Honda Power Equipment GA3.6HA, GA3.6H, GA-3.6HZ User Manual
OPERATION AND PARTS MANUAL
MODEL GA3.6H Series
GA-3.6HZ
GA3.6H
GA3.6HA
Portable Generators
(HONDA GASOLINE ENGINE)
Revision #0 (11/01/05)
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PAGE 2 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
NOTE PAGE
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 3
TABLE OF CONTENTS
Multiquip GA-3.6H Series
AC Portable Generators
Proposition 65 Warning ............................................. 2
Table Of Contents ..................................................... 4
Parts Ordering Procedures ....................................... 5
Safety Message Alert Symbols .............................. 6-7
Rules for Safe Operation ..................................... 8-10
Specifications (Generator/Engine) .......................... 11
Dimensions ............................................................. 12
General Information ................................................ 13
Load Application ..................................................... 14
Controls and Indicators ...................................... 15-17
Generator Refueling ............................................... 18
Installation .......................................................... 19-20
Pre-Inspection ......................................................... 21
Pre-Inspection (Engine) .......................................... 22
Initial Start-up (Engine) ........................................... 23
Initial Start-up/Generator Operation ....................... 24
Generator Operation/Shutdown.............................. 25
Preparation For Long Term Storage ....................... 26
Maintenance (Engine)........................................ 27-28
Wiring Diagram (GA-3HZ Generator) ..................... 29
Wiring Diagram (GA-3H Generator) ....................... 30
Wiring Diagram (GA-3HA Generator) ..................... 31
Troubleshooting (Engine) ...................................32-33
Troubleshooting (Generator) .................................. 34
Explanation of Code In Remarks Column ............... 36
Suggested Spare Parts ........................................... 37
HONDA GX240K1EDN2
ENGINE
Air Cleaner Assembly ......................................... 54-55
Camshaft Assembly ........................................... 56-57
Carburetor Assembly ......................................... 58-59
Control Assembly ............................................... 60-61
Crankcase Cover Assembly ............................... 62-63
Crankshaft Assembly ......................................... 64-65
Cylinder Barrel Assembly ................................... 66-67
Cylinder Head Assembly .................................... 68-69
Fan Cover Assembly .......................................... 70-71
Flywheel Assembly ............................................ 72-73
Ignition Coil Assembly ........................................ 74-75
Piston Assembly ................................................. 76-77
Recoil Starter Assembly..................................... 78-79
Solenoid Assembly ............................................. 80-81
Label Assembly .................................................. 82-83
Terms and Conditions Of Sale — Parts .................. 84
NOTE
Specification and part
number are subject to
change without notice.
Component DrawingsComponent Drawings
Component Drawings
Component DrawingsComponent Drawings
Nameplate and Decals....................................... 38-39
Generator Assembly .......................................... 40-41
Control Box Assembly (GA-3HZ) .......................42-43
Control Box Assembly (GA-3H) ......................... 44-45
Control Box Assembly (GA-3HA) ....................... 46-47
Muffler Assembly .............................................. 48-49
Pipe Frame Assembly (GA-3HZ) ....................... 50-51
Pipe Frame Assembly (GA-3H/GA-3.6HA) ........ 52-53
PAGE 4 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
Effective: June 1st, 2005
Ordering parts has never been easier!
PARTS ORDERING PROCEDURES
Choose from three easy options:
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■
View Parts Diagrams
■
Order Parts
■
Print Specification Information
Goto www.multiquip.com and click on
Order Par ts
to log in and save!
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Order via Phone:
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
parts@multiquip.com.
To obtain an MQ Account, contact your
District Sales Manager for more information.
internet
Use the
on
Standard orders
complete part numbers.*
Fax
your order in and qualify for a 3% Discount
on
Standard orders
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
and qualify for a 5% Discount
for all orders which include
for all orders which include
International Customers
their local Multiquip Representatives for
Parts Ordering information.
