Maintain & Service 1

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1 Maintain & Service 1

2 How to read hour meter The Hour Meter records the total running hours the generator set has been used. With the help of Hour Meter, user can more easy to follow the scheduled maintenance activities. And assure longer life of your generator set. How to read HOUR METER? Example-1: Calculation: 0x x1000+0x100+0x10+1x1+2x6=1hour and 12min. Example-2: Calculation: 0x x1000+6x100+1x10+8x1+9x6=618hours and 54min. 2

3 Maintenance schedule Item Total running time 50 Hrs 100 Hrs 200 Hrs 300 Hrs Lube Oil (Change) Air Filter (Clean) Spark Plug (Check or Change) Valve Clearance (Check or Adjust again) Combustion Chamber (Clean) Generator Set (Clean) ( ) ( ) Gas Hose (Change) Every 18 months 3

4 How to change lube oil Change oil when the engine is warm. Refer to the oil specification to select the proper grade of oil for your operating environment Step 01 Step 02 Step 03 Step 04 4

5 How to change lube oil Step 01 Step 02 Step 03 Step 04 Remove the OIL DRAIN PLUG. Let the oil to drain completely. Reinstall the OIL DRAIN PLUG. Remove OIL FILL CAP / DIPSTICK to add oil. For CC700, CC1200: 0.35L For CC1500, CC2000: 0.55L For CC3000 ~ CC6000XT: 0.90L NOTICE: Change lube oil after 1st 20hours or 30 days use. After 1st use, change lube oil every 100 hours use. 5

6 How to adjust inlet & outlet clearance 6

7 How to adjust inlet & outlet clearance Inlet & Outlet Valve Clearance Reference Value Engine Model Inlet Valve Clearance (cold) Outlet Valve Clearance (cold) CC700 CC ~0.10 (mm) 0.10~0.12 (mm) CC1500 CC ~0.08 (mm) 0.08~0.10 (mm) CC3000 CC4000 CC5000 CC6000XT 0.06~0.08 (mm) 0.08~0.10 (mm) 7

8 How to adjust inlet & outlet clearance Valve Clearance adjustment method as follow: 1. Disassemble Head Cover from the engine with Cap Screw Wrench, take Spark Plug Cap out 2. Let piston up to Top Dead Center, adjustment methods as follow: a. Pull the Starter Grip when resistance is felt and then pull slowly until maximum resistance, maximum resistance point is Top Dead Center b. Disassemble Spark Plug from the engine with Spark Plug Sleeve, insert a Screw Driver into cylinder, and pull the Starter Grip slowly, at the same time observe Screw Driver motion, when Screw Driver move to the highest point, so it is Top Dead Center Screw driver 8

9 How to adjust inlet & outlet clearance Following check inlet/outlet valve clearance is proper or not according to above table with Feeler Gauge, if not, firstly loose Locking Arm Nut with Screw Driver, secondly screw Pivot Adjusting Nut in or out, and measure inlet/outlet valve clearance with Feeler Gauge in designated size, pull Feeler Gauge until some resistance is felt, so it s ok, then tighten Locking Arm Nut with Screw Driver. Feeler Gauge Locking Arm Nut Pivot Adjusting Nut CC152F Type Engine NOTICE: Adjust valve clearance engine must be in cold state. 9

10 How to adjust inlet & outlet clearance CC154F engine Feeler gauge Locking arm nut Adjusting nut 10

11 How to adjust inlet & outlet clearance CC168F, CC177F, CC182F, CC188F engine Pivot adjusting nut Clearance gauge Locking arm nut Finally, assemble Head Cover ASSY to the engine with Cap Screw Wrench, wear Spark Plug Cap to Spark Plug. 11

