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 ACCOMPANYTHE EQUIPMENT AT ALLTIMES.

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

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

TABLE OF CONTENTS

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

Specification and part number are subject to change without notice.

Component 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

PARTS ORDERING PROCEDURES

www.multiquip.com

Ordering parts has never been easier!

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 Parts to log in and save!

If you have an MQ Account, to obtain a Username and Password, E-mail us at: [e-mail].

To obtain an MQ Account, contact your

District Sales Manager for more information.

Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Order via Fax (Dealers Only):

Fax your order in and qualify for a 3% Discount

All customers are welcome to order parts via Fax.

on Standard orders for all orders which include

Domestic (US) Customers dial:

complete part numbers.*

1-800-6-PARTS-7 (800-672-7877)

Note: Discounts Are Subject To Change

Order via Phone: Domestic (US) Dealers Call:

1-800-427-1244

Non-Dealer Customers:

International Customers should contact

Contact your local Multiquip Dealer for

their local Multiquip Representatives for

parts or call 800-427-1244 for help in

Parts Ordering information.

locating a dealer near you.

When ordering parts, please supply:

	Dealer Account Number	Specify Preferred Method of Shipment:
	Dealer Name and Address	Fed Ex/UPS	DHL
	Shipping Address (if different than billing address)	■ Priority One	Truck
		■ Ground
	Return Fax Number
		■ Next Day
	Applicable Model Number
		■ Second/ThirdDay

Quantity, Part Number and Description of Each Part

Unless otherwise indicated by customer, all orders are treated asStandard Orders and will ship NOTE within24hours.WewillmakeeveryefforttoshipAirShipmentsthesamedaytheorderisreceived,

if received prior to 2PM PST. Stock Orders must be noted on fax or web order form.

WE ACCEPT ALL MAJOR CREDIT CARDS!

GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 5

GA-3.6H Series — SAFETY MESSAGE ALERT SYMBOLS

FORYOUR 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 operation of the MQ Model GA-3.6 Series Portable Generators. Refer to the engine manufacturers instructions for data relative to its safe operation.

Before using these generators, ensure that the operating individual has read and understands all instructions in this manual.

HAZARD SYMBOLS

Potential hazards associated with the operation of the MQ GA-3.6H Series Portable Generators will be referenced with Hazard Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message Alert

Symbols.

WARNING Lethal Exhaust Gas Hazards

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.

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,

DANGER

You WILL be KILLED or SERIOUSLY INJURED if you DO NOT follow these directions.

WARNING

You CAN be KILLED or SERIOUSLY INJURED if you DO NOT follow these directions.

CAUTION

You CAN be INJURED if you DO NOT follow these directions.

WARNING Explosive Fuel Hazards

Gasoline is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids.

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.

WARNING

Burn Hazards

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.

WARNING

Respiratory Hazards

ALWAYS wear approved respiratory protection when required.

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

	CAUTION	Rotating Parts Hazards

NEVER operate equipment with covers, or guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury.

CAUTION Accidental Starting Hazards

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.

CAUTION Eye and Hearing Hazards

ALWAYS wear approved eye and hearing protection.

	CAUTION	Equipment Damage
		Hazards

Other important messages are provided throughout this manual to help prevent damage to your portable generator, other property, or the surrounding environment.

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

	DANGER	Read this manual!

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.

■NEVER operate this equipment when not

feeling well due to fatigue, illness or taking medicine.

■NEVER operate this equipment under the influence of drugs or alcohol.

■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.

■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. 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 or engine and may cause injury to people. Remember the

generator's engine gives off DEADLY carbon monoxide gas.

■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.

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

■NEVER disconnect any "emergency or safety devices". 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.

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 lay in water.

■NEVER stand in water while AC power from the generators 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.

Grounding Safety

■ALWAYS make sure that electrical circuits are properly grounded per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or death! by electrocution can result from operating an ungrounded generator.

■ALWAYS make sure the generators are properly grounded to a suitable earth ground (GROUND ROD). See installation in this manual.

■NEVER use gas piping as an electrical ground.

Maintenance Safety

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

■HighTemperatures – Always stop engine and allow the engine to cool before adding fuel, oil or performing service and maintenance functions. Contact with hot! components can cause serious burns.

■Keep the machinery in proper running condition.

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

■ALWAYS replace any worn or damaged warning decals.

