MULTIQUIP Model GA-9.7 HZ A.C. GENERATOR

Transcription

1 PARTS AND OPERATION MANUAL MULTIQUIP Model GA-9.7 HZ A.C. GENERATOR COPYRIGHT 200, MULTIQUIP INC. Revision #2 (03/05/0) MULTIQUIP INC. PARTS DEPARTMENT: 890 WILMINGTON AVE CARSON, CALIFORNIA FAX: SERVICE DEPARTMENT/TECHNICAL ASSISTANCE: FAX: FAX: www:multiquip.com Atlanta Boise Dallas Houston Newark Montreal, Canada Manchester, UK Rio De Janiero, Brazil Guadalajara, Mexico

2 PAGE 2 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

3 HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING PARTS DEPARTMENT or FAX: or SERVICE DEPARTMENT/TECHNICAL ASSISTANCE or FAX: WARRANTY DEPARTMENT , or FAX: MAIN or FAX: GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 3

4 Here's How To Get Help... 3 Table Of Contents... 4 Parts Ordering Procedures... 5 Rules For Safe Operation... 6 Operation and Safety Decals... 7 Specifications... 8 General Information... 9 Multiquip GA-9.7 HZ AC Generator Controls and Indicators... 0 Installation... Pre-Setup Instrumentation... 4 Load Application... 5 Operating Instructions... 6 Maintenance... 7 Preparation For Long Term Storage... 8 Wiring Diagram... 9 Troubleshooting (Engine) Troubleshooting (Generator) Explanation Of Codes In Remarks Column Suggested Spare Parts Generator Assembly Control Box Assembly Pipe Frame Assembly Nameplate And Decals TABLE OF CONTENTS Honda GX60 K Engine Cylinder Head Assembly Cylinder Barrel Assembly Crankcase Cover Assembly Crankshaft Assembly Piston Assembly Camshaft Assembly Recoil Starter Assembly Fan Cover Assembly Carburetor Assembly Air Cleaner Assembly Muffler Assembly Fuel Pump Assembly Flywheel Assembly Ignition Coil Assembly Starter Motor Assembly Governor Control Assembly Labels Gasket Kit Terms and Conditions Of Sale Parts NOTE Specification and part number are subject to change without notice. PAGE 4 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

5 n Dealer account number n Dealer name and address n Shipping address (if different than billing address) n Return fax number n Applicable model number n Quantity, part number and description of each part n Specify preferred method of shipment: UPS Ground UPS Second Day or Third Day UPS Next Day PARTS ORDERING PROCEDURES Federal Express Priority One (please provide us with your Federal Express account number) Airborne Express Truck or parcel post Normally shipped the same day the order is received, if prior to 2PM west coast time. Earn Extra Discounts when you order by FAX! All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts: Number of line items ordered Additional Discount -9 items 3% 0+ items 5% Extra Fax Discount for Domestic USA Dealers Only Get special freight allowances when you order 0 or more line items via FAX! n UPS Ground Service at no charge for freight n PS Third Day Service at one-half of actual freight cost No other allowances on freight shipped by any other carrier. Common nuts, bolts and washers (all items under $.00 list price) do not count towards the 0+ line items. DISCOUNTS ARE SUBJECT TO CHANGE Fax order discount and UPS special programs revised June, 995 Now! Direct TOLL-FREE access to our Parts Department! Toll-free nationwide: Toll-free FAX: 800/6-PARTS GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 5

6 RULES FOR SAFE OPERATION CAUTION: 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-9.7 HZ Generator: GENERAL SAFETY DO NOT operate or service this equipment before reading this entire manual. This equipment should not be operated by persons under 8 years of age. NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job. This generator is a source of potentially LETHAL high voltage. Never permit unqualified personnel-especially children to operate the generator. 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. This generator is equipped with a ground terminal for your protection. Always complete the grounding path from the generator to an external grounding source. NEVER operate this generator, or handle any electrical equipment while standing in water, while bare foot, while hands are wet, or in the rain. Electrical shock could occur causing severe bodily harm or even death. Keep electrical cords in good condition. Worn, bare or frayed wiring can cause electrical shock, leading to bodily harm or even death. 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 and may cause injury to people. NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing generator. Provide adequate ventilation when operating the generator. DO NOT operate the generator in any enclosed or narrow space. The generator's gasoline engine gives off DEADLY carbon monoxide gas. 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. Always make sure that the generator is secure on level ground so that it cannot slide or shift around, endangering workers. Also keep the immediate area free of bystanders. When using a concrete vibrator or a similar device that is immersed in a water based solution, make sure the device is equipped with short circuit protection. Always use rubber boots and gloves when operating a concrete vibrator or similar device. Use adequate size connecting cable for extension. Maintain electrical cords in good condition and frequently replace the entire cable of the concrete vibrator with a new one. High Temperatures Allow the machine and engine to cool before adding fuel or performing service and maintenance functions. Contact with hot components can cause serious burns. Emergencies Always know the location of the nearest fire extinguisher and first aid kit. Know the location of the nearest telephone. Also know the phone numbers of the nearest ambulance, doctor and fire department. This information will be invaluable in the case of an emergency. Maintenance Safety NEVER lubricate components or attempt service on a running machine. Always allow the machine a proper amount of time to cool before servicing. Keep the machinery in proper running condition. Fix damage to the machine immediately and always replace broken parts. 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 PAGE 6 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

