MULTIQUIP GA4.5R Specifications

OPERATION AND PARTS MANUAL
MODEL GA4.5R/GA4.5RA
PORTABLE AC GENERATOR
(ROBIN GASOLINE ENGINE)
Revision #1 (11/27/06)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALL TIMES.
PAGE 2 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
NOTE PAGE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 3
TABLE OF CONTENTS
GA-4.5R/GA-4.5RA — AC
Portable Generators
ROBIN EX270D Engine
(EPA)
California Proposition 65 Warning ............................. 3
Table Of Contents ..................................................... 4
Parts Ordering Procedures ....................................... 5
Safety Alert Message Symbols .............................. 6-7
Rules for Safe Operation ..................................... 8-10
Specifications .......................................................... 11
Dimensions ............................................................. 12
General Information ................................................ 13
Load Application ..................................................... 14
Controls and Indicators ...................................... 15-17
Generator Refueling ............................................... 18
Installation .......................................................... 19-20
Pre-Inspection ......................................................... 21
Pre-Inspection (Engine) .......................................... 22
Initial Start-up (Engine) ........................................... 23
Initial Start-up (Engine/Operation) ..................... 24-25
Preparation For Long Term Storage ....................... 26
Maintenance ...................................................... 27-28
Wiring Diagram (GA-4.5R) ...................................... 30
Wiring Diagram (GA-4.5RA) ................................... 31
Troubleshooting (Engine) ................................... 32-33
Troubleshooting (Generator) .................................. 34
Explanation Of Codes In Remarks Column ............ 36
Suggested Spare Parts ........................................... 37
Crankcase Assembly .........................................48-49
Crankshaft and Piston Assembly .......................50-51
Governor Assembly ...........................................52-53
Intake and Exhaust Assembly ............................54-55
Muffler Assembly ...............................................56-57
Air Cleaner Assembly.........................................58-59
Recoil Starter Assembly.....................................60-61
Carburetor Assembly .........................................62-63
Flywheel Assembly ............................................64-65
Terms and Conditions Of Sale — Parts .................. 66
NOTE
As a continuing effort to
update our parts book, contact
the MQ literature department
for the latest revision of your
"Operation and Parts Manual"
NOTE
Specification and part
number are subject to change
without notice.
Generator Component
Drawings
Nameplate and Decals....................................... 38-39
Generator Assembly .......................................... 40-41
Control Box Assembly (GA-4.5R) ...................... 42-43
Control Box Assembly (GA-4.5RA) .................... 44-45
Pipe Frame Assembly ........................................ 46-47
PAGE 4 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
www.multiquip.com
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Best Deal!
Order via Internet (Dealers Only):
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
parts@multiquip.com.
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Goto www.multiquip.com and click on
Order Parts to log in and save!
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 3% Discount
on Standard orders for all orders which include
complete part numbers.*
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Note: Discounts Are Subject To Change
Order via Phone: Domestic (US) Dealers Call:
1-800-427-1244
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
When ordering parts, please supply:
❒
❒
❒
❒
❒
❒
Dealer Account Number
Dealer Name and Address
Shipping Address (if different than billing address)
Return Fax Number
Applicable Model Number
Quantity, Part Number and Description of Each Part
NOTE
❒
Specify Preferred Method of Shipment:
✓ Fed Ex/UPS
✓ DHL
■ Priority One
✓ Truck
■ Ground
■ Next Day
■ Second/Third Day
Unless otherwise indicated by customer, all orders are treated as Standard Orders and will ship
within 24 hours. We will make every effort to ship Air Shipments the same day the order is received,
if received prior to 2PM PST. Stock Orders must be noted on fax or web order form.
WE ACCEPT ALL MAJOR CREDIT CARDS!
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 5
GA-4.5R/GA-4.5RA — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
Safety precautions should be followed
at all times when operating this
equipment. Failure to read and
understand the Safety Messages and
Operating Instructions could result in
injury to yourself and others.
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "Hazard Symbols" which
appear throughout this manual, and will be referenced in
Lethal Exhaust Gases
conjunction with Safety "Message Alert Symbols".
WARNING - LETHAL EXHAUST GASES
This Owner's Manual has been
developed to provide complete
instructions for the safe and efficient
operation of the MQ Model GA-4.5R/
NOTE
GA-4.5RA Portable Generators .
Refer to the engine manufacturers
instructions for data relative to its safe
operation.
Before using this generator, ensure that the operating
individual has read and understands all instructions in this
manual.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH if inhaled. NEVER operate this
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine
is running or hot.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
WARNING - BURN HAZARDS
WARNING
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
Engine components can generate extreme
heat. To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
operate the engine with heat shields or heat
guards removed.
DANGER - ELECTROCUTION HAZARDS
During operation of these generators, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
PAGE 6 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
CAUTION - ACCIDENTAL STARTING
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
CAUTION - OVER-SPEED CONDITIONS
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury and damage to the engine
or equipment can result if operating in
speed ranges above maximum allowable.
NOTE
CAUTION - RESPIRATORY HAZARDS
ALWAYS wear approved respiratory
protection.
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS wear approved eye and
hearing protection.
CAUTION - EQUIPMENT DAMAGE MESSAGES
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
This generator, other property,
or the surrounding environment
could be damaged if you do not
follow instructions.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 7
GA-4.5R/GA-4.5RA — RULES FOR SAFE OPERATION
DANGER - READ THIS MANUAL!
Failure to follow instructions in this manual may lead to
serious injury or even DEATH! This equipment is to be
operated by trained and qualified personnel only! This
equipment is for industrial use only.
The following safety guidelines should always be used when
operating the GA-4.5R/GA-4.5RA Portable Generators:
GENERAL SAFETY
■ DO NOT operate or service this
equipment before reading this entire
manual.
■ This equipment should not be operated by persons under
18 years of age.
■ NEVER operate this equipment without proper protective
clothing, shatterproof glasses, steel-toed boots and other
protective devices required by the job.
■ NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■ NEVER operate this equipment under the influence of
drugs or alcohol.
■ ALWAYS wear proper respiratory (mask),
hearing and eye protection equipment when
operating the generator.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Manufacturer does not assume responsibility for any
accident due to equipment modifications.
■ NEVER use accessories or attachments, which are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■ The engine section of this generator requires an adequate
free flow of cooling air. NEVER operate the generator in
any enclosed or narrow
area where free flow of the
air is restricted. If the air
flow is restricted it will
cause serious damage to
the generator or engine and
may cause injury to
people. Remember the
generator's engine gives
off DEADLY carbon
monoxide gas.
■ ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.
■ ALWAYS use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool. DO NOT smoke around or near the
machine. Fire or explosion could result
from fuel vapors, or if fuel is spilled on a
hot engine.
■ NEVER operate the generator in an
explosive atmosphere or near
combustible materials. An explosion or
fire could result causing severe bodily
harm or even death.
■ NEVER disconnect any "emergency or safety devices".
These devices are intended for operator safety. Disconnection
of these devices can cause severe injury, bodily harm or even
death! Disconnection of any of these devices will void all
warranties.
PAGE 8 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — RULES FOR SAFE OPERATION
■ ALWAYS be sure the operator is familiar with proper safety
precautions and operation techniques before using generator.
■ NEVER leave the generator unattended, turn off engine when
unattended.
■ Unauthorized equipment modifications will void all
warranties.
■ ALWAYS ensure generator is on level ground before use.
■ DO NOT place hands or fingers inside generator engine
compartment when engine is running.
Maintenance Safety
■ NEVER lubricate components or attempt service on a running
machine.
■ High Temperatures – Always stop engine and
allow the engine to cool before adding fuel, oil
or performing service and maintenance
functions. Contact with hot! components can
cause serious burns.
■ Keep the machinery in proper running condition.
■ NEVER run engine without air cleaner. Severe engine damage
may occur.
■ Fix damage to the machine immediately and replace any
broken parts immediately.
■ NEVER change or adjust the engine speed which has been
set at the factory prior to shipping.
■ ALWAYS replace any worn or damaged warning decals.
Power Cord Safety
■ NEVER let power cables or cords lay in water.
■ NEVER stand in water while AC power from the generator
is being transfer to a load.
■ NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.
■ NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.
■ ALWAYS make certain that proper power or extension cord
has been selected for the job See Table 3.
Grounding Safety
■ ALWAYS make sure 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
ungrounded generator.
■ ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children and un-authorized personnel.
■ The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits. Turn all circuit breakers OFF before
performing maintenance on the generator.
■ Dispose of hazardous waste properly. Examples of potentially
hazardous waste are used motor oil, fuel and fuel filters.
■ DO NOT use food or plastic containers to dispose of
hazardous waste.
■ DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
■ Removing the engine oil drain plug while
the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing
severe scalding to any persons in the general
area of the generator.
■ ALWAYS make sure generator is properly grounded to a
suitable earth ground (GROUND ROD). See installation
section in this manual.
■ NEVER use gas piping as an electrical ground.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 9
GA-4.5R/GA-4.5RA — RULES FOR SAFE OPERATION
DANGER -ELECTROCUTION HAZARDS
During operation of this generation, there
exists the possibility of electrocution,
electrical shock or burn, which can
cause severe bodily harm or even
DEATH!
Emergencies
■ ALWAYS know the location of the
nearest fire extinguisher.
■ ALWAYS know the location of the nearest
first aid kit.
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
receptacles, incorrect connections may cause damage
to the generator and electrical shock.
■ In emergencies 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 invaluable in the case of an
emergency.
NEVER grab or touch a live
power cord with wet hands, the
possibility exist of electrical
shock, electrocution, and even
death!
NEVER insert any objects into
the output receptacles during
operation. This is extremely
dangerous. ALWAYS turn-off
the generator and place all circuit breakers in the “OFF”
position when contact with the output receptacles is
required. There exist the possibility of electrocution,
electrical shock or burn, which can cause severe
bodily harm or even death!
Backfeed to a utility system can cause
electrocution and or property damage.
NEVER connect the generator to a
building's electrical system without a
transfer switch or other approved device.
All installations should be performed by
a licensed electrician in accordance
with all applicable laws and electrical
codes. Failure to do so could result in
electrical shock or burn causing serious
injury or even death!
PAGE 10 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — SPECIFICATIONS
Table 1. Specifications
MODEL
Type
Frequency (Hz)
GENERATOR
2-Pole, Brushless Type Revolving Field
60
Continuous Output (kW)
3 .7 0
Maximum Output (kW)
4.5
Voltages (VAC)
120/240
Max/Continuous Amps 120 VAC
37.5/30.8
Max/Continuous Amps 240 VAC
18.75/15.4
Rated Speed (RPM)
Power Factor
Dimension (L x W x H) in. (mm)
Dry Net Weight lbs. (kg)
Includes Engine
Model (Engine Specification)
Type
Displacement (cc)
ENGINE
GA-4.5R/GA-4.5RA
3600
1.0
23 X 18.5 X 20.25
(595 X 470 X 515)
149 (68)
ROBIN EX27OD20110 (GA-4.5R)
ROBIN EX27OD20220 (GA-4.5RA)
Air-cooled, 4-stroke, Single Cylinder, Overhead
Camshaft, Gasoline Engine
265
Continuous Output (kW/min)
5.1 @3600
Maximum Output (kW/min)
9.0 @4000
Fuel Tank Capacity Gal. (L)
4.2 (19)
Fuel
Lube Oil Capacity Qts. (L)
Speed Control Method
Star ting Method
Dimension (L x W x H) in. (mm)
Dry Net Weight lbs. (kg)
Non-leaded Automobile Gasoline
1.16 (1.1)
Centrifugal Fly-weight Type
Re co il S t a r t
13.97 X 16.5 X 16.14
(355 X 420 X 410)
46.3 (21)
Effects of Altitude and Heat
The maximum output of the engine listed above is 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 level, with a barometric
reading of 29.92 inches and a temperature of 60 degrees fahrenheit.
Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10° F
fahrenheit above the standard temperature of 60° F
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 11
GA-4.5R/GA-4.5RA — DIMENSIONS
Figure 1. Dimensions
PAGE 12 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — GENERAL INFORMATION
DANGER - ELECTRICAL SYSTEM HAZARDS
Before connecting this generator to any building’s electrical
system, a licensed electrician must install an isolation
(transfer) switch. Serious damage to the building’s
electrical system may occur without this transfer switch.
GA-4.5R/GA-4.5RA Familarization
General Inspection Prior to Operation
This generator has been thoroughly inspected and accepted
prior to shipment from the factory. However, be sure to check
for damaged parts or components, or loose nuts and bolts,
which could have become disloged in transit.
The MQ Model GA-4.5R andGA-4.5RA generators have been
designed as a portable lightweight power source for 60 Hz
(single-phase) vibrators, lighting facilities, power tools,
submersible pumps and other industrial and construction
machinery.
These generators are powered by a 9.0 HP ROBIN air-cooled
gasoline engine. The alternator, a brushless revolving-field
type, is permanently aligned to the engine through rigid
coupling.
These generators are mounted on rubber vibration isolators
that have a steel base backplate which is attached to the
protective steel pipe carrying frame. The protective carrying
frame is made of steel tubing and fully wraps around the
generator to protect against damage.
This portable generator is supplied with a electrical control
panel. The control panel includes items as listed below.
Control Panel
The generator control panel has the following componets:
■ NEMA 5-20R GFCI duplex receptacle, (120V, 20 amps),
GA-4.5RA has two.
Excitation System
The GA-4.5R/GA-4.5RA generator uses a magnet attached
to a flywheel to produce AC voltage from a lamp coil beneath
the flywheel. As the magnet passes the coil it produces
approximately 19-22 AC volts.
This voltage (19-22 VAC) is then sent to the control box that
contains three rectifying diodes:
z Excitation (diode 1)
z Battery (diode 2)
z Slow Down (diode 3)
The AC voltage will pass through the excitation diode that
converts the voltage to DC power.
This DC power is then sent to the excitation windings housed
within the main windings commonly called the "stator".
This voltage is then transferred into the rotor through
induction. The rotor contains two diodes within it which rectify
the DC voltage and send it out through the main windings,
as AC voltage.
Engine
The four-cycle air-cooled ROBIN gasoline engine is designed
to meet every performance requirement of this generator.
Reference Table 1, for engine specifications.
Figures 2A through 2E show the basic controls and
indicators for the GA-4.5R/ GA-4.5RA generators.
NOTE
In keeping with Multiquip's
policy of constantly
improving its products, the
specifications quoted herein
are subject to change without
prior notice.
■ NEMA L5-20R, twist-lock receptacle, (125V, 20 amps)
■ NEMA L5-30R, twist-lock receptacle, (125V, 30 amps)
■ NEMA L14-20R , twist-lock receptacle, (125/250V, 20 amps)
■ Circuit Breaker, 2-pole, 15 amps
■ AC Voltmeter
■ Operation Switch
■ Idle Control Switch
■ Full Power Switch
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 13
GA-4.5R/GA-4.5RA — LOAD APPLICATION
Single Phase Load
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily 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.
NOTE
If wattage is not given on the equipment's
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 1.0 See Table 2 below
when connecting loads.
To determine the running wattage for your load, multiply
the running wattage as indicated by steps 1, 2, and 3 below:
1.
INCANDESCENT LOADS
Lights, heaters and similar appliances.
Total the running wattage and multiply by 1.
Example:
29 light bulbs @ 100W each = 2.9 KW
use a 3 KW generator.
2.
SMALL MOTORS
Drills and other small power tools.
Total the running wattage and multiply by 2.
Example:
A 1 inch drill runs at 1 KW
use a 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.
Table 2. Power Factor By Load
Type Of Load
Power Factor
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
Fluorescent lamps, mecury
lamps
0.4 - 0.9
Electronic devices,
communication equipment
1.0
Common power tools
0 .8
NOTE
CAUTION - ADEQUATE EXTENSION CABLE
Motors and motor-driven equipment draw much greater
current for starting than during operation. Always use an
adequate size extension cable which can carry the
required load.
Extension Cables
When using a combination of dual
receptacles, total load should not
exceed the rated capacity of the
generator.
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 3 ) as a
guide for selecting proper cable size.
NOTE
The idle control device is operated at a
minimum load capacity of 100W. If the
load capacity is less than 100W, place
the idle control switch in the OFF position.
PAGE 14 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — CONTROLS AND INDICATORS
Figure 2A. Generator Controls and Components
1.
Lifting Bail Eye – Attach a rope or chain to this lifting eye
when lifting of the generator is required. Never stand
underneath the generator while it is being lifted. Place lifting
eye in down position when not in use.
5.
GFCI Duplex Receptacle – NEMA 5-20R receptacle will
provide 120V, 20 amps. The position of the full power switch
does not effect the voltage output at the receptacle. The
GA-4.5RA has two GFCI receptacles.
2.
AC-Voltmeter – This voltmeter indicates (with a mark) the
rated 60 Hz, single phase output voltage. In addition the
voltmeter can also be used 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 and consult your authorized MQ service dealer.
6.
120 VAC Receptacle – NEMA L5-20R twist-lock
receptacle will provide 120V, 20 amps when the full power
switch is placed in either the 120 or 240 volt position.
7.
