Generac Power Systems NP-40G Series Service Manual

Computer controlled variable speed rv generators

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Table of Contents

Safety Information
Generator Fundamentals
Introduction to Ccg's
Why Variable Speed Control?
Major Components
Permanent Magnet Rotor
Rotor Hub
Stator Retaining Ring
Stator Assembly
Stepper Motor
The Genistor
The CCG Circuit Board
Operational Description
Block Diagram - AC Generator System
Insulation Resistance
Dirt and Moisture
Stator Leads
Test All Stator Windings to Ground
Test for Shorts between Windings
Results of Tests
Cleaning the Generator
Using Solvents for Cleaning
Drying the Generator
Components Testing
Symptoms of Stator Failure
Testing the Stator with a vom
Testing Power Phase Windings
Testing Power Supply Windings
Testing the Timing Winding
Short Circuit between Windings
Genistor Testing
Symptoms of Genistor Failure
Testing the Battery Charge Circuit
Testing the CCG Circuit Board
Symptoms of Circuit Failure
Control Panel Exploded View
Sheet Metal
General Information
4-Cycle Engine Theory
Recommended Fuels
Recommended Engine Oil
Storage Instructions
Return to Service after Storage
Engine Tuneup
Exploded View of Engine Long Block
Valve Train Components
Valve Components Removal
Valve Service
Valve Seats
Valve Components Installation
Valve Tappets
Valve Springs
Adjusting Valve Clearance
Rocker Arm Cover Installation
Piston, Rings, Connecting Rod
Oversize Piston and Rings
Piston Removal from Connecting Rod
Check for Piston Wear
Piston Rings
Checking Piston Ring End Gap
Piston Assembly and Installation
Cylinder Service
Reboring the Cylinder
Crankshaft and Camshaft
Crankcase Cover Removal
Camshaft Removal and Inspection
Crankshaft Removal
Crankshaft Inspection
Compression Release Mechanism
Installing the Crankshaft
Installing the Camshaft
Gasoline Fuel System
Recommended Fuel
Evaporation Control Systems
Air Cleaner and Air Intake
Fuel Filter
Fuel Pump
Carburetor Operation
Carburetor Disassembly
Carburetor Cleaning and Inspection
Carburetor Adjustment
Engine Speed
Throttle Linkage Adjustment
Carburetor Removal
Automatic Choke
Pre-Choke Adjustment
Choke Solenoid Adjustment
Speed Control System
CCG Control Board
Stepper Motor Problems
Testing the Stepper Motor
Gaseous Fuel System
Vapor Withdrawal
Fuel Supply Lines
Excess Flow Valve
Gaseous Carburetion
Leakage Testing
Shutoff Valve and Regulator
The LP Gas Regulator
Testing the Fuel Lockoff Solenoid
Carburetor Technical Data
Engine Oil and Cooling System
Oil Flow
Oil Pickup Screen
Oil Pump
Crankshaft Oil Seals
Pressure Relief Valve
Breather Assembly
Oil Sump
Oil Filter Support
Engine Cooling System
Generator Air Flow
Air Flow into Generator Compartment
Compensating for Restrictions
Engine Electrical System
Engine DC Control System
Engine Controller Board
Engine Cranking System
Recommended Battery
Battery Cables
Testing a Battery
Start-Run-Stop Switch
Starter Contactor Testing
Engine Ignition System
Ignition Cage Assembly
Ignition Sensor
Ignition Module
Ignition Coil
Spark Plug
Ignition System Testing
Testing for Spark
Checking Engine Miss
Check Power Supply
Check Ignition Sensor
Testing Ignition Coil
Testing Ignition Module
Engine Protective Devices
Oil Pressure Switch
Oil Temperature Switch
Optional Remote Panel
Remote Panel Cables
Wiring Connections
Troubleshooting
Generator and Speed Control System Troubles
Engine DC Control System Troubles
Priming Function Does Not Work
Engine will Not Crank
Engine Cranks but will Not Start
Engine Starts Hard and Runs Rough
Engine Starts then Shuts down after a few Seconds
Check 15 Amp Fuse
Check Power to Switch
Check Power to Fuel Pump
Check Battery/Battery Circuit
Test Primer Switch
Check Wire 14A to Fuel Pump
Check Power Supply to Starter Motor
Check Wire 56 Power to Starter Contactor
Check Engine Controller Board Power Supply
Test Start-Stop Switch
Check Fuel Supply
Check Spark Plug
Check Ignition Power Supply
Check Engine Controller Board Output to Wire 14
Check Carburetion
Check Engine
Isolate the CCG System
Test Oil Pressure Switch
Test CCG System
Specifications
Electrical Schematic
Wiring Diagram
Engine Specifications

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Generac Power Systems NP-40G Series Service Manual

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