7 OPERATION AND SAFETY DECALS Machine Safety Decals The GA-9.7 HZ portable generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below shows these decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 7

8 GA-9.7 HZ SPECIFICATIONS MODEL Table. Specifications GA-9.7 HZ Type 2-pole, Brushless Type Revolving Field 60 Engine Cycle Generator Dimension (LXWXH) Effects of Altitude and Heat Max. Rated Rated Rated Output Output (continuous) Voltage Current 9700 Watts 8400 Watts 20/240 V 20.0/30.0 A P hase Single Phase (3-wire) Frequency Rated Speed 60 Hz 3600 RPM P ower Factor 00% Max Model Type Bore Current (Main Breaker) X Stroke Displacement 2-pole 35 Amps Honda GX60KV D Air-cooled 4 stroke OVH 90 V- Twin horizontal shaft gasoline engine 3.03 in X 2.60 in 8.8 cc R ated Output 8.0 H.P./3600 R.P.M. Fuel Fuel Lube Speed Starting Tank Capacity Oil Capacity Control Method Method Approx. 0 U.S. Gallons Unleaded Automobile Gasoline 3 /6 pints Centrifugal Fly-weight Typ e Electric/Recoil Start 800 X 540 X 700 mm D ry Net Weight 344 lbs (56 Kg. ) 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 inches and a temperature of 60 degrees fahrenheit. Generally, the engine output power will decrease 3 /2% for each 000 feet of altitude above sea level, and % for each 0 F fahrenheit above the standard temperature of 60 F PAGE 8 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

9 GA-9.7 HZ GENERAL INFORMATION WARNING: Before connecting this generator to any building s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious injury or death may result without this transfer switch. GA-9.7 HZ FAMILIARIZATION Generator The Multiquip Model GA-9.7 HZ generator has been designed as a portable lightweight power source for 60 Hz (singlephase) vibrators, lighting facilities, power tools, submersible pumps and other industrial and construction machinery. This generator is powered by a HONDA gasoline engine. The alternator, a brushless revolving-field type, is permanently aligned to the engine through rigid coupling. The generator is 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 box. To reduce vibration caused by the engine, the control box is also placed on rubber isolators. Excitation System All GA-series generators use 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 9-22 AC volts. This voltage (9-22 VAC) is then sent to the control box that contains three rectifying diodes: l Excitation (diode ) l Battery (diode 2) l 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 HONDA gasoline engine is designed to meet every performance requirement of this generator. Reference Table, page 8 for engine specifications. Figure (page 0) shows the basic controls and indicators for the GA-9.7 HZ generator. Control Box The control box is provided with the following: l Three 20/240V output receptacles (single phase). l Two 20 V output GFI receptacles (single phase)., l Five circuit breakers, one for each receptacle. l One 240 V, 60 Hz main circuit breaker. l AC Voltmeter. NOTE In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice. l Idle Control Switch. l Full Power Switch. l Operation Switch. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 9

10 GA-9.7 HZ CONTROLS AND INDICATORS Figure. Controls and Indicators PAGE 0 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

11 GA-9.7 HZ INSTALLATION Outdoor Installation Install the generator in a location where it will not be exposed to rain or sunshine. Make sure that 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. 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. Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear, not only to the engine parts, but also to the alternator parts. CAUTION : Pay close attention to ventilation when operating the generator inside confined areas. The engine exhaust contains noxious elements. Indoor Installation 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. 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. CAUTION : Preventing electrical shock. Pay close attention to handling when operating concrete vibrators. Always use rubber boots and gloves to insulate the body from a short circuit. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE

12 GA-9.7 HZ PRE-SETUP General Inspection Prior to Operation This generator has been thoroughly inspected prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occurred in transit. Circuit Breaker To protect the generator from an overload, circuit breakers are provided for single (60 Hz) phase on the control box. Make sure to switch the circuit breakers to the "OFF" position prior to starting the engine. Ground The nut and ground terminal on the generator should always be used to connect the generator to a suitable ground. The ground path should be of #8 size wire. Connect the terminal of the ground wire between the lock washer and the nut and tighten the nut fully. Connect their end of the wire to a suitable ground. Extension Cable When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 2 ) as a guide for selecting proper cable size. Ground the Generator Ground the generator from its ground connector so that resistance to ground is 500 ohms or less. Ground the Tool Ground the tool (load) in the same manner as the generator. Table 2. Cable Selection (60 Hz, single phase operation) Current in Amperes Load In Watts At 20 Volts At 240 Volts Maximum Allowable Cable Length # 0 Wire # 2 Wire # 4 Wire #6 Wire ft. 600 ft. 375 ft. 250 ft ft. 300 ft. 200 ft. 25 ft ft. 200 ft. 25 ft. 00 ft ft. 50 ft. 00 ft ft. 00 ft. 65 ft ft. 75 ft. 50 ft ft. 50 ft. 35 ft. CAUTION: Equipment damage can result from low voltage. PAGE 2 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

