MMD Equipment NGK-2900H User manual

SERVICE MANUAL
GENERATORS
NGK-2900H, NGK-4300H,
NGK-6000H, NGK-7000H
MMD Equipment Inc.
121 High Hill Road
Swedesboro, NJ 08085
Tel: [phone]
Fax: [phone]
www.mmdequipment.com

TABLE OF CONTENTS
Safety Precautions 1
Specifications and Maintenance Schedule 2
Repair Questionnaire 3
Pre-Operation Checks
5
Starting Procedures 5
Using A.C. Electric Power 6
Stopping Procedures 7
Component Function
GFCIs
Circuit Breakers
Idle Control
Oil Sensor
7
7
8
8
Wattage Information 8
Extension Cord Usage 9
Special Tools 10
Disassembly Instructions 11
Assembly Instructions 14
Troubleshooting Trees
Engine
Generator 18 19
Detailed Troubleshooting Instructions 20
Test Values for Rotor, Stator, and Condensers 23
Full Power Switch and Circuit Breaker
25
Wiring Diagrams 26
Exploded Views of Generator 32
Torque Values 34

SAFETY PRECAUTIONS:
Your safety is very important to us. While we cannot warn you about every possible hazard
associated with operating your NAC portable generator, following the precautions listed below
will assist you in operating your NAC generator safely. It is the operator’s responsibility to be
familiar with and to follow these important safety precautions.
1. Use extreme caution near gasoline and other flammables.
•Do not fill the fuel tank while the engine is running.
1WARNING! Do not smoke or use open flame near the generator.
1WARNING! Do not place flammables such as gasoline, oily rags, straw, trash, or matches near the
generator.
•Take care not to spill fuel on the generator when re-fueling. If fuel is spilled, wipe it off and allow it
to dry completely.
2. Operate the generator in a well-ventilated area.
1WARNING!Engine exhaust contains poisonous carbon monoxide gas, which can be fatal if inhaled.
1WARNING! Do not operate the generator indoors. If the generator must be operated indoors, the area
MUST be well ventilated and EXTREME CAUTION must be taken to prevent inhalation
of poisonous carbon monoxide gasses.
•Do not enclose the generator or cover it with a box. The engine and generator are air-cooled and may
overheat if operated in an enclosed space.
•Keep the generator at least 3 feet (1 meter) from building walls and other equipment during operation.
3. Operate the generator on a dry, level surface.
•Operating the generator on an inclined surface may cause the splash lubrication system to operate
improperly. The engine oil may flow away from the oil scraper and over the oil sensor. Therefore, the
oil sensor will not stop the engine, even though there is no oil lubricating the engine components. This
could cause the engine to seize and is not covered under warranty.
4. Always operate the generator in a dry environment.
1WARNING!Do not operate the generator in the rain, snow, or with wet hands. Severe electrical shock
may occur.
1WARNING! Do not clean the generator with a pressure washer or any other water hose. Use a damp
cloth to wipe down the generator, and be especially careful not to get water into the
receptacles.
1WARNING! Ensure there is no electrical wiring underneath the generator frame. Vibration from the
generator frame could wear through the wiring and cause sparks, fire, or shock hazard.
5. Additional safety information.
1WARNING!Do not connect the generator directly to household or other indoor wiring or to any
commercial power line. This could cause fatal injuries to Utility Service Personnel or
damage to the generator. A licensed electrician must install a Manual Transfer Switch to
the main circuit breaker panel in order to use a generator for back-up power.
•Although NAC generators are neutral grounded to the frame and should provide more than adequate
safety, use a grounding rod in accordance with local and OSHA safety requirements for optimum
grounding.
•The muffler and engine crankcase are extremely hot during and after operation. Allow the engine
adequate time to cool before touching the muffler or crankcase.
1

