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