Document Outline

• SERVICE
• Manual
  • Foreword
    • PURPOSE OF MANUAL:
    • USER’S RESPONSIBILITY:
    • SAFETY:
    • FASTENERS:
    • REPLACEMENT PARTS:
    • NP and IM Series
    • 1.2 Liter, Liquid-Cooled Gas/Gasoline Engine Models
    • NP and IM Series
    • Liquid Cooled 1.2 Liter Gas Engine Models
    • TABLE OF CONTENTS
      • 1.1
      • 1.2
      • 1.6
      • Manual Familiarization
  • Section 1.1- HOW GENERATORS PRODUCE ELECTRICITY
    • Magnetic Induction
    • A Simple AC Generator
    • A More Sophisticated Generator
    • A Typical AC Generator
    • Rotor Residual Magnetism
    • Field Boost
    • Excitation System
      • BRUSHES AND SLIP RINGS:
    • Stator AC Power Connection Systems
    • stator AC Power Connection Systems (Continued)
      • 3-PHASE DELTA STATOR SYSTEM:
    • Introduction
    • Generator Disassembly
    • Inspection of Major Components
  • Section 1.3- INSULATION RESISTANCE TESTS
    • Effects of Moisture and Dirt
    • Insulation Resistance Testers
    • Insulation Resistance- Main Stator
    • Rotor insuiation Resistance
    • Cleaning the Generator
    • Drying the Generator
    • Drying the Generator (Continued)
  • Section 1.4- INTRODUCTION TO TROUBLESHOOTING
    • Introduction
    • Tools and Equipment
    • Rotor Rotational Speed
    • Rotor Rotational Speed (Continued)
    • Relationship of Voltage & Frequency
    • Visuai inspection
    • Constant Excitation Test
    • Measuring Current
    • Measuring Resistance
    • Effects of Engine Power
  • 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:
      • EXHAUST MANIFOLD NUTS:
      • CARBURETOR BOLTS:
    • Adjusting Vaive Clearance
      • VALVE CLEARANCE HOT INTAKE s 0.010 Inch (0.25mm)
    • Checking Drive Beits
      • NEW BELT a 0.59^).75 inch (15-19m) USED BELTaO.71-0.87 inch (18-22mm)
    • Measuring Compression Pressure
      • DIFFERENCE BETWEEN CYLINDERS SHOULD NOT EXCEED 14 PSI (1.0 kg/cm^)
    • Timing Belt Precautions
    • Timing Beit Removai
      • BELT TEETH ARE WORN:
    • 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
      • BEARING CLEARANCE
      • CRANKSHAFT:
    • Assembly (Continued)
  • Section 3.1- LUBRICATION SYSTEM FAMILIARIZATION
    • Engine Lubrication Circuit
    • Recommended Oils
    • Low Oil Pressure Shutdown
    • Checking Low Oil Pressure Shutdown
    • Oil Pressure Check
  • Section 3.2- ENGINE OIL PUMP
    • Oil Pump Disassembly
    • Oil Pump Inspection
    • Oil Pump Inspection (Continued)
    • NP and IM Series
    • Liquid Cooled 1.2 Liter Gas Engine Modeis
  • Section 4.1- COOLING SYSTEM FAMILIARIZATION
    • Introduction
    • Recommended Coolant
    • High Coolant Temperature Switch
      • DESCRIPTION:
      • TESTING HIGH TEMPERATURE SHUTDOWN:
      • TESTING THE SWITCH:
  • Section 4.2- WATER PUMP AND THERMOSTAT
    • Water Pump
    • Thermostat
  • Section 4.3- COOLING AND VENTILATING AIR
    • General
    • Types of Cooling Fans
    • Air Flotw- Pusher Fan Units
    • Air Flow- Suction Fan Units
    • Installation Manual
      • Figure 7. Typical Installation- Unit with Suction Type Fan
  • Section 4.4- OPTIONAL REMOTE RADIATOR FAN
    • Compartment Fan
    • A Remote Radiator Assembly
      • COMPONENTS:
      • OPERATION:
      • Figure 9. Remote Radiator Fan Operating Diagram
    • L
      • 14 AMP
      • FUSE
    • 7777777
  • Section 4.5- OPTIONAL HEAT RECOVERY SYSTEM
    • General
    • Operation
    • Customer Remote Heater
    • Exploded View of Heat Recovery System
    • TABLE OF CONTENTS
      • Fuel Recommendations
      • Fuel System Components
      • General
      • Testing the Fuel Pump
      • Removal
      • Disassembly
      • Reassembly
      • Installation
      • Automatic Choke Adjustment
    • TABLE OF CONTENTS
      • General
      • Vapor Withdrawal System
      • Liquid Withdrawai System
        • Figure 2. A Typical Vapor Withdrawal System
      • Gas Carburation
      • LP Gas Conversion Kit
      • Introduction
      • Fuel Solenoid Assembly
      • Vaporizer-Regulator Assembly
      • Carburetor Assembly
        • DESCRIPTION:
        • ADJUSTMENTS:
      • Carburetor Assembly (Continued)
        • ADJUSTMENTS (CONTINUED):
      • Introduction
      • Fuel Solenoid Assembly
      • Pressure Reducer Valve
      • Carburetor Assembly
    • TABLE OF CONTENTS
  • Section 7.1- MECHANICAL GOVERNOR
    • General Description
    • Governor Maintenance
    • dC Alternator Removal
    • Governor Lubrication
    • Engine Governor Adjustment
    • Engine Governor Adjustment (Continued)
  • Section 7.2- ELECTRONIC GOVERNOR
    • General
  • LirJ
    • Governor Actuator Relay
      • DESCRIPTION;
      • TESTING:
    • Governor Actuator Adjustment
    • Electronic Governor Setup
    • Magnetic Pickup
    • TABLE OF CONTENTS
      • Major Components Service Data and Specifications
  • Section 8.2- TESTS, CHECKS AND ADJUSTMENTS
    • Ignition Coil
      • PRIMARY WINDING RESISTANCE AT 68* F. (20‘ C.)
