Baldor PC13R User Manual

OPERATOR'S MANUAL FOR YOUR

MODEL PC13R

SERIAL NUMBER _______________

BALDOR GENERATORS

3815 OREGON STREET ◊ P.O. BOX 200 ◊ OSHKOSH WI 54902-0200
TELEPHONE: [phone] ◊ FAX: [phone]

FORM#: S-PSG-002-25 D:\ISO9001\FORMS\S-PSG-002-37\msw
EFFECTIVE/REVISED: 6/29/01

FORWARD

This manual contains the information you need to safely and efficiently operate your generator
set. During the preparation of this manual every effort was made to ensure the accuracy of its
contents.

DO NOT OPERATE THIS GENERATOR SET UNTIL YOU CAREFULLY READ THIS
MANUAL AND UNDERSTAND THE SAFETY WARNINGS AND INSTRUCTIONS
CONTAINED IN IT. While safety is built into every Baldor Pow'R Gard generator set, careless or

improper operation could possibly result in mechanical failure, property damage, severe injury
or even death.

Note that this manual covers only very basic information in regards to the engine. A separate
owner's manual for the engine is supplied with this unit for your use. Please refer to this manual
for information relative to engine operation, maintenance, recommendations and additional
safety warnings.

As soon as you receive your generator set, inspect it closely for shipping damage. If you find
some damage, notify the transportation company immediately and file a freight damage claim.

Think of this manual as a tool to help you get the most out of your generator set. WE

STRONGLY SUGGEST THAT YOU KEEP THIS MANUAL WITH YOUR GENERATOR SET
AND MAKE IT AVAILABLE TO ANYONE USING THE GENERATOR SET. You should refer

to the manual when questions arise in regards to the operation of the generator set and
carefully observe all safety warnings and instructions contained in it.

Baldor Generators, formerly Pow'R Gard Generator Corporation has been in business since

1965. The generator sets we manufacture have earned the reputation of being of high quality
and a dependable product. We take pride in this fact and continue to keep our quality standards
high on our list of priorities. We are also constantly researching new technological ideas to
determine if they could be used to make our generator sets even better.

Thank you for purchasing your Baldor Pow'R Gard Generator Set.

- i -

SAFETY WARNINGS

♦

Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley,
belt, etc. are left exposed, they are potentially hazardous.

♦ When cleaning, repairing or inspecting, make sure all moving parts have stopped.

♦ Prior to working on the generator set, disconnect the spark plug and battery to prevent accidental starting.

♦ Use only original equipment or authorized replacement parts. Use of correct parts will assure the operator of

the safety integrity that was designed into the unit.

♦ Unauthorized modifications to the generator set may impair the function and/or safety of the unit.

♦ Do not operate the generator set without a muffler. Inspect periodically and replace if necessary.

♦ Do not touch the hot exhaust components or the high voltage spark plug and coil terminals. While Spark Plug

Voltages are not normally lethal, an involuntary jerk of the hand caused by a hot surface or by an electrical
shock can result in injury.

♦ Repair of electrical generating equipment requires specialized skills. Repair personnel must have a

thorough understanding of generator and small engine repair procedures.

♦ Never inhale exhaust gases. They contain carbon monoxide; a colorless, odorless and extremely

dangerous gas that can cause unconsciousness or death. Symptoms of carbon monoxide poisoning
can include: dizziness, nausea, headaches, sleepiness, vomiting or incoherency. If you or anyone else
experiences any of these symptoms, get out into the fresh air immediately. Shut the unit down and
do not operate it until it has been inspected and, if necessary, repaired.

♦ Never Operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave.

♦ CALIFORNIA PROPOSITION 65 WARNING: engine exhaust from this product contains chemicals known to

the state of California to cause cancer, birth defects or other reproductive harm.

♦ Know how to stop the engine quickly and understand the operation of all controls.

- ii -

SAFETY WARNINGS

♦ Never permit anyone to operate the generator set without proper instructions.

♦ Never allow children to operate the generator set.

♦ Children and pets must be kept away from the area of operation due to the possibility of burns from hot

engine components or injury from any equipment the generator set is powering.

♦ Always wear eye protection and Hearing protection when working near the generator set.

♦ Operate the generator set only with the guards, shields and other safety items in place and working

properly.

♦ Do not put hands, feet, tools or other objects near rotating parts.

♦ Use reasonable care when moving or lifting the unit. The generator set may move around inside the wrap

frame creating "Pinch Points".

♦ Do not run the generator set while it is being moved.

♦ Do not support the generator set from the top of the wrap frame.

♦ Do not operate the generator set while under the influence of alcohol, drugs or medication.

♦ When transporting or using a generator set with the wheel option, secure the unit to prevent it from moving

around.

♦ Do not tamper with or change the engine speed as it has been preset at the factory for proper operation.

♦ Keep hands and face away from the carburetor when the air cleaner is being moved. A sudden backfire can

cause serious burns.

♦ Be careful of hot parts. The muffler and other generator parts become very hot while the engine is running.

♦ Do not "jump start" the generator set.

♦ Sulfuric acid can cause severe injury and can give off gases, which are corrosive and potentially explosive.

Avoid contact with skin, eyes, and clothing. In case of contact, flush area immediately with water.

♦ When transporting a generator set, secure it to prevent it from moving or shifting.

♦ Know how to stop the engine quickly and understand the operation of all controls.

♦ Do not operate electrical equipment while standing in water, on wet ground or with wet hands or shoes.

♦ Use extreme caution when working on electrical components. Potentially dangerous voltage is present

when the engine is running.

- iii -

SAFETY WARNINGS

♦ Always treat the electrical circuits as if they were energized.

♦ Disconnect all leads plugged into the unit Prior to working on it.

♦ Have the electrical circuits serviced only by qualified technicians.

♦ Inspect wiring frequently and replace frayed, broken or poor leads.

♦ Do not connect this unit to any building's electrical system unless you utilize an approved transfer switch or

the main service entrance switch has been disconnected and locked open.

♦ Circuit overload protection must be provided in accordance with national electrical codes and local

regulations.

♦ Check GFCI Receptacles monthly by using the "Test" and "Reset" buttons designed into them.

♦ Depending on your application it may be mandatory to ground or not ground this unit to earth ground.

Comply with local electrical codes.

○ ○ ○ ○ FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ○ ○ ○ ○

♦ Operate the generator set on a level surface. If the generator set is tilted, fuel spillage may result.

♦ Handle fuel with care. It is highly flammable. Use only clean, properly marked and approved safety

containers for refueling and storing fuel.

♦ Stop the engine and allow it to cool before refueling.

♦ Do not overfill the fuel tank. Only fill the tank to within 1/2" of the top of the tank to allow space for fuel

expansion.

♦ If fuel is spilled, wipe it up carefully and wait until the fuel has dried before starting the engine.

♦ Make sure the fuel cap is properly closed after refueling.

♦ Never operate the generator set while smoking.

♦ Never operate the generator set near an open flame.

♦ Never store the generator set with fuel in the tank indoors or in an enclosed, poorly ventilated enclosure

where fuel fumes may reach an open flame, electrical spark or pilot light as on a furnace, water heater,
clothes dryer, etc.

♦ When transporting over long distances or rough roads, drain the fuel tank to prevent leakage and spillage.

- iv -

SAFETY WARNINGS

○ ○ ○ ○ FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ○ ○ ○ ○

♦ Check all fuel supply piping and their connections on a monthly basis for fuel leaks.

♦ Use only approved piping and componentry in your fuel supply system.

♦ A professional, experienced technician should only install the fuel supply system.

♦ Do not run the fuel line up against any sharp objects.

♦ Comply with NFPA regulations and your local codes in regard to shut-off valves, regulators, etc. and any

other recommendations or requirements they may have.

♦ Keep the generator set at least three feet away from buildings or other structures.

♦ Keep the generator set away from flammable and other hazardous materials (trash, rags, lubricants,

explosives, paints, etc.)

♦ Keep the generator set free of grass, leaves and excessive grease and oils.

♦ Allow the generator set to cool before transporting it or storing it indoors.

♦ Have fire extinguisher accessible and nearby while operating the generator set.

