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Robin America RGV7500 Service Manual

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SERVICE
MANUAL
Model
RGV7500
PlJB-GS1436
Rev.
05/00

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Summary of Contents for Robin America RGV7500

  • Page 1 SERVICE MANUAL Model RGV7500 PlJB-GS1436 Rev. 05/00...

  • Page 2: Table Of Contents

    Section Title Page ....................... l.'SPECIFICATIONS ................... PERFOMANCE CURVES ........................FEATURES ..................... 3-1 A.V.R. ALTERNATOR ......................3-2 OIL SENSOR ..................... QUIET OPERATION ....................RADIO NOISE ....................3-5 LARGE FUELTANK ................3-6 RUGGED TUBULAR FRAME ................. COMPACT AND LIGHT WEIGHT ..................3-8 MINIMAL MAINTENANCE ..................

  • Page 3: Title

    Sectior! Title Page ......................STATOR ................... ROTOR ASSEMBLY ........................ 9-6 BRUSH ..........9-7 A.V.R. (AUTOMATIC VOLTAGE REGULATOR) ..................IDLE CONTROL UNIT ..................... 9-9 DIODE RECTIFIER ....................OIL SENSOR ....................9-11 EXCITING COIL ................1O.DISASSEMBLY AND ASSEMBLY ..............10-1 PREPARATION PRECAUTIONS ...............

  • Page 4: L.'specifications

    1. SPECIFICATIONS Model RGV7500 Brush, Self Exciting, 2-Pole, Single Phase 60 Hz 7300 W Maximum Output Rated Output 6000 W Rated 120V1240V Voltage 50N25A Current Power Factor A (1 00 W) V-8.3 DC Output Regulator Voltage Type Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine EH41 Model in.)

  • Page 5: Perfomance Curves

    2. PERFOMANCE CURVES RGV7500 / kVN240V) ( 6 . 0 Load Rated OUTPUT ....DC Voltage ....DC Ampere 8 . 3 ....DC output left indicates the characteristic of DC output The voltage curve shown in the when charging a battery. The voltage be decreased by 20% when the resistance load is applied.

  • Page 6: Features

    FEATURES AVR ALTERNATOR Output votage becomes more stable due to AVR system. OIL SENSOR Oil sensor automatically shuts off the engine whenever the oil level falls down below the lower limit to protect the engine from seizure. QUIET OPERATION Robin RGV series generator delivers a quiet operation with A quiet 4-stroke Robin Rro OHV engine.

  • Page 7: Long-Life Durability

    LONG-LIFE DURABILITY heavy-duty stroke Robin engine Full rubber mount in a sturdy tubular frame. forged steel crankshaft supported by main ball bearings. pointless electronic ignition system. cast-iron cylinder liner.

  • Page 8: General Description

    4. GENERAL DESCRIPTION 4-1 EXTERNAL VIEW FUEL GAUGE CONTROL PANEL AIR CLEANER RECOIL STARTER IL GAUGE (OIL FILLER) SENSOR OIL DRAIN PLUG OIL FUEL TANK CHOKE LEVER SPARK PLUG OUTLET...

  • Page 9: Control Panel

    CONTROL PANEL LAMP HOUR METER VOLTMETER PILOT :\ . E T3i : ; F E Y STARTER TYPE) ’ IDEL BREAKER NO-FUSE DC OUTPUT SWITCH TERMINAL DC CIRCUIT BREAKER SWITCH ENGINE (RECOIL STARTER TYPE) SERIAL 4-3 LOCATION NUMBER SPECIFICATION NUMBER Serial number and specification are stamped on stuck on the...

  • Page 10: Construction And Function

    5. CONSTRUCTION AND FUNCTION CONSTRUCTION STATOR. COMPLETE EARING BALL RUBBER MOUNT COVER TROUGH BOLT FRONT Fig. FUNCTION 5-2-1 STATOR The stator consists a laminated silicon steel sheet core, a main coil and a condenser coil which are wound in the core slots. The condenser c o i l excites the rotor field coil which voltage generates AC...
  • Page 11 5-2-2 ROTOR The rotor consists o f a laminated silicon steel sheet core coil which i s wound over the core. field current in the coil magnetizes the steel field sheet core. permanent magnets are provided primary exciting action. Slip rings are provided on the rotor shaft to re- ceive exciting current from A.V.R..
  • Page 12 IDLE CONTROL UNIT 5-2-5 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 the ZCT 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"...
  • Page 13 Table. 5-2 Caution : The duplex receptacle protected 120V GFCl (Ground Fault Circuit Interrupter). TWIST GFCl shuts off the output current from the duplex receptacle when a ground fault 120V occurs in the generator or the appliance. Please note that other receptacles are not pro- tected by GFCI.
  • Page 14 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 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.
  • Page 15 Utility high line breaker House circuit 120v appliance 240V appliance 120v appliance , A - " " " " " " " " " " " " " " " " " " Receptacle Fjg. (b) Install A transfer switch must be installed to transfer the load from the commercial power source to the generator.

