Honda EG3600CX Manual
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82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分
How to use this manual
A Few Words About Safety
How to use this manual
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
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 man-
ual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and precau-
tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda EG3600CX

  • Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2: Table Of Contents

    82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING FUEL SYSTEM GOVERNOR SYSTEM GENERATOR/CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL MUFFLER ENGINE REMOVAL/INSTALLATION CYLINDER HEAD CYLINDER BLOCK TECHNICAL FEATURES WIRING DIAGRAMS INDEX...
  • Page 3 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Mo- tor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 4 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
  • Page 5 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Auto Voltage Regulator...
  • Page 6: Specifications

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 PERFORMANCE CURVES························· 1-11 SPECIFICATIONS ·········································1-3 DIMENSIONAL DRAWINGS······················· 1-25...
  • Page 7 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS SERIAL NUMBER LOCATION SPECIFICATIONS The engine serial number is stamped on the cylinder barrel, and the frame serial number is stamped on the engine bed. Refer to it when ordering parts or making technical inquiries. ENGINE SERIAL NUMBER FRAME SERIAL NUMBER...
  • Page 8 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS SPECIFICATIONS EG3600CX/EG4000CX DIMENSIONS AND WEIGHTS Model EG3600CX EG4000CX Type RHH, KH, MH, RH, LDH Description code EBHC Overall length 681 mm (26.8 in) Overall width 530 mm (20.9 in) Overall height 571 mm (22.5 in) Dry weight 71.0 kg (156.5 lbs)
  • Page 9 82Z3000001.fm 4 ページ 2010年6月28日 月曜日 午前9時34分 SPECIFICATIONS GENERATOR Model EG3600CX EG4000CX Type KH, MH, RH Description code EBHC Generator type Double electrode field rotation type Excitation Self–excitation Voltage regulation system Digital AVR (Automatic Voltage Regulator) Phase Single phase Rotating direction Counterclockwise (Viewed from the generator)
  • Page 10 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG4500CX/EG5000CX DIMENSIONS AND WEIGHTS Model EG4500CX EG5000CX Type UH, RGH RHH, KH, MH, RH, LDH, SH, SKH Description code EBFC Overall length 681 mm (26.8 in) Overall width 530 mm (20.9 in) Overall height 571 mm (22.5 in) Dry weight 82.5 kg (181.9 lbs) Operating weight...
  • Page 11 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS GENERATOR Model EG4500CX EG5000CX Type KH, MH, SH, SKH Description code EBFC Generator type Double electrode field rotation type Excitation Self–excitation Voltage regulation system Digital AVR (Automatic Voltage Regulator) Phase Single phase Rotating direction Counterclockwise (Viewed from the generator) Rated 4000 VA 4500 VA...
  • Page 12 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG5500CX/EG6500CX DIMENSIONS AND WEIGHTS Model EG5500CX EG6500CX Type RHH, KH, MH, RH, LDH, LTH, SH, SKH Description code EBCC Overall length 681 mm (26.8 in) Overall width 530 mm (20.9 in) Overall height 571 mm (22.5 in) Dry weight 84.0 kg (185.2 lbs) Operating weight...
  • Page 13 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS GENERATOR Model EG5500CX EG6500CX Type KH, MH, RH LDH, LTH SH, SKH Description code EBCC Generator type Double electrode field rotation type Excitation Self–excitation Voltage regulation system Digital AVR (Automatic Voltage Regulator) Phase Single phase Rotating direction Counterclockwise (Viewed from the generator) Rated...
  • Page 14 82Z30000.book 9 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG5500CXS/EG6500CXS DIMENSIONS AND WEIGHTS Model EG5500CXS EG6500CXS Type UH, RGH RHH, KH, MH, RH, LDH, LTH, SH, SKH Description code EBDC Overall length 844 mm (33.2 in) Overall width 530 mm (20.9 in) Overall height 571 mm (22.5 in) Dry weight 87.0 kg (191.8 lbs)
  • Page 15 82Z30000.book 10 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS GENERATOR Model EG5500CXS EG6500CXS Type KH, MH, LDH, LTH SH, SKH Description code EBDC Generator type Double electrode field rotation type Excitation Self–excitation Voltage regulation system Digital AVR (Automatic Voltage Regulator) Phase Single phase Rotating direction Counterclockwise (Viewed from the generator) Rated 5000 VA...
  • Page 16 – Performance may vary to some degree depending on ambient temperature and humidity. – The output voltage will be higher than usual when the generator is still cold, immediately after the engine starts. EG3600CX UH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (13.3 A)
  • Page 17 82Z30000.book 12 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG4000CX RHH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (13.9 A) LOAD CURRENT (A) 1-12...
  • Page 18 82Z30000.book 13 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG4000CX KH/MH/RH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (16.4 A) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-13...
  • Page 19 82Z30000.book 14 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG4000CX LDH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (15 A) (AC OUTPUT VOLTAGE 240 V) RATED CURRENT (30 A) (AC OUTPUT VOLTAGE 120 V) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected.
  • Page 20 82Z30000.book 15 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG4500CX UH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (16.6 A) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-15...
  • Page 21 82Z30000.book 16 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG4500CX RGH type/EG5000CX RHH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (17.4 A) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE (EG4500CX RGH type only) RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-16...
  • Page 22 82Z30000.book 17 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG5000CX KH/MH/RH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (18.2 A) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-17...
  • Page 23 82Z30000.book 18 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG5000CX LDH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (18.8 A) (AC OUTPUT VOLTAGE 240 V) RATED CURRENT (37.5 A) (AC OUTPUT VOLTAGE 120 V) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected.
  • Page 24 82Z30000.book 19 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG5000CX SH/SKH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (20.5 A) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-19...
  • Page 25 82Z30000.book 20 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG5500CX UH type/EG5500CXS UH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (20.8 A) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-20...
  • Page 26 82Z30000.book 21 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG6500CX RHH type/EG5500CXS RGH type/EG6500CXS RHH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT 21.7A LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE (EG5500CXS RGH type only) RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-21...
  • Page 27 82Z30000.book 22 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG6500CX KH/MH/RH type/EG6500CXS KH/MH/RH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (22.7 A) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-22...
  • Page 28 82Z30000.book 23 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG6500CX LDH/LTH type/EG6500CXS LDH/LTH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (22.9 A) (AC OUTPUT VOLTAGE 240 V) RATED CURRENT (45.8 A) (AC OUTPUT VOLTAGE 120 V) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected.
  • Page 29 82Z30000.book 24 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG6500CX SH/SKH type/EG6500CXS SH/SKH type AC EXTERNAL CHARACTERISTIC CURVES RATED CURRENT (25 A) LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE RATED CURRENT (8.3 A) LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected. 1-24...
  • Page 30 82Z30000.book 25 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS DIMENSIONAL DRAWINGS Except EG5500CXS/EG6500CXS Unit: mm (in) 681 (26.8) 530 (20.9) 240 (9.4) 1-25...
  • Page 31 82Z30000.book 26 ページ 2010年6月25日 金曜日 午後5時50分 SPECIFICATIONS EG5500CXS/EG6500CXS Unit: mm (in) 844 (33.2) 681 (26.8) 530 (20.9) 240 (9.4) 1-26...
  • Page 32: Service Information

