MULTIQUIP GA-Series Manuel utilisateur

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SCHEMATICS ○TEST PROCEDURES ○MAINTENANCE SPECS

Manual No. GAGENSM

SERVICE

Updated 10/20/15

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

Proposition 65 Warning:

Engine exhaust and some of its constituents, and some dust created by power

sanding, sawing, grinding, drilling and other construction activities contains

chemicals known to the State of California to cause cancer, 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 work with approved safety equipment, such as dust mask

that are specially designed to filter out microscopic particles.

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

Read the operator's manual for safety instructions before you attempt to troubleshoot. Use extreme

caution when troubleshooting power equipment. Never start or run power equipment inside a closed

area, breathing exhaust fumes can kill.

Basically, a tool is an object that enables you to take advantage of the laws of physics and mechanics

in such a way that you can seriously injure yourself.

This service manual is intended to provide information and procedures to safely maintain, repair and

give a basic understanding of service techniques for the GA series 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 or

you may visit our website at service.multiquip.com

For your safety and the safety of others carefully read, understand and observe all instruction

described in this manual.

THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON GA-SERIES GENERATORS

MANUFACTURED UP TO THE TIME OF PUBLICATION. MULTIQUIP INC. RESERVES THE RIGHT

TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE.

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

Maintenance Specifications…………………………………….…………………5

Inspection…………………………………………………………………………6-8

How AC Voltage is Produced……………………………………………………..9

TROUBLESHOOTING

Troubleshooting………………………………….………………………….…10-11

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

GA-9.7HEA …………………………………………………………………..…..45

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

GA2.5HR GA2.9RGA3.6HR GA4.5R

GA6H

Engine Model

Honda GX160

Robin EX170

Honda GX240

Robin EX270D

Honda GX340

Horse Power

5.5

5.7

Engine (RPM)

Hi-speed rated under load

High 3600

Low 2500

Fuel Type

Gasoline

Fuel Capacity

3.17 gal.

3.6 gal.

5 gal.

Fuel filter (inside tank)

300 hrs,

300 hrs.

100 hrs.

Sparkplug

NGK BPR6ES

NGK BR6HS

NGK BPR6ES

NGK BR6HS

Sparkplug Gap

.028"-.031"

.024"-.027"

.028"-.031"

.024"-.027"

028"-.031"

Eng. Oil Type

SAE 10W30

Eng. Oil Capacity

.63 QT

1.16 QT

Eng. Oil Service

100 hrs.

Engine Compression

85-121PSI

85-121 PSI

Valve

Clearance (Cold)

Intake: .006"

Exhaust: .008"

Intake: .003”

Exhaust: .005"

Intake: .006"

Exhaust: .008"

Intake: .003"

Exhaust: .005"

Intake: .006"

Exhaust: .008"

Air Filters

50 hrs.

50hrs.

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

20.8

Engine (RPM)

Hi-speed rated under load

High 3600

Low 2500

Fuel Type

Gasoline

Fuel Capacity

5 gal.

10 gal.

Fuel filter (inside tank)

100hrs.

300hrs.

Sparkplug

NGK BR6HS

NGK BPR6ES

Sparkplug Gap

028"-.031"

.028"-.031"

Eng. Oil Type

SAE 10W30

Eng. Oil Capacity

.8 QT

1.8 QT

Eng. Oil Service

100 hrs.

Coolant capacity

N/A

Engine Compression

85-121 PSI

Valve

Clearance (Cold)

Intake: .003"

Exhaust: .005"

Intake: .006"

Exhaust: .008"

Air Filters

50hrs.

Battery

Interstate

12N24-3A

Interstate

SP30

Generator End

Brushless ( No maintenance required )

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

Before you try to diagnose a generator problem, check the engine to make sure that it

has been serviced and is operating correctly. Perform proper maintenance and tune-up

procedures before evaluating the generator.

Check the engine governor to ensure the

engine remains at a stable rpm when electrical

loads are applied. The generator engine's

governed rpm isn't as critical for power tools

and resistance loads, such as electric wire

heaters, as it is for machines tuned to 60 cycles

per second (cps) current. For example, if an

engine must run at 3,600 rpm, it must 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

environmental factors that might contribute to the problem.

As you remove the generator control box cover and begin

your inspection, look for the following:

1. Rusted or corroded connections. An oxidized connection will prevent the circuit

from being completed. This applies not only to the major cables externally, but

also to the electronic control devices internally.

