Subaru Robin Power Products R1200 Users Manual GENERATOR SERVICE

R1200 to the manual dfaec164-1124-454a-9f47-a9fb229404b5

2015-02-02

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Generator

TechnicalData& OverhaulInstructions

SERVICE MANUAL

FOREWORD

This manual was compiled for dealers’ mechanics and includes descriptions on
specifications, items, performance, structure, features, and maintenance procedures
of the R1200 Generator.
We ask each dealer to master the contents of this manual and provide users complete
service after sales or proper guidance on how to use this generator.
This manual includes only brief descriptions on important points, so we ask you to
supplement this with your own experience and determination in practical guidance for
your customers. We are also going to have seminars or other events to exchange
necessary information to improve our service to customers.

CONTENTS

Section
1.

Title

SPECIFICATIONS
1-1
1-2

FEATURES

COMPONENT

FUNCTION

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

IDENTlFlCATlON
OF EACH

COMPONENT

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

6
7
7
9

Electronic ignition Mechanism ......................................
Description of Generating Operation
..................................

11
12

OF MAIN

LIMITS

OPERATIONS

OF THE GENERATOR

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

AC Output
...................................................
DC Output
...................................................
Simultaneous Use of AC/DC Output
..................................
Wire Length ...................................................
PROCEDURES

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

Meters ......................................................
Measurement of AC Output ........................................
Measurement of DC Output ........................................
Measurement of Insulation Resistance .................................

FUNCTIONAL
8-1
8-2
8-3
8-4
8-5
8-6
8-7
8-8

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

MEASURING
7-1
7-2
7-3
7-4

1
2

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

OPERATIONAL
6-1
6-2
63
6-4

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

DESCRIPTION
5-1
5-2

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

items .......................................................
Performance Curves .............................................

4-1
4-2

Page

CHECK

OF EACH

COMPONENT.

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

Control Panel. .................................................
Diode Stack (Rectifier)
...........................................
AVR .......................................................
Stator .......................................................
Rotor .......................................................
Brush .......................................................
Ignition Coil ..................................................
Exciting Coil ..................................................

14
14
16
16
17
18
18
20
20
20
22
22
23
24
25
26
26
27
27

Title

Section
9.

DISASSEMBLY
9-1
9-2
9-3
9-4
9-5

10.

PRECAUTIONS.

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

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

Fire Prevention
...............................................
Precautions for Exhaust Gases. ......................................
Other Precautions ...............................................

11.

TROUBLESHOOTING

12.

CRITERIA

13.

WIRING

14.

MAINTENANCE
14-1
14-2
14-3
14-4
14-5
14-6
14-7

ASSEMBLY

Preparation and Remarks ..........................................
Special Tools for Disassembly/Assembly
................................
Disassembly Sequence ............................................
Assembly Procedure .............................................
Carburetor
...................................................

SAFETY
10-1
10-2
10-3

AND

Page

TABLE

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

DIAGRAM

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

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

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

Daily Checks and Maintenance (Every 8 Hours) ...........................
Checks and Maintenance for Every 20 Hours .............................
Checks and Maintenance for Every 50 Hours (Every 10 Days) ..................
Checks and Maintenance for Every 200 Hours (Every Month) ..................
Checks and Maintenance for Every 500 Hours (Semi-Annually)
.................
Checks and Maintenance for Every 1000 Hours (Annually) ....................
How to Store the Generator for Long Period ..............................

28
28
28
29
48
67
72
72
72
72
73
91
94
95
95
95
95
96
96
96
96

SPECIFICATIONS

l-l

ITEMS
I

Model
Engine:

Type
Displacement

143 cc (8.73 cu. in.)

Fuel tank capacity

3.5 lit. (0.93 U.S. gal.)

Oil pan capacity

Ignition system

Generator:

Forced air-cooled, 4-stroke, side valve, gasoline engine

R1200

600 cc (1.28 U.S pints)

Starting system

Rated continuous
operating hours

I
I
I

Solid state ignition
Recoil starter
I
Approx.

Exciting

Voltage regulating
system

Self-exciting

system

Maximum

output

I
AVR (Automatic
j
I

1000 w

Rated output

800W

AC Frequency

50 Hz
110,220,230,24OV

DC output

I
Dimensions

12V -8.3A
I

1200 w

I
I
1
I

1000 w
60 Hz
110,120,220v

(1OOW)

S.T.D type, nema, germany: 2 ea.
France, Australia, England, Switzerland:

DC receptable

One

Over current
protection

Voltmeter

Standard equipment

4B6x2BBx410mm
(19.1 x 11.3 x 16.1 in.)

AC receptacle

Circuit breaker

(L x W x H):
I

Dry weight

Voltage Regulator)

AC Voltage

3.5 hours

2-pole, revolving field type

Type

Approx.

4 hours

27.5 kg (60.6 Ibs)

-l-

1 ea.

1-2 PERFORMANCE

CURVES

AC OUTPUT
Power Factor . . . . . .. . . . . . . . . 1.0

1
‘;;
I
-I0’
s
z
E
IA
z
&
2 t

z
>

’ ’ I
1 1 1 1 1! output i

Output Max. ............... 1000 w
Rated ........... 800 W
Frequency ..................
50 Hz
Voltage .....................
220 v

1000
50
800

600

z
s
P

230

400

220
210

200

240

n
”

Current (A)-

52
51

Output Max. ................ 1000 W
Rated ........... 800 W
50 Hz
Frequency ..................
230 V
Voltage .....................

1000

50
800

600

si
w
2

240

400

230
220

200

250

I I I I I I I I I I I I0
1

Current (A) -

Ti
I-t

z
iiL
;I
LL

52
51

1000

49
50

800
600

z
8
8 I
z>

260
250

400

240
230

200

Output Max. ............... 1000 w
Rated ........... 800 W
50 Hz
Frequency ..................
240
V
.....................
Voltage
I
s
‘;
P
s
0

Current (A) -2-

;;;
I
0”
-IE
?T
L

52
51

Output Max. ............... 1000 W
Rated ........... 800 W
Frequency ..................
50 Hz
Voltage .....................
110 v

1000

50
49
49

800
600

120
120-llOr
110

400

100

t
z
s
0.
B
3
3

200

Current (A)-

1000

60
61

800

59
600
120

400

Output Max. ............... 1200 w
Rated ........... 1000 W
Frequency ..................
60 Hz
110 v
Voltage .....................
f
z
s
Q
5
0

110
100

200

Current (A)-

Output Max. ............... 1200 w
Rated ........... 1000 W
Frequency ..................
60 Hz
Voltage .....................
220 v

Ti
I
0”
-tE
z
e
l.L

62
61

1000

800

59
z
8 t
2
%

600

240
230
220
210

400

f
z
w
2
5
0

200
01

Current(A)-

-3-

G
I
0”
-1
f
ltE
z
28I
s

........... 1200 w
Output Max.
...... 1000 W
Rated
.............
60 Hz
Frequency
12ov
...............
Voltage

1000

61
800

60
59

600
400

130
120
110

t
z
s
P
s
0

200

Current (A) -

DC Output
DC output from this generator is rated especially for charging batteries. When the rated
current (8.3A) flows into a battery the voltage is 12V, but the voltage becomes higher when
the load is smaller (or when the current is smaller than the rated one), and lower when the
load is bigger (or when the current is bigger than the rated one). Note that the voltage
under no load is approximately from 18V up to 25V.

-4-

FEATURES

(1)

Weight of this compact generator with excellent portability is 27.5 kg, which means that
the generator is the lightest one in this class.

(2)

This generator with an excellent high performance engine and a large size 3.51i fuel tank
can run continuously for about 4 hours (at the rated load of 50 Hz).

(3)

The operating system is concentrated on the front panel, which enables users to easily
handle this generator.

(4)

Operations of choking, running, and stopping the engine can easily be executed with a
notch.

(5)

As a circuit breaker based on the push button system is employed in this generator,
replacement of a fuse is unnecessary. Troubles which happen in an overload or failure of
devices used can easily be resolved.

