Robin RGV4000 User manual

IISSUE EM D-GS08591

6

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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.

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

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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

kEm

,

VMEtER

I

63

0

RGV6000

:

SWITZERLAND,

50Hz-220V

f0

0

o\

ON

0

E

-

17

-

RGV6000

:

AUSTRALIA,

50HZ-240V

0

RGV4000, RGV6000

:

(With optional electric starter and idle control)

-

la

-

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