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
© COPYRIGHT 2004, MULTIQUIP INC. Multiquip Inc, the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written
permission. All other trademarks are the property 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
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
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
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
or
SERIOUSLY INJURED
SERIOUSLY INJURED
if
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 — 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.
or
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
r.
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
as an electrical ground.
or
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
or
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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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)
°°
F
F
GDP-5H — SPECIFICATIONS (ENGINE)
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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
spmal
NOTE
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When using a combination of dual receptacles, total load
exceed
the rated capacity of the
generator.
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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
to
start
upward
Close
the
Open
the
19. Engine Oil Drain Plug – Remove this drain plug when
to
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
or
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.
60
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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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!
GDP-5H — INITIAL START-UP (ENGINE)
2. Place the
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
DO NOT attempt to operate this generator until the Safety, General Information and Inspection sections of this manual have been
thoroughly understood
This section is intended to assist the operator with the
start-up
this section be read carefully before attempting to use the generator in the field.
Before Starting the Engine
1. Be sure to
2. NEVER start the engine with the 60 or 180 Hz
of the portable generator. It is extremely important that
disconnect all electrical loads
generator prior to starting the engine.
breakers in the “ON" position. Place both circuit breakers (Figure 11) in the OFF position.
read and
.
initial
from the
circuit
if starting a
3. Place the if starting a
4. Place the " position.
choke lever
cold
Figure 13. Choke Lever
choke lever
warm engine
generator ON/OFF switch
(Figure 13) in the "
engine.
(Figure 13) in the "
or the
CLOSED
temperature is warm.
(Figure 14) in the "
OPEN
" position
" position
ON
Figure 11. 60 and 180 Hz
Circuit Breakers (OFF Position)
Starting the Engine
1. Place the engine position.
Figure 12. Engine Fuel Valve Lever (ON Position)
fuel valve lever
(Figure 12) to the "ON"
Figure 14. Generator On/Off Switch (ON)
5. Grasp the starter grip (Figure 15) 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 15. Starter Grip
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
DO NOT pull the starter rope all the way to the end. DO NOT
rewind as soon as possible.
release the starter rope after pulling. Allow it to
PAGE 26 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — INITIAL START-UP/GENERATOR OPERATION
6. If the engine has started, slowly return the choke lever (Figure 13 ) to the started repeat steps 1 through 5.
7. Before the generator is placed into operation, run the engine for 3-5 minutes. Check for abnormal smells, fuel leaks, and noises that would associate with lose components.
8.
Place
the
idle control switch
“OPEN”
position. If the engine has not
(Figure 16) in the "OFF"
(down) position. This will allow the engine speed to run
2. Place the full power switch (Figure 19) in the 120V position (up).
Figure 19. Full Power Switch 120 V Position (Up)
at speed about 3600 RPM's
NOTE
Figure 16. Idle Control Switch (Off)
Placing the the OFF position (Figure 16) allows
NOTE
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 the 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.
the engine to operate at a maximum speed of about 3600 RPM's. When the idle control switch is placed in the up position (ON) (Figure 17),
idle control switch
3. Read the
in
(Figure 20) and verify that 120 VAC is present at the 120V twist-lock and GFCI duplex receptacles. For additional verification of voltage, an external voltmeter can be used to measure the output voltage as shown in Figure 20.
When the
full power switch
is in the 120 V position, the 240V twist-lock receptacle cannot be used.
voltmeter
on the front panel of the generator
Figure 17. Idle Control Switch (On)
60 Hz Operation
1. Place the 60 Hz, 15 amp circuit breaker (Figure 18) in the ON position.
4. Place the full power switch (Figure 21) in the 240V position (down).
Figure 18. 60 Hz Circuit Breaker (ON)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 27
Figure 21. Full Power Switch 240/120 V Position (Down)
Figure 20. 120 V and GFCI Receptacles
GDP-5H — INITIAL START-UP/GENERATOR OPERATION
5. Read the (Figure 22) and verify that 240 VAC is present at the 240V twist-lock receptacle. Using an external voltmeter verify that 120V is present at the at the 120V twist-lock and GFCI duplex receptacles.
voltmeter
on the front panel of the generator
180 Hz Operation
1. Place the 180 Hz, 12.5 amp circuit breaker (Figure 23) in the ON position.
Figure 23. 60 and 180 Hz Breakers (ON)
5. Use an external voltmeter to measure the 230 VAC output voltage on the 180 Hz twist-lock receptacles as shown in Figure 24.
Figure 22. 60 Hz Output Receptacles
When the full power switch is in the 240
NOTE
receptacle and up to half of the rated power of the set at 120 volts from the 120V twist-lock receptacle; or full rated power of the genset at 240 volts from the 240V twist-lock receptacle.
NOTE
Connecting the Load
1. If small wattage power tools are required, connect them to the 60 Hz output receptacles at this time.
volt (down) position, you can take up to
half of the rated power
set at 120 volts from the GFCI duplex
When using a combination of dual receptacles, total load should not exceed the rated capacity of the generator.
of the generating
NOTE
Connecting the Load
1. If high-cycle vibrators are going to be used, connect them to the 180 Hz output receptacles at this time.
Figure 24. 180 Hz Output Receptacles
When using the 180 Hz output receptacles, the AC voltmeter on the generator cannot be used for monitoring of the 3-phase voltage.
PAGE 28 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — SHUTDOWN/ LONG TERM STORAGE
Stopping the Engine
1. Place both the 60 and180 Hz circuit breakers (Figure
5. Place the engine position.
25) in the OFF position.