  • Page 16: Generator Operation

    DESCRIPTION GENERATOR OPERATION 5-3-1 PRIMARY EXCITING ACTION When the generator is started, the permanent magnet on the engine rotates to generator a volt- age in the exciting coil. This voltage is regulated a diode in the A.V.R. to feed a current to the generator field coil.
  • Page 17 (Dual 5-3-3 FULL POWER SWITCH 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. 120/240v r - - - 240v t. - Fig. 5- Fig.
  • Page 18 Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower voltage (120V). These main coils are wound to be in the same phase. The full power switch reconnects these main coils in parallel or in series. Fig.

  • Page 19: Oil Sensor

    5-4 OIL SENSOR 5 4 1 DESCRIPTION The oil sensor mainly functions to detect posi- tion of surface o f engine oil in the crankcase o f engines for general use to stop the en- gine automatically when the oil level goes down below lower limit specified.
  • Page 20 [Judgement of level] When sufficient oil is in the crankcase, both of inner and outer electrodes are immersed in the oil through which current flows across the electrodes. The sensor judges that oil 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 air is considered to be electrically nonconductive.
  • Page 21 ..Detection circuit This detects quantity of oil, sufficient or not, according to 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 the oil level due to the engine being slanted or affected by vibration in spite of sufficient oil in the crankcase.

  • Page 22: Safety Precautions

    6. SAFETY PRECAUTIONS 1. Use extreme caution near fuel. A constant danger of explosion or fire exists. is running. Do not smoke or use open flame near the fuel tank. not fill the fuel tank while the engine Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before starting the engine. 2.

  • Page 23: Range Of Applications

    7. RANGE OF APPLICATIONS Generally, the power rating o f an electrical appliance indicates the amount of work that can be done by it. The electric power required for operating an electrical appliance is not always equal to the output watt- age o f the appliance.
  • Page 24 (5) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a .case, power consumption is to worked out according to the numerical formula mentioned below.
  • Page 25 NOTES : Wiring between generator and electrical appliances 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.

  • Page 26: Measuring Procedures

    8. MEASURING PROCEDURES MEASURING INSTRUMENTS "Dr. ROBIN" GENERATOR TESTER. The "Dr. Robin" generator tester is exclusively designed for fast, easy diagnosis and repair of Robin generators. The "Dr. Robin" has the follow- ing features : (1) Functions of voltmeter, frequency meter, megger tester, capacitance meter and circuit tester are combined in one unit.
  • Page 27 8-1-2 INSTRUMENTS (1) VOLTMETER AC voltmeter necessary. The approximate AC voltage ranges of the voltmeters to be used for various types o f generators are as follows: 0 to 150V : Type with an output voltage of 11 0 or 120V an output voltage of 0 to 300V : Type with 220,...
  • Page 28 CIRCUIT TESTER Used measuring resistance, etc. (5) MEGGER TESTER Used.for measuring generator insulation re- sistance. Select one with testing voltage range of 500V. Fig. 8-6 (6) TACHOMETER Use the contactless type tacho meter. Fig. 8-7...

  • Page 29: Ac Output Measuring

    8-2 AC OUTPUT MEASURING TO AC RECEPTACLE Fig. Use a circuit shown in Fig.8-8 for measuring output. hot plate or lamp a power factor o f like the with may be used as a load. the load and rpm. and check that the voltage range i s as specified Adjust Table 8-2 at the rated amperage rated rpm.

  • Page 30: Measuring Insulation Resistance

    8-4 MEASURING INSULATION RESISTANCE Use a "Dr. Robin" generator tester in megger tester mode or use a megger tester to check insula- tion resistance. Remove the control panel, and disconnect the connector o f lead for GREEN ground. Connect a megger tester to one o f re- ceptacle output terminals and the ground termi- nal, then' measure the insulation resistance.
  • Page 31 CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts. Fig. is less than Any part where the insulation resistance M Q has faulty insulation, and may cause electric leakage and electric shock. Replace the faulty part.

  • Page 32: Checkmg Functional Members

    ...^ ’ 9. CHECKING FUNCTIONAL MEMBERS 9-1 VOLTMETER Check the voltmeter if it is turned on by applying specific voltage. Voltmeter cannot be checked with circuit tester because its resistance is too large. Check that no disconnection nor short-circuit occurs with a tester, and the internal resistance is around O O k ohms normally.

