Robin America RGV7500 User manual

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

Section Title Page
l.'SPECIFICATIONS ....................................................................................................... 1
2 . PERFOMANCE CURVES ........................................................................................... 2
3 . FEATURES .................................................................................................................. 3
3-1A.V.R. ALTERNATOR ............................................................................................. 3
3-2 OILSENSOR
........................................................................................................ 3
3-3
QUIET OPERATION ............................................................................................. 3
3-4 NO RADIO NOISE ................................................................................................ 3
3-5 LARGE FUELTANK
.............................................................................................. 3
3-6 RUGGEDTUBULAR FRAME ............................................................................... 3
3-7 COMPACTAND LIGHT WEIGHT ......................................................................... 3
3-8 MINIMAL MAINTENANCE .................................................................................... 3
3-9 LONG-LIFE DURABILITY
..................................................................................... 4
4 . GENERAL DESCRIPTION .......................................................................................... 5
4-1 EXTERNALVIEW ................................................................................................. 5
4-2 CONTROLPANEL ................................................................................................ 6
4-3 LOCATION
of SERIAL NUMBER and SPECIFICATION NUMBER ...................... 6
5. CONSTRUCTIONAND FUNCTION ........................................................................... 7
5-1CONSTRUCTION .................................................................................................. 7
5-2 FUNCTION ............................................................................................................ 7
5-3 GENERATOR OPERATION ................................................................................ 13
5-4 OILSENSOR ...................................................................................................... 16
6. SAFETY PRECAUTIONS ......................................................................................... 19
7 . RANGE OF APPLICATIONS .................................................................................... 20
8 . MEASURING PROCEDURES .................................................................................. 23
8-1 MEASURING INSTRUMENTS ........................................................................... 23
8-2AC OUTPUT MEASURING
................................................................................. 26
8-3 DC OUTPUT MEASURING ................................................................................. 26
8-4 MEASURING INSULATION RESISTANCE
........................................................ 27
9 . CHECKMG FUNCTIONAL MEMBERS .................................................................... 29
9-1 VOLfMtrER ....................................................................................................... 29
9-2 AC RECEPTACLES ............................................................................................ 29
9-3 No-FUSE BREAKER
........................................................................................... 29

Sectior! Title . Page
9-4 STATOR .............................................................................................................. 30
9-5 ROTORASSEMBLY ........................................................................................... 30
9-6 BRUSH
................................................................................................................ 31
9-7A.V.R. (AUTOMATICVOLTAGE REGULATOR)
.................................................. 31
9-8 IDLE CONTROL UNIT ........................................................................................ 33
9-9 DIODE RECTIFIER ............................................................................................. 34
9-1 0 OIL SENSOR .................................................................................................... 35
9-11 EXCITINGCOIL
................................................................................................ 35
1O.DISASSEMBLYAND ASSEMBLY ........................................................................... 36
10-1PREPARATION and PRECAUTIONS ................................................................ 36
10-2DISASSEMBLY PROCEDURES
....................................................................... 37
10-3 ASSEMBLY PROCEDURES ............................................................................ .. 45
10-4CHECKING, DISASSEMBLY
and REASSEMBLY of the FRONT PANEL ........ 50
11 . TROUBLESHOOTING ............................................................................................ 52
11-1 NO ACOUTPUT ................................................................................................ 52
11-2AC VOLTAGE IS TOO HIGHOR TOO LOW ..................................................... 53 \
11-3AC VOLTAGE IS NORMALAT NO.LOAD.
I
BUTTHE LOAD CANNOT BE APPLIED ..................................... 54
11 -4 NO DC OUTPUT ................................................................................................ 55
11-5 IDLE CONTROL(OPTI0NALEQUIPMENT) ..................................................... 56
12 . WIRING DIAGRAM ................................................................................................. 59
NOTE : As forthe servicing information on engine protion. pleasereferto the EH41 engine
sewice manual .

1. SPECIFICATIONS
Model RGV7500
j: U
Brush, Self Exciting, 2-Pole, Single Phase
60
Hz
~~ ~ ~ ~
Maximum Output
6000
W
Rated Output
7300
W
Rated
Current
Voltage 120V1240V 50N25A
Power Factor
1 .o I
DC Output 12V-8.3
A (1 00 W) I
VoltageRegulator I AVRType I
I Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine I
Model EH41
D I
Displacement 404cm3(24.63cu.in.)
I
Rated Output 9.5
HP I 3600 rpm I
Fuel Automobile Gasoline
I
Fuel Tank Capacity 7.26 U.S. gal. (27.5 liters)
Rated Coutinuous Operation I Approx.7.0hours I
Oil Capacrty 0.32
US. gal. (1.2 liters)
Starting System
I RecoilStarterandOptionalElectricStarter I
Dimensions (L x W x H)
* Electric starter motor is availableasoption.
198.4 Ibs. (209.4 Ibs.)' 190kg (95 kg)*
Dry Weight
27.2
x 20.9 x 20.9 in. (690 x 530 x 530 mm)
- 1-

2. PERFOMANCE CURVES
RGV7500 / 60 Hz (6.0 kVN240V)
Load Rated
DC OUTPUT
DC Voltage ................. 12 V
DC Ampere ................ 8.3 A
DC output ................... 100 W
The voltage curve showninthe left indicates the characteristic of 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.
f
\
- 2-

3. FEATURES
3-1 AVR ALTERNATOR
Output votage becomes more stable dueto AVR system.
3-2 OIL SENSOR
Oil sensor automatically shuts off the engine whenever theoil level fallsdown below the lowerlimitto
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.
3-4 NO RADIO NOISE
Noise suppressor spark plugisequipped standardto prevent radio frequency interference.
3-5 LARGE FUELTANK
The large fuel tank (27.5 L) allows more than 7 hours of continuous operation which is sufficient for a half
day or one day
work without refueling.
3-6 RUGGEDTUBULAR FRAME
Full cradle type rugged tubuler frame protects the generator all around.
3-7 COMPACT AND LIGHT WEIGHT
".
Newly developed brushless alternator enabled the RGV generators to be very compactinsize and light
in weight.
3-8 MINIMAL MAINTENANCE
A drip-proof alternator design.
No-fuse circuit breakers.
An electronic pointless ignition system.
- 3-

3-9 LONG-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.
I
\
- 4-

4. GENERAL DESCRIPTION
4-1 EXTERNAL VIEW
FUEL GAUGE
CONTROL
PANEL
AIR CLEANER
RECOIL STARTER
IL GAUGE (OIL FILLER)
OILDRAINPLUGOIL
SENSOR
FUEL TANK
CHOKE LEVER
SPARK PLUG
CAP
OUTLET
- 5-

4-2 CONTROL PANEL
HOUR METERVOLTMETER PILOT LAMP
:\.ET3i STARTER TYPE) \ :;FEY AKCLE
\ \ I I
’
NO-FUSEBREAKERIDELCONTROL DC OUTPUT
SWITCH TERMINAL
I
ENGINESWITCH 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.
I
NOTE : Always specify these numbers when inquiring about the generator or ordering spare parts in
order to get correct parts and accurate service.
LABEL, MODEL NAME
- 6-

5. CONSTRUCTION AND FUNCTION
5-1 CONSTRUCTION
STATOR. COMPLETE
MOUNTRUBBERBALLBEARING
TROUGH BOLTFRONTCOVER
Fig. 51
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 woundinthe core slots.
The condenser
coil excites the rotor field coil which
generates
AC voltage inthe main coil.
3
Fig. 5-2
- 7-