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MQ Power GA-9.7HEA Operation And Parts Manual

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OPERATION AND PARTS MANUAL
MODEL GA-9.7HEA
PORTABLE GENERATOR
(HONDA GX630RVD GASOLINE ENGINE)
Revision #1 (09/18/19)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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  • Page 1 OPERATION AND PARTS MANUAL MODEL GA-9.7HEA PORTABLE GENERATOR (HONDA GX630RVD GASOLINE ENGINE) Revision #1 (09/18/19) To find the latest revision of this publication, visit our website at: www.multiquip.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING PAGE 2 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS GA-9.7HEA 60 Hz Component Drawings Nameplate and Decals Assembly ....46–47 Portable Generator Generator Pipe Frame Assembly ....48–49 Proposition 65 Warning ........... 2 Control Box Assy. (S/N 5681188 and Below) .. 50–51 Table of Contents ............. 3 Control Box Assy.
  • Page 4 NOTES PAGE 4 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)

  • Page 5: Nameplate/Safety Information

    For safety label part numbers, reference the parts Figure 1. Keep these safety labels clean at all times. When section of this manual. the safety labels become worn or damaged, contact your nearest dealer or the Multiquip Parts Dept. GA-9.7HEA AC CIRCUIT BREAKER IDLE OPERATION START...

  • Page 6: Safety Information

    SAFETY INFORMATION Do not operate or service the equipment before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all equipment will be referenced with hazard symbols which times when operating this equipment. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
  • Page 7 SAFETY INFORMATION GENERAL SAFETY „ ALWAYS know the location of the nearest phone or keep a phone on the job site. Also, know the phone numbers CAUTION of the nearest ambulance, doctor and fi re department. This information will be invaluable in the case of an „...
  • Page 8 SAFETY INFORMATION ENGINE SAFETY to prevent accidental discharge of sparks or fl ames from the engine exhaust. Spark arresters are qualifi ed DANGER and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding „...
  • Page 9 SAFETY INFORMATION „ NEVER use fuel as a cleaning agent. „ Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections „ DO NOT smoke around or near the may cause electrical shock and damage to the equipment.
  • Page 10 SAFETY INFORMATION ENVIRONMENTAL SAFETY/DECOMMISSIONING „ If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin, rinse skin or clothing NOTICE immediately with plenty of water. Decommissioning is a controlled process used to safely „ If the battery liquid (dilute sulfuric acid) comes into retire a piece of equipment that is no longer serviceable.
  • Page 11 SAFETY INFORMATION EMISSIONS INFORMATION NOTICE The gasoline engine used in this equipment has been designed to reduce harmful levels of carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxides (NOx) contained in gasoline exhaust emissions. This engine has been certifi ed to meet US EPA Evaporative emissions requirements in the installed confi guration.

  • Page 12: Specifications (Generator)

    SPECIFICATIONS (GENERATOR) Table 1. Specifications (Generator) Model GA9.7HEA Type Brushless Revolving Field Type Excitation Solid State, Statically Excited System Speed 3,600 RPM Cooling System Self-Ventilation Max Power Output 9.7 kW Continuous Power Output 8.4 kW AC Generator 60 Hz AC Power Source Rated Voltage 120/240V Current Max/Continuous (120V)

  • Page 13: Specifications (Engine)

    SPECIFICATIONS (ENGINE) Table 2. Specifications (Engine) Model HONDA GX630RVD Air-cooled 4 stroke, OHV 90° V-Twin, Type Horizontal Shaft Gasoline Engine 3.07 in. X 2.83 in. Bore X Stroke (78 mm X 72 mm.) Displacement 42.0 cu-in (688 cm Engine Max Output 20.8 H.P./3600 R.P.M.

  • Page 14: Dimensions

    DIMENSIONS FRONT VIEW SIDE VIEW GA-9.7HEA AC CIRCUIT BREAKER START IDLE OPERATION QUARTZ QUARTZ BUTTON CONTROL SWITCH for 120V for 120V for 240V for 120/240V AC VOLTMETER HOUR METER 120V 240V 120V/240V AC CIRCUIT BREAKER G.F.C.I Protection MANUAL RESET MANUAL RESET for main GA-9.7H...

