Small AC Generator Repair and Service Manual — 3rd Edition Volume 1
  This comprehensive service manual 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 & Stratton, Homelite, Honda, Kawasaki, Kohler, Kubota, Lombardini, Onan, Suzuki, Tanaka, Tecumseh, Wisconsin, Wisconsin Robin, and Yamaha.
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 & 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 & Stratton Accessories | Briggs & 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 Disctributors.
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