~

Model

Generator
LfiiB0!!lLfif20

LGlWJ)!iiLG24O/L6340 LEKl2L?+/LGKKl8E7

1 ISSUE EMD-GS0408

CONTENTS
Page

Section

Title

1. SPECIFICATIONS 2. PERFORMANCE 2-1 2-2 2-3 2-4 2-5 3. 4. Model Model Model Model Model LG080 LG120 LG180 LG240 LG340

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

1 4 4 5 6 7 8 9

FEATURES.. GENERAL 4- 1 4-2 4-3

................................................ DESCRIPTION of GENERATOR. .......................

10 10 11 14 15 15 17 20 21 22 25 25 27 27 29 29 29 30 30 32 33 34 34 34 35 43 50 51 51 55 56

External View of Generator ................................. Control Panel ............................................ Location of Serial Number and Specification Number and FUNCTION ................................

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

5.

CONSTRUCTION 5- 1 5-2 5-3

............................................ Construction Function ................................................ Description of Generator Operation ........................... PRECAUTIONS of APPLICATIONS PROCEDURES ...... ............ ..................... ..................................... ....................................

6. 7. 8.

SAFETY RANGE

MEASURING 8-1 8-2 8-3

..................................... Measuring Instruments AC Output Measuring ..................................... Measuring Insulation Resistance .............................. FUNCTIONAL MEMBERS ............................

9.

CHECKING

............................................ 9-1 Pilot Lamp.. .......................................... 9-2 AC Receptacles 9-3 Circuit Breaker ........................................... .................................................. 9-4 Stator ................................................ 9-5 Rotor.. .............................................. 9-6 Condenser 10. DISASSEMBLY 10-1 10-2 10-3 10-4 10-5 11. and ASSEMBLE .................................

................................ Preparation and Precautions Special Tools for Disassembly and Assembly .................... Disassembly Sequence .................................... Assembly Sequence ....................................... Optional Full-Frame Types ................................ .........................................

TROUBLESHOOTING 11-1 11-2

........................................... No AC Output AC Voltage is Too High or Too Low .......................... DIAGRAMS ..........................................

12.

CIRCUIT

Model

LG080

LG080D

LG120

LGISOD

LG180

LG180D

ryr-lt -- -_ .
Frequency

_... 50Hz 60Hz 50Hz

--

-_.--

Brushless, Self-Exctting, 50Hz 60Hz 50Hz

P-Poles, Single Phase 60Hz 50Hz 60Hz 50Hz 60Hz

60Hz ..-----...

Power Factor --. -.--. DC Output - -_ Voltage Regulatot + -.. .. .Type --_ _-Rt?~lllilliOrl

----

..-. --.

Not Available ..-..- ..- _..-Cot-&riser

-,

Voltage

.- ._.. .-. -__._ ,, EY08D --. _- -... -

. ..-.---. .

Jlotlel

-. Displacetnent _-- .._

.-__ . FUCI -. -. .-_. .- 1.5V (0.40 US. gal.) Fuel Tank Capacity --. . - ._.- --.-.--0.4V (0.9 pint) 311 Capacity -. __. -. __- .. Revolutiott --. ..-. _.. .._.__ -_ - ., .. Ignition System -.. -_. . ._-. Slatttttg Systern -. ----.--. --. .__ .-_. 50 H7 Fuel Cotlsumption 60Hz Ratio O.rlV/Hr (0.9 pint) 0.6V/Hr (1.3 pitt t) --.-.- ----., - .__ -.. -..-. ----~ F ramo type Handle type Lutlyttl(iri) 339 mm (15.7 in) 433 mm (17.0 itt) --_-.__ . .. _. Dtmcttstons -.--._ --. Drv Weiuht Ilt)s) 18 ka (39.7 t bs) __-.. ._-. 19.5 k(l (43.0 Ibs)

Ratetl 011 tput

_. _ ._ .78 cc (4.76 cu. it).) - -- .,_.... -.-..- ._._- __.. - -,.. ,-.-. 1,4HP/3600rptn --,. .-. ,,,--

within 14% - ,-Robin Air Cooled 4-Cycle Gasoline Engtne -----EY15D (Wl-145)+ EY20D (WI-185) ------..-_ -..-.-143 cc (8.73 cu. in.) 183 cc (11.17 cu. in.) 2.7HV3600rptn Automobile Gasoline ---.2.8V (0.74 US. gal.) 3.6HP/3600rpm

----.50Hz--

0.6V (1 .3 pint) -,...---3000rpm, 60Hz-- -3600rpm -. Robtn Solid State Ignttion System Recoil Starter

3.811 (1 .OO US. gal.) -0.6V (1.3 pint)

50 Hr O.BV/Hr (1.7 pint)

6OHz l.OK/Hr (2.1 pittt) ---- . Handle type Frame type 472 mm (18.6 in) 501 mm (19.7 in) ---.- ,--- _.... -_. 372 mm (14.7 in) -..-. - .-. .---430 mm (16.9 it)) _______....___ 28 k!l (61.6 Ibs) 26.5 k(l (58.5 Ibs)

50 Hz l.OK/Hr (2.1 pint) Handle type 522 mm (20.6 in) -~. 362 mtn (14.3 in) 425 tnrn (16.7 in) -33 ka (72.8 Ibs)

60Hr 1.3K/Hr (2.8 pint) Frame type 558 mm (22.0 in) ---386 mm (15.2 in) 435 mtn (17.1 in) 34.5 kq (76.2 Ibs)

__- _ - -----Type

_ ..-------Model LG240

LG240D

LG340 2-Poles, Single Phase 60Hz 3400w 50H7 3ooow -25oow .--

LG340D

I 60Hz 3400w 2900w

I--

---.-

Brushless, Self-Exciting, ----------

__.____-__

---

-.--

-------. 11 OVl22OV (18.2A/9.1A)

(Rated Current) -, - ----. --- - - --Power Factor _-_----_-DC Output _______ -.-----. Regulator __-_--- .-- -Voltage Regulatioti _------- + Type ____. __._ __- __--, M0dd __-_ -_-._---Displacornent ---I-.---------

(15.5A/7.7A) 12OVl24OV (16.7Al8.3A)

-IIOV (22.7A) . 220v (11.4A) ------240V (10.4A) 1 .o

--

-.---

2900w 12ov (24.2A) _ -- -220V (13.2A)

11 ov/22ov (26.4A/13.2A) 11 OVJ22OV (22.7A/11.4A) _ --12OVl24OV (24.2A/12.1A)

__--_-_--_-_---~ Fuel --_---------Fk~el Tur\k Capacity .----.---,-,- - -... Oil Capacity --__-__-Ravolutmn __- - --.--------..----Igt,itiorl System __---.- - - - ----.-.--.---------A-Startirlg System _---___-_----Fud Consurnptiorl Ratio .---.. ---,----

VCJltiJcJC Roted 011 tpllt

---d-m --, .-.--------,-------.--.---.--EY20D

---

Not Available Condenser ---within 14%

--

Rubirl .Air Cootcd 4-Cycl<! Gasolint! Engine EY28D (WI-280). 273 cc (16.66 cu. in.3 5.5HP:3600rpm Automobile Gasoline 5.511 (1.45 us. gal.) 0.85V (1.8 pint) 50Hz - -3OOOrl)m, 60H7- .- 3600rpm --_------_-_Robin Solid State Ignition System -Recoil Starter Z.lV/Hr

.,-_.

