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 ALLTIMES.
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NOTE PAGE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 3
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TABLE OF CONTENTS
ROBIN EX270D Engine
GA-4.5R/GA-4.5RA — AC
(EPA)
Portable Generators
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
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
Terms and Conditions Of Sale — Parts .................. 66
As a continuing effort to
update our parts book, contact
the MQ literature department
for the latest revision of your
"Operation and Parts Manual"
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)
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PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Best Deal!
Order via Internet (Dealers Only)
Orderpartson-lineusingMultiquip’sSmartEquipwebsite!
:
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
■
■
■
View Parts Diagrams
Order Parts
PrintSpecificationInformation
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.*
Gotowww.multiquip.comandclickon
to log in and save!
Order Parts
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
Domestic (US) Dealers Call:
1-800-427-1244
Order via Phone:
Non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒
❒
❒
❒
❒
❒
Dealer Account Number
❒
Specify Preferred Method of Shipment:
✓
Fed Ex/UPS
✓ DHL
Dealer Name and Address
■
■
Priority One
Ground
✓
Truck
Shipping Address (if different than billing address)
Return Fax Number
Applicable Model Number
■ Next Day
■
Second/ThirdDay
Quantity, Part Number and Description of Each Part
Unless otherwise indicated by customer, all orders are treated asStandard Orders and will ship
within24hours.WewillmakeeveryefforttoshipAirShipmentsthesamedaytheorderisreceived,
if received prior to 2PM PST. Stock Orders must be noted on fax or web order form.
NOTE
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
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GA-4.5R/GA-4.5RA — SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "Hazard Symbols" which
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.
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
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
developed to provide complete
instructions for the safe and efficient
operation of the MQ Model GA-4.5R/
GA-4.5RA Portable Generators.
Refer to the engine manufacturers
instructions for data relative to its safe
operation.
DEATH if inhaled. NEVER operate this
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
Before using this generator, ensure that the operating
individual has read and understands all instructions in this
manual.
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.
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.
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.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
WARNING - BURN HAZARDS
WARNING
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.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
DANGER - ELECTROCUTION HAZARDS
You CAN be injured if you do not follow directions
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)
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GA-4.5R/GA-4.5RA — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - RESPIRATORY HAZARDS
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
ALWAYS wear approved respiratory
protection.
CAUTION - ACCIDENTAL STARTING
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
ALWAYS wear approved eye and
hearing protection.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - EQUIPMENT DAMAGE MESSAGES
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.
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
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GA-4.5R/GA-4.5RA — RULES FOR SAFE OPERATION
■
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
DANGER - READTHIS 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:
■
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
GENERAL SAFETY
■
DO NOT operate or service this
equipment before reading this entire
manual.
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
■
■
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.
monoxide gas.
■
■
ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
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 this equipment under the influence of
drugs or alcohol.
■
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 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.
■
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.
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.
PAGE 8 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
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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.
Maintenance Safety
■
NEVER lubricate components or attempt service on a running
machine.
NEVER leave the generator unattended, turn off engine when
unattended.
■
HighTemperatures – 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.
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.
■
■
Keep the machinery in proper running condition.
Fix damage to the machine immediately and replace any
broken parts immediately.
■
■
NEVER run engine without air cleaner.Severe engine damage
may occur.
■
■
ALWAYS replace any worn or damaged warning decals.
NEVER change or adjust the engine speed which has been
set at the factory prior to shipping.
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.
Power Cord Safety
■
NEVER let power cables or cords lay in water.
■
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.
■
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.
■
■
■
Dispose of hazardous waste properly.Examples of potentially
hazardous waste are used motor oil, fuel and fuel filters.
NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.
DO NOT use food or plastic containers to dispose of
hazardous waste.
ALWAYS make certain that proper power or extension cord
has been selected for the job See Table 3.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
Grounding Safety
■
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
severescaldingtoanypersonsinthegeneral
area of the generator.
■
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 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
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GA-4.5R/GA-4.5RA — RULES FOR SAFE OPERATION
Emergencies
DANGER-ELECTROCUTION HAZARDS
■
ALWAYS know the location of the
nearest fire extinguisher.
During operation of this generation, there
exists the possibility of electrocution,
electrical shock or burn, which can
cause severe bodily harm or even
DEATH!
■
■
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)
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GA-4.5R/GA-4.5RA — SPECIFICATIONS
Table 1. Specifications
MODEL
GA-4.5R/GA-4.5RA
Type
2-Pole, Brushless Type Revolving Field
Frequency (Hz)
60
3.70
Continuous Output (kW)
Maximum Output (kW)
Voltages (VAC)
4.5
120/240
37.5/30.8
18.75/15.4
3600
Max/Continuous Amps 120 VAC
Max/Continuous Amps 240 VAC
Rated Speed (RPM)
Power Factor
GENERATOR
1.0
23 X 18.5 X 20.25
(595 X 470 X 515)
Dimension (L x W x H) in. (mm)
Dry Net Weight lbs. (kg)
Includes Engine
149 (68)
ROBIN EX27OD20110 (GA-4.5R)
ROBIN EX27OD20220 (GA-4.5RA)
Model (Engine Specification)
Type
Air-cooled, 4-stroke, Single Cylinder, Overhead
Camshaft, Gasoline Engine
Displacement (cc)
265
5.1 @3600
Continuous Output (kW/min)
Maximum Output (kW/min)
Fuel Tank Capacity Gal. (L)
Fuel
9.0 @4000
4.2 (19)
ENGINE
Non-leaded Automobile Gasoline
1.16 (1.1)
Lube Oil Capacity Qts. (L)
Speed Control Method
Starting Method
Centrifugal Fly-weight Type
Recoil Start
13.97 X 16.5 X 16.14
(355 X 420 X 410)
Dimension (L x W x H) in. (mm)
Dry Net Weight lbs. (kg)
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
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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)
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GA-4.5R/GA-4.5RA — GENERAL INFORMATION
Excitation System
DANGER - ELECTRICAL SYSTEM HAZARDS
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.
