Robin America R600 User manual

.
Model

CONTENTS
Section Title Page
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SPECIFICATIONS ..........................................
1
PERFORMANCE CURVES ....................................
2
2-1 ACOutput .......................................... 2
2-2 DCOutput .......................................... 3
FEATURES .............................................. 5
SERIAL and SPECIFICATION NUMBER LOCATION ................
6
SAFETY PRECAUTIONS ..................................... 7
5-1 Fire Prevention .......................................
5-2 Precautions for Exhaust Gases. .............................
5-3 Other Precautions ......................................
7
7
7
COMPONENT IDENTIFICATION ...............................
8
FUNCTION OF EACH COMPONENT
............................
11
7-1 Generator ...........................................
7-2 Engine ............................................. 11
12
DESCRIPTION OF MAIN COMPONENTS .........................
14
8-1
Electronic lgnition System ................................ 14
8-2 Generator Operation .................................... 15
OPERATIONAL LIMITS OF THE GENERATOR. ...................
17
9-1
ACOutput .......................................... 17
9-2 DCOutput .......................................... 19
9-3 Simultaneous Use the AC/DC Output ......................... 20
9-4 Wire Length. ......................................... 20
MEASURING PROCEDURES ..................................
21
10-1 Meters .............................................
10-2 Measuring AC Output ...................................
10-3 Measuring DC Output ...................................
21
23
23
10-4 Measuring Insulation Resistance . . . . . . . . . . . . . . . . . . . . . 23

Section Title Page
11. FUNCTIONAL CHECK OF EACH COMPONENT.. . . . . . . . . . . . . . . . . . 25
11-1 Control Panel
11-2 Stator.....
11-3 Rotor . . . . .
11-4 lgnition Coil
11-5 Condenser
11-6 Rectifier . .
. .
. . .
. . .
.
. .
. . .
.
. . .
. .
. .
. .
. . . .
. . .
. . . .
. . .
. . .
. . . .
. . . . .
. . . . . .
. . . .
. . .
......
......
......
......
. . . . .
. . .
25
. . 27
. . . 29
. . 29
. . 30
. . . 30
12. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12-1 Preparation and Precautrons ............................... 31
12-2 Special Tools for Disassembly and Assembly .................... 31
12-3 Disassembly Sequence ................................... 32
12-4 Assembly Procedure .................................... 38
12-5 Carburetor .......................................... 48
13. TROUBLESHOOTING . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .
51
14. CRITERIA TABLE FOR ADJUSTMENT . . . . . . . . . . . . . . . 68
15. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
16. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
16-1 Daily Checks and Maintenance (every 8 hours) ................... 72
16-2 Checks and Maintenance for Every 20 Hours .................... 72
16-3 Checks and Maintenance for Every 50 Hours (every 10 days) ......... 72
16-4 Checks and Maintenance for Every 200 Hours (monthly) ............ 73
16-5 Checks and Maintenance for Every 500 Hours (semi-annually) ........ 73
16-6 Checks and Maintenance for Every 1000 Hours (annually) ........... 73
16-7 When the Generator is not used for Prolonged Periods: ............. 73

1. SPECIFICATIONS
Model R600
Engine: i Type Forced air-cooled, 4-stroke, side valve,
gas01ine engine
L-- Displacement 78 cc (4.76 cu.in.1
Fuel tank capacity 2 lit. (0.53 U.S. gal.)
Oil pan capacity 350 cc (0.75 U.S. pints)
Ignition system Solid state ignition
~~
Starting system Recoil starter
Rated continuous Approx. 4 hours (50 Hz)
operating hours Approx. 3.5 hours (60 Hz)
Generator: Type 2-pole, revolving field type
Exciting system Self-exciting
Voltage regulating
system Condenser type
Maximum output 500 w 600 W
Rated output 400 w 500w
AC Frequency 50 Hz 60 Hz
AC Voltage 110, 220,230,24OV 110, 120,220v
DC output 12V - 100 W (8.3 A)
AC receptacle Standard: 2 ea.
(special: 1 ea.)
DC terminal Two
Over current
protection Circuit breaker
Frequency meter Standard equipment
Pilot light Standard equipment
Dimensions (L x W x H): 370 x 265 x 345 mm
(14.6 x 10.4 x 13.6 in.)
Dry weight 18.5 kg (40.7 Ibs)
-1-