(Wl-185)

183cc (11.17 cu. in.) -==I=3.6HP/3600rpm

3.81: (1 .OO US. gal.) ------0.6V (1.3 pint)

(4.5 pint)

Lcrigth(in) _----

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

Dry weight (Ibs)

34 kg (75.1 Ibs)

35.5 kg (78.4 Ibs)

45.5 kg (100.4 Ibs)

47 kg (103.8 Ibs)

Model Type Frequency output 0 I I j 1 Max. Rated

I I

LGK120 Brushless Self-Exerting 50Hz 1ooow BOOW 11ov 7.3A I 3.6A 240V 3.3A 1.0 Not AvarIable Condenser Within Robin Air-Cooled EY15DK 143 cc (8.73 cu. in.) 2.2HP 3600 r.p.m. Kerosene (Automobile Kerosen 2.6E (0.69 US. gal.) Gasoline 0.1 G (0.03 US. gal.) 0.6c (1.3pintsl 50Hz-3000 r.p.m. 60Hz-3600 14% I 60Hz 12oow 1 ooow 11ov 12OV _ 220v 1 8.3A 4.5A 220v 240V

LGKl80 Z-Pole, Single Phase 50Hz. 15OOW 13OOW 11.8A 120v 5.9A 220v 5.4A 6.8A 12.5A 60Hz 18OObV 15oow

E g 2 ti

4 Itage 1 Rated Current

220V

Power Factor DC output Voltage Regulator Voltage Regulation Type Model Displacement Rated Output w z G 2 w Fuel Fuel Tank Capacity Oil Capacity Revolution Ignition System Starting System Fuel Consumption Ratio 0.9s Hr (50Hz)

4Cycle

Keronse Engine EY20DK 183 cc (11.17 cu. in.) 3.1 HP.3600 r.p.m.

Gasoline for Starting) Kerosene 3.6c (0.95 US. gal.1 Gasoline 0.15C(O.95 US. gal.)

r.p.m.

Robin Solid State Ignition System Recoil Starter I

Length (in) Dimensions Width (in) Height (in) Dry Weight (Ibs)

I 1.1 c?Hr l.li-Hr I 1 (6OHzi i50Hz) I (Handle Type) 1 (Frame Type1 1 (Handle Type) 472 mm (18.6 in) 1 501 mm (19.7 in) 522 mm (20.6 in) 355 mm (14.0 in) 372 mm (14.7 in) 413 mm (16.3 It-t) 27.0 kg (59.5 Ibs) 430 mm (16.9 in! 28.5 kg (62.8 Ibs)

1.4P Hr !60Hz) (Frame Type) 558 mm (22.0 in)

362 mm (14.3 in) 1 386 mm (15.2 in) (425 mm (16.7 in) 33.5 kg (73.8 Ibs) 435 mm (17.1 in) 35.0 kg (77.1 Ibs)

-3-

2. PERFORMANCE
2-1 MODEL LG080

t 5 240 -1/o/-7*
800

50Hz/220V OUTPUT MAX. RATED

Type . . . . . . . . . . . 650W . . . . . . . . . . 550W

400

5 CL k 0

. 200

CURRENT

(A)

60Hdl2OV OUTPUT MAX. RATED

600

Type . . . . . . . . . . . 800W . . . . . . . . . . 700W

: 5 560

65 : I/ : I I
I

4 CURRENT

6 (A)

-4-

2-2

MODEL

LG120 50Hzl220V Type . . . . . . . . . . . l,OOOW .......... 800W

2
w

240
I

I I

I I I

I J

OUTPUT MAX.
800

RATED

I ----Y-i

400

l-

I 200 /! /

1
0 1 3 2 CURRENT (A) 4

I
5O 1200

60Hz/l2OV OUTPUT MAX.

Type . . . . . . . . . . . 1,200W . . . . . . . . . . l,OOOW

2 e 2 6 >

130 120 110

1000

RATED

44

800

600 -C I & z 2 ; K u 65 60 55 200 400

5 E 2

0 0 2 6 4 CURRENT (A) 8 10

-5-

2-3

MODEL

LG180

50Hd220V
I 240:,6ii

Type . . . . . . . . . . . 1,500W . . . . . . . . . . 1,300W

OUTPUT
VOLTAGE

MAX. RATED

I I/

i-l

800

2 iii IL

W
2 > 55 g 50 45 CURRENT (A)

400

60Hz/l2OV OUTPUT MAX. RATED

Type . . . . . . . . . . . 1,800W . . . . . . . . . . 1,500W

CURRENT

(Ai

-6-

2-4

MODEL

LG240 50Hd220V OUTPUT MAX. . . . . . . . . . . . 2,000W . . . . . . . . . . 1,700W Type

z : a t1 :

240 220 200

1600

RATED

1200 s 2 E

> CJ W 2 W cc u
55

800

50

400

45

4 6 CURRENT (A)

0 10

60Hz/l2OV OUTPUT MAX. RATED

Type . . . . . . . . . . . 2,400W . . . . . . . . . . 2,000W

iz u
i

CURRENT

(A)

-7-

2-5

MODEL

LG340

50Hz/22OV

Type . . . . . . . . . . . 3,000W . . . . . . . . . . 2,500W

> 240

W
z 220
I )/

OUTPUT

q3200

MAX. RATED

1600

CURRENT

(A)

60Hz/l2OV OUTPUT
3200

Type . , . . . . . . . . . 3,400W . . . . . . . . . . 2,900W

MAX. RATED

800

CURRENT

(A)

-8-

3. FEATURES
1. Maintenance free

Adoption of brushless alternator, circuit breaker, pointless ignition system and dust-proof cyclone air cleaner provides generators free irom troublesome maintenance. 2. Quiet operation Quiet G-stroke Robin engine equipped it-ith large sized low-noise muffler and silent c>-clone air cleaner provides extra quiet operation. 3. Compact and lightweight Simple and clean design such as integrated control box makes compact and light\veight generators. 4. Durable and long life Hea\->--duty 1 stroke Robin engines with pointless ignition system, cast iron c!-linder liner. forged steel crankshaft. t\vo main bearings and forged aluminum connecting rod delivers greater reliability and durability. 5. Full Power Switch for Dual Voltage Type Dual voltage type models have Full Power SLvitch which enables you both voltages. to use
f~111

power of generator at

6. Easy Starting Light pulling recoil starter and strong spark b)- Solid State Ignition provide extra-sasp starting.

-9-

4. GENERAL
4-1 EXTERNAL

DESCRIPTION

of GENERATOR

VIEW of GENERATOR
FUEL I I COCK

CARRYING

HANDLE

FUEL

TANK

SPEED

CON ITROL

ilG..iz4
CbNTROL BOX AIR CLEANER

MUFFLER

RECOIL

STARiER

-10-

4-2

CONTROL

PANEL

CIRCUIT

BREAKER

PILOT

LAMP

AC 1lOV
@

--

%I ox
O

CIRCUIT REAKER

OFF -I-

\
MODEL

LG

\\

EARTH(GROUND)

TERMINAL

AC RECEPTACLE

.50Hz-220V .50Hz-240V l 60Hz-240V

TYPE TYPE TYPE

CIRCUIT \ \

(LG080,

LG120,

LG180,
PILOT

LG240,
LAMP

LG340)

BREAKER

EARTH

[GROUND)

TERMINAL

AC RECEPTACLE

. LGOSO, LG120,
CIRCUIT

LG180:
BREAKER

1 lOV/22OV

TYPE
PILOT LAMP FULL POWER SWlTCH

\
@ AT

@\
MODEL

@
\ \ \ AC RECEPTACLE

0
I ! / EARTH

LGIBU

[GROUND)

