Instruction/ maintenance manual of the product R600 Subaru Robin Power Products
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. Model.
CONTENTS Section Title Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. SPECIFICATIONS .......................................... 1 PERFORMANCE CURVES .................................... 2 2-1 AC Output .......................................... 2 2-2 DC Output .
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 . . . . . . . . . . . . . . . . . . . . . . . . .
1. SPECIFICATIONS Model R600 Engine: i Type Forced air-cooled, 4-stroke, side valve, gas01 ine 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.
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.
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 1 2 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.
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 .
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.
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.
” - . . . - . . - - 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.
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.
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.
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 keeps the body temperature lower for greater safety and extends service life.
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 pover transistor impulses controlling the current.
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 permane.
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 as shown in Fig.
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.
9-l-4 IN THE SITUATION THAT POWER CONSUMPTION IS NOT SHOWN ON THE RATING PANEL: Occasionally. the rating panel of an electric appliance does not carry its power consumption but only shows the mechanical equivalent to the power consumption. In such a situation.
9-2 DC OUTPUT When the generator is employed to recharge batteries. care must be exercised about the specific gravity of electrolk-te rn each batter. case. 9-2-l MEASURING THE SPECIFIC GRAVITY OF ELECTROLYTE: The specific gravity changes with temperature; therefore.
9-3 SIMULTANEOUS USE THE AC/DC OUTPUT If you use the AC’DC output simultaneously in this generator, be careful not to exceed the total power consumption.
10. MEASURING PROCEDURES AC VOLTMETER DC VOLTMETER 10-l METERS 10-1-l VOLTMETERS Both AC and DC voltmeters are nesessar! . The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows: 0 to 1 SOV: Type with an output voltage of 110 or 12ov 0 to 300V: Type with an output voltage of 220.
10-l-4 CIRCUIT TESTER A circuit tester is used for measuring resistances and others. Fig. 104 10-l-5 MEGGER TESTER To measure the insulation resistance of the generator. Use voltage capacity of 5OOV. Fig. 10-5 10-l-6 TACHOMETER Use the contact-less tl pe tachometer.
10-2 MEASURING AC OUTPUT SWlTFf; LOAj TOACd+)@ km77 With the circuit shown in Fig.lO-7.measurement 1s made of the AC output of the generator. An electric heater or an in- candescent lamp with a power factor of 1 .O is suitable as a load for the generator.
10-4-1 STATOR Measure the resistances the stator and the core. betlveen red coupler leading from Fig. lo-10 1 O-4-2 ROTOR d Measure the insulation resistance across one of the soldered terminals of the rotor and the core. Fig. 10-11 10-4-3 CONTROL PANEL Measure the insulation resistances between the live parts and the grounded part.
-- 11. FUNCTIONAL CHECK of EACH COMPONENT 11-l CONTROL PANEL 11-l-l ENGINE SWITCH Using the circuit tester. check continuity across the black and green top terminals of the 6P coupler. When continuity between the termmals is confirmed with the engine switch turn2d off.
11-1-4 AC RECEPTACLES Using the circuit tester. check continuity between the tvo terminals at the rear of the XC receptacles while the receptacle is mounted on the control panel. When continuity is confirmed between the output terminals of the receptacle Lvvlth a vtre connected across these terminals.
11-2 STATOR Measure the resistance of each stator coil using the circuit tester. Classified coil I Main coil : Condenser coil I ! I I Cord color of @ AC coil For use with the I frequency meter / DC co.
FL?. 7 l-7 Fig. 1 l-8 Fi:g. 1 l-9 Fig. 11-10 -28.
Table 1 l-2 Fig. 11-11 NOTE 1: Measure the resistance of each coil winding while the diode and each resistor are disconnected with the/r solder removed. NOTE 2: If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous read- mngs.
11-5 CONDENSER Measurement of capacity substitutes for checking the condenser. The capacity of the condenser cannot be measured by using the circuit tester. Therefore. the generator is run with a new condenser to see whether or not the generator performs normally.
- *- 12. DISASSEMBLY and ASSEMBLY 12-1 PREPARATION and PRECAUTIONS 1) Be sure to remember the locations of individual parts when disassembling the generator so that the generator can be reassembled correctly. Tie tags noted with the necessary information to facilitate easier and smoother reassembly.
12-3 DISASSEMBLY SEQUENCE I I Sequence Part to remove I Description Precautions Necessary tools 1 Side cover (Lj (1 j Remove both the left and right ! 2 PlUj screw- and (Rj co-2rs.
