MULTIQUIP GA-3.6 HZ Parts And Operation Manual

PARTS AND OPERATION MANUAL

MULTIQUIP

Model GA-3.6 HZ

A.C. GENERATOR

© COPYRIGHT 2001, MULTIQUIP INC.

Revision #2 (03/05/01)

MULTIQUIP INC

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
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

..

. PARTS DEPARTMENT:

..

SERVICE DEPARTMENT/TECHNICAL ASSISTANCE:

PAGE 2 — GA-3.6 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-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 3

TABLE OF CONTENTS

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-3.6 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

Muffler Assembly ............................................... 32-33

Nameplate And Decals ...................................... 34-35

Honda GX240K1 Engine

Cylinder Head Assembly .................................... 36-37

Cylinder Barrel Assembly ................................... 38-39

Crankcase Cover Assembly...............................40-41

Crankshaft Assembly .........................................42-43

Piston Assembly .................................................44-45

Camshaft Assembly ...........................................46-47

Recoil Starter Assembly.....................................48-49

Fan Cover Assembly .......................................... 50-51

Carburetor Assembly .........................................52-53

Air Cleaner Assembly.........................................54-55

Flywheel Assembly ............................................56-57

Ignition Coil Assembly ........................................58-59

Governor Control Assembly...............................60-61

Fuel Cock Assembly ..........................................62-63

Terms and Conditions Of Sale — Parts .................. 64

NOTE

Specification and part number
are subject to change without
notice.

PAGE 4 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

PARTS ORDERING PROCEDURES

n

Dealer account number

n

Dealer name and address

n

Shipping address (if different than billing address)

n

Return fax number

n

Applicable model number

n

Quantity, part number and description of each part

n

Specify 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!**

n

UPS Ground Service at no charge for freight

n

PS 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.

Extra Fax DiscountExtra Fax Discount

Extra Fax Discount

Extra Fax DiscountExtra Fax Discount

for Domestic USAfor Domestic USA

for Domestic USA

for Domestic USAfor Domestic USA

Dealers OnlyDealers Only

Dealers Only

Dealers OnlyDealers Only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

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

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

RULES FOR SAFE OPERATION

■

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-3.6HZ 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

could result from fuel vapors, or if fuel is spilled on a hot
engine.

■

This generator is equipped with a
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

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

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.

smoke around or near the machine. Fire or explosion

ground terminal

for your

water, while bare foot, while

bodily harm or

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

■

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.

■

High Temperatures – Allow the machine and engine to cool
before adding fuel or performing service and maintenance
functions. Contact with
burns.

Emergencies

■

Always know the location of the nearest
and

first aid kit

Also know the phone numbers of the nearest

doctor

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

bodily harm or even death.

. Know the location of the nearest telephone.

and

fire department

hot

components can cause serious

fire extinguisher

ambulance

. This information will be

,

PAGE 6 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

OPERATION AND SAFETY DECALS

Machine Safety Decals

The GA-3.6 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-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 7

GA-3.6 HZ — SPECIFICATIONS

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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
fahrenheit above the standard temperature of 60

PAGE 8 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

°

°

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F

GA-3.6 HZ — GENERAL INFORMATION

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-3.6 HZ FAMILIARIZATION
Generator

The Multiquip Model GA-3.6 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

box

. To reduce vibration caused by the engine, the control

box is also placed on rubber isolators.

control

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:

l

Excitation (diode 1)

l

Battery (diode 2)

l

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.

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-3.6 HZ generator.

Control Box

The control box has the following: (all outputs are 60 Hz,
single phase)

l

One 120V output receptacle.

l

One 240V output receptacle.

l

One 120V output receptacle (GFI protected).

l

One main 13.5 amp circuit breaker.

l

AC Voltmeter

l

Idle Control Switch

l

Full Power Switch

l

Operation Switch

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 9

NOTE

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

GA-3.6 HZ — CONTROLS AND INDICATORS

Figure 1. Controls and Indicators

PAGE 10 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — INSTALLATION

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.

CAUTION :

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

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 :

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-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 11

GA-3.6 HZ — PRE-SETUP

General Inspection Prior to Operation

This generator has been thoroughly inspected and accepted
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.

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.

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Circuit Breaker

To protect the generator from an overload,

circuit breaker is provided on the control box. Make sure to
switch this circuit breaker to the "OFF" position prior to
starting the engine.

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.

a 2-pole 13.5 amp

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PAGE 12 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — PRE-SETUP

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 screw
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.

Fuel

Close the fuel cock before filling the tank. 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.

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GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 13

GA-3.6 HZ — INSTRUMENTATION

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 120/240 volt 60 Hz (single­phase) receptacles.

l

Single Phase
One 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)

Main Circuit Breaker (2-Pole 120/240V 60 Hz)

This 2-pole 13.5 amp breaker protects the generator from
short circuiting or overloading from the 120/240V 60 Hz single
phase load.

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-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — LOAD APPLICATION

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:

CAUTION:

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.

