Wacker Neuson GP2500A Operator's Manual
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Summary of Contents for Wacker Neuson GP2500A
- Page 1 Operator’s Manual Portable Generator GP2500A / 4000A / 5500A / 7000A Machine Type Portable Generator 5100070606 / 3300033472 Material Number Version Date 04/2023 Language [en-US]...
- Page 2 California Proposition 65 Warning WARNING The engine exhaust from this product contains chemi- cals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING Cancer and Reproductive Harm www.P65Warnings.ca.gov WARNING Batteries, battery posts, terminals and related acces- sories contain lead and lead compounds, and other chemicals known to the State of California to cause can- cer and birth defects or other reproductive harm.
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Page 3: Table Of Contents
Overview of the Labels ..............29 Safety Label Meanings ..............32 Information Label Meanings ............35 5 Transportation Transporting the Machine .............. 37 6 Commissioning Assembly ..................38 [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual iii... - Page 4 10 Troubleshooting 10.1 Generator..................65 10.2 Engine.................... 65 11 Technical Data 11.1 Generator and Engine ..............66 12 Emission Information Index ...................... 68 iv Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 5: Foreword
Model number: _____________________________ Serial number: _____________________________ Purchase date: _____________________________ The model data decal locations (1) are shown below. Fig. 1: Model data decals [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual 5... -
Page 6: Machine Identification
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 poisoning. 6 Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... -
Page 7: Machine Documentation
Spark arresters are qualified and rated by the United States Forest Service for this purpose. In order to comply with local [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual 7... -
Page 8: Manufacturer's Approval
In the State of California, a spark arrester is required by law (Section 4442 8 Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 9 Foreword of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual 9...
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Page 10: Limited Warranty
10Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 11 SUME FOR THEM ANY OTHER OBLIGATION. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual11...
- Page 12 Wacker Neu- son and sold in the United States and Canada. To locate your nearest Authorized Wacker Neuson Service Center, dial 1-800-770-0957. 12Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 13: Usage
It has been carefully engineered to eliminate hazards as far as practicable and to increase operator safety through protective guards and labeling. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual13... -
Page 14: Special Requirements
Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction in your area. 14Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... -
Page 15: Safety
► To avoid possible damage from this type of hazard, obey all safety messages that follow this signal word. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual15... -
Page 16: Read This Manual Before Operating
They also must meet the following qualifications: • Have received instruction on how to properly use the machine • Are familiar with required safety devices 16Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 17 Differences in power, voltage, and frequency re- [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual17...
- Page 18 • Do not operate the machine in snow, rain, or standing water. • Do not stand on the machine. 18Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 19: Operator Safety While Using Internal Combustion Engines
Never operate the machine inside an enclosed area, such as a tunnel, unless adequate venti- lation is provided through items such as ex- haust fans or hoses. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual19... - Page 20 • Use tools specifically meant for refueling (for ex- ample, a fuel hose or funnel). • Do not smoke when refueling the machine. • Do not refuel a hot or running engine. 20Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 21: Additional Instructions
Always use any recommended protective apparel that may be needed to operate the equipment safely. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual21... -
Page 22: Description Of The Machine
Description of the Machine Description of the Machine Component Locations—GP2500 Note: Line drawings used in this manual may not represent your specific model. Fig. 2: GP2500 component locations 22Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 23 Description of the Machine Fig. 3: GP2500 component locations, continued [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual23...
- Page 24 12 Carbon canister 13 Control panel 14 Engine oil dipstick 15 Engine oil drain plug 16 Ground terminal 17 Muffler heat shield 18 Ground terminal 24Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 25: Component Locations-Gp4000 / 5500 / 7000
Component Locations—GP4000 / 5500 / 7000 Note: Line drawings used in this manual may not represent your specific model. Fig. 5: GP4000 / 5500 / 7000 component locations [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual25... - Page 26 Description of the Machine Fig. 6: GP4000 / 5500 / 7000 component locations, continued 26Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
- Page 27 16 Engine oil dipstick 17 Engine oil drain plug 18 Support bracket 19 Handle stop pin 20 Handle 21 Ground terminal 22 Spark arrester (if equipped) [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual27...
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Page 28: Control Panels
120V, 20A, duplex GFCI recepta- cles (5-20R) 120V, 30A, twist-lock receptacle 10 120/240V, 30A, twist-lock recepta- (L5-30R) cle (L14-30R) 11 Power selection switch — — 28Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... -
Page 29: Overview Of The Labels
INCENDIES AUTOUR DE LA VÉGÉTATION SÈCHE. UN PARE-ÉTINCELLES PEUT ÊTRE NÉCESSAIRE. L'OPÉRATEUR DOIT CONTACTER LES SERVICES D'INCENDIE LOCAUX POUR CONNAÎTRE LES LOIS OU RÉGLEMENTATIONS RELATIVES AUX EXIGENCES DE PRÉVENTION DES INCENDIES. Fig. 9: GP2500 label locations [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual29... - Page 30 Description of the Machine Fig. 10: GP2500 label locations, continued 30Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
- Page 31 Description of the Machine Fig. 11: GP4000 / 5500 / 7000 label locations [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual31...
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Page 32: Safety Label Meanings
Never use inside a home or garage, even if doors and windows are open. Only use outside and far away from windows, doors, and vents. 32Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 33 Engine emits toxic carbon monoxide. Do not operate generator in enclosed area. Do not operate generator in wet weather, or in wet condition. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual33...
- Page 34 Pinch hazard Look before you pump! Do not use fuel containing greater than 10% ethanol! 34Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 35: Information Label Meanings
Stopping the generator Disconnect electrical devices. Place start switch in the off position. Close fuel valve. Fuel valve positions Engine choke and run positions [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual35... - Page 36 Add lubricant to full mark to start. Engine will not start or will shut off if sensor detects low lubricant level. Engine oil fill 36Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 37: Transportation
Secure generator with straps or tie downs to prevent tip over and damage from sliding. NOTE: Do not operate the generator while it is on the transport vehicle. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual37... -
Page 38: Commissioning
Insert the clip (6) through the hole in the axle to secure the assembly. Repeat this process for the other wheel. Fig. 13: Axle, wheel, wash- ers, mounting hole, and clip 38Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 39 Slide the M8 x 16 bolts (5) through the support bracket and frame. Fig. 14: Feet, bolts, Tighten the M8 nuts (6) onto the bolts to se- bracket, and nuts cure the assembly. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual39...
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Page 40: Operation
► Always use a carbon monoxide detector in any occupied buildings near the running en- gine. 40Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 41 • If you experience headache, nausea, dizziness, sleepiness, or weakness while the generator is running, move to fresh air and seek medical at- tention immediately. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual41...
- Page 42 Repair or replace all damaged or defective parts and keep all safety guards in place and in proper working order before using the gen- erator. 42Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
- Page 43 Never move or tip the generator while operating. Use generator only for its [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual43...
- Page 44 44Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
- Page 45 ► To avoid engine and fuel system damage, do not use any fuel system cleaning additives. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual45...
- Page 46 Do not to fill the fuel tank above the maximum fuel level (1) to allow room for fuel expansion. For fuel capacity, see Technical Data on page Fig. 17: Maximum fuel level 46Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
- Page 47 ► Inspect all electrical cords before using them and do not use any cords that are damaged or showing bare wires. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual47...
- Page 48 Using a transfer switch is recommended when con- necting a generator directly to a building’s electrical system. Connections for a portable generator to a 48Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 49: Starting The Machine
Prepare to start the machine. For further infor- mation, see Operating Checklist on page [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual49... - Page 50 Turn the engine control switch to the ON posi- tion. Fig. 22: Engine switch in ON position 50Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 51: Idle Control
120 volt configuration. By placing the switch in the 120 volt position, the generator wind- ings are placed into parallel allowing the current to be doubled. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual51... -
Page 52: Selecting The Power (Gp2500 Only)
► Inspect all electrical cords before using them and do not use any cords that are damaged or showing bare wires. 52Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 53 LED will go dark. Should the above test fail, discontinue use of the generator until it can be serviced by a qualified ser- vice technician. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual53...
- Page 54 (surge watts) for the electrical de- vices you wish to power. Exceeding the capacity of generator can damage the generator and/or electri- 54Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
- Page 55 Refer to the chart below to understand the loads electrical devices create when running. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual55...
- Page 56 1,750 – 2,000 Furnace fan (3/5 hp) Television 200 – 500 Garage door opener 500 – 750 Toaster 1,000 – 1,650 Hair dryer 1,200 Weed trimmer 56Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 57: Stopping The Machine
/ 5500 / 7000 on page 25, de- pending on your model. Fig. 27: Fuel valve in OFF Allow the engine to cool completely before position storing. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual57... -
Page 58: Maintenance
NOTE: This Maintenance chapter refers to all parts of the generator except engine. Please refer to the engine manual for engine maintenance information. 58Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... -
Page 59: Engine Maintenance
See Technical Data for oil quantity and type. Install the oil filler plug. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual59... -
Page 60: Engine Idle Adjustment
The engine idle speed is set at the factory and should not require user adjustment. Tampering with the governor can damage your engine and/or gener- ator and will void the warranty. 60Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... -
Page 61: Cleaning The Spark Arrester
Replace the spark arrester if the screen has holes or other damage. Insert the spark the now cleaned or replaced spark arrester into the muffler/exhaust pipe and replace retaining screw(s). [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual61... -
Page 62: Cleaning
25 psi to clear dirt and debris from the machine surfaces, vents, and cooling slots. Then, wipe the exterior clean with a damp cloth. 62Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... -
Page 63: Storage
Store the generator in a clean, dry area that is out of direct sunlight. 9.1.2 Storing for More Than Two Months Make sure the engine is completely cool. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual63... - Page 64 Clean the generator. For further information, see Maintenance on page Store the generator in a clean, dry area that is out of direct sunlight. 64Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
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Page 65: Troubleshooting
Fuel old or stale Remove stale fuel and re- place it with fresh fuel. Engine needs service Take to an authorized ser- vice center. [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual65... -
Page 66: Technical Data
0.58 (0.61) 1.1 (1.16) 1) Generator per Portable Generator Manufacturers’ Association (PGMA) stan- dard ANSI / PGMAG6300-2015, Safety and Performance of Portable Genera- tors 66Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... -
Page 67: Emission Information
• Carbon canister Ignition System • Spark plug • Ignition module Exhaust System • Exhaust manifold • Muffler • Pulsed air valve • Catalyst [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual67... -
Page 68: Index
...... 18 the support bracket.... 39 the wheels ...... 38 Emission information .... 67 Engine choke ...... 24, 27, 50 control switch ...... 28 idle adjustment...... 60 maintenance ...... 59 68Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]... - Page 69 Stopping the machine.... 57 Storage more than two months .... 63 two months or less .... 63 Support bracket ...... 27 assembling and installing.. 39 [en-US] | 04/2023 | 5100070606 | GP2500A / 4000A / 5500A / 7000A | Operator’s Manual69...
- Page 70 Technical data ...... 66 Transporting the machine.. 18, 37 Troubleshooting engine ........ 65 generator ........ 65 Twist-lock receptacles .... 28 Vibration ........ 19 Voltage selecting........ 51 selector switch ...... 28 Warranty ........ 10 Wheels installation....... 38 70Operator’s Manual | GP2500A / 4000A / 5500A / 7000A | 5100070606 | 04/2023 | [en-US]...
- Page 72 Material Number: 5100070606 Language: [en-US]...