3000W Chinese Gensets Info.
professor95 wrote: EDIT ADDED 45/5/2013- When this thread started in March of 2005, I never expected to see it survive this long or amass the quantity of information that has been shared here. In...
Forum Discussion
While taking the time to go page by page of this thread for ideas I may have missed or to refresh myself with some information, I ran by a poster's suggestion to silicone the plastic cooling fan of the 3500 Watt Champion Genny. They reported hearing some extra noise in the front of the motor. There was some extra noise in the front of my 196cc motor and was more dominant under a load. I tried to get some pictures of the sound from the generator with no load and then with load. The load was the 13,500 btu ac and the water heater element. The decibel reading with no load was 70db and increased to 74db. I removed the black cover (note the position of the pull cord both before and after repair) and put my fingers on the white plastic fan. (please note: for first timers, motor was not running) I was able to shimmy the plastic fan easily. The pictures are large for detail purposes only.
Edit: found the original poster for the repair
Above shows the 23 feet measured, decibel reading may or may not be clear.
Above shows the no load decibel reading, gennie running.
Above shows with load. (AC unit and water heater element)
Above shows unit assembled, pre-repair, note position of pull cord.
Above shows the black cover removed, 3 screws and I used a 10mm socket.
Above: pointing out the fins of the fan. It is held in place by the center nut. I used a 19mm socket. I used a flat head screw driver and placed it in one of the two indentations of the flywheel and rested against the block or head assembly of the motor. The indentation used was the one without the magnet for the coil to avoid the risk of damage. This nut was removed after removing the yellow cover, see below.
Above, yellow cover removed, giving more access to the fan and the flywheel.
Above shows the fan removed. Note the partial holes in the flywheel and the holes in the pull cord assembly cup, they are intended to hold the fan in place. However, due to the size difference, the fan is allowed to move in place. The motor creates power only on the power stroke once every two turns. All the while, a heavy load on the generator head is slowing the motor down. So this rapid speed up, slow down of the motor causes the fan to move in its position. Thus creating some extra sound.
Above shows the knubs in the fans surface where they ride into the flywheel.
Above shows the application of Goop, Marine glue. This is my personal preference. I have used Goop RV and Marine and it applies like silicone and has that underlying flexibility to it but adheres like nothing I've seen. It is merely my opinion on the product.
Above, finally: all assembled. While reassembling, I discovered that the cover will fit in one of two positions. I always wondered why the cord was where it was. In the new position, I feel that it is easier to grab and pull in the upward direction which is where I am standing. Now, when I stand in front of the generator, being right handed, all of the controls are to my right with the generator to my left. This allows me to place my left hand on the generator for stability.
Edit: found the original poster for the repair
StaJs (entered 06/02/2006) wrote:
Your right!
My Champion C46540 is now quiet! This is what I found. The cooling fan on these engines are not cast with the flywheel as found on older engines but is a separate piece of plastic held only by the flywheel/starter cup nut. This apparently causes some vibration/oscillation with the fan while running. Some may be worse than others as mine was very loud.
The cure?
I removed the start recoil (10mm x 3)
than the housing (10mm x 4). Next the flywheel nut (19mm x 1).
The plastic flywheel will fall off, I cleaned the flywheel surface and backside of the fan to remove any grease or oil than ran a bead of silicone around the center hole and around the outside of the flywheel leaving a gap for the ignition magnet. Put the whole thing back together and let it set for 24 hours. (well, 19 hours - I couldn't wait to hear the results!).
QUIET! Not that much louder than my Honda 1000 inverter unit!
And to think I almost sold it at work last night!
Now for the test. Will it hold together? I think so. Did I void the warranty? At this point I don't care. I'm just so happy it is as quiet as everyone elses!
Happy boondocking!
Above shows the 23 feet measured, decibel reading may or may not be clear.
Above shows the no load decibel reading, gennie running.
Above shows with load. (AC unit and water heater element)
Above shows unit assembled, pre-repair, note position of pull cord.
Above shows the black cover removed, 3 screws and I used a 10mm socket.
Above: pointing out the fins of the fan. It is held in place by the center nut. I used a 19mm socket. I used a flat head screw driver and placed it in one of the two indentations of the flywheel and rested against the block or head assembly of the motor. The indentation used was the one without the magnet for the coil to avoid the risk of damage. This nut was removed after removing the yellow cover, see below.
Above, yellow cover removed, giving more access to the fan and the flywheel.
Above shows the fan removed. Note the partial holes in the flywheel and the holes in the pull cord assembly cup, they are intended to hold the fan in place. However, due to the size difference, the fan is allowed to move in place. The motor creates power only on the power stroke once every two turns. All the while, a heavy load on the generator head is slowing the motor down. So this rapid speed up, slow down of the motor causes the fan to move in its position. Thus creating some extra sound.
Above shows the knubs in the fans surface where they ride into the flywheel.
Above shows the application of Goop, Marine glue. This is my personal preference. I have used Goop RV and Marine and it applies like silicone and has that underlying flexibility to it but adheres like nothing I've seen. It is merely my opinion on the product.
Above, finally: all assembled. While reassembling, I discovered that the cover will fit in one of two positions. I always wondered why the cord was where it was. In the new position, I feel that it is easier to grab and pull in the upward direction which is where I am standing. Now, when I stand in front of the generator, being right handed, all of the controls are to my right with the generator to my left. This allows me to place my left hand on the generator for stability.
