.

Model

CONTENTS

Section 1. 2.

Title

Page

SPECIFICATIONS PERFORMANCE
2-1 2-2 AC Output DC Output

.......................................... CURVES ....................................

1 2 2 3 5

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

3. 4. 5.

FEATURES SERIAL SAFETY

5-1 5-2 5-3

.............................................. NUMBER LOCATION ................

and SPECIFICATION PRECAUTIONS

Fire Prevention Precautions Other

6 7 7 7 7 8 11 11 12

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

for Exhaust Gases. ............................. ...................................... Precautions

6. 7.

COMPONENT FUNCTION
7-1 7-2

IDENTIFICATION OF EACH

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

COMPONENT

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

Generator ........................................... Engine .............................................

8.

DESCRIPTION 8-1
8-2 Electronic Generator

OF MAIN
lgnition Operation

COMPONENTS
System

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

14 14 15

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

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

9.

OPERATIONAL 9-1
9-2 9-3 9-4 AC Output DC Output Simultaneous

LIMITS

OF THE

GENERATOR.

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

17 17 19

.......................................... .......................................... Use the AC/DC Output ......................................... .........................

20 20 21 21 23 23 23

Wire Length.

10.

MEASURING
10-1 10-2 10-3 10-4

PROCEDURES

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

Meters ............................................. ................................... Measuring AC Output ................................... Measuring DC Output Measuring Insulation Resistance . . . . . . . . . . . . . . . . . . . . .

Section

Title

Page

11.

FUNCTIONAL
11-1 11-2 11-3 11-4 11-5 11-6 Control Stator.....

CHECK
Panel

OF EACH

COMPONENT..

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

25
25 27 29 29 30 30

Rotor . . . . . lgnition Coil Condenser Rectifier . .

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

. .. . . . . .

. . . . . .

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

. . . ... .. .

. . . .

.. .. .. . ..

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

. . .

12.

DISASSEMBLY
12-1 12-2 12-3 12-4 12-5 Preparation Special Assembly Carburetor

AND

ASSEMBLY

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

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

31
31 31 32 38 48

and Precautrons Sequence Procedure

Tools for Disassembly

............................... and Assembly ....................

Disassembly

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

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

13. 14. 15. 16.

TROUBLESHOOTING CRITERIA WIRING TABLE DIAGRAM . .

. .

. . . .

. . . . .. . .

. .

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

51

FOR ADJUSTMENT . . . . . . . . . . . . . ..

68 71 72
72

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

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

MAINTENANCE
16-1 16-2 16-3 16-4 16-5 16-6 16-7 Daily

. . . . . . .
(every 8 hours)

Checks and Maintenance

................... .................... (every 10 days) (monthly) .........

Checks and Maintenance Checks and Maintenance Checks and Maintenance

for Every 20 Hours for Every 50 Hours for Every 200 Hours

72 72 73 73 73 73

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

Checks and Maintenance for Every 500 Hours (semi-annually) ........ Checks and Maintenance for Every 1000 Hours (annually) ........... When the Generator is not used for Prolonged Periods: .............

1. SPECIFICATIONS

Model
Engine: i L-Displacement Fuel tank capacity Oil pan capacity Ignition Starting system ~~ system Recoil starter Approx. Approx. 2-pole, system regulating 78 cc (4.76 cu.in.1 Type Forced air-cooled, gas01 ine engine

R600
4-stroke, side valve,

2 lit. (0.53 U.S. gal.) 350 cc (0.75 U.S. pints) Solid state ignition

Rated continuous operating hours Generator: Type Exciting Voltage system Maximum

4 hours (50 Hz) 3.5 hours (60 Hz) revolving field type

Self-exciting Condenser type 600 W 500w 60 Hz 110, 120,220v

output

500 w 400 w 50 Hz 110, 220,230,24OV

Rated output AC Frequency AC Voltage DC output AC receptacle

12V - 100 W (8.3 A) Standard: (special: Two Circuit meter Standard Standard breaker equipment equipment 2 ea. 1 ea.)

DC terminal Over current protection Frequency Pilot light Dimensions Dry weight (L x W x H):

370 x 265 x 345 mm (14.6 x 10.4 x 13.6 in.) 18.5 kg (40.7 Ibs)

-1-

2. PERFORMANCE
2-1
Power

CURVES

AC OUTPUT
Factor . . .
1 .o

1 I

! !

1 I

1 I

Output

Max. Rated

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

500W 400W 50 Hz 220V

1 OUTPUT

Frequency. Voltage.

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

i
3 w 3 -t

240

//

I i/: Y

FRECiENC 1

I
I

I i

1 300

CURRENT

IA)

I ,

Output
500

Max. Rated

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

500W 400W 50 Hz 230V. 240V

50 49-

: I

: I

, OUTPUT 1.1 j
I II

-i----l

Frequency.
400 t I

/\I //
I /

Voltage

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

/
:

I I
I I

FREQUENCY I 1 a , :
!

300

260

0vi

0.5 1

1 : CURRENT

1.5
(Al -

2.5

-2-

w
U
LL

. . . . . . . . . . . . . . . 500W Rated . . . . . . . . . . . . . . . 400W Frequency . . . . . . . . . . . . . . . . . 50Hz Voltage . . . . . . . . . . . . . . . . . . . 11OV

Output Max.
1

-1
w > U
1

CURRENT ( A )

600

I N

U
w

tI
3
LL

62 61 60 59

500

400 300

. . . . . . . . . . . . . . . 600W Rated . . . . . . . . . . . . . . . 500W Frequency . . . . . . . . . . . . . . . . . 60 Hz OV Voltage . . . . . . . . . . . . . . . . . . . 1 1

Output Max.

3
0

-1
1

w > 17

120

200

3 I -

I -

110

100

100

>
2 0 1
3

CURRENT ( A )

I N

600

Output Max.

. . . . . . . . . . . . . . . 600W Rated . . . . . . . . . . . . . . . 500W

62
3

500

E
U

61 60 59

400

13 I-

Frequency Voltage.

. . . . . . . . . . . . . . . . . 60 HZ . . . . . . . . . . . . . . . . . . 220V

300

>
(3

240 230
200

2 I 3 0

5 0

220
210
100

>

0.5

1.5

CURRENT ( A )

2.5

-4

600 52 51 50 49 500

Output

Max. Rated

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

500W 400W 50 Hz 11OV

Frequency Voltage.
400 300 t 3 + 3 E 2

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

200

2 CURRENT

3 IA) -

I I I I I
62 61 60 59 FREQUENCY r I 120 110 100

1
400

Output

Max. Rated

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

600W 500W 60 HZ 11OV

Frequency Voltage.
I

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

300

3
f k 0

200

100

0 0 1 2 CURRENT 3 IA) 4 5 6

Output

Max. Rated

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

600W 500W 60 Hz 220V

Frequency Voltage

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

0.5

1 CURRENT

1.5 (A) -

2.5

-4-

3. FEATURES
l l l

Robin Exhaust Fan Cooling System for low body temperatures, low noise. longer engine life and reliable performance. Large 78cc 4Stroke Engine provides enough power for constant 500W (at 60 Hz) rated output.

Simple One-Touch Engine Control Switch with the engine and fuel on/off levers and choke all integrated into one switch.

Easy and Reliable Starting with pointless ignition. This generator is also a brush-less type generator for maintenance-free operation.

l l

Simple Design for a clean appearance and easy maintenance. Compact and Lightweight with an easy one-hand carrying handle grip. This generator also offers a high power-to-weight ratio and economical operation.

l l

Circuit Breaker Protection for safe operation. Replacement of fuses is not necessary in case of an overload. Unique Dual Output Design so that two separate A.C. and D.C. electrical appliances can be used at the same time.

-5-

4. SERIAL

and SPECIFICATION

NUMBER

LOCATION

The serial number is stamped on the crankcase at the opposite side of the carburetor. The specification and specification number are shown on the nameplate located on the rear cover. Always specify these numbers when inquiring about the e oenerator or ordering parts in order to get correct parts and accurate service.

SPECIFICATION

SPECIFICATION

NUMBER

SERIAL

NUMBER

Fig. 4-7

-6-

. . .

5. SAFETY- PRECAUTIONS 51
FIRE PREVENTION

1) Keep the generator away from combustible materials during operation. Take special precautions with flammable substances.

2) Do not run the generator in a incline position or while it is slanted at an angle. Avoid moving the generator while it
is in operation to prevent the generator from falling over or leaking fuel. 3) 4) 5) 6) 7) 8) 5-2 Do not place a carton or similar object over the generator while the generator is running. If covered, cooling will be diminished and cause the generator to overheat. Operate the generator at least lm away from a building or wall. Be sure to stop the engine before filling fuel into the fuel tank. If fuel is filled while the engine is running, fuel vapors may rise from the fuel tank resulting in a potential fire hazard. Fuel used in engine operation is very volatile and highly flammable. Take special precautions not to spill fuel when filling the fuel tank. If fuel is spilt, wipe it off thoroughly and let dry before starting the engine. Do not overfill the fuel tank and always be sure to fill iuel only up to the level specified at the fuel supply- port. Do not smoke or use open flame when filling the fuel tank.
PRECAUTIONS for EXHAUST GASES

1) Avoid operating the generator in poorly ventilated locations such as an office, warehouse. narrow tunnel. well, hold. tank. etc.. If the generator is run continuously in such poorly ventilated areas. the operator may suffer carbon monoxide poisoning. 3 5-3 Always operate the generator with the exhaust port directed toward the open air or where good ventilation is assured.
OTHER PRECAUTtONS

1) To prevent electric shock. do not touch the generator with wet hands. For example, when the generator is used to drive a submersible pump, be sure to connect the earth cord of the generator to the earth cable of the pump. 2) Do not splash water over the generator during operation. And also avoid operating the generator in the rain. If the generator gets wet. it may fail to start or short-circuit. and the operator may possibly receive a severeelectric shock. 3) 4) Do not connect the generator to existing power lines which have been originally installed as the power supply system of a building. If connected. the generator will burn out. Avoid running the generator with its cover removed.

-7-

6. COMPONENT

IDENTIFICATION

hUFFLE9 C 0 V E F1 AlFl CLEALER

Al=

CLEdYER

CO\.ER

Fig. 6- 7

FUEL

T.ANY

GEZERATOS

\* z FLER /

C:O\.ER

RECOIL

STIRTE?

Fig. 6-3

SPARK

PLUG

Ffg. 6-4

-9-

CAPBLRETOR

Fig. 6-5

#El3 PIPE AIR \;EJTl

Fig. 6-6

10-

7. FUNCTION
7-1
7-1-1

of EACH COMPONENT

REAR

HOUSING

GENERATOR
STATOR
RECTIFIER

The stator consists of a laminated silicon steel sheet core, a main coil and condenser coil which are wound in the core slots. AC and DC output are taken out from the main coil. (DC output is taken out from the part of main coil which is in the middle of the main coil.) The condenser coil excites the stator field coil which generates AC output in the main coil.
7-1-2 CONDENSER Fig. 7- 7

The condenser is mounted on the rear housing and is connected to the condenser coil which is wound in the stator. The condenser coil magnetizes the rotor which increases the density of magnetic flux.
7-1-3 RECTIFIER

The rectifier is also mounted on the rear housing and it converts AC current output from the main coil to DC current. The DC output from the diode of this rectifier is connected to the DC terminal.
7-1-4 ROTOR

The rotor consists of a lamination silicon steel sheet core and field coil which is wound over the core. DC current m the field coil magnetizes the steel sheet core. Two permanent magnets are provided at 90 degrees from the poles for the primary exciting action. A securely mounted fan is pressure-fitted on the end of the rotor shaft to cool the individual coils. iron cores. rectifier. and other integral parts. Cooling air from the fan is drawn in from the ventilation vents in the rear housing. and is discharged from the exhaust port in the front housing.
7-l-5 CONTROL PANEL Fig. 7-2

The panel on the front of the housing has a receptacle with a ground terminal and AC output is taken out with a male
Plug.

The frequency meter is provided to see if the frequency of generated power shows 50 Hz (or 60 Hz). terminals.
Fig. 7-3

DC output is

taken out from the red (positive. +) and black (.negative. -)

-11-

7-2
7-2-l

ENGINE
CYLINDER and CRANKCASE

The cylinder and the crankcase of the engine are of an one-piece aluminum die-cast design. The cast iron cylinder liner is cast-fitted inside the cylinder. Both the intake and exhaust ports are positioned at the lateral side of the cylinder and these ports are formed by using a mold with die-cast cores. The crankcase has its joint face located on the generator side.
7-2-2 The MAIN BEARING COVER

main bearing cover is aluminum die-cast and is mounted on the generator side. By removing the main bearing cover.

the interior of the engine can be inspected.