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
should contact
When ordering parts, please supply:
❒❒
❒
Dealer Account Number
❒❒
❒❒
❒
Dealer Name and Address
❒❒
❒❒
❒
Shipping Address (if different than billing address)
❒❒
❒❒
❒
Return Fax Number
❒❒
❒❒
❒
Applicable Model Number
❒❒
❒❒
❒
Quantity, Part Number and Description of Each Part
❒❒
NOTE
www.multiquip.com
Unless otherwise indicated by customer, all orders are treated as
within 24 hours. We will make every effort to ship
if received prior to 2PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 5
❒❒
❒
Specify Preferred Method of Shipment:
❒❒
✓
Fed Ex/UPS
■
■
■ Next Day
■
Stock Orders
✓ DHL
Priority One
Ground
Second/Third Day
✓
Tr u c k
Standard Orders
Air Shipments
must be noted on fax or web order form.
the same day the order is received,
and will ship
GA-3.6H Series — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
Safety precautions should be followed
at all times when operating this
equipment. Failure to read and
understand the Safety Messages and
Operating Instructions could result in
injury to yourself and others.
This Owner's Manual has been
developed to provide complete
instructions for the safe and efficient
NOTE
Before using these generators, ensure that the operating
individual has read and understands all instructions in this
manual.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,
operation of the MQ Model GA-3.6
Series
Portable Generators
the engine manufacturers instructions
for data relative to its safe operation.
. Refer to
HAZARD SYMBOLS
Potential hazards associated with the operation of the
GA-3.6H Series Portable Generators
Hazard Symbols which appear throughout this manual, and
will be referenced in conjunction with Safety Message Alert
Symbols.
Engine exhaust gases contain
poisonous carbon monoxide. This gas
is colorless and odorless, and can
cause death if inhaled. NEVER operate
this equipment in a confined area or
enclosed structure that does not provide
ample free flow air.
Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
Lethal Exhaust Gases
WARNINGWARNING
WARNING
WARNINGWARNING
WARNINGWARNING
WARNING
WARNINGWARNING
Lethal Exhaust Gas Hazards
Explosive Fuel Hazards
MQ
will be referenced with
DANGERDANGER
DANGER
DANGERDANGER
You WILL be
if you DO NOT follow these directions.
WARNINGWARNING
WARNING
WARNINGWARNING
You CAN be KILLED or
you DO NOT follow these directions.
CAUTICAUTI
CAUTION
CAUTICAUTI
You CAN be
these directions.
KILLED
INJURED
if you DO NOT follow
or
SERIOUSLY INJURED
SERIOUSLY INJURED
if
DO NOT fill the fuel tank while the engine is running or
hot. DO NOT overfill tank, since spilled fuel could ignite if
it comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
WARNINGWARNING
WARNING
WARNINGWARNING
Engine components can generate extreme
heat. To prevent burns, DO NOT touch
these areas while the engine is running or
immediately after operations. Never
operate the engine with heat shields or heat
guards removed.
WARNINGWARNING
WARNING
WARNINGWARNING
ALWAYS wear approved
protection when required.
Burn Hazards
Respiratory Hazards
respiratory
PAGE 6 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
GA-3H/GA-3HA — SAFETY MESSAGE ALERT SYMBOLS
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
ALWAYS place the power source, circuit
breakers or ON/OFF switch in the OFF
position, when the generators is not in use,
unless connected to transfer switch.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
ALWAYS wear approved eye and
hearing protection.
Rotating Parts Hazards
Accidental Starting Hazards
Eye and Hearing Hazards
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Other important messages are provided throughout this
manual to help prevent damage to your portable generator,
other property, or the surrounding environment.
Equipment Damage
Hazards
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 7
GA-3.6H Series — RULES FOR SAFE OPERATION
■
DANGERDANGER
DANGER
DANGERDANGER
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-3.6H Series Portable 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.
Read this manual!
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generators.
■
The engine section of this generators requires an adequate
free flow of cooling air.
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 or engine
and may cause injury to
people. Remember the
generator's engine gives off
monoxide gas.
NEVER
operate the generator in
DEADLY
carbon
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■
NEVER operate this equipment under the influence of
drugs
■
ALWAYS wear proper respiratory (mask),
hearing and eye protection equipment when
operating the generator.
