5. Preparing for Service
5-1
TROUBLESHOOTING
Refer to
Section 6. Troubleshooting
and work
through the appropriate subsections before starting
work on the genset. It has the following subsec-
tions:
• Control System
• Generator
• Primary Systems
The subsections list typical problems along with
possible causes and corrective actions. Note that
some problems might have several possible
causes. It may be necessary to investigate several
possible causes in order to isolate the actual source
of the problem.
SPECIAL TOOLS
The following special tools are required to service
the genset. See the Onan Tool Catalog.
Engine Tools
Torque wrench (0-75 lbs-ft or 0-100 N-m)
Feeler gauge
Leak Down Tester
Spark plug gap gauge
Cylinder compression tester
Flywheel puller
Snap ring pliers
Cylinder ridge reamer
Piston ring compressor
Piston ring spreader
Cylinder hone
Valve seat cutter
Valve spring compressor
Piston groove cleaner
Outside micrometer set (0 to 4 in.)
Telescoping gauge set (1/2 in. to 6 in.)
Hole gauge (0.300 in. to 0.400 in.)
Plasti-Gage bearing clearance guide
Generator Tools
Lead or dead-blow hammer
Steel rod (.45 inch dia. x 7.875 inch long)
Battery hydrometer
VOM multi-tester
Frequency meter
Armature growler
Load test panel
Jumper wires
SAFETY CONSIDERATIONS
Always consider the safety aspects of any service
procedure. Servicing gensets presents several
hazards that the service technician must be aware
of to safely complete the job. Study the safety pre-
cautions at the beginning of this manual and famil-
iarize yourself with the hazards listed in Table 5-1 on
Page 5-2. Approach the job in a safety-conscious
manner. Being safety conscious is the most effec-
tive way to avoid injury to yourself and to others. Re-
duce the risk of an accident by adopting the follow-
ing safeguards.
Safeguards to Avoid Hazards
Use personal protection:
Protect your body by
wearing the appropriate safety equipment such as:
• Safety shoes
• Gloves
• Safety glasses
• Hard hats
• Ear plugs
Do not wear rings, jewelry or loose clothing: these
can get caught on equipment, or conduct electricity.
Reduce the hazard:
A safe, orderly work area and
well-maintained equipment reduce the risk of haz-
ard. Leave all guards and shields in place on ma-
chinery, and maintain equipment in top condition.
Store flammable liquids in approved containers,
away from fire, flame, spark, pilot light, arc-produc-
ing equipment and other ignition sources. Keep the
work area clean, well-lighted, and well-ventilated.
Keep fire extinguishers and safety equipment
nearby, and be prepared for any emergency.
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