2. PERFORMANCE
2-1 AC OUTPUT
Power Factor . . .
CURVES
1 .o
3
-t
w
3
a
I I I I 1 ! 1 I 1 1
I ’ I I
!
1 OUTPUT’
i ,
I FRECiENC
i/: ‘1 I 1
Y I i 300
t
240
/ I
/ I I $
CURRENT IA) -
1 I , ,
I 1 I 1 1 i
, OUTPUT
1.1 j 500
: :
50 i I I I II
-i----l
49- /‘\I
// FREQUENCY 400 t
I
I
/ I 1 a I , :
I / I I !
300
260
I / : I I
Output Max. ............... 500W
Rated ............... 400W
Frequency. ................ 50 Hz
Voltage. .................. 220V
Output Max. ............... 500W
Rated ............... 400W
Frequency. ................ 50 Hz
Voltage ................... 230V. 240V
vi : I1 0 0.5 1 1.5 2 2.5 0
CURRENT (Al -
-2-

w
U
LL
-1 1 w >
U
a
CURRENT (A) -
1
N
-
I
tI
U
3
w
U
LL
-1 1 > w
17
I-
a
J
0
>
N
-
I
3
E
U
U
>
(3
a
5
0
>
62
61
60
59
120
110
100
0 12 3 4 5 6
CURRENT
(A) -
62
61
60
59
240
230
220
210
a 0.5 1 1.5 2 2.5
CURRENT (A) -
3
1
600
500
400
1
I
3
300
3
0
I-
200 2
100
0
600
500
400 1
-
3
300 -
I-
2
200 3
I-
0
100
a
Output Max. ............... 500W
Rated ............... 400W
Frequency ................. 50Hz
Voltage
................... 11OV
Output Max.
............... 600W
Rated
............... 500W
Frequency
................. 60 Hz
Voltage
................... 1 1OV
Output Max.
............... 600W
Rated ...............500W
Frequency
................. 60 HZ
Voltage.
.................. 220V
-4 -

52
51
50
49
0 1 2 3 4 5 6
CURRENT IA) -
I I I I I 1
62
61
60
59 FREQUENCY
r
I
120
110
100
0 1 2 3 4 5 6
CURRENT IA) -
0 0.5 1 1.5 2 2.5
CURRENT (A) -
600
500
400 t
3
300 +
3
E
200 2
400 I
300
3
f
k
200 ‘0
100
0
Output Max. ............... 500W
Rated ............... 400W
Frequency ................. 50 Hz
Voltage. .................. 11OV
Output Max. ............... 600W
Rated ............... 500W
Frequency ................. 60 HZ
Voltage. .................. 11OV
Output Max. ............... 600W
Rated ............... 500W
Frequency ................. 60 Hz
Voltage ................... 220V
-4-

3. FEATURES
l Robin Exhaust Fan Cooling System for low body temperatures, low noise. longer engine life and reliable performance.
l Large 78cc 4Stroke Engine provides enough power for constant 500W (at 60 Hz) rated output.
l Simple One-Touch Engine Control Switch with the engine and fuel on/off levers and choke all integrated into one
switch.
l Easy and Reliable Starting with pointless ignition. This generator is also abrush-lesstype generator for maintenance-free
operation.
l Simple Design for a clean appearanceand easymaintenance.
l Compact and Lightweight with an easy one-hand carrying handle grip. This generator also offers ahigh power-to-weight
ratio and economical operation.
l Circuit Breaker Protection for safe operation. Replacement of fusesis not necessaryin caseof an overload.
l Unique Dual Output Design so that two separateA.C. and D.C. electrical appliances can be used at the sametime.
-5-

