Multiquip GAC2.2H User Manual

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OPERATION AND PARTS MANUAL

MODEL GAC2.2H

PORTABLE GENERATOR

(HONDA GX160 GASOLINE ENGINE)

Revision #1 (03/31/10)

To ﬁnd the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

TABLE OF CONTENTS

GAC2.2H Portable 60 Hz Generator

Table Of Contents .................................................... 2

Parts Ordering Procedures ...................................... 3

Safety Information ................................................ 4-8

Speciﬁcations (Generator) ..................................... 10

Speciﬁcations (Engine) .......................................... 11

Dimensions ............................................................ 12

Installation ........................................................14-15

General Information ............................................... 16

Components (Generator) .................................. 17-18

Inspection/Setup ............................................... 19-20

Operation .......................................................... 21-22

Preparation For Long Term Storage ...................... 23

Maintenance ..................................................... 24-25

Generator Wiring Diagram .................................... 26

Troubleshooting (Engine) .................................. 27-28

Troubleshooting (Generator) .................................. 29

Explanation of Code in Remarks Column ............. 30

Suggested Spare Parts ......................................... 31

Honda GX160K1EMA2/ GX160U1EMAN Engines

Cylinder Head Assembly .................................. 40-41

Cylinder Barrel Assembly ................................. 42-43

Crankcase Cover Assembly. ............................. 44-45

Crankshaft Assembly ........................................ 46-47

Piston Assembly ............................................... 48-49

Camshaft Assembly .......................................... 50-51

Recoil Starter Assembly ................................... 52-53

Fan Cover Assembly ......................................... 54-55

Carburetor Assembly ........................................ 56-57

Air Cleaner Assembly ....................................... 58-59

Mufﬂer Assembly .............................................. 60-61

Flywheel Assembly ........................................... 62-63

Ignition Coil Assembly ...................................... 64-65

Governor Control Assembly. ............................. 66-67

Engine Decals Assembly .................................. 68-69

Tool Kit ............................................................. 70-71

Terms and Conditions of Sale — Parts .................. 72

Component Drawings

Nameplate and Decals Assembly ..................... 32-33

Generator Assembly ......................................... 34-35

Control Box Assembly ...................................... 36-37

Pipe Frame Assembly ....................................... 38-39

NOTICE

Speciﬁcations and part numbers are subject to change without notice.

PAGE 2 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

If you have an MQ Account, to obtain a Username

Effective:

Choose from three easy options:

January 1st, 2006

Best Deal!

Order via Internet (Dealers Only):

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

■ View Parts Diagrams

■ Order Parts

■ Print Speciﬁ cation Information

Goto www.multiquip.com and click on

Order Parts

to log in and save!

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877)

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

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

com.

To ob ta in an MQ Acc o unt , co nt act your District Sales Manager for more information.

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

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

Note: Discounts Are Subject To Change

When ordering parts, please supply:

❒ Dealer Account Number ❒ Dealer Name and Address ❒ Shipping Address (if different than billing address) ❒ Return Fax Number ❒ Applicable Model Number ❒ Quantity, Part Number and Description of Each Part

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

❒ Specify Preferred Method of Shipment: ✓ UPS/Fed Ex ✓ DHL

■ Priority One ✓ Truck

■ Ground

■ Next Day

■ Second/Third Day

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 3

SAFETY INFORMATION

Do not operate or service the equipment before reading the

Potential hazards associated with the operation of this

entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages speciﬁ cally address the level of exposure to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION or NOTICE.

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING

equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

Indicates a hazardous situation which, if not avoided,

COULD result in DEATH or SERIOUS INJURY.

CAUTION

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

PAGE 4 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by Multiquip for this equipment. Damage

Also, know the

and

This information will be invaluable in

emergency or safety devices.

Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these

ensure generator is on level ground before use.

keep the machine in proper running condition.

store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel

CAUTION

 NEVER operate this equipment without proper protective

clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.

NEVER operate this equipment under the inﬂ uence of

drugs or alcohol.

ALWAYS check the equipment for loosened threads or bolts before starting.

DO NOT use the equipment for any purpose other than

its intended purposes or applications.

to the equipment and/or injury to user may result.

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest

phone or keep a phone on the job site. phone numbers of the nearest ambulance, doctor

ﬁ re department.

the case of an emergency.

GENERATOR SAFETY

DANGER

 NEVER operate the equipment in an explosive

atmosphere or near combustible materials. An explosion or ﬁ re could result causing severe

bodily harm or even death.

WARNING

NOTICE

This equipment should only be operated by trained and qualiﬁ ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and

safety decals when they become difﬁ cult read.

Manufacturer does not assume responsibility for any

accident due to equipment modiﬁ cations. Unauthorized equipment modiﬁ cation will void all warranties.

 NEVER disconnect any

These devices are inten ded for operator safety.

devices will void all warranties.

CAUTION

 NEVER lubricate components or attempt service on a

running machine.

NOTICE

 ALWAYS

 Fix damage to machine and replace any broken parts

immediately.

 ALWAYS

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 5

SAFETY INFORMATION

ENGINE SAFETY



from the engine exhaust. Spark arresters are qualiﬁ ed

add fuel to equipment if it is placed inside truck

start the engine near spilled fuel or combustible ﬂ uids. Diesel fuel is extremely ﬂ ammable and its vapors

overﬁ ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from

to prevent accidental discharge of sparks or ﬂ ames

DANGER

 The engine fuel exhaust gases contain poisonous carbon

monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine of this equipment requires an adequate free ﬂ ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free ﬂ ow of the air is restricted. If the air ﬂ ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

WARNING

 NEVER operate the engine with heat shields or

guards removed.

 DO NOT remove the engine oil drain plug while

the engine is hot. Hot oil will gush out of the engine crankcase and severely scald any persons in the general area of the generator.

and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.

FUEL SAFETY

DANGER

 DO NOT

bed with plastic liner. Possibility exists of explosion or ﬁ re due to static electricity.

CAUTION

NEVER touch the hot exhaust manifold,

mufﬂ er or cylinder. Allow these parts to cool before servicing equipment.

NOTICE

 NEVER run engine without an air ﬁ lter or with a dirty air

ﬁ lter. Severe engine damage may occur. Service air ﬁ lter frequently to prevent engine malfunction.

NEVER tamper with the factory settings of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable.

 State Health Safety Codes and Public Resources

Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed

 DO NOT

can cause an explosion if ignited.

 ALWAYS refuel in a well-ventilated area, away from

sparks and open ﬂ ames.

 ALWAYS use extreme caution when working with

ﬂ ammable liquids.

 DO NOT ﬁ ll the fuel tank while the engine is running

or hot.

 DO NOT

the ignition system.

 Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and ﬂ ames.

PAGE 6 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

SAFETY INFORMATION

 NEVER use fuel as a cleaning agent.

 Make sure power cables are securely connected to the

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

make sure that electrical circuits are properly

Severe injury or death by

can result from operating an ungrounded

drop the battery. There is a possibility that the

charge battery if frozen. Battery can explode.

keep the battery charged. If the battery is not

environment to avoid the risk of a dangerous concentration

 DO NOT smoke around or near the

equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a

hot engine.

ELECTRICAL SAFETY

DANGER

 Turn generator and all circuit breakers OFF before

performing maintenance on the generator or making contact with output receptacles.

 NEVER insert any objects into the

output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death.

 Backfeed to a utility system can cause

electrocution and/or property damage. NEVER connect the generator to a

building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious

injury or even death.

Power Cord/Cable Safety

DANGER

 NEVER let power cords or cables lay in water.

 NEVER stand in water while AC power from the

generator is being transferred to a load.

 NEVER use damaged or worn cables or cords when

connecting equipment to generator. Inspect for cuts in the insulation.

 NEVER grab or touch a live power

cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.

generator’s output receptacles. Incorrect connections may cause elect r i cal sho ck and dama ge to the generator.

NOTICE

 ALWAYS

Chart in this manual.

Grounding Safety

DANGER

 ALWAYS

grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator.

electrocution

generator.

 NEVER use gas piping as an electrical ground.

BATTERY SAFETY (ELECTRIC START ONLY)

DANGER

 DO NOT

battery will explode.

 DO NOT expose the battery to open ﬂ ames,

sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a ﬂ ame or spark, an explosion could occur.

 DO NOT

When frozen, warm the battery to at least 61°F (16°C).

WARNING

 ALWAY S wear sa fety gl a ss e s when

handling the battery to avoid eye irritation. The battery contains acids that can cause injury to the eyes and skin.

 Use well-insulated gloves when picking up the battery.

 ALWAYS

charged, combustible gas will build up.

 ALWAYS recharge the battery in a well-ventilated

of combustible gasses.

