Multiquip Portable Generator GA 36RZ2 User Manual

PARTS AND OPERATION MANUAL  
MULTIQUIP  
Model GA-3.6RZ2  
A.C. GENERATOR  
Revision #2 (03/05/01)  
MULTIQUIPINC.  
PARTS DEPARTMENT:  
18910 WILMINGTON AVE.  
800-427-1244  
CARSON, CALIFORNIA 90746 FAX: 800-672-7877  
310-537-3700  
800-421-1244  
SERVICE DEPARTMENT/TECHNICAL ASSISTANCE:  
800-478-1244  
FAX:310-537-3927  
FAX:310-631-5032  
E-mail:[email protected] www:multiquip.com  
Atlanta • Boise • Dallas • Houston • Newark  
Montreal, Canada • Manchester, UK  
Rio De Janiero, Brazil • Guadalajara, Mexico  
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HERE'S HOW TO GET HELP  
PLEASE HAVE THE MODEL AND SERIAL NUMBER  
ON-HAND WHEN CALLING  
PARTS DEPARTMENT  
800-427-1244 or 310-537-3700  
FAX: 800-672-7877 or 310-637-3284  
SERVICE DEPARTMENT/TECHNICAL ASSISTANCE  
800-478-1244 or 310-537-3700  
FAX: 310- 537-4259  
WARRANTY DEPARTMENT  
888-661-4279, or 310-661-4279  
FAX: 310- 537-1173  
MAIN  
800-421-1244 or 310-537-3700  
FAX: 310-537-3927  
GA-3.6RZ2 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (03/05/01) — PAGE 3  
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TABLE OF CONTENTS  
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  
ROBIN EH-25 Engine  
Crankcase Assembly ........................................34-35  
Crankshaft & Piston Assembly ...........................36-37  
Intake & Ehaust Assembly .................................38-39  
Governor Assembly ...........................................40-41  
Cooling & Starting Assembly .............................42-43  
Carburetor..........................................................44-45  
Ignition Coil Assembly And Spark Plug ..............46-47  
Fuel Strainer ......................................................48-49  
Multiquip GA-3.6RZ2 —  
AC Generator  
Terms and Conditions Of Sale Parts .................. 50  
Controls and Indicators ........................................... 10  
Installation ............................................................... 11  
Pre-Setup ........................................................... 12-13  
Instrumentation ....................................................... 14  
Load Application ..................................................... 15  
Operating Instructions............................................. 16  
Maintenance ........................................................... 17  
Preparation For Long Term Storage ....................... 18  
Wiring Diagram ....................................................... 19  
Troubleshooting (Engine)................................... 20-21  
Troubleshooting (Generator) ............................. 22-23  
Explanation Of Codes In Remarks Column ............ 24  
Suggested Spare Parts ........................................... 25  
Generator Assembly .......................................... 26-27  
Control Box Assembly ........................................ 28-29  
Pipe Frame Assembly ........................................ 30-31  
Name Plate And Decals ..................................... 32-33  
NOTE  
Specification and part number  
are subject to change without  
notice.  
PAGE 4 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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PARTS ORDERING PROCEDURES  
Dealer account number  
Dealer name and address  
Shipping address (if different than billing address)  
Return fax number  
Applicable model number  
Quantity, part number and description of each part  
Specify preferred method of shipment:  
UPS Ground  
UPS Second Day or Third Day*  
UPS Next Day*  
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  
1-9 items  
3%  
10+ items**  
5%  
Get special freight allowances  
when you order 10 or more  
line items via FAX!**  
Now! Direct TOLL-FREE access  
to our Parts Department!  
UPS Ground Service at no charge for freight  
PS Third Day Service at one-half of actual freight cost  
No other allowances on freight shipped by any other carrier.  
Toll-free nationwide:  
800-421-1244  
**Common nuts, bolts and washers (all items under $1.00 list price)  
do not count towards the 10+ line items.  
Toll-free FAX:  
*DISCOUNTS ARE SUBJECT TO CHANGE*  
800/6-PARTS-7 800-672-7877  
Fax order discount and UPS special programs revised June 1, 1995  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 5  
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RULES FOR SAFE OPERATION  
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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  
monoxide gas.  
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.  
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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.  
The following safety guidelines should always be used when  
operating the GA-3.6RZ2 Generator:  
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.  
GENERAL SAFETY  
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DO NOT operate or service this equipment before reading  
CAUTION:  
CAUTION:  
this entire manual.  
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HighTemperatures Allow the machine  
This equipment should not be operated by persons under 18  
years of age.  
and engine to cool before adding fuel or  
performing service and maintenance  
functions. Contact with hot components can  
cause serious burns.  
NEVER operate this equipment without proper protective  
clothing, shatterproof glasses, steel-toed boots and other  
protective devices required by the job.  
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This generator is a source of providing LETHAL high voltages.  
Never permit unqualified personnel-especially children to  
operate the generator.  
Emergencies  
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Always know the location of the nearest fire  
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Always refuel in a well-ventilated area, away from sparks and  
open flames.  
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.  
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 flames or sparks, or if fuel is spilled on a hot  
engine.  
Maintenance Safety  
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NEVER lubricate components or attempt service on a running  
machine.  
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This generator is equipped with a ground terminal for your  
protection. Always complete the grounding path from the  
generator to an external grounding source.  
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Always allow the machine a proper amount of time to cool  
before servicing.  
NEVER operate this generator, or handle any electrical  
equipment while standing in water, while bare foot, while  
hands are wet, or in the rain. Dangerous electrical shock  
could occur causing severe bodily harm or even death.  
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Keep the machinery in proper running condition.  
Fix damage to the machine immediately and always replace  
broken parts.  
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Dispose of hazardous waste properly.Examples of potentially  
hazardous waste are used motor oil, fuel and fuel filters.  
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Keep electrical cords in good condition. Worn, bare or frayed  
wiring can cause electrical shock, thus causing bodily harm  
or even death.  
DO NOT use food or plastic containers to dispose of  
hazardous waste.  
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.  
DO NOT pour waste, oil or fuel directly onto the ground,  
down a drain or into any water source.  
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NEVER touch the hot exhaust manifold, muffler or cylinder.  
Allow these parts to cool before servicing generator.  
