Wacker Neuson GP 2500A User Manual
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Wacker Neuson GP 2500A User Manual

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Operator's Manual
Portable Generator
GP 2500A
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5200003184
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Summary of Contents for Wacker Neuson GP 2500A

  • Page 1 Operator’s Manual Portable Generator GP 2500A 5200003184 0512...
  • Page 2 Wacker Neuson Production Americas LLC. Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights. Violators will be prosecuted.

  • Page 3: Gp 2500A

    Refer to the separate Repair Manual for detailed instructions on servicing and repairing the machine. If you are missing any of these documents, please contact Wacker Neuson to order a replacement or visit www.wackerneuson.com. When ordering parts or requesting service information, be prepared to provide the machine model number, item number, revision number, and serial number.
  • Page 4 Serious injury hazards to the operator and persons in the work area Permanent damage to the machine which will not be covered under warranty Contact your Wacker Neuson dealer immediately if you have questions about approved or unapproved parts, attachments, or modifications.

  • Page 5: Table Of Contents

    GP 2500A Table of Contents Foreword Safety Information Signal Words Used in this Manual ............7 Machine Description and Intended Use ..........8 Operating Safety .................. 9 Operator Safety while Using Internal Combustion Engines ....12 Service Safety ..................13 Labels Label Locations ..................
  • Page 6 Emission Control Systems Information and Warranty Emission Control System Background Information ......45 Limited Defect Warranty for Exhaust Emission Control System ..46 Limited Defect Warranty for Wacker Neuson Evaporative Emission Control Systems ..............46 California Evaporative Emission Control Warranty Statement ....49 Limited Defect Warranty for Exhaust Emission Control System ..50...

  • Page 7: Safety Information

    GP 2500 Safety Information Safety Information Signal Words Used in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol.

  • Page 8: Machine Description And Intended Use

    GP 2500 Machine Description and Intended Use This machine is a portable electric power source. The Wacker Neuson Portable Generator consists of a tubular steel frame surrounding a fuel tank, a gasoline engine, a control panel, and an electric alternator. The control panel includes controls and receptacles.

  • Page 9: Operating Safety

    Familiarize yourself with the location and proper use of all controls and safety devices. Contact Wacker Neuson for additional training if necessary. When operating this machine: Do not allow improperly trained people to operate the machine. People operating the machine must be familiar with the potential risks and hazards associated with it.
  • Page 10 Do not operate the machine if any safety devices or guards are missing or inoperative. Do not modify or defeat the safety devices. Only use accessories or attachments that are approved by Wacker Neuson. Safe When operating this machine: operating Remain aware of the machine’s moving parts.
  • Page 11 GP 2500 Safety Information Transporting Never allow untrained personnel to operate or service the generator. The and installing generator set should be set up by a certified electrician. the machine Do not stand under the machine while it is being hoisted or moved. Do not attach equipment to the machine when it is suspended.

  • Page 12: Operator Safety While Using Internal Combustion Engines

    Safety Information GP 2500 Operator Safety while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below.

  • Page 13: Service Safety

    Machine When servicing or maintaining the machine: modifications Use only accessories/attachments that are approved by Wacker Neuson. When servicing or maintaining the machine: Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker Neuson.
  • Page 14 Safety Information GP 2500 Cleaning When cleaning and servicing the machine: Keep the machine clean and free of debris such as leaves, paper, cartons, etc. Keep the labels legible. When cleaning the machine: Do not clean the machine while it is running. Never use gasoline or other types of fuels or flammable solvents to clean the machine.

  • Page 15: Labels

    GP 2500A Labels Labels Label Locations wc_gr008555 Label Meanings Wacker Neuson machines use international pictorial labels where needed. These labels are described below. DANGER! Read the Operator’s Manual. No sparks, flames, or burning objects near the machine. Stop the engine before refueling.
  • Page 16 Labels GP 2500A DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. — NEVER use inside a home or garage, EVEN IF doors and windows are open.
  • Page 17 GP 2500A Labels — Turn the engine switch to the ON position. — Pull the rewind starter. — Open the choke. — Turn the engine switch to “OFF”. — Close the fuel flow valve. DANGER Improper connection of generator to a building’s electrical system can allow electrical...
  • Page 18 Labels GP 2500A Important Emissions Information This equipment meets California EVP emis- sion regulations for small off-road engines. A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the infor-...

  • Page 19: Lifting And Transporting

    GP 2500A Lifting and Transporting Lifting and Transporting Lifting the Machine This generator, while compact, is heavy enough to cause injury if proper lifting techniques are not used. Observe the following guidelines when lifting the generator. • Do not attempt to lift and carry the generator unassisted. Use appropriate lifting equipment such as slings, chains, hooks, ramps, or jacks.

  • Page 20: Operation

    4.1.2 Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance. 4.1.3 Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for.

  • Page 21: Refueling The Machine

    GP 2500A Operation Refueling the Machine Requirements • Machine shut down • Engine cool • Machine/fuel tank level with the ground • Fresh, clean fuel supply Procedure Perform the procedure below to refuel the machine. WARNING Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns.

  • Page 22: Determining Power Requirements

    Check with your nearest Wacker Neuson Dealer, or contact the manufacturer or dealer of the tool or appliance, with questions regarding its power requirements.

  • Page 23: Generator Derating

    GP 2500A Operation Generator Derating All generators are subject to derating for altitude and temperature. Internal combustion engines, unless modified, run less efficiently at higher altitudes due to the reduction of air pressure. This translates into a lack of power and thus reduction in generator output.

