Toro 62012, 62018, 62025, 62030, 62027 Service Manual

TUBE FRAME GENERATOR

Table of Contents – Page 1 of 3

PREFACE

SAFETY INSTRUCTIONS

FOR YOUR SAFETY

IDENTIFICATION

T1200 SPECIFICATIONS MODEL 62012 PRODUCT SPECIFICATIONS MODEL 62012 GENERATOR SPECIFICATIONS MODEL 62012 ENGINE SERVICE SPECIFICATIONS

MODEL 62012 CARBURETOR SPECIFICATIONS

MODEL 62012 FASTENER TORQUES

T1800 SPECIFICATIONS

MODEL 62018 PRODUCT SPECIFICATIONS

MODEL 62018 GENERATOR SPECIFICATIONS MODEL 62018 ENGINE SERVICE SPECIFICATIONS MODEL 62018 CARBURETOR SPECIFICATIONS MODEL 62018 FASTENER TORQUES

T2500 & T2500D SPECIFICATIONS MODELS 62025 & 62027 PRODUCT SPECIFICATIONS MODEL 62025 & 62027 GENERATOR SPECIFICATIONS MODELS 62025 & 62027 ENGINE SERVICE SPECIFICATIONS MODELS 62025 & 62027 CARBURETOR SPECIFICATIONS MODELS 62025 & 62027 FASTENER TORQUES

T3000 & T3000D SPECIFICATIONS MODELS 62030 & 62032 PRODUCT SPECIFICATIONS MODEL 62030 & 62032 GENERATOR SPECIFICATIONS MODELS 62030 & 62032 ENGINE SERVICE SPECIFICATIONS MODELS 62030 & 62032 CARBURETOR SPECIFICATIONS MODELS 62030 & 62032 FASTENER TORQUES

SPECIAL TOOLS

TROUBLESHOOTING ENGINE DOES NOT PRODUCE SPARK ENGINE FLOODS DURING STARTING ENGINE DOES NOT GET FUEL DURING STARTING ENGINE DIFFICULT TO START ENGINE LACKS POWER ENGINE KNOCKS

TUBE FRAME GENERATOR

Table of Contents – Page 2 of 3

TROUBLESHOOTING - Continued ENGINE MISSES UNDER LOAD ENGINE OVERHEATS

ENGINE SURGES OR RUNS UNEVENLY

ENGINE VIBRATES EXCESSIVELY ENGINE USES EXCESSIVE OIL OR SMOKES

MAINTENANCE MAINTENANCE - AIR CLEANER MAINTENANCE - SPARK PLUG MAINTENANCE - CHANGING OIL MAINTENANCE - FUEL SEDIMENT BOWL MAINTENANCE - FREQUENCY ADJUSTMENT MAINTENANCE - VALVE CLEARANCE MAINTENANCE - VALVE CLEARANCE INSPECTION MAINTENANCE - VALVE CLEARANCE ADJUSTMENT MAINTENANCE - DECARBONING SPARK ARRESTER MAINTENANCE - STORAGE

SECTION 1 CARBURETOR CARBURETOR - OPERATION CARBURETOR - REMOVAL CARBURETOR - DISASSEMBLY CARBURETOR - SERVICE CARBURETOR - REASSEMBLY CARBURETOR - INSTALLATION

SECTION 2 FUEL SYSTEM FUEL TANK AND STRAINER FUEL TANK AND STRAINER - REMOVAL FUEL TANK AND STRAINER - INSTALLATION FUEL TANK CAP FUEL TANK CAP - SERVICE FUEL SHUTOFF AND SEDIMENT BOWL FUEL SHUTOFF AND SEDIMENT BOWL - REMOVAL FUEL SHUTOFF AND SEDIMENT BOWL - SERVICE FUEL SHUTOFF AND SEDIMENT BOWL - INSTALLATION

SECTION 3 IGNITON SYSTEM IGNITION OPERATION IGNITION OPERATION - FLYWHEEL IGNITION OPERATION - IGNITION COIL IGNITION OPERATION - TRIGGER CIRCUIT IGNITION OPERATION - SPARK PLUG IGNITION COIL - TESTING

TUBE FRAME GENERATOR

Table of Contents – Page 3 of 3

SECTION 3 IGNITON SYSTEM - Continued IGNITION COIL - REMOVAL IGNITION COIL - INSTALLATION

SPARK PLUG

SPARK PLUG - REMOVAL SPARK PLUG - INSTALLATION

SECTION 4 RECOIL STARTER RECOIL STARTER - REMOVAL RECOIL STARTER - DISASSEMBLY RECOIL STARTER - REASSEMBLY RECOIL STARTER - INSTALLATION

SECTION 5 LOW OIL SHUTDOWN LOW OIL SHUTDOWN CIRCUIT - PURPOSE LOW OIL SHUTDOWN CIRCUIT - OPERATION LOW OIL SHUTDOWN CIRCUIT - TESTING LOW OIL SHUTDOWN SWITCH - REMOVAL LOW OIL SHUTDOWN SWITCH - INSTALLATION

SECTION 6 ENGINE ENGINE - DISASSEMBLY ENGINE - CLEANING AFTER DISASSEMBLY ENGINE - INSPECTION ENGINE - REASSEMBLY

SECTION 7 GENERATOR DEFINITION OF TERMS GENERATOR OPERATION GENERATOR TESTING GENERATOR SERVICE TROUBLESHOOTING

SECTION 8 CONTROL PANEL CONTROL PANEL- DISASSEMBLY

SECTION 9 SCHEMATICS SCHEMATICS

PREFACE

This Service and Overhaul Manual was written expressly for the Tor0 T1200, T1800, T2500 and T3000 electric generators. This manual will cover both single and dual voltage models of the T2500 and T3000 generator.

The Tor0 Company has made every effort to make this Service Manual a useful and lasting addition to every Service Facility. To assure proper and effective repairs, and to provide optimum performance for the life this manual carefully, referencing

This manual contains a brief section on electrical theory which is essential to

understanding generator operation, troubleshooting and maintenance The

complete manual also provides the service technician with a working guideline of

maintenance, troubleshooting, test, repair and overhaul procedures.

The Toro Company reserves the right to change product specifications or this manual without notice.

The Tor0 Company gratefully acknowledges the assistance provided by the Suzuki

Motor Company in the writing

it

as necessary when generator service is required.

of

this manual.

of

the machine, you are urged to read

COPYRIGHT®©

©The Tor0 Company

Minneapolis,

ALL

RIGHTS

MN

55420

RESERVED

1988

USA

Reference Information

TABLE

OF

C

O

N

T

E

N

T

S

Page

Service Procedures

Section One Carburetor

Safety Instructions Identification Specifications 3 Special Tools 19 Troubleshooting* Maintenance 24

*

For generating troubleshooting information, see Section

I

7,

page

74.

i

operation removal 30 disassembly service 31 reassembly 3 1 installation 31

i

1

2

20

Page

29

30

Section Two Fuel System

Fuel Tank and Strainer

removal 33 installation 33

Fuel Tank Cap

service 33

Fuel Shutoff and Sediment

removal 34 service 34 installation

Section Three Ignition System

Ignition Operation

flywheel 36 ignitioncoil 36 trigger circuit 36 sparkplug 37

Bowl

35

TABLE

Service Procedures (cont'd)

OF

CONTENTS

I

(cont'd)

Section Three

Section Four

Section Five

Ignition System (cont'd)

Ignition Coil

removal installation

Spark Plug

removal installation

Recoil Starter

removal disassembly reassembly installation

Low

Oil

Shutdown

Low

Oil

Shutdown Circuit purpose operation testing

Low Oil Shutdown Switch

removal installation

Page

38

39

I

40 40

41 41 42 43

44 44 44

I

45 45

Section Six

Section Seven

Engine

disassembly cleaning after disassembly inspection reassembly

Generator

Definition

Generator Operation

of

Terms

exciter coil and permanent magnet AVR and rotor coil stator coil and receptacles

generatingprocess automatic voltage regulator

45

51

55

64

65

66 66

66

TABLE OF CONTENTS (cont’d)

Service Procedures (cont’d)

Section Seven

Generator (cont’d)

Generator Testing

measuring AC voltage measuring DCvoltage measuring stator coil resistance measuring rotor coil resistance measuring exciter coil resistance. sensor circuit continuity DC circuit diodes

brush inspection ................................................

Generator Service

disassembly ...................................................

reassembly

Troubleshooting

noACoutput...................................................7

IowACoutput

high

ACoutput noDCoutput

engine labors heavily low output on dual voltage generators

canIuseDCandACatthesametime?

...........................................

...................................

....................................

..................................

..........................................

...............................................

....................................................

..................................................

.................................................

...................................................

;‘.

.................................

..............................

.............................

.........

Page

68 68 68 69 69 70 70

71

72

4 74 75 75 76 76 76

Section Eight Control Panel

disassembly ...................................................

inspection .....................................................

reassembly

Section Nine

Schematic Diagram

T1200 T1800 T2500..

T3000

T2500D T3000D

....................................................

.........................................................

.......................................................

.........................................................

.......................................................

77 77 77

78 78 79 79 80 80

SAFETY

This safety symbol means WARNING AND/OR CAUTION

PERSONAL SAFETY INSTRUCTION Read the instruction because Failure to comply with may result in personal injury or death.

it

has to do with safety.

the

instruction

INSTRUCTIONS

This manual is intended to be a service and repair manual only The safety instructions provided in this manual are for the troubleshooting and service of the

product only. Individual Operator's Manuals will contain safety information for the operation of the generators that are described is this manual.

Operator's Manuals with complete operational safety instructions are available through:

The Toro Company

Publications Department

81

11

Lyndale Avenue South

~Minneapolis,

MN

55420

U.S.A.

FOR

Mishandling gasoline and oil can be deadly. Gasoline is explosive and should never be exposed to a flame or spark. Do not smoke while working around gasoline.

Avoid the accidental misuse of gasoline by always using a storage container designed for gasoline.

Avoid fire hazards by operating the generator no closer combustible material.

When decarboning the muffler, burning pieces of carbon may be discharged. Make sure there is no combustible material in area.

Spilled oil or gasoline can present a fire hazard or cause injury through falls. Always remove spilled oil or gasoline.

than

one meter, (three feet) to any

YOUR

the

SAFETY

Engine exhaust fumes can cause death. Never operate an engine in a confined area or without venting the exhaust fumes to outside atmosphere.

a

in

or

the

spark plug.

line.

generator operation

You can be killed by the electricity

produces. While a generator is never/ touch any portion of your body to

exposed or uninsulated terminals

Make sure that the engine will not accidentally

start while completing a service procedure by

pulling

Electrical line workers can be electricuted by backfeeding electricity. Never connect a

generator to your house wiring without using

a

generator from

the

spark plug wire

double throw switch to separate the

the

incoming

off

the

wiring.

1

IDENTIFICATION

Each Tor0 whole good is assigned a model and serial number. ,The model number has five digits and

In

indicates the size and style of the product. serial number which serves to differentiate products with the same model number. The serial number has seven digits, the first of which identifies the year of manufacture (ie. built

in

1986.)

addition to the model number, each product also has a unique

6000386

indicates that the product was

These numbers are printed on a decal that the decal located on the lower cross brace of the tube frame under the engine end of the generator. On

1986

and newer units, the decal can be

decal in correspondence or when replacement parts are needed. An engine number

service information, please include the engine number.

is

also located on the block of the engine. When filing warranty claims or requesting

is

found

about

1

"

behind the

high and 3"wide. Units built

gas

tank. Always refer to specific numbers

in

1984

and

1985

have

on

the

2

i

TI200

Model 62012 Product Specifications

SPECIFICATIONS

Model 62012 Generator Specifications

3

TI200

SPECIFICATION$

Model 62012 Generator Specifications (cont'd)

*

1

KVA

=

1000

Watts true power with a power factor of one.

(cont'd)

I

Model 62012 Engine Service Specifications

Standard Dimension

Spark

Plug

Spark Plug Gap

Ignition Coil Air Gap (External Mount)

Width of Valve Seat Contact

Intake Guide to Valve Stem Clearance

NGK BPR-6HS .75mm

(.030")

.38

(.015”)

fixed

1.OO

to

1.40

mm

(.039

to

.055”)

.80

to

1.OO

mm

(.032

to

.040")

.050

mm

(.002”)

NIA

.025

to

.055

mm

(,0010

to

.0022")

Allowable Limit

NIA NIA

!

N/A

NIA

.030

mm

(.0012")

.080

mm

.0032

"

TI200

SPECIFICATIONS

(cont'd)

Model

62012

Stem Clearance

Bearing Diameter (Big End)

Side Clearance (Big End)

Engine Service Specifications (cont'd)

35.5

to

25.990

.005

to

36.5

to

26.000

.025

mm

Cylinder Distortion

5

TI200

SPECIFICATIONS

(cont'd)

Model

62012

Engine Service

Carburetor

Specifications

(cont'd)

Model

62012

Fastener

Torques

Torque

.88

2.0

6.5 kg .7

kg

1.3

1.O

.88

50

.75 kg

.22

.88

55

kg m (6.4 kg m (14.5

m

(47

ft

m

(5.0

ft

kg m (9.4 kg

m

(7.2

kg m (6.4 kg m (6.4 kg

m

(3.6

m

(5.4

kg

m

(1.6

kg m (6.4 kg m (6.4 kg m (4.0

ft

Ibs)

ft

ft ft

ft

ft ft

Ibs)

ft

Ibs)

Ibs) Ibs) Ibs) Ibs) Ibs) Ibs) Ibs)

Ibs)

Ibs) Ibs)

i

I

!

1.1

kg

m

(8.0

ft

6

Ibs)

i

TI800

SPECIFICATIONS

Model

62018

Product Specifications

Specification

air cooled 4-stroke, side valve

66

mm (2.60")

56

mm (2.20”)

191.6 cc (11.69 cu. in.)

2.8 kilowatt (3.8 counterclockwise (as viewed from aluminum with

ball

plain

float

unleaded regular gasoline

7.00

liters (1.84 gal.)

5.0

hours at rated load

I

-

HP) @ 3600 rpm

-

~

cast

iron liner

-

PTO

end)

-

-I---

_

___I___

_

I

Model

6201

transistorized

25°

BTDC

NGK

BPR-6HS

recoil splash .7 liters (23.7 oz) detergent float type 3600 rpm

3000

rpm

oiled foam type element

40

kg

(88.5

54.1

x 33.7 x48.5 cm (21.3 x 13.3 x 19.1 in)

8

Generator Specifications

@

3600 rpm

SAE

10W30 or' 30,

Ibs)

-

~~

I

--------_-

API

rating of

-

____

SC,

SD,

-~-

I

__

SE,

_

_I_

or

-

_

-

SF

_

___I_

-

7

TI

800

SPECIFICATIONS

Model 6201 8 Generator Specifications (cont'd)

Specification

12.5 amperes. 12 volts DC

8.3

Amperes

1.5

KVA

(kilovolt amps)*

Maximum Power

1.8

KVA

60Hz at

3600

RPM

(kilovolt amps)

3600

RPM

(cont'd)

i

revolving field, self

1

.o

-

excited

directly coupled to engine

Automatic Voltage Regulator

*

1

KVA

=

1000

Watts true power with

electronic solid state design.

a

power factor of one.