(6)

Direct current for charging batteries can also be taken out.

(7)

Simultaneous use of DC is possible even when AC is used. However, total AC output and
DC output should be within the range of the rated output.

(8)

Voltage fluctuation ratio is below 5% because of employment of AVR (Automatic Voltage
Regulator). Accordingly, the stable voltage is always maintained even if the load
fluctuates.

(9)

Generally maintenance-free or maintenance is easy because the engine, with a transistor
ignition system, has an excellent startability and no point is employed in this generator.

(10)

An ignition plug with a resistor and a plug cap have been employed to prevent electric
wave noises.

-5-

COMPONENT

IDENTIFICATION
Engine Control Switch
(CHOKE-RUN-STOP)

DC Circuit
Breaker
\

rter
Recoil Starter
Ground Terminal
Air Cleaner Cover

Muffler /
ler /

crew
,,.,.,rnal)

Fig. 3-1
, Carrying Handle
Spark Plug Cover,
Tank Cap

Fuel Tank

Fig 3-2
-6-

4.
4-l

FUNCTION

OF EACH COMPONENT

GENERATOR

4-l-l
STATOR
The stator consists of a laminated silicon steel
sheet core, and a copper coil wound around the
core with a lead wire from which AC and DC
output are taken out. The copper wire coil
consists of a main coil and a DC coil, and AC
output is taken out from the main coil, while
DC output is taken out from the DC coil.

4-l-2
ROTOR
The rotor consists of a laminated silicon steel
sheet core, a field coil which is wound around
the core, and a cooling fan mounted on one
end of the shaft, with a slip ring on the
opposite end. One end of the lead wire from
the field coil is connected to the slip ring.
The field coil becomes an electromagnet when
DC current flows from the slip ring. The
cooling fan is for cooling the generator by
inducting cooling air from the slip ring side
and discharging it from the fan side.

Fan

F& 4-l-2

4-l-3 BRUSH
Exciting current from the AVR is supplied
through this bush to the rotor. The brush is
made of carbon, while the brush holder is
made of plastic. In order to run the generator
efficiently without failures, it is necessary to
maintain the contact voltage between the
brush and the slip ring within a range, which
needs management of the brush length.

Fig. 4-l-3

-7-

4-l-4 AVR (Automatic Voltage Regulator)
This is a device to automatically regulate
voltage with an electronic circuit.

Fig. 4-14

4-l-5
CONTROL PANEL
The control panel has a double receptacle with
a ground terminal, and AC output is taken out
with a male plug.
DC current is taken out from the DC receptacle with a special plug.
The voltmeter displays output voltage from
the generator. The circuit breaker for AC and
DC in the upper section of the control panel
prevents too big an output current from being
taken out, or excess current in short circuit.
F& 4-l-5

-8-

4-2 ENGINE

4-2-l
CYLINDER AND CRANKCASE
The cylinder and the crankcase of the engine are of a one-piece aluminum die-cast design. The
specific iron cylinder is cast-fitted inside the cylinder. Both the intake and exhaust ports are
positioned at the lateral side of the cylinder. These ports are also cast by using a mould with
die-cast cores. The crankcase has its joint face located on the generator side, and it is of an
assembly structure.
4-2-2 MAIN BEARING COVER
The main bearing cover is alminum die-cast and is mounted on the generator side. By removing
it, the interior of the engine can be inspected.
4-2-3 CRANKSHAFT
The crankshaft is constructed of forged carbon steel, and the crankpin is induction-hardened. A
crank gear is pressure-fitted on the generator side of the engine.
CONNECTING ROD AND PISTON
The connecting rod is made of forged aluminum alloy with both the major and minor ends utilized
as bearings. An oil scraper is cast on the major end. The aluminum alloy casting piston has slots
on which two compression rings and one oil ring can be assembled.
4-2-4

4-2-5 CAMSHAFT
The camshaft is made of special cast iron and has intake and exhaust valve drive cams, each of
which engages with the camgear. An exclusive aluminum alloy is used on each end of the
camshaft in the place of bearings. (Ball bearings are not used.)
4-Z-6 VALVE ARRANGEMENT
The intake valve is arranged in the generator side, while the exhaust valve is arranged in the
recoil side.
4-2-7 CYLINDER HEAD
The cylinder head is die-cast aluminum and has a Ricardo type combustion chamber featuring
greater volume capacity for improved combustion efficiency. For easier ignition plug maintenance the cylinder head is positioned vertically.
4-2-8 GOVERNOR
The centrifugal weight governor ensures constant engine speed, regardless of load fluctuations
(the governor is mechanically linked to the governor drive gear).
4-2-9 COOLING SYSTEM
The cooling system with a cooling fan, which also functions as a flywheel, compulsorily sends
cooling air to the cylinder and the cylinder head and cools them. This forced air cooling system
has a baffle plate and a head cover.
LUBRICATION SYSTEM
The moving and sliding parts inside the engine are lubricated with the oil scraper fitted on the
connecting rod by scraping and splashing oil in the crankcase.
4-Z-10

-9-

4-2-l 1 IGNITION SYSTEM
The ignition system is based on a flywheel/magneto system and its ignition timing is set at 230C
before top dead center. The magneto consists of a flywheel and an ignition coil. The flywheel
(functioning also as a fan) is mounted on the crankshaft, while the ignition coil is mounted on the
crankcase.
4-2-12 CARBURETOR
The horizontal suction type carburetor employed here can provide excellent starting, good
acceleration, low fuel consumption, and superior output. The carburetor setting is matched to
the generator set. (On details concerning the carburetor construction and others, see the
paragraph dealing with carburetor construction and disassembly/assembly.)
4-2-13 AIR CLEANER
The air cleaner is a semi-wet type and contains a sponge element.

-10-

5.
5-l

DESCRIPTION
ELECTRONIC

OF MAIN OPERATIONS

IGNITION

MECHANISM

The engine has a current chopping contact point-free ignition system in which a power transistor
is used as a current control element. This system is called T.I.C. (Transistor Ignitor Circuit).
This electronic ignition system is completely free from ignition failure which generally results
from contamination or burning of the contact points, oxydation during storage for a long time, or
abrasion of mechanical sections, all of which are typical with contact type ignition systems. The
maintenance-free ignition system can maintain proper discharging and is not affected by
moisture, oil, dust, or other contaminants.
The T.1.C system consists of a transistor-incorporated ignition coil and a flywheel with a
permanent magnet mounted on. The basic principle is shown below.

I
*go
E
LT
$1

E @
.$
‘1
r

b
.-z
P
f

Q
f
.-z Ll
E

\s>l

Ignition Coil

‘CC
,”

=
8

?“f

=
8

I 5

;