  • Page 24: Grounding The Generator

    Operation GP 2500A Grounding the Generator Location A ground connection (a) is located on the generator frame. wc_gr000544 Function This ground connection is used for electrically grounding the generator when necessary to comply with the National Electrical Code and other federal, state, and local regulations. For grounding...

  • Page 25: Use Of Extension Cords

    GP 2500A Operation Use of Extension Cords 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.

  • Page 26: Control Panel

    Operation GP 2500A Control Panel Ref. Description Ref. Description GFI duplex receptacle—120V GFI test button Circuit breaker—20 Amp. GFI reset button Duplex receptacle—120V Engine ON-OFF switch wc_tx000447gb.fm...

  • Page 27: Ground Fault Interrupt (Gfi / Gfci)

    GP 2500A Operation 4.10 Ground Fault Interrupt (GFI / GFCI) 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.

  • Page 28: Before Starting

    Operation GP 2500A 4.12 Before Starting 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.

  • Page 29: Starting

    GP 2500A Operation 4.13 Starting 4.13.1 Ensure that the generator is properly installed in an outdoor location. See Sections Installation and Operator Safety while using Internal Combustion Engines for installation warnings and safety guidelines. 4.13.2 Disconnect all loads from the generator.

  • Page 30: Emergency Shutdown Procedure

    Operation GP 2500A 4.15 Emergency Shutdown Procedure Procedure If a breakdown or accident occurs while the machine is operating, follow the procedure below: 4.15.1 Stop the engine. 4.15.2 Turn off the fuel supply. 4.15.3 Disconnect tools from the machine. 4.15.4 Allow the machine to cool.

  • Page 31: Maintenance

    Wacker Neuson. The use of service parts that are not equivalent in performance and durability to authorized parts may impair the effectiveness of the emission control system and may have a bearing on the outcome of a warranty claim.

  • Page 32: Engine Oil

    Maintenance GP 2500A Engine Oil 5.3.1 Drain the oil while the engine is still warm. 5.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off.

  • Page 33: Servicing The Air Cleaner

    GP 2500A Maintenance Servicing the Air Cleaner Service the air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run the engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner.

  • Page 34: Spark Plug

    Maintenance GP 2500A Spark Plug Clean or replace the spark plug as needed to ensure proper operation. Refer to your engine operator’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.

  • Page 35: Cleaning The Sediment Cup

    GP 2500A Maintenance Cleaning the Sediment Cup 5.6.1 Turn the fuel valve off. 5.6.2 Remove the sediment cup (a) and the O-ring (b). 5.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 5.6.4 Turn the fuel valve on and check for leaks.

  • Page 36: Adjusting The Carburetor

    Maintenance GP 2500A Adjusting the Carburetor 5.7.1 Start the engine and allow it to warm up to operating temperature. 5.7.2 Set the pilot screw (a) two turns out. See Note. 5.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm.

  • Page 37: Long-Term Storage

    GP 2500A Maintenance Long-Term Storage Before storing the generator for a long period of time: 5.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 5.9.2 Disconnect the fuel line from the carburetor. Place the open end of the fuel line into a suitable container and open the fuel valve to drain the fuel from the tank.

  • Page 38: Troubleshooting

    GP 2500A Troubleshooting Problem / Symptom Reason / Remedy If engine doesn't start, check • Engine switch is on "Start". that: • 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.

  • Page 39: Technical Data

    GP 2500A Technical Data Technical Data Generator Item No. GP 2500A Generator Maximum Output 2500 Continuous Output 2250 Type Single voltage, single phase, Auto voltage regulator system AC Voltages Available volts phase 1ø Frequency Power Factor AC receptacles: 125V GFI duplex...

  • Page 40: Engine

    Technical Data GP 2500A Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. GP 2500A Item No. Engine Engine Make Honda Engine Model GX 160 RT 2 VWWN Maximum rated power 3.6 (4.8) @ 3600 rpm...
  • Page 41 GP 2500A Technical Data Notes: wc_td000190gb.fm...

  • Page 42: Schematics

    Schematics GP 2500A Schematics Wire Colors Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Light blue Electrical Schematic Components Ref. Description Ref. Description Ref. Description Generator Control Box Engine Ref. Description Ref. Description Main stator winding Duplex receptacle—120V...

  • Page 43: Electrical Schematic

    GP 2500A Schematics Electrical Schematic wc_tx001860gb.fm...
  • Page 44 Schematics GP 2500A wc_tx001860gb.fm...

  • Page 45: Emission Control Systems Information And Warranty

    Carbon monoxide does not react in the same way, but it is toxic. Wacker Neuson utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. Evaporative Emissions...

  • Page 46: Limited Defect Warranty For Exhaust Emission Control System

    Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny a warranty claim. Among those acts that constitute tampering are: Removing or altering of any part of the air intake, fuel, or exhaust systems.
  • Page 47 For the components listed in the following table, an authorized Wacker Neuson dealer/service center will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine/equipment complies with the applicable EPA regulations.
  • Page 48 For owners located more than 100 miles from an authorized dealer/service center (excluding the states with high-altitude areas as identified in 40 CFR Part 1068, Appendix III), Wacker Neuson will pay for pre-approved shipping costs to and from an authorized Wacker Neuson dealer/service center.

  • Page 49: California Evaporative Emission Control Warranty Statement

    Wacker Neuson at no charge to you. The owner shall not be charged for diagnostic labor that leads to determination that a warranted part is in fact defective, provided that such diagnostic work is performed at a Wacker Neuson authorized service center.

  • Page 50: Limited Defect Warranty For Exhaust Emission Control System

    What is covered The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if Wacker Neuson demonstrates that the portable generator has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part.
  • Page 52 Tel. : (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) 3605 5360, Fax: (852) 2758 0032...

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