SERVICE MANUAL Model RGV7500 PlJB-GS1436 Rev.
Section Title Page l.'SPECIFICATIONS....................................................................................................... 1 2 PERFOMANCE CURVES........................................................................................... 2 3. FEATURES .................................................................................................................. 3 . 3-1 A.V.R. ALTERNATOR .............................................................................................
Title . Page 9-4STATOR .............................................................................................................. 30 Sectior! ........................................................................................... 30 9-6 BRUSH................................................................................................................ 31 9-7 A.V.R. (AUTOMATIC VOLTAGE REGULATOR).................................................. 31 9-8 IDLE CONTROL UNIT ......................
1. SPECIFICATIONS j: Model RGV7500 Brush, Self Exciting, 2-Pole, Single Phase 60 Hz ~~ ~ ~ ~ Maximum Output 7300 W Rated Output 6000 W U Voltage Rated Current Power Factor DC Output Regulator Voltage 120V1240V I V-8.3 12 A (100 W) I I Type AVR I I Air-Cooled 4-Cycle, Overhead Valve Gasoline EngineI 1.o EH41D Model in.) (24.63 cu. cm3 404 Displacement 9.5 Rated Output I hours 7.0 Approx. Dry Weight I I I I 0.32 U S . gal. (1.2 liters) Oil Capacrty Dimensions (L x Wx H) I 7.
2. PERFOMANCE CURVES RGV7500 / 60 Hz (6.0kVN240V) Load Rated DC OUTPUT DC Voltage................. 12 V DC Ampere ................ 8.3A DC output................... 100 W The voltage curve shownin the left indicates the characteristicof DC output when charging a battery. The voltage may be decreasedby 20% when the resistanceload is applied. NOTE :It is possible to use both DC and AC outputs simultaneously up to the rated output in total.
3. FEATURES 3-1 AVR ALTERNATOR Output votage becomes more stable due to AVR system. 3-2 OIL SENSOR Oil sensor automatically shutsoff the engine whenever theoil level fallsdown below the lowerlimit to protect the engine from seizure. 3-3 QUIET OPERATION Robin RGV series generator delivers a quiet operation with : A quiet 4-stroke Robin Rro OHV engine. Extra large muffler and large air cleaner provide remakable quiet operation.
3-9LONG-LIFE DURABILITY The heavy-duty 4 stroke Robin OHV engine : Full rubber mount in a sturdy tubular frame. * A forged steel crankshaft supported by two main ball bearings. A pointless electronic ignition system. * A cast-iron cylinder liner.
4.
4-2 CONTROL PANEL HOUR VOLTMETER METER :\.ET3iSTARTER \ IDEL TYPE) : ; F E Y I \ ’ BREAKER SWITCH \ PILOT LAMP A K C L E I I NO-FUSE DC OUTPUT TERMINAL DC CIRCUIT BREAKER SWITCH ENGINE (RECOIL STARTER TYPE) 4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped onthe LABEL (MODEL NAME) stuck on the side wall of rear cover.
5. CONSTRUCTION AND FUNCTION 5-1 CONSTRUCTION STATOR. COMPLETE COVER TROUGH FRONTBOLT EARING BALL RUBBER MOUNT Fig. 5 1 5-2 FUNCTION 5-2-1 STATOR The stator consists of a laminated silicon steel sheet core, a main coil and a condenser coil which are wound in the core slots. The condensercoil excites the rotor field coil which generates AC voltage in the main coil. 3 Fig.
5-2-2 ROTOR The rotor consistsof a laminated siliconsteel sheet core and a field coil which is wound overthe core. DC current in the field coil magnetizes the steel sheet core. Two permanent magnets are provided for the primary exciting action. Slip rings are provided on the rotor shaft to receive DC exciting current from A.V.R.. Fig. 5-3 5-2-3 BRUSW 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.
5-2-5 IDLE CONTROL UNIT The idle control unit releases throttle valve when the applied load current exceeds 0'.04A. The two output wires from the main coils must go through theZCT in the same direction. NOTE : It is normal that the engine speed goes up for a moment when you turn the key switch to "STOP" while the Auto Idle Switchis in "ON" position. I Fig. 5-6 5-2-6 NO-FUSE BREAKER The no-fuse breaker protects the generatorfrom getting damageby overloading or short circuitin the appliance.
