Honda Power Equipment GA-2.5H User Manual
OPERATION AND PARTS MANUAL
MODEL GA-2.5H
PORTABLE AC GENERATOR
(HONDA GASOLINE ENGINE)
S/N 5496762 AND BELOW
S/N 5496763 AND ABOVE
Revision #4 (10/07/05)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PAGE 2 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
NOTE PAGE
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 3
TABLE OF CONTENTS
MQ GA-2.5H — AC
Portable Generator
Proposition 65 Warning .............................................. 2
Table Of Contents ...................................................... 4
Parts Ordering Procedures ........................................5
Safety Alert Message Symbols .............................. 6-7
Rules for Safe Operation ...................................... 8-10
Specifications (Generator) ....................................... 11
Specifications (Engine) ............................................ 12
Dimensions .............................................................. 13
General Information ................................................. 14
Load Application ...................................................... 15
Controls and Indicators ...................................... 16-17
Generator Refueling ................................................. 18
Installation .......................................................... 19-20
Pre-Inspection .......................................................... 21
Pre-Inspection (Engine) ........................................... 22
Initial Start-up (Engine) ............................................ 23
Initial Start-up (Engine/Operation) ........................... 24
Preparation For Long Term Storage .........................25
Maintenance....................................................... 26-27
Wiring Diagram S/N 5496762 & below) ................... 28
Wiring Diagram (S/N 5496763 & above) .................. 29
Troubleshooting (Engine) ................................... 30-31
Troubleshooting (Generator) .................................... 32
Explanation Of Codes In Remarks Column .............34
Suggested Spare Parts ............................................ 35
Honda GX160K1EMA2
Gasoline Engine
Cylinder Head Assembly .................................... 48-49
Cylinder Barrel Assembly ................................... 50-51
Crankcase Cover Assembly ............................... 52-53
Crankshaft Assembly ......................................... 54-55
Piston Assembly................................................. 56-57
Camshaft Assembly ........................................... 58-59
Recoil Starter Assembly ..................................... 60-61
Fan Cover Assembly .......................................... 62-63
Carburetor Assembly ......................................... 64-65
Air Cleaner Assembly......................................... 66-67
Muffler Assembly................................................ 68-69
Flywheel Assembly ............................................ 70-71
Ignition Coil Assembly ........................................ 72-73
Governor/Control Assembly ............................... 74-75
Labels................................................................. 76-77
Terms and Conditions Of Sale — Parts ...................78
Generator Component
Drawings
Nameplate and Decals ....................................... 36-37
Generator Assembly .......................................... 38-39
Control Box Assembly (S/N 5496762 & below).. 40-41
Control Box Assembly (S/N 5496763 & above) . 42-43
Pipe Frame Assembly (S/N 5496762 & below) .. 44-45
Pipe Frame Assembly (S/N 5496763 & above).. 46-47
PAGE 4 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
Effective: June 1st, 2005
Ordering parts has never been easier!
PARTS ORDERING PROCEDURES
Choose from three easy options:
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■
View Parts Diagrams
■
Order Parts
■
Print Specification Information
Goto www.multiquip.com and click on
Order Parts
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
parts@multiquip.com.
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the
internet
Standard orders
on
complete part numbers.*
Fax
your order in and qualify for a 3% Discount
on
Standard orders
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
International Customers
their local Multiquip Representatives for
Parts Ordering information.
and qualify for a 5% Discount
for all orders which include
Note: Discounts Are Subject To Change
for all orders which include
Note: Discounts Are Subject To Change
should contact
When ordering parts, please supply:
❒❒
❒
Dealer Account Number
❒❒
❒❒
❒
Dealer Name and Address
❒❒
❒❒
❒
Shipping Address (if different than billing address)
❒❒
❒❒
❒
Return Fax Number
❒❒
❒❒
❒
Applicable Model Number
❒❒
❒❒
❒
Quantity, Part Number and Description of Each Part
❒❒
NOTE
www.multiquip.com
Unless otherwise indicated by customer, all orders are treated as
within 24 hours. We will make every effort to ship
received, if received prior to 2PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 5
❒❒
❒
Specify Preferred Method of Shipment:
❒❒
✓
Fed Ex/UPS
Priority One
■
■
Ground
■ Next Day
Second/Third Day
■
✓ DHL
✓
Tr uck
Standard Orders
Air Shipments
Stock Orders
must be noted on fax or web order form.
the same day the order is
and will ship
GA-2.5H — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
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.
