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BONHOEFFER BON-P-GG-2.8KW Workshop Manual

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WORKSHOP MANUAL
GESOLINE GENERATOR
BON-P-GG-2.8KW, 3.7KW, 5.0KW, 7.5KW, 9.0KW,
9.5KW, 12.0KW, 13.5KW, 16.0KW, 18.5KW

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Summary of Contents for BONHOEFFER BON-P-GG-2.8KW

  • Page 1 WORKSHOP MANUAL GESOLINE GENERATOR BON-P-GG-2.8KW, 3.7KW, 5.0KW, 7.5KW, 9.0KW, 9.5KW, 12.0KW, 13.5KW, 16.0KW, 18.5KW...
  • Page 2 CONTENTS CONTENTS 1. PREFACE ..............................1 1-1 Component Identification ........................ 1 Page Drawing..................1 1-2 Specifications ..........................2 1-3 Maintenance Standard ........................3 Specification..................2 1-3-1 R2200 ........................... 3 1-3-2 R2800 ........................... 5 1-3-3 R3000 ........................... 7 Engine oil..................3 2. MAINTENANCE ............................ 10 2-1 Maintenance Schedule........................
  • Page 3 PAGE DRAWING 3. characteristics and controls Choke lever Shelf Fuel cap Air filter Start lever indicator Fuel tank Support Final cover Engine switch Muffler Control Panel Cylinder head Wheel Push handle Battery...
  • Page 4 Functions and controls Shelf Fuel level indicator Fuel cap Air filter Fuel hose Engine Control panel Support leg Panel shield Battery Voltage Regulator Silencer shield Muffler Fuel switch Back cover Oil cap Rotor and stator Long handle Front support...
  • Page 5 SPECIFICATIONS SINGLE-PHASE SPECIFICATIONS FEATURE Engine Style OHV, air cooled, four stroke ENGINE PARAMETER Ignition system Starting style Manual Recoil Start Oil capacity (L) Voltage (V) Frequency(Hz) Rated power (kw) Maximum power (kw) Power factor SERIES PARAMETER Isolation rate Max fuel (L) Operating temperature (C) Max altitude of...
  • Page 6 SPECIFICATIONS SPECIFICATION PARAMETER TABLE FEATURE OHV, air cooled, four stroke ENGINE PARAMETER Manual Recoil Start SERIES PARAMETER...
  • Page 7 Specification parameter table FEATURE Model Engine OHV, air cooled, four stroke, OHV, air cooled, four stroke, Style horizontal horizontal ENGINE PARAMETER inductive inductive Displacement Electrical start Electrical start Ignition system Starting style Oil capacity (L) Frequency(Hz) Rated power (kw) Maximum power (kw) Power factor SERIES PARAMETER...
  • Page 8 3. TROUBLESHOOTING 2-2 Engine Oil Draining can be performed rapidly and OIL DIPSTICK completely while the engine is still warm. 1) Remove the oil dipstick and drain UPPER LEVEL plug to drain the oil. 2) Reinstall the drain plug, then tighten the plug securely.
  • Page 9 2. MAINTENANCE element for complete and clean. 2) If the air cleaner element is dirty, please clean the air cleaner element: Wash the air cleaner element in a solution of household detergent and warm water, then rinse thoroughly or wash in nonflammable or high flash point solvent: Drop a few points engine oil in, then, squeeze out.
  • Page 10 3. TROUBLESHOOTING 2-5 Spark Plug Service Recommended spark plugs: F7RTC or other equivalents 1) Remove the spark plug cap. 2) Clean any dirt around the spark plug base. 3) Use the plug wrench to remove the spark plug. PLUG WRENCH SPARK PLUG CAP 4) Visually inspect the spark plug if the insulator is cracked, if cracked, replace with a new spark plug.
  • Page 11 3. TROUBLESHOOTING 2-7 Governor ① Reassembly or disassembly BOLT (M6×10) THROTTLE PLATE BOLT (M6×10) STOPPER SPRING FIXING BOLT GOVERNOR SPRING SCREW (M5×25) GOVERNOR ROD RETURN SPRING GOVERNOR BRACKET NUT（M6）...
  • Page 12 2. MAINTENANCE GOVERNOR ARM GOVERNOR SPRING THROTTLE VALVE(FULLY OPEN) THROTTLE GOVERNOR ROD RETURNING SPRING ②Governor adjustment： a) Dismount the fuel tank b) Loosen the nut M6. Be sure that the carburetor throttle valve is fully open c) Rotate the governor arm shaft fully to the right (governor fully closed position), and retighten the nut.
  • Page 13 3. TROUBLESHOOTING 3. TROUBLESHOOTING 3-1 Troubleshooting 3-1-1 Starting Difficult TROUBLE CAUSE REMEDY There is no enough fuel in fuel Fill fuel, open fuel cock. tank and fuel cock is closed. Air vent in the fuel filler cap is Dredge air vent. Fuel supply clogged is not...
  • Page 14 3. TROUBLESHOOTING TROUBLE CAUSE REMEDY Piston ring is worn to or even Replace over its wear limit Piston ring is broken. Replace Piston ring is sticking. Clear up carbon fouling. Tighten with a gasket in. Spark plug is not installed tighten Check cylinder gasket, and the or without a gasket.
  • Page 15 3. TROUBLESHOOTING Install the spark plug cap.  Turn the engine switch to “ON”position.  Pass negative pole (thread) of the spark plug through cylinder cover to connect  grounding and pull the recoil starter grip to observe the spark. 3-1-2 Power Lack TROUBLE CAUSE...