TERMINAL

. LG240,

LG340:
CIRCUIT

llOV,
BREAKER

120V TYPE
PI LC-T LAMP \

1 ;? \\

ON -n-

OFF -n-

TOTAL

15A MAX

EARTH

/ I

II

MODEL

\
TERMINAL AC RECEPTACLE

IGROUNDI

12-

LG240,

LG340:
CIRCUIT

11OV/22OV
BREAKER

TYPE
PILOT LAMP FULL POWER SWITCH

I II I
EARTH (GROUND) TERMINAL

\i \ \ \
AC RECEPTACLE

. LG340:

llOV,
CIRCUIT

120V TYPE
BREAKER PILOT LAMP

:
EARTii !GROUNDi TERMINAL

i \ AC RECEPTACLE

-13-

LG340:

110/22OV
CIRCUIT \ \ i

TYPE
PI LOT LAMP FULL I POWER SWITCH

BREAKER

\
EARTii IGROUND) TERMINAL AC RECEPTACLE

4-3

LOCATION

of SERIAL

NUMBER

and SPECIFICATION

NUMBER

Serial number is stamped on the LABEL (MODEL NAME) stuck on the rear cover. Specification number is stamped on the stator cover. * Always specify these numbers when inquiring about the generator or ordering parts in order to get correct parts and accurate service.

LABEL

(MODEL

NAME1

SPEC. NUMBER

CARRYING

HANDLE

iz--;,,,,,,

PANEL

sTrDR

COVER

BDLT

CONDENSEH I

,, I.

MDLJNT

HUBBFR \ ROTOf

RkAH

C0VE.H / THRDIJGH BDI T

STATOH

COVER FHDNT COVER

CHANKSHAFT

CARRYING

HANDLE

CONDENSER BRACKET

CONDENSER

If 1

MDUbiT

RlJBBER \ ROTOR

REAH

CDbEH / THRDlJGH BOLT

STATDH

COVER FRDNTCDVER

CRANKSHAFT

5-2

FUNCTION

5-2- 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. The condenser coil excites the stator field coil which generates AC output in the main coil

Fig. 5- 1 (L GOSO, LG 720)

Fig. 5-2 lLG180,

LG240, LG340)

5-2-2

CONDENSER

The condenser is mounted on the rear cover and is connected to the condenser coil which is wound in the stator. The condenser coil magnetizes the rotor which increases the densit>- of magnetic flux.

JL
Fig. 5-3 (LG080, LG120) Fig. 5-4 ILG 180, LG240, LG3401

-17-

. 5-2-3 ROTOR

The rotor consists of a laminated silicon steel sheet core and field coil which is wound over the core. DC current in the field soil magnetizes the steel sheet core. Two permanent magnets are provided for the primary csciting action. A cooling fan is pressure-fitted on the end of the rotor shaft to cool the individual coils, iron cores, rectifier. and other integral parts. (See Fig. 5-5 and 5-6. j

Fig. 5-5 (LG080, LG120)

Fig. 5-6 (LG180, LG240, LG3401

X diode rectifier and resister or surge absorber is mounted inside of the insulator. (See Fig. 5- -! and 5-8.)

DIODE

RECTIFIER

ODE RECTIFIER d RESISTOR

Fig. 5-7 (LGU80, LG 7201

Fig. 5-8 (LG780, LG240, LG3401

Cooling air is sucked b>- the fan on the rotor through the slits of the rear cover and exhausted through the outlets of the front sol-er.

- 18-

5-2-4

CONTROL

PANEL

AC receptacles, circuit breakers, pilot lamp. ground terminal and Full Power Switch for dual voltage types are mounted on the control panel.
CIRCUIT BREAKER PILOT LAMP

c7 --- :a 3

-1;

OFF r-

i
EARTi IGROUND) TERMINAL AC P;:ECEPTACLE

CIRCUIT

BREAKER

PILOT

LAMP

FULL

\, \\

POWER I

SWITCH

EARTH

(GROUND)

TERMINAL

AC RECEPTACLE

Fig. 5-9

19-

5-3

DESCRIPTION

of GENERATOR

OPERATION

INITIAL EXCITATION PERMANENT MAGNETO

STATOR ----I

i
FIELD ROTOR COIL

I--

IL

J-=
RECEPTACLE AND PLUG

RESIST OR or SURGE ABSOR

/
BER

DIODE

MAIN

COIL

COIL

CONDENSER

L -----_

_I

Fig. 5- 10

5-3-l

GENERATION

of NO-LOAD

VOLTAGE

1) \Vhen the generator starts turning the permanent magneto built-in to the flywheel. it generates 3 to 61 of AC \-oltage in the main soil and condenser coil 3, The condenser soil is connected to a condenser. Sowhen a voltage is generated in the condenser coil. minimum current .x flows in the condenser coil. At this time. small flux is produced. \i-ith which the magnstic force of the rotors magnetic pole is intensified. \Vhen this magnetic force is intensified. the respective voltages in the main coil and condenser coil rise. Current .s flowing in the condenser coil increases. with the magnetic flux density of the rotors magnetic pole increasing further. Also. the main coil voltage and condsnser coil L-oltageincreases. These l-oltages continue rising as this process is repeated. 3) -4s current flows in the condenser coil. the magnetic flux density in the rotor changes. AC voltage is induced in the field coil n-hen the magnetic flus density varies. Sucsessiwly. AC current is rectified by the rectifiers connected to both 2nds of the field coil. and DC current s flows in the field soil. \Vith this current. the rotor core is magnstized. alIo\ving the generator to output steady- voltage. -Ii LVhen generator speed reaches Z-00 to 2800 r?m (50Hz spsciikationj or 3000 to 3300 rpm (60Hz spesiGcationi. the current in the condenser coil and field coil increases rapidly-. This acts to stablilize the respective coil output \-oltapes. If generator sFecd further rises to the rated value. the generator output voltage Lvill reach the rated value.
5-3-2 VOLTAGE FLUCTUATIONS UNDER LOAD

When load current ?. fo\vs from the generator 10 the electrical equipment. the magnetic flus which is proAducsd as current ,ILJ flo\vs in the main coil. this flus serx-esto increase current xl flowing in the condenser coil. \Vith current x increased. the magnetic flux dsnsity across the rotor core rises. As a result. the current flouing in the field coil increases. and the generator output voltage is prevented from decreasing.

- 20 -

6. SAFETY
1. Use extreme

PRECAUTIONS
near gasoline. A constant danger of explosion or fire exists.

caution

Do not fill the fuel tank with gasoline Lvhile the engine is runnin g. Do not smoke or use open tlame near the fuel tank. Be careful not to spill fuel Lvhen refueling. If spilt. Lvipe it and let dry before starting the engine.
2: Do not place inflammable materials near the generator.

Be careful not to put gasoline. matches. gunpowder. oil cloth, straw. trash and any other inflammables near the generator.
3. Do not operate the generator in a room, cave or tunnel. Always operate in a well-ventilated area.

Otherwise the engine may become ox-erheated and also. the poisonous carbon monoxide contained in the exhaust gases will endanger human lives. Keep the generator at least 1 m (4 feet) awal- from structures or facilities during use.
4. Operate the generator on a level surface.

If the generator is tilted or moved during use. there is a danger of fuel spillage and a chance that the generator ma)- tip over.
5. Do not operate with wet hands or in the rain.

