DIAGNOSTIC REPAIR MANUAL - Northwest Trek Fun Club

1 Models:4389, 4758 (6 kW NG, 7 kW LP)4456, 4759 (12 kW NG, 12 kW LP)4390, 4760 (13 kW, 15 kW LP) DIAGNOSTIC REPAIR MANUALAUTOMATIC HOME STANDBY GENERATORS Visit us online REPAIR MANUALAIR-COOLED PARTTITLES pecifications1 General Information2AC Generators3V-Type Prepackaged Transfer Switches4DC Control5 Operational Tests and Adjustments6 Disassembly7 Electrical DataDIAGNOSTICREPAIR MANUALAir-cooled, PrepackagedAutomatic StandbyGeneratorsModels:04389, 04758 (6 kW NG, 7 kW LP)04456, 04759 (12 kW NG, 12 kW LP)04390, 04760 (13 kW NG, 15 kW LP)TABLE OF CONTENTSTO FINDKNOWN VALUES1-PHASE3-PHASEKILOWATTS (kW)Volts, Current, Power FactorE x IE x I x x PF10001000 KVAV olts, CurrentE x IE x I x , Volts, Power FactorkW x 1000kW x 1000EE x x PFWATTSV olts, Amps, Power FactorVolts x AmpsE x I x x PFNO.

2 OF ROTORF requency, RPM2 x 60 x Frequency2 x 60 x frequencyPOLESRPMRPMFREQUENCYRPM, No. of Rotor PolesRPM x PolesRPM x Poles2 x 602 x 60 RPMF requency, No. of Rotor Poles2 x 60 x Frequency2 x 60 x FrequencyRotor PolesRotor PoleskW (required forMotor Horsepower, EfficiencyHP x x )EfficiencyEfficiencyRESISTANCEV olts, AmperesEEIIVOLTSOhm, AmperesI x RI x RAMPERESOhms, VoltsEERRE = VOLTSI = AMPERESR = RESISTANCE (OHMS)PF = POWER FACTORELECTRICAL FORMULASPage 1 SPECIFICATIONSPage 2 GENERATORM odels 04389, 04758 Models 04456, 04759 Model 04390, 04760 Rated Max. Continuous Power Capacity (Watts*)6,000 NG/7,000 LP12,000 NG/12,000 LP13,000 NG/15,000 LPRated Voltage120/240120/240120/240 Rated Max.

3 Continuous Load Current (Amps)120 Volts** LP240 LPMain Line Circuit Breaker30 Amp50 Amp60 Amp/70 AmpPhase111 Number of Rotor Poles222 Rated AC Frequency60 Hz60 Hz60 HzPower Factor111 Battery RequirementGroup 26/26 RGroup 26/26 RGroup 26/26R12 Volts and 12 Volts and 12 Volts and350 Cold-cranking550 Cold-cranking550 Cold-crankingAmperes MinimumAmperes MinimumAmperes MinimumWeight452 Pounds470 Pounds487 PoundsOutput Sound Level @ 23 ft (7m) at full load68 db (A) (A) db (A)Normal Operating Range-20 F ( C) to 104 F (40 C)* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc.

4 Maximum powerdecreases about percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6 C (10 F) above 16 C (60 F) ambient temperature.** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240 volts. 15,000 watt with upgrade kit 04578-0. Kit includes power harnesses and 70 amp 2-pole circuit 04389, 04758 Models 04456, 04759 Models 04390, 04760 Type of EngineGH-410GT-990GT-990 Number of Cylinders122 Rated @ 3,600 rpm26 @ 3,600 rpm30 @ 3,600 rpmDisplacement410cc992cc992ccCylinder BlockAluminum w/CastAluminum w/CastAluminum w/CastIron SleeveIron SleeveIron SleeveValve ArrangementOverhead ValvesOverhead ValvesOverhead ValvesIgnition SystemSolid-state w/MagnetoSolid-state w/MagnetoSolid-state w/MagnetoRecommended spark PlugRC12 YCRC12 YCRC12 YCSpark Plug mm ( inch) mm ( inch) mm ( inch)