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 7

 If the battery liquid (dilute sulfuric acid) comes into

contact with clothing or skin, rinse skin or clothing

ENVIRONMENTAL SAFETY

pour waste, oil or fuel directly onto the ground,

immediately with plenty of water.

SAFETY INFORMATION

NOTICE

 If the battery liquid (dilute sulfuric acid) comes into

contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

CAUTION

 ALWAYS disconnect the NEGATIVE battery terminal

before performing service on the generator.

 ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

TRANSPORTING SAFETY

CAUTION

 NEVER allow any person or animal to stand underneath

the equipment while lifting.

NOTICE

 Before lifting, make sure that the equipment parts (lifting

bail if equipped) are not damaged and screws are not loose or missing.

 Dispose of hazardous waste properly.

Examples of potentially hazardous waste are used motor oil, fuel and fuel ﬁ lters.

 DO NOT use food or plastic containers to

dispose of hazardous waste.

 DO NOT

down a drain or into any water source.

 Always make sure crane or liﬁ tng device has been

properly secured to the lifting bail (hook) of the equipment.

 ALWAYS shutdown engine before transporting.

 NEVER lift the equipment while the engine is running.

 Tighten fuel tank cap securely and close fuel cock to

prevent fuel from spilling.

 Use adequate lifting cable (wire or rope) of sufﬁ cient

strength.

 Use one point suspension hook and lift straight

upwards.

 DO NOT lift machine to unnecessary heights.

 ALWAYS tie down equipment during transport by

securing the equipment with rope.

PAGE 8 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

NOTES

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 9

SPECIFICATIONS (GENERATOR)

Table 1. Speciﬁcations (Generators)

Model GAC 2.2H

Type Brushless Revolving Field Type

Excitation Solid State, Statically Excited System

Speed 3,600 RPM

Cooling System Self-Ventilation

AC Generator

60 Hz AC Power Sourc

Dimensions (L x W x H)

Dry Net Weight

Continuous Power Output 1.8 kW

Max Power Output 2.2 kW

Rated Voltage 120V

Current Max/Continuous (120V) 15 amps

Phase Single Phase (2 wire)

Frequency 60 Hz

Power Factor 1

19.68 x 16.14 X 18.30 in. (500 X 410 X 465 mm)

106 lbs. (48 kg.)

NOTICE

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

PAGE 10 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

SPECIFICATIONS (ENGINE)

Table 2. Speciﬁcations (Engine)

Engine

Dimensions (L x W x H)

Dry Net Weight

Model

Type

Bore X Stroke

Displacement 9.95 cu-in (163 cm

HONDA GX160K1EMA2

HONDA GX160U1EMAN

4 stroke, Single Cylinder, OHV,

Gasoline Engine

2.68 in. X 1.77 in.

(68 mm x 45 mm.)

)

Max Output 5.5 H.P./3600 R.P.M.

Fuel Unleaded Automobile Gasoline

Fuel Capacity 3.16 gallons (12 liters)

Lube Oil Capacity .63 quarts (0.6 liters)

Oil Alert System Yes

Speed Control Method Centrifugal Fly-weight Type

Starting Method Recoil Start

12.0 x 14.4 X 13.2 in.

(304 X 362 X 335 mm)

33.1 lbs. (15 kg.)

Effects of Altitude and Heat

The maximum output of the engines listed above are applicable to supplying electrical power for continuous service at ambient conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric reading of 29.92 inches and a temperature of 60° F (15.5° C).

Generally, the engine's output power will decrease 3-1/2% for each 1000 feet (305 meters) of altitude above sea level, and 1% for each 10° F (-12.2° C) above the standard temperature of 60° F (15.5° C).

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 11

DIMENSIONS

18.30 IN.

(465 MM)

211052

GRPRISE DE

TERRE

GAC-2.2H

Honda Engines

19.7 IN.

(500 MM)

120V 15A

ACVOLTMETER

VOLTOMETRECA

OFF

NEUTRALBONDED TO FRAME

120

NEUTREMIS A LAMASSE A LACARCASSE DU MOTEUR

AC CIRCUIT BREAKER

INTERRUPTEUR DE

COURANT PRINCIPAL

A21210011

16.1 IN.

(410 MM)

Figure 1. Dimensions

PAGE 12 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

NOTE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 13

CONNECTING THE GROUND

The nut and ground terminal on the generators should always be used to connect the generators to a suitable ground. The ground cable sho uld be #8 size wire minimum.

At the generator, connect the terminal of the ground cable between the lock washer and the nut (Figure 2) and tighten the nut fully. Connect the other end of the ground cable to a suitable earth ground (ground rod).

INSTALLATION

GENERATOR GROUND LUG

211052

GRPRISE DE

TERRE

GAC-2.2H

Honda Engines

#8 MINIMUM

120V 15A

ACVOLTMETER

VOLTOMETRECA

GROUND

CABLE

120

OFF

NEUTRALBONDED TO FRAME NEUTREMIS A LAMASSE A LACARCASSE DU MOTEUR

AC CIRCUITBREAKER

INTERRUPTEUR DE

COURANT PRINCIPAL

A21210011

GROUND ROD

FOR EARTH

GROUND

CONNECT TO

BUILDING

GROUND

IF REQUIRED

8 FT. MINIMUM

REFERENCE NEC 250-52(C)

Figure 2. Generator Grounding

PAGE 14 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

INSTALLATION

OUTDOOR INSTALLATION

If possible install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around.

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

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

INDOOR INSTALLATION

WARNING

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area

GENERATOR GROUNDING

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and speciﬁes that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 2) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) speciﬁes that the earth ground rod should be buried a minimum of 8 ft. into the ground.

Exhaust gases from gas 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.

PLACEMENT

The generators should always be placed on a ﬂat level surface when it is running. DO NOT place the generator on slopes, the possibility exists that the generator could slide.

DANGER

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.

NOTICE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 15

GAC2.2H FAMILIARIZATION

Generator

The Multiquip GAC2.2H generator has been designed as a portable dual purpose power source for 60 Hz (single phase) lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

This 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 generators to protect against damage. See Figures 3, and 4 for the basic controls and indicators for the generator.

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

GENERAL INFORMATION

DANGER

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.

The control box is provided with the following:

 120V GFCI receptacle.

 15 Amp Main Circuit Breaker.

 AC Voltmeter

 Ground Terminal

PAGE 16 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

COMPONENTS (GENERATOR)

GAC-2.2H

Honda Engines

211052

GRPRISE DE

TERRE

Figure 3. Generator Components

1. GFCI Duplex Receptacle – NEMA 5-15R, GFCI receptacle will provide 120V @ 15 amps.

2. AC-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 due to low output voltage, turn the generator OFF and consult your authorized Multiquip service dealer.

120V 15A

ACVOLTMETER

VOLTOMETRECA

OFF

NEUTRALBONDED TO FRAME

120

NEUTREMIS A LAMASSE A LACARCASSE DU MOTEUR

AC CIRCUIT BREAKER

INTERRUPTEUR DE

COURANT PRINCIPAL

A21210011

5. Chassis Ground – This ground connection point should be connected to a good earth ground (ground rod).

6. Engine ON/OFF Switch – Use this switch to start and stop the engine. Place switch in ON position to start engine, to stop engine place switch in OFF position.

7. GFCI Ground – GFCI ground connection point.

3. Main Breaker – single-pole, 15 amp circuit breaker protects the generator from shor t circuiting or overloading. When starting the generator always have circuit breaker placed in the OFF position.

4. Engine Oil Filler Cap – Remove cap/dipstick when the adding of engine oil is required. See Table 4 for recommended type engine oil.

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 17

COMPONENTS (GENERATOR)

Figure 4. Generator Components (Continued)

8. Mufﬂer/Heat Shield – Used to reduce noise and emissions. NEVER touch this heat shield when the generator/welder is in use. Always allow time for engine to cool before servicing.

9. Air Cleaner – Prevents dirt and other debris from entering the fuel system. Remove wing-nut on top of air ﬁlter cannister to gain access to ﬁlter element. NEVER run the engine without an air cleaner.

10. Spark Plug – Provides spark to the ignition system. Set spark plug gap to 0.6 - 0.7 mm (0.028 - 0.031 inch) Clean spark plug once a week.

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

12. Fuel Cock Lever – Turn lever downward to start (down) the ﬂow of fuel into the carburetor. Turn upward to stop (up) the ﬂow of fuel.

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

14. Throttle Lever – Regulates engine speed.

15. Engine – This generator uses a 5.0 HP Honda aircooled, 4-stroke, single cylinder, overhead camshaft gasoline engine. Engine uses unleaded gasoline.

16. Engine Oil Drain Plug – Remove this plug to drain engine oil from the crankcase.

17. Recoil Starter (pull rope) – Manual-starting method. Pull the starter grip until resistance is felt, then pull briskly and smoothly.

