In detail: DIY repair of a Honda petrol generator from a real master for the site my.housecope.com.
Gasoline generators, even if they are made in China, very reliable with proper care ... Nevertheless, during their operation, small problems can arise that can usually be quickly fixed with your own hands. Serious breakdowns with the knowledge of the owner of the device and the principle of operation of the generator will also not be able to disable it for a long time.
If you arrange possible malfunctions of the gas generator in a kind of rating, you get the following list:
Failure or contamination of the spark plug: difficult or impossible starting, unstable operation.
Clogged carburetor: difficult starting, excessive fuel consumption, unstable operation under constant load.
Failure of the ignition coil: no spark, inability to start.
Starter breakdowns: breakage, biting of the cable, destruction of the ratchet.
Violation of valve clearances: difficult starting, increased noise during operation.
Wear of brushes (on synchronous generators) - lack of output voltage.
Speed governor malfunction: floating engine speed, dips when changing the load.
Wear of the bearings of the crankshaft and the rotor of the generator - an increase in operating noise, oil leakage.
Wear of the cylinder, piston rings - difficult starting of a cold engine, excessive oil consumption.
It does not take into account breakdowns that result from a gross violation of the rules for operating the generator: for example, seizures on the crankshaft neck due to insufficient oil level, burnout of the generator windings or voltage converter (on inverter gas generators) with frequent overloads.
Video (click to play).
In fact, malfunctions of a gasoline generator can be divided into three groups: mechanical, electrical and fuel / ignition system malfunctions .
Difficulty starting the generator, which manifested itself suddenly and not accompanied by an increase in engine noise, is a clear sign of either deviations in the operation of the carburetor (too lean or rich mixture), or a faulty ignition system (weak or intermittent spark formation). Since the diagnostics of the state of these systems is interconnected, it is combined into one section.
Remove the spark plug and inspect the carbon deposits on the electrodes.
Dense and dry black carbon deposits - a sign of a rich mixture (the carburetor is faulty, the air filter is clogged);Oily black carbon - a sign of severe wear of the piston rings, oil enters the combustion chamber;White soot - a sign of running on a lean mixture, it is necessary to check the carburetor.Brick brown carbon deposits - normal for carburetor engines.Red, green-red carbon deposits - a consequence of working on low-quality fuel.It is simple to check the performance of the ignition system itself because of its extreme simplicity: turn on the ignition, insert a known good spark plug into the plug cap and, putting it on the nearest metal part of the engine with its skirt, turn the recoil starter abruptly. If there is no spark, disconnect the ignition switch and the oil level sensor from the ignition coil in turn: if, when both elements are disconnected, there is still no spark, replace the ignition coil.
If the spark is present and strong enough (white or blue-white), remove the spark plug after several starting attempts. A candle filled with gasoline is a sign of an over-enrichment of the mixture, a dry one is a lack of fuel.
Sometimes, after long storage, the needle and the carburetor float stick and prevent gasoline from flowing inside. Several times sharply, but do not hit the float chamber lid very hard and start again.
The most common carburetor malfunction is contamination. The ingress of dirt into the air channels leads to an over-enrichment of the mixture, into the fuel jets - to a depletion. Dirt on the float shut-off needle leads to loss of tightness and overfilling of the float chamber, which will be immediately noticeable by the leakage of fuel from the carburetor.
Let's take a look at the carburetor maintenance on the example of a Honda GX engine - its design is typical for a gasoline generator.
Remove the float chamber cover (4). Wash it in gasoline or a carburetor spray cleaner - dirt and deposits accumulate on the bottom.
Proceed in the same way with the gas valve sump (22).
Check if the gas valve is blown in the "open" position.
Take out the float shaft (3), take out the float and the shut-off needle (2). Blow out the channel with air.
Blow out the fuel jet (25), emulsion tube (11) and all carburetor passages with an aerosol cleaner or compressed air.
Remove the adjusting screw (5), blow out its channel. Then screw it in until it stops and loosen, depending on the type of air filter, by 2 (foam, paper filters) - 2.5 turns (cyclone filters).
Assemble the carburetor.
The electrical system of gas generators is quite reliable. Most often, you can face two problems: lack of battery charging on generators with electric start or lack of voltage at the generator output .