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.
This voltage (19-22 VAC) is then sent to the control box that
contains three rectifying diodes:
GA-4.5R/GA-4.5RA Familarization
General Inspection Prior to Operation
z
z
z
Excitation (diode 1)
Battery (diode 2)
Slow Down (diode 3)
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 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".
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.
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.
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.
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.
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.
Figures 2A through 2E show the basic controls and
indicators for the GA-4.5R/ GA-4.5RA generators.
This portable generator is supplied with a electrical control
In keeping with Multiquip's
panel. The control panel includes items as listed below.
policy
of
constantly
Control Panel
improving its products, the
specifications quoted herein
are subject to change without
prior notice.
The generator control panel has the following componets:
■
NEMA 5-20R GFCI duplex receptacle, (120V, 20 amps),
GA-4.5RA has two.
■
■
■
■
■
■
■
■
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
ACVoltmeter
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
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GA-4.5R/GA-4.5RA — LOAD APPLICATION
To determine the running wattage for your load, multiply
the running wattage as indicated by steps 1, 2, and 3 below:
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.
1. INCANDESCENT LOADS
Lights, heaters and similar appliances.
Total the running wattage and multiply by 1.
Example:
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.
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.
If wattage is not given on the equipment's
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate amperage.
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.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 1.0 See Table 2 below
when connecting loads.
Table 2. Power Factor By Load
CAUTION - ADEQUATE EXTENSION CABLE
Type Of Load
Power Factor
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.
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
Fluorescent lamps, mecury
lamps
0.4 - 0.9
Extension Cables
Electronic devices,
communication equipment
1.0
0.8
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.
Common power tools
When using a combination of dual
receptacles, total load should not
exceed the rated capacity of the
generator.
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)
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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
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.
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.
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.
3. 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.
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.
10. Frame Ground – This ground connection point should
4. 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).
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
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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
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.
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.
Figure 2D. Full Power Switch 120/240VAC (Down)
SimplifiedWiring Diagram
Figure 2C. Full Power Switch 120VAC (Up)
SimplifiedWiring Diagram
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)
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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
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.
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.
20. Oil Drain Plug – Remove this plug to drain engine oil from
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.
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.
14. Throttle Lever – Used to adjust engine RPM speed.This
unit is set at the factory and is not adjustable.
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
15. Engine – This generator uses a 9.0 HP ROBIN air-
cooled, 4-stroke , single cylinder, overhead camshaft
gasoline engine. Engine uses unleaded fuel.
23. Generator Housing – Contains the rotor, rectifer field
coil assembly, aramature, bearings and other components
that make up generator asembly.
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.
24. Fuel Gauge – Read this gauge to determine when fuel is
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.
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).
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.
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 17
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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
surroundingtheengineisdry. Ifgeneratorisplaced
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)
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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.
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.
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.
Generator Grounding
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
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.
WARNING - LETHAL EXHAUST GASES
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.
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
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.
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
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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)
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GA-4.5R/GA-4.5RA — PRE-INSPECTION
General Inspection Prior to Operation
Ground Power Tools
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 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!
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)
Load In Watts
At 120 Volts
300
Maximum Allowable Cable Length
Current in
Amperes
#10 Wire
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
#12 Wire
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
#14 Wire
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
#16 Wire
250 ft.
2.5
5
600
125 ft.
7.5
10
15
20
900
100 ft.
1200
1800
2400
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
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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)
Table 4. Oil Type
ALWAYS wear approved eye and hearing
protection before operating the generator.
Season
Temperature
25°C or Higher
25°C~10°C
Oil Type
Before Starting
Summer
Spring/Fall
Winter
SAE 10W-30
SAE 10W-30/20
SAE 10W-10
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.
0°C or Lower
DANGER - EXPLOSIVE FUEL
3.
4.
5.
Check the air filter for dirt and dust. If air filter is dirty, replace
air filter with a new one as required.
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.
Check carburetor for external dirt and dust. Clean with dry
compressed air.
Check fastening nuts and bolts for tightness.
Engine Oil Check
1.
To check the engine oil level, place the generator on secure
level ground with the engine stopped.
Fuel Check
1. Close the fuel cock before filling the fuel tank.
2. Remove the fuel cap located on top of fuel tank.
2.
Remove the filler dipstick from the engine oil filler hole
(Figure 6) and wipe clean.
3. Readthefuelgaugelocatedontopofthefueltank(Figure8)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. Insertandremovethedipstickwithoutscrewingitintothefiller
neck. Check the oil level shown on the dipstick.
