.

Model

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 CONTENTS

Section Title Page

1. SPECIFICATIONS .......................................... 1

2. PERFORMANCE CURVES .................................... 2

2-1 AC Output .......................................... 2

2-2 DC Output .......................................... 3

3. FEATURES .............................................. 5

4. SERIAL and SPECIFICATION NUMBER LOCATION ................ 6

5. SAFETY PRECAUTIONS ..................................... 7

5-1 Fire Prevention ....................................... 7

5-2 Precautions for Exhaust Gases. ............................. 7
5-3 Other Precautions ...................................... 7

6. COMPONENT IDENTIFICATION ............................... 8

7. FUNCTION OF EACH COMPONENT ............................ 11

7-1 Generator ........................................... 11

7-2 Engine ............................................. 12

8. DESCRIPTION OF MAIN COMPONENTS ......................... 14

8-1 Electronic lgnition System ................................ 14

8-2 Generator Operation .................................... 15

9. OPERATIONAL LIMITS OF THE GENERATOR. ................... 17

9-1 AC Output .......................................... 17

9-2 DC Output .......................................... 19
9-3 Simultaneous Use the AC/DC Output ......................... 20
9-4 Wire Length. ......................................... 20

10. MEASURING PROCEDURES .................................. 21

10-1 Meters ............................................. 21

10-2 Measuring AC Output ................................... 23
10-3 Measuring DC Output ................................... 23
10-4 Measuring Insulation Resistance . . . . . . . . . . . . . . . . . . . . . 23

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 Section Title Page

11. FUNCTIONAL CHECK OF EACH COMPONENT.. . . . . . . . . . . . . . . . . . 25

11-1 Control Panel . . . . . ...... ... 25

11-2 Stator..... ... .. . ... . . .. ...... . . 27
11-3 Rotor . . . . . . .. . . . . . . . .. ...... . . . 29
11-4 lgnition Coil . . . . ... ... . .. ...... . . 29
11-5 Condenser .. . . .. .. . . ..... .. 30
11-6 Rectifier . . . .. . . .. . .. . . . 30

12. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

12-1 Preparation and Precautrons ............................... 31

12-2 Special Tools for Disassembly and Assembly .................... 31
12-3 Disassembly Sequence ................................... 32
12-4 Assembly Procedure .................................... 38
12-5 Carburetor .......................................... 48

13. TROUBLESHOOTING . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 51

14. CRITERIA TABLE FOR ADJUSTMENT . . . . . . . . . . . . . . . 68

15. WIRING DIAGRAM . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . 71

16. MAINTENANCE . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 72

16-1 Daily Checks and Maintenance (every 8 hours) ................... 72

16-2 Checks and Maintenance for Every 20 Hours .................... 72
16-3 Checks and Maintenance for Every 50 Hours (every 10 days) ......... 72
16-4 Checks and Maintenance for Every 200 Hours (monthly) ............ 73
16-5 Checks and Maintenance for Every 500 Hours (semi-annually) ........ 73
16-6 Checks and Maintenance for Every 1000 Hours (annually) ........... 73
16-7 When the Generator is not used for Prolonged Periods: ............. 73

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 1. SPECIFICATIONS

Model R600

Engine: Forced air-cooled, 4-stroke, side valve,

i Type gas01 ine engine
L--
Displacement 78 cc (4.76 cu.in.1

Fuel tank capacity 2 lit. (0.53 U.S. gal.)

Oil pan capacity 350 cc (0.75 U.S. pints)

Ignition system Solid state ignition

~~
Starting system Recoil starter

Rated continuous Approx. 4 hours (50 Hz)

operating hours Approx. 3.5 hours (60 Hz)

Generator: Type 2-pole, revolving field type

Exciting system Self-exciting

Voltage regulating
Condenser type
system

Maximum output 500 w 600 W

Rated output 400 w 500w

AC Frequency 50 Hz 60 Hz

AC Voltage 110, 220,230,24OV 110, 120,220v

DC output 12V - 100 W (8.3 A)

AC receptacle Standard: 2 ea.

(special: 1 ea.)

DC terminal Two

Over current
Circuit breaker
protection

Frequency meter Standard equipment

Pilot light Standard equipment

370 x 265 x 345 mm

Dimensions (L x W x H):
(14.6 x 10.4 x 13.6 in.)

Dry weight 18.5 kg (40.7 Ibs)

-1-

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 2. PERFORMANCE CURVES

2-1 AC OUTPUT
Power Factor . . . 1 .o

I I I I 1 ! 1 I 1 1 Output Max. ............... 500W

I ’ I I
! 1 OUTPUT’ Rated ............... 400W
Frequency. ................ 50 Hz

Voltage. .................. 220V

i , I FRECiENC
i/: ‘1 I 1
i 300 t
// I
3 Y I
w
3
240 I I $
-t
a

CURRENT IA) -

1 I I, , 1 I 1 1 i Output Max. ............... 500W

, OUTPUT Rated ............... 400W
1.1 j 500
: :
50 i I I I II -i----l Frequency. ................ 50 Hz

49- /‘\I 400 t Voltage ................... 230V. 240V

// FREQUENCY I
I
I 1 a
I
/ I , :
/ I I !
300
I
260 / : I I

0vi 0.51 1: I 1.5 2 2.5 0

CURRENT (Al -

-2-

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 Output Max. . . . . . . . . . . . . . . . 500W
Rated . . . . . . . . . . . . . . . 400W
Frequency . . . . . . . . . . . . . . . . . 50Hz
w
U Voltage . . . . . . . . . . . . . . . . . . . 11OV
LL

1
3

-1
>
w
1

U
a

CURRENT ( A ) -
1

-I
N 600
Output Max. . . . . . . . . . . . . . . . 600W

tI 62 500
Rated . . . . . . . . . . . . . . . 500W
Frequency . . . . . . . . . . . . . . . . . 60 Hz

1
3
U 61
w
U
Voltage . . . . . . . . . . . . . . . . . . . 1 1OV
LL
60 400
59 I

3
300

-1
>
w
1

17
a
120

110
200
3
0
I-
2
I-
J 100 100
0
>
0
2 0 1 3

CURRENT ( A ) - 4 5 6

-I
N
600
Output Max. . . . . . . . . . . . . . . . 600W
Rated . . . . . . . . . . . . . . . 500W
62 500
3
E
U
U
61
60
59
400 1- Frequency
Voltage.
. . . . . . . . . . . . . . . . . 60 HZ
. . . . . . . . . . . . . . . . . . 220V

300 -3
I-
> 240 2I-
230 200 3
(3 0
a 220
5
0 210 100
>
a
a 0.5 1 1.5
CURRENT ( A ) - 2 2.5

-4 -

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 600 Output Max. ............... 500W
52
Rated ............... 400W
51 500
Frequency ................. 50 Hz
50
Voltage. .................. 11OV
49
400 t

3
300 +
3
E
200 2

0 1 2 3 4 5 6

CURRENT IA) -

I I I I I 1 Output Max. ............... 600W

Rated ............... 500W
62
Frequency ................. 60 HZ
61
Voltage. .................. 11OV
60 400
I
59
FREQUENCY
r 300
3
I f
k
120 200 ‘0

110

100 100

0
0 1 2 3 4 5 6

CURRENT IA) -

Output Max. ............... 600W

Rated ............... 500W
Frequency ................. 60 Hz
Voltage ................... 220V

0 0.5 1 1.5 2 2.5

CURRENT (A) -

-4-

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 3. FEATURES

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

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

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

l Simple Design for a clean appearance and easy maintenance.

l 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 Circuit Breaker Protection for safe operation. Replacement of fuses is not necessary in case of an overload.

l Unique Dual Output Design so that two separate A.C. and D.C. electrical appliances can be used at the same time.

-5-
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 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 eoenerator or ordering parts in order to get correct parts and accurate
service.

SPECIFICATION

SPECIFICATION NUMBER

SERIAL NUMBER

Fig. 4-7

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 ” - . . . - . . - -

5. SAFETY- PRECAUTIONS

51 FIRE PREVENTION

1) Keep the generator away from combustible materials during operation. Take special precautions with flammable sub-
stances.
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) 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.
4) Operate the generator at least lm away from a building or wall.
5) 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.
6) 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.
7) Do not overfill the fuel tank and always be sure to fill iuel only up to the level specified at the fuel supply- port.
8) Do not smoke or use open flame when filling the fuel tank.

5-2 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 mono-
xide poisoning.
3 Always operate the generator with the exhaust port directed toward the open air or where good ventilation is assured.

5-3 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) 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.
4) Avoid running the generator with its cover removed.

-7-
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 6. COMPONENT IDENTIFICATION

h’UFFLE9
C 0 V E F1

AlFl CLEALER

Al= CLEdYER CO\.‘ER

Fig. 6- 7

FUEL T.ANY

GEZERATOS

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 \*’ ” z FLER C:O\.‘ER

RECOIL STIRTE?