This Owner's Manual has been
developed to provide complete
instructions for the safe and efficient
NOTE
Before using this generator, ensure that the operating
individual has read and understands all instructions in this
manual.
SAFETY MESSAGE ALERT SYMBOLS
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,
operation of the MQ Model GA-2.5H
Portable Generator
engine manufacturers instructions for
data relative to its safe operation.
. Refer to the
HAZARD SYMBOLS
Potential hazards associated with the operation of a
GA-2.5H Portable Generator
Symbols which appear throughout this manual, and will be
referenced in conjunction with Safety Message Alert
Symbols.
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.
Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
WW
ARNINGARNING
W
ARNING
WW
ARNINGARNING
WW
ARNINGARNING
W
ARNING
WW
ARNINGARNING
MQ
will be referenced with Hazard
Lethal Exhaust Gas Hazards
Explosive Fuel Hazards
DANGERDANGER
DANGER
DANGERDANGER
You WILL be
you DO NOT follow these directions.
WW
W
WW
You CAN be KILLED or
you DO NOT follow these directions.
CAUTICAUTI
CAUTION
CAUTICAUTI
You CAN be
these directions.
KILLED
ARNINGARNING
ARNING
ARNINGARNING
INJURED
or
SERIOUSLY INJURED
SERIOUSLY INJURED
if you DO NOT follow
if
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
if
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
WW
ARNINGARNING
W
ARNING
WW
ARNINGARNING
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.
WW
ARNINGARNING
W
ARNING
WW
ARNINGARNING
ALWAYS wear approved
protection when required.
Burn Hazards
Respiratory Hazards
respiratory
PAGE 6 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
GA-2.5H — SAFETY MESSAGE ALERT SYMBOLS
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
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.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
ALWAYS wear approved eye and
hearing protection.
Rotating Parts Hazards
Accidental Starting Hazards
Eye and Hearing Hazards
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Other important messages are provided throughout this
manual to help prevent damage to your portable generator,
other property, or the surrounding environment.
Equipment Damage
Hazards
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 7
GA-3.6H— RULES FOR SAFE OPERATION
DANGERDANGER
DANGER
DANGERDANGER
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 MQ GA-2.5H Portable Generator:
GENERAL SAFETY
■
DO NOT operate or service this
equipment before reading this entire
manual.
■
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.
Read this manual!
■
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■
The engine section of this generator requires an adequate
free flow of cooling air.
any enclosed or narrow
area where free flow of the
air is restricted. If the air
flow is restricted it will
cause serious damage to
the generator or engine
and may cause injury to
people. Remember the
generator's engine gives
off
DEADLY
monoxide gas.
carbon
NEVER
operate the generator in
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■
NEVER operate this equipment under the influence of
drugs
■
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.
■
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.
or
alcohol
.
■
ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.
■
ALWAYS use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT
the machine. Fire or explosion could
result from fuel vapors, or if fuel is spilled
on a hot engine.
■
NEVER operate the generator in an
explosive atmosphere or near
combustible materials. An explosion or
fire could result causing severe
smoke
around or near
bodily
harm or even death.
■
NEVER disconnect any
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.
"emergency or safety devices"
.
PAGE 8 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
GA-2.5H — RULES FOR SAFE OPERATION
■
ALWAYS be sure the operator is familiar with proper safety
precautions and operation techniques before using generator.
■
NEVER leave the generator unattended, turn off engine when
unattended.
■
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.
■
NEVER run engine without air cleaner. Severe engine damage
may occur.
■
NEVER change or adjust the engine speed which has been
set at the factory prior to shipping.
Power Cord Safety
■
NEVER let power cables or cords
■
NEVER
is being transfer to a load.