Figure 28. Engine Fuel Valve Lever (OFF Position)
Figure 25. 60 and 180 Hz Breakers (Off)
2. Place the
idle control switch
(Figure 26) in the OFF
6. Remove the
Generator Storage
position.
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.
fuel valve lever
load
from the generator.
(Figure 28) to the "OFF"
Run the engine until the gasoline in the carburetor is completely consumed.
Figure 26. Idle Control Switch (Off)
3. Let the engine run at idle with no load for 2-3 minutes.
4. To shut-down the engine, place the generator ON/OFF switch (Figure 27) in the OFF position
Figure 27. Generator On/Off Switch (Off)
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 spark 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-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 29
GDP-5H — MAINTENANCE (ENGINE)
Use Table 7 as a general maintenance guideline when servicing your engine. For more detail engine maintenance information, refer to the Honda engine owner's manual supplied with your engine.
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PAGE 30 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — MAINTENANCE (ENGINE)
Maintenance
Perform the scheduled maintenance procedures as defined by Table 6 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. Check the gearbox for oil leaks. Repair or replace as needed.
ENGINE AIR CLEANER
DANGERDANGER
DANGER
DANGERDANGER
DO NOT use gasoline as a cleaning solvent, because that would create a risk of fire or explosion.
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.
Figure 29. Spark Plug Gap
ENGINE OIL
warm
1. Drain the engine oil when the oil is Figure 30.
2. Remove the oil drain bolt and sealing washer and allow the oil to drain into a suitable container.
as shown in
1. Remove the air cleaner cover and foam filter element as shown in Figure 31.
2. Clean foam element in warm, soapy water or nonflammable solvent. Rinse and dry thoroughly. Dip the element in clean engine oil and completely squeeze out the excess oil from the element before installing.
Figure 31. Engine Air Cleaner
3. Replace engine oil with recommended type oil as listed in Table 6. For engine oil capacity, see Table 2 (engine specifications). DO NOT overfill.
4. Install drain bolt with sealing washer and tighten se­curely.
Figure 30. Engine Oil (Draining)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 31
GDP-5H — WIRING DIAGRAM (GENERATOR) S/N 5541049 AND BELOW
Figure 32. Generator Wiring Diagram
(S/N 5541049 and below)
PAGE 32 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — WIRING DIAGRAM (GENERATOR) S/N 5543731 AND ABOVE
Figure 33. Generator Wiring
Diagram (S/N 5543731 and above)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 33
GDP-5H — 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 8) and
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?dersigulpkrapS .tinunoitingirotsinartkcehC.deluofsigulpkrapS
?etihw-eulbsigulpkrapS
Generator Troubleshooting (Table 9) information shown below and on the proceeding pages. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant.
leuffieesotroterubractcepsnI
GNITOOHSELBUORTENIGNE.8ELBAT
enilleufkcehC
erastejroterubraC.gnikaelriadetcejni,noisserpmoctneiciffusnI
.)wolfrevo(deggolc
?gulp
?liooN .deriuqersalioddA
?gnitratsnopu
?esool
"noisserpmoc
"noisserpmoc"
on"tuptuorewoptneiciffusnI
?esoolsigulpkrapS .gulpkrapsecalpeR
?sgnirnotsipnroW .sgnirnotsipecalpeR
tuptuorewoptneiciffusnI
?daeh
krapsfopittatneserpkrapsoN
sknilbpmalmralaerusserpliO
?revonruttonlliwenignE .tniojlexayrassecenfidnanotsipdnarednilycecalpeR
stlobgnitcennocdaehrednilyC
?degamadteksagdaehrednilyC .teksagdaehrednilycecalpeR
?taesevlavfonoitcnuflaM .sevlavtaes-eR
renaelc-rianinoitcnuflaM
?deggolcretlifria,metsys
ecafretnimorfnignikaelriA
rednilycdnaroterubracneewteb
.deluoffigulpkrapsecalpeR.nekorbhctiwspotS/tratS
."rosneslio"tiucricnwodtuhscitamotuAkcehC
.stlobgnitcennocdaehrednilycnethgiT
.retlifriaecalperronaelC
.teksagdaehrednilyc
.nekorbrodekcarcdrocegatlovhgih,nekorbtinunoitingirotsinarT
ecalpeR.daehrednilycdnaroterubracneewtebstlobnethgiT
?metsysleufninoitcnuflaM
.retlifleufecalperronaelC
.roterubracecalperronaelC
.taolfroterubrackcehC
PAGE 34 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — TROUBLESHOOTING (ENGINE)
)DEUNITNOC(GNITOOHSELBUORTENIGNE.8ELBAT
MOTPMYS MELBORPELBISSOP NOITULOS
tuptuorewoptneiciffusnI
staehrevodna"noisserpmoc"
leufhcumotsnruB
ylsuoinitnocsiroloctsuahxE
"ETIHW"
ylsuoinitnocsiroloctsuahxE
"KCALB"
?stcudorp
?ytisocsiv
?sgnirnroW sgnirecalpeR
?nafgniloocninoitcnuflaM .nafgniloocecalperrokcehC
?deggolcretlifekat-niriA .retlifekat-niriaecalperronaelC
tsuahxefonoitalumuccarevO
?gulpkrapsgnorW .gulpkrapsepytdetseggusserutcafunamhtiwgulpkrapsecalpeR
gnorwsiliognitacirbuL
?deggolcrennaelcriA .renaelcriaecalperronaelC
tesneebtonsahevlavekohC
