Pramac P2200i Maintenance Manual
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Pramac P2200i Maintenance Manual

Pramac P2200i Maintenance Manual

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MAINTENANCE MANUAL
P2200i

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  • Page 1 MAINTENANCE MANUAL P2200i...

  • Page 2: Safety Precautions

    SAFETY PRECAUTIONS Static electric sparks caused by fuel flowing • Thoroughly read this MANUAL before through a service station’s pump nozzle can operating the generator set. Safe operation ignite gasoline. Never fuel the generator set and top performance can only be attained with a service station’s pump nozzle.
  • Page 3 SAFETY PRECAUTIONS Make sure that fasteners and clamps on the Benzene and lead may be found in gasoline • • generator set are tight. Keep guards in and have been identified by some states and position over fans, rotors, etc. federal agencies as causing cancer or reproductive toxicity.

  • Page 4: Table Of Contents

    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 ..........4 SECTION 3 MAINTENANCE 3-1 Maintenance Schedule ..............
  • Page 5 TABLE OF CONTENTS 4-4-2 Cylinder Head / Valves............27 4-4-3 Flywheel / Ignition Coil/Recoil Starter ..........33 4-4-4 Carburetor ..............37 4-5 Generator................. 40 4-5-1 Fuel Tank ..............40 4-5-2 Muffler................ 41 4-5-3 Frame/Bedplate Combination ............ 43 4-5-4 Motor................. 44 4- 5-5 Inverter...............

  • Page 6: Section 1. Introduction

    SECTION 1. INTRODUCTION 1-1 Generator Components Spark plug maintenance cover Fuel tank cap Tank cap Spark plug After tha panel cover Panel comp The left panel Floor Oil-level gauge Carburetor filter Starting handle Silencer The right panel Muffler baffle Chassis suspension rubber pad - 1 -...

  • Page 7: Parameters

    SECTION 1. INTRODUCTION 1-2 Parameters Model No. P2200i Type Inverter Frequency /Hz Rated Voltage /V Max. output power / Rated output power /k Power factor Generator AC output quality ISO8528 G1 ≤ Control by inverter overload protection Overload Protection(AC) program Engine Model No.

  • Page 8: Section 2 Maintenance Standard

    SECTION 2 MAINTENANCE STANDARD 2-1 Engine Maintenance Standard Part Item Standard Allowable limit 5000rpm Max no-load speed Gasoline 6000 rpm Cylinder compression engine ≧1.17Mpa（1400rpm） Cylinder Cylinder I.D. 52mm 52.015mm Cylinder Warpage 0.10mm head Skirt O.D. 51.98mm 51.97mm Piston-to-cylinder 0.015-0.055mm 0.1mm clearance Piston Piston pin bore I.D.

  • Page 9: Generator Maintenance Standard

    SECTION 2 MAINTENANCE STANDARD 2-2 Generator Maintenance Standard Table of resistance values between windings rated 230V 1.9kW Part Wire color Resistance Main winding 4.26Ω±0.34Ω Secondary winding White 0.43Ω±0.04Ω DC winding Blue 0.113Ω±0.01Ω 2-3 Fastener Torque Specification Tightening torque Part Fastener size Kg·m ft·lb （N·m）...

  • Page 10: Section 3 Maintenance

    SECTION 3 MAINTENANCE 3-1 Maintenance Schedule Accidental starting of the generator Good maintenance is essential to safe, economical set during maintenance can cause severe and zero-failure operation, and is also good for personal injury or death. Before performing environment protection. Under hot or dusty operating maintenance, disconnect the spark plug wire conditions some maintenance operations should be from the spark plug.

  • Page 11: Engine Oil

    SECTION 3. MAINTENANCE 3-2 Engine Oil NOTE: Drain the oil while the engine is still Max oil level warm to assure rapid and complete draining. 1) Place the generator on a level surface and warm up for several minutes. Min oil level 2) Remove the screw ①, a nd then remove the oil fill cover ②.

  • Page 12: Air Cleaner

    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.

  • Page 13: Fuel Sediment Cup Cleaning

    SECTION 3. MAINTENANCE 3-4 Fuel Sediment Cup Cleaning After reassembly, check for leaks, The fuel sediment cup prevents dirt or water and make sure the work area is dry before which may be in the fuel tank from entering the starting the engine.

  • Page 14: Spark Plug

    SECTION 3. MAINTENANCE W16FP / W16FPR (DENSO) 3-6 Spark Plug W6BC / WR6BC (BOSCH) A spark plug of a wrong model or If the machine needs EMC Certification, engine wrong heat range may deteriorate the must use E6RTC spark plug engine’s performance or even damage the If the electrode is damaged, or insulation is engine.

