Subaru Robin Power Products RGV7500 User Manual

SERVICE

MANUAL

Model

RGV7500

PlJB-GS1436

Rev.

05/00

Section

Title

Page

l.'SPECIFICATIONS

.......................................................................................................

1

2

.

PERFOMANCE CURVES

...........................................................................................

2

3

.

FEATURES

..................................................................................................................

3

3-1 A.V.R. ALTERNATOR

.............................................................................................

3

3-2 OIL SENSOR

........................................................................................................

3

3-3

QUIET

OPERATION

.............................................................................................

3

3-4

NO

RADIO

NOISE

................................................................................................

3

3-5 LARGE FUELTANK

..............................................................................................

3

3-6 RUGGED TUBULAR FRAME

...............................................................................

3

3-7

COMPACT AND LIGHT WEIGHT

.........................................................................

3

3-8 MINIMAL MAINTENANCE

....................................................................................

3

3-9 LONG-LIFE DURABILITY

.....................................................................................

4

4

.

GENERAL DESCRIPTION

..........................................................................................

5

4-1 EXTERNAL VIEW

.................................................................................................

5

4-2 CONTROL PANEL

................................................................................................

6

4-3 LOCATION

of

SERIAL NUMBER

and

SPECIFICATION NUMBER

......................

6

5 .

CONSTRUCTION AND FUNCTION

...........................................................................

7

5-1 CONSTRUCTION

..................................................................................................

7

5-2 FUNCTION

............................................................................................................

7

5-3

GENERATOR OPERATION

................................................................................

13

5-4 OIL SENSOR

......................................................................................................

16

6 .

SAFETY PRECAUTIONS

.........................................................................................

19

7

.

RANGE

OF

APPLICATIONS

....................................................................................

20

8

.

MEASURING PROCEDURES

..................................................................................

23

8-1 MEASURING INSTRUMENTS

...........................................................................

23

8-2 AC OUTPUT MEASURING

.................................................................................

26

8-3

DC OUTPUT MEASURING

.................................................................................

26

8-4 MEASURING INSULATION RESISTANCE

........................................................

27

9

.

CHECKMG

FUNCTIONAL MEMBERS

....................................................................

29

9-1 VOLfMtrER

.......................................................................................................

29

9-2

AC RECEPTACLES

............................................................................................

29

9-3 No-FUSE BREAKER

...........................................................................................

29

Sectior! Title . Page

9-4

STATOR

..............................................................................................................

30

9-5

ROTOR ASSEMBLY

...........................................................................................

30

9-6 BRUSH

................................................................................................................

31

9-7 A.V.R. (AUTOMATIC VOLTAGE REGULATOR)

..................................................

31

9-8

IDLE CONTROL UNIT

........................................................................................

33

9-9

DIODE RECTIFIER

.............................................................................................

34

9-1 0 OIL SENSOR

....................................................................................................

35

9-11 EXCITING COIL

................................................................................................

35

1O.DISASSEMBLY AND ASSEMBLY

...........................................................................

36

10-1 PREPARATION

and

PRECAUTIONS

................................................................

36

10-2 DISASSEMBLY PROCEDURES

.......................................................................

37

10-3

ASSEMBLY PROCEDURES

............................................................................

..

45

10-4 CHECKING, DISASSEMBLY

and

REASSEMBLY

of

the

FRONT PANEL

........

50

11

.

TROUBLESHOOTING

............................................................................................

52

11-1

NO AC OUTPUT

................................................................................................

52

11-2 AC VOLTAGE

IS

TOO HIGH OR

TOO

LOW

.....................................................

53

\

11 -3 AC VOLTAGE

IS

NORMAL AT NO.LOAD.

I

BUT THE LOAD CANNOT

BE

APPLIED

.....................................

54

11

-4

NO

DC OUTPUT

................................................................................................

55

11-5

IDLE CONTROL(OPTI0NAL EQUIPMENT)

.....................................................

56

12

.

WIRING

DIAGRAM

.................................................................................................

59

NOTE

:

As

for the servicing information

on

engine protion. please refer to the

EH41

engine

sewice

manual

.

1.

SPECIFICATIONS

Model

RGV7500

j:

U

Brush, Self Exciting, 2-Pole, Single Phase

60

Hz

~~ ~ ~ ~

Maximum Output

6000

W

Rated Output

7300

W

Rated
Current

Voltage

120V1240V

50N25A

Power

Factor

1

.o

I

DC Output

12 V-8.3

A

(1

00

W)

I

Voltage Regulator

I

AVR Type

I

I

Air-Cooled 4-Cycle, Overhead Valve Gasoline Engine

I

Model

EH41

D

I

Displacement

404 cm3 (24.63 cu. in.)

I

Rated Output

9.5

HP

I

3600

rpm

I

Fuel

Automobile Gasoline

I

Fuel Tank Capacity 7.26

U.S.

gal. (27.5 liters)

Rated

Coutinuous

Operation

I

Approx. 7.0 hours

I

Oil Capacrty

0.32

US.

gal. (1.2 liters)

Starting System

I

Recoil Starter and Optional Electric Starter

I

Dimensions

(L

x W

x

H)

*

Electric

starter motor is available asoption.

198.4 Ibs. (209.4 Ibs.)' 190 kg (95 kg)*

Dry Weight

27.2

x

20.9 x 20.9 in.

(690

x

530

x 530 mm)

-

1-

2. PERFOMANCE CURVES

RGV7500

/

60

Hz

(6.0

kVN240V)

Load

Rated

DC

OUTPUT

DC Voltage

.................

12

V

DC Ampere

................

8.3

A

DC output

...................

100

W

The voltage curve shown in the

left

indicates the characteristic

of

DC

output

when charging a battery.

The voltage

may

be decreased by

20%

when the resistance load

is

applied.

NOTE

:

It is possible to use both

DC

and

AC

outputs simultaneously up to the rated output

in

total.

f

\

-

2-

3.

FEATURES

3-1

AVR ALTERNATOR

Output votage becomes more stable due to

AVR

system.

3-2

OIL SENSOR

Oil

sensor automatically shuts

off

the engine whenever the oil level falls down below the lower limit to

protect the engine from seizure.

3-3

QUIET OPERATION

Robin RGV series generator delivers a quiet operation with

:

A

quiet 4-stroke Robin Rro

OHV

engine.

Extra large muffler and large air cleaner provide remakable quiet operation.

3-4

NO RADIO NOISE

Noise suppressor spark plug is equipped standard to prevent radio frequency interference.

3-5

LARGE FUEL TANK

The large fuel tank

(27.5

L)

allows more than 7 hours of continuous operation which is sufficient for a half

day or one day

work

without refueling.

3-6

RUGGED TUBULAR FRAME

Full cradle type rugged tubuler frame protects the generator all around.

3-7

COMPACT

AND

LIGHT WEIGHT

".

Newly developed brushless alternator enabled the RGV generators to be very compact in size and light
in weight.

3-8

MINIMAL MAINTENANCE

A

drip-proof alternator design.

No-fuse circuit breakers.

An

electronic pointless ignition system.

-

3-

3-9

LONG-LIFE DURABILITY

The

heavy-duty

4

stroke

Robin

OHV

engine

:

*

Full rubber mount in a sturdy tubular

frame.

*

A

forged

steel

crankshaft supported by

two

main ball bearings.

A

pointless electronic ignition system.

*

A

cast-iron cylinder liner.

I

\

-

4-

4.

GENERAL

DESCRIPTION

4-1

EXTERNAL

VIEW

FUEL GAUGE

CONTROL

PANEL

AIR

CLEANER

RECOIL STARTER

IL GAUGE (OIL FILLER)

OIL DRAIN PLUG OIL

SENSOR

FUEL TANK

CHOKE LEVER

SPARK PLUG

CAP

OUTLET

-

5-

4-2

CONTROL PANEL

HOUR

METER VOLTMETER PILOT

LAMP

:\.ET3i

STARTER TYPE)

\

:;FEY

AKCLE

\

\

I

I

’

NO-FUSE BREAKER IDEL CONTROL

DC

OUTPUT

SWITCH TERMINAL

I

ENGINE SWITCH

DC

CIRCUIT

BREAKER

(RECOIL STARTER TYPE)

4-3

LOCATION

of

SERIAL

NUMBER

and

SPECIFICATION NUMBER

Serial

number

and specification

number

are stamped on

the

LABEL

(MODEL

NAME)

stuck on the

side

wall

of rear cover.

I

NOTE

:

Always specify these numbers when inquiring about the generator or ordering spare

parts

in

order to get correct parts and accurate service.

LABEL,

MODEL

NAME

-

6-

5. CONSTRUCTION AND FUNCTION

5-1

CONSTRUCTION

STATOR. COMPLETE

MOUNT RUBBER BALL BEARING

TROUGH

BOLT FRONT COVER

Fig.

