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MULTIQUIP GA-Series, Service Manual

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SCHEMATICS 

○ TEST PROCEDURES ○ MAINTENANCE SPECS 

Manual No. GAGENSM 

SERVICE 

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Updated 10/20/15 

Summary of Contents for GA-Series

Page 1: ...G GA A S SE ER RI IE ES S G GE EN NE ER RA AT TO OR RS S SCHEMATICS TEST PROCEDURES MAINTENANCE SPECS Manual No GAGENSM SERVICE M MA AN NU UA AL L Updated 10 20 15 ...

Page 2: ...cer birth defects and other reproductive harm Some examples of these chemicals are Lead and lead based paint Crystalline silica from bricks Cement and other masonry products Arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals ALWAYS work in a well ventilated area and wor...

Page 3: ...generators You must be familiar with the operations of the GA series generator before attempting to troubleshoot or make repairs Basic operating and maintenance procedures are described in the operation and parts manual supplied with the generator Use the supplied manual to order replacement parts If you are missing the operation and parts manual please contact Multiquip Inc to order a replacement...

Page 4: ... TEST PROCEDURES Excitation 12 Diode Rectifier 13 Stator 14 Rotor 15 GENERATOR TIPS Current Flow Diagram 16 Rotor Removal Tips 17 GFCI 18 Flashing the Field 19 Circuit Breakers Short Circuits 20 Meg Ohm Meter 21 ENGINES Index 22 37 WIRING SCHEMATICS GA 2 5HR 38 GA 2 9R 39 GA 3 6HR 40 GA 4 5R 41 GA 6HR 42 GA 6HRS 43 GA 6REA 44 C CO ON NT TE EN NT TS S GA 9 7HEA 45 ...

Page 5: ... Intake 003 Exhaust 005 Intake 006 Exhaust 008 Intake 003 Exhaust 005 Intake 006 Exhaust 008 Air Filters 50 hrs 50hrs 50 hrs 50 hrs 50 hrs Generator End Brushless No maintenance required Always review and follow detailed maintenance service instructions as provided in the equipment manual GA6R GA9 7HEA Engine Model Robin EH6 Honda GX630 Horse Power 11 20 8 Engine RPM Hi speed rated under load High...

Page 6: ...have a 60 cps current to time it If the current is 61 cps the engine would run at 3 660 61 cycles x 60 seconds rpm Having a volt ohm meter VOM that accurately measures alternating current is a must when servicing generators The first step in generator troubleshooting is to conduct a visual inspection before doing any electrical tests Looking the generator over carefully should expose any environme...

Page 7: ...a community inside the generator Their nests and debris can cause electrical shorts Generators left out in the elements such as for running water wells provide a nice home for critters such as spiders wasps and mice 6 Loose bolts screws and fasteners This condition will either prevent full time service or give intermittent service depending on the situation 7 Problems in quick disconnect connector...

Page 8: ...ked on the generator before you 12 Fuses circuit breakers and ground fault interrupts These can easily be tested with a volt ohm meter After conducting a thorough physical inspection of the generator replace the cover and start the engine Take voltage readings on all the receptacles What are they Does a 120V AC receptacle read 128V AC Is this bad Normally it isn t Lower voltages are more detriment...

Page 9: ...from the full wave diode rectifier via wires J K to excitation winding which are located in the stator This produces a magnetic field in the stator 5 Rotor creates AC and is converted to DC see page 15 Excitation windings on the rotor pass through the magnetic field of the stator creating AC voltage AC voltage in the rotor is then converted to DC voltage by use of full wave diode rectifiers mounte...

Page 10: ...itch Defective diode rectifier Check diode rectifier see pg 13 Defective slowdown unit Check slowdown unit see pg 27 High speed out of adjustment Adjust to specification Engine does not idle down all the way Governor out of adjustment Check governor is adjusted correctly and linkage is not obstructed Carburetor out of adjustment Check carburetor is adjusted correctly and tension spring is not obst...

Page 11: ... Check or replace clogged air filter Intake valve stuck open or closed Inspect valves and valve clearance No spark Check condition of spark plug and ignition coil Inspect wires to the on off switch Engine backfires Defective anti backfire solenoid Check solenoid see pg 24 Engine runs good at no load but bogs down when loads are applied Engine speed is to low Raise engine speed to rated RPM Generat...

Page 12: ...Volts Honda GX Series Green White to Green White 23 Volts Robin EH Series Green White to Green White 23 Volts Robin EX Series One set of charge coil wires is for excitation One set is for the idle control slowdown AC voltage is produced from charge coils and permanent magnets which are located on the flywheel of the engine Check voltage output with engine running Disconnect the charge coil leads b...

Page 13: ...low 12 18V DC ALL Diode Rectifier Continuity To properly check continuity you must disconnect un solder or isolate the leads connected to the Diode Check for continuity no continuity as shown below Yellow Wires The Diode Rectifier supplies DC voltage to the stator To check Diode voltage output disconnect the J K wires at the harness that are connected to the stator with yellow wires The two yellow...

