Wacker Neuson GP 2500A User manual

5200003184 01 0512
5200003184
Operator’s Manual
Portable Generator
GP 2500A
EN

Copyright
notice
© Copyright 2012 by Wacker Neuson Production Americas LLC
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
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.
Trademarks All trademarks referenced in this manual are the property of their respective owners.
Manufacturer Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: [phone] · Fax: [phone] · Tel: [phone]
www.wackerneuson.com
Original
instructions
This Operator’s Manual presents the original instructions. The original language of this
Operator’s Manual is American English.

Foreword
wc_tx001857gb.fm 3
Foreword
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models listed below. These instructions must be followed during
installation and maintenance of the generator (and battery, if equipped).
Machines
covered in
this manual
Machine
documentation
From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
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.
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change
any portion of this information without notice.
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.
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 dis-
charge 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.
Machine Item Number
GP 2500A 5200002844

Foreword
4 wc_tx001857gb.fm
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and modifica-
tions. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following conse-
quences:
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.

wc_bo5200003184_01TOC.fm 5
Table of Contents
GP 2500A
Foreword 3
1 Safety Information 7
1.1 Signal Words Used in this Manual ....................................................... 7
1.2 Machine Description and Intended Use ............................................... 8
1.3 Operating Safety .................................................................................. 9
1.4 Operator Safety while Using Internal Combustion Engines ............... 12
1.5 Service Safety .................................................................................... 13
2 Labels 15
2.1 Label Locations .................................................................................. 15
2.2 Label Meanings .................................................................................. 15
3 Lifting and Transporting 19
4 Operation 20
4.1 Preparing the Machine for First Use ................................................... 20
4.2 Refueling the Machine ........................................................................ 21
4.3 Determining Power Requirements ..................................................... 22
4.4 Installation .......................................................................................... 22
4.5 Generator Derating ............................................................................. 23
4.6 Grounding the Generator ................................................................... 24
4.7 Operating Heavy Loads ...................................................................... 24
4.8 Use of Extension Cords ...................................................................... 25
4.9 Control Panel ...................................................................................... 26
4.10 Ground Fault Interrupt (GFI / GFCI) ................................................... 27
4.11 Circuit Breaker .................................................................................... 27
4.12 Before Starting ................................................................................... 28
4.13 Starting ............................................................................................... 29
4.14 Stopping ............................................................................................. 29
4.15 Emergency Shutdown Procedure ....................................................... 30

6 wc_bo5200003184_01TOC.fm
Table of Contents GP 2500A
5 Maintenance 31
5.1 Maintaining the Emission Control System ...........................................31
5.2 Periodic Maintenance Schedule ..........................................................31
5.3 Engine Oil ............................................................................................32
5.4 Servicing the Air Cleaner .....................................................................33
5.5 Spark Plug ...........................................................................................34
5.6 Cleaning the Sediment Cup ................................................................35
5.7 Adjusting the Carburetor .....................................................................36
5.8 Engine Speed ......................................................................................36
5.9 Long-Term Storage .............................................................................37
5.10 Transporting the Machine ....................................................................37
6 Troubleshooting 38
7 Technical Data 39
7.1 Generator ............................................................................................39
7.2 Engine .................................................................................................40
8 Schematics 42
8.1 Wire Colors ..........................................................................................42
8.2 Electrical Schematic Components .......................................................42
8.3 Electrical Schematic ............................................................................43
9 Emission Control Systems Information and Warranty 45
9.1 Emission Control System Background Information .............................45
9.2 Limited Defect Warranty for Exhaust Emission Control System .........46
9.3 Limited Defect Warranty for Wacker Neuson Evaporative
Emission Control Systems ..................................................................46
9.4 California Evaporative Emission Control Warranty Statement ............49
9.5 Limited Defect Warranty for Exhaust Emission Control System .........50

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GP 2500 Safety Information
1 Safety Information
1.1 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.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo avoid death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
fTo avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fTo avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.

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8
Safety Information GP 2500
1.2 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. As the engine runs, the generator converts mechanical
energy into electric power. The operator connects loads to the electric power
receptacles.
This machine is intended for the purpose of supplying electrical power to
connected loads. Refer to the product specifications for the output voltage and
frequency of this generator, and the maximum output power limit of this generator.
This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons in the area. Machine
damage caused by misuse is not covered under warranty.
The following are some examples of misuse:
Connecting a load that has voltage and frequency requirements that are
incompatible with the generator output
Overloading the generator with a load that draws excessive power during either
continuous running or start-up
Operating the generator in a manner that is inconsistent with all federal, state
and local codes and regulations
Using the machine as a ladder, support, or work surface
Using the machine to carry or transport passengers or equipment
Operating the machine outside of factory specifications
Operating the machine in a manner inconsistent with all warnings found on the
machine and in the Operator’s Manual.
This machine has been designed and built in accordance with the latest global
safety standards. It has been carefully engineered to eliminate hazards as far as
practicable and to increase operator safety through protective guards and labeling.
However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:
Heat, noise, exhaust, and carbon monoxide from the engine
Fire hazards from improper refueling techniques
Fuel and its fumes
Electric shock and arc flash
Personal injury from improper lifting techniques
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.