?noitisoptcerrocehtot
nolaes,evitcefedroterubraC
?nekorbroterubrac
tnemtsujdaroterubracrooP
?hcirootsnurenigne"
.sevlavkcehcdnanaelC
.yrassecenfiecalper,relffumkcehC
.ytisocsivtcerrochtiwliognitacirbulecalpeR
.noitisoptcerrocehtotevlavekohctsujdA
.laesroroterubracecalpeR
.roterubractsujdA
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 35
GDP-5H — TROUBLESHOOTING (GENERATOR)
MOTPMYS MELBORPELBISSOP NOITULOS
egatlovwoL ?wolootdeepsenignE .MPRdetarotdeepsenigneesiaR
?gnikrowtonretemtlovCA .retemtlovcAecalpeR
GNITOOHSELBUORTROTARENEG.9ELBAT
?noitcnuflam
deepsenignE.egatlovwoL
)eldi(MPR0052
"DAOLON"
"DAOLON"hgih
,)dedaolnu(MPR0563lamron
.hgihoottuptuoegatloV ?hgihootdeepsenignE .MPRdetarotdeepsenignerewoL
enignE.hgihoottuptuoegatloV
MPR0563lamrondeeps
)eldi(MPR0052,)dedaolnu(
nonruttonlliwrekaerbtiucriC
nonrutlliwrekaerbtiucriC
.yletaidemmispirttub"DEDAOL"
otwolmorfetareleccatonseoD
noitcnuflam
?dioneloskcutS .dioneloskcehC
gniriwlanretnixoblortnoC
?liocnoitingievitcefeD fiseriwnoitingiecalpeR.seriwnoitingineergdnaderkcehC
.yrassecen
?noitcnuflamgnidniwrotoR .rotorecalperrokcehC
?noitcnuflamgnidniwrotatS .rotatsecalperrokcehC
?noitcnuflamrekaerbegakaeL .2BCro1BCecalperrokcehC
?noitcnuflamhctiwsrewoplluF .tiucrichctiwsrewopllufdnahctiwsrewopllufkcehC
gniriwlanretnixoblortnoC
?rekaerbtiucricevitcefeD .rekaerbtiucricecalpeR
?noitidnoCdaolrevO .rekaerbecalperrodaolecudeR
?detrohssitiucricdaoL .trohsroftiucricdaolkcehC
?hctiwslortnoceldIdaB .hctiwslortnoceldiecalperrokcehC
.gniriwxoblortnockcehC
.gniriwxoblortnockcehC
?noitcnuflamhctiwslortnoceldI .hctiwslortnoceldiecalperrokcehC
EVITCADAOL"hgih
onetarelecedtonseoD
."TUPTUOEGATLOV"
."TUPTUOEGATLOV"
otwolmorfetareleccatonseoD
?evitcefed
?dionelosevitcefeD .dionelosecalperrokcehC
?dionelosevitcefeD .ecivedlortnoceldiecalperrokcehC
sahtubetarelecedtonseoD
?dionelosevitcefeD .dionelosecalperrokcehC
?noitcnuflamecivedlortnoceldI .ecivedlortnoceldiecalperrokcehC
gniriwlaretnixoblortnoC
?sgnidniwrotorevitcefeD .rotorecalperrokcehC
?ecivedlortnoceldievitcefeD .ecivedlortnoceldiecalperrokcehC
?noitcnuflamgniriwxoblortnoC .stnenopmocevitcefedynaecalper,gniriwxoblortnockcehC
?noitcnuflamecivedlortnoceldI .ecivedlortnoceldiecalperrokcehC
.gniriwxoblortnockcehC
PAGE 36 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
NOTE PAGE
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 37
GDP-5H — EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.
Items Found In the “Items Number” Column
All parts with same symbol in the number column,
, belong to the same assembly or kit.
If more than one of the same
NOTE
reference number is listed, the last one listed indicates newest (or latest) part available.
, #, +, %, or
*
NOTE
The contents of this catalog are subject to change without notice
.
PAGE 38 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H 1 TO 3 UNITS WITH HONDA GX340K1EDN2 ENGINE
1 to 3 Units
Qty. P/N Description
1 ........ A9924800014 ........... CAP FUEL TANK
1 ........ A9924800004 ........... FILTER FUEL
1 ........ 3015419604 .............. SHOCK MOUNT
4 ........ 1665419004 .............. SHOCK MOUNT
1 ........ 9807955846 .............. SPARK PLUG
1 ........ 34150ZH7003 ........... ALERT UNIT, OIL
2 ........ 28462ZV7003 ...........ROPE, RECOIL
2 ........ 17211899000 ............ELEMENT AIR CLEANER
GDP-5H — SUGGESTED SPARE PARTS
Part numbers on this Sug-
NOTE
gested Spare Parts List may supercede/replace the P/N shown in the text pages of this book.
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 39
GDP-5H — NAMEPLATE AND DECALS.
PAGE 40 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — NAMEPLATE AND DECALS.
NAME PLATE ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 A4561000103 DECAL; MQ MULTIQUIP 5000 1 2 0600500047 DECAL; CHOKE 1
3 1980680004 DECAL; FUEL COCK .................................................. 1......... S-3704
4 A4511200102 DECAL; CONTROL PANEL ......................................... 1......... A41120010
5 0600500045 DECAL; AIR CLEANER 1
6 NAMEPLATE .............................................................. 1 ......... CONTACT MQ PARTS DEPT.
7 0800628504 DECAL; GROUND ....................................................... 1......... S-1123
8 A9521200104 DECAL; OPERATING INSTRUCTIONS ...................... 1 ......... A92120010
9 0820610404 DECAL; WARNING ...................................................... 1......... S-3627
10 A9511100004 DECAL; WARNING ...................................................... 1......... A91110000
11 7900636004 DECAL; CAUTION OPER. AT 3600 RPM ONLY ......... 1......... S-4461
12 8700611804 DECAL; WARNING DANGEROUS GAS ..................... 1......... S-4984
13 8700611904 DECAL; DANGER ELECTRICAL SHOCK HAZ. ......... 1......... S-4985
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 41
GENERATOR ASSY.
