Multiquip GDP-5H User Manual

OPERATION AND PARTS MANUAL

MODEL GDP-5H

High Cycle Generator

(HONDA GASOLINE ENGINE)

Revision #2 (10/05/05)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mq@multiquip.com Internet: www.multiquip.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

MAYCO PARTS

800-306-2926 310-537-3700

SERVICE DEPARTMENT

800-421-1244 310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

WARRANTY DEPARTMENT

800-421-1244, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-537-3927

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-537-4259

FAX:

310-631-5032

FAX:

310-537-1173

permission. All other trademarks are the property of thier respective owners and used with permission. This manual

remain with the unit if resold. The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are

based on the are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should

MQ GDP-5H Portable Generator.

Illustrations, descriptions, references and technical data contained in this manual

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 3

TABLE OF CONTENTS

Multiquip GDP-5H — AC Portable Generator

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

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

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

Safety Message Alert Symbols .............................. 6-7

Rules for Safe Operation ..................................... 8-10

Operation and Safet Decals .................................... 11

Specifications (Generator) ...................................... 12

Specifications (Engine) ........................................... 13

Dimensions ............................................................. 14

General Information ................................................ 15

Load Application ..................................................... 16

Load Application/Earth Leakage Breaker ............... 17

Controls and Indicators ...................................... 18-20

Generator Refueling ............................................... 21

Installation .......................................................... 22-23

Pre-Inspection ......................................................... 24

Pre-Inspection (Engine) .......................................... 25

Initial Start-up (Engine) ........................................... 26

Initial Start-up/Generator Operation .................. 27-28

Shut-down/Long Term Storage ............................... 29

Maintenance (Engine)........................................ 30-31

Wiring Diagram Gen. (S/N 5541049 & below) ........ 32

Wiring Diagram Gen. (S/N 5543731 & above) ........ 33

Troubleshooting (Engine) ................................... 34-35

Troubleshooting (Generator) .................................. 36

Explanation of Code In Remarks Column ............... 38

Suggested Spare Parts ........................................... 39

HONDA GX340K1EDN2 ENGINE

Air Cleaner Assembly ........................................ 50-51

Camshaft Assembly .......................................... 52-53

Carburetor Assembly ........................................ 54-55

Control Assembly .............................................. 56-57

Crankcase Cover Assembly .............................. 58-59

Crankshaft Assembly ........................................ 60-61

Cylinder Barrel Assembly .................................. 62-63

Cylinder Head Assembly ................................... 64-65

Fan Cover Assembly ......................................... 66-67

Flywheel Assembly ........................................... 68-69

Ignition Coil Assembly ....................................... 70-71

Piston Assembly ................................................ 72-73

Recoil Starter Assembly.................................... 74-75

Solenoid Assembly ............................................ 76-77

Label Assembly ................................................. 78-79

Terms and Conditions Of Sale — Parts ..................80

NOTE

Specification and part number are subject to change without notice.

Component DrawingsComponent Drawings

Component Drawings

Component DrawingsComponent Drawings

Nameplate and Decals....................................... 40-41

Generator Assy. ................................................. 42-43

Control Box Assy. ............................................... 44-45

Muffler Assy........................................................ 46-47

Pipe Frame Assy. ............................................... 48-49

PAGE 4 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ Dealer account number

❒❒ ❒❒

❒ Dealer name and address

❒❒ ❒❒

❒ Shipping address (if different than billing address)

❒❒ ❒❒

❒ Return fax number

❒❒ ❒❒

❒ Applicable model number

❒❒ ❒❒

❒ Quantity, part number and description of each part

❒❒ ❒❒

❒ Specify preferred method of shipment:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u c k

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mq@multiquip.com Internet: www.multiquip.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

MAYCO PARTS

800-306-2926 310-537-3700

SERVICE DEPARTMENT

800-421-1244 310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

WARRANTY DEPARTMENT

800-421-1244, 310-537-3700,

EXT. EXT.

279 279

310-537-3927

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-537-4259

FAX:

310-631-5032

FAX:

310-537-1173

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier. **Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

at no charge for freight

MULTIQUIP INC.

18910 WILMINGTON AVENUE POST OFFICE BOX 6254 CARSON, CALIFORNIA 90749 310-537-3700 • 800-421-1244 FAX: 310-537-3927 E-MAIL: mq@multiquip.com INTERNET: www.multiquip.com

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

GDP-5H — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

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.

This Owner's Manual has been developed to provide complete instructions for the safe and efficient

NOTE

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words: DANGER,

operation of the MQ Model GDP-5H

Portable Generator

engine manufacturers instructions for data relative to its safe operation.

