LC3500i

Maintenance Manual

LONCIN MOTOR CO., LTD.

Safety Precautions
Please carefully read the Manual before operating  Electrostatic sparks caused by the fuel oil flowing
the generator unit. Safe operation and optimum through the nozzles of oil pumps of gasoline
performance will only be achieved when the the stations may ignite the gasoline. Nozzles of oil
equipment is operated and maintained correctly. pumps of gasoline stations are not allowed for
filling fuel oil to the generator unit. Instead, the
Following marks will be found throughout the Manual
fuel oil shall be filled to a explosion-proof fuel
to remind you that there may be danger for the
tank placed on the ground first, and then to the
operator, maintenance personnel and equipment.
generator unit slowly.
Remind you that there may be  The fuel oil shall not be filled to the generator
imperative danger that may cause severe personal during operation. The engine of high temperature
injury or death. may ignite the fuel oil.
Remind you that there may be  To prevent fire resulted from fuel oil leakage, fuel
dangerous situation that may cause severe personal valves must be closed and the generator unit must
injury or death or unsafe operation. be cooled down before transporting the generator
unit or preserving it in a closed space.
Remind you that there may be
 Smoking and open fire are strictly prohibited
dangerous situation that may cause personal injury,
adjacent to the generator unit. Flame, sparks,
equipment damage or property loss or unsafe electric switches, pilot torches, electric arcs,
operation. equipment generating electric arc as well as any
Electricity, fuel oil, exhaust emissions, moving parts other ignition sources must be kept away from the
and batteries may cause dangers, and safety generator unit.
precautions for them must be followed to prevent
severe personal injury or death.
The Voltage of Generator Unit may Cause
Death.
Exhaust Emissions may Cause Death.
 It is not allowed to connect the generator unit to
 The electric generator can only be operated the electric system of buildings directly. The
outdoors and the operator shall keep away from it. feedback current may cause death of electric
power circuit workers due to electric shock and
Exhaust port.
equipment damages. An approved switchgear
 Ensure that exhaust emissions from the generator must be used to prevent the connection with
unit will not enter windows, doors, air vents or air generator unit. Under circumstances of using the
inlets of adjacent buildings, vehicles or vessels. generator unit as power supply for emergencies,
 The generator unit is not allowed to be used in trained and experienced electricians must be
residences, garages, basements, granary, wigwam, selected to conduct electrical connection.
cabins, vessels, vessel houses, entertainment Make sure your clothes, shoes and skin are dry
vehicles or tents, closed outdoor spaces (e.g. when operating electrical equipment.
alleys, irrigation canals and ditches, parking
It is strictly prohibited to operate the generator
garages or courtyards) or any other spaces where
unit in rains or snows or on wet ground.
exhaust emissions may accumulate. It shall be
noted that even though the unit is placed indoors
with all windows and doors opened and the air Moving Parts may Cause Severe Personal
blower turned on, the concentration of carbon Injury or Death.
monoxide, which is harmful, in exhaust emissions
from the engine will also accumulate.  The spark plug wire shall be disconnected before
any maintenance for the generator unit.
 Both of your hands must keep away from moving
The Gasoline is Inflammable/Explosive.
parts.
 The fuel oil can only be filled outdoors.

b
Safety Precautions
 It is not allowed to repair the generator unit with  To reduce electric arcs generated from
loose clothes or jewelry as they may be caught disconnecting or reconnecting cables of batteries,
into moving parts. The jewelry may cause short negative (-) electrodes of batteries must be
circuit of electric terminals, sparks, flame and disconnected in advance and connected at last for
electric shock. re-connection.
 Make sure fasteners and fixtures on the generator
unit are securely installed. Shields of fans, rotors, General Precautions
etc. shall be installed in place.  Make sure that children are away from the
generator unit.
The Gas Emitted by Batteries is Explosive.  Hearing protective devices must be worn when
getting close to the generator unit under operation.
 Protective glasses shall be worn when repairing
batteries.  A multi-class (ABC) fire extinguisher shall be
placed near hand. The class-A fire is caused by
 Smoking shall not be allowed.
general inflammables such as wood and cloth.
The class-B fire is caused by inflammable and
explosive liquid and gas fuels. And the class-C
fire is caused by live equipment (refer to NFPA
NO. 10).

The following instructions and precautions in an incorrect way may

cause severe personal injury or death.

Please follow procedures and precautions in the Manual carefully.

Rocker arm
Incorrect maintenance or repair may result in unsafe situations and
may cause severe injury or death of your clients or other personnel.

Please follow procedures and precautions in the Manual and other

maintenance materials carefully.

c
Contents

Chapter I Introduction
1-1 Structure of electric generator........................................................................................................................1

1-2 Technical specifications .................................................................................................................................2

Chapter II Repair standards

2-1 Standards for engine repair ............................................................................................................................3

2-2 Standards for electric generator repair ...........................................................................................................4

2-3 Torque parameters of fasteners ......................................................................................................................4

2-4 Torque parameters of standard parts ..............................................................................................................5

Chapter III Maintenance

3-1 Maintenance schedule ....................................................................................................................................6

3-2 Change engine oil ..........................................................................................................................................7

3-3 Air filter .........................................................................................................................................................8

3-4 Cleaning of the fuel filter ...............................................................................................................................9

3-5 Spark canceller...............................................................................................................................................9

3-6 Spark plug ....................................................................................................................................................10

3-7 Adjustment of valve clearance .....................................................................................................................11

Chapter IV Faults & Repair

4-1 Fault diagnosis .............................................................................................................................................12

4-1-1 Difficulty in starting ..............................................................................................................................12

4-1-2 Low power ............................................................................................................................................13

4-1-3 Unstable speed ......................................................................................................................................14

4-1-4 Low speed/voltage ................................................................................................................................15

4-1-5 Abnormal exhaust colors ......................................................................................................................16

4-1-6 No alternating current output voltage ...................................................................................................17

4-1-7 No direct-current output voltage ...........................................................................................................17

4-2 Prepare for repairs ........................................................................................................................................18

4-2-1 Safety Precautions .................................................................................................................................18

4-2-2 Special tools ..........................................................................................................................................18

4-3 Diagram for disassembly ..............................................................................................................................19

4-4 Engine ..........................................................................................................................................................20

d
Contents
4-4-1 Crankshaft/piston ..................................................................................................................................20

4-4-2 Cylinder head/valve ..............................................................................................................................28

4-4-3 Flywheel/ignition coil/igniter/hand starter ............................................................................................34

4-4-4 Carburetor .............................................................................................................................................37

4-5 Generator ......................................................................................................................................................40

4-5-1 Fuel tank................................................................................................................................................40

4-5-2 Silencer .................................................................................................................................................41

4-5-3 Rack baseplates .....................................................................................................................................42

4-5-4 Motor parts ............................................................................................................................................43

4-5-5 Inverter parts .........................................................................................................................................45

4-5-6 Control panel parts ................................................................................................................................48

4-5-7 Appearance assembly ............................................................................................................................53

Chapter V Circuit Diagram ...............................................................................................................................54

e
Chapter I Introduction

1-1 Structure of electric generator

Gum cover of oil inlet

Fuel tank cap

Top cover of rack

Hand tube
combination
Right shell of electric
generator

Control
panel parts

Right
Inverter
appearance
parts
cover plate

Maintenance
cover of
batteries Supporting
Batteries wheel parts
Starting
Brake handle handle