GDP-5H — GENERATOR ASSY.
PAGE 42 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — GENERATOR ASSY.
GENERATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1
*
1-1 1-2
1-3*0601820037 RECTIFIER ........................................ 1 ................ S10VB60
1-4*0601822640 SURGE ABSORBER .......................... 1 ................ TNR15G471K
1-5*0071206304 BEARING ........................................... 1 ................ 6304DDU
2 7851017204 SET BOLT ROTOR 1 3 0801086104 SET WASHER BEARING 1
4 030210250 SPRING WASHER ............................. 1 ................ REPLACES 0040010000
5 A4135000003 ARMATURE ASSY. 1 6 7851315502 END BRACKET 1 7 0017108020 HEX HEAD BOLT 4 8 A4154000002 END BRACKET 1 9 A4138000003 FIELD ASSY. EXCITER 1
10 011208025 HEX HEAD BOLT ............................... 4 ................ REPLACES P/N 0017108025
11 1961324003 GROMMET 1 12 1961313003 GUIDE PANEL AIR 1
13 0011305100 HEX HEAD BOLT ............................... 4 ................ REPLACES P/N 0017105012
14 7851334204 COVER 1 15 7851316804 SET BOLT STATOR 4
16 030208200 SPRING WASHER ............................. 4 ................ REPLACES P/N 0040008000
17 031108160 PLAIN WASHER ................................. 4 ................ REPLACES P/N 0041208000
18 7851331103 COVER 1 19 0310300090 SEAL 1 20 0017105012 HEX HEAD BOLT 4 21 0601820083 RECTIFIER, S25VB60 3 22 A4184000004 BRACKET 3 23 0027104020 MACHINE SCREW 3 23A 0038404000 HEX NUT 3 24 0017108015 HEX HEAD BOLT 6
7851000203 ROTOR ASSY. .................................... 1 ................ INCLUDES ITEMS W/
* *
FIELD ASSY. ...................................... 1 ................ NOT SOLD SEPERATELY
ARMATURE ASSY. EXCITER ............ 1 ................ NOT SOLD SEPERATELY
*
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 43
CONTROL BOX ASSY.
GDP-5H — CONTROL BOX ASSY.
PAGE 44 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 A3214000003 CONTROL BOX 1
2 0601851755 GROMMET ........................................1 .................. C-30-NG-79-R
3 0601823204 RECTIFIER .......................................4 .................. S5VB60
4 0027103012 MACHINE SCREW 4 5 0601823853 SLOW DOWN UNIT 1 6 0027104010 MACHINE SCREW 2
6 0030004000 NUT HEX ...........................................2 .................. REPLACESP/N 0207004000
7 A4224000003 CONTROL PANEL 1
8 0601802651 CIRCUIT BREAKER ..........................1 .................. KM-2 15A
9 4341817004 BRACKET CIRCUIT BREAKER 1 10 0021004010 MACHINE SCREW 2
11 0601806819 AC VOLTMETER ...............................1 .................. DE450-011 0~120/240V
12 0601812598 RECEPTACLE ...................................1 .................. 5-20R
13 0601811035 RECEPTACLE ...................................1 .................. L5-30R
14 0601811032 RECEPTACLE ...................................1 .................. L60-20R
15 0601812594 RECEPTACLE ...................................3 .................. 7410B
16 0021004010 MACHINE SCREW 12
16A 0030004000 NUT HEX ......................................... 12 .................. REPLACESP/N 0207004000
17 0601830737 FULL POWER SWITCH .................... 1 .................. ET-330D12
18 0601831620 IDLE CONTROL SWITCH ................. 1 .................. C1550WA
19 0601831620 OPERATION SWITCH .......................1 .................. C1550WA
20 0021004015 MACHINE SCREW 1
20A 0030004000 NUT HEX ...........................................1 .................. REPLACESP/N 0207004000
21 A3262800004 CAPACITOR ASSY. ........................... 1 .................. VR1H102MHA 50V 1000 F
22 0017106016 HEX HEAD BOLT 4 23 0017105010 HEX HEAD BOLT 4 24 0601842415 RESISTOR, 7 OHM 1 25 0027104010 MACHINE SCREW 2 26 0601807480 CIRCUIT BREAKER, 12 AMPS 1 27 0027104070 MACHINE SCREW 2
27A 0030004000 NUT HEX ...........................................2 .................. REPLACESP/N 0207004000
28 0601815465 TERMINAL BOARD 1 29 0027104020 MACHINE SCREW 2
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 45
MUFFLER ASSY.
GDP-5H — MUFFLER ASSY.
PAGE 46 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — MUFFLER ASSY.
MUFFLER ASSY.
