Wacker Neuson GV 2500A User manual

Generator
GV 2500A
OPERATOR’S MANUAL
0157385en 004
0908
0157385EN

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.

GV 2500A Table of Contents
wc_bo0157385en_004TOC.fm 3
1. Foreword 5
2. Safety Information 6
2.1 Operating Safety .................................................................................. 7
2.2 Operator Safety while using Internal Combustion Engines .................. 8
2.3 Service Safety ...................................................................................... 9
2.4 Label Locations .................................................................................. 10
2.5 Safety and Operating Labels .............................................................. 11
3. Operation 13
3.1 Determining Power Requirements ..................................................... 13
3.2 Installation .......................................................................................... 15
3.3 Generator Derating ............................................................................. 16
3.4 Grounding the Generator ................................................................... 17
3.5 Operating Heavy Loads ...................................................................... 17
3.6 Use of Extension Cords ...................................................................... 18
3.7 Control Panel ...................................................................................... 20
3.8 Before Starting ................................................................................... 21
3.9 To Start ............................................................................................... 22
3.10 To Stop ............................................................................................... 22
4. Maintenance 23
4.1 Engine Maintenance ........................................................................... 23
4.2 Periodic Maintenance Schedule ......................................................... 23
4.3 Engine Oil ........................................................................................... 24
4.4 Air Cleaner ......................................................................................... 25
4.5 Spark Plug .......................................................................................... 26
4.6 Engine Speed ..................................................................................... 27
4.7 Carburetor Adjustment ....................................................................... 28
4.8 Storage ............................................................................................... 29
4.9 Transport ............................................................................................ 29
4.10 Troubleshooting .................................................................................. 30
4.11 Wiring Diagram ................................................................................... 31

Table of Contents GV 2500A
wc_bo0157385en_004TOC.fm 4
5. Technical Data 32
5.1 Generator ............................................................................................32
5.2 Engine .................................................................................................33
5.3 Sound Specifications ...........................................................................33

Foreword
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1. Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker Neuson 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 Neuson
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 Neuson
Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Neuson Corporation
reserves the right to change any portion of this information without
notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2008 by Wacker Neuson 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 Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker
Neuson 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.

Safety Information GV 2500A
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2. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE 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.
NOTICE:Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
DANGER
WARNING
CAUTION

GV 2500A Safety Information
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2.1 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 the
machine. Machines 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 machine before
being allowed to operate it.
2.1.1 NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
2.1.2 NEVER operate the generator, or tools attached to the generator, with
wet hands.
2.1.3 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
2.1.4 NEVER run the electrical cords under the generator, or over vibrating
or hot parts.
2.1.5 NEVER enclose or cover the generator when it is in use or when it is
hot.
2.1.6 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.
2.1.7 NEVER operate the machine in snow, rain, or standing water.
2.1.8 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a certified electrician.
2.1.9 ALWAYS 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.
DANGER
WARNING

Safety Information GV 2500A
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2.1.10 ALWAYS be sure the machine is on a firm, level surface and will not
tip, roll, slide, or fall while operating.
2.1.11 ALWAYS transport the generator in an upright position.
2.1.12 ALWAYS keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
2.1.13 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.
2.1.14 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
2.1.15 DO NOT ground this generator.
2.2 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 standards could result in severe injury or death.
NEVER install a generator in an enclosed area such as a tunnel or a
trench. Using a generator in a tunnel or a trench CAN KILL YOU IN
MINUTES. Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell. NEVER use this generator inside a
tunnel or a trench.
2.2.1 DO NOT smoke while operating the machine.
2.2.2 DO NOT smoke when refueling the engine.
2.2.3 DO NOT refuel a hot or running engine.
2.2.4 DO NOT refuel the engine near an open flame.
2.2.5 DO NOT spill fuel when refueling the engine.
2.2.6 DO NOT run the engine near open flames.
2.2.7 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.
2.2.8 ALWAYS refill the fuel tank in a well-ventilated area.
2.2.9 ALWAYS replace the fuel tank cap after refueling.
2.2.10 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
DANGERDANGER