PAGE 6 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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OPERATION AND SAFETY DECALS  
Machine Safety Decals  
The GA-3.6RZ2 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-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 7  
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GA-3.6RZ2 SPECIFICATIONS  
Table 1. Specifications  
MODEL  
GA-3.6RZ2  
Type  
2-pole, Brushless Type Revolving Field  
Max. Output  
Rated Output (continuous)  
Rated Voltage  
Phase  
3600 Watts  
3200 Watts  
120V/240V  
Single Phase (4-wire)  
60 Hz  
Generator  
Frequency  
Rated Speed  
Power Factor  
Model  
3600 RPM  
100%  
Robin EH-25  
Air-cooled 4 cycle,vertical OVH type,  
gasoline engine  
Type  
Number of cylinders  
Bore X Stroke  
1
1-2.95 in x 2.24 in  
15.32 cc  
Displacement  
Engine  
Max Output  
8 H.P./3600 R.P.M.  
Approx. 5 U.S. Gallons  
Unleaded Automobile Gasoline  
2-1/8 pints  
Fuel Tank Capacity  
Fuel  
Lube Oil Capacity  
Speed Control Method  
Starting Method  
Centrifugal Fly-weight Type  
Recoil Start  
605X 420 X 570 mm  
(23.8 in X 16.5 inX 22.4)  
Dimension (LXWXH)  
Dry Net Weight  
140 lbs (64kg)  
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  
PAGE 8 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 GENERAL INFORMATION  
GA-3.6RZ2 FAMILIARIZATION  
Generator  
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 magnetic passes the coil it produces approximately  
19-22 AC volts.  
The Multiquip Model GA-3.6RZ2 generator has been designed  
as a portable lightweight power source for 60 Hz (single-  
phase) vibrators, lighting facilities, power tools, sermersible  
pumps and other industrial and construction machinery.  
This voltage (19-22 VAC) is then sent to the control box that  
contains three rectifying diodes:  
This generator employs the highly reliable ROBIN engine.  
The alternator, a brushless revolving-field type, single phase  
is permanently aligned to the engine through rigid coupling.  
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Excitation (diode 1)  
Battery (diode 2)  
Slow Down (diode 3)  
The entire 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.  
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 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.  
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.  
Control Box  
The control box has the following: ( outputs are 60 Hz, single  
phase)  
Engine  
The four-cycle air-cooled ROBIN gasoline engine is designed  
to meet every performance requirement of this generator.  
Reference Table 1, page 8 for engine specifications  
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One 120V output receptacle.  
One 240V output receptacle.  
One 120V output receptacle (GFCI protected).  
One main 13.5 amp circuit breaker.  
AC Voltmeter  
In keeping with Multiquip's policy of constantly improving  
its products, the specifications quoted herein are subject to  
change without prior notice.  
Figure 1 (page 10) shows the basic controls and indicators  
for the GA-3.6RZ2 generator.  
Idle Control Switch  
Full Power Switch  
GroundTerminal  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 9  
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GA-3.6RZ2 CONTROLS AND INDICATORS  
Figure 1. Controls and Indicators  
PAGE 10 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 INSTALLATION  
Outdoor Installation  
Install the generator in a location where it will not be exposed to Exhaust gases from gasoline engines are extremely  
Indoor Installation  
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.  
poisonous. Whenever an engine is installed indoors the  
exhaust fumes must be vented to the outside. The engine  
should be installed at least two feet from any outside wall.  
Using an exhaust pipe which is too long or too small can  
cause excessive back pressure which will cause the engine  
to heat excessively and possibly burn the valves.  
The installation site must be relatively free from moisture and  
dust. All electrical equipment should be protected from excessive  
moisture.Failure to do will result in deterioration of the insulation  
and will result in short circuits and grounding.  
Eliminate the danger of deadly carbon monoxide gas.  
Remember that exhaust fumes from any gasoline engine  
are very poisonous if discharged in a closed room, but  
harmless if allowed to mix with the outside air.If the generator  
is installed indoors, you must make provisions for venting  
the engine exhaust to the outside of the building.  
Foreign materials such as dust, sand, lint and abrasive materials  
have a tendency to cause excessive wear, not only to the engine  
parts, but also to the alternator parts.  
CAUTION :  
CAUTION :  
An electric shock is apt to happen when  
vibrators are used. Pay close attention to  
handling when operating vibrators and  
always use rubber boots and gloves to  
insulate the body from a short circuit.  
Pay close attention to ventilation when  
operating the generator inside tunnels and  
caves. The engine exhaust contains  
noxious elements.  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 11  
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GA-3.6RZ2 PRE-SETUP  
General Inspection Prior to Operation  
Circuit Breaker  
This generator has been thoroughly inspected and accepted A 2-pole, 13.5 amp circuit breaker is provided on the control  
prior to shipment from the factory.However, be sure to check box to protect the generator from an overload. Make sure to  
for damaged parts or components, or loose nuts and bolts, switch the circuit breakers to the "OFF" position prior to  
which could have occurred in transit.  
starting the engine.  
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.  
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 the  
other end of this wire to a suitable ground.  
Table 2. Cable Selection (60 Hz, single phase operation)  
Load In Watts  
At 120 At 240  
Maximum Allowable Cable Length  
Current  
in  
Amperes  
#10 Wire  
#12 Wire  
#14 Wire  
#16 Wire  
Volts  
Volts  
2.5  
5
300  
600  
1000 ft.  
500 ft.  
350 ft.  
250 ft.  
150 ft.  
125 ft.  
600 ft.  
300 ft.  
200 ft.  
150 ft.  
100 ft.  
75 ft.  
375 ft.  
200 ft.  
125 ft.  
100 ft.  
65 ft.  
250 ft.  
125 ft.  
100 ft.  
600  
1200  
1800  
2400  
3600  
4800  
7.5  
10  
15  
20  
900  
1200  
1800  
2400  
50 ft.  
CAUTION: Equipment damage can result from low voltage.  
PAGE 12 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 PRE-SETUP  
Fuel  
Lubrication Oil  
Close the fuel cock before filling the tank. Fill the fuel tank  
with clean and fresh unleaded gasoline. Do not fill the tank  
beyond capacity.  
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 screw  
into the filler hole, verify that the oil level is maintained  
between the two notches on the dipstick.  
Pay attention to the fuel tank capacity when replenishing  
fuel. Refer to the fuel tank capacity listed on page 8  
Specification Table1.  
The oil listed in Table 3 is recommended to ensure better  
engine performance. Use class SC or higher grade motor  
oil.  
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.  
NOTE  
This ROBIN 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.  
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  
Type Oil  
SAE 30  
104° F ~ 23° F  
(40° C ~ -5°C)  
23° F ~ 5° F  
SAE 20 or sae 10W-30  
SAE 10W or SAE 10W-30  
(-5° C ~ -15°C)  
Below 5° C (-15°)  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 13  
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GA-3.6RZ2 INSTRUMENTATION  
Start Switch  
CAUTION :  
Push this switch to start the engine (electric start only). If a  
recoil starter is used, pull the starter rope to start the engine.  
