LONCIN LC3000i User manual

LC3000i
Service Manual
LONCIN MOTOR CO., LTD.

SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL
before operating the generator set. Safe
operation and top performance can only be
attained when equipment is operated and
maintained properly.
The following symbols, found throughout this
manual, alert you to potentially dangerous
conditions to operators, service personnel and
equipment.
This symbol alerts you to an
immediate hazard that will result in severe
personal injury or death.
This symbol alerts you to a
hazard or unsafe practice that can result in
severe personal injury or death.
This symbol alerts you to a
hazard or unsafe practice that can result in
personal injury or damage to equipment or
property.
Electricity, fuel, exhaust, moving parts and
batteries present hazards against which
precautions must to taken to prevent severe
personal injury or death.
Exhaust Gas Is Deadly
•Operate the generator set outdoors only.
Stay away from the exhaust outlet.
•Make sure generator set exhaust will not
enter windows, doors, vents or air intakes of
adjacent buildings, vehicles or boats.
•Never use the generator set inside a
home, garage, crawl space, barn, shed,
cabin, boat, boat house, rv or tent, or in a
con¬fined outdoor space such as an alley,
ditch, parking garage or courtyard, or in any
other space where exhaust can accumulate.
note that hazardous carbon monoxide
levels from engine exhaust can accumulate
indoors even when all windows and doors
are open and fans are running.
Gasoline is Flammable / Explosive
•Refuel the generator set outdoors only.
•Static electric sparks caused by fuel flowing
through a service station pump nozzle can
ignite gasoline. Never fill the generator set
with a service station pump nozzle. Instead,
fill a safety tank sitting on the ground and
then slowly transfer fuel to the generator set
from the safety tank.
•Do not fill fuel tanks while the engine is run-
ning. A hot engine can ignite the fuel.
•To prevent fire due to fuel leakage, always
close the fuel valve and let the generator set
cool before transporting it or storing it in a
confined space.
•Do not smoke or allow an open flame near
the generator set. Keep flames, sparks,
electrical switches, pilot lights, electrical arcs,
arc-producing equipment and all other
sources of ignition well away.
Generator Voltage is Deadly
•Do not connect the generator set directly to
any building electrical system. Back-feed
could cause electrocution of utility line
workers and damage to equipment. An
approved switching device must be used to
prevent interconnections. A trained and
experienced electrician must make electrical
connections when the generator set is used
for emergency power.
•Make sure clothing, shoes and skin are dry
when handling electrical equipment.
• Never operate the generator set in rain or
snow or when it is sitting on wet ground.
Moving Parts Can Cause Severe
Personal Injury or Death
•Before performing any maintenance on the
generator set, disconnect the spark plug wire
and the negative (–) cable of the battery to
prevent accidental starting.
• Always keep hands away from moving parts.
•Do not wear loose clothing or jewelry while
servicing the generator set. Loose clothing
and jewelry can become caught in moving
parts. Jewelry can short out electrical
contacts causing sparks, flame and electrical
shock.
•Make sure that fasteners and clamps on the
generator set are tight. Keep guards in
position over fans, rotors, etc.
a

SAFETY PRECAUTIONS
Battery Gases are explosive
•Wear safety glasses when servicing
batteries.
•Do not smoke.
•To reduce arcing when disconnecting or
reconnecting battery cables, always
disconnect the negative (–) cable of the
battery first and reconnect it last.
General Precautions
•Keep children away from the generator set.
•Wear hearing protection when near an
operating generator set.
•Keep a multi-class ABC fire extinguisher
readily at hand. Class A fires involve
ordinary combustible materials such as
wood and cloth. Class B fires involve
combustible and flammable liquids and
gaseous fuels. Class C fires involve live
electrical equipment. (ref. NFPA No. 10)
•Benzene and lead may be found in gasoline
and have been identified by some state and
federal agencies as causing cancer or
reproductive toxicity. Do not ingest, inhale or
contact gasoline.
•Used engine oils have been identified by
some state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
inhale or contact used engine oil or its
vapors.
•Keep the generator set clean and dry at all
times. Excess grease and oil can catch fire
and/or accumulate dirt, which can cause
overheating.
•Do not store anything on the generator set,
such as oil cans, oily rags, chains or wooden
blocks. A fire could result or operation could
be adversely affected
•Do not work on the generator set when you
are mentally or physically fatigued or have
consumed alcohol or drugs.
Failure to properly follow instructions and precautions can cause
you to be seriously hurt or killed.
Follow the procedures and precautions in this manual carefully.
Improper service or repairs can create an unsafe condition that
can cause your customer or others to be seriously hurt or killed.
Follow the procedures and precautions in this manual and other
service materials carefully.
b

