Robin America R1200 manual

Rozh -J) &ii Generator Technical Data & Overhaul Instructions SERVICE MANUAL[...]

FOREWORD This manual was compiled for dealers’ mechanics and includes descriptions on specifications, items, performance, structure, features, and maintenance procedures of the R1200 Generator. 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. T[...]

CONTENTS Section Title Page 1. SPECIFICATIONS ................................................... 1 1-1 items ....................................................... 1 1-2 Performance Curves ............................................. 2 2. 3. 4. FEATURES ....................................................... 5 COMPONENT IDENTlFlCATlON ..........[...]

Section Title Page 9. 10. 11. 12. 13. 14. DISASSEMBLY AND ASSEMBLY ....................................... 28 9-1 Preparation and Remarks .......................................... 28 9-2 Special Tools for Disassembly/Assembly ................................ 28 9-3 Disassembly Sequence ............................................ 29 9-4 Assembly P[...]

1. SPECIFICATIONS l-l ITEMS Model I R1200 Engine: Type I Forced air-cooled, 4-stroke, side valve, gasoline engine Displacement Fuel tank capacity 143 cc (8.73 cu. in.) 3.5 lit. (0.93 U.S. gal.) I Oil pan capacity , 600 cc (1.28 U.S pints) I Ignition system I Solid state ignition Starting system i Recoil starter I Rated continuous I I operating hour[...]

1-2 PERFORMANCE CURVES AC OUTPUT Power Factor . . . . . . . . . . . . . . . 1.0 ‘;; I -I 0’ s z E IA z & 2 t z > 1 1 1 1 1 1 ’ ’ I ! output i 1000 50 49 800 I 600 z s 240 P 230 400 2 220 210 200 n 0 1 2 3 4 5 ” Current (A)- 52 51 1000 50 49 800 I 600 si w 250 2 240 400 2 230 220 200 I I I I I I I I I I I I 0 1 2 3 4 5 0 Current (A)[...]

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

G I -1 0” f E lt z 8 2 I s 62 1000 61 60 800 t 59 z 600 s P s 130 400 0 120 110 200 0 2 4 6 8 10 0 Current (A) - Output Max. ........... 1200 w Rated ...... 1000 W Frequency ............. 60 Hz Voltage ............... 12ov DC Output DC output from this generator is rated especially for charging batteries. When the rated current (8.3A) flows into [...]

2. FEATURES (1) Weight of this compact generator with excellent portability is 27.5 kg, which means that the generator is the lightest one in this class. (2) This generator with an excellent high performance engine and a large size 3.51i fuel tank can run continuously for about 4 hours (at the rated load of 50 Hz). (3) The operating system is conce[...]

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

4. FUNCTION OF EACH COMPONENT 4-l 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 output are taken out. The copper wire coil consists of a main coil and a DC coil, and AC output is taken out from the main coil, while DC output is taken [...]

4-l-4 AVR (Automatic Voltage Regulator) I This is a device to automatically regulate 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. The voltmeter displays outpu[...]

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 by using a mould with die-cast cores. The cra[...]

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. 4-2-12 CARBURETOR The ho[...]

5. DESCRIPTION OF MAIN OPERATIONS 5-l ELECTRONIC IGNITION MECHANISM 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[...]

5-2 DESCRIPTION OF GENERATING OPERATION I------- = , 8 I P I ‘3 ‘6 x I L ---w_J Magneto F@. 5-2- I 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 th[...]

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. 5-2-3. Fig [...]

6. 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 a[...]

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. 0.8 Fluorescent lamps: 0.7 x0.8 Example: As for a 40 W fluorescent lam[...]

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. s20 = St + 0.0007 (t - 20) whe[...]

64 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. Cross sectional araa No. of[...]

7. 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 with an output voltage of 110 or 120V 0 to 300V: For a voltmeter with an output of 220, 230, or 240V Measurable range for the DC voltmeter is from 0 to 20V. 7-l-2 AMMETER Both AC[...]

7-l-4 CIRCUIT TESTER The circuit tester is used for measuring resist- ance and others. I Fig. 7-l-4 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-5 I 1 Fig. 7-l-6 -19-[...]

7-2 MEASUREMENT OF AC OUTPUT +ii+~~ To an AC Receptacle Fig. 7-2 Measurement is executed with the circuit as shown in Fig. 7-2. An electric heater or an 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 speci[...]

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. 7-4-3 ROTOR Measure the insulation resistance between either one of two s[...]

