Robin RGV12000, Service Manual

Page 1: ...MANUAL Models RGVl2000 13OOOT GENERATORS PUB GS1328 Rev Ol OO ...

Page 2: ...28 8 6 BRUSH 29 8 7 A V R AUTOMATIC VOLTAGE REGULATOR l l l l l l l l l l l l l 29 8 8 CURRENTTRANSFORMER RGV13000T only l l l l l l l l l l l l 30 8 9 ECU ELECTRONIC CONTROL UNIT l l l l l l l l l l l l l l l 30 8 10 IDLE CONTROL UNIT RGV12000 only l l l l l l l l l l l l l l 31 8 11 DIODE UNIT RGV13000T only l l l l l l l l l l l l l l l l l 32 9 DISASSEMBLY and REASSEMBLY l l l l l l l l l l l ...

Page 3: ... 02 ...

Page 4: ...n cylinder Air cooled 4 stroke Overhead valve engine 653 cm3 22 HP 3600 rpm 18 HP 3600 rpm Unleaded automobile gasoline I Oil capacity 1 55 liters Starting system Fuel tank capacity Rated continuous 314Rated operation per a tankful of fuel Rated Electric starter 43liters 21 5liters x 2 Approx 8 8 hours Approx 9 5 hours Approx 8 0 hours Approx 8 7 hours Noise level Rated dB 7m 77 0 dB 77 0 dB 5 Lar...

Page 5: ...ORMANCE CURVES l RGV12000 60Hz 9 5 KW240V Hz 63 HZ 62 I1 61 60 VI 250 125 240 24OVl12OV 120 230 115 220 110 I 112 Load 4 4 Rated RGV13000T 60Hz 12OW208V Hz 63 62 61 60 230 T 220 t 208V 0 l 2 414 Load Rated 2 ...

Page 6: ... TANK CAP iLTANK COOLING AIR INLET PORT K FUEL COCK BATTERY STOPPER OIL FILLER CAP SPARK PLUG CAP CHbKE KNOB RGV13000T only CONNECTOR FOR REMOTE CONTROL RGV12000 only END COVER RGV13000T only OIL GAUGE OIL DkAlN PLUG ELECTRIC STARTER 3 ...

Page 7: ...R PILOT LAMP I HOUR METER EARTH GROUND CONNECTOR AC RECEPTACLE TERMINAL FOR REMOTE CONTROL RGVI 3000T OIL PURESSURE VOLT METER WARNING LAMP NO FUSE BREAKER PILOT LAMP HOUR METER KEY SWITCH c AUTO IDEL SWITCH I EARTH GROUND TERMINAL KEY SWITCH AC RECEPTACLE AC OUTPUT TERMINAL 4 ...

Page 8: ...abel stuck on the end cover NOTE Always specify serial number when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service RGV13000T RGV12000 SERIAL NUMBER stamped label SERIAL NUMBER stamped label 5 ...

Page 9: ...TOR COMPLETE y I FRONT COVER BALL BEARING I TROUGH BOLT SLIP RING I MOUNT RUBBER 4 2 FUNCTION 4 2 l 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 6 ...

Page 10: ...rings are provided on the rotor shaft to receive DC exciting current from AVR RGV12000 and diode unit RGVl3000T A surge absorber is mounted inside of the insulator 4 2 3 BRUSH I BRUSH HOLDER An exciting current is supplied from the A V R to the rotor The brushes are made of carbon and the brush holder of plastic It is necessary to keep the contact pressure between the brushes and slip rings within...

Page 11: ...tput voltage CURRENT TRANSFORMER 4 2 5 A V R AUTOMATIC VOLTAGE REGULATOR RGV12000 only The automatic voltage regulator employs an electronic circuit to automatically regulate voltage 4 2 6 ECU ELECTRONIC CONTROL UNIT ECU controls the start stop of an engine enabling the fuel cut while stop It also automatically stops the engine if an abnormal oil pressure occurs 8 DIODE UNIT ...