51

5-2

FUNCTION

5-2-1

STATOR

The stator consists

of

a laminated silicon steel
sheet core, a main coil and a condenser coil which
are wound in the core slots.

The condenser

coil

excites the rotor field coil which

generates

AC

voltage

in the main coil.

3

Fig.

5-2

-

7-

5-2-2

ROTOR

The

rotor consists of a laminated silicon

steel

sheet

core

and

a

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.

Slip

rings

are

provided

on the rotor shaft to

re-

ceive

DC

exciting current from

A.V.R..

5-2-3

BRUSW

BRUSH

HOLDER

An

exciting current

is

supplied

from

the

A.V.R

to

the rotor. The brushes are made

of

carbon and

the

brush-holder of plastic.

It

is

necessary to

keep

the

contact

pressure

be-

tween

the brushes

and

slip

rings

withing

specific

limits.

Thus,

care

must

be taken of

brush

length.

Fig.

5-3

5-2-4

A.V.R. (AUTOMATIC VOLTAGE REGULATOR)

The

automatic voltage regulator employs an elec-

tronic circuit

to

automatically regulate voltage.

Fig.

5-5

~

Fig.

5-4

-

a-

5-2-5

IDLE

CONTROL

UNIT

The idle control unit releases throttle valve when

the applied load current exceeds

0'.04A.

The

two

output wires from the main coils must go

through the

ZCT

in the same direction.

NOTE

:

It

is

normal that the engine speed goes up for

a

moment when you turn the key switch to

"STOP"

while the Auto Idle Switch

is

in

"ON"

position.

I

Fig.

5-6

5-2-6

NO-FUSE

BREAKER

The no-fuse breaker protects the generator

from

getting damage

by

overloading

or

short circuit in the

appliance. Table

5-1

shows the capacity of no-fuse breaker

by

each spec. and their object of protection.

I

SPECIFICATION

OBJECT

of

PROTECTION

NO-FUSE BREAKER

60

HZ-

120

V/

240V

'

Total

output

amperage

25 A (2-Pole, 2-Element)

Table.

5-1

5-2-7

DC

CIRCUIT

BREAKER

The

10

ampere

DC

circuit breaker mounted on

the control panel protects whole

DC

circuit from

getting damage by overload or short circuit.

Fig.

5-7

-

9-

Table.

5-2

Caution

:

The duplex

120V

receptacle

is

protected

by

a

GFCl

(Ground Fault Circuit Interrupter).

GFCl shuts

off

the output current from the

duplex

120V

receptacle when a ground fault

occurs

in

the generator or the appliance.

Please note that other receptacles are

not

pro-

tected

by

GFCI.

1

\

TWIST

1

Caution

:

To

connect the appliance to locking

receptacle, insert the

plug

into the

re-

ceptacle and

turn

it

clockwise to lock.

-

10-

5-2-9

GFCI

RECEPTACLE

After starting the engine, check the

GFCI

for'proper functioning by the following test procedure.

Push blue TEST button, The red

RESET

button

will

pop out exposing the word TRIP. Power is now

off

at

the outlets protected by the GFCI, indicating that the device is functioning properly.

If

TRIP

dose not appear when testing,

do

not

use

the generator. Call a qualified electrician.

To

restore power, push

RESET

button.

WARNING

:

If

the

RESET

button pops out during operation, stop the generator immediately and

call

a

qualified electrician for checking generator and the appliances.

5-2-10

CONNECTING

TO

DOMESTIC CIRCUITS

(HOUSE

WIRING)

Fig.

5-9

WARNING

:

This generator

is

a neutral grounded

type.

ff

a

generator

is

to

be connected to residential or commercial power lines, such as a stand-by

Faitwe

in

connection may result in death, personal injury, damage to generator, damage to appli-

ances, damage to the building's wiring or fire.

(a)

When

contnecting a Robin generator to a house wiring, generator output power must be taken from

.

power

source

during power outage,

all

connections must be made by a licensed electrician.

the

240V-4P

receptacle.

-

11

-

Utility

high line

House circuit

breaker

-

v

I

I

I

120v

appliance

I

120v

appliance

-

240V

I

I

,A-

appliance

I

"

-

I

I

"""""""""""""""""

=

4P-

Receptacle

Fjg.

5-

70

(b) Install a transfer switch.

i

I

A

transfer switch must be installed to transfer the load from the commercial power source to the

1

generator. This switch is necessary

to

prevent accidents

caused

by the recovery from power outage.

'

Use a transfer switch of the correct capacity. Install transfer switch between the meter and the fuse or

AC

breaker box.

Caution

:

If

the neutral wire of house wiring is grounded,

be

sure to ground the ground terminal

of

the

generator. Otherwise an electric shock may occur to the operator.

(c) Operating the generator.

Set the full power switch to

120W

240V

side.

Turn the house AC breaker

off

before starting the generator.

Start the generator and warm

it

up.

Turn the house AC breaker on.

Caution

:

Do

not start the generator

with

electrical appliance

(s)

connected and with their switches on.

Otherwise the appliance

(s)

may be damaged by the surge voltage at starting.

i

-

12

-

53

DESCRIPTION

Of

GENERATOR

OPERATION

5-3-1

PRIMARY

EXCITING

ACTION

When the generator is started, the permanent

magnet on the engine rotates to generator a volt­age in the exciting coil. This voltage is regulated
by

a

diode in the A.V.R. to feed a current to the

generator field coil. (FC). (See Fig.

5-11)

The rotor is turned an electromagnet by that cur­rent and rotates

so

that voltage are generated in
the stator coils (main coil and sub coil). The volt­age generated in the sub coils is operated

by

the
A.V.R. to feed a current to increase the field coil
current. (See Fig.

5-12)

As a result, the rotor magnetism increases.
This operation is repeated to generate the rated

voltage at

60

Hz

in the main coil and

DC

coil.

5-3-2

VOLTAGE REGULATING MECHANISM

Connect a load to the AC output terminal and in­crease current. Output voltage varies as shown

in Fig.

5-13

depending on whether an automatic

voltage regulator is used or not.
The operation

of

the A.V.R. is explained below.

When an AC output is taken, the engine is loaded
and its rpm falls, Also the AC voltage fails due to
the voltage drop caused by the internal resistance
of the coils. The

A.V.R.

detects this voltage drop
and its built-in SCR automatically increase the
current flows to the field coil. As a result, the rotor
magnetism increase, the voltage fallen by the load
current is raised: and the output voltage is kept
constant. If the AC output

is

reduced, the SCR
operates in the opposite way to similarly keep the
output voltage constant.co,ndenser coil. When
current a increases, the density of magnetic flux
across the rotor core rises. As a result, the cur­rent flowing

in

the field

coil

increases and the gen-

erator

output

voltage

is

prevented from decreas-

ing.

FC

n

EC

i

L""""""-J

ENGINE

MAGNETO

Fig.

5-

11

Fig.

5-12

WITHOUT AVR

RATED VOLTAGE

v

I

4A

Fig.

5-

13

-

13-

5-3-3

FULL

POWER

SWITCH

(Dual

Voltage

Type)

The full power switch is provided for the dual voltage type to take out the full rated power

from

one

receptacle

in

each voltage.

120/240v

r---

1

MC1

240v

1

-

-

t.-

Fig.

5-

14

MC1

MC2

Fig.

5-

15

MC1

MC2

1

Fig.

5-

15

-

1

REC.~

r

Switch

RECEPTACLE RECEPTACLE

Position

HIGHER VOLTAGE

LOWER VOLTAGE

MC1

1

RECB

Rated output

Half

of

rated output

120/240

V

Table.

5-3

-

-

MC2

I

I

-

Fig.

5-

16

-

14-

Two main coils are wound over stator core. Each main coil outputs half the rated power at the lower

voltage (120V). These main coils are wound to be in the same phase. The full power switch reconnects
these main coils in parallel or

in

series.

Fig. 5-14 shows a circuit diagram. When the full power switch is set for single lower voltage indication
(120V), the switch position is as indicated by the lower solid line in the diagram. Fig.

5-1

5

is a simplified

representation of this circuit, showing the

two

main coils connected in parallel. In this case, the higher

voltage

(240V)

at Rec. 3 cannot be taken out. Rec. 2 for the lower voltage can output

up

to the rated

power (up to

30A

if

the rated current is over

30A),

and Rec. 1 can output up to a total of 15A.

When the full power switch is set for double voltage indication (120V/240V), the switch position is as

indicated by the upper dotted line in Fig. 5-1

4.

Fig.

5-1

6

is a simplified representation of this circuit,

showing the

two

main coils connected in series. In this case, power can be taken simultaneously from

the receptacles for the both voltages. Rec.