7-2-3 CRANKSHAFT

The crankshaft is constructed of forged carbon steel. The crankpin is induction-hardened and has a pressure-fitted crank gear located on the generator side of the engine.
7-2-4 CONNECTING ROD and PISTON

The connecting rod is constructed of forged aluminum alloy with both the major and minor ends utilized as bearings. The oil scraper and cap for the major end are cast together. The aluminum alloy casting piston has two compression rings and one oil ring.
7-2-5 CAMSHAFT

The camshaft is constructed of special cast iron and has intake and exhaust valve drive cams. each of which engageswith the cam gear. An exclusive aluminum alloy is used on each end of the camshaft in the place of bearings.
7-2-6 VALVE ARRANGEMENT

The intake valve is installed at the oil port side and the exhaust valve at the generator side.
7-2-7 CYLINDER HEAD

The cylinder head is die-cast aluminum and has Ricardo type combustion chamber featuring greater volume capacity for improved combustion efficiency. greater access.
7-2-8 GOVERNOR

For easier spark plug maintenance. the cylinder head is positioned at an angle to allow

The centrifugal weight type governor ensures constant engine speed, regardless of load fluctuations (the governor is mechanically linked to the governor drive gear).

-12-

7-2-9

EXHAUST

FAN

COOLING

SYSTEM

Instead of blowing outside air on the engine. the Exhaust Fan Cooling System of this generator intakes the cool air and forces the hot air outside from one outlet. This keeps the body temperature lower for greater safety and extends service life.

7-2-10

LUBRICATION

SYSTEM

The moving and sliding parts inside the engine are lubricated with the oil scraper fitted on the connecting rod. As the crankshaft rotates, the connecting rod moves up and down and the oil scraper moves in conjuction with the connecting rod movements to scrape up oil in the crankcase and splash it over the surfaces of the moving and sliding parts. 7-2-l 1
IGNITION

A flywheehmagneto ignition system is employed with the ignition timing set at 23 before top dead center. The magneto is composed of the tl)wheel and ignition coil with the fll-wheel mounted on the rotor shaft. The ignition coil is fitted to the front housing.
7-2-l 2 CARBURETOR

The horizontal suction type carburetor is adjusted so that the engine will provide excellent starting. good acceleration. low fuel consumption. and superior output [for details concerning carburetor construction. see the paragraph dealing with carburetor construction and disassembly/assembly (Page49)]
7-2-13 AIR CLEANER

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

- 13-

8. DESCRIPTION
8-1 ELECTRONIC

OF MAIN COMPONENTS OPERATION

IGNITION SYSTEM (Solid State Ignition System)

The electronic ignition system features a polver transistor as the current control element. Therefore. the ignition system is an electronic contact point-free type that operates with the po\ver transistor impulses controlling the current. This system also called TIC (transistor igniter circuit) is virtually free of ignition failure which generally results from contamination of the contact points. a typical problem vvrth contact type ignition systems. Because this ignition system has no contact points. it is not affected by moisture. oil. dust. or other contaminants. 4s a result. this electronic ignition system ensures sure and positive ignition lvith reduced maintenance. The TIC mechanism consists of a transistor-mcorporated ignition coil and a permanent magneto built-in flywheel which is pressure-fitted on the rotor shaft of the generator.

//////

I
IGNITION COIL

IGNITION TIMING DETECTING CIRCUIT

PLUG

FLYWHEEL COOLING

FAN

Fig. 8- 1

1) When the permanent magneto built-in flywheel starts rotating. power is generated in the primary coil of the ignition coil and current tlows to the resistor @ _ From the resistor, current flows to the power transistor. RYth this current. the power transistor turns on. releasing current I(@ Thrs stage corresponds to the closmg of contact points. 2) As the tlywheel comes to the point of ignition. the ignition timing detecting circuit is activated while the current @ is flowing through the circuit. When the ignition timing detecting circuit is activated. the signal transmitter transistor actuates hzith current 8 flowing. \Vhen current ,$$ starts flovving. current s flowing through the power transistor is cut quickly. As a result. high voltage is produced in the secondary coil and this voltage is applied simultaneously to the spark plug which ignites for ignition. This stage corresponds to the opening of contact points.

-14

.I

8-2

GENERATOR

OPERATION

INITIAL EXCITATION PERMANENT MAGNETO

STATOR

FIELD ROTOR

COIL :

i I RECEPTACLE

RESIS

-----

DIODE

MAIN

COIL

CONDENSER

COIL

CONDENSER

L ------

A
Fig. 8-2

8-2-l 1)

GENERATION

of NO-LOAD

VOLTAGE

When the generator starts turning the permanent magneto built-in to the flywheel generates@ 1 to 2\ of AC voltage in the main coil and also generates 1 to 4 of AC voltage in the condenser coil. The capacitor coil is connected to a capacitor so when a voltage is applied to the condenser coil. minimun current @ flows in the condenser coil. At this time, minimum flus is produced. vvith which the magnetic force of the rotors magnetic pole is intensified. When this magnetic force is intensified. the respective voltages in the main coil and Also. the main coil voltage and condenser coil voltage increases. These voltages condenser coil rise. Current 1s flowing in the condenser coil increases. with the magnetic tlux densit)- of the rotors magnetic pole increasing further. continue rising as this process is repeated.

2)

3)

As current flows in the condenser coil. the magnetic flux density changes. DC voltage is induced in the field coil when the magnetic flus density varies. Successively. DC current is rectified bl the rectifiers connected to both ends of the field coil. and DC current @ flows in the field circuit. With this current. the rotor core is magnetized. allowing the generator to output steady voltage. When generator speed reaches 2000 to 2300 rpm (50 Hz specification) or 3000 to 3300 rpm (60 Hz specification). the current in the condenser coil and field coil increases sudden&. This acts to stabilize the respective coil output voltages. If generator speed further rises to the rated v-alue.the generator output voltage will reach the rated value.

41

8-2-2

VOLTAGE

FLUCTUATIONS

UNDER

LOAD

When load current -s flows from the electric equipment to the generator. the magnetic flux which is produced as current .s flows in the main coil. this serves to increase current $ flowing in the capacitor coil. With current @increased. the magnetic flux density across the rotor core rises. As a result. the current flowing in the field coil increases, and the generator output voltage is prevented from decreasing.

-15-

8-2-3

DC OUTPUT

DC output is taken out from the main coil and is fed to the diode at which time the output undergoes full-wave rectification prior to being supplied to the load connected to the generator. The diode rectifier works to allow the current to tlow in @ direction but does not allow the current to flow in s direction as shown in Fig. S-3. Fig. 84 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 C. current !~flows in the direction shown in the figure while no current flows between C and B because current is cut off by the diode D2. Contraq to the aforementioned, if the voltage in C is higher than that in A, current a flows in the direction as sholvn in the
MAIN COIL B

Fig. 8-3

Dl

figure. with no current flowing between A and B. This is because the diode Dl cuts off the current between A and B. As a result. voltage generated between the DC terminals has a waveform with t\vo peaks in one cycle. as in the case of the output waveform shown in Fig. 8-5.
Fig. 8-4

BETWEEN

AND

OUTPUT

WAVEFORM

BETWEEN

C AND

=w=

CURRENT FLOWING BETWEEN AAND B

CURRENT FLOWING BETWEEN CAND B

Fig. 8-5

- 16 -

9. OPERATIONAL
9-1 AC OUTPUT:

LIMITS

OF THE GENERATOR

Electric appliances normally have rating labels, showing the rated voltage. frequency. power consumption (input power). and other listings. The input power specified on such labels is what is required to drive the appliance. When an appliance is to be connected to the generator. the power factor. starting current. and other factors of the appliance must be taken into account.
9-l-l NET RESISTANCE LOAD:

Incandescent lamps. electric heaters, etc.. can be run off the generator if its capacity matches the total of the respective appliances. Each of these appliances normally have a power factor of 1.O. Example :
9-l-2

This generator can provide enough power to operate five 1OOWincandescent lamps.
APPLIANCES WITH A POWER FACTOR LESS THAN 1.0:

ELECTRIC

Fluorescent lamps and mercury lamps normally have a low po\ver factor. Therefore. the generator is required to generate approximately 1.2 to 2 times the power consumed by each load appliance. Example:
9-l-3

With this generator. three to five 8OW mercury lamps can be operated.
LOAD:

MOTOR

Generally. motors require a large starting current every time they are started. Therefore. when the generator is used to run a motor, the greatest motor starting load is applied. The rates of power supply which the generator is required to produce for motor loads. are categorized into two sections. depending on the types of motor and load conditions at time of starting. 1) Motors (mainly rectifier motors) used for electric drills and similar devices: Sormally, the motors used for electric drills and similar appliances require the generator to produce approximateI>- I.1 to 3 times the power consumed at time of starting. Example: To drive a 2OOWelectric drill. a generator with capacity of about 300 to 600W is necessary. 2) Motors (mainly induction motors) used for pumps and compressors: Pump and compressor drive motors require the generator to produce 3 to 5 times the power consumed when they are running. at time of starting. This is because these motors have loads w-hen the>- start. Example: To drive a 2OOWsubmersible pump. a generator with a capacity of approximately 600 to IOOOWis necessary.

-17

9-l-4

IN THE

SITUATION

THAT

POWER

CONSUMPTION

IS NOT SHOWN

ON THE

RATING

PANEL:

Occasionally. the rating panel of an electric appliance does not carry its power consumption but only shows the mechanical equivalent to the power consumption. involved. through 9-I-3 above. (Power consumption) = (Mechanical equivalent of device) + (Efficiency) Efficiency Motors: 0.6 - 0.8 lamp with a lighting output of 40W and assuming that the power consumption of this lamp is Fluorescent lamps: 0.7 - 0.8 Example : A 4OW fluorescent 0.7, the power consumption is calculated as follows: 40 + 0.7 = 57W Further, as per paragraph 9-l-2, the said power consumption is multiplied by a factor of 1.2 to 2. producing a power consumption of 70 to 11SW. Therefore. with this generator, four to seven 40W fluorescent lamps can be used. Example: In the case of a 2OOWmotor. the mechanical equivalent of the motor is 200W. Assuming that the efficiency of the motor is 0.7. the power consumption is calculated as 200 f 0.7 = 285W. Similar to the above, the calculated power consumption is then multiplied as per paragraphs 3-1) or 3-2). taking into account the types of motor and starting conditions. The table below shows the range of loads applicable to this generator. In such a situation. it is necessary to calculate the power consumption of the device Depending on the types of load. the calculated power consumption is adjusted according to paragraphs 9-l-l

Range of workable loads Electric devices

50 Hz 60 Hz up to 5oow 300W 300W 150W / Up to approx. Up to approx. Up to approx. 400W 350W 200W

Incandescent Fluorescent Motor-driven

lamp, electric lamp, mercury tools etc.

heater,

etc.

up to 4oow Up to approx.
I

I I

lamp, etc.

Up to approx. drive motors I Up to approx.

Pump and compressor

Table 9- 7

NOTE

7: With motor-driven and 9-l-4, respective supply

tools and the motor-driven of the said capacities

pumps

and compressors only

specified

in paragraphs the motors

9-7-3 of the to

the generators appliance.

are required the power

when starting

Once the motor decreases thereafter

has started,

which

the generator 1.2 to 2 times

is required

to the motor . the surplus

to a level approximately

the rated power

consumption Therefore, NOTE 2: As for starting

capacity

of the generator specified

may be used for other electric

appliances. requirement for

the motor-driven varies according

devices

in paragraph

9- 7-3 and 9-l -4, the power

to the types of motor

and the load conditions

at time of starting.

- 18-

9-2

DC OUTPUT

When the generator is employed to recharge batteries. care must be exercised about the specific gravity of electrolk-te rn each batter\. case.
9-2-l MEASURING THE SPECIFIC GRAVITY OF ELECTROLYTE:

The specific gravity changes with temperature; therefore. it is converted to another corresponding to 20C. S20 = St + 0.0007 (t - 10) where S~J = Specific gravity corresponding to 20C SI t = Measured value = Temperature at time of measurement

9-2-2

REMAINING CAPACITY ELECTROLYTE: I

ESTIMATED

WITH

REFERENCE

TO

THE

SPECIFIC

GRAVITY

OF

Specific gravity (20C)

1.260 1.240 1.220 1.200 1.180 1.160 1.140

Remaining battery (%I

100

I Remarks
I

I 87 75 62 50 37 25 , I

Good charged condition

Charging

is necessary.

Immediate

charging

is necessary.