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!
4. If the oil level is low (Figure 7), fill to the edge of the oil filler
holewiththerecommendedoiltype(Table4).Maximum oil
capacity is 1.16 quarts (1.1 liters)
PAGE 22 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
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GA-4.5R/GA-4.5RA — INITIAL START-UP (ENGINE)
2. Placethechokelever (Figure11)inthe"CLOSED"position
CAUTION - READ MANUAL
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.
Figure 11. Choke Lever
3. Place the choke lever (Figure 11) in the "OPEN " position
if starting a warm engine or the temperature is warm.
Before Starting the Engine
1. Be sure to disconnect all electrical loads from the
4. Place the operation switch (Figure 12) in the "RUN "
generator prior to starting the engine.
position.
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)
5. Grasp the starter grip (Figure 13) and slowly pull it out.The
resistancebecomesthehardestatacertainposition,corre-
spondingtothecompressionpoint.Pullthestartergripbriskly
andsmoothlyforstarting.
Figure 9. Main Breaker (OFF Position)
Starting the Engine
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
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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. Beforethegeneratorisplacedintooperation,runtheengine
for3-5minutes. Checkfor abnormalsmells,fuelleaks, and
noises that would associate with lose components.
Figure 16. ACVoltmeter (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
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
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.
Figure 15. Full Power Switch (Up)
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)
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GA-4.5R/GA-4.5RA — INITIAL START-UP ENGINE/OPERATION
3. Place the main circuit breaker (Figure 21) in the ON
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.
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. 240/120VAC Receptacle
Figure 22. Idle Control Switch (2200 rpm's)
When the full power switch is
in the 240V (down) position, up
to half of the rated power of the
generator is available at the
4. Place the operation switch (Figure 23) in the STOP
position.
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.
Figure 23. Operation Switch (Stop)
5. Place the engine fuel valve lever (Figure 24) to the "OFF"
position.
”
Connecting the Load
1. Connect the load to the desired voltage output
receptacle.
2. Place the idle control switch (Figure 20) in the ON position
(Up).
Figure 24. Engine Fuel Valve Lever (OFF Position)
Emergency Showdown
Figure 20. Idle Control Switch (Up)
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
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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)
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GA-4.5R/GA-4.5RA — MAINTENANCE (ENGINE)
UseTable 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
FIRST
EVERY
EVERY
EVERY
YEAR
OR
EVERY
2 YEARS
OR
MONTH 3 MONTHS 6 MONTHS
OR
DESCRIPTION (3)
OPERATION
BEFORE
OR
OR
10 HRS.
25 HRS.
50 HRS.
100 HRS.
200 HRS.
CHECK
CHANGE
CHECK
X
Engine Oil
X
X
X
Air Cleaner
All Nuts & Bolts
Spark Plug
CHANGE
X (1)
Re-tighten If
Necessary
CHECK-CLEAN
REPLACE
CHECK
X
X
X
Cooling Fins
Spark Arrester
Fuel Tank
CLEAN
X
X
CLEAN
Fuel Filter
CHECK
X
Idle Speed
CHECK-ADJUST
CHECK-ADJUST
CHECK
X (2)
Valve Clearance
Fuel lines
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
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GA-4.5R/GA-4.5RA — MAINTENANCE (ENGINE)
Maintenance
Cleaning the Fuel Strainer
Perform the scheduled maintenance procedures as defined by
Table 6 and below:
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.
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.
DANGER - EXPLOSIVE FUEL
WEEKLY
DO NOT use gasoline as a cleaning solvent,
because that would create a risk of fire or
explosion.
■
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.
ENGINEAIRCLEANER
1. Remove the air cleaner cover and foam filter element as
shown in Figure 27.
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
elementfromtheaircleanercaseside.NEVER brushoffdirt.
Brushingwillforcedirtintothefibers.Replacethepaperfilter
element if it is excessively dirty.
Figure 25. Spark Plug Gap
ENGINEOIL
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 se-
curely.
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)
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NOTE PAGE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 29
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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)
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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
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GA-4.5R/GA-4.5RA —TROUBLESHOOTING (ENGINE)
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.
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
TABLE 6. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Inspect carburetor to see if fuel
is reaching it?
Check fuel line
No Fuel?
Add Fuel
Water in fuel tank?
Fuel filter clogged?
Stuck carburetor?
Spark plug is red?
Flush or replace fuel tank.
Replace fuel filter
Check float mechanism.
Poor starting
Spark plug is fouled. Check tranistor ignition unit.
Insufficient compression, injected air leaking. Carburetor jets are
clogged (overflow).
Spark plug is blue-white?
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.
No oil?
Add oil as required.
Oil pressure alarm lamp blinks
upon starting?
Check Automatic shutdown circuit "oil sensor".
Replace cylinder and piston and if necessary axel joint.
Tighten cylinder head connecting bolts.
Engine will not turn over?
Cylinder head connecting bolts
loose?
Cylinder head gasket damaged? Replace cylinder head gasket.
Insufficient power output "no
compression"
Malfunction of valve seat?
Spark plug is loose?
Worn piston rings?
Re-seat valves.
Replace spark plug.
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.