NO PART NO PART NAME QTY. REMARKS
1 7852310003 MUFFLER 1
2 18320ZC2000 PROTECTOR ......................... 1 ......... REPLACES P/N 0602302001
3 18325ZB4000 PROTECTOR ......................... 1 ......... REPLACES P/N 0602302002
4 18329ZB4000 SEAL ..................................... 2 ......... REPLACES P/N 0602302003
5 18355ZB4630 ARRESTOR, SPARK ............. 1 ......... REPLACES P/N 0602313060
6 0602322060 TAPPING SCREW ................. 1 ......... REPLACES P/N 90183671003
7 0105050616 BOLT HEX HEAD .................. 5 ......... REPLACES P/N 0017106012
8 18333ZB4800 GASKET ................................ 1 ......... REPLACES P/N 0602320175
9 0602322061 HEX HEAD BOLT .................. 2 ......... REPLACES P/N 957000802000
10 7855469004 BRACKET 1
11 011008020 BOLT HEX HEAD .................. 1 ......... REPLACES 0017108020
12 011008020 BOLT HEX HEAD .................. 1 ......... REPLACES 0017108020
13 7905469004 BRACKET 1
14 011206020 BOLT HEX HEAD .................. 1 ......... REPLACES 0017106020
15 0105050616 BOLT HEX HEAD .................. 4 ......... REPLACES 0017106012
1
1 7852310003 FFLER 1
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 47
PIPE FRAME ASSY.
GDP-5H — PIPE FRAME ASSY.
PAGE 48 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
GDP-5H — PIPE FRAME ASSY.
PIPE FRAME ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 A4417000102 PIPE FRAME 1 2 A3417100004 BRACKET 1 3 0017106016 HEX HEAD BOLT 4 4 7855411203 BASE 1 5 3015419604 RUBBER SUSPENSION 2
6 1665419004 RUBBER SUSPENSION .................... 2 ................ REPLACES P/N 1725419214
7 020108060 NUT HEX ............................................ 8 ................ REPLACES P/N 0207008000
8 011208030 BOLT HEX HEAD ............................... 2 ................ REPLACES P/N 0017108030
9 0017108040 HEX HEAD BOLT 2 9A 0207008000 HEX NUT 2 10 7905512002 FUEL TANK 1 11 A9924800014 CAP FUEL TANK 1 12 A9924800004 FUEL FILTER 1 13 0602125034 FUEL GAUGE 1
14 16950ZB4015 FUEL STRAINER ............................... 1 ................ REPLACES P/N 0605510068
14-1 16952ZB4005 SCREEN SET .................................... 1 ................ REPLACES P/N 0605510069
15 950014521040 HOSE ................................................. 1 ................ REPLACES P/N 0605513146
16 9500202080 HOSE BAND ...................................... 2 ................ REPLACES P/N 0605515178
17 7855525514 RUBBER CUSHION 2 18 7855525604 COLLAR 2
19 011208030 BOLT HEX HEAD ............................... 2 ................ REPLACES P/N 0017108030
20 011208030 BOLT HEX HEAD ............................... 2 ................ REPLACES P/N 0017108020
21 A9117200103 HANGER 1 22 0601850097 STOPPER 1 23 0021008025 MACHINE SCREW 1 23A 0207008000 HEX NUT 1 24 A9311100004 PLASTIC WASHER 2 25 0011308025 HEX HEAD BOLT 2 25A 0037908000 HEX NUT 2 25B 0042108000 PLAIN WASHER 2 26 0019206016 HEX HEAD BOLT 1 27 7915456004 STOPPER 1 28 0017106016 HEX HEAD BOLT 2 29 7915455103 COVER 1 30 7855455003 COVER 1 31 0017106016 HEX HEAD BOLT 6 32 A4484400004 COVER 1 33 0017106016 HEX HEAD BOLT 3
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 49
AIR CLEANER ASSY.
HONDA GX340K1EDN2 ENGINE — AIR CLEANER ASSY.
PAGE 50 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — AIR CLEANER ASSY.
AIR CLEANER ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 15721ZB4000 TUBE BREATHER 1 2 17211899000 ELEMENT, AIR CLEANER 1 3 17212ZB4003 SEPARATOR, AIR CLEANER 1 4 17220ZB4003 HOUSING, AIR CLEANER 1 5 17222ZC2000 STAY, AIR CLEANER 1 6 17231899000 COVER, AIR CLEANER 1 7 17235899000 CLIP A, AIR CLEANER WIRE 2 8 17236899000 CLIP B, AIR CLEANER WIRE 2 9 17252899000 SEAL, AIR CLEANER 1 10 17367413690 FILTER, DRAIN TUBE 1 11 9405005000 NUT, FLANGE (5MM) 6 12 9405006000 NUT, FLANGE (6MM) 3
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 51
CAMSHAFT ASSY.
HONDA GX340K1EDN2 ENGINE — CAMSHAFT ASSY.
PAGE 52 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — CAMSHAFT ASSY.
CAMSHAFT ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 14100ZE3020 CAMSHAFT ASSY. ...................................1 ............. INCLUDES ITEMS/W
2 14410ZE3013 ROD, PUSH 2 3 14431ZE2000 ARM, VALVE ROCKER 2 3 14431ZE2010 ARM, VALVE ROCKER 2 4 14441ZE2000 LIFTER, VALVE 2 5 14451ZE1013 PIVOT, ROCKER ARM 2 6
*
7 14711ZE3000 VALVE, IN. 1 8 14721ZE3000 VALVE, EX. 1 9 14751ZE2003 SPRING, VALVE 2 10 14771ZE2000 RETAINER, IN. VALVE SPRING 1 11 14773ZE2000 RETAINER, EX. VALVE SPRING 1 12 14775ZE2010 SEAT, VALVE SPRING 1 13 14781ZE2000 ROTATOR, VALVE 1 14 14791ZE2010 PLATE, PUSH ROD GUIDE 1 15 90012ZE0010 BOLT, PIVOT (8MM) 2 16 90206ZE1000 NUT, PIVOT ADJ. 2
14568ZE1000 SPRING, WEIGHT RETURN 1
*
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 53
CARBURETOR ASSY.
