R650 GENERATOR SERVICE MANUAL
Contents
1. at 21 100V 50 60Hz 120V 60Hz 110V 50 60Hz 220V 50 60Hz 240V 50 60Hz Table 9 1 NOTE the circuit tester is not sufficiently accurate it may not show the values given and may give errone ous readings 6P COUPLER WIRING GREEN YELLOW YELLOW BROWN WHITE COUPLER WIRING BLUE LIGHT BLUE WHITE MAIN COIL CONDENSER COIL 26 AC COIL SR WHITE FOR 60Hz LIGHT 7 DC COIL CONDENSER COIL FOR 60Hz lt 27 9 3 ROTOR 1 Unsolder the diode and the resistor from the ro tor terminal Unsolder one wire of each part DIODE RECTIFIER and RESISTOR Fig 9 9 2 Check the resistance between the wire ends of rotor winding at the terminals 11 50 NORMAL RESISTANCE 3 Check the diode Touch the positive RED probe of the circuit tester to the cathode mark side of the diode and touch the negative BLACK probe to the other side of the diode Normal resistance is 160 S NORMAL RESISTANCE Reverse the polarity of the circuit tester At this time the resistance is infinity Remedy If the diode is defectrive replace with a new one CATHODE MARK Fig 9 11 28 9 4 IGNITION COIL Using a circuit tester measure the resistance of the ignition coil MEN RESISTANCE VALUE MEASUREMENT LOCATION 0 612 Between the core and th2. GEAR Fig 10 19 Fig 10 20 Shown in Fig 10 21 is the method to measure the side clearance of the crankshaft According to this BR GELEE method measure the clearance between the ma chined face of the crankcase and the adjusting col lar The machined face of the crankcase is mounted with packing so it is necessary to set the clearance properly by allowing for a packing thickness of 0 22 mm x 25 mm bolt 8 pcs M6 x 55 mm bolt 1 pc MACHINED FACE OF THE CRANKCASE Fig 10 21 50 8 INSTALLING THE INTAKE AND EXHAUST VALVES Prior to installing remove carbon and gum deposits from the valve valve seat intake and exhaust ports and valve guide NOTE If the valve face is worn replace the valve with a new one NOTE If the clearance between the valve guide and valve stem is excessively large replace the valve guide with a new one Replace the valve guide by using a pull block and pull bolt as shown in Fig 10 23 VALVE FACE VALVE GUIDE PUL LER VALVE SEAT VALVE STEM VALVE GUIDE VALVE SPRING VALVE RETAINER Fig 10 23 Fig 10 22 C Valve guide inside diameter 5 56 yu 0 020 0 032 0 056 oi 50 074 L LOOSE D Valve stem outside diameter Clearance clearance between C and D between valve quide and valve stem Table 10 3 51 9 TAPPET ADJUSTMENT Set the tappet at the
3. Hz ETE gt 9 z s 5 z i m m Z M dA 51 500 L BIEN Is SIR HE 2 92 mL Que dc lt 61 de o V ul gt m too EI E a 9 TET TIE gt 100 5 100 O KERM 9 Lag pg pu I u p EIE 0 05 1 15 2 25 1 2 3 4 5 6 CURRENT A CURRENT gt 50Hz 60Hz 220V Type 60 Hz 120V Type OUTPUT OUTPUT 550W 50Hz 650W 60Hz Maxis 650W Rated 450W 50Hz 550W 60Hz Rated 550W 2 2 DC OUTPUT H Rated voltage 12V Rated B 3A EE 15 s eta ela Rated output 100W VOLTAVE lt 3 FEATURES Exhaust Fan Cooling System for low body temperatures low noise longer engine life and reliable per formance Large 78 cc 4 Stroke Engine provides enough power for constant 550W at 60 Hz rated output e Simple One Touch Engine Control Switch with the engine and fuel on off levers and choke all integrated into one switch Easy and Reliable Starting with pointless ignition This generator is also a brush less type generator for maintenance free operation Simple Design for a clean appearance and easy maintenance Compact and Lightweight with an easy one hand carrying handle grip This generator also offers a high power to weight ratio and economical operatio
4. C green veliow terminal ondenser Eo o white Ignition l Voltmeter unit X x EE a Spark BT 28 Stop switch MEMO ISSUE EMD GS0455 FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS DIV 2ND Subaru Bldg 1 1 Choume Miyahara cho Omiya shi Saitama 330 0038 Japan PHONE Omiya 48 653 5811 FACSIMILE Omiya 48 653 5691 PRINTED IN JAPAN Janunarv 1968
5. CRANKCASE CRANKSHAFT GOVERNOR SHAFT 46 10 4 ASSEMBLY PROCEDURE 10 4 1 PRECAUTION IN ASSEMBLY 1 Thoroughly clean each part When cleaning take special care for the piston cylinder crankshaft con necting rod and bearing 2 Be sure to completely remove the carbon deposits on the cylinder head and piston head Also thorough ly clean and remove carbon deposits from each piston ring groove 3 Apply lubricating oil to the lip of each seal Confirm that the lip of each oil seal is not damaged If dam aged replace with a new one 4 Replace the gaskets and similar items with new ones do not reuse old gaskets 5 Replace the keys pins bolts nuts etc with new ones if necessary 6 Do not apply torque exceeding the specified value 7 Apply lubricating oil to both moving and sliding parts when they are assembled 8 Prior to assembly check the clearance of each part and adjust it if necessary 9 When each of the main components are assembled turn it by hand to check for smoothness of rotation and unusual noise 10 4 2 ASSEMBLY SEQUENCE AND PRECAUTIONS 1 GOVERNOR SHAFT Put the governor shaft into crankcase then drive the clip into position to secure the governor shaft 2 CRANKSHAFT a Insert the crankshaft into the ball bearings of the crankcase b Fig 10 13 shows the dimentional tolerance of the crankpin OUTSIDE 256 0 037 DIAMETER 9 0 050 width 1797
6. NORMAL RESISTANCE HIGH TENSION CORD GREEN WIRE 0 6152 Fig 11 1 63 NORMAL RESISTANCE CORE GREEN WIRE 0 752 11 1 2 CHECK THE FUEL SYSTEM 1 CHECKING THE FUEL IN THE FUEL TANK Deteriorated fuel or the water mixed in the fuel causes bad starting If the fuel is deteriorated or the water is mixed drain the tank and carburetor completely then refuel the fresh gasoline Fig 11 2 NOTE Sometimes when a generator is stored for more than a few months the gasoline in the tank deterio rates until it lost so much volatility that starting becomes difficult In that case replace the fuel with fresh gasoline 2 CHECKING THE FUEL FILTER There are two types of fuel filter attached to the generator The first type is a disposable filter put in the middle of the fuel line The second type is a fine mesh filter built in the fuel cock W The first type Disposable type Disconnect the fuel lines and replace the fuel fil ter with a new one FUEL FILTER The second type Filter built in fuel cock a Remove the fuel tank following the disassembly procedures Fig 11 3 b Remove the fuel cock from the tank c Clean the filter mesh 18 d If the gaskets 15 are broken replace them with 17 new ones at re assembly FUEL FILTER 64 3 CHECKING THE CARBURETOR Remove the carburetor from engine Remove the float chamber from the carburetor and check to see if t
7. Fig 11 11 5 Check the generator for overheating COOLING AIR OUTLET Remove any obstacles that are clogging or blocking the cooling air inlet or the cooling air outlet COOLING AIR INLET Fig 11 12 70 12 CIRCUIT DIAGRAMS 12 1 50Hz 60Hz VARIABLE TYPE Rectifier Circuit breaker Resistor Main coil 27 4 O O AZn s y n B Field coil n brown brown in pilot lamp el x Ku brown Resistor Ir Il fos mm gt LS p MY amp 2 zen SUN n ME I i green yeliow green 1 Rectifier po 8 yellow N receptacle gt ed Condenser back coil DC suam terminal x yellow m dd 9 TS DC Condenser terminal Ignition unit white Voltmeter 3 x N AC lead wire color code EN Spark plug Voltage Micro switch Stop switch 110V 220 240V white green 12 2 60Hz 120V TYPE Rectifier Circuit breaker Resistor Main coil FEE REG Field coil brown brown Pilot lamp N ET 3 SS ls E Resistor 1 a EE NE mena UIE gt Hired IP S Q green Recufier pex S yelow d receptacle 8 whitey C c e Condenser E red red a OC black l terminal es EE yellow green green
8. Robin Generator R650 42 2 Technical Data amp Overhaul Instructions SERVICE MANUAL CONTENTS Section Title Page 4 2 Location of Serial Number Specification and Specification Number Section Title Page 11 2 Voltmeter does not work or pilot lamp does not turn on No AC output 11 4 Output voltage is normal at no load but generator won t work 69 12 1 SPECIFICATIONS Forced air cooled 4 stroke side valve gasoline engine ENGINE Type Displacement 78 cc 4 76 cu in Fueltank capacity 2 lit 0 53 U S gal pan capacity 350 0 75 U S pints Ignition system Solid state ignition Starting system Recoil starter Rated continuous Approx 4 5 hours 50Hz operating hours Approx 4 0 hours 60Hz GENERATOR Type 2 revolving field type Exciting system Self exciting Voltage regulating system Condenser type Maximum output 550W 650W Rated output 450W 550W AC frequency 50Hz 60Hz 60Hz AC voltage 110 220 240V 120V DC output 12V 100W 8 3A Standard 2 ea AC receptacle P Special 1 ea DC terminal A couple current Eea protection Circuit breaker Voltmeter Standard Pilot lamp Standard Dimensions L x W x H Mac TA EE Dry weight 18 5 kg 40 7 Ibs 2 PERFORMANCE CURVES 2 1 AC OUTPUT ELT oe ie EE SW
