Owners Manual
Contents
1. 2 11 Electrical System 1 Remove the panel of the generator 2 Remove the screws in the plastic panel enclosure 3 Push in at the clip location not the screw location to remove the plastic panel 4 Replace outlets or switches if there is any damage Replace any wires that may be burnt Burnt wires are usually from loose terminals TU raga n Top IA i V T iy obra po PE ga ur SMS S Fuh au oe een A rst e D vga i T eng TH gg P taa rir capu dM 3 fias Ls TE 1 ZEE P D A Ls j Fut Pd e LJ y Li 5 E al ks 1 JUI F sm E ha a see trouble shooting section for more information 32 84 ploum cx jias Bajad Lg ae ers 1 3 Bu pu E TEN T yoda BAG o P el IHOR TRELLIS 420 CHO OTO NO BLD TLS HEL ae GE a ERS HA P op Ap P mm e e EE uo ELI I T Tes iF MA RE DILE VE r Buirpuimt 50g epoltg g Buipuja div DE ADbc AOEI LJ 1 EJ MI IH wo ig ig 2338 J HO LIC cw Of AO Wwe 2 12 Wiring Diagram 33 Chapter 3 Defect Analysis and Troubleshooting 3 1 General Ignition Coil 1 Check Air Gap 2 Faulty Carburetor Hard Starting 1 Dirty 2 Linkage Spark Plug 1 Faulty 2 Gap Will not go high speed Governor Adjustment Valve 1 Clearance Adjustment 2 Seat Sealing Problems 3 Valve Train Issues Cylinder 1 Piston Wear 2 Ring Wear 3 Cylinder W2. air cleaner element foam pad Replace as necessary clean the element follow a b c d steps A Never use gasoline low burning point solvent acid or alkaline to clean the element Use detergent only Cleaning the element foam pad Dip the element in the detergent and wring it out Apply motor oil and wring out excess oil Install element 3 Remove the plastic inner housing by removing the six nuts around the perimeter 12 4 Remove the enclosure by removing the two nuts inside the enclosure and one on the backside 5 Remove the carburetor gasket and choke mechanism Some models may not have automatic chokes and the choke mechanism will not need to be removed It is built onto the carburetor in this case 6 Remove the lines to the carburetor and remove the carburetor 2 4 Maintenance of Fuel System 1 Remove the bowl of the fuel cock 2 Remove the screen inside the fuel cock 3 Remove the fuel cock 13 4 5 Pull out the screen inside the tank Clean or replace both screens and reassemble 2 5 Maintenance of the Exhaust System wS Remove the outer heat shield from the muffler Bend the anti rotation tabs back around the engine exhaust bolts Remove the bolts from the engine side of the exhaust pipe Remove the two bolts from the muffler to the generator head to separate the muffler from the generator Lift the muffler out of the frame and inspect for cracks Inspect the spark a
3. insulation is melted replace the parts 19 11 To remove the rotor from the engine install the bolt that came out of the shaft center Screw it in until only 1 is left until the head comes in contact with the bearing 12 Forcefully strike the screw with a large blacksmith hammer to remove the rotor from the engine 2 8 Maintenance of the Cylinder Head and Valve 1 Remove the spark plug 2 Remove the valve cover head bolt located in the center of the valve cover 3 Check the gasket of the cover Check the condition of the valve cover gasket 4 Check the valve clearance of the engine If they have to be adjusted loosen the valve adjustment nut and then adjust the clearance a Clearance for intake 15mm 02mm 006 001 b Clearance for exhaust valve 20mm 02mm 008 001 20 adjustment nut tightening nut 5 Tighten the nut with the following torque a Adjustment nut 10 N m 88 in lbf b Tightening nut 10 N m 88 in lbf 6 Remove the rocker arm for inspection 7 Remove the lifters and inspect Rolling them on a flat surface will help to check if they are bent rocker arm of valve 8 Remove the rocker arm bolts so you can remove the rocker arm guide plate and inspect the plastic inserts in the plate for damage a Torque of the rocker arm bolt is 24N m 210 in Ibf 9 Inspect the flute and the protruding parts of the rocker arm 10 Remove the four head bolts When tightening the 4 head bol
