Page 3 - CONTENTS; Section; course of technical progress, at anytime without notice.
CONTENTS Section Title Page 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2-1 EXTERNAL VIEW . . . . . ....
Page 4 - Model; AC; Specifications are subject to change without notice.; DC; Engine
– 1 – 1. SPECIFICATIONS Model Type Starting System Hz W L mm mL(cc) L kg Model Type Frequency kVA Rated Output AC Rated Output Fuel Tank Capacity h Lubrication Oil Capacity Ignition System Dry Weight Specifications are subject to change without notice. Dimensions L × W × H Displacement Air-Cooled 4-...
Page 5 - Alternator
– 2 – Model Type Starting System Hz W L mm mL(cc) L kg Model Type Frequency Rated Output Fuel Tank Capacity h Lubrication Oil Capacity Ignition System Dry Weight Dimensions L × W × H Displacement Air-Cooled 4-stroke OHC Gasoline engine Oil Sensor STD Multi Monitor STD Over-current Protection Recoil ...
Page 6 - GENERAL DESCRIPTION
– 3 – 2. GENERAL DESCRIPTION 2-1-1) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE DC TERMINALS DRAIN PLUG GROUND TERMINAL AC RECEPTACLES DC CIRCUIT BREAKER FUEL TANK OIL LEVEL GAUGE FUEL LEVEL GAUGE MULTI MONITOR SPARK PLUG FRAME SPECIFICATIONS LABEL AIR CLEANER MUFFLER (EXHAUST OUTLET) ENGINE SWI...
Page 12 - -3) LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER; Number and Production Number.
– 9 – 2-3) LOCATION OF SERIAL NUMBER AND PRODUCTION NUMBER Generator serial number and production number are stamped on the label stuck on the side of fuel tank. For soundproof type models, remove the side cover (R) to check these numbers. NOTE : When inquiring about your generator or ordering spare...
Page 14 - shall be required to drive the lamps.; (3) Mercury lamps with a smaller power factor; RANGE OF APPLICATIONS
– 11 – 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 th...
Page 15 - (5) Appliances without any indication as to power consumption; Efficiencies of some electrical appliances are as follows :; Applications
– 12 – (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. Efficiencies of ...
Page 17 - MEASURING AND CHECKING PROCEDURES; NOTE : Be careful of the frequency meter's input voltage
– 14 – 4. MEASURING AND CHECKING PROCEDURES 4-1) MEASURING 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 150 V : Type with an output voltage of 110 or 120 V 0 to 300 V : Type w...
Page 19 - MODEL; checking generator parts.
(7) "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 following features : 1) Functions of voltmeter, frequency meter, megger tester, capacitance meter and circui...
Page 20 - Voltage range
– 17 – 4-2) AC OUTPUT MEASURING SWITCH LOAD TO AC RECEPTACLE F A ~ V ~ Use a circuit above for measuring AC output. A hot plate or lamp with a power factor of 1.0 may be used as a load. Adjust the load and rpm, and check that the voltage range is as specified in the following table at the rated ampe...
Page 22 - Output Wires
– 19 – 4-5) CHECKING FUNCTIONAL MEMBERS (1) STATOR Disengage connectors on the wires from stator and check the resistance between the wires using a circuit tester referring to the table below. NOTE : If the circuit tester is not sufficiently accurate, it may not show the values given and may give er...
Page 23 - Checking table for analogue circuit tester; Check that no live part or wire or plastic part is burnt.
– 20 – (3) DIODE RECTIFIER The circuit inside the diode rectifiers is as shown in the chart above. Check continuity between each terminal by using a circuit tester. The rectifier is normal when continuity is as follows: Diode rectifier Circuit tester Yellow Yellow Yellow Yellow Gray Gray Orange Oran...
Page 24 - Oil sensor
– 21 – (5) DC CIRCUIT BREAKER Check that there is continuity between the two terminals of DC circuit breaker when its push button is pressed. (6) FLOAT TYPE OIL SENSOR Check the oil sensor when it is installed on the engine. Check that sufficient engine oil is filled in the crankcase. Check that the...
Page 25 - DISASSEMBLY AND ASSEMBLY; Part Name; FLYWHELL HOLDER; Part Number; DRIVESHAFT HOLDER
– 22 – 5. DISASSEMBLY AND ASSEMBLY 5-1) 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...