13 GA-9.7 HZ PRE-SETUP Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole, but do not overfill. Make sure the generator is level. With the dipstick inserted all the way, but without being screwed into the filler hole, verify that the oil level is maintained between the two notches on the dipstick. The oil listed in Table 3 is recommended to ensure better engine performance. Use class SC or higher grade motor oil. NOTE This HONDA engine is equipped with a low oil shutdown capability. A built in sensor will automatically turn off the engine should the oil level fall below a safe operating condition. Make sure the generator is placed on level ground. Placing the generator on level ground will ensure that the low oil sensor will function properly. Fuel Fill the fuel tank with clean and fresh unleaded gasoline. Do not fill the tank beyond capacity. Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed on page 8 Specification Table. The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. CAUTION : Never fill the fuel tank while the engine is running or in the dark. Gasoline spillage on a hot engine can cause a fire or explosion. If gasoline spillage occurs, wipe up the spilled gasoline completely to prevent fire hazards. Table 3. Recommended Motor Oil Temperature Range 04 F ~ 23 F (40 C ~ -5 C) 23 F ~ 5 F (-5 C ~ -5 C) Type Oil SAE 30 SAE 20 or sae 0W-30 B elow 5 C (-5 ) SAE 0W or SAE 0W-30 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 3

14 GA-9.7 HZ INSTRUMENTATION CAUTION : Power Outlets When using a combination of dual receptacles, total load should not exceed the rated capacity of the generating. The generator has the following 60 Hz 20/240 volt singlephase receptacles. l Single Phase Two Duplex NEMA (GFCI) 5-20R (20V, 20 Amp) One Twist Lock NEMA L5-30R (20V, 30 Amp) One Twist Lock NEMA L6-20R (240V, 20 Amp) One Twist Lock NEMA L5-30R (20/240, 30 Amp) Main Circuit Breaker (2-Pole 60 Hz) This 2-pole 35 amp breaker protects the generator from short circuiting or overloading from the 60 Hz single phase load. 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 2500 rpm (lowspeed 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. Fuel Gauge The fuel gauge is located on the fuel tank and allows easy monitoring of the fuel level. 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 Multiquip service dealer. PAGE 4 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

15 GA-9.7 HZ 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 30 50% 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 CAUTION: Motors and motor-driven equipment draw much greater current for starting than during operation. An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. The idle control is operated at minimum load capacity of 00W. If the load capacity is less than 00W, throw the idle control switch to the OFF position. To determine the running wattage for your load, multiply the running wattage as indicated by steps, 2, and 3 below:. INCANDESCENT LOADS Lights, heaters and similar appliances. Total the running wattage and multiply by. Example: 29 light 00W 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 inch drill runs at 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. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 5

16 GA-9.7 HZ OPERATING INSTRUCTIONS Before Starting. Be sure to disconnect the electrical load and switch the main circuit breaker to the OFF position prior to starting the engine. 2. Never start the engine with the main circuit breaker ON. 3. Check the lubricating oil level prior to starting the engine. Make sure the generator is level. The oil level must be maintained between two notches on the dipstick. 4. When there is not enough lubricating oil, fill the crankcase with high grade motor oil. Use a high quality detergent oil classified SC, SD or SE. (See Table 3 on page 3) CAUTION: l If gasoline spillage occurs, completely wipe up the spilled gasoline. Starting. Place the idle control switch in the ON (up) position. 2. Close the choke. Adjust the opening of the choke valve according to operating conditions. When the engine is warm or the air temperature is high, close the choke valve halfway or open it all the way. 3. Confirm that the main circuit breaker on the generator control box is OFF. 4. Set the operation switch to the ON position and grasp the starting rope and slowly pull it out. The resistance becomes hardest at a certain position, corresponding to the compression point. Rewind the rope a little from that point and pull out sharply. 5. If the engine fails to start, repeat the procedure. CAUTION: l NEVER start the engine when the oil level is below the lower mark on the dipstick. l Check the fuel level on the fuel gauge. When fuel is low, fill the fuel tank with clean fresh unleaded automotive gasoline. l DO NOT pull the starter rope all the way to the end. l DO NOT release the starter rope after pulling. Allow it to rewind as soon as possible. Warm up. When the engine starts, open the choke slowly. 2. Run the engine at low speed for 3 minutes without load until the engine warms up. 3. Turn the idle control switch to the "OFF" (down) position and check the voltage by referring to the voltmeter on the control box. CAUTION:. Check the generator for abnormal noise and smells. Then connect the load to the receptacles of the generator. 2. Switch the main circuit breaker to the ON position and turn the idle control switch to the ON (down) position for normal (load) engine operation. Operation Check the voltage by referring to the voltmeter on the control box. When the voltmeter indicates 20 volts, 20 volts from the 20V receptacles and 240 volts from the 240V receptacle can be obtained at the same time. Refer to Figure, Controls and Indicators, item 4 on page 0. Stopping the Engine CAUTION: DO NOT change the engine speed control lever which has been set at the factory prior to shipping. NEVER stop the engine suddenly while running at high speeds.. Remove the load from the generator. Place the circuit breaker in the OFF position. Refer to Figure, item 5 on page 0. Run the engine (no-load) with the idle control switch set to the ON position for three to five minutes, then stop the engine. 2. Turn the START/STOP switch to the STOP position. 3. Never stop the engine suddenly while running at high speed. PAGE 6 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