TABLE OF CONTENTS
SECTION 1 INTRODUCTION
1-1 Generator Components ..............................................................1
1-2 Parameters ........................................................................2
SECTION 2 MAINTENANCE STANDARD
2-1 Engine Maintenance Standard ........................................................3
2-2 Generator Maintenance Standard......................................................4
2-3 Fastener Torque Specification ........................................................4
2-4 Standard Fastener Torque Specification................................................5
SECTION 3 MAINTENANCE
3-1 Maintenance Schedule...............................................................6
3-2 Engine Oil..........................................................................8
3-3 Air Cleaner .........................................................................9
3-4 Clean fuel filter.....................................................................10
3-5 Spark Arrester .....................................................................10
3-6 Spark Plug ........................................................................11
3-7 Valve Clearance ...................................................................12
SECTION 4 DISASSEMBLY AND SERVICE
4-1 Troubleshooting ....................................................................13
4-1-1 Hard Starting...................................................................13
4-1-2 Low Power.....................................................................14
4-1-3 Speed Unstable ................................................................15
4-1-4 Low Speed/Voltage .............................................................16
4-1-5 Exhaust Color Abnormal .........................................................17
4-1-6 No AC Output Voltage...........................................................18
4-1-7 No DC Output Voltage...........................................................18
4-2 Preparing to Service ................................................................19
4-2-1 Safety Precautions..............................................................19
4-2-2 Special Tools...................................................................19
4-3 Disassembly Chart..................................................................20
4-4 Engine ............................................................................21
4-4-1 Crankcase/Camshaft / Piston....................................................21
c

TABLE OF CONTENTS
4-4-2 Cylinder Head / Valves ..........................................................29
4-4-3 Generator / Ignition Coil/Recoil Starter.............................................35
4-4-4 Carburetor .....................................................................40
4-5 Generator .........................................................................43
4-5-1 Fuel Tank......................................................................43
4-5-2 Muffler ........................................................................44
4-5-3 Frame/Bedplate Combination.....................................................43
4-5-4 Inverter .......................................................................48
4-5-5 Control Panel ..................................................................51
4-5-6 Outer case assembly............................................................55
SECTION 5 WIRING DIAGRAMS ........................................................56
d

SECTION 1. INTRODUCTION
1-1 Generator Components
THE BOTTOM
PLATE FRAME
OILING PORT
RUBBER SLEEVE
RECOIL STARTER
RIGHT
APPEARANCE
COVER PLATE
CONTROL PANEL
PANEL BED
FUEL TANK CAP
OIL OBSERVATION
WINDOWS
LOUVER
MUFFLER
SPARK PLUG
COVER
- 1 -

SECTION 1. INTRODUCTION
1-2 Parameters
Model No. LC3000i
Generator
Type Inverter
Frequency/Hz 50/60/50&60
Rated Voltage/V 100/110/120/230
Max. output power /kVA 2.5
Rated output power /kVA 2.3
Power factor 1.0
AC output quality ISO8528 G2
THD/% ≤5
Noise Level dB/LpA/LwA/K
4m (3/4 load)
64.7
DC Output/ V-A 12-8.3
Overload
Protection
DC Non-fuse Protector
AC
Control by inverter overload protection
program
Engine
Engine Model No. 165F-4
Engine Type
Single cylinder, 4-Stroke, forced air
cooling, OHV
Displacement/cc 149
Fuel Type Unleaded Gasoline
Engine
Fuel Tank Capacity/L 4.0
Continuous Running
Time/h (at rated output)
2.7
Engine Oil Capacity/L 0.6
Spark Plug Model F7RTC
Starting Mode Recoil starter
Dimensions
Length × Width ×
Height/mm
565×339×467
Net weight/kg 27
- 2 -

