R1210 GENERATOR SERVICE MANUAL
Contents
1. Continuity exists Fig 9 7 CATHODE MARK POLARITY OF CIRCUIT TESTER 9 4 CONDENSER m Use a Dr Robin in capacitance meter mode to check the capacity of condensers See Fig 9 8 NOTE Be sure to discharge condensers by shorting condenser leads each other be fore checking their capacitance or the accurate reading cannot be obtained Normal Capacity of Condenser Fig 9 8 m If such an instrument is unavailable the condenser can be checked by replacing with a new one If the generator performs good with new condenser the cause of trouble is defect in original condenser 9 5 DIODE RECTIFIER Red Green _ Ps Green Green Green Fig 9 9 DIODE RECTIFIER N gt CIRCUIT 2 Fig 9 10 The internal circuit of the diode rectifier is as shown in Fig 9 9 Check continuity between each terminal using a circuit tester as shown in Fig 9 10 m Checking table for analogue circuit tester Apply black needle of the circuit tester I CR RECH onen anay Table 9 2 1 Analogue circuit tester Apply red needle of the circuit tester m Checking table for digital circuit tester Apply red needle of the circuit tester se om nr Digital circuit tester Apply black O needle of the circuit tester Green nn No continuity No continuity ann on Red Continuity i Continuity Table 9 2 2 NOTE 1 Becaus2. Fig 10 25 Sage See fm Im 13 Rotor 4 Screw the bolt into the thread of the rotor shaft 5 Torque the bolt using a socket wrench Socket wrench until the rotor comes off loose The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft 4 Wipe off oil throughly from rotor shaft and engine PTO shaft Fig 10 26 Front bracket 1 Remove the front bracket which is mounted on the main bearing cover of the engine by taking out four M8 X 18 bolts See Fig 10 27 13 mmbox spanner Sn Pano reno 15 Mount 1 Remove mount bracket from engine 12 mm wrench rubbers Remove mount rubbers from mount bracket 8 Nut 3pcs or 2pcs Mount bracket Mount rubber Fig 10 28 10 3 ASSEMBLY PROCEDURES 10 3 1 FRONT BRACKET Install the front bracket on the main bearing cover of the engine engaging the faucet joint See Fig 10 29 M8 X 20mm bolt and washer ass y TIGHTENING TORQUE 120 140 kg gt cm 1175 1370ON cm 8 7 10 1 ft Ibs 10 3 2 ROTOR 1 Wipe off oil from the tapered portion of engine shaft and matching tapered hole of rotor shaft See Figs 10 30 and 10 31 Fig 10 30 2 Install rotor on the engine shaft and tighten the through bolt Apply a wrench on the head of through bolt and hit wrench handle clockwise with a ham mer to tighten See Fig 10 32 If an impact wrench is available use
3. co na a ud a PORTABLE GENE ERATOR LSZ HES t Technical Data amp Overhaul Instructions SERVICE MAN VAL CONTENTS Section Title Page TROUBLE ij L NO WIRING DIAGRAM 1 110050x60x40000 0000080400400 5004 200880200 EN EE EE ENEE EE un RG 32 SERVICE NEWS ir Robin Generators FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS DIV MODEL SUBJECT R1210 Oil Sensor change This Service News is to inform of the change of the oil sensor and wiring equipped with the ROBIN engine EY15 for R1210 generator set 1 Purpose To improve the performance of the oil sensor 2 Main points of the modification 1 The oil level sensing mechanism of the oil sensor is changed from piezo resonator type to potentiometer type 2 The electric wiring and clamp are also changed 3 Change of part number For the detail refer to the attached figures New Parts set NO Part Name Part number Q ty 1 Oil sensor CP 6 KS3 11015 01 1 2 Wire 7 CP 227 73107 01 1 3 Clamp 056 60002 50 1 Current parts set NO Part name Part number Q ty 4 Oil level sensor CP 227 76035 01 1 5 Wire 22 CP 214 73122 01 1 6 Clamp CP 206 75501 01 1 Interchangeability It is interchangeable only when the all parts are replaced as a set that is to say the current parts set item NO 4 to 6 can be replaced with new parts set item NO 1 to 3 However there is no interchangeability
4. for the individual part 4 Execution This oil sensor change is adopted to the new ROBIN generator set to be produced in and after September 1995 j Attachment A oil sensor installation change New installation Current installation Attachment B 1 Oil sensor change New OIL SENSOR CP 6 KS3 11015 01 gt Current OIL LEVEL SENSOR CP 227 76035 01 2 Electric wiring change New WIRE 7 CP 227 73107 01 Current WIRE22CP 214 73122 01 3 Clamp change New CLAMP 056 60002 50 Current CLAMP CP 206 75501 01 1 SPECIFICATIONS 110V 7 3 A 110V 9 1 A AC Voltage 220V 3 6 A 120V 8 3 A Rated current a aa 230V 3 5 A 220V 4 5 A 240V 3 3 A Max 1000 W 1200 W AC Output Rated 800 W 1000 W DC Output 12V 8 3A 100 W Voltage regulation system Condenser system Enai T Forced air cooled 4 stroke side valve ngine ype gasoline engine Displacement 143cc 6 73 cu in Bore x Stroke 63 x 46 mm 2 48 X 1 81 in Fuel i Automotive gasoline Fuel tank capacity 3 5 liters 0 9 U S gal Oil pan capacity 600 cc 1 3 U S pints Approx 4 3 hours 50 Hz Approx 3 5 hours 60 Hz Ignition system Solid state ignition Starting system Recoil starter 486 x 288 x 410 mm 19 1 x 11 3 X 16 1 in Dry weight 27 5 kg 60 6 Ibs Rated continuous operating hours Dimensions L x W x H 2 PERFORMANCE CURVES 2 1 AC OUTPUT SS PS 233