9. The muffler is installed while secured to the muffler flange using two M6 nuts and also to the muffler bracket by using one M6 bolt d Install the outer muffler cover in place using seven M5 tapping screws Torque 70 90 kg cm 26 INSTALLING THE CHOKE CABLE Insert the inner wire of the choke cable into the swivel of the choke lever b Insert the outer end of the choke cable into the wire bracket of the carburetor and temporarily tighten the outer end so that it will not slip out of the wire bracket NOTE The inner wire is installed later Leave it loose in the swivel 27 INSTALLING THE FUEL LINE a Connect the fuel line to the inlet joint of the carburetor Then clamp the line with a hose clamp so that it will not come off the line joint b Secure the fuel line with the clamp of the cylinder baffle 55 28 INSTALLING THE FRONT COVER Using two M6 x 8 mm flange bolts install the front cover assembled with the control panel to the base plate Keep the engine switch set at STOP 29 INSTALLING THE FUEL TANK a Keep the strainer shaft at the lower part of the fuel tank in a position that will allow the setscrews to be tightened from the opposite direction of the muffler b Insert the flexible shaft extending from the rear side of the engine switch which is mounted on the con trol panel into the square hole of the strainer shaft Align the mounting holes at the lateral side of the front cover with those
10. CIRCUIT SPARK PLUG POWER TRANSISTOR PRIMARY COIL SECONDARY COIL SIGNAL TRANS MITTER TRAN SISTOR FLYWHEEL COOLING FAN RESISTOR Fig 5 10 1 When the permanenet magneto built in flywheel starts rotating power is generated in 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 releasing current This stage corresponds to the closing of contact points 2 As the flywheel comes to the point of ignition the ignition timing detecting circuit is activated while the current C is flowing through the circuit When the ignition timing detecting circuit is activated the signal transmitter transistor actuates with cur rent d flowing When current d starts flowing current flowing through the power transistor is cut quickly As a result high voltage is produced in the secondary coil and this voltage is applied simul taneously to the spark plug which ignites for ignition This stage corresponds to 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 gasoline while the engine is running Do not smoke or use open 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 Do not plac
11. Fig 10 13 247 TOLERANCE OF NEWLY INSTALLED PARTS Thrust directional tolerance between the cylinder and piston skirt 0 008L 0 047L Spare rings Spare ring Oil ring 0 010L 0 065L Inside and outside diameter 0 0371 0 063 Clearance between connecting rod small end and piston 0 010L 0 029L Clearance between piston pin and piston pin hole 0 009T 0 010L L Loose T Tight Clearance of piston ring joint Clearance between piston ring Clearance between connecting rod large end and crankpin Table 10 2 NOTE The clearance between the piston and cylinder is checked by measuring the clearance between the piston and cylinder skirt 3 PISTON and PISTON RINGS OPEN ENDS OF PISTON RINGS a If a ring expander is not available set the ring joint at the first land of the piston as shown in Fig 10 14 so that the ring can be slided into its groove NOTE Be careful not to twist or expand exces sively each ring The oil ring is fitted first on to the piston followed by the second ring and top ring The top and second rings must be fitted with their marked sides kept upward Fig 10 14 b The connecting rod is assembled to the piston by the piston pin NOTE Before assembly apply sufficient lubricating oil to the connecting rod small end NOTE Be sure to fit the clips to both sides of the piston pin STD EQUIPMENT SPARE PARTS Oil ring Type
12. M6 x 8 flange bolts THROUGH BOLT See Fig 10 9 10 mm box spanner 1 Tum the starter pulley by hand to set the piston to the compres sion stroke top where the pulley becomes heavy Using a hammer strike the box wrench set over the head of the through bolt to remove the bolt Then remove the pulley See Fig 10 10 12 mm box spanner STARTING PULLEY RECOIL STARTER FLANGE BOLT 3 pcs Pss 7 SOME Le SRLS x 4 s 2 VN r M 1222 FEES 7 2 i Fig 10 9 Fig 10 10 37 ae mee sem 7 15 Stator assembly 1 Remove three M6 x 85 bolts clamping the rear housing of the stator assembly and the front housing together Disconnect six wires from the micro switch on the speed con trol unit 50Hz 60Hz variable type only 2 Remove the stator assembly from the front housing The stator and rear housing are removed together by using a plastic hammer to light ly strike the boss of the rear housing 3 Remove both the capacitor and diode from the rear housing by remving two M5 x 10 screws 4 Remove the wiring between the stator and rear housing Discon connect three wires from the diode two wires from the capaci tor and the ground wire from the rear housing 10 mm box spanner Plastic hammer See Fig 10 11 Plus screw driver 6P COUPLER STA
13. Necessary tools 10 mm box spanner Governor and related parts 1 Remove the governor lever from the governor shaft 2 Remove the governor rod rod spring and governor spring Speed control unit 1 Remove the speed control unit from the crankcase 1 Remove the voltage changeover unit from the crankcase 22 Carburetor 1 Remove the carburetor from the crankcase 10 mm box spanner CARBURETOR BOLT amp WASHER 2 pcs GOVERNOR SPRING SPEED CONTROL UNIT VOLTAGE CHANGEOVER UNIT NUT GOVERNOR LEVER BOLT amp WASHER 41 23 Head cover 1 Remove two MS screws from the screw driver lateral side of the head cover to M5 SCREW amp WASHER remove the head cover 1 Remove the 5 screw from the main bearing cover to remove the cylinder baffle 10 mm box spanner Plus screw driver HEAD COVER CYLINDER BAFFLE _ 42 see 25 Spark plug 1 Remove the spark plug from the 19 mm box spanner cylinder head Cylinder head 1 Remove the sen x 32 boltsto Mark the head gasket 10 mm box spanner remove the cylinder head with its mounting posi 10 mm box spanner 2 Remove the head gasket tion accurately match ing the cylinder head also mark the gasket mounting fac
14. die cast and is mounted on the generator side By removing the main bearing cover the interior of the engine can be inspected 3 CRANKSHAFT The crankshaft is constructed of forged carbon steel The crankpin is induction hardened and has a press fitted crank gear located on the generator side of 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 casting piston has two compression rings and one oil ring 5 CAMSHAFT The camshaft is constructed of special cast iron and has intake and exhaust valve drive cams each of which engages with the cam gear An exclusive aluminum alloy is used on each end of the camshaft in the place of bearings 6 VALVE ARRANGEMENT The intake valve is installed at the oil port side and the exhaust valve at the generator side 7 CYLINDER HEAD The cylinder head is die cast aluminum and has Ricardo type combustion chamber featuring greater volume capacity for improved combustion efficiency For easier spark plug maintenance the cylinder head is posi tioned at an angle to allow greater access 8 GOVERNOR The centrifugal weight type governor ensures constant engine speed regardless of load fluctuations the governor is mechanically linked to the governor drive gear 9 EXHAUST FAN COOLING SYSTEM See Fig 5 5 Instead of
15. fuel pressure at the needle valves the valve closes to keep the fuel at the correct level e SCHEMATIC DIAGRAM OF THE FUEL SYSTEM BY A CAUSE LE PILOT OUTLET 1 FLOAT PILOT AIR JET MAIN NEEDLE PILOT Jer MAIN AIR JET PC EE VALVE mi FLOAT MAIN JET Fig 10 32 58 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 system operates with the fuel flowing through the main jet nozzle and up to the pilot jet nozzle where the fuel is measured When the fuel is mixed with air the volume of the air fuel mixture is also measured by the pilot air jet From this stage the mixture is supplied to the engine from the pilot outlet and bypass During idle fuel is supplied mainly from the pilot outlet 3 MAIN JET NOZZLE SYSTEM The main jet nozzle system supplies fuel for middle and high speed operation The fuel flows to the main jet nozzle where the fuel quantity is measured and then flows to the main nozzle Air volume which is measured by the main air jet enters from the breath hole of the main nozzle and mixes with fuel to form a gas mist The gas mist flows out of the main bore and is again mixed with air from the air cleaner From this stage the correct air fuel mixture is supplied to the engine 4 CHOKE The choke helps in starting the engine in cold weather When the engine is started