120 VAC Receptacle – NEMA L5-30R twist-lock
receptacle will provide 120V when the full power switch is
placed in either the 120 or 240 volt position.
8.
240 VAC Receptacle – NEMA L14-20R twist-lock
receptacle will provide 240V when the full power switch is
placed in the 240/120 volt position (down). When the full
power switch is placed in the 120 volt position (up), 120V
will be available.
9.
Main Circuit Breaker – 2-pole circuit breaker (240V/18.75
amps or 120V/30.8 amps) protects the generator from short
circuiting or overloading. When starting the generator
always have the circuit breaker placed in the "OFF"
position.
3.
4.
Idle Control Switch – This unit is provided with an
automatic idle control for noise suppression and reduced
fuel consumption. The automatic idle control automatically
engages under a no-load condition. With the automatic
idle control switched “ON”, the engine revolutions will
automatically drop to about 2600 rpm (low-speed
operation) within 3 seconds after the load stops. When the
operation is resumed, the engine speed is automatically
increased to about 3600 rpm (high-speed operation) as
soon as the load is connected.
Operation Switch – Place this rocker switch in the "RUN"
position (up) for normal operation. To turn-off the generator
place this switch in the "STOP" position (down).
10. Frame Ground – This ground connection point should
be connect to a good earth ground (ground rod).
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 15
GA-4.5R/GA-4.5RA — CONTROLS AND INDICATORS
Figure 2B. Generator Controls and Components (continued)
11. Full Power Switch – The generators are provided with a
full power switch. Figures 2C and 2D 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 generators at
120 volts from the GFCI duplex receptacle and the120V
twist-lock receptacle, or a combination of both receptacles
as long as the total load does not exceed the generating
set capacity.
When the switch is in the 240 volt (down) position, you can
acess half of the rated power of the generating set at 120
volts from the GFCI duplex receptacle and up to half of the
rated power of the set at 120 volts from 120V twist-lock
receptacle; or full rated power of the set at 240 volts from
the 240V twist-lock receptacle.
Figure 2D. Full Power Switch 120/240 VAC (Down)
Simplified Wiring Diagram
Figure 2C. Full Power Switch 120VAC (Up)
Simplified Wiring Diagram
NOTE
When the full power switch is in the
120V position, the 240V twist-lock
receptacle cannot be used.
PAGE 16 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — CONTROLS AND INDICATORS
Figure 2E. Generator Controls and Components (continued)
12. Choke Lever – Used for starting the engine. Close the
choke lever 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.
13. Fuel Cock Lever – Turn this lever downward to start
(down)the flow of fuel to the carburetor. Turn upward to
stop (up) the flow of fuel.
14. Throttle Lever – Used to adjust engine RPM speed. This
unit is set at the factory and is not adjustable.
15. Engine – This generator uses a 9.0 HP ROBIN aircooled, 4-stroke , single cylinder, overhead camshaft
gasoline engine. Engine uses unleaded fuel.
16. Recoil Starter (Pull Rope) – Used for manual-starting of
the engine. Pull the starter grip until resistance is felt, then
pull briskly and smoothly.
17. Air Cleaner – Prevents dirt and other debris from entering
the fuel system. Remove wing-nut on top of air filter
cannister to gain access to filter element. NEVER run the
engine without an air cleaner.
18. Muffler/Heat Shield – Used to reduce noise and emissions.
NEVER touch this heat shield when the generator is in
use. Always allow time for the generator to cool down before
performing maintenance.
19. Oil Dipstick/ Filler Cap– Remove the filler cap dipstick
when checking the engine oil level. Add engine oil through
this filler port. See Table 4 for recommended type engine
oil.
20. Oil Drain Plug – Remove this plug to drain engine oil from
the crankcase.
21. Carburetor Fuel Cup – Inspect the fuel cup weekly for
water and dirt. Clean as referenced in the maintenance
section of this manual.
22. Spark Plug – Provides spark to the ignition system. Set
spark plug gap to 0.6 - 0.7 mm (0.024 - 0.028 inch). Clean
spark plug once a week
23. Generator Housing – Contains the rotor, rectifer field
coil assembly, aramature, bearings and other components
that make up generator asembly.
24. Fuel Gauge – Read this gauge to determine when fuel is
low.
25. Fuel Gauge/Tank – Remove this cap to add unleaded
gasoline to the fuel tank. Replenish with clean unleaded
gasoline. Make sure cap is tightened securely. DO NOT
over fill. Fuel tank capacity is 5 gallons (19 liters).
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 17
GA-4.5R/GA-4.5RA — GENERATOR REFUELING
DANGER - REFUELING HAZARD
Adding fuel to the tank should be done only when
the engine is stopped and has had an opportunity
to cool down. In the event of a fuel spill, DO NOT
attempt to start the engine until the fuel residue
has been completely wiped up, and the area
surrounding the engine is dry. If generator is placed
in a truck bed with a plastic liner, REMOVE generator from truck
bed and place on ground (Figure 3) to refuel. This possibility
exist of fire or explosion due to static electricity.
Figure 3. Generator Refueling
PAGE 18 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — INSTALLATION
Outdoor Installation
Indoor Installation
Install the generator in a area that is free of debris ,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.
Exhaust gases from gasoline engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
Eliminate the danger of deadly carbon monoxide gas.
Remember that exhaust fumes from any gasoline engine
are very poisonous if discharged in a closed room, but
harmless if allowed to mix with the outside air. If the generator
is installed indoors, you must make provisions for venting
the engine exhaust to the outside of the building.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
WARNING - LETHAL EXHAUST GASES
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements.
Mounting
The generator should always be mounted on a flat level
surface to isolate vibration of the generator when it is
running. DO NOT place the generator on slopes, the
possibility exists that the generator could slide.
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 generator to
ground the generator.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 4) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 19
GA-4.5R/GA-4.5RA — INSTALLATION
Connecting the Ground
The nut and ground terminal on the generator should always be used to connect the generator to a suitable ground. The
ground cable should be #8 size wire minimum.
At the generator, connect the terminal of the ground cable between the lock washer and the nut (Figure 4) and tighten the
nut fully. Connect the other end of the ground cable to a suitable earth ground (ground rod).
Figure 4. Generator Grounding
PAGE 20 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — PRE-INSPECTION
General Inspection Prior to Operation
Extension Cable
Ground Power Tools
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 3) as a guide for selecting proper cable size.
When using power tools or electrical equipment requireing AC
power from the generator, make sure connecting (power tool)
cable has a ground pin as shown in Figure 5.
Never! use power tools or
equipment that do not have a
ground capability, the possibility
exists of electrocution, electrical
shock or burn, which can cause
severe bodily harm or even
DEATH!
NOTE
Main Circuit Breaker
To protect the generator from an overload always place the main
circuit breaker in the "OFF" position prior to starting the engine.
Figure 5. Ground Cables/Plugs
Table 3. Cable Selection (60 Hz, Single Phase Operation)
Current in
Amperes
Load In Watts
Maximum Allowable Cable Length
At 120 Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
300
1000 ft.
600 ft.
375 ft.
250 ft.
5
600
500 ft.
300 ft.
200 ft.
125 ft.
7.5
900
350 ft.
200 ft.
125 ft.
100 ft.
10
1200
250 ft.
150 ft.
100 ft.
15
1800
150 ft.
100 ft.
65 ft.
20
240 0
125 ft.
75 ft.
50 ft.
CAUTION: Equipment damage can result from low voltage.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 21
GA-4.5R/GA-4.5RA — PRE-INSPECTION (ENGINE)
CAUTION
NEVER operate the generator in a confined
area or enclosed area structure that does
not provide ample free flow of air.
Figure 7. Engine Oil Dipstick (Oil Level)
ALWAYS wear approved eye and hearing
protection before operating the generator.
Before Starting
1.
Read safety instructions at the
beginning of manual.
2.
Clean the generator, removing dirt
and dust, particularly the engine
cooling air inlet, carburetor and air
cleaner.
3.
Check the air filter for dirt and dust. If air filter is dirty, replace
air filter with a new one as required.
4.
Check carburetor for external dirt and dust. Clean with dry
compressed air.
5.
Check fastening nuts and bolts for tightness.
Table 4. Oil Type
Season
Temperature
Oil Type
Summer
25°C or Higher
SAE 10W-30
Spring/Fall
25°C~10°C
SAE 10W-30/20
Winter
0°C or Lower
SAE 10W-10
DANGER - EXPLOSIVE FUEL
Motor fuels are highly flammable and can be
dangerous if mishandled. DO NOT smoke
while refueling. DO NOT attempt to refuel the
generator if the engine is hot! , running or in
the dark.
Engine Oil Check
1.