5. it TIGHTENING TORQUE 120 140 ko cm 1370 N cm 10 1 ft Ibs 1179 8 7 ES a 1 Fig 10 32 10 3 3 STATOR 1 Holding the rear bracket and stator fit them to the front bracket Match the mounting hole of the rear bracket and that of the rotor bear ing and softly strike the outside periphery of the rear bracket with a plastic hammer See Fig 10 33 2 Attach the stator cover around the stator Fig 10 33 3 Tighten the three M6 bolts to fix the rear bracket to the front bracket TIGHTENING TORQUE Rear bracket 55 75 kg cm 535 735 N cm 40 54 ft lbs 4 Put the grommet in the groove of the rear bracket and secure the wire Note Fix the wire from the stator and diode stack with the clamp at the bottom of the groove 10 3 4 CONDENSER Put condenser to rear cover 5 X 10 mm tapping screw een 2 pcs TIGHTENING TORQUE 33 55 ko cm 325 535 N cm 24 AO ft lbs Condenser 10 3 5 END COVER Set the end cover on the rear bracket with three M4 X8 screws Bracket Cover 10 3 6 BRACKET COVER 7 LN i Mount the bracket cover on the rear bracket and secure them with M8 X 30 bolts i End cover Fig 10 35 10 3 7 FUEL TANK AND FUEL PIPE CONNECTION 1 Connect the rubber pipe to the engine carburetor and fasten it with a hose clamp Attach the banjo to the opposite end of the rubbe
6. its cover removed The operator may be injured or suffer electric shock CAUTION If the circuit breaker tripped off as a result of using an electrical appliance the cause can be an overload or a short circuit In such a case stop operation immediately and carefully check the electrical appliance and plugs for faulty wiring T RANGE OF APPLICATIONS Generally the power rating of an electrical appliance indicates the amount of work that can be done by it The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance The electrical appliances generally have a label showing their rated voltage frequency and power consumption input wattage The power consumption of an electrical appliance is the power necessary for using it When using a generator for operating an electrical appliance the power factor and starting wattage must be taken into consideration In order to determine the right size generator it is necessary to add the total wattage of all appliances to be connected to the unit Refer to the followings to calculate the power consumption of each appliance or equipment by its type 1 2 3 4 Incandescent lamp heater etc with a power factor of 1 0 Total power consumption must be equal to or less than the rated output of the generator Example A rated 1000W generator can turn ten 100W incandescent lamps on Fluorescent lamps mercury lamps et
7. 8 ON Si SG O o N ke PG ak E ZE ae gt 52 Sace ae ki V 6 5 D 3 3 D a o 9 o S 85 gt 25 O UL gt O u gt M LNdINO oO Q MW LNALNO S gt 2 3 gt n o pa amp s co gt N 8 g 2 O O oO amp gt N NG TI lt 5 5 5 2 BENg NIN 9 N CC CC lt 3 F 5 i i gt N CH LO o O a 8 R ee AJADVLIOA 2 W39VL10A ZH AON3NDIYHH CURRENT A 2 2 DC OUTPUT VOLTAGE V mm CURRENT A gt DC Voltage PUPPY APP TPP TF TETE 1 2V DC Ampere een NG KGG pia 83A DC output PAPA PA PPO boss atte 100W 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 3 3 3 4 3 5 3 6 3 7 FEATURES BRUSHLESS ALTERNATOR New brushless alternator has put an end to costly brush maintenance and down time CONDENSER VOLTAGE REGULATOR Condenser voltage regulation ensures stable voltage output under all working conditions COMPACT LIGHTWEIGHT CARRYING EASE As the new burshless alternator makes the Robin R1210 lightest in the class at 27 5 kgs you can easily carry it around using the convenient carrying handle EASY OPERATION One touch engine control switch integrates engine on off switch and choke lever All controls are conveniently concentra
8. AC RECEPTACLES Using a Dr Robin or 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 continuity 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 receptacles are also normal Fig 9 1A Fig 9 1B 9 1 2 DC RECEPTACLE Check continuity between the DC terminals at the rear of the receptacle using a circuit tester under the condition that the receptacle is mounted on the control panel When continuity between the DC terminals of the receptacle is confirmed with a wire connected across the terminals and is not confirmed if the wire is removed the DC receptacle is normal Fig 9 2 9 1 3 CIRCUIT BREAKER Check continuity between the two terminals at the rear side of the circuit breaker using a circuit tester while it is mounted on the control panel If continuity is confirmed when the breaker is ON and no continuity is confirmed when the breaker is OFF the circuit breaker is normal 9 1 4 VOLTMETER Check the voltmeter if it operates correctly by applying specified voltage Voltmeters cannot be checked with a circuit tester because its internal resistance is too large Voltmeter Fig 9 4 9 2 STATOR Disengage connectors on the wires from sta