SECTION 2 MAINTENANCE STANDARD
2-1 Engine Maintenance Standard
Unspecified unit：mm
Part Item LC165F-4
Standard Service limit
Engine Maximum speed
3850±150rpm
－
Cylinder Cylinder bore 65.0 65.165
Piston
Skirt O.D. 64.985 64.845
Piston-to-cylinder clearance 0.015-0.05 0.12
Piston pin bore ID 13.002 13.048
Piston pin-to-piston pin bore
clearance
0.002-0.014 0.06
Piston pin Outside diameter 13.0 12.954
Piston rings
Ring side clearance (Top/Second) 0.015-0.045 0.15
Ring end gap (Top/Second) 0.2-0.4 1.0
Ring end gap (Oil ring) 0.15-0.35 1.0
Ring height (Top/Second) 1.0 0.9
Ring height (Oil ring) 2.5 2.37
Ring width (Top) 2.3-2.5 2.27
Ring width (Second) 2.5-2.7 2.44
Ring width (Oil ring) 2.43-2.83 2.37
Connecting rod
Small end I.D. 13.005 13.07
Big end I.D. 25.02 25.066
Big end oil clearance
0.04-0.063 0.12
Big end side clearance 0.1-0.7 1.1
Crankshaft Crankpin O.D. 24.98 24.92
Valves
Clearance(cold) (IN) 0.10~0.15 －
Clearance(cold) (EX) 0.10~0.15 －
Stem O.D. (IN) 5.48 5.318
Stem O.D. (EX) 5.44 5.275
Valve guide I.D. (IN,EX) 5.50 5.572 Stem-to-guide clearance (IN) 0.02-0.044 0.10
Stem-to-guide clearance (EX) 0.06-0.087 0.12
Valve seat Seat width 0.8 2.0
Valve spring Free length 30.5 29.5
Camshaft Cam height (IN) 27.7 27.45 Cam height (EX) 27.75 27.50
O.D. (bearing section) 13.984 13.916
Crankcase cover Camshaft holder I.D. 14.0 14.048
Spark plug Gap 0.7-0.8 －
Ignition coil Resistance Primary coil 0.8-1.0Ω －
- 3 -

SECTION 2 MAINTENANCE STANDARD
Resistance Secondary coil 5.9-7.1Ω －
Air gap (at flywheel) 0.3-0.4 －
2-2 Generator Maintenance Standard
Table of resistance values of windings rated 230 V 2.3KW:
Part
Wire color
Resistance
Main winding
Brown
3.06Ω±15%
Power supply winding
Orange
0.42Ω±15%
DC winding
Blue
0.086Ω±15%
Table of resistance values between windings rated 120V 2.3KW:
Part
Wire color
Resistance
Main winding
Brown
0.97Ω±15%
Power supply winding
Orange
0.42Ω±15%
DC winding
Blue
0.086Ω±15%
2-3 Fastener Torque Specification
Item Thread specification Torque range(N.m)
Connecting rod bolt M6×1 12-14
Cylinder head bolt M8×1.25 32-35
Flywheel mounting nut M14×1.5 80-90
Crankcase cover bolt M8×1.25 27-30
Air cleaner mounting nut M6×1 8-12
Valve lock nut M5×0.5 5-8
Muffler mounting nut M8×1.25 20-28
Muffler mounting bolt M8×1.25 20-28
Breather chamber cap bolt M5×0.75 5-8
Starter motor fastening bolt M6×1.25 8-12
Spark plug 25-30
- 4 -