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

2. Carbon flash deposits around the 120V AC and 240V AC receptacles. This will

indicate whether the device that was plugged into the generator shorted out the

receptacle. The device may have shorted the generator to ground and caused a

carbon flash when the plug prongs touched the receptacle.

3. Signs of overheating. Discoloration and a burnt smell should be noticeable inside

the generator. Look to see if the windings turned black. The insulative sprays that

manufacturers use to insulate the windings may vary in color from shades of

reddish brown to light brown to dark brown, so try to compare the color to that of

a new unit.

4. Wire insulation that is heat-hardened. Fabric and plastic insulation hardens over

time due to heat exposure and overheating. Long-term heating should be more

uniform. A short, excessive heat cycle may have less hardening and burning at

the unit's outer perimeters and excessive heat signs toward the center or heat

source.

5. Insects that have developed 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 connectors. These are often overlooked. A quick

disconnect could have one to a dozen male-female connections. These are often

inside some plastic or rubber cover that prevents you from seeing any possible

corrosion. In electrical troubleshooting, always unplug and plug in all connectors

three times to produce a freshly scraped metallic surface for good electrical

contact. If the unit works after that, soak the connectors first in vinegar for a few

minutes, then in a baking soda solution. Rinse the unit thoroughly, with distilled

water. This acid/base wash will remove corrosion, but not oil or grease. Blow dry

thoroughly. If you know how to use an ohm meter, check for zero ohms on all

connections. Spray the contacts with an electrical insulative spray before

reassembling them.

- continued -

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

8. Crimp connections. These connections have several problems. Even though

they're widely used, they represent the least professional fix. First, they come

loose as the machine vibrates, and lose consistent, quality contact. Second,

because dissimilar metals are in contact, a galvanic cell is set up that result in

corrosion when moisture is present.

9. Solder joints that have cracked or broken loose. This condition occurs much less

frequently than crimped connections and basically results from poor-quality

workmanship.

10. Worn insulation allowing wires to short. Insulation deteriorates from physical

contact when wires rub together due to vibrations. Eventually, the internal wires

can short to each other or to ground.

11. Crossed wires. Mistakes happen, especially if someone else worked 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 detrimental than higher voltages. Lower voltages overload electric motors very

easily and cause them to burn. How high should a voltage go? No more than 130 volts

for some appliances and less for others. Keep the output voltage approximately 120 to

125V AC. Electricity providers deliver 128V AC to residential homes.

Resistance measurements can be taken and compared to specifications. With the

generator isolated from any alternating current source, a volt-ohm meter often pins down

the problem without having to take voltage readings internally while the unit is running.

- continued -

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

1)Engine (see engine manual)

The engine running at 3600 rpm (60Hz) creates excitation voltage.

2)Excitation (see page 12)

AC Voltage is produced from magnets which are located on the flywheel of the

engine. As the magnets pass a set of windings (charge coils) beneath the

flywheel they produce alternating current, (AC).

3)Diode Rectifier AC/DC (see page 13)

A full wave diode rectifier converts the AC voltage to DC voltage.

4)Stator (see page 14)

The DC voltage is sent 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 mounted on the rotor, producing a rotating magnet.

6)AC is produced

The rotating magnetic field passes through the main windings located in the

stator (U1, V1, U2, and V2). These windings provide AC voltage to the

receptacles through a circuit breaker.

(

)

Multiquip Inc. ◦ GA Series Generators ◦ Manual No. GAGENSM

SYMPTOM

POSSIBLE PROBLEM

SOLUTION

Low voltage.

Engine speed to low

Adjust to specification

Low or no voltage, engine

RPM is good.

Defective excitation lamp coil

Check coil see pg.12

Loose wire connection

Check all wire connections and control

box wiring.

Defective diode rectifier

Check diode rectifier see pg.13

Leakage breaker malfunction

Check circuit breaker.

GFCI circuit breaker is open

Reset GFCI circuit breaker

Engine does not accelerate

from low to high speed.

Stuck idle control solenoid

Check or replace solenoid

Defective Idle control switch

Check or replace switch

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 obstructed

Idle control solenoid

Check solenoid is in correct position

and working properly

Check power connection from lamp coil

and rectifier

The following is a few basic scenarios. If you

don’t see your situation here, try checking

the Technical Information (TI) Documents on

our website at service.multiquip.com or

contact one of our Technical Support

coordinators at (888) 661-8992

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