LONCIN HomeSite Power LC5000-AS Service Manual Download Page 27

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SECTION 4. DISASSEMBLY AND SERVICE

- 22 -

4-3 Disassembly Chart

This chart is a quick-reference guide for
disassembling the product. Be sure to follow
the sequence shown here for better and safer
work.

Example:To remove the frame.
a) Remove

the

end

cover.

b) Remove

the

control

box.

c) Remove the fuel tank
d) Remove

the

muffler

e) Remove

the

frame

GENERATOR DISASSEMBLY

FUEL TANK

MUFFLER

END COVER

CONTROL BOX

AVR

BRUSH

STATOR

ROTOR

MOUNT RUBBER

FRAME

ENGINE

REAR HOUSING

AIR CLEANER

CARBURETOR

RECOIL STARTER

FAN COVER

FLYWHEEL

STARTER MOTOR

Summary of Contents for HomeSite Power LC5000-AS

Page 1: ...Service Manual HomeSite Power LC5000 AS LC5000D AS LC6500 AS LC6500D AS LC8000 AS LC8000D AS Portable Generator Set Loncin Motor Co LTD...

Page 2: ...parks caused by fuel flowing through a service station pump nozzle can ignite gasoline Never fill the generator set with a service station pump nozzle Instead fill a safety tank sitting on the ground...

Page 3: ...cies as causing cancer or reproductive toxicity Do not ingest inhale or contact gasoline Used engine oils have been identified by some state and federal agencies as causing cancer or reproductive toxi...

Page 4: ...ngine Oil 10 3 3 Air Cleaner 11 3 4 Fuel Sediment Cup Cleaning 12 3 5 Spark Arrester 12 3 6 Spark Plug 13 3 7 Valve Clearance 14 3 8 Governor 14 SECTION 4 DISASSEMBLY AND SERVICE 4 1 Troubleshooting 1...

Page 5: ...4 4 2 Flywheel Starter Motor 29 4 4 3 Cylinder head Valves 33 4 4 4 Recoil Starter Fan Cover 37 4 4 5 Air Cleaner 40 4 4 6 Carburetor 41 4 5 Generator 42 4 5 1 Fuel Tank 42 4 5 2 Muffler 43 4 5 3 Gen...

Page 6: ...ents FIGURE 1 5000 6500 8000AS COMPONENT LOCATIONS MUFFLER SPARK PLUG BOOT FUEL VALVE DC OUTPUT CHOKE LEVER AIR CLEANER STARTER GRIP FUEL GAUGE FUEL TANK CAP GROUND TERMINAL AC CIRCUIT BREAKER AC BREA...

Page 7: ...1L 0 29gal 1 1L 0 29gal Fuel tank capcity 25L 6 6gal 25L 6 6gal 25L 6 6gal Fuel consumption 374g Kw h Continuing time 9h 9h 8h Rated frequency 50 Hz 60 Hz Rated voltage 110V 115V 120V 220V 230V 240 V...

Page 8: ...95 mm 0 785 in Piston to piston pin bore clearance 0 002 0 014 mm 0 0001 0 0006 in 0 08 mm 0 003 in Piston rings Ring side clearance Top second oil 0 030 0 060 mm 0 0012 0 0024 in 0 15 mm 0 0006 in Ri...

Page 9: ...11mm 0 004 in EX 0 050 0 080 mm 0 0020 0 0031 in 0 13 mm 0 005 in Seat width 1 1 mm 0 04 in 2 0mm 0 08 in Spring free length 39 0 mm 1 54 in 37 5 mm 1 48 in Camshaft Cam height IN 32 40 32 80 mm 1 27...

Page 10: ...Piston to piston pin bore clearance 0 002 0 014 mm 0 0001 0 0006 in 0 08 mm 0 003 in Piston rings Ring side clearance Top second oil 0 030 0 060 mm 0 0012 0 0024 in 0 15 mm 0 0006 in Ring end gap Top...

Page 11: ...mm 0 004 in EX 0 050 0 080 mm 0 0020 0 0031 in 0 13 mm 0 005 in Seat width 1 1 mm 0 04 in 2 0mm 0 08 in Spring free length 39 0 mm 1 54 in 37 5 mm 1 48 in Camshaft Cam height IN 32 40 32 80 mm 1 276 1...