Insufficient power output
"compression"
Clean or replace fuel filter.
Clean or replace carburetor.
Check carburetor float.
Malfunction in fuel system?
PAGE 32 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
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GA-4.5R/GA-4.5RA —TROUBLESHOOTING (ENGINE)
TABLE 6. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
POSSIBLE PROBLEM
Malfunction in blower?
SOLUTION
Check or replace blower.
Insufficient power output
"compression" and overheats
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.
Burns to much fuel
Wrong spark plug?
Replace spark plug with manufactures suggested type spark plug.
Replace lubricating oil with correct viscosity.
Replace rings
Lubricating oil is wrong
viscosity?
Exhaust color is continiously
"WHITE"
Worn 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.
Exhaust color is continiously
"BLACK"
Carburetor defective, seal on
carburetor broken?
Replace carburetor or seal.
Adjust carburetor.
Poor carburetor adjustment
"engine runs too rich?
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 33
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GA-4.5R/GA-4.5RA —TROUBLESHOOTING (GENERATOR)
diagnosis based on the GeneratorTroubleshooting (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.
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
TABLE 7. GENERATOR TROUBLESHOOTING
SYMPTOM
Low voltage
POSSIBLE PROBLEM
Engine speed too low?
SOLUTION
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.
Low voltage. Engine speed
normal 3650 RPM (unloaded),
2500 RPM (idle)
Rotor winding malfunction?
Stator winding malfunction?
Breaker malfunction?
Check or replace rotor.
Check or replace stator.
Check or replace CB1.
Voltage output too high.
Engine speed too high?
Lower engine speed to rated RPM.
Check control box wiring.
Voltage output too high. Engine
speed normal 3650 RPM
(unloaded), 2500 RPM (idle)
Control box internal wiring
malfunction
Circuit breaker will not turn on
"NO LOAD"
Defective circuit breaker?
Replace circuit breaker.
Overload?
Reduce load or replace breaker.
Check load circuit for short.
Check solenoid.
Circuit breaker will turn on
"LOADED" but trips immediately.
Load circuit is shorted?
Stuck solenoid?
Does not accelerate from low to
high "NO LOAD"
Does not accelerate from low to
high "LOAD ACTIVE
Control box interal wiring
defective?
Check control box wiring.
Defective rotor windings?
Defective solenoid?
Check or replace rotor.
Check or replace solenoid.
Does not decelerate no
"VOLTAGE OUTPUT".
Defective idle control device?
Defective solenoid?
Check or replace idle control device.
Check or replace idle control device.
Check control box wiring, replace any defective components.
Check or replace solenoid.
Control box wiring malfunction?
Defective solenoid?
Does not decelerate but has
"VOLTAGE OUTPUT".
Idle control device malfunction?
Check or replace idle control device.
PAGE 34 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
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NOTE PAGE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 35
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GA-4.5R/GA-4.5RA — EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and remarks QTY. Column
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.
Numbers Used - Item quantity can be indicated by a number,
a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other parts
that are sold in bulk and cut to length.
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.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
Sample Parts List:
REMARKS Column
NO. PART NO. PART NAME
QTY. REMARKS
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.
1
2
2
3
4
12345
BOLT ....................... 1.... INCLUDES ITEMS W/
WASHER, 1/4 IN. ........... NOT SOLD SEPARATELY
WASHER, 3/8 IN. .... 1.... MQ-45TONLY
HOSE .................... A/R.. MAKE LOCALLY
BEARING ................ 1.... S/N2345B AND ABOVE
*
*
*
12347
12348
12349
Assembly/Kit - All items on the parts list with the same unique
symbol will be included when this item is purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
NO. Column
Unique Symbols - All items with same unique symbol
Serial Number Break - Used to list an effective serial number
range where a particular part is used.
( , #,
+
, %, or >) in the number column belong to the same
*
assembly or kit, which is indicated by a note in the “Remarks”
column.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
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.
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.
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.
NOTE
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.
PART NO. Column
Numbers Used - Part numbers can be indicated by a number,
a blank entry, orTBD.
“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.
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.
PAGE 36 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
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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
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
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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)
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GA-4.5R/GA-4.5RA — NAME PLATE AND DECALS
NAMEPLATE AND DECALS
NO.
1
1
2
3
4
5
6
7
PART NO.
A4511200002
A4511200702
PART NAME
QTY.
REMARKS
DECAL;CONTROL PANEL .................................... 1 ............ A41120000 GA-4.5R ONLY
DECAL;CONTROL PANEL .................................... 1 ............ A41120070 GA-4.5RA ONLY
NAMEPLATE ......................................................... 1 ............ CONTACT MQ PARTS DEPT.
DECAL; GROUND .................................................. 1 ............ S-1123
0800628504
1630680104
A4561000003
0820610404
35137
DECAL; FUEL COCK ............................................. 1 ............ S-1407
DECAL; MQ MULTIQUIP
DECAL;WARNING................................................. 1 ............ S-3627
DECAL;WARNING READ MANUAL
1
1
8
9
10
11
12
8700611804
8700611904
7900636004
A9521200004
A9511100103
DECAL;WARNING DANGEROUS GAS ................ 1 ............ S-4984
DECAL; DANGER ELECTRICAL SHOCK HAZ. .... 1 ............ S-4985
DECAL; CAUTION OPER. AT 3600 RPM ONLY .... 1 ............ S-4461
DECAL;OPERATING INSTRUCTIONS ................. 1 ............ A92120000
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
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GA-4.5R/GA-4.5RA — GENERATOR ASSY.