18. Fuel Tank – Fuel tank capacity is 3.16 gallons (12 liters)

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

NOTICE

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

PAGE 18 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

INSPECTION/SETUP

GENERAL INSPECTION PRIOR TO OPERATION

Ground Power Tools

When using power tools or electrical equipment requireing AC power from the generator, make sure power tool cord has a ground pin or is double insulated as shown in Figure 5.

Figure 5. Ground Pin

Extension Cable

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generators and point of use (load) is held to a minimum. Use the cable selection chart (Table 3) as a guide for selecting proper cable size.

DANGER

NEVER use power tools or equipment that do not

have a ground capability, the possibility exists of electrocution, electrical shock or burn, which can cause severe bodily harm or even DEATH!

Main Circuit Breaker

ALWAYS place the main circuit breaker in the OFF position

prior to starting the engine.

NOTICE

Double-insulated power tools and small appliances have specially insulated housings that eliminate the need for a ground pin. These types of double-insulated power cords are designed so that no part of the device will be electrically live even if the internal insulation fails.

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

Current In

Amperes

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.

Load In Watts Maximum Allowable Cable Length

120 Volts 240 Volts #10 Wire #12 Wire #14 Wire

#16 Wire

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 19

Before Starting

1. Read safety instructions at the beginning of manual.

2. Clean the generator, removing dirt and dust, particularly the engine cooling air inlet, carburetor and air cleaner.

3. Check the air ﬁlter for dirt and dust. If air ﬁlter is dirty, replace air ﬁlter with a new one as required.

4. Check carburetor for external dirt and dust. Clean with dry compressed air.

5. Check fastening nuts and bolts for tightness

Engine Oil Check

1. To check the engine oil level, place the generator on secure level ground with the engine stopped.

2. Remove the ﬁller dipstick from the engine oil ﬁller hole (Figure 6) and wipe clean.

INSPECTION/SETUP

Figure 7. Engine Oil Dipstick(Oil Level)

Table 4. Oil Type

Season Temperature Oil Type

Summer 25°C or Higher SAE 10W-30

Spring/Fall 25°C~10°C SAE 10W-30/20

Winter 0°C or Lower SAE 10W-10

Fuel Check

Figure 6. Engine Oil Dipstick Removal

3. Insert and remove the dipstick without screwing it into the ﬁller neck. Check the oil level shown on the dipstick.

4. If the oil level is low (Figure 7), ﬁll to the edge of the oil ﬁller hole with the recommended oil type (Table 4). Maximum oil capacity is .63 quarts (0.6 liters).

1. Close the fuel cock before ﬁlling the fuel tank.

2. Remove the fuel cap located on top of fuel tank.

3. Read the fuel gauge located on top of the fuel tank (Figure 8) to determine if the fuel level is low. If fuel is low, replenish with clean unleaded fuel.

Figure 8. Fuel Gauge

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

PAGE 20 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

OPERATION

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

Before Starting the Engine

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

2. NEVER start the engine with the main circuit breaker in the ON position. Always place this circuit breaker (Figure 9) in the OFF position before starting.

Figure 9. Main Circuit Breaker (OFF)

Starting the Engine

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

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

4. Place the engine ON/OFF switch (Figure 12) in the ON position.

Figure 12. Engine ON/OFF Switch (ON)

5. Grasp the starter grip (Figure 13) and slowly pull it out. The resistance becomes the hardest at a certain position, corresponding to the compression point. Pull the starter grip briskly and smoothly for starting.

Figure 10. Engine Fuel Valve Lever (ON)

2. Place the choke lever (Figure 11) in the CLOSED position if starting a cold engine.

Figure 11. Choke Lever

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 21

Figure 13. Starter Grip

6. If the engine has started, slowly return the choke lever (Figure 11) to the OPEN position. If the engine has not started repeat steps 1 through 5.

7. Before the generator is placed into operation, run the engine for 3-5 minutes. Check for abnormal smells, fuel leaks, and noises that would associate with lose components.

NOTICE

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.

OPERATION

8. Place main circuit breaker (Figure 14) in the ON position.

Figure 14. Main Circuit Breaker (ON)

9. Read the voltmeter on the front panel of the generator (Figure 15) and verify that 120 VAC is present at the GFCI duplex receptacle. For additional veriﬁcation of voltage, an external voltmeter can be used to measure the output voltage as shown in Figure 15.

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

3. Place the engine ON/OFF switch (Figure 17) in the OFF position.

Figure 17. Engine ON/OFF Switch (OFF)

4. Place the engine fuel valve lever (Figure 18) in the OFF position.

Figure 15. 120V/GFCI Receptacle

10. Connecting of loads (power tools, lighting ect.) to the generator receptacles can now be done.

Stopping the Engine (Normal Shutdown)

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

Figure 16. Main Circuit Breaker (OFF)

Figure 18. Engine Fuel Valve Lever (OFF)

5. Remove all loads from the generator.

Emergency Shutdown

1. Place the engine ON/OFF switch (Figure 17) in the

OFF position.

PAGE 22 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

PREPARATION FOR LONG TERM STORAGE

Generators Storage

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

 Drain the fuel tank completely, or add STA-BIL to the

fuel.

 Run the engine until the gasoline in the carburetor is

completely consumed.

 Completely drain the oil from the crankcase and reﬁll

with fresh oil.

 Remove the spark plug, pour 2 or 3 cc of SAE 30 oil into

the cylinder and crank slowly to distribute the oil.

 Slowly rotate the engine a few times with the starter rope

and install a new plug.

 Pull out the star ter 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.

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 23

MAINTENANCE

Use Table 5 as a general maintenance guideline when servicing your engine. For more detail engine maintenance information, refer to the engine owner's manual supplied with your engine.

Table 5. Engine Maintenance Schedule

DESCRIPTION

(3)

Engine Oil

Air Cleaner

All Nuts & Bolts

Spark Plug

Cooling Fins CHECK X

Spark Arrester CLEAN X

Fuel Tank CLEAN X

Fuel Filter CHECK X

Idle Speed CHECK-ADJUST X (2)

Valve Clearance CHECK-ADJUST X (2)

Fuel lines CHECK Every 2 years, replace if necessary (2)

(1) Service more frequently when used in DUSTY areas.

(2) These items should be serviced by your service dealer, unless you have the proper tools and are mechanically proﬁcient. Refer to the HONDA Shop Manual for service procedures.

(3) For commercial use, log hours of operation to determine proper maintenance intervals.

OPERATION BEFORE

CHECK X

CHANGE

CHECK

CHANGE X (1)

RETIGHTEN IF

NECESSARY

CHANGE X

X X

REPLACE

FIRST

MONTH OR

10 HRS.

EVERY 3

MONTHS

OR 25 HRS.

EVERY 6

MONTHS

OR 50 HRS.

EVERY

YEAR OR

100 HRS.

EVERY

2 YEARS OR

200 HRS.

PAGE 24 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

Maintenance

Perform the scheduled maintenance procedures as deﬁned by Table 5:

Daily

 Thoroughly remove dirt and oil from the engine and

control area. Clean or replace the air cleaner elements as necessary. Check and retighten all fasteners as necessary.

Weekly

 Remove the fuel ﬁlter cap and clean the inside of the

fuel tank.

MAINTENANCE

Figure 20. Draining Engine Oil

Engine Air Cleaner

 Remove or clean the ﬁlter at the bottom of the tank.

 Remove and clean the spark plug (Figure 19), then adjust

the spark gap to 0.024 ~0.028 inch (0.6~0.7 mm). This unit has electronic ignition, which requires no adjustments.

Figure 19. Spark Plug Gap

Engine Oil

1. Drain the engine oil when the oil is warm as shown in

Figure 20.

2. Remove the oil drain bolt and sealing washer and allow

the oil to drain into a suitable container.

1. Remove the air cleaner cover and foam ﬁlter element as shown in Figure 21.

DANGER

DO NOT use gasoline as a cleaning

solvent, the possibility exists of fire or explosion which can cause damage to the equipment and severe bodily harm or even DEATH!

2. Clean foam elemen t in warm, soapy water or nonﬂammable solvent. Rinse and dry thoroughly. Dip the element in clean engine oil and completely squeeze out the excess oil from the element before installing.

3. Replace engine oil with recommended type oil as listed in Table 4. For engine oil capacity, see Table 2 (engine speciﬁcations). DO NOT overﬁll.