Motors and motor-driven equipment draw

much greater current for starting than

during operation.

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-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 15

GA-3.6 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:CAUTION:

CAUTION:

CAUTION:CAUTION:

l

NEVER start the engine when the oil level
is below the lower mark on the dipstick.

l

Check the fuel level on the fuel gauge.
When fuel is low, fill the fuel tank with
clean fresh unleaded automotive gasoline.

l

If 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”.

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:CAUTION:

CAUTION:

CAUTION:CAUTION:

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:CAUTION:

CAUTION:

CAUTION:CAUTION:

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

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:CAUTION:

CAUTION:

CAUTION:CAUTION:

l

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

l

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

PAGE 16 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

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.

4. Close the fuel cock.

GA-3.6 HZ — MAINTENANCE

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.

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.

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 17

Figure 5. Spark Plug Gap

GA-3.6 HZ — PREPARATION FOR LONG -TERM STORAGE

Generator Storage

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

l

Drain the fuel tank completely.

l

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

l

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

l

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

l

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

l

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

l

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

l

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

PAGE 18 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — WIRING DIAGRAM

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 19

GA-3.6 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 5)
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.

MOTPMYS MELBORPELBISSOP NOITULOS

?tignihcaersi

?leuFoN leuFddA

?knatleufniretaW .knatleufecalperrohsulF

?deggolcretlifleuF retlifleufecalpeR

?roterubrackcutS .msinahcemtaolfkcehC

gnitratsrooP

?dersigulpkrapS .tinunoitingirotsinartkcehC.deluofsigulpkrapS

leuffieesotroterubractcepsnI

?etihw-eulbsigulpkrapS

GNITOOHSELBUORTENIGNE.5ELBAT

enilleufkcehC

erastejroterubraC.gnikaelriadetcejni,noisserpmoctneiciffusnI

.)wolfrevo(deggolc

?gulp

?liooN .deriuqersalioddA

?gnitratsnopu

?esool

"noisserpmoc

"noisserpmoc"

on"tuptuorewoptneiciffusnI

?esoolsigulpkrapS .gulpkrapsecalpeR

?sgnirnotsipnroW .sgnirnotsipecalpeR

?deggolcretlifria

tuptuorewoptneiciffusnI

?daeh

krapsfopittatneserpkrapsoN

sknilbpmalmralaerusserpliO

?revonruttonlliwenignE .tniojlexayrassecenfidnanotsipdnarednilycecalpeR

stlobgnitcennocdaehrednilyC

?degamadteksagdaehrednilyC .teksagdaehrednilycecalpeR

?taesevlavfonoitcnuflaM .sevlavtaes-eR

,metsysrenaelc-rianinoitcnuflaM

ecafretnimorfnignikaelriA

rednilycdnaroterubracneewteb

.deluoffigulpkrapsecalpeR.nekorbhctiwspotS/tratS

."rosneslio"tiucricnwodtuhscitamotuAkcehC

.stlobgnitcennocdaehrednilycnethgiT

.retlifriaecalperronaelC

.teksagdaehrednilyc

.nekorbrodekcarcdrocegatlovhgih,nekorbtinunoitingirotsinarT

ecalpeR.daehrednilycdnaroterubracneewtebstlobnethgiT

PAGE 20 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

?metsysleufninoitcnuflaM

.retlifleufecalperronaelC

.roterubracecalperronaelC

.taolfroterubrackcehC

GA-3.6 HZ — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.5ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuorewoptneiciffusnI

staehrevodna"noisserpmoc"

leufhcumotsnruB

ylsuoinitnocsiroloctsuahxE

"ETIHW"

ylsuoinitnocsiroloctsuahxE

"KCALB"

?stcudorp

?sgnirnroW sgnirecalpeR

?nafgniloocninoitcnuflaM .nafgniloocecalperrokcehC

?deggolcretlifekat-niriA .retlifekat-niriaecalperronaelC

tsuahxefonoitalumuccarevO

?gulpkrapsgnorW .gulpkrapsepytdetseggusserutcafunamhtiwgulpkrapsecalpeR

?ytisocsivgnorwsiliognitacirbuL .ytisocsivtcerrochtiwliognitacirbulecalpeR

?deggolcrennaelcriA .renaelcriaecalperronaelC

ottesneebtonsahevlavekohC

?noitisoptcerroceht

nolaes,evitcefedroterubraC

?nekorbroterubrac

tnemtsujdaroterubracrooP

?hcirootsnurenigne"

.sevlavkcehcdnanaelC

.yrassecenfiecalper,relffumkcehC

.noitisoptcerrocehtotevlavekohctsujdA

.laesroroterubracecalpeR

.roterubractsujdA

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 21

GA-3.6 HZ — TROUBLESHOOTING (GENERATOR)

Practically all generator 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 Generator Troubleshooting (Table 6)
information shown below and on the preceding 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.