HONDA GX340K1EDN2 ENGINE — CARBURETOR ASSY.
PAGE 54 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — CARBURETOR ASSY.
CARBURETOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1
*
2
*
3
*
4
*
5
*
6 16024124760 SCREW SET, DRAIN 1 7
*
8 16100ZE3F11 CARBURETOR ASSY. (BE82B B) ......................... 1 ........ INCLUDES ITEMS W/
9
*
10
*
11
*
12
*
13 16211ZE3700 INSULATOR, CARBURETOR 1 14 16221ZE3800 GASKET, CARBURETOR 1 15 16223ZE3800 GASKET, INSULATOR 1 16
*
17 16260ZE2722 STAY ASSY., MANUAL CHOKE ............................ 1 ........ INCLUDES ITEMS W/#
18# 16261ZE2702 STAY, SOLENOID 1 19# 16262ZE2711 LEVER, CHOKE 1 20# 16263ZA0000 JOINT, ROD 1 21# 16264ZE2701 ROD, CHOKE 1 22# 16265ZE2721 STOPPER, CHOKE ROD 1 23# 16268ZE2721 SPRING, MANUAL CHOKE 1 24 16269ZA0800 GASKET, AIR CLEANER 2 25# 16400ZE2703 DIAPHRAGM ASSY. 1 26# 16611ZE2711 ROD, CHOKE CONTROL 1 27# 16613893000 GROMMET, CHOKE ROD 1 28# 16615893000 GUIDE, CHOKE ROD 1 29 36135ZF6D41 VALVE, DASHPOT CHECK 1 30# 53149964003 BUSH, ARM PIVOT 1 31 88911MJ3000 GROMMET, FENDER 1 32# 90431ZE2700 WASHER, CHOKE LEVER 1 33# 90432ZE2700 SEAL, CHOKE LEVER 2 34# 90433ZE2700 WASHER, THRUST (2.7X8) 1 35# 90434ZE2700 COLLAR, LEVER 1 36 90650SD9003 CLIP, WIRE HARNESS 1 37# 93500050120A SCREW, PAN (5X12) 2 38 938920501208 SCREW, WASHER (5X12) 2 39 9405006000 NUT, FLANGE (6MM) 2 40# 9410305000 WASHER, PLAIN (5MM) 1 41# 9454002010 E-RING (2MM) 1 42# 9454004010 E-RING (4MM) 1 43# 9454007010 E-RING (7MM) 1 44 9500202070 CLIP, TUBE (B7) 4 45 950053500810M BULK HOSE, VACUUM (3.5X8000) (3.5X75) 1 46 950053500810M BULK HOSE, VACUUM (3.5X8000) (3.5X130) 1 47
*
47
*
47
*
48
*
16010ZE3701 GASKET SET 1 16011ZA0931 VALVE SET, FLOAT 1 16013ZA0931 FLOAT SET 1 16015ZA0931 CHAMBER SET, FLOAT 1 16016ZH7W01 SCREW SET 1
16028ZA0931 SCREW SET B 1
16124ZE0005 SCREW, THROTTLE STOP 1 16148141881 CAP, CHOKE LEVER DUST 1 16166ZE3F10 NOZZLE, MAIN 1 16172ZE3W10 COLLAR, SET 1
16230ZE3701 VALVE ASSY., SOLENOID 1
99101ZH80950 JET, MAIN (#95) (OPTIONAL) 1 99101ZH80980 JET, MAIN (#98) (OPTIONAL) 1 99101ZH81000 JET, MAIN (#100) 1 99204ZE00350 JET SET, PILOT (#35) 1
*
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 55
CONTROL ASSY.
HONDA GX340K1EDN2 ENGINE — CONTROL ASSY.
PAGE 56 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — CONTROL ASSY.
CONTROL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 16550ZE3700 ARM, GOVERNOR 1 3 16555ZE3000 ROD, GOVERNOR 1 4 16561ZE3000 SPRING, GOVERNOR 1 5 16562ZE3700 SPRING, THROTTLE RETURN 1
9 16570ZE3700 CONTROL ASSY. ................................................ 1 ... INCLUDES ITEMS W/
19 23 90013883000 BOLT, FLANGE (6X12) (CT200) 2 24 90015ZE5010 BOLT, GOVERNOR ARM 1 30 33 9405006000 NUT, FLANGE (6MM) 1
16584883300 SPRING, CONTROL ADJUSTING 1
*
93500050350A SCREW, PAN (5X35) 1
*
*
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 57
HONDA GX340K1EDN2 ENGINE — CRANKCASE COVER ASSY.
CRANKCASE COVER ASSY.
PAGE 58 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — CRANKCASE COVER ASSY.
CRANKCASE COVER ASSY.
NO. PART NO. PART NAME QTY. REMARKS
2 11300ZE3020 COVER ASSY., CRANKCASE (S-TYPE) ............ 1 ........ INCLUDES ITEMS W/
3 11381ZE3801 GASKET, CASE COVER 1 4 15600ZG4003 CAP ASSY., OIL FILLER 1 5 15600735003 CAP ASSY., OIL FILLER 1 6 15625ZE1003 GASKET, OIL FILLER CAP 2
7 16510ZE3000 GOVERNOR ASSY. ............................................. 1 ........ INCLUDES ITEMS W/#
8# 16511ZE8000 WEIGHT, GOVERNOR 3 9# 16512ZE3000 HOLDER, GOVERNOR WEIGHT 1 10# 16513ZE2000 PIN, GOVERNOR WEIGHT 3 11 16531ZE2000 SLIDER, GOVERNOR 1 12 90602ZE1000 CLIP, GOVERNOR HOLDER 1 13 90701HC4000 PIN, DOWEL (8X12) 2 14 15# 9410106800 WASHER, PLAIN (6MM) 1 16 957010804000 BOLT, FLANGE (8X40) 7 17 18
92102ZE3004 OIL SEAL (35X52X8) 1
*
961006202000 BEARING, RADIAL BALL (6202) 1
*
961006207000 BEARING, RADIAL BALL (6207) 1
*
*
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 59
CRANKSHAFT ASSY.
