Robin RGV7500 Service Manual
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Robin RGV7500 Service Manual

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ISSUE EMD-GS1494
R
Model
RGV7500

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Summary of Contents for Robin RGV7500

  • Page 1 ISSUE EMD-GS1494 Model RGV7500...

  • Page 2: Table Of Contents

    CONTENTS Section Title Page 1. SPECIFICATIONS ....................... 1 2. PERFOMANCE CURVES ................... 2 3. FEATURES ........................3 3-1 A.V.R. ALTERNATOR .................... 3 3-2 OIL SENSOR ......................3 3-3 QUIET OPERATION ..................... 3 3-4 NO RADIO NOISE ....................3 3-5 LARGE FUEL TANK ....................3 3-6 RUGGED TUBULAR FRAME ................

  • Page 3: Section Title Page

    Section Title Page 9-4 STATOR ......................28 9-5 ROTOR ASSEMBLY ................... 28 9-6 BRUSH ........................ 29 9-7 A.V.R. (AUTOMATIC VOLTAGE REGULATOR) ..........29 9-8 DIODE RECTIFIER ..................... 31 9-9 OIL SENSOR ...................... 32 9-10 EXCITING COIL ....................32 10.DISASSEMBLY AND ASSEMBLY ................33 10-1PREPARATION and PRECAUTIONS ..............

  • Page 4: Specifications

    1. SPECIFICATIONS t i c - r i n i l e l i n i l y t i y t i l i o * Electric starter motor is available as option. - 1 -...

  • Page 5: Perfomance Curves

    2. PERFOMANCE CURVES 60Hz ( Hz ) ( V ) ( 125 ) 240V/120V ( 120 ) ( 115 ) ( 110 ) Load Rated 50Hz ( Hz ) ( V ) ( 125 ) 240V ( 120 ) ( 115 ) 220V/110V ( 110 ) ( 105 )

  • Page 6: Features

    Oil sensor automatically shuts off the engine whenever the oil level falls down below the lower limit to protect the engine from seizure. 3-3 QUIET OPERATION Robin RGV7500 generator delivers a quiet operation with : * High performance 4-stroke Robin OHV engine. * Extra large muffler and large air cleaner provide remakable quiet operation.

  • Page 7: General Description

    4. GENERAL DESCRIPTION 4-1 EXTERNAL VIEW FUEL STRAINER TANK CAP FUEL GAUGE ( FUEL COCK ) FRAME CONTROL PANEL AIR CLEANER RECOIL STARTER OIL GAUGE (OIL FILLER) OIL DRAIN PLUG OIL SENSOR FUEL TANK EARTH ( GROUND ) CHOKE LEVER TERMINAL MUFFLER COVER...

  • Page 8: Control Panel

    4-2 CONTROL PANEL * 50Hz-110V, 60Hz-110V, 60Hz-120V VOLTMETER PILOT LAMP AC RECEPTACLE KEY SWITCH (ELECTRIC STARTER TYPE) DC OUTPUT NO-FUSE BREAKER TERMINAL ENGINE SWITCH DC CIRCUIT BREAKER (RECOIL STARTER TYPE) * 50Hz-220V, 230V, 240V, 60Hz-220V VOLTMETER PILOT LAMP AC RECEPTACLE KEY SWITCH (ELECTRIC STARTER TYPE)

  • Page 9: Location Of Serial Number And Specification Number

    * 50Hz, 60Hz-110/220V, 60Hz-120/240V VOLTMETER PILOT LAMP FULL POWER AC RECEPTACLE KEY SWITCH SWITCH (ELECTRIC STARTER TYPE) NO-FUSE BREAKER DC OUTPUT TERMINAL ENGINE SWITCH DC CIRCUIT BREAKER (RECOIL STARTER TYPE) 4-3 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL (MODEL NAME) stuck on the side wall of rear cover.

  • Page 10: Construction And Function

    5. CONSTRUCTION AND FUNCTION 5-1 CONSTRUCTION STATOR COMPLETE BRUSH HOLDER STATOR BOLT REAR COVER ROTOR COMPLETE SLIP LING MOUNT RUBBER BALL BEARING TROUGH BOLT FRONT COVER 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.
  • Page 11 5-2-2 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. Slip rings are provided on the rotor shaft to re- ceive DC exciting current from A.V.R..
  • Page 12 5-2-5 NO-FUSE BREAKER The no-fuse breaker protects the generator from getting damage by overloading or short circuit in the appliance. Table 5-1 shows the capacity of no-fuse breaker by each spec. and their object of protection. Table. 5-1 5-2-6 DC CIRCUIT BREAKER The 10 ampere DC circuit breaker mounted on the control panel protects whole DC circuit from getting damage by overload or short circuit.
  • Page 13 5-2-7 RECEPTACLE and AC PLUG These are used for taking AC output power from the generator. A total of six kinds of receptacles, each varying in rated voltage and current from another, are used. Each model has at least one receptacle to deliver the rated generator output.