MOTPMYS MELBORPELBISSOP NOITULOS

egatlovwoL ?wolootdeepsenignE .MPRdetarotdeepsenigneesiaR

?gnikrowtonretemtlovCA .retemtlovcAecalpeR

gniriwlanretnixoblortnoC

?noitcnuflam

?liocnoitingievitcefeD fiseriwnoitingiecalpeR.seriwnoitingineergdnaderkcehC

deepsenignE.egatlovwoL

,)dedaolnu(MPR0563lamron

)eldi(MPR0052

?noitcnuflamgnidniwrotoR .rotorecalperrokcehC

?noitcnuflamgnidniwrotatS .rotatsecalperrokcehC

?noitcnuflamrekaerbegakaeL .2BCro1BCecalperrokcehC

GNITOOHSELBUORTROTARENEG.6ELBAT

.gniriwxoblortnockcehC

.yrassecen

?noitcnuflamhctiwsrewoplluF .tiucrichctiwsrewopllufdnahctiwsrewopllufkcehC

.hgihoottuptuoegatloV ?hgihootdeepsenignE .MPRdetarotdeepsenignerewoL

enignE.hgihoottuptuoegatloV

MPR0563lamrondeeps

)eldi(MPR0052,)dedaolnu(

nonruttonlliwrekaerbtiucriC

"DAOLON"

nonrutlliwrekaerbtiucriC

.yletaidemmispirttub"DEDAOL"

otwolmorfetareleccatonseoD

"DAOLON"hgih

otwolmorfetareleccatonseoD

"EVITCADAOL"hgih

noitcnuflam

?noitiaolrevO .rekaerbecalperrodaolecudeR

?dioneloskcutS .dioneloskcehC

?evitcefed

gniriwlanretnixoblortnoC

?rekaerbtiucricevitcefeD .rekaerbtiucricecalpeR

?detrohssitiucricdaoL .trohsroftiucricdaolkcehC

?hctiwslortnoceldIdaB .hctiwslortnoceldiecalperrokcehC

?noitcnuflamhctiwslortnoceldI .hctiwslortnoceldiecalperrokcehC

?noitcnuflamecivedlortnoceldI .ecivedlortnoceldiecalperrokcehC

gniriwlaretnixoblortnoC

.gniriwxoblortnockcehC

.gniriwxoblortnockcehC

PAGE 22 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — TROUBLESHOOTING (GENERATOR)

MOTPMYS MELBORPELBISSOP NOITULOS

?sgnidniwrotorevitcefeD .rotorecalperrokcehC

)DEUNITNOC(GNITOOHSELBUORTROTARENEG.6ELBAT

onetarelecedtonseoD

."TUPTUOEGATLOV"

sahtubetarelecedtonseoD

."TUPTUOEGATLOV"

?dionelosevitcefeD .dionelosecalperrokcehC

?ecivedlortnoceldievitcefeD .ecivedlortnoceldiecalperrokcehC

?dionelosevitcefeD .ecivedlortnoceldiecalperrokcehC

?noitcnuflamgniriwxoblortnoC .stnenopmocevitcefedynaecalper,gniriwxoblortnockcehC

?dionelosevitcefeD .dionelosecalperrokcehC

?noitcnuflamecivedlortnoceldI .ecivedlortnoceldiecalperrokcehC

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 23

GA-3.6 HZ — EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts
book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column,

■

, belong to the same assembly or kit.

If more than one of the same reference number is
listed, the last one listed indicates newest (or latest)
part available.

, #, +, %, or

*

NOTE

PAGE 24 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

NOTE

The contents of this catalog are
subject to change without notice

.

GA-3.6HZ 1 TO 5 UNITS WITH HONDA
GX240K1VD ENGINE

1 to 5 Units

Qty. P/N Description

5 ............ 9807955846......... SPARK PLUG

1 ............ 15510ZE2W01 ..... OIL LEVEL SWITCH

1 ............ 15600735700 ...... DIPSTICK

1 ............ 28400ZEZW01ZB RECOIL STARTER

5 ............ 17211899000 ...... ELEMENT AIR

1 ............ 16100ZEZF00 ..... CARBURETOR ASSY.

1 ............ 16950ZB4015 ...... FUEL COCK ASSY.

5 ............ 0810107103......... FUEL FILTER

2 ............ 0810106004......... CAP, FUEL TANK

2 ............ 0601805327......... CIRCUIT BREAKER

3 ............ 0601823204......... RECTIFIER

2 ............ 0601812597......... RECEPTACLE

2 ............ 0601811031......... RECEPTACLE, 125V, 30A

2 ............ 0601811032......... RECEPTACLE, 250V 20A

GA-3.6 HZ — SUGGESTED SPARE PARTS

NOTE

Part numbers on this Suggested
Spare Parts List may supercede/
replace the P/N shown in the text
pages of this book.

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 25

GENERATOR ASSY.

GA-3.6 HZ — GENERATOR ASSY.