  • Page 15: Installation

    (ground rod). The ground terminal on the generator should always be used to connect the generator to a suitable ground when required. GA-9.7HEA AC CIRCUIT BREAKER IDLE OPERATION START...
  • Page 16 INSTALLATION OUTDOOR INSTALLATION GENERATOR GROUNDING NOTICE If possible install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure The Occupational Safety and Health Administration the generator is on secure level ground so that it cannot (OSHA) and the National Electrical Code (NEC) slide or shift around.

  • Page 17: General Information

    GENERAL INFORMATION FAMILIARIZATION DANGER Generator Before connecting this generator to any building’s electrical system, a licensed electrician must install an The Multiquip GA9.7HEA generator is designed as a isolation (transfer) switch. portable dual purpose power source for 60 Hz (single phase) lighting facilities, power tools, submersible pumps Serious injury or death may result without this transfer and other industrial and construction machinery.

  • Page 18: Components (Generator)

    COMPONENTS (GENERATOR) GA-9.7HEA GA-9.7HEA GA-9.7HEA AC CIRCUIT BREAKER AC CIRCUIT BREAKER AC CIRCUIT BREAKER IDLE OPERATION START IDLE OPERATION START IDLE OPERATION START QUARTZ QUARTZ BUTTON CONTROL SWITCH BUTTON BUTTON CONTROL SWITCH CONTROL SWITCH for 120V for 120/240V for 120V...
  • Page 19 COMPONENTS (GENERATOR) 10. 120/240V Output Receptacle – NEMA L14-30R twist- lock receptacle will provide 120/240V, 30 amps, 60 Hz. 11. 240V Output Receptacle – NEMA L6-20R twist-lock receptacle will provide 240V, 20 amps, 60 Hz. 12. 120V Output Receptacle – NEMA L5-30R twist-lock receptacle will provide 120V, 30 amps, 60 Hz.

  • Page 20: Components (Generator)

    COMPONENTS (GENERATOR) GA-9.7H GA-9.7H Figure 5. Generator Components (Continued) 18. Charcoal Canister – A container filled with activated 28. Spark Plug – Provides spark to the ignition system. charcoal that traps gasoline vapors emitted by the Set spark plug gap to 0.6 - 0.7 mm (0.028 - 0.031 inch) fuel system.

  • Page 21: Inspection/Setup

    INSPECTION/SETUP 120 VAC GFCI RECEPTACLES SINGLE PHASE LOAD There are two 120 VAC, 20 amp GFCI (Duplex Nema Always be sure to check the nameplate on the generator 5-20R) receptacles. Each receptacle is protected by a 20 and equipment to insure the wattage, amperage, frequency, amp circuit breaker (CB4/CB5).
  • Page 22 INSPECTION/SETUP GROUND POWER TOOLS EXTENSION CABLE When using power tools or electrical equipment requiring When electric power is to be provided to various tools or AC power from the generator, make sure the power tool loads at some distance from the generator, extension cords cord has a ground pin or is double insulated as shown in are normally used.
  • Page 23 INSPECTION/SETUP BEFORE STARTING 1. Read safety instructions at the beginning of manual. ENGINE OIL 2. Clean the generator, removing dirt and dust, particularly DIPSTICK 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.
  • Page 24 INSPECTION/SETUP FUEL CHECK When connecting battery do the following: 1. NEVER use worn or damaged battery cables. 1. Close the fuel cock before filling the fuel tank. Replacedefective battery cables immediately. 2. Remove the fuel cap located on top of fuel tank. 2.