HONDA GX340K1EDN2 ENGINE — CRANKSHAFT ASSY.
PAGE 60 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
NO. PART NO. PART NAME QTY. REMARKS
6 13310ZE3701 CRANKSHAFT (E-TYPE) 1 7 13351ZE3010 WEIGHT, BALANCER 1 11 961006207000 BEARING, RADIAL BALL (6207) 1
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 61
HONDA GX340K1EDN2 ENGINE — CYLINDER BARREL ASSY.
CYLINDER BARREL ASSY.
PAGE 62 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — CYLINDER BARREL ASSY.
CYLINDER BARREL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 12000ZE3817 CYLINDER ASSY. (ALERT)................................. 1 ........
2 15510ZE2043 SWITCH ASSY., OIL LEVEL 1 3 16541ZE3010 SHAFT, GOVERNOR ARM 1 4 31161ZE2000 WIRE, GROUND 1 5 90013883000 BOLT, FLANGE (6X12) (CT200) 1 6 90131896650 BOLT, DRAIN PLUG 2 7 90446KE1000 WASHER (8.2X17X0.8) 1 8
*
9
*
10 91353671003 O-RING (13.5X1.5) (ARAI) 1 11 9405010000 NUT, FLANGE (10MM) 1 12 9410912000 WASHER, DRAIN PLUG (12MM) 2 13 9425110000 PIN, LOCK (10MM) 1 14 957010601200 BOLT FLANGE (6X12) 2 15
91201ZE3004 OIL SEAL (35X52X8) 1 91203952771 OIL SEAL (8X14X5) 1
961006202000 BEARING, RADIAL BALL (6202) 1
*
INCLUDES ITEMS W/
*
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 63
CYLINDER HEAD ASSY.
HONDA GX340K1EDN2 ENGINE — CYLINDER HEAD ASSY.
PAGE 64 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 12200ZF6W01 CYLINDER HEAD 1 2 12204ZE2306 GUIDE, VALVE (OS) (OPTIONAL) 1 3 12205ZE2305 GUIDE, EX. VALVE (OS) (OPTIONAL) 1 4 12216ZE2300 CLIP, VALVE GUIDE 1 5 12251ZE3W00 GASKET, CYLINDER HEAD 1 6 12310ZE2020 COVER, HEAD 1 8 12391ZE2020 GASKET, CYLINDER HEAD COVER 1 10 90014ZE2000 BOLT, HEAD COVER 1 11 90042ZE3700 BOLT, STUD (8X106) 2 12 92900080320E BOLT 2, STUD (8X32) 2 13 90441ZE2010 WASHER, HEAD COVER 1 14 9430112200 PIN A, DOWEL (12X20) 2 15 957011008000 BOLT, FLANGE (10X80) 4 16 9807955846 SPARK PLUG (BPR5ES) (NGK) (OPTIONAL) 1 16 9807955855 SPARK PLUG (W16EPR-U) (DENSO) 1
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 65
FAN COVER ASSY.
HONDA GX340K1EDN2 ENGINE — FAN COVER ASSY.
PAGE 66 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — FAN COVER ASSY.
FAN COVER ASSY.
NO. PART NO. PART NAME QTY. REMARKS
2 19610ZE3700ZB COVER, FAN *NH1* (BLACK) 1 3 19631ZE3W00 SHROUD 1 6 81329567020 GROMMET, DRAIN HOLE 1 7 90013883000 BOLT, FLANGE (6X12) (CT200) 6 8 90654SA4003 CLIP, WIRE HARNESS (6MM) (WHITE) 2
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 67
FLYWHEEL ASSY.
HONDA GX340K1EDN2 ENGINE — FLYWHEEL ASSY.
PAGE 68 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — FLYWHEEL ASSY.
FLYWHEEL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 19511ZE3000 FAN, COOLING 1 6 31100ZE3712 FLYWHEEL, LAMP 1 8 90201ZE3V00 NUT, SPECIAL 16MM 1 9 90741ZE2000 KEY, SPECIAL WOODRUFF (25X18) 1
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 69
IGNITION COIL ASSY.
HONDA GX340K1EDN2 ENGINE — IGNITION COIL ASSY.
PAGE 70 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — IGNITION COIL ASSY.
IGNITION COIL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 30500ZE2023 COIL ASSY., IGNITION 1 2 30700ZE1013 CAP ASSY., NOISE SUPPRESSOR 1 3 31510ZE1811 COIL ASSY., LAMP (12V/25W) 1 4 31510ZE3003 COIL ASSY., LAMP (12V/25W) 1 6 31511ZE3000 CLAMP, WIRE 1 7 31512ZE2000 GROMMET, WIRE 1 10 36101ZE3800 WIRE, STOP SWITCH (470MM) 1 11 36103ZE1000 HOLDER, STOP SWITCH WIRE 1 12 90012888000 BOLT, FLANGE (6X40) 4 13 90013883000 BOLT, FLANGE (6X12) (CT200) 1 15 90015883000 BOOT, FLANGE (6X28) 2
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 71
PISTON ASSY.
