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OPERATION AND PARTS MANUAL

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

MODEL GA-9.7HEA

PORTABLE GENERATOR

(HONDA GX630RVD GASOLINE ENGINE)

Revision #1 (09/18/19)

Summary of Contents for GA-9.7HEA

Page 1: ... THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES To find the latest revision of this publication visit our website at www multiquip com MODEL GA 9 7HEA PORTABLE GENERATOR HONDA GX630RVD GASOLINE ENGINE Revision 1 09 18 19 ...

Page 2: ...PAGE 2 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 PROPOSITION 65 WARNING ...

Page 3: ...28 Preparation for Long Term Storage 29 Maintenance 30 36 Gen Wiring Digram S N 5681188 and Below 38 Gen Wiring Digram S N 5681189 and Above 39 Troubleshooting Engine 40 41 Troubleshooting Generator 42 Explanation of Code in Remarks Column 44 Suggested Spare Parts 45 Component Drawings Nameplate and Decals Assembly 46 47 Generator Pipe Frame Assembly 48 49 Control Box Assy S N 5681188 and Below 50...

Page 4: ...PAGE 4 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 NOTES ...

Page 5: ...LA MASSE A LA CARCASSE DU MOTEUR 211052 120 V OFF GAC 2 2H POWERED by Honda Engines 120V 15A GR PRISE DE TERRE AC CIRCUIT BREAKER INTERRUPTEUR DE COURANT PRINCIPAL NEUTRAL BONDED TO FRAME NEUTRE MIS A LA MASSE A LA CARCASSE DU MOTEUR 211052 NEVER use in enclosed or partially enclosed areas Utilisation INTERDITE dans un espace clos ou partiellement clos ONLY use outdoors and away from open windows ...

Page 6: ...safety 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 which if not avoided WILL result in DEATH or SERIOUS INJURY WARNING Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY CAUTION Indicates a hazardous situation...

Page 7: ...ot 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 first aid kit ALWAYS know the location of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be i...

Page 8: ...te Health Safety Codes and Public Resources 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 sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply wit...

Page 9: ...ity 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 the generator NOTICE ALWAYS make certain that proper power or extension cord has been selected for the job See Cable Selection Chart in this manual Grounding Safety DANGER ALWAYS make sure that elect...

Page 10: ...ht 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 controlled process used to safely retire a piece of equipment that is no longer serviceable If the equipment poses an unacceptable and unrepairable safety risk due to wear or damage or is no longer cost...

Page 11: ...ed 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 Additionally modifying the fuel system may adversely affect evaporative emissions resulting in fines or other penalties Emission Control Label The emission control label is an integral part of the emissio...

Page 12: ... Voltage 120 240V Current Max Continuous 120V 80 8 70 amps Current Max Continuous 240V 40 4 35 amps Phase Single Phase 3 wire Frequency 60 Hz Power Factor 1 Fuel Capacity 10 gallons 38 liters Battery 12V 28 Amp CCA 280 Battery Dimensions L x W x H 7 50 X 5 0 X 7 25 in 190 X 127 X 184 mm Generator Dimensions L x W x H 31 50 X 21 25 X 27 5 in 800 X 540 X 700 mm Dry Net Weight 342 lbs 155 kg Weight w...

Page 13: ...g Method Electric Start Recoil Dimensions L x W x H 15 94 X 16 14 X 17 24 in 405 X 410 X 438 mm Dry Net Weight 98 lbs 44 4 kg SPECIFICATIONS ENGINE Effects of Altitude and Heat The maximum output of the engines listed above are 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...

Page 14: ...TMETER GA 9 7HEA AC CIRCUIT BREAKER G F C I Protection for main 20A 20A 30A 20A 30A AC CIRCUIT BREAKER 20A 30A 30A for 120V for 120V 20A for 240V for 120 240V A FRONT VIEW SIDE VIEW B C GA 9 7H QUARTZ QUARTZ HOUR METER MANUAL RESET P O W E R F A U L T MANUAL RESET P O W E R F A U L T Table 3 Generator Dimensions REFERENCE LETTER DESCRIPTION DIMENSIONS IN MM A HEIGHT 27 50 700 B WIDTH 21 25 540 C L...

