Wacker Neuson G2.5A User manual

www.wackergroup.com
Generator
G 2.5A
OPERATOR'SMANUAL
0152792en 002
0902
0152792EN

DANGER
CARBON MONOXIDE
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or
smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot
smell the exhaust, you could be breathing CO.
• NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed
areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh air.
• ONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the home. ALWAYS use a
battery-powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh
air RIGHT AWAY. See a doctor. You could have carbon monoxide poison.

Foreword
wc_tx000001gb.fm
Engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
1. Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker model. For your own safety and protection
from injury, carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especially copying and distribution rights are reserved.
Copyright 2002 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.
WARNING

G2.5A
ii
Serial Number
Numéro de Série
My machine’s numbers are / Les numéros de ma machine sont :
Revision
Niveau de revision
Item Number
Numéro de référence
Model number
Modèle
G2.5A
0009256 101 5010101
Nameplate / Plaque signalétique
A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit. Please
recordtheinformationfoundonthisplatesoitwillbeavailableshouldthenameplatebecomelostordamaged.When
orderingpartsorrequestingserviceinformation,youwillalwaysbeaskedtospecifythemodel,itemnumber,
revision number, and serial number of the unit.
Une plaque signalétique mentionnant le modèle, le numéro de référence, le niveau de revision et le numéro de série
est fixée sur chaque machine. Veuillez noter les informations relevées sur cette plaque de façon à ce qu’elles soient
toujoursdisponiblessilaplaquesignalétiquevenaitàêtreperdueouendommagée. Lorsquevouscommandezdes
piècesdétachéesou voussollicitezdesinformations auprès-vente,onvousdemandera toujoursdepréciser
le modèle, le numéro de référence, le niveau de revision et le numéro de série de la machine.
1038SD43

G2.5A
Operating Information 1A
1A-1
1.1 Safety Information ..............................................................................1A-2
1.2 Operating Safety ................................................................................1A-3
1.3 Operator Safety while using Internal Combustion Engines.................1A-4
1.4 Service Safety....................................................................................1A-4
1.5 Technical Data ...................................................................................1A-5
1.6 Safety and Operating Labels ..............................................................1A-6
1.7 Label Locations ..................................................................................1A-7
1.8 Application and Power Requirements.................................................1A-8
1.9 Grounding the Generator ...................................................................1A-8
1.10 Outdoor Operation..............................................................................1A-8
1.11 Indoor Operation ................................................................................1A-9
1.12 Use of Extension Cords......................................................................1A-9
1.13 Ground Fault Circuit Interrupt (GFI)..................................................1A-10
1.14 Circuit Breaker Protection ................................................................1A-10
1.15 Before Starting .................................................................................1A-10
1.16 To Start ............................................................................................1A-11
1.17 To Stop ............................................................................................1A-11
1.18 Operating Heavy Loads....................................................................1A-11
1.19 EngineMaintenance.........................................................................1A-12
1.20 New Machines..................................................................................1A-12
1.21 Periodic Maintenance Schedule .......................................................1A-12
1.22 Changing Oil ....................................................................................1A-12
1.23 Servicing Air Cleaner........................................................................1A-13
1.24 Cleaning Sediment Cup....................................................................1A-13
1.25 Carburetor Adjustment .....................................................................1A-14
1.26 Setting Engine Speed.......................................................................1A-14
1.27 Transporting .....................................................................................1A-14
1.28 Storage ............................................................................................1A-15
1.29 Troubleshooting ...............................................................................1A-15
1.30 Wiring Schematic .............................................................................1A-16
Table of Contents