Fig. 6-3

SPARK PLUG

Ffg. 6-4

-9-

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 CAPBLRETOR

Fig. 6-5

#El3 PIPE
AIR \;E’JTl

Fig. 6-6

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 7. FUNCTION of EACH COMPONENT
REAR HOUSING

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

7-1-2 CONDENSER

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 ex- Fig. 7-2
haust port in the front housing.

7-l-5 CONTROL PANEL

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). DC output is
taken out from the red (positive. +) and black (.negative. -)
terminals.

Fig. 7-3

-11-
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 7-2 ENGINE
7-2-l 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 MAIN BEARING COVER

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

7-2-8 GOVERNOR

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

-12-

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 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 flywheeh’magneto 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.

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 8. DESCRIPTION OF MAIN COMPONENTS OPERATION

8-1 ELECTRONIC 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 PLUG
DETECTING
CIRCUIT

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 flow-
ing. \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 -

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 c .I

8-2 GENERATOR OPERATION

INITIAL EXCITATION STATOR

PERMANENT MAGNETO

FIELD COIL i
ROTOR : I
RECEPTACLE

RESIS
-----

DIODE MAIN COIL

CONDENSER COIL

CONDENSER
L ------ A
Fig. 8-2

8-2-l GENERATION of NO-LOAD VOLTAGE

1) 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.
2) 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 rotor’s
magnetic pole is intensified. When this magnetic force is intensified. the respective voltages in the main coil and
condenser coil rise. Current 1s flowing in the condenser coil increases. with the magnetic tlux densit)- of the rotor’s
magnetic pole increasing further. Also. the main coil voltage and condenser coil voltage increases. These voltages
continue rising as this process is repeated.
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.
41 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.

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 genera-
tor output voltage is prevented from decreasing.

-15-

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 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 recti-
fication prior to being supplied to the load connected to
the generator. The diode rectifier works to allow the cur-
rent to tlow in @ direction but does not allow the current
to flow in s direction as shown in Fig. S-3. Fig. 8-3
Fig. 84 shows the DC output circuit of the generator.
DC voltage is generated in the main coil; when the voltage Dl +
in A is higher than that in C. current !~flows in the direc-
tion 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 B
COIL
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 A AND B

OUTPUT WAVEFORM

BETWEEN C AND B

CURRENT 0 CURRENT @
=w= FLOWING FLOWING
BETWEEN BETWEEN
AAND B CAND B

Fig. 8-5

- 16 -

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 9. OPERATIONAL LIMITS OF THE GENERATOR

9-1 AC OUTPUT:

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 appli-
ance 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 : This generator can provide enough power to operate five 1OOWincandescent lamps.

9-l-2 ELECTRIC APPLIANCES WITH A POWER FACTOR LESS THAN 1.0:

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

9-l-3 MOTOR LOAD:

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 neces-
sary.

-17 -

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 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. In such a situation. it is necessary to calculate the power consumption of the device
involved. Depending on the types of load. the calculated power consumption is adjusted according to paragraphs 9-l-l
through 9-I-3 above.
(Power consumption) = (Mechanical equivalent of device) + (Efficiency)

Efficiency
Motors: 0.6 - 0.8
Fluorescent lamps: 0.7 - 0.8
Example : A 4OW fluorescent lamp with a lighting output of 40W and assuming that the power consumption of this lamp is
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.

Range of workable loads

Electric devices
50 Hz 60 Hz

I Incandescent lamp, electric heater, etc. up to 4oow up to 5oow I

Fluorescent lamp, mercury lamp, etc. Up to approx. 300W Up to approx. 400W

I
I
Motor-driven tools etc. Up to approx. 300W Up to approx. 350W

Pump and compressor drive motors I Up to approx. 150W / Up to approx. 200W

Table 9- 7

NOTE 7: With motor-driven tools and the motor-driven pumps and compressors specified in paragraphs 9-7-3

and 9-l-4, the generators of the said capacities are required only when starting the motors of the
respective appliance. Once the motor has started, the power which the generator is required to
supply to the motor decreases thereafter to a level approximately 1.2 to 2 times the rated power

consumption .

Therefore, the surplus capacity of the generator may be used for other electric appliances.

NOTE 2: As for the motor-driven devices specified in paragraph 9- 7-3 and 9-l -4, the power requirement for

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

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 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 20°C.
S20 = St + 0.0007 (t - 10)
where
S~J = Specific gravity corresponding to 20°C
SI = Measured value
t = Temperature at time of measurement

9-2-2 REMAINING CAPACITY ESTIMATED WITH REFERENCE TO THE SPECIFIC GRAVITY OF

ELECTROLYTE:

c I
Specific gravity Remaining battery I
Remarks
(20°C) (%I
I

1.260 100
I Good charged condition
1.240 87

1.220 75 I Charging is necessary.

1.200 62

1.180 50 ,
Immediate charging is necessary.
1.160 37

1.140 25

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.

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 9-3 SIMULTANEOUS USE THE AC/DC OUTPUT
If you use the AC’DC output simultaneously in this generator, be careful not to exceed the total power consumption.

50 Hz below 3OOW
60 Hz below 3OOIV
NOTE: Max. output of DC is 1OOW /12V x 8.3A).

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.

No. of con-
Cross ductorsl
Allowable
sectional Resistance Current
current conductor
area
diameter

mm’ A No./mm ,0,/l OOm 1A ’ 3A 5A 8A ’ 10A 12A 15A

0.75 7 30/O. 18 2.477 2.5U 8U 12.5U - ‘- - ;-:

I
:
1.25 12 5OiO.18 1.486 l.5U 5u 7.5u l2U 15u 18U I - , 8
t
2.0 17 3710.26 0,952 1u 3u 5U 8U 1 1ou ; l2U 15u 0”
8
3.5 23 4510.32 0.517 - 1.5U ’ 2.5U ’ 4U 5U 6.5U - 7.5U ; <
I
>
5.5 35 7OiO.32 0.332 - 1U 2U : 2.5U 3.5u ; 4u 5u
L I

Table 9-3

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 10. MEASURING PROCEDURES
AC VOLTMETER DC VOLTMETER

10-l METERS
10-1-l VOLTMETERS
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
Both AC and DC ammeters are necessary. DC AMMETER

The AC ammeter must have a scale range from 0 to ap-

proximately 10A.
The DC ammeter must have a scale range from 0 to ap-
proximately 15A.

Fig. 10-2

10-l-3 FREQUENCY METER

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

Fig. 70-3

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 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

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 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 in-
candescent 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 I
11ou 12ou 220u 230,240U
rating

Range of
108% 12OU 118- 130U 218 - 240U 235 - 260U
voltage

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: 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 do not to overcharge the battery.

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. When the measured insulation
resistance of the generator is over lMI2. it is normal (over
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. rotor and control panel. Fig. 10-9

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 10-4-1 STATOR
Measure the resistances betlveen red coupler leading from
the stator and the core.

Fig. lo-10

1O-4-2 ROTOR d
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 poten- _
tial danger of electrical shock.

Fig. 10-12

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 --

11. FUNCTIONAL CHECK of EACH COMPONENT

11-l CONTROL PANEL

11-l-l ENGINE 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 con-
tinuity 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

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 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) Fig. 1 l-4(81

11-1-5 DC TERMINALS
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
Lvith a wire connected across these terminals. the DC
terminals are normal. When the wire is removed and no
continuity is <onfirmed between these terminals. the
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 BLUE
YELLOW

RED

BLACK

BROWN

WHITE

Fig. 11-6

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 11-2 STATOR
Measure the resistance of each stator coil using the circuit tester.

Main coil : Condenser coil

I
Classified coil ! I Cord color of @
I
AC coil For use with the I
DC coil : Condenser coil
frequency meter /
I
Measurement Rectifier 1 Between
6P coupler j 6P coupler
location connector j connectors
I
50Hz-110V 3.4R ’ 0.2251 1.1n I 8.9R : White/Green
I
60Hz-110V 2.6 I 0.16 0.9 : 7.6 White/Red

50Hz-120V j 3.3 j 0.22 1.1 8.9 Brown

I
I
60Hz-120V 2.7 ’ 0.16 , 0.9 7.6 1 Blue
I
50 Hz - 220V ! 13.9 0.22 1.1 8.9 : Gray

60 Hz - 220V 11.4 0.16 , 0.9 i 7.6 Pink

50 Hz - 230V 15.2 0.22 1.1 8.9 i Orange

50 Hz - 240V 15.2 0.22 1.1 j 8.9 Orange

I

Table 11-l (at 21cC)

NOTE: If the circuit tester is not sufficient/y accurate, it may not show the values given and may give erroneous readings.
Erroneous readings will also occur when there is a wide variation of resistance among coil windings or when measurement is

performed at ambient temperatures different from the values specified in the space directly upper the table.

[6P coupler wiring]

DARK BLUE

YELLOW

RED

BLACK

BROWN

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 FL?. 7 l-7 Fig. 1 l-8

Fi:g. 1 l-9 Fig. 11-10

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 Table 1 l-2

Fig. 11-11

NOTE 1: Measure the resistance of each coil winding while the diode and each resistor are disconnected with the/r solder
removed.
NOTE 2: If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous read-

mngs.
Erroneous -eadings will also occur when there is a wide variation of resrstance among coil windings or v/hen measurement
is performed at ambient temperatures different from the values specified in the space directly below the table.