Severe electric shock may occur. If the generator is moistened by rain or snow. kvipe it and fully dry it before starting. Dont pour water over the generator directl)- nor wash it Lvith water. If the generator is wet with water. the insulations will be adversely affected and mal- cause current leakage and electric shock.
6. Do not connect the generator to the commercial power lines.

This may cause a short-circuit or destroy the generator. Use a transfer w-itch for connecting with indoor Lviring.
NOTE: The parts numbers Table 6- 1. of the transfer switches and of the plastic box to store them are as shown in

I Part No. i65 45604 08 3674560508 3674300808 I ) Part Name TRANSFER TRANSFER PLASTIC SWITCH SWITCH BOX Table 6- 1

Qw
1 1 1

Maximum
Current 15A 30A 30A I

-21-

7. RANGE of APPLICATIONS
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 operatin g an electrical appliance is not always equal to the amount of work that can be done by it. Electrical products genrally have a label showing their rated voltage. frequency, and power consumption !input power). The power consumption of an electrical products is the power necessary for using it. When using a generator for operaring an electrical product. however. the power factor and starting current must also be taken into consideration. Determine the capacity of your generator from the power required for operating electrical products referring to the folio\\-ings:
1. Incandescent lamps, hot plates, etc. with a power factor of 1.0

Total power consumption must be equal to or less than the rated output of generator. Example: A generator with a rated output power of 1OOOKcan light ten 1OOWlamps.
2. Fluorescent lamps, mercury lamps, etc. with a smaller power factor

Select a generator with a rated output equipment to 1.3 to 2 times the power consumption of the load. Example: X generator with a capacity of 1OOW-10160n is necessary for lighting a 8OW fluorescent lamp. A generator with a rated output of 1OOORcan light six to ten 4OW fluorescent lamps.
NOTE: Wattage of the fluorescent lamp generally does not indicate the power consumption but indicates the output of the lamp. Therefore, if the fluorescent lamp has no special indication as to the power consumption or input power, efficiency should be taken into accounts as explained in I tern 5 on the folio wing page. tools, etc. that are driven by a motor

3.

Electric

1.3 to 3 times large power consumption of a motor-driven tool is required for starting. Select a generator with a maximum output 1.3 to 3 times large to the loard. Example: A 3OOW motor-driven drill requires a generator with a maximum output of 400 to 9OOW or more.
4. Water pumps, compressors, etc. that are driven by a motor and are initially loaded

3 to 5 times large power is necessary for starting. Select a generator with 3 to 5 times large output of load. Example: A water pump with a power consumption of 1OOWrequires a generator with a maximum output of 1300 to 20001V or more.
NOTE 1: Motor-driven products mentioned in Items 3 and 4 required the aforementioned generator capacities only when starting their motors.- Once their motors are started, the products consume about 1.2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances. NOTE 2: Motor-driven products mentioned in Items 3 and 4 vary in their required motor starting power depending on the kind of motor and start-up load. If it is difficult to determine the optimum generator capacity, select a generator with a larger capacity.

-- 22 -

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 according to the numerical formula mentioned below. (Output of electrical appliance) (Efficiency) Single-phase motor Three-phase motor = (Power consumption)

Efficiencies of some electrical appliances are as follows: . _ . . _ . . . . . . . 0.6 - 0.5 . . . . . . . . . . . _ . 0.65 - 0.9 I- 0.8 The smaller the motor, the lo\\-er the efficienq-.

Fluorescent lamp . . _ . . _ . . . . . . . . . . . 0.:

Example 1: A 4OLVfluorescent lamp means that its luminous output is 4OLV.Its efficiency is 0. and accordingly. power consumption will be 40 t 0. = S-IV. As explained in Item 2, multiply this power consumption value of 5-\V bp 1.2 - 3 and you will get the figure of the necessar) capacity of a generator. In other words, a generator with a rated output of 1000Wcapacity can light nine to fourteen 4OW fluorescent lamps. Example 2: Generally speaking, a 4OOWmotor means that its work load is 1OOW.Efficiency of this motor is O.- and power consumption will be 400 t 0.7 = 5OB.. \Vhen this motor is used for a motor-driven tool. the capacity of the generator should be multipled by 1.3 to S and 570W as explained in the Item 3.

Model Frequency Incandescent lamp, hot plate, etc. Fluorescent lamp, mercury lamp, etc. Motor-driven tool, general-purpose motor, etc. Water pump, compressor, etc. / /

LG080 LGOBOD 50Hz

I

LG120 LGl 20D 50Hz 800W about 450w 60Hz 1 ooow about 600W about 600W

LG180 LG180D 50Hz

I

I 1 60Hz

LG240 LG240D 1 60Hz ,

LG340 LG340D 50Hz 2500W about 165OW about 1 1500w about ] I 60Hz 29OOW ! i about i 19OOW abour 1 JOOW j about

60Hz 1 JOOW I I / about ; 4oow abour 4oow about 18OW

1 50Hz

550W about 3oow about 3oow about 1 oow

13oow about 850W about

j 1500w ! I about 1 ooow about 850W about 4oow

I ; about 1lOOW ! about 1 ooow about 5oow

1 JOOW i ZOOOW I i about 1300w F about 12oow about 600W

I about ; 5oow about 230W

J5OW
about 350w

I I
i

1 ;%i

1 J5OW j 850W

Table 7- 1

- 23 -

NOTES: Wiring between generator and electrical appliances 1. Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load (electrical appliance). If the input current is higher than the allowable current of the cable used, the cable will become excessively heated and deteriorate the insulation, possibly burning it out. Table 7-2 shows cables and their allowable currents for your reference. 2. Cable length if a long cable is used, a voltage drop occurs due to the increased resistance in the conductors so that the input voltage to the load (electrical product) decreases. As a result, the load can be damaged. Table 7-2 shows voltage drops per 100 meters of cable.

Nominal cross section mm 0.75 1.27 2.0 3.5 5.5

*.W.G. Gauge No. No. 18 16 14 12 - 10 10 - 8

I 1 Aowabe current A 7 2 17 23 35

No. of : stra,,&/strand dia. No. i

I I

Resistance

Current IA 2.5 1.5v 1v 3A 8V 5v 3V 1.5v 1v 5A 12.5V 7.5v 5V 2.5V 2v 8A 12V 8V 4V 2.5V

Amp. 10A - 15V : 1OV 5V 3.5v 15A . 15v 7.5v 5v 8 + $ i!j

mm

.O..lOO 2.477

12A , 18V 12V 6.5V 4v

30 0.18 I 500.18 37:0.26 45:0.32 70:0.32 i

1.486 0.952 0.517 0.332

Table 7- 2

Voltage decrease indicates as c = -&

xRxIxE

R means resistance (Q 100 rn.1on the above table. I means electric current through the u-ire (.Xi. f means the length of ths nire imi. The length of the wire indicates round length. it means twice the length from generator to electrical tools.

- 24-

8. MEASURING
8-1 8-l -1 MEASURING VOLTMETER

PROCEDURES

INSTRUMENTS

XC voltmeter is necessan. The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follow: 0 to 15OV: Type Lvith an output voltage of 110 or 1ZOV 0 to 3001;: Type with an output voltage of 230. 230. or 21OV 0 to 15OV. 0 to 3001?: Dual voltage type

FOR

AC

Fig. 8- 1

8-l-2

AMMETERS

7
3 :
FOR AC

AC ammeter is necessary. An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable. (.-About 10x. ZOA. 100X)

Fig. 8-2

8-l-3 NOTE:

FREQUENCY

METER meters input

Frequent?; range: About 45 to 65Hz

Be careful of the frequency voltage range.

