 W)

Condenser Type

Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine

EH34D

338 cm3 (20.63 cu. in.)

8.0 HP / 3600 rpm Automobile Gasoline

5.67U.S. gal. (21.5 liters)

7.0hours

0.32U.S. gal. (1.2 liters)

Recoil Starter and Optional Electric Starter 26.8 x 18.5 x 24.8 in. (680 x 470 x 630 mm)

172 lbs. (180 lbs.)* / 78 kg (81.5 kg)*

* Electric starter motor is available as option.

2. PERFOMANCE CURVES

(Hz)
63								Hz
62
61
60
(V)
250
(125)
240								230V/115V
(120)
230
(115)
220
(110)
0								1/2					4/4
								Load					Rated

- 3 -

DC OUTPUT

DC Voltage .................	12 V
DC Ampere ................	8.3 A
DC output ...................	100 W

The voltage curve shown in the left indicates the characteristic of DC output when charging a battery. The voltage may be decreased by 20% when the resistance load is applied.

NOTE : It is possible to use both DC and AC outputs simultaneously up to the rated output in total.

- 4 -

3. FEATURES

3-1 BRUSHLESS ALTERNATOR

Newly developed brushless alternator eliminates troublesome brush maintenance.

3-2 CONDENSER TYPE VOLTAGE REGULATOR

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

3-3 OIL SENSOR

Oil sensor automatically shuts off the engine whenever the oil level falls down below the lower limit to protect the engine from seizure.

3-4 QUIET OPERATION

Robin RGV series generator delivers a quiet operation with :

*A large super silent muffler.

*A quiet 4-stroke Robin Rro OHV engine.

*A silent cyclone air cleaner.

3-5 NO RADIO NOISE

Noise suppressor spark plug is equipped standard to prevent radio frequency interference.

3-6 LARGE FUEL TANK

The large fuel tank allows more than 7 to 10 hours of continuous operation which is sufficient for a half day or one day work without refueling.

3-7 RUGGED TUBULAR FRAME

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

3-8 COMPACT AND LIGHT WEIGHT

Newly developed brushless alternator enabled the RGV generators to be very compact in size and light in weight.

- 5 -

3-9 MINIMAL MAINTENANCE

*A brushless alternator release the operator from periodical brush maintenance.

*A trouble free condenser type voltage regulator.

*A drip-proof alternator design.

*No-fuse circuit breakers.

*An electronic pointless ignition system.

*A dust-proof cyclone air cleaner.

3-10 LONG-LIFE DURABILITY

The heavy-duty 4 stroke Robin Rro OHV engine and virtually maintenance-free brushless alternator ensure greater durability with :

*A brushless alternator with a condenser voltage regulator.

*Full rubber mount in a sturdy tubular frame.

*A forged steel crankshaft supported by two main ball bearings.

*A pointless electronic ignition system.

*A cast-iron cylinder liner.

*A forged aluminum connecting rod.

- 6 -

4. GENERAL DESCRIPTION

4-1 EXTERNAL VIEW

FUEL GAUGE	TANK CAP VOLTMETER ENGINE SWITCH
FULL POWER
SWITCH
DC OUTPUT
TERMINAL
	IDEL CONTROL
DC CIRCUIT	SWITCH
BREAKER NO-FUSE	OIL SENSOR
BREAKER	CHOKE KNOB
AC
RECEPTACLE	AIR CLEANER
EARTH
TERMINAL
	RECOIL STARTER
SPARK PLUG

ENGINE
EMISSION LABEL	MUFFLER

OIL DRAIN PLUG

OILGAUGE (OIL FILLER)

- 7 -

4-2 CONTROL PANEL

* RGV2800 : U.S.A., 60Hz-120V [NEMA RECEPTACLE]

AC OUTPUT

V METER

ENGINE SWITCH

RESET	RESET	TEST	TEST
			ON

AC MAX 20A

DC 12V-8.3A	ON OFF	OFF
BATTERY CHARGE ONLY
DC OUTPUT	DC BREAKER	AC BREAKER

* RGV4100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE]