PAGE 26 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 7911002003 ROTOR ASS;Y 1
1-1 7661080003 FIELD COIL 1
1-2 0601823207 RECTIFIER 2 D3SB60(S)

0771706304 SURGE ABSSORBER 2 TNR15G431K
1-3 0771017004 BEARING 1 6304 2RUNYCM
2 7911-17004 SET BOLT, ROTOR 1
3 0801086104 SET WASSHER, BEARING 1
4 0040010000 SPRING WASHER 1
5 7911344003 ARMATURE ASS’Y1
6 7901315502 END BRACKET 1
7 7871315022 END BRACKET 1
8 7875021513 GUIDE PANEL, AIR 1
9 7661331003 COVER 1
10 7911316004 SET BOLT, STATOR 4
11 0040008000 SPRING WASHER 4
12 0041208000 PLAIN WASHER 4
13 7871329514 GROMMET 1
14 0601851760 CAP 1 0B-13
15 0010108020 HEX. HEAD BOLT 4

0040008000 SPRING WASHER 4

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 27

CONTROL BOX ASSY.

GA-3.6 HZ — CONTROL BOX ASSY.

PAGE 28 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

1 7911811403 CONTROL BOX 1
2 0601850102 GROMMET 1 G-3
3 0601823853 SLOW DOWN UNIT 1 ND-80
4 0027104010 MACHINE SCRE 2

0207004010 HEX. NUT 2
5 7911821413 CONTROL PANEL 1
6 7910501212 NAME PLATE 1 N5431B uptoS/N.2975451

7910501222 NAME PLATE 1 N-5431CfrS/N..2975452
7 0601800258 AC VOLTMETER 1 8283:0-120V.0-240V
8 0601805327 CIRCUIT BREAKER 1 KM-2:265V,13.5A
9 4341817004 BRACKET, CIRCUIT BREAKER 1
10 0027104010 MACHINE SCREW 2
11 0601812597 RECEPTACLE 1 5-20R,GF5352(GFCI)
12 0601811035 RECEPTACLE 1 L5-30R:125V,30A
13 0601811032 RECEPTACLE 1 L6-20R:250V,20A
14 0027104010 MACHINE SCREW 6

0207004000 HEX. NUT 6
15 0601830737 FULL POWER SWITCH 1 ET1330D12
16 0601830727 IDLE CONTROL SWITCH 1 ET115A12
17 0601830738 OPERATION SWITCH 1 ET210K12
18 0601815109 GROUND TERMINAL 1 T-381
19 0601823204 RECTIFIER 2 S5VB60
20 0027103020 MACHINE SCREW 2
21 0017105010 HEX. HEAD BOLT 4
22 0805088004 RUBBER CUSHION 2
23 0805088304 COLLAR 2
24 0017106020 HEX. HEAD BOLT 2
25 0017106016 HEX. HEAD BOLT 1

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 29

PIPE FRAME ASSY.

GA-3.6 HZ — PIPE FRAME ASSY.

PAGE 30 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — PIPE FRAME ASSY.

PIPE FRAME ASSY.

NO PART NO PART NAME QTY. REMARKS

1 7915412002 PIPE FRAME 1
2 7915415004 BRACKET 1
3 0017106016 HEX. HEAD BOLT 4
4 7915443003 BASE 1
5 7895419004 RUBBER SUSPENSION 2
6 0207008000 HEX. NUT 4
7 1725419214 RUBBER SUSPENSION 2
8 0207008000 HEX. NUT 4
9 0017108040 HEX. HEAD BOLT 2
10 0017108040 HEX. HEAD BOLT 2

0207008000 HEX. NUT 2
11 7915455103 COVER 1
12 7915455003 COVER 1
13 0017106016 HEX. HEAD BOLT 6
14 7905512002 FUEL TANK 1
15 0810106004 CAP,FUEL TANK 1
16 0810107103 FUEL FILTER 1
17 0602125031 FUEL GAUGE 1
18 7855525514 RUBBER CUSHION 2
19 7855525604 GCOLLAR 2
20 0017108030 HEX. HEAD BOLT 2
21 0017108020 HEX. HEAD BOLT 2
22 0605511087 FUEL COCK 1
23 0605513140 HOSE 1
24 0605515096 HOSE BAND 2

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 31

MUFFLER ASSY.

GA-3.6 HZ — MUFFLER ASSY.

PAGE 32 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ — MUFFLER ASSY.