The lack of battery charging is a consequence of the failure of the rectifier or low-voltage winding. It is easy to check this system with your own hands: connect a 12-volt light bulb in parallel with the low-voltage winding of the generator and start it. A lit light means that the generator itself is working properly, and it is necessary to replace the rectifier.
The absence of voltage at the generator output is most often the result of wear on the brushes. Remove them and assess the degree of wear, replace if necessary. If your generator is an inverter type, check if the voltage comes to the input of the converter by connecting a low-power 220 V lamp in parallel with it.
Video about the phased repair of the gas generator
VIDEO One of the routine maintenance provided by the instruction manual for gas generators is the control and adjustment, if necessary, of the valve mechanism clearances. An increase in clearances above the norm will lead to a decrease in engine power, an increase in noise during operation. The most dangerous is a decrease in the gap, since it is not audible during operation, but the pinched valves, especially the exhaust, begin to burn rapidly. As a result, the engine starts to work unstably and, when the plate is burned out, it stops starting.
Valve Adjustment Procedure pretty simple:
Remove all components that interfere with the removal of the engine valve cover.
Remove the spark plug.
Remove the valve cover.
Set the crankshaft to top dead center of the compression stroke by the mark on the flywheel (if any) or by controlling the movement of the piston through the spark plug hole. Do not confuse compression TDC (both valves are closed ) with TDC issue (the outlet valve closes, the inlet valve opens ).
Loosen the locknuts of the adjusting screws and, using a flat feeler inserted between the rocker arm and the end of the valve, set the clearances by turning the screw. Typically, a clearance of 0.2 mm is adopted for the outlet valve, and 0.15 for the inlet valve (check in the operating instructions).
Tighten the locknuts and turn the crankshaft twice to TDC. If everything is done correctly, at the next dead center both gaps will go away, after another turn they will take the set value. Increased gaps after the first revolution are a sign that they were adjusted at TDC of the exhaust stroke.
Assemble the generator.
Manual starter malfunctions - perhaps the most common mechanical problem ... Either the cable breaks, or the starter refuses to rewind it due to a broken return spring, or the ratchet does not turn the crankshaft.
Remove the starter by unscrewing the bolts around its casing. By unscrewing the screw (1), the ratchet can be removed. Check its cams (4) and return springs (5). Then carefully remove the pulley with the spring (7). Replace a broken cable or broken spring, whichever caused the repair.
When reassembling the starter, care must be taken to ensure that the spring remains in engagement with the shroud and pulley during installation. The cable must be fully wound around the pulley. With the ratchet in place, check the cable travel and how the starter returns to its original position.
Review and repair of the gas generator Einhell STE800
VIDEO
Sometimes it happens that the generator needs to be started urgently, and the recoil starter failed at that very moment. There are several emergency start methods if necessary.
The methods listed below unsafe !
Remove the starter cover. A flywheel with a cooling impeller is located under it, which is pulled to the crankshaft by a nut. To make it spin, you can:
With a rope wrapped around the flywheel, use it in the same way as a recoil starter rope. Note that if it snags on the fan blades, the rope will turn into a whip whip when starting the motor, so be careful. Stand so that the rope cannot get caught in your hands or head.
Low-power engines can also be started manually: with the ignition off, turn the crankshaft several times, turning the pulley by hand in the desired direction. In this case, the gas valve must be open, and the shutter of the starting device must be closed. After that, turning on the ignition, bring the crankshaft to the compression TDC (you will feel an increase in the effort on the flywheel), and then turn the pulley with a sharp jerk so that the spark energy is enough to ignite the mixture.
A powerful cordless drill and an extension head from the tool kit are a good replacement for a quick electric starter. Clamp the extension in the chuck, put a head of a suitable size on it and unscrew the crankshaft by the flywheel nut. True, in this way it will be possible to start only a low-power generator - for a large-volume engine, the drill torque is not enough to turn it on the compression stroke.
A number of faults, alas, are quite difficult to fix with your own hands, without sufficient qualifications: for example, a faulty inverter converter or voltage regulator can only be repaired with a good understanding of the principle of operation and circuitry of such devices. Not every owner of a gas generator will take up the engine bulkhead, although this is not as difficult as it might seem.
In this case, it is worth contacting a specialized repair shop. You can find out the coordinates of workshops in your city on the Internet or in shops selling gasoline-powered tools.