To check the engine oil level, place the generator on secure
level ground with the engine stopped.
2.
Remove the filler dipstick from the engine oil filler hole
(Figure 6) and wipe clean.
Fuel Check
1. Close the fuel cock before filling the fuel tank.
2. Remove the fuel cap located on top of fuel tank.
3. Read the fuel gauge located on top of the fuel tank (Figure 8) to
determin if the fuel level is low. If fuel is low, replenish with
clean unleaded fuel.
Figure 8. Fuel Gauge
Figure 6. Engine Oil Dipstick (Removal)
3. Insert and remove the dipstick without screwing it into the filler
neck. Check the oil level shown on the dipstick.
4. If the oil level is low (Figure 7), fill to the edge of the oil filler
hole with the recommended oil type (Table 4). Maximum oil
capacity is 1.16 quarts (1.1 liters)
4. When refueling, be sure to use a strainer for filtration. DO
NOT top-off fuel. DO NOT fill the tank beyond capacity.
Wipe up any spilled fuel immediately!
PAGE 22 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — INITIAL START-UP (ENGINE)
CAUTION - READ MANUAL
2. Place the choke lever (Figure 11) in the "CLOSED " position
if starting a cold engine.
DO NOT attempt to operate this
generator until the Safety, General
Information and Inspection sections of
this manual have been read and
thoroughly understood.
DO NOT attempt to operate this generator until the Safety,
General Information and Inspection sections of this manual have
been read and thoroughly understood.
This section is intended to assist the operator with the initial
start-up of the trash generator. It is extremely important that this
section be read carefully before attempting to use the generator
in the field.
Before Starting the Engine
3. Place the choke lever (Figure 11) in the "OPEN " position
if starting a warm engine or the temperature is warm.
1. Be sure to disconnect all electrical loads from the
generator prior to starting the engine.
4. Place the operation switch (Figure 12) in the "RUN "
position.
Figure 11. Choke Lever
2. NEVER start the engine with the main circuit breaker
in the “ON" position. Place the main circuit breaker
(Figure 9) in the OFF position.
Figure 12. Operation Switch (RUN)
Figure 9. Main Breaker (OFF Position)
Starting the Engine
5. Grasp the starter grip (Figure 13) and slowly pull it out. The
resistance becomes the hardest at a certain position, corresponding to the compression point. Pull the starter grip briskly
and smoothly for starting.
1. Place the engine fuel valve lever (Figure 10) to the "ON"
position.”
Figure 13. Starter Grip
CAUTION - RECOIL STARTER
Figure 10. Engine Fuel Valve Lever (ON Position)
DO NOT pull the starter rope all the way to the end.
DO NOT release the starter knob after pulling. Allow it to
rewind as soon as possible.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 23
GA-4.5R/GA-4.5RA — INITIAL START-UP ENGINE/OPERATION
6. If the engine has started, slowly return the choke lever
(Figure 11 ) to the “OPEN” position. If the engine has not
started repeat steps 1 through 6.
7. Before the generator is placed into operation, run the engine
for 3-5 minutes. Check for abnormal smells, fuel leaks, and
noises that would associate with lose components.
Figure 16. AC Voltmeter (120VAC)
8. Place the idle control switch (Figure 14) in the "OFF"
(down) position. This will allow the engine run at speed
about 3600 RPM's
11. If desired, verify with a voltmeter (Figure17) that 120
VAC is present at the GFCI receptacle and all three
twist-lock receptacles as shown below.
Figure 14. Idle Control Switch (3600 rpm's)
Placing the idle control switch in
the down position allows the
NOTE
engine to operate at a maximum
speed of about 3600 RPM's. When
the idle control switch is placed in
the 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
the 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.
9. Place the full power switch (Figure 15) in the "120V"
(Up) position.
Figure 17. 120 VAC Receptacles
NOTE
Figure 15. Full Power Switch (Up)
The 240V L14-20R receptacle
is not operational (no voltage)
when the full power switch is in
the 120V position. This receptacle
is active (voltage) only when the
full power switch is in the 240V
position.
12. Place the full power switch (Figure 18) in the "240/
120V" (Down) position.
10. Refer to the AC voltmeter (Figure 16) on the control
box. The voltage indicated on the voltmeter should be
120 VAC with no load applied.
Figure 18. Full Power Switch (Down)
PAGE 24 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — INITIAL START-UP ENGINE/OPERATION
13. Refer to the AC voltmeter (Figure 19) on the control
box. The voltage indicated on the voltmeter should be
240 VAC with no load applied. If desired, verify with a
voltmeter that 240V is present at the NEMA L14-20R
twist-lock receptacle. In addition verify that 120VAC is
present at the NEMA 5-20R GFCI duplex receptacle
and the two NEMA L5-20R, L5-30R twist-lock
receptacles.
3. Place the main circuit breaker (Figure 21) in the ON
position.
Figure 21. Main Circuit Breaker (ON)
Stopping The Engine
Normal Shutdown
1. Place the main circuit breaker (Figure 9) in the OFF
position.
2. Remove the load from the generator.
3. Place the idle control switch (Figure 22) in the up
position (ON), and let the engine run at idle (2200 RPM's)
for 3-5 minutes.
Figure 19. 240/120 VAC Receptacle
Figure 22. Idle Control Switch (2200 rpm's)
When the full power switch is
in the 240V (down) position, up
NOTE
to half of the rated power of the
generator is available at the
120V GFCI duplex receptacle,
L5-20R and L5-30R twist-lock
receptacles; or full rated power can be obtained at the
L14-20R (240V) receptacle. Rembmber, when using a
combination of dual receptacles, total load should not
exceed the rated capacity of the generator.
Connecting the Load
4. Place the operation switch (Figure 23) in the STOP
position.
Figure 23. Operation Switch (Stop)
5. Place the engine fuel valve lever (Figure 24) to the "OFF"
position.”
1. Connect the load to the desired voltage output
receptacle.
2. Place the idle control switch (Figure 20) in the ON position
(Up).
Figure 20. Idle Control Switch (Up)
Figure 24. Engine Fuel Valve Lever (OFF Position)
Emergency Showdown
1. Place the operation switch (Figure 23) in the STOP
position.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 25
GA-4.5R/GA-4.5RA — PREPARATION FOR LONG -TERM STORAGE
Generator Storage
For storage of the generating set for over 30 days, the
following is required:
■ Drain the fuel tank completely, or add STA-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.
■ Slowly rotate the engine a few times with the starter Rope and
install a new plug.
■ Pull out the starter rope slowly and stop at the compression
point.
■ Clean all external parts of the generating set with a cloth.
■ Cover the generating set and store in a clean, dry place.
PAGE 26 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — MAINTENANCE (ENGINE)
Use Table 5 as a general maintenance guideline when servicing
your engine. For more detail engine maintenance information,
refer to the engine owner's manual supplied with your engine.
Table 5. Engine Maintenance Schedule
DESCRIPTION (3)
OPERATION
BEFORE
CHECK
X
FIRST
EVERY
MONTH 3 MONTHS
OR
OR
10 HRS.
25 HRS.
EVERY
6 MONTHS
OR
50 HRS.
EVERY
YEAR
OR
100 HRS.
EVERY
2 YEARS
OR
200 HRS.
Engine Oil
CHANGE
CHECK
X
X
Air Cleaner
CHANGE
All Nuts & Bolts
Re-tighten If
Necessary
X (1)
X
CHECK-CLEAN
X
Spark Plug
REPLACE
X
Cooling Fins
CHECK
X
Spark Arrester
CL E A N
X
Fuel Tank
CLEAN
X
Fuel Filter
CHECK
X
Idle Speed
CHECK-ADJUST
X (2)
Valve Clearance
CHECK-ADJUST
Fuel lines
CHECK
X (2)
Every 2 years (replace if necessary) (2)
(1) Service more frequently when used in DUSTY areas.
(2) These items should be serviced by your service dealer, unless you have the proper tools and are mechanically
proficient. Refer to the ROBIN Shop Manual for service procedures.
(3) For commercial use, log hours of operation to determine proper maintenance intervals.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 27
GA-4.5R/GA-4.5RA — MAINTENANCE (ENGINE)
Maintenance
Perform the scheduled maintenance procedures as defined by
Table 6 and below:
DAILY
■ Thoroughly remove dirt and oil from the engine and control
area. Clean or replace the air cleaner elements as necessary.
Check and retighten all fasteners as necessary. Check the
gearbox for oil leaks. Repair or replace as needed.
WEEKLY
■ Remove the fuel filter cap and clean the inside of the fuel
tank.
■ Remove or clean the filter at the bottom of the tank.
