Robin-Subaru RGV4100 - Manuals

Page 2 - CONTENTS; Section Title Page

CONTENTS Section Title Page 1. SPECIFICATIONS ....................................................................................................... 1 2. PERFOMANCE CURVES ........................................................................................... 3 3. FEATURES ........................

Page 4 - * Electric starter motor is available as option.; ENGINE

- 1 - 1. SPECIFICATIONS * Electric starter motor is available as option. ENGINE AL TERNA TO R l e d o M0 0 8 2 V G R0 0 1 4 V G R e p y T e s a h P el g ni S , el o P- 2 , g nit i c x E fl e S , s s el h s ur B C A y c n e u q er F z H 0 6 t u pt u Om u mi x a MW 0 0 8 2W 0 0 1 4 t u pt u O d et a R...

Page 7 - DC OUTPUT

- 4 - 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 :...

Page 8 - Robin RGV series generator delivers a quiet operation with :; -7 RUGGED TUBULAR FRAME

- 5 - 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 automaticall...

Page 9 - -9 MINIMAL MAINTENANCE

- 6 - 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 cleane...

Page 10 - GENERAL DESCRIPTION

- 7 - 4. GENERAL DESCRIPTION 4-1 EXTERNAL VIEW FUEL GAUGE VOLTMETER ACRECEPTACLE EARTH TERMINAL SPARK PLUG NO-FUSE BREAKER OIL DRAIN PLUG OILGAUGE (OIL FILLER) ENGINE SWITCH CHOKE KNOB AIR CLEANER RECOIL STARTER OIL SENSOR TANK CAP MUFFLER FULL POWERSWITCH DC CIRCUIT BREAKER DC OUTPUTTERMINAL IDEL C...

Page 12 - -3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER; order to get correct parts and accurate service.

- 9 - * RGV6100 : U.S.A., 60Hz-120V/240V [NEMA RECEPTACLE] 4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL (MODEL NAME) stuck on the sidewall of control box. NOTE : Always specify these numbers when inquiring about the generator ...

Page 13 - CONSTRUCTION AND FUNCTION

- 10 - 5. CONSTRUCTION AND FUNCTION 5-1 CONSTRUCTION 5-2 FUNCTION 5-2-1 STATOR The stator consists of a laminated silicon steelsheet core, a main coil and a condenser coil whichare wound in the core slots. The condenser coil excites the rotor field coil whichgenerates AC voltage in the main coil. Fi...

Page 16 - NOTE : If your generator has receptacles pecu-; Caution : To connect the appliance to locking; TWIST

- 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 aGFCI (Ground Fault Circuit Interrupter).GFCI shuts off the output current from theduplex 120V receptacle when a ground faultoccurs in the generato...

Page 17 - generator. Otherwise an electric shock may occur to the operator.; MAIN POWER LINE

- 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 connected to residential or commercial power lines, such as a stand-bypower source during power outage, all connections must be made by a licensed electric...

Page 19 - -3 GENERATOR OPERATION

- 16 - 5-3 GENERATOR OPERATION 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 co...

Page 22 - OIL SENSOR

- 19 - 5-4 OIL SENSOR 5-4-1 DESCRIPTION * The oil sensor mainly functions to detect posi- tion of the surface of engine oil in the crankcaseof engines for general use and to stop the en-gine automatically when the oil level goes downbelow the lower limit specified. This prevents sei-zure of engine f...

Page 23 - lized power to necessary circuits.

- 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 flows across the electrodes. The sensor judges that oil in the crankcase is sufficient. Whenoil level goes down and the inner electrode is exposed ...

Page 24 - resistance across inner and outer electrodes.; -4-5 CAUTIONS TO BE TAKEN ON HANDLING THE SENSOR; ing wire in particular may lead to malfunction or breakdown.

- 21 - 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 ...

Page 25 - SAFETY PRECAUTIONS; Do not place inflammable materials near the generator.

- 22 - 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 sta...

Page 26 - RANGE OF APPLICATIONS; factor; shall be required to drive the lamps.; (3) Mercury lamps with a smaller power factor; 000 W generator can power two or three 400 W mercury lamps.

- 23 - 7. RANGE OF APPLICATIONS Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it.The electric power required for operating an electrical appliance is not always equal to the output watt-age of the appliance. The electrical appliances generall...

Page 27 - (5) Appliances without any indication as to power consumption; Efficiencies of some electrical appliances are as follows :

- 24 - (5) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) isindicated. In such a case, power consumption is to be worked out according to the numerical formulamentioned below. Efficiencies of so...