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■
Manufacturer does not assume responsibility for any
accident due to equipment modifications.
■
NEVER use accessories or attachments, which are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
or
alcohol
.
■
■
■
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
machine. Fire or explosion could result
from fuel vapors, or if fuel is spilled on a
hot engine.
NEVER operate the generators in an
explosive atmosphere or near
combustible materials. An explosion or
fire could result causing severe
smoke
around or near the
bodily
harm or even death.
NEVER disconnect any
These devices are intended for operator safety. Disconnection
of these devices can cause severe injury, bodily harm or even
death! Disconnection of any of these devices will void all
warranties.
"emergency or safety devices"
.
PAGE 8 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
GA-3.6H Series — RULES FOR SAFE OPERATION
■
ALWAYS be sure the operator is familiar with proper safety
precautions and operation techniques before using
generators.
■
NEVER leave the generators unattended, turn off engine
when unattended.
■
Unauthorized equipment modifications will void all
warranties.
■
ALWAYS ensure generators are on level ground before use.
■
DO NOT place hands or fingers inside generators engine
compartment when engine is running.
■
NEVER run engine without air cleaner. Severe engine damage
may occur.
■
NEVER change or adjust the engine speed which has been
set at the factory prior to shipping.
Power Cord Safety
■
NEVER let power cables or cords
■
NEVER
is being transfer to a load.
■
NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.
■
NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.
■
ALWAYS make certain that proper power or extension cord
has been selected for the job See Table 4.
stand in water
while AC power from the generators
lay in wate
r.
Grounding Safety
■
ALWAYS make sure that electrical circuits are properly
grounded
local codes before operating generator. Severe
death!
ungrounded generator.
per the
National Electrical Code
(NEC) and
injury
by electrocution can result from operating an
Maintenance Safety
■
■
■
■
■
ALWAYS replace any worn or damaged warning decals.
■
■
■
■
■
■
or
NEVER lubricate components or attempt service on a running
machine.
High Temperatures – Always stop engine and
allow the engine to cool before adding fuel, oil
or performing service and maintenance
hot!
functions. Contact with
cause serious burns.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and replace any
broken parts immediately.
ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children and unauthorized personnel.
The electrical voltage required to operate the generators can
cause severe injury or even death through physical contact
with live circuits.
performing maintenance on the generator.
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.
Removing the engine oil drain plug while
the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing
severe scalding to any persons in the general
area of the generator.
Turn all circuit breakers OFF before
components can
■
ALWAYS make sure the generators are properly grounded to
a suitable earth ground (GROUND ROD). See installation in
this manual.
■
NEVER use
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 9
gas piping
as an electrical ground.
GA-3.6H Series— RULES FOR SAFE OPERATION
DANGERDANGER
DANGER
DANGERDANGER
During operation of this generation, there
exists the possibility of
electrical shock or burn
cause
DEATH!
To avoid these hazards:
severe bodily harm
NEVER use
ELECTROCUTION HAZARDSELECTROCUTION HAZARDS
-
ELECTROCUTION HAZARDS
ELECTROCUTION HAZARDSELECTROCUTION HAZARDS
damaged
or
electrocution
, which can
or even
worn
cables when connecting
,
equipment to the generator. Make sure power
Emergencies
■
ALWAYS know the location of the
nearest
■
ALWAYS know the location of the nearest
first aid kit
■
connecting cables are securely connected to the
generator’s output receptacles, incorrect connections
may cause damage to the generators and electrical
shock.
NEVER grab or touch a live
power cord with wet hands, the
possibility exist of electrical
shock, electrocution, and even
death!
fire extinguisher
.
In emergencies
nearest phone or
Also know the phone numbers of the nearest
ambulance, doctor
information will be invaluable in the case of an
emergency.
always
.
know the location of the
keep a phone on the job site
and
fire department
.
. This
NEVER insert any objects
into the output receptacles
during operation. This is
extremely dangerous.
ALWAYS turn-off the generators and place all circuit
breakers in the “OFF” position when contact with the
output receptacles is required. There exist the possibility
of
electrocution, electrical shock or burn, which can
cause severe bodily harm or even death
Backfeed to a utility system can cause
electrocution
NEVER connect the generators to a
building's electrical system without a
transfer switch or other approved device.