Sequence Part to remove Description Precautions Necessary tools 6 Rear cover ( 1) Remove the rear :over at the 1Omm box opposing sid2 of the control spannsr pan21 by unscrewing th2 four I $16 flange bolts. 7 Fuel tank (.I) Loosen the set screw of th2 ,z Plus screw- strainer shaft at th2 rear of the driver engine control switch.
Sequence 1 Part to remove Description Precautions Necessary tools 12 Bas2 platz (1) Remove one set screw of the T Plus screw- earth wire which grounds the ; u driver rear housing and base plate I togethsr (Zr)OV system onlv). I (2) Rsmove four 5115 x 10 bolts from j under the base plate.
Sequence Part to remove 16 ’ Rotor assembl) Description (1) Fit the rotor puller to th2 rotor shaft. and drive it into place to Precautions ! Necessary tools ’ Rotor puller remove the rotor from the engine shaft. Plastic hammer 1; Plug cap (1 j Remove the plug cap from th2 spark plug in advance.
Sequence 20 Part to remove Governor and related parts Description (. 1) Remove the governor lever from the governor shaft. (~j Remove the governor rod, rod spring.
Sequence Part to remove Description I I Precautions Necessary tools 28 ’ Camshaft (1) Pull out the camshaft from the Set the crankcase crankcase. sideways so that it will not fall i and damage the ! tappets. 29 ; Tappets (1 j Remove the tappets from the I crankcase.
12-4 ASSEMBLY PROCEDURE 0 Precautions in Assembly 1) Thoroughly clean each part. When cleaning. take special care for the piston. cylinder, crankshaft, connecting rod, and bearings. 7) Be sure to completely remove the carbon deposits on the cylinder head and piston head.
l Tolerances of Newly Installed Parts Thrust directional tolerance between the cylinder and piston skirt 0.008L - 0.047L I I Top ring ! 0.2L - 0.4L Clearance of piston ring joint Second ring 0.2L - 0.4L ’ Oil ring ! 0.05L - 0.25L 1 Spare rings Top ring 0.
STD EQUIPMENT ! SPARE PARTS - Top ring ’ Taper Second ring Taper ‘ Oil ring I Fig. 72-72 Taper I . ‘, x. Undercut :. q . . 1244 INSTALLING THE CRANKCASE 1) The connecting rod is put into the cylinder while holding it with the piston ring guide.
12-4-6 INSTALLING THE TAPPETS and CAMSHAFT Install the tappets. and then the camshaft. NOTE: Align the timing mark at the base of the cam gear with the timing mark of the crank gear. If the valve timing is set incorrectly, the engine will not run or operate proper- ly.
*Shown in Fig. 12-18. is the method to measure the side clearance of the crankshaft. According to this method, measure the clearance between the machined face of the crankcase and the adjusting collar.
12-4-9 TAPPET ADJUSTMENT Set the tappet at 1112 loa-est position to depress the valve. Then measure the clearance between the valve and tappet stem. using a clearance gauge inserted into the clearance. (See Fig. 12-21.) NOTE: As with the intake and exhaust valves, the clearance between the valve and tappet stem must be within 0.
12-4-13 INSTALLING THE HEAD COVER The head cover is installed over each of the left and right parts of the c>-linder head. using the 345 x 1Omm screws. 124-14 INSTALLING THE GOVERNOR and RELATED PARTS Model EYOSD has a centrifugal iveight type governor which is installed while engaged with the governor gear.
. *. 124-16 INSTALLING THE CENTER BAFFLE and FRONT HOUSING 1 j Set the knock hole of the front housing to the knock of the main bearing cover and assemble them together. During assembly. place the center baffle between the main bearing cover and front housing.
12-4-23 RUBBER TUBES for USE as AIR VENTS Connect two rubber tubes to the air vent connectors of the carburetor. Keep theje rubber tubes suspended downward from the air vent connectors. 12-4-24 INSTALLING THE BASE FRAME 1) Install the base frame with its rear side facing the welded nut area of rubber mount (A).
3) Align the mounting holes at the lateral side of the front cover with those in the bracket which are bolted to the fuel tank. Then. install the fuel tank. using tvo $16 x Emm flange bolts. 4) hlake sure that the flexible shait on the control dial side is inserted in the square hole of the strainer shaft.
12-5 CABURETOR 12-5-1 FUNCTION and COMPONENTS (See Fig. 12-28) 1) Float system The float chamber is located direct& under the carburetor. Flat and needle valves. maintain a constant id level inside the float chamber. The fuel in the tank tlovs into the float chamber from the needle valve.