Spark plug
Fuel tank

Carburetor

Shutter

Silencer

Oil-level Air
gauge filter

Left
Inspection appearance
window for cover plate
engine oil

-1-
Chapter I Introduction

1-2 Technical specifications

Unit Model LC3500i

Type Variable frequency

Frequency/Hz 50/60
Nominal voltage/V 100/120/230
Maximum power output/kVA 3.3
Rated power output/kVA 3.0
Power factor 1.0
Electric Generator Quality of AC output ISO8528 G2
Waveform deviation factor/% ≤5
Noise acoustical power (3/4
87.5
load)
DC output/V-A 12-8
DC No fuse overcurrent protector
Overload
protection Controlled by the overcurrent protection
AC
program of inverter
Model of engine LC170FD-3
Single-cylinder, four-stroke-cycle, forced-air
Type of engine
Engine cooling and overhead valve
Displacement/cc 212
Type of fuel oil Unleaded gasoline
Fuel tank capacity/L 9
Continuous operating period/h
6
(rated output)
Capacity for engine oil/mL 600 ml
Engine
E6TC/E6RTC
Model of spark plug
BPR6ES/BP6ES (NGK)
Starting mode Hand starting
External Dimensions L × W × H/mm 578 * 440 * 510
Net Weight/kg 45

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Chapter II Repair Standards

2-1 Standards for engine repair

Unspecified unit: mm

Part Item Standard Service limit

Maximum no-load speed 5,000 rpm 6,000 rpm
Engine
Cylinder pressure ≧ 1.17 Mpa (1,400 rpm) --
Cylinder Inner diameter of cylinder 70 70.165
Skirt O.D. 69.985 69.845
Piston-to-cylinder clearance 0.015-0.05 0.12
Piston
Piston pin bore ID 18.002 18.048
Piston -to-piston pin bore clearance 0.002-0.014 0.06
Piston pin Outside diameter 18.0 17.954
Ring side clearance (Top/Second) 0.015-0.045 0.15
Ring end gap (Top/Second) 0.2-0.4 1.0
Piston rings Ring end gap(Oil ring) 0.15-0.35 1.0
Ring width (Top/Second) 1.0 0.88
Ring width (Oil ring) 2.5 2.37
Small end I.D. 18.002 18.07
Big end I.D. 30.02 30.066
Connecting rod
Big end oil clearance 0.04-0.063 0.12
Big end side clearance 0.1-0.7 1.1
Crankshaft Crankshaft O.D. 29.98 29.92
Clearance(cold) (IN) 0.10~0.15 －
Clearance(cold) (EX) 0. 10~0.15 －
Valves
Stem O.D. (IN) 5.48 5.318
Stem O.D. (EX) 5.44 5.275
I.D. (IN,EX) 5.50 5.572
Valve guide Stem-to-guide clearance (IN) 0.02-0.044 0.10
Stem-to-guide clearance (EX) 0.06-0.087 0.12
Valve seat Seat width 0.8 2.0
Valve spring Free length 30.5 29.5
Cam height (IN) 27.7 27.45
Camshaft Cam height (EX) 27.75 27.50
O.D. (bearing section) 13.984 13.916
Crankcase cover Camshaft holder I.D. 14.0 14.048
Main nozzle 0.65 －

Carburetor Float height 13.7±1.5 －

Number of turning circles of mixture
2-1/8 circles －
adjusting screw
Spark plug Gap 0.7-0.8 －
Ignition coil Air gap (at flywheel) 0.4±0.05 －
-3-
Chapter II Repair Standards

2-2 Standards for electric generator repair

The resistance among windings of 230 V 2 KW is as follows:
Color of Guide Line Resistance
Main winding Brown 2.0-2.4 Ω
Power supply Orange 0.50-0.55 Ω
winding
DC winding Blue 0.19-0.21 Ω
The resistance among windings of 120 V 2 KW is as follows:
Color of Guide Line Resistance

Main winding Brown 0.75-0.85 Ω

Power supply Orange 0.50-0.55 Ω
winding
DC winding Blue 0.19-0.21 Ω

The resistance among windings of 100 V 2 KW is as follows:

Color of Guide Line Resistance
Main winding Brown 0.57-0.67 Ω
Power supply
Orange 0.50-0.55 Ω
winding
DC winding Blue 0.19-0.21 Ω

2-3 Torque parameters of fasteners

Fastening Item Fastening Parts Fastening Torque (N.m)

Fastening bolt of connecting-rod M7 × 1 12-14

Fastening bolt of cylinder head M8 × 1.25 32-35

Fastening bolt of flywheel M8 × 1.5 30-36

Fastening bolt of crankcase cover M8 × 1.25 26-32

Seal screw plug (crankcase-body oil
M10 × 1.25 20-25
drain plug)
Mounting nut of air filter M6 × 1 8-12

Mounting nut of silencer M8 × 1.25 27-30

Fastening nut of speed-regulating
M6 × 1.0 9-13
support
Fastening bolt of starting motor M6 × 1.25 8-12

Spark plug 27-30

-4-
Chapter II Repair Standards

2-4 Torque parameters of standard parts

Fastening Parts Fastening Torque (N.m)

5 mm Bolt and nut 4-7

Standard Torque Value 6 mm Bolt and nut 8-12
8 mm Bolt and nut 20-28
10 mm Bolt and nut 35-40
12 mm Bolt and nut 50-60

-5-
Chapter III Maintenance
3-1 Maintenance schedule periodic maintenance and provide evidence for your
Favorable maintenance is the best guarantee to warranty requirement.
achieve the safe, economical and zero fault operation. In
addition, it also contributes to the environmental Accidental starting of the generator unit
protection. When operating in hot or dusty environment, during maintenance may cause severe personal injury
or death. The spark plug wire must be disconnected
the frequency of some maintenance shall be increased as prior to maintenance.
specified in notes below the table.
The data of maintenance and operation shall be The generator unit of high temperature
may cause severe scald. Maintenance or repair must
recorded. Maintenance records will help you to conduct be conducted after the generator unit is completely
cooled down.

Periodic Maintenance Schedule

20 H or the First 50 H or 100 H or

Time 300 H or
Periodic Maintenance Schedule Month of Initial Every 3 Every 6
of Use Every Year (3)
Use (3) Months (3) Months (3)

Check the
○
oil level
Engine oil
Replaceme
○ ○
nt

Check ○
Air filter
Clear ○(1)

Fuel filter Clear ○

Spark canceller Clear ○

Spark plug Clear ○ Replacement

Readjustme
Valve clearance ○(2)
nt

Cylinder head Wash Every 500 h (2)

Fuel tank & strainer Wash Every 2 years (2)

Replaceme
Oil pipe Every 2 years (2)
nt

(1) Maintenance intervals shall be shortened when it is used in a place full of dusts.
(2) These maintenance items shall be conducted with supports from LONCIN franchised dealers.
(3) Under circumstances of frequent use, long-term use can only be guaranteed through maintenance with
correct intervals specified above.

-6-
Chapter III Maintenance
5) Place the oil basin below the baseplate of machine,
3-2 Change engine oil remove the oil drain plug ⑥ and the the engine oil
Note: the engine oil shall be discharged under the will be discharged from the fuel tank.
circumstance of heat engine, so that the discharge 6) Check the oil level gauge ④, seal ring ⑤, drain
can be conducted rapidly and completely. Do not plug ⑥ and seal gasket ⑦. If any damages are
discharge the engine only immediately after the observed, please replace them at once.
electric generator is powered off. As the temperature
of engine oil is extremely high, please be careful to
prevent scald during operation.
1) Please place the electric generator onto the level
plane.
2) Loosen the hand-rotary type unloosening screw ①
and remove the inspection window for engine oil
②

7) Re-install the oil drain plug and seal gasket.

8) Place the engine onto a level position in halt status
and fill new engine oil till the oil level reaches the
upper limits of the gauge. Screw the oil-filling
cover.

3) Uplift and tilt the machine, remove the end cap on

the baseplate ③.

9) Re-install the inspection window for engine oil and

fasten the screw; re-install the drain end cap.
Note: prior to each use, please place the electric
generator onto a level plane and check the engine oil
level in halt status of the engine.
4) Open the oil-filling cover ④ and pour out the 1. Remove the oil level gauge and wipe out the engine
engine oil in the crankcase. oil.
2. Insert the oil level gauge into the oil-filling hole but
do not screw it up, then check the oil level.
3. If the oil level is too low, fill the recommended
engine till it reaches the upper limits indicated by the oil
level gauge.