■
NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.
■
NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
■
ALWAYS make certain that proper power or extension cord
has been selected for the job See Table 3.
stand in water
while AC power from the generator
lay in wate
r.
Grounding Safety
■
ALWAYS make sure that electrical circuits are properly
grounded
local codes before operating generator. Severe
death!
ungrounded generator.
per the
National Electrical Code
(NEC) and
injury
by electrocution can result from operating an
Maintenance Safety
■
■
■
■
■
■
■
■
■
■
■
or
NEVER lubricate components or attempt service on a
running machine.
High Temperatures – Always stop engine
and allow the engine to cool before adding
fuel, oil or performing service and
maintenance functions. Contact with
components can cause serious burns.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and replace any
broken parts immediately.
ALWAYS replace any worn or damaged warning decals.
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.
The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits.
performing maintenance on the generator.
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, fuel and
fuel filters.
DO NOT use food or plastic containers to dispose of
hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
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.
Turn all circuit breakers OFF before
hot!
■
ALWAYS make sure generator is properly grounded to a
suitable earth ground (GROUND ROD). See installation in
this manual.
■
NEVER use
gas piping
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 9
as an electrical ground.
GA-2.5H — RULES FOR SAFE OPERATION
DANGERDANGER
DANGER
DANGERDANGER
During operation of this generation, there
exists the possibility of
electrical shock or burn
cause
DEATH!
To avoid these hazards:
severe bodily harm
NEVER use
ELECTROCUTION HAZARDSELECTROCUTION HAZARDS
-
ELECTROCUTION HAZARDS
ELECTROCUTION HAZARDSELECTROCUTION HAZARDS
electrocution
, which can
or even
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.
NEVER grab or touch a live
power cord with wet hands, the
possibility exist of electrical
shock, electrocution, and even
death!
Emergencies
■
ALWAYS know the location of the
nearest
■
ALWAYS know the location of the nearest
first aid kit
■
In emergencies
nearest phone or
Also know the phone numbers of the nearest
ambulance, doctor
information will be invaluable in the case of an
emergency.
fire extinguisher
.
always
keep a phone on the job site
.
know the location of the
and
fire department
. This
.
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
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
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!
and or property damage.
licensed electrician
!
PAGE 10 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
GA-2.5H — SPECIFICATIONS (GENERATOR)
GA-2.5H — OPERATION AND SAFETY DECALS
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Effects of Altitude and Heat
The maximum output of the engines listed above are 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's 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
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 11
°
°°
°°
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°°
GA-2.5H — SPECIFICATIONS (ENGINE)
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NOTE
In keeping with Multiquip's policy of
constantly improving its products, the
specifications quoted herein are subject
to change without prior notice.
PAGE 12 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
GA-2.5H — DIMENSIONS
Figure 1. Dimensions
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 13
GA-2.5H — GENERAL INFORMATION
WW
ARNINGARNING
W
ARNING
WW
ARNINGARNING
Before connecting this generators to any building’s
electrical system, a licensed electrician must install an
isolation (transfer) switch.
Serious injury or death may result without this transfer
switch.
GA-2.5H FAMILIARIZATION
Generator
The Multiquip GA-2.5H 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.
These generators are 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
generators to protect against damage. See Figures 2A and
2B for the basic controls and indicators for the GA-2.5H
generator.
This portable generator is supplied with a electrical
box
. To reduce vibration caused by the engine, the control
box is also placed on rubber isolators.
Control Box
The control box is provided with the following:
■
120V twist-lock receptacle, single phase. (S/N 5496763
and above)
control
Excitation System
The GA-2.5H generator uses 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:
z
z
z
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.
Alternator
The alternator, a brushless revolving-field type, is
permanently aligned to the engine through rigid coupling.
Engine
This generator is powered by a 5.5 HP, air-cooled, 4-stroke
HONDA gasoline engine. Reference Table 2, for engine
specifications.
