Subaru Robin Power Products R1200 User 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.
This manual includes only brief descriptions on important points, so we ask you to

supplement this with your own experience and determination in practical guidance for
your customers.

We are also going to have seminars or other events to exchange

necessary information to improve our service to customers.

CONTENTS

Section

Title

Page

1.

SPECIFICATIONS

...................................................

1

1-1

items ....................................................... 1

1-2

Performance Curves .............................................

2

2.

3.

4.

FEATURES

.......................................................

5

COMPONENT IDENTlFlCATlON

........................................

6

FUNCTION OF EACH COMPONENT

.....................................

7

4-1

Generator ....................................................

7

4-2

Engine ......................................................

9

5.

DESCRIPTION OF MAIN OPERATIONS

.................................. 11

5-1

Electronic ignition Mechanism ......................................

11

5-2

Description of Generating Operation ..................................

12

6.

OPERATIONAL LIMITS OF THE GENERATOR

.............................

14

6-1

AC Output

...................................................

14

6-2

DC Output ...................................................

16

63

Simultaneous Use of AC/DC Output ..................................

16

6-4

Wire Length ...................................................

17

7.

MEASURING PROCEDURES

...........................................

18

7-1

Meters

......................................................

18

7-2

Measurement of AC Output ........................................

20

7-3 Measurement of DC Output ........................................

20

7-4

Measurement of Insulation Resistance

.................................

20

8.

FUNCTIONAL CHECK OF EACH COMPONENT. ............................

22

8-1

Control Panel. .................................................

22

8-2

Diode Stack (Rectifier) ...........................................

23

8-3

AVR

.......................................................

24

8-4

Stator

.......................................................

25

8-5

Rotor

.......................................................

26

8-6

Brush

.......................................................

26

8-7

Ignition Coil ..................................................

27

8-8

Exciting Coil ..................................................

27

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 Procedure ............................................. 48

9-5

Carburetor ................................................... 67

SAFETY PRECAUTIONS. ............................................. 72

10-1

Fire Prevention ............................................... 72

10-2 Precautions for Exhaust Gases.

......................................

72

10-3 Other Precautions ............................................... 72

TROUBLESHOOTING ................................................

73

CRITERIA TABLE FOR ADJUSTMENT ................................... 91

WIRING DIAGRAM .................................................

94

MAINTENANCE ....................................................

95

14-1 Daily Checks and Maintenance (Every 8 Hours) ........................... 95

14-2 Checks and Maintenance for Every 20 Hours ............................. 95

14-3 Checks and Maintenance for Every 50 Hours (Every 10 Days) .................. 95

14-4 Checks and Maintenance for Every 200 Hours (Every Month) .................. 96

14-5 Checks and Maintenance for Every 500 Hours (Semi-Annually) ................. 96

14-6 Checks and Maintenance for Every 1000 Hours (Annually) .................... 96

14-7 How to Store the Generator for Long Period .............................. 96

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 hours

Approx. 4 hours

Approx. 3.5 hours

I

I

Generator:

Type

2-pole, revolving field type

I

Exciting system

Self-exciting

I

Voltage regulating

I

system

AVR (Automatic Voltage Regulator)

I

I

Maximum output j

1000 w

!

1200 w

I

I

Rated output

800W

I

1000 w
AC Frequency
AC Voltage
DC output

50 Hz

1
I

60 Hz

110,220,230,24OV

110,120,220v

12V -8.3A (1OOW)

I

AC receptacle

I

S.T.D type, nema, germany: 2 ea.

I

France, Australia, England, Switzerland: 1 ea.

DC receptable

!

One

Over current
protection

I

Circuit breaker

I

Voltmeter

1

Standard equipment

Dimensions (L x W x H):

4B6x2BBx410mm

I

(19.1 x 11.3 x 16.1 in.)

I

Dry weight

I

I

27.5 kg (60.6 Ibs)

-l-

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) -

Ti
I -t

52

1000

z 51

;I 50

ii

L 49

800

I

LL

s

z

I

600 ‘;

8

260

P

s

8 250

400 0

z

> 240

230

200

0

1 2 3 4 5

0

Current (A) -

Output Max.

...............

1000 w

Rated ........... 800 W

Frequency

..................

50 Hz

Voltage

.....................

220 v

Output

Max. ................

1000 W

Rated

...........

800 W

Frequency

.................. 50 Hz

Voltage

.....................

230 V

Output Max.

............... 1000 w

Rated

........... 800 W

Frequency

.................. 50 Hz

Voltage

.....................

240 V

-2-

;;;

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 Max.

...............

1000 W

Rated

...........

800 W

Frequency

..................

50 Hz

Voltage

.....................

110 v

Output Max.

...............

1200 w

Rated

...........

1000 W

Frequency

..................

60 Hz

Voltage

.....................

110 v

Output Max.

...............

1200 w

Rated

...........

1000 W

Frequency

..................

60 Hz

Voltage

.....................

220 v

-3-

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 a battery the voltage is 12V, but the voltage becomes higher when
the load is smaller (or when the current is smaller than the rated one), and lower when the
load is bigger (or when the current is bigger than the rated one).

Note that the voltage

under no load is approximately from 18V up to 25V.

-4-

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 concentrated on the front panel, which enables users to easily

handle this generator.

(4) Operations of choking, running, and stopping the engine can easily be executed with a

notch.

(5) As a circuit breaker based on the push button system is employed in this generator,

replacement of a fuse is unnecessary.

Troubles which happen in an overload or failure of

devices used can easily be resolved.

(6) Direct current for charging batteries can also be taken out.
(7) Simultaneous use of DC is possible even when AC is used. However, total AC output and

DC output should be within the range of the rated output.

(8) Voltage fluctuation ratio is below 5% because of employment of AVR (Automatic Voltage

Regulator). Accordingly, the stable voltage is always maintained even if the load

fluctuates.

(9) Generally maintenance-free or maintenance is easy because the engine, with a transistor

ignition system, has an excellent startability and no point is employed in this generator.

(10) An ignition plug with a resistor and a plug cap have been employed to prevent electric

wave noises.

-5-

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 out from the DC coil.

4-l-2 ROTOR

The rotor consists of a laminated silicon steel
sheet core, a field coil which is wound around
the core, and a cooling fan mounted on one
end of the shaft, with a slip ring on the
opposite end. One end of the lead wire from
the field coil is connected to the slip ring.

The field coil becomes an electromagnet when

DC current flows from the slip ring. The
cooling fan is for cooling the generator by
inducting cooling air from the slip ring side
and discharging it from the fan side.

4-l-3 BRUSH
Exciting current from the AVR is supplied

through this bush to the rotor. The brush is
made of carbon, while the brush holder is
made of plastic. In order to run the generator

efficiently without failures, it is necessary to

maintain the contact voltage between the

brush and the slip ring within a range, which
needs management of the brush length.

Fan

F& 4-l-2

Fig. 4-l-3

-7-

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 output voltage from

the generator. The circuit breaker for AC and

DC in the upper section of the control panel
prevents too big an output current from being
taken out, or excess current in short circuit.

Fig. 4-14

F& 4-l-5

-8-

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 crankcase has its joint face located on the generator side, and it is of an
assembly structure.

4-2-2 MAIN BEARING COVER
The main bearing cover is alminum die-cast and is mounted on the generator side. By removing

it, the interior of the engine can be inspected.
4-2-3 CRANKSHAFT

The crankshaft is constructed of forged carbon steel, and the crankpin is induction-hardened. A
crank gear is pressure-fitted on the generator side of the engine.

4-2-4

CONNECTING ROD AND PISTON

The connecting rod is made of forged aluminum alloy with both the major and minor ends utilized

as bearings. An oil scraper is cast on the major end. The aluminum alloy casting piston has slots
on which two compression rings and one oil ring can be assembled.

4-2-5 CAMSHAFT
The camshaft is made of special cast iron and has intake and exhaust valve drive cams, each of

which engages with the camgear. An exclusive aluminum alloy is used on each end of the
camshaft in the place of bearings. (Ball bearings are not used.)

4-Z-6 VALVE ARRANGEMENT
The intake valve is arranged in the generator side, while the exhaust valve is arranged in the

recoil side.
4-2-7 CYLINDER HEAD

The cylinder head is die-cast aluminum and has a Ricardo type combustion chamber featuring

greater volume capacity for improved combustion efficiency. For easier ignition plug mainte­nance the cylinder head is positioned vertically.

4-2-8 GOVERNOR
The centrifugal weight governor ensures constant engine speed, regardless of load fluctuations

(the governor is mechanically linked to the governor drive gear).
4-2-9 COOLING SYSTEM

The cooling system with a cooling fan, which also functions as a flywheel, compulsorily sends
cooling air to the cylinder and the cylinder head and cools them.

This forced air cooling system

has a baffle plate and a head cover.

4-Z-10

LUBRICATION SYSTEM

The moving and sliding parts inside the engine are lubricated with

the

oil scraper fitted on the

connecting rod by scraping and splashing oil in the crankcase.

