TUBE FRAME GENERATOR Table of Contents – Page 1 of 3 PREFACE SAFETY INSTRUCTIONS FOR YOUR SAFETY IDENTIFICATION T1200 SPECIFICATIONS MODEL 62012 PRODUCT SPECIFICATIONS MODEL 62012 GENERATOR SPECIFICATIONS MODEL 62012 ENGINE SERVICE SPECIFICATIONS MODEL 62012 CARBURETOR SPECIFICATIONS MODEL 62012 FASTENER TORQUES T1800 SPECIFICATIONS MODEL 62018 PRODUCT SPECIFICATIONS MODEL 62018 GENERATOR SPECIFICATIONS MODEL 62018 ENGINE SERVICE SPECIFICATIONS MODEL 62018 CARBURETOR SPECIFICATIONS MODEL 62018 FASTENER TORQ
TUBE FRAME GENERATOR Table of Contents – Page 2 of 3 TROUBLESHOOTING - Continued ENGINE MISSES UNDER LOAD ENGINE OVERHEATS ENGINE SURGES OR RUNS UNEVENLY ENGINE VIBRATES EXCESSIVELY ENGINE USES EXCESSIVE OIL OR SMOKES MAINTENANCE MAINTENANCE - AIR CLEANER MAINTENANCE - SPARK PLUG MAINTENANCE - CHANGING OIL MAINTENANCE - FUEL SEDIMENT BOWL MAINTENANCE - FREQUENCY ADJUSTMENT MAINTENANCE - VALVE CLEARANCE MAINTENANCE - VALVE CLEARANCE INSPECTION MAINTENANCE - VALVE CLEARANCE ADJUSTMENT MAINTENANCE - DECARBONIN
TUBE FRAME GENERATOR Table of Contents – Page 3 of 3 SECTION 3 IGNITON SYSTEM - Continued IGNITION COIL - REMOVAL IGNITION COIL - INSTALLATION SPARK PLUG SPARK PLUG - REMOVAL SPARK PLUG - INSTALLATION SECTION 4 RECOIL STARTER RECOIL STARTER - REMOVAL RECOIL STARTER - DISASSEMBLY RECOIL STARTER - REASSEMBLY RECOIL STARTER - INSTALLATION SECTION 5 LOW OIL SHUTDOWN LOW OIL SHUTDOWN CIRCUIT - PURPOSE LOW OIL SHUTDOWN CIRCUIT - OPERATION LOW OIL SHUTDOWN CIRCUIT - TESTING LOW OIL SHUTDOWN SWITCH - REMOVAL LOW OI
PREFACE This Service and Overhaul Manual was written expressly for the Tor0 T1200, T1800, T2500 and T3000 electric generators. This manual will cover both single and dual voltage models of the T2500 and T3000 generator. The Tor0 Company has made every effort to make this Service Manual a useful and lasting addition to every Service Facility.
TABLE OF CONTENTS Reference Information Page Safety Instructions 1 Identification 2 Specifications 3 SpecialTools 19 Troubleshooting* 20 Maintenance 24 * For generating troubleshooting information, see Section 7, page 74.
TABLE OF CONTENTS (cont'd) Service Procedures (cont'd) I Section Three Ignition System (cont'd) Page Ignition Coil removal installation Spark Plug removal installation Section Four 38 39 I 40 40 Recoil Starter removal disassembly reassembly installation Section Five 41 41 42 43 Low Oil Shutdown Low Oil Shutdown Circuit purpose operation testing 44 44 44 I Low Oil Shutdown Switch removal installation Section Six 45 45 Engine disassembly cleaning after disassembly inspection reassembly 45 51
TABLE OF CONTENTS (cont’d) Service Procedures (cont’d) Section Seven Generator (cont’d) Page Generator Testing measuring AC voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . measuring DCvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 measuring stator coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . measuring rotor coil resistance . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INSTRUCTIONS This manual is intended to be a service and repair manual only The safety instructions provided in this manual are for the troubleshooting and service of the product only. Individual Operator's Manuals will contain safety information for the operation of the generators that are described is this manual. This safety symbol means WARNING AND/OR CAUTION PERSONAL SAFETY INSTRUCTION Read the instruction because it has to do with safety.
IDENTIFICATION Each Tor0 whole good is assigned a model and serial number. ,The model number has five digits and indicatesthe size and style of the product. Inadditionto the model number, each product also has a unique serial number which serves to differentiate products with the same model number. The serial number has seven digits, the first of which identifies the year of manufacture (ie. 6000386 indicatesthat the product was built in 1986.
