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Robin America RGV12100 Service Manual

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SERVICE
MANUAL
Models
RGV12100 / 13100T
GENERATORS
PUB-GS1328
Rev. 09/01

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Summary of Contents for Robin America RGV12100

  • Page 1 SERVICE MANUAL Models RGV12100 / 13100T GENERATORS PUB-GS1328 Rev. 09/01...

  • Page 2: Table Of Contents

    8-6 EXCITING COIL 8-7 BRUSH 8-8 A.V.R (AUTOMATIC VOLTAGE REGULATOR) 8-9 CURRENT TRANSFORMER (RGV13100T only) 8-10 ECU (ELECTRONIC CONTROL UNIT) 8-11 IDLE CONTROL UNIT (RGV12100 only) 8-12 DIODE UNIT (RGV13100T only) 9. DISASSEMBLY and REASSEMBLY 9-1 PREPARATION and PRECAUTIONS 9-2 DISASSEMBLY PROCEDURES...

  • Page 4: Specifications

    1. SPECIFICATIONS Model RGV12100 RGV13100T Brush, Self-exciting, Brush, Self-exciting, Type 2-pole, Single phase 2-pole, 3-phase Rated frequency 60Hz Rated voltage 120V / 240V 120V / 208V Maximum output 12000VA 13000VA Rated output 9500VA 10000VA Power factor Voltage regulator A.V.R type C.T.

  • Page 5: Performance Curves

    2. PERFORMANCE CURVES RGV12100 ( Hz ) ( V ) ( 125 ) 240V/120V ( 120 ) ( 115 ) ( 110 ) Load Rated RGV13100T ( Hz ) ( V ) 208V Load Rated...

  • Page 6: General Description Of Generator

    PANEL COOLING AIR INLET PORT FUEL COCK BATTERY OIL FILLER CAP OIL FILTER SPARK PLUG CAP CHOKE KNOB (RGV13100T only) MUFFLER CONNECTOR FOR REMOTE CONTROL SPARK PLUG (RGV12100 only) END COVER (RGV13100T only) OIL GAUGE OIL DRAIN PLUG ELECTRIC STARTER...

  • Page 7: Control Panel

    CONTROL PANEL (RGV12100) OIL PURESSURE VOLTMETER WARNING LAMP NO-FUSE BREAKER PILOT LAMP HOUR METER KEY SWITCH IDLE CONTROL SWITCH EARTH (GROUND) CONNECTOR AC RECEPTACLE TERMINAL FOR REMOTE CONTROL (RGV13100T) OIL PURESSURE VOLTMETER WARNING LAMP NO-FUSE BREAKER PILOT LAMP HOUR METER...
  • Page 8 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) SERIAL NUMBER stamped label SERIAL NUMBER...

  • Page 9: Construction And Function

    4. CONSTRUCTION AND FUNCTION 4-1 CONSTRUCTION END COVER (RGV13100T only) BRUSH HOLDER STATOR COMPLETE STATOR BOLT REAR COVER ROTOR COMPLETE FRONT COVER MOUNT RUBBER BALL BEARING TROUGH BOLT 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.
  • Page 10 (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.
  • Page 11 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.
  • Page 12 4-2-7 IDLE CONTROL UNIT (RGV12100 only) The idle control unit 1 1 releases throttle valve when the applied load current exceeds 0.04A.
  • Page 13 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 ; Model Specification No-fuse Breaker Object of Protection RGV12100 60Hz-120V/240V Total output amperage RGV13100T 60Hz-120V/208V Total output amperage...
  • Page 14 50A or less 30A or less 20A or less 30A or less Total 30A or less Total 50A or less (RGV12100) (RGV13100T) CAUTION To connect the appliance to the locking TWIST type receptacle, insert the plug in to the receptacle and then turn it clockwise to...
  • Page 15 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 gen- erator.
  • Page 16 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 prop- erly.
  • Page 17 UTILITY HIGH LINE MAIN POWER LINE CONNECTING BOX 240V RECEPTACLE TRANSFER SWITCH Utility high line House circuit breaker Meter box X W Y 120V appliance 240V appliance 120V appliance Transfer switch X W Y Generator Generator ( W ) ( W ) ( X ) ( Y ) ( Y )
  • Page 18 (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. CAUTION Do not start the generator with electrical appliance (s) connected and with their switch- es on.
  • Page 19 AC (THREE PHASE) RECEPTACLE (RGV13100T only) RGV13100T has a receptacle for three plase (208V) and single phase (120V) as follows : SINGLE PHASE AC120V THREE PHASE AC208V Three phase application (208V) Insert the plug into the receptacle X, Y and Generator rated output : 10000VA 3-PHASE OUTPUT Single phase lower application (120V)

