Subaru Robin Power Products Portable Generator 13100T User Manual

SERVICE  
MANUAL  
Models  
RGV12100 / 13100T  
GENERATORS  
PUB-GS1328  
Rev. 09/01  
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04  
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1. SPECIFICATIONS  
Model  
RGV12100  
RGV13100T  
Brush, Self-exciting,  
2-pole, Single phase  
Brush, Self-exciting,  
2-pole, 3-phase  
Type  
Rated frequency  
Rated voltage  
Maximum output  
Rated output  
Power factor  
Voltage regulator  
Model  
60Hz  
120V / 240V  
12000VA  
9500VA  
1.0  
120V / 208V  
13000VA  
10000VA  
0.8  
A.V.R type  
EH65D  
C.T. type  
EH63D  
Type  
V-Twin cylinder, Air-cooled, 4-stroke, Overhead valve engine  
3
Displacement  
Maximum output  
Fuel  
653 cm  
22 HP/ 3600 rpm  
18 HP/ 3600 rpm  
Unleaded automobile gasoline (RON87 or higher)  
Oil capacity  
1.55 liters  
Electric starter  
44 liters  
Starting system  
Fuel tank capacity  
3/4 Rated  
Rated  
Approx. 9.0 hours  
Approx. 8.2 hours  
77.0 dB  
Approx. 9.7 hours  
Approx. 8.9 hours  
77.0 dB  
Rated continuous  
operation per a  
tankful of fuel  
Noise level  
Length  
Rated (dB-7m)  
826  
mm  
1
Width  
611 mm (752 mm * )  
1
Height  
771 mm (845 mm * )  
2
2
Dry weight  
141 kg (149 kg )  
143 kg (151 kg )  
*
*
*1: ( ) shows dimensions with castors.  
*2: ( ) shows dry weight with castors installed.  
- -  
1
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2. PERFORMANCE CURVES  
RGV12100  
(
Hz  
)
63  
Hz  
62  
61  
60  
( )  
V
250  
125  
(
(
(
(
)
)
)
)
240V/120V  
240  
120  
230  
115  
220  
110  
0
1/2  
4/4  
Load  
Rated  
RGV13100T  
(
Hz  
)
63  
Hz  
62  
61  
60  
( )  
V
230  
220  
210  
200  
208V  
0
1/2  
4/4  
Load  
Rated  
- -  
2
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3. GENERAL DESCRIPTION OF GENERATOR  
FUEL TANK  
TANK CAP  
CONTROL  
PANEL  
AIR CLEANER  
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  
CAP  
(RGV12100 only)  
END COVER  
(RGV13100T only)  
OIL GAUGE  
OIL DRAIN PLUG  
ELECTRIC STARTER  
- -  
3
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CONTROL PANEL  
(RGV12100)  
OIL PURESSURE  
WARNING LAMP  
VOLTMETER  
NO-FUSE BREAKER  
PILOT LAMP  
HOUR METER  
KEY SWITCH  
110  
120  
0
IDLE CONTROL  
SWITCH  
EARTH (GROUND)  
TERMINAL  
CONNECTOR  
FOR REMOTE CONTROL  
AC RECEPTACLE  
(RGV13100T)  
OIL PURESSURE  
WARNING LAMP  
VOLTMETER  
NO-FUSE BREAKER  
PILOT LAMP  
HOUR METER  
KEY SWITCH  
1
1
0
0
1
2
0
AC RECEPTACLE  
(
AC THREE PHASE  
and SINGLE PHASE  
RECEPTACLE  
EARTH (GROUND)  
TERMINAL  
)
- -  
4
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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)  
(RGV12100)  
SERIAL NUMBER  
stamped label  
- -  
5
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4. CONSTRUCTION AND FUNCTION  
4-1 CONSTRUCTION  
END COVER  
(RGV13100T only)  
BRUSH HOLDER  
STATOR COMPLETE  
STATOR BOLT  
REAR COVER  
ROTOR COMPLETE  
FRONT COVER  
TROUGH BOLT  
MOUNT RUBBER  
BALL BEARING  
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.  
- -  
6
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4-2-2 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 (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.  
It is necessary to keep the contact pressure  
between the brushes and slip rings withing  
specific limits. Thus, care must be taken of  
brush length.  
4-2-4 CURRENT TRANSFORMER  
/ DIODE UNIT (RGV13100T only)  
The current transformer and diode unit will perform a role to step up the voltage lowered by the  
load and stabilize the output voltage.  
1 2 3  
1 2 3  
1 2 3  
CURRENT TRANSFORMER  
DIODE UNIT  
- -  
7
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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.  
Function  
Description of Operation  
When the lubrication oil pressure drops below the safety limit (Oil pressure  
2
becomes less than 1kg/cm ) and/or the engine speed ups above the safety  
Warning lamp  
limit (Engine speed increases higher than 4,500 r/min for 7 seconds), the  
warning lamp repeats turning on and off, and the engine stops automati-  
cally. The warning lamp turns off after 3 minutes.  
When the engine started and reaches 1,050 r/min, the starter motor is  
automatically stopped.  
Starter motor control  
When the engine is operating, the starter motor can not start.  
- -  
8
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Function  
Description of Operation  
When the key switch or the remote control switch is turned to "START", the  
fuel cut-off valve of the carburetor opens. When the key switch or the  
remote control switch is turned to "STOP", the fuel cut-off valve closes.  