9. Dr ROBIN GENERATOR TESTER The Dr Robin generator tester is exclusively designed for fast easy diagnosis and repair of Robin generators The Dr Robin has the following features 1 Functions of voltmeter frequency meter megger tester capacitance meter and circuit tester are combined in one unit 2 Fast and easy readout by digital indicator 3 Built in automatic battery checker indicates the time to change batteries Fig 8 1 4 Tester and accessories are installed in a handy sturdy case for easy carrying e SPECIFICATIONS C Circuit Protector Fuse Measuring Range Power Source Accessories Dimensions L X W X H Table 8 1 The Dr Robin generator tester can be ordered from Robin generator distributors by the following part number Dr Robin Part Number 388 47565 08 If you do not have a Dr Robin generator tester use the instruments described in the following section for checking generator parts 8 1 2 INSTRUMENTS 1 VOLTMETER AC voltmeter is necessary The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows Oto 150V Type with an output voltage of 110 or 120V Oto 300V Type with an output voltage of 220 230 or 240V 0 to 150V 0 to 330V Dual voltage type 2 AMMETERS AC ammeter is necessary An AC ammeter with a range that can be changed according to the current ra
10. ION COIL MAGNETO WVYSVIG ONIXIM A FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS DIV OVERSEAS SALES DEPT Subaru Bldg 1 7 2 Nishi Shinjuku Shinjuku ku Tokyo 160 Japan TEL Tokyo 03 3347 2414 5 TELEX 232 2401 FUJI J CABLE ADDRESS FUJIHEAVY TOKYO FACSIMILE TOKYO 03 3347 2418
11. ar cover by unscrewing Plus driver three M5 X 8 screws and two M8 X 10 screws See Fig 10 2 Control panel 1 Pull the knob off the control lever and Plus driver remove the control panel by unscrewing four M5 X 8 screws See Fig 10 3 ES ae 4 Couplers 1 Disengage the couplers of stator wires Pull the couplers while and plugs from the wires of control panel pushing the locking Discon 6P couplers Yellow Red Green hook nection Yellow Brown White See Fig 10 4 2 Disengage the connectors of grounding wire Pin terminal Green Yellow See Fig 10 5 H i Press the hook of the coupler and pull out to disconnect CONTROL PANEL SIDE STATOR SIDE Front cover Description Remarks Tool 1 Remove the element cover by unscrewing M6 X 12 screw See Fig 10 7 E 5 2 Remove the front cover by unscrewing three M5 X 8 screws See Fig 10 8 Driver ANI vs el pe See S ne 2 te SE BLES iy Ha hu Be N x XOX T Fuel pipe 1 Discharge fuel from the tank Use utmost care about and plug 1 Shut the fuel striner fire hazard Discon 2 Remove the strainer cup i nection 3 Put a vessel to receive fuel under the Wipe off spilt fuel strainer and open the fuel cock to throughly discharge fuel See Fig 10 9 4 Attach the strai
12. c with a smaller power factor Select a generator with a rated output equivalent to 1 2 to 2 times of the power consumption of the load Example A 400W mercury lamp requires 600W to 700W power source to be turned on A rated 1000W generator can power one 400W mercury lamp 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 1000W generator may unable to drive a 400W mercury lamp without power factor correction capacitors NOTE 2 Nominal wattage of the fluorescent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption efficiency should be taken into account as explained in item 5 on the following page Motor driven tools and light electrical appliances Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times lager than thetr running wattage Example A rated 250W electric drill requires a 400W generator to start it Initially loaded motor driven appliances such as water pumps compressors etc These appliances require large starting wattage which is 3 to 5 times of running wattage Example A rated 900W compressor requires a 4500W generator to drive it NOTE 1 Motor driven appliances require the aforementioned generator output only at the starting Once their motors are started the appl
