GA Service Manual - Multiquip Service & Support Center
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1. Generator Engine Wiring Schematic GA 4 5RA 42 Multiquip Inc GA Series Generators Manual No GA2009CD GA 6HA WIRING SCHEMATIC GA 6HA WIRING DIAGRAM cogn ao 0141095 T ad _ E ais 9 p I pS GENERATOR ssa uu Mw ER fe 5 B35 de Me 35 a 01 Tdi i B 35 E es EU e Es 7 LO LES G G EXW magneto coil Re CN4 CN G GR s M re E er Lia i m RU BE Spark plug Fuel cut solenoid 5B m 1 unt Qil level siet iis Ignition coll ENGINE Ne a A O HH M ms Y orm o 2 YMBOL DESIGNATION CB CIRCUIT BREAKER 25A 240 504 9120 COLOR CODE m 1 CON 1 RECEPTACLE 15 208 20A 125V Wrecoior WIRE COLOR B BLACK R RED CM CN3 CON2 WHITE CON3 RECEPTACLE L14 30R 30A 125 250V BR BROWN vELLOW ON 4 5 RECEPTACLE 5208 20A 125V VIOLET Plen li CN4 CNS CONNECTOR ARRANGEMENT RC IDLE CONTROL DEVICE VIEW FROM INSERTING WIRE SIDE Generators Wiring Schematic GA 6HA Multiquip Inc GA Series Generators Manual No GA2009CD 43 GA 6HEA WIRING SCHEMATIC CN5 CN6 0075 75 CAROS ZA SW _ GRO 75 W 0 75 CNI B35 aee OO 01 AN 2 a DIY ln Luis QUOUUD a Pg AI EXW 5 NE e2. pa Es o x o md 72 OIL 4 SENSOR m gt UNIT ENGINE SYMBOL DESIGNATION FOP COLOR CODE __ WIRECOLOR __ WIRE COLOR B BLACK RIRED RECTIFER CIRCUIT BREAKER 22 AC VOLTMETER 120V CON 1 RECEPTACLE L5 20R 20A 125V CON 2 RECEPTACLE 5 20R 20A 125V BROWN Y YELLOW V VIOLET ORANGE PINK Generator Engine Wiring Schematic 40 Multiquip Inc GA Series Generators Manual No GA2009CD GA 3 6HA WIRING SCHEMATIC GA 3 6H WIRING DIAGRAM 00 75 RO E 0 15 ONG W R GR D 7 0 Fe 9 GENERATOR 4 E gie a Rx SW m EC HUM LA oro 8 G reg G G G B35 er en Engine magneto coil E gt GR do veru CN3 G W GW m e Se Spark plug Fuel cut solenoid gum Beg 1 Ea ou is init Gil level EC IE Ignition coil ENGINE aa m HM P T a MM n 22 E a YMBOL DESIGNATION ARMATURE WINDING Fg P ASSEMBLY EXCITATION WINDING EXCITATION WINDING AC VOLTMETER 120 240V RE 1 2 RECTIFIER CIRCUIT BREAKER 25 240 37 5A 120 COLOR CODE RECEPTACLE L5 20R 20A 125V TRE coLOR wine Cove lil BLACK RED CON 2 RECEPTACLE L5 30R 30
3. 14 ROOT aa 15 GENERATOR TIPS Current Flow Diagrama EA desde bases 16 SOtor Removal MPS assinei Ds adido QU NES 17 PO o DG 18 PIAS MING EE 19 Circult Breakers Short CIFCUIS DARE RESP 20 AS 21 ENGINES P UT 22 37 dl dei RREO O 40 CAORA EE 41 E rol RC Mcr TERRE 42 GA OHA uie ea ups 43 fusa 44 ae a a ME MUEVE RN UU GN dr DU 45 aA deat E pane tad ARS CR Las eiu 46 Multiquip Inc GA Series Generators Manual No GA2009CD MAINTENANCE SPECIFICATIONS GA2 5H GA2 9R GA3 6HA 4 5 GA6HA Engine Model Honda GX160 Robin EX170 Honda GX240 Robin EX270D Honda GX340 Horse Power Engine RPM High 3600 High 3600 High 3600 High 3600 High 3600 Hi speed rated under load Low 2500 Low 2500 Low 2500 Fuel Type Gasoline Gasoline Gasoline Gasoline Gasoline Fuel Capacity 3 2 gal 3 6 5 gal Fuel filter inside tank 300 hrs 100 hrs 300 hrs 100 hrs 300 hrs Sparkplug BPR6ES BR6HS BPR6ES BR6HS NGKB6HS Sparkplug Gap 028 031 024 027 028 031 024 027 028 031 Eng Oil Type SAE 10W30 Eng Oil Capaci
4. N L CN3 m FEI 29 00000 Y 0 75 J L W W G i G y BR 00 75 Engine 5 magneto coil Spark plug E a 000000 un Ko OUD 2 B am B W mod ENGINE _ COLOR CODE 413 o ar COLOR BICIK B BLACK CN CN3 T A BR BROWN 4 coa aga N ke G GREEN c Hs spe P PNK CN4 CN5 CN6 CONNECTOR ARRANGEMENT VIEW FROM INSERTING WIRE SIDE GA 6HEA Generator Wiring Schematic 44 B35 120 240V lt gt 120 N5 5 GN5 W R arm wa TUN B 35 fr Y ass M Battery Starter Fuel cut solenoid G E G W 3 mo NN 011 level switch M VBO D NATION ARMATURE WINDING Fg P N ROTOR ASSEMBLY EXCITATION WINDING EXCITATION WINDING AC VOLTMETER 120 240V RE 1 3 RECTIFER CIRCUIT BREAKER 25A 240 37 5A 120 CON 1 RECEPTACLE L5 20R 20A 125V CON 2 L5 30R 30A 125V CON 3 RECEPTACLE L14 30R 30A 125 250V IDLE CONTROL SOLENOID C Multiquip Inc GA Series Generators Manual No GA2009CD GA 6REA WIRING SCHEMATIC CNS CNGE 0075 R015 le oe GENERATOR 1 o sr dT RE SS ee ps PN 35 P ut ATX 835 SW Men JN Tg DEEE D gt oo ca a sa to oe gt Cc mo x
5. 1 630 3 6 GA 4 5 GA 6 180 GA 97 Battery Charging Windings Resistance Model Ato B 10 GA 6 GA 9 7 14 Inc GA Series Generators e Manual No GA2009CD ROTOR The rotor can not be tested Perform all other test to eliminate all other possible problems before replacing the rotor This brushless designed rotor has integrated diode rectifiers When the rotor rotates in the stator AC voltage is generated in the rotor windings The AC voltage is sent to the diode rectifiers located on the rotor and is converted to DC voltage producing a rotating magnet While the rotating magnet field passes through the main windings located in the stator this produces AC Voltage 120V AC GA Series Rotor Multiquip Inc GA Series Generators Manual No GA2009CD 15 CURRENT FLOW DIAGRAM Excitation Charge Coil Creates AC Diode Rectifier a Converts to DC Cu oe Circuit Breaker NOTE Current flow diagram represents the basic flow in the generator and does not include controls example Idle control switch and slowdown module RC see pg 27 120 240 power switch see operation and parts manual for specific model Receptacle Multiquip Inc GA Series Generators Manual GA2009CD ROTOR REMOVAL TIP Remove and modify existing rotor bolt fig 1 Measure back and cut bolt head off Make a shallow groove on shaft this w
6. OFFOON G rer SE 3 1 BR 0015 R G ga Engine magneto Col a Ly Rel p s E SS 0 3 G W Spark plug E Ignition coil COLOR CODE a 3 p WREE BRR B Back RIRE ET m JL TA BR BROWN Y veuow __ ana V GHT GREEN V_ VIOLET O ORANGE P CN5 CONNECTOR ARRANGEMENT VIEW FROM INSERTING WIRE SIDE CN6 2 R R W R CN2 W R P M P F 909 k 3 5 5 2 B 35 Battery Starter Fuel cut solenoid GR G ns G W pg 4 pos mu i i zz Oil level switch G tre rh 011 alert unit EE nn SYMBOL DESIGNATION ____ ARMATURE WINDING Fg P N ROTOR ASSEMBLY Ex W1 EXCITATION WINDING EXCITATION WINDING ACVOLTMETER 120 240V RE 1 3 RECTIFER CON 4 5 RECEPTACLE 520R GFCI 20A 125V IDLE CONTROL SWITCH OPERATION SWITCH SWA STARTER SWITCH IDLE CONTROL DEVICE IDLE CONTROL SOLENOID CAPACITOR GA 6REA Generator Wiring Schematic Multiquip Inc GA Series Generators Manual No GA2009CD 45 GA 9 7 HE WIRING SCHEMATIC SYMBOL PARTS NAME cL Ar Armature Winding AE Field Winding 16 5 4 Excitation Winding CNI CN2 CN3 AC Voltmeter Rei 5 Rectifier CONNECTOR Viewed at
7. Yellow 2 gt m COLOR CODE WIRE COLOR __ WIRE COLOR FIELD WINDING Em EXW1 2 EXCITATION WINDING BROWN CIRCUIT BREAKER 204 LIGHT BLUE LIGHT GREEN AC VOLTMETER 120V vioLET JORANGE _ Re RECTFER RECEPTACLE 5 20R 20A 125V Generator Engine Wiring Schematic S N 5496762 and below 38 Multiquip Inc GA Series Generators Manual No GA2009CD GA 2 5H WIRING SCHEMATIC S N 5496763 AND ABOVE GENERATOR Spark plug i21 Ragine m gaute toil Operation Switch QUI wait deret seitca ENGINE cea wu ee mm E COLOR CODE eae RE FIELD WINDING UE W WHITE EXCITATION WINDING BROWN Y YELLOW CIRCUIT BREAKER 204 LG LIGHT GREEN __ ____ 123 ORANGE Re RECTIFER CON 1 RECEPTACLE 5 20R 20A 125V CON 2 RECEPTACLE L5 20R 20 125V Generator Engine Wiring Schematic S N 5496763 and above PINK _ WIRECOLOR __ B BLACK R W BROWN Y G GREEN LB V O P Multiquip Inc GA Series Generators Manual No GA2009CD 39 GA 2 9R WIRING SCHEMATIC B20 GENERATOR ERRO 55 B2ON 1 CON2 E CON VB20 B20 O N YO75 J R m CONTROL BOX ENGINE MAGNETO COIL SPARK e PLUG mum en IGNITION cB coL JB
