Robin America R1200 User manual

Rozh -J) &ii
Generator
TechnicalData&OverhaulInstructions
SERVICE MANUAL

FOREWORD
This manual was compiled for dealers’ mechanics and includes descriptions on
specifications, items, performance, structure, features, and maintenance procedures
of the R1200 Generator.
Weask each dealer to master the contents of this manual and provide userscomplete
service after sales or proper guidance on how to usethis generator.
This manual includes only brief descriptions on important points, so we ask you to
supplement this with your own experience and determination in practical guidance for
your customers. We are also going to have seminars or other events to exchange
necessary information to improve our service to customers.

CONTENTS
Section
Title Page
1. SPECIFICATIONS ................................................... 1
1-1 items ....................................................... 1
1-2 Performance Curves ............................................. 2
2.
3.
4.
FEATURES ....................................................... 5
COMPONENT IDENTlFlCATlON ........................................ 6
FUNCTION OF EACH COMPONENT ..................................... 7
4-1 Generator .................................................... 7
4-2 Engine ...................................................... 9
5. DESCRIPTION OF MAIN OPERATIONS .................................. 11
5-1 Electronic ignition Mechanism ...................................... 11
5-2 Description of Generating Operation .................................. 12
6. OPERATIONAL LIMITS OF THE GENERATOR ............................. 14
6-1 AC Output ................................................... 14
6-2 DC Output ................................................... 16
63 Simultaneous Use of AC/DC Output .................................. 16
6-4 Wire Length ................................................... 17
7. MEASURING PROCEDURES ........................................... 18
7-1 Meters ...................................................... 18
7-2 Measurement of AC Output ........................................ 20
7-3 Measurement of DC Output ........................................ 20
7-4 Measurement of Insulation Resistance ................................. 20
8. FUNCTIONAL CHECK OF EACH COMPONENT. ............................ 22
8-1 Control Panel. ................................................. 22
8-2 Diode Stack (Rectifier) ........................................... 23
8-3 AVR ....................................................... 24
8-4 Stator ....................................................... 25
8-5 Rotor ....................................................... 26
8-6 Brush ....................................................... 26
8-7 Ignition Coil .................................................. 27
8-8 Exciting Coil .................................................. 27

Section Title Page
9.
10.
11.
12.
13.
14.
DISASSEMBLY AND ASSEMBLY ....................................... 28
9-1 Preparation and Remarks .......................................... 28
9-2 Special Tools for Disassembly/Assembly ................................ 28
9-3 Disassembly Sequence ............................................ 29
9-4 Assembly Procedure ............................................. 48
9-5 Carburetor ................................................... 67
SAFETY PRECAUTIONS. ............................................. 72
10-1 Fire Prevention ............................................... 72
10-2 Precautions for Exhaust Gases. ...................................... 72
10-3 Other Precautions ............................................... 72
TROUBLESHOOTING ................................................ 73
CRITERIA TABLE FOR ADJUSTMENT ................................... 91
WIRING DIAGRAM ................................................. 94
MAINTENANCE .................................................... 95
14-1 Daily Checks and Maintenance (Every 8 Hours) ........................... 95
14-2 Checks and Maintenance for Every 20 Hours ............................. 95
14-3 Checks and Maintenance for Every 50 Hours (Every 10 Days) .................. 95
14-4 Checks and Maintenance for Every 200 Hours (Every Month) .................. 96
14-5 Checks and Maintenance for Every 500 Hours (Semi-Annually) ................. 96
14-6 Checks and Maintenance for Every 1000 Hours (Annually) .................... 96
14-7 How to Store the Generator for Long Period .............................. 96

1. SPECIFICATIONS
l-l ITEMS
Model I R1200
Engine: Type I Forced air-cooled, 4-stroke, side valve, gasoline engine
Displacement
Fuel tank capacity
143 cc (8.73 cu. in.)
3.5 lit. (0.93 U.S. gal.)
I
Oil pan capacity , 600 cc (1.28 U.S pints)
I
Ignition system I Solid state ignition
Starting system i Recoil starter I
Rated continuous I
I
operating hours Approx. 4 hours Approx. 3.5 hours
I
I
Generator: Type 2-pole, revolving field type
I Exciting system Self-exciting
I
Voltage regulating I
system AVR (Automatic Voltage Regulator)
I
I Maximum output j 1000 w ! 1200 w
I I
Rated output 800W I 1000 w
AC Frequency
AC Voltage
DC output
50 Hz 1
I 60 Hz
110,220,230,24OV 110,120,220v
12V -8.3A (1OOW)
I
AC receptacle I S.T.D type, nema, germany: 2 ea.
I France, Australia, England, Switzerland: 1 ea.
DC receptable ! One
Over current
protection
I
Circuit breaker
I Voltmeter 1 Standard equipment
Dimensions (L x W x H): 4B6x2BBx410mm
I (19.1 x 11.3 x 16.1 in.)
I
Dry weight
I
I 27.5 kg (60.6 Ibs)
-l-