5 Compression :1 Starter12 Vdc12 Vdc12 VdcOil Capacity Including FilterApprox. QtsApprox. QtsApprox. QtsRecommended Oil FilterGenerac Part # 070185 Generac Part # 070185 Generac Part # 070185 Recommended Air FilterGenerac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127 Operating RPM3,6003,6003,600 FUEL CONSUMPTIONM odel #Natural Gas*LP Vapor**1/2 Load Full Load1/2 Load Full Load04389, , , * Natural gass is in cubic feet per hour. **LP is in gallons per hour/cubic feet per WINDING RESISTANCE VALUES / ROTOR RESISTANCEM odel 04692 Models 04389 Models 04456 Models 0439004679, 0475804759 04760 Power Winding: Across 11 & ohmsPower Winding: Across 33 & ohmsExcitation Winding: Across 2 & ohmsEngine Run Winding: Across 55 & ohmsBattery Charge Winding.

6 Across 66 & ohmsRotor ohmsPage 3 SPECIFICATIONSMOUNTING DIMENSIONSPage 4 SPECIFICATIONSMOUNTING DIMENSIONSSPECIFICATIONSPage 5 MAJOR FEATURES12 kW and 15 kW, V-twin GT-990 Engine7 kW, Single Cylinder GH-410 Installation Before , Cleaning and Protective Operating ParametersPART 1 GENERAL INFORMATIONAir-cooled, PrepackagedAutomatic Standby GeneratorsModels:04389, 04758 (6 kW NG, 7 kW LP)04456, 04759 (12 kW NG, 12 kW LP)04390, 04760 (13 kW NG, 15 kW LP)TABLE OF CONTENTSSECTION IDENTIFICATIONGENERAL INFORMATIONPART 1 Page DIAGNOSTIC REPAIR MANUAL has been preparedespecially for the purpose of familiarizing servicepersonnel with the testing, troubleshooting and repairof air-cooled, prepackaged automatic standbygenerators.

7 Every effort has been expended toensure that information and instructions in the manualare both accurate and current. However, Generacreserves the right to change, alter or otherwiseimprove the product at any time without MANUAL has been divided into ten PARTS. EachPART has been divided into SECTIONS. EachSECTION consists of two or more is not our intent to provide detailed disassembly andreassemble instructions in this MANUAL . It is our intentto (a) provide the service technician with anunderstanding of how the various assemblies andsystems work, (b) assist the technician in finding thecause of malfunctions, and (c) effect the expeditiousrepair of the NUMBER:Many home standby generators are manufactured tothe unique specifications of the buyer.

8 The ModelNumber identifies the specific generator set and itsunique design NUMBER:Used for warranty tracking 1. A Typical Data PlateSECTION INSTALLATION BASICSGENERAL INFORMATIONINTRODUCTIONI nformation in this section is provided so that theservice technician will have a basic knowledge ofinstallation requirements for prepackaged homestandby systems. Problems that arise are oftenrelated to poor or unauthorized installation typical prepackaged home standby electric systemis shown in Figure 1 (next page). Installation of such asystem includes the following: Selecting a Location Grounding the generator.

9 Providing a fuel supply. Mounting the load center. Connecting power source and load lines. Connecting system control wiring. Post installation tests and A LOCATIONI nstall the generator set as close as possible to theelectrical load distribution panel(s) that will be poweredby the unit, ensuring that there is proper ventilation forcooling air and exhaust gases. This will reduce wiringand conduit lengths. Wiring and conduit not only add tothe cost of the installation, but excessively long wiringruns can result in a voltage THE GENERATORThe National Electric Code requires that the frameand external electrically conductive parts of thegenerator be property connected to an approvedearth ground.

10 Local electrical codes may also requireproper grounding of the unit. For that purpose, agrounding lug is attached to the unit. Grounding maybe accomplished by attaching a stranded copper wireof the proper size to the generator grounding lug andto an earth-driven copper or brass grounding-rod(electrode). Consult with a local electrician forgrounding requirements in your FUEL SUPPLYP repackaged units with air-cooled engine wereoperated, tested and adjusted at the factory usingnaturalgas as a fuel. These air-cooled engine units can beconverted to use LP (propane) gas by making a fewadjustments for best operation and (propane) gas is usually supplied as a liquid inpressure tanks.