Robin America R1200 Service Manual Download Page 16

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Summary of Contents for R1200

Page 1: ...Rozh J ii Generator TechnicalData Overhaul Instructions SERVICE MANUAL ...

Page 2: ... contents of this manual and provide users complete service after sales or proper guidance on how to usethis generator This manual includes only brief descriptions on important points so we ask you to supplement this with your own experience and determination in practical guidance for your customers We are also going to have seminars or other events to exchange necessary information to improve our...

Page 3: ...rating Operation 12 6 OPERATIONAL LIMITS OF THE GENERATOR 14 6 1 AC Output 14 6 2 DC Output 16 63 Simultaneous Use of AC DC Output 16 6 4 Wire Length 17 7 MEASURING PROCEDURES 18 7 1 Meters 18 7 2 Measurement of AC Output 20 7 3 Measurement of DC Output 20 7 4 Measurement of Insulation Resistance 20 8 FUNCTIONAL CHECK OF EACH COMPONENT 22 8 1 Control Panel 22 8 2 Diode Stack Rectifier 23 8 3 AVR 2...

Page 4: ...er Precautions 72 TROUBLESHOOTING 73 CRITERIA TABLE FOR ADJUSTMENT 91 WIRING DIAGRAM 94 MAINTENANCE 95 14 1 Daily Checks and Maintenance Every 8 Hours 95 14 2 Checks and Maintenance for Every 20 Hours 95 14 3 Checks and Maintenance for Every 50 Hours Every 10 Days 95 14 4 Checks and Maintenance for Every 200 Hours Every Month 96 14 5 Checks and Maintenance for Every 500 Hours Semi Annually 96 14 6...

Page 5: ...nerator Type 2 pole revolving field type I Exciting system Self exciting I Voltage regulating I system AVR Automatic Voltage Regulator I I Maximum output j 1000 w 1200 w I I Rated output 800W I 1000 w AC Frequency AC Voltage DC output 50 Hz 1 I 60 Hz 110 220 230 24OV 110 120 220v 12V 8 3A 1OOW I AC receptacle I S T D type nema germany 2 ea I France Australia England Switzerland 1 ea DC receptable ...

Page 6: ...50 49 800 I 600 si w 250 2 240 400 2 230 220 200 I I I I I I I I I I I I 0 1 2 3 4 5 0 Current A Ti I t 52 1000 z 51 I 50 ii L 49 800 I LL s z I 600 8 260 P s 8 250 400 0 z 240 230 200 0 1 2 3 4 5 0 Current A Output Max 1000w Rated 800 W Frequency 50 Hz Voltage 220 v Output Max 1000W Rated 800 W Frequency 50 Hz Voltage 230V Output Max 1000w Rated 800 W Frequency 50 Hz Voltage 240 V 2 ...

Page 7: ...rent A 62 1000 61 60 800 f 59 z 600 s Q 5 120 400 0 110 100 200 0 2 4 6 8 10 Current A 62 1000 61 60 800 f 59 600 z w 240 2 5 230 400 0 220 210 200 01 2 3 4 5 0 Current A Output Max 1000W Rated 800W Frequency 50 Hz Voltage 110v Output Max 1200w Rated 1000W Frequency 60 Hz Voltage 110v Output Max 1200w Rated 1000W Frequency 60 Hz Voltage 220v 3 ...

Page 8: ...om this generator is rated especially for charging batteries Whenthe rated current 8 3A flows into a battery the voltage is 12V but the voltage becomes higher when the load is smaller or when the current is smaller than the rated one and lower when the load is bigger or when the current is bigger than the rated one Note that the voltage under no load is approximately from 18V up to 25V 4 ...

Page 9: ...ator replacement of a fuse is unnecessary Troubles which happen in an overload or failure of devices used can easily be resolved 6 Direct current for charging batteries can also be taken out 7 Simultaneous use of DC is possible even when AC is used However total AC output and DC output should be within the range of the rated output 8 Voltage fluctuation ratio is below 5 becauseof employment of AVR...

Page 10: ...DENTIFICATION DC Circuit Breaker Engine Control Switch CHOKE RUN STOP Ground Terminal rter Air Cleaner Cover Muffler Recoil Starter ler crew rnal Spark Plug Fuel Tank Fig 3 1 Carrying Handle Cover Tank Cap Fig 3 2 6 ...

Page 11: ...d of the shaft with a slip ring on the opposite end One end of the lead wire from the field coil is connected to the slip ring The field coil becomes an electromagnet when DC current flows from the slip ring The cooling fan is for cooling the generator by inducting cooling air from the slip ring side and discharging it from the fan side 4 l 3 BRUSH Exciting current from the AVR is supplied through...

Page 12: ...e with a ground terminal and AC output is taken out with a male plug DC current is taken out from the DC recepta cle with a special plug The voltmeter displays output voltage from the generator The circuit breaker for AC and DC in the upper section of the control panel prevents too big an output current from being taken out or excess current in short circuit Fig 4 14 F 4 l 5 8 ...