Make sure the operation switch is in the ON position (up),  
otherwise engine will not start.  
When using a combination of dual  
receptacles, total load should not exceed  
the rated capacity of the generating.  
Full Power Switch  
The unit is provided with a full power switch. Figures 2 and  
3 show simplified wiring diagrams of the dual voltage system.  
Power Outlets  
The generator has the following 120/240 volt 60 Hz (single-  
phase) receptacles.  
When the full power switch is in the 120 volt (up) position,  
you can take up full rated power of the generator at 120  
volts from the single duplex receptacle, single locking type  
120 volt receptacle, or a combination of these receptacles  
as long as the total load does not exceed the generating set  
capacity.  
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Single Phase  
One Duplex NEMA (GFCI) 5-20R (120V, 20 Amp)  
One Twist Lock NEMA L5-30R (120V, 30 Amp)  
One Twist Lock NEMA L6-20R (240V, 20 Amp)  
Main Circuit Breaker (2-Pole 120/240V 60 Hz)  
This 2-pole 21 amp breaker protects the generator from short  
circuiting or overloading from the 120/240V 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 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.  
Figure 2. 120 V Simplified Diagram (Switch Up)  
NOTE  
When the full power switch is in the 120 volt  
position, the locking type 240 volt receptacle  
cannot be used.  
Fuel Gauge  
When the full power switch is in the 240 volt (down) position,  
you can take up to half of the rated power of the generating  
set at 120 volts from the duplex receptacle and up to half of  
the rated power of the set at 120 volts from the locking type  
120 volt receptacle; or full rated power of the set at 240  
volts from the locking type 240 volt receptacle.  
The fuel gauge is located on the fuel tank and allows easy  
monitoring of the fuel level.  
ACVoltmeter  
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.  
Operation Switch  
This switch must be in the ON position (up) for normal  
operation.  
Figure 3. 240 V Simplified Diagram (Switch Dn.)  
PAGE 14 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 LOAD APPLICATION  
Single Phase Load  
CAUTION:  
Motors and motor-driven equipment draw  
much greater current for starting than  
during operation.  
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.  
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.  
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.  
The idle control is operated at minimum load capacity of  
100W. If the load capacity is less than 100W, throw the idle  
control switch to the OFF position.  
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  
To determine the running wattage for your load, multiply the  
running wattage as indicated by steps 1, 2, and 3 below:  
1. INCANDESCENT LOADS  
Lights, heaters and similar appliances.  
Total the running wattage and multiply by 1.  
Example:  
29 light bulbs @ 100W each = 2.9 KW  
use a 3 KW generator.  
2. SMALL MOTORS  
Drills and other small power tools.  
Total the running wattage and multiply by 2.  
Example:  
A 1 inch drill runs at 1 KW  
use a 2 KW generator.  
3. LARGE MOTORS  
Submersible pumps, table saws etc.  
Total the running wattage and multiply by 3.  
Example:  
A conveyor belt runs at 8 KW  
use a 24 KW generator.  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 15  
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GA-3.6RZ2 OPERATING INSTRUCTIONS  
Before Starting  
Warm up  
1. Be sure to disconnect the electrical load and switch the  
main circuit breaker to theOFFposition prior to starting  
the engine.  
1. 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.  
2. Never start the engine with the main circuit breakerON.  
3. Turn the idle control switch to the "OFF" (down) position  
and check the voltage by referring to the voltmeter on  
the control box.  
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.  
CAUTION:  
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 13)  
DO NOT change the engine speed control  
lever which has been set at the factory prior  
to shipping.  
CAUTION:  
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NEVER start the engine when the oil level  
is below the lower mark on the dipstick.  
1. Check the generator for abnormal noise and smells.Then  
connect the load to the receptacles of the generator.  
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Check the fuel level on the fuel gauge.  
When fuel is low, fill the fuel tank with  
clean fresh unleaded automotive gasoline.  
2. Switch the main circuit breaker to the ONposition and  
turn the idle control switch to the ON(down) position  
for normal (load) engine operation.  
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If gasoline spillage occurs, completely  
wipe up the spilled gasoline.  
Operation  
Check the voltage by referring to the voltmeter on the control  
box. When the voltmeter indicates 120 volts, 120 volts from  
the 120V receptacle can be obtained. Refer to Figure 1,  
Controls and Indicators, item 5 on page 10.  
Starting  
1. Open the fuel cock located below the fuel tank.The fuel  
starts to flow when the fuel cock lever is turned  
downward.  
2. Place the idle control switch in the ON(up) position.  
Stopping the Engine  
3. 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.  
CAUTION:  
NEVER stop the engine suddenly while  
running at high speeds.  
4. Confirm that the main circuit breaker on the generator  
control box is OFF.  
5. Set the operation switch to the ONposition and grasp  
the starting knob 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.  
1. Remove the load from the generator. Place the circuit  
breaker in the OFFposition. Refer to Figure 1, item 2  
on page 10. Run the engine (no-load) with the idle control  
switch set to the ON position for three to five minutes,  
then stop the engine.  
6. If the engine fails to start, repeat the procedure.  
2. Turn the START/STOP switch to the STOPposition.  
CAUTION: l  
DO NOT pull the starter rope all the way  
to the end.  
3. Close the fuel cock.  
l
DO NOT release the starter knob after  
pulling. Allow it to rewind as soon as  
PAGE 16 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 MAINTENANCE  
General Inspection  
Service Daily  
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.  
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.  
Engine Side (Refer to the Engine Instruction Manual)  
Cleaning the Fuel Strainer  
Check Oil Level  
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.  
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  
Spark Plug  
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.  
Remove carbon build-up on the spark plug (Figure 4) with a  
wire brush. Set the spark plug gap to 0.60.7mm (0.024-  
0.028 inch).Tighten with a spark plug socket wrench. Clean  
the spark plug every 50 operating hours or once a week.  
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.  
Figure 4. Spark Plug Gap  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 17  
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GA-3.6RZ2 PREPARATION FOR LONG -TERM STORAGE  
Generator Storage  
For storage of the generating set for over 30 days, the  
following is required:  
l
l
Drain the fuel tank completely.  
Run the engine until the gasoline in the carburetor is  
completely consumed.  
l
l
l
l
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.  
l
l
Clean all external parts of the generating set with a cloth.  
Cover the generating set and store in a clean, dry place.  
PAGE 18 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 WIRING DIAGRAM  
G
ENGINE  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 19  
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GA-3.6RZ2 TROUBLESHOOTING (ENGINE)  
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.  
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  
L
TABLE 4. 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?  
Malfunction of valve seat?  
Spark plug is loose?  
Replace cylinder head gasket.  
Re-seat valves.  
