Generac 86640 Manual de usuario

Manual Part No. 86640SERVICEManualNP and IM SeriesRECREATIONAL VEHICLE AND INDUSTRIAL MOBILE AC GENERATORSLiquid-Cooled 1.2 Liter Gas Engine ModelsCOR

stator AC Power Connection Systems (Continued)3-PHASE DELTA STATOR SYSTEM:Figure 17 is a schematic representation of a 3-phase Delta Stator co

Part 10 OPTIONS ANDACCESSORIESNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORS1.2 Liter, Liquid-Cooled Gas/Gasoline Engine M

Section 10.1- REMOTE START-STOP PANELSGeneralRemote start-stop panels are available which, when properly installed and connected, allow the engi

Model 9043 Remote PanelDESCRIPTION:The Model 9043 remote panel mounts a start-stop ^switch, a "Generator Run" lamp and an hourmeter.Figure 5

Section 10.2- REMOTE GAUGE PANELDescriptionThe Model 9060 remote gauge panel provides remote starting and stopping capability. The panel also m

Part 11SPECIFICATIONSANDELECTRICALDATANP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORS1.2 Liter, Liquid-Cooled Gas/Gasoline E

Table 11.1- Nominal Resistances of AC Generator WindingsMODELROTORRESISTANCESTATOR RESISTANCEPOWER WINDINGDPE WINDINGNP80G8.8 ohms0.21/0.21 ohm1.00 oh

Table 11.4- Tightening Torques for Standard Metric BoltsGRADETORQUESIZE N-m fRBsM6 3-42.2-2.9M8 8-11 5.8-8.04TM1016-2212-16M1226-3620-27M14 46-6234-4

Camshaft Bend (Total Indicated Reading)Standard...Less than 0.008 inch(0.02mm)Maximum Tolerance ... 0.004 Inch (0.1mm)Camshaft

Table 11-5. Engine Service Data (Continued)^CRANKSHAFT;Main Journal DiameterGrade No. 0 ...1.7703-1.7705 Inch(44.966-44.970mm)Grad

Table 11-6. Index to Electrical Schematics & Wiring DiagramsMODELSERIESRATED kWWIRINGDIAGRAMELECTRICALSCHEMATICFUELSYSTEMPAGE9049-0NP 874874GASOLI

Section 1.2- MAJOR GENERATOR COMPONENTSIntroductionThis section will discuss generator disassembly, Inspection of components, and reassembly. See Fig

TJO)(Q(ùO)r22 11 4 4 1 6 íé <6 5 4 3 2 1 §oO1 —t UJzu.)ELECTRONIC VOUACE WCUUIOflIq -|-]cB4 p]WIRE NUTthermalPROTECTOR BYPASS (SERVICE USE

o>COo00<CCO<Q(DZQC5d>O)rao.• 1 □- —BLK- BLK-;j0WRE SIDE nREMOTESTART0 17 14 18—®— RUN UGHTREMOTE STOPCUSTOMER REMOTE |_ PLUG CONNECTION _

WIRING DIAGRAM (82134)miPage 11-8

WIRING DIAGRAM (82661)Page 1 i-9

. ELECTRICAL SCHEMATIC (82663)éCONNCCnON OPTIONSLEGANOAR -ALTERNATOR ROTORAS -alternator statorCBl-CiRCUlT BREAKER 4SA CBJ-CIRCUIT BREAKER (TOA) CB4-C

WIRING DIAGRAM (82123)Page 11-11

ELECTRICAL SCHEMATIC (80771)éLEGENDAR -alternator rotorAS -alternator statorC01-CIRCUIT BREAKER 45A CB3-C1RCUIT BREAKER (10A) CBA-ORCUIT breaker (5A)C

WIRING DIAGRAM (82660)Page 11-13

5 ELECTRICAL SCHEMATIC (82662)#éCONNCCnON OPTIONS(o'ci’r'^ ^...^20V «OHI nOV SOHirnr'^a120V «OHI 110V SOHi240V AOHi 120V SOH