Page 13: ... be assembled 4 2 5 CAMSHAFT The camshaft is made of special cast iron and has intake and exhaust valve drive cams each of which engages with the camgear An exclusive aluminum alloy is used on each end of the camshaft in the place of bearings Ball bearings are not used 4 Z 6 VALVE ARRANGEMENT The intake valve is arranged in the generator side while the exhaust valve is arranged in the recoil side ...

Page 14: ...nition coil is mounted on the crankcase 4 2 12 CARBURETOR The horizontal suction type carburetor employed here can provide excellent starting good acceleration low fuel consumption and superior output The carburetor setting is matched to the generator set On details concerning the carburetor construction and others see the paragraph dealing with carburetor construction and disassembly assembly 4 2...

Page 15: ...th a permanent magnet mounted on The basic principle is shownbelow I Ignition Coil I E r go 1 r 1 Q b z E P LT s l f Ll f CC 8 r 8 I z E 5 l f 5 2 o j 5 I ki f rn F iTI F 5 7 1 When the flywheel starts rotating power is generated in the primary coil of the ignition coil and current flows to the resistor With this current the power transistor turns on releasing current B This stage corresponds to t...

Page 16: ... coil by repeating this operation 5 2 2 VOLTAGE REGULATION UNDER LOAD When a load is connected to an AC receptacle and current is increased output voltage fluc tuates and the voltage fluctuations in the case where an AVR is in the circuit and in the case where no AVR is in the circuit differ as shown in Fig 5 2 2 The AVR operates as follows When AC output is taken out load is put on the engine The...

Page 17: ... main coil When the voltage in A is higher than that in B the current flows in the direction shown in the figure while no current flows between CF and DE because the current is cut off by the diodes G4 and G2 On the contrary when the voltage in B is higher than that in A the current Iflows in the direction as shown in the figure No current flows between CD and EF because the current is cut off by ...

Page 18: ...e a large starting current every time they are started or begin rotating The motor starting load supplied from the generator becomes the largest when starting a normal operation mode The rates of power supply which the generator is required to produce for motor loads are categorized into two cases depending on the types of the motor used and load condition at the time of starting 1 Motors mainly r...

Page 19: ...ed power consumption is then multiplied as per 3 a or 3 a taking into account the type of the motor used and the starting condition The table below shows the range of loads applicable to the generator with 1000 Wrated output Electric appliance Range of applicable load 50 Hz 60 Hz I Incandescent lamp electric heater etc I Up to 800 W I Upto 1ooow I Fluorescent lamp mercury lamp etc Up to approx 500...

Page 20: ...TED WITH REFERENCE TO THE SPECIFIC GRAVITY Specific gravity 20 C Remaining capacity I I 260 100 I 240 87 1 220 75 Remarks Charging is not necessary Charging is necessary I I 200 62 1 180 1 160 I I40 I 50 37 25 Immediate charging is necessary I 6 2 3 BATTERY CAPACITY The battery capacity is expressed in the unit of AH amperehour One AH stands for the capacity capable of one ampere current for one h...

Page 21: ...re with different cross sectional areas and varied resistances Cross sectional araa No of 1 Alloweble j COIldUCtO current conductor i Rasistanca diameter Current I mm2 j A j No mm a lOOm 1 1A 3A 5A 8A 10A i 12A 1 15A I 0 75 7 3010 18 2 477 2 5V 8V 12 5V _ I j I 1 25 12 5010 18 1 466 1 w 5v i 7 5V 12v 15v 18V i 17 I I I b 2 0 37 0 26 0 952 1v 3v 1 5V 8V 1ov i 12v 15v d 0 z 3 5 23 4510 32 0 517 j 1 ...

Page 22: ...ble range for the DC voltmeter is from 0 to 20V 7 l 2 AMMETER Both AC and DC ammeters are necessary The AC ammeter must have a scale range from 0 to approximately 15A and the DC ammeter also must have a scale range from 0 to approximately 15A 7 l 3 FREQUENCY METER The frequency meter must have a scale range from 45 to approximately 65 Hz Note Note the input voltage range for the frequency meter Fo...

Page 23: ...d for measuring resist ance and others I Fig 7 l 4 7 l 5 MEGGER TESTER This unit measures insulation resistance of the generator Use one with voltage capacity of 5oov 7 l 6 TACHOMETER Use the contact less type tachometer Fig 7 l 5 I 1 Fig 7 l 6 19 ...

Page 24: ...A by adjusting the load to the generator If the voltage is within the range from 1OVto 14V the voltage output is normal Note If a battery is connected as a load to the generator the DC output voltage will increase by approximately 1 to 2V Therefore carefully observe the electrolyte level and don t overcharge the battery 7 4 MEASUREMENT OF INSULATION RESISTANCE 7 4 l TO MEASURE INSULATION RESIST AN...