Excitation (diode 1)
Battery (diode 2)
Slow Down (diode 3)
■
120V GFCI single phase duplex output receptacle
■
20 amp main circuit breaker
■
AC Voltmeter
■
Ground Terminal (S/N 5496762 and below)
PAGE 14 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
GA-2.5H — LOAD APPLICATION
Single Phase Load — 60 Hz
Always be sure to check the nameplate on the generators
and equipment to insure the wattage, amperage and
To determine the running wattage for your load, multiply
the running wattage as indicated by steps 1, 2, and 3 below:
1. INCANDESCENT LOADS
frequency requirements are satisfactorily supplied by the
generators for operating the equipment.
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
2. SMALL MOTORS
starting system of the equipment.
If wattage is not given on the equipment's
NOTE
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate amperage.
3. LARGE MOTORS
WATTS = VOLTAGE x AMPERAGE
The power factor of this generators is 1.0 See Table 3 below
when connecting loads.
Lights, heaters and similar appliances.
Total the running wattage and multiply by 1.
Example:
29 light bulbs @ 100W each = 2.9 KW
use a 3 KW generator.
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.
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.
spmal
spmal
NOTE
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CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Motors and motor-driven equipment draw much greater
current for starting than during operation.
an adequate size
extension cable
which can carry the
Always
use
required load. See Table 4.
Extension Cables
When electric power is to be provided to various tools or
loads at some
are normally used.
distance
from the generator, extension cords
Cables should be sized to allow for
distance in length and amperage so that the voltage
drop between the generators and point of use (load) is
held to a minimum
. Use the cable selection chart (Table 4 )
as a guide for selecting proper cable size.
The idle control device is operated at a
NOTE
minimum load capacity of 100W. If the
load capacity is less than 100W, place
the idle control switch in the OFF
position.
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 15
GA-2.5H — CONTROLS AND INDICATORS
Figure 2A. Generator Components
1. 120V Output Receptacle – This NEMA L5- 20R twist-
6. ON-OFF Switch – place engine ON/OFF switch in the
lock receptacle will provide 120V, 20 amps, 60 Hz.
Applies to units with S/N 5496763 and above.
2. GFCI Receptacle – This 5-20R duplex receptacle will
provide 120V at all times.
3. 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 MQ service dealer.
4. Ciruit Breaker – To protect the generator from an
overload, a 2- pole 20 amp circuit breaker is provided on
the control box. Make sure to place the circuit breaker to
the "OFF" postion prior to starting the engine.
5. GFCI Ground – This ground connection point should
be connect to a good earth ground (ground rod).
Applies
7. Chassis Ground – This ground connection point should
level ground. Placing the generator on level ground will ensure
that the low oil sensor will function properly.
to units with S/N 5496762 and below.
"ON" position for normal operation. To turn- off the
generator place switch in the "OFF" position.
be connect to a good earth ground (ground rod). Applies
to units with S/N 5496763 and above.
This
NOTE
HONDA
with a low oil shutdown
capability. A built in sensor will
automatically turn off the engine
should the oil level fall below a
safe operating condition. Make
sure the generator is placed on
engine is equipped
PAGE 16 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
Figure 2B. Generator Components
GA-2.5H — CONTROLS AND INDICATORS
8. Generator Housing – Contains the rotor, rectifer field
coil assembly, aramature, bearings and other components
that make up generator asembly.
9. Spark Plug – Provides spark to the ignition system. Set
spark plug gap to 0.6 - 0.7 mm (0.024 - 0.028 inch). Clean
spark plug once a week.
10. Muffler/Heat Shield – Used to reduce noise and
emissions. NEVER touch this
generator is in use. Always allow time for the generator to
cool down before performing maintenance.
11. Oil Dipstick/ Filler Cap– Remove the filler cap dipstick
when checking the engine oil level. Add engine oil through
12. Oil Drain Plug – Remove this plug to drain engine oil
from the crankcase.
13. Carburetor Fuel Cup – Inspect the fuel cup weekly for
water and dirt. Clean as referenced in the maintenance
section of this manual.
