914-0500 Onan 2EGMBB 2.5EGMBG HomeSite Portable Genset
Contents
1. w coc x eo fF mx oO o 9 5 q co w ga n NEL c Em Ss ae N ja 9 o 5 51 Redistribution or publication of this document by any means is strictly prohibited Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 763 574 5000 Fax 763 528 7229 Cummins and Onan are registered trademarks of Cummins Inc Redistribution or publication of this document by any means is strictly prohibited2. Factory Allowable limit Specification 18 002 mm 18 048 mm 0 7087 in 0 7105 in PISTON TO PISTON PIN BORE CLEARANCE Factory ae Specification Allowable limit 0 004 016 mm 0 08 mm 0 00016 0 0006 in 0 0 003 in CRANKPIN OD Factory Allowable limit Specification 29 985 mm 29 92 mm 1 181 in 1 178 in CONNECTING ROD SMALL END ID CONNECTING ROD BIG END SIDE CLEARANCE Factory TE Factory D Specification Allowable limit Specification Allowable limit 18 006 mm 18 07 mm 0 1 0 7 mm 1 1 mm 0 7089 in 0 711 in 0 0040 028 in 0 043 in 25 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE CAMSHAFT DIAMETER Factory ee Specification Allowable limit IN 27 45 27 7 mm 1 09in 1 081 in EX 27 75mm 27 50mm 1 093 in 1 083 in CAMSHAFT CAM DIAMETER Factory Allowable limit Specification 13 984 mm 13 916 mm 0 5506 in 0 5479 in CAMSHAFT HOLDER ID Factory Specification Allowable limit 16 048 mm 26 0 5531 in Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 4 2 Flywheel a DISASSEMBLY ASSEMBLY SPARK PLUG LEAD M ot REASSEMBLY Clamp securely to the crankcase TS with the two clamps WOODRUFF KEY REASSEMBLY SPARK PLUG LEAD After instal
3. SECTION 4 DISASSEMBLY AND SERVICE 4 3 Disassembly Chart END COVER MUFFLER FUEL TANK MOUNT RUBBER FRAME BRUSH ENGINE CARBURATOR FLYWHEEL FAN COVER AIR CLEANER CONTROL BOX REAR HOUSING STATOR i ROTOR STARTER MOTOR RECOIL STARTER GENERATOR DISASSEMBLY Example To remove the frame This chart is a quick reference guide for disassembling the product Be sure to follow the sequence shown here for better and safer work a b 20 Remove the end cover Remove the control box Remove the fuel tank Remove the muffler Remove the frame Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 4 Engine 4 4 1 Crankshaft piston a DISASSEMBLY ASSEMBLY Crankshaft PISTON REASSEMBLY Check that the decompressor weight moves smoothly and REASSEMBLY nr the spring is not weak or worn Install with the triangle mark toward the push DECOMPRESSOR rods WEIGHT VALVE LIFTER REASSEMBLY Install the tappets immediately before installing the camshaft OIL ALERT UNIT CONNECTING ROD CAP REASSEMBLY Install with the oil dipper toward the camshaft CRANKSHAFT REASSEMBLY Push in until the bearing touches the crankcase Be careful not to damage the oil seal The ribs on the cap and connecting rod must be aligned 21
4. EXHAUST PIPE REASSEMBLY Attach after removing the carbon from the screen with a wire brush MUFFLER REASSEMBLY Install after removing the carbon deposits from the muffler using a plastic hammer 39 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 5 3 Generator a DISASSEMBLLY REASSEMBLY CRANKCASE GROMMET GENERATOR ASSY REASSEMBLY RERSSEMBEY Check to be sure the grommet Wipe dirt or oil off the tapered is inserted sec portion of the rotor and crankshaft before installing BRUSH HOLDER ASSY DISASSEMBLY Remove the brush holder before the rotor and stator ROTOR BOLT REASSEMBLY 43 47 N m 430 470 kg cm 31 0 33 9 ft lb STATOR BOLT REASSEMBLY Tighten in crisscross pattern in 2 3 steps After tightening make sure there is no clearance between the crankcase cover and stator cover 8 12 N m 80 120 kg cm 5 8 8 7 ft lb RUBBER MOUNT REASSEMBLY Insert the alignment tabs onto the holes Make sure the rubber is not chipped hard or worn Note the installation direction 40 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE REAR HOUSING REAR HOUSING BRUSH HOLDER ASSY AVR ASSY AC OUTPUT TERMINAL GENERATOR COOLING FAN STATOR COVER STATOR DISASSEMBLY Install the ap
5. Agencies such as the Red Cross and public safety departments offer courses in first aid CPR and fire control Take advantage of this information to be ready to respond to an accident Learn to be safety conscious and make safety procedures part of the work routine TABLE 4 1 HAZARDS AND THEIR SOURCES e Leaking or spilled fuel Fire an e Hydrogen gas from battery Explosion Oily rag improperly stored e Flammable liquids improperly stored e Hot exhaust pipes Burns e Hot engine and generator surfaces Poisonous Operating genset where exhaust Gas gases can accumulate e Improper generator connections Electrical Shock AC Working in damp conditions e Jewelry touching electrical components Rotating e Fan guards not in place Machinery Slipper PER e Leaking or spilled oil Surfaces Heavy e Removing genset form vehicle Objects e Removing heavy components 4 2 2 Special Tools Engine A complete set of standard and metric shop tools are required to service the engine Control and Generator A complete set of standard and metric shop tools are required to service the control and generator Also needed are Lead or dead blow hammer Battery hydrometer Torque wrench VOM millimeter Frequency meter Armature growler Load bank Jumper wires Rotor Puller 9999995429 19 Redistribution or publication of this document by any means is strictly prohibited
6. Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE b PISTON PISTON RING PISTON RING REASSEMBLY 1 Install all rings with the markings facing upward Be sure that the top chrome plated and second rings are not interchanged 2 3 Check that the rings rotate smoothly after installation 4 Space the piston ring end gaps 120 degrees apart and do not align the gaps with the piston pin bore TOP RING CHROME PLATED es ls 5 MARKING OIL RING SECOND RING PISTON PISTON PIN PISTON PIN CLIP REASSEMBLY Install by setting one end of the clip in the piston groove holding the PISTON FIN other end with long nosed pliers and rotating the clip in Do not align the end gap of the clip with the cut out in the piston pin bore REASSEMBLY Install the connecting rod with the long end toward the triangle marked side of the piston 22 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE c CAMSHAFT CRANKSHAFT d OIL LEVEL SWITCH Ckeck continuity of the switch with an ohmmeter REASSEMBLY 1 Hold the switch in its normal position The Align the index marks on the ohmmeter should read zero resistance camshaft and timing gear 2 Hold the switch upside down The ohmmeter should read infinity cc resistance CRANKSHAFT 3 Inspect t
7. 5 50 mm 0 217 in 5 572 mm 0 2193 in Replace the cylinder header if they are over the allowable limit GUIDE TO STEM CLEARANCE Subtract each valve stem O D from the corresponding guide 1 0 to the stem to guide clearance Factory Allowable limit Specification IN 0 02 0 044 mm 0 10 mm 0 0008 0 0016 in 0 004 in EX 0 06 0 087 mm 0 12 mm 0 0002 0 0034 in 0 005 in If the stem to guide clearance exceeds the Allowable limit determine if the new guide with standard dimensions would bring the clearance within tolerance If so replace any guide as necessary and ream to fit If the stem to guide clearance exceeds the allowable limit with new guides replace the valves as well NOTE Recondition the valve seats whenever the valve guides are replaced 31 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE VALVE SPRING FREE LENGTH VALVE STEM OD Measure the free length of the valve springs Inspect each valve for face irregularities bending or abnormal stem wear Replace the valve if Factory Allowable limit necessary Measure and record each valve stem Specification O D 30 0 mm 1 18 in 28 5 mm 1 122 in 5 S Allowable limit IN P 5 318 Replace the springs if they are shorter than the i llowable limit 5 48 0 216 a mm 0 216 in 0 2093 in EX 5 275 mm 44 214
8. Crankshaft 1 1817 in 1 1837 in Big end oil clearance 0 030 0 050 mm 0 12 mm 0 0012 0 0020 in 0 0048 in Big end side clearance 0 1 0 7 mm PM 0 004 0 028 in 0 043 in Crankehan Crankshaft O D 29 985 mm 29 92 mm Connecting rod Big end 1 181 in 1 178 in Redistribution or publication of this document by any means is strictly prohibited SECTION 2 DIMENSIONS AND TORQUE 2400 Part Item Factory Specification Allowable limit Valves Valve Lash IN 0 10 0 02 mm 0 004 0 001 in 0 15 0 02 0 006 0 001 Stem IN 5 48 mm 5 318 mm 0 216 in 0 2094 in EX 5 47 mm 5 275 mm 0 215 in 0 2077 in Guide D IN EX 5 50 mm 5 572 mm 0 217 in 0 2194 in Stem clearance IN 0 02 0 044 mm 0 10mm 0 0008 0 0017 in 0 004 in EX 0 06 0 087 mm 0 12 mm 0 0024 0 0034 in 0 005 in Seat width 0 8 mm 2 0mm 0 03 in 0 08 in Spring fee length 30 0 mm 28 5 mm 1 18 in 1 122 in Camshaft Cam height IN 27 7mm 27 45 mm 1 09 in 1 081 in EX 27 75 mm 27 5mm 1 093 in 1 083 in 13 984 mm 13 916 mm 0 5506 in 0 5479 in Crankcase Camshaft holder I D 14 0 mm 14 048 mm cover 0 55 in 0 5531 in Spark plug Gap 0 7 0 8 mm 0 028 0 031 in Ignition coil Resistance Primary coil 0 8 1 0 O Air gap at flywheel Secondary coil 5 9 7 1 KO 0 4 0 2 mm 0 016 0 008 in Redistribution or publicati
9. F7RTC 0 028 in 0 7 mm 0 0039 0 006 inches 0 10 0 15 mm 20 BTDC Recoil 197 cc 106 6 Ib 48 kg 24 1 inches 612 mm 19 6 inches 497 mm 19 3 inches 490 mm 4 0 US gal 15 L 12 Hours Redistribution or publication of this document by any means is strictly prohibited SECTION 2 DIMENSIONS AND TORQUE 2 1 Engine Dimensions 2400 Part Item Factory Specification Allowable limit Engine Maximum speed 3750 150 rpm Idle speed 1400 150 rpm Cylinder compression 6 0 8 5 kg cm 1 5 2 13 kg in at 600 rpm Cylinder Sleeve I D 68 015 mm 68 165 mm 2 6778 in 2 6837 in Cylinder head Warpage 0 10 mm 0 004 in Piston Skirt O D 67 985 mm 67 845 mm 2 6766 in 2 6711 in Piston to cylinder clearance 0 030 0 050 mm 0 12 mm 0 0012 0 0020 in 0 005 in Piston pin bore 1 0 18 002 mm 18 048 mm 0 7087 in 0 7105 in Pin O D 17 998 mm 17 954 mm 0 7086 in 0 7068 in Piston to piston pin bore 0 004 0 016 mm 0 06 mm clearance 0 00016 0 0006 in 0 002in Piston rings Ring side clearance 0 015 0 045 mm 0 15 mm Top second oil 0 0006 0 0018 in 0 0006 in Ring end gap Top second 0 2 0 4 mm 1 0 mm oil 0 008 0 016 in 0 04 in Ring Width Top second 1 5 mm 1 37 mm 0 06 in 0 054 in Oil 2 5 mm 2 37 mm 0 10 in 0 093 in Connecting Small end 1 0 18 007 mm 18 07 mm rod Pin End 0 7089 in 0 711 in Big end I D 30 015 mm 30 0667 mm
10. FS G L L Position OFF e 9 ON 9 9 When switch to OFF position IG is connecting to E When switch to ON position L is connecting to L DC BREAKER RESET SWITCH Check continuity between the breaker terminals There should be continuity with the breaker button pushed in AC BREAKER RESET SWITCHES Check continuity between the breaker terminals There should be continuity with the breaker button pushed in VOLTMETER Using an ohmmeter check for continuity between the terminals Continuity should exist between them AC RECEPTACLE Connect the terminals of the receptacles with a piece of wire Using an ohmmeter check for continuity between the terminals If there is no continuity the receptacle is defective and must be replaced 49 Redistribution or publication of this document by any means is strictly prohibited SECTION 5 WIRING DIAGRAMS 5 1 The Wiring Diagram of 2400 e M ESSET e tH mr N wo cc o 42 50 milo ga E ae oa lt w w Zo gt B SEES ies ve v 5 Redistribution or publication of this document by any means is strictly prohibited SECTION 5 WIRING DIAGRAMS 5 2 The Wiring Diagram of 3500 e J ole yy ail e tu 7 20
11. SWITCH GFCI VOLTMETER SWITCH 12 Volt DC Terminals PANEL FRONT COVER 45 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 3500 PANELENDCOVER FUSE AND FUSE COVER VOLTAGE SELECTOR WITCH AC BREAKER DC BREAKER RESET SWITCHES AC BREAKER RESET SWITCH RESET SWITCH VOLTMETER AC RECEPTACLE 120 240VAC EARTH GROUND START ON STOP SWITCH GFCI 12 Volt DC Terminals PANEL FRONT COVER 46 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 2400 DC DIODE 4P COUPLER SS AC OUTPUT TERMINAL STRIP c c 2 2 gt wu m gt 1 Red 2 Blue n m QU EOSIN YL 9 3 S EXCITER WINDING 4P COUPLER GROUND CABLE 3 Blue 4 Green 5 White ng ua 47 s is strictly prohibited publication of this document by any mean Redistribution or SECTION 4 DISASSEMBLY AND SERVICE 3500 DC DIODE 4P COUPLER 1 Red 2 Blue GROUND CABLE Yellow Blue EXCITER WINDING 4P COUPLER AVR 3 3 Blue B 4 Green 5 White Tt SECTION 4 DISASSEMBLY AND SERVICE b INSPECTION ENGINE SWITCH Check for continuity between the terminals with the switch in each position Wire Yellow Green Black Pc White white Ped White IG E
12. base 4 Use the wrench supplied in the tool kit to remove the spark plug SPARK PLUG TORQUE 20N m 25Nem PLUG WRENCH PLUG CAP 5 Visually inspect the spark plug Discard it if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 6 Measure the plug gap with a feeler gauge Correct as necessary by carefully bending the side electrode SIDE ELECTRODE 0 7 0 80mm METAL BRUSH The gap should be 0 70 0 80 mm 0 028 0 031 in 11 7 Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross threading 8 After the spark plug is seated tighten with a spark plug wrench to compress the washer If installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer CAUTION he spark plug must be securely tightened An improperly tightened spark plug could damage the engine Never use spark plugs which have an improper heat range Use only the recommended spark plugs or equivalent Redistribution or publication of this document by any means is strictly prohibited SECTION 3 MAINTENANCE 3 7 Valve Clearance ACAUTION Valve clearance inspection and adjustment must be performed with the engine cold 1 Remove the cylinder head cover and set the piston at top de
13. document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 2 Preparing to Service 4 2 1 Safety Considerations There are hazards in servicing gensets Study Safety precautions and become familiar with the hazards listed in table 4 1 Note the following safeguards and ways of avoiding hazards e Use personal protection Wear appropriate protective safety equipment such as safety shoes and safety glasses e Do not wear rings or jewelry and do not wear loose or damp clothing that might get caught in equipment or conduct electricity e Reduce the hazard A safety order workshop area and well maintained reduce the hazard potential Keep guards and shields in place on machinery and maintain equipment in good working condition Store flammable liquids in approved containers away form fire flame spark pilot light switches arc producing equipment and other ignition sources Keep the workshop clean and well lighted and provide adequate ventilation e Develop safe work habits Unsafe actions cause accidents with tools and machines Be familiar with the equipment and know how to use them safely Use the correct tool for the job and check its condition before starting Comply with the warnings in this manual and take special precautions when working around electrical equipment Do not work alone if possible and take no risks e Be prepared for an accident Keep fire extinguishers and safety equipment nearby
14. means is strictly prohibited SECTION 3 MAINTENANCE 3 3 Air Cleaner ACAUTION A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when operating the generator in extremely dusty areas A WARNING Using gasoline or flammable solvent to clean the filter element can cause a fire or explosion Use only soapy water or nonflammable solvent AIR CLEANER COVER A WARNING Never run the generator without the air cleaner Rapid engine wear will result 1 Remove the cleaner cover by unsnapping the two spring clips Clean more often in dusty environments 2 Remove the two foam filter elements and thoroughly wash them with soap and water Let them dry thoroughly 3 Knead in 1 teaspoon 5 cm of clean engine oil into each foam filter element The oil should be distributed evenly throughout each filter elements 4 Reinstall the filter elements the gray filter first finer pores and then the black filter larger pores 5 Secure the cover with the spring clips SOAP amp WATER ENGINE OIL SQUEEZE Redistribution or publication of this document by any means is strictly prohibited SECTION 3 MAINTENANCE 3 4 Fuel Sediment Cup Cleaning The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor If the engine has not been run for a long time the sediment
15. operate the generator set in rain or snow or when it is sitting on wet ground Moving Parts Can Cause Severe Personal Injury or Death Before performing any maintenance on the generator set disconnect the spark plug wire Always keep hands away from moving parts Do not wear loose clothing or jewelry while servicing the generator set Loose clothing and jewelry can become caught in moving parts Jewelry can short out electrical contacts causing sparks flame and electrical shock Make sure that fasteners and clamps on the generator set are tight Keep guards in position over fans rotors etc Redistribution or publication of this document by any means is strictly prohibited SAFETY PRECAUTIONS Battery Gases are explosive Wear safety glasses when batteries Do not smoke To reduce arcing when disconnecting or reconnecting battery cables always disconnect the negative cable of the battery first and reconnect it last General Precautions servicing Keep children away from the generator set Wear hearing protection when near an operating generator set Keep a multi class ABC fire extinguisher readily at hand Class A fires involve ordinary combustible materials such as wood and cloth Class B fires involve combustible and flammable liquids and gaseous fuels Class C fires involve live electrical equipment ref NFPA No 10 Benzene and lead may be found in gasoline and have been identified by so