SPECIFICATIONS:
Model NGK-2900H NGK-4300H NGK-6000H/E NGK-7000H/E
Type Brushless, 2-pole, self-exciting, revolving field type
Max AC output 2900W 4300W 6000W 7000W
Rated AC output 2400W 3800W 5000W 6000W
Rated voltage 120 V 120/240 V 120/240 V 120/240 V
Rated current 20 A 31.7/15.9 A 41.7/20.8 A 50/25 A
Phase Single
Voltage regulation Condenser type
GENERATOR
Frequency 60 Hz
Model Honda GX-160 Honda GX-240 Honda GX-340 Honda GX-390
Spec. number ED2 ED2 ED6 / EDD2 ED6 / EDD2
Horsepower 5.5 8.0 11.0 13.0
Fuel tank capacity 3.0 gal. 4.5 gal. 4.5 gal. 4.5 gal.
Recommended fuel Unleaded gasoline (86 Octane or higher)
Oil capacity 0.63 US qt. 1.16 US qt. 1.16 US qt. 1.16 US qt.
Recommended oil SAE 10W-30 API SF or SG
ENGINE
Starting system Recoil Recoil Recoil or electric* Recoil or electric*
Dimensions (in.)
(L x W x H) 22.4 x 17.3 x 18.9 24.2 x 20.2 x 20.1 26.0 x 21.3 x 20.5 26.0 x 21.3 x 20.5
Dry weight 95 lbs. 150 lbs. 176 lbs. 191 lbs.
* Electric start models are available as NGK-6000HE AND NGK-7000HE generators only.
Recoil start models cannot be converted to electric start.
**Use a GROUP 51 battery on electric start models.
MAINTENANCE SCHEDULE:
REGULAR SERIVCE PERIOD
Perform at every indicated month or operating period,
whichever comes first.
Each
use
First
month
or
20 hrs.
Every 3
months
or
50 hrs.
Every 6
months
or
100 hrs.
Every
year
or
300 hrs.
Check level •
Engine oil Change ••
Inspect •
Air cleaner Clean
•ℵ
Fuel strainer cup Clean •
Spark plug Inspect-Clean •
Spark arrester Clean •
Valve clearance Check-Adjust •
Fuel tank and filter Clean •
Fuel line Inspect
(Replace if necessary) Every 2 years
* For detailed engine information, refer to the Honda Engine Shop Manual.
Note: ℵService more frequently in dusty areas.
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QUESTIONS TO ASK WHEN A CUSTOMER BRINGS A GENERATOR IN FOR
SERVICE
1. What brand is the generator? ___________________________
2. Which model? ______________________________________
3. What is the serial number of the generator? ______________________________
4. Briefly describe the problem with the generator._____________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
5. When did the failure occur?______________________________________________________
6. Were there any tools connected to the generator when the failure occurred? Yes No
a. Which tools were being used when the failure occurred?
Tool #1 Quantity used:______
Brand: ___________________
Model: ___________________
Running amps (found on tool nameplate):_____
Tool #2 Quantity used:______
Brand: ___________________
Model: ___________________
Running amps (found on tool nameplate):_____
Tool #3 Quantity used:______
Brand: ___________________
Model: ___________________
Running amps (found on tool nameplate):_____
Tool #4 Quantity used:______
Brand: ___________________
Model: ___________________
Running amps (found on tool nameplate):_____
b. Which receptacle was the tool plugged into? Circle one
i) Tool #1: GFCI (left) GFCI (right) 120V twist-lock (left) 120V twist-lock (right)
240V twist- lock
Did you use an extension cord? Yes No How many feet?____ What gauge?____
ii) Tool #2: GFCI (left) GFCI (right) 120V twist-lock (left) 120V twist-lock (right)
240V twist- lock
Did you use an extension cord? Yes No How many feet?____ What gauge?____
iii) Tool #3: GFCI (left) GFCI (right) 120V twist-lock (left) 120V twist-lock (right)
240V twist- lock
Did you use an extension cord? Yes No How many feet?____ What gauge?____
iv) Tool #4: GFCI (left) GFCI (right) 120V twist-lock (left) 120V twist-lock (right)
240V twist- lock
Did you use an extension cord? Yes No How many feet?____ What gauge?____
7. Is the engine running properly? Yes No If not, explain symptoms._______________________
____________________________________________________________________________________________
3