1A-2
1A OPERATION G2.5A
Laws Pertaining to Spark Arresters
Notice: Somelocalauthoritiesrequirethatincertainlocations,sparkarrestersbeusedoninternalcombustionengines.
Aspark arresteris adevice designedto preventthe dischargeof sparksor flamesfrom theengine exhaust.It isoften
required when operating equipment on forested land to reduce the risk of fires. Consult the engine distributor or local
authorities and make sure you comply with regulations regarding spark arresters.
1.1 Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the
possibility of personal injury, damage to the equipment, or improper service.
CAUTION: Used without the safety alert symbol,
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
Note:
Contains additional information
important to a procedure.
Thisisthesafetyalertsymbol. Itisusedtoalertyoutopotential
personal injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
!
WARNING
!
CAUTION
!
!
DANGER

1A-3
G2.5A OPERATION 1A
1.2 Operating Safety
Familiarity and proper training are required for the safe operation of electrical equipment! Equipment operated
improperlyor byuntrained personnel can be dangerous! Read theoperating instructionsand familiarizeyourself with
the location and proper use of all instruments and controls. Inexperienced operators should receive instruction from
someone familiar with the equipment before being allowed to operate the generator.
NEVER operate generator when open containers of
fuel, paint, or other flammable liquids are near.
NEVER operate generator, or tools attached to the
generator, with wet hands.
NEVER use worn electrical cords. Severe electrical
shock and equipment damage may result.
NEVER rungeneratorindoorsorinan enclosed area
unless adequate ventilation, through such items as
exhaustfansorhoses,is provided.Exhaustgasfrom
theenginecontainspoisonouscarbonmonoxidegas;
exposure to carbon monoxide can cause loss of
consciousness and may lead to death.
NEVER run electrical cords under the generator, or
over vibrating or hot parts.
NEVER enclose or cover generator when in use or
when hot.
NEVER overload generator. The total amperage of
the tools and equipment attached to the generator
must not exceed the load rating of the generator.
NEVER stand on the machine.
NEVER allow untrained personnel to operate or ser-
vice the generator. Know how to operate and stop
generator before starting it.
NEVER operate generator in snow, rain, or standing
water.
ALWAYS keep generator at least one meter away
from structures, buildings, and other equipment dur-
ing use.
ALWAYSkeepgeneratoroutofreachofchildrenand
pets.
ALWAYSkeeptheareaimmediatelysurroundingthe
generator clean, neat and free of debris.
ALWAYS position and operate generator on a firm,
level surface.
ALWAYS remove all tools, cords, and other loose
items from generator before starting it.
ALWAYS make certain generator is well-grounded
and securely fastened to a good earthen ground.
ALWAYS transport generator in an upright position.
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN
CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS!
Improperconnectionofgeneratortoabuilding'selectricalsystemcanallowelectricalcurrentfromthegenerator
tobackfeedinto utility lines.Thismay result inelectrocutionof utility workers,fire,or explosion. Connectionsto
a building's electrical system must be made by a qualified electrician and comply with all applicable laws and
electrical codes.
If connected to a building's electrical system the generator must meet the power, voltage, and frequency
requirementsofthe equipment inthebuilding. Differences inpower,voltage, and frequencyrequirementsmay
exist and improper connection may lead to equipment damage, fire, and personal injury or death.
!
DANGER
WARNING
!

