Robin R1210 Brushless Service Manual Download Page 1

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Summary of Contents for R1210 Brushless

Page 2: ...r Operation 10 SAFETY PRECAUTIONS 12 RANGE OF APPLICATIONS 13 MEASURING PROCEDURES 17 8 1 Measuring Instruments 17 8 2 AC Output Measuring 20 8 3 DC Output Measuring 20 8 4 Measuring Insulation resistance 21 CHECKING FUNCTIONAL MEMBERS 23 9 1 Control panel 23 9 2 Stator 24 9 3 Rotor 25 9 4 Condenser 26 9 5 Diode Rectifier 26 DISASSEMBLY AND ASSEMBLY 2 7 10 1 Preparation and Precautions 27 10 2 Dis...

Page 3: ...realsochanged 3 Change of part number For the detail refer to the attached figures New Parts set NO Part Name Part number 1 Oil sensor CP 6 KS3 11015 01 k 2 Wire 7 CP 227 73 107 O1 1 3 Clamp 056 60002 50 1 Current parts set NO Part name Parl number Q tv 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 interchangeableonly when the a...

Page 4: ...Attachment A oil sensorinstallation change New installation Clamping in detail Current installation ...

Page 5: ...Attachment B 1 Oil sensorchange New OIL SENSOR CP 6 KS3 11015 01 Current OIL LEVEL SENSOR CP 227 76035 01 3 ...

Page 6: ...2 Electric wiring change New wIRE7CP 227 73107 01 Current wm 22 cP 214 73122 01 3 Clamp change New CLAMP 056 60002 50 d 6 5 Current CLAMP CP 206 75501 01 3 I J IA c I 3 A I Section A A 4 ...

Page 7: ... Rated 800 W 1000 w DC Output 12V 8 3A lOOW Voltage regulation system Condenser system Type Forced air cooled 4 stroke side valve gasoline engine Displacement 143 cc 6 73 cu in Bore x Stroke 63 x 46 mm 2 48 x 1 81 in I 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 Rated continuous operating hours Dimensions L X W X H Dry weight 486 x 288...

Page 8: ...0 800 9 200 600 F i 2 A 55 5 400 0 5 6 50 3 s E 45 200 1 I t I I 5 0 0 1 2 3 4 5 CURRENT A oI i 1 2 3 4 5 600 g i z s 400 200 0 Output Max 1 J w Rated 8OOW Frequency 50Hz Voltage 220v Output Max 12o w Rated oooW Frequency 60 Voltage 12ov CURRENT A 2 ...

Page 9: ...C Ampere 8 3A DC output ow 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 I 0 2 4 6 8 10 CURRENT A 3 ...

Page 10: ...ntly concentrated on the front panel 3 5 LONG CONTINUOUS OPERATION The large 3 5 liters fuel tank allows four hours of operation at 50Hz rated output 3 5 MINIMAL MAINTENANCE l Brushless alternator eliminates time consuming brush maintenance l Trouble free condenser voltage regulation for greater dependability l No fuse resettable circuit breakers 0 Electronic pointless ignition system for sure sta...

Page 11: ... GENERATOR 4 1 EXTERNAL VIEW of GENERATOR DC Circuit Breaker Engine Control Switch CHOKE RUN STOP AC Receptacle Ground Terminal Air Cleaner Cover Spark Plug Cover Fuel Tank Drain Plug Oil Filler Cap 5 Carrying Handle Fuel Tank Cap ...

Page 12: ...he LABEL MODEL NAME stuck on the rear cover NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service LABEL SPEC Example LABEL MODEL r PROD NO RGOl2216010 Specification No 1234 SER NO 1000001 1 Production No L L 4 Serial No 6 ...

Page 13: ...IER STATOR COVER I I CONDiNSER MOUNT BBER THROtiGH BOLT FRONT OVER Fig 5 7 5 2 FUNCTION 5 2 i 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 I I I I I Fig 5 2 7 ...

Page 14: ...urrent 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 th...

Page 15: ...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 I Fig 5 6 9 ...