3

for the higher voltage can output up to the rated power, but

Rec.

1

and Rec. 2 for the lower voltage can output only up to half the rated power each.

Table

5-4

is a summary

of

the above explanation. Select.the proper output voltage by full power switch in

'

accordance with the appliance to be used.

-

15-

5-4

OIL

SENSOR

541

DESCRIPTION

The

oil

sensor mainly functions

to

detect posi-

tion

of

the

surface of

engine

oil

in

the crankcase

of engines

for

general

use

and

to stop

the

en-

gine automatically

when

the

oil level goes

down

below

the

lower

limit

specified.

This

prevents

sei-

zure

of

engine from occurring

due

to insufficient

amount of oil

in

the crankcase.

Since

the

sensor

has

been

designed

to.consume

a part

of

power supplied to the igniter

to

ener-

gize

its

electronics circuit, any other external

power

supply

is

not

necessary

so

that

it

can

be

mounted at the oil

filler

port.

OIL

SENSOR

Fig.

5-

17

Introduction

of

newly

developed

sensing

principle features

super

durability and no change

with

the

passage

of

time

as

it

does

not

use

any

moving part.

Merits

due

to introduction of electrical conductivity detection are

as

follows

;

@

It

has resistance

to

mechanical shocks

and

property

of

no

change

with

the passage

of

time as

@

At

the

same time,

it

is

capable of detecting the

oil

level

stably

as

it

is

not influenced

by

engine

@

No

error occurs due to foam and

flow

of the oil.

@I

Influence against

the

ignition

system

or

the

electronics

units

can

be neglected because an electric

sensing

element

consists

simply

of electrodes having no moving parts.

vibrations.

current

supplied

to

the

sensor can be decreased.

5-4-2

PRINCIPLE

OF

SENSING OIL LEVEL

There

is

a great

difference

between electric resistance

of

air

and

that

of

oil. Since the resistance

of

air

is

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

the

oil

than

through

the

air, although

absolute value of the current

is

very

small.

The

sensor

detects

this

current difference and

make

use

of

it.

The

sensor

judges

the oil quantity,

by

comparing a current flowing across a pair of electrodes (inner

and

outer)

with

the

reference,

in

such

a way

that

if

a

current

flows

between the electrodes

more

than the

reference, sufficient oil

is

in

the

crankcase, on

the

other

hand,

if

a

current flows

less

than

the

reference,

oil

is

not sufficient. Since an electric current

is

flown

to

detect

oil

quantity,

this

is

called the “electrical

conductivity detection” type of sensor.

The

oil

level

to

be detected

is

determined

by

the length

of

elec-

trodes

and

their mounting positions

with

the engine.

5-4-3

HOW

IT

OPERATES

[Power

supply]

The sensor makes use

of

a part of primary power source

for

ignition

of

the engine

(igniter)

to

drive

the

sensor

circuit. Power to

the

sensor

can

usually

be

derived

from

the

“stop button”

by

branching

wires

out.

-

16-

[Judgement

of

oil

level]

When sufficient oil is in the crankcase, both of inner and outer electrodes are immersed in the oil through
which current flows across the electrodes. The sensor judges that oil in the crankcase is sufficient. When

oil level goes down and the inner electrode is exposed to the air due to consumption of oil, no current flow
between the electrodes as air is considered to be electrically nonconductive. The sensor in this case

judges that oil is insufficient.

[Decision

of

oil

shortage]

.Oil level at the electrodes may go down momentarily probably due to the engine being slanted or affected

by vibration even

if

a sufficient oil is in the crankcase. For that reason, the sensor has an electronic timer

circuit to prevent it from interpreting as short

of

oil

when amount of oil is sufficient. The sensor has been

designed

so

that the engine is to be stopped only when oil-shortage is detected for 5 seconds uninter-

rupted. 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 oil level where the sensor decides as oil-

shortage, when oil level goes down gradually, is called "threshold level".

[Automatic

stop

of

engine]

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

of

engine. Once the stopping circuit is activated, it keeps functioning until it confirms that the engine

has made a complete stop, then the circuit stops functioning automatically.

5-4-4 BLOCK

DIAGRAM

OF

THE

CIRCUIT

Power circuit

igniter

Inner pole

-

Detection

-

circuit

circuit

'

Deley

circuit

Stopping

oil

1

+

-Pole

Engine ground

Fig.

5-18

0

Power

circuit

..........

This rectifies a part of power to the igniter and regulates it

to

supply the st&+

lized power

to

necessary circuits.

-

17-

@

Detection circuit

.....

This detects quantity of

oil,

sufficient or not, according to difference of electric

resistance across inner and outer electrodes.

@

Delay circuit

...........

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

by momentary lowering of the oil level due to the engine being slanted or

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

@I

Stopping circuit

......

This automatically stops the engine running.

5-4-5

CAUTIONS TO

BE

TAKEN ON HANDLING THE SENSOR

(1)

Oil sensor unit

0

Be sure not to damage each

wire.

Broken or short-circuited power supply wires and/or a ground-

ing wire in particular may lead to malfunction or breakdown.

@

The sensor is not interchangeable from engine to engine because the sensor is to be exclusively

installed individually in each engine employed.

(2)

Mounting and wiring of oil sensor unit

0

Although this has been designed to have enough antinoise properties in practical use,

do

not

route the sensor wirings in the vicinity of noise-generating sources such

as

ignition plugs or high

I

voltage

cords.

This may cause malfunction or breakdown.

@

Since capacity of power source is limited, current flown in the electronic circuit

of

the sensor is

kept as low as possible. Be sure

to

use terminals with a high contact reliability of more than that

of

tinned terminals.

\

(3)

Operation of oil sensor

@

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.

I

Operate the engine by keeping

it

level.

@

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

it

stops

j

automatically after it runs for

5

seconds.

i

@

When the engine has been stopped by the oil sensor, voltage remained in the electronic circuit
prevents the sensor from being restarted for

3

seconds after the engine stop. Try to restart the

~

engine after 3 seconds or more.

I

i

-

18-

6.

SAFETY

PRECAUTIONS

1.

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

Do

not

fill

the fuel tank while the engine is running.

Do

not smoke or use open flame near the fuel tank.

Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before starting the engine.

2. Do

not place inflammable materials near the generator.

Be careful not to put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the

generator.

3.

Do

not operate

the

generator in a room, cave or tunnel. Always operate in a well-ventilated

-

area.

Othetwise the engine may overheat and also, the poisonous carbon monoxide contained in the ex­haust gases

will

endanger human lives. Keep the generator at least

1

m

(4

feet) away

from

structures

or

facilities during use.

4.

Operate the generator on a level surface.

If the generator is tilted or moved during use, there is a danger

of

fuel spillage and a chance that the

generator may tip over.

5.

Do

not operate with wet hands or

in

the rain.

Severe electric shock may occur.

If

the generator is wet by rain or snow, wipe it and thoroughly dry

it

before starting. Don’t pour water over the generator directly nor wash it with water. If the generator is
wet with water, .the insulations

will

be adversely affected and may cause current leakage and electric

shock.

6.

Do

not connect the generator to the commercial power lines.

This may cause a short-circuit

or

damage to the generator. Use a transfer switch (Optional parts) for

connecting with indoor wiring.

NOTE

:

The

parts numbers of the

transfer

switches

and

of the plastic box to store them

are

as

Table

6-

1.

Part No. Part Name

Q’ty

Phase Allowable

Current

36545604-08

Transfer Switch

1

1

15

A

NOTE

:

The

parts numbers of the

transfer

switches

and

of the plastic box to store them

are

as

Table

6-

1.

Table.

6-1

7.

Be

sure

to

check

and

remedy the cause of circuit.breaker tripping before resetting

it

367-45605-08

Transfer Switch

1

1

30

A

340-45606-08

Transfer Switch

1

1

60

A

367-43008-08

Plastic

Box

1

1

30

A

1

34843009-08

I

Plastic

Box

I

1

I

1

I

60

A

Table.

6-1

7.

Be

sure

to

check

and

remedy the cause of circuit.breaker tripping before resetting

it

~ shown

in

on.

CAUTION

:

ff

the

circuit

breaker tripped

off

as

a result of using an electrical appliance, the cause

can

be an overload or a short-circuit.

In

such a case, stop operation immediately and carefully

check

the

electrical appliance and

AC

plugs for faulty wiring.

-

19

-

7.

RANGE

OF

APPLICATIONS

Generally,

the

power rating

of

an electrical appliance indicates the

amount

of

work that

can

be done

by

it.

The electric power required

for

operating

an

electrical appliance

is

not

always equal

to

the

output

watt-

age of the appliance.