Table. 5-2 1 Caution : The duplex 120V receptacle is protected by a GFCl (Ground Fault CircuitInterrupter). GFCl shuts off the output current from the duplex 120V receptacle when a ground fault occurs in the generator or the appliance. Please note thatother receptacles arenot protected by GFCI. \ TWIST 1 Caution :To connect theappliance to locking receptacle, insert theplug into the receptacle and turn it clockwise to lock.
5-2-9 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 properly. If TRIP dose not appear when testing, do not use the generator. Call a qualified electrician. To restore power, pushRESET button.
Utility high line House circuitbreaker - I v I I I I 120v - I ,A" appliance 240V 120v appliance I appliance I I " " " " " " " " " " " " " " " " " = 4P-Receptacle Fjg. 5-70 (b) Install Ii A transfer switch must be installed to transfer the load from the commercial power sourceto the 1 generator. This switchis necessary to prevent accidentscaused by the recovery from power outage. ' Use a transfer switch of the correct capacity.
5 3 DESCRIPTION Of GENERATOR OPERATION 5-3-1 PRIMARY EXCITING ACTION When the generator is started, the permanent magnet on the engine rotates to generator a voltage in the exciting coil. This voltage is regulated FC by a diode in the A.V.R. to feed a current to the generator field coil. (FC). (See Fig. 5-11) n The rotoris turned an electromagnet by that current and rotatesso that voltage are generated in the stator coils (main coil and sub coil).
5-3-3FULL POWER SWITCH (Dual Voltage Type) The full power switch is provided for the dual voltage type to take out the full rated power from one receptacle in each voltage. r--- 1 120/240v MC1 240v -- 1 t.Fig. 5-14 MC1 MC2 1 Fig. 5- 15 - r 1REC.~ Switch Position LOWER VOLTAGE HIGHER VOLTAGE RECEPTACLE RECE MC1 1 120/240 V RECB Half of rated output Table. 5-3 -MC2 Fig.
Two main coils are wound over stator core. Each maincoil outputs half the rated power at the lower voltage (120V). These main coils are wound to be in the same phase. Thefull power switch reconnects these main coilsin parallel or in series. Fig. 5-14 shows acircuit diagram. When thefull power switchis set for single lower voltage indication (120V), the switch positionis as indicated by the lower solid line in the diagram. Fig.
5-4 OIL SENSOR 5 4 1 DESCRIPTION The oil sensor mainly functionsto detect position of the surface of engine oil in the crankcase of engines for general use and to stop the engine automaticallywhen the oil level goesdown below the lower limit specified.This prevents seizure of engine from occurringdue to insufficient amount of oil in the crankcase. OIL SENSOR Since the sensor has been designed to.
[Judgement of oil level] When sufficient oilis in the crankcase, both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes. The sensor judgesoilthat in the crankcase is sufficient. When oil level goes down and the inner electrode is exposed to the air due to consumption of oil, no c between the electrodes as airis considered to be electrically nonconductive. The sensor in this case judges that oil is insufficient. [Decisionof oil shortage] .
@ Detection circuit..... This detects quantity ofoil, sufficient or not, accordingto difference of electric resistance across inner and outer electrodes. @ Delay circuit...........This his prevents the sensor from making an unnecessary stop of the engin by momentary lowering of theoil level due to the engine being slanted or affected by vibrationin spite of sufficient oilin the crankcase. @ Stopping I circuit...... This automatically stops the engine running.
6. SAFETY PRECAUTIONS 1. Use extremecaution near fuel. A constant danger of explosion or fire exists. Do not fillthe fuel tank while the engine is running. Do not smoke or use open flame near the fuel tank. Be careful notto spill fuelwhen refueling. If spilt, wipeit and let dry before starting the engine. 2. Do not place inflammablematerials near the generator. Be careful notto put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the generator. 3.
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 requiredfor operating an electrical applianceis not always equalto the output wattage of the appliance.The electrical appliancesgenerally have a label showing their rated voltage, frequency, and power consumption (input wattage). Thepower consumption of an electrical appliance is the power necessary for using it.