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 HOW TO READ CONNECTOR DRAWINGS ··················································· 2-9 TORQUE VALUES ········································2-5 FRAME/ENGINE CABLE/HARNESS ROUTING ···················································· 2-10 LUBRICATION & SEAL POINT ····················2-6 CONTROL PANEL HARNESS TOOLS···························································2-6 ROUTING ···················································· 2-19 TUBE ROUTING ········································· 2-49...
  • Page 33 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE EG3600CX/EG4000CX Unit: mm (in) Part Item Standard Service limit Engine Engine Except EG4000CX 3,000 ± 100 min (rpm) – speed LDH type EG4000CX 3,600 ± 100 min (rpm) –...
  • Page 34 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION EG4500CX/EG5000CX Unit: mm (in) Part Item Standard Service limit Engine Engine Except EG5000CX 3,000 ± 100 min (rpm) – speed SH/SKH/LDH type EG5000CX 3,600 ± 100 min (rpm) – SH/SKH/LDH type 1.37 MPa (14 kgf/cm , 199 psi) Cylinder compression –...
  • Page 35 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION EG5500CX/EG6500CX/EG5500CXS/EG6500CXS Unit: mm (in) Part Item Standard Service limit Engine Engine Except EG6500CX speed SH/SKH/LDH/LTH type 3,000 ± 100 min (rpm) – /EG6500CXS SH/SKH/LDH/LTH type EG6500CX SH/SKH/LDH/LTH type 3,600 ± 100 min (rpm) /EG6500CXS SH/SKH/LDH/LTH type 1.37 MPa (14 kgf/cm , 199 psi)
  • Page 36 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION TORQUE VALUES ENGINE Thread Dia. Torque values Item Remarks and pitch (mm) N·m kgf·m lbf·ft Spark plug M14 x 1.25 Drain plug bolt M12 x 1.5 22.5 Recoil spring retainer center screw M6 x 1.0 0.55 Cylinder head bolt M10 x 1.25...
  • Page 37 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION LUBRICATION & SEAL POINT Location Material Remarks Camshaft cam profile and journal Engine oil Valve lifter stem, stem end and slipper Valve stem sliding surface and stem end Valve rocker arm tappet surface and pivot Cylinder barrel inner surface Piston outer surface Piston rings...
  • Page 38 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION Attachment, 62 × 68 mm Attachment, 72 × 75 mm Driver, 22 mm I.D. 07746-0010500 07746-0010600 07746-0020100 Driver attachment, 20 mm I.D. Driver, 40 mm I.D. Driver attachment, 30 mm I.D. 07746-0020400 07746-0030100 07746-0030300 Driver attachment, 35 mm I.D.
  • Page 39 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION Seat cutter, 35 mm (45° EX) Seat cutter, 40 mm (45° IN) Flat cutter, 35 mm (32° EX) 07780-0010400 07780-0010500 07780-0012300 Flat cutter, 38.5 mm (32° IN) Interior cutter, 37.5 mm (60° IN/EX) Cutter holder, 6.6 mm 07780-0012400 07780-0014100 07781-0010202...
  • Page 40 82Z30000.book 9 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins and the shape of terminal (male or female). Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are shown for the dedicated connectors.
  • Page 41 82Z30000.book 10 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION FRAME/ENGINE CABLE/HARNESS ROUTING CX TYPE Viewed from the generator side: FUEL CUT SOLENOID WIRE HARNESS BAND Terminal Wire color CONNECTOR number Terminal Wire color Main wire number harness side Bl/W GENERATOR Terminal Wire color WIRE POWER COIL 2P number...
  • Page 42 82Z30000.book 11 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CXS TYPE Viewed from the generator side: FUEL CUT SOLENOID WIRE HARNESS BAND CONNECTOR Terminal Wire color number Terminal Wire color number Main wire harness side Bl/W GENERATOR Terminal Wire color WIRE POWER COIL 2P number CONNECTOR FUEL CUT...
  • Page 43 82Z30000.book 12 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION ( + ) BATTERY CABLE HARNESS BAND TERMINAL STARTER SOLENOID CABLE TERMINAL Do not secure the starter Terminal Wire color cable at harness band Terminal Wire color number number Bl/W Black Brown Terminal Wire color Yellow Orange STARTER SOLENOID...
  • Page 44 82Z30000.book 13 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION IGNITION COIL SIDE: IGNITION COIL WIRE HIGH TENSION CORD Terminal Wire color number IGNITION COIL CONNECTOR Black Brown Yellow Orange CRANKCASE Bu Blue Lb Light blue BREATHER TUBE Green Lg Light green Pink W White Gr Gray HIGH TENSION CORD...
  • Page 45 82Z30000.book 14 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION FUEL CUT/CHARGE COIL/POWER COIL SIDE (EG3600CX/EG4000CX) FUEL CUT/CHARGE COIL WIRE POWER COIL WIRE FUEL CUT/CHARGE COIL/POWER COIL SIDE (EXCEPT EG3600CX/EG4000CX) FUEL CUT/CHARGE COIL WIRE POWER COIL WIRE 2-14...
  • Page 46 82Z30000.book 15 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION FUEL CUT SOLENOID SIDE: HARNESS BANDS FUEL CUT SOLENOID WIRE GROUND CABLE (UH TYPE ONLY): GROUND CABLE Terminal Wire color number Black Brown Yellow Orange Bu Blue Lb Light blue Green Lg Light green Pink W White Gr Gray...
  • Page 47 82Z30000.book 16 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION GENERATOR SIDE (MH, RH, KH, UH, SH, SKH, RGH TYPE): HARNESS BAND GROUND TERMINAL MAIN WINDING TERMINAL EXCITER WINDING 3P CONNECTOR MAIN WINDING TERMINAL FIELD WINDING WIRE CONNECTOR FIELD WINDING WIRE CONNECTOR CABLE TIE MAIN WINDING TERMINAL DC WINDING 3P...
  • Page 48 82Z30000.book 17 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION GENERATOR SIDE (RHH TYPE): HARNESS BAND GROUND TERMINAL EXCITER WINDING MAIN WINDING 3P CONNECTOR TERMINAL CABLE TIE MAIN WINDING TERMINAL FIELD WINDING WIRE CONNECTOR FIELD WINDING WIRE CONNECTOR MAIN WINDING TERMINAL Black Brown Yellow Orange MAIN WINDING Bu Blue...
  • Page 49 82Z30000.book 18 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION GENERATOR SIDE (LDH, LTH TYPE): HARNESS BAND GROUND TERMINAL MAIN WINDING TERMINAL EXCITER WINDING MAIN WINDING TERMINAL 3P CONNECTOR MAIN WINDING TERMINAL FIELD WINDING WIRE CONNECTOR MAIN WINDING TERMINAL FIELD WINDING WIRE CONNECTOR DC WINDING 3P CONNECTOR CABLE TIE MAIN WINDING TERMINAL...
  • Page 50 82Z30000.book 19 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL HARNESS ROUTING JUNCTION BOX/GENERATOR SIDE (CX-RHH TYPE) Black Brown Yellow Orange JUNCTION BOX 16P Bu Blue Lb Light blue JUNCTION BOX 4P CONNECTOR Green Lg Light green CONNECTOR Pink W White Gr Gray JUNCTION BOX 6P CONNECTOR JUNCTION BOX 1P...
  • Page 51 82Z30000.book 20 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/GENERATOR SIDE (CXS-RHH TYPE) Black Brown Yellow Orange JUNCTION BOX 16P Bu Blue Lb Light blue CONNECTOR JUNCTION BOX 4P Green Lg Light green CONNECTOR Pink W White Gr Gray JUNCTION BOX 6P CONNECTOR JUNCTION BOX 1P CONNECTOR...
  • Page 52 82Z30000.book 21 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/GENERATOR SIDE (CX-MH, UH, RH, KH, SH, SKH, RGH TYPE) Black Brown Yellow Orange JUNCTION BOX 16P Bu Blue Lb Light blue JUNCTION BOX 4P CONNECTOR Green Lg Light green CONNECTOR Pink W White Gr Gray JUNCTION BOX 6P CONNECTOR...
  • Page 53 82Z30000.book 22 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/GENERATOR SIDE (CXS-MH, UH, RH, KH, SH, SKH, RGH TYPE) Black Brown Yellow Orange JUNCTION BOX 16P Bu Blue Lb Light blue JUNCTION BOX 4P CONNECTOR Green Lg Light green CONNECTOR Pink W White Gr Gray JUNCTION BOX 6P CONNECTOR...
  • Page 54 82Z30000.book 23 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/GENERATOR SIDE (CX-LDH, LTH TYPE) Black Brown Yellow Orange JUNCTION BOX 16P Bu Blue Lb Light blue JUNCTION BOX 4P CONNECTOR Green Lg Light green CONNECTOR Pink W White Gr Gray JUNCTION BOX 6P CONNECTOR JUNCTION BOX 1P CONNECTOR...
  • Page 55 82Z30000.book 24 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/GENERATOR SIDE (CXS-LDH, LTH TYPE) Black Brown Yellow Orange JUNCTION BOX 16P Bu Blue Lb Light blue JUNCTION BOX 4P CONNECTOR Green Lg Light green CONNECTOR Pink W White Gr Gray JUNCTION BOX 6P CONNECTOR JUNCTION BOX 1P CONNECTOR...
  • Page 56 82Z30000.book 25 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CX-RHH TYPE) Black Brown WARNING INDICATOR Yellow Orange JUNCTION BOX 8P 2P CONNECTOR Bu Blue Lb Light blue CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR VOLT METER 3P JUNCTION BOX 10P...
  • Page 57 82Z30000.book 26 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CXS-RHH TYPE) Black Brown WARNING INDICATOR Yellow Orange JUNCTION BOX 8P 2P CONNECTOR Bu Blue Lb Light blue CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR VOLT METER 3P JUNCTION BOX 10P...
  • Page 58 82Z30000.book 27 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CX-MH, RH, KH, SH, RGH TYPE) Black Brown Yellow Orange JUNCTION BOX 8P Bu Blue Lb Light blue CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR VOLT METER 3P JUNCTION BOX 10P...
  • Page 59 82Z30000.book 28 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CXS-MH, RH, KH, SH, RGH TYPE) Black Brown Yellow Orange JUNCTION BOX 8P Bu Blue Lb Light blue CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR VOLT METER 3P JUNCTION BOX 10P...
  • Page 60 82Z30000.book 29 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CX-UH TYPE) Black Brown Yellow Orange JUNCTION BOX 8P Bu Blue Lb Light blue CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR JUNCTION BOX 10P ENGINE STOP SWITCH JUNCTION BOX 1P CONNECTOR...
  • Page 61 82Z30000.book 30 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CXS-UH TYPE) Black Brown JUNCTION BOX 8P Yellow Orange Bu Blue Lb Light blue CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR JUNCTION BOX 10P COMBINATION SWITCH JUNCTION BOX 1P CONNECTOR...
  • Page 62 82Z30000.book 31 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CX-SKH TYPE) Black Brown Yellow Orange JUNCTION BOX 8P Bu Blue Lb Light blue CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR VOLT METER 3P JUNCTION BOX 10P ENGINE STOP SWITCH CONNECTOR...
  • Page 63 82Z30000.book 32 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CXS-SKH TYPE) Black Brown Yellow Orange JUNCTION BOX 8P Bu Blue Lb Light blue CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR VOLT METER 3P JUNCTION BOX 10P COMBINATION SWITCH CONNECTOR...
  • Page 64 82Z30000.book 33 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CX-LDH, LTH TYPE) Black Brown Yellow Orange JUNCTION BOX 8P JUNCTION BOX 4P Bu Blue Lb Light blue CONNECTOR CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR VOLT METER 3P JUNCTION BOX 10P...
  • Page 65 82Z30000.book 34 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION JUNCTION BOX/CONTROL PANEL SIDE (CXS-LDH, LTH TYPE) Black Brown Yellow Orange JUNCTION BOX 8P JUNCTION BOX 4P Bu Blue Lb Light blue CONNECTOR CONNECTOR Green Lg Light green Pink W White Gr Gray CIRCUIT BREAKER 4P CONNECTOR VOLT METER 3P JUNCTION BOX 10P...
  • Page 66 82Z30000.book 35 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CX-RHH TYPE) RECEPTACLE RECEPTACLE TERMINAL ([B] MARK) TERMINAL ([B] MARK) RECEPTACLE TERMINAL ([B] MARK) CIRCUIT BREAKER RECEPTACLE TERMINAL TERMINAL DIODE 4P (WHITE TAPE) CONNECTOR RECEPTACLE TERMINAL RECEPTACLE TERMINAL GROUND TERMINAL CIRCUIT BREAKER TERMINAL Terminal Wire color...
  • Page 67 82Z30000.book 36 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CXS-RHH TYPE) RECEPTACLE RECEPTACLE TERMINAL ([B] MARK) TERMINAL ([B] MARK) RECEPTACLE CIRCUIT BREAKER TERMINAL ([B] MARK) TERMINAL (WHITE TAPE) RECEPTACLE TERMINAL DIODE 4P CONNECTOR RECEPTACLE TERMINAL RECEPTACLE TERMINAL GROUND TERMINAL CIRCUIT BREAKER TERMINAL REGULATOR/RECTIFIER 3P CONNECTOR...
  • Page 68 82Z30000.book 37 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CX-MH TYPE) CIRCUIT BREAKER CIRCUIT PROTECTOR DIODE 4P TERMINAL CIRCUIT PROTECTOR CONNECTOR CONNECTOR (WHITE TAPE) CONNECTOR (+) DC OUTPUT TERMINAL ( – ) DC OUTPUT TERMINAL CIRCUIT BREAKER TERMINAL GROUND TERMINAL RECEPTACLE TERMINAL ([B] MARK) RECEPTACLE...
  • Page 69 82Z30000.book 38 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CXS-MH TYPE) CIRCUIT BREAKER CIRCUIT PROTECTOR DIODE 4P TERMINAL CIRCUIT PROTECTOR CONNECTOR CONNECTOR (WHITE TAPE) CONNECTOR (+) DC OUTPUT TERMINAL ( – ) DC OUTPUT TERMINAL CIRCUIT BREAKER TERMINAL GROUND RECEPTACLE TERMINAL REGULATOR/RECTIFIER TERMINAL ([B] MARK)
  • Page 70 82Z30000.book 39 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CX-RH, KH, SH TYPE) CIRCUIT BREAKER CIRCUIT PROTECTOR DIODE 4P TERMINAL CIRCUIT PROTECTOR CONNECTOR CONNECTOR (WHITE TAPE) CONNECTOR (+) DC OUTPUT TERMINAL ( – ) DC OUTPUT TERMINAL CIRCUIT BREAKER GROUND TERMINAL TERMINAL RECEPTACLE...
  • Page 71 82Z30000.book 40 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CXS-RH, KH, SH TYPE) CIRCUIT BREAKER CIRCUIT PROTECTOR DIODE 4P TERMINAL CIRCUIT PROTECTOR CONNECTOR CONNECTOR (WHITE TAPE) CONNECTOR (+) DC OUTPUT TERMINAL ( – ) DC OUTPUT TERMINAL CIRCUIT BREAKER TERMINAL GROUND REGULATOR/RECTIFIER TERMINAL...
  • Page 72 82Z30000.book 41 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CX-UH TYPE) DIODE 4P CIRCUIT BREAKER CIRCUIT PROTECTOR CONNECTOR TERMINAL CIRCUIT PROTECTOR CONNECTOR (WHITE TAPE) CONNECTOR (+) DC OUTPUT TERMINAL ( – ) DC OUTPUT TERMINAL CIRCUIT BREAKER GROUND TERMINAL TERMINAL RECEPTACLE TERMINAL ([B] MARK) RECEPTACLE...
  • Page 73 82Z30000.book 42 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CXS-UH TYPE) REGULATOR/RECTIFIER 3P CONNECTOR CIRCUIT PROTECTOR CONNECTOR DIODE 4P CIRCUIT BREAKER CONNECTOR CIRCUIT PROTECTOR TERMINAL CONNECTOR (WHITE TAPE) (+) DC OUTPUT TERMINAL ( – ) DC OUTPUT TERMINAL CIRCUIT BREAKER GROUND TERMINAL TERMINAL...
  • Page 74 82Z30000.book 43 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CX-SKH TYPE) RECEPTACLE RECEPTACLE TERMINAL ([C] MARK) TERMINAL ([B] MARK) RECEPTACLE RECEPTACLE TERMINAL ([B] MARK) TERMINAL ([C] MARK) RECEPTACLE RECEPTACLE TERMINAL ([B] MARK) TERMINAL ([C] MARK) RECEPTACLE TERMINAL CIRCUIT BREAKER TERMINAL (WHITE TAPE) RECEPTACLE TERMINAL RECEPTACLE...
  • Page 75 82Z30000.book 44 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CXS-SKH TYPE) RECEPTACLE RECEPTACLE TERMINAL ([C] MARK) TERMINAL ([B] MARK) RECEPTACLE RECEPTACLE TERMINAL ([B] MARK) TERMINAL ([C] MARK) RECEPTACLE RECEPTACLE TERMINAL ([B] MARK) TERMINAL ([C] MARK) RECEPTACLE TERMINAL CIRCUIT BREAKER TERMINAL (WHITE TAPE) RECEPTACLE TERMINAL RECEPTACLE...
  • Page 76 82Z30000.book 45 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CX-RGH TYPE) DIODE 4P CIRCUIT BREAKER CIRCUIT PROTECTOR CONNECTOR TERMINAL (WHITE TAPE) CIRCUIT PROTECTOR CONNECTOR CONNECTOR (+) DC OUTPUT TERMINAL ( – ) DC OUTPUT TERMINAL CIRCUIT BREAKER GROUND TERMINAL TERMINAL RECEPTACLE RECEPTACLE TERMINAL...
  • Page 77 82Z30000.book 46 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CXS-RGH TYPE) DIODE 4P CIRCUIT BREAKER CIRCUIT PROTECTOR CONNECTOR CIRCUIT PROTECTOR TERMINAL (WHITE TAPE) CONNECTOR CONNECTOR (+) DC OUTPUT TERMINAL ( – ) DC OUTPUT TERMINAL CIRCUIT BREAKER TERMINAL GROUND TERMINAL RECEPTACLE RECEPTACLE TERMINAL...
  • Page 78 82Z30000.book 47 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CX-LDH, LTH TYPE) RECEPTACLE RECEPTACLE TERMINAL TERMINAL ([B] MARK) ([C] MARK) RECEPTACLE TERMINAL ([B] MARK) RECEPTACLE TERMINAL ([C] MARK) RECEPTACLE TERMINAL ([B] MARK) DIODE 4P RECEPTACLE CONNECTOR RECEPTACLE TERMINAL TERMINAL ([B] MARK) ([C] MARK) CIRCUIT BREAKER RECEPTACLE...
  • Page 79 82Z30000.book 48 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION CONTROL PANEL SIDE (CXS-LDH, LTH TYPE) RECEPTACLE RECEPTACLE TERMINAL TERMINAL ([B] MARK) ([C] MARK) RECEPTACLE TERMINAL ([B] MARK) RECEPTACLE TERMINAL ([C] MARK) RECEPTACLE TERMINAL ([B] MARK) DIODE 4P RECEPTACLE CONNECTOR RECEPTACLE TERMINAL TERMINAL ([B] MARK) ([C] MARK) CIRCUIT BREAKER RECEPTACLE...
  • Page 80 82Z30000.book 49 ページ 2010年6月25日 金曜日 午後5時50分 SERVICE INFORMATION TUBE ROUTING EG3600/EG4000: TUBE (3.5 x 65 mm) DIAPHRAGM TUBE EG4500/EG5000/EG5500/EG6500: TUBE (3.5 x 75 mm) Route the diaphragm tube over the governor rod. TUBE CLIP B7 TUBE CLIP B7 TUBE CLIP C12 TUBE CLIP B7 The marked side of fuel tank tube is facing up.
  • Page 81 82Z30000.book 50 ページ 2010年6月25日 金曜日 午後5時50分 MEMO...
  • Page 82: Maintenance