17 GA-9.7 HZ MAINTENANCE General Inspection At least daily or prior to each use, the generating set should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel or oil leaks. Engine Side (Refer to the Engine Instruction Manual) Check Oil Level Check the crankcase oil level prior to each use, or when the fuel tank is filled. Make sure the generating set is level. The oil level must be between the two notches on the dipstick. Changing Oil Change oil after the first 20 hours of operation. Drain and refill the engine crankcase every 50 operating hours or once a week thereafter. Drain crankcase oil into a suitable container while engine is still warm. Replace the drain plug tightly. Add oil through the filler hole. Air Cleaner Every 50 hours: Remove air cleaner element (std. or heavy duty types), and wash in kerosene or liquid detergent and hot water. Wrap foam element in a cloth and squeeze dry. Wipe heavy duty paper element dry with toweling. Saturate element with kerosene; squeeze excess from foam element. Wipe excess from heavy duty paper element. Service Daily If engine is operating in very dusty and dry grass conditions. A clogged air cleaner will result in high fuel consumption, loss of power and excessive carbon buildup in the combustion chamber. 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. Spark Plug Remove carbon build-up on the spark plug (Figure 5) with a wire brush. Set the spark plug gap to mm ( inch). Tighten with a spark plug socket wrench. Clean the spark plug every 50 operating hours or once a week. Figure 5. Spark Plug Gap GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 7

18 GA-9.7 HZ PREPARATION FOR LONG -TERM STORAGE Generator Storage For storage of the generating set for over 30 days, the following is required: l Drain the fuel tank completely. l Run the engine until the gasoline in the carburetor is completely consumed. l Completely drain the oil from the crankcase and refill with fresh oil. l Remove the spark plug, pour 2 or 3 cc of SAE 30 oil into the cylinder and crank slowly to distribute the oil. l Slowly rotate the engine a few times with the starter Rope and install a new plug. l Pull out the starter rope slowly and stop at the compression point. l Clean all external parts of the generating set with a cloth. l Cover the generating set and store in a clean, dry place. PAGE 8 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

19 GA-9.7 HZ WIRING DIAGRAM GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 9

20 GA-9.7 HZ 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 4) 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. SYMPTOM TABLE 4. ENGINE TROUBLESHOOTING POSSIBLE PROBLE M SOLUTION Inspect carburetor to see if fuel is reaching it? No Fuel? Check fuel line Add Fuel W ater in fuel tank? Flush or replace fuel tank. Fuel filter clogged? Replace fuel filter Poor starting (Engine will not start) S tuck carburetor? Check float mechanism. S park plug is black? Spark plug is fouled. Check tranistor ignition unit. Spark plug is blue-white? Insufficient compression, clogged (overflow). injected air leaking. Carburetor jets are No spark present at tip of spark plug? Tranistor ignition unit broken, high voltage cord cracked or broken. Start/Stop switch broken. Replace spark plug if fouled. N o oil? Add oil as required. Low oil or oil pressure shutdown sensor is defective? Check oil level, add oil if necessary. Check automatic oil shutdown circuit "oil sensor" Replace oil sensor. E ngine will not turn over? Replace cylinder and piston and if necessary axel joint. Cylinder loose? head connecting bolts Tighten cylinder head connecting bolts. Insufficient power output "no compression" C ylinder head gasket damaged? Replace cylinder head gasket. M alfunction of valve seat? Re-seat valves. S park plug is loose? Replace spark plug. W orn piston rings? Replace piston rings. Insufficient power output "compression" Malfunction in air-cleaner system, air filter clogged? Air leaking in from interface between carburetor and cylinder head? Malfunction in fuel system? Clean or replace air filter. Tighten bolts between cylinder head gasket. Clean or replace fuel filter. Clean or replace carburetor. Check carburetor float. carburetor and cylinder head. Replace PAGE 20 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

21 GA-9.7 HZ TROUBLESHOOTING (ENGINE) TABLE 4. ENGINE TROUBLESHOOTING (CONTINUED) SYMPTOM POSSIBLE PROBLE M SOLUTION Insufficient power output "compression" and overheats Burns to much fuel Exhaust color is continiously "WHITE" M alfunction in cooling fan? Check or replace cooling fan. A ir 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. W rong spark plug? Replace spark plug with manufactures suggested type spark plug. L ubricating oil is wrong viscosity? Replace lubricating oil with correct viscosity. Worn rings? Replace rings A ir cleanner clogged? Clean or replace air cleaner. Exhaust color is continiously "BLACK" Choke valve has not been set to the correct position? Carburetor defective, seal on carburetor broken? Poor carburetor adjustment "engine runs too rich? Adjust choke valve to the correct position. Replace carburetor or seal. Adjust carburetor. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 2