Fig. 8-l-l (a) 8-l-2 DC RECEPTACLE Check continuity between the DC terminals at the rear of the receptacle by using a circuit tester, under the condition that the receptacle is mounted on the control panel. When continuity between the DC terminals of the receptacle is confirmed with a wire con- nected across the terminals, and is not con- firmed if[...]

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. Fig. 8-l-4 8-2 DIODE STACK (RECTIFIER) (Orange) 0 0 cl (White) (Yellow) 0 - (Brown) Fig 8-2-l Fig. 8-2-2 Fis. 8-2-3 Circuit inside the diode stack is as shown i[...]

83 AVR Whether the AVR is defective or normal can be determined by checking the appearance, by 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 bla[...]

84 STATOR Confirm the resistance between the coupler terminals with a circuit tester. Red 3+-J a-@ White Orange Q Green @ OB rown @Black Circuit Tester F&. 8-4 Coil name I Main coil DC coil Sub-coil Measurement ’ Diode location 6P coupler connector 6P coupler Wiring color White @ - Red @ 1 White - Yellow White @ - Green @ 50Hz - IOOV 0.951 0.[...]

8-5 ROTOR 8-5-l MEASURE RESISTANCE IN THE FIELD COIL OF THE ROTOR WITH A CIRCUIT TESTER Resistance El 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 periph[...]

8-7 IGNITION COIL Measure resistance in the coil of the ignition coil unit with a circuit tester. ! Resistance ( I Measurement location 13K!G? i 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, unevenne[...]

9. DISASSEMBLY AND ASSEMBLY 9-l PREPARATION AND REMARKS (1) Be sure to remember the locations of individual parts when disassembling the generator so that the generator can be reassembled correctly. Tie tags with the necessary information written in to facilitate easier and smoother reassembly. (2) For more convenience, group the related parts and [...]

9-3 DISASSEMBLY SEQUENCE I Sequence I Part to ! , remove j Description 1 I Precautions ! Necessary I tools 1 1 Side cover ! (1) First remove the side i I 0 Plus screw ! cover by unscrewing I driver I I four M5 x 8 screws. ! I 2 ; Rear cover i (1) Remove the rear cover by , @ Plus driver ! unscrewing three MS x 8 , ! screws and two M 8 x 10 ! I I sc[...]

’ Part to ! I I Sequence ] remOve : Description I Precautions Necessary I I I ; tools 3 icontrol I(l) Pull the knob of the I 1 panel 1 @ Plus driver I control lever and remove I I the control panel by un- ! I I I screwing four M5 x 8 I screws. I I I I I I Knob L Control Lever by , Fig 9-3-2 - 30 -[...]

1 Part to I Sequence 1 j remove 1 Description i Precautions I Necessary tools I 4 ( Couplers Disconnect the (6P) i 1 and plugs i (1) , Pull the couplers generator coupler from ! while pushing the , , (Discon- ’ the other (6P) coupler I retainer claws. j nection) 1 I extending from the control panel. ! I / (2) Disconnect the (4P) coupler I , I of [...]

Sequence I Part to remove j Description I Precautions I Necessary I tools 5 iFront cover (1) Remove the element 0 Driver ( cover by unscrewing the M6 x 12 screw. 1 I(2) Remove the front cover 1 I @ Driver by unscrewing three ! I I M5 x 8 screws. M6x12 Screw ’ Front Cover / M5x8 Screw (3 PCS.) FJ$. 9-3-5 -32-[...]

1 Part to ’ Sequence j remOve Description I Precautions j Necessary I tools 6 Fuel pipe (1) Remove the cap from the ’ ‘and plug fuel strainer and take out (Discon- i nection) the gasoline from inside the fuel tank. (2) With pliers, hold the fuel Be careful not to Pliers pipe clamp which is in- damage the fuel serted in the fuel strainer pipe.[...]

Sequence, Part to remove I Description Precautions Necessary tools I 7 Fuel tank (1) Remove the handle cover The fuel tank can be , @ Driver I handle by unscrewing the two removed without M3 x 10 screws. I disassembling the I handle. (2) Pull out the breather pipe : for air ventilation. I (3) Remove the handle body by 113 m/m box taking off the two[...]

1 1 Sequence Part to ’ Description , Precautions Necessary remove tools 9 i(l) j$Ez; 1 Remove the bracket cover i 13 m/m box from the generator by i spanner ’ 1 taking out the two M8 x 30 bolts. 10 End cover /(l) Remove the end cover from. the generator by unscrew- i i @ Driver ing the four M5 x 10 I I I screws. 11 IBrash holder((1) Remove the [...]