Table 11-8. Length EquivalentsUNITcmInchfeetyardmeterkilometermilecm0.39370.032810.010940.010.00001— —Inch 2.5410.08330.027780.02540.00003—feet 30.481

Figure 21. Exploded View of AC Generator AssemblyITEMQTYDESCRIPTION ITEM QTY DESCRIPTION1 1Rotor Assembly 271Spacer2 1Blower Housing28 1Flex Plate31Ai

Table 11-11. Number of 20 Gallon Propane Cylinders Required at Various indicated Temperatures when Kept at Least Half Full (Vapor Withdrawal Systems)W

STATOR ASSEMBLY;Clean the Stator can exterior surfaces with a soft brush or cloth. Use clean, dry, low pressure air (25 psi maximum) to clean the Stat

Section 1.3- INSULATION RESISTANCE TESTSEffects of Moisture and DirtThe insulation in RV and IM generators is moisture resistant. However, pro

Drying the Generator (Continued)2. Disconnect Wires No. 4 from the Voltage Regulator.3. Provide an external source to blow warm, dry air through the

Section 1.4- INTRODUCTION TO TROUBLESHOOTINGIntroductionA revolving field RV/IM type generator does not have a large number of parts. However, the par

Rotor Rotational Speed (Continued)1. A 4-Pole Rotor must be operated at 1800 rpm to supply a 60 Hertz AC output frequency: or at 1500 rpm for a 50 Her

Measuring CurrentAlternating current measurements can be taken with a 'clamp-on* type ammeter. Amperage should never exceed the nameplat

Section 1.5- TROUBLESHOOTING FLOW CHARTTEST 1-CHECK NO-LOAD VOLTAGE AND FREQUENCYVOLTAGE & FREQUENCY BOTH GOODVOLTAGE & FREQUENCY BOTH HIGHIV

li -!ForewordPURPOSE OF MANUAL:This Service Manual has been written and published by Generac Corporation to aid our Dealers" mechanics and compan

Using the Troubleshooting Flow ChartWhen a problem occurs with an RV/IM series generator set, the first step is to determine exactiy what that problem

Section 1.6- TROUBLESHOOTING TEST PROCEDURESIntroductionThe following numbered tests may be performed in conjunction with identically numbered tests

Test 3- Check Load Watts and Amperes (Continued)NOTE; The best way to check load wattage and amperage la to use a load bank. A load bank will allow th

Figure 28. Checking Rotor ResistanceTest 9> Check Brushes and Slip RingsDISCUSSION:if the fixed (constant) excitation test did not result in an AC

Test 12< Test DPE Circuit Breaker (Continued)PROCEDURE:1. With the generator shut down, disconnect the leads from the two breaker terminals, to pr

NOTE: Before attempting to test the Stator excitation winding, be sure the thermal protector has not failed open. See Teat 13.PR^OCEDUR

Test 17- Check Voltage Regulator (Continued)1. Sensing loss shutdown- if sensing is not availabie to the Regulator (sensing leads 11 and 22), the Reg

Part 2 ENGINE MECHANICALNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORSLiquid Cooled 1.2 Liter Gas Engine ModelsTABLE OF CON

Section 2.1- BASIC ENGINE MECHANICALIntroductionThis section covers some of the basic engine servicing tasks. Included In the Section are commonly use

Measuring Compression Pressure (Continued)then crank the engine and read the compression pressure. The pressure reading shouid be as follows:^TANDAR^

SERVICEMANUALNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILE ACGENERATORS1.2 Liter, Liquid-Cooled Gas/Gasoline Engine ModelsTABLE OF CON

Section 2.2- TIMING BELTTiming Belt PrecautionsComply with the following precautions when removing,Installing or inspecting the timing belt:D Make sur

Timing Belt Inspection (Continued) TOOTH BROKEN OR TOOTH ROOT CRACKED:Caused by camshaft jamming, distributor jamming, damaged crankshaft or camshaf