ki
rn

2
I%
5

o$j
&F
iTI-

~~~
F&. 5-7

(1)

When the flywheel starts rotating, power is generated in the primary coil of the ignition
coil and current flows to the resistor @. With this current? the power transistor turns on
releasing current B . This stage corresponds to the closing of the contact points.

(2)

As rotation of the cooling fan reaches the ignition point, the ignition timing detecting
circuit is activated, releasing the current 0. The signal transmitter transistor actuates to
release the current @. When the current @ starts flowing, current @, flowing through
the power transistor, is cut immediately. As a result, high voltage is generated in the
secondary coil by current fluctuation. This voltage is simultaneously applied to the spark
plug which ignites the ignition. This stage corresponds to the opening of the contact
points.

-11-

5-2

DESCRIPTION

OF GENERATING

OPERATION

I------- =
8
P
‘3
‘6
x
L ---w_J

,
I
I
I

Magneto
F@. 5-2- I

5-2-l
GENERATION OF NON-LOAD VOLTAGE
When the generator starts turning, the permanent magneto incorporated in the flywheel in the
engine side starts rotating, which generates voltage in the exciting coil. The voltage, rectified
by the diodes in the AVR, causes the flow of the current @through the field coil wound around
the rotor in the generator. The rotor is then turned to an electromagnet by the current and at
the same time when it starts rotating, voltage is generated in the coils (main coil, sub-coil, and
DC coil) of the stator. -Then, the voltage generated in the sub-coil is rectified by the AVR, and
the current @ flows so that current in the field coil is increased. This increases magnetic
intensity to the rotor. Rated voltage is generated in the main coil and the DC coil by repeating
this operation.
5-2-2 VOLTAGE REGULATION UNDER LOAD
When a load is connected to an AC receptacle
and current is increased, output voltage fluctuates and the voltage fluctuations in the case
where an AVR is in the circuit and in the case
where no AVR is in the circuit differ as shown
in Fig. 5-2-2. The AVR operates as follows.
When AC output is taken out, load is put on
the engine. The AC voltage becomes lower
because rpm of the engine becomes fewer and
the voltage decreases on account of inner
resistance of the coil. The AVR detects the
voltage decrease and automatically increases
the current flowing through the field coil with
a thyrister inside the AVR. As a result,
magnetic intensity to the rotor is increased
while the decreased voltage is raised again by
taking out loaded current, which in turn maintains the output voltage at a constant level.
When the AC output becomes lower the thyrister provides reverse operation, and in this
case, the voltage is also maintained at a
constant level.
-12-

Rated Level

Current (A)
F& 5-2-2

j-2-3 DC OUTPUT
DC output is taken out from a part of the
main coil and is fed to the diode stack (rectifier) where the output undergoes full-wave
rectification and is then supplied to the load.
The diode works to allow the current to flow
in the direction @, but does not allow the
current to flow in the direction @I, as shown
in Fig. 5-2-3.

Fig. 5-2-4 shows the DC output circuit of the
generator. DC voltage is generated in the
main coil. When the voltage in A is higher
than that in B, the current @ flows in the
direction shown in the figure, while no current
flows between CF and DE because the current
is cut off by the diodes G4 and G2. On the
contrary, when the voltage in B is higher than
that in A, the current @I flows in the direction
as shown in the figure.
No current flows
between CD and EF because the current is cut
off by the diodes G1 and G3.

As a result, the voltage generated at the
output terminal has a waveform with two
peaks in one cycle, as in the case of the output
waveform shown in Fig. 5-2-5.

Fig 5-23

=
8

Fis. 5-24

Output Waveform
Current @

Curr&t

F&. 5-2-5

- 13 -

OPERATIONAL

LIMITS

OF THE GENERATOR

6-1 AC OUTPUT

Electric appliances normally have rating levels showing the rated voltage, frequency, power
consumption (input power), and other things. The power consumption specified on such a label is
required to drive the appliance. However, when an appliance is connected to the generator, the
power factor and starting current should also be taken into account.
6-l-l
NET RESISTANCE LOAD
Incandescent lamps, electric heaters etc. can be run on the generator having a capacity
equivalent to the total of the respective appliances. Each of these appliances normally has a
power factor of 1.0.
Example:

The generator having a rated voltage output of 1000 W can provide enough power to
operate up to ten 100 W lamps.

6-l-2 ELECTRIC APPLIANCES WITH A POWER FACTOR OF LESS THAN 1.0
Fluorescent lamps and mercury lamps normally have a low power factor, and accordingly, the
generator is required to generate approximately 1.2 to 2 times the power consumed by each
loaded appliance.
Example:

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

6-l-3
MOTOR LOAD
Generally, motors require a large starting current every time they are started or begin rotating.
The motor starting load supplied from the generator becomes the largest when starting a normal
operation mode. The rates of power supply, which the generator is required to produce for motor
loads, are categorized into two cases, depending on the types of the motor used and load
condition at the time of starting.
(1) Motors (mainly rectifier motors) used for electric drills and similar devices:
Normally, the motors used for electric drills and similar appliances require the generator to
produce approximately 1.2 to 3 times the power consumed at the time of starting.
Example:

To drive a 300 W electric drill, a generator with a maximum output of about 400 W to
900 W or more is necessary.

(2) Motors (mainly induction motors) used for pumps and compressors:
As pumps and compressors have loads even when they are started, the generator is required to
produce 3 to 5 times the power consumed during normal running.
Example:

To drive a 200 W submersible pump, a generator with a maximum output of 600 W to
1000 W or more is necessary.

6-l-4

IN THE CASE WHERE POWER CONSUMPTION IS NOT DISPLAYED ON
THE RATING PANEL
Sometimes, the rating panel of an electric appliance does not carry its power consumption, but
only shows the mechanical equivalent to the power consumption. In this case, it is necessary to

-14

calculate the power consumption of the device involved. The calculated power consumption is
adjusted depending on the type of the load, and according to paragraphs from (1) to (3).
(Power consumption) = (Mechanical equivalent of a device) + (Efficiency)
Efficiency
Motors: 0.6 2. 0.8
Fluorescent lamps: 0.7 x0.8
Example:

As for a 40 W fluorescent lamp with a lighting output of 40 W, and assuming that the
power consumption of this lamp is 0.7, the power consumption can be calculated as
follows:
40 + 0.7 = 57 W
Furthermore, as per paragraph (2), the power consumption is multiplied by a factor of
1.2 to 2, producing a power consumption of 70 to 115 W. Therefore, with a generator
having a rated output of 1000 W, 8 to 14 lamps can be used.

Example:

In the case of a 200 W motor, the mechanical equivalent of the motor is 200 W.
Assuming that the efficiency of the motor is 0.7, the power consumption is calculated
as 200 I 0.7 = 285 W. Similar to the above, the calculated power consumption is then
multiplied as per (3)a, or (3)-a, taking into account the type of the motor used and
the starting condition. The table below shows the range of loads applicable to the
generator with 1000 W rated output.
Range of applicable

load

Electric appliance
