Generac-power-systems 941-2 Uživatelský manuál

SERIES IMPACT 36 PLUS IIModels 940-2 & 941-2SERVICEMANUALManual Part No. 0D9057Printed in U.S.ARevision A - 07/15/03P.O. Box 297 • Whitewater, WI

Section 1.1GENERATOR FUNDAMENTALSCAPACITIVE REACTANCE:This condition occurs when current leads voltage(Figure 9). It might be thought of as the abilit

Section 6.4ENGINE IGNITION SYSTEMIGNITION MODULE (CONTINUED)Figure 4. Ignition ModuleIGNITION COILPrimary ignition voltage (12 VDC) is delivered fromt

Section 6.4ENGINE IGNITION SYSTEMTESTING FOR SPARK:To test the ignition system, a suitable spark testermay be used. Such spark testers are commerciall

Section 6.4ENGINE IGNITION SYSTEMTESTING THE SYSTEM (CONTINUED)CHECK POWER SUPPLY (CONT’D):b.If battery voltage is NOT indicated in Step 7,test Wire 1

Section 6.5SHUTDOWN FEATURESGENERALThe engine mounts an Oil Pressure Switch (LOP) andan Oil Temperature Switch (HTO). These two switch-es, in conjunct

Section 6.5SHUTDOWN FEATURESADDITIONAL SHUTDOWN FEATURESThe A6060 Circuit Board also incorporates the follow-ing protective shutdown features:LOSS OF

Section 6.6OPTIONAL REMOTE PANELGENERALAn optional remote-mounted Start-Stop panel is avail-able. This panel will permit the generator to be startedan

Section 6.6OPTIONAL REMOTE PANELPage 6.6-2

PART 7TROUBLE-SHOOTINGCOMPUTERCONTROLLEDVARIABLESPEED RVGENERATORSSeries Impact 36 PlusSECTION TITLE7.1 GENERATOR & SPEED CONTROL7.2 ENGINE DC CON

NOTES

Section 7.1GENERATOR & SPEED CONTROL SYSTEMPROBLEM POSSIBLE CAUSE REMEDY PAGE1. Engine starts, accelerates, a. Carburetor linkage sticking with a

Section 1.1GENERATOR FUNDAMENTALS3. When the generator circuit breaker is turned to the “ON” position,AC voltage is delivered to the Full Bridge Recti

Section 7.1GENERATOR & SPEED CONTROL SYSTEMPage 7.1-2

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGINTRODUCTIONThis Section contains troubleshooting information pertaining to the engine DC cont

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-2PROBLEM 2 - ENGINE WILL NOT CRANKPROBLEM 3 - ENGINE CRANKS BUT WILL NOT START

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-3PROBLEM 3 - ENGINE CRANKS BUT WILL NOT START (CONTINUED)

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-4PROBLEM 4 - ENGINE STARTS HARD AND RUNS ROUGH

12SHUTS DOWNTEST 31TEST INVERTER(Pg. 7.2-18)FAILREPLACE INVERTERSection 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-5PROBLEM 5 - ENGINE S

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-6PROBLEM 6 - GENERATOR DOESN’T PULL FULL LOADPROBLEM 7 - GENERATOR CIRCUIT BREAKER TR

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-7PROBLEM 8 - ENGINE SHUTS DOWN UNDER LOAD12PROBLEM 9 - GENERATOR LOSES AC POWER THEN

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-812-WIRE1212PROBLEM 10 - NO AC OUTPUT

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-9PROBLEM 10 - NO AC OUTPUT (CONTINUED)

Section 1.1GENERATOR FUNDAMENTALSPage 1.1-6

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGTEST 1- CHECK 7.5 AMP FUSEDISCUSSION:The panel-mounted 7.5 amp fuse is connected inseries with

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGRESULTS:1. If unit is being tested because the priming function doesn't work:a.!f battery

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGThis test will determine if battery voltage is availableto the Starter Motor for cranking the

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGTEST 11- TEST STARTER CONTACTORDISCUSSION:See "Starter Contactor" on Page 6.3-2. Rep

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGFigure 8. Checking Spark Plug GapRESULTS:1. Clean and regap or replace spark plug as necessary

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGIf the engine cranks but won't start, it is possible thata failure in the circuit board h

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGENGINE COMPRESSION PRESSURENOMINAL PRESSURE: 60 psiMINIMUM ALLOWABLE: 55 psiNOTE: Full compres

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGTEST 29 - 12 POSITION HARNESSCONTINUITY TEST1) Set VOM to measure Resistance.2. Measure from p

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGTEST 31 - STATIC TESTS ON INVERTERASSUMPTION:• Inverter not connected to generator.• Inverter