MUFFLER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 7912310003 MUFFLER 1
2 0602302000 PROTECTOR, MUFFLER 1 HONDA18320ZB4000
3 0602302002 PROTECTOR, MUFFLER 1 HONDA18325ZB4000
4 0602302003 SEAL 2 HONDA18329ZB4000
5 0602322060 ARRESTER, SPARK 1 HONDA18355ZB4630
6 0602322060 TAPPING SCREW 1 HONDA90183-671-003
7 0017106012 HEX. HEAD BOLT 5
8 0602320175 GASSKET 1 HONDA18333ZB4800
9 0602322061 HEX. HEAD BOLT 2 HONDA95700-08020-00
10 7915461004 BRACKET 1
11 0017108020 HEX. HEAD BOLT 1
12 7915460004 BRACKET 1
13 0017108025 HEX. HEAD BOLT 2

0207008000 HEX. NUT 2
14 0017108020 HEX. HEAD BOLT 2
15 7915469004 BRACKET 1
16 0017106020 HEX. HEAD BOLT 1
17 0017106012 HEX. HEAD BOLT 2

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 33

NAMEPLATE AND DECALS

GA-3.6 HZ— NAMEPLATE AND DECALS

PAGE 34 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

GA-3.6 HZ— NAMEPLATE AND DECALS

NAMEPLATE AND DECALS

NO PART NO PART NAME QTY. REMARKS

1 0800628504 DECAL : GROUND 1 S-1123
2 1980680004 DECAL : FUEL COCK 1 S-3704
3 7900638004 DECAL : OPERATING INSTRUCTIONS 1 S-4605
4 7910501222 DECAL : MQ GA-3.6HZ 1
5 7910631002 DECAL : MQ 3600 1 S-3753
6 0820610304 DECAL : CAUTION 1
7 0820610404 DECAL : WARNING 1
8 7900636004 DECAL : OPERATE AT 3600 RPM ONLY 1
9 8700611804 DECAL : WARNING 1
10 8700611904 DECAL : DANGER 1

SEE ADDITIONAL DECAL ILLUSTRATIONS ON PAGE 7.

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 35

HONDA GX240K1 ENGINE — CYLINDER HEAD ASSY.

CYLINDER HEAD ASSY.

HONDA GX240K1 ENGINE — CYLINDER HEAD

PAGE 36 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — CYLINDER HEAD ASSY.

CYLINDER HEAD ASSY.

NO PART NO PART NAME QTY. REMARKS
1 122AOZH9000 HEAD COMP., CYLNDER 1
2 12204ZE2325 GUIDE, IN. VALVE (OVER SIZE) 1
3 12205ZE2315 GUIDE, EX. VALVE (OVER SIZE) 1
4 12216ZE2300 CLIP, VALVE GUIDE 1
5 12251ZE2800 GASKET, CYLINDER HEAD 1
6 12310ZE2010 COVER COMP., HEAD 1
7 12391ZE2010 PACKING, HEAD COVER 1
8 18330ZE3700 PIPE, EX. 1
9 18333ZE3800 GASKET, EX. PIPE 1
10 90014ZE2000 BOLT, HEAD COVER 1
11 90042ZE2700 BOLT, STUD, 8X98 2
12 90047ZE2000 BOLT, STUD, 8X47 2
13 90441ZE2010 WASHER COMP., HEAD COVER 1
14 9405008000 NUT, FLANGE, 8MM 2
15 9430112200 PIN, DOWEL, 12X20 2
16 957251008000 BOLT, FLANGE, 10X80 4
17 9807955846 PLUG, SPARK (BPR5ES NGK) 1

9807955855 PLUG, SPARK (W16EPR-U ND) 1

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 37

HONDA GX240K1 ENGINE — CYLINDER BARREL ASSY.

CYLINDER BARREL ASSY.

PAGE 38 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — CYLINDER BARREL ASSY.

CYLINDER BARREL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 120A0GZE2813 BARREL ASSY., CYLINDER 1
2 15510ZE2W01 SWITCH ASSY., OIL LEVEL 1
3 16541ZE2000 SHAFT, GOVERNOR ARM 1
4 90131883000 BOLT, DRAIN PLUG 2
5 90446KE1000 WASHER, 8.2X17X0.8 1
6 9410912000 WASHER, DRAIN PLUG 2
7 91201890003 OIL SEAL 1
8 91253671004 OIL SEAL 1
9 91353671004 O RING, 14MM 1
10 9405010000 NUT, FLANGE, 10MM 1
11 9425108000 PIN, LOCK, 8MM 1

12 957010601200 BOLT, FLANGE, 6Z12 2

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 39

HONDA GX240K1 ENGINE — CRANKCASE COVER ASSY.

CRANKCASE COVER ASSY.

PAGE 40 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — CRANKCASE COVER ASSY.

CRANKCASE COVER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 06165ZE2000 GOVERNOR KIT 1
2 11300ZE2000 COVER ASSY., CRANKCASE 1
3 11381ZE2800 PACKING, CASE COVER 1
4 15600735700 CAP ASSY., OIL FILLER 1
5 15620ZG4910 CAP, OIL FILLER 1
6 15620735700 CAP, OIL FILLER 1
7 15621896010 PACKING, OIL FILLER CAP 1
8 15625ZE1000 PACKING, OIL FILLER CAP 1
9 16510ZE2000 GOVERNOR ASSY. 1
10 16511ZE2000 WEIGHT, GOVERNOR 2
11 16512ZE2000 HOLDER, GOVERNOR WEIGHT 1
12 16513ZE2000 PIN, GOVERNOR WEIGHT 2
13 16531ZE2000 SLIDER, GOVERNOR 1
14 90473147000 WASHER, 6X16 1
15 90602ZE1000 CLIP, GOVERNOR HOLDER 1
16 90701HC4000 PIN, DOWEL, 8X12 2
17 91201890003 OIL SEAL, 30X46X8 1
18 9410106800 WASHER, PLAIN, 6MM 1
19 959000803500 BOLT, FLANGE, 8X35 1
20 961006206000 BEARING, RADIAL BALL 6206 1
21 961006207000 BEARING, RADIAL BALL 6207 1

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 41

CRANKSHAFT ASSY.