60 Hz

50 Hz

Incandescent lamp, electric heater, etc.

Up to 800 W

Upto

1ooow

Fluorescent lamp, mercury lamp, etc.

Up to approx. 500 W

Up to approx.

Motordriven

Up to approx.

500 W

Up to approx. 600 W

Up to approx. 250 W

Up to approx. 300 W

tools etc.

Pump and compressor drive motors

650 W

Note 1: With motor-driven tools specified in paragraphs (3) and (4), the generator of the
said capacities are required only when starting the motors for the respective
appliance. Once the motor has started, power necessary for normal running is
only 1.2 to 2 times larger than the rated power, and the surplus capacity of the
generator may be used for other electric appliances.
Note 2: As for the tools using the motors specified in paragraphs (3) and (4), the power
requirement for starting the tools varies according to the types of motor and the
load conditions at the time of starting.

-15-

6-2 DC OUTitJT

When the generator is employed to recharge batteries, attentions should be paid to the specific
gravity of electrolyte in each battery.
6-2-l
MEASUREMENT OF ELECTROLYTE’S SPECIFIC GRAVITY
The specific gravity of an electrolyte varies according to temperature; so it is converted to one
in case of 200C.
s20 = St + 0.0007 (t - 20)
where
S20: The specific gravity at 200C
St : Measured value
t : Temperature at the time of measurement (Electrolyte)
6-2-2

REMAINING CAPACITY ESTIMATED WITH REFERENCE TO THE SPECIFIC
GRAVITY
Specific gravity
(20°C)

Remaining capacity
(%I

I .260

100

I .240

1.220

I .200

1.180

Remarks

Charging is not necessary.

1.160
I .I40

Charging is necessary.

Immediate charging is necessary.
37
25

6-2-3 BATTERY CAPACITY
The battery capacity is expressed in the unit of AH (amperehour).
capacity capable of one ampere current for one hour.
6-3 SIMULTANEOUS

One AH stands for the

USE OF AC/DC OUTPUT

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

below 700 W
below 900 W

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

-16-

WIRE LENGTH

When long wires are used, resistance in each wire increases while voltage drop occurs.
Consequently, the input voltage to an electric appliance declines, often damaging the appliance.
The table below shows that the voltage decreases in 100 m wire with different cross sectional
areas and varied resistances.
No. of

Cross
sectional
araa

Alloweble
current

conductor
diameter

mm2

COIldUCtO~/

No./mm

i
!

Current

Rasistanca

a/lOOm

3010.18

’

2.477

2.5V

1.25

I
*
I
I
:

5010.18

!
I

1.466

1.w

2.0

37/0.26

0.952

,3v

3.5

4510.32

0.517

5.5

7010.32

0.332

0.75

,
’

-17-

j’

1.5V

i
I
I
1

12.5V

-/-

7.5V

10A

12A
_

1 15A
]
.

12v

15v

18V

1ov

12v

15v

2.5V

’

3.5v

7.5v

b
d
0
z
5
>

MEASURING

PROCEDURES

7-1 METERS

7-l-l
VOLTMETERS
Both AC and DC voltmeters are necessary.
Measurable range of the AC voltmeter is as
follows.
0 to 15OV: For a voltmeter with an
output voltage of 110 or 120V
0 to 300V: For a voltmeter with an
output of 220, 230, or 240V
Measurable range for the DC voltmeter is
from 0 to 20V.

For AC

For DC

Fig. 7-l- 1

7-l-2 AMMETER
Both AC and DC ammeters are necessary.
The AC ammeter must have a scale range
from 0 to approximately 15A, and the DC
ammeter also must have a scale range from 0
to approximately 15A.

For AC

For DC

FI& 7-l-2

7-l-3 FREQUENCY METER
The frequency meter must have a scale range
from 45 to approximately 65 Hz.
Note:

Note the input voltage range for the
frequency meter.

’

;i ,71;
.: [m
mI-

Fig. 7- l-3
-18-

7-l-4
CIRCUIT TESTER
The circuit tester is used for measuring resistance and others.

Fig. 7-l-4

7-l-5 MEGGER TESTER
This unit measures insulation resistance of the
generator. Use one with voltage capacity of
5oov.

Fig. 7-l-5

7-l-6 TACHOMETER
Use the contact-less type tachometer.

Fig. 7-l-6

-19-

7-2 MEASUREMENT

OF AC OUTPUT

+ii+~~
To an AC Receptacle

Fig. 7-2

Measurement is executed with the circuit as shown in Fig. 7-2. An electric heater or an
incandescent lamp with a power factor of 1.0 is suitable as a load for the generator. When the
AC output measured at the rated load and rated speed is confirmed to be within the voltage
range specified in the table below, the AC output is normal.
1
I
240V
120v I 220v
230V
Rated voltage 1 1OOV 1 1lOV
Voltage range i 98~105V 108~115V~118~125V~218~~225V 228~235V 238~245V
73

MEASUREMENT

OF DC OUTPUT

To a DC Receptacle

Fig. 73

Measurement of DC output is executed with the switch turned ON while the current is regulated
at 8.3A by adjusting the load to the generator. If the voltage is within the range from 1OV to
14V, the voltage output is normal.
Note: If a battery is connected as a load to the generator, the DC output voltage will increase
by approximately 1 to 2V. Therefore, carefully observe the electrolyte level and don’t
overcharge the battery.
7-4 MEASUREMENT

OF INSULATION

RESISTANCE

7-4-l TO MEASURE INSULATION RESISTANCE, CONNECT THE MEGGER TESTER
ACROSS EITHER ONE OF THE TWO OUTPUT
TERMINALS OF THE AC RECEPTACLE AND
THE EARTH TERMINAL.
Measurement
should be executed after the AC circuit
breaker is turned ON. When the measured
insulation resistnace is over lMQ, it is normal
(or, over 1OMQ at the time of shipment).
When the measured insulation resistance is
below lMn, disassemble the generator and
measure the insulation resistances of the
stator, rotor, and control panel for each.
-20-

F&. 74-1

7-4-2 STATOR
Measure the resistance between the red or
white coupler leading from the stator and the
core.
If there is a section where insulation resistance is below 1MQ replace the part because it
may cause insulation failure or such accidents
as electric shock or leakage.

Fig. 74-2

7-4-3 ROTOR
Measure the insulation resistance between
either one of two slip rings of the rotor and
the core.
If there is a section where insulation resistance is below lMS2, replace the part because it
may cause insulation failure or such accidents
as electric shock or leakage.

Fig. 74-3

7-4-4 CONTROL PANEL
Measure the insulation resistance between the
charging section (a part where electric current
flows) and the grounded part.
If there is a section where insulation resistance is below lMS2, replace the part because it
may cause insulation failure, or such accidents
as electric shock or leakage.

Fig. 744

-21-

FUNCTIONAL

8-1 CONTROL

CHECK OF EACH COMPONENT

PANEL

8-l-l
AC RECEPTACLES
Check continuity between the two terminals at the rear of the AC receptacles by using a circuit
tester under the condition that the receptacle is mounted on the control panel. When continuity
between the output terminals is confirmed with a wire connected across the terminals, and is not
confirmed if the wire is removed, the AC receptacle is normal.

Fig. 8-l-l

(a)

Fig. 8- I- 1 (b)

8-l-2 DC RECEPTACLE
Check continuity between the DC terminals at
the rear of the receptacle by using a circuit
tester, under the condition that the receptacle
is mounted on the control panel.
When continuity between the DC terminals of
the receptacle is confirmed with a wire connected across the terminals, and is not confirmed if the wire is removed, the DC receptacle is normal.
Fig. 8-l-2

8-l-3

CIRCUIT BREAKER

Check continuity between the two terminals
at the rear side of the circuit breaker by using
a circuit tester under the condition that the
circuit breaker is mounted on the control
panel.
If continuity is confirmed when the breaker is
ON, and no continuity is confirmed when the
breaker is OFF, the circuit breaker is normal.
F&J. 8-7-3

-22-

8-l-4 VOLTMETER
When AC voltage (1OOV)is loaded between the
two terminals on the rear side of the voltmeter, and at the same time, the voltmeter
shows the value, the voltmeter is normal.