SERVICE QUESTIONAIRE PAGE 2
8. Did the circuit breaker trip? Yes No If yes, which one? 30A (left) 30A (right) Main
a. Did you reset the circuit breaker and try to continue using the generator? Yes No
b. If yes, did the circuit breaker trip again? Yes No
c. If yes, how long did it take for the breaker to trip again? Immediately 30 sec. 1min. 2 min.
5 min. other_______
d. How many times did you try to reset the breaker? 1 5 10 20+
9. Did the GFCI trip? Yes No
a. Did you reset the GFCI and try to continue using the generator? Yes No
b. If yes, did the GFCI trip again? Yes No
10. Was the IDLE CONTROL SWITCH On or Off
11. Which position was the FULL-POWER SWITCH in? 120 120/240
12. What was the approximate temperature where the generator was operating? _______
13. What were the weather conditions where the generator was operating? Rain Snow Dry
4

PRE-OPERATION CHECKS:
Note: Before performing pre-operational checks, ensure the generator is located on a clean and level surface
with the engine stopped.
INSPECT THE OVERALL CONDITION OF THE GENERATOR
1. Look around the generator for signs of oil or gasoline leaks.
2. Ensure the cooling vents on the engine’s recoil assembly and generator head are free of debris or
obstructions.
3. Check that all nuts, bolts, and screws are tightened.
4. Inspect the generator for any signs of damage (especially on the control panel, fuel tank, and fuel hoses).
5. Ensure the green, grounding wire located between the aluminum generator cover and the frame is
securely connected.
CHECK ENGINE OIL
Note: The generator MUST be located on a level surface with the engine stopped when checking the oil
level. Failure to do so could result in improper lubrication of the engine, which could cause engine
damage!
1. Remove the oil dipstick and wipe it clean.
2. Insert and remove the dipstick (without screwing it into the filler neck).
3. Fill the crankcase to the lower edge of the dipstick hole with the recommended oil. Honda recommends
that you use API SERVICE category SF or SG oil.
¾SAE 10W-30 is recommended for general use (-5°F to 110°F). (Consult the Honda engine owner’s
manual for additional information)
4. Inspect the color of the oil. If the oil appears excessively dark, cloudy, or has a metallic tint, change the
oil. (Consult the Honda engine owner’s manual for instructions about changing the oil)
CHECK AIR CLEANER
1. Remove the air cleaner cover and inspect the foam filter (element). Clean or replace dirty filters. If the
foam filter is damaged, replace the filter.
¾To clean the filter, wash it in warm soapy water, rinse, and allow it to dry thoroughly. Coat the
filter in engine oil, then squeeze out the excess. The engine will smoke when started if too much oil
is left in the filter.
CHECK ENGINE FUEL
1WARNING! Never check the fuel level or refuel the tank while the engine is running, near open flame, or
while smoking.
1. Remove the fuel cap and check fuel level. If level is low, refuel with fresh, clean, unleaded gasoline (86
Octane or higher).
STARTING PROCEDURES:
RECOIL START MODELS
1. Ensure the switches on the generator control panel are in the correct position prior to starting the engine.
a) All CIRCUIT BREAKERS should be turned off.
b) IDLE CONTROL switch should be turned off.
c) Engine RUN/STOP switch should be switched to “RUN.”
2. Open the fuel cock located at the base of the fuel tank just above the recoil starter. When the fuel cock
lever is perpendicular to the ground (straight up & down), the fuel cock is open.
3. Close the choke valve by pulling the CHOKE LEVER.
4. Grasp the black starter handle and pull slowly until you feel resistance. Return the starter handle to its
original position, then pull briskly. Slowly return the starter handle to its original position.
5. Once the engine has started, push the CHOKE LEVER back to its original position.
6. Allow the engine to warm up for 3 minutes before you use the generator.
5