HONDA GX240K1 ENGINE — CRANKSHAFT ASSY.

PAGE 42 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — CRANKSHAFT ASSY.

CRANKSHAFT ASSY.

NO PART NO PART NAME QTY. REMARKS

1 13310ZE2701 CRANKSHAFT COMP. 1
2 14311ZE2310 GEAR, TIMING 1
3 16505ZE2300 GEAR, GOVERNOR DRIVE 1

4 961006206000 BEARING, RADIAL BALL, 6206 1

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 43

PISTON ASSY.

HONDA GX240K1 ENGINE — PISTON ASSY.

PAGE 44 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — PISTON ASSY.

PISTON ASSY.

NO PART NO PART NAME QTY. REMARKS

1 13020ZE2013 RING SET, PISTON (STD) 1

13010ZE2014 RING SET, PISTON (STD) 1
13011ZE2013 RING SET, PISTON (0.25) 1
13011ZE2014 RING SET, PISTON (0.25) 1
13012ZE2013 RING SET, PISTON (0.50) 1
13012ZE2014 RING SET, PISTON (0.50) 1
13013ZE2013 RING SET, PISTON (0.75) 1
13013ZE2014 RING SET, PISTON (0.75) 1

2 13101ZE2W00 PISTON (STD) 1

13102ZE2W00 PISTON (0.25) 1
13103ZE2W00 PISTON (0.50) 1

13104ZE2W00 PISTON (0.75) 1
3 13111ZE2000 PIN, PISTON 1
4 13200ZE2000 ROD ASSY., CONNECTING 1
5 90001ZE8000 BOLT, CONNECTING ROD 2
6 90551ZE1000 CLIP, PISTON PIN, 18MM 2

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 45

CAMSHAFT ASSY.

HONDA GX240K1 ENGINE — CAMSHAFT ASSY.

PAGE 46 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — CAMSHAFT ASSY.

CAMSHAFT ASSY.

NO PART NO PART NAME QTY. REMARKS

1 14100ZE2W00 CAMSHAFT ASSY. 1
2 14410ZE2013 ROD, PUSH 2
3 14431ZE2000 ARM, VALVE ROCKER 2
4 14441ZE2000 LIFTER, VALVE 2
5 14451ZE1003 PIVOT, ROCKER ARM 2
6 14568ZE1000 SPRING, WEIGHT RETURN 1
7 14711ZE2000 VALVE, IN 1
8 14721ZE2000 VALVE, EX. 1
9 14751ZE2003 SPRING, VALVE 2
10 14771ZE2000 RETAINER, IN. VALVE SPRING 1
11 14773ZE2000 RETAINER, EX. VALVE SPRING 1
12 14775ZE2010 SEAT, VALVE SPRING 2
13 14781ZE2000 ROTATOR, VALVE 1
14 14791ZE2010 PLATE, PUSH ROD GUIDE 1
15 90012ZE0010 BOLT, PIVOT 2
16 90206ZE1000 NUT, PIVOT ADJUSTING 2

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 47

RECOIL STARTER ASSY.

HONDA GX240K1 ENGINE — RECOIL STARTER ASSY.

PAGE 48 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — RECOIL STARTER ASSY.

RECOIL STARTER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 28400ZE2W01ZB STARTER ASSY, RECOIL 1
2 28410ZE2W01ZB CASE COMP., RECOIL STARTER 1
3 28421ZE2W01 PULLEY, RECOIL STARTER 1
4 28422ZE2W01 RATCHET, STARTER 2
5 28441ZE2W01 SPRING, FRICTION 1
6 28442ZE2W01 SPRING, STARTER RETURN 1
7 28443ZE2W01 SPRING, RATCHET 2
8 28444ZE2W01 RETAINER, SPRING 1
9 28445ZE2W01 HOLDER, SPRING 1
10 28461ZE2W01 GRIP, STARTER 1
11 28462ZE2W01 ROPE, RECOIL STARTER 1
12 28469ZE2W01 GRID REINFORCEMENT 1
13 90004ZE2W01 SCREW, CENTER 1

14 957010600800 BOLT, FLANGE, 6X8 3

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 49

FAN COVER ASSY.

HONDA GX240K1 ENGINE — FAN COVER ASSY.

PAGE 50 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — FAN COVER ASSY.