  • Page 15: Valve Clearance

    SECTION 3. MAINTENANCE d) Recheck valve clearance after tightening 3-7 Valve Clearance the lock nut. Valve clearance inspection and adjustment must be performed with the engine cold. 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 FEELER GAUGE compression stroke (both valves fully closed).

  • Page 16: Troubleshooting

    SECTION 4. DISASSEMBLY AND SERVICE ENGINE FLOODED to much fuel 4-1 Troubleshooting ( TRY AGAIN AFTER A FEW MINUTES ) 4-1-1 Hard Starting FUEL LEVEL too low ( ADD FUEL INTO FUEL TANK ) FUEL SYSTEM FUEL FILTER clogged (SEE 3-4) CARBURETOR out of adjustment (SEE 4-4-4) AIR FILTER dirty...

  • Page 17: Low Power

    SECTION 4. DISASSEMBLY AND SERVICE 4-1-2 Low Power FUEL QUALITY poor (ADD CLEAN FRESH FUEL OF DESIGNATED QUALITY INTO TANK) FUEL FILTER clogged (SEE 3-4) FUEL SYSTEM CARBURETOR out of adjustment (SEE 4-4-4) CHOKE LEVER not fully open (MOVE TO “RUN” POSITION) AIR FILTER dirty (SEE 3-3) SPARK PLUG faulty...

  • Page 18: Speed Unstable

    SECTION 4. DISASSEMBLY AND SERVICE 4-1-3 Speed Unstable FUEL low / poor quality / contaminated ADD CLEAN FRESH FUEL OF DESIGNATED QUALITY INTO TANK FUEL FILTER clogged FUEL SYSTEM (SEE 3-4) CARBURETOR clogged (SEE 4-4-4) VALVE CLEARANCE incorrect (SEE 3-7) SPEED COMPRESSION VALVE SEAT worn and leak...

  • Page 19: Low Speed/Voltage

    SECTION 4. DISASSEMBLY AND SERVICE 4-1-4 Low Speed / Voltage AIR FILTER dirty (SEE 3-3) FUEL QUALITY poor / contaminated ADD CLEAN FRESH FUEL OF DESIGNATED FUEL SYSTEM QUALITY INTO TANK CARBURETOR has water (SEE 4-4-4) CHOKE LEVER not fully open (MOVE TO “RUN”...

  • Page 20: Exhaust Color Abnormal

    SECTION 4. DISASSEMBLY AND SERVICE 4-1-5 Exhaust Color Abnormal AIR CLEANER dirty (SEE 3-3) BLACK CARBURETOR faulty (SEE 4-4-4) LOAD excessive (REMOVE EXTRA LOAD) ENGINE temperature too low EXHAUST (WHEN STARTING NORMALLY) COLOR WHITE ABNORMAL FUEL QUALITY poor/ contaminated ADD CLEAN FRESH FUEL OF DESIGNATED QUALITY INTO TANK FUEL QUALITY poor/ contaminated ADD CLEAN FRESH FUEL OF DESIGNATED...

  • Page 21: No Ac Output Voltage

    SECTION 4. DISASSEMBLY AND SERVICE 4-1-6 No AC Output Voltage OUTPUT RECEPTACLE faulty (CHECK FOR BURN, IF SO, REPLACE IT) ENGINE SPEED abnormal (CHECK IT AND ADJUST) NO AC OUTPUT VOLTAGE STATOR WINDING COIL defective (SEE 4-5-4) INVERTER faulty (SEE 4-5-5) - 16 -...

  • Page 22: Preparing To Service

    SECTION 4. DISASSEMBLY AND SERVICE 4-2 Preparing to Service 4-2-1 Safety Precautions There are hazards in servicing gensets. Study TABLE 4-1 HAZARDS AND THEIR SOURCES Safety precautions and become familiar with the • Leaking or spilled fuel hazards listed in table 4-1. Note the following •...

  • Page 23: Disassembly Chart

    SECTION 4. DISASSEMBLY AND SERVICE 4-3 Disassembly Chart LEFT RIGHT CARRYING HANDLES CONTROL PANEL LOUVER PANEL BED FUEL TANK INVERTER FRAME BEDPLATE MOUNT RUBBER BRACKET STATOR ROTOR MAIN UNIT BUFFER MOTOR REAR SUPPOER MUFFLER ENGINE CARBURETOR FLYWHEEL FAN COVER RECOIL STARTER AIR CLEANER GENERATOR DISASSEMBLY This chart is a quick-reference guide for...

