Poulan Pro PPG 6000 User manual

Portable Electric Generator
Service Manual
Model: PPG6000

Contents
Chapter 1 General Information…………………………………………….. 3-7
General Description of Generator…………………………………. 3
Safety Information…………………………………………………… 4
Model Parameters…………………………...……………………….
Maintenance and Adjusting Data……………..……………………. -7
Chapter 2 Maintenance of the Generator Set………………………………8
2.1 Maintenance of Starting System……………………………….. 8-10
2.2 Maintenance of Lubrication System…………………………… 10-11
2.3 Maintenance of Inlet System…………………………………… 12-13
2.4 Maintenance of Fuel System………………..………………… 13-14
2. Maintenance of Exhaust System……………………………… 14-1
2.6 Maintenance of Ignition System……………………………….. 16-17
2.7 Maintenance of Generator………………………………………18-20
2.8 Maintenance of Cylinder Head and Valve……………………. 20-24
2.9 Maintenance of Crankcase, Crankshaft and Camshaft……... 2 -28
2.10 Maintenance of Connecting Rod, Piston and Cylinder…….. 29-31
2.11 Electrical System ………...................................................... 32
2.12 Wiring Diagram…………………………………………………. 33
Chapter 3 Trouble Shooting…................................................................. 34
3.1 General…………………………………………………………… 34
3.2 Hard Starting…………………………………………………….. 3
3.3 Ignition System……………………………………………………3
3.4 Generator Power Flow Chart…………………………………… 36
3. Electrical Troubleshooting Stator……………………………… 37
3.6 General Troubleshooting……………………………………….. 38
Chapter 4 Exploded View and Bill of Materials (BOM)………………….. 39
4.1 Exploded Views………………………………………………… 39-42
4.2 Bill of Materials (BOM)………………………………………….. 42- 0

Chapter 1 General Information
PPG6000 Generator is equipped with a single cylinder, 4 stroke, forced air-cooled, OHV 2 ° slant,
internal combustion engine. It is equipped with an electronic ignition system and is tuned to meet all
EPA and California Emissions Requirements.
Figure 1.1
General Description:
1. Gas Tank
2. Choke
3. Fuel Shut Off
4. Pull Starter
. Oil Dipstick
6. 120 Volt Outlet
7. Ground
8. Circuit Breaker
9. On Off Switch
10. Gas Cap
11. Gas Tank
12. Valve Cover
13. Air Filter
14. Frame
1 . Muffler

Safety Information:
This symbol is nown as the safety alert symbol and points out safety instructions that can lead
to injury or death.
Attention:
Please read and understand this manual
and the safety information prior to
starting the Generator.
Danger: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
Caution: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
SAFETY INSTRUCTIONS
This generator is designed to supply electrical power. Please read and understand all of the safety instructions
and warning labels associated with this generator.
1) Do not operate indoors.
2) Generator must be on a flat stable surface. Surface slope not to exceed 4 degrees.
3) Operate in a well-lit and ventilated area.
4) Do not operate in moist or wet conditions including the surrounding ground.
) The generator should be a minimum of 3 feet away from all combustible materials and should not be used
around hazardous materials.
6) Operating at a gas or natural gas filling station is forbidden.
7) Do not touch muffler or cylinder during or after operation. They are hot.
8) No smoking when filling the gas tank.
9) Do not overflow gas tank. Fill the tank to 1 inch below the top neck to allow for gas expansion. Ensure the
ventilation hole in the gas cap is not plugged with foreign matter such as dirt or leaves.
10) The engine should be shut off for at least 2 minutes before adding gas or oil.
11) Do not open the gas tank or oil reservoir while the engine is running.
12) Be mindful of the danger, warning and caution labels on the generator.
13) Keep away from children. Children should be kept at a minimum of 6 feet away from the generator at all
times.
14) In a normal situation the generator should be shut off using the instructions found on the front panel label.

