Robin R1300 Page 42 Service Manual Download | Manualshive

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Summary of Contents for R1300

Page 1: ... Generator Technical Data Overhaul Instructions SERVICE MANUAL ...

Page 2: ...ecautions 16 RANGE OF APPLICATIONS C 17 7 1 AC Output 17 7 2 DC Output 19 MEASURING PROCEDURES 21 8 1 Measuring Instruments o 21 8 2 AC Output Measuring 24 8 3 DC Output Measuring 24 8 4 Measuring Insulation Resistance o 25 CHECKING FUNCTIONAL MEMBERS 27 9 1 Control Panel 27 9 2 Stator 28 9 3 Rotor S 29 9 4 Condenser 9 5 Diode Rectifier 30 30 9 6 Oil Sensor Option 32 Disassembly AND ASSEMBLY 32 10...

Page 3: ...em TY Pe ForcedAir cooled 4 Stroke Side Valve I Gasoline Engine Displacement I 143cm3 8 73cu in Bore x Stroke 63 X 46 mm 2 48 X 1 81 in Fuel Oil pan capacity 3 5 liters 0 9 U S gal Fueltank capacity Automotive Gasoline unleaded Approx 3 6 hours Approx 4 3 hours Continuous operating hours per tank 600 cc 1 3U S pints Ignition system I Solid state ignition Starting system I Recoil starter Dimensions...

Page 4: ...2 PERFORMANCECURVES 2 1 AC OUTPUT 1050 1000 800 55 50 45 j CURRENT A 3 400 200 0 0 1 2 3 4 5 6 7 CURRENT A 8 9 10 1300 1200 1000 800 t 400 200 2 ...

Page 5: ...L 10 0 2 4 6 8 10 CURRENT A DCVoltage DCAmpere DC output 12v 8 3A 1oow Thevoltagecurveshown in theleftindicatesthe characteristic of DC output when charging a battery Thevoltagemaybedecreasedby 20 whenthe resistance load is applied 3 ...

Page 6: ...onveniently located on the front panel LONG OPERATION The large 3 5 liter fuel tank allows about 4 3 hours of continuous operation at 50Hz rated load MINIMAL MAINTENANCE The brushless design and condenser voltage regulator system ensure maintenance free operation FUNCTIONAL FEATURES The ACDC push button circuit breaker allows for easy and safe operation when an overload occurs Equipped with voltme...

Page 7: ...IEW o f GENERATOR DC terminal Engine control switch Frequency adjusting screw internal c Voltmeter Fuel cock Fuel strainer withoil sensor type Air cleaner cover Muffler Spark Fuel tank I Fuel tank cap Drain Iplug Oil filler cap Fig 4 1 5 ...

Page 8: ...al number and specification number are stamped on the LABEL MODEL NAME stuck on the fuel tank NOTE Always specify these numbers when inquiring about the generator or ordering spare parts in order to get correctparts and accurateservice LABEL MODEL NAME Fig 4 2 6 ...

Page 9: ... 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 I I I Fig 5 2 7 ...

Page 10: ...he core DCcurrect in thefieldcoilmagnetizesthesteel sheetcore Two permanentmagnetsareprovided for the primary exciting action A cooling fan is pressure fitted on the end of the rotorshaft to coolthecoils cores rectifier and other generator parts See Fig 5 4 A diode rectifier and resister are mounted insideof the insulator See Fig 5 5 Cooling air is sucked by the rotor fan through the slits of ther...

Page 11: ...uble AC receptacle with a ground terminals andDC terminals The voltmeter displays output voltage of the gen erator The circuit breaker forAC and DC protects the generator from getting damages caused by overloading or defective appliance i Fig 5 6 9 ...

Page 12: ... 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 rectifierin the field coil circuit rectifies this AC voltage into DC Thus a DC current 1 3 flows through the field coil and magnetizes the rotor coreto generate an output voltage in the main coil When generator speed reaches 2700 to 2800 r p ...

Page 13: ...rent is cut off by the diodes D Onthecontrary whenthevoltage in C ishigher than that in A the current a flows in the direction as shown in the figure No current flows between A and B becausethecurrentis cut off by the diodes Dl A MAIN COIL C Fig 5 8 1 Dl Fig 5 8 2 As a result the voltage generated at the output terminal has a wave form with two peaks in one cycle as in the case of the output wave ...

Page 14: ...which is press fittedon the rotor shaft of the generator IGNITION TIMING DETECTING CIRCUIT IGNITION COIL PLUG Fig 5 9 1 When the permanent magneto built in flywheel start rotating power is generated in the primary coil of the ignition coil and current flows to the resistor z From the resistor current flows the power transistor With this current the power transistor turns on releasing current s Thi...

Page 15: ... flow of the oil Influenceagainsttheignitionsystemortheelectronicunitscanbeneglectedbecauseanelectric current supplied to the sensor can be decreased A 5 5 2 PRINCIPLE OF SENSING OIL LEVEL There isa great difference between electric resistanceof air and thatof 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 a...

Page 16: ... sensor has been designed so that the engine is to be stopped only when oil shortage is detected for 5 seconds uninterrupted The timer employs an integration circuit and it is to be reset when the inner electrode is soakedin the oil again before the sensor decidesit as oil shortage The oillevelwherethesensordecides asoil shortage whenoillevelgoesdowngradually iscalled threshold level Automatic sto...

Page 17: ...ti 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 malfunctionor breakdown Since capacity of power source is limited current flown in the electronic circuit of the sensor is A kept as low as possible Be sure to use terminals with a high contact reliability of more than that of ...

Page 18: ...during use there is a danger of fuel spillage and a chance that the v generator may tip over DO not pperate with wet hands or in the rain Severe electric shock may occur If the generator is wetby rain or snow wipe it andthoroughly 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 ...

Page 19: ...3 times lager than their running wattage Example A rated 250W electric drill requires a 400W generator to startit NOTE I If apowerfactorcorrectioncapacitoris not applied to the fluorescent lamp the more power shall be required todrive 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 indicatio...

Page 20: ...hat its work load is 400W Efficiency of this motoris0 7andpowerconsumptionwillbe400 0 7 570W Whenthismotoris 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 I Applicable wattage Appliance i i 50Hz 60Hz lncandesent lamp hot plate up to 800W I up to 1ooow I Fluorescentlamp mercurylamp Electrictool up to about600W up to a...

Page 21: ...length from generator to electrical tools 7 2DCOUTPUT NOTE Do not use DCand 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 ...

Page 22: ... Remarks 1 260 87 1 240 100 Charging is not necessary I 1 220 I i 75 I Charging is necessary 1 200 1 180 50 1 160 37 1 140 Immediate Chargingis necessary Table 7 3 7 2 3BATTERYCAPACITY The batterycapacity is expressedintheunit of AH ampere hour One AH standsforthecapacity capable of one ampere current for one hour 20 ...

Page 23: ...y case for easy carrying P Fig 8 1 0 SPECIFICATIONS Model 388 47565 08 Pag Number Dr Robin Voltage 5 i Frequency E c tu Condenser Capacity 0 1 1 999 0 Resistance a 0 5OOV AC m 25 70Hz 0 L 3 v a i 10 100 uF 1 InsulationResistance 3MR Circuit Protector 2 x 6F44P 006P Dry Cell Battery Power Source Fuse Accessories I Testleadswith needle probes 1 set Testleadswithjack plugs 1 set Dimensions L x W x H ...

Page 24: ...anoutputvoltage of 220 230 or 240V 0 to 15OV 0 to 33OV Dual voltage type 110 or 12OV For AC Fig 8 2 2 AMMETERS ACammeter isnecessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10A 20A 100A I II For AC Fig 8 3 3 FREQUEXCYMETER Frequency range About 45 to 65Hz NOTE Be careful of the frequency meter s input voltage range...

Page 25: ...ltage range of 1 500V Fig 8 6 I 6 ENGINETACHOMETER There are various types of tachometers such ascontactlesstype contacttype andstrobe type Thecontacttypecanbe usedonlywhen j the generator and engine have been dis assembled The contactless type is recom mended ThePET 2100Eenginetachometerisavailable from your Robin distributors PleaseinquirebythepartnumberPET 2100E 1 Fig 8 7 23 ...

Page 26: ...ltage IlOV 120v 235 260V 21 5 238V 1 17 1 30V 107 119V Voltage range 220V I 240V Table 8 2 8 3 DC OUTPUTMEASURING I To DC Terminal l 9Fig 8 9 Measurement of DC output is executed with the switch turned ON while the current is regulated at8 3A by adjusting the load to the generator If the voltage is within the range from 6V to 14V the voltage output is normal Note Ifabattery is connected as a load ...

Page 27: ...esistanceatthe time of shipmentfromthefactoryis 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 Fig 8 10 0 STATOR 1 Measure the insulation resistance 2 Measure the insulation resistance 3 Measure the insulation resistance BROWN lead and the core YELLOW lead and the core BLACK lead and t...

Page 28: ...sulation resistances between the live parts and the grounded parts Fig 8 13 Any part where the insulation resistance is less than 1MO has faulty insulation and may cause electric leakage and electric shock Replace the faultypart 2 6 ...

Page 29: ...etween 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 outputterminals of thereceptaclewithawireconnectedacrosstheseterminals 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 2A Fig 9 25 27 ...

Page 30: ...e 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 breakeris normal 9 1 4 VOLTMETER Checkthe voltmeter if it operatescorrectly by applyingspecifiedvoltage Voltmeterscannotbe checkedwithacircuittesterbecauseitsinter...

Page 31: ...Using the Dr Robin or a circuit tester measure the resistance of the field coil See Fig 9 5 R x l Q 1 0 E Resistance NOTE 1 Because a diode is soldered to the coil ends at the Iterminals resistance may be measured only when tester probes touch the terminals in one combination of polarity Therefore ifnoresistance reading appears try checking in re verse polarity NOTE 2 Ifthecircuittesteris not suff...

Page 32: ...I Normal Capacity of Condenser I 10 2 F Fig 9 6 W If such an instrument is unavailable the condenser can be checked by replacing with a new one If thegeneratorperformsgoodwithnewcondenser thecause of troubleisdefect in original condenser 9 5 DIODE RECTIFIER Green Red Green I Fig 9 7 Red Green Green Fig 9 8 The internal circuit of the diode rectifier is as shownin Fig 9 7 Check continuity between e...

Page 33: ...i of the circuit tester I I Continuity I Continuity Table 9 2 2 NOTE 1 NOTE 2 NOTE 3 Because of the difference of measuring method between the analogue circuit tester and the digital circuit tester polarity of tester needles should be reversed Continuity meansforwarddirectioncharacteristicsofthediode and differentfromshort circuitcondition inwhich a pointer of the testergoesoutofitsnormalscale sho...

Page 34: ... fails to stopwithin 5 seconds afterthe wirings have checked the sensor is wrong Replace the sensor with new one 10 DISASSEMBLYAND ASSEMBLY 10 1 PREPARATION and PRECAUTIONS 1 Besure to memorizethelocation of individualpartswhendisassemblingthegenerator so thatthe generator can be reassembled correctly Tag the disassembled part with the necessary information to facilitate easier and smoother reasse...

Page 35: ...SeeFig 10 1 I Plus screw driver 2 Rear cover I 1 Remove the rear cover by unscrewing three M5 X 8 screws and hvo M8 X 10 i screws See Fig 10 2 I i Plus driver 3 I Control panel I j I I I Ii I I i Fig 70 1 Fig 10 2 1 Pulltheknoboffthe control lever and remove the control panel by unscrewing four M 5 X 8 screws SeeFig 10 3 Fig 10 3 1 33 Plus driver ...

Page 36: ... control panel 6P couplers Yellow Red Green Yellow Brown ire See Fig 10 4 2 Disengage the ConnectorS of oil warning lamp option See Fig 10 5 Remarks I Tool Pull the couplers Lvhile I pushing the locking hook I Fig 10 4 I Press the hook of the coupler and i pull out to disconnect CONTROL PANEL SIDE STATOR SIDE Fig 10 5 i I 34 ...

Page 37: ...gefuel from the tank 1 Shut the fuel striner 2 Remove he strainer cup 3 Put a vessel to receive fuel under the strainer and open the fuel cock to discharge fuel See Fig 10 7 4 Attach the strainer cup to the strainer body 2 Disconnectfuel hose from thestrainer Loosen the hose clamp on top of the strainer and pull out the fuel hose from the strainer See Fig 10 3 b e utmost care about fire hazard Vip...

Page 38: ...oved without Driver The fuel tank can be Fuel tank I 1 Remove the handle cover by unscrewing Tool Remarks handle 2 Pull off the breather pipe 3 Remove the handle body by taking off the nvo 348 nuts 12mm box wrench Breather pipe Handle 1 i M8X Nut 2 pcs Fuel tank M8xNut 2 pcs Fig 10 9 36 ...

Page 39: ...k 1 1 8n u s from the bottom of the tank See Fig 10 1 1 9 10 Bracket Cover End cover Tool lOmm box wrench 12mm box wrench Fig 10 70 Fig 70 7 7 1 Remove the bracket cover from the generator by loosening the two M 8 X 30 bolts See Fig 10 12 1 Removethe end cover from the generator by unscrewing the four M5 X 10screws See Fig 10 12 i Bracket Cover Fig 70 72 12mm box wrench Driver 37 ...

Page 40: ...e the connector of the diode 1 rectifier and then remove the earth cable terminal from the rear bracket See Fig 10 14 I Tool lOmm box wrench Box spanner Box spanner and screw driver W I Cover bolt 3pcs Fig 10 13 evenly with a plastic mallet See Fig 10 15 i 5 Remove mount rubbers from rear cover I See Fig 10 16 Fig 10 15 Fig 10 14 Plastic mallet Wrench Fig 10 16 38 ...

Page 41: ...ove the stator cover See Fig 10 17 i 2 Pulloff the stator from the frontcover tapping the core Lvith a plastic mallet I See Fig lO lS I i I Fig 70 17 Stator I I i Xever tap on the I Plastic mallet winding and the lead 1 Fig 10 18 Fig 10 19 I i Ii i Fig 10 20 I 39 ...

Page 42: ...n the working table j I recoil saner side doxvn i out rotor in the following procedures 1 Pour engine oil into the center hole of rotor shaft 1 Fill Lvith oil to the shaft end See Fig 10 23 i thread size h 18X P 1 25 the tip of the bolt See Fig 10 23 I 2 Prepare a bolt with the following 3 Apply a few turns of seal tape around I Box wrench Plastic hammer 3j Lse a boltandoil asa tool for pulling I ...

Page 43: ...aulic pressure inside the rotor shaft takes apart the rotor from the engine shaft 4 Wipe off oil throughly from rotor shaft and engine IT0shaft i i Fig 10 24 1 Remove the front bracket which is I mounted on the main bearing cover of the engine by taking out four M 8 X 18 bolts See Fig 10 25 I i TooI 12mm box spanner or Socket wrench 12mm box spanner 41 ...

Page 44: ...o remove I Descriptlon Remarks 15 Mount i 1rubben Ii I I 1 Remove mount bracket from engine i Remove mount rubbers from mount bracket 6 6 Xut 3pcs or pa I Mount bracket Mount rubber J Fig 10 26 Tool 12mm wrench 42 ...

Page 45: ...10 3 2 ROTOR Fig 10 27 1 Wipe off oil from the tapered portionof engine shaft and matching tapered holeof rotor shaft See Figs 10 28 and 10 29 Fig 10 28 2 Install rotor on the engine shaft and tighten the through bolt Applyawrenchonthehead of throughbolt andhitwrenchhandle clockwise with a ham mer to tighten See Fig 10 30 If an impact wench is available use it TIGHTENING TORQUE 1175 1370N cm 120 1...

Page 46: ...around the stator 3 Tighten the three M6 bolts to fix the rear bracket to the front bracket TIGHTENING TORQUE 535 735 N cm 75 kg cm 4 0 5 4 i t Ibs 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 ofthe groove 10 3 4 CONDENSER Put condenserto rear cover 5 iX 10 mm tapping screw 2 pcs TIGHTENING TO...

Page 47: ...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 secureit with two 348 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...

Page 48: ...uel 1 Fuel tank M8 Nut 2pcs Banjo Rubber hose Fig 10 34 10 3 9 FRONT COVER AND ELEMENT COVER 1 Securethefrontcover on whichfuelstrainer have been mounted with three 345 X 8 screws See Fig 10 35 2 Secure the element cover with M6 X 12 screws See Fig 10 3 Fig 10 35 46 ...

Page 49: ...CTIONS BETWEEN CONTROL PANEL AND STATOR 6PcouplerWirecolor Yellow Red Greenh ellow Brown White GreenNell Brown Yellow Red White CONTROL PANEL SIDE STATOR SIDE 10 3 11 CONTROLPANEL 1 Putthecontrolpanelover thecontrollever 2 Attach the knob to the control lever and secure it with four 345 screws Note After the couplersandconnectorshave been connected and securedto the control panel secure the wires ...

Page 50: ...10 3 12 REAR COVER Secure the rear cover with three M5x8 screws and two M8 X 10 screws Fig 10 38 10 3 13 SIDE COVER Secure the side cover with four M5X 8 screws Fig 10 39 48 ...

Page 51: ...place with new one 11 1 2 CHECKING CONDENSER If an instrument Q C meter or C meter for measuring capacityof condenser is available check the capacity of condenser 1O uF If you do not have such an instrument you can check condenser by replacing with new one and test running If thegeneratorperformnormallywithnewcondenser thecause of trouble is defectinoriginal condenser 11 1 3 CHECKING ROTOR 1 Remov...

Page 52: ...ble them and then solder 11 2 AC VOLTAGE IS TOO HIGH OR TOO LOW 11 2 1 CHECKING ENGINE r p m If the e ngine r p m is too high or too low adjust it to the rated r p m mow to adjust engine r p m w Loosen the nut on the adjusting screw w Turn the adjusting screw clockwise to in decreaseenginespeedorcounter clockwise to increase engine speed Normal engine speed atno load is 3150 3200 r p m for 50 Hz t...

Page 53: ...12 WIRING DIAGRAM J 51 ...

Page 54: ...With Oil Sensor Option type 52 ...

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Page 57: ...EMD GSQ993I F U J I HEAVY INDUSTRIESLTD INDUSTRIAL PRODUCTSDIV Subaru Bldg 1 7 2 Nishi Shinjuku Shinjuku ku Tokyo 160 Japan PHONE Tokyo 03 3347 2420 FACSIMILE Tokyo 03 3347 2418 PRINTED I N JAPAN December 1995 ...

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