Multiquip GBP5000H User Manual

OPERATION AND PARTS MANUAL

MODEL GDP5000H

HIGH CYCLE GENERATOR

Revision #2 (07/23/08)

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

PAGE 2 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

NOTES

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help .......................................... 3

Table Of Contents ................................................... 4

Parts Ordering Procedures ..................................... 5

Rules For Safe Operation ....................................... 6

Operation and Safety Decals .................................. 7

Specifications .......................................................... 8

General Information ................................................ 9

Multiquip GDP-5000H — AC Generator

Controls and Indicators .......................................... 10

Installation .............................................................. 11

Pre-Setup .......................................................... 12-13

Instrumentation ...................................................... 14

Load Application ...............................................15-16

Operating Instructions............................................ 17

Maintenance .......................................................... 18

Preparation For Long Term Storage ...................... 19

Wiring Diagram ...................................................... 20

Troubleshooting (Engine) .................................. 21-22

Troubleshooting (Generator) ............................23-24

Explanation Of Codes In Remarks Column ............ 7

Spare Parts List .................................................... 25

Engine/Generator Assy. .................................... 26-27

Generator Assy. ................................................28-29

Control Box Assy. ..............................................30-31

Muffler Assy.......................................................32-33

Pipe Frame Assy. .............................................. 34-35

Nameplate Assy. .................................................... 36

Honda GX340K1 GasolineHonda GX340K1 Gasoline

Honda GX340K1 Gasoline

Honda GX340K1 GasolineHonda GX340K1 Gasoline EngineEngine

Engine

EngineEngine

Cylinder Head Assy. .......................................... 38-39

Recoil Starter Assy............................................ 40-41

Fan Cover Assy. ................................................ 42-43

Camshaft /Valves Assy. ..................................... 44-45

Piston/Rings Assy.............................................. 46-47

Air Cleaner Assy................................................ 48-49

Cylinder Barrel Assy. (Recoil Starter) ............... 50-51

Cylinder Barrel Assy. (Electric Start) ................. 52-53

Crankcase Governor Assy. ............................... 54-55

Flywheel/Fan Assy. ........................................... 56-57

Coil Assy............................................................ 58-59

Crankshaft Assy. ............................................... 60-61

Electric Starter Assy. ......................................... 62-63

Governor Control Assy. ..................................... 64-65

Carburetor Assy. ............................................... 66-67

Solenoid Assy. ................................................... 68-69

Fuel Cock Assy. ................................................ 70-71

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

NOTE

Specification and part number are subject to change without notice.

PAGE 4 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

Effective:

January 1

, 2006

Best Deal!

Order via Internet (Dealers Only):

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

■

View Parts Diagrams

■

Order Parts

■

Print Specification 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)

Non-Dealer Customers:

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

Order via Phone:

If you have an MQ Account, to obtain a Username and Password, E-mail us at:

parts@multiquip.com.

To obtain an MQ Account, contact your District Sales Manager for more information.

internet

Use the on

Standard orders

and qualify for a 5% Discount

for all orders which include

complete part numbers.*

Fax

your order in and qualify for a 2% Discount

Standard orders

for all orders which include

complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers

their local Multiquip Representatives for Parts Ordering information.

Note: Discounts Are Subject To Change

should contact

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

❒❒

All orders are treated as

Standard Orders

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

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 5

Specify Preferred Method of Shipment:

❒❒

✓

UPS/Fed Ex

■

Priority One

■

Ground

■ Next Day

■

Second/Third Day

✓ DHL ✓

Tr u c k

RULES FOR SAFE OPERATION

■

CAUTION:

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and

qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the GDP-5000H Generator:

GENERAL SAFETY

■

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

■

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

■

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

■

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

■

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

■

Always use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool.

DO NOT

could result from fuel vapors, or if fuel is spilled on a hot engine.

■

This generator is equipped with a protection. Always complete the grounding path from the generator to an external grounding source.

