Operator’s Manual Portable Generator GP 2500A EN 5200003184 5 2 0 0 01 0 0 0512 3 1 8 4
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.
Foreword 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).
Foreword Manufacturer’s This manual contains references to approved parts, attachments, and modificaapproval 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.
GP 2500A 1 Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 1.5 2 Table of Contents Signal Words Used in this Manual ....................................................... 7 Machine Description and Intended Use ............................................... 8 Operating Safety .................................................................................. 9 Operator Safety while Using Internal Combustion Engines ............... 12 Service Safety ..................................................
Table of Contents 5 GP 2500A Maintenance 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 31 Maintaining the Emission Control System ...........................................31 Periodic Maintenance Schedule ..........................................................31 Engine Oil ............................................................................................32 Servicing the Air Cleaner .....................................................................33 Spark Plug ...............................
GP 2500 1 1.1 Safety Information Safety Information 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. This is the safety alert symbol. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.
Safety Information 1.2 GP 2500 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.
GP 2500 1.3 Safety Information Operating Safety 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. f NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Safety Information Safety devices, controls, and attachments GP 2500 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.
GP 2500 Transporting and installing the machine Safety Information General Safety Generator vibration After use = Cleaning 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.
Safety Information 1.4 GP 2500 Operator Safety while Using Internal Combustion Engines 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. f Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. DANGER f Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO).
GP 2500 1.5 Safety Information 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.
Safety Information Cleaning GP 2500 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.
GP 2500A 2 2.1 Labels Labels Label Locations C A E C F D G K H J B B wc_gr008555 2.2 Label Meanings Wacker Neuson machines use international pictorial labels where needed. These labels are described below. A DANGER! Read the Operator’s Manual. No sparks, flames, or burning objects near the machine. Stop the engine before refueling. B WARNING! Hot surface wc_si000611gb.
Labels GP 2500A 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. 16 wc_si000611gb.
GP 2500A Labels 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. E DANGER 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.
Labels GP 2500A G Important Emissions Information This equipment meets California EVP emission regulations for small off-road engines. H 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 nameplate so it will be available should the nameplate become lost or damaged.
GP 2500A 3 Lifting and Transporting 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.
Operation 4 4.1 GP 2500A Operation Preparing the Machine for First Use 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. f NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas.
GP 2500A 4.2 Operation Refueling the Machine Requirements • Machine shut down • Engine cool • Machine/fuel tank level with the ground • Fresh, clean fuel supply Procedure Perform the procedure below to refuel the machine. WARNING Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns. f Keep all sources of ignition away from the machine while refueling. f Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner.
Operation 4.3 GP 2500A 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.
GP 2500A 4.5 Operation 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.
Operation 4.6 GP 2500A Grounding the Generator Location A ground connection (a) is located on the generator frame. wc_gr000544 Function This ground connection is used for electrically grounding the generator when necessary to comply with the National Electrical Code and other federal, state, and local regulations. For grounding requirements in your area, consult with a qualified electrician, electrical inspector, or local agency having jurisdiction over electrical compliance. 4.
GP 2500A 4.8 Operation Use of Extension Cords WARNING Current When a long extension cord is used to connect an appliance or tool to the generator, a voltage loss occurs—the longer the cord, the greater the voltage loss. This results in less voltage being supplied to the appliance or tool and increases the amount of current draw or reduces performance. A heavier cord with a larger wire size will reduce the voltage loss.
Operation 4.9 GP 2500A Control Panel Ref. Description Ref. Description a GFI duplex receptacle—120V d GFI test button b Circuit breaker—20 Amp. e GFI reset button c Duplex receptacle—120V f Engine ON-OFF switch 26 wc_tx000447gb.
GP 2500A 4.10 Operation Ground Fault Interrupt (GFI / GFCI) The 120V, 20 Amp receptacle (a) is equipped with a ground fault circuit interrupt (GFI). The GFI shuts off the power to the receptacle when a ground fault occurs in the generator or to a piece of equipment attached to the generator. This GFI also protects the second 120V, 20A receptacle (c). The GFI should be tested for proper operation every time the generator is used. To test GFI: Start generator. Push TEST button (d) on receptacle in.
Operation 4.12 GP 2500A Before Starting DANGER f 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. 4.12.1 Read and understand the safety and operating labels and instructions at the beginning of this manual. 4.12.
GP 2500A 4.13 Operation Starting 4.13.1 Ensure that the generator is properly installed in an outdoor location. See Sections Installation and Operator Safety while using Internal Combustion Engines for installation warnings and safety guidelines. 4.13.2 Disconnect all loads from the generator. 4.13.3 Open the fuel valve (a1). Note: If the engine is cold, move the choke lever to the closed position (b2). If the engine is hot, set the choke to the open position (b1). 4.13.
Operation 4.15 GP 2500A Emergency Shutdown Procedure Procedure If a breakdown or accident occurs while the machine is operating, follow the procedure below: 4.15.1 Stop the engine. 4.15.2 Turn off the fuel supply. 4.15.3 Disconnect tools from the machine. 4.15.4 Allow the machine to cool. 4.15.5 Contact the rental yard or machine owner for further instructions. 30 wc_tx000447gb.
