Robin R650 User manual

Generator
TechnicalData&OverhaulInstructions
SERVICE MANUAL

CONTENTS
Section Title Page
1. SPECIFICATIONS ....................................... 1
2. PERFORMANCE CURVES ................................ 2
2-1 ACOutput ........................................ 2
2-2 DC Output ........................................ 2
3. FEATURES ............................................ 3
4. GENERAL DESCRIPTION OF THE GENERATOR ............ 4
4- 1 Component Identification ............................ 4
4-2 Location of Serial Number, Specification and
Specification Number. ............................... 7
5. CONSTRUCTION AND FUNCTION OF THE GENERATOR ..... 8
5-1 Construction ...................................... 8
5-2 Function of Each Component ......................... 9
5-3 Description of Generator Operation ..................... 12
5-4 Electronic Ignition System ............................ 14
6. SAFETY PRECAUTIONS .................................
15
7. RANGE OF APPLICATIONS .............................. 16
7-1 ACOutput ........................................ 16
7-2 DC Output ........................................ 18
8. MEASURING PROCEDURES ................ a. ............ 20
8-1 Measuring Instruments ............................... 20
8-2 Measuring AC Output ............................... 22
8-3 Measuring DC Output ............................... 22
8-4 Measuring Insulation Resistance ........................ 22
9. CHECKING FUNCTIONAL MEMBERS ...................... 24
9-1 Control Panel ...................................... 24
9-2 Stator ............................................ 26
9-3 Rotor ............................................ 28
9-4 Ignition Coil ....................................... 29
9-5 Condenser ........................................ 29
9-6 Diode Rectifier. .................................... 29
9-7 Micro-Switch ...................................... 30
10. DISASSEMBLY AND ASSEMBLY .......................... 31
10-1 Preparation and Precautions ........................... 31
10-2 Special Tools for Disassembly and Assembly .............. 31
10-3 Disassembly Sequence ............................... 32
10-4 Assembly Procedure ................................. 47
10-5 Carburetor ........................................ 58
10-6 Frequency Changeover System ......................... 61

Section Title Page
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11- 1 Engine does not start or engine does not run normally. . . . . . . 63
11-2 Voltmeter does not work or pilot lamp does not turn on.
No AC output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11-3 No DC output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11-4 0utput voltage is normal at no-load,
but generator won’t work on-load. . . . . . . . . . . . . . . . . . . . . 69
12. CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12-1 50Hz/GOHz Variable Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12-2 60Hz-120V Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1. SPECIFICATIONS
ENGINE I Type 1 Forced air-cooled, &troke, side valve,
I gasoline engine
I Displacement 78 cc (4.76 cu. in.)
, Fuel tank capacity 1 2 lit. (0.53 U.S. gal.)
I
Oil pan capacity I 350 cc (0.75 U.S. pints)
Ignition system I Solid state ignition
Starting system Recoil starter
Rated continuous ( Approx. 4.5 hours (50Hz)
operating hours Approx. 4.0 hours (60Hz)
GENERATOR Type I 2-pole revolving field type
Exciting system Self-exciting
I
: y regulating 1 Condenser type
aximum output I 55OW/65OW 650W
I
Rated output 45ow/55ow 550w
I
AC frequency I 50Hz/60Hz 60Hz
AC voltage I 110,220,24OV 12ov
DC output 12V-1OOW (8.3A)
AC receptacle Standard: 2 ea.
1 (Special: 1 ea.)
I
DC terminal A couple
Over current
protection 1 Circuit breaker
I
Voltmeter Standard
Pilot lamp Standard
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 CURVES
2-l AC OUTPUT
HZ
>
2
i
W
a
LL
I
v
W
>
a
!i
2 t
62
61
60
59
52
51
50
49
240
230
220
210
w
I
5
“c
2
600
500
400
300
”
0 0.5 1 1.5 2 2.5
CURRENT - A
. 50Hz/60He220V Type
OUTPUT
Max. . . . 550W/50Hz, 650W/60Hz
Rated . . 450W/50Hz, 550W/60Hz
200
100
2-2 DC OUTPUT
18
16
14
12
10
a
HZ
4
w
62
; 61
a
LL
i
60
59
v
w 130
z
I
120
5 110
2
’ 600 W
500
t
400
300
‘200 z
5
100 0
n
0 1 2 3 4 5 6”
CURRENT - A
l 60 Hz- 12OV Type
OUTPUT
Max. . . . . . . . . . . . . . . .65OW
Rated . . . . . . . . . . . . . .55OW
Rated voltage ............. 12V
Rated current ............ 8.3A
Rated output ............ 1OOW
0 1 2 3 4 5 6 7 8 9 10
CURRENT - A
-2-