13. ctive voltages in the main coil and condenser coil rise up As the current increases the magnetic flux at the rotor s magnetic pole increases further Thus the voltages at the main coil and condenser coll keep rising by repeating this process As AC current flows through the condenser coil the density of magnetic flux in the rotor changes This change of magnetic flux induces AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies this AC voltage into DC Thus a DC current amp flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil When generator speed reaches 2700 to 2800 rpm 50Hz type or 3000 to 3300 rpm 60Hz type the current in the condenser coil and field coil increases rapidly This acts to stabilize the output voltage of each coils If generator speed further increases to the rated value the generator output voltage will reach to the rated value 5 3 2 VOLTAGE FLUCTUATIONS UNDER LOAD When the output current flows through the main coil to the appliance a magnetic flux is produced and serves to increase current amp in the condenser coil When current increases the density of magnetic flux across the rotor core rises As a result the current flowing in the field coil increases and the generator output voltage is prevented from decreasing 5 3 3 DC OUTPUT DC output is taken out from the DC coil and is fed to the diode stack rectifier
14. e of the difference of measuring method between the analogue circuit tester and the digital circuit tester polarity of tester needles should be reversed NOTE 2 Continuity means forward direction characteristics of the diode and different from short circuit condition in which a pointer of the tester goes out of its normal scale shows resistance to some extent When result of the checking indicates failure even in one section replace with a new one NOTE 3 Simpson brand analogue testers have the characteristic as same as the digital circuit tester 10 DISASSEMBLY AND ASSEMBLY 10 1 PREPARATION and PRECAUTIONS 1 Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly Tag the disassembled part with the necessary information to facilitate easier and smoother reassembling 2 For more convenience divide the parts into several groups and store them in boxes 3 To prevent bolts and nuts from being misplaced or installed incorrectly place them temporarily back at their original position 4 Handle disassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools properly and use the proper tool for each specific job 10 2 DISASSEMBLY PROCEDURES Side cover 1 Remove the side cover by unscrewing Plus screw four M5 X 8 screws See Fig 10 1 driver Rear cover 1 Remove the re
15. ews See Fig 10 37 2 Secure the element cover with M6 X12 screws See Fig 10 38 i ara zZ 2 a TETE FH MER NG ran rl 1 i n I d 7 EE _ a A ZA pa Ng vi LAN rel N xd r poe Fo et x f Fig 10 37 10 3 10 CONNECTION OF WIRES 1 Connect the wires drawn out from the stator to the wires from the control box See Fig 10 39 2 Press the couplers until the locking hook engages securely 3 Connect the grounding wire See Fig 10 40 Fig 10 39 Fig 10 40 WIRE CONNECTIONS BETWEEN CONTROL PANEL AND STATOR 6P coupler Wire color Yellow Red Green Yellow Brown White Red Green Yellow nun Yellow Brown Brown Yellow Red wits Green Yellow CONTROL PANEL SIDE STATOR SIDE Earth Ground wire Pin terminal Wire color Green Yellow 10 3 11 CONTROL PANEL 1 Put the control panel over the control lever and secure it with four M5 screws 2 Attach the knob to the control lever Note After the couplers and connectors have been connected and secured to the control panel secure the wires with a wire band to the control panel Fig 10 41 10 3 12 REAR COVER Secure the rear cover with three M5X8 screws and two M8 X10 screws 10 3 13 SIDE COVER Secure the side cover with four M5X8 screws Fig 10 43 m g d u Hl 0 6 E 11 TROUBLESHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING STATOR N Remove control pane
16. generator parts See Fig 5 4 A diode rectifier and resister are mounted inside of the insulator See Fig 5 5 Cooling air is sucked by the rotor fan through the slits of the rear cover and is expelled through the outlets of the front cover Fig 5 3 Fig 5 4 DIODE RECTIFIER and RESISTOR 5 2 4 CONTROL PANEL The control panel has a double AC receptacle with a ground terminal and a DC receptacle The voltmeter displays output voltage of the gen erator The circuit breaker for AC and DC in the upper section of the control panel protects the generator from getting damages caused by over loading or defective appliance Fig 5 6 5 3 DESCRIPTION of GENERATOR OPERATION INITIAL EXCITATION STATOR PERMANENT MAGNETO 1 RECEPTACLE AND PLUG J RESISTOR or X SURGE ABSORBER slice DIODE MAIN COIL CONDENSER COIL 5 3 1 GENERATION of NO LOAD VOLTAGE 1 2 3 4 When the generator starts running the permanent magnet built in to the rotor generates 3 to 6V of AC voltage in the main coil and condenser coil wound on the stator As one or two condensers are connected to the condenser coil the small voltage at the condenser coil generates a minute current which flows through the condenser coil At this time a small flux is produced with which the magnetic force at the rotor s magnetic pole is intensified When this magnetic force is intensified the respe