16. leak from the nozzle and cause engine trouble 4 MAIN JET NOZZLE a Remove bolt 15 and float chamber body 13 b Remove main jet nozzle 19 from carburetor body 9 c Firmly secure the main jet nozzle when assembling Otherwise air fuel mixture will become excessively rich and the engine will not operate properly d Torque for bolt 15 is 70 kg cm 2 5 FLOAT SYSTEM Pull out float pin 12 and remove float 11 and needle valve 20 Avoid using a drill or a wire to clean the fuel passages they may damage the orifice of the pilot and main jet nozzles Use compressed air The float pin is peen secured to the carburetor body the needle valve and float can be removed out from the opposite side of the peen secured part by lightly striking the float pin with a thin bar like object 13 17 16 14 o s Fig 10 33 60 10 6 FREQUENCY CHANGEOVER SYSTEM 50 Hz 60 Hz Selectable Type 10 6 1 CONSTRUCTION AND FUNCTION When the control lever 13 is turned to upper position the lever 12 is pulled back by the governor spring 10 to decrease the spring force of the governor spring to set the engine speed at 3 000 rpm 50 Hz At the same time the cam 14 combined with the control lever 13 releases the micro switches 18 to switch the circuits in the condenser coil and the main coil from 60 Hz to 50 Hz When the control lever 13 is turned to lower position the adjusting screw 22 on
17. means twice the length from generator to electrical tools 7 2 DC OUTPUT When the generator is employed to recharge batteries care must be exercised about the specific gravity of electrolyte in each battery case 7 2 1 MEASURING THE SPECIFIC GRAVITY OF ELECTROLYTE The specific gravity changes with temperature therefore it is converted to another corresponding to 20 S20 0 0007 20 where 20 Specific gravity corresponding to 20 St Measured value t Temperature at time of measurement 7 2 2 REMAINING CAPACITY ESTIMATED WITH REFERENCE TO THE SPECIFIC GRAVITY OF ELECTROLYTE SPECIFIC GRAVITY REMAINING BATTERY 20 87 75 37 25 Good charged condition Immediate charging is necessary Table 7 3 18 7 2 3 BATTERY CAPACITY The battery capacity is expressed in units of ampere hour AH One AH stands for the capacity capable of providing one ampere of current for one hour 7 2 4 SIMULTANEOUS USE OF THE AC DC OUTPUT If you use the AC DC output simultaneously in this generator be careful not to exceed the total power con sumption 50 Hz V M below 250W 60 Hz below 350W NOTE Max output of DC is 100W 12V x 8 3A 19 8 MEASURING PROCEDURES 8 1 MEASURING INSTRUMENTS 8 1 1 VOLTMETER AC voltmeter is necessary The approximate AC volt age ranges of the voltmeters to be used for various types of generators are as follow
18. no AC voltage is being produced check the generator following the procedure outlined in Section 11 2 3 Check the DC coil m Remove the left side cover right side cover front panel and the recoil starter m Disconnect the green wire and white wire from the rectifier Check the resistance between these wires with a circuit tester NORMAL RESISTANCE GREEN WHITE 0 722 4 Check the diode rectifier Refering to Section 9 6 on page 29 check the resistance between the terminals of the rectifier with a circuit tester If the rectifier is defective replace it with a new one 11 4 OUTPUT VOLTAGE IS NORMAL AT NO LOAD BUT GENERATOR WON T WORK ON LOAD 1 Check the engine speed Start the engine and check the engine speed at no load Adjust the engine speed to 3 100 3 150 r p m for 50 Hz type and 3 700 3 750 r p m for 60 Hz type 2 Check for over load Check the total wattage of the load s applied to the generator If the generator is over loaded remove or turn off some of the appliances 3 Check the appliances Check the appliances for defects If any are defective repair or replace them 69 4 Check the generator insulation Stop the engine Measure the insulation between the live part AC receptacle and the ground terminal Any part with an insulation resistance of less than 1 has faulty insulation that could cause elec tric shock or leakage Replace any such parts
19. pull it aside Then pull out the line 1 Insert the tip of a screwdriver into the groove of the choke cable blacket and turn it to remove the choke cable See Fig 10 7 Minus screw driver CHOKE CABLE HOSE CLAMP FUEL HOSE 35 a _ Muffler cover and 1 Remove the outer cover this is Take care not to drop Plus screw driver muffler done by removing seven M5 the removed screws tapping screws down into the cooling 2 Remove one M6 x 12 flange bolt air channel of the muffler bracket and two See Fig 10 8 M6 nuts from the muffler flange Then remove the flange 3 Remove four MS x 8 lock screws from inside inside of the muffler and remove the inner cover 10 mm box spanner Minus screw driver Remove one set screw of the Plus screw driver earth wire which grounds the rear housing and base plate 1 together 2 Remove four M5 x 10 bolts from the bottom of the base plate lt 2 lt MUFFLER COVER INNER M5 LOCK SCREW 4 pcs 8 mm box spanner M6 NUT 2 pcs MUFFLER SET SCREW BO yen BASE PLATE b MUFFLER COVER uc amp OUTER BOLT amp WASHER 4 pcs M6 FLANGE BOLT M5 TAPPING SCREW 7 pcs EXECUTIONI CR NN 1 Remove the recoil starter from the rear housing by removing Starter pulley three
20. the position If the engine has already been warmed up the control switch should be in the RUN position There should be sufficent gasoline in the fuel tank The spark plug cap should fit snugly on the spark plug electric appliances should either be disconnected from the generator or their switches should be turn ed off A generator often will not start if a load is already turned ON at starting 11 1 2 CHECK THE IGNITION SYSTEM 1 CHECKING SPARK AT SPARK PLUG Open the spark plug cover and remove the plug cap Remove the spark plug and check to see that it is clean and has an adequate plug gap Use the correct spark plug BMR4A or CHAMPION 8 Keep the plug gap between 0 6 0 7 mm 0 02 0 03 in Insert the spark plug into the plug cap Ground the metal body of the spark plug against the metal part of the generator Set the control switch in the position pull the starter handle and check the spark If the spark is strong the ignition system is normal If the spark is weak or if there is no spark at all the ignition system is defective 2 CHECKING IGNITION COIL If next step is to check the ignition coil a strong spark is not produced at spark plug the Remove the side covers left and right Remove the muffler cover muffler and the inner muffler cover Using a circuit tester check the resistance be ween the green wire and the core of the ignition coil
21. the control lever pushes the lever 12 to pull the governor spring 10 increasing the spring force to set the engine speed at 3 600 rpm 60 Hz At the same the cam 14 pushes the micro switchs 18 to switch the circuit from 50 Hz to 60 Hz The frequency of the output electricity can be adjusted by turning the adjusting screws 22 for 60 Hz or the screw 21 for 50 Hz ADJUSTING SCREW 50Hz ps ow CAM Je 14 10 CONTROL LEVER GOVERNER SPRING 16 SPRING Fig 10 34 61 D 22 60Hz el 10 6 2 DISASSEMBLY 1 Unhook the spring 16 and remove the control lever 13 with knob 15 Dri mem IE 1 7N 11 WN 4 12 i J i I Fig 10 35 2 Remove the clip 9 to disassemble the lever 12 and cam 14 3 Remove two screws 19 to detach the micro switches 18 62 GOVERNOR SPRING 10 LEVER 12 CAM 14 CONTROL LEVER 13 ADJUSTING SCREW 22 FOR 60Hz ADJUSTING SCREW 21 FOR 50Hz MICRO SWITCH 18 11 TROUBLESHOOTING In troubleshooting the generator you will encounter certain categories of problems It is important to check each component step by step You will certainly find the cause of any trouble through a systematic Troubleshooting 11 1 ENGINE DOES NOT START OR ENGINE DOES NOT RUN NORMALLY 11 1 1 CHECK THE BASICS 1 2 3 4 The control switch should be in
22. with the choke valve closed negative pressure applied to the main nozzle rises allowing most of fuel to flow through the main nozzle A mixture with a high gasoline concentration is fed to the engine resulting in easier engine starting 10 5 2 DISASSEMBLY AND ASSEMBLY OF CARBURETOR The most common trouble with the carburetor is failure to provide the correct air fuel mixture This is gen erally caused by blockage in the air and fuel passages at other times it is caused by fuel level fluctuations in the float chamber In order to maintain the carburetor in normal operating condition it is vital that the air and fuel passages be kept clean The following descriptions are the procedures for carburetor disassembly and assembly See Fig 10 33 1 THROTTLE MECHANISM a Remove Philips head screw 27 throttle valve 28 and pull out the throttle shaft 29 b When removing the throttle stop screw a spring 31 will also come off Be careful when handling the throttle valve to prevent the valve edge from damage 2 CHOKE a Remove Philips head screw 22 choke valve 23 and pull out choke shaft 24 b Be sure to keep the notch of the choke valve positioned forward the main air jet side when the choke shaft is installed 3 PILOT JET NOZZLE a Remove pilot jet nozzle 21 When removing use a proper tool so that the nozzle will not be damaged b Firmly secure the jet nozzle when the carburetor is assembled Otherwise fuel will
