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Chapter IV Disassembly & Repair

- 49 -

Wire harness

Remove the wire harness from panel, rectifier

bridge and converter. Check if there is obvious damage
on the insulating layer of guide line.If yes, replace the
wire harness.

Check the switching of each guide line with

ohmmeter and confirm each guide line is of conductivity.
Replace the wire harness if the resistance is infinite.

Note: disassemble and assemble wiring harness

with a clamp. Take proper force to avoid damaging
guide line and its connector clips.

Multimeter

①

Multimeter

②

LCD

③

Operational key

④

Oil warning indicator light

⑤

Fault indicator light

⑥

AC indicator light

LCD

Normal operation:

Under normal operation, the operational key

③

used to switch the display content circularly:

Voltage - current - power - cumulative time -

current time.

Under operation in fault

a. Display AC overvoltage, as well as character AC

(display AC and numbers alternately);

a. Display DC overvoltage, as well as character dc

(display dc and numbers alternately);

a. Display AC undervoltage, as well as character

AC (display AC and numbers alternately);

a. Display DC undervoltage, as well as character dc

(display dc and numbers alternately);

Output overcurrent of generator;

Output short circuit of generator;

Generator overheating;

Service time;

Содержание LC3500i

Страница 1: ...LC3500i Maintenance Manual LONCIN MOTOR CO LTD...

Страница 2: ...lso accumulate The Gasoline is Inflammable Explosive The fuel oil can only be filled outdoors Electrostatic sparks caused by the fuel oil flowing through the nozzles of oil pumps of gasoline stations...

Страница 3: ...ection General Precautions Make sure that children are away from the generator unit Hearing protective devices must be worn when getting close to the generator unit under operation A multi class ABC f...

Страница 4: ...Change engine oil 7 3 3 Air filter 8 3 4 Cleaning of the fuel filter 9 3 5 Spark canceller 9 3 6 Spark plug 10 3 7 Adjustment of valve clearance 11 Chapter IV Faults Repair 4 1 Fault diagnosis 12 4 1...

Страница 5: ...ywheel ignition coil igniter hand starter 34 4 4 4 Carburetor 37 4 5 Generator 40 4 5 1 Fuel tank 40 4 5 2 Silencer 41 4 5 3 Rack baseplates 42 4 5 4 Motor parts 43 4 5 5 Inverter parts 45 4 5 6 Contr...

Страница 6: ...e Fuel tank Spark plug Silencer Inspection window for engine oil Hand tube combination Inverter parts Starting handle Supporting wheel parts Control panel parts Maintenance cover of batteries Batterie...

Страница 7: ...V A 12 8 Overload protection DC No fuse overcurrent protector AC Controlled by the overcurrent protection program of inverter Engine Model of engine LC170FD 3 Type of engine Single cylinder four stro...

Страница 8: ...idth Oil ring 2 5 2 37 Connecting rod Small end I D 18 002 18 07 Big end I D 30 02 30 066 Big end oil clearance 0 04 0 063 0 12 Big end side clearance 0 1 0 7 1 1 Crankshaft Crankshaft O D 29 98 29 92...

Страница 9: ...100 V 2 KW is as follows Color of Guide Line Resistance Main winding Brown 0 57 0 67 Power supply winding Orange 0 50 0 55 DC winding Blue 0 19 0 21 2 3 Torque parameters of fasteners Fastening Item...

Страница 10: ...rds 5 2 4 Torque parameters of standard parts Standard Torque Value Fastening Parts Fastening Torque N m 5 mm Bolt and nut 4 7 6 mm Bolt and nut 8 12 8 mm Bolt and nut 20 28 10 mm Bolt and nut 35 40 1...

Страница 11: ...f high temperature may cause severe scald Maintenance or repair must be conducted after the generator unit is completely cooled down Periodic Maintenance Schedule Periodic Maintenance Schedule Time of...

Страница 12: ...the oil drain plug and the the engine oil will be discharged from the fuel tank 6 Check the oil level gauge seal ring drain plug and seal gasket If any damages are observed please replace them at once...

Страница 13: ...sion process of engine will be accelerated 1 Remove the unloosening screw and the appearance cover plate 2 Remove the air filter cover and foam filter cartridge 3 Wash the foam filter cartridge with s...

Страница 14: ...tall the oil tube back as well as the clamp switch on the fuel valve and check if there is any leakage 7 Install the appearance cover plate back The gasoline is extremely inflammable and explosive Smo...

Страница 15: ...rs If it can be further used sweep away the impurities including carbon deposition etc accumulated on the spark plug with wire brush 5 Measure the clearance of spark plug with thickness gauge Adjust t...