GENERATO
PAGE 40 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
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GA-4.5R/GA-4.5RA — GENERATOR ASSY.
GENERATOR ASSY.
NO
1
PART NO
PART NAME
QTY.
REMARKS
A3110200003
7661080003
0601823213
0601822638
0071706304
7661017104
0801086104
0040010000
A4135000103
7661315112
7871315022
7875021523
7661331003
7661344204
0040008000
0041208000
7871329514
0601851760
0013608020
0040008000
ROTOR ASSY. ......................................................... 1 ......... INCLUDES ITEMS W/
*
1-1
FIELD COIL ASSY.
RECTIFIER
SURGE ABSORBER
BEARING
1
2
2
1
1
1
1
1
1
1
1
1
4
4
4
1
1
4
4
*
1-2
1-2
1-3
2
*
SET BOLT, ROTOR
SET WASHER, BEARING
SPRING WASHER
ARMATURE ASSY.
END BRACKET
END BRACKET
GUIDE PANEL, AIR
COVER
SET BOLT, STATOR
SPRING WASHER
PLAIN WASHER
GROMMET
3
4
5
6
7
8
9
10
11
12
13
14
15
CAP
HEX. HEAD BOLT
WASHER, LOCK
15A
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 41
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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)
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MQ GA-4.5R — CONTROL BOX ASSY.
CONTROL BOX ASSY. (GA-4.5R ONLY)
NO
1
2
3
4
5
6
6A
7
8
PART NO
PART NAME
QTY.
1
1
2
2
1
2
2
1
1
1
2
1
1
1
1
1
8
8
1
1
1
1
1
1
4
4
1
2
REMARKS
A3214000003
0601850102
0601823204
0027103012
0601823853
0027104010
0207004000
A3224000003
0601802651
4341817004
0021004010
0601806819
0601812598
0601812592
0601811035
0601814010
0021004010
0207004000
0601830737
0601831620
0601831620
0021004015
0207004000
A3262800004
0017106016
0017105010
0601842426
0027104010
CONTROL BOX
GROMMET
RECTIFIER, S5VB60
MACHINE SCREW
SLOW-DOWN UNIT
MACHINE SCREW
HEX NUT
CONTROL PANEL
CIRCUIT BREAKER, 15 AMP
BRACKET, CIRCUIT BREAKER
MACHINE SCREW
AC VOLTMETER, 0 ~ 120/240V
RECEPTACLE, 5-20R : 125V, 20A
RECEPTACLE, L5-20R : 125V, 20A
RECEPTACLE, L5-30R : 125V, 30A
RECEPTACLE, L14-20R :125/250V, 30A
MACHINE SCREW
9
10
11
12
13
14
15
16
16A
17
18
19
20
20A
21
22
23
24
25
HEX NUT
SWITCH, FULL POWER
SWITCH, IDLE CONTROL
SWITCH, OPERATION
MACHINE SCREW
HEX NUT
CONDENSER ASSY. 50V @ 1000 µF
HEX. HEAD BOLT
HEX. HEAD BOLT
RESISTOR, 40W 400 OHMS
MACHINE SCREW
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 43
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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)
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MQ GA-4.5RA — CONTROL BOX ASSY.
CONTROL BOX ASSY. (GA-4.5RA ONLY)
NO
1
2
3
4
5
6
6A
7
8
PART NO
PART NAME
QTY.
1
1
2
2
1
2
2
1
1
1
2
1
1
1
1
1
8
8
1
1
1
1
1
1
4
4
1
2
REMARKS
A3214000103
0601850102
0601823204
0027103012
0601823853
0027104010
0207004000
A3224000103
0601802651
4341817004
0021004010
0601806819
0601812598
0601812592
0601811035
0601814010
0021004010
0207004000
0601830737
0601831620
0601831620
0021004015
0207004000
A3262800004
0017106016
0017105010
0601842426
0027104010
CONTROL BOX
GROMMET
RECTIFIER, S5VB60
MACHINE SCREW
SLOW-DOWN UNIT
MACHINE SCREW
HEX NUT
CONTROL PANEL
CIRCUIT BREAKER, 15 AMP
BRACKET, CIRCUIT BREAKER
MACHINE SCREW
AC VOLTMETER, 0 ~ 120/240V
RECEPTACLE, 5-20R : 125V, 20A
RECEPTACLE, L5-20R : 125V, 20A
RECEPTACLE, L5-30R : 125V, 30A
RECEPTACLE, L14-20R :125/250V, 30A
MACHINE SCREW
9
10
11
12
13
14
15
16
16A
17
18
19
20
20A
21
22
23
24
25
HEX NUT
SWITCH, FULL POWER
SWITCH, IDLE CONTROL
SWITCH, OPERATION
MACHINE SCREW
HEX NUT
CONDENSER ASSY. 50V @ 1000 µF
HEX. HEAD BOLT
HEX. HEAD BOLT
RESISTOR, 40W 400 OHMS
MACHINE SCREW
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 45
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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)
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MQ GA-4.5R/GA-4.5RA — PIPE FRAME ASSY.
