Multiquip GA-6RZR2 User Manual

PARTS AND OPERATION MANUAL

MULTIQUIP

Model GA-6RZR2

A.C. GENERATOR

© COPYRIGHT 2001, MULTIQUIP INC.

Revision #5 (09/16/05)

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-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05)

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-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05) — 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-6RZR2—
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

Name Plate And Decals ..................................... 32-33

ROBIN EH-34YD Engine

Crankcase Assembly ......................................... 34-35

Crankshaft & Piston Assembly ........................... 36-37

Intake Exhaust Assembly ................................... 38-39

Governor Assembly ........................................... 40-41

Cooling & Recoil Starter Assembly ....................42-43

Carburetor Assembly .........................................44-45

Electric Coil Assembly And Spark Plug .............. 46-47

Oil Level Sensor & Solenoid Assembly .............. 48-49

Terms and Conditions Of Sale — Parts .................. 50

NOTE

Specification and part number
are subject to change without
notice.

PAGE 4 — GA-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05)

PARTS ORDERING PROCEDURES

■■

■ Dealer account number

■■

■■

■ Dealer name and address

■■

■■

■ Shipping address (if different than billing address)

■■

■■

■ Return fax number

■■

■■

■ Applicable model number

■■

■■

■ Quantity, part number and description of each part

■■

■■

■ 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!**

■■

■

UPS Ground Service at no charge for freight

■■

■■

■

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-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05) — 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-6RZR2RGenerator:

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-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05)

OPERATION AND SAFETY DECALS

Machine Safety Decals

The GA-6RZR2 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-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05) — PAGE 7

GA-6RZR2— SPECIFICATIONS

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Effects of Altitude and Heat

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

°°

°

°°

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

°°

°

fahrenheit above the standard temperature of 60

PAGE 8 — GA-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05)

°°

F

F

GA-6RZR2— 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-6RZR2 FAMILIARIZATION
Generator

The Multiquip Model GA-6RZR2 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 ROBIN 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:

z

Excitation (diode 1)

z

Battery (diode 2)

z

Slow Down (diode 3)

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

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

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

Engine

The four-cycle air-cooled ROBIN 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-6RZR2 generator.

Control Box

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

z

One 120V output receptacle.

z

One 240V output receptacle.

z

One 120V output receptacle (GFI protected).

z

One main 21 amp circuit breaker.

z

AC Voltmeter

z

Idle Control Switch

z

Full Power Switch

z

Operation Switch

GA-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05) — 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-6RZR2 — CONTROLS AND INDICATORS

Figure 1. Controls and Indicators

PAGE 10 — GA-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05)

GA-6RZ2— 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-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05) — PAGE 11

GA-6RZR2— 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 21 amp

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PAGE 12 — GA-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05)

GA-6RZR2— 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.

NOTE

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

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-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05) — PAGE 13

GA-6RZR2— 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.

zz

z

Single Phase

zz

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.

Idle Control Switch

Start Switch

Push this switch to start the engine (electric start only). If a
recoil starter is used, pull the starter rope to start the engine.
Make sure the operation switch is in the ON position (up),
otherwise engine will not start.

Full Power Switch

The unit is provided with a full power switch. Figures 2 and
3 show simplified wiring diagrams of the dual voltage system.

When the full power switch is in the 120 volt (up) position,
you can take up
volts from the single duplex receptacle, single locking type
120 volt receptacle, or a combination of these receptacles
as long as the total load does not exceed the generating set
capacity.

full rated power

of the generator at 120

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.

Figure 2. 120 V Simplified Diagram (Switch Up)

When the full power switch is in the 120 volt
position, the locking type 240 volt receptacle
cannot be used.

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 duplex receptacle and up to half of
the rated power of the set at 120 volts from the locking type
120 volt receptacle; or full rated power of the set at 240
volts from the locking type 240 volt receptacle.

NOTE

Operation Switch

This switch must be in the ON position (up) for normal
operation.

PAGE 14 — GA-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05)

Figure 3. 120/240V Simplified Diagram (Sw Dn.)

GA-6RZR2— 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-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05) — PAGE 15

GA-6RZR2— 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:

z

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

z

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

z

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

Starting

1. Open the fuel cock located below the fuel tank. The fuel

starts to flow when the fuel cock lever is turned
downward.

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

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 8 on page 10.

DO NOT change the engine speed control

lever which has been set at the factory prior
to shipping.

3. 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.

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

5. 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.

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

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

z

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

z

DO NOT release the starter rope after

pulling. Allow it to rewind as soon as
possible.

PAGE 16 — GA-6RZR2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #5 (09/16/05)

Stopping the Engine

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

1. Remove the load from the generator. Place the circuit
breaker in the “OFF” position. Refer to Figure 1, item 9
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. Close the fuel cock.

NEVER stop the engine suddenly while
running at high speeds.