Insufficient power output "no  
compression"  
Replace spark plug.  
Replace piston rings.  
Worn 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 20 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 TROUBLESHOOTING (ENGINE)  
TABLE 4. ENGINE TROUBLESHOOTING (CONTINUED)  
SYMPTOM  
POSSIBLE PROBLEM  
Malfunction in cooling fan?  
Air in-take filter clogged?  
SOLUTION  
Check or replace cooling fan.  
Insufficient power output  
"compression" and overheats  
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.  
Lubricating oil is wrong viscosity? Replace lubricating oil with correct viscosity.  
Exhaust color is continiously  
"WHITE"  
Worn rings?  
Replace rings  
Air cleanner clogged?  
Clean or replace air cleaner.  
Adjust choke valve to the correct position.  
Choke valve has not been set 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-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 21  
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GA-3.6RZ2 TROUBLESHOOTING (GENERATOR)  
diagnosis based on the GeneratorTroubleshooting (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.  
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 5. 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.  
Full power switch malfunction?  
Engine speed too high?  
Check full power switch and full power switch circuit.  
Lower engine speed to rated RPM.  
Check control box wiring.  
Voltage output too high.  
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"  
Bad Idle control switch?  
Idle control switch malfunction?  
Check or replace idle control switch.  
Check or replace idle control switch.  
Does not accelerate from low to  
high "LOAD ACTIVE"  
Idle control device malfunction?  
Check or replace idle control device.  
Check control box wiring.  
Control box interal wiring  
defective?  
PAGE 22 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 TROUBLESHOOTING (GENERATOR)  
TABLE 5. GENERATOR TROUBLESHOOTING (CONTINUED)  
SYMPTOM  
POSSIBLE PROBLEM  
Defective rotor windings?  
Defective solenoid?  
SOLUTION  
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.  
Does not decelerate but has  
"VOLTAGE OUTPUT".  
Control box wiring malfunction?  
Check control box wiring, replace any defective components.  
Defective solenoid?  
Check or replace solenoid.  
Idle control device malfunction?  
Check or replace idle control device.  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 23  
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GA-3.6RZ2 EXPLANATION OF CODE IN REMARKS COLUMN  
How to read the marks and remarks used in this parts  
book.  
Items Found In the RemarksColumn  
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 NumberColumn  
All parts with same symbol in the number column, , #,  
, belong to the same assembly or kit.  
+, %, or  
*
I
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-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 SUGGESTED SPARE PARTS  
GA-3.6RZ2 WITH ROBIN  
EH-25 ENGINE  
5 to 10 Units  
1 to 5 Units  
Qty.  
P/N........................ Description  
Qty.  
P/N........................ Description  
2 ............ 0601805327 .......... CIRCUIT BREAKER  
2 ............ 0601811031 .......... RECEPTACLE, GFCI  
2 ............ 0601812597 .......... RECEPTACLE, 125V, 30A  
2 ............ 0601811032 .......... RECEPTACLE, 250V, 20A  
2 ............ 0601823204 .......... RECTIFIER  
1 ............ 0601805327 .......... CIRCUIT BREAKER  
1 ............ 0601811031 .......... RECEPTACLE, GFCI  
1 ............ 0601812597 .......... RECEPTACLE, 125V, 30A  
1 ............ 0601811032 .......... RECEPTACLE, 250V, 20A  
1 ............ 0601823204 .......... RECTIFIER  
2 ............ 0810106004 .......... CAP, FUEL TANK  
4 ............ 0810107103 .......... FUEL FILTER, STRAINER  
2 ............ 0605510024 .......... FUEL COCK  
1 ............ 0810106004 .......... CAP, FUEL TANK  
2 ............ 0810107103 .......... FUEL FILTER, STRAINER  
1 ............ 0605510024 .......... FUEL COCK  
5 ............ 2343260407 .......... ELEMENT, AIR CLEANER ROUND  
5 ............ 2343600203 .......... ELEMENT, AIR CLEANER RECT.  
5 ............ 0650140150 .......... SPARK PLUG  
10 .......... 2343260407 .......... ELEMENT, AIR CLEANER ROUND  
10 .......... 2343600203 .......... ELEMENT, AIR CLEANER RECT.  
10 .......... 0650141030 .......... SPARK PLUG  
2 ............ KS31102301 ......... OIL SENSOR  
1 ............ KS31102301 ......... OIL SENSOR  
1 ............ 0669900217 .......... SWITCH, ON/OFF  
2 ............ 0669900207 .......... SWITCH, ON/OFF  
1 ............ 0601823853 .......... SLOWDOWN UNIT  
1 ............ 0601800258 .......... AC VOLTMETER  
1 ............ 0601810695 .......... OIL ALARM LAMP  
2 ............ 7895419004 .......... RUBBER SUSPENSION  
4 ............ 7685115504 .......... RUBBER SUSPENSION  
1 ............ 2545020100 .......... RECOIL STARTER ASSY.  
1 ............ 2536240400 .......... CARBURETOR ASSY.  
1 ............ 2547943011 .......... IGNITION COIL  
NOTE  
Part numbers on this Suggested  
Spare Parts List may supercede/  
replace the P/N shown in the text  
pages of this book.  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 25  
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GA-3.6RZ2 GENERATOR ASSY.  
GENERATOR ASSY.  
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GA-3.6RZ2 GENERATOR ASSY.  
GENERATOR ASSY.  
NO  
1
PART NO  
PART NAME  
QTY.  
REMARKS  
7911000403  
7661080003  
0601823207  
0601822636  
0071706304  
7661017104  
0801086104  
0040010000  
7911340403  
7661315112  
7871315022  
7875021513  
7661331003  
7661344204  
0040008000  
0041208000  
7871329514  
0601851760  
0017108020  
ROTOR ASSY. .................................. 1 ..............INCLUDES ITEMS W/  
*
1-1  
1-2  
FIELD COIL  
1
*
*
*
RECTIFIER ....................................... 2 ..............D3SB60(S)  
SURGE ABSORBER ........................ 2 ..............TNR15G431K  
BEARING, 6304................................ 1 ..............2RUNYCM  
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  
CAP  
HEX. HEAD BOLT  
1
1
1
1
1
1
1
1
4
4
4
1
1
4
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
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GA-3.6RZ2 CONTROL BOX ASSY.  
CONTROL BOX ASSY.  
PAGE 28 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 CONTROL BOX ASSY.  
CONTROL BOX ASSY.  
NO  
1
PART NO  
PART NAME  
QTY.  