♦ This generator set must not be used on or near any forest covered brush covered or grass covered land

unless the engine's exhaust system is equipped with a spark arrester and it must be maintained
in effective working order by the operator.

♦ Operation inside an enclosed compartment or building is a potential fire hazard and should not be done

unless approval is obtained from Baldor Generators. Engine/Generator overheating can cause severe
damage due to restricted, obstructed or improper airflow that is necessary for the proper cooling of the unit.

♦ Hot exhaust gases being discharged by the engine must never be directed toward anything that could catch

fire or explode.

- v -

Section

Warranty Information............................................................................................... 51

1

.

2

.

3

.

4

.

5

.

6

.

7

.

.

Title

Page

8

.

9

.

10

.

11

.

12

.

1

SPECIFICATIONS

Generator

Engine

TY Pe

T-

Frequency

AC Voltage (Rated current)

Max.

AC Output

:

Rated

DC

Output

Voltage regulation system

Type

I

Displacement
Bore

x

Stroke
Fuel
Fuel tank capacity

Oil pan capacity
Continuous operating hours per tank

Brushless, self-exciting, 2-pole, single phase,
revolving field

60

Hz

120V

(8.3

A)

1300

W

I

1ooow

’

12V-

8.3A

cu. in

gal
pints

3.6

(100 W)

(143

cm’)

in

(63

(3.5

(600

hours

x

liters

cc)

46 mm)

j

I

I

Condenser system

I

:

Forced Air-cooled, 4-Stroke, Side Valve,

I

Gasoline Engine

I

I

8.73

i

I

2.48 x 1.81

i

1

Automotive Gasoline (unleaded)

I

0.9

i

I

I

8

I

U.S.

1.3

U.S.

Approx.
Ignition system
Starting system

I

Dimensions

Dry

weight

Specifications are subject to change without notice.

(L

X

W X H)

1

I

1

I

I

I

I

I

Solid state ignition
Recoil starter

19.3

60.6

x

1

1.3 x 16.1

Ibs.

(27.5 kg)

in

(490 x 288 X 41

Omm)

-1-

2.

PERFORMANCE

2-1

AC

OUTPUT

CURVES

7300

1200

1000

800

A

I

s

600 e

3

E

3

0

400

2-2

DC

OUTPUT

200

1

2

3

4567

CURRENT(A)

9

10

11

The voltage curve shown in the

of

DC

characteristic

output when charging a battery.
The voltage may be decreased
resistance load

is

applied.

by

left

20%

indicates the

when the

”

0

2

4

CURRENT

6

(A)

8

-

10

-2-

3.

FEATURES

LOW-NOISE

Mounting of Air-cooled, 4-Cycle, Super Side Valve ROBIN Engine (EYlSD-SSVR) and introduction
of a larger muffler into the machine realized low-noise operation.

0

LIGHT-WEIGHT COMPACT

The machine is easy to carried about due to its light-weight (27.5kg) and compact design.

0

HIGH

The 1300W output is an increase of lOOW over the

0

EASY OPERATION

OUTPUT (increased maximum

output)

6OHz

maximum output of the current R1210.

The one-touch engine control switch integrates the engine on/off switch and the choke. All controls are
conveniently located on the front panel.

0

LONG OPERATION

The large

0.9

U.S.

gal. (3.5 liter) fuel tank allows about

3.6

hours of continuous operation at

rated load.

4

60Hz

0

MINIMAL MAINTENANCE

The brushless design and condenser voltage regulator system ensure maintenance

0

FUNCTIONAL FEATURES

The AC/DC push button circuit breaker allows for easy

is

or when the machine

not functioning properly.

and

safe operation when an overload occurs

free

operation.

Equipped with voltmeter for reading AC output voltage.

DC

output can be obtained for the re-chargeable battery.

0

NOISE PREVENTION

Resistor spark plug prevent electric-wave noise for radio,

0

OIL

SENSOR (optional)

T.V.,

etc.

The oil sensor detects when oil decreases below the designated level, stopping the engine and
preventing engine damage.

-d

-3-

4.

GENERAL

DESCRIPTION

4-1

TERNAL

EX

DC

VIEW

terminal Engine control

of

GENERATOR

(CHOKE-RUN-STOP)

1

switch

Frequency adjusting

,screw (internal)

starter

Fuel cock

'

Fuel strainer

I

\

I

Oil warning lamp
(With

oil

sensor type)

\

Air

cleaner cover

\

Muffler

Carrying handle

.

Fuel tank cap

Drain plug Oil

filler

Fig.

4-1

-4-

cap

4-2

LOCATION

of

SERIAL NUMBER

and

SPECIFICATION NUMBER

Serial number and specification number are stamped
tank.

NOTE:

Always speciiy these numbers when inquiring about the generator or ordering spare parts in

parts

and

order to get correct

Label

(Model

name)

accurate service.

\

on

the

LABEL

(MODEL

NAME)

stuck

on

the fuel

-1

Fig.

4-2

-5-

5.

CONSTRUCTION

5-1

CONSTRUCTION

6P

coupler

AND

\rll

FUNCTION

Rear

cover

Rotor complete

\

\

Stator complete

I

'I

Condenser Mount rubber

5-2

FUNCTION

5-2-1

The stator consists
core, a main coil and a condenser coil which are

wound

The condenser
generates

STAT0

in

the core slots.

AC

Diode rectifier

R

of

a laminated silicon steel sheet

coil

excites the rotor field coil which

voltage

in

the main coil.

'

Ball

Fig.

bearing

5-1

I

Through bolt

\

Stator cover

Front cover

-6-

Fig.

5-2

5-2-2

A

CONDENSER

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 regu­late the output voltage.

Fig.

5-3

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
rotor shaft to cool the
generator parts.

A

diode rectifier

the .insulator. (See Fig.

is

pressure-fitted on the end of the

coils,

cores, rectifier, and other

(See

Fig.

5-4)

and

resister are mounted inside of

5-5)

Cooling air is sucked by the rotor fan through the
slits of the rear cover and is expelled through the

of

outlets

the front cover.

Fig.

5-4

-7-

Fig.

5-5

5-2-4

CONTROL

PANEL

The control panel has a double

ground terminals, and

DC

AC

terminals.

receptacle with a

The voltmeter displays output voltage of the gener­ator. The circuit breaker for
generator

from getting damages caused

AC and

DC

protects the

by

over-

loading or defective appliance.

Fig.

5-6

-8-

5-3

GENERATOR OPERATION

PERMANENT MAGNET
FOR

INITIAL EXCITATION

I
I

Fig.

I

‘CONDENSER

5-7

5-3-1

SURGE

ABSORBER

GENERATION

Of

NO-LOAD VOLTAGE

When the generator starts running, the permanent magnet built-in to the rotor generates 3 to
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
is

produced with which the magnetic force at the rotor’s magnetic pole

which flows through the condenser coil. At this time, a small flux

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.

of

As AC current flows through the condenser coil, the density

AC

This change of magnetic flux induces

‘AC

coil circuit rectifies this

voltage into
magnetizes the rotor core to generate an output voltage in
When generator speed reaches

3000

voltage in the field coil, and the diode rectifier in the field

DC.

Thus a DC current @ flows through the field coil and

the

to

3300

r.p.m. , the current in

magnetic flux in the rotor changes.

main coil.

the

condenser coil and field coil

increases rapidly.
This acts to stabilize the output voltage of each coils.

If

generator speed further increases

value, the generator output voltage will reach to the rated value.

to

the rated

6V

of

5-3-2

VOLTAGE FLUCTUATIONS UNDER LOAD

When the output current @ flows through the main coil to the appliance, a magnetic flux

@

serves to increase current
flux across the rotor core rises.

in the condenser coil. When current @ increases, the density of magnetic

As

a result, the current flowing in the field coil increases and the

generator output voltage is prevented from decreasing.

-9-

is

produced and

w

5-3-3

DC

OUTPUT

-

DC output
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
the direction
flow in the direction

Fig.

5-8-2

ator.
the voltage in

@

flows in the direction shown in the figure, while
no current flows between
current

On

the

that in
shown in the figure.