22 GA-9.7 HZ 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 5) 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 5. GENERATOR TROUBLESHOOTING SYMPTOM POSSIBLE PROBLE M SOLUTION L ow voltage E ngine speed too low? Raise engine speed to rated RPM. A C voltmeter not working? Replace Ac voltmeter. Control box internal wiring malfunction? Check control box wiring. Low voltage. Engine speed normal 3650 RPM (unloaded), 2500 RPM (idle) Defective ignition coil? Check red and necessary. R otor winding malfunction? Check or replace rotor. green ignition wires. Replace ignition wires if S tator winding malfunction? Check or replace stator. L eakage breaker malfunction? Check or replace CB or CB2. F ull power switch malfunction? Check full power switch and full power switch circuit. V oltage output too high. E ngine 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" Circuit breaker will turn on "LOADED" but trips immediately. Does not accelerate from low to high "NO LOAD" D efective circuit breaker? Replace circuit breaker. O verloaition? Reduce load or replace breaker. L oad circuit is shorted? Check load circuit for short. S tuck solenoid? Check solenoid. B ad Idle control switch? Check or replace idle control switch. I dle control switch malfunction? Check or replace idle control switch. Does not accelerate from low to high "LOAD ACTIVE" I dle control device malfunction? Check or replace idle control device. Control box internal wiring Check control box wiring. defective? PAGE 22 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

23 GA-9.7 HZ TROUBLESHOOTING (GENERATOR) TABLE 5. GENERATOR TROUBLESHOOTING (CONTINUED) SYMPTOM POSSIBLE PROBLE M D efective rotor windings? Check or replace rotor. SOLUTION Does not decelerate no "VOLTAGE OUTPUT". D efective solenoid? Check or replace solenoid. D efective idle control device? Check or replace idle control device. D efective solenoid? Check or replace idle control device. Does not decelerate but has "VOLTAGE OUTPUT". C ontrol box wiring malfunction? Check control box wiring, replace any defective components. D efective solenoid? Check or replace solenoid. I dle control device malfunction? Check or replace idle control device. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 23

24 GA-9.7 HZ EXPLANATION OF CODE IN REMARKS COLUMN How to read the marks and remarks used in this parts book. Items Found In the Remarks Column Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used. Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant. Items Found In the Items Number Column All parts with same symbol in the number column,, #, +, %, or, belong to the same assembly or kit. NOTE If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available. NOTE The contents of this catalog are subject to change without notice. PAGE 24 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

25 GA-9.7 HZ SUGGESTED SPARE PARTS GA-9.7 TO 3 UNITS WITH HONDA GX60KVD ENGINE to 3 Units Qty. P/N Description RECTIFIER RELAY CIRCUIT BREAKER RECEPTABLE RECEPTACLE, 250V, 20A RECEPTACLE RECEPTACLE CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER IDLE CONTROL SWITCH OPERATION SWITCH BUTTON STARTER FUSE CAP FUEL STRAINER GAUGE FUEL 2... D SUSPENSION RUBBER A... SUSPENSION RUBBER SPARK PLUG PR CARTRIDGE FILTER, OIL ZJ82... SWITCH ASSY, OIL LEVEL ZJ CARBURETOR ASSY ZJ ELEMENT SET AIR CLEANER ZE FILTER COMP FUEL NOTE Part numbers on this Suggested Spare Parts List may supercede/ replace the P/N shown in the text pages of this book. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 25

26 GA-9.7 HZ GENERATOR ASSY. GENERATOR ASSY. PAGE 26 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

27 GENERATOR ASSY. GA-9.7 HZ GENERATOR ASSY. NO PART NO PART NAME QTY. REMARKS A ROTOR ASSY. INCLUDES ITEMS W/ - FIELD ASSY RECTIFIER BEARING......REPLACES A FAN 3 4 A SET BOLT, ROTOR SET WASHER BEARING SPRING WASHER 6 7 A A ARMATURE ASSY. END BRACKET 8 A END BRACKET 9 0 A A COVER, STATOR SET BOLT, STATOR SPRING WASHER PLAIN WASHER REPLACES GROMMET 4 A COVER, BEARING MACHINE SCREW 3 HEX, HEAD BOLT REPLACES SPRING WASHER 4 7 A COVER RIVET 4 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 27

28 GA-9.7 HZ CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 28 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

29 CONTROL BOX ASSY. GA-9.7 HZ CONTROL BOX ASSY. NO PART NO PART NAME QTY. REMARKS 2 A CONTROL BOX GROMMET 2 G TERMINAL PLATE HEX, HEAD BOLT RECTIFIER 5 5 S5VB MACHINE SCREW RELAY MACHINE SCREW MPR-2TS DC2V 9 A CONTROL PANEL A AC VOLTMETER HEX, NUT V/240V CIRCUIT BREAKER KM52 2P 265V,35A BRACKET, CIRCUIT BREAK MACHINE SCREW RECEPTACLE L4-30R 25/250V,30A, RECEPTACLE L6-20R 250V,20A, RECEPTACLE L5-30R25V,30A, REPLACES RECEPTACLE R 20V,20A, REPLACES MACHINE SCREW 0 HEX. NUT REPLACES CIRCUIT BREAKER CP32E/30N AC250V,30A CIRCUIT BREAKER CIRCUIT BREAKER CP32E/20N AC250V,30A CP3E/30N AC250V,30A CIRCUIT BREAKER 2 CP3E/20N AC250V,20A MACHINE SCREW IDLE CONTROL SWITCH 0 S-B OPERATION SWITCH ET225N START SWITCH ST-403 REPLACES GROUND TERMINAL T IDLE CONTROL DEVICE ND MACHINE SCREW 2 HEX. HEAD BOLT REPLACES HEX. HEAD BOLT FUSE 2 0A AC250V GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 29