Page 12: ...ectric starter is shut off automatically after 3 seconds When the engine dose not start engine speed dose not reach 1 050 rpm the electric starter is stopped after 21 seconds When the remote controller is connected the electric starter dose not run when the switch of remote controller is turned OFF even if the key switch on the generator is turned to START When the key switch or remote control swi...

Page 13: ... 0 kg cm2 OIL FILTER I CAMSHAFT OIL PRESSljRE SWITCH OIL PUMP FILTER 4 2 10 AC SWITCH NO FUSE BREAKER The AC switch no fuse breaker protects the generator from getting damage by overloading or short circuit in the appliance The capacity of AC switch no fuse breaker is as follows Model Specification RGV12000 60Hz 12OV 24OV RGVl3000T 60Hz 12OV 208V No fuse Breaker 39A 24A Object of Protection Total ...

Page 14: ...les each matching the corresponding receptacle are provided The rated current for each receptacle and terminal is shown as follows CAUTION Be careful not to use the receptacles and terminal beyond the specified amperage limits to prevent burning Total 5Oh or less RGV12000 CAUTION To connect the appliance to the locking type receptacle insert the plug in to the receptacle and then turn it clockwise...

Page 15: ...nerator immediately check the appliance and or generator for overloading or detect and have repaired as necessary by Robin dealer or service shop CAUTION The duplex 120V receptacle is protected by a GFCI Ground Fault Circuit Interrupter GFCI 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 a...

Page 16: ... generator dam age to appliances damage to the building s wiring or fire a When connecting a Robin generator to a house wiring generator output power must be taken from the 24OV 4P receptacle b Install a transfer switch A transfer switch must be installed to transfer the load from the commercial power source to the generator This switch is necessary to prevent accidents caused by the recovery from...

Page 17: ...erator is running or the operator may suf fer severe electric shock resulting in death w Be sure to shut down the generator before connecting or changing connection of power cables to the generator This generator has four output terminals of three phase four wire system Connect power cables to the generator output terminals according to the type of application n 14 ...

Page 18: ...nd W Maximum one second l 2 of generator output can be utilized from each phase Generator rated output 5760VA 208V x 27 7A 3 Single phase lower application 120V Connect the power cables to terminals 0 and U 0 and V and 0 and W Maximum one third l 3 of generator out put can be utilized from each phase Generator rated output 3324VA 12OV x 27 7A 3 PHASE OUTPUT 0 u v w 0 L c 3 4 SINGLE PHASE OUTPUT SI...

Page 19: ...n the main coil and DC coil 4 3 2 VOLTAGE REGULATING MECHANISM RGV12000 Connect a load to the AC output terminal and increase current Output voltage varies as shown in Fig 4 3 depending on whether an automatic voltage regulator is used or not The operation of the AVR is explained below When an AC output is taken the engine is loaded and its rpm falls Also the AC voltage fails due to the voltage dr...

Page 20: ...eld coil creates a strong magnetic field in the rotor which falls with the amount of the load increasing the voltage G r iENERATOR CONTROL BOX ___ ir __ __ __ __ __ __ AC output 1 terminal 0 ll 4 3 4 THE ADVANTAGES OF CURRENT TRANSFORMER CONTROL RGV13000T With AVR control control is effected according to variations in output voltage When an inductive load is applied a large starting current is req...

Page 21: ...e the generator on a level surface If the generator is tilted or moved during use there is a danger of fuel spillage and a chance that the generator may tip over 5 Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is wet by rain or snow wipe it and thor oughly dry it before starting Don t pour water over the generator directly nor wash it with water If t...

Page 22: ...ires 600 W to 700 W power source to be turned on A rated 3060 W generator can power four or five 400 W mercury lamps NOTE 1 If a power factor correction capacitor is not applied to the mercury lamp or fluorescent lamp the more power shall be required to drive those lamps A rated 3000W generator can drive one or two 400W mercury lamps without power fac tor correction capacitors NOTE 2 Nominal watta...