-7-
Chapter III Maintenance
2) Remove the air filter cover and foam filter cartridge
①
3) Wash the foam filter cartridge with solvent and dry
it
4) Drop clean engine oil into the foam filter cartridge
and knead it till even, edge out redundant engine oil
and make it be distributed evenly in the filter
cartridge. Do not twist the foam filter cartridge hard
Recommended engine oil: to avoid damage.
SAE 10W -30
Recommended engine oil level:
API standard SE or higher level
Capacity for the engine oil:
0.6 L (0.72US qt, 0.6 lmp qt)

Skin cancer may be caused by the

long-term and frequent contact with engine oil.
Though it is not inevitable, we still recommend
washing your skin contacted the engine oil clean
with soap and water.
3-3 Air filter
Air filterAir inflow will be affected and
the power of engine will be reduced after the filter
cartridge gets dirty. If the operation area is full of
dust, the maintenance shall be conducted more
frequently.

Washing the filter cartridge with

gasoline or inflammable solvent may case fire or
explosion. Only soap water or nonflammable solvent
can be used.

It is strictly prohibited to operate the

electric generator without air filter, or the abrasion
process of engine will be accelerated.
1) Remove the unloosening screw ① and the
appearance cover plate ②. 5) Place the foam filter cartridge into the air filter.
Hint
Please confirm that the surface of foam filter
cartridge is cling to the air filter without any
interspaces for air leakage
Do not start the engine without air filter as the
excessive poison gas and abrasion of the fuel tank
-8-
Chapter III Maintenance
will be caused. The gasoline is extremely inflammable
6) Install the filter cover to its original position. and explosive. Smoking, open fire and sparks are
3-4 Cleaning of the fuel filter strictly prohibited in the operation area.
The fuel filter cup is to prevent the dust or water After the re-installation is completed,
from entering into the carburetor. The filter cup shall be the operator shall check if there is any fuel leakage
cleaned after long time without operation of the engine. and make sure the operation area is dry prior to
1) Remove the unloosening screw ① and the starting the engine.
appearance cover plate ②, then pour out the 3-5 Spark canceller
fuel oil in the fuel tank ③.
The silencer of high temperature may
2) Hold the clamp ④ and move it down, then pull cause severe scald. The generator unit shall be cooled
out the oil tube ⑤ connected to the fuel tank down prior to the maintenance of silencer.
downward. Please refer to the “Maintenance Schedule” for the
3) Take out the fuel filter ⑥. cleaning of spark canceller. Remove the mesh of spark
canceller after the electric generator is cooled. Check if
4) Wash the fuel filter with gasoline. there are any damages and change damaged one. Sweep
away the carbon deposition accumulated on the mesh
5) Wipe out the fuel filter, install it onto the oil
with wire brush. Re-install the spark canceller and
nozzle ⑦ of fuel tank and screw it down, then fasten the screws.
place the oil tube onto the oil nozzle and install
the clamp.
6) Install the oil tube back as well as the clamp,
switch on the fuel valve and check if there is
any leakage.
7) Install the appearance cover plate back.

-9-
Chapter III Maintenance
3-6 Spark plug 5) Measure the clearance of spark plug with thickness
gauge. Adjust the clearance through bending the
The use of spark plug with incorrect models or side electrodes carefully. The clearance between
heat values may reduce the engine performance or electrodes shall be 0.60-0.70 mm.
damage the engine.
The spark plug and silencer will be overheated Side electrode
under the continuous operation of the engine. Take care
0.6-0.7 mm
not to touch the silencer or spark plug. Wire brush
1) Loosen the unloosening screw ① and remove the left
appearance cover plate ②.

6) Check the status of gasket of spark plug. Screw in

the spark plug with hands during the installation of
spark plug to prevent incorrect match of screw
2) Remove the spark plug cap ③, place the sleeve ④ threads.
onto a proper position on the spark plug. 7) After pressing the gasket with spark plug, impact
3) Insert the driver ⑤ into the sleeve and rotate it along them tightly with the socket spanner of spark plug.
anti-clockwise direction to remove the spark plug.
When installing new spark plug, screw 1/2 circle
more after the gasket is impacted. When
re-installing the used spark plug, screw 1/8-1/4
circle more after the gasket is impacted.
Spark plug torque value: 20.0 N*m (2.0 kgf*m,
14.8 lbf*ft)
The spark plug must be securely
fastened, or the engine may be damaged.
Please use the recommended or
equivalent spark plug.Spark plug of improper heat
values shall be prohibited.
4) Check the spark plug.Model of the spark plug:
E7RTC/F7TC
BPR6ES / BP6ES (NGK)
If the machine is required to meet the EMC
certification, only the E6RTC spark plug can be
used.
The spark plug shall be replaced under
circumstances of damaged electrodes and insulators. If it
can be further used, sweep away the impurities
including carbon deposition, etc. accumulated on the
spark plug with wire brush.
- 10 -
Chapter III Maintenance
d) Re-check the valve clearance after fastening
3-7 Adjustment of valve clearance the lock nut.
The check and adjustment of valve
clearance must be conducted when the engine is cold.
1) Take apart the cylinder-head cover, pull the
FEELER GAUGE
starting handle until you feel the obvious resistance
to make the piston reach nearby upper dean center
of compression stroke. At this time, both inlet and
exhaust valves are in the closed status.
2) Insert the thickness gauge into the clearance
between the rocker arm and valve to measure the
valve clearance.

Standard Valve Inlet 0.10 ~ 0.15 mm

Clearance
Exhaust 0.10 ~ 0.15 mm

LOCK NUT

PIVOT

ROCKER ARM

To increase valve clearance, screw out the pivot

To decrease valve clearance, screw in the pivot

3) Operate as per the following steps if the adjustment

is required:
a) Fix the valve-adjusting screw with a clamp
and unscrew the valve lock nut with a spanner.
b) Rotate the valve-adjusting screw and adjust it
to the specified valve clearance.
c) Fix the valve-adjusting screw with a clamp
and fasten the valve lock nut.

- 11 -
Chapter IV Disassembly & Repair

4-1 Fault diagnosis Excess fuel oil flowing into the engine
(Re-start after stopping for several minutes)
4-1-1 Difficulty in starting
Fuel oil level too low
Fuel system (Add fuel oil into the fuel tank)
Fuel filter blocked
(Refer to Section 3-4)
Improper adjustment of carburetor
(Refer to Section 4-4-4)
Air filter dirty
(Refer to Section 3-3)

Engine oil level two low

(Refer to Section 3-2)
Improper spark plug gap
(Refer to Section 3-6)
Fault of spark plug cap
(Refer to Section 4-4-3)
Difficulty in
starting Fault of ignition coil
Ignition system
(Refer to Section 4-4-3)
Fault of starting switch
(Refer to Section 4-5-6)

Fault of engine-oil protective system

(Refer to Section 4-4-1)

Improper valve clearance

(Refer to Section 3-7)

Cylinder-head gasket damaged
(Refer to Section 4-4-2)
Loosen fastening bolt of cylinder head
(Refer to Section 4-4-2)
Compression Valve fault
system (Refer to Section 4-4-2)
Wear of cylinder/piston/piston ring
(Refer to Section 4-4-2)
Excessive wear of camshaft
(Refer to Section 4-4-1)
- 12 -
Chapter IV Disassembly & Repair

