MULTIQUIP ga2.5Hr, Operation And Parts Manual

Page 1: ...HIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES To find the latest revision of this publication visit our website at www multiquip com MODEL ga2 5Hr portable generator HONDA GX160RT2EMAN GASOLINE...

Page 2: ...PROPOSITION 65 START FIRES WARNINGS Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrestor may be required The operator should contact local fire ag...

Page 3: ...ubleshooting Engine 30 31 troubleshooting Generator 32 Explanation Of Code In Remarks Column 34 Suggested Spare Parts 35 Component Drawings Nameplate And Decals Assembly 36 37 Generator Assembly 38 39...

Page 4: ...A E EL R NEUTRAL BONDED TO FRAME LNAE UCTARREC M AS ISS A E LDAU M MAOSTSEEU A R 211052 120 V OFF GAC 2 2H POWERED by Honda Engines 11250AV GR TPERRIS REE DE A CC IO N U C TE R IRR ACR NUU TIT P P TB...

Page 5: ...te View Parts Diagrams Order Parts Print Specification Information Note Discounts Are Subject To Change Goto www multiquip com and click on Order Parts to log in and save Use the internet and qualify...

Page 6: ...afety messages specifically address the level of exposure to the operator and are preceded by one of four words dANgER WARNiNg CAuTiON or NOTiCE sAFETY sYmBOls dANgER Indicates a hazardous situation w...

Page 7: ...t recommended by Multiquip for this equipment Damage to the equipment and or injury to user may result AlWAYs know the location of the nearest fire extinguisher AlWAYs know the location of the nearest...

Page 8: ...Codes specify that in certain locations spark arresters must be used on internal combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of...

Page 9: ...y exists of electrical shock electrocution or death Make sure power cables are securely connected to the generator s output receptacles Incorrect connections may cause electrical shock and damage to t...

Page 10: ...t upwards dO NOT lift machine to unnecessary heights AlWAYs tie down equipment during transport by securing the equipment with rope ENviRONmENTAl sAFETY dECOmmissiONiNg NOTICE Decommissioning is a con...

Page 11: ...d configuration Attempting to modify or make adjustments to the engine emmission system by unauthorized personnel without proper training could damage the equipment or create an unsafe condition Addit...

Page 12: ...System Self Ventilation Fuel Capacity 3 2 gallons 12 liters 60 Hz AC Power Source Continuous Power Output 2 2 kW Max Power Output 2 5 kW Rated Voltage 120V Current Max Continuous 120V 20 8 18 3 amps P...

Page 13: ...Type Starting Method Recoil Start Dimensions L x W x H 12 2 x 14 3 X 13 6in 312 X 362 X 346 mm Dry Net Weight 33 lbs 15 1 kg SPECIFICATIONS engine Effects of Altitude and Heat The maximum output of th...

Page 14: ...o order F B C E AC CIRCUIT BREAKER OFF 22A GA 2 5HR 120 V 120 AC VOLTMETER QUARTZ 20A 120V 20A GFCI PROTECTED A D Table 3 Generator Dimensions REFERENCE LETTER DESCRIPTION DIMENSIONS IN MM A LENGTH FR...

Page 15: ...GA2 5HR 60 hz GENERATOR operation and parts manual rev 0 12 15 14 page 15 note...

Page 16: ...minimum If copper wire is used 10 size wire minimum should be used At the generator connect the terminal of the ground cable between the lock washer and the nut Figure 3 and tighten the nut fully Conn...

Page 17: ...the generator could slide WARNING Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to...

Page 18: ...ng and fully wraps around the generator to protect against damage Reference Figure 4 and Figure 5 for the basic controls and indicators for the GA2 5HR generator These portable generator are supplied...

Page 19: ...ing or overloading When starting the generator always have the circuit breaker placed in the OFF position 6 Engine Oil Filler Cap Remove this cap dipstick when the adding of engine oil is required See...

Page 20: ...nerator part of the UWKB Wheel Kit Assembly 19 Carburetor Cup Inspect the fuel cup weekly for water and dirt Clean as referenced in the maintenance section of this manual 20 Engine Oil Drain Plug Remo...