3. FEATURES
l Exhaust Fan Cooling System for low body temperatures, low noise, longer engine life and reliable per-
formance.
0 Large 78 cc 4-Stroke Engine provides enoughpower for constant 55OW(at 60 Hz) rated output.
0 Simple One-Touch Engine Control Switch with the engine and fuel on/off leversand choke all integrated
into one switch.
0 Easy and Reliable Starting with pointless ignition. This generator is also a brush-lesstype generator for
maintenance-free operation.
l Simple Designfor acleanappearanceand easymaintenance.
0 Compact and Lightweight with an easyone-hand carrying handle grip. This generator also offers a high
power-to-weight ratio and economical operation.
0 Circuit BreakerProtection for safeoperation. Replacement of fusesisnot necessaryin caseof anoverload.
0 Unique Dual Output Design so that two separateA.C. and D.C. electrical appliancescan be used at the
sametime.
0 Frequency ChangeoverSwitch enableschangingoutput frequency from 50 Hz to 60 Hz.
0 Optional Oil Warning System automatically stops the engine if the oil level drops below the lower limit.
(Factory Option)
0 Resistor Spark Plugis usedasstandard to prevent radio frequency noise.
0 Standard Tools areattached in the baseplate for easymaintenance.
0 AC Voltmeter is astandard equipment for monitoring output voltage.
-3-

4. GENERAL DESCRIPTION OF THE GENERATOR
4-1 COMPONENT IDENTIFICATION
HANDLE
MUFFLER COVER
MUFFLER
ENGINE
Fig. 4- 1
FUEL TANK
AIR CLEANER
AIR CLEANER COVER
GENERATOR
Fig. 4-2

RECOIL STARTER
FREQUENCY ADJUSTING UNIT
(60Hz:120V TYPE1
Fig. 4-3
MUFFLER COVER
FREQUENCY CHANGEOVER UNIT
l50Hz~60Hz VARIABLE TYPEI
Fig. 4-4
-5-

FRONT HOUSING
RECOIL STARTER
CARBURETOR
Fig. 4-5
RUBBER PIPE
(FOR AIR VENT)
:E WIRE
BASE PLATE
Fig. 4-6
-6-

4-2 LOCATION OF SERIAL NUMBER, SPECIFICATION AND
SPECIFICATION NUMBER
The serialnumber is stampedon the crankcaseat the opposite sideof the carburetor and alsostampedon the
label stuck abovethe oil filler cap.
The specification and specification number areshown on the nameplatelocated on the rear cover.
Always specify these numbers when inquiring about the generator or ordering parts in order to get correct
parts and accurateservice.
SPECIFICATION
SPECIFICATION NI
SERIAL NUMBER
Fig. 4-7
-7-

5. CONSTRUCTION AND FUNCTION OF THE GENERATOR
5-l CONSTRUCTION
FUEI TANK -
SPARK PLUG
THROUGH BOLT \ CYLINDER
CRANKCASE
RECOIL STARTER ,
IR n_ \ iI ~!ll::iill:!;ill:;il!l,
CRANKSHAFT
BALL BEARING ’
\ ’
FIELD COlL \
FIELD CORE STATOR CO IL STATOR CORE COOLING FAN VIBRATION ISOLATOR
Fig. 5- 1
-8-