-9-

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 horizontal suction type carburetor employed here can provide excellent starting, good

acceleration, low fuel consumption, and superior output. The carburetor setting is matched to
the generator set. (On details concerning the carburetor construction and others, see the

paragraph dealing with carburetor construction and disassembly/assembly.)

4-2-13 AIR CLEANER

The air cleaner is a semi-wet type and contains a sponge element.

-10-

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 results
from contamination or burning of the contact points, oxydation during storage for a long time, or
abrasion of mechanical sections, all of which are typical with contact type ignition systems. The
maintenance-free ignition system can maintain proper discharging and is not affected by
moisture, oil, dust, or other contaminants.

The T.1.C system consists of a transistor-incorporated ignition coil and a flywheel with a
permanent magnet mounted on. The basic principle is shown below.

I

Ignition Coil

I

E @

r

*go .$

$1 r

‘1 Q

b

z

.-

E

P

=

LT

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f

Ll

f

‘CC = 8

r 8

I

z

.-

E

? ~~~

@5

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5

2

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5

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ki

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iTI-

F&. 5-7

(1) When the flywheel starts rotating, power is generated in the primary coil of the ignition

coil and current flows to the resistor @. With this current? the power transistor turns on
releasing current B .

This stage corresponds to the closing of the contact points.

(2) As rotation of the cooling fan reaches the ignition point, the ignition timing detecting

circuit is activated, releasing the current 0. The signal transmitter transistor actuates to
release the current @.

When the current @ starts flowing, current @, flowing through

the power transistor, is cut immediately.

As a result, high voltage is generated in the

secondary coil by current fluctuation.

This voltage is simultaneously applied to the spark

plug which ignites the ignition.

This stage corresponds to the opening of the contact

points.

-11-

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 the AVR, causes the flow of the current @through the field coil wound around
the rotor in the generator. The rotor is then turned to an electromagnet by the current and at
the same time when it starts rotating, voltage is generated in the coils (main coil, sub-coil, and
DC coil) of the stator. -Then, the voltage generated in the sub-coil is rectified by the AVR, and
the current @ flows so that current in the field coil is increased. This increases magnetic
intensity to the rotor. Rated voltage is generated in the main coil and the DC coil by repeating
this operation.

5-2-2 VOLTAGE REGULATION UNDER LOAD

When a load is connected to an AC receptacle
and current is increased, output voltage fluc­tuates and the voltage fluctuations in the case
where an AVR is in the circuit and in the case

where no AVR is in the circuit differ as shown
in Fig. 5-2-2. The AVR operates

as

follows.

When AC output is taken out, load is put on

the engine.

The AC voltage becomes lower

because rpm of the engine becomes fewer and

the voltage decreases on account of inner
resistance of the coil. The AVR detects the

voltage decrease and automatically increases

the current flowing through the field coil with

a thyrister inside the AVR.

As a result,
magnetic intensity to the rotor is increased
while the decreased voltage is raised again by
taking out loaded current, which in turn main­tains the output voltage at a constant level.
When the AC output becomes lower the thyris­ter provides reverse operation, and in this

case,

the voltage is also maintained at a

constant level.

Rated Level

Current (A)

F& 5-2-2

-12-

j-2-3 DC OUTPUT
DC output is taken out from a part of the

main coil and is fed to the diode stack (recti­fier) 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 5-23

Fig. 5-2-4 shows the DC output circuit of the
generator.

DC voltage is generated in the
main coil. When the voltage in A is higher
than that in B, the current @ flows in the
direction shown in the figure, while no current
flows between CF and DE because the current
is cut off by the diodes G4 and G2. On the
contrary, when the voltage in B is higher than
that in A, the current @I flows in the direction
as shown in the figure. No current flows
between CD and EF because the current is cut
off by the diodes G1 and G3.

=
8

Fis. 5-24

As a result, the voltage generated at the
output terminal has a waveform with two

peaks in one cycle, as in the case of the output
waveform shown in Fig. 5-2-5.

Output Waveform

Current @

Curr&t @

F&. 5-2-5

- 13 -

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 and starting current should also be taken into account.
6-l-l NET RESISTANCE LOAD

Incandescent lamps, electric heaters etc.

can be run on the generator having a capacity

equivalent to the total of the respective appliances.

Each of these appliances normally has a

power factor of 1.0.

Example: The generator having a rated voltage output of 1000 W can provide enough power to

operate up to ten 100 W lamps.

6-l-2 ELECTRIC APPLIANCES WITH A POWER FACTOR OF LESS THAN 1.0
Fluorescent lamps and mercury lamps normally have a low power factor, and accordingly, the

generator is required to generate approximately 1.2 to 2 times the power consumed by each

loaded appliance.
Example:

With the generator having a rated voltage output of 1000 W, six to ten 80 W mercury
lamps can be operated.

6-l-3 MOTOR LOAD
Generally, motors require a large starting current every time they are started or begin rotating.

The motor starting load supplied from the generator becomes the largest when starting a normal
operation mode. The rates of power supply, which the generator is required to produce for motor
loads, are categorized into two cases, depending on the types of the motor used and load
condition at the time of starting.

(1) Motors (mainly rectifier motors) used for electric drills and similar devices:

Normally, the motors used for electric drills and similar appliances require the generator to

produce approximately 1.2 to 3 times the power consumed at the time of starting.
Example:

To drive a 300 W electric drill, a generator with a maximum output of about 400 W to

900 W or more is necessary.

(2) Motors (mainly induction motors) used for pumps and compressors:

As pumps and compressors have loads even when they are started, the generator is required to

produce 3 to 5 times the power consumed during normal running.

Example: To drive a 200 W submersible pump, a generator with a maximum output of 600 W to

1000 W or more is necessary.

6-l-4 IN THE CASE WHERE POWER CONSUMPTION IS NOT DISPLAYED ON

THE RATING PANEL

Sometimes, the rating panel of an electric appliance does not carry its power consumption, but

only shows the mechanical equivalent to the power consumption.

In this case, it is necessary to

-14

-

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 lamp with a lighting output of 40 W, and assuming that the

power consumption of this lamp is 0.7, the power consumption can be calculated as
follows:

40 + 0.7 = 57 W

Furthermore, as per paragraph (2), the power consumption is multiplied by a factor of

1.2 to 2, producing a power consumption of 70 to 115 W. Therefore, with a generator
having a rated output of 1000 W, 8 to 14 lamps can be used.

Example: In the case of a 200 W motor, the mechanical equivalent of the motor is 200 W.

Assuming that the efficiency of the motor is 0.7, the power consumption is calculated
as 200 I 0.7 = 285 W. Similar to the above, the calculated power consumption is then

multiplied as per (3)a, or (3)-a, taking into account the type of the motor used and
the starting condition. The table below shows the range of loads applicable to the
generator with 1000 W rated output.

Electric appliance

Range of applicable load

50 Hz

60 Hz

I

Incandescent lamp, electric heater, etc.

I

Up to 800 W

I

Upto 1ooow

I

Fluorescent lamp, mercury lamp, etc. Up to approx. 500 W
Motordriven tools etc.

Up to approx. 500 W

Pump and compressor drive motors Up to approx. 250 W

Up to approx. 650 W
Up to approx. 600 W
Up to approx. 300 W

Note 1: With motor-driven tools specified in paragraphs (3) and (4), the generator of the

said capacities are required only when starting the motors for the respective
appliance.

Once the motor has started, power necessary for normal running is
only 1.2 to 2 times larger than the rated power, and the surplus capacity of the
generator may be used for other electric appliances.

Note 2: As for the tools using the motors specified in paragraphs (3) and (4), the power

requirement for starting the tools varies according to the types of motor and the
load conditions at the time of starting.

-15-

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)

where

S20: The specific gravity at 200C
St :

Measured value

t : Temperature at the time of measurement (Electrolyte)

6-2-2 REMAINING CAPACITY ESTIMATED WITH REFERENCE TO THE SPECIFIC

GRAVITY

Specific gravity

(20°C)

Remaining capacity

(%I

I .260

100

I .240

87

1.220

75

Remarks

Charging is not necessary.

Charging is necessary.

I

I .200 62

1.180

1.160
I .I40

I

50
37
25

Immediate charging is necessary.

I

6-2-3 BATTERY CAPACITY

The battery capacity is expressed in the unit of AH (amperehour). One AH stands for the
capacity capable of one ampere current for one hour.

6-3 SIMULTANEOUS USE OF AC/DC OUTPUT

With a generating engine of rated 1000 W output, AC and DC are simultaneously available but, in
this case, be careful not to exceed the total power consumption.

50 Hz

below 700 W

60 Hz

below 900 W

Note:

Max. DC output is 100 W (12V x 8.3A).

-16-

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 1

Alloweble j

COIldUCtO~/

current conductor i

Rasistanca

diameter !

Current

I

mm2 j A j No./mm

a/lOOm 1 1A 3A 5A 8A ! 10A i 12A 1

15A

I

’

0.75 * 7 : 3010.18 2.477 2.5V 8V 12.5V _
I

-/- ] - j

.