Page 12: ...fication Main winding Br W Resistance 0 50 0 61 Exciter winding Bu Bu Resistance 1 90 2 31 Field winding Resistance 47 88 58 52 DC winding G G Resistance 0 11 0 16 Carbon brush Brush length 5 9 mm Bat...

Page 13: ...ir cleaner mounting nut 6 1 0 mm 7 10 70 100 5 1 7 2 Muffler mounting bolt 8 1 25 mm 20 28 200 280 14 5 20 2 Oil drain bolt 12 1 5 mm 20 25 200 250 14 5 18 1 Fuel tank mounting bolt nut 6 1 0 mm 8 12...

Page 14: ...generator set can cause severe burns Always allow the generator set to cool before performing any maintenance or service TABLE 3 PERIODIC MAINTENANCE SCHEDULE 1 See GENERAL INSPECTIONS on OPREATOR S...

Page 15: ...e engine stopped 1 Remove the oil filler cap and wipe the dipstick clean 2 Check the oil level by inserting the dipstick into the filler neck without screwing it in 3 If the level is low add the recom...

Page 16: ...e air cleaner Rapid engine wear will result 1 Remove the cleaner cover by unsnapping the two spring clips Clean more often in dusty environments 2 Remove the two foam filter elements and thoroughly wa...

Page 17: ...is extremely flammable and is explosive Do not smoke or allow flames or sparks in the area After reassembly check for leaks and make sure the area is dry before starting the engine 3 5 Spark Arrester...

Page 18: ...rrect as necessary by carefully bending the side electrode The gap should be 0 70 0 80 mm 0 028 0 031 in 7 Check that the spark plug washer is in good condition and thread the spark plug in by hand to...

Page 19: ...nut 3 8 Governor 1 Take down the fuel tank 2 Loosen the nut on the governor arm pinch bolt 3 Move the arm until the throttle is completely open and hold it in that position 4 Rotate the governor arm s...

Page 20: ...YSTEM COMPRESSION SYSTEM SEE 3 3 SEE 4 4 6 SEE 3 4 ADD FUEL INTO FUEL TANK FUEL low FUEL FILTER clogged CARBURETOR out of adjustment AIR FILTER dirty OIL low SPARK PLUG GAP incorrect SPARK PLUG CAP fa...

Page 21: ...Low Power FUEL SYSTEM IGNITION SYSTEM COMPRESSION SYSTEM CARBURETOR out of adjustment FUEL FILTER clogged CHOKE ROD not open AIR FILTER dirty SPARK PLUG faulty CAMSHAFT worn CYLINDER PISTON PISTON RIN...

Page 22: ...SEE 3 8 REPLACE SPEED UNSTABLE FUEL SYSTEM GOVERNOR SYSTEM COMPRESSION SYSTEM FUEL low poor quality contaminated FUEL FILTER clogged CARBURETOR clogged GOVERNOR out of adjustment ANTI SURGE SPRING inc...

Page 23: ...UEL SYSTEM GOVERNOR SYSTEM CARBURETOR has water CHOKE LEVER not open AIR FILTER dirty GOVERNOR out of adjustment ANTI SURGE SPRING incorrect MUFFLER clogged ALTERNATOR temperature is too high OTHER SE...

Page 24: ...FRESH FUEL NORMAL WHEN STARTING REMOVE EXTRA LOAD SEE 4 4 6 SEE3 3 EXHAUST COLOR ABNORMAL BLACK WHITE CARBURETOR faulty LOAD excessive AIR FILTER dirty ENGINE temperature is too low FUEL contaminated...

Page 25: ...HECK IT AND ADJUST NO AC OUTPUT VOLTAGE STATOR MAIN COIL defective BRUSH defective ENGINE SPEED abnormal EXCITATION VOLTAGE too low AVR defective RESET BREAKERS BREAKER tripped REINSERT IT SEE 4 5 4 N...