23. 114 127V 211 234V 227 253V voltage Table 8 1 8 3 MEASURING DC OUTPUT DC TERMINAL Fig 8 8 Measurement is made of the DC output of the generator with the switch shown in the above circuit turned on while the generator is kept running at its rated speed The DC output should be within 11 to 14 with the current regulated at 8 3A by adjusting the load connected to the generator NOTE If a battery is connected as a load to the generator the DC output voltage will increase by approxi mately 1 to 2V Therefore carefully observe the electrolyte level and do not overcharge the battery 8 4 MEASURING INSULATION RESISTANCE To measure insulation resistance connect the meg ger tester across either one of the two output termi nals of the socket and the earth terminal When the measured insulation resistance of the generator is over 1 it is normal over 10M2 at time of ship ment Be sure to turn on the circuit breaker when measur ing insulation resistance If the insulation resistance is less than disas semble the generator and measure the respective resistances of the stator rotor and control panel 22 8 4 1 STATOR Measure the insulation resistance between the RED lead and the core The resistance should be larger than 1 If the resistance is less than 1 the insulation is failed Replace the stator with a new one 8 4 2 ROTOR Measure the insulation resistance acros
24. ACLES Using a circuit tester check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel When continuity is confirmed between the output terminals of the receptacle with a wire connected across these terminals the AC receptacle is normal When the wire is re moved and no continuity is confirmed between these terminals the receptacles are also normal Fig 9 3 A Fig 9 3 B 9 1 5 DC TERMINALS Using a circuit tester check continuity between the DC terminals at the rear side of the control panel while they are mounted on the panel When continuity is confirmed between the DC ter minals with a wire connected across these terminals the DC terminals are normal When the wire is re moved and no continuity is confirmed between these terminals the terminals are also normal Fig 9 4 9 1 6 CIRCUIT BREAKER Check continuity between each of two terminals at the rear of the circuit breaker while it is mounted on the control panel Normally there is continuity between each of the two when the circuit breaker is on while there is no continuity when the circuit breaker is off 6P COUPLER WIRING GREEN YELLOW BROWN WHITE Fig 9 5 25 9 2 STATOR Measure the resitance of each stator coil using the circuit tester R x 19 10 Brown Blue White Green 6P coupler 3P coupler 6P coupler 3P coupler Rectifier 3P coupler 3P coupler
25. Always specify these numbers when inquiring about the generator or ordering parts in order to get correct parts and accurate service SPECIFICATION SPECIFICATION NUMBER SERIAL NUMBER Fig 4 7 5 CONSTRUCTION AND FUNCTION OF THE GENERATOR 5 1 CONSTRUCTION FUEL TANK SPARK PLUG CYLINDER CRANKCASE THROUGH BOLT RECOIL STARTER CRANKSHAFT k N Mm HE e eoo gt ry Y 29 ms ku 41 LU BALL BEARING FIELD COIL FIELD CORE STATOR COIL STATOR CORE COOLING FAN VIBRATION ISOLATOR Fig 5 1 5 2 FUNCTION OF EACH COMPONENT 5 2 1 GENERATOR 1 STATOR The stator consists of a laminated silicon steel sheet core a main coil and condenser coil which are wound in the core slots AC and DC output are taken out from the main coil DC output is taken out from the part of main coil which is in the middle of the main coil The condenser coil excites the stator field coil which generates AC output in the main coil 2 CONDENSER REAR HOUSING QU STATOR Z IS KI RECTIFIER Fig 8 2 The condenser is mounted on the rear housing and is connected to the condenser coil which is wound in the stator The condenser coil magnetizes the rotor which increases the 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 fr
26. E OF APPLICABLE LOADS Incandescent lamp electric heater etc Up to 450W Up to 550W Fluorescent lamp mercury lamp etc Up to approx 350W Up to approx 450W Pump and compressor drive motors Up to approx 150W Up to approx 180W Table 7 1 ELECTRIC DEVICES 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 shows 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 3 No of pue m oem o Ts Loss ome ss mes v in lt lt N H gt 53 B lt m m B o gt lt lt Voltage drop Table 7 2 2 1 100 R means resistance 52 100 m on the above table I means electric current through the wire A 9 means the length of the wire m Voltage decrease indicates as V The length of the wire indicates round length it
27. Fig 10 15 48 4 INSTALLING THE CRANKCASE The connecting rod is put into the cylinder while holding it with the piston ring guide as shown in Fig 10 16 in the case that a piston ring guide is not available press rings inward with fingers and at the same time strike down the piston using a wooden block The connecting rod must be mounted in place with its and MA marks directed to the ball bearing side of the crankcase NOTE Apply a sufficient quantity of oil to the pis ton rings connecting rod surfaces and cylinder NOTE The top second and oil rings are fitted to the piston with their ring joints arranged 90 off each adjacent joint 5 INSTALLING THE CONNECTING ROD MAJOR END CAP a Manually turn the crankshaft until the piston reaches top dead center Gently strike down the piston head until the connecting rod touches the crankpin to install the connecting rod major end cap b The cap is installed with the oil scraper position ed right downward See Fig 10 17 NOTE Be sure to use a new lock washer and carefully bend the washer correctly NOTE When the cap has been installed turn the crankshaft to see if the connecting rod moves smoothly PISTON RING GUIDE SCRAPER NOTE The correct torque for installing the connecting rod major end cap is 60 to 80 kg cm NOTE See Table 10 2 for details regarding the clearances between the piston piston rings and connect ing rod and their
28. NSER COIL Fig 5 6 5 3 1 GENERATION OF NO LOAD VOLTAGE 1 2 3 4 When the generator starts turning the permanent magneto built in to the flywheel it generates 1 to 4V of AC voltage in the main coil and condenser coil 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 condenser coil increases with the magnetic flux density of the rotor s magnetic pole increasing further Also the main coil voltage and condenser coil voltage increases These voltage continue rising as this process is repeated As current flows in the condenser coil the magnetic flux density in the rotor changes AC voltage is in duced in the field coil when the magnetic flux density varies Successively AC current is rectified by the rectifiers connected to both ends of the field coil and DC current b flows in the field coil With this current the rotor core is magnetized allowing the generator to output steady voltage 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 increases rapidly This acts to stabili
29. STALLING THE CYLINDER BAFFLE The cylinder baffle is installed to the crankcase using the M6 x 20 mm screw and to the main bearing cover using the M5 x 10 mm screw The cylinder baffle and fuel line clamp are installed together to the crankcase 52 13 INSTALLING THE HEAD COVER The head cover is installed over each of the left and right parts of the cylinder head using the M5 x 10 mm Screws 14 INSTALLING THE GOVERNOR AND RELATED PARTS Model EYO8D has a centrifugal weight type governor which is installed while engaged with the governor gear With the governor the throttle valve of the carburetor is controlled automatically by using a lever link mech anism Therefore engine speed is constantly maintained even under load variations a Using two M6 x 12 mm bolts install the speed control assembly to the crankcase b Temporarily install the carburetor with two M6 flange nuts c Join the throttle lever and governor lever of the carburetor to the governor rod and rod spring d Insert the governor lever into the governor shaft e Insert a minus screwdriver into the groove of the governor shaft and turn the screwdriver fully in the clockwise direction Push the governor lever clockwise at this time the throttle valve is fully opened and fasten the governor lever with the lock boit Torque for the governor lever 70 90 kg cm Link the governor lever and speed controller with the governor spring one of which is insert