I

1.25 : 12 : 5010.18 ! 1.466 1.w ! 5v i 7.5V 12v 15v 18V -

i 17

I I

I

b

2.0 37/0.26

,

0.952 1v ,3v 1 5V ! 8V 1ov
i

12v 15v d

0
z

3.5 23 4510.32

’

0.517

’

- j 1.5V 2.5V 1 4V ’ 5V 6% 7.5v 5
>

5.5 35 7010.32 0.332 - 3.5v 4v

-17-

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 and DC ammeters are necessary.
The AC ammeter must have a scale range

from 0 to approximately 15A, and the DC
ammeter also must have a scale range from 0
to approximately 15A.

7-l-3 FREQUENCY METER
The frequency meter must have a scale range

from 45 to approximately 65 Hz.
Note: Note the input voltage range for the

frequency meter.

For AC

For DC

Fig. 7-l- 1

For AC

For DC

FI& 7-l-2

II ’

m

;i ,71;

.: [m j

I-

1

Fig. 7- l-3

-18-

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 specified in the table below, the AC output is normal.

I

1

Rated voltage 1 1OOV 1

1lOV 120v I 220v 230V

240V

Voltage range

i 98~105V 108~115V~118~125V~218~~225V 228~235V 238~245V

73 MEASUREMENT OF DC OUTPUT

To a DC Receptacle

Fig. 73

Measurement of DC output is executed with the switch turned ON while the current is regulated

at 8.3A by adjusting the load to the generator.

If the voltage is within the range from 1OV to

14V, the voltage output is normal.
Note:

If a battery is connected as a load to the generator, the DC output voltage will increase
by approximately 1 to 2V.

Therefore, carefully observe the electrolyte level and don’t

overcharge the battery.

7-4 MEASUREMENT OF INSULATION RESISTANCE

7-4-l TO MEASURE INSULATION RESIST­ANCE, CONNECT THE MEGGER TESTER

ACROSS EITHER ONE OF THE TWO OUTPUT
TERMINALS OF THE AC RECEPTACLE AND
THE EARTH TERMINAL.

Measurement
should be executed after the AC circuit
breaker is turned ON.

When the measured
insulation resistnace is over lMQ, it is normal
(or, over 1OMQ at the time of shipment).
When the measured insulation resistance is
below lMn, disassemble the generator and
measure the insulation resistances of the
stator, rotor, and control panel for each.

F&. 74-1

-20-

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 resist­ance 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 slip rings of the rotor and
the core.

If there is a section where insulation resist­ance is below lMS2, replace the part because it
may cause insulation failure or such accidents
as electric shock or leakage.

7-4-4 CONTROL PANEL
Measure the insulation resistance between the

charging section (a part where electric current
flows) and the grounded part.

If there is a section where insulation resist­ance is below lMS2, replace the part because it
may cause insulation failure, or such accidents
as electric shock or leakage.

I

Fig. 74-2

Fig. 74-3

Fig. 744

-21-

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 con­nected across the terminals, and is not con­firmed if the wire is removed, the DC recept­acle is normal.

8-l-3 CIRCUIT BREAKER

Check continuity between the two terminals
at the rear side of the circuit breaker by using
a circuit tester under the condition that the
circuit breaker is mounted on the control
panel.

If continuity is confirmed when the breaker is
ON, and no continuity is confirmed when the
breaker is OFF, the circuit breaker is normal.

Fig. 8- I- 1 (b)

8.

FUNCTIONAL CHECK OF EACH COMPONENT

8-1 CONTROL PANEL

8-l-l AC RECEPTACLES
Check continuity between the two terminals at the rear of the AC receptacles by using a circuit

tester under the condition that the receptacle is mounted on the control panel. When continuity
between the output terminals is confirmed with a wire connected across the terminals, and is not
confirmed if the wire is removed, the AC receptacle is normal.

Fig. 8-l-2

F&J. 8-7-3

-22-

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 in Fig. 8-2-l.

Confirm continuity between each

terminal by using a circuit tester as shown in Fig. 8-2-3. The rectifier is normal when continuity
is confirmed as follows.

I

Connect black s

terminal of the circuit tester

I

I

Yellow ; White . Orange Brown

No continuity ; Continuity

Connect red 0 terminal
of the circuit tester

I

Table 8-2- 1

Note 1: In checking the diode, direction of connection is contrary to the ordinary case because

of characteristics of the diode and battery incorporated in the tester.

Note 2:

“Continuity” means forward direction characteristics of the diode, and, different from
short circuit condition (in which a pointer of the tester goes out of its normal scale),
shows resistance to some extent.

When results of the checking indicates failure even in

one section, replace with Assy.

- 23 -

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 black, or if epoxy resin on the surface

has melted down, it can often be said that the AVR is defective.

8-3-2 THE CASE WHERE DETERMINATION BY MEASURING THE RESISTANCE

BETWEEN THE LEAD LINE AND THE COUPLER IS POSSIBLE:

Measure the resistance between the coupler
terminal and the lead line of the AVR. In the

normal case, the measured values should be as

shown below.

Fig. 83

Wire color

Yellow

Connect to the 8 terminal of the circuit tester

Red

White Green Black

5

.E

E

.;s

x

@W

W-

fE

OE

CL
t;s

Eg

6%

1

m 1 600K-1MR 1 75K-120KS2

Yellow

/ ;ft;; I zr;;;;ding ; 7K-lOKS2

I

4

1 400K-500KR :

4 4

! 4

250K-300KR ! ; 400K-5OOKS2
120K-130KS1 j

I
\ 2OOK-220KR

250K-300Kn ,\

7 45K-5OKR

4

500K-lMS2 75K-110KR \

7K-9KQ

\ 1 400K-500KS1

4

; 400K-5OOKfi 1

40K-46KQ j =

\ ! 200K-250KS2 1 4

i 4

[Wiring in the 4P coupler]

Red @--

Green @I

@White

@I Black

Note 1: Upper section of each column corresponds to

the case of 220, 230 or 240V specifications,
while the lower section corresponds to 100,
110 or 120V specifications.

Note 2: Sometimes the measured value does not

match the values in the table above because
errors of a circuit tester are big and in­fluenced peripheral temperature.

- 24 -

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

0.32Q

4.452

60Hz - 1oov 0.6

0.23

3.6

50Hz - I IOV !

1.2

0.44

I

4.4

60Hz - 1 IOV 0.9

I

0.32 3.6

60Hz - 120v 0.9

0.32

I

3.6

50Hz - 220V !

5.0

0.70

I

4.4

60HZ - 220V i

3.5

0.42

3.6

50Hz - 230V !

5.0

0.70 4.4

50Hz - 240V 5.0

0.70

I

4.4

Note: Sometimes the measure values do not match the values shown in the

table above because of errors by the circuit tester, unevenness of coil
windings, or peripheral temperature.

- 25 -

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 peripheral temperatuer.

8-5-2 CLEANING OF SLIP RING
When the surface of the slip ring is smooth it

is normal.

When it is dirty or abraded, it

should be repaired.

When the slip ring is dirty efficiency of the
generator may become lower and sufficient
voltage and output can not be obtained. In

this case, sand around the slip ring with fine
sandpaper.

Note:

When sandpaper is used, be careful not
to damage the coils of the rotor.

Stlip

Slip Ring

F&T 8-S 1

Fig. 8-5-2

8-6 BRUSH

If the surface of the brush contacting the slip

ring is smooth, it is normal. If not, make it

smooth with sandpaper.

Unless the surface is smooth, an arc may be
generated between the brush and the slip ring,
which may damage the brush and the slip ring.

The brush length should be, as shown in Fig. 8-

6, within the range from 1.5 mm to 5 mm. If
it is below 5 mm, it should be exchanged with
a proper one. When contact voltage between

the brush and the slip ring becomes lower,

efficiency of the generator also becomes

lower and sufficient voltage and output can
not be obtained.

5mm-5mm

Fig. 8-6

- 26 -

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, unevenness of coil winding, or peripheral
temperature.

8-8 EXCITING COIL

Measure resistance of the exciting coil and voltage at the rated rpm with a circuit tester.

Resistance value

( Voltage (AC) :
I

at rated rpm 1

Measurement location

I
I

10 Q 3ov ;

Between the terminals of the

I

i exciting coil

Note: The measured value does not always match the values shown in the table above,

because of errors by the circuit tester, unevenness of coil winding, or peripheral
temperature.

-

27

-

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 store them in the same box.
(3) To prevent bolts and nuts from being misplaced or installed incorrectly, place them

temporarily at their original positions.
(4) Handle the disassembled parts with care and clean them before reassembly using neutral

cleaning oil. (Be careful not to clean electric parts with neutral cleaning oil.)
(5) Use proper tools for disassembly/assembly.

9-2 SPECIAL TOOLS FOR DISASSEMBLY/ASSEMBLY

Fig 9-2

No. i Tool No. !

Tool name

Description

2099500407 1 Flywheel puller (with bolts)

For pulling out the flywheel

I

!

@ 1 2079500307 i

Valve spring retainer

For attaching valve spring,
retainer, retainer lock

I

2279500107 I

Valve guide puller

For pulling out the valve

i guide

I

,

-

28

-

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

screws.