[APPROX 162: I

11-4 IGNITION COIL

Resistance value Measurement location

0.61’1 B~tl::ee? The con-e and the gree? cord

7.52 Betkseen the grew cord and the high-ttvsor cord

Table 7 7-3

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 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 20°C).

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. The rectifier is
considered normal when the respective resistances have the
values specified below.
NOTE: Each of the given values changes with the polarity

of the circuit tester.

Green Red White@ [

01 3 :...16RI

@ #3 . . .160 1

\ ,
Y

The polarity of the circuit tester

Table 7 l-4

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 - *-

12. DISASSEMBLY and ASSEMBLY

12-1 PREPARATION 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) For more convenience, divide the parts into several groups and store them in boxes.
3) To prevent bolts and nuts from being misplaced or installed incorrectly. place them temporarily back at their original
positions.
4) 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. Tool No. ; Name of tool , Description

For disassembling and assembling the intake

1 2309500107 Valve spring retainer
and exhaust valves

2 2309500207 Valve guide puller To pull out the valve guide

3 3589500107 : Rotor puller To pull out the rotor

Table 12-l

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 12-3 DISASSEMBLY SEQUENCE

I I
Sequence Part to remove I Description Precautions Necessary tools

1 Side cover (Lj (1 j Remove both the left and right ! 2 PlUj screw-
and (Rj co\-2rs. by taking out eight 31-C driver
I flang2 screws.
I
-I Couplsrs (dis- 1 (1) Disconnect th2 (6Pj coupler of Pull them under
connection) the generator from the other (6P) while pressing
extending from the control panel. 1 down the retainer
claws.
622 Fig. 1Z-2.) !

3 ’ Choke cab12 (1) Set the engine control to STOP. rs Minus

and remove the screw from the screw-driver
II tip of the choke cable to dis-
connect the choke cable from
the dial plate. I
(2) Disconnect the outer cable of the 1 1Omm box spanner
choke cable from the fuel tank
bracket.
(3) Loosen the M4 screw of the 13 Plus screw-
! carburetor choke lever swivel to driver
pull out the inner Loire from the
choke cable.

4 Fuel line (1) Hold thz fuel line clamp inserted / Be careful not to Pliers
inside the felt strainer using pliers, ’ damage the hose. :
and pull it backward to remove
the fu21 line from inside the
I strainsr. I

5 ’ Fuel tank (1) Push up the end of the cover

handle I fitted to the handle with finger.
r (2) Pull out the rubber tube use; as
the air vent pipe.
a (3) Remove two bolts (tank). and 1Omm box
remove the handle. I I spanner
I

Fig. 12-2

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 Sequence Part to remove Description Precautions Necessary tools

6 Rear cover ( 1) Remove the rear :over at the 1Omm box

opposing sid2 of the control spannsr
pan21by unscrewing th2 four
I $16 flange bolts.
7 Fuel tank (.I) Loosen the set screw of th2 ,z Plus screw-
strainer shaft at th2 rear of the driver
engine control switch.
(2) Remove two M5 flange bolts , (,SeeFig. 1Z-3.) ! 1Omm box
clamping the front cover and spanner
tank bracket together. and tank
bracket together. and then
remove the fuel tank.

8 Front cover (.l j Rsmove two MS tlange bolts 1Omm box

clamping the front cover to spanner
the basr to rrmove the front
cover.
,
9 Fuel hose (1) Using pliers. hold the fuel line Be careful not Electricians’
clamp at the fuel support joint to damage the ! pliers
of the carburetor (L-joint ’ fuel line.
I directed downward) to pull it
aside. Then. pull out the line.
10 Choke cable (1 j Insert the tip of a screwdriver 3 Minus
(.tlat-headed type) in the groove screwdriver
of the choke cable bracket pro-
truding from the head cover.

11 I Muffler cover (1) Remove the out2r cover; this is Take care not to -3 Plus screw-
and muffler done by removing seven M5 drop the removed driver
tapping screws. screws down into
! (2) R2move one M6 x 1’ flange the cooling air ! IOmm box
bolt of the muffler bracket. and 1 channel. spanner
two M6 nuts from the muffler ’ (See Fig. 11.4.)
tlange. Then. remov2 th2 flange.
(3) Remove four 315 x 8 lock screws 3 Minus screw-
from inside the muffler t I remove driver
the inner cover. I
I

flUFFI

Fig. 123 Fig. 124

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 Sequence 1 Part to remove Description Precautions Necessary tools

12 Bas2 platz (1) Remove one set screw of the ; uT Plus screw-
earth wire which grounds the I
driver
rear housing and base plate
togethsr (Zr)OV system onlv). I
(2) Rsmove four 5115x 10 bolts from j Smm box spanner
under the base plate.

13 Recoil starter (1) Remove the recoil starter from 1Omm box
the rear housing. by removing spanner
three 516 x 8 flange bolts. (See Fig. 12-S.)

Starter pullek (1 j Turn the starter pulley b]- hand 1?mm box
to set the piston to the compres- spanner
sion stroke limit (lvhere the pulle)
becomes heavy). Csing a hammer Handle hammer
strike the box wrench set ov2r the (See Fig. 1Z-6.)
I
head of the through bolt to remove
I the bolt. Then remove the pulleb _
I

Fig. 12-5 Fig. 12-6

Sequence Part to remove Description Precautions , Necessary tools

I

15 Stator assemblq- (1 j Remove three M6 x 85 bolts ’ 1Omm box

clamping the rear housing of the spanner
stator assembly. and the front
housing together.
(2j Remove the stator assembly-from Plastic hammer
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.) j
(3) Remove the lead from the clamp 3 Plus screw-
I . . b_~-taking out. one M4 x 8 scre\v. _ driver
1 (4) Kemove both the capacitor and I : Cd Plus screw-
I diode from the rear housing by driver
I removing three M5 x 30 scre\\s.
/ (5) Remove the wiring between the
stator and rear housing. Discon- i
nest three terminals irom the
diode. t\vo terminals from the
capacitor. and the ground \vire
from the r2ar housing.

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 Sequence Part to remove Description Precautions ! Necessary tools

16 ’ Rotor assembl) (1) Fit the rotor puller to th2 rotor ’ Rotor puller
shaft. and drive it into place to
remove the rotor from the engine Plastic hammer
shaft.

1; Plug cap (1 j Remove the plug cap from th2

spark plug in advance.
(3) Remove the clamp of the high-
voltage power cable.

18 Front housing (1 j Remove the front housing and 1Omm box spanner
and center center baffle from the engine I
baffle main bearing. b) removmg thrze j
M6 x Xmm bolts and one M5
x 55mm bolt. (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 driver
cleaner cover. filter element. and
element retainer.
A
(2) Remove the M5 screw at the lower \fi Plus screw-
right inside the element chamber. driver
(3) Remove tvvo M6 flange nuts i 1Omm box
clamping the air cleaner and the spanner
carburetor together to remove the
air cleaner. ! (See Fig. 12-9.) I

AIR CLEANER ELEMENT & ELEMENT

* RETAINER

ELEMEN/T ? Al R ‘CLEANER COVER

FIQ. 10-9

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 Sequence Part to remove Description Precautions / Necessary tools
I
20 Governor and (.1) Remove the governor lever from Loosen the bolt 1Omm box spanner
related parts the governor shaft. (unnecessary to
(~j Remove the governor rod, rod remove it)
spring. and governor spring.

‘1 Carburetor (1 j Remove the carburetor from I

the stud area of the intake side
flange of the crankcase.
7-3
-- Head cover , (1 j Remove two M5 screws from the .B Plus screw-
lateral side of the head cover to driver
I remove the head cover.

33 Qlinder baffle (1 j Remove the M6 bolt from the i 1Omm box

crankcase and the $15 bolt from 5 anner
the main bearing cover to remove 5 Plus screw-
+
!he cylinder baffle. driver

24 Spark plug (1) Remove the spark plug from the : 19mm box
cylinder head. spanner

25 Cylinder head (1 j Remove sev2n M6 x 32 bolts to ; Mark the head 1Omm box
remove the cl-linder head. gasket with its spanner
(3) Remove the head gasket. mounting position
accurately match-
ing the cylinder
head, also mark
the gasket mount-
ing face of the
, cylinder head.
i Intake valve (1) Remove both the inner and outer B2 sure to posi- t 1Omm box
tappet chamber covers from the tion the notch in spanner
crankcase. by removing two Y6 the spring retain-
x 1: bolts. er’s outside peri-
: (3) Remove both the intake and phery to the front 13 Minus screw-
exhaust valves. and hook the driver
(3) Remove the valve spring and minus screw-
retainer. i driver (medium
I side) in the recess
I / (lower side) of I
a the retainer. I
Then pull the
spring retainer ’
backward to re-
move it.