  • Page 14: Description Of Generator Operation

    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 volt- age in the exciting coil. This voltage is regulated by a diode in the A.V.R. to feed a current to the generator field coil.
  • Page 15 5-3-3 FULL 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. Fig. 5-11 Fig. 5-12 Fig. 5-13 - 12 -...
  • Page 16 Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower voltage (110V or 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 17: Oil Sensor

    5-4 OIL SENSOR 5-4-1 DESCRIPTION * The oil sensor mainly functions to detect posi- tion of the surface of engine oil in the crankcase of engines for general use and to stop the en- gine automatically when the oil level goes down below the lower limit specified.
  • Page 18 [Judgement of oil 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 current flow between the electrodes as air is considered to be electrically nonconductive.
  • Page 19 2 Detection circuit ..This detects quantity of oil, sufficient or not, according to difference of electric resistance across inner and outer electrodes. 3 Delay circuit ... This his prevents the sensor from making an unnecessary stop of the engine 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 20: Safety Precautions

    6. 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.

  • Page 21: Range Of Applications

    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 required for operating an electrical appliance is not always equal to the output watt- age of the appliance.
  • Page 22 (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.
  • Page 23 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 insulation, possibly burning it out.

  • Page 24: Measuring Procedures

    The “Dr. Robin” generator tester can be ordered from Robin generator distributors by the following part number. Dr. Robin Part Number : 388-47565-08 If you do not have a “Dr. Robin” generator tester, use the instruments described in the following section for checking generator parts. - 21 -...
  • Page 25 8-1-2 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 150V : Type with an output voltage of 110 or 120V 0 to 300V : Type with an output voltage of 220, 230 or 240V 0 to 150V, 0 to 330V : Dual voltage type...
  • Page 26 (4) CIRCUIT TESTER Used for measuring resistance, etc. Fig. 8-5 (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 - 23 -...

  • Page 27: Ac Output Measuring

    8-2 AC OUTPUT MEASURING Fig. 8-8 Use a circuit like the shown in Fig.8-8 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 specified in Table 8-2 at the rated amperage and rated rpm.

  • Page 28: 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 the insula- tion resistance. Remove the control panel, and disconnect the connector of GREEN lead for ground. Connect a megger tester to one of re- ceptacle output terminals and the ground termi- nal, then measure the insulation resistance.
  • Page 29 * 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 1MΩ has faulty insulation, and may cause electric leakage and electric shock. Replace the faulty part. - 26 -...

  • Page 30: Checking Functional Members

    Fig. 9-1 9-2 AC RECEPTACLES Using a “Dr. Robin” or a circuit tester, check con- tinuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel. When continuity is...

  • Page 31: Stator

    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. 9-4 Ω Ω Ω Ω 〜 Ω Ω Ω Ω...

  • Page 32: Brush

    2) Cleaning Slip rings The slip ring surfaces must be uniformly bright. ROTOR Slip rings showing black spots, excessive wear, SLIP RING 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 33 (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 34: Diode Rectifier

    9-8 DIODE RECTIFIER Fig. 9-9 Fig. 9-10 Circuit inside of the diode rectifiers is as shown in Fig. 9-10. Check continuity between each terminal by using a circuit tester as shown in Fig. 9-11. The rectifier is normal when condtinuity is as follows: * Checking table for analogue circuit tester.

  • Page 35: Oil Sensor

    NOTE 1 : Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester, polarity of tester needles should be reversed. NOTE 2 : ”Continuity” 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 36: Disassembly And Assembly

    10. 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 information to facilitate easier and smoother reassembly. 2) For more convenience, divide the parts into several groups and store them in boxes.