Page 14: ...U to V 6 Ω GA 2 5 GA 2 9 U1 to V1 25 Ω GA 3 6 GA 4 5 U1 to V1 16 Ω GA 6 U to V 4 Ω GA 9 7 Excitation Windings Resistance Model J to K 1 46 Ω GA 2 5 GA 2 9 1 63 Ω GA 3 6 GA 4 5 GA 6 1 8 Ω GA 9 7 Battery Charging Windings Resistance Model A to B 1 Ω GA 6 GA 9 7 The GA series stators have output wires that lead from the inner stator windings which provide 120V AC output and lead to a circuit breaker ...

Page 15: ... Rotor This brushless designed rotor has integrated diode rectifiers When the rotor rotates in the stator AC voltage is generated in the rotor windings The AC voltage is sent to the diode rectifiers located on the rotor and is converted to DC voltage producing a rotating magnet While the rotating magnet field passes through the main windings located in the stator this produces AC Voltage 120V AC ...

Page 16: ...tor Stator Receptacle Circuit Breaker C CU UR RR RE EN NT T F FL LO OW W D DI IA AG GR RA AM M NOTE Current flow diagram represents the basic flow in the generator and does not include controls example Idle control switch and slowdown module RC see pg 27 120 240 power switch see operation and parts manual for specific model ...

Page 17: ...Take a piece of brass and squarely put it up against the end of the crankshaft nut and rap it with a 3 lb hammer to shock the tapered connection apart Fig 3 B d Rock the rotor assembly back and forth if it moves independently of the crankshaft it can be removed if not repeat steps 6 C D if needed Please Note The following procedure will require the purchase of a new set bolt for re assembly save t...

Page 18: ...it breakers are designed to protect equipment and power lines by reacting to excessive current flow normally in the order of 15 to 20 amps 5 GFCI s are designed to protect people by reacting to leakage currents to ground in the order of 005 amps Except in the case of GFCI circuit breaker combinations sold to be installed in building installations they are separate devices performing separate funct...

Page 19: ...lds In some cases a generator that has been out of service for an extended period may lose its residual magnetism and require flashing Residual magnetism is restored by flashing the field thereby causing a current surge in the generator This type of generator relies on the residual magnetism stored in the armature to produce the needed voltage to create the magnetic field to complete the generator...

Page 20: ...be reset either manually or automatically to resume normal operation NOTE always place the main circuit breaker in the OFF position prior to starting the engine A short circuit sometimes abbreviated to short or s c in an electrical circuit is one that allows a current to travel along a different path from the one originally intended The electrical opposite of a short circuit is an open circuit whi...

Page 21: ...t a good insulation has the ability to keep a high resistance A suitable way of measuring resistance can tell us how good the insulation is Also if regular insulation measurements are made you can track trends towards its deterioration Causes of Bad Insulation When generators welders and electric motors are new the insulation should be at its highest level of resistance During equipment use insula...

Page 22: ...ors The following information is to provide the service technician with a base level of knowledge on engine maintenance For more on engine repairs see engine manufacturer s service manual HONDA Carburetor 32 Ignition Coil 33 Oil Level Switch 34 Engine Part Details Carburetors 23 Anti Back Fire Solenoid 24 Spark Plugs 25 26 Slowdown Module RC 27 Engine Maintenance Engine Maintenance 28 Oil Leaks 29...

Page 23: ...ld your carburetor Does the engine run well under load does it idle ok does the governor hunt Is the carburetor in usable condition throttle shafts linkages loose After removing the bowl do you have water corrosion varnish or dirt Is there any sign of warpage on the mounting surfaces Is the float and bowl ok are they pitted and possibly leaking Is the carburetor leaking fuel while just setting pos...

Page 24: ...the solenoid a magnetic field is created This magnetic force in the coil overcomes the spring force holding the pintle inward The pintle now is pushed outward by the magnetism blocking the fuel jet orifice in the carburetor The blockage of this orifice prevents fuel from being drawn into the engine during rundown Summary of Circuit Function The power source for this circuit comes from the engine a...

Page 25: ...tery support for the parts that conduct electricity Terminal place where a current conducting wire is attached Spline hollow channel Resistance device that controls the strength of the current Ground electrode current device that unites the electrodes Spark plug gap space separating the current conductors Center electrode central current conductor Gasket spot where two part join together Spark plu...

Page 26: ... Lead deposits on the insulator nose These are usually a yellowish brown in color Lead content of petrol used is too high Try petrol with a lower lead content BREAKAGE Physical damage to the insulator nose Usually caused by abnormal thermal expansion in the combustion chamber Maybe thermal heating or cooling shock Causes as for overheating above NORMAL LIFE Growth of the plug gap during a plug s w...

Page 27: ...ation When the idle control switch is in the on position the RC is activated and sends voltage to the idle control solenoid causing the solenoid to pull the engine throttle to idle speed lower RPM Generator output wires pass through the center of the RC before reaching the receptacles When voltage is used from one of the receptacles the RC senses the activity and cuts the voltage to the idle contr...