I

I

Rear Cover

M8x 10 Screw,

Side Cover

/

Fig 9-3-l

- 29 -

’ 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 the AVR from the (4P)

I
coupler extending from the ;
control panel.

i

(3) Remove the plug for

grounding.

i

i

I

I

I

I

!

1

I

I

I

Fig. 9-3-3

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.
and pull it forward to
remove the fuel pipe from !

the strainer.

I

I(3) Disconnect the plug re-

1

ceptacle of the engine

from the plug of the AVR. ;

I

Pipe

Clamp

Strainer

FI& 93-6

-33-

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 M8 nuts. i

Lpanner

8

Fuel tank

i (1) Remove the two M6 x 12

‘10 m/m box

flange bolts clamping the I

spanner

!

I

blower housing.

I

(2) Remove the fuel tank by

taking off the two M8 nuts

from the bottom of the

/

13 m/m box

spanner

’

I

tank.

I

I

Handle Cover

M3xlO Screw (2 PCS.)

\

/

M8 nut (2 pcs ) -7, @gfiJpcp

2

piy

\

M6xl2 Flange Bolt

\

Tank

I

Blower Housing

Fig. 9-3-7

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 brash holder

‘If the rear bracket

/ @ Driver

I

fitted to the brash holder

1 is removed from the :

I

base by unscrewing the two igenerator without

jremoving the brash

!

M5 x 20 screws.

holder, the brash

i

I

\

may break. Always
!
I

i remember to remove
/the brash holder.

1

1

(2) Remove the connector

’

I

) In assembling, be
i careful that the

I

1 wiring is properly

!

connected.

M5x20 Screw (2 PCS.)

Brush Holder

Rear Bracket

Brush Holder Basedi>

Bracket (Cover)

I

M5xlO Screw (4 PCS.)

\

End Cover

Fig. 9-3-8

-35-

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 make j

the d&e stack and then irregular wiring in

(

remove the lead from the

, assembling. I

I
I

rear bracket clamp.

I

1

Rear Bracket

/

Diode Stack

Fig 9-3-9

Plastic Hammer

-36-

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.)

I

I
I

Stator

Stator cover

Fig. 9-3-l 1

F&. 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 the

I

I

through bolt, thus keeping
a2 3 mm clearance be- 1
tween them.

(See Fig. 9-3-14)

I

,

’ (2) Hit the through bolt head

/ Never hit the slip : Plastic hammer

I

with a plastic hammer to

ring and the winding I

loosen the crank shaft and ’ sections. When hit-

!

i

the rotor shaft taper.

1 ting the through I

I

Then remove the rotor.

I bolt, hit it straight

I

(See Fig. 9-3-15)

[

I

j so as not to bend the ’
; bolt.

I

Through Bolt

Fig. 9-3- 13

siw‘ , ,_,
*

iI

L$z

2 .;I _

- ,ea

I=‘~ !jI-: ,~-’ ‘1

~-~~~i ~,

L

, il

,f!jF

Fi@. 9-3-14

F&. 9-3-15

-38-

! 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 head cover

I10 m/m box

‘& cylinder j

from the cylinder head and

spanner

baffle / the cylinder baffle from

the cylinder by taking out
the two M6 x 8 flange ,

bolts.

I

Blower Housing

M6xB Flange Bolt (2 PCS.)

\

M6x12 Flange Bolt (2 PCS.)

M6x8-kange Bolt (2 pcs.1

Fig 9-3-78

-41-

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 clamped toge-

x 10 flange bolt.

ther.

(3) Remove the gas exhaust

,

pipe.

I

Pipe, Air Vent

Air Cleaner Body

M6 Flange Bolt

I

I

Air Cleaner Case

I

Element Retainer

M6xlO Screw

/

Element

/

Element Cover

Fig 93-79

-42-

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 nuts and

Brace nuts

10 m/m box

one M6 x 12 bolt.

I

I

j spanner

Muffler Cover

nge Bolt (3 PCS.)

M6x12 Bolt, Cross Recess

I Part to 1

Sequence j remOve

Description

Precautions ’

Necessary

,

tools

22

’ Governor

lever and
! its related
i parts

l-

(1)

Remove the governor lever j
from the governor shaft, by:

110 m/m box

taking out one M6 x 25

I The bolt has only to Ispanner or

bolt.

i be loosened.

j10 m/m spanner

(2) Remove the governor and

the rod spring from the

I

. .

I

carburetor

I

Governor Lever

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 tak­ing out one M4 nut. Insert
a box spanner or socket
wrench into the nuts of the
flywheel and strongly hit

!

Never insert such 810 m/m box
tools as driver into spanner or socket
the flywheel.

/wrench.

Hit it in a counter-

clockwise direction

it with a hammer, thus re-

with a hammer.

moving the nuts and the

I

spring washer.

25

Flywheel

(1) Remove the flywheel from i Assemble the tool to Flywheel puller

the crankshaft .

!

!

I

26

i &cocci*n

.

i (1) Remove the ignition plug

cap from the ignition plug

I

I

I

I

and the ignition coil from
the crank case by taking

pull out the flywheel

magneto as shown in
Fig. 9-3-23. To re­move the flywheel
turn the central bolt
counterclockwise.

I

out two M6 x 25 bolts.

27

’ Exciting

Remove the two M6x25

1 coil

j (1)

bolts from Crankcase

I

I

Washer built-in bolt 10 m/m box

: spanner

Washer built-in bolt / 10 m/m box

1 spanner

Spark Plug Cap

Ignition Coil 1

Crankcase

M6 x 25 Bc

,-I ---I

/

- A-- l

Flywheel

Flywheel Puller

Carburetor

I

Fig. 9-3-22 Fig. 9-3-23

-44-

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 head I

I
I

I

gasket from the crankcase. ,

30

/ Intake/

i (1) Remove the tappet cover

I Be sure to position i 10 m/m box

1 exhaust , and the breather plate

/ the notch in the : spanner

lvalve ,

from the crankcase by

1 spring retainer’s

’

I

!

taking taking out the two

outside periphery to

)

M6 x 12 flange bolts.

[ the front and hook

i

I

! (2)

Pull out the intake valve

’ the minus driver

I

and the exhaust valve.

j (medium sizej in the ;
, recess (lower side)

i

:

, (3) Remove the valve spring

Front

!

I

and the spring retainer.

i of the retainer.

Then pull the spring

I

[ 0 Driver

I

retainer frontward

1

j to remove the valve. n

i

31

1 Main bear- / (1)

Remove the main bearing

Washer built-in bolt. 10 m/m box

I ing cover !

cover locking bolts (eight

I

1

M6 x 30 bolts) from the

, spanner
I

I

crank case.

I

i (2)

1

Remove the cover by tap- ! Be careful not to

I ;

ping it evenly with a

I

damage the oil seal.

plastic hammer.

lntak Valve,

, Exhaust Valve

, M8x40 Flange Bolt (8 PCS.)

Muffler

/

Flange Bolt (2 PCS.)

M6x30 Bolt (8 PCS.)

Fig. 9-3-24

Tappet Cover

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

Intake Valve

\

Valve Spring,

i i
L

Governor Gear,

Camshaft

F&T. 9-3-25

-46-

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 from the
crankshaft.

:lO m/m box
i spanner or

/ 10 m/m spanner

35

!(3) Turn the crankshaft until
I

I

the piston comes to the top

I

position. Then push the

!

connecting rod to remove j

I

I

the piston from the cylin-

I

der top.

I

I

‘Piston bc

(1) Remove the piston from 1 Be careful not to

! Piston ring :

the connecting rod edge by i damage the inside i

undipping the two piston i of the rod edge.

pin clips.

(2) Open the ring joint wide Be careful not to

and remove the piston ring open the joint too i i
from the piston.

wide, or it will
break.

36

37

Crankshaft (1) Remove the woodruff key

(for the magneto).

:(2) Remove the crankshaft

i Be careful not to !
while tapping the magneto i damage the oil seal. I
tip.

I

i Mount ;(l) Remove the four M8 :

‘12 m/m box

flange nut of engine side i

i

& generator side I

! spanner or

I

) 12 m/m spanner

Piston Ring

Clip

Piston

/

Connecting Rod Cap

<--- Rod Lock Washer

;‘;

ti

G

F&. 9-3-26

Connecting Rod Bolt

-47-

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 from each piston ring groove.
Check whether the lip of each oil seal is damaged or not, and if damaged, replace it with a

new one. Also, while assembling, apply lubricating oil to the lip of each seal.

Replace the gaskets and other similar items with new ones.
Check the keys, pins, bolts, nuts etc.,

and replace them, if necessary, with new ones.

Apply torque, according to the specified rate, to those sections where the torque is rated.

Apply lubricating oil to rotating and sliding parts when they are assembled.
Check the clearance of each part prior to assembly and adjust them if necessary.
When each of the main components

have

been assembled, turn each one

by

hand and check

for smoothness of rotation and unusual noise.

-48-

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.

