MULTIQUIP GDP-5H Operation And Parts Manual Download

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OPERATION AND PARTS MANUAL

Revision #2 (10/05/05)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

MODEL GDP-5H

High Cycle Generator

(HONDA GASOLINE ENGINE)

Summary of Contents for GDP-5H

Page 1: ...OPERATION AND PARTS MANUAL Revision 2 10 05 05 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES MODEL GDP 5H High Cycle Generator HONDA GASOLINE ENGINE...

Page 2: ...PAGE 2 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05...

Page 3: ...ademarks 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 ThismanualMUSTa...

Page 4: ...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...

Page 5: ...37 3700 FAX 310 637 3284 MAYCO PARTS 800 306 2926 FAX 800 672 7877 310 537 3700 FAX 310 637 3284 SERVICE DEPARTMENT 800 421 1244 FAX 310 537 4259 310 537 3700 TECHNICAL ASSISTANCE 800 478 1244 FAX 310...

Page 6: ...DP 5H Portable Generator will be referenced with Hazard Symbols which appear throughout this manual and will be referenced in conjunction with Safety Message Alert Symbols Engine exhaust gases contain...

Page 7: ...TION CAUTION CAUTION Eye and Hearing Hazards CAUTION CAUTION CAUTION CAUTION CAUTION Other important messages are provided throughout this manual to help prevent damage to your portable generator othe...

Page 8: ...hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or generator ALWAYS wear proper respiratory mask hearing and eye protection equipment when operating the gene...

Page 9: ...re that electrical circuits are properly grounded per the National Electrical Code NEC and local codes before operating generator Severe injury or death by electrocution can result from operating an u...

Page 10: ...n emergency DANGER DANGER DANGER DANGER DANGER ELECTROCUTION HAZARDS ELECTROCUTION HAZARDS ELECTROCUTION HAZARDS ELECTROCUTION HAZARDS ELECTROCUTION HAZARDS Duringoperationofthisgeneration there exist...

Page 11: ...ble 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...

Page 12: ...i t a t i c x E m e t s y S d e t i c x E y l l a c i t a t S e t a t S d i l o S d e e p S M P R 0 0 6 3 m e t s y S g n i l o o C n o i t a l i t n e V f l e S y t i c a p a C l e u F s r e t i l 9...

Page 13: ...e n i l o s a G t f a h S l a t n o z i r o H e n i g n E e k o r t S X e r o B n i 0 3 2 X n i 0 9 2 m m 8 5 x m m 3 7 t n e m e c a l p s i D m c 9 8 3 n i u c 0 7 3 2 3 t u p t u O x a M M P R 0 0...

Page 14: ...PAGE 14 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 GDP 5H DIMENSIONS Figure 2 Dimensions...

Page 15: ...itation System 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...

Page 16: ...2 KW generator 3 LARGE MOTORS Submersible pumps table saws etc Total the running wattage and multiply by 3 Example A conveyor belt runs at 8 KW use a 24 KW generator Extension Cables When electric po...

Page 17: ...eakage breaker s earth leakage detection sensitivity is 30 mA and the actuation time is 0 1 sec How to Use Always conduct the following in order that the earth leakage breakerwilloperatesafely Also if...

Page 18: ...d 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 an...

Page 19: ...gures 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 full rated power of the generator at 120 volts f...

Page 20: ...er when starting a cold engine or in cold weather conditions The choke enriches the fuel mixture Open the choke lever if starting a warm engine or in warm weather conditions 17 Recoil Starter pull rop...

Page 21: ...ashadanopportunity tocooldown Intheeventofafuelspill DONOT attempt to start the engine until the fuel residue has been completely wiped up and the area surrounding the engineisdry Ifgeneratorisplacedi...

Page 22: ...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 generato...

Page 23: ...y Connect the other end of the ground cable to a suitable earth ground ground rod GDP 5H INSTALLATION Figure 6 Generator Grounding Some of the MQ GDP5H portable generators S N 5541050 and below have b...