■

NEVER operate this generator, or handle any electrical equipment while standing in

hands are wet, or in the rain. Electrical shock could occur causing severe bodily harm or even death.

■

Keep electrical cords in good condition. Worn, bare or frayed wiring can cause electrical shock, leading to

even death.

■

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

smoke around or near the machine. Fire or explosion

ground terminal

for your

water, while bare foot, while

bodily harm or

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

■

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

■

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

■

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

■

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

■

Use adequate size connecting cable for extension.

■

High Temperatures – Allow the machine and engine to cool before adding fuel or performing service and maintenance functions. Contact with burns.

Emergencies

■

Always know the location of the nearest and

first aid kit

Also know the phone numbers of the nearest

doctor

invaluable in the case of an emergency.

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

■

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

■

Keep the machinery in proper running condition.

■

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

■

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

■

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

■

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

bodily harm or even death.

. Know the location of the nearest telephone.

and

fire department

hot

components can cause serious

fire extinguisher

ambulance

. This information will be

■

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

PAGE 6 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

OPERATION AND SAFETY DECALS

Machine Safety Decals

The GDP-5000H portable generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below shows these decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 7

GDP5000H — SPECIFICATIONS

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Effects of Altitude and Heat

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

°°

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

°°

Fahrenheit above the standard temperature of 60

°°

PAGE 8 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

GDP-5000H — GENERAL INFORMATION

WARNING:

Before connecting this generator to any

building’s electrical system, a licensed electrician must install an isolation (transfer) switch.

Serious injury or death may result without this transfer switch.

GDP-5000H FAMILIARIZATION Generator

The Multiquip Model GDP-5000H 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. In addition the Model GDP-5000H has been designed as a power source for 180 Hz, 3-phase concrete vibrators.

This generator is powered by a HONDA gasoline engine. The alternator, a brushless revolving-field type, is permanently aligned to the engine through rigid coupling.

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

This portable generator is supplied with a electrical

box

. To reduce vibration caused by the engine, the control

box is also placed on rubber isolators.

control

Excitation System

The GDP-5000H-series generators use a magnet attached to a flywheel to produce AC voltage from a lamp coil beneath the flywheel. As the magnetic passes the coil it produces approximately 19-22 AC volts.

This voltage (19-22 VAC) is then sent to the control box that contains three rectifying diodes:

Excitation (diode 1)

Battery (diode 2)

Slow Down (diode 3)

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

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

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

Engine

The four-cycle air-cooled HONDA gasoline engine is designed to meet every performance requirement of this generator. Reference Table 1, page 8 for engine specifications

Figure 1 (page 11) shows the basic controls and indicators for the GDP-5000H generator.

Control Box

The control box is provided with the following:

Three 240V output receptacles (three phase).

One 120V output output receptacle (single phase).

One 120/240V output output receptacle (single phase).

One 120V output receptacle, GFIC (single phase).

One main 60 Hz (single phase) circuit breaker.

One main 180 Hz (three phase) circuit breaker.

AC Voltmeter

Ground Terminal

Full Power Switch

Idle Control Switch

Operation Switch

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 9

NOTE

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

GDP-5000H — CONTROLS AND INDICATORS

Figure 1. Controls and Indicators

PAGE 10 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

GDP-5000H — INSTALLATION

Outdoor Installation

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

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

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

CAUTION :

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

Indoor Installation

Exhaust gases from gasoline engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

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

CAUTION :

Preventing electrical shock. Pay close attention to handling when operating concrete vibrators. Always use rubber boots and gloves to insulate the body from a short circuit.

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 11

GDP-5000H — PRE-SETUP

General Inspection Prior to Operation

This generator has been thoroughly inspected prior to

Ground the Tool

Ground the tool (load) in the same manner as the generator.

shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occurred in transit.

Ground

Circuit Breaker

To protect the generator from an overload,

provided for both 60 and 180 phases on the control box. Make sure to switch the circuit breakers to the "OFF" position

The nut and ground terminal on the generator should always

prior to starting the engine.

be used to connect the generator to a suitable ground. The ground path should be of #8 size wire.

