Generac 86640 User Manual
Service manual
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Manual Part No. 86640
SERVICE
Manual
NP and IM Series
RECREATIONAL
VEHICLE AND
INDUSTRIAL MOBILE
AC GENERATORS
Liquid-Cooled 1.2 Liter
Gas Engine Models
C O R P O R A T I O N
♦ P. O. Box 8
♦ Phone: (414) 544-4811
♦Waukesha, Wisconsin 53187
♦ FAX: (414) 544-4851
Original laaua (02/28/93)
Printed In U.SJt.
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Table of contents
Document Outline
- SERVICE
- Manual
- Foreword
- Section 1.1- HOW GENERATORS PRODUCE ELECTRICITY
- Section 1.3- INSULATION RESISTANCE TESTS
- Section 1.4- INTRODUCTION TO TROUBLESHOOTING
- Section 1.5- TROUBLESHOOTING FLOW CHART
- Using the Troubleshooting Flow Chart
- Introduction
- Test 1> Check No-Load Voltage and Frequency
- Test 2- Check Load Voltage and Frequency
- Test 3- Check Load Watts and Amperes
- Test 6- Do a Fixed Excitation Test
- Test 7- Check Wires 1 and 4
- Test 8- Check Rotor
- Test 9> Check Brushes and Slip Rings
- Test 10- Test Main Circuit Breaker
- Test 11- Check AC Power Lead Connections
- Test 12- Test DPE Circuit Breaker
- Test 12< Test DPE Circuit Breaker (Continued)
- Test 13- Test Thermal Protector
- Test 14- Test Stator DPE Windings
- Test 15- Test Stator AC Power Windings
- Test 16- Check Sensing Leads
- Test 17- Check Voltage Regulator
- Test 17- Check Voltage Regulator (Continued)
- Introduction
- Tightening Cylinder Head Boits
- Tighten Manifoid, Exhaust Manifoid and Carburetor Fasteners INTAKE MANIFOLD NUTS:
- Adjusting Vaive Clearance
- Checking Drive Beits
- Measuring Compression Pressure
- Timing Belt Precautions
- Timing Beit Removai
- Timing Belt Installation
- Cylinder Head Removal
- Checking Cylinder Head Distortion
- Checking Cylinder Head Distortion (Continued)
- Valve Guide Replacement
- Valve Inserts
- Camshaft Bearing Clearance
- Valve Dimensions
- Valve Spring Squareness, Free Length and Tension
- Cylinder Head Assembly
- Cylinder Head Assembly (Continued)
- Installation
- Oil Pump Removal
- Inspection
- Installation
- Camshaft Oil Seal Replacement
- Crankshaft Front Oil Seal Replacement
- Disassembly
- Inspection
- Assembly (Continued)
- Section 3.1- LUBRICATION SYSTEM FAMILIARIZATION
- Section 3.2- ENGINE OIL PUMP
- Section 4.1- COOLING SYSTEM FAMILIARIZATION
- Section 4.2- WATER PUMP AND THERMOSTAT
- Section 4.3- COOLING AND VENTILATING AIR
- Section 4.4- OPTIONAL REMOTE RADIATOR FAN
- Section 4.5- OPTIONAL HEAT RECOVERY SYSTEM
- General
- Operation
- Customer Remote Heater
- Exploded View of Heat Recovery System
- TABLE OF CONTENTS
- TABLE OF CONTENTS
- TABLE OF CONTENTS
- Section 7.1- MECHANICAL GOVERNOR
- Section 7.2- ELECTRONIC GOVERNOR
- LirJ
- Section 8.2- TESTS, CHECKS AND ADJUSTMENTS
- Ignition Coil
- Checking the Condenser
- Distributor Cap and Rotor Head
- Contact Set
- Check Governor Advance
- Spark Plugs (Continued)
- Ignition Timing
- Checking Ignition Wires
- TABLE OF CONTENTS
- Components
- DC Alternator
- DC Voltage Regulator
- Introduction
- DC Alternator Description
- DC Alternator Adjustments
- Testing
- Testing (Continued)
- Cranking System Description
- Operational Analysis
- Engine Control Circuit Board
- Start-Stop Switch
- 10 Amp Circuit Breaker
- Starter Contactor
- starter Contactor (Continued)
- Starter
- Battery
- Battery (Continued)
- Section 9.4- ENGINE CONTROL CIRCUIT
- Section 9.5- TROUBLESHOOTING GUIDE
- •l
- Problem 2. Engine Cranks But Will Not Start
- Test 8- Check Wire 56 Volts at Starter Contactor (Continued) ROCEDURE:
- Test 9- Check Starter Contactor Ground
- Test 10. Check Wire 56
- Test 12- Test Start-Stop Switch
- Test 13. Check Power Supply to Circuit Board
- Test 11. Test 10 Amp Circuit Breaker
- Test 14. Check Fuel Supply
- Test 15. Check Engine Control Circuit Board Wire #14 Output
- Test 16. Check Fuel Valve
- Test 17. Check Fuel Pump
- Test 18. Test Automatic Choke
- Test 19. Check Engine Ignition System
- Test 20. Check Engine Fuel System
- Test 21- Check Engine Mechanical Systems
- Section 10.1- REMOTE START-STOP PANELS
- Section 10.2- REMOTE GAUGE PANEL