I@ RETAIN-
1 ER
PULL BACK

(1) Remove the Woodruff key from

the crankshaft.
(2) Remove five M6 x 15 bolts locking 1Omm box
the main bearing cover from the spanner
crankcase. ’ Plastic hammer
(3) Using a plastic hammer or a Be careful not
similar tool. strike the mam to damage the
bearing cover uniformly around i lip of the oil seal.
its peripheq to remov-ethe cover. ;

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 Sequence Part to remove Description II Precautions Necessary tools

28 ’ Camshaft (1) Pull out the camshaft from the Set the crankcase
crankcase. sideways so that
it will not fall
i and damage the
! tappets.

29 ; Tappets (1 j Remove the tappets from the Be sure to mark

I crankcase. the tappets to
, distinguish them
; from each other;
i one for the intake
1 valve and the
other for the
exhaust valve.

30 Connecting rod ! (1) Scrape off the carbon deposits i Confirm the 1 e Minus screw-
and piston from the cylinder and piston head. , mounting direc- i driver
Push open the bend of the connect- tion of the oil
I ing rod lock washer, and remove scraper. Pliers
I two bolts.
(2) Remove the lock washer and con- 1Omm box
netting rod cap from the crank- spanner
shaft.
(3) Turn the crankshaft until the
piston comes to its top position.
and push the piston from the
upper part of the cylinder.

31 Piston and (1) Remove two clips from the piston (1) Replace
piston rings pin and take out the piston pin. these clips
Remove the piston from the vvith new
connecting rod. ones: do not
(2) Each of the piston rings can be reuse them.
removed from the piston by open- : (2) Be careful
ing wide the ring joint. not to
1 damage the
I minor rod ;
end. I
(3) Be careful
not to open
the ring
joint exces-
sivelv .

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 !

33 Governor shaft
shaft. and pull out the governor !
I
I shaft from the crankcase.
I I

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 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) 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.
4) Replace the gaskets and similar items with new ones; do not reuse old gaskets.
5) Replace the keys. pins, bolts, nuts. etc., with new ones if necessary.
6) Do not apply torque exceeding the specified value.
7) Apply lubricating oil to both moving and sliding parts when they are assembled.
8) Prior to assembly, check the clearance of each part, and adjust it if necessary.
9) When each of the main components are assembled, turn it by hand to check for smoothness of rotation and unusual
noise.

l Assembly Sequence and Precautions

12-4-l GOVERNOR SHAFT

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

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 l Tolerances of Newly Installed Parts

Thrust directional tolerance between the cylinder and piston skirt 0.008L - 0.047L
I
I
Top ring ! 0.2L - 0.4L

Clearance of piston ring joint Second ring 0.2L - 0.4L

Spare rings
’ Oil ring ! 0.05L - 0.25L 1

Top ring 0.09OL - 0.135L

Clearance between piston ring Second ring 1 0.06OL - 0.105L

I Spare rings
Oil ring O.OlOL-0.065L ,

Inside and outslde diameter

0.037 L - 0.063L
Clearance between connecting clearance
rod major end and crankpin I
Side clearance 0.1 L - 0.7L

Clearance between connecting rod minor end and piston pin O.OlOL - 0.029L

Clearance between piston pin and piston pin hole 0.009T - 0.01 OL

L = Loose T = Tight
Table 12-2

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

cylinder skirt.

124-3 PISTON and PISTON RINGS

OPEN ENDS OF
1) If a ring expander is not available. set the ring joint at PISTON RINGS
the first land of the piston. as shown in Fig. 12-l 1 so
that the ring can be slided into its groove.
NOTE: Be careful not to twist or expand exces-

sively each ring. The oil ring is fitted first on to the

piston, followed by the second ring and top ring-

The top and second rings must be fitted with their

marked sides kept upward.

Fig. 12-l 1

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

NOTE: Before assembly, apply sufficient lubricating oil to the connecting rod minor end

NO JE: Be sure to fit the clips to both sides of the piston pin.

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 STD EQUIPMENT ! SPARE PARTS

- Top ring ’ Taper Taper

I
. \ ‘,\
\ x.
Second ring Taper Undercut :.
q \ ..
‘\
\
Oil ring
I

Fig. 72-72

1244 INSTALLING THE CRANKCASE

1) The connecting rod is put into the cylinder while

GUIDE
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: Apply a sufficient quantity of oil to the

piston rings, connecting rod surfaces, and cylinder.

NOTE: The top, second and oil rings are fitted to Fig. 72-73
the piston with their ring joints arranged 90’ off each

adjacent joint.

12-4-5 INSTALLING THE CONNECTING ROD

MAJOR END CAP

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.) OIL SCIRAPER
NOTE: Be sure to use a new lock washer; and care-

fully bend the washer correctly.

NOTE: When the cap has been installed, turn the

crankshaft to see if the connecting rod moves smooth-

Iv.
NOTE: The correct torque for installing the connect- Fig. 72-74

ing rod major end cap is 60 to 80 kg-cm.

NOTE: See Table 72-2 for details regarding the

clearances between the piston, piston rings, and

connecting rod and their counterparts.

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 12-4-6 INSTALLING THE TAPPETS and CAMSHAFT

Install the tappets. and then the camshaft.

NOTE: Align the timing mark at the base of the cam gear

with the timing mark of the crank gear. If the valve timing

is set incorrectly, the engine will not run or operate proper-

ly. (See Fig. 72-75.)

NOTE: If the intake and exhaust valves are installed in

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. (See Fig. 72-76.)

If the oil seal requires replacement, pressure-fit the new oil seal in position before installing the main bearing cover.

NOTE: Prior to installation, apply oil to the bearing and oil seal. Apply a small amount of oil to the cover fitting face,

as specified, in preparation for installing the bearing cover packing. Place the oil seal guide over the crankshaft so that the

oil sea7 lip will not be damaged during installation. Make sure that the side clearance of the crankshaft is within 0 to 0.2mm.

If necessary, adjust the clearance, using the adjusting collar. (see Fig. 72- 7 7.)

NOTE: Torque for the main bearing cover: 80 - 700 kg-cm.

MAIN BEARING COVER. fY;ie;

GOVERNOR GEAR ‘-

Fig. 72-77

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 *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 thick-
ness 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: If the valve face is worn, replace the valve with a new one.
NOTE: If the clearance between the valve guide and valve stem is excessively large, replace the valve guide with a new one.

Replace the valve guide by using a pull block and pull bolt as shown in Fig. 72-20.

VALVE FACE
A

E GUIDE
PULLER
VALVE SEAT

- VALVE STEM

VALVE GUIDE

VALVE SPRING

Fig. 72-79 ‘VALVE RETAINER

Fig. 72-20

A: Valve face angle 45”

B: Valve seat angle 45O

C: Valve guide inside diameter I 5 59 +0.018

I 0
I
-0.020
Intake valve I 5’59 -0.032
D: Valve stem outside diameter
I -0.056
Exhaust valve 5.5@ -0.074

Intake valve 0.02OL - 0.05OL

Clearance (clearance between C and D)
between valve guide and valve stem
Exhaust valve 0.056L - 0.072L

L: LOOSE
Table 72-3

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 12-4-9 TAPPET ADJUSTMENT
Set the tappet at 1112 loa-est position to depress the valve. Then measure the clearance between the valve and tappet stem.
using a clearance gauge inserted into the clearance. (See Fig. 12-21.)
NOTE: As with the intake and exhaust valves, the clearance between the valve and tappet stem must be within 0.1 f. 0.02.

INTAKE & EXHAUST VALVE VALVE SPRING

NCE GAUGE

Fig. 12-27 Fig. 12-22

NOTE: If the clearance is smaller than that specified, slightly grind down the valve stem end using a grinder, then measure

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

to adjust the clearance.

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

clearance.

*Installing the valve spring retainer:

Using the special tool. place the retainer over the valve stem
with the notch in the outside periphery of the retainer kept
@
toward the front.
1
FRONT
12-4-10 INSTALLING THE CYLINDER HEAD
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: Torque for each cylinder head lock bolt: 90 - 7 70 kg-cm

12-4-11 INSTALLING THE SPARK PLUG

Torque for spark plug: 120 - 130 kg-cm

12-4-12 INSTALLING THE CYLINDER BAFFLE

The 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.

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 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 gover-
nor rod and rod spring.
4) Insert the governor lever into the governor shaft.
5) 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
Fig. 12-24
center hole (of the three) of the governor lever and
the remaining end inserted into the hole of the speed controller.

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 re-
tainer. 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.

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 . *.

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. (use CEMEDINE 575).
2) Fit the plug cap on the spark plug.

124-18 INSTALLING THE ROTOR ASSEMBLY

Install the rotor assembly to the taper of the crankshaft with their keyways in line.
NOTE: Thoroughly clean the tapers (both male and female tapers) of oily substances.

12-4-19 INSTALLING THE STATOR ASSEMBLY

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

Refer to paragraph 9-2 for @.

Connect the ground cord to the rear housing. using
one M6 x 8mm screw.
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) Also fit another rubber mount (A) to the bossesat the lower part of the stator assembly of the generator.

124-21 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.

