Generator Technical Data & Overhaul Instructions SERVICE MANUAL ...

CONTENTS Section Title Page 1. SPECIFICATIONS ....................................... 1 2. PERFORMANCE CURVES ................................ 2 2-1 AC Output ........................................ 2 2-2 DC Output ..................

Section Title Page 11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 1 1 - 1 Engine does not start or engine does not run normally. . . . . . . 63 11-2 Voltmeter does not work or pi...

1. SPECIFICATIONS ENGINE I Type 1 Forced air-cooled, &troke, side valve, I gasoline engine I Displacement 78 cc (4.76 cu. in.) , Fuel tank capacity 1 2 lit. (0.53 U.S. gal.) I Oil pan capacity I 350 cc (0.75 ...

2. PERFORMANCE CURVES 2-l AC OUTPUT HZ > 2 i W a LL I v W > a !i 2 t 62 61 60 59 52 51 50 49 240 230 220 210 w I 5 “c 2 600 500 400 300 ” 0 0.5 1 1.5 2 2.5 CURRENT - A . 50Hz/60He220V Ty...

3. FEATURES l Exhaust Fan Cooling System for low body temperatures, low noise, longer engine life and reliable per- formance. 0 Large 78 cc 4-Stroke Engine provides enough power for constant 55OW (at 60 Hz) rated output. 0 Simple One...

4. GENERAL DESCRIPTION OF THE GENERATOR 4-1 COMPONENT IDENTIFICATION HANDLE MUFFLER COVER MUFFLER ENGINE Fig. 4- 1 FUEL TANK AIR CLEANER AIR CLEANER COVER GENERATOR Fig. 4-2 ...

RECOIL STARTER FREQUENCY ADJUSTING UNIT (60Hz:120V TYPE1 Fig. 4-3 MUFFLER COVER FREQUENCY CHANGEOVER UNIT l50Hz~60Hz VARIABLE TYPEI Fig. 4-4 -5- ...

FRONT HOUSING RECOIL STARTER CARBURETOR Fig. 4-5 RUBBER PIPE (FOR AIR VENT) :E WIRE BASE PLATE Fig. 4-6 -6- ...

4-2 LOCATION OF SERIAL NUMBER, SPECIFICATION AND SPECIFICATION NUMBER The serial number is stamped on the crankcase at the opposite side of the carburetor and also stamped on the label stuck above the oil filler cap. The specification an...

5. CONSTRUCTION AND FUNCTION OF THE GENERATOR 5-l CONSTRUCTION FUEI TANK - SPARK PLUG THROUGH BOLT CYLINDER CRANKCASE RECOIL STARTER , I R n _ i I ~!ll::iill:!;ill:;il!l, CRANKSHAFT BALL BEARING ’ ’ FIELD CO...

5-2 FUNCTION OF EACH COMPONENT 5-2-l GENERATOR (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 ...

5-2-2 ENGINE (1) CYLINDER and CRANKCASE The cylinder and the crankcase of the engine are of a one-piece aluminum die-cast design. The cast iron cyl- inder liner is molded inside the cylinder. Both the intake and exhaust ports are p...

(11) IGNITION A flywheel/magneto igntion system is employed with the ignition timing set at 23” before top dead center. The magneto is composed of the flywheel and ignition coil with the flywheel mounted on the rotor shaft. T...

5-3 DESCRIPTION OF GENERATOR OPERATION INITIAL EXCITATION STATOR PERMANENT MAGNETO FIELD COIL ROTOR ----- --- DIODE CONDENSER COIL L ------ A Fig. 5-6 5-3-l GENERATION OF NO-LOAD VOLTAGE 1) 2) 3) 4) When the generator ...

5-3-3 DC OUTPUT DC output is taken out from the main coil and is fed to the diode at which time the output undergoes full-wave rectification prior to being supplied to the load connnected to the generator. The diode recti- ...

5-4 ELECTRONIC IGNITION SYSTEM The electronic ignition system features a power transistor as the current control element. Therefore, the igni- tion system is an electronic contact point-free type that operates with the power transistor...

6. SAFETY PRECAUTIONS 1. Use extreme caution near gasoline. A constant danger of explosion or fire exists. Do not fill the fuel tank with gasoline while the engine is running. Do not smoke or use open flame near the fuel tank....

