Multiquip GA-9.7 HZ User Manual

PARTS AND OPERATION MANUAL

MULTIQUIP

Model GA-9.7 HZ

A.C. GENERATOR

© COPYRIGHT 2001, MULTIQUIP INC.

Revision #2 (03/05/01)

MULTIQUIP INC.	PARTS DEPARTMENT:
18910 WILMINGTON AVE.	800-427-1244
CARSON, CALIFORNIA 90746	FAX: [phone]
310-537-3700	SERVICE DEPARTMENT/TECHNICAL ASSISTANCE:
800-421-1244	800-478-1244
FAX:[phone]	FAX:[phone]

E-mail:[e-mail] • www:multiquip.com

Atlanta • Boise • Dallas • Houston • Newark Montreal, Canada • Manchester, UK

Rio De Janiero, Brazil • Guadalajara, Mexico

PAGE 2 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

800-427-1244 or 310-537-3700 FAX: [phone] or 310-637-3284

SERVICE DEPARTMENT/TECHNICAL ASSISTANCE

800-478-1244 or 310-537-3700 FAX: [phone]

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279 FAX: [phone]

MAIN

800-421-1244 or 310-537-3700 FAX: [phone]

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 3

Here's How To Get Help ............................................	3
Table Of Contents .....................................................	4
Parts Ordering Procedures .......................................	5
Rules For Safe Operation .........................................	6
Operation and Safety Decals ....................................	7
Specifications ............................................................	8
General Information ..................................................	9

Multiquip GA-9.7 HZ —

AC Generator

Controls and Indicators ...........................................	10
Installation ...............................................................	11
Pre-Setup ...........................................................	12-13
Instrumentation .......................................................	14
Load Application .....................................................	15
Operating Instructions.............................................	16
Maintenance ...........................................................	17
Preparation For Long Term Storage .......................	18
Wiring Diagram .......................................................	19
Troubleshooting (Engine) ...................................	20-21
Troubleshooting (Generator) .............................	22-23
Explanation Of Codes In Remarks Column ............	24
Suggested Spare Parts ...........................................	25
Generator Assembly ..........................................	26-27
Control Box Assembly ........................................	28-29
Pipe Frame Assembly ........................................	30-31
Nameplate And Decals ......................................	32-33

TABLE OF CONTENTS

Honda GX610 K1 Engine

Cylinder Head Assembly ....................................	34-35
Cylinder Barrel Assembly ...................................	36-37
Crankcase Cover Assembly ...............................	38-39
Crankshaft Assembly .........................................	40-41
Piston Assembly .................................................	42-43
Camshaft Assembly ...........................................	44-45
Recoil Starter Assembly.....................................	46-47
Fan Cover Assembly ..........................................	48-49
Carburetor Assembly .........................................	50-51
Air Cleaner Assembly.........................................	52-53
Muffler Assembly ...............................................	54-55
Fuel Pump Assembly .........................................	56-57
Flywheel Assembly ............................................	58-59
Ignition Coil Assembly ........................................	60-61
Starter Motor Assembly .....................................	62-63
Governor Control Assembly ...............................	64-65
Labels ................................................................	66-67
Gasket Kit ................................................................	68
Terms and Conditions Of Sale — Parts ..................	69

NOTE

Specification and part number are subject to change without notice.

PAGE 4 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

PARTS ORDERING PROCEDURES

nDealer account number

nDealer name and address

nShipping address (if different than billing address)

nReturn fax number

nApplicable model number

nQuantity, part number and description of each part

nSpecify preferred method of shipment:

•UPS Ground

•UPS Second Day or Third Day*

•UPS Next Day*

•Federal Express Priority One (please provide us with your Federal Express account number)*

•Airborne Express*

•Truck or parcel post

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when you order by FAX!

All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts:

Number of
line items ordered	Additional Discount
1-9 items	3%
10+ items**	5%

Get special freight allowances when you order 10 or more line items via FAX!**

nUPS Ground Service at no charge for freight

nPS Third Day Service at one-half of actual freight cost

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price) do not count towards the 10+ line items.

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

	Extra		Fax	Discount
						USA
	for	Domestic
		Dealers			Only

Now! Direct TOLL-FREE access to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

800/6-PARTS-7 • 800-672-7877

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 5

CAUTION:

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the GA-9.7 HZ Generator:

GENERAL SAFETY

■DO NOT operate or service this equipment before reading this entire manual.