I j Part to 1 Sequence I remOve Description Precautions j Necessary tools I 12 ’ Rear ‘bracket I j (1) Loosen and take out the 1 10 m/m box three M6 bracket bolts. , spanner i (2) Remove the rear bracket, a tapping it evenly with a ’ plastic hammer. I (See Fig. g-3-10) I i Plastic hammer I I I / (3) Remove the connector of ’ Be careful to m[...]

I I I Sequence I rpearfito~~ i Description I I Precautions Necessary tools 13 1 Stator I I ! 1 I c (1) Pull away the stator cover. i (2) Pull away the stator from 1 Never pat the wind- ’ plastic hammer the front cover. If it is impossible, pull it away / ing and the lead. I tapping outside the core 1 with a plastic hammer. ; ! (See Fig. 9-3-12.) [...]

Sequence , Part to ’ remove I Description I Precautions Necessary tools 14 ‘Rotor i (1) Insert a box spanner or a 1 Never insert a /13 m/m box socket wrench between the driver or other tools spanner or socket wrench I through bolt and the rotor into the fan of the I shaft, and hit it in a rotor. I clockwise direction with a I hammer to loosen t[...]

! Part to / Sequence j remove ’ Description I I i Precautions : Necessary tools I I 15 j Front (1) Remove the front bracket, i 13 m/m box i bracket which is mounted on the I , I main bearing cover of the / spanner I 1 engine, by taking out four I I I MS x 18 bolts. / / Main Bearing Cover Front Bracket Fig. 9-3- 76 -39-[...]

I Part to i Sequence ! remOve ; I Description I I I Precautions I Necessary tools 16 Recoil j(l) Remove the recoil starter -10 m/m box mstarter by taking out the four 1 spanner 1 M6 x 8 flange bolts. I 1 I RecoilvStarter Fig. 9-3- 77 -40-[...]

, 1 j I Sequence 1 Part to Description Precautions 1 Necessary remove j I tools I I 17 Blower i (1) Remove the blower housing The two flange ’ 10 m/m box 1 housing from the crank case by bolts, taken out taking out the two M6 x 12 1 when the fuel tank , spanner I I flange bolts. i is removed, are not I I / included. 18 !Head cover I(l) Remove the[...]

I Description ! I Precautions . Necessary tools I Air cleaner : (1) Remove the air cleaner @ Driver body, elements, and ele- ment retainer from the cleaner body, by taking out I one M6 x 10 flange bolt. I i (2) Remove the air cleaner The air cleaner case ! 10 m/m box body from the carburetor and the carburetor /spanner by taking out the two M6 are [...]

I Sequence 1 Part to j - remove ! Description I Precautions Necessary tools 20 i Muffler j (1) Remove the muffler cover ’ :lO m/m box I cover ! from the muffler by taking i spanner i out the three M6 x 8 flange bolts. 21 Muffler I(1) Remove the muffler from 112 m/m box the cylinder section of ’ spanner the crank case by taking out the two M8 nu[...]

1 Part to ’ I Sequence 1 remove : Description Precautions 1 Necessary tools 23 24 Carburetor (1) Remove the carburetor I from the cylinder section ’ 1 of the crankcase. Starting (1) Remove the starting pully PUllY j from the flywheel, by tak- ing out one M4 nut. Insert a box spanner or socket wrench into the nuts of the flywheel and strongly hi[...]

1 Part to Sequence. 1 remOve ! Description I Precautions Necessary tools 28 I Ignition I (1) Remove the ignition plug 1 ! 21 m/m box 1 plug from the cylinder head. i spanner 29 / Cylinder I ! 12 m/m box , head j(1) Remove the cylinder head from the crankcase by i spanner I taking out the eight M8 x ! 1 1 40 flange bolts. I(2) Remove the cylinder he[...]

I I I Sequence Part to remove Description ! Precautions i Necessary tools 32 i Camshaft (1) Pull the camshaft away I Set the crankshaft ! from the crankcase. ; on its side SO that i j it will not fall and b i damage the tappets. 33 Tappet i (1) Remove the tappets from the crankcase. ; ~~~a~s~~a~~ E:dthe tappets to distin- I i guish them from one 1 [...]

r Part to Wuence remOve Description Precautions Necessary tools , 34 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. (2) Remove the oil scraper, 1 ! lock washer, and connect- I 1 ing rod cap [...]

