0163727en 0509 Generator GP 2500A OPERATOR’S MANUAL 0 1 6 3 7 2 7 E N 005
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.
WARNING 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. 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.
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GP 2500A 1 Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 1.5 1.6 2 Table of Contents Laws Pertaining to Spark Arresters ...................................................... 7 Operating Safety .................................................................................. 8 Operator Safety while using Internal Combustion Engines ................ 10 Service Safety .................................................................................... 11 Label Locations ...........................
Table of Contents 3 Maintenance 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 4 GP 2500A 26 Engine Maintenance ............................................................................26 Periodic Maintenance Schedule ..........................................................26 Engine Oil ............................................................................................27 Servicing Air Cleaner ...........................................................................
GP 2500A 1. Safety Information 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.
Safety Information 1.2 GP 2500A Operating Safety DANGER DANGER WARNING 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.
GP 2500A Safety Information 1.2.8 NEVER allow untrained personnel to operate or service the generator. The generator set should be set up by a certified electrician. 1.2.9 NEVER stand on the machine. 1.2.10 DO NOT stand under the machine while it is being hoisted or moved. 1.2.11 DO NOT attach equipment to the machine when it is suspended. 1.2.12 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. 1.2.
Safety Information 1.3 GP 2500A Operator Safety while using Internal Combustion Engines WARNING 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. 1.3.1 NEVER use this generator inside a home or garage, EVEN IF doors and windows are open.
GP 2500A 1.4 Safety Information Service Safety WARNING 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. 1.4.
Safety Information Label Locations GND 1 2 3 4 5 6 1 2 12 88897 1.
GP 2500A 1.6 Safety Information Safety and Operating Labels Wacker Neuson 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. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide.
Safety Information GP 2500A Label Meaning WARNING! To reduce the risk of electrical shock and arc flash, 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 Label Safety Information Meaning Open the fuel flow valve. Close the choke. 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.
Safety Information Label GP 2500A Meaning This equipment does not meet 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.
GP 2500A 2. Operation Operation 2.1 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.
Operation 2.2 GP 2500A 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. DANGER DANGER Using a generator indoors CAN KILL YOU IN MINUTES.
GP 2500A 2.3 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 2.4 GP 2500A Grounding the Generator A ground connection (a) is located on the generator frame. For proper operating safety, this ground terminal must be connected to a good ground source. This ground connection must comply with National Electrical Code standards, and state and local regulations. wc_gr000544 2.5 Operating Heavy Loads Limit operations requiring the maximum rated output of 2600 Watts to 20–30 minutes.
GP 2500A 2.6 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 2.7 Ref. GP 2500A Control Panel Description Ref. Description a GFI duplex receptacle—120V d GFI test button b Circuit breaker—20 Amp.
GP 2500A 2.8 Operation Ground Fault Interrupt (GFI) 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 GP 2500A 2.10 Before Starting 2.10.1 Read and understand the safety and operating labels and instructions at the beginning of this manual. 2.10.2 Inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 2.10.3 Check: • oil level in engine • fuel level • condition of air cleaner • tightness of external fasteners • condition of fuel lines. Note: The engine is equipped with an oil alert system.
GP 2500A Operation 2.11 To Start 2.11.1 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. 2.11.2 Disconnect all loads from the generator. 2.11.3 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). 2.11.
Maintenance 3. GP 2500A Maintenance 3.1 Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to your engine operator’s manual for additional information on engine maintenance. 3.2 Periodic Maintenance Schedule Daily before starting Check the fuel level. Check the engine oil level. Inspect the air filter. Replace as needed. Check external hardware. After first 20 hrs. Clean the air cleaner element.* Every 50 hrs. Every 100 hrs. Every 300 hrs.
GP 2500A 3.3 Maintenance Engine Oil 3.3.1 Drain the oil while the engine is still warm. 3.3.2 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. 3.3.3 Install the drain plug. 3.3.
Maintenance 3.4 GP 2500A Servicing 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: 3.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 3.4.
GP 2500A 3.5 Maintenance 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. 3.5.1 Remove the spark plug and inspect it. 3.5.
Maintenance 3.6 GP 2500A Cleaning the Sediment Cup 3.6.1 Turn the fuel valve off. 3.6.2 Remove the sediment cup (a) and the O-ring (b). 3.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 3.6.4 Turn the fuel valve on and check for leaks.
GP 2500A 3.7 Maintenance Carburetor Adjustment 3.7.1 Start the engine and allow it to warm up to operating temperature. 3.7.2 Set the pilot screw (a) two turns out. See Note. 3.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 3.7.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
Maintenance 3.8 GP 2500A Adjusting Engine Speed Generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constant speed. There is no throttle control. To set the engine to the proper speed: Turn the speed adjusting screw (b) in or out to obtain a no-load speed. See Technical Data.
GP 2500A Maintenance 3.10 Transport Let the engine cool before transporting the generator or storing it indoors, to avoid burns or fire hazards. WARNING When transporting the generator: 3.10.1 Turn the engine fuel valve to the OFF position. 3.10.2 Position the generator level to prevent fuel from spilling. 3.10.3 Secure the generator by tying it down with a suitable rope. WARNING When transporting the machine by hand, be sure to employ manpower commensurate with the weight of the machine.
Maintenance GP 2500A 3.12 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 3.13 Wiring Schematic Ref. Description A Generator Ref. Description Ref. Description Ref. B Control Box C Ref.
GP 2500A Maintenance 8 11 9 10 35
Technical Data 4. GP 2500A Technical Data 4.1 Generator Item No. GP 2500A 0620128 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.
GP 2500A 4.2 Technical Data Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 2500A 0620128 Engine Engine Make Honda Engine Model GX 160 K1VX 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.
Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · 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.