16. 4 5 Air Cleaner DISASSEMBLLY REASSEMBLY BREATHER TUBE REASSEMBLY Connect between the air cleaner case and tappet cover ELEMENT Sy Oy AIR CLEANER CASE AIR CLEANER GASKET SEPARATOR REASSEMBLY Make sure the gasket is not AIR CLEANER COVER damaged broken or bent Install correctly as shown REASSEMBLY Make sure to seat the gasket in the groove on the edge of the case all the way around properly 36 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 4 6 Carburetor DISASSEMBLLY REASSEMBLY AL WARNING Gasoline is flammable and explosive Close the fuel shut off valve and drain the carburetor before servicing the carburetor CARBURETOR BODY REASSEMBLY Check the screw head PILOT SCREW f REASSEMBLY Clean internal passages and orifices with compressed air before for wear or damage before installing INITIAL 12599 OPENING 1 5 8 turns d installing out A i MAIN JET REASSEMBLY REASSEMBLY Check for correct installation Clean thoroughly with MAIN NOZZLE compressed air before installation REASSEMBLY Clean thoroughly with compressed air before installation REASSEMBLY Check for smooth movement after installing FLOAT VALVE REASSEMBLY Check for worn valve or weak spring before SET BOLT installation m REASSEMBLY amp DRAIN SCREW After assembly check for
17. 50 14 5 18 1 Oil level switch mounting nut 10x1 25 mm 8 12 80 120 5 8 8 7 Flywheel mounting nut 14x1 25 mm 80 90 800 900 58 865 3 2 4 Standard Torques Specification 5 mm bolt nut 4 7 40 70 2 9 5 1 6 mm bolt nut 8 12 80 120 5 8 8 7 Standard torque values 8 mm bolt nut 20 28 200 280 14 5 20 2 10 mm bolt nut 35 40 350 400 14 5 20 2 12 mm bolt nut 50 60 500 600 36 2 43 4 6 Redistribution or publication of this document by any means is strictly prohibited SECTION 3 MAINTENANCE 3 1 Maintenance Schedule Periodic maintenance is essential for top performance Use Table 3 as a guide Under hot or dusty operating conditions some maintenance operations should be performed more frequently as indicated by the footnotes in the table Keep a log of maintenance performed and the hours run Recording maintenance will help you keep it regular and provide a basis for supporting warranty claims Accidental starting of the generator set during maintenance can cause severe personal injury or death Before performing maintenance disconnect the spark plug wire from the spark plug NIN A hot generator set can cause severe burns Always allow the generator set to cool before performing any maintenance or service TABLE 3 PERIODIC MAINTENANCE SCHEDULE SERVICE THESE ITEMS 20 HOURS General Inspection Check Oil Level Test GFCI Change Engine Oil Clean Air Cleaner Clean Cylinder Cooling Fins Cl
18. EMBLY Before installation clean and adjust the spark plug 30 a D eh 2 09 a SEU LIN EXHAUST VALVE REASSEMBLY Check both ends for wear and check the rod for straightness Be sure the rod ends are firmly seated in the lifter E IHE j T M C PUSH ROD REASSEMBLY Before installation remove carbon deposits and inspect the valve INTAKE VALVE VALVE HEAD DIAMETER IN 24 mm 0 94 in EX 22mm 0 87 in REASSEMBLY Do not interchange with the exhaust valve Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE b INSPECTION FEELER GAUGE CYLINDER HEAD Remove carbon deposits from the combustion chamber Clean off any gasket material from the cylinder head surface Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and a feeler gauge Allowable limit 0 1 mm 0 004 in VALVE SEAT WIDTH Measure the valve seat width If the valve seat width is under the factory section or over the service limit recondition the valve seat Factory Specification 0 8 mm 0 03 in Allowable limit 2 0 mm 0 08 in VALVE GUIDE ID NOTE Ream the valve guides to remove any carbon deposits before measuring Measure and record each valve guide I D Factory Specification Allowable limit
19. HAFT GOVERNOR NUT SPRING GOVERNOR ARM THROTTLE LIMITING SCREW ANTI SURGE SPRING 12 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE ENGINE FLOODED too much fuel TRY AGAIN AFTER A FEW MINUTES 4 1 Troubleshooting 4 1 1 Hard Starting FUEL low ADD FUEL INTO FUEL TANK FUEL FILTER clogged FUEL SYSTEM CARBURETOR out of adjustment SEE 4 4 6 AIR FILTER dirty SEE 3 3 SPARK PLUG GAP incorrect SPARK PLUG CAP faulty SEE 4 4 2 IGNITION SYSTEM IGNITION COIL GAP incorrect SEE 4 4 2 IGNITION COIL faulty SEE 4 4 2 START SWITCH faulty SEE 4 5 4 HARD STARING OIL ALERT SYSTEM faulty SEE 4 4 1 VALVE LASH incorrect CYLINDER HEAD GASKET faulty SEE 4 4 3 YLINDER HEAD BOLT faul COMPRESSION e OLT SYSTEM SEE 4 4 3 VALVE faulty SEE 4 4 3 CYLINDER PISTON PISTON RING worn SEE 4 4 1 CAMSHAFT wore SEE 4 4 1 T m m 6 N 13 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 1 2 Low Power FUEL poor ADD CLEAN FRESH FUEL INTO TANK FUEL FILTER clogged FUEL SYSTEM SEE 3 4 CARBURETOR out of adjustment SEE 4 4 6 CHOKE ROD not open MOVE TO RUN POSITION AIR FILTER dirt