REMARKS  
7911811503  
7911811513  
0601850102  
0601823204  
0027103020  
0601823853  
0027104010  
0027004000  
7911821503  
7911821513  
7910501302  
0601800258  
0601805327  
4341817004  
0027104010  
0610811031  
0601812597  
0601811032  
0027104010  
0207004000  
0601830737  
0601830727  
0601815109  
0602123555  
0017105016  
0017106016  
CONTROL BOX .............................................1............ UP TO S/N 5116919  
CONTROL BOX .............................................1............ FROM S/N 5116920  
GROMMET .....................................................1............  
2
3
4
5
6
RECTIFIER .................................................... 2 ............ S5VB60  
MACHINE SCREW  
2
SLOW DOWN UNIT ...................................... 1 ............ ND-80  
MACHINE SCREW  
HEX NUT  
2
2
7
CONTROL PANEL ........................................ 1 ............ UP TO S/N 5116919  
CONTROL PANEL ........................................ 1 ............ FROM S/N 5116920  
NAME PLATE................................................. 1 ............ N-5641  
8
9
AC VOLTMETER  
1
1
1
2
10  
11  
12  
13  
14  
15  
16  
CIRCUIT BREAKER, 13.5A  
BRACKET, CIRCUIT BREAKER  
MACHINE SCREW  
RECEPTACLE, 5-20R GFCI ......................... 1 ............ REPLACES 0601811035  
RECEPTACLE, L5-30R,125V,30A  
RECEPTACLE, L6-20R,250V,20A  
MACHINE SCREW  
1
1
6
6
HEX NUT  
17  
18  
19  
20  
21  
22  
FULL POWER SWITCH ............................... 1 ............ ET330D12  
IDLE CONTROL SWITCH ............................ 1 ............ ET115A12  
GROUND TERMINAL  
1
OIL ALARM LAMP ......................................... 1 ............ 06-106PR  
HEX. HEAD BOLT  
HEX. HEAD BOLT  
4
3
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 29  
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GA-3.6RZ2 PIPE FRAME ASSY.  
PIPE FRAME ASSY.  
PAGE 30 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 PIPE FRAME ASSY.  
PIPE FRAME ASSY.  
NO  
1
PART NO  
PART NAME  
QTY.  
REMARKS  
7915411102  
7915411112  
7915414103  
7915414113  
0017106016  
7915442103  
7895419004  
0207008000  
7685115504  
0207008000  
0017108030  
0207008000  
0017108040  
0207008000  
7915455003  
7915455103  
0017106016  
7915456004  
0017106016  
7945510102  
0810106004  
0810107103  
0602125031  
0017108020  
0642008900  
PIPE FRAME .............................................. 1 ............. UP TO S/N 5116919  
PIPE FRAME .............................................. 1 ............. FROM S/N 5116920  
BRACKET .................................................. 1 ............. UP TO S/N 5116919  
BRACKET .................................................. 1 ............. FROM S/N 5116920  
HEX,HEAD BOLT  
BASE  
RUBBER SUPENSION  
HEX,NUT  
RUBBER SUPENSION  
HEX,NUT  
HEX,HEAD BOLT  
HEX,NUT  
HEX,HEAD BOLT  
HEX,NUT  
COVER  
COVER  
HEX,HEAD BOLT  
STOPPER  
HEX, HEAD BOLT  
FUEL, TANK  
CAP, FUEL TANK  
FUEL FILTER  
FUEL GAUGE  
HEX, HEAD BOLT  
2
S
3
4
5
6
7
8
9
2
1
1
2
2
4
2
2
1
1
1
1
6
1
2
1
1
1
1
4
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
FUEL COCK ............................................... 1 ............. SEE PAGES 48 AND 49  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 31  
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GA-3.6RZ2 NAME PLATE AND DECALS  
NAME PLATE AND DECALS  
PAGE 32 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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GA-3.6RZ2 NAME PLATE AND DECALS  
NAME PLATE AND DECALS  
NO  
1
PART NO  
PART NAME  
DECAL : GROUND  
QTY. REMARKS  
0800628504  
1980680004  
7900638204  
7910501302  
7910631002  
0820610804  
0820610404  
7900636004  
8700611804  
8700611904  
1
1
1
1
1
1
1
1
1
1
S-1123  
S-3704  
S-4605  
S-5641  
S-3753  
S-3311  
S-3627  
S-4461  
S-4984  
S-4985  
2
DECAL : FUEL COCK  
DECAL : OPERATING INSTRUCTIONS  
DECAL : MQ GA-3.6RZ2  
DECAL : MQ 3600  
3
4
5
6
DECAL : CAUTION  
DECAL : WARNING  
7
8
DECAL : OPERATE AT 3600 RPM ONLY  
DECAL : WARNING  
9
10  
11  
DECAL : DANGER  
PLATE, SERIAL NO. .................................... 1 ..... CONTACT MQ SERVICE DEPT. W/MODEL & S/N  
DCLGA36RZ2 KIT, DECAL .................................................. 1 ..... INCLUDES ITEMS W/  
*
SEE DECAL ILLUSTRATIONS ON PAGE 7.  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 33  
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ROBIN EH-25 ENGINE CRANKCASE ASSY.  
ROBIN GX240K1 ENGINE CYLINDER HEAD  
CRANKCASE ASSY.  
PAGE 34 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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ROBIN EH-25 ENGINE CRANKCASE ASSY.  
CRANKCASE ASSY.  
NO  
PART NO  
PART NAME  
QTY.  
REMARKS  
10  
2541010111  
2541010101  
2461420203  
0440300030  
0600300220  
0600150010  
0310060020  
0013208500  
0401140030  
0211140020  
2541110301  
CRANKCASE................................ 1 .......... INCLS. ITEMS W/+ FROM S/N 1032215 TO 1032214  
CRANKCASE  
VALVE GUIDE  
OIL SEAL  
BALL BEARING  
BALL BEARING  
DOWEL PIN  
STUD  
PLUG  
GASKET  
1
2
1
1
1
2
2
2
2
20#  
30+  
40+  
45+  
50+  
60#  
80  
90  
210  
MAIN BEARING COVER .............. 1 .......... INCLUDES ITEMS W/%  
OIL SEAL  
220% 0440300030  
230% 0600300220  
240% 0600150010  
1
1
1
1
1
1
1
1
8
BALL BEARING  
BALL BEARING  
GOVERNOR GEAR  
GOVERNOR SLEEVE  
OIL GAUGE  
GASKET  
GASKET MA BEARING COVER  
BOLT & WASHER  
250  
260  
270  
280  
290  
300  
610  
2344500101  
2054190103  
2276360103  
0213160010  
2541600103  
0011308300  
2541300111  
2541300101  
2541500113  
0110100040  
2541550103  
2541600503  
0310060020  
0110060020  
2541430101  
2541440101  
2461600603  
2461600703  
0851080000  
2549900107  
*
*
CYLINDER HEAD ......................... 1 .......... INCLS. ITEMS W/# FROM S/N 1032215 TO 1032214  
CYLINDER HEAD  
1
1
4
1
1
2
6
1
1
1
1
1
620  
GASKET CYL HEAD  
FLANGE BOLT  
*
630#  
680  
ROCKET COVER  
690  
GACKET ROCKET COVER  
DOWEL PIN  
*
700  
710  
810  
820  
830  
FLANGE BOLT  
BREATHER COVER  
BREATHER PLATE  
GASKET BREATHER COVER  
GASKET BREATHER PLATE  
RUBBER PIPE, 8X11X75 mm  
*
840  
850  
*
GASKET SET ............................... 1 .......... INCLUDES ITEMS W/ ALSO INCLUDES  
*
GASKETS FROM THE INTAKE & EXHAUST ASSY.  