Page 25: ... slip rings of the rotor and the core If there is a section where insulation resist ance is below lMS2 replace the part because it may cause insulation failure or such accidents as electric shock or leakage 7 4 4 CONTROL PANEL Measure the insulation resistance between the charging section a part where electric current flows and the grounded part If there is a section where insulation resist ance i...

Page 26: ...r by using a circuit tester under the condition that the circuit breaker is mounted on the control panel If continuity is confirmed when the breaker is ON and no continuity is confirmed when the breaker is OFF the circuit breaker is normal Fig 8 I 1 b 8 FUNCTIONAL CHECK OF EACH COMPONENT 8 1 CONTROL PANEL 8 l l AC RECEPTACLES Check continuity between the two terminals at the rear of the AC recepta...

Page 27: ... continuity is confirmed as follows I Connect black s terminal of the circuit tester I I Yellow White Orange Brown No continuity Continuity Connect red 0 terminal of the circuit tester I Table 8 2 1 Note 1 In checking the diode direction of connection is contrary to the ordinary case because of characteristics of the diode and battery incorporated in the tester Note 2 Continuity means forward dire...

Page 28: ...ne of the AVR In the normal case the measured values should be as shown below Fig 83 Wire color Yellow Connect to the 8 terminal of the circuit tester Red White Green Black 5 E E sx W W fE OE CL t s Eg 6 1 m 1 600K 1MR 1 75K 120KS2 Yellow ft I zr ding 7K lOKS2 I 4 1 400K 500KR 4 4 4 250K 300KR 400K 5OOKS2 120K 130KS1 j I 2OOK 220KR 250K 300Kn 7 45K 5OKR 4 500K lMS2 75K 110KR 7K 9KQ 1 400K 500KS1 4...

Page 29: ...iring color White Red 1 White Yellow White Green 50Hz IOOV 0 951 0 32Q 4 452 60Hz 1oov 0 6 0 23 3 6 50Hz I IOV 1 2 0 44 I 4 4 60Hz 1IOV 0 9 I 0 32 3 6 60Hz 120v 0 9 0 32 I 3 6 50Hz 220V 5 0 0 70 I 4 4 60HZ 220V i 3 5 0 42 3 6 50Hz 230V 5 0 0 70 4 4 50Hz 240V 5 0 0 70 I 4 4 Note Sometimes the measure values do not match the values shown in the table above becauseof errors by the circuit tester unev...

Page 30: ...and output can not be obtained In this case sand around the slip ring with fine sandpaper Note Whensandpaper is used be careful not to damage the coils of the rotor Stlip Slip Ring F T 8 S 1 Fig 8 5 2 8 6 BRUSH If the surface of the brush contacting the slip ring is smooth it is normal If not make it smooth with sandpaper Unless the surface is smooth an arc may be generated between the brush and t...

Page 31: ...use of errors by the circuit tester unevennessof coil winding or peripheral temperature 8 8 EXCITING COIL Measure resistance of the exciting coil and voltage at the rated rpm with a circuit tester Resistance value Voltage AC I at rated rpm 1 Measurement location I I 10 Q3ov Between the terminals of the I i exciting coil Note The measured value does not always match the values shown in the table ab...

Page 32: ...isplaced or installed incorrectly place them temporarily at their original positions 4 Handle the disassembled parts with care and clean them before reassembly using neutral cleaning oil Be careful not to clean electric parts with neutral cleaning oil 5 Useproper tools for disassembly assembly 9 2 SPECIAL TOOLS FOR DISASSEMBLY ASSEMBLY Fig 9 2 No i Tool No Tool name Description 2099500407 1 Flywhe...

Page 33: ...ssary I tools 1 1 Side cover 1 First remove the side i I 0 Plus screw cover by unscrewing I driver I I four M5 x 8 screws I 2 Rear cover i 1 Remove the rear cover by Plus driver unscrewing three MSx 8 screws and two M8 x 10 I I screws I I Rear Cover M8x 10 Screw Side Cover Fig 9 3 l 29 ...

Page 34: ...ion I Precautions Necessary I I I tools 3 icontrol I l Pull the knob of the I 1 panel 1 Plus driver I control lever and remove I I the control panel by un I I I screwing four M5 x 8 I screws I I I I I I Knob L Control Lever by Fig 9 3 2 30 ...

Page 35: ...gs i 1 Pull the couplers generator coupler from while pushing the Discon the other 6P coupler Iretainer claws jnection 1 I extending from the control panel I 2 Disconnect the 4P coupler I I of the AVR from the 4P I coupler extending from the control panel i 3 Remove the plug for grounding i i I I I I 1 I I I Fig 9 3 3 ...

Page 36: ...recautions I Necessary I tools 5 iFront cover 1 Remove the element 0 Driver cover by unscrewing the M6 x 12 screw 1 I 2 Remove the front cover 1 I Driver by unscrewing three I I M5 x 8 screws M6x12 Screw Front Cover M5x8 Screw 3 PCS FJ 9 3 5 32 ...