Page 29 - MEASURING PROCEDURES; -1 MEASURING INSTRUMENTS; time to change batteries.; ll

- 26 - 8. MEASURING PROCEDURES 8-1 MEASURING INSTRUMENTS 8-1-1 “Dr. ROBIN” GENERATOR TESTER The “Dr. Robin” generator tester is exclusivelydesigned for fast, easy diagnosis and repair ofRobin generators. The “Dr. Robin” has the follow-ing features : (1) Functions of voltmeter, frequency meter, megge...

Page 31 - Use the contactless type tacho meter.

- 28 - (4) CIRCUIT TESTER Used for measuring resistance, etc. (5) MEGGER TESTER Used for measuring generator insulation re-sistance. Select one with testing voltage rangeof 500V. (6) TACHOMETER Use the contactless type tacho meter. Fig. 8-5 Fig. 8-6 Fig. 8-7

Page 33 - -4 MEASURING INSULATION RESISTANCE

- 30 - 8-4 MEASURING INSULATION RESISTANCE Use a “Dr. Robin” generator tester in megger testermode or use a megger tester to check the insula-tion resistance. Connect a megger tester to oneof receptacle output terminals and the ground ter-minal, then measure the insulation resistance. Aninsulation r...

Page 35 - CHECKING FUNCTIONAL MEMBERS; Check that no disconnection nor short-circuit

- 32 - 9. CHECKING FUNCTIONAL MEMBERS 9-1 VOLTMETER Check the voltmeter if it is turned on by applyingspecific voltage. Voltmeter cannot be checked withcircuit tester because its resistance is too large. 1 Check that no disconnection nor short-circuit occurs with a tester, and the internal resistanc...

Page 37 - capacitance, or the accurate reading cannot be obtained.

- 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 is soldered to the coil ends atthe terminals, resistance may be measured onlywhen tester probes touche the terminals in onecombination of polarit...

Page 38 - * Checking table for analogue circuit tester.

- 35 - * If such an instrument is unavailable, the condenser can be checked by replacing with a new one. If thegenerator performs good with new condenser, the cause of trouble is defect in original condenser. 9-7 DIODE RECTIFIER Circuit inside of the diode rectifiers is as shown in Fig. 9-7. Check c...

Page 39 - * Checking table for digital circuit tester.; sensor at the connection.

- 36 - * Checking table for digital circuit tester. NOTE 1 : Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester, polarity of tester needles should be reversed. NOTE 2 : ”Continuity” means forward direction characteristics of the diode, an...

Page 40 - DISASSEMBLY AND ASSEMBLY; 0-1 PREPARATION and PRECAUTIONS; their original position.

- 37 - 10. DISASSEMBLY AND ASSEMBLY 10-1 PREPARATION and PRECAUTIONS 1) Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly. Tag the disassembled part with the necessary information tofacilitate easier and smoother ...

Page 41 - 0-2 DISASSEMBLY PROCEDURES

- 38 - p e t S e v o m e r o t t r a P n o i t p i r c s e D s k r a m e R l o o T 1 x o b l o r t n o C f o m o t t o b e h t m o r f g n i h s u b e h t f f o e k a T ) 1 ( ) . 1 - 0 1 . g i F e e S ( . x o b l o r t n o c e h t g n i r i w e h t n o s r o t c e n n o c e h t t c e n n o c s i D )...

Page 42 - RUBBER PIPE

- 39 - p e t S e v o m e r o t t r a P n o i t p i r c s e D s k r a m e R l o o T 2 k n a T l e u F . k a n t e h t m o r f l e u f e g r a h c s i D ) 1 ( . r e n i a r t s l e u f e h t t u h S . 1 . p u c r e n i a r t s e h t e v o m e R . 2 e h t r e d n u l e u f e v i e c e r o t l e s s e v...

Page 45 - REAR COVER

- 42 - p e t S e v o m e r o t t r a P n o i t p i r c s e D s k r a m e R l o o T 5 r e v o c r a e R ) . 1 1 - 0 1 . g i F e e S ( . r e v o c d n e e h t e v o m e R ) 1 ( ) 0 0 1 6 V G R t p e c x E ( 6 φ . s c p 3 . . . t l o b r o r e n n a p s m m 0 1 h c n e r w x o b e h t n e t s a f h c i...

Page 47 - SEAL TAPE

- 44 - p e t S e v o m e r o t t r a P n o i t p i r c s e D s k r a m e R l o o T 7 r o t o R . t l o b h g u o r h t e h t f f o e k a T ) 1 ( f o d a e h e h t n o h c n e r w x o b a y l p p A h t i w e l d n a h h c n e r w e h t t i H . t l o b h g u o r h t . n e s o o l o t e s i w k c o l c...