■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. Turn all circuit breakers OFF before 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 severescaldingtoanypersonsinthegeneral area of the generator.

GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 9

GA-3.6H Series— RULES FOR SAFE OPERATION

DANGER-ELECTROCUTION HAZARDS

During operation of this generation, there exists the possibility of electrocution, electrical shock or burn, which can cause severe bodily harm or even

DEATH!

To avoid these hazards:

NEVER use damaged or worn cables when connecting equipment to the generator. Make sure power 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!

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 and or property damage. NEVER connect the generators to a building's electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn causing serious injury or even death!

Emergencies

■ALWAYS know the location of the nearest fire extinguisher.

■ALWAYS know the location of the nearest first aid kit.

■In emergencies always know the location of the nearest phone or keep a phone on the job site. Also know the phone numbers of the nearest ambulance, doctor and fire department. This information will be invaluable in the case of an emergency.

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)

Table 1. Specifications

		MODEL	GA-3.6H/GA-3.6HA/GA-3.6HZ
		Type	2-pole, Brushless Type Revolving Field
		Max. Output	3600 Watts
		Rated Voltage	120/240 V
		Max./Cont. Amps @ 120V	30/26.6
	60 Hz Generator	Max./Cont. Amps @ 240V	15/13.3
		Main Circuit Breaker	2-Pole 13.5 Amps
		Phase	Single Phase
		Frequency	60 Hz
		Rated Speed	3600 RPM
		Power Factor	100%
		Fuel Tank Capacity	Approx. 5.0 U.S. Gallons (19 Liters)
	Dry Net Weight		170 lbs. (74 Kg.) GA3.6H/GA3.6HA
			178 lbs. (81 Kg.) GA3.6HZ

		Table 2. ENGINE SPECIFICATIONS
		Model	HONDA GX240K1EDN2
		Type	Air-cooled 4 stroke, Single Cylinder, OHV,
			Horizontal Shaft Gasoline Engine
		Bore X Stroke	2.90 in. X 2.30 in.
			(73 mm x 58 mm.)
	Engine	Displacement	14.81 cc
		Max Output	8.0 H.P./3600 R.P.M.
		Fuel	Unleaded Automobile Gasoline
		Lube Oil Capacity	2.33 pints
		Speed Control Method	Centrifugal Fly-weight Type
		Starting Method	Recoil Start
	Dimension		14.0 x 16.9 X 16.1 in.
	(L x W x H)		(355 X 430 X 410 mm.)
	Dry Net Weight		55.1 lbs (25 Kg.)

Effects of Altitude and Heat

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° F Fahrenheit above the standard temperature of 60° F

GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 11

GA-3.6H Series— DIMENSIONS

PAGE 12 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)

GA-3.6H Series — GENERAL INFORMATION

WARNING

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.

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. 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:

■NEMA L14-20R, twist-lock receptacle,125/250V, 20 amps.

■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

Excitation System

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:

zExcitation (diode 1)

zBattery (diode 2)

zSlow 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, 4- stroke HONDA gasoline engine. Reference Table 2, for engine specifications.

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.

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

The power factor of this generators is 1.0 See Table 3 below when connecting loads.

Table 3. Power Factor By Load

	Type Of Load	Power Factor
	Single-phase induction motors	0.4 - 0.75
	Electric heaters, incandescent	1.0
	lamps
	Fluorescent lamps, mecury	0.4 - 0.9
	lamps
	Electronic devices,	1.0
	communication equipment
	Common power tools	0.8

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

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.

CAUTION

Motors and motor-driven equipment draw much greater current for starting than during operation.Always use an adequate size extension cable which can carry the required load.

Extension Cables

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.

The idle control device is operated at a 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.GFCIDuplexReceptacle– NEMA 5-20R, GFCI receptacle will provide 120V, 20 amps.(GA-3.6HA has two.)

6. 120V Output Receptacle – NEMA L5-20R twist-lock receptacle will provide 120V, 20 amps, 60 Hz.

7. 120V Output Receptacle – NEMA L5-30R twist-lock receptacle will provide 120V, 30 amps, 60 Hz.

8. 120V/240V Output Receptacle – NEMA L14-30R twistlock receptacle will provide (120V, 50 amps, or 240V, 25 amps, 60 Hz.)