Page 37: ...scon inection the gasoline from inside the fuel tank 2 With pliers hold the fuel Be careful not to Pliers pipe clamp which is in damage the fuel serted in the fuel strainer pipe and pull it forward to remove the fuel pipe from the strainer I I 3 Disconnect the plug re 1 ceptacle of the engine from the plug of the AVR I Pipe Clamp Strainer FI 93 6 33 ...

Page 38: ...the breather pipe for air ventilation I 3 Remove the handle body by 113m m box taking off the two M8 nuts i Lpanner 8 Fuel tank i 1 Remove the two M6 x 12 10 m m box flange bolts clamping the I spanner I blower housing I 2 Remove the fuel tank by taking off the two M8 nuts from the bottom of the 13 m m box spanner I tank I I Handle Cover M3xlO Screw 2 PCS M8 nut 2 pcs 7 gfiJpcp 2 piy M6xl2 Flange ...

Page 39: ... 11 IBrash holder 1 Remove the brash holder If the rear bracket Driver I fitted to the brash holder 1 is removed from the I baseby unscrewing the two igenerator without jremoving the brash M5 x 20 screws holder the brash i I may break Always I iremember to remove the brash holder 1 1 2 Remove the connector I In assembling be icareful that the I 1 wiring is properly connected M5x20 Screw 2 PCS Brus...

Page 40: ...6 bracket bolts spanner i 2 Remove the rear bracket a tapping it evenly with a plastic hammer I SeeFig g 3 10 I i Plastic hammer I I I 3 Remove the connector of Be careful to make j the d e stack and then irregular wiring in remove the lead from the assembling I I I rear bracket clamp I 1 Rear Bracket Diode Stack Fig 9 3 9 Plastic Hammer 36 ...

Page 41: ...r I I 1 I c 1 Pull away the stator cover i 2 Pull away the stator from 1Never pat the wind plastic hammer the front cover If it is impossible pull it away ing and the lead I tapping outside the core 1 with a plastic hammer SeeFig 9 3 12 I I I Stator Stator cover Fig 9 3 l 1 F 9 3 12 ...

Page 42: ...irection with a I hammer to loosen the I I through bolt thus keeping a2 3 mm clearance be 1 tween them See Fig 9 3 14 I 2 Hit the through bolt head Never hit the slip Plastic hammer I with a plastic hammer to ring and the winding I loosen the crank shaft and sections Whenhit i the rotor shaft taper 1ting the through I I Then remove the rotor Ibolt hit it straight I See Fig 9 3 15 I jso as not to b...

Page 43: ...recautions Necessary tools I I 15 jFront 1 Remove the front bracket i 13 m m box ibracket which is mounted on the I I main bearing cover of the spanner I 1 engine by taking out four I I I MSx 18 bolts Main Bearing Cover Front Bracket Fig 9 3 76 39 ...

Page 44: ...equence remOve I Description I I I Precautions I Necessary tools 16 Recoil j l Remove the recoil starter 10 m m box mstarter by taking out the four 1 spanner 1 M6 x 8 flange bolts I 1 I RecoilvStarter Fig 9 3 77 40 ...

Page 45: ...out taking out the two M6 x 12 1when the fuel tank spanner I I flange bolts i is removed are not I I included 18 Head cover I l Remove the head cover I10 m m box cylinder j from the cylinder head and spanner baffle the cylinder baffle from the cylinder by taking out the two M6 x 8 flange bolts I Blower Housing M6xB Flange Bolt 2 PCS M6x12 Flange Bolt 2 PCS M6x8 kange Bolt 2 pcs 1 Fig 9 3 78 41 ...

Page 46: ...one M6 x 10 flange bolt I i 2 Remove the air cleaner The air cleaner case 10 m m box body from the carburetor and the carburetor spanner by taking out the two M6 are clamped toge x 10 flange bolt ther 3 Remove the gas exhaust pipe I Pipe Air Vent Air Cleaner Body M6 Flange Bolt I I Air Cleaner Case I Element Retainer M6xlO Screw Element Element Cover Fig 93 79 42 ...

Page 47: ...ase by taking out the two M8 nuts and Brace nuts 10 m m box one M6 x 12 bolt I I jspanner Muffler Cover nge Bolt 3 PCS M6x12 Bolt Cross Recess I Part to 1 Sequence j remOve Description Precautions Necessary tools 22 Governor lever and its related iparts l 1 Remove the governor lever j from the governor shaft by 110m m box taking out one M6 x 25 IThe bolt has only to Ispanner or bolt ibe loosened j...

Page 48: ...with a hammer moving the nuts and the I spring washer 25 Flywheel 1 Remove the flywheel from i Assemble the tool to Flywheel puller the crankshaft I 26 i cocci n i 1 Remove the ignition plug cap from the ignition plug I I I I and the ignition coil from the crank case by taking pull out the flywheel magneto as shown in Fig 9 3 23 To re move the flywheel turn the central bolt counterclockwise I out ...