Timing Beit instaiiation (Continued)5. Loosen the tensioner lock nut. With all spark plugs removed, rotate the camshaft pulley two full tur

Section 2.3- CYLINDER HEADCylinder Head Removal1. Remove timing belt (Section 2.2). Then, remove OIL PUMP IDLER GEAR.2. Remove the cylinder head. Loos

Checking Cylinder Head Distortion (Continued)Valve Guide ClearanceUse a suitable dial indicator to measure valve stem to guide clearance. The valve s

5. Ream the valve guides to a finished size of 0.2758-0.,2764 inch (7.005-7.020mm).Valve InsertsInspect valve inserts for evidence of pitting

Valve DimensionsCheck dimensions of all valves. Refer to the appropriate SPECIFICATIONS chart.Figure 34. Valve DimensionsT (Margin thickness!NOTE: Whe

Cylinder Head Assembly (Continued)6. Install oil pump Idler gear and oil pump regulator spring. Make sure the spring faces in the proper direction.Fi

Installation (Continued)5. Tighten upper dust cover bolts to 2.9-3.6 foot-pounds (4-5 N-m) (Figure 45).6. Instail spark plugs and tighten to 14-22 foo

Section 2.4- OIL PAN AND OIL PUMPOil Pump RemovalDrain engine oil. Then, remove oil pump assembly with oil strainer. BE CAREFUL NOT TO DROP THE OIL PU

Part 1 THE ACGENERATORNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORSLiquid Cooled 1.2 Liter Gas Engine ModelsTABLE OF CONTE

Section 2.5- OIL SEAL REPLACEMENTCamshaft Oil Seal ReplacementjpidlerRemove timing belot, oil pump idler gear. Remove bolt stoppers and rocker shaft w

Section 2.6- ENGINE OVERHAULDisassembly1. Place engine on workstand. Remove timing belt cover and timing belt Remove cylinder head and oil pan.

Inspection (Continued)a. DO NOT turn the crankshaft or connecting rod when Plastigage^ is being inserted.b. When bearing clearance exceeds the

8. Surface warpage must be less than 0.004 inch (0.1mm). If beyond the specified limit, resurface the cylinder block. Resurfacing limit of the c

Inspection (Continued)Numbers that correspond to the cylinder number are stamped on connecting rods and connecting rod caps. Pistons, connect

Cylinder Block, Crankshaft and PistonRear oil seal retainermWater pump suction pipeCrankshaft rear oil sealEngine rear rubberApply soaping water to 0-

INSTALL PISTONAssembly (Continued)STON ASSEMBLY:1. Install piston rings as shown in Figure 69.MAIN BEARING CAPS:Install main bearing caps and tighten

Part 3 ENGINE LUBRICATION SYSTEMNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORSLiquid Cooled 1.2 Liter Gas Engine ModelsSECT

Section 3.1- LUBRICATION SYSTEM FAMILIARIZATIONEngine Lubrication CircuitFigure 1, below, shows the engine lubrication circuit in block diagram form a

Oil Pressure CheckWarm up the engine. Then, shut down and remove the oil pressure switch, install a direct reading pressure gauge in the oil pressure

Section 1.1- HOW GENERATORS PRODUCE ELECTRICITYMagnetic InductionIt has long been №own that a relationship exists between magnetism and electricity.

Section 3.2- ENGINE OIL PUMPOil Pump DisassemblyWhen removing the oil pump, be careful not to drop the oil pump drive shaft. When installing the pump,

Oil Pump Inspection (Continued)ROTOR TIP CLEARANCE Less than 0.008 inch (0.2mm)OUTER ROTOR TO BODY CLEARANCE Less than 0.008 inch (0.2mm)ROTOR TO STRA

Part 4 ENGINE COOLING SYSTEMNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILE AC GENERATORSLiquid Cooled 1.2 Liter Gas Engine ModeisFABLE

Section 4.1- COOLING SYSTEM FAMILIARIZATIONIntroductionThe generator cooling system is of the closed recovery type. Major cooling system components co