Connect the terminal of the ground wire between the lock washer and the nut and tighten the nut fully. Connect their end of the wire to a suitable ground.

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

Ground the Generator

Ground the generator from its ground connector so that the

point of use (load) is held to a minimum. Use the cable selection chart (Tables 2 and 3) as a guide for selecting proper cable size.

resistance to ground is 500 ohms or less.

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PAGE 12 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

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GDP-5000H — PRE-SETUP

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but do not overfill. Make sure the generator is level. With the dipstick inserted all the way, but without being

Fuel

Close the fuel cock before filling the tank. Fill the fuel tank with clean and fresh unleaded gasoline. Do not fill the tank beyond capacity.

screwed into the filler hole, verify that the oil level is maintained between the two notches on the dipstick.

Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed on page 8

The oil listed in Table 4 is recommended to ensure better

Specification Table 1.

engine performance. Use class SC or higher grade motor oil.

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The fuel tank cap must be closed tightly after filling.

Handle fuel in a safety container. If the container does not have a spout, use a funnel.

CAUTION :

Never fill the fuel tank while the engine is running or in the dark. Gasoline spillage on a hot engine can cause a fire or explosion. If gasoline spillage occurs, wipe up the spilled gasoline completely to prevent fire hazards.

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 13

GDP-5000H — INSTRUMENTATION

Power Outlets

The generator has the following single and 3-phase receptacles.

Single Phase

One Duplex NEMA (GFCI) 5-20R (120V, 30 Amp) One Twist Lock NEMA L5-30R (120V, 30 Amp) One Twist Lock NEMA L6-20R (240V, 20 Amp)

3- Phase

ThreeTwist Lock NEMA 7410 (240V, 30 Amp)

Full Power Switch

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

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

full rated power

of the generator at 120

CAUTION :

60 Hz Circuit Breaker

This breaker protects the generator from short circuiting or overloading from the 60 Hz single phase load.

The 180 Hz Leakage Breaker

The 180 Hz leakage breaker (Figure 4) is a earth leakage breaker with the following conditions:

The circuit is broken when the load side shorts or there is over current.

During use it detects when there is defective insulation on the load side and breaks the circuit in response.

Idle Control Switch (both 60 and 180 Hz)

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

When using a combination of dual

receptacles, total load should not exceed the rated capacity of the generator.

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

Figure 2. 120 V Simplified Diagram (Switch Up)

NOTE

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

When the switch is in the 240 volt (down) position, you can take up to half of the rated power of the generating set at 120 volts from the duplex receptacle and up to half of the rated power of the set at 120 volts from the locking type 120 volt receptacle; or full rated power of the set at 240 volts from the locking type 240 volt receptacle.

as the load is connected.

Fuel Gauge

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

AC Voltmeter

This voltmeter indicates output voltage for both 60 and 180 Hz phases. In addition this voltmeter can also be used as a diagnostic tool.

If the voltmeter indicator (needle) is elow the rated voltage, engine problems may exist (low/high RPM's). To prevent damage to the generator or power tools turn the generator OFF and consult your authorized Multiquip service dealer.

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

PAGE 14 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

GDP-5000H — LOAD APPLICATION

Single Phase Load — 60 Hz

CAUTION:

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

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

NOTE

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

WATTS = VOLTAGE x AMPERAGE

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

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

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

CAUTION:

Three Phase Load — 180 Hz

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

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.

1. INCANDESCENT LOADS Lights, heaters and similar appliances. Total the running wattage and multiply by 1. Example: 29 light bulbs @ 100W each = 2.9 KW use a 3 KW generator.

2. SMALL MOTORS Drills and other small power tools. Total the running wattage and multiply by 2. Example: A 1 inch drill runs at 1 KW use a 2 KW generator.

3. LARGE MOTORS Submersible pumps, table saws etc. Total the running wattage and multiply by 3. Example: A conveyor belt runs at 8 KW use a 24 KW generator.