■This equipment should not be operated by persons under 18 years of age.

■NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

■This generator is a source of potentially LETHAL high voltage. Never permit unqualified personnel-especially children to operate the generator.

■Always refuel in a well-ventilated area, away from sparks and open flames.

■Always use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT smoke around or near the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

■This generator is equipped with a ground terminal for your protection. Always complete the grounding path from the generator to an external grounding source.

■NEVER operate this generator, or handle any electrical equipment while standing in water, while bare foot, while hands are wet, or in the rain. Electrical shock could occur causing severe bodily harm or even death.

■Keep electrical cords in good condition. Worn, bare or frayed wiring can cause electrical shock, leading to bodily harm or even death.

■This generator requires an adequate free flow of cooling air. Never operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator and may cause injury to people.

■NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing generator.

RULES FOR SAFE OPERATION

■Provide adequate ventilation when operating the generator. DO NOT operate the generator in any enclosed or narrow space. The generator's gasoline engine gives off DEADLY carbon monoxide gas.

■NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe bodily harm or even death.

■Always make sure that the generator is secure on level ground so that it cannot slide or shift around, endangering workers. Also keep the immediate area free of bystanders.

■When using a concrete vibrator or a similar device that is immersed in a water based solution, make sure the device is equipped with short circuit protection.

■Always use rubber boots and gloves when operating a concrete vibrator or similar device.

■Use adequate size connecting cable for extension.

■Maintain electrical cords in good condition and frequently replace the entire cable of the concrete vibrator with a new one.

■HighTemperatures – Allow the machine and engine to cool before adding fuel or performing service and maintenance functions. Contact with hot components can cause serious burns.

Emergencies

■Always know the location of the nearest fire extinguisher and first aid kit. Know the location of the nearest telephone. Also know the phone numbers of the nearest ambulance, doctor and fire department. This information will be invaluable in the case of an emergency.

Maintenance Safety

■NEVER lubricate components or attempt service on a running machine.

■Always allow the machine a proper amount of time to cool before servicing.

■Keep the machinery in proper running condition.

■Fix damage to the machine immediately and always replace broken parts.

■Dispose of hazardous waste properly.Examples of potentially hazardous waste are used motor oil, fuel and fuel filters.

■DO NOT use food or plastic containers to dispose of hazardous waste.

■DO NOT pour waste, oil or fuel directly onto the ground, down a drain or into any water source

PAGE 6 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

OPERATION AND SAFETY DECALS

Machine Safety Decals

The GA-9.7 HZ portable generator is equipped with a number of safety decals.These decals are provided for operator safety and maintenance information.The illustration below shows these decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 7

		GA-9.7 HZ — SPECIFICATIONS
	Table 1. Specifications
	MODEL	GA-9.7 HZ
	Type	2-pole, Brushless Type Revolving Field
	Max. Output	9700 Watts
	Rated Output (continuous)	8400 Watts
	Rated Voltage	120/240 V
60 Cycle Generator	Rated Current	20.0/30.0 A
	Phase	Single Phase (3-wire)
	Frequency	60 Hz
	Rated Speed	3600 RPM
	Power Factor	100%
	Max Current (Main Breaker)	2-pole 35 Amps
	Model	Honda GX610K1VD
	Type	Air-cooled 4 stroke OVH 90 V- Twin
		horizontal shaft gasoline engine
	Bore X Stroke	3.03 in X 2.60 in
	Displacement	18.8 cc
Engine	Rated Output	18.0 H.P./3600 R.P.M.
	Fuel Tank Capacity	Approx. 10 U.S. Gallons
	Fuel	Unleaded Automobile Gasoline
	Lube Oil Capacity	3 1/16 pints
	Speed Control Method	Centrifugal Fly-weight Type
	Starting Method	Electric/Recoil Start
Dimension (LXWXH)		800 X 540 X 700 mm
Dry Net Weight		344 lbs (156 Kg.)

Effects of Altitude and Heat

The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambient conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric reading of 29.92 inches and a temperature of 60 degrees fahrenheit.

Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10° F fahrenheit above the standard temperature of 60° F

PAGE 8 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

WARNING:

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch.

Serious injury or death may result without this transfer switch.

GA-9.7 HZ FAMILIARIZATION

Generator

GA-9.7 HZ — GENERAL INFORMATION

Excitation System

All GA-series generators use a magnet attached to a flywheel to produce AC voltage from a lamp coil beneath the flywheel. As the magnet passes the coil it produces approximately

19-22 AC volts.

This voltage (19-22 VAC) is then sent to the control box that contains three rectifying diodes:

λExcitation (diode 1)

λBattery (diode 2)

λSlow Down (diode 3)

The Multiquip Model GA-9.7 HZ generator has been designed as a portable lightweight power source for 60 Hz (singlephase) vibrators, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

This generator is powered by a HONDA gasoline engine.

The alternator, a brushless revolving-field type, is permanently aligned to the engine through rigid coupling.

The generator is mounted on rubber vibration isolators that have a steel base backplate which is attached to the protective steel pipe carrying frame.The protective carrying frame is made of steel tubing and fully wraps around the generator to protect against damage.

This portable generator is supplied with a electrical control box. To reduce vibration caused by the engine, the control box is also placed on rubber isolators.

Control Box

The control box is provided with the following:

The AC voltage will pass through the excitation diode that converts the voltage to DC power.

This DC power is then sent to the excitation windings housed within the main windings commonly called the "stator".

This voltage is then transferred into the rotor through induction.The rotor contains two diodes within it which rectify the DC voltage and send it out through the main windings, as AC voltage.

Engine

The four-cycle air-cooled HONDA gasoline engine is designed to meet every performance requirement of this generator. Reference Table 1, page 8 for engine specifications.

Figure 1 (page 10) shows the basic controls and indicators for the GA-9.7 HZ generator.

λThree 120/240V output receptacles (single phase).

λTwo 120 V output GFI receptacles (single phase).

λFive circuit breakers, one for each receptacle.

λOne 240 V, 60 Hz main circuit breaker.

λAC Voltmeter.

λIdle Control Switch.

λFull Power Switch.

λOperation Switch.

NOTE

In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 9

GA-9.7 HZ — CONTROLS AND INDICATORS

Figure 1. Controls and Indicators

PAGE 10 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

Outdoor Installation

Install the generator in a location where it will not be exposed to rain or sunshine. Make sure that the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture.Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear, not only to the engine parts, but also to the alternator parts.

GA-9.7 HZ — INSTALLATION

Indoor Installation

Exhaust gases from gasoline engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Eliminate the danger of deadly carbon monoxide gas.

Remember that exhaust fumes from any gasoline engine are very poisonous if discharged in a closed room, but harmless if allowed to mix with the outside air. If the generator is installed indoors, you must make provisions for venting the engine exhaust to the outside of the building.

CAUTION : CAUTION :

Pay close attention to ventilation when operating the generator inside confined areas. The engine exhaust contains noxious elements.

Preventing electrical shock. Pay close attention to handling when operating concrete vibrators. Always use rubber boots and gloves to insulate the body from a short circuit.

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 11

GA-9.7 HZ — PRE-SETUP

General Inspection Prior to Operation

Circuit Breaker

This generator has been thoroughly inspected prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occurred in transit.

To protect the generator from an overload, circuit breakers are provided for single (60 Hz) phase on the control box. Make sure to switch the circuit breakers to the "OFF" position prior to starting the engine.

Ground

The nut and ground terminal on the generator should always be used to connect the generator to a suitable ground. The ground path should be of #8 size wire.

Connect the terminal of the ground wire between the lock washer and the nut and tighten the nut fully. Connect their end of the wire to a suitable ground.

Extension Cable

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 2 ) as a guide for selecting proper cable size.

Ground the Generator

Ground the generator from its ground connector so that resistance to ground is 500 ohms or less.

Ground the Tool

Ground the tool (load) in the same manner as the generator.