If the starter motor is locked by any reason, the starter motor is shut off  
automatically after 3 seconds.  
When the engine dose not start (engine speed does not reach 1,050  
r/min), the starter motor is stopped after 21 seconds.  
Fail-safe function  
When the remote controller is connected, the electric starter dose not run  
when the switch of remote controller is turned "OFF" even if the key switch  
on the generator is turned to "START".  
When the engine speed increases higher than 4,500 r/min for 7 seconds,  
the engine is shut down automatically and the warning lamp repeats turn-  
ing on and off for 3 minutes.  
When the key switch or remote control switch is turned to "START", the  
warning lamp lights up for a moment to indicate that the bulb for the warn-  
ing lamp is normal.  
Self checking function for  
warning lamp bulb  
4-2-7 IDLE CONTROL UNIT  
(RGV12100 only)  
1
The idle control unit  
releases throttle  
1
valve when the applied load current exceeds  
0.04A.  
The two output wires  
from the main coils  
2
must go through the ZCT  
direction.  
in the same  
3
NOTE :  
3
2
It is normal that the engine speed goes up for  
a moment when you turn the key switch to  
"STOP" while the Idle Control Switch is in  
"ON" position.  
- -  
9
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4-2-8 OIL PRESSURE SWITCH  
The oil pressure switch sends a signal to ECU to stop the engine when the engine oil pressure  
2
drops to 1.0 kg/cm  
4-2-9 RELIEF VALVE  
2
The relief valve begins to open when the engine's oil pressure increases above 3.0 kg/cm  
OIL FILTER  
CAMSHAFT  
OIL PRESSURE SWITCH  
CRANKSHAFT  
OIL PUMP  
RELIEF VALVE  
OIL PUMP FILTER  
4-2-10 AC SWITCH (NO-FUSE BREAKER)  
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  
60Hz-120V/240V  
60Hz-120V/208V  
No-fuse Breaker  
Object of Protection  
Total output amperage  
Total output amperage  
RGV12100  
RGV13100T  
39A  
24A  
10  
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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, are  
used. As many AC plugs as the receptacles, each matching the corresponding receptacle, are  
provided.  
The rated current for each receptacle is shown as follows;  
CAUTION  
Be careful not to use the receptacles  
beyond the specified amperage limits to  
prevent burning.  
MAX 20A  
MAX  
30A  
MAX  
30A  
MAX  
50A  
MAX  
20A  
MAX  
20A  
AC120V  
AC 120V / 240V  
30A or less 20A or less  
30A or less  
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  
type receptacle, insert the plug in to the  
receptacle and then turn it clockwise to  
lock.  
TWIST  
11  
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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.  
Style  
Ampere  
Receptacle  
AC plug  
Description  
GFCI (Ground Fault Circuit  
Interrupter) Receptacle, duplex  
(REC1)  
NEMA  
5-20R  
NEMA  
5-20P  
up to 20A  
NEMA  
L5-30R  
NEMA  
L5-30P  
Locking Receptacle  
(REC2)  
up to 30A  
up to 30A  
up to 50A  
up to 30A  
NEMA  
L14-30R  
NEMA  
L14-30P  
Locking Receptacle  
(REC3)  
Locking Receptacle  
(REC4)  
NEMA  
L21-30R  
NEMA  
L21-30P  
Locking Receptacle  
(REC5)  
TABLE 1  
NOTE :  
When the no-fuse breaker turns off during operation, the generator is over loaded or the appli-  
ance is defective. Stop the generator immediately, check the appliance and / or generator for  
overloading or detect and have repaired as necessary by Robin dealer or service shop.  
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.  
12  
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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.  
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.  
CONNECTING TO DOMESTIC CIRCUIT (HOUSE WIRING)  
WARNING  
This generator is neutral grounded 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, dam-  
age to appliances, damage to the building's wiring or fire.  
(a) When connecting 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.  
13  
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UTILITY HIGH LINE  
CONNECTING BOX  
MAIN POWER LINE  
240V  
RECEPTACLE  
TRANSFER SWITCH  
Utility high line  
House circuit breaker  
Meter box  
X W Y  
X W Y  
120V  
appliance  
240V  
appliance  
120V  
appliance  
Transfer  
switch  
X W Y  
Generator  
Generator  
( )  
( )  
W
W
W
OR  
X
Y
( )  
X
( )  
Y
( )  
Y
( )  
X
( )  
G
( )  
G
240V  
4P- Receptacle  
240V  
4P- Receptacle  
14  
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(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.  
Otherwise the appliance (s) may be damaged by the surge voltage at starting.  
4-2-12 3-PHASE APPLICATION (RGV13100T only)  
Connection of Power Cables  
WARNING  
Do not touch output terminals while the generator is running or the operator may suf-  
fer severe electric shock resulting in death.  
Be sure to shut down the generator before connecting or changing connection of  
power cables to the generator.  
This generator has four output terminals of three phase, four wire system.  
Connect power cables to the generator output terminals according to the type of application.  
15  
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AC (THREE PHASE) RECEPTACLE  
(RGV13100T only)  
RGV13100T has a receptacle for three plase  
(208V) and single phase (120V) as follows :  
W
Z
X
Y
SINGLE PHASE AC120V  
THREE PHASE AC208V  
Three phase application (208V)  
Insert the plug into the receptacle X, Y and  
Z.  