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTING5. Momentarily jump Wire #15 (located at the fuse holder) to Wire#56 (located at the Starter C

Section 1.2MAJOR GENERATOR COMPONENTS INTRODUCTIONMajor components of the generator proper are shownin Figure 1, below. External sheet metal and other

Section 7.2ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTINGPage 7.2-20

PART 8 SPECIFICATIONSAND CHARTSCOMPUTERCONTROLLEDVARIABLESPEED RVGENERATORSSeries Impact 36 PlusPAGE TITLE8-1 General Specifications8-1 Nominal Resist

NOTES

Part 8SPECIFICATIONS & CHARTSTYPE Impact 36 G Impact 36 LPMODEL 0940 0941TYPE OF ROTOR Permanent Magnet Type Permanent Magnet TypeRATED WATTS 3600

Part 8SPECIFICATIONS & CHARTSPage 8-2341091121ACAC1DCDCBR1 BR2BR3BR4GRNT1AC2TIM2TIM1TIMINGPOWERSL2SL1WINDINGPOWER SUPPLYPS1PS2AC11785180CB1GRNBATT

Part 8SPECIFICATIONS & CHARTSPage 8-3LOPF1ICSMTCHTOISGRDIMSCBCR 12VBATTERYCUSTOMERSUPPLIEDVIODCDCACGENERATOR CONTROLENGINE GENERATORSW2STATORMREM

ALLOWABLEEND PLAY 0.006-0.023 inch(0.14-0.60mm)Part 8SPECIFICATIONS & CHARTSPage 8-4MODEL GV-220 VALVE SEAT WIDTH:DESIGN WIDTH 0.034-0.044 inch (0

Part 8SPECIFICATIONS & CHARTSPage 8-5CRANKCASE ASSEMBLY MODEL GV-220CYLINDER BORE:DESIGN DIAMETER 2.953-2.954 inch(75.000-75.025mm)VALVE TAPPET B

Part 8SPECIFICATIONS & CHARTSPage 8-6CRANKSHAFTMODEL GV-220CRANKPIN DIAMETER: DESIGN DIAMETER 1.180-1.181 inch(29.99-30.01mm)CRANKSHAFTMAIN BEARIN

Part 8SPECIFICATIONS & CHARTSPage 8-7PISTON (CONTINUED)MODEL GV-220WRIST PIN BOREDIAMETER:DESIGN DIAMETER 0.708-0.709 inch(18.000-18.011mm)TOP RIN

Section 1.2MAJOR GENERATOR COMPONENTS ROTOR HUBSee Figure 2 on previous page. The Rotor Hub is bal-anced with the Rotor and must be replaced with theR

Part 8SPECIFICATIONS & CHARTSPage 8-8CAMSHAFT ASSEMBLYMODEL GV-220MAIN CAMSHAFT BEARING DIAMETER(FLYWHEEL END): DESIGN DIAMETER 1.022-1.023 inch(

Part 8SPECIFICATIONS & CHARTSPage 8-9OIL PUMP (CONTINUED)MODEL GV-220OIL PRESSURE RELIEFVALVE SPRING: Forcerequired to compress 0.85-0.95 poundssp

Part 8SPECIFICATIONS & CHARTSPage 8-10MAJOR FEATURES AND DIMENSIONSGENERATOR

Part 8SPECIFICATIONS & CHARTSPage 8-11MAJOR FEATURES AND DIMENSIONSINVERTER

Section 1.2MAJOR GENERATOR COMPONENTS Figure 5. Schematic- Stator WindingsPage 1.2-3

Section 1.2MAJOR GENERATOR COMPONENTS Page 1.2-4

Section 1.3OPERATIONAL ANALYSISGENERALFigure 1, below, is a block diagram of the Impact Pluscomputer controlled RV generator. The diagram isIntended o

Section 1.3OPERATIONAL ANALYSISOPERATIONAL DESCRIPTION (CONTINUED)7. The A6060 circuit board controls all functions of the generator,i.e.:a.Engine DC

Section 1.4INSULATION RESISTANCEDIRT AND MOISTUREIf moisture is permitted to remain in contact with thegenerator Stator windings, some of it will be r

SAFETYThroughout this publication, "DANGER!" and "CAUTION!" blocks are used to alert the mechanic to specialinstructions concernin

Section 1.4INSULATION RESISTANCETEST ALL STATOR WINDINGS TO GROUNDConnect the ends of all Stator leads together. Makesure none of the leads are touchi

Section 1.4INSULATION RESISTANCEFigure 3. Schematic - Stator WindingsUSING SOLVENTS FOR CLEANING:A solvent is generally required when dirt contains oi