Fig. 8-3

- 25 -

8-l-4

TESTER

Used for measuring resistance. etc.

I Fig. 8-4

8-l-5

MEGGER

TESTER

Used for measuring generator insulation resistance. Select one with testing voltage range of 5001.

Fig. 8-5

8-l -6 TACHOMETER

There are various t)-pes of tachometers, such as contactless t>-pe. contact &pe. and strobe t>-pe. The contact t&-pe can be used onl)- when the generator and engine have been disassembled. The contactless type is recommended.

STROBE

TYPE

Fig. 8-6

-26-

8-2

AC OUTPUT

MEASURING

TO AC RECEPTACLE

I Fig. 8-7

Use a circuit like the one shown in Fig. 8- for measuring XC output. X hot plate or lamp with a power factor of 1.O may be used as a load. Adjust the load and rpm, and check that the voltage range is as specified in Table 8- 1 at the rated amperage and rated rpm.
Rated voltage Voltage range IIOV 107119v 120v 117%130v Table 8- 1 220v 215-238 240V 235-260

8-3

MEASURING

INSULATION

RESISTANCE

Connect a megger tester to one of receptacle output terminals and the ground terminal, then measure the insulation resistance. An insulation resistance of 1 megohm or more is normal. (The original insulation resistance at the time of shipment from the factory is 10 megohms or more.) If it is less than 1 megohm. disassemble the generator and measure the insulation resistance of the stator, rotor and control panel individually-.

Fig. 8-8
l

STATOR

1) Measure the insulation resistance between BLUE lead and the core. 11 Measure the insulation resistance betlveen IS-HITE lead and the core. 31 Disconnect the lvires which sonnezt condenser and stator. and check the insulation resistance between one wire from stator and the core. (See Fig. 8-9.j

Fig. 8-9

- 27 -

. ROTOR

Measure the insulation across one of the soldered terminals of the rotor and the core. iSee Figs. S-10 and 8-11.)

Fig. 8- 70 (LG080, LG120)

Fig. 8- 11 (LG 180, LG240, LG340J

. CONTROL

PANEL

Measure the insulation resistances between the live parts and the grounded parts. iSee Fig. 8-l.:)

Fig. 8- 12

.\n~- part Lvhere the insulation resistance is less than 1M-IRhas fault)- insulation. and ma!- cause electric leakape and electric shock. Replace the fault)- part.

- 28 -

9. CHECKING
9-l PILOT LAMP

FUNCTIONAL

MEMBERS

Check the pilot lamp to be turned on by applping specified voltage. Pilot lamp cannot be checked with circuit tester because its resistance is too large. (See Fig. 9- 1.1

PILOT

LAMP

Fig. 9- 1

. LG080,

LG120

All specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot lamp should be turned on at 70 to 1201.

. LG180, LG240, LG340

1 lOI:, 1201- and all Dual Voltage specifications . . . . . ..*................... Pilot lamp should be turned on at 70 to 12OV. 1Oi and 24OV specifications -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot lamp should be turned on at 110 to 2401:.

9-2

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. W-hen continuity is confirmed between the output terminals of the receptacle with a wire connected across these terminals. the AC receptacle is normal. Khen the wire is removed and no continuit)- is confimled beween these terminals. the receptacles are also normal.

AC RECEPTACLE AC RECEPTACLE TESTER

Fig. 9-2A (Front)

Fig. 9-2B (Rear)

- 29 -

9-3

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 when the circuit breaker is on while there is no continuity when the circuit breaker is off.

Fig. 9-3

9-4

STATOR

STATOR i

Disconnect couplers on the wires from stator and check the resistance between \\-ires with a circuit tester referring to the following table.

COUPLER I

Fig. 9-4

(R x
VlODEL SPECIFICATION HZ Voltage : i Brown-White AC Winding Blue-Sky Blue I I

152 *lo%)

Condenser Winding Black-Black

3.5,0,

6.322

I I
50

11ov 220v 11ov 220v 240V

I 3.3n : j I 4.19 2.2R , 2.5R

I

3.3R I 4.1s I

5.2R

5.2R

LG120 220v i 60 1 11ov 220v 120v 120V 240V

Table 9-1A

- 30 -

(I3 x 1R klO%)
I MODEL SPECIFICATION : Hz Voltage 11ov 1 50 LG180 i itov 220v 220v l2OV 120V 240V 11ov j I LG240 : 50 ! 220v 11ov 220v 240V 220v ' 60 , ' I 50 11ov 220v 120v 120V 240V 1lOV 220v 11ov 220v 240V LG340 ' 220v 60 I 11ov 220v 120 120V 240V j 0.4R 0.659 0.421 0.652 I 1.2a 1.2R ! , 0.7R ' 0.79 1.39 0.65!d i 1.3n 0.8R 0.9s I 0.65R ! 1.39 1 I ! 1.3,o. 0.8Q 0.9R 3.39 2.3.0. 2.39 I I l.3R I j 1.19 1.19 3.30 1.2n I I 1.2n 1.3n 3.1a 3.19 I 220v 11ov 220v 240V 1.752! 1.759 4.1R 1.45.Q 1.45R j 4.l.r2 I White-Red AC Winding : Black-Blue Condenser Winding Yellow-Yellow

60

Table 9- 7B

NOTE:

If the circuit tester is not sufficientlly 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 2OC (68F).

-31-

9-5

ROTOR

1) Using the circuit tester. measure the resistance of the field coil. I
MODEL
Resistance

(R x 1st &lo%)
LG240 9.1n LG340 6.4R

LGO80 10.8R

LG120 8.19

1 LG180 8.5R

Table 9-2

NOTE

7: Measure the resistance of each coil with their solder removed.

winding

while

the diode and each resister are disconnected

NOTE 2: If the circuit tester is not sufficientlly 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 2OC (68F).

Fig. 9- 5 (L G080, L G 120)

Fig. 9-6 IL G 180, L G240, L G340)

- 32 -

2j Measure the resistance of the resister. . _ . . . . . . . I Sormal resistance is 15KS2. I Check if the surge absorber is burnt. Check the resistance of surge absorber. Normal resistance is 42.

. . . . . . . . LG080. LG130

Fig. 9- 7 (L G080, L G 120)

Fig. 9- 8 IL G 780, L G240, L G340)

3) Measure the resistance of the diode.

CATHODE MARK POLARITY OF CIRCUIT TESTER

icontinuity

exists.]

