Wacker Neuson GP2500A Service And Repair Manual
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Summary of Contents for Wacker Neuson GP2500A
- Page 1 Service and Repair Manual Portable Generator GP2500A / 4000A / 5500A / 7000A Machine Type Portable Generator Material Number 5100071820 Version Date 05/2023 Language [en-US]...
- Page 3 California Proposition 65 Warning WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other repro- ductive harm. WARNING Cancer and Reproductive Harm www.P65Warnings.ca.gov WARNING Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
- Page 4 This page is intentionally left blank.
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Page 5: Table Of Contents
Component Locations—GP4000 / 5500 / 7000 ................ 34 Type Label Engine Number ...................... 35 Technical Data .......................... 35 7.4.1 Engine............................ 35 Troubleshooting .......................... 36 [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... - Page 6 9.5.4 Testing the Capacitor........................ 72 9.5.5 Testing the Idle Control....................... 73 9.5.6 Testing the Circuit Breaker ...................... 75 9.5.7 Testing the GFCI Receptacle...................... 76 Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
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Page 7: Foreword
Wacker Neuson website at http://www.wackerneuson.com/. When ordering parts or requesting service information, be prepared to provide the machine model number, item number, and serial number. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 8: Expectations For Information In This Manual
• Permanent damage to the machine which will not be covered under warranty Contact your dealer immediately if you have questions about approved or unapproved parts, attachments, or modifications. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 9: Disclaimers 1.6
This warranty is limited to one (1) year from the date of original retail pur- chase for any Wacker Neuson brand outdoor product that is used for rental or commercial purposes, or any other income-producing purpose. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... - Page 10 APPLY TO YOU. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
- Page 11 Wacker Neuson and sold in the United States and Canada. To locate your nearest Authorized Wacker Neuson Service Center, dial 1-800-770-0957. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
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Page 12: Safety
► To avoid possible damage from this type of hazard, obey all safety messages that follow this signal word. Note: A Note contains additional information important to a procedure. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 13: Operator Safety While Using Internal Combustion Engines 2.2
• Use tools specifically meant for refueling (for example, a fuel hose or funnel). • Do not smoke when refueling the machine. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 14: Additional Instructions
C) Failure to properly ground the generator will create an electrical shock hazard that could result in severe injury or death. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 15: Safety During Testing 2.5
Use a digital multimeter or any other CONNECTED me- tering system to monitor voltage locations. Never touch any wiring while the generator is running. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... - Page 16 Clean up any fuel leaks or spills. Also wipe down the tank if there are spills during fueling of the tank. Fig. 1: Safety During Testing Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
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Page 17: General Information
55 (75) 70 (95) 80 (108) 50 (68) 75 (102) 95 (129 110 (149) 55 (75) 90 (122) 100 (136) 120 (163) [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... - Page 18 1000 (1356) M24 X 2 392 (531) 542 (735) 527 (715) 729 (988) 1475 (2000) M27 X 2 569 (771) 788 (1068) Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
- Page 19 Use the following formula to calculate the correct torque wrench setting to achieve a specific torque value. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
- Page 20 TS = 65 ft. lbs. (12 in. / (12 in. + 6 in.)) TS = 65 ft. lbs. (12 in. / (18 in.)) TS = 65 ft. lbs. (0.666) TS = 43.33 ft. lbs. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
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Page 21: Service Information
The spark tester gives clear indication if the coil is providing high voltage to the spark plug. A bright, vivid spark indicates that the coil is operating properly. Fig. 6: Spark Tester [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... - Page 22 Alligator leads will help when making continuity tests. You can use stand- alone leads or alligator clips that attach to the DMM leads. Fig. 10: Alligator Leads Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
- Page 23 A crimping tool will make secure crimping of electrical connectors. Always use the crimping die that matches the connector you will be using. Fig. 13: Crimping Tool [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
- Page 24 You can add more lights to increase the loading of the generator as long as you do not overload the receptacle(s). Fig. 17: Halogen Work Light Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
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Page 25: 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] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 26: Maintenance
25 psi to clear dirt and debris from the machine surfaces, vents, and cooling slots. Then, wipe the exterior clean with a damp cloth. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 27: Servicing The Air Cleaner 6.3
Rinse it thoroughly in clean water. Allow the element to dry thoroughly. Soak the element in clean engine oil and squeeze out excess oil. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 28: Adjusting The System Voltage