■ Remove and clean the spark plug (Figure 25), then adjust
the spark gap to 0.024 ~0.028 inch (0.6~0.7 mm). This unit
has electronic ignition, which requires no adjustments.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.
DANGER - EXPLOSIVE FUEL
DO NOT use gasoline as a cleaning solvent,
because that would create a risk of fire or
explosion.
ENGINE AIR CLEANER
1. Remove the air cleaner cover and foam filter element as
shown in Figure 27.
Figure 25. Spark Plug Gap
2. Tap the paper filter element (Figure 27) several times on a
hard surface to remove dirt, or blow compressed air [not
exceeding 30 psi (207 kPa, 2.1 kgf/cm2)] through the filter
element from the air cleaner case side. NEVER brush off dirt.
Brushing will force dirt into the fibers. Replace the paper filter
element if it is excessively dirty.
ENGINE OIL
1. Drain the engine oil when the oil is warm as shown in
Figure 26.
2. Remove the oil drain bolt and sealing washer and allow
the oil to drain into a suitable container.
3. Replace engine oil with recommended type oil as listed
in Table 4. For engine oil capacity, see Table 1 (engine
specifications). DO NOT overfill.
4. Install drain bolt with sealing washer and tighten securely.
Figure 27. Engine Air Cleaner
Figure 26. Engine Oil (Draining)
PAGE 28 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
NOTE PAGE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 29
MQ GA-4.5R — WIRING DIAGRAM
Figure 28. Generator/Engine Wiring Diagram
(GA-4.5R Only)
PAGE 30 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
MQ GA-4.5RA — WIRING DIAGRAM
Figure 29. Generator/Engine Wiring Diagram
(GA-4.5RA Only)
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 31
GA-4.5R/GA-4.5RA — TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the
diagnosis based on the Engine Troubleshooting (Table 6)
information shown below and on the proceeding page. If the
problem cannot be remedied, please leave the unit just as it
is and consult our company's business office or service
plant.
TABLE 6. ENGINE TROUBLESHOOTING
SYMPTOM
Poor star ting
Insufficient power output "no
compression"
Insufficient power output
"compression"
POSSIBLE PROBLEM
SOLUTION
Inspect carburetor to see if fuel
is reaching it?
Check fuel line
No Fuel?
Add Fuel
Water in fuel tank?
Flush or replace fuel tank.
Fuel filter clogged?
Replace fuel filter
Stuck carburetor?
Check float mechanism.
Spark plug is red?
Spark plug is fouled. Check tranistor ignition unit.
Spark plug is blue-white?
Insufficient compression, injected air leaking. Carburetor jets are
clogged (overflow).
No spark present at tip of spark
plug?
Tranistor ignition unit broken, high voltage cord cracked or broken.
Star t/Stop switch broken. Replace spark plug if fouled.
No oil?
Add oil as required.
Oil pressure alarm lamp blinks
upon star ting?
Check Automatic shutdown circuit "oil sensor".
Engine will not turn over?
Replace cylinder and piston and if necessary axel joint.
Cylinder head connecting bolts
loose?
Tighten cylinder head connecting bolts.
Cylinder head gasket damaged?
Replace cylinder head gasket.
Malfunction of valve seat?
Re-seat valves.
Spark plug is loose?
Replace spark plug.
Worn piston rings?
Replace piston rings.
Malfunction in air-cleaner
system, air filter clogged?
Clean or replace air filter.
Air leaking in from interface
between carburetor and cylinder
head?
Tighten bolts between carburetor and cylinder head. Replace
cylinder head gasket.
Malfunction in fuel system?
Clean or replace fuel filter.
Clean or replace carburetor.
Check carburetor float.
PAGE 32 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — TROUBLESHOOTING (ENGINE)
TABLE 6. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
Insufficient power output
"compression" and overheats
Burns to much fuel
Exhaust color is continiously
"WHITE"
Exhaust color is continiously
"BLACK"
POSSIBLE PROBLEM
SOLUTION
Malfunction in blower?
Check or replace blower.
Air in-take filter clogged?
Clean or replace air in-take filter.
Over accumulation of exhaust
products?
Clean and check valves.
Check muffler, replace if necessary.
Wrong spark plug?
Replace spark plug with manufactures suggested type spark plug.
Lubricating oil is wrong
viscosity?
Replace lubricating oil with correct viscosity.
Worn rings?
Replace rings
Air cleanner clogged?
Clean or replace air cleaner.
Choke valve has not been set
to the correct position?
Adjust choke valve to the correct position.
Carburetor defective, seal on
carburetor broken?
Replace carburetor or seal.
Poor carburetor adjustment
"engine runs too rich?
Adjust carburetor.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 33
GA-4.5R/GA-4.5RA — TROUBLESHOOTING (GENERATOR)
Practically all generator breakdowns can be prevented by
proper handling and maintenance inspections, but in the event
of a breakdown, please take a remedial action following the
diagnosis based on the Generator Troubleshooting (Table 7)
information shown below and on the preceding page. If the
problem cannot be remedied, please leave the unit just as it
is and consult our company's business office or service
plant.
TABLE 7. GENERATOR TROUBLESHOOTING
SYMPTOM
Low voltage
POSSIBLE PROBLEM
SOLUTION
Engine speed too low?
Raise engine speed to rated RPM.
AC voltmeter not working?
Replace AC voltmeter.
Control box internal wiring
malfunction?
Check control box wiring.
Defective ignition coil?
Check red and green ignition wires. Replace ignition wires if
necessary.
Rotor winding malfunction?
Check or replace rotor.
Stator winding malfunction?
Check or replace stator.
Breaker malfunction?
Check or replace CB1.
Voltage output too high.
Engine speed too high?
Lower engine speed to rated RPM.
Voltage output too high. Engine
speed normal 3650 RPM
(unloaded), 2500 RPM (idle)
Control box internal wiring
malfunction
Check control box wiring.
Circuit breaker will not turn on
"NO LOAD"
Defective circuit breaker?
Replace circuit breaker.
Overload?
Reduce load or replace breaker.
Load circuit is shor ted?
Check load circuit for shor t.
Does not accelerate from low to
high "NO LOAD"
Stuck solenoid?
Check solenoid.
Does not accelerate from low to
high "LOAD ACTIVE
Control box interal wiring
defective?
Check control box wiring.
Defective rotor windings?
Check or replace rotor.
Defective solenoid?
Check or replace solenoid.
Defective idle control device?
Check or replace idle control device.
Defective solenoid?
Check or replace idle control device.
Control box wiring malfunction?
Check control box wiring, replace any defective components.
Defective solenoid?
Check or replace solenoid.
Idle control device malfunction?
Check or replace idle control device.
Low voltage. Engine speed
normal 3650 RPM (unloaded),
2500 RPM (idle)
Circuit breaker will turn on
"LOADED" but trips immediately.
Does not decelerate no
"VOLTAGE OUTPUT".
Does not decelerate but has
"VOLTAGE OUTPUT".
PAGE 34 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
NOTE PAGE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 35
GA-4.5R/GA-4.5RA — EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and remarks
used in the Parts section of this manual. Use the help numbers
found on the back page of the manual if there are any questions.
The contents and part numbers listed in the parts section are
subject to change without notice . Multiquip does not
guarantee the availability of the parts listed.
Sample Parts List:
NO.
1
2
2
3
4
REMARKS
INCLUDES ITEMS W/
NOT SOLD SEPARATELY
MQ-45T ONLY
MAKE LOCALLY
S/N 2345B AND ABOVE
*
A/R (As Required) is generally used for hoses or other parts
that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed to
describe the item can also be shown.
Assembly/Kit - All items on the parts list with the same unique
symbol will be included when this item is purchased.
Indicated by:
NO. Column
“INCLUDES ITEMS W/(unique symbol)”
Unique Symbols - All items with same unique symbol
( , #, +, %, or >) in the number column belong to the same
assembly or kit, which is indicated by a note in the “Remarks”
column.
*
Duplicate Item Numbers - Duplicate numbers indicate
multiple part numbers are in effect for the same general item,
such as different size saw blade guards in use or a part that
has been updated on newer versions of the same machine.
NOTE
Numbers Used - Item quantity can be indicated by a number,
a blank entry, or A/R.
REMARKS Column
PART NO. PART NAME
QTY.
12345
BOLT ....................... 1....
WASHER, 1/4 IN. ...........
12347
WASHER, 3/8 IN. .... 1....
12348
HOSE .................... A/R ..
12349
BEARING ................ 1....
*
*
QTY. Column
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.
PART NO. Column
Numbers Used - Part numbers can be indicated by a number,
a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a part that
has not been assigned a formal part number at time of
publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will be
clarified in the “Remarks” Column.
