Subaru Robin Power Products RGV6100 Manuale Utente

PUB-GS1277Rev. 1/04SERVICEMANUALRGV2800, RGV4100,RGV6100ModelsGenerators

- 7 -4. GENERAL DESCRIPTION4-1 EXTERNAL VIEWFUEL GAUGE VOLTMETERACRECEPTACLEEARTH TERMINALSPARK PLUGNO-FUSE BREAKEROIL DRAIN PLUG OILGAUGE (OIL FILLER

- 8 -4-2 CONTROL PANEL* RGV2800 : U.S.A., 60Hz-120V [NEMA RECEPTACLE]* RGV4100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE]ENGINE SWITCHAC OUTPUTAC MA

- 9 -* RGV6100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE]4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBERSerial number and specification number

- 10 -5. CONSTRUCTION AND FUNCTION5-1 CONSTRUCTION5-2 FUNCTION5-2-1 STATORThe stator consists of a laminated silicon steelsheet core, a main coil and

- 11 -5-2-2 CONDENSEROne or two condensers are installed in the con-trol box and are connected to the condenser coilof the stator.These condensers and

- 12 -5-2-4 NO-FUSE BREAKERThe no-fuse breaker protects the generator from getting damage by overloading or short circuit in theappliance. Table 5-1 s

- 13 -NOTE : If your generator has receptacles pecu-liar to your country, Table 5-2 does notapply.Caution :The duplex 120V receptacle is protected by

- 14 -5-2-8 CONNECTING TO DOMESTIC CIRCUITS (HOUSE WIRING)WARNING :All Robin generators are a neutral ungrounded type.If a generator is to be connecte

- 15 -Utility high lineMeter boxGeneratorHouse circuit breakerXWYX(X)(Y)(G)(W)WYTransferswitch240V4P- Receptacle120Vappliance120Vappliance240Vapplianc

- 16 -5-3 GENERATOR OPERATION5-3-1 GENERATION of NO-LOAD VOLTAGE(1) When the generator starts running, the permanent magnet built-in to the rotor gene

CONTENTSSection Title Page1. SPEC

- 17 -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

- 18 -Two main coils are wound over stator core. Each main coil outputs half the rated power at the lowervoltage (120V). These main coils are wound to

- 19 -5-4 OIL SENSOR5-4-1 DESCRIPTION* The oil sensor mainly functions to detect posi-tion of the surface of engine oil in the crankcaseof engines for

- 20 -[Judgement of oil level]When sufficient oil is in the crankcase, both of inner and outer electrodes are immersed in the oil throughwhich current

- 21 -2 Detection circuit ... This detects quantity of oil, sufficient or not, according to difference of electricresistance across inner and outer

- 22 -6. SAFETY PRECAUTIONS1. Use extreme caution near fuel. A constant danger of explosion or fire exists.Do not fill the fuel tank while the engine

- 23 -7. RANGE OF APPLICATIONSGenerally, the power rating of an electrical appliance indicates the amount of work that can be done by it.The electric

- 24 -(5) Appliances without any indication as to power consumptionSome appliances have no indication as to power consumption; but instead the work lo

- 25 -NOTES : Wiring between generator and electrical appliances1. Allowable current of cableUse a cable with an allowable current that is higher than

- 26 -8. MEASURING PROCEDURES8-1 MEASURING INSTRUMENTS8-1-1 “Dr. ROBIN” GENERATOR TESTERThe “Dr. Robin” generator tester is exclusivelydesigned for fa

Section Title Page9-4 STATOR ...

- 27 -8-1-2 INSTRUMENTS(1) VOLTMETERAC voltmeter is necessary. The approximateAC voltage ranges of the voltmeters to be usedfor various types of gener

- 28 -(4) CIRCUIT TESTERUsed for measuring resistance, etc.(5) MEGGER TESTERUsed for measuring generator insulation re-sistance. Select one with testi

- 29 -8-2 AC OUTPUT MEASURINGUse a circuit like the shown in Fig.8-8 for measuring AC output. A hot plate or lamp with a power factor of1.0 may be use

- 30 -8-4 MEASURING INSULATION RESISTANCEUse a “Dr. Robin” generator tester in megger testermode or use a megger tester to check the insula-tion resis

- 31 -* CONTROL PANELMeasure the insulation resistances between thelive parts and the grounded parts.Any part where the insulation resistance is less