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 SPARK ARRESTER CLEANING (UH TYPE ONLY) ·········································· 3-6 ENGINE OIL LEVEL CHECK ························3-3 VALVE CLEARANCE CHECK/ ADJUSTMENT ·············································· 3-7 ENGINE OIL CHANGE··································3-4 COMBUSTION CHAMBER CLEANING ······· 3-8 AIR CLEANER CHECK/CLEANING ·············3-4 FUEL TANK AND FILTER CLEANING ········ 3-8 SEDIMENT CUP CLEANING ························3-5 FUEL TUBE CHECK ·····································...
  • Page 83 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE REGULAR SERVICE PERI- Every OD (2) Every Every Each First Perform at every indicated 6 months year Refer month or months month or operating hour in- 20 hrs. terval, whichever comes first. 100 hrs.
  • Page 84 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE ENGINE OIL LEVEL CHECK Place the engine on a level surface. Remove the oil filler cap (1), and wipe the oil level gauge (2) clean. Insert the oil filler cap without screwing it into the oil filler neck (3).
  • Page 85 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE ENGINE OIL CHANGE Drain the oil in the engine while the engine is warm. Warm oil drains quickly and completely. Place the engine on a level surface, and place a suitable container under the drain plug bolt. Remove the oil filler cap (1), drain plug bolt (2), and drain plug washer (3) to drain the oil into the suitable container.
  • Page 86 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE Clean the filter (1) in warm soapy water (2), rinse, and allow to dry thoroughly, or clean with a non-flammable solvent and allow to dry thoroughly. Dip the filter in clean engine oil (3), and squeeze out all Squeeze the excess oil.
  • Page 87 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE Visually check the spark plug. Replace the plug if the insulator (1) is cracked or chipped. Check the sealing washer (2) for damage. Replace the spark plug if the sealing washer is damaged. SPARK PLUG: BPR5ES (NGK) Measure the plug gap with a wire-type feeler gauge.
  • Page 88 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE VALVE CLEARANCE CHECK/ ADJUSTMENT Disconnect the breather hose (1). Remove the head cover bolt (2), the head cover (3). Check the head cover packing (4) for damage or deterioration and replace if necessary. Disconnect the spark plug cap from the spark plug. Set the piston near top dead center of the cylinder compression stroke (both valves fully closed) by pulling the recoil starter slowly.
  • Page 89 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder head (page 13-3). Clean any carbon deposits from the combustion chamber (1). FUEL TANK AND FILTER CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
  • Page 90 82Z30000.book 9 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE FUEL TUBE CHECK Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Check the fuel tube (1) and fuel tank tube (2) for deterioration, cracks or signs of leakage.
  • Page 91 82Z30000.book 10 ページ 2010年6月25日 金曜日 午後5時50分 MAINTENANCE BATTERY CHECK (CXS TYPE ONLY) A battery can explode if you do not follow the proper procedure, causing serious injury to anyone near- Follow all procedures carefully and keep sparks and open flames away from the battery. The battery contains sulfuric acid (electrical) which is highly corrosive and poisonous.
  • Page 92: Troubleshooting