W
G
X
Z
Generator rated output : 10000VA  
Y
3-PHASE OUTPUT  
Single phase lower application (120V)  
Insert the plug into the receptacle W and X,  
W and Y, W and Z.  
W
G
X
Maximum one-third (1/3) of generator output  
can be utilized from each phase.  
Z
Generator rated output :  
3324VA (120V x 27.7A)  
Y
SINGLE-PHASE OUTPUT  
16  
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4-3 DESCRIPTION of GENERATOR OPERATION  
4-3-1 PRIMARY EXCITING ACTION  
(RGV12100)  
AVR  
When the generator is started, the perma-  
nent magnet on the engine rotates to genera-  
tor a voltage in the exciting coil.  
FC  
This voltage is regulated by a diode in the  
AVR to feed a current to the generator field  
coil. (FC). (See Fig. 4-1)  
a
EC  
The rotor is turned an electromagnet by that  
current and rotates so that voltage are gener-  
ated in the stator coils (main coil and sub  
coil). The voltage generated in the sub coils  
is operated by the AVR to feed a current to  
increase the field coil current. (See Fig. 4-2)  
As a result, the rotor magnetism increases.  
This operation is repeated to generate the  
rated voltage at 50 Hz or 60 Hz in the main  
coil and DC coil.  
ENGINE MAGNETO  
Fig. 4-1  
MC  
SC  
4-3-2 VOLTAGE REGULATING MECHANISM  
(RGV12100)  
b
FC  
AVR  
Connect a load to the AC output terminal and  
increase current. Output voltage varies as  
shown in Fig. 4-3 depending on whether an  
automatic voltage regulator is used or not.  
The operation of the AVR is explained below.  
When an AC output is taken, the engine is  
loaded and its rpm falls, Also the AC voltage  
fails due to the voltage drop caused by the  
internal resistance of the coils. The AVR  
detects this voltage drop and its built-in SCR  
automatically increase the current flows to  
the field coil. As a result, the rotor magnetism  
increase, the voltage fallen by the load cur-  
rent is raised, and the output voltage is kept  
constant. If the AC output is reduced, the  
SCR operates in the opposite way to similarly  
keep the output voltage constant.  
Fig. 4-2  
WITHOUT AVR  
RATED VOLTAGE  
V
WITH AVR  
A
Fig. 4-3  
17  
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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. This magnetizing current passing  
through a diode to field coil creates a strong magnetic field in the rotor which falls with the  
amount of the load, increasing the voltage.  
GENERATOR  
CONTROL BOX  
AC output receptacle  
(120V : Single phase)  
(208V : Three phase) REC5  
AC output  
receptacle  
Grn  
R
Grn  
(
)
120V  
REC1  
Hour  
meter  
No-fuse  
breaker  
Pilot  
1
3
Y
R
Hr  
V
PL  
lamp  
G
R
2
W
Z
W
H
X
1
3
Y
Y
G
W
W
2
W
G
W
1
3
Y
Blk  
Blk  
2
Blk  
AC output receptacle  
Current  
transformer  
(
)
120V REC2  
Brush  
Brn  
Brush  
Grn/W  
(
)
Key switch -M  
Earth  
(Ground)  
terminal  
Grn/Y  
4-3-4 THE ADVANTAGES OF CURRENT TRANSFORMER CONTROL (RGV13100T)  
With AVR control, control is effected according to variations in output voltage.  
When an inductive load is applied, a large starting current is required (current variations are  
greater than voltage variation), precise control becomes difficult.  
Current transformer control, on the other hand, controls the output voltage according to the  
load current, which is better for using inductive load.  
18  
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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.  
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-venti-  
lated 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 (3 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 thor-  
oughly 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 insulation s 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.  
7. Be sure to check and remedy the cause of circuit breaker tripping before re-setting 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 opera-  
tion immediately and carefully check the electrical appliance and AC plugs  
for faulty wiring.  
19  
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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). The power con-  
sumption of an electrical appliance is the power necessary for using it. When using a generator  
for operating an electrical appliance, the power factor and starting wattage must be taken into  
consideration.  
In order to determine the right size generator, it is necessary to add the total wattage of all  
appliances to be connected to the unit.  
Refer to the followings to calculate the power consumption of each appliance or equipment by  
its type.  
(1) Incandescent lamp, heater, etc. with a power factor of 1.0  
Total power consumption must be equal to or less than the rated output of generator.  
Example : A rated 3000 W generator can turn thirty 100W incandescent lamps on.  
(2) Fluorescent lamps, mercury lamps, etc. with a smaller power factor  
Select a generator with a rated output equivalent to 1.2 to 2 times of the power consump-  
tion of the load.  
Example : A 400W mercury lamp requires 600 W to 700 W power source to be turned on.  
A rated 3000 W generator can power four or five 400 W mercury lamps.  
NOTE 1 : If a power factor correction capacitor is not applied to the mercury lamp or fluorescent  
lamp, the more power shall be required to drive those lamps.  
A rated 3000W generator can drive one or two 400W mercury lamps without power fac-  
tor correction capacitors.  
NOTE 2 : Nominal wattage of the fluorescent lamp generally indicates the output wattage of the  
lamp.  