30. TOR M6 BOLT amp WASHER 3 pcs 3P COUPLER REAR HOUSING Fig 10 11 38 FINE Rotor assembly Spark plug cap 18 Front housing and center baffle 1 Insert a rotor puller into the Rotor puller rotor shaft and tighten it until the rotor comes loose See Fig 10 12 10 mm box spanner SPARK PLUG CAP FLANGE BOLT Remove the plug cap from the spark plug 2 Remove the clamp of the high tension cord Remove the front housing and center baffle from the engine main bearing cover by removing three M6 x 25 mm bolts and one MS x 55 mm bolt CENTER BAFFLE FRONT HOUSING HIGH TENSION CORD M6 BOLT amp WASHER 3 pcs ENGINE FRONT HOUSING CENTER BAFFLE M5 BOLT ROTOR 39 19 Air cleaner 1 Remove the center screw of the air cleaner cover to remove the cleaner cover filter element and element retainer 2 Remove the M5 screw at the lower right inside the element chamber 1 3 Remove two nuts clamping the air cleaner and the carburetor together to remove the air cleaner ELEMENT MS SCREW 40 Minus screw driver Plus screw driver 10 mm box spanner AIR CLEANER CASE NUT ELEMENT RETAINER GROMMET AIR CLEANER COVER ELEMENT CENTER SCREW Part to remove Description Loosen the bolt unnecessary to remove it
31. ake vale and the other for exhaust valve WOODRUFF KEY MAIN BEARING COVER CAMSHAFT M6 BOLT amp WASHER 5 pcs 44 s sanan namn N 31 Connecting rod and 1 Scrape off the carbon deposits Confirm the mounting 2 Minus Screw piston from the cylinder and piston head direction of the oil driver Push and open the bend of the scraper Pliers connecting rod lock washer and remove two bolts Remove the lock washer and con 10 mm box spanner necting rod cap from the crank aft Turn the crankshaft until the piston comes to its top position and push the piston from the upper part of the cylinder Piston and piston Remove two clips from the piston 1 Replace these rings pin and take out the piston pin clips with new Remove the piston from the ones do not connecting rod reuse them Each of the piston rings can be 2 Be careful not to removed from the piston by open damage the minor ing wide the ring joint rod end Be careful not to open the ring joint excessively PISTON RINGS SEEM CONNECTING ROD ROD LOCK WASHER BOLT 2 pcs OIL SCRAPER 45 Crankshaft 1 Pull out the crankshaft from the crankcase If unable to pull it out by hand use a plastic hammer to gently strike the main bearing joint face and pull the crankshaft out 1 Remove the clip of the governor shaft and pull out the governor shaft from the crankcase
32. 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 10 LUBRICATION SYSTEM The moving and sliding parts inside the engine are lubricated with the oil scraper fitted on the connecting rod As the crankshaft rotates the connecting rod moves up and down and the oil scraper moves in conjunc tion with the connecting rod movements to scrape up oil in the crankcase and splash it over the surfaces of the moving and sliding parts 10 11 IGNITION A flywheel magneto igntion system is employed with the ignition timing set at 23 before top dead center 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 paragraph dealing with carburetor construction and disassembly assembly Page 59 13 AIR CLEANER The air cleaner is a semi wet type and contains a sponge element Fig 5 5 11 5 3 DESCRIPTION OF GENERATOR OPERATION INITIAL EXCITATION STATOR PERMANENT MAGNETO RECEPTACLE AND PLUG MAIN COIL CONDE
33. control switch lever and disconnect the choke wire from the lever Loosen the small screw on the fuel petcock m Remove the four bolts and take off the control panel Loosen the three bolts and remove the recoil starter m Remove the wire clamp Disconnect the wires connecting the condenser coil to the condenser m Using a circuit tester check the resistance between the three leads of the condenser coil Refer to the Table 9 1 on page 26 for the normal resistance value If the resistance is much larger or smaller the condenser coil is defective Replace the stator with a new one 5 Check the condenser m If an instrument QC meter or C meter for measuring the capacity of a condenser is available check the capacity of condenser NORMAL CAPACITY 10 11uF 66 m Usually the instrument is expensive and difficult to obtain we suggest instead that you install a new con denser and see if the generator works If the generator works with a new condenser the old one is defective 6 Check the rotor m Disassemble the generator to remove the rotor Unsolder the diode and the resister from the rotor terminal Unsolder one wire of each part DIODE RECTIFIER and RESISTOR Check the resistance between the wire ends of ro tor winding at the terminals NORMAL RESISTANCE 11 50 If the resistance is much different rotor is difective m Check the insulation resistance across one
34. counterparts 6 INSTALLING THE TAPPETS AND CAM SHAFT 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 properly See Fig 10 18 NOTE If the intake and exhaust valves are installed in reverse order tappet clearance will be incorrect MOE O TIMING MARK if i TIMING MARK CRANK GEAR Fig 10 18 49 7 INSTALLING THE MAIN BEARING COVER Install the main bearing cover to the crankcase NOTE The governor gear is already mounted to the bearing cover therefore it is necessary to confirm that the governor gear is meshed with the cam gear See Fig 10 19 If the oil seal requires replacement press fit the new oil seal in position before installing the main bearing cover NOTE Prior to installation apply oil to the bearing and oil seal Apply a small amount of oil to the cover fit ting face as specified in preparation for installing the bearing cover packing Place the oil seal guide over the crankshaft so that the oil seal lip will not be damaged during installation Make sure the the side clearance of the crankshaft is within 0 to 0 2 mm If necessary adjust the clearance using the adjusting collar See Fig 10 20 NOTE Torque for the main bearing cover 80 100 kg cm MAIN BEARING COVER MAIN BEARING COVER
35. e green cord Between the green cord and the high tension cord Table 9 2 9 5 CONDENSER If an instrument QC meter or C meter for measuring the capacity of a condenser is available check the ca pacity of the condenser NORMAL CAPACITY 10 114F m Usually the instrument is expensive and difficult to obtain we suggest instead that you install a new condenser and see if the generator works If the generator works with a new condenser the old one is defective 9 6 DIODE RECTIFIER Using a circuit tester measure the resistance between XR each of the two terminals of the rectifier The recti fier is considered normal when the respective resist ances have the values specified below RED The polarity of the circuit tester GREEN WHITE Fig 9 13 29 9 7 MICRO SWITCH Check the micro switch using a circuit tester BUTTON BUTTON 9 6 Fig 9 14 30 10 DISASSEMBLY AND ASSEMBLY 10 1 PREPARATION AND PRECAUTIONS 1 Be sure to remember the locations of individual parts when disassembling the generator so that the gen erator can be reassembled correctly Tie tags noted with the necessary information to facilitate easier and smoother reassembly 2 For more convenience divide the parts into several groups and store them in boxes 3 To prevent bolts and nuts from being misplaced or installed incorrectly place them temprorarily back at their original position 4 Handle d
36. e inflammable materials near the generator Be careful not to put gasoline matches gunpowder oil cloth straw trash and any other inflammables near the generator Operate the generator at least 1 meter 4 feet away from a building or wall Do not operate the generator in a room cave or tunnel Always operate in well ventilated area Otherwise the engine may become overheated and also the poisonous carbon monoxide contained in the exhaust gases will endanger human lives Keep the generator at least 1 m 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 Operate the generator on a level surface Do not operate the generator on a inclined surface Do not move or carry the generator while it is running Do not operate with wet hands or in the rain Severe electric shock may occur If the generator is moistened by rain or snow wipe it and fully dry it before starting Do not pour water over the generator directly nor wash it with water If the generator is wet with water the insulations will be adversely affected and may cause current leak age and electric shock Do not connect the generator to the residential power source This could result in a malfunction of or damge to the generator or appliance to which it is connected or could even lead to fire 7 Do not cover the generator with a carton a box or
