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Rozh -J) &ii
Generator
Technical Data & Overhaul Instructions
SERVICE MANUAL
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FOREWORD This manual was compiled for dealers’ mechanics and includes descriptions on specifications, items, performance, structure, features, and maintenance procedures of the R1200 Generator. We ask each dealer to master the contents of this manual and provide users complete service after sales or proper guidance on how to use this generator. This manual includes only brief descriptions on important points, so we ask you to supplement this with your own experience and determination in p
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CONTENTS Section Title Page SPECIFICATIONS ................................................... 1 1. 1-1 items ....................................................... 1 2 1-2 Performance Curves ............................................. FEATURES ....................................................... 5 2. ........................................ 6 3. COMPONENT IDENTlFlCATlON ..................................... 7 4. FUNCTION OF EACH COMPONENT 4-1 Generator .......................
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Section Title Page 9. DISASSEMBLY AND ASSEMBLY ....................................... 28 9-1 Preparation and Remarks .......................................... 28 9-2 Special Tools for Disassembly/Assembly ................................ 28 9-3 Disassembly Sequence ............................................ 29 9-4 Assembly Procedure ............................................. 48 9-5 Carburetor ................................................... 67 10. SAFETY PRECAUTIONS. ..........
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1. SPECIFICATIONS l-l ITEMS I Model R1200 Forced air-cooled, 4-stroke, side valve, gasoline engine Engine: Type I Displacement 143 cc (8.73 cu. in.) Fuel tank capacity 3.5 lit. (0.93 U.S. gal.) , Oil pan capacity 600 cc (1.28 U.S pints) I I I Solid state ignition Ignition system Starting system i Recoil starter I I Rated continuous I Approx. 4 hours Approx. 3.5 hours operating hours I I 2-pole, revolving field type Generator: Type Exciting system Self-exciting I I
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1-2 PERFORMANCE CURVES AC OUTPUT Power Factor . . . . . . . . . . . . . . . 1.0 1 ’ ’ I Output Max. ............... 1000 w ‘;; 1 1 1 1 1 ! output i I Rated ........... 800 W 1000 Frequency .................. 50 Hz 0’ -I 50 s Voltage ..................... 220 v z 49 800 I E IA z 600 s z P 240 & t 230 400 2 2 z 220 > 210 200 n 0 1 2 3 4 5 ” Current (A)- Output Max. ................ 1000 W 52 800 W Rated ........... 51 1000 .................. 50 Hz Frequenc
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............... Output Max. 1000 W ;;; 52 I ........... Rated 800 W 51 51 1000 .................. Frequency 50 Hz 0” -I E Voltage ..................... 110 v 50 50 ?T 49 49 800 t L z z 600 600 s s 0. B 3 120 120-- 400 3 . llOr 110 100 200 0 0 2 4 6 8 10 Current (A)- Output Max. ............... 1200 w Rated ........... 1000 W .................. 62 Frequency 60 Hz 1000 ..................... Voltage 110 v 60 800 61 f 59 z 600 s Q 5 120 400 0 110 10
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........... 1200 w Output Max. G 1000 W I Rated ...... ............. 60 Hz 62 1000 Frequency 0” ............... 12ov -1 Voltage f 61 E 800 t 60 lt z 59 600 s z P s 8 I 400 0 130 2 120 s 200 110 0 8 10 0 2 4 6 Current (A) - DC Output DC output from this generator is rated especially for charging batteries. When the rated current (8.3A) flows into a battery the voltage is 12V, but the voltage becomes higher when the load is smaller (or when the current is small
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FEATURES 2. (1) Weight of this compact generator with excellent portability is 27.5 kg, which means that the generator is the lightest one in this class. (2) This generator with an excellent high performance engine and a large size 3.51i fuel tank can run continuously for about 4 hours (at the rated load of 50 Hz). (3) The operating system is concentrated on the front panel, which enables users to easily handle this generator. (4) Operations of choking, running, and stopping the engine c
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COMPONENT IDENTIFICATION 3. Engine Control Switch (CHOKE-RUN-STOP) DC Circuit Breaker \ / rter Recoil Starter crew Ground Terminal / Muffler / ,,.,.,rnal) ler / Air Cleaner Cover Fig. 3-1 , Carrying Handle Cover, Spark Plug Tank Cap Fuel Tank Fig 3-2 -6-
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FUNCTION OF EACH COMPONENT 4. 4-l GENERATOR 4-l-l STATOR The stator consists of a laminated silicon steel sheet core, and a copper coil wound around the core with a lead wire from which AC and DC The copper wire coil output are taken out. consists of a main coil and a DC coil, and AC output is taken out from the main coil, while DC output is taken out from the DC coil. 4-l-2 ROTOR Fan The rotor consists of a laminated silicon steel sheet core, a field coil which is wound around t