180 cycle, three phase, 230V, motor-in-head vibrators can be operated with this generator. When operating more than one concrete vibrator, the ON/OFF switch of each concrete vibrators shall be turned on one at a time.

If they are switched on simultaneously, the circuit breaker may trip or the engine may be overloaded.

NOTE

If output (kVA) is not given on the vibrators nameplate, approximate output may be determined by multiplying voltage by amperage by .

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 15

GDP-5000H — LOAD APPLICATION

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Always use a vibrator with short circuit protection.

Always use rubber boots and gloves when operating the vibrator.

Use adequate size connecting cable for extension.

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

Earth Leakage Breaker (180 Cycle)

The 180 Hz leakage breaker (Figure 4) is an earth leakage breaker, so please use it after carefully reading the following:

WARNING:

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation

(transfer) switch. Serious injury or death may result without

this transfer switch.

How to Use

Always conduct the following in order that the earth leakage breaker will operate safely. Also, if the leakage breaker should for some reason actuate, first stop the generator and then repair or eliminate the source of the earth leakage before resetting the leakage breaker. When setting up the generator perform the following:

Ground the Generator

Ground the generator from its ground connector so that resistance to ground is 500 ohms or less.

Ground the Tool

Ground the tool (load) in the same manner as the generator.

Figure 4. Earth Leakage Breaker

Test Operation

For safety’s sake, the operation of the earth leakage breaker should be tested periodically according to the following

NOTE

Before operating generator press earth leakage test button.

The earth leakage breaker's earth leakage detection sensitivity is 30 mA, and the actuation time is 0.1 sec.

procedure:

1. Start the engine and set it to high speed.

2. Turn the leakage breaker ON.

3. During normal operation, press the earth leakage indicator

4. Push the indicator button back in when resetting

NOTE

Simply because the generator is equipped with a earth leakage breaker does not mean that grounding of the load can be neglected, please be sure to properly ground load equipment.

test button on the front of the generator and observe that indicator button pops out and the leakage breaker trips.

PAGE 16 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

GDP-5000H — OPERATING INSTRUCTIONS

Before Starting

1. Be sure to disconnect the electrical load and switch

both main circuit breakers (60 and 180 Hz) to the “OFF” position prior to starting the engine.

2. Never start the engine with the main circuit breaker “ON”.

3. Check the lubricating oil level prior to starting the engine.

Make sure the generator is level. The oil level must be maintained between two notches on the dipstick.

4. When there is not enough lubricating oil, fill the crankcase

with high grade motor oil. Use a high quality detergent oil classified SC, SD or SE. (See Table 4 on page 13)

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

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

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

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

Starting

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

starts to flow when the fuel cock is turned downward.

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

Warm up

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

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

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

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

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

2. Switch both main circuit breakers (60 and 180 Hz) to the “ON” position and turn the idle control switch to the “ON” (down) position for normal (load) engine operation.

Operation

Check the voltage by referring to the voltmeter on the control box. When the voltmeter indicates 120 volts, 120 volts from the 120V receptacles and 240 volts from the 240V receptacle can be obtained at the same time. Refer to Figure 1, Controls and Indicators, item 7 on page 10.

DO NOT change the engine speed control

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

3. Close the choke. Adjust the opening of the choke valve according to operating conditions. When the engine is warm or the air temperature is high, close the choke valve halfway or open it all the way.

4. Confirm that both main circuit breakers (60 and 180 Hz) on the generator control box are in the “OFF” position.

5. Set the operation switch to the “ON” position and grasp the starting knob and slowly pull it out. The resistance becomes hardest at a certain position, corresponding to the compression point. Rewind the rope a little from that point and pull out sharply.

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

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

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.

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 17

Stopping the Engine

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

1. Remove the load from the generator. Place the circuit breaker in the “OFF” position (See Figure. 3 on page 9). Run the engine (no-load) with the idle control switch set to the ON position for three to five minutes, then stop the engine.