Table 2. Cable Selection (60 Hz, single phase operation)

	Current	Load In Watts		Maximum Allowable Cable Length
	in
		At 120	At 240	#10 Wire	#12 Wire	#14 Wire	#16 Wire
	Amperes
		Volts	Volts
	2.5	300	600	1000 ft.	600 ft.	375 ft.	250 ft.
	5	600	1200	500 ft.	300 ft.	200 ft.	125 ft.
	7.5	900	1800	350 ft.	200 ft.	125 ft.	100 ft.
	10	1200	2400	250 ft.	150 ft.	100 ft.
	15	1800	3600	150 ft.	100 ft.	65 ft.
	20	2400	4800	125 ft.	75 ft.	50 ft.
	30	3600	7200	75 ft.	50 ft.	35 ft.

CAUTION: Equipment damage can result from low voltage.

PAGE 12 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but do not overfill. Make sure the generator is level.

With the dipstick inserted all the way, but without being screwed into the filler hole, verify that the oil level is maintained between the two notches on the dipstick.

The oil listed in Table 3 is recommended to ensure better engine performance. Use class SC or higher grade motor oil.

NOTE

This HONDA engine is equipped with a low oil shutdown capability. A built in sensor will automatically turn off the engine should the oil level fall below a safe operating condition. Make sure the generator is placed on level ground. Placing the generator on level ground will ensure that the low oil sensor will function properly.

Table 3. Recommended Motor Oil

Temperature

Type Oil

Range

104° F ~ 23° F

SAE 30

(40° C ~ -5°C)

23° F ~ 5° F

SAE 20 or sae 10W-30

(-5° C ~ -15°C)

Below 5° C (-15°) SAE 10W or SAE 10W-30

GA-9.7 HZ — PRE-SETUP

Fuel

Fill the fuel tank with clean and fresh unleaded gasoline. Do not fill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed on page 8 Specification Table1.

The fuel tank cap must be closed tightly after filling.

Handle fuel in a safety container. If the container does not have a spout, use a funnel.

CAUTION :

Never fill the fuel tank while the engine is running or in the dark. Gasoline spillage on a hot engine can cause a fire or explosion. If gasoline spillage occurs, wipe up the spilled gasoline completely to prevent fire hazards.

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 13

CAUTION :

When using a combination of dual receptacles, total load should not exceed the rated capacity of the generating.

Power Outlets

The generator has the following 60 Hz 120/240 volt singlephase receptacles.

λSingle Phase

Two Duplex NEMA (GFCI) 5-20R (120V, 20 Amp)

One Twist Lock NEMA L5-30R (120V, 30 Amp) One Twist Lock NEMA L6-20R (240V, 20 Amp)

One Twist Lock NEMA L5-30R (120/240, 30 Amp)

Main Circuit Breaker (2-Pole 60 Hz)

This 2-pole 35 amp breaker protects the generator from short circuiting or overloading from the 60 Hz single phase load.

GA-9.7 HZ — INSTRUMENTATION

Idle Control Switch

This unit is provided with an automatic idle control for noise suppression and reduced fuel consumption. The automatic idle control automatically engages under a no-load condition. With the automatic idle control switched “ON”, the engine revolutions will automatically drop to about 2500 rpm (lowspeed operation) within 3 seconds after the load stops.When the operation is resumed, the engine speed is automatically increased to about 3600 rpm (high-speed operation) as soon as the load is connected.

Fuel Gauge

The fuel gauge is located on the fuel tank and allows easy monitoring of the fuel level.

AC Voltmeter

This voltmeter indicates (with a mark) the rated 60 Hz, single phase output voltage. In addition the voltmeter can also be used as a diagnostic tool.

If the voltmeter indicator (needle) is below the rated voltage, engine problems may exist (low/high RPM's). To prevent damage to the generator or power tools turn the generator

OFF and consult your authorized Multiquip service dealer.

PAGE 14 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and frequency requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130— 150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and starting system of the equipment.

NOTE

If wattage is not given on the equipment's name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

To determine the running wattage for your load, multiply the running wattage as indicated by steps 1, 2, and 3 below:

1.INCANDESCENT LOADS

Lights, heaters and similar appliances. Total the running wattage and multiply by 1.

Example:

29 light bulbs @ 100W each = 2.9 KW use a 3 KW generator.

2.SMALL MOTORS

Drills and other small power tools.

Total the running wattage and multiply by 2.

Example:

A 1 inch drill runs at 1 KW use a 2 KW generator.

3.LARGE MOTORS

Submersible pumps, table saws etc.