Model 6201 8 Engine Service Specifications

Item Spark Plug Spark Plug Gap

Ignition Coil Air Gap (External Mount)

Ignition Coil Air Gap (Internal Mount)

Valve

Margin

NGK

BPR-6HS

75

mm

(.030")

1.35

to

(.053

to .073")

1.85

mm

!

Width

of

Valve

Seat Contact Valve

I

Lash

-

Valve Head Runout (Both)

_

I

-

Intake Guide to Valve Stem Clearance

_____-_

.80

to

1

.OO

mm

(.032

to

.039')

.050

mm

(.002”)

N/A

,025 to

(.0010

.055

to .0022")

mm

8

_._

I

-

TI

800

SPECIFICATIONS

(cont'd)

Model

62018

Item

Exhaust Guide to Valve Stem Clearance

Valve Spring Free Length

Cam Height Intake and Exhuast

Connecting Journal Diameter

Connecting Bearing Diameter (Big End)

Connecting Oil Clearance

Connecting Side Clearance (Big End)

Piston Pin Clearance in Connecting

Cylinder Diameter Piston Measuring Point

Engine Service Specifications (cont'd)

Rod

Journal

Rod

Standard Dimension

.035

to

.065

mm

(.0014

to

.0026')

to

36.5

35.5 (1.398

32.465 (1.2781

25.990 (1.0232

26.005 (1.0238

.005

to

(.0002

.200

to

(.0079

to

.006 (.0002

mm

to

1.437")

to

32.505

to

1.2797")

to

26.000

to

1.0236')

to

26.01

5

to

1.0242")

..025

mm

to

.OOlO”)

.900

to

.0354')

.019

mm

to

.0008)

mm

N/A

15

mm

(59')

I

~-.

-

Piston Diameter Piston to Cylinder

Clearance Cylinder Distortion

Piston Ring End Gap (Compression Rings Only)

Oil Ring End Gap

Piston Ring Side Clearance (Top Ring Only)

Piston Ring Side Clearance (2nd Ring Only)

Piston Ring Thickness (Compression Rings Only)

Piston Ring Groove Width (Compression Ring Grooves Only)

NIA

.045

to

(.0018

NIA

.200

to

(.0079

.20

to

(.008

to

.020

to

(.001

to

.020

to

(.001

to

1.97 (.0776

to

2.01 (.0791

.065

to

.0026')

.400

to

.0158')

.40

mm

.016')

.060

.003')

.060

.003")

1.99

to

.0783")

2.03

to

.0799")

mm

-_._---

mm

9

TI800 SPECIFICATIONS

(cont'd)

Model 62018 Engine Service Specifications (cont'd)

Model 62018 Carburetor Specifications

Item

#75 (fixed)

#40

(fixed)

I

Main Jet Pilot Jet

(STD)

Model 62018 Fastener Torques

Fastener

Spark Plug Cylinder Head Bolts Flywheel Connecting

Nut

Rod

Nuts

Frame Bolts

Torque

.88

kg

2.0

kg

6.5 kg .70 kg

1.3 kg

rn rn rn

rn rn

(6.4 (15 (47 (5.1 (9.4

ft

Ibs)

Ibs) Ibs)

Ibs)

I

i

-

.I

I

_

-

..~

-

~

-

Generator Through Bolt Starter

CUP

Capscrews Recoil Pulley Screw Recoil Mounting Screws

Air Cleaner

Nuts

Air Cleaner Capscrew

Throttle Plate Screws

Crankcase Screws Shroud Fasteners Muffler

Nuts

1.O

kg

rn

(7.2

.88

kg m (6.4

.88

kg m (6.4

.50

kg

rn

(3.6

.75 kg

rn

(5.4

.22

kg

rn

(1.6

.88

kg

rn

(6.4

.88

kg

rn

(6.4

.55

kg m (4.0

-

1.05 kg m (7.6

ft

Ibs)

ft

Ibs)

ft

Ibs)

ft

Ibs)

ft

Ibs)

ft

Ibs)

ft

Ibs)

ft

Ibs)

ft

lbs)

ft

io

-

Ibs)

-

---.___.___

I

_I_

-

I

-

~

-

_

-

-~______

-

T2500 & T2500D

SPECIFICATIONS

Models

62025 & 62027

Item

Type Bore

Stroke Displacement Rated Continuous Output Engine Rotation Cylinder Material Crankshaft Bearing Material (Mag) Crankshaft Bearing Material (PTO) Connecting

Rod

Bearing (Lower) Carburetor Fuel Fuel Tank Run Time Ignition System

Product Specifications

Specification air

cooled,

72 mm (2.83 62 mm (2.44

4-stroke, side' valve

"

)

"

)

252.4 cc (15.40 cu. in.)

3.7 kilowatt

(5.0

counterclockwise (as viewed from PTO end) aluminum with cast iron Sleeve

ball ball

plain float unleaded regular gasoline

11

.O

liters (2.91 gal.)

5.0

hours at rated load

-

transistorized

I

_I-

HP) at 3600 rpm

___

_._

----__

~

-

I

Ignition Timing Spark Plug Starting System Lubrication Oil Capacity Oil Level Alarm Recommended Oil Governed Engine Speed Governed Engine Speed

Air Cleaner

Dry Weight Dimensions (L

Model

62025 & 62027

x

Item

W

x

H)

@

25° BTDC

3600 rpm NGK BPR-6HS recoil splash

.O

liters (33.8

1

oz)

float type

SAE

10W30or'30,

(60

(50

hz) hz)

detergent

3600

rpm

3000

rpm

oiled foam type element

52.8 kg (1 16.5 Ibs)

56.6

x

36.3 x 53.6 cm (22.6 x 14.3 x 21.1 in)

Generator Specifications

Specification

I

i

API

rating of SC, SD, SE, or SF

I

-..-_-

-

I

-

AC Voltage

120

-

220 volts, plus or minus 10%

T2500 & T2500D SPECIFICATIONS

Models 62025 & 62027 Generator Specifications :(cont'd)

(cont'd)

Models 62025

Item Spark Plug Spark Plug Gap

"

___I-

Ignition Coil Air Gap (External Mount)

Ignition Coil Air Gap (Internal Mount)

Valve

Margin

Width of Valve

Seat Contact

Valve

Lash

Valve Head Runout (Both)

&

62027 Engine Service Specifications

N/A

.030

mm

(.0012”)

Intake Guide to Valve Stem Clearance

12

.080

mm

.0032

"

T2500 & T2500D SPECIFICATIONS

(cont'd)

Models

ecting

62025 & 62027

Guide

to

Valve

Rod

Journal

Engine Service Specifications (cont'd)

Standard

.040

39.5

(1.2784

27.991

28.013 (1

.1029

.013

(.0005

.400

.006

to

40.5

to

.036”

to

.800

to

.019

.070

to

28.000

28.027

to

.0014")

Dimension

mm

1.2800')

mm

1 1

034")

mm

iston Ring End Gap

8.0

mm

0.200

to

(0.0079

0.20

to

0.030

to

(0.001

to

0.020

to

(0.001

to

2.46

2.51

to

(.0988

to

0.400

mm

to

0.01

58')

0.80

mm

0.070

mm

0.003')

0.060

mm

0.003")

2.48

mm

2.53

mm

.0996”)

13

T2500

&

T2500D

SPECIFICATIONS

(cont'd)

Models

62025 & 62027

Engine Service Specifications (cont'd)

Carburetor Specifications

Models

Connecting

Generator Through Starter Cup Capscrews

Recoil Pulley Screw Recoil Mounting Screws Air Cleaner Nuts Air Cleaner Capscrew Throttle Plate Screws

62025 & 62027

Rod

Nuts

Bolt

Fastener Torques

Torque

.88

;__-

kg m (6.4

2.5

kg m (19

6.5

kg m (47

1.8 kg

1.3 kg

1.O

kg m (7.3

.88

kg m (6.4

.88

kg m (6.4

.50

kg m (3.6

.75 kg m (5.4

.22 kg

.88

kg m (6.4

.88

kg m (6.4

.55

kg m (4.0

1.1 kg

m m

m

(13 (9.0

(1.6

(8.0

ft ft

ft

ft ft

ft

Ibs) Ibs) Ibs) Ibs)

Ibs)

Ibs) Ibs) Ibs) Ibs)

Ibs) Ibs) Ibs)

Ibs)

-__I.

-~.-

-

I

i

I

-

I

__-

-

__

-

14

T3000

Models 62030 & 62032 Product Specifications

&

T3000D

SPECIFICATIONS

Model 62030

&

62032 Generator specifications

15

T3000 & T3000D

SPECIFICATIONS

Models 62030 & 62032 Generator Specifications' (cont'd)

(cont'd)

Models 62030

Ignition Coil Air Gap

Width

of Valve

Valve Head Runout

&

62032 Engine Service Specifications

Standard Dimension NGK

BPR-6HS

.75mm

(.030')

.38

(.015”)

fixed

.95

to

1.45 mm

to

1.10 mm

to

mm

.057")

.043")

(.037

.90

(.035

.050

(.002”)

(Both)

N/A

i

!

i

!

i

I

i

I

N/A

.030

mm

(.0012”)

I

.025

(.0010

to

.055

mm

.0022")

.080 mm .0032”

16

T3000

&

T3000D

SPECIFICATIONS

(cont'd)

Models 62030 & 62032 Engine Service Specifications (cont'd)

Exhaust Guide to Valve

Rod

ecting

Journal

.040

to

(.0016

to

39.5 (1.555

to

32.472 (1.2784

27.991 (1.1020

28.01 3 (1.1029

.013

to

(.0005

to

.400

to

(.0158

to

.006 (.0002

to

NIA

8.0

mm

(.32")

.070

mm

.0028')

40.5

mm

1.595")

to

32.51 2

to

1.2800”)

to

28.000

to

1.1024")

to

28.027

to

1.1034")

.036

"

.0014')

.800

.0315")

.019

mm

.0008)

mm

I

i

Piston

Ring

End

Gap

NIA

.030

to

.050

(.0012

to

.0020”)

NIA

.20

to

.40

mm

(.008

to

.Ol6”)

to

.80

.20

(.008

.030 (.001

.020

(.001

2.46

(.0969

2.51

(.0988

mm

to

.032")

to

.070

to

.0003”)

to

.060

to

.003")

to

2.48

to

.0976')

to

2.53

to

.0996”)

mm

!

-

,.~

-

17

T3000 & T3000D

SPECIFICATIONS

(cont'd)

Models 62030 & 62032 Engine Service Specifications (cont'd)

Models 62030

&

62032 Carburetor Specifications

stainless

1

1/4

steel

Models 62030 & 62032 Fastener Torques

18

SPECIAL TOOLS

19

TROUBLESHOOTING

Engine Does Not Produce Spark

Possible Causes

engine switch in “off’ position spark plug fouled or damaged spark plug wire damaged ignition coil primary wire grounding out ignition coil has failed

Engine Floods During Starting

Possible Causes

no spark

stale gasoline

I

engine overchoked

choke not opening

I

1

leaking needle/seat

water in fuel

I

plugged air filter

Remedy

I

move switch to “on” position replace spark plug replace coil repair damaged wire with electrical tape replace ignition coil

Remedy

see “Engine Does Not Produce Spark’ troubleshooting section above

fill tank with fresh unleaded gasoline open choke, close fuel shutoff valve

and turn over until engine fires

replace damaged parts

I 1

clean carburetor and pressure check

1

drain tank and fill with fresh gasoline clean air filter

I

I I

Engine Does Not Get Fuel During Starting

Possible Causes

fuel shutoff closed fuel tank empty

plugged fuel line or filter

fuel cap not venting properly

r-~---

* For generating troubleshooting information, see Section 7, page 74.

20

Remedy

open fuel shutoff valve fill fuel tank with fresh unleaded gasoline clean or replace plugged component

repair or replace fuel cap

I

TROUBLESHOOTING

(cont'd)

Engine Difficult

I

engine not getting fuel

engine

Engine Lacks

Possible

choke partially closed

has

low compression compare compression to compression of

Power

Causes

to

Start

Remedy

see "Engine Does Not Produce Spark” troubleshooting section (page see "Engine Does Not

Starting

see "Engine Floods During Starting troubleshooting section (page

new unit

Remedy

open choke

adjust carburetor

"

troubleshooting section (page

--

repair as necessary

Get

8)

Fuel During

"

8)

lack

of

lubrication

Engine Knocks

replace flywheel key fill crankcase with proper lubricant clean or replace air cleaner

grind valves and set valve lash

see

"

Generator Troubleshooting Guide",

page

74

compare compression to new unit and overhaul

Remedy

.__^_.--

clean carbon from combustion chamber

replace damaged or worn parts tighten flywheel nut

-

__

tighten rotor bolt

replace key

___

if

necessary

-

_I-

__

-

*

For generating troubleshooting information, see Section

21

7,

page

74.

TROUBLESHOOTING

Engine Misses Under Load

Engine Overheats

(cont’d)

Engine Surges or Runs Unevenly

*

For generating troubleshooting information, see Section

7,

page

74.

22

TROUBLESHOOTING

Engine Vibrates Excessively

(cont'd)

Engine Uses Excessive

*

For generating troubleshooting information, see Section

Oil

or

Smokes

7,

page

replace damaged

tighten engine mounting bolts

Remedy

set engine to proper speed

drain excess oil

ensure that cap does not pass oil or air replace damaged or worn parts overhaul engine

74.

parts

23

MAINTENANCE

Maintenance

The air cleaner should be serviced every

Maintenance may have to be completed as often as every 25 hours or dusty conditions.

1. Shut the generator off and close the fuel shutoff valve.

2. Remove the thumb screw retaining the air cleaner cover. See Figure 1.

Remove the dust cup, baffel, foam element and

3.

element holder.

4.

Wash the element in soap and water or made for cleaning air cleaner elements.

Air

Cleaner

50

hours.

if

the generator is being operated in dirty

Figure

1

a

solvent

Maintenance

The spark plug is the ignition source for

in the combustion chamber of the engine. The engine

will not run properly

replaced cleaned; spark plug cleaners will leave grit on the plug that can cause rapid :engine wear.

Type:

Substitute: Champion L92Y/L92YC

Maintenance Changing Oil

Tor0 generators are shipped without oil. generator until you have added the correct amount of

Service Classification Oil change frequency:

I

1. Stop the engine and remove the spark plug wire from the spark plug.

2.

Remove the oil

3.

Position and drain pan under the engine and remove the drain plug.

Spark

a8

required. Spark plugs should not be

if

the plug is fouled or dirty, replace

Plug

the

if

the spark plug is not inspected and

NGK BP-

5HS

I

.6-.7mm (.024-.028')

-

Every 100 hours

-

105 Kg-cm (80-120

70

-

lbs)

in

Do

not start the

see spec. on page

30

summer 20 fall, spring 10 winter

MS,

SC,

SD,

SE

fill

After the first every

plug.

See

50

Figure 2.

20

hrs. thereafter.

fuel air mix

it.

Abrasive

_

-

3

hrs. and

~_~..~~

5.

Squeeze the element dry Saturate the element with

6.

then squeeze the excess oil out of the element. Note: an element that is too heavily saturated with oil may restrict air flow and cause a rich running condition for the engine.

7.

Reinstall the element holder, foam element, baffel and dust cup.