17. iances consume about 1 2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances NOTE 2 Motor driven appliances mentioned in items 3 and 4 vary in their required motor starting power depending on the kind of motor and start up load If it is difficult to determine the optimum generator capacity select a generator with a larger capacity 5 Appliances without any indication as to power consumption Some appliances have no indication as to power consumption but instead the work load output is indicated In such a case power consumption is to be worked out according to the numerical formula mentioned below Output of electrical appliance Output TE appliance Efficiency Efficiencies of some electrical appliances are as follows Single phase motor tree 0 6 0 75 The smaller the motor the Three phase motor een 0 65 0 9 lower the efficiency Fluorescent lamp Heer ren 0 7 0 8 Example 1 A 40W 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 57W by 1 2 2 and you will get the figure of the necessary capacity of a generator In other words a generator with a rated output of 1000Wcapacity can light nine to fourteen 40W fluorescent lamps Example 2 Generally speaking a 400W m
18. indicatesas V O XRXIXxZ R means resistance S2 100 m on the above table I means electric current through the wire A means the length of the wire m The length of wire indicates round length it means twice the length from generator to electrical tools 7 1 DC OUTPUT NOTE Do not use DC and AC output simultaneously Due to a characteristic of the condenser voltage regulation simultaneous use of DC and AC output creates voltage drop in DC output resulting in incapability for charging batteries When the generator is employed to charge batteries attentions should be paid to the specific gravity of electrolyte in the battery 7 24 SPECIFIC GRAVITY OF BATTERY ELECTROLYTE The specific gravity of electrolyte varies by temperature so it must be converted to the one at 20 C S20 St 0 0007 t 20 where S29 The specific gravity at 20 C St Measured value t Temperature at the time of measurement Electrolyte 7 2 2 SPECIFIC GRAVITY OF BATTERY ELECTROLYTE AND CHARGING CONDITION Specific gravity 20 C Charging condintion Remarks 1 260 Charging is not necessary 1 220 75 Charging is necessary 62 1 200 1 180 Immediate Charging is necessary 1 160 1 140 Table 7 3 7 2 3 BATTERY CAPACITY The battery capacity is expressed in the unit of AH ampere hour One AH stands for the capacity capable of one ampere current for one hour 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1
19. l and disconnect cou plers on wiring E Measure the resistance between terminals on stator leads Refer to Table 9 1 on page 24 for normal resistance Remedy If stator is defective replace with new one COUPLER Fig 11 1 11 1 2 CHECKING CONDENSER H If an instrument Q C meter or C meter for measuring capacity of condenser is available check the capacity of condenser NORMAL CAPACITY OF CONDENSER CAPACITY m If you do not have such an instrument you can check condenser by replacing with new one and test running If the generator perform normally with new condenser the cause of trouble is defect in original condenser 11 1 3 CHECKING ROTOR XY S Remove rear cover and stator L A NE GEN i L e N NN i ni i RSS N H si JAN n DIODE RECTIFIER and RESISTOR Fig 11 2 B Measure the resistance of field coil with a circuit tester See Fig 11 3 NORMAL RESISTANCE R x 12 10 RESISTANCE 8 5 2 Remedy m If the resistance is not normal replace rotor with new one Fig 11 3 Unsolder and take out the diodes and the resistors Measure the resistance of 2 pieces of diode CATHODE MARK POLARITY OF CIRCUIT TESTER Continuity exists Measure the resistance of each resistor Al k NORMAL RESISTANCE m Check the magnetic force of magnets molded in the rotor Remedy 1 If the magnetic force is weak replace the ro
20. n inquiring about the generator or ordering spare parts in order to get correct parts and accurate service LABEL SPEC N SS IN WAAL Ar NN SS IN x NN N gt LABEL MODEL NAME Example PROD NO RG012216010 1234 SER NO Specification No 1000001 Production No Serial No 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION ROTOR COMPLETE 6P COUPLER REAR COVER STATOR COMPLETE END COVER i i j DIODE RECTIFIER i BALL BEARING STATOR COVER i i j i CONDENSER MOUNT RUBBER THROUGH BOLT FRONT COVER Fig 5 1 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 5 2 2 CONDENSER A condenser is mounted on the rear cover and is connected to the condenser coil which is wound on the stator This condenser and condenser coil regu late the output voltage 5 2 3 ROTOR The rotor consists of a laminated silicon steel sheet core and field coil which is wound over the core DC current in the field coil magnetizes the steel sheet core Two permanent magnets are provided for the primary exciting action A cooling fan is pressure fitted on the end of the rotor shaft to cool the coils cores rectifier and other