RESET RESET

AC 120V	FULL POWER SWITCH AC 120V / 240V	V METER	ENGINE SWITCH
	120V		ON
	120V
	240V

OFF

TEST			ON	IDEL CONTROL
TEST	30A	20A		ON
	125V
AC MAX 20A	AC MAX 30A	AC MAX 20A		OFF
	DC 12V-8.3A	ON OFF	OFF
	BATTERY CHARGE ONLY
	DC OUTPUT	DC BREAKER	AC BREAKER

- 8 -

* RGV6100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE]

AC 120V	FULL POWER SWITCH		AC 120V / 240V	V METER	ENGINE SWITCH
	120V	120V
		/240V
					ON
RESET
RESET					OFF
TEST	30A
TEST			20A
	150V
	AC MAX 30A		AC MAX 20A	ON	IDEL CONTROL
AC MAX 20A
					ON
					OFF
	DC 12V-8.3A	ON	OFF
				OFF
BATTERY CHARGE ONLY
	DC OUTPUT	DC BREAKER		AC BREAKER

4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER

Serial number and specification number are stamped on the LABEL (MODEL NAME) stuck on the side wall of control box.

NOTE : Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service.

LABEL,

MODEL NAME

- 9 -

5. CONSTRUCTION AND FUNCTION

5-1 CONSTRUCTION

END COVER	BALL BEARING	STATOR COMPLETE		ROTOR COMPLETE
		REAR COVER	STATOR COVER		CRANKSHAFT

MOUNT RUBBER

THROUGH BOLT

COVER BOLT

FRONT COVER

Fig. 5-1

5-2 FUNCTION

5-2-1 STATOR

The stator consists of a laminated silicon steel sheet core, a main coil and a condenser coil which are wound in the core slots.

The condenser coil excites the rotor field coil which generates AC voltage in the main coil.

Fig. 5-2

- 10 -

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.

Fig. 5-3

5-2-3 ROTOR

The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core.

DC current in the field coil magnetizes the steel sheet core. Two permanent magnets are provided for the primary exciting action.

Fig. 5-4

A diode rectifier and surge absorber is mounted inside of the insulator.

Fig. 5-5A

Fig. 5-5B

- 11 -

5-2-4 NO-FUSE BREAKER

The no-fuse breaker protects the generator from getting damage by overloading or short circuit in the appliance. Table 5-1 shows the capacity of no-fuse breaker by each spec. and their object of protection.

	MODEL	SPECIFICATION	NO-FUSE BREAKER	OBJECT or PROTECTION
	RGV2800	60 Hz-120V	20 A	Total output amperage
	RGV4100	60 Hz-120 V/ 240V	15 A (2-Pole, 2-Element)	Total output amperage
			20 A (2-Pole, 2-Element)	Total output amperage
	RGV6100	60 Hz-120 V/ 240V
			30 A	Output from 30A receptacle

Table. 5-1

5-2-5 DC CIRCUIT BREAKER

The 10 ampere DC circuit breaker mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit.

Fig. 5-6

5-2-6 RECEPTACLE and AC PLUG (STD. SPEC.)

These are used for taking AC output power from the generator. A total of six kinds of receptacles, each varying in rated voltage and current from another, are used. Each model has at least one receptacle to deliver the rated generator output. As many AC plugs as the receptacles, each matching the 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.

- 12 -

Style	Ampere	Receptacle	AC plug	Description
				GFCI (Ground Fault
	up to 20A	NEMA 5-20A	NEMA 5-20P	Circuit Interrupter)
				Receptacle, duplex
				(REC1)
	up to 20A	NEMA L14-20R	NEMA L14-20P	Locking Receptacle
				(REC2)
	up to 30A	NEMA L5-30R	NEMA L5-30P	Locking Receptacle
				(REC3)
		Table. 5-2

NOTE : If your generator has receptacles peculiar to your country, Table 5-2 does not apply.