4. the values noted in section 1 1 of this manual If the plug is brown in color the engine is working normally 9 Check for carbon build up on the spark plug Check the gap of the spark plug The values for the gap are found in section 1 1 of this manual 10 Remove the flywheel Use a screwdriver to hold the flywheel from moving while unloosening the flywheel nut The torque value of the nut is 113N m or 83 ft Ib 11 Remove the flywheel by using a gear puller 12 Check for any damage to the flywheel Rust can me remove from the magnet section by light sanding 17 2 Maintenance of the Generator 1 Remove the two bolts on the rear cover of the generator head 2 Remove the main bolt in the center of the rotor Check the bearing 3 Remove the screws on the outside of the generator head housing 4 Remove the AVR large plastic part with wires coming out Automatic Voltage Regulator 18 5 Remove the bolts in the brushes and remove the brushes 6 Remove the mounting nuts from the rubber engine and generator head mounts There are four total two under the engine and two under the generator head This will allow you to lift the engine generator combination out of the frame 7 Remove the rear housing from the generator as shown 8 Remove the stator cover 9 Remove the generator stator 10 Check the stator and rotor for damage or burnt wires If there are any contact marks or wires that have burnt or the
5. 027 spark plug Spark plug gap 031 spark plug capacity Resistance 7 5 12 5K ohms Resistance of primary coil Ignition Coil Resistance of secondary coil 5 9 7 5 ohms Air Gap 4 2mm 016 007 Torque Values Torque Torque in Ibf M8X1 25 special bolt 14 124 34 300 113 183 ETI 10 88 24 212 10 88 nut bolt 75 mmer vo s 75 23 203 m 369 Standard Torque Values Bolt and nut 24 Flange bolt and flange nut Fitting Directions Co oo gt 212 2 487 106 230 300 922 O1 co 1 When fitting the piston in the cylinder the mark A on the piston top must be aimed to the intake valve direction upper 2 When fitting the piston rings on the piston the R N mark on the first and second ring must be upwards and the gap of all three rings should be 120 apart 3 he timing marks on the gears must be matched to each other Generator Information Ara Item Standard Resistance Resistance Resistance Resistance Length 9mm 354 eso Se a P MS i a Sen Tw pan T D 3 E U D LJ xe L i EPA and Engine Serial Number 5mm 197 EPA and Engine Serial Number are located on the panel side of the generator in the location shown Chapter 2 Maintenance of the Generator Set 2 1 Maintenance of the Manual Starting System The integral configuration of the starting device is shown below Check the condition of the starter Replace if d
6. GPP GENERAL POWER PRODUCTS General Power Products Portable Electric Generator Service Manual Model APP 6000 Contents Chapter 1 General Information cc ccc eee e cece eee e teats esas eeaeeeaees 3 7 General Description of Generator ccccce eee cease eee eeees 3 OLY IIOvalloliasscveedqeve tuer utum qvim UR M UE esters 4 Model Parameters ssesssssssseessssr nnne 5 Maintenance and Adjusting Data seseeeesseeeesse 5 7 Chapter 2 Maintenance of the Generator Set suuuss 8 2 1 Maintenance of Starting System sssssseeseeesuss 8 10 2 2 Maintenance of Lubrication System 10 11 2 3 Maintenance of Inlet System essesesueese 12 13 2 4 Maintenance of Fuel System eeeseeesseess 13 14 2 5 Maintenance of Exhaust System ssuesuus 14 15 2 6 Maintenance of Ignition System sssuesueusue 16 17 2 Maintenance of Generator ssseesseeesseesseeeee 18 20 2 8 Maintenance of Cylinder Head and Valve 20 24 2 9 Maintenance of Crankcase Crankshaft and Camshaft 25 28 2 10 Maintenance of Connecting Rod Piston and Cylinder 29 31 2 11 Electrical SYSTEM iioi tinet bes ortu cota scite et Unread estis 32 2 12 AINA EVI UN eesis ideam rate ere Did canat tn P