  • Page 16 3. TROUBLESHOOTING 3-1-7 Unable Generating Electricity TROUBLE CAUSE REMEDY Clean the surface of the collector Collector ring carbon brush ring and grind the carbon brush arc contacting poor face. Brush pressure abnormal Replace the spring or adjust it. Stator, rotor output leads contacting Check the adjusting winding for poor.
  • Page 17 3. TROUBLESHOOTING 3-1-9 No AC Output Voltage TROUBLE CAUSE REMEDY Engine speed abnormal Check and adjust Stator main coil defective Check and adjust Brush defective Check and adjust No AC output voltage Excitation voltage too low Check and adjust AVR defective Check and adjust Breaker tripped Reset breakers...
  • Page 18 3. TROUBLESHOOTING Stator and rotor iron core partly friction result iron core Grind the rotor iron core arc to remove iron heating. friction. 3-1-12 Stator Winding Overheat Overload Adjust the load according to specified load. Vent is clogged, Periodically check and remove the foreign matter in the generator for good heat dispersion Stator winding open circuit and connecting to ground.
  • Page 19 3. TROUBLESHOOTING 3-3 Dismounting Chart HANDLE FLYWHEEL MOTOR TAIL COVER FUEL TANK VOLTAGE REGULATOR BRUSH MUFFLER CONTROL PANNEL CUSHION FRAME MOTOR BRACKET STATOR ROTOR ENGINE CARBURETOR FLYWHEEL IGNITION COIL AIR CLEANER SHROUD RECOIL STARTER...
  • Page 20 3. TROUBLESHOOTING 3-4-2 Flywheel HIGH VOLTAGE IGNITION LINE SPARK PLUG CAP (Check the insulator for damage, if damaged, please replace it) FLYWHEEL STOP ENGINE WIRE STARTING CUP NUT M14 IMPELLER IGNITION COIL BOLT (M6×25) IGNITION COIL a) Remove the fuel tank, air cleaner, carburetor and recoil starter assy.
  • Page 21 3. TROUBLESHOOTING PILOT JET IDLE SPEED SCREW WASHER CARBURETOR (Clean with PILOT SCREW compressed before installation) FLOAT PIN FLOAT VALVE MAIN NOZZLE FLOAT (After installing, check for operation by MAIN JET lightly pushing with a finger) GASKET DRAIN BOLT FLOAT CHAMBER (Install Set Bolt (Tighten the so that the drain bolt facing to bolt...
  • Page 22 3. TROUBLESHOOTING STUD M8X34 GASKET SPARK PLUG EXHAUST VALVE Clean and adjust before installation GASKET CYLINDER HEAD COVER INTAKE VALVE STUD M6X96 CLIP BOLT M6X12 Apply oil to thread Loosen and tighten the bolts crisscross pattern, especially BREATHE TUBE tightening, uniformly and gradually tighten, finally to STUD the specified torque.
  • Page 23 3. TROUBLESHOOTING 120° MAKER TOP RING SECOND RING MARK“△” OIL RING CONNECTION ROD REASSEMBLY： Make sure that the longer end marked is toward the piston head with the “△” b) Piston pin clip Piston Pin Clip Install by setting front end of the clip in the piston groove, holding the other end with long nosed pliers, and rotating the clip in.
  • Page 24 3. TROUBLESHOOTING 3-5-3 Generators Removal/Installation： R2200 ROTOR （Make sure to clean the dunghill, oil, butter and others） MOTOR BRACKET WASHER （Φ23×Φ8×3） STATOR BOLT（M6×135） CARBON BRUSH TORQUE： 8-10 N.m BOLT（M5×12） torque：5-7N.m BOLT（M8×180） Torque：28-30N.m Loose and tighten the bolt adopt the method of cross, especially tighten the bolts equally and gradually and tighten to the standard value.
  • Page 25 3. TROUBLESHOOTING ROTOR（Make sure to clean the dunghill, oil, butter and others） MOTOR BRACKET CONNECTION BOARD STATOR WASHER dummyhead dummyhead （Φ23×Φ8×3） CARBON BRUSH SERVICE INFORMATION LUBRICATION & SEAL POINTS BOLT （M5×12） torque： 5-7N.m Material Location Remarks Model Specification Torque Engine oil Crankshaft pin and gear teeth R2800 M8×1×210 28-30N.m...
  • Page 26 dummyhead dummyhead SERVICE INFORMATION LUBRICATION & SEAL POINTS Material Location Remarks Engine oil Crankshaft pin and gear teeth Piston outer surface, ring groove, and piston pin hole Piston pin outer surface Piston ring entire surface Cylinder inner surface Connecting rod big and small end bearing Camshaft cam lobes and journal Balancer shaft gear teeth and bearing Valve lifter pivot, pivot end, and slipper surface...
  • Page 27 TOOLS SPECIAL TOOLS Remover weight Valve guide driver, 6.6 mm Attachment, 32 × 35 mm 07936-371020A 07942-6570100 07746-0010100 dummyhead dummyhead SERVICE INFORMATION Attachment, 52 × 55 mm Attachment, 72 × 75 mm Driver, 40 mm I.D. 07746-0010400 07746-0010600 07746-0030100 Driver attachment, 35 mm I.D. Pilot, 15 mm Pilot, 35 mm 07746-0030400...
  • Page 28 WIRING DIAGRAM 2-3KW ELECTRIC START...
  • Page 29 2-3KW RECOIL START...
  • Page 30 4-8.5KW ELECTRIC START...
  • Page 31 4-8.5KW RECOIL START...
  • Page 32 ELECTRIC START 4-8.5KW (THREE-PHASE)
  • Page 33 WIRING DIAGRAM 2. Diagrama de cableado • Fase única SINGLE PHASE...
  • Page 34 • Tres fases THREE PHASES...
  • Page 35 SCAN VISIT WEBSITE CORPORATE OFFICE...

This manual is also suitable for:

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