OPERATION AND PARTS MANUAL
MODEL GDP-5H
High Cycle Generator
(HONDA GASOLINE ENGINE)
Revision #2 (10/05/05)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
Download from Www.Somanuals.com. All Manuals Search And Download.
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-537-3927
Email: mq@multiquip.com
Internet:www.multiquip.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
MAYCO PARTS
800-306-2926
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-421-1244
FAX:310-537-4259
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
FAX:310-631-5032
FAX:310-537-1173
WARRANTYDEPARTMENT
800-421-1244,EXT.279
310-537-3700,EXT.279
© COPYRIGHT 2004, 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 thier 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 GDP-5H Portable Generator. 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.
To find the latest revision of this
publication, visit our website at:
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 3
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TABLE OF CONTENTS
Multiquip GDP-5H — AC
HONDA GX340K1EDN2 ENGINE
Air Cleaner Assembly........................................ 50-51
Camshaft Assembly .......................................... 52-53
Carburetor Assembly ........................................ 54-55
Control Assembly .............................................. 56-57
Crankcase Cover Assembly.............................. 58-59
Crankshaft Assembly ........................................ 60-61
Cylinder Barrel Assembly.................................. 62-63
Cylinder Head Assembly ................................... 64-65
Fan Cover Assembly ......................................... 66-67
Flywheel Assembly ........................................... 68-69
Ignition Coil Assembly ....................................... 70-71
Piston Assembly................................................ 72-73
Recoil Starter Assembly.................................... 74-75
Solenoid Assembly............................................ 76-77
Label Assembly................................................. 78-79
Portable Generator
Here's How To Get Help ............................................ 3
Table Of Contents ..................................................... 4
Parts Ordering Procedures ....................................... 5
Safety Message Alert Symbols .............................. 6-7
Rules for Safe Operation .....................................8-10
Operation and Safet Decals.................................... 11
Specifications (Generator) ...................................... 12
Specifications (Engine) ........................................... 13
Dimensions ............................................................. 14
General Information ................................................ 15
Load Application ..................................................... 16
Load Application/Earth Leakage Breaker ............... 17
Controls and Indicators ......................................18-20
Generator Refueling ............................................... 21
Installation ..........................................................22-23
Pre-Inspection ......................................................... 24
Pre-Inspection (Engine) .......................................... 25
Initial Start-up (Engine) ........................................... 26
Initial Start-up/Generator Operation ..................27-28
Shut-down/Long Term Storage ............................... 29
Maintenance (Engine)........................................30-31
Wiring Diagram Gen. (S/N 5541049 & below) ........ 32
Wiring Diagram Gen. (S/N 5543731 & above)........ 33
Troubleshooting (Engine)...................................34-35
Troubleshooting (Generator) .................................. 36
Explanation of Code In Remarks Column............... 38
Suggested Spare Parts ........................................... 39
Terms and Conditions Of Sale — Parts ..................80
Specification and part
number are subject to
change without notice.
Component Drawings
Nameplate and Decals....................................... 40-41
Generator Assy. ................................................. 42-43
Control Box Assy. ............................................... 44-45
Muffler Assy........................................................ 46-47
Pipe Frame Assy. ............................................... 48-49
PAGE 4 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
❒
❒
❒
❒
❒
❒
Dealeraccountnumber
Dealernameandaddress
Shipping address (if different than billing address)
Returnfaxnumber
Applicable model number
Quantity,part number and description of each part
Specifypreferredmethodofshipment:
✓
✓
✓
✓
✓
✓
FedEx or UPS Ground
FedEx or UPS Second Day or Third Day
FedEx or UPS Next Day
Federal Express Priority One
DHL
Note:Unlessotherwiseindicatedbycustomer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours.We will make every effort to ship
“Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
Truck
Place Your Parts Order Via Web or Fax
For Even More Savings!
Here’s how to get help...
Please have the model and serial number
on hand when calling.
(Domestic USA Dealers Only)
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
Email: mq@multiquip.com
800-421-1244
FAX: 310-537-3927
Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
Ordered
via
Standard
orders
Stock orders
PARTS DEPARTMENT
800-427-1244
310-537-3700
MAYCO PARTS
800-306-2926
310-537-3700
SERVICE DEPARTMENT
800-421-1244
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTY DEPARTMENT
800-421-1244, EXT. 279
310-537-3700, EXT. 279
($750 list and above)
FAX: 800-672-7877
FAX: 310-637-3284
Fax
3%
5%
10%
10%
Web
FAX: 800-672-7877
FAX: 310-637-3284
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other carrier.
FAX: 310-537-4259
FAX: 310-631-5032
FAX: 310-537-1173
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
NOTE:DISCOUNTSARESUBJECTTOCHANGE
MULTIQUIP INC.
Direct TOLL-FREE access
to our Parts Department:
18910WILMINGTON AVENUE
POST OFFICE BOX 6254
CARSON, CALIFORNIA 90749
310-537-3700 • 800-421-1244
FAX:310-537-3927
Toll-free nationwide — 800-427-1244
INTERNET:www.multiquip.com
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 5
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GDP-5H — SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
Potential hazards associated with the operation of a GDP-
5H Portable Generator will be referenced with Hazard
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.
Symbols which appear throughout this manual, and will be
Lethal Exhaust Gases
referenced in conjunction with Safety Message Alert
Symbols.
Lethal Exhaust Gas Hazards
WARNING
This Owner's Manual has been
developed to provide complete
instructions for the safe and efficient
Engine exhaust gases contain
poisonous carbon monoxide. This gas
is colorless and odorless, and can
cause death if inhaled. NEVER operate
this equipment in a confined area or
enclosed structure that does not provide
ample free flow air.
operation of the MQ Model GDP-5H
Portable Generator. Refer to the
engine manufacturers instructions for
data relative to its safe operation.
Before using this generator, ensure that the operating
individual has read and understands all instructions in this
manual.
Explosive Fuel Hazards
SAFETY MESSAGE ALERT SYMBOLS
WARNING
Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
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,
DO NOT fill the fuel tank while the engine is running or
hot. DO NOT overfill tank, since spilled fuel could ignite if
it comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
DANGER
You WILL be KILLED or SERIOUSLY INJURED
if you DO NOT follow these directions.
Burn Hazards
WARNING
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 CAN be KILLED or SERIOUSLY INJURED if
you DO NOT follow these directions.
CAUTION
You CAN be INJURED if you DO NOT follow
these directions.
Respiratory Hazards
WARNING
ALWAYS wear approved respiratory
protection when required.
PAGE 6 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — SAFETY MESSAGE ALERT SYMBOLS
Equipment Damage
Rotating Parts Hazards
CAUTION
CAUTION
Hazards
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
Other important messages are provided throughout this
manual to help prevent damage to your portable generator,
other property, or the surrounding environment.
Accidental Starting Hazards
CAUTION
ALWAYS place the power source, circuit
breakers or ON/OFF switch in the OFF
position, when the generator is not in use,
unless connected to transfer switch.
Eye and Hearing Hazards
CAUTION
ALWAYS wear approved eye and
hearing protection.
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 7
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GDP-5H — RULES FOR SAFE OPERATION
■
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
Read this manual!
DANGER
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 GDP-5H Portable Generator:
■
The engine section of this generator requires an adequate
free flow of cooling air. NEVER operate the generator in
any enclosed or narrow area where free flow of the air is
restricted. If the air flow is
GENERAL SAFETY
■
DO NOT operate or service this
equipment before reading this entire
manual.
restricted it will cause
serious damage to the
generator or engine and
may cause injury to people.
Remember the generator's
engine gives off DEADLY
carbon monoxide gas.
