Description
This slightly used manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the Kawasaki GE4000 and the GE4500 Portable Generators.
Table of contents includes:
General Information
Before Servicing, Mechanical Systems,, Electrical Systems, Electrical Connectors,, Female Connectors, Male Connectors, Model Identification,, General Specifications, Dimensions, Generator, Engine, Loaded AC Output, Periodic Maintenance Chart, Periodic Maintenance Chart, GE4000 GE4500 Wiring Diagram (110 V/50 Hz), GE4000, GE4500 Wiring Diagram (110 V/60 Hz), GE4000, GE4500 Wiring Diagram (220 V, 240 V/50 Hz), GE4000, GE4500 Wiring Diagram {220 V/60 Hz), GE4000, GE4500 Wiring Diagram (110V/220V), GE4000, GE4500 Wiring Diagram (115 V/230 V), GE4000, GE4500 Wiring Diagram (120 V/240V), Wiring Code, Color Code
Fuel System
Specifications, Carburetor, Carburetor Theory, Starter System, Pilot System, Main System, Float System, Carburetor Adjustments, Running Speed Adjustment, Pilot Screw Adjustment, Idle Speed Adjustment, Float Level Adjustment, Idle Control Cable Adjustment, Carburetor Service, Carburetor Removal, Carburetor Installation, Carburetor Disassembly, Carburetor Assembly, Carburetor Cleaning, Carburetor Inspection, Automatic Choke, Automatic Choke Removal, Automatic Choke Installation, Diaphragm Actuator Inspection,, Manual Choke Lever,, Manual Choke Lever Disassembly, Manual Choke Lever Assembly, Fuel Cutoff Valve, Fuel Cutoff Valve Removal, Fuel Cutoff Valve Installation, Fuel Cutoff Valve Test, Air Cleaner, Air Cleaner Element, Air Cleaner Removal, Air Cleaner Installation, Air Cleaner Element Cleaning, Air Cleaner Element Inspection, Air Cleaner Housing, Air Cleaner Housing Removal, Air Cleaner Housing Installation, Air Cleaner Housing Inspection, Fuel Tank, Fuel Tank Removal, Fuel Tank Installation, Fuel Tank Draining, Fuel Tank Cleaning, Fuel Tank Inspection, Fuel Gauge, Fuel Gauge Removal, Fuel Gauge Installation, Fuel Gauge Inspection, Fuel Valve, Fuel Valve Removal, Fuel Valve Installation, Fuel Valve Disassembly, Fuel Valve Assembly, Fuel Valve Cleaning, Fuel Valve Inspection, Fuel Valve Sediment Bowl, Fuel Valve Sediment Bowl Removal, Fuel Valve Sediment Bowl Installation, Fuel Valve Sediment Bowl Inspection
Controls
Specifications, Control Panel, Tools and Equipment, Control Panel, Control Panel Removal, Control Panel Installation, Control Panel Disassembly, Control Panel Assembly, Fuses, Fuse Replacement, Control Panel Components, General Information, Idle Control Cable, Idle Control Cable Adjustment, Idle Control Cable Removal, Idle Control Cable Installation, Idle Control Cable Inspection, Idle Control Circuit, Idle Control Unit, Idle Control Unit Removal, Idle Control Unit Installation, Idle Control Unit Test, Idle Control Actuator Solenoid, Idle Control Actuator Solenoid Removal, Idle Control Actuator Solenoid Installation, Idle Control Actuator Solenoid Test, Idle Control Switch, Idle Control Switch Removal, Idle Control Switch Installation, Idle Control Switch Test, AC Power Supply, AC Supply to Idle Control Unit Test, DC Power Supply, DC Supply to Idle Control Unit Test, Idle Control Circuit Wiring, Idle Control Circuit Wiring and Fuse Test, Pilot Lamp, Pilot Lamp Socket Removal, Pilot Lamp Socket Installation, Pilot Lamp Test, Oil Alarm Circuit, Oil Alarm Circuit Control Unit, Oil Alarm Circuit Control Unit Removal, Oil Alarm Circuit Control Unit Installation, Oil Alarm Circuit Control Unit Test, Low Oil Level Sensor, Low Oil Level Sensor Removal, Low Oil Level Sensor Installation, Low Oil Level Sensor Test,, Engine Switch, Engine Switch Removal, Engine Switch Installation, Engine Switch