Page 15: ...one end of the ground cable terminal to the generator ground point Figure 3 Connect the other end of the ground cable to a suitable earth ground ground rod GROUND CABLE 8 MINIMUM IF THE GENERATOR IS PROVIDING ELECTRIC POWER TO A BUILDING VIA A TRANSFER SWITCH IT MUST BE CONNECTED TO A GROUND ROD REFERENCE NEC 250 CONNECT TO BUILDING GROUND IF REQUIRED 8 FT MINIMUM 240V 120V 240V 120V 120 V 120 120...

Page 16: ...rea DANGER 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 GENERATOR GROUNDING If applicable to guard against electrical shock and possible damage to the generator it is important to provide a good EARTH ground Figure 3 Article 250 Grounding of the NE...

Page 17: ...ator is supplied with a electrical control 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 120 240V twist lock output receptacle single phase 240V twist lock receptacle single phase 120V GFCI single phase duplex output receptacles 40 Amp Main CB 2 Pole S N 5681188 and below 35 Amp Main CB 2 p...

Page 18: ... in the OFF position 3 20 Amp Breaker 2 pole 20 amp circuit breaker protects the 240V twist lock receptacle When starting the generator always have this circuit breaker placed in the OFF position 4 30 Amp Breaker 2 pole 30 amp circuit breaker protects the 120 240V twist lock receptacle When starting the generator always have this circuit breaker placed in the OFF position 5 AC Voltmeter This voltm...

Page 19: ...0R GFCI receptacle will provide 120V 20 amps 14 Ground Terminal This ground connection point should be connected to a good earth ground ground rod 15 GFCI Sensing Module Interrupts power when a ground fault exist Used on S N 5681189 and above 16 Main Breaker This 2 pole 35 amp circuit breaker protects the generator from short circuiting or overloading When starting the generator always have the ci...

Page 20: ...d fuel Fuel tank capacity is 10 gallons 38 liters 28 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 29 Air Cleaner Prevents dirt and other debris from entering the fuel system Release retaining clips on top of air filter cover to gain access to filter element NEVER run the engine without an air cleaner 30 Engine Oil D...

Page 21: ...atisfactorily 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 WATTS VOLTAGE x AMPERAGE The power factor of this welder generator is 1 0 Se...

Page 22: ...ve even if the internal insulation fails 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 Table 5 as a guide fo...

Page 23: ...ith the engine stopped 2 Remove the dipstick from its holder Figure 9 and wipe clean Figure 9 Engine Oil Dipstick Removal 3 Re Insert dipstick Figure 10 then remove dipstick from its holder Check the oil level shown on the dipstick OIL LEVEL DIPSTICK Figure 10 Engine Oil Dipstick 4 If the oil level is low remove the oil filler cap Figure 11 and fill to a safe operating level max as indicated by th...

Page 24: ...t of battery terminal treatment compound around both battery terminals This will ensure a good connection and will help prevent corrosion around the battery terminals POLARITY The polarity of the battery is extremely important When an inverted circuit connection takes place the circuit will be in short circuit instantaneously resulting in possible damage to the control box electronics and starter ...

Page 25: ...quate ventilationwhen operating Direct exhaust away from nearby personnel WARNING NEVER manually start the engine with the main GFCI duplex or auxiliary circuit breakers in the ON closed position OFF OFF TEST S N 5681188 AND BELOW S N 5681189 AND ABOVE OFF 20A 30A 30A for 120V for 120V 20A for 240V for 120 240V STARTINGTHE ENGINE 1 Place the choke knob Figure 16 in the CLOSED position if starting ...

Page 26: ...e up position ON 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 a 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 ON ON TEST S N 5681188 AND BELOW S N 5681189 AND ABOVE ON 9 Place GFCI and AUX circuit breakers Figure 22 in the ON pos...

Page 27: ...V twist lock receptacle Figure 24 240V Receptacle 12 The L14 30R receptacle is a dual voltage receptacle 120 240 volts Reference Figure 25 and Figure 26 to verify voltages at this receptacle NOTICE When using a combination of dual receptacles total load should not exceed the rated capacity of the generator Figure 25 120 240V Receptacle 120V Figure 26 120 240V Receptacle 240V 13 Connecting of loads...