TI200 SPECIFICATIONS Model 62012 Product Specifications Model 62012 Generator Specifications 3
TI200 SPECIFICATION$ (cont'd) I Model 62012 Generator Specifications (cont'd) * 1 KVA = 1000 Watts true power with a power factor of one. Model 62012 Engine Service Specifications Standard Dimension Allowable Limit Spark Plug NGK BPR-6HS NIA Spark Plug Gap .75mm NIA (.030") Ignition Coil Air Gap (External Mount) .38 (.015”) fixed ! N/A 1.OO to 1.40mm (.039to .055”) Width of Valve Seat Contact .80to 1.OO mm (.032to .040") .050mm NIA (.002”) Intake Guide to Valve Stem Clearance NIA .
TI200 SPECIFICATIONS (cont'd) Model 62012 Engine Service Specifications (cont'd) Stem Clearance 35.5to 36.5mm 25.990 to 26.000 mm Bearing Diameter (Big End) .005to .
TI200 SPECIFICATIONS (cont'd) Model 62012 Engine Service Specifications (cont'd) Model 62012 Carburetor Specifications Model 62012 Fastener Torques Torque .88 kg m (6.4 ft Ibs) 2.0 kg m (14.5 ft Ibs) 6.5 kg m (47 ft Ibs) .7 kg m (5.0ft Ibs) 1.3 kg m (9.4 ft Ibs) 1.O kg m (7.2 ft Ibs) i .88 kg m (6.4 ft Ibs) .88 kg m (6.4 ft Ibs) 50 kg m (3.6ft Ibs) .75 kg m (5.4 ft Ibs) I .22 kg m (1.6 ft Ibs) ! .88 kg m (6.4 ft Ibs) .88 kg m (6.4 ft Ibs) ! 5 5 kg m (4.0 ft Ibs) 1.1 kg m (8.
T I 8 0 0SPECIFICATIONS Model 62018 Product Specifications __ _ _ I ____ __I Specification I - air cooled 4-stroke, side valve 66 mm (2.60") 56 mm (2.20”) 191.6 cc (11.69 cu. in.) I - 2.8 kilowatt (3.8 HP) @ 3600 rpm end) counterclockwise viewed from - (as~ -PTOaluminum with cast iron liner ball ball plain float unleaded regular gasoline 7.00 liters (1.84 gal.) 5.0 hours at rated load transistorized _- I ~ _ _ - 25° BTDC @ 3600 rpm NGK BPR-6HS ____I_ _ - recoil - ~ ~ --------_- splash .
T I 800 SPECIFICATIONS (cont'd) Model 62018 Generator Specifications (cont'd) Specification 12.5 amperes. 12 volts DC 8.3 Amperes i 1.5 KVA (kilovolt amps)* Maximum Power 1.8 KVA (kilovolt amps) 60Hz at 3600 RPM 3600 RPM revolving field, self-excited 1.o directly coupled to engine Automatic Voltage Regulator electronic solid state design. * 1KVA = 1000 Watts true power with a power factor of one. ! Model 62018 Engine Service Specifications Item Spark Plug NGK BPR-6HS Spark Plug Gap 75 mm (.
T I 800 SPECIFICATIONS (cont'd) Model 62018 Engine Service Specifications (cont'd) Item Standard Dimension Exhaust Guide to Valve Stem Clearance .035to .065mm (.0014to .0026') Valve Spring Free Length Cam Height Intake and Exhuast 35.5to 36.5mm (1.398to 1.437") 32.465 to 32.505 mm (1.2781to 1.2797") Connecting Rod Journal Diameter 25.990to 26.000 mm (1.0232to 1.0236') Connecting Rod Bearing Diameter (Big End) 26.005to 26.015 mm (1.0238to 1.
T I 8 0 0SPECIFICATIONS (cont'd) Model 62018 Engine Service Specifications (cont'd) I Model 62018 Carburetor Specifications Item I Main Jet (STD) #75 (fixed) I Pilot Jet #40 (fixed) I Model 62018 Fastener Torques Fastener Torque Spark Plug .88 kg rn (6.4 ft Ibs) Cylinder Head Bolts 2.0 kg rn (15 ft Ibs) Flywheel Nut 6.5 kg rn (47 ft Ibs) Connecting Rod Nuts .70 kg rn (5.1 ft Ibs) Frame Bolts 1.3 kg rn (9.4 ft Ibs) Generator Through Bolt 1.O kg rn (7.2 ft Ibs) Starter CUP Capscrews .
T2500 & T2500D SPECIFICATIONS Models 62025 & 62027 Product Specifications Item Specification Type Bore air cooled, 4-stroke, side'valve Stroke 62 mm (2.44") Displacement 252.4 cc (15.40 cu. in.) Rated Continuous Output 3.7 kilowatt (5.
T2500 & T2500D SPECIFICATIONS (cont'd) Models 62025 & 62027 Generator Specifications :(cont'd) Models 62025 & 62027 Engine Service Specifications Item Spark Plug Spark Plug Gap "___I- Ignition Coil Air Gap (External Mount) N/A Ignition Coil Air Gap (Internal Mount) Valve Margin Width of Valve Seat Contact Valve Lash .030mm Valve Head Runout (Both) (.0012”) .080mm .