B

because the current is cut off by the diodes

is

taken out

@,

shows the DC output circuit

DC

voltage

A

is

cut off by the diodes

contrary, when the voltage in C is higher than

A,

the current

from

the DC coil and is fed to

flow

but does not allow the current to

8,

as shown

is

generated in the

is higher than that

@

flows in the direction as

No

current flows between A and

in

Fig.

5-8-1.

of

DC

coil. When

in

Cy

the current

B

and C because the

D,.

the gener-

D,.

in

Main
coil

4

-a

-0

Fig.

5-8-1

Dl

+

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 form shown in Fig.

Between A and

\

'"0

Between c and

-.

0\

CAUTION : Do not use DC and

-

Due to a characteristic
and

AC

output creates voltage drop In

batterles.

/

I

\

\

AC

output simultaneously.

of

Fig.

5-8-2

5-8-3.

6

/

B

/-

'\

/

I

\

1

j

Fig.

5-8-3

the condenser voltage regulation, simultaneous use of DC

DC

output resulting in incapability for charging

Output

Curre'nt

flowing flowing

between between

A

and

B

0

waveform

C

and

B

-

10

-

5-4

ELECTRONIC

The electronic ignition system features a power transistor as the current control element. Therefore, the
ignition system
controlling the current. This system
ignition failure which generally results from contamination
contact type ignition systems.
Because this ignition system has
contaminants.
maintenance.

TIC

The
flywheel which

mechanism consists of a transistor-incorporated ignition coil and a permanent magneto built-in

IGNITION

is

an electronic contact point-free type that operates with the power transistor impulses

As

a result, this electronic ignition system ensures sure and positive ignition with reduced

is

press-fitted

SYSTEM

is

also

called TIC (transistor igniter circuit) and

no

contact points, it

on

the rotor shaft of the generator.

is

virtually free of

of

the contact points, a typical problem with

is

not affected by moisture,

oil,

dust, or other

4

Fig.

5-9

(1)

When the permanent magneto built-in flywheel start rotating, power

@

of the ignition coil and current flows to the resistor
From the resistor, current flows the power transistor. With this current, the power transistor turns
releasing current

(2)

As

the flywheel comes to the point of ignition, timing detecting circuit

@

is flowing through the circuit.
When the ignition timing detecting circuit
current @ flowing. When current @ starts flowing, current @ flowing through the power transistor

cut

quickly.
simultaneously to the spark plug which ignites for ignition. This stage corresponds to the opening of
contact points.

a.

This stage corresponds to the closing of contact points.

As

a result, high voltage is produced

is

activated, the signal transmitter transistor actuates with

.

in

the secondary coil and this voltage

is

generated in the primary coil

is

activated while the current

is

applied

on,

is

-

11

-

5-5

-

OIL SENSOR

(OPTION)

-

5-5-1

0

0

DESCRIPTION

The oil sensor mainly functions to detect position
of the surface of engine oil in the crankcase
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

in

to insufficient amount of oil
Since the sensor has been designed to consume a
part

of

power supplied to the igniter to energize its
electronic circuit, any other external power supply
is not necessary
oil filler port.
Introduction of newly developed sensing principle
features super durability and
passage

Merits due to introduction

0

@

@

@

of

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.
At the same time, it
vibrations.

No

error occurs due to foam and flow of the oil.

Influence against the ignition system or the electronic units
current supplied to the sensor can be decreased.

so

that it can be mounted at the

time as it does not use any moving part.

is

the crankcase.

no

change with the

of

electrical conductivity detection are as follows;

capable of detecting the oil level stably as it

of

I

I

I

!

i

\

oil

sensor

Fig.

5-10

is

not influenced

can

be neglected because an electric

by

engine

I

I

i

i

1

i

5-5-2

There is a great difference between electric resistance of air and that of oil.
Since the resistance
through the
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
outer) with the reference, in such a way that if a current flows between the electrodes more than the
reference, sufficient oil
oil is
Since an electric current is flown to detect oil quantity, this
detection” type
The oil level to be detected is determined by the length of electrodes and their mounting positions with
the engine.

5-5-3

”

[Power

The sensor makes use of a part of primary power source for ignition of the engine (igniter) to drive

sensor circuit. Power to the sensor can usually be derived from the ”stop button” by branching wires out.

PRINCIPLE

air,

not

sufficient.

’

HOW

IT

supply]

OF

SENSING

of

air is far higher than that of oil, more electric current passes through the oil than

although absolute value of the current

is

in the crankcase, on the other hand,

of sensor.

OPERATES

OIL

LEVEL

is

very smalI.

of

electrodes (inner and

if

a current flows less than the reference,

is

called the “electrical conductivity

the

-

12

-

[Judgement

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

The sensor in this case judges that oil

of

oil

level]

is

considered to be electrically non-conductive.

is

insufficient.

4

[Decision

Oil level at the electrodes may go
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
when oil-shortage
The 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

“threshold level”.

[Automatic stop

When

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

of

oil

shortage]

down

momentarily probably due to the engine being slanted or affected

so

that the engine is to be stopped only

is

detected

oil level where the sensor decides

of

engine]

the

sensor decides as oil-shortage, it makes the engine to stop running automatically for protection

BLOCK

DIAGRAM

for

5

OF THE

seconds uninterrupted.

as

oil-shortage, when oil level goes down gradually,

CIRCUIT

is

called

e

Power circuit

Inner pole

oil

Outer

0

Power circuit----*-*---- This rectifies a part of power to the igniter and regulates it to supply the

-

I

pole

Detection

circuit

stabilized power

-

Deley circuit

Fig.

to

necessary circuits.

-

5-1

1

13-

Stopping

circuit

Igniter

LED

indicator

Engine ground

-1

@

Detection circuit*****-* This detects quantity of oil, sufficient or not, according to difference of

electric resistance across inner and outer electrodes.

Delay circuit

@

stopping circuit

5-5-5

(1)

(2)

”

CAUTIONS TO

Oil sensor unit

0

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.

Mounting and wiring of oil sensor unit

0

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
cords. This may cause malfunction or breakdown.

@

Since capacity of power source
kept as low as possible.
Be sure to use terminals with a high contact reliability

**.*.-**.-*

-

-

* * *

BE

This prevents the sensor from making an unnecessary stop of the engine by

oil

momentary lowering of the
affected by vibration in spite of sufficient oil in the crankcase.

-

This automatically stops the engine running.
Also, the LED indicator for warning can be’
stopped. We have the wires

TAKEN ON HANDLING

is

limited, current flown in the electronic circuit of the sensor is

THE

level due

to

be connected to LED available.

SENSOR

of

more than that

to

the engine being slanted or

lit

while the engine

as

ignition plugs or high voltage

of

tinned terminals.

is

being

(3)

Operation of oil sensor

0

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.

the

Operate

@

When starting the engine with an insufficient oil in the crankcase, engine starts once then

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

Try

to re-start the engine after 3 seconds or more.

engine by keeping it level.

3

seconds after the engine stop.

it

stops

-

14-

6.

Use extreme caution near fuel. A constant danger of explosion or fire exists.

Do

not fill the fuel tank while the engine

tank. Be careful not to spill fuel when refueling. If spilt, wipe

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

Always operate

Otherwise the engine may overheat and also, the poisonous carbon monoxide contained
gases will endanger human lives. Keep the generator at least
facilities during use.

Operate

If the generator

generator may tip over.

the

the

generator in a room,cave or

in

a well-ventilated area.

generator

is

on

a level surface.

tilted or moved during use, there

is

running.

Do

not smoke or use open flame near the fuel

it

and let dry before starting the engine.

tunnel.

in

the exhaust

1

m

(4

feet) away from structures or

is

a danger of fuel spillage and a chance that the

4

Do

not operate with wet hands or in the rain.

Severe electric shock may occur. If the generator
before starting.
Don’t pour water over the generator directly nor wash

If

the generator is wet with water, the insulations will be adversely affected and may cause current

leakage and electric shock.

Do

not connect

This may cause a short-circuit or damage to the generator.

Never connect the generator to the existing house wiring.
when the commercial power source is recovered.

Don’t operate the generator with its cover removed.

The operator may be injured or suffer electric shock.