Fig. 8-l-4

8-2 DIODE STACK (RECTIFIER)

(Orange)

(Yellow)

Fig 8-2-l

0
-

(White)

(Brown)

Fig. 8-2-2

Fis. 8-2-3

Circuit inside the diode stack is as shown in Fig. 8-2-l. Confirm continuity between each
terminal by using a circuit tester as shown in Fig. 8-2-3. The rectifier is normal when continuity
is confirmed as follows.

Connect black

terminal of the circuit tester

Yellow

;

White

Orange
No continuity

Brown
; Continuity

Connect red 0 terminal
of the circuit tester
I

Table 8-2- 1

Note 1: In checking the diode, direction of connection is contrary to the ordinary case because
of characteristics of the diode and battery incorporated in the tester.
Note 2: “Continuity” means forward direction characteristics of the diode, and, different from
short circuit condition (in which a pointer of the tester goes out of its normal scale),
shows resistance to some extent. When results of the checking indicates failure even in
one section, replace with Assy.

- 23 -

AVR

Whether the AVR is defective or normal can be determined by checking the appearance, by
measuring the resistance between the lead lines with a circuit tester, or by practically loading it
onto the generator.
8-3-l

THE CASE WHERE DETERMINATION ACCORDING TO THE APPEARANCE
IS POSSIBLE:
If some electronic part of the AVR is burnt, has become black, or if epoxy resin on the surface
has melted down, it can often be said that the AVR is defective.
8-3-2

THE CASE WHERE DETERMINATION BY MEASURING THE RESISTANCE
BETWEEN THE LEAD LINE AND THE COUPLER IS POSSIBLE:
Measure the resistance between the coupler
terminal and the lead line of the AVR. In the
normal case, the measured values should be as
shown below.

Fig. 83
Connect to the 8 terminal of the circuit tester
Yellow

Wire color
1
Yellow

5.E
E
.;s x

Red

White

1 600K-1MR

1 400K-500KR

@W
W-

250K-300Kn

75K-120KS2

Green
/ ;ft;;
I

zr;;;;ding

250K-300KR

120K-130KS1

j
7

;
I

7K-lOKS2

;
I
\

400K-5OOKS2
2OOK-220KR
45K-5OKR

OE
CL
t;s

500K-lMS2
\

Eg
6%

[Wiring in the 4P coupler]

Red @-Green @I

Black

@White
@I Black

75K-110KR

7K-9KQ

1 400K-500KS1
; 400K-5OOKfi

4
40K-46KQ

! 200K-250KS2

Note 1: Upper section of each column corresponds to
the case of 220, 230 or 240V specifications,
while the lower section corresponds to 100,
110 or 120V specifications.
Note 2: Sometimes the measured value does not
match the values in the table above because
errors of a circuit tester are big and influenced peripheral temperature.
- 24 -

STATOR

Confirm the resistance between the coupler
terminals with a circuit tester.

Circuit Tester
Red 3+-J

a-@

White

F&. 8-4

OB rown

Orange Q

@Black

Green @

Coil name

Measurement
location

’

Main coil

DC coil

Sub-coil

6P coupler

Diode
connector

6P coupler

White @ -

Wiring color

Red @

White - Yellow

50Hz - IOOV

0.951

0.32Q

60Hz - 1oov

0.6

0.23

50Hz - I IOV

60Hz - 1 IOV

1.2

0.44

0.9

0.32

White @ 4.452
3.6
I
I

4.4
3.6
4.4

3.6

0.9

0.32

50Hz - 220V

5.0

0.70

60HZ - 220V

3.5

0.42

3.6

50Hz - 230V

5.0

0.70

4.4

5.0

0.70

60Hz - 120v

50Hz - 240V

Note: Sometimes the measure values do not match the values shown in the
table above because of errors by the circuit tester, unevennessof coil
windings, or peripheral temperature.

- 25 -

4.4

Green @

8-5

ROTOR

8-5-l

MEASURE RESISTANCE IN THE
FIELD COIL OF THE ROTOR WITH
A CIRCUIT TESTER
Resistance
value
El 10.7J-z

Stlip

Note 1: Measure the coil resistance between
the two slip rings.
Note 2: Sometimes the measured values do
not match the values shown in the
table above because of errors by the
circuit tester, unevenness of the coil
windings, or peripheral temperatuer.

8-5-2 CLEANING OF SLIP RING
When the surface of the slip ring is smooth it
is normal. When it is dirty or abraded, it
should be repaired.
When the slip ring is dirty efficiency of the
generator may become lower and sufficient
voltage and output can not be obtained. In
this case, sand around the slip ring with fine
sandpaper.
Note:

F&T 8-S 1

Slip Ring

When sandpaper is used, be careful not
to damage the coils of the rotor.
Fig. 8-5-2

8-6 BRUSH

If the surface of the brush contacting the slip
ring is smooth, it is normal. If not, make it
smooth with sandpaper.
Unless the surface is smooth, an arc may be
generated between the brush and the slip ring,
which may damage the brush and the slip ring.
The brush length should be, as shown in Fig. 86, within the range from 1.5 mm to 5 mm. If
it is below 5 mm, it should be exchanged with
a proper one. When contact voltage between
the brush and the slip ring becomes lower,
efficiency of the generator also becomes
lower and sufficient voltage and output can
not be obtained.

- 26 -

5mm-5mm
Fig. 8-6

8-7

IGNITION

COIL

Measure resistance in the coil of the ignition coil unit with a circuit tester.
!

Resistance
13K!G?

i
Note:

8-8

Measurement location

(
I

Measure the resistance between the black cord and the high
tension cord.

The measured value does not always match the values shown in the table above
because of errors by the circuit tester, unevenness of coil winding, or peripheral
temperature.

EXCITING

COIL

Measure resistance of the exciting coil and voltage at the rated rpm with a circuit tester.
( Voltage (AC) : Measurement location
II at rated rpm 1
I
10 Q 3ov
; Between the terminals of the
i exciting coil
I
The measured value does not always match the values shown in the table above,
because of errors by the circuit tester, unevenness of coil winding, or peripheral
temperature.
Resistance value

Note:

- 27 -

9.
9-l

DISASSEMBLY
PREPARATION

AND ASSEMBLY

AND REMARKS

(1)

Be sure to remember the locations of individual parts when disassembling the generator so
that the generator can be reassembled correctly. Tie tags with the necessary information
written in to facilitate easier and smoother reassembly.

(2)

For more convenience, group the related parts and store them in the same box.

(3)

To prevent bolts and nuts from being misplaced or installed incorrectly,
temporarily at their original positions.

(4)

Handle the disassembled parts with care and clean them before reassembly using neutral
cleaning oil. (Be careful not to clean electric parts with neutral cleaning oil.)

(5)

Use proper tools for disassembly/assembly.

9-2 SPECIAL TOOLS

place them

FOR DISASSEMBLY/ASSEMBLY

Fig 9-2

No. i

Tool No.

Description

Tool name

2099500407 1 Flywheel puller (with bolts)
!

@ 1 2079500307 i

Valve spring retainer

2279500107 I
I

Valve guide puller

- 28 -

For pulling out the flywheel
For attaching valve spring,
retainer, retainer lock
For pulling out the valve
i guide
,

9-3

DISASSEMBLY

SEQUENCE

to
SequenceI, Part
remove

!
j

Description

1Side cover ! (1) First remove the side
!
cover by unscrewing
I
four M5 x 8 screws.
I
!

; Rear cover i (1)
!
!
I

Remove the rear cover by
unscrewing three MS x 8 ,
screws and two M 8 x 10
screws.
I

Rear Cover
M8x 10 Screw,

Side Cover /
Fig 9-3-l

- 29 -

Precautions

Necessary
tools

I 0 Plus screw
driver
I
I
, @ Plus driver
!I
I

’ Part to
Sequence ] remOve
I
3

icontrol
1panel
I
I

!
:
I
I(l)
I
I
II
I

I
I

Description
Pull the knob of the
control lever and remove
the control panel by unscrewing four M5 x 8
screws.

Precautions

Necessary
tools

;

1 @ Plus driver

!
I
I

I
II
I

Knob
L
Control

Lever by
,

Fig 9-3-2

- 30 -

Part to
Sequence11 remove
4

( Couplers
1and plugs
, (Disconj nection)
I

I
I

j
1

Precautions

Description

, Pull the couplers
i (1) Disconnect the (6P)
! while pushing the
generator coupler from
I retainer claws.
the other (6P) coupler
’
extending from the
1
!
control panel.
I
, I
/ (2) Disconnect the (4P) coupler I
