Professional Documents
Culture Documents
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
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 Function ................................................ Description of Generator Operation ........................... PRECAUTIONS of APPLICATIONS PROCEDURES ...... ............ ..................... ..................................... ....................................
6. 7. 8.
SAFETY RANGE
..................................... 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 ................................ .........................................
........................................... No AC Output AC Voltage is Too High or Too Low .......................... DIAGRAMS ..........................................
12.
CIRCUIT
Model
LG080
LG080D
LG120
LGISOD
LG180
LG180D
ryr-lt -- -_ .
Frequency
--
-_.--
60Hz ..-----...
Power Factor --. -.--. DC Output - -_ Voltage Regulatot + -.. .. .Type --_ _-Rt?~lllilliOrl
----
..-. --.
-,
Voltage
. ..-.---. .
Jlotlel
.-__ . 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)
_. _ ._ .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
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--
---.-
__.____-__
---
-.--
(Rated Current) -, - ----. --- - - --Power Factor _-_----_-DC Output _______ -.-----. Regulator __-_--- .-- -Voltage Regulatioti _------- + Type ____. __._ __- __--, M0dd __-_ -_-._---Displacornent ---I-.---------
--
-.---
__--_-_--_-_---~ Fuel --_---------Fk~el Tur\k Capacity .----.---,-,- - -... Oil Capacity --__-__-Ravolutmn __- - --.--------..----Igt,itiorl System __---.- - - - ----.-.--.---------A-Startirlg System _---___-_----Fud Consurnptiorl Ratio .---.. ---,----
---
--
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)
(4.5 pint)
Lcrigth(in) _----
-- -_._ -------
34 kg (75.1 Ibs)
47 kg (103.8 Ibs)
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
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.
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)
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
400
5 CL k 0
. 200
CURRENT
(A)
: 5 560
65 : I/ : I I
I
4 CURRENT
6 (A)
-4-
2-2
MODEL
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
2 e 2 6 >
1000
RATED
44
800
5 E 2
0 0 2 6 4 CURRENT (A) 8 10
-5-
2-3
MODEL
LG180
50Hd220V
I 240:,6ii
OUTPUT
VOLTAGE
MAX. RATED
I I/
i-l
800
2 iii IL
W
2 > 55 g 50 45 CURRENT (A)
400
CURRENT
(Ai
-6-
2-4
MODEL
z : a t1 :
1600
RATED
1200 s 2 E
> CJ W 2 W cc u
55
800
50
400
45
4 6 CURRENT (A)
0 10
iz u
i
CURRENT
(A)
-7-
2-5
MODEL
LG340
50Hz/22OV
> 240
W
z 220
I )/
OUTPUT
q3200
MAX. RATED
1600
CURRENT
(A)
60Hz/l2OV OUTPUT
3200
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
(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
STATOH
CHANKSHAFT
CARRYING
HANDLE
CONDENSER BRACKET
CONDENSER
If 1
MDUbiT
RlJBBER \ ROTOR
REAH
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
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
X diode rectifier and resister or surge absorber is mounted inside of the insulator. (See Fig. 5- -! and 5-8.)
DIODE
RECTIFIER
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
STATOR ----I
i
FIELD ROTOR COIL
I--
IL
J-=
RECEPTACLE AND PLUG
/
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-.
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. / /
LG120 LGl 20D 50Hz 800W about 450w 60Hz 1 ooow about 600W about 600W
I 1 60Hz
LG340 LG340D 50Hz 2500W about 165OW about 1 1500w about ] I 60Hz 29OOW ! i about i 19OOW abour 1 JOOW j about
1 50Hz
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.
I 1 Aowabe current A 7 2 17 23 35
Resistance
mm
.O..lOO 2.477
Table 7- 2
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
Fig. 8-3
- 25 -
8-l-4
TESTER
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.)
. 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
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.
- 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%)
3.5,0,
6.322
I I
50
3.3R I 4.1s I
5.2R
5.2R
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
winding
while
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).
- 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
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
LG240 2O/*F
LG340
1 17/1F +20/.1F
- 33 -
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
! I I
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
Precaution
Necessary tool
COLPLERS (Disconnection)
(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)
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.
CONDENSER
CONDENSER
REAR
COVER
REAR
COVER
Sequence
Part to remove
Description
Precaution
Necessary tool
MOUST RLBBERS
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
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
*-
..-
\
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.
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
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
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
CONDENSER
CONDENSER
Fig. lo-25
(LGl80,
LG240)
LG340:
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
COVER
BOLT:
3 pcs.
Fig. lo-29
- 46 -
Dimensions
of cover bolts
LG120
I
I
1 1
-z-
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
Fig. lo-31
- 47 -
[WIRE
CONNECTiONS
BETWEEN
CONDENSER
AND STATOR
(CONDENSER
COIL)
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
* 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
BLUE
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
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
MODEL Capacity
; I i
LG080 10~F
LG120 lOl.tF
! /
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
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
- 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
[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
[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
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
11-2-3
CHECKING
CONDENSER
11-2-4
CHECKING
ROTOR
-55-
12. CIRCUIT
l
DIAGRAMS
LG080,
LG120
(1 lOV, 12OV)
Circuit (Blue),
breaker
Spark plug
Magneto
Rectifier
L - - _ _ _] 1 ,------I
LG080,
LG120
(22OV, 24OV)
Circuit
breaker
L&-------ir_
Rectifier
L-
-_
-J
(Black)
/ Condenser
/
:;
- 56 -
. LG080D,
LGlZOD
(1 lOV/22OV)
Resister
r - - - T -
/i-----J
Diode Rectifier
----
0 LG180 (llOV,
12OV)
Spark plug !
Magneto /
stop button
I (Whiteli i----
I 1 ii 1 I I I:1
L---L7 ----
--------&J
(Yellow) Conde&kr
lgiition
coil
- 57 -
LG180
(22OV. 24OV)
Spark plug 1
Magneto /
stop button
coil mm mm-
Condenser
. LG 180D ( 11 OV/22OV,
12OV/24OV)
Spark plug !
Magneto 1
stop button
.J
--_
- -J I----____
--_
A+-----A--J
0 (Yellow) a 2 Condenser .-
\ Ignition
coil mm mm-
-58-
LG240
(1 lOV, 12OV)
Circuit breaker
Spark plug i
Magneto /
stop button
,yLcec ,I-----I : J
&;(Red)
I (H
iI
I I I I J 1 I L--
Condenser
mm mmmm-
. LG240
(22OV. 24OV)
Circuit breaker
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
Ignition
coil
/I
Condenser
- 59 -
. LG240D
(1 lOV/22OV,
12OV/24OV)
Spark plug ,
Magneto ,/
stop button
l-,L---$+--A
L-------i------&--J
_----
----
J coil
CondeGser
. LG340
(1 lOV, 12OV)
Fieldcoil
I -l i! iI
Circuit breaker
Spark plug I
Magneto /
Diode Rectifier
I i Ignition
coil
Condenser
- 60 -
LG340
(22OV, 24OV)
Spark plug
Magneto
, Stop button
i I
L-l
i, Ignition
SIU
i I I
coil
Condenser
LG340D
(1 lOV/22OV,
12OV/24OV)
Magneto /
r
stop button
i G reen)
i------~--J
: j 1 I \ \
L
L------w
Condenser
Ignition
coil
mm mm mm
-61-
0 LG340D
(12OV/24OV
for U.S.A.)
240V AC Receptacle
Spark plug /
Magneto /
Diode Rectifier
---
\, -+----
II
ISIU I;
J coil
- 62 -
FUJI
HEAVY
INDUSTRIES
LTD.