Page 16: ...d 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 flows through the field coil and magnetizes the rotor core to generate an outp...

Page 17: ...le 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 2 flows in the x B direction as shown in the figure No current flows between CD and EF because the current is cut off by the diodes Gl and G3 Fig 5 8 2 As a result the voltage generated at the output terminal has a wave form with tw...

Page 18: ...uring 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 a...

Page 19: ...r factor correction capacitor is not applied to the mercury lamp or fluorescent amp the more power shaN be required to drive those lamps A rated 1OOOWgenerator 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...

Page 20: ...cy of this motor is 0 7 and power consumption will be 400 0 7 57OW 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 Electrical appliance Applicable limit 50Hz 60Hz lncandesent lamp heater etc Fluorescent lamp mercury lamp etc approx 800W I approx 1 OOOW approx SOW I approx 650W Motor driven tool gener...

Page 21: ...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 l SPECIFIC GRAVITY OF BATTERY ELECTROLYTE The specific gravity of electrolyte varies by t...

Page 22: ...00 1 240 87 1 220 75 1 200 62 1 180 50 1 160 37 1 140 25 Remarks Charging is not necessary Charging is necessary Immediate Charging is necessary Table 7 3 7 2 3 BAlTERY 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 16 ...

Page 23: ...dy sturdy case for easy carrying Fig 8 1 l SPECIFICATIONS Model Part Number Voltage i l 2 Frequency P Resistance C 2 9 Condenser Capacity 2 Insulation Resistance Circuit Protector Power Source Accessories Dimensions L X W X H Weight Dr Robin 388 47565 08 0 500V AC 25 70Hz 0 1 l 999 0 lo 100 YF 3MQ Fuse 2 x 6F44P 006P Dry Cell Battery Test leads with needle probes 1 set Test leads with jack plugs 1...

Page 24: ...V 0 to 300V Type with an output voltage of 220 230 or 240V 0 to 15OV 0 to 330V Dual voltage type For AC Fig 8 2 2 AMMETERS AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About lOA 20A 1OOA For AC 1 Fig 8 3 3 FREQUENCY METER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input v...

Page 25: ...tester is used for measuring re sistance etc MEGGER TESTER Used for measuring generator insulation sistance Select one with testing voltage range 5oov 6 TACHOMETER Use the contact less type tachometer re of Fig 8 5 I 1 Fig 8 6 Fig 8 7 19 ...

Page 26: ...voltage 1lOV 120v 220v 240V Voltage range 1 107 119v i 117 130V 215 236V 235 260V Table 8 2 8 3 DC OUTPUT MEASURING 4 To AC Receptacle 1 Load Fig 8 9 Measurement of DC output is executed with the swirch turned OK while the current is regulated at 8 3A by adjusting the load to the generator If the voltage is within the range from 1OV to 14V the voltage output is normal Note If a battery is connecte...

Page 27: ...esistance at the time of shipment from the factory is 10 megohm or more If it is less than 1 megohm disassemble the I generator and measure the insulation resistance of the stator rotor and control panel individually Fig 8 10 l 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 res...

Page 28: ...sulation resistances between the live parts and the grounded parts Fig 8 13 Any part where the insulation resistance is less than 1MQ has faulty insulation and may cause electric leakage and electric shock Replace the faulty part 22 ...

Page 29: ...9 l 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 16 Fig 9 2 9 l 3 CIR...

Page 30: ... 9 5 Rx1 Q 10 Hz Specification Voltage 1 AC Winding DC Winding Condenser Winging i I Brown White Yellow Red Black Black 11ov I 1 7 0 0 84 0 220v 50 6 3 Q 4 9 0 220V O DE spec i 7 3 0 1 0 0 240V 8 1 Q 0 84 Q 11ov 1 0 0 12ov 1 3 0 60 0 56 0 4 2 220v Q 4 0 Q I I 240V 5 0 n Table 9 1 NOTE If the circuit tester is not sufficiently accuratejt may not show the values given and may give erroneous readings...