4-1-2 Low power

Poor quality of fuel oil
(Use new fuel oil of specified quality)
Fuel filter blocked
(Refer to Section 3-4)
Fuel system
Improper adjustment of carburetor
(Refer to Section 4-4-4)
Choke-valve handle not opened completely
(Under the “operation” position)
Air filter dirty
(Refer to Section 3-3)
Fault of spark plug cap
Ignition system (Refer to Section 3-6)
Fault of ignition coil
(Refer to Section 4-4-3)
Wear of cylinder/piston/piston ring
(Refer to Section 4-4-1)
Low power
Compression Improper adjustment of valve clearance
system
(Refer to Section 3-7)
Wear or damage of valve seat
(Refer to Section 4-4-2)
Wear of camshaft
(Refer to Section 4-4-1)
Cooling fan dirty

(Clean)
Cylinder cooling fin dirty
(Clean)
Others Silencer blocked
(Refer to Section 4-5-2)
Motor phase loss & short circuit for some
turn-to-turn of machine winding
(Refer to Section 4-5-4)
Excessive electrical load
(Disconnect surplus load)
- 13 -
Chapter IV Disassembly & Repair

4-1-3 Unstable speed

Fuel oil is of low level/of poor
quality/polluted

(Use new fuel oil of specified quality)

Fuel system Fuel filter blocked
(Refer to Section 3-4)

Carburetor blocked
(Refer to Section 4-4-4)

Improper adjustment of valve clearance

Unstable (Refer to Section 3-7)
speed Compression
system Wear and air leakage of valve seat
(Refer to Section 4-4-2)

Wear of camshaft
(Refer to Section 4-4-1)

Speed-regulating step motor damaged

(Refer to Section 4-4-4)
Speed-regulating
system
Speed-regulating part of converter
damaged
(Refer to Section 4-5-5)

Engine oil level too low

(Add new engine oil)
Others
Excessive electrical load
(Disconnect surplus load)

- 14 -
Chapter IV Disassembly & Repair

4-1-4 Low speed/voltage

Air filter dirty

(Refer to Section 3-3)

Fuel oil is of poor quality/polluted

Fuel system (Use new fuel oil of specified quality)

Water inside the carburetor

(Refer to Section 4-4-4)

Choke-valve handle not opened completely

Low (Under the “operation” position)
speed/voltage

Fault of step motor

Speed-regulating (Refer to Section 4-4-4)

system
Fault of converter
(Refer to Section 4-5-5)

Motor phase loss and short circuit for some

turn-to-turn of machine winding

(Refer to Section 4-5-4)

Others High temperature of alternator
(Refer to Section 4-5-4)

High temperature of alternator

(Refer to Section 4-5-4)

Excessive electrical load

(Disconnect surplus load)

- 15 -
Chapter IV Disassembly & Repair

4-1-5 Abnormal exhaust colors

Air filter excessively dirty

(Refer to Section 3-3)

Black Fault of carburetor

(Refer to Section 4-4-4)

Overloaded
(Disconnect surplus load)

Low temperature of engine

Abnormal (Normal starting)

White
exhaust color
Fuel oil is of poor quality/polluted
(Use new fuel oil of specified quality)

Fuel oil is of poor quality/ polluted

(Use new fuel oil of specified quality)

Wear of cylinder/piston/piston ring

Blue (Refer to Section 4-4-1)

Excessive engine oil

(Refer to Section 3-2)

Fault of cylinder head

(Refer to Section 4-4-2)

- 16 -
Chapter IV Disassembly & Repair

4-1-6 No alternating current output voltage

Fault of output socket

(Check if the socket is burned; if yes, replace it

with a new one)

Abnormal engine speed

(Check and adjust)
No alternating
current
output
voltage
Fault of stator winding coil
(Refer to Section 4-5-4)

Fault of converter
(Refer to Section 4-5-5)

4-1-7 No direct-current output voltage

Rectifier bridge wiring loose or fault

断路器跳闸
(Reinsert it; refer to Section 4-5-5)

No
direct-current DC winding short-circuit or open-circuit
output
(Replace motor part)
voltage

Converter fault
(Refer to Section 4-5-5)

- 17 -
Chapter IV Disassembly & Repair
Table 4-1 Danger and Danger Sources
4-2 Prepare for repairs
 Fuel leakage or spill
4-2-1 Safety Precautions
 Hydrogen emitted from batteries
There will be dangers during repairing the generator unit. Fire and  Inappropriate storage of cloth pieces
Read safety precautions carefully and be familiar with explosion with oil
the dangers listed in Table 4-1. Note the safety measures  Inappropriate storage of flammable
and methods of the following danger preventions. liquid
 Use personal protective equipment: wear proper  Exhaust pipe of high temperature
safety protective equipment, such as safety shoes and Burns  Engine and engine surface of high
protective glasses. temperature
 Do not wear earrings or jewelry; do not wear loose or Toxic waste  Operate the electric generator in
gas unventilated area or indoors
wet clothes as they may be caught in the equipment or
cause electric shock.  Incorrect wiring of generator
 Line fault
 Reduce risk: a safe workshop in order and under good Electric
maintenance can reduce potential risks. The protective shock (AC)  Operate in humid environment
equipment and shield of machinery shall be installed in  Metal objects contact with electrical
place and be kept at normal position so as to keep elements
equipment be under the good operation. Flammable Rotating
liquid shall be stored in approved container, and be kept machinery  Without fan shield installed
away from open fire, sparks, pilot torches, switch, Extremely
equipment generating electric arcs as well as other smooth  Leaked or spilled engine oil
ignition sources. The workshop must be kept clean with surface
sufficient lighting and adequate ventilation.  Disassemble the generator unit from
Heavy stuffs vehicle
 Develop the habit of safe operation: unsafe behavior
will cause equipment and machinery accidents. Be  Disassemble heavy elements.
familiar with equipment and the methods how to use
them safely. Use correct tools during operation and 4-2-2 Special tools
check the status before starting. Follow the warnings Engine
mentioned in the Manual and take special precautions To repair engine, a complete set of standard metric
when working near electrical equipment. If possible, do special tools is required.
not work alone and take risks. Control device and generator
 Be prepared for dealing with accidents: prepare a fire To the repair control device and generator, a complete
extinguisher and safety equipment at the place near set of standard metric workshop tools is required. In
yourself. Red Cross and public safety agencies have addition, following tools are also required:
provided some courses in term of first aid, CPR and fire  Plumb bob or soft-surface plastic hammer
control. Make use of these materials to prepare well to  Torque wrench
deal with accidents. Learn how to possess safety
 Multimeter
consciousness and treat safety rules as a part of routine
work.  Frequency meter
 Armature tester
 Load box
 Rotor puller

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Chapter IV Disassembly & Repair

4-3 Diagram for disassembly

Left/right
appearance cover
plate

Left/right generator
Control panel casing
Shutter at tail

Fuel tank
Panel seat

Fuel tank bracket

Inverter
Combination of Vertical framework
rack baseplate
Rack baseplate Rack baseplate

Cushion seat of
main engine
Brake and wheel

Support plate of
engine

Silencer Engine Fan housing

Carburetor Stator Rotor

Air filter Diagram for disassembly Impeller

of generator
The above diagram is for quick reference for
disassembling products. In order to operate better
and more safely, please ensure to follow
above-mentioned orders.

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 Chapter IV Disassembly & Repair

4-4 Engine
4-4-1 Crankshaft/piston
a. Disassembly/assembly Camshaft

Assembly:
Bolt: M8 × 32 Check if the spring is worn
Torque: (26 ~ 32) N•m and out of elasticity to ensure
Crankcase cover the decompression hammer
can operate flexibly, then Crankshaft parts
align to the timing mark for
Sealing gasket of assembly. Assembly:
crankcase cover During assembly, do
not damage the oil
Reducing
seal. Pull it in until
valve the bearing contacts
with crankcase.