  • Page 33: Stator

    9-4 STATOR Disengage connectors the wires from stator and check the resistance between wires with a “Dr. Robin” a circuit tester referring to the fol-. lowing table. Fig. 44 Stator coil coil Hz-Voltage Red-White Black-Blue BrownBrown WhiteLight green 60-1 20 / 240 0.16 SZ 0.16 SZ 0.11...

  • Page 34: Brush

    2) Cleaning Slip rings 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 generator efficiency and output volt- age. Polish the slip rings with fine sandpaper while turning the rotor until rough spots disappear.
  • Page 35 (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 table on'next page, the A.V.R.

  • Page 36: Idle Control Unit

    9-8 IDLE CONTROL UNIT Check the resistance between five terminals IDLE CONTROL UNIT with circuit tester. Terminal number of the IDEL CONTROL UNIT Fig. 9-8A Terminal number the IDLE CONTROL UNIT Fig. 9-8B Apply blac needle of the circu li t break Sircuit tester (with battery l o I s power source 1.5 V)

  • Page 37: Diode Rectifier

    RECTIFIER 9-9 DIODE DIODE RECTIFIER Brown Orange Brown CIRCUIT TESTER Fig. Fig. Circuit inside the diode rectifiers is as shown in Fig. 9-1 0. Check continuity between each terminal by normal using a circuit tester as shown in Fig. 9-11. The rectifier is when condtinuity is as follows: Checkina table for analoaue circuit tester.

  • Page 38: Exciting Coil

    NOTE Because of the difference of hieasdnng 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.

  • Page 39: O.disassembly And Assembly

    DISASSEMBLY AND ASSEMBLY 10-1 PREPARATION PRECAUTIONS 1) Be sure to memorize the location individual parts when disassembling the generator so that the generator can be reassembled correctly. Tag the disassembled part with the necessary information to facilitate easier and smoother reassembly. 2) For more convenience, divide the parts into several groups and store them in boxes.
  • Page 40 10-2 DISASSEMBLY PROCEDURES Description Remarks Tool remove Step Part to Screw driver Take off the eight screws and remove Control box the control panel from the control box. (See Fig. 10-1 .) mm screw and . . . washer pcs. Ass'y (black) (2) Disconnect the connectors on the wiring...
  • Page 41 Part to remove Description Remarks Step Tool %el Tank (9) Discharge fuel from the tnak. Use utmost care about hazard. strainer. fuel fire Shut 2. Remove the strainer cup. off split fuel 3. Put a vessel to receive fuel under the Wipe strainer and open the fuel cock to thoroughly.
  • Page 42 Remarks Tool Step Part remove Description mm spanner or (1) Remove the muffler cover from the T l M u f f l e r and box wrench Muffler cover muffler. 10 mm bolt and washer Ass'y pcs. (See Fig. 10-7.) 10 mm spanner or (2) Remove the two bolts which fix the muffler to the rear cover.
  • Page 43 to remove Description Remarks Part Tool 'ipe Frame 1) Remove the nuts which are fixing engine 12 mm spanner and alternator to the mount rubbers. (See Fig. 10-1 0.) 2) Using a chain-block, sling up the engine Remove the air and alternator and dismount from the cleaner cover for frame.
  • Page 44 Remarks Tool to remove itep Part Description (1) Remove the brush holder. Brush and (See Fig. 10-1 2 . ) Rear cover pcs, 64screw.. four 10 mm spanner or (2) Remove the bolts which fasten the rear cover to the front cover. box wrench (See Fig.
  • Page 45 to remove Remarks Step Part Tool Description (1) Remove the stator cover. Stator STATOR COVER Fig. 10-15 STATOR COVER STATOR p c s . WASHER : 4 SPR'NG COVER BOLT : pcs. Fig. 10-16...
  • Page 46 Remarks Tool Part to remove Description Box wrench Take off the through bolt. 3otor Apply a box wrench on the head of Plastic hammer 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.
  • Page 47 Part to remove Description Remarks Tool 3otor 4. Screw the bolt into the thread of the rotor not stick your face over the rotor. shaft. 5. Torque the bolt using a socket wrench It may jump Socket wrench until the rotor comes loose.