Therefore, if the fluorescent lamp has no special indication as to the power consumption,  
efficiency should be taken into account as explained in item (5) on the following page.  
(3) Motor driven tools and light electrical appliances  
Generally the starting wattage of motor driven tools and light electrical appliances are 1.2  
to 3 times lager than their running wattage.  
Example : A rated 250 W electric drill requires a 400 W generator to start it.  
(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.  
These appliances require large starting wattage which is 3 to 5 times of running wattage.  
Example : A rated 900 W compressor requires a 4500 W generator to drive it.  
NOTE 1 : Motor-driven appliances require the aforementioned generator output only at the starting.  
Once their motors are started, the appliances consume about 1.2 to 2 times their rated  
power consumption so that the excess power generated by the generator can be used for  
other electrical appliances.  
20  
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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 the  
optimum generator capacity, select a generator with a larger capacity.  
(5) Appliances without any indication as to power consumption  
Some appliances have no indication as to power consumption; but instead the work load  
(output) is indicated. In such a case, power consumption is to be worked out according to  
the numerical formula mentioned below.  
(Output of electrical appliance)  
(Power consumption)  
(Efficiency)  
Efficiencies of some electrical appliances are as follows:  
Single-phase motor ・・・・・・・・ 0.6 to 0.75  
The smaller the motor, the lower  
the efficiency.  
Three-phase motor・・・・・・・・・ 0.65 to 0.9  
Fluorescent lamp・・・・・・・・・・ 0.7 to 0.8  
Example 1 : A 40 W fluorescent lamp means that its luminous output is 40W. Its efficiency is  
0.7 and accordingly, power consumption will be 40 0.7=57W. As explained in  
÷
Item(2), multiply this power consumption value of 57 W by 1.2 to 2 and you will  
get the figure of the necessary capacity of a generator. In other words, a genera-  
tor with a rated output of 1000 W capacity can light nine to fourteen 40W fluores-  
cent lamps.  
Example 2 : Generally speaking, a 400 W motor means that its work load is 400 W.  
Efficiency of this motor is 0.7 and power consumption will be 400 0.7=570 W.  
÷
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  
Fluorescent Lamp, Electric Tool  
Pump, Compressor  
10000  
4950  
2500  
21  
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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.  
Table 7-2 shows cables and their allowable currents for your reference.  
2. Cable length  
If a long cable is used, a voltage drop occurs due to the increased resistance in the conduc-  
tors decreasing the input voltage to the load (electrical product). As a result, the load can be  
damaged.  
Table 7-2 shows voltage drops per 100 meters of cable.  
Nominal A.W.G.  
Allowable No.of strands  
Resistance  
cross  
Gauge  
No.  
Current Amp.  
current  
/ strands dia.  
section  
2
mm  
No.  
18  
A
No./mm  
30/0.18  
50/0.16  
37/0.26  
45/0.32  
70/0.32  
1A 3A 5A 8A 10A 12A 15A  
Ω/100m  
0.75  
1.27  
2.0  
7
2.477 2.5V 8V 12.5V  
16  
12  
17  
23  
35  
1.486 1.5V 5V 7.5V 12V 15V 18V  
14  
0.952  
0.517  
0.332  
1V 3V 5V 8V 10V 12V 15V  
3.5  
12 to 10  
10 to 8  
1.5V 2.5V 4V 5V 6.5V 7.5V  
1V 2V 2.5V 3.5V 4V 5V  
5.5  
1
100  
I
× × ×  
Voltage drop indicates as V=  
R
R
I
means resistance (Ω / 100 m) on the above table.  
means electric current through the wire (A).  
means the length of the wire (m).  
The length of wire indicates round length, it means twice the length from generator to  
electrical tools.  
22  
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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  
0 to 150 V, 0 to 330 V : Dual voltage type  
FOR AC  
(2) AMMETER  
AC ammeter is necessary.  
An AC ammeter with a range that can be  
changed according to the current rating  
of a given generator is most desirable.  
(About 10 A, 20 A, 100 A)  
FOR AC  
(3) FREQUENCY METER  
Frequency range : About 45 to 65Hz  
NOTE : Be careful of the frequency meter's input  
voltage range.  
23  
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(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  
A
~
F
V
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. Adjust the load and rpm. and check that the voltage range is as speci-  
fied in the following table at the rated amperage and rated rpm.  
24  
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Rated voltage  
208 V  
Model  
120 V  
240 V  
RGV12100  
RGV13100T  
112V  
-
128V  
--------------  
224V  
-
256V  
--------------  
218V-249V  
--------------  
7-3 MEASURING INSULATION RESISTANCE  
Use a megger tester to check the insulation  
resistance. Connect a megger tester to one  
of receptacle output terminals and the ground  
terminal, then measure the insulation resis-  
tance.  
Ω
An insulation resistance of 1M or more is  
normal.  
Ω
If it is less than 1M , disassemble the gen-  
erator and measure the insulation resistance  
of the stator, rotor and control panel individu-  
ally.  
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.  
(4) Measure the insulation resistance  
between RED lead and the core.  
25  
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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  
Ω
transformer.  
Any part where the insulation resistance is  
Ω
less than 1M has faulty insulation, and may  
cause electric leakage and electric shock.  
Replace the faulty part.  
26  
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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.  
