Page 2 - CONTENTS; Section Title Page
CONTENTS Section Title Page 1. SPECIFICATIONS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 1 2. PERFORMANCE CURVES ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 2 3. GENERAL DESCRIPTION OF GENERATOR ・ ・ ・ ・ ...
Page 4 - Dimensions
− − 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 ...
Page 5 - PERFORMANCE CURVES
− − 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
Page 6 - GENERAL DESCRIPTION OF GENERATOR
− − 3 − − 3. GENERAL DESCRIPTION OF GENERATOR SPARK PLUG CAP FUEL COCK BATTERY TANK CAP SPARK PLUGCAP OIL FILLER CAP MUFFLER CONNECTOR FOR REMOTE CONTROL (RGV12100 only) END COVER (RGV13100T only) FUEL TANK CONTROLPANEL AIR CLEANER COOLING AIR INLET PORT OIL FILTER CHOKE KNOB (RGV13100T only) OIL GA...
Page 7 - CONTROL PANEL
− − 4 − − CONTROL PANEL (RGV12100) KEY SWITCH OIL PURESSURE WARNING LAMP 0 240 110 120 220 IDLE CONTROL SWITCH VOLTMETER PILOT LAMP HOUR METER NO-FUSE BREAKER AC RECEPTACLE EARTH (GROUND)TERMINAL CONNECTORFOR REMOTE CONTROL (RGV13100T) KEY SWITCH OIL PURESSURE WARNING LAMP 0 240 110 120 220 VOLTMETE...
Page 8 - SERIAL NUMBER; Serial number is stamped on the label stuck on the end cover.; to get correct parts and accurate service.
SERIAL NUMBER stamped label SERIAL NUMBERstamped 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) ...
Page 9 - CONSTRUCTION AND FUNCTION
− − 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 siliconsteel sheet core, a mai...
Page 11 - Warning lamp
− − 8 − − 4-2-5 A.V.R (AUTOMATIC VOLTAGE REGULATOR)(RGV12100 only) The automatic voltage regulator employs anelectronic circuit to automatically regulatevoltage. 4-2-6 ECU (ELECTRONIC CONTROL UNIT) ECU controls the start/stop of an engineenabling the fuel cut while stop.It also automatically stops t...
Page 12 - Function
− − 9 − − 4-2-7 IDLE CONTROL UNIT (RGV12100 only) The idle control unit 1 1 releases throttle valve when the applied load current exceeds0.04A.The two output wires 2 2 from the main coils must go through the ZCT 3 3 in the same direction. NOTE :It is normal that the engine speed goes up fora moment ...
Page 13 - Total output amperage
− − 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 pressuredrops to 1.0...
Page 14 - TWIST
− − 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, areused. As many AC plugs as the receptacles, each matching the corresponding receptacle, areprovided.The r...
Page 15 - TABLE 1; CAUTION; Style
− − 12 − − ■ Check the amperage of the receptacles used referring to TABLE 1, and be sure not to take acurrent exceeding the specified amperage. ■ Be sure that the total wattage of all appliances dose not exceed the rated output of the gen-erator. TABLE 1 NOTE :When the no-fuse breaker turns off dur...
Page 16 - GFCI RECEPTACLE; CONNECTING TO DOMESTIC CIRCUIT (HOUSE WIRING); WARNING
− − 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. Poweris now off at the outlets protected by the GFCI, indicating that the device is function...
Page 17 - OR
− − 14 − − MAIN POWER LINE TRANSFER SWITCH UTILITY HIGH LINE CONNECTING BOX 240VRECEPTACLE Utility high line Meter box Generator House circuit breaker X W Y X (X) (Y) (G) (W) W Y X W Y Transfer switch 240V 4P- Receptacle 120V appliance 120V appliance 240V appliance OR Generator (X) (Y) (G) (W) 240V ...
Page 18 - Connection of Power Cables
− − 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 switch-es on. Otherwise the appliance (s) may...