The

electrical appliances

generally

have a label

showing

their rated voltage, fre-

quency, and power consumption

(input

wattage). The

power

consumption

of

an

electrical appliance

is

the

power

necessary

for

using

it. When

using

a

generator

for

operating

an

electrical appliance, the

power

factor

and

starting wattage

must

be

taken

into

consideration.

In

order

to

determine the

right

size generator,

it

is

necessary

to

add the

total

wattage

of

all appliances

to

be connected

to

the

unit.

Refer

to

the

followings

to

calculate the power

consumption

of

each appliance

or

equipment

by

its

type.

(1)

Incandescent lamp, heater, etc. with a power factor

of

1.0

Total power consumption

must

be equal

to

or

less than

the

rated

output

of

the generator.

Example

:

A

rated

3000W

generator can

turn

thirty

1

OOW

incandescent lamps

on.

factor

Select a generator

with

a rated

output

equivalent

to

1.2

to

2

times

of

the power

consumption

of

the

load. Generally the

starting

wattage

of

motor

driven

tools

and

light

electrical appliances are

1.2

to

3

times lager than

their

running

wattage.

Example

:

A

rated

250

W

electric

drill

requires

a

400

W

generator

to

start

it.

(2)

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

NOTEl

:

If a power factor correction capacitor is not applied to the fluorescent lamp, the more power

shall be required to drive the lamps.

NOTE2

:

Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp.

Therefore,

if

the fluorescent lamp has no special indication as to the power consumption, effi-

ciency should be taken into account as explained in Item

(5)

on the following page.

(3)

Mercury lamps with a smaller power factor

Loads

for

mercury lamps require

2

to

3

times the indicated wattage

during

start-up.

Example

:

A

400

W

mercury lamp requires

800

W

to

1200

W

power

source

to

be

turned

on.

A

rated

3000

W

generator

can

power

two

or

three

400

W

mercury lamps.

(4)

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

These appliances require large starting wattage which

is

3

to

5

times

of

running

wattage.

Example

:

A

rated

900

W

compressor requires a

4500

W

generator

to

drive it.

NOTEl

:

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

7.2

to 2 times their rated power con-

sumption

so

that the excess power generated by the generator can be used for other electrical

appliances.

NOTE2

:

Motor-driven appliances mentioned in items

(3)

and

(4)

vary in their required motor starting

power depending on the kind of motor and start-up load. If

it

is difficun to determine

the

optimum

generator capacify, select

a

generator with a larger capacity

-

20-

'*

8'

(5)

Appliances without any indication as to

power

consumption

Some appliances have no indication as to power consumption; but instead the work load (output) is
indicated. In such a .case, power consumption is to

be

worked out according to the numerical formula

mentioned below.

(Output of electrical appliance)

(Efficiency)

=

(Power consumpition)

Eff iciencies.of some electrical appliances are as follows

:

Single-phase motor

................................

0.6

t0

0.75

The smaller the motor, the

Fluorescent lamp

...................................

0.7

to

0.8

(

lower the efficiedCY.

Example

1:

A

40W fluorescent lamp means that its luminous output is

40W.

Its efficiency is

0.7

and

accordingly, power consumption will be 40

+

0.7=

57W.

As

explained in Item

(2),

multiply

this power consumption value of

57

W by 1.2 to 2 and you will get the figure of the neces­sary capacity of a generator. In other words, a generator with a rated output of 1 OOOW
capacity can light nine to fourteen

40

W fluorescent lamps.

Example

2

:

Generally speaking, a

400

W motor means that its work load is 400

W.

Efficiency of this

motor is

0.7

and power consumption

will

be 400+0.7=

570

W. When this motor is used for

a motor-driven tool, the capacity ofthe generator should be multiple of

570

W

by 1.2

to 3 as

explained in the Item

(3).

570

(W)

x

1.2 to

3

=

684

(W) to

1710

(W)

I

Frequency

I I

60

Hz

I

lncandesent lamp, heater, etc.

6000

W

Fluorescent lamp, Motordriven tool,
general-potpose

approx.

3000

W

Mercury lamp, etc. approx.

2000

W

Pump, compressor, etc.

approx.

1400

W

Table.

7-1

-

21

-

NOTES

:

Wiring between generator and electrical appliances

1.

Allowable current of cable
Use a cable with an allowable current that is higher than the rated input current of the load (electrical

appliance). If the input current is higher than the allowable current of the cable used, the cable will
become excessively heated and deteriorate the insulation, possibly burning it out. Table

7-2

shows

cables and their allowable currents for your reference.

2.

Cable length

If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors de-
creasing the input voltage to the load (electtical product). As

a

result, the load can be damaged. Table

7-2

shows

voltage drops per

100

meters

of

cable.

i

Sectional

mm

current

/

A

area

/

mm3

Resistance

wire

e,ement

No’

Allowable

15A 12A lOA

8A

SA

3A

1A

ohm”00m

Voltage

drop

per

100

m

0.75

5V

4V

3.5V

2.5V

2V

1V

0.332

70

J

0.32

35

5.5

7.5

V

6.5

U

5

V

4

V

2.5

V

1.5

V

0.517

45

I

0.32

23 3.5

15V 12V

1OV

8V

5.0V

3V

1.OV

0.952

37

I

0.26 17

2.0

1av

15~ 12~ 7.5~

sv

1.5~

1.486

,50

/

0.18

12

1.25

12.5

V

8

V

2.5

V

2.477

30 10.18

7

Table.

7-2

(

1

Voltage drop indicates as V=

100

xRxIxL

R

means resistance

(

SZ

/

100

m)

on

the above table.

I

means electric current through the wire

(A).

L

means the length

of

the wire (m).

The length

of

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

tools.

-

22-

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 of

Robin generators. The "Dr. Robin" has the follow-

ing 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.

sturdy case for easy carrying.

(4)

Tester and accessories are installed in a handy,

SPECIFICATIONS

Fig.

8-1

MODEL

Dr. Robin

I

Part Number

0

to 500

V

AC

Voltage

388-47565-08

I

Frequency

I

~~

25 to 70

Hz

I

Measuring
Range

Resistance

0.1 to 1.999

Q

Condenser Capacity

Fuse

Circuit Protector

3M

Q

Insulation Resistance

10 to

100

pF

Power Source

I

2 x 6F44P (006P)

Dry

Cell Battery

I

Accessories

I

Test leads with needle probes

.

.

.

1 set

Test leads

with

jack plugs

. .

.

1 set

I

Dimensions

(L

x

W

x

H)

1.6 kg

Weight

285 mm

x

200

rnm

x

110 mm

Table.

8-1

The

"Dr.

Robin" generator tester can be ordered from Robin generator distributors by the following part

number.

~

If

you do not

have

a "Dr. Robin" generator tester, use the instruments described in the following section

far

checking generator parts.

-

23-

8-1-2

INSTRUMENTS

(1) VOLTMETER

AC voltmeter

is

necessary. The approximate

AC voltage ranges

of

the voltmeters to

be

used

for various types

of

generators are

as

follows:

0

to 150V : Type with an output voltage

of

11

0

0

to 300V : Type with

an

output

voltage

of

220,

0

to

15OV,

0

to 330V : Dual voltage type

or

120V

230

or

240V

FOR

AC

Fig.

8-2

(2)

AMMETER

I

AC ammeter is necessary. An AC ammeter
with a range that can be changed according
to the current rating

of

a given generator

is

most desirable. (About 10A, 20A, 100A)

(3)

FREQUENCY

METER

Frequency range

:

About

45

to

65Hz

NOTE

:

Be careful

of

the frequency meter’s input

voltage range.

FOR

AC

Fig.

8-3

-

24-

1

(4)

CIRCUIT TESTER

Used

for

measuring resistance, etc.

(5)

MEGGER TESTER

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

of

500V.

I

I

Fig.

8-6

(6)

TACHOMETER

Use the contactless type tacho meter.

1

f

Fig.

8-7

-

25-

8-2

AC

OUTPUT

MEASURING

TO

AC

RECEPTACLE

v

Fig.

8-8

Use a circuit

like

the

shown

in

Fig.8-8

for

measuring

AC

output. A hot plate or lamp

with

a power factor of

1

.O

may be

used

as a load.

Adjust

the load and

rpm.

and

check that

the

voltage range

is

as specified

in

Table

8-2

at

the

rated amperage

and

rated

rpm.

I

I

I

Rated

voltage

120

v

240

W

Voltage

range

Table.

8-2

224

-

256

V

112

-128

V

I

8-3

DC

OUTPUT MEASURING

1

To

DC

Terminal

9

T

i.

.i

Fig.

8-9

Measurement

of

DC

output

is

executed

with

the switch turned

ON

while

the current

is

regulated at

8.3A

by

adjusting

the

load to

the

generator.