14. Choke Lever – Used for starting the engine.
choke lever when starting a cold engine or in cold weather
conditions. The choke enriches the fuel mixture.
the choke lever if starting a warm engine or in warm
weather conditions.
heat shield
when the
Close
Open
15. Fuel Cock Lever – Turn this lever
16. Throttle Lever – Used to adjust engine RPM speed.
17. Recoil Starter (Pull Rope) – Used for manual-starting
18. Engine – This generator uses a 5.5 HP HONDA air-
19. Air Cleaner – Every 50 hours: Prevents dirt and other
20. Fuel Gauge – Read this gauge to determine when fuel
the
21. Fuel Gauge/Tank – Remove this cap to add unleaded
downward
(down)the flow of fuel to the carburetor. Turn
stop (up)
This unit is set at the factory and is not adjustable.
of the engine. Pull the starter grip until resistance is felt,
then pull briskly and smoothly.
cooled, 4-stroke , single cylinder, overhead camshaft
gasoline engine. Engine uses unleaded gasoline.
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.
low
is
gasoline to the fuel tank.
gasoline. Make sure cap is tightened securely. DO NOT
over fill. Fuel tank capacity is 3.2 gallons (12 liters).
the flow of fuel.
.
Replenish
with
clean unleaded
to
start
upward
to
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 17
MQ GA-2.5H — GENERATOR REFUELING
DANGERDANGER
DANGER
DANGERDANGER
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 3) to refuel. This possibility exist of
due to static electricity.
fire
or
explosion
Figure 3. Generator Refueling
PAGE 18 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
GA-2.5H — INSTALLATION
Outdoor Installation
Install the generator in a area that is free of
bystanders
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.
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.
Pay close attention to ventilation when
operating the generator inside tunnels
and caves. The engine exhaust contains
noxious elements.
, and
overhead obstructions
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
. Make sure the
debris
Indoor Installation
,
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.
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.
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
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.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
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.
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.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 19
GA-2.5H — 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 4) and tighten the
nut fully. Connect the other end of the ground cable to a suitable earth ground (ground rod).
Figure 4. Generator Grounding
PAGE 20 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
GA-2.5H — PRE-INSPECTION
General Inspection Prior to Operation
Ground Power Tools
When using power tools or electrical equipment requireing AC
power from the generator, make sure connecting (power tool)
cable (Figure 5) has a ground as shown in Figure.
Figure 5. Ground Cables/Plugs
Extension Cable
When electric power is to be provided to various tools or loads
at some distance from the generator, extension cords are
normally used. Cables should be sized to allow for distance in
length and amperage so that the voltage drop between the
generator and point of use (load) is held to a minimum. Use
the cable selection chart (Table 4) as a guide for selecting
proper cable size.
Never!
use power tools or
equipment that do not have a
NOTE
ground capability, the possibility
of electrocution, electrical
exists
shock or burn
severe bodily harm
, which can cause
or even
DEATH!
Main Circuit Breaker
To protect the generator from an overload always place the
main circuit breaker in the "OFF" position prior to starting the
engine.
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GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 21
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
NEVER operate the generator in a
confined area or enclosed area structure
that does not provide ample
.
air
ALWAYS wear approved eye and hearing
protection before operating the generator.
free flow of
GA-2.5H — PRE-INSPECTION (ENGINE)
Figure 7. Engine Oil Dipstick (Oil Level)
epyTliO.5elbaT
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.
3. Check the air filter for dirt and dust. If air filter is dirty,
replace air filter with a new one as required.
4. Check carburetor for external dirt and dust. Clean with
dry compressed air.
5. 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.
2. Remove the filler dipstick from the engine oil filler hole
(Figure 6) and wipe clean.
Fuel Check
1. Close the fuel cock before filling the fuel tank.
2. Remove the fuel cap located on top of fuel tank.
3. Read the fuel gauge located on top of the fuel tank (Figure 8)
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DANGER EXPLOSIVE FUELDANGER EXPLOSIVE FUEL
DANGER EXPLOSIVE FUEL
DANGER EXPLOSIVE FUELDANGER EXPLOSIVE FUEL
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
or in the dark
to determin if the fuel level is low. If fuel is low, replenish
with
.
clean unleaded fuel
hot! , running
.
