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TUBE FRAME GENERATOR
Table of Contents – Page 1 of 3
T1200 SPECIFICATIONS
MODEL 62012 PRODUCT SPECIFICATIONS
MODEL 62012 GENERATOR SPECIFICATIONS
MODEL 62012 ENGINE SERVICE SPECIFICATIONS
MODEL 62012 CARBURETOR SPECIFICATIONS
T1800 SPECIFICATIONS
MODEL 62018 PRODUCT SPECIFICATIONS
MODEL 62018 GENERATOR SPECIFICATIONS
MODEL 62018 ENGINE SERVICE SPECIFICATIONS
MODEL 62018 CARBURETOR SPECIFICATIONS
T2500 & T2500D SPECIFICATIONS
MODELS 62025 & 62027 PRODUCT SPECIFICATIONS
MODEL 62025 & 62027 GENERATOR SPECIFICATIONS
MODELS 62025 & 62027 ENGINE SERVICE SPECIFICATIONS
MODELS 62025 & 62027 CARBURETOR SPECIFICATIONS
MODELS 62025 & 62027 FASTENER TORQUES
T3000 & T3000D SPECIFICATIONS
MODELS 62030 & 62032 PRODUCT SPECIFICATIONS
MODEL 62030 & 62032 GENERATOR SPECIFICATIONS
MODELS 62030 & 62032 ENGINE SERVICE SPECIFICATIONS
MODELS 62030 & 62032 CARBURETOR SPECIFICATIONS
MODELS 62030 & 62032 FASTENER TORQUES
TROUBLESHOOTING
ENGINE DOES NOT GET FUEL DURING STARTING
TUBE FRAME GENERATOR
Table of Contents – Page 2 of 3
TROUBLESHOOTING - Continued
ENGINE SURGES OR RUNS UNEVENLY
ENGINE USES EXCESSIVE OIL OR SMOKES
MAINTENANCE
MAINTENANCE - FUEL SEDIMENT BOWL
MAINTENANCE - FREQUENCY ADJUSTMENT
MAINTENANCE - VALVE CLEARANCE INSPECTION
MAINTENANCE - VALVE CLEARANCE ADJUSTMENT
MAINTENANCE - DECARBONING SPARK ARRESTER
SECTION 1 CARBURETOR
SECTION 2 FUEL SYSTEM
FUEL TANK AND STRAINER - REMOVAL
FUEL TANK AND STRAINER - INSTALLATION
FUEL SHUTOFF AND SEDIMENT BOWL
FUEL SHUTOFF AND SEDIMENT BOWL - REMOVAL
FUEL SHUTOFF AND SEDIMENT BOWL - SERVICE
FUEL SHUTOFF AND SEDIMENT BOWL - INSTALLATION
SECTION 3 IGNITON SYSTEM
IGNITION OPERATION - IGNITION COIL
IGNITION OPERATION - TRIGGER CIRCUIT
IGNITION OPERATION - SPARK PLUG
TUBE FRAME GENERATOR
Table of Contents – Page 3 of 3
SECTION 3 IGNITON SYSTEM - Continued
SECTION 4 RECOIL STARTER
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 OIL SHUTDOWN SWITCH - INSTALLATION
SECTION 6 ENGINE
ENGINE - CLEANING AFTER DISASSEMBLY
SECTION 7 GENERATOR
SECTION 8 CONTROL PANEL
SECTION 9 SCHEMATICS
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. To assure proper and effective repairs, and to provide optimum performance for the life
of
the machine, you are urged to read this manual carefully, referencing it as necessary when generator service is required.
This manual contains a brief section on electrical theory which is essential to understanding generator operation, troubleshooting and maintenance The complete manual also provides the service technician with a working guideline of maintenance, troubleshooting, test, repair and overhaul procedures.
The Toro Company reserves the right to change product specifications or this manual without notice.
The Tor0 Company gratefully acknowledges the assistance provided by the Suzuki
Motor Company in the writing
of
this manual.
COPYRIGHT®© ALL
RIGHTS RE
S
ERVED
©The Tor0 Company
1988
Minneapolis, MN 55420 USA
TABLE OF
C
ON
T
E
N
T
S
Reference Information
Troubleshooting*
*
For generating troubleshooting information, see Section
7,
page
74.
Page
20
Service Procedures
Section One Carburetor
service reassembly installation
Section Two Fuel System
Fuel Tank and Strainer
Fuel Shutoff and Sediment
Bowl
Section Three Ignition System
Ignition Operation
flywheel ignitioncoil trigger circuit
i
I
Page
TABLE OF CONTENTS
(cont'd)
Service Procedures (cont'd)
I
Section Three
Ignition System (cont'd)
Ignition Coil
Spark Plug
I
Section Four
Recoil Starter
Section Five
Low Oil Shutdown
Low Oil Shutdown Circuit
Low Oil Shutdown Switch
cleaning after disassembly inspection
I
Section Seven
Generator
Generator Operation
exciter coil and permanent magnet
stator coil and receptacles generatingprocess automatic voltage regulator
Page
TABLE OF CONTENTS (cont’d)
Service Procedures (cont’d)
Section Seven
Generator (cont’d)
Page
Generator Testing
Troubleshooting noACoutput...................................................7 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel
Schematic Diagram
SAFETY INSTRUC
T
IONS
This safety symbol means WARNING
AND/OR CAUTION
PERSONAL SAFETY
INSTRUCTION Read the instruction because it has to do with safety.
Failure to comply with the instruction may result in personal injury or death.
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.
Operator's Manuals with complete operational safety instructions are available through:
The Toro Company
Publications Department
81 11
Lyndale Avenue South
MN
55420
U.S.A.
FOR
YOUR
SAFETY
Mishandling gasoline and oil can be deadly.
Gasoline is explosive and should never be exposed to a flame or spark. Do not smoke while working around gasoline.
Avoid the accidental misuse of gasoline by always using a storage container designed for gasoline.
Avoid fire hazards by operating the generator no closer than one meter, (three feet) to any combustible material.
When decarboning the muffler, burning pieces of carbon may be discharged. Make sure there is no combustible material in the area.
Spilled oil or gasoline can present a fire hazard or cause injury through falls. Always remove spilled oil or gasoline.
Engine exhaust fumes can cause death. Never operate an engine in a confined area or without venting the exhaust fumes to the outside atmosphere.
You can be killed by the electricity
a
generator produces. While a generator is in operation never/ touch any portion of your body to exposed or uninsulated terminals
or
wiring.
Make sure that the engine will not accidentally start while completing a service procedure by pulling the spark plug wire
off
the spark plug.
Electrical line workers can be electricuted by backfeeding electricity. Never connect a generator to your house wiring without using
a
double throw switch to separate the generator from the incoming line.
1
IDENTIFICATION
Each Tor0 whole good is assigned a model and serial number. ,The model number has five digits and indicates the size and style of the product. In addition to 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
indicates that the product was built in
1986.)
These numbers are printed on a decal that
is
about
1"
high and 3"wide. Units built in
1984
and
1985
have the decal located on the lower cross brace of the tube frame under the engine end of the generator. On
1986
and newer units, the decal can be
found
behind the
gas
on
the decal in correspondence or when replacement parts are needed.
An engine number
is
also located on the block of the engine. When filing warranty claims or requesting service information, please include the engine number.
2
i
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
Spark
Plug
Spark Plug Gap
Ignition Coil Air Gap
(External Mount)
Standard Dimension
NGK BPR-6HS
.75mm
(.030")
.38
(.015”)
fixed
!
Allowable Limit
NIA
NIA
N/A
Width of Valve
Seat Contact
Intake Guide to Valve
Stem Clearance
(.039 .055”)
1.OO
mm
(.032 .040")
(.002”)
NIA
.025
.055
mm
NIA
(.0012")
.0032"
TI200
SPECIFICATIONS
(cont'd)
Model
62012
Engine Service Specifications (cont'd)
Stem Clearance to
36.5
to
26.000
Bearing Diameter (Big End)
Side Clearance (Big End)
.005 .025
Cylinder Distortion
5
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
(5.0 Ibs)
1.3 kg m (9.4
ft
Ibs)
1.O kg m
(7.2
ft
Ibs)
.88 kg m
(6.4
ft
Ibs)
.88 kg m (6.4 ft
Ibs) kg m
(3.6
Ibs)
.75 kg m (5.4
ft
Ibs)
.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
(8.0
ft
Ibs)
i i
!
I
!
6
Model
62018
Product Specifications
__ _ _
I
_ _ _ _ _ I
Specification
air cooled 4-stroke, side valve
66 mm (2.60")
56
mm (2.20”)
191.6 cc (11.69 cu. in.)
2.8 kilowatt (3.8
HP)
@ 3600 rpm
-
- ~ -
PTO
aluminum 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
recoil
____I _ _ -
- ~ ~ --------_- splash
.7 liters (23.7 oz) detergent
SAE
10W30 or' 30,
API
rating of float type
3600 rpm
3000 rpm oiled foam type element
I
40
kg
(88.5
Ibs)
54.1
x 33.7 x48.5 cm (21.3 x 13.3 x 19.1 in)
SE,
SF
_-
_ _ _ ___
I
_-
Model
6201 8
Generator Specifications
7
T I
800
SPECIFICATIONS
(cont'd)
Model 6201 8 Generator Specifications (cont'd)
Maximum Power
Specification
12.5 amperes.
12 volts DC
8.3
Amperes
1.5
KVA (kilovolt amps)*
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.
*
1
KVA
=
1000
Watts true power with
a
power factor of one.
!
i
Model 6201 8 Engine Service Specifications
Item
Spark Plug
Spark Plug Gap
NGK BPR-6HS
75
mm
(.030")
Ignition Coil Air Gap
(External Mount)
Ignition Coil Air Gap
(Internal Mount)
Valve
Margin
Width
of
Valve
Seat Contact
Valve
Lash
Valve Head Runout (Both)
1.35
to
1.85
mm
_____-_
.80 1 .OO
mm to
.039')
(.002”)
N/A
Intake Guide to Valve
Stem Clearance
,025 to
.055
(.0010
to .0022")
I
_._-
8
T I
800
SPECIFICATIONS
(cont'd)
Model 62018 Engine Service Specifications (cont'd)
Item
Exhaust Guide to Valve
Stem Clearance
Valve Spring
Free Length
Cam Height
Intake and Exhuast
Connecting
Rod
Journal Diameter
Connecting
Rod
Bearing Diameter (Big End)
Connecting
Rod
Journal
Oil Clearance
Connecting
Rod
Side Clearance (Big End)
Piston Pin Clearance in Connecting
Rod
Cylinder Diameter
Piston Measuring Point
Piston Diameter
Piston to Cylinder
Clearance
Cylinder Distortion
Piston Ring End Gap
(Compression Rings Only)
Oil Ring
End Gap
Piston Ring Side Clearance
(Top Ring Only)
Piston Ring Side Clearance
(2nd Ring Only)
Piston Ring Thickness
(Compression Rings Only)
Piston Ring Groove Width
(Compression Ring Grooves Only)
Standard Dimension
to
.065
to
.0026')
to
36.5
to
1.437")
to
32.505
to
1.2797")
to
26.000
to
1.0236')
to
26.01
mm to
1.0242")
to
..025
.OOlO”)
to
.900
to
.0354')
to
.019
to
.0008)
N/A
15
mm
(59')
NIA
to
.065
to
.0026')
NIA
I
~-.- to
.400
to
.0158')
to
.40
to
.016')
to
.060
to
.003')
to
.060
to
.003")
to
1.99
mm to
.0783")
to
2.03
to
.0799")
9
(cont'd)
Model 62018 Engine Service Specifications (cont'd)
Model 62018 Carburetor Specifications
Item
I
Main Jet
(STD)
Pilot Jet
#75 (fixed)
I
I
I
Model 62018 Fastener Torques
Fastener
Spark Plug
Cylinder Head Bolts
Flywheel Nut
Connecting
Rod
Nuts
Frame Bolts
Generator Through Bolt
Starter
CUP
Capscrews
Recoil Pulley Screw
Recoil Mounting Screws
Air Cleaner
Nuts
Air Cleaner Capscrew
Throttle Plate Screws
Crankcase Screws
Shroud Fasteners
Muffler
Nuts
Torque
.88
kg rn
(6.4 ft
Ibs)
2.0
kg rn (15 ft
Ibs)
6.5 kg rn (47 ft
Ibs)
.70 kg rn (5.1 ft
Ibs)
1.3 kg rn (9.4 ft
Ibs)
I i
.