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 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). Match the
rubber mount (A) which is fitted to the lower part of
the engine and generator. Base frame is installed
using four MZ bolts.
3) Insert each rubber tube from the air vent connector
of the carburetor into the hole in the base frame.
3) Fasten the ground terminal of the ZOOV power -/
system to the rear housing using the $16 bolt. EASE PLATE

Fig. 12-27
12-4-25 INSTALLING THE MUFFLER and MUFFLER COVER

1) Fit the gasket (for the muffler cover) to the studs of the exhaust flange of the crankcase.
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.
3) 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: The inner wire is installed later. Leave it loose in the swivel.

12-4-27 INSTALLING THE FUEL 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 c’onn2ctor.
2) Secure the fuel line with the clamp of the cylinder baffle.

124-28 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 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.
2) 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.

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 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 pro-
trusion.
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.

12-4-32 INSTALLING THE FUEL LINE

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

124-34 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.

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 12-5 CABURETOR
12-5-1 FUNCTION and 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
THROTTLE
CHOKE - BY PASS; r VALVE ,-PILOT OUTLET

FLOAT

PILOT AIR JET

L-d
.“.- MAIN NEEDLE

PILOT JETJ’

MAIN AIR JET? /.-NEEDLE VALVE

FLOAT i ‘MAIN JET

Fig. 72-28

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 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 t‘rom 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 bl-
blockage 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 t‘uel channels be kept clean. The following
descriptions are the procedures for carburetor disassembly and assembly. (See Fig. 12-19.)
1) Throttle mechanism
a) Remove Philips-head screw (77): throttle valve (~8), and pull out the throttle shaft (39).
b) 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) Remove Philips-head screw (12). choke valve (23). and pull out choke shaft (24’).
b) Be sure to keep the notch of the choke valve positioned forward the main air jet side when the choke shaft is
installed.
3) Pilot jet nozzle
a) Remove pilot jet nozzle (?I ). When removin,.0 use a proper tool so that the nozzle will not be damaged.
b) Firmly secure the jet nozzle when the carburetor is assembled. Otherwise, fuel will leak from the nozzle and
cause engine trouble.
4) Main jet nozzle
a) Remove bolt (15). and float chamber bodl- ( 13).
b) Remove main jet nozzle ( 19) from carburetor bodk (9j.
c) 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.

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 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 op-
posite side of the peen-secured part b>-lightly striking the float pin with a thin bar-like object.

27 24
/
28 1'

Fig. 72-29

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 13. TROUBLESHOOTING
DIAG: DIAGNOSIS

8 DIAGNOSIS BY THE CUSTOMER

0 DIAG. 01 Engine fails to start.
?-
-) DIAG. 02 Electricity not generated.
If the generator doesn’t perform properI>- or fails to run after troubleshooring. ask a qualified service dealer to
check it.

n DIAGNOSIS BY THE SHOP

A. Fails to start
3) DIAG. 11 The fuel tank is emptk-
4) DIAG. 1: Contaminated by water or dirt
5) DIAG. 13 Spark is weak of wire harness
6) DIAG. 14 Spark is strong of wire harnzss
7) DIAG. 15 Compression is insufficient
8) DIAG. 16 Compression is nonexistent
9) DIAG. 1’ Cloggsd fuel pipe
10) DIAG. 18 The fuel doesn’t enter into the carburetor (No flow from the pipe)
11) DIAG. 19 The fuel doesn‘t enter into the float chamber (Flow from the pipe)
12) DIAG. 20 The fuel doesn’t enter into the combustion chamber (Fuel exists in the float)
13) DIAG. 21 Carburetor flooded

B. Engine defective
14) DIAG. 3 I Excessive noise (Improper maintenance) . .... Check oil element
15) DIAG. 32 Oil consumption increases (gets thin)
16) DIAG. 33 Excessive noise occurs and engine suddenly stops
17) DIAG. 34 Black exhaust fumes (Excessively large fuel consumption)
18) DIAG. 35 White fumes produced (Excessively large lubricating oil consumption)

C. Control Panel
19) DJAG. 36 Pilot light fails to light up
20) DIAG. 37 The frequency meter fails to show any reading, with the needle resting at zero

D. Engine operates but voltage is not normal

21) DIAG. 41 No AC voltage is output (Resistance load)
23) DIAG. 41 No DC voltage is output (Resistance load)
23) DIAG. 43 No DC voltage is output
14) DIAG. 44 The DC output voltage is only 50% of the rated value
25) DIAG. 45 130% higher or more DC is output
26) DIAG. 46 So AC voltage is generated
27) DIAG. 3: AC output voltage is onl! 20% of the rated value

E. Power lacking and performance poor

28) DIAG. 5 1 Poor operating condition
29) DIAG. 52 Engine speed does not increase
30) DIAG. 53 Knocking. engine overheats
31) DIAG. 54 Failure to generate output. no compression
32) DIAG. 55 Poor performance (Backfire)
33) DIAG. -6 Misfire or combustion outside the combustion chamber

-51 -
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 DIAG. 12 I 1 DIAG. 13

Engine fails Engine fails

lostart to St;lrt Engine fails
Check fuel Check fuel t o stllrt
Check spat k Spark is t o o
quentity quality weak o f wire
harness

L1 Parts Fuel tank

Fuel strainer

I
Air gap is
too wide
I
Coil is
shorted or
wire broken
L Rotor

Weak
magnet
High voltage
code

Coil is
shorted or
wire broken
Plug cap

High voltage
code and
conlacl
trouble
0Spark plug

Icr lz: v: r" 1

Items t o Measure the Without

Check the air coil resist-
check and Check Check ga P special equip-
procedurc ance ment, i t Check Clean plug
Searcher Circuit tester doesn't work

I
I
r-
1 E l r::1
I

=a: Wire
Air gap is broken
Checking
N o fuel Moisture or t o o wide on: Sl1ort Weak
Plug cap Dirt present
criteria dust exists Standard is Standard cot1tact Insulation
first : 0.6 1 S2 magnet defective
0.4-0.5 troublc
second :
7.5 ki2
L
II
r- I
Remedies
Fill with
Replace fuel
fuel
Adjust and
reform Replace Replace the
rotor
Repair or
replace
Repair o r
replace
Clean o r
teplacc

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 --- -.

Sym(~lollls

_. . .-

_--..
I,.
P0ssil1lc SI icky
CilllSCS

___-. -_.
I
8
_ ..-_- -- 1

I
Grmcl lhc
Oil VillVe
Mcasurc end ol' lhc
Ilclns 10 (Ilwck lllc SlClIl ilrld wlve
check and (‘heck dcglcc 111 (‘heck ;1nd
gaskcl n1ove
atljllsl IllC

I
proccdllt c lcvcl11css
sm00111ly
iappct Spa""

- ..]

-r
-- ..,
-. -- J . -_-

I.- -_ I - ..- -. .I.. -r --. .---

F

Not SCCUIcd
1 Lhlllil#Xi
(‘I~ill~ltlCC
Narrow ...
(‘hccking ovet the Over Ilie lighlly gasket OI I.~iltljllSl
Not level SI Icky
critcliil service liillil sclvicc liiiiil Gasket tlefec- ovcrst poke Wide . . .
I ivc rmgc WplilCe

._ . _. 1
I- --

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 -71 rt--.. -_-_,,.-.- -DIAC. 18 -1
-I
No I’ucl t’lows OUI
t-tiigitic I’uils IO ~1211
CVCII wlwn Ill0 I’IICI
Syrnplorns Pucl tlow

Ll L- -.,--I
II01 ClllCl
pipe is diswrinccl-

-I-...
_--
irllo llic ~;II~~III~~~I
cd' flOll1 the

. .-- c;lrhrelor

-..-?- -,,..-
---.-
.-- _ ..- --- .-. --.
-- -,. --.--.- - -1 . ._

-.
PiIrIS

-.
-I .-

- 1.
--_ -
Fuel sl rnincr :IWI
I’illcr

-.-
..-

L
.__ --

-.,
r 1L_ _-.
Fuci slrniticr

I
-_-. -.
i Fuel pipe

- -I -. ..-
-.