All installations should be performed by
licensed electrician
a
with all applicable laws and electrical
codes. Failure to do so could result in
electrical shock or burn causing serious
injury or even death!
and or property damage.
in accordance
!
NOTE
In keeping with Multiquip's policy
of constantly improving its
products, the specifications quoted
herein are subject to change without
prior notice.
PAGE 10 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
GA-3.6H Series— SPECIFICATIONS (GENERATOR/ENGINE)
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The maximum output of the engines listed above are 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's output power will decrease 3-1/2% for each 1000 feet of altitude above sea level, and 1% for each 10
°°
°
Fahrenheit above the standard temperature of 60
°°
F
F
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 11
GA-3.6H Series— DIMENSIONS
Figure 2. Dimensions
PAGE 12 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
GA-3.6H Series — GENERAL INFORMATION
Excitation System
WARNINGWARNING
WARNING
WARNINGWARNING
Before connecting this generators 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.F
GA-3.6H Series Familiarzation
Generator
The Multiquip GA-3.6H series generators have been designed
as a portable dual purpose power source for 60 Hz (single
phase) lighting facilities, power tools, submersible pumps
and other industrial and construction machinery.
These generators are 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
generators to protect against damage. See Figures 2A
through 2E for the basic controls and indicators for the GA-
3.6H Series generators.
These portable generators are supplied with a electrical
control box
control box is also placed on rubber isolators.
Control Box
The control box is provided with the following:
■
NEMA L14-20R, twist-lock receptacle,125/250V, 20 amps.
. To reduce vibration caused by the engine, the
The GA-3.6H series generators use a magnet attached to a
flywheel to produce AC voltage from a lamp coil beneath
the flywheel. As the magnetic 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:
z
Excitation (diode 1)
z
Battery (diode 2)
z
Slow Down (diode 3)
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.
Alternator
The alternator, a brushless revolving-field type, is
permanently aligned to the engine through rigid coupling.
Engine
These generators are powered by a 8.0 HP, air-cooled, 4stroke
HONDA gasoline engine. Reference Table 2, for
engine specifications.
■
NEMA L5-20R, twist-lock receptacle, 125V, 20 amps.
■
NEMA L6-30R, twist-lock receptacle, 250V, 30 amps.
(GA-3.6HZ only)
■
NEMA L5-30R, twist-lock receptacle, 125V, 30 amps.
■
NEMA 5-20R, GFCI duplex receptacle,125V, 20 amps
(GA-3.6HA has two).
■
13.5 amp main circuit breaker.
■
AC Voltmeter
■
G.F.C.I. Ground Terminal (GA-3.6HZ only)
■
Full Power Switch
■
Idle Control Switch
■
Operation Switch
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 13
GA-3.6H Series— LOAD APPLICATION
Single Phase Load — 60 Hz
Always be sure to check the nameplate on the generators
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generators 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.
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:
NOTE
If wattage is not given on the equipment's
name plate, approximate wattage may be
A 1 inch drill runs at 1 KW
use a 2 KW generator.
determined by multiplying nameplate
voltage by the nameplate amperage.
3. LARGE MOTORS
Submersible pumps, table saws etc.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generators is 1.0 See Table 3 below
when connecting loads.
Total the running wattage and multiply by 3.
Example:
A conveyor belt runs at 8 KW
use a 24 KW generator.
spmal
spmal
NOTE
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When using a combination of dual
receptacles, total load
exceed
the rated capacity of the
generator.
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CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Motors and motor-driven equipment draw much greater
current for starting than during operation.
adequate size
extension cable
Always
use an
which can carry the
required load.
Extension Cables
When electric power is to be provided to various tools or
loads at some
are normally used.
distance
from the generator, extension cords
Cables should be sized to allow for
distance in length and amperage so that the voltage
drop between the generators and point of use (load) is
held to a minimum
. Use the cable selection chart (Table 3)
as a guide for selecting proper cable size.
