R1300 GENERATOR SERVICE MANUAL
Contents
1. 1 e oejdeoei 7 SI J 2V umoiq 7 Oy 2 Robin America Inc 940 Lively Blvd Wood Dale IL 60191 Phone 630 350 8200 Fax 630 350 8212 e mail sales www robinamerica com R1300 Copyright 1998 Robin America Inc 98 4 Robin America Inc 940 Lively Blvd Wood Dale IL 60191 Phone 630 350 8200 Fox 630 350 8212 e mail sales robinamerica com www robinamerica com PRINTED IN THE USA Robin America Inc2. CURRENT 3 FEATURES e LOW NOISE Mounting of Air cooled 4 Cycle Super Side Valve ROBIN Engine EY15D SSVR and introduction of a larger muffler into the machine realized low noise operation 9 LIGHT WEIGHT COMPACT The machine is easy to carried about due to its light weight 27 5kg and compact design HIGH OUTPUT increased maximum output The 1300W output is an increase of 100W over the 60Hz maximum output of the current R1210 e EASY OPERATION The one touch engine control switch integrates the engine on off switch and the choke controls are conveniently located on the front panel 9 LONG OPERATION The large 0 9 U S gal 3 5 liter fuel tank allows about 3 6 hours of continuous operation at 60Hz rated load MINIMAL MAINTENANCE The brushless design and condenser voltage regulator system ensure maintenance free operation 9 FUNCTIONAL FEATURES The AC DC push button circuit breaker allows for easy and safe operation when an overload occurs or when the machine is not functioning properly Equipped with voltmeter for reading AC output voltage DC output can be obtained for the re chargeable battery NOISE PREVENTION Resistor spark plug prevent electric wave noise for radio T V etc OIL SENSOR optional The oil sensor detects when oil decreases below the designated level stopping the engine and preventing engine damage 4 GENERAL DESCRIPTION 4
3. 3 Check the magnetic force of magnets molded in the rotor Remedy 1 Ifthe magnetic force is weak replace the rotor with a new one 2 Ifthe diode or the resistor is faulty replace rotor assembly with new one When all removed these parts are good assemble them and then solder 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW If the engine r p m is too high or too low adjust it to the rated r p m How to adjust engine r p m Loosen the nut on the adjusting screw W Turn the adjusting screw clockwise to in de crease engine speed or counter clockwise to increase engine speed Normal engine speed at no load is 3750 3800 r p m High speed 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 4 CHECKING ROTOR Check rotor referring to Step 11 1 3 w 12 WIRING DIAGRAM 103515 Ae Joxeauq endis c Ve Bujuiem H euro TRUE Aper oM S E udi youms dois S 22702 12819 2 opoejg gt p d MV 09916 HO9 lt 195090002 0000000 pai Hum TEL moja u 16 A N 4 5 jeur 16
4. Mount bracket Mount rubber Fig 10 26 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 27 M8 X 18mm bolt and washer assy 4pcs TIGHTENING TORQUE 87 10 1 ft Ibs 1175 1370N cm 120 140 kg cm 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 28 and 10 29 Fig 10 28 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 hammer to tighten See Fig 10 30 If an impact wrench is available use it TIGHTENING TORQUE 87 10 1 8 1370 1175 140 120 Fig 10 30 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 bearing and softly strike the outside periphery of the rear bracket with a plastic hammer See Fig 10 31 2 Attach the stator cover around the stator 3 Tighten the three M6 bolts to fix the rear brack et to the front bracket TIGHTENING TORQUE 40 5 4 6 535 735 N cm 55 75 kg 4 Put the grommet in the groove of the rear bracket and secure the wire Fig 10 31 Note Fix the wire from the stator and diode stack with the clamp
5. No mm m m 30 0 18 2 5V 8V 50 0 18 1 5V 5 37 0 26 1 0V 3V 45 0 32 1 5V 70 0 32 Table 7 2 Voltage drop indicates as V XRXIX R means resistance Q 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 2 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 2 1 SPECIFIC GRAVITY OF BATTERY ELECTROLYTE The specific gravity of electrolyte varies by temperature so it must be converted to the one at 20 520 5 0 0007 t 20 where 520 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 Immediate Charging is necessary 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 IN