' * 8' (5) Appliances without any indicationas to power consumption Some appliances have no indication asto power consumption; but instead the work load (output)is indicated. In such a .case, power consumption is to be worked out accordingto the numerical formula mentioned below. (Output of electrical appliance) = (Power consumpition) (Efficiency) : Eff iciencies.of some electrical appliances are as follows Single-phase motor................................ 0.6 t0 0.75 Fluorescent lamp ................
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 appliance). If the input current is higher than the allowable current of the cable used, the cable will become excessively heated and deteriorate the insulation, possibly burning it out. Table 7-2 shows cables and their allowable currents for your reference. 2.
8. MEASURING PROCEDURES 8-1 MEASURING INSTRUMENTS 8-1-1 "Dr. ROBIN" GENERATOR TESTER. The "Dr. Robin" generator tester is exclusively designed for fast, easy diagnosisand repair of Robin generators. The "Dr. Robin" has the following features: (1) Functions of voltmeter, frequency meter, megger tester, capacitance meter and circuit tester are combined in one unit. (2)Fast and easy readout by digital indicator. (3) Built-in automatic battery checker indicates the time to change batteries. Fig.
8-1-2 INSTRUMENTS (1) VOLTMETER AC voltmeter is necessary. The approximate of the voltmeters be to used AC voltage ranges for various typesof generators areas follows: 0 to 150V:Type with an output voltage of 110 or 120V 0 to 300V:Type withan output voltage of 220, 230 or 240V 0 to 15OV,0 to 330V : Dual voltage type FOR AC Fig. 8-2 I (2) AMMETER AC ammeter is necessary. AnAC ammeter with a range that can be changed according to the current rating of a given generator is most desirable.
1 (4) CIRCUIT TESTER Used for measuring resistance, etc. (5) MEGGER TESTER Used.for measuring generator insulation resistance. Select one with testing voltage range of 500V. I I Fig. 8-6 (6) TACHOMETER Use the contactless type tacho meter. 1 f Fig.
8-2 AC OUTPUT MEASURING TO AC RECEPTACLE v Fig. 8-8 Use a circuit like the shown in Fig.8-8 for measuring AC output. A hot plate or lampwith a power factorof 1.O may be used as a load. Adjust the load and rpm. and check that the voltage range is as specified in Table 8-2at the rated amperageand rated rpm. I Rated voltage Voltage range I 120 v 112 -128 V I 240 W - 224 256 V Table. 8-2 8-3 DC OUTPUT I MEASURING 1 To DC Terminal 9 T I i. .i Fig.
8-4 MEASURING INSULATION RESISTANCE Use a "Dr. Robin"generator tester in megger tester mode or use a megger tester to check the insulation resistance. Remove the control panel, and disconnect the connector of GREEN lead for ground. Connect a megger tester to one of receptacle output terminals and the ground terminal, then' measure the insulation resistance. An insulation resistanceof 1 megohm or moreis normal.
CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts. Fig. 8- 13 Any part where the insulation resistance is less than 1M Q has faulty insulation, and may cause electric leakage and electric shock. Replace the faulty part.
’ ...^ :.. . 9. CHECKING FUNCTIONAL MEMBERS 9-1 VOLTMETER Check the voltmeterif it is turned on by applying specific voltage. Voltmeter cannot be checked with circuit tester because its resistance is too large. 0 Check that no disconnection nor short-circuit occurs with a tester, and the internal resistance is aroundOOk ohms normally. @ Turn on the commercial power supply input and check the indication. VOLTMETER Fig. 9-7 9-2 AC RECEPTACLES Using a “Dr.
9-4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a “Dr.Robin” or a circuit tester referring to the fol-. lowing table. Fig. 44 r Stator coil DC coil Hz-Voltage 60-1 20/ 240 Red-White Black-Blue 0.16 SZ 0.16 SZ BrownBrown WhiteLight green 0.11 D 0.61 SZ NOTE :If the circuit tester is not sufficiently accurate, it may not show the values given and may erroneous readings.
2) Cleaning Slip rings The slip ring surfaces must be uniformly bright. Slip rings showing black spots, excessive wear, or uneven wear mustbe repaired.A stained slip ring lowers generator efficiency and output voltage. Polish the slip rings with fine sandpaper while turning the rotor until rough spots disappear. Care should be taken notto touch the rotor coils with the sandpaper. Fj3. 9-6 9-6 BRUSH The brushes mustbe smooth where they contact the slip rings.