Total the running wattage and multiply by 3. Example:

A conveyor belt runs at 8 KW use a 24 KW generator.

GA-9.7 HZ — LOAD APPLICATION

CAUTION:

Motors and motor-driven equipment draw much greater current for starting than during operation.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable.

The idle control is operated at minimum load capacity of 100W. If the load capacity is less than 100W, throw the idle control switch to the OFF position.

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 15

GA-9.7 HZ — OPERATING INSTRUCTIONS

Before Starting

1.Be sure to disconnect the electrical load and switch the main circuit breaker to the “OFF” position prior to starting the engine.

2.Never start the engine with the main circuit breaker “ON”.

3.Check the lubricating oil level prior to starting the engine.

Make sure the generator is level. The oil level must be maintained between two notches on the dipstick.

4.When there is not enough lubricating oil, fill the crankcase with high grade motor oil. Use a high quality detergent oil classified SC, SD or SE. (See Table 3 on page 13)

CAUTION:

λNEVER start the engine when the oil level is below the lower mark on the dipstick.

λCheck the fuel level on the fuel gauge.

When fuel is low, fill the fuel tank with clean fresh unleaded automotive gasoline.

λIf gasoline spillage occurs, completely wipe up the spilled gasoline.

Starting

1.Place the idle control switch in the “ON” (up) position.

2.Close the choke. Adjust the opening of the choke valve according to operating conditions. When the engine is warm or the air temperature is high, close the choke valve halfway or open it all the way.

3.Confirm that the main circuit breaker on the generator control box is “OFF”.

4.Set the operation switch to the “ON” position and grasp the starting rope and slowly pull it out. The resistance becomes hardest at a certain position, corresponding to the compression point. Rewind the rope a little from that point and pull out sharply.

5.If the engine fails to start, repeat the procedure.

CAUTION:

λDO NOT pull the starter rope all the way to the end.

λDO NOT release the starter rope after pulling. Allow it to rewind as soon as possible.

Warm up

1.When the engine starts, open the choke slowly.

2.Run the engine at low speed for 3 minutes without load until the engine warms up.

3.Turn the idle control switch to the "OFF" (down) position and check the voltage by referring to the voltmeter on the control box.

CAUTION:

DO NOT change the engine speed control lever which has been set at the factory prior to shipping.

1.Check the generator for abnormal noise and smells.Then connect the load to the receptacles of the generator.

2.Switch the main circuit breaker to the “ON” position and turn the idle control switch to the “ON” (down) position for normal (load) engine operation.

Operation

Check the voltage by referring to the voltmeter on the control box. When the voltmeter indicates 120 volts, 120 volts from the 120V receptacles and 240 volts from the 240V receptacle can be obtained at the same time. Refer to Figure 1, Controls and Indicators, item 4 on page 10.

Stopping the Engine

CAUTION:

NEVER stop the engine suddenly while running at high speeds.

1.Remove the load from the generator. Place the circuit breaker in the “OFF” position. Refer to Figure 1, item 5 on page 10. Run the engine (no-load) with the idle control switch set to the ON position for three to five minutes, then stop the engine.

2.Turn the START/STOP switch to the “STOP” position.

3.Never stop the engine suddenly while running at high speed.

PAGE 16 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

General Inspection

At least daily or prior to each use, the generating set should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel or oil leaks.

Engine Side (Refer to the Engine Instruction Manual)

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Make sure the generating set is level. The oil level must be between the two notches on the dipstick.

Changing Oil

Change oil after the first 20 hours of operation. Drain and refill the engine crankcase every 50 operating hours or once a week thereafter.Drain crankcase oil into a suitable container while engine is still warm. Replace the drain plug tightly. Add oil through the filler hole.

Air Cleaner

Every 50 hours: Remove air cleaner element (std. or heavy duty types), and wash in kerosene or liquid detergent and hot water. Wrap foam element in a cloth and squeeze dry.

Wipe heavy duty paper element dry with toweling. Saturate element with kerosene; squeeze excess from foam element.

Wipe excess from heavy duty paper element.