4. Install drain bolt with sealing washer and tighten securely.

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 25

Figure 21. Engine Air Cleaner

GENERATOR WIRING DIAGRAM

SYMBOL PART NAME

Ar Armature Winding

Fg-PN Field Winding

EXW1~2 Excitation Winding

V AC Voltmeter (120/240)

Re Rectiﬁer

CON Receptacle 5-15R

CB UPM-1 15A

CB1 CP-31E/15N 15A

Symbol Color Symbol Color

BR BROWN Y YELLOW

GR GRAY LG LIGHT GREEN

Wiring Color Code

B BLACK R RED

L BLUE W WHITE

G GREEN LB LIGHT BLUE

V VIOLET O ORANGE

P PINK

Figure 22. Generator Wiring Diagram

PAGE 26 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

TROUBLESHOOTING

Table 6. Engine Troubleshooting

Symptom Possible Cause Solution

Spark plug bridging? Check gap, insulation or replace spark plug.

Difﬁcult to start. Fuel is available but no SPARK at spark plug.

Difﬁcult to start. Fuel is available and SPARK is present at the spark plug.

Difﬁcult to start. Fuel is available, SPARK is present at the spark plug and compression is normal.

Difﬁcult to start. Fuel is available, SPARK is present at the spark plug and compression is low.

Carbon deposit on spark plug? Clean or replace spark plug.

Short circuit due to deﬁcient spark plug insulation?

Improper spark plug gap? Set to proper gap.

ON/OFF switch is shorted? Check switch wiring. Replace switch.

Ignition coil defective? Replace ignition coil.

Improper spark gap, points dirty? Set correct spark gap and clean points.

Condenser insulation worn or short circuiting?

Spark plug wire broken or short circuiting? Replace defective spark plug wiring.

Wrong fuel type?

Water or dust in fuel system? Flush fuel system.

Air cleaner dirty? Clean or replace air cleaner.

Suction/exhaust valve stuck or protruded? Reseat valves.

Piston ring and/or cylinder worn? Replace piston rings or piston.

Cylinder head and/or spark plug not tightened properly?

Head gasket and/or spark plug gasket damaged?

Check spark plug insulation. Replace if worn.

Replace condenser.

Flush fuel system and replace with correct type of fuel.

Torque cylinder head bolts and spark plug.

Replace head and spark plug gaskets.

Fuel not available in fuel tank? Fill with correct type of fuel.

Fuel cock does not open properly?

No fuel present at carburetor.

Weak in power. Compression is proper and does not misﬁre.

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 27

Fuel ﬁlter clogged? Replace fuel ﬁlter.

Fuel tank cap breather hole clogged? Clean or replace fuel tank cap.

Air in fuel line? Bleed fuel line

Air cleaner dirty? Clean or replace air cleaner.

Improper level in carburetor? Check ﬂoat adjustment. Rebuild carburetor.

Defective spark plug? Clean or replace spark plug.

Apply lubricant to loosen fuel cock lever. Replace if necessary.

TROUBLESHOOTING

Table 6. Engine Troubleshooting (Continued)

Symptom Possible Cause Solution

Weak in power. Compression is proper but misﬁres.

Engine overheats.

Rotational speed ﬂuctuates.

Recoil starter malfunction.

Water in fuel system?

Dirty spark plug? Clean or replace spark plug

Ignition coil defective? Replace ignition coil.

Spark plug heat value improper? Replace with correct type of spark plug.

Incorrect type of fuel? Replace with correct type of fuel.

Cooling ﬁns dirty? Clean cooling ﬁns.

Governor adjusted correctly? Adjust governor

Governor spring defective? Replace governor spring.

Fuel ﬂow restricted? Check entire fuel system for leaks or clogs.

Recoil mechanism clogged with dust and dirt?

Spiral spring loose? Replace spiral spring.

Flush fuel system and replace with correct type of fuel.

Clean recoil assembly with soap and water.

PAGE 28 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

TROUBLESHOOTING

Table 7. Generator Troubleshooting

Symptom Possible Problem Solution

Low voltage Engine speed too low? Raise engine speed to rated RPM.

AC voltmeter not working? Replace Ac voltmeter.

Control box internal wiring malfunction?

Low voltage. Engine speed normal 3650 RPM (unloaded), 2500 RPM (idle)

Voltage output too high. Engine speed too high? Lower engine speed to rated RPM.

Voltage output too high. Engine speed normal 3650 RPM (unloaded), 2500 RPM (idle)

Circuit breaker will not turn on "NO LOAD"

Circuit breaker will turn on "LOADED" but trips immediately.

Does not accelerate from low to high "NO LOAD"

Defective ignition coil?

Rotor winding malfunction? Check or replace rotor.

Stator winding malfunction? Check or replace stator.

Leakage breaker malfunction? Check or replace CB1.

Full power switch malfunction?

Control box internal wiring malfunction

Defective circuit breaker? Replace circuit breaker.

Overload Condition? Reduce load or replace breaker.

Load circuit is shorted? Check load circuit for short.

Stuck solenoid? Check solenoid.

Bad Idle control switch? Check or replace idle control switch.

Check control box wiring.

Check red and green ignition wires. Replace ignition wires if necessary.

Check full power switch and full power switch circuit.

Check control box wiring.

Idle control switch malfunction? Check or replace idle control switch.

Does not accelerate from low to high "LOAD ACTIVE"

Does not decelerate no"VOLTAGE OUTPUT".

Does not decelerate but has "VOLTAGE OUTPUT".

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 29

Idle control device malfunction? Check or replace idle control device.

Control box interal wiring defective? Check control box wiring.

Defective rotor windings? Check or replace rotor.

Defective solenoid? Check or replace solenoid.

Defective idle control device? Check or replace idle control device.

Defective solenoid? Check or replace idle control device.

Control box wiring malfunction?

Defective solenoid? Check or replace solenoid.

Idle control device malfunction? Check or replace idle control device.

Check control box wiring, replace any defective components.

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and

PART NO. Column

QTY. Column

— Item quantity can be indicated by a

A/R (As Required) is generally used for hoses or other

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁ ed in the “Remarks”

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed

same unique symbol will be included when this item is

— Used to list an effective serial

— Indicates that the part

part is NOT used on a speciﬁ c model or model number

available items. Examples include battery cables, shims,

— Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available

remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

Numbers Used

number, a blank entry, or A/R.

NOTICE

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTICE

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

parts that are sold in bulk and cut to length.

Column.

REMARKS Column

to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the

purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Speciﬁ c Model Number Use

is used only with the speciﬁ c model number or model number variant listed. It can also be used to show a

variant.

Indicated by:

Numbers Used — Part numbers can be indicated by a number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clariﬁ ed in the “Remarks” Column.

PAGE 30 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

“XXXXX ONLY” “NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can be purchased at any hardware shop or made out of

and certain washers and nuts.

“Not Sold Separately”

for sale through Multiquip.

SUGGESTED SPARE PARTS

GAC2.2H PORTABLE 60 HZ GENERATOR WITH HONDA GX160K1EMA2/ GX160U1EMAN GASOLINE ENGINES

1 to 3 units

Qty. P/N Description

1............0810106004 ..........CAP FUEL TANK

1............0810107103 ..........FILTER FUEL

4............7935419204 ..........RUBBER SUSPENSION

4............7935419304 ..........RUBBER SUSPENSION

3............9807956846 ..........SPARK PLUG

1♦ .........34150ZH7003 ....... SWITCH ASSY., OIL ALERT

1◊ ........34150ZH7013 .......SWITCH ASSY., OIL ALERT

2............28462ZH8003 ....... ROPE, RECOIL

3............17211ZB2000 ....... ELEMENT AIR CLEANER

NOTICE

Part numbers on this Suggested Spare Parts list may supersede/replace the part numbers shown in the following parts lists.

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 31

NAMEPLATE AND DECALS

S/N 5560983 AND BELOW

CAUTION

Do not use in rain or snow.

ATTENTION

Ne pas utiliser en cas de pluie ou neige.

A3520000A

CAUTION/ATTENTION

HOT PARTS can burn skin.

DO NOT touch until the

has sufficiently cooled.lamp

Danger de brûlure, pièces chaudes. Ne touchez pas avant que l’appareil

ne soit suffisamment refroidi.

FUELCOCK

ROBINET’D ESSENCE

ON/OUVERT

OFF/ FERMER

A90820000

READ OWNER’S SERVICE MANUAL BEFORE OPERATING OR SERVICING THIS MACHINE.

ALWAYSKEEP UNAUTHORIZED INEXPERICENCED UNTRAINED PEOPLE AWAYFROM THIS MACHINE.

MAKE SURE ALL SAFETY DEVICES ARE OPERATIONAL BEFORE THIS MACHINE IS STARTED. MAKE SURE ENGINE IS TURNED OFF AND SPARK PLUG WIRE DISCONNECTED BEFORE SERVICING THE MACHINE OR COMING IN CONTACTWITH ANY MOVING PART. IF EQUIPMENT IS POWERED BY AN ELECTRIC MOTOR DISCONNECT ELECTRICAL PLUG.