Page 26: ...ons when working around electrical equipment Do not work alone if possible and take no risks Be prepared for an accident Keep fire extinguishers and safety equipment nearby Agencies such as the Red Cr...

Page 27: ...here for better and safer work Example To remove the frame a Remove the end cover b Remove the control box c Remove the fuel tank d Remove the muffler e Remove the frame GENERATOR DISASSEMBLY FUEL TAN...

Page 28: ...immediately before installing the camshaft REASSEMBLY Install with the oil dipper toward the camshaft and the ribs on the cap and connecting rod must be aligned REASSEMBLY Push in until the bearing to...

Page 29: ...e other end with long nosed pliers and rotating the clip in Do not align the end gap of the clip with the cut out in the piston pin bore PISTON PIN CLIP REASSEMBLY 1 Install all rings with the marking...

Page 30: ...de down The ohmmeter should read infinity resistance 3 Inspect the float by dipping the switch into a container of oil The ohmmeter reading should go from zero to infinty as the switch is lowered REAS...

Page 31: ...ory Specification Allowable limit 5000 6500 87 985 mm 3 4640 in 87 85 mm 3 459 in 8000 89 985 mm 3 543 in 89 85 mm 3 537 in PISTON TO CYLINDER CLEARANCE Factory Specification Allowable limit 0 015 0 0...

Page 32: ...imit 20 002 mm 0 7875 in 20 042 mm 0 7891 in PISTON TO PISTON PIN BORE CLEARANCE Factory Specification Allowable limit 0 002 0 014 mm 0 0001 0 0006 in 0 08 mm 0 0 003 in CONNECTING ROD SMALL END ID Fa...

Page 33: ...limit 0 1 0 7 mm 0 0040 028 in 1 1 mm 0 043 in CAMSHAFT CAM HEIGHT Factory Specification Allowable limit IN 32 40 32 80 mm 1 276 1 291 in 32 25 mm 1 270 in EX 31 89 32 29 mm 1 256 1 271 in 31 75 mm 1...

Page 34: ...MBLY After installing the flywheel check to be sure that the woodruff key is still in its slot on the crankshaft HIGH TENSION CORD REASSEMBLY Check for cracked or damaged insulation replace if necessa...

Page 35: ...over the pinion stop collar and drive the collar down exposing the snap ring DISASSEMBLY Check for smooth movement by rotating the pinion gear Check the gear teeth for wear or damage replace if necess...

Page 36: ...e of the secondary side of the coil by removing the spark plug cap and touching one test lead to the spark plug lead wire while touching the other test lead to the iron core Note A false reading will...

Page 37: ...charging coil STARTER SOLENOID 6500 model only Connect a 12 V battery between the starter terminal and the solenoid body and check for continuity between the terminals Continuity should exist when the...

Page 38: ...e compression of the cylinder head after reassembly TORQUE 32 38 N m 320 380 kg cm 23 1 28 5 ft lb ASSEMBLY DISASSEMBLY Tighten and un tighten using a cross pattern CYLINDER HEAD COVER GASKET CYLINDER...

Page 39: ...for wear and check the rod for straightness Be sure the rod ends are firmly seated in the lifter REASSEMBLY Do not interchange with the exhaust valve INTAKE VALVE REASSEMBLY Before installation remove...

Page 40: ...VALVE GUIDE ID NOTE Ream the valve guides to remove any carbon deposits before measuring Measure and record each valve guide I D Factory Specification Allowable limit 6 60 mm 0 260 in 6 66 mm 0 262 in...

Page 41: ...f the stem to guide clearance exceeds the allowable limit determine if the new guide with standard dimensions would bring the clearance within tolerance If so replace any guide as necessary and ream t...

Page 42: ...disassembling and assembling take care not to damage the fan blades COOLING FAN RECOIL STARTER ASSY REASSEMBLY Install with the starter grip position as shown DISASSEMBLY REASSEMBLY Remove and install...

Page 43: ...nstall with the starter grip position as shown REEL COVER REASSEMBLY Align the ratchet with the reel cover notch REASSEMBLY Install on the starter case after installing the return spring STARTER REEL...