20. NG REASSEMBLY Hook the outer hook in the groove of the starter reel and inner hook on the starter case tab STARTER ROE REASSEMBLY Install with the starter grip position as shown 34 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE c RECOIL STARTER ASSEMBLY c With a short length of the rope extending from the starter reel notch pull the end of the rope Wear gloves and eye wear to protect out of the case feed it through the starter grip your hands and eyes and tie a knot in the end of the rope AA WARNING Do not let the return spring jump a Hook the spring outer hook in the reel groove and install the reel on the starter case so that the spring inner hook is hooked to the starter case tab by turning the reel counterclockwise d Install the friction plates friction spring ratchet pin guide plate and reel cover Tighten the reel cover bolt b Feed the end of the rope through the hole in the starter reel and tie the rope end Wind the rope onto the direction shown and wedge the Rotate the reel three full turns in the direction of rope end in the notch on the edge of the reel the arrow f Check the operation of the ratchet by pulling the starter rope out several times 35 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4
21. NT LOCATIONS Redistribution or publication of this document any means is strictly prohibited SECTION 1 INTRODUCTION FUEL FUEL TANK CAP AC BREAKER RESET SWITCH EARTH GROUND LUG AC BREAKER RESET SWITCH AC RECEPTACLE AIR CLEANER 240VAC AC VOLTMETER VOLTAGE SELECT 12 VOLT DC SWITCHE RECOIL STARTER GRIP TERMINALS ON OFF 120VAC RECEPTACLE SWITCH GFCI MUFFLER FIGURE 2 3500 COMPONENT LOCATIONS Redistribution or publication of this document by any means is strictly prohibited SECTION 1 INTRODUCTION 1 2 Specifications GENERATOR AC OUTPUT Frequency Hertz Voltage Rated Power Rated Current DC OUTPUT ENGINE Engine Type Engine Speed RPM Fuel Engine Oil Capacity Spark Plug Type Spark Plug Gap Engine Valve Lash Intake Exhaust Ignition Timing fixed Starting System Displacement GENERATOR SET Dry Weight Dimensions Length Width Height Fuel Tank Capacity Operating Time at Rated Output 2400 60 Hz 120 Volts 2000 Watts 16 6 Amps 12 VDC 8 3 Amps 3500 60 Hz 120 240 Volts 2500 Watts 20 8 10 4 Amps 12 VDC 8 3 Amps Single Cylinder Forced Air Cooling 4 Stroke 3600 Gasoline 0 63 US qt 0 6 L F7RTC 0 028 in 0 7 mm 0 0039 0 006 inches 0 10 0 15 mm 20 BTDC Recoil 197 cc 99 9 Ib 45 kg 24 1 inches 612 mm 19 6 inches 497 mm 19 3 inches 490 mm 4 0 US gal 15 L 13 Hours 3600 Gasoline 0 63 US qt 0 6 L
22. Service Manual HomeSite Power 2400 2EGMBB 5267 3500 2 5EGMBG 5268 Portable Generator Set Printed in U S A 03 06 914 0500 SAFETY PRECAUTIONS Thoroughly read the OPERATOR S MANUAL before operating the generator set Safe operation and top performance can only be attained when equipment is operated and maintained properly The following symbols found throughout this manual alert you to potentially dangerous conditions to operators service personnel and equipment This symbol alerts you to an immediate hazard that will result in severe personal injury or death This symbol alerts you to a hazard or unsafe practice that can result in severe personal injury or death This symbol alerts you to a hazard or unsafe practice that can result in personal injury or damage to equipment or property Electricity fuel exhaust moving parts and batteries present hazards against which precautions must to taken to prevent severe personal injury or death Exhaust Gas Is Deadly e Operate the generator set outdoors only Stay away from the exhaust outlet e Make sure generator set exhaust will not enter windows doors vents or air intakes of adjacent buildings vehicles or boats e NEVER USE THE GENERTOR SET INSIDE a home garage crawl space barn shed cabin boat boat house RV or tent or in a confined outdoor space such as an alley ditch parking garage or courtyard or in any other space where exhaust ca
23. ad center of the compression stroke both valves fully closed Pull the starter until the piston is at top dead center of the compression or exhaust stroke 2 Insert a feeler gauge between the rocker arm and valve to measure valve clearance IN 0 10 0 02 mm Standard valve 0 004 0 001 in clearance EN 0 2 0 02 mm 0 008 0 001 in ROCKER ARM LOCK NUT 10N m 140N m To increase valve clearance screw lock nut out To decrease valve clearance screw lock nut in 3 If adjustment is necessary proceed as follows a Hold the rocker arm pivot and loosen the pivot lock nut b Turn the rocker arm pivot to obtain the specified clearance c Retighten the lock nut while holding the rocker arm pivot d Recheck valve clearance after tightening the lock nut FEELER GAUGE 3 8 Governor 1 Take down the fuel tank 2 Loosen the nut on the governor arm pinch bolt 3 Move the arm until the throttle is completely open and hold it in that position 4 Rotate the governor arm shaft as far as it will go in same direction it was just moved by the governor arm and then tighten the governor arm pinch bolt 5 Whether check the arm and throttle move smoothing 6 Install the fuel tank 7 Startthe engine and adjust the limiting screw to produce the standard until the engine warm up to normal operating temperature Idle speed 3600 150rpm GOVERNOR GOVERNOR ARM PINCH ARM S
24. adjustment LOW GOVERNOR VOLTAGE ANTI SURGE SPRING incorrect REPLACE MUFFLER clogged SEE 4 5 2 OTHER ALTERNATOR temperature is too high SEE 4 5 3 CLEAN ALTERNATOR FAN AND END COVER ELECTRICAL LOADS too high REMOVE EXTRALOADS 16 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 1 5 Exhaust Color Abnormal AIR FILTER dirty SEE3 3 CARBURETOR faulty BLACK SEE 4 4 6 LOAD excessive REMOVE EXTRA LOAD ENGINE temperature is too low NORMAL WHEN STARTING EXHAUST COLOR i ABNORMAL FUEL contaminated ADD FRESH FUEL FUEL contaminated with oil CHANGE TO FRESH FUEL CYLINDER PISTON PISTON RING worn SEE 4 4 1 OIL too much SEE 3 2 BREATHER icing issue CLEAN BREATHER 17 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 1 6 No AC Output Voltage ENGINE SPEED abnormal CHECK IT AND ADJUST STATOR MAIN COIL defective SEE 4 5 3 BRUSH defective NO AC SEE 4 5 3 OUTPUT VOLTAGE EXCITATION VOLTAGE too low SEE 4 5 3 AVR defective SEE 4 5 3 BREAKER tripped RESET BREAKERS 4 1 7 No DC Output Voltage BREAKER tripped NO DC RESET BREAKERS OUTPUT VOLTAGE OTHER REASON 18 Redistribution or publication of this
