Wacker Neuson G2.5A User manual

www.wackergroup.com
Generator
G 2.5A
OPERATOR’S MANUAL
0152792en 003
0104
0152792EN

G 2.5A Table of Contents
wc_bo0152792003enTOC.fm 1
1. Foreword 3
2. Safety Information 4
2.1 Laws Pertaining to Spark Arresters ...................................................... 4
2.2 Operating Safety .................................................................................. 5
2.3 Operator Safety while using Internal Combustion Engines .................. 6
2.4 Service Safety ...................................................................................... 7
2.5 Label Locations .................................................................................... 8
2.6 Safety and Operating Labels ................................................................ 9
3. Technical Data 12
3.1 Generator ........................................................................................... 12
3.2 Engine ................................................................................................ 13
4. Operation 14
4.1 Determining Power Requirements ..................................................... 14
4.2 Outdoor Installation ............................................................................ 15
4.3 Indoor Installation ............................................................................... 15
4.4 Generator Derating ............................................................................. 16
4.5 Grounding the Generator ................................................................... 17
4.6 Operating Heavy Loads ...................................................................... 17
4.7 Use of Extension Cords ...................................................................... 18
4.8 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

Table of Contents G 2.5A
wc_bo0152792003enTOC.fm 2
5. Maintenance 23
5.1 Engine Maintenance ............................................................................23
5.2 Periodic Maintenance Schedule ..........................................................23
5.3 Engine Oil ............................................................................................24
5.4 Air Cleaner ..........................................................................................25
5.5 Spark Plug ...........................................................................................26
5.6 Cleaning the Sediment Cup ................................................................27
5.7 Carburetor Adjustment ........................................................................27
5.8 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

Foreword
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CALIFORNIA
Proposition 65 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.
WARNING

Safety Information G 2.5A
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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 indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
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.
DANGER
WARNING
CAUTION

G 2.5A Safety Information
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2.2 Operating Safety
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.
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.
DANGER
WARNING

Safety Information G 2.5A
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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 ALWAYSremovealltools, cords, and other looseitemsfromgenerator
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
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.
DANGER

G 2.5A Safety Information
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2.4 Service Safety
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.
WARNING

Safety Information G 2.5A
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2.5 Label Locations
w c _ g r 0 0 1 0 3 0
GND
88897
1
2
3
4
5
1
2
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 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 .
WARNING
STOP
DANGER
GEFAHR
PELIGRO
DANGER

G 2.5A Safety Information
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2.6 Safety and Operating Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label 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.
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. Fail-
ure to do so increases the risk of injury to your-
self or others.
CAUTION!
Lifting point
STOP
DANGER
GEFAHR
PELIGRO
DANGER
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 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 .
WARNING

Safety Information G 2.5A
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Electrical ground.
Open fuel flow valve.
Open choke.
Push or turn engine switch to ON position.
Pull rewind starter.
Close fuel flow valve.
Label Meaning
GND
88897
123
4
5
12

G 2.5A Safety Information
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Close choke.
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 infor-
mation found on this plate so it will be avail-
able 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.
Label Meaning

Technical Data G 2.5A
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3. Technical Data
3.1 Generator
Item No. G2.5A
0009256
Generator
Maximum Output W2500
Continuous Output W2250
Type Single voltage, single phase,
Auto voltage regulator system
AC Voltages Available volts
phase 120
1ø
Frequency Hz 60
Power Factor 1.0
AC receptacles:
120V GFI duplex
120V GFI duplex amp
amp 15
15
Main Circuit Breaker amp 20
L x W x H mm (in.) 685 x 445 x 435 (27 x 17.5 x 17)
Weight (dry) Kg (lbs.) 43 (94)

G 2.5A Technical Data
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3.2 Engine
Item No. G2.5A
0009256
Engine
Engine Make Honda
Engine Model GX 160 K1VX
Rated Power kW (Hp) 4.1 (5.5)
Spark Plug BPR6ES / W20EPR-U
Electrode Gap mm (in.) 0.7 - 0.8 (0.028 - 0.031)
Engine Speed - full load rpm 3600 ± 100
Engine Speed - no load rpm 3700 ± 100
Air Cleaner type Dry type with oil-wetted foam pre-cleaner
Engine Lubrication oil grade SAE 10W30 service class SF, SE, SD or SC
Engine Oil Capacity l (qts.) 1.1 (1.2)
Fuel type Regular unleaded gasoline
Fuel Tank Capacity l (gal.) 3.7 (3.9)
Fuel Consumption l (qts.)/hr. 1.7 (1.8)
Running Time - full load hrs. 2.1

Operation G 2.5A
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4. Operation
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 watt-
age 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 start-
ing.
• 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

G 2.5A Operation
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4.2 Outdoor Installation
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.
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.
DANGER

Operation G 2.5A
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4.4 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 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) Derate Factor
45 (113) 3 % 0.97
50 (122) 6 % 0.94
55 (131) 9 % 0.91
60 (140) 12 % 0.88
Altitude
m (ft.) Derate Factor
1500 (4900) 3 % 0.97
2000 (6600) 6 % 0.94
2500 (8200) 9 % 0.91
3000 (9900) 12 % 0.88
3500 (11500) 15 % 0.85
4000 (13100) 18 % 0.82

G 2.5A Operation
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4.5 Grounding the Generator
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.
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.
w c _ g r 0 0 0 5 4 4
=

Operation G 2.5A
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4.7 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. A heavier cord with a larger wire size will reduce the
voltage loss.
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.
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.
Current Load in Watts Maximum Cable Length in Feet
(Amps) 120V 240V #10 #12 #14 #16
2.5 300 600 1000 ft. 600 375 250
5 600 1200 500 300 200 125
7.5 900 1800 350 200 125 100
10 1200 2400 250 150 100 -
15 1800 3600 150 100 65 -
20 2400 4800 125 75 50 -
WARNING