.
~ -
1.O
kg rn (7.2 ft
Ibs)
- - - - . _ _ _ . _ _ _ ~ -
.88
kg
m
(6.4 ft
Ibs)
.88
kg
m
(6.4 ft
Ibs)
I
.50
kg rn (3.6 ft
Ibs)
~ -
.75 kg rn (5.4 ft
Ibs)
kg rn (1.6 ft
Ibs)
.88
kg rn (6.4 ft
Ibs)
.88
kg rn (6.4 ft
Ibs)
.55
kg
m
(4.0
ft lbs)
1.05 kg
m
(7.6 ft
Ibs)
I
_-
- - ~ _ _ __ _ _ -
i o
T2500
&
T2500D SPECIFICATIONS
Models
62025
&
62027
Product Specifications
Item
Type
Bore
Stroke
Displacement
Rated Continuous Output
Engine Rotation
Cylinder Material
Crankshaft Bearing Material (Mag)
Crankshaft Bearing Material (PTO)
Connecting
Rod
Bearing (Lower)
Carburetor
Fuel
Fuel Tank
Run Time
Ignition System
Ignition Timing
Spark Plug
Starting System
Lubrication
Oil Capacity
Oil Level Alarm
Recommended Oil
Governed Engine Speed (60 hz)
Governed Engine Speed (50 hz)
Air Cleaner
Dry Weight
Dimensions (L
x
W
x
H)
Specification
I
air
cooled,
4-stroke, side' valve
72 mm (2.83")
62 mm (2.44")
252.4 cc (15.40 cu. in.)
3.7 kilowatt
(5.0
counterclockwise (as viewed from PTO end) aluminum with cast iron Sleeve ball ball plain float unleaded regular gasoline
-____._
I
11
.O
liters (2.91 gal.)
----__ transistorized
25° BTDC @ 3600 rpm
NGK BPR-6HS recoil splash
I
1 liters (33.8
oz)
float type i detergent SAE
10W30or'30,
API rating of SC, SD, SE, or SF
3600 rpm
3000 rpm
I oiled foam type element
52.8 kg (1 16.5 Ibs)
56.6
x
36.3
x
53.6 cm (22.6
x
14.3
x
21.1 in)
~-
Model
62025
&
62027
Generator Specifications
Item
AC Voltage
Specification
120
-
220 volts, plus or minus 10%
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)
Ignition Coil Air Gap
(Internal Mount)
Valve
Margin
Width of Valve
Seat Contact
Valve Lash
Valve Head Runout (Both)
Intake Guide to Valve
Stem Clearance
N/A
(.0012”)
.0032"
12
T2500
&
T2500D SPECIFICATIONS
(cont'd)
Models
62025
&
62027
Engine Service Specifications (cont'd)
Guide to Valve
Standard Dimension to
.070
39.5
mm
ecting
Rod
Journal to
1.2800')
27.991 to 28.000 to 28.027 to
1 1 034") to
.036” to .0014") to
.800 to
.019
8.0 mm
iston Ring End Gap to
0.400 to
5 8 ' )
to
0.80 to
0.070 to
0.003') to 0.060 to 0.003") to
2.48
2.51 to
2.53
mm
.0996”)
13
T2500
&
T2500D SPECIFICATIONS
(cont'd)
Models
62025
&
62027
Engine Service Specifications (cont'd)
Models
62025
&
62027
Carburetor Specifications
Models
62025
&
62027
Fastener Torques
Connecting
Rod
Nuts
Generator Through
Bolt
Starter Cup Capscrews
Recoil Pulley Screw
Recoil Mounting Screws
Air Cleaner Nuts
Air Cleaner Capscrew
Throttle Plate Screws
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)
1.3 kg
m
(9.0 ft Ibs)
1.O
kg
m
(7.3 ft
Ibs)
.88
kg
m
(6.4 ft Ibs)
.88
kg
m
(6.4 ft Ibs)
.50
kg
m
(3.6 ft Ibs)
;__-
.75 kg
m
(5.4 ft Ibs)
.22 kg
m
(1.6 ft
Ibs)
.88
kg
m
(6.4 ft Ibs)
.88
kg
m
(6.4 ft
Ibs)
.55
kg
m
(4.0 ft Ibs)
1.1 kg
m
(8.0
ft
Ibs)
-~.--
-__I.- i i
I i
I
14
-__-
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
Ignition Coil Air Gap
Ignition Coil Air Gap
Width of Valve
Valve Head Runout (Both)
Standard Dimension
NGK BPR-6HS
.75mm
(.030')
.38
(.015”) fixed
.95 to
1.45 mm
(.037
to
.057")
.90
1.10 mm
(.035
.043")
.050
mm
(.002”)
N/A to .055
(.0010
to
.0022")
i i
!
I i
!
N/A
N/A
i
I i
N/A
(.0012”)
.080 mm
.0032”
16
I
T3000
&
T3000D
SPECIFIC
A
TIONS
(cont'd)
Models 62030
&
62032 Engine Service Specifications (cont'd)
Exhaust Guide to Valve ecting
Rod
Journal
Piston
Ring End
Gap to
.070
to
.0028')
39.5
40.5
mm to
1.595")
to
32.51
to
1.2800”)
27.991
to
28.000
to
1.1024")
to
28.027
to
1.1034")
to
.036"
to
.0014')
to
.800
to
.0315")
to
.019
to
.0008)
NIA
I i
(.32")
NIA
NIA
to
.050
to
.0020”)
!
, . ~ to
.40
to
.Ol6”)
.80
mm to
.032")
to
.070
.0003”)
to
.060
to
.003")
to
2.48
(.0969
.0976')
2.51
to
2.53
.0996”)
17
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
engine switch in “off’ position spark plug fouled or damaged spark plug wire damaged ignition coil primary wire grounding out ignition coil has failed
I Remedy
move switch to “on” position replace spark plug replace coil repair damaged wire with electrical tape replace ignition coil
I
Engine Floods During Starting
Possible Causes
no spark
I
stale gasoline engine overchoked
I
choke not opening
1 leaking needle/seat
I
water in fuel plugged air filter
Remedy
see “Engine Does Not Produce Spark’ troubleshooting section above fill tank with fresh unleaded gasoline open choke, close fuel shutoff valve and turn over until engine fires replace damaged parts
I
1 clean carburetor and pressure check
1 drain tank and fill with fresh gasoline clean air filter
I
I
I
I
Engine Does Not Get Fuel During Starting
Possible Causes
fuel shutoff closed fuel tank empty plugged fuel line or filter
r-~---
fuel cap not venting properly
* For generating troubleshooting information, see Section 7, page 74.
I
Remedy
open fuel shutoff valve fill fuel tank with fresh unleaded gasoline clean or replace plugged component repair or replace fuel cap
I
20
TROUBLESHOOTING
(cont'd)
Engine Difficult to Start
I
engine not getting fuel engine
has
low compression
Remedy
see "Engine Does Not Produce Spark” troubleshooting section (page
8)
see "Engine Does Not Get Fuel During
Starting" troubleshooting section (page
8)
see "Engine Floods During Starting" troubleshooting section (page
8)
compare compression to compression of new unit--repair as necessary
Engine Lacks
Power
Possible
Causes choke partially closed lack
of
lubrication
Remedy
open choke adjust carburetor replace flywheel key fill crankcase with proper lubricant clean or replace air cleaner grind valves and set valve lash see "Generator Troubleshooting Guide", page
74
compare compression to new unit
__-
and overhaul if necessary
Engine Knocks
Remedy
clean carbon from combustion chamber replace damaged or worn parts
*
For generating troubleshooting information, see Section
7,
page
74.
tighten rotor bolt replace key
21
TROUBLESHOOTING
(cont’d)
Engine Misses Under Load
Engine Overheats
Engine Surges or Runs Unevenly
*
For generating troubleshooting information, see Section
7,
page
74.
22
TROUBLESHOOTING
(cont'd)
Engine Vibrates Excessively
replace damaged
parts
tighten engine mounting bolts
Engine Uses Excessive
Oil or
Smokes
*
For generating troubleshooting information, see Section
7 ,
page
74.
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
23
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
Maintenance Spark Plug
The spark plug is the ignition source for the fuel air mix in the combustion chamber of the engine. The engine will not run properly
if
the spark plug is not inspected and replaced
a8
required. Spark plugs should not be cleaned;
if
the plug is fouled or dirty, replace it.
Abrasive spark plug cleaners will leave grit on the plug that can cause rapid :engine wear.
Type:
Substitute:
I
NGK
BP-5HS
Champion L92Y/L92YC
.6-.7mm (.024-.028')
_ -
Every 100 hours
70-105 Kg-cm (80-120 in-lbs)
Maintenance Changing Oil
Tor0 generators are shipped without oil. Do not start the generator until you have added the correct amount of
3.
4.
5.
6.
7.
8.
9.
1
Remove the dust cup, baffel, foam element and element holder.
Wash the element in soap and water or
a
solvent made for cleaning air cleaner elements.
Squeeze the element dry
of
the cleaning solution.
Saturate the element with 30 weight motor oil and then squeeze the excess oil out of the element.
Note: an element that is too heavily saturated with oil may restrict air flow and cause a rich running condition for the engine.
Reinstall the element holder, foam element, baffel and dust cup.
Secure the air cleaner cover with the single mounting screw.
Make sure the breather hose is properly connected to the body of the air cleaner. see spec. on page
3
Service Classification
20 fall, spring
10 winter
MS,
SC,
SD,
SE
After the first 20 hrs. and
I
Oil change frequency: every
50
hrs. thereafter.
1. Stop the engine and remove the spark plug wire from the spark plug.
2.
Remove the oil fill plug.
3.
Position and drain pan under the engine and remove the drain plug. See Figure 2.
~ _ ~ .
.
~ ~ -
24
Maintenance - Changing Oil (cont’d)
4.
Reinstall the drain plug and dispose of the used oil at a proper waste oil disposal site.
r‘, 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.
-__1_
t
5.
Empty the fuel bowl and clean it of any debris.
6.
The filter screen is located in the head of the bowl and may be removed and cleaned at this time. See
Figure 4.
7.
8.
On reinstallation make sure the screen is properly seated to prevent unfiltered fuel from entering the carburetor.
Reinstall the sediment bowl and tighten the plastic c o l l a r .
9 leaks.
SCREEN
----.
Figure 3
.-----l_l___
r\
Maintenance - Fuel Sediment Bowl
The T1200 - T3000 generators are equipped with a fuel sediment bowl and strainer that will filter debris from the fuel and will trap water before the fuel reaches the carburetor. The sediment bowl should be cleaned at least once a season.
Cleaning the fuel sediment bowl will require working with gasoline.
CAUTION: Misuse of gasoline can cause death. Do not work with gasoline around open flames. Do not smoke in the presence of gasoline. Always keep gasoline in a container designed for the storage of flammable liquids.
1.
Stop the engine and remove the spark plug wire.
2.
Close the fuel shutoff valve.
3.
Prepare a drain pan to catch a small amount of gasoline that may be spilled or released when the fuel bowl is removed.
4.
Unscrew the plastic’collar retaining the fuel bowl and pull the fuel bowl off the head assembly.
10.
Return the valve to the “off’ position when the cleaning and inspection are complete.
Maintenance - Frequency Adjustment
All Toro generators including the T1200 - T300O are designed to run at a speed of 3600 rpm. The frequency of the el,ectricity produced is (controlled by the engine speed) 60 cycles of alternating current per second
(6OHz); ,This is, of course, the same as 60 engine revolutions per second or 3600 rpm.
~~~~~~~~~~-~~
1.
Check the engine oil level.
2.
Disconnect any load that may be connected to the generator.
3.
