Wacker Neuson GP 2500A User manual

Operator’s Manual
Manual del operador
Manuel d’utilisation
Portable Generator
Generador Portátil
Générateur Portatif
GP2500A, GP3800A
GP5600A, GP6600A
Type GP2500A, GP3800A,
GP5600A, GP6600A
Document 5100042314
Date 0419
Revision 08
Language EN-FR-ES

Copyright notice © Copyright 2019 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.

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CALIFORNIA Proposition 65 Warning
CALIFORNIA Proposition 65 Warning
WARNING
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
WARNING
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
WARNING
Cancer and Reproductive Harm -
www.P65Warnings.ca.gov.
WARNING
Batteries, battery posts, terminals and related accessories contain lead and lead
compounds, and other chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

CALIFORNIA Proposition 65 Warning Proposition 65 Warning
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GP Foreword
wc_tx004571gb.fm 5
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
identification
A nameplate listing the model number, item number, revision number, and serial
number is attached to this machine. The location of the nameplate is shown above.
Machine Item Number
GP2500A 5100041977
GP3800A 5100041978
GP5600A 5100041979
GP6600A 5100042220
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, buildings, 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 homes, buildings, windows,
doors, and vents. Windows, doors, and vents can pull in generator exhaust.
►Point the engine exhaust away from homes, buildings, windows, doors, and
vents. Also, point the engine exhaust away from combustible materials.
►Even when you use a generator correctly, CO may leak into the home or build-
ing. ALWAYS use a battery-powered or battery-backup CO alarm in the home or
building.
►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
poisoning.
wc_gr014737
Model : Rev. :
Serial No. :

Foreword GP
6 wc_tx004571gb.fm
Serial number
(S/N)
For future reference, record the serial number in the space provided below. You will
need the serial number when requesting parts or service for this machine.
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.
For spare parts information, please see your Wacker Neuson Dealer, or visit the
Wacker Neuson website at http://www.wackerneuson.com/.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, 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.
The illustrations, parts, and procedures in this manual refer to Wacker Neuson
factory-installed components. Your machine may vary depending on the
requirements of your specific region.
CALIFORNIA
Proposition
65 Warning
Combustion 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
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.
Serial Number:

GP Foreword
wc_tx004571gb.fm 7
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. 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
consequences:
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.

Foreword GP
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Table of Contents
GP
wc_bo5100042314_08TOC.fm 9
CALIFORNIA Proposition 65 Warning 3
Foreword 5
1 Safety Information 13
1.1 Signal Words Used in this Manual ............................................................. 13
1.2 Machine Description and Intended Use ..................................................... 13
1.3 Operating Safety ........................................................................................ 15
1.4 Operator Safety while Using Internal Combustion Engines ....................... 18
1.5 Service Safety ............................................................................................ 19
2 Labels 21
2.1 Label Locations .......................................................................................... 21
2.2 Label Meanings .......................................................................................... 23
3 Lifting and Transporting 27
4 Operation 28
4.1 Spark Arrester ............................................................................................ 28
4.2 Preparing the Machine for First Use ........................................................... 28
4.3 Refueling the Machine ................................................................................ 29
4.4 Recommended Fuel ................................................................................... 29
4.5 Determining Power Requirements ............................................................. 30
4.6 Installation .................................................................................................. 30
4.7 Positioning the Generator for Operation ..................................................... 31
4.8 Generator Derating ..................................................................................... 32
4.9 Grounding the Generator ........................................................................... 33
4.10 Operating Heavy Loads .............................................................................. 33
4.11 Use of Extension Cords .............................................................................. 34
4.12 Control Panel—GP2500A .......................................................................... 35
4.13 Control Panel—GP3800A .......................................................................... 35
4.14 Control Panel—GP5600A .......................................................................... 36
4.15 Control Panel—GP6600A .......................................................................... 37
4.16 Ground Fault Circuit Interrupt (GFCI) ......................................................... 37
4.17 Circuit Breaker ............................................................................................ 38
4.18 Twist-Lock Receptacles ............................................................................. 38
4.19 Engine Auto Idle ......................................................................................... 39
4.20 Engine Speed ............................................................................................. 39