If

the

voltage

is

within

the

range from

6V

to

14V,

the

voltage output

is

normal.

NOTE

:

If a battery is connected as a load

to

the generator,

the

DC

output voltage will increase by

approximately

1

to

2

V:

Therefore, carefully observe the electrolyte level

and

do

not overcharge

the 6attev.

I

I

\

-

26-

8-4

MEASURING INSULATION RESISTANCE

Use a

"Dr.

Robin"

generator

tester

in

megger tester

mode

or

use

a megger tester to check

the

insula-

tion resistance. Remove the control panel,

and

disconnect

the

connector of

GREEN

lead

for

ground. Connect a megger

tester

to one of

re-

ceptacle

output

terminals and the ground termi-

nal, then' measure the insulation resistance.

An

insulation resistance

of

1

megohm or more

is

nor­mal. (The original insulation resistance at the time
of

shipment

from

the factory

is

10

megohm or

more.)

If

it

is

less than 1 megohm, disassemble
the generator and measure the insulation resis­tance of the stator, rotor and control panel

indi-

vidually.

NOTE : Turn

on

the no-fuse breaker before

mea-

surement.

Fig.

8-10

STATOR

(1)

Measure

the

insulation resistance between

(2)

Measure the insulation resistance

between

(3)

Measure

the

insulation resistance between

BLUE

lead and the core.

WHITE

lead and the core.

BROWN

lead and the core.

I

Fig.

8-

11

ROTOR

Measure

the

insulation across one of

the

soldered

terminals of the rotor and

the

core.

Fig.

8-12

-

27-

CONTROL PANEL

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

Fig.

8-

13

Any part where the insulation resistance

is

less than 1 M Q has faulty insulation, and may cause electric

leakage and electric shock.

Replace the faulty part.

-

28-

’

...^

.

:.

.

9.

CHECKING FUNCTIONAL

MEMBERS

9-1

VOLTMETER

Check the voltmeter

if

it is turned on by applying
specific voltage. Voltmeter cannot be checked with
circuit tester because its resistance is too large.

0

Check that no disconnection nor short-circuit
occurs with a tester, and the internal resistance
is around OOk ohms normally.

@

Turn on the commercial power supply input
and check the indication.

9-2

AC RECEPTACLES

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

AC

receptacles while the receptacle

is

mounted on the control panel. When continuity is
found between the

output

terminals of the recep-

tacle with a wire connected across these termi-

nals, the

AC

receptacle

is

normal. When the wire

is removed and no continuity is found between
these terminals, the receptacles are also normal.

9-3

NO-FUSE

BREAKER

Check continuity between each of two terminals
at the rear of the no-fuse breaker while it is

mounted on the control panel. Normally, there

is

continuity between each of the

two

when the no-

fuse

breaker is on while there is no continuity when

the no-fuse breaker is

off.

VOLTMETER

Fig.

9-7

Fig.

9-2

I

Fig.

9-3

-

29-

9-4

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

fol-.

lowing table.

Fig.

44

r

Stator

coil

DC

coil

Hz-Voltage

Red-White

BrownBrown

WhiteLight green

Black-Blue

60-1 20

/

240

0.61

SZ

0.11

D

0.16

SZ

0.16

SZ

NOTE

:

If the circuit tester is not sufficiently accurate, it may not show the values given and may give

erroneous readings. Erroneous readings will also occur when there is

a

wide variation

of

resis-

tance among

mil

windings or when measurement is performed at ambient temperatures differ-

ent from

20

OC

(68

OF).

9-5

ROTOR

ASSEMBLY

I)

Field coil

Remove

the

brush holder

and

measure resistance

between the slip rings.

Resistance

NOTE : If the circuit tester is not sMicientIy accu­rate,

it

may

not show the values given and may

give erroneous readings.
Erroneous reading will also occur when there is a

wide variation

of

resistance among coil windings
or when measurement is performed at ambient
temperatures different from from

20

’

C

(68

’

F).

-

‘SUP

UNG

Fig.

9-5

-

30-

2)

Cleaning Slip rings

The slip ring surfaces must be uniformly bright.

Slip rings showing black spots, excessive wear,
or uneven wear must be repaired.

A

stained slip
ring lowers generator efficiency and output volt­age. Polish the slip rings with fine sandpaper while
turning the rotor until rough spots disappear. Care
should be taken not to touch the rotor coils with
the sandpaper.

9-6

BRUSH

The brushes must be smooth where they contact
the slip rings.

If

not, polish smooth the brushes

with sandpaper.

A

brush that is not smooth pro-

duces arcs between the brush and slip ring lead-

ing to possible damage. Usable brush lengths are

from

5

mm

to

15

mm

(0.2

"

to

0.6").

A

brush shorter than 5 mm must be replaced be­cause decreased contact pressure between the
brush and slip ring lowers generator efficiency and

output voltage.

9-7

A.V.R

(AUTOMATIC

VOLTAGE

REGULATOR)

1)

Features

This

AVR

operates to control the field current in

order to maintain the output voltage for the

AC

current, which generated by the magnetic flux by
the field

coil.

2)

A.V.R.

trouble may

be

identified by simply look-

ing at the

A.V.R.,

or by the inter-lead resistance

with a'tester,

or

actually mounting it

in

the gen-

erator and operating

it.

Fj3.

9-6

Fig.

9-7

of

the

A.V.R.

-

1

Fig.

9-8

-

3.1

-

..

(a)

A.V.R.

TROUBLE IDENTIFICATION by APPEARANCE

If

an

A.V.R.

electronic part is burnt dark, or the surface epoxy resin melted, it often indicates A.V.R.

trouble.

(b) IDENTIFYING A.V.R. TROUBLE by CHECKING INTER-LEAD RESISTANCE

Check the inter-lead resistance of the A.V.R. with a tester, referring to the following table.

If

the tester readings very greatly from the values specified in the table on'next page, the

A.V.R.

is

faulty.

NOTE

:

lake teater inaccuracy into account

in

reading the tester.

(c) IDENTIFYING A.V.R. TROUBLE by MOUNTING and OPERATING in

THE

GENERATOR

SCR

or

transistor damage cannot be detected by simply looking at the A.V.R. or checking the lead

resistance. Check it by mounting the suspectedly faulty A.V.R.

in

a normal generator,

or

mount a

mormal A.V.R. in a generator which fails to generate voltage.

Checking

table

for analogue circuit tester.

~~ ~~

Apply black (minus) needle

of

the circuit tester

Analogue circuit tester

Yellow

Red

Light

Brown or

White

Yellow

green

Yellow

-

03

03

03

03

Red

03

circuit tester

100

kQ

03

-

46

kQ

03

White

needle

of

the

200

kSZ

03

105

kQ

-

Apply red (PW

Light green

-

03

100

kSZ

200

kS2

03

Brown or Yellow

6

kQ

-

130

kS2

250

kS2

7.5

k0

L

Table.

9-2

\

-

32-

9-8

IDLE

CONTROL UNIT

Check the resistance between five terminals

of

IDLE CONTROL

UNIT

with circuit tester.

L'

Terminal number

of

the

IDEL

CONTROL

UNIT

Fig.

9-8A

Terminal number

of

the IDLE CONTROL UNIT

Fig.

9-8B

C

li

t break

k

0

needle

of

the circu Apply blac

Sircuit tester (with battery

power source

1.5

V)

@

lo

Is

110kQ

I

03

,110

kSZ

50

kQ

F,

50

kQ

110

kQ

110

ksl

0

0

Apply red

0

needle

of

the

0

circuit breaker

0

0
0

@

03

03

03

110

kQ

110

kQ

50

kQ

03

03

03

03

03

03

110

kQ

50

kQ

85

kQ

80

kQ

85kQ

I

03

80

kQ

OQ

I

?r

rneasu

ng

range

tt

1000

kS2

Table.

!

NOTE : The resistance readings vary depending on the @pes

of

circuit testers.

The above table shows an example

of

the resistance readings measured by an ordinary ana-

logue circuit tester with

1.5

volt battery power source:

It

is advisable for

you

to check the resistance readings using your standard circuit tester and

revise the checking table.

-

33-

9-9

DIODE

RECTIFIER

DIODE RECTIFIER

Brown

Orange

Brown

Fig.

9-

10

CIRCUIT TESTER

Fig.

9-

11

Circuit inside

of

the diode rectifiers is as shown in Fig.

9-1

0.

Check continuity between each terminal by

using a circuit tester as shown in Fig.

9-11.

The rectifier is

normal

when condtinuity is as follows:

*

Checkina table for analoaue circuit tester.