GA-9.7 HZ — MAINTENANCE

Service Daily

If engine is operating in very dusty and dry grass conditions. A clogged air cleaner will result in high fuel consumption, loss of power and excessive carbon buildup in the combustion chamber.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Spark Plug

Remove carbon build-up on the spark plug (Figure 5) with a wire brush. Set the spark plug gap to 0.6—0.7mm (0.024-

0.028 inch). Tighten with a spark plug socket wrench. Clean the spark plug every 50 operating hours or once a week.

Figure 5. Spark Plug Gap

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 17

GA-9.7 HZ — PREPARATION FOR LONG -TERM STORAGE

Generator Storage

For storage of the generating set for over 30 days, the following is required:

λDrain the fuel tank completely.

λRun the engine until the gasoline in the carburetor is completely consumed.

λCompletely drain the oil from the crankcase and refill with fresh oil.

λRemove the spark plug, pour 2 or 3 cc of SAE 30 oil into the cylinder and crank slowly to distribute the oil.

λSlowly rotate the engine a few times with the starter Rope and install a new plug.

λPull out the starter rope slowly and stop at the compression point.

λClean all external parts of the generating set with a cloth.

λCover the generating set and store in a clean, dry place.

PAGE 18 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-9.7 HZ —WIRING DIAGRAM

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 19

GA-9.7 HZ —TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the

diagnosis based on the Engine Troubleshooting (Table 4) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant.

TABLE 4. ENGINE TROUBLESHOOTING

	SYMPTOM	POSSIBLE PROBLEM	SOLUTION
		Inspect carburetor to see if fuel	Check fuel line
		is reaching it?
		No Fuel?	Add Fuel
		Water in fuel tank?	Flush or replace fuel tank.
		Fuel filter clogged?	Replace fuel filter
		Stuck carburetor?	Check float mechanism.
	Poor starting
		Spark plug is black?	Spark plug is fouled. Check tranistor ignition unit.
	(Engine will not start)
		Spark plug is blue-white?	Insufficient compression, injected air leaking. Carburetor jets are
			clogged (overflow).
		No spark present at tip of spark	Tranistor ignition unit broken, high voltage cord cracked or broken.
		plug?	Start/Stop switch broken. Replace spark plug if fouled.
		No oil?	Add oil as required.
		Low oil or oil pressure shutdown	Check oil level, add oil if necessary. Check automatic oil shutdown
		sensor is defective?	circuit "oil sensor" Replace oil sensor.
		Engine will not turn over?	Replace cylinder and piston and if necessary axel joint.
		Cylinder head connecting bolts	Tighten cylinder head connecting bolts.
		loose?
	Insufficient power output "no	Cylinder head gasket damaged?	Replace cylinder head gasket.
	compression"
		Malfunction of valve seat?	Re-seat valves.
		Spark plug is loose?	Replace spark plug.
		Worn piston rings?	Replace piston rings.
		Malfunction in air-cleaner system,	Clean or replace air filter.
		air filter clogged?
		Air leaking in from interface	Tighten bolts between carburetor and cylinder head. Replace
	Insufficient power output	between carburetor and cylinder	cylinder head gasket.
	"compression"	head?
			Clean or replace fuel filter.
		Malfunction in fuel system?	Clean or replace carburetor.
			Check carburetor float.

PAGE 20 — GA-9.7 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-9.7 HZ —TROUBLESHOOTING (ENGINE)

TABLE 4. ENGINE TROUBLESHOOTING (CONTINUED)

SYMPTOM	POSSIBLE PROBLEM	SOLUTION
Insufficient power output	Malfunction in cooling fan?	Check or replace cooling fan.
"compression" and overheats	Air in-take filter clogged?	Clean or replace air in-take filter.
	Over accumulation of exhaust	Clean and check valves.
Burns to much fuel	products?	Check muffler, replace if necessary.
	Wrong spark plug?	Replace spark plug with manufactures suggested type spark plug.
Exhaust color is continiously	Lubricating oil is wrong viscosity?	Replace lubricating oil with correct viscosity.
"WHITE"	Worn rings?	Replace rings
	Air cleanner clogged?	Clean or replace air cleaner.
	Choke valve has not been set to	Adjust choke valve to the correct position.
Exhaust color is continiously	the correct position?
"BLACK"	Carburetor defective, seal on	Replace carburetor or seal.
	carburetor broken?
	Poor carburetor adjustment	Adjust carburetor.
	"engine runs too rich?

GA-9.7 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 21