7. RANGE OF APPLICATIONS 7-1 AC OUTPUT Generally, the rated power of an electrical appliance often refers to the amount of work that can be done by it. The electric power required for operating an electrical appliance is not al...

(5) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a case, power consumption is to be worked out a...

Nominal cross Table 7-2 Voltage decrease indicates as V = -&- xRxIx!J R means resistance (a! 100 m) on the above table. I means electric current through the wire (A). Q means the length of the wire (m). The length of the wire ind...

7-2-3 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. 7-2-4 SIMULTANEOUS USE OF THE AC/DC OUTPUT If you ...

8-1 MEASURING INSTRUMENTS 8-l -1 VOLTMETER AC voltmeter is necessary. The approximate AC volt- age ranges of the voltmeters to be used for various types of generators are as follows: oto150v : Type with an output voltage of 11OV ...

8-1-4 CIRCUIT TESTER Used for measuring resistance, etc. 8-l-5 MEGGER METER Used for measuring generator insulation resistance. Select one with testing voltage range of 5OOV. 8-1-6 TACHOMETER Use a contact-less type tachometer. Fig...

8-2 MEASURING AC OUTPUT TO A Fig. 8-7 With the circuit shown in Fig. 8-7 , measurment is made of the AC output of the generator. An electric heat- er or an incandescent lamp with a power factor of 1 .O is suitable as a load for the g...

8-4- 1 STATOR Measure the insulation resistance between the RED lead and the core. The resistance should be larger than 1 Ma. If the resistance is less than 1 Ma, the insulation is failed. Replace the stator with a new one. 8-4-Z ROTO...

9. CHECKING FUNCTIONAL MEMBERS 9-l CONTROL PANEL 9- I- 1 ENGINE SWITCH Using a circuit tester, check continuity across the black and green top terminals of the 6P coupler. When continuity between the terminals is confirmed with ...

9-1-4 AC RECEPTACLES Using a circuit tester, check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel. When continuity is confirmed between the output termin...

9-2 STATOR Measure the resitance of each stator coil using the circuit tester. 240V - 50160Hz 12.OQ Table 9- 7 0.7R 8.1!iI 7.3i-l (at 21’C) NOTE: If the circuit tester is not sufficiently accurate, it may not show the va...

AC COIL DC COIL / f- F/Q. 9-7 CONDENSER COIL FOR 60Hz FOR 5OHz ORANdE , Fig. 9-8 - 27 - ...

9-3 ROTOR 1) Unsolder the diode and the resistor from the ro- tor terminal. Unsolder one wire of each part. E RECTIFIER 2) Check the resistance between the wire ends of rotor winding at the terminals. 3) Check the diode. I N...

9-4 IGNITION COIL Using a circuit tester, measure the resistance of the ignition coil. Primary coil Secondary coil RESISTANCE VALUE MEASUREMENT LOCATION 0.61S2 Between the core and the green cord 7.5kR Between the green cord...

9-7 MICRO-SWITCH Check the micro-switch using a circuit tester. Pushed in 00 0 out 0 Do BUTTON F&. 9- 14 - 30 - ...

10. DISASSEMBLY AND ASSEMBLY 10-l PREPARATION AND PRECAUTIONS 1) Be sure to remember the locations of individual parts when disassembling the generator so that the gen- erator can be reassembled correctly. Tie tags noted with the ...

10-3 DISASSEMBLY SEQUENCE step Part to remove Description Precautions Necessary tools 1 Side cover (L) and (R) ’ (1) Remove both left and right cover 0 + Plus screw-driver by taking out eight MS flange screws. 2 Couplers...

r Step Part to remove Description Precautions Necessary tools 3 i Choke cable , (1) Set the control switch to STOP and disconnect the choke cable from the lever. i (2) Disconnect the outer cable of the (See Fig. 10-3.) 10 m...

Step Part to remove Description Precautions Necessary tools 5 Fuel tank handle (1) Push up the end of the cover fitted to the handle with finger. (2) Pull out the rubber tube used as the air vent pipe. (3) Remove two bolts ...

Step I Part to remove Description 8 Front cover (1) Remove two M5 flange bolts clamping the front cover to the base, and remove the front cover. Precautions ti 10 mm box spanner 9 Fuel hose 7- (1) Using pliers, hold the ...