Secure the air cleaner cover with the single

8.

mounting screw. Make sure the breather hose is properly connected

9.

to the body of the air cleaner.

of

the cleaning solution.

30

weight motor oil and

24

5.

Maintenance - Changing Oil (cont’d)

4.

Reinstall the drain plug and dispose of the used oil at a proper waste oil disposal site.

r

‘,

5.

Fill the crankcase with oil. See the Specification Section on page 3 for the proper quantity. When replacing the oil it will be helpful to tilt the generator back about

the filler neck without spilling. See Figure 3.

100-15’,

-__1_

this will allow the oil to enter

-----

t

Empty the fuel bowl and clean it of any debris.

6.

The filter screen is located in the head of the bowl

and may be removed and cleaned at this time. See Figure 4.

7.8.On reinstallation make sure the screen is properly seated to prevent unfiltered fuel from entering the carburetor.

Reinstall the sediment bowl and tighten the plastic

collar.

9.

Turn the fuel valve back on and visually check for

leaks.

SCREEN

r

----.

Figure 3

.-----l_l___

\

Maintenance - Fuel Sediment Bowl

The

T1200 - T3000

sediment bowl and strainer that will filter debris from the fuel and will trap water before the fuel reaches the carburetor. The sediment bowl should be cleaned at least once a season.

Cleaning the fuel sediment bowl will require working with gasoline.

presence of gasoline. Always keep gasoline in a container designed for the storage of flammable liquids.

1.

Stop the engine and remove the spark plug wire.

2.

Close the fuel shutoff valve.

3.

Prepare a drain pan to catch a small amount of gasoline that may be spilled or released when the fuel bowl is removed.

4.

Unscrew the plastic’collar retaining the fuel bowl and pull the fuel bowl off the head assembly.

generators are equipped with a fuel

CAUTION: Misuse of gasoline can cause death. Do not work with gasoline around open flames. Do not smoke in the

10.

Return the valve to the “off’ position when the cleaning and inspection are complete.

Maintenance - Frequency Adjustment

All Toro generators including the T1200 designed to run at a speed of 3600 rpm. The frequency