Test,, Battery Charging Circuit Rectifier, Battery Charging Circuit Rectifier Removal, Battery Charging Circuit Rectifier Installation, Battery Charging Circuit Rectifier Test, AC Voltage Meter, AC Voltage Meter Removal,, AC Voltage Meter Installation,, AC Voltage Motor Test, AC Voltage Selector Switch, AC Voltage Selector Switch Removal, AC Voltage Selector Switch Installation, AC Voltage Selector Switch Test, Generator Ground Terminal, Generator Ground Terminal Removal, Generator Ground Terminal Installation, AC Receptacle, AC Receptacle Removal, AC Receptacle Installation, AC Receptacle Inspection, DC Terminals, DC Terminals Removal, DC Terminals Installation, AC Circuit Breakers, AC Circuit Breaker Removal, AC Circuit Breaker Installation, AC Circuit Breaker Test, 12 VDC Circuit Breaker, 12 VDC Circuit Breaker Removal, 12 VDC Circuit Breaker Installation, 12 VDC Circuit Breaker Test
Recoil Starter
Recoil Starter Removal, Recoil Starter Installation, Recoil Starter Disassembly, Spring Replacement, Recoil Starter Assembly, Recoil Starter Cleaning, Recoil Starter Inspection
Electrical Starting System
Specifications, Tools and Equipment, Electric Starter System,, Starter Motor Circuit, Starter Solenoid Test,, Starter Motor, Starter Motor Removal,, Starter Motor Installation, Starter Motor Test, Starter Motor Disassembly,, Starter Motor Assembly, Starter Motor Brush Length, Starter Motor Brush Spring Inspection, Starter Motor Armature Inspection, Starter Motor Yoke Assembly Inspection, Pinion Clutch Inspection, Battery, Battery Removal, Battery Installation, Electrolyte, Electrolyte Level Inspection, Battery Charging, Battery Condition, Battery Initial Charging, Battery Ordinary Charging, Battery Test Charging, Charging System, Charging Coil, Charging Coil Removal, Charging Coil Installation, Charging Circuit Rectifier, Charging Circuit Rectifier Removal, Charging Circuit Rectifier Installation, Charging Circuit Rectifier Test, Charging System Inspection, Initial Inspection
Ignition System
Specifications, Tools and Equipment, Ignition System, Ignition Coil Unit, Ignition Coil Removal, Ignition Coil Installation, Armature Air Gap Adjustment, Ignition Coil Test, Igniter, Igniter Removal, Igniter Installation, Igniter Test, Spark Plug, Spark Plug Removal, Spark Plug Installation, Spark Plug Cleaning and Inspection, Spark Plug Gap
Engine
Specifications, Tools and Equipment, Cylinder Head, Cylinder Head Assembly Removal, Cylinder Head Assembly Installation, Cylinder Head Disassembly, Cylinder Head Assembly, Cylinder Head Cleaning, Cylinder Head Warp, Push Rod Bend, Rocker Shaft and Arm Bearing Wear, Valves, Guides Seats and Springs,, Valves,, Valve Clearance Check, Valve Clearance Adjustment, Valve Removal,, Valve Installation,, Valve Visual Inspection, Valve Head Thickness, Valve Stem Bend, Valve Stem Diameter, Valve Guides, Valve Guide Inside Diameter, Valve Guide Replacement, Valve Seats, Valve Seat Inspection, Valve Seat Repair, Valve Springs, Valve Spring Removal, Valve Spring Installation, Valve Spring Inspection, Breather, Breather Valve (Reed Valve) Removal, Breather Valve Installation, Breather Valve Inspection, Cylinder, Piston, and Rings, Cylinder Removal/Installation, Cylinder Removal, Cylinder Installation, Piston and Ring Removal/Installation, Piston and Ring Removal, Piston and Ring Installation, Cylinder, Piston, and Ring Maintenance, Compression Measurement, Cylinder Wear, Cylinder Boring and Honing, Piston/Cylinder Seizure, Piston Cleaning, Piston Ring and Ring Groove Wear, Piston Ring End Gap, Piston Pin, Piston Pin Hole, and, Connecting Rod Wear, Exhaust System, Spark Arrester, Spark Arrester