7. Inspect the valve stem diameter 20 Measure the distortion value of the valve stem end with a micrometer following the 1 and 2 position in the figure Replace the valve and valve guide if the distortion value is over the limit of maintenance a Inlet valve 12mm 005 b Exhaust valve 16mm 007 measure the width of valve end surface 21 Inspect the valve seat area as shown a Width of valve end surface 2 0mm 079 max 24 2 9 Maintenance of the Crankcase Crankshaft and Camshaft 1 Make sure all the oil is drained from the crankcase 2 Remove the flange mounting bolts See section 1 1 standard torque values drain lubricating oil fixing bolt 3 Remove the crankcase cover Slight tapping with a plastic hammer may be required Never use a screwdriver between the cover and the crankcase or you will damage the sealing surface crankcase cover crankcase paper cushion 4 Remove all residue of the gasket Use a new gasket when reassembling 5 Inspect the crankcase cover and crank bearing area for cracks or unusual wear The values for the diameters can be found in section 1 1 6 Replace the crankcase cover oil seal as necessary 25 clean crankcase cover crankcase cover oil sealing 7 Inspect the crankshaft and camshaft gears Worn or damaged gears will need to be replaced 8 Remove the locking pin from the governor shaft 9 Remove the governor shaft 10 Note the marks on the gears They should line up
8. amaged A There is a spring inside the starter device that is under stress Wear safety goggles and watch for flying debris when it is removed Remove the perimeter bolts to remove the starter housing Check the condition of the starter system Replace any broken or damaged parts as follows Inspect the rope for abrasions Replace as necessary Dismantle the starter pawl guide bolt with a socket Remove the pawls and pawl spring Visually inspect all parts a 5 Inspect the flute of the starting draw wheel 6 Remove the shroud from the engine for inspection of the fan blades 7 Replace parts as necessary 10 2 2 Maintenance of the Lubrication System Chose the oil type according to the local temperature of operation Use Four stroke engine oil SE SF or equivalent to SG grade oil SAE 30 When temp is below 50 F SAE 10W30 is recommended SAE 5W 30 is recommended when temp is below 5 F 1 It is best to change the engine oil when the engine is warm This allows the oil to flow better for a complete drain 2 Drain the oil from the cylinder block by removing the plug at the base of the engine Check the condition of the dipstick and o ring seal Replace the drain plug Fill with oil See specifications in section 1 1 parameters for amount to add pus 11 2 3 Maintenance of the Inlet system 1 Remove the air cleaner outer cover by releasing the latches at the top and bottom 2 Remove the
9. arge end flank clearance Crankshaft Flank clearance of Piston ring Closed gap of the first and second ring Crankshaft pin outside diameter Standard 3750 150 No Load 588 834KPa 600RPM 85 120PSI 600PSI 88 00mm 3 465 Extreme Max Min 88 1 mm 3 471 10mm 004 6 60mm 260 6 75mm 2657 87 985mm 3 464 87 85mm 3 459 015 052mm 001 12mm 005 20 002mm 787 20 042mm 789 20 00mm 787 19 95mm 785 002 014mm 0006 08mm 003 030 060mm 002 15mm 006 20 40mm 012 1 0mm 039 20 70mm 002 1 0mm 039 2 0mm 079 1 75mm 069 2 8mm 110 2 mm 106 20 005mm 7876 36 025mm 1 418 040 066mm 002 1 7mm 019 35 985mm 1 4167 20 07mm 790 36 070mm 1 420 12mm 005 1 0mm 039 35 93mm 1 4146 ier Intake valve stem diameter 6 59mm 259 6 44mm 253 Valve Exhaust valve stem diameter 6 55mm 258 6 40mm 252 Valve guide inside diameter 6 60mm 260 6 66mm 262 Clearance of intake valve and guide 010 03 mm 001 10mm 004 Clearance of exhaust valve and guide 050 077mm 002 12mm 005 Valve seat width 1 1mm 043 2 0mm 079 Spring free length 39 0mm 1 535 37 5mm 1 476 32 44 32 60mm 32 24mm 1 269 Intake valve cam height 1 279 Camshaft 31 94 32 10mm 31 4mm 1 249 Exhaust valve cam height 1 260 Camshaft collar 15 984mm 6292 15 92mm 6268 Camshaft hole 16 0mm 6299 16 05mm 6318 0 7 0 8mm