T2500 & T2500D SPECIFICATIONS (cont'd) Models 62025 & 62027 Engine Service Specifications (cont'd) Standard Dimension Guide to Valve .040to .070mm 39.5to 40.5 mm (1.2784to 1.2800') 27.991 to 28.000 mm 28.013to 28.027mm (1 .1029to 1 1 034") ecting Rod Journal .013to .036”mm (.0005to .0014") .400to .800 .006to .019mm 8.0 mm iston Ring End Gap 0.200to 0.400mm (0.0079to 0.015 8 ' ) 0.20to 0.80mm 0.030to 0.070 mm (0.001to 0.003') 0.020to 0.060mm (0.001to 0.003") 2.46to 2.48mm 2.51 to 2.53 mm (.0988to .
T2500 & T2500D SPECIFICATIONS (cont'd) Models 62025 & 62027 Engine Service Specifications (cont'd) Models 62025 & 62027 Carburetor Specifications Models 62025 & 62027 Fastener Torques Torque -~.-- .88 kg m (6.4 ft Ibs) 2.5 kg m (19 ft Ibs) 6.5 kg m (47 ft Ibs) 1.8 kg m (13 ft Ibs) Connecting Rod Nuts 1.3 kg m (9.0 ft Ibs) Generator Through Bolt 1.O kg m (7.3 ft Ibs) Starter Cup Capscrews .88 kg m (6.4 ft Ibs) Recoil Pulley Screw .88 kg m (6.4 ft Ibs) Recoil Mounting Screws .50 kg m (3.
T3000 & T3000D SPECIFICATIONS Models 62030 & 62032 Product Specifications Model 62030 & 62032 Generator specifications 15
T3000 & T3000D SPECIFICATIONS (cont'd) Models 62030 & 62032 Generator Specifications'(cont'd) Models 62030 & 62032 Engine Service Specifications Standard Dimension NGK BPR-6HS N/A .75mm (.030') i Ignition Coil Air Gap .38 (.015”) i Ignition Coil Air Gap fixed ! N/A ! .95 to 1.45 mm (.037 to .057") Width of Valve .90to 1.10 mm (.035to .043") i I ii I .050 mm N/A (.002”) Valve Head Runout (Both) N/A .030mm (.0012”) .025to .055mm (.0010 to .0022") .080 mm .
T3000 & T3000D SPECIFICATIONS (cont'd) Models 62030 & 62032 Engine Service Specifications (cont'd) Exhaust Guide to Valve .040to .070mm (.0016to .0028') 39.5to 40.5 mm (1.555to 1.595") 32.472to 32.512 mm (1.2784to 1.2800”) 27.991 to 28.000mm (1.1020to 1.1024") 28.013 to 28.027mm (1.1029to 1.1034") ecting Rod Journal I i .013to .036"mm (.0005to .0014') .400to .800 (.0158to .0315") .006to .019mm (.0002to .0008) NIA 8.0mm (.32") NIA .030to .050mm (.0012to .0020”) NIA ! - Piston Ring End Gap .20to .
T3000 & T3000D SPECIFICATIONS (cont'd) Models 62030 & 62032 Engine Service Specifications (cont'd) Models 62030 & 62032 Carburetor Specifications stainless steel 1 1/4 Models 62030 & 62032 Fastener Torques 18
SPECIAL TOOLS 19
TROUBLESHOOTING Engine Does Not Produce Spark Possible Causes I Remedy engine switch in “off’ position move switch to “on” position spark plug fouled or damaged replace spark plug spark plug wire damaged replace coil ignition coil primary wire grounding out repair damaged wire with electrical tape ignition coil has failed replace ignition coil I Engine Floods During Starting Possible Causes Remedy no spark I see “Engine Does Not Produce Spark’ troubleshooting section above stale gasoline
TROUBLESHOOTING (cont'd) Engine Difficult to Start Remedy see "Engine Does Not Produce Spark” troubleshooting section (page 8) see "Engine Does Not Get Fuel During Starting" troubleshooting section (page 8) I engine not getting fuel see "Engine Floods During Starting" troubleshooting section (page 8) engine has low compression compare compression to compression of new unit--repair as necessary Engine Lacks Power Possible Causes Remedy choke partially closed open choke adjust carburetor replace flywh
TROUBLESHOOTING (cont’d) Engine Misses Under Load Engine Overheats Engine Surges or Runs Unevenly * For generating troubleshooting information, see Section 7, page 74.
TROUBLESHOOTING (cont'd) Engine Vibrates Excessively replace damaged parts tighten engine mounting bolts Engine Uses Excessive Oil or Smokes Remedy set engine to proper speed drain excess oil ensure that cap does not pass oil or air replace damaged or worn parts overhaul engine * For generating troubleshooting information, see Section 7 , page 74.