of the

el,ectricity

speed) 60 cycles of alternating current per second

(6OHz); ,This

revolutions per second or 3600 rpm.

~~~~~~~~~~-~~

1.

Check the engine oil level.

2.

Disconnect any load that may be connected to the generator.

3.

Start the generator.

4.

5.

/

Connect a load to the generator that is similar to

the load the generator is normally under when

used by the customer.

Adjust the speed of the engine with the speed adjustment screw to 3600 rpm. The speed adjust-

produced is (controlled by the engine

is, of course, the same as 60 engine

T300O

are

Maintenance Frequency Adjustment (cont'd)

ment screw is located behind the air cleaner and connects

6.

With the engine at 3600 rpm the front of the generator will resonate. (some models are not equipped with a frequency meter.) See Figure

to

the governor arm.

5.

60Hz

MENT

reed on the

SCREW

closing completely and the valve clearance will have be adjusted.

.05-.15

for both intake and exhaust valves.

Adjustment Frequency: Every

I

Maintenance Valve Clearance Inspection

1.

Stop /the generator and remove the spark plug

wire. Close the fuel shutoff valve.

2.

Remove the single screw retaining the air cleaner

3.

to

bracket Remove the two screws retaining the air cleaner

4.

assembly

5.

Pull

Remove the two screws retaining the breather

6.

assembly

the engine block.

to

the carburetor.

the breather hose

off

mm

(.002-.006”)

300

hrs

the breather assembly.

to

I

7.

The speed of the engine may also be set using a variety of tachometers. Once the engine speed is

adjusted be set at

Maintenance Valve Clearance

The

T1200

The valves are opened and closed with solid cam followers. If the clearance between the end of the valve stem and the cam follower is close. The clearance is factory set at

(.002-.006'”).

face may wear causing the valve stem and follower clearance degrades after many hours of use, the valves may not be

to

3600

rpm the electrical frequency will

60

Hz.

T3000 generators use side valve engines.

too

small the valve may not

.05-.15

After many hours of use the valve seat and

to

decrease. If the performance of the engine

mm

Remove the breather assembly. Take note of how

7.

the gaskets and reed plate are installed.

Measure the valve clearance with the engine cold

8.

and on top dead center (TDC) of the compression

stroke. See Figure

To determine TDC; remove the spark plug and

place: a clean wooden dowel opening

Rotate the engine until both valves are closed (watch the cam followers When both valves reaches the highest point of the with more accuracy by using a depth reading dial indicator.

so

the dowel rests on the top of the piston.

compression

6.

Figure

6

in

the spark plug

in

the breather opening.)

stop

moving as the dowel

in

its

travel you have TDC

stroke. TDC can be determined

26

Maintenance Valve Clearance Inspection (cont'd)

9.

The correct clearance is .05-.15 mm (.002-.006'”).

If the clearance is not within tolerance, the valves must be removed from the engine and the

approprlate

amount

of material ground

off

the stem

of the valve.

Maintenance Valve Clearance Adjustment

1.

Follow steps

2.

Remove the fuel hose from the carburetor.

3. Remove front control panel. See Figure

1

7

as described above.

two

hair pin clips from the bottom of the

7.

Remove the valves.

9.

After the valves are removed the ends of the stems

10. should be ground to provide

the

required

clearance.

11.

Check the condition face. Recondition the face and seat

12.

Reinstall the valves and keepers. Reinstall the head of the engine. Consult the

13.

of

the valve seat and valve

if

necessary.

Specification Section for correct head bolt torque.

14.

Replace the metal shield over the cylinder head of the engine. This shroud is part of the cooling system and must be properly installed.

Remount the fuel tank with the four hair pin clips.

15.

Install the fuel hose on the carburetor.

16.

1

7.

Reinstall the spark plug wire.

Maintenance Decarboning Spark Arrester

All

Toro generators are fitted with spark arresting

mufflers.'

If

the spark arrester is not serviced, the ability of the engine to exhaust will be restricted and the performance of the generator will drop.

4.

Remove

two

gasoline tank. See Figure

Figure

hair pin clips from the bottom of the

7

8.

I

Figure

5.

Lift

the tank and front panel assembly forward and

away from the head of the engine.

6.

Remove the screws retaining the metal shield on

the head of the engine (three screws on the T1200,

T1800

and four on the T2500, T3000).

7.

Remove the screws retaining the head of the

engine.

8.

Use a valve spring compressor to remove the valve keepers.

8

Decarboning

Interval: 100 hrs

1.

Stop the engine.

2.

Remove the spark plug wire.

3. Remove the

Figure

4.

Remove the single screw retaining the spark

9.

two

spark arrester clean

Figure

9

out

-__^_-

arrester tube in the end of the exhaust pipe and pull

the tube out of the pipe. See Figure

5.

Take the generator to a well ventilated area that is

9

free of combustible material.

6.

Start the generator and tap on the side of the muf

bolts.

above.

See

-

27

Maintenance Decarboning Spark Arrester (cont'd)

fler to dislodge any carbon build up within the spark arrester.

CAUTION: Exhaust fumes can cause death. Operate the generator only ventilated area.

CAUTION: The muffler will cause burns if

7.

Allow the muffler to cool. Remove any remaining

carbon from the clean out ports and the exhaust discharge opening.

8.

Reinstall the muffier clean out bolts.

10.

Reinstall the spark arrester.

Maintenance Storage

If

the generator is not going to be used for a period of

three months or more the following long term storage

procedures should

1.

Drain all gasoline from the fuel tank into a container designed for storing flammable liquids.

be

completed:

In

it

is touched.

a well

CAUTION: Misuse of gasoline can cause

while working with gasoline.

Never expose gasoline to open

flame or fire.

working

while'

2.

Start

the generator and run the remaining fuel out

of the

carburetor.

Turn the engine over

3.

feel the resistance of compression; this will

indicate that both valves are in' sealing the cylinder.

4.

Drain :the existing engine oil and refill the engine

with fresh oil.

5.

Remove the spark plug and pour one or tablespoons of plug.

6.

Service the air cleaner element. See the instructions on page maintenance

7.

Check the tightness of all fasteners.

8.

cover the generator and put

Always

with gasoline.

with

oil

into the cylinder and replace the

death.

use

the recoil starter until you

24

Never smoke

proper ventilation

the

closed position

on air cleaner

it

away for storage.

two

28

SECTION

1

CARBURETOR

Carburetor Operation The carburetor receives fuel from the gasoline tank and

mixes

it

with air in the right proportions to provide a

highly combustible mixture to the engine.

As

the piston moves up on the compression stroke, a partial vacuum is created within the engine crankcase, causing the greater atmospheric pressure to force air to flowthrough the carburetor into the cylinder. Thevelocity of the air increases as

it

flows through the carburetor venturi and the air pressure is reduced at this point to less than atmospheric pressure. The low pressure in the venturi of the carburetor causes atmospheric pressure to push raw fuel from the float bowl into the air stream in the throat of the carburetor, where

it

breaks up into a fine spray, or becomes atomized, and mixes with the air stream.

See

Figure

Atmospheric

Pressure

10.

,Venturi

from the float bowl. This fuel premixes with the incoming

is

air, then See Figure

discharged into the intake port of the engine.

12.

Pilot System

Pilot Jet

,Pilot Air Fitting

COLD

START

Figure

11

Carburetor

Bore

Float Bowl

To

Engine

When starting the engine an extra rich mixture is

is

required. The choke plate provide an approximate

closed by the operator to

8:l

ratio of fuel to air for this rich mixture. Closing the choke plate further reduces the air pressure in the venturi to increase the fuel pushed into

the carburetor throat. In this condition fuel also flows from the float bowl through the pilot system ports as well

as the main discharge tube to achieve the proper starting mixture.

See

Figure

11.

Fuel atomization becomes more efficient, due to heat, once the engine has reached normal operating

temperature. As a result the engine does not require the

rich mixture

it

did for starting and the choke plate must be moved to the open position. The engine speed is now regulated by the throttle plate. In no load conditions a small portion of the fuel may be drawn from the main

fuel

discharge tube, however the primary from the pilot circuit. Air passing through the pilot

the pilot air fitting draws fuel

out

supply is drawn

jet

from

of the pilot jet orifice

Pilot System /Pilot Jet

Fitting

NO

LOAD

Figure

12

As the throttle plate is opened to compensate for engine load, the main discharge tube becomes the main source of fuel. Opening the throttle plate increases the flow of air through the venturi and strengthens the low pressure area at the main discharge tube. Fuel discharge

increases at the main discharge tube as it decreases from the pilot system. Air is drawn from the air correction jet

through holes along the length of the main discharge

tube. This premixes air with the fuel before

it

enters the

29

Carburetor Operation (cont'd)

carburetor throat for more efficient atomizing of the fuel.

See

Figure

Throttle

Main

Plate

Discharge

Tube

13.

Float

,Pilot System

UNDER

Correction Jet

LOAD

7.

Slide /the carburetor off

its

studs and disconnect

the governor link rod.

8.

There will be a small amount of gasoline in the bowl of the carburetor. Drain this gasoline into a suitable container by opening the drain screw on the bottom of the carburetor.

CAUTION: Mishandling gasoline can cause death. Always work with gasoline in a well ventilated area free

Do

flame or sparks.

not smoke around

gasoline

Carburetor Disassembly

1.

Remove the carburetor bowl nut. necessary to remove the drain screw.

15.

of

It

See

open

is not

Figure

13

Carburetor Removal

1.

Stop the generator and remove the spark plug

wire.

2.

Close the fuel shutoff valve.

3.

Remove the single screw retaining the air cleaner body to the engine block.

4..

Remove the'

two

screws retaining the air cleaner to

the carburetor.

5.

Remove the fuel inlet hose.

6.

Remove the two nuts retaining the carburetor to

the

engine. See Figure

14.

Figure

15

Figure

14

30

2.

The main

jet

is threaded into the carburetor bowl nut. The float and inlet needle may be removed by pulling out the float hinge pin. Note: one end of the hinge'

is flattened slightly. The pin must be

removed from this end. See Figure

3.

The pilot jet may be removed from the top of the

16.

carburetor and can be cleaned or replaced. Fuel flows through the small opening in the end of the

Carburetor Disassembly (cont'd)

jet and air enters through the holes in the side. The

opening on the top of the jet is a drilling passage and is plugged.

The pilot screw controls air in the pilot circuit.

should be open 1 to 1 Figure

17.

1/2

turns on all engines. See

t

FLAT

CAUTION: Be sure safety glasses when using compressed air. Use pressure

It

3.

If

it

is

suspected that the seat is leaking, the carburetor can be pressure tested after cleaned. Use Toro Pressure tester, Number

41-7910.

(7

should be completed with the carburetor turned

upside down See Figure the 'needle and try the test again. If the carburetor fails again, the seat is bad and the carburetor must

be replaced

If

psi) for at least

of no more than

the seat is good,

10

so

the seat holds the needle closed.

18.

If

the pressure leaks down, replace

it

will hold

seconds. This procedure

40

to

PSI.

it

has been

.5

wear

kg/cm

2

Figure

PILOT

Figure

Carburetor Service

1.

The metallic body of the carburetor may be cleaned in carburetor cleaner. Plastic parts may be damaged by some carburetor cleaners.

16

17

Figure

Carburetor Reassembly

1.

Replace the main nozzle and bowl gasket.

2.

Install the pilot jet and pilot screw. Refer to Figure

17.

The pilot screw should be open 1 to 1 -

3.

Hook the inlet needle into the float and secure the

float and needle in place with the hinge pin.

Figure Remount the bowl and gasket.

4.

Carburetor Installation

19.

18

1/2

turns.

See

Carburetor passages may be cleaned compressed air.

2.

Replace any components that show wear or damage. The inlet needle is replaceable but the seat is not.

out

with

31

1.

Mount one gasket, one spacer and one additional gasket on the carburetor mounting studs.

2.

Connect the tension spring from the governor arm to the throttle shaft.

Carburetor Installation (cont’d)

3.

Connect the governor link rod. See Figure 20.

5.

Straighten the governor arm

allow

connection

of

if

the linkage rod to the

carburetor.

6.

lnstail the carburetor mounting nuts.

7.

Connect the fuel inlet hose.

8.

If

the

~governor

arm has been removed to provide additional working clearance, make sure correctly reset.

it

has been bent to

it

is

Figure 19

I

Figure 20

4.

Install the carburetor on the mounting studs.

FLAT

The governor shaft

is

turned

full

counterclockwise while; the governor holds the throttle plate wide open.

The governor spring connects in the upper hole

of

the governor arm. See Figure 21.

I

i

Figure 21

14. Remount the air cleaner body to the carburetor with

two

screws.

15. Secure the air cleaner bracket to the engine block. Carburetor reinstallation is now complete.

32

SECTION

FUEL TANK AND STRAINER

See the Specification Section for fuel tank and approximate running time under full load. The required fuel is regular unleaded gasoline.

Fuel Tank and Strainer Removal

1. Shut off the generator.

2. Drain the fuel tank. Remove the line on the inlet side of the fuel shutoff valve. See Figure 22.

the

capacity of each

2

FUEL

8.

SYSTEM

Examine the fuel tank for debris and wash the tank

with a cleaning solvent

if

necessary.

NOTE:

liquids available to receive the gasoline from the tank.

flame or sparks. Do not smoke around

gasoline.

Have a container suitable for flammable

Figure 22

CAUTION: Mishandling gasoline can cause death. Always work with gasoline in a

well ventilated area free of open

Fuel Tank and Strainer Installation

1.

Install the fuel tank on the front panel.

2. Reset the fuel tank frame and install the hairpin clips.

3. Connect the fuel hose to the fitting on the shutoff valve and sediment bowl. distorted

4. Install the fuel strainer and tank cap.

FUEL

TANK

The fuel tank cap is an important

of the fuel system. must do:

It

must allow atmospheric pressure into the tank and must allow any buildup of pressure out of the tank. The cap also' has to keep fuel in the tank.

it

CAP

It

must keep debris, water, etc., out of the tank.

and

front panel on the generator

If

the clamp is bent or

should be replaced.

but

often ignored part

It

has several important jobs that

it

Remove the fuel tank cap.

3.

4.

Pull

the fuel strainer out of the tank.

Examine the fuel strainer for debris and wash it out

5.

in a suitable solvent. Removethe four hairpin clips retaining the fuel tank

6.

and front panel to the frame of the generator.

7.

Lift

the fuel tank away from the engine and remove

the

five

screws retaining fuel tank to the front panel.

The fuel tank is now separate from the generator.

See

Figure 23.

Fuel Tank Cap Service

1.

Examine the condition of the cap. Look for distortion or bending.

2.

Examine the gasket. The gasket should indicate an even seal for a full 360 degrees. The gasket part number is 53

See

Figure 24.

3.

Make sure the cap is venting properly. be, able to force air through the cap from the inside out and the outside in. Replace the cap not vent properly.

33

-

1420 for T1200 -:T3000 generators.

You

should

if

it

does

Fuel Tank Cap Service (cont'd)

Fuel Shutoff and Sediment Bowl Removal

Drain the fuel tank. Removethe line on the inlet side

1.

of

the fuel shutoff valve. See Figure

22

on page

33.

A

STRAINER

NOTE:

liquids available to receive the gasoline from the tank.

flame or sparks. Do not smoke around gasoline.

2.

Disconnect the outlet hose from the fuel shutoff

valve.

Fuel Shutoff and Sediment Bowl Service

1.

Complete service of the valve may be accomplished without removing the valve from mounting bracket.

2.

Remove the sediment bowl by unscrewing the collar around the

Have a container suitable for flammable

CAUTION: Mishandling

gasoline can cause death. Always work with gasoline in a

i

well ventilated area free of open

bowl.

See Figure

26.

its

Figure

24

4.

Install the cap and make sure the tabs on the cap pull

it

fully against the tank as

FUEL SHUTOFF AND SEDIMENT BOWL

The

T1200

valve and sediment bowl. The valve is mounted to the tube frame under the fuel tank. See Figure 25.

T3000

generators use a combined shutoff

it

is turned in place.

Figure

3.

Take:

note

that there is a filter screen in the head of

the valve that may be cleaned or replaced as

required. The See Figure

part

27.

26

number of the screen is

50-3770.

Figure

25

34

4.

The valve may be serviced by removing the set

screw on the side of the valve. Use care, as the

valve stem is under spring pressure and must be

restrained as the set screw is loosened.

Fuel

Shutoff

and Sediment

Bowl

Service (cont'd)

6.

When the stem and valve cylinder are removed, the

be

valve may solvent.

cleaned in a nonflammable cleaning

Figure

27

5.

After the valve stem is removed, the plastic valve cylinder may be withdrawn with a needle nose pliers.

SCREEN

Fuel Shutoff and Sediment

1.

Reassemble the valve by inserting the valve cylinder and stem in the body of the valve. Make sure the cylinder and hole

up 'with the handle of the valve stem. Restriction

of

fuel flow may occur

indexed correctly.

2.

Install the valve stem retaining screw. Make sure the valve is free to turn. likely that the end of the retaining screw is not located in the slot on the side The slot is there to limit the rotation about

90

degrees.

Fasten the valve to its mounting plate with

3.

screws.

4.

Install the inlet and outlet hoses to the valve.

Bowl

If

Installation

in

the

valve

if

the

two

parts

the valve will not turn

of

the valve stem.

of

cylinder lines

are not

it

is

the valve to

two

35

SECTION

IGNITION

SYSTEM

IGNITION OPERATION

The firing of the spark plug at the proper time is the culmination of a number of components working together. In the T1200 T3000 generator, the

components used are:

Flywheel Ignition coil Trigger circuit (molded into the ignition coil) Spark plug

See

Figure

28.

secondary coil must have many more windings than the primary. The higher the ratio between the primary coil

to secondary coil windings, the greater the voltage

amplification will be.

Figure 28

The following describes the function of each of the above

components.

Ignition Operation Flywheel

The engine flywheel is the generating force for the

ignition system. Imbedded in the flywheel are permanent magnets. These