. Refer to the

HAZARD SYMBOLS

Potential hazards associated with the operation of a

5H Portable Generator

Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message Alert Symbols.

Engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air.

Gasoline is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids.

will be referenced with Hazard

Lethal Exhaust Gases

WARNINGWARNING

WARNING

WARNINGWARNING

WARNING

WARNINGWARNING

Lethal Exhaust Gas Hazards

Explosive Fuel Hazards

GDP-

DANGERDANGER

DANGER

DANGERDANGER

You WILL be if you DO NOT follow these directions.

WARNINGWARNING

WARNING

WARNINGWARNING

You CAN be KILLED or you DO NOT follow these directions.

CAUTICAUTI

CAUTION

CAUTICAUTI

You CAN be these directions.

KILLED

INJURED

if you DO NOT follow

SERIOUSLY INJURED

DO NOT fill the fuel tank while the engine is running or hot. DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

WARNINGWARNING

WARNING

WARNINGWARNING

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. Never operate the engine with heat shields or heat guards removed.

WARNINGWARNING

WARNING

WARNINGWARNING

ALWAYS wear approved protection when required.

Burn Hazards

Respiratory Hazards

respiratory

PAGE 6 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

GDP-5H — SAFETY MESSAGE ALERT SYMBOLS

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

NEVER operate equipment with covers, or guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

ALWAYS place the power source, circuit breakers or ON/OFF switch in the OFF position, when the generator is not in use, unless connected to transfer switch.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

ALWAYS wear approved eye and hearing protection.

Rotating Parts Hazards

Accidental Starting Hazards

Eye and Hearing Hazards

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Other important messages are provided throughout this manual to help prevent damage to your portable generator, other property, or the surrounding environment.

Equipment Damage

Hazards

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 7

GDP-5H — RULES FOR SAFE OPERATION

■

DANGERDANGER

DANGER

DANGERDANGER

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-5H Portable 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.

Read this manual!

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■

The engine section of this generator requires an adequate free flow of cooling air. 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 or engine and may cause injury to people. Remember the generator's engine gives off carbon monoxide gas.

NEVER

DEADLY

operate the generator in

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence of

drugs

■

ALWAYS wear proper respiratory (mask), hearing and eye protection equipment when operating the generator.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications.

■

NEVER use accessories or attachments, which are not recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result.

alcohol

■

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

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

harm or even death.

NEVER disconnect any

These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death! Disconnection of any of these devices will void all warranties.

smoke

around or near the

bodily

"emergency or safety devices"

PAGE 8 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

GDP-5H — RULES FOR SAFE OPERATION

■

ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using generator.

■

NEVER leave the generator unattended, turn off engine when unattended.

■

Unauthorized equipment modifications will void all warranties.

■

ALWAYS ensure generator is on level ground before use.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

■

NEVER run engine without air cleaner. Severe engine damage

may occur.

■

NEVER change or adjust the engine speed which has been

set at the factory prior to shipping.

Power Cord Safety

■

NEVER let power cables or cords

■

NEVER is being transfer to a load.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper power or extension cord has been selected for the job See Tables 4 and 5.

stand in water

while AC power from the generator

lay in wate

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

High Temperatures – Always stop engine and allow the engine to cool before adding fuel, oil or performing service and maintenance

hot!

functions. Contact with cause serious burns.

Keep the machinery in proper running condition. Fix damage to the machine immediately and replace any

broken parts immediately.

ALWAYS replace any worn or damaged warning decals.

ALWAYS 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 un-authorized personnel.

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. performing maintenance on the generator.

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.

Turn all circuit breakers OFF before

components can

Grounding Safety

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

death!

ungrounded generator.

■

ALWAYS make sure generator is properly grounded to a suitable earth ground (GROUND ROD). See installation section in this manual.

■

NEVER use

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

gas piping

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 9

as an electrical ground.

■

Removing the engine oil drain plug while the engine is hot will result in hot oil to gush out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

GDP-5H — RULES FOR SAFE OPERATION

DANGERDANGER

DANGER

DANGERDANGER

During operation of this generation, there exists the possibility of

electrical shock or burn

cause

DEATH!

To avoid these hazards:

severe bodily harm

NEVER use

ELECTROCUTION HAZARDSELECTROCUTION HAZARDS

ELECTROCUTION HAZARDS

ELECTROCUTION HAZARDSELECTROCUTION HAZARDS

damaged

electrocution

, which can

or even

worn

cables when connecting equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output receptacles, incorrect connections may cause damage to the generator and electrical shock.