Crankcase
6205 bearing

Oil level
sensor

Connecting rod cap

Assembly:
Make the direction of oil spoon
towards nose end of
speed-regulating arm, and align the Wind scooper
connecting rod to the lug boss of Oil seal 25 × 41.25 × 6
connecting rod cap for assembly.
Piston Assembly:
Valve lifter When passing
Assembly: through the
During assembly, Assembly: crankshaft, do not
make the direction Assemble the camshaft roll up the edge of
of piston top arrow immediately after the tapper oil seal.
as same as that of is assembled.
oil spoon of
connecting rod.
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Chapter IV Disassembly & Repair
b. Piston/piston ring
Piston ring

Assembly:
1) Put upward the manufacturer’s mark during assembly.
2) Do not misplace the gas rings 1 (chromed) and 2.
3) Check if the piston ring can rotate flexibly after installation.
4) Avoid the direction of piston ring for each opening of piston ring by staggering for 150° ~ 210°.

Gas ring 1 (chromed)

Manufacture’s mark Oil ring

Gas ring 2
Piston

Piston pin

Snap ring of piston pin

pin
Assembly:
Put an end of snap ring in the groove of
Connecting piston and use nipper pliers to clamp the
rod other end, rotate and assemble it into
groove. Do not make the opening of snap
Assembly: ring towards the gap of piston pin hole.
Make the longer side of big
large end towards the mark “▽”
of piston and assemble it on
piston.

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Chapter IV Disassembly & Repair

Crankshaft
c. Camshaft/crankshaft Camshaft
Reference sign
When assembling camshaft, align the camshaft gear wheel to the
Reference sign of timing gear (pinion of crankshaft) for assembly.

d. Check

Check of piston
Check the contact between piston and cylinder,
defects of ring groove, erosion at the top, crack, etc.
It shall be replaced for severe damages (e.g. crack).
Remove carbon deposition
Carbon deposition accumulates at the edge of the
top of piston and upper opening of cylinder.
Remove carbon deposition prior to detection.
Wet the carbon deposition with kerosene, and then
remove it with blunt scraper or metallic brush.

1) Outer diameter of piston skirt

Measure the outer diameter of piston skirt with
outside micrometer. Replace the piston skirt if
it exceeds the use limit.

Standard Maintenance Limit

69.985 mm 69.845 mm

2) Clearance between piston and cylinder

The difference between the maximum diameter of cylinder and the diameter of the piston skirt is the clearance
between piston and cylinder.

Standard Maintenance Limit

0.015-0.050 mm 0.12 mm

3) Clearance to the side of the piston ring

When checking, put each ring in corresponding
piston ring slot. The piston shall be able to rotate
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Chapter IV Disassembly & Repair
freely, neither loose nor inflexible. Then insert feeler
gauge into the clearance between the ring and the
slot to measure the clearance.

Standard Maintenance Limit

0.015-0.045 mm 0.15 mm

4) Thickness of piston ring

Standard Maintenance Limit

Ring 1/2 1.0 mm 0.88 mm

5) Clearance to the end of piston ring

Standard Maintenance Limit

Ring 1/2 0.02-0.04 mm 1.0 mm

Before measuring the clearance, the piston ring shall be

assembled on piston correctly, then put the piston in
cylinder. And rings 1 and 2 shall be also replaced for
the use of oil rings.

6) Outer diameter of piston pin hole

Standard Maintenance Limit

18.0 mm 17.954 mm

7) Inner diameter of piston pin hole

Standard Maintenance Limit

18.002 mm 18.048 mm

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Chapter IV Disassembly & Repair
8) Clearance between piston pin hole and piston pin
Measure the inner diameter of piston pin hole and the outer diameter of piston pin with inside micrometer and outside
micrometer. Then calculate the clearance value based on the measured result. Replace the piston or piston pin if it
exceeds the use limit.

Standard Maintenance Limit

0.002-0.014 mm 0.06 mm

9) Inner diameter of cylinder

Standard Maintenance Limit

70 mm 70.165 mm

Detection of connecting rod

The connecting rod shall be scrapped to change a new one when it is bent, warped, or the out ring of its bearing bush
in big end and the shaft sleeve in the small end is moving, or has crack.

1) Inner diameter of the small end of connecting rod

Replace the connecting rod if the inner diameter is less or more
than maintenance limit.

Standard Maintenance Limit

18.002 mm 18.07 mm

2) Detect the inner diameter of big end

Replace the connecting rod if the inner diameter is less or more
than maintenance limit.

Standard Maintenance Limit

30.02 mm 30.066 mm

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Chapter IV Disassembly & Repair

3) Outer diameter of crankshaft journal

Standard Maintenance Limit

29.98 mm 29.92 mm

4) Side clearance of the big end of connecting rod

Standard Maintenance Limit

0. 1-0.7mm 1.1mm

5) Oil-film clearance of big end of connecting rod (radial direction)

a) Wipe away the engine on the surface of crankshaft journal. 12 N.m
b) Set plastigauge on crankshaft journal then assemble connecting
rod,Fasten the bolt as per the specified torque.
Fastening torque: 12-14 N.m
Note: do not make the crankshaft rotate when fastening the bolt.
c) Disassemble the connecting rod and measure the thickness of plastigauge.
d) Check the connecting rod when the clearance exceeds
maintenance limit,and re-check the clearance.

If the clearance still exceeds the maintenance limit after a new

connecting rod is used, grind the crankshaft journal and use the
connecting rod with the clearance less than the standard value.

Standard Maintenance Limit

0.04-0.063 mm 0.12 mm Plastigauge
Scale

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Chapter IV Disassembly & Repair
Detection of camshaft
The camshaft is the main engine drive element of valve mechanism of gasoline engine, controlling inlet or exhaust
valve to open or close in a regular manner. For appearance, check whether the cam surface and the height is damaged,
whether the camshaft and bearing is loose and worn. If yes, change the whole unit.

1) Cam height of camshaft

Standard Maintenance Limit

Inlet 27.7 mm 27.45 mm
Exhaust 27.75 mm 27.50 mm

2) Outer diameter of camshaft

Standard Maintenance Limit

13.984 mm 13.916 mm

3) Inner diameter of camshaft hole

Standard Maintenance Limit

14.0 mm 14.048 mm

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Chapter IV Disassembly & Repair
Check of bearing
Backlash
Clean and dry the bearing.
Rotate the bearing with hands and check the backlash. Replace Backlash
it in case of abnormal noise or movement.

Axial Radial

Oil-level sensor
Measure the conductivity of senor with ohmmeter.
When the engine oil in tank is insufficient or empty, the
black wire of sensor is conductive with the earth wire;
otherwise the black wire of sensor is not conductive with
the ground, which means the sensor is under normal status.

(OFF) (ON)

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Chapter IV Disassembly & Repair

4-4-2 Cylinder head/valve

a. Disassembly/assembly

Bolt M6 × 14 (4)
Assembly/disassembly:
Unscrew and screw bolt in the
manner of cross.
Torque value: 8-12 N·m
Spark plug
Air guide sleeve Assembly:
Clean and adjust the spark
Filter Gasket plug prior to assembly.
Torque value: 25-28 N·m

Double-end bolt
(exhaust)

Cylinder-head
cover

Breather pipe Cylinder-head cover

Assembly/disassembly:
Make one end connect
cylinder-head cover and
the other end connecting
the breather mouth Cylinder-head
vertical to breather slot sealing gasket
cover plate.
Double-end bolt
(inlet)
Cylinder head
Cylinder-head bolt: M8 × 60 (4)
Assembly:
Torque value: (32 ~ 35) N•m Prior to assembly, clear away the carbon
Assembly/disassembly: deposition in combustor and check the
Unscrew and screw bolt in the seal status of valve seat then conduct
manner of cross. assembly.
Measure the pressure of cylinder head
after completing assembly.
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 Chapter IV Disassembly & Repair

b. Disassembly/assembly

Exhaust valve Inlet valve

Assembly: Assembly:
Confirm if the conical part is defected Don’t confuse these valves.
or there is excessive carbon deposition Be careful during installation and
prior to installation. don’t damage the valve stem.