Start the generator.
4. the load the generator is normally under when used by the customer.
5.
Adjust the speed of the engine with the speed adjustment screw to 3600 rpm. The speed adjust-
Maintenance Frequency Adjustment (cont'd)
ment screw is located behind the air cleaner and connects to the governor arm.
6.
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.
MENT SCREW
closing completely and the valve clearance will have to be adjusted.
.05-.15
mm
(.002-.006”)
for both intake and exhaust valves.
Adjustment Frequency: Every
300 hrs
I
I
Maintenance Valve Clearance Inspection
1.
Stop /the generator and remove the spark plug wire.
2.
3.
4.
5.
6.
7.
8.
Close the fuel shutoff valve.
Remove the single screw retaining the air cleaner bracket to the engine block.
Remove the two screws retaining the air cleaner assembly to the carburetor.
Pull
the breather hose off the breather assembly.
Remove the two screws retaining the breather assembly
Remove the breather assembly. Take note of how the gaskets and reed plate are installed.
Measure the valve clearance with the engine cold and on top dead center (TDC) of the compression
7.
The speed of the engine may also be set using a variety of tachometers. Once the engine speed is adjusted to
3600 rpm the electrical frequency will be set at
60
Hz.
Maintenance Valve Clearance
The
T1200
T3000 generators use side valve engines.
The valves are opened and closed with solid cam followers. If the clearance between the end of the valve stem and the cam follower is too small the valve may not close. The clearance is factory set at
.05-.15
mm
(.002-.006'”).
After many hours of use the valve seat and face may wear causing the valve stem and follower clearance to decrease. If the performance of the engine degrades after many hours of use, the valves may not be
26
Figure
6
To determine TDC; remove the spark plug and place: a clean wooden dowel in the spark plug opening
so
the dowel rests on the top of the piston.
Rotate the engine until both valves are closed
(watch the cam followers in the breather opening.)
When both valves
stop
moving as the dowel reaches the highest point in
its
travel you have TDC of the compression stroke. TDC can be determined with more accuracy by using a depth reading dial indicator.
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 approprlate amount 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
Figure
7
4.
Remove two hair pin clips from the bottom of the
I
9.
Remove the valves.
10. After the valves are removed the ends of the stems should be ground to provide the required clearance.
11. Check the condition
of
the valve seat and valve face. Recondition the face and seat if necessary.
12.
13.
Reinstall the valves and keepers.
Reinstall the head of the engine. Consult the
Specification Section for correct head bolt torque.
14. Replace the metal shield over the cylinder head of the engine. This shroud is part of the cooling system and must be properly installed.
15.
Remount the fuel tank with the four hair pin clips.
16.
Install the fuel hose on the carburetor.
1
7.
Reinstall the spark plug wire.
Maintenance Decarboning Spark Arrester
All Toro generators are fitted with spark arresting mufflers.' If the spark arrester is not serviced, the ability of the engine to exhaust will be restricted and the performance of the generator will drop.
D e c a r b o n i n g
Interval: 100 hrs
1.
Stop the engine.
2. Remove the spark plug wire.
3. Remove the
two
spark arrester clean
out
bolts. See
Figure
9.
-__^_-
Figure
8
5.
Lift the tank and front panel assembly forward and away from the head of the engine.
6.
Remove the screws retaining the metal shield on the head of the engine (three screws on the T1200,
T1800
and four on the T2500, T3000).
7.
Remove the screws retaining the head of the engine.
8.
Use a valve spring compressor to remove the valve keepers.
4.
9
Remove the single screw retaining the spark arrester tube in the end of the exhaust pipe and pull
the tube out of the pipe. See Figure
above.
5. Take the generator to a well ventilated area that is free of combustible material.
6.
Start the generator and tap on the side of the muf-
27
Maintenance Decarboning Spark Arrester (cont'd) fler to dislodge any carbon build up within the spark arrester.
CAUTION: Exhaust fumes can cause death. Operate the generator only In a well ventilated area.
CAUTION: The muffler will cause burns if it is touched.
7.
Allow the muffler to cool. Remove any remaining carbon from the clean out ports and the exhaust discharge opening.
8.
Reinstall the muffier clean out bolts.
10.
Reinstall the spark arrester.
Maintenance Storage
If the generator is not going to be used for a period of three months or more the following long term storage procedures should
be
completed:
1.
Drain all gasoline designed for storing flammable liquids.
CAUTION: Misuse of gasoline can cause death.
Never smoke while working with gasoline. flame or fire.
Never expose gasoline to open
Always
use
while' working with gasoline. proper ventilation
2.
3.
Start the generator and run the remaining fuel out of the
carburetor.
with the recoil starter until you feel the resistance of compression; this will indicate that both valves are in' the closed position sealing the cylinder.
4.
Drain :the existing engine oil and refill the engine with fresh oil.
5.
Remove the spark plug and pour one or
two
tablespoons of oil into the cylinder and replace the plug.
6.
Service the air cleaner element. See the instructions on page
24
on air cleaner maintenance
7.
Check the tightness of all fasteners.
8.
cover the generator and put it away for storage.
28
SECTION
1
CARBURETOR
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. from the float bowl. This fuel premixes with the incoming air, then
is
discharged into the intake port of the engine.
Pilot System
Pilot Jet
,Pilot Air Fitting
As
the piston moves up on the compression stroke, a partial vacuum is created within the engine crankcase, causing the greater atmospheric pressure to force air to flowthrough the carburetor into the cylinder. Thevelocity of the air increases as it flows through the carburetor venturi and the air pressure is reduced at this point to less than atmospheric pressure. The low pressure in the venturi of the carburetor causes atmospheric pressure to push raw fuel from the float bowl into the air stream in the throat of the carburetor, where it breaks up into a fine spray, or becomes atomized, and mixes with the air stream. See Figure
10.
Atmospheric
Pressure
Float Bowl To Engine
,Venturi
Carburetor
Bore
COLD START
1 1
Pilot System /Pilot Jet
Fitting
When starting the engine an extra rich mixture is required. The choke plate
is
closed by the operator to provide an approximate
8:l
ratio of fuel to air for this rich mixture. Closing the choke plate further reduces the air pressure in the venturi to increase the fuel pushed into the carburetor throat. In this condition fuel also flows from the float bowl through the pilot system ports as well as the main discharge tube to achieve the proper starting mixture.
Fuel atomization becomes more efficient, due to heat, once the engine has reached normal operating temperature. As a result the engine does not require the rich mixture it did for starting and the choke plate must be moved to the open position. The engine speed is now regulated by the throttle plate. In no load conditions a small portion of the fuel may be drawn from the main discharge tube, however the primary fuel supply is drawn from the pilot circuit. Air passing through the pilot jet from the pilot air fitting draws fuel
out
of the pilot jet orifice
NO LOAD
Figure
12
As the throttle plate is opened to compensate for engine load, the main discharge tube becomes the main source of fuel. Opening the throttle plate increases the flow of air through the venturi and strengthens the low pressure area at the main discharge tube. Fuel discharge increases at the main discharge tube as it decreases from the pilot system. Air is drawn from the air correction jet through holes along the length of the main discharge tube. This premixes air with the fuel before it enters the
29
Carburetor Operation (cont'd)
carburetor throat for more efficient atomizing of the fuel.
,Pilot System
Throttle
Plate
Main
Discharge
Tube
Correction Jet
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.
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
Carburetor Disassembly
1.
Remove the carburetor bowl nut. It is not necessary to remove the drain screw.
See
Float
UNDER LOAD
Figure
13
Carburetor Removal
1.
Stop the generator and remove the spark plug wire.
2.
Close the fuel shutoff valve.
3.
Remove the single screw retaining the air cleaner body to the engine block.
4..
Remove the' two screws retaining the air cleaner to the carburetor.
5.
Remove the fuel inlet hose.
6.
Remove the two nuts retaining the carburetor to the
Figure
14
30
Figure
15
2.
3.
The main jet is threaded into the carburetor bowl nut. The float and inlet needle may be removed by pulling out the float hinge pin. Note: one end of the pin is flattened slightly. The pin must be
removed from this end. See Figure
The pilot jet may be removed from the top of the carburetor and can be cleaned or replaced. Fuel flows through the small opening in the end of the
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.
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.
t
FLAT
CAUTION: Be sure to wear safety glasses when using compressed air. Use pressure of no more than 40 PSI.
3.
If it
is
suspected that the seat is leaking, the carburetor can be pressure tested after it has been cleaned. Use Toro Pressure tester, Number
41-7910.
If the seat is good, it will hold
.5
2
(7
psi) for at least
10
seconds. This procedure should be completed with the carburetor turned upside down
so
the seat holds the needle closed.
If the pressure leaks down, replace the 'needle and try the test again. If the carburetor fails again, the seat is bad and the carburetor must be replaced
Figure
16
PILOT
17
Carburetor Service
1.
The metallic body of the carburetor may be cleaned in carburetor cleaner. Plastic parts may be damaged by some carburetor cleaners.
Carburetor passages may be cleaned out with compressed air.
2.
Replace any components that show wear or damage. The inlet needle is replaceable but the seat is not.
Figure
18
Carburetor Reassembly
1.
Replace the main nozzle and bowl gasket.
2.
Install the pilot jet and pilot screw. Refer to Figure
17.
The pilot screw should be open
1
to
1
-1/2
turns.
3.
Hook the inlet needle into the float and secure the float and needle in place with the hinge pin. See
4.
Remount the bowl and gasket.
Carburetor Installation
1.
Mount one gasket, one spacer and one additional gasket on the carburetor mounting studs.
2.
Connect the tension spring from the governor arm to the throttle shaft.
31
Carburetor Installation (cont’d)
3.
Connect the governor link rod. See Figure 20.
FLAT
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 ~governor 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.
The governor spring connects in the upper hole
of
the governor arm. See Figure 21.
Figure 19
I
Figure 20
4.
Install the carburetor on the mounting studs.
I
Figure 21 i
14. Remount the air cleaner body to the carburetor with two screws.
15. Secure the air cleaner bracket to the engine block.
Carburetor reinstallation is now complete.
32
SECTION
2
FUEL SYSTEM
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.
8.
Examine with a cleaning solvent if necessary.
Fuel Tank and Strainer Removal
1. Shut off the generator.
2. Drain the fuel tank. Remove the line on the inlet side
of the fuel shutoff valve. See Figure 22.
NOTE:
Have a container suitable for flammable liquids available to receive the gasoline from the tank.
Figure 22
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.
3.
4.
5.
6.
7.
Remove the fuel tank cap.
Pull
the fuel strainer out of the tank.
Examine the fuel strainer for debris and wash it out in a suitable solvent.
Removethe four hairpin clips retaining the fuel tank and front panel to the frame of the generator.
Lift the fuel tank away from the engine and remove the
five
screws retaining fuel tank to the front panel.
The fuel tank is now separate from the generator.
See Figure 23.
Fuel Tank and Strainer Installation
1.
Install the fuel tank on the front panel.
2. Reset the fuel tank and front panel on the generator frame and install the hairpin clips.
3. Connect the fuel hose to the fitting on the shutoff valve and sediment bowl. If the clamp is bent or distorted it should be replaced.
4. Install the fuel strainer and tank cap.
FUEL T A NK CAP
The fuel tank cap is an important
but
often ignored part of the fuel system. It has several important jobs that it must do: It must keep debris, water, etc., out of the tank.
It must allow atmospheric pressure into the tank and it must allow any buildup of pressure out of the tank. The cap also' has to keep fuel in the tank.
Fuel Tank Cap Service
1. Examine the condition of the cap. Look for distortion or bending.
2.
Examine the gasket. The gasket should indicate an even seal for a full 360 degrees. The gasket part number is 53-1420 for T1200 -:T3000 generators.
3. Make sure the cap is venting properly.
You
should be, able to force air through the cap from the inside out and the outside in. Replace the cap if it does not vent properly.
33
Fuel Tank Cap Service (cont'd)
A
STRAINER
Fuel Shutoff and Sediment Bowl Removal
1.
Drain the fuel tank. Removethe line on the inlet side
of
the fuel shutoff valve. See Figure
on page
33.
