Multiquip GAC-9.7HZ User Manual
OPERATION AND PARTS MANUAL
MODEL GAC-9.7HZ
PORTABLE GENERATOR
(HONDA GX610 GASOLINE ENGINE)
Revision #2 (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
GAC9.7HZ 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 ............................................... 19-21
Operation .......................................................... 22-24
Operation/Shutdown .............................................. 24
Preparation For Long Term Storage ...................... 25
Maintenance ..................................................... 26-28
Generator Wiring Digram ...................................... 29
Troubleshooting (Engine) .................................. 30-31
Troubleshooting (Generator) .................................. 32
Explanation of Code in Remarks Column ............. 34
Suggested Spare Parts ......................................... 35
Honda GX610K1VD/GX610U1VD
Engines
Air Cleaner Assembly ....................................... 44-45
Camshaft Assembly .......................................... 46-47
Carburetor Assembly ........................................ 48-51
Control Assembly .............................................52-53
Crankcase Cover Assembly. ............................. 54-55
Crankshaft Assembly ........................................ 56-57
Cylinder Barrel Assembly ................................. 58-59
Cylinder Head Assembly .................................. 60-61
Fan Cover Assembly ......................................... 62-63
Flywheel Assembly ........................................... 64-65
Ignition Coil Assembly ...................................... 66-67
Piston Assembly ............................................... 68-69
Recoil Starter Assembly ................................... 70-71
Muffler Assembly .............................................. 72-73
Auto Throttle Assembly ..................................... 74-75
Starter Motor Assembly .................................... 76-77
Fuel Pump Assembly ........................................ 78-79
Rectifer Assembly ............................................. 80-81
Engine Decals Assembly .................................. 82-83
Tool Kit .............................................................. 84-85
Component Drawings
Nameplate and Decals Assembly ..................... 36-37
Generator Assembly ......................................... 38-39
Control Box Assembly ...................................... 40-41
Pipe Frame Assembly ....................................... 42-43
Terms And Conditions Of Sale — Parts ................ 86
NOTICE
Specifications and part numbers are subject to change
without notice.
PAGE 2 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (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!
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (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 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (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
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (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 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (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.
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (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 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
NOTES
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 9
AC Generator
60 Hz AC Power Source
SPECIFICATIONS (GENERATOR)
Table 1. Specifications (Generator)
Model GAC9.7HZ
Type Brushless Revolving Field Type
Excitation Solid State, Statically Excited System
Speed 3,600 RPM
Cooling System Self-Ventilation
Max Power Output 9.7 kW
Continuous Power Output 8.4 kW
Rated Voltage 120/240V
Current Max/Continuous (120V) 80.8/70 amps
Current Max/Continuous (240V) 40.4/35 amps
Phase Single Phase (3 wire)
Frequency 60 Hz
Power Factor 1
Battery
Dimensions
(L x W x H)
Dry Net Weight
Weight with Fuel
12V CCA 230
31.49 x 21.25 X 27.55 in.
(800 X 540 X 700 mm)
342 lbs. (155 kg.)
408 lbs. (185 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 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
SPECIFICATIONS (ENGINE)
Table 2. Specifications (Engine)
Engine
Dimensions
(L x W x H)
Dry Net Weight
Model
Type
Air-cooled 4 stroke, Single Cylinder, OHV,
Bore X Stroke
Displacement 37.46 cu-in (614 cm
HONDA GX610K1VD
HONDA GX610U1VD
Horizontal Shaft Gasoline Engine
3.03 in. X 2.59 in.
(77 mm x 66 mm.)
3
)
Max Output 18.0 H.P./3600 R.P.M.
Fuel Unleaded Automobile Gasoline
Fuel Capacity 10 gallons (38 liters)
Lube Oil Capacity 1.90 quarts (1.8 liters)
Oil Alert System Yes
Speed Control Method Centrifugal Fly-weight Type
Starting Method Electric Start/Recoil
Battery 12 Volt @ 35 Ah
15.27 x 17.99 X 17.79 in.
(388 X 457 X 452 mm)
114.6 lbs. (42 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).
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 11
31.49 IN
(800 MM.)
DIMENSIONS
9700
27.55 IN.
(700 MM.)