The idle control device is operated at a
NOTE
minimum load capacity of 100W. If the
load capacity is less than 100W, place
the idle control switch in the OFF position.
PAGE 14 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
GA-3.6H Series— CONTROLS AND INDICATORS
Figure 2A. Generators Components
1. Lifting Bail Eye – Attach a rope or chain to this lifting eye
when lifting of the generators is required. Never stand
underneath the generators while it is being lifted. Place
lifting eye in down position when not in use.
2. 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 generators or power tools turn the generators
OFF and consult your authorized Multiquip service dealer.
3. Idle Control Switch – The generators are provided with
an automatic idle control device 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 2600 rpm (low-speed
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.
5. GFCI Duplex Receptacle – NEMA 5-20R, GFCI receptacle
6. 120V Output Receptacle –
7. 120V Output Receptacle – NEMA L5-30R twist-lock
8. 120V/240V Output Receptacle – NEMA L14-30R twist-
9. Main Breaker – This 2-pole circuit breaker (120/240V,
10. Ground – This ground connection point should be
will provide 120V, 20 amps. (GA-3.6HA has two.)
NEMA L5-20R twist-lock
receptacle will provide 120V, 20 amps, 60 Hz.
receptacle will provide 120V, 30 amps, 60 Hz.
lock receptacle will provide (120V, 50 amps, or 240V,
25 amps, 60 Hz.)
13.5 amps) protects the generators from short circuiting or
overloading. When starting the generators
the circuit breaker placed in the "OFF" position.
connect to a good earth ground (ground rod). GA-3.6H and
GA3.6HA models only
always
have
4. Operation Switch – Place this
position (up) for normal operation. To turn-off the generators,
place the operation switch in the "OFF" position (down).
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 15
rocker
switch in the "ON"
NOTE
GA-3.6H Series— CONTROLS AND INDICATORS
Model GA3.6HZ shown. Location of Full
Power Switch for Models GA3.6H and
GA-3.6HA, is on front control panel.
Figure 2B. Generators Components
11. Full Power Switch – The generators are provided with a
full power switch. Figures 2C and 2D show simplified wiring
diagrams of the dual voltage system.
When the full power switch is in the 120 volt (up) position,
you can access the
120 volts from the GFCI duplex receptacle and the120V
twist-lock receptacle, or a combination of both receptacles
as long as the total load does not exceed the generating
set capacity.
Figure 3C. 120V Full Power Switch
Simplified Diagram (Up Position)
NOTE
full rated power
When the
full power switch
of the generators at
is in the
120V position, the 240V twist-lock
receptacle
cannot be used
.
When the switch is in the 240 volt (down) position, you can
acess
half of the rated power
of the generating set at 120
volts from the GFCI duplex receptacle and up to half of the
rated power of the set at 120 volts from 120V twist-lock
receptacle; or full rated power of the set at 240 volts from
the 240V twist-lock receptacle.
Figure 3D. 120/240V Full Power Switch
Simplified Diagram (Down Position)
12. 120V Output Receptacle – NEMA L6-20R twist-lock
receptacle will provide 240V, 20 amps, 60 Hz. GA-3.6HZ
only.
13. GFCI Ground – This ground connection point should be
connected to a good earth ground (ground rod).
Applies
to GA3.6HZ only.
PAGE 16 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
NOTE
GA-3.6H Series— CONTROLS AND INDICATORS
Models GA3.6H and GA3.6HA shown.
Componet location for GA3.6HZ is
similar.
Figure 2E. Generators Components
14. Fuel Cock Lever – Turn this lever
(down)the flow of fuel into the carburetor. Turn
stop (up)
15. Spark Plug – Provides spark to the ignition system. Set
spark plug gap to 0.6 - 0.7 mm (0.028 - 0.031 inch) Clean
spark plug once a week.
16. Muffler/Heat Shield – Used to reduce noise and emissions.
NEVER touch this
is in use. Always allow time for the generators to cool down
before performing maintenance.
17. Choke Lever – Used for starting the engine.
choke lever when starting a cold engine or in cold weather
conditions. The choke enriches the fuel mixture.
choke lever if starting a warm engine or in warm weather
conditions.