- 32 -9. CHECKING FUNCTIONAL MEMBERS9-1 VOLTMETERCheck the voltmeter if it is turned on by applyingspecific voltage. Voltmeter cannot be checked withc

- 33 -9-4 STATORDisengage connectors on the wires from statorand check the resistance between wires with a“Dr. Robin” or a circuit tester referring to

- 34 -9-5 ROTOR ASSEMBLY(1) Using a “Dr. Robin” or a circuit tester, measure the resistance of the field coil at the terminals.NOTE 1 :Because a diode

- 35 -* If such an instrument is unavailable, the condenser can be checked by replacing with a new one. If thegenerator performs good with new condens

- 36 -* Checking table for digital circuit tester.NOTE 1 : Because of the difference of measuring method between the analogue circuit tester and thedi

- 1 -1. SPECIFICATIONS* Electric starter motor is available as option.ENGINEALTERNATORledoM0082VGR0014VGRepyT esahPelgniS,eloP-2,gniticxEfleS,sselhsur

- 37 -10. DISASSEMBLY AND ASSEMBLY10-1 PREPARATION and PRECAUTIONS1) Be sure to memorize the location of individual parts when disassembling the gener

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- 39 -petSevomerottraPnoitpircseDskrameRlooT2knaTleuF.kantehtmorfleufegrahcsiD)1(.reniartsleufehttuhS.1.pucreniartsehtevomeR.2ehtrednuleufeviecerotles

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- 43 -petSevomerottraPnoitpircseDskrameRlooT6rotatS.revocrotatsehtevomeR)1(Fig. 10-14Fig. 10-15SPRINGWASHER : 4 pcs.REAR COVERCOVER BOLT : 4 pcs.STATO

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- 45 -petSevomerottraPnoitpircseDskrameRlooT7rotoRrotorehtfodaerhtehtotnitlobehtwercS.4.tfahshcnerwtekcosagnisutlobehteuqroT.5.esoolffosemocrotorehtli

- 46 - 10-3 ASSEMBLY PROCEDURES10-3-1 FRONT COVERAttach the front cover to the engine main bearingcover. Match the faucet joint and tighten the bolts.

- 2 -* Electric starter motor is available as option.ENGINEALTERNATORledoM0016VGRepyT esahPelgniS,eloP-2,gniticxEfleS,sselhsurBCAycneuqerFzH06tuptuOmu

- 47 -10-3-3 STATOR(1) Put the stator in the rear cover setting the fourgrooves on the side of stator with thread holesof the rear cover.(2) Attach th

- 48 -10-3-5 END COVER (RGV4100 only)Attach the end cover to the rear cover.10-3-6 FRAME(1) Attach the mount rubbers to the frame. Insertthe setting t

- 49 -(4) Fasten the other earth cable with 5 mm termi-nal to the unpainted bolt hole on the frame.(See Fig.10-28.)10-3-7 MUFFLER and MUFFLER COVER(1)

- 50 -3 For RGV2800 and 6100 : Tighten the two bolts to fix the muffler bracket to the front cover, rear cover,and then the two bolts for the muffler

- 51 -10-3-9 FRONT PANELMount the front panel assembly to the frame.Refer to Section 10-4 for disassembly, checking and reassembly procedures of the f

- 52 -10-4-3 REASSEMBLY(1) Install the receptacles, no-fuse breaker, terminals, switches, etc. on the control panel and wire them.NOTE : Circuit diagr

- 53 -11. TROUBLESHOOTING11-1 NO AC OUTPUT11-1-1 CHECKING CONDENSER(1) Check the capacity of condensers using a “Dr. Robin” generator tester in capaci

- 54 -(3) Check the insulation resistance between sta-tor core and each stator lead using a Dr. Robingenerator tester in megger tester mode or amegger

- 55 - (3) Measure the insulation across one of the sol-dered terminals of the rotor and the core.(Fig.11-6)If insulation is bad, replace rotor with a

- 56 -11-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED.11-3-1 CHECK THE ENGINE SPEED.If the engine speed is low, adjust it to the

- 3 -2. PERFOMANCE CURVESHz(Hz)(V)(125)63250(120)240(115)230(110)2206261600 1/2 4/4Load Rated230V/115V

- 57 -11-4 NO DC OUTPUT11-4-1 CHECK THE AC OUTPUT.Check the generator by following Step 11-1-1 through Step 11-1-3.11-4-2 CHECK THE DC BREAKER.If the