Page 28: ...FF 3 Place idle control switch Figure 29 in theOFFposition Figure 29 Idle Control Switch OFF 4 Let engine run at idle with no load for 2 3 minutes 5 To shut down the engine place the generator s operation switch Figure 30 in the OFF position Figure 30 Operation Switch OFF 6 Remove all loads from the generator OFF OFF TEST S N 5681188 AND BELOW S N 5681189 AND ABOVE OFF 20A 30A 30A for 120V for 120...

Page 29: ...TA BIL to the fuel Run the engine until the gasoline in the carburetor is completely consumed Completely drain the oil from the crankcase and refill with fresh oil Remove the spark plug pour 2 or 3 cc of SAE 30 oil into the cylinder and crank slowly to distribute the oil Crank the engine a few times and install a new spark plug Clean all external parts of the generating set with a cloth Cover the ...

Page 30: ... 200 HRS Engine Oil CHECK X CHANGE Air Cleaner CHECK X X CHANGE X 1 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 Filter CHECK X Idle Speed CHECK ADJUST X 2 Valve Clearance CHECK ADJUST X 2 Fuel lines CHECK Every 2 years replace if necessary 2 1 Service more frequently when used in DUSTY areas 2 These items ...

Page 31: ...ear and tightness Tighten all hose clamps and check fuel or leaks 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 clean the fuel strainer Figure 31 with solvent Figure 31 Fuel Strainer SPARK PLUG 1 Remove and clean the spark plug Figure 32 then adjus...

Page 32: ...TH THIN LAYER OF OIL OIL FILTER MOUNTING BASE CLEAN HAND TIGHTEN A B C MAINTENANCE 5 Screw on new oil filter by hand Figure 35B until seal contacts the filter mounting base 6 Using an oil filter socket tool Figure 35C tighten filter and additional 3 4 inch turn Tighten filter to 9 ft lbs 12 N m 7 Install drain bolt with sealing washer and tighten securely 8 Replace engine oil with recommended type...

Page 33: ...the possibility exists of fire or explosion which can cause damage to the equipment and severe bodily harm or even DEATH AIR CLEANER COVER LATCH AIR CLEANER CASE PACKING FOAM FILTER ELEMENT PAPER FILTER ELEMENT AIR CLEANER COVER WING NUT AIR CHAMBER Figure 38 Cleaning Inner Paper Filter 6 Clean foam element Figure 39 in warm soapy water or non flammable solvent Rinse and dry thoroughly 7 Next dip ...

Page 34: ...by keeping the tank full with fuel IN LINE FUEL FILTER GA 9 7H FUEL DRAIN PLUG REMOVE MAINTENANCE CLEANING INSIDETHE FUELTANK 1 If necessary drain the fuel inside the fuel tank completely Using a spray washer Figure 42 wash out any deposits or debris that have accumulated inside the fuel tank Figure 42 Fuel Tank Cleaning FUELTANK INSPECTION In addition to cleaning the fuel tank the following compo...

Page 35: ...cuit perform this test with no load 1 Start the generator as outlined in the start up procedure in this manual 2 Place the main circuit breaker Figure 45 in the ON position Figure 45 Circuit Breaker ON GFCI Test MUFFLER SPARK ARRESTER RETAINING SCREW SPARK ARRESTER SCREEN WIRE BRUSH OFF ON 3 On the GFCI module Figure 46 verify that the green POWER LED is ON Figure 46 GFCI Module Green LED ON 4 Als...

Page 36: ...ON Figure 51 GFCI Module Green LED ON Reset ON OFF 120 240 V MANUAL RESET P O W E R F A U L T PRESS GREEN POWER LED MAINTENANCE 9 Verify that the AC voltmeter is registering a voltage reading as indicated by Figure 52 Figure 52 AC Voltmeter 120 240V 120 240 V NOTICE It is recommended that the GFCI unit be tested when the generator is initially taken out of the box Then the generator should be test...

Page 37: ...GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 PAGE 37 NOTES ...