Page 19 - Generator rated output :
− − 16 − − SINGLE-PHASE OUTPUT W G Y X Z ■ Three phase application (208V)Insert the plug into the receptacle X, Y andZ. 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 lo...
Page 20 - -3 DESCRIPTION of GENERATOR OPERATION
− − 17 − − 4-3 DESCRIPTION of GENERATOR OPERATION 4-3-1 PRIMARY EXCITING ACTION (RGV12100) When the generator is started, the perma-nent magnet on the engine rotates to genera-tor a voltage in the exciting coil.This voltage is regulated by a diode in theAVR to feed a current to the generator fieldco...
Page 22 - SAFETY PRECAUTIONS; Do not place inflammable materials near the generator.; s will be adversely affected and may cause; Do not connect the generator to the commercial power lines.; This may cause a short-circuit or damage to the generator.
− − 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 thefuel tank. Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before...
Page 23 - RANGE OF APPLICATIONS; A rated 3000 W generator can power four or five 400 W mercury lamps.; (3) Motor driven tools and light electrical appliances
− − 20 − − 6. RANGE OF APPLICATIONS Generally, the power rating of an electrical appliance indicates the amount of work that can bedone by it. The electric power required for operating an electrical appliance is not always equalto the output wattage of the appliance. The electrical appliances genera...
Page 24 - (5) Appliances without any indication as to power consumption; Efficiencies of some electrical appliances are as follows:; Applications
− − 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 theoptimum generator capacity, select a generator with a larger capacity. (5) Appliances without any...
Page 25 - NOTES : Wiring between generator and electrical appliances; Voltage drop indicates as V=; Nominal; mm; Voltage drop
− − 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 allowablecurrent of the cable used, the ca...
Page 26 - MEASURING PROCEDURES; Frequency range : About 45 to 65Hz; NOTE : Be careful of the frequency meter's input; -1 MEASURING INSTRUMENTS; to 300 V : Type with an output voltage
− − 23 − − FOR AC 7. MEASURING PROCEDURES (2) AMMETER AC ammeter is necessary. An AC ammeter with a range that can bechanged according to the current ratingof 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...
Page 27 - -2 AC OUTPUT MEASURING
− − 24 − − (4) CIRCUIT TESTER Used for measuring resistance, etc. (5) MEAGER TESTER Used for measuring generator insulationresistance.Select one with testing voltage range of500V. 7-2 AC OUTPUT MEASURING SWITCH LOAD TO AC RECEPTACLE F A ~ V ~ Use a circuit above for measuring AC output. A hot plate ...
Page 28 - -3 MEASURING INSULATION RESISTANCE; or more is; STATOR; between WHITE lead and the core.; oltage range
− − 25 − − 7-3 MEASURING INSULATION RESISTANCE Use a megger tester to check the insulationresistance. Connect a megger tester to oneof receptacle output terminals and the groundterminal, then measure the insulation resis-tance.An insulation resistance of 1M Ω or more is normal.If it is less than 1M ...
Page 29 - , replace the current
− − 26 − − ● ROTOR Measure the resistance between the slip ringand the core. ● CONTROL PANEL Measure the insulation resistance betweenthe live parts and the grounded parts. ● CURRENT TRANSFORMER (RGV13100T) Measure the insulation resistance betweeneach terminal and the core.If it is less than 1M Ω ,...
Page 30 - CHECKING FUNCTIONAL MEMBERS; -1 PILOT LAMP and VOLTMETER
− − 27 − − 8. CHECKING FUNCTIONAL MEMBERS PILOT LAMP 8-2 AC RECEPTACLES Using a circuit tester, check continuitybetween the two terminals at the rear of theAC receptacles while the receptacle ismounted on the control panel. When continu-ity is found between the output terminals ofthe receptacle with...