Page 49 - 0-3 ASSEMBLY PROCEDURES

- 46 - 10-3 ASSEMBLY PROCEDURES 10-3-1 FRONT COVER Attach the front cover to the engine main bearingcover. Match the faucet joint and tighten the bolts. M8 x 20 mm bolt . . . 4 pcs. M8 spring washer . . . 4 pcs. 10-3-2 ROTOR (1) Wipe off oil, grease and dust from the tapered portion of engine shaft ...

Page 51 - FRAME UPPER

- 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. Insert the setting tongue of mount rubber into the holeon the frame and tighten the nut from the bot-tom of the frame. M8 flange nut . . . 4 pcs. NOTE : The mount ru...

Page 52 - EARTH CABLE

- 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) Temporarily fix the muffler bracket to either the rear or front covers for RGV6100 or RGV2800.M8 x 20 mm bolt and washer Ass’y . . . 2 pcs. (2) A...

Page 54 - 0-4 CHECKING, DISASSEMBLY and REASSEMBLY of the FRONT PANEL

- 51 - 10-3-9 FRONT PANEL Mount the front panel assembly to the frame. Refer to Section 10-4 for disassembly, checking and reassembly procedures of the front panel. (1) Connect the wires from the front panel and the engine. (2) Connect the wires drawn out from the stator to the wires from the front ...

Page 56 - COUPLER

- 53 - 11. TROUBLESHOOTING 11-1 NO AC OUTPUT 11-1-1 CHECKING CONDENSER (1) Check the capacity of condensers using a “Dr. Robin” generator tester in capacitance meter mode. NOTE : Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance, or the accurate...

Page 58 - 1-2 AC VOLTAGE IS TOO HIGH OR TOO LOW; * Loosen the lock nut on the adjusting screw.

- 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 newone. 11-2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11-2-1 CHECKING ENGINE SPEED If the engine speed is too high or too low, adjust itto the rated r.p.m...

Page 60 - FUSE

- 57 - 11-4 NO DC OUTPUT 11-4-1 CHECK THE AC OUTPUT. Check the generator by following Step 11-1-1 through Step 11-1-3. 11-4-2 CHECK THE DC BREAKER. If the DC breaker turned off while charging a bat-tery, check the cables for short-circuit or connec-tion in reverse polarity before resetting it on. NO...

Page 61 - WHEN A LOAD IS APPLIED

- 58 - 11-4-6 CHECK THE DC COIL Check the resistance between two brown leads from stator with a circuit tester. If the resistance reading is much larger or smaller than the specified value, the DC coil of the stator isfaulty. Replace stator with a new one. 11-5 IDLE CONTROL 11-5-1 ENGINE SPEED IS NO...

Page 62 - (4) Check the wiring through ZCT on the IDLE; * Single Voltage Type; IDEL CONTROL UNIT

- 59 - (4) Check the wiring through ZCT on the IDLE CONTROL UNIT. * Single Voltage Type Make sure that an output wire from main coil ispassing through the ZCT on the IDLE CONTROLUNIT. * Dual Voltage Type Check that two output wires (black wire and redwire) from main coils are passing through theZCT ...

Page 63 - SOLENOID

- 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 wiring of SOLENOID. Check two leads from SOLENOID are securely connected. (3) Check the wiring of IDLE CONTROL UNIT. Check all leads from IDLE CONTR...

Page 67 - Specifications are subject to change without notice.

- 64 - 1. SPECIFICATIONS Specifications are subject to change without notice. * : Electric starter motor model : RGV4101 and RGV6101. ENGINE AL TERNA TOR l e d o M1 0 1 4 V G R1 0 1 6 V G R e p y T e s a h P el g ni S , el o P- 2 , g nit i c x E fl e S , s s el h s ur B C A y c n e u q er F z H 0 6 ...

Page 68 - GENERATOR TROUBLESHOOTING

- 65 - 2. GENERATOR TROUBLESHOOTING 2-1 NO AC OUTPUT 2-1-1 CHECKING CONDENSER (1) Check the capacity of condensers using a “Dr. Robin” generator tester in capacitance meter mode. NOTE : Be sure to discharge condensers by shorting condenser leads each other before checking their capacitance, or the a...

Page 70 - -2 AC VOLTAGE IS TOO HIGH OR TOO LOW

- 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 newone. 2-2 AC VOLTAGE IS TOO HIGH OR TOO LOW 2-2-1 CHECKING ENGINE SPEED If the engine speed is too high or too low, adjust itto the rated r.p.m. [...

Page 77 - RANGE OF APPLICATIONS

- 74 - 3. 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 watt-age of the appliance. The electrical appliances generall...