Free Shipping in the USA
Phone Number 214-385-4890 or 888-255-2950 M-F 8AM-4PM CT
Free Shipping, Low Price, & Best Selection ! - Motor Vehicle DIY Repair Manuals and How-to Books!
DIY ManualsDIY Manuals >> Service & Repair >> Power Equipment >> Generator >> Small AC Generator Service and Repair Manual 3rd Edition
Small AC Generator Service and Repair Manual 3rd EditionClick To Enlarge Product Image

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

Item #PE-GSM3
MSRP: $31.95
(You Save $5.00)
Usually ships the next business day
Safe ShoppingEasy Returns
Free Ground Shipping
  • Item Description
  • Table of Contents
  • Specifications

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.

If you're looking for a Dayton generator repair manual, this is the guide you need. 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


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.


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.


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



AG4200, AG5500, AG7500.

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.

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.

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

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

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.

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

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

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.

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

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

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.

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.

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

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


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


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


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

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.

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

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

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


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.

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

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.

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.

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.

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 Series / Haynes Manuals
  • Pages: 536 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.5 x 11 inches
  • ISBN: 978-0-87288-467-0
  • Questions & Answers about Small AC Generator Service and Repair Manual 3rd Edition

    Ask a question about Small AC Generator Service and Repair Manual 3rd Edition. Click here