In large cities like many workshops , here are just a small part of them:
Posted on Jan 2, 2018 by generator-prosto. No comments yet
Gasoline generators, even if they are made in China, very reliable with proper care ... Nevertheless, during their operation, small problems can arise that can usually be quickly fixed with your own hands. Serious breakdowns with the knowledge of the owner of the device and the principle of operation of the generator will also not be able to disable it for a long time.
If you arrange possible malfunctions of the gas generator in a kind of rating, you get the following list:
Failure or contamination of the spark plug: difficult or impossible starting, unstable operation.
Clogged carburetor: difficult starting, excessive fuel consumption, unstable operation under constant load.
Failure of the ignition coil: no spark, inability to start.
Breakdown of the recoil starter: breakage, biting of the cable, destruction of the ratchet.
Violation of valve clearances: difficult starting, increased noise during operation.
Wear of brushes (on synchronous generators) - lack of output voltage.
Speed governor malfunction: floating engine speed, dips when changing the load.
Wear of the bearings of the crankshaft and the rotor of the generator - an increase in operating noise, oil leakage.
Wear of the cylinder, piston rings - difficult starting of a cold engine, excessive oil consumption.
It does not take into account breakdowns that result from a gross violation of the rules for operating the generator: for example, seizures on the crankshaft neck due to insufficient oil level, burnout of the generator windings or voltage converter (on inverter gas generators) with frequent overloads.
In fact, malfunctions of a gasoline generator can be divided into three groups: mechanical, electrical and fuel / ignition system malfunctions .
Difficulty starting the generator, which manifested itself suddenly and not accompanied by an increase in engine noise, is a clear sign of either deviations in the operation of the carburetor (too lean or rich mixture), or a faulty ignition system (weak or intermittent spark formation). Since the diagnostics of the state of these systems is interconnected, it is combined into one section.
Remove the spark plug and inspect the carbon deposits on the electrodes.
Dense and dry black carbon deposits - a sign of a rich mixture (the carburetor is faulty, the air filter is clogged);Oily black carbon - a sign of severe wear of the piston rings, oil enters the combustion chamber;White soot - a sign of running on a lean mixture, it is necessary to check the carburetor.Brick brown carbon deposits - normal for carburetor engines.Red, green-red carbon deposits - a consequence of working on low-quality fuel.It is simple to check the performance of the ignition system itself because of its extreme simplicity: turn on the ignition, insert a known good spark plug into the plug cap and, putting it on the nearest metal part of the engine with its skirt, turn the recoil starter abruptly. If there is no spark, disconnect the ignition switch and the oil level sensor from the ignition coil in turn: if, when both elements are disconnected, there is still no spark, replace the ignition coil.
If the spark is present and strong enough (white or blue-white), remove the spark plug after several starting attempts. A candle filled with gasoline is a sign of an over-enrichment of the mixture, a dry one is a lack of fuel.
Sometimes, after long storage, the needle and the carburetor float stick and prevent gasoline from flowing inside. Several times sharply, but do not hit the float chamber lid very hard and start again.
The most common carburetor malfunction is contamination. The ingress of dirt into the air channels leads to an over-enrichment of the mixture, into the fuel jets - to a depletion. Dirt on the float shut-off needle leads to loss of tightness and overfilling of the float chamber, which will be immediately noticeable by the leakage of fuel from the carburetor.
Let's take a look at the carburetor maintenance on the example of a Honda GX engine - its design is typical for a gasoline generator.
Remove the float chamber cover (4). Wash it in gasoline or a carburetor spray cleaner - dirt and deposits accumulate on the bottom.
Proceed in the same way with the gas valve sump (22).
Check if the gas valve is blown in the "open" position.
Take out the float shaft (3), take out the float and the shut-off needle (2). Blow out the channel with air.
Blow out the fuel jet (25), emulsion tube (11) and all carburetor passages with an aerosol cleaner or compressed air.
Remove the adjusting screw (5), blow out its channel. Then screw it in until it stops and loosen, depending on the type of air filter, by 2 (foam, paper filters) - 2.5 turns (cyclone filters).
Assemble the carburetor.
The electrical system of gas generators is quite reliable. Most often, you can face two problems: lack of battery charging on generators with electric start or lack of voltage at the generator output .