10. ation prior to starting the Generator DANGER Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury dA WARNING Warning Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Caution Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury SAFETY INSTRUCTIONS This generator is designed to supply electrical power Please read and understand all of the safety instructions and warning labels associated with this generator Do not operate indoors Generator must be on a flat stable surface Surface slope not to exceed 4 degrees Operate in a well lit and ventilated area Do not operate in moist or wet conditions including the surrounding ground The generator should be a minimum of 3 feet away from all combustible materials and should not be used around hazardous materials Operating at a gas or natural gas filling station is forbidden Do not touch muffler or cylinder during or after operation They are hot No smoking when filling the gas tank Do not overflow gas tank Fill the tank to 1 inch below the top neck to allow for gas expansion Ensure the ventilation hole in the gas cap is not plugged with foreign matter such as dirt or leaves 10 The engine should be shut off for at least 2 minutes before adding gas or oil 11 Do not open th
11. e gas tank or oil reservoir while the engine is running 12 Be mindful of the danger warning and caution labels on the generator 13 Keep away from children Children should be kept at a minimum of 6 feet away from the generator at all times 14 In a normal situation the generator should be shut off using the instructions found on the front panel label cuc E a Models Parameters APP 6000 Dimension Weight Model APP6000 Net Weight Box Gross Weight Full Generator Model APP6000 Rated 120V 240V Voltage Rated Rated Current 27 2A Rated Output 6 0KW SakW 5 2 O S lt Engine Modeli OHV13H 4 stroke overhead valve cylinder tilt 25 Engine Type capacity Bore x Stroke 88x64 mm Forced Air Cooling Cooling System Ignition System Transistor Magnet Ignition Spark Plug NGK BP6ES Engine Oil Volume 1 1Qt Fuel Volume 6 6 Gallon Compression Ratio 8 0 1 Maintenance and Adjusting Data Tolerance Parameters Cylinder Cylinder bore diameter Max Speed Cylinder Pressure Cylinder head Valve bushing Outside Diameter of piston skirt Gap of piston and cylinder Inside diameter of piston pin hole Outside diameter of piston pin Clearance of piston and piston pin hole Piston Ring Closed gap of the oil ring Width of the first ring Width of the oil ring Small end diameter Large end diameter Connecting Rod Large end clearance L
12. ear 34 3 2 Hard Starting Er Ignition Fill Fuel Spark Plug Bad Spark Plug Air Gap of Coil Flooded carburetor bowl Bad Coil Compression Valve Clearance Blockage Carburetor 2 Fuel Line 3 3 Ignition System Will Not Start Switch is ON No Spark 1 Plug Bad 2 Gap 3 Switch Bad disconnect the black wire from the engine switch if it still does not work a Coil Defective b Aiur gap of coil Spark Test A WARNING Never hold the plug wire when wet There is no fuel present Do not test near the plug hole to avoid fire hazards Remove the plug and ground the electrode against the engine with the cap attached Turn on the engine switch and pull the recoil Soark should jump across the electrodes 35 3 4 Generator Power Flow Chart Brush Voltage Running 22 5V DC AV between 1 and 2 Low NO Voltage AC Voltage at Terminals 1 120 V between 3 and 4 2 120 V between 5 and 6 Engine RPM 1 Governor 2 3750 no load Electrical Panel Wires 1 Broken 2 Loose 1 Clean Brushes 2 Check Rotor resistance between slip rings 52 62 ohms brushes Brush Rotor disconnected 3 If fails replace rotor check brush voltage again 12 Volt battery test Blue 3 Blue Brush 1 Green U White White 120V 3 Red 2 Neutral 4 Vv Neutral 5 vv Es tg 120V 6 Blue Red AVR 36 3 5 Electrical Troubleshooting Stator 12 Volt Batt