Page 38: ...PAGE 38 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 GENERATOR WIRING DIAGRAM S N 5681188 AND BELOW ...

Page 39: ...GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 PAGE 39 GENERATOR WIRING DIAGRAM S N 5681189 AND ABOVE ...

Page 40: ...rk plug and compression is normal Wrong fuel type Flush fuel system and replace with correct type of fuel Water or dust in fuel system Flush fuel system Air cleaner dirty Clean or replace air cleaner Difficult to start Fuel is available SPARK is present at the spark plug and compression is low Suction exhaust valve stuck or protruded Reseat valves Piston ring and or cylinder worn Replace piston ri...

Page 41: ...defective Replace ignition coil Engine overheats Spark plug heat value improper Replace with correct type of spark plug Incorrect type of fuel Replace with correct type of fuel Cooling fins dirty Clean cooling fins Rotational speed fluctuates Governor adjusted correctly Adjust governor Governor spring defective Replace governor spring Fuel flow restricted Check entire fuel system for leaks or clog...

Page 42: ...will not turn on NO LOAD Defective circuit breaker Replace circuit breaker Circuit breaker will turn on LOADED but trips immediately Overload Condition Reduce load or replace breaker Load circuit is shorted Check load circuit for short Does not accelerate from low to high NO LOAD Stuck solenoid Check solenoid Bad Idle control switch Check or replace idle control switch Does not accelerate from low...

Page 43: ...GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 PAGE 43 NOTES ...

Page 44: ...s 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 Column Numbers Used Item quantity can be indicated by a number a blank entry or A R A R As Required is generally used for hoses or other parts that are sold in bulk and cut to length A blank entry ge...

Page 45: ...4 CIRCUIT BREAKER 1P 30A 1 0601806423 CIRCUIT BREAKER 1P 20A 1 0601800699 HOUR METER 1 0601830771 IDLE CONTROL SWITCH 1 0601830799 OPERATION SWITCH 1 0602100102 START SWITCH 2 A9924800104 CAP FUEL TANK 2 0605505120 FUEL FILTER TANK 1 0602125032 GAUGE FUEL 2 0805083204 SUSPENSION RUBBER 2 A6415800004 SUSPENSION RUBBER NOTICE S N 5681188 AND BELOW S N 5681189 AND ABOVE S N 5681197 AND ABOVE HONDA GX...

Page 46: ...tall use or service this equipment S 4985 DANGER Do not touch output terminals or internal wiring while unit is operating Turn off power before servicing Only qualified personnel should install use or service this equipment ELECTRICAL SHOCK HAZARD CAUTION OPERATE AT 3600 RPM ONLY FULL THROTTLE DAMAGE MAY RESULT IF OPERATED AT LOWER SPEEDS WARNING B e f o r e c o n n e c t i n g t h i s g e n e r a...

Page 47: ...0420000 11 A9504000014 DECAL DANGER CARBON MONOXIDE 1 A90400001 7 D9531100104 DECAL DANGER ELECTROCUTION 1 D93110010 8 W0800689404 DECAL 1 S 2090 9 W0800689504 DECAL 1 S 2091 10 B9504000304 DECAL CAUTION HOT PARTS 1 B90400030 11 D2552000404 DECAL OPERATING INSTRUCTIONS 1 D25200040B 12 A6551000504 DECAL OPERATION SWITCH 1 A65100050 13 A9511100103 DECAL WARNING 1 A91110010 14 A6561000903 DECAL MQ PO...

Page 48: ...PAGE 48 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 GA9 7HEA GENERATOR ASSY ...

Page 49: ...0000 WASHER LOCK 1 6 A6136000103 ARMATURE ASSY 1 S N 5681188 AND BELOW 6 A6135000503 ARMATURE ASSY 1 S N 5681189 AND ABOVE 7 A6155100102 END BRACKET 1 8 A6155000002 END BRACKET 1 9 A6133300003 COVER STATOR 1 10 A6133500004 SET BOLT STATOR 4 11 0040008000 WASHER LOCK 4 12 0401450080 WASHER FLAT 4 REPLACES P N 0041208000 13 7871329514 GROMMET 1 14 A6155400104 COVER BEARING 1 15 0027105012 MACHINE SC...