9-4 ASSEMBLY PROCEDURE n Precautions in assembly (1) (2) (3) (4) (5) (6) (7) (8) (9) Thoroughly clean each part. When cleaning, take special care with the piston, cylinder, 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 f[...]

HAssembly sequence and precautions 9-4-l CRANKSHAFT (1) 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. (2) (3) Mount the woodruff key (for the mag- neto). Dimentional tolerance of the crankpin[...]

9-4-2 PISTON AND PISTON RING (1) 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. The oil ring is fitted onto the piston, followed by the s[...]

9-4-3 CONNECTING ROD (1) 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. (2) Set the connecting rod cap according to the rod guide mark. (3) Set the oil scraper in the magneto side. Note: Be sure to use a new lock washer. Bed the washer carefully and c[...]

i 1 Fi$. 94-7 F&. 948 * 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. As the packing is installed on the processing face of the crankcase, determine the clearance by taking i[...]

WV&e h valve guide clearance Valve Face 3=53' / Valve Spring Spring Retainer Fig. 94 7 1 Valve Seat Valve Stem Valve Guide A: Valve face angle B: Valve seat angle I C: Valve guide inside diameter D: Valve stem outside diameter Intake valve 1 6.5$1$;; Exhaust valve i -0.056 6*50- 0.078 Clearance between the valve guide Intake valve 0.025L -[...]

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. This holds tru[...]

9-4-10 IGNITION PLUG * Torque for the ignition plug: 230 ad 250 kg-cm (As for a new one (head plug): 120 s 150 kg-cm) 9-4-11 IGNITION COIL, EXCITING COIL, FLYWHEEL AND STARTING PULLEY (a) 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 flywh[...]

WHanging position of the governor spring Generally, the governor spring should be hung in 1 (See Fig. 9-4-15). (4) 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. (5) Insert a driver into the governor shaft groove and turn it clockwise (until the governor shaft [...]

9-4-14 MUFFLER AND MUFFLER COVER (1) Insert the gasket (exhaust) to the studs of the exhaust flange of the crankcase and then mount the muffler. Install the muffler by securing the muffler flange with two brass nuts and the muffler bracket with one M6 x 12 bolt. (2) Secure the muffler cover with three M6 x 8 flange bolts. Muffler <??g?g;/M8 Nut [...]

9-4-16 HEAD COVER AND BLOWER HOUSING (1) Set the head cover with the M6 x 8 flange bolts (at two places in the generator side). (2) 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. Blower Housing M6x8 Flange Bolt He[...]

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: 120 0u 140 kg-cm Note: Set the front bracket so that the cooling air outlet window of the generator is positioned in the upper side, and the slit section is positioned in the bottom side. 9-4-l 9 [...]

9-4-20 REAR BRACKET AND STATOR Mount the diode stack on the rear bracket and combine them with the stator. Connect the connecting terminals according to the circuit chart. Note: See 8.2 “Diode stack” 9-4-21 STATOR (1) Holding the rear bracket and stator, fit them to the inlet port of the front bracket. Match the mounting hole of the rear bracke[...]

9-4-22 BRASH HOLDER (1) Mount the brash holder base on the rear bracket with PI5 x 10 screws. (2) 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 scr[...]

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. M5x20 Screw (2 PCS.) /$a/” Brush Holder Rear Bracket Bracket Brush Holdey , , p h Cover M5xlO Screw (4 PCS.) I d M8x30 iiolt (2 PCS.) Ft& 9425 [...]

[...]

9-4-27 FUEL PIPE (CONNECTION) (1) Mount the fuel strainer on the front cover. Note: Mount the fuel strainer with the banjo outlet upward. (2) Insert the fuel pipe into the fuel inlet/outlet port of the fuel strainer and secure it with the clamp. 9-4-28 FRONT COVER AND ELEMENT COVER (1) Secure the front cover, on which the AVR and fuel strainer have[...]

9-4-29 CONNECTION OF COUPLER AND PLUG (1) Connect th e coupler (6P) from the generator with the coupler thrusting from the control planel. (2) Connect the coupler (4P) thrusting from the AVR with the coupler (4P) thrusting from the control panel. (3) Connect the plug for grounding. 9-4-30 CONTROL PANEL (1) Thrust the control lever through the contr[...]

9-4-31 REAR COVER - Secure the rear cover with three "I x 8 screws and two &I8 x 10 screws. 9-4-32 SIDE COVER Secure the side cover with four M5 x 8 screws. M8x10 Screw (2 pcs.) Rear Cover F&. 94-29 -66 -[...]