9. Main Breaker – This 2-pole circuit breaker (120/240V, 13.5 amps) protects the generators from short circuiting or overloading. When starting the generators always have the circuit breaker placed in the "OFF" position.

10. Ground – This ground connection point should be connect to a good earth ground (ground rod). GA-3.6H and GA3.6HA models only

4. Operation Switch – Place this rocker switch in the "ON" 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

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.

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 full rated power of the generators at 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)

When the full power switch is in the 120V position, the 240V twist-lock receptacle cannot be used.

Figure 2B. Generators Components

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)

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 downward to start (down)the flow of fuel into the carburetor.Turn upward to stop (up) the flow of fuel.

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/HeatShield– Used to reduce noise and emissions. NEVER touch this heat shield when the generator/welder is in use. Always allow time for the generators to cool down before performing maintenance.

17. Choke Lever – Used for starting the engine. Close the choke lever when starting a cold engine or in cold weather conditions.The choke enriches the fuel mixture.Open the 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.

20.Engine Oil Drain Plug – Remove this drain plug when draining of the oil from the engine crankcase is required. Fill with recommeded type oil as listed in Table 4.

21. Air Cleaner – Prevents dirt and other debris from entering 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.

22. Fuel Tank Cap – Remove this cap to add unleaded gasoline to the fuel tank. Replenish with clean unleaded gasoline. Make sure cap is tightened securely. DO NOT over fill.

23. Fuel Gauge – This gauge is located on top of the fuel tank. Read this gauge to determine when fuel is low.

24. FuelTank – Fuel tank capacity is 5 gallons (19 liters).

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 generators is placed

on level ground. Placing the generators on level ground will ensure that the low oil sensor will function properly.

GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 17

GA-3.6H Series — GENERATOR REFUELING

DANGER

Addingfueltothetankshouldbedoneonlywhen theengineisstoppedandhashadanopportunity to cool down. In the event of a fuel spill, DONOT 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, REMOVEgenerators from truck bed and place on ground (Figure3)torefuel.Thispossibilityexistoffireorexplosiondue tostaticelectricity.

Figure 3. Generators Refueling

PAGE 18 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)

Outdoor Installation

Install the generator/welder in a area that is free of debris, bystanders, and overhead obstructions. Make sure the 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.

CAUTION

Pay close attention to ventilation when operating the generators inside tunnels and caves.The engine exhaust contains noxious elements.

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.

CAUTION

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.

GA-3.6H Series — 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 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.

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.

Figure 5. Ground Cables/Plugs

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.

Never! use power tools or equipment that do not have a ground capability, the possibility exists of electrocution, electrical shock or burn, which can cause severe bodily harm or even

DEATH!

Main Circuit Breaker

To protect the generators from an overload always place the main circuit breaker in the "OFF" position prior to starting the engine.

Table 3. Cable Selection (60 Hz, Single Phase Operation)

Current in	Load In Watts			Maximum Allowable Cable Length
Amperes	At 120 Volts	#10 Wire			#12 Wire		#14 Wire		#16 Wire
2.5	300	1000 ft.			600	ft.	375 ft.		250 ft.
5	600	500	ft.		300	ft.	200 ft.		125 ft.
7.5	900	350	ft.		200	ft.	125 ft.		100 ft.
10	1200	250	ft.		150 ft.		100 ft.
15	1800	150 ft.			100 ft.		65 ft.
20	2400	125 ft.			75 ft.		50 ft.
CAUTION: Equipment damage can result from low voltage.

GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 21

GA-3H/HA Series — PRE-INSPECTION (ENGINE)

CAUTION

NEVERoperatethegenerators in a confined area or enclosed area structure that does not provide ample free flow of air.

ALWAYS wear approved eye and hearing protection before operating the generator.

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.

Figure 6. Engine Oil Dipstick (Removal)

3.Insertandremovethedipstickwithoutscrewingitintothefiller 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)

Figure 7. Engine Oil Dipstick (Oil Level)

Table 4. Oil Type

Season	Temperature	Oil Type
Summer	25°C or Higher	SAE 10W-30
Spring/Fall	25°C~10°C	SAE 10W-30/20
Winter	0°C or Lower	SAE 10W-10

DANGER EXPLOSIVE FUEL

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 hot! , 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.Readthefuelgaugelocatedontopofthefueltank(Figure8)to determin if the fuel level is low. If fuel is low, replenish with clean unleaded fuel.