21. ncrease by approximately 1 to 2V Therefore carefully observe the electrolyte level and do not overcharge the battery 8 4 MEASURING INSULATION RESISTANCE Use a Dr Robin generator tester in megger tester mode or use a megger tester to check the insu lation resistance Connect a megger tester to one of receptacle output terminals and the ground ter minal then measure the insulation resistance An insulation resistance of 1 megohm or more is normal The original insulation resistance at the time of shipment from the factory is 10 megohm or more If it is less than 1 megohm disassemble the generator and measure the insulation resistance of the stator rotor and control panel individually e STATOR 1 Measure the insulation resistance between BROWN lead and the core 2 Measure the insulation resistance between YELLOW lead and the core 3 Measure the insulation resistance between BLACK lead and the core e ROTOR Measure the insulation across one of the soldered terminals of the rotor and the core i MEGGER TESTER Q i adi n w gt aes ee Fig 8 11 e CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Any part where the insulation resistance is less than 1M has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 9 CHECKING FUNCTIONAL MEMBERS 9 1 CONTROL PANEL 9 1 1
22. ner cup to the strainer Do not lose the filler body screen 2 Disconnect fuel hose from the strainer j Loosen the hose clamp on top of the strainer and pull out the fuel hose from the strainer See Fig 10 10 Fig 10 10 ao nto nor ken TT ma 7 Fuel tank 1 Remove the handle cover by unscrewing The fuel tank can be Driver handle the two M3 X 10 screws removed without disassembling the handle 2 Pull off the breather pipe 3 Remove the handle body by taking off 13mm box wrench the two M8 nuts Handie cover Breather pipe Handle Fuel tank M8X Nut 2 pcs gt mere ei Fuel tank 1 Remove the two M6X12 flange bolts from the blower housing See Fig 10 12 2 Remove the fuel tank by taking off the two M8 nuts from the bottom of the tank See Fig 10 13 10mm box wrench 13mm box wrench Ka Wy iy WW NG AN Bracket Cover 1 Remove the bracket cover from the generator by loosening the two M8 X 30 bolts See Fig 10 14 13mm box wrench End cover 1 Remove the end cover from the generator by unscrewing the three M4 X 8 screws See Fig 10 14 Driver Bracket Cover End cover Fig 10 14 11 Rear bracket 1 Loosen and take out the three M6 10mm box wrench bracket bolts See Fig 10 15 2 Remove conden
23. otor means that its work load is 400W Efficiency of this motor is 0 7 and power consumption will be 400 0 7 570W When this motor is used for a motor driven tool the capacity of the generator should be multiplied by 1 2 to 3 and 570W as explained in the item 3 Applicable limit Electrical appliance Incandesent lamp heater etc approx 800W approx 1000W Fluorescent lamp mercury lamp etc H approx 550W approx 650W Motor driven tool general purpose motor etc approx 500W approx 600W Water pump compressor etc approx 250W approx 300W Table 7 1 NOTES Wiring between generator and electrical appliances 1 Allowable current of cable Use a cable with an allowable current that is larger than the rated input current of the load electrical appliance If the input current is larger than the allowable current of the cable used the cable will become excessively heated and deteriorate the insulation possibly burning it out Table 7 2 shows cables and their allowable currents for your reference 2 Cable length lf a long cable is used a voltage drop occurs due to the increased resistance in the conductors decreasing the input voltage to the load electrical appliance As a result the load can be damaged Table 7 2 shows voltage drops per 100 meters of cable No of Gauge No ca 37 10 26 70 0 32 0 332 ic 2V Q 0 Ben kel o D o gt Voltage drop
