Robin RGV2200, RGV2600, RGV6000, RGV4000 Service Manual
IISSUE EM D-GS08591
6
mEab
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HRdi!!!I!@MGASOLINEENGINEGENERATQ
SERVICE MANUAL
@FUJl HEAVYINDUSTRIESLTD.
CONTENTS
Section
Title Page
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
SPECIFICATIONS ..........." ....". """.......".. "". . ..... . .. . . ........ ...." ...."" . ... . . . .. 1
PERFORMANCE CURVES .. ..." .. ... . ....."... "....".. "... "...... ......... .... ........" 3
FEATURES .. . . .......... ......" ......" ...."... "". "....... . . ......... . ..... .... .." ......... . . 5
GENERAL DESCRIPTION OF THE GENERATOR ...-”” .”... -. ...”. o........”...... 6
4-1
External View of Generator
.. . ...... . . . . . .... . . . . . . . . . . . . ..... . ... . ... . .... . .... . . . ...
6
4-2 Control Panel
.... . .... . . ... . ... . .... ....... . . . ..... . . . . . . . . ...... . ... . .... ... . .... . . ...
7
4-3 Location of Serial Number and Specification Number . . . . . . . ...”...............”.. 20
Construction AND FUNCTION .. . . . . .."... ".- ... . . . . . . .....-. -C.---... -"--------- 21
5-1
Construction
... .. . ...." .. ..."... ".... . . .." .. ..". . ....." .. . . . . . ...." .. . . ... . ... . . .... . 21
5-2 Function . ... . . . ...... . .... . ..." .. . ... . . . ..... . . .." ...."" . . . . . . ...." ... . ... . ... . . ... . . . 21
5-3 Description of Generator Operation
..... .... . . . . . . . . . . . ..... . . . ... . ....... .... . . . .. 25
SAFETY PRECAUTIONS ................" ..... ..." . ............. . . ............. ..... . . . 28
RANGE OF APPLICATIONS .. ... . .... . ....... . . . . . .......... . .." . . ... . .... . ... . .... ..- 29
MEASURING PROCEDURES ..".. ".. .." . . . ... . . . . . . .. . . . . .... . . . . ... . .... .... . .... . . . 32
8-1
Measuring Instruments ..... . ... . .... . . . . .... . . . ..... ..... . ....... C.. . . ..... . . .... ..- 32
8-2 AC Output Measuring
.. . ...... . .." . ....... ....... . . . . . . . . ....... ....... ..". "........ 35
8-3 Measuring Insulation Resistance .. ....... .... ... . . . ....... . . . . . ... .... . ... . .... ...- 35
CHECKING FUNCTIONAL MEMBERS ..... . .. . ............ . .................... .... 37
9-1
Pilot LamP .. . . . . ..... . .... . ... . ... ... . . . . . .... . . . . . ..... ..... ..... . .... . .... .... . . .... 37
9-2 AC Receptacles
.... . ... ... . . ... . ... . . . . . ... . . . . . ... . . . . . . . . .. ....... ... .... .... . . ....
9-3 Circuit Breaker
37
.. . . . ... . ... . ... . . ... . ...... . . ... ... . . . . . . . ....... . . ... . ... . ... .... . . . . 38
9-4 Stator . .... . . . ....... . .... . . ... .... . ... . . . . .. .. ....... . . . . . . . . . ... .. C... . .... .... . . .... 38
9-5 Rotor . ...... . . . . . .... . . ....... .... . .... . . . . .... . . . . . ........ . . . . . ... . ... . . .. C. . . ... . .. 39
9-6 Condenser .... . . . . .... . . ... . ... . ....... ... . .... . . . . . .. . . . .... . . . . ... . ....... .... . . ... 39
9-7 Diode Rectifier
.... . ... . .... . ... . .... . .. ..... . . . .... . . . . . . . ....... .... . . ... .... .... . . .
40
Disassembly AND ASSEMBLY ... . .. ..... . . . . . .... . .... ........ C... . . ... . .... . . ... 41
10-1 Preparation and Precautions . . ... . . ....."... ".. ".. "... .... . . . . . .. . .... ... . .... . . ... 41
10-2 Special Tools for Disassembly and Assembly
.... . . . . . ...... . . .... . .... ... . . ..... . 41
10-3 Disassembly Procedures . . ... . ....... . . . . . .... .. . .......... . . . . ... . ....... .... . . .... 42
10-4 Assembly Procedures .." . . ... ... . .... . . . . .... . . . . . . . . . . .... . . . . ... . .... . ... . .... . . . . 51
10-5 Checking, Disassembly and Reassembly of the Control Box . ... . . ... . ... ....--.. 58
Troubleshooting .. . ...." .. . ....." . . . . . .... . . . . . ... . . . . . . . . ...... .... . .... .... ... . . . 59
11-1 No AC Output . . . . . ... . . .... . ... . ... ....... . . ....... . . . . . . . . ...... ... . .... .... . . .... . . 59
11-2 AC voltage is too high or too low
... . . . .... . . . . . .... . .. . . . ...... .... . .... .... .... . . .