■
■
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.
■
■
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 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — 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
NEVER leave the generator unattended, turn off engine when
unattended.
machine.
■
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 Tables 4 and 5.
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 severe scalding to any persons
in the general 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.
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 9
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GDP-5H — 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 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — OPERATION AND SAFETY DECALS
Machine Safety Decals
The GDP-5H portable generator is equipped with a number of safety decals (Figure 1). 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.
Figure 1. Operation and Safety Decals
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 11
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GDP-5H — SPECIFICATIONS (GENERATOR)
Table 1. Specifications (Generator)
Model
GDP-5H
Type
Brushless Revolving Field Type
Excitation
Solid State, Statically Excited System
AC Generator
Speed
3,600 RPM
Self-Ventilation
5 gallons (19 liters)
3.6 kW
Cooling System
Fuel Capacity
Continuous Output
Stanby Output
Rated Voltage
Rated Current
Rated Current
Phase
4.0 kW
120/240 V
30 amps (120V)
15 amps (240V)
Single Phase (4 wire)
60 Hz
60 Cycle AC Power
Source
Frequency
Power Factor
Continuous Output
Rated Voltage
Rated Current
Phase
1
5 kVA
230 V
12.5 A
180 Cycle AC Power
Source
Three Phase (4 wire)
180 Hz
Frequency
Power Factor
80% (Lag)
28.34 x 22.04 X 21.25 in.
(720 X 560 X 540 mm)
Dimensions
(L x W x H)
235 lbs. (107 kg.)
269 lbs. (122 kg.)
Dry Net Weight
Weight (With Fuel)
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 12 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — SPECIFICATIONS (ENGINE)
Table 2. Specifications (Engine)
Model
HONDA GX340K1EDN2
Air-cooled 4 stroke, Single
Cylinder, OHV,
Horizontal Shaft Gasoline
Engine
Type
2.90 in. X 2.30 in.
(73 mm x 58 mm.)
Bore X Stroke
Displacement
Max Output
23.70 cu-in (389 cm3)
11.0 H.P./3600 R.P.M.
Unleaded Automobile Gasoline
1.16 quarts (1.1 liters)
Yes
Engine
Fuel
Lube Oil Capacity
Oil Alert System
Speed Control Method
Starting Method
Centrifugal Fly-weight Type
Recoil Start
Dimension
(L x W x H)
15.0 x 17.7 X 17.4 in.
(380 X 450 X 443 mm.)
Dry Net Weight
68.4 lbs (31 Kg.)
In keeping with Multiquip's policy of
constantly improving its products, the
specifications quoted herein are subject
to change without prior notice.
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 13
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GDP-5H — DIMENSIONS
Figure 2. Dimensions
PAGE 14 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — GENERAL INFORMATION
Excitation System
WARNING
Before connecting this generator to any building’s
electrical system, a licensed electrician must install an
isolation (transfer) switch.
The GDP-5H-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.
This voltage (19-22 VAC) is then sent to the control box that
contains three rectifying diodes:
Serious injury or death may result without this transfer
switch.
z
z
z
Excitation (diode 1)
Battery (diode 2)
Slow Down (diode 3)
GDP-5H FAMILIARIZATION
Generator
The Multiquip Model GDP-5H generator has been designed
as a portable dual purpose power source for 60 Hz (single
phase) lighting facilities, power tools, submersible pumps
and other industrial and construction machinery. In addition
the Model GDP-5H has been designed as a power source
for 180 Hz, 3-phase concrete vibrators or other equipment
that may require 3-phase power for operation.
The AC voltage will pass through the excitation diode that
converts the voltage to DC power.
This DC power is then sent to the excitation windings housed
within the main windings commonly called the "stator".
This voltage is then transferred into the rotor through
induction.The rotor contains two diodes within it which rectify
the DC voltage and send it out through the main windings,
as AC voltage.
The generator is mounted on rubber vibration isolators that
have a steel base backplate which is attached to the
protective steel pipe carrying frame.The protective carrying
frame is made of steel tubing and fully wraps around the
generator to protect against damage. See Figures 4A through
4E for the basic controls and indicators for the GDP-5H
generator.
Alternator
The alternator, a brushless revolving-field type, is
permanently aligned to the engine through rigid coupling.
Engine
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 generator is powered by a 11 HP, air-cooled, 4-stroke
HONDA gasoline engine. Reference Table 2, for engine
specifications.
Control Box
3-PhaseVibrator Application
The control box is provided with the following:
When using this generator with 3-phase vibrators do the
following:
■
Three 230V twist-lock output receptacles (three phase).
■
240V twist-lock output receptacle (single phase).
■
■
ALWAYS use a vibrator with short circuit protection.
■
■
■
■
120V twist-lock receptacle (single phase).
120V GFCI duplex output receptacle, (single phase).
60 Hz (single phase) circuit breaker.
ALWAYS use rubber boots and gloves when operating the
vibrator.
■
■
ALWAYS use adequate size connecting cable for extension.
ALWAYS maintain electrical cords in good condition and
frequently replace the entire cable of the vibrator with a new
one.
180 Hz (three phase) earth leakage circuit breaker.
■
■
■
■
■
AC Voltmeter
Ground Terminal
Full Power Switch
Idle Control Switch
Operation Switch
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 15
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GDP-5H — 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 — 60 Hz
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 3 below
when connecting loads.
Table 3. Power Factor By Load
CAUTION
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
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 (Tables
4 and 5 ) as a guide for selecting proper cable size.
Electronic devices,
communication equipment
1.0
0.8
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 16 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — LOAD APPLICATION/EARTH LEAKAGE BREAKER
Three Phase Load — 180 Hz
How to Use
180 Hz, three phase, 230V, motor-in-head vibrators can be
operated with this generator. When operating more than one
concrete vibrator, the ON/OFF switch of each concrete
vibrators shall be turned on one at a time.
Always conduct the following in order that the earth leakage
breaker will operate safely. Also, if the leakage breaker should
for some reason actuate, first stop the generator and then
repair or eliminate the source of the earth leakage before
resetting the leakage breaker.When setting up the generator
perform the following:
If they are switched on simultaneously, the circuit breaker
may trip or the engine may be overloaded.
The vibrators can be operated simultaneously if the total
power consumption does not exceed the rated output of the
generator (5.0 KVA).
Ground the Generator
Ground the generator from its ground connector so that
resistance to ground is 500 ohms or less.
If output (kVA) is not given on the
vibrators nameplate, approximate output
may be determined by multiplying
Ground the Tool
Ground the tool (load) in the same manner as the generator.
voltage by amperage by
Simply because the generator is
equipped with a earth leakage breaker
does not mean that grounding of the load
can be neglected, please be sure to
properly ground load equipment.
Earth Leakage Breaker (180 Hz)
Test Operation
The earth leakage detection breaker (Figure 3) is used for
180 Hz application (3-phase vibrators). Before operating the
generator test this breaker to make sure that is functioning
correctly.
For safety’s sake, the operation of the earth leakage breaker
should be tested periodically according to the following
procedure:
1. Start the engine and set it to high speed.
2. Turn the leakage breaker ON.
3. During normal operation, press the earth leakage indicator
test button on the front of the generator and observe
that indicator button pops out and the leakage breaker
trips.
4. Push the indicator button back in when resetting.
Figure 3. Earth Leakage Breaker
Before operating generator press earth
leakage test button.The earth leakage
breaker's earth leakage detection
sensitivity is 30 mA, and the actuation
time is 0.1 sec.
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 17
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GDP-5H — CONTROLS AND INDICATORS
Figure 4A. Generator Components
6. Idle Control Switch – This generator is provided with an
automatic idle control device 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.