ELECTRIC START MODELS
1. Follow steps 1) through 3) of the RECOIL START section. (Disregard step 1c)
2. Insert the key into the key slot and turn it clockwise to the “START” position.
3. Release the key as soon as the engine starts (the key should automatically return to the “RUN”
position).
CAUTION! If the engine does not start within 5 seconds, release the key. Wait at least 30
seconds and try to start the engine again.
Do not turn the key to the “START” position while the engine is running.
4. Once the engine has started, push the CHOKE LEVER back to its original position.
5. Allow the engine to warm up for 3 minutes before you use the generator.
USING A.C. POWER FROM THE GENERATOR:
1. Single Voltage (120V only)
a) Leave the CIRCUIT BREAKERS off until your electrical appliances are properly connected
to the generator.
b) Turn off the switches on all electrical appliances before connecting them to the generator.
Note: Before plugging any appliances into the generator, check the wattage of each appliance to be
used. The TOTAL wattage of all appliances should not exceed the rated output of the
generator.
c) Insert the plugs from your electrical appliances into the generator.
Note: To use power from the round, locking receptacles, insert the plug into the receptacle and turn it
clockwise to lock the plug.
d) Place the FULL POWER switch in the 120V position (The 240V receptacle can NOT be used
when the FULL POWER switch is in the 120V position).
e) Switch the CIRCUIT BREAKERS on.
2. Dual Voltage (120V/240V)
a) Follow steps a) through c) above.
b) Place the FULL POWER switch in the 120V/240V position.
c) Switch the CIRCUIT BREAKERS on.
CAUTION! The FULL POWER switch should always be kept in the 120V position unless you
are using the 240V receptacle.
6

STOPPING PROCEDURES:
1. Ensure all appliances are turned off.
2. Place CIRCUIT BREAKERS in the “OFF” position.
3. Turn the IDLE CONTROL switch to the “OFF” position.
4. Before stopping the engine, allow it to run for at least three minutes with all appliances turned off, so the
engine can cool down.
5. Once the engine has cooled down, turn the ON/OFF switch on the generator control panel to the “OFF”
position.
6. On Electric Start generators (NGK-6000HE & NGK-7000HE), turn the key switch to the “OFF”
position.
7. Close the fuel cock located at the base of the fuel tank just above the recoil starter. When the fuel cock
lever is parallel to the ground (left to right), the fuel cock is closed.
Note: If the engine does not stop when the ON/OFF switch is placed in the “OFF” position, there are two
ways to stop the engine.
a) Close the fuel cock located at the base of the fuel tank just above the recoil starter. When the fuel
cock lever is parallel to the ground (left to right), the fuel cock is closed. After a few minutes, the
engine will stop.
b) If you need to stop the engine quickly, grasp the spark plug cap and gently pull it off the spark plug.
This will stop the engine immediately.
Note: If you are not going to use the generator for 48 hours or more, stop the engine by following the
instructions in step a) above. This will prevent old gas from clogging fuel passages in the carburetor.
FUNCTION OF ADDITIONAL FEATURES:
GFCI RECEPTACLES
GFCI stands for Ground Fault Circuit Interrupter. The GFCI compares the amount of current leaving the
GFCI receptacle with the amount of current returning to the GFCI receptacle. If the amount of current
leaving the GFCI receptacle exceeds the amount of current returning to the GFCI receptacle by 5 milliamps
or more, the GFCI will trip. The GFCI is designed to stop the flow of electricity leaving the receptacle, in
order to protect the person operating the appliances that are plugged into the GFCI. The GFCI will not limit
the amount of current experienced if you are shocked, but it will limit the duration of the shock. This is why
it is important to regularly test the GFCIs on your NAC generator.
TESTING GFCIs
1. The generator must be running with the CIRCUIT BREAKERS in the “ON” position to test the GFCIs.
2. Press the TEST button located between the two outlets on the GFCI. The RESET button should pop out.
•If the RESET button does not pop out, the receptacle may be defective. Do not use the generator;
contact your authorized NAC service center for repair.
3. To restore power, depress the RESET button until an audible click is heard. The TEST and RESET
buttons should be level to each other.
•If the GFCI trips during operation, turn the CIRCUIT BREAKERS off and unplug the appliances
connected to the GFCI. Test the appliance for ground faults and repair faulty appliances before re-
connecting them to the GFCI.
•If the GFCI continues to trip, stop the generator and contact your authorized NAC service center.
CIRCUIT BREAKERS
The circuit breakers on NAC generators are “NO-FUSE” circuit breakers. These circuit breakers protect the
GENERATOR from damage due to overload or short circuit in the appliance. They do NOT protect the
operator from shock or electrocution. When the circuit breaker trips, there is no voltage present at the
receptacles.
7

