Portable generator engine replacement

[ehenry]

Has anyone ever replaced or removed an engine from a portable generator? I have a 8.5 kw Winco generator that the engine has shot crapps on. My hat is off to it because its been a goodun!!! The generator itself is in good shape and I have access to an engine just like the one that died to go back on it. To the life of me I can't see how the generator is connected to the engine unless its on the inside of the generator itself. The only bolts that are accessable where the generator connects to the engine are the engine side cover bolts. I can see through the cooling grill of the generator behind the finned cooling wheel there are 4 bolts that look like what I'm looking for but getting to them is the question. I was wondering if any of you guys might have some experience in doing this. I hope all that makes sense.

 

[12Footer]

Re: Portable generator engine replacement

It depends totally on the make/model, and I have only dealt with Yammaha and Onan. But on some of the Onans, I had to pull the shroud off the generator to get at two of the 4 bolts.<br />So in the absence of the shop manual, I would start strippin her down one piece at a time. The mounting hardware will show itself after the air cooling,and other shrouds no longer cover them. (JMHO).

 

[Jack Shellac]

Re: Portable generator engine replacement

There's got to be some kind of coupling between the motor shaft and the generator shaft. I looked at mine {Kawasaki engine/Honda gen] and it's under the generator endcap. Disassemble slowly and remember where everything went. With my memory, I use notebooks and Polaroids.

 

[jhreed]

Re: Portable generator engine replacement

Hello, when I had the exact same choice, years ago, I ended up getting another new generator. This is because the replacement cost of my engine was identical to the cost of the whole generator... unless you get the replacement free, I would give this some serious thought.Jim Reed

 

[norman158]

Re: Portable generator engine replacement

does this say Generac on it any where? if so i can tell you how to do it

 

[ehenry]

Re: Portable generator engine replacement

Thanks guys. Its a WINCO generator with an 11 horse Honda engine. The replacement engine is identical. I'm getting the engine for an eighth of the cost of what it would cost to replace this gnerator with one of the same rating. Still looking for any help yall can give.

 

[norman158]

Re: Portable generator engine replacement

not sure of the exact steps on a Winco, but im sure that the rotor has to be pulled out with the motor as it is a taper fit on the crankshaft. take the rear cover off and see if there is a long bolt going through the center of the rotor,if so remove it, then remove the nuts holding the motor in the frame.then remove the bolts holding gen unit together CAREFULLY slide the motor,rotor,and the front 1/3 of the gen away from the windings and rear bearing carrier out of the frame. to remove the rotor start the long bolt back in the center of the rotor and while supporting the rotor tap on the bolt to break the taper fit loose.remove the rotor. remove the 4 bolts holding the front 1/3 of the gen unit to the motor.after you get it back together you wil need to restore the magnetism in the rotor Winco has directions on how to do this on there web site . <br />most of the consumer units come apart this way

 

[ehenry]

Re: Portable generator engine replacement

Norman158, would you be refering to the field flash proceedure in WINCO's trouble shooting section?<br /><br />Field Flashing Procedures<br />Material Required <br /><br />1. 9 Volt DC Transistor Battery <br /> <br />2. Jumper wires 20 to 22 gauge. <br /> <br />(Each wire should have a clip on one end and be stripped about 3/8 of an inch on the other.) <br />Winco Generators <br /> <br />Procedure <br />Winco Generators <br /> <br />Caution: Insure there is no open or spilled fuel in the area of the unit when flashing the fields. Insure the wires used to flash the field have no bare spots on them. <br />1. Clip the jumper wires to the terminals on the battery. <br /> <br />2. Start the engine generator set. <br /> <br />3. Locate the 120 volt receptacle with the two flat blade slots. <br /> <br />4. Making sure not to touch the bare wire, momentarily insert the bare ends of the wires into the appropriate slots. <br /> <br />5. BRIEFLY POKE THE WIRES INTO THE RECEPTACLES, BUT DO NOT HOLD THE WIRES IN THE RECEPTACLE. THIS RECEPTACLE WILL ENERGIZE TO 120 VOLTS IMMEDIATELY

 

[norman158]

Re: Portable generator engine replacement

yea but i think i would try and flash the slip rings(where the brushes contact the rotor)before i put the plate on the end. (1 wire off the 9v battery to each ring for about 3 sec)and then start it up and see if it will make power first. this is a safer way to do the same thing.if it dont work then do it there way. you will need to set the gov on the new motor to run at about 3700 rpm with no load

 

[ehenry]

Re: Portable generator engine replacement

I still have not been able to rmove the rotor from the engine on this generator. If anyone has any suggestions I sure would appreciate them. Thanks.

 

[norman158]

Re: Portable generator engine replacement

do you have the motor/rotor out of the frame?

 

[ehenry]

Re: Portable generator engine replacement

Yes, I've got it all out and on my work bench....I talked to the folks at WINCO yesterday and they told me to remove the 3/8 stud in the end of the rotor. Then take a slide hammer, screw it into where the stud was and start hammering it away from thet engine. .....I've got to get a bolt that will screw in where the stud is and go from there.

 

[ehenry]

Re: Portable generator engine replacement

FINALLY!!!!! Got the rotor apart from the engine. It took one stomp down heavy slide hammer to break it loose from the engine. I never knew a tapered bearing would get a grip like that one did. After going inside the engine it, looks like I'm going to get away with just having to buy a rod, set of rings and a gasket set. OH...and a manual for a honda 340GX 11 h.p. engine so I can get the cam timed right and the govenor set. To the tune of about 100 bucks. Thats a whole lot better than the $850 a new engine was going to cost me.

 

[norman158]

Re: Portable generator engine replacement

glad to hear you got it loose. check your cyl bore before you go and order parts. you might need to bore it and go over size. cam timing, just line up the mark on the cam gear with the mark on the crank gear