HONDA GX340K1EDN2 ENGINE — PISTON ASSY.
PAGE 72 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — PISTON ASSY.
PISTON ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 13010ZE3003 RING SET, PISTON (STD) 1 1 13011ZE3003 RING SET, PISTON (OS 0.25) (OPTIONAL) 1 1 13012ZE3003 RING SET, PISTON (OS O.50) (OPTIONAL) 1 1 13013ZE3003 RING SET, PISTON (0.75) (OPTIONAL) 1 2 13101ZE3W00 PISTON (STD) 1 3 13111ZF6000 PIN, PISTON 1 4 13200ZE3010 ROD ASSY., CONNECTING (STD) 1 5 90001ZE8000 BOLT, CONNECTING ROD 2 6 90601ZE3000 CLIP, PISTON PIN (20MM) 2
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 73
HONDA GX340K1EDN2 ENGINE — RECOIL STARTER ASSY.
RECOIL ST ARTER ASSY.
PAGE 74 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — RECOIL STARTER ASSY.
RECOIL STARTER ASSY.
NO. PART NO. PART NAME QTY. REMARKS
28400ZE3W01ZB STARTER ASSY., RECOIL *NH1* (BLACK) 1 2 28410ZE3W01ZB CASE, RECOIL STARTER *NH1* (BLACK) 1 3 28421ZE3W01 PULLEY, RECOIL STARTER 1 4 28422ZE2W01 RATCHET, STARTER 2 5 28441ZE2W01 SPRING, FRICTION 1 6 28442ZE2W01 SPRING, STARTER RETURN 1 7 28443ZE2W01 SPRING, RATCHET 2 8 28444ZE2W01 RETAINER, SPRING 1 9 28445ZE2W01 HOLDER, SPRING 1 10 28461ZE2W02 GRIP, STARTER 1
11 08560ZG92111 ROPE, RECOIL STARTER .................................. 1 ........ REPLACES P/N 28462ZE3W01
13 90004ZE2W01 SCREW, CENTER 1 14 90008ZE2003 BOLT, FLANGE (6X10) 3
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 75
SOLENOID ASSY .
HONDA GX340K1EDN2 ENGINE — SOLENOID ASSY.
PAGE 76 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — SOLENOID ASSY.
SOLENOID ASSY .
NO. PART NO. PART NAME QTY. REMARKS
1 16268893000 SPRING, CHOKE RETURN 1 2 17850ZD1E30 LEVER, THROTTLE 1 3 36160ZB4003 SOLENOID ASSY. 1 4 90013883000 BOLT, FLANGE (6X12) (CT200) 1 5 93500050080A SCREW, PAN (5X8) 2
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 77
LABELS ASSY.
HONDA GX340K1EDN2 ENGINE — LABELS ASSY.
PAGE 78 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
HONDA GX340K1EDN2 ENGINE — LABELS ASSY.
LABELS ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 87521ZE3W01 EMBLEM 1 4 87528898620 MARK, CHOKE 1 6 87533ZC0630 MARK, AIR CLEANER 1 10 87594ZB4A00 MARK, OIL CAUTION 1
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 79
Effective: October 1, 2002
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
Terms of payment for parts are net 10 days.
FREIGHT POLICY
All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.
MINIMUM ORDER
The minimum charge for orders from Mul­tiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.
RETURNED GOODS POLICY
Return shipments will be accepted and credit will be allowed, subject to the following provi­sions:
1. A Returned Material Authorization must be approved by Multiquip prior to ship­ment.
2. To obtain a Return Mater ial Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quanti­ties, and descriptions of the items to be returned.
a. The parts numbers and descriptions
must match the current parts price list.
b. The list must be typed or computer
generated.
c. The list must state the reason(s) for
the return.
d. The list must reference the sales
order(s) or invoice(s) under which the items were originally purchased.
e. The list must include the name and
phone number of the person request­ing the RMA.
3. A copy of the Return Material Authoriza­tion must accompany the return shipment.
4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point.
5. Parts must be in new and resalable con-
6. The following items are not returnable:
7. The sender will be notified of any material
8. Such material will be held for five working
9. Credit on returned parts will be issued at
10. In cases where an item is accepted, for
11. Credit issued will be applied to future
PRICING AND REBATES
Prices are subject to change without prior notice. Price changes are effective on a spe­cific date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.
Multiquip reserves the right to quote and sell
dition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.
a. Obsolete parts. (If an item is in the
price book and shows as being re­placed by another item, it is obsolete.)
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings, and other rubber parts) that were pur­chased more than six months prior to the return date.
c. Any line item with an extended dealer
net price of less than $5.00.
d. Special order items.
e. Electrical components. f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.
received that is not acceptable.
days from notification, pending instruc­tions. If a reply is not received within five days, the material will be returned to the sender at his expense.
dealer net price at time of the original purchase, less a 15% restocking charge.
which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.
purchases only.
direct to Government agencies, and to Origi­nal Equipment Manufacturer accounts who use our products as integral parts of their own products.
SPECIAL EXPEDITING SERVICE
A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.
LIMITATIONS OF SELLER’S LIABILITY
Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental dam­ages.
LIMITATION OF WARRANTIES
No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufac­tured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of war­ranty packaged with such units, and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. Apart from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.
PAGE 80 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
NOTE PAGE
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 81
OPERATION AND PARTS MANUAL
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
Your Local Dealer is:
MULTIQUIP INC
18910 WILMINGTON AVE. CARSON, CALIFORNIA 90746 800-421-1244 • 310-537-3700 FAX: 310-537-3927 E-mail:mq@multiquip.com Internet:multiquip.com
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