wc_si000706gb.fm 9
GP 2500 Safety Information
1.3 Operating Safety
Operator
training
Before operating the machine:
Read and understand the operating instructions contained in all manuals
delivered with the machine.
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.
Operator
qualifications
Only trained personnel are permitted to start, operate, and shut down the machine.
They also must meet the following qualifications:
have received instruction on how to properly use the machine
are familiar with required safety devices
The machine must not be accessed or operated by:
children
people impaired by alcohol or drugs
Application
area
Be aware of the application area.
Keep unauthorized personnel, children, and pets away from the machine.
Remain aware of changing positions and the movement of other equipment and
personnel in the application area/job site.
Be aware of the application area.
Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
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.
fNEVER use a generator inside homes, garages, crawlspaces, or other partly
enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Using a fan or opening windows and doors does NOT supply enough fresh air.
fONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
fEven when you use a generator correctly, CO may leak into the home. ALWAYS
use a battery-powered or battery-backup CO alarm in the home.
fIf 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
poison.

wc_si000706gb.fm
10
Safety Information GP 2500
Safety
devices,
controls, and
attachments
Only operate the machine when:
All safety devices and guards are in place and in working order.
All controls operate correctly.
The machine is set up correctly according to the instructions in the Operator’s
Manual.
The machine is clean.
The machine’s labels are legible.
To ensure safe operation of the machine:
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
operating
practices
When operating this machine:
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
When operating this machine:
Do not operate a machine in need of repair.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
Installing as
backup power
Special hazards exist when installing this machine as a backup power supply.
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.
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
Backfeed from the generator into the public power distribution system can cause
serious injury or death to utility workers!
fConnections to a building’s electrical system must be made by a qualified elec-
trician and comply with all applicable laws and electrical codes.

wc_si000706gb.fm 11
GP 2500 Safety Information
Transporting
and installing
the machine
Never allow untrained personnel to operate or service the generator. The
generator set should be set up by a certified electrician.
Do not stand under the machine while it is being hoisted or moved.
Do not attach equipment to the machine when it is suspended.
Always transport the generator in an upright position.
Always position and operate the generator on a firm, noncombustible, level
surface.
Always make certain the machine is well-grounded and securely fastened to a
good earthen ground per national and local regulations.
Always remove all tools, cords, and other loose items from the generator before
starting it.
General
Safety
Do not operate the generator when open containers of fuel, paint, or other
flammable liquids are near.
Do not operate the generator, or tools attached to the generator, with wet hands.
Do not run the electrical cords under the generator, or over vibrating or hot
parts.
Do not enclose or cover the generator when it is in use or when it is hot.
Do not overload the generator. The total amperage of the tools and equipment
attached to the generator must not exceed the load rating of the generator.
Do not operate the machine in snow, rain, or standing water.
Do not stand on the machine.
Generator
vibration
Generators vibrate in normal use. During and after the use of the generator, inspect
the generator as well as extension cords and power supply cords connected to it
for damage from vibration.
Have damaged items repaired or replaced as necessary.
Do not use plugs or or cords that show signs of damage such as broken or
cracked insulation or damaged blades.
= After use Store the machine properly when it is not being used. The machine should be
stored in a clean, dry location out of the reach of children.
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. Fumes from fuels and solvents can become explosive.

wc_si000706gb.fm
12
Safety Information GP 2500
1.4 Operator Safety while Using Internal Combustion Engines
Refueling
safety
When refueling the engine:
Do not smoke.
Do not refuel if the generator is sitting in a truck fitted with a plastic bed liner.
Static electricity can ignite the fuel or fuel vapors.
Do not refuel a hot or running engine.
Do not refuel the engine near an open flame.
When refueling the engine, always:
Refill the fuel tank in a well-ventilated area.
Replace the fuel tank cap after refueling.
Operating
safety
When operating the generator:
Check the fuel lines and the fuel tank for leaks and cracks before starting the
engine.
Do not run the machine if fuel leaks are present or the fuel lines are loose.
Do not run the engine near open flames.
Do not start the engine if fuel has spilled or a fuel odor is present. Move the
generator away from the spill and wipe the generator dry before starting.
Do not smoke while operating the machine.
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.
fRead and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
fCarbon 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.