ON PAGES 38 & 39 ITEMS 340, 555 & 560.  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 35  
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ROBIN EH-25 ENGINE CRANKSHAFT & PISTON ASSY.  
CRANKSHAFT & PISTON ASSY.  
PAGE 36 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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ROBIN EH-25 ENGINE CRANKSHAFT & PISTON ASSY.  
CRANKSHAFT & PISTON ASSY.  
NO  
10  
40  
PART NO  
PART NAME  
QTY.  
1
REMARKS  
2542090101  
0230300170  
0230300180  
0230300190  
0021818000  
0032018000  
0323030010  
2542410103  
2542250100  
2462300103  
2542330103  
2542340103  
2542340203  
2542340303  
2542350107  
2542350207  
2542350307  
0565180010  
CRANKSHAFT, STD 1IN. KEYED  
SPACER T =0.6 mm  
SPACER T =0.8 mm  
SPACER T =1.0 mm  
NUT  
1
1
1
50  
1
60  
SPRING WASHER  
WOODRUFF KEY  
BALANCER SHAFT  
1
70  
1
210  
310  
320  
350  
360  
1
CONNECTING ROD ....................................... 1 .......... INCLUDES ITEMS W/  
*
CONN ROD BOLT  
PISTON PIN  
PISTON  
2
1
1
1
1
1
1
1
2
*
PISTON, 0.25 mm  
PISTON, 0.50 mm  
PISTON RING SET  
PISTON RING SET, 0.25 mm  
PISTON RING SET, 0.50 mm  
CLIP  
370  
380  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 37  
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ROBIN EH-25 ENGINE INTAKE & EXHAUST ASSY.  
INTAKE & EXHAUST ASSY.  
PAGE 38 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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ROBIN EH-25 ENGINE INTAKE & EXHAUST ASSY.  
INTAKE & EXHAUST ASSY.  
NO  
PART NO  
PART NAME  
QTY.  
REMARKS  
10  
2543170101  
2543330103  
2543360103  
2463370113  
2543340103  
2543350103  
0051904100  
2543640103  
0031522000  
2393500103  
2463610110  
2463610110  
0149080021  
0170080090  
2543612013  
25430410101  
2543420101  
2463520103  
0170080030  
0152050010  
0011008160  
0180080010  
2543610103  
2543400101  
0105080410  
2543480101  
0110060050  
2543300101  
0105060190  
2543260210  
2343600308  
2343260407  
2343290103  
2463600113  
0011308280  
2343590203  
0011006120  
2263921200  
2393260110  
2343600203  
2343600303  
0023706000  
CAMSHAFT ................................... 1 .............. INCLUDES ITEMS W/#  
TAPPET  
50  
2
2
2
1
1
1
1
1
1
60  
VALVE SPRING  
SPRING RETAINER  
INTAKE VALVE  
EXHAUST VALVE  
SPRING PIN  
RELEASE LEVER  
SNAP RING  
ROCKER SHAFT  
70  
80  
90  
100#  
105#  
115#  
200  
210  
220  
230  
PUSH ROD .................................... 2 .............. REPLACES 2483530111  
ROCKER ARM .............................. 2 .............. INCLUDES ITEMS W/  
*
ADJUSTING SCREW  
NUT  
2
2
1
1
1
2
2
4
1
2
1
*
240  
250  
*
SPACER  
MUFFLER  
310  
320  
340  
350  
360  
365  
370  
380  
400  
410+  
420  
425  
500  
505%  
510  
511  
520  
540  
555  
556  
560  
580  
590  
610  
620$  
630$  
670  
MUFFLER COVER  
GASKET MUFFLER  
NUT  
TAPPING SCREW  
BOLT& WASHER  
FLANGE NUT  
LOCK WASHER  
EXHAUST PIPE ............................. 1 .............. INCLUDES ITEMS W/+  
STUD  
2
1
EXHAUST PIPE COVER  
FLANGE BOLT .............................. 1 .............. REPLACES 0110060010  
INTAKE PIPE ................................. 1 .............. INCLUDES ITEMS W/%  
STUD ............................................. 2 .............. REPLACES 0105060191  
AIR CLEANER ASSY. .................... 1 .............. INCLUDES ITEMS W/  
PACKING  
1
1
1
1
3
2
1
2
ELEMENT  
INSULATOR  
GASKET INPIPE  
BOLT& WASHER  
GASKET 2 (INSULATOR)  
BOLT& WASHER  
NUT & WASHER  
AIR CLEANER ASSY. .................... 1 .............. INCLUDES ITEMS W/$  
ELEMENT  
GASKET  
FLANGE NUT  
1
1
2
REPLACES 0023806000  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 39  
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ROBIN EH-25 ENGINE GOVERNOR ASSY.  
GOVERNOR ASSY.  
PAGE 40 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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ROBIN EH-25 ENGINE GOVERNOR ASSY.  
GOVERNOR ASSY.  
NO  
PART NO  
PART NAME  
QTY.  
1
REMARKS  
10  
2544230101  
2464220103  
2544270101  
2544280103  
0031306000  
0011406250  
0186060020  
2544250113  
2274330200  
2274330201  
2274360103  
2274350113  
2274500203  
0043106300  
020106050  
0110060050  
2544420001  
0043500480  
020106050  
GOVERNOR LEVER  
GOVERNOR SHAFT  
GOVERNOR ROD  
ROD SPRING  
CLIP  
20  
1
30  
1
40  
1
50  
2
60  
BOLT & WASHER  
NUT  
GOVERNOR SPRING  
1
70  
1
80  
1
310  
320  
330  
340  
350  
360  
370  
380  
410  
430  
440  
SPEED CONTROL ASSY. ................. 1 ......... INCLUDES ITEMS W/  
*
SPEED CONTROL CP  
KNOB  
1
1
*
*
STOP PLATE ..................................... 1 .......... REPLACES 2274350101  
SPRING WASHER  
SCREW PANHEAD  
1
1
NUT.................................................... 1 ......... REPLACES 0022706000  
FLANGE BOLT  
WIRE BRACKET  
1
1
SCREW PANHEAD ........................... 1 ......... REPLACES 0043104080  
NUT.................................................... 1 ......... REPLACES 0022706000  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 41  
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ROBIN EH-25 ENGINE COOLING & STARTING ASSY.  