Section 4.2- WATER PUMP AND THERMOSTATWater PumpThe engine water pump (Figure 3) cannot be disassem- bied and must be replaced as a unit. Check the

Section 4.3- COOLING AND VENTILATING AIRGeneralService technicians sho work on the Series NP (recreational vehicle) and IM (industrial mobile) genera

Section 4.4- OPTIONAL REMOTE RADIATOR FANSome NP senes engine-generators are not equipped with a unit-mounted radiator. The radiator on such

ITEM QTYDESCRIPTIONITEM QTYDESCRIPTION1 1Radiator Assembly10 4M6 Flatwasher21 Radiator Fan11 4M6 Lockwasher34 Fan Mounting Bracket 12 4 M6 Hex Nut4 1

Section 4.5- OPTIONAL HEAT RECOVERY SYSTEMGeneralSome IM (Industrial Mobile) engine-generators are equipped with a heat recovery system. If desir

Figure 12. Exploded View of Heat Recovery SystemPage 4.5-2

A More Sophisticated GeneratorFigure 4 Is a diagram of a more sophisticated generator. A regulated direct current (DC) is delivered to the rotat

Part 5 GASOLINE FUEL SYSTEMNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORS1.2 Liter, Liquid-Cooled Gas/Gasollne Engine Mode

Section 5.1- GENERAL INFORMATION#Fuel RecommendationsAny high quality LEADED or UNLEADED regular grade?iasoline having a minimum posted octane n

Section 5.2- FUEL PUMPGeneralThe fuel pump Is energized ON during cranking and running when an engine controller circuit board delivers 12 vol

Section 5.3- CARBURETORRemovalRemove carburetor air intake components as necessary to gain access to the carburetor. Disconnect the carburetor- govern

Page 5.3-2

Part 6 GASEOUS FUEL SYSTEMNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORS1.2 Liter, Liquid-Cooled Gas/Gasoline Engine Model

Section 6.1- INTRO. TO GASEOUS FUEL SYSTEMSGeneralSome NP/IM series engine-generators may be equif^ed with optional LP (liquefied petroleum) gas fuel

As the throttle is opened wider, air flow increases through the carburetor venturi and the vacuum at the venturi throat Increases proportionally. Di

Section 6.2- LIQUID WITHDRAWAL SYSTEMSIntroductionFigure 8 (next page) is an Exploded View of a typical LIQUID WITHDRAWAL type gaseous fuel syste

Parts List for Liquid Withdrawal Fuel System3/8ITEM QTYDESCRIPTION ITEM QTY11Air Cleaner Stud 1612 1Air Cleaner Cover 17131Air Cleaner Element18441Air

#□ The VOLTAGE REGULATOR will continue to increase or decrease direct current flow to the ROTOR, In an attempt to maintain STATOR AC PO

Carburetor Assembly (Continued)ADJUSTMENTS (CONTINUED):5. Apply an electrical load to the unit equal to the generator’s rated maximum continuous watta

Section 6.3- VAPOR WITHDRAWAL SYSTEMIntroductionFigure 10 (below) is an Exploded View of a typical VAPOR WITHDRAWAL type gaseous fuel sy

•a, aiPressure Reducer ValveThe pressure reducer valve used in the Model 9251 LP gas conversion kit is an IMPCO Model IMP-52. LP gas, in vapor form,

Part 7 ENGINE SPEED CONTROL SYSTEMNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORS1.2 Liter, Liquid-Cooled Gas/Gasoline Engi

Section 7.1- MECHANICAL GOVERNORGeneral DescriptionThe mechanical engine governor utilizes the principle of spring tension versus centrifugal force to

4Figure 4. Exploded View of Governor-DC Alternator AssemblyITEM12345678910 11 121314151617181920 21 22 2325262728DESCRIPTIONGovernor Housing 0-Rlng Se

Engine Governor Adjustment (Continued)a. Check the AC frequency reading under load.b. If frequency drops below about 58 Hertz (60 Hertz units) or 49 H

Section 7.2- ELECTRONIC GOVERNORGeneralSome industrial mobile (IM) series generators may be equipped with an electronic engine governor system.