8. SCHEMATICS o TEST PROCEDURES o MAINTENANCE SPECS GA 2009 CD Manual No GA2009CD CALIFORNIA Proposition 65 Warning Engine exhaust and some of its constituents and some dust created by power sanding sawing grinding drilling and other construction activities contains chemicals known to the State of California to cause cancer birth defects and other reproductive harm Some examples of these chemicals are Lead and lead based paint Crystalline silica from bricks Cement and other masonry products Arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals ALWAYS work in a well ventilated area and work with approved safety equipment such as dust mask that are specially designed to filter out microscopic particles Multiquip Inc GA Series Generators Manual No GA2009CD IMPORTANT Read the operator s manual for safety instructions before you attempt to troubleshoot Use extreme caution when troubleshooting power equipment Never start or run power equipment inside a closed area breathing exhaust fumes can kill Basically a tool is an object that enables you to take advantage of the laws of physics and mechanics in such a way that you can seriously injure yourself This service manual is intended to provide information and procedures to safely maintain repair and give a basic under
9. 27 Multiquip Inc GA Series Generators Manual No GA2009CD ENGINE MAINTENANCE From the day that you start your new engine for the first time your engine is on a road to the engine graveyard Only you have control over how long it takes to get there The secret to a long life for your new piece of equipment is called engine maintenance Each time the piston goes up and down or the crankshaft make a revolution a small amount of wear occurs not measurable to you The control you have over this wear determines engine life Dirt entering an engine is the main reason for premature wear Here are some of the things that you have control over that cause premature engine failure Dirt entering the internal parts of your engine Engine oil and filters not changed at regular intervals Engine cooling fins plugged with debris causing overheating Governor linkage sticking or binding causing over speeding Operating the engine with abnormal or excessive loads overheating it Using engine oil types not recommended in your owners manual Using non original parts such as air amp oil filters DUO All of the above problems be avoided with a few simple maintenance practices The GA series Honda and Robin engines are designed with systems built in to prevent such things as dirt from entering the engine or keeping the engine from overheating while it is running These systems work very well but do require periodic maintena
10. Someone using the equipment might receive a shock but it will be a very short duration 1 30 of a second There is a chance that a shock even of this short duration might cause someone to experience a fall or similar injury but electrocution will normally be prevented 3 does not prevent all electrocutions The reacts to electric current flowing from the power line to ground It does not react to current flow between power lines In other words the GFCI will react to someone standing in water and comes in contact with one of the power lines It will not protect someone who is hold the neutral power line in one hand and hot wire with the other 4 A GFCI does not replace fuses or circuit breakers Fuses and circuit breakers are designed to protect equipment and power lines by reacting to excessive current flow normally in the order of 15 to 20 amps 5 GFCI s are designed to protect people by reacting to leakage currents to ground in the order of 005 amps Except in the case of GFCI circuit breaker combinations sold to be installed in building installations they are separate devices performing separate functions Is the ground wire still needed The GFCI will work and perform its function with or without the tool being grounded but the ground system is an important safety feature and should always be maintained and retested on a regular basis Further if a ground fault should occur the leakage current will pass down
11. SP30 GeneratorEnd End Brushless No maintenance required Multiquip Inc GA Series Generators Manual No GA2009CD GENERATOR INSPECTION Before you try to diagnose a generator problem check the engine to make sure that it has been serviced and is operating correctly Perform proper maintenance and tune up procedures before evaluating the generator Check the engine governor to ensure the engine remains at a stable rpm when electrical loads are applied The generator engine s governed rpm isn t as critical for power tools and resistance loads such as electric wire heaters as it is for machines tuned to 60 cycles per second cps current For example if an engine must run at 3 600 rpm it must have a 60 cps current to time it If the current is 61 the engine would run at 3 660 61 cycles x 60 seconds rpm Having a volt ohm meter VOM that accurately measures alternating current is a must when servicing generators The first step in generator troubleshooting is to conduct a gt visual inspection before doing any electrical tests Looking SS the generator over carefully should expose lt Z gt environmental factors that might contribute to the problem Mm i As you remove the generator control box cover and begin your inspection look for the following 1 Rusted or corroded connections An oxidized connection will prevent the circuit from being completed This applies not only
12. at least a half tank of fresh treated fuel in it 3 Run the engine for 10 minutes after treating the fuel so that the stabilizer gets into the entire fuel system 4 Start the unit up every month or two to keep fresh fuel in the carburetor during the season Fuel does evaporate from the carburetor The important thing to understand is that gasoline does not do well when stored in small quantities or open sunlight If you don t use much fuel during the season then try to keep what you have fresh and in a cool shaded area Most small engine shops sell gasoline stabilizer as do hardware stores etc Fuel stabilizer will keep fuel fresh for two years If you already have the stale fuel problem then start by cleaning as much of the old fuel out as possible then with fresh fuel in the tank try starting it If it won t start or runs erratic it s a trip to the repair shop So let s keep that fuel fresh 3l Multiquip Inc GA Series Generators Manual No GA2009CD CARBURETOR CLEANING Honda Before disassembling the carburetor for cleaning a well illuminated clean surface is essential to good carburetor cleaning The best cleaner for the carburetor is a spray type carburetor cleaner The pressure in the can works to dislodge dirt and the chemicals aren t as caustic as dip tank cleaners NOTES 1 A carburetor is not repairable if it has a damaged body casting 2 Carburetor cleaner will not clean water corrosion 1 Begin by r
13. can feel the resistance of compression when pulling the rope Electric start models can be a little harder to tell without the right equipment Keep in mind that you have to obtain a significant amount of engine speed when you pull the rope or you will not develop enough compression A low battery can cause the same problem When checking compression use a compression gauge Ideally you want to see 85 pounds or more after a couple of pulls Low compression can be caused by a worn engine or burnt or sticky valves Stale fuel from setting during storage can cause even a new engine to have a valve stick in the open position You must have a good spark to fire the fuel mixture once it is in the cylinder A good way to test for spark if you don t have a tester is to take an old spark plug and cut the electrode off so the spark has to jump from the center to the side of the plug Lay the plug on the engine so that it can ground and spin the engine If you don t have good spark check for a faulty switch or disconnected wire before condemning the Magneto The spark must be steady and a bright blue color The engine must receive a proper mixture of fuel and air so that the spark can ignite it and start the engine Besides the fuel and air the engine governor must open the carburetor throttle to allow the mixture to reach the cylinder A stuck throttle shaft can cause a no start so check the simple things first If you suspect that the carburetor is not supplyi