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

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

4. After the engine has stopped, close the fuel cock.

NEVER stop the engine suddenly while running at high speeds.

GDP-5000H — MAINTENANCE

General Inspection

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

Engine Side (Refer to the Engine Instruction Manual)

Check Oil Level

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

Changing Oil

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

Air Cleaner

Every 50 hours: Remove air cleaner element (std. or heavy duty types), and wash in kerosene or liquid detergent and hot water. Wrap foam element in a cloth and squeeze dry.Wipe heavy duty paper element dry with toweling. Saturate element with kerosene; squeeze excess from foam element. Wipe excess from heavy duty paper element.

Service Daily

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

Cleaning the Fuel Strainer

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

Spark Plug

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

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

Figure 5. Spark Plug Gap

PAGE 18 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

GDP-5000H — PREPARATION FOR LONG -TERM STORAGE

Generator Storage

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

Drain the fuel tank completely.

Run the engine until the gasoline in the carburetor is completely consumed.

Completely drain the oil from the crankcase and refill with fresh oil.

Remove the spark plug, pour 2 or 3 cc of SAE 30 oil into the cylinder and crank slowly to distribute the oil.

Slowly rotate the engine a few times with the starter Rope and install a new plug.

Pull out the starter rope slowly and stop at the compression point.

Clean all external parts of the generating set with a cloth.

Cover the generating set and store in a clean, dry place.

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 19

GDP-5000H — WIRING DIAGRAM

PAGE 20 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

GDP-5000H — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the

diagnosis based on the Engine Troubleshooting (Table 6) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant.

MOTPMYS MELBORPELBISSOP NOITULOS

?tignihcaersi

?leuFoN leuFddA

?knatleufniretaW .knatleufecalperrohsulF

?deggolcretlifleuF retlifleufecalpeR

?roterubrackcutS .msinahcemtaolfkcehC

gnitratsrooP

)tratstonlliwenignE(

?kcalbsigulpkrapS .tinunoitingirotsinartkcehC.deluofsigulpkrapS

leuffieesotroterubractcepsnI

?etihw-eulbsigulpkrapS

GNITOOHSELBUORTENIGNE.6ELBAT

enilleufkcehC

erastejroterubraC.gnikaelriadetcejni,noisserpmoctneiciffusnI

.)wolfrevo(deggolc

?gulp

?liooN .deriuqersalioddA

?evitcefedsirosnes

?esool

"noisserpmoc

"noisserpmoc"

on"tuptuorewoptneiciffusnI

?esoolsigulpkrapS .gulpkrapsecalpeR

?sgnirnotsipnroW .sgnirnotsipecalpeR

?deggolcretlifria

tuptuorewoptneiciffusnI

?daeh

krapsfopittatneserpkrapsoN

nwodtuhserusserplioroliowoL

?revonruttonlliwenignE .tniojlexayrassecenfidnanotsipdnarednilycecalpeR

stlobgnitcennocdaehrednilyC

?degamadteksagdaehrednilyC .teksagdaehrednilycecalpeR

?taesevlavfonoitcnuflaM .sevlavtaes-eR

,metsysrenaelc-rianinoitcnuflaM

ecafretnimorfnignikaelriA

rednilycdnaroterubracneewteb

.deluoffigulpkrapsecalpeR.nekorbhctiwspotS/tratS

.rosneslioecalpeR"rosneslio"tiucric

.stlobgnitcennocdaehrednilycnethgiT

.retlifriaecalperronaelC

.teksagdaehrednilyc

.nekorbrodekcarcdrocegatlovhgih,nekorbtinunoitingirotsinarT

nwodtuhsliocitamotuakcehC.yrassecenfiliodda,levelliokcehC

ecalpeR.daehrednilycdnaroterubracneewtebstlobnethgiT

?metsysleufninoitcnuflaM

.retlifleufecalperronaelC

.roterubracecalperronaelC

.taolfroterubrackcehC

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 21

GDP-5000H — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.6ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuorewoptneiciffusnI

staehrevodna"noisserpmoc"

leufhcumotsnruB

ylsuoinitnocsiroloctsuahxE

"ETIHW"

ylsuoinitnocsiroloctsuahxE

"KCALB"