5-2 FUNCTION OF EACH COMPONENT
5-2-l GENERATOR
(1) STATOR
The stator consistsof a laminated silicon steelsheet
core, a main coil and condenser coil which are
wound in the core slots.
AC and DC output aretaken out from the main coil.
(DC output is taken out from the part of main coil
which isin the middle of the main coil.)
The condensercoil excites the stator field coil which
generatesAC output in the main coil.
(2) CONDENSER
REAR HOUSING 4 . STATOR
Fig. 5-2
The condenser is mounted on the rear housing andis connected to the condensercoil which is wound in the
stator. The condensercoil magnetizesthe rotor which increasesthe density of magnetic flux.
(3) RECTIFICER
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.
(4) ROTOR
The rotor consistsof alamination silicon steelsheet
core and field coil which iswound over the core.
DC current in the filed coil magnetizes the steel
sheetcore.
Two permanent magnetsare provided at 90 degrees
from the poles for the primary exciting action.
A securelymounted fan is pressure-fitted on the end
of the rotor shaft to cool the individual coils, iron s
cores,rectifier, and other integral parts.
Cooling air from the fan is drawn in from the venti- I
lation vents in the rear housing, and is discharged
from the exhaust port in the front housing.
Fig. 5-3
(5) CONTROL PANEL
The panel on the front of the housinghasarecepta-
cle with a ground terminal and AC output is taken
out with amale plug.
DC output is taken out from the red (positive: +>
and black (negative,-) terminals.
Control switch, circuit breaker, voltmeter and pilot
lamp areinstalled on the control panel.
Fig. 5-4
-9-

5-2-2 ENGINE
(1) CYLINDER and CRANKCASE
The cylinder and the crankcaseof the engine are of a one-piecealuminum die-castdesign.The castiron cyl-
inder liner is molded inside the cylinder. Both the intake and exhaust ports arepositioned at the lateral side
of the cylinder and these parts are formed by using a mold with die-cast cores.The crankcasehas its joint
face located on the generator side.
(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 enginecanbe inspected.
(3) CRANKSHAFT
The crankshaft is constructed of forged carbon steel. The crankpin is induction-hardened and hasa press-
fitted crank gearlocated on the generator sideof the engine.
(4) CONNECTING ROD and PISTON
The connecting rod is constructed of forged aluminum alloy with both the large and small ends utilized as
bearings.The oil scraper and large end cap are molded together. The aluminum alloy castingpiston hastwo
compressionrings and one oil ring.
(5) CAMSHAFT
The camshaft is constructed of special cast iron and has intake and exhaust valvedrive cams,eachof which
engageswith the cam gear. An exclusive aluminum alloy isusedon eachend of the camshaft in the place of
bearings.
(6) VALVE ARRANGEMENT
The intake valveis installed at the oil port sideand the exhaust valveat the generator side.
(7) CYLINDER HEAD
The cylinder head is die-cast aluminum and has Ricardo type combustion chamber featuring greatervolume
capacity for improved combustion efficiency. For easierspark plug maintenance, the cylinder head isposi-
tioned at an angleto allow greater access.
(8) GOVERNOR
The centrifugal weight type governor ensures constant engine speed, regardlessof load fluctuations (the
governor ismechanically linked to the governor drive gear).
(9) EXHAUST FAN COOLING SYSTEM (See Fig. 5-5.)
Instead of blowing outside air on the engine, the Exhaust Fan Cooling Systemof 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.
(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 movesup and down and the oil scrapermovesin conjunc-
tion with the connecting rod movements to scrapeup oil in the crankcaseand splashit over the surfacesof
the moving and sliding parts.
-10-