1A-4
1A OPERATION G2.5A
1.4 Service Safety
Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly
overalongperiodoftime,periodicmaintenanceandoccasionalrepairsarenecessary.Ifthegeneratorisexperiencing
problemsorisbeingserviced,attacha“DO NOTSTART”signtothecontrolpaneltonotifyotherpeopleofitscondition.
1.3 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation and fueling! Read and follow warning
instructions in engine owner's manual and safety guidelines below. Failure to follow the safety guidelines described
below could result in severe injury or death.
NEVER allow water to accumulate around the base
of the generator set. If water is present, move the
generator and allow it to dry before servicing.
NEVER service generator if clothing or skin is wet.
NEVERusegasolineorotherlowflashpointsolvents
to clean air filter elements.
NEVER allow untrained personnel to service this
equipment.Onlytrainedelectricaltech-niciansshould
beallowedtoservicetheelectricalcomponentsofthis
equipment.
NEVER modify the equipment without express writ-
ten approval from WACKER Corporation.
ALWAYS replace all guards and safety devices im-
mediately after servicing.
ALWAYSturnengineoffbeforeservicinggenerator.If
enginehas electric start,disconnect negative terminal
on battery.
ALWAYS keep generator clean and labels legible.
Replace all missing and hard-to-read labels. Labels
provide important operating instructions and warn of
dangers and hazards.
ALWAYSletenginecoolbeforetransportingorservic-
ing.
ALWAYS remain aware of moving parts and keep
hands,feet,andlooseclothingawayfrommovingparts
on generator and engine.
ALWAYS keep fuel lines in good condition and prop-
erly connected. Leaking fuel and fumes are extremely
explosive.
DO NOT run engine indoors or in an enclosed area
unless adequate ventilation, through such items as
exhaust fans or hoses, is provided.
DO NOT fill or drain fuel tank near an open flame,
while smoking, or while engine is running.
DO NOT fill fuel tank indoors or in an enclosed area
unless adequate ventilation, through such items as
exhaust fans, is provided.
DO NOT touch or lean against hot exhaust pipes.
DO NOT operate with the fuel tank cap loose or
missing.
DO NOT add fuel to a hot or running engine.
DONOTstartengineiffuelhasspilledoranodoroffuel
ispresent.Movegeneratorawayfromthespillandwipe
generator dry before starting.
!
DANGER
WARNING
!

1A-5
G2.5A OPERATION 1A
Maximum Output W2500
Continuous Output W2250
Type Single voltage, single phase, brushless system
AC Voltages available volts phase 120 1ø
Frequency Hz 60
Power Factor 1.0
AC Receptacles
120V GFI duplex amp 15
120V duplex amp 15
Main Circuit Breaker amp 20
L x W x H in. (mm) 27 x 17.5 x 17 (685 x 445 x 435)
Weight (dry) lbs. (kg) 94 (43)
1.5 Technical Data
Generator
Engine
Engine Make Honda
Engine Model GX 160 K1VX
Power @ 3600 rpm Hp (kW) 5.5 (4.1)
Operating Speed - no load rpm 3700 ± 100
Operating Speed - full load rpm 3600 ± 100
Spark Plug NGK / ND BPR6ES / W20EPR-U
Electrode Gap in. (mm) 0.028 – 0.031 (0.7 – 0.8)
Fuel type Regularunleaded
Fuel Consumption qt. (l)/hr 1.8 (1.7)
Fuel Tank Capacity qt. (l) 3.9 (3.7)
Running Time hrs. 2.1
Air Cleaner type Dry type with oil-wetted foam pre-cleaner
Oil Capacity oz. (l) 1.2 (1.1)
Lubrication oil grade SAE 10W30 - service class SF, SE, SD or SC
Engine Lubrication

1A-6
1A OPERATION G2.5A
1.6 Safety and Operating Labels
This WACKER machine uses international pictorial labels where needed. These labels are described below:
Turn engine switch to "OFF"
position.
Close choke.
1
2
3
4
5
1
2
Close fuel flow valve.
Open choke.
Pull rewind starter.
Turn engine switch to "ON"
position.
Open fuel flow valve.
110426
88897
GND
Electrical ground location.
Pictorial Meaning Pictorial Meaning
Warning!
Hot surface.
Danger! Engines emit carbon monoxide; operate only
in well ventilated area. Read the operator's manual.
No sparks, flames or burning objects near machine.
Shut off engine before refueling.
111023
STOP
DANGER
GEFAHR
PELIGRO
DANGER
CAUTION
PRECAUTION
PRECAUCION
VORSICHT
Caution! Read and understand the supplied
operator's manual before operating this machine.
Failure to do so increases the risk of injury to
yourself or others.
117045
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
117039
IMPROPER CONNECTION OF GENERATOR
TO A BUILDING'S ELECTRICAL
SYSTEM CAN ALLOW ELECTRICAL
CURRENT FROM THE GENERATOR TO
BACKFEED INTO UTILITY LINES.
THIS MAY RESULT IN ELECTROCUTION
OF UTILITY WORKERS, FIRE OR
EXPLOSION. CONNECTIONS TO A
BUILDING'S ELECTRICAL SYSTEM MUST BE MADE
BY A QUALIFIED ELECTRICIAN AND COMPLY WITH
ALL APPLICABLE LAWS AND ELECTRICAL CODES.
DANGER
88456
DANGER! Electric shock hazard!

