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Portable Electric Generator

Service Manual

Model: PPG6000

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Summary of Contents for PPG 6000

Page 1: ...Portable Electric Generator Service Manual Model PPG6000...

Page 2: ...6 Maintenance of Ignition System 16 17 2 7 Maintenance of Generator 18 20 2 8 Maintenance of Cylinder Head and Valve 20 24 2 9 Maintenance of Crankcase Crankshaft and Camshaft 25 28 2 10 Maintenance...

Page 3: ...e It is equipped with an electronic ignition system and is tuned to meet all EPA and California Emissions Requirements Figure 1 1 General Description 1 Gas Tank 2 Choke 3 Fuel Shut Off 4 Pull Starter...

Page 4: ...erate in a well lit and ventilated area 4 Do not operate in moist or wet conditions including the surrounding ground 5 The generator should be a minimum of 3 feet away from all combustible materials a...

Page 5: ...ke overhead valve cylinder tilt 25 Cylinder discharge capacity 389 cc Bore x Stroke 88x64 mm Cooling System Forced Air Cooling Ignition System Transistor Magnet Ignition Spark Plug NGK BP6ES Engine Oi...

Page 6: ...790 Large end diameter 36 025mm 1 418 36 070mm 1 420 Large end clearance 040 066mm 002 12mm 005 Large end flank clearance 1 7mm 019 1 0mm 039 Crankshaft Crankshaft pin outside diameter 35 985mm 1 416...

Page 7: ...7 5 66 Air filter nut M6X1 0 8 5 75 Drain plug M12X1 25 23 203 Rotor bolt M10X210 44 389 Standard Torque Values M5 5 44 M6 10 88 M8 24 212 M10 37 327 M12 55 487 M6 12 106 M8 26 230 M10 34 300 M12 59...

Page 8: ...ng Resistance 2 ohms Field Winding Resistance 52 62 ohms Exciter Winding Resistance 1 2 ohms Main Winding Resistance 4 ohms Carbon Brush length Length 9mm 354 5mm 197 EPA and Engine Serial Number are...

Page 9: ...hown below Check the condition of the starter Replace if damaged There is a spring inside the starter device that is under stress Wear safety goggles and watch for flying debris when it is removed Rem...

Page 10: ...smantle the starter pawl guide bolt with a socket 3 Remove the pawls and pawl spring 4 Visually inspect all parts 5 Inspect the flute of the starting draw wheel 6 Remove the shroud from the engine for...

Page 11: ...low better for a complete drain 2 Drain the oil from the cylinder block by removing the plug at the base of the engine 3 Check the condition of the dipstick and o ring seal 4 Replace the drain plug 5...

Page 12: ...g the six nuts around the perimeter 4 Remove the enclosure by removing the two nuts inside the enclosure and one on the backside 5 Remove the carburetor gasket and choke mechanism Some models may not...

Page 13: ...ntenance of Fuel System 1 Remove the bowl of the fuel cock 2 Remove the screen inside the fuel cock 3 Remove the fuel cock 4 Pull out the screen inside the tank 5 Clean or replace both screens and rea...

Page 14: ...or head to separate the muffler from the generator 5 Lift the muffler out of the frame and inspect for cracks 6 Inspect the spark arrestor mounted over the outlet of the muffler It should be clear of...

Page 15: ...e engine block 4 Remove the spark plug cap and unplug the other wires so the ignition coil can be removed 5 Using a multi meter capable of measuring resistance or an ohmmeter connect one end of the te...

Page 16: ...ction 1 1 of this manual 10 Remove the flywheel Use a screwdriver to hold the flywheel from moving while unloosening the flywheel nut The torque value of the nut is 113N m or 83 ft lb 11 Remove the fl...

Page 17: ...e the bolts in the brushes and remove the brushes 6 Remove the mounting nuts from the rubber engine and generator head mounts There are four total two under the engine and two under the generator head...

Page 18: ...at have burnt or the insulation is melted replace the parts 11 To remove the rotor from the engine install the bolt that came out of the shaft center Screw it in until only is left until the head come...

Page 19: ...ance of the engine If they have to be adjusted loosen the valve adjustment nut and then adjust the clearance a Clearance for intake 15mm 02mm 006 001 b Clearance for exhaust valve 20mm 02mm 008 001 5...

Page 20: ...the protruding parts of the rocker arm 10 Remove the four head bolts When tightening the 4 head bolts use an across the head sequence f Torque of the head bolts is 34N m 300 in lbf 11 Remove the head...