25. any sign of fuel leakage REASSEMBLY Clean thoroughly with compressed air and check for leaks after installation 37 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 5 Generator 4 5 1 Fuel Tank DISASSEMBLLY REASSEMBLY AWARNING Gasoline is flammable and explosive Drain the fuel tank and fuel line before disassembly Wipe up spilled fuel immediately FUEL TANK CAP REASSEMBLY Make sure that the air vent X hole is clean and FUEL METER E unclogged Blow with compressed air if REASSEMBLY S JSE necessary After reassembly check the operation of the float FUEL STRAINER REASSEMBLY Check to be sure the strainer is clean and undamaged before installation FUEL TANK FUEL VALVE ESE RSF LL REASSEMBLY AA Or Wash the tank to REASSEMBLY dip remove sediment Make sure the passages are not clogged Check for fuel leakage after installation FUEL FILTER SEDIMENT CUP REASSEMBLY Check to be sure the filter is clean and undamaged REASSEMBLY Wash to remove sediment and dry thoroughly before installation 38 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 5 2 Muffler DISASSEMBLLY REASSEMBLY EXHAUST PIPE REASSEMBLY Install after removing the carbon deposits from the exhaust pipe
26. cup should be cleaned 1 Turn the fuel valve to the OFF position Remove the sediment cup and o ring 2 Clean the sediment cup and o ring in nonflammable or high flash point solvent 3 Reinstall o ring and sediment cup 4 Turn the fuel valve ON and check for leaks FUEL VALVE SEDIMENT CUP A WARNING Gasoline is extremely flammable and is explosive Do not smoke or allow flames or sparks in the area AA WARNING After reassembly check for leaks and make sure the area is dry before starting the engine 3 5 Spark Arrester AL WARNING A hot muffler can cause severe burns Allow the generator set to cool before servicing the muffler Refer to MAINTENANCE SCHEDULE for scheduled spark arrester cleaning After letting the generator set cool down remove the spark arrester screen Inspect for damage and replace if defective Clean any deposits on the screen with a wire brush Reinstall the spark arrester and tighten the screw securely SPARK ARRESTOR 10 Redistribution or publication of this document by any means is strictly prohibited SECTION 3 MAINTENANCE 3 6 Spark Plug To ensure proper engine operation the spark plug must be properly gapped and free of deposits If the engine has been running the spark plug and muffler will be very hot Be careful not to touch the muffler or spark plug 1 Turn off generator 2 Remove the spark plug cap 3 Clean any dirt from around the spark plug
27. ean Spark Plug Clean the Spark Arrestor Clean Fuel Sediment Cup Clean Fuel Tank Adjust Valve Clearance Check fuel line 1 See GENERAL INSPECTIONS EVERY 3 MONTH OR MONTHS OR 50 HOURS SERVICE INTERVAL EVERY MONTH MONTHS OR YEAR OR 100 HOURS 300 HOURS EVERY 6 Every 2 years Replace if necessary 2 Service more frequently when used in dusty environments 3 These items must be performed by a trained and experienced mechanic authorized Onan dealer 7 Redistribution or publication of this document by any means is strictly prohibited SECTION 3 MAINTENANCE 3 2 Engine Oil NOTE Drain the oil while the engine is still warm to assure rapid and complete draining 5 Reinstall the oil filler cap and tighten it securely 1 Remove the oil filler cap and drain plug 2 Drain the oil from the crankcase RECOMMENDED ENGINE OIL SAE 10W 30 is recommended for general all temperature use service classification SG SF CC CD Oil drain bolt M10 3 Reinstall the drain plug securely 30 20 10 0 10 20 30 40 C pn 20 0 20 40 60 80 100F AA WARNING Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Thoroughly wash your hands with soap and water as soon as possible after handling used oil UPPER LEVEL Engine Oil Capacity 1 16 US qt 1 1 L Redistribution or publication of this document by any
28. he float by dipping the switch into a container of oil The ohmmeter reading should INDEX MARKS CAMSHAFT go from zero to infinty as the switch is lowered 23 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE d INSPECTION CYLINDER ID Inside Diameter Factory Specification Allowable limit 68 015 mm 2 6778 in 68 165 mm 2 684 in PISTON SKIRT OD Outside Diameter Factory Specification Allowable limit 67 985 mm 2 6766 in 67 845 mm 2 6711 in PISTON TO CYLINDER CLEARANCE Factory Specification Allowable limit 0 03 0 05 mm 0 0012 0 002 in 0 12 mm 0 005 in PISTON RING SIDE CLEARANCE Factory Specification Allowable limit 0 030 0 060 mm 0 0012 0 0024 in 0 15 mm 0 006 in PISTON RING END GAP Factory Specification Allowable limit 0 2 0 4 mm 1 0 mm 0 008 0 016 in 0 04 in PISTON PIN OD Factory TE Specification Allowable limit 17 998 mm 17 954 mm 0 7086 in 0 7068 in Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE CONNECTING ROD BIG END ID Factory Allowable limit Specification 30 015 mm 30 066 mm 1 1817 in 1 1837 in PISTON PIN BORE ID
29. i Se Replace the valves if their O D is smaller than the allowable limit 32 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 4 4 Recoil Starter Fan Cover a DISASSEMBLY ASSEMBLY STARTER PULLEY FLANGE NUT 16mm DISASSEMBLY REASSEMBLY REPS SEMEL Hold the flywheel by placing a Install by aligning the hole in the screwdriver into the pulley pulley with the lug on the cooling FAN COVER DISASSEMBLY REASSEMBLY Remove and install with the recoil starter ASSY COOLING FAN RECOIL STARTER ASSY REASSEMBLY Install by aligning the three lugs on the rear REASSEMBLY side of the fan with the small hole in the flywheel Install with the starter grip position as shown When disassembling and assembling take care not to damage the fan blades 33 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE b DISASSEMBLY RECOIL STARTER ASSY AA WARNING The recoil starter can cause personal injury Wear safety glasses Do not let the recoil spring snap REEL COVER STARTER REEL REASSEMBLY Align the ratchet with the reel cover REASSEMBLY Install on the starter case after installing the return spring RATCHET REASSEMBLY Check for wear or damage Note the installation direction RETURN SPRI