Page 31: ...reading appears try checking in re verse polarity NOTE 2 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 pera tures different from 20 C 68 F Fig 9 6 2 Measure the resistance of the res...

Page 32: ...L Fig 9 8 n 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 Green Red Green Red Green Green Fig 9 9 DIODE RECTIFIER CIRCUIT TESTE Fig 9 10 The internal circuit of the diode rectifier is as shown in Fig 9 9 Check continuity between ...

Page 33: ... 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 Table 9 2 2 10 DISASSEMBLY AND ASSEMBLY 1O l PREPARATION and PRECAUTIONS 1 Be sure to memorize the locarion of individual parts when disassembling the generator so that the generator c...

Page 34: ...g Plusscrew four M5 X 8 screws SeeFig 10 l driver 2 Rearcover 1 Remove the rear cover by unscrewing Plusdriver threeM5 X 8 screwsand two M8 X 10 screws SeeFig 10 2 3 Control panel Fig lo 2 1 Pull the knob off the control lever and removethe control panelby unscrewing four M 5X 8 screws SeeFig 10 3 _ Fig IO 3 Plusdriver 28 ...

Page 35: ...m thewires of controlpanel 6Pcouplers Yellow Red Green Yellow Brown White SeeFig 10 4 2 Disengagethe connector of grounding wire Pin terminal GreenA ellow SeeFig 10 T Pull the couplerswhile pushingthelocking hook Fig 10 4 Fig 10 5 Press the hook of the coupler and pull out to disconnect CONTROL PANEL SIDE STATOR SIDE I Fig IO 6 I 29 ...

Page 36: ...fuel from thetank Use utmost care about 1 Shutthefuel striner 2 Removethestrainercup I fire hazard 3 Put a vesselto receivefuel underthe i Wipe off spilt fuel strainer and open the fuel cock to throughly dischargefuel SeeFig 10 9 4 Attach the strainercup to the strainer body 2 Disconnectfuel hosefrom thestrainer Loosen the hose clamp on top of the strainerand pull out the fuel hosefrom thestrainer...

Page 37: ...verby unscrewing thehvo I43 X 10screws The fuel tank can be removedwithout disassembling the handle Driver 2 Pull off thebreatherpipe 3 Removethe handle body by taking off thehv0 M8 nuts Handle cover 13mmboxwrench Breather pipe A Handle M3x IO Screw 2 PCS Full tank M8xNut 2 pm Fig 10 11 31 ...

Page 38: ...ng off the hv0 M8 nuts from the bottom of the tank SeeFig 10 13 I I I Tool 1Ommboxwrench 13mmboxwrench Bracket Cover Endcover Fig 10 72 Fig 70 13 1 Remove the bracket cover from the generatorby looseningthetwo M8 X 30 bolts SeeFig 10 14 1 Remove the end cover from the generatorby unscrewingthethree I X 8 screws SeeFig 10 14 Fig lo 14 13mmboxwrench Driver 32 ...

Page 39: ... the diode rectifier andthen removethe earthcable terminalfrom therearbracket SeeFig 10 16 Remarks Tool 1Omm boxwrench Box spanner Box spanner ant screwdriver Bracketbolt 3PCS Fig IO 15 4 Remove the rear bracket tapping it evenlywith a plasticmallet SeeFig 10 U 5 Removemountrubbersfrom rearcover SeeFig 10 18 Fig 70 16 Plasticmallet Wrench mallet Fig IO 17 Fig 10 18 33 ...

Page 40: ... Remarks Tool 12 Stator 1 Remove thestatorcover SeeFig 10 19 2 Pull off the stator from the front cover tapping the core with a plastic mallet SeeFig 10 20 Nevertaponthe winding andthelead Plasticmallet Fig 10 79 Fig IO 20 Fig 70 22 ...