Table 9-2

9-2-3

BATTERY

CAPACITY:

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

-19-

9-3

SIMULTANEOUS

USE THE

AC/DC

OUTPUT

If you use the ACDC output simultaneously in this generator, be careful not to exceed the total power consumption. 50 Hz
60 NOTE:

below 3OOW below 3OOIV

of DC is 1OOW /12V x 8.3A).

Hz
Max. output

9-4

WIRE

LENGTH

When long Lvires are used between the generator and a load, the resistance of each wire increases and a voltage drop occurs. Consequently. the input voltage to the load declines and occasionall!- damages the load. Exercise caution Lvhen deciding on wire length. For reference. the table below shows the voltage decreasesthat occur in 100 m (300 ftt) long wires with different cross sectional areas and varied resistances.

Cross
sectional area mm
0.75 1.25 2.0 3.5 5.5

Allowable current

No. of conductorsl conductor diameter

No./mm 30/O. 18 5OiO.18 3710.26 4510.32 7OiO.32

Resistance

Current

A
7 12 17 23 35

,0,/l

OOm
2.477 1.486 0,952 0.517 0.332

1A 2.5U l.5U 1u -

3A 8U 5u 3u 1.5U 1U

5A 12.5U 7.5u 5U 2.5U 2U

8A l2U 8U 4U : 2.5U L

10A I 15u 1 1ou 5U 3.5u

12A 18U ; l2U I 6.5U ;-: I

15A

15u

- 7.5U 5u

: , 8 t 0 8 ; < >

; 4u I

Table 9-3

- 20 -

10. MEASURING
10-l 10-1-l METERS VOLTMETERS

PROCEDURES
AC VOLTMETER DC VOLTMETER

Both AC and DC voltmeters are nesessar! . The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows: 0 to 1SOV: Type with an output voltage of 110 or 12ov 0 to 300V: Type with an output voltage of 220.230 or 21OV
Fig. 70-l

10-l-2

AMMETER
AC AMMETER DC AMMETER

Both AC and DC ammeters are necessary. The AC ammeter must have a scale range from 0 to approximately 10A. The DC ammeter must have a scale range from 0 to approximately 15A.

Fig. 10-2

10-l-3

FREQUENCY

METER

The frequency meter must have a scale range from 45 to approximately 65 Hz.
NOTE: meter. Note the range of input voltage of the frequency

Fig. 70-3

-2l-

10-l-4

CIRCUIT

TESTER

A circuit tester is used for measuring resistances and others.

Fig. 104

10-l-5

MEGGER

TESTER

To measure the insulation resistance of the generator. Use voltage capacity of 5OOV.

Fig. 10-5

10-l-6

TACHOMETER

Use the contact-less tl pe tachometer.

Fig. 10-6

- 22 -

10-2

MEASURING

AC OUTPUT

SWlTFf;

LOAj

TOACd+)@

km77

With the circuit shown in Fig.lO-7.measurement 1smade of the AC output of the generator. An electric heater or an incandescent lamp with a power factor of 1.O is suitable as a load for the generator. When the measured AC output of the generator is confirmed to be wnhin the voltage range specified in the table belon. over its voltage rating. the AC output is normal. Measurement must be made under rated load and at rated speed; sometimes. load and speed adjustments are necessary-.
Voltage rating Range of voltage 11ou

12ou

220u 218 - 240U

230,240U 235 - 260U

108% 12OU

118-

130U

Table 10-l

10-3

MEASURING

DC OUTPUT
SWITCH

DC TERMINAL

Fig. 10-8

Measurement is made of the DC output of the generator with the witch shown in the abobe circuit turned on while the generator is kept running at its rated speed. The DC output should be aithin 1 1 to 14V. Lvith the current regulated at 8.3A by adjusting the load connected to the generator.
NOTE: Therefore, If a battery carefully is connected as a load to the generator, the DC output voltage the battery. will increase by approximately 1 to 2V. observe the electrolyte level and do not to overcharge

IO-4

MEASURING

INSULATION

RESISTANCE

To measure insulation resistance. connect the megger tester across either one of the two output terminals of the socket and the earth terminal. 1OMR at time of shipment). (Be sure to turn on the circuit breaker when measuring insulation resistance.) If the insulation resistance is less than 1X19. drsassemble the generator. and measure the respective resistancesof the
stator.

When the measured insulation

resistance of the generator is over lMI2. it is normal (over

rotor and control panel.

Fig. 10-9

- 23 -

10-4-1

STATOR

Measure the resistances betlveen red coupler leading from the stator and the core.

Fig. lo-10

1O-4-2

ROTOR

Measure the insulation resistance across one of the soldered terminals of the rotor and the core.

Fig. 10-11

10-4-3

CONTROL

PANEL

Measure the insulation resistances between the live parts and the grounded part. If the measured resistance of a component is below 1MR. the insulation is defective. Promptly replace the defective component because there may be leakage of current from the generator and a potential danger of electrical shock. _

Fig. 10-12

- 24 -

--

11. FUNCTIONAL
11-l 11-l-l CONTROL ENGINE

CHECK of EACH COMPONENT

PANEL SWITCH

Using the circuit tester. check continuity across the black and green top terminals of the 6P coupler. When continuity between the termmals is confirmed with the engine switch turn2d off. the switch is normal. It is also normal if there is no continuity between thrse terminals, when the engine switch is set at RUN or CHOKE position.

Fig. 11-l

1 l-l-2

FREQUENCY

METER

Also check with the circuit tester. th2 continuity across the yellow and blue top tsrminals of the 6P coupler. If continuity is confirmed between these terminals. the frequency meter is normal.

Fig. 7 l-2

11-1-3

PILOT

LIGHT

Using the circuit tester, check continuity between the red and yellow top terminals of the 6P coupler.

Fig. 1 l-3

- 25 -

11-1-4

AC

RECEPTACLES

Using the circuit tester. check continuity between the t\vo terminals at the rear of the XC receptacles while the receptacle is mounted on the control panel. When continuity is confirmed between the output terminals of the receptacle Lvvltha \vtre connected across these terminals. the AC receptacle is normal. When the wire is removed and no continuity- is eonfirmed between these terminals. the receptacles are also normal.

Fig. 7 7-4(A) 11-1-5 DC TERMINALS

Fig. 1 l-4(81

Csmg the circuit tester. check continuity between the DC terminals at the rear side of the control panel while they are mounted on the panel. Ben continuity- is confirmed bet\veen the DC terminals When the wire is removed and no between these terminals. the Lvith a wire connected across these terminals. the DC terminals are normal. continuity is <onfirmed

terminals are also normal.

Fig. 1 l-5 11-1-6 CIRCUIT BREAKER

Check continuity between each of two terminals at the rear of the circuit breaker while it is mounted on the control panel. Normally. there is continuity between each of the two lvhen the circuit breaker is on while there is no continuiq when the circuit breaker is ofi.

16P coupler

wiring] DARK YELLOW RED BLACK BROWN WHITE BLUE

Fig. 11-6

- 26 -

11-2

STATOR

Measure the resistance of each stator coil using the circuit tester.
I

Main coil Classified coil AC coil ! For use with the frequency meter I I
/

: DC coil I : I

Condenser coil Condenser coil

Cord color of @

Measurement location 50Hz-110V 60Hz-110V 50Hz-120V 60Hz-120V 50 Hz - 220V 60 Hz - 220V 50 Hz - 230V 50 Hz - 240V ! j

6P coupler 3.4R 2.6 3.3 2.7 13.9 11.4 15.2

j I j

6P coupler 0.2251 0.16 0.22 0.16 0.22 0.16 0.22 0.22 , I ,

Rectifier connector 1.1n 0.9 1.1 0.9 1.1 0.9 1.1 1.1

1 j I I I :

Between connectors 8.9R 7.6 8.9 7.6 8.9 I 1 I : : White/Green White/Red Brown Blue Gray Pink i Orange Orange

7.6 8.9

15.2

8.9

I Table 11-l (at 21cC)

NOTE: Erroneous performed

If the circuit readings at ambient

tester is not sufficient/y will also occur temperatures

accurate,

it may not show the values given and may give erroneous of resistance among coil windings upper

readings. is

when there is a wide variation different from

or when measurement the table.

the values specified

in the space directly

[6P coupler wiring]

DARK YELLOW RED BLACK BROWN BLUE

- 27 -

FL?. 7 l-7

Fig. 1 l-8

Fi:g. 1 l-9

Fig. 11-10

-28

Table 1 l-2

Fig. 11-11 NOTE removed. NOTE mngs. Erroneous is performed -eadings will also occur temperatures when there is a wide variation from of resrstance among coil windings below or v/hen measurement the table. 2: If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous read1: Measure the resistance of each coil winding while the diode and each resistor are disconnected with the/r solder

at ambient

different

the values specified

in the space directly

[APPROX

162:

11-4

IGNITION

COIL

Resistance value 0.611 7.52

B~tl::ee? Betkseen

Measurement location
The con-e and the grew cord the gree? the cord high-ttvsor cord

and

Table 7 7-3

29 -

11-5

CONDENSER

Measurement of capacity substitutes for checking the condenser. The capacity of the condenser cannot be measured by using the circuit tester. Therefore. the generator is run with a new condenser to see whether or not the generator performs normally. If the generator performs normall>-. the condenser is normal.
Reference: If an instrument ii available for measuring the capacity of the condenser, the total capacity range should be 70 to 7 7pF fat 20C). When the condenser displays its total capacity within this range, it is normal.

11-6

RECTIFIER

Using the circuit tester. measure the resistance between each of the two terminals of the rectifier. values specified below.
NOTE: Each of the given tester. values changes with the polarity

The rectifier is

considered normal when the respective resistances have the

of the circuit

Green

Red

White@
3

[
:...16RI

01

#3

. . .160

The polarity

of the circuit

tester

Table 7 l-4

-30-

*-

12. DISASSEMBLY
12-1 PREPARATION

and ASSEMBLY
and PRECAUTIONS

1) Be sure to remember the locations of individual parts when disassembling the generator so that the generator can be reassembled correctly. Tie tags noted with the necessary information to facilitate easier and smoother reassembly. 2) 3) 4) For more convenience, divide the parts into several groups and store them in boxes. To prevent bolts and nuts from being misplaced or installed incorrectly. place them temporarily back at their original positions. Handle disassembled parts with care; clean them before reassembly using a neutral cleansing fluid. 5) Us2 all disassembly/assembly tools properly, and use the right tool for each specific job.
12-2 SPECIAL TOOLS for DISASSEMBLY and ASSEMBLY

b \o
3
-

(D

Fig. 12- 1

No.
1 2 3

Tool No.
2309500107 2309500207 3589500107

Name of tool
Valve spring retainer Valve guide puller

Description
For disassembling and assembling and exhaust valves To pull out the valve guide To pull out the rotor the intake

Rotor

puller

Table 12-l

-31-

12-3

DISASSEMBLY

SEQUENCE
I I

Sequence 1

Part to remove

Description

Precautions

Necessary tools 2 PlUj screwdriver

Side cover (Lj and (Rj I I Couplsrs (disconnection)

(1 j Remove both the left and right co\-2rs. by taking out eight 31-C flang2 screws. 1 (1) Disconnect th2 (6Pj coupler of the generator from the other (6P) extending from the control panel.

-I

Pull them under while pressing 1 down the retainer claws. ! 622 Fig. 1Z-2.) rs Minus screw-driver I 1 1Omm box spanner 13 Plus screwdriver

Choke cab12 I I

(1) Set the engine control to STOP. and remove the screw from the tip of the choke cable to disconnect the choke cable from the dial plate. (2) Disconnect the outer cable of the choke cable from the fuel tank bracket. (3) Loosen the M4 screw of the carburetor choke lever swivel to pull out the inner Loire from the choke cable. (1) Hold thz fuel line clamp inserted inside the felt strainer using pliers, and pull it backward to remove the fu21 line from inside the strainsr.

Fuel line

Be careful not to Pliers damage the hose. : I

I 5 Fuel tank handle

(1) Push up the end of the cover fitted to the handle with finger. I r (2) Pull out the rubber tube use; as the air vent pipe. a (3) Remove two bolts (tank). and remove the handle.