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4-l-4 AVR (Automatic Voltage Regulator) I This is a device to automatically regulate voltage with an electronic circuit. Fig. 4-14 4-l-5 CONTROL PANEL The control panel has a double receptacle with a ground terminal, and AC output is taken out with a male plug. DC current is taken out from the DC 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
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4-2 ENGINE 4-2-l CYLINDER AND CRANKCASE The cylinder and the crankcase of the engine are of a one-piece aluminum die-cast design. The Both the intake and exhaust ports are specific iron cylinder is cast-fitted inside the cylinder. These ports are also cast by using a mould with positioned at the lateral side of the cylinder. die-cast cores. The crankcase has its joint face located on the generator side, and it is of an assembly structure. 4-2-2 MAIN BEARING COVER The main bearing cover
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4-2-l 1 IGNITION SYSTEM The ignition system is based on a flywheel/magneto system and its ignition timing is set at 230C before top dead center. The magneto consists of a flywheel and an ignition coil. The flywheel (functioning also as a fan) is mounted on the crankshaft, while the ignition coil is mounted on the crankcase. 4-2-12 CARBURETOR The horizontal suction type carburetor employed here can provide excellent starting, good acceleration, low fuel consumption, and superior output. T
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5. DESCRIPTION OF MAIN OPERATIONS 5-l ELECTRONIC IGNITION MECHANISM The engine has a current chopping contact point-free ignition system in which a power transistor is used as a current control element. This system is called T.I.C. (Transistor Ignitor Circuit). This electronic ignition system is completely free from ignition failure which generally results from contamination or burning of the contact points, oxydation during storage for a long time, or abrasion of mechanical sections, all
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5-2 DESCRIPTION OF GENERATING OPERATION I------- = , 8 I I P ‘3 ‘6 x I L ---w_J Magneto F@. 5-2- I 5-2-l GENERATION OF NON-LOAD VOLTAGE When the generator starts turning, the permanent magneto incorporated in the flywheel in the engine side starts rotating, which generates voltage in the exciting coil. The voltage, rectified by the diodes in the AVR, causes the flow of the current @through the field coil wound around the rotor in the generator. The rotor is then turned to an elec
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j-2-3 DC OUTPUT DC output is taken out from a part of the main coil and is fed to the diode stack (recti- fier) where the output undergoes full-wave rectification and is then supplied to the load. The diode works to allow the current to flow in the direction @, but does not allow the current to flow in the direction @I, as shown in Fig. 5-2-3. Fig 5-23 Fig. 5-2-4 shows the DC output circuit of the generator. DC voltage is generated in the main coil. When the voltage in A is higher t
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6. OPERATIONAL LIMITS OF THE GENERATOR 6-1 AC OUTPUT Electric appliances normally have rating levels showing the rated voltage, frequency, power consumption (input power), and other things. The power consumption specified on such a label is required to drive the appliance. However, when an appliance is connected to the generator, the power factor and starting current should also be taken into account. 6-l-l NET RESISTANCE LOAD Incandescent lamps, electric heaters etc. can be run on the
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The calculated power consumption is calculate the power consumption of the device involved. adjusted depending on the type of the load, and according to paragraphs from (1) to (3). (Power consumption) = (Mechanical equivalent of a device) + (Efficiency) Efficiency Motors: 0.6 2. 0.8 Fluorescent lamps: 0.7 x0.8 Example: As for a 40 W fluorescent lamp with a lighting output of 40 W, and assuming that the power consumption of this lamp is 0.7, the power consumption can be calculated as fol
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6-2 DC OUTitJT When the generator is employed to recharge batteries, attentions should be paid to the specific gravity of electrolyte in each battery. 6-2-l MEASUREMENT OF ELECTROLYTE’S SPECIFIC GRAVITY The specific gravity of an electrolyte varies according to temperature; so it is converted to one in case of 200C. s20 = St + 0.0007 (t - 20) where S20: The specific gravity at 200C St : Measured value t : Temperature at the time of measurement (Electrolyte) 6-2-2 REMAINING CAPACITY ES