PIPE FRAME ASSY.
NO
1
1
2
3
4
5
6
7
PART NO
PART NAME
QTY.
REMARKS
A4417000002
A4417000202
A3417100004
0017106016
A3304100003
A9312601704
7935416004
0207008000
0207008000
0017108040
0207008000
A4364000002
A9924800014
A9924800004
0602125034
0605510026
0642007810
0642006410
0605513194
0605515062
7855525514
7855525604
0017108030
0017108020
A9117200103
0601850097
0021008025
0207008000
A9311100004
0601851116
0011308025
0037908000
0042108000
0019206016
A3305200104
0017106016
A3414500004
A4924200004
PIPE FRAME ............................................ 1 ................. GA-4.5R ONLY
PIPE FRAME ............................................ 1 ................. GA-4.5RA ONLY
BRACKET
1
4
1
2
2
8
2
2
2
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
HEX. HEAD BOLT
ENGINE BASE
RUBBER SUSPENSION
RUBBER SUSPENSION
HEX. NUT
HEX. NUT
HEX. HEAD BOLT
HEX. NUT
8
9
9A
10
11
12
13
14
14-1
14-2
15
16
17
18
19
20
21
22
23
23A
24
24
25
25A
25B
26
27
28
29
30
FUELTANK
CAP, FUEL TANK
FUEL FILTER
FUEL GUAGE
FUEL STRAINER
CUP, FILTER FUEL STRAINER
PACKING, FUEL STRAINER CUP
HOSE
HOSE BAND
RUBBER CUSION
COLLAR
HEX. HEAD BOLT
HEX. HEAD BOLT
HANGER
STOPPER
MACHINE SCREW
HEX NUT
PLASTIC WASHER ................................... 2 ................. GA-4.5R ONLY
PLASTIC WASHER ................................... 2 ................. GA-4.5RA ONLY
HEX HEAD BOLT
HEX NUT
WASHER, FLAT
HEX HEAD BOLT
STOPPER
HEX HEAD BOLT
COVER
2
2
2
1
1
2
1
1
ROBIN ENGINE, EX27D
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 47
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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)
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ROBIN EX270D20220 — CRANKCASE ASSY.
CRANKCASE ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
10
2791010121
2371420203
2771601001
0440300160
0600300340
2771501103
0105080250
0105060410
0440060020
0401140020
0211140020
2791100111
CRANKCASE ASSY. ................................................ 1 ........ INCLUDES ITEMS W/
*
20%
26%
VALVE GUIDE
STEM SEAL
OIL SEAL
BALL BEARING
PIPE KNOCK
STUD
STUD
OIL SEAL
PLUG
2
1
1
1
2
2
2
1
2
2
30
*
46
*
50
*
60%
70%
75
80
90
210
GASKET
MAIN BEARING COVER .......................................... 1 ........ INCLUDES ITEMS W/+
220+ 0440300160
230+ 0600300020
OIL SEAL
1
1
1
1
1
1
1
7
1
BALL BEARING
GOVERNOR GEAR
GOVERNOR SLEEVE
FILLER PLUG
GASKET
GASKET
FLANGE BOLT
GASKET, MUFFLER 26D 9DX58P 0.2T
CYLINDER HEAD ASSY .......................................... 1 ........ INCLUDES ITEMS W/%
GASKET HEAD
FLANGE BOLT
250
260
275
280$
281
300
340$
610
620$
630
631
680
690$
700
710
850
960
2774500421
2774190103
2796500103
0213200050
0213200050
0010408350
2773520103
2791300111
2791500113
0110080240
0010408350
2771550101
2771600103
2771501103
0110060020
0851080000
2799900107
1
4
1
1
1
2
4
1
FLANGE BOLT
ROCKER COVER
GASKET, ROCKET COVER
PIPE KNOCK
FLANGE BOLT
RUBBER PIPE
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
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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)
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ROBIN EX270D20110/EX270D20220 — CRANKSHAFT AND PISTON ASSY.
CRANKSHAFT AND PISTON ASSY.
NO
10
50
PART NO
PART NAME
CRANKSHAFT CP
FLANGE NUT
QTY.
REMARKS
2792020121
0180180010
0323030010
2792250120
2792300103
2792330103
2792340103
2792340303
2792340403
2792351107
2792351207
2792351107
0565180010
1
1
1
70
WOODRUFF KEY
310
320
350
360
360
360
370
370
370
380
CONNECTING ROD ASSY. ......................... 1 ......... INCLUDES ITEM W/
CONNECTING ROD BOLT
PISTON PIN
*
2
1
1
1
1
1
1
1
2
*
PISTON, STANDARD
PISTON OVERSIZE 0.25 MM
PISTON OVERSIZE 0.50 MM
PISTON RING SET, STANDARD
PISTON RING SET, O.25 MM
PISTON RING SET, STANDARD
CLIP
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 51
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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)
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ROBIN EX270D20110/EX270D20220 — GOVERNOR ASSY.
GOVERNOR ASSY.