Section 1.4INSULATION RESISTANCEPage 1.4-4

Section 1.5COMPONENTS TESTINGINTRODUCTIONProblems that occur In the computer-controlled RVgenerator generally involve the following systems orcomponen

Section 1.5COMPONENTS TESTINGSTATOR ASSEMBLY (CONTINUED)Figure 2. Schematic- Stator WindingsTESTING POWER SUPPLY WINDINGS:A. To test the Power Supply

Section 1.5COMPONENTS TESTING7.Connect one test lead to Stator lead PS1, theother to Stator lead 77. The VOM should read"infinity".8.Connect

Section 1.5COMPONENTS TESTINGPage 1.5-4

Section 1.6CONTROL PANELCONSTRUCTIONThe panel is constructed of sheet metal and includesa panel box, a panel back cover and a front controlpanel. The

Section 1.6CONTROL PANELPage 1.6-2

Section 1.7SHEET METALSee "Exploded View of Sheet Metal" on next page. ADIVIDER PLATE (Item 1) separates the AC generatorcomponents from the

PART TITLE1 THE AC GENERATOR2 ENGINE MECHANICAL3 GASOLINE FUEL SYSTEM4 GASEOUS FUEL SYSTEM5 ENGINE OIL & COOLING SYSTEM6 ENGINE ELECTRICAL SYSTEM7

Section 1.7SHEET METALPage 1.7-253578633342344455330295253959593320212254526423045935722383572431TO CARBURETOR4041532930315323747503728273960493751363

Section 1.7SHEET METALITEM QTY DESCRIPTION1 1 PLATE, DIVIDER2 2 M6-1.0 HEX NUT3 1 SEAL RUBBER EXTRUSION 3.5 FT4 1 WRAPPER, BOX5 31 TAPTITE, M5- .8 x 1

Section 1.7SHEET METALPage 1.7-45357863334234445533029525392233202122542647530423112238311243140415329303153239307577727866571737974767021251194851751

Section 1.7SHEET METALITEM QTY DESCRIPTION1 1 PLATE, DIVIDER2 32 CRIMPTITE 10-24 x 1/2"3 3.5' SEAL, RUBBER EXTRUSION4 1 BOX, WRAPPER5 31 TAP

Section 1.7SHEET METALPage 1.7-6

PART 2 ENGINEMECHANICALCOMPUTERCONTROLLEDVARIABLESPEED RVGENERATORSSeries Impact 36 PlusSECTION TITLE2.1 GENERAL INFORMATION2.2 VALVE TRAIN2.3 PISTON,

NOTES

Section 2.1GENERAL INFORMATIONINTRODUCTIONThe engine used on Impact 36 plus Series recreationalvehicle AC generators is a Generac Series GV-220,vertic

Section 2.1GENERAL INFORMATIONTIMING:Valve timing and ignition timing must be preciselycontrolled if the engine is to operate properly and effi-cientl

Section 2.1GENERAL INFORMATIONEngine crankcase oil capacity without oil filter changeis about 29 fluid ounces (850m.Engine crankcase oil capacity (wit

Section 2.1GENERAL INFORMATIONITEM QTY DESCRIPTION1 1 Connecting Rod2 1 Piston Pin3 1 Piston Ring Set (STD)4 2 1/4" Pipe Plug5 1 Breather Cover6

Section 2.2VALVE TRAINVALVE TRAIN COMPONENTSValve train components are listed below and shown inFigure 1, below.ITEM QTY DESCRIPTION1 2 Tappet2 2 Pus

Section 2.2VALVE TRAINFigure 4. Cylinder Head RemovalDANGER! ALWAYS WEAR SAFETY GLASSESWHEN REMOVING THE VALVE SPRINGS.5. See Figure 5, next page. Hol

Section 2.2VALVE TRAINNOTE: After the valve guides have been over-sized, be sure to recut the valve seats so they willalign with the guides.Figure 8.

