Multiquip GA6HZR User Manual

OPERATION AND PARTS MANUAL

MODEL GA6HZR

PORTABLE GENERATOR

(HONDA GX340 GASOLINE ENGINE)

Revision #3 (03/30/11)

To find the latest revision of this publication, visit our website at: www.multiquip.com

THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.

PROPOSITION 65WARNING

PAGE 2 — GA-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

NOTE PAGE

GA-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 3

GA6HZR Portable 60 Hz

Generator

Here's How To Get Help ............................................	2
Table Of Contents .....................................................	3
Parts Ordering Procedures .......................................	4
Rules For Safe Operation .........................................	5
Operation and Safety Decals ....................................	6
Explanation Of Codes In Remarks Column ..............	7
Specifications ............................................................	8
General Information ..................................................	9
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 .......................................................	20
Troubleshooting (Engine) ...................................	21-22
Troubleshooting (Generator) .............................	23-24
Suggested Spare Parts ...........................................	25
Generator Assembly ..........................................	26-27
Control Box Assembly ........................................	28-29
Pipe Frame Assembly ........................................	30-31
Muffler Assembly ...............................................	32-33
Nameplate Assembly .........................................	34-35

TABLE OF CONTENTS

Honda GX340K1EDN2

Engine

Cylinder Head Assembly ....................................	36-37
Recoil Starter Assembly.....................................	38-39
Fan Cover Assembly ..........................................	40-41
Camshaft/Valves Assembly ................................	42-43
Piston/Rings Assembly.......................................	44-45
Air Cleaner Assembly.........................................	46-47
Cylinder Barrel (Recoil) Assembly .....................	48-49
Cylinder Barrel (Electric) Assembly ...................	50-51
Crankcase Cover/Governor Assembly ..............	52-53
Flywhee/Fan Assembly ......................................	54-55
Coil Assembly.....................................................	56-57
Crankshaft Assembly .........................................	58-59
Governor Controls Assembly .............................	60-61
Carburetor Assembly .........................................	62-63
Solenoid Assembly.............................................	64-65
Fuel Cock Assembly ..........................................	66-67
Terms and Conditions Of Sale — Parts ..................	68

NOTE

Specification and part number are subject to change without notice.

PAGE 4 — GA-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

www.multiquip.com

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

Effective:

January 1st, 2006

Best Deal! Order via Internet (Dealers Only):

If you have an MQ Account, to obtain a Username

Order parts on-line using Multiquip’s SmartEquip website!

and Password, E-mail us at: parts@multiquip.

■ View Parts Diagrams

com.

■ Order Parts

To obtain an MQ Account, contact your

■ Print Specification Information

District Sales Manager for more information.

Goto www.multiquip.com and click on

Use the internet and qualify for a 5% Discount

on Standard orders for all orders which include

Order

Parts

to log in and save!

complete part numbers.*

Note: Discounts Are Subject To Change

Order via Fax (Dealers Only):

Fax your order in and qualify for a 2% 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	UPS/Fed Ex	DHL
	Shipping Address (if different than billing address)	Priority One	Truck
	Return Fax Number	Ground
		Next Day
	Applicable Model Number
		Second/Third Day

Quantity, Part Number and Description of Each Part

NOTICE

All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

GA-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 5

CAUTION:

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

The following safety guidelines should always be used when operating the GA-6HZRGenerator:

GENERAL SAFETY

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

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

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

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

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

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

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

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

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

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

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

RULES FOR SAFE OPERATION

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

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

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

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

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

■Use adequate size connecting cable for extension.

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

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

Emergencies

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

Maintenance Safety

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

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

■Keep the machinery in proper running condition.

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

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

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

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

PAGE 6 — GA-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

OPERATION AND SAFETY DECALS

Machine Safety Decals

The GA-6HZR 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-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 7

GA-6HZR — GENERAL INFORMATION

WARNING:

Excitation System

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-6HZR FAMILIARIZATION

Generator

The Multiquip Model GA-6HZR generator has been designed as a portable lightweight power source for 60 Hz (singlephase) vibrators, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

This generator is powered by a HONDA gasoline engine.

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

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

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

Control Box

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

One 120V output receptacle.

One 240V output receptacle.

One 120V output receptacle (GFI protected).

One main 21 amp circuit breaker.

AC Voltmeter

Idle Control Switch

Full Power Switch

Operation Switch

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:

Excitation (diode 1)

Battery (diode 2)

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-6HZR generator.