.. (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 indicates 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 tableon'next page, theA.V.R. is faulty. NOTE :lake teater inaccuracy into account in reading the tester.
9-8 IDLE CONTROL UNIT Check the resistance between five terminalsof IDLE CONTROLUNIT with circuit tester. L' Terminal numberof the IDEL CONTROL UNIT Fig. 9-8A Terminal numberof the IDLE CONTROL UNIT Apply blacCk 0needle of the circulit break Sircuit tester (with battery power source 1.5 V) @ 110kQ 0 Apply red 0 needle of the circuit breaker 0 0 0 0 0 @ Fig.
9-9 DIODE RECTIFIER DIODE RECTIFIER Brown Orange Brown CIRCUIT TESTER Fig. 9-10 Fig. 9-11 Circuit insideof the diode rectifiersis as shownin Fig. 9-10. Check continuity between each terminal by using a circuit tester as shown in Fig. 9-11. The rectifieris normal when condtinuity is as follows: * Checkina table for analoaue circuit tester.
. .. NOTE 1 :Because of the difference hieasdnng of method between the analogue circuit tester and the digital circuit tester, polarity of testemeedles should be reversed. NOTE 2 :"Continuiv means forward direction characteristics of the diode, and different from short circuit condition (in which a pointer of the tester goes out of its normal scale), shows resistance to some extent. When results of the checking indicates failure even in one section, replace with a new one.
IO. 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 informationto facilitate easier and smoother reassembly. 2) For more convenience, divide the partsinto several groups and store them in boxes.
10-2 DISASSEMBLY PROCEDURES ~ Description Step Part to remove ~ Tool Screw driver (+) (1) Take off the eight screws and remove Control box 1 ~ Remarks the control panel from the control box. (See Fig. 10-1 .) 5 x 12 mm screw and washer Ass'y (black) . . . 8 pcs. (2)Disconnect the connectors on wiring the from the control box to the alternator. (3)Take off the bushing from the back of the control box. (See Fig. 10-2.) Press the upper end of the bushing and pull out. Fig. 10-1 Fig.
Step Part to remove %el Tank 2 Description Remarks (9) Discharge fuel from the tnak. Use utmost care about hazard. strainer. fuel fire 1.the Shut 2. Remove the strainer cup. 3. Put a vessel to receive fuel under the Wipe off split fuel strainer and open the fuel cock to thoroughly. discharge fuel. (See Fig.10-4.) 4. Attach the strainer cup to the strainer Do not lose the filter body. Tool screen. Fig. 10-4 ?hers (2) Disconnect rubber pipe from the strainer.
Step Part to remove T l M u f f l e r and Muffler cover Remarks Description Tool 12 mm spanner or box wrench (1) Remove the muffler cover from the muffler. 6 x 10 mm bolt andwasher Ass'y . . . 4 pcs. (See Fig. 10-7.) ~ 10 mm spanner or box wrench (2) Remove the two bolts whichfix the muffler to the rear cover. Loosen the two bolts on the muffler flange and remove the muffler from the engine. 8 x 20 mm bolt and washerAss'y . . - 2pcs. 8 mm spring washer. . .2pcs. Muffler gasket . . 1 pce. . Fig.
Description Part to remove 'ipe Frame Remarks Tool 1) Removethe nuts which are fixing engine and alternator to the mount rubbers. (See Fig. 10-10.) 12 mm spanner 2) Using a chain-block, sling up the engine Remove the air and alternator and dismount from the cleaner cover for dismounting. frame. I MOUNT (ALTER MOUNT RUBBER (ENGINE SIDE : Ppcs) Fig. 10- 10 12 mm spanner or socket wrench 3 ) Remove the mount rubbers from the frame. Loosen the nuts on the bottom side of the frame. (See Fig. 10-11.
itep Part to remove 5 Brush and Rear cover Description Remarks Tool (1) Remove the brush holder. (See Fig. 10-12.) 64screw.. .2 pcs, (2) Remove the four bolts which fasten the rear cover to the front cover. (See Fig. 10-73.) 64bolt.. . 4 pcs. 10 mm spanner or box wrench I . Fig. 10- 13 7. 10-12 (3) Removethe rear coverby hitting on theDo not give a strong hit Plastic hammer on theboss or legs. legs of rear cover with a plastic hammer to loosen. Fig.