*Electronic Governor Setup (Continued)Set Jumper J2 to Its "FAST* position.4. Adjust Speed Pot R5 clockwise to obtain the correct AC frequency.5

Part 8 ENGINE IGNITION SYSTEMNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORS1.2 Liter, Liquid-Cooled Gas/Gasoline Engine Mo

Excitation SystemGENERAL:The excitation system is shown schematically in Figure 9. During operation, unregulated AC current from the Stator excitation

Major Components Service Data and SpecificationsThe engine ignition system consists of (af ignition coil,(b) a distributor, (c) spark piugs, (d) spar

Page 8.1-2

Section 8.2- TESTS, CHECKS AND ADJUSTMENTSIgnition CoilSee Figure 3. Connect the test leads of an ohmmeter across the positive and negative termi

Spark Plugs (Continued)Ignition TimingUse an automotive timing iight to check and adjust ignition timing. A timing mark is provided on the cra

Part 9 ENGINE DCELECTRICALSYSTEMNP and IM SeriesRECREATIONAL VEHICLE & INDUSTRIAL MOBILEAC GENERATORS1.2 Liter, Liquid-Cooled Gas/Gasoline Engine

Section 9.1- STANDARD BATTERY CHARGING SYSTEMComponentsA DC ALTERNATOR supplies charging current to the unit battery during engine operation, a

Section 9.2- THE "DELCO®" CHARGING SYSTEMIntroductionSome industrial-mobile (IM) engine-generators may be equipped with a ’Delcotron®“ batte

Testing (Continued)2, Disconnect the battery ground cable. Connect an ammeter jin series at “BAT" terminal of DC alternator. See Figure 5.'

Section 9.3- ENGINE CRANKING SYSTEMCranking System DescriptionSee Figure 7, below. Battery power is available to a large terminal stud of the

starter Contactor (Continued)>2. Connect the positive VOM test iead to the large contactor terminal stud to which the starter cabie attaches and th

NOTE: At the time thie Manual was written, all NP/IM Series generators were equipped with the dual, 1-phasa stator configuration. Some other

Figure 10. Starter Assemblyo---------“BO O Ù ^BRUSH & SPRING KITPARTS INCOMMUTATOR CAPCOMMUTATORCAPTHRU BOLTSI0QDRIVE KITDRIVE PINIONDRIVE CAPARMA

ADDING WATER:Water is lost from the battery as a result of charging and ^discharging, and must be replaced. If the water is not replaced an

Section 9.4- ENGINE CONTROL CIRCUITEngine Control Circuit BoardAn engine control circuit board (Figure 11), noused in the generator control panel, con

Enqine Control Circuit Board (Continued)See Figure 11 on previous page. The service technician hould be aware of the following features on the

Section 9.5- TROUBLESHOOTING GUIDEProblem 1. Engine Will Not CrankTEST 1- CHECK 10 AMP CIRCUIT BREAKER POSITIONCLOSEDhhh^TEST 2-CHECK VOLTAGE AT START

•lProblem 2. Engine Cranks But Will Not StartTEST 14-CHECK FUEL SUPPLYiO.KjTEST 15-CHECK ENGINE CONTROL CIRCUIT BOARD WIRE #14 OUTPUTiO.KjTEST 16-CHE

IntroductionTest numbers in the test procedures that follow correspond to the numbered tests in the troubleshooting flow charts of Pages 9.5-

m-Test 8- Check Wire 56 Volts at Starter Contactor (Continued) ROCEDURE:See "STARTER CONTACTOR" on Pages 9.3-1 and9.3-2.RESULTS:1. If batter

Test 15. Check Engine Control Circuit Board Wire #14 OutputDISCUSSiON:During a startup attempt, when the start-stop switch is set to “Start“, engine c

Test 20. Check Engine Fuel SystemDISCUSSION:It the engine cranks normally but will not start, the fuel Fsystem may be the cause of the problem. Refer