CAUTION; If the circuit breaker tripped

can be an overload or a short-circuit.

In

appliance and plugs for faulty wiring.

the

generator to the commercial power lines.

off

such a case, stop operation immediately and carefully check the electrical

is

as a result

wet by rain

it

with water.

If

of

using an electrical appliance, the cause

or

snow, wipe

connected, the generator will burn out

it

and thoroughly dry it

4

-

15-

7.

-

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

it.

the power necessary for using

factor and starting wattage must be taken into consideration.

In

order to determine the right size generator, it

be connected to the unit.

Refer to the followings to calculate the power consumption of each appliance or equipment by its type.

When using a generator for operating an electrical appliance,the power

is

necessary to add the total wattage of all appliances to

Incandescent lamp, heater, etc. with a power factor of

Total power consumption must be equal to or less than the rated output

Example:

Fluorescent lamps, Motor driven tools, light electrical appliances, etc. with a smaller power
factor

A

rated 1OOOW generator can turn ten lOOW incandescent lamps

1

.O

of

the generator.

on.

Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the

of

load. Generally the starting wattage

motor driven tools and light electrical appliances are 1.2 to

times lager than their running wattage.

Example:

NOTE

NOTE

Mercury lamps with a smaller power factor

A

rated 250W electric drill requires a 400W generator to

7:

If a power factor correction capacitor
power shall be required to drive the lamp.

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

is

not applied to the fluorescent lamp, the more

start

it.

(5)

on the following page.

Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.

Example:

A

400W mercury lamp requires

A

rated 1OOOW generator can power one 400W mercury lamp

800W

to 1200W power source to be turned

on.

3

Initially loaded motor driven appliances such as water pumps,compressors,etc.

These appliances require large starting wattage which

Example:

NOTE

NOTE

A

rated

9OOW

1:

Motor-driven appliances require the aforementioned generator output only at the starting.
Once their motors are started, the appliances consume about

power consumption

for other electrical appliances.

2:

Motor-driven appliances mentioned in items

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.

compressor requires a 4500W generator to drive it.

so

that the excess power generated

-

16-

is

3

to 5 times of running wattage.

1.2

to 2 times their rated

by

the generator can be used

(3)

and

(4)

vary in their required motor

Appliances without any indication as to power consumption

Some appliances have no indication as to power consumption; but instead the work load (output)
indicated.
formula mentioned below.

Efficiencies of some electrical appliances are as follows:

Example

Example

In

such a case, power consumption

(Output of electrical appliance)

(Efficiency)

Single-phase motor
Three-phase motor
Fluorescent lamp

1

:

A

40W fluorescent lamp means that
efficiency
explained in
you will get the figure of the necessary capacity
generator with a rated output
fluorescent lamps.

2:

Generally speaking, a 400W motor means that its work load

this motor

is

used for a motor-driven tool, the capacity of the generator should be multiplied by

1.2

- - - -

- - - -

to 3 and

- - - - - -

*

- - -

*

*

- -

- -

- - - - -

is

0.7

and accordingly, power consumption will be

Item(2),

is

0.7

and power consumption will be

570W

is

to

be worked out according to the numerical

-

-

(Power consumption)

*

-

-

0.6

-

- -

-

*

0.65

- -

0.7

multiply this power consumption value of 57W by

as

explained in the

0.75

-

0.9

-

0.8

of

1OOOWcapacity can light nine to fourteen 40W

The smaller the motor, the

>lower the efficiency.

its

luminous output

of

a generator. In other words, a

is

400

+

0.7=

570W. When this motor

item(3).

is

40

400W. Efficiency of

40W.

+

Its

0.7=

1.2 - 2

57W.

is

*

As

and

Applicable wattage

Appliance

60Hz

lncandesent lamp,

Fluorescent lamp, mercury lamp , Electric

Pump, compressor up to about

I

NOTES: Wiring between generator and electrical appliances

1.

Allowable current

Use a cable with an allowable current that is larger than the rated input current of the load

(electricalappliance).
the cable will become excessively heated and deteriorate the insulation, possibly burning it
out.

Table

2.

Cable length

If

conductors decreasing the input voltage to the load (electrical appliance). As a result, the load
can be damaged.

Table

7-2

a long cable is

7-2

hot

plate

Table

of

cable

If

the input current is larger than the allowable current

shows cables and their allowable currents for your reference.

used,

shows voltage drops per

a voltage drop occurs due to the increased resistance in the

tool

100

I

I

I

I

7-1

meters

of

up

up to about

cable.

to

lOOOW

800W

250W

of

I

I

I

I

the

cable used,

w

-

17-

Sectional

mm'

Allowable

A

Gauge

wlre element current area

No./

No./mm

I

Voltage

0.75

1.25

2.0

5.5

7

12

17

23 3.5
35

Voltage drop indicates as V

R

means resistance

I

means electric current through

4!

means the length of the wire

The length

7-2 DC OUTPUT

of

wire indicates round length, it means twice the length from generator to electrical tools.

(

52

3010.18

5010.18
37

10.26

45

10.32

7010.32

=

100

/lo0

m)

Table

XRXIXl

on

the above table.

the

wire

(A).

(m).

7-2

NOTE

When the generator

:

Do not use DC and AC output simultaneously.

to

a

Due
AC output creates voltage drop in DG output resulting in incapability

characteristic

is

employed

electrolyte in the battery.

7-2-1 SPECIFIC

The specific gravity

S20 = St

GRAVITY

of

electrolyte varies by temperature

+

0.0007

where

S20 : The specific gravity at

St : Measured value
t

:

Temperature at the time

of

the condenser voltage regulation, simultaneous

to

charge batteries, attentions should be paid to the specific gravity

OF

BATTERY ELECTROLYTE

(t-20)

20°C

of

measurement (Electrolyte)

use

of

DC and

for

charging batteries.

of

;

so

it

must be converted to the one at

20°C.

-

18

-

7-2-2

SPECIFIC GRAVITY

OF

BATTERY

ELECTROLYTE AND

CHARGING

CONDITION

Specific gravity (20.c)

1.260

1.240

1.220

1.200

1.180

1.160

I

7-2-3

BATTERY

1.140

CAPACITY

1

The battery capacity is expressed

of

capable

one ampere current for one hour.

in

100

the unit

87

75

62

50

37

25

Charging

Charging

Immediate Charging is necessary.

I

of

AH (ampere-hour). One

Remarks Charglng condintion

is

not necessary.

is

necessary.

AH

stands for the capacity

w

-

19-

8.

MEASURING PROCEDURES

-

8-1

MEASURING INSTRUMENTS

8-1

-1

“Dr.

ROBIN” GENERATOR TESTER

The “Dr. Robin”generator tester is exclusively de­signed for fast, easy diagnosis and repair
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.

(4)

Tester and accessories are installed in a handy, sturdy case for easy carrying.

0

SPECIFICATIO

US

of

Robin

I

Fig.

8-7

Model

a

m-

d

CI)

.-

K

Voltage
Frequency

Resistance

Dr.

Robin

0-5OOV

25-70HZ

0.1 -1,999

AC

R

5’

8

Condenser Capacity

s

insulation Resistance

I

Circuit Protector

I

Power Source

Accessories

Dimensions

Weight

(L X W

X

H)

I

Test leads with needle probes
Test leads with jack plugs

285 mmx200 rnmxl10 mm

I

Table

8-1

10-100

3MR

Fuse

1.6kg

,uF

.

.

.

. . .

.

.

I

1 set

1 set

The “Dr. Robid’generator tester can be ordered from Robin generator distributors by the following part
number.

I

Dr.

Robin

-

If you do not have a “Dr. Robid’generator tester,use the instruments described

Part

Number

:

388-47565-08

1

for checking generator parts.

-

20

-

in

the following section

8-1-2

INSTRUMENTS

VOLTMETER

AC

voltmeter is necessary. The approximate
voltage ranges
various types

0

to

15OV:

of

the voltmeters to be used

of

generators are as follows:

Type with

an

output voltage

or 120V

0

to

300V:

Type with an output voltage
230 or 240V

0

to 150V, 0 to 330V: Dual voltage type

(2)

AMMETERS

is

AC ammeter

necessary.

An

AC

ammeter with

a range that can be changed according to the

of

current rating
desirable. (About

a given generator

10A,

20A,

1OOA)

is

of

of

AC

for

110

220,

most

I

For

AC

fig.

8-2

(3)

FREQUENCY METER
Frequency range : About 45 to

NOTE:

Be

careful

input

voltage range.

65Hz

of

the frequency meter’s

I

For

Fig.

Fig.

AC

8-3

8-4

-1

-

21

-

-

(4)

CIRCUIT TESTER

is

This circuit tester

used for measuring re-

sistance, etc.

(5)

MEGGER TESTER
Used for measuring generator insulation re­sistance.
Select one with testing voltage range of

500V.

I

Fig.

8-5

(6)

ENGINE TACHOMETER

of

There are various types

tachometers,
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.

such

as

-

22

-

Fig.

Fig.

8-6

8-7

8-2

AC

OUTPUT MEASURING

4

To

AC

receptacle

Fig.

8-8

Measurement is executed with the circuit as shown in Fig.

1.0

lamp with a power factor of
the rated load and rated speed

is

the AC output

8-3

DC

OUTPUT MEASURING

normal.

I

Rated voltage

Voltage range

I

To

DC

Terminal

-l

is suitable

is

confirmed to be within the voltage range specified in the table below,

Table

I

8-2

as

a load for the generator. When the AC output measured at

120v

1

17-1

30V

I

P

8-8.

An electric heater or an incandescent

I

Measurement of DC output
by adjusting the load to the generator.
output is normal.

Note : If a battery is connected

approximately
the battery.

is

executed with the switch turned

as

I

to

2V.

Therefore, carefully observe the electrolyte level and do not overcharge

Fig.

8-9

ON

while the current is regulated at 8.3A

If

the voltage is within the range from

a

load to the generator, the

-

23

-

DC

6V

to

14V,

the voltage

output voltage will increase by

8-4

MEASURING INSULATION

RESISTANCE

Use a “Dr. Robin”generator tester in megger tester
mode or use a megger tester to check
resistance. Connect a megger tester

to

the

insulation

one

of

recep­tacle output terminals and the ground terminal, then
measure the insulation resistance. An insulation re­sistance
original insulation resistance at the time
from the factory

If

it

ator and measure the insulation resistance

of

1

megohm or more

is

10

megohm or more.)

is

less than 1 megohm, disassemble the gener-

is

normal. (The

of

shipment

of

the

stator, rotor and control panel individually.

fig.

8-70

0

STATOR

(1)

Measure the insulation resistance between
BROWN lead and the core.

(2)

Measure the insulation resistance between

LOW lead and the core.

(3)

-

Measure
BLACK lead and the core.

0

ROTOR

the

insulation resistance between

Measure the insulation across one

of

terminals

the rotor and the core.

of

the soldered

YEL-

I

I

Fig.

8-1

1

J

Fig.

8-12

-

24

-

0

CONTROL

PANEL

Measure the insulation resistances between the live
parts and the grounded parts.

Any part where the insulation resistance
leakage and electric shock.
Replace the faulty part.

is

less than

I

1M8

Fig.

has faulty insulation,

8-13

and

may cause electric

I

-

25

-1

-

9.

CHECKING FUNCTIONAL MEMBERS

9-1

CONTROL PANEL

Fig.

9-1

9-1

-1

AC RECEPTACLES

Using a “Dr. Robin”or a circuit tester, check continuity between the two terminals at the rear

on

receptacles while the receptacle is mounted

the control panel. When continuity is found between the

of

the AC

output terminals of the receptacle with a wire connected across these terminals, the AC receptacle
normal. When the wire

is

removed and

no

continuity is found between these terminals, the receptacles

are also normal.

is

-

Fig.

9-2A

-

26

-

Fig.

9-26

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

if

is not confirmed

the wire

is

removed, the DC terminals are normal. (See Fig.

9-1.)

w

9-1-3

Check continuity between the two terminals
while it is mounted

If

OFF,

9-14

Check the voltmeter

CIRCUIT

continuity

BREAKER

is

confirmed when the breaker

the circuit breaker

VOLTMETER

on

the control panel.

is

is

normal.

if

it operates correctly by apply-

at

the rear side of the circuit breaker using a circuit tester

ON,

ing specified voltage. Voltmeters caunot be checked
with a circuit tester because its internal resistance
too large.

and no continuity is confirmed when the breaker is

AC

is

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 follow­ing table.

-

27

-

I

I

Fig.

9-4

-

Hz

Specification

Voltage

AC

Windlng

Brown

I

White

DC

Windlng

Green

I

Green

(Rxl

R

+lo%)

Condenser Winging

Black / Black

60

1

20v

Table

1.4

9-1

Q

0.62

Q

4.8

NOTE: If the circuit tester is not sufficiently accurate$ 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

ZO"C(68"F).

9-3

ROTOR

1)

Using the "Dr. Robin"or a circuit tester, measure the resistance

Fig.

(See

-

9-5.)

(RxlR+10%)

Resistance

ef

the field coil.

R

_-

NOTE

I:

Because a diode is soldered to
ends at the terminals, resistance may
measured only when tester probes touch
the terminals in one combination of polar­ity. Therefore, if no resistance reading
appears, try checking in reverse polarity.

NOTE

2:

If

the circuit tester is not sufficiently accu-

rate,

it

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

peratures different from

2)

Measure the resistance

may

not show the values given

at

ambient tem-

20°C

of

the resister.

the

(68°F).

coil

be

Fig.

9-5

-

28

-

9-4

CONDENSER

w

Use a "Dr. Robin" in capacitance meter mode to check the capacity

of

condensers. (See Fig.

9-6.)

NOTE:

If
If

condenser.

9-5

DIODE

Be sure to discharge condensers by short­ing condenser leads each other before
checking their capacitance,or the accurate
reading cannot be obtained.

10

,uF

such

an

instrument

is

unavailable, the condenser can be checked by replacing with a new one.

the generator performs good with new condenser, the cause

RECTIFIER

of

Fig.

trouble

9-6

is

defect in original

Geen>

Green

Fig.

9-7

h

Diode rectifier

'4

Circuit tester\

Fig.

9-8

The internal circuit
Check continuity between each terminal using a circuit tester

of

the diode rectifier is as shown

in

Fig.

9-7.

as

shown in Fig.

Green Green

9-8.

-

29

-

Checking table for analogue circuit tester.

~~~ ~ ~ ~~~ ~

Analogue clrcult tester

Green

@

Apply red

of

the clrcult tester

needle

Green

Red

Checking table for digital circuit tester.

~~ ~ ~~ ~ ~~ ~

Apply black Oneedle

Green

of

Green

the clrcult tester

Red

No

continuity

_-

NOTE

NOTE

NOTE

Digital

Apply black

of

the clrcult tester

1:

Because
digital circuit tester, polarity

2:

“Continuity” means forward direction characteristics

circuit condition (in which

clrcult tester

0

needle

of

the difference

Green
Green

Red

Table

of

measuring method between the analogue circuit tester and the

of

tester needles should be reversed,

a

pointer

of

resistance to some extent. When result

Apply red @needle

Green Green Red

9-2-2

of

the diode, and different from short

the tester goes out

of

the checking indicates failure even in one

of

the clrcult tester

of

its

normal scale), shows

No

continuity

section,replace with a new one.

3:

“Simpson“ brand analogue testers have the characteristic as same as the digital circuit tester.

L

-

30

-

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.

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 the oil sensor removed and

~~ ~

Fig.

9-9

confirm if;

5

a. Engine stops after

b.

Engine does not stop after more than

NOTE : The sensor will not operate properly when wire is broken or poorly connected.

Check the wires for correct connection.

If

it fails to stop within 5 seconds after the wirings have checked, the sensor

Replace the sensor with new one.

seconds which

is

normal, or

10

seconds which

is

unusual.

is

wrong.

10.

10-1

DISASSEMBLY

PREPARATION

1)

Be

sure to memorize the location of individual parts when disassembling the generator so that the

AND

and

PRECAUTIONS

ASSEMBLY

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.

-

31

-

10-2

DISASSEMBLY

c

itep

-

1.

Side

cover

2.

PROCEDURES

(1)

Remove the side cover
four

M5

X

8

screws. (See Fig.

(1)

Remove the rear cover
three

M5

X

8

screws and

screws. (See Fig.

10-2.)

by

unscrewing

10-1

by

unscrewing Rear cover

two

M8

(+)

Plus screw

driver

(+)

Plus driver

Tool

~~~ ~~

.)

X

10

3.

Control panel

Fig.

(1)

10-

1

Pull the
remove
four

M5

I

knob

off

the

control panel

X

8

screws.

the

control lever and

by

unscrewing

(See

Fig.

Fig.

10-3.)

10-3

Fig.

10-2

I

(+)

Plus driver

-

-

32

-

'art

to remove

'I

Description

I

Remarks

Tool

Couplers

and plugs

(D'

Iscon-

nection)

(1)

Disengage the couplers

from

the

wires

of

control panel. pushing the

6P

couplers (Yellow, Red,

Yellow,

Brown,

(See Fig.

(2)

Disengage the connectors

White)

10-4.)

lamp (option)
(See Fig.

10-5.)

of

stator wires Pull the couplers while

\

Green/

of

oil warning

hook.

locking

Fig.

Press

the hook

pull

out

to disconnect.

Press the hook
pull out to disconnect.

CONTROL PANEL SIDE

of

the coupler and

of

the coupler and

10-4

STATOR SIDE

-

33

-

Fig.

10-5

5.

'art

to

remove

Front cover

(1)

Remove the element cover
unscrewing
(See Fig.

(2)

Remove the
three

M5

M6

X

12

10-6.)

front

cover by unscrewing

X

8

screws. (See Fig.

1

by

screw.

10-6.)

(-)

(+)

Tool

~

Driver

Driver

6.

Fuel pipe

and plug
(Discon­nection)

(1)

Discharge fuel from the

1.

Shut the fuel striner.

2.

Remove

3.

Put a vessel

the

strainer cup.

to

Element

tank.

receive fuel under the

Fig.

cover

10-6

strainer and open the fuel cock
discharge fuel.

4.

Attach the strainer

(See

Fig.

cup

10-7.)

to the strainer

body

(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.)

Use utmost care about

fire hazard.

Wipe off spilt fuel

to

throughly.

Do

not lose the filler

screen.

Pliers

Fig.

70-7

II

-

34

-

Fig.

10-8

Step

-

'art to remove

7.

Fuel tank
handle

Description

(1) Remove the handle cover

the

two

M3

X

10

screws.

(2)

Pull

off

the breather

(3)

Remove the handle
the

two

M8

M3

x

nuts.

pipe.

body

Handle cover

by

unscrewing

by

taking

I

The

removed without
disassembling the
handle.

off

Remarks

fuel tank

can

be

I

(+)

12mm

Tool

Driver

box

wrench

M8

Nut

(2

I

pcsj

Fig.

-1

10-9

-

35

-

Part

to

remove

Description

Remarks

I

Tool

Fuel tank

Bracket
(Cover)

(1)

Remove the

two

M6X

12

flange bolts
from the blower housing.
(See Fig.

10-10.)

(2) Remove the fuel tank by taking off the

two

M8

nuts from

tank.

(See

Fig.

Fig.

10-1

0

(1)

Remove the bracket cover from the
generator by loosening the
bolts. (See Fig.

10-1

10-12.)

1.)

the

bottom

two

M8

of

X

the

30

Fig.

10-1

lOmm box wrench

12mm

box wrench

7

12mm box wrench

End cover

(1)

Remove the end cover from the generator
by unscrewing the four
(See Fig.

10-12.)

M5

X

Fig.

10

screws.

10-12

I
I

(+)

Driver

-

36

-

I

step

I

Part

to

remove

I

Description

I

Remarks

I

Tool

11.

Rear bracket

(1) Loosen and take out the three

bolt.

(See

Fig. 10-13.)

(2)

Remove condenser from

(3)

Remove the connector
rectifier and then remove the
terminal from the rear bracket.
(See Fig. 10-14.)

rear

of

M6

cover

bracket.

the diode

earth

cable

lOmm box wrench

Box spanner
Box spanner and

screw driver

(+)

Fig.

10-13

(4) Remove

evenly with a plastic mallet.
(See Fig. 10-15.)

(5)

Remove mount rubbers from rear cover.

(See Fig. 10-16.)

the

rear

bracket, tapping it

Fig.

10-14

Plastic mallet

Wrench

I

Fig.

10-15

-

37

-

Fig.

10-16

Itep

-

12.

Part

Stator

to remove

(1)

Remove the stator

(See

Fig.

10-17.)

Descrlptlon

cover.

I

Remarks

Tool

(2)

Pull off the stator from the front cover Never
tapping the core. with

(See

Fig.

10-18.)

Fig.

10-17

a

plastic mallet. winding and the lead.

tap

n

on

the

Fig.

Plastic mallet

10-18

-

38

-

\

Fig.

10-19

Fig.

cover

10-20

Step

-

13.

'art

to

Rotor

remove

Descrlptlon

(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.

Fig.

10-21

(2) Put the engine on the working table

recoil starter side down.

Remarks

Tool

Box wrench
Plastic hammer

(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

3.

Apply a few turns

:

M8

X

P

1.25

of

seal tape around

the tip of the bolt.

(See Fig.

10-23.)

:

Fig.

10-22

I

Fig.

10-23

-

39

-

Dart

to

remove

Descrlptlon

I

Remarks

Tool

13.

Rotor

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

takes

shaft
engine shaft.

(4) Wipe off oil throughly from rotor shaft

and engine

apart the

PTO

shaft.

rotor

from the

12mm box spanner

or

Socket wrench

14.

Front bracket

(1)

Remove the front bracket, which

mounted on the main bearing cover

the engine,

bolts.

(See

by

taking out four

Fig.

10-25.)

Fig.

Fig.

10-24

M8

10-25

is

12mm box spanner

of

X

18

-

-

40

-

Part to remove

Mount
rubbers

Description

(1)

Remove mount bracket

Remove mount rubbers
bracket.

8

q.5

Nut

~

:

Spa.

or

2pcs.

from

engine.

from

mount

Remarks

Tool

I

12

mm

wrench

Mount bracket

Fig.

10-26

\

Mount rubber

-

41

-

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

TIGHTENING TORQUE

10.1

ft

9

Ibs.

1175

-

1370N-crn

140

kg

=

cm

10-3-2

1)

ROTOR

Wipe off oil from the tapered portion of engine shaft and matching tapered hole of rotor shaft.
(See Figs. 10-28 and

10-29.)

-.***..-..-*

4pcs.

Fig.

10-27

Fig.

Fig.

10-28

70-29

Install rotor on the engine shaft and tighten the
through-bolt.

of

Apply a wrench on the head

hit

wrench handle clockwise with a hammer

tighten.

If

I

I

(See

Fig.

10-30.)

an impact wrench

TIGHTENING TORQUE

8.7

-

10.1

ft

1175

-

1370N-cm

120

-

140

kg

is

available, use it.

Ibs.

cm

through bolt and

I

-

to

42

-

I

Fig.

10-30

10-3-3

STATOR

Holding the rear bracket and stator, fit them to
the front bracket. Match the mounting hole
the rear bracket and that of the rotor bearing,

and softly strike the outside periphery

bracket with a plastic hammer.

4.0

55

10-31.)

-

5.4

-

735 N cm

-

M6

boll

ft

Ibs.

75kg-cm

i

to fix the rear brack-

(See Fig.

Attach the stator cover around the stator.

Tighten the three

et to the front bracket .

TIGHTENING TORQUE

535

of

the rear

of

Fig.

10-31

(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

10-3-4

Put condenser to rear cover.

CONDENSER

5

0

X

10

mm tapping Screw ----..----*.----..

TIGHTENING TORQUE

2.4

-

325

-

4.0

ft

-

Ibs.

535 N cm

55

kg

cm

2

pcs.

clamp

Condenser

at

the

bottom

of

the groove.

-43-

Fjg.

10-32

10-3-5

"

Set the end cover

M5

10-3-6 BRACKET (COVER)

END COVER

X

10

screws.

on

the rear bracket with four

Mount the bracket (cover)

M8

secure them with

10-3-7

(1)

FUEL TANK AND FUEL

Connect the rubber pipe to the engine carburetor and fasten

X30

Attach the banjo to the opposite end

on

the rear bracket and

bolts.

PIPE

(CONNECTION)

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

Insert the attaching bolts

M8

nuts.

on

the other end of tank into the mount bracket hole and

Fig.

it

with a hose clamp.

10-33

M6

secure

X12

bolts.

it with two

(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

fuel tank.

10-3-8 FUEL TANK HANDLE

(1)

Match

(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

(3)

Fix both ends of the handle cover with

hole

the

handle hole with the bolt

is

directed upward.

so

that it may easily be connected to the strainer and the

on

the top of the fuel tank and secure it with M8 nuts.

M3

X

10

screws.

-

44

-

so

that the

M3

Handle cover

x

10

Screw

(2

pcs.)

-1

To

Carburetor

To

Carburetor

Is

Hose clamp

M8

/

Nut

(2

pcs.)

10-3-9

(I)

(2)

FRONT COVER

Secure the front cover, on which fuel strainer
have been mounted, with three
(See Fig.

10-35.)

Secure the element cover with

(See Fig.

10-35.)

Hose clamp

AND

ELEMENT COVER

M5

M6

X

X

12

8

screws.

screws.

Rubber hose

Rubber hose

Fig.

10-34

"..,-

Fuel strainer

-

45

-

Element cover

F@.

10-35

10-3-10 CONNECTION

-

.

(1)

Connect the wires drawn out from the stator to

the wires from the control

OF

WIRES

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.)

[WIRE CONNECTIONS BETWEEN CONTROL PANEL AND STATOR]

\

fig.

10-36

6P coupler Wire color

Green / Yellow

CONTROL

10-3-1 1 CONTROL PANEL

(1)

Put the control panel over the control lever and

secure it with four

(2)

Attach the

knob

to

:

Yellow, Red, GreenrYellow, Brown, White

M5

PANEL

screws.

SIDE

the control lever.

Green / Yellow

STATOR

SIDE

Note

:After

c

the couplers and connectors have been

connected and secured to the control panel,

secure

control panel.

the wires with a wire band to the

-

46

-

Fig.

10-37

10-3-1

2

REAR

COVER

Secure the rear cover with three

M8

X

two

10-3-13

Secure the side cover

10 screws.

SIDE

COVER

with

four

M5X8

M5X8

screws.

screws and

Fig.

70-38

-

47

-

-

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

11

w

is

defective, replace with new one.

-1

-2

CHECKING

CONDENSER

If an instrument (Q.C.-meter or C-meter) for measuring capacity of condenser

of

capacity

NORMAL CAPACITY

condenser.

OF

CONDENSER

Fig.

11-1

is

available, check the

1

OpF

w

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

condenser.

1 1-1

-3

CHECKING ROTOR

1) Remove rear cover and stator.

of

trouble

is

defect in original

-

48

-

2)

Measure the resistance of field coil with a circuit
tester. (See Fig.

NORMAL RESISTANCE

lRemedy1

If

the resistance

with new one.

3)

Check the magnetic force
the rotor.

[Remedy1

1.

If the magnetic force

2.

If the diode
When all removed these parts are good, assemble them and then solder.

11-3.)

(R

x

195

or

the resistor

10%)

is

not normal, replace rotor

of

magnets molded in

is

weak, replace the rotor with a new one.

is

faulty, replace rotor assembly with new one.

Fig.

11-3

11-2 AC VOLTAGE

11-2-1 CHECKING ENGINE

If the engine r.p.m.

mow

to adjust

Loosen the nut on the adjusting screw.

H

Turn the adjusting screw clockwise to in de­crease engine speed or counter-clockwise to
increase engine speed.
Normal engine speed at no load

3750 - 3800

11 -2-2 CHECKING

Check stator referring to Step

11-2-3

Check condenser referring to Step

CHECKING

IS

TOO HIGH

is

too high or too low, adjust it to the rated r.p.m.

engine

r.p.m.

r.p.m.

STATOR

r.p.m.

.]

OR

.

is

TOO

:

11-1-1.

CONDENSER

11-1-2.

LOW

d

.

Fig.

7

1-5

11-2-4

Check rotor referring

CHECKING

ROTOR

to

Step

11-1-3.

-

49

-

circuit breaker

AC

Resistor

I

I

0

0

- 51 -

HAVE JOINED FORCES TO BRING YOU THE BEST

ENGINE/GENERATOR WARRANTY IN THE INDUSTRY!

3-YEAR WARRANTY

ON

BALDOR GENERATORS

AND

ROBIN SUBARU ENGINES

SEE ATTACHED WARRANTY STATEMENTS

FOR DETAILS:

BALDOR GENERATORS

3815 OREGON STREET OSHKOSH WI 54902

PHONE: [phone] FAX: [phone]

WWW.BALDOR.COM

Robin Subaru Limited Engine Warranty

- 52 -

For Baldor Generators

(Effective for original Robin Subaru engines powering Baldor portable generators purchased after August 16, 2000)
Robin America, Inc., a division of Fuji Heavy Industries, Ltd. (herein "Robin"), warrants that each new engine sold by it will be
free, under normal use and service, from defects in material and workmanship for a period listed below from the date of sale to the
original retail purchaser. Robin's obligation under this Limited Warranty shall be limited to the repair and replacement, at Robin's
option of any part or parts which upon examination is/are found, in Robin's judgment, to have been defective in material or
workmanship. It shall be a condition of Robin's obligation under this limited warranty that Robin, directly or through one of its
Distributors or Service Centers authorized to service the particular engine involved, receive prompt notice of any warranty claim
and that the engine or the part or parts claimed to be defective be promptly delivered, transportation prepaid, to such Distributor or
Service Center for inspection and repair. All repairs qualifying under this Limited Warranty must be performed by Robin or one of
its authorized Distributors or Service Centers.

WARRANTY PERIODS: Robin Four-Cycle, Air Cooled, Gasoline Engines Limited 3 Years Warranty
Robin Four-Cycle, Air Cooled, Diesel Engines Limited 1 Year Warranty

The repair or replacement of any part or parts under this Limited Warranty shall not extend the term of the engine warranty beyond
the original term as set forth above.
LIMITATIONS AND EXCLUSIONS: This limited Warranty shall not apply to:

1. Bent or broken crankshaft or resultant damage caused by vibration related to bent or broken crankshaft. Also, damage

caused by loose engine mounting bolts or improper or imbalanced accessories or blades mounted to the crankshaft.

2. Repairs required because of prolonged storage including damage caused by old or contaminated fuel in the fuel tank, fuel

lines or carburetor, sticky valves or corrosion and rust of engine parts.

3. Repair required due to overheating (Most often caused by overloaded or clogged or damaged or missing flywheel, fan,

inlet air passages, cooling fins or air shrouds).

4. Dirt or grit related wear caused by improper air cleaner maintenance (most often resulting in worn piston rings, cylinders,

valve guides, carburetor or other internal components).

5. Broken or scored parts caused by low oil level, dirty or improper grade of oil.

6. Engine tune-ups and normal maintenance service including, but not limited to, valve adjustment, normal replacement of

service items, fuel and lubricating oil, etc.

7. Any engine which has been subject to negligence, misuse, accident, mis-application or over -speeding.

8. Any engine that has been installed, repaired or altered by anyone in a manor which in Robin's sole judgment adversely

affects its performance or reliability.

9. Any engine which has been fitted with or repaired with parts or components not manufactured or approved by Robin

which in Robin's sole judgment adversely affects its performance or reliability.

10. Instances when normal use has exhausted the life of a component or an engine.
The customer is responsible for all transportation charges in connection with any warranty work.
Robin reserves the right to modify, alter or improve any engines or parts without incurring any obligation to modify or replace, any
engine or parts previously sold without such modification, alteration or improvement.
No person is authorized to give any other warranty or to assume any additional obligation on Robin's behalf unless made in writing
and signed by an officer of Robin.
THIS WARRANTY, AND ROBIN'S OBLIGATION HERE UNDER, ARE IN LIEU OF ANY OTHER WARRANTIES OR
OBLIGATIONS OF ANY KIND, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON
THE FACE HERE-OF. ROBIN SHALLIN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES.

LIMITED WARRANTY

- 53 -

Unless otherwise provided, Baldor generators are warranted against defects in Baldor workmanship and
materials for a period of time as set forth in the Warranty Period chart on the following page. All warranty
claims must be submitted to a Baldor Generator repair facility prior to the expiration of the warranty
period. Baldor Generators shall have no responsibility or liability for any defect, latent or otherwise,
discovered after the expiration of the warranty period provided herein. Extended warranties are available
for certain Baldor products. These warranties are described in Baldor’s catalog and other sales literature.
Extended warranties are subject to the terms and conditions of this Limited Warranty as modified by the
additional terms of the extended warranty. If a Baldor product is defective due to Baldor workmanship or
materials and the defect occurs during the warranty period, then Baldor will either repair the product or
replace it with a new one, whichever Baldor believes to be appropriate under the circumstances. Warranty
service is available for all Baldor Generator products from Baldor Generators’ Customer Service
Department in Oshkosh, Wisconsin, and from Baldor Generator repair facilities. A list of Baldor’s
generator repair facilities may be obtained by contacting Baldor Generators at: Customer Service, Baldor
Generators, 3815 Oregon Street, Oshkosh, Wisconsin 54902, 920-236-4200 (telephone), 920-236-4219
(facsimile). All Baldor products requiring warranty service shall be transported or shipped freight pre-paid,
at the risk of the party requiring warranty service, to Baldor Generators’ Customer Service Department in
Oshkosh, Wisconsin, or to a Baldor Generator repair facility. Written notification of the alleged defect in
addition to a description of the manner in which the Baldor generator is used, and the name, address and
telephone number of the party requiring warranty service must be included. Baldor is not responsible for
removal and shipment of the Baldor product to the service center or for the reinstallation of the Baldor
product upon its return to the party requiring warranty service. Customers who are unable to take or ship
the Baldor product to a Baldor Generator repair facility, or who desire a repair to be made by other than a
Baldor Generator repair facility, should contact Baldor Generators’ Customer Service Department at
920-236-4200. Baldor, in advance of such service, must approve a repair by anyone other than a Baldor
Generator repair facility in writing. Problems with Baldor products can be due to improper maintenance,
faulty installation, non-Baldor additions or modifications, or other problems not due to defects in Baldor
workmanship or materials. If a Baldor Generator repair facility determines that the problem with a Baldor
product is not due to defects in Baldor workmanship or materials, then the party requiring warranty service
will be responsible for the cost of any necessary repairs. Parties requiring warranty service not satisfied
with a determination that a problem is outside of warranty coverage should contact Baldor Generators’
Customer Service Department at 920-236-4200 for further consideration. EXCEPT FOR THE
EXPRESSED WARRANTY SET FORTH ABOVE, BALDOR GENERATORS DISCLAIMS ALL
OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES
OF FITNESS FOR A PARTICULAR PURPOSE AND MECHANTABILITY. NO OTHER
WARRANTY, EXPRESSED OR IMPLIED, WHETHER OR NOT SIMILAR IN NATURE TO ANY
OTHER WARRANTY PROVIDED HEREIN, SHALL EXIST WITH RESPECT TO THE GOODS SOLD
UNDER THE PROVISIONS OF THESE TERMS AND CONDITIONS. ALL OTHER SUCH
WARRANTIES ARE HEREBY EXPRESSLY WAIVED BY THE BUYER. UNDER NO
CIRCUMSTANCES SHALL BALDOR GENERATORS BE LIABLE OR RESPONSIBLE IN ANY
MANNER WHATSOEVER FOR ANY INCIDENTAL, CONSEQUENTIAL OR PUNATIVE
DAMAGES, OR ANTICIPATED PROFITS RESULTING FROM THE DEFECT, REMOVAL,
REINSTALLATION, SHIPMENT OR OTHERWISE. This is the sole warranty of Baldor Generators and
no other affirmations or promises made by Baldor Generators shall be deemed to create an expressed or
implied warranty. Baldor Generators has not authorized anyone to make any representations or warranties
other than the warranty contained herein.

Revised\Effective 6/26/03
Form # S-PSG-003-3 Warranty Policy S-PSG-003-3.doc

- 54 -

WARRANTY PERIOD

Generator Series Labor* Parts

Portable Products

(Premier, PowerChief,

1 Year 3 Years

DG Series, K Series)

Towable Products

(TS)

3600 RPM Standby Systems

(Some AE Models)

1800 RPM Standby Systems

(Some AE Models, DLC,

GLC)

Industrial Standby Systems

Industrial Prime Power

Systems

International

1 Year or 3,000 Hours

Whichever comes first

1 Year or 1,000 Hours

Whichever comes first

1 Year or 3,000 Hours

Whichever comes first

1 Year or 1,000 Hours

Whichever comes first

1 Year or 1,000 Hours

Whichever comes first

1 Year or 1,000 Hours

Whichever comes first

3 Years or 3,000 Hours

Whichever comes first

3 Years or 1,000 Hours

Whichever comes first

3 Years or 3,000 Hours

Whichever comes first

2 Years or 1,000 Hours

Whichever comes first

1 Year or 1,000 Hours

Whichever comes first

1 Year or 1,000 Hours

Whichever comes first

*Labor coverage for warrantable repairs is provided for the applicable period not to exceed published rates
as contained in the Baldor Generators Warranty Policy. Mileage is allowed only for permanent
installations not to exceed published rates as contained in the Baldor Generators Warranty Policy.

Warranty registration within 30 days of purchase is required for portable and towable products to qualify
for any warranty consideration. Proof of purchase date, serial number and model number will be required
for all warranty work.

For all other products, a Start-up Inspection Form / Warranty Registration must be completed in its entirety
and submitted to Baldor Generators within 30 days of start-up to qualify for any warranty consideration.

Owner’s Responsibilities:

The owner is obligated to operate and maintain the generator in accordance with the recommendations
published by Baldor Generators in the Operator’s Manual for the generator. The owner is responsible for
the costs associated with maintenance and any adjustments that may be required.

The owner is responsible for payment of any of the following expenses that might be incurred as a result of
a failure under the terms of this warranty:

1. Rental equipment used to replace the equipment being repaired.

2. Telephone or other communication expenses.

3. Living and travel expenses of persons performing service, except as specifically included within the terms of
specific warranty.

4. The premium costs for overtime labor requested by the owner.

5. All parts transportation costs.

Revised\Effective 6/26/03
Form # S-PSG-003-3 Warranty Policy S-PSG-003-3.doc

- 55 -

Limitations:

Baldor Generators is not responsible for the repair of generators required because of normal wear, accident,
misuse, abuse, improper installation, lack of maintenance, unauthorized modifications or improper storage.

Normal Wear: This warranty will not cover repair where normal use has exhausted the life of a part or
generator. It should be remembered that the service life of any generator is dependent on the care it
receives and the conditions under which it has to operate. Some applications are very often used in dusty or
dirty conditions, which can cause what appears to be excessive wear. Such wear, when caused by dirt, dust,
grit or other abrasive material, which has entered the generator because of improper maintenance, is not
covered by Warranty.

For all product lines, the engine manufacturer warrants engine systems. Contact Baldor Generators for
current engine warranties.

3815 Oregon Street • Oshkosh, Wisconsin 54902

Phone: [phone] • 800-872-7697 • Fax: [phone]

www.baldor.com

Revised\Effective 6/26/03
Form # S-PSG-003-3 Warranty Policy S-PSG-003-3.doc

CALIFORNIA PROPOSITION 65 WARNING

Engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects,
and other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some constituents are known to
the state of California to cause cancer, birth defects, and
other reproductive harm.

Revised: 4/13/01 C:\ISO9001\FORMS\S-PSG-001-1.msw
Effective: 2/26/98
Form#:S-PSG-001-1

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