Section 2.2VALVE TRAINVALVE COMPONENTS INSTALLATION(CONTINUED)3. Install the valve spring washers, valve springs and valve springretainers over the va

Section 2.2VALVE TRAINVALVE CLEARANCE GV-220 ENGINEINTAKE VALVE: 0.001-0.0022 inch (0.03-0.056mm)EXHAUST VALVE: 0.0018-0.003 inch (0.046-0.07mm)Adjust

Section 2.2VALVE TRAINPage 2.2-6

Section 2.3PISTON, RINGS, CONNECTING RODOVERSIZE PISTON & RINGSWorn or scored cylinders may be rebored to 0.010(0.25mm) or 0.020 (0.50mm) oversize

Section 2.3PISTON, RINGS, CONNECTING RODFigure 4. Piston Minor DiameterPISTON MINOR DIAMETER GV-220)Design DIAMETER: 2.747-2.748 inch (69.789-69.809mm

Section 2.3PISTON, RINGS, CONNECTING RODFigure 7. Ring Locations in Piston GroovesCHECKING PISTON RING END GAP:To check piston rings end gap, proceed

Page 1PART 1 GENERAL INFORMATIONCOMPUTERCONTROLLEDVARIABLESPEED RVGENERATORSSeries Impact 36 Plus IISECTION TITLE1.1 GENERATOR FUNDAMENTALS1.2 GENERAT

Section 2.3PISTON, RINGS, CONNECTING RODhammer handle to gently tap the piston down into the cylinder.4. Check that the connecting rod's large di

Section 2.4CRANKSHAFT AND CAMSHAFTGENERALPrior to removal of the crankcase cover, gain accessto the engine and generator by removing surroundingsheet

Section 2.4CRANKSHAFT AND CAMSHAFTCAMSHAFT INSPECTIONCarefully inspect the entire camshaft for wear, nicks,damage. All areas indicated in Figure 4 sho

Section 2.4CRANKSHAFT AND CAMSHAFTFigure 6. Bearing Bore in Crankcase CoverCOMPRESSION RELEASE MECHANISMA mechanical compression release is provided o

Section 2.4CRANKSHAFT AND CAMSHAFTFigure 9. Timing Mark on Crankshaft Gear Figure 10. Alignment of Timing MarksPage 2.3-8

PART 3 GASOLINE FUELSYSTEMCOMPUTERCONTROLLEDVARIABLESPEED RVGENERATORSSeries Impact 36 PlusSECTION TITLE3.1 INTRODUCTION TO FUEL SYSTEM3.2 AIR CLEANER

NOTESPage 2

Section 3.1INTRODUCTION TO FUEL SYSTEMGENERALRecreational vehicle generators equipped with agasoline fuel system are usually installed so that theysha

Section 3.1INTRODUCTION TO FUEL SYSTEMaltered. Service technicians working on the RV gener-ator systems must not do anything that might changethe vehi

Section 3.2AIR CLEANER AND INTAKEAIR CLEANERDESCRIPTION: The air cleaner assembly consists of (a) an air clean-er BASE, (b) a PAPER FILTER, and (c) a

NOTES

Section 3.2AIR CLEANER AND INTAKEPage 3.2-2

Section 3.3FUEL FILTER AND FUEL PUMPFUEL FILTERThe fuel filter should be removed and replaced every100 hours of operation or once each year, whichever

Section 3.3FUEL FILTER AND FUEL PUMPPage 3.3-2

Section 3.4CARBURETORGENERAL INFORMATIONProper engine performance depends on the carbure-tion system. The use of clean, fresh gasoline and awell-maint

Section 3.4CARBURETORCARBURETOR DISASSEMBLYSee Figure 3. The carburetor can be disassembled asfollows:1. Remove the BOWL NUT (Item 3) and the FIBER WA

Section 3.4CARBURETORADJUSTMENTThe carburetor used on the GV-220 engine has aFIXED, NON-ADJUSTABLE Low Speed Jet.ENGINE SPEEDEngine speed is controlle

Section 3.4CARBURETORPage 3.4-4Figure 6. Carburetor Removal

Section 3.5AUTOMATIC CHOKEGENERALThe GV-220 vertical shaft engines are equipped withan automatic choke. A choke solenoid is attached tothe carburetor

Section 3.5AUTOMATIC CHOKEPage 3.5-2

Section 3.6SPEED CONTROL SYSTEMGENERALThe AC generator's output voltage is controlled by a"computerized" speed control system. This sys

Section 1.1GENERATOR FUNDAMENTALSMAGNETISMMagnetism can be used to produce electricity andelectricity can be used to produce magnetism.Much about magn

Section 3.6SPEED CONTROL SYSTEMELECTRICAL CONNECTIONS BROKEN:If one or more of the electrical connections to thestepper motor are broken or disconnect

PART 4 GASEOUS FUELSYSTEMCOMPUTERCONTROLLEDVARIABLESPEED RVGENERATORSSeries Impact 36 PlusSECTION TITLE4.1 INTRODUCTION TO FUEL SYSTEM4.2 SHUTOFF VALV

NOTES

Section 4.1INTRODUCTION TO FUEL SYSTEMGENERAL INFORMATIONSome RV generator models are equipped with fuelsystems that utilize LP gas as a fuel. The ini