Page 23: ... 0 9 the efficiency Fluorescent lamp l l l l 9 l l l l l 0 7 to 0 8 Example 1 A 40 W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and accordingly power consumption will be 40 0 7 57W As explained in item 2 multiply this power consumption value of 57 W by 1 2 to 2 and you will get the figure of the necessary capacity of a generator In other words a genera tor with a ...

Page 24: ...hows cables and their allowable currents for your reference 2 Cable length if a long cable is used a voltage drop occurs due to the increased resistance in the conduc tors decreasing the input voltage to the load electrical product As a result the load can be damaged Table 7 2 shows voltage drops per 100 meters of cable Voltage drop indicates as V X RXIX Q R means resistance Q 100 m on the above t...

Page 25: ... output voltage ofllOor120V 0 to 300 V Type with an output voltage of 220 230 or 240 V 0 to 150 V 0 to 330 V Dual voltage type 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10 A 20 A 100 A FOR AC 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s ...

Page 26: ...lect one with testing voltage range of 5oov 7 2 AC OUTPUT MEASURING TO AC Use a circuit above for measuring AC output A hot plate or lamp with a power factor of 1 O may be used as a load Adjust the load and rpm and check that the voltage range is as speci fied in the following table at the rated amperage and rated rpm 23 ...

Page 27: ......

Page 28: ...ts and the grounded parts CURRENT TRANSFORMER RGV13000T Measure the insulation resistance between each terminal and the core If it is less than 1MQ replace the current transformer Any part where the insulation resistance is less than 1M Q has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 225 ...

Page 29: ...ge 8 2 AC RECEPTACLES Using a circuit tester check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel When continu ity is found between the output terminals of the receptacle with a wire connected across these terminals the AC receptacle is normal When the wire is removed and no continuity is found between these terminals the...

Page 30: ...k the resistance between wires with a circuit tester referring to the following specification table NOTE If the circuit tester is not sufficiently accu rate it may not show the values given and may give erroneous readings Erroneous readings will also occur when there is a wide variation of resistance among coil windings or when measure ment is performed at ambient tempera tures different from 20 c...

Page 31: ...a wide variation of resistance among coil windings or when measure ment is performed at ambient tempera tures different from from 2O c 68 F SilP RING 2 Cleaning Slip rings The slip ring surfaces must be uniformly bright Slip rings showing black spots excessive wear or uneven wear must be repaired A stained slip ring lowers gener ator efficiency and output voltage Polish the slip rings with fine sa...

Page 32: ...for the AC current which generated by the magnetic flux by the field coil 0 2 Distinguish the Good and Bad Parts For making a simple Good G No Good NG judgement refer to the following table showing continuity test criteria when mea sured between lead wires using a circuit tester O Y0 0 2 t BRUSH Circuit tester with measuring range of more than 1MQ When measuring continuity set the cir cuit tester ...

Page 33: ...ith new one 8 9 ECU ELECTRONIC CONTROL UNIT Check the resistance between 13 terminals of ECU with circuit tester Terminal number of the ELECTRONIC CON TROL UNIT I Tester 4 cxlcowwwwwwwwww 0 co co ccl co a3 co co co co co co co 03 18 4MR 1OMR 10 2MQ 03 10 4MR 1lMR 14 4MR 5 3MC I 03 03 co rester Co CO CO CQ Co CO Co 03 03 03 03 Co I co CO Co 00 CO Co 03 2675kQ Co Co 00 CO 1 I CO 1 CO 1 00 1 Co 1 CO ...

Page 34: ... needle of the circuit breaker needle of the cir Tester measuring range 1000 k Q NOTE The resistance readings vary depending on the types of circuit testers The above table shows an example of the resistance readings measured by an ordi nary analogue circuit tester with 1 5 volt battery power source it is advisable for you to check the resistance readings using your standard circuit tester and rev...

Page 35: ...convenience divide the parts into several groups and store them in boxes 3 To prevent bolts and nuts from being misplaced or installed incorrectly replace them tem porarily to their original position 4 Handle disassembled parts with care clean them before reassemble using a neutral clean ing fluid 5 Use all disassembly assembly tools properly and use the proper tool for each specific job 9 2 COMPO...