Page 31 - Light green
− − 28 − − Model Hz/Voltage Stator coil Red-White Black-Blue Black-Red White- Light green Black-White RGV12100 60/120/240 0.11 Ω 0.11 Ω ------------ 0.37 Ω ------------ RGV13100T 60/120/208 0.23 Ω ------------ 0.23 Ω ------------ 0.23 Ω 8-4 STATOR Disengage connectors on the wires from stator and ch...
Page 32 - NOTE : If the circuit tester is not sufficiently accu-; ) Cleaning Slip rings; ) Check the resistance between two yellow; Resistance; ) Check the AC voltage between these two; AC voltage
− − 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 andmay give erroneous readings.Erroneous reading will also occur whenthere is a wide variat...
Page 33 - BRUSH; NOTE : Take teater inaccuracy into account in reading the tester.
− − 30 − − 8-7 BRUSH The brushes must be smooth where theycontact the slip rings. If not, polish smooththe brushes with sandpaper. A brush that isnot smooth produces arcs between the brushand slip ring leading to possible damage.Usable brush lengths are from 5 mm to 15mm (0.2 " to 0.6").A br...
Page 34 - If current transformer is found to be faulty, replace with new one.
− − 31 − − * Checking table for analogue circuit tester. Analogue circuit tester Apply black - needle of the circuit tester Yellow Black 1 1 White 2 2 Light green 3 3 Brown 4 4 orYellow Apply red + needle of the circuit tester Yellow --------------- ∞ ∞ ∞ ∞ Black 1 1 ∞ --------------- 200 k Ω ∞ 300 ...
Page 35 - Tester; -11 IDLE CONTROL UNIT; Circuit tester (with battery
− − 32 − − Tester (-) Tester ( ) Pin No. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 ! !00 ! !11 ! !22 ! !33 1 1 ------- ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ 2 2 ∞ ------- ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ 3 3 ∞ 18.4M ------- 10M 10.2M ∞ 10.4M 11M 14.4M 5.3M ∞ ∞ ∞ 4 4 ∞ ∞ ∞ ------- 0.1 ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ 5 5 ∞ ∞ ∞ 0.1 ------- ∞ ∞ ∞ ∞ ...
Page 37 - DISASSEMBLY AND ASSEMBLY; -1 PREPARATION and PRECAUTIONS; porarily to their original position.; -2 DISASSEMBLY PROCEDURES; from the front panel to the alternator.
− − 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 neces-sary information to facilitate easier and smoot...
Page 38 - NOTE : Temporarily tighten the through bolt; NOTE : The stator is heavy. Be careful do not
− − 35 − − 9-3 COMPONENT PARTS For disassembling and assembling, the following illustrations show the major component partsand 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 t...
Page 43 - Tighten the through bolt.; -4 GENERATOR ASSEMBLING PROCEDURES; Tightening torque
− − 40 − − 9-4-1 FRONT COVER Attach the front cover to the engine mainbearing cover. Match the faucet joint andtighten 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 andmatching tapered hole of rotor shaft. (2) ...
Page 44 - (1) Put the stator in the rear cover setting the
− − 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 withthread holes of the rear cover.Tighten the four bolts tentatively to checkif the grooves and thread holes arealigned correctly. (See Fig.9-8) (2) Remove the four bolts. STATOR COV...
Page 45 - (1) Put the rear cover with stator and stator; NOTE : Be careful not to give cuts to wires when; (2) Tap on the rear cover evenly with a plastic; SCREW
− − 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 wiredrawn out from the rear cover.Press the smaller...
Page 46 - NOTE : When tightening the nuts, slightly lift the; (7) Fasten the earth cable to the unpainted; Install the brush cover.
− − 43 − − NOTE : When tightening the nuts, slightly lift the alternator assembly so that the weight isnot 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 e...
Page 47 - 0-2 AC Voltage is too high or too low
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 ...
Page 48 - dose not operate; ) No fuel in the tank or the fuel
− − 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 hasbeen stopped. Wait for more than 2 seconds and then turn thekey switch to "START" position....
