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Robin LG072, Service Manual

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Summary of Contents for LG072

Page 1: ...6 Generator Model 16072 LG102 lG152 LGZOl LG301 LG2OlD LG301D LGK102 LGK152 ...

Page 2: ...escription of Generator Operation 24 6 SAFETYPRECAUTIONS 25 7 APPLICABLE RANGESofGENERATOR 26 8 MEASURINGPROCEDURE 29 8 1 Meters 29 8 2 AC Output Measuring 31 8 3 DC Output Measuring 31 8 4 Insulation Resistance Measuring 31 9 CHECKING FUNCTIONAL MEMBERS 33 9 1 Stator Assembly 33 9 2 Rotor Assembly 33 9 3 Brushes 34 9 4 AVR Automatic Voltage Regulator 34 9 5 Fuse Holder andNo FuseBreaker 36 9 6 Re...

Page 3: ...1 SPECIFICATIONS T N I 0 m E P f 0 0 0 n I m N I P P 0 V a p 9 I f a a a m m m a Y I i I LT a I t i I 1 I i I 9 0 W E E 0 0 0 P n I m m I i i I c 3N19N3 t101Vt13N30 I 1 ...

Page 4: ... 9 0 N E E N N m N I 54 N I W 0 N I 5 N 0 I W a a I 0 r n m i a00 N N L I 9 r I i I I i t L L a i i I I I c z z T i 0 0 m i N N 3NION3 I 2 ...

Page 5: ... 0 CURRENT A 900 Output Max 700W 4 53 52 t700 Rated 600W 5 1 600 Frequency 50 Hz 5 50 500 Voltage 220V 49 I 2 8 U 300 2 L L 1200 210 W 220 0 a I 5 0 1 2 3 4 CURRENT A f Output Max 700W 2 Rated 600W 1 900 I u 49 L 500 8 50 Frequency 50 Hz 700 1 2 52 53 T 300 2 250 0 2 4 0 IlOO I W 2 51 600 Voltage 240V CT t 2 230 220 NOTE These characteristics are typical Those of 60 Hz 1 2 3 4 120 V and 50 Hz 11OV...

Page 6: ...0 1000 3 800 f 600 3 0 400 1200 t 1000 I 600 o 3 aoo 2 i II 1200 10001 3 aoo 2 t 600 5 Output Max 12OOW Rated 1OOOW Frequency 60 HZ Voltage 110V Output Max 1OOOW Rated 800W Frequency 50 Hz Voltage 220V Output Max 1OOOW Rated 800W Frequency 50 HZ Voltage 240V NOTE These characteristics are typical Those of 60Hz 120 V and 50 Hz 11OV or 230 V are similar to the above 4 ...

Page 7: ...RRENT A c 1700 I1500 I 3 1300I I 2 ill00 I900 115001 41300 2 I I I I I 3 tlloo E t 0 3 1 1500 4 13002 I I 1100 2 t 9 0 0 i i Output Max 1700W Rated 1500W Frequency 60Hz Vcltage 11OV Output Max 1500W Rated 1300W Frequency 50 Hz Voltage 220V Output Max 1500W Rated 1300W Frequency 50 Hz Voltage 240V NOTE These characteristics are typical Those of 60 Hz 120 V and 50 Hz 1IOV or 230 V are similar to the...

Page 8: ...60 Hz Voltage 110V i 42000 i500 CURRENT AI I2000 11 504 2 loo0 5 I o I 1 2 3 4 5 6 7 8 9 CURRENT A OutputMax 2000W Rated 1700W Frequency 50 HZ Voltage 220V OutputMax 2000W Rated 1700W Frequency 50 Hz Voltage 240V I500 NOTE These characteristicsare typical Those of 60 Hz 120 V and 50 Hz 1IOV or 230 V are similar to ihe above 6 ...

Page 9: ...oltage 120 VI240 V Output Max 240 V 24OOW 120 v 12oow x 2 Rated 240 V 2OOOW 120 v 1ooow x 2 Frequency 60 Hz n U t U I 0 a 5 0 CURRENT A Voltage 110 VI120 V Output Max 220 V 2OOOW 110 v 2ooow x 2 Rated 220 V 17OOW 110 V 850W X 2 Frequency 50 Hz NOTE These characteristics are typical Those of 60 Hz 110 V 220 Vand50 Hz 120 V 240 V are similar to the above 7 ...