Crankcase

Valve-spring seat

Valve spring (2)

Valve lock nut (2)

Oil drip pan

Valve lock clamp (2)

Valve-adjusting bolt (2) Tappet combination

Assembly: Assembly:
Check if contact Check if both ends are worn and
surfaces of the bolt and Valve rocker arm (2) the tappet body is straight firstly,
vale are worn before then across cylinder head and
assembly. Assembly: assemble it into the tappet hole in
Check if contact surfaces of crankshaft tank in place.
central hole and valve
tapper are worn before
assembly.

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Chapter IV Disassembly & Repair

c. Check
1) Outer diameter of valve stem
Check outer diameter of valve stem with micrometer.
Replace a new valve when the diameter is less or more
than maintenance limit or there are the visible ablation or
crack on valve surface with naked eyes.

Standard Value Maintenance Limit

Inlet 5.48 mm 5.318 mm
Exhaust 5.44 mm 5.275 mm

2) Free length of valve spring

Measure the free length of valve spring.
Replace the spring if the inner diameter is less or more than
maintenance limit.

Standard Maintenance Limit

30.5 mm 29.5 mm

Ruler
3) Cylinder head
Remove the carbon deposition in combustor and
gasket residues attached on the cylinder head.
Check whether there are cracks on spark plug hole
valve seat surface and valve guide.
Check whether the cylinder block is deformed with
ruler and feeler gauge.
Thickness gauge

Maintenance Replace it in case of

Limit exceeding 0.10 mm

4) Valve guide
Check:
a) Check whether the internal surface of the valve guide is
smooth and clean, with scratch and strain; whether
the coordination between valve guide and cylinder
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Chapter IV Disassembly & Repair
cover is fixed.
b) Remove the carbon deposition in valve guide with
valve guide rimer before measuring the inner diameter of
valve guide.
Valve
Replace the guide if the inner diameter is less or more guide
reamer
than the maintenance limit.

Standard Maintenance Limit

5.50 mm 5.072 mm

Replace:
a) Freeze the valve guide to be replaced.
in freezing chamber for about 1 h.
b) Disassemble the valve guide from the combustor side
with a valve guide remover.

Be careful not to damage the cylinder head when disassembling

The valve guide.
c) Assemble the new valve guide from the valve spring side
of cylinder head.
Exhaust valve side: tap the exhaust valve guide until the
Valve guide remover
retainer ring contacts with cylinder head completely.
Inlet valve side: tap the inlet valve guide until it reaches
specified height (measure from the top of inlet valve guide
to the surface of cylinder)
d) check whether the there are damages on guide after
assembling and replace the valve guide in case of
damages.

Trim:
Finish ream with reamer on valve guide must be
Correct Wrong
conducted at room temperature so as to achieve good effect.
a) Coat a layer of cutting oil on valve reamer and guide.
Screw the reamer clockwise until it is screwed in valve

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Chapter IV Disassembly & Repair
guide completely. Continue to unscrew clockwise the
Retaining
valve reamer from valve guide. ring of valve Valve
Tool: valve guide reamer guide guide
remover
b) Remove the dirt and scraps on cylinder head thoroughly.
c) Check the valve guide hole. The hole shall be at the central
of valve guide and straight and unobstructed. Insert the
Valve guide
valve and check whether the operation is unobstructed. If Installation
not, the valve guide may have been bent when being height 1mm

assembled. If it has been bent or damaged, replace it.

d) Check the clearance between the valve stem and guide.
e) The clearance between valve stem and guide: the clearance
between valve stem and guide is calculated by
corresponding inner diameter of valve guide minus the outer
diameter of valve stem.
f) If the clearance between the valve stem and guide exceeds the
maintenance limit, judge whether to replace it with a new guide
can make the clearance in maintenance. If yes, change the valve
guide and stick the valve guide. When replacing valve guide,
please re-repair the valve seat.

Valve
surface
5) Valve seat:
a) Remove the carbon deposition in combustor and on
valve seat. Coat a layer of red lead power or other colorful
painting which is easy to scrub and stick.
b) Insert valve and press it for several times, and ensure
not to rotate it on the valve seat. Valve seat coated with
painting indicates it contacts with valve tightly; otherwise,
it does not contact with valve, which means that the valve is not
concentric to valve seat.
c) Grind the valve seat with a 45° grinder to make a smooth
concentric valve seat, clockwise rotation is allowed only.
And the counterclockwise rotation is prohibited.
Tool: valve grinder
d) Narrow and adjust the valve seat with a 32°-45° grinder to
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Chapter IV Disassembly & Repair
make it contact with the central part of the conical surface
of valve. Valve seat
cutter

Grind the top edge of valve seat with a 32° grinder (the
contact is too high).
Grind the top edge of valve seat with a 45° grinder (the Contact
too high
contact is too low).
Ensure that the contact width of completed valve is withing IN: 32°
EX: 32°
the specified range. Contact
too low IN: 45°
Standard Maintenance Limit EX: 45°
0.8 mm 2.0 mm

e) Grind slightly with a 45° grinder to remove all burrs

on the edge of valve seat.
f) Check the width of valve seat after re-repairing the valve
seat. Coat colorant on the conical surface of valve, insert
the valve and press it for several times, and ensure that it does
not rotate it on the valve seat. Where the conical surface of
valve is coated the colorant uniformly as shown as figure, it
indicates the valve contacts with the conical surface of
valve seat well.
g) Coat abradant on the conical surface of valve seat
and abrade the valve seat by rotating valve abrasive
tool.
h) Check the valve clearance after assembly.
0.8 mm

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Chapter IV Disassembly & Repair

4-4-3 Flywheel/ignition coil/igniter/hand starter

a. Disassembly/assembly

Ignition coil
Assembly/disassembly:
Check if the insulated cost is
cracked or damaged prior to Motor stator
assembly to avoid electric
leakage.

Bolt M6 × 65 (4)
Toque: (7 ~ 13) N•m

Cooling fan
Note: do not damage the
blade during maintenance.

Starting cup

Flange bolt: M8 × 28
Torque: (30~36) N•m Igniter

Fan housing

Assembly/disassembly: Motor rotor

Bolt: M6 × 8, Four Remove the dust in fan Disassembly:
Torque: (8 ~ 12) N•m housing before assembly. Disassemble with flywheel
remover (a special tool).
Prohibit tapping with
Hand-starting parts hammer.

Assembly：
Remove the soil and grass attached around
these parts prior to assembly and note the
assembly direction.

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Chapter IV Disassembly & Repair

c. Disassembly/assembly (starter assembly)

The maintenance of hand-starting parts may cause personal injury accident, so please wear protective
glasses and do not make the starting return spring popup.

hexagonal-head shaft shoulder bolt

Assembly:
Pull rope Coat the thread
Drive cam
compressed spring retardant on the thread.
Assembly:
Check whether the pull rope Assembly:
Check whether it is Assembly:
is broken or worn prior to Grease shall be
assembly. broken or worn prior
to assembly and note coated.
the assembly
direction.
Handle of pull rope

Torsional spring

Drive guide plate

Assembly:
Make the end of drive
cam expose from the
gap of guide plate
during assembly.
Pull rope disk
Pull rope disk
Assembly:
Start return spring Assemble the return spring
Note: do not make the return on pull rope disk then
spring popup during assembly. In assemble the pull rope disk
addition, wear gloves for on the cover.
operation.
Assembly:
Hang the hook outside in the slot
of spool of pull rope disk, and
then hang the hook inside on the
jack catch of pull rope disk cover.