Page 41: ...to the centerholeof rotorshaft I Fill with oil to theshaftend SeeFig 10 24 2 Prepare a bolt with the following threadsize M8 X P 1 25 3 Apply a few turns of sealtapearound thetip of thebolt SeeFig 10 25 Descrlptlon Remarks 1 Takeoff thethrough bolt Apply a box wrench on the head of throughbolt Hit thewrenchhandlewith ahammercounter clockwiseto loosen I Tool Box wrench Plastichammer Fig 70 24 Fig 1...

Page 42: ...erotor comesoff loose The hydraulicpressureinsidetherotor shaft takes apart the rotor from the engineshaft 4 Wipe off oil throughly from rotor shaft andenginePTOshaft Remarks Fig 10 26 1 Remove the front bracket which is mountedon the main bearingcover of the engine by taking out four M8 X 18 bolts SeeFig 10 27 Socketwrench 13mmboxspanner Fig 10 27 36 ...

Page 43: ...tep 15 art to remove Mount rubbers Description 1 Removemountbracketfrom engine Remove mount rubbers from mount bracket Remarks 8 I Nut 3pcs or Zpcs Mount bracket Mount rubber Fig 10 28 Tool 12mmwrench 37 ...

Page 44: ...OTOR Fig 70 29 1 Wipe off oil from the tapered portion of engine shaft and matching tapered hole of rotor shaft See Figs lo 30 and 10 31 Fig lo 30 Fig 10 31 2 Install rotor on the engine shaft and tighten the I through bolt Apply a wrench on the head of through bolt i and hit wrench handle clockwise with a ham mer to tighten See Fig 10 32 If an impact wrench is available use it I I I Fig 10 32 38 ...

Page 45: ...ch the stator cover around the stator Fig lo 33 3 4 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 4 0 5 4 ft l Ibs 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 c...

Page 46: ... mounting tab on the bottom of the fuel tank and the blower housing with M6 X 12 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 t...

Page 47: ...t 2 PCS Rubber hose k Hose clamp Fuel strainer Cup Rubder hose Fig lo 36 10 3 9 FRONT COVER AND ELEMENT COVER 1 Secure the front cover on which fuel strainer have been mounted with three M5 X 8 screws See Fig 10 37 2 Secure the element cover with M6 X 12 screws See Fig 10 38 Fig lo 37 41 Fig lo 38 ...

Page 48: ... STATOR 6P coupler Wire color Yellow Red Green Yellow Brown White Green Yell Brown Yellow Red White CONTROL PANEL SIDE STATOR SIDE 0 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...

Page 49: ...10 3 12 REAR COVER r I I Secure the reaTcover with three M5X8 screws and two M8 X 10 screws I Fig lo 42 10 3 13 SIDE COVER I r II L r I Secure the side cover with four M5X 8 screws I Fig IO 43 43 ...

Page 50: ...7 1 11 I 2 CHECKING CONDENSER n If an instrument Q C meter or C meter for measuring capacity of condenser is available check the capacity of condenser n NORMAL CAPACITY OF CONDENSER n 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 1l l ...

Page 51: ...the resistors w Measure the resistance of 2 pieces of diode CATHODE MARK P0LARll Y OF CIRCUIT TESTER Continuity exists n Measure the resistance of each resistor NORMAL RESISTANCE n Check the magnetic force of magnets molded in the rotor Remedy1 1 If the magnetic force is weak replace the rotor with a new one 2 If the diode or the resistor is faulty replace them with new one When all these parts ar...

Page 52: ...high or too low adjust it to the rated rpm mow to adjust engine rpm n Loosen the nut on the adjusting screw n 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 1l 2 2 CHECKING STATOR Check stator referring to Step 11 1 1 1l 2 3 CHECKING CONDENSER Chec...

Page 53: ...EAKER AC RECEPTACLE RESISTOR SPARK PLUG I DIODE 1 J whltn I I t V IGNITION I COIL I I MAGNETO DC COIL CONDENSER COIL 1 I I 2P COUPLER i DIODE STACK ASSY I RECTIFIRE DC RECEPTACLE GROUND TERMINAL CONDENSER DC dlRCUlT BREAKER STOP SWITCH ...

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Robin R1210 Brushless, Service Manual

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