Generac Power Systems NP-40G Series Manuals

Manuals and User Guides for Generac Power Systems NP-40G Series. We have 1 Generac Power Systems NP-40G Series manual available for free PDF download: Service Manual

Generac Power Systems NP-40G Series Service Manual (127 pages)

Computer Controlled variable Speed RV Generators

Brand: Generac Power Systems | Category: Inverter | Size: 5.75 MB

Safety Information
2
Generator Fundamentals
5
Introduction to Ccg's
8
Why Variable Speed Control?
9
Major Components
11
Permanent Magnet Rotor
11
Rotor Hub
12
Stator Retaining Ring
12
Stator Assembly
12
Stepper Motor
12
The Genistor
13
The CCG Circuit Board
13
Operational Description
15
Block Diagram - AC Generator System
15
Insulation Resistance
17
Dirt and Moisture
17
Stator Leads
17
Test All Stator Windings to Ground
17
Test for Shorts between Windings
18
Results of Tests
18
Cleaning the Generator
18
Using Solvents for Cleaning
18
Drying the Generator
19
Components Testing
21
Symptoms of Stator Failure
21
Testing the Stator with a vom
21
Testing Power Phase Windings
21
Testing Power Supply Windings
22
Testing the Timing Winding
22
Short Circuit between Windings
22
Genistor Testing
23
Symptoms of Genistor Failure
23
Testing the Battery Charge Circuit
23
Testing the CCG Circuit Board
24
Symptoms of Circuit Failure
24
Control Panel Exploded View
27
Sheet Metal
29
General Information
34
4-Cycle Engine Theory
34
Recommended Fuels
35
Recommended Engine Oil
35
Storage Instructions
35
Return to Service after Storage
35
Engine Tuneup
36
Exploded View of Engine Long Block
37
Valve Train Components
38
Valve Components Removal
38
Valve Service
39
Valve Seats
39
Valve Components Installation
40
Valve Tappets
40
Valve Springs
40
Adjusting Valve Clearance
41
Rocker Arm Cover Installation
42
Piston, Rings, Connecting Rod
44
Oversize Piston and Rings
44
Piston Removal from Connecting Rod
44
Check for Piston Wear
44
Piston Rings
45
Checking Piston Ring End Gap
45
Piston Assembly and Installation
46
Cylinder Service
46
Reboring the Cylinder
47
Crankshaft and Camshaft
48
Crankcase Cover Removal
48
Camshaft Removal and Inspection
48
Crankshaft Removal
48
Crankshaft Inspection
49
Compression Release Mechanism
50
Installing the Crankshaft
50
Installing the Camshaft
50
Gasoline Fuel System
52
Recommended Fuel
53
Evaporation Control Systems
53
Air Cleaner and Air Intake
55
Fuel Filter
57
Fuel Pump
57
Carburetor Operation
59
Carburetor Disassembly
59
Carburetor Cleaning and Inspection
60
Carburetor Adjustment
60
Engine Speed
61
Throttle Linkage Adjustment
61
Carburetor Removal
62
Automatic Choke
63
Pre-Choke Adjustment
63
Choke Solenoid Adjustment
63
Speed Control System
65
CCG Control Board
65
Stepper Motor Problems
65
Testing the Stepper Motor
66
Gaseous Fuel System
67
Vapor Withdrawal
68
Fuel Supply Lines
69
Excess Flow Valve
69
Gaseous Carburetion
70
Leakage Testing
70
Shutoff Valve and Regulator
72
The LP Gas Regulator
72
Testing the Fuel Lockoff Solenoid
72
Carburetor Technical Data
74
Engine Oil and Cooling System
76
Oil Flow
77
Oil Pickup Screen
77
Oil Pump
77
Crankshaft Oil Seals
78
Pressure Relief Valve
78
Breather Assembly
78
Oil Sump
79
Oil Filter Support
79
Engine Cooling System
81
Generator Air Flow
81
Air Flow into Generator Compartment
81
Compensating for Restrictions
81
Engine Electrical System
83
Engine DC Control System
84
Engine Controller Board
86
Engine Cranking System
88
Recommended Battery
88
Battery Cables
88
Testing a Battery
88
Start-Run-Stop Switch
89
Starter Contactor Testing
89
Engine Ignition System
92
Ignition Cage Assembly
92
Ignition Sensor
92
Ignition Module
92
Ignition Coil
93
Spark Plug
93
Ignition System Testing
93
Testing for Spark
94
Checking Engine Miss
94
Check Power Supply
94
Check Ignition Sensor
94
Testing Ignition Coil
95
Testing Ignition Module
95
Engine Protective Devices
96
Oil Pressure Switch
96
Oil Temperature Switch
96
Optional Remote Panel
98
Remote Panel Cables
98
Wiring Connections
98
Troubleshooting
100
Generator and Speed Control System Troubles
101
Engine DC Control System Troubles
103
Priming Function Does Not Work
103
Engine will Not Crank
104
Engine Cranks but will Not Start
104
Engine Starts Hard and Runs Rough
106
Engine Starts then Shuts down after a few Seconds
107
Check 15 Amp Fuse
108
Check Power to Switch
108
Check Power to Fuel Pump
108
Check Battery/Battery Circuit
109
Test Primer Switch
109
Check Wire 14A to Fuel Pump
109
Check Power Supply to Starter Motor
109
Check Wire 56 Power to Starter Contactor
110
Check Engine Controller Board Power Supply
110
Test Start-Stop Switch
111
Check Fuel Supply
111
Check Spark Plug
111
Check Ignition Power Supply
112
Check Engine Controller Board Output to Wire 14
112
Check Carburetion
113
Check Engine
113
Isolate the CCG System
114
Test Oil Pressure Switch
114
Test CCG System
114
Specifications
117
Electrical Schematic
119
Wiring Diagram
120
Engine Specifications
121

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