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Small AC Generator Repair and Service Manual - 3rd Edition Volume 1

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The Small AC Generator Repair and Service Manual by Clymer provides detailed information on maintenance, repair and troubleshooting procedures, as well as wiring schematics, for small AC generators.

Hundreds of exploded views and illustrations guide you through the complete adjustment and repair process. Covered are stationary and portable generators weighing approximately 300 pounds or less which generate under 8 kw alternating current and are driven by air-cooled engines.

This manual covers small AC generators by: Acme, Coleman, Dayton, Deere, Generac, Homelite, Honda, Kawasaki, Kohler, Kubota, McCulloch, Onan, Pincor, Robin, Suzuki, Tanaka, and Yamaha.

The engine service section includes: Acme, Briggs and Stratton, Homelite, Honda, Kawasaki, Kohler, Kubota, Lombardini, Onan, Suzuki, Tanaka, Tecumseh, Wisconsin, Wisconsin Robin, and Yamaha.


Book Excerpt

COLEMAN GENERATOR: MAINTENANCE
All bearings are sealed and require no lubrication, but should be inspected for smooth operation when generator is disassembled. Inspect unit periodically for condition of receptacles, electrical connections and operation of all switches.

TROUBLESHOOTING
If little or no output is generated, check the following: The engine must be in good condition and maintain a governed speed under load of 3600 rpm. Check condition of circuit breakers and make sure all wiring connections are clean and tight. Rotor slip rings and brushes must be in good condition. A faulty capacitor, open or shorted diodes, open stator windings, loss of residual magnetism of rotor or open or shorted rotor windings are also possible causes of no generator output.

If field coils have lost their residual magnetism, there will be no excitation voltage produced. To check voltage, remove brush cover (8-Fig.C10) from end bell and start generator. Using a voltmeter set on 250 volts DC scale, touch positive test lead to top or right brush and negative test lead to bottom or left brush.

Meter should read 95 volts for 4000 series generators, 144 volts for 5000 series generators or 150 volts for 7000 series generators. No voltage indicates loss of residual magnetism or an open in excitation circuit. Low voltage indicates short in stator or rotor windings, faulty capacitor or faulty diodes.


IGNITION SYSTEM FUNDAMENTALS
The ignition system provides a properly timed surge of extremely high voltage electrical energy which flows across the spark plug electrode gap to create the ignition spark. Small engines may be equipped with either a magneto or battery ignition system.

A magneto ignition system generates electrical energy, intensifies (transforms) this electrical energy to the extremely high voltage required and delivers this electrical energy at the proper time for the ignition spark.

In a battery ignition system, a storage battery is used as a source of electrical energy and the system transforms the relatively low electrical voltage from the battery into the high voltage required and delivers the high voltage at the proper time for the ignition spark. Thus, the function of the two systems is somewhat similar except for the basic source of electrical energy. The fundamental operating principles of ignition systems are explained in the following paragraphs.



Subject: Small AC generator service, maintenance, repair. ISBN-10: 0872884678 | ISBN-13: 9780872884670 | Clymer GSM3

TABLE of CONTENTS:

GENERATOR SERVICE SECTION

ACME
AG4200, AG5500, AG7500.

COLEMAN POWERMATE
PM40-1000, PM40-1750, PM40-1755, PM45-4002, PM45-4022, PM45-5002, PM45-5022, PM45-7022, PM52-2000, PM52-4000, PM52-4020, PM52-5000, PM52-5020, PM54-2000, PM54-4000, PM54-4000, PM54-4020, PM54-5000, PM54-5020, PM54-7020.

DAYTON
1W761A, 1W762A, 1W831A, 1W832A, 2W183, 2W183A, 3W091, 3W091A, 3W092, 3W092A, 3W093A, 3W093B, 3W013, 3W013A, 3W013C, 3W013D, 3W014, 3W014I, 3W014J, 3W014K, 3W014L, 3W015, 3W015G, 3W015H, 3W015I, 3W015J, 3W016, 3W016A, 3W016B, 3W017C, 3W017D, 3W056B, 3W057B, 3W057C, 3W181, 3W181A, 3W181B, 3W182, 3W182A, 3W182B, 3W182C, 3W177, 3W177A, 3W177C, 3W178, 3W178A, 3W178C, 3W179, 3W179A, 3W179B, 3W180, 3W180A, 3W180B, 3W232, 3W232B, 3W232C, 2W644, 3W351, 3W152, 2W512.

JOHN DEERE
225, 325, 375, 500, 650,1750W, 3000W, 4000W, 5000W.

GENERAC
G1000, G1600, G2600, G4000, S4000, S4002, S5002.