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 flame or sparks. Do not smoke around well ventilated area free of open gasoline.
2.
Disconnect the outlet hose from the fuel shutoff valve.
Fuel Shutoff and Sediment Bowl Service
1.
Complete service of the valve may be accomplished without removing the valve from
its
mounting bracket.
2.
Remove the sediment bowl by unscrewing the collar around the
bowl.
i
4.
Figure
24
Install the cap and make sure the tabs on the cap pull it fully against the tank as it is turned in place.
FUEL SHUTOFF AND SEDIMENT BOWL
The
T1200 T3000
generators use a combined shutoff valve and sediment bowl. The valve is mounted to the
tube frame under the fuel tank. See Figure 25.
Figure
25
34
4.
Figure
26
3.
Take: that there is a filter screen in the head of the valve that may be cleaned or replaced as required. The part number of the screen is
50-3770.
The valve may be serviced by removing the set screw on the side of the valve. Use care, as the valve stem is under spring pressure and must be restrained as the set screw is loosened.
Fuel
Shutoff
and Sediment
Bowl
Service (cont'd)
SCREEN
Figure
27
5.
After the valve stem is removed, the plastic valve cylinder may be withdrawn with a needle nose pliers.
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.
2.
3.
4.
Reassemble the valve by inserting the valve cylinder and stem in the body of the valve. Make sure the cylinder and hole in the valve cylinder lines up 'with the handle of the valve stem. Restriction
of
fuel flow may occur if the
two
parts
are not indexed correctly.
Install the valve stem retaining screw. Make sure the valve is free to turn.
If
the valve will not turn
it
is likely that the end of the retaining screw is not located in the slot on the side
of
the valve stem.
The slot is there to limit the rotation
of
the valve to about
90
Fasten the valve to its mounting plate with
two
screws.
Install the inlet and outlet hoses to the valve.
35
SECTION
IGNITION
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
SYSTEM
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.
Figure 28
The following describes the function of each of the above components.
Ignition Operation Flywheel
The engine flywheel is the generating force for the ignition system.
Imbedded in the flywheel are permanent magnets. These magnets rotate past the coil to generate electricity.
Imbedded in the opposite side of the flywheel is a steel counterweight which offsets the weight of the three magnets.
It is not magnetic.
Ignition Operation Ignition Coil
The ignition coil is actually a transformer. It is positioned close to the flywheel to allow the magnetic field of the flywheel magnets to cut through the coils to generate
Low voltage is produced in the primary coil which is sent to the trigger circuit. This voltage would be much too low to produce a spark at the spark plug.
The secondary coil serves to amplify the voltage produced in the primary. To accomplish this, the
I
Figure 29
Even though the secondary coil has considerably many more windings than the primary, the voltage produced is still not high enough to produce sparkacross the spark plug electrodes To further amplify the voltage, the trigger circuit is used.
Ignition Operation Trigger Circuit
The trigger circuit amplifies the voltage in the secondary coil by breaking the primary circuit just as the primary voltage reaches its peak. This breaking of the primary circuit results in a rapid collapse of the magnetic field surrounding g the primary coil. The collapse of the primary magnetic field induces a large voltage surge in the the spark plug electrodes.
Before getting into the actual electronics used inside the trigger circuit, it is important to have an understanding of the voltage waveform produced by the flywheel magnets moving by the ignition coil.
As
the magnets rotate past the coil, voltage is produced.
This voltage,' when uninterrupted, is first positive, then negative as the magnet passes by the coil. This effect is caused by the two opposing poles of the magnet.
Explanation of the trigger circuit also requires an
understanding of the NPN transistor. See Figure 31.
36
Ignition Operation Trigger Circuit (cont'd)
3.
Current
I1
flowing through Tr2 induces a larger current,
l2. I1
is very small and that
12
is much larger. See Figure
34.
Ignition coil
PRIMARY VOLTAGE WAVEFORM
Figure
30
C (Collector)
!
MTI unit
Figure
32
Ignition coil
B (Base)
Figure
33
MTI unit Ignition
coil
E
(Emitter)
NPN-type
Figure
31
A
transistor has a certain minimum voltage that it requires across the base and emitter (points
B
and
E
in the Figure above) before it will "turn on". Once it has turned on it allows a small current,
11.
to flow as shown above. At the same time the transistor allows a large current,
12,
E.
The magnitude of current
12
will vary in proportion to the smaller current,
11.
Thus, the transistor functions as an amplifier in that it allows a small current to control a large one.
The following is the process the trigger circuit uses to break the primary circuit to produce spark:
1.
The magnet passes by the coil and induces an alternating voltage.
2.
As
the voltage begins to increase (approximately
and current flows from point "c" to point "d" through
Ground
Spark plug
4.
When the voltage is at the point "a" level as denoted
"off' mode and allows no current
13
or
1
to flow. See Figure
35.
Ignition coil
Spark plug.
37
Ignition Operation Trigger Circuit (cont'd)
5.
As the voltage produced in the primary coil reaches its negative peak (point
“b”
transistor Trl is turned on and allows small current
1
and large current
14
to flow.
6.
When transistor Trl turns on, nearly all of the current flow through
R4
path
14
since it is the path of least resistance. This drop in current
I1
results in transistor Tr2 turning
Off.
7.
When Tr2 turns off, current
12
drops rapidly and causes the magnetic field surrounding the primary coil to rapidly collapse. This in turn causes a voltage surge in the secondary which is sufficient to produce a spark across the spark plug.
Ignition Operation
-
Spark Plug
The spark plug is used to ignite the air fuel mixture by producing a spark just before the piston reaches top dead center. A spark plug is typically constructed as
HEAD INSULATOR
COPPER CORE
Excessive gap or fouling can delay firing enough to cause a
loss
of power or stalling.
The other important area is the insulator. The insulator prevents arcing from taking place in another portion of the plug, away from the electrodes. Because of the extremely high voltage present, even a slight crack or fouling of the head insulator can result in arcing and a malfunction of the plug.
IGNITION
COIL
Ignition Coil Testing
The operation of the ignition coil should be tested before
.the product' is disassembled.
1.
2.
3.
4.
5.
Shut
off
the fuel supply valve and disconnect any appliances that may be plugged into the generator.
Remove the rubber spark plug cover and remove the sp'ark plug.
Inspect the spark plug and ensure that it is in good condition. Make sure there are no particles bridging the spark gap.
Ground the body of the plug on the side of the engine. Turn the ignition switch on. Pull the starter cord and watch for a spark at the gap of the plug.
If there is a strong spark, the ignition module is intact and working properly.
6.
If
there is a lack of spark, check the oil level in the engine. The engine uses a low oil shut down device that will prevent the engine from starting if the oils low. For operation of the low oil level shut down device, see Low Oil Shutdown, page
44.
7.
If the oil level is normal, disconnect the yellow wire connected to the low oil shut down module.
Access to the yellow wire may be obtained by removing the single screw that retains a wlre connector bracket on the front crossframe of the generator. See Figure
37
the wire.
LEG INSULATOR
GROUND ELECTRODE GAP
Figure
36
There are two critical areas important to proper spark plug function. The first is that the electrodes are properly gapped and are clean. This ensures that
a
strong spark will be present and that it occurs at the proper time.
38
Ignition Coil Testing (cont'd)
8. Insulate the 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.
10. Unplug the black ignition kill wire and and the entire coil may be removed.
Ignition Coil Removal
1. Stop the generator and remove the spark plug wire.
2.
3.
Close the fuel shutoff valve.
Remove the four screws retaining blower housing of the generator.
4.
5.
6.
Pull
some slack in the spark plug wire and remove the blower housing.
On the T1200 and T1800 the coil is now exposed and may be removed after unplugging the ignition kill wire.
T1200 and T1800 generators built in 1983 and all
T2500 and T3000 generators have the ignition coil mounted on the engine block behind the flywheel.
The flywheel magnets are located on an internal counterbore in the flywheel. The flywheel must be removed to expose the ignition coil.
7
Remove the flywheel nut and the three screws retaining the starter cup.
Figure 38
8. Use a puller or remover to remove the flywheel.
See the section on special tools on page 19, for the correct tool and part number. See Figure 39.
9. The ignition on T2500 and T3000 generators is now
39
Figure
40
Ignition Coil Installation
1. Mount the ignition coil on the engine block. On the
T1200 and T1800 an air gap
of
.381 mm (.015") should be set between the coil and flywheel. On the T2500 and T3000 and 1983 models
of
T1200 and T1800 that have ignition coils that are mounted on the engine block behind the flywheel, the ignition coil location is fixed and no adjustment is possible
2.
3.
4.
Route and secure the spark plug wire in the wire retainer on the back of the engine block.
On models with internal ignition coils, remount the flywheel. Make sure the taper on the flywheel and the taper on the crankshaft are clean. Torque the flywheel nut to 6.0 7.0 kg m (43 50 ft Ibs) on all
Remount the blower housing with the recoil starter attached.
Ignition
Coil
Installation (cont'd)
5.
Reconnect the Ignition kill wire. gap on the electrodes of the plug is
.6
.028").
Spark Plug
Removal
1. Stop the engine and remove the 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. Grit
will
eventually fall out of the plug and cause engine damage. Dirty spark plugs Should be replaced.
Figure 41
SPARK PLUG
The correct spark plug is an
NGK BP-5HS.
An acceptable substitute is a Champion L92Y or L92YC. The correct
Spark Plug Installation
1.
Use an NGK
BP-5HS
or Champion L92Y
or
L92YC spark plug.
2.
Set the plug gap to
.6
3.
Install the plug with a 19 mm
(3/4')
use a release agent
or
oil on the threads
of
the plug.
4. Torque the plug to
1.2 kg m (8.5 ft Ibs).
5.
Replace the spark plug wire.
6.
Reinstall the rubber dust cover.
40
SECTION
4
RECOIL STARTER
Recoil Starter Removal
1.
Turn off the generator, shut disconnect the spark plug.
off
the fuel and
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. This will unload the spring tension without rewinding the cord on the reel.
NOTE: The rope is wound around the reel in a counterclockwise direction as you are looking at the bottom of the reel.
Figure 43
Figure 42
3. Remove the friction disc retaining nut. This nut is under a small amount of spring tension, release
It slowly.
4. Carefully lift off the friction plate. Note how the spring is mounted on the center post and engages the starter pawl. See Figure 43.
5.
Remove the starter pawl and pivot pin. See Figure
44.
6.
Remove the starter pawl spring.
7.
Remove the bushing and nylon washer from the center post of the starter assembly.
8.
9.
Figure 44
R,emove the knot from the starter grip and remove the grip.
If, replacement of the starter rope is all that is necessary the rope may be removed and replaced at this time.
10.
Lift the reel out of the starter housing. Be careful not to disturb the coil spring under the reel.
CAUTION: The recoil spring may cause injury. The spring is captured in the recoil housing and may rapidly expand out
of
the housing
if
disturbed or dropped.
41
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 engage the slots on the outside diameter
of the /spring case. See Figure
WASHER-
1 1.
Figure
45
The coil spring should not be removed unless it is broken and needs to be replaced. Use extreme care when relieving spring tension. Hold the body of the spring in place with a gloved hand and slowly withdraw the spring from the inside out with a pair of pliers until the spring is completely relaxed.
Recoil Starter Reassembly
1.
New recoil springs are secured with a wire around the circumference of the spring. Install it in the spring case with the outside hook of the spring engaging the slot in the outside rim of the spring
Figure
47
6.
lnstall' starter pawl pivot pin. Then install the pawl.
Figure
46
2.
The inside hook of the recoil spring engages the slot on the inside diameter of the recoil housing.
Figure
48
7.
Mount the bushing and nylon washer on the center post of the recoil assembly.
8.
Install ;the spring and friction disc. Make sure the spring engages the starter pawl.
Refer to Figure
43.
9.
Install the friction disc retaining nut.
42
Recoil Starter Reassembly (cont'd)
10.
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 in the 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 provide sufficient spring tension to pull the cord back into the recoil assembly when released.
Starter
Installation
1.