  • Page 48: Assembly Procedures

    10-3 ASSEMBLY PROCEDURES FRAME 10-3-1 ENGINE (1) Attach the mount rubbers to the frame. Insert FRAME UPPER the setting tongue of mount rubber into the hole .on the frame and tighten the nut from the bot- tom of the frame. flange nut pcs.
  • Page 49 ROTOR 10-3-3 Wipe oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft. Mount the rotor to the engine shaft. Tighten the through bolt. Apply wrench through bolt and wrench handle clockwise with hammer to tighten.
  • Page 50 10-3-5 REAR COVER (1) Put the rear cover with stator over the rotor. Tap on the rear cover evenly with 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.
  • Page 51 10-3-6 BRUSH / BRUSH HOLDER (1) Install the brush holders in the rear cover. Pass the mounting screws through the brush hold- ers, 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.
  • Page 52 MUFFLER COVER (FRONT) MUFFLER BRACKET MUFFLER (REAR) Fig. 10-30 COVER Attach the muffler to the exhaust pipe and gen- erator rear cover without tightening. (5) Tighten the muffler to the exhaust pipe. Fig.10-31.) (See M8 x 20 mm bolts .2 pcs. kgcm (6) Tighten the muffler bracket to the generator cover.
  • Page 53 Tghten the muffler bracket to the generator cover. (See Fig.10-33.) x 20 bolt and washer Ass’y . 2 pcs. kg-cm ft-lb 3 . 6 (8) Assemble the muffler cover (from). Fig. 10-33 M6 x 12 mm flange bolt . .2 pcs. 10-3-8 FUEL TANK FYEL GAUGE Hand tighten the strainer screw as far as...
  • Page 54 10-3-9 CONTROL PANEL Mount the control panel assembly to the control box. Refer to Section for disassembly, checking and reassembly procedures of the control panel. 10-4 Connect the wires from the control panel and the engine. Connect the wires drawn out from the stator to the wires from the control panel.
  • Page 55 10-4-3 REASSEMBLY Install the receptacles, no-fuse breaker, terminals, switches, etc. on the control panel and wire them. NOTE : Circuit diagrams are shown in Section 12. Colored wires used for easy identification, and are of the correct capacity and size. Use heat-resistant type wires (permissible temperature range over) in the specified gauge shown in the circuit diagrams.

  • Page 56: Troubleshooting

    11. TROUBLESHOOTING 11-1 NO AC OUTPUT 11 -1-1 CHECKING STATOR (1) Remove control panel and disconnect stator wires at the connectors. (2) Measure the resistance between terminals on stator leads. (See Fig.11-1) Refer to Table of Section STATOR for normal resistance. I f stator is faulty, replace it with a new one.
  • Page 57 2) Cleaning Slip rings 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 generator efficiency and output volt- age. Polish the slip rings with fine sandpaper while turning the rotor until rough spots disappear.
  • Page 58 11-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT LOAD CANNOT APPLIED. 11-3-1 CHECK THE ENGINE SPEED. I f the engine speed is low, adjust it to the rated r.p.m. *Refer to Step 11 -2-1 for engine speed adjustment. 11-3-2 CHECK THE TOTAL WAnAGE OF APPLIANCES CONNECTED TO THE GENERATOR. Refer to Section "RANGE OF APPLICATIONS"...

  • Page 59: No Dc Output

    11-4 NO DC OUTPUT THE AC OUTPUT. 11-4-1 CHECK Check the generator by following Step through Step 11 -1 -1 11 -1 -2. 11-4-2 CHECK THE BREAKER. If the DC breaker turned off while charging a bat- tery, check the cables for short-circuit or connec- tion in reverse polarity before resetting it the DC NOTE...
  • Page 60 11-5 IDLE CONTROL 11-51 ENGINE SPEED NOT INCREASED WHEN A LOAD APPLIED (1) Inspect the solenoid bracket. Check the bond angle solenoid bracket. If the bracket is dis- torted, correct the angle with proper tool. soLENolD BOLT (2) Check the wattage load applied to the gen- erator.
  • Page 61 (5) IDLE CONTROL UNIT Check the resistance between terminals five with circuit tester. IDLE CONTROL UNIT Terminal number of the IDEL CONTROL UNIT Fig. 11-13A Fig. 11 3rcuit tester (with battery Apply blal power source 1.5 V) Apply red needle circuit breaker 1lOkSZ 110kQ 85kO...
  • Page 62 11-5-2 ENGINE SPEED IS NOT REDUCED WHEN LOAD IS .OFF. Check the distortion of the SOLENOID BRACKET as shown in step 11-5-1-(l).. Check the wiring of SOLENOID. Check 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.

  • Page 63: Wiring Diagram

    12. WIRING DIAGRAM U.S.A., 6OHZ-120V/240V ELECTRIC STARTER TYPE ..K 3 > O C 3 ..6 0 -...
  • Page 64 U.S.A., 60H~-120V/240V WITHOUT ELECTRIC STARTER TYPE "- " " " "...

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