Page 44: ...hole in the starter reel and tie the rope end Wind the rope onto the direction shown and wedge the rope end in the notch on the edge of the reel c With a short length of the rope extending from the s...

Page 45: ...REASSEMBLY Make sure to seat the gasket in the groove on the edge of the case all the way around properly REASSEMBLY Make sure the gasket is not damaged broken or bent Install correctly as shown BREA...

Page 46: ...y with compressed air before installation MAIN NOZZLE REASSEMBLY Clean thoroughly with compressed air before installation MAIN JET FLOAT VALVE REASSEMBLY Check for worn valve or weak spring before ins...

Page 47: ...ogged Check for fuel leakage after installation FUEL VALVE REASSEMBLY Wash to remove sediment and dry thoroughly before installation SEDIMENT CUP REASSEMBLY Make sure that the air vent hole is clean a...

Page 48: ...DISASSEMBLLY REASSEMBLY REASSEMBLY Install after removing the carbon deposits from the muffler using a plastic hammer MUFFLER REASSEMBLY Install after removing the carbon deposits from the exhaust pi...

Page 49: ...BLY 43 47 N m 430 470 kg cm 31 0 33 9 ft lb ROTOR BOLT DISASSEMBLY Remove the brush holder before the rotor and stator BRUSH HOLDER ASSY REASSEMBLY Tighten in crisscross pattern in 2 3 steps After tig...

Page 50: ...block and a shop rag under the rotor for support NOTE If torquing the rotor puller does not free the rotor from the crankshaft tap the end of the puller with a brass hammer to help loosen the rotor T...

Page 51: ...rush holder Visually inspect the slip rings for free dust rust or other damage If necessary wipe them with a clean lint free cloth If they are rusted or damaged remove the rotor and wipe with fine eme...

Page 52: ...e and Blue wires in the 4P coupler If the resistance is zero or infinity replace the stator DC WINDING Using an ohmmeter measure the resistance between the green wire leads at the DC diode connecter R...

Page 53: ...SECTION 4 DISASSEMBLY AND SERVICE 48 4 5 4 Control Panel a DISASSEMBLLY REASSEMBLY FUEL CUT OFF SOLENOID LEAD GENERATOR END COVER CONTROL PANEL ASSY PANEL FRONT COVER...

Page 54: ...SASSEMBLY AND SERVICE 49 WIRE HARNESS ASSY PANEL END COVER AC RECEPTACLE AC BREAKER RESET RECTIFIER BRIDGE DC BREAKER RESET AC BREAKER RESET START ON STOP SWITCH CONTROL PANEL 12 VOLT DC TERMINAL OUTP...

Page 55: ...SECTION 4 DISASSEMBLY AND SERVICE 50 Black Red AC OUTPUT TERMINAL STRIP AVR DC WINDING 2P COUPLER 1 Green White Red EXCITER WINDING 4P COUPLER 1 Blue 2 Light Blue 3 White GROUND CABLE...

Page 56: ...IG FS G OFF ON START Wire Position Black White White ST BAT OFF ON START When switch to OFF position IG is connecting to E and FS is connecting to G When switch to ON position L is connecting to L and...

Page 57: ...inals If there is no continuity the receptacle is defective and must be replaced FUSE TUBE Check the continuity between two terminals If failed replace the fuse tube RECTIFIER Test the continuity betw...

Page 58: ...Green Red White Use black test lead to measure Green Break Break Make Green Break Make Make Red Make Make Make White Break Break Break Note 1 Continuity refers to the diode s on state characteristic i...

Page 59: ...SECTION 5 WIRING DIAGRAMS 54 5 1 The Wiring Diagram of LC5000 AS LC6500 AS LC8000 AS...

Page 60: ...SECTION 5 WIRING DIAGRAMS 55 5 2 The Wiring Diagram of LC5000D AS LC6500D AS LC8000D AS...

Page 61: ...Ltd Add No 99 Hualong Road Jiulongpo District Chongqing China Tel 86 23 8906 7577 7599 Fax 86 23 8906 7533 99 86 23 8906 7577 7599 86 23 8906 7533 Web site www loncinengine com E Mail marketing loncin...

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