Section 4.1INTRODUCTION TO FUEL SYSTEMIMPORTANT CONSIDERATIONS (CONTINUED)NOTE: A PRIMARY REGULATOR, between thetank and the fuel lockoff solenoid, is

Section 4.1INTRODUCTION TO FUEL SYSTEMGASEOUS CARBURETIONGas at positive pressure is delivered from the fuellockoff solenoid to the inlet of the regul

Section 4.1INTRODUCTION TO FUEL SYSTEMPage 4.1-4

Section 4.2SHUTOFF VALVE AND REGULATORGENERALSee Figure 1. The fuel shutoff valve (lockoff solenoid)and the secondary regulator are retained to a flat

Section 4.2SHUTOFF VALVE AND REGULATORTEST PROCEDURE:1. Set a volt-ohm-milliammeter (VOM) to read battery voltage (12VDC).2. Connect the VOM test lead

Section 4.3CARBURETORGENERALThe carburetor is designed for use with LP gas in itsvapor form. The following specifications apply:Carburetor Inlet Diame

Section 1.1GENERATOR FUNDAMENTALSALTERNATING CURRENTA simple generator consists of a coil of wires called aStator and a magnetic field called a Rotor.

Section 4.3CARBURETORPage 4.3-2

PART 5 ENGINE OIL &COOLING SYSTEMCOMPUTERCONTROLLEDVARIABLESPEED RVGENERATORSSeries Impact 36 PlusSECTION TITLE5.1 ENGINE OIL SYSTEM5.2 ENGINE COO

NOTES

Section 5.1ENGINE OIL SYSTEMINTRODUCTION TO OIL SYSTEMThe engine oil system serves to (a) reduce frictionbetween parts, (b) cool the engine, and (c) e

Section 5.1ENGINE OIL SYSTEMOIL PUMP (CONTINUED)INSPECTION (CONT'D):Inspect the outer drive pins on the camshaft. Look forbreakage, bending, othe

Section 5.1ENGINE OIL SYSTEMThe breather serves to maintain a partial vacuum inthe engine crankcase, to prevent oil from being forcedpast oil seals, g

Section 5.1ENGINE OIL SYSTEMPage 5.1-4

Section 5.2ENGINE COOLING SYSTEMIt is absolutely essential that an adequate flow of airfor cooling, ventilating and engine combustion be sup-plied to

Section 5.2ENGINE COOLING SYSTEMFigure 3 — Suspended Mount Inlet DoorFigure 4. DuctworkFigure 5 — Air Inlet in Vehicle SkirtCOMPENSATING FOR RESTRICTI

PART 6 ENGINEELECTRICALSYSTEMCOMPUTERCONTROLLEDVARIABLESPEED RVGENERATORSSeries Impact 36 PlusSECTION TITLE6.1 ENGINE DC CONTROL SYSTEM6.2 A6060 CIRCU

Section 1.1GENERATOR FUNDAMENTALSFigure 6. Electrical UnitsOHM:The OHM is the unit of RESISTANCE. In every circuitthere is a natural resistance or opp

NOTES

Section 6.1ENGINE DC CONTROL SYSTEMGENERALThe engine DC control system consists of all thoseelectrical components required for cranking, startingand r

Section 6.1ENGINE DC CONTROL SYSTEMHOW IT WORKSENGINE NOT RUNNING:1. Battery output (12VDC) is available to the contacts of a startercontactor (SC). H

Section 6.2A6060 CIRCUIT BOARDGENERALThe A6060 circuit board controls all phases of engineoperation including cranking, starting, running andshutdown.

Section 6.2A6060 CIRCUIT BOARDCIRCUIT BOARD CONNECTIONS(CONTINUED)RECEPTACLE J4:The A6060 circuit board mounts a 3-pin receptacleJ4. A 3-pin connector

Section 6.3ENGINE CRANKING SYSTEMINTRODUCTIONCOMPONENTS:The engine cranking system is shown schematicallyin Figure 1, below. The system consists of th

Section 6.3ENGINE CRANKING SYSTEMBATTERY (CONTINUED)TESTING A BATTERY:The best method of testing a battery is with an auto-motive type battery hydrome

Section 6.3ENGINE CRANKING SYSTEMFigure 3. Starter ContactorSTARTER MOTORDESCRIPTION:The Starter Motor is a 12 volts negative ground type.It is capabl

Section 6.3ENGINE CRANKING SYSTEMPage 6.3-4

Section 6.4ENGINE IGNITION SYSTEMINTRODUCTIONThe engine ignition system consists of the followingmajor components:• Ignition Cage Assembly.• Ignition