The lack of battery charging is a consequence of the failure of the rectifier or low-voltage winding. It is easy to check this system with your own hands: connect a 12-volt light bulb in parallel with the low-voltage winding of the generator and start it. A lit light means that the generator itself is working properly, and it is necessary to replace the rectifier.
The absence of voltage at the generator output is most often the result of wear on the brushes. Remove them and assess the degree of wear, replace if necessary. If your generator is an inverter type, check if the voltage comes to the input of the converter by connecting a low-power 220 V lamp in parallel with it.
Video about the phased repair of the gas generator
VIDEO
One of the routine maintenance provided by the instruction manual for gas generators is the control and adjustment, if necessary, of the valve mechanism clearances. An increase in clearances above the norm will lead to a decrease in engine power, an increase in noise during operation. The most dangerous is a decrease in the gap, since it is not audible during operation, but the pinched valves, especially the exhaust, begin to burn rapidly. As a result, the engine starts to work unstably and, when the plate is burned out, it stops starting.
Valve Adjustment Procedure pretty simple:
Remove all components that interfere with the removal of the engine valve cover.
Remove the spark plug.
Remove the valve cover.
Set the crankshaft to top dead center of the compression stroke by the mark on the flywheel (if any) or by controlling the movement of the piston through the spark plug hole. Do not confuse compression TDC (both valves are closed ) with TDC issue (the outlet valve closes, the inlet valve opens ).
Loosen the locknuts of the adjusting screws and, using a flat feeler inserted between the rocker arm and the end of the valve, set the clearances by turning the screw. Typically, a clearance of 0.2 mm is adopted for the outlet valve, and 0.15 for the inlet valve (check in the operating instructions).
Tighten the locknuts and turn the crankshaft twice to TDC. If everything is done correctly, at the next dead center both gaps will go away, after another turn they will take the set value. Increased gaps after the first revolution are a sign that they were adjusted at TDC of the exhaust stroke.
Assemble the generator.
Manual starter malfunctions - perhaps the most common mechanical problem ... Either the cable breaks, or the starter refuses to rewind it due to a broken return spring, or the ratchet does not turn the crankshaft.
Remove the starter by unscrewing the bolts around its casing. By unscrewing the screw (1), the ratchet can be removed. Check its cams (4) and return springs (5). Then carefully remove the pulley with the spring (7). Replace a broken cable or broken spring, whichever caused the repair.
When reassembling the starter, care must be taken to ensure that the spring remains in engagement with the shroud and pulley during installation. The cable must be fully wound around the pulley. With the ratchet in place, check the cable travel and how the starter returns to its original position.
Review and repair of the gas generator Einhell STE800
VIDEO Sometimes it happens that the generator needs to be started urgently, and the recoil starter failed at that very moment. There are several emergency start methods if necessary.
The methods listed below unsafe !
Remove the starter cover. A flywheel with a cooling impeller is located under it, which is pulled to the crankshaft by a nut. To make it spin, you can:
With a rope wrapped around the flywheel, use it in the same way as a recoil starter rope.Note that if it snags on the fan blades, the rope will turn into a whip whip when starting the motor, so be careful. Stand so that the rope cannot get caught in your hands or head.
Low-power engines can also be started manually: with the ignition off, turn the crankshaft several times, turning the pulley by hand in the desired direction. In this case, the gas valve must be open, and the shutter of the starting device must be closed. After that, turning on the ignition, bring the crankshaft to the compression TDC (you will feel an increase in the effort on the flywheel), and then turn the pulley with a sharp jerk so that the spark energy is enough to ignite the mixture.
A powerful cordless drill and an extension head from the tool kit are a good replacement for a quick electric starter. Clamp the extension in the chuck, put a head of a suitable size on it and unscrew the crankshaft by the flywheel nut. True, in this way it will be possible to start only a low-power generator - for a large-volume engine, the drill torque is not enough to turn it on the compression stroke.
A number of faults, alas, are quite difficult to fix with your own hands, without sufficient qualifications: for example, a faulty inverter converter or voltage regulator can only be repaired with a good understanding of the principle of operation and circuitry of such devices. Not every owner of a gas generator will take up the engine bulkhead, although this is not as difficult as it might seem.