Страница 16: ...etween the rocker arm and valve to measure the valve clearance 3 Operate as per the following steps if the adjustment is required a Fix the valve adjusting screw with a clamp and unscrew the valve loc...

Страница 17: ...el system Refer to Section 3 3 Refer to Section 4 4 4 Refer to Section 3 4 Add fuel oil into the fuel tank Fuel oil level too low Fuel filter blocked Improper adjustment of carburetor Air filter dirty...

Страница 18: ...on system Compression system Improper adjustment of carburetor Fuel filter blocked Choke valve handle not opened completely Air filter dirty Fault of spark plug cap Fault of ignition coil Wear of cyli...

Страница 19: ...on 4 4 2 Refer to Section 4 4 1 Refer to Section 3 7 Unstable speed Fuel system Compression system Improper adjustment of valve clearance Wear and air leakage of valve seat Wear of camshaft Refer to S...

Страница 20: ...arburetor Choke valve handle not opened completely Air filter dirty Fault of step motor Motor phase loss and short circuit for some turn to turn of machine winding High temperature of alternator Other...

Страница 21: ...rmal starting Disconnect surplus load Refer to Section 4 4 4 Refer to Section 3 3 Abnormal exhaust color Black White Fault of carburetor Overloaded Air filter excessively dirty Low temperature of engi...

Страница 22: ...he socket is burned if yes replace it with a new one No alternating current output voltage Abnormal engine speed Fault of stator winding coil Fault of output socket Fault of converter Replace motor pa...

Страница 23: ...recautions when working near electrical equipment If possible do not work alone and take risks Be prepared for dealing with accidents prepare a fire extinguisher and safety equipment at the place near...

Страница 24: ...oned orders Diagram for disassembly of generator Silencer Left right generator casing Shutter at tail Control panel Panel seat Stator Rotor Combination of rack baseplate Rack baseplate Support plate o...

Страница 25: ...of connecting rod cap for assembly Crankcase cover Bolt M8 32 Torque 26 32 N m Crankcase Wind scooper Reducing valve Assembly Check if the spring is worn and out of elasticity to ensure the decompres...

Страница 26: ...g of piston ring by staggering for 150 210 Manufacture s mark Piston Piston pin Connecting rod Assembly Make the longer side of big large end towards the mark of piston and assemble it on piston Pisto...

Страница 27: ...tection Wet the carbon deposition with kerosene and then remove it with blunt scraper or metallic brush 1 Outer diameter of piston skirt Measure the outer diameter of piston skirt with outside microme...

Страница 28: ...it Ring 1 2 1 0 mm 0 88 mm 5 Clearance to the end of piston ring Standard Maintenance Limit Ring 1 2 0 02 0 04 mm 1 0 mm Before measuring the clearance the piston ring shall be assembled on piston cor...

Страница 29: ...Standard Maintenance Limit 70 mm 70 165 mm Detection of connecting rod The connecting rod shall be scrapped to change a new one when it is bent warped or the out ring of its bearing bush in big end an...

Страница 30: ...specified torque Fastening torque 12 14 N m Note do not make the crankshaft rotate when fastening the bolt c Disassemble the connecting rod and measure the thickness of plastigauge d Check the connec...

Страница 31: ...r For appearance check whether the cam surface and the height is damaged whether the camshaft and bearing is loose and worn If yes change the whole unit 1 Cam height of camshaft Standard Maintenance L...

Страница 32: ...ormal noise or movement Oil level sensor Measure the conductivity of senor with ohmmeter When the engine oil in tank is insufficient or empty the black wire of sensor is conductive with the earth wire...

Страница 33: ...sembly clear away the carbon deposition in combustor and check the seal status of valve seat then conduct assembly Measure the pressure of cylinder head after completing assembly Cylinder head bolt M8...

Страница 34: ...it into the tappet hole in crankshaft tank in place Tappet combination Assembly Don t confuse these valves Be careful during installation and don t damage the valve stem Inlet valve Assembly Confirm i...

Страница 35: ...alve spring Replace the spring if the inner diameter is less or more than maintenance limit 3 Cylinder head Remove the carbon deposition in combustor and gasket residues attached on the cylinder head...

Страница 36: ...the valve spring side of cylinder head Exhaust valve side tap the exhaust valve guide until the retainer ring contacts with cylinder head completely Inlet valve side tap the inlet valve guide until i...

Страница 37: ...tenance limit judge whether to replace it with a new guide can make the clearance in maintenance If yes change the valve guide and stick the valve guide When replacing valve guide please re repair the...