  • Page 20: Description Of Generator Operation

    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 the AVR to feed a current to the generator field coil.
  • Page 21 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.

  • Page 22: Safety Precautions

    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.

  • Page 23: Range Of Applications

    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 show- ing their rated voltage, frequency, and power consumption(input wattage).
  • Page 24 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) Applicable Wattage (W) Applications RGV12100 (60 Hz) Incandescent Lamp, Heater 10000 Fluorescent Lamp, Electric Tool 4950...
  • Page 25 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 insula- tion, possibly burning it out.

  • Page 26: Measuring Procedures

    7. MEASURING PROCEDURES 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...

  • Page 27: Ac Output Measuring

    (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 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.

  • Page 28: Measuring Insulation Resistance

    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.
  • Page 29 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 1M , replace the current transformer.

  • Page 30: Checking Functional Members

    8. CHECKING FUNCTIONAL MEMBERS 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 PILOT LAMP too large.

  • Page 31: Ac Switch (No-Fuse Breaker)

    Normally, there is continuity between each of the 2 terminals when the breaker is ON, while no continuity when the breaker is OFF. RGV12100 RGV13100T 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.

  • Page 32: Rotor Assembly

    SANDPAPER pear. Care should be taken not to touch the rotor coils with the sandpaper. 8-6 EXCITING COIL (RGV12100 only) 1) Disconnect the two yellow wires which come out from the exciting coil through the Ignition coil hole of the crankcase and connected with A.V.R.

  • Page 33: Brush

    8-7 BRUSH The brushes must be smooth where they BRUSH contact the slip rings. If not, polish smooth HOLDER 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 15 to 5 mm mm (0.2 "...

  • Page 34: Current Transformer (Rgv13100T Only)

    * Checking table for analogue circuit tester. Apply black - needle of the circuit tester Analogue circuit tester Black 1 1 White 2 2 Light green 3 3 Brown 4 4 orYellow Yellow Yellow --------------- Black 1 1 --------------- 200 k 300 k Apply red + needle of...

  • Page 35: Idle Control Unit (Rgv12100 Only)

    5.3M ! ! 2 2 ------- ! ! 3 3 ------- 8-11 IDLE CONTROL UNIT (RGV12100 only) Check the resistance between five terminals of IDLE CONTROL UNIT with circuit tester. Terminal number of the IDLE CONTROL UNIT Apply black needle of the circuit breaker Circuit tester (with battery power source 1.5 V)

  • Page 36: Diode Unit (Rgv13100T Only)

    8-12 DIODE UNIT (RGV13100T only) Check the resistance between five wires of DIODE UNIT with circuit tester. Apply black needle of the circuit breaker Diode unit Brown Yellow 1 Yellow 2 Yellow 3 Light green Brown ------- Yellow 1 ------- Apply red Yellow 2 -------...

  • Page 37: Disassembly And Reassembly

    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 smoother reassemble. 2) For more convenience, divide the parts into several groups and store them in boxes.