Page 10: ...A 14 OutputMax 3400W Rated 2900W Frequency 60 Hz Voltage 11OV CURRENT A c 3000 OutputMax 3000W 2500 A Rated 2500W 200 I Frequency 50 Hz Voltage 220V z 1500 2 1000 CURRENT A OutputMax 3000W Rated 2500W Frequency 50 Hz Voltage 240V 3000 2500 t3 I 2 000 5 0 1500 000 NOTE These characteristics are typical Those of 60 Hz 120 V and 50 Hz 110V or 230 V are similar to the above 8 ...

Page 11: ...W 120 VI240 V 120 V 17OOW Rated 240 V 29OOW 120 V 145OW Frequency 60 Hz 1500 11000 I t500 x 2 x 2 t3000 t2000 110 V 125OW X 2 i Voltage 110 VI220 V Output Max 220 V 3OOOW 110 V 15OOW X 2 t2500t z Rated 220 V 25OOW 2 Frequency 50 Hz 11500 2 11000 t500 MOTE These characteristics are typical Those of 60 HZ 1 10 V E 2 0 Vand 50 Hz 120 VR40 V are similar to the above 9 ...

Page 12: ...to charge it its DC output voltage increases The battery is charged at the increased voltage level Performance curve applies to a case undera resistanceload only and curve i J represents battery charging characteristics NOTE Up to the rated ouqoutit is possible to take outsimultaneously the output of both AC and DC in total 10 ...

Page 13: ...ously available with an AC output Therefore the generator can charge a battery from its DC output terminal while also supplying anAC output The combined AC and DC outputs must be kept undr the ratedlevel Dual Voltages Are Availableon LC201D and LG301D A dual voltage type which suppliestwo AC voltages is availablein the 2kW and 3 kU classes Output Voltage Waveform Closeto Sine Wave Output voltagewa...

Page 14: ...4 GENERALDESCRIPTION of GENERATOR 4 1 EXTERNALVIEW Of GENERATOR MODEL LGO721 f 12 ...

Page 15: ...4 2 EXTERNALVIEW of GENERATOR MODELLG1021 W U U I 13 ...

Page 16: ...4 3 EXTERNAL VIEW of GENERATOR MODELS LG152 aLG2011 14 ...

Page 17: ...4 4 EXTERNALVlEWofGENERATOR MODELLGKlO2 LGK1521 15 ...

Page 18: ...4 5 EXTERNALVIEW of GENERATOR MODELLG301I 16 ...

Page 19: ...4 6 EXTERNAL VIEW Of GENERATORPANEL 7 5 0 W v 3 U V a W v V 0 v c3 0 N c I n v U W I W I 0 J v W J V 5 a t W W V U V a V a W v 3 U V a W v 3 U W 0 N c z 0 N d 2 2 l7 N N N v W U 2 v 1 7 ...

Page 20: ...5 CONSTRUCTION and FUNCTIONS 5 1 CONSTRUCTION 18 ...

Page 21: ...iliary coil and DC coil AC output power is taken from the main coil and DC output power from the DC coil The outside diameters and laminatedcore thicknesses of various models are as shown below Fig 5 1 Fig 5 2 LG102 LG152 1 LG201 I LG301 LG072 1 LGKlO2 1 LGK152 I LG2OlD I LG301 D D mm 5 47 I 5 47 1 6 97 6 97 6 97 inch 139 139 177 1 177 i 177 2 76 3 94 2 17 i 2 76 2 36 inch 70 100 55 70 60 mm 1 L T...

Page 22: ... con nected to the slip rings anddirectcurrent DC to the field coil turns the rotor and magnet The cooling fans cool the generator by drawing coolingair from the slip rings 2nd dis charging it through the fans BEARING Fig 5 3 Fig 5 4 i LG102 I LG152 LG2OlD LG301D i LGKlO2 LGK152 LG201 I MODEL I LG072 LG301 I I mm I 55 70 I 60 70 100 inch 2 17 2 76 I 2 36 I 2 76 I 3 94 I Table 5 2 20 ...