Page 50: ...PAGE 50 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 GA9 7HEA CONTROL BOX ASSY S N 5681188 AND BELOW ...

Page 51: ...ES P N 0601811035 18 0601814024 RECEPTACLE 5 20R GF20LA 120V 20A 2 REPLACES P N 0601814013 19 0021004010 MACHINE SCREW 10 19A OEMAA8 HEX NUT 10 REPLACES P N 0207004000 20 0601806425 CIRCUIT BREAKER 2P 250V 30A 1 21 0601806036 CIRCUIT BREAKER 2P 250V 20A 1 22 0601806424 CIRCUIT BREAKER 1P 250V 30A 1 23 0601806423 CIRCUIT BREAKER 1P 250V 20A 2 24 0027103005 MACHINE SCREW 10 25 0601830771 IDLE CONTRO...

Page 52: ...PAGE 52 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 GA9 7HEA CONTROL BOX ASSY S N 5681189 AND ABOVE ...

Page 53: ... 20A 1 22 0601806424 CIRCUIT BREAKER 1P 250V 30A 1 23 0601806423 CIRCUIT BREAKER 1P 250V 20A 2 24 0027103005 MACHINE SCREW 10 25 0601830771 IDLE CONTROL SWITCH 1 26 0601830799 OPERATION SWITCH 1 27 0602100102 START SWITCH 1 28 0021004015 MACHINE SCREW 1 29 0601823853 IDLE CONTROL DEVICE 1 30 0021004010 MACHINE SCREW 2 31 Y0016905012 HEX HEAD BOLT 4 32 0016906020 HEX HEAD BOLT 4 33 0601802137 FUSE ...

Page 54: ...PAGE 54 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 GA9 7HEA PIPE FRAME ASSY ...

Page 55: ...X NUT 3 15 0012308030 HEX HEAD BOLT 2 16 A6424400003 BRACKET 1 16 1 A6498200004A LINING 1 REPLACES P N A6498200004 17 0016906015 HEX HEAD BOLT 8 18 A6418400304 AIR GUIDE 1 19 0016906015 HEX HEAD BOLT 2 20 A6435300003D HANGER 1 REPLACES P N A6435300003 21 0017110025 HEX HEAD BOLT 4 22 A6355400103 CHOKE CABLE 1 23 A6355200104 BRACKET 1 24 0016906015 HEX HEAD BOLT 1 25 Y0605507003 CANISTER 1 S N 5753...

Page 56: ...PAGE 56 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 GA9 7HEA BATTERY ASSY ...

Page 57: ... SHEET 1 33 D1343200204 BATTERY BAND 1 34 0805082704 BATTERY BOLT 2 35 0037806000 WING NUT 2 36 0040006000 WASHER LOCK 2 37 952404470 WASHER FLAT 2 REPLACES P N 0041206000 38 0802276803 TERMINAL CAP RED 1 38A 0845041304 TERMINAL CAP BLK 1 REPLACES P N 0602220601 43 Y0165103819 BATTERY 12 VOLT 1 NEUTON 38B19R GA9 7HEA BATTERY ASSY ...

Page 58: ...PAGE 58 GA9 7HEA 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 09 18 19 GA9 7HEA ENGINE SERVICE PARTS 2 1C 1A 3 4 HONDA GX630 1B 1 ...

Page 59: ... INCLUDES ITEMS W 1A 17218Z6L0001 AIR FILTER OUTER FOAM 1 REPLACES P N 17218Z6L000 1B 17232Z2E000 GROMMET 1 1C AIR FILTER INNER 1 NOT SOLD SEPARATELY 2 16910Z6L003 IN LINE FUEL FILTER 1 3 980795587GA SPARK PLUG ZFR5F 1 REPLACES P N 980795587G 4 15400PLMA01PE OIL FILTER CARTRIDGE 1 REPLACES P N 15400RTA004 GA9 7HEA ENGINE SERVICE PARTS ...

Page 60: ...a contained in this manual 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 Manufactured for MQ Power Inc by DENYO MANUFACTURING CO HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER O...

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