1A-7
G2.5A OPERATION 1A
1.7 Label Locations
1
2
3
4
5
1
2
88897
GND
STOP
DANGER
GEFAHR
PELIGRO
DANGER
CAUTION
PRECAUTION
PRECAUCION
VORSICHT
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
IMPROPER CONNECTION OF GENERATOR
TO A BUILDING'S ELECTRICAL
SYSTEM CAN ALLOW ELECTRICAL
CURRENT FROM THE GENERATOR TO
BACKFEED INTO UTILITY LINES.
THIS MAY RESULT IN ELECTROCUTION
OF UTILITY WORKERS, FIRE OR
EXPLOSION. CONNECTIONS TO A
BUILDING'S ELECTRICAL SYSTEM MUST BE MADE
BY A QUALIFIED ELECTRICIAN AND COMPLY WITH
ALL APPLICABLE LAWS AND ELECTRICAL CODES.
DANGER
1038SD43
Danger!
Electric shock will cause serious injury or death.
155503
Neutral bonded to frame.
119593

1A-8
1A OPERATION G2.5A
1.8 Application and Power Requirements
Chart1:ApproximateStartingPowerRequirements
Incandescent lights and appliances such as
irons and hot plates, which use a resistive-type
heating element, require the same wattage to
start and run as is stated on their nameplates.
Fluorescent and mercury lamps require 1.2–2
times their stated wattage to start.
Electrical motors and many types of electrical
tools often require a large starting current. The
amount of starting current depends on the type
of motor and its use.
Most electrical tools require 1.2–3 times their
stated wattage for running.
Loads such as submersible pumps and air
compressors require a very large force to start.
They need as much as 3–5 times the wattage
stated on the nameplate in order to start.
1.9 Grounding the Generator
The generator should be grounded to a good ground
source in compliance with National Electric Code stan-
dards and local regulations.
Use #8 wire and secure one end to the ground terminal
(a)providedonthegeneratorframeandtheotherendto
a suitable ground source.
1001SD02
a
This generator is designed to operate single-phase,
60 Hz appliances running at 120 VAC.
Some appliances and tools require a surge of current
when starting. This means that the amount of power
needed to initially start the equipment is larger than the
powerrequiredtokeepitrunning.Thegeneratormustbe
capableof supplyingthis “surge”current. Other types of
appliancesrequiremorepowerthanisactuallystatedon
theirnameplate.
Chart1isofferedonlyasageneralguidelinetohelpyou
determine power requirements for different types of
equipment. Check with your nearest WACKER Dealer,
or contact the manufacturer or dealer of the tool or
appliance, if you have questions regarding power re-
quirements.
CAUTION: If a tool or appliance does not reach full
speedwithina few secondsafter it is switchedon, turn it
off immediately to avoid damage.
1.10 Outdoor Operation
Place the generator in an area where it will not be
exposedtorain,snow,orotherformsofmoisture.Make
sureitispositionedonfirm,levelgroundsoitwillnotslide
orshift.Positionengineexhaustawayfromareaswhere
people may be present.
Ifoperatingthegeneratorinsideatunnelordeeptrench,
make sure there is adequate ventilation. Precautions
similartothoserequiredwhenoperatingindoorsmaybe
necessary.