8-2 AC RECEPTACLES  
Using a circuit tester, check continuity  
between the two terminals at the rear of the  
AC receptacles while the receptacle is  
mounted on the control panel. When continu-  
ity is found between the output terminals of  
the receptacle with a wire connected across  
these terminals, the AC receptacle is normal.  
When the wire is removed and no continuity  
is found between these terminals, the recep-  
tacles are also normal.  
27  
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8-3 AC SWITCH (NO-FUSE BREAKER)  
Check continuity between each of 2 terminals at the back side of AC switch (no-fuse breaker)  
while it is mounted on the control panel.  
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.  
NOTE : If the circuit tester is not sufficiently accu-  
rate, it may not show the values given and  
may give erroneous readings.  
Erroneous readings will also occur when  
there is a wide variation of resistance  
among coil windings or when measure-  
ment is performed at ambient tempera-  
tures different from 20  
(68 F).  
°
Stator coil  
Black Red  
Model  
Hz/Voltage  
White  
Light green  
-
Red-White  
Black  
-Blue  
-
Black-White  
RGV12100  
60/120/240  
------------  
------------  
0.11Ω  
0.11Ω  
0.37Ω  
RGV13100T 60/120/208  
------------  
------------  
0.23Ω  
0.23Ω  
0.23Ω  
28  
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8-5 ROTOR ASSEMBLY  
1) Field coil  
Remove the brush holder and measure resistance between the slip rings.  
Rotor (Slip ring)  
Resistance  
RGV12100  
4.11Ω  
RGV13100T  
69.6Ω  
NOTE : If the circuit tester is not sufficiently accu-  
rate, it may not show the values given and  
may give erroneous readings.  
Erroneous reading will also occur when  
there is a wide variation of resistance  
among coil windings or when measure-  
ment is performed at ambient tempera-  
tures different from from 20 (68 F).  
°
ROTOR  
2) Cleaning Slip rings  
SLIP RING  
The slip ring surfaces must be uniformly  
bright. Slip rings showing black spots,  
excessive wear, or uneven wear must be  
repaired. A stained slip ring lowers gener-  
ator efficiency and output voltage. Polish  
the slip rings with fine sandpaper while  
turning the rotor until rough spots disap-  
pear. Care should be taken not to touch  
the rotor coils with the sandpaper.  
SANDPAPER  
8-6 EXCITING COIL (RGV12100 only)  
1) Disconnect the two yellow wires which  
come out from the exciting coil through the  
hole of the crankcase and connected with  
A.V.R. in the control box.  
2) Check the resistance between two yellow  
wires with a circuit tester.  
Exciting coil for A.V.R.  
Resistance  
RGV12100  
2.35Ω  
3) Check the AC voltage between these two  
yellow wires when the engine speed at no  
AC voltage  
35 to 45 V  
load ; 3600-3800 rpm with a circuit tester.  
29  
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8-7 BRUSH  
The brushes must be smooth where they  
contact the slip rings. If not, polish smooth  
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  
mm (0.2 " to 0.6").  
BRUSH  
HOLDER  
15 to 5 mm  
(0.6" to 0.2")  
A brush shorter than 5 mm must be replaced  
because decreased contact pressure  
between the brush and slip ring lowers gen-  
erator efficiency and output voltage.  
BRUSH  
8-8 A.V.R  
(AUTOMATIC VOLTAGE REGULATOR)  
2
1
4
3
1) Features  
Terminal number  
of the A.V.R.  
This AVR operates to control the field current  
in order to maintain the output voltage for the  
AC current, which generated by the magnetic  
flux by the field coil.  
Yellow  
2) A.V.R. trouble may be identified by simply  
looking at the A.V.R., or by the inter-lead  
resistance with a tester, or actually mount-  
ing it in the generator and operating it.  
(a) A.V.R. TROUBLE IDENTIFICATION by APPEARANCE  
If an A.V.R. electronic part is burnt dark, or the surface epoxy resin melted, it often indi-  
cates A.V.R. trouble.  
(b) IDENTIFYING A.V.R. TROUBLE by CHECKING INTER-LEAD RESISTANCE  
Check the inter-lead resistance of the A.V.R. with a tester, referring to the following table.  
If the tester readings very greatly from the values specified in the table on next page, the  
A.V.R. is faulty.  
NOTE : Take teater inaccuracy into account in reading the tester.  
(c) IDENTIFYING A.V.R. TROUBLE by MOUNTING and OPERATING in THE GENERATOR  
SCR or transistor damage cannot be detected by simply looking at the A.V.R. or checking  
the lead resistance. Check it by mounting the suspectedly faulty A.V.R. in a normal gener-  
ator, or mount a mormal A.V.R. in a generator which fails to generate voltage.  
30  
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* Checking table for analogue circuit tester.  
Apply black  
-
needle of the circuit tester  
Analogue circuit tester  
Yellow  
Yellow  
---------------  
1
2
3
4
Black  
White  
Light green  
Brown  
orYellow  
---------------  
60 kΩ  
1
2
Black  
White  
200 kΩ  
---------------  
125 kΩ  
100 kΩ  
300 kΩ  
100 kΩ  
14 kΩ  
Apply red
needle of  
the circuit  
tester  
---------------  
3
Light green  
16 kΩ  
350 kΩ  
250 kΩ  
---------------  
4
Brown  
orYellow  
8-9 CURRENT TRANSFORMER  
(RGV13100T only)  
Disconnect the connectors and couplers of  
current transformer.  