Page 36: ... 1 Generator assembly STATOR Jw i M BUSHING 1 cFLANGE NUT j I 11 13 7Nm 1 120 140Kg cm 1 COVER I MOUNT RUBBER Wk I END COVER RGV13000T onlv I 33 ...

Page 37: ...l Box RGV12000 PLAT E I I I CONNECTOR I I I _ EMOTE EARTH CONNECTOcd for RI CONTROL IDEL CONTROL SWITCH AC RECEPTACLE L NO FUSE BREAKER 1 CiAMP e AC RECEPTACLE STARTER SWITCH PRESSURE FINING LAMP I7 VOLi METER 34 ...

Page 38: ... 2 2 Control Box RGVI 3000T PLATF CURRENT TRANSFORMER EARTH GROUND I r ND FUSE BREAKER VOLT METER AC dUTPUT TERMINAL 35 ...

Page 39: ... 3 Fuel Tank FILTER PACKING CUP FUELTANK w j BRACKET STRAINER PURSE LOCK 36 ...

Page 40: ... Apply a wrench on the through bolt and hit wrench handle clockwise with a ham mer to tighten If an impact wrench is available use it I Tightening torque I 230 250kg cm 22 5 24 5 N m 16 6 19 5 ft lbs 3 STATOR 1 Put the stator in the rear cover setting the four grooves on the side of stator with thread holes of the rear cover Tighten the four bolts tentatively to check if the grooves and thread hol...

Page 41: ...nstall the brush holders in the rear cover Pass the mounting screws through the brush holders push the brush holders so that the brushes will be perpendicular to the slip rings and tighten the screws NOTE There are two kinds of brush holders If a brush is installed oblique to the slip ring the brush holder can break when the screw is tightened or the brush may break when the generator of started A...

Page 42: ...0T only Attach the end cover to the rear cover 6 Tighten the nuts over the mount rubber bolts to fix I Tightening torque I 1 120 140kg cm 11 8 13 7 N rn 8 7 10 1 ft lbs NOTE When tightening the nuts slightly lift the alternator assembly so that the weight is not applied to the mount rubbers 7 Fasten the earth cable to the unpainted bolt hole on the frame 39 ...

Page 43: ...age is too high or too low Check engine speed Nominal engine speed at no load 3 100 to 3 150 rpm If engine speed is too high or too low adjust to the rated rpm l Check stator for winding resistance and insulation Refer to 9 4 and 8 3 l Check rotor for resistance and insulation Refer to 9 5 and 8 3 Checking the idle control unit RGV12000 Refer to 9 l 0 If insulation is NG replace idle control unit ...

Page 44: ...dose not operate netted switch of remote controller must be turns into ON position 3 The above possible causes1 The ECU is defective and 2 dose not apply Replace with new one 2 Warning lamp turns on and off when engine is stopped 1 No fuel in the tanks or the fuel cocksare closed 2 Oil level is low or oil is contami nated Supply fuel or open the fuel cocks Add or change engine oil 3 Engine is auto...

Page 45: ...C output receptacle l20V receptxle l Z40V receptacle l20 24OV 1 4Gm Y i Ik L __ _ 7 Exciting coil Engine Red White Yellow BWR BlecWRed FtiW R White LGm Light green Wiring color cord Btk Biick BrmVi BrawvWhite R BMW Bteck Whnte Gm Green W Blr Blue GnW GreenWhite Y LBlu Liptblue Org Orange Bm Brown Gry Gray Pik Pink Gmh GreemWeilow 42 ...

Page 46: ...a RGVI 3000T ONTROL BOX _ LGm 1 r w p w1 wi C I 7 I I L to earth terminal Key switch Iv m ssur GENERATOR CONTROL BOX __ __ _ _ 1 AC output terminal 0 Earth Ground terminal 43 ...

Page 47: ...Robin America Inc 940Uvely Blvd l Wood Dale It 60191 l Phone 630 350 8200 l Fax 630 350 8212 e mail sales robinamerica com l wwwrobinamerica com 0 Copyright 2000 Robin America inc PRINTED IN THE USA ...