1Omm box I spanner

Fig. 12-2

-32-

Sequence

Part to remove

Description

Precautions

Necessary tools

6 I 7

Rear cover

( 1) Remove the rear :over at the opposing sid2 of the control pan21by unscrewing th2 four $16 flange bolts. (.I) Loosen the set screw of th2 strainer shaft at th2 rear of the engine control switch. (2) Remove two M5 flange bolts clamping the front cover and tank bracket together. and tank bracket together. and then remove the fuel tank. (.l j Rsmove two MS tlange bolts clamping the front cover to the basr to rrmove the front cover. (1) Using pliers. hold the fuel line clamp at the fuel support joint of the carburetor (L-joint directed downward) to pull it aside. Then. pull out the line. (1 j Insert the tip of a screwdriver (.tlat-headed type) in the groove of the choke cable bracket protruding from the head cover. (1) Remove the out2r cover; this is done by removing seven M5 tapping screws. (2) R2move one M6 x 1 flange bolt of the muffler bracket. and two M6 nuts from the muffler tlange. Then. remov2 th2 flange. (3) Remove four 315 x 8 lock screws from inside the muffler t I remove the inner cover. Be careful not to damage the fuel line.

1Omm box spannsr

Fuel tank

,z Plus screwdriver , (,SeeFig. 1Z-3.) ! 1Omm box spanner

Front cover

1Omm box spanner

, 9 Fuel hose I 10 Choke cable

Electricians ! pliers

Minus screwdriver

11

I Muffler cover and muffler !

Take care not to -3 Plus screwdrop the removed driver screws down into the cooling air ! IOmm box 1 channel. spanner (See Fig. 11.4.) 3 Minus screwdriver I

flUFFI

Fig. 123

Fig. 124

- 33 -

Sequence 12

1 Part to remove

Description

Precautions

Necessary tools

Bas2 platz

(1) Remove one set screw of the earth wire which grounds the rear housing and base plate togethsr (Zr)OV system onlv). (2) Rsmove four 5115 10 bolts from x under the base plate. (1) Remove the recoil starter from the rear housing. by removing three 516 x 8 flange bolts. (1 j Turn the starter pulley b]- hand to set the piston to the compression stroke limit (lvhere the pulle) becomes heavy). Csing a hammer strike the box wrench set ov2r the head of the through bolt to remove the bolt. Then remove the pulleb _

T ; u Plus screwdriver Smm box spanner 1Omm box spanner

I j

13

Recoil starter

(See Fig. 12-S.) 1?mm box spanner Handle hammer (See Fig. 1Z-6.)

Starter pullek

I I

Fig. 12-5

Fig. 12-6

Sequence

Part to remove

Description

Precautions

,
I

Necessary tools

15

Stator assemblq-

I 1 I I /

(1 j Remove three M6 x 85 bolts clamping the rear housing of the stator assembly. and the front housing together. (2j Remove the stator assembly-from the front housing. The stator and rear housing are removed together by using a plastic hammer to light11 strike the boss of the rzar housing. (See Fig. 12-7.) (3) Remove the lead from the clamp taking out one M4 x 8 scre\v. . . . b_~(4) Kemove both the capacitor and I diode from the rear housing by removing three M5 x 30 scre\\s. (5) Remove the wiring between the i stator and rear housing. Disconnest three terminals irom the diode. t\vo terminals from the capacitor. and the ground \vire from the r2ar housing.

1Omm box spanner Plastic hammer

j 3 Plus screw_ driver : Cd Plus screwdriver

-34 -

Sequence

Part to remove

Description

Precautions

Necessary tools

16

Rotor assembl)

(1) Fit the rotor puller to th2 rotor shaft. and drive it into place to remove the rotor from the engine shaft. (1 j Remove the plug cap from th2 spark plug in advance. (3) Remove the clamp of the highvoltage power cable. (1 j Remove the front housing and center baffle from the engine main bearing. b) removmg thrze M6 x Xmm bolts and one M5 x 55mm bolt.

Rotor puller Plastic hammer

1;

Plug cap

18

Front housing and center baffle

1Omm box spanner I j (See Fig. 11.8.) t

CENTER

BAFFL

FRO

Fig. 12-7

Fig. 128

Sequence

Part to remove !

Description

Precautions

Necessary tools i? ;s Minus screw-

19

Air cleaner

(1) Remove the center screw of the air cleaner cover to remove the cleaner cover. filter element. and element retainer. (2) Remove the M5 screw at the lower right inside the element chamber. (3) Remove tvvo M6 flange nuts clamping the air cleaner and the carburetor together to remove the air cleaner.
AIR CLEANER *

driver \fi Plus screwdriver i 1Omm box spanner ! (See Fig. 12-9.) I
A

ELEMENT RETAINER

& ELEMENT

ELEMEN/T

Al R CLEANER

COVER

FIQ. 10-9 -35-

Sequence 20

Part to remove

Description

Precautions

/ I

Necessary tools

Governor and related parts

(.1) Remove the governor lever from the governor shaft. (~j Remove the governor rod, rod spring. and governor spring. (1 j Remove the carburetor from the stud area of the intake side flange of the crankcase. , I (1 j Remove two M5 screws from the lateral side of the head cover to remove the head cover. (1 j Remove the M6 bolt from the crankcase and the $15 bolt from the main bearing cover to remove !he cylinder baffle. (1) Remove the spark plug from the cylinder head. (1 j Remove sev2n M6 x 32 bolts to remove the cl-linder head. (3) Remove the head gasket. :

Loosen the bolt (unnecessary to remove it) I

1Omm box spanner

Carburetor

7-3 --

Head cover

.B Plus screwdriver i 1Omm box 5 anner + Plus screw5 driver 19mm box spanner 1Omm box spanner

33

Qlinder baffle

24 25

Spark plug Cylinder head

; Mark the head gasket with its mounting position accurately matching the cylinder head, also mark the gasket mounting face of the , cylinder head.
B2 sure to position the notch in the spring retainers outside periphery to the front and hook the minus screwi driver (medium side) in the recess / (lower side) of a the retainer. Then pull the spring retainer backward to remove it.

i Intake valve

(1) Remove both the inner and outer tappet chamber covers from the crankcase. by removing two Y6 x 1: bolts. (3) Remove both the intake and exhaust valves. (3) Remove the valve spring and retainer.

t 1Omm box spanner 13 Minus screwdriver

I I

I I

I@
1 PULL

RETAINER BACK

(1) Remove the Woodruff key from the crankshaft. (2) Remove five M6 x 15 bolts locking the main bearing cover from the crankcase. (3) Using a plastic hammer or a similar tool. strike the mam bearing cover uniformly around its peripheq to remov-ethe cover.

1Omm box spanner Plastic hammer

Be careful not to damage the i lip of the oil seal. ;

-36 -

Sequence

Part to remove

Description

I I

Precautions

Necessary tools

28

Camshaft

(1) Pull out the camshaft from the crankcase.

Set the crankcase sideways so that it will not fall i and damage the ! tappets. Be sure to mark the tappets to distinguish them from each other; one for the intake valve and the other for the exhaust valve. 1 e Minus screwi driver Pliers 1Omm box spanner

29

; Tappets I

(1 j Remove the tappets from the crankcase. , ; i 1

30 I I

Connecting rod ! and piston

i Confirm the (1) Scrape off the carbon deposits from the cylinder and piston head. , mounting direcPush open the bend of the connecttion of the oil ing rod lock washer, and remove scraper. two bolts. (2) Remove the lock washer and connetting rod cap from the crankshaft. (3) Turn the crankshaft until the piston comes to its top position. and push the piston from the upper part of the cylinder. (1) Remove two clips from the piston pin and take out the piston pin. Remove the piston from the connecting rod. (2) Each of the piston rings can be removed from the piston by opening wide the ring joint. (1) Replace these clips vvith new ones: do not reuse them. : (2) Be careful not to damage the 1 minor rod end. (3) Be careful not to open the ring joint excessivelv .

31

Piston and piston rings

; I

32

Crankshaft

(1 j Pull out the crankshaft from the crankcase. If unable to pull it out by hand, use a plastic hammer to gently strike the main bearing joint tace. and pull the crankshaft pulled out. (1) Remove the clip of the governor shaft. and pull out the governor shaft from the crankcase. ! ! I I

33 I

Governor shaft I

-37-

12-4

ASSEMBLY

PROCEDURE

0 Precautions in Assembly

1) Thoroughly clean each part. When cleaning. take special care for the piston. cylinder, crankshaft, connecting rod, and bearings.
7) Be

sure to completely remove the carbon deposits on the cylinder head and piston head. Also, thoroughly clean and

remove carbon deposits from each piston ring groove. 3)

4)

Apply lubricating oil to the lip of each seal. Confirm that the lip of each oil seal is not damaged. If damaged, replace with new one. Replace the gaskets and similar items with new ones; do not reuse old gaskets. Replace the keys. pins, bolts, nuts. etc., with new ones if necessary. Do not apply torque exceeding the specified value. Apply lubricating oil to both moving and sliding parts when they are assembled. Prior to assembly, check the clearance of each part, and adjust it if necessary. When each of the main components are assembled, turn it by hand to check for smoothness of rotation and unusual noise.

5) 6) 7)
8)

9)

Assembly Sequence and Precautions GOVERNOR SHAFT

12-4-l

Put the governor shaft into crankcase, then drive the clip into position to secure the governor shaft.
124-2 CRANKSHAFT

1) Insert the crankshaft into the ball bearings of the crankcase.

2)

Fig. 104-l shows the dimentional tolerance of the crankpin.

OUTSI DE -DIAMETER

Fig. 72-10

-38-

Tolerances of Newly Installed Parts

Thrust directional tolerance between I Top ring Clearance of piston ring joint Second Oil ring Top ring Clearance between piston ring Second Oil ring Inside and clearance ring 1 I ring ! the cylinder and piston skirt 0.008L 0.2L - 0.047L - 0.4L

I !

0.2L - 0.4L Spare rings 0.05L 0.09OL 0.06OL - 0.25L - 0.135L - 0.105L Spare rings O.OlOL-0.065L , 1

outslde diameter
I

Clearance between connecting rod major end and crankpin

0.037 L - 0.063L 0.1 L - 0.7L

Side clearance Clearance Clearance between between connecting piston rod minor end and piston pin hole pin

O.OlOL - 0.029L 0.009T - 0.01 OL L = Loose T = Tight

pin and piston

Table 12-2

NOTE: cylinder 124-3

The clearance skirt. and

between

the piston

and cylinder

is checked

by measuring

the clearance

between

the piston

and

PISTON

PISTON

RINGS
OPEN ENDS OF PISTON RINGS

1) If a ring expander is not available. set the ring joint at the first land of the piston. as shown in Fig. 12-l 1 so that the ring can be slided into its groove.
NOTE: sively piston, The top marked Be careful each ring. followed not to twist or expand first exces-

The oil ring is fitted

on to the

by the second ring and top ringrings must be fitted with their

and second

sides kept upward.

Fig. 12-l 1

~j

The connecting rod is joined to the piston by the piston pin.

NOTE: NO JE: Before assembly, apply sufficient lubricating oil to the connecting pin. rod minor end Be sure to fit the clips to both sides of the piston

-39-

STD EQUIPMENT \ Second \ \ Oil ring I Fig. 72-72 1244 INSTALLING THE CRANKCASE ring Taper Top ring Taper

SPARE PARTS Taper

I Undercut

. \ ,\ x. :. q \ ..

1) The connecting rod is put into the cylinder while holding it with the piston ring guide. as shown in Fig. lo-13 (in the case that a piston ring guide is not available, press rings inward with fingers and at the same time. strike down the piston. using a wooden block). The connecting rod must be mounted in place with its @ and MA marks directed to the ball bearing side of the crankcase.
NOTE: piston NOTE: the piston adjacent 12-4-5 Apply a sufficient quantity of oil to the GUIDE

rings, connecting The top,

rod surfaces,

and cylinder. to Fig. 72-73

second

and oil rings are fitted arranged

with their ring joints joint. THE CAP

90 off each

INSTALLING MAJOR END

CONNECTING

ROD

1j

Manually turn the crankshaft until the piston reaches top dead center. Gently strike down the piston head until the connecting rod touches the crankpin to install the connecting rod major end cap.

3)

The cap is installed with the 011scraper positioned right-downward. (See Fig. 13-14.)
NOTE: fully Be sure to use a new lock washer; and carebend the washer correctly. When the cap has been installed, turn the OIL SCIRAPER

NOTE: crankshaft Iv. NOTE:

to see if the connecting

rod moves smooth-

The correct

torque

for installing

the connect-

Fig. 72-74

ing rod major NOTE: clearances connecting See

end cap is 60 to 80 kg-cm. Table 72-2 the for piston, details piston regarding rings, the and

between

rod and their counterparts.

-40-

12-4-6

INSTALLING

THE

TAPPETS

and

CAMSHAFT

Install the tappets. and then the camshaft.

NOTE: with Align the timing mark mark at the base of the cam gear If the valve timing properthe timing of the crank gear.

is set incorrectly, ly.

the engine

will not run or operate

(See Fig. 72-75.) If the intake and exhaust valves are installed in

NOTE:

reverse order,

tappet

clearance

will be incorrect.