Page 49: ... taking taking out the two outside periphery to M6 x 12 flange bolts the front and hook i I 2 Pull out the intake valve the minus driver I and the exhaust valve j medium sizej in the recess lower side i 3 Remove the valve spring Front I and the spring retainer i of the retainer Then pull the spring I 0 Driver I retainer frontward 1 j to remove the valve n i 31 1Main bear 1 Remove the main bearing ...

Page 50: ...amshaft away I Set the crankshaft from the crankcase on its side SO that i j it will not fall and b i damage the tappets 33 Tappet i 1 Remove the tappets from the crankcase a s a E dthe tappets to distin I i guish them from one 1 Intake Valve Valve Spring i i L Governor Gear Camshaft F T 9 3 25 46 ...

Page 51: ...the piston from the cylin I der top I I Piston bc 1 Remove the piston from 1Be careful not to Piston ring the connecting rod edge by i damage the inside i undipping the two piston i of the rod edge pin clips 2 Open the ring joint wide Be careful not to and remove the piston ring open the joint too i i from the piston wide or it will break 36 37 Crankshaft 1 Remove the woodruff key for the magneto ...

Page 52: ... damaged replace it with a new one Also while assembling apply lubricating oil to the lip of each seal Replace the gaskets and other similar items with new ones Check the keys pins bolts nuts etc and replace them if necessary with new ones Apply torque according to the specified rate to those sections where the torque is rated Apply lubricating oil to rotating and sliding parts when they are assem...

Page 53: ...rance between the cylinder and piston skirt 0 02OL 0 059L Clearance between the piston ring joints 0 2L 0 4L 1 i Top ring 0 09OL 0 135L Clearance between the piston rings Second ring 0 060L 0 105L I Oil ring O OlOL 0 065L Clearance between the connecting rod major ring and crank pin 1 Clearance between the internal and s external diameters 0 037 L 0 063 L 1 Side clearance 0 1 L 0 3L Clearance betw...

Page 54: ...to assembly apply sufficient lub ricating oil to the connecting rod minor edge Note Be sure to secure the clips to both sides of the piston pin 3 In setting the connecting rod hold it with a piston ring guide as shown in Fig 9 4 5 or if there is no ring guide tap the piston head with a wooden object pressing the piston ring with a finger tip to push it in Set it to the position of the mark or MA m...

Page 55: ... and sometimes may not run at all SeeTable 9 4 6 Note If the intake and exhaust valves are set in reverse order the tappet clearance will also be incorrect g zq 5g y J f Rd q eyr p gm4 L n I Fig 94 6 9 4 5 MAIN BEARING COVER The main bearing cover is installed in the crankcase Note As the governor gear has been mounted on the main bearing cover it is necessary in setting to confirm that the govern...

Page 56: ...king which is 0 22 mm Main Bearing Cover I Dial Gauge Processing Face of Crankcase Fig 9 4 9 9 4 6 INTAKE VALVE AND EXHAUST VALVE Scrape off deposits such as carbon gum from the valves valve seat intake exhaust ports and valve guide Note If the valve face is worn replace the valve with a new one Valve Guide Puller Note If the clearance between the valve guide and valve stem is too large re place t...

Page 57: ...alve Guide A Valve face angle B Valve seat angle I C Valve guide inside diameter D Valve stem outside diameter Intake valve 1 6 5 1 Exhaust valve i 0 056 6 50 0 078 Clearance between the valve guide Intake valve 0 025L 0 062L and valve stem clearance between C and D Exhust valve 0 056L O lOOL Table 9 4 2 53 ...

Page 58: ... larger than the specified allowance replace the valve with a new one and adjust the clearance using some compound etc Note Install the valve spring retainers after completing adjustment of the tappet clearance Then recheck the clearance Installment of spring retainers Place the retainer using a special tool over the valve stem with the retainer s notch facing towards the front Front 9 4 8 BREATHE...

Page 59: ...ket in this order Then install the air cleaner body and secure it with two M6 flange nuts Also lock the air cleaner body with Ml6 x 10 flange bolts Torque for the air cleaner clamping 70 Q90 kg cm Note Set the control bracket at the position of RUN and then mount it onto the air cleaner 9 4 13 GOVERNOR LEVER The governor used in the engine of this generator is of centrifugal weight type and is joi...

Page 60: ...tle valve has been fully opened and then lock it 5 Insert a driver into the governor shaft groove and turn it clockwise until the governor shaft becomes unable to turn to lock the governor shaft and the governor lever with the governor lever s locking bolt Torque for the governor lever 90 Q110kg cm Speed Control Stop Switch Governor Shaft Choke Lever Governor Lever Choke Spring F 9 b 15 56 ...

Page 61: ... 12 bolt 2 Secure the muffler cover with three M6 x 8 flange bolts Muffler g g M8 Nut Muffler Cover M6x8 Flange Bolt 3 PCs 1 F 9 4 16 9 4 15 AIR CLEANER In the air cleaner body which is fitted to the carburetor set the element retainer element and cleaner case in this order and clamp them with M6 x 10 screws Note Installment of the element cover is done after the front cover has been installed M6 ...