WHAT TO DO IF THE CIRCUIT BREAKER TRIPS:
If the circuit breaker trips during operation, the generator may be overloaded or the appliance being used is
defective.
1. Add the wattage from all appliances being used on the generator. If the total wattage exceeds the
RATED output of the generator, the generator is overloaded.
•Reduce the number of appliances used on the generator.
•Use a NAC generator with higher wattage output.
2. If the total wattage being used is less than the RATED output of the generator, check the appliance for
defects and repair faulty appliances before reconnecting them to the generator.
3. If the circuit breaker continues to trip, do not use the generator. Contact your authorized NAC service
center.
IDLE CONTROL SYSTEM (NGK-4300H/6000H/7000H):
The idle control system automatically reduces the engine speed to improve fuel economy, reduce noise, and
prolong engine life.
HOW TO USE THE IDLE CONTROL SYSTEM:
1. After the engine has warmed up, place the IDLE CONTROL switch in the “ON” position.
•The engine will idle at approximately 2400 rpm until the appliance is turned “ON.”
•1~2 seconds after the appliance is activated, the engine speed will increase to the rated rpm.
•5~10 seconds after the appliance is turned off, the engine will idle back down.
2. Turn the IDLE CONTROL switch “OFF” when you are finished using the appliances, and allow the
engine to cool down for at least 3 minutes before stopping the engine.
OIL SENSOR
The oil sensor is designed to protect the engine from damage if you forget to maintain the proper oil level.
•If the oil level in the engine drops too low, the oil sensor will automatically stop the engine.
•If the engine stops automatically, check to ensure there is fuel in the gas tank and oil in the engine.
Refill with fresh gasoline and/or oil if necessary and re-start the engine.
•If the engine fails to start, follow the steps in the Troubleshooting section of this manual.
WATTAGE INFORMATION:
Some appliances require more power to start than they do during operation. All NAC generators have an
overload capacity designed to allow overload for short periods. It is extremely important to use the proper
size generator for the appliances you need to use. The information below gives the additional wattage
required by certain appliances. The additional starting wattage required by these appliances must be
considered when choosing the NAC generator best suited for your needs.
1) Incandescent lamps require no additional wattage to start.
2) Fluorescent lamps and mercury lamps require 1.2 to 2 times the running wattage to start.
3) Motor driven tools require 1.2 to 3 times the running wattage to start.
4) Motors that start under heavy loads such as compressors, refrigeration systems, and submersible pumps
require high current for long periods while starting. These appliances require 3~5 times the running
wattage to start.
•Check with the manufacturer of the appliance for specific information about the running and
starting wattage requirements.
Note: To determine running wattage, multiply the amperage on the tool nameplate by the voltage used. To
determine starting wattage, multiply the running wattage by the factors listed above.
•For example: A 5 amp submersible pump that runs on 120 volts has a running wattage of 600
watts (5A x 120V = 600W) and requires about 3000 watts to start (600W x 5 = 3000W).
8