14. e Spline hollow channel e Resistance device that controls the strength of the current e Ground electrode current device that unites the electrodes e Spark plug gap space separating the current conductors e Center electrode central current conductor e Gasket spot where two part join together e Spark plug body metal part of the spark plug e Hex nut hexagonal piece of metal used to screw in a spark plug 25 Multiquip Inc GA Series Generators Manual No GA2009CD SPARK PLUGS Diagnostic Chart NORMAL Light brown tan or grey firing end DRY AND WET FOULING Fouling either dry top matt black sooty or wet bottom gloss black sticky OVERHEATING When overheating occurs deposits which have accumulated on the insulator tip may melt and give the tip a glazed appearance DEPOSITS Insulator nose and electrodes encrusted with a build of deposits usually off white in color LEAD FOULING Lead deposits on the insulator nose These are usually a yellowish brown in color BREAKAGE Physical damage to the insulator nose NORMAL LIFE Growth of the plug gap during a plug s working life is normal However the increased gap will mean the spark is less efficient and hence fuel is wasted and strain is put on the ignition system ABNORMAL EROSION This is accelerated growth of the gap MELTING The electrode surface will probably appear lustrous and uneven EROSION COROSION OXIDATION The s
15. the ground wire and trip the GFCI without the operator receiving a shock at all So YES please retain the ground system How can we be sure the GFCI is working There are two methods of testing GFClI s All GFCI s sold in this country are provided with a test and reset button During maintenance intervals simply plug a tool in to the GFCI and press the test button The tool should turn off and the reset button should pop out Depressing the reset button should restart the equipment This is an adequate test for most applications To measure the actual trip current of a GFCI requires a GFCI tester The tester allows you to read the actual GFCI trip current on a meter identifying the GFCI s that do not operate within the required four to six milliamp range One test that should not be performed on GFCI s is a high load test The GFCI contains small electronic parts that are damaged if high voltages are applied to them DO NOT test any on a HI POT dialectic or Doyle type tester 18 Multiquip Inc GA Series Generators Manual No GA2009CD FLASHING THE FIELD Generator Field Flashing The GA series generator DOES NOT require flashing the field as it is equipped with a self excitation lamp coil The lamp coil behind the engine flywheel produces AC voltage that is then converted to DC voltage by a rectifier in the control panel This DC voltage is used to assist the stator in creating the needed magnetic field to complete the ge
16. to the major cables externally but also to the electronic control devices internally Multiquip Inc GA Series Generators Manual No GA2009CD GENERATOR INSPECTION continued Carbon flash deposits around the 120V AC and 240V AC receptacles This will indicate whether the device that was plugged into the generator shorted out the receptacle The device may have shorted the generator to ground and caused a carbon flash when the plug prongs touched the receptacle Signs of overheating Discoloration and a burnt smell should be noticeable inside the generator Look to see if the windings turned black The insulative sprays that manufacturers use to insulate the windings may vary in color from shades of reddish brown to light brown to dark brown so try to compare the color to that of a new unit Wire insulation that is heat hardened Fabric and plastic insulation hardens over time due to heat exposure and overheating Long term heating should be more uniform A short excessive heat cycle may have less hardening and burning at the unit s outer perimeters and excessive heat signs toward the center or heat source Insects that have developed a community inside the generator Their nests and debris can cause electrical shorts Generators left out in the elements such as for running water wells provide a nice home for critters such as spiders wasps and mice Loose bolts screws and fasteners This condition will either prevent full t
17. with sludge oil caused by lack of maintenance can cause an oil level switch to stick Checking oil level prior to running the engine is good maintenance practice as well as changing engine oil frequently am cce al body with an jet ES 1 Hold the switch in its normal position The ohmmeter 5 NS J should read zero resistance 2 Hold the switch down The ohmmeter should read infinity resistance 3 Inspect the float by dipping the switch into a AS container of oil The ohmmeter should go from zero sl to infinity as the switch is lowered 34 Multiquip Inc GA Series Generators Manual No GA2009CD IGNITION COIL Robin The only service or adjustment to the ignition coil is the air gap between the coil and the flywheel The only time air gap needs to be set is if it has been removed or tampered with There are adjustment slots on the coil to allow for up and down movement on the coil NOTE ohmmeter resistance data for the Robin ignition coil is N A at time of publishing Air Gap Adjustment Specification EX amp EH series engine 0 3 0 5 mm 012 020 in THICKNESS z IGNITION COIL 35 Multiquip Inc GA Series Generators Manual No GA2009CD OIL LEVEL SWITCH Robin The oil level switch is designed to shut the engine off in the event the oil level drops The oil level switch is mounted to the engine crankc
18. A 125V W wurE MEL L BLUE WHITE RECEPTACLE L14 30R 30A 125 250V BR BROWN YELLOW MAAA 4 RECEPTACLE 520R 20A 125V GR GRAY LG LIGHT GREEN EE ES FULL POWER SWITCH T T CN4 CN5 IDLE CONTROL SWITCH PERATION SWITCH CONNECTOR ARRANGEMENT VIEW FROM INSERTING WIRE SIDE Generator Wiring Schematic GA 3 6HA Multiquip Inc GA Series Generators Manual No GA2009CD 41 GA 4 5RA WIRING SCHEMATIC CN 3 1 SW2 CN4 5 CN3 R ER to R rm ae WV 1 No G W R W cnt 2444 4342 GENERATOR YMBOL DESIGNATION Ar ARMATUREWNDING EXCITATION WINDING c EXCITATION WINDING ees uem e sw lt O x 4B 6B gt PLUG ENGINE MAGNETO i 05555555500 B CON 1 RECEPTACLE L5 20R 20A 125V CON 2 RECEPTACLE 15 308 30A 125V B Y RECEPTACLE 114 208 20A 125 250V e G CON 4 RECEPTACLE 5 20R GFCI 20 125V FULL POWER SWITCH SW2 IDLE CONTROL SWITCH OPERATION SWITCH IDLE CONTROL DEVICE IDLE CONTROL SOLENOID CONTROL BOX GROUND TERMINAL CAPACITOR i m R RESISTOR 2 COLOR CODE E __ WIRE COLOR BLACK RIRED 1 2 CM BR BROWN Y YELLOW GREEN ARRANGEMENT VIEW FROM INSERTING WIRE SIDE V VIOLET O ORANGE
19. Winding Side Receptacle 120V 240V ___ T 2 Receptacle 240 Bs cu i Receptacie 120V GFCI gt ret mea Circuit Breaker for MAIN B Rodo mf gt L sy _ from Bi Circuit Breaker 120V 240V 30A from SW3 Swi 5 F2 B2 Circuit Breaker 240V 20A a Circuit Breaker 120V 30A T Circuit Breaker 120 204 GENERATOR MLECS S idle Control Switch 1 wit Operation Switch Start Switch RC Control Device NVa9VIG 5 Ry Relay FiF2 Fu se Condenser WENN MN EU en Ciee er ero pm Eta E puat i Sl T LG fuir AREEN 1 v Moer ORANGE SORTE DS Multiquip Inc GA Series Generators Manual GA2009CD 46 Matin ice 800 421 1244 What Department do need Parts Salles Orders need to order a part need help looking up a part need a price on a part Parts vechnicall need a parts breakdown sent to me Why doesn t this part fit my machine why won t it work received the wrong part need a part and don t know what model have Salles Complete Products Accessories am interested in purchasing a product and would like some information Can purchase that separately would like to purchase a product v eclimiical Sport need