_
I L 1
-
Fuel I’illcr

--_
--_ - -

-_

-.
Possible
CiIIISCS

I L I
l’lic air bleed is
clogged

1
..- ,-.--.. --.
The air hlectl is
cloggc1l

1
..- I

_. ..-_ L- .-
AlXllllllllilll1~l1

----.
I- -
01’ ail

- r .--.
Dcl’cclivc
I’il~Cl

--_
1
---
I’ucl

-- 1

Chock IIN bolt 01

Items IO
nihher pipe iri the
cllcck atld Clwck (‘heck (‘llcck
Ilanlllc
[“‘occtlllrc
EXAM 3 I

-- -. .- 1
T- -
-. .- . -.._ I-- - -_. -1... ,-.-- - -- _I _--.- .-

Clhccking
crilerh The ;lir tdcccl is Air buhhlc exisls l)c~cclivc I’iiel I’illc~
Closed posilion
clogged

L -_-- .- . . -
I .-.
.-L- - -. 7 -‘-

r
__ .A--. -, - L__ . ..- .- ._

IL
(‘lci~r, llw I’illcl
Sel in lhe closed
VICi#Il or ICplilCe 1 posil ion Vent lllc ilir Cl~lllCl~l OI’ lCi7lilW
I 1 IIIC SllilillCl
-- --._. J L.. . ., _ --- ..A &..-,- .-.. .- .- --. A

Downloaded from www.Manualslib.com manuals search engine

 rl
Syl~lploms

--.I.---

Measure the
tloar hcighl.
(‘twk The stmit’i-
(‘heck (‘tlcck
(Tly lo 111ovc) cnt ion is IS 3
111111t’l0111
body
-._ --. __ ,_-. .,-
I 1

Downloaded from www.Manualslib.com manuals search engine

 -.-.. -.-....--._
- DIAC. 32
1
Engine opcr;il ion

!I I
dmornial
Synlplollls Excessive noise l.nbric:iting oil
consunipt ion
increases (gels thin)

._I.
T' --."-

L :
Fuel

.-._-
..-.
L-._ - ..I
---r ,.-

I
Lhn~agetl or
lJxcossivcly wortl Excessively worn
Possihtc clogged
sliding paris sliding parts

Li ‘1
CBUSCS
. . (Lack ol’ Iilainlc-
(llsc ol’old oil) ((‘tlilllgC the oil)
IlilIlCC)
l r ..,.- -. _ .--..
it2
-. r --

Cheek lhl! COIll- I Check 1tic COIU- Check thcjel Kcplaco will1
prcssion prcssioii Cltlcck (Jut number, m)rm11 1’ucI :ind
To 111AC. t 5 or To DIAG. IS or
looseness) illICe ol’ pislon ring check
lb 16

-----I i._..I -.

Dislalett
Wrong jet lirnil

--- -.,- --

-I-

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 Sylllt~IolnS Noise protlucctl and

I-
Lxccssivcly IillgC I’UCI

r: ,, ._-. -

--.
r-
1. .--.

L .-1
Fuel

._
('ICillNZr ClClllClll

..-. I ---.
I
_- I -- 1 __.- .-

I..1 I’ossiblc
C'Il1sw
L

-
Scizurc
ot'

__..-..
ltic
connecliiig

I
01 d;magc
piston
rod
01

.- I
_ .,,.
(‘logging of’ It1e air
clcmcr clcnrcnl

,.- I .--.- - -.
Rich rJJixlurc

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

--

Cheek IIIC main jcl

(i)r loosc~~css antI ,jct Repli\cc with normal

j
(‘llcck (‘heck I’ucl ;III~I cheek
nlllnhcl
To DIAG. 2I

‘, ..- .-..
,.. .-- I- -I- -.-- I-’ --
-.,...- ._-
‘-- ‘-1I)islorlctl . ..
Scizut c OI' tlillllJlgC Tighlel1
C'tlccking
01‘ I tic piston 01 I>ii I Wrongjel
crileria
connecling rod To I)tA(;. 2 I

--
--I I-

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 Ll
Hnginc
Ir011hlc Excessively
Wtlilc t’~jlllcs Iqo luhri-
protlucctl citlirig oil
co~~suriiption
--- _

----

Possihlc
- -. _..--I -. r-
VillVC
1Nll
-
and
WOrll r I--
c;Iuscs
WOlIl Ollf Sticky rctllln valve
&,gglXl

- III-
.' I .--
.I-
1
I -.-_.

(Ihcck
clcararicc of Cheek (‘heck C’hcck (‘heck
pislon ring

I --.--
-r
-. - 1 ---
(‘orilnriiina-
over tt,e I ion (mixed Over ttic ACctIlI\IIlil-
Checking Assclllt~lccl Over ltic Oil Icakage
service with ot!iet slaiidard lioii of’
crilerio upside down service liniil qlltiIllily
limit ll1illCriillS carboll

like carbon’)

____.‘T. .._....
-

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 - MAC. 36
- ----I
I._ I
(‘or~lrot /XlIlCt
rncler I;lilS IO StlOW
Ttlc pilot light
Sylllptl~llls
I;lilS 10 light Op.

.- 7
--.__..
_ ._-- the needle res(ilig
.

11I ._
PiNlS

1 .. -. -...- _I-- -- -I

‘lie diode is The I’ilamcn~ is tkl’cclive soltlcr, Wile broken OI

Wilt hlc~kcll OI
tlc(‘cct ive and leutl broken stwrlctl
ShCM 14

I ‘W
-
% _, .__ I ___ L-- 1 -, I ___
_.._1---.-
___ - I ..-...
.-_
I
1
IlClllS lo Mci\llSrc the
1 Mc;wrc ltic
Icsislwlcc
. . L
MCLSIJIC
rcsiul~~iicc
‘
IIIO

(ACIOSS ltic Icrrni-

1
(‘lwck
paI I
the sol&xcd
Mcasurc
illlO (LICIOSS
LIIC rcsisl-
1 tie
(‘lwk IIIC I’rcctu-
cncy nictc~ I’or
clwk and rcsislnncc (Across lhc Icr- t~l3l~ilMlS) clcclrical con-
iliiii;ils) IlillS) Circuil lcslc~
ploccdurc (hl’ coiiplcr) (‘ircuii lesler lirluily
c’ircuil Icslcf Circuil tester

L. I-- I----- I
I

-
.I-__

Me;lsure I hc When 42 . . . tt1e

Wl1cn 42 .*,
WllCll 41 ...
rcsisl*lrlCC
. ‘ rcatling ol’ Ilic’ Wire hrokw

!.
(‘lwcking Witc hlokw When 42 ...
(ilCIl!SS lhc ICI’-
circuil Icslcr mq Itic WhWl a2 .. .
CI ilcl i;i Wire hrokcll Wilt hlokcn
wtlcll OS1 . . . miii;lls) ICiltl Zllld SOldL!f LIIC
Stlorlctl
SIIOI lCll ttefcc~ive
c’itcuil lcslcr
7

.-

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

Mcasurc AC outpul MCISIJW AC output Measure DC OIII~UI

EXAM I EXAM 1

AC voltage is low by

.---
- _ _.__-..
.,.-
. _.,._-.
_I_
Kerr1cdies
I I
To DlA(;. 40
I
To DIAG 45 To INAG. 43
-ir To I)IAC. 44
1

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 - --.,. --.-
DIAC,. 44
-_... _- -. __..-
1
The IX’ oulput
vollagc is only SCYj%
Sylllpllm
01’ lhc ralctl value

.--.. -

.-,L.
L.-I 1
Slulor IX1 coil

I
--..
Stator main coil

- -I
;7
r -1
-
IXiltl

Tile soldered pilrt is

Wire hrokcn OI One diode is def’cctivc dcl’cclivc, ;rd
;rd the lead
the
The diode is tlct’cctivc
shor INi is hrokcn

- --I... . -- I

Measure Ihc rcsisl- Measure ~IIC tesislance Mcasurc I~IC resistance

1 Measure 1hc resistance Mciisurc the iosislance
(;wwis the lcrniinas) (across the lcrminals (xross lhe Icroiinals) (iICrOSS lllc Icrniin~ils)
cliodc terniinds of Circuil leslcr 01’ tlw 61’ coupler) Circuil lcslci
(‘iicuil lcslei

..L
.-
(‘ircuil lcslcr

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

lI ___--. ___._- I -_ - 1 ..----

Wllerl 42 ... WllCll 42 . . .

1
When l hc rcsislnnce Whcri tlic resistaucc
Wire blokcn 1 Wilt broken
differs 1’1om the tlil’fcrs I’rom lhc
WllCll OS2 . . . wl\cll OS2 . . .
slandard value Stillld~lld Villue
Stlortcd Shorlcd

- -.- . --._.