Specifications
PPG6000
Dimension/Weight Engine
Model PPG6000
LxHxW - Inches
26.8x20x21.3
Net Weight, Box Incl.
18 lb
Gross Weight, Full of
Fuel
220lb
Model OHV13H
Engine Type 4-stroke, overhead valve, cylinder tilt 2 °
Cylinder discharge
capacity 389 cc
Bore x Stro e 88x64 mm
Cooling System Forced Air Cooling
Ignition System Transistor Magnet Ignition
Spar Plug NGK, BP6ES
Engine Oil Volume 1.1Qt
Fuel Volume) 6.6 Gallon
Compression Ratio
8.0:1
Model
PPG6000
Rated
Voltage 120V / 240V
Rated
Frequency 60HZ
Rated
Current 27.2A
Rated Output 6.0KW
Max Output 6.3KW

Generator
Maintenance and Adjusting Data
Tolerance Parameters
Parts Item Standard Extreme Max/Min
Max Speed 37 0+ 1 0, No Load -
Cylinder Pressure
88-
834KPa@600RPM
8 -120PSI@600PSI
-
Cylinder Cylinder bore diameter 88.00mm, 3.46 " 88.17mm, 3.471"
Warpage .10mm, .004"
Valve bushing 6.60mm, .260" 6.7 mm, .26 7"
Outside Diameter of piston skirt 87.98 mm, 3.464" 87.8 mm, 3.4 9"
Gap of piston and cylinder .01 -.0 2mm, .001" .12mm, .00 "
Inside diameter of piston pin hole 20.002mm, .787" 20.042mm, .789"
Outside diameter of piston pin 20.00mm, .787" 19.9 mm, .78 "
Clearance of piston and piston pin hole .002-.014mm, .0006" .08mm, .003"
Flank clearance of Piston ring .030-.060mm, .002" .1 mm, .006"
Closed gap of the first and second ring .20-.40mm, .012" 1.0mm, .039"
Closed gap of the oil ring .20-.70mm, .002" 1.0mm, .039"
Width of the first ring 2.0mm, .079" 1.7 mm, .069"
Width of the oil ring 2.8mm, .110" 2.7mm, .106"
Small end diameter 20.00 mm, .7876" 20.07mm, .790"
Large end diameter 36.02 mm, 1.418" 36.070mm, 1.420"
Large end clearance .040-.066mm, .002" .12mm. .00 "
Large end flank clearance .1-.7mm, .019" 1.0mm, .039"
Cran shaft Crankshaft pin outside diameter 3 .98 mm, 1.4167" 3 .93mm, 1.4146"
Intake valve adjusted clearance .1 +.02mm,
.006+.001"
Exhaust valve adjusted clearance .20+.02mm,
.008+.001"
Intake valve stem diameter 6. 9mm, .2 9" 6.44mm, .2 3"
Exhaust valve stem diameter 6. mm, .2 8" 6.40mm, .2 2"
Valve guide inside diameter 6.60mm, .260" 6.66mm, .262"
Clearance of intake valve and guide .010-.037mm, .001" .10mm, .004"
Clearance of exhaust valve and guide .0 0-.077mm, .002" .12mm, .00 "
Valve seat width 1.1mm, .043" 2.0mm, .079"
Spring free length 39.0mm, 1. 3 " 37. mm, 1.476"
Intake valve cam height 32.44-32.60mm,
1.279"
32.24mm, 1.269"
Exhaust valve cam height 31.94-32.10mm,
1.260"
31.74mm, 1.249"
Camshaft collar 1 .984mm, .6292" 1 .92mm, .6268"
Cran shaft case cover Camshaft hole 16.0mm, .6299" 16.0 mm, .6318"
spar plug Spark plug gap 0.7-0.8mm, .027-
.031"
spar plug capacity Resistance 7. -12. K ohms
Resistance of primary coil .8-1.0 ohms
Resistance of secondary coil .9-7. ohms
Air Gap .4+.2mm, .016+.007"