SECTION 2 MAINTENANCE STANDARD
2-4 Standard Fastener Torque Specification
Faster Thread specification Torque range（N.m
）
Bolt, nut
5mm bolt, nut 4-7
6mm bolt, nut 8-12
8mm bolt, nut 20-28
10mm bolt, nut 35-40
12mm bolt, nut 50-60
- 5 -

SECTION 3 MAINTENANCE
3-1 Maintenance Schedule
Good maintenance is essential to safe,
economical and zero-failure operation, and is also
good for environment protection. Under hot or dusty
operating conditions some maintenance operations
should be performed more frequently, as indicated
by the footnotes to the table.
Keep a log of maintenance performed and the
hours run. Recording maintenance will help you
keep it regular and provide a basis for supporting
warranty claims.
Accidental starting of the generator
set during maintenance can cause severe
personal injury or death. Before performing
maintenance, disconnect the spark plug wire
from the spark plug.
A hot generator set can cause
severe burns. Always allow the generator set
to cool adequately before performing any
maintenance or service.
PERIODIC MAINTENANCE SCHEDULE
Item Routine Pre-operation
check(daily) 6 months or 100 Hr 12 months or 300 Hr
Engine oil
Check oil level
in engine.
○
Replace ○(1)
Spark plug
Check condition.
Clean and replace
if necessary.
○
Fuel
Check fuel level
and leakage.
○
Fuel hose
Check fuel hose for
cracks or damage,
Replace if necessary.
○
Air filter
Check condition.
Clean.
○(2)
Muffler screen
Check condition.
Clean and replace
if necessary.
○
Spark arrester
Check condition.
Clean and replace
if necessary.
○
Fuel filter
Clean and replace
if necessary.
○
Crankcase
breather hose
Check hose weather
for cracks or damage.
Replace if necessary.
○
Cylinder head
Decarbonizes
cylinder head
More frequently
★
- 6 -

SECTION 3 MAINTENANCE
if necessary
Valve
clearance
Check and adjust
when engine is cold
★
Fittings/
fasteners
Check all fittings
and fasteners.
Correct if necessary.
★
The point where abnormality
was recognized by use
○
(1) Initial replacement of the engine oil is after before one month or after 20 hours of operation.
(2) The air filter needs to be cleaned more frequently when using in unusually wet or dusty areas.
★Since these items require tools, date and technical skills, you should
find a local dealer perform the service.
- 7 -

SECTION 3. MAINTENANCE
3-2 Engine Oil
NOTE: Drain the oil while the engine is still
warm to assure rapid and complete draining.
1. Place the generator on a level surface.
2. Remove the screws ①, and then remove the
cover ②.
3. Remove the oil filler cap ③.
4. Fill with the specified amount of the
recommended engine oil, and then install and
tighten the oil filler cap.
5. Install the cover and tighten the screws.
Note: Before each time of use, the generator must
be placed on a horizontal surface and check the oil
level after stopping the engine.
1.Remove the oil dipstick and wipe it clean
2. Insert dipstick into oil filler hole but don’t tighten it,
check oil level.
3. If oil level is too low, add the recommended
engine oil until oil level reaches the upper limited
shown by the dipstick.
Used motor oil may cause skin cancer
if repeatedly left in contact with the skin for
prolonged periods. Thoroughly wash your hands
with soap and water as soon as possible after
handling used oil though the cancer is not certain
to occur.
Recommended engine oil:
SAE 10W -30
Recommended engine oil grade:
API Service SE type or higher
Engine oil quantity:
0.6 L
- 8 -

SECTION 3. MAINTENANCE
3-3 Air Cleaner
A dirty air cleaner will restrict air
flow to the carburetor, causing a lower engine
power. Service air cleaner more frequently
when operating the generator in extremely
dusty areas.
Using gasoline or flammable
solvent to clean the filter element can cause a
fire or explosion. Use only soapy water or
nonflammable solvent.
Never run the generator without the
air cleaner. Rapid engine wear will result.
1) Remove the screw ①remove the cover ②
and oil observation window ③
2) Remove the air filter case cover and then
remove the foam element ④.
3) Wash the foam element in solvent and dry it.
4) Oil the foam element and squeeze out excess
oil. The foam element should be wet but not
dripping.
5) Insert the foam element into the ir filter case.
6) Install the air filter case cover in its
original position and tightenthe screw.
- 9 -

SECTION 3. MAINTENANCE
3-4 Clean fuel filter
The fuel filte prevents dirt or water which may
be in the fuel tank from entering the carburetor. If
the generator has not been run for a long time, the
fuel filte should be cleaned.
1) Remove the screw ①and then remove the
cover ②and Oil observation window ③.
2) Drain the fuel in the fuel tank④. Hold the tube
clip ⑦toward downward and pull out the fuel
tube ⑧which connect on the fuel
tank, then disassemble fuel filter.
3) Put the fuel filter into non-combustible or
higher flash point solvent and clean it.
4) Assemble fuel filter to the main jet ⑤on the
fuel tank，then assemble fuel tube to main jet on
the fuel tank and install tube clip.
Gasoline is extremely flammable
and explosive. Do not smoke or allow flames or
sparks in the work area.
After reassembly, check for leaks,
and make sure the work area is dry before
starting the engine.
3-5 Spark Arrester
A hot muffler can cause severe
burns. Allow the generator set to cool before
servicing the muffler.
1. Unscrew 6 bolts ①，and take off
shutter ②.
2. Loosen the bolt ③and then rem
muffler screen .
3. Clean the carbon on the muffler screen
by wire brush.
4. Check the muffler screen and spark
arrester, replace if it damage.
5. Install spark arrester.
6. Install the cover and tighten the screws.
- 10 -

SECTION 3. MAINTENANCE
3-6 Spark Plug
A spark plug of a wrong model or
wrong heat range may deteriorate the
engine’s performance or even damage the
engine.
If the engine is run continuously, the spark plug
and muffler will be very hot. Be careful not to touch
the muffler or spark plug.
1) Remove the spark plug cap ①,Insert the tool
④,through the hole from the outside of the
cover.
2) nsert the handlebar ③in to the tool ④and turn
it counterclockwise to remove the
spark plug
3) Check for discoloration and remove any carbon
deposits.
The porcelain insulator around the center
electrode of spark plug should be a medium to
light tan color.
4) Check the spark plug type and gap
0.6-0.7mm
SIDE
ELECTRODE
WIRE BRUSH
Standard spark plug:
F7RTC
spark plug
Gap: 0.7-0.8mm (0.028-0.031in)
- 11 -

SECTION 3. MAINTENANCE
5）Install the spark plug
If installing a new spark plug, tighten l/2 turn after
the spark plug has firmly pressed on the washer. If
reinstalling a used spark plug, tighten l/8 - l/4 turn
after the spark plug has firmly pressed on the
washer.
6）Install the spark plug cap and spark plug cover
Spark Plug Torque: 25~.30 N*m
The spark plug must be securely
tightened. An improperly tightened spark plug
could damage the engine.
Never use spark plugs which have an
improper heat range. Use only the recommended
spark plugs or equivalent.
3-7 Valve Clearance
Valve clearance inspection and
adjustment must be performed with the engine
cold.
1) Remove the cylinder head cover, and pull the
starter grip (until a resistance is clearly felt) to
set the piston at top dead center of the
compression stroke (both valves fully closed).
2) Insert a feeler gauge between the rocker arm
and valve to measure valve clearance.
3) If adjustment is necessary, proceed as follows:
a) Use a clamp to hold the rocker arm pivot
and use a wrench to loosen the pivot lock
nut.
b) Turn the rocker arm pivot to obtain the
specified valve clearance.
c) Retighten the lock nut while using a clamp
to hold the rocker arm pivot.
d) Recheck valve clearance after tightening
the lock nut.
Standard
valve
clearance
IN. 0.10~0.15 mm
EX. 0.10~0.15 mm
FEELER GAUGE
ROCKER ARM
LOCK NUT
- 12 -