Figure 8. Fuel Gauge

4.When refueling, be sure to use a strainer for filtration. DO NOT top-off fuel. DO NOT fill the tank beyond capacity.

Wipe up any spilled fuel immediately!

PAGE 22 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)

GA-3.6H Series— INITIAL START-UP (ENGINE)

CAUTION

DO NOT attempt to operate this generators until the Safety, General Information and Inspection sections of this manual have been read and thoroughly understood.

This section is intended to assist the operator with the initial start-up of the portable generator. It is extremely important that this section be read carefully before attempting to use the generators in the field.

Before Starting the Engine

1.Be sure to disconnect all electrical loads from the generators prior to starting the engine.

2.NEVER start the engine with the main circuit breaker in the “ON" position. Always place this circuit breakers

(Figure 9) in the OFF position before starting.

Figure 9. Main Circuit Breaker (OFF Position)

Starting the Engine

1.Place the engine fuel valve lever (Figure 10) to the "ON" position.”

Figure 10. Engine Fuel Valve Lever (ON Position)

2.Placethechokelever (Figure11)inthe"CLOSED"position if starting a cold engine.

Figure 11. Choke Lever

3.Place the choke lever (Figure 11) in the "OPEN " position if starting a warm engine or the temperature is warm.

4.Placethegenerator's operationswitch(Figure12)inthe "ON"position.

Figure 12. Generator Operation Switch (ON)

5.Grasp the starter grip (Figure 13) and slowly pull it out.The resistancebecomesthehardestatacertainposition,corresponding to the compression point. Pull the starter grip briskly and smoothly for starting.

Figure 13. Starter Grip

CAUTION

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 “OPEN” position. If the engine has not started repeat steps 1 through 5.

7.Beforethegeneratorisplacedintooperation,runtheengine for3-5minutes. Checkfor abnormalsmells,fuelleaks, and noises that would associate with lose components.

8.Place the idle control switch (Figure 14) in the "OFF"

(down) position. This will allow the engine speed to run at speed about 3600 RPM's

Figure 14. Idle Control Switch (Off)

Placing the idle control switch in the OFF position (Figure 14) allows 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),

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.

Figure 15. Idle Control Switch (On)

60 Hz Operation

1. Place main circuit breaker (Figure 16) in the ON position.

2.Place the full power switch (Figure 17) in the 120V position (up).

Figure 17. Full Power Switch 120 V Position (Up)

When the full power switch is in the 120 V position, the 240V twist-lock receptacle cannot be used.

3.Read the voltmeter on the front panel of the generator

(Figure 18) and verify that120 VAC is present at the

120V twist-lock and GFCI duplex receptacles. For additional verification of voltage, an external voltmeter can be used to measure the output voltage as shown in

Figure 18.

Figure 18. 120 V and GFCI Receptacles

4.Place the full power switch (Figure 19) in the 240V position (down).

Figure 17. Main Circuit Breaker (ON)

Figure 19. Full Power Switch 240/120 V Position (Down)

PAGE 24 — GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05)

GA-3.6H Series— GENERATOR OPERATION/SHUTDOWN

5.Read the voltmeter on the front panel of the generator (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.

Figure 20. 60 Hz Output Receptacles

When the full power switch is in the 240 volt (down) position, you can take up to 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 the 120V twist-lock receptacle; or full rated power of the genset at 240 volts from the 240V twist-lock receptacle.

When using a combination of dual receptacles, total load should not exceed the rated capacity 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 idle control switch (Figure 22) in the OFF position.

Figure 22. Idle Control Switch (Off)

3.Let the engine run at idle with no load for 2-3 minutes.

4.To shut-down the engine, place the generator's operation switch (Figure 23) in the OFF position.

Figure 23. Generator Operation Switch (Off)

5.Place the engine fuel valve lever (Figure 24) to the "OFF" position.”

Connecting the Load

1. If small wattage power tools are required, connect them

to the 60 Hz output receptacles at this time. Figure 24. Engine Fuel Valve Lever (OFF Position)

6. Remove all loads from the generator.

GA-3.6H SERIES A.C. GENERATORS — OPERATION & PARTS MANUAL — REV. #0 (11/01/05) — PAGE 25

GA-3.6H Series— PREPARATION FOR LONGTERM 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)