9-6

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 \\-ith a new condenser to see whether or not the generator performs normally. If the generator performs normally. the condenser is normal. If an instrument (.QC-meter or C-meter) for measuring capasiq of condenser is a\-ailable. check the capacityof condenser. Sormal capacity- of condenser is as follows:

MODEL Capacity

LG080 lOl.tF

LG120 10/.~F

LG180 17/~F Table 9-3

LG240 2O/*F

LG340

1 17/1F +20/.1F

- 33 -

10. DISASSEMBLY and ASSEMBLY

10-l PREPARATION and PRECAUTIONS

1) Be sure to remember the locations of individual parts when djsassembling 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 sexeral groups and store them in boxes. 3) To prevent bolts and nuts from being misplac2 ,d or installed incorrectly. place them temporarily back at their original position. 4) Handle disassembled parts with care: clean them before reassembl)- using a neutral cleaning fluid. 51 Use all disassembl>- assembly tools properl)-- and use thz right tool for each specific job.
10-2 SPECIAL [ROTOR TOOLS for DISASSEMBLY PULLER] and ASSEMBLY

MODEL LG080 LG120

PART NUMBER 2309500307 2269500207 , I

PART NAME ROTOR PULLER ROTOR PULLER

MODEL LG180 LG240 I I I

PART NUMBER 3785437608 3785437608 3805438008

! I I

PART NAME BOLT BOLT BOLT Table 10-l

PART NUMBER 3785437508 I 379 54377 08 3805437908 I i

PART NAME ROTOR PULLER ROTOR PULLER ROTOR PULLER 1

LG340

- 34 -

10-3

DISASSEMBLY

SEQUENCE
I

Sequence

Part to remove

Description

Precaution

Necessary tool

CONTROL PXSEL

RemoL-econtrol panel. (See Fig. 10-l.) 4~ screw and washer ass)-: 3 PCS.

@ screw driver

COUPLkR 2

CONTROL

PANEL

42 SCREW

and WASHER

ASSY:

4 PCS.

Fig. 10- 1

Sequence

Part to remove

Description (1) Disconnect the couplers on the wiring

Precaution

Necessary tool

COLPLERS (Disconnection)

from stator to control panel. (See Fig. 10-Z.)

Push the hook on the coupler and pull out to disconnect.

LG180 LG240 LG340 f

6P couplers (Black. Blue. Red. IVhite)

(2j Disconnect the ccuplers on the wiring from condenser to condenser coil. (See Fig. 10-3.) ~~~~~ 3 Pin terminals (2 Black wires) iEiI:-JLG340 Pin terninals (2 Yellow wires) 4P couplers (2 Yellow wires and 2 Brown wires)

Push the hook on the coupler and pull out to dixonnect.

CONTROL

PANEL

SIDE

STATOR

SIDE

Fig. 10-Z

Fig. 10-3

- 36 -

Description

Precaution

Necessary tool

(1) Remove three cover bolts. 60 bolt and washer assy: 3 pcs. (See Fig. 10-1.) (2) Tap on the rear cover with a plastic hammer to remove. (See Fig. 10-S.) Put a wooden block under the front cover to lift rear cover.

10 mm box wench

I
Fig. 10-4

PLASTIC

HAMMER

Fig. 10-5

Sequ;ce

1 ,,9,:;

remove

Description

Precaution

Necessary tool

Remove basket from rear cover. (ISeeFig. lo-6.j 60 bolt and washer ass!-: 1 PCS.
60 BOLT and WASHER ASSY. 3 PCS.

BASKET

REAR

COVER

COVER

BOLT:

3 PCS.

REAR

COVER

Fig. 10-6

- 37 -

Sequence

Part to remove

Description

Precaution

Necessary tool

CONDESSER

Remove condenser from rear cover. (See Figs. 10-7 and lo- 3.) LG080. LGlZO . . . 50 tapping screw: 2 PCS. LG180. LG1--IO. . . 40 scre\v: 3 PCS. LG340 . . .40 screw : 5 PCS.

8 mm box spanner + screw driver

CONDENSER

CONDENSER

CONDENSER BRACKET CONDENSER

REAR

COVER

REAR

COVER

Fig. 10-7 (LG080, LGl201

Fig. 10-8 (LG780, LG240, LG3401

Sequence

Part to remove

Description

Precaution

Necessary tool

MOUST RLBBERS

Remove mount rubbers from rear cover. (See Fig. 10-9.)

12 mm wrench

CONDENSER

BRACKET

CONDENSER

EAR

COVER

.EQ :k _I ---2

Fig. 70-9
MOUNT RUBBER

- 38 -

Sequence 7

Part to remove

Description

Precaution
unit.

Necessary tool

STXTOR COVER STATOR

Remove stator cover (See Fig. 10-10.) Remove stator. (See Fig. 10-11.)

from

generator

Tap on the stator core , with a plastic hammer to remove. Sever hit on the coil winding.

r,-

*-/ ---

.~

-.--;_--

.-

STATOR ;

STATOR !

COVER

Fig. lo- 10

Fig. IO- 11

STATOR

STATOR

Sequence 9

Part to remove

Description

Precaution

Necessary tool

ROTOR

11 I Turn the rotor bl- hand and s2t it in the position when you f221compression Place a wrench on the head of throuhbolt and hit it counter-clockwise to loosen. (See Fig. lo-l?., 80 bolt and washer ass). __LGOSO.LGIZO Bolt . . . LG180, LC?40 and LG340 , :,I Insert a rotor-p&r shaft into the rotor shaft and tighten the rotor-puller bolt

LG080. LG120: 12 mm wencl 1LG180. LGZ40: 1 13 mm wencl LG340: 14 mm wrencl

I I 14 mm wrench Only for LG340: 17 mm wench

*-

..-

\
ROTOR

,
ROTOR-P;LLER HROUGH BOL BOLT

Fig. lo- 12

Fig. lo- 13

i~R0tiGH

BOLT

Sequence

Part to remove
I

Description

Precaution

Necessary tool

10

FROST COVER

Remove front cover. 1 (See Fig. 10-14.) 8 Q bolt and washer ass! 4 PCS. ; Remove handle from front cover. (See Fig. 10-15.) 80 bolt and washer assy : 3 PCS.

I13mmbos : wrench ] 13mmbos wrench

11

1 HASDLE

FRONT

COVER

HANbLE

Fig. lo- 14

Fig. lo- 15

HANDLE

80 BOLT

and WASHER

ASSY:

3 pcs.

80 BOLT

and WASHER

ASSY:

3 PCS.

Description

Precaution

Necessary tool

Remove mount bracket from engine. Remove mount rubbers from mount bracket. (See Figs. 10-16 and 10-17.) 80 nut: 3 pcs. or 2 pcs.

12 mm wrench

MOUNT ;

BRACKET

VlOUVT MOUNT BRACKET I

RUBBER

Fig. lo- 16

Fig. lo-77

NOTE: Mount bracket is to be used only for the models 50 Hz specification LG 180, LG.740 and L G340.

P
ENGINE \ FLANGE NUT B k

MOUNT

RUBBER

- 42 -

10-4 10-4-1

ASSEMBLY HANDLE

PROCEDURES

Fix handle on the front cover. (See Fig. 10-18.) 89 x 18 mm bolt and washer assy . . . 3 PCS. (with spring washer)

HANDLE

Fig. 10- 18

10-4-2

FRONT

COVER

Install the front cover on the main bearing cover of the engine, engaging the foucer joint. (See Fig. 1O-l 9.) 8Q x 70 mm bolt and washer assy . . . 4 PCS. (with spring washer) Tightening torque : 120 to 140 kg-cm

FRONT

Fig. lo- 19

10-4-3

ROTOR

1j Wipe off oil or stains from tapered portion of P.T.O. shaft and rotor shaft. (See Figs. lo-20 and lo-21 .j

Fig. lo-20

Fig. 10-27

- 43 -

1 -J

Install rotor on the P.T.O. shaft and tighten the through-bolt. Apply a wrench on the head of through bolt and hit it clockwise with a hammer to tighten. (See Fig. 1O-22.)