2) Pilot jet nozzle system The pilot jet nozzle system controls the fuel supply for engine speeds ranging from idle to low-speed running. The sytem operatzs with the fuel flowng through the main jet nozzle and up to the pilot jet nozzle where the tuel is measured.
5) Float system Pull out tloat pin (13) and remove float (I 1 j and needle valve (,30). * Avoid using a drill or a wire to clean the fuel passages (they map damage the orifice of the pilot and main jet nozzles’).
13. TROUBLESHOOTING DIAG: DIAGNOSIS 8 DIAGNOSIS BY THE CUSTOMER 0 DIAG. 01 Engine fails to start. ?- -) DIAG. 02 Electricity not generated. If the generator doesn’t perform properI>- or fails to run after troubleshooring. ask a qualified service dealer to check it.
DIAG. 12 I 1 DIAG. 13 Engine fails to stllrt Check spat k Engine fails to St;lrt Check fuel quality Engine fails lo start Check fuel quentity Spark is too weak of wire harness L1 Parts I Fuel tank Fue.
--- -. Sym(~lollls _. . .- P0ssil1lc CilllSCS ___-. -_. SI icky I 8 I _--.. I ,. (Ilwck lllc I gaskcl (‘heck -r - ] . . --. .--- Lhlllil#Xi gasket OI ovcrst poke rmgc -- 1 Mcasurc dcglcc 111 lcvcl11css . -_- I -_ - ..- Not level Grmcl lhc end ol' lhc wlve ;1nd F atljllsl IllC iappct Spa"" _ .
---.- r -.. -_ ,, .- DIAC. 18 -1 -71 Ll Syrnplorns . .-- -- -,. T I PiIrIS - .- t- -_ .- - -I No I’ucl t’lows OUI CVCII wlwn Ill0 I’IICI t-tiigitic I’uils IO ~1211 pipe is diswrinccl- Pucl tlow II01 ClllCl irllo llic ~;II~~III~~~I cd' flOll1 the c;lrhrelor L- ? -.
rl Syl~lploms - (‘twk (Tly lo 111ovc) -._ I --. (‘heck __ 1 ,_-. .,- --.I.--- Measure the tloar hcighl. The stmit’i- cnt ion is IS 3 111111 t’l0111 body (‘tlcck.
-. -. . . !I Synlplollls Excessive noise Possihtc l r CBUSCS . . ..,.- it2 .- ._- ..-. L -._ lJxcossivcly wortl Li sliding paris (llsc ol’old oil) -. ‘1 --- Cheek lhl! COIll- I prcssion To 111 AC. t 5 or lb ----- I Excessively worn sliding parts ((‘tlilllgC the oil) Check 1 tic COIU- prcssioii To DIAG.
r: Sylllt~IolnS ,, ._-. - ._ I’ossiblc I.. 1 C'Il1sw L -.,...- ._- C'tlccking crileria -- Noise protlucctl and _- I -- Scizurc 01 d;magc ot' ltic piston 01 connecliiig rod - __.. -.. I .- _ .,,. (‘llcck I j ..- .-.. ‘, Scizut c OI' tlillllJlgC 01‘ I tic piston 01 connecling rod --I .
Hnginc Ir011hlc Ll Excessively Wtlilc t’~jlllcs Iqo luhri- protlucctl citlirig oil co~~suriiption --- _ -. _..-- I -. WOlIl Ollf III- Sticky - 1 .' I .
MAC. 36 I - ----I rncler I;lilS IO StlOW the needle res(ilig (‘or~lrot /XlIlCt Ttlc pilot light I;lilS 10 light Op. -- . _ _.. _ ._ -- 7 I I - Sylllptl~llls .
Kerr1cdies I I To DlA(;. 40 I Mcasurc AC outpul EXAM I AC voltage is low by Vc~y low 01 rlotIIing? hginc is opcr;rtirrg well MCISIJW AC output Measure DC OIII~UI EXAM 1 .
Sylllpllm .--.. - [_1, I~eiiiedies .-, L. L 1 Slulor IX1 coil I --.. .- I Wire hrokcn OI shor INi Measure Ihc rcsisl- cliodc terniinds of Wllerl 42 . . . Wire blokcn WllCll OS2 . . . Stlortcd The diode is tlct’cctivc - --I... . Measure ~IIC tesislance (;wwis the lcrniinas) Circuil leslcr -_ ,.
--. --.- -.... ..- r1 Symptoms -- . r] PiirIS .-. . IN’%, higher or more IX: is output i l+rigirie running speed is high ..__ T -. A . . -.. . - 1 -. - .._-J- ! 1 SlillOr coiidenser coil -.- ._, T L.- -.-. r 1 Condenser r -,..-. ..,, .._- -r _I. .- L 1 Staler tllilill coil -7’ --- - _-_- Wire broken OI shortctl 1 ,, r I-z .