Caution :

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

5-2-7 GFCI RECEPTACLE

TWIST

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

Fig. 5-8

After starting the engine, check the GFCI for proper functioning by the following test procedure.

Push yellow TEST button, The red RESET button will pop out exposing the word TRIP. Power is now off at the outlets protected by the GFCI, indicating that the device is functioning properly.

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

To restore power, push RESET button.

WARNING :

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

- 13 -

5-2-8 CONNECTING TO DOMESTIC CIRCUITS (HOUSE WIRING)

WARNING :

All Robin generators are a neutral ungrounded type.

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

(a)When contnecting a Robin generator to a house wiring, generator output power must be taken from the 240V-4P receptacle.

(b)Install a transfer switch.

A transfer switch must be installed to transfer the load from the commercial power source to the generator. This switch is necessary to prevent accidents caused by the recovery from power outage. Use a transfer switch of the correct capacity. Install transfer switch between the meter and the fuse or AC breaker box.

Caution : If the neutral wire of house wiring is grounded, be sure to ground the ground terminal of the generator. Otherwise an electric shock may occur to the operator.

UTILITY HIGH LINE

MAIN POWER LINE

CONNECTING BOX

240V RECEPTACLE

TRANSFER SWITCH

Fig. 5-9

- 14 -

Utility high line
Meter box	House circuit breaker
X W Y	120V
	appliance	240V
X W Y	120V	appliance
	appliance
	Transfer
	switch
Generator

(W)

(X) (Y) (G)

240V

4PReceptacle

Fig. 5-10

(c)Operating the generator.

Set the full power switch to 120V/ 240V side.

Turn the house AC breaker off before starting the generator. Start the generator and warm it up.

Turn the house AC breaker on.

Caution : Do not start the generator with electrical appliance (s) connected and with their switches on. Otherwise the appliance (s) may be damaged by the surge voltage at starting.

- 15 -

5-3 GENERATOR OPERATION

Fig. 5-11

5-3-1 GENERATION of NO-LOAD VOLTAGE

(1)When the generator starts running, the permanent magnet built-in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator.

(2)As one or two condensers are connected to the condenser coil, the small voltage at the condenser coil generates a minute current a 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 a increases, the magnetic flux at the rotor’s magnetic pole increases further. Thus the voltages at the main coil and condenser coil keep rising by repeating this process.

(3)As AC current flows through the condenser coil, the density of magnetic flux in the rotor changes. This change of magnetic flux induces AC voltage in the field coil, and the diode rectifier in the field coil circuit rectifies this AC voltage into DC. Thus a DC current b flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil.

(4)When generator speed reaches 3000 to 3300 rpm, the current in the condenser coil and field coil increases rapidly. This acts to stabilize the output voltage of each coils. If generator speed further increases to the rated value, the generator output voltage will reach to the rated value.

5-3-2 VOLTAGE FLUCTUATIONS UNDER LOAD

When the output current c flows through the main coil to the appliance, a magnetic flux is produced and serves to increase current a in the condenser coil. When current a 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.

- 16 -

5-3-3 FULL POWER SWITCH (Dual Voltage Type)

The full power switch is provided for the dual voltage type to take out the full rated power from one receptacle in each voltage.

Fig. 5-12

Fig. 5-13

Switch	LOWER VOLTAGE	HIGHER VOLTAGE
Position	RECEPTACLE	RECEPTACLE
120/240 V	Half of rated output	Rated output
	Table. 5-3

Fig. 5-14

- 17 -

Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower voltage (120V). These main coils are wound to be in the same phase. The full power switch reconnects these main coils in parallel or in series.

Fig. 5-12 shows a circuit diagram. When the full power switch is set for single lower voltage indication (120V), the switch position is as indicated by the lower solid line in the diagram. Fig. 5-13 is a simplified representation of this circuit, showing the two main coils connected in parallel. In this case, the higher voltage (240V) at Rec. 3 cannot be taken out. Rec. 2 for the lower voltage can output up to the rated power (up to 30A if the rated current is over 30A), and Rec. 1 can output up to a total of 15A.