Removal, Spark Arrester Installation, Spark Arrester Cleaning, Muffler, Muffler Removal, Muffler Installation, Flywheel Housing, Flywheel Housing Removal, Flywheel Housing Installation, Flywheel, Flywheel Removal, Flywheel Installation, Engine Oil, Engine Oil Change, Engine Oil Draining, Engine Oil Filling, Oil Filter Change, Crankcase, Crankcase Assembly Removal/Installation, Crankcase Assembly Removal, Crankcase Assembly Installation, Crankcase Splitting, Crankcase Disassembly, Crankcase Assembly, Crankcase Oil Seals, Crankcase Oil Seal Removal, Crankcase Oil Seal Installation, Ball Bearing, Crankcase Cover Ball Bearing Removal, Crankcase Cover Ball 8earing Installation , Ball Bearing Inspection, Plain Bearings, Plain Bearing Inspection, Pressurized Lubrication System, Engine Oil Flow, Engine Oil Pressure Test, Oil Pump, Relief Valve and Oil Screen, Oil Pump, Oil Pump Removal, Oil Pump Installation, Oil Pump Inspection, Relief Valve,, Relief Valve Removal, Relief Valve Installation, Relief Valve Inspection,, Oil Screen, Oil Screen Removal,, Oil Screen Installation, Oil Screen Inspection,, Crankshaft and Connecting Rod,, Crankshaft and Connecting Rod Removal/Installation, Crankshaft and Connecting Rod Removal, Crankshaft and Connecting Rod Installation , Crankshaft and Connecting Rod Inspection/Maintenance,, Crankshaft Inspection, Under-Size Connecting Rod, Connecting Rod Inspection, Connecting Rod Bend/Twist, Crankshaft End Play Measurement,, Crankshaft End Play Adjustment,, Camshaft-, Camshaft Removal, Camshaft Installation, Cam Wear Inspection, Camshaft Inspection, Camshaft End Play, Compression Release Mechanism, Compression Release Mechanism Operation, Compression Release Mechanism Inspection, Governor,, Governor Operation,, Governor Adjustment, Governor External Components, Governor External Components Removal, Governor External Components Installation , Governor Internal Components,, Governor Internal Components Removal,, Governor Internal Components Installation, Governor Internal Components Inspection, Low Oil Level Sensor,, Low Oil Level Sensor Removal, Low Oil Sensor Installation, Low Oil Level Sensor Switch Test
Generator
Specifications, Generator, Main Coil Resistance, Field Coil Resistance and Brush Specifications Voltage Regulator Sampling Circuit and, Sub Coil Resistance, Tools and Equipment, Generator Components, Stator, Main coil (Mc), Sub coil (Sc), Rotor, Field coil (Fc), AVR (Automatic Voltage Regulator), AVR Pick-Up Circuit, Capacitor (Integrated into AVR), Diodes, Brushes , Generator Theory, Generator Operation, Internal Circuit of AVR, DC Output Circuit, Frequency, Fine Tuning Frequency, Generator End Case, Generator End Case Removal, Generator End C3se Installation, Stator, Stator Removal, Stator Installation, Rotor, Rotor Removal, Rotor Installation, AC Output,, Inspections and Tests,, Single Voltage Generator AC Output, Voltage Measurement, Dual Voltage Generator AC Output, Voltage Measurement, Initial Inspection, Main coil Resistance Measurement, Voltage Regulator Operation Test, Method of Checking AVR, Battery Setting, Battery Check, Wiring, AVR Type Judgement:, Type A and Type B, AVR Inspection, Field Coil Resistance Measurement, Voltage Regulator Sampling Circuit, Resistance Measurement, Sub Coil Resistance Measurement, DC Output, Inspections and Tests, DC Output Voltage Measurement, AC Voltage to Diodes Test, Diode Test, Engine Power Output Tests,, Inspections and Tests, AC Voltage, AC Unloaded Voltage Measurement, AC Rated Output Measurement, AC Rated Output,, AC Voltage Variation,, DC Voltage, DC Unloaded Voltage Measurement, DC Rated Output Measurement
Troubleshooting