Mount the recoil assembly to the generator with
R e connect the spark plug wire
.
43
SECTION 5 LOW
O I L SH
U
TDOWN
LOW OIL SHUTDOWN CIRCUIT With low oil there should be a complete circuit to ground.
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 Operation
The circuit operation is described in the following steps.
to help clarify how the circuit works.
1. There is a magnetic float in the sump of the engine that will close the contacts of a reed switch when the oil level drops to the "low" point on the dipstick.
2. The reed switch completes a circuit to ground that turns on a silicon controlled rectifier
(SCR).
3.
The
SCR
closes a circuit that turns on the warning light and at the same time grounds the engine ignition.
4.
The light remains illuminated until the engine stops rotating. The engine cannot be restarted until the oil level is returned to normal.
Low
Oil
Shutdown Circuit Testing
Verify the operation of the float operated switch in the sump by checking for continuity between the yellow wire coming off the switch and the engine block.
1. Stop the generator by turning off the ignition
2. switch.
Locate the yellow wire from the float switch.
It is routed ,along the inside of the blower housing and exits the blower housing along with the spark plug wire.
3.
The wire is retained by a plastic clip to the crossbar of the tube frame on the front of the generator.
Remove the clip with one screw and disconnect the wire See Figure
50.
Alarm lamp
To transistor
Oil level sensor
Figure
49
5.
The operation of the
SCR
may be verified by grounding the yellow wire while the engine is running. The yellow wire is at magneto potential and the engine should stop as soon as the wire is grounded.
6.
If the engine does not stop with the yellow wire grounded the module containing the
SCR
is defective and must be replaced.
7.
The operation of the oil switch may be verified by checking continuity between the switch connecting wire and ground. With the correct amount of oil there should be no circuit to ground.
4.
5.
6.
7.
a.
9.
Place the probe of a continuity tester or resistance tester
(R x
1 scale) on the terminal end of the yellow wire coming from the engine block.
Place the other probe of your tester on the engine block itself.
With the proper level of oil there should be no continuity.
Drain the oil out of the engine and complete the test again With no oil there should be a complete circuit between the yellow wire and ground.
If the switch operates normally but the engine does not stop with low oil or will not run with a normal oil level, the low oil shutdown module may be defective.
The low oil shutdown module on the T1200 T3000 is located inside the control panel of the
44
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
FRONT PANEL
Figure
51
10.
Replace the module by separating it from the harness and install a new unit.
LOW OIL SHUTDOWN SWITCH
Low Oil Shutdown Switch Removal
1.
Stop the engine and remove the spark plug wire.
2.
Close the fuel shutoff valve.
3. a drain pan under the engine and remove the oil drain plug.
4.
Remove the two engine base mounting bolts. With the bolts removed, use a prying tool to lift the engine to increase clearance between the base of the engine and the tube frame crossbar.
5.
Remove the four screws retaining the oil level switch. See Figure
52.
4.
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
1.
Replace the gasket if necessary.
2.
Make sure the float is free to move, and install the float assembly in the bottom of the engine.
3.
4.
5.
6.
7.
8.
9.
Ground the short wire with the eyelet to the bottom
of
the engine.
Install the wire protector and route the yellow wire with the grommet out from underneath the bottom of the engine.
Reconnect the yellow wire to the single connector with the yellow wire from the oil shutdown module.
Connect the wire retainer clip to the tube frame crossbar.
Remount the engine
base
to the tube frame.
Replace the drain plug and fill the engine with the correct amount of engine oil. See the Specification
Section for the correct type and amount.
Reconnect the spark plug wire.
45
SECTION
6
ENGINE
Engine Disassembly
1.
Turn the engine off and remove the spark plug wire.
2.
Remove the fuel hose and drain any gasoline remaining in the tank.
4.
Drain the engine
oil
as described in the
Maintenance Section on page
24.
5.
Remove the end cover of the generator.
54.
Disconnect and 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.
Unplug the black ignition kill wire and the yellow low oil shutdown wire. These are located on the front of the generator under the frame crossbar.
See Figure
56.
Figure
53
CAUTION: Misuse of gasoline can cause death. Do not work with gasoline around open flames. do not smoke in the presence of gasoline. always keep gasoline in a container designed for the storage of flammable liquids.
3.
After draining the fuel, crimp or seal the end of the hose to prevent the entrance of dirt.
Figure
54
WILL
46
9.
Remove the hair pin clips retaining the fuel tank and front panel to the frame of the generator. See
Figure
57.
10.
The gasoline tank and front panel may now be lifted away from the generator.
11.
The upper tube frame may be removed to provide additional clearance. Remove the four bolts
retaining the frame halves. See Figure
Engine Disassembly (cont’d)
I
57
Figure
60
14. Remove the four generator through bolts. See
Figure 61.
_ _.-
Figure
58
12. Remove the engine and generator from the tube frame by removing the four mounting bolts. See
Figure
59.
I
Figure 61
15. Use a plastic hammer to remove the end cover and
stator assembly. See Figure 62.
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 62
16. Remove the recoil starter as shown
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
Figure 63
17.
Hold the crankshaft in place with a screwdriver or bar through the recoil starter cup and remove the
Figure 66
21.
Remove the carburetor. Use care as the carburetor fuel bowl will still contain gasoline. See Figure
67.
Figure
64
18.
Remove the blower housing and all other sheet metal from the engine.
65
48
22. Remove the carburetor bowl and drain the gasoline into a suitable container.
23.
Use a rotor remover bolt (see the Special Tool
Section on page
19
for the correct part number) to remove the rotor assembly. The rotor is secured to the crankshaft of the engine with a tapered fit. The crankshaft has an external taper and the rotor has
24.
Hold the starter cup in place and remove the
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
29. Turn the engine around and remove the front
generator housing. See Figure 71.
Figure 68
Figure 69
25. The next step is to remove the three screws retaining the starter cup.
Figure 71
30. Remove the governor lever and the governor spring bracket. See Figure 72.
Figure 70
49
31. Remove the crankcase breather assembly. See
Figure 73.
32.
Remove the cylinder head. See Figure 74.
33. Use a valve spring compressor to compress the valve springs and then remove the valve spring keepers. See Figure 75.
Engine Disassembly
(cont’d)
73
Figure
76
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 reassembly these marks must
line up with one another. See Figure
Figure
74
34.
Remove the crankcase side cover. Take care not to damage the seals or crankshaft on removal of the cover.
Figure
77
36.
Straighten the locking tabs on the connecting rod
37.
Remove the connecting rod nuts, splasher plate
(with locking tabs) and rod cap. Please take note of the orientation
of
the rod cap for proper reinstallation.
38.
The piston and connecting rod may be withdrawn from the cylinder block.
Please note the arrow on the face of the piston and the arrow
on
the connecting rod. When the piston and connecting rod are reinstalled thses arrows
should point to the valves. See Figure
50
Engine Disassembly (cont'd)
Figure 78
Figure 79
Figure
80
39. The crankshaft may now be removed. See Figure
81.
I
Figure 81
Engine Cleaning After Disassembly
1. Clean all parts in appropriate solvents according to the solvent manufacturer's recommendations.
2. Inspect all parts for wear and damage. Make certain that moving parts will move freely.
3.
4.
5.
6.
7.
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.
Clean the air filter element in soap and water.
Moisten the air filter element with clean 30 weight engine oil before installation.
Clean the fuel strainer
on
the tank inlet.
Clean the fuel sediment bowl and filter screen.
Refer to the Maintenance Section on page 24 for more information on scheduled maintenance.
Engine Inspection
Inspect all parts for wear and damage. Do not reuse parts that are damaged or worn beyond specification.
Valve guide valve stem clearance:
T120 T1800 T2500 T3000
Maximum allowable clearance:
.100 mm (.0039') valve seat contact width:
T1200, T1800
Minimum allowable width:
Intake
.8
mm (.0315")
Exhaust .8 mm (.0315")
51
Engine Inspection (cont'd)
T2500, T3000
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. If the pattern is not within specification, the
valve seat must be reconditioned. See Figure 82.
The Special tools required for valve seat reconditioning are as follows:
Special Tools
“T”
handle wrench
Adaptor
Expandable pilot
75°/15°
cutter
46°
cutter
45° cutter
50,-9400
50-94
1
0
50-9500
50-9450
50-9440
50-9430
4. Cylinder head distortion:
T1200, T1800, T2500, T2000
Maximum allowable distortion:
.030 mm (.0012') distortion with a straightedge and thickness gauge. Take a clearance reading at several places.
If the clearance at any position exceeds the limit, replace the cylinder head. See Figure
84.
!
Figure 82
3. Valve seat reconditioning:
Two cuts
(15°
and
46°)
are required to properly recondition the valve seat on the T1200.
Three cuts
(15°,
45°,
75°)
are required to properly recondition the valve seat on the T1800, T2500,
(For
SE
(For SE1800/2500)
Figure
83
52
5. Cylinder bore wear:
T1200, T1800, T2500, T3000
.100
mm
(.004")
Cylinder wear
is
determined by taking measurements of the diameter in six locations. See
Figure '85.
The amount of wear
is
the difference between the is exceeded the cylinder must be bored oversize.
Engine Inspection (cont’d)
6.
Piston diameter:
T1200
Figure
85
allowable piston diameter:
T1800
Minimum allowable piston diameter:
65.88 mm (2.5937”)
T2500, T3000
Minimum allowable piston diameter:
71.88 mm (2.8299”)
Measure the outside diameter of the piston.
If
the piston is smaller in diameter that the wear limit dimension the piston must be replaced. See Figure
86.
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
.05 mm
(.002’)
Measure the difference between the diameter
of
the piston pin and the piston pin bearing in the connecting rod. See Figure 87 and Figure 88.
*T1200-1800
15mm (.059 in.)
T2500-3000
8mm (.032 in.)
53
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, replace the connecting rod. See
Figure
89. ring and ring groove.
If
the clearance exceeds the maximum allowable clearance value the rings or
Figure
90
10. Crank pin to connecting rod clearance:
T1200, T1800
Maximum crank pin to rod clearance:
T2500, T3000
Maximum crank pin to rod clearance:
I
.080
mm (.0031")
Measure the diameter
of
the crank pin and the diameter of the big end of the connecting rod. The difference between the two will be the crank pin to connecting rod clearance. If the clearance is beyond specification replace the connecting rod
and or the crankshaft. See Figure 90.
I
I
11. Piston ring to groove, clearance limit:
T1200, T1800, T2500, T3000
Maximum piston ring to groove clearance:
Top ring
2nd ring
.120 mm (.0047")
.100 mm
(.0039')
Use a feeler gauge to measure the clearance between the top ring and ring groove and the 2nd
__--.-__(.
Figure 91
12. Piston ring groove width:
T1200, T1800
Maximum piston ring groove width:
Top groove
2nd groove
2.03 mm (.0799")
2.03 mm
(.0799")
T2500, T3000
Maximum piston ring groove width:
Top groove
2nd groove
Use a thickness gauge to measure the width of the top and 2nd ring groove. If the width is greater than the maximum allowable clearancevalue the piston
must be replaced. See Figure 92.
54
Engine Inspection (cont'd) ring
2nd ring
Figure 92
13. Piston ring thickness:
T1200, T1800
Minimum piston ring thickness:
Top ring
2nd ring
1.97 mm (.0776')
1.97 mm (.0776')
T2500, T3000
Top ring
2nd ring
2.46 mm (.0969')
2.47 mm (.0972")
Measure the thickness of the piston rings with a micrometer or precision measuring device. If the ring measures less than the minimum allowable thickness it
must be replaced See Figure 93.
T1800
Maximum allowable gap:
Top ring
2nd ring
Oil ring 1.5 mm (.0591")
T2500 T3000
Maximum allowable gap:
Oil ring
.7 mm (.0276')
.8
mm (.03151")
1.5 mm (.0591")
When measuring piston ring end gap, place the ring in an area
of
the cylinder where there is a m'inimum amount
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. Use a piston to push the ring squarely into the cylinder. insert a feeler gauge and measure the end gap.
Rings that exceed the maximum allowable gap
Top ring
2nd ring
14.