magnets rotate past the coil to generate electricity. Imbedded in the opposite side of the flywheel is a steel

counterweight which offsets the weight of the three

magnets.

Ignition Operation Ignition Coil

The ignition coil is actually a transformer. It is positioned close to the flywheel to allow the magnetic field of the flywheel magnets to cut through the coils to generate electricity. See Figure

Low voltage is produced in the primary coil which is sent to the trigger circuit. This voltage would be much too low to produce a spark at the spark plug.

It

is not magnetic.

29.

I

Figure 29

Even though the secondary coil has considerably many more windings than the primary, the voltage produced is still not high enough to produce sparkacross the spark plug electrodes To further amplify the voltage, the

trigger circuit is used.

Ignition Operation Trigger Circuit

The trigger circuit amplifies the voltage in the secondary

coil by breaking the primary circuit just as the primary

its

voltage reaches

circuit results in a rapid collapse surrounding g the primary coil. The collapse of the primary magnetic field induces a large voltage surge in the secondary' which is sufficient to produce a spark across

the spark plug electrodes.

Before getting into the actual electronics used inside the trigger circuit, of the voltage waveform produced by the flywheel magnets moving by the ignition coil.

As

the magnets rotate past the coil, voltage is produced.

This voltage,' when uninterrupted, is first positive, then

negative as the magnet passes by the coil. This effect is caused by the two opposing poles

peak. This breaking of the primary

of

the magnetic field

it

is important to have an understanding

See

Figure 30.

of

the magnet.

The secondary coil serves to amplify the voltage produced in the primary. To accomplish this, the

Explanation of the trigger circuit also requires an understanding of the

NPN

transistor. See Figure 31.

36

Ignition Operation Trigger Circuit (cont'd)

3.

Current current,

12

that

I1

flowing through Tr2 induces a larger

l2.

Note that current

is much larger.

MTI

unit Ignition coil

See

I1

is very small and

Figure

34.

PRIMARY

B

VOLTAGE

Figure

(Base)

30

WAVEFORM

C

(Collector)

E

(Emitter)

NPN-type

Figure

31

A

transistor has a certain minimum voltage that

requires across the base and emitter (points B and E in

it

the Figure above) before

turned on

above. current, current

11.

Thus, the transistor functions as an amplifier in that it

it

allows a small current,

At

the same time the transistor allows a large

12,

to flow from point C to

12

will vary in proportion to the smaller current,

will "turn on". Once

11.

to flow as shown

E.

The magnitude of

allows a small current to control a large one.

it

has

!

MTI unit Ignition coil

Figure

MTI unit Ignition

it

4.

When the voltage is at the point "a" level as denoted above in Figure

30,

allows no current

MTI

unit Ignition

32

33

Trl is still in the

13

or

14

to flow.

coil

"

off'

See

coil

Ground

Spark plug

mode and

Figure

35.

The following is the process the trigger circuit uses to

break the primary circuit to produce spark:

1.

The magnet passes by the coil and induces an

alternating voltage.

2.

As

the voltage begins to increase (approximately

point

"a"

in Figure

and current flows from point

R3, R4,

and Tr2.

See

Figure

32.

30),

transistor Tr2 is turned on

"c"

to point "d" through

See

Figure

33.

Spark plug.

37

Ignition Operation Trigger Circuit (cont'd)

5.

As the voltage produced in the primary coil

“b”

reaches its negative peak (point transistor Trl is turned on and allows small current

13

and large current

6.

When transistor Trl turns on, nearly all of the current flow through

14

path

drop in current

Off.

7.

When Tr2 turns

causes the magnetic field surrounding the primary coil to rapidly collapse. This in turn causes a voltage surge in the secondary which is sufficient to produce a spark across the spark plug.

Ignition Operation The spark plug is used to ignite the air fuel mixture by

producing a spark just before the piston reaches top dead center. shown in Figure

since

A

spark plug is typically constructed as

36.

14

to flow.

R4

and Tr2 is diverted through

it

is the path of least resistance. This

I1

results in transistor Tr2 turning

off,

current

-

Spark Plug

12

in Figure

drops rapidly and

30),

Excessive gap or fouling can delay firing enough to

loss

cause a

The other important area is the insulator. The insulator

prevents arcing from taking place in another portion of the plug, away from the electrodes. Because extremely high voltage present, even a slight crack or

fouling of

malfunction of the plug.

IGNITION

Ignition Coil Testing The operation of the ignition coil should be tested before

.the product' is disassembled.

1.

Shut appliances that may be plugged into the generator.

2.

Remove the rubber spark plug cover and remove

the sp'ark plug.

Inspect the spark plug and ensure that

3.

condition. Make sure there are no particles bridging the spark gap.

of power or stalling.

the

head insulator can result in arcing and a

COIL

off

the fuel supply valve and disconnect any

it

is in good

of

the

HEAD INSULATOR

COPPER

LEG

CORE

INSULATOR

4.

Ground the body of the plug on the side of the engine. Turn the ignition switch on. Pull the starter cord and watch for a spark at the gap of the plug.

5.

If

there is a strong spark, the ignition module is

intact and working properly.

6.

If

there is a lack of spark, check the oil level in the

engine. The engine uses a low oil shut down device

will

that

low. For operation of the low oil level shut down device, see Low Oil Shutdown, page

7.

If connected to the low oil shut down module. Access to the yellow wire may be obtained by removing the single screw that retains a wlre connector bracket on the front crossframe of the generator.

the wire.

prevent the engine from starting

the

oil

level is normal, disconnect the yellow wire

See

Figure

37

for the exact location

44.

if

the oils

of

GROUND

There are plug function. The first is that the electrodes are properly gapped and are clean. This ensures that will be present and that it occurs

ELECTRODE

Figure

36

two

critical areas important to proper spark

a

strong spark

at

the proper time.

GAP

38

Ignition Coil Testing (cont'd)

8. Insulate the wire from ground and attempt to start the generator.

If

the

ignition has spark the low oil shut down circuit is at fault. See the section on the low oil shutdown circuit, page 44.

9

If

the ignition has no spark with the low oil shut

down circuit disconnected the fault is with the

Ignition circuitry and the coil may have to

be

removed. See the section on coil removal below.

Ignition Coil Removal

Stop the generator and remove the spark plug

1. wire.

Close the fuel shutoff valve.

2.

10. Unplug the black ignition kill wire and and the entire coil may be removed.

3.

Remove

the

four screws retaining blower housing

of the generator.

Pull

4.

some slack

in

the spark plug wire and remove

the blower housing.

On the T1200 and T1800 the coil is now exposed

5.

and may be removed after unplugging the ignition

kill wire.

T1200 and T1800 generators built in 1983 and all

6.

T2500 and T3000 generators have the ignition coil

mounted on the engine block behind the flywheel.

The flywheel magnets are located on an internal

counterbore in the flywheel. The flywheel must be removed to expose the ignition coil.

Remove the flywheel nut and the three screws

7

retaining the starter cup.

See

Figure 38.

40

Figure

Ignition

1.

Coil

Installation

Mount the ignition coil on the engine block. On the T1200 and T1800 an air gap

of

.381 mm (.015") should be set between the coil and flywheel. On the T2500 and T3000 and 1983 models and T1800 that have ignition coils that are mounted on the engine block behind the flywheel, the ignition coil location is fixed and no adjustment is possible

of

T1200

Figure 38

8. Use a puller or remover to remove the flywheel.

See

the section on special tools on page 19, for the

part

correct tool and

number. See Figure 39.

9. The ignition on T2500 and T3000 generators is now exposed. See Figure

40.

39

2.

Route and secure the spark plug wire in the wire retainer on the back of the engine block.

On models with internal ignition coils, remount the

3. flywheel. Make sure the taper on the flywheel and the taper on the crankshaft are clean. Torque the flywheel nut to

kg m (43

50

6.0

7.0

engines. See Figure 41. Remount the blower housing with the recoil starter

4.

attached.

ft

Ibs) on all

Ignition

5.

Coil

Installation (cont'd)

Reconnect the Ignition kill wire.

gap on the electrodes of the plug is

.028").

.6

.7

mm (.024

SPARK PLUG

Figure 41

Spark Plug

1. Stop the engine and remove the rubber dust cover.

2. Remove the spark plug wire.

3.

Clean debris from around the spark plug does not

removed

4. Remove the plug with a 19 mm (3/4”) wrench.

5.

Spark 'plugs should not cleaners and reused. Grit the plug and cause engine damage. Dirty spark

plugs

Spark Plug Installation

1.

Use an spark plug.

2.

Set the plug gap to

3.

Install the plug with a 19 mm

use a release agent

4. Torque the plug to

Removal

fall

into the engine when the plug

Should be replaced.

NGK

BP-5HS

or Champion L92Y

.6

or

oil on the threads

1.2

kg m (8.5

be

cleaned by abrasive

will

eventually fall out of

.7

mm (.024 .028")

(3/4')

wrench.

of

ft

Ibs).

so

dirt

or

L92YC

Do

not

the plug.

is

NGK

The correct spark plug is an

substitute is a Champion L92Y or L92YC. The correct

BP-5HS.

An acceptable

5.

Replace the spark plug wire.

6.

Reinstall the rubber dust cover.

40

SECTION 4 RECOIL STARTER

Recoil Starter Removal

1.

Turn

off

the generator, shut

disconnect the spark plug.

2.

Remove the three screws retaining the recoil starter. Note the position of the recoil handle for proper reinstallation.

Recoil Starter Disassembly

1.

Begin disassembly by relieving the spring tension on the reel. Pull approximately 30 cm (12 starter cord out of the reel and hold the reel in place.

off

the fuel and

"

) of

2. Place the cord in the notch in release

without rewinding the cord on the reel.

NOTE: The rope is wound around the reel in a counterclockwise direction as you are looking at

the bottom of the reel.

the

reel. This will unload the spring tension

See

the

reel and slowly

Figure 42.

Figure 43

Figure 44

Figure 42

3.

Remove the friction disc retaining nut. This nut is under a small amount of spring tension, release slowly.

4. Carefully spring is mounted on the center post and engages

the starter pawl. See Figure 43.

5.

Remove the starter pawl and pivot pin. See Figure

44.

6.

Remove the starter pawl spring.

7.

Remove the bushing and nylon washer from the center post of the starter assembly.

lift

off

the friction plate. Note how the

See

Figure

It

45.

41

8.

R,emove the knot from the starter grip and remove

the grip.

9.

If,

replacement of the starter rope is all that necessary the rope may be removed and replaced at this time.

10.

Lift

the reel out

not to disturb the coil spring under

the

housing

of

the starter housing. Be careful

the

CAUTION: The recoil spring

may cause injury. The spring is captured and may rapidly expand out

if

disturbed or dropped.

in

the recoil housing

is

reel.

of

Recoil Starter Disassembly (cont'd)

3.

If

the recoil rope has been removed insert a new

it

rope and wind

in a counterclockwise direction

around the reel. The recoil rope is approximately

120

cm

(48')

long.

4.

Feed the end of the rope through the opening in

the recoil housing and attach the

5.

lnstall' the reel. The bosses on the inside diameter

“T”

of the reel engage the slots on the outside diameter of the /spring case. See Figure

47.

handle.

WASHER

1

1.

The coil spring should not be removed unless

-

Figure

45

broken and needs to be replaced. Use extreme care when relieving spring tension. Hold the body of the spring in place with a gloved hand and slowly

withdraw the spring from the inside out with a pair

of pliers until the spring is completely relaxed.

Recoil Starter Reassembly

1.

New recoil springs are secured with a wire around

the circumference of the spring. Install

spring case with the outside hook of the spring engaging the slot in the outside rim of the spring case. See Figure

46.

it

in the

it

is

6.

lnstall' starter

the

pawl.

Figure

starter

See

47

pawl

pivot pin. Then install the

Figure

48.

Figure

46

2.

The inside hook of the recoil spring engages the slot on the inside diameter of the recoil housing.

42

Figure

7.

Mount the bushing and nylon washer on the center post

of

the recoil assembly.

8.

Install ;the spring and friction disc. Make sure the spring engages the starter

9.

Install the friction disc retaining nut.

48

pawl.

Refer

to

Figure

43.

Recoil Starter Reassembly (cont'd) provide sufficient spring tension to pull the cord

back into the recoil assembly when released.

10.

Pull

about

30

cm

(1

2')

of

cord out of the recoil. Turn

(it

the

about

will now

cord as

15

the reel

so

the notch in the outside diameter

up with

Pull

rotate the reel counterclockwise one or revolutions to

cm

be

under some spring tension)

of

the reel lines

it

leaves the recoil assembly.

(6')

of cord

up

into the notch and the recoil grip facing the front of the generator.

two

r

e

S

tart

1.

Mount the recoil assembly to the generator with

e

connec

R

Installation

t

h

r

pa

k

e

s

l

p

u

.

r

g

i

w

e

43

SECTION

5

LOW

O

I

L

SHUTDOWN

LOW OIL SHUTDOWN CIRCUIT

Low Oil Shutdown Circuit -Purpose

If

the engine oil drops below a safe level or is operated at an extreme angle, the oil alarm will turn on a warning light and at the same time ground the engine ignition.

Low

Oil

Shutdown Circuit Operation

The circuit operation is described in the following steps.

49

Please see Figure

1. There is a magnetic float in the sump of the engine

that will close the contacts of a reed switch when

the oil level drops to the

2. The reed switch completes a circuit to ground that

turns on a silicon controlled rectifier

3.

The

SCR

light and at the same time grounds the engine ignition.

4.

The

light remains illuminated until the engine stops rotating. The engine cannot be restarted until the oil level is returned to normal.

to help clarify how the circuit works.

"

low" point on the dipstick.

closes a circuit that turns on the warning

if

the engine

(SCR).

With low oil there should be a complete circuit to ground.

Low

Oil

Shutdown Circuit Testing

Verify the operation of the float operated switch in the sump by checking for continuity between the yellow wire coming

1. Stop the generator by turning

2.

3.

off

the

switch and the engine block.

off

the ignition

switch.

Locate

routed ,along the inside of the blower housing and exits the blower housing along with the spark plug wire.

The wire is retained by a plastic clip to the crossbar

of the tube frame on the front of the generator.

Remove the clip with one screw and disconnect the wire See Figure

the yellow wire from the float switch.

50.

It

is

Alarm lamp

To transistor

Figure

5.

The operation of the grounding the yellow wire while the engine is running. The yellow wire is at magneto potential and the engine should stop as soon as the wire is grounded.

6.

If

the engine does not stop with the yellow wire grounded the module containing the defective and must be replaced.

7.

The operation of the oil switch may be verified by checking continuity between the switch connecting wire and ground. With the correct amount of oil there should be no circuit to ground.

SCR

Oil

level

49

may be verified by

sensor

SCR

is

4.

Place the probe

tester

(R

x

wire coming from the engine block.

Place the other probe of your tester on the engine

5.

block itself.

With the proper level of oil there should be no

6.

continuity. Drain the oil out of the engine and complete the

7.

test again With no oil there should be a complete

circuit between the yellow wire and ground.

If

a.

9.

the switch operates normally but the engine does not stop with low oil or will not run with a normal oil level, the low oil shutdown module may be defective.

low

The

is located inside the control panel of the

oil shutdown module on the T1200 T3000

of

a continuity tester or resistance

1 scale) on the terminal end of the yellow

44

Low Oil Shutdown Circuit Testing (cont'd)

generator. Remove the six screws retaining the

front panel and disconnect the module. See Figure

51.

OIL

LOW

SHUT DOWN

MODULE

FRONT

PANEL

4.

Repair of the float switch is not possible. switch is defective (determined by continuity testing)

it

must

be

replaced.

If

the

Figure

10.

Replace the module by separating

51

harness and install a new unit.

LOW OIL SHUTDOWN SWITCH

Low Oil Shutdown Switch Removal

1.

Stop the engine and remove the spark plug wire.

2.

Close the fuel shutoff valve.

3.

Place a drain pan under the engine and remove the oil drain plug.

4.

Remove

the

two

engine base mounting bolts. With the bolts removed, use a prying tool to engine to increase clearance between the base of the engine and the tube frame crossbar.

5.

Remove the four screws retaining the oil level switch.

See

Figure

52.

it

from the

lift

the

Low Oil Shutdown Switch Installation

Replace the gasket

1.

2.

Make sure the float is free to move, and install the

if

necessary.

float assembly in the bottom of the engine. Ground the short wire with the eyelet to the bottom

3.

of

the engine.

Install the wire protector and route the yellow wire

4.

with

the

grommet out from underneath the bottom

of the engine. Reconnect the yellow wire to the single connector

5.

with

the

yellow wire from

Connect the wire retainer clip to the tube frame

6.

the

oil shutdown module.

crossbar.

Remount the engine

7.

Replace the drain plug and

8.

correct amount of engine oil.

base

to the tube frame.

fill

the engine with

See

the Specification

Section for the correct type and amount.

Reconnect the spark plug wire.

9.

the

45

Engine Disassembly

1.

Turn the engine

2.

Remove

remaining in the tank.

off

the

fuel hose and drain any gasoline

SECTION

and remove the spark plug wire.

See

Figure

53.

6

ENGINE

4.

Drain the engine

Maintenance Section on page

5.

Remove the end cover of the generator.

54.

6.

Disconnect and remove the AC output wires at the

terminal block. See Figure

7.

Disconnect the control wiring plug on the top of

the generator assembly. See Figure

8.

Unplug the black ignition kill wire and the yellow low oil shutdown wire. These are located on the

front of the generator under the frame crossbar.

See Figure

56.

oil

as described in the

24.

See

55.

Figure

53

CAUTION:

presence of gasoline. always keep gasoline in a container designed for the storage of flammable liquids.

3.

After draining the fuel, crimp or seal the end of the

hose to prevent the entrance of dirt.

Misuse can cause death. Do not work with gasoline around open flames. do not smoke in the

of

gasoline

Remove the hair pin clips retaining the fuel tank

9.

and front panel to the frame of the generator.