30 GA-9.7 HZ PIPE FRAME ASSY. PIPE FRAME ASSY. PAGE 30 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

31 PIPE FRAME ASSY. GA-9.7 HZ PIPE FRAME ASSY. NO PART NO PART NAME QTY. REMARKS A PIPE FRAME 2 A FLOOR PANEL 3 A FUEL TANK CAP, FUEL TANK INCLUDES ITEM W/ REPLACES FUEL FILTER DRAIN PLUG O RING FUEL GAUGE HEX. HEAD BOLT REPLACES HEX. HEAD BOLT REPLACES A D BASE RUBBER SUSPENSION HEX. NUT A RUBBER SUSPENSION REPLACES HEX. NUT HEX. HEAD BOLT HEX. NUT HEX. HEAD BOLT A BRACKET 6-7 A LINING HEX, HEAD BOLT 8 8 A COVER A HEX. HEAD BOLT AIR GUIDE HEX. HEAD BOLT A HANGER HEX. HEAD BOLT Z ROTARY SOLENOID REPLACES ARM, SOLENOID HEX. HEAD BOLT REPLACES HEX. NUT REPLACES A WIRE STOPPER HEX. HEAD BOLT 29 A BRACKET, SOLENOID HEX. NUT HEX. HEAD BOLT HEX. NUT REPLACES A HEX. HEAD BOLT THROTTLE WIRE MACHINE SCREW A COVER, SOLENOID HEX. HEAD BOLT 4 37 A BATTERY SHEET D BATTERY BAND BATTERY BOLT WING NUT SPRING WASH PLAIN WASHER REPLACES TERMINAL CAP (RED) TERMINAL CAP (BLK) D TERMINAL CAP HEX. HEAD BOLT HOSE HOSE BAND HOSE BAND GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 3

32 GA-9.7 HZ NAMEPLATE ASSY. NAMEPLATE ASSY. PAGE 32 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

33 NAMEPLATE ASSY. NO PART NO PART NAME QTY. REMARKS NAME PLATE ORDER FROM MULTIQUIP SERVICE DEPT. BY MODEL & SERIAL NUMBER DECAL; GROUND S DECAL; BATTERY DECAL; OIL DRAIN S DECAL; FUEL DRAIN S DECAL; WARNING DANGEROUS DECAL; DANGER ELECTRICAL S-4984 S B DECAL; CAUTION HOT PARTS B D DECAL; OPERATING INSTRUCTIONS D B DECAL; CAUTION! REPLACES DECAL; WARNING! DECAL; 3600RPM ONLY DECAL; CAUTION OIL LEVEL GAUGE 3 A DECAL; MQ MULTIQUIP SEE PAGE 7 FOR DECAL ILLUSTRATIONS. GA-9.7 HZ NAMEPLATE ASSY. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 33

34 CYLINDER HEAD ASSY. HONDA GX60K ENGINE CYLINDER HEAD ASSY. HONDA GX60K ENGINE CYLINDER HEAD PAGE 34 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

35 CYLINDER HEAD ASSY. HONDA GX60K ENGINE CYLINDER HEAD ASSY. NO PART NO PART NAME QTY. REMARKS 220ZJ000 CYLINDER HEAD COMP., R INCLUDES ITEMS W/ ZJU80 CYLINDER HEAD COMP., L INCLUDES ITEMS W/ ZE2305 GUIDE, EX. VALVE (OS) ZE2300 CLIP, VALVE GUIDE ZJ003 GASKET, CYLINDER HEAD ZJ000 COVER, HEAD ZJ ZJ000 COVER, HEAD FILLER GASKET, HEAD COVER CAP, OIL 0 70ZJ000 75ZJ003 MANIFOLD, IN. GASKET, IN. MANIFOLD ZJ000 BOLT, FLANGE (6X25) (CT200) B O-RING (26X2.7) BOLT, STUD (8X25) PIN A, DOWEL (2X20) BOLT, FLANGE (6X32) BOLT, FLANGE (0X75) BOLT, FLANGE (0X30) SPARK PLUG (BPR6ES) (NGK) 2 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 35

36 CYLINDER BARREL ASSY. HONDA GX60K ENGINE CYLINDER BARREL ASSY. PAGE 36 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

37 CYLINDER BARREL ASSY. HONDA GX60K ENGINE CYLINDER BARREL ASSY. NO PART NO PART NAME QTY. REMARKS 2000ZJ80 CYLINDER BARREL ASSY INCLUDES ITEMS W/ ZJ000 COVER, BREATHER ZJ000 GASKET, BREATHER COVER ZE2300 VALVE, BREATHER 5 332ZJ000 BEARING A, MAIN (BLUE) 3322ZJ000 BEARING B, MAIN (BLACK) ZJ PR3004 BEARING C, MAIN (BROWN) FILTER, OIL VD600 COLLAR, FILTER SETTING ZJ ZJ82 CLAMP, WIRE SWITCH ASSY., OIL LEVEL ZE6000 BOLT, FLANGE (6X35) PN HOLDER, OIL FILTER BOLT, FLANGE (6X6) ZE000 BOLT, FLANGE (6X32) ZJ003 OIL SEAL (38X58X) O-RING (4MM) BOLT, DRAIN PLUG (4MM) NUT, FLANGE (0MM) WASHER, DRAIN PLUG (4MM) BOLT, FLANGE (6X75) BEARING, RADIAL BALL (6003) 20A0ZJ000 CYLINDER ASSY. GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 37