__--. ,. r .- - - --‘-‘-- A(: OUllW1 VOlliIgC is only 20f% ol’ lhc ralcti value ._ ._ ,1 Rotor c (lonclenser _._- --..- u Pitrls hgine The cnginc speed is lower than norrrial ---I- - -7 The coil is shortcd - ----‘T’ _ -- Shorting 0I’Ihe coil rotor resistor .
--- Sylllpll~llls ..- I I T” - Possible ! C3IISCS ---- - _- -- Iiems lo CllCCk ;I1111 produie ._- -.. _ C’hecking CrilL’riil -. - J Dcl’ective selliiig ol’ the governw lever illld level shnl’t I .- --.-.. --- _..-- -- Check ihe set posil ion --- _-_.
._.- Possible r1 C’I 11 scs L __ .-._ ,,, ..--. I (‘hccking crilcriil . .- ..-. Ikt’ecl ivc sell irig -_. --- I -.- Check the SCI t ing I EXAM 54 -7 A - .- I ~-.- The goveinor is in- correctly set, iulcr- f’eriiig with lhc lhrolllc valve’s opciiing.
- _ --. ..- ..---- -- .---- .-.- l I. r 1 ldeclric lid ---I-- -- .__ L-.-. i, Spark plug -- r--- l .._ -I -.....- L 1 Cnrburctor ___-_ .-- I __I ._-- Cylinder heiltl I 1 hind cylinder _. -. .-. _. ._ .- 1 ,_______ -l.---. I 1 (‘ylimler licad rnul’fler .
I No trutpu1 Poor No comprcs- pdorniancc -. , , siou Backl’irc Poor Misfire or cond~~stion performnnce ou,side the L..- - .J L- .-,--J L_-+ Moisture in fuel 1 Check (Inside of cilrhl~riltl~r cliambcr) Dcfccl ivc soldel 7 -- T Rich niix- lure. -r -_ -- - Possihlc CilllSCS I , .
14. CRITERIA TABLE for ADJUSTMENT I terns of adjustment Criteria , Limit of application Description Tools Remarks Levelness of cylinder head Below 0.1 0.15 Surface plate and searcher Repalr I Cylinder lnslde dia. Seat width of Intake and exhaust valves 510+o.
Items of adjustment I I I Criteria , limit of application Description Tools Ramarks I 1 Crankpm outside dia. , 19.920 ! Mtcrometer Replacement Crankshaft 1 Generator 20e, -0.003 ! Crankshaft side -0.012 19.950 I Micrometer Replacement journal outside dia.
Items of adjustment (Tightening torque) Criteria Limit of ’ application Description ’ Tools 1 Connecting rod bolts 60 -80 kg-cm I Main bearing cover bolts 80-100 [ Cylinder head bolts go-110 I I S.
15. WIRING DIAGRAM RECTIFIER CIRCUIT BREAKER MAIN COIL r ----- +----- AC RECEPTACLE ril _---- FIELD COIL CONDENSER COIL It-J / CONDENSER 4 [DARK BL”E,’ 4 FM ’ ’ FREQUENCY (DARK BLUE1 1 METER r.
16. MAINTENANCE The following standard maintenarxe procedurss are necessary to ensure th 2 generator’s normal performance under normal operating conditions. Therefore. the mstructions described below are for ref2rence only and varl- depending on how th2 generator is operated.
16-4 CHECKS and MAINTENANCE for EVERY 200 HOURS (monthly) Check and maintenance items Description (1 j Drain the oil from the crankcase and replace with (1) The us2 of contaminated oil will subject parts to new oil. (every 100 hours) excessive wear. (2) Clean the fuel strainer and the fuel tank interior.
R&&I Generator.
R -America, Inc. 940 lively Blvd. Q Wood Dale, 1160191 ● Phone: 630-350-8200 ● Fax 630-350-8212 e-mail: sales @robinamerica.com ● wwwrobinamerica.
An important point after buying a device Subaru Robin Power Products R600 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Subaru Robin Power Products R600 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Subaru Robin Power Products R600 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Subaru Robin Power Products R600 you will learn all the available features of the product, as well as information on its operation. The information that you get Subaru Robin Power Products R600 will certainly help you make a decision on the purchase.
If you already are a holder of Subaru Robin Power Products R600, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Subaru Robin Power Products R600.
However, one of the most important roles played by the user manual is to help in solving problems with Subaru Robin Power Products R600. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Subaru Robin Power Products R600 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