HOMELITE
9A34-1, 9A34-1A, 9A34-3, 9A34-3A, 10A35-1L, 10A35-2L, 251A35-1, 251A35-2, 112A15-1, 113A25-1, 116A50-2, 116A502L, 118A35-1, 118A35-2, 119A35-1, 119A35-1L, 119A352, 119A35-2L, 124A10-1, 125A15-1, 126A22-1, 127A30-1, 128A10-1, 128A10-1B, 129A15-1, 129A15-1B, 130A22-1, 130A22-1B, 130A221-C, 131A30-1, 131A30-1B, 132A40-1, E1350-1, E1700-1, E2250-1, E3000-1, E3000-1A, E4000-A, E40001A, 151A15-1, 151A15-1A, 151A15-1B, 151A25-1, 152A27-1A, 153A35-1, 153A35-1A, 154A20-1, 155A50-1, 155A50-1A, 170A15-1, 170A15-1A, 170B16, 172A20-1, 172A20-1A, 172A20-1B, 172B26, 174A27-1, 174A27-1A, 174A27-1B, 176A35-1, 176A35-1A, 176A35-1B, 176A35-1C, 176B40, 177D38-1, 178A50-1, 178A50-1A, 178A50-1B, 178B48, 180A75-1, 180A75-1A, 270A20-1, 270A20-1A, 270A20-1B, 270A20-1C, G3600-1, G3600-2, G4800-1, G4800-2, HSB50-1, XLA115, HG600, HG1400, HG1500, HG2100, HG2500, HG3500.

HONDA
E300A, E300C, E300E, E300U, ER400, EM400, E600A, E600S, E900, E1000A, E1000S, E1500A, E2000A, E2000S, E2500A, E2500S.

KAWASAKI
GA1800A, GA2300A, GA3200A/AS, KG4000A/AS, KG5000A/AS, KG700A, KG1000B, KG1500B, KG2600B, KG550A, KG550B, KG750A, KG750B, KG1100A, KG1100B, KG1600A, KG1600B, KG2900A, KG2900B.

KOHLER
1.75MBM25, 1.75MM26, 2.25MBM25, 3.5CM65, 3.5MBM25, 3.5MBM65, 3.5MM25, 3.5MM65, 5CM65, 5MBM25, 5MBM65, 5MM25, 5MM65, Power Play 600 (Dayton 2W512), Power Play 800/950.

KUBOTA
A500, A650, A450, A1000, A1400, A2100, A3000, A3500.

McCULLOCH
HP1200, HP2000, HP3000, HP3500, HP3500DLX, RA120, RA121, RA122, RA150, RA151, RA152, RA200, RA201, RA202, RA330, RA330A, RA330ES, RA331, RA332, HP5000, HP5000DLX.

ONAN
0.5AK-1M, 0.5AK-2M, 0.5AK-1R, 0.5AK-2R, 0.7AK-1M, 0.7AK-2M, 0.7AK-1R, 0.7AK-2R, 1.0AJ-1M, 1.0AJ-2M, 1.0AJ-1R, 1.0AJ-2R, 1.5AK-1M, 1.5AK-2M, 1.5AK-1P, 1.5AK-2P, 2.5AJ-1M, 2.5AJ-2M, 2.5AJ-3M, 2.5AJ-1P, 2.5AJ-2P, 2.5AJ-3P, 2.5AJ-1R, 2.5AJ-2R, 2.5AJ-3R, 2.5LK-1M, 2.5LK-1R, 2.5LK-3CR, 2.5LK-3M, 2.5LK-3R, 4.0BFA-1R, 4.0CCK-3CE, 4.0CCK-3CP, 4.0CCK-3CR, 5.0BGA-3CR, 5.0CCK-3CE, 5.0CCK-3CP, 5.0CCK-3CR, 6.5NH-3CE, 6.5NH-3CR, PC, PD, PE, PF, PG, PH, PK, PM, TN, TP, TR, TS, TT, 1.7PC-1P, 2.2PE-1P, 3.0PL-1P, 3.0PL-3P, 3.2PF-3P, 3.7PF-3P, 5.0PK-3E, 5.0PK-3P, 5.0PN-3E, 5.0PN-3P, 6.5PM-3E, 6.5PM-3P.