In this case, it is worth contacting a specialized repair shop. You can find out the coordinates of workshops in your city on the Internet or in shops selling gasoline-powered tools.
In large cities like many workshops , here are just a small part of them:
A portable electric generator is an irreplaceable source of energy in conditions when there is no possibility of connecting to electric mains or the supply of electricity through them is interrupted. They use ordinary motor gasoline as fuel.
A portable power generator will be useful wherever there is no permanent power source, for example, on a trip to nature.
Diesel power generators have a large mass, therefore, they are installed permanently as a backup source of electricity. Their gasoline counterpart is much lighter, therefore, it is quite mobile and is often taken with them to remote, inaccessible places. Therefore, in the event of a breakdown of a gas generator, it is extremely problematic to call a repair specialist; it becomes necessary to repair it yourself, with your own hands.
The device of a portable gasoline electric generator.
Such a machine is a mechanism for generating alternating current based on the synchronous rotation of its elements. Moreover, such a current, depending on its model and power, can be either single-phase or three-phase. The first has the ability to generate a voltage of 220 V and supply a single-phase load with current, which is necessary for electric lighting and the operation of most household electrical appliances. The second one can give a load in three phases and provide a voltage of 380 V, which makes it possible to connect, first of all, welding machines.
The gas generator consists of an electric generator and a gasoline engine that supplies it with energy. They are connected to each other by a special elastic coupling. A metal box is installed near the generator, where a device for turning it on, instruments for measuring operating parameters and automatic fuses in case of short circuits are mounted. The gasoline engine can have from 1 to 8 cylinders, depending on the required power, and also be two- or four-stroke. The latter are used more often, since they are more economical and have a higher efficiency. The method of switching on can be either from a spark obtained mechanically with the help of a manual drive, or from a battery.
The main reasons for failures in the operation of a portable gas generator can be either engine breakdown or failure of an electric generator. To find out the specific cause of the malfunction, you will have to check one by one all the nodes that can cause the failure.
Generator internal circuit diagram: 1. Fuel filters. 2. Crankshaft. 3. Air filter. 4. Part of the ignition system. 5. Cylinder. 6. Valve. 7. Crankshaft bearing.
In addition, the load on the generator may exceed its capacity. Then you need to turn it off and check the work. If, during the operation of the unit, smoke begins to rise from it and a burning smell appears, it means that a short circuit has occurred in the winding, then self-repair is extremely problematic, a complete rewinding of the windings is needed.
VIDEO
In general, repairing a gas generator on your own is quite affordable even in the field.
It is necessary to deal with the TSS-ELAB 5500E gas generator with electric start. KIPOR has a similar functional counterpart. Contacting a service center is problematic due to the lack of such a service in Omsk.
the generator worked for 3 years without any problems. Changed the engine oil once a year. operating time per year about 50-60 hours
First of all, you need to check the flow of fuel into the carburetor glass. If it is not supplied enough, after a while there will be interruptions in the speed, then it will stall and for a while it will not start until the glass is full. If so, check the presence and cleanliness of the filter in the tank and the fuel cock.
Cheb5030 thanks! the second person is already sinning on the fuel system. I'll check it first. Checked the oil level. But how to check the oil muffler? But that's okay for now. the fuel system first.
eugin_b wrote:
A black candle indicates that there is a lot of fuel (very much), but little air. Try playing with the fuel cock. Those. start and as soon as it starts to goat or cut off the feed a little earlier. If everything settles down (for a while), then the float is frozen or its valve is leaking (overflowing fuel). By the way, when overflowing, the exhaust is smoky and stinks of gasoline. But oil is not at all in the subject here, it should be just in level and that's it.
valerich wrote:
The exhaust is not smoky, does not stink with gasoline - completely normal operation of the gas generator
Repairing a gas generator begins with identifying the cause of the breakdown and eliminating it. The main reason for the occurrence of failures in the operation of gasoline generators is the failure of a gasoline engine or an electric generator. To carry out repair work, you should independently study the design and principle of operation of the equipment.
Gas generators are needed to power the network or various devices.
A portable gas generator is an indispensable device for generating electricity in conditions where there is no possibility of connecting to centralized power supply lines. The industry offers consumers a choice of gasoline and diesel generators. As fuel in gasoline installations, ordinary motor gasoline is used.Gasoline generators are small in size, which is their advantage if you need to transport the device.