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING···················4-2 TROUBLESHOOTING ·································· 4-2...
  • Page 93 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Use a known-good battery for troubleshooting. • Check that the connectors are connected securely. • Check for sufficient fresh fuel in the fuel tank. • Read the circuit tester's operation instructions carefully, and observe the instructions during inspection. •...
  • Page 94 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 TROUBLESHOOTING From page 4-2 Compression is too high Perform the cylinder compression test (page Check the valve clearance (page 3-7) and 13-5). then perform the cylinder compression test. If the cylinder compression is too high, remove carbon deposits in the combustion chamber (page 3-8).
  • Page 95 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 TROUBLESHOOTING ENGINE SPEED DOES NOT STABILIZE Clogged Check the air cleaner element (page 3-4). Clean the air cleaner element. Clean Abnormal Check the valve clearance (page 3-7). Adjust the valve clearance. Normal Abnormal Remove the spark plug and check the Inspect the spark plug and adjust the spark electrodes for carbon and proper gap (page plug gap.
  • Page 96 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 TROUBLESHOOTING From page 4-4 Abnormal Check the ignition coil air gap (page 8-5). Adjust the ignition coil air gap. Normal Check the ignition coil (page 8-6). Replace the ignition coil if abnormalities are found, and recheck. ENGINE DOES NOT STOP WHEN COMBINATION/ ENGINE STOP SWITCH IS TURNED OFF •...
  • Page 97 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 TROUBLESHOOTING ENGINE DOES NOT STOP WHEN ENGINE OIL LEVEL IS LOW Engine stop Start the engine. Replace the oil level switch (page 14-4). Disconnect the oil level switch Yellow wire connector (1) and short it of the oil level switch side and engine ground using a jumper wire.
  • Page 98: Fuel System

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 5. FUEL SYSTEM TOOLS···························································5-2 CARBURETOR DISASSEMBLY/ ASSEMBLY ··················································· 5-7 FUEL CUT SYSTEM DIAGRAM ···················5-3 CHOKE DIAPHRAGM DISASSEMBLY/ ASSEMBLY ··················································· 5-8 FUEL TANK REMOVAL/INSTALLATION ····5-4 CHOKE DIAPHRAGM INSPECTION············ 5-8 FUEL VALVE REMOVAL/ INSTALLATION·············································5-5 CARBURETOR BODY CLEANING ·············· 5-9 AIR CLEANER REMOVAL/ INSTALLATION·············································5-5 CARBURETOR INSPECTION ······················...
  • Page 99 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 FUEL SYSTEM TOOLS FUEL SYSTEM Float level gauge 07401-0010000...
  • Page 100 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 FUEL SYSTEM FUEL CUT SYSTEM DIAGRAM ENGINE STOP SWITCH (CX type) COMBINATION SWITCH (CXS type) DIODE ENGINE STOP SWITCH (CX type) COMBINATION SWITCH (CXS type) CONNECTION TABLE Bu G/W JUNCTION BOX Bl/W GND2 Bl/W BLACK GREEN YELLOW BLUE FUEL CUT...
  • Page 101 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the control panel (page 10-2).
  • Page 102 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 FUEL SYSTEM FUEL VALVE REMOVAL/ INSTALLATION Disconnect the fuel tank tube (1) and fuel tube (2). Remove the fuel valve (3) from the fuel valve stay (4). Install and tighten the fuel valve nut while holding the nut part (5) of fuel valve stay by a tool.
  • Page 103 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 FUEL SYSTEM CARBURETOR REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the air cleaner base (page 5-5).
  • Page 104 O-RING Turn the pilot screw in until it is lightly seated, then FLOAT VALVE turn the screw out the required number of turns. EG3600CX/EG4000CX: 1 - 1/4 turns out FLOAT VALVE SPRING /EG4500CX/EG5000CX: 1 - 3/4 turns out EG5500CX/EG6500CX FLOAT...
  • Page 105 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 FUEL SYSTEM CHOKE DIAPHRAGM DISASSEMBLY/ ASSEMBLY MANUAL CHOKE ROD CHOKE ROD GROMMET DIAPHRAGM STAY E-RING CHOKE ROD GUIDE WASHER (2.7 x 8 mm) CHOKE ROD CHOKE DIAPHRAGM STOPPER E-RING SCREW (5 x 12 mm) (2) RETURN SPRING LEVER COLLAR CHOKE LEVER...
  • Page 106 Check the container for instructions. If you are in doubt, do not use these products to clean a Honda carburetor. • High air pressure may damage the carburetor. Use low air pressure (0.2 MPa (30 psi) or less) when cleaning passages and ports.
  • Page 107 82Z30000.book 10 ページ 2010年6月25日 金曜日 午後5時50分 FUEL SYSTEM FLOAT VALVE Check for a worn float valve (1) and valve seat (2) contamination. CLEAN REPLACE FUEL CUT SOLENOID Connect the 12 V battery to the solenoid wire connectors. The solenoid needle should extend out when the battery is connected and retract when the battery is disconnected.
  • Page 108: Governor System

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 6. GOVERNOR SYSTEM GOVERNOR ARM REMOVAL/ GOVERNOR ADJUSTMENT ························ 6-3 INSTALLATION·············································6-2...
  • Page 109 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 GOVERNOR SYSTEM GOVERNOR ARM REMOVAL/INSTALLATION GOVERNOR SYSTEM Remove the fuel tank (page 5-4). GOVERNOR SPRING GOVERNOR ROD/THROTTLE RETURN SPRING REMOVAL/INSTALLATION: MH, RH, KH, RHH, UH, RGH type: Turn the throttle arm to a point where the groove of throttle arm lines up with the governor rod, and then lift the governor rod out of the hole of throttle arm and unhook the throttle return spring.
  • Page 110 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 GOVERNOR SYSTEM GOVERNOR ADJUSTMENT Loosen the nut (1) on the governor arm pinch bolt (2), and move the governor arm to fully open the throttle. Rotate the governor arm shaft (4) as far as it will go in the same direction and governor arm moved to open the throttle.
  • Page 111 82Z30000.book 14 ページ 2010年6月25日 金曜日 午後5時50分 MEMO...
  • Page 112: Generator/Charging System