4. SERIAL and SPECIFICATION NUMBER LOCATION
The serial number is stamped on the crankcase at the opposite side of the carburetor.
The specification and specification number are shown on the nameplate located on the rear cover.
Always specify thesenumbers when inquiring about the e
oenerator or ordering parts in order to get correct parts and accurate
service.
SPECIFICATION
SPECIFICATION NUMBER
SERIAL NUMBER
Fig. 4-7
-6-

” - . . . - . . - -
5. SAFETY- PRECAUTIONS
51
1)
2)
3)
4)
5)
6)
7)
8)
5-2
1)
3
5-3
1)
2)
3)
4)
FIRE PREVENTION
Keep the generator away from combustible materials during operation. Take special precautions with flammable sub-
stances.
Do not run the generator in a incline position or while it is slanted at an angle. Avoid moving the generator while it
is in operation to prevent the generator from falling over or leaking fuel.
Do not place a carton or similar object over the generator while the generator is running. If covered, cooling will be
diminished and causethe generator to overheat.
Operate the generator at least lm away from a building or wall.
Be sure to stop the engine before filling fuel into the fuel tank.
If fuel is filled while the engine is running, fuel vapors may rise from the fuel tank resulting in apotential fire hazard.
Fuel used in engine operation is very volatile and highly flammable. Take special precautions not to spill fuel when
filling the fuel tank. If fuel is spilt, wipe it off thoroughly and let dry before starting the engine.
Do not overfill the fuel tank and always be sure to fill iuel only up to the level specified at the fuel supply-port.
Do not smoke or useopen flame when filling the fuel tank.
PRECAUTIONS for EXHAUST GASES
Avoid operating the generator in poorly ventilated locations such as an office, warehouse. narrow tunnel. well, hold.
tank. etc.. If the generator is run continuously in such poorly ventilated areas.the operator may suffer carbon mono-
xide poisoning.
Always operate the generator with the exhaust port directed toward the open air or where good ventilation is assured.
OTHER PRECAUTtONS
To prevent electric shock. do not touch the generator with wet hands. For example, when the generator is usedto
drive a submersible pump, be sure to connect the earth cord of the generator to the earth cable of the pump.
Do not splash water over the generator during operation. And also avoid operating the generator in the rain. If the
generator getswet. it may fail to start or short-circuit. and the operator may possibly receive a severeelectric shock.
Do not connect the generator to existing power lines which havebeen originally installed asthe power supply system
of a building. If connected. the generator will burn out.
Avoid running the generator with its cover removed.
-7-