Page 23: ...OR The automatic voltage regulator employs an electronic cir cuit to automatically reglate voltage Fig 5 6 5 2 5 VOLTMETER The voltmeter comes in two types a 150V maximum type and a 300 V maximum type The voltmeter indicates gen erator outputvoltages The generators with a generated volt age of 110V or 120 V use the 150 V maximum type volt meter and those6f 220 V 230 V and 240 V specifications and ...

Page 24: ...ng AC output power from the gener I RECEPTACLES ator Each generator has two receptacles three or four re ceptacles for the dual voltage type The 125 V maximum 110 V 120 V type and 250 V maximum 200 V 230 V 240 V type differ from each other in the shape of the indi vidual output terminals L AC PLUG The AC plugs also differ in shape between the 125 V maxi mum type and 250 V maximum type The same num...

Page 25: ... for takingcooling air in Thevents are designed to prevent fingers from entering 5 2 11 RUBBER MOUNTS RUBBER VIBRATION ISOLATORS Specially designed rubber pads for controlling generatorvi bration and dislocation These are made of superior quality rubber material for optimum shape and hardness 5 2 12CARRYINGHANDLE The LC072 has a single hand carrying handle andthe other models have two hand carryin...

Page 26: ...oltage is generated in the stator coils main coil sub coil andDC coil The voltage generated in the sub coil is regulated by the AVR to feed current in orderto in crease the fieldandcurrent SeeFig 5 16 As aresult the rotor magnetismincreases Ths operation is repeated to generatetherated voltage at 50 Hz or 60 Hz in the main coil andDC coil 5 3 2VOLTAGEREGULATINGMECHANISM Connect a load to the AC ou...

Page 27: ... rain Severe electric shock may occur If the generator is moistened by rain or snow wipe it and fully dry it before starting Don t pour water over the generator directly orwash it with water If the generator is wet with water the insulations will be adversely affected andmay cause current leakage and electric shock Do not connectthe generator to the commercia powerlines This may cause a short circ...

Page 28: ...scentlamp generally doesnot indicate thepower consumption but indicates theouwut of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption or input power efficiency should be taken intoaccountsas explainedin Item 5 on the followingpage Electric tools etc that aredriven by a motor Power 1 Z to 3 times the power consumption of a motor driven tool is required...

Page 29: ...ng a 400 W motor means that its work load is 400 W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570 W When this motor is used for a motor driven tool th2 capa city of the generator shouldbe multipled by 1 2to 3 and 570 W as explained in the Item 3 Model Frequency hot plate etc Incandescentlamp Fluorescent lamp mercury lamp etc Motor driven tool general purpose motor etc Wa...

Page 30: ...their allowable currents for your reference 2 Cablelength If a long cable is used a voltage drop occurs dueto the increased resistancein the conductorsso that the input voltage to the load electricalproduct decreases Asa result the load can be damaged table 7 2shows voltage drops per100 meters of cable Current Amp 0 75 7 3010 1 a 2 477 i 2 5 I av I 1 2 5 U 1 a v 1 2 v 1 5 v 1 25 12 5010 1a 1 1 486...

Page 31: ...V 0 to 300 V Dual voltage type The DC voltmeter range is approximately from 0 to 200 V Fig 8 1 FOR AC FOR DC 8 1 2 AMMETERS AC and DC ammeters are necessary An AC ammeterwitha range that cap be changed according to the current rating of a given generator is mostdesirable About 10 A 20 A 100A The DC ammeter range is approximatelyfrom 0 to 15 A FOR AC FOR DC Fig 8 2 8 1 3 FREQUENCY METER Frequency r...

Page 32: ...age capacity of 500 V 8 1 6 TACHOMETER There are various typesoftachometers such as contact less type contactftype and strobe type The contact type can j C _ J T A T L E TYPE be used only when the generator and engine have been dis assembled The contact less type is recommended Q 3 C0NTisC T TYPE STRO BE I Y P E Fig 8 6 30 ...

Page 33: ...ttery is connected as the load the ouwut voltage increases by about 1 to 2 V possibly causingbattery over charge Control battery liquid level during chargingto prevent overcharging 8 4 MEASURING INSULATION RESISTANCE Connect amegger tester to one of thetwo receptacle output terminals and the ground terminal then measure the insula tion resistance Ifyourgeneratoris theno fisebreakertype close the n...