  • Page 25: Operation

    OPERATION STARTING THE ENGINE This section is intended to assist the operator with the initial start-up of the portable generator. It is extremely important 1. Place the choke knob (Figure 16) in the CLOSED that this section be read carefully before attempting to use position if starting a cold engine.
  • Page 26 OPERATION 9. Place GFCI and AUX. circuit breakers (Figure 22) in 7. Place idle control switch (Figure 19) in the OFF (down) the ON position. position. This will allow the engine speed to run at about 3600 RPM's. for 120V for 120/240V for 120V for 240V...
  • Page 27 OPERATION 11. Read voltmeter on front panel of generator (Figure 24) and verify that 240 VAC is displayed. Using an external voltmeter as shown in Figure 24, verify that 240 VAC is present at the 240V twist-lock receptacle. Figure 25. 120/240V Receptacle (120V) Figure 24.
  • Page 28 OPERATION STOPPING THE ENGINE (NORMAL SHUTDOWN) EMERGENCY SHUTDOWN 1. Place main circuit breaker (Figure 27) in the OFF 1. Place operation switch (Figure 30) in the OFF position. position. TEST S/N 5681189 S/N 5681188 AND ABOVE AND BELOW Figure 27. Main Circuit Breaker (OFF) 2.

  • Page 29: Preparation For Long Term Storage

    PREPARATION FOR LONG TERM STORAGE GENERATOR STORAGE For storage of the generating set for over 30 days, the following is required: „ Drain the fuel tank completely, or add STA-BIL to the fuel. „ Run the engine until the gasoline in the carburetor is completely consumed.

  • Page 30: Maintenance

    MAINTENANCE Use Table 7 as a general maintenance guideline when servicing your engine. For more detail engine maintenance information, refer to the engine owner's manual supplied with your engine. Table 7. Engine Maintenance Schedule FIRST EVERY 3 EVERY 6 EVERY EVERY DESCRIPTION OPERATION...
  • Page 31 MAINTENANCE MAINTENANCE SPARK PLUG Perform the scheduled maintenance procedures as defined 1. Remove and clean the spark plug (Figure 32), by Table 7 on the previous page: then adjust the spark gap to 0.024 ~0.028 inch (0.6~0.7 mm). This unit has electronic ignition, which DAILY requires no adjustments.
  • Page 32 MAINTENANCE 3. Use an oil filter socket tool and remove oil filter as 5. Screw on new oil filter by hand (Figure 35B) until seal shown in Figure 34. contacts the filter mounting base. 6. Using an oil filter socket tool (Figure 35C), tighten NOTICE filter and additional 3/4-inch turn.
  • Page 33 MAINTENANCE ENGINE AIR CLEANER DANGER DO NOT use gasoline as a cleaning solvent, the possibility exists of fire or explosion which can cause damage to the equipment and severe bodily harm or even DEATH! 1. Pull the air cleaner cover latch (Figure 37) to the unlock position, and remove the cover.
  • Page 34 MAINTENANCE IN-LINE FUEL FILTER (200 HOURS) CLEANING INSIDE THE FUEL TANK 1. Replace the engine fuel filter (Figure 40) every 200 1. If necessary, drain the fuel inside the fuel tank hours. completely. Using a spray washer (Figure 42) wash out any deposits or debris that have accumulated inside the fuel tank.
  • Page 35 MAINTENANCE SPARK ARRESTER CLEANING 3. On the GFCI module (Figure 46), verify that the green POWER LED is ON. Clean the spark arrester every 6 months or 100 hours. 1. Remove retaining screw (Figure 43) that secures spark arrester to muffler, then remove spark arrester. MUFFLER GREEN POWER...

  • Page 36: Maintenance

    MAINTENANCE 9. Verify that the AC voltmeter is registering a voltage 6. Also verify that the main circuit breaker (Figure 49) reading as indicated by Figure 52. switch trips to the OFF position. Figure 49. Circuit Breaker OFF (GFCI Test) 7.
  • Page 37 NOTES GA9.7HEA 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (09/18/19) — PAGE 37...

  • Page 38: Gen. Wiring Digram (S/N 5681188 And Below)

    GENERATOR WIRING DIAGRAM (S/N 5681188 AND BELOW) PAGE 38 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)

  • Page 39: Gen. Wiring Digram (S/N 5681189 And Above)

    GENERATOR WIRING DIAGRAM (S/N 5681189 AND ABOVE) GA9.7HEA 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (09/18/19) — PAGE 39...

