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Robin America R1200 Service Manual

Robin generator service manual
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-J) &ii
Generator
Technical Data & Overhaul Instructions
SERVICE MANUAL

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Summary of Contents for Robin America R1200

  • Page 1 Rozh -J) &ii Generator Technical Data & Overhaul Instructions SERVICE MANUAL...

  • Page 2: Specifications

    This manual was compiled specifications, items, performance, structure, features, and maintenance procedures of the R1200 Generator. We ask each dealer to master the contents of this manual and provide users complete service after sales or proper guidance on how to use this generator.

  • Page 3: Table Of Contents

    Section Title SPECIFICATIONS items ... Performance Curves FEATURES COMPONENT IDENTlFlCATlON FUNCTION OF EACH COMPONENT Generator Engine DESCRIPTION OF MAIN OPERATIONS Electronic ignition Mechanism Description of Generating Operation OPERATIONAL LIMITS OF THE GENERATOR AC Output DC Output Simultaneous Use of AC/DC Output Wire Length MEASURING PROCEDURES...

  • Page 4: Table Of Contents

    Title Section DISASSEMBLY AND ASSEMBLY Preparation and Remarks ... Special Tools for Disassembly/Assembly Disassembly Sequence ... Assembly Procedure Carburetor SAFETY PRECAUTIONS. 10-1 Fire Prevention 10-2 Precautions for Exhaust Gases..10-3 Other Precautions TROUBLESHOOTING CRITERIA TABLE FOR ADJUSTMENT WIRING DIAGRAM MAINTENANCE 14-1 Daily Checks and Maintenance...

  • Page 5: Engine

    DC receptable Over current protection Voltmeter Dimensions (L x W x H): Dry weight R1200 Forced air-cooled, 4-stroke, side valve, gasoline engine 143 cc (8.73 cu. in.) 3.5 lit. (0.93 U.S. gal.) 600 cc (1.28 U.S pints) Solid state ignition Recoil starter Approx.

  • Page 6: Ac Output

    1-2 PERFORMANCE CURVES AC OUTPUT Power Factor ....1.0 1 1 1 1 1 ‘;; -I 0’ & > Current (A)- I I I I I I I I I I I I Current (A) - I -t ii L...
  • Page 7 ;;; I 0” 51 51 50 50 49 49 120-- llOr Current (A)- 61 60 Current (A)- 0” Current(A)- Output Max..1000 W Frequency ... 1000 Voltage ... B 0. Output Max..1200 w Frequency ... 1000 Voltage ... Output Max.