24. r pipe tighten it with a hose clamp and fasten the pipe to the fuel strainer with the banjo bolt Note Mount the fuel strainer with the banjo outlet upward 2 Fasten the strainer to the front bracket with the joint nuts 3 Secure the mounting tab on the bottom of the fuel tank and the blower housing with M6 X12 bolts Insert the attaching bolts on the other end of tank into the mount bracket hole and secure it with two M8 nuts 4 Connect the rubber pipe First fit the hose clamp on the rubber pipe connect the strainer and fuel tank then fasten the rubber pipe with the hose clamps Note Apply a drop of oil to the rubber pipe so that it may easily be connected to the strainer and the fuel tank 10 3 8 FUEL TANK HANDLE 1 Match the handle hole with the bolt on the top of the fuel tank and secure it with M8 nuts 2 Completely insert the breather pipe over the bolt Note There is a hole at the center of the breather pipe for air bleeding Set the breather pipe so that the hole is directed upward 3 Fix both ends of the handle cover with M3 X 10 screws Handle cover Breather pipe M3X 10 Screw 2pcs Handle to Carburetor Plug cover il of Rubber hose Fuel tank cap C J Hose clamp Fuel filter Hose cl M8 Nut 2 pcs SS Rubber hose Fig 10 36 10 3 9 FRONT COVER AND ELEMENT COVER 1 Secure the front cover on which fuel strainer have been mounted with three M5 X8 scr
25. se open flame near the fuel tank Be careful not to spill fuel when refueling If spilt wipe it and let dry before starting the engine Do not place inflammable materials near the generator Be careful not to put fuel matches gunpowder oily cloth straw and any other inflammables near the generator Do not operate the generator in a room cave or tunnel Always operate in a well ventilated area Otherwise the engine may overheat and also the poisonous carbon monoxide contained in the exhaust gases will endanger human lives Keep the generator at least 1 m 4 feet away from structures or facilities during use Operate 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 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 thoroughly dry it before starting Don t pour water over the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leakage and electric shock Do not connect the generator to the commercial power lines This may cause a short circuit or damage to the generator Never connect the generator to the existing house wiring If connected the generator will burn out when the commercial power source is recovered Don t operate the generator with
26. ser from rear bracket Box spanner 3 Remove the connector of the diode Box spanner and rectifier and then remove the earth cable screw driver terminal from the rear bracket See Fig 10 16 Bracket bolt 3 pcs Fig 10 16 4 Remove the rear bracket tapping it Plastic mallet evenly with a plastic mallet See Fig 10 17 5 Remove mount rubbers from rear cover Wrench See Fig 10 18 Plastic mallet Mount rubber Fig 10 17 Fig 10 18 12 Stator 1 Remove the stator cover See Fig 10 19 2 Pull off the stator from the front cover Never tap on the Plastic mallet tapping the core with a plastic mallet winding and the lead See Fig 10 20 Fig 10 19 Fig 10 20 Stator Fig 10 22 13 Rotor 1 Take off the through bolt Box wrench Apply a box wrench on the head of Plastic hammer through bolt Hit the wrench handle with a hammer counter clockwise to loosen Fig 10 23 2 Put the engine on the working table recoll starter side down i 3 Use a bolt and oil as a tool for pulling out rotor in the following procedures 1 Pour engine oil into the center hole of rotor shaft Fill with oil to the shaft end See Fig 10 24 thread size M8 X P 1 25 3 Apply a few turns of seal tape around the tip of the bolt 2 Prepare a bolt with the following See Fig 10 25 Seal tape
27. ted on the front panel LONG CONTINUOUS OPERATION The large 3 5 liters fuel tank allows four hours of operation at 50Hz rated output MINIMAL MAINTENANCE e Brushless alternator eliminates time consuming brush maintenance Trouble free condenser voltage regulation for greater dependability No fuse resettable circuit breakers Electronic pointless ignition system for sure starts LONG LIFE DURABILITY Tough heavy duty Robin EY15 engine incorporates a cast iron cylinder liner forged steel crankshaft and two main ball bearings for longer service life The brushless alternator dose not have any expendable parts such as brushes and slip rings or fragile circuit board assuring trouble free operation for longer service life 4 GENERAL DESCRIPTION OF THE GENERATOR 4 1 EXTERNAL VIEW of GENERATOR Engine Control Switch CHOKE RUN STOP DC Circuit Breaker AC Circuit Breaker Frequency Adjusting Screw Internal AC Receptacle Recoil Starter DC Receptacle am in IYA pus Voltmeter i Muffier Fuel Strainer Ground Terminal Air Cleaner Cover Carrying Handle Spark Plug Cover Fuel Tank Cap Fuel Tank a a 2 T e Oil Filler Cap Drain Plug 4 2 LOCATION of SERIAL NUMBER and SPECIFICATION NUMBER cover Serial number and specification number are stamped on the LABEL MODEL NAME stuck on the rear NOTE Always specify these numbers whe