1A-9
G2.5A OPERATION 1A
1.11 Indoor Operation
If the generator must be operated indoors, adequate
ventilation or exhaust hoses must be provided. When
venting exhaust fumes, make sure the exhaust piping is
large enough to prevent excessive back pressure to the
engine. Back pressure reduces engine efficiency and
may cause the engine to overheat.
Exhaust gas from the engine contains poisonous
carbon monoxide gas; exposure to carbon monox-
ide can cause loss of consciousness and may lead
to death. Never run generator indoors or in an
enclosedareaunlessadequateventilation,through
such items as exhaust fans or hoses, is provided.
Whenoperated indoors, steps to prevent fire and explo-
sionsuchasprovidingagoodearthenground,removing
all flammable materials near generator, and using only
electriccablesingoodcondition,mustbeobserved.See
Section Operating Safety.
!
DANGER
1.12 Use of Extension Cords
When a long extension cord is used to connect an
applianceortooltothegenerator,avoltagelossoccurs—
the longer the cord, the greater the voltage loss. This
resultsin less voltage being supplied to theappliance or
toolandincreasestheamountofcurrentdraworreduces
performance. A heavier cord with a larger wire size will
reduce the voltage loss.
CAUTION: Operating equipment at low voltage can
cause it to overheat.
Usethe chart as aguidefor selecting propercable size.
Use only extension cords rated for outdoor use and
equipped with a third-wire ground.
Current Load in Watts Maximum Cord Length in Ft.
Amps 120V 240V #10 #12 #14 #16
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Damagedcordscancauseelectricalshock.Electric
shock can cause serious injury or death. DO NOT
useworn,bare, or frayedcords.Replace damaged
cords immediately.
TABLE 3 Maximum Extension Cord Length
WARNING
!

1A-10
1A OPERATION G2.5A
120 VAC 20 AMP
a
d
e
bcwc_gr000268
1.15 Before Starting
1. Read and understand safety and operating instruc-
tions at beginning of this manual.
2. Readandunderstandthemeaningsofallwarningand
operatinglabels.
3. Inspectgeneratorforanysignsofdamagewhichmay
affectoperationorposeasafetyhazard. Tightenany
loose nuts or bolts.
4. Check engine oil and fill to recommended level.
Note: Theengineisequippedwithanoilalertsystem.
If the oil level in the engine drops too low the engine
will not start.
5. Fill fuel tank with fresh, regular, unleaded grade
gasoline.DONOTuseanoil/gasmixture. Theuseof
gasoholoranyfuelcontainingmorethan10%ethanol
isnotrecommended.Consultengineowner’smanual
for complete fuel specifications.
1.13 Ground Fault Circuit Interrupt (GFI)
The120V,20Ampduplexreceptacle(a)isequippedwith
agroundfaultcircuitinterrupt(GFI).TheGFIshutsoffthe
powertothereceptaclewhenagroundfaultoccursinthe
generator or to a piece of equipment attached to the
generator. This GFI also protects the second 120V,
20Amp duplex receptacle (c).
TheGFIshouldbetestedforproperoperationeverytime
the generator is used.
To test GFI:
Startgenerator.Push TEST button(d)onreceptacle in.
The RESET button (e) will pop out. Power is now off at
thereceptacle.IftheRESETbuttondoesnotpopout,the
GFIisnotworking.Donotrungeneratoruntiltheproblem
can be corrected. To restore power to receptacle, push
the RESET button in.
If the RESET button pops out during operation, stop the
generator and check it and equipment for defects.
1.14 Circuit Breaker Protection
The generator is also protected by a 20 Amp circuit
breaker (b) located on the control panel.
The circuit breaker protects the generator from severe
overloads or short circuits. If the circuit breaker opens,
turntheengineoffimmediatelyanddeterminethecause
before restarting. Check the appliances and tools at-
tached to the generator for defects and make sure their
power requirements do not exceed the power rating of
the generator or the current limit of the receptacles.
When the circuit breaker opens, the breaker button will
pop out. To reset circuit breaker, push button in.