Figure

57.

WILL

See

Figure

54

46

The gasoline tank and front panel may now

10.

away from the generator. The upper tube frame may be removed to provide

11.

additional clearance. Remove the four bolts

retaining the frame halves. See Figure

58.

be

lifted

Engine Disassembly (cont’d)

I

Figure

57

Figure

60

14. Remove the four generator through bolts. See Figure 61.

_I_.-

Figure

58

12. Remove the engine and generator from the tube frame by removing the four mounting bolts. See

Figure

13.

To

must be removed from the engine. Continue disassembly by removing the brush holder. See Figure

59.

Figure

completely tear down the engine the generator

59

60.

I

Figure 61

15. Use a plastic hammer to remove the end cover and stator assembly. See Figure 62.

Figure 62

in

16. Remove the recoil starter as shown

Figure

63.

Engine

Disassembly

(cont’d)

19.

Remove the air cleaner assembly as shown in Figure

20.

Remove the engine. See Figure

65.

two

nuts securing the muffler to

66.

the

Figure

17.

Hold the crankshaft in place with a screwdriver or

63

bar through the recoil starter cup and remove the rotor set bolt. See Figure

Figure

18.

Remove the blower housing and all other sheet

64.

64

metal from the engine.

Figure

21.

Remove the carburetor. Use care as the carburetor

66

fuel bowl will still contain gasoline. See Figure

67.

Figure

65

48

22.

Remove the carburetor bowl and drain the gasoline into a suitable container.

23.

Use a rotor remover bolt (see the Special Tool Section on page

19

for the correct part number) to

remove the rotor assembly. The rotor is secured to

the crankshaft of the engine with a tapered fit. The

crankshaft has an external taper and the rotor has

an internal taper. See Figure

24.

Hold the starter cup

flywheel nut. See Figure

68.

in

place and remove the

69.

Engine Disassembly

(cont’d)

26.

If

the generator uses an external ignition coil

coil should be removed at this time.

27. Remove the flywheel using Tor0 flywheel puller

part

number 41 -7650.

the

Figure 68

28. If the generator uses as internal ignition coil

be

exposed on removal of the flywheel and should

be,

removed.

29. Turn the engine around and remove the front generator housing. See Figure 71.

See Figure 70.

Figure 71

it

will

Figure 69

25. The next step is to remove the three screws retaining the starter cup.

30. Remove the governor lever and the governor spring bracket. See Figure 72.

31. Remove the crankcase breather assembly. See Figure 73.

32. Remove the cylinder head. See Figure 74.

Figure 70

33. Use a valve spring compressor to compress the valve springs and then remove the valve spring keepers. See Figure 75.

49

Engine Disassembly

(cont’d)

Figure

73

74

Figure

35.

The camshaft may now be pulled out crankcase Take note of the location of the timing

marks on the crankshaft and camshaft gear prior to disassembly On reassembly these marks must line up with one another. See Figure

76

77.

of

the

34.

Remove the crankcase side cover. Take care not to damage the seals or crankshaft on removal of the cover.

See

Figure

76.

50

Figure

36.

Straighten the locking tabs on the connecting rod nuts. See Figure

37.

Remove the connecting rod nuts, splasher plate

(with locking tabs) and rod cap. Please take note of the orientation reinstallation.

38.

The piston and connecting rod may be withdrawn from the cylinder block.

Please note the arrow on the face of the piston and the arrow and connecting rod are reinstalled thses arrows should point to the valves. See Figure

on

78.

See

the connecting rod. When the piston

77

of

the rod cap for proper

Figure

79.

80.

Engine Disassembly (cont'd)

Figure 78

Figure 79

I

Engine Cleaning After Disassembly

1.

Clean all parts in appropriate solvents according

to the solvent manufacturer's recommendations.

2.

Inspect all parts for wear and damage. Make certain that moving parts will move freely.

Remove carbon from the cylinder head and

3.

combustion chamber. Carbon can be removed

with a non

damage the cylinder head or bore. Clean the air filter element in soap and water.

4.

Moisten the air filter element with clean 30 weight

engine oil before installation.

Clean the fuel strainer

5.

Clean the fuel sediment bowl and filter screen.

6.

Refer to the Maintenance Section on page 24 for

7.

more information on scheduled maintenance.

Figure 81

-

marring scraper. Be careful not to

on

the tank inlet.

Figure

39. The crankshaft may now be removed.

81.

80

See

Figure

Engine Inspection

Inspect all parts for wear and damage. that are damaged or worn beyond specification.

Valve guide valve stem clearance: T120 T1800 T2500 T3000

Maximum allowable clearance:

valve seat contact width: T1200, T1800

Minimum allowable width:

Intake

51

Exhaust .8 mm (.0315

Do

.080

mm (.0032")

.100 mm (.0039')

.8

mm (.0315")

not reuse parts

"

)

Engine Inspection (cont'd)

T2500, T3000

Valve seat contact is determined by coating the valve seat with Prussian blue and rotating the valve

in

the seat. The width of the contact area will be

disclosed on the face of the valve.

The Special tools required for valve seat

reconditioning are as follows:

Special Tools

“T”

handle wrench 50,-9400

Adaptor 50

Expandable pilot 50-9500

75°/15°

46°

45° cutter 50

cutter 50-9450

cutter 50-9440

-

94

-

9430

1

0

The pattern must

break. If the pattern is not within specification, the

valve seat must be reconditioned. See Figure 82.

3. Valve seat reconditioning: Two cuts

recondition the valve seat on the T1200.

(15°

be

Figure 82

and

46°)

a

continuous ring without a

are required to properly

4. Cylinder head distortion:

T1200, T1800, T2500, T2000

Maximum allowable distortion:

.030 mm (.0012')

Check :the gasket surface of the cylinder head' for distortion with a straightedge and thickness gauge. Take a clearance reading at several places. If the clearance at any position exceeds the limit, replace the cylinder head. See Figure

!

84.

(15°,

45°,

75°)

Three cuts

recondition the valve seat on the T1800, T2500,

T3000. See Figure

(For

SE

1200)

Figure

are required to properly

83.

(For

SE1800/2500)

83

52

5.

Cylinder bore wear: T1200, T1800, T2500, T3000

.100

mm

(.004")

Cylinder wear measurements of the diameter Figure '85.

The amount of wear largest, is exceeded the cylinder must be bored oversize.

and

smallest measurement. If the wear limit

is

determined by taking

in

six locations. See

is

the difference between the

Engine Inspection (cont’d)

7.

Piston

to

cylinder clearance

T1200, T1800, T2500, T3000

6.

Piston diameter:

T1200

T1800

Figure

85

allowable piston diameter:

Minimum allowable piston diameter:

Maximum piston

to

.120 mm

cylinder clearance:

(.0047”)

Calculate the difference between the piston diameter and the cylinder diameter. If the figure exceeds the clearance limit, the cylinder bored and an oversize piston installed or replace

the

cylinder and piston.

Piston pin

8.

to

connecting rod clearance:

T1200, T1800, T2500, T3000

.05 mm

(.002’)

Measure the difference between the diameter the piston pin and the piston pin bearing in the connecting rod. See Figure 87 and Figure 88.

must

be

of

65.88 mm (2.5937”)

T2500, T3000

Minimum allowable piston diameter:

71.88 mm (2.8299”)

Measure the outside diameter of the piston.

If

the piston is smaller in diameter that the wear limit dimension

the

piston must be replaced.

See

Figure

86.

*T1200-1800

T2500-3000

15mm

8mm

(.059

(.032

in.)

53

Engine Inspection (cont'd)

9. Connecting rod side clearance: T1200, T1800, T2500, T3000

Maximum rod side clearance:

1.200 mm (.0472')

If

ring and ring groove. maximum allowable clearance value the rings or

pistion~must be replaced. See Figure 91.

the clearance exceeds the

Measure the side clearance

while secured to the crankshaft. If the clearance

exceeds the limit, replace the connecting rod. See Figure

10. Crank pin to connecting rod clearance: T1200, T1800

89.

Figure 89

Maximum crank pin to rod clearance:

of

the connecting rod

Figure

90

.070

mm (.0027")

T2500, T3000

Maximum crank

I

Measure the diameter diameter difference between the two will be the crank pin to

connecting rod clearance. If the clearance is

beyond specification replace the connecting rod

and or the crankshaft. See Figure 90.

11. Piston ring to groove, clearance limit: T1200, T1800, T2500, T3000

Use a feeler gauge to measure the clearance between the top ring and ring groove and the 2nd

of

Maximum piston ring to groove clearance:

Top ring .120 mm (.0047 2nd ring .100 mm

.080

the big end of the connecting rod. The

to rod clearance:

mm (.0031")

of

the crank pin and the

(.0039')

__--.-

I

12. Piston ring groove width:

__

(.

Figure 91

I

T1200, T1800

Maximum piston ring groove width:

Top groove 2.03 mm (.0799

2nd groove 2.03 mm

T2500, T3000

Maximum piston ring groove width: Top groove

2nd groove

"

)

Use a thickness gauge to measure the width of the top and 2nd ring groove. If the width is greater than the maximum allowable clearancevalue the piston

must be replaced. See Figure 92.

"

)

(.0799")

54

Engine Inspection (cont'd)

T1800

Maximum allowable gap:

ring

Figure 92

13. Piston ring thickness:

T1200, T1800

Minimum piston ring thickness:

Top ring 1.97 mm (.0776') 2nd ring 1.97 mm (.0776')

T2500, T3000

2nd ring

Top ring

2nd ring Oil ring 1.5 mm (.0591

"

)

T2500 T3000

Maximum allowable gap:

.7 mm (.0276')

.8

mm (.03151")

"

Oil ring 1.5 mm (.0591

)

When measuring piston ring end gap, place the

ring in an area

m'inimum amount

of

the cylinder where there is a

of

wear, e.g. near the top of the cylinder. Remember, we are trying to determine how much the ring has worn, not the cylinder. Use

a piston to push the ring squarely into the cylinder.

insert a feeler gauge and measure the end gap. Rings that exceed the maximum allowable gap m:ust be replaced. See Figure

94.

Top ring 2.46 mm (.0969') 2nd ring 2.47 mm (.0972

Measure the thickness of the piston rings with a micrometer or precision measuring device. ring measures less than the minimum allowable

thickness

it

must be replaced See Figure 93.

Top

2nd ring

Figure 93

14.

Piston ring end gap:

T1200

ring

"

)

If

the

I

Figure 94

Maximum allowable gap:

Top ring 2nd ring

.8

mm (.3151")

Engine Reassembly

1. Examine the bearings and seals in the block engine. Replace the bearings and or seals necessary.

55

of

the

if

Engine Reassembly

2.

Install the intake and exhaust valves. Coat the valve

(cont'd)

stems with a liberal amount of engine oil and insert

them into the valve guides in the cylinder. See

Figure

95

for correct placement of the intake and exhaust valves. The intake valve has the letters stamped in the head of the valve.

I

-

"IN"

Figure

3.

Install the valve springs, spring retainers and valve keepers.

See

Figure

95

96.

OPERATING

6.

Mount the piston rings on the piston. Use a ring expander and make sure the

I

SHAFT

Figure

POINT TH

Figure

97

E

DIRECTION

SAME

98

"R"

mark faces the top

of the/piston on each ring. See Figure

99.

Figure

4.

Install the governor operating shaft in the

96

crankcase side cover. Mount the governor shift fork to the shaft with thread locking compound, e.g. Loctite

I

threads of the screws. See Figure

5.

Mount the connecting the piston pin with engine oil and retain

piston with a circlip on either end. The arrow mark

on the head of the piston should point in the same

direction as the arrow on the connecting rod for

proper installation.

two

mounting screws. Use a

97.

rod

to the piston. Lubricate

See

Figure

98.

242,

on the

it

in the

Figure

99

7.

The piston and connecting rod may now be

installed from the top entire:

piston

has been lubricated with engine oil.

of

the cylinder. Make sure the

The arrow on the connecting rod and piston should face the valve side of the engine. Use a piston ring

compressor as shown in Figure

100

piston.

to install the

56

Engine - Reassembly (cont’d)

POINT

iOWAR0

VALVES

Figure 100

Install the crankshaft. Lubricate the area of the

8.

crankshaft that must pass through the crankcase

seal and bearing. If necessary wrap the crankshaft

with a plastic sleeve to prevent seal damage.

Figure 102

11.

Mount the governor flyweight assembly to the camshaft drive gear. Make sure the flyweights are

properly retained with two cotter pins. See Figure

103.

Mount the rod, splasher, lock plate and rod cap to

9. the crankshaft as shown in Figure 101. Take note

of the match marks on the rod cap and rod for proper assembly.

Mate

Figure 101

T1200, T1600,

T2500, T3000

Rod cap bolt torque:

.4

kg m (3.5 ft Ibs)

Bend the tabs on the locking plate to prevent

10. loosening of the rod bolts. See Figure 102.

Figure 103

Lubricate and install the cam followers. If the same

12. cam followers that came out of the engine are

being reinstalled, make sure they are put in the

same guide they came out of, a wear pattern will

have been established that should be maintained. Install the camshaft in the crankcase. Take care to

13.

properly line up the matchmarks for correct valve

timing. See Figure 104.

14.

Lubricate the inside diameter of the governor collar

and install it on the flyweight assembly. Make sure the lower edge of the collar engages the flyweights. Also, make sure the slit in the governor collar

engages the cam shaft gear. See Figure 105.

Install a gasket on the crankcase and install the

15. crankcase side cover. Lubricate the crankshaft to assist installation. Take care not to damage the seal in the side cover. Secure the side cover mounting screws as shown in Figure 106.

57

Engine Reassembly (cont'd)

16. Measure the valve clearance. T1200, T1800, T2500, T3000

Valve clearance specification:

Figure 104

Intake .05 Exhaust .05

If

the valve clearance is not within specification the valves should be removed and adjusted per the Specifications Section for your particular engine.

See

Figure 107.

I

-

.15

-

.15

Figure 107

mm

(.002-.006')

mm

(.002-.006”)

Figure 105

Figure 106

T1200, T1800, T2500, T3000

Side cover screw torque:

1

.O

kg m (7.2

ft

Ibs)

6

2

4

Figure 108

17. Install: a new head gasket and the cylinder head.

T1200, T1800

Headbolt torque:

1

.O

T2500

I

kg m (7.0

Headbolt torque:

2.5 kg m (1 8

ft

Ibs)

I

58

Engine Reassembly (cont'd)

T3000

Headbolt torque:

3.2 kg m

Tighten the head bolts in a diagonal sequence

(23

ft

Ibs)

to

prevent warping of the head. See Figure 108.

18. Install the generator front bracket. The bracket "up"

should be installed with the

mark of the inner

surface of the bracket facing up. See Figure 109.

INSTALL

WAY

THIS

"UP"

.

Figure 109

Tighten the bolts in a diagonal sequence as shown

19.

in

Figure 110.

T1200, T2500, T3000

T1800,

Generator front bracket torque:

2.0 kg m (14.5

Install the ignition coil on units that have ignition

20. coils that are internal

to

ft

Ibs)

the flywheel. The position of the coil is fixed on these units. Apply thread locking compound

tighten the screws

On units with ignition coils that are external

21.

to

the mounting screws and

to

1 kg m

(7

ft

Ibs).

flywheel the next step is to install the flywheel key

and flywheel. See Figure 1 1 1.

as

Install the starter cup

22.

shown in Figure 1 12.

to

I

Figure 11 1

the

59

Engine Reassembly (cont'd)

23. Install the flywheel nut. See Figure 113. T1200,

T1800,

T2500, T3000

27.

Route

the oil sensor wire in the channel provided in the crankcase. The wire groove is accessible with the flywheel installed. See Figure 115.

_--

Figure 113

If

24.

25. Route the spark plug wire and

26. Install the oil level sensor in the crankcase of the

the generator is equipped with an externally

mounted coil, the coil should be installed with an

"

air gap of .38 mm (.015

through the grommet in the block of the engine.

The spark plug wire should pass through the wire

retainer mounted on the block of the engine.

engine.

See

Figure 114.

).

the

ignition wires

28. Inspect the rotor assembly for defects; broken wires: worn or damaged slip rings, damaged insulation.

29. Install the rotor assembly. Some units use a key or pin to align the rotor to the crankshaft. Make sure the tapers are clean and that the rotor and crankshaft line up correctly.

See

Figure 1 16.

Figure 114

Figure 1 16

T1200, T1800, T2500, T3000

Rotor set bolt torque:

2.2 kg m (16

30. Inspect the stator assembly for defects. Check for broken wires, bad insulation, broken wire ties etc.

ft

Ibs)

60

Engine Reassembly (cont'd)

31. Remove the brush holder

if

it

is still installed on the

stator.

32. Align the through bolt holes with the holes in the front generator cover (the cover bolted

to

the

engine) and install the stator. Take extreme care

not

to

damage any

of

the coils

in

the stator. See

Figure 1 17.

Figure 117

Tighten the through bolts

33.

shown

in

Figure

118.

in

the sequence

T1200, T1800, T2500, T3000

The brush holder may be reinstalled at this time.

34.

Continue engine reassembly by installing the

35.

breather assembly. Make sure the parts are assembled as shown in Figure 119. Incorrect assembly will result

in

a

breather that leaks oil. The projection on the outside cover always points down. See Figure 119.

Install the governor arm (throttle control lever) and

36. the governor spring bracket. Tighten the governor

arm screw only temporarily at this time. See Figure

120.

as

Figure 119

Figure 120

37. Hook the carburetor control rod and rod spring

of

the

into the throttle control lever on the end

throttle shaft. Connect the other end

carburetor control rod

to

the governor arm and install the carburetor. The correct sequence is one gasket, spacer, and one gasket. Tighten the

two

61

Engine Reassembly (cont’d)

nuts securing the carburetor to the engine. See Figure 121.

39. lnstall the muffler. Mount one gasket and secure the muffler with

two

nuts. See Figure 123.

I

Figure 121

38. Adjust the governor by rotating the governor shaft fully counterclockwise. The slotted for a screwdriver. Move the governor arm

(throttle control lever) to the full throttle position

it

(rotate

retaining nut on the governor arm. Make sure the throttle control spring is installed in the upper hole on the governor arm. See Figure 122.

fully counterclockwise). Tighten the

end

of the shaft is

Figure 123

40. Install the sheet metal components on the engine. See Figure 124 and 125.

Figure 124

41.

Remount the generator in the tube frame.

Attach the upper frame amd reinstall the fuel tank

42. and control panel.

Figure 122

62

Reconnect the AC output wires on the terminal

43.

block. Be sure to match the color coding. See Figure 126.

Reconnect the lead wire from the control panel to

44. the connector on the top of the generator. See

Figure 127. Reconnect the ignition ground wire and yellowwire

45. from:

the

low oil level shut down system. Clamp

these wires under the front frame rail of the

generator. Use the plastic retainer,

is

secured to the frame rail with one screw.

that

P/N

55-0230,

Engine Reassembly (cont'd)

I

Figure 125

Figure 127

Install the air cleaner element. Make sure the

46. element has been cleaned and oiled. See the Maintenance Section on page 24 for details on air cleaner maintenance.