28. ting of a given generator is most desirable About 10A 20A 100A For AC Fig 8 3 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range 4 CIRCUIT TESTER This circuit tester is used for measuring re sistance etc Fig 8 5 5 MEGGER TESTER r Used for measuring generator insulation re sistance Select one with testing voltage range of 500V 6 TACHOMETER Use the contact less type tachometer Fig 8 7 8 2 AC OUTPUT MEASURING SW A Load OO m Dr SL A To AC Receptacle OO A YO Fig 8 8 Measurement is executed with the circuit as shown in Fig 8 8 An electric heater or an incandescent lamp with a power factor of 1 0 is suitable as a load for the generator When the AC output measured at the rated load and rated speed is confirmed to be within the voltage range specified in the table below the AC output is normal Rated voltage 110V 120V 220V oam Voltage range 107 119V 117 130V 215 238V 235 260V Table 8 2 8 3 DC OUTPUT MEASURING To AC Receptacle Measurement of DC output is executed with the switch turned ON while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 10V to 14V the voltage output is normal Fig 8 9 Note If a battery is connected as a load to the generator the DC output voltage will i
29. tor and check the resistance between wires with a Dr Robin or a circuit tester referring to the following table COUPLER Rx19 41096 Specification AC Winding DCWinding Condenser Winging Voltage Brown White Yellow Red Black Black I 110V 1 70 220V VDE spec Table 9 1 NOTE If the circuit tester is not sufficiently accurate it may not show the values given and may give erroneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from 20 C 68 F 9 3 ROTOR 1 Using the Dr Robin or a circuit tester measure the resistance of the field coil See Fig 9 6 RX 19 10 NOTE 1 NOTE 2 Because a diode is soldered to the coil ends at the terminals resistance may be measured only when tester probes touch the terminals in one combination of polarity Therefore if no resistance reading appears try checking in re verse polarity If the circuit tester is not sufficiently accurate it may not show the values given and may give erroneous readings Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when meas urement is performed at ambient tem peratures different from 20 C 68 F 2 Measure the resistance of the resister Normal resistance 15 KO 3 Measure the resistance of the diode
30. tor with a new one 2 If the diode or the resistor is faulty replace them with new one When all these parts are good assemble them and then solder Reassembling 1 Place the resistors at the bottom 2 On the resistors put the diodes taking care of its polarity 3 Solder them to the terminal Resistor has no polarity CROSS SECTION x N RESISTOR D pce ICH DS AH SOLDERING Ir si YELLOW CATHODE MARK Fig 11 4 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11 2 1 CHECKING ENGINE rpm If the engine rpm is too high or too low adjust it to the rated rpm How to adjust engine rpm m Loosen the nut on the adjusting screw M Turn the adjusting screw clockwise to de crease engine speed or counter clockwise to increase engine speed Normal engine speed at no load is 3150 3200 rpm for 50 Hz type 3750 3800 rpm for 60 Hz type 11 2 2 CHECKING STATOR Check stator referring to Step 11 1 1 11 2 3 CHECKING CONDENSER Check condenser referring to Step 11 1 2 11 2 CHECKING ROTOR Check rotor referring to Step 11 1 3 Fig 11 5 FIELD COIL MAIN COIL AC CIRCUIT BREAKER AC RECEPTACLE 6P COUPLER VOLTMETER Control Panel RESISTOR Generator Engine DC COIL CONDENSER COIL green yellow gt D KG t 1 2 DIODE STACK ASSY 2P COUPLER RECTIFIRE DC RECEPTACLE GROUND TERMINAL CONDENSER DC CIRCUIT BREAKER STOP SWITCH SPARK PLUG IGNIT
31. where the output undergoes full wave rectification and is then supplied to the load The diode works to allow the current to flow in the direction but does not allow the current to flow in the direction D as shown in Fig 5 8 1 Fig 5 8 1 Fig 5 8 2 shows the DC output circuit of the generator DC voltage is generated in the DC coll When the voltage in A is higher than that in B the current flows in the direction shown in the figure while no current flows between CF and DE because the current is cut off by the diodes G4 and G2 On the contrary when the voltage in B is higher than that in A the current flows in the direction as shown in the figure No current flows between CD and EF because the current is cut off by the diodes G1 and G3 DC COIL Fig 5 8 2 As a result the voltage generated at the output terminal has a wave form with two peaks in one Output Waveform cycle as in the case of the output wave form shown in Fig 5 8 3 Current 1 Cycle Current d Fig 5 8 3 CAUTION Do not use DC and AC output simultaneously Due to a characteristic of the condenser voltage regulation simultaneous use of DC and AC output creates voltage drop in DC output resulting in incapability for charging batteries 6 SAFETY PRECAUTIONS Use extreme caution near fuel A constant danger of explosion or fire exists Do not fill the fuel tank while the engine is running Do not smoke or u
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