Multiquip GAC2.2H User Manual
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
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
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.)
3
)
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
POWERED by
Honda Engines
19.7 IN.
(500 MM)
120V
15A
V
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
POWERED by
Honda Engines
#8 MINIMUM
120V
15A
ACVOLTMETER
VOLTOMETRECA
GROUND
CABLE
120
V
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)
1
2
GAC-2.2H
POWERED by
Honda Engines
211052
GRPRISE DE
TERRE
7
6
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.
5
120V
15A
V
ACVOLTMETER
VOLTOMETRECA
OFF
NEUTRALBONDED TO FRAME
120
NEUTREMIS A LAMASSE A
LACARCASSE DU MOTEUR
AC CIRCUIT BREAKER
INTERRUPTEUR DE
COURANT PRINCIPAL
3
A21210011
4
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
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