6. Stator cover Fig 10 17 Fig 10 18 Stator cover Fig 10 20 1 Take off the through bolt Apply a box wrench on the head of through bolt Hit the wrench handle with a hammer counter clockwise to loosen Box wrench Plastic hammer Fig 10 21 2 Put the engine on the working table recoil starter side down 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 22 2 Prepare a bolt with the following thread size M8 X P 1 25 3 Apply a few turns of seal tape around the tip of the bolt See Fig 10 23 Seal tape Fig 10 22 Fig 10 23 4 Screw the bolt into the thread of the rotor shaft 5 Torque the bolt using a socket wrench until the rotor comes off loose The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft 12mm box spanner or Socket wrench 4 Wipe off oil throughly from rotor shaft and engine PTO shaft Fig 10 24 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 25 12mm box spanner Fig 10 25 1 Remove mount bracket from engine Remove mount rubbers from mount bracket 8 Nut 3pcs or 2pcs 12 mm wrench
7. in the condenser coil When current 8 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 9 5 3 3 DC OUTPUT DC output is taken out from the DC coil and is fed to the diode stack rectifier 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 8 but does not allow the current to flow in the direction D as shown in Fig 5 8 1 9 Fig 5 8 1 Fig 5 8 2 shows the DC output circuit of the gener Di ator DC voltage is generated in the DC coil When the voltage in A is higher than that in C the current O flows in the direction shown in the figure while no current flows between B and C because the current is cut off by the diodes D Ms On the contrary when the voltage in C is higher than col B that in A the current flows in the direction as shown in the figure No current flows between and B because the current is cut off by the diodes D 02 5 8 2 As result the voltage generated at the output terminal has wave form with two peaks in cycle as in the case of the output wave form shown in Fig 5 8 3 Between and B Output waveform N Between C ana B st im Pd S Pl IEEE C 1
8. according to the current rating of a given generator is most desirable About 10A 20A 100A 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 Used for measuring generator insulation re sistance Select one with testing voltage range of 500V 6 ENGINE TACHOMETER There are various types of tachometers such as contactless type contact type and strobe type The contact type can be used only when the generator and engine have been disassembled The contactless type is recommended The PET 2100E engine tachometer is available from your Robin distributors Please inquire by the part number PET 2100E 8 2 AC OUTPUT MEASURING To AC receptacle 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 Voltage range 117 130V Table 8 2 8 3 DC OUTPUT MEASURING To DC Terminal Fig 8 9 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 genera
9. at the bottom of the groove 10 3 4 CONDENSER Put condenser to rear cover 5 0 10mm tapping screw cH 2 pes TIGHTENING TORQUE 24 4 0 ft lbs 325 535 33 55 kg cm Fig 10 32 10 3 5 END COVER Set the end cover on the rear bracket with four Bracket Cover M5 X10 screws 10 3 6 BRACKET COVER Mount the bracket cover on the rear bracket and secure them with M8 X 30 bolts End cover Fig 10 33 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 rubber 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 8 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 sec
10. 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 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 5 2 4 CONTROL PANEL The control panel has a double AC receptacle with a ground terminals and DC terminals The voltmeter displays output voltage of the gener ator The circuit breaker for AC and DC protects the generator from getting damages caused by over loading or defective appliance Fig 5 6 5 3 GENERATOR OPERATION wu PERMANENT MAGNET FOR INITIAL EXCITATION STATOR MAIN COIL FIELD COIL RECEPTACLE RESISTER APPLIANCE SURGE ABSORBER DIODE CONDENSER COIL D CONDENSER Fig 5 7 w 5 3 1 GENERATION of NO LOAD VOLTAGE 1 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 c
11. 1 EXTERNAL VIEW of GENERATOR DC terminal Engine control switch Frequency adjusting i CHOKE RUN STOP screw internal Ground terminal Voltmeter Recoil starter AC receptacle AC circuit breaker DC circuit breaker Fuel cock Fuel strainer Muffler Oil warning lamp Air cleaner cover With oil sensor type Spark plug cover Carrying handle Fuel tank cap Fuel tank Engine emission label Drain plug Oil filler cap Fig 4 1 4 4 2 LOCATION SERIAL NUMBER and SPECIFICATION NUMBER Serial number and specification number are stamped on the LABEL MODEL stuck on the fuel tank NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service Label Model name Fig 4 2 5 CONSTRUCTION AND FUNCTION 5 1 CONSTRUCTION 6P coupler Rotor complete End cover Stator complete Rear cover HET WSS re NE 127 Diode rectifier Ball bearing Stator cover Condenser Mount rubber Through boit 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 condenser is mounted on the rear cover and is connected to the condenser coil