20. aker can be reset either manually or automatically to resume normal operation NOTE always place the main circuit breaker in the OFF position prior to starting the engine SHORT CIRCUITS A short circuit sometimes abbreviated to short or s c in an electrical circuit is one that allows a current to travel along a different path from the one originally intended The electrical opposite of a short circuit is an open circuit which is an infinite resistance between two nodes It is common to misuse short circuit to describe any electrical malfunction regardless of the actual problem Damage from short circuits can be reduced or prevented by employing fuses circuit breakers or other overload protection which disconnect the power in reaction to excessive current Dude why such long wires Don t want any short circuits 20 Multiquip Inc GA Series Generators Manual No GA2009CD MEG OHM METER Good Insulation Every generator winding motor and extension cord have electric wire that is covered with some form of insulation Electrical wire is normally copper and it is a good conductor of the electric current that powers motors The wires insulation must be the opposite of a conductor it should resist the current and keep it in its path along the conductor The purpose of the insulation around a conductor is similar to that of pipe carrying water Pressure on water from a pump causes flow along the pipe If the pipe was
21. ase clogged or stuck oil level switch will allow the engine to run without or with a low oil level which can cause damage to the engine An engine with sludge oil caused by lack of maintenance can cause an oil level switch to stick Checking oil level prior to running the engine is good maintenance practice as well as changing engine oil frequently Pa OIL SENSOR 5 L SENSOR Construction and Operation The oil sensor is composed of the float permanent magnet incorporated into the float and oil sensor In accordance with the oil level the float moves up and down Permanent magnet When the oil is at the upper level the float moves up Lead switch When the oil is at the lower level the float moves down The permanent magnet is closed to the lead switch and the lead switch is activated by the magnetic force Magnetic force 36 Multiquip Inc GA Series Generators Manual No GA2009CD ENGINE MANUFACTURERS CONTACT INFORMATION ENGINES Honda ENGINGS 678 339 2600 VVGD SING www honda engines com RODIN AMG 630 350 8200 5 www robinamerica com 37 Multiquip Inc GA Series Generators Manual No GA2009CD GA 2 5H WIRING SCHEMATIC S N 5496762 AND BELOW GENERATOR STATOR P Ground terminal Ignition Switch Black
22. comes the oil Oil that is to thin because of gasoline dilution can cause all kinds of leaking problems and smoking conditions as can water in the crankcase which causes foaming In the summer heat many engine manufacturers recommend 30W oil Crankcase pressure can be a big problem and can have more than one cause Many times it takes a trained technician with the right equipment to figure it out Not all oil leaks are serious to repair It could be as simple as a loose drain plug loose oil fill plug or overfilled crankcase Check it out determine the cause and then make an intelligent decision on whether to replace the unit or have it repaired Most of all check the oil level often 29 Multiquip Inc GA Series Generators Manual No GA2009CD MY ENGINE WON T START pull the rope and nothing happens now what That s a fairly simple question but it may require more than a simple answer Let s take a look at the situation from a service technician s point of view Air cooled engines need three basic things to run Take away any of one of the three and it s no start time So let s review these things and see if we can simplify that question 1 The engine must be able to develop compression 2 The engine must have ignition better known as spark 3 The engine must receive fuel and air through the carburetor If the engine cannot develop enough compression to draw fuel and air from the carburetor then it cannot run Normally you
23. e a varnish problem If you have a water corrosion problem which looks like a white powder rust you may want to just replace the carburetor Carburetor cleaner will not clean water corrosion Do not take the carburetor totally apart until you have the repair kit You do need to determine if you need a new float bowl or other parts not included in the repair kit Most repair kits include a needle valve and all gaskets 23 Multiquip Inc GA Series Generators Manual No GA2009CD ANTI BACK FIRE SOLENOID The anti back fire solenoid is sometimes confused with a fuel shutdown solenoid A fuel shutdown solenoid on a diesel engine stops the fuel supply to the engine and is the main component to shut the engine down On a gasoline engine the engine is shutdown by grounding the ignition coils secondary winding During engine run down as the piston travels downward in the cylinder vacuum is still being created in the carburetor This vacuum continues to drawn raw fuel into the engine and to the hot muffler Since the fuel does not combust in a controlled burn without the spark ignition the fuel can then ignite from hot spots in the muffler This explosion or uncontrolled burn during engine run down is called back fire The fuel will continue to be drawn through the engine until the engine comes to a complete stop The anti back fire solenoids job is to prevent the fuel from being drawn into the cylinder during engine run down Anti bac
24. effects which can cause it to fail These causes can be mechanical damage vibrations excessive heat or cold dirt oil corrosive vapors and even moisture from humidity During the life of a conductor s insulation all of these causes are at work in combination with electrical stresses If a pin hole or even a crack in the insulation develops moisture and foreign matter can penetrate the surfaces of the insulation This provides for a low resistance path for leakage current Once the insulation has begun to deteriorate all elements of causes tend to combine until excessive current leakage is allowed through the insulation At times the drop in insulation resistance can be sudden such as occurs if the equipment is flooded Normally insulation resistance drops gradually and gives plenty of warning if checked as a preventative maintenance Periodic checks would allow planned reconditioning prior to operation failure and the ability to remove from service if the insulation resistance became dangerously low Equipment with no checks may not only be dangerous to touch with voltage applied but also be subject to total burn out A failed insulator becomes a partial conductor For more information on Meg Ohm Meters visit our website at www multiquip com look at Technical Information bulletins under Meg Ohm Meters 21 Multiquip Inc GA Series Generators Manual No GA2009CD ENGINES The GA Series generators are powered by four cycle engines and are
25. emoving the float bowl If the inside is not gummed or corroded you can remove the jet and use carb cleaner and a jet cleaner to clean it 2 f contaminants are found it is probably a good idea to drain and flush the fuel tank 3 Remove the main jet and clean any dirt and or varnish from the jet and float bowl 4 Use a cabinet screwdriver to remove the main jets to reduce the possibility of damaging the threads This is what they re supposed to look like Each hole is precisely sized and shaped and your goal is to clean them out without reshaping them Here s a cross section of a jet The orifice has E ip transitions for fuel to enter and exit with muc mac RAK Carburetor jets are brass and they need to be treated with care and respect minimum of turbulence Here s the same jet clogged by a winter s worth of gasoline plaque Not much gas will flow through good technician will select the correct jet cleaner to fit this jet size and gently clean out the deposits Just remember that the result of your effort should be a jet thats clean as new without any modification to its shape And remember there are passages in the body that need to be clean too Spray cleaner through all the air and fuel passages until cleaner flows freely And this is what the jet will look like So much for the smooth transitions REMEMBER EYE PROTECTION 22 Multiquip Inc GA Series G
26. enerators Manual No GA2009CD IGNITION COIL Honda The only service or adjustment to the ignition coil is the air gap between the coil and the flywheel The only time air gap needs to be set is if it has been removed or tampered with There are adjustment slots on the coil to allow for up and down movement on the coil The primary and secondary coil can be tested by inspection see below ae P Air Gap Adjustment Specification GX Series 160 240 340 610 0 4 0 2 mm 15 007 in Ignition coil Flywheel Inspection Remove and isolate the ignition coil to be tested Primary side Measure the resistance by attaching the ohm meter lead to the ignition coils primary black lead while touching the other test lead on the iron core Secondary side Measure the resistance by removing the spark plug cap and touching one test lead Resistance Specification to the spark plug lead wire while touching 0 8 1 00 the other lead to the iron core Resistance Specification 5 9 7 10 33 Multiquip Inc GA Series Generators Manual No GA2009CD OIL LEVEL SWITCH Honda The oil level switch is designed to shut the engine off in the event the oil level drops The oil level switch is located inside the engine crankcase clogged or stuck oil level switch will allow the engine to run without or with a low oil level which can cause damage to the engine An engine
27. es excitation voltage 2 Excitation see page 12 e AC Voltage is produced from magnets which are located on the flywheel of the engine As the magnets pass a set of windings charge coils beneath the flywheel they produce alternating current AC 3 Diode Rectifier AC DC see page 13 e A full wave diode rectifier converts the AC voltage to DC voltage 4 Stator see page 14 e The DC voltage is sent from the full wave diode rectifier via wires J amp K to excitation winding which are located in the stator This produces a magnetic field in the stator 5 Rotor creates AC and is converted to DC see page 15 e Excitation windings on the rotor pass through the magnetic field of the stator creating AC voltage e AC voltage in the rotor is then converted to DC voltage by use of full wave diode rectifiers mounted on the rotor producing a rotating magnet 6 AC is produced e The rotating magnetic field passes through the main windings located in the stator U1 V1 U2 and V2 These windings provide AC voltage to the receptacles through a circuit breaker Multiquip Inc GA Series Generators Manual No GA2009CD TROUBLESHOOTING The following is a few basic scenarios If you don t see your situation here try checking the Technical Information bulletins our website www multiquip com or contact one of our Technical Support coordinators at 800 421 1244 SYMPTOM POSSIBLE PROBLEM SOLUTION Low voltage Eng
28. h is closed the circuit to the anti back fire solenoid is complete as is the ignition coil circuit completes direct to ground With the operation switch in the off position and the circuit now closed power flows through the anti back fire solenoid coil creating a magnetic field The magnetic field influences the pintle in the solenoid causing it to extend into the carburetors fuel orifice Testing the Anti Back Fire Solenoid Testing the solenoid can be done by applying DC voltage The use of a 12V battery or 9V battery can be used Place the positive lead from the battery to the solenoid lead and a negative lead from the battery to the solenoid case or in two wire type solenoids connect to the negative lead A properly functioning solenoid will have a sharp distinct movement and normally have an audible clicking sound when the power is applied 24 Multiquip Inc GA Series Generators Manual No GA2009CD SPARK PLUGS A spark plug directs a high voltage charge to the spark gap to ignite the charge in the combustion chamber spark plug terminal spline center electrode insulator hex nut spark plug gasket spark plug body 41 spark plug gap ground electrode e Spark plug electric part generating sparks to ignite an internal combustion engine e Ceramic insulator pottery support for the parts that conduct electricity e Terminal place where a current conducting wire is attached
29. ill allow you to thread the rotor bolt into the engine shaft using a flat head screw driver fig 2 NOTE a replacement bolt will be required for re assembly Save this modified bolt as a tool for future repairs Measure 3 4 from the bottom of the hex head and cut the set bolt P Cut a shallow groove here for a flat head screwdriver Figure 2 A three 3 4 recess of the set bolt into the rotor assembly shaft P Set Bolt Field Windings Not Shown Engine Rotor Assembly Shaft Install a 12mm 1 5 hex head bolt into the end of the rotor assembly shaft fig 3 Torque the down until the rotor separates from the engine shaft 17 Multiquip Inc GA Series Generators Manual No GA2009CD GFCI What is a Ground Fault Circuit Interrupter A ground fault circuit interrupter GFCI is a small device that compares the amount of electricity flowing to and from the tool used on the generator If there is a difference of more then 5 milliamps 005 amps the GFCI opens the circuit What are the limits of a GFCI There are several limitations that you should be aware of 1 A GFClis not a tool tester The GFCI does not have the sensitivity detection circuits nor the polarity reversal features needed to perform the function of a tool tester The GFCI makes an excellent life protection device but a very poor tool tester 2 does not prevent shocks The GFCI is only operated when a ground fault occurs
30. ime service or give intermittent service depending on the situation Problems in quick disconnect connectors These are often overlooked A quick disconnect could have one to a dozen male female connections These are often inside some plastic or rubber cover that prevents you from seeing any possible corrosion In electrical troubleshooting always unplug and plug in all connectors three times to produce a freshly scraped metallic surface for good electrical contact If the unit works after that soak the connectors first in vinegar for a few minutes then in a baking soda solution Rinse the unit thoroughly with distilled water This acid base wash will remove corrosion but not oil or grease Blow dry thoroughly If you know how to use an ohm meter check for zero ohms on all connections Spray the contacts with an electrical insulative spray before reassembling them Multiquip Inc GA Series Generators Manual No GA2009CD GENERATOR INSPECTION continued 8 Crimp connections These connections have several problems Even though they re widely used they represent the least professional fix First they come loose as the machine vibrates and lose consistent quality contact Second because dissimilar metals are in contact a galvanic cell is set up that result in corrosion when moisture is present 9 Solder joints that have cracked or broken loose This condition occurs much less frequently than crimped connections and basicall