?stcudorp

?sgnirnroW sgnirecalpeR

?nafgniloocninoitcnuflaM .nafgniloocecalperrokcehC

?deggolcretlifekat-niriA .retlifekat-niriaecalperronaelC

tsuahxefonoitalumuccarevO

?gulpkrapsgnorW .gulpkrapsepytdetseggusserutcafunamhtiwgulpkrapsecalpeR

?ytisocsivgnorwsiliognitacirbuL .ytisocsivtcerrochtiwliognitacirbulecalpeR

?deggolcrennaelcriA .renaelcriaecalperronaelC

ottesneebtonsahevlavekohC

?noitisoptcerroceht

nolaes,evitcefedroterubraC

?nekorbroterubrac

tnemtsujdaroterubracrooP

?hcirootsnurenigne"

.sevlavkcehcdnanaelC

.yrassecenfiecalper,relffumkcehC

.noitisoptcerrocehtotevlavekohctsujdA

.laesroroterubracecalpeR

.roterubractsujdA

PAGE 22 — GDP-5000H A.C. GENERATOR— OPERATION AND PARTS MANUAL — REV. #2 (07/23/08)

GDP-5000H — TROUBLESHOOTING (GENERATOR)

Practically all generator breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the

diagnosis based on the Generator Troubleshooting (Table 7) information shown below and on the preceding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant.

MOTPMYS MELBORPELBISSOP NOITULOS

egatlovwoL ?wolootdeepsenignE .MPRdetarotdeepsenigneesiaR

?gnikrowtonretemtlovCA .retemtlovcAecalpeR

?noitcnuflam

deepsenignE.egatlovwoL

,)dedaolnu(MPR0563lamron

)eldi(MPR0052

gniriwlanretnixoblortnoC

?liocnoitingievitcefeD fiseriwnoitingiecalpeR.seriwnoitingineergdnaderkcehC

?noitcnuflamgnidniwrotoR .rotorecalperrokcehC

?noitcnuflamgnidniwrotatS .rotatsecalperrokcehC

?noitcnuflamrekaerbegakaeL .2BCro1BCecalperrokcehC

GNITOOHSELBUORTROTARENEG.7ELBAT

.gniriwxoblortnockcehC

.yrassecen

?noitcnuflamhctiwsrewoplluF .tiucrichctiwsrewopllufdnahctiwsrewopllufkcehC

.hgihoottuptuoegatloV ?hgihootdeepsenignE .MPRdetarotdeepsenignerewoL

enignE.hgihoottuptuoegatloV

MPR0563lamrondeeps

)eldi(MPR0052,)dedaolnu(

nonruttonlliwrekaerbtiucriC

"DAOLON"

nonrutlliwrekaerbtiucriC

.yletaidemmispirttub"DEDAOL"

otwolmorfetareleccatonseoD

"DAOLON"hgih

otwolmorfetareleccatonseoD

"EVITCADAOL"hgih

noitcnuflam

?noitiaolrevO .rekaerbecalperrodaolecudeR

?dioneloskcutS .dioneloskcehC

?evitcefed

gniriwlanretnixoblortnoC

?rekaerbtiucricevitcefeD .rekaerbtiucricecalpeR

?detrohssitiucricdaoL .trohsroftiucricdaolkcehC

?hctiwslortnoceldIdaB .hctiwslortnoceldiecalperrokcehC

?noitcnuflamhctiwslortnoceldI .hctiwslortnoceldiecalperrokcehC

?noitcnuflamecivedlortnoceldI .ecivedlortnoceldiecalperrokcehC

gniriwlaretnixoblortnoC

.gniriwxoblortnockcehC

GDP-5000H A.C. GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (07/23/08) — PAGE 23

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