  • Page 8: Dc Output

    -1 0” f E lt 8 2 I Current (A) - DC Output DC output from this generator is rated especially for charging batteries. When the 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).
  • Page 9 FEATURES Weight of this compact generator with excellent portability is 27.5 kg, which means that the generator is the lightest one in this class. 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). The operating system is concentrated on the front panel, which enables users to easily handle this generator.
  • Page 10 COMPONENT IDENTIFICATION Engine Control Switch (CHOKE-RUN-STOP) DC Circuit Breaker rter Recoil Starter crew Ground Terminal Muffler / ,,.,.,rnal) ler / Air Cleaner Cover Fig. 3-1 , Carrying Handle Cover, Spark Plug Tank Cap Fuel Tank Fig 3-2...
  • Page 11 FUNCTION OF EACH COMPONENT GENERATOR 4-l-l STATOR The stator consists of a laminated silicon steel sheet core, and a copper coil wound around the core with a lead wire from which AC and DC The copper wire coil output are taken out. consists of a main coil and a DC coil, and AC output is taken out from the main coil, while DC output is taken out from the DC coil.
  • Page 12 4-l-4 AVR (Automatic Voltage Regulator) This is a device to automatically voltage with an electronic circuit. 4-l-5 CONTROL PANEL The control panel has a double receptacle with a ground terminal, and AC output is taken out with a male plug. DC current is taken out from the DC recepta- cle with a special plug.
  • Page 13 4-2 ENGINE 4-2-l CYLINDER AND CRANKCASE The cylinder and the crankcase of the engine are of a one-piece aluminum die-cast design. The specific iron cylinder is cast-fitted inside the cylinder. Both the intake and exhaust ports are positioned at the lateral side of the cylinder. These ports are also cast die-cast cores.
  • Page 14 4-2-l 1 IGNITION SYSTEM The ignition system is based on a flywheel/magneto system and its ignition timing is set at 230C before top dead center. The magneto consists of a flywheel and an ignition coil. The flywheel (functioning also as a fan) is mounted on the crankshaft, while the ignition coil is mounted on the crankcase.
  • Page 15 DESCRIPTION OF MAIN OPERATIONS ELECTRONIC IGNITION The engine has a current chopping contact point-free ignition system in which a power transistor is used as a current control element. This system is called T.I.C. (Transistor Ignitor Circuit). This electronic ignition system is completely free from ignition failure which generally results from contamination or burning of the contact points, oxydation during storage for a long time, or abrasion of mechanical sections, all of which are typical with contact type ignition systems.
  • Page 16 DESCRIPTION OF GENERATING 5-2-l GENERATION OF NON-LOAD VOLTAGE When the generator starts turning, the permanent magneto incorporated in the flywheel in the engine side starts rotating, which generates voltage in the exciting coil. The voltage, rectified by the diodes in the AVR, causes the flow of the current @through the field coil wound around the rotor in the generator.
  • Page 17 j-2-3 DC OUTPUT DC output is taken out from a part of the main coil and is fed to the diode stack (recti- fier) where the output undergoes full-wave rectification and is then supplied to the load. The diode works to allow the current to flow in the direction @, but does not allow the current to flow in the direction @I, as shown in Fig.
  • Page 18 OPERATIONAL LIMITS OF THE GENERATOR 6-1 AC OUTPUT Electric appliances normally have rating levels showing the rated voltage, frequency, power consumption (input power), and other things. The power consumption specified on such a label is required to drive the appliance. However, when an appliance is connected to the generator, the power factor and starting current should also be taken into account.
  • Page 19 calculate the power consumption of the device involved. The calculated power consumption is adjusted depending on the type of the load, and according to paragraphs from (1) to (3). (Power consumption) = (Mechanical equivalent of a device) + (Efficiency) Efficiency Motors: 0.6 2.
  • Page 20 6-2 DC OUTitJT When the generator is employed to recharge batteries, attentions should be paid to the specific gravity of electrolyte in each battery. 6-2-l MEASUREMENT OF ELECTROLYTE’S SPECIFIC GRAVITY The specific gravity of an electrolyte varies according to temperature; so it is converted to one in case of 200C.

  • Page 21: Wire Length

    WIRE LENGTH When long wires are used, resistance in each wire increases while voltage drop occurs. Consequently, the input voltage to an electric appliance declines, often damaging the appliance. The table below shows that the voltage decreases in 100 m wire with different cross sectional areas and varied resistances.

  • Page 22: Meters

    MEASURING PROCEDURES 7-1 METERS 7-l-l VOLTMETERS Both AC and DC voltmeters are necessary. Measurable range of the AC voltmeter is as follows. 0 to 15OV: For a voltmeter output voltage of 110 or 120V 0 to 300V: For a voltmeter output of 220, 230, or 240V Measurable range for the DC voltmeter is from 0 to 20V.
  • Page 23 7-l-4 CIRCUIT TESTER The circuit tester is used for measuring resist- ance and others. 7-l-5 MEGGER TESTER This unit measures insulation resistance of the generator. Use one with voltage capacity of 5oov. 7-l-6 TACHOMETER Use the contact-less type tachometer. Fig. 7-l-4 Fig.