Page 27 - Choke wire; (1) Loosen the four screws and remove the upper
– 24 – Battery cables Fuel strainer (3) Remove the fuel strainer. [ For electric start models ] (4) Remove the battery cover and disconnect battery cables. (5) Remove the battery from frame. 5-3-4 GROUNDING WIRE Remove the grounding wire at the right bottom side of control panel. M6 Nut : 1pce. Cho...
Page 28 - Wire band; NOTE : At this step, electric wires are still connected to; Muffler cover
5-3-8 WIRE BAND Cut the wire bands that are binding wires behind thecontrol panel. For electric start models, cut the wire band that is bindingbattery cables also. Tools : Nipper Wire band (3) Loosen the five bolts and remove the cover bracket from the inverter unit. M6 x 12mm Flange bolt : 2pcs. M...
Page 29 - FUEL TANK AND FUEL SYSTEM PARTS
– 26 – 5-3-9 FUEL TANK Loosen the four bolts and remove the fuel tank from frame. M6 x 20mm Flange reamer bolt : 4pcs. Rubber : 4pcs. Tools : 10mm Box wrench NOTE1 : Be sure to drain fuel from the tank before removing the tank. NOTE2 : Take care not to misplace the four mounting rubbers for the ta...
Page 30 - Regulator
– 27 – 5-3-10 AUTOTHROTTLE COUPLER Disengage the coupler from the auto-throttle unit of carburetor. Auto-throttle coupler 5-3-11 WIRE HARNESS (1) Disengage the couplers of wire harness from the control panel and monitor unit. (2) Disengage the couplers of wire harness from the control panel, inverte...
Page 31 - INVERTER UNIT; M6 Bolt; the back side before loosening the bolt.; Screw and Washer; INVERTER UNIT COMPONENTS
– 28 – 5-3-12 GROUNDING WIRE (2) Disconnect the two grounding wires from the alternator and the inverter unit. Tools : Screw driver 5-3-13 CONTROL BOX and INVERTER UNIT Removing the cover bracket from the bottom of the inverter unit, separate the control box and inverter unit. For further taking apa...
Page 35 - Cleaner cover; remove the carburetor from the insulator.; Sponge insulator
– 32 – 5-3-17 AIR CLEANER and CARBURETOR (1) Remove the air cleaner cover and element from the air cleaner. (2) Loosen the two M6 nuts and one M6 bolt, and remove the air cleaner body. M6 Flange nut : 2pcs. M6 x 20mm Flange bolt : 1pce. Tools : 10mm Box wrench Cleaner cover Element Air cleaner Carbu...
Page 37 - To loosen
– 34 – 5-3-20 REAR COVER Loosen the four M6 bolts that fasten the rear cover to the blower housing. M6 x 25mm Bolt : 4pcs. Tools : 10mm Box wrench 5-3-21 THROUGH BOLT and ROTOR (1) Remove the through bolt. M10 x 55mm Bolt : 1pce. Tools : Socket wrench NOTE : Since the thread of the through bolt is i...
Page 38 - ALTERNATOR COMPONENTS
– 35 – Hand-pressing machine (2) Using a special tool, Rotor Puller, remove the rear cover together with rotor and stator. Special tools : Rotor Puller (33B9990501) NOTE 1: Usually, you do not need to separate the rotor from the stator. However, should it benecessary, use a hand-pressing machine top...
Page 39 - Recoil starter
– 36 – 5-3-22 RECOIL STARTER Loosen the three M6 bolts and remove the recoil starter. M6 x 18mm Flange bolt : 3pcs. Tools : 10mm Box wrench NOTE : Refer to section 5-5 for further instruction for disassembly/reassembly procedures of recoil starter. Recoil starter 5-3-23 BOTTOM EXTENSION PLATE Loosen...
Page 41 - NOTE : The mount rubbers are designed to isolate the
– 38 – Top side of frame Base plate (Lower) Sponge (Base) Brake Battery base Wheel Base plate (Upper) Shaft 5-4) REASSEMBLY PROCEDURES 5-4-2 SOUND INSULATOR for SOUND-PROOF MODELS (1) WHEELS Inset the Shafts to the Base Plate (Lower) andassemble the four Wheels to the Shafts. (2) BRAKE Assemble the ...
Page 43 - Assemble the Recoil Starter to blower housing.
– 40 – Recoil starter Tightening torque : 6.5-8.5 N ・ m 65-85 kgf ・ cm (4.8-6.3 ft ・ lbs) 5-4-7 RECOIL STARTER Assemble the Recoil Starter to blower housing. M6 x 18mm Bolt : 3pcs. NOTE : Refer to section 5-5 for further instruction for disassembly/reassembly procedures of recoil starter. 5-4-8 REAR...
Page 44 - ASSEMBLY ONTO FRAME; Install the engine and alternator assembly onto frame; Soundproof type; kgf
– 41 – 5-4-10 COVER (CRANKSHAFT) for the frame type FAN (SILENT) for the soundproof type For the frame type generator: Assemble the Cover (Crankshaft) to the main bearing cover. M8 x 12mm Flange bolt : 2 pcs. For the soundproof type generator: Assemble the Fan (Silent) to the crankshaft. M8 x 25mm B...
Page 48 - GROUND WIRES; Clamp the choke cable and ground wires using a wire
– 45 – 5-4-21 AUTO THROTTLE (1) Connect the wires to Auto Throttle Unit of the carburetor. (2) Temporarily connect the choke cable to the carburetor choke lever. 5-4-22 FUEL TANK (1) Install the fuel tank onto the frame. Be sure to insert the mount rubbers between the tank and the frame. M6 x 20mm F...
Page 50 - BATTERY CABLES; (1) Align the shaft of engine switch to the Fuel Strainer; Battery; Brand; Yuasa; NOTE: Battery information below
- 47 - 5-4-27 GROUND WIRE Fasten the ground wire to the frame. M6 Nut : 1pce. 5-4-26 CHOKE WIRE Fix the Choke wire to the carburetor choke lever makingsure that the choke valve is fully closed when engineswitch is turned to "CHOKE" position. NOTE : Be sure to install the return spring. 5-4-2...
Page 52 - ) Disassembly procedures; Starter handle
– 49 – 5-5) RECOIL STARTER Tools used : Long-nose pliers, retaining-ring pliers, protective goggles The recoil starter of this device is located between the alternator assembly and the engine, so remove the recoil starter after removing the alternator assembly. Caution : Please wear protective goggl...
Page 53 - with the ring pliers.
– 50 – Caution : The reel is disassembled with the spring still assembled, so place it on a flat table without dropping, or shaking. Retaining-ring C Retaining-ring pliers (2) Remove the small parts. -1 Hold the case, and remove the retaining-ring C with the ring pliers. -2 Beginning at the top, rem...
Page 54 - Please wear protective goggles before starting assembly.; ) Assembly procedure
– 51 – (2) Install the ratchet and friction spring. Install the ratchet and friction spring into the reel. Friction plate Retaining-ring C Ratchet Friction spring (3)Installation of friction plate and retaining ring C. Install by putting the Tab of friction plate into the hole of the ratchet. Fasten...
Page 55 - Five turns in counter-clockwise; Do not release the pressure to hold the reel
– 52 – (4) Wind the spiral spring. -1 Holding the case, turn the reel five turns in counter-clockwise. -2 Fix the reel in the position that the rope hole of reel aligns with the rope guide. (5) Inserting the rope. (this should be done by two people) -1 Thread the rope end through the rope guide and ...
Page 56 - ) Checking items after assembly; Reel
– 53 – 3) Checking items after assembly (1) Try to pull the starter handle for 2 to 3 times. (a)When the starter handle is difficult to pull, please make sure the parts, etc., are installed in the right direction. (b)When the ratchet does not operate, please re-check if there are any missing parts s...
Page 57 - No output power or Low output; Resistance value of the stator windings for reference; Wire Color
– 54 – 6.TROUBLE SHOOTING No output power or Low output Engine start Engine start Change INV C/U ＜ Resistance value of the stator windings for reference ＞ Surrounding temperature 20 ℃ Red White Blue Measured resistance value Generator (Refer to the table below) Measure the resistance value between A...
Page 58 - Improper revolutions (Electronic throttle)
– 55 – Improper revolutions (Electronic throttle) Engine starts but stops suddenly. Go to the start malfunction section No Yes Yes Does not run ・ Engine revolution does not increase. ・ Hunting Confirm connection of electronic throttle coupler. Confirmed Runs ・ Pull the recoil starter lightly with th...