  • Page 24: Section 4. Disassembly And Service

    SECTION 4. DISASSEMBLY AND SERVICE Camshaft 4-4 Engine 4-4-1 Camshaft / piston Assembly: Check that the decompressor a.DISASSEMBLY/ REASSEMBLY w eight moves smoothly, and Bolt: M6 × 20 the spring is not weak or Crankshaft Torque: (8 ~ 12) N•m worn.
  • Page 25 SECTION 4. DISASSEMBLY AND SERVICE b.PISTON/ PISTON RING PISTON RING REASSEMBLY: 1) Install all rings with the markings facing upward. 2) Be sure that the top (chrome plated) and second rings are not interchanged. 3) Check that the rings rotate smoothly after installation. 4) Set the piston ring end gaps 120 degrees apart, and do not align the gaps with the piston pin bore.

  • Page 26: Piston-To-Cylinder Clearance

    SECTION 4. DISASSEMBLY AND SERVICE CRANKSHAFT c.CAMSHAFT/ CRANKSHAFT PUNCH CAMSHAFT MARKS While installing the camshaft, align the punch marks on the camshaft gear and timing gear (small gear on the crankshaft.) d. INSPECTION PISTON Check contact between piston and cylinder, defect of ring grooves, burn of piston top, cracks, etc. If the damage is severe, such as cracks, replace the piston.

  • Page 27: Piston Ring End Gap

    SECTION 4. DISASSEMBLY AND SERVICE and groove’s upper or lower surface to measure the clearance. Standard Service limit 0.15 mm 0.015-0.045 mm 4) PISTON RING WIDTH Standard Service limit Top/Second 1.5 mm 1.37 mm 5) PISTON RING END GAP Standard Service limit Top/second 0.02-0.04 mm...

  • Page 28: Connecting Rod

    SECTION 4. DISASSEMBLY AND SERVICE 8) PISTON PIN-TO-PISTON PIN BORE CLEARANCE Use an inside micrometer and an outside micrometer to measure piston pin bore’s inside diameter and piston pin’s outside diameter, then use the measured values to calculate the difference; if difference is beyond service limit, replace piston or piston pin according to wear status.

  • Page 29: Connecting Rod Big End Side Clearance

    SECTION 4. DISASSEMBLY AND SERVICE 3) CRANKPIN O.D. Standard Service limit 21.985 mm 21.925 mm 4) CONNECTING ROD BIG END SIDE CLEARANCE Standard Service limit 0. 1-0.7mm 1.1mm 5) CONNECTING ROD BIG END OIL CLEARANCE (RADIAL) 12N.m a) Clean all oil from crank pin surface. b) Place a piece of plastigauge, install connecting rod, and tighten the bolts to the specified torque.
  • Page 30 SECTION 4. DISASSEMBLY AND SERVICE CAMSHAFT As the main driving piece of the gasoline engine’s valve actuating mechanism, the camshaft controls opening and closing of intake and exhaust valves following a regular rule. Check cam surface and cam height for damage, check whether camshaft and bearings have play or are worn, if so, replace all of them. 1) CAMSHAFT CAM HEIGHT Standard Service limit...

  • Page 31: Oil Level Switch

    SECTION 4. DISASSEMBLY AND SERVICE PLAY PLAY BEARING Clean bearing in solvent and dry it. Spin the bearing by hand and check for play. replace the bearing if it is noisy or has excessive play AXIAL RADIAL OIL LEVEL SWITCH Measure continuity of oil level switch with an ohmmeter.

  • Page 32: Cylinder Head / Valves

    SECTION 4. DISASSEMBLY AND SERVICE 4-4-2 Cylinder Head / Valves a. DISASSEMBLY/ REASSEMBLY BREATHER TUBE REMOVAL/ INSTALLATION: Connect one end to cylinder head cover, the other end to breather chamber cap’s vertical-up vent. CYLINDER HEAD REASSEMBLY: Cylinder head Before installation, remove carbon deposits SHROUD from the combustion chamber and inspect cover breathing...

  • Page 33: Rocker Arm Shaft

    SECTION 4. DISASSEMBLY AND SERVICE b. DISASSEMBLY/ REASSEMBLY INTAKE EXHAUST VALVE VALVE REASSEMBLY: REASSEMBLY: Do not interchange with Check valve face for the exhaust valve. damage and carbon Be careful not to damage deposit, then install. valve stem. VALVE STEM SEAL VALVE SPRING PI VOT LOCK...