  • Page 24: Measurement Of Dc Output

    7-2 MEASUREMENT OF AC OUTPUT +ii+~~ To an AC Receptacle Measurement is executed with the circuit as shown in Fig. 7-2. incandescent lamp with a power factor of 1.0 is suitable as a load for the generator. When the AC output measured at the rated load and rated speed is confirmed to be within the voltage range specified in the table below, the AC output is normal.
  • Page 25 7-4-2 STATOR Measure the resistance between the red or white coupler leading from the stator and the core. If there is a section where insulation resist- ance is below 1MQ replace the part because it may cause insulation failure or such accidents as electric shock or leakage.
  • Page 26 FUNCTIONAL CHECK OF EACH COMPONENT 8-1 CONTROL PANEL 8-l-l AC RECEPTACLES Check continuity between the two terminals at the rear of the AC receptacles by using a circuit tester under the condition that the receptacle is mounted on the control panel. When continuity between the output terminals is confirmed with a wire connected across the terminals, and is not confirmed if the wire is removed, the AC receptacle is normal.

  • Page 27: Diode Stack (Rectifier)

    8-l-4 VOLTMETER When AC voltage (1OOV) is loaded between the two terminals on the rear side of the volt- meter, and at the same time, the voltmeter shows the value, the voltmeter is normal. 8-2 DIODE STACK (RECTIFIER) Fig 8-2-l Circuit inside the diode stack is as shown in Fig.
  • Page 28 Whether the AVR is defective or normal can be determined by checking the appearance, measuring the resistance between the lead lines with a circuit tester, or by practically loading it onto the generator. 8-3-l THE CASE WHERE DETERMINATION ACCORDING TO THE APPEARANCE IS POSSIBLE: If some electronic part of the AVR is burnt, has become black, or if epoxy resin on the surface has melted down, it can often be said that the AVR is defective.

  • Page 29: Stator

    STATOR Confirm the resistance between the coupler terminals with a circuit tester. Red 3+-J Orange Q Green @ Coil name Measurement ’ location White @ - Wiring color 50Hz - IOOV 60Hz - 1oov 50Hz - I IOV 60Hz - 1 IOV 60Hz - 120v 50Hz - 220V 60HZ - 220V...

  • Page 30: Rotor

    8-5 ROTOR 8-5-l MEASURE RESISTANCE IN THE FIELD COIL OF THE ROTOR WITH A CIRCUIT TESTER Resistance value 10.7J-z Note 1: Measure the coil resistance between the two slip rings. Note 2: Sometimes the measured values do not match the values shown in the table above because of errors by the circuit tester, unevenness of the coil windings, or peripheral temperatuer.