31. ine speed to low Adjust to specification Defective excitation lamp coil Check coil see pg 12 Check all wire connections and control Loose wire connection box wiring Low or no voltage engine RPM is good Defective diode rectifier Check diode rectifier see pg 13 Leakage breaker malfunction Check circuit breaker GFCI circuit breaker is open Reset GFCI circuit breaker Stuck idle control solenoid Check or replace solenoid Defective Idle control switch Check or replace switch from low to high speed Defective diode rectifier Check diode rectifier see pg 13 Defective slowdown unit Check slowdown unit see pg 27 Engine does not accelerate High speed out of adjustment Adjust to specification Check governor is adjusted correctly Governor out of adjustment and linkage is not obstructed Check carburetor is adjusted correctly Carburetor out of adjusiment and tension spring is not obstructed Engine does not idle down all the way Check solenoid is in correct position and working properly Idle control solenoid Check power connection from lamp coil and rectifier 10 Multiquip Inc GA Series Generators Manual No GA2009CD TROUBLESHOOTING For more on engines see engine manufactures manual or you may contact one of our Technical Support coordinators at 800 421 1244 SYMPTOM POSSIBLE PROBLEM SOLUTION Nas e uis ET Turn fuel valve to the On position position or partially closed Engine sw
32. ing above Possibly due to age engine standing for a long time without use This is due to chemical reaction between the nickel alloy electrodes and the lead compounds in petrol Multiquip Inc GA Series Generators Manual No GA2009CD SLOWDOWN MODULE RC The slowdown module RC senses amperage usage and relays a signal to the idle control solenoid The RC is powered by a lamp coil located behind the flywheel of the engine in the same location as the excitation lamp coil see page 11 AC voltage is produced from the lamp coil and sent to a diode rectifier The diode rectifier converts the AC to DC and supplies DC voltage to the RC for operation When the idle control switch is in the on position the RC is activated and sends voltage to the idle control solenoid causing the solenoid to pull the engine throttle to idle speed lower RPM Generator output wires pass through the center of the RC before reaching the receptacles When voltage is used from one of the receptacles the RC senses the activity and cuts the voltage to the idle control solenoid thus allowing the engine to return to high speed high RPM Slowdown module Checking the Slowdown Module RC Unplug the connector and take an Ohms reading engine off Red to White 11 Ohms White to Red Infinity Green to Black Infinity Black to Green 50 Ohms
33. itch is in the Off position Fill crankcase to proper oil level or Low oil level place generator on level surface Set switch to the On position Check fuel filter and ensure fuel flow to carburetor is sufficient Also check fuel Fuel delivery system tank for contaminated or stale fuel Generator will not start or replace if necessary starts and runs rough Flooded Wait 5 minutes and re crank engine Carburetor inadequate air supply Intake valve stuck open or closed Inspect valves and valve clearance Check condition of spark plug and No spark ignition coil Inspect wires to the on off switch Engine backfires Check solenoid see pg 24 solenoid Engine speed is to low Raise engine speed to rated RPM Check connected device amperage is application sufficient Engine runs good at no load but bogs down Short circuit in a connected D when loads are applied pine isconnect shorted electrical device Check or replace clogged air fiter or replace Check or replace clogged air fiter air filter Check or replace clogged air filter Generator is overloaded Carburetor inadequate Ensure carburetor jets are not clogged 11 Multiquip Inc GA Series Generators Manual No GA2009CD EXCITATION LAMP COIL How to check the coil AC voltage is produced from charge coils and permanent magnets which are located on the flywheel of the engine Check voltage output w
34. ith engine running Disconnect the charge coil leads by removing a black plastic protector sheath at the engine wiring harness Lamp coil Example engine shown Honda GX series One set of charge coil wires is for excitation One set is for the idle control slowdown WHITE GREEN Ge ED kg WHITE DONE d Lamp Coil AC Nominal readings 10 engine speed 3600 RPM no load Output Wires Voltage AC Engine Green to White 22 Volts Honda GX Series Green White to Green White 23 Volts Robin EH Series Green White to Green White 23 Volts Robin EX Series 12 Inc GA Series Generators Manual No GA2009CD DIODE RECTIFIER AC DC How to test the Diode Rectifier There are two ways to check the diode rectifier The Diode Rectifier supplies DC voltage to the stator To check Diode voltage output disconnect the amp K wires at the harness that are connected to the stator with yellow wires The two yellow wires will be connected with quick disconnect connectors Diode Rectifier Output DC Nominal readings 10 engine speed 3600 RPM no load Output Wires Voltage DC Model Yellow to Yellow 12 18V DC ALL Yellow Wires Diode Rectifier Continuity To properly check continuity you must disconnect un solder or isolate the leads connected to the Diode Check for continuity no continuity as
35. k fire solenoids can function in two ways as a power to run or a power on shutdown The Honda engine solenoids used on Multiquip GA series generators operate on a power to shutdown The anti back fire solenoid works by electromagnetism and a spring During normal engine operation the spring holds the pintle inward With the pintle held in the fuel can pass into and through the carburetor During engine shutdown the solenoid becomes energized With direct current passing through the coil of the solenoid a magnetic field is created This magnetic force in the coil overcomes the spring force holding the pintle inward The pintle now is pushed outward by the magnetism blocking the fuel jet orifice in the carburetor The blockage of this orifice prevents fuel from being drawn into the engine during rundown Anti Back Fire Solenoid _ Summary of Circuit Function The power source for this circuit comes from the engine accessory lamp coil When the flywheel containing magnets rotates past this lamp coil an alternating current is induced into the coil The alternating current flows to a full diode rectifier located in the control panel This converts the alternating current into a useable direct current Direct current is needed to form a magnetic field in the anti back fire or fuel cut solenoid Once converted to a direct current power flows to the main operation switch When the switc
36. manufactured by Honda and Robin The next few pages are tips and instructions on basic maintenance for the engines used on the GA Series generators The following information is to provide the service technician with a base level of knowledge on engine maintenance For more on engine repairs see engine manufacturer s service manual INDEX Engine Part Details S edo TU UT 23 gt JAntl Back Fire ues aua 24 S E A 25 26 te 27 Engine Maintenance gt Engine NIGIMEN ANCE ina Ibex dims ee 28 B OIN CARSS ss CR 29 gt MY ENGINE Von ESTAR ES pred ua uud oett ac 30 A oe FUE ETE 31 HONDA gt gt 32 dra ET pP 33 Oil Eevel SWC nest diese RASE Run 34 M es ES e 35 Z Olevi _ ________ 36 Engine Manufacturer s Contact Information ue 37 22 Multiquip Inc GA Series Generators gt Manual No GA2009CD CARBURETORS Idle mixture screw Idle speed screw Choke plate Throttle plate Fuel air mixture flows to engine Fuel filter Float Float bowl Jet Pedestal Carburetor and fuel problem
