Section
5
-
Preparing
to
Service
TROUBLESHOOTING
Before servicing the generator set, locate and isolate
the problem using systematic troubleshooting pro-
cedures.
To
aid servicing, this manual divides the
generator set into four logical groups and provides a
separate section for each:
Engine
-
Primary Systems
Control
Generator
0
Engine
-
Block Assembly
This manual provides troubleshooting tables to help
locate the cause of various malfunctions. Some rnal-
functions may have several causes. Thus, several
likely problem areas may have to be investigated to
isolate the source of the malfunction. Because of the
complexity of the product, troubleshooting tables
cannot list every malfunction and its cause. In some
situations, the serviceperson will have to rely on
experience and knowledge
of
the product to locate
and correct the problem.
SPECIAL
TOOLS
The following special tools may be required to ser-
vice the generator set. Some of these tools can be
purchased from Onan, while others must be pur-
chased from outside suppliers. Tool Catalog
#900-
0019
(available from Onan Dealers or Distributors)
lists all tools available from Onan.
Engine
Tools
Torque wrench,
0-175
Ft-Lbs
(0-240
Nom)
Feeler gauge
Pressure gauge
Spark plug gap gauge
Carburetor adjustment wrench
Points adjustment tool
Flywheel puller
Snap ring pliers
Gear puller with puller ring
Cylinder ridge reamer
Combination main and cam bearing remover
Combination main and cam bearing driver
Oil seal loader and driver
Piston ring compressor
Piston ring spreader
Cylinder hone
Valve seat cutter
Valve spring compressor
Valve lock replacer
Valve seat driver
--
-
Slide hammer
Piston groove cleaner
Outside micrometer set,
0-4
In. (1-102 mm)
Telescoping gauge set,
0.5-6
In.
(12-154
mm)
Hole gauge,
0.300-0.400
In.
(7.50-1
1.00
mm)
Plasti-gage bearing clearance guide
Generator and Control
Tools
Lead or dead-blow hammer
Battery hydrometer
VOM
m ul t i-tester
Frequency meter
Armature growler
J
um per wires
Load test panel
SAFETY
CONSIDERATIONS
Always consider the safety aspects
of
any service
procedure. Generator sets present several hazards
that the serviceperson must be aware of if the job is to
be completed safely. Read through the safety precau-
tions listed on the inside cover and familiarize your-
self with the various hazards shown in Table
5-1.
Once th-e hazards are known, approach the
job
with a
safety conscious attitude. Being safety conscious is
the most effective way to avoid injury to yourself or
others. Reduce the chance that an accidentwill occur
by adopting the following safeguards.
Safeguards to Avoid Hazards
Use Personal Protection-When the situation calls
for it, protect your body by wearing the approp-
riate safety equipment. Protective clothing in-
cludes such items as safety shoes, gloves, safety
glasses and hard hats. Leave ringsand jewelry
off
and don't wear loose clothing that might get
caught on equipment.
Work to Reduce the Hazard -The workshop area
and all pieces of equipment used can contribute
to reducing the hazard potential. Keep guards
and shields in place on equipment in good work-
ing condition. Store flammable liquids
in
ap-
proved containers away from open flame. Keep
the workshop clean and well-lighted, and provide
adequate ventilation. Keep
fire
extinguishers and
safety equipment nearby and be prepared to
respond to an emergency.
'5-1
Redistribution or publication of this document
by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
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