  • Page 31: Ignition Coil

    8-7 IGNITION COIL Measure resistance in the coil of the ignition coil unit with a circuit tester. Resistance 13K!G? Measure the resistance between the black cord and the high tension cord. Note: The measured value does not always match the values shown in the table above because of errors by the circuit tester, unevenness of coil winding, or peripheral temperature.
  • Page 32 DISASSEMBLY AND ASSEMBLY PREPARATION AND REMARKS Be sure to remember the locations of individual parts when disassembling the generator so that the generator can be reassembled correctly. written in to facilitate easier and smoother reassembly. For more convenience, group the related parts and store them in the same box. To prevent bolts and nuts from being misplaced or installed incorrectly, place them temporarily at their original positions.
  • Page 33 9-3 DISASSEMBLY SEQUENCE Sequence I Part to ! , remove 1 Side cover ! (1) First remove the side ; Rear cover i (1) Remove the rear cover by M8x 10 Screw, Side Cover / Description cover by unscrewing four M5 x 8 screws. unscrewing three MS x 8 screws and two M 8 x 10 screws.
  • Page 34 ’ Part to ! Sequence ] remOve icontrol I(l) Pull the knob of the 1 panel control lever and remove the control panel by un- screwing four M5 x 8 screws. Precautions Description Fig 9-3-2 - 30 - Necessary tools 1 @ Plus driver Knob Control...
  • Page 35 1 Part to Sequence 1 remove i (1) Disconnect the (6P) ( Couplers 1 and plugs generator coupler from , (Discon- ’ the other (6P) coupler extending from the j nection) control panel. / (2) Disconnect the (4P) coupler I of the AVR from the (4P) I coupler extending from the ;...
  • Page 36 Sequence I Part to remove iFront cover (1) Remove the element cover by unscrewing the M6 x 12 screw. I(2) Remove the front cover by unscrewing three M5 x 8 screws. M5x8 Screw (3 PCS.) Description FJ$. 9-3-5 -32- Necessary Precautions tools 0 Driver...
  • Page 37 1 Part to ’ Sequence j remOve Fuel pipe (1) Remove the cap from the ’ fuel strainer and take out ‘and plug the gasoline from inside (Discon- i nection) the fuel tank. (2) With pliers, hold the fuel pipe clamp which is in- serted in the fuel strainer and pull it forward to remove the fuel pipe from !
  • Page 38 Part to Sequence, remove Fuel tank (1) Remove the handle cover I handle by unscrewing the two (2) Pull out the breather pipe I (3) Remove the handle body by taking off the two M8 nuts. i Fuel tank i (1) Remove the two M6 x 12 (2) Remove the fuel tank by Handle Cover M3xlO Screw (2 PCS.)
  • Page 39 Part to ’ Sequence remove i(l) Remove the bracket cover i j$Ez; from the generator by taking out the two M8 x 30 bolts. End cover /(l) Remove the end cover from. the generator by unscrew- i ing the four M5 x 10 screws.
  • Page 40 j Part to 1 Sequence I remOve j (1) Loosen and ’ Rear ‘bracket i (2) Remove the rear bracket, a / (3) Remove the connector of Diode Stack Fig 9-3-9 Description out the take three M6 bracket bolts. tapping it evenly with a ’...
  • Page 41 Sequence I rpearfito~~ i 1 Stator (1) Pull away the stator cover. i (2) Pull away the stator from Description 1 Never pat the wind- ’ plastic hammer the front cover. If it is / ing and the lead. impossible, pull it away tapping outside the core with a plastic hammer.
  • Page 42 Sequence , Part to ’ remove ‘Rotor i (1) Insert a box spanner or a socket wrench between the driver or other tools spanner or socket through bolt and the rotor shaft, and hit it in a clockwise direction with a hammer to loosen the through bolt, thus keeping tween them.
  • Page 43 ! Part to / Sequence j remove ’ j Front (1) Remove the front bracket, i i bracket which is mounted on the main bearing cover of the engine, by taking out four I MS x 18 bolts. Front Bracket Description Precautions Main Bearing Cover...
  • Page 44 Part to i Sequence ! remOve ; I j(l) Recoil mstarter Description Remove the recoil starter by taking out the four M6 x 8 flange bolts. RecoilvStarter Fig. 9-3- 77 -40- Necessary Precautions tools -10 m/m box 1 spanner...
  • Page 45 Part to remove j Sequence 1 Blower i (1) Remove the blower housing The two flange 1 housing from the crank case by taking out the two M6 x 12 1 when the fuel tank flange bolts. !Head cover I(l) Remove the head cover ‘&...