6. COMPONENT IDENTIFICATION
h’UFFLE9
C 0 V E F1
AlFl CLEALER
Al= CLEdYER CO\.‘ER
Fig. 6- 7
FUEL T.ANY
GEZERATOS

RECOIL STIRTE?
Fig. 6-3
\*’” z
/
FLER C:O\.‘ER
SPARK PLUG
Ffg. 6-4
-9-

CAPBLRETOR
Fig. 6-5
#El3 PIPE
AIR \;E’JTl
Fig. 6-6
- 10-

7. FUNCTION of EACH COMPONENT
7-1 GENERATOR
7-1-1 STATOR
The stator consists of a laminated silicon steel sheet core,
a main coil and condenser coil which are wound in the core
slots.
AC and DC output are taken out from the main coil. (DC
output is taken out from the part of main coil which is in
the middle of the main coil.)
The condenser coil excites the stator field coil which
generatesAC output in the main coil.
7-1-2 CONDENSER
REAR HOUSING
RECTIFIER
Fig. 7- 7
The condenser is mounted on the rear housing and is connected to the condenser coil which is wound in the stator. The
condenser coil magnetizes the rotor which increasesthe density of magnetic flux.
7-1-3 RECTIFIER
The rectifier is also mounted on the rear housing and it converts AC current output from the main coil to DC current. The
DC output from the diode of this rectifier is connected to the DC terminal.
7-1-4 ROTOR
The rotor consists of a lamination silicon steel sheet core
and field coil which is wound over the core.
DC current m the field coil magnetizes the steel sheet core.
Two permanent magnets are provided at 90 degreesfrom
the poles for the primary exciting action.
A securely mounted fan is pressure-fitted on the end of the
rotor shaft to cool the individual coils. iron cores. rectifier.
and other integral parts.
Cooling air from the fan is drawn in from the ventilation
vents in the rear housing. and is discharged from the ex-
haust port in the front housing.
Fig. 7-2
7-l-5 CONTROL PANEL
The panel on the front of the housing hasa receptacle with
a ground terminal and AC output is taken out with amale
Plug.
The frequency meter is provided to seeif the frequency of
generated power shows 50 Hz (or 60 Hz). DC output is
taken out from the red (positive. +) and black (.negative.-)
terminals.
-11-
Fig. 7-3

7-2 ENGINE
7-2-l CYLINDER and CRANKCASE
The cylinder and the crankcase of the engine are of an one-piece aluminum die-cast design. The cast iron cylinder liner is
cast-fitted inside the cylinder. Both the intake and exhaust ports are positioned at the lateral side of the cylinder and these
ports are formed by using a mold with die-cast cores. The crankcasehas its joint face located on the generator side.
7-2-2 MAIN BEARING COVER
The main bearing cover is aluminum die-cast and is mounted on the generator side. By removing the main bearing cover.
the interior of the engine can be inspected.
7-2-3 CRANKSHAFT
The crankshaft is constructed of forged carbon steel. The crankpin is induction-hardened and has a pressure-fitted crank
gearlocated on the generator side of the engine.
7-2-4 CONNECTING ROD and PISTON
The connecting rod is constructed of forged aluminum alloy with both the major and minor ends utilized as bearings.
The oil scraper and cap for the major end are cast together. The aluminum alloy casting piston hastwo compression rings
and one oil ring.
7-2-5 CAMSHAFT
The camshaft is constructed of special cast iron and has intake and exhaust valve drive cams.each of which engageswith the
cam gear. An exclusive aluminum alloy is used on eachend of the camshaft in the place of bearings.
7-2-6 VALVE ARRANGEMENT
The intake valve is installed at the oil port side and the exhaust valve at the generator side.
7-2-7 CYLINDER HEAD
The cylinder head is die-cast aluminum and has Ricardo type combustion chamber featuring greater volume capacity for
improved combustion efficiency. For easier spark plug maintenance. the cylinder head is positioned at an angle to allow
greater access.
7-2-8 GOVERNOR
The centrifugal weight type governor ensures constant engine speed,regardlessof load fluctuations (the governor is mecha-
nically linked to the governor drive gear).
-12-

7-2-9 EXHAUST FAN COOLING SYSTEM
Instead of blowing outside air on the engine. the Exhaust Fan Cooling System of this generator intakes the cool air and
forces the hot air outside from one outlet.
This keepsthe body temperature lower for greater safety and extends servicelife.
7-2-10 LUBRICATION SYSTEM
The moving and sliding parts inside the engine are lubricated with the oil scraper fitted on the connecting rod. As the
crankshaft rotates, the connecting rod moves up and down and the oil scraper moves in conjuction with the connecting rod
movements to scrapeup oil in the crankcaseand splashit over the surfaces of the moving and sliding parts.
7-2-l 1 IGNITION
A flywheeh’magneto ignition system is employed with the ignition timing set at 23” before top dead center. The magneto is
composed of the tl)wheel and ignition coil with the fll-wheel mounted on the rotor shaft. The ignition coil is fitted to the
front housing.
7-2-l 2 CARBURETOR
The horizontal suction type carburetor is adjusted so that the engine will provide excellent starting. good acceleration.
low fuel consumption. and superior output [for details concerning carburetor construction. seethe paragraph dealing with
carburetor construction and disassembly/assembly (Page49)]
7-2-13 AIR CLEANER
The air cleaner is a semi-wet type and contains a spongeelement.
- 13-