MAINTENANCE Maintenance Air Cleaner The air cleaner should be serviced every 50 hours. Maintenance may have to be completed as often as every 25 hours if the generator is being operated in dirty or dusty conditions. 1. Shut the generator off and close the fuel shutoff valve. 2. Remove the thumb screw retaining the air cleaner cover. See Figure 1. Maintenance Spark Plug The spark plug is the ignition source for the fuel air mix in the combustion chamber of the engine.
r‘, Maintenance - Changing Oil (cont’d) 5. Empty the fuel bowl and clean it of any debris. 4. Reinstall the drain plug and dispose of the used oil at a proper waste oil disposal site. 6. 5. Fill the crankcase with oil. See the Specification Section on page 3 for the proper quantity. When replacing the oil it will be helpful to tilt the generator back about 100-15’, this will allow the oil to enter the filler neck without spilling. See Figure 3.
closing completely and the valve clearance will have to be adjusted. Maintenance Frequency Adjustment (cont'd) ment screw is located behind the air cleaner and connects to the governor arm. 6. .05-.15 mm (.002-.006”) for both intake and exhaust valves. With the engine at 3600 rpm the 60Hz reed on the front of the generator will resonate.(some models are not equipped with a frequency meter.) See Figure 5. Adjustment Frequency: Every 300 hrs I I Maintenance Valve Clearance Inspection 1.
Maintenance Valve Clearance Inspection (cont'd) 9. The correct clearance is .05-.15 mm (.002-.006'”). If the clearance is not within tolerance, the valves must be removed from the engine and the approprlateamount of material ground off the stem of the valve. Maintenance Valve Clearance Adjustment 1. Follow steps 1 7 as described above. 2. Remove the fuel hose from the carburetor. 3. Remove two hair pin clips from the bottom of the front control panel. See Figure 7. 9. Remove the valves. 10.
Maintenance Decarboning Spark Arrester (cont'd) fler to dislodge any carbon build up within the spark arrester. CAUTION: Misuse of gasoline can cause death. Never smoke while working with gasoline. Never expose gasoline to open flame or fire. Always use proper ventilation while'working with gasoline. CAUTION: Exhaust fumes can cause death. Operate the generator only In a well ventilated area. 2. Start the generator and run the remaining fuel out of the 3.
SECTION 1 CARBURETOR from the float bowl. This fuel premixes with the incoming air, then is discharged into the intake port of the engine. See Figure 12. Carburetor Operation The carburetor receives fuel from the gasoline tank and mixes it with air in the right proportions to provide a highly combustible mixture to the engine.
Carburetor Operation (cont'd) carburetor throat for more efficient atomizing of the fuel. See Figure 13. 7. Slide /the carburetor off its studs and disconnect the governor link rod. 8. There will be a small amount of gasoline in the bowl of the carburetor. Drain this gasoline into a suitable container by opening the drain screw on the bottom of the carburetor. ,Pilot System CAUTION: Mishandling gasoline can cause death. Always work with gasoline in a well ventilated area free of open flame or sparks.
Carburetor Disassembly (cont'd) jet and air enters through the holes in the side. The opening on the top of the jet is a drilling passage and is plugged. CAUTION: Be sure to wear safety glasses when using compressed air. Use pressure of no more than 40 PSI. The pilot screw controls air in the pilot circuit. It should be open 1 to 1-1/2 turns on all engines. See Figure 17. 3. t FLAT If it is suspected that the seat is leaking, the carburetor can be pressure tested after it has been cleaned.
Carburetor Installation (cont’d) 3. Connect the governor link rod. See Figure 20. 5. Straighten the governor arm if it has been bent to allow connection of the linkage rod to the carburetor. 6. lnstail the carburetor mounting nuts. 7. Connect the fuel inlet hose. 8. If the~governorarm has been removed to provide additional working clearance, make sure it is correctly reset. The governor shaft is turned full counterclockwise while; the governor holds the throttle plate wide open.
SECTION 2 FUEL SYSTEM 8. FUEL TANK AND STRAINER See the Specification Section for the capacity of each fuel tank and approximate running time under full load. The required fuel is regular unleaded gasoline. Examinethe fuel tank for debris and wash the tank with a cleaning solvent if necessary. Fuel Tank and Strainer Removal 1. Shut off the generator. 2. Drainthe fuel tank.Remove the line on the inlet side of the fuel shutoff valve. See Figure 22.