Page 21: ...tion chart Table 4 as a guide for selecting proper cable size NOTICE Double insulated power tools and small appliances have specially insulated housings that eliminate the need for a ground pin These...

Page 22: ...dipstick without screwing it into the filler neck Check the oil level shown on the dipstick NOTICE ALWAYS place the main circuit breaker in the OFF position prior to starting the engine 4 If the oil...

Page 23: ...position if starting a cold engine Figure 12 Choke Lever OFF 20 CLOSED OPEN CHOKE LEVER 3 Place the choke lever Figure 12 in the OPEN position if starting a warm engine or the temperature is warm 4 P...

Page 24: ...es can now be done ON 20A 120V OFF V V 300 mV A A V COM 120 VAC GFCI L5 20R 120 V G W 120VAC X NOTICE When using a combination of dual receptacles total load should not exceed the rated capacity of th...

Page 25: ...oline in the carburetor is completely consumed Completely drain the oil from the crankcase and refill with fresh oil Remove the spark plug pour 2 or 3 cc of SAE 30 oil into the cylinder and crank slow...

Page 26: ...X CHANGE X 1 Charcoal Canister 4 REPLACE All Nuts Bolts RETIGHTEN IF NECESSARY X Spark Plug CHANGE X REPLACE X Cooling Fins CHECK X Spark Arrester CLEAN X Fuel Tank CLEAN X Fuel Strainer CHECK X X Idl...

Page 27: ...If any hose fuel or oil lines are defective replace them immediately Fuel Strainer 1 Thoroughly clean the area around the fuel cap 2 Remove the fuel cap from the fuel tank 3 Next remove inspect and c...

Page 28: ...NE OIL FOAM ELEMENT SQUEEZE THOROUGHLY maintenance spark arrester cleaning Clean the spark arrester every 6 months or 100 hours 1 Removethemufflerprotectorretainingbolts Figure25 then remove muffler p...

Page 29: ...GA2 5HR 60 hz GENERATOR operation and parts manual rev 0 12 15 14 page 29 generator wiring diagram...

Page 30: ...park plug ON OFF switch is shorted Check switch wiring replace switch Ignition coil defective Replace ignition coil Improper spark gap points dirty Set correct spark gap and clean points Condenser ins...

Page 31: ...lace air cleaner elements as necessary Oil level too low or too high Adjust oil to proper level Rotational speed fluctuates Governor adjusted incorrectly Adjust governor Governor spring defective Repl...

Page 32: ...heck or replace rotor Stator winding malfunction Check or replace stator Circuit breaker malfunction Check or replace CB1 Voltage output too high Engine speed too high Lower engine speed to rated RPM...

Page 33: ...GA2 5HR 60 hz GENERATOR operation and parts manual rev 0 12 15 14 page 33 notes...

Page 34: ...not guarantee the availability of the parts listed NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order QTY C...

Page 35: ...120 CAP FUEL TANK 1 0605505162 FILTER FUEL 1 16081471831 CUP fuel strainer 2 7935419204 rubber suspension 2 7935419304 rubber suspension 3 9807956846 SPARK PLUG 1 34150ZH7013 SWITCH ASSY OIL ALERT 2 2...

Page 36: ...ACR NUU TIT P P TB RER IU NER CA ID P KA E EL R NEUTRAL BONDED TO FRAME LNAE UCTARREC M ASISS A E LDAU M MAOSTSEEU A R 211052 NEVER use in enclosed or partially enclosed areas Utilisation INTERDITE da...

Page 37: ...03 DECAL MQ POWER GA2 5H 1 5 87528ZB2630 DECAL CHOKE 1 REPLACES P N Y0600500046 6 1980680004 DECAL FUEL COCK 1 S3704 7 87533ZC0630 DECAL AIR CLEANER 1 REPLACES P N 0600500045 8 87521Z4M000 EMBLEM GX16...

Page 38: ...page 38 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 GA2 5HR GENERATOR ASSY...

Page 39: ...ING WASHER 1 5 A2135000203 ARMATURE ASSY 1 6 7931315002 END BRACKET C SIDE 1 7 7931315102 END BRACKET B SIDE 1 8 7875021523 GUIDE PANEL AIR 1 9 7681331003 COVER 1 10 7681344204 SET BOLT STATOR 4 11 00...

Page 40: ...page 40 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 GA2 5HR CONTROL BOX ASSY...

Page 41: ...IT BREAKER 20A 1 7 3011816004 BRACKET CIRCUIT BREAKER 1 8 0021004010 MACHINE SCREW 2 9 0601806819 AC VOLTMETER 0 120V 1 10 0601812598 RECEPTACLE 5 20R 1 11 0601811092 RECEPTACLE L5 20R 1 REPLACES P N...

Page 42: ...page 42 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 GA2 5Hr PIPE FRAME ASSY...

Page 43: ...ACES P N Y0605510063 11 91424ZBH801 HOSE 1 REPLACES P N Y0605513217 12 950024080008 HOSE BAND 2 REPLACES P N 0605515241 13 W7855525514 RUBBER CUSHION 2 14 7855525604 COLLAR 2 15 011208030 HEX HEAD BOL...

Page 44: ...5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 GA2 5HR UWKB wheel kit ASSY option 2 1 3 12 11 13 14 15 16 17 4 10 7 LARGE CLAMP SMALL CLAMP 8 18 PUMP FRAME 9 6 HANDLE MOUNT 6 5 6 7 9 3...

Page 45: ...T W A RIGHT 3 5 8 1 5 WK34715 SCREW M6 X 45 4 6 0948 WASHER FLAT SAE 1 4 24 7 WK34717 NUT NYLOC M6 12 8 WK2250 CLAMP SMALL 4 9 WK2300 CLAMP LARGE 4 10 29787 PIN CLEVIS 5 16 X 1 1 2 2 11 0300 B WASHER...

Page 46: ...page 46 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine cylinder head ASSY...

Page 47: ...IDE EX VALVE OVER SIZE 1 4 12216ZE5300 CLIP VALVE GUIDE 1 5 12251ZL0003 GASKET CYLINDER HEAD 1 6 12310Z4M000 COVER COMP HEAD 1 7 12391ZE1000 PACKING HEAD COVER 1 9 15721883030 TUBE BREATHER 1 10 90013...

Page 48: ...page 48 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine cylinder barrel ASSY...

Page 49: ...16531Z4M000 SLIDER GOVERNOR 1 8 16541Z4M000 SHAFT GOVERNOR ARM 1 9 90131ZE1000 BOLT DRAIN PLUG 2 11 90601ZE1000 WASHER DRAIN PLUG 2 12 90602ZE1000 CLIP GOVERNOR HOLDER 1 13 91001ZF1003 BEARING RADIAL...

Page 50: ...page 50 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine crankcase cover ASSY...

Page 51: ...DES ITEMS W 3 11381ZH8801 PACKING CASE COVER 1 4 15600Z0T810 CAP ASSY OIL FILLER 1 INCLUDES ITEM W 5 15600Z0T820 CAP ASSY OIL FILLER 1 INCLUDES ITEM W 6 15625Z0T800 PACKING OIL FILLER CAP 2 7 91201Z0T...

Page 52: ...page 52 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine flywheel assy...

Page 53: ...2 15 14 page 53 honda gx160rt2eman engine flywheel assy NO PART NO PART NAME QTY REMARKS 1 13331357000 KEY SPECIAL WOODRUFF 25X18 1 2 19511ZE1000 FAN COOLING 1 4 28451ZH8801 PULLEY STARTER 1 6 31100Z4...

Page 54: ...page 54 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine ignition coil ASSY...

Page 55: ...REMARKS 1 30500Z0T802 COIL ASSY IGNITION 1 2 30700Z0T811 CAP ASSY NOISE SUPPRESSOR 1 4 31510ZE1811 COIL ASSY LAMP 12V 25W 1 5 31511ZE1000 CLAMPER CORD 1 6 31512ZE1000 GROMMET CORD 1 9 36101ZE1010 COR...

Page 56: ...page 56 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine crankshaft ASSY...

Page 57: ...GA2 5HR 60 hz GENERATOR operation and parts manual rev 0 12 15 14 page 57 NO PART NO PART NAME QTY REMARKS 9 13310Z4M680 CRANKSHAFT COMP 1 honda gx160rt2eman engine crankshaft ASSY...