8. DESCRIPTION OF MAIN COMPONENTS OPERATION
8-1 ELECTRONIC IGNITION SYSTEM (Solid State Ignition System)
The electronic ignition system features a polver transistor as the current control element. Therefore. the ignition system is
an electronic contact point-free type that operates with the po\ver transistor impulses controlling the current. This system
also called TIC (transistor igniter circuit) is virtually free of ignition failure which generally results from contamination of
the contact points. a typical problem vvrth contact type ignition systems.
Because this ignition system has no contact points. it is not affected by moisture. oil. dust. or other contaminants. 4s a
result. this electronic ignition system ensuressureand positive ignition lvith reduced maintenance.
The TIC mechanism consists of a transistor-mcorporated ignition coil and a permanent magneto built-in flywheel which is
pressure-fitted on the rotor shaft of the generator.
I
//////
IGNITION COIL
IGNITION
TIMING
DETECTING
CIRCUIT
FLYWHEEL
COOLING FAN
PLUG
Fig. 8- 1
1) When the permanent magneto built-in flywheel starts rotating. power is generated in the primary coil of the ignition
coil and current tlows to the resistor @ _
From the resistor, current flows to the power transistor. RYth this current. the power transistor turns on. releasing
current I(@ Thrs stagecorresponds to the closmg of contact points.
2) As the tlywheel comes to the point of ignition. the ignition timing detecting circuit is activated while the current @
is flowing through the circuit.
When the ignition timing detecting circuit is activated. the signal transmitter transistor actuates hzith current 8 flow-
ing. \Vhen current ,$$ starts flovving. current s flowing through the power transistor is cut quickly. As a result. high
voltage is produced in the secondary coil and this voltage is applied simultaneously to the spark plug which ignites for
ignition. This stagecorresponds to the opening of contact points.
-14 -

c
.I
8-2
GENERATOR OPERATION
INITIAL EXCITATION
PERMANENT MAGNETO
FIELD COIL i
ROTOR : I
RESIS -----
DIODE
8-2-l
1)
GENERATION of NO-LOAD VOLTAGE
2)
3)
41
When the generator starts turning the permanent magneto built-in to the flywheel generates@ 1to 2\’ of AC voltage
in the main coil and also generates1 to 4 of AC voltage in the condenser coil.
The capacitor coil is connected to a capacitor so when a voltage is applied to the condenser coil. minimun current
@ flows in the condenser coil. At this time, minimum flus is produced. vvith which the magnetic force of the rotor’s
magnetic pole is intensified. When this magnetic force is intensified. the respective voltages in the main coil and
condenser coil rise. Current 1s flowing in the condenser coil increases.with the magnetic tlux densit)- of the rotor’s
magnetic pole increasing further. Also. the main coil voltage and condenser coil voltage increases. These voltages
continue rising asthis processis repeated.
As current flows in the condenser coil. the magnetic flux density changes. DC voltage is induced in the field coil when
the magnetic flus density varies. Successively. DC current is rectified bl the rectifiers connected to both ends of the
field coil. and DC current @ flows in the field circuit. With this current. the rotor core is magnetized. allowing the
generator to output steady voltage.
When generator speedreaches2000 to 2300 rpm (50 Hz specification) or 3000 to 3300 rpm (60 Hz specification). the
current in the condenser coil and field coil increasessudden&. This acts to stabilize the respective coil output voltages.
If generator speedfurther risesto the rated v-alue.the generator output voltage will reach the rated value.
STATOR
RECEPTACLE
MAIN COIL
CONDENSER COIL
CONDENSER
L ------ A
Fig. 8-2
8-2-2 VOLTAGE FLUCTUATIONS UNDER LOAD
When load current -s flows from the electric equipment to the generator. the magnetic flux which is produced ascurrent
.s flows in the main coil. this servesto increase current ‘$ flowing in the capacitor coil. With current @increased. the
magnetic flux density acrossthe rotor core rises. As a result. the current flowing in the field coil increases,and the genera-
tor output voltage is prevented from decreasing.
-15-