A gasoline generator is a unit for generating alternating current. The generation of electric current is carried out on the basis of the synchronous rotation of the installation elements. Depending on the design and purpose of the device, the generated current can be either single-phase or three-phase. Depending on the purpose of the installation, they may differ among themselves not only in the parameters of the electric current, but also in the power of the installation itself. Devices that generate a single-phase current with a voltage of 220 V are designed to power a household consumer network. Generators that produce a three-phase current with a voltage of 380 V are most often used to power various devices, such as welding machines.
Diagram of a gasoline generator.
The design of the gasoline generator consists of two blocks. One of the blocks is a generator that generates electricity, and the second block of the plant is a gasoline engine that supplies the electric generator with energy. Structural blocks are connected to each other using an elastic coupling. The electric generator in its design has a block with devices designed to turn on the generator, devices for monitoring the parameters of the device and automatic devices that protect the installation from accidental short circuits.
A gasoline propulsion system can include from one to eight cylinders. The number of cylinders in a gasoline engine depends on the power of the engine. These engines can be either two-stroke or four-stroke. Four-stroke engines are more economical and more efficient than two-stroke engines.
The task of the installation is to convert mechanical energy generated by an internal combustion engine into electrical energy, which is generated by an electric generator. Repair of a gas generator is associated with the replacement of engine and generator elements that fail during operation.
The propulsion system is equipped with a whole range of systems that ensure its operation. Such systems are:
The principle of operation of a portable gas generator.
launch system;
engine speed stabilization system;
propulsion system cooling system;
exhaust gas removal system;
air purification and supply system to create a combustible mixture.
The propulsion system is started using a manual start or an electric starter.
In modern installations, autorun systems are used. It is possible to independently repair only those installations that are equipped with a mechanical starting system. If it is necessary to repair propulsion systems equipped with automation, it is impossible to do without the use of specialized equipment.
Power from the combustion engine is transmitted to the generator shaft through a flexible coupling. This flexible connection, in addition to transmitting power, provides vibration damping.
Connection diagram of a portable gas generator.
The main breakdowns during the operation of a portable gasoline generator set occur in the engine or generator of the set.
Most often, the following systems can fail in a propulsion system:
fuel supply system;
combustible mixture preparation system;
gas distribution system;
gas distribution mechanism drive;
engine starting system.
To identify the specific cause of the malfunction, it is required to check all the components that may be the cause of the unit breakdown.
The main breakdown and malfunction of the fuel supply system is a clogged fuel line from the gas tank to the carburetor.The system is capable of clogging up as a result of the use of low-quality fuel during the operation of the installation. To repair a gas generator with your own hands, you need to dismantle the fuel supply system and clean the tap and the supply pipe. During operation, the fuel level sensor in the fuel tank can fail. If the sensor is found to be damaged, it should be dismantled and replaced with a new one.
Stopping the engine may be due to the failure of the carburetor due to clogging and sticking of moving structural elements. To eliminate the blockage of the needle channel, which is responsible for fuel injection, it is required to blow the channel with compressed air. As a result of the use of low-quality fuel, the float mechanism that supplies the fuel may stick. To eliminate sticking, it is necessary, using a special liquid for cleaning carburetors, to moisten the float and its needle and manually move the float.
VIDEO
If you suspect a malfunction in the engine timing system, remove the cover from the valve block and try to move the rocker arms. If, during the movement, the valves of the gas distribution mechanism do not open, then sticking or sticking of the valves has occurred. Such phenomena are observed in the case of using low quality fuel during the operation of the installation. To clean the valve, moisten it with a special carburetor cleaning fluid, then turn the rocker arm and hammer the valve to the end with a hammer. After that, by turning the shaft, push the valve back. This procedure should be repeated several times until the valve moves freely in the seat.
Checking the oil level of the gas generator.
If a belt is used as a drive for the engine timing mechanism, it can stretch and break during operation. In case of failure, it must be replaced with a new one.
If there is an electric starter, the gas generator may not start as a result of the battery being dead or uncharged.
In the event of a malfunction in the generator block, it is better to invite a specialist to carry out repairs, since this requires special knowledge.
The main signs of a generator breakdown are the lack of voltage in the network during operation and voltage instability.