37. nce to be performed on them Start out right by reading your owners manual before you operate the engine Here s a list of things that you can do to give your engine a long life span 1 Change the oil and filter at recommended intervals more frequently when dirty conditions exist use recommended oil 2 Replace the air filter whenever it becomes dirty cleaning of paper filters is not recommended 3 Clean your engine regularly making sure the cooling fins are clean of debris use compressed air 4 Use clean fresh fuel and store it with a fuel additive when you put it away when not in use leave the tank at least half full with fuel stabilizer 5 Always use original equipment parts to insure a quality fit every time an improper air filter can ruin an engine in a few minutes of dirty operation These maintenance procedures are not complicated and can be done easily by most end users Besides the normal procedures listed above always be aware of any change in your engines operation or unusual noises or vibrations Have these checked immediately if you don t know what s causing them Check for any loose bolts and make sure the governor linkage is not binding Prevention is better then cure 28 Multiquip Inc GA Series Generators Manual No GA2009CD OIL LEAKS These words cause many people to gasp and think about trading in their equipment Oil leaks can be a very misunderstood problem In many cases the problem may be mino
38. nerator process Generators that require flashing the field this condition is usually caused by insufficient residual magnetism in the exciter and generator fields In some cases a generator that has been out of service for an extended period may lose its residual magnetism and require flashing Residual magnetism is restored by flashing the field thereby causing a current surge in the generator This type of generator relies on the residual magnetism stored in the armature to produce the needed voltage to create the magnetic field to complete the generator process When residual magnetism is not present this is known as generators that will lose their magnetism or go flat The GA series generator does not rely on stored residual magnetism to create a magnetic field thus eliminating the need to flash the field If the GA series generator has low or no AC voltage output it is not due to loss of residual magnetism See the troubleshooting section in this service manual for low or no voltage 19 Inc GA Series Generators e Manual No GA2009CD CIRCUIT BREAKERS circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit lts basic function is to detect a fault condition and by interrupting continuity to immediately discontinue electrical flow Unlike a fuse which operates once and then has to be replaced a circuit bre
39. ng fuel you can give a small squirt of starting fluid into the air intake usually with the air filter removed and see if the engine fires momentarily If it does then you probably have a plugged carburetor Once again we are back to the stale gasoline problem Even a good engine may not start on stale gasoline so stick your nose in the tank and take a whiff if you come out gasping for air then you d better get rid of that fuel If you resolve the three problems above the engine will run usually In most cases one of these three items will be at fault So next time your unit will not start make a quick check E 5 gt Ne YU SS Lt CD 30 Multiquip Inc GA Series Generators Manual GA2009CD STALE FUEL Every year during hurricane season we hear the same story It ran good last year If you take the gas cap off and the odor almost knocks you off your feet What has happened is the small amount of gasoline in the tank and carburetor has gone bad and in many cases turned into a varnish This varnish clogs the fuel metering ports and causes the engine to run erratic or not at all What s the best thing to do to prevent this from happening Run the tank dry before putting it away No Not a good idea the small amount of fuel left in the system can turn to varnish as it dries up Here s what is recommended 1 Treat the last tank of fuel with a gasoline stabilizer 2 Always put the engine in storage with
40. r and easily repaired Usually by the time you get around to checking out an oil leak you have oil everywhere and it s impossible to tell where it is coming from The best thing to do is start fresh and clean the unit up so you can get an idea where the fresh oil is coming from A few questions you need to ask yourself to help determine the problem Does the unit leak oil when it is not running Where is the highest point where you see fresh oil Does the Engine blow oil or smoke bad when running Is the engine over full on oil or is the oil thin Is the engine leaking from more than one place when running n m We probably missed some questions but these will give you a good start So let s review them If the engine is leaking while setting This is usually caused by a loose drain or fill plug bad gasket oil seal or possibly a crack or pinhole in the crankcase The latter would normally have showed up when the unit was new though How high on the engine is the fresh oil Could it possibly be a blown head gasket or loose oil fill plug Does the engine smoke badly It could mean internal wear or possibly crankcase pressure All modern engines run with a slight vacuum in the crankcase This is maintained by the crankcase breather valve built in to the valve cover If this valve is not functioning you can be building a pressure in the crankcase Many engine gaskets seals and governor shafts are not designed to handle a pressure so out
41. s can fall into several categories and it is important to determine what is happening before proceeding with a rebuilt on the carburetor If the carburetor is leaking fuel especially while setting or just not getting fuel you may have a contaminated fuel problem You should look first at the fuel in your tank for any signs of dirt water rust or varnish build up Before you consider rebuilding or replacing the carburetor you must have good clean fuel flow to it When possible install the proper fuel filter for your application Non fuel pump engines use a different filter then fuel pump engines in most cases It does no good to clean a carburetor and put contaminated or old fuel back into it In some cases a rusty or badly varnished fuel tank will need to be replaced Here s a list of things to think about when evaluating whether to rebuild your carburetor Does the engine run well under load does it idle ok does the governor hunt Is the carburetor in usable condition throttle shafts linkages loose After removing the bowl do you have water corrosion varnish or dirt Is there any sign of warpage on the mounting surfaces Is the float and bowl ok are they pitted and possibly leaking Is the carburetor leaking fuel while just setting possibly into the crankcase After evaluating the questions above you will be able to make a more informed decision on whether to rebuild or replace your carburetor Clean up is important especially if you hav
42. shown below AC wire B 4 DO wire DO wire D AC wire A fo B Continuity B to At Continuity A fo Df No Continuity D to A Continuity G fo B Continuity B to No Continuity O to D Continuity D to G 5 No Continuity 13 Multiquip Inc GA Series Generators Manual No GA2009CD STATOR How to check the Stator The GA series stators have output wires that lead from the inner stator windings which provide 120V AC output and lead to a circuit breaker then to the receptacles and two excitation wires labeled J amp K that receive 12V DC from the diode rectifier Some stators will have 2 extra wires for battery charging purpose Stator Windings Voltage AC Nominal readings 10 engine speed 3600 RPM no load Output Windings Voltage AC Model U1to V amp U2to V2 120V AC ALL gt gt gt NOTE Winding resistance specifications taken 209 68 F lt lt lt O Resistance Nominal readings 10 engine off Output Windings Resistance Model UtoV 60 GA 2 5 2 9 U1to V1 250 GA 3 6 GA 4 5 U1 to V1 160 GA 6 UtoV 40 GA 9 7 Excitation Windings Resistance Model JtoK 1 46 O GA 2 5 GA 2 9