Figure 93
Piston ring end gap:
T1200
Maximum allowable gap:
Top ring
2nd ring
.8
mm (.3151")
I
Figure 94
Engine Reassembly
1. Examine the bearings and seals in the block
of
the engine. Replace the bearings and or seals if necessary.
55
Engine Reassembly
(cont'd)
2. Install the intake and exhaust valves. Coat the valve stems with a liberal amount of engine oil and insert them into the valve guides in the cylinder. See
95
exhaust valves. The intake valve 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.
POINT T H E SAME
DIRECTION
I
Figure
98
6.
Mount the piston rings on the piston. Use a ring expander and make sure the
"R"
mark faces the top
of the/piston on each ring. See Figure
I
Figure
96
4.
Install the governor operating shaft in the crankcase side cover. Mount the governor shift fork to the shaft with two mounting screws. Use a thread locking compound, e.g. Loctite
242,
on the
threads of the screws. See Figure
5. Mount the connecting
rod
to the piston. Lubricate the piston pin with engine oil and retain it in the piston with a circlip on either end. The arrow mark on the head of the piston should point in the same direction as the arrow on the connecting rod for proper installation.
See
Figure
98.
56
Figure
99
7.
The piston and connecting rod may now be installed from the top
of
the cylinder. Make sure the
The arrow on the connecting rod and piston should face the valve side of the engine. Use a piston ring compressor as shown in Figure
100
to install the piston.
4
Engine - Reassembly (cont’d)
POINT iOWAR0
VALVES
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.
Figure 102
11.
Mount the governor flyweight assembly to the camshaft drive gear. Make sure the flyweights are properly retained with two cotter pins. See Figure
103.
Mate
Figure 101
T1200, T1600, T2500, T3000
Rod cap bolt torque:
.4
kg m (3.5 ft Ibs)
10.
Bend the tabs on the locking plate to prevent loosening of the rod bolts. See Figure 102.
12.
13.
14.
15.
Figure 103
Lubricate and install the cam followers. If the same cam followers that came out of the engine are being reinstalled, make sure they are put in the same guide they came out of, a wear pattern will have been established that should be maintained.
Install the camshaft in the crankcase. Take care to properly line up the matchmarks for correct valve timing. See Figure 104.
Lubricate the inside diameter of the governor collar and install it on the flyweight assembly. Make sure the lower edge of the collar engages the flyweights.
Also, make sure the slit in the governor collar engages the cam shaft gear. See Figure 105.
Install a gasket on the crankcase and install the crankcase side cover. Lubricate the crankshaft to assist installation. Take care not to damage the seal in the side cover. Secure the side cover mounting screws as shown in Figure 106.
57
Engine Reassembly (cont'd) 16. Measure the valve clearance.
T1200, T1800, T2500, T3000
Valve clearance specification:
Intake .05-.15
mm
(.002-.006')
Exhaust .05-.15
mm
(.002-.006”)
If
the valve clearance is not within specification the valves should be removed and adjusted per the
Specifications Section for your particular engine.
Figure 104
I
Figure 107
6
2
4
Figure 105
Figure 106
T1200, T1800, T2500, T3000
Side cover screw torque:
1
.O
kg
m
(7.2 ft Ibs)
58
Figure 108
17. Install: a new head gasket and the cylinder head.
T1200, T1800
Headbolt torque:
1
.O
kg
m
(7.0 ft Ibs)
T2500
I
Headbolt torque:
2.5 kg
m
(1 8 ft
Ibs)
I
Engine Reassembly (cont'd)
T3000
Headbolt torque:
3.2 kg m
(23
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.
INSTA
L
L THIS
WAY "UP".
19.
Figure 109
Tighten the bolts in a diagonal sequence as shown in Figure 110.
T1200,
T1800,
T2500, T3000
Generator front bracket torque:
2.0 kg m (14.5 ft Ibs)
20. Install the ignition coil on units that have ignition coils that are internal to the flywheel. The position of the coil is fixed on these units. Apply thread locking compound to the mounting screws and tighten the screws to 1 kg m
(7
ft
Ibs).
21.
On units with ignition coils that are external to the flywheel the next step is to install the flywheel key
and flywheel. See Figure 1 1 1.
22. Install the starter cup
as
59
I
Figure 11 1
Engine Reassembly (cont'd)
23. Install the flywheel nut. See Figure 113.
T1200,
T1800,
T2500, T3000
27.
Route
the oil sensor wire in the channel provided in the crankcase. The wire groove is accessible with the flywheel installed. See Figure 115.
_--
Figure 113
24. If the generator is equipped with an externally mounted coil, the coil should be installed with an air gap of .38 mm (.015").
25. Route the spark plug wire and the ignition wires through the grommet in the block of the engine.
The spark plug wire should pass through the wire retainer mounted on the block of the engine.
26. Install the oil level sensor in the crankcase of the engine.
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. Make sure the tapers are clean and that the rotor and crankshaft line up correctly.
Figure 114
60
T1200, T1800, T2500, T3000
Rotor set bolt torque:
2.2 kg m (16 ft Ibs)
30. Inspect the stator assembly for defects. Check for broken wires, bad insulation, broken wire ties etc.
Engine Reassembly (cont'd)
31. Remove the 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 119
33.
Tighten the through bolts in the sequence
as
T1200, T1800, T2500, T3000
34. The brush holder may be reinstalled at this time.
35.
Continue engine reassembly by installing the breather assembly. Make sure the parts are
assembled as shown in Figure 119. Incorrect
assembly will result in
a
breather that leaks oil. The projection on the outside cover always points
36.
Install the governor arm (throttle control lever) and the governor spring bracket. Tighten the governor arm screw only temporarily at this time. See Figure
120.
Figure 120
37. Hook the carburetor control rod and rod spring into the throttle control lever on the end of the throttle shaft. Connect the other end of the carburetor control rod to the governor arm and install the carburetor. The correct sequence is one gasket, spacer, and one gasket. Tighten the two
61
Engine Reassembly (cont’d)
nuts securing the carburetor to the engine. See
Figure 121.
I
39. lnstall the muffler. Mount one gasket and secure the muffler with two
38. 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. Make sure the throttle control spring is installed in the upper hole
on the governor arm. See Figure 122.
Figure 123
40. Install the sheet metal components on the engine.
Figure 122
62
41.
42.
43.
44.
45.
Figure 124
Remount the generator in the tube frame.
Attach the upper frame amd reinstall the fuel tank and control panel.
Reconnect the AC output wires on the terminal block. Be sure to match the color coding. See
Figure 126.
Reconnect the lead wire from the control panel to the connector on the top of the generator. See
Figure 127.
Reconnect the ignition ground wire and yellowwire from: the low oil level shut down system. Clamp these wires under the front frame rail of the generator. Use the plastic retainer,
P/N
55-0230, that is secured to the frame rail with one screw.
Engine Reassembly (cont'd)
I
Figure 125
Figure 126
Figure 127
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.
49.
Install the recoil starter. The handle should face toward the front of the generator.
I
Fill the crankcase with motor oil. Check the
Specification Section for the correct amount and type of oil.
63
DEFINITION OF TERMS
SECTION 7
GENERATOR
to the maximum level, this is sometimes called "Pulsating
Direct Current". See Figure 128.
I
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 150 watt light bulb will have 96 (ohms) of resistance and a current flow of 1.25 amperes. 1.25 amperes
X
96
=
120 volts.
Definition of Terms Amperage
Amperage (I) is a measure of electric current or the flow of electrons in a circuit. Electric current flow is measured in amperes. Think of amperage as being similar to the quantity of oil flowing in a hydraulic hose. Amperage is equal to the voltage in the circuit divided by the resistance in the circuit. A 150 watt light bulb will operate at 120 volts and will have an internal resistance of
96
ohms. 120 volts
+
96
ohms
=
1.25 amperes.
Definition of Terms Alternating Current
Alternating' current (AC) has a voltage level that will vary equally above and below a 0 reference line. The alternating 'current we use in our homes will vary from a
+
120 volts to a -120 volts
60
times each second. The voltage is :actually reversing its direction above and below a
0
reference line. See Figure 129.
Definition
of
Terms Resistance
Resistance
(R)
is measured in ohms and uses the greek letter omega as a symbol. Resistance is that value that opposes the flow of electric current. Think of resistance as a restriction in a hydraulic hose. Resistance is equal to the voltage in the circuit divided by the amperage in the circuit.
A
150 watt light bulb will operate at 120 volts with a current flow of 1.25 amperes. 120 volts
+
1.25 amperes
=
96
ohms of resistance.
Definition of Terms Wattage
Wattage (P) is a measure of electric power or work that is being done. Power is measured in watts. Wattage is equal to the voltage in the circuit multiplied by the amperage in the circuit. A light bulb connected to a 120 volt source with a current of 1.25 amperes flowing through it will dissipate 150 watts of power. The power is given off in the form of heat and light. 120 volts
X
1.25 amperes
=
150 watts.
Definition of Terms Direct Current
Direct current (DC) has a voltage level that may vary in intensity but will not drop below a 0 reference line. A battery may gradually lose
its
charge but the voltage level will always be above the 0 reference line. Batteries produce direct current that is very stable and will vary only as the charge decreases. Generators and rectifiers produce direct current that may vary in intensity from 0
Figure 129
Definition of Terms Frequency
Alternating' current will reverse
its
direction at a frequency controlled by the speed of the engine. When the engine
is
running at 3600 RPM (3600 revolutions per minute or revolutions per second), the frequency of the alternating current will be 60 cycles per second (60
Hz).
The sp'eed of all Tor0 generators is governed at 3600
RPM.
Definition
of
Terms Automatic Voltage Regulator
An automatic voltage regulator (AVR) will control the output of
a
generator. When
a
load is applied to the generator the voltage tends to drop; the AVR will sense this and will increase the amount of DC current being
64
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 removed from a generator the voltage will tend to increase; the
AVR
will respond to this by decreasing the size of the field. The
AVR
will hold the voltage to within 10% of the rated voltage.
Definition of Terms Diode
A
diode is an electronic component that allows electric current :to pass only in one direction.
A
Definition of Terms Rectifier
rectifier
is an electronic device made of one or more diodes and is used to change alternating current to direct current
Definition of Terms Field
The word field refers to the magnetic field produced in the rotor. The magnetic field will spin with the rotor to generate electricity in the stator. The size of the field is controlled by the
AVR
and the
AVR
will in turn regulate the output of the generator.
Definition of Terms Rotor
The rotor is a single coil of wire wrapped on a laminated steel core. During operation the rotor becomes an electromagnet and produces the field that causes electricity to be produced in the stator. The rotor is bolted to the engine crankshaft and spins at the same speed as the engine. Two small permanent magnets are bonded to the rotor core to get the generating process started.
Definition of Terms Slip Rings
The slip rings (two) are an integral part of the rotor. One ring is attached to each end of the rotor coil.
It is through the slip rings and the brushes that the exciter coil and
AVR
provide electricity to the rotor.
Definition of Terms Induction
Electricity is produced when a magnetic field moves across a conductor (wire), this is called induction.
GENERATOR OPERATION
Generator Operation Exciter Coil and Permanent
Magnet
In
its simplest
moving field n produced form, a generator is a permanent magnet close to a fixed coil of wire. When the magnetic moves across the wires in the coil a voltage is xi. The exciter coil is part of the stator assembly and the the en it will I permanent magnets are fixed to the rotor. When ne is started, the rotor with the magnets fixed to begin to spin. The field of the magnets will move across process the wires of the exciter coil and the generating
will begin. See Figure 130 and 131.
Exciter
Coil
Starts Generating Process
Definition of Terms Brushes
The brushes are made of carbon and connected to the
AVR.
The brushes ride on the slip rings and act as the connector between the
AVR
and the rotor.
Definition of Terms Stator
The stator is made of three separate coils of wire wrapped on an laminated steel core:
1. Main coil The main coil provides 120 volts direct to the generator outlet.
AC
2.
3.
Exciter coil -The exciter coil provides
AC
electricity to the
AVR
where it is rectified into
DC
electricity and sent to the rotor to create the field.