Page 21: ...lips from the valve springs Holding the valve up and using a pair of pliers push down on the retainer At the same time slide the retainer towards the larger hole and slowly let the retainer up It shou...

Page 22: ...20 Measure the distortion value of the valve stem end with a micrometer following the 1 and 2 position in the figure Replace the valve and valve guide if the distortion value is over the limit of main...

Page 23: ...r Slight tapping with a plastic hammer may be required Never use a screwdriver between the cover and the crankcase or you will damage the sealing surface 4 Remove all residue of the gasket Use a new g...

Page 24: ...nor shaft 10 Note the marks on the gears They should line up with each other Remember this for assembly 11 Remove the camshaft 12 Remove the rod bolts a Torque value 14N m 125 in lbf 13 Remove the con...

Page 25: ...the tappet surface for scratches Both the diameter and the surface the cam rides on 19 Inspect the cam lobes Replace the cam if the value is lower than the minimum values b Height for both intake and...

Page 26: ...section 1 1 table Remember to measure the diameter in at least three different locations for instance top middle and bottom 3 Measure the side clearance of the piston ring with the cylinder with a fe...

Page 27: ...the piston pin 10 Inspect the rod end cap 11 Burnish the piston top with 400 granular sandpaper Remove the carbon deposits of the piston ring slots with a non metal tool taking care not to scratch the...

Page 28: ...necessary 14 Measure the piston ring slot Inspect for abrasion on the piston Replace if the value is greater than the value found in section 1 1 table 15 Measure the external diameter of the piston sk...

Page 29: ...astic panel enclosure 3 Push in at the clip location not the screw location to remove the plastic panel 4 Replace outlets or switches if there is any damage Replace any wires that may be burnt Burnt w...

Page 30: ...2 12 Wiring Diagram...

Page 31: ...ark Test 1 Never hold the plug wire when wet 2 There is no fuel present 3 Do not test near the plug hole to avoid fire hazards 1 Remove the plug and ground the electrode against the engine with the ca...

Page 32: ...12 Volt Batter Test for Stator Troubleshooting Location Point Number Specified Voltage Voltage Variance Component Replacement Main 1 3 and 4 59 VAC 5 low Stator Main 2 5 and 6 59 VAC 5 low Stator Exci...

Page 33: ...t the valve clearance Piston and piston rings worn Replace piston and rings Too much carbon on piston and head Remove carbon Crankshaft is damaged Replace Camshaft wear Replace Rocker arm wear Replace...

Page 34: ...Chapter 4 Exploded View and Bill of Materials BOM...

Page 35: ...Exploded View of Engine Assembly...

Page 36: ...Exploded View of Frame Assembly...

Page 37: ...nder Barrel No Part No Description Quantity 161 91306 90820817000 WASHER 8 2 17 0 8 1 162 91103 MB30 0000 BOLT DRAIN PLUG 2 163 91302 91202020000 DRAIN PLUG WASHER 2 165 T1105035005200800 OIL SEAL 35...

Page 38: ...T 1 125 1 13103 QB62 0000 FIRST RING SET PISTON 1 125 2 13104 QB62 0000 SECOND RING SET PISTON 1 125 3 13108 QB62 0000 THIRD RING SET PISTON 1 126 13105 PB52 0000 PISTON PIN CLIP 2 127 13101 QB62 0000...

Page 39: ...LIP 6MM 1 187 21530 PB52 0600 FAN COVER COMP 1 188 B057890006001270B BOLT M6X12 6 189 19111 KB03 0000 DRAIN HOLE GROMMET 1 Carburetor Assembly No Part No Description Quantity 209 17100 QB62 1100 CARBU...

Page 40: ...FRONT 1 28 16109 MB32 0000 GEMEL 1 30 16102 MB32 0000 AIR CLEANER SEAL 1 33 B061700004000060B NUT 4MM 6 31 B061770106000060B NUT M6 1 34 B061770106000060B NUT M6 1 Muffler Assembly No Part No Descrip...

Page 41: ...USH 4 Control Panel Assembly No Part No Description Quantity 6 TD2000 C03 2000 CONTROL PANEL ASSY 1 7 TD2006 C03 0100 CONTROL PANEL COMP 1 8 TD9001 C03 0000 CASE CONTROL PANEL 1 14 B057890006002070B B...

Page 42: ...MPER FOR FOOT 2 226 18 B094410006001870B M6 18 2 Stator Housing Assembly No Part No Description Quantity 70 B057890006001670B BOLT FLANGE M6 16 2 71 TD1441 B98 0500 COVER GENERATOR END 1 72 B057890005...

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