FAN COVER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 19610ZE2700ZD COVER COMP., FAN 1
2 19631ZH9000 SHROUD 1
3 81329567020 GROMMET, DRAIN HOLE 1
4 90013883000 BOLT, FLANGE, 6X12 6

5 90654SA4003 CLIP 2

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 51

CARBURETOR ASSY.

HONDA GX240K1 ENGINE — CARBURETOR ASSY.

PAGE 52 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — CARBURETOR ASSY.

CARBURETOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 16010ZE3701 GASKET SET 1
2 16011ZA0931 VALVE SET, FLOAT 1
3 16013ZA0931 FLOAT SET 1
4 16015ZA0931 CHAMBER SET, FLOAT 1
5 16016ZH7W01 SCREW SET 1
6 16024124761 SCREW SET, DRAIN 1
7 16028ZA0931 SCREW SET 1
8 16100ZE2F00 CARBURETOR ASSY. 1
9 16124ZE0005 SCREW, THROTTLE STOP 1
10 16148141881 CAP, CHOKE DUST 1
11 16166ZE2015 NOZZLE, MAIN 1
12 16230ZE3701 VALVE ASSY., SOLENOID 1
13 16211ZE2700 INSULATOR, CARBURETOR 1
14 16221ZA0800 PACKING, CARBURETOR 1
15 16223ZA0800 PACKING, INSULATOR 1
16 16260ZE2722 STAY, MANUAL CHOKE 1
17 16261ZE2702 STAY, COMP., SOLENIOD 1
18 16262ZE2711 LEVER, CHOKE 1
19 16263ZA0000 JOINT, ROD 1
20 16264ZE2701 ROD, CHOKE 1
21 16265ZE2721 STOPER, CHOKE ROD 1
22 16268ZE2721 SPRING, MANUAL CHOKE 1
23 16269ZA0800 PACKING, AIR CLEANER 2
24 16400ZE2703 DIAPHRAGM ASSY. 1
25 16611ZE2711 ROD, CHOKE CONTROL 1
26 16613893000 GROMMET, CHOKE ROD 1
27 16615893000 GUIDE, CHOKE ROD 1
28 36135ZV003 VALVE, DASHPOT CHECK 1
29 53149964003 BUSH, ARM PIVOT 1
30 88911MJ3000 GROMMET, FENDER 1
31 90431ZE2700 WASHER, CHOKE LEVER 1
32 90432ZE2700 SEAL, CHOKE LEVER 2
33 90433ZE2700 WASHER, THRUST 1
34 90434ZE2700 COLLAR, LOVER 1
35 90650SD9003 CLIP, WIRE HARNESS 1
36 93500050120A SCREW, PAN, 5X12 2
37 938920501208 SCREW, WASHER 5X12 2
38 9410305000 WASHER, PLAIN 5MM 1
39 9454002010 E-RING 2MM 1
40 9454004010 E-RING 4MM 1
41 9454007010 E-RING 7MM 1
42 9500202070 CLIP B7, TUBE 4
43 950053506510 TUBE, 3.5X65 1
44 950053513010 TUBE, 3.5X130 1
45 99101ZF50750 JET, MAIN, #78 1

99101ZF50780 JET, MAIN, #80 1
99101ZF50800 JET, MAIN, #82 1

46 99204ZA00450 JET SET, PILOT, #45 1

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 53

AIR CLEANER ASSY.

HONDA GX240K1 ENGINE — AIR CLEANER ASSY.

PAGE 54 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — AIR CLEANER ASSY.

AIR CLEANER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 15721ZB4000 TUBE BREATHER 1
2 17211899000 ELEMENT, AIR CLEANER 1
3 17212ZB4003 SEPARATOR, AIR CLEANER 1
4 17220ZB4003 CASE COMP., AIR CLEANER 1
5 17222ZB4000 STAY, AIR CLEANER 1
6 17231899000 COVER COMP., AIR CLEANER 1
7 17235899000 CLIP A, AIR CLEANER WIRE 2
8 17236899000 CLIP B, AIR CLEANER WIRE 2
9 17252899000 SEAL, AIR CLEANER 1
10 17367413690 FILTER, DRAIN TUBE 1
11 9405005000 NUT, FLANGE, 5 MM 6
12 9405006000 NUT, FLANGE, 6 MM 3

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 55

FLYWHEEL ASSY.

HONDA GX240K1 ENGINE — FLYWHEEL ASSY.

PAGE 56 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — FLYWHEEL ASSY.

FLYWHEEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 19511ZE2000 FAN, COOLING 1
2 28451ZE2W01 PULLEY, STARTER 1
3 31100ZE2811 FLYWHEEL COMP. 1
4 90201ZE3790 NUT, SPECIAL, 16MM 1
5 90741ZE2000 KEY, SPECIAL WOODRUFF 1

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 57

IGNITION COIL ASSY.

HONDA GX240K1 ENGINE — IGNITION COIL ASSY.

PAGE 58 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — IGNITION COIL ASSY.