.Crankshaft

Crankcase

Oil Seal Guide

External Diameter 24~) Z-03;

I

I

Fig. 942

WTolerances of new installed parts

I

Thrust directional tolerance between the cylinder and piston skirt

0.02OL - 0.059L

Clearance between the piston ring joints

0.2L - 0.4L
1
i Top ring 0.09OL - 0.135L

Clearance between the piston rings

! Second ring 0.060L - 0.105L
I

/ Oil ring O.OlOL - 0.065L

Clearance between the connecting rod
major ring and crank pin

1 Clearance between the internal and

s

’ external diameters

0.037 L - 0.063 L

1 Side clearance 0.1 L - 0.3L

Clearance between the connecting minor rod edge and piston pin

O.OlOL - 0.029L

Clearance between the piston pin and piston hole

i

0.009L - 0.01 OL

Table 94 7

Note: The clearance between the piston and cylinder is checked by measuring the clearance

between the piston and cylinder skirt.

-49-

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 second ring and top ring.

F&. 9-43

Top Ring

Second Ring
Oil Ring

Fig. 9-4-4

(2) The connecting rod is joined to the

piston with the piston pin.

Note: Prior to assembly, apply sufficient lub-

ricating oil, to the connecting rod

minor edge.

Note: Be sure to secure the clips to both sides

of the piston pin.

(3) In setting the connecting rod, hold it

with a piston ring guide, as shown in Fig.

9-4-5, (or, if there is no ring guide, tap
the piston head with a wooden object
pressing the piston ring with a finger tip
to push it in).

Set it to the position of
the @ mark or MA mark of the connect­ing rod in the flywheel magneto side.

Note: Prior to assembly, apply sufficient

lubricating oil to the piston ring, con­necting rod metal, and cylinder wall.

Note: Fit the piston with the piston rings

arranged 90* from the periphery of the
piston.

Piston Ring Guide

F&T 94-5

-50-

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 correctly.
Note: When the connecting rod cap has been installed, manually turn the crankshaft to confirm

that

the connecting rod moves smoothly.

Note: The specified torque for installing the connecting rod cap is from 90 to 115 kg-cm.

Note: For details regarding the clearances between the piston, piston ring, and rod, see Table 9-

4-l.

9-4-4 TAPPETS AND CAMSHAFT

Install the tappets first, 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
operate correctly and sometimes may
not run at all. (See Table 9-4-6).

Note: If the intake and exhaust valves are set

in reverse order the tappet clearance
will also be incorrect.

~g?zq$==

\

{

,:5g*y

+-J-&[@ f@

Rd q

;:;; :eyr$&p&+&&

gm4;;

L

n

I

Fig. 94-6

9-4-5 MAIN BEARING COVER

The main bearing cover is installed in the crankcase.
Note: As the governor gear has been mounted on the main bearing cover, it is necessary in

setting, to confirm that the governor gear is meshed with the cam gear (See Fig. 9-4-7).
If replacement of the oil seal is required, pressure-fit the new oil seal prior to installing
the main bearing cover to the specified position.

Note: Prior to installation apply lubricating oil to the bearings, oil seal lip, and to the cover face

to make a thin oil layer on the surface for the purpose of installing the main bearing cover
packing in the specified position.

Also cover the oil seal guide over the crankshaft so that

the oil seal lip will not be damaged.

Make sure the side clearance of the crankshaft is in the range of 0 to 0.2 mm. Adjust it if

necessary, using the adjusting color (See Fig. 9-4-8).

Note: Torque for the main bearing cover:

80 - 100 kg-cm

-51-

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 pro­cessing face of the crankcase and adjusting
color.

As the packing is installed on the
processing face of the crankcase, determine
the clearance by taking into consideration
the thickness of this packing which is 0.22
mm.

!

Main Bearing Cover

I

Dial Gauge

Processing Face
of Crankcase

/

Fig. 9-4-9

9-4-6 INTAKE VALVE AND EXHAUST VALVE
Scrape off deposits such as carbon gum from

the valves, valve seat, intake/exhaust ports,

and valve guide.

Note: If the valve face is worn, replace the

valve with a new one.

Valve Guide Puller

Note: If the clearance between the valve

guide and valve stem is too large, re-

place the valve guide with a new one

provided by the supplier.

While replace@, pull out the valve guide by
using a pull block and a pull bolt and then
pressure-fit the new one.

Fig. 9410

-52-

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 - 0.062L

and valve stem (clearance between

-

C and D)

Exhust valve

0.056L - O.lOOL
,

Table 9-4-2

-53-

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 true for both the intake valve and the exhaust valve.

e+ig+.

e;

~<Wty!.&<~~

. i’

/:

\

_I ’

.I

-Lq

c

p-.

7;: ;:,z<- 1

<y,- ;,: :/ :m

‘2 < j ’ ij>m,Y,,

--A’
C-J.

A./,,-, _”

Ii-\ i,

.-

J L

Clearance Gauge

Fig. 9-4-12

Intake Valve ‘a

r Exhaust Valve

Valve Spring

Fig. 94 13

Note: If the clearance is smaller than the specified one, grind down slightly the valve stem tip

with a grinder and measure the clearance again.
If the clearance is larger than the specified allowance, replace the valve with a new one

and adjust the clearance using some compound etc.

Note: Install the valve spring retainers after completing adjustment of the tappet clearance.

Then recheck the clearance.

* Installment of spring retainers

Place the retainer, using a special tool, over
the valve stem with the retainer’s notch
facing towards the front.

Front

9-4-8 BREATHER PLATE AND TAPPET COVER
Note: Pay attention to installing procedure of the gaskets and position of the breather valve,

which should be located in the intake valve side.

9-4-9 CYLINDER HEAD
Before installing the cylinder head, be sure to remove any carbon deposits from the combustion

chamber, and scrape off any dust in the section between the cooling fans.
Also check the level of the cylinder head.

Note: Replace the cylinder head gasket with a new one.
Note: Torque for the cylinder head: 190 % 230 kg-cm

-54-

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 flywheel.

Note: Installment should be done after wiping away any oil from the crankshaft and taper

section of the flywheel.

Torque for the flywheel:

600 Q 650 kg-cm

(b)

Measure air gap between the ignition coil, exciting coil and the flywheel and then clamp
the ignition coil.

The air gap is 0.4 s 0.5 mm.

9-4-l 2 CARBURETOR

In the part of crankcase cylinder, install the gasket, insulator, gasket, carburetor, gasket, control

bracket, and gasket, in this order.

Then install the air cleaner body and secure it with two M6

flange nuts. Also lock the air cleaner body with Ml6 x 10 flange bolts.

Torque for the air cleaner clamping:

70 Q 90 kg-cm

Note:Set the control bracket at the position of “RUN”, and then mount it onto the air cleaner.
9-4-13 GOVERNOR LEVER

The governor used in the engine

of

this generator is

of

centrifugal weight type and is joined with

the governor lever.

With the governor lever,

the throttle valve

of

the carburetor is

automatically regulated, therefore the engine speed is kept constant under load fluctuation.

Regulation procedure is as stated below (See Fig. 9-4-14, and Fig. 9-4-15)

(1)

Join the carburetor throttle lever with the governor lever and install them in the governor
shaft.

(2)

Install the speed control in the cylinder head.

(3)

Join the governor and the speed control with the governor spring.

,

a@==-

,,

//

SE+

yl I Ir;; L

- /-!

!zsc-

@

2s

j&f

-&

cc=+

$T, +,

&

\.T< I’

G

‘L--

Governor Lever

Governor Lever

Locking

Nut

F&. 9-4-14

-55-

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 becomes unable to turn) to lock the governor shaft and the governor lever with the
governor lever’s locking bolt.

Torque for the governor lever:

90 Q 110 kg-cm

Speed Control

Stop Switch

Governor Shaft

Choke Lever

Governor Lever

Choke Spring

F@. 9-b 15

- 56 -

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

.

, ’

Muffler Cover

M6x8 Flange Bolt

(3 PCs.1

F&. 9-4-16

9-4-15 AIR CLEANER

In the air cleaner body which is fitted to the carburetor, set the element retainer, element, and
cleaner case in this order, and clamp them with M6 x 10 screws.

Note: Installment of the element cover is done after the front cover has been installed.

M6 Flange Bolt

Air Cleaner Case

Element

Fig. 94-17

-57-

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

Head Cover

(2

PCs.1

I

2 Flange Bolt (2

Clamped with

the fuel tank

PCs.1

M6x12 Flange Bolt (2

PCS.)

Fjg. 94-78

9-4-1’7 RECOIL STARTOR
Set the recoil startor with four M6 x 8 flange bolts.
Note: Don’t use bolts which are longer than 8mm.

If used, they might run against fans of the

flywheel.

v

M6x8 Flange Bolt (4

PCS.)

Recoil Starter

Fig. 94 79

- 58 -

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 ROTOR
Mount the rotor onto the taper section of the crankshaft and clamp it with through bolts.
Note: Wipe off well oil or stains from the taper section.

Main Bearing Cover

Rotor

Through Bolt

Outlet Window

(Set position)

Slit Section

M8x18 Bolt (4 PCS.)