Page 28: ... and Robin engines are designed with systems built in to prevent such things as dirt from entering the engine or keeping the engine from overheating while it is running These systems work very well but do require periodic maintenance to be performed on them Start out right by reading your owners manual before you operate the engine Here s a list of things that you can do to give your engine a long...

Page 29: ...or pinhole in the crankcase The latter would normally have showed up when the unit was new though How high on the engine is the fresh oil Could it possibly be a blown head gasket or loose oil fill plug Does the engine smoke badly It could mean internal wear or possibly crankcase pressure All modern engines run with a slight vacuum in the crankcase This is maintained by the crankcase breather valve...

Page 30: ...age can cause even a new engine to have a valve stick in the open position You must have a good spark to fire the fuel mixture once it is in the cylinder A good way to test for spark if you don t have a tester is to take an old spark plug and cut the electrode off so the spark has to jump from the center to the side of the plug Lay the plug on the engine so that it can ground and spin the engine I...

Page 31: ...er 2 Always put the engine in storage with at least a half tank of fresh treated fuel in it 3 Run the engine for 10 minutes after treating the fuel so that the stabilizer gets into the entire fuel system 4 Start the unit up every month or two to keep fresh fuel in the carburetor during the season Fuel does evaporate from the carburetor The important thing to understand is that gasoline does not do...

Page 32: ...he jet and float bowl 4 Use a cabinet screwdriver to remove the main jets to reduce the possibility of damaging the threads Good Bad This is what they re supposed to look like Each hole is precisely sized and shaped and your goal is to clean them out without reshaping them Carburetor jets are brass and they need to be treated with care and respect Here s a cross section of a jet The orifice has tr...

Page 33: ...tested by inspection see below Air Gap Adjustment Specification GX Series 160 240 340 610 0 4 0 2 mm 15 007 in Inspection Remove and isolate the ignition coil to be tested Primary side Secondary side Flywheel Ignition coil Air gap Measure the resistance by attaching the ohm meter lead to the ignition coils primary black lead while touching the other test lead on the iron core Resistance Specificat...

Page 34: ...ad infinity resistance 3 Inspect the float by dipping the switch into a container of oil The ohmmeter should go from zero to infinity as the switch is lowered Inspection Check the continuity between the switch and switch body with an ohmmeter A clogged or stuck oil level switch will allow the engine to run without or with a low oil level which can cause damage to the engine An engine with sludge o...

Page 35: ...p between the coil and the flywheel The only time air gap needs to be set is if it has been removed or tampered with There are adjustment slots on the coil to allow for up and down movement on the coil NOTE ohmmeter resistance data for the Robin ignition coil is N A at time of publishing Air Gap Adjustment Specification EX EH series engine 0 3 0 5 mm 012 020 in ...

Page 36: ...by lack of maintenance can cause an oil level switch to stick Checking oil level prior to running the engine is good maintenance practice as well as changing engine oil frequently Construction and Operation The oil sensor is composed of the float permanent magnet incorporated into the float and oil sensor In accordance with the oil level the float moves up and down When the oil is at the upper lev...

Page 37: ...nual No GAGENSM E EN NG GI IN NE E M MA AN NU UF FA AC CT TU UR RE ER R S S C CO ON NT TA AC CT T I IN NF FO OR RM MA AT TI IO ON N Honda Engines 678 339 2600 Website engines honda com Robin America 847 540 7300 Website www subarupower com ...

Page 38: ...G A 2 5 H R WI R I N G D I A G R A M ...

Page 39: ...PAGE 28 MQ GA 2 9R A C GENERATOR OPERATION PARTS MANUAL REV 0 10 28 04 Generator EngineWiring Diagram GA 2 9R WIRING DIAGRAM ...

Page 40: ...G A 3 6 H R WI R I N G D I A G R A M ...

Page 41: ...PAGE 30 GA 4 5R GA 4 5RA A C GENERATOR OPERATION PARTS MANUAL REV 1 11 27 06 Generator EngineWiring Diagram GA 4 5R WIRING DIAGRAM GA 4 5R ...

Page 42: ...G A 6 H R WI R I N G D I A G R A M ...

Page 43: ...G A 6 H R S WI R I N G D I A G R A M ...

Page 44: ...GA 6RE GA 6REA A C GENERATORS OPERATION PARTS MANUAL REV 0 06 06 05 PAGE 33 GA 6REA GeneratorWiring Diagram GA 6REA WIRING DIAGRAM GENERATOR ...

Page 45: ...IELD WINDING EXCITATION WINDING AC VOLTMETER RECTIFIER RECEPTACLE 120V 240VJ RECEPTACLE 2 4 OVJ RECEPTACLE 120VJ RECEPTACLE 120V GFCI CIRCUIT BREAKER GFCI for MAIN CIRCUIT BREAKER I 20V 240V 30A CIRCUIT BREAKER 240V 20Al CIRCUIT BREAKER 120V 30Al CIRCUIT BREAKER 120V 20Al IDLE CONTROL SWITCH OPERATION SWITCH START SWITCH IDLE CONTROL DEVICE SOLENOID RELAY FUSE RESISTOR rilil l3TITil tm J t m D 1 C...

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