30. ling the flywheel check to be sure that the woodruff key is REASSEMBLY Check for cracked or damaged still in its slot on the crankshaft insulation replace if necessary 27 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE b INSPECTION IGNITION COIL 0 0164 0 008 in AIR GAP AT FLYWHEEL Measure the air gap between of the ignition and flywheel by thickness gauge 0 4 0 2 mm 0 016 0 008 in Air gap at flywheel IGNITION COIL RESISTANCE Primary side resistance value 0 8 1 0 5 9 7 1 KO Secondary side resistance value 1 Measure the resistance of the primary coil by attaching one ohm meter lead to the ignition coil s primary lead while touching the other test lead to the iron core 2 Measure the resistance of the secondary side of the coil by removing the spark plug cap and touching one test lead to the spark plug lead wire while touching the other test lead to the iron core NOTE A false reading will result if the spark plug cap is not removed If the resistance is not as specified replace the ignition coil SPARK PLUG CAP Measure the resistance of the spark plug cap by attaching one ohm meter If the resistance is not as specified change the spark plug cap Spark Plug Cap 5K 28 Redistribution or publication of this document by any mea
31. me state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact gasoline Used engine oils have been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used engine oil or its vapors Keep the generator set clean and dry at all times Excess grease and oil can catch fire and or accumulate dirt which can cause overheating Do not store anything on the generator set such as oil cans oily rags chains or wooden blocks A fire could result or operation could be adversely affected Do not work on the generator set when you are mentally or physically fatigued or have consumed alcohol or drugs A WARNING A Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed Follow the procedures and precautions in this manual and other service materials carefully A WARNING A Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this manual carefully Redistribution or publication of this document by any means is strictly prohibited TABLE OF CONTENTS Title SECTION 1 INTRODUCTION 1 1 Generator Components 1 2 Specifications SECTION 2 DIMENSIONS AND TORQUE 2 1 Engine Dimensions 2 2 Generator Dimensions 2 3 Torque Specification 2 4 Standard Torque
32. n accumulate Note that HAZARDOUS CARBON MONOXIDE LEVELS FROM ENGINE EXHAUST CAN ACCUMULATE INDOORS EVEN WHEN ALL WINDOWS AND DOORS ARE OPEN AND FANS ARE RUNNING Gasoline is Flammable Explosive Refuel the generator set outdoors only Static electric sparks caused by fuel flowing through a service station pump nozzle can ignite gasoline Never fill the generator set with a service station pump nozzle Instead fill a safety tank sitting on the ground and then slowly transfer fuel to the generator set from the safety tank DO NOT fill fuel tanks while the engine is running A hot engine can ignite the fuel To prevent fire due to fuel leakage always close the fuel valve and let the generator set cool before transporting it or storing it in a confined space DO NOT SMOKE OR ALLOW AN OPEN FLAME near the generator set Keep flames sparks electrical switches pilot lights electrical arcs arc producing equipment and all other sources of ignition well away Generator Voltage is Deadly DO NOT CONNECT THE GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Back feed could cause electrocution of utility line workers and damage to equipment approved switching device must be used to prevent interconnections A trained and experienced electrician must make electrical connections when the generator set is used for emergency power Make sure clothing shoes and skin are dry when handling electrical equipment Never
33. ns is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 4 3 Cylinder Head Valves a DISASSEMBLY ASSEMBLY CYLINDER HEAD REASSEMBLY Before installation remove carbon deposits from the combustion chamber and inspect the valve seats Measure the compression of the cylinder head CYLINDER HEAD GASKET after reassembly CYLINDER HEAD BOLT CYLINDER HEAD COVER CYLINDER HEAD COVER GASKET CRANKCASE CYLINDER HEAD COVER BOLT CYLINDER HEAD BOLT CYLINDER HEAD COVER BOLT TORQUE TORQUE 26 28 N m 260 280 kg cm 18 7 20 2 ft Ib 12 14 N m 120 140 kg cm 8 7 17 4 ft Ib REASSEMBLY DISASSEMBLY REASSEMBLY DISASSEMBLY Tighten and untighten using a cross pattern Tighten and untighen using a cross pattern 29 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE ROCKER ARM SPARK PLUG REASSEMBLY Check the pivot bolt push rod and rocker arm before installing VALVE ROTATOR REASSEMBLY if the valve rotator is not installed the valve may drop into the cylinder when starting the engine ACAUTION Do not remove the valve spring retainers while the cylinder head is installed or the valves will drop into the cylinder DISASSEMBLY Compress the value spring and slide the retainer out to the side so the valve stem slips through the hole at the side of the retainer REASS