Apply black (minus) needle

of

the circuit tester

Analogue circuit tester

Brown

Brown

I

White

Orange

Brown

Brown

Continuity Continuity

Orange

Continuity

No

continuity

-

No

continuity Brown

Continuity

No

continuity

No

continuity

-

-

Continuity

Apply red (plus) needle

of

the circuit tester

Brown

I

White

-

No

continuity

No

continuity

No

continuity

.

Table.

9-4-7

Checkina table for diaital circuit tester.

Apply red (plus) needle

of

the circuit tester

Digital circuit tester

Brown

Brown

I

White

Orange

Brown

.I

I

BlQWtl

Continuity

No

continuity

No

continuity

-

*

Apply black

(minus)

needle

of

the

circuit

tester

BmWn

Continu'@

No

continuity

-

No

continuity

Orange

Continuity

-

Continutty

Continuity

Brown

I

White

-

No

continuity

No

continuity

No

continuity

Table.

942

-

34-

.

..

NOTE

1

:

Because of the difference of

hieasdnng

method between the analogue circuit tester and the

digital circuit tester, polarity of testemeedles should be reversed.

NOTE

2 : "Continuiv means forward direction characteristics of the diode, and different from short

circuit condition (in which

a

pointer of the tester goes

out

of its normal scale), shows resistance
to some extent. When results of the checking indicates failure even in one section, replace
with a new one.

NOTE

3

:

Simpson brand analogue testers have the characteristics as same

as

the digital circuit tester.

9-10

OIL

SENSOR

(1)

Disconnect

two

(2)

wires comming from the

(2)

Loosen the sensor to remove

it

from the en-

gine.

(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

(5)

Start the engine with the oil sensor removed

sensor at the connection.

sensor.

and confirm

if

;

a. Engine

stops

after 5 seconds which is normal, or

b.

Engine does not stop after more than

10

seconds which is unusual.

Fig.

9-12

NOTE : The sensor will not operate properly when wire is broken or pooriy connected. Check the wires

for correct connection. If

it

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

sensor is wrong. Replace the sensor with new one.

9-11

Exciting

coil

(1)

Disconnect

two

(2)

yellow wires which come out from the exciting coil through the hole

of

the

(2)

Check the resistance between these

two

(2)

yellow wires with a circuit tester.

crankcase and connected with

AVR

in the control box

.

Resistance

24

Q

-

35-

IO.

DISASSEMBLY AND ASSEMBLY

10-1

PREPARATION

and

PRECAUTIONS

1)

Be sure to memorize the location

of

individual parts when disassembling the generator

so

that the

'

generator can be reassembled correctly. Tag the disassembled part with the necessary information to
facilitate easier and smoother reassembly.

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, replace them temporarily to

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.

their original position.

-

36-

10-2

DISASSEMBLY

PROCEDURES

r

Step

1

Part

to

remove

Control box

Description

(1)

Take

off

the eight screws and remove

the control panel from the control box.

(See

Fig.

10-1

.)

5

x

12

mm screw and

washer

Ass'y

(black)

. . .

8

pcs.

(2)

Disconnect the connectors on the wiring
from the control box

to

the

alternator.

(3)

Take

off

the

bushing from the

back

of

the control

box.

(See

Fig.

10-2.)

~ ~ ~

Remarks

Tool

Screw driver

(+)

Press the upper end

of

the bushing and pull
out.

Fig.

10-1

Fig.

10-2

I I

(4)

Take

off

the

flange four

bolts

and

I

10

rnrn

box

wrench

Fig.

10-3-

1

Fig.

10-3-2

I

1

I

I

-

37-

-

Step

2

-

Part

to remove

%el Tank

Description

Remarks

(9)

Discharge fuel from the tnak. Use utmost care about

1.

Shut the fuel strainer. fire hazard.

2.

Remove the strainer cup.

3.

Put a vessel to receive fuel under the Wipe

off

split fuel
strainer and open the fuel cock to thoroughly.
discharge fuel. (See Fig.

10-4.)

body. screen.

4.

Attach the strainer cup to the strainer

Do

not lose the filter

Fig.

10-4

(2)

Disconnect rubber pipe from the strainer.
Loosen the hose clamp on the top of the

strainer and pull

out

the rubber pipe from

the strainer.

(3)

Remove the rear plate.

(4)

Take

off

the four bolts and rubber (fuel

tank) and then remove the fuel tank.

(See

Fig.

10-6.)

I

VI

I

Tool

?hers

~ ~~~ ~

12

mm spanner

a

DOX

wrench

10

mm spanner

a

3ox

wrench

Fig.

10-5

Fig.

10-6

I

I

I

I

-

38-

Step

Part

to

remove

TlMuffler and

Muffler cover

Description

Remarks

(1)

Remove the muffler cover from the
muffler.

6

x

10

mm bolt and washer

Ass'y

.

.

.4

pcs.

(See Fig. 10-7.)

(2)

Remove the

two

bolts which fix the

muffler to the rear cover. Loosen the

two

bolts on the muffler flange and remove
the muffler from the engine.

8 x 20

mm

bolt

and washer

Ass'y

. .

-2

pcs.

8

mm spring washer.

.

.2

pcs.

Muffler gasket

.

.

.

1

pce.

Fig.

10-7

Tool

12

mm

spanner or

box wrench

~

10

mm spanner

or

box wrench

Fig.

10-8

I

I

-

39-

Part

to remove

'ipe Frame

Description

1)

Remove the nuts which are fixing engine

and alternator to the mount rubbers.

(See Fig.

10-1

0.)

2)

Using a chain-block, sling

up

the engine

and alternator and dismount from the

frame.

Remarks

Remove the air

cleaner cover for
dismounting.

MOUNT
(ALTER

MOUNT

RUBBER

(ENGINE

SIDE

:

Ppcs)

Fig.

10- 10

3)

Remove the mount rubbers from the
frame. Loosen the nuts on the bottom
side of the frame. (See

Fig.

10-1

1

.)

d8

flange nut.

.

.4

pcs.

n

I

Tool

12

mm spanner

12

mm spanner or

socket wrench

Fig-

10-11

I

-

40-

-

itep

5

-

Part

to remove

Brush

and

Rear cover

Description

Remarks

(1) Remove the brush holder.

(See Fig. 10-1

2.)

64screw..

.2

pcs,

rear cover to the front cover.

(2)

Remove the

four

bolts which fasten the

(See Fig. 10-73.)

64bolt..

.4

pcs.

L

Tool

10 mm spanner or

box

wrench

I.

7.

10-12

Fig.

10-

13

(3) Remove

the

rear cover by hitting on the

to

loosen.

on the

boss

or

legs.

legs of rear cover with a plastic hammer

Do

not give a strong hit

Fig.

10-14

-

41

-

Plastic hammer

Step

6

-

Part

to

remove

Stator

Description

Remarks

(1)

Remove the stator cover.

E

STATOR

COVER

Fig.

10-15

Tool

STATOR

COVER

STATOR

-

\

SPR'NG

WASHER

:

4

pcs.

COVER

BOLT

:

4

pcs.

Fig.

10-16

I I

-

42-

7

~

Part

to

remove

3otor

Description

Remarks

(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.

10-17

I

Tool

(2)

Put the engine on the working table

~ ~~

recoil starter side down.

(3)

Use

a bolt and oil

as

a tool for pulling out

rotor in the following procedures

:

1.

Pour engine oil into the center hole

of

rotor shaft. Fill with oil to the shaft end.
(See Fig.

10-18.)

2.

Prepare a

bolt

with the following thread

size

:

M12

x

P

1.5

3.

Apply a few turns

of

seal tape around the

tip

of

the bolt. (See Fig.

10-1

9.)

Box

wrench

Plastic hammer

Fig.

10-

18

1

Fig.

10-

19

I

I I

I

-

43-

Part to remove

3otor

3ont Cover

Description

4.

Screw the bolt into the thread of the rotor

5.

Torque the bolt using a socket wrench

shaft.

until the rotor comes

off

loose.

The hydraulic pressure inside the
rotor shaft takes apart the rotor from
the engine shaft.

:4)

Wipe

off

oil thoroughly from rotor shaft

and enaine PTO

shaft.

Remarks

Do

not stick

out

your
face over the rotor.
It may

jump

up

on

separation.

(1)

Remove the front cover.

Loosen the four

bolts

and remove the

front cover.

M8

x

20mm bolt and washer

Ass'y

.

.

.4

pcs.

I

Fig.

1021

7

-

44-

Tool

Socket wrench

12

mm socket

wench

10-3

ASSEMBLY

PROCEDURES

10-3-1

ENGINE

and

FRAME

(1)

Attach the mount rubbers to the frame. Insert
the setting tongue of mount rubber into the hole

.on the frame and tighten the nut from the bot-

tom

of

the frame.

M8

flange nut

. .

.4

pcs.

11.8

-

13.7

N-m

120

-

140

kg-cm

8.7

-

10.8

ft-lb

FRAME

UPPER

-

Fig.

10-22

NOTE : The mount rubbers are selected to reduce vibration most effectively by model. Be sure to use the

correct mount rubber for your generator. Although mount rubbers have the same appearance,
their characteristics are different.

(2)

Install the engine into the frame from the

side

of

it.

Tighten the nuts over the mount rubber bolts to

fix.

M8

nuts

. .

.2

pcs.

120 - 140

kg-crn

8.7 - 10.8

ft-lb

NOTE : Remove the air cleaner cover for easier installation.
NOTE

:

When tightening the nuts, slightly

lift

the engine

so

that the weight is not applied to the mount

rubbers.

10-3-2

FRONT

COVER

Attach the front cover to the engine main bearing
cover. Match the faucet joint and tighten the bolts.

M8

x

20

mm

bolt.

.

-4

pcs.

M8 spring washer.

.

.4

pcs.

11.8 - 13.7

N-m

120

-

140

kg-cm

8.7

-

10.1

ft-lb

Fig.

10-23

-

45-

10-3-3

ROTOR

(1)

Wipe

off

oil,

grease and

dust

from

the

tapered

portion

of

engine

shaft

and

matching

tapered

hole

of

rotor shaft.

(2)

Mount

the

rotor

to

the

engine shaft.

Tighten

the

through

bolt.

Apply

a

wrench

on

the

through

bolt and

hit

wrench handle clockwise

with

a

hammer

to

tighten.

If

an impact wrench

is

available, use it.

Tightening

torque

:

22.5

-

24.5

N-m

230 - 250

kg-cm

16.6

-

18.5

ft-lb

10-3-4

STATOR

(1)

Put

the

stator

in

the

rear cover setting

the

four

grooves on

the

side

of

stator with thread holes

of

the

rear cover.

(2)

Attach the stator cover around the stator.

Fig. 10-25a

Fig.

10-24

STAT0

Fig.

TO-25b

-

46-

10-3-5

REAR

COVER

(1) Put the rear cover with stator over the rotor.

Tap on the rear cover evenly with a plastic

hammer to press the rotor bearing into the rear
cover.

(2)

Fix the rear cover to the adaptor with four bolts,

spring washers, and washers.

M6x160mmbolt

...

4pcs.

M6 spring washer.

.

.4 pcs.

M6 washer

. .

.4 pcs.

50

-

60

kgcm

3.6 - 4.3

ft-lb

(3)

Attach the bushing over the lead wire drawn

out

from the rear cover. Press the smaller end

of the bushing into the window of the rear

cover.

(4)

Attach the 5 mm terminal of the grounding wires

(green

/

yellow) to the unpainted thread hole

of the frame base plate using a

5

mm brass

screw.

(5)

Install the alternator assembly into the frame
Tighten the nuts over the mount rubber bolts
to fix.

M8

nuts.

.

.2

pcs.

120

-

140

kg-cm

8.7 - 10.8

ft-lb

NOTE

:

When tightening the nuts, slightly lift the

alternator assembly

so

that the weight

is not applied

to

the mount rubber.,;

(6)

Fasten the other earth cable with 5 mm termi-

nal

to

the unpainted bolt hole on the frame.

(See fig.

1

0-28.)

Fig.

10-27

1

Fig.

10-28

-

47-

10-3-6

BRUSH / BRUSH HOLDER

(1)

Install the brush holders in the rear cover. Pass
the mounting screws through the brush hold-

ers, push the brush holders

so

that the brushes
will be perpendicular to the slip rings, and
tighten the screws.

NOTE

:

There are two kinds of brush holders.

If

a brush is installed oblique to the slip
ring, the brush holder can break when
the screw is tightened

;

or the brush may
break when the generator of started.Afier
insblling the brush holders, measure the

resistances across the brushes and ter-

minals with a tester if they are from

5

ohrms to

7.5

ohrms. If

so,

the brush hold-

ers are correctly mounted.

Fig.

10-29

(2)

Attach the connetors to the brush holders. Connector the green wire to the stator end and the

brown wire to the bearing end.

(3)

Fix

the brush cover with

two

bolt and washer

Ass'y.

10-3-7

MUFFLER

and

MUFFLER

COVER

(1)

Assemble the exhaust pipe to engine.

M8

nuts

.

.

.2

pcs.

Tightening torque

22.5

-

26.5

N-m

230

-

270

kg-

'

16.6 - 19.5

ft-lb

(2)

Assemble the muffler bracket to the muffler.

(See

Fig.10-30.)

M8

flange nuts

.

.

.4

pcs.

fler.

(See

Fig.10-30.)

M6

x

12

mm

flange bolts

.

.

.2

pcs.

(3)

Assemble the muffler cover (rear) to the muf-

I

-

48-

.

..

@

MUFFLER

COVER

(FRONT)

/

MUFFLER

BRACKET

MUFFLER

COVER

(REAR)

Fig.

10-30

(4)

Attach the muffler to the exhaust pipe and gen-

erator rear cover without tightening.

(5)

Tighten the muffler to the exhaust pipe.

(See

Fig.10-31.)

I

M8

x

20

mm bolts

.

.

.2

pcs.

230

-

270

kgcm

(6)

Tighten the muffler bracket to the generator cover. (See Fig.10-32.)

16.6

-

19.5

ft-lb

M8

x

20

mm bolt

and

washer

A&’y

. .

.2

pcs.

I

1

E

Fig.

10-31

-

49-

Fig.

10-32

(7)

Tghten the muffler bracket to the generator
cover. (See Fig.10-33.)

M8

x

20

mm

bolt and washer Ass’y

. .

.2 pcs.

50

-

60

kg-cm

3.6

-

4.3

ft-lb

(8)

Assemble the muffler cover (from).

M6

x

12 mm flange bolt

.

.

.2

pcs.

10-3-8

FUEL

TANK

(1)

Hand tighten the strainer screw as far as it

will

go, loosen

it

again by one or

two

rotations (fuel

outlet faces down), then tighten the lock nut.

I

Tightening

torque

I

4.5 - 6.9

N-m

50

-

70

kg-cm

3.6

-

5.1

ft-lb

(2) Mount the fuel tank on the frame with rubber

washers between the tank flange and the
frame.

M6

x

20 mm bolt (black)

. .

.

4

pcs.

Rubber washer.

. .

4

pcs.

NOTE

:

For easy tank assembly, glue the rubber

washers over the mounting

holes

of

the

frame.

(3)

Connect

the

rubber pipe.

First,

fit

the hose clamps on the rubber pipe and

’

connect it

to

the

strainer and

the

carburetor. Then

fasten it with

Ute

hose clamps.

NOTE

:

Apply

a

drop

of oil

to

the

rubber

pipe for

easier connection.

w

Fig.

10-33

FYEL GAUGE

FUELTANKCAP

a

4

Fig.

10-34

-

50-

10-3-9

CONTROL PANEL

Mount the control panel assembly to the control box.

Refer to Section

10-4

for disassembly, checking and reassembly procedures of the control panel.

(1)

Connect the wires from the control panel and

(2)

Connect the wires drawn

out

from the stator to

the engine.

the wires from the control panel.

NOTE : Connect the wires

of

the same color.

(3)

Press the upper end

of

the bushing into the

(4)

Mount the control panel to the control box.

bottom window of the control panel.

M5 x

12

mm bolt

and

washer Ass’y

. .

.8

pcs.

Fig.

10-35

~ ~~

10-4

CHECKING, DISASSEMBLY

and

REASSEMBLY

of

the

CONTROL

PANEL

10-4-1

CHECKING

OF

THE CONTROL

PANEL

Dismount the control panel from frame. Remove the control panel and check each components and
wiring. Refer to Section

9

for the detail of checking procedure for the components in the front panel.

10-4-2

DISASSEMBLY

(1)

Remove the control panel from the control box.
M4 screw

. .

.8

pcs.

(2)

Disconnect the connectors on the wires to detach the control panel.

(3)

After disconnecting individual wires, remove the control panel components.

NOTE : Full power

switch

and pilot lamp have their wires soldered. Unsolder them to remove those parts

if necessary.

-

51

-

10-4-3

REASSEMBLY

(1)

Install the receptacles, no-fuse breaker,

terminals, switches, etc.

on

the control panel and wire them.

NOTE

:

Circuit diagrams are shown in Section

12.

Colored wires

are

used for easy identification, and are

of the correct capacity and size. Use heat-resistant type wires (permissible temperature range

75°C

or

over) in the specified gauge shown in the circuit diagrams.

(2)

Connect the wires

of

control panel components.

(3)

Attach the control panel to the control

box.