37. e of the cylinder head Intake valve and Exhaust valve 1 Remove both the inner and outer tappet chamber covers from the crankcase by removing two M6 x Be sure to position the notch in the spring retain er s outside periphery to 12 bolts the front and hook the s minus screw driver 2 Remove both the intake and medium size in the Minus screw recess lower side of exhaust valves driv the retainer Then pull the spring retainer backward to remove it 3 Remove the valve spring and retainer SPARK PLUG Q RETAINER t PULL BACK CYLINDER HEAD EXHAUST VALVE INTAKE VALVE HEAD GASKET VALVE SPRING SPRING RETAINER TAPPET COVER M6 FLANGE BOLT 2 pcs 43 1 Remove the Woodruff key from the crankshaft 2 Remove five M6 x 25 bolts lock ing the main bearing cover from the crankcase 3 Using a plastic hammer or a similar tool strike the main bearing cover uniformly around its periphery to remove the cover Main bearing cover 10 mm box spanner Be careful not to dam Plastic hammer age the lip of the oil seal 1 Pull out the camshaft from the crankcase Set the crankcase side ways so that it will not fall and damage the tappets 1 Remove the tappets from the crankcase Be sure to mark the tappets to distinguish them from each other one for the int
38. ecause the diode D1 cuts off the current between A and B As a result voltage generated be tween the DC terminals has a waveform with two peaks in one cycle as in the case of the output wave form with two peaks in one cycle as in the case of the output waveform shown in Fig 5 9 BETWEEN AND B BETWEEN C AND B Fig 5 7 BATTERY MAIN B COIL OUTPUT WAVEFORM 7 1 CYCLE 5 CURRENT CURRENT FLOWING FLOWING BETWEEN BETWEEN A AND B CANDB Fig 5 9 13 5 4 ELECTRONIC IGNITION SYSTEM The electronic ignition system features a power transistor as the current control element Therefore the igni tion system is an electronic contact point free type that operates with the power transistor impulses control ling the current This system is also called TIC transistor igniter circuit and is virtually free of ignition fail ure which generally results from contamination of the contact points a typical problem with contact type ignition systems Because this ignition system has no contact points it is not affected by moisture oil dust or other contami nants As a result this electronic ignition system ensures sure and positive ignition with reduced maintenance The TIC mechanism consists of a transistor incorporated ignition coil and a permanent magneto built in fly wheel which is press fitted on the rotor shaft of the generator IGNITION COIL RESISTOR IGNITION TIMING DETECTING
39. ed into the center hole of the three of the governor lever and the remaining end inserted into the hole of the speed controller GOVERNOR LEVER SPEED CONTROL LEVER CONTROL KNOB N gt u ADJUSTING SCREW FOR 60Hz ADJUSTING SCREW FOR 50Hz CARBURETOR Fig 10 29 60 Hz 120V _ 53 Fig 10 30 15 INSTALLING THE CARBURETOR AND AIR CLEANER Place the carburetor gasket insulator gasket and carburetor in the correct positions Next fit the air cleaner gasket and air cleaner case and install them using the M6 nut and M5 x 10 mm screw Set the element small type element retainer element and cleaner cover and tighten them with screws slot head type Torque for installing carburetor 90 100 kg cm NOTE See page 59 for details concerning disassembly and assembly of the carburetor 16 INSTALLING THE CENTER BAFFLE AND FRONT HOUSING Set the dowel pin hole of the front housing to the dowel pin of the main bearing cover and assemble them together During assembly place the center baffle between the main bearing cover and front housing Torque for the front housing 80 100 kg cm 17 INSTALLING THE IGNITION COIL a Install the ignition coil and grommet IG COIL to the front housing Simultaneously set temporarily the generator rotor in position And assemble the ignition coil and magnet together while adjusting the air gap between the two to 0 4 to 0 5 mm F
40. he main jet or the pilot jet has been clogged up Refer to Section 10 5 2 on page 59 Use a compressor and high pressure air to blow the clogged dust or gum out of the jets and fuel passage Remove the float pin and the float Check the needle valve If the needle valve is worn replace it and the valve seat Clean and re assemble the carburetor 11 1 3 CHECK THE COMPRESSION If the engine s starting difficulty or power drop has not been caused by a faulty ignition or fuel system the final step is to check the compression of the engine 1 2 3 4 5 6 Check the spark plug Loose or broken spark plug can cause low compression If the spark plug is broken replace with a new one Check the head gasket Remove fuel tank head cover and cylinder head to check the head cover If the head gasket is broken replace it with a new one Remove carbon deposits from the cylinder head and piston top Check and adjust the tappet clearance Check the valve system Remove any carbon deposits from the valves valve seats intake and exhaust ports and valve guides If the valve face or the valve guide is worn replace it Check and adjust the tappet clearance when reassembling Refer to Sections 10 4 2 8 and 10 4 2 9 on pages 51 and 52 Check the piston and piston rings If the compression is still not sufficient you ll have to dismantle the engine and examine the piston and piston rings m Disassemble the engi
41. in the bracket which are bolted to the fuel tank Then install the fuel tank using two M6 x 8mm flange bolts d Make sure that the flexible shaft on the control dial side is inserted in the square hole of the strainer shaft then fasten the flexible shaft 30 INSTALLING THE REAR COVER Align the mounting holes at the lateral side of the rear cover with those in the fuel tank bracket Then install the rear cover using two M6 x 8 mm flange bolts Also align the holes at the lower part of the rear cover with those in the base plate and install the rear cover by two M6 x 8 mm flange bolts NOTE Pull out the fuel drain pipe of the carburetor through the hole on the rear cover The frequency changeover switch knob have to be drawn out through the rubber shield 31 INSTALLING THE FUEL TANK HANDLE 8 Set the bolt to secure the tank handle in the handle and assemble the O ring to this bolt from the op posite side Then tighten the to install the handle to the fuel tank NOTE Be sure to direct the less slanted part of the handle toward the front cover b Insert the rubber tube end over the protrusion of the bolt for the fuel tank and push it down to the base of the protrusion NOTE Be sure to keep the air breathe hole at the center of the rubber tube directed upward c Place the handle cover over the handle 32 INSTALLING THE FUEL LINE Insert the fuel line end over the fuel strainer joint be sure to push the line end d
42. irmly bond the grommet to the front housing ensuring that there is no residual clearance Use CEME DINE 575 b Fit the plug cap on the spark plug 18 INSTALLING THE ROTOR ASSEMBLY Install the rotor assembly to the taper of the crankshaft with their key ways in line NOTE Thoroughly clean the tapers both male and female tapers of oil or grease before assembly 19 INSTALLING THE STATOR ASSEMBLY a Install the stator correctly into the recess of the rear housing Note the leads and their positions b Install the wiring between the stator and rear housing Connect the wires from the stator to the condenser with these wires joined to two black top terminals Also connect the wires from the stator to the rectifier with these wires joined to three terminals Connect the ground cord to the rear housing using one M6 x 8 mm screw c Install the stator assembly correctly into the recess of the front housing If necessary strike softly the rear housing with a plastic hammer be careful not to strike the condenser and rectifier d Fasten the front housing to the rear housing of the stator assembly using three M6 bolts while the three bosses of the front housing are set to their counterparts of the rear housing Torque for each bolt 65 10 kg cm e Clamp the lead of the 6P coupler and the lead from the ignition coil to the bolts specified in paragraph d using wire bands 20 INSTALLING RUBBER MOUNT A a Fit rubber mount
43. isassembled parts with care clean them before reassembly using a neutral cleaning fluid 5 Use all disassembly assembly tools properly and use the right tool for each specific job 6 Drain fuel tank of fuel and crankcase of oil before disassembly 10 2 SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY NN j 7 Fig 10 1 No TOOL NO NAME OF TOOL DESCRIPTION For disassembling and deassembling the intake 230 95002 07 Valve guide puller To pull out the valve guide Table 10 1 is 10 3 DISASSEMBLY SEQUENCE Side cover L and R 1 Remove both left and right cover 3 Plus screw driver by taking out eight M5 flange screws Couplers discon 1 Disconnect the 6P coupler of nection the generator from the other 6P extending from the con trol panel Pull them downward while pressing down the retainer claws See Fig 10 2 SIDE COVER L SIDE COVER R M5 FLANGE SCREW 8 pcs Fig 10 2 32 3 i Choke cable 1 x G FUEL HOSE HOSE CLAMP CHOKE CABLE Fig 10 3 Set the control switch to STOP and disconnect the choke cable from the lever Disconnect the outer cable of the choke cable from the fuel tank bracket Loosen the M4 screw of the carburetor choke lever swivel to pull out the inner wire from the choke cable See Fig 10 3 10 mm box spanner P