Page 34: ...lation resistance betweenthecoreand one of the slip rings of the rotor CONTROL BOX Measure the insulation between the live parts and the casing or grounded part i _ c g Any part which has an insulation resistance of less than 1 megohm has afaulty insolation whichcan cause electric shock orleakage Replace such parts Fig 8 12 32 ...

Page 35: ...shownin the Tables9 I 9 2 and 9 3 I WHITE I 0 7 6 5 2 I 0 1 0 9R 2 5 5 0R I Table 9 1 LG152 LG201 LG301 LGK152 WHITE 0 2 3 1R I 1 5 4 lQ BLUE BLUE 0 1 0 5R Table 9 2 Fig 9 1 LG201D LG301D Wire cotor RED BLACK 1 GREEN I WHITE I 0 4 1 3R 0 4 1 3s1 1 7 3 6R A BLUE BLUE 0 1 0 5R Table 9 3 9 1 2 MEASURING INSULATION RESISTANCE ROTOR Refer to 8 4 MEASURING INSULATION RESISTANCE 9 2 ROTOR ASSEMBLY 9 2 1 ...

Page 36: ...m 5 mm to 15 mm as shown in Fig 9 4 A brush shorter than 5 mm must be replacedbecause decreased con tact pressure between the brush and slip ring lowers genera tor efficiency andoutput voltage Fig 9 3 f i 1 5 m m 5 m m 1 5 m m 5 m Fig 9 4 9 4AVR AUTOMATICVOLTAGEREGULATOR AVR trouble may be identified by simply koking at theAVR or by checking the inter lead resistance with a tester or actu ally mou...

Page 37: ...I 1 Yetlow j Red White Green i Brown 1 i I I m i 700K 1MR 72K 120KQ Another One wire OS2 i 6 5K 10KQ Yellow t I m 400K 500KR 72K 120KR Another oo I I 250K 300KR Red m I 400K 500Kn _ 130K 140KR m 220K 250KQ White I i 130K 140KR I m i 45K 50KSL 600K 1MS2 i 70K 110KQ i 400K 500Kn 70K 11OKR I i 7K 9 5KR I 6 5K 8 5KQ Green I 400K 500KR 40K 46KR 1 200K 300Kfi i 40K 4 6 K n j m I m Black Upper rowsare fo...

Page 38: ... 9 6 TESTER 50Hz 60Hz 110V I 220V I 230V I 240V 11ov I 120v DC I I I I 6A I 3A I 3A 7A 6A I 3A LG072 I 10A 1 10A 4A 4A 10A 8A 4A LG102 LG152 15A 6A I 6A 6A 15A I 15A i LG201 20A 15A 8A 1 8A 8A 20A Table 9 6 50Hz 1201240V 1 1 Ol220V 11Ol220V 60Hz 1201240V DC LG2Ol D 10A 8 A x 2 10Ax 2 10Ax 2 8 A x 2 LG301 LG301 D employ a no fuse breaker Table9 7 9 5 2 NO FUSE BREAKER Only the LC301 and LG301Dhave ...

Page 39: ...the voltmeter reads normal 9 8 DIODE STACK ASSEMBLY Fig 9 9 The internalcircuitry of thediodestack assembly is as shown in Fig 9 9 Check inter terminal continuity with a tester as showninFig 9 10 to see that the resultsare as shown inTable 9 8 VOLTMETER Fig 9 8 _ 1 I I I Fig 9 10 NOTE A B Current flows from A to B 6 C D Current does not flow from C I to D 1 Check both terminals Table 9 8 37 ...

Page 40: ...exciting circuit as follows A Disconnect the control box and operate the generatorat therated rpm Disconnect the two yellow wires from the excit ing coil to the AVR and momentarily connect the positive and negative leads of a batteryin their place If no output voltage is generated reconnect the battery leads the otherway If output voltage is generated the exciting coil is defective B If no output ...

Page 41: ...tools in the correctway 10 2 HOW TO DISASSEMBLE Order Remarks I Tool Procedures Item 1 Remove cord bushing by j 3 Disengagelead connector which con i ently forcorrect reassem I connector which connects generator to i 2 Move controlbox and disengagelead 1 Leads are colored differ or screwdriver generator See Fig 10 1 8 mm box wrench Control box 1 Remove bolts fastening control box to i S o bolt 4 p...