  • Page 46 Description Air cleaner : (1) Remove the air cleaner body, elements, and ele- ment retainer from the cleaner body, by taking out I one M6 x 10 flange bolt. i (2) Remove the air cleaner body from the carburetor by taking out the two M6 x 10 flange bolt.
  • Page 47 I Sequence 1 Part to j - remove i Muffler j (1) Remove the muffler cover ’ I cover from the muffler by taking out the three M6 x 8 flange bolts. Muffler I(1) Remove the muffler from the cylinder section of the crank case by taking out the two M8 nuts and one M6 x 12 bolt.
  • Page 48 1 Part to ’ Sequence 1 remove Carburetor (1) Remove the carburetor from the cylinder section of the crankcase. Starting (1) Remove the starting pully from the flywheel, by tak- PUllY ing out one M4 nut. Insert a box spanner or socket wrench into the nuts of the flywheel and strongly hit it with a hammer, thus re-...
  • Page 49 1 Part to Sequence. remOve I (1) Remove the ignition plug I Ignition 1 plug from the cylinder head. / Cylinder j(1) Remove the cylinder head , head from the crankcase by taking out the eight M8 x 40 flange bolts. I(2) Remove the cylinder head I gasket from the crankcase.
  • Page 50 Part to Sequence remove (1) Pull the camshaft away i Camshaft i (1) Remove the tappets from Tappet Intake Valve Valve Spring, Governor Gear, Description from the crankcase. the crankcase. F&T. 9-3-25 -46- Necessary Precautions Set the crankshaft ; on its side that j it will not fall and damage the tappets.
  • Page 51 Part to Wuence remOve i Connecting i(l) Scrape off the carbon de- : rod and posits from the cylinder : piston and piston head. Then? in j order to remove the two bolts, open the bending section of the connecting rod lock washer.
  • Page 52 9-4 ASSEMBLY PROCEDURE Precautions in assembly Thoroughly clean each part. crankshaft, connecting rod, and each bearing. Be sure to completely scrape off th carbon deposits on the cylinder head and piston head. Also, thoroughly remove carbon deposits from each piston ring groove. Check whether the lip of each oil seal is damaged or not, and if damaged, replace it with a new one.
  • Page 53 HAssembly sequence and precautions 9-4-l CRANKSHAFT Fit the crankshaft oil seal guide onto the crankshaft tip and assemble it with the crank case as shown in Fig. 9-4-l. No te: When the oil seal guide is not used, be careful not to damage the oil seal lip. Mount the woodruff key (for the mag- neto).
  • Page 54 9-4-2 PISTON AND PISTON RING If a ring expander is not available, set the ring joint at the first land of the piston, as shown in Fig. 9-4-4. Then, open the joint wide so that the ring can be slid into the fegular groove. Note: Be careful not to twist or expand each ring too excessively.
  • Page 55 9-4-3 CONNECTING ROD Turn the crankshaft as far as the bottom dead point. Then, set the connecting rod, gently striking the piston head until it touches the crankpin. Set the connecting rod cap according to the rod guide mark. Set the oil scraper in the magneto side. Note: Be sure to use a new lock washer.
  • Page 56 Fi$. 94-7 * Fig. 9-4-9 shows an example of the methods to measure the side clearance of the crank- shaft. In this case, it is measured by measuring the clearance between the pro- cessing face of the crankcase and adjusting color.
  • Page 57 h valve guide clearance WV&e Valve Spring Spring Retainer Valve face angle Valve seat angle Valve guide inside diameter Valve stem outside diameter Clearance between the valve guide and valve stem (clearance between C and D) Valve Face 3=53' Valve Seat Valve Stem Valve Guide Fig.
  • Page 58 9-4-7 TAPPET ADJUSTMENT Set the tappet at the lowest point and push down the valve. Measure the clearance between the valve and the tappet stem, using a clearance gauge inserted into the clearance (See Fig. g-4-12). Note: When the engine is not running, the clearance between the valve and tappet stem must be in the range of 0.110.02.