’61
11-3 AC voltage is normal at no-load, but the load cannot be applied ..-. ---... ”...-”. 62
11-4 No DC Output ..... . .... . . .... ........ . . . . . ... . . . . . . ... .. .... . .. .... .... . ... . .... . . ... 63
11-5 idle Control . .. ..... . .... . . .... .... . .... . . . .... . . . . . .......... . . . . ...... . . .. . ..... . . ..- 64
WIRING DIAGRAM
.. . . .... ..... . . .... . . .... . . . .... . . . .... . . . ....... . . .... . ... . . ... .... . .
67
NOTE: As for the servicing information on engine portion, please refer to the
EHI 7, EH25 and EH34 engine service manual.
1.
SPECIFICATIONS
-
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-2-
2.
PERFOMANCE CURVES
63T
\
250
(1 25)
23ov/115v
220
0
1 /2
414
Load Rated
50Hz
(Hz)
Hz
51
00
250
(1 25) 24ov/12ov
230V/115V
220
21
0
(1
05)
0
1 12
414
Load Rated
-3-
DC
OUTPUT
DC Voltage
........................
DCAmpere
........................
DC output
........................
12v
8.3A
1
oow
The voltage curve shown in the left indicates the
characteristic
of
DC output when charging a battery.
The voltage may be decreased
by
20%
when the
resistance load is applied.
NOTE:
It is possible to use both DC and
AC
out-
puts simultaneously up to the rated output
in total.
CURRENT
(AI&
-4-
3.
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
FEATURES
BRUSHLESS ALTERNATOR
Newly developed brushless alternator eliminates troublesome brush maintenance.
CONDENSER TYPE VOLTAGE REGULATOR
A
trouble free condenser type voltage regulator ensures a stable voltage under all working
conditions.
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
:
0
A large super silent muffler.
0
A quiet 4-stroke Robin Rro OHV engine.
0
A
silent cyclone air cleaner.
NO RADIO NOISE
Noise suppressor spark plug and spark plug cap are equipped standard to prevent radio frequency
interfe.rence.
LARGE FUEL TANK
The large fuel tank allows more than 5 to
11
hours
of
continuous operation which
is
sufficient for a
half day or one day work without refueling.
RUGGED TUBULAR FRAME
Full cradle type rugged tubuler frame protects the generator all around.
COMPACT AND LIGHT WEIGHT
Newly developed brushless alternator enabled the
RGV
generators to be very compact
in
size and
light
in
weight.
MINIMAL MAINTENANCE
0
A brushless alternator release the operator from periodical brush maintenance.
0
A trouble free condenser type voltage regulator.
0
A drip-proof alternator design.
0
No-fuse circuit breakers.
0
An electronic pointless ignition system.
0
A
dust-proof cyclone air cleaner.
3-10 LONG-LIFE DURABILITY
The heavy-dut! 4 stroke Robin Rro
OHV
engine and virtually maintenance-free brushless alternator
ensure greater durability with
:
0
A brushless alternator with a condenser voltage regulator.
Full
rubber mount
in
a sturdy tubular frame.
0
A
forged ste.el crankshaft supported by two main ball bearings.
A
pointless electronic ignition system.
0
A
cast-iron cylinder liner.
0
A
forged aluminum connecting rod.
-5-
4.
4-1
GENERAL DESCRIPTION
OF
THE GENERATOR
EXTERNAL VIEW
of
GENERATOR
VOLT?JETER FUEL LEVEL GAUGE TANK CAP
STOP
BUTON
CHOKE KNOB
kC
AIR CLEANER
..
DC
RECOIL STARTER
,
DC CIRCUIT BREAKEFi AC CIRCUIT BREAKER
OIL SENSOR
SPARK PLUG MUFFLER
31L DRAIN PLUG OIL LEVEL GAUGE
-6-
4-2 CONTROL PANEL
RGV2200, RGV2600 : SOHz, 60HZ-1 lOV, 60Hz-120V TYPE
RGV2200, RGV2600 : 50H~-220V, 240V, 60HZ-220V TYPE
-7-
RGV2200, RGV2600 : SOHZ, 60H~-lIOV/220V DUAL VOLTAGE TYPE
RGV2200, RGV2600, RGV4000
:
U.K.,
50H~-110V/120V
[BS
RECEPTACLE]
-8-
RGV2600 : U.S.A., 60Hz-120V [NEMA RECEPTACLE]
RGV2200, RGV2600, RGV4000
:
GERMANY, 50Hz-220V
-9-
RGV2200, RGV2600, RGV4000 : SOUTH
AFRICA,
50HZ-220V
I
RGV2200, RGV2600, RGV4000 SWITZERLAND, 50HZ-22OV
-
10
-
RGV2200, RGV2600, RGV4000
:
AUSTRALIA,
50HZ-240V
RGV4000 : 5OHZ, 60Hz-11 OV, 60HZ-120V
TYPE
-
11
-
RGV4000 : 50H~-220V, 240V, 60HZ-220V
TYPE
0
RGV4000 : SOHZ, 6OHZ-l10V/220V
TYPE
-
12
-
RGV4000 : U.S.A., 60H~-120V/240V [NEMA RECEPTACLE]
@I
.