      • 1.3-1.5 ohms
      • SECONDARY WINDING RESISTANCE AT 68* F. (20* C.)
    • Checking the Condenser
    • Distributor Cap and Rotor Head
    • Contact Set
      • BREAKER POINT GAP
      • 0.018-0.022 Inch (0.45-0.55mm)
    • Check Governor Advance
    • Spark Plugs (Continued)
    • Ignition Timing
    • Checking Ignition Wires
    • TABLE OF CONTENTS
      • Components
      • DC Alternator
      • DC Voltage Regulator
      • Introduction
        • Delcotron Series 10 SI
      • DC Alternator Description
      • DC Alternator Adjustments
      • Testing
        • GENERAL:
        • UNDERCHARGED BATTERY:
      • Testing (Continued)
      • Cranking System Description
      • Operational Analysis
      • Engine Control Circuit Board
      • Start-Stop Switch
        • DESCRIPTION;
        • TESTING THE SWITCH:
      • 10 Amp Circuit Breaker
      • Starter Contactor
        • DESCRIPTION:
        • TESTING THE STARTER CONTACTOR:
      • starter Contactor (Continued)
      • Starter
        • DESCRIPTION:
        • STARTER MOTOR SERVICING:
        • STARTER PERFORMANCE TEST:
      • Battery
        • RECOMMENDED BATTERY:
        • BA’TTERY CABLES:
        • EFFECTS OF TEMPERATURE ON BATTERY:
        • ADDING WATER:
        • CHARGING A BATTERY:
      • Battery (Continued)
  • Section 9.4- ENGINE CONTROL CIRCUIT
    • Engine Control Circuit Board
    • Enqine Control Circuit Board (Continued)
    • Overspeed Shutdown Adjustment
  • Section 9.5- TROUBLESHOOTING GUIDE
    • Problem 1. Engine Will Not Crank
• •l
  • Problem 2. Engine Cranks But Will Not Start
    • DISCUSSION:
    • PROCEDURE:
    • RESULTS:
    • RESULTS:
    • DISCUSSION:
    • RESULTS:
    • DISCUSSION:
    • RESULTS:
    • DISCUSSION:
    • PROCEDURE:
    • RESULTS:
    • DISCUSSION:
    • PROCEDURE:
    • RESULTS:
    • DISCUSSION:
    • DISCUSSION:
  • Test 8- Check Wire 56 Volts at Starter Contactor (Continued) ROCEDURE:
    • RESULTS:
  • Test 9- Check Starter Contactor Ground
    • DISCUSSION:
    • PROCEDURE”
  • Test 10. Check Wire 56
    • ISCUSSION:
    • PROCEDURE:
    • RESULTS:
  • Test 12- Test Start-Stop Switch
    • DISCUSSION:
    • PROCEDURE:
    • RESULTS:
  • Test 13. Check Power Supply to Circuit Board
    • DISCUSSION:
    • PROCEDURE:
    • RESULTS:
  • Test 11. Test 10 Amp Circuit Breaker
    • DISCUSSION:
    • PROCEDURE:
    • RESULTS:
  • Test 14. Check Fuel Supply
    • DISCUSSION:
    • PROCEDURE:
    • RESULTS:
  • 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
    • DISCUSSION:
    • RESULTS:
  • Test 21- Check Engine Mechanical Systems
    • DISCUSSION:
    • PROCEDURE:
  • Section 10.1- REMOTE START-STOP PANELS
    • General
    • Model 9042 Remote Panel
      • DESCRIPTION:
    • GENERAC
      • GENERATOR
      • MOUNTING:
      • CONNECTIONS:
      • DESCRIPTION:
      • MOUNTING:
      • CONNECTIONS:
  • Section 10.2- REMOTE GAUGE PANEL
    • Description
    • Instailation
    • Panel Mounting
    • NP and IM Series
    • 1.2 Liter, Liquid-Cooled Gas/Gasoline Engine Models
    • Table 11.2- General Engine Specifications
    • Table 11.3- Tightening Torques for Engine Bolts
    • Table 11.5- Engine Service Data
    • Table 11-5. Engine Service Data (Continued)
      • 33
    • 5
      • HOW TO USE TABLE 11-12: