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 -