(3). Using a Phillips screwdriver, turn the screw clockwise (4) to increase the voltage or counterclockwise (5) Fig. 19: Measuring Volts to decrease the voltage. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 29: Changing The Engine Oil 6.5
For oil quantity and type, see Engine on wc_gr010582 plug, and crankcase page 35 Install the oil filler plug. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 30: Cleaning And Checking The Spark Plug
Check the electrode gap (5) and adjust as needed. For the recom- mended gap setting, see Engine on page Reinstall the spark plug. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 31: Cleaning The Spark Arrester 6.7
Replace the spark arrester if the screen has holes or other damage. Insert the now cleaned or replaced spark arrester into the muffler/ exhaust pipe and replace retaining screw(s). [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 32: Cleaning The Sediment Cup
After the pilot screw is adjusted, turn the throttle stop screw (2) to obtain the standard idle speed. For further information, see Engine on page Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 33: Engine
Oil dipstick/filler Engine valve cover Fuel valve Carburetor Fuel line Carbon cannister Oil sensor Air filter Spark arrestor Starter recoil — — [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 34: Component Locations-Gp4000 / 5500 / 7000
Oil dipstick/filler Engine valve cover Fuel valve Carburetor Fuel line Carbon cannister Oil sensor Air filter Spark arrestor Starter recoil — — Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 35: Type Label Engine Number 7.3
Engine oil capacity 0.6 L (0.7 qt) 1.1 L (1.16 qt) Spark plug NGK BPR6ES / ND W2OEPR 0.7—0.8 mm (0.028—0.031 in.) [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 36: Engine
6. Carburetor out of adjustment Adjust or replace. 7. Fuel line is blocked Replace the fuel line; verify fuel tank and fuel valve are clean. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 37: Generator
Rotor bolt Stator Capacitor connectors Rotor Panel harness ground connection Capacitor Panel harness capacitor leads Harness connector Alternator cover Alternator harness — — [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 38: Technical Data
Stator 1—2 Stator 3—4 Rotor Exciter 0.970Ω 0.970Ω 2.62Ω 5.460Ω 0.709Ω 0.709Ω 3.25Ω 5.330Ω 5 / 6.8 0.326Ω 0.326Ω 4.38Ω 2.012Ω Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 39: Voltage And Frequency Tolerances
Voltage L1 – N 119v +/- 1v Voltage L2 – N 119v +/- 1v Voltage L1 – L2 242v +/- 1v Frequency 57Hz +/- 3Hz [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 40: Theory Of Operation
“neutral”. Between each hot and the neutral, 120 volts exist. The hots are 180º out of phase with one another which can be seen on an oscillo- scope screen. Fig. 34: Oscilloscope Screen Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... - Page 41 Through the engine governor and the ex- citer / capacitor regulation, the voltage is maintained in a safe range. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
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Page 42: Troubleshooting
9. Stator coils are out of tolerance Test the stator / replace alternator if necessary. 10. Rotor coils are out of tolerance Replace alternator. [} 44] Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... - Page 43 3. Frequency is out of tolerance when load tested Refer to engine manufacturer’s service manual for — across range of generator testing and adjusting procedure. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
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Page 44: Repair
► Do not wear loose-fitting clothing, dangling drawstrings, or any other hanging items that could become entangled in moving parts while operating. ► Tie up long hair and remove jewelry before operating. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... - Page 45 Note: When removing the housing from the frame being careful of the two wire harnesses leading to the engine. Disconnect the har- nesses. Fig. 36: R&I Alternator [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
- Page 46 12. Using a 13mm socket and an impact wrench, remove the rotor bolt (23). 13. Have an assistant cradle the bottom of the alternator with their hands. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
- Page 47 Inspect it for signs of damage, cracking or any condition that may weaken its integrity. If nothing abnormal is found, it way be reused. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
- Page 48 Note: If the frequency is not in this range, the engine speed will need to be adjusted. For further information, see Adjusting the System Voltage on page 28 Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
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Page 49: Component Testing 8.6
120 volts. 5-20P 120v Main 5-20P 120v L14-30P 120/240v Fig. 44: Tungsten Load Bank Schematic [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 50: Restoring Lost Magnetism
When the generator has not been used for a long period of time, the residual magnetism within the rotor can be lost. Without residual mag- netism, the generator will not create electricity. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... - Page 51 Connect the remaining alligator clips to these leads. The completed fixture should look like (2). [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
- Page 52 Note: Make sure they do not touch one another or any part of the generator frame. Fig. 47: Flashing the Capacitor Connect the two free alligator leads to the battery (4). Note: Polarity is not important. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
- Page 53 If the unit once again fails to pro- duce electricity, the capacitor may be bad and should be tested. For further information, see Testing the Capacitor on page [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
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Page 54: Testing The Stator (120/240 Vac)