Step Part to remove 6 Stator Remarks Description Tool (1) Remove the stator cover. STATOR COVER E Fig. 10-15 STATOR COVER STATOR - \ WASHER :4 pcs. SPR'NG COVER BOLT :4 pcs. Fig.
~ Part to remove 3otor 7 Remarks Description I Tool Box wrench Plastic hammer (1) Take off the through bolt. Apply a box wrench on the headof through bolt. Hit the wrench handle with a hammer counter-clockwise to loosen. Fig. 10-17 ~ ~~ (2) Put the engine on the working table recoil starter side down. (3)Use a bolt and oil as a toolfor pulling out rotor in the following procedures: 1. Pour engineoil into the center hole of rotor shaft. Fill with oil tothe shaft end. (See Fig. 10-18.) 2.
Part to remove 3otor Description Remarks 4. Screw the boltinto the thread of the rotorDo not stickout your face over the rotor. shaft. 5. Torque the bolt using a socket wrenchIt may jump up on until the rotor comes separation. off loose. Tool Socket wrench The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft. :4) Wipe off oil thoroughly from rotor shaft and enaine PTOshaft. 3ont Cover 12 mm socket wench (1) Remove the front cover.
10-3 ASSEMBLY PROCEDURES - 10-3-1 ENGINE and FRAME (1) Attach the mount rubbersto the frame. Insert the setting tongue of mount rubber into the hole .on the frame and tighten the nut from the bottom of the frame. FRAME UPPER M8 flange nut . . . 4 pcs. - 11.8 13.7 N-m 120 - 140 kg-cm 8.7 - 10.8 ft-lb Fig. 10-22 NOTE :The mount rubbers are selected to reduce vibration most effectively by model. Be sure to use correct mount rubber for your generator.
10-3-3 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. Apply a wrench on the through bolt and hit wrench handle clockwise with a hammer to tighten. If an impact wrench is available, use it. Tightening torque : Fig. 10-24 - 22.5 24.5 N-m 230 250 kg-cm 16.6 18.
10-3-5 REAR COVER (1) Put the rear cover with stator over the rotor. Tap on the rear cover evenlywith a plastic hammer to press the rotor bearing into the rear cover. (2) Fix the rear cover to the adaptor with four bolts, spring washers, and washers. M6x160mmbolt ... 4pcs. M6 spring washer. . . 4 pcs. M6 washer . . . 4 pcs. - 50 60 kgcm 3.6 4.3ft-lb - (3) 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.
10-3-6 BRUSH / BRUSH HOLDER (1) 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. 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.
. .. @ MUFFLER COVER (FRONT) / MUFFLER BRACKET Fig. 10-30 MUFFLER COVER (REAR) (4) Attach the muffler to the exhaust pipe and gen- erator rear cover without tightening. (5) Tighten the muffler to the exhaust pipe. (See Fig.10-31.) I M8 x bolts 20 mm - . . .2pcs. 230 270 kgcm 16.6 - 19.5 ft-lb (6) Tightenthemufflerbrackettothegeneratorcover.(SeeFig.10-32.) M8 x 20 mm bolt and washer A&’y . . . 2 pcs. I 1 E Fig. 10-31 Fig.
(7)Tghten the muffler bracket to the generator cover. (See Fig.10-33.) M8 x 20 m m bolt and washer Ass’y. . . 2 pcs. - 50 60 kg-cm 3.6 - 4.3 ft-lb w (8) Assemble the muffler cover (from). Fig. 10-33 M6 x 12 mm flange bolt. . .2pcs. 10-3-8 FUEL TANK (1) Hand tighten the strainer screw as far it will as FUELTANKCAP go, loosenit again by one two or rotations (fuel outlet faces down), then tighten the lock nut. I a4 FYEL GAUGE Tightening torque I - 4.5 6.9 N-m 50 70 kg-cm 3.6 5.