COOLING & STARTING ASSY.  
PAGE 42 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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ROBIN EH-25 ENGINE COOLING & STARTING ASSY.  
COOLING & STARTING ASSY.  
NO  
PART NO  
PART NAME  
QTY.  
REMARKS  
10  
2545345101  
2549170303  
0110060020  
2545270103  
2545020100  
2155051508  
2345012018  
1065011308  
2265010008  
1615012508  
2275013108  
2275013508  
2545014508  
2275015008  
1615015008  
2275015208  
0110060010  
0110060030  
0732004350  
BLOWER HOUSING, BLACK  
LABEL TRADE MARK  
FLANGE BOLT  
1
1
5
1
20  
40  
90  
HEAD COVER  
210  
RECOIL STARTER ........................ 1 ........... INCLUDES ITEMS W/  
*
210-1  
210-2  
210-3  
210-4  
210-5  
210-6  
210-7  
SPIRAL SPRING  
REEL  
STARTER ROPE  
STARTER KNOB  
RATCHET  
1
1
1
1
2
1
2
1
1
1
1
4
1
1
*
*
*
*
*
*
*
FRICTION SPRING  
RETURN SPRING  
PULLEY  
210-11  
210-13  
210-35  
210-49  
220  
230  
240  
*
*
*
*
KNOB CAP  
RATCHET GUIDE  
SET SCREW  
FLANGE BOLT  
FLANGE BOLT  
LABEL OHV  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 43  
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ROBIN EH-25 ENGINE CARBURETOR ASSY.  
CARBURETOR ASSY.  
PAGE 44 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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ROBIN EH-25 ENGINE CARBURETOR ASSY.  
CARBURETOR ASSY.  
NO  
PART NO  
PART NAME  
QTY.  
REMARKS  
70  
2346260101  
0851060230  
1561110020  
2536240400  
2206253608  
2376245108  
2366252808  
2376245108  
2536242008  
2466243608  
2096244508  
2366252008  
2396256008  
2366260008  
2366245108  
2266255008  
1616235208  
2366251008  
2366255108  
2366245008  
2366254008  
5806083350  
2386244008  
2536240108  
5806083210  
2466243508  
2366244508  
2476255008  
2366268008  
2356242508  
2366263108  
2466255108  
FUEL PIPE .............................................. 1 .......................... INCLUDES ITEMS W/#  
80#  
RUBBER PIPE, 6X12X70mm  
HOSE CLAMP  
1
2
REPLACES 0851060000  
90#  
210  
CARBURETOR ...................................... 1 .......................... INCLUDES ITEMS W/  
*
210-1  
210-2  
210-3  
210-4  
210-5  
210-6  
210-7  
210-8  
210-9  
THROTTLE VALVE  
SCREW  
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
*
*
*
*
*
*
*
*
*
CHOKE VALVE  
SCREW  
PILOT JET  
PILOT SCREW  
SPRING  
CHOKE LEVER  
RING  
210-11  
210-12  
210-13  
210-14  
210-15  
210-16  
210-17  
210-18  
210-19  
210-20  
210-22  
210-32  
210-40  
210-41  
210-61  
210-62  
210-89  
THROTTLE SHAFT  
BOLT  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
RING  
NEEDLE  
PIN  
FLOAT CHAMBER BODY  
PACKING  
PACKING  
FLOAT .................................................... 1 .......................... REPLACES 2366250508  
MAIN NOZZLE  
MAIN JET  
1
1
SEAL ....................................................... 1 .......................... REPLACES 1066239208  
ADJUSTING SCREW  
SPRING  
1
1
1
1
1
1
1
CAP CHOKE  
SEAL  
GUIDE HOLDER  
RING  
210-101  
210-119  
*
*
CAP  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 45  
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ROBIN EH-25 ENGINE IGNITION COIL ASSY. AND SPARK PLUG  
IGNITION COIL ASSY. AND SPARK PLUG  
PAGE 46 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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ROBIN EH-25 ENGINE IGNITION COIL ASSY. AND SPARK PLUG  
IGNITION COIL ASSY. AND SPARK PLUG  
NO  
PART NO  
PART NAME  
FLY WHEEL  
QTY.  
1
REMARKS  
10  
2347012108  
2547013018  
0043506250  
0669900217  
0150040090  
0566000250  
0659000010  
0650140150  
0655000051  
2067550101  
2347020301  
2277963201  
0110060010  
2547100203  
0043506250  
2267550103  
KS31102301  
2147900301  
2147312201  
0566120050  
20  
IGNITION COIL ................................ 1 ........... REPLACES 2547943011  
30  
BOLT & WASHER  
2
60  
SWITCH............................................ 1 ........... REPLACES 0669900207  
70  
TAPPING SCREW  
CLAMP  
PLUG TERMINAL  
2
1
1
90  
95  
100  
110  
209  
210  
212  
215  
220  
235  
280  
700  
755  
760  
770  
SPARK PLUG ................................... 1 ........... REPLACES 0650141030  
PLUG CAP  
CLAMP  
1
1
1
1
1
1
2
1
1
1
1
1
FLYWHEEL  
CHARGING COIL  
FLANGE BOLT  
RING GEAR  
SCREW & WASHER  
GROMMET  
OIL SENSOR  
CLAMP  
WIRE 22  
CLAMP  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 47  
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ROBIN EH-25 ENGINE FUEL STRAINER  
FUEL STRAINER ASSY.  
PAGE 48 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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ROBIN EH-25 ENGINE FUEL STRAINER  
FUEL STRAINER ASSY.  
NO.  
10  
PART NO.  