RGV2200, RGV2600, RGV4000 : FRANCE, 50Hz-220V
L
PRISES
CA
CHARGE
DE
BATTERIE
SEULEMENT
-
13-
0
RGV6000 : 50Hz, 60Hz-1 lOV, 60Hz-IiOV TYPE
I
!
L
!
@
1
0
I
U
VMEIER
1
RGV6000 : 50H~-220V, 240V, 60Hz-220V TYPE
f0
0 0
o\
\O
~
0
0)
-
14-
RGV6000 : 50Hz, 60H~-llOV/220V DUAL VOLTAGE
TYPE
..
-
15
-
RGV6000 : U.S.A., 60H~-120V/240V [NEMA RECEPTACLE]
RGV6000
:
GERMANY,
50Hz-220V
f0 0 0
I
\O
0
-
16
-
RGV6000 : SOUTH
AFRICA,
50Hz-220V
h
A
J
U
U
kEm
,
VMEtER
I
I
63
0
RGV6000 : SWITZERLAND,
50Hz-220V
f0
0
0
o\
ON
0
E
-
17
-
RGV6000
:
AUSTRALIA,
50HZ-240V
0
RGV4000, RGV6000 : (With optional electric starter and idle control)
-
la
-
RGV6000
:
FRANCE,
50H~220V
VOLTMETRE
0
0
RGV4000, RGV6000 : (With optional electric starter and idle control)
/@
PRlSES
CA
-
19
-
4-3
LOCATION
of
SERIAL NUMBER
and
SPECIFICATION NUMBER
Serial number and specification number are stamped
on
the
LABEL
(MODEL
NAME)
stuck on the end
cover.
NOTE:
Always specify these numbers when inquiring about the generator or ordering spare parts in
order
to
get correct parts and accurate service.
MODEL
NAME
-
20
-
5.
CONSTRUCTION AND FUNCTION
5-1
CONSTRUCTION
END
COVER
REAR
COVER
ROTOR
COMPLETE
STATOR
COMPLETE
MOUNT
RUBBER
STATOR
BOLT
BALL
BEARING
THROUGH
BOLT SUPPORT
RING
FRONT
COVER
Fig.
5-7
5-2 FUNCTION
5-2-1 STATOR
I
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 condenser coil excites the rotor field coil
i
-I
which generates
AC
voltage
in
the
main
coil.
i
1
I
I
I
Fig.
5-2
-
21
-
5-2-2 CONDENSER
One
or
two condensers are installed
in
the control
box and are connected to the condenser coil
of
the
stator.
These condensers and condenser coil regulate the
:
output voltage.
5-2-3
ROTOR
The rotor consists
of
a laminated silicon steel
sheet core and a field coil which is xound over the
core.
DC
current in the fie.ld coil magnetizes the steel
sheet core.
Tw~o
permanent magnets are provided
for the primary exciting action.
Fig.
5-4
A
diode rectifier and surge absorber is mounted inside
of
the insulator.
1
!
!.
-
22
-
5-2-4
DC CIRCUIT
BREAKER
(1)
The
10
ampere
DC
circuit breaker mounted
on
the control panel protects whole
DC
circuit
from getting damage by overload or short
circuit.
j
Fig.
5-6
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.
I
MODEL
1
SPECIFICATION
I
NO-FUSE
BREAKER
j
OBJECT
of
PROTECTION
I
50HZ-11 OV
Total output amperage
6.5A 50HZ-220V, 240V
Total output amperage
15A
60Hz-11 OV, 120v
Total output amperage
12A
60HZ-220V
8A
Total output amperage
RGV2200
'
I
50HZ-11 OVI22OV
'
Total output amperage
6.5A (2-Pole, 2-Element)
60HZ-120VI240V
'
I
8A (2-Pole. 2-Element)
Total output amperage
.
50HZ-11 OV.
I
18A
Total output amperage
9A 50Hz-220V
Total output amperage
..
20A 60HZ-11 OV. 12Ov
Total output amperage
RGV2600
1 OA
.i
Total output amperage 60HZ-220V
!