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 7. GENERATOR/CHARGING SYSTEM TOOLS···························································7-2 BATTERY TRAY REMOVAL/INSTALLATION (CXS TYPE ONLY)······································ 7-14 GENERATOR SYSTEM DIAGRAM ··············7-3 MAIN WINDING INSPECTION···················· 7-15 GENERATOR SYSTEM TROUBLESHOOTING···································7-4 FIELD WINDING INSPECTION ·················· 7-17 BEFORE CHARGING SYSTEM D-AVR UNIT INSPECTION ························· 7-18 TROUBLESHOOTING (CXS TYPE ONLY) ········································7-7 EXCITER WINDING INSPECTION ·············...
  • Page 113 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM TOOLS GENERATOR/CHARGING SYSTEM Driver attachment, 20 mm I.D. Driver, 22 mm I.D. Flywheel pulley set 07746-0020400 07746-0020100 07935-8050004 Sliding shaft Remover weight 07736-0010101 07741-0010201...
  • Page 114 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM GENERATOR SYSTEM DIAGRAM UH/RGH/RHH/KH/MH/RH/SH/SKH type: AC OUTLET MH TYPE AC OUTLET UH TYPE Except RHH type TERMINAL ( - ) ( + ) GROUND GROUND TERMINAL GND3 TERMINAL GND3 CIRCUIT BREAKER PROTECTOR AC OUTLET RH, KH, SH TYPE AC OUTLET RHH TYPE...
  • Page 115 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM GENERATOR SYSTEM TROUBLESHOOTING No or Low AC Output Discolored Remove the generator end cover (page 7-15) Replace the stator (page 7-13). and inspect the stator winding (1) for discoloration. Normal Abnormal Check the engine speed. Adjust the governor (page 6-3).
  • Page 116 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM From page 7-4 Abnormal Replace the power coil (page 7-10). Measure the resistance of the power coil (page 7-19). Normal Abnormal Measure the resistance of the exciter coil Measure the voltage of the exciter coil (page 7-18).
  • Page 117 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM From page 7-4 Abnormal Inspect the field coil blush (page 7-19). Replace the field coil blush (page 7-11). Normal Abnormal Measure the resistance of the rotor slip rings Replace the rotor (page 7-13). (page 7-17). No DC Output Abnormal Replace the stator (page 7-13).
  • Page 118 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM BEFORE CHARGING SYSTEM TROUBLESHOOTING (CXS TYPE ONLY) • Use a known-good battery for troubleshooting. • Check that the connectors are connected securely. • Read the circuit tester's operation instructions carefully, and observe the instructions during inspection. •...
  • Page 119 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM CHARGING SYSTEM TROUBLESHOOTING (CXS TYPE ONLY) Abnormal Replace the fuse (page 10-3). Check the fuse. Normal Abnormal Replace the fuel cut/charge coil (page 7-10). Check the fuel cut/charge coil (page 7-22). Normal Abnormal Replace the regulator/rectifier (page 10-3). Check the regulator/rectifier (page 7-22).
  • Page 120 82Z30000.book 9 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM FAN COVER REMOVAL/INSTALLATION Remove the following: – Fuel valve (page 5-5) – Carburetor/carburetor insulator (page 5-6) – Recoil starter grip (page 9-4) FAN COVER BOLT (CT) (6 x 12 mm) (5)
  • Page 121 – Fan cover (page 7-9) – Ignition coil (page 8-4) FUEL CUT/CHARGE COIL CORD CLAMPER EG3600CX/EG4000CX: BOLT (6 x 35 mm) Except EG3600CX/ Except EG3600CX/EG4000CX: EG4000CX: EG3600CX/ BOLT (6 x 45 mm) EG4000CX: CORD GROMMET BOLT SPECIAL NUT (6 x 12 mm)
  • Page 122 82Z30000.book 11 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM GENERATOR REMOVAL Remove the engine (page 12-2). EG3600CX/EG4000CX: BOLT (10 x 203 mm) EG4500CX/EG5000CX: BOLT (10 x 237 mm) FRONT HOUSING EG5500CX/EG6500CX/ DOWEL PIN (8 x 12 mm) (2) EG5500CXS/EG6500CXS: BOLT (10 x 250 mm)
  • Page 123 82Z30000.book 12 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM GENERATOR INSTALLATION Rotate the crankshaft and align the mark (1) on the starter pulley with the hole (2) of recoil starter case. Make sure the piston is at top dead center on the compression stroke. Install two dowel pins (3) and front housing (4).
  • Page 124 82Z30000.book 13 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM GENERATOR DISASSEMBLY/ASSEMBLY Remove the generator (page 7-11). LDH/LTH type: WASHER (5 mm) (4) LDH/LTH type: Except LDH/LTH type: AC OUTPUT BOLT (5 x 20 mm) (4) WASHER (5 mm) (2) TERMINAL Except LDH/LTH type: BOLT (5 x 20 mm) (2) TAPPING SCREW STATOR COVER...
  • Page 125 82Z30000.book 14 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM BATTERY TRAY REMOVAL/INSTALLATION (CXS TYPE ONLY) BATTERY SET PLATE BATTERY SET BOLT (2) BATTERY BOX BOLT (8 x 12 mm) BOLT (6 x 30 mm) (8) BOLT (6 x 12 mm) BATTERY GUARD PLATE BATTERY TRAY BASE NUT (6 mm) (12)
  • Page 126 82Z30000.book 15 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM MAIN WINDING INSPECTION VOLTAGE INSPECTION Remove the two screws (1) and generator end cover (2). Start the engine and measure the AC voltage between the terminals according to the table below. RH, KH, MH type Voltage Main winding terminal (VAC)
  • Page 127 82Z30000.book 16 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM CONTINUITY INSPECTION SINGLE MAIN WINDING TYPE: Remove the generator end cover (page 7-15). Remove the nuts and disconnect the main winding terminal and main winding terminal Measure the resistance between the stator side terminals according to the table below. Resistance (Ω) Main winding terminal (at 20 °C/68 °F)
  • Page 128 82Z30000.book 17 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM DUAL MAIN WINDING TYPE: Remove the generator end cover (page 7-15). Remove the nuts and disconnect the main winding terminal , main winding terminal , main winding terminal , main winding terminal Measure the resistance between the stator side terminals according to the table below.
  • Page 129 82Z30000.book 18 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM If the specified voltage is not obtained, stop the engine and remove the screw (1) and brush holder (2). Measure the resistance between the slip rings (2). Resistance (Ω) Type (at 20 °C/68 °F) EG3600, 4000 EG4500, 5000 EG5500, 6500...
  • Page 130 82Z30000.book 19 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM If the specified voltage is not obtained, stop the engine and disconnect the exciter winding 3P connector (1). Measure the resistance between the exciter winding 3P connector stator side No.1 (Blue) terminal and No.3 (Blue) terminal. Resistance (Ω) Type (at 20 °C/68 °F)
  • Page 131 82Z30000.book 20 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM BRUSH LENGTH MEASUREMENT Remove the brush holder (page 7-11). Measure the brush length. If the brush length is less than the service limit, replace the brush and brush holder. STANDARD: 9.0 mm (0.35 in) SERVICE LIMIT: 5.0 mm (0.20 in) DC DIODE INSPECTION (EXCEPT RHH TYPE)
  • Page 132 82Z30000.book 21 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM DC WINDING INSPECTION (EXCEPT RHH TYPE) Remove the generator end cover (page 7-15). Disconnect the DC winding 3P connector Measure the resistance between the DC winding 3P connector stator side No.1 (White/Red) terminal and No.2 (Brown) terminal.
  • Page 133 82Z30000.book 22 ページ 2010年6月25日 金曜日 午後5時50分 GENERATOR/CHARGING SYSTEM CIRCUIT PROTECTOR INSPECTION (EXCEPT RHH TYPE) Remove the circuit protector (1) (page 10-3). Check continuity between the terminals. There should be continuity in the ON position (button in) and no continuity in the OFF position (button out). Replace the circuit protector if the correct continuity is not obtained.
  • Page 134: Ignition System

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 8. IGNITION SYSTEM IGNITION SYSTEM DIAGRAM ·····················8-2 OIL ALERT UNIT REMOVAL/ INSTALLATION ············································ 8-5 IGNITION SYSTEM TROUBLESHOOTING···································8-3 SPARK TEST ················································ 8-6 IGNITION COIL REMOVAL/ IGNITION COIL INSPECTION ······················ 8-6 INSTALLATION·············································8-4 OIL ALERT UNIT INSPECTION ··················· 8-7 IGNITION COIL INSTALLATION/ ADJUSTMENT···············································8-5 OIL LEVEL SWITCH INSPECTION ··············...
  • Page 135 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 IGNITION SYSTEM IGNITION SYSTEM DIAGRAM IGNITION SYSTEM ENGINE STOP SWITCH (CX type) COMBINATION SWITCH (CXS type) ENGINE STOP SWITCH (CX type) COMBINATION SWITCH (CXS type) CONNECTION TABLE * : Y/G : CX type : CXS type D-AVR JUNCTION BOX Bl Bl...
  • Page 136 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING NO SPARK AT SPARK PLUG • Check the engine oil level before troubleshooting. Engine does not starts Disconnect the ignition coil Black wire Check the ignition coil (page 8-6). connector and start the engine. Engine starts Abnormal Check the oil level switch (page 8-7).
  • Page 137 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove the fan cover (page 7-9). ENGINE WIRE HARNESS SPARK PLUG CAP IGNITION COIL BOLT (6 x 28 mm) (2)
  • Page 138 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 IGNITION SYSTEM IGNITION COIL INSTALLATION/ ADJUSTMENT Attach the ignition coil (1) and loosely tighten the two bolts (2). Insert the thickness gauge (3) of proper thickness between the ignition coil and flywheel. IGNITION COIL AIR GAP: 0.2 –...
  • Page 139 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 IGNITION SYSTEM SPARK TEST Inspect the following before spark test. • Faulty spark plug • Loose spark plug cap • Water in the spark plug cap (Leaking the ignition coil secondary voltage) • Loose ignition coil connector. Disconnect the spark plug cap (1) from the spark plug (2).
  • Page 140 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 IGNITION SYSTEM OIL ALERT UNIT INSPECTION Remove the oil alert unit (page 8-5). Measure the resistance between the wire connector terminals of the oil alert unit and oil alert unit body. (+) probe Ground (Black) (Yellow) (–) –...
  • Page 141 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 IGNITION SYSTEM SWITCH INSPECTION Remove the oil level switch (page 14-4). Check for continuity between the oil level switch (1) wire connector (Yellow) terminal and switch body with an ohmmeter. Check the float by dipping the switch into a container of oil.
  • Page 142: Starting System