[_1,
I~eiiiedies

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 ..-
IN’%, higher or more
--.
--.-
-....
IX: is output
Symptoms

. T -.A
l+rigirie running speed

_I..- .._-J-
is high
r1 -- i ..__

.. -.. . - -. -
L.- -.-. 1

r].-.
. r PiirIS

..,, .._-
-r
Condenser

r
-,..-.1L
-.
1! 1
._.--- - _-_-
Staler tllilill coil

-7’ ---
SlillOr

-.- ._,
coiidenser

T
coil

---

1,, 1
I. Wire broken
The cngille running Wire broken OI Wire hrokcn or shorlcd
Possible 2. Kotor resistor is
spcctl is higher lhan shortctl shorled
CilllS~S dcl’cct ivc
nornd
3. Kotor tliotlc is
del’ccl ivc
I- - -_-- r I-z .- - --I -- ,.-- 1

I lerris lo
McilstJre the capacily Mcasure LIIC rGst:lllcc MCilsurc 111~resistance
1 Mci\sure the resislancc
across tlic resistors,
with solilcr imoved.
To DIAG. 52

_11
__
_r
..-.-
_-,-
check ;md (circuil tester c;~ii nol (bclwccn llic Icr- (between the ter- MCiISIJICtile resislawc

lmxedure
C’hcck 111egovernor hc used li)r this riiimds) IlliJliJlS) 01’ the rolor rcsislor,
Tlrc circuit tester The circuit lcstcr ilntl cllcck 111~ tliotlc
li)r lll~lIllIilCy
A

~-_.- --l- _-- 1 I-

I) When 42 ...
Wire brokcll
When 42 .., When 42 . . .
WllCll t-Is2 ...

x-.--_
..-
(‘hecking DilTcrcnl I’rwn the Wire hroken Wire blokcn
Shorlcd
criteria slilrltlad WlilC When OS2 . . . WhCll u2 ...
) TIIC resisI:lrlcc

._
.._.
_
.-_-
Shorted Shorlcil tliI’l’crs by as tiiuch

-_ -.--.-
as 10%~ from lhc
- ____ -. .- -,.....- -_ _-.-. --.. - slarldard value

IL .._--.
I ‘1AI - I T 1--- .--
I1 r-” 7
Kcnicdies

L..-----I _-_-.--____ 1 L.
Replace the condcnscr

---1
1 L., ._.... ___ ,- ..,,,
..A L _
Keplilce

- ..-__
the

,_-.
rolor

-.- J

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 .-- ---‘-‘--
__--. ,.

r
A(: OUllW1 VOlliIgC
is only 20f% ol’ lhc
ralcti value

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

u Pitrls

,1 c. .-.-.L..__..
---I- -- -
Rotor (lonclenser hgine

I
E
I
1 Possible
causes

-7 __
The coil is shorted

--_-_.
.-A--
1
_-
-.-
The coil is shortcd

- ----‘T’ _ --
Shorting

rotor
0I’Ihe

resistor
coil
Aged or broken

-
The cnginc speed is
lower than norrrial

. ..- - -1. . . -.. -. -

Mcasurc the resist- Mensurc the capa-

Measure the rcsist- Measure the resist-
llcn1s lo 311Cl! citance (Ihe circuit
iItlcC (hctwecn the To DIAG. 53,
cheek and (6P coupler ler- lcster can not be
lerminals) Cheek fhe governor
procedure lninills) used for I his mea-
Circuit tester Circuil tester
Circuit lcsler surement)

.-. _ .., . .. .,

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

IS%, lower than I he

TIIC rcsislance is TIIC rcsist;lucc is coil ililllllilId ...
Dil’Tcrcnt I’roiri Ihc
l Sfjh lower 1lli111 llle 1.5% lower iliaii the Shorted standard value
Checking
criteria Slillldilld VillUC ... standard vihe .., IO’%, tlit’ferciicc tllilll Aged
Shorlccl Shorled llje resister stillltl~lKl ... Broken
Old

ElRemedies

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 ---

Sylllpll~llls

..-
I I T”

-
I---
Dcl’ective selliiig
Poor or clcl’cclive
ol’ the governw I,eilll nlixlurc

L
Possible perli)rmullcc
C3IISCS lever illld level
shnl’t
.- --.-.. .._
---- ! - r
-.,_ .I---.--- --

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

(‘lwck ihc II~OVC- (‘llcck I hc I’ucl pipe

Iiems lo
Check ihe set ‘I’0 I)IAG. I7
CllCCk ;I1111 of cnburctor
posil ion
produie

--- _-_. -___. - ----, .- 1 : _.,.._-... .- -

T
.
._-

-.. _ _ 1. .- 1 ._ _-. _-,,-L-_-

Incorrecl llilllg-
ing posiliorl .,.
Worn 0111 .,, C‘0lllillTli~lilli1~ll ...
1
Kcplacc
C’hecking Dc~cctivc wiling Keplacc ClCilll
Dcl’cctivc govcrritri

I
CrilL’riil
spring . . .
KeplilCe
-. - J
-_ _ -.
T
..-_.-
T-j- --I

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 DIAC. 52

Kngiiic speed 110CS

--_---
no1 illcreils~

4
.. . .-.. _ .--_
I I

._.- ,n a Valve

..-,- -.-, -, ---

I
C’ilrburclor and ilir
cleaner

---_- -1._...-
-.~
t%?Clriciil load

---

r1
__
Possible
C’I
L 11scs

.-._

-_.
Ikt’ecl

---
ivc

I
sell

-.-
irig
The liming
valves is tlcl’ectivc.
ol’ ihe
Mixture

-. .,,_,--.-
-
is incorrect. and iiiul’ller ilre / Ovill~;iillil

Cheek the carbura- Correct to the

Check the SCIt ing tor. Stilllcl~rd hltl
t;XAM (‘heck by eyes
(‘heck lhc ;lirclenncr AC ; To WAC; 46

,,,
..--. --,
-_--
EXAM 54 owner’s iiianuil DC; To DIAG 43
I

-
-7
.- I ~-.-
A - ...-.- ZIIY
The
correctly
goveinor
set,
is in-
iulcr- 1
I
(‘hccking Acljuslmcni ol’cleilr-
f’eriiig with lhc
crilcriil iIIlCL! is incorrecl OWrlOilCi

L
lhrolllc valve’s
opciiing.

. .- ..-.
i=:
--I- - I --.-

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

__I._--,_______
r--- -I -.....-I.
-l.---..._ l .---- .-.-
l .__L-.-.

I 1I 1 L 1 r 1
Cylinder heiltl (‘ylimler licad ldeclric lid Spark plug
Cnrburctor
PiIrIS hind cylinder rnul’fler

. . ___-_ .-- i, --
1 _. -. .-. _. ._ .-
1 I I ---I-- --
---I. ._-
.. __- ,... -._ 1 _- _.

----._._.. J 1
I’ossib lc (‘ooling I’;llls iIN! AClXllllllliltil~ll Of
Overloading
.
CiIlISCS clogged. carhi

) I! ,- ,, --.
-.I. - -r
8 - ___A ._.

1
--
I
Mcasurc I hc insula-

wcii OVCdlillll Lilltl

(‘llcck
Cylinder hcild tion resklilnc~
* .
Spccilj
llcrlls to check IIIC corburc- Adjust to the *
IrXAM SO ISM K4.A
cl\cck iIIIt1 (or. standard IWli
Mul‘llcr (NGK)
proccdurc Air compressor AC ; To 111AC, 46
I’XAM 65 I’XAM 5 I

3I --.’
IJXAM IX’; To DIAC; 43
--J
-_. - ,_-.-_
” -I
-
_--_ ,.-

-- 1
7
Tllcrml ril t ing of’
Checking Dirt illld clogging Overlootl tllc spilrk plug is
IlOt illlCX~ll~lt~.
critcriii

,.. -L. .,.---

I-- 1 l----‘------l I---- --

I-
Kc~tiove the carbun
dcposi I.
.-----I
I IlSilgC
IOild.
Ol’ Sl~lrlliiIrd

I-..
Replace
spccificd
__--I
with the
plug.

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 I No trutpu1
Poor
Poor
Misfire or
cond~~stion
pdorniancc
-. , , No comprcs- performnnce ou,side the
siou Backl’irc

L..- - .J L- .-,--J L_-+

-- -
Worn out Rich niix- Dcfccl ivc Moisture in
Possihlc (‘onlacl lure. soldel fuel
CilllSCS
I , point is
dcl’cclivc
-_ -- 7 1
.- .- _ --
l --
!
-.-.-r -
T
-. -.

Check the Replace with Check

Check the ,jet fol 11~2correct (Inside of
C’hcck 1hr
ltcrlls IO tappet Ckiir- llN,scl~ess cilrhl~riltl~r
check and IappCl ClCilr- piIdS illld
ancc. ((‘heck the chuck cliambcr)
procetlul c ilncc.
$1 number)

-,, -r-- -
Narrow . . .
Adiusl to
Loscncss .. . C:lnltoct
COlllilCl Moisture in
Tighten point by
Clhcckiug rhc ml of fuel
Wrong,jel .. . soil is fail
criteria Ill0 ViilVC
Keplncc
Wiilc . . .
Replace

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 14. CRITERIA TABLE for ADJUSTMENT

, Limit of
I terns of adjustment Criteria Description Tools Remarks
application

Surface plate
Levelness of cylinder head Below 0.1 0.15 Repalr
and searcher
I
510+o.o19
lnslde dia. 5 1 .cl6Q 1 Cylinder gauge
0

Seat width of Intake and Slide calipers ’ Repair

Cylinder 0.5 1a
exhaust valves and cutter

5,50A0.018
1 lnstde dia. of valve guide 5.656 Center dia. Cylinder gauge Replacement
. 0

Piston skirt’s outs,de 0 I

50.9920 -o,02 50.92 Micrometer Replacement
dia. I” thrust dIrectIon
I
, ,5 +0.025
’ TOP 1.65 Slide calipers Replacement
0
I
’ Ring groove , ,5 ~0.025
Second 1.65 Slide calipers Replacement
width 0

2.5 ao.035
011 2.65 Slide calipers Replacement
Piston 0

, ,O +0.002
i Pin hole 11 .O35 Cylinder gauge Replacement
-0.009

Clearance between piston ’ Cylinder gauge

skirt and cylmder wall 0.008 - 0.047 0.14 Replacement
and mxrometer ,

’ Top 0.090 -0.135 0.26 Searcher Replacement

, Clearance be-
tween ring and Second 0.060 -0.105 0.23 Searcher Replacement
ring groove - Spare rings v
Oil 0.010 -0.065 0.19 ’ Searcher Replacement

Clearance between piston Winder Saw ’ Replacement

0.009T - O.OlOL 0.06L
and piston pin and micrometer
I
Top 0.2 - 0.4 1.5 Searcher Replacement I
Joint gap Second 0.2 -0.4 1.5
Spare rings
I Oil 0.02 -0.25 1 .5

Piston -0.09
rings I Top 1.5 -0.11 1.3 Micrometer Replacement

Width Second ’ .5 -0.06 1.33 MIcrometer Replacement

-0.08
Spare rings !