Fig. 72-75

12-4-7

INSTALLING

THE

MAIN

BEARING

COVER

Install the main bearing cover to the crankcase.

NOTE: The governor gear is already mounted to the bearing cover; therefore, it is necessary to confirm that the governor gear is meshed with the cam gear. replacement, apply (See Fig. 72-76.) pressure-fit the new oil seal in position and oil seal. cover packing. Apply before installing the main bearing cover. face,

If the oil seal requires NOTE: Prior

to installation, in preparation

oil to the bearing the bearing

a small amount

of oil to the cover fitting

as specified,

for installing during

Place the oil seal guide over the crankshaft of the crankshaft is within

so that the 0 to 0.2mm.

oil sea7 lip will not be damaged If necessary, NOTE: adjust

installation.

Make sure that the side clearance collar. 700 kg-cm. (see Fig. 72- 7 7.)

the clearance,

using the adjusting cover: 80 -

Torque

for the main bearing

MAIN

BEARING

COVER.

fY;ie;

GOVERNOR

GEAR

Fig. 72-77

-41

*Shown in Fig. 12-18. is the method to measure the side clearance of the crankshaft. According to this method, measure the clearance between the machined face of the crankcase and the adjusting collar. The machined face of the crankcase is mounted with packing so it is necessary to set the clearance properly by allowing for a packing thickness of O.??mm. -I M6 x 25mm bolt . . . . . . . . . 8 PCS. M6 x 55mm bolt . . . . . . . . . 1 pc.

Fig. 72-78 12-4-8 INSTALLING THE INTAKE and EXHAUST VALVES

Prior to installing. remove carbon and gum deposits, from the valve, valve seat, intake and exhaust ports, and valve guide.
NOTE: NOTE: Replace If the valve face is worn, If the clearance between replace the valve with a new one. large, replace the valve guide with a new one. the valve guide and valve stem is excessively and pull bolt as shown

the valve guide by using a pull block A

VALVE FACE

in Fig. 72-20.

E GUIDE PULLER VALVE VALVE SEAT STEM

VALVE

GUIDE

VALVE

SPRING

Fig. 72-79 A: B: C:

VALVE

RETAINER

Fig. 72-20 45 45O I I I Intake valve I I 5 59 +0.018 0 -0.020 559 -0.032 -0.056 5.5@ -0.074 0.02OL 0.056L - 0.05OL - 0.072L L: LOOSE

Valve face angle

Valve seat angle Valve guide inside diameter

D:

Valve stem outside

diameter Exhaust Intake Exhaust Table 72-3 valve valve valve

Clearance (clearance between C and D) between valve guide and valve stem

-42-

12-4-9 Set

TAPPET

ADJUSTMENT

the tappet at 1112 loa-est position to depress the valve. Then measure the clearance between the valve and tappet stem.
As with the intake and exhaust valves, the clearance between the valve and tappet stem must be within 0.1 f. 0.02.

using a clearance gauge inserted into the clearance. (See Fig. 12-21.)
NOTE:

INTAKE

& EXHAUST

VALVE

VALVE

SPRING

NCE

GAUGE

Fig. 12-27 NOTE: If the clearance is smaller than that specified, slightly grind down

Fig. 12-22 the valve stem end using a grinder, then measure

the clearance. If the clearance to adjust NOTE: clearance. is larger than that specified, replace the valve with a new one. Spot the valve seat and use some compound

the clearance. After completing adjustment of tapper clearance, install the valve spring retainers, and then recheck the tappet

*Installing the valve spring retainer: Using the special tool. place the retainer over the valve stem with the notch in the outside periphery of the retainer kept toward the front.
12-4-10 INSTALLING THE CYLINDER HEAD

@ 1
FRONT

Fig. 12-23

Before reinstalling the cylinder head. be sure to remove carbon deposits from the combustion chamber. and clean between the cooling fins. Also check the cylinder head for levelness.
NOTE: Replace the cylinder head gasket with a new one.

The cylinder head is installed using seven 516 x 32mm bolts.

NOTE: 12-4-11 Torque for each cylinder THE head lock bolt: PLUG 90 7 70 kg-cm

INSTALLING

SPARK

Torque for spark plug: 120 - 130 kg-cm

12-4-12 The INSTALLING THE CYLINDER BAFFLE

cylinder baffle is installed to the crankcase, using the M6 x 20mm screw and to the main bearing cover. using the M5

x 1Omm screw. The cylinder baftle and fuel line clamp are installed. together to the crankcase.

-43

12-4-13

INSTALLING

THE

HEAD

COVER

The head cover is installed over each of the left and right parts of the c>-linder head. using the 345 x 1Omm screws.
124-14 INSTALLING THE GOVERNOR and RELATED PARTS

Model EYOSD has a centrifugal iveight type governor which is installed while engaged with the governor gear. With the governor. the throttle valve of the carburetor is controlled automatically by using a lever link mechanism. Therefore. engine speed is constantlq- maintained even under load variations.

1) Using two $16 x 1Omm bolts. install the speed control assembly to the crankcase. j Temporarily install the carburetor with two h-16 tlange nuts. 3) Join the throttle lever of the carburetor to the governor rod and rod spring.
4) 5)

Insert the governor lever into the governor shaft. Insert a minus screwdriver into the groove of the governor shaft. and turn the screwdriver fully in the counterclockwise direction. Push the governor lever clockwise (at this time. the throttle valve is fully opened) and fasten the governor lever with the lock bolt. Torque for the governor lever: 70 - 90 kg-cm

6)

Link the governor lever and speed controller with the governor spring. one end of which is inserted into the center hole (of the three) of the governor lever and the remaining end inserted into the hole of the speed controller.
Fig. 12-24

IING

Fig. 12-25

Fig. 12-26

12-4-15

INSTALLING

THE

CARBURETOR

and

AIR

CLEANER

Place the carburetor gasket. insulator. gasket. and carburetor in the correct positions. Kest. fit the air cleaner gasket and air cleaner case. and install them. using the hi6 flange nut and 315 x 1Omm screw. Set the element (small type). element retainer. element. and cleaner cover. and tighten them with screws (slot head tk-pej. Torque for installing the carburetor and air cleaner: 50 - 60 kg-cm
NOTE: See page lo-26 for details concerning disassembly and assembly of the carburetor.

-44

. *.

124-16

INSTALLING

THE

CENTER

BAFFLE

and

FRONT

HOUSING

1j

Set the knock hole of the front housing to the knock of the main bearing cover and assemblethem together. During assembly. place the center baffle between the main bearing cover and front housing. Torque for the front housing: 80 - 100 kg-cm

12-4-17

INSTALLING

THE

IGNITION

COIL

1) Install the ignition coil and grommet (IG-COIL) to the front housing. Simultaneousl>-. temporarily set the generator rotor in position. -4nd assemble the ignition co11and magnet together while adjusting the air gap between the two to 0.4 to 0.5 mm. Firmly bond the grommet to the front ensuring that there is no residual clearance. 2)
124-18
(use

CEMEDINE 575).

Fit the plug cap on the spark plug.

INSTALLING THE ROTOR ASSEMBLY

Install the rotor assembly to the taper of the crankshaft with their keyways in line.
NOTE: 12-4-19 Thoroughly INSTALLING clean the tapers (both male and female tapers) THE STATOR ASSEMBLY of oily substances.

1) Install the stator correctly into the recess of the rear housing. Sate the leads and their positions. 2) Install the wiring between the stator and rear housing. Connect the wires from the stator IO the capacitor (with these wires joined to two black top terminals). Also connect the wires from the stator to the rectifier (with these wires joined to three terminals).
GREEN RED :EJ

Connect the ground cord to the rear housing. using one M6 x 8mm screw.

Refer to paragraph

9-2 for

@.

Install the stator assembly correctly into the recess of the front housing. If necessary, softly strike the rear housing with a plastic hammer (be careful not to strike the capacitor and diode). Fasten the front housing to the rear housing of the stator assembly. using three M6 bolts, while the three bossesof the front housing are set to their counterparts of the rear housing. Torque for each bolt: 65 2 10 kg-cm Clamp the lead of the 6P x coupler and the lead from the ignition coil to the bolts specified in paragraph d above. using the wire bands.
124-20 INSTALLING RUBBER MOUNT (A)

1) Fit rubber mount (Aj to the bosses(two) at the lower center of the crankcase. 2)
124-21

Also fit another rubber mount (A) to the bossesat the lower part of the stator assembly of the generator.
INSTALLING THE STARTER PULLEY

Install the starter pulle) to the rotor shaft using the rotor through bolt. Torque for the through bolt: 100 - 150 kg-cm
124-22 INSTALLING THE RECOIL STARTER

Install the recoil starter to the rear housing using the M6 flange bolt.

-45-

12-4-23

RUBBER

TUBES

for

USE as AIR

VENTS

Connect two rubber tubes to the air vent connectors of the carburetor. Keep theje rubber tubes suspended downward from the air vent connectors.
12-4-24 INSTALLING THE BASE FRAME

1)

Install the base frame with its rear side facing the welded nut area of rubber mount (A). the engine and generator. using four MZ bolts. Match the rubber mount (A) which is fitted to the lower part of Base frame is installed

3)

Insert each rubber tube from the air vent connector of the carburetor into the hole in the base frame. Fasten the ground terminal of the ZOOV power system to the rear housing using the $16 bolt.
EASE

3)

-/
PLATE

12-4-25

INSTALLING

THE

MUFFLER

and

MUFFLER

COVER

Fig. 12-27

1) Fit the gasket (for the muffler cover) to the studs of the exhaust flange of the crankcase. 3) 3) Using the 545 scre\vs, install the muffler cover in place.
NOTE: Be careful not to drop the screws into the cooling air channel.

Set the gasket (for the exhaust port) on the studs of the exhaust port flange. Then, mount the asbestossheets to the upper and lateral sides of the muffler. The muffler is installed while secured to the muffler flange using two M6 nuts, and also to the muffler bracket by using one M6 bolt.

4)

Install the outer muffler cover place using seven MS tapping screws. Torque: 70 - 90 kg-cm

124-26

INSTALLING

THE CHOKE

CABLE

1) insert the inner wire of the choke cable into the swivel of the choke lever. 2) Insert the outer 2nd of the choke cable into the wire bracket of the head cover; temporarily tighten the outer end so that it will not slip out of the uzir2 bracket.
NOTE: 12-4-27 The inner wire is installed THE FUEL later. Leave it loose in the swivel.

INSTALLING

LINE

1) Connect the fuel line to the line connector at the fuel supply port of the carburetor. Then. fasten the line so that it will not come oii the line conn2ctor. 2)
124-28

Secure the fuel line with the clamp of the cylinder baffle.
INSTALLING THE FRONT COVER

Using two h16 x 8mm flange bolts. install the front cover installed with the control pan21to the base plate. Keep the engine switch set at STOP.
12-4-29 INSTALLING THE FUEL TANK

1j 2)

Keep the strainer shaft at the lower part of th2 fuel tank m a position that will allow the setscrews to be tightened from the opposite direction of the muffler. Insert the flexible shaft extendmg from the rear side of the engine switch which is mounted on the control panel into the square hole of thr strainer shaft.

-46-

3) Align the mounting holes at the lateral side of the front cover with those in the bracket which are bolted to the fuel tank. Then. install the fuel tank. using t\vo $16 x Emm flange bolts. 4) hlake sure that the flexible shait on the control dial side is inserted in the square hole of the strainer shaft. then fasten the flexible shait .
124-30 INSTALLING THE REAR COVER

Align the mounting holes at the lateral side of the rear co\-er urth those in the fuel tank bracket. Then install the rear cover-. using two 516 x gmm Slang2 bolts. Also align the holes at the lolver part of the rear cover s-ith those in the base plate. and install the rear co\-er by two M6 x Smm flange bolts.
124-31 INSTALLING THE FUEL TANK HANDLE

1) Set the bolt (to secure the tank handle) in the handle and assemble the O-ring to this bolt from the opposite side. Then. tighten the bolt to install the handle to the fuel tank.
NOTE: Be sure to direct the less slanted part of the handle toward the front cover.

2)

Insert the rubber tube end over the protrusion oi the bolt (for the 15121tank) and push it down to the base of the protrusion.
NOTE: Be sure to keep the air bleed hole at the center of the rubber tube directed upward.

3)

Place the handle cover over the handle.