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 9. STARTING SYSTEM STARTING SYSTEM DIAGRAM RECOIL STARTER INSPECTION ················ 9-8 (CXS TYPE ONLY) ········································9-2 STARTER MOTOR REMOVAL/ STARTING SYSTEM TROUBLESHOOTING INSTALLATION (CXS TYPE ONLY) ············ 9-9 (CXS TYPE ONLY) ········································9-3 STARTER MOTOR DISASSEMBLY/ RECOIL STARTER REMOVAL/ ASSEMBLY (CXS TYPE ONLY)·················...
  • Page 143 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM STARTING SYSTEM DIAGRAM (CXS TYPE ONLY) STARTING SYSTEM COMBINATION SWITCH Bl/W JUNCTION BOX FUSE (10A) Bl/W COMBINATION SWITCH CONNECTION TABLE STARTER MOTOR GND1 BLACK WHITE BATTERY...
  • Page 144 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM STARTING SYSTEM TROUBLESHOOTING (CXS TYPE ONLY) STARTER MOTOR DOES NOT OPERATE Abnormal Replace with a known-good battery. Check the battery condition. If the battery runs down again, perform the CHARGING SYSTEM Normal TROUBLESHOOTING(page 7-7). Low voltage Check the battery voltage between the Replace battery positive (+) cable.
  • Page 145 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM RECOIL STARTER REMOVAL/ INSTALLATION RECOIL STARTER GRIP REMOVAL: Before removing the recoil starter grip, pull the recoil starter grip and tie a temporary knot in the middle of the recoil starter rope as shown. 10 mm (0.4 in) INSTALLATION:...
  • Page 146 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM RECOIL STARTER DISASSEMBLY To prevent serious eye injury, always wear safety goggles or other eye protection when using compressed air. Remove the recoil starter (page 9-4). RECOIL STARTER ROPE RECOIL STARTER PULLEY STARTER RETURN SPRING RECOIL STARTER CASE RATCHET (2) RATCHET SPRING (2)
  • Page 147 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM RECOIL STARTER ASSEMBLY To prevent serious eye injury, always wear safety goggles or other eye protection when using compressed air. Pass the recoil starter rope (1) through the hole (2) of the recoil starter pulley (3), and then tie the rope as shown.
  • Page 148 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM Apply grease to the two ratchets (1). Install the two ratchets and the two ratchet springs (2) to the recoil starter pulley as shown. Apply grease to the inside of the spring retainer (1). Set the friction spring (2) and friction plate (3), spring retainer to the recoil starter pulley in the direction as shown.
  • Page 149 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM RECOIL STARTER INSPECTION RECOIL STARTER OPERATION Remove the recoil starter (page 9-4). Pull the recoil starter rope several times to inspect that the ratchets (1) are operated properly (the ratchet ends come out from the spring retainer (2). STARTER PULLEY Remove the recoil starter (page 9-4).
  • Page 150 82Z30000.book 9 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM STARTER MOTOR REMOVAL/INSTALLATION (CXS TYPE ONLY) Disconnect the starter motor wires and battery (+) cable from the starter motor. Remove the fan cover (page 7-9). BOLT (8 x 35 mm) STARTER MOTOR STARTER SOLENOID WIRE NUT (6 mm) BATTERY POSITIVE (+) CABLE...
  • Page 151 82Z30000.book 10 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM STARTER MOTOR DISASSEMBLY/ASSEMBLY (CXS TYPE ONLY) Remove the starter motor (page 9-9). BRUSH HOLDER ASSEMBLY: BRUSH HOLDER Install the insulator, brush holder, SCREW (2) negative brush terminals, and NEGATIVE two screws to the center bracket BRUSH (2) as shown.
  • Page 152 82Z30000.book 11 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM STARTER MOTOR INSPECTION (CXS TYPE ONLY) STARTER SOLENOID Connect the positive (+) lead of a 12V battery to the solenoid terminal (1) and the negative (-) lead to the solenoid body. Measure the resistance between the battery and starter motor terminals as shown.
  • Page 153 82Z30000.book 12 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM ARMATURE MICA DEPTH Visually inspect the commutator surface for dust, rust, or other damage. If necessary, wipe it with a clean lint- free cloth. If rusted or damaged, dress with a fine emery cloth. When the mica is clogged, or its depth is smaller than the service limit value, recut the grooves using a hacksaw blade or a small file.
  • Page 154 82Z30000.book 13 ページ 2010年6月25日 金曜日 午後5時50分 STARTING SYSTEM STARTER SOLENOID WIRE Check the starter solenoid wire for continuity. 9-13...
  • Page 155 82Z30000.book 14 ページ 2010年6月25日 金曜日 午後5時50分 MEMO...
  • Page 156: Other Electrical

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 10. OTHER ELECTRICAL CONTROL PANEL REMOVAL/ ENGINE STOP SWITCH INSPECTION INSTALLATION···········································10-2 (CX TYPE) ················································· 10-18 CONTROL PANEL DISASSEMBLY/ COMBINATION SWITCH INSPECTION ASSEMBLY ·················································10-3 (CXS TYPE)··············································· 10-19 D-AVR COVER/D-AVR UNIT VOLT METER INSPECTION REMOVAL/INSTALLATION······················10-17 (EXCEPT UH TYPE) ································· 10-19 CIRCUIT BREAKER INSPECTION···········10-17 JUNCTION BOX INSPECTION·················...
  • Page 157 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CONTROL PANEL REMOVAL/INSTALLATION OTHER ELECTRICAL Remove the following: – Harness clip base (page 8-5) – Generator end cover (page 7-15) EG6500CXS-LDH TYPE shown: TAPPING SCREW LDH/LTH type: FIELD WINDING (5 x 14 mm) SPRING SCREW WIRE CONNECTORS WASHER (4)
  • Page 158 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CONTROL PANEL DISASSEMBLY/ASSEMBLY CX-RHH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) (4 mm) (4) FUSE RECEPTACLE COVER JUNCTION FUSE BOLT (6 x 12 mm) DIODE SCREW (4 x 10 mm) (4) CONTROL PANEL D-AVR COVER/ D-AVR UNIT...
  • Page 159 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CXS-RHH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) (4 mm) (4) FUSE RECEPTACLE COVER JUNCTION FUSE BOLT (6 x 12 mm) DIODE SCREW (4 x 10 mm) (4) CONTROL PANEL D-AVR COVER/ D-AVR UNIT...
  • Page 160 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CX-RH, CX-KH, CX-SH type GENERATOR WIRE CONTROL PANEL HARNESS CASE BOLT (6 x 20 mm) (3) (4 mm) (4) FUSE RECEPTACLE COVER JUNCTION FUSE CIRCUIT PROTECTOR BOLT WASHER (6 x 12 mm) DIODE SCREW (4 x 10 mm) (4) CONTROL PANEL D-AVR COVER/...
  • Page 161 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CXS-RH, CXS-KH, CXS-SH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) (4 mm) (4) FUSE RECEPTACLE COVER JUNCTION FUSE CIRCUIT PROTECTOR BOLT WASHER (6 x 12 mm) DIODE SCREW (4 x 10 mm) (4) CONTROL PANEL D-AVR COVER/...
  • Page 162 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CX-UH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) SET PLATE (2) FUSE COVER JUNCTION FUSE BOLT (6 x 12 mm) RECEPTACLE DIODE SCREW (4 x 20 mm) (8) D-AVR COVER/ WASHER D-AVR UNIT...
  • Page 163 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CXS-UH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) SET PLATE (2) FUSE BOLT COVER (6 x 30 mm) JUNCTION FUSE BOLT (6 x 12 mm) RECEPTACLE DIODE SCREW (4 x 20 mm) (8) D-AVR COVER/ WASHER...
  • Page 164 82Z30000.book 9 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CX-MH type GENERATOR WIRE CONTROL PANEL HARNESS CASE BOLT (6 x 20 mm) (3) (4 mm) (4) FUSE RECEPTACLE COVER JUNCTION FUSE CIRCUIT PROTECTOR BOLT WASHER (6 x 12 mm) DIODE SCREW (4 x 10 mm) (4) CONTROL PANEL D-AVR COVER/ D-AVR UNIT...
  • Page 165 82Z30000.book 10 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CXS-MH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) (4 mm) (4) FUSE RECEPTACLE COVER JUNCTION FUSE CIRCUIT PROTECTOR BOLT WASHER (6 x 12 mm) DIODE SCREW (4 x 10 mm) (4) CONTROL PANEL D-AVR COVER/ D-AVR UNIT...
  • Page 166 82Z30000.book 11 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CX-LDH, CX-LTH type CONTROL PANEL GENERATOR WIRE CASE HARNESS BOLT (6 x 20 mm) (3) FUSE COVER JUNCTION FUSE NUT (4 mm) (6) RECEPTACLE (20 A – 125 V) DIODE RECEPTACLE BOLT (30 A – 125/250 V) (6 x 12 mm) CONTROL PANEL D-AVR COVER/...
  • Page 167 82Z30000.book 12 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CXS-LDH, CXS-LTH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) FUSE COVER JUNCTION FUSE NUT (4 mm) (6) RECEPTACLE (20 A – 125 V) DIODE RECEPTACLE BOLT (30 A – 125/250 V) (6 x 12 mm) CONTROL PANEL D-AVR COVER/...
  • Page 168 82Z30000.book 13 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CX-SKH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) FUSE COVER SET PLATE (3) JUNCTION FUSE PACKING (3) DIODE BOLT RECEPTACLE (6 x 12 mm) D-AVR COVER/ D-AVR UNIT SCREW (4 x 16 mm) (12) GROUND...
  • Page 169 82Z30000.book 14 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CXS-SKH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) FUSE COVER SET PLATE (3) JUNCTION FUSE PACKING (3) DIODE BOLT RECEPTACLE (6 x 12 mm) D-AVR COVER/ D-AVR UNIT SCREW (4 x 16 mm) (12) GROUND...
  • Page 170 82Z30000.book 15 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CX-RGH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) PACKING FUSE COVER RECEPTACLE (16 A – 250 V) JUNCTION FUSE RECEPTACLE SET PLATE DIODE (32 A – 230 V) BOLT SCREW (6 x 12 mm)
  • Page 171 82Z30000.book 16 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL CXS-RGH type CONTROL PANEL CASE GENERATOR WIRE HARNESS BOLT (6 x 20 mm) (3) PACKING CIRCUIT PROTECTOR FUSE COVER RECEPTACLE (16 A – 250 V) JUNCTION FUSE RECEPTACLE SET PLATE DIODE (32 A – 230 V) BOLT SCREW (6 x 12 mm)
  • Page 172 82Z3000010.fm 17 ページ 2010年7月22日 木曜日 午後1時5分 OTHER ELECTRICAL D-AVR COVER/D-AVR UNIT REMOVAL/ INSTALLATION Remove the junction box (page 10-3). Remove the D-AVR cover/D-AVR unit (1) from the junction box (2) by pushing the two tabs (3) and lifting up the D-AVR cover. Installation is in the reverse order of removal.
  • Page 173 82Z30000.book 18 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL VOLTAGE SELECTOR SWITCH INSPECTION Remove the voltage selector switch (page 10-3). Check for continuity between the voltage selector switch 12P connector terminals shown in the table below. Terminal Position 120V 240V ENGINE STOP SWITCH INSPECTION (CX TYPE) Remove the engine stop switch (page 10-3).
  • Page 174 82Z3000010.fm 19 ページ 2010年7月8日 木曜日 午後1時29分 OTHER ELECTRICAL COMBINATION SWITCH INSPECTION (CXS TYPE) Remove the combination switch (page 10-3). Check for continuity between the combination switch 8P connector terminals shown in the table below. TERMINAL No. VOLT METER INSPECTION (EXCEPT UH TYPE) Remove the volt meter (page 10-3).
  • Page 175 82Z30000.book 20 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL JUNCTION BOX INSPECTION MH, RH, KH, RHH, RGH, UH, SH, SKH type Remove the junction box (page 10-3). Check for continuity between the each junction box terminal as shown. JUNCTION BOX (GENERATOR SIDE): JUNCTION BOX (CONTROL PANEL SIDE): JUNCTION BOX INNER CIRCUIT: 10-20...
  • Page 176 82Z30000.book 21 ページ 2010年6月25日 金曜日 午後5時50分 OTHER ELECTRICAL LDH, LTH type Remove the junction box (page 10-3). Check for continuity between the each junction box terminal as shown. JUNCTION BOX (GENERATOR SIDE): JUNCTION BOX (CONTROL PANEL SIDE): JUNCTION BOX INNER CIRCUIT: 10-21...
  • Page 177 82Z30000.book 22 ページ 2010年6月25日 金曜日 午後5時50分 MEMO...
  • Page 178: Muffler