  • Page 34: Spring Free Length

    SECTION 4. DISASSEMBLY AND SERVICE c.INSPECTION 1) VALVE STEM O.D. Inspect each valve stem’s outer diameter, if it is less than standard value or beyond service limit, or valve face has visible burns or cracks, replace it with a new one. Standard Service limit 4.968 mm...
  • Page 35 SECTION 4. DISASSEMBLY AND SERVICE measuring. Replace valve guides if their inner diameters are smaller than standard value or beyond service limit. VALVE GUIDE Standard Service limit REAMER 5 mm 5.072 mm Replace: a) Put replacement valve guides in a refrigerator’s freezing chamber to freeze it for about 1 hour.

  • Page 36: Valve Seat

    SECTION 4. DISASSEMBLY AND SERVICE d) Check the valve stem-to-guide clearance. e) Valve stem-to-guide clearance: Deduct the valve stem VALVE GUIDE outside diameter from the valve guide bore’s inside diameter VALVE CLIP GUIDE to get the clearance between the valve guide and valve stem. DRIVER f) If the clearance is over the service limit, judge whether a if it...
  • Page 37 SECTION 4. DISASSEMBLY AND SERVICE e) Make a light pass with the 45°cutter to remove any possible burrs at the edges of the seat. f）After resurfacing seats, inspect for even valve seating. width Apply colorant to the valve’s tapered face, insert the valve and press it forcefully several times, be sure the valve does not rotate on the seat.

  • Page 38: Flywheel / Ignition Coil/Recoil Starter

    SECTION 4. DISASSEMBLY AND SERVICE 4-4-3 Flywheel / Ignition Coil/Recoil Starter a. DISASSEMBLY/ REASSEMBLY IGNITON COIL DISASSEMBLY/ REASSEMBLY: Check for cracked or damaged insulation before installation , to avoid electric leakage Flywheel DISASSEMBLY: Use a special tool (flywheel puller)to remove. Never knock with a hammer. REASSEMBLY: Remove oil or any other dirty matter from crankshaft and flywheel s ’...
  • Page 39 SECTION 4. DISASSEMBLY AND SERVICE b.INSPECTION CHARGE COIL, IGNITION COIL Attach one ohmmeter lead to charge coil’s black lead while touching the other tester to the iron core. Measured resistance value should be 0Ω. Attach one ohmmeter lead to charge coil’s red/white lead while touching the other tester to the iron core.
  • Page 40 SECTION 4. DISASSEMBLY AND SERVICE c. DISASSEMBLY/ REASSEMBLY (STARTER ASSY) The recoil starter can cause personal injury, Wear safety glasses. Do not let the recoil spring snap out. HEXAGON SHOULDER BOLT REASSEMBLY: Apply thread locking STARTER ROE Friction RATCHET compound to thread spring REASSEMBLY: first.
  • Page 41 SECTION 4. DISASSEMBLY AND SERVICE ASSEMBLY OF RECOIL STARTER STARTER Wear glovers and safety glasses to protect your CASE hands and eyes. RETURN SPRING Don’t let return spring snap out. 1) Put return spring into spring cover, hook spring’s outer hook firmly to the cover’s gap and align with starter reel’s STARTER groove, then install cover into starter reel.

  • Page 42: Carburetor

    SECTION 4. DISASSEMBLY AND SERVICE 4-4-4 Carburetor a. DISASSEMBLY/ REASSEMBLY Stepper motor protective cover Insulation gasket of carburetor Screw M3 × 8 (2) Torque: (1~1.5) N•m Sealing gaske t of carburetor Speed-regulating stepper motor Carburetor Sealing gasket of carburetor - 37 -...
  • Page 43 SECTION 4. DISASSEMBLY AND SERVICE b.DISASSEMBLY/ REASSEMBLY Gasoline is flammable and explosive. Close the fuel shut off valve, and drain the carburetor before servicing the carburetor. Smoking and fire are prohibited. CHOKE ASSY THROTTLE ASSY CARBURETOR BODY REASSEMBLY: Clean internal passages orifices with...
  • Page 44 SECTION 4. DISASSEMBLY AND SERVICE c.INSPECTION SPEED VARIABLE STEPPER MOTOR Measure resistance between ends of stepper motor socket 2’s diagonal, resistance value should be 50±1Ω，if it is exceeded, replace the stepper motor. Rotate stepper motor’s central shaft when the motor’s power is on, the shaft should not be stuck or has play, if so, replace the motor.