12. Cycle Current C Current d flowing flowing between between and B C and Fig 5 8 3 CAUTION Do not use DC and AC output simuitaneously 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 5 4 ELECTRONIC IGNITION SYSTEM The electronic ignition system features a power transistor as the current control element Therefore the ignition system is an electronic contact point free type that operates with the power transistor impulses controlling the current This system is also called TIC transistor igniter circuit and is virtually free of ignition failure which generally results from contamination of the contact points a typical problem with contact type ignition systems Because this ignition system has no contact points it is not affected by moisture oil dust or other contaminants As a result this electronic ignition system ensures sure and positive ignition with reduced maintenance The TIC mechanism consists of a transistor incorporated ignition coil and a permanent magneto built in flywheel which is press fitted on the rotor shaft of the generator Ignition coil Resistor Ignition timing detecting circuit Spark plug Power transistor Primary coil Secondary coil Flywheel cooling fan Resistor Signal transmitter transistor Fig 5 9 1 When the permanent magneto bu
13. Robin Power Equipment SERVICE MANUAL R1300 Generator WITH EMISSION CERTIFIED ENGINE PUB GS1185 Rev 4 98 Robin SUBARU CONTENTS Section Title Page 1 SPECIFICATIONS Brushless self exciting 2 pole single phase revolving field AC Voltage Rated current 120V 8 3 A AC Output Generator DC Output i 12V 8 3A 100 W Voltage regulation system Condenser system Forced Air cooled 4 Stroke Side Valve Gasoline Engine Fuel Automotive Gasoline unleaded Starting system Recoil starter Dimensions L x W x H 19 3 x 11 3 x 16 490 x 288 x 410mm Dry weight 60 6 Ibs 27 5 kg Specifications are subject to change without notice 2 PERFORMANCE CURVES 2 1 AC OUTPUT 1300 Output 1300W 1 1200 Rated 1000W gt Frequency ET LE LL 60Hz Voltage 1 20 1000 60Hz 120V 8 3A 5 gt 800 1 R 600 s D 5 5 8 amp 8 c 200 00 1 2 3 4 5 7 8 9 10 11 120 2 2 DC OUTPUT DC Voltage S 12V DC Ampere dns son ue esses stre es 8 3A DC output 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 VOLTAGE
14. STRUMENTS 8 1 1 Dr ROBIN GENERATOR TESTER The Dr Robin generator tester is exclusively de signed for fast easy diagnosis and repair of Robin generators The Robin has the following features 1 Functions of voltmeter frequency meter meg Ber 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 SPECIFICATIONS Des Cmm Test leads with needle probes 1 set Measuring Range Accessories Weight 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 0 to 300V Type with an output voltage of 220 230 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
15. age 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 appliances 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 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 6 Output of electrical appliance a Power consumipt n Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 6 0 75 The smaller the motor the Three phase motor 0 65 0 9 lower the efficiency Fluorescent 0 7 0 8 Example 1 40W fluorescent lamp means that its luminous output is 40 Its efficiency is 0 7 and accordingly power consumption will be 40 0 72 57W As explained in 2 m
16. c 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 Motor driven toois light electrical appliances etc 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 Generally the starting wattage of motor driven tools and light electrical appliances are 1 2 to 3 times lager than their running wattage Example A rated 250W electric drill requires a 400W generator to start it NOTE 1 a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamp 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 Mercury lamps with a smaller power factor Loads for mercury lamps require 2 to 3 times the indicated wattage during start up Example A 400W mercury lamp requires 800W to 1200W power source to be turned on rated 1000W generator can power one 400W mercury lamp 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 watt