Emergencies

■

ALWAYS know the location of the

nearest

■

ALWAYS know the location of the nearest

first aid kit

■

In emergencies

nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

NEVER grab or touch a live power cord with wet hands, the possibility exist of electrical shock, electrocution, and even

death!

fire extinguisher

always

know the location of the

keep a phone on the job site

and

fire department

. This

NEVER insert any objects into the output receptacles during operation. This is extremely dangerous. ALWAYS turn-off the generator and place all circuit breakers in the “OFF” position when contact with the output receptacles is required. There exist the possibility of

electrocution, electrical shock or burn, which can cause severe bodily harm or even death

Backfeed to a utility system can cause

electrocution

NEVER connect the generator to a

building's electrical system without a transfer switch or other approved device. All installations should be performed by

licensed electrician

a with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn causing serious injury or even death!

and or property damage.

in accordance

PAGE 10 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

GDP-5H — OPERATION AND SAFETY DECALS

Machine Safety Decals

The GDP-5H portable generator is equipped with a number of safety decals (Figure 1). 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.

Figure 1. Operation and Safety Decals

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 11

GDP-5H — SPECIFICATIONS (GENERATOR)

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ledoMH5-PDG

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rotareneGCA

deepSMPR

metsySgnilooCnoitalitneV-fleS

yticapaCleuF)sretil91(snollag5

006,3

tuptuOsuounitnoCWk6.

tuptuOybnatSWk0.4

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ecruoS

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tnerruCdetaRspma03)V021(

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ecruoS

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)leuFhtiW(thgieW

.ni52.12X40.22x43.82

)mm045X065X027(

).gk701(.sbl532

).gk221(.sbl962

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 12 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

°°

GDP-5H — SPECIFICATIONS (ENGINE)

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elgniS,ekorts4delooc-riA

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In keeping with Multiquip's policy of

NOTE

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 13

constantly improving its products, the specifications quoted herein are subject to change without prior notice.

GDP-5H — DIMENSIONS

Figure 2. Dimensions

PAGE 14 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

GDP-5H — GENERAL INFORMATION

Excitation System

WARNINGWARNING

WARNING

WARNINGWARNING

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-5H FAMILIARIZATION Generator

The GDP-5H-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:

z z z

Excitation (diode 1) Battery (diode 2) Slow Down (diode 3)

The Multiquip Model GDP-5H 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-5H has been designed as a power source for 180 Hz, 3-phase concrete vibrators or other equipment that may require 3-phase power for operation.

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 4A through 4E for the basic controls and indicators for the GDP-5H generator.

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 Box

The control box is provided with the following:

■

Three 230V twist-lock output receptacles (three phase).

■

240V twist-lock output receptacle (single phase).

■

120V twist-lock receptacle (single phase).

■

120V GFCI duplex output receptacle, (single phase).

■

60 Hz (single phase) circuit breaker.

■

180 Hz (three phase) earth leakage circuit breaker.

■

AC Voltmeter

control

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.

Alternator

The alternator, a brushless revolving-field type, is permanently aligned to the engine through rigid coupling.

Engine

This generator is powered by a 11 HP, air-cooled, 4-stroke HONDA gasoline engine. Reference Table 2, for engine specifications.

3-Phase Vibrator Application

When using this generator with 3-phase vibrators do the following:

■

ALWAYS use a vibrator with short circuit protection.

■

ALWAYS use rubber boots and gloves when operating the vibrator.

■

ALWAYS use adequate size connecting cable for extension.

■

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

■

Ground Terminal

■

Full Power Switch

■

Idle Control Switch

■

Operation Switch

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 15

GDP-5H — LOAD APPLICATION

Single Phase Load — 60 Hz

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.

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

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:

NOTE

If wattage is not given on the equipment's name plate, approximate wattage may be

A 1 inch drill runs at 1 KW use a 2 KW generator.

determined by multiplying nameplate voltage by the nameplate amperage.

3. LARGE MOTORS Submersible pumps, table saws etc.

WATTS = VOLTAGE x AMPERAGE The power factor of this generator is 1.0 See Table 3 below

when connecting loads.

Total the running wattage and multiply by 3. Example: A conveyor belt runs at 8 KW use a 24 KW generator.

spmal

NOTE

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,secivedcinortcelE

tnempiuqenoitacinummoc

slootrewopnommoC8.0

When using a combination of dual receptacles, total load

exceed

the rated capacity of the

generator.

daoLyBrotcaFrewoP.3elbaT

0.1

9.0-4.0

0.1

should not

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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

extension cable

Always

use an

which can carry the

required load.

Extension Cables

When electric power is to be provided to various tools or loads at some are normally used.

distance

from the generator, extension cords

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 (Tables

4 and 5 ) as a guide for selecting proper cable size.