M4

screw

.

.

.8

pcs.

1.2 - 1.5

N-m

12

-

15

kgcrn

8.7

-

10.9

f"

-

52-

11.

TROUBLESHOOTING

11-1

NO

AC

OUTPUT

11

-1-1

CHECKING

STATOR

(1)

Remove control panel and disconnect stator

wires at the connectors.

(2)

Measure the resistance between terminals on

stator leads. (See Fig.11-1) Refer to Table

9-1

of Section

9-4

STATOR

for normal resistance.

If

stator is

faulty,

replace it with a new one.

(3)

Check the insulation resistance between sta-

tor core and each stator lead using a Dr. Robin
generator tester in megger tester mode or a
megger tester. (Fig.

11

-3)

If

insulation is bad, replace stator with a new

one.

11-1-2

CHECKING

ROTOR

1)

Field coil

Remove the brush holder and measure resistance
between the slip

rings.

Refer to Section

9-5

RO-

TOR

ASSEMBLY

for normal resistance.

NOTE : If the circuit tester

is

not sufficiently accu­rate, it may not show the values given and may
give erroneous readings.

Erroneous reading will also occur when there is a

wide variation

of

resistance among coil windings

or when measurement is performed at ambient

temperatures different from from

20”

C

(68°F).

I

I

’

\-

Fig.

11-1

Fig-

11-2

I

‘SUP

UNG

Fig.

11-3

-

53-

2) Cleaning Slip rings
The slip ring surfaces must be uniformly bright.

Slip rings showing black spots, excessive wear,

or

uneven wear must be repaired. A stained slip
ring lowers generator efficiency and output volt­age. Polish the slip rings with fine sandpaper while
turning the rotor until rough spots disappear. Care
should

be

taken not

to

touch the rotor coils with

the sandpaper.

11-2

AC

VOLTAGE

IS

TOO

HIGH

OR

TOO

LOW

11 -2-1 CHECKING ENGINE SPEED

If

the engine speed is too high or too low, adjust

it

to the rated r.p.m.

[How

to

adjust

engine

r.p.m.1

*

Loosen the lock nut on the adjusting screw.

*

Turn the adjusting screw clockwise

to

decrease
engine speed or counterclockwise to increase
engine speed.

Normal

engine

speed

at

no

load

3700

to

3750

rpm

11

-2-2

CHECKING

STATOR

Check stator referring to Step 11

-1

-1.

11

-2-3

CHECKING

ROTOR

Check rotor referring

to

Step

11

-1

-2.

Fig.

11-4

ADJUSTING

SCREW

\

Fig.

11-5

11-3

AC VOLTAGE

IS

NORMAL

AT

NO-LOAD, BUT

THE

LOAD CANNOT

BE

APPLIED.

11-3-1 CHECK THE ENGINE SPEED.

If

the engine speed is low, adjust

it

to the rated r.p.m.

*Refer to Step

11

-2-1

for engine speed adjustment.

11-3-2 CHECK THE TOTAL WAnAGE

OF

APPLIANCES CONNECTED TO THE GENERATOR.

Refer to Section 7 "RANGE

OF

APPLICATIONS" for the wattage of the appliances.

If

the generator is overloaded, reduce the load to the rated output of the generator.

11-3-3 CHECK THE APPLIANCE

FOR

TROUBLE.

If

the appliance is faulty, repair it.

11-3-4

CHECK

IF

THE ENGINE

IS

OVERHEATED.

-

If

the cooling air inlet and/or cooling air outlet

is

clogged with dirt, grass, chaff or other debris, re­move it.

(ALTERNATOR)

Fig.

11-6

11-3-5

CHECK THE INSULATION

OF

THE GENERATOR.

(1)

Stop the engine. Remove the control panel;
and disconnect the connector of GREEN lead
for ground.

(2)

Measure the insulation resistance between the

live terminal

of

the receptacle and the ground

terminal.

If

the insulation resistance is less than

1

M

Q

,

disassemble the generator and check the in­sulation resistance of the stator, rotor and the
live parts in the control box. (Refer to Section

Any part where the insulation resistance is less
than

1

M

SZ

,

the insulation is faulty and may

cause electric leakage.

Replace

the

faulty

part

8-3.)

-

55-

11-4

NO

DC

OUTPUT

11-4-1

CHECK

THE

AC

OUTPUT.

Check the generator

by

following Step

11

-1

-1

through Step

11

-1

-2.

11-4-2

CHECK THE

DC

BREAKER.

If

the DC breaker turned

off

while charging a bat­tery, check the cables for short-circuit or connec­tion in reverse polarity before resetting it

on.

NOTE

:

If

the

DC

output

is

used

to

charge a large

capacity battery or

an

over-discharged

battery,

an

excessive current may flow

causing.

11-4-3

CHECK THE

WIRING.

Check all the wires to be connected correctly.

11-4-4

CHECK THE DIODE RECTIFIER.

Remove the control panel and check the diode
rectifier with

a

circuit tester.

Refer to Section

9-7

"DIODE RECTIFIER" for the

checking procedure.

Fig.

17-8

DIODE

RECTIFIER

~-

Fig.

71-9

11-44

CHECK THE DC COIL

Check the resistance between

two

brown leads from stator with a circuit tester.

If the resistance reading

is

much larger or smaller than the specified value, the

DC

coil of the stator

is

faulty. Replace stator with a new one.

Table.

11-3

-

56-

11-5

IDLE

CONTROL

11-51

ENGINE SPEED

IS

NOT INCREASED

WHEN A LOAD

IS

APPLIED

(1)

Inspect the solenoid bracket. Check the bond
angle

of

solenoid bracket.

If

the bracket is dis-

torted, correct the angle with proper tool.

(2)

Check the wattage

of

load applied to the gen-

erator.

If

the generator is loaded over the rated
wattage, the engine speed can not be in­creased. Most induction loads such as elec­tric motor or electric tools

or

welding machine

require

three

to five times large wattage of their
ratings at starting. This starting wattage must
not exceed the rated output

of

the generator.

(3)

Check the slow set r.p.m.

,

The normal idling speed by the IDLE CON-

TROL

is as follows

:

2200

to

2400

r.p.m.

The above speed setting is for cold engine con­dition. Loosen the

two

bolts and move the

so-

lenoid bracket.

(4)

Check the wiring through ZCT on the IDLE
CONTROL

UNIT.

Single Voltage lype

Make sure that an output wire from main coil is

passing through the ZCT on the

IDLE

CONTROL

UNIT.

*

Dual

Voltage Type

Check that

two

output wires (black wire and red
wire) from main coils are passing through the
ZCT

on

the IDLE CONTROL

UNIT

in the same

direction.

soLENolD

M6

BOLT

I

Fig.

11-10

~

Fig.

11-11

IDEL CONTROL

UNIT

Fig.

11-12

-

57-

(5)

IDLE

CONTROL

UNIT

Check the resistance between

five

terminals

of

IDLE

CONTROL

UNIT

with

circuit tester.

Terminal number

of

the

IDEL

CONTROL

UNIT

Fig.

11-13A

I

3rcuit tester (with battery Apply blal

power source

1.5

V)

Apply red

0

needle

of

the

circuit breaker

to

I

CF,

co

-

@

1lOkSZ 110kQ

co

@

85kO

85

kQ

co

@

85kQ 85kQ

05

Fig.

11 - 138

Table.

1

1-4

NOTE

:

The resistance readings vary depending on the types of circuit testers. The above table shows

an example

of

the resistance readings measured by an ordinary analogue circuit tester with

1.5

volt battery power source. It is advisable for you to check the resistance readings using your

standard circuit tester and revise the checking table.

!

-

58-

11-5-2

ENGINE

SPEED

IS

NOT REDUCED WHEN LOAD

IS

.OFF.

(1)

Check the distortion of the SOLENOID BRACKET as shown in step

11-5-1-(l)..

(2)

Check the wiring of SOLENOID.

Check

two

leads from SOLENOID are securely connected.

(3)

Check the wiring of IDLE CONTROL UNIT.

Check all leads from IDLE CONTROL UNIT are securely and correctly connected.

(4)

Checking the SOLENOID.

Measure the resistance between two leads

from SOLENOID.

I

Normal

Resistance

I

15-

19

Q

SOLENOID

\

If

the resistance is larger or smaller than this range,

SOLENOID

is defective,

Replace with a new one.

-

59-

12.

WIRING

DIAGRAM

U.S.A., 6OHZ-120V/240V

ELECTRIC

STARTER

TYPE

..........

K3>OC3

FF

..........

-

60-

U.S.A.,

60H~-120V/240V

WITHOUT ELECTRIC STARTER

TYPE

0

0

si

"

t

1

"-

r

"""

I

I
I

-

61

-