IGNITION COIL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 30500ZE2013 COIL ASSY., IGNITION 1
2 30700ZE1013 CAP ASSY., NOISE SUPPRESSO 1
3 30701883000 CLIP, HIGH TENSION CORD 1
4 31501ZE1811 COIL ASSY., LAMP 12V/25W 1

31510ZE3003 COIL ASSY., LAMP 12V/25W 1
5 31511ZE2000 CLAMPER, CORD 1
6 31512ZE2000 GROMMET, CORD 1
7 36101ZE2701 CORD, STOP SWITCH 1
8 90013883000 BOLT, FLANGE, 6X12 1
9 90015883000 BOLT, FLANGE, 6X28 6

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 59

HONDA GX240K1 ENGINE — GOVERNOR/CONTROL ASSY.

GOVERNOR/CONTROL ASSY.

PAGE 60 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — GOVERNOR/CONTROL ASSY.

GOVERNOR/CONTROL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 16550ZE2700 ARM, GOVERNOR 1
2 16555ZE2000 ROD, GOVERNOR 1
3 16561ZE2000 SPRING, GOVERNOR 1
4 16562ZE2700 SPRING, THROTTLE RETURN 1
5 16570ZE2701 CONTROL ASSY. 1
6 16584883300 SPRING, CONTROL ADJUSTING 1
7 90013883000 BOLT, FLANGE, 6X12 2
8 90015ZE5010 BOLT, GOVERNOR ARM 1
9 93600050350A SCREW, PAN, 5X35 1

10 9405006000 NUT, FLANGE, 6MM 1

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 61

FUEL COCK ASSY.

HONDA GX240K1 ENGINE — FUEL COCK ASSY.

PAGE 62 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

HONDA GX240K1 ENGINE — FUEL COCK ASSY.

FUEL COCK ASSY.

NO PART NO PART NAME QTY. REMARKS

1 16173001004 PACKING, FUEL STRAINER CUP 1
2 16950ZB4015 COCK ASSY., FUEL 1
3 16952ZB4005 SCREEN, FUEL STRAINER 1
4 16958397771 O-RING 1
5 16959471831 FILTER CUP 1
6 16967GA6671 CUP, FUEL STRAINER 1
7 90854ZB2000 RUBBER, FUEL TUBE 1
8 950014519040 TUBE, FUEL, 4.5X190 1
9 9500202080 CLIP B8, TUBE 2

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 63

Effective: July 1, 2000

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a signed
manifest has been obtained from the carrier,
and any claim for shortage or damage must be
settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit
will be allowed, subject to the following
provisions:

1. A Returned Material Authorization must
be approved by Multiquip prior to shipment.

2. To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers,
quantities, and descriptions of the items to
be returned.

a. The parts numbers and descriptions

must match the current parts price
list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which
the items were originally purchased.

e. The list must include the name and

phone number of the person
requesting the RMA.

3. A copy of the Return Material
Authorization must accompany the return
shipment.

4. Freight is at the sender’s expense. All

5. Parts must be in new and resalable

6. The following items are not returnable:

7. The sender will be notified of any material

8. Such material will be held for 5 working

9. Credit on returned parts will be issued at

10. In cases where an item is accepted for

11. Credit issued will be applied to future

PRICING AND REBATES

parts must be returned freight prepaid to
Multiquip’s designated receiving point.

condition, in the original Multiquip package
(if any), and with Muiltiquip part numbers
clearly marked.

a. Obsolete parts. (If an item is listed

in the parts price book as being
replaced by another item, it is
obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.
d. Special order items.
e. Electrical components.
f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.

received that is not acceptable.

days from notification, pending
instructions. If a reply is not received
within 5 days, the material will be returned
to the sender at his expense.

dealer net price at time of the original
purchase, less a 15% restocking charge.

which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.

purchases only.

Prices are subject to change without prior
notice. Price changes are effective on a specific
date and all orders received on or after that date
will be billed at the revised price. Rebates for
price declines and added charges for price
increases will not be made for stock on hand at
the time of any price change.

Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.

SPECIAL EXPEDITING SERVICE

A $20.00 to $50.00 surcharge will be added to
the invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for
damages in excess of the purchase price of the
item with respect to which damages are claimed,
and in no event shall Multiquip be liable for loss
of profit or good will or for any other special,
consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in
connection with the sale of parts or trade
accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes not
authorizes any person to assume for it any
other obligation or liability whatever in
connection with the sale of its products. A part
from such written statement of warranty, there
are no warranties, express, implied or statutory,
which extend beyond the description of the
products on the face hereof.

PAGE 64 — GA-3.6 HZ A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (03/05/01)

NOTE PAGE

GA-3.6 HZ A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 65

PARTS AND OPERATION MANUAL

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]

Manufactured for MULTIQUIP INC.
by
DENYO MANUFACTURING CO., JAPAN

MULTIQUIP INC.

POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: [phone]
E-MAIL: [e-mail]
WWW: multiquip.com

Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX

Atlanta • Boise • Dallas • Houston • Newark