Fig. 9420

- 59 -

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 bracket and that of the rotor bear-

ing,

and softly strike the outside
periphery of the rear bracket with a
plastic hammer.

Note: Set the cable so that it comes out from

the bottom of the stator. Be careful
not to position it between the stator
and the rear bracket.

Fig. 94-27

(2) Wind th e s a t t or cover around the stator.

Fig. 9-4-22

(3) Fit the screw boss, located in three places of the front bracket, with the boss in three

points of the rear bracket, and clamp them with three M6 bracket bolts.

Torque for the rear bracket:

55 .^u 75 kg-cm

(4) Put the grommet in the groove of the rear bracket and secure the wire.

Note: Fix the wire from the stator and diode stack with the clamp at the bottom of the groove.

-6O-

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 screw is clamped, or the brash
itself may break when the engine is
started.

After the brash holder has been instal­led? measure the resistance between
the brash terminals, with a circuit
tester. If the resistance is from 6 to 13
ohms, it is regular.

I

Fig. 94-23

(3) Insert the connecting terminals of the brash holder, as shown in Fig. 9-4-24.

Lead (Black)

\

/

Lead (Green)

Stator

Rotor

Fig. 94-24

-61-

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 Holde\y ,

,

\

p h Cover

M5xlO Screw (4 PCS.)

I

d

M8x30 iiolt (2 PCS.)

Ft& 9425

-62-

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 been mounted, with three

M5 x 8 screws.

(2) Secure the element cover with M6 x 12 screws.

Element Cover

/

M6x12 Screw

Front Cover

M5x8 Screw (3 PCS.)

FQ 94-27

-64 -

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 control panel and secure it with four M5 x 8 screws.
(2) Set the knob on the control lever.
Note: After the coupler and plug have been connected and secured to the control panel, secure

the wire with the receptacle clamp on the control panel.

Fig. 94-28

-65-

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 enters the chamber the float rises and when the buoyancy of the valve
balances with the fuelin-flow pressure the needle valve is interrupted to keep the fuel at the
correct level.

(2) Pilot System
The system controls the fuel supply for engine speeds ranging from idling to low-speed running.

The fuel flows through the main jet into the pilot jet where the fuel quantity is measured. Then,
the fuel is mixed with air measured in the pilot air jet, and is supplied from the pilot outlet by­pass to the engine. Fuel for idling is supplied mainly from the pilot outlet.

(3) Main System

The system supplies fuel for medium and high speed operations. The fuel is measured in the main

jet, and then flows into the main nozzle. Air measured in the main air jet mixes with the fuel

from the bleed hole of the main nozzle bursting into the main bore in the form of gas mist. Then
it is again mixed with air inducted through the air cleaner to get appropriate density, and finally
it is supplied to the engine.

(4) Choke System
The choke system helps start the engine in cold weather.
When the choke is closed and the engine is started, the load to the main nozzle increases and

inducts a large quantity of fuel, thus facilitating starting.

-67

-

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 keep the air and fuel channels always clean so that the fuel flows normally.

Disassembling and assembling procedures are as shown below (Refer to Fig. 9-5-2).

(1) Throttle System

@ Remove the cross-screw (31), the throttle valve (26), and then pull out the throttle shaft

(27).

0

When the throttle stop screw (29) is removed, the spring (28) will also come off. Be

careful when handling the throttle valve not to damage the valve edge.

(2) Choke System

@) Remove the. cross screw (20), and the choke valve (21), and then pull out the choke shaft

(22).

@ When installing the choke shaft be sure to keep the notch of the choke valve in the main

air jet side.

(3) Pilot System

@ Remove the pilot jet (30). When removing it, use a proper tool so that the nozzle will not

be damaged.

@ Firmly fix the pilot jet when assembling the carburetor. Otherwise fuel leakage will

occur resulting in engine trouble.

(4) Main System

@ Remove the bolt (18) and the float chamber body (16).
@ Remove the main jet (19) from the body (12).
@ When assembling, firmly fix the main jet. Otherwise the air-fuel mixture will become too

rich, causing engine troubles.

@ Torque for the bolt (18) is 70 kg-cm.

(5) Float System

@ Pull out the float pin (15), and then remove the float (14) and the needle valve (23). When

replacing the needle valve, exchange it with a rubber needle.

* Don’t use a wire or a drill to clean the fuel passages (they may damage the orifice

controlling the fuel flow). Use compressed air.

* The float pin is peensecured to the carburetor body; the needle valve can be removed from

the opposite side of the peen-secured part by slightly striking the float with a thin bar-like
object.

-69-

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, there is a risk of the generator falling or fuel leakage.

(3) If the generator is enclosed or covered by an object while running, cooling efficiency will

become lower, which may result in over-heating of the generator.
(4) Keep the generator at least 1 m away from a building.
(5) Be sure to stop the engine before filling the fuel tank. If the fuel is filled while the engine

is running, fuel vapor from the fuel tank or spilt fuel may be ignited, thus causing a fire.

(6) Fuel u se d in an engine is very volatile and flammable. Take special precautions not to spill

the fuel when filling the fuel tank. If the fuel is spilt, wipe it off thoroughly and let it dry

before restarting the engine.
(7) Be sure to fill the fuel only up to the level specified at the fuel supply port.
(8) When filling the fuel tank, be careful not to smoke or use an open flame.

10-2 PRECAUTIONS FOR EXHAUST GASES

(1) Don’t use the generator in poorly ventilated places such as an office, warehouse, narrow

tunnel, well, hold, or tank etc. If the generator is used in such places as mentioned above,
the operator may suffer carbon monoxide poisoning.

(2) Always direct the exhaust port toward the well ventilated open space.

103 OTHER PRECAUTIONS

(1) To prevent electric shock, don’t handle the generator with wet hands. When the generator

is used to drive a submersible pump or other similar equipment, be sure to connect the
earth cord of the generator to the earth cable of the pump.

(2) Don’t splash water over the generator and avoid using the generator in the rain. If the

generator gets wet, it may fail to start smoothly and the operator may possibly receive

severe electric shock.
(3) Never connect the generator to the existing indoor cable. If connected, the generator will

burn out.
(4) Don’t use the generator with its cover removed as the operator may be injured or receive

electric shock.

- 71 -

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 engine, when encountered with a trouble, should
determine the cause, supplementing the following criteria with his own experiences, and provide
complete countermeasures.

Compression is nonexistent.

A. Starting Failures

A-l

A-2

A-3
A-4
A-5
A-6
A-7

Compression is insufficient, or little.
There is no fuel in the fuel tank.
The fuel is contaminated by water or dust.
The fuel flows only a little, or does not flow at all.
The fuel does not enter into the float chamber of the carburetor.
The fuel does not flow into the combustion chamber although the fuel exists in the float
chamber of the carburetor.

A-8
A-9

The carburetor is overflooded.
Sparks do not come out from the tip of the high voltage cord, or the sparks are weak, if
any.

A-10

Sparks do not come out, or are weak, when the ignition plug is connected.

B.

Abnormal Running

B-l

B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-l 1

Compression is insufficient.
Overheating and knocking of the engine
Fluctuation in rpm

rpm of the engine does not increase.

Missfire or explosion outside the tube.
Engine lacks power (Air-fuel mixture blow back to the air cleaner).
Fuel consumption is too high (Black exhaust gas comes out).

Lubricant oil consumption is too high (White exhaust gas comes out).

Excessive engine noise

Abnormal noise is generated and the engine stops suddenly.

The lubricating oil becomes diluted and its consumption rate increases.

C. Failure of Indications on the Control Panel

C-l No voltage output (1).
C-2 No voltage output (2).

D. Abnormal Voltage Output

D-l No DC voltage output.
D-2 Voltage is abnormally high.
D-3 Voltage is abnormally low (1).
D-4 Voltage is abnormally low (2).

-72-

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 lubri­cating oil
onto value

stem or re-

place the

valve stem.

Replace the
piston ring
when its
operational

limit is ex­ceeded.

Modify the
cylinder bore
when opera­tional limit is

exceeded.

Tightening in
case of insuf­ficient clamp-

ing

In case of
gasket break­age, replace

it.

.-.

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
pipe

check fuel strainer

Check the fuel pipe

-J

Confirm condi-

tion of the cock

Checking
method

Checking
criteria

Confirm fuel

In case the fuel
tank is empty,
supply fuel.

In case of pipe

clogging, clean it.

In case the fuel
path is clogged,
clean or replace it.

In case water or
dust is mixed with
the fuel, take the
contaminatnt away
or replace the fuel.

In case the air stays
in the pipe, let it

In case the cock is

closed, open it.

out.

Let air into the

strainer cock

El

Remedies

r-

1

Clean or replace
the fuel strainer

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 com­bustion 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
contaminated with

dust, etc., clean it.

2. In cast the valve does
not work well, replace
the valve.

If the fuel path is

clogged, clean it.

-“. -------I

I

‘\.

‘*-X.

‘...,

“L.., ,A’

/“”

,,,- 1.

-1..

,,,/ , .“*. A\,+,,

/iiimlLIIl ry-$j-q pzlzq Fr1 Ilr~

Replace the packiny or tighten

I

1. In case of pack­ing failure, re­place it.

2. In case of clamp­ing torque fail­ure, tighten it
more.

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.