GV 2500A Safety Information
wc_si000106gb.fm 9
2.3 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.
2.3.1 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.
2.3.2 DO NOT attempt to clean or service the machine while it is running.
2.3.3 DO NOT modify the machine without the express written approval of
the manufacturer.
2.3.4 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.
2.3.5 DO NOT service the machine if your clothing or skin is wet.
2.3.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
2.3.7 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.
2.3.8 ALWAYS replace the safety devices and guards after repairs and
maintenance.
2.3.9 ALWAYS let the engine cool before transporting or servicing it.
2.3.10 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
2.3.11 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.
2.3.12 ALWAYS keep the fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.
WARNING

Safety Information GV 2500A
wc_si000106gb.fm 10
2.4 Label Locations
wc_
g
r001289
PETROL
GASOLINA
ISSINCI
BENZIN
CALDO !
HEISS !
HOT !
CHAUD !
DANGER
GEFAHR
PELIGRO
DANGER

GV 2500A Safety Information
wc_si000106gb.fm 11
2.5 Safety and Operating Labels
Wacker Neuson machines use international pictorial labels where
needed. These labels are described below:
Label Meaning
WARNING!
Hot surface!
Close the choke.
Gasoline
Potential Earth.
WARNING!
Electric shock will cause serious injury or
death.
WARNING!
Electric shock hazard. Read Operator’s Man-
ual for instructions.
CALDO !
HEISS !
HOT !
CHAUD !
PETROL
GASOLINA
ISSINCI
BENZIN

Safety Information GV 2500A
wc_si000106gb.fm 12
DANGER!
Asphyxiation hazard. Read the Operator’s
Manual for instructions.
DANGER!
No sparks, flames or burning objects near
machine.
Fuel valve
Guaranteed sound power level in dB(A).
A 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 plate so it will be available
should the nameplate become lost or dam-
aged. When ordering parts or requesting ser-
vice information, you will always be asked to
specify the model number, item number, revi-
sion number, and serial number of the unit.
Label Meaning
DANGER
GEFAHR
PELIGRO
DANGER

GV 2500A Operation
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3. Operation
3.1 Determining Power Requirements
This generator is designed to operate single-phase 50 Hz appliances
running at 230 VAC.
NOTICE: Do not exceed the power output of the generator. Damage
to tools or generator will occur. See Technical Data.
Check the nameplate or label provided on tools and appliances to
make sure their power requirements are met by the power output of the
generator. If the wattage is not given for a particular tool or appliance,
contact the tool manufacturer for wattage requirements.
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 Neuson dealer, or contact the manufacturer or dealer of the
tool or appliance, if you have questions regarding power requirements.
NOTICE:DO NOT exceed the rated current limit of any receptacle.
NOTICE: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.

Operation GV 2500A
wc_tx000269gb.fm 14
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

GV 2500A Operation
wc_tx000269gb.fm 15
3.2 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.
The surrounding area must be free from water and moisture. All
components must be protected from excessive moisture.
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 this generator inside a home or garage, EVEN IF
doors and windows are open. Only use this generator OUTSIDE and
far away from windows, doors, and vents.
NEVER install a generator in an enclosed area such as a tunnel or a
trench. Using a generator in a tunnel or a trench CAN KILL YOU IN
MINUTES. Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell. NEVER use this generator inside a
tunnel or a trench.
DANGER
DANGERDANGER

Operation GV 2500A
wc_tx000269gb.fm 16
3.3 Generator Derating
All generators are subject to derating for altitude and temperature.
Internal combustion engines, unless modified, run less efficiently at
higher altitudes due to the reduction of air pressure. This translates
into a lack of power and thus reduction in generator output.
Temperature affects both engine and generator performance. As
temperature increases, an engine will run less efficiently and 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