NO
10
20
30
40
50
60
70
80
310
340
350
355
360
365
370
435
395
396
440
450
480
485
PART NO
PART NAME
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
REMARKS
2794230113
2774220113
2794270101
2774280113
0031305000
0130060240
0186060020
2794250223
2774330113
2774350103
0200060170
0217060070
0140060180
2374500423
0021706000
2774600101
2774390203
0131050030
0043104080
0023506000
2774510103
0110060020
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
1
1
1
1
1
2
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 53
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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)
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ROBIN EX270D20110/EX270D20220 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
NO.
10
25
PART NO.
PART NAME
QTY.
REMARKS
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
CAMSHAFT CP......................................... 1 ............. INCLUDES ITEMS W/
*
PIN, CAMSHAFT, 9DX78.5L
O RING, 5.8DX9.6DX1.9T
SPRING PIN, 4DX7.5DX11L
RELEASE LEVER
CLIP, 13.8DX20.3DX0.4T
RETURN SPRING
VALVE SPRING, 17DX2.3DX27L N=5.8
SPRING RETAINER
INTAKE VALVE, 28.5DX5.5DX67.8L
EXHAUST VALVE, 26.5DX5.5DX67.8L
COLLET VALVE
TIMING CHAIN CP, 100 LINK
TENTIONER
SPRING, TENTIONER
PIN, TENTIONER, 6DX13DX34L
CHAIN GUIDE
PIN, ROCKER, 6DX9DX41L
CLIP
ROCKER ARM ASSY. IN .......................... 1 ............. INCLUDES ITEMS W/
CHOKE LEVER CP
ROCKER ARM ASSY. EX ......................... 1 ............. INCLUDES ITEMS W/
1
1
1
1
1
1
2
2
1
1
4
1
1
1
1
1
1
1
27
34
*
35
*
37
*
38
60
70
*
80
90
95
150
160
163
166
170
200
210
220
224
225
#
#
1
230
240
290
540
550
#
#
ADJUST SCREW, M5X0.5X23L
NUT, M5X0.5X4.1H
FLANGE BOLT, M6X1.0X12L
INSULATOR
1
1
1
1
1
GASKET, INSULATOR
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 55
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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)
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ROBIN EX270D20110/EX270D20220 — MUFFLER ASSY.
MUFFLER ASSY.
NO.
310
320
340
350
360
361
365
PART NO.
PART NAME
QTY.
REMARKS
2793010121
2793420111
2773520103
9802008280
0152060090
0110060010
0110080150
MUFFLER, CP
1
1
1
2
2
1
1
MUFFLER COVER CP
GASKET, MUFFLER 26D 9DX58P 0.2T
FLANGE NUT
TAPPING BOLT, M6X1.0X10L
FLANGE BOLT, M6X1.0X8L
FLANGE BOLT, M8X1.25X12L
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 57
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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)
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ROBIN EX270D20110/EX270D20220 — AIR CLEANER ASSY.
AIR CLEANER ASSY.
NO.
PART NO.
PART NAME
QTY. REMARKS
510
2793262030
2793263308
2793265008
2793264508
2793260907
AIR CLEANER ASSY. LOW PROFILE ................. 1 ......... INCLUDES ITEMS W/
*
510-200
510-220
510-250
BODY CP
GASKET
COVER, LOW PROFILE
ELEMENT ASSY.
1
1
1
1
*
*
*
520
*
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 59
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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)
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ROBIN EX270D20110/EX270D20220 — RECOIL STARTER ASSY.
RECOIL STARTER ASSY.
NO
10
20
40
60
61
80
81
210
210-1
210-2
210-3
210-4
210-5
210-6
210-7
210-11
210-35
210-49
220
PART NO
PART NAME
QTY.
REMARKS
2795120101
0732005140
0110060030
2795271111
2795270203
0016508120
0110060020
2795020200
2265071608
2795012008
2795011008
2265070108
2795012508
2265073108
2265075208
2795014508
2265074108
2265075318
0110060010
BLOWER HOUSING CP
LABEL, TRADEMARK 64D
FLANGE BOLT
1
1
4
1
1
1
1
BAFFLE 1, CASE CP
BAFFLE 2, HEAD
BOLT
FLANGE BOLT
RECOIL STARTER ASSY. ................................... 1 ......... INCLUDES ITEM W/
SPIRAL SPRING
REEL
*
1
1
1
1
2
1
2
1
1
1
4
*
*
STARTER ROPE
STARTER KNOB
RATCHET
FRICTION SPRING
RATCHET SPRING
STARTER PULLEY
FRICTION PLATE
CENTER SCREW
FLANGE BOLT
*
*
*
*
*
*
*
*
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 61
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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)
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ROBIN EX270D20110/EX270D20220 — CARBURETOR ASSY.
CARBURETOR ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
210
2796230210
2796253508
2516245008
2796252508
2796242008
2796235408
2796252008
2796252008
2796253008
2516245308
2796251508
2796255008
2796235008
2796254008
2796250508
2796240008
2796240108
2796235508
2796256108
2796235308
2796244508
2796256208
2796255208
2516248008
2796245208
2796245108
0652007810
0642006410
CARBURETOR ASSY. ...................................... 1 ......... INCLUDES ITEM W/
*
210-1
210-2
210-3
210-5
210-6
210-7
210-8
210-11
210-12
210-15
210-16
210-17
210-18
210-19
210-22
210-22
210-28
210-32
210-40
210-41
210-60
VALVE THROTTLE
SCREW
VALVE CHOKE
JET SLOW
SCRE IDLE ADJUSTING
SPRING
SHAFT CHOKE
SHAFT SUB ASSY., THROTTLE
SCREW
PIN FLOAT LEVER
CHAMBER FLOAT
GASKET
GASKET CHAMBER
FLOAT SUB ASSY.