2. If the valve
works abnormal­ly, replace it.

T

_- _.. ..__-

If the float is

broken, replace it.

Adjust the oil level

if it is too high.

I

r-----l1Ill

I

check the float

Confirm the oil
level

1 Remedies / 1

~~,ne$,ree$~~

Adjust theoil level.

1 1

Replace the float

I 1

Check breather
pipe

Clean the pipe
if it is clogged.

Clean the
breather pipe

I

I

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 dirt

E

Demagnetization

a

Air gap is too wide.

1. Breaking of wire

2. Short circuit

I

=I

I

Check the air gap

Measure resistance
valve between the
terminals with a
circuit tester

I

the ignition

Check
plug

Exchange the
magneto with a
new one and
restart it.

Checking
met hod

--

Check the ignition
Plug cap

In case contact
with the ignition
plug is not normal,
adjust or replace it.

I

I

-.

Checking

I

criteria

-

1. In case of insulation
failure, replace the

ignition plug.

2. In case of carborn
deposit or dirt, clean
or replace the ignition

plug.

In case the air gap
is too wide, adjust
it.
Normal : 0.5mm

In case of -S2 . . .

Breaking of wire

in case of OS1 . . .

Short circuit

In case of de­magnetization,
replace it.

0

Remedies

Adjust the air gap

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

Check the cylinder
head, muffler, and
the exhaust hole.

Check the

carburetor

I--

Confirm the load

Checking
method

Confirm the
ignition plug

In case of fuel
path clogging,
clean it.

In case of carbon

deposit, clean it.

When an ignition
plug not specified
is used, exchange it
with a specified
one.

In case of overload,
modify it to the
rated load.

50Hz: 8OOW
60Hz: looow

In case the cooling

fin is dirty, clean it.

Checking
criteria

I

l-l

Remedies

ICleanthefuelpath.)

Clean the cylinder
head, muffler, and
the exhaust hole,

Clean 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 posi­tion 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, adjust or re­place the governor
weight and gover­nor sleeve.

-7

--A-

Adjust or replace
the governor
weight or the
governor sleeve.

In case of fuel path

clogging clean the

path.

bluyylly “I l”Ul

1, Gasket failure

path (Mixing rati

Clogging or col-

of air with fuel i!

laps of fuel path

2. Clamping is

too low)

insufficient

I I

II

1

Governor weight
Governor sleeve

--

1. Governor spring

is defective

2. Hanging posi­tion is not
normal

1. Abration

2. Abnormal
operation

Check governor

weight and gover-

Check the

Check the fuel

carburetor

path

Check the gasket
or the clamping
torque

I

I I

In case of clogging
or collapse of the
fuel path, clean or
adjust it.

Clean the fuel

I I

Clean or replace

path

the fuel path.

I

-- .-

1. In case of
gasket failure,
raplace the
gasket

2. In case of
clamping torque
failure, tighten
it more.

I

Replace or tighten
the gasket more

­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 opening/

closing timing

failure

--‘I-’

I

Measure tappet
clearance

If the clearance is
different from the
standard, adjust
the clearance or
replace it.
Normal :

0.1 +O.O2mm

I

Carburetor
Air cleaner

Mixing ratio of air

with fuel is not

normal.

I

Check the
carburetor, or
the air cleaner

In case the mixing
ratio of air with
fuel is abnormal,
adjust the mixing
ratio or clean the
carburetor and the
air cleaner.

r-

Muffler
Exhaust valve

G

Carbon deposit

Chock the muffler
and the exhaust
valve

In case of carbon
deposit, clean the
muffler and the
exhaust valve.

I
Clean the muffler
and the exhaust
valve

Load

Over load

I

I

I

Confirm the load

In case of overload,

modify the load to

the rated one.

50Hz: 800W
60Hz: 1ooow

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

Remedies

Adjust the tappet

clearance or

replace the tappet,

Check the jets

1. In case of jets
failure, replace
them.

2. In case of clamp­ing failure,
tighten it again.

Check the fuel

In case water is
mixed the fuel,
replace the fuel

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. Clamping failure
(Mixing ratio of air

with the fuel is too

Contaminants exist

‘,

Checking
method

Measure tappet
clearance

Check the bearing

surface

Check the jets

Check the fuel

Check the element

1

If the clearance is
different from the
standard, adjust
the clearance, or
replace the tappet.
Normal :

0.1 +O.O2mm

1. In case the jets
are defective, re­place them.

2. In case of clamp­ing failure,

tighten it again.

In case the fitting

of the valve seat is

insufficient, adjust
it or replace the
valve seat.

In case of inappro­priate fuel, replace
the fuel

Checking

criteria

In case the element

is blind, clean it.

I

I

.A

q

Remedies

/

1 Erii;e or tighten /

Adjust or replace
the intake valve
and the valve seat

Adjust the tappet
clearance, or re-

place the tappet.

,

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.

If the clearance

is

not within the

range of opera.

tional limits, re-

J

place both the

intake/exhaust
valve and the
guide.

In case of
abnormal
operation,

pour lubri­cating oil

onto the

valve or re­place the gas
vent valve.

-l-

I

In case there

is too much
oil, adjust it
to the rated

level,

Normal:

6OOcc

I

In case the
oil back hole
is clogged,
clean the
hole.

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 becomes diluted
and its consumption rate increases

I

bolts and nuts

become lower.

Burning or

n

breakage

r

Carburetor

I

Cylinder,
Piston,

Piston ring

I

Fuel

In case of
burning or
breakage,

adjust or

replace them.

Mixing rate is too
high md al the same
time the cngino has

tmen run 100 long
under a light lord.

ve, replace them

Abrasion

1

If the measured

valves are not

within the range
of operational
limits, adjust or
replace them

In case

of do­fective fuel,
replace it,

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
with a 4P coupter)

-l--

If the displayed value

is different from the
input voltage, replace
the AVR

Brush

contact surface of

2. Abrasion of the

1. Confirm contact
condition of the

slip ring

2, Measure length of

the brush

1. In case of conta­mination, clean
the brush.

2. In case the brush
is shorter than the
standard one,
replace it with
a regular one.

Clean or replace
the brush.

l-7

Slip ring

I

J

1. Contamination
of the brush’s
contact surface

2. Abnormal abrasion
of the slip ring

Confirm condition of

the brush’s contact sur-

face

1. If the brush’s contact
surface is contami­nated, clean it.

2. In case of abnormal
abrasion, replace it.

Cean or replace the slip

rings

Lead line

I

Breakage of welded
section or lead line

Measure continuation

with a circuit tester

111

case

of 00 52, the

lead line is defective.

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

(Measure with a 6P

coupler)

In case of * $1 . . .

Disconnection

In case of OS1 . . .

Short circuit

I

Measure resistance

value between the
terminals with a
circuit tester

(Measure with a 6P
coupler)

In case of OQ Sl .., In case of 00 dl . . .

Disconnection

Disconnection

In case of On . . .

In case of

OS1

. . .

Short circuit

Short circuit

Measure resistance

value between the slip
rings with a circuit
tester

Measure the resistance
value between the
terminals with a

circuit tester

In case of 00

$1 . . .

Disconnection

In case of

Oil...

Short circuit

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
(Measure at the
section where diodes

are connected)

In case of OQ

bl

. . .

Disconnection

In case of

Oil . . .

Short circuit

r

Replace the stator

I

Confirm continuity
between the terminals

with a circuit tester

Refer to 8-2) “Diode

stack”

Replace the diode

stack

Measure continuity

with a circuit tester

In case of 00

51,

the

lead line is defective.

Replace the lead line

Measure resistance

value between the
terminals with a
circuit tester

(Measure with a 4P
coupler)

If the resistance is
different from the
standard, replace

the AVR

rpm of the engine

increases too much
(Frequency is too

Measure rpm at the
rated load

50Hz: 3000+30rpm
60Hz: 3600”30rpm

Regulate rpm

L

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 surface

2. Abnormal abrasion of the 2. Abnormal abrasion of the
brush’s contact surface brush’s contact surface

Measure resistance between
the terminals with a circuit
tester
(Measure with a 6P coupler)

I

In case the measured resis­tance is lower than 15% of
the standard, it suggests a
short circuit.

/

Measure resistance between
the terminals with a circuit
tester

(Measure with a 6P coupler)

In case the measured resis­tance is lower than 15% of
the standard, it suggests a
short circuit.

Measure resistance value
between the slip rings with

a circuit tester

1. In case the resistance is
lower than 553, it suggests

short circuit

2. In case the measured
resistance is more than

1452, check the slip

rings.

Confirm condition of the
brush’s contact surface

1. If the brush’s contact
surface is contaminated,
clean it.

2. In case of abnormal abra.
sion, replace it.

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.

2. If the brush length is
shorter than the standard,
replace it.

Measure resistance between
the terminals with a circuit
tester

(Measure with a 4P coupler)

If the measure resistance
is different from the
standard, replace the AVR.