Step I Part to remove I 11 Muffler cover and muffler 12 Base plate Description Precautions Necessery tools (1) Remove the outer cover; this is done by removing seven M5 tapping screws. (2) Remove one M6 x 12 flange bolt of ...

Step Part to remove Description Precautions Necessary tools 13 Recoil starter (1) Remove the recoil starter from the rear housing by removing (See Fig. 10-9.) 10 mm box spanner three M6 x 8 flange bolts. 14 Starter pulley (1)...

Step Part to remove Description Precfhutions Necessary tools 15 Stator assembly (1) Remove three M6 x 85 bolts clamping the rear housing of the 10 mm box spanner stator assembly and the front housing together. Disconnect six wir...

Step Part to remove Description Precautions Necewary tools L I l6 Rotor assembly (1) Insert a rotor-puller into the Rotor puller rotor shaft and tighten it until the rotor comes loose. 17 Spark plug cap (1) Remove the plu...

Step Part to remove Description Precautions 19 Air cleaner (1) Remove the center screw of the air cleaner cover to remove the cleaner cover, filter element, and element retainer. 1 (2) R emove the M5 screw at the lower I right ...

Step Part to remove Description Precautions Necessary tools 20 Governor and related (1) Remove the governor lever from Loosen the bolt 10 mm box spanner parts the governor shaft. (unnecessary to remove it). (2) Remove the govern...

Step Part to remove Description Precautions Necessary tools 23 Head cover (1) Remove two MS screws from the lateral side of the head cover to 0 t Plus screw-driver remove the head cover. 24 Cylinder baffle (1) Remove the MS ...

Step Part to remove Description Precautions Necessary tools 25 Spark plug (1) Remove the spark plug from the cylinder head. 19 mm box spanner 26 Cylinder head (1) Remove the sen M6 x 32 bolts to remove the cylinder head. (2)...

Step Part to remove Description Precautions Necessary tools 28 Main bearing cover (1) Remove the Woodruff key from the crankshaft. (2) Remove five M6 x 25 bolts lock- ing the main bearing cover from the crankcase. 10 mm box spa...

Step Part to remove Description Precautions Necessary tools 31 Connecting rod and (1) Scrape off the carbon deposits Confirm the mounting piston from the cylinder and piston head. direction of the oil @Minus screw- driver P...

I Step I Part to remove 33 Crankshaft ( 34 / Governor shaft Description 11) 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 face, ...

10-4 ASSEMBLY PROCEDURE 10-4-l PRECAUTION IN ASSEMBLY (1) Thoroughly clean each part. When cleaning, take special care for the piston, cylinder, crankshaft, con- necting rod, and bearing. (2) Be sure to completely remove the carbo...

l TOLERANCE OF NEWLY INSTALLED PARTS Thrust directional tolerance between the cylinder and piston skirt I 0.008L - 0.047 L I I Top ring I 0.2 L - 0.4L I Clearance of piston ring joint Second ring 0.2L - 0.4L Oil ...

(4) INSTALLING THE CRANKCASE The connecting rod is put into the cylinder while holding it with the piston ring guide, as shown in Fig. lo- 16 (in the case that a piston ring guide is not available, press rings inward with fing...

(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...

(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 ...

(9) TAPPET ADJUSTMENT Set the tappet at the lowest 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. 10-24.) NOTE: As with the i...

(13) INSTALLING THE HEAD COVER The head cover is installed over each of the left and right parts of the cylinder head, using the M5 x 10 mm screws. (14) INSTALLING THE GOVERNOR AND RELATED PARTS Model EY08D has a centrifugal weig...

(15) INSTALLING THE CARBURETOR AND AIR CLEANER Place the carburetor gasket, insulator, gasket, and carburetor in the correct positions. Next, fit the air cleaner gasket and air cleaner case, and install them, using the M6 nut and MS x 1...

(21) INSTALLING THE STARTER PULLEY Install the starter pulley to the rotor shaft using the rotor through bolt. Torque for the through bolt: 100 - 150 kg-cm (22) INSTALLING THE RECOIL STARTER Install the recoil starter to the re...