1A-11
G2.5A OPERATION 1A
f
c2
c1
1015SD03 1015SD04
1005SD47 1005SD49
e1
e2
CHOKE
d1
d2
1.16 To Start
Beforestarting,besureyoureadandunderstand allthe
safety and operating instructions in this manual.
1. Disconnect all loads from the generator.
2. Open fuel valve by moving lever to the right (c1).
Note: If engine is cold, move choke lever to closed
position (d1). If engine is hot, set choke to open
position (d2).
3. Turn engine switch to “ON” (e1).
4. Pull starter rope (f).
Note: If the oil level in the engine is low, the engine
will not start. If this happens, check oil level and add
oil as needed.
5. As engine warms up move choke lever to OPEN
position (d2).
6. Allowenginetowarmupafewminutesbeforeattach-
ing loads.
1.17 To Stop
1. Turn off and disconnect all tools and appliances
attached to the generator.
2. Turn engine switch to “OFF” (e2).
3. Close fuel valve by moving lever to the left (c2).
Note: To stop engine quickly in an emergency, turn
engine switch to "OFF" (e2).
1.18 Operating Heavy Loads
Limit operations requiring the maximum rated output
of2500Wto20–30minutes. Forcontinuousoperation
do not exceed the continuous rated output of 2250 W.
CAUTION: DONOTexceedthecurrentlimitspecified
on the control panel for any one receptacle.

1A-12
1A OPERATION G2.5A
1.19 Engine Maintenance
The Periodic Maintenance Schedule below lists basic maintenance intervals for the engine and generator. Please
read the detailed maintenance procedures for the engine described in engine Owner’s Manual. This manual was
supplied with the generator. Replacement copies of these manuals can be ordered from WACKER Corporation or
directly from the engine manufacturer.
1.20 New Machines
Change engine oil and replace oil filter after the first 20 hours of operation.
1.21 Periodic Maintenance Schedule
1.22 Changing Oil
Drain oil while engine is still warm.
1. Removeoilfillplug(g)anddrainplug (h)todrainoil.
2. Install drain plug.
3. Fill engine crankcase with recommended oil up to
level of plug opening (i).
Oil Capacity: 21 oz. (0.6 liters)
4. Install oil filler cap.
Note: Intheinterestsofenvironmentalprotection,place
a plastic sheet and a container under the machine to
collectany liquid which drains off. Disposeof this liquid
inaccordancewithenvironmentalprotectionlegislation.
1005SD53 h
g
i
Check engine oil. Fill to correct level.
Check air cleaner.
Clean air cleaner.*
Change engine oil.
Check sediment cup at carburetor.
Clean and adjust spark plug.
Clean spark arrester (optional accessory).
Check shockmounts. Replace when necessary.
Check and adjust valve clearance.*
Clean fuel tank.*
Check condition of fuel line. Replace when necessary.
* Service more frequently in dusty conditions.
Daily
Before
Starting
Every 3
months or
50 hours
Every 6
months or
100 hours
Every year
or 300
hours

1A-13
G2.5A OPERATION 1A
1.23 Servicing Air Cleaner
Theengineisequippedwithadualelementaircleaner—
service frequently to prevent carburetor malfunction.
CAUTION: NEVER run engine without air cleaner.
Severe engine damage will occur.
e
d
1001SD13
1001SD12
1.24 Cleaning Sediment Cup
Turnfuelvalveoff.Removesedimentcup (e)andO-ring
(d). Wash them thoroughly in a nonflammable solvent.
Dry them and reinstall. Turn fuel valve on and check for
leaks.
a
c
b
1. Remove wing nut and air cleaner cover (a). Remove
both elements and inspect them for holes or tears.
Replace damaged elements.
2. Foam Element (c)
Wash in solution of mild detergent and warm water.
Rinsethoroughlyincleanwater.Allowelementtodry
thoroughly.
Soak element in clean engine oil and squeeze out
excess oil.
3. Paper element (b)
Tap element lightly to remove excess dirt or blow
compressed air through filter from the inside out.
Replace paper element if it appears heavily soiled.
NEVER use gasoline or other types of low flash
pointsolventsforcleaningtheaircleaner.Afireor
explosion could result.
WARNING
!

1A-14
1A OPERATION G2.5A
1.27 Transporting
When transporting the generator:
1. Turn the engine fuel valve to the off position.
2. Position the generator level to prevent fuel from
spilling.
3. Secure the generator by tying it down with suitable
rope.
Let engine cool before transporting generator or
storing indoors, to avoid burns or fire hazards.
WARNING
!
1.26 Setting Engine Speed
Generatorsrequireafixedenginespeedtomaintainthe
correctvoltage.Enginespeediscontrolledbyagovernor
which automatically adjusts to varying loads on the
enginetomaintainaconstantspeedof 3600–3700rpm.
To set governor speed:
Turn governor speed adjusting screw (j) in or out to
obtain a no-load speed of 3700 rpm.
CAUTION: Setting the governor speed too high or too
lowmaydamagetoolsandotherappliancesattachedto
the generator.
j
1001SD15
1.25 Carburetor Adjustment
The pilot screw (a) is fitted with a limiter cap to prevent
excessive enrichment of the air-fuel mixture in order to
comply with emission regulations. The mixture is set at
thefactory and noadjustment should benecessary. Do
not attempt to remove the limiter cap. The limiter cap
cannot be removed without breaking the pilot screw.
a
1015SD05

1A-15
G2.5A OPERATION 1A
1.28 Storage
Before storing generator for a long period of time:
1. Closethefuelvalveandremoveandemptysediment
cup under carburetor.
2. Disconnect the fuel line from the carburetor. Place
openendoffuellineintoasuitablecontainerandopen
fuel valve to drain fuel from tank.
3. Loosen the drain screw on the carburetor and drain
any remaining fuel from carburetor.
4. Change the engine oil.
5. Remove the spark plug and pour approximately one
tablespoon (1 ounce) of clean engine oil into the
cylinder.Cranktheengineafewturnstodistributethe
oil to the inside of the cylinder walls.
6. Pull the starter rope slowly until resistance is felt and
leave handle in this position. This ensures that the
intake and exhaust valves are closed.
7. Store generator in a clean, dry area.
Gasolineisextremelyflammable. Drainfueltankin
awell-ventilatedarea. DONOTdraintankinanarea
with flames or sparks.
1.29 Troubleshooting
If engine doesn't start, check that:
1. Engine switch is on "Start".
2. Fuel valves under fuel tank and on engine are open.
3. Fuel tank has fuel.
4. Choke lever is in correct position. Choke should be
closed when starting a cold engine.
5. All loads are disconnected from generator.
6. Spark plug is in good condition.
7. Spark plug cap is tight.
8. Engine oil level is adequate.
If engine starts but there is no power at receptacles,
check that:
1. Circuit breaker is closed.
2. Connector from generator to control panel is tight.
WARNING
!

1A-16
1A OPERATION G2.5A
1.30 Wiring Schematic
Wire Colors
B - Black W- White
G - Green Y - Yellow
L - Blue Br- Brown
R - Red T - Tan
O - Orange
B
G
W/Y
G/Y
B/R
20A
B/Y 120VAC
B
Y
G/Y
20A
20A
120VAC
B
A
R
1
W
R
W2
3
B
4
B
25 uF
400 V
G/W
G
wc_gr000262
BC
1
2
3
4
5
7 6
01
A=Generator B=Control Box C=Engine 1=Main Windings 2=Auxiliary Windings 3=Capacitor 4=Rotor Windings 5=Ingnition Switch 6=Oil Level Switch 7=Coil