NEVER LEAVE MACHINE UNATTENDED WHEN OPERATING ALWAYSSTOP ENGINE AND ALLOW ENGINE TO COOL BEFOREADDING FUELOR OIL.

CAUTION

II est impératif de lire le manuel d’utilisation avant d’utiliser ou de réparer cet équipement.

II est impératif degarder tout personnel non authorisé ou non qualifié à distance de cetequipement.

Assurez vous que tout equipement de sécurité est fonctionnel avant d’engager l’equipement. Assurez vous que le moteur est éteint et que lefil de labougie est d’econnecté avant de réparer la machine ouvant tout contact avec toute pièce en mouvement. Si l’equipement est alimenté par un moteur électrique débranchez l’appareil.

Ne laissez jamis l’appareil sans supervision quand il est en marche, II est impératif d’arrêterle motour et de la laisser refroidir avant d’ajouter

A55200070A

de l’huile ou du carburant.

WARNING/ATTENTION

Onlyoperate machine in well ventilatedareas. Donot inhale exhaust gases. N’utilizezl’equipment que dans desendroits bien aérés. Nerespirez paz les gas d’échappement.

Onlyqualified personnel should install, use,

Dangerous

orservice this equipment.

Gas/Gas

Seulun personnel qualifié devrait avoir

dangereux

l’authorisationd’installer d’utilisier ou deréparer cet équipement.

A63210090A

A65200040A

CAUTION

2200

OFF

NEUTRALBONDED TOFRAME

120

NEUTREMIS ALA MASSEA LACARCASSE DUMOTEUR

ACCIRCUIT BREAKER

INTERRUPTEURDE

COURANTPRINCIPAL

211052

GRPRISE DE

TERRE

GAC-2.2H

Honda Engines

120V 15A

Donot touch output terminals orinternal wiringwhile unit is operating. Turnoff power before servicing. Netouchez ni les terminaux externesou le cablageelectrique interne lorsque que l’ quipement est en operation.é Eteindreavant de réparer.

Onlyqualified personnel should install, use,

Electrical

orservice this equipment.

shockhazard Possibilité

Seulun personnel qualifié devrait avoir

dechoc electrique

l’authorisationd’installer d’utilisier ou

A63210100A

deréparer cet équipement.

Insulation System --- B Maximum ambient

Temperature --- 40°C (104°F)

A5520080

Systéme d’insulation --- B Températureambiante

maximum --- 40°C (104°F)

A33210030A

S/N 5560984~ 5582067

THE POSSIBILITY EXISTS OF IF GENERATOR/WELDERIS NOTPROPERLY GROUNDED. ALWAYSCONNECTEARTH GROUND (GROUND ROD)TO GENERATORGROUND POINT.

ILY AURAITUN RISQUE D’ÉLECTROCUTIONÀ MOINS QUELA GÉNÉRATRICE/SOUDEUSENE SOIT PROPREMENT MISEA LATERRE. S’ASSURER DERELIER A LAMASSE (BARREDE MASSE) LEPOINT DE MISEA LATERRE DE L’APPAREIL.

GROUNDROD FOR EARTHGROUND BARREDE MASSE

CONNECTTOBUILDING GROUNDIF REQUIRED ARELIERÀ LAMASSE D’OUVRAGEEVENTUELLEMENT

8FT.MINIMUM 8PIEDS MINIMUM

REFERENCENEC 250-52(C) RÉFERÉNCENEC 250-52(C)

ELECTROCUTION

GROUNDTERMINAL PRISEDE TERRE

GROUNDCABLE #8MINIMUM CÂBLEDE MASSE #8MINIMUM

FORFURTHER GROUNDING INSTRUCTIONSREAD MANUAL POURPLUS DEDÉTAILS CONCERNANTLAMISE ÁLA TERRE,LIRE LEMANUEL

A91110020

S/N 5582068~ 5623308 S/N 5623309 AND ABOVE

Usinga generator indoors . Utilserun générateur à l’ intérieur VOUS TUERAEN QUELQÙES MINUTES.

Exhaustcontains carbon monoxide, a poison gas you cannotsee or smell. Lesgaz d’ échappement contiennent du monoxyde decarbon, un gaz toxique invisibleet inodore.

NEVERuse in enclosed or partially enclosedareas. UtilisationINTERDITE dans un espaceclos ou partiellement clos.

CAUTION

Do not use in rain or snow.

ATTENTION

Ne pas utiliser en cas de pluie ou neige.

A3520000A

NEUTRALBONDEDTOFRAME

120V

120 V

GAC-2.2H

NEUTREMISALAMASSEA

15A

LACARCASSEDUMOTEUR

POWEREDby

HondaEngines

211052

ACCIRCUITBREAKER INTERRUPTEURDE

OFF

GRPRISEDE

COURANTPRINCIPAL

TERRE

DANGER

CANKILL YOU IN MINUTES

NEUTRALBONDEDTOFRAME

120V

120 V

GAC-2.2H

NEUTREMISALAMASSEA

15A

LACARCASSEDUMOTEUR

POWEREDby

HondaEngines

211052

ACCIRCUITBREAKER INTERRUPTEURDE

OFF

GRPRISEDE

COURANTPRINCIPAL

TERRE

NEUTRALBONDEDTOFRAME

120V

120 V

GAC-2.2H

NEUTREMISALAMASSEA

15A

LACARCASSEDUMOTEUR

POWEREDby

HondaEngines

211052

ACCIRCUITBREAKER INTERRUPTEURDE

OFF

GRPRISEDE

COURANTPRINCIPAL

TERRE

ONLYuse outdoors and away from openwindows, doors, and vents. UtilisationUNIQUEMENT à l’ extér leur porteset trous d’ aération

A9504000104

WARNING

Operation of this equipment may create sparks that can start fires around dry vegetation.

Aspark arrestormay berequired. The operator should contact local fire agencies for laws or regulation relating to fire prevention requirements.

Des étincelles pouvant enflammer la végétation séche environnante peuvent être produites pendant le fonctionnement de cet équipement.

Un pare étincelles peut être requis. L’opérateurdoit contacterles agences anti–incendie locales pour s’ informer des lois ou feglementations concernant les exigences de prévention––incendie

A90400020

PAGE 32 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

CAUTION

Do not use in rain or snow.

ATTENTION

Ne pas utiliser en cas de pluie ou neige.

A3520000A

NAMEPLATE AND DECALS

NO. PART NO. PART NAME QTY. REMARKS

1 A3552000004A DECAL; CAUTION, RAIN SNOW .......................1................A35200000A

2 A6552000404A DECAL; CAUTION, HOT PARTS .......................1................A65300040A

3 A6532100904A DECAL; WARNING, EXHAUST GASES ............1................A63210090A

4 A6532101004A DECAL; DANGER, ELECTROCUTION .............1................A63210100A

5 A5552000804 DECAL; OPERATING INSTR. (FRENCH) ..........1................A552200080

6 A5552000704A DECAL; OPERATING INSTR. (ENGLISH) .........1................A55200070A

7 A9508200004 DECAL; FUEL COCK .........................................1................A90820000

8 A1562000803 DECAL; MQ LOGO 2200 STRIPE .....................1................A16200080

9 A2512100112 DECAL; FRONT NAMEPLATE GAC2.2H ..........1................A21210011

10 A3532100304A DECAL; SPECIFICATION ..................................1................A33210030A

11 A9511100204 DECAL; DANGER, GROUND ROD ...................1................A91110020

.............................................................................................S/N 5560984~5582067

12 A9504000104 DECAL; DANGER, DANGEROUS GASES ........1................A90400010

.............................................................................................S/N 5582068~5623308

13 A9504000204 DECAL; WARNING, SPARK ARRESTOR ..........1................A90400020

.............................................................................................S/N 5623309 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 33

GENERATOR ASSY.

PAGE 34 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 7931000203 ROTOR ASSY. 1 1-1 7681080003 FIELD COIL 1 1-2 0601823213 RECTIFIER 2 0601822637 SURGE ABSSORBER 2 1-3 0603000040 BEARING 1 2 7681017104 SET BOLT, ROTOR 1 3 0801086004 SET WASHER, BEARING 1 4 0040008000 WASHER, LOCK 1 5 A2136000503 ARMATURE ASSY. 1 6 7931315002 END BRACKET 1 7 7931315102 END BRACKET 1 8 7875021523 GUIDE PANEL, AIR 1 9 7681331003 COVER 1 10 7681344204 SET BOLT, STATOR 4 11 0040006000 WASHER, LOCK 4 12 0041206000 WASHER, FLAT 4 13 7871329514 GROMMET 1 14 0601851760 CAP 1 15 0017408020 HEX. HEAD BOLT 4 16 7935420104 STAY, MUFFLER 1 17 0021806010 MACHINE SCREW 2 18 7935420004 STAY, MUFFLER 1 19 0207206000 HEX. NUT 2 20 0017108020 HEX. HEAD BOLT 1

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 35

CONTROL BOX ASSY.