1. 230V Output Receptacles– These three NEMA 7410
twist-lock receptacles will provide 230V, 12.5 amps,
180 Hz.
2. 180 Hz Earth Leakage Circuit Breaker – This 3-pole
earth leakage circuit breaker allows the circuit to be broken
when the load side shorts or there is an over-current
condition. In addition, during operation of the generator it
can detect when there is defective insulation on the load
side and breaks the circuit in response. When starting the
generator always have the circuit breaker placed in the
"OFF" position.
7. Operation Switch – Place this rocker switch in the "ON"
position (up) for normal operation.To turn-off the generator
place this switch in the "OFF" position (down).
3. Lifting Bail Eye – Attach a rope or chain to this lifting eye
when lifting of the generator is required. Never stand
underneath the generator while it is being lifted. Place lifting
eye in down position when not in use.
8.
GFCI Duplex Receptacle – This NEMA 5-20R, GFCI
receptacle will provide 120V, 20 amps.
9. Ground – This ground connection point should be connect
4. 60 Hz Circuit Breaker – This 2-pole circuit breaker (240/
15 amps or 120/30 amps) protects the generator from short
circuiting or overloading. When starting the generator
always have the circuit breaker placed in the "OFF"
position.
to a good earth ground (ground rod).
10. 240V Output Receptacle – This NEMA L6-20R twist-
lock receptacle will provide 240V, 15 amps, 60 Hz.
11. 120V Output Receptacle – This NEMA L5-30R twist-
5. AC-Voltmeter – This voltmeter indicates (with a mark) the
rated 60 Hz (single-phase) output voltage. In addition the
voltmeter can also be used as a diagnostic tool. If the
voltmeter indicator (needle) is below the rated voltage,
engine problems may exist (low/high RPM's). To prevent
damage to the generator or power tools turn the generator
OFF and consult your authorized Multiquip service dealer.
This meter cannot be used for 180 Hz applications.
lock receptacle will provide 120V, 30 amps, 60 Hz.
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GDP-5H — CONTROLS AND INDICATORS
Figure 4B. Generator Components
12. Full Power Switch – The generator is provided with a full
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
power switch. Figures 4C and 4D 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 generator at
120 volts from the GFCI duplex receptacle and the120V the 240V twist-lock receptacle.
twist-lock receptacle, or a combination of both receptacles
as long as the total load does not exceed the generating
set capacity.
Figure 4D. 120/240V Full Power Switch
Simplified Diagram (Down Position)
Figure 4C. 120V Full Power Switch
Simplified Diagram (Up Position)
When the full power switch is in the
120V position, the 240V twist-lock
receptacle cannot be used.
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 19
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GDP-5H — CONTROLS AND INDICATORS
Figure 4E. Generator
13. Fuel Cock Lever – Turn this lever downward to start
(down)the flow of fuel into the carburetor.Turn upward to
stop (up) the flow of fuel.
19. Engine Oil Drain Plug – Remove this drain plug when
draining of the oil from the engine crankcase is required.
Fill with recommeded type oil as listed in Table 6.
14. Spark Plug – Provides spark to the ignition system. Set
spark plug gap to 0.6 - 0.7 mm (0.028 - 0.031 inch) Clean
spark plug once a week.
20. 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.
15. Muffler/Heat Shield – Used to reduce noise and emissions.
NEVER touch this heat shield when the generator/welder
is in use. Always allow time for the generator to cool down
before performing maintenance.
21. Fuel Tank Cap – 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.
16. Choke Lever – Used for starting the engine. Close the
choke lever when starting a cold engine or in cold weather
conditions.The choke enriches the fuel mixture.Open the
choke lever if starting a warm engine or in warm weather
conditions.
22. Fuel Gauge – This gauge is located on top of the fuel tank.
Read this gauge to determine when fuel is low.
23. FuelTank – Fuel tank capacity is 5 gallons (19 liters).
17. Recoil Starter (pull rope) – Manual-starting method. Pull
the starter grip until resistance is felt, then pull briskly and
smoothly.
This HONDA engine is equipped
with a low oil shutdown capability.A
18. Engine Oil Filler Cap – Remove this cap/dipstick when
the adding of engine oil is required. See Table 6 for
recommended type engine oil.
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.
PAGE 20 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — GENERATOR REFUELING
DANGER
Adding fuel to the tank should be done only when
the engine is stopped and has had an opportunity
to cool down. In the event of a fuel spill, DO NOT
attempt to start the engine until the fuel residue
has been completely wiped up, and the area surrounding the
engine is dry. If generator is placed in a truck bed with a plastic
liner, REMOVE generator from truck bed and place on ground
(Figure 5) to refuel.This possibility exist of fire or explosion due
to static electricity.
Figure 5. Generator Refueling
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 21
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GDP-5H — INSTALLATION
Outdoor Installation
Indoor Installation
Install the generator/welder 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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground. Always use the ground terminal on the generator to
ground the generator. Ground the generator from its ground
connector so that the resistance to ground is 500 ohms or less.
CAUTION
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements.
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.
Mounting
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
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.
CAUTION
2. When grounding the generator (Figure 3) 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.
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.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
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GDP-5H — 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 6) and tighten the
nut fully. Connect the other end of the ground cable to a suitable earth ground (ground rod).
DANGER
Some of the MQ GDP5H portable
generators (S/N 5541050 and
below) have been configured with
the ground of the aramature
floating. This configuration may
lead to an electrical shock if the generator is not properly
grounded.To prevent electrical shock, ALWAYS connect
generator to a good earth ground.
MQ GDP5H portable generators
(S/N 5543730 and above) have
the aramature grounded.
These units are grounded
properly.
Figure 6. Generator Grounding
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 23
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GDP-5H — 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 (Tables 4 and 5) 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 (Figure 7) has a ground as shown in Figure.
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!
60 and 180 Hz Circuit Breakers
To protect the generator from an overload, circuit breakers are
provided for both 60 and 180 Hz operation. Make sure to switch
the these circuit breakers to the "OFF" position prior to starting
the engine.
Figure 7. Ground Cables/Plugs
Table 4. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Maximum Allowable Cable Length
Current In
Amperes
120 Volts
240 Volts
600
#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
300
600
1200
125 ft.
7.5
10
15
20
900
1800
100 ft.
1200
1800
2400
2400
3600
4800
50 ft.
CAUTION: Equipment damage can result from low voltage.
Table 5. Cable Selection (180 Hz, 3-Phase Operation)
Length (ft.)
50
100
150
200
250
300
Load
3 kVA
#14 Wire
#14 Wire
#14 Wire
#14 Wire
#14 Wire
#14 Wire
#14 Wire
#14 Wire
#14 Wire
#12 Wire
#14 Wire
#14 Wire
#12 Wire
#10 Wire
#12 Wire
#14 Wire
2 kVA
1 kVA
#14 Wire
#14 Wire
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GDP-5H — 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 9. Engine Oil Dipstick (Oil Level)
Table 6. Oil Type
ALWAYS wear approved eye and hearing
protection before operating the generator.
Season
Summer
Spring/Fall
Winter
Temperature
25°C or Higher
25°C~10°C
Oil Type
SAE 10W-30
SAE 10W-30/20
SAE 10W-10
Before Starting
1.
Read safety instructions at the
beginning of manual.
2.
Clean the generator, removing dirt
and dust, particularly the engine
cooling air inlet, carburetor and air
cleaner.
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 8) and wipe clean.
3. Readthefuelgaugelocatedontopofthefueltank(Figure10)
todeterminifthefuellevelislow. Iffuelislow,replenishwith
clean unleaded fuel.
Figure 10. Fuel Gauge
Figure 8. 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 9), fill to the edge of the oil filler
holewiththerecommendedoiltype(Table6).Maximum oil
capacity is 1.16 quarts (1.1 liters)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 25
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GDP-5H — INITIAL START-UP (ENGINE)
2. Placethechokelever (Figure13)inthe"CLOSED"position
CAUTION
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.
This section is intended to assist the operator with the initial
start-up of the portable generator. It is extremely important that
this section be read carefully before attempting to use the
generator in the field.
Figure 13. Choke Lever
3. Place the choke lever (Figure 13) in the "OPEN " position
Before Starting the Engine
if starting a warm engine or the temperature is warm.
1. Be sure to disconnect all electrical loads from the
4. Placethegenerator ON/OFFswitch(Figure14)inthe"ON
generator prior to starting the engine.
"position.
2. NEVER start the engine with the 60 or 180 Hz circuit
breakers in the “ON" position. Place both circuit breakers
(Figure 11) in the OFF position.
Figure 14. Generator On/Off Switch (ON)
5. Graspthestartergrip(Figure15)andslowlypullitout.The
resistancebecomesthehardestatacertainposition,corre-
sponding to the compression point. Pull the starter grip
brisklyandsmoothlyforstarting.
Figure 11. 60 and 180 Hz
Circuit Breakers (OFF Position)
Starting the Engine
1. Place the engine fuel valve lever (Figure 12) to the "ON"
position.
”
Figure 15. Starter Grip
CAUTION
DO NOT pull the starter rope all the way to the end.
DO NOT release the starter rope after pulling. Allow it to
rewind as soon as possible.
Figure 12. Engine Fuel Valve Lever (ON Position)
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GDP-5H — INITIAL START-UP/GENERATOR OPERATION
6. If the engine has started, slowly return the choke lever
2. Place the full power switch (Figure 19) in the 120V
position (up).
(Figure 13 ) to the “OPEN” position. If the engine has not
started repeat steps 1 through 5.
7. Beforethegeneratorisplacedintooperation,runtheengine
for3-5minutes. Checkfor abnormalsmells,fuelleaks, and
noises that would associate with lose components.
8. Place the idle control switch (Figure 16) in the "OFF"
(down) position.This will allow the engine speed to run
at speed about 3600 RPM's
Figure 19. Full Power Switch 120 V Position (Up)
When the full power switch is in the 120 V
position, the 240V twist-lock receptacle
cannot be used.
Figure 16. Idle Control Switch (Off)
3. Read the voltmeter on the front panel of the generator
(Figure 20) and verify that 120 VAC is present at the
120V twist-lock and GFCI duplex receptacles. For
additional verification of voltage, an external voltmeter
can be used to measure the output voltage as shown in
Figure 20.
Placing the idle control switch in
the OFF position (Figure 16) 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) (Figure 17),
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.
Figure 17. Idle Control Switch (On)
60 Hz Operation
Figure 20. 120V and GFCI Receptacles
1. Place the 60 Hz, 15 amp circuit breaker (Figure 18) in
4. Place the full power switch (Figure 21) in the 240V
position (down).
the ON position.
Figure 18. 60 Hz Circuit Breaker (ON)
Figure 21. Full Power Switch 240/120 V Position (Down)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 27
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GDP-5H — INITIAL START-UP/GENERATOR OPERATION
5. Read the voltmeter on the front panel of the generator
180 Hz Operation
(Figure 22) and verify that 240 VAC is present at the
240V twist-lock receptacle. Using an external voltmeter
verify that 120V is present at the at the 120V twist-lock
and GFCI duplex receptacles.
1. Place the 180 Hz, 12.5 amp circuit breaker (Figure 23)
in the ON position.
Figure 23. 60 and 180 Hz Breakers (ON)
5. Use an external voltmeter to measure the 230VAC output
voltage on the 180 Hz twist-lock receptacles as shown
in Figure 24.
Figure 22. 60 Hz Output Receptacles
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 GFCI duplex
receptacle and up to half of the rated power of the set at 120
volts from the 120V twist-lock receptacle; or full rated power
of the genset at 240 volts from the 240V twist-lock
receptacle.
Figure 24. 180 Hz Output Receptacles
When using the 180 Hz output receptacles,
When using a combination of dual
receptacles, total load should not exceed
the rated capacity of the generator.
the AC voltmeter on the generator cannot
be used for monitoring of the 3-phase
voltage.
Connecting the Load
Connecting the Load
1. If small wattage power tools are required, connect them
to the 60 Hz output receptacles at this time.
1. If high-cycle vibrators are going to be used, connect
them to the 180 Hz output receptacles at this time.
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GDP-5H — SHUTDOWN/ LONGTERM STORAGE
Stopping the Engine
5. Place the engine fuel valve lever (Figure 28) to the "OFF"
position.
”
1. Place both the 60 and180 Hz circuit breakers (Figure
25) in the OFF position.
Figure 28. Engine Fuel Valve Lever (OFF Position)
6. Remove the load from the generator.
Figure 25. 60 and 180 Hz Breakers (Off)
2. Place the idle control switch (Figure 26) in the OFF
Generator Storage
position.
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.
Figure 26. Idle Control Switch (Off)
■
■
■
■
Completely drain the oil from the crankcase and refill with
fresh oil.
3. Let the engine run at idle with no load for 2-3 minutes.
Remove the spark plug, pour 2 or 3 cc of SAE 30 oil into the
cylinder and crank slowly to distribute the oil.
4. To shut-down the engine, place the generator ON/OFF
switch (Figure 27) in the OFF position
Slowly rotate the engine a few times with the starter rope and
install a new spark 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.
Figure 27. Generator On/Off Switch (Off)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 29
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GDP-5H — MAINTENANCE (ENGINE)
UseTable 7 as a general maintenance guideline when servicing
your engine. For more detail engine maintenance information,
refer to the Honda engine owner's manual supplied with your
engine.
Table 7. 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 HONDA Shop Manual for service procedures.
(3) For commercial use, log hours of operation to determine proper maintenance intervals.
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GDP-5H — MAINTENANCE (ENGINE)
Maintenance
DANGER
DO NOT use gasoline as a cleaning solvent,
because that would create a risk of fire or
explosion.
Perform the scheduled maintenance procedures as defined by
Table 6 and below:
DAILY
■
Thoroughly remove dirt and oil from the engine and control
area.Clean or replace the air cleaner elements as necessary.
Check and retighten all fasteners as necessary. Check the
gearbox for oil leaks. Repair or replace as needed.
ENGINEAIRCLEANER
WEEKLY
1. Remove the air cleaner cover and foam filter element as
shown in Figure 31.
■
Remove the fuel filter cap and clean the inside of the fuel
tank.
2. Cleanfoamelementinwarm,soapywaterornonflammable
solvent. Rinseanddrythoroughly. Diptheelementinclean
engineoilandcompletelysqueezeouttheexcessoilfromthe
element before installing.
■
■
Remove or clean the filter at the bottom of the tank.
Remove and clean the spark plug (Figure 29), 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.
Figure 29. Spark Plug Gap
ENGINEOIL
1. Drain the engine oil when the oil is warm as shown in
Figure 31. Engine Air Cleaner
Figure 30.
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 6. For engine oil capacity, see Table 2 (engine
specifications). DO NOT overfill.
4. Install drain bolt with sealing washer and tighten se-
curely.
Figure 30. Engine Oil (Draining)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 31
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GDP-5H —WIRING DIAGRAM (GENERATOR) S/N 5541049 AND BELOW
Figur
PAGE 32 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H —WIRING DIAGRAM (GENERATOR) S/N 5543731 AND ABOVE
Fi
Diag
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 33
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GDP-5H —TROUBLESHOOTING (ENGINE)
GeneratorTroubleshooting (Table 9) information shown below
and on the proceeding pages. 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
diagnosis based on the EngineTroubleshooting (Table 8) and
TABLE 8. 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 34 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H —TROUBLESHOOTING (ENGINE)
TABLE 8. 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.
Replace lubricating oil with correct viscosity.
Lubricating oil is wrong
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?
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 35
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GDP-5H —TROUBLESHOOTING (GENERATOR)
TABLE 9. 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?
Leakage breaker malfunction?
Full power switch malfunction?
Engine speed too high?
Check or replace rotor.
Check or replace stator.
Check or replace CB1 or CB2.
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 Condition?
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?
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 36 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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NOTE PAGE
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 37
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GDP-5H — EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
The contents of this catalog are
subject to change without notice.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the “Items Number” Column
All parts with same symbol in the number column, , #,
, belong to the same assembly or kit.
+
, %, or
*
■
If more than one of the same
reference number is listed, the
last one listed indicates newest
(or latest) part available.
PAGE 38 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — SUGGESTED SPARE PARTS
GDP-5H 1 TO 3 UNITS WITH HONDA
GX340K1EDN2 ENGINE
Part numbers on this Sug-
gested Spare Parts List
1 to 3 Units
may supercede/replace
the P/N shown in the text
pages of this book.
Qty.
P/N
Description
1 ........A9924800014 ...........CAP FUEL TANK
1 ........A9924800004 ...........FILTER FUEL
1 ........3015419604 ..............SHOCK MOUNT
4 ........1665419004 ..............SHOCK MOUNT
1 ........9807955846 ..............SPARK PLUG
1 ........34150ZH7003 ...........ALERT UNIT, OIL
2 ........28462ZV7003 ...........ROPE, RECOIL
2 ........17211899000............ELEMENT AIR CLEANER
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 39
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GDP-5H — NAMEPLATE AND DECALS.
PAGE 40 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — NAMEPLATE AND DECALS.
NAME PLATE ASSY.
NO.
1
2
3
4
PART NO.
PART NAME
DECAL; MQ MULTIQUIP 5000
DECAL; CHOKE
DECAL; FUEL COCK .................................................. 1......... S-3704
DECAL;CONTROL PANEL ......................................... 1......... A41120010
DECAL; AIR CLEANER
QTY.
1
1
REMARKS
A4561000103
0600500047
1980680004
A4511200102
0600500045
5
1
6
7
8
9
10
11
12
13
NAMEPLATE .............................................................. 1......... CONTACT MQ PARTS DEPT.
DECAL; GROUND ....................................................... 1......... S-1123
DECAL;OPERATING INSTRUCTIONS ...................... 1......... A92120010
DECAL;WARNING...................................................... 1......... S-3627
DECAL;WARNING...................................................... 1......... A91110000
DECAL; CAUTION OPER. AT 3600 RPM ONLY ......... 1......... S-4461
DECAL;WARNING DANGEROUS GAS ..................... 1......... S-4984
DECAL; DANGER ELECTRICAL SHOCK HAZ. ......... 1......... S-4985
0800628504
A9521200104
0820610404
A9511100004
7900636004
8700611804
8700611904
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 41
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GDP-5H — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 42 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — GENERATOR ASSY.
GENERATOR ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
7851000203
ROTOR ASSY. .................................... 1 ................ INCLUDES ITEMS W/
*
*
1-1
FIELD ASSY....................................... 1 ................ NOT SOLD SEPERATELY
ARMATURE ASSY. EXCITER ............ 1 ................ NOT SOLD SEPERATELY
RECTIFIER ........................................ 1 ................ S10VB60
SURGE ABSORBER.......................... 1 ................ TNR15G471K
BEARING ........................................... 1 ................ 6304DDU
SET BOLT ROTOR
SET WASHER BEARING
*
1-2
1-3
1-4
1-5
2
*
*
*
*
0601820037
0601822640
0071206304
7851017204
0801086104
030210250
1
1
3
4
SPRINGWASHER ............................. 1 ................ REPLACES 0040010000
5
6
7
8
A4135000003
7851315502
0017108020
A4154000002
A4138000003
011208025
1961324003
1961313003
0011305100
7851334204
7851316804
030208200
ARMATURE ASSY.
END BRACKET
HEX HEAD BOLT
END BRACKET
1
1
4
1
1
9
FIELD ASSY. EXCITER
HEX HEAD BOLT ............................... 4 ................ REPLACES P/N 0017108025
GROMMET
GUIDE PANEL AIR
HEX HEAD BOLT ............................... 4 ................ REPLACES P/N 0017105012
COVER
SET BOLT STATOR
SPRINGWASHER ............................. 4 ................ REPLACES P/N 0040008000
PLAIN WASHER ................................. 4 ................ REPLACES P/N 0041208000
COVER
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
1
1
4
031108160
7851331103
0310300090
0017105012
0601820083
A4184000004
0027104020
0038404000
0017108015
1
1
4
3
3
3
3
6
SEAL
HEX HEAD BOLT
RECTIFIER, S25VB60
BRACKET
MACHINE SCREW
HEX NUT
23A
24
HEX HEAD BOLT
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 43
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GDP-5H — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 44 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
6
7
PART NO.
PART NAME
QTY.
REMARKS
A3214000003
0601851755
0601823204
0027103012
0601823853
0027104010
0030004000
A4224000003
0601802651
4341817004
0021004010
0601806819
0601812598
0601811035
0601811032
0601812594
0021004010
0030004000
0601830737
0601831620
0601831620
0021004015
0030004000
A3262800004
0017106016
0017105010
0601842415
0027104010
0601807480
0027104070
0030004000
0601815465
0027104020
CONTROL BOX
1
GROMMET........................................1 .................. C-30-NG-79-R
RECTIFIER .......................................4 .................. S5VB60
MACHINE SCREW
SLOW DOWN UNIT
MACHINE SCREW
NUT HEX ...........................................2 .................. REPLACESP/N 0207004000
CONTROL PANEL
CIRCUIT BREAKER ..........................1 .................. KM-2 15A
BRACKET CIRCUIT BREAKER
MACHINE SCREW
AC VOLTMETER ...............................1 .................. DE450-011 0~120/240V
RECEPTACLE ...................................1 .................. 5-20R
RECEPTACLE ...................................1 .................. L5-30R
RECEPTACLE ...................................1 .................. L60-20R
RECEPTACLE ...................................3 .................. 7410B
4
1
2
1
8
9
1
2
10
11
12
13
14
15
16
16A
17
18
19
20
20A
21
22
23
24
25
26
27
27A
28
29
MACHINE SCREW
12
NUT HEX .........................................12 .................. REPLACESP/N 0207004000
FULL POWER SWITCH ....................1 .................. ET-330D12
IDLE CONTROL SWITCH .................1 .................. C1550WA
OPERATION SWITCH .......................1 .................. C1550WA
MACHINE SCREW
1
NUT HEX ...........................................1 .................. REPLACESP/N 0207004000
CAPACITOR ASSY. ...........................1 .................. VR1H102MHA 50V 1000 F
HEX HEAD BOLT
4
4
1
2
1
2
HEX HEAD BOLT
RESISTOR, 7 OHM
MACHINE SCREW
CIRCUIT BREAKER, 12 AMPS
MACHINE SCREW
NUT HEX ...........................................2 .................. REPLACESP/N 0207004000
TERMINAL BOARD
MACHINE SCREW
1
2
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 45
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GDP-5H — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 46 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — MUFFLER ASSY.
MUFFLER ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
MUFFLER
QTY.
1
REMARKS
7852310003
18320ZC2000
18325ZB4000
18329ZB4000
18355ZB4630
0602322060
0105050616
18333ZB4800
0602322061
7855469004
011008020
PROTECTOR ......................... 1 ......... REPLACES P/N 0602302001
PROTECTOR ......................... 1 ......... REPLACES P/N 0602302002
SEAL ..................................... 2 ......... REPLACES P/N 0602302003
ARRESTOR, SPARK ............. 1 ......... REPLACES P/N 0602313060
TAPPING SCREW ................. 1 ......... REPLACES P/N 90183671003
BOLT HEX HEAD .................. 5 ......... REPLACES P/N 0017106012
GASKET ................................ 1 ......... REPLACES P/N 0602320175
HEX HEAD BOLT .................. 2 ......... REPLACES P/N 957000802000
9
10
11
12
13
14
15
BRACKET
1
BOLT HEX HEAD .................. 1 ......... REPLACES 0017108020
BOLT HEX HEAD .................. 1 ......... REPLACES 0017108020
BRACKET
BOLT HEX HEAD .................. 1 ......... REPLACES 0017106020
BOLT HEX HEAD .................. 4 ......... REPLACES 0017106012
011008020
7905469004
011206020
1
0105050616
1
1
7852310003
FFLER
1
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 47
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GDP-5H — PIPE FRAME ASSY.
PIPE FRAME ASSY.
PAGE 48 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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GDP-5H — PIPE FRAME ASSY.
PIPE FRAME ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
PIPE FRAME
BRACKET
HEX HEAD BOLT
BASE
RUBBER SUSPENSION
RUBBER SUSPENSION .................... 2 ................ REPLACES P/N 1725419214
NUT HEX ............................................ 8 ................ REPLACES P/N 0207008000
BOLT HEX HEAD ............................... 2 ................ REPLACES P/N 0017108030
QTY.
REMARKS
A4417000102
A3417100004
0017106016
7855411203
3015419604
1665419004
020108060
1
1
4
1
2
011208030
9
0017108040
0207008000
7905512002
A9924800014
A9924800004
0602125034
16950ZB4015
16952ZB4005
950014521040
9500202080
7855525514
7855525604
011208030
HEX HEAD BOLT
HEX NUT
FUELTANK
CAP FUEL TANK
FUEL FILTER
FUEL GAUGE
2
2
1
1
1
1
9A
10
11
12
13
14
14-1
15
16
17
18
19
20
21
22
23
23A
24
25
25A
25B
26
27
28
29
30
31
32
33
FUEL STRAINER ............................... 1 ................ REPLACES P/N 0605510068
SCREEN SET .................................... 1 ................ REPLACES P/N 0605510069
HOSE ................................................. 1 ................ REPLACES P/N 0605513146
HOSE BAND ...................................... 2 ................ REPLACES P/N 0605515178
RUBBER CUSHION
COLLAR
BOLT HEX HEAD ............................... 2 ................ REPLACES P/N 0017108030
BOLT HEX HEAD ............................... 2 ................ REPLACES P/N 0017108020
HANGER
STOPPER
MACHINE SCREW
HEX NUT
PLASTIC WASHER
HEX HEAD BOLT
HEX NUT
PLAIN WASHER
HEX HEAD BOLT
STOPPER
2
2
011208030
A9117200103
0601850097
0021008025
0207008000
A9311100004
0011308025
0037908000
0042108000
0019206016
7915456004
0017106016
7915455103
7855455003
0017106016
A4484400004
0017106016
1
1
1
1
2
2
2
2
1
1
2
1
1
6
1
3
HEX HEAD BOLT
COVER
COVER
HEX HEAD BOLT
COVER
HEX HEAD BOLT
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 49
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HONDA GX340K1EDN2 ENGINE — AIR CLEANER ASSY.
AIR CLEANERASSY.
PAGE 50 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — AIR CLEANER ASSY.
AIR CLEANER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
15721ZB4000
17211899000
17212ZB4003
17220ZB4003
17222ZC2000
17231899000
17235899000
17236899000
17252899000
17367413690
9405005000
9405006000
TUBE BREATHER
1
1
1
1
1
1
2
2
1
1
6
3
ELEMENT, AIR CLEANER
SEPARATOR, AIR CLEANER
HOUSING, AIR CLEANER
STAY, AIR CLEANER
COVER, AIR CLEANER
CLIP A, AIR CLEANER WIRE
CLIP B, AIR CLEANER WIRE
SEAL, AIR CLEANER
FILTER, DRAIN TUBE
NUT, FLANGE (5MM)
9
10
11
12
NUT, FLANGE (6MM)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 51
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HONDA GX340K1EDN2 ENGINE — CAMSHAFT ASSY.
CAMSHAFT ASSY.
PAGE 52 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — CAMSHAFT ASSY.
CAMSHAFT ASSY.
NO.
1
2
3
3
4
5
6
*
7
8
PART NO.
PART NAME
QTY.
REMARKS
14100ZE3020
14410ZE3013
14431ZE2000
14431ZE2010
14441ZE2000
14451ZE1013
14568ZE1000
14711ZE3000
14721ZE3000
14751ZE2003
14771ZE2000
14773ZE2000
14775ZE2010
14781ZE2000
14791ZE2010
90012ZE0010
90206ZE1000
CAMSHAFT ASSY. ................................... 1............. INCLUDES ITEMS/W
*
ROD, PUSH
2
2
2
2
2
1
1
1
2
1
1
1
1
1
2
2
ARM, VALVE ROCKER
ARM, VALVE ROCKER
LIFTER, VALVE
PIVOT, ROCKER ARM
SPRING, WEIGHT RETURN
VALVE, IN.
VALVE, EX.
SPRING, VALVE
9
10
11
12
13
14
15
16
RETAINER, IN. VALVE SPRING
RETAINER, EX. VALVE SPRING
SEAT, VALVE SPRING
ROTATOR, VALVE
PLATE, PUSH ROD GUIDE
BOLT, PIVOT (8MM)
NUT, PIVOT ADJ.
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 53
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HONDA GX340K1EDN2 ENGINE — CARBURETOR ASSY.
CARBURETOR ASSY.
PAGE 54 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — CARBURETOR ASSY.
CARBURETOR ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
*
2
*
3
*
4
*
5
*
6
16010ZE3701
16011ZA0931
16013ZA0931
16015ZA0931
16016ZH7W01
16024124760
16028ZA0931
16100ZE3F11
16124ZE0005
16148141881
16166ZE3F10
16172ZE3W10
16211ZE3700
16221ZE3800
16223ZE3800
16230ZE3701
16260ZE2722
16261ZE2702
16262ZE2711
16263ZA0000
16264ZE2701
16265ZE2721
16268ZE2721
16269ZA0800
16400ZE2703
16611ZE2711
16613893000
16615893000
36135ZF6D41
53149964003
88911MJ3000
90431ZE2700
90432ZE2700
90433ZE2700
90434ZE2700
90650SD9003
93500050120A
938920501208
9405006000
GASKET SET
1
1
1
1
1
1
1
VALVE SET, FLOAT
FLOAT SET
CHAMBER SET, FLOAT
SCREW SET
SCREW SET, DRAIN
SCREW SET B
7
*
8
CARBURETOR ASSY. (BE82B B) ......................... 1 ........ INCLUDES ITEMS W/
*
9
SCREW, THROTTLE STOP
CAP, CHOKE LEVER DUST
NOZZLE, MAIN
1
1
1
1
1
1
1
1
*
10
*
11
*
12
*
COLLAR, SET
13
INSULATOR, CARBURETOR
GASKET, CARBURETOR
GASKET, INSULATOR
VALVE ASSY., SOLENOID
14
15
16
*
17
STAY ASSY., MANUAL CHOKE ............................ 1 ........ INCLUDES ITEMS W/#
18#
19#
20#
21#
22#
23#
24
STAY, SOLENOID
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
2
2
2
1
1
1
1
4
1
1
1
1
1
1
LEVER, CHOKE
JOINT, ROD
ROD, CHOKE
STOPPER, CHOKE ROD
SPRING, MANUAL CHOKE
GASKET, AIR CLEANER
DIAPHRAGM ASSY.
25#
26#
27#
28#
29
30#
31
32#
33#
34#
35#
36
37#
38
39
40#
41#
42#
43#
44
45
46
ROD, CHOKE CONTROL
GROMMET, CHOKE ROD
GUIDE, CHOKE ROD
VALVE, DASHPOT CHECK
BUSH, ARM PIVOT
GROMMET, FENDER
WASHER, CHOKE LEVER
SEAL, CHOKE LEVER
WASHER, THRUST (2.7X8)
COLLAR, LEVER
CLIP, WIRE HARNESS
SCREW, PAN (5X12)
SCREW, WASHER (5X12)
NUT, FLANGE (6MM)
WASHER, PLAIN (5MM)
E-RING (2MM)
9410305000
9454002010
9454004010
E-RING (4MM)
9454007010
E-RING (7MM)
9500202070
CLIP, TUBE (B7)
950053500810M
950053500810M
99101ZH80950
99101ZH80980
99101ZH81000
99204ZE00350
BULK HOSE, VACUUM (3.5X8000) (3.5X75)
BULK HOSE, VACUUM (3.5X8000) (3.5X130)
JET, MAIN (#95) (OPTIONAL)
JET, MAIN (#98) (OPTIONAL)
JET, MAIN (#100)
47
*
47
*
47
*
48
*
JET SET, PILOT (#35)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 55
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HONDA GX340K1EDN2 ENGINE — CONTROL ASSY.
CONTROL ASSY.
PAGE 56 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — CONTROL ASSY.
CONTROL ASSY.
NO.
1
3
4
5
PART NO.
PART NAME
ARM, GOVERNOR
ROD, GOVERNOR
SPRING, GOVERNOR
SPRING,THROTTLE RETURN
CONTROL ASSY. ................................................1... INCLUDES ITEMS W/
SPRING, CONTROL ADJUSTING
BOLT, FLANGE (6X12) (CT200)
BOLT, GOVERNOR ARM
SCREW, PAN (5X35)
QTY.
REMARKS
16550ZE3700
16555ZE3000
16561ZE3000
16562ZE3700
16570ZE3700
16584883300
90013883000
90015ZE5010
93500050350A
9405006000
1
1
1
1
9
*
19
23
24
1
2
1
1
1
*
30
33
*
NUT, FLANGE (6MM)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 57
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HONDA GX340K1EDN2 ENGINE — CRANKCASE COVER ASSY.
CRANKCASE COVER ASSY.
PAGE 58 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — CRANKCASE COVER ASSY.
CRANKCASE COVER ASSY.
NO.
2
3
4
5
6
7
8#
9#
10#
11
12
13
PART NO.
PART NAME
QTY.
REMARKS
11300ZE3020
11381ZE3801
15600ZG4003
15600735003
15625ZE1003
16510ZE3000
16511ZE8000
16512ZE3000
16513ZE2000
16531ZE2000
90602ZE1000
90701HC4000
92102ZE3004
9410106800
COVER ASSY., CRANKCASE (S-TYPE) ............ 1 ........ INCLUDES ITEMS W/
*
GASKET, CASE COVER
CAP ASSY., OIL FILLER
CAP ASSY., OIL FILLER
GASKET, OIL FILLER CAP
GOVERNOR ASSY.............................................. 1 ........ INCLUDES ITEMS W/#
WEIGHT, GOVERNOR
HOLDER, GOVERNORWEIGHT
PIN, GOVERNOR WEIGHT
SLIDER, GOVERNOR
CLIP, GOVERNOR HOLDER
PIN, DOWEL (8X12)
OIL SEAL (35X52X8)
WASHER, PLAIN (6MM)
BOLT, FLANGE (8X40)
1
1
1
2
3
1
3
1
1
2
1
1
7
1
1
14
15#
16
*
957010804000
961006202000
961006207000
17
18
*
BEARING, RADIAL BALL (6202)
BEARING, RADIAL BALL (6207)
*
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 59
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HONDA GX340K1EDN2 ENGINE — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
PAGE 60 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
NO.
6
7
PART NO.
PART NAME
QTY.
REMARKS
13310ZE3701
13351ZE3010
961006207000
CRANKSHAFT (E-TYPE)
WEIGHT, BALANCER
BEARING, RADIAL BALL (6207)
1
1
1
11
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 61
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HONDA GX340K1EDN2 ENGINE — CYLINDER BARREL ASSY.
CYLINDER BARREL ASSY.
PAGE 62 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — CYLINDER BARREL ASSY.
CYLINDER BARREL ASSY.
NO.
1
2
3
4
PART NO.
PART NAME
QTY.
REMARKS
12000ZE3817
15510ZE2043
16541ZE3010
31161ZE2000
90013883000
90131896650
90446KE1000
91201ZE3004
91203952771
91353671003
9405010000
9410912000
9425110000
957010601200
961006202000
CYLINDER ASSY. (ALERT)................................. 1 ........ INCLUDES ITEMS W/
*
SWITCH ASSY., OIL LEVEL
SHAFT, GOVERNOR ARM
WIRE, GROUND
BOLT, FLANGE (6X12) (CT200)
BOLT, DRAIN PLUG
WASHER (8.2X17X0.8)
OIL SEAL (35X52X8)
OIL SEAL (8X14X5)
O-RING (13.5X1.5) (ARAI)
NUT, FLANGE (10MM)
WASHER, DRAIN PLUG (12MM)
PIN, LOCK (10MM)
BOLT FLANGE (6X12)
BEARING, RADIAL BALL (6202)
1
1
1
1
2
1
1
1
1
1
2
1
2
1
5
6
7
8
*
9
*
10
11
12
13
14
15
*
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 63
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HONDA GX340K1EDN2 ENGINE — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
PAGE 64 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
NO.
1
2
3
4
5
6
8
10
11
12
13
14
15
16
16
PART NO.
PART NAME
QTY.
1
1
1
1
1
1
1
1
2
2
1
2
4
1
1
REMARKS
12200ZF6W01
12204ZE2306
12205ZE2305
12216ZE2300
12251ZE3W00
12310ZE2020
12391ZE2020
90014ZE2000
90042ZE3700
92900080320E
90441ZE2010
9430112200
CYLINDER HEAD
GUIDE, VALVE (OS) (OPTIONAL)
GUIDE, EX. VALVE (OS) (OPTIONAL)
CLIP, VALVE GUIDE
GASKET, CYLINDER HEAD
COVER, HEAD
GASKET, CYLINDER HEAD COVER
BOLT, HEAD COVER
BOLT, STUD (8X106)
BOLT 2, STUD (8X32)
WASHER, HEAD COVER
PIN A, DOWEL (12X20)
BOLT, FLANGE (10X80)
SPARK PLUG (BPR5ES) (NGK) (OPTIONAL)
SPARK PLUG (W16EPR-U) (DENSO)
957011008000
9807955846
9807955855
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 65
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HONDA GX340K1EDN2 ENGINE — FAN COVER ASSY.
FAN COVER ASSY.
PAGE 66 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — FAN COVER ASSY.
FAN COVER ASSY.
NO.
2
3
6
7
PART NO.
PART NAME
COVER, FAN *NH1* (BLACK)
SHROUD
GROMMET, DRAIN HOLE
BOLT, FLANGE (6X12) (CT200)
CLIP, WIRE HARNESS (6MM) (WHITE)
QTY.
REMARKS
19610ZE3700ZB
19631ZE3W00
81329567020
90013883000
90654SA4003
1
1
1
6
2
8
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 67
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HONDA GX340K1EDN2 ENGINE — FLYWHEEL ASSY.
FLYWHEEL ASSY.
PAGE 68 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — FLYWHEEL ASSY.
FLYWHEEL ASSY.
NO.
1
6
8
9
PART NO.
PART NAME
QTY.
REMARKS
19511ZE3000
31100ZE3712
90201ZE3V00
90741ZE2000
FAN, COOLING
1
1
1
1
FLYWHEEL, LAMP
NUT, SPECIAL 16MM
KEY, SPECIAL WOODRUFF (25X18)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 69
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HONDA GX340K1EDN2 ENGINE — IGNITION COIL ASSY.
IGNITION COIL ASSY.
PAGE 70 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — IGNITION COIL ASSY.
IGNITION COIL ASSY.
NO.
1
2
3
4
6
7
10
11
12
13
15
PART NO.
PART NAME
QTY.
REMARKS
30500ZE2023
30700ZE1013
31510ZE1811
31510ZE3003
31511ZE3000
31512ZE2000
36101ZE3800
36103ZE1000
90012888000
90013883000
90015883000
COIL ASSY., IGNITION
CAP ASSY., NOISE SUPPRESSOR
COIL ASSY., LAMP (12V/25W)
COIL ASSY., LAMP (12V/25W)
CLAMP, WIRE
1
1
1
1
1
1
1
1
4
1
2
GROMMET, WIRE
WIRE, STOP SWITCH (470MM)
HOLDER, STOP SWITCH WIRE
BOLT, FLANGE (6X40)
BOLT, FLANGE (6X12) (CT200)
BOOT, FLANGE (6X28)
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 71
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HONDA GX340K1EDN2 ENGINE — PISTON ASSY.
PISTON ASSY.
PAGE 72 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — PISTON ASSY.
PISTON ASSY.
NO.
1
1
1
1
2
3
4
5
PART NO.
PART NAME
QTY.
REMARKS
13010ZE3003
13011ZE3003
13012ZE3003
13013ZE3003
13101ZE3W00
13111ZF6000
13200ZE3010
90001ZE8000
90601ZE3000
RING SET, PISTON (STD)
RING SET, PISTON (OS 0.25) (OPTIONAL)
RING SET, PISTON (OS O.50) (OPTIONAL)
RING SET, PISTON (0.75) (OPTIONAL)
PISTON (STD)
1
1
1
1
1
1
1
2
2
PIN, PISTON
ROD ASSY., CONNECTING (STD)
BOLT, CONNECTING ROD
CLIP, PISTON PIN (20MM)
6
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 73
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HONDA GX340K1EDN2 ENGINE — RECOIL STARTER ASSY.
RECOILSTARTERASSY.
PAGE 74 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — RECOIL STARTER ASSY.
RECOIL STARTER ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
28400ZE3W01ZB STARTER ASSY., RECOIL *NH1* (BLACK)
28410ZE3W01ZB CASE, RECOIL STARTER *NH1* (BLACK)
1
1
1
2
1
1
2
1
1
1
2
3
4
5
6
7
8
9
10
11
13
14
28421ZE3W01
28422ZE2W01
28441ZE2W01
28442ZE2W01
28443ZE2W01
28444ZE2W01
28445ZE2W01
28461ZE2W02
08560ZG92111
90004ZE2W01
90008ZE2003
PULLEY, RECOIL STARTER
RATCHET, STARTER
SPRING, FRICTION
SPRING, STARTER RETURN
SPRING, RATCHET
RETAINER, SPRING
HOLDER, SPRING
GRIP, STARTER
ROPE, RECOIL STARTER .................................. 1 ........ REPLACES P/N 28462ZE3W01
SCREW, CENTER
BOLT, FLANGE (6X10)
1
3
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 75
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HONDA GX340K1EDN2 ENGINE — SOLENOID ASSY.
SOLENOIDASSY.
PAGE 76 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — SOLENOID ASSY.
SOLENOIDASSY.
NO.
1
2
3
4
PART NO.
PART NAME
QTY.
REMARKS
16268893000
17850ZD1E30
36160ZB4003
90013883000
93500050080A
SPRING, CHOKE RETURN
LEVER, THROTTLE
SOLENOID ASSY.
1
1
1
1
2
BOLT, FLANGE (6X12) (CT200)
SCREW, PAN (5X8)
5
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 77
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HONDA GX340K1EDN2 ENGINE — LABELS ASSY.
LABELS ASSY.
PAGE 78 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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HONDA GX340K1EDN2 ENGINE — LABELS ASSY.
LABELS ASSY.
NO.
1
4
6
10
PART NO.
PART NAME
QTY.
REMARKS
87521ZE3W01
87528898620
87533ZC0630
87594ZB4A00
EMBLEM
1
1
1
1
MARK, CHOKE
MARK, AIR CLEANER
MARK, OIL CAUTION
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 79
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Effective: October 1, 2002
TERMS AND CONDITIONS OF SALE — PARTS
Multiquipreservestherighttoquoteandsell
directtoGovernmentagencies,andtoOrigi-
nal Equipment Manufacturer accounts who
useourproductsasintegralpartsoftheirown
products.
PAYMENT TERMS
5. Partsmustbeinnewandresalablecon-
dition,intheoriginalMultiquippackage(if
any), and with Multiquip part numbers
clearlymarked.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
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-
placedbyanotheritem,itisobsolete.)
A$35.00surchargewillbeaddedtotheinvoice
forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
andotherrubberparts)thatwerepur-
chasedmorethansixmonthspriorto
thereturndate.
LIMITATIONSOFSELLER’SLIABILITY
MINIMUMORDER
Multiquip shall not be liable hereunder for
damagesinexcessofthepurchasepriceofthe
item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
otherspecial,consequentialorincidentaldam-
ages.
The minimum charge for orders from Mul-
tiquipis$15.00net.Customerswillbeasked
for instructions regarding handling of orders
notmeetingthisrequirement.
c. Anylineitemwithanextendeddealer
netpriceoflessthan$5.00.
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-
turedbyMultiquip.Suchwarrantiesmadein
connectionwiththesaleofnew,completeunits
aremadeexclusivelybyastatementofwar-
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 80 — GDP-5H A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (10/05/05)
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NOTE PAGE
GDP-5H A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (10/05/05) — PAGE 81
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OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-537-3927
Email: mq@multiquip.com
Internet:www.multiquip.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
MAYCO PARTS
800-306-2926
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-421-1244
FAX:310-537-4259
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
FAX:310-631-5032
FAX:310-537-1173
WARRANTYDEPARTMENT
800-421-1244,EXT.279
310-537-3700,EXT.279
Your Local Dealer is:
MULTIQUIP INC.
18910 WILMINGTONAVE.
CARSON, CALIFORNIA 90746
800-421-1244 • 310-537-3700
FAX:310-537-3927
E-mail:mq@multiquip.com
Internet:multiquip.com
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