DC
coil -The
DC
coil. is a separate coil in the stator that provides
AC
electricity to a rectifier where it is changed to approximately
14
volts
DC.
The rectifier is connected directly to the
DC
terminals on the generator.
Produces Low
Voltage
Figure 130
Generator tor Operation
AVR
and Rotor Coil
Electricity from the exciter coil is sent to the-AVR where it is rectified (changed to
DC)
and
is
then sent to the rotor to form an electromagnet. The
AVR
will control the size of the magnetic field based on how much electricity the generator is being asked to produce. See Figure 132.
65
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. it out put voltage through two sensor circuit wires.)
6.
The rotor spins inside the stator coil which produces the output voltage.
i
AVR
Regulates
Voltage to Rotor
i i
I i i
Figure
131
AVR
Regulates Voltage to Rotor
Generator Operation Stator Coil and Receptacles
The magnetic field surrounding the rotor (which is now an electromagnet) will move across the wires of the stator coil and will induce
AC
electricity. The speed of the rotor is constant
so
any variation in the amount of electricity produced will be controlled by the size of the magnetic field. The stator coil is connected to the electrical outlets
of
the generator and to two sensor wires that let the
AVR
know how much voltage is being
Generator Operation Generating Process
1.
The engine turns the crankshaft.
2.
The crankshaft turns the rotor which houses the exciter magnets.
3.
The exciter magnets rotate past the exciter coil to start the generation process.
4.
The exciter coil initially produces about
6
volts and sends it to the automatic voltage regulator,
(AVR).
Figure
133
Generator Operation Automatic Voltage Regulator
The automatic voltage regulator
(AVR)
functions much like the governor on a small engine.
It keeps the output voltage very' close to the required
120
(or
240)
volts and compensates for varying loads.
The
AVR
is piaced between the exciter coil and the rotor.
It regulates the low voltage going into the rotor. In doing
so
it controls the size
of
the electromagnetic field around the rotor and in turn controls the output voltage. The
AVR
decides how much voltage to send to the rotor by sampling the output voltage through the sensor wires
shown in the pictorial diagram in Figure
Figure
134
During operation the ends of the exciter coil
(E.C.)
will alternate positive
!
60Hz.
(+) and negative (-) at a frequency
of
66
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.
3.
4.
5.
6.
7.
8.
Diode D l will not conduct as it is reverse biased.
The flat end (cathode) is connected to the positive end of the exciter coil. SCR will not conduct until it has the proper voltage at its gate.
Current will flow through D3 and
R1
to the gate of
SCR1.
With current at
its
gate SCRl will turn on and conduct because it is also forward biased.
Current will not flow through D4, R2 or SCR2 because they are reverse biased; (their anode ends are connected to the negative end of the exciter coil). Initially current will not flow through the transistor (Tr) as it has not been turned on with the proper base current.
When SCRl turns on it provides a very low resistance path for current to flow from the positive end of the exciter coil to the field coil (rotor) where it will build an electromagnetic field.
Return current can now flow from the field coil
(rotor) through diode D2 (it will conduct in this direction because it is forward biased), back to the negative end of the Exciter coil.
When the
end
of the exciter coil labeled
"B”
becomes positive, diode D4 and SCR2 will become forward biased.
A
repeat of steps 1-7 using D4, R2 and SCR2 will occur. It is important to note that the arrangement of Dl, D2, SCRl and SCR2 form a full wave bridge rectifier and will send DC electricity to the field coil.
The amount of current that
is
sent to the field coil
is
controlled by the transistor (Tr) and zener diode (ZD).
The control circuit operates as follows:
1. Two sensor wires are connected to the main coil
(MC) to monitor the output voltage of the generator.
2. The electricity from the sensor wires is changed to
DC by the full wave bridge rectifier
(D).
3. The electricity from the rectifier (D) Rows to a voltage divider network made
up
of
resistors
R3
and R4. When the voltage at the connecting point
(C) reaches the breakdown level of the zener diode
(ZD), the zener diode will allow current to flow to the base (b) of the transistor (Tr).
4. The current at the base of the transistor will turn the transistor "on" and will allow current to flow with almost no resistance from point
E
to point F.
5.
Electricity from R1 and R2 that would normally be used to turn on SCRl and SCR2 is now diverted through the transistor and the
SCR'S
remain in the
"off' mode. Electricity will not flow from the anode to cathode of the SCR.
6.
The amount of current flowing through the transistor
is
very small and flows through the field coil, creating an insignificant magnetic field and then back to the exciter coil.
I
7.
When the output voltage of the main coil drops the zener diode will turn off and block current to the base of the transistor. The SCR's will turn on and full current flow will return to the field coil.
GENERATOR
TESTING
The following tests will be CAUTION: completed with the generator running. The electricity this generator produces can cause death. Never touch any part of your body to exposed or uninsulated terminals or wiring.
Generator Testing Color Code
P
G
R
Pink
Green
.Red
Black B
W
Y
BI
Br
Or
Ltbl
White
.Yellow
Blue
Brown
.Orange
.Light Blue
Ltg Light Green
Ltg/R Light Green with Red Tracer
W/R .White with Red Tracer
R/B
Y/G
R/W
W/B
G/W
BI/R
Bl/W
G/R
Br/Y
G/Y
Red with Black Tracer
Yellow with Green Tracer
Red
with White Tracer
.White with Black Tracer
Green with White Tracer
.Blue with Tracer
Blue with White Tracer
Green with Red Tracer
Brown with Yellow Tracer
Green with Yellow Tracer
67
Generator Testing Measuring AC Voltage
1. Check the oil in the engine of the generator.
2. Unplug any appliances that may be connected to the generator.
3. Start the generator.
4.
Place
a
multimeter on the 250 volt AC scale.
5.
Insert the probes in the AC outlet and measure the voltage. The unloaded output voltage should be
120 volts 10%. See Figure 135.
I
4.
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 three, terminals measure between the terminals with the red and blue wires.
I
Scale:
DC 25V
I
Scale:
AC 250V
I
I
I
I '
Figure 135
Generator Testing Measuring DC voltage
1. Check the oil in the engine of the generator.
2. Unplug any appliances that may be connected to the generator.
4.
Set your multimeter on the 25 VDC scale.
5.
Connect the probes to the DC terminals on the generator, plus to plus and minus to minus, (red to red and black to black). The unloaded DC voltage should be approximately 14 VDC. At
full
load (8.3 amps) the voltage may drop as
low
as 1 volts. See
Figure 136.
Generator Testing Measuring Stator Coil
Resistance
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. Disconnect the main
AC
output wires that lead to the control panel.
J
Figure 136
5.
The stator coils should have the following resistance value
+ or 20%
T1200
Stator coil resistance
1.733 ohms
T i 8 0 0
Stator coil resistance
1.05 ohms
T2500
Stator coil resistance
0.5
ohms
I
T2500,D
Stator coil resistance
1.86 ohms
68
Generator Testing Measuring Stator Coil
Resistance (cont’d)
The resistance values measured will be very low and the accuracy of some meters may not indicate
10th’s of an ohm.
It is important to remember that the main values that we are looking for are short circuits
(0
resistance). resistance) or open circuits (infinite
Generator Testing Measuring Rotor Coil
Resistance
1. Stop the generator and pull the spark plug wire
off
the spark plug.
2. Remove the
two
screws retaining the end cover of the generator.
3.
Remove the wires connected to the brushes.
4. The resistance measurement will be taken at the brush holder.
5.
Disconnect the wires connected to the brush holder.
6. Place your multimeter on the
R X
1 scale and measure the resistance of the rotor through the
Scale: R x 10
T1800
Rotor coil resistance
51.5
ohms
T2500
Rotor coil resistance
68.8 ohms
-
T2500D
T3000
I
Rotor coil resistance
68.8 ohms
Rotor coil resistance
74.5 ohms
_I
I
T3000D
Rotor coil resistance
74.5
ohms
NOTE
The resistance values measured will be low and the accuracy of some meters may not indicate 10th’s of an ohm. It
is
important to remember that the values we are looking for are short circuits
(0 ohms or a value that deviates more than 20% below the standard resistance) or open circuits (infinite resistance).
If the measurement is more than
20% above the standard resistance the brushes should be removed and the meter probes applied directly to the slip rings. The brushes should not add more than a fraction of one ohm of resistance to the rotor circuit. If the resistancevalue of the rotor is normal when measured at the slip rings it indicates that there is a problem with the brushes or brush contact to the slip rings.
Figure 137
7. The rotor coil should have the following resistance
+ or
20%.
T1200
Rotor coil resistance
46.1 ohms
69
Generator Testing Measuring Exciter Coil
Resistance
1. Stop the generator and remove the spark plug wire.
2. Remove the two screws retaining the end cover of the; generator.
3. Disconnect the four prong connector at the
AVR.
4. Measure the exciter coil resistance at the the end of the wire connector that leads to the generator
wiring harness. See Figure 138.
Generator Testing Measuring Exciter Coil
Resistance (cont'd)
Scale:
R x
1
Figure 138
5.
The exciter coil should have the following resistance
+ or 20%. Take your measurement at the terminals connected to the color coded wires indicated in the chart below. See color code chart on page
67.
T1200
T1800
T2500
T2500D
Exciter coil resistance and wire color
T3000
Exciter coil resistance and wire color
BI
T3000D
Exciter coil resistance and wire color
2.10 ohms
BI
&
BI
The resistance values measured will be very low and the accuracy of some meters may not indicate
10th’s of 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. i
Generator Testing Sensor Circuit Continuity
The sensor circuit continuously monitors the AC output of the generator to determine how much voltage the AVR should send from the exciter coil to the rotor coil. The sensor circuit is wired in parallel with the main AC output wires. The continuity measurement is taken at the four pin connector from the harness that connects to the AVR.
Two of the terminals connect to the exciter coil, the other two connect to the sensor circuit.
I
The resistance measurement will be from 2 ohms on the
T1200 and T1800 to over 13,000 ohms on the T3000. The most likely failure will be an open circuit that will measure infinite resistance.
I
Generator /Testing DC Circuit Diodes
Tor0 generators use a center tapped coil with two diodes to accomplish full wave rectification for DC output.
Generators with a serial number that starts with "3" use part of the AC coil for DC output, and all other units use a separate DC coil. The cathode ends of the diodes are wired together for form the positive output terminal. The anode ends are connected to opposite ends of the coil with the center tap forming the negative output terminal.
Tor0 generators use both single piece molded diode assemblies and dual piece assemblies with two separate diodes bonded to a common plate. When testing the diodes of either assembly the diodes must be disconnected from the circuit.
1.
Disconnect the diodes from the generator wiring.
2.
3.
Check the continuity of each individual diode. The diode should
pass
current with low resistance in one direction and block the flow of current in the oppositedirection. If a diode blocks current in both directions or allows current to flow in both directions the diode is bad and the entire diode assembly will have to be replaced.
If a diode
is
tested
in
circuit, a false reading may result by current flow back through the DC coil and the diode you don't intend to test. The diode you
70
Generator Testing DC Circuit Diodes (cont'd) are attempting to check may actually have an open circuit that would not bediscovered because of 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.
Brush length limit
3.5 mm (.138')
Figure 140
Figure 141 i
Figure 139
GENERATOR SERVICE
Generator Service Disassembly
1. Turn the engine off and remove the spark plug wire.
2. Turn the fuel shut off valve to the "off” position.
3.
4.
5.
6.
Remove the end cover of the generator. See Figure
140.
Disconnect and remove the
AC
output wires at the
terminal block. See Figure 141.
Disconnect the control wiring plug on the top of the generator assembly.
Continue disassembly
by
removing the brush
Figure
142
7.
Remove the two nuts securing the rear frame of the generator
to
the tube frame shock mounts. The rear right- hand nut also retains the muffler bracket.
8.
Remove the four generator through bolts. See
Figure 143.
71
Generator Service Disassembly (cont'd)
Figure 143
9. Use a plastic hammer to remove the 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.
10.
11.
Figure 144
Remove the recoil starter.
Hold the crankshaft in place with a screw driver or bar through the recoil starter cup and remove the rotor set bolt. See Figure 145.