GV 2500A Operation
wc_tx000269gb.fm 17
3.4 Grounding the Generator
The neutral of this machine is not connected to ground. Under
standard operating conditions, do not connect the frame PE stud to
earth ground. Refer to local codes if machine is used to power a
building or similar distribution system.
3.5 Operating Heavy Loads
Limit operations requiring the maximum rated output of the generator
to 20–30 minutes. For continuous operation, do not exceed the
continuous rated output of the generator. Refer to the Generator
Technical Data specification chart.
CAUTION
wc_gr001286

Operation GV 2500A
wc_tx000269gb.fm 18
3.6 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 cord with a larger cross section will reduce the voltage
loss.
NOTICE: Operating equipment at low voltage can cause it to overheat.
Use only tough rubber-sheathed cable in accordance with IEC 245-4.
Damaged cords can cause electric shock. Electric shock can cause
serious injury or death. DO NOT use worn, bare, or frayed cords.
Replace damaged cords immediately.
Do not exceed the rating of the cord.
Contact the cord manufacturer if in doubt about cord use.
Choose the cord size from the Minimum Extension Cord Size Table or
calculate minimum cord size using the Minimum Extension Cord Size
Graph. The X axis of the graph represents A x m (Ampere x meter)
values. The Y axis represents wire size in mm2. Multiply the operating
current for the load in amps (A) by the desired extension cord length in
meters (m). Find the result along the X axis. Move up the graph until
you reach the appropriate sloped line for your application. Move to the
Y axis; this is the recommended minimum cord size.
Example:
For a 3-phase, 400V application, if the operating current for the load is
15 A, and the desired extension cord length is 100 m, then:
15 A x 100 m = 1500 A x m.
1500 A x m = 2.5 mm2.
WARNING

GV 2500A Operation
wc_tx000269gb.fm 19
Minimum Extension Cord SizeTable
Minimum Extension Cord Size Graph
Minimum Extension Cord Size
230V/1~/50Hz 400V/3~/50Hz
Amp
Rating
Length m Length m
25 50 100 200 25 50 100 200
Cross sectional area of wire in mm2
2 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
4 1.5 1.5 1.5 2.5 1.5 1.5 1.5 1.5
6 1.5 1.5 1.5 4 1.5 1.5 1.5 2.5
8 1.5 1.5 2.5 6 1.5 1.5 1.5 2.5
10 1.5 1.5 4 6 1.5 1.5 1.5 4
15 1.5 2.5 4 10 1.5 1.5 2.5 6
20 1.5 4 6 16 1.5 1.5 4 6
30 2.5 4 10 25 1.5 2.5 6 10
40 4 6 16 --- 1.5 4 6 ---
10
6
4
2.5
1.5
01000 2000 3000 4000 5000 6000
A x m
mm
2
16
25
1
~
2
3
0
V
5
0
H
z
3
~
4
0
0
V
5
0
H
z

Operation GV 2500A
wc_tx000269gb.fm 20
3.7 Control Panel
See Graphic: wc_gr001251
The circuit breaker protects the generator from severe overloads or
short circuits. If the circuit breaker opens, turn the engine off
immediately and determine the cause before restarting. Check the
appliances and tools attached to the generator for defects and make
sure their power requirements do not exceed the power rating of the
generator or the current limit of the receptacles.
When the circuit breaker opens, the button will pop out. To reset circuit
breaker, push button in.
Note: Enlargements of receptacles show protective covers removed
for identification purposes only. Never remove protective covers.
Ref. Description Ref. Description
a Main circuit breaker - 10 amps
b1 Schuko IP44 (CEE 7) receptacle
230V, 16 Amp
b2 CEE receptacle IP44 2P+E
230V, 16 Amp
b3 Swiss IP44 receptacle
230V, 16 Amp
b4 French IP44 receptacle
230V, 16 Amp
wc_
g
r001251
ab1 b2
b3 b4