Figure 6. Engine Oil Dipstick (Removal)
3. Insert and remove the dipstick without screwing it into the
filler neck. Check the oil level shown on the dipstick.
4. If the oil level is low (Figure 7), fill to the edge of the oil filler
hole with the recommended oil type (Table 5). Maximum oil
capacity is .63 quarts (0.6 liters)
PAGE 22 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
4. When refueling, be sure to use a strainer for filtration. DO
Figure 8. Fuel Gauge
NOT top-off fuel.
Wipe up any spilled fuel
DO NOT fill the tank beyond capacity.
immediately!
GA-2.5H — INITIAL START-UP (ENGINE)
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
DO NOT attempt to operate this
generator until the Safety, General
Information and Inspection sections
of this manual have been
thoroughly understood
This section is intended to assist the
operator with the
extremely important that this section be read carefully before
attempting to use the generator in the field.
Before Starting the Engine
1. Be sure to
generator prior to starting the engine.
2. NEVER
in the “ON" position. Place the main circuit breaker
(Figure 9) in the OFF position.
initial start-up
disconnect all electrical loads
start
the engine with the
read and
.
of the trash generator. It is
from the
main circuit breaker
3. Place the
if starting a
4. Place the
" position.
5. Grasp the starter grip (Figure 13) and slowly pull it out. The
resistance becomes the hardest at a certain position,
corresponding to the compression point. Pull the starter
grip briskly and smoothly for starting.
choke lever
warm engine
engine ON/OFF switch
Figure 12. Engine ON/OFF Switch (ON)
(Figure 11) in the "
or the
temperature is warm.
OPEN
(Figure 12) in the "
" position
ON
Figure 9. Main Breaker (OFF Position)
Starting the Engine
1. Place the engine
position.
Figure 10. Engine Fuel Valve Lever (ON Position)
2. Place the
position if starting a
”
choke lever
fuel valve lever
(Figure 11) in the "
cold
engine.
(Figure 10) to the "ON"
CLOSED
Figure 13. Starter Grip
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
DO NOT pull the starter rope all the way to the end.
DO NOT release the starter knob after pulling. Allow it
to rewind as soon as possible.
"
Figure 11. Choke Lever
GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05) — PAGE 23
GA-2.5H — INITIAL START-UP ENGINE/OPERATION
6. If the engine has started, slowly return the choke lever
(Figure 11 ) to the
started repeat steps 1 through 5.
7. Before the generator is placed into operation, run the
engine for 3-5 minutes. Check for abnormal smells, fuel
leaks, and noises that would associate with lose components.
“OPEN”
position. If the engine has not
8. Refer to the AC voltmeter (Figure 14) on the control
Stopping The Engine
Normal Shutdown
1. Place the
2. Remove the load from the generator, and let the engine
3. Place the
panel. The voltage indicated on the voltmeter should be
120 VAC with no load applied.
Figure 14. AC Voltmeter (120 VAC)
9. If desired, verify with a voltmeter (Figure15) that 120
4. Place the engine
VAC is present at the GFCI duplex receptacle and the
120V twist-lock receptacle.
main circuit breaker
(Figure 9) in the OFF
position.
run at idle for 3-5 minutes with the idle control switch in
the ON position (Up)
engine ON/OFF switch
position.
Figure 17. Engine ON/OFF Switch (OFF)
fuel valve lever
position.
”
(Figure 17) in the "
(Figure 18) to the "OFF"
OFF
"
Figure 15. 120 VAC GFCI Receptacle
Connecting the Load
1. Connect the load to the output receptacles.
2. Place the main circuit breaker (Figure 16) in the ON
position.
Figure 16. Main Circuit Breaker (ON)
Figure 18. Engine Fuel Valve Lever (OFF Position)
Emergency Showdown
1. Place the
engine ON/OFF swith
(Figure 17) in the
"OFF" position.
PAGE 24 — GA-2.5H A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #4 (10/07/05)
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