Page 58: ...page 58 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine piston ASSY...

Page 59: ...n ASSY NO PART NO PART NAME QTY REMARKS 1 13010Z4M801 RING SET PISTON STD RIKEN 1 1 13010Z4M802 RING SET PISTON STD TEIKOKU 1 2 13101Z4M800 PISTON STD 1 3 13111Z4M000 PIN PISTON 1 4 13200Z4M000 ROD AS...

Page 60: ...page 60 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine camshaft assy...

Page 61: ...14410Z4M000 ROD PUSH 2 4 14431ZE1000 ARM VALVE ROCKER 2 5 14441ZE1010 LIFTER VALVE 2 6 14451ZE1013 PIVOT ROCKER ARM 2 7 14568ZE1000 SPRING WEIGHT RETURN 1 8 14711Z4M000 VALVE IN 1 9 14721Z4M000 VALVE...

Page 62: ...page 62 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine control assy...

Page 63: ...63 honda gx160rt2eman engine control assy NO PART NO PART NAME QTY REMARKS 5 16551Z4M000 ARM GOVERNOR 1 7 16555Z4M000 ROD GOVERNOR 1 8 16561Z4M000 SPRING GOVERNOR 1 9 16562Z4M020 SPRING THROTTLE RETU...

Page 64: ...page 64 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine carburetor assy...

Page 65: ...CREW SET 1 INCLUDES ITEMS W 8 16044ZE0005 CHOKE SET 1 9 16100Z4MT51 CARBURETOR ASSY 1 INCLUDES ITEMS W 10 16124ZE0005 SCREW THROTTLE STOP 1 11 16166Z4MT31 NOZZLE MAIN 1 12 16211Z4M000 INSULATOR CARBUR...

Page 66: ...page 66 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine fan cover assy...

Page 67: ...ATE COMP SIDE ALERT AND LAMP 1 8 19630Z4M800 SHROUD COMP LOWER 1 10 34150ZH7013 ALERT UNIT OIL 1 12 35120Z0T851 SWITCH ASSY ENGINE STOP 1 15 90013883000 BOLT FLANGE 6X12 8 16 90022888010 BOLT FLANGE 6...

Page 68: ...page 68 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine recoil starter assy...

Page 69: ...OIL STARTER 1 4 28422ZH8801 RATCHET STARTER 2 5 28431ZH8801 PLATE FRICTION 1 6 28433ZH8801 GUIDE RATCHET 1 7 28441ZH8801 SPRING FRICTION 1 8 28442ZH8003 SPRING RECOIL STARTER 1 9 28443ZH8801 SPRING RE...

Page 70: ...page 70 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine air cleaner ASSY...

Page 71: ...1 17211ZB2000 ELEMENT AIR CLEANER 1 2 17212ZB2800 SEPARATOR AIR CLEANER 1 4 17231ZB2000 COVER AIR CLEANER 1 5 17239ZB2000 STAY AIR CLEANER 1 6 17252ZB2000 SEAL AIR CLEANER 1 7 90115459770 BOLT WINKER...

Page 72: ...page 72 GA2 5HR 60 hz gENERATOR operation and parts manual rev 0 12 15 14 honda gx160rt2eman engine muffler ASSY...

Page 73: ...ASSY NO PART NO PART NAME QTY REMARKS 1 18310ZB3C00 MUFFLER COMP 1 2 18330ZH8T90 PIPE COMP EX 1 3 18355898630 ARRESTER SPARK 1 4 18381Z0T811 GASKET MUFFLER 1 5 18381Z0T801 GASKET MUFFLER 1 8 18320ZB20...

Page 74: ...products h Items purchased in kits 7 The sender will be notified of any material received that is not acceptable 8 Such material will be held for five working days from notification pending instructi...

Page 75: ...GA2 5HR 60 hz GENERATOR operation and parts manual rev 0 12 15 14 page 75 notes...

Page 76: ...act sales multiquip co uk Tel 0161 339 2223 Fax 0161 339 3226 COPYRIGHT 2014 MULTIQUIP INC Multiquip Inc the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc and may not be use...