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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.
GP 2500A Table of Contents 1. Foreword 2. California Evaporative Emission Control Warranty Statement 4 3. Safety Information 3.1 3.2 3.3 3.4 3.5 3.6 4. 6 Laws Pertaining to Spark Arresters ...................................................... 6 Operating Safety .................................................................................. 7 Operator Safety while using Internal Combustion Engines .................. 9 Service Safety ..............................................................
Table of Contents 6. GP 2500A Maintenance 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 26 Engine Maintenance ............................................................................26 Periodic Maintenance Schedule ..........................................................26 Engine Oil ............................................................................................27 Servicing Air Cleaner ...........................................................................28 Spark Plug .
CALIFORNIA Proposition 65 Warning: WARNING 1. 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 model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual.
California Evaporative Emission Control Warranty Statement 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.
California Evaporative Emission Control Warranty Statement 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.
Safety Information 3. GP 2500A 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.
GP 2500A 3.2 Operating Safety DANGER WARNING wc_si000149gb.fm Safety Information 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.
Safety Information GP 2500A 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 noncombustible, level surface. the generator on a firm, 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.
GP 2500A 3.3 Operator Safety while using Internal Combustion Engines DANGER wc_si000149gb.fm Safety Information 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.
Safety Information 3.4 GP 2500A 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. 3.4.
GP 2500A Label Locations GND wc_si000149gb.fm 11 88897 3.
Safety Information 3.6 GP 2500A 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.
GP 2500A Safety Information Label Meaning GND 88897 Electrical ground 1 2 3 4 5 6 1 2 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. wc_si000149gb.
Safety Information Label GP 2500A Meaning 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.
GP 2500A 4. Technical Data Technical Data 4.1 Generator Item No. GP 2500A 0620009 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_td000149gb.
Technical Data 4.2 GP 2500A Engine Item No. GP 2500A 0620009 Engine Engine Make Honda Engine Model GX 160 K1VX Rated Power 4.1 (5.5) kW (Hp) Spark Plug Electrode Gap BPR6ES / W20EPR-U 0.7–0.8 (0.028–0.031) mm (in.) Operating Speed (Max.) rpm 3600 Air Cleaner type Dry type with oil-wetted foam pre-cleaner Engine Lubrication Engine Oil Capacity Fuel Fuel Tank Capacity Fuel Consumption Running Time - full load wc_td000149gb.fm oil grade SAE 10W30 service class SF, SE, SD, or SC 0.6 (0.
GP 2500A 5. Operation 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.
Operation 5.2 GP 2500A 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.
GP 2500A 5.4 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 5.5 GP 2500A Grounding the Generator See Graphic: wc_gr000544 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. = w c _ g r0 0 0 5 4 4 5.6 Operating Heavy Loads Limit operations requiring the maximum rated output of 2500 Watts to 20–30 minutes.
GP 2500A 5.7 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 5.8 GP 2500A Control Panel—GP 2500A See Graphic: wc_gr002324 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 wc_tx000447gb.
GP 2500A 5.9 Operation Ground Fault Interrupt (GFI) See Graphic: wc_gr002324 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.
Operation GP 2500A 5.11 Before Starting 5.11.1 Read and understand the safety and operating labels and instructions at the beginning of this manual 5.11.2 Inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 5.11.3 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 5.12 To Start See Graphic: wc_gr002818 5.12.1 Disconnect all loads from the generator. 5.12.2 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). 5.12.3 Turn the engine switch to "ON" (c1). 5.12.4 Pull the starter rope (d). Note: If the oil level in the engine is low, the engine will not start. If this happens, check the oil level and add oil as needed. 5.12.
Maintenance 6. GP 2500A Maintenance 6.1 Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to the engine manufacturer’s Operator’s Manual for additional information on engine maintenance. 6.2 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.
GP 2500A 6.3 Maintenance Engine Oil See Graphic: wc_gr000022 6.3.1 Drain the oil while the engine is still warm. 6.3.2 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. wc_tx000448gb.fm 6.3.3 Install the drain plug. 6.3.
Maintenance 6.4 GP 2500A Servicing Air Cleaner See Graphic: wc_gr002815 Service the air cleaner frequently to prevent carburetor malfunction. CAUTION: 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: 6.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 6.4.
GP 2500A 6.5 Maintenance Spark Plug See Graphic: wc_gr000028 Clean or replace the spark plug as needed to ensure proper operation. Refer to the engine owner’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 the Technical Data for the recommended spark plug type and the electrode gap setting. 6.5.1 Remove the spark plug and inspect it. 6.5.
Maintenance 6.6 GP 2500A Cleaning the Sediment Cup See Graphic: wc_gr000029 wc_tx000448gb.fm 6.6.1 Turn the fuel valve off. 6.6.2 Remove the sediment cup (a) and the O-ring (b). 6.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 6.6.4 Turn the fuel valve on and check for leaks.
GP 2500A 6.7 Maintenance Carburetor Adjustment See Graphic: wc_gr000032 6.7.1 Start the engine and allow it to warm up to operating temperature. 6.7.2 Set the pilot screw (a) two turns out. See Note. 6.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 6.7.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
Maintenance 6.8 GP 2500A Adjusting Engine Speed See Graphic: wc_gr000032 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 6.10 Transport Let the engine cool before transporting the generator or storing indoors, to avoid burns or fire hazards. WARNING When transporting the generator: 6.10.1 Turn the engine fuel valve to the OFF position. 6.10.2 Position the generator level to prevent fuel from spilling. 6.10.3 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 6.12 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 6.13 Wiring Schematic See Graphic: wc_gr002325 Ref. Description A Generator Ref. Description Ref. Description Ref. B Control Box C Ref.
GP 2500A wc_tx000448gb.
Maintenance GP 2500A Notes wc_tx000448gb.
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel.