17. conds or more 6 SAFETY PRECAUTIONS 1 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 use 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 2 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 3 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 4 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 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 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 6 Do not connect the generator to the commercial power lines This may cause a short ci
18. e and electric shock Replace the faulty part 9 CHECKING FUNCTIONAL MEMBERS 9 1 CONTROL PANEL Voltmeter DC terminal Green Yellow Ground terminal Circuit breaker 6P coupler Oil warning Brown lamp Yellow red Yellow Green Yellow 9 1 1 AC RECEPTACLES Using 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 9 1 2 DC TERMINAL Check continuity between the DC terminals at the rear of the control panel using a circuit tester under the condition that the DC terminals is mounted on the control panel See Fig 9 1 When continuity between the DC terminals is confirmed with a wire connected across the terminals and is not confirmed if the wire is removed the DC terminals are normal See Fig 9 1 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 voltm
19. e coupler and pull out to disconnect CONTROL PANEL SIDE STATOR SIDE Front cover 6 1 Remove the element cover by unscrewing M6 X 12 screw See Fig 10 6 NEN dE 2 Remove the front cover by unscrewing Driver three M5 X 8 screws See Fig 10 6 ont cover Ft Element cover Fig 10 6 Use utmost care about Fuel pipe 1 Discharge fuel from the tank and plug 1 Shut the fuel striner fire hazard Discon 2 Remove the strainer cup nection 3 Put a vessel to receive fuel under the Wipe off spilt fuel Strainer and open the fuel cock to discharge fuel See Fig 10 7 4 Attach the strainer cup to the strainer body throughly Do not lose the filler screen 2 Disconnect fuel hose from the strainer Loosen the hose clamp on top of the strainer and pull out the fuel hose from the strainer See Fig 10 8 7 Fueltank 1 Remove the handle cover by unscrewing The fuel tank can be Driver handle the two M3 X10 screws removed without ww disassembling the 2 Pull off the breather pipe 3 Remove the handle body by taking off 12mm box wrench the two M8 nuts Handle cover Breather pipe M3 x 10 Screw 2 pcs Fuel tank M8 Nut 2 pcs Fig 10 9 ww Fuel tank 1 Remove the two M6X12 flange bolts from the blower housing See Fig 10 10 2 Remove the fuel tank by taki
20. er 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 37 Secure the rear cover with three M5X8 screws and two M8 X10 screws 10 3 12 REAR COVER j M5 x 8 Screws M 10 3 13 SIDE COVER Secure the side cover with four M5X 8 screws Fig 10 39 11 TROUBLESHOOTING 11 1 NO AC OUTPUT 11 1 1 CHECKING STATOR 1 Remove control panel and disconnect couplers on wiring 2 Measure the resistance between terminals on stator leads Refer to Table 9 1 page 28 for normal re sistance Remedy If stator is defective replace with new one 11 1 2 CHECKING CONDENSER Fig 11 1 If an instrument Q C meter or C meter for measuring capacity of condenser is available check the capacity of condenser If you do not have such an instrument you can check condenser by replacing with new 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 1 Remove rear cover and stator Diode rectifier Fig 11 2 2 Measure resistance of field coil with a circuit tester See Fig 11 3 x 10 1096 Remedy If the resistance is not normal replace rotor with new one
21. eter if it operates correctly by apply ing specified voltage Voltmeters cannot be checked with a circuit tester because its intesnal resistance is too large Voltmeter Fig 9 3 9 2 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a Dr Robin or a circuit tester referring to the follow ing table Fig 9 4 puce 10 21096 Condenser Winging Voltage Brown White Black Black Table 9 1 NOTE 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 ef the field coil See Fig 9 5 19 10 1 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 polar ity Therefore if no resistance reading appears try checking in reverse polarity If the circuit tester is not sufficiently accu rate 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 ureme