(11) IGNITION
A flywheel/magneto igntion system is employed with the ignition timing set at 23” before top deadcenter.
The magneto is composed of the flywheel and ignition coil with the flywheel mounted on the rotor shaft.
The ignition coil is fitted to the front housing.
(12) CARBURETOR
The horizontal draft type carburetor is installed so that the engine will provide excellent starting, good ac-
celeration, low fuel consumption, and superior output. [For details concerning carburetor construction, see
the paragraphdealingwith carburetor construction and disassembly/assembly(Page59).]
(13) AIR CLEANER
The air cleaneris asemi-wet type and contains aspongeelement.
Fig. 5-5
-11-

5-3 DESCRIPTION OF GENERATOR OPERATION
INITIAL EXCITATION STATOR
PERMANENT MAGNETO
FIELD COIL
ROTOR
-----
---
DIODE
CONDENSER COIL
L ------ A
Fig. 5-6
5-3-l GENERATION OF NO-LOAD VOLTAGE
1)
2)
3)
4)
When the generator starts turning the permanent magneto built-in to the flywheel, it generates1 to 4V of
AC voltage in the main coil and condensercoil.
The condenser coil is connected to a condenser. So. when a voltage is generated in the condenser coil,
minimum current @ flows in the condenser coil. At this time, small flux is produced, with 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 @ flowing in the condensercoil
increases,with the magnetic flux density of the rotor’s magnetic pole increasingfurther. Also, the main
coil voltage and condensercoil voltage increases.Thesevoltage continue rising asthis processisrepeated.
As current flows in the condenser coil, the magnetic flux density in the rotor changes.AC voltageis in-
duced in the field coil when the magnetic flux density varies.Successively,AC current isrectified by the
rectifiers connected to both ends of the field coil, and DC current @ flows in the field coil. With this
current, the rotor core is magnetized, allowing the generator to output steadyvoltage.
When generator speed reaches 2000 to 2300 rpm (50 Hz specification) or 3000 to 3300 rpm (60 Hz
specification), the current in the condenser coil and field coil increasesrapidly. This actsto stabilize the
respective coil output voltages. If generator speedfurther risesto the rated value, the generator output
voltage will reach the rated value.
5-3-2 VOLTAGE FLUCTUATIONS UNDER LOAD
When load current @ flows from the generator to the electrical equipment, the magnetic flux which is pro-
duced ascurrent @ flows in the main coil, this flux servesto increasecurrent @ flowing in the condenser
coil. With current @ increased,the magnetic flux density acrossthe rotor core rises.As aresult, the current
flowing in the field coil increases,and the generator output voltage is prevented from decreasing.
-12-

5-3-3 DC OUTPUT
DC output is taken out from the main coil andis fed
to the diode at which time the output undergoes
full-wave rectification prior to being supplied to the
load connnected to the generator. The diode recti-
fier works to allow the current to flow in @ direc-
tion but does not allow the current to flow in @
direction asshown in Fig. 5-7.
Fig. 5-8 shows the DC output circuit of the genera-
tor.
DC voltage is generated in the main coil; when the
voltage in A is higher than that in C, current @
flows in the direction shown in the figure while no
current flows between C and B becausecurrent is
cut off by the diode D2. Contrary to the aforemen-
tioned, if the voltage in C is higher than that in A,
current @ flows in the direction as shown 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, voltagegeneratedbe-
tween the DC terminals has a waveform with two
peaksin one cycle, asin the caseof the output wave-
form with two peaksin one cycle, asin the caseof
the output waveform shown in Fig. 5-9.
Fig. 5-7
Dl
+
A
RY
MAIN B
COIL
Fig. 5-8
BETWEEN A AND B
OUTPUT WAVEFORM
BETWEEN C AND B
BETWEEN BETWEEN
AAND B CAND B
Fig. 5-9
-13-