12 How to adjust clearance of T.C.I. 1. Disassemble Fan Cover ASSY from the engine, measure clearance between T.C.I. Magnetic Steel and flywheel with Feeler Gauge, clearance value should be 0.35 mm, otherwise, adjust it. 2. Screw bolts out, move T.C.I. Magnetic Steel backward and forward flywheel, measure the clearance between T.C.I. Magnetic Steel and flywheel with Feeler Gauge until the clearance value is 0.35 mm. 3. Screw the bolts in, assemble Fan Cover ASSY. 12

13 How to adjust clearance of T.C.I. Fan cover assembly 13

14 How to adjust clearance of T.C.I. To ensure the ignition energy of T.C.I., ensure there is no friction between T.C.I. Magnetic Steel and flywheel, and ensure minimum magnetic resistance, it s necessary to measure and adjust the clearance between T.C.I. Magnetic Steel and flywheel, clearance value is 0.35 mm. Adjust clearance of T.C.I. Magnetic Steel method as follow: 14

15 How to adjust clearance of T.C.I. Flywheel 15

16 How to adjust clearance of T.C.I. T.C.I. Magnetic Steel Feeler Gauge Clearance Value 0.35 mm 16

17 How to adjust no-load voltage and frequency of generator set Generally, for generator set voltage will vary with engine rotating speed (frequency) changing. When rotating speed is up, frequency and voltage output is increasing; otherwise, rotating speed is down, frequency and voltage output is decreasing. Frequency adjustment is done by Adjusting Rod, screw Adjusting Rod in or out, get the calibrated frequency and voltage. 17

18 How to adjust no-load voltage and frequency of generator set Adjusting rod 18

19 How to adjust voltage output value 1. After starting the engine if frequency output is normal, but voltage output is abnormal you can get a calibrated voltage value through adjusting AVR, adjustment method as follow: 2. Disassemble Generator End Cover from generator set. 3. Disassemble AVR with Screw Driver. 4. Turn the AVR, adjust Adjusting Screw with Screw Driver, screw Adjusting Screw clockwise, voltage output is up, screw Adjusting Screw anticlockwise, voltage output is down. 5. Assemble Generator End Cover after finishing adjustment. 19

20 How to adjust voltage output value Adjusting screw 20

21 How to adjust idle speed After starting the engine if idle speed is unstable, you can get calibrated idle speed value through screwing Idle Screw in or out. Adjusting screw 21

22 How to clean spark plug Remove spark plug Not in good condition Adjust 0.7mm + 0.1mm In good condition Clean 22

23 How to clean spark plug 1. Remove the spark plug cap. 2. Use the wrench supplied to remove the spark plug. 3. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped. 4. Measure the plug gap with a feeler gauge. 5. The gap should be 0.7mm + 0.1mm, correct it if necessary by bending the side electrode. 6. Attach the plug washer. Thread the plug in by hand to prevent cross-threading. 7. Tighten a new spark plug 1/2 turn with the wrench to compress the washer. If you are reusing a plug, it should only take 1/8 ~ 1/4 turn after the plug seats. 23

24 Something you need to know 1. Allow the engine to cool before removing the spark plug. Otherwise, it may be damaged. 2. The spark plug must be securely tightened. An improperly tightened plug can become very hot and possibly damage the generator. 3. Use only GREEN POWER brand replacement natural gas or LPG spark plug. 24

25 How to clean air filter Open the air cleaner cover Wash the sponge in nonflammable or high flashpoint solvent Disport the sponge of air filter Soak the sponge in engine oil, then squeeze the engine oil out of the sponge 25

26 Something you need to know For engine: DO NOT spray engine with water, water can contaminate the fuel system. Use a damp cloth to clean exterior surfaces of the engine. Use a soft bristle brush to remove dirt and oil. Use an air compressor (25 PSI) to clear dirt and debris from the engine. Inspect all air vents and cooling slots to ensure that they are clean and unobstructed. 26

27 Something you need to know For generator set: Make certain that the generator is kept clean and stored properly. Only operate the unit on a flat, level surface in a clean, dry operating environment. DO NOT expose the unit to extreme conditions, excessive dust, dirt, moisture or corrosive vapors. 27

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