22. he engine is being stopped We have the wires to be connected to LED available 5 5 5 CAUTIONS TO BE TAKEN ON HANDLING THE SENSOR 1 Oil sensor unit D Be sure not to damage each wire Broken or short circuited power supply wires and or a grounding wire in particular may lead to malfunction or breakdown 2 Mounting and wiring of oil sensor unit Although this has been designed to have enough anti noise properties in practical use do not route the sensor wirings in the vicinity of noise generating sources such as ignition plugs or high voltage cords This may cause malfunction or breakdown 2 Since capacity of power source is limited current flown in the electronic circuit of the sensor is kept as low as possible Be sure to use terminals with a high contact reliability of more than that of tinned terminals 3 Operation of oil sensor D If operating with the engine kept tilted oil surface inside of the engine varies and the correct oil level can not to be detected which in turn obstructs the preventing function of engine seizure Operate the engine by keeping it level 2 When starting the engine with an insufficient oil in the crankcase engine starts once then it stops automatically after it runs for about 5 seconds When the engine has been stopped by the oil sensor voltage remained in the electronic circuit prevents the sensor from being re started for 3 seconds after the engine stop Try to re start the engine after 3 se
23. he timer employs an integration circuit and it is to be reset when the inner electrode is soaked in the oil again before the sensor decides it as oil shortage The oil level where the sensor decides as oil shortage when oil level goes down gradually is called thresbold level Automatic stop of engine When the sensor decides as oil shortage it makes the engine to stop running automatically for protection of engine Once the stopping circuit is activated it keeps functioning until it confirms that the engine has made a complete stop then the circuit stops functioning automatically 5 5 4 BLOCK DIAGRAM OF THE CIRCUIT Igniter Power circuit LED indicator Detection circuit Stopping Inner pole circuit Oil Outer pole Engine ground Fig 5 11 D Power circuit This rectifies a part of power to the igniter and regulates it to supply the stabilized power to necessary circuits 2 Detection circuit This detects quantity of oil sufficient or not according to difference of electric resistance across inner and outer electrodes Delay circuit This prevents the sensor from making an unnecessary stop of the engine by momentary lowering of the oil level due to the engine being slanted or affected by vibration in spite of sufficient oil in the crankcase Stopping circuit This automatically stops the engine running Also the LED indicator for warning can be lit while t
24. hould 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 9 6 OIL SENSOR OPTION 1 Disconnect two 2 wires comming from the sen sor at the connection 2 Loosen the sensor to remove it from the engine sensor 3 Plug the opening of oil filler hole created after sensor is removed with suitable means such as oil gauge 4 Connect the removed wires again with the oil Sensor 5 Start the engine with tbe oil sensor removed and confirm if a Engine stops after 5 seconds which is normal or b Engine does not stop after more than 10 seconds which is unusual NOTE The sensor will not operate properly when wire is broken or poorly connected Check the wires for correet connection If fails to stop within 5 seconds after the wirings have checked the sensor is wrong Replace the sensor with new one 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 i
25. ilt in flywheel start rotating power is generated in the primary coil of the ignition coil and current flows to the resistor 2 From the resistor current flows the power transistor With this current the power transistor turns on releasing current D This stage corresponds to the closing of contact points 2 As the flywheel comes to the point of ignition timing detecting circuit is activated while the current O is flowing through the circuit When the ignition timing detecting circuit is activated the signal transmitter transistor actuates with current flowing When current d starts flowing current flowing through the power transistor is cut quickly As a result high voltage is produced in the secondary coil and this voltage is applied simultaneously to the spark plug which ignites for ignition This stage corresponds to the opening of contact points 5 5 OIL SENSOR OPTION 5 5 1 DESCRIPTION The oil sensor mainly functions to detect position of the surface of engine oil in the crankcase of engines for general use and to stop the engine automatically when the oil level goes down below the lower limit specified This prevents seizure of engine from occurring due to insufficient amount of oil in the crankcase Since the sensor has been designed to consume a part of power supplied to the igniter to energize its i electronic circuit any other external power supply is not necessary so that it can be moun