Serial Number Break - Used to list an effective serial number
range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use - Indicates that the part is used
only with the specific model number or model number variant
listed. It can also be used to show a part is NOT used on a
specific model or model number variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally” - Indicates that the part can be
purchased at any hardware shop or made out of available
items. Examples include battery cables, shims, and certain
washers and nuts.
“Not Sold Separately” - Indicates that an item cannot be
purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available for
sale through Multiquip.
PAGE 36 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — SUGGESTED SPARE PARTS
GA-4.5R/GA-4.5RA 1 TO 3 UNITS WITH ROBIN
EX270D ENGINE
1 to 3 Units
Qty.
P/N
Description
1 ............ A9924800014 ........ CAP, FUEL TANK
1 ............ A9924800004 ........ FUEL FILTER, FUEL TANK
3 ............ 0650140150 .......... SPARK PLUG
3 ............ 2793260907 .......... ELEMENT, AIR CLEANER
1 ............ 2795011008 .......... ROPE, RECOIL STARTER
NOTE
Part numbers on this
Suggested Spare Parts
List may supercede/
replace the P/N shown in
the text pages of this
book.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 37
GA-4.5R/GA-4.5RA — NAME PLATE AND DECALS
NAMEPLATE AND DECALS
PAGE 38 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — NAME PLATE AND DECALS
NAMEPLATE AND DECALS
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
A4511200002
DECAL; CONTROL PANEL .................................... 1 ............ A41120000 GA-4.5R ONLY
1
A4511200702
DECAL; CONTROL PANEL .................................... 1 ............ A41120070 GA-4.5RA ONLY
2
NAMEPLATE ......................................................... 1 ............ CONTACT MQ PARTS DEPT.
3
0800628504
DECAL; GROUND .................................................. 1 ............ S-1123
4
1630680104
DECAL; FUEL COCK ............................................. 1 ............ S-1407
5
A4561000003
DECAL; MQ MULTIQUIP
1
6
0820610404
DECAL; WARNING ................................................. 1 ............ S-3627
7
35137
DECAL; WARNING READ MANUAL
1
8
8700611804
DECAL; WARNING DANGEROUS GAS ................ 1 ............ S-4984
9
8700611904
DECAL; DANGER ELECTRICAL SHOCK HAZ. .... 1 ............ S-4985
10
7900636004
DECAL; CAUTION OPER. AT 3600 RPM ONLY .... 1 ............ S-4461
11
A9521200004
DECAL; OPERATING INSTRUCTIONS ................. 1 ............ A92120000
12
A9511100103
DECAL; WARNINGS MULTIPLE ............................ 1 ............ A91110010 GA-4.5RA ONLY
............................................................................................... S/N 5529995 AND ABOVE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 39
GA-4.5R/GA-4.5RA — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 40 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
GA-4.5R/GA-4.5RA — GENERATOR ASSY.
GENERATOR ASSY.
NO
PART NO
1
A3110200003
1-1
* 7661080003
1-2
0601823213
1-2
0601822638
1-3
* 0071706304
2
7661017104
3
0801086104
4
0040010000
5
A4135000103
6
7661315112
7
7871315022
8
7875021523
9
7661331003
10
7661344204
11
0040008000
12
0041208000
13
7871329514
14
0601851760
15
0013608020
15A
0040008000
PART NAME
QTY.
REMARKS
ROTOR ASSY. ......................................................... 1 ......... INCLUDES ITEMS W/
*
FIELD COIL ASSY.
1
RECTIFIER
2
SURGE ABSORBER
2
BEARING
1
SET BOLT, ROTOR
1
SET WASHER, BEARING
1
SPRING WASHER
1
ARMATURE ASSY.
1
END BRACKET
1
END BRACKET
1
GUIDE PANEL, AIR
1
COVER
1
SET BOLT, STATOR
4
SPRING WASHER
4
PLAIN WASHER
4
GROMMET
1
CAP
1
HEX. HEAD BOLT
4
WASHER, LOCK
4
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 41
MQ GA-4.5R — CONTROL BOX ASSY.
CONTROL BOX ASSY. (GA-4.5R ONLY)
PAGE 42 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
MQ GA-4.5R — CONTROL BOX ASSY.
CONTROL BOX ASSY. (GA-4.5R ONLY)
NO
PART NO
PART NAME
QTY.
1
A3214000003
CONTROL BOX
1
2
0601850102
GROMMET
1
3
0601823204
RECTIFIER, S5VB60
2
4
0027103012
MACHINE SCREW
2
5
0601823853
SLOW-DOWN UNIT
1
6
0027104010
MACHINE SCREW
2
6A
0207004000
HEX NUT
2
7
A3224000003
CONTROL PANEL
1
8
0601802651
CIRCUIT BREAKER, 15 AMP
1
9
4341817004
BRACKET, CIRCUIT BREAKER
1
10
0021004010
MACHINE SCREW
2
11
0601806819
AC VOLTMETER, 0 ~ 120/240V
1
12
0601812598
RECEPTACLE, 5-20R : 125V, 20A
1
13
0601812592
RECEPTACLE, L5-20R : 125V, 20A
1
14
0601811035
RECEPTACLE, L5-30R : 125V, 30A
1
15
0601814010
RECEPTACLE, L14-20R :125/250V, 30A 1
16
0021004010
MACHINE SCREW
8
16A
0207004000
HEX NUT
8
17
0601830737
SWITCH, FULL POWER
1
18
0601831620
SWITCH, IDLE CONTROL
1
19
0601831620
SWITCH, OPERATION
1
20
0021004015
MACHINE SCREW
1
20A
0207004000
HEX NUT
1
21
A3262800004
CONDENSER ASSY. 50V @ 1000 µF
1
22
0017106016
HEX. HEAD BOLT
4
23
0017105010
HEX. HEAD BOLT
4
24
0601842426
RESISTOR, 40W 400 OHMS
1
25
0027104010
MACHINE SCREW
2
REMARKS
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 43
MQ GA-4.5RA — CONTROL BOX ASSY.
CONTROL BOX ASSY. (GA-4.5RA ONLY)
PAGE 44 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
MQ GA-4.5RA — CONTROL BOX ASSY.
CONTROL BOX ASSY. (GA-4.5RA ONLY)
NO
PART NO
PART NAME
QTY.
1
A3214000103
CONTROL BOX
1
2
0601850102
GROMMET
1
3
0601823204
RECTIFIER, S5VB60
2
4
0027103012
MACHINE SCREW
2
5
0601823853
SLOW-DOWN UNIT
1
6
0027104010
MACHINE SCREW
2
6A
0207004000
HEX NUT
2
7
A3224000103
CONTROL PANEL
1
8
0601802651
CIRCUIT BREAKER, 15 AMP
1
9
4341817004
BRACKET, CIRCUIT BREAKER
1
10
0021004010
MACHINE SCREW
2
11
0601806819
AC VOLTMETER, 0 ~ 120/240V
1
12
0601812598
RECEPTACLE, 5-20R : 125V, 20A
1
13
0601812592
RECEPTACLE, L5-20R : 125V, 20A
1
14
0601811035
RECEPTACLE, L5-30R : 125V, 30A
1
15
0601814010
RECEPTACLE, L14-20R :125/250V, 30A 1
16
0021004010
MACHINE SCREW
8
16A
0207004000
HEX NUT
8
17
0601830737
SWITCH, FULL POWER
1
18
0601831620
SWITCH, IDLE CONTROL
1
19
0601831620
SWITCH, OPERATION
1
20
0021004015
MACHINE SCREW
1
20A
0207004000
HEX NUT
1
21
A3262800004
CONDENSER ASSY. 50V @ 1000 µF
1
22
0017106016
HEX. HEAD BOLT
4
23
0017105010
HEX. HEAD BOLT
4
24
0601842426
RESISTOR, 40W 400 OHMS
1
25
0027104010
MACHINE SCREW
2
REMARKS
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 45
GA-4.5R/GA-4.5RA — PIPE FRAME ASSY.
PIPE FRAME ASSY.
PAGE 46 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
MQ GA-4.5R/GA-4.5RA — PIPE FRAME ASSY.
PIPE FRAME ASSY.
NO
PART NO
1
A4417000002
1
A4417000202
2
A3417100004
3
0017106016
4
A3304100003
5
A9312601704
6
7935416004
7
0207008000
8
0207008000
9
0017108040
9A
0207008000
10
A4364000002
11
A9924800014
12
A9924800004
13
0602125034
14
0605510026
14-1 0642007810
14-2 0642006410
15
0605513194
16
0605515062
17
7855525514
18
7855525604
19
0017108030
20
0017108020
21
A9117200103
22
0601850097
23
0021008025
23A
0207008000
24
A9311100004
24
0601851116
25
0011308025
25A
0037908000
25B
0042108000
26
0019206016
27
A3305200104
28
0017106016
29
A3414500004
30
A4924200004
PART NAME
QTY.