PINCOR
CRF20HM1, CRF20HM1A, CRF30HM1, CRF30HM1A, CRF30HM5, CRF30HM5A, CRF37HM1, CRF37HM1A, CRF37HM5, CRF37HM5A, CRF45HM1, CRF45HM1A, CRF45HM5, CRF45HM5A, CRF55HM1, CRF55HM1A, CRF55HM5, CRF55HM5A, FRF30HE5, FRF30HM5, FRF45HE5, FRF45HM5, FRF55HE5, FRF55HM5, RF10, RF12HM1, RF20HM1, RF30HE1, RF30HM1, RF30HE2, RF30HM2, RF30HM2A, RF30HE5, RF30HM5, RF30HM5A, RF37HE1, RF37HM1, RF37MH1A, RF37HE2, RF37HM2, RF37HM2A, RF37HE5, RF37HM5, RF37HM5A, RF50HE1, RF50HM1, RF50HM1A, RF50HE2, RF50HM2, RF50HM2A, RF50HE5, RF50HM5, RF50HM5A, RF60HE1, RF60HM1, RF60HM1A, RF60HE2, RF60HM2, RF60HM2A, RF65HE1, RF65HM1, RF65HM1A, RF65HE2, RF65HM2, RF65HM2A, RF70HE1, RF70HM1, RF70HM1A, RF70HE2, RF70HM2, RF70HM2A, RF1250H, RF1500H, RF1600H, RF2000H, RF2500H, RF2500HDV, RF3000H, RF3000HDV, RF3000HFP, RF3500H, RF3500HDV, RF3800HDV, RF4000H, RF4000HDV, RF4000HFP, CAG30SM1, CAG30SM2, CAG40SE1, CAG40SE2, CAG40SM1, CAG40SM2.

ROBIN
R600, R650, R1200, RGX180, RGX240, RGX305, RGX351, RGX500, RGD2500, RGD3300, RGD5000, RGX2400, RGX3500, RGX5500.

SUZUKI
SE300, SE500, SE500A, SE600A, SE800A, SE700, SE700A.

TANAKA
REG-800.

YAMAHA
EF1200, EF1400, 799, 7A4, 7E1, 7E.

ENGINE FUNDAMENTALS SECTION

Engine Operating Principles | Carburetor Fundamentals | Ignition System Fundamentals | Troubleshooting | Ignition Service | Carburetor Service | Engine Service | Service Shop Tool Buyer's Guide.

ENGINE SERVICE SECTION

ACME
ALN 290W, ALN 330W, AT 330, VT 88W, VT 94W.

BRIGGS and STRATTON
170000, 171000, 190000, 191000, 220000, 250000, 251000, 252000, 253000, 19, 19D, 191000, 193000, 200000, 23, 23A, 23C, 23D, 231000, 233000, 243000, 300000, 301000, 302000, 320000, 325000, 326000, 400400, 400700, 401400, 401700, 402400, 402700, 421400, 421700, 422400, 422700, Early 60000, Late 60000, 8B, 80000, 81000, 82000, 92000, 93500, 94000, 94500, 94900, 95500 | Servicing Briggs and Stratton Accessories | Briggs and Stratton Central Service Distributors.

KAWASAKI
FA76, FA130, FA210, KF24, KF34, KF53, KF64, KF68, KF82, KF100, KF150, FG150, FG200, FG300.

KOHLER
K90, K91, K-141, K-160, K161, K-181, K-241, K-301, K-321, K-341 | Servicing Kohler Accessories | Kohler Central Engine Distributors.

KUBOTA
GS90, GS130, GS280, GN550, GN1850, GN2500.

LOMBARDINI
530.

ONAN
LK, LKB, BF, BG, B43M, B43E, B43G, B48G, B48M, NH, NHA, NHB, NHC, T-260G, CCK, CCKA, CCKB, AJ, AK | Servicing Onan Accessories | Onan Central Parts Distributors.

SUZUKI
SE300, SE500, SE500A, GY15D, GY20D, SE700, SE700A.

TECUMSEH 4-STROKE
LAV25, LAV30, TVS75, H25, H30 prior to 1983, H30 after 1982, LV35, LAV35, TVS90, H35 prior to 1983, ECH90, H35 after 1982, LAV40, V40 external ignition, TVS105, HS40, ECV105, TNT100, TVS100, ECV100, V40, VH40, H40, HH40, ECV110, LAV50, ECV120, TNT120, TVS120, HS50, H50, HH50, V50, VH50, TVM125, H60, HH60, V60, VH60, TVM140.

TECUMSEH
VM70, HH70, VH70, HM70, TVM170, V80, VM80, HM80, HH80, VH80, TVM195, HM100, VM100, VH100, HH100, TVM220, HH120, OH120, OH140, OH150, OH160, OH180, HH140, HH150, HH160 | Tecumseh Central Parts Distributors.

WISCONSIN
ADH, AE, AEH, AEHS, AEN, AENL, AENS, AFH, AGH, AGND, AHH, AK, AKS, AKN, HBKN, HAENL, S-7D, HS-7D, S-8D, HS-8D, TR-10D, TRA-10D, S-10D, TRA-12D, S-12D, S-14D | Servicing Wisconsin Accessories.

WISCONSIN ROBIN
EY25W, EY27W, EY44W, EY21W, W1-145, W1-185, EY20D, EY28D, EY40D, DY23D, DY27D, DY41D | Servicing Wisconsin Robin Accessories | Teledyne Wisconsin Central Parts Distributors.

  • Publisher: Clymer Manuals
  • Pages: 536 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.5 x 11 inches
  • ISBN: 978-0-87288-467-0
  • Small AC Generator Service and Repair Manual 3rd Edition
    $26.95