Page 62: ... blower housing and head cover are used when the fuel tank is installed Blower Housing M6x8 Flange Bolt Head Cover 2 PCs 1 I 2 Flange Bolt 2 Clamped with the fuel tank PCs 1 M6x12 Flange Bolt 2 PCS Fjg 94 78 9 4 1 7 RECOIL STARTOR Set the recoil startor with four M6 x 8 flange bolts Note Don t use bolts which are longer than 8mm If used they might run against fans of the flywheel v M6x8 Flange Bol...

Page 63: ...t the cooling air outlet window of the generator is positioned in the upper side and the slit section is positioned in the bottom side 9 4 l 9 ROTOR Mount the rotor onto the taper section of the crankshaft and clamp it with through bolts Note Wipe off well oil or stains from the taper section Main Bearing Cover Rotor Through Bolt Outlet Window Set position Slit Section M8x18 Bolt 4 PCS Fig 9420 59...

Page 64: ... the rear bracket with a plastic hammer Note Set the cable so that it comes out from the bottom of the stator Be careful not to position it between the stator and the rear bracket Fig 94 27 2 Wind the s a t tor cover around the stator Fig 9 4 22 3 Fit the screw boss located in three places of the front bracket with the boss in three points of the rear bracket and clamp them with three M6 bracket b...

Page 65: ...brash holder is inclined to the slip ring the brash holder may break when the screw is clamped or the brash itself may break when the engine is started After the brash holder has been instal led measure the resistance between the brash terminals with a circuit tester If the resistance is from 6 to 13 ohms it is regular I Fig 94 23 3 Insert the connecting terminals of the brash holder as shown in F...

Page 66: ...h four M5 x 10screws 9 4 24 BRACKET COVER Mount the bracket cover and the spacer on the rear cover and clamp them with MSx 30 bolts M5x20 Screw 2 PCS a Brush Holder Rear Bracket Bracket Brush Holde y p h Cover M5xlO Screw 4 PCS I d M8x30 iiolt 2 PCS Ft 9425 62 ...

Page 67: ......

Page 68: ...fuel pipe into the fuel inlet outlet port of the fuel strainer and secure it with the clamp 9 4 28 FRONT COVER AND ELEMENT COVER 1 Secure the front cover on which the AVR and fuel strainer have been mounted with three M5 x 8 screws 2 Secure the element cover with M6 x 12 screws Element Cover M6x12 Screw Front Cover M5x8 Screw 3 PCS FQ 94 27 64 ...

Page 69: ...he coupler 4P thrusting from the control panel 3 Connect the plug for grounding 9 4 30 CONTROL PANEL 1 Thrust the control lever through the control panel and secure it with four M5 x 8 screws 2 Set the knob on the control lever Note After the coupler and plug have been connected and secured to the control panel secure the wire with the receptacle clamp on the control panel Fig 94 28 65 ...

Page 70: ...9 4 31 REAR COVER Secure the rear cover with three Ix 8 screws and two I8x 10 screws 9 4 32 SIDE COVER Secure the side cover with four M 5 x 8 screws M8x10 Screw 2 pcs Rear Cover F 94 29 66 ...

Page 71: ...e pilot jet where the fuel quantity is measured Then the fuel is mixed with air measured in the pilot air jet and is supplied from the pilot outlet by passto the engine Fuel for idling is supplied mainly from the pilot outlet 3 Main System The system supplies fuel for medium and high speedoperations The fuel is measured in the main jet and then flows into the main nozzle Air measured in the main a...

Page 72: ...Schematic Diagram of the Fuel System r By Pass Throttle Valve Pilot Outlet rChoke Pilot Jet i Jet Main Nozzle Main Jet Float Fig 9 5 l 68 ...

Page 73: ...installing the choke shaft be sure to keep the notch of the choke valve in the main air jet side 3 Pilot System Remove the pilot jet 30 Whenremoving it use a proper tool so that the nozzle will not be damaged Firmly fix the pilot jet when assembling the carburetor Otherwise fuel leakage will occur resulting in engine trouble 4 Main System Remove the bolt 18 and the float chamber body 16 Remove the...

Page 74: ...3i I 20 25 184 Fig 9 5 2 70 ...

Page 75: ...ry before restarting the engine 7 Be sure to fill the fuel only up to the level specified at the fuel supply port 8 Whenfilling the fuel tank be careful not to smoke or use an open flame 10 2 PRECAUTIONS FOR EXHAUST GASES 1 Don t use the generator in poorly ventilated places such as an office warehouse narrow tunnel well hold or tank etc If the generator is used in such places as mentioned above t...

Page 76: ...h the fuel exists in the float chamber of the carburetor A 8 A 9 The carburetor is overflooded Sparks do not come out from the tip of the high voltage cord or the sparks are weak if any A 10 Sparksdo not come out or are weak when the ignition plug is connected B Abnormal Running B l B 2 B 3 B 4 B 5 B 6 B 7 B 8 B 9 B 10 B l 1 Compression is insufficient Overheating and knocking of the engine Fluctu...