Страница 38: ...edge of valve seat f Check the width of valve seat after re repairing the valve seat Coat colorant on the conical surface of valve insert the valve and press it for several times and ensure that it d...

Страница 39: ...rohibit tapping with hammer Hand starting parts Assembly Remove the soil and grass attached around these parts prior to assembly and note the assembly direction Bolt M6 8 Four Torque 8 12 N m Assembly...

Страница 40: ...embly Grease shall be coated Drive cam Assembly Assemble the return spring on pull rope disk then assemble the pull rope disk on the cover Pull rope disk Start return spring Torsional spring Note do n...

Страница 41: ...and to hang the hook inside the return spring at the jack catch of starter cover 2 Tie a knot at one end of the pull rope and tread the other end from the pull rope hole of pull rope disk Then twine...

Страница 42: ...or Sealing gasket of carburetor Installing support of speed regulating stepper motor Screw M4 12 2 Torque 5 7 N m Support of choke valve Speed regulating stepper motor Sealing gasket of inlet pipe Ins...

Страница 43: ...on Bolt of float chamber Oil drain pipe Gasket Assembly Blow in some compressed air to remove the dirt in internal passage then conduct assembly Carburetor body Throttle valves Choke valves Check the...

Страница 44: ...of the 2 diagonals in the socket of stepper motor The resistance shall be 50 1 Replace the stepper motor in case of exceeding limit Rotate the center shaft of motor in case of stepper motor The cente...

Страница 45: ...ocked Check whether there is fuel leakage after assembly Oil switch Assembly Make sure the venthole is clean and not blocked Clean it with compressed air if necessary Assembly Check whether the meshes...

Страница 46: ...duct assembly Assembly Tap the silencer with plastic hammer to remove the carbon deposition inside and then conduct assembly Silencer Silencer Shield of silencer front shield Sealing gasket of exhaust...

Страница 47: ...te the assembly direction Nut M8 8 Torque 8 12 N m Clip nut M5 4 Square nut M6 6 Torque 8 12 N m Brake Cushion rubber Rack baseplates Vertical framework 2 Cushion seat of main engine 2 Support of hand...

Страница 48: ...duct assembly Engine Disassembly Make use of the disassembly thread on rotor and assemble proper rotor remover a special tool to disassemble Motor stator Fan cover Starting board Ignition coil Flange...

Страница 49: ...ply winding Orange 0 50 0 55 DC winding Blue 0 19 0 21 The resistance among windings of 120 V 2 KW is as follows Color of Guide Line Resistance Main winding Brown 0 75 0 85 Power supply winding Orange...

Страница 50: ...Chapter IV Disassembly Repair 45 4 5 5 Inverter parts a Disassembly assembly Installing support of inverter Inverter parts Cushion rubber 2 Cushion rubber 2...

Страница 51: ...hile the red light flashes when loading Resistance grade detects the three phase connector each resistance between every two connectors is required for detection Replace the converter if the resistanc...

Страница 52: ...al Multimeter Test with Red Needle Blue Blue Red Black Test with Black Needle Blue Not conductiv e Not conductive Conductiv e Blue Not conductive Not conductiv e conductive Red Conductive Conducti ve...

Страница 53: ...t is under the working status that is to say the two output terminals of microswitch are disconnected the oil switch is on choke valve is under the fully open state the engine can operate normally Whe...

Страница 54: ...r LCD Operational key Oil warning indicator light Fault indicator light AC indicator light LCD Normal operation Under normal operation the operational key is used to switch the display content circula...

Страница 55: ...ease At this time AC protector operates to stop the generation of the generator so as to protect the generator and its electrical equipment AC indicator light green will be off while the overload indi...

Страница 56: ...s required Frequency switching switch ON OFF If it is required to switch the output frequency of generator please stop the generator first then use flat bottle opener to adjust the position of frequen...

Страница 57: ...equipment and special cable The rated output power of parallel operation is 6 KVA the rated current of 100 V generator is 60 A the rated current of 120V generator is 50A and the rated current of 230 V...

Страница 58: ...electric generator Bolt M6 20 6 Torque 8 12 N m Left shell of electric generator Left appearance cover plate Inspection window for engine oil Maintenanc e cover of batteries Hand tubes 2 Panel seat W...

Страница 59: ...Chapter III Maintenance 54 5 1 LC3500i Circuit diagram 100V...

Страница 60: ...Chapter III Maintenance 55 120 V...

Страница 61: ...Chapter III Maintenance 56 50 Hz 230 V with parallel receptacle...

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