8-2-3 DC OUTPUT
DC output is taken out from the main coil and is fed to the
diode at which time the output undergoes full-wave recti-
fication prior to being supplied to the load connected to
the generator. The diode rectifier works to allow the cur-
rent to tlow in @ direction but does not allow the current
to flow in s direction asshown in Fig. S-3.
Fig. 84 shows the DC output circuit of the generator.
DC voltage is generated in the main coil; when the voltage
in A is higher than that in C. current !~flows in the direc-
tion shown in the figure while no current flows between C
and B becausecurrent is cut off by the diode D2. Contraq
to the aforementioned, if the voltage in C is higher than that
in A, current a flows in the direction as sholvn in the
figure. with no current flowing between A and B. This is
becausethe diode Dl cuts off the current between A and B.
As a result. voltage generated between the DC terminals has
a waveform with t\vo peaks in one cycle. as in the caseof
the output waveform shown in Fig. 8-5.
BETWEEN A AND B
BETWEEN C AND B
=w=
MAIN B
COIL
Fig. 8-3
Dl +
Fig. 8-4
OUTPUT WAVEFORM
CURRENT 0
FLOWING CURRENT @
FLOWING
BETWEEN BETWEEN
AAND B
CAND B
Fig. 8-5
- 16 -

9. OPERATIONAL LIMITS OF THE GENERATOR
9-1 AC OUTPUT:
Electric appliances normally have rating labels, showing the rated voltage. frequency. power consumption (input power).
and other listings.
The input power specified on such labels is what is required to drive the appliance.
When an appliance is to be connected to the generator. the power factor. starting current. and other factors of the appli-
ancemust be taken into account.
9-l-l NET RESISTANCE LOAD:
Incandescent lamps. electric heaters, etc.. can be run off the generator if its capacity matches the total of the respective
appliances. Each of these appliances normally have a power factor of 1.O.
Example : This generator can provide enough power to operate five 1OOWincandescent lamps.
9-l-2 ELECTRIC APPLIANCES WITH A POWER FACTOR LESS THAN 1.0:
Fluorescent lamps and mercury lamps normally have a low po\ver factor. Therefore. the generator is required to generate
approximately 1.2 to 2 times the power consumed by each load appliance.
Example: With this generator. three to five 8OWmercury lamps can be operated.
9-l-3 MOTOR LOAD:
Generally. motors require a large starting current every time they are started. Therefore. when the generator is used to run
a motor, the greatest motor starting load is applied.
The rates of power supply which the generator is required to produce for motor loads. are categorized into two sections.
depending on the types of motor and load conditions at time of starting.
1) Motors (mainly rectifier motors) used for electric drills and similar devices:
Sormally, the motors used for electric drills and similar appliances require the generator to produce approximateI>- I.1
to 3 times the power consumed at time of starting.
Example: To drive a 2OOWelectric drill. a generator with capacity of about 300 to 600W is necessary.
2) Motors (mainly induction motors) used for pumps and compressors:
Pump and compressor drive motors require the generator to produce 3 to 5 times the power consumed when they are
running. at time of starting. This is becausethese motors have loads w-henthe>-start.
Example: To drive a 2OOWsubmersible pump. a generator with a capacity of approximately 600 to IOOOWis neces-
sary.
-17 -