Page 42: ...der 60 screw 2 pcs If rear coverisremoved I screwdriver from generator without brushholder brush will break so be sure to re move brushholder screwdriver Fig 10 3 Fig 10 4 I Order Remarks I Tool Item I Procedures i I I 3 Rear cover I 1j Loosen and remove cover bolts I 10 mm box wrench I LG072 LG102 LGK 101 LGlS2 LG201 LG OlD LG301 I I 50 bolt 3 pcs i I i LG301D LGK152 1 i 69 bolt 3 pcs i 2 Remove ...

Page 43: ... 1 strike it hard counterclockwise w hammer to loosen through bolt I See Fig 10 7 LG072 6Qbolt 1 PC I LG102 152 201 ZOlD LGKl I LGKl52 i 89 bolt 1 PC LG301 301D I lOQ bolt 1 PC ith I I 02 I 2 Remoye rotor Lightly tap rotor core I with plastic hammer and remove rotor i from engine taper shaft If it is difficult to remove tapat a different angle I See Fig 10 8 I Be careful not to let 1 screwdriver b...

Page 44: ...fore prepare the tool in the dimensionsof the following for pullingout the rotor L U Ti k L F F c 4 MODEL Pitch D C B A 1 L LG301 LG301D For U S A and Canadian markets 250 mm 1 5 mm 20 mm 12 mm 33mm910 mm I g8 mm I LG152 0 79 Q0 31 I 00 24 7 2 1 3 0 39 1 0 06 LG201 LG201 D 7 7 I 1 3 90 31 1 90 24 0 79 0 39 0 06 LG301 LG301D I I I 8 6 90 24 0 79 0 39 i 0 06 1 2 90 31 i I Table 10 1 4 2 ...

Page 45: ... I I 366 54337 08 j SHAFT I LG201 LG201 D I I 367 54339 08 I SHAFT LG301 LG301 D I 3655433608 BOLT LG152 LG201 LG201D LG301 LG301 D Table 10 2 2 Remove a throughbolt and insert the shaft of rotor puller into the hole for throughbolt and push it up till the shaft reaches the screw hole of the P T 0 shaft on theside of engine 3 As hown in Fig 10 9 screw up the rotor puller shaft and remove therotor ...

Page 46: ...o longer bolts areused Remove spacer too 2 Remove handle and front cover LG072 Others 69 bolt 2 pcs Tool Order I Item I Procedures Remarks I 6 j Front cover 1 Remove bolts which fasten engine main bearingcover and front cover together j 10 mm box wrench 13 mm box wrench 10 mm box wrench I I I 86 bolt 3 pcs i 13 mm box wrench I 44 ...

Page 47: ...gine NOTE The LG102 LG301 and LG301D for U S A and Canadahave a spacer between the main bearing cover andfrontcover See Fig 10 11 Thus the bolts are 45mm long for LG102 and 25 mrn long for LG301 LG301D and are tightenedtogether with the spacer FOR LG301 LG301 D FOR LG102 Fig 10 11 10 3 2 ROTOR 1 Wipe the engine output shaft taperandrotorfemale taper to remove oil and dirt using a cloth 2 Install t...

Page 48: ...delsfor U S A and Canada 10 3 3 STATOR Table 10 2 I LG072 LG102 LGK102 1 Placethestator in thestator cover 2 Align it with the front cover faucet joint and install the stator See Fig 10 14 NOTE Make surethat thearc of the stator matches the faucet joint See Fig 10 13 The leadsmust be up so they can be taken out from the top FRONT COV ATOR COVER Fig IO 13 NOTE The outside diameter and laminated thi...

Page 49: ...t diagram and a connector to the diode stack DIODE I Fig 10 15 The diode has markings of input positive and negative 1 in this part LG072 LG102 LGK102 is yellow and white blue and 1 brown LG152 LG201 LG201D LG301 LG301D LGK152 Two leads are blue orange and 1 brown Pass all the leads that come out of the hole in the top of the rear cover fromthe statorand the diode NOTE LG152 LGK152 LG201 LG201D LG...