of the AVR from the (4P) I
coupler extending from the ;
control panel.
(3) Remove the plug for
grounding.
i

I
I

I
I
i
,

I
I
!1
I

Fig. 9-3-3

Necessary
tools

Part to
Sequence I remove
j
5

Description

iFront cover (1) Remove the element
cover by unscrewing
(
the M6 x 12 screw.

Precautions

Necessary
tools

I
0

Driver

1
I

I(2) Remove the front cover
by unscrewing three
M5 x 8 screws.

1
!

@ Driver
I

M6x12 Screw ’

Front Cover

/
M5x8 Screw (3 PCS.)
FJ$. 9-3-5

-32-

1 Part to ’
Sequencej remOve
6

Fuel pipe
‘and plug
(Disconi nection)

Precautions

Description

(1) Remove the cap from the
fuel strainer and take out
the gasoline from inside
the fuel tank.
(2) With pliers, hold the fuel
pipe clamp which is inserted in the fuel strainer
and pull it forward to
remove the fuel pipe from
the strainer.
I(3) Disconnect the plug receptacle of the engine
from the plug of the AVR.

j
I

’

Pliers

Be careful not to
damage the fuel
pipe.
!
I
1
;
I

Pipe

Clamp

Strainer

FI& 93-6

-33-

Necessary
tools

Part to
Sequence, remove
I
I
7
Fuel tank
Ihandle

Description
(1) Remove the handle cover
by unscrewing the two
M3 x 10 screws.

The fuel tank can be , @ Driver
removed without
I
I disassembling the
handle.

(2) Pull out the breather pipe
for air ventilation.
:
I (3) Remove the handle body by
taking off the two M8 nuts. i
Fuel tank

Necessary
tools

Precautions

i (1) Remove the two M6 x 12
flange bolts clamping the
I
blower housing.
(2) Remove the fuel tank by
taking off the two M8 nuts
from the bottom of the
tank.
I

113m/m box
Lpanner
‘10 m/m box
spanner

13 m/m box
spanner

/
’
I

Handle Cover

M6xl2

Flange Bolt
\

M3xlO Screw (2 PCS.)
\

Tank

/
M8 nut (2 pcs
-7, )

@gfiJpcp

piy
\

Blower Housing

Fig. 9-3-7

Part to
Sequence remove
9

’

, Precautions

Description

Necessary
tools

13 m/m box
Remove the bracket cover i
spanner
i
from the generator by
taking out the two M8 x 30 ’
1
bolts.
End cover /(l) Remove the end cover from.
i @ Driver
the generator by unscrew- i
II
I
ing the four M5 x 10
screws.
IBrash holder((1) Remove the brash holder ‘If the rear bracket / @ Driver
fitted to the brash holder 1is removed from the :
I
!
base by unscrewing the two igenerator without
I
jremoving the brash i
M5 x 20 screws.
\
holder, the brash
I may break. Always
!
i remember to remove
I
1
/the brash holder.
1
’
)In assembling, be
(2) Remove the connector
i careful that the
I
1wiring is properly
I
connected.
!
j$Ez;

i(l)
1

M5x20 Screw (2 PCS.)
Rear Bracket
Brush Holder

Brush Holder Basedi>

Bracket (Cover)

I
M5xlO

Screw (4 PCS.)

Fig. 9-3-8
-35-

End Cover

j Part to 1
Sequence I remOve
12

Precautions

Description

i (2) Remove the rear bracket,
tapping it evenly with a
plastic hammer.
I
(See Fig. g-3-10)

Necessary
tools

1 10 m/m box
, spanner

j (1) Loosen and take out the
three M6 bracket bolts.

’ Rear
‘bracket
I

a
’
I

/ (3) Remove the connector of ’ Be careful to make
the d&e stack and then
irregular wiring in
,
assembling.
remove
the
lead
from
the
I
rear bracket clamp.
I
I

i Plastic hammer
I
I
I
j
(
I
1

Rear Bracket

/
Diode Stack
Plastic Hammer
Fig 9-3-9

-36-

SequenceI rpearfito~~i
13

1Stator
I
I
!

I
c

Precautions

Description

Necessary
tools

(1) Pull away the stator cover. i
(2) Pull away the stator from
the front cover. If it is
impossible, pull it away
tapping outside the core
with a plastic hammer.
(See Fig. 9-3-12.)

1Never pat the wind- ’ plastic hammer
/ ing and the lead.
I
1
!
;
I
I
I

Stator cover

Stator

Fig. 9-3-l 1

F&. 9-3-12

Part to
Sequence, remove
14

‘Rotor

’
I

Description

i (1) Insert a box spanner or a
socket wrench between the
through
bolt and the rotor
I
I
shaft, and hit it in a
clockwise direction with a
hammer to loosen the
through bolt, thus keeping
I
a2 3 mm clearance between them.
(See Fig. 9-3-14)
’ (2) Hit the through bolt head
with a plastic hammer to
I
loosen the crank shaft and
the rotor shaft taper.
!
I
Then remove the rotor.
I
(See Fig. 9-3-15)
I

Through

1Never insert a
/13 m/m box
driver or other tools spanner or socket
into the fan of the wrench
I
rotor.

I
1
,I
/ Never hit the slip
: Plastic hammer
ring and the winding I
’ sections. When hit- i
1ting the through
I
I bolt, hit it straight [
j so as not to bend the ’
; bolt.
I

Bolt

Fig. 9-3- 13

siw‘ ,,_,
iI

*2
L$zI=‘~

.;I
- ,ea
!jI-: ,~-’

~-~~~i

_
‘1
, il

L
,f!jF

F&. 9-3-15

Fi@. 9-3-14
-38-

Necessary
tools

Precautions

! Part to
Sequencej remove
15

j Front
i bracket
I
1
I

/
’

Description

(1) Remove the front bracket,
which is mounted on the
I
main bearing cover of the
engine, by taking out four
MS x 18 bolts.
I

Main Bearing Cover

Front Bracket

Fig. 9-3- 76

-39-

i
,
I
I
/

Precautions

Necessary
tools

13 m/m box
/ spanner
/

Part to i
Sequence! remOve ;I
16

Recoil
mstarter

j(l)
11

Description

Remove the recoil starter
by taking out the four
M6 x 8 flange bolts.

Precautions

RecoilvStarter

Fig. 9-3- 77

-40-

II
I

Necessary
tools

-10 m/m box
1spanner
I

j Part to
Sequence1 remove
17

Description
Precautions
j
I
I
Blower
i (1) Remove the blower housing The two flange
1housing
bolts, taken out
from the crank case by
taking out the two M6 x 12 1when the fuel tank
I
I
flange bolts.
i is removed, are not
/ included.
I
I
!Head cover I(l) Remove the head cover
‘& cylinder j
from the cylinder head and
baffle
/
the cylinder baffle from
the cylinder by taking out
the two M6 x 8 flange
,
bolts.
I

1
I

’ 10 m/m box
,spanner

I10 m/m box
spanner

Blower Housing

M6xB Flange Bolt (2 PCS.)
\

M6x12 Flange Bolt (2 PCS.)

M6x8-kange

Bolt (2 pcs.1

Fig 9-3-78

-41-

Necessary
tools

Description

Precautions

@ Driver

Air cleaner : (1) Remove the air cleaner
body, elements, and element retainer from the
cleaner body, by taking out I
one M6 x 10 flange bolt.

Necessary
tools

i (2) Remove the air cleaner
body from the carburetor
by taking out the two M6
x 10 flange bolt.

The air cleaner case !10 m/m box
and the carburetor /spanner
are clamped together.

(3) Remove the gas exhaust
pipe.

,
I

Pipe, Air Vent
Air Cleaner Body

M6 Flange Bolt
I
I
Air Cleaner Case

M6xlO Screw
/

I
Element Retainer

Element
/
Element Cover

Fig 93-79
-42-

1 Partto j
ISequence
- remove !
20

Description

Precautions

j (1) Remove the muffler cover ’
from the muffler by taking
!
out the three M6 x 8 flange
bolts.
I(1) Remove the muffler from
the cylinder section of
the crank case by taking
out the two M8 nuts and
Brace nuts
one M6 x 12 bolt.
I

i Muffler
Icover

Necessary
tools
:lO m/m box
i spanner

i
21

Muffler

112m/m box
’spanner
10 m/m box
jspanner

Muffler Cover

nge Bolt (3 PCS.)

M6x12 Bolt, Cross Recess

Sequence

I Part to

Necessary
Precautions
’
,
tools
’ Governor l-(1) Remove the governor lever j
from the governor shaft, by:
lever and
110m/m box
taking out one M6 x 25
!its related
I The bolt has only to Ispanner or
bolt.
iparts
i be loosened.
j10 m/m spanner
(2) Remove the governor and
I
the .rod spring
from the
.
carburetor
I
I
j

remOve

Governor

Description

Lever

Sequence11 Part to ’
Description
remove :
23
Carburetor (1) Remove the carburetor
from the cylinder section
of the crankcase.
24
Starting
(1) Remove the starting pully
from the flywheel, by takPUllY
j
ing out one M4 nut. Insert
a box spanner or socket
wrench into the nuts of the
flywheel and strongly hit
it with a hammer, thus removing the nuts and the
spring washer.
I
25
Flywheel
(1) Remove the flywheel from
the crankshaft .

Precautions

I
1

Necessary
tools

I
1

’
Never insert such
tools as driver into
the flywheel.

810m/m box
spanner or socket
/wrench.

Hit it in a counter! clockwise direction
with a hammer.

i Assemble the tool to Flywheel puller
pull out the flywheel