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Chapter IV Disassembly & Repair
Assembly of hand starting parts
Wear gloves and goggles to protect your hands
and eyes. Cover of starter
Return
Do not make the starting return spring popup. spring

1) Put the return spring in the seat cover, hang the hook outside
the return spring at the gap of seat cover fixedly and make it
align to the slot of pull rope disk, then assemble to seat cover
unit to pull rope disk. Coat grease on the jack catch of starter
Pull rope disk
cover, rotate it toward the left and assemble it, and to hang the hook Race cover

inside the return spring at the jack catch of starter cover.

2) Tie a knot at one end of the pull rope, and tread the other
end from the pull rope hole of pull rope disk. Then twine
Pull rope
the pull rope disk for 5 circles anticlockwise.
Tread the starting pull rope from the hole of starter cover
and tie a 8-knot at the end of pull rope.

Center bolt

3) Assemble dirve cam, torsional spring and drive guide plate Drive guide plate
and fasten the center bolt. Drive cam
Torsional
Compressed spring spring

4) Pull the pull rope of starter for several times and check
the return status of drive cam.

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Chapter IV Disassembly & Repair

4-4-4 Carburetor
a. Disassembly/assembly

Speed-regulating stepper motor

Screw M3 × 5 (2)
Torque: (1~1.5) N•m

Installing support
of speed-regulating
stepper motor

Sealing gasket of Screw M4 × 12 (2)

inlet pipe Torque: (5~7) N•m

Insulation gasket
of carburetor

Sealing gasket
of carburetor
Support of
choke valve
Carburetor

Sealing gasket
of carburetor

Sealing gasket of
carburetor

- 37 -
Chapter IV Disassembly & Repair
b. Disassembly/assembly
The gasoline is flammable and explosive. The fuel valve must be closed before repairing carburetor
and drain fuel in the carburetor. And no open flames.

Choke valves
Throttle valves
Carburetor body

Assembly:
Blow in some compressed
air to remove the dirt in
Primary nozzle
internal passage then
Assembly: conduct assembly.
Blow in compressed air and
remove dirt in the passage
before installation.
Needle valve

Check the wear of the end

and action of spring before
installation.

Main jet

Assembly:
Remove the dirt in internal
Compressed spring
passage completely with
compressed air before
assembly. Float pin
O-ring

Float Assembly:
Check whether it is
Assembly: assembled in slot.
Check whether the float
moves freely after
assembly.

Gasket

Bolt of float chamber Oil drain plug of oil cup

Assembly: Assembly:
Confirm if there is fuel leakage Oil drain pipe Confirm if there is fuel leakage
after installation. after installation.

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Chapter IV Disassembly & Repair

c. Check
Speed-regulating stepper motor
Check the resistance of the 2 diagonals in the
socket of stepper motor. The resistance shall be 50±1 Ω.
Replace the stepper motor in case of exceeding limit.
Rotate the center shaft of motor in case of stepper
motor. The center shaft shall not get stuck or loose.
Replace the stepper motor in case of the above problems.

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Chapter IV Disassembly & Repair
4-5 Generator
4-5-1 Fuel tank
Disassembly/assembly
The Gasoline is inflammable and explosive. The oil in fuel tank and pipe shall be drained prior to
disassembly. The fuel oil spilled shall be wiped clean immediately.

Fuel tank cover

Assembly:
Make sure the venthole is clean and
not blocked. Clean it with compressed Gum cover of oil inlet
air if necessary.

Screen of fuel filter

Assembly:
Check whether the meshes
are blocked or damaged and
then conduct assembly.
Fuel tank

Assembly:
Remove the dirt or water
on the bottom, dry it fully
and then conduct
assembly.

Fuel filter

Assembly:
Oil switch Check whether the filter
cartridge is clean and
Assembly: ensure the damaged.
passage is not blocked.
Check whether there is fuel
leakage after assembly.

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Chapter IV Disassembly & Repair
4-5-2 Silencer
Disassembly/assembly
Shutter

Air director
Nut M8 (2)
Torque: (27 ~ 30) N•m
Sealing gasket of exhaust port

Shield of silencer
(front shield)
Motive power

Tapping
screw
Shield of silencer ST4 × 15 (6)
(back shield)
Silencer
Installation support of silencer

Silencer Spark canceller

Assembly: Assembly:
Tap the silencer with plastic hammer to Use wire brush to remove the carbon
remove the carbon deposition inside and then deposition and then conduct assembly.
conduct assembly.

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Chapter IV Disassembly & Repair
4-5-3 Rack baseplates
Disassembly/assembly Vertical framework (2)

Support of handle of pull rope

Vertical framework (2)

Cushion seat of
main engine (2)

Cushion rubber Cushion seat of

main engine (2)
Assembly:
Square nut M6 (6) Ensure the rubber is not cracked,
Torque: (8~12) N•m hardened or worn. And note the
assembly direction.

Clip nut M5 (4) 99

Guide pad of brake

Nut M8 (8) Rack baseplates

Torque: (8~12) N•m

Gasket (4)

Dust cover of
supporting wheel (4)
Protective cap of brake
Brake Parts of
supporting wheel (4)
Lock disk of wheel shaft

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Chapter IV Disassembly & Repair

4-5-4 Motor parts

a. Disassembly/assembly

Ignition coil
Assembly/disassembly:
Check whether the insulated part is
cracked or damaged prior to
assembly to avoid electric leakage.

Bolt M6 × 65 (4)
Torque: (7~13) N•m

Fan of motor

Starting board

Engine

Flange bolt M8 × 28 Assembly:

torque: (30 ~ 36) N•m Motor stator Wipe the dust or oil on
crankshaft or the conic
portion and then
Motor rotor conduct assembly.
Disassembly:
Fan cover
Make use of the disassembly
thread on rotor and assemble
proper rotor remover (a special
tool) to disassemble.

- 43 -
Chapter IV Disassembly & Repair
b. Check The resistance among windings of 230 V 2 KW is as
follows:
Color of Guide Resistance
Line
Main winding Brown 2.0-2.4 Ω
Power-supply
Orange 0.50-0.55 Ω
winding
DC winding Blue 0.19-0.21 Ω
The resistance among windings of 120 V 2 KW is
as follows:
Color of Guide Resistance
Line
Main winding Brown 0.75-0.85 Ω
Power -supply
Orange 0.50-0.55 Ω
Main winding/power-supply winding/DC winding winding
DC winding Blue 0.19-0.21 Ω
If there is not DC voltage output, check if the DC
over-current protector trips and the DC receptacle are The resistance among windings of 100V 2KW is as
follows:
damaged. If yes, replace the receptacle.
Color of Guide
Line Resistance
If there is no AC voltage output, check if the AC
receptacle is damaged. If yes, replace the receptacle. Main winding Brown 0.57-0.67 Ω
Power-supply Orange 0.50-0.55 Ω
Check if there is voltage between the motor stator and winding
power-supply winding. If yes, replace the converter. DC winding Blue 0.19-0.21 Ω
Otherwise replace the stator.

Replace the stator if the resistance is zero or infinite.

Disassemble the stator from motor.

Check if there is obvious damage on the varnished

wire of each winding and the insulating layer of guide line.
If yes, replace the stator.

Note: be careful not to damage the varnished wire of

each winding and the insulating layer of guide line when
disassembling and assembling stator.

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Chapter IV Disassembly & Repair
4-5-5 Inverter parts
a. Disassembly/assembly

Installing support of inverter

Cushion rubber (2)

Inverter parts

Cushion rubber (2)

- 45 -
 Chapter IV Disassembly & Repair

Inverter parts (detection)

Check if the color of the wire of inverter changes, if the

resin filled in inverter has bullate bulge, and if all electrical
apparatus elements, connectors and wiring on inverter have
visible color or damage.

Output shorted: when the green light is off while the red
light is on resistance grade detects the output end. Replace
the converter if the resistance is zero or infinite.

Microswitch

Input shorted (low voltage): when the red light is on

while the green light is off, there is no output. Resistance
grade detects the low-voltage connector. Replace the
converter if the resistance is zero or infinite.

When the leaf spring is in the bouncing status,

measure the resistance between two output terminals
with ohmmeter. Replace the microswitch if the
Input shorted (three phase): the green light is always on resistance is zero.
while the red light flashes (when loading). Resistance grade
When the leaf spring is in hold-down status,
detects the three-phase connector (each resistance between
measure the resistance between two output terminals
every two connectors is required for detection). Replace the
with ohmmeter. Replace the microswitch if the
converter if the resistance is zero or infinite.
resistance is infinite.

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Chapter IV Disassembly & Repair
Rectifier bridge The internal circuit of rectifier bridge is shown as
above. Detect the switching of each terminal of rectifier
Red
bridge with multimeter.
When the switching of rectifier bridge is shown as
below, the rectifier bridge is under the normal status:
Blue Black

Red Blue
Digital Test with Red Needle
Black Multimeter Blue Blue Red Black
Blue Black
Test Not
Not Conductiv
with Blue conductiv
conductive e
Black e
Not Not
Rectifier bridge Needle Blue conductive conductiv conductive
e
Conducti Conductiv
Red Conductive
ve e
Not Not
Not
Black conductiv conductiv
conductive
e e

Multimeter
Tip 1: “Switching” means the conductivity feature of
diode and differs from short circuit. When the
check of each section fails, replace with a new
rectifier bridge.

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Chapter IV Disassembly & Repair

4-5-6 Control panel parts

Control panel
Multimeter
AC socket

Waterproof endcap (2)

Parallel receptacle (2)

Idle switch Rectifier

Waterproof endcap bridge

Electrical starting switch

Waterproof endcap
Frequency-changeover
switch

DC socket

circuit is under the off status, that is to say, the two

a. Disassembly/assembly
output terminals of microswitch are conductive and the
ignition wire is grounded; when the oil switch is off, the
engine cannot operate.

When the combination switch is “ON”, ignition

circuit is under the working status, that is to say, the two
output terminals of microswitch are disconnected; the oil
switch is on; choke valve is under the fully open state, the
engine can operate normally.

When the combination switch is “CHOKE”, the

ignition circuit is under the working status, that is to say,
the two output terminals of microswitch are
Combination switch disconnected; the oil switch is on; the choke valve is
When the combination switch is at corresponding under the closed status;
positions, check the state of ignition circuit, fuel switch When the switch is at corresponding position,
and choke-valve switch. check the conductivity of switch terminal.

When the combination switch is “OFF”, ignition

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Chapter IV Disassembly & Repair
Wire harness LCD

Remove the wire harness from panel, rectifier

bridge and converter. Check if there is obvious damage
on the insulating layer of guide line.If yes, replace the
Normal operation:
wire harness.
Under normal operation, the operational key ③ is
Check the switching of each guide line with
used to switch the display content circularly:
ohmmeter and confirm each guide line is of conductivity.
Replace the wire harness if the resistance is infinite. Voltage - current - power - cumulative time -
current time.
Note: disassemble and assemble wiring harness
with a clamp. Take proper force to avoid damaging Under operation in fault
guide line and its connector clips. a. Display AC overvoltage, as well as character AC
(display AC and numbers alternately);

Multimeter a. Display DC overvoltage, as well as character dc

(display dc and numbers alternately);

a. Display AC undervoltage, as well as character

AC (display AC and numbers alternately);

a. Display DC undervoltage, as well as character dc

(display dc and numbers alternately);

Output overcurrent of generator;

Output short circuit of generator;

Generator overheating;
① Multimeter
② LCD Service time;
③ Operational key
④Oil warning indicator light
⑤Fault indicator light
⑥AC indicator light

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Chapter IV Disassembly & Repair
Oil-warning indicator light (red) electrical equipment has been overload, which will
cause inverter overheating or AC voltage increase. At
this time, AC protector operates, to stop the generation
of the generator so as to protect the generator and its
electrical equipment. AC indicator light (green) will be
off while the overload indicator light (red) will be on;
however, the engine will not stop operation.

When the overload indicator light is on and

generator unit has no output, please take following
When the oil in crankcase reduces to less than countermeasures:
safety line, the oil protection system will automatically 1. Shut down all connecting electrical equipment and
turn off the engine and the oil-warning indicator light stop the engine.
will be on; fill oil up to oil level, the engine will re-start. 2. Reduce the total power of connecting electrical
equipment to the range of rated output.
Tip: when the engine flames out or cannot be started, 3. Check if the inlet of cool air is blocked with foreign
screw the rotary knob of power switch to “ON” position, matters and whether related control parts are normal. If
then pull the starting handle. yes, eliminate the problems immediately.
When the oil warning indicator light flashes for
several seconds, it means the oil volume is insufficient, 4. Re-start the engine after check.
fill oil to make it re-start.
Check the indicator light with ohmmeter and Tip: when using the electrical equipment with
confirm its conductivity. Replace the indicator light if relatively high starting current (such as compressor and
the resistance is infinite. submersible pump), the overload indicator light may be
on for several seconds at the beginning, but this is not
the fault aforesaid.
Overload indicator light (red) Check the indicator light with ohmmeter and
confirm its conductivity. Replace the indicator light if
the resistance is infinite.

AC indicator light (green)

When the overload indicator light is on, the

generator can detect that the output of its connecting
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Chapter IV Disassembly & Repair
When the engine starts and operate normally, the AC ② “OFF”
indicator light will be on.
If it is required to switch the output frequency of
Check the indicator light with ohmmeter and generator, please stop the generator first, then use flat
confirm its conductivity. Replace the indicator light if bottle opener to adjust the position of frequency
the resistance is infinite. switching switch.And then re-start the generator.

Notice Only when generator is under the stopping

ESC switch
status, the frequency switching switch can achieve
functional frequency switching. The output frequency
will not change if the frequency is switched during
when the generator operates.

DC breaker protector

① “ON”
When the ESC switch is placed at the “ON’ position,
energy-efficient equipment will control the engine speed
as per the connected load, so as to obtain better fuel
consumption and low noise.
② “OFF” When the electronic equipment connects to
When the ESC switch is placed at the “OFF’ position, generator operates, if the current exceeds the rate
the engine will operate in rate speed (2,600 r/min)
whether it is connected load. current, the DC switch will automatically turn to the
“OFF” position. Please turn the DC switch to “ON”
Tip: when using following devices, such as air
compressor and sinking water pump, ESC must be position when re-operating the generator,
closed as relatively large starting current is required.

Frequency switching switch

Check the conductivity between terminals of DC

breaker protector with multimeter.
When the button of breaker protector is pressed, the
① “ON” breaker protector shall be conductive.
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Chapter IV Disassembly & Repair

Parallel terminal

The parallel terminal ① is used to connect the

two special LC3500i cables under parallel operation.
Parallel operation requires two LC3500i equipment and
special cable. (The rated output power of parallel
operation is 6 KVA, the rated current of 100 V generator
is 60 A, the rated current of 120V generator is 50A and
the rated current of 230 V generator is 26 A.)

Operation program and related precautions are detailed

in the part of parallel cable system. For related matters
about parallel cable system, please consult Loncin
dealer.

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 Chapter IV Disassembly & Repair

4-5-7 Appearance assembly

a. Disassembly/assembly

Gum cover of oil inlet

Waterproof endcap (4)

Left appearance
cover plate Top cover of rack

Inspection window Hand tubes (2)

for engine oil
Shuttle

Left shell of electric generator

Right shell of
electric generator
Panel seat

Maintenanc Bolt M6 × 20 (6)

e cover of Torque: (8 ~ 12) N•m Right appearance Decoration cover
batteries cover plate of handle mouth
of pull rope

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Chapter III Maintenance

5-1 LC3500i Circuit diagram

100V

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Chapter III Maintenance
120 V

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Chapter III Maintenance
50 Hz, 230 V with parallel receptacle

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