Page 50: ...over bolt andfoldthe edge around it to fasten it 10 3 5 BRUSH HOLDER 1 Install the brush holder in the rear cover Pass the mounting screws through the brush holders and tighten the screw while pressing to the slip ring perpendicular to it See Figs 10 17and 10 18 LG072 LG102 LGKl02 4 x 20 mm screw 2 pcs LG152 LG201 LG201D LG301 LG301D LGKl52 50 x 18 mm screw 2 pcs NOTE If the brushholder is mounted...

Page 51: ...2 LG102 LGK102 LG152 LG2C1 LG2OlD LG301 LG301D LGK152 Fig 10 19 NOTE LG072 LG702 LGK102 The green lead must be on the statorside BLACK WIRE 1 7 GREEN WIRE I BRUSHHOLD ENGINE P T O FRONT COVER COOLINGFAN REAR COVER 1 STATOR COIL STATOR COMPL RUBBER I MOUNT SHAFT Fig 10 20 49 ...

Page 52: ... the generator and control box Connect the connectorshaving the same colored lead NOTE All connectors canbe wired Theleads from the same point have the same colors but do not con nect themselves but connect to other leads of the same color 2j Mountthecontrol box on thegenerator See Fig 10 27 59 x 15 mm bolt 4 pcs NOTE Be careful not to let the leadsbe caughtbe There may be extra holes in the cover...

Page 53: ... front panel parts individually after discon nectingtheir leads NOTE Thefuse holder has its ledssoldered so that they must beunsolderedbeforeremoving the fuse holder Thedualvoltage type uses two fuseholders The other typesalsohave two fuseholders but use only one of them Theother is a spare Remove the AVR 4 Disconnect the DC terminal and DC fuse holder and Fig 10 24 remove them NOTE The fuseholder...

Page 54: ... Primary exciting circuit in AVR defective Resistance outside Slip ring defective TOK Brush defective Check windingresistance Field coil short range of 6 1 3 n or broken Main coil broken resistance in 9 1 See the description o f winding resistance in 9 1 OK Check AVR AVR Replace Replace Wire correctly Replace exciting coil 0 Replace AVR Clean replace Check replace Replace Replace stator Replace st...

Page 55: ...mal rpm See 11 Voltmeter does not work Fuse checked Fuse burnt out leads unconnected Characteristicsfaulty Diode broken DC coil broken 3 Voltage too high 0 Check for cause and replace Wire correctly Replace 0 Replace stator Check AVR AVR broken 0 Replace 53 ...

Page 56: ...ted IOK ng wiring Wrong wiring e wire joints Resistance more than 14R OK OK Brush defective Main coil shorted O K Sub coil shorted AVR broken 0 Remedy Adjust Wire correct Adjust Replace Clean replace Check replace Replace Replace Replace 54 ...

Page 57: ...t 0 Check and correct load Generator insulation I l defective I r Generator overheat Cooling air not t Fan faulty cooling circulating weli air passage biocked 0 Check Correc Replece OK 4 t o 6 1 3 R Resistance not withinrange of Slip ring defective Brush defective Slip rings checked Slip ring defective Brush defective Not checked properly Or opera tion returns t o normal when AVR AVR defective is ...

Page 58: ...12 CIRCUIT DIAGRAMS MODEL LG072 LG102 LGK1021 GENERATOR CONTROL BOX ENGINE MODEL LG152 LG201 LGK1521 GENERATOR CONTROL 56 ...

Page 59: ... MODEL LG OI I GENERATOR CONTROL BOX ENGINE MODEL L G I D 1 57 ...

Page 60: ...eld Winding Field Coil I I B I Brush I I AVR 1 Auto Voltage Regulator I I Voltage Meter I I Diode Stack Assy I 11OVREC 110V 1 20V Receptacle 220V REC 220V 240V Receptacle I T I DC Output Terminal I I NFB I No Fuse Breaker SP lg Spark Plug Excitor Coil ExC Exciting Coil Charge Coil EC Ignition Coil I Pulser Coil I I MG I Magneto I I SB I Stop Button I 1 S I U Solid State IgnitionUnit CDI 58 ...

Page 61: ... Rd mGenerator ...

Page 62: ...FUJI HEAVY INDUSTRIES LTD ...

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