  • Page 59 9-4-10 IGNITION PLUG * Torque for the ignition plug: 230 ad 250 kg-cm 9-4-11 IGNITION COIL, EXCITING COIL, FLYWHEEL AND STARTING PULLEY Temporarily set the ignition coil and exciting coil in the crankcase and install the flywheel in the crankshaft. Clamp the starting pulley together with the flywheel. Note: Installment should be done after wiping away any oil from the crankshaft and taper section of the flywheel.
  • Page 60 WHanging position of the governor spring Generally, the governor spring should be hung in 1 (See Fig. 9-4-15). Turn the speed control to the high speed side. Check to see that the carburetor throttle valve has been fully opened, and then lock it. Insert a driver into the governor shaft groove and turn it clockwise (until the governor shaft becomes unable to turn) to lock the governor shaft and the governor lever with the governor lever’s locking bolt.
  • Page 61 9-4-14 MUFFLER AND MUFFLER COVER Insert the gasket (exhaust) to the studs of the exhaust flange of the crankcase and then mount the muffler. Install the muffler and the muffler bracket with one M6 x 12 bolt. Secure the muffler cover with three M6 x 8 flange bolts. Muffler <??g?g;/M8 9-4-15...
  • Page 62 9-4-16 HEAD COVER AND BLOWER HOUSING Set the head cover with the M6 x 8 flange bolts (at two places in the generator side). Set the blower housing to the crankcase with M6 x 12 bolts. Note: The two M6 x 12 flange bolts for clamping the blower housing and head cover are used when the fuel tank is installed.
  • Page 63 9-4-18 FRONT BRACKET Match the mounting hole of the front bracket with the inlet port of the engine’s main bearing cover. Torque for the front bracket: Note: Set the front bracket so that the cooling air outlet window in the upper side, and the slit section is positioned in the bottom side. 9-4-l 9 ROTOR Mount the rotor onto the taper section of the crankshaft and clamp it with through bolts.
  • Page 64 9-4-20 REAR BRACKET AND STATOR Mount the diode stack on the rear bracket and combine them with the stator. connecting terminals according to the circuit chart. Note: See 8.2 “Diode stack” 9-4-21 STATOR Holding the rear bracket and stator, fit them to the inlet port of the front bracket.
  • Page 65 9-4-22 BRASH HOLDER Mount the brash holder base on the rear bracket with PI5 x 10 screws. To install the brash holder put the M5 x 20 screw through the brash holder, and turn the screw, keeping it vertical against the slip ring. (See Fig. 9-4-23) Note: If the brash holder is inclined to the slip ring? the brash holder may break when the screw is clamped, or the brash...
  • Page 66 9-4-23 END COVER Set the end cover on the rear bracket with four M5 x 10 screws. 9-4-24 BRACKET (COVER) Mount the bracket (cover) and the spacer on the rear cover and clamp them with MS x 30 bolts. Brush Holde\y Bracket M8x30 iiolt (2 PCS.) M5x20 Screw (2 PCS.)
  • Page 68 9-4-27 FUEL PIPE (CONNECTION) Mount the fuel strainer on the front cover. Note: Mount the fuel strainer with the banjo outlet upward. Insert the fuel pipe into the fuel inlet/outlet port of the fuel strainer and secure it with the clamp.
  • Page 69 9-4-29 CONNECTION OF COUPLER AND PLUG Connect th e coupler (6P) from the generator with the coupler thrusting from the control planel. Connect the coupler (4P) thrusting from the AVR with the coupler (4P) thrusting from the control panel. Connect the plug for grounding. 9-4-30 CONTROL PANEL Thrust the control lever through the control panel and secure it with four M5 x 8 screws.
  • Page 70 9-4-31 REAR COVER Secure the rear cover with SIDE COVER 9-4-32 Secure the cover with four side M8x10 Screw (2 pcs.) three screws and two " I &I8 screws. Rear Cover F&. 94-29 - 6 6 screws.
  • Page 71 9-5 CARBURETOR 9-5-l FUNCTION AND STRUCTURE Float System The float chamber is located directly under the carburetor. maintain a constant fuel level inside the float chamber while the engine is running. The fuel in the tank flows into the float chamber through the needle valve. When a certain quantity of the fuel enters the chamber the float rises and when the buoyancy of the valve balances with the fuelin-flow pressure the needle valve is interrupted to keep the fuel at the correct level.
  • Page 72 Schematic Diagram of the Fuel System By-Pass Choke Pilot Jet Throttle Valve Main Nozzle Pilot Outlet Main Jet Float Fig. 9-5-l -68-...