Page 77: ...nce if the 1 clearance is different from the standard value or replace I In case of sticking supply lubri cating oil onto value stem or re place the valve stem Replace the piston ring when its operational limit is ex ceeded Modify the cylinder bore when opera tional limit is exceeded Tightening in case of insuf ficient clamp ing In case of gasket break age replace it ...

Page 78: ...heck breather pipe check fuel strainer Check the fuel pipe J Confirm condi tion of the cock Checking method Checking criteria Confirm fuel In case the fuel tank is empty supply fuel In case of pipe clogging clean it In case the fuel path is clogged clean or replace it In case water or dust is mixed with the fuel take the contaminatnt away or replace the fuel In case the air stays in the pipe let i...

Page 79: ... Carburetor Packing Carburetor I Packing or clamp ing torque check Checking criteria 1 If the needle valve is contaminated with dust etc clean it 2 In cast the valve does not work well replace the valve If the fuel path is clogged clean it I I X L A 1 1 A iiimlLIIl ry j q pzlzq Fr1 Ilr Replace the packiny or tighten I 1 In case of pack ing failure re place it 2 In case of clamp ing torque fail ure...

Page 80: ... Checking criteria J Check the needle valve I I I 1 When dust etc is on the needle valve clean it 2 If the valve works abnormal ly replace it T _ _ __ If the float is broken replace it Adjust the oil level if it is too high I r l1Ill I check the float Confirm the oil level 1 Remedies 1 ne ree Adjust theoil level 1 1 Replace the float I 1 Check breather pipe Clean the pipe if it is clogged Clean th...

Page 81: ... I Check the air gap Measure resistance valve between the terminals with a circuit tester I the ignition Check plug Exchange the magneto with a new one and restart it Checking met hod Check the ignition Plug cap In case contact with the ignition plug is not normal adjust or replace it I I Checking I criteria 1 In case of insulation failure replace the ignition plug 2 In case of carborn deposit or ...

Page 82: ...ing fin Check the cylinder head muffler and the exhaust hole Check the carburetor I Confirm the load Checking method Confirm the ignition plug In case of fuel path clogging clean it In case of carbon deposit clean it When an ignition plug not specified is used exchange it with a specified one In case of overload modify it to the rated load 50Hz 8OOW 60Hz looow In case the cooling fin is dirty clea...

Page 83: ...ath clogging clean the path bluyylly I l Ul 1 Gasket failure path Mixing rati Clogging or col of air with fuel i laps of fuel path 2 Clamping is too low insufficient I I II 1 Governor weight Governor sleeve 1 Governor spring is defective 2 Hanging posi tion is not normal 1 Abration 2 Abnormal operation Check governor weight and gover Check the Check the fuel carburetor path Check the gasket or the...

Page 84: ...is different from the standard adjust the clearance or replace it Normal 0 1 O O2mm I Carburetor Air cleaner Mixing ratio of air with fuel is not normal I Check the carburetor or the air cleaner In case the mixing ratio of air with fuel is abnormal adjust the mixing ratio or clean the carburetor and the air cleaner r Muffler Exhaust valve G Carbon deposit Chock the muffler and the exhaust valve In...

Page 85: ...ng i criteria Measure tappet clearance If the clearance is different from the standard adjus the clearance or rc place the tappet Normal 0 1 O O2mm I 1 I I I I Remedies Adjust the tappet clearance or replace the tappet Check the jets 1 In case of jets failure replace them 2 In case of clamp ing failure tighten it again Check the fuel In case water is mixed the fuel replace the fuel ...

Page 86: ...re tappet clearance Check the bearing surface Check the jets Check the fuel Check the element 1 If the clearance is different from the standard adjust the clearance or replace the tappet Normal 0 1 O O2mm 1 In case the jets are defective re place them 2 In case of clamp ing failure tighten it again In case the fitting of the valve seat is insufficient adjust it or replace the valve seat In case of...

Page 87: ... the adherence piston ring adjust or is built in replace the improperly piston ring rearrange it If the clearance is not within the range of opera tional limits re J place both the intake exhaust valve and the guide In case of abnormal operation pour lubri cating oil onto the valve or re place the gas vent valve l I In case there is too much oil adjust it to the rated level Normal 6OOcc I In case ...

Page 88: ...normal running 7 The lubricating oil becomes diluted and its consumption rate increases I bolts and nuts become lower Burning or n breakage r Carburetor I Cylinder Piston Piston ring I Fuel In case of burning or breakage adjust or replace them Mixing rate is too high md al the same time the cngino has tmen run 100 long under a light lord ve replace them Abrasion 1 If the measured valves are not wi...

Page 89: ...Abrasion of the 1 Confirm contact condition of the slip ring 2 Measure length of the brush 1 In case of conta mination clean the brush 2 In case the brush is shorter than the standard one replace it with a regular one Clean or replace the brush l 7 Slip ring I J 1 Contamination of the brush s contact surface 2 Abnormal abrasion of the slip ring Confirm condition of the brush s contact sur face 1 I...