  • Page 37: Disassembly Procedures

    10-2 DISASSEMBLY PROCEDURES Fig. 10-1 Fig. 10-2 s t l M6 FLANGE BOLT : 2 pcs. M6 FLANGE BOLT : 1 pce. Fig. 10-3-1 Fig. 10-3-2 - 34 -...
  • Page 38 t i l . y l t l i f Fig. 10-4 e i l s t l HOSE CLAMP RUBBER PIPE Fig. 10-5 Fig. 10-6 - 35 -...
  • Page 39 l f f l f f l f f s t l x i f l f f s t l l f f Fig. 10-7 Fig. 10-8 Fig. 10-9 - 36 -...
  • Page 40 x i f n i l MOUNT RUBBER (ALTERNATOR SIDE : 2pcs) MOUNT RUBBER (ENGINE SIDE : 2pcs) Fig. 10-10 MOUNT RUBBER : 2pcs. EARTH CABLE M5 SCREW : 2pcs. MOUNT RUBBER : 2pcs. M8 FLANGE NUT : 2pcs. M8 FLANGE NUT : 2pcs. Fig.
  • Page 41 6φ s t l 6φ BRUSH HOLDER Fig. 10-12 Fig. 10-13 t t i c i t c i t REAR COVER Fig. 10-14 - 38 -...
  • Page 42 STATOR COVER STATOR Fig. 10-15 BRUSHING STATOR COVER STATOR REAR COVER SPRING WASHER : 4 pcs. COVER BOLT : 4 pcs. Fig. 10-16 - 39 -...
  • Page 43 . t l c i t . t l Fig. 10-17 n i l o l l l i o . t f l l i l i o o l l . t l SEAL TAPE Fig. 10-18 Fig. 10-19 - 40 -...
  • Page 44 i t s . t f l i t . t f l i o . t f Fig. 10-20 s t l Fig. 10-21 - 41 -...

  • Page 45: Assembly Procedures

    10-3 ASSEMBLY PROCEDURES 10-3-1 ENGINE and FRAME (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. M8 flange nut .
  • Page 46 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.
  • Page 47 10-3-5 REAR COVER (1) Put the rear cover with stator over the rotor. REAR COVER 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 48 10-3-6 BRUSH / BRUSH HOLDER (1) Install the brush holders in the rear cover. Pass BRUSH HOLDER 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.
  • Page 49 7 MUFFLER COVER ( FRONT ) 4.5 - 5.9 N m 50 - 60 kg cm 3 MUFFLER 2 MUFFLER BRACKET 4 M8 BOLT 22.5 - 26.5 N m 230 - 270 kg cm 1 EX. PIPE 4 M8 BOLT 22.5 - 26.5 N m 230 - 270 kg cm 22.5 - 26.5 N m...
  • Page 50 (7) Assemble the muffler cover (front). (See Fig. 10-33) M6 x 12 mm flange bolt . . . 2 pcs. - t f Fig. 10-33 10-3-8 FUEL TANK FUEL GAUGE (1) Hand tighten the strainer screw as far as it will FUEL TANK CAP go, loosen it again by one or two rotations (fuel outlet faces down), then tighten the lock nut.

  • Page 51: Checking, Disassembly And Reassembly Of The Front Panel

    10-3-9 CONTROL PANEL Mount the control panel assembly to the control box. Refer to Section 10-4 for 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.
  • Page 52 10-4-3 REASSEMBLY (1) 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 are used for easy identification, and are of the correct capacity and size. Use heat-resistant type wires (permissible temperature range 75 °...

  • Page 53: Troubleshooting

    Section 9-4 STATOR for normal resistance. If stator is faulty, replace it with a new one. (3) Check the insulation resistance between sta- tor core and each stator lead using a Dr. Robin generator tester in megger tester mode or a Fig. 11-1 megger tester.

  • Page 54: Ac Voltage Is Too High Or Too Low

    2) Cleaning Slip rings The slip ring surfaces must be uniformly bright. ROTOR Slip rings showing black spots, excessive wear, SLIP RING 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 55: But The Load Cannot Be Applied

    11-3 AC VOLTAGE IS NORMAL AT NO-LOAD, BUT THE LOAD CANNOT BE APPLIED. 11-3-1 CHECK THE ENGINE SPEED. If 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 WATTAGE OF APPLIANCES CONNECTED TO THE GENERATOR. Refer to Section 7 “RANGE OF APPLICATIONS”...

  • Page 56: Dc Output

    11-4 NO DC OUTPUT 11-4-1 CHECK THE AC OUTPUT. Check the generator by following Step 11-1-1 through Step 11-1-2. 11-4-2 CHECK THE DC 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 on.

  • Page 57: Wiring Diagram

    12. WIRING DIAGRAM Recoil starter model (50Hz-110V, 60Hz-110V, 60Hz-120V) - 54 -...
  • Page 58 Recoil starter model (50Hz-220V, 230V, 240V, 60Hz-220V) - 55 -...
  • Page 59 Recoil starter model (50Hz, 60Hz-110/220V, 60Hz-120/240V) - 56 -...
  • Page 60 Electric starter model (50Hz-110V, 60Hz-110V, 60Hz-120V) - 57 -...
  • Page 61 Electric starter model (50Hz-220V, 230V, 240V, 60Hz-220V) - 58 -...
  • Page 62 Electric starter model (50Hz, 60Hz-110/220V, 60Hz-120/240V) - 59 -...

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