26. nformation 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 gt 5 Use all disassembly assembly tools properly and use the proper tool for each specific job 10 2 DISASSEMBLY PROCEDURES 1 Sidecover 1 Remove the side cover by unscrewing 4 Plus screw four M5 X 8 screws See Fig 10 1 driver 2 Rear cover 1 Remove the rear cover by unscrewing three M5 X 8 screws and two M8 X 10 screws See Fig 10 2 Plus driver M5 x 8 Screws M8 10 Screws 1 Puil the knob off the control lever and remove the control panel by unscrewing four M5 X 8 screws See Fig 10 3 3 Control panel Plus driver Fig 10 3 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 ES 4 2 Disengage the connectors of oil warning lamp option See Fig 10 5 Press the hook of the coupler and pull out to disconnect Press the hook of th
27. ng off the two M8 nuts from the bottom of the tank See Fig 10 11 10mm box wrench 12mm box wrench Fig 10 10 Fig 10 11 Bracket Cover 1 Remove the bracket cover from the generator by loosening the two M8 X 30 bolts See Fig 10 12 12mm box wrench 10 End cover 1 Remove the end cover from the generator by unscrewing the four M5 10 screws See Fig 10 12 Driver Bracket Cover Fig 10 12 sep rentre 7 11 Rear bracket 1 Loosen and take out the three M6 cover 10mm box wrench bolt See Fig 10 13 2 Remove condenser from rear bracket Box spanner 3 Remove the connector of the diode Box spanner and rectifier and then remove the earth cable screw driver 4 terminal from the rear bracket See Fig 10 14 Earth cable terminal Condenser D Fig 10 14 iode rectifier Fig 10 13 4 Remove the rear bracket tapping it Plastic mallet with a plastic mallet See Fig 10 15 5 Remove mount rubbers from rear cover See Fig 10 16 Plastic mallet Mount rubber Fig 10 15 Fig 10 16 12 1 Remove the stator cover See Fig 10 17 2 Pull off the stator from the front cover Nevertap on the tapping the core with a plastic mallet winding and the lead See Fig 10 18 Plastic mallet
28. nt is performed at ambient tem peratures different from 20 C 68 2 Measure the resistance of the resister Normal resistance 5 1 kQ 9 4 CONDENSER Use a Dr Robin in capacitance meter mode to check the capacity of condensers See Fig 9 6 up NOTE Be sure to discharge condensers by short ing condenser leads each other before checking their capacitance or the accurate reading cannot be obtained Normal Capacity of Condenser Fig 9 6 Ifsuch an instrument is unavailable the condenser can be checked by replacing with a new If the generator performs good with new condenser the cause of trouble is defect in original condenser 9 5 DIODE RECTIFIER Red Green 0 Green Green Green Fig 9 7 Diode rectifier Fig 9 8 w The internal circuit of the diode rectifier is as shown in Fig 9 7 Check continuity between each terminal using a circuit tester as shown in Fig 9 8 B Checking table for analogue circuit tester Apply black needle of the circuit tester Analogue circuit tester Apply red needle of the circuit tester Table 9 2 1 B Checking table for digital circuit tester Digital circuit tester AT ne cre tester Nocontnuty of the circuit tester No continuity eme M Table 9 2 2 NOTE 1 Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester polarity of tester needles s
29. ondenser coil wound on the stator 2 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 respective 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 coil keep rising by repeating this process 3 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 D flows through the field coil and magnetizes the rotor core to generate an output voltage in the main coil 4 When generator speed reaches 3000 to 3300 r p m 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 O flows through the main coil to the appliance a magnetic flux is produced and serves to increase current 8
30. ot sufficient Since an electric current is flown to detect oil quantity this is called the electrical conductivity detection type of sensor The oil level to be detected is determined by the length of electrodes and their mounting positions with the engine 5 5 3 HOW IT OPERATES Power supply The sensor makes use of a part of primary power source for ignition of the engine igniter to drive the sensor circuit Power to the sensor can usually be derived from the stop button by branching wires out 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 non conductive The sensor in this case judges that oil is insufficient Decision of oil shortage Oil level at the electrodes may go down momentarily probably due to the engine being slanted or affected by vibration even if a sufficient oil is in the crankcase For that reason the sensor has an electronic timer circuit to prevent it from interpreting as short of oil when amount of oil is sufficient The sensor has been designed so that the engine is to be stopped only when oil shortage is detected for 5 seconds uninterrupted T