(28) INSTALLING THE FRONT COVER Using two M6 x 8 mm flange bolts, install the front cover assembled with the control panel to the base plate. Keep the engine switch set at STOP. (29) INSTALLING THE FUEL TANK a) Keep the straine...

(35) INSTALLING THE LEFT SIDE COVER Pull out the starter handle through the cover and install the left side cover to the generator with four M5 flange screws. (36) INSTALLING THE RIGHT SIDE COVER Fit the foam rubber stuck...

10-5 CARBURETOR 10-5-l FUNCTION AND COMPONENTS (See Fig. 10-32) (1) FLOAT SYSTEM The float chamber is located directly under the carburetor. Float and needle valve maintain a constant fuel level inside the float chamber. The ...

(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 system operates with the fuel flowing through the main jet nozzle and up to the pilot jet...

(5) FLOAT SYSTEM Pull out float pm (12) and remove float (11) and needle valve (20). l Avoid using a drill or a wire to clean the fuel passages (they may damage the orifice of the pilot and main jet nozzles). Use compressed air. ...

10-6 FREQUENCY CHANGEOVER SYSTEM (50 Hz/60 Hz Selectable Type) 10-6-l CONSTRUCTION AND FUNCTION When the control lever (13) is turned to upper position, the lever (12) is pulled back by the governor spring (10) to decrease the spr...

GOVERNOR SPRING (10) LEVER (12) CAM (14) CONTROL LEVER (13) ADJUSTING SCREW (22) (FOR 6OHz) ADJUSTING SCREW (211 [FOR 5OHz) MICRO-SWITCH (18) Fig. lo-35 10-6-Z DISASSEMBLY 1) Unhook the spring ( 16) and remove the control ...

Il. TROUBLESHOOTING In troubleshooting the generator, you will encounter certain categories of problems. It is important to check each component step by step.You will certainly find the cause of any trouble through a systematic Trouble...

NORMAL RESISTANCE CORE-GREEN WIRE I 0.75R I ll-l-2 CHECK THE FUEL SYSTEM. (1) CHECKING THE FUEL IN THE FUEL TANK Fig. 11-2 Deteriorated fuel or the water mixed in the fuel causes bad starting. If the fuel is deteriorated ...

(3) CHECKING THE CARBURETOR n Remove the carburetor from engine. n Remove the float chamber from the carburetor and check to see if the main jet or the pilot jet has been clogged up. (Refer to Section 10-5-2 on page 59.) Use a...

11-2 . VOLTMETER DOES NOT WORK OR PILOT LAMP DOES NOT TUNR ON. l NO AC OUTPUT (1) Normal voltage at wzeptacle? l (Run the engine.) Measure the voltage at AC receptacle with a circuit tester, while the engine is running at ...

n Usually the instrument is expensive and difficult to obtain, we suggest instead that you install a new con- denser and see if the generator works. If the generator works with a new condenser, the old one is defective. (6) Check the r...

n Check the resistance of the resistor. 1 NORMAL ;;,EISTANCE 1 n Check the diode. Touch the positive (RED) probe of the circuit tester to the cathode mark side of the diode, and touch the negative (BLACK) probe to the other ...

11-3 NO DC OUTPUT ( 1 ) Check the DC circuit breaker. rn Examine the DC circuit breaker to make sure it is in the “ON” position. * Sometimes, when a battery with a large capacity is being charged, the charging current excee...

(4) Check the generator insulation. l (Stop the engine.) Measure the insulation between the live part (AC receptacle) and the ground terminal. Any part with an insulation resistance of less than 1 MSt has faulty insulation that coul...

12. CIRCUIT DIAGRAMS 50Hd60Hz VARIABLE TYPE ,Rectifrer ,Circurt breaker ,Resistor -fYI /.I - ,.’ 1 [ 1 72’ n 1 receptacle Condenser’ I I- I--~- coil (yellow) DC I-1 Condenser Spark plug 220, 240V 1 white/green...

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1 ISSUE EMD-GS0455 ] @FUJI HEAVY INDUSTRIES LTD. INDUSTRIAL PRODUCTS DIV. 2ND Subaru Bldg. I-1, Choume, Miyahara-cho, Omiya-shi, Saitama 330-0038, Japan PHONE ; (Omiya 48) 653-5811 FACSIMILE ; (Omiya 48) 653-5691 PRINTED IN ...