SECTION 4. DISASSEMBLY AND SERVICE
(TRY AGAIN AFTER A FEW MINUTES)
4-1 Troubleshooting
4-1-1 Hard Starting
(SEE 4-4-1)
(SEE 4-4-1)
(SEE 4-4-2)
(SEE 4-4-2)
(SEE 4-4-2)
(SEE 3-7)
(SEE 4-4-1)
(SEE 4-5-5)
(Replace
(Replace
(SEE 3-6)
(SEE 3-2)
HARD
STARING
FUEL SYSTEM
IGNITION
SYSTEM
COMPRESSION
SYSTEM
(SEE 3-3)
(SEE 4-4-4)
(SEE 3-4)
(ADD FUEL INTO FUEL TANK)
FUEL LEVEL too low
FUEL FILTER clogged
CARBURETOR out of adjustment
AIR FILTER dirty
OIL low
SPARK PLUG GAP incorrect
SPARK PLUG CAP faulty
IGNITION COIL faulty
START SWITCH faulty
OIL ALERT SYSTEM faulty
VALVE CLEARANCE incorrect
CYLINDER HEAD GASKET faulty
CYLINDER HEAD BOLT faulty
VALVE faulty
CYLINDER / PISTON / PISTON RING worn
CAMSHAFT worn
ENGINE FLOODED to much fuel
- 13 -

SECTION 4. DISASSEMBLY AND SERVICE
(ADD CLEAN FRESH FUEL OF DESIGNATED
QUALITY INTO TANK)
4-1-2 Low Power
(SEE 4-4-1)
(WASH)
(SEE 4-5-2)
(SEE 4-5-4)
(SEE 4-4-4)
(MOVE TO “RUN” POSITION)
(SEE 3-3)
(SEE 4-4-3)
(SEE 3-6)
(SEE 4-4-1)
(SEE 3-7)
(WASH)
(SEE 4-4-2)
(SEE 3-4)
LOW
POWER
FUEL SYSTEM
IGNITION
SYSTEM
COMPRESSION
SYSTEM
CARBURETOR out of adjustment
FUEL FILTER clogged
CHOKE LEVER not fully open
AIR FILTER dirty
SPARK PLUG faulty
IGNITION COIL faulty
CYLINDER / PISTON / PISTON RING worn
VALVE CLEARANCE out of Spec
COOLING FAN dirty
VALVE SEAT worn or damaged
COOLING CYLINDER COOLING FINS dirty
MUFFLER clogged
MOTOR open phase, MOTOR WINDING
turn-to-turn short circuit
OTHER
FUEL QUALITY poor
(REMOVE EXTRA LOADS)
ELECTRICAL LOADS too high
CAMSHAFT worn
- 14 -

SECTION 4. DISASSEMBLY AND SERVICE
4-1-3 Speed Unstable
(SEE 4-4-2)
(SEE 4-4-1)
(SEE 3-4)
(ADD CLEAN FRESH FUEL OF DESIGNATED
QUALITY INTO TANK)
(SEE 4-4-4)
(SEE 3-7)
SPEED
UNSTABLE
FUEL SYSTEM
COMPRESSION
SYSTEM
FUEL low / poor quality / contaminated
FUEL FILTER clogged
CARBURETOR clogged
VALVE CLEARANCE incorrect
VALVE SEAT worn and leak
CAMSHAFT worn
(SEE 4-4-4)
GOVERNOR
SYSTEM
Speed variable stepper motor damaged
(SEE 4-5-4)
INVERTER’S SPEED GOVERNOR
damaged
(ADD NEW OIL)
OTHER
OIL low level
(REMOVE EXTRA LOADS)
ELECTRICAL LOADS too high
- 15 -