INSTALLING THE FUEL LINE

12-4-32

Insert the fuel line end over the fuel strainer joint (be sure to push the line end down to the joint base). and secure it with the clamp.
12-4-33 INSTALLING THE CHOKE CABLE

1j 2) 3) 4)
124-34

Insert the choke cable adjusting screw in its hole on the fuel tank bracket. Secure this adjusting screw with the M6 nut and tighten to the midway point of the threaded part. Set the dial of the control panel to STOP. and connect the locknut of the choke cable end to the panel. Pull the inner wire of the choke cable to clamp the wire to the choke lever. using the setscrew.
CONNECTING THE COUPLERS TOGETHER

Connect the coupler (6Pj from the generator to the coupler (6P) extending from the control panel. Also connect the stop wire (green) as required.
12-435 INSTALLING THE LEFT and RIGHT SIDE COVERS

Using the MS flange screlvs. install the left and right side covers in place.

-47-

12-5

CABURETOR
and

12-5-1 FUNCTION

COMPONENTS

(See Fig. 12-28)

1) Float system
The

float chamber is located direct& under the carburetor.

Flat and needle valves. maintain a constant id

level

inside the float chamber. The fuel in the tank tlo\vs into the float chamber from the needle valve. When a certain quantity of fuel enters the chamber. the float rises. When the buoyax)- oi the flat \-alve balances with the fuel in-flow pressure of the needle valves. the valves close to keep the fuel at the correct level.
Schematic diagram of the fuel system
CHOKE BY PASS; THROTTLE r VALVE ,-PILOT OUTLET

FLOAT PILOT AIR JET L-d PILOT JETJ ..MAIN NEEDLE

MAIN

AIR

JET?

/.-NEEDLE

VALVE

FLOAT

MAIN

JET

Fig. 72-28

-48-

2) Pilot jet nozzle system The pilot jet nozzle system controls the fuel supply for engine speeds ranging from idle to low-speed running. The sytem operatzs with the fuel flowng through the main jet nozzle and up to the pilot jet nozzle where the tuel is measured. When the fuel is mixed with air. the volume of the air-me1 mixture is also measurzd by the pilot air jet. From this stage. the mixture is supphed to the engine trom the pilot outlet and bb-pass. During idle. fuel is supplied mainly from the pilot outlet. 3) Main jet nozzle system The main jet nozzle system supplies fuel for middle and high speed operation. The fuel flows to the main jet nozzle where the fuel quantit) is measured. and then flows to the main nozzle. Air volume. which is measured by the main air jet ~enters from the bleed hole of the main nozzle and miszs with fuel to form a gas mist. The gas mist flows out of the main bore and is again mixed with air from the air cleaner. From this stage. the correct air-fu21 mixture is supplied to the engine.
4)

Choke The choke helps in starting the engine in cold weather. When the engine is started with the choke valve closed. negative pressure applied to the main nozzle rises. allowing most of fuel to flow through the main nozzle. -4 mixture with a high gasoline concentration is fed to the engine resulting in easier engine starting.

12-5-2

DISASSEMBLY

and

ASSEMBLY

of

CARBURETOR

The most common trouble with the carburstor is failure to provide the correct air-fuel mixture. This is generally caused blblockage in the air and fuel channels. at other times it is caused by fuel level fluctuations in the float chamber. In order to maintain the carburetor in normal operating condition. it is vital that the air and tuel channels be kept clean. The following descriptions are the procedures for carburetor disassembly and assembly. (See Fig. 12-19.) 1) Throttle mechanism a) b) Remove Philips-head screw (77): throttle valve (~8), and pull out the throttle shaft (39). When removing the throttle stop screw. a spring (3 1j will also come off. Be careful when handling the throttle valve to prevent the valve edge from damage. 2) Choke a) b) Remove Philips-head screw (12). choke valve (23). and pull out choke shaft (24). Be sure to keep the notch of the choke valve positioned forward the main air jet side when the choke shaft is installed. 3) Pilot jet nozzle a) b) 4) 0 Remove pilot jet nozzle (?I ). When removin,. use a proper tool so that the nozzle will not be damaged. Firmly secure the jet nozzle when the carburetor is assembled. Otherwise, fuel will leak from the nozzle and cause engine trouble. Main jet nozzle a) b) c) Remove bolt (15). and float chamber bodl- ( 13). Remove main jet nozzle ( 19) from carburetor bodk (9j. Firmly secure the main jet nozzle when assembling. Othzrwise. air-fuel mixture will become excessiveIF rich and the engine will not operate properly. d) Torque for bolt (15) is 70 kg-cm.

-49-

5)

Float system Pull out tloat pin (13) and remove float (I 1j and needle valve (,30). * Avoid using a drill or a wire to clean the fuel passages(they map damage the orifice of the pilot and main jet nozzles). Use compressed air. * The float pin is peen-secured to the carburetor body; the needle valve and float can be removed out from the opposite side of the peen-secured part b>-lightly striking the float pin with a thin bar-like object.

27 /

28

24 1'

Fig. 72-29

- 50 -

13. TROUBLESHOOTING DIAG: 8

DIAGNOSIS BY THE CUSTOMER

DIAGNOSIS

?-)

DIAG. 01 DIAG. 02

Engine fails to start. Electricity not generated.

If the generator doesnt perform properI>- or fails to run after troubleshooring. ask a qualified service dealer to check it.
n

DIAGNOSIS

BY THE SHOP

A. Fails 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13)

to start DIAG. DIAG. DIAG. DIAG. DIAG. DIAG. DIAG. DIAG. DIAG. DIAG. DIAG.

11 1: 13 14 15 16 1 18 19 20 21

The fuel tank is emptkContaminated by water or dirt Spark is weak of wire harness Spark is strong of wire harnzss Compression is insufficient Compression is nonexistent Cloggsd fuel pipe The fuel doesnt enter into the carburetor (No flow from the pipe) The fuel doesnt enter into the float chamber (Flow from the pipe) The fuel doesnt enter into the combustion chamber (Fuel exists in the float) Carburetor flooded

B. Engine defective DIAG. 3 I 14) 15) DIAG. 32 16) DIAG. 33 17) DIAG. 34 18) DIAG. 35 C. Control Panel 19) DJAG. 36 20) DIAG. 37

Excessive noise (Improper maintenance) . .... Check oil element Oil consumption increases (gets thin) Excessive noise occurs and engine suddenly stops Black exhaust fumes (Excessively large fuel consumption) White fumes produced (Excessively large lubricating oil consumption)

Pilot light fails to light up The frequency meter fails to show any reading, with the needle resting at zero

D. Engine operates but voltage is not normal No AC voltage is output (Resistance load) 21) DIAG. 41 No DC voltage is output (Resistance load) 23) DIAG. 41 No DC voltage is output 23) DIAG. 43 The DC output voltage is only 50% of the rated value 14) DIAG. 44 130% higher or more DC is output 25) DIAG. 45 So AC voltage is generated DIAG. 46 26) AC output voltage is onl! 20% of the rated value 27) DIAG. 3: E. Power lacking and performance poor Poor operating condition DIAG. 5 1 28) Engine speed does not increase 29) DIAG. 52 Knocking. engine overheats DIAG. 53 30) Failure to generate output. no compression DIAG. 54 31) Poor performance (Backfire) DIAG. 55 32) Misfire or combustion outside the combustion chamber DIAG. -6 33)

-51 -

DIAG. 12 Engine fails start Check fuel quentity

lo

DIAG. 13 Engine fails

t o stllrt

Engine fails
to
St;lrt

Check fuel quality

Check spat k

Spark is t o o weak o f wire harness

L1
Parts Items t o check and procedurc Check

I
Fuel tank Fuel strainer

I
Air gap is too wide

I Coil is
shorted or wire broken Weak magnet

L
Rotor Without special equipment, i t doesn't work Weak magnet

High voltage code

Plug cap

0
Spark plug Clean plug Dirt present Insulation troublc Clean o r teplacc

Coil is shorted or wire broken

High voltage code and conlacl trouble

1

rChecking criteria Remedies

r- I
Fill with
Replace fuel fuel

Icr lz: v: 1 E l r::1

r"
Measure the coil resistance Circuit tester Check Check the air ga P Searcher

Check

=a: Wire

I
Plug cap cot1tact defective

N o fuel

Moisture or dust exists

Air gap is t o o wide Standard is 0.4-0.5

on: Sl1ort

broken

I I
Adjust and reform Replace

Standard first : 0.6 1 S2 second : 7.5 ki2

Replace the

rotor

Repair or replace

Repair o r replace

---

-.

Sym(~lollls

_.

.-

P0ssil1lc
CilllSCS

___-.

-_.
-1

I 8 I

_ ..-_-

Ilclns

10

check and proccdllt c

(heck

Mcasurc dcglcc 111 lcvcl11css

-.

--

-r .., -ovet

. -_-

I.the Over

-_

I -

..-

_--.. I,. I
(Ilwck gaskcl lllc (heck
-. .I..

SI icky

Oil VillVe SlClIl ilrld

n1ove sm00111ly

Grmcl lhc
end ol' lhc ;1nd

wlve atljllsl
iappct

IllC
Spa""

- ..]
F

(hccking critcliil

service liillil

Ilie sclvicc liiiiil

Not level

Not SCCUIcd lighlly Gasket tlefecI ivc 1 I--

-r

--.

.--(I~ill~ltlCC

Lhlllil#Xi

gasket OI ovcrst poke rmgc

Narrow

... I.~iltljllSl

SI Icky

Wide . . . WplilCe

._

. _.

-71 Ll
Syrnplorns . .---,. PiIrIS T I .-

---.-

.-- _

..-

-.

-.

Possible
CiIIISCS

-.

- 1. --_ L I
llic air bleed is clogged ..,-.--.. --. 1 Chock IIN bolt 01 nihher pipe iri the Ilanlllc EXAM 3 I
. -.._

Fuel sl rnincr :IWI Iillcr ..L .__ --.,

-.-

_--I-... r 1L_
cd' flOll1

No Iucl tlows OUI CVCII wlwn Ill0 IIICI pipe is diswrincclthe

-_ .r-.. -_ ,, .tDIAC. 18

-1

-I

c;lrhrelor

---

.-.

Fuci slrniticr -_-.

--. --. - - -1 . ._ --. i Fuel pipe

-. _ -I -. ..-

_-.

-.

L- -.,-I -..- -,,..-? I L 1

Fuel Iillcr --_ --_ -_ Dclcclivc Iil~Cl r .--. --_ 1 --Iucl -1 (llcck

t-tiigitic Iuils IO ~1211 Pucl tlow II01 ClllCl irllo llic ~;II~~III~~~I

The air hlectl is cloggc1l ..1 I

_. ..-_ L.-

AlXllllllllilll1~l1

01

ail -

----. I-

Items [occtlllrc

IO

cllcck atld

Clwck

(heck

--. .I--

-. .-_. T-1... ,-.--

1 -_I _--..-

Clhccking crilerh

The ;lir tdcccl is clogged

Closed

posilion

Air buhhlc

exisls

l)c~cclivc

Iiiel Iillc~

-_--

.-

. . I

.-.L.VICi#Il

-. __

.A--. lllc ilir

--,

L__

. ..-

.-

._

or

ICplilCe

I L

Sel in lhe closed posil ion

(lci~r, llw Iillcl I L.. Vent . ., _

Cl~lllCl~l OI lCi7lilW

--

--._. J

IIIC &..-,-

SllilillCl

---

..A

.-.. .-

.- --.

rl
-

Syl~lploms

--.I.---

(twk (Tly lo 111ovc)

(heck

Measure the tloar hcighl. The stmiticnt ion is IS 3 111111 tl0111 body

(tlcck

-._ I

--.

__

,_-. .,1

-.. -. !I
Synlplollls Possihtc
CBUSCS . .

Excessive noise

-.-....--._ I ._I.
DIAC. 32 1
Engine opcr;il ion dmornial l.nbric:iting oil consunipt ion increases (gels thin)

T' --."-

l
it2

..,.-

.-..-. ._--._ L Li 1
lJxcossivcly wortl sliding paris (llsc olold oil) -. Cheek lhl! COIllprcssion To 111AC. t 5 or lb
I

L :
Fuel
- ..I

---r

,.-

Excessively worn sliding parts ((tlilllgC the oil)

Lhn~agetl or clogged (Lack ol IilainlcIlilIlCC)

_ .--.. -. r --

Check 1tic COIUprcssioii To DIAG. IS or 16

Cltlcck

Check thcjel (Jut number, looseness)

illICe

ol

pislon

ring

Kcplaco will1 m)rm11 1ucI :ind check

-----I

i._..I

-.

Dislalett Wrong jet

lirnil

---

-.,-I-

--

Sylllt~IolnS

Noise protlucctl

and

Lxccssivcly

IillgC IUCI

r: ,,

._-.

--.