Fuel Shutoff and Sediment Bowl Removal Drainthe fuel tank. Removetheline on the inlet side 1. of the fuel shutoff valve. See Figure 22 on page 33. Fuel Tank Cap Service (cont'd) NOTE: Have a container suitable for flammable liquids available to receive the gasoline from the tank. CAUTION: Mishandling gasoline can cause death. Always work with gasoline in a well ventilated area free of open flame or sparks. Do not smoke around gasoline. A 2. Disconnect the outlet hose from the fuel shutoff valve.
Fuel Shutoff and Sediment Bowl Service (cont'd) 6. When the stem and valve cylinder are removed,the valve may be cleaned in a nonflammable cleaning solvent. Fuel Shutoff and Sediment Bowl Installation 1. Reassemble the valve by inserting the valve cylinder and stem in the body of the valve. Make sure the cylinder and hole inthevalve cylinder lines up 'with the handle of the valve stem. Restriction of fuel flow may occur if the two parts are not indexed correctly. 2.
SECTION IGNITIONSYSTEM secondary coil must have many more windings than the primary. The higher the ratio between the primary coil to secondary coil windings, the greater the voltage amplification will be. IGNITION OPERATION The firing of the spark plug at the proper time is the culmination of a number of components working together. In the T1200 T3000 generator, the components used are: Flywheel Ignition coil Trigger circuit (molded into the ignition coil) Spark plug See Figure 28.
Ignition Operation Trigger Circuit (cont'd) 3. Current I1 flowing through Tr2 induces a larger current, l2.Note that current I1 is very small and that 12 is much larger. See Figure 34.
Excessive gap or fouling can delay firing enough to of power or stalling. cause a Ignition Operation Trigger Circuit (cont'd) 5. As the voltage produced in the primary coil reaches its negative peak (point “b” in Figure 30), transistor Trl is turned on and allows small current 13 and large current 14 to flow. 6. When transistor Trl turns on, nearly all of the current flow through R4 and Tr2 is diverted through path 14 since it is the path of least resistance.
10. Ignition Coil Testing (cont'd) 8. Insulatethe wire from ground and attempt to start the generator. If the ignition has spark the low oil shut down circuit is at fault. See the section on the low oil shutdown circuit, page 44. 9 If the ignition has no spark with the low oil shut down circuit disconnected the fault is with the Ignition circuitry and the coil may have to be removed. See the section on coil removal below. Unplugthe black ignition kill wire and and the entire coil may be removed.
gap on the electrodes of the plug is .6 Ignition Coil Installation (cont'd) .7mm (.024 .028"). 5. Reconnect the Ignition kill wire. Spark Plug Removal 1. Stop the engine and removethe rubber dust cover. 2. Remove the spark plug wire. 3. Clean debris from around the spark plug so dirt does not fall into the engine when the plug is removed 4. Remove the plug with a 19 mm (3/4”) wrench. 5. Spark 'plugs should not be cleaned by abrasive cleaners and reused.
SECTION 4 RECOIL STARTER Recoil Starter Removal 1. Turn off the generator, shut off the fuel and disconnect the spark plug. 2. Remove the three screws retaining the recoil starter. Note the position of the recoil handle for proper reinstallation. Recoil Starter Disassembly 1. Begin disassembly by relieving the spring tension on the reel. Pull approximately 30 cm (12") of starter cord out of the reel and hold the reel in place. 2. Place the cord in the notch in the reel and slowly release the reel.
Recoil Starter Disassembly (cont'd) 3. If the recoil rope has been removed insert a new rope and wind it in a counterclockwise direction around the reel. The recoil rope is approximately 120 cm (48') long. 4. Feed the end of the rope through the opening in the recoil housing and attach the “T” handle. 5. lnstall'the reel. The bosses on the inside diameter of the reel engagethe slots on the outside diameter of the /springcase. See Figure 47. WASHER- Figure 45 1 1.
Recoil Starter Reassembly (cont'd) 10. provide sufficient spring tension to pull the cord back into the recoil assembly when released. Pull about 30 cm (1 2') of cord out of the recoil. Turn the reel (it will now be under some spring tension) so the notch inthe outside diameter of the reel lines up with the cord as it leaves the recoil assembly. Pull about 15 cm (6') of cord up into the notch and rotate the reel counterclockwise one or two revolutions to 1.
SECTION 5 LOW OIL SHUTDOWN With low oil there should be a complete circuit to ground. LOW OIL SHUTDOWN CIRCUIT Low Oil Shutdown Circuit -Purpose If the engine oil drops below a safe level or if the engine is operated at an extreme angle, the oil alarm will turn on a warning light and at the same time ground the engine ignition.
Low Oil Shutdown Circuit Testing (cont'd) generator. Remove the six screws retaining the front panel and disconnect the module. See Figure 51. LOW OIL SHUT DOWN MODULE 4. FRONT PANEL Figure 51 10. Repair of the float switch is not possible. If the switch is defective (determined by continuity testing) it must be replaced. Low Oil Shutdown Switch Installation Replace the gasket if necessary. 1. Replace the module by separating it from the harness and install a new unit.