  • Page 38: Component Parts

    (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. Fig. 9-3 (8) Loosen the through bolt of the rotor. (9) Remove the rotor with the soft hammer. ROTOR THROUGH (See Fig.
  • Page 39 (1) Generator assembly FRONT COVER BOLT 22.5-24.5Nm 230-250Kg-cm STATOR ROTOR BEARING THROUGH BOLT REAR COVER STATOR COVER 11.8-13.7Nm 120-140Kg-cm BRUSH HOLDER BUSHING BRUSH COVER COVER BOLT GENERATOR BASE FLANGE NUT 11.8-13.7Nm 120-140Kg-cm 11.8-13.7Nm 120-140Kg-cm END COVER MOUNT RUBBER RGV13100T only...
  • Page 40 (2-1) Control Box (RGV12100) PLATE CONTROL BOX GROMMET WIRE IDLE CONTROL UNIT A.V.R. ( AUTOMATIC VOLTAGE REGULATOR ) ECU (P4) CONNECTOR CONNECTOR EARTH ( GROUND ) for REMOTE RELAY GROMMET CONTROL TERMINAL CLAMP IDEL CONTROL SWITCH AC RECEPTACLE NO-FUSE BREAKER...
  • Page 41 (2-2) Control Box (RGV13100T) CURRENT TRANSFORMER PLATE CONTROL BOX DIODE UNIT GROMET EARTH ( GROUND ) TERMINAL ECU ( P4 ) RELAY GROMMET WIRE CLAMP PILOT LAMP AC RECEPTACLE OIL PRESSURE WARNING LAMP NO-FUSE BREAKER STARTER SWITCH AC RECEPTACLE HOUR METER VOLTMETER CONTROL PANEL...
  • Page 42 (3) Fuel Tank FUEL TANK CAP FUEL GAUGE FILTER FUEL FILTER PACKING FRANGE BOLT ( M6 x 14 mm ) FUEL TANK HOSE CLAMP DETAIL A RUBBER PIPE ( 120 mm ) FUEL STRAINER PURSE RUBBER FLANGE BOLT LOCK WASHER ( M6 x 14 mm ) FUEL PUMP HOSE...

  • Page 43: Generator Assembling Procedures

    9-4 GENERATOR ASSEMBLING PROCEDURES 9-4-1 FRONT COVER FRONT COVER Attach the front cover to the engine main bearing cover. Match the faucet joint and WASHER tighten the bolts. Tightening torque 230-250 kg cm SPRING WASHER 22.5-24.5 N m 16.6-19.5 ft lbs BOLT Fig.
  • Page 44 9-4-3 STATOR (1) Put the stator in the rear cover setting the STATOR four grooves on the side of stator with thread holes of the rear cover. STATOR COVER Tighten the four bolts tentatively to check if the grooves and thread holes are aligned correctly.
  • Page 45 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.
  • Page 46 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.

  • Page 47: Troubleshooting

    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.

  • Page 48: Engine Dose Not Run

    10-4 Engine dose not run. Symptom Possible causes Remedy 1) The key switch (or remote switch) is turned to "START" Wait for more than 2 seconds and then turn the within 2 seconds the engine has key switch to "START" position. been stopped.

  • Page 49: Wiring Diagram

    11. WIRING DIAGRAM RGV12100 CONTROL BOX Auto choke LGrn ( Bimetal ) Fuel cut Oil pressure warning lamp ( Red ) Blk/W Blk/W Ignition coil (AC output) Idle solenoid Electronic control unit LBlu 9 8 7 Idle control unit Exciting...
  • Page 50 RGV13100T CONTROL BOX LGrn Fuel cut Oil pressure Ignition coil warning lamp Blk/W Blk/W ( Red ) Electronic control unit 9 8 7 Charge Battery 12V coil Grn/Y Grn/Y Electric Magnetic starter switch Grn/Y LBlu -M +M B L . IG ST Regulator START switch...
  • Page 51 940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.com • www.robinamerica.com © Copyright 2001 Robin America, Inc. PRINTED IN THE USA...

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