Torque Values
Torque Torque
N/m in*lbf *except
where note
Connecting rod bolt M8X1.2 (special bolt) 14 124
Cylinder head bolt M10X1.2 34 300
Flywheel nut M16X1. (special nut) 113 *83 ft*lbf
Roc er shaft nut M6X. 10 88
Roc er shaft bolt M8X1.2 (special bolt) 24 212
Fuel switch connecting nut M10X1.2 10 88
Exhaust pipe connecting
nut/bolt M8X1.2 24 212
Air filter bolts M6X1.0 7. 66
Air filter nut M6X1.0 8. 7
Drain plug M12X1.2 23 203
Rotor bolt M10X210 44 389
Standard Torque Values
M 44
M6 10 88
M8 24 212
M10 37 327
M12 487
M6 12 106
M8 26 230
M10 34 300
M12 9 22
M 4 3
M6 9 79
Fitting Directions:
1. When fitting the piston in the cylinder the mark “ ” on the piston top must be aimed to the intake
valve direction (upper).
2. When fitting the piston rings on the piston the “R,N’ mark on the first and second ring must be
upwards, and the gap of all three rings should be 120° apart.
3. The timing marks on the gears must be matched to each other.

Generator Information
Area Item Standard Service Limit
Main Winding Resistance .2 ohms
Field Winding Resistance 2-62 ohms
Exciter Winding Resistance 1.2 ohms
Main Winding Resistance .4 ohms
Carbon Brush length Length .9mm, .3 4" mm, .197"
EPA and Engine Serial Number are located on the panel side of the generator in the location shown.

Chapter 2 Maintenance of the Generator Set
2.1 Maintenance of the Manual Starting System
The integral configuration of the starting device is shown below. Check the condition of the starter.
Replace if damaged.
There is a spring inside the starter device that is under stress. Wear safety goggles and watch
for flying debris when it is removed.
Remove the perimeter bolts to remove the starter housing.
Check the condition of the starter system. Replace any broken or damaged parts as follows:

1. Inspect the rope for abrasions. Replace as necessary.
2. Dismantle the starter pawl guide bolt with a socket.
3. Remove the pawls and pawl spring.
4. Visually inspect all parts.
. Inspect the flute of the starting draw wheel.
6. Remove the shroud from the engine for inspection of the fan blades.
7. Replace parts as necessary.

2.2 Maintenance of the Lubrication System
Chose the oil type according to the local temperature of operation.
Use Four-stroke engine oil. SE, SF or equivalent to SG grade oil (SAE-30). When temp is below
0°F SAE 10W30 is recommended. SAE W-30 is recommended when temp is below °F.
1. It is best to change the engine oil when the engine is warm. This allows the oil to flow better for
a complete drain.
2. Drain the oil from the cylinder block by removing the plug at the base of the engine.
3. Check the condition of the dipstick and o-ring seal.
4. Replace the drain plug.
. Fill with oil. See specifications in section 1.1 (parameters) for amount to add.
2.3 Maintenance of the Inlet system
1. Remove the air cleaner outer cover by releasing the latches at the top and bottom.
2. Remove the air cleaner element (foam pad). Replace as necessary.
Never use gasoline, low-burning point solvent, acid or alkaline to clean the element. Use
detergent only!

Cleaning the element (foam pad)
Dip the element in the detergent and wring it out. Apply motor oil and wring out excess oil. Install
element.
3. Remove the plastic inner housing by removing the six nuts around the perimeter.
4. Remove the enclosure by removing the two nuts inside the enclosure and one on the
backside.
. Remove the carburetor gasket and choke mechanism. Some models may not have automatic
chokes and the choke mechanism will not need to be removed. It is built onto the carburetor in
this case.
6. Remove the lines to the carburetor and remove the carburetor.

2.4 Maintenance of Fuel System
1. Remove the bowl of the fuel cock.
2. Remove the screen inside the fuel cock.
3. Remove the fuel cock.
4. Pull out the screen inside the tank.
. Clean or replace both screens and reassemble.

2.5 Maintenance of the Exhaust System
1. Remove the outer heat shield from the muffler.
2. Bend the anti-rotation tabs back around the engine exhaust bolts.
3. Remove the bolts from the engine side of the exhaust pipe.
4. Remove the two bolts from the muffler to the generator head to separate the muffler from the
generator.
. Lift the muffler out of the frame and inspect for cracks.
6. Inspect the spark arrestor mounted over the outlet of the muffler. It should be clear of debris
and have no tears in the screen.
7. Replace the muffler or spark arrestor as necessary.
8. Inspect the gasket between the muffler and the engine head.
9. Inspect the engine head for carbon build up. Too much build up in the head or muffler can rob
the engine of power.