31. rcuit 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 7 Don t operate the generator with 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 overioad or a short circuit In such a case stop operation immediately and carefully check the electrical appliance and plugs for fauity wiring 7 RANGE OF APPLICATIONS 7 1 AC OUTPUT 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 a 2 3 4 Incandescent lamp heater et
32. ted at the oil filler port Introduction of newly developed sensing principle features super durability and no change with the Fig 5 10 passage of time as it does not use any moving part Oil sensor Merits due to introduction of electrical conductivity detection are as follows D It has resistance to mechanical shocks and property of no change with the passage of time as sensing element consists simply of electrodes having no moving parts 2 At the same time it is capable of detecting the oil level stably as it is not influenced by engine vibrations 3 No error occurs due to foam and flow of the oil 4 Influence against the ignition system or the electronic units can be neglected because an electric current supplied to the sensor can be decreased 5 5 2 PRINCIPLE OF SENSING OIL LEVEL There is a great difference between electric resistance of air and that of oil Since the resistance of air is far higher than that of oil more electric current passes through the oil than through the air although absolute value of the current is very small The sensor detects this current difference and make use of it The sensor judges the oil quantity by comparing a current flowing across a pair of electrodes inner and outer with the reference in such a way that if a current flows between the electrodes more than the reference sufficient oil is in the crankcase on the other hand if a current flows less than the reference oil is n
33. tor If the voltage is within the range from 6V to 14V the voltage output is normal Note If a battery is connected as a load to the generator the DC output voltage will increase 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 insulation resistance Connect a megger tester to one of recep tacle output terminals and the ground terminal then measure the insulation resistance An insulation re sistance 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 gener ator 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 YEL LOW lead and the core 3 Measure the insulation resistance between BLACK lead and the core ca Cal e ROTOR Measure the insulation across one of the soldered terminals of the rotor and the core Fig 8 12 CONTROL PANEL Measure the insulation resistances between the live parts and the grounded parts Any part where the insulation resistance is less than 1MQ has faulty insulation and may cause electric leakag
34. ultiply this power consumption value of 57W by 1 2 2 and you will get tbe 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 400W motor 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 wattage Appliance Fluorescent lamp mercury lamp Electric tool 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 If 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 w Table 7 2 shows voltage drops per 100 meters of cable Voltage drop 100 Sectlonal Allowable Gauge No current wire element
35. ure 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 44 M3 x 10 Screw 2 pcs M8 Nut 2 pcs Fuel tank Banjo Rubber hose Cup Hose clamp M8 Nut 2 pcs Fig 10 34 10 3 9 FRONT COVER AND ELEMENT COVER 1 Secure the front cover on which fuel strainer EE have been mounted with three M5 X 8 screws See Fig 10 35 FR qp 2 Secure the element cover with M6 X 12 screws A 4 See Fig 10 35 gum 72 Wiis ZF 72 WINS NU Handie cover Breather pipe Handle To Carburetor Plug cover Rubber hose f Hose clamp gt Hose clamp P Fuel strainer Fig 10 35 45 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 36 2 Press the couplers until the locking hook engages securely 3 Connect the oil warning lamp option wire See Fig 10 36 Fig 10 36 WIRE CONNECTIONS BETWEEN CONTROL PANEL AND STATOR 67 coupler Wire color Yellow Red Green Yellow Brown White Green Yellow Brown Yellow Red White CONTROL PANEL SIDE 10 3 11 CONTROL PANEL 1 Put the control panel ov
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