Page 90: ...circuit tester Measure with a 6P coupler In case of 1 Disconnection In case of OS1 Short circuit I Measure resistance value between the terminals with a circuit tester Measure with a 6P coupler In case of OQ Sl In case of 00dl Disconnection Disconnection In case of On In case of OS1 Short circuit Short circuit Measure resistance value between the slip rings with a circuit tester Measure the resist...

Page 91: ... In case of OQ bl Disconnection In case of Oil Short circuit rReplace the stator I Confirm continuity between the terminals with a circuit tester Refer to 8 2 Diode stack Replace the diode stack Measure continuity with a circuit tester In case of 00 51 the lead line is defective Replace the lead line Measure resistance value between the terminals with a circuit tester Measure with a 4P coupler If ...

Page 92: ... a circuit tester Measure with a 6P coupler I In case the measured resis tance is lower than 15 of the standard it suggests a short circuit Measure resistance between the terminals with a circuit tester Measure with a 6P coupler In case the measured resis tance is lower than 15 of the standard it suggests a short circuit Measure resistance value between the slip rings with a circuit tester 1 In ca...

Page 93: ... length of the brush 1 If contact surface of the slip ring is contaminated clean it 2 If the brush length is shorter than the standard replace it Measure resistance between the terminals with a circuit tester Measure with a 4P coupler If the measure resistance is different from the standard replace the AVR Measure rpm at the rated load 50Hz 3000 30rpm 60Hz 3600 30rpm Measure continuity with a circ...

Page 94: ... 0 020 0 059 0 25 ftip om Cylinder gauge and micrometer i Rep acement I in thrust 1 direction I 0 090 0 135 0 15 i Searcher Replacement 0 060 0 105 0 15 i Searcher Replacement 0 010 0 065 0 15 I Searcher Replacement Clearance between piston and piston pipe i 0 009T O OlOL 0 06L Cylinder gauge Replacamant r and micrometer Joint gap Top I 0 2 0 4 Second i 02 0 4 1 5 r Searcher 1 5 Searcher I Replace...

Page 95: ...enter I 1 Replacement Intake and exhaust valve guide Exhaust 0 056 0 100 j 0 3 I Cylinder gauge i Replacement falve Tappet Intake i 0 08 0 12 0 05 0 25 8 Searcher Replacement 1 clearance I Exhaust 0 08 0 12 0 05 0 25 1 Searcher i Replacement Clearance between groove and retainer Intake 0 1 0 3 0 5 Exhaust 0 1 0 3 0 5 I Slide calipers Replacement Slide calipers Replacement Valve stem end length Int...

Page 96: ...aring cover bolts kg cm 805100 Cylinder head bolts kg cm 190 230 Spark plug Air cleaner nuts Governor level nuts I kg cm j 230 250 kg cm i 70 90 kg cm go 110 I Rotor bolts kgcm 100 150 I Muffler nuts kg cm I 70 90 Front cover bolts kg cm I 1202140 I Flywheel nuts kg cm 1 600 650 j I 1 I I I Rear bracket bolts kg I 55 75 I I I I 92 ...

Page 97: ...AC Circuit Breaker AC Receptacle Generator ntroI Panel Engine Spark Plug i LT Tw Yellow I I mm I I il Diode Stack Assy Rectifier Ground Terminal I I Wire code I Cross section of wire I Magneto Exciting Coil I I 0 75 mm2 I I em l 1 25 mm2 I 93 ...

Page 98: ...e Should leakage be detected tighten or re i place the defective parts Check each part for looseness and 1 3 If the parts are loose vibration will tighten it if necessary I occur and may damage the generator Check quantity of oil in the crank 1 4 If the engine is run with a shortage of caseand fill oil if necessary oil it will burn and damage the gene rator 14 2 CHECKS AND MAINTENANCE FOR EVERY 20...

Page 99: ...lear ante 4 Replace the ignition plug I 14 5 CHECKS AND MAINTENANCE FOR EVERY 1000 HOURS ANNUALLY I Checks and maintenance items Description 1 Overhaul the engine for cleaning 1 Engine troubles such as power output adjusting and replacing parts I decline will be caused 2 Replace brush of the generator 2 and 3 3 Check rotor and stator of the gene Power output will decline rator 4 Replace the fuel p...

Page 100: ... loosenessand tighten them more if necessary Set the engine switch at the STOP position Pull the starting nob of the recoil starter and leave it at the position where some load is felt After cleaning the generator well wipe it with a cloth and use an anti rust spray on it Cover the engine with veneer etc and store it in a place with low humidity Note Be careful when draining fuel from the fuel tan...

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Page 102: ...MD GS0095 1 FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS DIV 2ND Subaru Bldg l l Choume Miyahara cho Omiya shi Saitama 330 0038 Japan PHONE Omiya 48 653 5811 FACSIMILE Omiya 48 653 5691 PRINTED IN JAPAN 198444 ...

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Robin America R1200, Service Manual

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