1-2 PERFORMANCE CURVES
AC OUTPUT
Power Factor ............... 1.0
‘;;
I
-I
0’
s
z
E
IA
z
&
2 t
z
>
1 1 1 1 1 1 ’ ’ I
! output i 1000
50
49 800 I
600 z s
240 P
230 400 2
220
210 200
n
0 1 2 3 4 5 ”
Current (A)-
52
51 1000
50
49 800 I
600 si w
250 2
240 400 2
230
220 200
I I I I I I I I I I I I
0 1 2 3 4 5 0
Current (A) -
Ti
I-t 52 1000
z 51
;I 50
ii
L 49 800 I
LL s
z
I
600 ‘;
8 260 P
s
8 250 400 0
z
> 240
230 200
0 1 2 3 4 5 0
Current (A) -
Output Max. ............... 1000w
Rated ........... 800W
Frequency .................. 50 Hz
Voltage ..................... 220v
Output Max. ................ 1000W
Rated ........... 800W
Frequency .................. 50 Hz
Voltage ..................... 230V
Output Max. ............... 1000w
Rated ........... 800W
Frequency .................. 50 Hz
Voltage ..................... 240V
-2-

;;;
I
-I
0”
E
?T
L
Ti
I
-t
0”
E
z
e
l.L
z
8
2 t
%
52
51
51 1000
5050
49
49 800 t
600 s
zz
600 s
B
0.
120--
120 400 3
3
llOr . 110
100 200
0 2 4 6 8 10 0
Current (A)-
62 1000
61
60 800 f
59 z
600 s
Q
5
120 400 0
110
100 200
0 2 4 6 8 10
Current (A)-
62 1000
61
60 800 f
59 600 z
w
240 2
5
230 400 0
220
210 200
01 2 3 4 5 0
Current(A)-
Output Max. ............... 1000W
Rated ........... 800W
Frequency .................. 50Hz
Voltage ..................... 110v
Output Max. ............... 1200w
Rated ........... 1000W
Frequency .................. 60 Hz
Voltage ..................... 110v
Output Max. ............... 1200w
Rated ........... 1000W
Frequency .................. 60 Hz
Voltage ..................... 220v
-3-

G
I
-1
0”
f
E
lt
z
8
2
I
s
62 1000
61
60 800 t
59 z
600 s
P
s
130 400 0
120
110 200
0 2 4 6 8 10 0
Current (A) -
Output Max. ........... 1200w
Rated ...... 1000W
Frequency ............. 60 Hz
Voltage ............... 12ov
DC Output
DC output from this generator is rated especially for charging batteries. Whenthe rated
current (8.3A) flows into a battery the voltage is 12V, but the voltage becomes higher when
the load is smaller (or when the current is smaller than the rated one), and lower when the
load is bigger (or when the current is bigger than the rated one). Note that the voltage
under no load is approximately from 18Vup to 25V.
-4-

2. FEATURES
(1) Weight of this compact generator with excellent portability is 27.5 kg, which means that
the generator is the lightest one in this class.
(2) This generator with an excellent high performance engine and a large size 3.51i fuel tank
can run continuously for about 4 hours (at the rated load of 50 Hz).
(3) The operating system is concentrated on the front panel, which enables users to easily
handle this generator.
(4) Operations of choking, running, and stopping the engine can easily be executed with a
notch.
(5) As a circuit breaker based on the push button system is employed in this generator,
replacement of a fuse is unnecessary. Troubles which happen in an overload or failure of
devices usedcan easily be resolved.
(6) Direct current for charging batteries can also be taken out.
(7) Simultaneous use of DC is possible even when AC is used. However, total AC output and
DC output should be within the range of the rated output.
(8) Voltage fluctuation ratio is below 5% becauseof employment of AVR (Automatic Voltage
Regulator). Accordingly, the stable voltage is always maintained even if the load
fluctuates.
(9) Generally maintenance-free or maintenance is easy becausethe engine, with a transistor
ignition system, hasan excellent startability andno point is employed in this generator.
(10) An ignition plug with a resistor and a plug cap have been employed to prevent electric
wave noises.
-5-

3. COMPONENT IDENTIFICATION
DC Circuit
Breaker \ /
Engine Control Switch
(CHOKE-RUN-STOP)
Ground Terminal
rter
Air Cleaner Cover / Muffler /
Recoil Starter
ler /
crew
,,.,.,rnal)
Spark Plug
Fuel Tank
Fig. 3-1
, Carrying Handle
Cover, Tank Cap
Fig 3-2
-6-