If

47.

the fuel line from the tank to the shut

been disconnected, reconnect the line. Connect

the fuel line from the shut

carburetor

off

valve to the

off

valve has

Figure 126

Install the recoil starter. The handle should face

48.

toward the front of the generator.

I

Fill the crankcase with motor oil. Check the

49. Specification Section for the correct amount and

type of oil.

63

SECTION

7

GENERATOR

DEFINITION OF TERMS

Definition of Terms Voltage

(E)

is

Voltage

measured the pressure that oil is under in a hydraulic hose. The voltage

multiplied by the resistance in the circuit. A 150 watt light

bulb will have

of 1.25 amperes. 1.25 amperes

Definition of Terms Amperage Amperage

of electrons

in

quantity of oil flowing

equal to the voltage

resistance

at 120 volts and will have an internal resistance of

ohms. 120 volts

Definition

Resistance

letter omega as a symbol. Resistance is that value that opposes the flow of electric current. Think of

resistance as a restriction

is equal to the voltage

amperage in the circuit.

at 120 volts with a current flow of 1.25 amperes. 120 volts

+

in

amperes. Think of amperage as being similar to the

1.25 amperes

a unit of electrical pressure and is

in

volts. Think of voltage as being similar to

a circuit is equal to the current in the circuit

96

(ohms) of resistance and a current flow

X

96

ohms = 120 volts.

(I)

is a measure of electric current or the flow

in

a circuit. Electric current flow is measured

in

a hydraulic hose. Amperage is

in

the circuit divided by the

in

the circuit. A 150 watt light bulb will operate

96

+

96

ohms = 1.25 amperes.

of

Terms Resistance

(R)

is measured in ohms and uses the greek

in

a hydraulic hose. Resistance

in

the circuit divided by the

A

150 watt light bulb will operate

=

96

ohms of resistance.

to the maximum level, this is sometimes called "Pulsating

"

Direct Current

Definition of Terms Alternating Current Alternating'

equally above and below a alternating 'current we use

+

120 volts to a -120 volts

voltage is :actually reversing its direction above and

below a

. See Figure 128.

I

current

0

reference line. See Figure 129.

(AC) has a voltage level that will vary

0

reference line. The

in

our homes will vary from a

60

times each second. The

Definition of Terms Wattage

Wattage (P) is a measure of electric power or work that

is being done. Power is measured

equal to the voltage

in

amperage volt source with a current of 1.25 amperes flowing

through

is given

amperes

Definition of Terms Direct Current

Direct current (DC) has a voltage level that may vary

intensity but will not drop below a 0 reference line.

battery may gradually lose

level will always be above the

produce direct current that is very stable and will vary

only as the charge decreases. Generators and rectifiers

produce direct current that may vary

the circuit. A light bulb connected to a 120

it

will dissipate 150 watts of power. The power

off

in

the form of heat and light. 120 volts X 1.25

=

150 watts.

in

the circuit multiplied by the

its

in

watts. Wattage is

charge but the voltage

0

reference line. Batteries

in

intensity from 0

in

A

Figure 129

Definition of Terms Frequency

its

Alternating' current will reverse frequency controlled by the speed of the engine. When

is

the engine

minute or revolutions per second), the frequency of

the alternating current will be

Hz).

The sp'eed of all Tor0 generators is governed at 3600

RPM.

Definition

An automatic voltage regulator (AVR) will control the

output of generator the voltage tends to drop; the

this and will increase the amount of DC current being

64

running at 3600 RPM (3600 revolutions per

60

of

Terms Automatic Voltage Regulator

a

generator. When a load is applied to

direction at a

cycles per second

AVR

(60

the

will sense

Definition of Terms Automatic Voltage Regulator (cont'd)

sent to the rotor to produce the magnetic field in the generator. The output of the generator will in turn

increase.

voltage will tend to increase; the

by decreasing the size of the field. The

voltage to within 10% of the rated voltage.

If

a heavy load is removed from a generator the

AVR

will respond to this

AVR

will hold the

Definition of Terms Diode

A

diode is an electronic component that allows electric

current :to pass only in one direction.

Definition of Terms Rectifier

A

rectifier

diodes and is used to change alternating current to direct

current

is an electronic device made of one or more

Definition of Terms Field

The word field refers to the magnetic field produced in the rotor. The magnetic field will spin with the rotor to

generate electricity in the stator. The size of the field is controlled by the the output of the generator.

Definition of Terms Rotor

The rotor is a single coil of wire wrapped on a laminated

steel core. During operation the rotor becomes an

electromagnet and produces the field that causes

electricity to the engine crankshaft and spins at the same speed as the engine. Two small permanent magnets are bonded to the rotor core to get the generating process started.

Definition of Terms Slip Rings The slip rings (two) are an integral part of the rotor. One

ring is attached to each end of the rotor coil.

the slip rings and the brushes that the exciter coil and

AVR

Definition of Terms Brushes

The brushes are made of carbon and connected to the

AVR.

connector between the

to

provide electricity to the rotor.

The brushes ride on the slip rings and act as the

AVR

and the

be produced in the stator. The rotor is bolted

AVR

will in turn regulate

and the rotor.

It

is through

Definition of Terms Induction Electricity is produced when a magnetic field moves

across

GENERATOR

Generator Operation Exciter Coil and Permanent Magnet

In moving field produced and the the en

it

across

process

a

conductor (wire), this is called induction.

OPERATION

its

will

simplest

n

I

form, a generator is a permanent magnet close to a fixed coil of wire. When the magnetic moves across the wires in the coil a voltage is

xi.

The exciter coil is part of the stator assembly permanent magnets are fixed to the rotor. When ne is started, the rotor with the magnets fixed to begin to spin. The field of the magnets will move

the

wires of the exciter coil and the generating

will begin. See Figure 130 and 131.

Starts

Exciter

Generating Process

Coil

Definition of Terms Stator

The stator is made of three separate coils of wire wrapped on an laminated steel core:

Main coil The main coil provides 120 volts

1. direct to the generator outlet.

-

Exciter coil

2. to the and sent to the rotor to create the field.

DC

3.

coil -The that provides changed to approximately

rectifier is connected directly to the on the generator.

The exciter coil provides

AVR

where it is rectified into

DC

coil. is a separate coil in the stator

AC

electricity to a rectifier where

14

AC

DC

volts

DC

AC

electricity electricity

it

is

DC.

The

terminals

Produces

Generator

Electricity from the exciter coil is sent to the

it

to form an electromagnet. The of the magnetic field based on how much electricity the

generator is being asked to produce.

tor Operation

is rectified (changed to

Low

Figure 130

AVR

and Rotor Coil

DC)

and

AVR

Voltage

-

AVR where

is

then sent to the rotor

will control the size

See

Figure 132.

65

Generator Operation AVR and Rotor Coil (cont'd)

5.

The

AVR

sends all or part of the electricity

produced in the exciter coil through the brushes to

it

the rotor.

out put voltage through two sensor circuit wires.)

6.

The rotor spins inside the stator coil which

produces the output voltage.

-

--si.-.

decides how much by measuring the

-

AVR

Regulates

Voltage

to

Rotor

Figure

131

AVR

Regulates Voltage to Rotor

Figure

Generator Operation Automatic Voltage Regulator

The automatic voltage regulator

like the governor on a small engine.

voltage very' close to the required

compensates for varying loads.

The

AVR

i

It regulates the low voltage going into the rotor. In doing

so

the rotor and in turn controls the output voltage. The

decides how much voltage to send to the rotor by

Generator Operation Stator Coil and Receptacles

I

The magnetic field surrounding the rotor (which is now an electromagnet) will move across the wires of the stator coil and will induce rotor is constant electricity produced will be controlled by the size of the magnetic field. The stator coil is connected to the electrical outlets that let the generated. See Figure

of

AVR

AC

electricity. The speed of the

so

any variation in the amount of

the generator and to two sensor wires

know how much voltage is being

133.

sampling the output voltage through the sensor wires shown in the pictorial diagram in Figure

is piaced between the exciter coil and the rotor.

it

controls the size

of

133

(AVR)

functions much

It

keeps the output

120

(or

240)

volts and

the electromagnetic field around

AVR

133.

i

Generator Operation Generating Process

1.

The engine turns the crankshaft.

2.

The crankshaft turns the rotor which houses the exciter magnets.

3.

The exciter magnets rotate past the exciter coil to

start the generation process.

4.

The exciter coil initially produces about 6 volts and

sends it to the automatic voltage regulator,

(AVR).

Figure

During operation the ends of the exciter coil

alternate positive

60Hz.

66

(+)

!

and negative

134

(E.C.)

(-)

at a frequency

will

of

Generator Operation Automatic Voltage Regulator (cont'd)

Refer to Figure 134 for the following description of the

AVR.

To begin, assume that the end of the exciter coil

labeled

will occur:

1.

2.

3.

4.

5.

6.

"A”

is positive. The following sequence of events

Diode D3 will be forward biased. The arrowhead end (anode) is positive (connected to the positive end of the exciter coil) and the diode will conduct.

it

Diode Dl will not conduct as The flat end of the exciter coil. SCR will not conduct until

it

Current will flow through D3 and

SCR1. With current at

conduct because

Current will not flow through D4, R2 or SCR2

because they are reverse biased; (their anode

ends are connected to the negative end of the

exciter coil). Initially current will not flow through the transistor (Tr) as the proper base current.

When SCRl turns on

resistance path for current to flow from the positive

end of the exciter coil to the field coil (rotor) where

it

end

(cathode) is connected to the positive

has the proper voltage at its gate.

its

gate SCRl will turn on and

it

is also forward biased.

it

has not been turned on with

will build an electromagnetic field.

is reverse biased.

R1

to the gate of

it

provides a very low

(ZD),

the zener diode will allow current to flow to

the base (b) of the transistor (Tr).

of

4. The current at the base "on"

the transistor almost no resistance from point

5.

Electricity from R1 and R2 that would normally be used to turn on SCRl and SCR2 is now diverted

through the transistor and the

"

off'

mode. Electricity will not flow from the anode

to cathode

6.

The amount of current flowing through the transistor

coil, creating an insignificant magnetic field and

then back to the exciter coil.

I

7.

When the output voltage of the main coil drops the

zener diode will turn base of the transistor. The SCR's will turn on and full current flow will return to the field coil.

GENERATOR

CAUTION: The following tests will be

is

TESTING

death. Never touch any part

or

uninsulated terminals

and will allow current to flow with

of

the SCR.

very small and flows through the field

completed with the generator running. The electricity this generator produces can cause

the transistor will turn

E

to point F.

SCR'S

off

and block current to the

of

your body to exposed

or

wiring.

remain in the

Return current can now flow from the field coil

7. (rotor) through diode D2 direction because negative end of the Exciter coil.

When the

8.

becomes positive, diode D4 and SCR2 will become forward biased. and SCR2 will occur. arrangement of Dl, D2, SCRl and SCR2 form a full wave bridge rectifier and will send DC electricity to the field coil.

The amount of current that

controlled by the transistor (Tr) and zener diode (ZD).

The control circuit operates as follows:

1. Two sensor wires are connected to the main coil (MC) to monitor the output voltage of the

generator.

2. The electricity from the sensor wires is changed to DC by the full wave bridge rectifier

3. The electricity from the rectifier (D) Rows to a

voltage divider network made and R4. When the voltage at the connecting point

(C) reaches the breakdown level of the zener diode

it

is forward biased), back to the

end

of the exciter coil labeled

A

repeat of steps 1-7 using D4, R2

(it

will conduct in this

It

is important to note that the

is

sent to the field coil

(D).

up

of

resistors

"B”

is

R3

Generator

Testing Color Code

P

G Green

R

B Black

W Y

BI Blue Br Brown Or .Orange Ltbl .Light Blue Ltg Light Green Ltg/R Light Green with Red Tracer

W/R .White with Red Tracer

R/B

Y/G Yellow with Green Tracer

R/W

W/B .White with Black Tracer

G/W

BI/R .Blue with Tracer Bl/W Blue with White Tracer G/R Green with Red Tracer Br/Y Brown with Yellow Tracer

G/Y

Red with Black Tracer

Red

with White Tracer

Green with White Tracer

Green with Yellow Tracer

Pink

.Red

White

.Yellow

67

Generator Testing Measuring AC Voltage

of

1. Check the oil in the engine

the generator. terminal block. On dual voltage models that have

4.

Place your multimeter on the

measure the stator resistance through the AC

R

X

1 scale and

2. Unplug any appliances that may be connected to three, terminals measure between the terminals the generator.

3. Start the generator.

4.

Place a multimeter on the 250 volt AC scale.

5.

Insert the probes in the AC outlet and measure the

voltage. The unloaded output voltage should be

120 volts 10%. See Figure 135.

AC

Scale:

250V

with the red and blue wires.

I

Scale:

DC

25V

I

Figure 136

5.

The stator coils should have the following

+

I'

resistance value

T1200

or 20%

I

J

Stator coil resistance

Figure 135

Ti800

Generator Testing Measuring DC voltage

1. Check the oil in the engine

2. Unplug any appliances that may be connected to the generator.

4.

Set your multimeter on the 25 VDC scale.

5.

Connect the probes to the DC terminals on the

I

generator, plus to plus and minus to minus, (red to red and black to black). The unloaded DC voltage should be approximately 14 VDC.

amps) the voltage may drop as

Figure 136.

Generator Testing Measuring Stator Coil Resistance

1. Stop the generator and pull the spark plug wire the spark plug.

of

the generator.

At full

low

as 1 1 volts.

T2500

I

T2500,D

load (8.3

See

off

1.733 ohms

Stator coil resistance

1.05 ohms

Stator coil resistance

0.5

ohms

Stator coil resistance

1.86 ohms

I

2. Remove the two screws retaining the generator end cover.

3. Disconnect the main

the control panel.

AC

output wires that lead to

68

Generator Testing Measuring Stator Coil Resistance (cont’d)

The resistance values measured will be very low

and the accuracy of some meters may not indicate

It

10th’s of an ohm.

the main values that we are looking for are short

(0

circuits resistance).

resistance) or open circuits (infinite

is important to remember that

T1800

T2500

Rotor coil resistance

51.5

ohms

Rotor coil resistance

68.8 ohms

Generator Testing Measuring Rotor Coil Resistance

1. Stop the generator and pull the spark plug wire the spark plug.

2. Remove the the generator.

3.

Remove the wires connected to the brushes.

4. The resistance measurement will be taken at the

brush holder.

5.

Disconnect the wires connected to the brush holder.

6. Place your multimeter on the

measure the resistance of the rotor through the brushes. See Figure 137.

two

screws retaining the end cover of

R

X

1 scale and

Scale:

R

x

off

10

T2500D

-

T3000

I

Rotor coil resistance

68.8 ohms

Rotor coil resistance

74.5 ohms

--_

I

_

T3000D

Rotor coil resistance

74.5

ohms

NOTE

low indicate 10th’s of an ohm. remember that the values we are looking for are short circuits

than 20% below the standard resistance) or open

circuits (infinite resistance).

The resistance values measured will be

and the accuracy of some meters may not

It

is

important to

(0

ohms or a value that deviates more

I

Figure 137

7. The rotor coil should have the following resistance

+

or

20%.

T1200

Rotor coil resistance

46.1 ohms

If

the measurement is more than standard resistance the brushes should be removed and the meter probes applied directly to

the slip rings. The brushes should not add more than a fraction of one ohm of resistance to the rotor

If

circuit. when measured at the slip rings it indicates that

there is a problem with the brushes or brush

Generator Testing Measuring Exciter

Resistance

1. Stop the generator and remove the spark plug wire.

2. Remove the the; generator.

3. Disconnect the four prong connector at the

4. Measure the exciter coil resistance at the the end of the wire connector that leads to the generator wiring harness. See Figure 138.

the resistancevalue of the rotor is normal

to

the

slip rings. contact

two

screws retaining the end cover of

20%

Coil

above the

AVR.

69

Generator Testing Measuring Exciter Coil

Resistance (cont'd)

Scale:

Figure 138

5.

The exciter coil should have the following

+

resistance the terminals connected to the color coded wires indicated in the chart below. See color code chart on page

or 20%. Take your measurement at

67.

R

x

1

T3000D

Exciter coil resistance and wire color

2.10 ohms

The resistance values measured will be very low and the accuracy of some meters may not indicate

10th’s of an ohm.

the main things we are looking for are short

circuits resistance). An open circuit or short circuit will require replacement

Generator Testing Sensor Circuit Continuity

The sensor of the generator to determine how much voltage the should send from the exciter coil to the rotor coil. The

sensor circuit is wired in parallel with the main AC output

wires. The continuity measurement is taken at the four

pin connector from the harness that connects to the

Two of the terminals connect to the exciter coil, the other

two

connect to the sensor circuit.

The resistance measurement will be from 2 ohms on the T1200 and T1800 to over 13,000 ohms on the T3000. The

most likely failure will be an open circuit that will measure infinite resistance.

(0

i

circuit

I

It

is important to remember that

resistance) or open circuits (infinite

of

the stator.

continuously monitors the AC output

BI & BI

AVR

AVR.

T1200

T1800

T2500

T2500D

T3000

Exciter coil resistance and wire color

Generator /Testing DC Circuit Diodes

Tor0 generators use a center tapped coil with to accomplish full wave rectification for DC output. Generators with a serial number that starts with

part of the AC coil for DC output, and all other units use a separate DC coil. The cathode ends of the diodes are wired together for form the positive output terminal. The anode ends are connected to opposite ends of the coil with the center tap forming the negative output terminal. Tor0 generators use both single piece molded diode assemblies and dual piece assemblies with