JET MAIN
JET MAIN
SCREW DRAIN
BUSH
SCREW ADJUSTING
SPRING
COLLAR
GASKET
CAP
O-RING
O-RING
FILTER CUP
PACKING, FILTER CUP
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
210-104
210-121
210-151
210-152
210-153
210-154
*
*
*
*
*
*
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 63
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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)
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ROBIN EX270D20110/EX270D20220 — FLYWHEEL ASSY.
FLYWHEEL ASSY.
NO
10
11
30
50
60
70
100
110
PART NO
PART NAME
QTY.
REMARKS
2797923001
2797943001
0011406250
2777310101
X660000420
0150040090
0650140150
0655000270
FLYWHEEL CP
1
1
2
1
1
2
1
1
IGNITION COIL CP
BOLT & WASHER ASSY.
WIRE 2 CP, W/OIL SENSOR
SWITCH ASSY.
TAPPING SCREW
SPARK PLUG, NGK BR6HS
SPARK PLUG CAP
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 65
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Effective: February 22, 2006
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5. Partsmustbeinnewandresalablecon- Multiquipreservestherighttoquoteandsell
dition,intheoriginalMultiquippackage(if directtoGovernmentagencies,andtoOriginal
any), and with Multiquip part numbers Equipment Manufacturer accounts who use
Terms of payment for parts are net 30 days.
FREIGHTPOLICY
clearlymarked.
our products as integral parts of their own
products.
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifesthasbeenobtainedfromthecarrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
SPECIALEXPEDITINGSERVICE
a. Obsolete parts. (If an item is in the
price book and shows as being re- A$35.00surchargewillbeaddedtotheinvoice
placedbyanotheritem,itisobsolete.) forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
(such as gaskets, seals, “O” rings,
b. Any parts with a limited shelf life
andotherrubberparts)thatwerepur- LIMITATIONSOFSELLER’SLIABILITY
MINIMUMORDER
chasedmorethansixmonthspriorto
thereturndate.
Multiquip shall not be liable hereunder for
damagesinexcessofthepurchasepriceofthe
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
c. Anylineitemwithanextendeddealer item with respect to which damages are
netpriceoflessthan$5.00.
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
otherspecial,consequentialorincidentaldam-
ages.
d. Special order items.
RETURNEDGOODSPOLICY
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremade
in connection with the sale of parts or trade
accessoriesnorastoanyenginenotmanufac-
tured by Multiquip. Such warranties made in
connectionwiththesaleofnew,completeunits
are made exclusively by a statement of war-
rantypackagedwithsuchunits,andMultiquip
neitherassumesnorauthorizesanypersonto
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
7. Thesenderwillbenotifiedofanymaterial
receivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Suchmaterialwillbeheldforfiveworking
days from notification, pending instruc-
tions.Ifareplyisnotreceivedwithinfive
days,thematerialwillbereturnedtothe
senderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspe-
cificdateandallordersreceivedonorafterthat
datewillbebilledattherevisedprice.Rebates
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All forpricedeclinesandaddedchargesforprice
partsmustbereturnedfreightprepaidto increaseswillnotbemadeforstockonhand
Multiquip’sdesignatedreceivingpoint.
atthetimeofanypricechange.
PAGE 66 — GA-4.5R/GA-4.5RA A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #1 (11/27/06)
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NOTE PAGE
GA-4.5R/GA-4.5RA A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #1 (11/27/06) — PAGE 67
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OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
UNITED STATES
Multiquip Corporate Office
18910 Wilmington Ave.
Carson, CA 90746
MQ Parts Department
800-427-1244
Tel. (800) 421-1244
Fax (800) 537-3927
Fax: 800-672-7877
Fax: 310-637-3284
310-537-3700
Contact: [email protected]
Mayco Parts
800-306-2926
310-537-3700
Warranty Department
800-421-1244, Ext. 279 Fax:310-537-1173
310-537-3700, Ext. 279
Fax:800-672-7877
Fax:310-637-3284
Service Department
800-421-1244
Technial Assistance
800-478-1244
Fax:310-537-4259
Fax:310-631-5032
310-537-3700
MEXICO
MQ Cipsa
UNITED KINGDOM
Multiquip (UK) Limited Head Office
Hanover Mill, Fitzroy Street,
Ashton-under-Lyne,
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla72760Mexico
Tel: (52) 222-225-9900
Fax: (52) 222-285-0420
Tel: 0161 339 2223
Fax: 0161 339 3226
Lancashire OL7 0TL
CANADA
Multiquip
BRAZIL
Multiquip
4110IndustrielBoul.
Laval, Quebec, Canada H7L 6V3
Tel: (450) 625-2244
Fax: (450) 625-8664
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
© 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
Your Local Dealer is:
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