The idle control device is operated at a

NOTE

minimum load capacity of 100W. If the load capacity is less than 100W, place the idle control switch in the OFF position.

PAGE 16 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

GDP-5H — LOAD APPLICATION/EARTH LEAKAGE BREAKER

Three Phase Load — 180 Hz

180 Hz, 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.

The vibrators can be operated simultaneously if the total power consumption does not exceed the rated output of the generator (5.0 KVA).

If output (kVA) is not given on the

NOTE

Earth Leakage Breaker (180 Hz)

The earth leakage detection breaker (Figure 3) is used for 180 Hz application (3-phase vibrators). Before operating the generator test this breaker to make sure that is functioning correctly.

vibrators nameplate, approximate output may be determined by multiplying voltage by amperage by .

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.

NOTE

Test Operation

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

1. Start the engine and set it to

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.

high speed

NOTE

2. Turn the leakage breaker ON.

3. During normal operation, press the earth leakage indicator test button on the front of the generator and observe that indicator button pops out and the leakage breaker trips.

4. Push the indicator button back in when resetting

Figure 3. Earth Leakage Breaker

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.

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 17

GDP-5H — CONTROLS AND INDICATORS

Figure 4A. Generator Components

1. 230V Output Receptacles– These three NEMA 7410

6. Idle Control Switch – This generator is provided with an

twist-lock receptacles will provide 230V, 12.5 amps, 180 Hz.

2. 180 Hz Earth Leakage Circuit Breaker – This 3-pole earth leakage circuit breaker allows the circuit to be broken when the load side shorts or there is an over-current condition. In addition, during operation of the generator it can detect when there is defective insulation on the load side and breaks the circuit in response. When starting the generator "OFF" position.

3. Lifting Bail Eye – Attach a rope or chain to this lifting eye when lifting of the generator is required. Never stand underneath the generator while it is being lifted. Place lifting eye in down position when not in use.

4. 60 Hz Circuit Breaker – This 2-pole circuit breaker (240/ 15 amps or 120/30 amps) protects the generator from short circuiting or overloading. When starting the generator

always

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. This meter cannot be used for 180 Hz applications.

always

have the circuit breaker placed in the "OFF"

have the circuit breaker placed in the

7. Operation Switch – Place this

8. GFCI Duplex Receptacle – This NEMA 5-20R, GFCI

9. Ground – This ground connection point should be connect

10. 240V Output Receptacle – This

11. 120V Output Receptacle – This NEMA L5-30R twist-

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.

rocker

switch in the "ON" position (up) for normal operation. To turn-off the generator place this switch in the "OFF" position (down).

receptacle will provide 120V, 20 amps.

to a good earth ground (ground rod).

NEMA L6-20R twist-

lock receptacle will provide 240V, 15 amps, 60 Hz.

lock receptacle will provide 120V, 30 amps, 60 Hz.

PAGE 18 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

GDP-5H — CONTROLS AND INDICATORS

Figure 4B. Generator Components

12. Full Power Switch – The generator is provided with a full power switch. Figures 4C and 4D show simplified wiring diagrams of the dual voltage system.

When the full power switch is in the 120 volt (up) position, you can access the 120 volts from the GFCI duplex receptacle and the120V twist-lock receptacle, or a combination of both receptacles as long as the total load does not exceed the generating set capacity.

Figure 4C. 120V Full Power Switch

Simplified Diagram (Up Position)

full rated power

of the generator at

When the switch is in the 240 volt (down) position, you can acess

half of the rated power

of the generating set at 120 volts from the GFCI duplex receptacle and up to half of the rated power of the set at 120 volts from 120V twist-lock receptacle; or full rated power of the set at 240 volts from the 240V twist-lock receptacle.

Figure 4D. 120/240V Full Power Switch

Simplified Diagram (Down Position)

NOTE

When the

full power switch

is in the 120V position, the 240V twist-lock receptacle

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 19

cannot be used

Figure 4E. Generator Components

GDP-5H — CONTROLS AND INDICATORS

13. Fuel Cock Lever – Turn this lever (down)the flow of fuel into the carburetor. Turn

stop (up)

14. 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.

15. Muffler/Heat Shield – Used to reduce noise and emissions. NEVER touch this is in use. Always allow time for the generator to cool down before performing maintenance.