ACCIRCUIT BREAKER
INTERRUPTEURDE COURANT CA
for120V
for120V
30A
15A
GR
PRISEDE
TERRE
for240V
15A 15A
120
MARCHE
MARCHE
ON
240
V
ARRET
OFF
ARRET
IDLE
OPERATION
CONTROL
CONTROL
DERALENTI
240V
20A
TOTALLOAD WITHIN 8.4kW
SWITCH
INTERRUPTEUR
DEOPERATION
120/240V
ACVOLTMETER
for120/240V
20A
VOLTOMETRECA
30A
120V
30A
CHARGETOTAL MAX. 8.4kW
Figure 1. Dimensions
ON
OFF
30A
BUTTON
BOUTONDE
DEMARRAGE
START
Honda Engines
211052
ACCIRCUIT
BREAKER
(formain)
INTERRUPTEURDE
COURANTPRINCIPAL
NEUTRALBONDED TO FRAME
NEUTREMIS A LAMASSE A
LACARCASSE DU MOTEUR
GAC-9.7HZ
POWEREDby
OFF
PAGE 12 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
NOTE
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 13
CONNECTING THE GROUND
The nut and ground terminal on the generator should always
be used to connect the generator to a suitable ground. The
ground cable should 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
Figure 2. Generator Grounding
PAGE 14 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (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.
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.
INDOOR INSTALLATION
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 generator 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.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 15
FAMILIARIZATION
Generator
The Multiquip GAC9.7HZ generator is 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.
The generator is mounted on rubber vibration isolators
that have a steel base backplate which is attached to the
protective steel pipe carrying frame. The protective carrying
frame is made of steel tubing and fully wraps around the
generator to protect against damage. See Figures 3, and
4 for the basic controls and indicators for the GAC9.7HZ
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:
120/240V twist-lock output receptacle (single phase).
240V twist-lock receptacle (single phase).
120V GFCI single phase duplex output receptacle.
35 Amp Main Circuit Breaker (2-pole)
Two 15 Amp GFCI Circuit Breakers (1-pole)
30 Amp Circuit Breaker (1-pole)
20 Amp Circuit Breaker (2-pole)
30 Amp Circuit Breaker (2-pole)
AC Voltmeter
Ground Terminal
Idle Control Switch
Operation Switch
Start Switch
PAGE 16 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
COMPONENTS (GENERATOR)
Figure 3. Generator Components
1. GFCI Breakers (2) – These single pole circuit breakers
(120V, 15 amps) protect the GFCI receptacles. When
star ting the generator always have these circuit
breakers placed in the "OFF" position.
2. 30 Amp Breaker – Single pole 30 amp circuit breaker
protects the 120V twist-lock receptacle. When starting
the generator always have this circuit breaker placed
in the "OFF" position.
3. 20 Amp Breaker – 2-pole 20 amp circuit breaker
protects the 240V twist-lock receptacle. When starting
the generator always have this circuit breaker placed
in the "OFF" position.
4. 30 Amp Breaker – 2-pole 30 amp circuit breaker
protects the 120/240V twist-lock receptacle. When
starting the generator always have this circuit breaker
placed in the "OFF" position.
5. AC-Voltmeter – This voltmeter indicates (with a
mark) the rated 60 Hz (single-phase) output voltage.
In addition the voltmeter can also be used as a
diagnostic tool. If the voltmeter indicator (needle) is
below the rated voltage, engine problems may exist
(low/high RPM's). To prevent damage to the generator
or power tools turn the generator OFF and consult your
authorized Multiquip service dealer.
6. Idle Control Switch – The generator is provided with
an automatic idle control device for noise suppression
and reduced fuel consumption.
The automatic idle control automatically engages under
a no-load condition. With the automatic idle control
switched “ON”, the engine revolutions will automatically
drop to about 2600 rpm (low-speed operation) within
3 seconds after the load stops. When the operation is
resumed, the engine speed is automatically increased
to about 3600 rpm (high-speed operation) as soon as
the load is connected.
7. Operation Switch – Place switch in the "ON" position
(up) for normal operation. To turn-off the generator,
place the operation switch in the "OFF" position (down).
8. Start Button – Press this pushbutton switch to start
the generator.
9. Main Breaker – 2-pole 35 amp circuit breaker protects
the generator from short circuiting or overloading.
When starting the generator always have this circuit
breaker placed in the "OFF" position.
10. 120/240V Output Receptacle – NEMA L14-30R twist-
lock receptacle will provide 120/240V, 30 amps, 60 Hz.
11. 240V Output Receptacle – NEMA L6-20R twist-lock
receptacle will provide 240V, 20 amps, 60 Hz.