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wc_bo5100042314_08TOC.fm
10
4.21 Voltage Selector—GP3800A, GP5600A, GP6600A ................................... 39
4.22 Before Starting ........................................................................................... 40
4.23 Starting—GP2500A .................................................................................... 41
4.24 Stopping—GP2500A .................................................................................. 41
4.25 Starting—GP3800A, GP5600A, GP6600A ................................................. 42
4.26 Stopping—GP3800A, GP5600A, GP6600A ............................................... 42
4.27 Emergency Shutdown Procedure ............................................................... 43
5 Maintenance 44
5.1 Maintaining the Emission Control System .................................................. 44
5.2 Periodic Maintenance Schedule ................................................................. 44
5.3 Changing the Engine Oil ............................................................................ 45
5.4 Servicing the Air Cleaner ............................................................................ 46
5.5 Cleaning and Checking the Spark Plug ...................................................... 47
5.6 Cleaning the Sediment Cup ....................................................................... 48
5.7 Adjusting the Carburetor ............................................................................ 48
5.8 Engine Speed ............................................................................................. 49
5.9 Storage ....................................................................................................... 49
6 Troubleshooting 50
7 Technical Data 51
7.1 Generator—GP2500A and GP3800A ........................................................ 51
7.2 Generator—GP5600A and GP6600A ........................................................ 52
7.3 Engine—GP2500A and GP3800A ............................................................. 53
7.4 Engine—GP5600A and GP6600A ............................................................. 54
8 Assembly Instructions—Wheel Kit 1
9 Emission Control Systems Information and Warranty—Gasoline 6
9.1 Emission Control System Background Information ...................................... 6
9.2 Limited Defect Warranty for Exhaust Emission Control System .................. 7
9.3 Limited Defect Warranty for Wacker Neuson Evaporative
Emission Control Systems ........................................................................... 7
9.4 California Evaporative Emission Control Warranty Statement ..................... 9
9.5 Limited Defect Warranty for Exhaust Emission Control System ................ 11

Table of Contents
GP
wc_bo5100042314_08TOC.fm 11
10 Schematics 12
10.1 Schematics—GP2500A .............................................................................. 12
10.2 Electrical Schematic Components .............................................................. 13
10.3 Schematics—GP3800A .............................................................................. 14
10.4 Electrical Schematic Components .............................................................. 15
10.5 Schematics—GP5600A .............................................................................. 16
10.6 Electrical Schematic Components .............................................................. 17
10.7 Schematics—GP6600A .............................................................................. 18
10.8 Electrical Schematic Components .............................................................. 19

Table of Contents GP
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GP 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.
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 AC 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 is the safety alert symbol. It is used to alert you to potential personal hazards.
►Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
►To avoid death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
►To 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.
►To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.

wc_si011087gb.fm
14
Safety Information GP
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_si011087gb.fm 15
GP 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
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, buildings, 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 homes, buildings, windows,
doors, and vents. Windows, doors, and vents can pull in generator exhaust.
►Point the engine exhaust away from homes, buildings, windows, doors, and
vents. Also, point the engine exhaust away from combustible materials.
►Even when you use a generator correctly, CO may leak into the home or
building. ALWAYS use a battery-powered or battery-backup CO alarm in the
home or building.
►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
poisoning.
WARNING
Risk of electric shock or electrocution.
►Do not operate this generator in rain, snow, or standing water.

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Safety Information GP
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.
Identify whether special hazards exist in the application area, such as toxic
gases or unstable ground conditions, and take appropriate action to eliminate
the special hazards before using the machine.
Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
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.
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

wc_si011087gb.fm 17
GP Safety Information
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.
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 operate near open windows, tents, or structural air intakes.
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.
WARNING
Backfeed from the generator into the public power distribution system can cause
serious injury or death to utility workers.
►Connections to a building’s electrical system must be made by a qualified
electrician and comply with all applicable laws and electrical codes.

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Safety Information GP
= 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 machine clean and free of debris such as leaves, paper, cartons, etc.
Keep labels legible.
Clean with soapy water only.
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.
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.
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.
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.

wc_si011087gb.fm 19
GP Safety Information
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.
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 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.
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.

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20
Safety Information GP
Cleaning When cleaning and servicing the machine:
Keep machine clean and free of debris such as leaves, paper, cartons, etc.
Keep labels legible.
Clean with soapy water only.
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.