Wacker Neuson GP 2500A User manual

www.wackergroup.com
Generator
GP 2500A
OPERATOR’S MANUAL
0160531en 002
1106
0160531EN

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.
• NEVER 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.
• ONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
Even 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.
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 poison.

GP 2500A Table of Contents
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1. Foreword 3
2. California Evaporative Emission Control Warranty Statement 4
3. Safety Information 6
3.1 Laws Pertaining to Spark Arresters ...................................................... 6
3.2 Operating Safety .................................................................................. 7
3.3 Operator Safety while using Internal Combustion Engines .................. 9
3.4 Service Safety .................................................................................... 10
3.5 Label Locations .................................................................................. 11
3.6 Safety and Operating Labels .............................................................. 12
4. Technical Data 15
4.1 Generator ........................................................................................... 15
4.2 Engine ................................................................................................ 16
5. Operation 17
5.1 Determining Power Requirements ..................................................... 17
5.2 Outdoor Installation ............................................................................ 18
5.3 Indoor Installation ............................................................................... 18
5.4 Generator Derating ............................................................................. 19
5.5 Grounding the Generator ................................................................... 20
5.6 Operating Heavy Loads ...................................................................... 20
5.7 Use of Extension Cords ...................................................................... 21
5.8 Control Panel—GP 2500A ................................................................. 22
5.9 Ground Fault Interrupt (GFI) ............................................................... 23
5.10 Circuit Breaker .................................................................................... 23
5.11 Before Starting ................................................................................... 24
5.12 To Start ............................................................................................... 25
5.13 To Stop ............................................................................................... 25

Table of Contents GP 2500A
wc_bo0160531en_002TOC.fm 2
6. Maintenance 26
6.1 Engine Maintenance ............................................................................26
6.2 Periodic Maintenance Schedule ..........................................................26
6.3 Engine Oil ............................................................................................27
6.4 Servicing Air Cleaner ...........................................................................28
6.5 Spark Plug ...........................................................................................29
6.6 Cleaning the Sediment Cup ................................................................30
6.7 Carburetor Adjustment ........................................................................31
6.8 Adjusting Engine Speed ......................................................................32
6.9 Storage ................................................................................................32
6.10 Transport .............................................................................................33
6.11 Troubleshooting ...................................................................................33
6.12 Wire Colors ..........................................................................................34
6.13 Wiring Schematic ................................................................................34

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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 2006 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

California Evaporative Emission Control Warranty Statement
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2. California Evaporative Emission Control Warranty Statement
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Wacker Corporation, Inc. are
pleased to explain the evaporative emission control system (EECS)
warranty on your model year 2006 and later portable generator. In
California, new portable generators must be designed, built and
equipped to meet the State’s stringent anti-smog standards. Wacker
Corporation must warrant the EECS on your portable generator for the
period of time listed below provided there has been no abuse, neglect
or improper maintenance of your portable generator.
Your EECS for the 2006 model year on your portable generator
includes the fuel line, fuel line clamps and fuel line fittings.
Where a warrantable condition exists, Wacker Corporation will repair
your portable generator at no cost to you including diagnosis, parts and
labor.
MANUFACTURER’S WARRANTY COVERAGE:
This EECS is warranted for two years from the initial date of purchase.
If any evaporative emission-related part on your equipment is
defective, the part will be repaired or replaced by Wacker Corporation
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
Corporation’s authorized service center.
WARRANTY PERIOD:
Any warranted part that is not scheduled for replacement as required
maintenance, or which is scheduled only for regular inspection to the
effect of “repair or replace as necessary” shall be warranted for two
years. Any warranted part that is scheduled for replacement as
required maintenance shall be warranted for a time not less than the
remaining warranty period.

California Evaporative Emission Control Warranty Statement
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OWNER’S WARRANTY RESPONSIBILITIES:
As the portable generator owner, you are responsible for performance
of the required maintenance listed in your owner’s manual. Wacker
Corporation recommends that you retain all receipts covering
maintenance on your portable generator, but Wacker Corporation
cannot deny warranty solely for the lack of receipts.
As the portable generator owner, you should however be aware that
Wacker Corporation may deny you warranty coverage if your portable
generator or a part has failed due to abuse, neglect, or improper
maintenance or unapproved modifications.
You are responsible for presenting your portable generator to Wacker
Corporation’s authorized service center as soon as the problem exists.
The warranty repairs should be completed in a reasonable amount of
time, not to exceed 30 days. If you have a question regarding your
warranty coverage, you should contact your nearest authorized
Wacker service center or call 1-800-770-0957.
WHAT IS NOT COVERED:
All failures caused by abuse, neglect, or improper maintenance are not
covered. In addition, the use of add-on or modified parts will be
grounds for disallowing a warranty claim.
WARRANTED PARTS:
The repair or replacement of any warranted part otherwise eligible for
warranty coverage may be excluded from such warranty coverage if
Wacker Corporation 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. That notwithstanding, any
adjustment of a component that has a factory installed, and properly
operating, adjustment limiting device is still eligible for warranty
coverage. The following emission warranty parts list is covered:
(1)Fuel Line.
(2)Fuel Line Clamps.
(3)Fuel Line Fittings.