SECTION 6 ENGINE Engine Disassembly 1. Turnthe engine off and remove the spark plugwire. 4. Remove the fuel hose and drain any gasoline remaining in the tank. See Figure 53. 5. 2. Drain the engine oil as described in the Maintenance Section on page 24. Removethe end cover of the generator. See Figure 54. 6. Disconnectand remove the AC output wires at the terminal block. See Figure 55. 7. Disconnect the control wiring plug on the top of the generator assembly. See Figure 55. 8.
Engine Disassembly (cont’d) I Figure 57 Figure 60 14. Remove the four generator through bolts. See Figure 61. _I_.- Figure 58 12. I Remove the engine and generator from the tube frame by removing the four mounting bolts. See Figure 59. Figure 61 15. Use a plastic hammer to remove the end cover and stator assembly. See Figure 62. Figure 59 13. To completely tear down the engine the generator must be removed from the engine. Continue disassembly by removing the brush holder. See Figure 60.
Engine Disassembly (cont’d) 19. Remove the air cleaner assembly as shown in Figure 65. 20. Remove the two nuts securing the muffler to the engine. See Figure 66. Figure 63 17. Hold the crankshaft in place with a screwdriver or bar through the recoil starter cup and remove the rotor set bolt. See Figure 64. Figure 66 21. Removethe carburetor. Use careas the carburetor fuel bowl will still contain gasoline. See Figure 67. 22.
Engine Disassembly (cont’d) 26. If the generator uses an external ignition coil the coil should be removed at this time. 27. Remove the flywheel using Tor0 flywheel puller part number 41-7650. 28. If the generator uses as internal ignition coil it will be exposed on removal of the flywheel and should be,removed. See Figure 70. 29. Turn the engine around and remove the front generator housing. See Figure 71. Figure 68 Figure 71 30. Remove the governor lever and the governor spring bracket.
Engine Disassembly (cont’d) Figure 76 Figure 73 35. The camshaft may now be pulled out of the crankcase Take note of the location of the timing marks on the crankshaft and camshaft gear prior to disassembly On reassemblythese marks must line up with one another. See Figure 77. Figure 74 Figure 77 36. Straighten the locking tabs on the connecting rod nuts. See Figure 78. 37. Remove the connecting rod nuts, splasher plate (with locking tabs) and rod cap.
Engine Disassembly (cont'd) Figure 81 I Figure 78 Engine Cleaning After Disassembly 1. Clean all parts in appropriate solvents according to the solvent manufacturer's recommendations. Figure 79 2. Inspect all parts for wear and damage. Make certain that moving parts will move freely. 3. Remove carbon from the cylinder head and combustion chamber. Carbon can be removed with a non-marring scraper. Be careful not to damage the cylinder head or bore. 4. Clean the air filter element in soap and water.
The Special tools required for valve seat reconditioning are as follows: Engine Inspection (cont'd) T2500, T3000 Special Tools “T”handle wrench Adaptor Expandable pilot 75°/15° cutter 46° cutter 45° cutter Valve seat contact is determined by coating the valve seat with Prussian blue and rotating the valve in the seat. The width of the contact area will be disclosed on the face of the valve. The pattern must be a continuous ring without a break.
Engine Inspection (cont’d) 7. Piston to cylinder clearance T1200, T1800, T2500, T3000 Maximum piston to cylinder clearance: .120 mm (.0047”) Calculate the difference between the piston diameter and the cylinder diameter. If the figure exceeds the clearance limit, the cylinder must be bored and an oversize piston installed or replace the cylinder and piston. 8. Piston pin to connecting rod clearance: T1200, T1800, T2500, T3000 Figure 85 6. .05 mm (.
ring and ring groove. If the clearance exceeds the maximum allowable clearance value the rings or pistion~mustbe replaced. See Figure 91. Engine Inspection (cont'd) 9. Connecting rod side clearance: T1200, T1800, T2500, T3000 Maximum rod side clearance: 1.200 mm (.0472') Measure the side clearance of the connecting rod while secured to the crankshaft. If the clearance exceeds the limit, replacethe connecting rod. See Figure 89. Figure 90 Figure 89 10.
T1800 Engine Inspection (cont'd) Maximum allowable gap: ring Top ring 2nd ring Oil ring 2nd ring 1.5 mm (.0591") T2500 T3000 Maximum allowable gap: .7 mm (.0276') .8 mm (.03151") 1.5 mm (.0591") Oil ring Figure 92 13. When measuring piston ring end gap, place the ring in an area of the cylinder where there is a m'inimumamount of wear, e.g. near the top of the cylinder. Remember, we are trying to determine how much the ring has worn, not the cylinder.