PAGE 36 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 A2215000103 CONTROL BOX 1 2 0301850215 GROMMET 1 3 0601823204 RECTIFIER 1 4 0027103020 MACHINE SCREW 2 5 0017106015 HEX.HEAD BOLT 4 6 A2225000503 CONTROL PANEL 1 7 0601806867 AC VOLTMETER 1 8 0038303000 HEX NUT 2 9 0601807462 CIRCUIT BREAKER, 15A 250V 1 10 0027104010 MACHINE SCREW 2 11 A3262800104 TERMINAL PLATE 1 12 0601815147 GROUND TERMINAL 1 12A 0040005000 WASHER, LOCK 1 12B 0031005000 HEX NUT 1 12C 0038305000 HEX NUT 1 13 0010005025 HEX HEAD BOLT 1 13A 0038305000 HEX NUT 1 14 0010005040 HEX HEAD BOLT 1 14A 0040505000 TOOTHED WASHER 1 14B 0031005000 HEX NUT 2 14C 0038305000 HEX. NUT 1 15 0017105010 HEX HEAD BOLT 4 15A 0040505000 TOOTHED WASHER 2 16 0601812590 RECEPTACLE, 515R GF5252 1 17 0027104016 MACHINE SCREW 2 17A 0038304000 HEX NUT 2 18 A2225200004 CB COVER 1 19 0027103010 MACHINE SCREW 2

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 37

PIPE FRAME ASSY.

PAGE 38 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

PIPE FRAME ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 A2418000202 PIPE FRAME 1 2 0801886104 WASHER 2 3 7935419204 RUBBER SUSPENSION 2 4 7935419304 RUBBER SUSPENSION 2 5 0207208000 HEX NUT 8 6 7935510102 FUEL TANK 1 7 0810106004 CAP FUEL TANK 1 8 0810107103 FUEL FILTER 1 9 0602125034 FUEL GAUGE 1

10 0605510065 FUEL STRAINER ...............................................1................INCLUDES ITEMS W/#

.............................................................................................REPLACES P/N 0605510065

10-1# 16950898633 CUP ...................................................................1................REPLACES P/N 0605510066

10-2# 16952883005 FILTER ...............................................................1................REPLACES P/N 0605510067

11 950014500160M HOSE .................................................................1................REPLACES P/N 0605513141

12 9500202080 HOSE BAND ......................................................2................REPLACES P/N 0605515188

13 90854ZB2000 GROMMET ........................................................1................REPLACES P/N 0601851775

14 7855525514 RUBBER WASHER 2 15 7855525604 COLAR 2 16 0017108030 HEX HEAD BOLT 2 17 0017108020 HEX HEAD BOLT 2 18 7935421004 BRACKET, MUFFLER COVER 1 19 0017106016 HEX HEAD BOLT 2 20 0017106016 HEX HEAD BOLT 3 21 0017106016 HEX HEAD BOLT 1 21A 0040506000 TOOTHED WASHER 1 22 0031308000 HEX NUT 2 23 0011308020 HEX HEAD BOLT 2 24 0040008000 WASHER, LOCK 2

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 39

HONDA GX160K1EMA2/U1EMAN ENGINE — CYL. HD ASSY.

PAGE 40 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — CYL. HD ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1♦ 12210ZH8020 HEAD COMP., CYLINDER .................................1................INCLUDES ITEMS W/#

1◊ 12210ZH8415 HEAD COMP., CYLINDER .................................1................INCLUDES ITEMS W/#

2# 12204ZE1306 GUIDE, IN. VALVE (OVER SIZE) 1 3# 12205ZE1315 GUIDE, IN. VALVE 1 4# 12216ZE5300 CLIP, VALVE GUIDE 1 5 12251ZF1800 GASKET, CYLINDER HEAD 1 6♦ 12310ZE1010 COVER COMP, HEAD 1 6◊ 12310ZE1020 COVER COMP, HEAD 1 7 12391ZE1000 PACKING, HEAD COVER 1 8♦ 15721732000 TUBE, BREATHER 1 8◊ 15721883030 TUBE, BREATHER 1 9 90013883000 BOLT, FLANGE 6X12 4 10 90043ZB2003 BOLT, STUD 6X94 2 11 90047ZE1000 BOLT, STUD 8X32 2 12 9430110160 PIN, DOWEL 10X16 2 13 957230806000 BOLT, FLANGE 8X60 4 14 9807956846 PLUG, SPARK (BPR6ES NGK) 1 14 9807956855 PLUB, SPARK (W20EPR-U ND) 1

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 41

HONDA GX160K1EMA2/U1EMAN ENGINE — CYL. BARREL ASSY.

PAGE 42 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — CYL. BARREL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

2♦ 12000ZH8406 BARREL ASSY, CYLINDER (OIL ALERT) .........1................INCLUDES ITEMS W/#

2◊ 12000ZH8426 BARREL ASSY, CYLINDER (OIL ALERT) .........1................INCLUDES ITEMS W/#

3♦ 15510ZE1033 SWITCH ASSY, OIL LEVEL 1 3◊ 15510ZE1043 SWITCH ASSY, OIL LEVEL 1

4♦ 16510ZE1000 GOVERNOR ASSY. ...........................................1................USE UP TO S/N 4913229

.............................................................................................INCLUDES ITEMS W/%

4♦ 16506ZL0000 GOVERNOR ASSY. ...........................................1................USE FROM S/N 4913230

.............................................................................................INCLUDES ITEMS W/%

4◊ 16506ZL0000 GOVERNOR ASSY. ...........................................1................INCLUDES ITEMS W/%

5%♦ 16511ZE1000 WEIGHT, GOVERNOR 2 6%♦ 16512ZE1000 HOLDER, GOVENOR WEIGHT 1 7%♦ 16513ZE1000 PIN, GOVERNOR WEIGHT 2 8 16531ZE1000 SLIDER, GOVERNOR 1 9 16541ZE1000 SHAFT, GOVERNOR ARM 1 12 90131ZE1000 BOLT, DRAIN PLUG 2 13 90451ZE1000 WASHER, THRUST 6MM 1 14 90601ZE1000 WASHER, DRAIN PLUG 10.2MM 2 15 90602ZE1000 CLIP, GOVERNOR HOLDER 1 16# 91001ZF1003 BEARING, RADIAL BALL (6205TMB) 1 17# 91201Z0T801 OIL SEAL 25X41X6 1 18 91353671004 O-RING, 13.5X1.5 1 19 9405010000 NUT, FLANGE, 10MM 1 20 9410106800 WASHER, PLAIN, 6MM 2 21 9425108000 PIN, LOCK, 8MM 1 22 957010601200 BOLT, FLANGE, 6X12 2 23 06111ZH8405 GASKET KIT 1

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 43

HONDA GX160K1EMA2/U1EMAN ENGINE — CRANKCASE CVR. ASSY.

PAGE 44 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — CRANKCASE CVR. ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 11300ZE1634 COVER ASSY, CRANKCASE ............................1................INCLUDES ITEMS W/%

3 11381ZH8801 GASKET, CASE COVER 1

4 15600ZE1003 CAP ASSY, OIL FILLER .....................................1................INCLUDES ITEMS W/#

5 15600ZG4003 CAP, OIL FILLER 1 8# 15625ZE1003 GASKET, OIL FILLER CAP 1 9% 91201Z0T801 OIL SEAL, 25X41X6 1 10 9430108140 PIN, DOWEL 8X14 2 11 957010803200 BOLT, LANGE 8X32 6 12% 961006205000 BEARING, RADIAL BALL, 6205 1

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 45

HONDA GX160K1EMA2/U1EMAN ENGINE — CRANKSHAFT ASSY.

PAGE 46 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — CRANKSHAFT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 13310ZB2000 CRANKSHAFT COMP. 1

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 47

HONDA GX160K1EMA2/U1EMAN ENGINE — PISTON ASSY.