44. lowest 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 10 24 NOTE As with the intake and exhaust valves the clearance between the valve and tappet stem must be 0 08 0 12 INTAKE amp EXHAUST VALVE VALVE SPRING SPRING RETAINER Fig 10 24 Fig 10 25 NOTE If the clearance is smaller than that specified slightly grind down the valve stem end using a grinder then measure the clearance f the clearance is larger than that specified repace the valve with a new one Spot the valve seat and use some compound to adjust the clearance NOTE After completing adjustment of tappet clearance install the valve spring retainers and then recheck the tappet clearance Installing the valve spring retainer Using the special tool place the retainer over the valve stem with the notch in the outside periphery of the retainer kept toward the front FRONT 10 INSTALLING THE CYLINDER HEAD En das Before reinstalling the cylinder head be sure to remove carbon deposits from the combustion chamber and clean between the cooling fins Also check the cylinder head for levelness NOTE Replace the cylinder head gasket with a new one The cylinder head is installed using seven M6 x 32 mm bolts NOTE Torque for each cylinder head bolt 90 110 kg cm 11 INSTALLING THE SPARK PLUG Torque for spark plug 120 150 kg cm 12 IN
45. lus screw driver Be careful not to damage the hose Hold the fuel line clamp inserted inside the strainer using pliers and pull it backward to remove the fuel line from inside the strainer See Fig 10 4 CHOKE CABLE Fig 10 4 33 EIN 5 Fuel tank handle Fuel tank 1 Push up the end of the cover fitted to the handle with finger 2 Pull out the rubber tube used as the air vent pipe 3 Remove two bolts tank and remove the handle OPlus screw driver 1 Remove the rear cover at the opposing side of the control panel by unscrewing the four M6 flange bolts 1 Loosen the set screw of the strainer shaft at the rear of the engine control switch 2 Remove two 5 flange bolts clamping the front cover and tank bracket together and then remove the fuel tank See Fig 10 5 10 mm box spanner HANDLE COVER FUEL TANK REAR COVER M6 FLANGE BOLT 4 pcs Wg J Z A M5 FLANGE BOLT 2 pes v Fig 10 5 34 bui mE clamping the front cover to the base and remove the front Fuel hose Be careful not to Electrician s pliers damage the fuel line Choke cable cover See Fig 10 6 FRONT COVER 1 Using pliers hold the fuel line clamp at the fuel support joint of the carburetor L joint direct ed downward and
46. n Circuit Breaker Protection for safe operation Replacement of fuses is not necessary in case of an overload Unique Dual Output Design so that two separate A C and D C electrical appliances can be used at the same time Frequency Changeover Switch enables changing output frequency from 50 Hz to 60 Hz Optional Oil Warning System automatically stops the engine if the oil level drops below the lower limit Factory Option Resistor Spark Plug is used as standard to prevent radio frequency noise Standard Tools are attached in the base plate for easy maintenance AC Voltmeter is a standard equipment for monitoring output voltage 4 GENERAL DESCRIPTION OF THE GENERATOR 4 1 COMPONENT IDENTIFICATION HANDLE MUFFLER COVER AIR CLEANER MUFFLER AIR CLEANER COVER FUEL TANK MUFFLER COVER RECOIL STARTER Fig 4 3 SPARK PLUG FREQUENCY ADJUSTING UNIT FREQUENCY CHANGEOVER UNIT 60Hz 120V TYPE 50Hz 60Hz VARIABLE Fig 4 4 FRONT HOUSING RECOIL STARTER CARBURETOR Fig 4 5 RUBBER PIPE FOR AIR VENT CHOKE WIRE BASE PLATE Fig 4 6 4 2 LOCATION OF SERIAL NUMBER SPECIFICATION AND SPECIFICATION NUMBER The serial number is stamped on the crankcase at the opposite side of the carburetor and also stamped on the label stuck above the oil filler cap The specification and specification number are shown on the nameplate located on the rear cover
47. ne and remove the piston and piston rings m Check the piston rings and grooves Clean off any carbon or gum deposits from the piston rings and grooves If a piston ring is worn replace with a new one Refer to Section 10 4 2 3 on page 48 65 11 2 e VOLTMETER DOES NOT WORK OR PILOT LAMP DOES NOT TUNR ON e NO AC OUTPUT 1 Normal voltage at receptacle e Run the engine Measure the voltage at AC receptacle with a circuit tester while the engine is running at rated r p m 50 Hz 3 000 r p m 60 Hz 3 600 r p m Remedy If the voltage is normal the voltmeter or pilot lamp is failed Replace it with a new one 2 Wiring correct Stop the engine Check all the wiring to be done correctly Remedy Correct wrong wiring tighten loose connection 3 Check the stator Remove the left side cover and disconnect the couplers on the wires connecting the stator and the control panel Referring to the Table 9 1 on page 26 of this manual check the resistance between the terminals If the resistance is much larger or smaller than the specified values on the Table the stator is defective Replace with a new one Measure the insulation resistance between the leads and stator core using a megger tester If the resistance is less than 1 the insulation is failed Replace the stator with a new one 4 Check the condenser coil m Remove the right side cover Loosen the small screws on the
48. of the soldered terminals and the rotor core using a meg ger tester If the resistance is less than 1 the insulation is faulty Replace the rotor with a new one Fig 11 7 67 m Check the resistance of the resistor NORMAL RESISTANCE 150 nia Hr A bs ALD 2s Fig 11 8 m Check the diode Touch the positive RED probe of the circuit tester to the cathode mark side of the diode and touch the negative BLACK probe to the other side of the diode Normal resistance is 1622 Reverse the polarity of the circuit tester At this time the resistance is infinity Remedy If the diode is defective replace with a new one v df KA x Pd uem uf Fig 11 9 NORMAL RESISTANCE NORMAL RESISTANCE fe CATHODE MARK CATHODE MARK Fig 11 10 68 11 3 NO DC OUTPUT 1 Check the DC circuit breaker m Examine the DC circuit breaker to make sure it is in the ON position Sometimes when a battery with a large capacity is being charged the charging current exceeds the maxi mum DC output the generator can produce This causes the circuit breaker to pop into the OFF position When this is the problem advise your customer to use a battery charger and take the power from the AC receptacle 2 Check the AC output m Using a circuit tester check the AC voltage at the AC receptacle If
49. om the diode of this rectifier is connected to the DC terminal 4 ROTOR The rotor consists of a lamination silicon steel sheet core and field coil which is wound over the core DC current in the filed coil magnetizes the steel sheet core Two permanent magnets are provided at 90 degrees from the poles for the primary exciting action A securely mounted fan is pressure fitted on the end of the rotor shaft to cool the individual coils iron cores rectifier and other integral parts Cooling air from the fan is drawn in from the venti lation vents in the rear housing and is discharged from the exhaust port in the front housing 5 CONTROL PANEL The panel on the front of the housing has a recepta cle with a ground terminal and AC output is taken out with a male plug DC output is taken out from the red positive and black negative terminals Control switch circuit breaker voltmeter and pilot lamp are installed on the control panel Fig 5 4 5 2 2 ENGINE 1 CYLINDER and CRANKCASE The cylinder and the crankcase of the engine are of a one piece aluminum die cast design The cast iron cyl inder liner is molded inside the cylinder Both the intake and exhaust ports are positioned at the lateral side of the cylinder and these parts are formed by using a mold with die cast cores The crankcase has its joint face located on the generator side 2 MAIN BEARING COVER The main bearing cover is aluminum
50. 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 can be 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 necessary for using it When using a generator for operating an electrical appliance however the pow er factor and starting current must also be taken into consideration Determine the capacity of your generator from the power required for operating electrical appliances refer ring to the followsings 1 2 3 4 Incandescent lamps hot plates etc with a power factor 1 0 power consumption must be equal to or less than the rated output of generator Example generator with a rated output power of SOOW can light five 100W lamps Fluorescent lamps mercury lamps etc with a smaller power factor Select a generator with a rated output equivalent to 1 2 to 2 times the power consumption of the load Example generator with a capacity of 100W to 160W is necessary for lighting a 80W fluorescent lamp A generator with a rated output of 500W can light three to five 40W fluorescent lamps NOTE Wattage of