GP 2500A 5 5.1 Maintenance Maintenance Maintaining the Emission Control System Normal maintenance, replacement, or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a dealer/service center authorized by Wacker Neuson.
Maintenance 5.3 GP 2500A Engine Oil 5.3.1 Drain the oil while the engine is still warm. 5.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation. 5.3.3 Install the drain plug. 5.3.
GP 2500A 5.4 Maintenance Servicing the Air Cleaner Service the air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run the engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING To service: 5.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 5.4.
Maintenance 5.5 GP 2500A Spark Plug Clean or replace the spark plug as needed to ensure proper operation. Refer to your engine operator’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. WARNING Note: Refer to section “Technical Data” for the recommended spark plug type and the electrode gap setting. 5.5.1 Remove the spark plug and inspect it. 5.5.
GP 2500A 5.6 Maintenance Cleaning the Sediment Cup wc_tx000448gb.fm 5.6.1 Turn the fuel valve off. 5.6.2 Remove the sediment cup (a) and the O-ring (b). 5.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 5.6.4 Turn the fuel valve on and check for leaks.
Maintenance 5.7 GP 2500A Adjusting the Carburetor 5.7.1 Start the engine and allow it to warm up to operating temperature. 5.7.2 Set the pilot screw (a) two turns out. See Note. 5.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 5.7.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
GP 2500A 5.9 Maintenance Long-Term Storage Before storing the generator for a long period of time: 5.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 5.9.2 Disconnect the fuel line from the carburetor. Place the open end of the fuel line into a suitable container and open the fuel valve to drain the fuel from the tank. WARNING 5.10 Gasoline is extremely flammable. Drain the fuel tank in a wellventilated area.
GP 2500A 6 Troubleshooting Problem / Symptom Reason / Remedy If engine doesn't start, check that: • Engine switch is on "Start". • Fuel valves under fuel tank and on engine are open. • Fuel tank has fuel. • Choke lever is in correct position. Choke should be closed when starting a cold engine. • All loads are disconnected from generator. • Spark plug is in good condition. • Spark plug cap is tight. • Engine oil level is adequate.
GP 2500A 7 Technical Data Technical Data 7.1 Generator Item No. GP 2500A Generator Maximum Output W 2500 Continuous Output W 2250 Type AC Voltages Available Frequency Single voltage, single phase, Auto voltage regulator system 120 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V GFI duplex 125V duplex amp amp 20 20 Main Circuit Breaker amp 20 LxWxH mm (in.) 565 x 435 x 445 (22.3 x 17 x 17.5) Weight (dry) Kg (lbs.) 44.5 (98) wc_td000190gb.
Technical Data 7.2 GP 2500A Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. GP 2500A Item No. Engine Engine Make Honda Engine Model GX 160 RT 2 VWWN Maximum rated power at rated speed 3.6 (4.8) @ 3600 rpm kW (Hp) Spark Plug Electrode Gap BPR6ES / W20EPR-U 0.7–0.8 (0.028–0.031) mm (in.
GP 2500A Technical Data Notes: wc_td000190gb.
Schematics 8 GP 2500A Schematics 8.1 Wire Colors Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue 8.2 Electrical Schematic Components Ref. Description A Generator Ref. Description Ref. Description Ref. B Control Box C Ref.
GP 2500A 8.3 Schematics Electrical Schematic 8 11 9 10 wc_tx001860gb.
Schematics GP 2500A 44 wc_tx001860gb.
Emission Control Systems Information and Warranty 9 Emission Control Systems Information and Warranty The Emission Control Warranty and associated information is valid only for the U.S.A., its territories, and Canada. 9.1 Emission Control System Background Information Introduction Wacker Neuson spark-ignited engines/equipment must conform with applicable Environmental Protection Agency (EPA) and the State of California emissions regulations.
Emission Control Systems Information and Warranty Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny a warranty claim. Among those acts that constitute tampering are: Removing or altering of any part of the air intake, fuel, or exhaust systems. Altering or defeating the speed-adjusting mechanism causing the engine to operate outside its design parameters. 9.
Emission Control Systems Information and Warranty the part in question is not related to the reason the engine/equipment requires repair, the claim will not be denied. For the components listed in the following table, an authorized Wacker Neuson dealer/service center will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine/equipment complies with the applicable EPA regulations.
Emission Control Systems Information and Warranty coverage solely for the lack of receipts or for the failure to ensure the performance of all scheduled maintenance. Normal maintenance, replacement, or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by an authorized Wacker Neuson dealer/ service center.
Emission Control Systems Information and Warranty 9.4 California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Wacker Neuson Sales Americas, LLC, N92 W15000 Anthony Avenue, Menomonee Falls, WI 53051, (hereinafter “Wacker Neuson”), are pleased to explain the evaporative emission control system (EECS) warranty on your model year 2008 and later portable generator.
Emission Control Systems Information and Warranty 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.
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, D-80809 München, Tel.: +49-(0)89-3 54 02-0 Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI 53051 Tel. : (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