magneto as shown in
Fig. 9-3-23. To remove the flywheel
turn the central bolt
counterclockwise.
I
i (1) Remove the ignition plug
Washer built-in bolt 10 m/m box
cap
from
the
ignition
plug
:spanner
I
and the ignition coil from
I
the crank case by taking
out
two M6 x 25 bolts.
I
j (1) Remove the two M6x25
Washer built-in bolt / 10 m/m box
1spanner
bolts
from
Crankcase
I

i &cocci*n
.
I
I

’ Exciting
I1coil

Spark Plug Cap

Ignition
Crankcase

Coil 1

M6 x 25 Bc
,-I ---I

- A--

Flywheel
Flywheel

Carburetor
Fig. 9-3-22

Fig. 9-3-23
-44-

Puller

Sequence.

28
29

1 Part to 1
remOve

I Ignition
1plug
/ Cylinder
,head
I
1

Description

I (1) Remove the ignition plug
from the cylinder head.
j(1) Remove the cylinder head
from the crankcase by
taking out the eight M8 x
40 flange bolts.
I(2) Remove the cylinder head
gasket from the crankcase.
I
i (1) Remove the tappet cover
,
and the breather plate
,
from the crankcase by
taking taking out the two
!
M6 x 12 flange bolts.
! (2) Pull out the intake valve
and the exhaust valve.
I
, (3) Remove the valve spring
and the spring retainer.
I

Precautions

I
!

Necessary
tools
! 21 m/m box
i spanner
! 12 m/m box
i spanner
1
I
I

I
,
/ Intake/
I Be sure to position i 10 m/m box
1exhaust
/ the notch in the
:spanner
lvalve
1spring retainer’s
’
outside periphery to
I
[ the front and hook i
)
minussizej
driver
j’ the
(medium
in the ;
I
i
, recess (lower side) :
Front
i of the retainer.
!
Then pull the spring [ 0 Driver
I retainer frontward i
I
j to remove the valve. n
1
1Main bear- / (1) Remove the main bearing Washer built-in bolt. 10 m/m box
I ing cover !
cover locking bolts (eight
,spanner
I
1
M6 x 30 bolts) from the
I
I
crank case.
I
1
i (2) Remove the cover by tap- ! Be careful not to
ping it evenly with a
I damage the oil seal.
I
;
plastic hammer.

lntak Valve,

Exhaust Valve

, M8x40 Flange Bolt (8 PCS.)
/

Muffler

Flange Bolt (2 PCS.)
M6x30 Bolt (8 PCS.)

Fig. 9-3-24

Tappet Cover

Part to
SequenceI remove

i Camshaft

Tappet

Precautions

Description

I
Set the crankshaft !
i
; on its side SO that
j it will not fall and b
i damage the tappets.

(1) Pull the camshaft away
from the crankcase.

i (1) Remove the tappets from
the crankcase.

Intake Valve

; ~~~a~s~~a~~ E:dthe
I
tappets to distini guish them from one 1

Valve Spring,
i i
L

Camshaft

Governor Gear,

F&T. 9-3-25

-46-

Necessary
tools

r
Wuence

Part to

remOve

,
i Connecting i(l)
:rod and
:piston

(2)
!
1
!(3)
II
I
I

‘Piston bc (1)
!Piston ring :
(2)

Crankshaft (1)
:(2)

i Mount

;(l)

Necessary
tools

Precautions

Description

Scrape off the carbon deposits from the cylinder
and piston head. Then? in j
order to remove the two
bolts, open the bending
section of the connecting
rod lock washer.
Remove the oil scraper,
1
lock washer, and connect- I
ing rod cap from the
crankshaft.
Turn the crankshaft until
the piston comes to the top
position. Then push the
connecting rod to remove j
the piston from the cylinder top.
I
Remove the piston from
1Be careful not to
the connecting rod edge by i damage the inside
undipping the two piston
i of the rod edge.
pin clips.
Open the ring joint wide
Be careful not to
and remove the piston ring open the joint too
from the piston.
wide, or it will
break.
Remove the woodruff key
(for the magneto).
Remove the crankshaft
i Be careful not to
while tapping the magneto i damage the oil seal.
tip.
Remove the four M8
:
flange nut of engine side i
& generator side
I

:lO m/m box
ispanner or
/10 m/m spanner

I
I
I
i
i
i

!
I
I
‘12 m/m box
!spanner or
)12 m/m spanner

Piston Ring

Clip

Piston

/
Connecting

Rod Cap
F&. 9-3-26

-47-

<--;‘;
ti
G

Rod Lock Washer
Connecting

Rod Bolt

9-4 ASSEMBLY

PROCEDURE

n Precautions in assembly

(1)

Thoroughly clean each part. When cleaning, take special care with the piston, cylinder,
crankshaft, connecting rod, and each bearing.

(2)

Be sure to completely scrape off th carbon deposits on the cylinder head and piston head.
Also, thoroughly remove carbon deposits from each piston ring groove.

(3)

Check whether the lip of each oil seal is damaged or not, and if damaged, replace it with a
new one. Also, while assembling, apply lubricating oil to the lip of each seal.

(4)

Replace the gaskets and other similar items with new ones.

(5)

Check the keys, pins, bolts, nuts etc., and replace them, if necessary, with new ones.

(6)

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

(7)

Apply lubricating oil to rotating and sliding parts when they are assembled.

(8)

Check the clearance of each part prior to assembly and adjust them if necessary.

(9)

When each of the main components have been assembled, turn each one by hand and check
for smoothness of rotation and unusual noise.

-48-

HAssembly sequence and precautions
9-4-l CRANKSHAFT
(1) Fit the crankshaft oil seal guide onto the
crankshaft tip and assemble it with the
crank case as shown in Fig. 9-4-l.
Note: When the oil seal guide is not used, be
careful not to damage the oil seal lip.

.Crankshaft

Mount the woodruff key (for the magneto).
Dimentional tolerance of the crankpin.

(2)

(3)

Crankcase
Oil Seal Guide

External Diameter

24~) Z-03;

Fig. 942

WTolerances of new installed parts

Thrust directional

tolerance between the cylinder

0.02OL - 0.059L

and piston skirt

0.2L - 0.4L

Clearance between the piston ring joints
1
i
Clearance between the piston rings

Clearance between the connecting
major ring and crank pin
Clearance between the connecting

rod

Top ring

0.09OL - 0.135L

!
I
/

Second ring

0.060L - 0.105L

Oil ring

O.OlOL - 0.065L

1
’

Clearance between the internal and
external diameters

Side clearance

0.1 L - 0.3L
O.OlOL - 0.029L

minor rod edge and piston pin

Clearance between the piston pin and piston hole

0.037 L - 0.063 L

0.009L - 0.01 OL

Table 94 7

Note: The clearance between the piston and cylinder is checked by measuring the clearance
between the piston and cylinder skirt.
-49-

9-4-2 PISTON AND PISTON RING
(1) If a ring expander is not available, set the ring joint at the first land of the piston, as shown
in Fig. 9-4-4. Then, open the joint wide so that the ring can be slid into the fegular groove.
Note: Be careful not to twist or expand each ring too excessively. The oil ring is fitted onto the
piston, followed by the second ring and top ring.

Top Ring
Second Ring
Oil Ring

F&. 9-43

Fig. 9-4-4

(2)

The connecting rod is joined to the
piston with the piston pin.
Note: Prior to assembly, apply sufficient lubricating oil, to the connecting rod
minor edge.
Note: Be sure to secure the clips to both sides
of the piston pin.

In setting the connecting rod, hold it
with a piston ring guide, as shown in Fig.
9-4-5, (or, if there is no ring guide, tap
the piston head with a wooden object
pressing the piston ring with a finger tip
to push it in). Set it to the position of
the @ mark or MA mark of the connecting rod in the flywheel magneto side.
Note: Prior to assembly, apply sufficient
lubricating oil to the piston ring, connecting rod metal, and cylinder wall.
Note: Fit the piston with the piston rings
arranged 90* from the periphery of the
piston.

Piston Ring Guide

(3)

-50-

F&T 94-5

9-4-3 CONNECTING ROD
(1) Turn the crankshaft as far as the bottom dead point. Then, set the connecting rod, gently
striking the piston head until it touches the crankpin.
(2) Set the connecting rod cap according to the rod guide mark.
(3) Set the oil scraper in the magneto side.
Note: Be sure to use a new lock washer. Bed the washer carefully and correctly.
Note: When the connecting rod cap has been installed, manually turn the crankshaft to confirm
that the connecting rod moves smoothly.