9-5 CARBURETOR 9-5-l FUNCTION AND STRUCTURE (1) Float System The float chamber is located directly under the carburetor. The float and the needle valves 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 [...]

Schematic Diagram of the Fuel System r By-Pass Throttle Valve Pilot Outlet r Choke Pilot Jet i Jet Main Nozzle Main Jet Float Fig. 9-5-l -68-[...]

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 kee[...]

3i I 20 25 184 Fig. 9-5-2 - 70 -[...]

10. SAFETY PRECAUTIONS 10-l FIRE PREVENTION (1) Keep the generator away from combustible materials during operations, or ground the generator by making use of its grounding terminal. Take special precautions towards flammable substances. (2) Do not run the generator in an inclined position. Avoid moving the generator while it is running. Otherwise,[...]

11. 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. Generally speaking, the causes of the troubles are different case by case. An operator of this en[...]

II Symptoms 1 Parts - A-l Starting failure Compression is nonexistent Intake/exhaust valve [ A-2 Starting failur; Compression is insufficient or little , Adjust tappet clearance if the 1 clearance is different from the standard value or replace I In case of sticking, supply lubri- cating oil onto value stem or re- place the valve stem. Replace the [...]

.-. n Symptoms A-3 Starting failure I Fuel tank is empty A-4 Starting failure I Water or dust is mixed with the fuel ] Fuel flows only a little, or does not Breather pipe (in the tank handle) Clogging of pipe Fuel tank, carbure- Fuel tank is empty Cock is closed Water or dust is mixed with the Air stays in the -7 Check the fuel I Check breather pip[...]

q - .-- A-6 Starting failure Symptoms The fuel does not enter into the float chamber of the carburetor The fuel does not flow into the com- bustion chamber although the fuel exists in the float chamber of the I r Fuel path (Carburetor) Packing (Carburetor) -- I Packing or clamp- - , ing torque check ---- Checking criteria 1. If the needle valve is [...]

q Symptoms q Parts ---- - Needle valve (Carburetor) Float (Carburetor) --.-- I Float Breather pipe (Carburetor) (Air-vent) 1 _~ q Possible causes Abnormal operation Breakage Oil level is abnormal (too high). I Clogging of pipe Checking method Checking criteria J Check the needle valve I - -.-.I I 1. When dust, etc. is on the needle valve, clean it.[...]

II Symptoms A-9 Starting failure Sparks do not come out from the tip of the high voltage cord A-10 Starting failure Sparks do not come out or are weak when the ignition plug is connected. a Ignition coil L Magneto (Flywheel) il Ignition coil plug cap Contact failure with the ignition plug Ignition plug 1. Insulation failure 2. Carbon deposit or dir[...]

q Symptoms B-2 Abnormal failure Overheating and knocking of the engine B-l Abnormal running Refer to A-l and A-2 (Clauses on compression failure) Cylinder, muffler, Carburetor 0 I Load Overload Ignition plug c _. r?J /’ Heat value is El inappropriate Clogging of fuel path (Mixing ratio of air with fuel is too low) I 2 I I Check the cooling fin [...]

El Symptoms B-3 Abnormal running Fluctuation of rpm rl Remedies In case of fitting failure, correct it. I Correct fitting of governor and level shaft hanging posi- tion is not normal. correct it. 2. In case the governor spring Is abnormal, replace it. Adjust the hanging position of the governor spring or In case of abration or abnormal opera- tion,[...]

- 7 Symptoms Checking methoh Checking criteria El Remedies B-4 Abnormal running rpm of the engine does not increase 0 Governor system Mounting failure (Throttle valve does not work normally) Confirm mounting of the governor system In case of mount- ing failure, adjust it. r 1 Adjust mounting of the governor system Intake/exhaust valve I Valve openi[...]

I I I B-5 Abnormal running Symptoms Missfire or explosion outside the tube c I I Parts Intake/exhaust valve I Carburetor I I I Ignition coil Fuel r I 1. Jets do not operate III Checking i criteria Measure tappet clearance If the clearance is different from the standard, adjus the clearance or rc- place the tappet Normal : 0.1 +O.O2mm I 1 I I I I Re[...]

u Symptoms ]I (Air-fuel mixture blow back to the air cleaner) B-7 Abnormal running Fuel consumption is too high. (Black exhaust gas comes out) 1 I 1 I Intake/exhaust valve Valve opening/ closing timing is not appropriate. ‘7-I Air cleaner element il Fuel a intake valve, Valve seat Fitting of valve seat is insufficient, Carburetor Blinding __: 2. [...]