13. ery Test of Stator Remove the AVR and connect a 12 volt battery to the brush terminals Make sure the positive and negative terminals are correctly wired Run the generator at full speed 3750 RPM no load Follow the chart below 12 Volt Batter Test for Stator Troubleshooting cation Point Specified Voltage Component mE Voltage Variance p EE 59 VAC 5 Sao 59 VAC 5 Sensor E 7 and 8 VAC 1 low high 12 VDC Battery Problem 6 Cans 8 56 VAC 3 11 It is unlikely but not impossible for all the windings to test low If all windings test low check the rotor resistance engine RPM and battery voltage again to make sure these are not the problem 37 3 6 General Troubleshooting Old oil Change and replace oS 38
14. ise Eden aesau keene 33 Chapter S Trouble SHOOlllTg esce iter eri totae mi t enn REPRE e kei eodera bre t risiede 34 SM CITIES 34 SA gel debe rit eer E TO 35 3 3 Ignition SYSTEM 0 cece cece cece e eee eee tenes mmn 35 3 4 Generator Power Flow Chatt cccccseeeeseeeeeeeeeeeeees 36 3 5 Electrical Troubleshooting Stator ccceceeeeeee sees eeeas 37 3 6 General TroubleShooting ccccc cece eeee cence esas eeaeeenees 38 Chapter 4 Exploded View and Bill of Materials BOM 39 A 1 IM OIO CCH MIO WS esiste EDI paesi EEEE EEREN 39 42 4 2 Bill of Materials BOM ccc cece cece eee ee eeeeeeeeeeeaaes 42 50 Chapter 1 General Information APP 6000 Generator is equipped with a single cylinder 4 stroke forced air cooled OHV 25 slant internal combustion engine It is equipped with an electronic ignition system and is tuned to meet all EPA and California Emissions Requirements Figure 1 1 General Description 1 Gas Tank 2 Choke 3 Fuel Shut Off 4 Pull Starter 5 Oil Dipstick 6 120 Volt Outlet 7 Ground 8 Circuit Breaker 9 On Off Switch 10 Gas Cap 11 Gas Tank 12 Valve Cover 13 Air Filter 14 Frame 15 Muffler 16 Safety Information This symbol is known as the safety alert symbol and points out safety instructions that can lead to injury or death A Attention Please read and understand this manual and the safety inform
15. r can be found in section 1 1 table Remember to measure the diameter in at least three different locations for instance top middle and bottom 3 Measure the side clearance of the piston ring with the cylinder with a feeler gauge This value is shown as the flank clearance in the table in section 1 1 4 Place the piston rings in the cylinder and measure the gap 5 With the piston rings removed put the piston in the cylinder and measure the terminal clearance Replace the piston or rings as necessary 6 Remove the piston retaining rings for inspection XT X a 1 7 Remove the piston pin and inspect 8 Remove the connecting rod The limits can be found in section 1 1 table 29 9 Measure the piston pin 10 Inspect the rod end cap 11 Burnish the piston top with 400 granular sandpaper Remove the carbon deposits of the piston ring slots with a non metal tool taking care not to scratch the piston 12 Measure the outside diameter of the piston pin with a micrometer The value can be found in section 1 1 table 13 Check whether the piston rings are scared or the elasticity is weak Replace as necessary 14 Measure the piston ring slot Inspect for abrasion on the piston Replace if the value is greater than the value found in section 1 1 table 30 15 Measure the external diameter of the piston skirt 16 When installing the piston rings all the gaps should be staggered 120 apart 31