  • Page 40: Troubleshooting (Engine)

    TROUBLESHOOTING (ENGINE) Table 8. Engine Troubleshooting Symptom Possible Cause Solution Spark plug bridging? Check gap, insulation or replace spark plug. Carbon deposit on spark plug? Clean or replace spark plug. Difficult to start. Fuel is available but no SPARK Short circuit due to deficient spark plug Check spark plug insulation.

  • Page 41: Troubleshooting (Engine)

    TROUBLESHOOTING (ENGINE) Table 8. Engine Troubleshooting (Continued) Symptom Possible Cause Solution Flush fuel system and replace with correct Water in fuel system? Weak in power. type of fuel. Compression is proper Dirty spark plug? Clean or replace spark plug but misfires. Ignition coil defective? Replace ignition coil.

  • Page 42: Troubleshooting (Generator)

    TROUBLESHOOTING (GENERATOR) Table 9. Generator Troubleshooting Symptom Possible Problem Solution Low voltage Engine speed too low? Raise engine speed to rated RPM. AC voltmeter not working? Replace Ac voltmeter. Control box internal wiring Check control box wiring. malfunction? Check red and green ignition wires. Defective ignition coil? Low voltage.
  • Page 43 NOTES GA9.7HEA 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (09/18/19) — PAGE 43...

  • Page 44: Explanation Of Code In Remarks Column

    EXPLANATION OF CODE IN REMARKS COLUMN QTY. Column The following section explains the different symbols and remarks used in the Parts section of this manual. Use the Numbers Used — Item quantity can be indicated by a help numbers found on the back page of the manual if there number, a blank entry, or A/R.

  • Page 45: Suggested Spare Parts

    SUGGESTED SPARE PARTS GA9.7HEA PORTABLE 60HZ GENERATOR HONDA GX630RVD GASOLINE ENGINE 1 to 3 units 1 to 3 units 3....980795587G ..SPARK PLUG (ZFR5F) Qty. Description 3....15400PLMA01PE .OIL FILTER CARTRIDGE 4....0602201357 ..REGULATOR 3....1728Z6L0001 ..AIR FILTER OUTER, FOAM 4....0601828508 ..RELAY 1....35480Z6L003 ..SWITCH ASSY., OIL LEVEL 2....0601802137 ..FUSE 2....16910Z6L003 ..IN-LINE FUEL FILTER 2....0601812529 ..RECEPTACLE, L14-30R...

  • Page 46: Nameplate And Decals Assembly

    GA9.7HEA— NAMEPLATE AND DECALS ASSY. GA-9.7HEA AC CIRCUIT BREAKER START IDLE OPERATION QUARTZ QUARTZ CONTROL SWITCH BUTTON for 120V for 120V for 240V for 120/240V AC VOLTMETER HOUR METER 120V 240V 120V/240V AC CIRCUIT BREAKER G.F.C.I Protection MANUAL RESET MANUAL RESET...
  • Page 47 D2552000404 DECAL: OPERATING INSTRUCTIONS.....1....D25200040B A6551000504 DECAL: OPERATION SWITCH ......1....A65100050 A9511100103 DECAL: WARNING ..........1....A91110010 A6561000903 DECAL: MQ POWER, GA-9.7H W7810680104 DECAL: FUEL DRAIN ........1....S-3060 W1630645004 DECAL: OIL DRAIN ...........1....S-1403 W8700611524 DECAL: CAUTION, OIL LEVEL GAUGE ...1....S-4926B GA9.7HEA 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (09/18/19) — PAGE 47...

  • Page 48: Generator Pipe Frame Assembly

    GA9.7HEA — GENERATOR ASSY. PAGE 48 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)
  • Page 49 GA9.7HEA — GENERATOR ASSY. PART NO. PART NAME QTY. REMARKS A6110200103 ROTOR ASSY............1....INCLUDES ITEMS W/# 1-1# FIELD ASSY............1....NOT SOLD SEPARATELY 1-2# 7871025004 RECTIFIER 1-3# 0071206304 BEARING A6113100004 A6113400004 SET BOLT, ROTOR 0801086104 SET WASHER BEARING 0040010000 WASHER, LOCK A6136000103 ARMATURE ASSY.