43. specifications for machine need a repair guide or information on how to repair my product need a daigram or schematic need repair specifications for an engine that s on an MQ product Where can get my product serviced or repaired How operate my product Does this machine come with Will this machine handle the job I m trying to do What type of material can use with my product What product do need for the type of job am doing have a serial number and need info on model purchase date who was the machine sold to Is my machine still under warranty Field Service My machine is down and need immediate assistance My machine is damaged can get an approval for warranty Who can talk to too come look at my machine How can get training on how to repair MQ products Field Service Mgr Coverage Area Don Petry AK CA NV HI OR WA Nathan Hall AZ CO ID MT NM UT WY Roger Gillis AL AR FL GA LA MS NC SC TN Tom Girard IA IL IN KS MI MN MO NE ND OK SD TX WI Tommy Tucker CT DE KY ME MA MD NH NY NJ OH PA RI VA WV 47 Inc GA Series Generators gt Manual No GA2009CD N a MULTIQUIP Corporate Headquarters o Multiquip Inc 18910 Wilmington Ave Carson Ca 90746
44. standing of service techniques for the GA series generators You must be familiar with the operations of the GA series generator before attempting to troubleshoot or make repairs Basic operating and maintenance procedures are described in the operation and parts manual supplied with the generator Use the supplied manual to order replacement parts If you are missing the operation and parts manual please contact Multiquip Inc to order a replacement or you may visit our website at www multiquip com For your safety and the safety of others carefully read understand and observe all instruction described in this manual CONSTRUCTION STARTS HERE EE ES THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON GA SERIES GENERATORS MANUFACTURED UP TO THE TIME OF PUBLICATION MULTIQUIP INC RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE Multiquip Inc GA Series Generators Manual No GA2009CD VVVVVVVV CONTENTS Maintenance 5 IL T Us 6 8 How AC Voltage is 2 7 7 7 7 7 2 24 TROUBLESHOOTING G casca PR 10 11 E NCIA a 12 13 SLO NR
45. to spring a leak you d waste water and lose some water pressure With electricity voltage is like the pump pressure causing current to move along the copper wire As with the flow of water in a pipe there is resistance to flow of current but it is much less along the conductor than through its insulation It should be noted that no insulation is perfect meaning has infinite resistance so some electricity does flow along the insulation or even through it to ground The current passing through the insulation may only be a millionth of an ampere one microampere but it is the basis of insulation testing A higher voltage tends to cause more current leakage through the insulation This current leakage would become a problem if the insulation has deteriorated All this leads us to determine what is good insulation Under normal conditions good means a relatively high resistance to current Or it can also be stated that a good insulation has the ability to keep a high resistance A suitable way of measuring resistance can tell us how good the insulation is Also if regular insulation measurements are made you can track trends towards its deterioration INSULATION ELECTRICAL i LEAK VOLTAGE COPPER WIRE gt gt mm RESISTANCE Ibi A Causes of Bad Insulation When generators welders and electric motors are new the insulation should be at its highest level of resistance During equipment use insulation is subject to many
46. ty 6 qt 1 1 qt 1 1 qt 1 1 qt 1 1 qt Eng Oil Service 100 hrs Engine Compression 85 121PSI 85 121 PSI 85 121 PSI 85 121 PSI 82 102 PSI Valve Intake 006 Intake 003 Intake 006 Intake 003 Intake 006 Clearance Cold Exhaust 008 Exhaust 005 Exhaust 008 Exhaust 005 Exhaust 008 AiFites 50hrs 100hs 100 hrs Generator End Brushless No maintenance required Always review and follow detailed maintenance amp service instructions as provided in the equipment manual GA6HEA GA6REA 9 7 Engine Model Honda Gx340 RobinEH36 000 000 Horse Power n n w DE naso Hi speed rated under load Low2500 Low2500 Low2500 Fuel Type Gasoline Gasoline Gasoline o o Fuel E 5 gal 5 gal 10 gal Fuel filter insidetank 300hrs 10 8 30h 0000 Sparkplug NGKB6HS NGKBOHS NGKBPRES SparkplugGap 028 031 028 031 028 034 Eng Oil Type SAE10W30 SAE10W30 SAE10W30 o y O Eng Oil Capacity 1 1 Itr 8 Itr 1 5 Itr _ wors moms Coolant capacity NA na fo Engine Compression 82102591 85121PS mas Valve Intake 006 Intake 003 Intake 006 Clearance EE ia E Exhaust 008 Exhaust 004 Exhaust 008 507 Interstate Interstate Interstate gore er a 12N24 3A 12N24 3A
47. urfaces of the electrodes are rough in extreme circumstances the electrode material will have oxidized to the point of turning green LEAD EROSION The ground electrode will appear worn away the central electrode will appear chipped and the insulator nose will take on a yellowish brown APPEARANCE POSSIBLE CAUSE A good indicator that the plug is functioning correctly and general engine conditions are good Can be caused by many different conditions Carbon deposits build up when the plug fails to fire correctly and burn them off Air fuel mixture too rich choke stuck on electrical problem extended periods of low speeds plug heat range too cold All should be investigated Possible causes are over advanced ignition timing air fuel mixture too lean water or oil level too low plugs not fitted tightened correctly plug heat range too hot This is often caused by oil leakage through the piston rings or valve seals Could be due to the wrong viscosity of oil being used Lead content of petrol used is too high Try petrol with a lower lead content Usually caused by abnormal thermal expansion in the combustion chamber Maybe thermal heating or cooling shock Causes as for overheating above Plugs are at the end of serviceable life Replace plugs as a set Due to the effects of corrosion oxidation and reaction with the lead in petrol Due to excessively high temperatures in the combustion chamber Causes as for overheat
48. y results from poor quality workmanship 10 insulation allowing wires to short Insulation deteriorates from physical contact when wires rub together due to vibrations Eventually the internal wires can short to each other or to ground 11 Crossed wires Mistakes happen especially if someone else worked on the generator before you 12 Fuses circuit breakers and ground fault interrupts These can easily be tested with a volt ohm meter After conducting a thorough physical inspection of the generator replace the cover and start the engine Take voltage readings on all the receptacles What are they Does a 120V AC receptacle read 128V AC Is this bad Normally it isn t Lower voltages are more detrimental than higher voltages Lower voltages overload electric motors very easily and cause them to burn How high should a voltage go No more than 130 volts for some appliances and less for others Keep the output voltage approximately 120 to 125V AC Electricity providers deliver 128V AC to residential homes Resistance measurements can be taken and compared to specifications With the generator isolated from any alternating current source a volt ohm meter often pins down the problem without having to take voltage readings internally while the unit is running Multiquip Inc GA Series Generators Manual No GA2009CD HOW IS AC VOLTAGE PRODUCED 1 Engine see engine manual e The engine running at 3600 rpm 60Hz creat
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