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

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

18. Engine Oil Filler Cap – Remove this cap/dipstick when the adding of engine oil is required. See Table 6 for recommended type engine oil.

the flow of fuel.

heat shield

downward

when the generator/welder

start

upward

the

Open

the

19. Engine Oil Drain Plug – Remove this drain plug when

20. Air Cleaner – Prevents dirt and other debris from entering

21. Fuel Tank Cap – Remove this cap to add unleaded

22. Fuel Gauge – This gauge is located on top of the fuel tank.

23. Fuel Tank – Fuel tank capacity is 5 gallons (19 liters).

on level ground. Placing the generator on level ground will ensure that the low oil sensor will function properly.

draining of the oil from the engine crankcase is required. Fill with recommeded type oil as listed in Table 6.

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.

gasoline to the fuel tank. gasoline. Make sure cap is tightened securely. DO NOT over fill.

Read this gauge to determine when fuel is

NOTE

Replenish

This 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

HONDA

with

clean unleaded

low

engine is equipped

PAGE 20 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

GDP-5H — GENERATOR REFUELING

DANGERDANGER

DANGER

DANGERDANGER

Adding fuel to the tank should be done only when the engine is stopped and has had an opportunity to cool down. In the event of a fuel spill, DO NOT attempt to start the engine until the fuel residue has been completely wiped up, and the area surrounding the engine is dry. If generator is placed in a truck bed with a plastic liner, REMOVE generator from truck bed and place on ground (Figure 5) to refuel. This possibility exist of to static electricity.

fire

explosion

due

Figure 5. Generator Refueling

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 21

GDP-5H — INSTALLATION

Outdoor Installation

Install the generator/welder in a area that is free of

bystanders

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 to engine and alternator parts.

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements.

Mounting

The generator should always be mounted on a flat level surface to isolate vibration of the generator when it is running. DO NOT place the generator on slopes, the possibility exists that the generator could slide.

, and

overhead obstructions

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

. Make sure the

debris

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.

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground. Always use the ground terminal on the generator to ground the generator. Ground the generator from its ground

connector so that the resistance to ground is 500 ohms or less.

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.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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.

PAGE 22 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

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

2. When grounding the generator (Figure 3) 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.

GDP-5H — INSTALLATION

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 6) and tighten the nut fully. Connect the other end of the ground cable to a suitable earth ground (ground rod).

DANGERDANGER

DANGER

DANGERDANGER

Some of the MQ GDP5H portable generators (S/N 5541050 and below) have been configured with the ground of the

floating

lead to an electrical shock if the generator is not properly grounded. To prevent electrical shock, ALWAYS connect generator to a good earth ground.

. This configuration may

aramature

MQ GDP5H portable generators

NOTE

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 23

(S/N 5543730 and above) have the aramature grounded. These units are grounded properly.

Figure 6. Generator Grounding

GDP-5H — PRE-INSPECTION

General Inspection Prior to Operation

Ground Power Tools

When using power tools or electrical equipment requireing AC power from the generator, make sure connecting (power tool) cable (Figure 7) has a ground as shown in Figure.

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 (Tables 4 and 5) as a guide for selecting proper cable size.

NOTE

60 and 180 Hz Circuit Breakers

To protect the generator from an overload, circuit breakers are provided for both

Figure 7. Ground Cables/Plugs

the these circuit breakers to the "OFF" position prior to starting the engine.

and

Never!

use power tools or equipment that do not have a ground capability, the possibility

of electrocution, electrical

exists

shock or burn severe bodily harm

, which can cause

or even

DEATH!

180 Hz

operation. Make sure to switch

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PAGE 24 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

NEVER operate the generator in a confined area or enclosed area structure that does not provide ample

ALWAYS wear approved eye and hearing protection before operating the generator.

free flow of air

GDP-5H — PRE-INSPECTION (ENGINE)

Figure 9. Engine Oil Dipstick (Oil Level)

epyTliO.6elbaT

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 8) and wipe clean.

Motor fuels are highly flammable and can be dangerous if mishandled. DO NOT smoke while refueling. DO NOT attempt to refuel the generator if the engine is

running or in the dark

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 10) to determin if the fuel level is low. If fuel is low, replenish with

clean unleaded fuel

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llaF/gnirpS C°01~C°52 02/03-W01EAS

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DANGER EXPLOSIVE FUELDANGER EXPLOSIVE FUEL

DANGER EXPLOSIVE FUEL

DANGER EXPLOSIVE FUELDANGER EXPLOSIVE FUEL

hot!

Figure 8. 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 9), fill to the edge of the oil filler hole with the recommended oil type (Table 6). Maximum oil capacity is 1.16 quarts (1.1 liters)

GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 25

4. When refueling, be sure to use a strainer for filtration. DO NOT top-off fuel.

Wipe up any spilled fuel

Figure 10. Fuel Gauge

DO NOT fill the tank beyond capacity.

immediately!

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