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 11. MUFFLER MUFFLER REMOVAL/INSTALLATION······11-2 11-1...
  • Page 179 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 MUFFLER MUFFLER REMOVAL/INSTALLATION MUFFLER The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Allow it to cool before proceeding. EG4500/EG5000: BOLT (8 x 30 mm) BOLT (8 x 16 mm)
  • Page 180: Engine Removal/Installation

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 12. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ·········12-2 12-1...
  • Page 181 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION Remove the following: – Muffler (page 11-2) – Fuel tank (page 5-4) – Recoil starter grip (page 9-4) NUT (10 mm) (4) INSTALLATION: Tighten the nut to the specified torque while holding the upper bracket of rubber mount by suitable tool.
  • Page 182: Cylinder Head

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 13. CYLINDER HEAD TOOLS·························································13-2 CYLINDER HEAD/VALVES INSPECTION··············································· 13-5 CYLINDER HEAD REMOVAL/INSTALLATION························13-3 VALVE GUIDE REPLACEMENT ················ 13-8 CYLINDER HEAD DISASSEMBLY/ VALVE GUIDE REAMING ·························· 13-9 ASSEMBLY ·················································13-4 VALVE SEAT RECONDITIONING············ 13-10 13-1...
  • Page 183 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD TOOLS CYLINDER HEAD Valve guide driver, 6.45 mm Seat cutter, 35 mm (45° EX) Seat cutter, 40 mm (45° IN) 07742-0010200 07780-0010400 07780-0010500 Flat cutter, 35 mm (32° EX) Flat cutter, 38.5 mm (32° IN) Interior cutter, 37.5 mm (60°...
  • Page 184 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD CYLINDER HEAD REMOVAL/INSTALLATION Set the piston at top dead center of the cylinder compression stroke (page 3-7). Remove the following parts: – Carburetor/carburetor insulator (page 5-6) – Control base (page 6-2) – Muffler (page 11-2) Installation is in the reverse order of removal.
  • Page 185 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD CYLINDER HEAD DISASSEMBLY/ASSEMBLY Remove the cylinder head (page 13-3). INTAKE/EXHAUST VALVE SPRING RETAINER DISASSEMBLY: Push down and slide the valve spring retainer EXHAUST VALVE to the side so that the valve stem slips through the hole at the side of the valve spring ASSEMBLY: retainer.
  • Page 186 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD CYLINDER HEAD/VALVES INSPECTION CYLINDER COMPRESSION CHECK Start the engine and warm up to normal operating temperature. Turn the fuel valve lever to the OFF position, and then remove the drain screw to drain the carburetor. Remove the spark plug cap (1) from the spark plug.
  • Page 187 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD VALVE SEAT WIDTH Remove the carbon deposits from the combustion VALVE LAPPER chamber (page 3-8). (Commercially Inspect each valve for face irregularities. available) If necessary, replace the valve (page 13-4). Apply a light coat of Prussian Blue or erasable felt- tipped marker ink to each valve seat.
  • Page 188 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD VALVE FACE Inspect each valve for face irregularities. If necessary, replace the valve (page 13-4). VALVE FACE VALVE STEM O.D. Inspect each valve for bending or abnormal stem wear. If necessary, replace the valve (page 13-4). Measure and record each valve stem O.D.
  • Page 189 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD VALVE SPRING PERPENDICULARITY Measure the valve spring perpendicularity. SERVICE LIMIT: 1.5° If the measured perpendicularity is more than the service limit, replace the valve spring (page 13-4). PUSH ROD RUNOUT Check both ends of the push rod for wear. Check the push rod for straightness.
  • Page 190 82Z30000.book 9 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD Drive the valve guides (1) out of the cylinder head from the combustion chamber side. TOOL: Valve guide driver, 6.45 mm (2) 07742-0010200 COMBUSTION CHAMBER SIDE When driving the valve guides out, be careful not to damage the cylinder head.
  • Page 191 82Z30000.book 10 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD Check the valve guide bore; it should be straight, round and centered in the valve guide. Insert the valve and check operation. If the valve does not operate smoothly, the guide may have been bent during installation.
  • Page 192 82Z30000.book 11 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER HEAD The 32° cutter removes material from the top edge CONTACT TO STANDARD (contact too high). TOOLS: Cutter holder 6.6 mm 07781-0010202 Flat cutter, 38.5 mm (32° IN) 07780-0012400 Flat cutter, 35 mm (32° EX) 07780-0012300 The 60°...
  • Page 193 82Z30000.book 12 ページ 2010年6月25日 金曜日 午後5時50分 MEMO...
  • Page 194: Cylinder Block

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 14. CYLINDER BLOCK TOOLS·························································14-2 GOVERNOR DISASSEMBLY/ ASSEMBLY ················································· 14-5 CRANKCASE COVER REMOVAL/ INSTALLATION···········································14-3 PISTON DISASSEMBLY/ASSEMBLY ······· 14-6 CRANKSHAFT/CAMSHAFT/BALANCER CYLINDER BLOCK INSPECTION·············· 14-7 WEIGHT (EXCEPT EG3600/EG4000)/PISTON REMOVAL/INSTALLATION························14-4 BEARING/OIL SEAL REPLACEMENT ···· 14-14 14-1...
  • Page 195: Tools

    82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER BLOCK TOOLS CYLINDER BLOCK Remover weight Attachment, 32 × 35 mm Attachment, 52 × 55 mm 07741-0010201 07746-0010100 07746-0010400 Attachment, 62 × 68 mm Attachment, 72 × 75 mm Driver, 40 mm I.D. 07746-0010500 07746-0010600 07746-0030100 Driver attachment, 30 mm I.D.
  • Page 196 DOWEL PIN (8 x 12 mm) (2) CASE COVER PACKING CRANKCASE COVER OIL FILLER CAP (With oil level gauge) OIL FILLER CAP PACKING EG3600CX/EG4000CX: BOLT (8 x 35 mm) (7) Except EG3600CX/EG4000CX: BOLT (8 x 40 mm) (7) 24 N·m (2.4 kgf·m, 18 lbf·ft) 14-3...
  • Page 197: Installation

