In detail: do-it-yourself hooter repair of a gas generator from a real master for the site my.housecope.com.
In an ideal world, equipment serves for a very long time, and repair of gas generators is required only because of their natural "old age". In reality, everything is somewhat different, since too many factors affect the duration and efficiency of the operation of such a device: the type of consumables used, the quality of spare parts and assembly, the weather conditions in the area. Among other things, the repair of gas generators is required to be done much more often if the user does not show special concern for the technique.
Equipment of this kind can perform different functions, each of which is extremely important:- Providing an autonomous backup power supply to the facility;
- Functioning on an ongoing basis if there is no power transmission line in the area.
Given the magnitude of the load on such a compact device, it is quite logical that gas generators need to be repaired from time to time. In order to have to do this as rarely as possible, the main components should be serviced on time. The increased load on such a device lies in the fact that several consumers can be powered from it at the same time, and the duration of operation is often quite long.
Thus, even despite the need to repair gas generators from time to time, it is sometimes necessary to have a device of this type in everyday life. Among other things, there is another factor that testifies in its favor - this is the organization of a stable output voltage for connecting equipment with sensitive automation.
The petrol generator is a liquid fuel device. Its task is to convert the mechanical energy of the engine into electrical energy, which is generated by the alternator. These are two main nodes that are interdependent. Repair of gas generators is most often associated precisely with the maintenance or replacement of elements that are part of the engine and alternator or functionally related to them.
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The engine is equipped with a number of systems: start, shaft speed stabilization, cooling, exhaust and air supply. This knot is set in motion most often in two ways:
- By means of manual traction;
- Electric starter.
In more functional models, the engine is driven by autostart. If the repair of autonomous gas generators of a mechanical-type starting system is quite possible to perform independently, then it is much more difficult to understand the automation.
A distinction is made between single-phase and three-phase devices. If the former are not as functional as the latter, but they are less powerful. However, the advantage of three-phase models is the ability, if necessary, to connect a single-phase network.
There are one-stroke and four-stroke models of alternators (generators). In gasoline mechanisms, the latter of these are most often used.
Repair of autonomous gas generators may be required for various reasons, but over time, an average list of the main types of common breakdowns has been formed:
In fact, there are much more probable breakdowns, therefore, most often it is difficult to repair a backup gas generator on its own in the absence of sufficient experience and knowledge base.
For users who have the necessary knowledge, a manual such as a gas generator repair manual is sufficient. As a rule, such brochures contain information on eliminating the most common malfunctions of devices that are in demand more than other models.
The instructions for repairing an autonomous gas generator will allow you to fix the problem yourself, which will further reduce costs.
The main advice of specialists is to prevent any breakdowns. This is possible if such equipment is serviced in time, for which it is necessary to control the level of fuel and oil, check the strength of bolted joints, and clean the air filter from contamination. As a result, the repair of reserve gasoline generators may never be required for the entire period of operation.
It is more likely that the repair of a gas generator with a Honda engine, like a number of other reliable manufacturers, is required an order of magnitude less often. However, it should be noted that even the quality of the engine is not a guarantee of the proper functioning of the rest of the structural units, the elements of which are made by another manufacturer.
When deciding how to repair a backup gas generator with your own hands, you should first weigh your strength. Secondly, the complexity of the breakdown is determined.Often, in order not to jeopardize expensive equipment, repair of Huter gas generators and a number of other reliable brands is carried out by service centers. The current can be completely confident that the mechanism will remain operational after disassembly and inspection.
In addition, the repair of Huter brand gas generators, in particular, if the necessary consumables from the same manufacturer are available, is greatly simplified. If you get down to business on your own, the repair of Huter gas generators or another well-known brand is usually stretched out in time, since the user has to look for spare parts on his own.
Thus, in most cases, only a service center can provide a high-quality repair, while repairing an autonomous gas generator with your own hands is more like a lottery, because the cause of a breakdown does not always lie on the surface. And the user will have to disassemble the mechanism again and again at intervals of about once a month, but there will still be no result. This means that repairing a gasoline backup generator with your own hands is recommended only in case of extreme confidence in the success of this event.
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.
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
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 assembling the starter, care must be taken to ensure that the spring remains in engagement with the shroud and pulley while it is being reinstalled. 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