011 2,5 -0.010 2.38 MIcrometer Replacement

A- -0.030

P!ston pin outside dia. “* 0

-0.008 10.060 ’ MIcrometer Replacement

20d+0 013
’ lnstde d:a. of large end 20.050 Cylinder gauge Replacement
0

I Clearance between mslde 1 Cylinder gauge

dia of large end and crankpin 0.037 -0.063 0.13 Replacement
and mlcrometer
Connecting
lnslde dia. of small end L-0 021
rod 11.080 ’ Cylinder gauge Replacement
“O-0.01rJ

1 Clearance between instde Cylinder gauge

0.01 - 0.029 0.12 Replacement
dla of small end and ptstonpln I and micrometer

Slide clearance of large

0.1 -0.7 1 .o Searcher ’ Replacement
i rod end
1 I

-68-
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 I ,
I limit of
Items of adjustment I Criteria Description Tools Ramarks
application
I
1 Crankpm outside dia. , 19.920 ! Mtcrometer Replacement

Generator 20e, -0.003 !

Crankshaft 1 19.950 I Micrometer Replacement
side -0.012
Crankshaft
journal outside
Counter- , 7. -0.003
‘6.950 Micrometer Replacement
dia. side -0.011

Cam crest 18.4%” 18.15 ! Micrometer ! Replacement

Camshaft
i &:erator ,O9-o.O’3 9.950 Mtcrometer ( Replacement
Camshaft -0.028 :
journal
outside dia. Counter- -0.01 3
9.959 Micrometer Replacement
I side log -0.028

Free length 25 24 Slide calipers Replacement

Valve
spring I
Squareness 1 .o Square Replacement

I ’
Intake 5.50 -0.020 5.440 1 Mtcrometer Replacement
-0.032 I
Outside dia.
of valve stem
-0.056
I Exhaust 5.5@ -0.074 5.409 Micrometer Replacement

Clearance be- Intake 0.02 - 0.05 0.2 Cylinder gauge Replacement

tween valve At valve guide
stem and center
Intake and
exhaust valve guide Exhaust 0.056 - 0.092 0.2 Cylinder gauge Replacement

valve i Searcher Replacement

’ Intake I 0.08 -0.12 0.05 - 0.25,
l Tappet
clearance 1 Searcher Replacement
I Exhaust 0.08 -0.12 0.05 - 0.25
I I
’ Clearance
between Intake 8 0.1 -0.3 i 0.5 , Slide calipers ’ Replacement

groove
retainer and Exhaust 0.1 -0.3 0.5 1 Slide calpers Replacement

Valve stem Intake 3.5 ! 2.5 1 Slide caltpers Replacement

end length Exhaust / 3.5 2.5 Sltde calipers Replacement

I
i Total length j 20.8 +i.” 20.3 ) Slide calipers Replacement
I
Tappet !
Clearance between stem 0.01 -0.03
1 and guide

I Spark
Plug
Type

Electrode gap
BMR-4A

0.6 -0.7
(NGKI

1.0 Searcher
I

Replacement
I

I
Fuel con- ’ 50 Hz rating 0.5
I
sumption
(l/hr) [ 60 Hz rating I 0.6
I~- ~~ I
Lubricating 1 50 Hz rating 4 20 :
Oil con- I
sumption
(cc!hr) 60 Hz rating 5 20 1
I
Quantity of lubricating oil cc 350 I I
AutomotIve engine oil of class over SC

I Inittal: 20 hours after start

Lubricating oil replacement Interval Regular: Every 100 hours I I
I I
I Pressure
Compression pressure (kg/cm2/rpm) 41800 1 guage ’
I I

-69-
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 Items of adjustment Limit of ’
Criteria Description ’ Tools
(Tightening torque) application

1 Connecting rod bolts 60 -80 kg-cm

I Main bearing cover bolts 80-100

[ Cylinder head bolts go-110 I I

Spark plug 120 -150 I 1 I
Air cleaner nuts 50 -60
I
Governor lever nuts 70 -90 I

I Front housing bolts 80-100 I I

I Rotor bolts 100-150 I I
1 Muffler nuts I
I Front cover bolts 55 -75 I I I

- 70 -
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 15. WIRING DIAGRAM

RECTIFIER CIRCUIT BREAKER

MAIN COIL r ----- +----- AC RECEPTACLE

ril
FIELD COIL

_----

CONDENSER
COIL

It-J ’ FREQUENCY
/ r+
4
_______ ------~
[DARK BL”E,’ 4 (DARK
L--------------A
BLUE1 FM ’
1 METER
CONDENSER

IGNITION COIL

SPARK PLUG IGNITION UNIT

& GT

AC lead wire color code

p< ” 1
I 1lOV 50 Hz White, green I
White, red

=.I Blue __i

I 22OV.50 Hz Gray I

I 220V ‘60 Hz Pink I

I 230V ‘50 Hz
240V 50 Hz

-71 -

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 16. MAINTENANCE

The following standard maintenarxe procedurss are necessary to ensure th 2 generator’s 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)

I
Check and maintenance items I Description
I
(I) Clean each component of dust ’ (1) If th2 joint of the governor is left in a dust! condition.
the governor ma>-fail to function normally.

(2) Check the fuel piping system and related parts for (2) Ii fuel leakage is not corrected. fuel economy will be
leakage. Should leakage be detected. tighten or reduced and there is a potential of fire.
replace the defective part.

(3) Check each part for looseness. Tighten if (3) If the parts are 10052.vibrations will occur. and ma)
necessary. subject the generator to troublz.

(3) Check the quantity of oil inside the crankcase: fill (4) If the engine is run with an insufficient quantity of oil.
oil as necessary-. th2 piston and other moving parts will be damaged.

(5) Check equipments of control panel. when found (5) Can’t obtain any output which is needed.
damages. replace them.
I

16-2 CHECKS and MAINTENANCE for EVERY 20 HOURS

I 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
I engine parts.

16-3 CHECKS and MAINTENANCE for EVERY 50 HOURS (every 10 days)

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) Check the spark plug for carbon sontammation. (2) Should the plug be left m contaminated condition.
If found dirt!. clean rt with gasoline. followed an sngine output will decline or it ma! fail
b>- sandpaper.

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 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 (1) The us2 of contaminated oil will subject parts to
new oil. (every 100 hours) excessive wear.

(2) Clean the fuel strainer and the fuel tank interior. I (2) If the contaminated fuel strainer and fuel tank are
used continually. engine performance will be lessened
I and may led to engine trouble.

16-5 CHECKS and MAINTENANCE for EVERY 566 HOURS (semi-annually)

Check and maintenance items Description

(1) Remove the cylinder head, and remove carbon ’ (1) If the engine is run with the cylinder head contami-
deposits. nated with carbon. it may led to engine trouble.

(2) Disassembly and cleaning of engine carburetor. (2) If the engine is run with the cylinder head contami-
nated with carbon. it may led to to engine trouble.
,
(3) Check the switch of engine and tlexible shaft. (3) If the engine is run with the cylinder head contami-
nated with carbon. it may led to engine trouble.

16-6 CHECKS and MAINTENANCE for EVERY 1660 HOURS (annually)

Check and maintenance items Description

(1) Overhaul the engine for cleaning. adjustment (1) If the engine is used continually without an annual
and parts replacement. overhaul. it may led to engine trouble.
I
(2) Replace the piston rings. ’ (2) If the engine is used continually without an annual
, overhaul. it may led to engine trouble.

(3) Replace the fuel pipe. j (3) An old fuel pipe is likely to leak.

(4) Check all the relative parts of the generator. (4) Can’t obtain any output which is needed.
I

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 20-
hour check and maintenance detailed in 16-Z.
~j Drain the fuel from the tank and from the tloat chamber of the carburetor.
3j 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.
4) Keep the piston stationary at the position where the piston stroke f22ls the heaviest.
5) Clean the engine exterior. using an oil impregnated cloth. and then place a vinyl cover or other cloth over the genera-
tor in a dry- place where it Lvill not be subject to high humidity.

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 R&&I Generator

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 R -America, Inc.
940lively
Blvd.
Q WoodDale,
1160191
● Phone:
630-350-8200
● Fax630-350-8212
e-mail: sales @robinamerica.com ● wwwrobinamerica. com PRINTED IN THE USA

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