  • Page 73: Disassembly And Assembly

    9-5-2 DISASSEMBLY AND ASSEMBLY OF CARBURETOR The most common trouble with the carburetor, apart from mechanical ones, is failure to provide the correct air-fuel mixture. This is generally caused by blockage in the air and fuel channels or fuel level fluctuation. In order to maintain the carburetor in a normal operating condition, it is vital to keep the air and fuel channels always clean so that the fuel flows normally.
  • Page 74 Fig. 9-5-2 - 70 -...

  • Page 75: Safety Precautions

    SAFETY PRECAUTIONS 10-l FIRE PREVENTION Keep the generator away from combustible materials during operations, or ground the generator by making use of its grounding terminal. flammable substances. Do not run the generator in an inclined position. Avoid moving the generator while it is running.

  • Page 76: Troubleshooting

    TROUBLESHOOTING Most generator troubles are caused by carelessness in routine handling, insufficient checks, or indifference to a slight trouble. Jn this section the causes and remedies to the major troubles concerning the generator are introduced. different case by case. An operator of this engine, when encountered with a trouble, should determine the cause, supplementing the following criteria with his own experiences, and provide complete countermeasures.
  • Page 77 Starting failure Symptoms Compression is nonexistent Intake/exhaust valve Parts Adjust tappet In case of clearance if the sticking, clearance is supply lubri- different from cating oil the standard onto value value or replace stem or re- place the valve stem. [ A-2 Starting failur;...
  • Page 78 Starting failure Starting failure Symptoms Water or dust is mixed with the Fuel tank is empty fuel Fuel tank, carbure- Water or dust is Fuel tank is empty mixed with the Checking Confirm fuel Check the fuel method In case water or In case the fuel dust is mixed with Checking...
  • Page 79 A-6 Starting failure The fuel does not Symptoms enter into the float chamber of the carburetor ---- 1. If the needle valve is contaminated with dust, etc., clean it. Checking criteria 2. In cast the valve does not work well, replace the valve.
  • Page 80 Symptoms ---- Needle valve Parts (Carburetor) Possible Abnormal - -.-.I operation causes Check the needle Checking method valve 1. When dust, etc. is on the needle valve, clean it. Checking 2. If the valve criteria works abnormal- ly, replace it. _- _..
  • Page 81 A-9 Starting failure Symptoms Sparks do not come out from the tip of the high voltage cord Ignition coil Air gap is too wide. Checking Check the air gap met hod In case the air gap is too wide, adjust Checking criteria Normal : 0.5mm...
  • Page 82 Abnormal Symptoms running Refer to A-2 (Clauses on compression failure) /’ \ Checking method Checking criteria Remedies B-2 Abnormal Overheating and knocking Cylinder, muffler, Check the cylinder Check the cooling head, muffler, and the exhaust hole. In case of carbon In case the cooling deposit, clean it.
  • Page 83 Symptoms 1. Governor spring is defective 2. Hanging posi- tion is not normal hanging posi- tion is not normal. correct In case of fitting failure, correct it. 2. In case the governor spring Is abnormal, replace it. Adjust the hanging Correct fitting of position of the Remedies...
  • Page 84 Symptoms Governor system Mounting failure (Throttle valve does not work normally) --‘I-’ Confirm mounting Checking of the governor methoh system Checking In case of mount- criteria ing failure, adjust it. Adjust mounting Remedies of the governor system B-4 Abnormal running rpm of the engine does not increase Carburetor Intake/exhaust...
  • Page 85 Symptoms Intake/exhaust Parts valve Measure tappet clearance If the clearance is different from the standard, adjus the Checking clearance or rc- criteria place the tappet Normal : 0.1 +O.O2mm Adjust the tappet Remedies clearance or replace the tappet, B-5 Abnormal running Missfire or explosion outside the tube Carburetor...
  • Page 86 Symptoms (Air-fuel mixture blow back to the air cleaner) Intake/exhaust valve Valve opening/ closing timing is not appropriate. ‘7-I Checking Measure tappet method clearance If the clearance is different from the standard, adjust Checking the clearance, or criteria replace the tappet. Normal : 0.1 +O.O2mm Adjust the tappet...
  • Page 87 Piston ring sured values on In case adherence, Checking are not within adjust or criteria replace the piston ring B-8 Abnormal running Consumption rate of lubricating oil is too high _-..- (White exhaust gas comes out) Intake/ex- Gas vent haust valve valve guide In case of...
  • Page 88 B-9 Abnormal running Engine noise is too loud Engine oil Engine oil has not been changed periodically (Abrasion of rub hing section) If the engine oil is conta- bolts and nuts minated or In case the if the engine element has oil has not been broken, been changed...
  • Page 89 Symptoms Voltemeter Voltmeter failure Input AC voltage Checking to terminals in the method voltmeter side -l-- If the displayed value is different from the input value, replace the voltmeter Remedies C-l No voltage is displayed on the voltmeter Brush contact surface of AVR failure 2.
  • Page 90 1. Disconnection 2. Short circuit Measure resistance value between the terminals with a Checking circuit tester method (Measure with a 6P coupler) In case of * $1 . . . Disconnection Checking In case of OS1 . . . criteria Short circuit C-2 No voltage is displayed on the voltmeter...
  • Page 91 Symptoms Parts Stator DC coil Possible 1. Disconnection causes 2. Short circuit Measure the resistance value between the terminals with a Checking circuit tester method (Measure at the section where diodes are connected) In case of OQ . . . Disconnection Oil .
  • Page 92 Symptoms Possible causes Measure resistance between the terminals with a circuit Checking tester method (Measure with a 6P coupler) In case the measured resis- tance is lower than 15% of checking the standard, it suggests a criteria short circuit. Remedies -..
  • Page 93 Symptoms r -. Parts Brush 1. Confirm condition the slip ring’s contact Checking surface method 2. Measure length of the brush 1. If contact surface of the slip ring is contaminated, Checking clean it. criteria 2. If the brush length is shorter than the standard, replace it.
  • Page 94 CRITERIA TABLE Items of adjustment Levelness of cylinder head Inside dia. Seat width of intake Cylinder exhaust valves Inside dia. of valve guide Piston skit-t’s outside dia. in thrust direction Ring groove ’ Second i width Piston Pin hole Clearance between piston skirt...
  • Page 95 Items of adjustment / Crankpin outside dia. ; Magneto side Crankshaft Crankshaft Counter- journal dia. outside side ’ Cam crest Camshaft 1 Magneto side Camshaft journal Counter- outside dia. side Free length Valve ipring Squareness Intake Outside dia. of valve stem Exhaust Intake Clearance...
  • Page 96 Items of adjustment Connecting rod bolts kg-cm Main bearing cover bolts kg-cm Cylinder head bolts kg-cm kg-cm Spark plug Air cleaner nuts kg-cm Governor level nuts kg-cm Rotor bolts kgcm Muffler nuts kg-cm kg-cm Front cover bolts Flywheel nuts kg-cm Rear bracket bolts Limit...