12. 120V Output Receptacle – NEMA L5-30R twist-lock
receptacle will provide 120V, 30 amps, 60 Hz.
13. GFCI Duplex Receptacle – NEMA 5-15R, GFCI
receptacle will provide 120V, 15 amps.
14. Ground Lug – This ground connection point should be
connect to a good earth ground (ground rod).
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 17
COMPONENTS (GENERATOR)
Figure 4. Generator Components (continued)
15. Engine Oil Drain Plug – Remove this drain plug
when draining of the oil from the engine crankcase
is required. Fill with recommeded type oil as listed in
Table 4
16. Engine Oil Dipstick – Remove oil dipstick to check
engine oil level.
17. Fuel Drain Plug – Remove plug to drain fuel.
18. Fuel Gauge – This gauge is located on top of the fuel
tank. Read this gauge to determine when fuel is low.
19. 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.
20. Recoil Starter (pull rope) – Manual-starting method.
Pull the starter grip until resistance is felt, then pull
briskly and smoothly.
21. Fuel Tank/Cap – Remove fuel cap to add fresh
unleaded fuel. Fuel tank capacity is 10 gallons (38
liters).
22. Battery – This generator is equipped with a 12 VDC
battery. Replace with only recommended type battery.
23. 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
24. 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.
25. Oil Filter – Replace oil filter as referenced in
maintenance section of this manual.
26. Engine Oil Filler Hole – Remove cap when the adding
of engine oil is required. See Table 4 for recommended
type engine oil.
27. Air Cleaner – Prevents dirt and other debris from
entering the fuel system. Release retaining clips on top
of air filter cover to gain access to filter element.
NEVER run the engine without an air cleaner.
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 generator is placed
on level ground. Placing the generator on level ground
will ensure that the low oil sensor will function properly.
PAGE 18 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
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.
INSPECTION/SETUP
NOTICE
Double-insulated power tools and small appliances
have specially insulated housings that eliminate the
need for a ground. 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.
Extension Cable
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum. Use the cable selection chart (Table 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!
Circuit Breakers
ALWAYS place the main, auxiliary and GFCI circuit
Figure 5. Ground Pin
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.
Load In Watts Maximum Allowable Cable Length
120 Volts 240 Volts #10 Wire #12 Wire #14 Wire
breakers in the OFF position prior to starting the engine.
#16 Wire
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.
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 19
INSPECTION/SETUP
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 dipstick from its holder (Figure 6) and wipe
clean.
3. Re-Insert dipstick (Figure 7), then remove dipstick from
its holder. Check the oil level shown on the dipstick.
Figure 7. Engine Oil Dipstick
Figure 6. Engine Oil Dipstick Removal
4. If the oil level is low, remove the oil filler cap (Figure 8)
and fill to a safe operating level (max) as indicated by
the dipstick. Fill with recommended type oil as listed in
Table 4. Maximum oil capacity is 1.90 quarts (1.8 liters).
Figure 8. Engine Oil Filler Port
PAGE 20 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
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
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 9) to determin if the fuel level is low. If fuel is
low, replenish with clean unleaded fuel.
INSPECTION/SETUP
Figure 9. 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!
Battery Check
ALWAYS be sure the battery cables (Figure 10) are
properly connected to the battery terminals as shown below.
The red cable is connected to the positive terminal of the
battery, and the black cable is connected to the negative
terminal of the battery.
Figure 10. Battery Connections
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 21
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 generator 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 circuit breaker (Figure 11)
in the OFF position before starting.
Figure 11. Main Circuit Breaker (OFF)
3. NEVER start the engine with the GFCI or AUX. circuit
breakers in the ON position. Always place these circuit
breakers (Figure 12) in the OFF position before starting
the engine.
6. Place the generator's operation switch (Figure 14) in
the ON position.
Figure 14. Operation Switch (ON)
7. Press the generator's pushbutton start switch (Figure
15) and listen for the engine to start. If the battery is
not installed proceed to step 6.
Figure 15. Start Pushbutton Switch
8. Grasp the starter grip (Figure 16) 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 12. GFCI/AUX. Circuit Breakers (OFF)
Starting the Engine
4. Place the choke knob (Figure 13) in the CLOSED
position if starting a cold engine.
Figure 13. Choke Knob
5. Place the choke knob (Figure 13) in the OPEN position
if starting a warm engine or the temperature is warm.
PAGE 22 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
Figure 16. Starter Grip
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..