Page 24: ...e l b a T n I t n e r r u C s e r e p m A s t t a W n I d a o L h t g n e L e l b a C e l b a w o l l A m u m i x a M s t l o V 0 2 1 s t l o V 0 4 2 e r i W 0 1 e r i W 2 1 e r i W 4 1 e r i W 6 1 5...

Page 25: ...e10 todeterminifthefuellevelislow Iffuelislow replenishwith clean unleaded fuel Engine Oil Check 1 Tochecktheengineoillevel placethegeneratoronsecure level ground with the engine stopped 2 Remove the...

Page 26: ...the choke lever Figure 13 in the OPEN position if starting a warm engine or the temperature is warm 4 Placethegenerator ON OFFswitch Figure14 inthe ON position 5 Graspthestartergrip Figure15 andslowly...

Page 27: ...lacing the idle control switch in the OFF position Figure 16 allows the enginetooperateatamaximum speed of about 3600 RPM s When the idle control switch is placed in the up position ON Figure 17 the g...

Page 28: ...down position you can take up to halfoftheratedpowerofthegenerating set at 120 volts from the GFCI duplex receptacle and up to half of the rated power of the set at 120 volts from the 120V twist lock...

Page 29: ...lowly 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...

Page 30: ...y r a s s e c e N X g u l P k r a p S N A E L C K C E H C X E C A L P E R X s n i F g n i l o o C K C E H C X r e t s e r r A k r a p S N A E L C X k n a T l e u F N A E L C X r e t l i F l e u F K C...

Page 31: ...o adjustments ENGINEOIL 1 Drain the engine oil when the oil is warm as shown in Figure 30 2 Remove the oil drain bolt and sealing washer and allow the oil to drain into a suitable container 3 Replace...

Page 32: ...PAGE 32 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 GDP 5H WIRING DIAGRAM GENERATOR S N 5541049 AND BELOW Figure 32 Generator Wiring Diagram S N 5541049 and below...

Page 33: ...GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 PAGE 33 GDP 5H WIRING DIAGRAM GENERATOR S N 5543731 AND ABOVE Figure 33 Generator Wiring Diagram S N 5543731 and above...

Page 34: ...h g i h n e k o r b t i n u n o i t i n g i r o t s i n a r T d e l u o f f i g u l p k r a p s e c a l p e R n e k o r b h c t i w s p o t S t r a t S l i o o N d e r i u q e r s a l i o d d A s k n...

Page 35: ...k r a p s g n o r W g u l p k r a p s e p y t d e t s e g g u s s e r u t c a f u n a m h t i w g u l p k r a p s e c a l p e R y l s u o i n i t n o c s i r o l o c t s u a h x E E T I H W g n o r w...

Page 36: ...c r i c e v i t c e f e D r e k a e r b t i u c r i c e c a l p e R n o n r u t l l i w r e k a e r b t i u c r i C y l e t a i d e m m i s p i r t t u b D E D A O L n o i t i d n o C d a o l r e v O...

Page 37: ...GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 PAGE 37 NOTE PAGE...

Page 38: ...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...

Page 39: ...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 REC...

Page 40: ...PAGE 40 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 GDP 5H NAMEPLATE AND DECALS...

Page 41: ...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 A9212...

Page 42: ...PAGE 42 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 GDP 5H GENERATOR ASSY GENERATOR ASSY...

Page 43: ...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 00171080...

Page 44: ...PAGE 44 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 GDP 5H CONTROL BOX ASSY CONTROL BOX ASSY...

Page 45: ...12598 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 0207...

Page 46: ...PAGE 46 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 GDP 5H MUFFLER ASSY MUFFLER ASSY...

Page 47: ...RRESTOR 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 0602...

Page 48: ...PAGE 48 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 GDP 5H PIPE FRAME ASSY PIPE FRAME ASSY...

Page 49: ...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 0605515...

Page 50: ...PAGE 50 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE AIR CLEANER ASSY AIR CLEANERASSY...