18. Recoil Starter (pull rope) – Manual-starting method. Pull
the starter grip until resistance is felt, then pull briskly and
smoothly.
19. Engine Oil Filler Cap – Remove this cap/dipstick when
the adding of engine oil is required. See Table 4 for
recommended type engine oil.
the flow of fuel.
heat shield
downward
when the generator/welder
to
start
upward
Close
the
Open
the
20. Engine Oil Drain Plug – Remove this drain plug when
to
21. Air Cleaner – Prevents dirt and other debris from entering
22. Fuel Tank Cap – Remove this cap to add unleaded
23. Fuel Gauge – This gauge is located on top of the fuel tank.
24. Fuel Tank – Fuel tank capacity is 5 gallons (19 liters).
on level ground. Placing the generators on level ground will
ensure that the low oil sensor will function properly.
draining of the oil from the engine crankcase is required.
Fill with recommeded type oil as listed in Table 4.
the fuel system. Remove wing-nut on top of air filter
cannister to gain access to filter element. NEVER run the
engine without an air cleaner.
gasoline to the fuel tank.
gasoline. Make sure cap is tightened securely. DO NOT
over fill.
Read this gauge to determine when fuel is
NOTE
Replenish
This
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 generators is placed
HONDA
with
clean unleaded
low
.
engine is equipped
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 17
GA-3.6H Series — GENERATOR REFUELING
DANGERDANGER
DANGER
DANGERDANGER
Adding fuel to the tank should be done only when
the engine is stopped and has had an opportunity
to cool down. In the event of a fuel spill, DO NOT
attempt to start the engine until the fuel residue
has been completely wiped up, and the area surrounding the
engine is dry. If generators is placed in a truck bed with a plastic
liner, REMOVE generators from truck bed and place on ground
(Figure 3) to refuel. This possibility exist of
to static electricity.
fire
or
explosion
due
Figure 3. Generators Refueling
PAGE 18 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
GA-3.6H Series — INSTALLATION
Outdoor Installation
Install the generator/welder in a area that is free of
bystanders
generators is on secure level ground so that it cannot slide
or shift around. Also install the generators 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 to
engine and alternator parts.
Pay close attention to ventilation when
operating the generators inside tunnels
and caves. The engine exhaust contains
noxious elements.
, and
overhead obstructions
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
. Make sure the
debris
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 generators
is installed indoors, you must make provisions for venting
the engine exhaust to the outside of the building.
Generators Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground. Always use the ground terminal on the generators to
ground the generator. Ground the generators from its ground
connector so that the resistance to ground is 500 ohms or less.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as practical.
Mounting
The generators should always be mounted on a flat level
surface to isolate vibration of the generators when it is
running. DO NOT place the generators on slopes, the
possibility exists that the generators could slide.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
An electric shock is apt to happen
when vibrators are used. Pay close
attention to handling when operating
vibrators and always use rubber
boots and gloves to insulate the
body from a short circuit.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generators to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generators (Figure 3) connect the
ground cable between the lock washer and the nut on
the generators and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 19
GA-3.6H Series — INSTALLATION
Connecting the Ground
The nut and ground terminal on the generators should always be used to connect the generators to a suitable ground. The
ground cable should be #8 size wire minimum.
At the generator, connect the terminal of the ground cable between the lock washer and the nut (Figure 4) and tighten the
nut fully. Connect the other end of the ground cable to a suitable earth ground (ground rod).
Figure 4. Generators Grounding
PAGE 20 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
GA-3.6H Series — PRE-INSPECTION
General Inspection Prior to Operation
Ground Power Tools
When using power tools or electrical equipment requireing AC
power from the generator, make sure connecting (power tool)
cable has a ground as shown in Figure 5.
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 generators and
point of use (load) is held to a minimum. Use the cable selection
chart (Table 3) as a guide for selecting proper cable size.
NOTE
Main Circuit Breaker
To protect the generators from an overload always place the
main circuit breaker in the "OFF" position prior to starting the
Figure 5. Ground Cables/Plugs
engine.