wc_si000706gb.fm 13
GP 2500 Safety Information
1.5 Service Safety
Service
training
Before servicing or maintaining the machine:
Read and understand the instructions contained in all manuals delivered with
the machine.
Familiarize yourself with the location and proper use of all controls and safety
devices.
Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
Do not allow improperly trained people to service or maintain the machine.
Personnel servicing or maintaining the machine must be familiar with the
associated potential risks and hazards.
Precautions Follow the precautions below when servicing or maintaining the machine.
Read and understand the service procedures before performing any service to
the machine.
All adjustments and repairs must be completed before operating the machine.
Do not operate the machine with a known problem or deficiency.
All repairs and adjustments shall be completed by a qualified technician.
Turn off the machine before performing maintenance or making repairs.
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
Reinstall the safety devices and guards after repair and maintenance
procedures are complete.
Machine
modifications
When servicing or maintaining the machine:
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.
Replacing
parts and
labels
Replace worn or damaged components.
Replace all missing and hard-to-read labels.
When replacing electrical components, use components that are identical in
rating and performance to the original components.
When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.

wc_si000706gb.fm
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. Fumes from fuels and solvents can become explosive.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
In addition, before servicing or maintaining the machine:
Tie back long hair.
Remove all jewelry (including rings).
Precautions Do not allow water to accumulate around the base of the machine. If water is
present, move the machine and allow the machine to dry before servicing.
Do not service the machine if your clothing or skin is wet.
Always turn the engine off before servicing the machine. If the engine has
electric start, disconnect the negative terminal on the battery before servicing
the machine.
Always let the engine cool before transporting or servicing the machine.

GP 2500A Labels
wc_si000611gb.fm 15
2 Labels
2.1 Label Locations
2.2 Label Meanings
Wacker Neuson machines use international pictorial labels where
needed. These labels are described below.
ADANGER!
Read the Operator’s Manual.
No sparks, flames, or burning objects near the
machine.
Stop the engine before refueling.
BWARNING!
Hot surface
wc_gr008555
AC
C
E
F
B
GK
D
B
JH

Labels GP 2500A
16 wc_si000611gb.fm
C
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.
—Only use OUTSIDE and far away from
windows, doors, and vents.
D
—CAUTION!
Use only clean, filtered gasoline fuel.
Check the fuel level.
—Open the fuel flow valve.
—Close the choke.

GP 2500A Labels
wc_si000611gb.fm 17
—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.
EDANGER
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.
FElectrical ground
GND
88897

Labels GP 2500A
18 wc_si000611gb.fm
GImportant Emissions Information
This equipment meets California EVP emis-
sion regulations for small off-road engines.
HA nameplate listing the model number, item
number, revision number, and serial number is
attached to each unit. Please record the infor-
mation found on this nameplate so it will be
available should the nameplate become lost
or damaged. When ordering parts or request-
ing service information, you will always be
asked to specify the model number, item num-
ber, revision number, and serial number of the
unit.
JThis machine may be covered by one or more
patents.
KEmission Control Information
This equipment meets U.S. EPA EVAP
standards.
Evaporative Family: CWIXNHEQCL2

GP 2500A Lifting and Transporting
wc_tx001858gb.fm 19
3 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.
• Make sure lifting equipment is attached securely and has enough
weight-bearing capacity to lift or hold the generator safely.
• Remain aware of the location of other people nearby when lifting
the generator.
Transporting the Machine
Observe the following guidelines when transporting the generator to
and from the job site.
• Allow the engine to cool before transporting the generator.
• Drain the fuel tank.
• Close the fuel valve.
• Ensure that the generator is securely strapped down in the
transport vehicle to prevent it from sliding or tipping.
• Do not refuel the generator in or on the transport vehicle. Move
the generator to its operating location and then fill the fuel tank.

Operation GP 2500A
20 wc_tx000447gb.fm
4 Operation
4.1 Preparing the Machine for First Use
Preparing for first use
To prepare your machine for first use:
4.1.1 Make sure all loose packaging materials have been removed from the
machine.
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.
4.1.4 Attach component parts not already attached.
4.1.5 Add fluids as needed and applicable, including fuel, engine oil, and
battery acid.
4.1.6 Move the machine to its operating location.
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.
fNEVER use a generator inside homes, garages, crawlspaces, or other partly
enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Using a fan or opening windows and doors does NOT supply enough fresh air.
fONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
fEven when you use a generator correctly, CO may leak into the home. ALWAYS
use a battery-powered or battery-backup CO alarm in the home.
fIf 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
poison.