12. Use a rotor remover bolt (see the Special Tool
Section, page 19, for the correct part number) to remove the rotor assembly. The rotor is secured to the crankshaft of the engine with a tapered fit. The crankshaft has an external taper and the rotor has an internal taper. See Figure 146.
Generator disassembly is now complete.
13. Inspect the individual generator components for obvious defects or failures. Inspect the integrity of all insulation and connections. Protect the rotor and stator coils from damage while the generator is disassembled
Generator Service Reassembly
1. Inspect the rotor assembly for defects; broken wires,' worn or damaged slip rings, damaged insulation.
2. Install the rotor assembly. Some units
use
a key or pin to, align the rotor to the crankshaft. Make sure the tapers are clean and that the rotor and crankshaft line up correctly.
3.
4.
2.2 kg m
(16
ft Ibs)
Inspect the stator assembly for defects. Check for broken wires, bad insulation, broken wire ties etc.
Remove the brush holder if it is still installed on the stator.
72
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 reinstalled at 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. Reconnect the AC output wires on the terminal block. Be sure to match the color coding. See
Figure 149.
6.
Tighten the through bolts in the sequence as shown
Through bolt torque
1.0 kg m (7 ft lbs)
9.
Reconnect the lead wire from the control panel to the connector on the top of the generator.
10. If ,the diode assembly has been disconnected it should be reinstalled at this time. On some units the assembly is soldered in place, others use connectors There are three wires connected to each diode assembly, two that supply AC power to the diodes and one positive output wire. The negative output wire comes directly from the center tap of the winding that supplies power for the DC circuit. The positive output wire is white on
T1200 through T2500 and pink on the T3000. The remaining two wires are connected to the anode
(positive) ends of the diodes. See Figure 150.
Diode Wire Colors
Br & Br
Figure 148
73
11.
12.
T3000 R&W/R
I
Reconnect the four pin connector to the AVR.
Make sure all wires are clamped in place and reinstall the end cover
of
the generator.
13.
Remount the generator to the shock mounts.
Secure the muffler bracket to the right-hand shock mount.
Generator Service Reassembly (cont'd)
Figure 150
TROUBLESHOOTING
When troubleshooting, remember to keep it simple and look for the most obvious cause for a failure. Most generator troubleshooting is very straight forward and most failures are easy to detect.
To use this troubleshooting guide, look for the failure description that matches the failure you have encountered and follow the outlined steps.
Troubleshooting No AC Output
(0
volts AC)
1.
Verify 3600 RPM engine speed.
2.
Check voltmeter on the generator panel. If it is indicating 120
-
240 volts, go to step 3. If it indicates
0
volts, go to step 4.
3.
4.
5.
Verify the operation of the circuit breaker. The meter is wired to the unswitched side of the circuit breaker and will indicate voltage if the breaker is open or failed. See Control Panel Inspection on page 77 for information on testing the circuit breakers.
Remove the end cover of the generator and measure the AC voltage at the terminal block. If the meter indicates 0 volts, go to step
5.
If the voltage is normal, 120 VAC (single voltage units), 240 VAC
(dual voltage units), repair the wiring between the terminal block and control panel.
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
'I).
If the brushes are short or not making contact replace the brush assembly. If the brushes are making contact go to step 6.
6.
7.
i
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.
Check the resistance of the stator main coil. See
Generator Testing, page 68 for the correct procedure and resistance value. If the resistance is out/
of
specification, high or low, replace the stator; If the resistance is within specification go to step
8,.
8.
9.
Check the resistance of the exciter coil. See
Generator Testing, page 69 for the correct procedure and resistance value. If the resistance is out' of specification, high or low, replace the stator.: If the resistance is within specification go to step 9.
Flash the field with a 12 volt battery. Start the generator and connect the 12 volt battery to the brush' terminals
+ to
+ and to Reverse connection will damage the AVR. Make sure the brushes are connected to the automatic voltage regulator (AVR) during this test.
CAUTION: There is exposed wiring that contains potentially lethal voltage
Do
not touch any exposed terminals.
of
the
10. Measure the AC output voltage. If the voltage is within' specification leave the generator running and disconnect the battery. If the voltage stays within :specification it indicates that the permanent magnets on the rotor were demagnetized.
Flashing the field should restore the magnetism. If on restarting the generator after flashing the field the voltage again is at
0
it may indicate that the brush, connections are reversed at the brushes.
Check the sections on
Schematics, pages
78,
and
8b
for correct wiring. If the voltage falls to 0 with disconnection of the battery, replace the AVR.
Troubleshooting Low AC Output
(3-6
volts)
An output of
3-6 volts indicates that the permanent magnets on' the rotor are functioning. It also indicates that the following components are operating:
.
The wiring to the receptacle is
OK.
The receptacle is
OK.
The circuit breaker
is
allowing current to flow.
The main stator coil has continuity.
74
Troubleshooting
(cont'd)
Low
AC Output
(3-6
1. Verify 3600 RPM engine speed.
2. 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.
3. Check the resistance of the rotor. See Generator
Inspection on 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
4.
4.
Check the exciter coil resistance. See Generator
Inspection on page 69 for the correct procedure and resistance value. If the resistance is out of specification, high or low, replace the stator. If the resistance is within specification go to step
5.
5.
Replace the automatic voltage regulator (AVR).
Troubleshooting High AC Output (over
132
volts
AC)
The no load AC voltage should be 120 volts
+ or 10%.
CAUTION: High voltage may cause damage and/or fires in connected appliances.
High AC output indicates too much voltage being sent to the field (rotor). The AVR determines how much voltage to send from the exciter coil to the rotor by continuously sampling the AC output voltage through two sensor circuit wires. If this circuit is damaged or open, the AVR will interpret this as a low AC output voltage situation and will respond by sending maximum exciter voltage to the rotor. High output voltage also indicates that the following components are operating or functional:
The stator coil has continuity.
The exciter coil has continuity.
The permanent magnets are OK.
The receptacle and wiring to the receptacle is OK.
The AC circuit breaker
is
OK.
The rotor coil has continuity.
The brushes are contacting the slip rings.
1.
2.
3.
Verify 3600 RPM engine speed.
Stop the generator and remove the end cover.
Disconnect the four pin connector at the AVR.
Check the sensor circuit for continuity. On the
T1200 and
T1800
this is done at terminal
S1
and
S2 of the four pin connector coming from the stator coil See Figure 151.
!
I
I
PLUG
FROM
HARNESS
Figure 151
4.
Sensor circuit continuity on the T2500 and T3000 is measured at
S1
and S2 as shown in Figure 152.
75 i
Figure 152
5. Refer to the Generator Testing section on page
70
for a complete description of sensor circuit testing procedures.
6.
7.
If the circuit is open (infinite resistance) the stator coil must be replaced.
if
the sensor circuit has continuity and the high voltage situation remains, replace the AVR.
Troubleshooting No DC Output
(0
volts DC)
1. Verify 3600 RPM engine speed.
2. verify AC output. If the AC output is normal go to step three.
If
the AC output is 0 volts, follow the steps in the No AC Output Procedure, page
74.
3.
4.
5.
Check the DC circuit breaker.
If
it has tripped, find the cause of the overload in the circuit wired to the
DC output terminals and reset the breaker.
Check the continuity of the DC coil. Place your multimeter in the
R X
1
mode and test continuity at the anode end of the two diodes (this will be where the wires from the DC winding are connected). If there is no continuity the stator coil must be replaced If there is continuity go to step
5.
Check the function of the diodes.
See
Generator testing DC Circuit Diodes, page
70. If
one or both diodes have an open circuit, replace the diode assembly.
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 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. The condition of the appliance, along with the length and condition of the extension cord will also be important factors in the ability of a generator to start and run a load.
3.
Verify the condition of the engine. An engine with long hours of use and wear may not be developing enough horse power to power a load that it may have easily run when new.
4.
Verify the condition of the muffler. If the muffler or spark arrestor is clogged with carbon, the engine may not be able to exhaust efficiently which will result in reduced output.
Troubleshooting Low Output Power On Dual
Voltage Generators
1. Dual voltage generators that were built in 1983 and
1984 were equipped with two 15 amp 120 volt
2. receptacles and one 240 volt receptacle. Full power available on these generators at 240 volts but because the main winding is center tapped only half the total power is available to each 120 volt outlet, e.g., a T3000D
of
1983-1984 design would provide only 1500 watts per 120 volt receptacle and
3000
In 1985 we introduce dual voltage generators that were equipped with a fourth receptacle that would provide full power at 120 volts. This is accomplished without switching or paralleling the windings. There is actually a bifilar winding on one of the; 120 main coil halves that supplies this receptacle. All outlets may be used at the same time
as
long as the total capacity of the generator is not exceeded
Troubleshooting Can
I
use DC and AC at the same time?,
1. On 19& and 1984 generators the DC winding was part of the AC winding and use of both AC and DC at the same time could lead to overheating.
2. 1985 and newer product use a DC winding that is separate from the AC winding and on these units it is possible to use both AC and DC at the same time. The DC circuit will consume about 100 watts when fully loaded.
76
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 four screws and secured to the front frame rail with two hair pin clips. Remove the two clips and then remove the four screws. The back of the control panel may now be exposed.
4.
On generators with a serial number starting with
"4" and above, it is necessary to remove only the six screws that retain the front panel to the control panel body.
5.
With the panel pulled open, the engine "on-off" switch, receptacles and circuit breakers are visible.
6.
The low oil level shut down module is mounted inside the control panel and is secured with one screw, it may also be removed if necessary.
7.
See the Schematic Diagrams on pages
78,79
and
80
to verify correct wiring of the control panel components.
Control Panel Inspection
1.
It is not necessary to remove individual components from the control panel for inspection and testing. Failure of most of the panel components will be obvious without disassembly of the panel.
2.
The operation of the circuit breakers may be verified with
a
multimeter. It is a good habit to always disconnect a component from the circuit when making a continuity or resistance check. This will eliminate the possibility of any other portion of the wiring causing a false reading.
3.
Place your multimeter in the
R X
1
mode and check the continuity of the AC circuit breaker (breakers) in the "on" and
"off” position. If the circuit breaker does not open and close under manual operation of the switch arm, the breaker must be replaced.
4.
The DC breaker is a thermally activated device and it is not possible to manually open its contacts. The breaker should open the circuit under a load of
8.3
amps DC. If the breaker does not appear to be operating properly, connect a DC ammeter in the series with the load in the DC circuit connected to the generator and measure the current to verify the point at which the circuit breaker trips.
5.
The engine ignition switch is a single pole, single throw switch that may be tested by disconnecting it
'from the circuit and checking the opening and closing of the contacts with a multimeter in the
R
X ~
I
6.
The receptacles are friction and twist lock connection devices. There are no moving parts and are not subject to failure uless they are mechanically damaged. The receptacles should be tested by disconnecting them from the circuit and checking for shorts and continuity with a test light or multimeter.
7.
The volt meter in the panel is connected in parallel with the AC output circuit of the generator. If the meter is not functioning, verify the AC output voltage with an external AC volt meter. If the AC voltage is normal and the meter is not indicating, verify its connections and replace the meter if necessary.
8.
The DC output terminals should be fully insulated from the front panel. Verify the the integrity of the insulation with a multimeter in the
R X 1
mode connected alternately, to each terminal and ground. There should be infinite resistance.
9.
NOTE: This test, as with other continuity tests, should be completed with the wires disconnected from the terminals.
The low oil level warning lamp may be tested by unplugging its connectors and checking the resistance of the lamp. It should measure approximately
18
ohms. If a reading of infinity is indicated the filament in the lamp is open and the lamp must be replaced.
Controi Panel Reassembly
1.
Remount any component that may have been re:moved from the panel.
2. Reconnect all panel components per the
Schematic Diagrams shown on pages
78,79
and
80
3.
Reinstall the low oil level shutdown module. Make sure the module is securely grounded.
4.
Remount the control panel with four or six screws as required.
5.
On 1983
models (serial number starts with a
"3")
install the two hair pin clips retaining the control panel to the front frame rail. That completes reassembly.
77
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