When the full power switch is set for double voltage indication (120V/240V), the switch position is as indicated by the upper dotted line in Fig. 5-12. Fig. 5-14 is a simplified representation of this circuit, showing the two main coils connected in series. In this case, power can be taken simultaneously from the receptacles for the both voltages. Rec. 3 for the higher voltage can output up to the rated power, but Rec. 1 and Rec. 2 for the lower voltage can output only up to half the rated power each.

Table 5-4 is a summary of the above explanation. Select the proper output voltage by full power switch in accordance with the appliance to be used.

- 18 -

5-4 OIL SENSOR

5-4-1 DESCRIPTION

*The oil sensor mainly functions to detect position of the surface of engine oil in the crankcase of engines for general use and to stop the engine automatically when the oil level goes down below the lower limit specified. This prevents seizure of engine from occurring due to insufficient amount of oil in the crankcase.

*Since the sensor has been designed to consume a part of power supplied to the igniter to energize its electronics circuit, any other external power supply is not necessary so that it can be mounted at the oil filler port.

OIL SENSOR

Fig. 5-15

Introduction of newly developed sensing principle features super durability and no change with the passage of time as it does not use any moving part.

Merits due to introduction of electrical conductivity detection are as follows ;

1It has resistance to mechanical shocks and property of no change with the passage of time as sensing element consists simply of electrodes having no moving parts.

2At the same time, it is capable of detecting the oil level stably as it is not influenced by engine vibrations.

3 No error occurs due to foam and flow of the oil.

4Influence against the ignition system or the electronics units can be neglected because an electric current supplied to the sensor can be decreased.

5-4-2 PRINCIPLE OF SENSING OIL LEVEL

There is a great difference between electric resistance of air and that of oil. Since the resistance of air is far higher than that of oil, more electric current passes through the oil than through the air, although absolute value of the current is very small. The sensor detects this current difference and make use of it. The sensor judges the oil quantity, by comparing a current flowing across a pair of electrodes (inner and outer) with the reference, in such a way that if a current flows between the electrodes more than the reference, sufficient oil is in the crankcase, on the other hand, if a current flows less than the reference, oil is not sufficient. Since an electric current is flown to detect oil quantity, this is called the “electrical conductivity detection” type of sensor. The oil level to be detected is determined by the length of electrodes and their mounting positions with the engine.

5-4-3 HOW IT OPERATES

[Power supply]

The sensor makes use of a part of primary power source for ignition of the engine (igniter) to drive the sensor circuit. Power to the sensor can usually be derived from the “stop button” by branching wires out.

- 19 -

[Judgement of oil level]

When sufficient oil is in the crankcase, both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes. The sensor judges that oil in the crankcase is sufficient. When oil level goes down and the inner electrode is exposed to the air due to consumption of oil, no current flow between the electrodes as air is considered to be electrically nonconductive. The sensor in this case judges that oil is insufficient.

[Decision of oil shortage]

Oil level at the electrodes may go down momentarily probably due to the engine being slanted or affected by vibration even if a sufficient oil is in the crankcase. For that reason, the sensor has an electronic timer circuit to prevent it from interpreting as short of oil when amount of oil is sufficient. The sensor has been designed so that the engine is to be stopped only when oil-shortage is detected for 5 seconds uninterrupted. The timer employs an integration circuit and it is to be reset when the inner electrode is soaked in the oil again before the sensor decides it as oil-shortage. The oil level where the sensor decides as oilshortage, when oil level goes down gradually, is called “threshold level”.

[Automatic stop of engine]

When the sensor decides as oil-shortage, it makes the engine to stop running automatically for protection of engine. Once the stopping circuit is activated, it keeps functioning until it confirms that the engine has made a complete stop, then the circuit stops functioning automatically.