Note: The specified torque for installing the connecting rod cap is from 90 to 115 kg-cm.
Note: For details regarding the clearances between the piston, piston ring, and rod, see Table 94-l.
9-4-4 TAPPETS AND CAMSHAFT
Install the tappets first, and then the camshaft.
Note: Align the timing mark at the base of
the cam gear with the timing mark of
the crank gear. If the valve timing is
set incorrectly, the engine will not
operate correctly and sometimes may
not run at all. (See Table 9-4-6).
Note: If the intake and exhaust valves are set
in reverse order the tappet clearance
will also be incorrect.

~g?zq$==
\
,:5g*y
Rd qf@
{ +-J-&[@
;:;; :eyr$&p&+&& gm4;;
L
n

Fig. 94-6

9-4-5 MAIN BEARING COVER
The main bearing cover is installed in the crankcase.
Note: As the governor gear has been mounted on the main bearing cover, it is necessary in
setting, to confirm that the governor gear is meshed with the cam gear (See Fig. 9-4-7).
If replacement of the oil seal is required, pressure-fit the new oil seal prior to installing
the main bearing cover to the specified position.
Note: Prior to installation apply lubricating oil to the bearings, oil seal lip, and to the cover face
to make a thin oil layer on the surface for the purpose of installing the main bearing cover
packing in the specified position. Also cover the oil seal guide over the crankshaft so that
the oil seal lip will not be damaged.
Make sure the side clearance of the crankshaft is in the range of 0 to 0.2 mm. Adjust it if
necessary, using the adjusting color (See Fig. 9-4-8).
Note: Torque for the main bearing cover: 80 - 100 kg-cm

-51-

Main Bearing Cover

i
1
Fi$. 94-7

F&. 948

* Fig. 9-4-9 shows an example of the methods
to measure the side clearance of the crankshaft.
In this case, it is measured by
measuring the clearance between the processing face of the crankcase and adjusting
color. As the packing is installed on the
processing face of the crankcase, determine
the clearance by taking into consideration
the thickness of this packing which is 0.22
mm.

Dial Gauge

Processing Face
of Crankcase

Fig. 9-4-9

9-4-6 INTAKE VALVE AND EXHAUST VALVE
Scrape off deposits such as carbon gum from
the valves, valve seat, intake/exhaust ports,
and valve guide.
Note: If the valve face is worn, replace the
valve with a new one.
Note: If the clearance between the valve
guide and valve stem is too large, replace the valve guide with a new one
provided by the supplier.

Valve Guide Puller

While replace@, pull out the valve guide by
using a pull block and a pull bolt and then
pressure-fit the new one.
Fig. 9410

-52-

WV&e

h valve guide clearance

Valve Face

3=53'

Valve Seat

Valve Stem

Valve Spring

Spring Retainer

Valve Guide

Fig. 94 7 1

Valve face angle

Valve seat angle

Valve guide inside diameter

Valve stem outside diameter

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

Intake valve

6.5$1$;;

Exhaust valve

-0.056
6*50- 0.078

Intake valve

0.025L - 0.062L

Exhust valve

0.056L - O.lOOL
,

Table 9-4-2

-53-

9-4-7 TAPPET ADJUSTMENT
Set the tappet at the lowest point and push down the valve. Measure the clearance between the
valve and the tappet stem, using a clearance gauge inserted into the clearance (See Fig. g-4-12).
Note: When the engine is not running, the clearance between the valve and tappet stem must be
in the range of 0.110.02. This holds true for both the intake valve and the exhaust valve.

~m,Y,,
--A’
A./,,-, _”
C-J.
Ii-\ i,
.J L

Clearance Gauge
Fig. 94 13

Fig. 9-4-12

Note: If the clearance is smaller than the specified one, grind down slightly the valve stem tip
with a grinder and measure the clearance again.
If the clearance is larger than the specified allowance, replace the valve with a new one
and adjust the clearance using some compound etc.
Note: Install the valve spring retainers after completing adjustment of the tappet clearance.
Then recheck the clearance.
* Installment of spring retainers
Place the retainer, using a special tool, over
the valve stem with the retainer’s notch
facing towards the front.
Front

9-4-8 BREATHER PLATE AND TAPPET COVER
Note: Pay attention to installing procedure of the gaskets and position of the breather valve,
which should be located in the intake valve side.
9-4-9 CYLINDER HEAD
Before installing the cylinder head, be sure to remove any carbon deposits from the combustion
chamber, and scrape off any dust in the section between the cooling fans.
Also check the level of the cylinder head.
Note: Replace the cylinder head gasket with a new one.
Note: Torque for the cylinder head: 190 % 230 kg-cm
-54-

9-4-10 IGNITION PLUG
* Torque for the ignition plug: 230 ad250 kg-cm
(As for a new one (head plug): 120 s 150 kg-cm)
9-4-11 IGNITION COIL, EXCITING COIL, FLYWHEEL AND STARTING PULLEY
(a) Temporarily set the ignition coil and exciting coil in the crankcase and install the flywheel
in the crankshaft. Clamp the starting pulley together with the flywheel.
Note: Installment should be done after wiping away any oil from the crankshaft and taper
section of the flywheel.
Torque for the flywheel: 600 Q 650 kg-cm
(b)

Measure air gap between the ignition coil, exciting coil and the flywheel and then clamp
the ignition coil.
The air gap is 0.4 s 0.5 mm.

9-4-l 2 CARBURETOR
In the part of crankcase cylinder, install the gasket, insulator, gasket, carburetor, gasket, control
bracket, and gasket, in this order. Then install the air cleaner body and secure it with two M6
flange nuts. Also lock the air cleaner body with Ml6 x 10 flange bolts.
Torque for the air cleaner clamping: 70 Q 90 kg-cm
Note:Set the control bracket at the position of “RUN”, and then mount it onto the air cleaner.
9-4-13 GOVERNOR LEVER
The governor used in the engine of this generator is of centrifugal weight type and is joined with
the governor lever.
With the governor lever, the throttle valve of the carburetor is
automatically regulated, therefore the engine speed is kept constant under load fluctuation.
Regulation procedure is as stated below (See Fig. 9-4-14, and Fig. 9-4-15)
(1) Join the carburetor throttle lever with the governor lever and install them in the governor
shaft.
(2) Install the speed control in the cylinder head.
(3) Join the governor and the speed control with the governor spring.

,
a@==//,,ylIIr;;L
SE+
- @
/-!
!zsc2s
-&
j&f
$T,
+,
cc=+
\.T<
G I’
&‘L--

Governor Lever

Governor

F&. 9-4-14

-55-

Lever Locking Nut

WHanging position of the governor spring
Generally, the governor spring should be hung in 1 (See Fig. 9-4-15).
(4)
(5)

Turn the speed control to the high speed side. Check to see that the carburetor throttle
valve has been fully opened, and then lock it.
Insert a driver into the governor shaft groove and turn it clockwise (until the governor
shaft becomes unable to turn) to lock the governor shaft and the governor lever with the
governor lever’s locking bolt.
Torque for the governor lever: 90 Q 110 kg-cm

Speed Control

Stop Switch

Governor Shaft

Choke Lever

Choke Spring
Governor

Lever

F@. 9-b 15

- 56 -

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

Muffler
Source Exif Data:
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File Type Extension : pdf
MIME Type : application/pdf
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Modify Date : 2000:05:12 13:55:11-05:00
Creator : Acrobat Capture 3.0
Producer : Adobe PDF Library 4.0
Create Date : 2000:04:27 12:04:13
Title : R1200 GENERATOR SERVICE MANUAL
Subject : Product Manuals
Author : Robin-Subaru
Page Count : 102
Page Mode : UseOutlines

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Subaru Robin Power Products R1200 Users Manual GENERATOR SERVICE

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