Measure rpm at the rated load

50Hz:

3000 * 30rpm

60Hz:

3600 + 30rpm

Measure continuity with
a circiut tester

In case of 00

Sl,

the lead line

is defective.

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 Inside dia. of valve guide

+0.022

6.50 o

6.650

Center dia. Cylinder gauge 1 Replacement

I

Piston skit-t’s outside

0 ;

dia. in thrust direction

62.980 --o.o2 62.880

Micrometer Replacement

,
L

TOP

; .

2 0 +0.035 i

0 ;

2.15

I Slide calipers Replacement

I

Ring groove ’

Second 2.0 :.035 !

2.15

( ~~

I

i width

i Slide calipers

1 Replacement

Piston

Oil

2.* +0.035 ;
0 I

2.95

( Slide calipers

Replacement

Pin hole

Clearance between piston
skirt and cylrnder wall

! Top

r Clearance be-

tween ring and ! Second

I ring groove

I Oil

I

+0002 I

‘4 -0:oos 1

14.035

, Cylinder gauge i Replacement

i Oil maximum i
: cylinder dia. !

;

’ 0.020 -0.059 ,

0.25 ’ ;;ftip~~om

Cylinder gauge

and micrometer i Rep’acement

I

in thrust

1 direction

I

0.090 -0.135

0.15 i

Searcher Replacement

’ 0.060-0.105 ! 0.15 i

Searcher

Replacement

: 0.010 -0.065

0.15

I Searcher

Replacement

Clearance between piston
and piston pipe

i 0.009T -O.OlOL

0.06L

Cylinder gauge ! Replacamant

r and micrometer

Joint gap

Top

I 0.2

-0.4 !

Second

i 02-0.4 )

1.5

r Searcher

1.5

’ Searcher

I

! Replacement
: Replacement

Piston
rings

’ Oil

TOP

I

0.2 5 0.4

o 2 -0.09

. -0.11

1.5

/ Searcher

Replacement

1.9

Micrometer

/ Replacement

Width Second

-0.06 :

Oa2 -0.08

1.9

I

Micmmeter

: Replacement

I

I Oil

I

2.B -0.10 i

-0.30 j

2.7

: Micrometer

Replacement

I

I

Piston pin outside dia.

14’ 1.00s

13.969

Micrometer

i Replacement

I

Inside dia. of large end

240 o

+0.013 ;

24.1~ :

Cylinder gauge

Replacement

/ ,“;;;~l~~;;~;~;~~kpin / 0.037 -0.063 ;

0.2

Cylinder gauge
and micrometer

Replacement

I

Connecting

Inside dia. of small end

+0.021

rod

14Q +0.010

14.080

Cylinder gauge

Replacement

I

Clearance between inside dia.

0.01 -0.029 )

0.12

Cylinder gauge

I of small end and pistonpin

and micrometer

! Replacement

I

! Sl;;;earance of large

0.1 -0.3

1 .o 1

’ Searcher Replacement

I

I

-9o-

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 Replacement

’

Cam crest

24.95 a.1

!

24.7

!

Micrometer 8 Replacement

!

Camshaft

1 Magneto -0.016

Camshaft

side

Micrometer

I

,50

-0.027

14.950

Replacement

journal
outside dia.

I

I

Counter-

I

side

,% -0.016

-0.027

14.956 !

Micrometer Replacement

I

Free length

37

I

35.5

With all length i

I

of valve spring

Slide ,.eplipers

Replacement

I

Valve

I

ipring Squareness

I

1.0

a Square

Replacement

i

Outside dia.
of valve stem

Intake

Exhaust

6.50 -$E ;

I

6.50

-0.056

-0.078

6.350

,

Micrometer \ Replacement

I

6.350

Micrometer Replacement

Clearance be-

Intake

0.025 -0.062 ’

0.3 8

I Cylinder gauge

tween valve

At valve guide

stem and

I

I center

I

1 Replacement ’

Intake and
exhaust

valve guide

Exhaust

0.056 -0.100 j

0.3

I

( Cylinder gauge i Replacement

falve

Tappet

Intake i 0.08-0.12 : 0.05-0.25 8

: Searcher : Replacement

1

clearance

I

Exhaust 0.08-0.12

’

0.05 -0.25

1

: Searcher i Replacement

Clearance

between

groove and
retainer

/ Intake

, 0.1 -0.3

0.5

Exhaust

0.1 -0.3 !

0.5

I

: Slide calipers

! Replacement

Slide calipers Replacement

’ Valve stem

end

length

Intake ,

1
! Exhaust

5.9

5.9 ’

4.9

4.9

Slide calipers 1 Replacement
Slide calipers Replacement

rappet

Total length

j 35.6 q-O6

35.1 I

Slide calipers

I

Replacement

Clearance between stem
and guide

0.013 -0.037 i
I

spark

’ Type

1lug

i Electrode gap

-uel con-

50 Hz rating
umption f
,l/hr) 60 HE rating

-ubricaing i

50

Hz

rating

,il con­;umption

cchr)

; 60 Hz rating

86HS

I

0.6 -0.7

1.0

Searcher

Adjustment or

! Replacement

0.8

)

!

1 .o

I

I

I

9 /

50

I

!

10

50

I

I

luantiry of lubricating oil cc

!

600 ’

I

dpplicated lubricating oil Automotive engine oil of class over SC

-ubricating oil replacement interval

Initial: 20

hours

after start

I Regular: Every 100 hours

Compression pressure (kg/cm’/rpm) wloo

I

: Reference value ,

Puressure guage ,

- 91 -

!

)

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-cm I

70 -90

Front cover bolts

kg-cm

I
! 1202140 /

I

Flywheel nuts

kg-cm

1 600 -650 j

I

1

I

I

I

Rear bracket bolts

kg-

I

55-75

I I I

I

- 92 -

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 specified intervals, but rather daily.

14-1 DAILY CHECKS AND MAINTENANCE (EVERY 8 HOURS)

r

Checks and maintenance items

Description

(1)

(2)

(3)
(4)

Clean away dust from each corn- (1

ponent

) If the joint section of the governor is

left in a dusty condition, the governor

may fail to function normally.

) Fuel leakage raises fuel costs and in-

creases the risk of fire.

Check the fuel piping system and 1 (2
related parts for leakage. Should ’
leakage be detected, tighten or re- i
place the defective parts.

Check each part for looseness and 1 (3) If the parts are loose, vibration will
tighten it if necessary.

I

occur, and may damage the generator.

Check quantity of oil in the crank 1 (4) If the engine is run with a shortage of
case and fill oil if necessary.

oil it will burn and damage the gene­rator.

14-2 CHECKS AND MAINTENANCE FOR EVERY 20 HOURS

I

Checks and maintenance items

!
I

Description

(1) Change oil in the crank

I (11 This procedure removes contamination

caused during initial operation.

14-3 CHECKS AND MAINTENANCE FOR EVERY 50 HOURS (EVERY 10 DAYS)

I

Checks and maintenance items

I

Description

(1) Clean the air cleaner
(2) Check the ignition plug. if the plug

is contaminated, clean it with gaso-

line and sand it with sandpaper.

(1) Otherwise, engine troubles will be

caused.

(2) Should the plug be left in a con-

taminated condition, the engine output
will decline,

resulting in starting

failure.

-94-

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 ignition plug clearance.

:

put decline, will be caused.

14-5 CHECKS AND MAINTENANCE FOR EVERY 500 HOURS (SEMI-ANNUALLY)

1

Checks and maintenance items

!

Description

(1) Remove the cylinder head and clean / (1) - (4)

away the carbon deposit.

Engine troubles such as power output

(2) Disassemble the carburetor and clean

decline will be caused.

each component.

~ (3) Check and regulate the valve clear-

ante.

~ (4) Replace the ignition plug.

I

14-5 CHECKS AND MAINTENANCE FOR EVERY 1000 HOURS (ANNUALLY)

I

Checks and maintenance items : Description

(1) Overhaul the engine for cleaning,

(1) Engine troubles such as power output

adjusting, and replacing parts.

I

decline will be caused.

(2) Replace brush of the generator.

(2) and (3)

(3) Check rotor and stator of the gene-

Power output will decline.

rator.

(4) Replace the fuel pipe.

( (4) Fuel leakage will cause risks such as

fire.

14-7 HOW TO STORE THE GENERATOR FOR A LONG PERIOD

(1) Remove the cap of the fuel strainer and open the fuel cock to completely drain fuel in the

tank. Then return the cap to the original position and close the fuel cock.

(2) Start the generator and keep it running until it stops (for about 1 - 2 minutes). The fuel is

completely consumed and drains the fuel in the carburetor.
(3) Replace the lubricating oil with new oil.
(4) Clean the air cleaner element.

-95-

(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 “STOP” position.
Pull the starting nob of the recoil starter, and leave it at the position where some load is

felt.
After cleaning the generator well, wipe it with a cloth and use an anti-rust spray on it.

Cover the engine with veneer etc., and store it in a place with low humidity.

Note: Be careful when draining fuel from the fuel tank.

Don’t sprinkle water over the engine

while cleaning it.

- 96 -