1.

r-

.--.

IL .1 1
Fuel ---. I:ucl riiixctl wit I1 foreigli si~hsl;rnccs

._ I..1
_Iossiblc
C'Il1sw L ot'

('ICillNZr

ClClllClll

..-.
I -01 d;magc piston 01 I 1 __.-

I .-

Scizurc ltic

connecliiig

rod .I

__..-..

_ .,,.

(llcck

..-

.-..

-.,...-

._-

I j

(logging of It1e air clcmcr clcnrcnl

Rich

rJJixlurc

,.-

I .--.-

-.

--

--

(heck

Cheek IIIC main jcl (i)r loosc~~css antI ,jct

nlllnhcl

Repli\cc with normal Iucl ;III~I cheek

To DIAG.

2I

,.. .-- II>ii I

-I-

-- -1
I)islorlctl . .. Tighlel1 Wrongjel To I)tA(;. 2 I

-.--

I-

--

C'tlccking crileria

Scizut c OI' tlillllJlgC 01 I tic piston 01

connecling rod

---I

I-

Ll
Hnginc
Ir011hlc

Excessively

Wtlilc t~jlllcs protlucctl --_

Iqo luhricitlirig oil co~~suriiption

----

-. _..-- -. I
WOlIl Ollf Sticky

r-

VillVC
rctllln &,gglXl

WOrll

I--

Possihlc
c;Iuscs -

1Nll

and

valve

III.' I 1

.I-

I -.-_.

.--

(Ihcck clcararicc
pislon ring

of

Cheek

(heck

Chcck

(heck

I -r -. -

--.-1 --(orilnriiinaI ion (mixed with ot!iet

ll1illCriillS Over Assclllt~lccl upside ttic

Checking
crilerio

over service

tt,e

limit

down

Over ltic service liniil

slaiidard qlltiIllily

ACctIlI\IIlillioii of
carboll

Oil Icakage

like carbon)

____. .._.... T. -

_ I._ I--.__..._-.- 7 11I

MAC. 36
/XlIlCt (or~lrot Sylllptl~llls

- ----I
rncler I;lilS
IO StlOW

Ttlc pilot light I;lilS 10 light Op.

the needle res(ilig

PiNlS

._

1 ..
lie tlc(cct diode ive is

-.

-...-

_I--

--

-I

Wilt

hlc~kcll

OI

The Iilamcn~ is

ShCM 14

% I

_, 1
IlClllS lo

.__

I I
Mci\llSrc the rcsislnncc (hl coiiplcr)

1
MCLSIJIC IIIO rcsiul~~iicc (ACIOSS ltic IcrrniIlillS) Circuil tester I

tklcclive soltlcr, and leutl broken

Wile broken
stwrlctl

OI

__ _

L--

-, 1
(lwck
paI I Circuil

I
the sol&xcd
lcslc~

___ 1 _ ___ .._ ---.Mcasurc

illlO (ircuii t~l3l~ilMlS) lesler

I ..-... .-_
(lwk IIIC Ircctucncy nictc~ Ior clcclrical conlirluily

Mc;wrc ltic
Icsislwlcc . . L (Across lhc Icriliiii;ils)
circuil Icslcf

LIIC rcsisl1 tie

(LICIOSS

clwk and ploccdurc

L. I--

I----WllCll 41 ...

.I-__

When When 42 ... 42 . . . tt1e Wl1cn 42 .*,

!.
(lwcking CI ilcl i;i

wtlcll

Witc hlokw OS1 . . .

SIIOI lCll

Me;lsure I hc rcsisl*lrlCC .
(ilCIl!SS lhc ICI-

miii;lls) citcuil lcslcr

Wire hrokcll

rcatling ol Ilic circuil Icslcr mq Itic ICiltl Zllld SOldL!f LIIC

ttefcc~ive 7

Wire hrokw
WhWl a2 Stlorlctl .. .

Wilt

hlokcn

.-

Vc~y low 01 rlotIIing? hginc is opcr;rtirrg well

Mcasurc AC outpul EXAM I

MCISIJW

AC output

Measure DC OIII~UI EXAM 1

AC voltage

is low by

Kerr1cdies I I

.---_ _ .,.- _._I_ - .__-..,. . _-.

To DlA(;. 40 I To DIAG 45 To INAG. 43

-ir

To I)IAC.

44

--.,. --.DIAC,. 44 -. __..-_... _1

The IX oulput vollagc is only SCYj% 01 lhc ralctl value

Sylllpllm

.--..

.-, L. L.- 1 I
Slulor IX1 coil --.. I Wire hrokcn shor INi OI The diode is tlctcctivc
--I... . --

Stator

main coil

-I

r
is defcctivc

;7
IXiltl

-1
-

One diode

Tile soldered pilrt is dclcclivc, ;rd the lead ;rd the is hrokcn 1

Measure Ihc rcsislcliodc terniinds of

Measure
(;wwis

~IIC tesislance
the lcrniinas)

Circuil

leslcr

Mcasurc I~IC resistance (across the lcrminals 01 tlw 61 coupler) (ircuil lcslcr

1
Measure 1hc resistance (xross lhe Icroiinals) (iicuil lcslei
Mciisurc (iICrOSS the iosislance

Circuil

lllc Icrniin~ils) lcslci

-_

,.lI

.-. I ___--.

___. _1

.._. ., . -. I

.--I

-.

----

Wllerl

42

...

Wire blokcn WllCll OS2 . . . Stlortcd

When
differs slandard

l hc

rcsislnnce the value

11om

WllCll 42 . . . Wilt broken wl\cll OS2 . . . Shorlcd

-_

- 1 ..----

..L .-

Whcri tlic resistaucc tlilfcrs Irom lhc Stillld~lld Villue

-.1

. --._.

[_1,
I~eiiiedies

..IN%, higher or more IX: is output

Symptoms

--. --.-....
l+rigirie is high ..__ running

. . r].-.
r1
--

T
-r

-. A
speed

L.- -.-.

PiirIS

..,, .._-

r
(circuil hc used

Condenser

_I. .._-J.-,..-. L 1 1! 1 r
.. -.. . -

-.

Staler

tllilill coil

SlillOr

coiidenser

coil

-.- ._,

-.

._.---

- _-_-

-7

---

---

Possible
CilllS~S

The cngille running spcctl is higher lhan nornd

Wire broken shortctl

OI

I-

-_--

I-z

1 ,,
.-

I. Wire hrokcn shorled or 2. 3.

Wire broken shorlcd Kotor resistor is dclcct ivc Kotor tliotlc is delccl ivc ,.-1

--I

___ 11 _r ..-._-,x ._.-_..-.--_ .._. _ I 1 AI

check ;md lmxedure
li)r

I lerris

lo

To DIAG. 52 Chcck 111e governor

McilstJre

the tester

capacily c;~ii this nol

Mcasure
(bclwccn riiimds)

LIIC llic

rGst:lllcc Icr-

MCilsurc (between
IlliJliJlS)

111~

resistance the terlcstcr

1
A

--

Mci\sure the resislancc across tlic resistors, with solilcr imoved.

MCiISIJIC tile

resislawc

Tlrc

circuit

tester

The

circuit

01 the rolor rcsislor, tliotlc ilntl cllcck 111~ li)r lll~lIllIilCy

~-_.-

--l-

_--

II) When 42 ...

(hecking criteria

DilTcrcnl

Irwn WlilC

the

slilrltlad

When 42 .., Wire hroken When OS2 . . . Shorted -. I .- -,.....-_

When 42 . . . Wire blokcn

WhCll u2 ...

Wire brokcll
WllCll t-Is2 ...

Shorlcd

Shorlcil _-.-. T --.. -

) TIIC resisI:lrlcc
tliIlcrs by
as 10%~ from as tiiuch lhc

____

-_

-.--. I .._--. L ---1

slarldard

value .-the
,_-. rolor -.- J

Kcnicdies

Replace

the condcnscr

L..-----I

_-_-.--_ ___

L.

I1

r- 7
..,,, ..A

1---

L., ._... ___ ,.

L
_

Keplilce
- ..-__

I E I

.------r _._--..u ,1 c.-.-..__.. . .L--7 1

__--.
A(:

,.

OUllW1

VOlliIgC

is only 20f% ol lhc ralcti value

._ ._

Pitrls

Rotor

(lonclenser

hgine

---I-

Possible causes

Shorting rotor

0IIhe

coil

The coil is shorted

The coil is shortcd _ --

Aged or broken

resistor

The cnginc speed is lower than norrrial

--_-_.
Mcasurc

__

1 .-A--

_-

- ----T

-.-

. ..-

-1.

. . -..

-.

the resist-

llcn1s lo cheek and procedure

311Cl!

Measure the rcsist-

(6P coupler lerlninills) Circuit lcsler

Circuit

tester

Measure the resistiItlcC (hctwecn the lerminals) Circuil tester

Mensurc the capacitance (Ihe circuit lcster can not be used for I his measurement) .-.

To DIAG. 53, Cheek fhe governor

_ I

..,

. .. .,

-.-. - ,...

--DilTcrcnt Iroiri Ihc standard value Aged Broken

Checking criteria

TIIC rcsislance is l Sfjh lower 1lli111 llle

Slillldilld VillUC ...

Shorlccl

TIIC rcsist;lucc is 1.5% lower iliaii the .., standard vihe Shorled

IS%, lower than I he coil ililllllilId ... Shorted IO%, tlitferciicc tllilll llje resister stillltl~lKl
Old

...

El
Remedies

---

Sylllpll~llls

..I I T

Possible
C3IISCS ---- ! -

Dclective selliiig ol the governw lever illld level shnlt .- --.-.. --_..-I --

Poor or clclcclive perli)rmullcc

I--L
I,eilll

nlixlurc

.._

_-

--

-.,_

.I---.---

Iiems

lo

(lwck Check ihe set posil ion

ihc

II~OVC-

CllCCk ;I1111 produie

(llcck I hc Iucl pipe of cnburctor

1
1 1

--

I0 I)IAG.

I7

._-.. _

--- _-_. _ 1. .Dc~cctivc wiling

-___.
1 ._ _-.

_-,,-L-_
C0lllillTli~lilli1~ll ClCilll

- ----,

.-

: _.,.._-... .- T

Checking CrilLriil

Incorrecl llilllging posiliorl .,. Kcplacc Dclcctivc govcrritri spring . . .

Worn

0111

.,,

...

-.

KeplilCe -_ _ -. T

..-_ .-

Keplacc

T-j-

--I

DIAC. 52

--_--,n a ._.r1
no1

Kngiiic

speed

110CS

illcreils~ 4 _ .--_ I

..

. .-..

I
t%?Clriciil load

Valve

Cilrburclor and ilir

cleaner

..-,- -.-, -, --I

---_-

-1._...-.~
is incorrect. and iiiulller
ilre

---

Possible CI 11 L scs

Iktecl

ivc

sell

irig

The

liming

ol

ihe

valves is tlclectivc.

Mixture

Ovill~;iillil

__

.-._

-_.

---

-.-

-. .,,_,--.-

Check the SCIt ing

,,, ..--. I
.The

Cheek the carburator. t;XAM (heck lhc ;lirclenncr

owners iiianuil

Correct
Stilllcl~rd

to the

hltl

(heck

by eyes

EXAM

54 I

-7
with

I ~-.-

A
is iniulcr-

...-.-

ZIIY
--.-

goveinor
set, lhc

(hccking
crilcriil

correctly feriiig

Acljuslmcni
iIIlCL! is incorrecl

olcleilr-

lhrolllc

valves

opciiing.

.-

..-.

--I-

i=: I

--, -_-L
OWrlOilCi

AC ; To WAC; 46 DC; To DIAG 43

- _ --. ..-..---- --

PiIrIS 1

Iossib lc CiIlISCS . ) I! ,-

8 I

-I __I ,_______ I. ._-- -l.---..._-.....I 1I 1 L 1 r 1 --._.. J 1 _. -r--l

.---Cylinder heiltl hind cylinder -. .-. _. (ylimler rnulfler licad Cnrburctor ___-_ .-I ldeclric lid _. ._ ._.

.-.-

l .__L-.-.
Spark -plug

. .

i,

.. __- ,... -._ 1 _-

---I.

---I--

--

._-

(ooling

I;llls

iIN!

AClXllllllliltil~ll

Of

clogged.

carhi

Overloading

,, --.

--

___A

-. I.