- 58 -11-4-6 CHECK THE DC COILCheck the resistance between two brown leads from stator with a circuit tester.If the resistance reading is much larger

- 59 -(4) Check the wiring through ZCT on the IDLECONTROL UNIT.* Single Voltage TypeMake sure that an output wire from main coil ispassing through the

- 60 -11-5-2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF.(1) Check the distortion of the SOLENOID BRACKET as shown in step 11-5-1-(1).(2) Check the w

- 61 -12. WIRING DIAGRAM* RGV2800 : U.S.A., 60Hz-120V TYPE [NEMA RECEPTACLE]* RGV4100 : U.S.A., 60Hz-120V/240V TYPE [NEMA RECEPTACLE]V+-REC1Field Wind

- 62 -*RGV6100 : U.S.A., 50Hz-120V/240V TYPE [NEMA RECEPTACLEV+-120V120V120/240V120/240V81953674289153674REC1GENERATOR CONTROL BOXField WindingAC Wind

- 63 -+-CONTROL BOX1.25Grn1.25R1.25Or0.75GrySTB-M+MIGKey switch0.75Blk(RGV4100)1.25Blk(RGV6100)DiodestackAssyENGINE0.75Blk0.75Blk/WOil sensor0.75Grn/Y

- 64 -1. SPECIFICATIONSSpecifications are subject to change without notice.* : Electric starter motor model : RGV4101 and RGV6101.ENGINEALTERNATORledo

- 65 -2. GENERATOR TROUBLESHOOTING2-1 NO AC OUTPUT2-1-1 CHECKING CONDENSER(1) Check the capacity of condensers using a “Dr. Robin” generator tester in

- 66 -(3) Check the insulation resistance between sta-tor core and each stator lead using a Dr. Robingenerator tester in megger tester mode or amegger

- 4 -DC OUTPUTDC Voltage ... 12 VDC Ampere ... 8.3 ADC output ... 100 WThe voltage curve shown in the left

- 67 - (3) Measure the insulation across one of the sol-dered terminals of the rotor and the core.(Fig.2-6)If insulation is bad, replace rotor with a

- 68 -2-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED.2-3-1 CHECK THE ENGINE SPEED.If the engine speed is low, adjust it to the ra

- 69 -2-4 NO DC OUTPUT2-4-1 CHECK THE AC OUTPUT.Check the generator by following Step 2-1-1 through Step 2-1-3.2-4-2 CHECK THE DC BREAKER.If the DC br

- 70 -Circuit inside of the diode rectifiers is as shown in Fig. 2-13. Check continuity between each terminal byusing a circuit tester as shown in Fig

- 71 -2-4-6 CHECK THE DC COILCheck the resistance between two brown leads from stator with a circuit tester.If the resistance reading is much larger o

- 72 -(4) Check the wiring through ZCT on the IDLECONTROL UNIT.* Single Voltage TypeMake sure that an output wire from main coil ispassing through the

- 73 -2-5-2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS OFF.(1) Check the distortion of the SOLENOID BRACKET as shown in step 2-5-1-(1).(2) Check the wir

- 74 -3. RANGE OF APPLICATIONSGenerally, the power rating of an electrical appliance indicates the amount of work that can be done by it.The electric

- 75 -(5) Appliances without any indication as to power consumptionSome appliances have no indication as to power consumption; but instead the work lo

- 76 -NOTES : Wiring between generator and electrical appliances1. Allowable current of cableUse a cable with an allowable current that is higher than

- 5 -3. FEATURES3-1 BRUSHLESS ALTERNATORNewly developed brushless alternator eliminates troublesome brush maintenance.3-2 CONDENSER TYPE VOLTAGE REGUL

- 77 -4. WIRING DIAGRAMRGV4101RGV4101 (Electric starter model)V+-120V120V120/240V120/240VREC1WWREC3GENERATOR CONTROL BOXField WindingAC Winding 2 AC W

- 78 -RGV6101RGV6101 (Electric starter model)V+-120V120V120/240V81953674289153674REC1REC3WWREC2GENERATOR CONTROL BOXField WindingAC Winding 2 AC Windi

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- 6 -3-9 MINIMAL MAINTENANCE* A brushless alternator release the operator from periodical brush maintenance.* A trouble free condenser type voltage re