Page 51: ...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 A...

Page 52: ...PAGE 52 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE CAMSHAFT ASSY CAMSHAFT ASSY...

Page 53: ...14431ZE2010 ARM VALVE ROCKER 2 4 14441ZE2000 LIFTER VALVE 2 5 14451ZE1013 PIVOT ROCKER ARM 2 6 14568ZE1000 SPRING WEIGHT RETURN 1 7 14711ZE3000 VALVE IN 1 8 14721ZE3000 VALVE EX 1 9 14751ZE2003 SPRING...

Page 54: ...PAGE 54 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE CARBURETOR ASSY CARBURETOR ASSY...

Page 55: ...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 CONTRO...

Page 56: ...PAGE 56 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 CONTROL ASSY HONDA GX340K1EDN2 ENGINE CONTROL ASSY...

Page 57: ...00 ROD GOVERNOR 1 4 16561ZE3000 SPRING GOVERNOR 1 5 16562ZE3700 SPRING THROTTLE RETURN 1 9 16570ZE3700 CONTROL ASSY 1 INCLUDES ITEMS W 19 16584883300 SPRING CONTROL ADJUSTING 1 23 90013883000 BOLT FLA...

Page 58: ...PAGE 58 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE CRANKCASE COVER ASSY CRANKCASE COVER ASSY...

Page 59: ...003 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 GOVERNORWEIGHT 1 10 16513ZE2000 PIN...

Page 60: ...PAGE 60 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 CRANKSHAFT ASSY HONDA GX340K1EDN2 ENGINE CRANKSHAFT ASSY...

Page 61: ...ION MANUAL REV 2 10 05 05 PAGE 61 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 HONDA GX...

Page 62: ...PAGE 62 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE CYLINDER BARREL ASSY CYLINDER BARREL ASSY...

Page 63: ...L 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 91201ZE3004 OIL SEAL 35X52...

Page 64: ...PAGE 64 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE CYLINDER HEAD ASSY CYLINDER HEAD ASSY...

Page 65: ...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 11 900...

Page 66: ...PAGE 66 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE FAN COVER ASSY FAN COVER ASSY...

Page 67: ...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 BO...

Page 68: ...PAGE 68 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE FLYWHEEL ASSY FLYWHEEL ASSY...

Page 69: ...REV 2 10 05 05 PAGE 69 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...

Page 70: ...PAGE 70 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE IGNITION COIL ASSY IGNITION COIL ASSY...

Page 71: ...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 3610...

Page 72: ...PAGE 72 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE PISTON ASSY PISTON ASSY...

Page 73: ...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 PISTO...

Page 74: ...PAGE 74 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE RECOIL STARTER ASSY RECOIL STARTERASSY...

Page 75: ...ZB 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 RATC...

Page 76: ...PAGE 76 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE SOLENOID ASSY SOLENOIDASSY...

Page 77: ...PAGE 77 SOLENOIDASSY 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 93500050...

Page 78: ...PAGE 78 GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 HONDA GX340K1EDN2 ENGINE LABELS ASSY LABELS ASSY...

Page 79: ...ION MANUAL REV 2 10 05 05 PAGE 79 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 1...

Page 80: ...tisnotacceptable 8 Suchmaterialwillbeheldforfiveworking days from notification pending instruc tions Ifareplyisnotreceivedwithinfive days thematerialwillbereturnedtothe senderathisexpense 9 Creditonre...

Page 81: ...GDP 5H A C GENERATOR PARTS OPERATION MANUAL REV 2 10 05 05 PAGE 81 NOTE PAGE...

Page 82: ...3700 FAX 310 637 3284 MAYCO PARTS 800 306 2926 FAX 800 672 7877 310 537 3700 FAX 310 637 3284 SERVICE DEPARTMENT 800 421 1244 FAX 310 537 4259 310 537 3700 TECHNICALASSISTANCE 800 478 1244 FAX 310 631...

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