34. on of this document by any means is strictly prohibited SECTION 2 DIMENSIONS AND TORQUE 2 2 Generator Dimensions 2400 2 0 kW Part Item Factory specification Main winding R Bu Resistance 0 51 0 53 O Field winding Resistance 40 50 O Exciter winding Bu Bu Resistance 3 1 3 3 DC winding Resistance 0 4 0 6 O Carbon brush Brush length 5 9 mm 3500 2 5 kW Part Item Factory specification Main winding I Br W Resistance 0 76 0 79 O Main winding II R Bu Resistance 0 76 0 79 O Field winding Resistance 35 45 Q Exciter winding Bu Bu Resistance 1 5 1 7 Q DC winding G G Resistance 0 4 0 6 O Carbon brush Brush length 5 9 mm 2 3 Torque Specification Part Fastener size Torque values N m kg lb ft Cylinder head bolt 8x1 25x55 mm 26 28 260 280 18 8 202 Pivot bolt 6x0 5 mm 8 12 80 120 5 8 8 7 Pivot adjusting nut 6x1 25 mm 22 26 220 260 15 9 18 8 Crankcase cover bolt 8x1 25x32 mm 24 26 240 260 17 4 18 8 Connecting rod bolt 7x1 25 mm 12 14 120 140 8 7 17 4 Air cleaner wing nut 6x1 0 mm 7 10 70 100 5 1 7 2 Air cleaner mounting nut 6x1 0 mm 7 10 70 100 5 1 7 2 Muffler mounting bolt 8x1 25 mm 20 28 200 280 14 5 20 2 Oil drain bolt 10x1 5 mm 20 25 200 250 14 5 18 1 Fuel tank mounting bolt nut 6x1 0 mm 8 12 80 120 5 8 8 7 Fuel valve joint nut 10x1 25 mm 20 25 200 2
35. propriate rotor puller special tool hold the flywheel and torque the puller to 6 9 Kg cm 50 ft lb ACAUTION To avoid damaging the rotor place a wooden block and a shop rag under the rotor for support NOTE If torquing the rotor puller does not free the rotor from the crankshaft tap the end of the puller with a brass hammer to help loosen the rotor NNN To prevent eye injury always wear safety glasses or goggles when striking the end of the rotor puller 41 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE b INSPECTION CARBON BRUSH SLIP RING Remove the carbon brushes from the brush holder Check the brush for length wearing condition or any other defect Replace if the length is less than 5 mm 0 20in NOTE Connect the Blue wire lead to the positive side of the brush holder Avoid damaging the brushes when removing and installing the brush holder Visually inspect the slip rings for dust rust or other damage If necessary wipe them with a clean lint free cloth If they are rusted or damaged remove the rotor and rub with fine emery cloth FIELD WINDING Remove the brushes and measure resistance between the slip rings 2400 40 50 2500 35 45 RESISTANCE If the specified resistance is obtained at the slip rings but not at the brush terminals clean or replace the brushes If the
36. s Specification SECTION 3 MAINTENANCE 3 1 Maintenance Schedule 3 2 Engine Oil 3 3 Air Cleaner 3 4 Fuel Sediment Cup Cleaning 3 5 Spark Arrester 3 6 Spark Plug 3 7 Valve Clearance 3 8 Governor SECTION 4 DISASSEMBLY AND SERVICE 4 1 Troubleshooting 4 1 1 Hard Starting 4 1 2 Low Power 4 1 3 Speed Unstable 4 1 4 Low Speed Voltage 4 1 5 Exhaust Color Abnormal 4 1 6 No AC Output Voltage 4 1 7 No DC Output Voltage 4 2 Preparing to Service 4 2 1 Safety Considerations 4 2 2 Special Tools 4 3 Disassembly Chart 4 4 Engine 4 4 1 Crankshaft Pistion 4 4 2 Flywheel 4 4 3 Cylinder head Valves 4 4 4 Recoil Starter Fan Cover 4 4 5 Air Cleaner 4 4 6 Carburetor 4 5 Generator 4 5 1 Fuel Tank 4 5 2 Muffler 4 5 3 Generator 4 5 4 Control Panel SECTION 5 WIRING DIAGRAMS 5 1 The Wiring Diagram of 2400 5 2 The Wiring Diagram of 3500 Page COONNDODO FP HPWH lO NO PD e c a c 2 2 2 2 2A 0 100 ON gt N O O CO Redistribution or publication of this document by any means is strictly prohibited SECTION 1 INTRODUCTION 1 1 Generator Components CHOKE ACE FUEL TANK CAP DC BREAKER RESET SWITCH LEVER AC BREAKER RESET SWITCH AC VOLTMETER 12 VOLT DC RECOIL STARTER GRIP TERMINALS ON OFF SWITCH 120VAC RECEPTACLE GFCI MUFFLER FIGURE 1 2400 COMPONE
37. specified resistance is not obtained at the slip rings clean or replace the rotor 42 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE AC OUTPUT TERMINALS AC OUTPUT TERMINALS LI l RI MAIN WINDING Using an ohmmeter measure the resistance between the AC output terminals 2400 0 51 0 53 RESISTANCE 3500 I 0 76 0 79 Q 3500 C II 0 76 0 790 NOTE Set the voltage selector switch to 120 V only position If the resistance is zero or infinity replace the stator EXCITER WINDING Using an ohmmeter measure the resistance between the Light green Red and Green wires in the 4P coupler 2400 3 1 3 3 Q RESISTANCE 3500 1 5 1 7 Q Slip ring Ground If the resistance is zero or infinity replace the stator DC WINDING Using an ohmmeter measure the resistance between the brown wire leads at the DC diode connecter RESISTANCE 0 4 0 6 Q If the resistance is out of specification replace the stator 43 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 5 4 Control Panel a DISASSEMBLLY REASSEMBLY GENERATOR END COVER CONTROL PANEL SECTION 4 DISASSEMBLY AND SERVICE 2400 PANEL END COVER AC BREAKER RESET SWITCHES DC BREAKER RESET
38. y SEE 3 3 SPARK PLUG faulty IGNITION SYSTEM SEE 3 6 CAMSHAFT worn SEE 4 4 1 CYLINDER PISTON PISTON RING worn SEE 4 4 1 COMPRESSION SYSTEM VALVE LASH out of Spec SEE 3 7 VALVE SEAT worn or damaged SEE 4 4 3 Low Power COOLING FAN dirty CLEAN COOLING CYLINDER FINS dirty CLEAN MUFFLER clogged SEE 4 5 2 GOVERNOR out of adjustment SEE 3 8 ELECTRICAL LOADS too high REMOVE EXTRA LOADS 14 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 1 3 Speed Unstable FUEL low poor quality contaminated ADD NEW FUEL INTO FUEL TANk FUEL FILTER clogged SEE 3 4 CARBURETOR clogged SEE 4 4 6 FUEL SYSTEM SEE 3 8 ANTI SURGE SPRING incorrect REPLACE GOVERNOR out of adjustment GOVERNOR SYSTEM SPEED UNSTABLE k SPARK PLUG spark plug wire faulty COMPRESSION SEE 4 4 2 SYSTEM CAMSHAFT worn SEE 4 4 1 OIL low level OTHER ADD NEW OIL ELECTRICAL LOADS too high REMOVE EXTRALOADS 15 Redistribution or publication of this document by any means is strictly prohibited SECTION 4 DISASSEMBLY AND SERVICE 4 1 4 Low Speed Voltage AIR FILTER dirty SEE 3 3 FUEL poor contaminated ADD NEW FUEL FUEL SYSTEM CARBURETOR has water SEE 4 4 6 CHOKE LEVER not open PUSH CHOKE ROD GOVERNOR out of
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