    82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER BLOCK CRANKSHAFT/CAMSHAFT/BALANCER WEIGHT (EXCEPT EG3600/ EG4000)/PISTON REMOVAL/INSTALLATION Remove the following: – Flywheel (page 7-10) – Crankcase cover (page 14-3) – Cylinder head (page 13-3) PISTON LOCK PIN (10 mm) INSTALLATION: MARK INSTALLATION: Install the lock pin immediately after installing the Install the piston to the cylinder governor arm shaft in the direction as shown.
  • Page 198: Assembly

    After installing the governor slider. slider, check to be sure it After installing the governor moves smoothly. Except slider, check to be sure it EG3600CX moves smoothly. EG3600CX /EG4000CX: /EG4000CX: GOVERNOR GOVERNOR HOLDER CLIP HOLDER CLIP...
  • Page 199: Piston Disassembly/Assembly

    82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER BLOCK PISTON DISASSEMBLY/ASSEMBLY Remove the piston(page 14-4). MAKER MARK TOP RING PISTON RING SET ASSEMBLY: Be sure that the top ring and second ring are 120° SECOND RING 120° not interchanged. 120° Install the top ring and second ring on the piston with the maker mark side facing up.
  • Page 200: Cylinder Block Inspection

    Measure and record the cylinder I.D. at three levels in both the “X” axis (perpendicular to crankshaft) and the “Y” axis (parallel to crankshaft). Take the maximum reading to determine cylinder wear and taper. EG3600CX/EG4000CX: STANDARD: 77.000 – 77.017 mm (3.0315 – 3.0322 in)
  • Page 201 EG3600CX/EG4000CX: STANDARD: 18.002 – 18.008 mm (0.7087 – 0.7090 in) SERVICE LIMIT: 18.042 mm (0.7103 in) Except EG3600CX/EG4000CX: STANDARD: 20.002 – 20.008 mm (0.7875 – 0.7877 in) SERVICE LIMIT: 20.042 mm (0.7891 in) If the measurement is less than the service limit, replace the piston (page 14-6).
  • Page 202 EG3600CX/EG4000CX: STANDARD: 17.994 – 18.000 mm (0.7084 – 0.7087 in) SERVICE LIMIT: 17.950 mm (0.7067 in) Except EG3600CX/EG4000CX: STANDARD: 19.994 – 20.000 mm (0.7872 – 0.7874 in) SERVICE LIMIT: 19.950 mm (0.7854 in) If the measurement is less than the service limit, replace the piston pin.
  • Page 203 EG3600CX/EG4000CX: STANDARD: 18.005 – 18.020 mm (0.7089 – 0.7094 in) SERVICE LIMIT: 18.07 mm (0.711 in) Except EG3600CX/EG4000CX: STANDARD: 20.005 – 20.020 mm (0.7876 – 0.7882 in) SERVICE LIMIT: 20.07 mm (0.790 in) If the measurement is more than the service limit, replace the connecting rod (page 14-6).
  • Page 204 EG3600CX/EG4000CX: STANDARD: 33.025 – 33.039 mm (1.3002 – 1.3007 in) SERVICE LIMIT: 33.07 mm (1.302 in) Except EG3600CX/EG4000CX: STANDARD: 36.025 – 36.039 mm (1.4183 – 1.4189 in) SERVICE LIMIT: 36.07 mm (1.420 in) If the measurement is more than the service limit, replace the connecting rod (page 14-6).
  • Page 205 EG3600CX/EG4000CX: STANDARD: 32.975 – 32.985 mm (1.2982 – 1.2986 in) SERVICE LIMIT: 32.92 mm (1.296 in) Except EG3600CX/EG4000CX: STANDARD: 35.975 – 35.985 mm (1.4163 – 1.4167 in) SERVICE LIMIT: 35.93 mm (1.415 in) If the measurement is less than the service limit, replace the crankshaft (page 14-4).
  • Page 206 82Z30000.book 13 ページ 2010年6月25日 金曜日 午後5時50分 CYLINDER BLOCK CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft. EG3600CX/EG4000CX: STANDARD: 31.524 – 31.924 mm (1.2411 – 1.2568 in) EX: 31.564 – 31.964 mm (1.2427 – 1.2584 in) SERVICE LIMIT: 31.22 mm (1.229 in) EX: 31.26 mm (1.231 in)
  • Page 207: Bearing/Oil Seal Replacement

    CRANKSHAFT OIL SEAL (35 x 52 x 8 mm) EG3600CX/EG4000CX: CRANKSHAFT BEARING (6206) Except EG3600CX/EG4000CX: CRANKSHAFT BEARING (6207) BALANCER WEIGHT BEARING (Except EG3600CX/ EG4000CX) Pull out the radial ball bearing (1) using the special tools. TOOLS: Bearing remover shaft, 15 mm (2) 07936-KC10500...
  • Page 208 EG3600CX/EG4000CX: TOOLS: Attachment, 62 × 68 mm (3) 07746-0010500 Pilot, 30 mm (4) 07746-0040700 Driver (5) 07749-0010000 Except EG3600CX/EG4000CX: TOOLS: Attachment, 72 × 75 mm (3) 07746-0010600 Pilot, 35 mm (4) 07746-0040800 Driver (5) 07749-0010000 (circumference) CRANKSHAFT OIL SEAL Remove the oil seal from the crankcase cover.
  • Page 209 Except EG3600CX/EG4000CX: CRANKSHAFT OIL SEAL (35 x 52 x 8 mm) GOVERNOR ARM SHAFT OIL SEAL (8 x 14 x 5 mm) (except EG3600CX/EG4000CX) BALANCER WEIGHT BEARING (Except EG3600CX/ EG4000CX) Pull out the radial ball bearing (1) using the special tools.
  • Page 210 Drive the oil seal in the position as shown using the special tools. EG3600CX/EG4000CX: TOOLS: Attachment, 45 × 50 mm (2) 07946-6920100 Driver (3) 07749-0010000 2 mm (0.08 in) Except EG3600CX/EG4000CX: TOOLS: Attachment, 52 × 55 mm (2) 07746-0010400 OIL SEAL RIP Driver (3) 07749-0010000 14-17...
  • Page 211 Drive the radial ball bearing until it is fully seated on the end using the special tools and hydraulic press. EG3600CX/EG4000CX: TOOLS: Driver attachment, 30 mm I.D. 07746-0030300 Driver, 40 mm I.D. (7) 07746-0030100 Except EG3600CX/EG4000CX: TOOLS: Driver attachment, 35 mm I.D. 07746-0030400 Driver, 40 mm I.D. (7) 07746-0030100 14-18...
  • Page 212: Technical Features

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 15. TECHNICAL FEATURES D-AVR (Digital Auto Voltage Regulator)···············15-2 15-1...
  • Page 213 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 TECHNICAL FEATURES D-AVR (Digital Auto Voltage Regulator) TECHNICAL FEATURES OUTLINE This model is equipped with D-AVR (Digital Auto Voltage Regulator) which improves the output capability. SYSTEM The conventional analog AVR relies upon a detection winding to detect the output voltage, which is prone to be affected by the change of temperature and load current.
  • Page 214: Wiring Diagrams

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 16. WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & WIRING DIAGRAMS ··································· 16-3 RELATED INFORMATION··························16-2 16-1...
  • Page 215 82Z30000.book 2 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAMS The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a...
  • Page 216 82Z30000.book 3 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS WIRING DIAGRAMS CX-RHH TYPE 16-3...
  • Page 217 82Z30000.book 4 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CXS-RHH TYPE 16-4...
  • Page 218 82Z30000.book 5 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CX-UH TYPE 16-5...
  • Page 219 82Z30000.book 6 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CXS-UH TYPE 16-6...
  • Page 220 82Z30000.book 7 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CX-MH, RH, KH, SH, RGH TYPE 16-7...
  • Page 221 82Z30000.book 8 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CXS-MH, RH, KH, SH, RGH TYPE 16-8...
  • Page 222 82Z30000.book 9 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CX-SKH TYPE 16-9...
  • Page 223 82Z30000.book 10 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CXS-SKH TYPE 16-10...
  • Page 224 82Z30000.book 11 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CX-LDH, LTH TYPE 16-11...
  • Page 225 82Z30000.book 12 ページ 2010年6月25日 金曜日 午後5時50分 WIRING DIAGRAMS CXS-LDH, LTH TYPE 16-12...
  • Page 226: Index

    82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分 INDEX INDEX AIR CLEANER CHECK/CLEANING ·······························3-4 GENERATOR REMOVAL ············································ 7-11 AIR CLEANER REMOVAL/INSTALLATION ···················5-5 GENERATOR SYSTEM DIAGRAM ······························· 7-3 BATTERY CHECK (CXS TYPE ONLY) ························3-10 GOVERNOR ADJUSTMENT·········································· 6-3 BATTERY TRAY REMOVAL/INSTALLATION GOVERNOR ARM REMOVAL/INSTALLATION············· 6-2 (CXS TYPE ONLY) ·······················································7-14 GOVERNOR DISASSEMBLY/ASSEMBLY ··················...

Table of Contents