www.wackergroup.com

0152792en

0104

003

Generator

G 2.5A

OPERATOR’S MANUAL

0 1 5 2 7 9 2 E N

G 2.5A

1.

Foreword

Table of Contents

3

2.

Safety Information

2.1

2.2

2.3

2.4

2.5

2.6

4

Laws Pertaining to Spark Arresters ...................................................... 4

Operating Safety .................................................................................. 5

Operator Safety while using Internal Combustion Engines .................. 6

Service Safety ...................................................................................... 7

Label Locations .................................................................................... 8

Safety and Operating Labels ................................................................ 9

3.

Technical Data

3.1

3.2

12

Generator ........................................................................................... 12

Engine ................................................................................................ 13

4.

Operation 14

4.1

4.2

4.3

4.4

4.5

4.6

Determining Power Requirements ..................................................... 14

Outdoor Installation ............................................................................ 15

Indoor Installation ............................................................................... 15

Generator Derating ............................................................................. 16

Grounding the Generator ................................................................... 17

Operating Heavy Loads ...................................................................... 17

4.7

4.8

Use of Extension Cords ...................................................................... 18

Control Panel ...................................................................................... 19

4.9

Ground Fault Interrupt (GFI) ............................................................... 20

4.10

Circuit Breaker Protection .................................................................. 20

4.11

Before Starting ................................................................................... 21

4.12

To Start ............................................................................................... 22

4.13

To Stop ............................................................................................... 22 wc_bo0152792003enTOC.fm

1

Table of Contents

5.

Maintenance

G 2.5A

23

5.5

5.6

5.7

5.8

5.1

5.2

5.3

5.4

Engine Maintenance ............................................................................23

Periodic Maintenance Schedule ..........................................................23

Engine Oil ............................................................................................24

Air Cleaner ..........................................................................................25

Spark Plug ...........................................................................................26

Cleaning the Sediment Cup ................................................................27

Carburetor Adjustment ........................................................................27

Engine Speed ......................................................................................28

5.9

Storage ................................................................................................29

5.10

Transport .............................................................................................29

5.11

Troubleshooting ...................................................................................30

5.12

Wire Colors ..........................................................................................30

5.13

Wiring Schematic ................................................................................31

wc_bo0152792003enTOC.fm

2

Foreword

CALIFORNIA

Proposition 65 Warning:

WARNING

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 2004 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.

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Safety Information G 2.5A

2.

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.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

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.

2.1

Laws Pertaining to Spark Arresters

Notice: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United States Forest Service for this purpose.

In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.

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G 2.5A

2.2

Operating Safety

Safety Information wc_si000064gb.fm

DANGER

BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER

DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR

DEATH TO UTILITY WORKERS!

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.

If connected to a building's electrical system the generator must meet the power, voltage, and frequency requirements of the equipment in the building. Differences in power, voltage, and frequency requirements may exist and improper connection may lead to equipment damage, fire, and personal injury or death.

WARNING

Familiarity and proper training are required for the safe operation of equipment! Equipment operated improperly or by untrained personnel can be dangerous! Read the operating instructions contained in both this manual and the engine manual and familiarize yourself with the location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine.

2.2.1

NEVER operate generator when open containers of fuel, paint, or other flammable liquids are near.

2.2.2

NEVER operate generator, or tools attached to the generator, with wet hands.

2.2.3

NEVER use worn electrical cords. Severe electrical shock and equipment damage may result.

2.2.4

NEVER run electrical cords under the generator, or over vibrating or hot parts.

2.2.5

NEVER enclose or cover generator when in use or when hot.

2.2.6

NEVER overload generator. The total amperage of the tools and equipment attached to the generator must not exceed the load rating of the generator.

2.2.7

NEVER operate machine in snow, rain, or standing water.

2.2.8

NEVER allow untrained personnel to operate or service the generator.

The generator set should be set up by a trained electrician.

2.2.9

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.

2.2.10

ALWAYS be sure machine is on a firm, level surface and will not tip, roll, slide, or fall while operating.

5

Safety Information G 2.5A

2.2.11

ALWAYS transport generator in an upright position.

2.2.12

ALWAYS keep machine at least one meter (three feet) away from structures, buildings and other equipment during use.

2.2.13

ALWAYS keep the area immediately surrounding and underneath the machine clean, neat, free of debris, and combustible materials. Make sure that the area overhead is clear of debris that could fall onto or into the machine, or exhaust compartment.