REMARKS
PIPE FRAME ............................................ 1 ................. GA-4.5R ONLY
PIPE FRAME ............................................ 1 ................. GA-4.5RA ONLY
BRACKET
1
HEX. HEAD BOLT
4
ENGINE BASE
1
RUBBER SUSPENSION
2
RUBBER SUSPENSION
2
HEX. NUT
8
HEX. NUT
2
HEX. HEAD BOLT
2
HEX. NUT
2
FUEL TANK
1
CAP, FUEL TANK
1
FUEL FILTER
1
FUEL GUAGE
1
FUEL STRAINER
1
CUP, FILTER FUEL STRAINER
1
PACKING, FUEL STRAINER CUP
1
HOSE
1
HOSE BAND
2
RUBBER CUSION
2
COLLAR
2
HEX. HEAD BOLT
2
HEX. HEAD BOLT
2
HANGER
1
STOPPER
1
MACHINE SCREW
1
HEX NUT
1
PLASTIC WASHER ................................... 2 ................. GA-4.5R ONLY
PLASTIC WASHER ................................... 2 ................. GA-4.5RA ONLY
HEX HEAD BOLT
2
HEX NUT
2
WASHER, FLAT
2
HEX HEAD BOLT
1
STOPPER
1
HEX HEAD BOLT
2
COVER
1
ROBIN ENGINE, EX27D
1
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 47
ROBIN EX270D20220 — CRANKCASE ASSY.
CRANKCASE ASSY..
PAGE 48 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20220 — CRANKCASE ASSY.
CRANKCASE ASSY.
NO
PART NO
10
2791010121
20% 2371420203
26% 2771601001
30
0440300160
*
46
* 0600300340
50
* 2771501103
60% 0105080250
70% 0105060410
75
0440060020
80
0401140020
90
0211140020
210
2791100111
220+ 0440300160
230+ 0600300020
250
2774500421
260
2774190103
275
2796500103
280$ 0213200050
281
0213200050
300
0010408350
340$ 2773520103
610
2791300111
620$ 2791500113
630
0110080240
631
0010408350
680
2771550101
690$ 2771600103
700
2771501103
710
0110060020
850
0851080000
960
2799900107
PART NAME
QTY.
REMARKS
CRANKCASE ASSY. ................................................ 1 ........ INCLUDES ITEMS W/
*
VALVE GUIDE
2
STEM SEAL
1
OIL SEAL
1
BALL BEARING
1
PIPE KNOCK
2
STUD
2
STUD
2
OIL SEAL
1
PLUG
2
GASKET
2
MAIN BEARING COVER .......................................... 1 ........ INCLUDES ITEMS W/+
OIL SEAL
1
BALL BEARING
1
GOVERNOR GEAR
1
GOVERNOR SLEEVE
1
FILLER PLUG
1
GASKET
1
GASKET
1
FLANGE BOLT
7
GASKET, MUFFLER 26D 9DX58P 0.2T
1
CYLINDER HEAD ASSY .......................................... 1 ........ INCLUDES ITEMS W/%
GASKET HEAD
1
FLANGE BOLT
4
FLANGE BOLT
1
ROCKER COVER
1
GASKET, ROCKET COVER
1
PIPE KNOCK
2
FLANGE BOLT
4
RUBBER PIPE
1
GASKET SET ........................................................... 1 ........ INCLUDES ITEMS W/$
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 49
ROBIN EX270D20110/EX270D20220 — CRANKSHAFT AND PISTON ASSY.
CRANKSHAFT AND PISTON ASSY.
PAGE 50 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20110/EX270D20220 — CRANKSHAFT AND PISTON ASSY.
CRANKSHAFT AND PISTON ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
10
2792020121
CRANKSHAFT CP
1
50
0180180010
FLANGE NUT
1
70
0323030010
WOODRUFF KEY
1
310
2792250120
CONNECTING ROD ASSY. ......................... 1 ......... INCLUDES ITEM W/
*
320
2792300103
CONNECTING ROD BOLT
2
*
350
2792330103
PISTON PIN
1
360
2792340103
PISTON, STANDARD
1
360
2792340303
PISTON OVERSIZE 0.25 MM
1
360
2792340403
PISTON OVERSIZE 0.50 MM
1
370
2792351107
PISTON RING SET, STANDARD
1
370
2792351207
PISTON RING SET, O.25 MM
1
370
2792351107
PISTON RING SET, STANDARD
1
380
0565180010
CLIP
2
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 51
ROBIN EX270D20110/EX270D20220 — GOVERNOR ASSY.
GOVERNOR ASSY.
PAGE 52 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20110/EX270D20220 — GOVERNOR ASSY.
GOVERNOR ASSY.
NO
PART NO
10
2794230113
20
2774220113
30
2794270101
40
2774280113
50
0031305000
60
0130060240
70
0186060020
80
2794250223
310
2774330113
340
2774350103
350
0200060170
355
0217060070
360
0140060180
365
2374500423
370
0021706000
435
2774600101
395
2774390203
396
0131050030
440
0043104080
450
0023506000
480
2774510103
485
0110060020
PART NAME
GOVERNOR LEVER
GOVERNOR SHAFT
GOVERNOR ROD CP
ROD SPRING
CLIP
BOLT AND WASHER ASSY.
NUT
GOVERNOR SPRING
SPEED CONTROL LEVER
STOP PLATE
WASHER
FRICTION WASHER
SCREW
SPRING, ADJUST
NUT
SPEED CONT. BRKT CP
CLAMP
SCREW AND WASHER ASSY.
SCREW
SELF LOCK NUT
RETURN SPRING
FLANGE BOLT
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
REMARKS
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 53
ROBIN EX270D20110/EX270D20220 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
PAGE 54 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20110/EX270D20220 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
NO.
10
25
27
34
*
35
*
37
*
38
*
60
70
80
90
95
150
160
163
166
170
200
210
220
224
225
230#
240#
290
540
550
PART NO.
2793160101
2773510103
0240060010
2773860103
2793640103
2773650103
2773870103
2793360103
2693370103
2793340113
2793350113
13210KA031
2793560111
2773691103
2773710103
2773690203
2773691313
2773500123
0031305000
2773620100
2774380101
2773620200
0149050020
0170050030
0110060020
2793290113
2793590123
PART NAME
QTY.
REMARKS
CAMSHAFT CP ......................................... 1 ............. INCLUDES ITEMS W/
*
PIN, CAMSHAFT, 9DX78.5L
1
O RING, 5.8DX9.6DX1.9T
1
SPRING PIN, 4DX7.5DX11L
1
RELEASE LEVER
1
CLIP, 13.8DX20.3DX0.4T
1
RETURN SPRING
1
VALVE SPRING, 17DX2.3DX27L N=5.8 2
SPRING RETAINER
2
INTAKE VALVE, 28.5DX5.5DX67.8L
1
EXHAUST VALVE, 26.5DX5.5DX67.8L
1
COLLET VALVE
4
TIMING CHAIN CP, 100 LINK
1
TENTIONER
1
SPRING, TENTIONER
1
PIN, TENTIONER, 6DX13DX34L
1
CHAIN GUIDE
1
PIN, ROCKER, 6DX9DX41L
1
CLIP
1
ROCKER ARM ASSY. IN .......................... 1 ............. INCLUDES ITEMS W/#
CHOKE LEVER CP
1
ROCKER ARM ASSY. EX ......................... 1 ............. INCLUDES ITEMS W/#
ADJUST SCREW, M5X0.5X23L
1
NUT, M5X0.5X4.1H
1
FLANGE BOLT, M6X1.0X12L
1
INSULATOR
1
GASKET, INSULATOR
1
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 55
ROBIN EX270D20110/EX270D20220 — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 56 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20110/EX270D20220 — MUFFLER ASSY.
MUFFLER ASSY.
NO.
310
320
340
350
360
361
365
PART NO.
2793010121
2793420111
2773520103
9802008280
0152060090
0110060010
0110080150
PART NAME
QTY.
MUFFLER, CP
1
MUFFLER COVER CP
1
GASKET, MUFFLER 26D 9DX58P 0.2T 1
FLANGE NUT
2
TAPPING BOLT, M6X1.0X10L
2
FLANGE BOLT, M6X1.0X8L
1
FLANGE BOLT, M8X1.25X12L
1
REMARKS
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 57
ROBIN EX270D20110/EX270D20220 — AIR CLEANER ASSY.
AIR CLEANER ASSY.
PAGE 58 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20110/EX270D20220 — AIR CLEANER ASSY.