Check the inter-terminal resistance of current  
transformer with a circuit tester.  
Terminal number  
1 and 2  
1 and 3  
2 and 3  
RGV13100T  
2.00Ω  
2.00Ω  
0.009Ω  
If current transformer is found to be faulty, replace with new one.  
8-10 ECU (ELECTRONIC CONTROL UNIT)  
Check the resistance between 13 terminals  
of ECU with circuit tester.  
1
2
3
4
9
5
8
6
7
13  
12  
11  
10  
Terminal number of the ELECTRONIC CON-  
TROL UNIT  
31  
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Tester (  
-)  
Pin No.  
1
1
-------  
2
3
4
5
6
7
8
9
!
0
!
1
!
2
!
3
-------  
-------  
-------  
-------  
-------  
2
18.4M  
10M  
10.2M  
10.4M  
11M  
14.4M  
5.3M  
3
-------  
0.1  
-------  
4
-------  
-------  
-------  
0.1  
5
6
Tester  
(
)
2675  
k
7
2590  
k
8
9
-------  
5.3M  
2392  
k
2389  
k
2438  
k
2664  
k
4
M
!
!
!
!
0
1
2
3
-------  
5.3M  
18M  
10.3M  
10.2M  
10.3M  
11M  
14M  
8-11 IDLE CONTROL UNIT  
(RGV12100 only)  
Check the resistance between five terminals  
of IDLE CONTROL UNIT with circuit tester.  
1
5
2
3
4
Terminal number of the IDLE CONTROL  
UNIT  
Apply black  
-needle of the circuit breaker  
Circuit tester (with battery  
power source 1.5 V)  
1
2
3
4
5
-------  
65  
65  
30  
1
2
3
4
5
-------  
Apply red +  
65  
-------  
65  
-------  
6.5  
30  
30  
-------  
needle of the cir-  
cuit breaker  
65  
65  
6.5  
6.5  
*Tester measuring range : 1000 k  
NOTE : The resistance readings vary depending on the types of circuit testers.  
The above table shows an example of the resistance readings measured by an ordi-  
nary analogue circuit tester with 1.5 volt battery power source.  
It is advisable for you to check the resistance readings using your standard circuit  
tester and revise the checking table.  
32  
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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  
Yellow 2  
Yellow 3  
Light green  
-------  
16  
-------  
Apply red +  
needle of the cir-  
cuit breaker  
16  
-------  
16  
-------  
16  
30  
16  
16  
-------  
33  
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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.  
3) To prevent bolts and nuts from being misplaced or installed incorrectly, replace them tem-  
porarily to their original position.  
4) Handle disassembled parts with care; clean them before reassemble using a neutral clean-  
ing fluid.  
5) Use all disassembly / assembly tools properly, and use the proper tool for each specific job.  
9-2 DISASSEMBLY PROCEDURES  
9-2-1 CONTROL PANEL  
(1) Remove the front panel.  
(2) Disconnect the connectors on the wiring  
from the front panel to the alternator.  
9-2-2 ALTERNATOR  
(1) Remove the end cover.  
(2) Remove the brush cover and the brush  
holder.  
(3) Take off the two flange-nuts and lift the  
front cover with a piece of lumber.  
(See Fig. 9-1)  
Fig. 9-1  
NOTE : Lift the front cover until completely  
the rear cover removes from the  
mount rubber. (See Fig. 9-2)  
REAR COVER  
(4) Remove the rear cover.  
(5) Remove the bushing.  
(6) Remove the stator cover.  
MOUNT RUBBER  
Fig. 9-2  
34  
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(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.  
(See Fig. 9-4)  
ROTOR  
THROUGH  
BOLT  
NOTE : Temporarily tighten the through bolt  
of the rotor when hit the rotor.  
(See Fig. 9-4)  
(10) Remove the front cover.  
SOFT  
HAMMER  
Fig. 9-4  
9-3 COMPONENT PARTS  
For disassembling and assembling, the following illustrations show the major component parts  
and 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.  
35  
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(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  
36  
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(2-1) Control Box (RGV12100)  
PLATE  
CONTROL BOX  
GROMMET  
WIRE  
IDLE CONTROL  
UNIT  
A.V.R.  
(
AUTOMATIC  
VOLTAGE  
REGULATOR  
)
ECU (P4)  
CONNECTOR  
CAP  
CONNECTOR  
for REMOTE  
CONTROL  
EARTH  
(
)
GROUND  
TERMINAL  
RELAY  
CLAMP  
GROMMET  
IDEL CONTROL  
SWITCH  
AC RECEPTACLE  
NO-FUSE  
BREAKER  
CONTROL  
PANEL  
STARTER SWITCH  
HOUR METER  
AC RECEPTACLE  
PILOT LAMP  
OIL PRESSURE  
WARNING LAMP  
VOLTMETER  
37  
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(2-2) Control Box (RGV13100T)  
CURRENT TRANSFORMER  
PLATE  
CONTROL BOX  
DIODE UNIT  
GROMET  
EARTH  
05  
(
)
GROUND  
TERMINAL  
(
)
ECU P4  
RELAY  
CLAMP  
GROMMET  
WIRE  
PILOT LAMP  
AC RECEPTACLE  
OIL PRESSURE  
WARNING LAMP  
NO-FUSE BREAKER  
AC RECEPTACLE  
STARTER SWITCH  
HOUR METER  
VOLTMETER  
CONTROL PANEL  
38  
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(3) Fuel Tank  
FUEL TANK CAP  
FUEL GAUGE  
FILTER  
FUEL FILTER  
FUEL TANK  
PACKING  
FRANGE BOLT  
(
)
M6 x 14 mm  
CUP  
HOSE CLAMP  
DETAIL A  
A
RUBBER  
(
)
PIPE 120 mm  
FUEL STRAINER  
FLANGE BOLT  
PURSE  
LOCK  
RUBBER  
WASHER  
(
)
M6 x 14 mm  
FUEL PUMP  
HOSE  
CLAMP  
RUBBER  
(
)
PIPE 630 mm  
39  
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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  
tighten the bolts.  