NOTE

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

GA-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 9

GA-6HZR — CONTROLS AND INDICATORS

1 2

			6000
			GA-6HZR
			POWERED by
			HONDA
		OFF			3
		AC CIRCUIT BREAKER
		V 120	ON	ON	4
H	12		OFF	OFF
		AC VOLTMETER	IDLE	OPERATION
			CONTROL	SWITCH

120V

ON	5
OFF

240/120V FULL POWER SWITCH

240V

6

120V	GFCI
	GROUND

11

10

9

8

7

NO. PARTS NAME

1CIRCUIT BREAKER

2AC VOLTMETER

3IDLE CONTROL SWITCH

4OPERATION SWITCH

5FULL POWER SWITCH

6RECEPTACLE (250V)

7RECEPTACLE (120V)

8FULL POWER SWITCH

9GFCI RECEPTACLE (120V)

10DIPSTICK

11OIL DRAIN PLUG

12STARTER GRIP

13FUEL TANK

14CONTROL BOX

15MUFFLER

L	W	H
27 IN.	21 IN.	23 IN.
(680 MM)	(530 MM)	(580 MM)

L

W

13

15

14

Figure 1. Controls and Indicators

PAGE 10 — GA-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

Outdoor Installation

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

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

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

GA-6HZR — INSTALLATION

Indoor Installation

Exhaust gases from gasoline engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall.

Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

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

CAUTION : CAUTION :

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

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-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 11

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.

GA-6HZR — PRE-SETUP

Circuit Breaker

To protect the generator from an overload, a 2-pole 13.5 amp 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.

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

	Current	Load In Watts		Maximum Allowable Cable Length
	in
		At 120	At 240	#10 Wire	#12 Wire	#14 Wire	#16 Wire
	Amperes
		Volts	Volts
	2.5	300	600	1000 ft.	600 ft.	375 ft.	250 ft.
	5	600	1200	500 ft.	300 ft.	200 ft.	125 ft.
	7.5	900	1800	350 ft.	200 ft.	125 ft.	100 ft.
	10	1200	2400	250 ft.	150 ft.	100 ft.
	15	1800	3600	150 ft.	100 ft.	65 ft.
	20	2400	4800	125 ft.	75 ft.	50 ft.
	CAUTION: Equipment damage can result from low voltage.

PAGE 12 — GA-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

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.

Table 3. Recommended Motor Oil

Temperature

Type Oil

Range

104° F ~ 23° F

SAE 30

(40° C ~ -5°C)

23° F ~ 5° F

SAE 20 or sae 10W-30

(-5° C ~ -15°C)

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

GA-6HZR — PRE-SETUP

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

GA-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 13

CAUTION :

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

Power Outlets

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

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 21 amp breaker protects the generator from short circuiting or overloading from the 120/240V 60 Hz single phase load.

GA-6HZR — INSTRUMENTATION

Idle Control Switch

This unit is provided with an automatic idle control for noise suppression and reduced fuel consumption. The automatic idle control automatically engages under a no-load condition.

With the automatic idle control switched “ON”, the engine revolutions will automatically drop to about 2500 rpm (lowspeed operation) within 3 seconds after the load stops.When the operation is resumed, the engine speed is automatically increased to about 3600 rpm (high-speed operation) as soon as the load is connected.

Fuel Gauge

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

ACVoltmeter

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-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

Single Phase Load

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

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

NOTE

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

WATTS = VOLTAGE x AMPERAGE

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

1.INCANDESCENT LOADS

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

Example:

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

2.SMALL MOTORS

Drills and other small power tools.

Total the running wattage and multiply by 2. Example:

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

3.LARGE MOTORS

Submersible pumps, table saws etc.

Total the running wattage and multiply by 3. Example:

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

GA-6HZR — LOAD APPLICATION

CAUTION:

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

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

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

GA-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 15

GA-6HZR — 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:

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

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

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”.

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:

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.

Warm up

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

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

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

CAUTION:

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

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

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

Operation

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

Stopping the Engine

CAUTION:

NEVER stop the engine suddenly while running at high speeds.

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

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

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

4.Close the fuel cock.

PAGE 16 — GA-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

General Inspection

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

Engine Side (Refer to the Engine Instruction Manual)

Check Oil Level

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

Changing Oil

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

Air Cleaner

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

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

Wipe excess from heavy duty paper element.

GA-6HZR — MAINTENANCE

Service Daily

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

Cleaning the Fuel Strainer

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

Spark Plug

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

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

Figure 5. Spark Plug Gap

GA-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 17

GA-6HZR — PREPARATION FOR LONG -TERM STORAGE

Generator Storage

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

Drain the fuel tank completely.

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 18 — GA-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

GA-6HZR —WIRING DIAGRAM

GA-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 19

GA-6HZR —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.

TABLE 5. ENGINE TROUBLESHOOTING

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

PAGE 20 — GA-6HZR A.C. GENERATOR— OPERATION AND MANUAL — REV. #3 (03/30/11)

GA-6HZR —TROUBLESHOOTING (ENGINE)

TABLE 5. ENGINE TROUBLESHOOTING (CONTINUED)

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

GA-6HZR A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #3 (03/30/11) — PAGE 21