5-4-4 BLOCK DIAGRAM OF THE CIRCUIT

						Power circuit			Igniter

Inner pole

Detection

Deley circuit

Stopping

circuit

circuit

Oil

Outer pole

Engine ground

Fig. 5-16

1 Power circuit ..........	This rectifies a part of power to the igniter and regulates it to supply the stabi-
	lized power to necessary circuits.

- 20 -

2 Detection circuit .....	This detects quantity of oil, sufficient or not, according to difference of electric
	resistance across inner and outer electrodes.
3 Delay circuit ...........	This his prevents the sensor from making an unnecessary stop of the engine
	by momentary lowering of the oil level due to the engine being slanted or
	affected by vibration in spite of sufficient oil in the crankcase.
4 Stopping circuit ......	This automatically stops the engine running.

5-4-5 CAUTIONS TO BE TAKEN ON HANDLING THE SENSOR

(1)Oil sensor unit

1 Be sure not to damage each wire. Broken or short-circuited power supply wires and/or a grounding wire in particular may lead to malfunction or breakdown.

2The sensor is not interchangeable from engine to engine because the sensor is to be exclusively installed individually in each engine employed.

(2)Mounting and wiring of oil sensor unit

1 Although this has been designed to have enough antinoise properties in practical use, do not route the sensor wirings in the vicinity of noise-generating sources such as ignition plugs or high voltage cords. This may cause malfunction or breakdown.

2Since capacity of power source is limited, current flown in the electronic circuit of the sensor is kept as low as possible. Be sure to use terminals with a high contact reliability of more than that of tinned terminals.

(3)Operation of oil sensor

1 If operating with the engine kept tilted, oil surface inside of the engine varies and the correct oil level can not to be detected which in turn obstructs the preventing function of engine seizure. Operate the engine by keeping it level.

2When starting the engine with an insufficient oil in the crankcase, engine starts once then it stops automatically after it runs for 5 seconds.

3When the engine has been stopped by the oil sensor, voltage remained in the electronic circuit prevents the sensor from being restarted for 3 seconds after the engine stop. Try to restart the engine after 3 seconds or more.

- 21 -

6.SAFETY PRECAUTIONS

1.Use extreme caution near fuel. A constant danger of explosion or fire exists.

Do not fill the fuel tank while the engine is running. Do not smoke or use open flame near the fuel tank. Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before starting the engine.

2.Do not place inflammable materials near the generator.

Be careful not to put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the generator.

3.Do not operate the generator in a room, cave or tunnel. Always operate in a well-ventilated area.

Otherwise the engine may overheat and also, the poisonous carbon monoxide contained in the exhaust gases will endanger human lives. Keep the generator at least 1 m (4 feet) away from structures or facilities during use.

4.Operate the generator on a level surface.

If the generator is tilted or moved during use, there is a danger of fuel spillage and a chance that the generator may tip over.

5.Do not operate with wet hands or in the rain.

Severe electric shock may occur. If the generator is wet by rain or snow, wipe it and thoroughly dry it before starting. Don’ t pour water over the generator directly nor wash it with water. If the generator is wet with water, the insulations will be adversely affected and may cause current leakage and electric shock.

6.Do not connect the generator to the commercial power lines.

This may cause a short-circuit or damage to the generator. Use a transfer switch (Optional parts) for connecting with indoor wiring.

NOTE : The parts numbers of the transfer switches and of the plastic box to store them are as shown in Table 6-1.

Part No.	Part Name	Q'ty	Phase	Allowable Current
365-45604-08	Transfer Switch	1	1	15 A
367-45605-08	Transfer Switch	1	1	30 A
340-45606-08	Transfer Switch	1	1	60 A
367-43008-08	Plastic Box	1	1	30 A
348-43009-08	Plastic Box	1	1	60 A
	Table. 6-1

7. Be sure to check and remedy the cause of circuit breaker tripping before resetting it on.

CAUTION : If the circuit breaker tripped off as a result of using an electrical appliance, the cause can be an overload or a short-circuit. In such a case, stop operation immediately and carefully check the electrical appliance and AC plugs for faulty wiring.

- 22 -