10-3-9 CONTROL PANEL Mount the control panel assembly to the control box. Refer to Section10-4for disassembly, checking and reassembly procedures of the control panel. (1) Connect the wires from the control panel and the engine. (2) Connect the wires drawn out from the stator to the wires from the control panel. NOTE :Connect the wiresof the samecolor. (3) Press the upper endof the bushing into the bottom window of the control panel. (4) Mount the control panel to the controlbox.
10-4-3 REASSEMBLY terminals, switches, etc. on the control panel and wire them. (1) Install the receptacles, no-fuse breaker, NOTE :Circuit diagramsare shown in Section 12. Colored wiresare used for easy identification, and are of the correct capacity andsize. Use heat-resistant type wires (permissible temperature range 75°Cor over) in the specified gauge shown in the circuit diagrams. (2) Connect the wiresof control panel components. (3) Attach the control panelto the controlbox. M4 screw . . . 8 pcs.
11. TROUBLESHOOTING 11-1 NO AC OUTPUT 11-1-1 CHECKING STATOR (1) Remove control panel and disconnect stator wires at the connectors. I (2) Measure the resistance between terminals on 9-1 stator leads. (See Fig.11-1) Refer to Table of Section 9-4 STATOR for normal resistance. If stator is faulty, replace it with a new one. (3)Check the insulation resistance between sta- I tor core and each stator lead using a Dr. Robin generator tester in megger tester mode or a megger tester. (Fig.11-3) ’ \Fig.
2) Cleaning Slip rings The slip ring surfaces must be uniformly bright. Slip rings showing black spots, excessive wear, or uneven wear mustbe repaired. A stained slip ring lowers generator efficiency and output voltage. Polish the slip rings with fine sandpaper while turning the rotor until rough spots disappear. Care should be taken notto touch the rotor coils with the sandpaper. Fig.
11-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUTTHE LOAD CANNOTBE APPLIED. 11-3-1 CHECK THE ENGINE SPEED. If the engine speedis low, adjust it to the rated r.p.m. *Refer to Step11-2-1 for engine speed adjustment. 11-3-2 CHECK THE TOTALWAnAGE OF APPLIANCES CONNECTED TO THE GENERATOR. Refer to Section7 "RANGE OF APPLICATIONS" for the wattage of the appliances. If the generatoris overloaded, reduce the loadto the rated output of the generator. 11-3-3 CHECK THE APPLIANCEFOR TROUBLE.
11-4 NO DC OUTPUT 11-4-1 CHECK THE AC OUTPUT. Check the generatorby following Step11-1-1 through Step11-1 -2. 11-4-2 CHECK THE DC BREAKER. If the DC breaker turned off while charginga battery, check the cables for short-circuit or connection in reverse polarity before resetting it on. NOTE :If the DC output is used to charge a large capacity batteryor an over-discharged battery, an excessive current may flow causing. Fig. 17-8 11-4-3 CHECK THEWIRING.
11-5 IDLE CONTROL 11-51 ENGINE SPEED IS NOT INCREASED WHEN A LOADI S APPLIED (1) Inspect the solenoid bracket. Check the bond angle of solenoid bracket.If the bracketis distorted, correct the angle with proper tool. soLENolDM6 BOLT (2) Check the wattageof load applied to the generator. If the generatoris loaded over the rated wattage, the engine speed can not be increased.
I (5) IDLE CONTROL UNIT Check the resistance between five terminals of IDLE CONTROL UNIT with circuit tester. ! Terminal numberof the IDEL CONTROL UNIT Fig. 11-13A - Fig. 11 138 3rcuit tester (with battery Apply blal power source1.5 V) to I CF, - co Apply red 0 needle of the circuit breaker @ @ @ 1lOkSZ 110kQ 85kO 85 kQ 85kQ co co 05 Table. 11-4 NOTE :The resistance readings vary depending on the types of circuit testers. The above table 1.
11-5-2 ENGINE SPEED IS NOT REDUCED WHEN LOADIS .OFF. (1)Check the distortion ofthe SOLENOID BRACKET as shownin step 11-5-1-(l).. (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 CONTROL UNIT are securely and correctly connected. (4) Checking the SOLENOID. Measure the resistance between two leads from SOLENOID.
12. WIRING DIAGRAM U.S.A., 6OHZ-120V/240V ELECTRIC STARTER TYPE .......... FF K3>OC3 ..........
U.S.A.