(13) Illustrates the electrical pin-out of the alternator connector including how the windings are connected to show proper phase relation. (14) Illus- trates the pin-out of the panel harness connector (6). Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... - Page 55 Does multimeter indicate an infinite amount of resistance? Fig. 52: Measuring Exciter Windings ð Yes—Stator is good. ð No—Stator is faulty. Replace stator. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
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Page 56: Electric
Fig. 53: Electrical Components Ref. Description Ref. Description Engine control switch Receptacle—120vAC, 30 amp, twist-lock Idle control switch Receptacle—120/240vAC, 30 amp, twist-lock Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 57: Theory Of Operation 9.2
RD 12AWG RD 12AWG BU 12AWG GY 12AWG WH 12AWG WH 12AWG BU 12AWG GY 12AWG GY 12AWG Fig. 54: G2500 Electrical Circuit [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 58: Power Selection Switch-Gp2500
(11). The last red wire leads from section 1 & 2 of the VSS to the other 5-15R GFCI receptacle (7) via its 20A push-button circuit breaker (8). Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 59: Voltage Selector Switch-Gp4000 / 5500 / 7000
Its purpose is to allow the user to select 120/240v op- eration or 120v operation where the current is effectively doubled. Fig. 57: Voltage Selector Switch [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 60: Current Meter-Gp4000 / 5500 / 7000
(18) of the engine to the en- gine control switch. Fig. 58: Current Meter Circuit Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 61: Schematics
(SPST) (SPDT) Double Pole, Single Throw Single Pole, Triple Throw (DPST) (SPTT) Normally Closed, Momen- Normally Open tary Pressure Switch — — [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... - Page 62 Circuit Protection Devices Symbol Description Symbol Description Fuse Circuit Breaker Motors and Generating Devices Symbol Description Symbol Description Electric Motor Pump Loudspeaker — — Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
- Page 63 Single-Element Light LED (Light Emitting Diode) Miscellaneous Symbols Symbol Description Symbol Description Enclosure Battery Ground (to earth) Ground (to chassis) Resistor Variable Resistor [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
- Page 64 BK Black Yellow OR Orange GN Green Brown Purple BU Blue VIO Violet Clear Shield PK Pink WH White Gray Light blue Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
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Page 65: Base Schematic W/Panel Layout-Gp2500
Main breaker—10 amp Spark plug Hour meter Ignition coil Power selection switch (PSS) Engine control switch Receptacle—120vAC, 20 amp, duplex Frame ground GFCI [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 66: Base Schematic W/Panel Layout-Gp4000 / 5500 / 7000
Electric 9.3 Schematics 9.3.3 Base Schematic w/Panel Layout—GP4000 / 5500 / 7000 Fig. 60: GP400/5500/7000 Electrical Schematic w/Panel Layout Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... - Page 67 Circuit breaker—20 amp Engine control switch Receptacle—120vAC, 30 amp, twist-lock Frame ground terminal Circuit breaker—30 amp Transformer—12v Receptacle—120/240vAC, 30 amp, twist-lock Rectifier—25 amp [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
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Page 68: Repair
Note: You can pull the wiring harness through the grommets if needed, but make sure not to damage the connectors. Fig. 62: Alternator Harness Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 69: Component Testing 9.5
(DMM) where you are physically touching the electrical com- ponents with probes. Never assume any part of the circuitry is dead. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 70: Testing For Voltage
Control Panel on page 68. The trouble is between the al- ternator and the receptacles; most likely the wiring itself. Fig. 66: Voltage Testing Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 71: Testing For Current
Do not clamp around both the hot and neutral leads (3). As above, this would cause the magnetic fields to be canceled out. Fig. 69: Ammeter Testing [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 72: Testing The Capacitor
(3). If needed, use insulated handled needle-nosed pliers by gripping the terminal body and pulling the connector off. Fig. 70: Testing the Capacitor Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... -
Page 73: Testing The Idle Control
Is the measurement approx. 12vDC? ð Yes—If by removing the load the voltage drops to zero, see en- gine manufacturer service manual. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... - Page 74 11. Place the idle control switch in the ON position. Did the 5 amp fuse open? ð Yes—Replace the idle control module. ð No—End Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]...
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Page 75: Testing The Circuit Breaker
ð YES—Trace the wiring for where the voltage is lost. Replace damaged / broken wire(s). ð NO—Replace the alternator. For further information, see Remov- ing and Installing the Alternator on page 44 [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual... -
Page 76: Testing The Gfci Receptacle
You should measure 123 volts from Hot to Neutral and Hot to Ground. Are 123 VAC indicated? ð YES—Proceed to step 8. ð NO—Receptacle is faulty. Replace receptacle. Service and Repair Manual | GP2500A / 4000A / 5500A / 7000A | 5100071820 | 05/2023 | [en-US]... - Page 77 10. Press the RESET button and verify the LED indicator is now GREEN. Are the LED colors verified? ð YES—Receptacle is good. ð NO—Receptacle is faulty. Replace receptacle. [en-US] | 05/2023 | 5100071820 | GP2500A / 4000A / 5500A / 7000A | Service and Repair Manual...
- Page 80 Wacker Neuson America Corporation N92W15000 Anthony Ave Menomonee Falls, WI 53051, USA Tel.: +1 800-770-0957 technical.support@wackerneuson.com www.wackerneuson.us Material Number: 5100071820 Language: [en-US]...
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