5-4 ELECTRONIC IGNITION SYSTEM
The electronic ignition systemfeatures apower transistor asthe current control element. Therefore, the igni-
tion system is an electronic contact point-free type that operateswith the power transistor impulsescontrol-
ling the current. This system is also called TIC (transistor igniter circuit) and isvirtually free of ignition fail-
ure which generally results from contamination of the contact points, a typical problem with contact type
ignition systems.
Becausethis ignition systemhasno contact points, it is not affected by moisture, oil, dust, or other contami-
nants. As aresult, this electronic ignition systemensuressureandpositive ignition with reduced maintenance.
The TIC mechanism consistsof a transistor-incorporated ignition coil and apermanent magneto built-in fly-
wheel which is press-fitted on the rotor shaft of the generator.
I
IGNITION COIL
IGNITION
TIMING
DETECTING
CIRCUIT
SPARK PLUG
Fig. 5- 70
(1) When the permanenet magneto built-in flywheel starts rotating, power isgeneratedin the primary coil of
of the ignition coil and current flows to the resistor @ .
From the resistor, current flows to the power transistor. With this current, the power transistor turns on,
releasingcurrent @ .This stagecorrespondsto the closing of contact points.
(2) As the flywheel comesto 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 signaltransmitter transistor actuateswith cur-
rent d flowing. When current @ starts flowing, current @ flowing through the power transistor is
cut quickly. As a result, high voltage is produced in the secondarycoil and this voltage is applied simul-
taneously to the spark plug which ignites for ignition. This stagecorrespondsto the opening of contact
points.
-14-

6. SAFETY PRECAUTIONS
1. Use extreme caution near gasoline. A constant danger of explosion or fire exists.
Do not fill the fuel tank with gasolinewhile the engineis running. Do not smokeor useopen flame near
the fuel tank. Be careful not to spill fuel when refueling. If spilt, wipe it and let it dry before starting the
engine.
2. Do not place inflammable materials near the generator.
0 Be careful not to put gasoline,matches, gunpowder, oil cloth, straw, trash and any other inflammables
near the generator.
l Operate the generator at least 1meter (4 feet) away from abuilding or wall.
3. Do not operate the generator in a room, cave or tunnel. Always operate in awell-ventilated area.
Otherwise the enginemay becomeoverheated and also,the poisonous carbon monoxide contained in the
exhaust gaseswill endangerhuman lives.Keep the generator at least 1m (4 feet) away from structures or
facilities during use, and always operate it with the exhaust pipe directed toward the open-air or where
good ventilation is assured.
4. Operate the generator on a level surface.
l Do not operate the generator on ainclined surface.
l Do not move or carry the generator while it isrunning.
5. Do not operate with wet hands or in the rain.
Severeelectric shock may occur. If the generator is moistened by rain or snow, wipe it and fully dry it
before starting.
l Do not pour water over the generator directly nor washit with water.
If the generator is wet with water, the insulations will be adverselyaffected andmay causecurrent le.ak-
ageand electric shock.
6. Do not connect the generator to the residential power source.
This could result in a malfunction of, or damgeto the generator or applianceto which it is connected or
could evenlead to fire.
7. Do not cover the generator with a carton, a box or other cover while it is running.
-15-