PAGE 48 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — PISTON ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1♦ 13010ZF1023 RING SET, PISTON (STD) 1 1◊ 13010Z4K004 RING SET, PISTON (STD) 1 1♦ 13011ZF1023 RING SET, PISTON (0.25) 1 1◊ 13011Z4K004 RING SET, PISTON (0.25) 1 1♦ 13012ZF1023 RING SET, PISTON (0.50) 1 1◊ 13012Z4K004 RING SET, PISTON (0.50) 1 1♦ 13013ZF1023 RING SET, PISTON (0.75) 1 1◊ 13013Z4K004 RING SET, PISTON (0.75) 1 2 13101ZH8010 PISTON (STD) 1 2 13102ZH8010 PISTON (0.25) 1 2♦ 13103ZH8000 PISTON (0.50) 1 2◊ 13103ZH8010 PISTON (0.50) 1 2♦ 13102ZH8010 PISTON (0.75) 1 2◊ 13104ZH8010 PISTON (0.75) 1 3 13111ZE1000 PIN, PISTON 1 4 13200ZE1010 ROD ASSY, CONNECTING 1 5 90001ZE1000 BOLT, CONNECTING ROD 2 6 90551ZE1000 CLIP, PISTON PIN, 18MM 2

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 49

HONDA GX160K1EMA2/U1EMAN ENGINE — CAMSHAFT ASSY.

PAGE 50 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — CAMSHAFT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1♦ 14100ZE1812 CAMSHAFT ASSY. ............................................1................UP TO S/N 4913229

1♦ 14100ZL0000 CAMSHAFT ASSY. ............................................1................FROM S/N 4913230

1◊ 14100ZL0000 CAMSHAFT ASSY. 1 2 14410ZE1010 ROD, PUSH 2 3 14431ZE1000 ARM, VALVE ROCKER 2 4 14441ZE1000 LIFTER, VALVE 2 5 14451ZE1013 PIVOT, ROCKER ARM 2 6 14568ZE1000 SPRING, WEIGHT RETURN 1 7 14711ZF1000 VALVE, IN 1 8 14721ZF1000 VALVE, EX 1 9 14751ZF1000 SPRING, VALVE 2 10 14771ZE1000 RETAINER, IN. VALVE SPRING 1 11 14773ZE1000 RETAINER, EX. VALVE SPRING 1 12 14781ZE1000 ROTATOR, VALVE 1 13 14791ZE1010 PLATE, PUSH ROD GUIDE 1 14 90012ZE0010 BOLT, PIVOT (8MM) 2 15 90206ZE1000 NUT, PIVOT ADJUSTING 2 18♦ 12209ZH8003 VALVE STEM 1

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 51

HONDA GX160K1EMA2/U1EMAN ENGINE — RECOIL STARTER ASSY.

PAGE 52 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — RECOIL STARTER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1♦ 28400ZH8013ZB STARTER ASSY, RECOIL “NH1” BLACK 1 1◊ 28400ZH8023ZB STARTER ASSY, RECOIL “NH1” BLACK 1 2 28410ZH8003ZB CASE, RECOIL STARTER “NH1” BLACK 1 3♦ 28420ZH8013 REEL, RECOIL STARTER 1 3◊ 28421ZH8801 REEL, RECOIL STARTER 1 4♦ 28422ZH8013 RATCHET, STARTER 2 4◊ 28422ZH8801 RATCHET, STARTER 2 5♦ 28433ZH8003 GUIDE, RATCHET 1 5◊ 28433ZH8801 GUIDE, RATCHET 1 6♦ 28441ZH8003 SPRING, FRICTION 1 6◊ 28441ZH8801 SPRING, FRICTION 1 7 28442ZH8003 SPRING, RECOIL STARTER 1 8 28443ZH8003 SPRING, RETURN 2 9 28461ZH8003 KNOB, RECOIL STARTER 1 10 28462ZH8003 ROPE, RECOIL STARTER 1 12♦ 90003ZH8003 SCREW, SETTING 1 12◊ 90003ZH8801 SCREW, SETTING 1 13 90008ZE2003 BOLT, FLANGE 6X10 3

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 53

HONDA GX160K1EMA2/U1EMAN ENGINE — FAN COVER ASSY.

PAGE 54 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — FAN COVER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

3* 16584883300 SPRING, CONTROL ADJUSTING 1 4 19610ZE1000ZC COVER, FAN “NH1” BLACK 1

7♦ 19611ZH8820 PLATE, SIDE ALERT & LAMP ...........................1................USE FROM S/N 475372719

7♦ 19612ZH8821 PLATE, SIDE ALERT & LAMP ...........................1................USE FROM S/N 4795906~537271

7♦ 19612ZH8830 PLATE, SIDE ALERT & LAMP ...........................1................USE UP TO S/N 4795905

7◊ 19611ZH8820 PLATE, SIDE ALERT & LAMP 1

10♦ 19613ZE1010 CLAMP, CORD ...................................................1................USE UP TO S/N 4367320

10♦ 90601ZH7013 CLAMP, CORD ...................................................1................USE FROM S/N 4367321

10◊ 90601ZH7013 CLIP, HARNESS 1 11 19630ZB2000 SHROUD COMP., LOWER 1

12♦ 19640ZB2010 SHROUD ASSY., UPPER ..................................1................USE UP TO S/N 5048024

` ............................................................................................INCLUDES ITEMS W/#

12♦ 19640ZH8R60 SHROUD ASSY., UPPER ..................................1................USE FROM S/N 5048025

.............................................................................................INCLUDES ITEMS W/#

12◊ 19640ZH8R60 SHROUD ASSY., UPPER 1

13♦ 32197ZH8003 SUB HARNESS .................................................1................USE UP TO S/N 4367320

14♦ 36100ZE1015 ENGINE, STOP SWITCH ..................................1................USE UP TO S/N 4368640

14♦ 36100ZH7003 ENGINE, STOP SWITCH ..................................1................USE FROM S/N 4368641

14◊ 36100ZF6P81 ENGINE, STOP SWITCH 1 17 90013883000 BOLT, FANGE 6X12 8 18 90022888010 BOLT, FLANGE 6X20 1

19# 93500050350A SCREW, PAN 5X35 ............................................1................USE UP TO S/N 5048024

19# 93500050400G SCREW, PAN 5X40 ............................................1................USE FROM S/N 5048025

21 957010600800 BOLT, FLANGE 6X8 1

23♦ 34150ZH7003 ALERT UNIT, OIL ...............................................1................USE FROM S/N 5372719

23◊ 34150ZH7003 ALERT UNIT, OIL 1

24♦ 957010600800 BOLT, FLANGE 6X8 ...........................................1................USE FROM S/N 5372719

24◊ 957010600800 BOLT, FLANGE 6X8 1

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 55

HONDA GX160K1EMA2/U1EMAN ENGINE — CARBURETOR ASSY.

PAGE 56 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — CARBURETOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1#%+ 16010ZB1015 GASKET SET 1 2$ 16011ZE0005 VALVE SET, FLOAT 1 3$ 16013ZE0005 FLOAT SET 1

4$♦ 16015ZE0831 CHAMBER SET, FLOAT ....................................1................USE FROM S/N BE67A A

4$♦ 16015ZE1811 CHAMBER SET, FLOAT ....................................1................USE FROM S/N BE51A A

4$◊ 16015ZE0831 CHAMBER SET, FLOAT 1 6$ 16016ZH7W01 SCREW SET 1

7 16024ZE1811 SCREW SET, DRAIN .........................................1................INCLUDES ITEMS W/%

8 16028ZE0005 SCREW SET, B ..................................................1................INCLUDES ITEMS W/+

9$ 16044ZE0005 CHOKE SET 1

10♦ 16100ZH8E81 CARBURETOR ASSY,(BE67A B) ......................1................INCLUDES ITEMS W/$

10◊ 16100Z4JE81 CARBURETOR ASSY,(BE67P A) ......................1................INCLUDES ITEMS W/$

.............................................................................................USE UP TO S/N 1030721

11$ 16124ZE0005 SCREW, THROTTLE STOP 1 12$ 16166ZH8E80 NOZZLE, MAIN 1 13 16211ZE1000 INSULATOR, CARBURETOR 1 14 16212ZH8800 GASKET, INSULATOR 1 15 16221ZH8801 GASKET, CARBURETOR 1 16 16269ZE1800 GASKET, AIR CLEANER 1

17 16610ZB2000 LEVER COMP., CHOKE ....................................1................INCLUDES ITEMS W/<

18< 9430520122 PIN, SPRING 2X12 1 19 99101ZH80700 JET, MAIN, #70, OPTION 1 19 99101ZH80720 JET, MAIN, #72, OPTION 1 19$ 99101ZH80750 JET, MAIN, #75, 1

20$ 99204ZE00350 JET SET, PILOT, #35 .........................................1................INCLUDES ITEMS W/#

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 57

HONDA GX160K1EMA2/U1EMAN ENGINE — AIR CLEANER ASSY.

