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SERVICE
MANUAL
Model
RGV7500
PlJB-GS1436
Rev. 05/00
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Section Title Page l.'SPECIFICATIONS ....................................................................................................... 1 2 . PERFOMANCE CURVES ........................................................................................... 2 3 . FEATURES .................................................................................................................. 3 3-1 A.V.R. ALTERNATOR ....................................................................................
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Sectior! Title . Page 9-4 STATOR .............................................................................................................. 30 9-5 ROTOR ASSEMBLY ........................................................................................... 30 9-6 BRUSH ................................................................................................................ 31 9-7 A.V.R. (AUTOMATIC VOLTAGE REGULATOR) .................................................. 31 9-8 IDLE C
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1. SPECIFICATIONS Model RGV7500 Brush, Self Exciting, 2-Pole, Single Phase 60 Hz ~~ ~ ~ ~ Maximum Output 7300 W Rated Output 6000 W j: U Rated Voltage 120V1240V 50N25A Current Power Factor 1 .o I 12 V-8.3 A (1 00 W) I DC Output I I I Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine I EH41 D I Model Displacement 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 I
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2. PERFOMANCE CURVES RGV7500 / 60 Hz (6.0 kVN240V) f Load Rated \ DC OUTPUT DC Voltage ................. 12 V DC Ampere ................ 8.3 A DC output ................... 100 W 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 outputs simultaneously up to the rated output in total. - 2-
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3. FEATURES 3-1 AVR ALTERNATOR Output votage becomes more stable due to AVR system. 3-2 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. 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 N
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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-
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4. GENERAL DESCRIPTION 4-1 EXTERNAL VIEW FUEL GAUGE CONTROL PANEL AIR CLEANER RECOIL STARTER IL GAUGE (OIL FILLER) OIL DRAIN PLUG OIL SENSOR FUEL TANK CHOKE LEVER SPARK PLUG CAP OUTLET - 5-
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4-2 CONTROL PANEL HOUR METER VOLTMETER PILOT LAMP :\.ET3i STARTER TYPE) \ :;FEY AKCLE \ \ I I I ’ DC OUTPUT SWITCH 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. I NOTE : Always specify these numbers when inquiring about the generator or ordering spare parts in order to
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5. CONSTRUCTION AND FUNCTION 5-1 CONSTRUCTION STATOR. COMPLETE TROUGH 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 wound in the core slots. The condenser coil excites the rotor field coil which generates AC voltage in the main coil. 3 Fig. 5-2 - 7- MOUNT RUBBER BALL BEARING BOLT FRONT COVER
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5-2-2 ROTOR The rotor consists of a laminated silicon steel sheet and a field coil which is wound over the core. 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.. 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
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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 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" while the Auto Idle Switch is in "ON" position. I Fig. 5-6 5-2-6 NO-FUSE BREAKER The no-fuse breaker protects the generator from getting dama
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Table. 5-2 1 Caution : The duplex 120V receptacle is protected by a GFCl (Ground Fault Circuit Interrupter). \ TWIST GFCl shuts off the output current from the duplex 120V receptacle when a ground fault occurs in the generator or the appliance. Please note that other receptacles are not pro- tected by GFCI. 1 Caution : To connect the appliance to locking receptacle, insert the plug into the re- ceptacle and turn it clockwise to lock. - 10-
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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, push RESET button. WARNING :
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Utility high line House circuit breaker - v I I 120v I appliance - 240V I appliance I 120v I appliance ,A- I I " - I """"""""""""""""" = 4P- Receptacle Fjg. 5- 70 (b) i I A transfer switch must be installed to transfer the load from the commercial power source to the 1 generator. This switch is necessary to prevent accidents caused by the recovery from power outage. ' Use a transfer switch of the correct capacity. Install transfer switch
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53 DESCRIPTION Of GENERATOR OPERATION 5-3-1 PRIMARY EXCITING ACTION When the generator is started, the permanent n magnet on the engine rotates to generator a volt- age 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) The rotor is turned an electromagnet by that cur- EC i rent and rotates so that voltage are generated in the stator coils (main coi
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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. 120/240v r--- 1 MC1 240v - - 1 t.- Fig. 5- 14 MC1 MC1 MC2 MC2 1 Fig. Fig. 5- 5- 15 15 - r 1 REC.~ HIGHER VOLTAGE Switch LOWER VOLTAGE Position RECEPTACLE RECEPTACLE MC1 120/240 V Half of rated output Rated output I RECB 1 I Table. 5-3 - - MC2 - Fig. 5- 16 - 14-
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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. 5-14 shows a circuit diagram. When the full power switch is set for single lower voltage indication 5-1 5 is a simplified (120V), the switch position is as indicated by the lower solid line in the
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5-4 OIL SENSOR 541 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. This prevents sei- zure of engine from occurring due to insufficient amount of oil in the crankcase. OIL SENSOR Since the sensor has been designed to.consume a part of power supplied to the igniter to ener- gize it
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[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. The sensor in