Engine Reassembly (cont'd) 2. Installthe intake and exhaust valves. Coat the valve stems with a liberalamount of engine oil and insert them into the valve guides in the cylinder. See Figure 95 for correct placement of the intake and exhaust valves. The intakevalve has the letters "IN" stamped in the head of the valve. I--- OPERATING SHAFT Figure 97 Figure 95 3. Install the valve springs, spring retainers and valve keepers. See Figure 96. POINT THE SAME DIRECTION I 6.
Engine - Reassembly (cont’d) Figure 102 POINT iOWAR0 VALVES 11. Figure 100 8. Install the crankshaft. Lubricate the area of the crankshaft that must pass through the crankcase seal and bearing. If necessary wrap the crankshaft with a plastic sleeve to prevent seal damage. 9. Mount the rod, splasher, lock plate and rod cap to the crankshaft as shown in Figure 101. Take note of the match marks on the rod cap and rod for proper assembly. Mount the governor flyweight assembly to the camshaft drive gear.
16. Engine Reassembly (cont'd) Measure the valve clearance. T1200, T1800, T2500, T3000 Valve clearance specification: Intake Exhaust .05-.15 mm (.002-.006') .05-.15 mm (.002-.006”) If the valve clearance is not within specificationthe valves should be removed and adjusted per the Specifications Section for your particular engine. See Figure 107. Figure 104 I Figure 107 6 2 4 Figure 105 Figure 108 17. Install:a new head gasket and the cylinder head. T1200, T1800 Headbolt torque: 1.O kg m (7.
Engine Reassembly (cont'd) T3000 Headbolt torque: 3.2 kg m (23ft Ibs) Tighten the head bolts in a diagonal sequence to prevent warping of the head. See Figure 108. 18. Install the generator front bracket. The bracket should be installed with the "up" mark of the inner surface of the bracket facing up. See Figure 109. INSTALL THIS WAY "UP". I Figure 111 Figure 109 19. Tightenthe bolts in a diagonal sequence as shown in Figure 110. T1200, T1800, T2500, T3000 Generator front bracket torque: 2.0 kg m (14.
Engine Reassembly (cont'd) 23. 27. Install the flywheel nut. See Figure 113. Route the oil sensor wire in the channel provided in the crankcase. The wire groove is accessible with the flywheel installed. See Figure 115. _-- T1200, T1800, T2500, T3000 28. Inspect the rotor assembly for defects; broken wires: worn or damaged slip rings, damaged insulation. 29. Install the rotor assembly. Some units use a key or pin to align the rotor to the crankshaft.
Engine Reassembly (cont'd) 31. Removethe brush holder if it is still installed on the stator. 32. Align the through bolt holes with the holes in the front generator cover (the cover bolted to the engine) and install the stator. Take extreme care not to damage any of the coils in the stator. See Figure 117. Figure 119 Figure 117 33. Tighten the through bolts in the sequence as shown in Figure 118. T1200, T1800, T2500, T3000 34. The brush holder may be reinstalled at this time. 35.
39. Engine Reassembly (cont’d) nuts securing the carburetor to the engine. See Figure 121. I Figure 123 Figure 121 38. lnstall the muffler. Mount one gasket and secure the muffler with two nuts. See Figure 123. 40. Adjust the governor by rotating the governor shaft fully counterclockwise. The end of the shaft is slotted for a screwdriver. Move the governor arm (throttle control lever) to the full throttle position (rotate it fully counterclockwise). Tighten the retaining nut on the governor arm.
Engine Reassembly (cont'd) I Figure 127 Figure 125 46. Install the air cleaner element. Make sure the element has been cleaned and oiled. See the Maintenance Section on page 24 for details on air cleaner maintenance. 47. If the fuel line from the tank to the shut off valve has been disconnected, reconnect the line. Connect the fuel line from the shut off valve to the carburetor 48. Install the recoil starter. The handle should face toward the front of the generator. 49.
SECTION 7 GENERATOR to the maximum level, this is sometimes called "Pulsating Direct Current". See Figure 128. DEFINITION OF TERMS Definition of Terms Voltage Voltage (E) is a unit of electrical pressure and is measured in volts. Think of voltage as being similar to the pressure that oil is under in a hydraulic hose. The voltage in a circuit is equal to the current in the circuit multiplied by the resistance in the circuit. A 150watt light bulb will have 96 (ohms) of resistance and a current flow of 1.
Definition of Terms Diode A diode is an electronic component that allows electric current :to pass only in one direction. Definition of Terms Automatic Voltage Regulator (cont'd) sent to the rotor to produce the magnetic field in the generator. The output of the generator will in turn increase. If a heavy load is removedfrom a generator the voltage will tend to increase; the AVR will respondto this by decreasing the size of the field. The AVR will hold the voltage to within 10% of the rated voltage.