Safety Information GP 2500A
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3. 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 a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could
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.
3.1 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

GP 2500A Safety Information
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3.2 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.
3.2.1 NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
3.2.2 NEVER operate the generator, or tools attached to the generator, with
wet hands.
3.2.3 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
3.2.4 NEVER run the electrical cords under the generator, or over vibrating
or hot parts.
3.2.5 NEVER enclose or cover the generator when it is in use or when it is
hot.
3.2.6 NEVER overload the generator. The total amperage of the tools and
equipment attached to the generator must not exceed the load rating
of the generator.
3.2.7 NEVER operate the machine in snow, rain, or standing water.
3.2.8 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a trained electrician.
3.2.9 NEVER stand on the machine.
3.2.10 DO NOT stand under the machine while it is being hoisted or moved.
3.2.11 DO NOT attach equipment to the machine when it is suspended.
DANGER
WARNING

Safety Information GP 2500A
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3.2.12 ALWAYS store the equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
3.2.13 ALWAYS position and operate the generator on a firm,
noncombustible, level surface.
3.2.14 ALWAYS transport the generator in an upright position.
3.2.15 ALWAYS keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
3.2.16 ALWAYS keep the area immediately surrounding and underneath the
machine clean, neat, and 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.
3.2.17 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
3.2.18 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.

GP 2500A Safety Information
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3.3 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
warnings and safety guidelines could result in severe injury or death.
3.3.1 DO NOT run the 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.
3.3.2 DO NOT smoke while operating the machine.
3.3.3 DO NOT smoke when refueling the engine.
3.3.4 DO NOT refuel a hot or running engine.
3.3.5 DO NOT refuel the engine near an open flame.
3.3.6 DO NOT spill fuel when refueling the engine.
3.3.7 DO NOT run the engine near open flames.
3.3.8 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.
3.3.9 ALWAYS refill the fuel tank in a well-ventilated area.
3.3.10 ALWAYS replace the fuel tank cap after refueling.
3.3.11 ALWAYS 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.
DANGER

Safety Information GP 2500A
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3.4 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.
3.4.1 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.
3.4.2 DO NOT attempt to clean or service the machine while it is running.
3.4.3 DO NOT modify the equipment without the express written approval of
the manufacturer.
3.4.4 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.
3.4.5 DO NOT service the machine if your clothing or skin is wet.
3.4.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
3.4.7 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
3.4.8 ALWAYS replace the safety devices and guards after repairs and
maintenance.
3.4.9 ALWAYS let the engine cool before transporting or servicing it.
3.4.10 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
3.4.11 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.
3.4.12 ALWAYS keep the fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.
WARNING

GP 2500A Safety Information
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3.5 Label Locations
GND
88897

Safety Information GP 2500A
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3.6 Safety and Operating Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label Meaning
DANGER!
No sparks, flames or burning objects near
machine.
Shut off the engine before refueling.
WARNING!
Hot surface!
DANGER!
Asphyxiation hazard. Read the operator’s
manual for instructions.
Use in a well-ventilated area. Do not use
indoors or near open windows. Fumes can
cause death.
WARNING!
To reduce the risk of electrical shock, read the
operator’s manual. Improper connection of the
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.

GP 2500A Safety Information
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Electrical ground
CAUTION!
Use only clean, filtered gasoline fuel.
Check the fuel level.
Open the fuel flow valve.
Close the choke.
Turn the engine switch to the ON position.
Label Meaning
GND
88897
1
12
23
456

Safety Information GP 2500A
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Pull the rewind starter.
Open the choke.
Turn the engine switch to "OFF".
Close the fuel flow valve.
Important Emissions Information
This equipment meets California EVP
emission 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
information found on this plate so it will be
available should the nameplate become lost or
damaged. When ordering parts or requesting
service information, you will always be asked
to specify the model number, item number,
revision number, and serial number of the unit.
This machine may be covered by one or more
patents.
Label Meaning

GP 2500A Technical Data
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4. Technical Data
4.1 Generator
Item No. GP 2500A
0620009
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:
125V GFI duplex
125V duplex
amp
amp
20
20
Main Circuit Breaker amp 20
L x W x H mm (in.) 565 x 435 x 445 (22.3 x 17 x 17.5)
Weight (dry) Kg (lbs.) 44.5 (98)

Technical Data GP 2500A
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4.2 Engine
Item No. GP 2500A
0620009
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)
Operating Speed (Max.) rpm 3600
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.) 0.6 (0.7)
Fuel type Regular unleaded gasoline
Fuel Tank Capacity l (gal.) 12 (3)
Fuel Consumption l (qts.)/hr. 1.7 (1.8)
Running Time - full load hrs. 7

GP 2500A Operation
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5. Operation
5.1 Determining Power Requirements
This generator is designed to operate single-phase, 60 Hz appliances
running at 120 VAC. Check the nameplate or label provided on tools
and appliances to make sure their power requirements match the
power output of the generator.
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 in determining power
requirements for different types of equipment. Check with your nearest
Wacker Dealer, or contact the manufacturer or dealer of the tool or
appliance, with questions regarding its power requirements.
CAUTION: If a tool or appliance does not reach full speed within a few
seconds when 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
wattage 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
starting.
• 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

Operation GP 2500A
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5.2 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 the 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.
5.3 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 the 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 the generator, and using only electrical cables in good condition,
must be observed. See Operating Safety.
DANGER