Fig. lo-22
l

Dimensions

of through

bolt

Table 10-2

lo- ,4-4 l! -3' -1

STATOR

Put stator cover on the stator. Set the pa\vls to the buttom side of the stator. Put stator to front cover. iSee Fig. 1O-23. )

<.\,; I

STATOR I

STATOR I

COVER

Fig. lo-23

- 44 -

10-4-5

CONDENSER

CONDENSER

Put condenser to rear cover. (See Fig. 10-24.) LG080 50 x 10 mm tapping screw . . . 2 PCS. LGlZO I Tightening torque: 35 to 55 kg-cm
CONDENSER BRACKET

Fig. lo-24

(LG080, LGl20)

LG180 LG240 I

49 x 10 mm screw and washer . . . 2 PCS.

CONDENSER

CONDENSER

Fig. lo-25

(LGl80,

LG240)

LG340:

4r$ x 10 mm screw and washer . . . 4 PCS.

COWDENSER

,I

I ~COUDEJSER 7r;F: / I

I
Fig. lo-26 IL G340)

- 45 -

10-4-6

BASKET
\

REAR

COVER

Fix basket on the rear cover. (See Fig. 10-27.) 69 x 10 mm bolt and washer ass? . . . 4 PCS.

Fig. lo-27

10-4-7

REAR

COVER

1) Set the bearing housing of rear cover to the rotor bearing. Tapping on the center of rear cover. put the rear cover to the stator. (See Fig. 1O-28. j
NOTE: Be careful not to let the leads be caught between the stator and rear cover.

Fig. lo-28

2) Tighten \\-ith three cover bolts.

First put txo lower bolts and then the upper one. (See Fig. 10-39.) Tightening torque: 30 to 60 kg-cm

COVER

BOLT:

3 pcs.

Fig. lo-29

- 46 -

Dimensions

of cover bolts

LG120

I
I

6mm 0.24 6mm

1 1

118mm 4.65 90mm 3.54 100 mm 3.94 130 mm 5.12 / 1

30 mm 1.18 15mm 0.54 15mm 0.54 15mm 0.54

-z-

LG180 0.24 6mm LG240 0.24 6mm LG340 0.24

Table 10-3

10-4-8

MOUNT

RUBBERS

Install mount rubbers under the engine and generator. (See Fig. 10-30.)
NOTE: Use mount bracket on the engine side of the models 5OHz specification L G 180, L G240 and LG340.

Fig. IO-30

10-4-9

CONTROL

PANEL

1j Connect condenser to condenser coil. (See Fig. 1O-3 1.1

Fig. lo-31

- 47 -

[WIRE

CONNECTiONS

BETWEEN

CONDENSER

AND STATOR

(CONDENSER

COIL)

* LG080 * LG120 * LG180 * LG240

1 Pin terminal 1 SP coupler

\Vire color: Two blacks Wire color: TWO yellows

YELLOW

YELLOW

YELLOW

YELLOW

CONDENSER

SIDE

STATOR

SIDE

* LG340

JP coupler

BROWN

CONDENSER

SIDE

STATOR

SIDE

3) Connect couplers on wires from main coil to control panel. (See Fig. lo-32:)

A
Fig. lo-32

- 48 -

[WIRE

CONNECTIONS

BETWEEN

CONTROL

PANEL

AND STATOR]

* LG080 * LG120

f 4P coupler

Wire color: Blue. Sky blue. White, Brown

* llOV,

120v
SK :Y BLUE BROWN

BLUE

WHITE

WHITE

BLUE

SKY

BLUE

CONTROL

PANEL

SIDE

STATOR

SIDE

22ov, 240v
BROWN SKY BLUE WHITE BLUE BLUE WHlTE SKY BROWN BLUE

CONTROL

PANEL

SIDE

STATOR

SIDE

011 ov/22ov
BROWN SKY BLUE WHITE

SK

CONTROL

PANEL

SIDE

STATOR

SIDE

- 49 -

* LG180

Main coil Wire color: Black, Blue. Red. White

* LG240 6P coupler * LG340 f

BLUE

BLACK WHITE RED RED WHITE BLACK

BLUE

CONTROL

PANEL

SIDE

STATOR

SIDE

0 Earth (Ground) wire: Pin terminal 37 Mount control panel on the control box. iSee Fig. 1O-33.) 40 x 8 mm screw-and washer. . . 4 PCS.

Wire calor: Green ,+J$ zzyx-~z3,>,: \* ,---=----c-nzs ~=====y=~===yy~~ yzi ^ -:iE-& .c -w-;I::;; e:. :i: /C?+ :p ~- -L: 33 ; 8, 1,s c. : 2 F1s. t= > ./ &h. 3 -t/L 2_ 2 1

Fig. lo-33

10-5

OPTIONAL

FULL-FRAME

TYPES

Fix mount rubbers on the frame first and then install the engine and generator unit. Ground rear cover to frame with an earth wire when installing mount rubbers.

EARTH

WIRE

Fig. lo-34

- 50 -

11. TROUBLESHOOTING
11-l 11-1-l
l

NO AC OUTPUT CHECKING STATOR

Remove control panel and disconnect couplers on wiring. 0 Measure the resistance between terminals on stator leads. (See Fig. 1 l-l .) Refer to Table 9 - 1 for normal resistance. (Pages 30 and 3 1)

[Remedy1
If stator is defective: replace with new one.

Fig. 1 1- 1

11-l -2
l

CHECKING

CONDENSER

CON DENSER

If an instrument (QC-meter or C-meter) for measuring capacity of condenser is available. check the capacity of condenser. (See Fig. 1 l-2.)

---

DENSER (17rFI

Fig. 7 1-2

. IrcORhlAL CAPACITY OF COSDEXSER

MODEL Capacity

; I i

LG080 10~F

LG120 lOl.tF

LG180 17gF Table 1 l-1

! /

LG240 201.1F i I

LG340 17;1Fr20gF

0 If you do not have such an instrument. y-ou can check condenser bj- replacing with new one and test running. If the generator performs normally with new condenser. the cause of trouble is defect in original condenser.

-51-

11-l -3
l

CHECKING

ROTOR

Remove rear cover and stator. 0 Unsolder the terminal from the field coil of the rotor. (See Figs. 1 l-3 and 1 l-4.)

SURGE \ ABSORBER

Fig. 11-3 (LG080, LG120)

Fig. 1 I-4 (LG 780, LG240, LG340)

Measure the resistance of field coil with a circuit tester. (See Fig. 11-5.:)

I
Fig. 11-5

I
(R x 19 ~1OXi / LG240 9.1.0, LG340 6.40

. SORXXL

RESIST.4SCE
MODEL Resistance LG080 10.8fi LG120 8.l.r! LG180 8.59

Table 11-2

[Remedy]
l

If the resistance is not normal, replace rotor Lvith new one.

- 52 -

. [LG080, LG1201
l l

Unsolder and take out the diodes and the resistors. Measure the resistance of diode.
CATHODE MARK -Y OF TESTER

NOTE:
l

L GO80 has a piece of diode, while L G 120 has 2 pieces of diode.

Measure the resistance of each resistor. 1Kormal resistance: 15 kS2

Check the magnetic force of magnets molded in the rotor.

[RemfWl
1. If the mapetic force is weak. replace the rotor Lvith a new one. 2. If the diode or the resistor is fault>-. replace them with new one. When all these parts are good. assemble them and then solder.
[Reassembling]

1. Place the resistors at the bottom. 2. On the resistors put the diodes. taking care of its polarity. LG080: 1 pee. LG120: 2 PCS. 3. Solder the terminal. *Resistor has no polarity.