38 CRANKCASE COVER ASSY. HONDA GX60K ENGINE CRANKCASE COVER ASSY. PAGE 38 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

39 CRANKCASE COVER ASSY. HONDA GX60K ENGINE CRANKCASE COVER ASSY. NO PART NO PART NAME QTY. REMARKS 300ZJ000 COVER ASSY., CRANKCASE ZJ ZAO70 GASKET, CASE COVER BOLT, SEALING 4 332ZJ000 BEARING A, MAIN (BLUE) 3322ZJ ZJ000 BEARING B, MAIN (BLACK) BEARING C, MAIN (BROWN) 5 520ZJ000 COVER ASSY., OIL PUMP ZJ ZJ000 ROTOR, OIL PUMP (OUTER) SPRING, RELIEF VALVE ZJ000 COVER, OIL FILTER ZJ ZJ000 SCREEN, OIL FILTER DIPSTICK, OIL 654ZJ000 SHAFT, GOVERNOR ARM ZJ ZJ003 FORK, GOVERNOR OIL SEAL (38X58X) NM0000 OIL SEAL (0X6X4.5) REPLACES MB A O-RING (3X3.0) SCREW, PAN (5X0) PIN A, DOWEL (8X4) BOLT, FLANGE (6X20) BOLT, FLANGE (8X50) BALL, STEEL (#2) (3/8) BOLT, SOCKET (6X6) 2 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 39

40 HONDA GX60K ENGINE CRANKSHAFT ASSY. CRANKSHAFT ASSY. PAGE 40 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

41 CRANKSHAFT ASSY. HONDA GX60K ENGINE CRANKSHAFT ASSY. NO PART NO PART NAME QTY. REMARKS 3 330ZJ0880 CRANKSHAFT COMP ZJ000 WASHER, CRANKSHAFT THRUST GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 4

42 HONDA GX60K ENGINE PISTON ASSY. PISTON ASSY. PAGE 42 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

43 PISTON ASSY. HONDA GX60K ENGINE PISTON ASSY. NO PART NO PART NAME QTY. REMARKS 300ZE860 RING SET, PISTON (STD) 2 30ZE860 RING SET, PISTON (0.25) 2 302ZE ZE860 RING SET, PISTON (0.50) RING SET, PISTON (0.75) ZJ000 PISTON 2 302ZJ ZJ000 PISTON (0.25) PISTON (0.50) ZJ000 PISTON (0.75) 2 3 3ZJ000 PIN, PISTON ZJ000 ROD SET, CONNECTING INCLUDES ITEM W/ 5 32ZJ003 BEARING A, CONNECTING ROD (BLUE) 4 322ZJ ZJ003 BEARING B, CONNECTING ROD (BLACK) BEARING C, CONNECTING ROD (BROWN) ZJ003 BEARING D, CONNECTING ROD (GREEN) 4 325ZJ ZJ003 BEARING E, CONNECTING ROD BEARING F CONNECTING ROD ZJ003 BEARING G CONNECTING ROD ML0000 BOLT, CONNECTING ROD KM3000 NUT, CONNECTING ROD CLIP, PISTON PIN (8MM) 4 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 43

44 HONDA GX60K ENGINE CAMSHAFT ASSY. CAMSHAFT ASSY. PAGE 44 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

45 CAMSHAFT ASSY. HONDA GX60K ENGINE CAMSHAFT ASSY. NO PART NO PART NAME QTY. REMARKS 2209ZE8003 SEAL, VALVE STEM ZJ80 CAMSHAFT ASSY INCLUDES ITEM W/ 3 40ZJ80 CAMSHAFT COMP INCLUDES ITEM W/# 4 440ZJ000 ROD, PUSH ZJ000 ARM, VALVE ROCKER ZE2000 LIFTER, VALVE ZJ000 SHAFT, ROCKER ARM ZJ800 SPRING, WEIGHT RETURN ZJ80 HOLDER, DECOMPRESSION PIN J80 PIN A, DECOMPRESSION (7.85) ZJ80 PIN B, DECOMPRESSION (7.95) REPLACES 4577ZJ ZJ ZJ800 PIN C, DECOMPRESSION (8.05) REPLACES 4578ZJ800 PIN D, DECOMPRESSION (8.5) ZJ800 PIN E, DECOMPRESSION (8.25) 2 # 458ZJ80 ROD, DECOMPRESSION ZJ800 SPRING, DECOMPRESSION PIN HOLDER ZJ000 VALVE, INLET ZJ ZE2003 VALVE, EX. SPRING VALVE ZE2000 RETAINER, IN. VALVE SPRING ZE200 SEAT, VALVE SPRING ZJ000 HOLDER, GOVERNOR WEIGHT ZJ000 PLATE, GOVERNOR WEIGHT HOLDER ZJ000 PIN, GOVERNOR WEIGHT HOLDER ZJ000 PLATE, GOVERNOR (LOWER) ZJ000 PLATE, GOVERNOR SLIDER ZJ003 SLIDER, GOVERNOR SCREW, TAPPET ADJ NUT, TAPPET ADJ WASHER, THRUST (7.2MM) ZJ003 BALL, STEEL (8) CIRCLIP (OUTER) (7MM) GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 45