  • Page 50: Control Box Assy. (S/N 5681188 And Below)

    GA9.7HEA — CONTROL BOX ASSY. (S/N 5681188 AND BELOW) PAGE 50 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)
  • Page 51 GA9.7HEA — CONTROL BOX ASSY. (S/N 5681188 AND BELOW) PART NO. PART NAME QTY. REMARKS A6214000603 CONTROL BOX 0601850102 GROMMET 8511864601A TERMINAL PLATE ..........1....REPLACES P/N W8511864604 0016906020 HEX, HEAD BOLT 0601823204 RECTIFIER 0027103020 MACHINE SCREW 0601828508 RELAY, DC12V 0017106015 HEX HEAD BOLT A6511100402 CONTROL PANEL 0601806819...

  • Page 52: Control Box Assy. (S/N 5681189 And Above)

    GA9.7HEA — CONTROL BOX ASSY. (S/N 5681189 AND ABOVE) PAGE 52 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)
  • Page 53 GA9.7HEA — CONTROL BOX ASSY. (S/N 5681189 AND ABOVE) PART NO. PART NAME QTY. REMARKS A6214000613 CONTROL BOX 0601850102 GROMMET 8511864601A TERMINAL PLATE ..........1....REPLACES P/N W8511864604 0016906020 HEX, HEAD BOLT 0601823204 RECTIFIER 0027103020 MACHINE SCREW 0601828508 RELAY, DC12V 0017106015 HEX HEAD BOLT A6511100602 CONTROL PANEL ..........1....S/N 5681189 ~5741196 A6511100612...

  • Page 54: Pipe Frame Assembly

    GA9.7HEA — PIPE FRAME ASSY. PAGE 54 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)
  • Page 55 GA9.7HEA — PIPE FRAME ASSY. PART NO. PART NAME QTY. REMARKS A6417000102 PIPE FRAME A6414100103 FLOOR PANEL A6361000204 FUEL TANK ............1....INCLUDES ITEMS W/# 3-1# A9924800104 CAP, FUEL TANK 3-2# 0605505120 FUEL FILTER 3015530004 DRAIN PLUG 0150200011 O-RING 0602125032 FUEL GAUGE 0016908020 HEX.

  • Page 56: Battery Assembly

    GA9.7HEA — BATTERY ASSY. PAGE 56 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)
  • Page 57 GA9.7HEA — BATTERY ASSY. PART NO. PART NAME QTY. REMARKS A6345200204 BATTERY SHEET D1343200204 BATTERY BAND 0805082704 BATTERY BOLT 0037806000 WING NUT 0040006000 WASHER, LOCK 952404470 WASHER, FLAT ..........2....REPLACES P/N 0041206000 0802276803 TERMINAL CAP (RED) 0845041304 TERMINAL CAP (BLK) ........1....REPLACES P/N 0602220601 Y0165103819 BATTERY, 12 VOLT ..........1....NEUTON 38B19R GA9.7HEA 60 HZ GENERATOR •...

  • Page 58: Engine Service Parts

    GA9.7HEA — ENGINE SERVICE PARTS PAGE 58 — GA9.7HEA 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (09/18/19)
  • Page 59 GA9.7HEA — ENGINE SERVICE PARTS PART NO. PART NAME QTY. REMARKS 17210Z6L010 AIR FILTER INCLUDES ITEMS W/ $ 17218Z6L0001 AIR FILTER OUTER, FOAM ......1....REPLACES P/N 17218Z6L000 17232Z2E000 GROMMET AIR FILTER INNER ..........1....NOT SOLD SEPARATELY 16910Z6L003 IN-LINE FUEL FILTER 980795587GA SPARK PLUG (ZFR5F) ........1....REPLACES P/N 980795587G 15400PLMA01PE OIL FILTER CARTRIDGE ........1....REPLACES P/N 15400RTA004 GA9.7HEA 60 HZ GENERATOR •...
  • Page 60 © COPYRIGHT 2019, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power 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 their respective owners and used with permission.

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