(CROSS SECTION)

SOLDERING

RESISTOR

I1 me.1

Fig. 11-6

- 53 -

. [LG180,
l

LG240,

LG3401

Unsolder the diode and check the resistance of diode (Each rotor has 3 PCS.of diode. Check the resistante of every diode.)
CATHODE MARK POLARITY OF CIRCUIT TESTER

[Continuity

exists.]

[-01

0 Measure the resistance of surge absorber connected to the diode holder. Tormal resistance is XL!.
l

Check the magnetic force of magnets molded in the rotor.

[Rem=Jyl
1. If the magnetic force of the rotor is weak or if the surge absorber is not good. replace the rotor with a new one. 3. If the diode is not good. replace it with a new one and assemble. When all the diodes are good. assemble them.
CAUTION: In case the diode troubles are frequent, check the surge absorber becuase it is broken in some cases even if its resistance is measured normal (4221. In such a case, replace the rotor with a new one.

[Reassembling]

1. As shown in Fig. 1 l-. on the magnet to the diodes so that cathode the bottom. 3. Solder the rotor coil to

place the whitz mark left and assemble the mark is to be placed at the terminal.
WHITE MA (IL1

DIODE

SURGE

ABSORBER

CATHODE

MARK

Fig. II- 7

- 54 -

11-2 11-2-l

AC VOLTAGE CHECKING

IS TOO HIGH ENGINE r.p.m.

OR TOO LOW

If the engine r.p.m. is too high or too low! adjust it to the rated r.p.m.
[How to adjust engine r.p.m.1
l l

Loosen the nut on the adjusting screw. Turn the adjusting screw crockwise to decrease engine speed or counter-clockwise to increase engine speed. Normal engine speed at no load is: 3 100 - 3 150 r.p.m. for 50Hz type 3700 - 3750 r.p.m. for 60Hz type

Fig. 11-8

11-2-2

CHECKING

STATOR

Check stator referring to Step 1 1- l-l.

11-2-3

CHECKING

CONDENSER

Check condenser referring to Step 1 1- 1-Z.

11-2-4

CHECKING

ROTOR

Check rotor referring to Step 1 l- l-3.

-55-

12. CIRCUIT
l

DIAGRAMS

LG080,

LG120

(1 lOV, 12OV)

Circuit (Blue),

breaker

Spark plug

Magneto

Rectifier

L - - _ _ _] 1 ,------I

/ 110Vor 120v AC Receptacle / Condenser

Earth terminal (Ground) Ignition coil

= 1.25 mm =0.75 mm:

LG080,

LG120

(22OV, 24OV)

Circuit

breaker

Spark plug -1-----

Magneto 7 1 Stop button I/

L&-------ir_

Rectifier

L-

-_

-J

(Black)

/ Condenser

220V or24OV AC Receptacle -1.25 -0.75

/
:;

IL----Earth ierminal (Ground) Ignition coil mmz mm

- 56 -

. LG080D,

LGlZOD

(1 lOV/22OV)

Resister

r - - - T -

/i-----J

Diode Rectifier

----

Earth terminal Ignition Condenser 11ov AC Receptacle = -0.75 coil

1.25 mm: mm:

0 LG180 (llOV,

12OV)

Circuit breaker Field coil

11OV or 120V AC Receptacle -----

Spark plug !

Magneto /

stop button

Diode Rectifier l-----IcoilLt --.-p&--i

I (Whiteli i----

I -.___.___. (White) (Blue)

I 1 ii 1 I I I:1
L---L7 ----

--------&J

(Yellow) Conde&kr

Earth terminal (Ground)

lgiition

coil

1.25 mm: ===0.75 mm

- 57 -

LG180

(22OV. 24OV)

Circuit breaker Field coil

220V or 240V AC Receptacle

Spark plug 1

Magneto /

stop button

Earth terminal (Ground)

\, Ignition =1.25 ====0.75

coil mm mm-

Condenser

. LG 180D ( 11 OV/22OV,

12OV/24OV)

Circuit breaker Field coil r

Full power Switch

220V or 240V AC Receptacle

Spark plug !

Magneto 1

stop button

/L-----J Diode Rectifier l-------

.J

--_
- -J I----____

--_
A+-----A--J

0 (Yellow) a 2 Condenser .-

Earth terminal (Ground) =1.25 -0.75

lL\ 11OV or 120V AC Receptacle

\ Ignition

coil mm mm-

-58-

LG240

(1 lOV, 12OV)

Circuit breaker

11OV or 120V AC Receptacle

Spark plug i

Magneto /

stop button
,yLcec ,I-----I : J

&;(Red)

I (H

Diode Rectifier ,-----,

iI
I I I I J 1 I L--

\ - -i \ IgAition -2.0 -1.25 -0.75 coil ---:

Earth terminal (Ground)

Condenser

mm mmmm-

. LG240

(22OV. 24OV)

Circuit breaker

220V or 240V AC Receptacle

1' I+I '

Spark plug :

Magneto I

Diode Rectifier

I I I L------------

I iI I! Io I ; I !
j I!

stop k / button

I 1

I; i SlUi
L-h

I I

JL---------J Earth terminal (Ground) -2.0 = -

Ignition

coil

/I
Condenser

mm1.25 mm4 0.75 mm-

- 59 -

. LG240D

(1 lOV/22OV,

12OV/24OV)

Circuit breaker Field coil r

Full power Switch

220V or 240V AC Receptacle

Spark plug ,

Magneto ,/

stop button

l-,L---$+--A

L-------i------&--J

_----

----

J coil

Earth terminal (Ground)

CondeGser

\i 11OV or 120V AC Receptacle

\ Ignition -2.0 -__-

mm 1.25 mmi 0.75 mm2

. LG340

(1 lOV, 12OV)

Fieldcoil

I -l i! iI

Circuit breaker

11OV or 120V AC Receptacle

Spark plug I

Magneto /

, Stop button I I I I I I1 I1 II .____. il ----JL-Lr----J Earth terminal (Ground)

Diode Rectifier

I i Ignition

coil

Condenser

-3.5 mm-2.0 mm = 1.25 mm -----0.75 ,,:

- 60 -

LG340

(22OV, 24OV)

Circuit breaker Field coil

!-

220V or 240V AC Receptacle

Spark plug

Magneto

, Stop button

,lL-----J Diode Rectifier r-------I

i I

(White) A (Green) l- ------------

I1 II 1 ;I &JL----i-----I Earth terminal (Ground)

L-l
i, Ignition

SIU

i I I

coil

Condenser

-2.0 mm: = 1.25 mm: ------0.75 mm2

LG340D

(1 lOV/22OV,

12OV/24OV)

Circuit breaker Field coil

Full power Switch

Spark plug 220V or 240V AC Receptacle i --, r--+--7/!!

Magneto /

r
stop button

/L-----J Diode Rectifier r-----IConde;yx ,lhlh:

i G reen)
i------~--J

: j 1 I \ \
L

L------w

Earth terminal !Ground) -2.0 -1.25 -0.75

Condenser

i 11OV or 120V AC Receptacle

Ignition

coil

mm mm mm

-61-

0 LG340D

(12OV/24OV

for U.S.A.)

Circuit breaker Field coil

Full power Switch

240V AC Receptacle

Spark plug /

Magneto /

Diode Rectifier

---

\, -+----

II

ISIU I;
J coil

\ Ignition Condenser 120v AC Receptacle -2.0 m

mm 1.25 mm4 0.75 ,,:

- 62 -

FUJI

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INDUSTRIES

LTD.