51. own to the joint base and secure it with the clamp 33 INSTALLING THE CHOKE CABLE a Insert the choke cable adjusting screw in its hole on the fuel tank bracket b Secure this adjusting screw with the M6 nut and tighten to the midway point of the threaded part c Set the dial of the control panel to STOP and connect the choke cable end to the lever of the panel d Pull the inner wire of the choke cable to clamp the wire to the choke lever using the setscrew 34 CONNECTING THE COUPLERS TOGETHER Connect the coupler 6P from the generator to the coupler 6P extending from the control panel Also connect the stop wire green as required 56 35 INSTALLING THE LEFT SIDE COVER Pull out the starter handle through the cover and install the left side cover to the generator with four M5 flange screws 369 INSTALLING THE RIGHT SIDE COVER Fit the foam rubber stuck inside of the right side cover to the air outlet window of the muffler cover and install the cover to the generator with four M5 flange screws 57 10 5 CARBURETOR 10 5 1 FUNCTION AND COMPONENTS See Fig 10 32 1 FLOAT SYSTEM The float chamber is located directly under the carburetor Float and needle valve maintain a constant fuel level inside the float chamber The fuel in the tank flows into the float chamber from the needle valve When a certain quantity of fuel enters the chamber the float rises When the buoyancy of the float balances with the
52. s 150V Type with an output voltage of 1 10V or 120V 0 to 300V Type with an output voltage of 220V 230V or 240V Fig 8 1 8 1 2 AMMETERS AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10A 20A 100A Prepare a DC ammeter which has a scale range of 15A Fig 8 2 8 1 3 FREQUENCY METER Frequency range About 45 to 65 Hz NOTE Be careful of the frequency meter s input voltage range Fig 8 3 20 8 1 4 CIRCUIT TESTER Used for measuring resistance etc 8 1 5 MEGGER METER Used for measuring generator insulation resistance Select one with testing voltage range of 500V 8 1 6 TACHOMETER Use a contact less type tachometer CONTACTLESS TYPE Fig 8 6 21 8 2 MEASURING AC OUTPUT SWITCH TO AC RECEPTACLE Fig 8 7 With the circuit shown in Fig 8 7 measurment is made of the AC output of the generator An electric heat er or an incandescent lamp with a power factor of 1 0 is suitable as a load for the generator When the measured AC output of the generator is confirmed to be within the voltage range specified in the table below over its voltage rating the AC output is normal Measurement must be made under rated load and at rated speed sometimes load and speed adjustments are necessary Voltage 110V 120V 220V 240V rating Range of 104 107V
53. s one of the soldered terminals of the rotor and the core The resistance should be larger than 1 If the resistance is less than 1 the insulation is failed Replace the rotor with a new one 8 4 3 CONTROL PANEL Measure the insulation resistance between the live parts and the grounded part If the measured resistance of a component is below 1 the insulation is defective Promptly replace the defective component because there may be leakage of current from the generator and a potential danger of electrical shock 23 9 CHECKING FUNCTIONAL MEMBERS 9 1 CONTROL PANEL 9 1 1 ENGINE SWITCH Using a circuit tester check continuity across the black and green top terminals of the 6P coupler When continuity between the terminals is confirmed with the engine switch turned off the switch is nor mal It is also normal if there is no continuity be tween these terminals when the engine switch is set at RUN or CHOKE position Fig 9 1 9 1 2 VOLTMETER Also check with the circuit tester the continuity across the white and brown top terminals of the 6 coupler If continuity is confirmed between these terminals the voltmeter is normal Fig 9 2 9 1 3 PILOT LAMP Check the pilot lamp to be turned on by applying specified voltage Pilot lamp cannot be checked with a circuit tester because it is a light emitting diode and its resistance is too large 24 9 1 4 AC RECEPT
54. 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 Item 5 on the following page Electric tools etc that are driven by a motor 1 2 to 3 times large power consumption of a motor driven tool is required for starting Select a generator with a maximum output 1 2 to 3 times large to the load Example A 300W motor driven drill requires a generator with a maximum output of 400 to 900W or more Water pumps compressors etc that are driven by a motor and are initially loaded 3 to 5 times large power is necessary for starting Select a generator with 3 to 5 times large output of load Example A water pump with a power consumption of 400W requires a generator with a maximum out put of 1200 to 2000W or more NOTE 1 Motor driven appliances mentioned in tems 3 and 4 required the aforementioned generator capacities only when starting their motors 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 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
55. the opti mum generator capacity select a generator with a larger capacity sies 5 Appliances without any indication as to 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 tput of electrical li AOUIDHEOE electrical oppie put es electrical appliance Power consumption Efficiency Efficiencies of some electrical appliances are as follows Single phase motor 0 6 0 75 The smailer the motor the lower Three phase motor 0 65 0 9 the efficiency Fluorescent lamp 0 7 0 8 Example 1 40W fluorescent lamp means that its luminous output is 40W Its efficiency is 0 7 and ac cordingly power consumption will be 40 0 7 57W As explained in 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 a rated output of 500W capacity can light four to seven 40W fluorescent lamps Example 2 Generally speaking a 400W motor means that its work load is 400W Efficiency of this mo tor is 0 7 and power consumption will be 400 0 7 570W When this motor is used for a motor driven tool the capacity of the generator should be multipled by 1 2 to 3 and 570W as explained in the Item 3 RANG
56. to the bosses two at the lower center of the crankcase b Also fit another rubber mount to the bosses at the lower part of the stator assembly of the generator 54 21 INSTALLING THE STARTER PULLEY Install the starter pulley to the rotor shaft using the rotor through bolt Torque for the through bolt 100 150 kg cm 22 INSTALLING THE RECOIL STARTER Install the recoil starter to the rear housing using the M6 flange bolt 23 RUBBER TUBE FOR BREATHER Connect rubber tube to the air vent joint of the carburetor Keep this rubber tube suspended downward from the air vent joint 24 INSTALLING THE BASE FRAME a Install the base frame with its rear side facing the welded nut area of rubber mount A Match the rubber mount which is fitted to the lower part of the engine and generator Base plate is in stalled using four 5 bolts b Insert rubber tube from the air vent joint of the carburetor into the hole in the base frame c Fasten the ground terminal to the rear housing using M6 bolt 25 INSTALLING THE MUFFLER AND MUFFLER COVER a Fit the gasket for the muffler cover to the studs of the exhaust flange of the crankcase b Using 5 screws install the muffler cover in place Note Be careful not to drop the screws into the cooling air channel c Set the gasket for the exhaust port on the studs of the exhaust port flange Then mount the asbestos to the upper and lateral sides of the muffler
57. ze the respective coil output voltages If generator speed further rises to 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 as current flows in the main coil this flux serves to increase current a flowing in the condenser coil With current a increased the magnetic flux density across the rotor core rises As a result 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 and is fed to the diode at which time the output undergoes full wave rectification prior to being supplied to the Joad connnected to the generator The diode recti fier works to allow the current to flow in 2 direc tion but does not allow the current to flow in b direction as shown 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 because current is cut off by the diode D2 Contrary to the aforemen tioned if the voltage in C is higher than that in A current d flows in the direction as shown in the figure with no current flowing between A and B This is b
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