Never!
use power tools or
equipment that do not have a
ground capability, the possibility
of electrocution, electrical
exists
shock or burn
severe bodily harm
, which can cause
or even
DEATH!
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GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 21
GA-3H/HA Series — PRE-INSPECTION (ENGINE)
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
NEVER operate the generators in a confined
area or enclosed area structure that does
not provide ample
ALWAYS wear approved eye and hearing
protection before operating the generator.
free flow of air
.
Figure 7. Engine Oil Dipstick (Oil Level)
epyTliO.4elbaT
Before Starting
1. Read safety instructions at the
beginning of manual.
2. Clean the generator, removing dirt
and dust, particularly the engine
cooling air inlet, carburetor and air
cleaner.
3. Check the air filter for dirt and dust. If air filter is dirty, replace
air filter with a new one as required.
4. Check carburetor for external dirt and dust. Clean with dry
compressed air.
5. Check fastening nuts and bolts for tightness.
Engine Oil Check
1. To check the engine oil level, place the generators on
secure level ground with the engine stopped.
2. Remove the filler dipstick from the engine oil filler hole
(Figure 6) and wipe clean.
Motor fuels are highly flammable and can
be dangerous if mishandled. DO NOT
smoke while refueling. DO NOT attempt to
refuel the generators if the engine is
running or in the dark
Fuel Check
1. Close the fuel cock before filling the fuel tank.
2. Remove the fuel cap located on top of fuel tank.
3. Read the fuel gauge located on top of the fuel tank (Figure 8) to
determin if the fuel level is low. If fuel is low, replenish with
clean unleaded fuel
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DANGER EXPLOSIVE FUEL
DANGER EXPLOSIVE FUELDANGER EXPLOSIVE FUEL
hot!
,
.
.
Figure 8. Fuel Gauge
Figure 6. Engine Oil Dipstick (Removal)
3. Insert and remove the dipstick without screwing it into the filler
neck. Check the oil level shown on the dipstick.
4. If the oil level is low (Figure 7), fill to the edge of the oil filler
hole with the recommended oil type (Table 4). Maximum oil
capacity is 1.16 quarts (1.1 liters)
PAGE 22 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
4. When refueling, be sure to use a strainer for filtration. DO
NOT top-off fuel.
Wipe up any spilled fuel
DO NOT fill the tank beyond capacity.
immediately!
GA-3.6H Series— INITIAL START-UP (ENGINE)
2. Place the
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
DO NOT attempt to operate this
generators until the Safety, General
Information and Inspection sections of
this manual have been
thoroughly understood
This section is intended to assist the operator with the
start-up
this section be read carefully before attempting to use the
generators in the field.
Before Starting the Engine
1. Be sure to
2. NEVER start the engine with the main
of the portable generator. It is extremely important that
disconnect all electrical loads
generators prior to starting the engine.
in the “ON" position. Always place this circuit breakers
(Figure 9) in the OFF position before starting.
read and
.
initial
from the
circuit breaker
if starting a
3. Place the
if starting a
4. Place the
ON
"
choke lever
cold
Figure 11. Choke Lever
choke lever
warm engine
generator's operation switch
" position.
(Figure 11) in the "
engine.
(Figure 11) in the "
or the
temperature is warm.
CLOSED
OPEN
(Figure 12) in the
" position
" position
Figure 9. Main Circuit Breaker (OFF Position)
Starting the Engine
1. Place the engine
position.
Figure 10. Engine Fuel Valve Lever (ON Position)
”
fuel valve lever
(Figure 10) to the "ON"
Figure 12. Generator Operation Switch (ON)
5. Grasp the starter grip (Figure 13) and slowly pull it out. The
resistance becomes the hardest at a certain position, corresponding to the compression point. Pull the starter grip
briskly and smoothly for starting.
Figure 13. Starter Grip
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
DO NOT pull the starter rope all the way to the end.
DO NOT release the starter rope after pulling. Allow it to
rewind as soon as possible.
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 23
GA-3.6H Series— INITIAL START-UP/GENERATOR OPERATION
6. If the engine has started, slowly return the choke lever
(Figure 11) to the
started repeat steps 1 through 5.
7. Before the generator is placed into operation, run the engine
for 3-5 minutes. Check for abnormal smells, fuel leaks, and
noises that would associate with lose components.
8.
Place
the
“OPEN”
idle control switch
position. If the engine has not
(Figure 14) in the "OFF"
(down) position. This will allow the engine speed to run
2. Place the full power switch (Figure 17) in the 120V
position (up).
Figure 17. Full Power Switch 120 V Position (Up)
at speed about 3600 RPM's
NOTE
3. Read the
Figure 14. Idle Control Switch (Off)
(Figure 18) and verify that120 VAC is present at the
120V twist-lock and GFCI duplex receptacles. For
Placing the
the OFF position (Figure 14) allows
NOTE
the generators will run at idle speed (2200 RPM's) until a load is
applied, at that time the engine speed will increase to 3600
RPM's as long as the load is being applied. When the load is not
in use, the engine speed will drop back to the idle mode after
about 3 seconds.
the engine to operate at a maximum
speed of about 3600 RPM's. When
the idle control switch is placed in
the up position (ON) (Figure 15),
idle control switch
in
additional verification of voltage, an external voltmeter
can be used to measure the output voltage as shown in
Figure 18.
When the
full power switch
is in the 120 V
position, the 240V twist-lock receptacle
cannot be used.
voltmeter
on the front panel of the generator
Figure 15. Idle Control Switch (On)
Figure 18. 120 V and GFCI Receptacles
60 Hz Operation
1. Place main circuit breaker (Figure 16) in the ON position.
4. Place the full power switch (Figure 19) in the 240V
position (down).
Figure 17. Main Circuit Breaker (ON)
PAGE 24 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
Figure 19. Full Power Switch 240/120 V Position (Down)
GA-3.6H Series— GENERATOR OPERATION/SHUTDOWN
5. Read the
(Figure 20) and verify that 240 VAC is present at the
240V twist-lock receptacle. Using an external voltmeter
verify that 120V is present at the 120V twist-lock and
GFCI duplex receptacles.
voltmeter
on the front panel of the generator
Stopping the Engine
1. Place the main circuit breaker (Figure 21) in the OFF
position.
Figure 21. Main Circuit Breakers (Off)
2. Place the
position.
3. Let the engine run at idle with no load for 2-3 minutes.
idle control switch
Figure 22. Idle Control Switch (Off)
(Figure 22) in the OFF
4. To shut-down the engine, place the generator's operation
switchg(Figure 23) in the OFF position.e
Figure 20. 60 Hz Output Receptacles
When the full power switch is in the 240
NOTE
receptacle and up to half of the rated power of the set at 120
volts from the 120V twist-lock receptacle; or full rated power
of the genset at 240 volts from the 240V twist-lock
receptacle.
NOTE
volt (down) position, you can take up to
half of the rated power
set at 120 volts from the GFCI duplex
When using a combination of dual
receptacles, total load should not exceed
the rated capacity of the generator.
of the generating
5. Place the engine
Figure 23. Generator Operation Switch (Off)
position.
fuel valve lever
”
(Figure 24) to the "OFF"
Connecting the Load
1. If small wattage power tools are required, connect them
to the 60 Hz output receptacles at this time.
GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 25
Figure 24. Engine Fuel Valve Lever (OFF Position)
6. Remove all
loads
from the generator.
GA-3.6H Series— PREPARATION FOR LONG TERM STORAGE
Generators Storage
For storage of the generating set for over 30 days, the
following is required:
■
Drain the fuel tank completely, or add STA-BIL to the fuel.
■
Run the engine until the gasoline in the carburetor is
completely consumed.
■
Completely drain the oil from the crankcase and refill with
fresh oil.
■
Remove the spark plug, pour 2 or 3 cc of SAE 30 oil into the
cylinder and crank slowly to distribute the oil.
■
Slowly rotate the engine a few times with the starter Rope and
install a new plug.
■
Pull out the starter rope slowly and stop at the compression
point.
■
Clean all external parts of the generating set with a cloth.
■
Cover the generating set and store in a clean, dry place.
PAGE 26 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)
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