PAGE 58 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — AIR CLEANER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 17211ZB2000 ELEMENT, AIR CLEANER 1 2♦ 17212ZB2000 SEPARATOR, AIR CLEANER 1 2◊ 17212ZB2800 SEPARATOR, AIR CLEANER 1 3♦ 17220ZB2000 CASE COMP., AIR CLEANER 1 3◊ 17220ZB2800 CASE COMP., AIR CLEANER 1 4 17231ZB2000 COVER AIR CLEANER 1 5 17239ZB2000 STAY AIR CLEANER 1 6 17252ZB2000 SEAL, AIR CLEANER 1 7 90115459770 BOLT, SETTING 4 8 9405006080 BOLT, FLANGE, 6MM 2 9 957010601000 BOLT, FLANGE, 6X10 1 10◊ 17232898000 GROMMET, AIR CLEANER 1

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 59

HONDA GX160K1EMA2/U1EMAN ENGINE — MUFFLER ASSY.

PAGE 60 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 18310ZB3C00 MUFFLER COMP. 1 2 18320ZB2000 PROTECTOR, MUFFLER OUTER 1 3 18325ZH8T90 PROTECTOR, MUFFLER INNER 1

4 18329ZB2000 SEAL, MUFFLER PROTECTOR 2 5 18330ZH8T90 PIPE COMP., EX 1 6 18355898630 ARRESTER, SPARK 1 8 18381ZE1800 GASKET, MUFFLER 1 9 18381ZH8800 GASKET, MUFFLER 1

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 61

HONDA GX160K1EMA2/U1EMAN ENGINE — FLYWHEEL ASSY.

PAGE 62 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — FLYWHEEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 13331357000 KEY, SPECIAL WOOD RUFF, 25X18 1 2 19511ZE1000 FAN, COOLING 1 3 28451ZH8003 PULLEY, STARTER 1 4 31100ZE1811 FLYWHEEL (LAMP) 1 5 90201878003 NUT, SPECIAL, 14MM 1

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 63

HONDA GX160K1EMA2/U1EMAN ENGINE — IGNITION COIL ASSY.

PAGE 64 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — IGNITION COIL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1♦ 30500ZE1033 COIL ASSY., IGNITION 1 1◊ 30500ZE1073 COIL ASSY., IGNITION 1 2 30700ZE1013 CAP ASSY., NOISE SUPPRESSOR 1 4 31510ZE1811 COIL ASSY., LAMP (12V25W) 1 5 31511ZE1000 CLAMPER, CORD 1 6 31511ZE1000 GROMMET, CORD 1 7 36101ZE1010 CORD, STOP SWITCH (370 MM) 1 8 90019883000 BOLT, FLANGE, 5X10 1 9 90015883000 BOLT, FLANGE, 6X28 2 10 90121952000 BOLT, FLANGE, 6X25 2

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 65

HONDA GX160K1EMA2/U1EMAN ENGINE — GOV. CONTROL ASSY.

PAGE 66 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — GOV. CONTROL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1♦ 16551ZE0010 ARM, GOVERNOR ............................................1................USE UP TO S/N 4913229

1♦ 16551ZL0010 ARM, GOVERNOR ............................................1................USE FROM S/N 4913230

1◊ 16551ZL0000 ARM, GOVERNOR 1 2 16555ZE1000 ROD, GOVERNOR 1

3♦ 16561ZH8D00 SPRING, GOVERNOR ......................................1................USE UP TO S/N 4913229

3♦ 16561ZL0U30 SPRING, GOVERNOR ......................................1................USE FROM S/N 4913230~5048024

3♦ 16561ZL0000 SPRING, GOVERNOR ......................................1................USE FROM S/N 5048025

3◊ 16561ZL0000 SPRING, GOVERNOR 1 4 16562ZE1020 SPRING, THROTTLE RETURN 1 5 90015ZE5010 BOLT, GOVERNOR ARM 1 6 9405006000 NUT, FLANGE, 6MM 1

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 67

HONDA GX160K1EMA2/U1EMAN ENGINE — DECAL ASSY.

PAGE 68 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — DECAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 87533ZC0630 DECAL, AIR CLEANER 1 2 87528ZB2630 DECAL, CHOKE 1 3♦ 87521ZH8020 EMBLEM, 5.5 HP 1 3◊ 87521ZH8040 EMBLEM, 5.5 HP 1

4◊ 87516ZH7000 MARK OPERATOR CAUTION (ENGLISH) ........1................USE UP TO S/N 1253961

4◊ 87516ZH7010 MARK OPERATOR CAUTION (ENGLISH) ........1................USE FROM S/N 1253962

4◊ 87516ZH7010 MARK OPERATOR CAUTION (PICTOGRAPH) 1

♦GX160K1EMA2: Model GAC2.2H, JUNE 2006 AND BELOW

◊ GX160U1EMAN: Model GAC2.2H, FEBUARY 2007 AND ABOVE

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 69

HONDA GX160K1EMA2/U1EMAN ENGINE — TOOL KIT

PAGE 70 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

HONDA GX160K1EMA2/U1EMAN ENGINE — TOOL KIT

NO. PART NO. PART NAME QTY. REMARKS

1 89000ZE1000 TOOL KIT ...........................................................1................INCLUDES ITEMS W/#

2# 89218ZE1000 WRENCH COMP. (SPARK PLUG) 1 3# 89219805000 HANDLE, BOX WRENCH 1 4# 9900110120 SAPNNER, 10X12 1 5# 9900114170 SAPNNER, 14X17 1 6# 9900802300 BAG TOOL 1

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 71

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

5. Par ts must be in new and resalable

Multiquip reserves the right to quote and

who use our products as integral parts of their

LIMITATIONS OF SELLER’S LIABILITY

liable for loss of proﬁ t or good will or for any

connection with the sale of its products. Apart

statutory, which extend beyond the description

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All ship ments 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 acce pted and credit will be allowed, subject to the following provisions:

1. A Returne d Material Autho riza tion 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 deﬁ nes item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions

b. The list must be typed or computer

c. The list must state the reason(s)

d. The list must reference the sales

e. The list must include the name

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

4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point.

must match the current parts price list.

generated.

for the return.

ord e r ( s) or i n v o i c e( s ) u n de r which the items were originally purchased.

and phone number of the person requesting the RMA.

co ndit ion, in th e origin al Multiq uip package (if any), and with Multiquip part numbers clearly marked.

6. The following items are not returnable:

a. Obsolete parts. (If an item is in the

price book and shows as being replaced by anoth er 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

deal e r net pric e of less th an $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7. The sender will be notiﬁ ed of any material received that is not acceptable.

8. Suc h mat eri al will be held for five working days from notiﬁ cation, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

9. Credit on returned parts will be issued at dealer net price at time of the original pur ch a s e, less a 15 % restocking charge.

10. In cases where an item is accepted, for 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.

11. Credit issued will be applied to future purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a speciﬁ c 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.

sell direct to Government agencies, and to Original Equipment Manufacturer accounts

own products.

SPECIAL EXPEDITING SERVICE

A $35.00 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.

Multiquip shall not be liable hereunder 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

other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warran ties, expr ess or implie d, 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 nor auth orize s any per son to ass ume for it any other obligation or liability whatever in

from such written statement of warrant y, there are no warranties, express, implied or

of the products on the face hereof.

Effective: February 22, 2006

PAGE 72 — GAC2.2H 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (03/31/10)

NOTES

GAC2.2H 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/31/10) — PAGE 73

OPERATION AND PARTS MANUAL

HERE’S HOW TO GET HELP

Multiquip Inc and the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property

The information and speciﬁ cations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change speciﬁ cations, design or the information published

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

UNITED STATES

Multiquip Corporate Ofﬁ ce MQ Parts Department

18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com

Mayco Parts Warranty Department

Tel. (800) 421-1244 Fax (800) 537-3927

800-427-1244 310-537-3700

Fax: 800-672-7877 Fax: 310-637-3284

800-306-2926 310-537-3700

Service Department Technical Assistance

800-421-1244 310-537-3700

Fax: 800-672-7877 Fax: 310-637-3284

Fax: 310-537-4259 800-478-1244 Fax: 310-631-5032

800-421-1244, Ext. 279 310-537-3700, Ext. 279

Fax: 310-537-1173

MEXICO UNITED KINGDOM

MQ Cipsa Multiquip (UK) Limited Head Ofﬁ ce

Carr. Fed. Mexico-Puebla KM 126.5 Momoxpan, Cholula, Puebla 72760 Mexico Contact: pmastretta@cipsa.com.mx

Tel: (52) 222-225-9900 Fax: (52) 222-285-0420

Unit 2, Northpoint Industrial Estate, Global Lane, Dukinﬁ eld, Cheshire SK16 4UJ Contact: sales@multiquip.co.uk

Tel: 0161 339 2223 Fax: 0161 339 3226

CANADA

Multiquip

4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 Contact: jmartin@multiquip.com

of their respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

Tel: (450) 625-2244 Tel: (877) 963-4411 Fax: (450) 625-8664

in this publication at any time without notice and without incurring any obligations.

Your Local Dealer is:

Multiquip GAC2.2H User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual