Revision #5 03/04/08
OPERATION AND PARTS MANUAL
MODEL GA-2.5H
PORTABLE AC GENERATOR
Page
NOTE PAGE
Control Box Assembly S/N 5496762 & below
TABLE OF CONTENTS
Controls and Indicators
Generator Assembly
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DANGER
GA-2.5H - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
CAUTION Accidental Starting Hazards
GA-2.5H - SAFETY MESSAGE ALERT SYMBOLS
Equipment Damage
Rotating Parts Hazards
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GENERAL SAFETY
GA-3.6H- RULES FOR SAFE OPERATION
DANGER
GA-2.5H - RULES FOR SAFE OPERATION
Power Cord Safety
Grounding Safety
Maintenance Safety
Emergencies
GA-2.5H - RULES FOR SAFE OPERATION
DANGER-ELECTROCUTION HAZARDS
DEATH
Weight With Fuel
Table 1. Specifications Generator
Dimensions Approximate
Dry Net Weight
Dry Net Weight
GA-2.5H - SPECIFICATIONS ENGINE Table 2. Specifications Engine
Dimension L x W x H
Model
Figure 1. Dimensions
GA-2.5H - DIMENSIONS
Excitation System
GA-2.5H - GENERAL INFORMATION
GA-2.5H FAMILIARIZATION Generator
Control Box
GA-2.5H - LOAD APPLICATION
Single Phase Load - 60 Hz
Table 3. Power Factor By Load
Figure 2A. Generator Components
GA-2.5H - CONTROLS AND INDICATORS
to units with S/N 5496763 and above
to units with S/N 5496762 and below
Figure 2B. Generator Components
GA-2.5H - CONTROLS AND INDICATORS
Figure 3. Generator Refueling
MQ GA-2.5H - GENERATOR REFUELING
DANGER
Mounting
GA-2.5H - INSTALLATION
Outdoor Installation
Figure 4. Generator Grounding
GA-2.5H - INSTALLATION
Connecting the Ground
Extension Cable
GA-2.5H - PRE-INSPECTION
General Inspection Prior to Operation Ground Power Tools
Table 4. Cable Selection 60 Hz, Single Phase Operation
Before Starting
GA-2.5H - PRE-INSPECTION ENGINE
DANGER EXPLOSIVE FUEL
Table 5. Oil Type
Figure 9. Main Breaker OFF Position Starting the Engine
GA-2.5H - INITIAL START-UP ENGINE
Figure 12. Engine ON/OFF Switch ON
Before Starting the Engine
Figure 14. AC Voltmeter 120 VAC
GA-2.5H - INITIAL START-UP ENGINE/OPERATION
Figure 15. 120 VAC GFCI Receptacle Connecting the Load
Figure 17. Engine ON/OFF Switch OFF
Generator Storage
MQ GA-2.5H - PREPARATION FOR LONG -TERM STORAGE
EVERY
MQ GA-2.5H - MAINTENANCE ENGINE
Table 6. Engine Maintenance Schedule
FIRST
ENGINE AIR CLEANER
MQ GA-2.5H - MAINTENANCE ENGINE
Cleaning the Fuel Strainer
Maintenance
Figure 22. Generator/Engine Wiring Diagram S/N 5496762 and below
GA-2.5H - WIRING DIAGRAM S/N 5496762 AND BELOW
Figure 23. Generator/Engine Wiring Diagram S/N 5496763 and above
GA-2.5H - WIRING DIAGRAM S/N 5496763 AND ABOVE
POSSIBLE PROBLEM
GA-2.5H - TROUBLESHOOTING ENGINE
TABLE 7. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
GA-2.5H - TROUBLESHOOTING ENGINE
TABLE 7. ENGINE TROUBLESHOOTING CONTINUED
SYMPTOM
POSSIBLE PROBLEM
GA-2.5H - TROUBLESHOOTING GENERATOR
TABLE 8. GENERATOR TROUBLESHOOTING
SYMPTOM
NOTE PAGE
QTY. Column
GA-2.5H - EXPLANATION OF CODE IN REMARKS COLUMN
NO. Column
PART NO. Column
Description
GA-2.5H - SUGGESTED SPARE PARTS
GA-2.5H 1 TO 5 UNITS WITH HONDA GX160K1EMA2 ENGINE
1 to 5 Units
Machine Safety Decals
GA-2.5H - NAMEPLATE AND DECALS
REMARKS
GA-2.5H - NAMEPLATE AND DECALS
PART NAME
GENERATOR ASSY
MQ GA-2.5H - GENERATOR ASSY
INCLUDES ITEMS W
MQ GA-2.5H - GENERATOR ASSY
PART NAME
REMARKS
CONTROL BOX ASSY. S/N 5496762 AND BELOW
MQ GA-2.5H - CONTROL BOX ASSY. S/N 5496762 AND BELOW
CONTROL BOX ASSY. S/N 5496762 AND BELOW
MQ GA-2.5H - CONTROL BOX ASSY. S/N 5496762 AND BELOW
PART NAME
REMARKS
CONTROL BOX ASSY. S/N 5496763 AND ABOVE
MQ GA-2.5H - CONTROL BOX ASSY. S/N 5496763 AND ABOVE
L5-20R125V, 20A
MQ GA-2.5H - CONTROL BOX ASSY. S/N 5496763 AND ABOVE
PART NAME
REMARKS
PIPE FRAME ASSY. S/N 5496762 AND BELOW
MQ GA-2.5H - PIPE FRAME ASSY. S/N 5496762 AND BELOW
BRACKET, MUFFLER COVER
MQ GA-2.5H - PIPE FRAME ASSY. S/N 5496762 AND BELOW
PART NAME
REMARKS
PIPE FRAME ASSY. S/N 5496763 AND ABOVE
MQ GA-2.5H - PIPE FRAME ASSY. S/N 5496763 AND ABOVE
REMARKS
MQ GA-2.5H - PIPE FRAME ASSY. S/N 5496763 AND ABOVE
PART NAME
CYLINDER HEAD ASSY
HONDA GX160K1EMA2 ENGINE - CYLINDER HEAD ASSY
GUIDE, IN. VALVE OVER SIZE
HONDA GX160K1EMA2 ENGINE - CYLINDER HEAD ASSY
PART NAME
REMARKS
CYLINDER BARREL ASSY
HONDA GX160K1EMA2 ENGINE - CYLINDER BARREL ASSY
CYLINDER BARREL ASSY
HONDA GX160K1EMA2 ENGINE - CYLINDER BARREL ASSY
PART NAME
REMARKS
CRANKCASE COVER ASSY
HONDA GX160K1EMA2 ENGINE - CRANKCASE COVER ASSY
CRANKCASE COVER ASSY
HONDA GX160K1EMA2 ENGINE - CRANKCASE COVER ASSY
PART NAME
REMARKS
CRANKSHAFT ASSY
HONDA GX160K1EMA2 ENGINE - CRANKSHAFT ASSY
PART NAME
QTY. REMARKS
HONDA GX160K1EMA2 ENGINE - CRANKSHAFT ASSY
PISTON ASSY
HONDA GX160K1EMA2 ENGINE - PISTON ASSY
QTY. REMARKS
HONDA GX160K1EMA2 ENGINE - PISTON ASSY
PART NAME
CAMSHAFT ASSY
HONDA GX160K1EMA2 ENGINE - CAMSHAFT ASSY
UP TO S/N
HONDA GX160K1EMA2 ENGINE - CAMSHAFT ASSY
PART NAME
REMARKS
RECOIL STARTER ASSY
HONDA GX160K1EMA2 ENGINE - RECOIL STARTER ASSY
RECOIL STARTER ASSY
HONDA GX160K1EMA2 ENGINE - RECOIL STARTER ASSY
PART NAME
QTY. REMARKS
FAN COVER ASSY
HONDA GX160K1EMA2 ENGINE - FAN COVER ASSY
REMARKS
HONDA GX160K1EMA2 ENGINE - FAN COVER ASSY
SPRING, CONTROL ADJUSTING
PART NAME
CARBURETOR ASSY
HONDA GX160K1EMA2 ENGINE - CARBURETOR ASSY
USE FROM S/N BE67A A
HONDA GX160K1EMA2 ENGINE - CARBURETOR ASSY
PART NAME
REMARKS
AIR CLEANER ASSY
HONDA GX160K1EMA2 ENGINE - AIR CLEANER ASSY
PART NAME
HONDA GX160K1EMA2 ENGINE - AIR CLEANER ASSY
SEPARATOR, AIR CLEANER
CASE COMP., AIR CLEANER
MUFFLER ASSY
HONDA GX160K1EMA2 ENGINE - MUFFLER ASSY
SEAL, MUFFLER PROTECTOR
HONDA GX160K1EMA2 ENGINE - MUFFLER ASSY
PART NAME
QTY. REMARKS
HONDA GX160K1EMA2 ENGINE - FLYWHEEL ASSY
QTY. REMARKS
HONDA GX160K1EMA2 ENGINE - FLYWHEEL ASSY
PART NAME
IGNITION COIL ASSY
HONDA GX160K1EMA2 ENGINE - IGNITION COIL ASSY
CAP ASSY., NOISE SUPPRESSOR
HONDA GX160K1EMA2 ENGINE - IGNITION COIL ASSY
PART NAME
QTY. REMARKS
GOVERNOR/CONTROL ASSY
HONDA GX160K1EMA2 ENGINE - GOVERNOR/CONTROL ASSY
USE FROM S/N 4913230~5048024
HONDA GX160K1EMA2 ENGINE - GOVERNOR/CONTROL ASSY
PART NAME
REMARKS
HONDA GX160K1EMA2 ENGINE - LABELS ASSY
REMARKS
HONDA GX160K1EMA2 ENGINE - LABELS ASSY
PART NAME
PAYMENT TERMS
TERMS AND CONDITIONS OF SALE - PARTS
11. Credit issued will be applied to future purchases only
SPECIAL EXPEDITING SERVICE
NOTE PAGE
OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
Service Department