9. If the engine has started, slowly return the choke lever
(Figure 13) to the OPEN position. If the engine has not
started repeat steps 1 through 8.
10. 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.
OPERATION
11. Place idle control switch (Figure 17) in the OFF (down)
position. This will allow the engine speed to run at about
3600 RPM's.
Figure 17. Idle Control Switch (OFF)
NOTICE
Placing the idle control switch in the OFF position
(Figure 17) allows the engine to operate at a maximum
speed of about 3600 RPM's.
When the idle control switch (Figure 18) is placed in the
up position (ON), the generator will run at idle speed
(2200 RPM's) until a load is applied, at that time the
engine speed will increase to 3600 RPM's as long as
a load is being applied.
When the load is not in use, the engine speed will drop
back to the idle mode after about 3 seconds.
14. Read voltmeter on front panel of generator (Figure 21)
and verify that 120 VAC is displayed. Using an external
voltmeter as shown in Figure 21, verify that 120 VAC
is present at the 120V twist-lock and GFCI duplex
receptacles..
Figure 21. 120V GFCI/AUX. Receptacles
15. Read voltmeter on front panel of generator (Figure 22)
and verify that 240 VAC is displayed. Using an external
voltmeter as shown in Figure 22, verify that 240 VAC
is present at the 240V twist-lock receptacle.
Figure 18. Idle Control switch (ON)
12. Place main circuit breaker (Figure 19) in the ON
position.
Figure 19. Main Circuit Breaker (ON)
13. Place GFCI and AUX. circuit breakers (Figure 20) in
the ON position.
Figure 22. 240V Receptacle
Figure 20. GFCI/AUX. Circuit Breakers (ON)
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 23
OPERATION/SHUTDOWN
NOTICE
When using a combination of dual receptacles, total
load should not exceed the rated capacity of the
generator.
16. The L14-30R receptacle is a dual voltage receptacle
(120-240 volts). Reference Figures 23 and 24 to verify
voltages at this receptacle.
Stopping the Engine (Normal Shutdown)
1. Place main circuit breaker (Figure 25) in the OFF
position.
Figure 25. Main Circuit Breaker (OFF)
2. Place GFCI and AUX. circuit breakers (Figure 26) in
the OFF positing.
Figure 26. GFCI/AUX. Circuit Breakers (OFF)
3. Place idle control switch (Figure 27) in the OFF position.
Figure 23. 120/240V Receptacle (120V)
Figure 24. 120/240V Receptacle (240V)
17. Connecting of loads (power tools, lighting ect.) to the
generator receptacles can now be done.
Figure 27. Idle Control switch (OFF)
4. Let engine run at idle with no load for 2-3 minutes.
5. To shut-down the engine, place the generator's
operation switch (Figure 28) in the OFF position).
Figure 28. Operation Switch (OFF)
6. Remove all loads from the generator.
Emergency Shutdown
1. Place operation switch (Figure 28) in the OFF position.
PAGE 24 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
PREPARATION FOR LONG TERM STORAGE
Generator Storage
For storage of the generating set for over 30 days, the
following is required:
Drain the fuel tank completely, 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.
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 25
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
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.
X
PAGE 26 — GAC9.7HZ 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #2 (03/31/10)
MAINTENANCE
Maintenance
Perform the scheduled maintenance procedures as defined
by Table 5 and below:
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.
Remove or clean the filter at the bottom of the tank.
Remove and clean the spark plug (Figure 29), 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.
3. Use an oil filter socket tool and remove oil filter as
shown in Figure 31
Figure 31. Oil Filter Removal
4. Clean oil filter mounting base, and coat oil filter seal
(Figure 31) with clen engine oil.
5. Screw on new oil filter by hand until seal contacts the
filter mounting base. Using an oil filter socket tool,
tighten filter and additional 7/8-inch turn. Tighten filter
to 16ft-lbs. (22 N.m).
6. Install drain bolt with sealing washer and tighten
securely.
Figure 29. Spark Plug Gap
Engine Oil and Filter
1. Drain engine oil when the oil is warm as shown in
Figure 30.
2. Remove oil drain bolt and sealing washer and allow
engine oil to drain into a suitable container.
7. Replace engine oil with recommended type oil as listed
in Table 4. For engine oil capacity, see Table 2 (engine
specifications ). Fill to upper limit as shown in Figure 30.
Figure 30. Draining Engine Oil
GAC9.7HZ 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (03/31/10) — PAGE 27
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