16. rrestor mounted over the outlet of the muffler It should be clear of debris and have no tears in the screen Replace the muffler or spark arrestor as necessary 14 8 Inspect the gasket between the muffler and the engine head 9 Inspect the engine head for carbon build up Too much build up in the head or muffler can rob the engine of power 15 2 6 Maintenance of the Ignition System 1 Check the gap between the ignition coil and the flywheel The gap should be 0 4mm 0 2mm 016 007 2 Check the status of the spark from the ignition coil It should be a blue spark and must be above 10 000 Volts 3 When there is no output voltage from the ignition coil remove the coil by removing the bolts that hold the ignition coil to the engine block 4 Remove the spark plug cap and unplug the other wires so the ignition coil can be removed 5 Using a multi meter capable of measuring resistance or an ohmmeter connect one end of the tester to the spark plug lead Connect the other end to the core of the ignition coil Resistance value of the secondary end of the coil is 2 5K to 2 8K ohms 16 6 Connect one end of the ohmmeter to the primary small black wire lead the other end to the core of the ignition coil same location as before The resistance value of the primary coil is 25 to 30 ohms 7 Replace as necessary a i 8 Remove the spark plug Check the cylinder pressure Is should fall in
17. ts use an across the head sequence a Torque of the head bolts is 34N m 300 in Ibf 21 11 Remove the head and inspect the head gasket Sometimes the head may need a tap up with a plastic hammer Never use a screwdriver between the head and the cylinder or you will damage the surface 12 Remove the alignment pins 13 Fill the inlet and exhaust with cleaning fluid from the parts washer and look for leaks around the valves If there are leaks the valves will need to be lapped and inspected 14 Clean the carbon deposits off the head Do not gouge the head surface this will cause a hot spot and melt the head 22 A Make sure you have on your eye protection 15 Remove the spring retainer clips from the valve springs Holding the valve up and using a pair of pliers push down on the retainer At the same time slide the retainer towards the larger hole and slowly let the retainer up It should slide off the valve stem 16 Inspect the valve guide inner diameters The value for the diameter is listed in section 1 1 tolerance parameters table Never reuse the guides after they have been pressed out 17 Inspect the valve seats Use a vernier caliper to measure the width of the inlet and exhaust valve seat a Width of seat std value 1 1mm up to 2 0mm 043 to 079 measure the distortion value of valve stem 23 18 Inspect the valve spring free height The values are found in section 1 1 tolerance parameters table 19
18. with each other Remember this for assembly lockpin of speed regulating shaft 11 Remove the camshaft 12 Remove the rod bolts a Torque value 14N m 125 in Ibf driving gear mark amp timing can 8 timing cam 26 13 Remove the connecting rod cap and inspect for damage See section 1 1 for clearance values 14 Remove the lifters and inspect 15 Remove the crankshaft and inspect for damage 16 Clean the crankcase and inspect for cracks and damage The diameters can be found in section 1 1 crankshaft bearing timing cam hole 17 Remove the bolt in the governor gear center and remove the governor gear Inspect for damage 27 18 Inspect the tappet surface for scratches Both the diameter and the surface the cam rides on 19 Inspect the cam lobes Replace the cam if the value is lower than the minimum values a Height for both intake and exhaust minimum is 31 35mm 1 234 20 Check the cam journals a Minimum is 15 92mm 627 21 Check the MCR manual compression release It should be free to move and the spring should easily return it to position 22 Inspect the crankshaft rod journal a Diameter should be a minimum of 32 92mm 1 2960 28 2 10 Maintenance of the Connecting Rod Piston and Cylinder 1 Remove the piston from the cylinder Remove the carbon deposits from the top of the piston 2 Inspect the inner wall of the cylinder for damage The values for the diamete
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