  • Page 97: Wiring Diagram

    WIRING DIAGRAM 6P Coupler Generator i LT-Tw Yellow --mm Diode Stack Assy (Rectifier) 4P Coupler AC Circuit Breaker /ntroI Panel Ground Terminal Wire code Cross section of wire 0.75 mm2 1.25 mm2 em--- -93- AC Receptacle Engine Spark Plug Magneto Exciting Coil...

  • Page 98: Maintenance

    MAINTENANCE The following standard maintenance procedures are necessary to ensure the generator’s normal performance under normal conditions. Therefore, it does not always mean that maintenance is not necessary until specified times. For instance, if the generator is operated in a dusty area, the air cleaner must be cleaned, not at the specified intervals, but rather daily.
  • Page 99 CHECKS AND MAINTENANCE Checks and maintenance items (1) Drain oil from the crankcase and (1) Use of contaminated oil will cause replace with new oil (every 100 hours) (2) E;p the fuel strainer and the fuel ! (2) and (3) (3) Regulate ignition plug clearance.
  • Page 100 Remove the ignition plug, and pour 5 - 10 cc oil into the ignition plug hole. Then quietly pull the startig nob of the recoil starter to distribute the oil to everywhere inside the cylinder, and then mount the ignition plug. Check bolts and nuts for looseness and tighten them more if necessary.
  • Page 102 1 ISSUE EMD-GS0095 @FUJI HEAVY INDUSTRIES LTD. INDUSTRIAL PRODUCTS DIV. 2ND Subaru Bldg. l-l, Choume, Miyahara-cho, Omiya-shi, Saitama 330-0038, Japan PHONE ; (Omiya 48) 653-5811 FACSIMILE ; (Omiya 48) 653-5691 PRINTED IN JAPAN 198444...

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