AIR CLEANER ASSY.
NO.
510
510-200
*
510-220
*
510-250
*
520
*
PART NO.
2793262030
2793263308
2793265008
2793264508
2793260907
PART NAME
QTY. REMARKS
AIR CLEANER ASSY. LOW PROFILE ................. 1 ......... INCLUDES ITEMS W/
*
BODY CP
1
GASKET
1
COVER, LOW PROFILE
1
ELEMENT ASSY.
1
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 59
ROBIN EX270D20110/EX270D20220 — RECOIL STARTER ASSY.
RECOIL STARTER ASSY.
PAGE 60 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20110/EX270D20220 — RECOIL STARTER ASSY.
RECOIL STARTER ASSY.
NO
PART NO
10
2795120101
20
0732005140
40
0110060030
60
2795271111
61
2795270203
80
0016508120
81
0110060020
210
2795020200
210-1
2265071608
* 2795012008
210-2
* 2795011008
210-3
* 2265070108
210-4
* 2795012508
210-5
* 2265073108
210-6
* 2265075208
210-7
* 2795014508
210-11
* 2265074108
210-35
* 2265075318
210-49
* 0110060010
220
PART NAME
QTY.
REMARKS
BLOWER HOUSING CP
1
LABEL, TRADEMARK 64D
1
FLANGE BOLT
4
BAFFLE 1, CASE CP
1
BAFFLE 2, HEAD
1
BOLT
1
FLANGE BOLT
1
RECOIL STARTER ASSY. ................................... 1 ......... INCLUDES ITEM W/
*
SPIRAL SPRING
1
REEL
1
STARTER ROPE
1
STARTER KNOB
1
RATCHET
2
FRICTION SPRING
1
RATCHET SPRING
2
STARTER PULLEY
1
FRICTION PLATE
1
CENTER SCREW
1
FLANGE BOLT
4
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 61
ROBIN EX270D20110/EX270D20220 — CARBURETOR ASSY.
CARBURETOR ASSY.
PAGE 62 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20110/EX270D20220 — CARBURETOR ASSY.
CARBURETOR ASSY.
NO
PART NO
210
2796230210
210-1
2796253508
*
210-2
2516245008
*
2796252508
210-3
*
210-5
2796242008
*
2796235408
210-6
*
210-7
2796252008
*
2796252008
210-8
*
210-11
2796253008
*
2516245308
210-12
*
210-15
2796251508
*
2796255008
210-16
*
210-17
2796235008
*
210-18
2796254008
*
210-19
2796250508
*
210-22
2796240008
*
210-22
2796240108
*
210-28
2796235508
*
210-32
2796256108
*
210-40
2796235308
*
210-41
2796244508
*
210-60
2796256208
*
210-104
2796255208
*
210-121
* 2516248008
210-151
* 2796245208
210-152
2796245108
*
210-153
* 0652007810
210-154
0642006410
*
PART NAME
QTY.
REMARKS
CARBURETOR ASSY. ...................................... 1 ......... INCLUDES ITEM W/
*
VALVE THROTTLE
1
SCREW
2
VALVE CHOKE
1
JET SLOW
1
SCRE IDLE ADJUSTING
1
SPRING
1
SHAFT CHOKE
1
SHAFT SUB ASSY., THROTTLE
1
SCREW
1
PIN FLOAT LEVER
1
CHAMBER FLOAT
1
GASKET
1
GASKET CHAMBER
1
FLOAT SUB ASSY.
1
JET MAIN
1
JET MAIN
1
SCREW DRAIN
1
BUSH
1
SCREW ADJUSTING
1
SPRING
1
COLLAR
1
GASKET
1
CAP
1
O-RING
1
O-RING
1
FILTER CUP
1
PACKING, FILTER CUP
1
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 63
ROBIN EX270D20110/EX270D20220 — FLYWHEEL ASSY.
FLYWHEEL ASSY.
PAGE 64 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
ROBIN EX270D20110/EX270D20220 — FLYWHEEL ASSY.
FLYWHEEL ASSY.
NO
PART NO
10
2797923001
11
2797943001
30
0011406250
50
2777310101
60
X660000420
70
0150040090
100
0650140150
110
0655000270
PART NAME
FLYWHEEL CP
IGNITION COIL CP
BOLT & WASHER ASSY.
WIRE 2 CP, W/OIL SENSOR
SWITCH ASSY.
TAPPING SCREW
SPARK PLUG, NGK BR6HS
SPARK PLUG CAP
QTY.
1
1
2
1
1
2
1
1
REMARKS
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 65
TERMS AND CONDITIONS OF SALE — PARTS
Effective: February 22, 2006
PAYMENT TERMS
5.
Parts must be in new and resalable condition, in the original Multiquip package (if
any), and with Multiquip part numbers
clearly marked.
6.
The following items are not returnable:
Terms of payment for parts are net 30 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a signed
manifest has been obtained from the carrier,
and any claim for shortage or damage must be
settled between the consignee and the carrier.
a. Obsolete parts. (If an item is in the
price book and shows as being replaced by another item, it is obsolete.)
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were purchased more than six months prior to
the return date.
MINIMUM ORDER
Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
SPECIAL EXPEDITING SERVICE
A $35.00 surcharge will be added to the invoice
for special handling including bus shipments,
insured parcel post or in cases where Multiquip
must personally deliver the parts to the carrier.
LIMITATIONS OF SELLER’S LIABILITY
RETURNED GOODS POLICY
d. Special order items.
Return shipments will be accepted and credit
will be allowed, subject to the following provisions:
e. Electrical components.
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of the
item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental damages.
f. Paint, chemicals, and lubricants.
LIMITATION OF WARRANTIES
g. Decals and paper products.
1.
h. Items purchased in kits.
No warranties, express or implied, are made
in connection with the sale of parts or trade
accessories nor as to any engine not manufactured by Multiquip. Such warranties made in
connection with the sale of new, complete units
are made exclusively by a statement of warranty packaged with such units, and Multiquip
neither assumes nor authorizes any person to
assume for it any other obligation or liability
whatever in connection with the sale of its
products. Apart from such written statement of
warranty, there are no warranties, express,
implied or statutory, which extend beyond the
description of the products on the face hereof.
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
2.
A Returned Material Authorization must
be approved by Multiquip prior to shipment.
To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers, quantities, and descriptions of the items to be
returned.
a. The parts numbers and descriptions
must match the current parts price
list.
b. The list must be typed or computer
generated.
c. The list must state the reason(s) for
the return.
d. The list must reference the sales
order(s) or invoice(s) under which the
items were originally purchased.
e. The list must include the name and
phone number of the person requesting the RMA.
3.
A copy of the Return Material Authorization must accompany the return shipment.
4.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
c. Any line item with an extended dealer
net price of less than $5.00.
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 instructions. If a reply is not received within five
days, the material will be returned to the
sender at his expense.
9.
Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a specific date and all orders received on or after that
date will be billed at the revised price. Rebates
for price declines and added charges for price
increases will not be made for stock on hand
at the time of any price change.
PAGE 66 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
NOTE PAGE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 67
OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
18910 Wilmington Ave.
Tel. (800) 421-1244
Carson, CA 90746
Fax (800) 537-3927
Contact: mq@multiquip.com
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
MQ Parts Department
800-427-1244
310-537-3700
MEXICO
UNITED KINGDOM
MQ Cipsa
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: pmastretta@cipsa.com.mx
Tel: (52) 222-225-9900
Fax: (52) 222-285-0420
Fax: 800-672-7877
Fax: 310-637-3284
Warranty Department
800-421-1244, Ext. 279 Fax: 310-537-1173
310-537-3700, Ext. 279
Technial Assistance
800-478-1244
Fax: 310-631-5032
Multiquip (UK) Limited Head Office
Hanover Mill, Fitzroy Street,
Ashton-under-Lyne,
Lancashire OL7 0TL
Contact: sales@multiquip.co.uk
Tel: 0161 339 2223
Fax: 0161 339 3226
CANADA
BRAZIL
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: jmartin@multiquip.com
Multiquip
Av. Evandro Lins e Silva, 840 - grupo 505 Tel: 011-55-21-3433-9055
Barra de Tijuca - Rio de Janeiro
Fax: 011-55-21-3433-9055
Contact: cnavarro@multiquip.com.br, srentes@multiquip.com.br
Tel: (450) 625-2244
Fax: (450) 625-8664
© COPYRIGHT 2006, MULTIQUIP INC.
Multiquip Inc, the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the
property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the MQ GA4.5R and GA4.5RA
Portable Generators. Illustrations, descriptions, references and technical data 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 MULTIQUIP INC.
by
DENYO MANUFACTURING CO., JAPAN
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