WASHER  
Tightening torque  
230  
22.5  
16.6  
-250 kg cm  
SPRING WASHER  
-24.5 N m  
BOLT  
-19.5 ft lbs  
Fig. 9-5  
9-4-2 ROTOR  
(1) Wipe off oil, grease and dust from the  
tapered portion of engine shaft and  
matching tapered hole of rotor shaft.  
(2) Mount the rotor to the engine shaft.  
Tighten the through bolt.  
Tightening torque  
120  
11.8  
8.7  
-140 kg cm  
-13.7 N m  
-10.1 ft lbs  
Fig. 9-6  
40  
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9-4-3 STATOR  
(1) Put the stator in the rear cover setting the  
four grooves on the side of stator with  
thread holes of the rear cover.  
STATOR  
STATOR COVER  
Tighten the four bolts tentatively to check  
if the grooves and thread holes are  
aligned correctly. (See Fig.9-8)  
(2) Remove the four bolts.  
Fig. 9-7  
Fig. 9-8  
41  
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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.  
Press the smaller end of the bushing into  
the window of the rear cover.  
Fig. 9-9  
(2) Tap on the rear cover evenly with a plastic  
hammer to press the rotor bearing into  
the rear cover.  
(3) Fix the rear cover with four bolts, spring  
washers, and washers.  
Tightening torque  
120  
11.8  
8.7  
-140 kg cm  
-13.7 N m  
Fig. 9-10  
-10.1 ft lbs  
(4) Install the brush holders in the rear cover.  
Pass the mounting screws through the  
brush holders, push the brush holders so  
that the brushes will be perpendicular to  
the slip rings, and tighten the screws.  
BRUSH  
HOLDER  
FLANGE  
BOLT  
NOTE : There are two kinds of brush holders.  
If a brush is installed oblique to the  
slip ring, the brush holder can break  
when the screw is tightened ; or the  
brush may break when the generator  
of started.After installing the brush  
holders, measure the resistances  
across the brushes and terminals  
with a tester if they are from 5 ohms  
to 7.5 ohms.If so, the brush holders  
are correctly mounted.  
SCREW  
BRUSH  
COVER  
Fig. 9-11  
42  
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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.  
Fig. 9-12  
Tightening torque  
120  
11.8  
8.7  
-140 kg cm  
-13.7 N m  
-10.1 ft lbs  
NOTE : When tightening the nuts, slightly lift the  
alternator assembly so that the weight is  
not applied to the mount rubbers.  
(7) Fasten the earth cable to the unpainted  
bolt hole on the frame.  
EARTH CABLE  
Fig. 9-13  
43  
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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.  
If insulation is NG, replace brush and slip ring with new one.  
* Check stator for winding resistance between terminals. (Refer to 8-4.)  
If stator is faulty, replace with new one.  
(Refer to 8-5 and 8-7.)  
* Checking stator for insulation resistance.  
If insulation is NG, replace stator with new one.  
* Checking the A.V.R . (RGV12100)  
(Refer to 7-3.)  
(Refer to 8-8.)  
If insulation is NG, replace A.V.R with new one.  
* Checking the diode unit and C.T . (RGV13100T)  
(Refer to 8-9 and 8-12.)  
If insulation is NG, replace diode unit and C.T with new one.  
10-2 AC Voltage is too high or too low  
* Check engine speed.  
Nominal engine speed at no load ; 3,700 to 3,750 rpm  
If engine speed is too high or too low, adjust to the rated rpm.  
* Check stator for winding resistance and insulation.  
* Check rotor for resistance and insulation.  
(Refer to 8-4 and 7-3.)  
(Refer to 8-5 and 7-3.)  
(Refer to 8-11.)  
* Checking the idle control unit. (RGV12100)  
If insulation is NG, replace idle control unit with new one.  
10-3 AC voltage is nominal at no-load, but load cannot be applied.  
* Check engine speed.  
If engine speed is low, adjust to the rated rpm.  
* Check total wattage of appliances connected to generator.  
If the generator is overloaded, reduce the load to the rated output of generator.  
* Check appliance for trouble.  
If the appliance is faulty, replace it.  
* Check if engine is overheated.  
If generator cooling air inlet and/or outlet is clogged with dirt, grass, chaff or other debris,  
remove it.  
* Check insulation of generator.  
(Refer to 7-3.)  
44  
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10-4 Engine dose not run.  
Symptom  
Possible causes  
Remedy  
1) The key switch (or remote  
switch) is turned to "START"  
within 2 seconds the engine has  
been stopped.  