  • Page 45: Generator

    SECTION 4. DISASSEMBLY AND SERVICE 4-5 Generator 4-5-1 Fuel Tank DISASSEMBLY/ REASSEMBLY Gasoline is flammable and explosive, drain carburetor fuel tube before disassembly, spilled fuel must be wiped off immediately. Screen of fuel filter Fuel tank cover Assembly: Assembly: Check whether the meshes Make sure the venthole is clean and are blocked or damaged and not blocked.

  • Page 46: Muffler

    SECTION 4. DISASSEMBLY AND SERVICE 4-5-2 Muffler DISASSEMBLY/ REASSEMBLY EXHAUST PIPE MUFFLER GASKET MUFFLER PROTECTOR COVER NUT M6（2） Torque: (8~12) N•m SPARK ARRESTER REASSEMBLY: Remove carbon deposits with a wire brush before installation. REASSEMBLY: Install after removing the carbon deposits from the muffler using a plastic hammer.
  • Page 47 SECTION 4. DISASSEMBLY AND SERVICE Muffler cover seal rubber Nut M6 (2) Torque: (8 ~ 12) N•m Sealing gasket of exhaust port Motive power Silencer Shield of silencer (back shield) Shield of silencer (front shield) - 42 -...

  • Page 48: Frame/Bedplate Combination

    SECTION 4. DISASSEMBLY AND SERVICE 4-5-3 Frame/Bedpl ate Combination DISASSEMBLY/ REASSEMBLY MAIN UNIT BUFFER MOUNT (4) REASSEMBLY: Align with frame/bedplate combination’s installation hole install it. CUSHING RUBBER Make sure the rubber is not chapped, hardened, or worn. REASSEMBLY: Pay attention to installing direction. Install it under the engine, make sure rubber has no cracks, hardening or wear.

  • Page 49: Motor

    SECTION 4. DISASSEMBLY AND SERVICE 4-5-4 Motor a. DISASSEMBLY/ REASSEMBLY Motor rotor Disassembly: Make use of the disassembly thread on rotor and assemble proper rotor remover (a special tool) to disassemble. Bolt M6× 30(2) Torque: (7~13) N•m Nut M12 Engine Fan of motor Assembly: Wipe the dust or oil on...
  • Page 50 SECTION 4. DISASSEMBLY AND SERVICE b. INSPECTION Table of resistance between windings rated ： P2200i (INVERTER) 230V 1.9kW P2500i (IRONSIDE) 230V 2.0kW Part Wire color Resistance Main winding 4.26Ω±0.34Ω Secondary winding White 0.43Ω±0.04Ω DC winding Blue 0.113Ω±0.01Ω If resistance is zero or infinite, replace the stator.

  • Page 51: Inverter

    SECTION 4. DISASSEMBLY AND SERVICE 4-5-5 Inverter a. DISASSEMBLY/ REASSEMBLY Inv erte r parts Installing support of inverter Bolt M6×12(6) - 46 -...
  • Page 52 SECTION 4. DISASSEMBLY AND SERVICE Inverter Check whether colors of inverter’s leads have changed, whether inverter’s packing resin has bulging blisters, check whether all the inverter’s electric parts, connectors, and connecting wires have visible color change or damage. Output shorted: When the green light is off and the red light is on, the resistance level determines the output terminal.

  • Page 53: Control Panel

    SECTION 4. DISASSEMB LY AND SERVICE 4-5-6 Control Panel Control panel Indicator light Idle switch AC protector AC socket Waterproof endcap Ground bolt parallel socket a. DISASSEMBLY/ REASSEMBLY When combination switch is in “OFF” postion, ingnition circuit is close, which means INSPECTION inching switch’s two output terminals are made, ignition lead is earthed;...
  • Page 54 SECTION 4. DISASSEMBLY AND SERVICE alert system will automatically shut the engine, and oil warning light goes on; the engine cannot be Wire harness started until oil is added to reach the required level. Note: If the engine stalls or cannot be started, turn power switch into “ON”...
  • Page 55 SECTION 4. DISASSEMBLY AND SERVICE Power down switch engine. 2. Lower total power of all connected electrical equipment into the range of rated output. 3. Check cooling air intake port for obstruction by foreign matters, and whether relevant control parts are abnormal, if so, solve the problem immediately.

  • Page 56: Outer Case Assembly

    SECTION 4. DISASSEMB LY AND SERVICE 4-5-7 Outer case assembly a. DISASSEMBLY/ REASSEMBLY The right panel Muffler baffle Spark plug maintenance cover The left frame The left panel After tha panel cover - 51-...

  • Page 57: Section 5 Wiring Diagrams

    SECTION 5 WIRING DIAGRAMS - 52-...

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