Generator Operation AVR and Rotor Coil (cont'd) 5. The AVR sends all or part of the electricity produced in the exciter coil through the brushes to the rotor. itdecides how much by measuring the out put voltage through two sensor circuit wires.) 6. The rotor spins inside the stator coil which produces the output voltage. -s i . .
(ZD), the zener diode will allow current to flow to the base (b) of the transistor (Tr). Generator Operation Automatic Voltage Regulator (cont'd) Refer to Figure 134 for the following description of the AVR. To begin, assume that the end of the exciter coil labeled "A” is positive. The following sequence of events will occur: 1. Diode D3 will be forward biased. The arrowhead end (anode) is positive (connected to the positive end of the exciter coil) and the diode will conduct. 2.
1. Check the oil in the engine of the generator. Place your multimeter on the R X 1 scale and measure the stator resistance through the AC terminal block. On dual voltage models that have 2. Unplug any appliances that may be connected to the generator. three,terminals measure between the terminals with the red and blue wires. Generator Testing Measuring AC Voltage 3. Start the generator. 4. Place a multimeter on the 250 volt AC scale. 5.
T1800 Generator Testing Measuring Stator Coil Resistance (cont’d) Rotor coil resistance The resistance values measured will be very low and the accuracy of some meters may not indicate 10th’sof an ohm. It is important to remember that the main values that we are looking for are short circuits (0 resistance) or open circuits (infinite resistance). 51.5 ohms T2500 Rotor coil resistance 68.8 ohms Generator Testing Measuring Rotor Coil Resistance 1.
T3000D Generator Testing Measuring Exciter Coil Resistance (cont'd) Exciter coil resistance and wire color Scale: R x 1 2.10 ohms BI & BI The resistance values measured will be very low and the accuracy of some meters may not indicate 10th’sof an ohm. It is important to remember that the main things we are looking for are short circuits (0 resistance) or open circuits (infinite resistance). An open circuit or short circuit will require replacement of the stator.
Generator Testing DC Circuit Diodes (cont'd) are attemptingto check may actually havean open circuit that would not bediscoveredbecauseof the parallel wiring that exists with these diodes. Generator Testing Brush Inspection 1. Stop the generator and pull the spark plug wire off the spark plug. 2. Remove the two screws retaining the generator end cover. 3. Remove the brush holder. 4. Use a caliper or other measuring device to determine the length of the brushes. See Figure 139.
Generator Service Disassembly (cont'd) Figure 143 9. Use a plastic hammer to removethe end cover and stator assembly. IMPORTANT: when setting the stator aside do not place the stator on its coil ends, this may damage the windings. Allow the stator to rest on its laminations only. See Figure 144. 13. Generator Service Reassembly 1. Inspect the rotor assembly for defects; broken wires,' worn or damaged slip rings, damaged insulation. Figure 144 10. Remove the recoil starter. 11.
Generator Service Reassembly (cont'd) 5. Align the through bolt holes with the holes in the front generator cover .(the cover bolted to the engine) and install the stator. Take extreme care not to damage any of the coils in the stator. See Figure 147. 7. The brush holder may be reinstalledat this time. If the wires have been disconnected from the holder make certain that the polarity is correct. The brush wire with the collar that is marked + must be connected to the positive brush terminal. 8.
i Generator Service Reassembly (cont'd) 6. Check the resistance of the rotor. See Generator Testing, page 69 for the correct procedure and resistance value. If the resistance is out of specification, high or low, replace the rotor. If the resistance is within specification go to step 7. 7. Check the resistance of the stator main coil. See Generator Testing, page 68 for the correct procedure and resistance value.
T1200 and T1800 this is done at terminal S1 and S2 of the four pin connector comingfrom the stator coil See Figure 151. Troubleshooting Low AC Output (3-6volts) (cont'd) 1. Verify 3600 RPM engine speed. 2. 3. Check the contact of the brushes with the slip rings on the rotor. The brushes should be of the appropriate length (minimum 3.5 mm, .138"). If the brushes are short or not making contact replace the brush assembly. If the brushes are making contact go to step 3.
Troubleshooting Engine Labors Heavily The generator will start and run but will not carry the load, the engine labors heavily. 1. Verify 3600 RPM no load engine speed. 2. Verify the current demand or power consumption of the load. Make sure the generator is not being overloaded. Inductive loads such as motors may require 3 to 4 times normal running power just to get them started. A one H.P. induction motor (one H.P. = 750 watts) may require 3000 watts just to get it started.
SECTION 8 CONTROL PANEL Control Panel Disassembly 1. Turn the engine off and pull the spark plug wire off the spark plug. 2. Turn the fuel shut off valve to the "off" position. 3. On generators with a serial number starting with "3”the control panel is secured to the fuel tank with four screws and secured to the front frame rail with two hair pin clips. Removethe two clips and then remove the four screws. The back of the control panel may now be exposed. 4.
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