2.6 Maintenance of the Ignition System
1. Check the gap between the ignition coil and the flywheel. The gap should be 0.4mm + 0.2mm,
.016” + .007”.
2. Check the status of the spark from the ignition coil. It should be a blue spark and must be
above 10,000 Volts.
3. When there is no output voltage from the ignition coil, remove the coil by removing the bolts
that hold the ignition coil to the engine block.
4. Remove the spark plug cap and unplug the other wires so the ignition coil can be removed.
. Using a multi-meter capable of measuring resistance or an ohmmeter, connect one end of the
tester to the spark plug lead. Connect the other end to the core of the ignition coil. Resistance
value of the secondary end of the coil is 2. K to 2.8K ohms.
6. Connect one end of the ohmmeter to the primary (small black wire) lead, the other end to the
core of the ignition coil (same location as before). The resistance value of the primary coil is
.2 to .30 ohms.
7. Replace as necessary.

8. Remove the spark plug. Check the cylinder pressure. Is should fall in the values noted in
section 1.1 of this manual. If the plug is brown in color the engine is working normally.
9. Check for carbon build up on the spark plug. Check the gap of the spark plug. The values for
the gap are found in section 1.1 of this manual.
10. Remove the flywheel. Use a screwdriver to hold the flywheel from moving while unloosening
the flywheel nut. The torque value of the nut is 113N*m or 83 ft*lb.
11. Remove the flywheel by using a gear puller.
12. Check for any damage to the flywheel. Rust can me remove from the magnet section by light
sanding.
2.7 Maintenance of the Generator
1. Remove the two bolts on the rear cover of the generator head.
2. Remove the main bolt in the center of the rotor. Check the bearing.

3. Remove the screws on the outside of the generator head housing.
4. Remove the AVR (large plastic part with wires coming out) Automatic Voltage Regulator.
. Remove the bolts in the brushes, and remove the brushes.
6. Remove the mounting nuts from the rubber engine and generator head mounts. There are four
total, two under the engine and two under the generator head. This will allow you to lift the
engine generator combination out of the frame.
7. Remove the rear housing from the generator as shown.
8. Remove the stator cover.

9. Remove the generator stator.
10. Check the stator and rotor for damage or burnt wires. If there are any contact marks or wires
that have burnt or the insulation is melted, replace the parts.
11. To remove the rotor from the engine install the bolt that came out of the shaft center. Screw it
in until only ¼” is left until the head comes in contact with the bearing.
12. Forcefully strike the screw with a large blacksmith hammer to remove the rotor from the
engine.

2.8 Maintenance of the Cylinder Head and Valve
1. Remove the spark plug.
2. Remove the valve cover head bolt located in the center of the valve cover.
3. Check the gasket of the cover. Check the condition of the valve cover gasket.
4. Check the valve clearance of the engine. If they have to be adjusted loosen the valve
adjustment nut and then adjust the clearance.
a. Clearance for intake .1 mm + .02mm, .006” + .001”
b. Clearance for exhaust valve .20mm + .02mm, .008” + .001”.
. Tighten the nut with the following torque:
c. Adjustment nut 10 N*m, 88 in*lbf
d. Tightening nut 10 N*m. 88 in*lbf
6. Remove the rocker arm for inspection.
7. Remove the lifters and inspect. Rolling them on a flat surface will help to check if they are bent.

8. Remove the rocker arm bolts so you can remove the rocker arm guide plate and inspect the
plastic inserts in the plate for damage.
e. Torque of the rocker arm bolt is 24N*m, 210 in*lbf
9. Inspect the flute and the protruding parts of the rocker arm.
10. Remove the four head bolts. When tightening the 4 head bolts use an across the head
sequence.
f. Torque of the head bolts is 34N*m, 300 in*lbf
11. Remove the head and inspect the head gasket. Sometimes the head may need a tap up with a
plastic hammer. Never use a screwdriver between the head and the cylinder or you will
damage the surface.
12. Remove the alignment pins.