The most common cause of generator failure and breakdown is damage to the stator or rotor windings. The first sign of a malfunction during operation is the appearance of burning and smoke from the generator unit. The appearance of these signs may indicate the occurrence of an interturn short circuit or short circuit of the output ends of the windings.
VIDEO Repairing a breakdown of this type is an expensive operation, since the winding rewinding procedure is quite expensive and is carried out using special equipment.
In the event of voltage surges generated by the generator of the installation, in the absence of a smell of burning and smoke, the stability of the voltage regulator should be checked, which prevents the appearance of surges. If a malfunction is detected, this structural element should be repaired and the condition of the brushes of the generator device should be checked.
In the Yugo-Vostok workshop, repairs of gasoline generator engines of any complexity are carried out. We repair engines such as: Honda, Honda analogues, Briggs & Stratton, Kohler, Mitsubishi, Robin-Subaru, Vanguard and others. The cost of work on the bulkhead of the engine of any gas generator is 5000 rubles.
The main malfunctions of motors requiring overhaul:
Crankshaft bearing noise
Crank knock during operation or when changing the load
Broken connecting rod
Wedge engine
Mechanical governor malfunction
Engine smokes under load or idle (CPG wear)
High oil consumption
Oil leaks from the crankcase cover or crankshaft oil seals
In rare cases, lack of compression (sticking rings)
Timely scheduled maintenance will significantly extend the life of the engine.
We often receive generators, the main malfunction of which is smoke during operation and high oil consumption. As practice shows, two-thirds of such generators were used in violation of operating rules. without air filter. How much will such a repair cost?
Let's take a look at the example of an analogue of the Honda GX 390. Most gasoline generators are assembled on the basis of the original Hondas and their counterparts. If your generator is equipped with a Subaru, Mitsubishi, Briggs and Stratton engine or another, the engine structure is the same overhead valve as that of Honda.
What is the analogue of the Honda GX390?
This is what the original Honda GX390 looks like. ... A characteristic difference from analogs is:
High quality
And this is how Honda's analogues look like:
As you can see in the photo, the engines of the 188 f series have an identical structure and differ only in price, quality of materials, color, manufacturer and various small parts (tank cover, starter handle, filter cover). Many analog parts fit together, for the original Honda and vice versa.
So we have a smoking generator with an analog engine. Why does the engine smoke? Everything is very simple: the oil scraper rings do not fulfill their functions and the oil enters the combustion chamber and smoke is produced during combustion. Accordingly, it is necessary to replace the rings, this can save if there is no wear and tear on the cylinder. If you put new rings on the worked-out pot, it is possible that the engine will stop smoking for a while, but then the symptoms will return. Therefore, it is necessary to change the crankcase and rings together, and, if necessary, the piston. The cost of replacing the piston and rings of any generator is 5000 rubles with oil.
This is what the crankcase looks like
As you can see in the photo, these engines do not have a separate cylinder. That is, if there are seizures on the cylinder, it is necessary to change the entire block, it will not be possible to replace the cylinder separately. You can try honing the original Honda, but the success rate is 50%. Analogues are not honed at all, due to vague materials. 188 F (390cc) crankcase costs range from $ 100-120 for analog parts and around $ 250 for an original Honda crankcase. In order to avoid such malfunctions, it is necessary to constantly change the air filters and exclude the possibility of working without a filter. The cost of such repairs is considered the most expensive and amounts to 6,000 rubles of work with oil and a crankcase gasket (for any generator) + the cost of spare parts.
We often repair generators with seized or knocking connecting rods. The main reason for wedge or knocking is insufficient oil or high speed (over 3000). Recently, engines for power engineering began to supply an oil level sensor, but many simply turn it off. For good reason, it is not recommended to turn it off, but if it is turned off, you must constantly check the oil. If you hear extraneous knocks, you must immediately stop work and contact a specialized workshop.
Engine Connecting Rod 188F
A mechanical speed controller is installed in each engine of the gas generator. The function of this part is to close the carburetor flap by means of a rod and a regulator rod. In other words, when the engine starts to run at more than 3000 rpm, the governor pushes the rod attached to the carburetor choke. Failure can be dirt and engine deposits, as well as the production of a part. The main symptoms are very high revs.
Mechanical regulator
Video (click to play).