2.2.14

ALWAYS remove all tools, cords, and other loose items from generator before starting it.

2.2.15

ALWAYS make certain machine is well-grounded and securely fastened to a good earthen ground per national and local regulations.

2.3

Operator Safety while using Internal Combustion Engines

DANGER

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 warnings and safety guidelines could result in severe injury or death.

2.3.1

DO NOT run machine indoors or in an enclosed area such as a deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided. Exhaust gas from the engine contains poisonous carbon monoxide gas; exposure to carbon monoxide can cause loss of consciousness and may lead to death.

2.3.2

DO NOT smoke while operating machine.

2.3.3

DO NOT smoke when refueling engine.

2.3.4

DO NOT refuel hot or running engine.

2.3.5

DO NOT refuel engine near open flame.

2.3.6

DO NOT spill fuel when refueling engine.

2.3.7

DO NOT run engine near open flames.

2.3.8

DO NOT start engine if fuel has spilled or an odor of fuel is present.

Move generator away from the spill and wipe generator dry before starting.

2.3.9

ALWAYS refill fuel tank in well-ventilated area.

2.3.10

ALWAYS replace fuel tank cap after refueling.

2.3.11

ALWAYS check fuel lines and fuel tank for leaks and cracks before starting engine. Do not run machine if fuel leaks are present or fuel lines are loose.

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G 2.5A

2.4

Service Safety

Safety Information

WARNING

Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. If the generator is experiencing problems or is being serviced, attach a

"DO NOT START" sign to the control panel to notify other people of its condition.

2.4.1

DO NOT use gasoline or other types of fuels or flammable solvents to clean parts, especially in enclosed areas. Fumes from fuels and solvents can become explosive.

2.4.2

DO NOT attempt to clean or service machine while it is running.

2.4.3

DO NOT modify the equipment without express written approval of the manufacturer.

2.4.4

DO NOT allow water to accumulate around the base of the machine.

If water is present, move the machine and allow it to dry before servicing.

2.4.5

DO NOT service machine if clothing or skin is wet.

2.4.6

DO NOT allow untrained personnel to service this equipment. Only trained electrical technicians should be allowed to service the electrical components of this equipment.

2.4.7

ALWAYS keep machine clean and labels legible. Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards.

2.4.8

ALWAYS replace safety devices and guards after repairs and maintenance.

2.4.9

ALWAYS let engine cool before transporting or servicing.

2.4.10

ALWAYS keep hands, feet, and loose clothing away from moving parts on generator and engine.

2.4.11

ALWAYS turn engine off before servicing machine. If the engine has electric start, disconnect negative terminal on battery

2.4.12

ALWAYS keep fuel lines in good condition and properly connected.

Leaking fuel and fumes are extremely explosive.

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Safety Information

2.5

Label Locations

STOP

DANGER

GEFAHR

PELIGRO

DANGER

G 2.5A

WARNING

I M P R O P E R C O N N E C T I O N O F G E N E R A T O R

T O A B U I L D I N G ' S E L E C T R I C A L

S Y S T E M C A N A L L O W E L E C T R I C A L

C U R R E N T F R O M T H E G E N E R A T O R T O

B A C K F E E D I N T O U T I L I T Y L I N E S .

T H I S M A Y R E S U L T I N E L E C T R O C U T I O N

O F U T I L I T Y W O R K E R S , F I R E O R

E X P L O S I O N . C O N N E C T I O N S T O A

B U I L D I N G ' S E L E C T R I C A L S Y S T E M M U S T B E M A D E

B Y A Q U A L I F I E D E L E C T R I C I A N A N D C O M P L Y W I T H

A L L A P P L I C A B L E L A W S A N D E L E C T R I C A L C O D E S .

GND w c _ g r 0 0 1 0 3 0 wc_si000064gb.fm

8

G 2.5A

2.6

Safety and Operating Labels

Safety Information

Wacker machines use international pictorial labels where needed.

These labels are described below:

Label

STOP

DANGER

GEFAHR

PELIGRO

DANGER

Meaning

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.

WARNING

I M P R O P E R C O N N E C T I O N O F G E N E R A T O R

T O A B U I L D I N G ' S E L E C T R I C A L

S Y S T E M C A N A L L O W E L E C T R I C A L

C U R R E N T F R O M T H E G E N E R A T O R T O

B A C K F E E D I N T O U T I L I T Y L I N E S .