- -r

._.

llcrlls

to

cl\cck iIIIt1 proccdurc

wcii 3 --. I
-I

Cylinder hcild IrXAM SO Mulllcr IXAM 65

OVCdlillll

Lilltl

check IIIC corburc(or. Air compressor IJXAM

Mcasurc I hc insula* . tion resklilnc~ Adjust to the * standard IWli AC ; To 111AC, 46 IX; To DIAC; 43 _--_ ,.-

(llcck Spccilj ISM K4.A (NGK) IXAM 5 I

--J -_. - ,_-.-_ -- 1 7

Tllcrml ril t ing of tllc spilrk plug is
IlOt illlCX~ll~lt~.

Checking
critcriii

Dirt illld

clogging

Overlootl

I--

,.. -L.

.,.---

l----------l

Kc~tiove the carbun dcposi I. I.-----I

I---I-..

-Replace

IlSilgC

Ol Sl~lrlliiIrd

IOild.

spccificd
__--I

with the plug.

I
-. , ,

No trutpu1
No comprcssiou

Poor pdorniancc Backlirc

Poor performnnce

Misfire or cond~~stion ou,side the

L..- -

.J L-

.-,--J

L_-+

-Possihlc
CilllSCS , I .-. .-

Worn out
(onlacl

Rich niixlure. ! -r -.-. -_

--

Dcfccl ivc
soldel

Moisture fuel

in

point is dclcclivc _ -l --.

7 T
Check (Inside
cilrhl~riltl~r

ltcrlls

IO

Chcck 1hr

Check ancc.

the

check and procetlul c

IappCl ClCilrilncc.

tappet Ckiir-

Check the ,jet fol llN,scl~ess ((heck the $1 number)

Replace with 11~2correct

piIdS illld

of

chuck

cliambcr)

-,, -r-- Narrow . . . Adiusl to

COlllilCl

Clhcckiug criteria

rhc ml Ill0 ViilVC Wiilc . . . Replace

of

Loscncss .. . Tighten Wrong,jel .. . Keplncc

C:lnltoct

point by soil is fail

Moisture fuel

in

14.

CRITERIA

TABLE

for

ADJUSTMENT

I terns of adjustment

Criteria

Limit of application 0.15 5 1 .cl6Q

Description

Tools Surface plate and searcher 1 Cylinder gauge

Remarks Repalr I

Levelness

of cylinder

head

Below 0.1 510+o.o19 0 and 0.5 5,50A0.018 . 0 50.9920 0 -o,02

lnslde dia. Seat width of Intake exhaust valves

Cylinder

1a Center dia. I 50.92

Slide calipers and cutter Cylinder Micrometer gauge

Repair

1 lnstde dia. of valve guide Piston skirts dia. I thrust outs,de dIrectIon
TOP

5.656

Replacement

Replacement I

, ,5 +0.025 0 , ,5 ~0.025 0 2.5 ao.035 0 , ,O +0.002 -0.009 0.008 0.090 0.060 0.010 0.009T - 0.047 -0.135 -0.105 -0.065 - O.OlOL

1.65

Slide calipers

Replacement

Ring groove width

Second

1.65

Slide calipers

Replacement

Piston i Pin hole

011

2.65

Slide calipers

Replacement

11 .O35

Cylinder

gauge

Replacement

Clearance between piston skirt and cylmder wall Clearance between ring and ring groove Top Second Oil Clearance between and piston pin
I

0.14 0.26 0.23 Spare rings 0.19 0.06L 1.5 1.5 Spare rings 1 .5 1.3 1.33 Spare rings

Cylinder gauge and mxrometer Searcher Searcher v Searcher Winder Saw and micrometer Searcher

Replacement Replacement Replacement Replacement

piston

Replacement Replacement

Top Joint gap I Piston rings I Width Second Oil Top Second

0.2 - 0.4 0.2 -0.4 0.02 -0.25 -0.09 1.5 -0.11 .5 -0.06 -0.08 2,5 -0.010 -0.030 * 0 -0.008 013 0 0.037 -0.063

Micrometer MIcrometer ! MIcrometer

Replacement Replacement

AP!ston pin outside dia.

011

2.38

Replacement

10.060 20.050

MIcrometer Cylinder gauge

Replacement Replacement

lnstde d:a. of large end

20d+0

I Clearance between mslde dia of large end and crankpin Connecting rod lnslde dia. of small end 1 Clearance between instde dla of small end and ptstonpln Slide clearance rod end of large

0.13

1 Cylinder gauge and mlcrometer Cylinder gauge

Replacement Replacement Replacement

L-0 021 O-0.01rJ 0.01 - 0.029 I 0.1 -0.7

11.080 0.12

Cylinder gauge and micrometer Searcher I

i 1

1 .o

Replacement

-68-

Items of adjustment 1 Crankpm outside dia. Generator side

I I

Criteria

limit of application

Description

Tools Mtcrometer

Ramarks Replacement

I
, 20e, -0.003 -0.012 , 7. -0.003 -0.011 18.4% 19.920 19.950 ! !

Crankshaft

1 Crankshaft journal outside dia. Cam crest

I Micrometer

Replacement

Counterside

6.950 18.15 9.950 9.959 24 1 .o I !

Micrometer

Replacement

Micrometer Mtcrometer Micrometer Slide calipers Square Mtcrometer I

! Replacement ( Replacement Replacement Replacement Replacement Replacement

Camshaft

i
Camshaft journal outside dia. I Free length Squareness I

&:erator
Counterside

,O9-o.O3 -0.028 log -0.01 3 -0.028 25

Valve spring

Intake Outside dia. of valve stem I Clearance between valve stem and valve guide l I Tappet clearance Clearance between groove and retainer Valve stem end length i Total length stem Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust / j 8 I

5.50 -0.020 -0.032 -0.056 5.5@ -0.074 0.02 - 0.05 0.056 - 0.092

5.440

5.409 0.2 0.2 0.05 - 0.25, 0.05 - 0.25 I i 0.5 0.5 ! 2.5 2.5 I 20.3 ) 1

Micrometer Cylinder Cylinder i Searcher 1 Searcher , Slide calipers 1 Slide calpers Slide caltpers Sltde calipers Slide calipers gauge gauge

Replacement Replacement Replacement Replacement Replacement I Replacement Replacement Replacement Replacement Replacement

Intake exhaust and valve

At valve guide center

0.08 -0.12 0.08 -0.12 0.1 -0.3 0.1 -0.3 3.5 3.5 20.8 +i. 0.01 -0.03 BMR-4A (NGKI

Tappet
Clearance between 1 and guide

Spark Plug Fuel consumption (l/hr)

I~-

Type Electrode [ gap

I 1.0
I

I Replacement

0.6 -0.7 0.5 I 0.6

Searcher I
I

50 Hz rating 60 Hz rating
~~

Lubricating Oil consumption (cc!hr) Quantity

1 50 Hz rating 60 Hz rating of lubricating oil cc

4 5 350 I AutomotIve

20 20

: 1 I I

engine oil of class over SC I I Pressure guage

Lubricating Compression

oil replacement pressure

Interval

Inittal: 20 hours after start Regular: Every 100 hours 41800 I I I

I I 1

(kg/cm2/rpm)

-69-

Items of adjustment (Tightening torque) 1 Connecting rod bolts cover bolts

Criteria 60 -80 80-100 go-110 120 -150 kg-cm

Limit of application

Description

Tools

I
[

Main bearing Cylinder Spark

head bolts plug nuts lever nuts bolts

I I I I

1
I I

I I I
I

Air cleaner Governor

50 -60 70 -90 80-100 100-150

Front Rotor

housing bolts nuts

I
I

1 Muffler Front

cover bolts

55 -75

- 70 -

15. WIRING

DIAGRAM

RECTIFIER MAIN FIELD COIL COIL ril r -----

CIRCUIT +-----

BREAKER AC RECEPTACLE

_----

CONDENSER COIL

It-J /
CONDENSER IGNITION COIL r+ 4 _______ ------~ [DARK BLE, 4 (DARK L--------------A BLUE1 FM

FREQUENCY METER

SPARK

PLUG

IGNITION

UNIT

&

GT

AC lead wire color code

p<
I
=.I 1lOV 50 Hz Blue 22OV.50 Hz 220V 60 Hz 230V 50 Hz 240V 50 Hz Gray Pink

White, green White, red __i

1
I I I

I I

-71

16. MAINTENANCE
The following standard maintenarxe procedurss are necessary to ensure th 2 generators normal performance under normal operating conditions. Therefore. the mstructions described below are for ref2rence only and varl- depending on how th2 generator is operated. For instance. if the gsnsrator is operated in a dusty ar2a the air cleaner must be cleaned daily- ah~h diffsrs from the interval specified below.
16-l DAILY CHECKS and MAINTENANCE (every 8 hours)

Check and maintenance

items

(I) Clean each component of dust

I I I

Description

(1) If th2 joint of the governor is left in a dust! condition. the governor ma>-fail to function normally. (2) Ii fuel leakage is not corrected. fuel economy will be reduced and there is a potential of fire.

(2) Check the fuel piping system and related parts for leakage. Should leakage be detected. tighten or replace the defective part. (3) Check each part for looseness. Tighten if necessary. (3) Check the quantity of oil inside the crankcase: fill oil as necessary-. (5) Check equipments of control panel. when found damages. replace them.

(3) If the parts are 10052.vibrations will occur. and ma) subject the generator to troublz. (4) If the engine is run with an insufficient quantity of oil. th2 piston and other moving parts will be damaged. (5) Cant obtain any output which is needed. I

16-2

CHECKS

and MAINTENANCE

for EVERY

20 HOURS

Check and maintenance

items

Description

( 1) Drain the oil from the crankcase.

( 1) Replace \vith n2w oil. The oil used a&r the initial period of operation is likely to be heavily contaminated with fine metal powder and other foreign substances from various engine parts. I
for EVERY 50 HOURS (every 10 days)

16-3

CHECKS

and MAINTENANCE

Check and maintenance

items

Description

(I ) Clean the air <Isaner at the prrscribed intsnal.

i (1) If th2 air cleaner is continually used in contaminated condition. it may lead to engine trouble. (2) Should the plug be left m contaminated condition. an sngine output will decline or it ma! fail

(2) Check the spark plug for carbon sontammation. If found dirt!. clean rt with gasoline. followed b>- sandpaper.

- 72 -

16-4

CHECKS

and MAINTENANCE

for EVERY

200 HOURS

(monthly)

Check and maintenance

items

Description

(1 j Drain the oil from the crankcase and replace with new oil. (every 100 hours) (2) Clean the fuel strainer and the fuel tank interior.

(1) The us2 of contaminated oil will subject parts to excessive wear. I (2) If the contaminated fuel strainer and fuel tank are used continually. engine performance will be lessened and may led to engine trouble. I
(semi-annually)

16-5

CHECKS

and MAINTENANCE

for EVERY

566 HOURS

Check and maintenance

items

Description

(1) Remove the cylinder head, and remove carbon deposits. (2) Disassembly and cleaning of engine carburetor.

(1) If the engine is run with the cylinder head contaminated with carbon. it may led to engine trouble. (2) If the engine is run with the cylinder head contaminated with carbon. it may led to to engine trouble. , (3) If the engine is run with the cylinder head contaminated with carbon. it may led to engine trouble.

(3) Check the switch of engine and tlexible shaft.

16-6

CHECKS

and MAINTENANCE

for EVERY

1660 HOURS

(annually)

Check and maintenance

items

Description

(1) Overhaul the engine for cleaning. adjustment and parts replacement. (2) Replace the piston rings.

(1) If the engine is used continually without an annual overhaul. it may led to engine trouble. I (2) If the engine is used continually without an annual overhaul. it may led to engine trouble. , j (3) An old fuel pipe is likely to leak. I (4) Cant obtain any output which is needed.

(3) Replace the fuel pipe. (4) Check all the relative parts of the generator.

16-7

WHEN

THE

GENERATOR

IS NOT

USED for PROLONGED

PERIODS:

Ij

Be sure to check the generator daily as instructed in 16-1 aboLe and it is required that the generator receive the 20hour check and maintenance detailed in 16-Z. Drain the fuel from the tank and from the tloat chamber the carburetor.

~j

of

3j 4)

To prevent the cylinder wall from rusting. remove the spark plug and lubricate the interior at the cylinder. Then. pull the recoil starter knob two or three times. and replace the spark plug. Keep the piston stationary at the position where the piston stroke f22ls the heaviest. tor in a dry- place where it Lvill not be subject to high humidity. - 73 -

5) Clean the engine exterior. using an oil impregnated cloth. and then place a vinyl cover or other cloth over the genera-

R&&I

Generator

R -America,
e-mail: sales @robinamerica.com
q

Inc.
wwwrobinamerica. com
PRINTED IN THE USA

940 lively Q Wood Blvd. Dale, 1160191Phone: q 630-350-8200 630-350-8212 q Fax