, B-8 Abnormal running Consumption rate of lubricating oil is too high (White exhaust gas comes out) I _-..- Piston ring I Intake/ex- haust valve guide I Gas vent valve I Engine oil Checking criteria sured values on are not within In case of In case the adherence, piston ring adjust or is built-in replace the improperly, piston ring rearrange it. I[...]

B-9 Abnormal running Engine noise is too loud I Engine oil Engine oil has not been changed periodically r (Abrasion of rub hing section) I If the engine oil is conta- minated or if the engine oil has not been changed periodically, replace it. In case the element has been broken, replace it. I---- - B-l 1 Abnormal running 7 The lubricating oil becom[...]

1 Symptoms Checking method u Remedies C-l No voltage is displayed on the voltmeter (1 I I Voltemeter Voltmeter failure Input AC voltage to terminals in the voltmeter side If the displayed value is different from the input value, replace the voltmeter I AVR AVR failure Measure resistance value between the terminals with a circuit tester (Measure wit[...]

C-2 No voltage is displayed on the voltmeter (2) Stator sub-coil I Rotor 1 Exciting coil 1. Disconnection 2. Short circuit I 1. Disconnection 2. Short circuit -.---- 1. Disconnection 2. Short circuit 1. Disconnection 2. Short circuit I Checking method Checking criteria I I Measure resistance value between the terminals with a circuit tester (Measur[...]

I 2 I Symptoms D-l No DC voltage is output ( 1 D-2 Voltag,eistoo high q Parts Possible q causes I Stator DC coil 1. Disconnection 2. Short circuit I Diode stack The diode is defective I Lead line Disconnection of the lead line AVR AVR failure Checking method L Remedies I Measure the resistance value between the terminals with a circuit tester (Meas[...]

I Ez I L Symptoms Possible q causes Checking method checking criteria Remedies -.. - Stator sub.coil I I Rotor Rotor Slip ring Slip ring 1 I Short circuit of the coil Short circuit of the coil Short circuit of the coil Short circuit of the coil ---- ---- I I. Contamination of the I. Contamination of the brush’s contact surface brush’s contact s[...]

q Symptoms D-4 Voltage is abnormally low I I _- Ll r -. I I I I Parts Brush AVR Engine Lead line I I I I 1 ;I Fi c ’ Fl Breakage of lhe lead line AVR failure I Checking method Checking criteria 1. Confirm condition of the slip ring’s contact surface 2. Measure length of the brush 1. If contact surface of the slip ring is contaminated, clean it.[...]

12. CRITERIA TABLE FOR ADJUSTMENT Items of adjustment I Criteira ! Limit of ’ application I Description Tools Remarks I Levelness of cylinder head Below 0.1 0.15 j Surface plate ! and searcher : Repair Inside dia. 63Q +0.019 0 53.650 Cylinder gauge I Cylinder Seat width of intake and exhaust valves I I 2.5 Slide calipers I and cutter Repair ( I I[...]

Items of adjustment I I Criteira I Limit of ! Dercription ! application Tools Remarks / Crankpin outside dia. -0.037 ’ 240 -0.050 1 23.50 / Micrometer , Replacement t I I Crankshaft ; Magneto Crankshaft 1 side 250 ro”:g; ; ! 24.950 ; Micrometer : Replacement : journal outside , dia. Counter- 1 250 -0.003 : side -0.012 24.950 Micrometer Replacem[...]

! ) Items of adjustment I Criteira Limit of application ; Description i Tools ! Remarks Connecting rod bolts kg-cm 90-115 kg-cm I Main bearing cover bolts kg-cm 805100 ! Cylinder head bolts kg-cm : 190-230 ! Spark plug Air cleaner nuts Governor level nuts I kg-cm j 230-250 / kg-cm i 70 -90 kg-cm go-110 I Rotor bolts kgcm : 100-150 I Muffler nuts kg[...]

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

14. 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 specif[...]

144 CHECKS AND MAINTENANCE FOR EVERY 200 HOURS (EVERY MONTH) I Checks and maintenance items I Description (1) Drain oil from the crankcase and (1) Use of contaminated oil will cause replace with new oil (every 100 rapid abrasion. hours) I (2) E;p the fuel strainer and the fuel ! (2) and (3) a Engine troubles, including power out- (3) Regulate ignit[...]

(5) (6) (7) (8) (9) (10) 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. Set the engine switch at the [...]

[...]

1 ISSUE EMD-GS0095 1 @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[...]