7. RANGE OF APPLICATIONS
7-1 AC OUTPUT
Generally, the rated power of an electrical appliance often refers to the amount of work that canbe done by
it. The electric power required for operating an electrical appliance is not always equal to the amount of
work that can be done by it. Electrical appliances generally have a label showing their rated voltage: fre-
quency, and power consumption (input power). The power consumption of an electrical appliance is the
power necessaryfor using it. Whenusinga generator for operating an electrical appliance, however, the pow-
er factor and starting current must alsobe taken into consideration.
Determine the capacity of your generator from the power required for operating electrical appliancesrefer-
ring to the followsing:
(1) Incandescent lamps, hot plates, etc. with a power factor 1.O
Total power consumption must be equal to or lessthan the rated output of generator.
Example: A generator with arated output power of 500W canlight five 1OOWlamps.
(2) Fluorescent lamps, mercury lamps, etc. with a smaller power factor
Select a generator with a rated output equivalent to 1.2to 2 times the power consumption of the load.
Example: A generator with a capacity of 1OOWto 16OWis necessaryfor lighting a 8OWfluorescent lamp.
A generator with arated output of 5OOWcanlight three to five 40W fluorescent lamps.
NOTE: Wattage of the fluorescent lamp generally does not indicate the power consumption but indi-
cates the output of the lamp. Therefore, if the fluorescent lamp has no special indication as to
the power consumption of input power, efficiency should be taken into accounts as explained in
Itern 5 on the following page.
(3) Electric tools, etc. that are driven by a motor
1.2 to 3 times largepower consumption of amotor-driven tool is required for starting. Selectagenerator
with amaximum output 1.2 to 3 times largeto the load.
Example: A 300W motor-driven drill requires a generator with a maximum output of 400 to 9OOWor
more.
(4) Water pumps, compressors, etc. that aredriven by a motor and are initially loaded
3 to 5 times large power is necessaryfor starting. Select a generator with 3 to 5 times large output of
load.
Example: A water pump with apower consumption of 400W requires agenerator with a maximum out-
put of 1200 to 2000W or more.
NOTE 1: Motor-driven appliances mentioned in Items 3 and 4 required the aforementioned generator
capacities only when starting their mo tars. Once their motors are started, the appliances con-
sume about 1.2 to 2 times their rated power consumption so that the excess power generated
by the generator can be used for other electrical appliances.
NOTE 2: Motor-driven appliances mentioned in Items 3 and 4 vary in their required motor starting pow-
er depending on the kind of motor and start-up load. If it is difficult to determine the opti-
mum generator capacity, select a generator with a larger capacity.
- 16-

(5) Appliances without any indication asto 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 electkd amfiance) = (Power consumption)
(Efficiency)
Efficiencies of someelectrical appliancesareasfollows:
Single-phasemotor . . . . . . . . . . . . . . . 0.6 - 0.75
Three-phasemotor . . . . . . . . . . . . . . . 0.65 - 0.9 t The smaller the motor, the lower the efficiency.
Fluorescent lamp . . . . . . . . . . . . . . . . 0.7 - 0.8
Example 1: A 40W fluorescent lamp meansthat its luminous output is 40W. Its efficiency is 0.7 and ac-
cordingly, power consumption will be 40 + 0.7 = 57W.As explained in Item 2, multiply this
power consumption value of 57W by 1.2 - 2 and you will get the figure of the necessary
capacity of a generator. In other words, a generator with arated output of 500W capacity
canlight four to seven40W fluorescent lamps.
Example 2: Generally speaking,a400W motor meansthat its work load is 400W. Efficiency of this mo-
tor is 0.7 and power consumption will be400 t 0.7 = 570W. Whenthis motor is usedfor a
motor-driven tool, the capacity of the generator should be multipled by 1.2 to 3 and 570W
asexplained in the Item 3.
ELECTRIC DEVICES
Incandescent lamp, electric heater, etc.
Fluorescent lamp, mercury lamp, etc.
RANGE OF APPLICABLE LOADS
50 Hz 60 Hz
up to 450w up to 550w
Up to approx. 350W Up to approx. 450W
Motor-driven tools etc. Up to approx. 350W Up to approx. 400W I
Pump and compressor drive motors Up to approx. 15OW Up to approx. 18OW
Table 7- 7
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 (elec-
trical 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 buring it out.
Table 7-2 she ws cables and their allowable current for your reference.
2. Cable length
If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors so
that the input voltage to the load (electrical product) decreases. As a result, the load can be dam-
aged.
Trable 7-2 shows voltage drops per 100 meters of cable.
- 17-