60HZ-240V
50HZ-11 OVl220V
.
9A (2-Pole. 2-Element) Total output amperage
. .
aA
I
Total output amperage
I
~
60Hz-11 OVi22OV, 12OVi24OV
i
1
OA (2-Pole. 2-Element)
1
Total output amperage
50HZ-11 OV
!
27A Total output amperage
I
I
60142-1
lov,
120v
.
j
30A Total output amperage
.
50Hz-220V
I
14A
Total output amperage
I
RGV4000
60HZ-220V 15A
!
!
Total output amperage
.12A Total output amperage
..
-5OHZ-240V
I
50HZ-11 OVi220V
I
14A (2-Pole, 2-Element)
i
Total output amperaqe
I
.60Hz-11 OV!22OV. 120V!240V
[
15A (2-Pole, 2-Element) Total output amperage
Total output amperage
50HZ-11 OV
40A
1
60HZ-11 OV. 120V
50HZ-220V. 60Hz-220V
50HZ-240V
50HZ- 1
1
OV/22OV.
.I
!
.
30A
Output from 30A receptacle
RGV6000
I
20A
20A (2-Pole. 2-Element) Total output amperage
18A
I
Total output amperage
Total output amperage
I
60HZ- 1 1 OVi22OV.
.
60Hz-120Vi240V 30A
i
Output from 30A receptacle
Table
5-
1
-
23
-
5-2-6
RECEPTACLE
and
AC PLUG (STD.SPEC.)
These are used for taking
AC
output power from the generator. A total
of
five 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.
As
many
AC
plugs as the receptacles, each matching the
corresponding receptacle, are provided. Table
5-2
shows the rated current for each receptacle. Be careful
not to use the receptacles and
AC
plugs beyond the specified amperage limits to prevent burning.
I
I
up
to
30
amperes
(See Caution.)
I
I
Table
5-2
Caution:
To
connect the appliance to locking receptacle,
insert the plug into the receptacle and turn it
clockwise to lock.
Fig. 5-7
NOTE: If your generator has receptacles peculiar to your country, Table
5-2
does not apply.
NOTE: The generator for
U.S.A.
market is equipped with
NEMA
standard receptacles shown in table
5-3.
Use the proper plug for connecting appliance to the generator.
Style
Ampere
125V
20A
Receptacle
NEMA
5-20R
NEMA
L14-20R
AC plug
NEMA
5-20P
NEMA
L14-20P
Description
GFCl
(Ground Fault Circuit
Interrupter)
Receptacle, duplex
Locking Receptacle
NEMA
Locking Receptacle
L5-30P
Table
5-3
-
24
-
5-3
DESCRIPTION
Of
GENERATOR OPERATION
PERMANENT MAGNET
FOR
INITIAL EXCITATION
STATOR MAIN COIL
.
RECEPTACLE
SURGE
ABSORBER
'""""_I
Fig.
5-8
5-3-1
GENERATION
Of
NO-LOAD VOLTAGE
When the generator starts running, the permanent magnet built-in to the
rotor
generates 3 to 6V of
AC voltage in the main coil and condenser coil wound
on
the stator.
As
one
or
two condensers are connected
to
the condenser coil, the small voltage at the condenser
coil generates a minute current
!z
which
flows
through the condenser coil. At this time: a small
flux
is produced with which the magnetic force
at
the rotor's magnetic pole is intensified.When this
magnetic force
is
intensified, the respective voltages
in
the main coil and condenser coil rise up.
As
the current
:s
increases, the magnetic
flux
at the
rotor's
magnetic pole increases further. Thus the
voltages at the main coil and condmser coil keep rising
by
repeating this process.
As AC current flows through the condenser coil, the density of magnetic
flux
in the rotor changes.
This change of magnetic
flux
induces
AC
voltage in the field coil, and the diode rectifier
in
the field
coil circuit rectifies this AC voltage into DC. Thus a DC current
(8
flows
through the field coil and
magnetizes the rotor core
to
generate
an
output voltage
in
the main coil.
When generator speed reaches
2700
to
2800
rpm (50Hz type)
or
3000
to
3300
rpm (60Hz type), the
current
in
the condenser coil and field coil increases rapidly.
This acts to stabilize the output voltage of each coils.
If
gene.rator speed further increases to the rated
value, the generator output voltage
will
reach to the rated value.
5-3-2
VOLTAGE FLUCTUATIONS UNDER LOAD
When the output current
:g
flows through the
main
coil to the appliance, a magnetic
flux
is
produced and
serves to increase current
;zn
in
the condenser coil. When current
83
increases, the density
of
magnetic
flux
across the rotor core rises.
As
a
result, the current flowing
in
the field -coil increases and the
-
generator output voltage is prevented from decreasing.
-
25
-
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