PART NAME  
QTY. REMARKS  
0642008900  
0642000220  
0642000230  
0642001910  
0642002360  
0642000250  
0642000330  
0642000240  
0642002790  
0642000330  
0642002410  
0642003230  
2696260401  
2696800403  
0561110020  
0521070042  
FUEL STRAINER ASSY...... 1.......... INCLUDES ITEMS W/# REPLACES 0605510024  
10-1  
10-2  
10-3  
10-4  
10-5  
10-6  
10-7  
10-8  
10-9  
#
#
#
#
#
#
#
#
#
FILTER  
GASKET  
CUP (NYLON)  
LOCK NUT  
GASKET  
1
1
1
1
2
1
1
1
1
1
1
O--RING  
BANJO BOLT  
LOCK BOLT  
O--RING  
LOCK NUT  
SPRING  
10-10  
10-15  
20  
#
#
FUEL PIPE 4 CP................. 1.......... INCLUDES ITEMS W/  
*
30  
RUBBER PIPE  
HOSE CLAMP  
BANJO  
1
2
1
*
40  
*
50  
*
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 49  
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Effective: July 1, 2000  
TERMS AND CONDITIONS OF SALE PARTS  
PAYMENT TERMS  
4. Freight is at the senders expense. All PRICINGANDREBATES  
partsmustbereturnedfreightprepaidto  
Multiquipsdesignatedreceivingpoint.  
Terms of payment for parts are net 10 days.  
Prices are subject to change without prior  
notice.Pricechangesareeffectiveonaspecific  
5. Parts must be in new and resalable dateandallordersreceivedonorafterthatdate  
condition,intheoriginalMultiquippackage willbebilledattherevisedprice. Rebatesfor  
(ifany),andwithMuiltiquippartnumbers price declines and added charges for price  
FREIGHTPOLICY  
All parts orders will be shipped collect or  
prepaidwiththechargesaddedtotheinvoice.  
All shipments are F.O.B. point of origin.  
Multiquipsresponsibilityceaseswhenasigned  
manifesthasbeenobtainedfromthecarrier,  
andanyclaimforshortageordamagemustbe  
settledbetweentheconsigneeandthecarrier.  
clearlymarked.  
increaseswillnotbemadeforstockonhandat  
thetimeofanypricechange.  
6. Thefollowingitemsarenotreturnable:  
Multiquip reserves the right to quote and sell  
directtoGovernmentagencies,andtoOriginal  
Equipment Manufacturer accounts who use  
our products as integral parts of their own  
products.  
a. Obsolete parts. (If an item is listed  
inthepartspricebookasbeing  
replaced by another item, it is  
obsolete.)  
b. Any parts with a limited shelf life  
(such as gaskets, seals, Orings,  
andotherrubberparts)thatwere  
purchasedmorethansixmonths  
priortothereturndate.  
MINIMUMORDER  
SPECIALEXPEDITINGSERVICE  
TheminimumchargeforordersfromMultiquip  
is $15.00 net. Customers will be asked for  
instructionsregardinghandlingofordersnot  
meetingthisrequirement.  
A$20.00to$50.00surchargewillbeaddedto  
theinvoiceforspecialhandlingincludingbus  
c. Anylineitemwithanextendeddealer shipments, insured parcel post or in cases  
netpriceoflessthan$5.00.  
where Multiquip must personally deliver the  
partstothecarrier.  
d. Special order items.  
RETURNEDGOODSPOLICY  
e. Electricalcomponents.  
Returnshipmentswillbeacceptedandcredit  
will be allowed, subject to the following  
provisions:  
LIMITATIONSOFSELLERSLIABILITY  
f.  
Paint,chemicals,andlubricants.  
Multiquip shall not be liable here under for  
damagesinexcessofthepurchasepriceofthe  
itemwithrespecttowhichdamagesareclaimed,  
andinnoeventshallMultiquipbeliableforloss  
of profit or good will or for any other special,  
consequentialorincidentaldamages.  
g. Decalsandpaperproducts.  
h. Itemspurchasedinkits.  
1. AReturnedMaterialAuthorizationmust  
beapprovedbyMultiquippriortoshipment.  
7. Thesenderwillbenotifiedofanymaterial  
receivedthatisnotacceptable.  
2. ToobtainaReturnMaterialAuthorization,  
alistmustbeprovidedtoMultiquipParts  
Sales that defines item numbers,  
quantities,anddescriptionsoftheitemsto  
bereturned.  
8. Such material will be held for 5 working  
days from notification, pending  
instructions. If a reply is not received  
within5days,thematerialwillbereturned  
tothesenderathisexpense.  
LIMITATIONOFWARRANTIES  
a. Thepartsnumbersanddescriptions  
mustmatchthecurrentpartsprice  
list.  
Nowarranties,expressorimplied,aremadein  
connection with the sale of parts or trade  
accessories nor as to any engine not  
manufacturedbyMultiquip.Suchwarranties  
made in connection with the sale of new,  
complete units are made exclusively by a  
statement of warranty packaged with such  
units, and Multiquip neither assumes not  
authorizes any person to assume for it any  
other obligation or liability whatever in  
connectionwiththesaleofitsproducts.Apart  
fromsuchwrittenstatementofwarranty,there  
arenowarranties,express,impliedorstatutory,  
which extend beyond the description of the  
productsonthefacehereof.  
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. Thelistmuststatethereason(s)for  
thereturn.  
d. The list must reference the sales  
order(s)orinvoice(s)underwhich  
theitemswereoriginallypurchased.  
11. Credit issued will be applied to future  
purchasesonly.  
e. Thelistmustincludethenameand  
phonenumberoftheperson  
requestingtheRMA.  
3. A copy of the Return Material  
Authorizationmustaccompanythereturn  
shipment.  
PAGE 50 GA-3.6RZ2 A.C. GENERATORPARTS & OPERATION MANUAL REV. #2 (03/05/01)  
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NOTE PAGE  
GA-3.6RZ2 A.C. GENERATOR PARTS & OPERATION MANUAL REV. #2 (03/05/01) PAGE 51  
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PARTS AND OPERATION MANUAL  
HERE'S HOW TO GET HELP  
PLEASE HAVE THE MODEL AND SERIAL NUMBER  
ON-HAND WHEN CALLING  
PARTS DEPARTMENT  
800-427-1244 or 310-537-3700  
FAX: 800-672-7877 or 310-637-3284  
SERVICE DEPARTMENT/TECHNICAL ASSISTANCE  
800-478-1244 or 310-537-3700  
FAX: 310- 537-4259  
WARRANTY DEPARTMENT  
888-661-4279, or 310-661-4279  
FAX: 310- 537-1173  
MAIN  
800-421-1244 or 310-537-3700  
FAX: 310-537-3927  
Manufactured for MULTIQUIP INC.  
by  
DENYO MANUFACTURING CO., JAPAN  
MULTIQUIP INC.  
POST OFFICE BOX 6254  
CARSON, CA 90749  
310-537-3700 800-421-1244  
FAX:310-537-3927  
WWW:multiquip.com  
Atlanta Boise Dallas Houston Newark  
Quebec, Canada Manchester, UK Rio De Janiero, BR Guadalajara, MX  
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