T H I S M A Y R E S U L T I N E L E C T R O C U T I O N

O F U T I L I T Y W O R K E R S , F I R E O R

E X P L O S I O N . C O N N E C T I O N S T O A

B U I L D I N G ' S E L E C T R I C A L S Y S T E M M U S T B E M A D E

B Y A Q U A L I F I E D E L E C T R I C I A N A N D C O M P L Y W I T H

A L L A P P L I C A B L E L A W S A N D E L E C T R I C A L C O D E S .

DANGER!

Electric shock hazard. Read operator’s manual for instructions.

WARNING!

Hot surface!

CAUTION!

Read and understand the supplied operator's manuals before operating this machine. Failure to do so increases the risk of injury to yourself or others.

CAUTION!

Lifting point wc_si000064gb.fm

9

Safety Information

Label

GND

Meaning

Electrical ground.

G 2.5A

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Open fuel flow valve.

Open choke.

Push or turn engine switch to ON position.

Pull rewind starter.

Close fuel flow valve.

10

G 2.5A

Label Meaning

Close choke.

Safety Information

Push or turn engine switch to OFF position.

Neutral bonded to frame.

A nameplate listing the Model Number, Item

Number, Revision, and Serial Number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model, item number, revision number, and serial number of the unit.

This machine may be covered by one or more patents.

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Technical Data

3.

Technical Data

3.1

Generator

Item No.

Maximum Output

Continuous Output

Type

W

W

AC Voltages Available volts phase

Hz Frequency

Power Factor

AC receptacles:

120V GFI duplex

120V GFI duplex

Main Circuit Breaker

L x W x H

Weight (dry) amp amp amp mm (in.)

Kg (lbs.)

G2.5A

0009256

Generator

2500

2250

Single voltage, single phase,

Auto voltage regulator system

120

1ø

60

1.0

15

15

20

685 x 445 x 435 (27 x 17.5 x 17)

43 (94)

G 2.5A

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G 2.5A

3.2

Engine

Technical Data

Item No.

Engine Make

Engine Model

Rated Power

Spark Plug kW (Hp)

Electrode Gap mm (in.)

Engine Speed - full load rpm

Engine Speed - no load rpm

Air Cleaner type oil grade Engine Lubrication

Engine Oil Capacity l (qts.)

Fuel

Fuel Tank Capacity type l (gal.)

Fuel Consumption l (qts.)/hr.

Running Time - full load hrs.

G2.5A

0009256

Engine

Honda

GX 160 K1VX

4.1 (5.5)

BPR6ES / W20EPR-U

0.7 - 0.8 (0.028 - 0.031)

3600 ± 100

3700 ± 100

Dry type with oil-wetted foam pre-cleaner

SAE 10W30 service class SF, SE, SD or SC

1.1 (1.2)

Regular unleaded gasoline

3.7 (3.9)

1.7 (1.8)

2.1

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Operation

4.

Operation

G 2.5A

4.1

Determining Power Requirements

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 power required to keep it running. The generator must be capable of supplying this “surge” current. Other types of appliances require more power than is actually stated on their nameplate.

The information in “Approximate Starting Power Requirements” is offered only as a general guideline to help you 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 requirements.

CAUTION: If a tool or appliance does not reach full speed within a few seconds after it is switched on, turn it off immediately to avoid damage.

Approximate Starting Power Requirements

• 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 starting.

• 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.

If the wattage is not given for a particular tool or appliance, it can be calculated by multiplying its voltage and amperage requirements:

Single Phase: VOLTS x AMPS = WATTS

Three Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS wc_tx000158gb.fm

14

G 2.5A

4.2

Outdoor Installation

Operation

Place the generator in an area where it will not be exposed to rain, snow or direct sunlight. Make sure it is positioned on firm, level ground so it will not slide or shift. Position engine exhaust away from areas where people may be present.

If operating the generator inside a tunnel or deep trench, make sure there is adequate ventilation. Precautions similar to those required when operating indoors may be necessary.

The surrounding area must be free from water and moisture. All components must be protected from excessive moisture.

4.3

Indoor Installation

If the generator must be installed 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.

DANGER

Exhaust gas from the engine contains poisonous carbon monoxide gas; exposure to carbon monoxide can cause loss of consciousness and may lead to death. Never run generator indoors or in an enclosed area unless adequate ventilation, through such items as exhaust hoses or fans, is provided.

When installed indoors, steps to prevent fire and explosion such as providing a good earthen ground, removing all flammable materials near generator, and using only electrical cables in good condition, must be observed. See Operating Safety.

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Operation

4.4

Generator Derating

G 2.5A

All generators are subject to derating for altitude and temperature.

Internal combustion engines, unless modified, run less efficiently at higher altitudes due to the lack of air pressure. This translates into a lack of power and thus reduction in generator output. Temperature affects both engine and generator performance. As temperature increases, an engine will run less efficiently and the more resistance will be found in electrical components. Therefore, as the temperature increases, the output of the generator decreases. Altitude also affects the cooling capacity of air—the higher the altitude the less dense the air is and thus the lower its ability to transfer heat.

For every increase in altitude of 500 m (1650 ft.) above 1000 m (3300 ft.), the output of the generator will be reduced by 3%. For every increase of 5° C (9° F) in ambient temperature above 40° C (104° F), the output of the generator will be reduced by 3%. Use the tables shown for altitude and temperature deration factors. It may be necessary to consider both altitude and ambient temperature deration factors to determine true generator output.

Ambient Temp.

°C (°F)

45 (113)

50 (122)

55 (131)

60 (140)

Derate

3 %

6 %

9 %

12 %

Factor

0.97

0.94

0.91

0.88

Altitude m (ft.)

1500 (4900)

2000 (6600)

2500 (8200)

3000 (9900)

3500 (11500)

4000 (13100)

Derate

3 %

6 %

9 %

12 %

15 %

18 %

Factor

0.97

0.94

0.91

0.88

0.85

0.82

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G 2.5A

4.5

Grounding the Generator

Operation

See Graphic: wc_gr000544

A ground connection (a) is located on the generator frame. For proper operating safety, this ground terminal must be connected to a good ground source. This ground connection must comply with National

Electrical Code standards, and state and local regulations.

w c _ g r 0 0 0 5 4 4

4.6

Operating Heavy Loads

Limit operations requiring the maximum rated output of 2500 Watts to

20–30 minutes. For continuous operation, do not exceed the continuous rated output of 2250 Watts.

CAUTION: DO NOT exceed the current limit specified on the control panel for any receptacle.

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17

Operation

4.7

Use of Extension Cords

G 2.5A

Current

(Amps)

2.5

5

7.5

10

15

20

When a long extension cord is used to connect an appliance or tool to the generator, a voltage loss occurs—the longer the cord, the greater the voltage loss. This results in less voltage being supplied to the appliance or tool and increases the amount of current draw or reduces performance. A heavier cord with a larger wire size will reduce the voltage loss.

WARNING

Damaged extension cords can cause electrical shock, resulting in serious injury or death. DO NOT use worn, bare, or frayed cords.

Replace damaged cords immediately.

Use the chart below as a guide for selecting proper cable size.

Load in Watts

120V

300

600

900

1200

1800

2400

240V

600

1200

1800

2400

3600

4800

#10

Maximum Cable Length in Feet

1000 ft.

500

350

250

150

125

#12

600

300

200

150

100

75

#14

375

200

125

100

65

50

#16

250

125

100

-

-

-

Use only extension cords rated for outdoor use and equipped with a third-wire ground.

CAUTION: Operating equipment at low voltage can cause it to overheat.

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18

G 2.5A

4.8

Control Panel

See Graphic: wc_gr000553

Control Panel

Ref.

Description a GFI Duplex receptacle - 120V b Circuit Breaker -20 Amp.

c Duplex receptacle - 120V

Ref.

Description d GFI Test button e GFI Reset button

Operation

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Operation

4.9

Ground Fault Interrupt (GFI)

G 2.5A

See Graphic: wc_gr000553

The 120V, 20 Amp receptacle (a) is equipped with a ground fault circuit interrupt (GFI). The GFI shuts off the power to the receptacle when a ground fault occurs in the generator or to a piece of equipment attached to the generator. This GFI also protects the second 120V,

20A receptacle (c).

The GFI should be tested for proper operation every time the generator is used.

To test GFI:

Start generator. Push TEST button (d) on receptacle in. The RESET button (e) will pop out. Power is now off at the receptacle. If the RESET button does not pop out, the GFI is not working. Do not run generator until the problem 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.

4.10 Circuit Breaker Protection

See Graphic: wc_gr000553

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, turn the engine off immediately and determine the cause before restarting. Check the appliances and tools attached 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. wc_tx000158gb.fm

20

G 2.5A

4.11 Before Starting

Operation

4.11.1

Read and understand safety and operating labels and instructions at the beginning of this manual

4.11.2

Inspect generator for any signs of damage which may affect operation or pose a safety hazard.

4.11.3

Check:

• oil level in engine

• fuel level

• condition of air cleaner

• tightness of external fasteners

• condition of fuel lines.

Note: The engine is equipped with an oil alert system. If the oil level in the engine drops too low, the engine will not start.

4.11.4

Fill fuel tank with fresh, regular, unleaded grade gasoline. DO NOT use an oil/gas mixture. The use of gasohol or any fuel containing more than 10% ethanol is not recommended. Consult engine owner's manual for complete fuel specifications.

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21

Operation

4.12 To Start

G 2.5A

See Graphic: wc_gr000554

4.12.1

Disconnect all loads from the generator.

4.12.2

Open fuel valve by moving lever to the right (a1).

Note: If engine is cold, move choke lever to closed position (b1) . If engine is hot, set choke to open position (b2) .

4.12.3

Turn engine switch to "ON" (c1).

4.12.4

Pull starter rope (d).

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.

4.12.5

Open choke as engine warms (b2).

4.12.6

Allow engine to warm up a few minutes before attaching loads.

4.12.1

= >

?

?

=

> w c _ g r 0 0 0 5 5 4

4.13 To Stop

See Graphic: wc_gr000554

4.13.1

Turn off and disconnect all tools and appliances attached to the generator.

4.13.2

Turn engine switch to “OFF” (c2).

4.13.3

Close fuel valve by moving lever to the left (a2).

Note: To stop engine quickly in an emergency, turn engine switch to

“OFF” (c2) .

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22

G 2.5A

5.

Maintenance

Maintenance

5.1

Engine Maintenance

The chart below lists basic machine and engine maintenance. Refer to engine manufacturer’s Operator’s Manual for additional information on engine maintenance.

5.2

Periodic Maintenance Schedule

Check fuel level.

Check engine oil level.

Inspect air filter. Replace as needed.

Check and tighten external hardware.

Clean air cleaner element.*

Inspect shockmounts for damage.

Change engine oil.*

Clean sediment cups.

Check and clean spark plug.

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

•

•

•

•

After first

20 hrs.

•

Every

50 hrs.

•

Every

100

hrs.

Every

300 hrs.

•

•

•

•

•

•

• wc_tx000170gb.fm

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Maintenance

5.3

Engine Oil

G 2.5A

See Graphic: wc_gr000022

5.3.1

Drain oil while the engine is still warm.

5.3.2

Remove the oil fill plug (a) and drain plug (b) to drain oil.

Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation.

5.3.3

Install drain plug.

5.3.4

Fill the engine crankcase with recommended oil up to the level of the plug opening (c). See Technical Data for oil quantity and type.

5.3.5

Install the oil filler plug.

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G 2.5A

5.4

Air Cleaner

Maintenance

See Graphic: wc_gr000025

The engine is equipped with a dual element air cleaner. Service air cleaner frequently to prevent carburetor malfunction.

CAUTION: NEVER run engine without air cleaner. Severe engine damage will occur.

NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner. A fire or explosion could result.

WARNING

To service:

5.4.1

Remove air cleaner cover (a). Remove both elements and inspect them for holes or tears. Replace damaged elements.

5.4.2

Wash foam element (b) in solution of mild detergent and warm water.

Rinse thoroughly in clean water. Allow element to dry thoroughly. Soak element in clean engine oil and squeeze out excess oil.

5.4.3

Tap paper element (c) lightly to remove excess dirt. Replace paper element if it appears heavily soiled.

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Maintenance

5.5

Spark Plug

G 2.5A

See Graphic: wc_gr000028

Clean or replace spark plug as needed to ensure proper operation.

Refer to the engine Owner’s Manual.

The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot.

WARNING

Note: Refer to the Technical Data for the recommended spark plug type and the electrode gap setting.

5.5.1

Remove spark plug and inspect it.

5.5.2

Replace plug if the insulator is cracked or chipped.

5.5.3

Clean spark plug electrodes with a wire brush.

5.5.4

Set the electrode gap (a).

5.5.5

Tighten spark plug securely.

CAUTION: A loose spark plug can become very hot and may cause engine damage.

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G 2.5A

5.6

Cleaning the Sediment Cup

Maintenance

See Graphic: wc_gr000029

5.6.1

Turn fuel valve off.

5.6.2

Remove sediment cup (a) and O-ring (b).

5.6.3

Wash both thoroughly in a nonflammable solvent. Dry and reinstall them.

5.6.4

Turn fuel valve on and check for leaks.

5.7

Carburetor Adjustment

See Graphic: wc_gr000032

5.7.1

Start engine and allow it to warm up to operating temperature.

5.7.2

Set pilot screw (a) 2-5/8 turns out.

5.7.3

Set auto idle switch to "Auto" so engine is idling. Adjust pilot screw in or out to produce the highest rpm.

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Maintenance

5.8

Engine Speed

G 2.5A

See Graphic: wc_gr000114

Generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constant speed of

3000 rpm. There is no throttle control.

To set the engine to the proper speed:

Turn the speed adjusting screw (a) in or out to obtain a no-load speed of 3000 rpm.

CAUTION: Setting the engine speed too high or too low may damage tools and other appliances attached to the generator.

a wc_gr000114 wc_tx000170gb.fm

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G 2.5A

5.9

Storage

Maintenance

Before storing generator for a long period of time:

5.9.1

Close the fuel valve and remove and empty sediment cup under carburetor.

5.9.2

Disconnect the fuel line from the carburetor. Place open end of fuel line into a suitable container and open fuel valve to drain fuel from tank.

Gasoline is extremely flammable. Drain fuel tank in a well ventilated area. DO NOT drain tank in an area with flames or sparks.

WARNING

5.9.3

Loosen the drain screw on the carburetor and drain any remaining fuel from carburetor.

5.9.4

Change the engine oil.

5.9.5

Remove the spark plug and pour approximately 30 ml (1 ounce) of clean engine oil into the cylinder. Crank the engine a few turns to distribute the oil to the inside of the cylinder walls.

5.9.6

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.

5.9.7

Store generator in a clean, dry area.

5.10 Transport

WARNING

Let the engine cool before transporting the generator or storing indoors, to avoid burns or fire hazards.

When transporting the generator:

5.10.1

Turn the engine fuel valve to the OFF position.

5.10.2

Position the generator level to prevent fuel from spilling.

5.10.3

Secure the generator by tying it down with a suitable rope.

WARNING

When transporting the pump by hand, be sure to employ manpower commensurate with the weight of the pump. To avoid back injury when lifting the pump, bend the knees to pick it up rather than bending your back only.

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Maintenance

5.11 Troubleshooting

G 2.5A

Problem / Symptom

If engine doesn't start, check that:

Reason / Remedy

• Engine switch is on "Start".

• Fuel valves under fuel tank and on engine are open.

• Fuel tank has fuel.

• Choke lever is in correct position. Choke should be closed when starting a cold engine.

• All loads are disconnected from generator.

• Spark plug is in good condition.

• Spark plug cap is tight.

• Engine oil level is adequate.

• Circuit breaker is closed.

• Connector from generator to control panel is tight.

If engine starts but there is no power at receptacles, check that:

If engine starts but runs erratically, check that:

• Hose routing from the fuel tank to the engine is correct. For proper operation, the hose must run through the bushing in the lifting bracket. Refer to the Parts Book for illustration.

5.12 Wire Colors

L

P

B

G

Black

Green

Blue

Pink

R

T

V

W

Red

Tan

Violet

White

Wire Colors

Y Yellow

Br

Cl

Gr

Brown

Clear

Gray

Or

Pr

Sh

LL

Orange

Purple

Shield

Light Blue wc_tx000170gb.fm

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G 2.5A

5.13 Wiring Schematic

Maintenance

See Graphic: wc_gr000767

Ref.

Description

A Generator

Ref.

B

Description

Control Box

Ref.

Description

1.

Main Windings

2.

Aux Winding

3.

Capacitor 25 µF 400 V

4.

Rotor Windings

Ref.

C

Ref.

Description

5.

Ignition Switch

6.

7.

Oil Level Switch

Coil

Description

Engine

G / Y

2 0 A

G / W

G / Y

W / Y

1 2 0 V A C

2 0 A

B / Y 1 2 0 V A C

2 0 A

2 5 u F

4 0 0 V

B / R w c _ g r 0 0 0 7 6 7 wc_tx000170gb.fm

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Maintenance G 2.5A

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