46 HONDA GX60K ENGINE RECOIL STARTER ASSY. RECOIL STARTER ASSY. PAGE 46 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

47 RECOIL STARTER ASSY. HONDA GX60K ENGINE RECOIL STARTER ASSY. NO PART NO PART NAME QTY. REMARKS 28400ZE3W0ZA STARTER ASSY., RECOIL R8 (BRT. RED) INCLUDES ITEMS W/ ZE3W0ZA CASE COMP. RECOIL STARTER R8 (BRT RED) ZE3W0 PULLEY, RECOIL STARTER ZE2W0 RATCHET STARTER ZE2W0 SPRING, FRICTION ZE2W0 SPRING, STARTER RETURN ZE2W0 SPRING, RATCHET ZE2W0 RETAINER, SPRING ZE2W0 HOLDER, SPRING ZE2W0 GRIP, STARTER 28462ZH8003 ROPE, RECOIL STARTER REPLACES 28462ZE3W ZE2W0 GRIP, REINFORCEMENT ZE2W0 SCREW, CENTER BOLT, FLANGE (6X8) 3 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 47

48 HONDA GX60K ENGINE FAN COVER ASSY. FAN COVER ASSY. PAGE 48 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

49 FAN COVER ASSY. HONDA GX60K ENGINE FAN COVER ASSY. NO PART NO PART NAME QTY. REMARKS 2 96ZJ800ZB COVER, FAN R8 (RECOIL STARTER)(BRT.RED) 4 962ZJ000 PLATE, R. SIDE ZJ ZJ000 PLATE, L SIDE HOOD FAN COVER 7 967ZJ4000 COVER, R. SIDE PLATE 0 963ZJ ZJ000 SHROUD, R. SHROUD, L ZJ80ZB SPACER, RECOIL START MOUNT R8 (BRT RED)) GC COLLAR B,TAILLIGHT BOLT, FLANGE (6X2) ZE000 BOLT, FLANGE (6X23) ZJ ZE000 BOLT, STUD (6X75) SCREW, TAPPING (4X6) GF6000 BOLT, FLANGE (6X20) GE SD978 BOLT, FLANGE (6MM) (BLACK) CLIP (20MM) NUT, FLANGE (6MM) BOLT, FLANGE (6X8) 2 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 49

50 HONDA GX60K ENGINE CARBURETOR ASSY. CARBURETOR ASSY. PAGE 50 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

51 CARBURETOR ASSY. HONDA GX60K ENGINE CARBURETOR ASSY. NO PART NO PART NAME QTY. REMARKS 2357ZJ000 TUBE, BREATHER CLIP, BREATHER TUBE 3 # 600ZG8000 GASKET SET VALVE SET, FLOAT REPLACES 60GK ZV4005 FLOAT SET 6 605ZJ000 CHAMBER SET, FLOAT INCLUDES ITEMS W/# 7 606ZJ00 SCREW SET 8 # SCREW SET,DRAIN ZG8000 SCREW SET 0 608ZV4650 SCREW-WASHER 4 600ZJ0892 CARBURETOR ASSY. (BG2E B) INCLUDES ITEMS W/ CAP, CHOKE LEVER DUST 3 65ZJ0020 JET SET (#60) 4 666ZJ00 NOZZLE, MAIN REPLACES 666ZJ O-RING (5.8X.9) ZJ003 VALVE ASSY., SOLENOID 7 62ZJ000 INSULATOR, CARBURETOR 8 622ZG8000 GASKET, CARBURETOR ZG8003 GASKET, AIR CLEANER ZJ000 ELBOW COMP., AIR CLEANER INCLUDES ITEMS W/ ZA0000 COLLAR, DISTANCE CLIP B, CABLE SCREW-WASHER (5X2) CLIP, TUBE (B8) BULK HOSE, VAC (4.5X460) BOLT, FLANGE (6X05) ZG80880 JET SET, MAIN (#88) 9920ZG80820 JET SET, MAIN (#82 HIGH ALTITUDE) 9920ZG80850 JET SET, MAIN (#85 HIGH ALTITUDE) GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 5

52 HONDA GX60K ENGINE AIR CLEANER ASSY. AIR CLEANER ASSY. PAGE 52 GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0)

53 AIR CLEANER ASSY. HONDA GX60K ENGINE AIR CLEANER ASSY. NO PART NO PART NAME QTY. REMARKS 700ZJ000 ELEMENT SET, AIR CLEANER INCLUDES ITEMS W/ 2 726ZJ000 GASKET A, ELEMENT 3 727ZJ000 GASKET B, ELEMENT 4 728ZJ000 FILTER (OUTER) ZJ000 HOUSING COMP., AIR CLEANER ZJ ZJ000 COVER, AIR CLEANER GROMMET, AIR CLEANER ZJ000 HOSE, AIR CLEANER ZJ TUBE, AIR CLEANER CONN. BAND, AIR CLEANER CONN. TUBE 7257HB3000 BAND, AIR CLEANER (B) ZJ ZE000 BOLT, AIR CLEANER BOLT, FLANGE (6X23) COLLAR, AIR CLEANER HOUSING A G SCREW, PAN (4X20) SCREW, PAN (4X25) SCREW, WASHER BOLT, FLANGE (6X8) REPLACES GA-9.7 HZ A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/0) PAGE 53