Wait for more than 2 seconds and then turn the  
key switch to "START" position.  
Both the key switch of the generator and the  
switch of remote controller must be turns into  
"ON" position.  
1. Electric starter  
dose not operate  
2) The remote controller is con-  
nected.  
3) The above possible causes 1)  
and 2) dose not apply.  
The ECU is defective.  
Replace with new one.  
1) No fuel in the tank or the fuel  
cock is closed.  
Supply fuel or open the fuel cocks.  
Add or change engine oil.  
2. Warning lamp  
turns on and off  
when engine is  
stopped  
2) Oil level is low or oil is contami-  
nated.  
3. Engine is auto-  
matically stopped  
but the warning  
lamp dose not  
light up  
1) The bulb of warning lamp failed.  
Replace the bulb with a new one.  
45  
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11. WIRING DIAGRAM  
(RGV12100)  
CONTROL BOX  
R
LGrn  
Auto choke  
W
W
W
(
)
Bimetal  
Grn  
Gry  
Fuel cut  
Oil pressure  
warning lamp  
R/W  
R
Blk/W  
(
)
Red  
Blk/W  
Blk  
(AC output)  
Ignition coil  
W
W
Blk  
Idle  
solenoid  
1
2
3
4
5
6
Electronic control unit  
LBlu  
1
5
2
3
W
W
W
W
13 12 11 10 9  
8
7
4
Idle  
Org  
control  
unit  
Charge  
coil  
Exciting  
coil  
Grn/Y  
Idle control  
switch  
Y
Brn  
Org  
Org  
R
Y
Y
LBlu  
(
)
AVR  
Org  
R
Grn/Y  
Org  
Grn/Y  
Electric  
starter  
Magnetic  
switch  
Grn/Y  
LBlu  
Grn  
Gry  
.
-M +M  
B
L IG ST  
OFF  
ON  
Key  
switch  
Grn  
Regulator  
START  
to earth  
terminal  
R15  
Gry  
ST Relay  
-
+
Oil pressure  
switch  
Battery 12V  
Grn/Y LBlu  
Grn Gry  
Connector  
(
)
Remote control  
W
AC output  
AC output  
AC output  
receptacle(120/240V)  
receptacle(120V)  
receptacle(120/240V)  
GENERATOR  
CONTROL BOX  
Grn/Y  
Blk  
Blk  
REC5  
G
REC1  
REC2  
G
G
G
REC4  
Field  
Winding  
W
W
Y
Y
H
H
X
X
W
W
G
Blu  
R
R
AC otuput  
receptacle(120V)  
Hr  
V
PL  
Brush  
REC3  
Auxiliary  
Winding  
W
Grn/Y  
W
W
No-fuse breaker  
Blk  
W
W
LGrn  
LGrn  
Brm  
AVR  
Brm  
Key switch -M  
Idle control unit 3  
Y
Y
Earth(Ground)  
terminal  
Grn/Y  
Y Y  
Exciting coil  
(Engine)  
Wiring color cord  
Blk  
:
:
:
:
:
Black  
Brn/W  
:
:
:
:
:
Brown/White  
Green  
R
W
Y
:
:
:
:
:
Red  
Blk/R : Black/Red  
Blk/W  
Blu  
Black/White  
Blue  
Grn  
White  
R/W : Red/White  
Grn/W  
Org  
Green/White  
Orange  
Yellow  
Pink  
LGrn : Light green  
LBlu  
Brn  
Light blue  
Brown  
Pik  
Gry  
Gray  
Grn/Y  
Green/Yellow  
46  
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(RGV13100T)  
CONTROL BOX  
LGrn  
Fuel cut  
W
W
Oil pressure  
warning lamp  
R/W  
R
Blk/W  
Blk  
Grn  
Gry  
Ignition coil  
Blk/W  
(
)
Red  
W
W
1
2
3
4
5
6
Electronic control unit  
13 12 11 10 9  
8
7
-
+
Org  
Charge  
coil  
Battery 12V  
Grn/Y  
Blk  
Y
Org  
R
Brn  
Org  
R
Org  
Grn/Y  
Electric  
starter  
Magnetic  
switch  
Org  
Grn  
Gry  
Grn/Y  
LBlu  
.
-M +M  
B
L IG ST  
Blk  
Blk  
OFF  
Grn  
ON  
Key  
switch  
Regulator  
START  
to earth  
terminal  
Gry  
ST Relay  
Oil pressure  
switch  
GENERATOR  
CONTROL BOX  
AC output receptacle  
(120V : Single phase)  
(208V : Three phase) REC5  
AC output  
receptacle  
Grn  
Grn  
R
(
)
120V  
REC1  
Hour  
meter  
No-fuse  
breaker  
Pilot  
1
3
Y
R
Hr  
V
PL  
lamp  
G
R
2
2
2
W
Z
W
H
X
1
3
Y
Y
G
W
Blk  
W
W
G
W
1
3
Y
Blk  
Blk  
AC output receptacle  
Current  
transformer  
(
)
120V REC2  
Brush  
Brush  
Brn  
Grn/W  
(
)
Key switch -M  
Earth  
(Ground)  
terminal  
Grn/Y  
47  
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940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212  
© Copyright 2001 Robin America, Inc.  
PRINTED IN THE USA  
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