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…………………………...……………………….5
Maintenance and Adjusting Data……………..…………………….5-7
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
2.5 Maintenance of Exhaust System……………………………… 14-15
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……...25-28
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…………………………………………………….. 35
3.3 Ignition System……………………………………………………35
3.4 Generator Power Flow Chart……………………………………36
3.5 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)………………………………………….. 42-50

Chapter 1 General Information
PPG6000 Generator is equipped with a single cylinder, 4 stroke, forced air-cooled, OHV 25° 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
5. 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
15.Muffler

Safety Information:
This symbol is known 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.
5) 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. 185lb
Gross Weight, Full of
Fuel 220lb
Model OHV13H
Engine Type 4-stroke, overhead valve, cylinder tilt 25°
Cylinder discharge
capacity 389 cc
Bore x Stroke 88x64 mm
Cooling System Forced Air Cooling
Ignition System Transistor Magnet Ignition
Spark 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 3750+ 150, No Load -
Cylinder Pressure 588-
834KPa@600RPM
85-120PSI@600PSI -
Cylinder Cylinder bore diameter 88.00mm, 3.465" 88.17mm, 3.471"
Warpage .10mm, .004"
Valve bushing 6.60mm, .260" 6.75mm, .2657"
Outside Diameter of piston skirt 87.985mm, 3.464" 87.85mm, 3.459"
Gap of piston and cylinder .015-.052mm, .001" .12mm, .005"
Inside diameter of piston pin hole 20.002mm, .787" 20.042mm, .789"
Outside diameter of piston pin 20.00mm, .787" 19.95mm, .785"
Clearance of piston and piston pin hole .002-.014mm, .0006" .08mm, .003"
Flank clearance of Piston ring .030-.060mm, .002" .15mm, .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" 1.75mm, .069"
Width of the oil ring 2.8mm, .110" 2.7mm, .106"
Small end diameter 20.005mm, .7876" 20.07mm, .790"
Large end diameter 36.025mm, 1.418" 36.070mm, 1.420"
Large end clearance .040-.066mm, .002" .12mm. .005"
Large end flank clearance .1-.7mm, .019" 1.0mm, .039"
Crankshaft Crankshaft pin outside diameter 35.985mm, 1.4167" 35.93mm, 1.4146"
Intake valve adjusted clearance .15+.02mm,
.006+.001"
Exhaust valve adjusted clearance .20+.02mm,
.008+.001"
Intake valve stem diameter 6.59mm, .259" 6.44mm, .253"
Exhaust valve stem diameter 6.55mm, .258" 6.40mm, .252"
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 .050-.077mm, .002" .12mm, .005"
Valve seat width 1.1mm, .043" 2.0mm, .079"
Spring free length 39.0mm, 1.535" 37.5mm, 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 15.984mm, .6292" 15.92mm, .6268"
Crankshaft case cover Camshaft hole 16.0mm, .6299" 16.05mm, .6318"
spark plug Spark plug gap 0.7-0.8mm, .027-
.031"
spark plug capacity Resistance 7.5-12.5K ohms
Resistance of primary coil .8-1.0 ohms
Resistance of secondary coil 5.9-7.5 ohms
Air Gap .4+.2mm, .016+.007"

Torque Values
Torque Torque
N/m in*lbf *except
where note
Connecting rod bolt M8X1.25(special bolt) 14 124
Cylinder head bolt M10X1.25 34 300
Flywheel nut M16X1.5(special nut) 113 *83 ft*lbf
Rocker shaft nut M6X.5 10 88
Rocker shaft bolt M8X1.25(special bolt) 24 212
Fuel switch connecting nut M10X1.25 10 88
Exhaust pipe connecting
nut/bolt M8X1.25 24 212
Air filter bolts M6X1.0 7.5 66
Air filter nut M6X1.0 8.5 75
Drain plug M12X1.25 23 203
Rotor bolt M10X210 44 389
Standard Torque Values
M5 5 44
M6 10 88
M8 24 212
M10 37 327
M12 55 487
M6 12 106
M8 26 230
M10 34 300
M12 59 522
M5 4 35
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 52-62 ohms
Exciter Winding Resistance 1.2 ohms
Main Winding Resistance .4 ohms
Carbon Brush length Length .9mm, .354" 5mm, .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.
5. 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.