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