diodes bonded to a common plate. When testing the

diodes of either assembly the diodes must be

disconnected from the circuit.

Disconnect the diodes from the generator wiring.

1.

Check the continuity of each individual diode. The

2. diode should one direction and block the flow of current in the oppositedirection. If a diode blocks current in both directions or allows current to flow in both directions the diode is bad and the entire diode assembly will have to be replaced.

pass

current with low resistance in

two

diodes

"3"

use

separate

Exciter coil resistance and wire color

BI

70

If

3.

a diode result by current flow back through the DC coil and the diode you don't intend to test. The diode you

is

tested

in

circuit, a false reading may

Generator Testing DC Circuit Diodes (cont'd)

are attempting to check may actually have an open

circuit that would not bediscovered because of the parallel wiring that exists with these diodes.

Generator Testing Brush Inspection

1.

Stop the generator and pull the spark plug wire

off

the spark plug.

2.

Remove the

two

screws retaining the generator

end cover.

3. Remove the brush holder.

4. Use a caliper or other measuring device to determine the length of the brushes. See Figure

139. Brush length limit

3.5 mm (.138')

Figure 140

Figure 139

GENERATOR SERVICE

Generator Service Disassembly

Turn the engine

1. Turn the fuel shut

2. Remove the end cover of the generator. See Figure

3.

off

and remove the spark plug wire.

off

valve to the

"off”

140.

4.

Disconnect and remove the

AC

output wires at the

terminal block. See Figure 141.

Disconnect the control wiring plug on the top of

5.

the

generator assembly.

6.

Continue disassembly

by

removing the brush

holder. See Figure 142.

position.

i

Figure 141

Figure

7.

Remove the generator rear right

8.

Remove the four generator through bolts. See

two

nuts securing the rear frame of the

to

the tube frame shock mounts. The

-

hand nut also retains the muffler bracket.

Figure 143.

142

71

Generator Service Disassembly (cont'd)

Figure 143

9. Use a plastic hammer to remove the end cover and stator assembly.

IMPORTANT:

when setting the stator aside do not

place the stator on its coil ends, this may damage the windings. Allow the stator to rest on its laminations only. See Figure 144.

Figure 144

Remove the recoil starter.

10. Hold the crankshaft in place with a screw driver or

11. bar through the recoil starter cup and remove the rotor set bolt. See Figure 145.

13. Inspect the individual generator components for obvious defects or failures. Inspect the integrity of all insulation and connections. Protect the rotor and stator coils from damage while the generator is disassembled

Generator Service Reassembly

1.

Inspect the rotor assembly for defects; broken

wires,' worn or damaged slip rings, damaged

insulation.

2.

Install the rotor assembly. Some units

use

a key or pin to, align the rotor to the crankshaft. Make sure the tapers are clean and that the rotor and crankshaft line up correctly.

12.

Use a rotor remover bolt (see the Special Section, page 19, for the correct part number) to remove the rotor assembly. The rotor is secured to

the crankshaft of the engine with a tapered

crankshaft has an external taper and the rotor has an internal taper. See Figure 146.

Generator disassembly is now complete.

fit.

Tool

The

72

2.2 kg m

3.

Inspect the stator assembly for defects. Check for

(16

ft

Ibs)

broken wires, bad insulation, broken wire ties etc.

4.

Remove

the

brush holder

if

it

is still installed on the

stator.

Generator Service Reassembly (cont'd)

5.

Align

the through bolt holes with the holes

front generator cover .(the cover bolted to the

engine) and install the stator. Take extreme care not to damage any

of

the coils in the stator. See

Figure 147.

in

the

7. The brush holder may be reinstalled at this time. the wires have been disconnected from the holder

make certain that the polarity is correct. The brush

+

wire with the collar that is marked

must

connected to the positive brush terminal.

8. Reconnect

the

AC output wires on the terminal block. Be sure to match the color coding. See Figure 149.

If

be

6.

Tighten the through bolts shown

in

Figure 148.

Figure 147

in

the sequence as

Through bolt torque

kg m (7 ft

1.0

lbs)

Figure 149

Reconnect the lead wire from the control panel to

9.

the

connector on the top

10.

If ,the diode assembly has been disconnected

of

the generator.

should be reinstalled at this time. On some units

the assembly is soldered in place, others use

connectors There are three wires connected to each diode assembly,

two

that supply AC power

to the diodes and one positive output wire. The

negative output wire comes directly from the

center tap of the winding that supplies power for the DC circuit. The positive output wire is white on T1200 through T2500 and pink on the T3000. The

remaining

two

wires are connected to the anode

(positive) ends of the diodes. See Figure 150.

Diode Wire Colors

Br

&

Br

T3000 R&W/R

11.

I

Reconnect the four pin connector to the

it

AVR.

Figure 148

73

12.

Make sure all wires are clamped in place and

reinstall the end cover

Remount the generator to the shock mounts.

13.

of

the generator.

Secure the muffler bracket to the right

mount.

-

hand shock

Generator Service Reassembly (cont'd)

Figure 150

i

Check the resistance of the rotor. See Generator

6. Testing, page 69 for the correct procedure and

resistance value. specification, high or low, replace the rotor. resistance is within specification go to step

7.

Check the resistance of the stator main coil. See Generator Testing, page 68 for the correct procedure and resistance value. is out/ stator; step

8.

Check the resistance of the exciter coil. See Generator Testing, page 69 for the correct

procedure and resistance value.

is out' of specification, high or low, replace the stator.: step 9.

of

specification, high or low, replace the

If

the resistance is within specification go to

8,.

If

the resistance is within specification go to

If

the resistance is out of

If

the resistance

If

the resistance

If

the

7.

TROUBLESHOOTING

it

When troubleshooting, remember to keep

look for the most obvious cause for a failure. Most generator troubleshooting is very straight forward and most failures are easy to detect.

To use this troubleshooting guide, look for the failure description that matches the failure you have encountered and follow the outlined steps.

Troubleshooting No AC Output

Verify 3600 RPM engine speed.

1. Check voltmeter on the generator panel.

2.

-

indicating 120

0

volts, go to step 4.

Verify the operation of the circuit breaker. The

3. meter is wired to the unswitched side of the circuit breaker and will indicate voltage open or failed. See Control Panel Inspection on

77

page breakers.

Remove the end cover of the generator and

4.

measure the AC voltage at the terminal block. If the meter indicates is normal, 120 VAC (single voltage units), 240 VAC (dual voltage units), repair the wiring between the

terminal block and control panel.

Check the contact of the brushes with the slip rings

5.

on the rotor. The brushes should be of the

appropriate length (minimum 3.5 mm, .138

brushes are short or not making contact replace

the brush assembly. If the brushes are making

contact go to step 6.

240 volts, go to step 3.

for information on testing the circuit

0

volts, go to step

(0

simple and

volts AC)

If

it

indicates

if

the breaker is

5.

If

the voltage

If

it

'I).

If

the

is

9.

10. Measure the AC output voltage.

Troubleshooting Low AC Output An output

magnets on' the rotor are functioning. It also indicates

that the following components are operating:

.

the

Flash generator and connect the 12 volt battery to the brush' terminals connection will damage the brushes are connected to the automatic voltage regulator (AVR) during this test.

within' specification leave the generator running

and disconnect the battery.

within :specification

magnets on the rotor were demagnetized. Flashing the field should restore the magnetism. on restarting the generator after flashing the field the voltage again is at brush, connections are reversed at the brushes. Check the sections and

with disconnection of the battery, replace the

The wiring to the receptacle is The receptacle is The circuit breaker

The main stator coil has continuity.

field with a 12 volt battery. Start the

+

to + and to Reverse

AVR.

Make sure the

CAUTION: There is exposed wiring that contains potentially lethal voltage

exposed terminals.

8b

for correct wiring. If the voltage falls to

of

3-6 volts indicates that the permanent

Do

not touch any

If

the voltage is

If

the voltage stays

it

indicates that the permanent

0

it

may indicate that the

on

Schematics, pages

(3-6

volts)

OK.

is

allowing current to flow.

of

78,

AVR.

the

79

If

0

74

Troubleshooting

Low

AC Output

(3-6

volts)

(cont'd)

1. Verify 3600 RPM engine speed.

2. Check the contact of the brushes with the slip rings on the rotor. The brushes should be of the

appropriate length (minimum 3.5 mm, .138

"

). If the

brushes are short or not making contact replace

the brush assembly.

If

the brushes are making

contact go to step 3.

3. Check the resistance of the rotor. Inspection on page

69

for the correct procedure

See

Generator

and resistance value. If the resistance is out of specification, high or low, replace the rotor. resistance is within specification go to step

4.

Check the exciter coil resistance. See Generator

69

Inspection on page and resistance value.

for the correct procedure

If

the resistance is specification, high or low, replace the stator. resistance is within specification go to step

5.

Replace the automatic voltage regulator (AVR).

If

4.

out

If

5.

the

of

the

T1200 and

T1800

this is done at terminal S2 of the four pin connector coming from the stator coil

See

Figure 151.

PLUG

I

!

I

FROM

HARNESS

Figure 151

4.

Sensor circuit continuity on

is measured at

S1

and S2 as shown in Figure 152.

the

T2500 and T3000

S1

and

Troubleshooting High AC Output (over

132

volts

AC)

+

The no load AC voltage should be 120 volts

or 10%.

CAUTION: High voltage may cause

in

damage and/or fires

connected

appliances.

High AC output indicates too much voltage being sent to the field (rotor). The

AVR

determines how much voltage to send from the exciter coil to the rotor by continuously sampling the AC output voltage through

two

sensor circuit wires.

open, the

AVR

will interpret this as a low AC output

If

this circuit is damaged or

voltage situation and will respond by sending maximum exciter voltage to the rotor. High output voltage also

indicates that the following components are operating or

functional:

The stator coil has continuity. The exciter coil has continuity. The permanent magnets are The receptacle and wiring to the receptacle is The AC circuit breaker

is

OK.

OK. The rotor coil has continuity. The brushes are contacting the slip rings.

1.

Verify

3600 RPM engine speed.

i

5.

Refer to the Generator Testing section on page

for a complete description

Figure 152

of

sensor circuit testing

procedures.

6.

If

the circuit is open (infinite resistance) the stator

coil

must be replaced.

7.

if

the sensor circuit has continuity and the high

voltage situation remains, replace the

Troubleshooting No DC Output

1.

Verify 3600 RPM engine speed.

2.

verify AC output. step three. steps in the

3.

Check the DC circuit breaker.

the

cause of the overload in the circuit wired to the

If

the AC output is normal go to

If

the AC output is 0 volts, follow the

No

AC Output Procedure, page

(0

volts DC)

If

it has tripped, find

DC output terminals and reset the breaker.

4.

Check the continuity of the DC coil. Place your multimeter in the the anode end of the

R

X

1

mode and test continuity at

two

diodes (this will be where the wires from the DC winding are connected). there is no continuity the stator coil must be

If

replaced

there is continuity go to step

70

AVR.

74.

If

5.

Stop the generator and remove the end cover.

2.

Disconnect the four pin connector at the

3. Check the sensor circuit for continuity. On the

AVR.

75

5.

Check the function of the diodes. testing DC Circuit Diodes, page

See

70.

diodes have an open circuit, replace the diode assembly.

Generator

If

one or both

Troubleshooting Engine Labors Heavily The generator will start and run but will not carry the load,

the engine labors heavily.

1. Verify

2. Verify the current demand or power consumption

3.

4.

3600

RPM no load engine speed.

of the load. Make sure the generator is not being overloaded. Inductive loads such as motors may require get them started. H.P. get with the length and condition of the extension cord will also be important factors in the ability of a generator to start and run a load.

Verify the condition of the engine. An engine with long hours enough horse power to power a load that have easily run when new.

Verify the condition of the muffler. spark arrestor is clogged with carbon, the engine may not be able to exhaust efficiently which will result in reduced output.

3

to 4 times normal running power just to

A

one H.P. induction motor (one

=

750

watts) may require

it

started. The condition of the appliance, along

of

use and wear may not be developing

3000

watts just to

If

the muffler or

it

may

receptacles and one 240 volt receptacle. Full power available on these generators at 240 volts but because the main winding is center tapped

only half the total power is available to each 120 volt outlet, e.g., a T3000D would provide only 1500 watts per 120 volt

3000

receptacle and

2.

In 1985 we introduce dual voltage generators that were equipped with a fourth receptacle that would

provide full power at 120 volts. This is accomplished without switching or paralleling the windings. There is actually a bifilar winding on one

of the; 120 main coil halves that supplies this

receptacle.

as

time

is not exceeded

Troubleshooting Can same time?,

1. On 19& and 1984 generators the DC winding was part of the AC winding and use of both AC and DC

at the same time could lead to overheating.

All

long as the total capacity of the generator

watts at 240 volts.

outlets may be used at the same

I

use DC and AC at the

of

1983-1984 design

Troubleshooting Low Output Power On Dual Voltage Generators

1. Dual voltage generators that were built in 1983 and 1984 were equipped with

two

15 amp 120 volt

2. 1985 and newer product use a DC winding that is separate from the AC winding and on these units

it

is possible to use both AC and DC at the same time. The DC circuit will consume about 100 watts when fully loaded.

76

SECTION

Control Panel Disassembly

1.

Turn the engine the spark plug.

2.

Turn

the

fuel shut

3.

On generators with a serial number starting with

"3”

the control panel is secured to the fuel tank with

four screws and secured to the front frame rail with

two

hair pin clips. Remove the two clips and then remove the four screws. The back of the control panel may now be exposed.

4.

On generators with a serial number starting with

"4"

and above, it is necessary to remove only the six screws that retain the front panel to the control panel body.

5.

With the panel pulled open, the engine "on-off switch, receptacles and circuit breakers are visible.

6.

The low oil level shut down module is mounted

inside the control panel and is secured with one screw,

7.

See the Schematic Diagrams on pages

80

components.

it

may also be removed

to verify correct wiring of the control panel

off

and pull the spark plug wire

off

valve to the

"

off

"

if

necessary.

8

position.

78,79

CONTROL PANEL

5.

The engine ignition switch is a single pole, single

off

"

and

throw switch that may be tested by disconnecting

it

'from the circuit and checking the opening and

closing of the contacts with a multimeter in the

X~

I

mode.

6.

The receptacles are friction and twist lock connection devices. There are no moving parts and are not subject to failure uless they are mechanically damaged. The receptacles should be tested by disconnecting them from the circuit and checking for shorts and continuity with a test light or multimeter.

7.

The volt meter in the panel is connected in parallel with the AC output circuit of the generator.

meter is not functioning, verify the AC output voltage with an external AC volt meter. voltage is normal and the meter is not indicating, verify its connections and replace the meter

necessary.

8.

The DC output terminals should be fully insulated from the front panel. Verify the the integrity of the

insulation with a multimeter in the connected alternately, to each terminal and

ground. There should be infinite resistance.

R

X

If

the AC

1

mode

R

If

the

if

Control Panel Inspection

1.

It

is not necessary to remove individual components from the control panel for inspection and testing. Failure of most of the panel components will be obvious without disassembly of the panel.

2.

The operation of the circuit breakers may be verified with always disconnect a component from the circuit when making a continuity or resistance check. This will eliminate the possibility of any other portion of the wiring causing a false reading.

3.

Place your multimeter in the

the continuity of the AC circuit breaker (breakers)

"on"

in the

does not open and close under manual operation

of the switch arm, the breaker must be replaced.

4.

The DC breaker is a thermally activated device and

it

is not possible to manually open its contacts. The

breaker should open the circuit under a load of

amps DC.

operating properly, connect a DC ammeter in the series with the load in the DC circuit connected to

the generator and measure the current to

point at which the circuit breaker trips.

a

multimeter.

and

"off”

position.

If

the breaker does not appear to be

It

is a good habit to

R

X

1

mode and check

If

the circuit breaker

verify

8.3

the

NOTE: This test, as with other continuity tests, should be completed with the wires disconnected

from the terminals.

9.

The

low oil level warning lamp may be tested by unplugging its connectors and checking the resistance of the lamp.

18

approximately

indicated the filament in the lamp is open and the lamp must be replaced.

Controi Panel Reassembly

1.

Remount any component that may have been re:moved from the panel.

2.

Reconnect all panel components per the Schematic Diagrams shown on pages

80

3.

Reinstall the low oil level shutdown module. Make sure the module is securely grounded.

4.

Remount the control panel with four or six screws

as required.

5.

On

1983

models (serial number starts with a install the panel to the front frame rail. That completes reassembly.

two

ohms.

hair pin clips retaining the control

It

should measure

If

a reading of infinity is

78,79

and

"3"

)

77

J

I

78

f

SECTION

9

SCHEM

A

TICS

J

a

W

r

Toro 62012, 62018, 62025, 62030, 62027 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual