Operator's manual

Portable Generator
GV
2500A

Model GV 2500A

Document 5100004228

Issue 04.2016

Version 04

Language en
 Copyright © 2016 Wacker Neuson Produktion GmbH & Co. KG
Printed in Germany
All rights are reserved, in particular the world-wide applicable copyright, right of duplication
and right of distribution.
This document may only be used by the recipient for the intended purpose. The document
may not be reproduced entirely or partially, or translated into any other language.
Reproduction or translation, even extracts thereof, only with written approval of Wacker
Neuson Produktion GmbH & Co. KG.
Any breach of the statutory provisions, in particular the protection of copyright, will lead to
civil and criminal prosecution.
Wacker Neuson Produktion GmbH & Co. KGis constantly working on the improvement of its
products as part of the technical further development. Therefore, we reserve the right to
make changes to the illustrations and descriptions in this documentation without incurring
any obligation to make changes to machines already delivered.
Errors excepted.
The machine on the cover may have special equipment (options).

Manufacturer
Wacker Neuson Produktion GmbH & Co. KG
Preußenstraße 41
80809 München
www.wackerneuson.com
Tel.: +49-(0)89-354 02-0
Fax: +49-(0)89-354 02-390

Translation of the original operator's manual in German

1 Foreword .................................................................................................................... 5
2 Introduction ............................................................................................................... 6
2.1 Means of representation for this operator's manual ....................................................... 6
2.2 Wacker Neuson representative...................................................................................... 7
2.3 Described machine types............................................................................................... 7
2.4 Identification of the machine .......................................................................................... 7
3 Safety Regulations .................................................................................................... 8
3.1 Safety information in this operator's manual .................................................................. 8
3.2 Description and purpose of the machine........................................................................ 9
3.3 Operational safety ........................................................................................................ 10
3.4 Operator qualifications ................................................................................................. 11
3.5 Safety when using combustion engines....................................................................... 14
3.6 Service safety............................................................................................................... 15
4 Safety and information labels ................................................................................ 17
5 Standard package ................................................................................................... 19
6 Lifting and transporting ......................................................................................... 20
7 Operation ................................................................................................................. 21
7.1 Prepare the machine for first-time application.............................................................. 21
7.2 Use and input current................................................................................................... 22
7.3 Performance loss with high altitude application ........................................................... 23
7.4 Heavy duty operation ................................................................................................... 24
7.5 Installation .................................................................................................................... 24
7.6 Use of extension cables ............................................................................................... 25
7.7 Before starting.............................................................................................................. 28
7.8 Starting......................................................................................................................... 28
7.9 Stopping ....................................................................................................................... 29
7.10 Emergency stop procedure .......................................................................................... 29
8 Maintenance ............................................................................................................ 30
8.1 Period maintenance schedule...................................................................................... 30
8.2 Engine oil ..................................................................................................................... 31
8.3 Air cleaner maintenance .............................................................................................. 32
8.4 Spark plug .................................................................................................................... 33
8.5 Setting the engine speed ............................................................................................. 34
8.6 Carburetor setting ........................................................................................................ 35
8.7 Long-term storage........................................................................................................ 35

5100004228IVZ.fm 3
9 Basic troubleshooting ............................................................................................ 36
10 Disposal ................................................................................................................... 37
10.1 Disposal of waste electrical and electronic equipment ................................................. 37
11 Technical data ......................................................................................................... 38
11.1 GV 2500 ....................................................................................................................... 38
11.2 Combustion engine....................................................................................................... 40
12 Glossary ................................................................................................................... 41
13 Diagram .................................................................................................................... 43
13.1 GV 2500A - Wiring diagram.......................................................................................... 43
EC declaration of conformity ................................................................................. 45

4 5100004228IVZ.fm
 1 Foreword

1 Foreword
This operator's manual contains important information and procedures for the
safe, proper and economic operation of this Wacker Neuson machine. Carefully
reading, understanding and observing is an aid to avoiding hazards, repair costs
and downtime, and therefore to increasing the availability and service life of the
machine.

This operator's manual is not a manual for extensive maintenance or repair work.
Such work should be carried out by Wacker Neuson service or by technically
trained personnel. The Wacker Neuson machine should be operated and main-
tained in accordance with this operator's manual. An improper operation or im-
proper maintenance can pose dangers. Therefore, the operator's manual should
be constantly available at the location of the machine.

Defective machine parts must be exchanged immediately!

If you have any questions concerning the operation or maintenance, a Wacker
Neuson contact person is always available.

100_0000_0002.fm 5
2 Introduction

2 Introduction

2.1 Means of representation for this operator's manual

Warning symbols
This operator's manual contains safety information of the categories:
DANGER, WARNING, CAUTION, NOTICE.
They should be followed to prevent danger to life and limb of the operator or da-
mage to equipment and exclude improper service.

GEFAHR
This warning notice indicates immediate hazards that result in serious injury or
even death.
 Danger can be avoided by the following the actions mentioned.

WARNUNG
This warning notice indicates possible hazards that can result in serious injury
or even death.
 Danger can be avoided by the following the actions mentioned.

VORSICHT
This warning notice indicates possible hazards that can result in minor injury.
 Danger can be avoided by the following the actions mentioned.

ACHTUNG
This warning notice indicates possible hazards that can result in material dama-
ge.
 Danger can be avoided by the following the actions mentioned.

Notes

Hinweis: Complementary information will be displayed here.

6 100_0000_0003.fm
 2 Introduction

Instructions
 This symbol indicates there is something for you to do.
1. Numbered instructions indicate that you have to carry out something in a de-
fined sequence.
 This symbol is used for lists.

2.2 Wacker Neuson representative

Depending on your country, your Wacker Neuson representative is your Wacker

Neuson service, your Wacker Neuson affiliate or your Wacker Neuson dealer.
You can find the addresses in the Internet at www.wackerneuson.com.
The address of the manufacturer is located at the beginning of this operator's
manual.

2.3 Described machine types

This operator's manual is valid for different machine types from a product range.
Therefore some figures can differ from the actual appearance of your machine.
It is also possible that the descriptions include components which are not a part
of your machine.
Details for the described machine types can be found in the chapter Technical
data.

2.4 Identification of the machine

Nameplate data

The nameplate lists information that uniquely identifies your machine. This infor-
mation is needed to order spare parts and when requesting additional technical
information.
 Enter the information of your machine into the following table:

Designation Your information

Group and type
Construction year
Machine no.
Version no.
Item no.

100_0000_0003.fm 7
3 Safety Regulations

3 Safety Regulations

3.1 Safety information in this operator's manual

This operator's manual contains safety regulations in the categories:

DANGER, WARNING, CAUTION, NOTE and COMMENT. These are to
be followed in order to reduce the danger of injury, damage to equipment
or improper service.
This is a safety warning symbol that warns against possible danger of injury.
 Comply with all safety regulations that follow this warning symbol.

GEFAHR
DANGER indicates a hazardous situation that leads to serious injury or death if
this warning is not observed.
 In order to avoid fatal accidents and serious injuries, observe all safety inst-
ructions precisely that follow this signal word.

WARNUNG
WARNING indicates a hazardous situation that can lead to serious injury or de-
ath if this warning is not observed.
 In order to avoid possible fatal accidents and serious injuries, observe all sa-
fety instructions precisely that follow this signal word.

VORSICHT
CAUTION indicates a hazardous situation that can lead to minor to moderate in-
jury if this warning is not observed.
 In order to avoid possible minor or moderate injuries, observe all safety inst-
ructions precisely that follow
this signal word.

NOTE: When this word appears without a safety warning symbol, NOTE indica-
tes a hazardous situation that can lead to damage if not observed.
Comment: A comment contains additional important information about a work
process.

8 100_0402_si_0003.fm
 3 Safety Regulations

3.2 Description and purpose of the machine

This machine is a portable power source. The portable generator from

Wacker Neuson consists of a steel pipe frame, which includes a fuel tank, a
gasoline engine, a control panel and an electrical alternator. The control panel
contains controls and bushings. When the engine is running, the generator con-
verts the mechanical energy into electrical energy. The operator connects elec-
tronic loads to the mains sockets.
This machine is used for the electric power supply of connected electronic loads.
See the product specifications for output voltage and frequency of the generator
as well as the maximum power limitation of this generator.
This machine was designed and built exclusively for the aforementioned purpo-
se. Use of the machine for any other purpose could permanently damage the
machine or cause serious injury to the operator or other persons in the vicinity.
Machine damage due to misuse is not covered by the warranty.
The following practices are considered misuse:
 Connection to an electronic load whose voltage and frequency are not com-
patible with the generator output
 Overloading the generator with a load that takes too much power during con-
tinuous operation or when starting
 Operating the generator in a manner that is inconsistent with the national,
statewide and local standards and regulations
 Use of the machine as a ladder, support or working surface
 Operation of the machine to carry or transport people or equipment
 Operation of the machine outside of the plant specifications
 Operation of the machine contrary to warning notices attached to the machi-
ne and contained in the operator's manual.
This machine was designed and built according to the latest global safety stan-
dards. In order to eliminate dangers as much as possible, it was technically de-
signed with great care and contains protective side plates and warning labels for
an increased safety of the operator. Additional risks may exist despite these pro-
tective measures. These are designated as residual risks. Possible residual risks
with this machine:
 Heat, noise, exhaust and carbon monoxide from the engine
 Risk of fire due to incorrect refueling procedure
 Gasoline or gasoline vapors
 Electric shock and arc discharge
 Injury due to incorrect hoisting technology
For your own protection and the protection of other people, make sure that the
safety instructions in this manual have been closely read and understood before
starting the machine.

100_0402_si_0003.fm 9
3 Safety Regulations

3.3 Operational safety

GEFAHR
Carbon monoxide.
The application of a generator in buildings can
LEAD TO DEATH WITHIN MINUTES. The exhaust fumes from the generator
contain carbon monoxide (CO). This is an invisible odorless poison. If the
exhaust fumes of the generator can be smelled, CO is being inhaled. Even if no
exhaust fumes can be smelled, CO could still be being inhaled.
 NEVER use the generator in buildings, garages, crawl spaces or other parti-
ally enclosed areas. Carbon monoxide can build up to deadly levels in these
areas. A fan or open window does NOT provide sufficient fresh air.
 ONLY use generators outdoors and far away from windows, doors and aera-
tion. These openings can draw in generator exhaust fumes.
 CO can penetrate into a home, even if a generator is used properly. AL-
WAYS use a battery-powered or battery-backup CO alarm in the home.
 IMMEDIATELY get to fresh air if you feel unwell, dizzy or weak after using
the generator. Consult a physician. It could be carbon monoxide poisoning.

WARNUNG
Electric shock or risk of fire or explosion. Incorrect connection of the generator
to a building's mains supply can lead to current being lead from the generator
back into the power supply system. This can cause electric shock, serious injury
or death of the worker in the public utility company!
 The following connection prerequisites are to be met.

10 100_0402_si_0003.fm
 3 Safety Regulations

Connection prerequisites
The following prerequisites are to be met to connect the generator to the buil-
ding's mains supply.
 The generator must meet the prerequisites with regard to performance, vol-
tage and frequency of the equipment.
 The generator must be disconnected from the electric power supply.
 Connections from the generator to the power supply system of a building
must be established by a licensed electrician.
 The electrical connections must meet all laws and electrical regulations.

WARNUNG
Prerequisites for safe operation are familiarity with the machine and proper trai-
ning. Machines that are incorrectly operated or that are operated by un-
trained personnel may pose a danger. Read through the operating inst-
ructions in this manual and in the engine manual to make yourself famili-
ar with the job and the proper use of the operator's controls. Inexperien-
ced operators must be instructed by personnel who are familiar with the
machine before they are allowed to operate the machine.

3.4 Operator qualifications

Only trained personnel may start, operate and switch off the machine.
The personnel must also have the following qualifications:
 be trained in the correct operation of the machine
 be familiar with the necessary safety devices
Access to the machine and operation of the machine is not permitted for:
 Children
 People under the influence of alcohol, drugs or medication

Personal Protective Equipment (PPE)

The following personal protective clothing (PPE) is to be worn when operating
this machine:
 Close-fitting work clothes that do not impede movement
 Safety glasses with protective sides
 Ear protection
 Work shoes or boots with toe protection

100_0402_si_0003.fm 11
3 Safety Regulations

 NEVER use generator near open containers of fuel, paint or other flam-
mable liquids.
 NEVER touch the generator or tools connected to it if you have wet
hands.
 NEVER use damaged power cables. Electric shock and major machine
damage could occur.
 NEVER place power cable below the generator or on vibrating or hot
parts.
 NEVER cover hot or running generator.
 NEVER overload generator. The total amperage of the parts connected
to the generator may not exceed the output limit.
 NEVER operate the machine in snow, rain or standing water.
 NEVER allow untrained personnel to operate or maintain the generator.
Familiarize yourself with the operation and shutdown before starting the
generator.
 ALWAYS store the machine properly when not in use. Store the machine
in a clean dry place and keep it out of reach of children.
 ALWAYS make sure that the machine is stable and cannot tip, roll, slide
or fall during operation.
 ALWAYS transport the generator in an upright position.
 ALWAYS keep at least one meter distance from facilities, buildings or
other machines while operating the machine.
 ALWAYS keep the area immediately around and under the machine cle-
an, tidy and free of grime and flammable materials. Check that there is
also no grime above the machine that could fall onto or into the machine
or the exhaust area.
 ALWAYS keep all tools, power cables and other loose objects away from
the generator before starting.
 Do NOT ground this generator.
 If more than one electronic device is connected to the generator, the ad-
ditional connected electronic equipment must be connected to the gene-
rator via an isolating transformer or a suitable FI switch (PRCD), whereby
each additional electronic device must be operated via a separate isola-
ting transformer or PRCD.

12 100_0402_si_0003.fm
 3 Safety Regulations

Generator vibration
Generators vibrate during normal operation. Check during and after use of the
generator whether the generator or the extension cord and power cable show da-
mage due to vibration.
 Repair any damage as needed or replace the parts affected.
 Do not use any plugs or cables that show signs of damage, such as damaged
or cracked insulation or blades.

100_0402_si_0003.fm 13
3 Safety Regulations

3.5 Safety when using combustion engines

WARNUNG
Combustion engines pose a particular danger during operation and when refue-
ling. Failure to follow the warning notices and safety standards can lead to seri-
ous injury or death.
 Read and always observe the warning notices in the operator's manual of
the engine and the safety instructions below.

GEFAHR
Carbon monoxide. Use of the generator in buildings can LEAD TO DEATH WI-
THIN MINUTES. The exhaust fumes from the generator contain carbon monoxi-
de (CO). This is an invisible odorless poison. If the exhaust fumes of the gene-
rator can be smelled, CO is being inhaled. Even if no exhaust fumes can be
smelled, CO could still be being inhaled.

Operational safety
When running the engine:
 Keep the area around the exhaust pipe free of flammable materials.
 Inspect the fuel lines and fuel tank for leaks and cracks before starting the en-
gine. Do not operate the machine if there are leaks or if the fuel lines are loo-
se.
When running the engine:
 Do not smoke while operating the machine.
 Do not operate the engine near sparks or open flames.
 Do not touch the engine or the muffler while the engine is running or shortly
after switching the engine off.
 Do not operate the machine with a loose or missing fuel cap.
 Do not start the engine if fuel has been spilled or there is an odor of gas. Move
the machine away from the spilled fuel and wipe away the spilled fuel before
starting.

14 100_0402_si_0003.fm
 3 Safety Regulations

Safety when refueling

When refueling the machine:
 Immediately wipe away any spilled fuel.
 Fill the fuel tank in a well-ventilated area.
 Reattach the fuel tank cap after refueling.
 Do not smoke.
 Do not refuel hot or running engines.
 Do not refuel the engine near sparks or open flames.
 Do not refuel the machine while it is on plastic-coated surfaces of pick-ups.
Static electricity can ignite the fuel or fuel vapors.

3.6 Service safety

WARNUNG
Carelessly maintained machines can pose dangers! Regular maintenance
and occasional repairs are necessary to ensure the safe and correct fun-
ctioning over longer time periods. If problems should occur with the ge-
nerator or while the machine is being maintained, always attach a "DO
NOT START" sign to the control panel in order to alert others of this.

Personal Protective Equipment (PPE)

Wear the following personal protective equipment during maintenance or repair
work:
 Close-fitting work clothes that do not impede movement
 Safety glasses with protective sides
 Ear protection
 Work shoes or boots with toe protection
Additional notes before operating the machine:
 Tie up long hair.
 Take off all jewelry (including rings)

100_0402_si_0003.fm 15
3 Safety Regulations

 Do NOT use any gasoline or other types of fuel or flammable solvents to cle-
an the machine parts, especially not in closed areas. The vapors from fuels
and solvents may explode.
 NEVER operate equipment without protective devices or with damaged pro-
tective devices.
 NEVER modify the machine without written approval from the manufacturer.
 NEVER allow water to collect at the bottom of the generator. If water should
collect, remove the generator and allow it to dry thoroughly before main-
taining.
 NEVER maintain the machine with wet clothing or wet skin.
 NEVER have the machine serviced by untrained personnel. Electronic ele-
ments of this machine should only be maintained by qualified electricians.
 ALWAYS keep the machine clean and ensure that the labels are legible.
Replace all missing and hard-to-read labels. The labels contain important
operating instructions and warn against dangers.
 ALWAYS reattach protective devices and safety equipment to the unit after
repair and maintenance.
 ALWAYS allow the engine to cool completely before transport.
 ALWAYS watch out for the rotating parts of the generator and engine and
keep hands, feet and loose clothing parts away from these rotating parts.
 ALWAYS switch the engine off before maintenance. Disconnect the negative
connection of the battery on machines with electric starters.
 ALWAYS keep fuel lines in a good condition and connected correctly. Lea-
king fuel and gases are highly explosive.
 If spare parts are required for this machine, only use parts from
Wacker Neuson or parts that match the original exactly in terms of dimensi-
ons, model, intensity and material.

16 100_0402_si_0003.fm
 4 Safety and information labels

4 Safety and information labels

There are labels on your equipment that contain important information and safety
instructions.
 Keep all labels legible.
 Replace missing or illegible labels.
The item numbers on the labels can be found in the parts book.

Item Label Description

1 Guaranteed sound power level.

2 DANGER!
Danger of suffocation.
 Engines give off carbon monoxide.
 Do not run the machine indoors or in
enclosed areas.
 NEVER operate in houses or garages,
EVEN IF doors and windows are open.
 Only use OUTDOORS and away from
windows, doors and aeration.
 Read through the operator's manual.
 No sparks, flames or burning objects
are permitted near the machine.
 Stop the engine before refueling.

3 Warning against hot surface.

4 Warning against hot surface.

PE = Potential grounding - Connect cable
from grounding rod here.
WARNING!
Electric shock will cause serious injury or
death.

100_0402_ls_0004.fm 17
4 Safety and information labels

Item Label Description

5 When connecting more than one piece of

electronic equipment,
 special precautions must be taken.
 Read through the operator's manual.

18 100_0402_ls_0004.fm
 5 Standard package

5 Standard package
The standard package includes:
 Equipment.
 Operator's manual.
 Parts book.
 General safety instructions.

100_0402_sd_0001.fm 19
6 Lifting and transporting

6 Lifting and transporting

Lifting the machine
This compact generator is heavy enough to cause injury in the event of incorrect
hoisting technology. Observe the following instructions to lift the generator:
 Do not try to lift the generator without help. Use suitable lifting bars e. g.
loops, chains, twisting hooks, ramps or car jacks.
 Make sure that the lifting bars are firmly attached and have sufficient carrying
capacity to safely lift or hold the generator.
 Pay attention to surrounding persons when lifting the generator.

Transporting the machine

Observe the following instructions when the generator is transported from and to
the construction site.
 Allow the engine to cool off before refueling the generator.
 Empty the fuel tank.
 Close the fuel cock.
 Firmly fasten the generator to the transport vehicle so that it does not slide or
tip over.
 Do not refuel the generator in or on the transport vehicle. Transport the
generator to the work location first and refuel the fuel tank there.

20 100_0402_tr_0001.fm
 7 Operation

7 Operation

7.1 Prepare the machine for first-time application

Prepare the machine for first-time application:

1. Ensure that all loose packaging material has been removed from the
machine.
2. Check the machine and its components for damage. Do not operate the
machine if you find visible damage! Ask the Wacker Neuson dealer for advice
at once.
3. Check whether all of the parts belonging to the machine have been delivered
and whether all loose parts and fasteners are present.
4. Now attach components that are not yet fastened.
5. Fill fluids as needed, including fuel, engine oil and battery acid.
6. Bring the machine to its site of operation.

GEFAHR
Carbon monoxide.
The application of a generator in buildings can
LEAD TO DEATH WITHIN MINUTES. The exhaust fumes from the generator
contain carbon monoxide (CO). This is an invisible odorless poison. If the ex-
haust fumes of the generator can be smelled, CO is being inhaled. Even if no
exhaust fumes can be smelled, CO could still be being inhaled.
 NEVER use the generator in buildings, garages, crawl spaces or other par-
tially enclosed areas. Carbon monoxide can build up to deadly levels in
these areas. A fan or open window does NOT provide sufficient fresh air.
 ONLY use generators outdoors and far away from windows, doors and aera-
tion. These openings can draw in generator exhaust fumes.
 CO can penetrate into a home, even if a generator is used properly. AL-
WAYS use a battery-powered or battery-backup CO alarm in the home.
 IMMEDIATELY get to fresh air if you feel unwell, dizzy or weak after using
the generator. Consult a physician. It could be carbon monoxide poisoning.

Use of gasoline / ethanol mixtures

This portable generator may not be used with gasoline / ethanol mixtures with
more than 15 % ethanol content.

100_0402_op_0002.fm 21
7 Operation

7.2 Use and input current

This generator is intended for the operation of single-phase 50 Hz electrical

equipment for 230 V.
NOTE: Do not exceed the performance limit of the generator, as this may lead to
damage of the generator or the tools.
See Technical Data.
Check the nameplates or labels of the tools and electronic equipment to be
connected to ensure that the current values conform with those of the generator.
Always inquire with the manufacturer if equipment is lacking the wattage.
Some electrical equipment requires more power to start than to operate. The
generator must be able to provide this power. Some equipment actually requires
more current than specified on the nameplate.
The "general input current when starting" information only applies as a general
guideline to assist you in determining the input current. In the event of questions,
the nearest Wacker Neuson service station will be able to assist you.
NOTE: Do not exceed the specified current limit at any plug receptacle.
NOTE: If a tool or electrical equipment should not reach the full RPM a few
seconds after starting, switch it off immediately in order to prevent damage.

General power requirements for starting

 White light bulbs and electronic goods, such as irons and hot plates, use a
resistor heating element and require the same amount of power during start-
up that is listed on the nameplate.
 When starting, neon and mercury lamps require 1.2-2 times the specified
wattage.
 Many electric motors and power tools use a large amount of power when
starting. The electrical supply required during start-up depends on the type of
motor and the intended application.
 When starting, most power tools require 1.2-3 times the specified wattage.
 Connection units, such as submersible pumps and air compressors, require
a large amount of power when starting, even up to 3-5 times the specified
wattage.
If the wattage of a tool or electrical equipment is not specified, this can be
calculated by multiplying the voltage requirements with the amperage
requirements.
Single-phase: VOLTS x AMPS = WATTS
Three-phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS

22 100_0402_op_0002.fm
 7 Operation

7.3 Performance loss with high altitude application

Generators run differently due to altitude and temperature differences.

Unmodified internal combustion engines have reduced performance at high
altitudes due to the lower air pressure. This means less performance and
therefore a reduced power exploitation. As soon as temperatures increase, an
engine runs less economically and electrical components have more resistance.
For every 500 meters above high altitudes of 1000 meters above sea level, the
performance of the generator is reduced by 3%. For outside temperatures above
40 degrees Celsius, the generator performance is reduced by 3% for every
additional 5 degrees. The tables shown help with the high altitude and outside
temperature performance devaluation. In order to determine the true generator
performance, it may be necessary to consider both the high altitude and
temperature devaluation factors.

Outside
temperature Devaluation Factor
°C

45 3% 0.97
50 6% 0.94
55 9% 0.91
60 12 % 0.88

High altitude
Devaluation Factor
m
1500 3% 0.97
2000 6% 0.94
2500 9% 0.91
3000 12 % 0.88
3500 15 % 0.85
4000 18 % 0.82

100_0402_op_0002.fm 23
7 Operation

VORSICHT
The mid-point (neutral) conductor of this equipment is not grounded. Do not
drive the PE rod into the ground under normal operating conditions.
Refer to the local regulations if the equipment is intended to power a
building or similar system.

wc_gr001286

For generator sets that are to supply a facility in a TT network, or if residual

current protection is required in the TT network, or if this equipment must be used
for additional protection due to conditions or regulations, only 30 mA residual
current protective switches may be used as protective devices. The 30 mA
residual current protective switch must be installed ON the generator set itself,
but at least on the nearest possible position in relation to the generator set. Only
with this type of installation is it allowed and necessary to establish the ground
connection of the generator framework via the point provided on the frame (see
ground symbol 5019).

7.4 Heavy duty operation

Do not operate this generator for longer than 20-30 minutes under maximum
electrical load rating. For continuous operation, do not exceed the continuous
(prime) power output of the generator. See technical data of the generator in this
operator's manual.

7.5 Installation

Set up the generator so it is protected from rain, snow or other forms of moisture.
The ground must be solid and level in order to prevent slipping or displacement.
Do not direct the engine exhaust to an area with people.
Both the work area as well as the components must be protected from all forms
of moisture.

24 100_0402_op_0002.fm
 7 Operation

7.6 Use of extension cables

A loss of power takes place when connecting electrical equipment or a

tool to the generator with an extension cable — the longer the cable,
the greater the loss of power. This means that less voltage is
conveyed to the electrical equipment and the input current is increased
or the performance is reduced. A larger extension cable diameter
reduces the loss of voltage.
NOTE: Operation of electrical equipment under low voltage may lead
to overheating.
The table serves as a guideline for selecting the correct cable size.
Only strong, rubber-covered cables can be used that correspond to
regulation IEC 245-4.

WARNUNG
Damaged cables may cause electric shock, which can lead to serious injury or
death. NEVER use worn, bare or frayed cables. Replace damaged
cables immediately.

Never exceed the cable's rated power.

Contact the cable manufacturer if you have questions about using the
cable.
Select the cable size from the table Minimum cross-section of
extension cables or calculate the minimum cross-section using the
graph Minimum cross-section of extension cables. The X-axis of the
graph stands for the values A x m (ampere x meter). The Y-axis stands
for the cross-section in mm². Multiply the steady state (operating)
current for the load in ampere (A) with the desired length of the
extension cable in meters (m). Now look for your result on the X-axis.
Go along the graph until you have found the point for your field of
application. Now read the recommended minimum cable length on the
Y-axis.
Example
For example, if there is a triple-phase application with 400 V of steady
state (operating) current available for the load at 15 A and the desired
extension cable length is 100 m, then:
15 A x 100 m = 1500 A x m.
1500 A x m = 2.5 mm².

100_0402_op_0002.fm 25
7 Operation

Table for extension cable minimum size

Extension cable minimum size

230V/1~/50Hz 400V/3~/50Hz

Length in m Length in m
Ampere-
performanc 25 50 100 200 25 50 100 200
e variable
Cross-section surface 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 ---

Diagram for extension cable minimum size

25 z
230V 50 H
16 1~
10 z
400V 50 H
mm 2 6 3~
4
2.5
1.5

0 1000 2000 3000 4000 5000 6000

Axm

26 100_0402_op_0002.fm
 7 Operation

0.1 Control panel

See blueprints: wc_gr001251
The circuit breaker protects the generator from significant overloads or
short circuits. If the circuit breaker reacts, shut down the engine
immediately and determine the cause by starting the engine again.
Check the electrical equipment and tools connected to the generator
and make sure that their input current does not exceed the
performance limit of the generator or the power limitations of the plug
receptacle.
The button will pop out if the circuit breaker responds Push the button
to reactivate the circuit breaker.
Comment: The protective covers are only missing in the enlarged plug
receptacles for reasons of identification. Never remove the protective
cover.

No. Description No. Description

a Main safety cutout - 10 A
b1 Schuko IP44 (CEE 7) plug recep- b2 CEE plug receptacle IP44 2P+E
tacle 230 V, 16 A
230 V, 16 A
b3 Switzerland IP44 plug receptacle b4 French IP44 plug receptacle
230 V, 16 A 230 V, 16 A

100_0402_op_0002.fm 27
7 Operation

7.7 Before starting

GEFAHR
Carbon monoxide.
The application of a generator in buildings can
LEAD TO DEATH WITHIN MINUTES. The exhaust fumes from the generator
contain carbon monoxide (CO). This is an invisible odorless poison. If the ex-
haust fumes of the generator can be smelled, CO is being inhaled. Even if no
exhaust fumes can be smelled, CO could still be being inhaled.
1. Read and understand the safety and operator's manual at the start of these
operating instructions.
2. Read and understand all statements of the safety and warning signs.
3. Check:
• Engine oil level.
• Fuel level.
• State of the air cleaner.
• Tight fit of the outer bracket.
• State of the fuel lines.

7.8 Starting

See blueprints: wc_gr001279

1. Disconnect all connections from the generator.
2. Open fuel shut-off valve (a1).
Comment: Close the choke if the engine is cold (b1). Open the choke if the
engine is warm (b2).
3. Put the engine switch in the "ON" position (c1).
4. Pull the starter rope (d).
Comment: Do not start the engine if the oil level is low. In this case, check the
engine oil level and top off if necessary.
5. Open the choke while the engine is warming up (b2).
6. Allow the engine to warm up for a few minutes before connecting electrical
equipment.

28 100_0402_op_0002.fm
 7 Operation

7.9 Stopping

See blueprints: wc_gr001279

1. Switch off all electrical equipment and tools and disconnect from the
generator.
2. Put the engine switch in the "OFF" position (c2).
3. Close the fuel shut-off valve.
Comment: To turn off quickly in cases of emergency, put the engine
switch in the "OFF" position (c2).

7.10 Emergency stop procedure

Procedure
In the case of an accident of a failure of the machine during operation,
the following procedure is to be applied:
1. Stop the engine.
2. Shut off the fuel supply.
3. Disconnect the tools from the machine.
4. Let the machine cool.
5. Please contact the machine rental or machine owner for additional manuals.

100_0402_op_0002.fm 29
8 Maintenance

8 Maintenance

8.1 Period maintenance schedule

The following table contains the basic maintenance jobs for the machine. Jobs
selected with a check mark can be performed by the operator. The jobs marked
with a small box require special training and special equipment.

Daily After the Every Every Every

before first 50 hours 100 300 hours
Opera- 20 hours hours
tion

Check the fuel level. 

Check the engine oil level. 
Check the air cleaner. Replace when nec-
essary.*

Check external fastening parts. 
Clean air cleaner elements.* 
Check shockmount for damage. 
Change the engine oil.*  

Check and clean spark plug. 

Check and adjust


valve interval.

Clean fuel tank.* 

Check the fuel line.


Replace when necessary.

* Clean more often in dusty areas.

30 100_0402_mt_0003.fm
 8 Maintenance

8.2 Engine oil

See blueprint: wc_gr000022

1. Drain the engine oil when the engine is warm.
2. Remove the sealing plug (a) and the drain plug (b) to drain the oil.
Comment: For environmental reasons, a bin should be placed under machine
to catch the fluid and a waterproof sheet should also be placed under the
machine to protect the ground. The fluid must be dispose of according to the
relevant regulations.
3. Reinsert the drain plug.
4. Fill the engine crankcase with the recommended engine oil up to the oil level
marking (c). For the oil quantity and type, see Technical Data.
5. Screw the sealing plug back in.

wc_gr000022

100_0402_mt_0003.fm 31
8 Maintenance

8.3 Air cleaner maintenance

See blueprint: wc_gr0001287

This engine is outfitted with a single-element air cleaner.
Frequent cleaning of the air cleaner prevents carburetor malfunctions.
NOTE: NEVER run the engine without an air cleaner, as this can result in major
engine damage.
NEVER clean air cleaner with gasoline or other solvents with a low combustion
point, as this can result in fire or explosions.

WARNING

Maintenance:
1. Loosen the locks (a) on the upper and lower sides of the air cleaner (filter)
cover (b).
2. Check the filter element (c). Replace if damaged.
3. Clean filter element in warm water and mild laundry soap. Wash out with
clean water thoroughly. Allow element to dry thoroughly. Impregnate the
element in clean engine oil and press out the excessive oil.
4. Reattach the element and air cleaner (filter) cover.

wc_gr001287

32 100_0402_mt_0003.fm
 8 Maintenance

8.4 Spark plug

See blueprint: wc_gr000028

Clean or replace the spark plug as needed. See engine manual.
The exhaust will become very hot during operation and also remains hot for a
while after the engine is switched off. Never touch a hot exhaust.

WARNING
Comment: See the technical data for the recommended spark plug and spark
plug air gap.
1. Remove and check the spark plug.
2. Replace the spark plug if the isolator is cracked or split.
3. Clean spark plug electrodes with a wire brush.
4. Adjust the spark plug air gap (a).
5. Screw in and tighten the spark plug.
NOTE: A loose spark plug can become very hot and lead to engine damage.

100_0402_mt_0003.fm 33
8 Maintenance

8.5 Setting the engine speed

See blueprint: wc_gr001288

Generators require a non-adjustable engine speed in order to maintain the
correct voltage. The engine speed is controlled by a governor that automatically
adjusts to the changing loads of the engine in order to maintain a constant RPM.
There is no gas regulator.
To set the correct engine speed:
Unscrew the RPM adjusting screw (a) in and out until a zero load RPM of 3100
RPM is reached.
NOTE: Tools and other electrical equipment can be damaged if the engine
speed is set too high or too low.

Use the technical data to set engine speed without load or idle.
1. Start the engine and allow it to warm up to the normal operating temperature.
2. Screw in the choke coil stop screw (a) to increase the speed. Unscrew the
choke coil stop screw to reduce the speed. Ensure that the throttle lever is
touching the choke coil stop screw before measuring the RPM.

34 100_0402_mt_0003.fm
 8 Maintenance

8.6 Carburetor setting

See blueprint: wc_gr0001061

The fuel adjusting screw (a) is provided with a limiter cap according to the
environmental pollution provisions. The mixture is set at the plant in order to
prevent an enrichment of the air/fuel mixture. No adjustment should be
necessary. The limiter cap may not be removed, as the adjusting screw will break
otherwise.

8.7 Long-term storage

Before long-term storage:

1. Put engine fuel shut-off valve in the closed position.
2. Disconnect fuel line from the carburetor. Place the open end of the line in an
appropriate bin and open the fuel shut-off valve to empty the tank.
Gasoline is highly flammable. Drain the fuel tank in a well-vented area and away
from flames or sparks.

WARNING

3. Open the drain plug on the carburetor and drain any remaining fuel from the
carburetor.
4. Change the engine oil.
5. Remove the spark plug and pour about 30 ml of clean engine oil in the
cylinder. Turn the engine over a few times to spread the oil on the inner walls
of the cylinder.
6. Pull the starter rope slowly until you notice resistance and put the handle in
this position. This ensures that the intake and exhaust vales are closed.
7. Store the generator in a dry and clean place.

100_0402_mt_0003.fm 35
9 Basic troubleshooting

9 Basic troubleshooting

Problem / symptom Cause / remedy

Check the following if the engine  Engine switch is in the "Start" position.
does not start:  Fuel cock is open.
 Fuel is replenished.
 Choke lever is in the correct position. The choke should be
closed when starting a cold engine.
 No electronic equipment is connected to the generator.
 Spark plug is in good condition.
 Spark plug cap is firmly seated.
 Engine oil level is sufficient.
Check the following if the engine  Fuse switch is closed.
starts, but the generator does not  Wiring from the generator to the plug receptacles is secured.
deliver any power to plug
receptacles:
Check the following if the engine  Air cleaner condition.
starts, but runs irregularly:  Condition of the spark plug and spark plug cap.
 How new the fuel is.

36 100_0402_ts_0001.fm
 10 Disposal

10 Disposal

10.1 Disposal of waste electrical and electronic equipment

Professional disposal of this machine avoids negative effects on human health

and the environment, helps with the targeted treatment of pollutants and makes
it possible to recycle valuable raw materials.

For customers in EU countries

This machine is subject to the European directive for old electrical and electronic
equipment (Waste Electrical and Electronic Equipment (WEEE)), as well as the
corresponding national laws. The WEEE directive provides the framework for an
EU-wide treatment of old electrical equipment.
The machine is marked with the following symbol of a crossed-out
garbage bin. This means that you do not dispose of the battery in
normal household waste but that it must be disposed of in a sepa-
rate, environmentally friendly collection facility.
This unit is provided as a professional electrical tool exclusively for
commercial use (a so-called B2B device according to the WEEE directive). Un-
like equipment mostly used in private households (so-called B2C devices), this
machine may therefore not be disposed of in some EU countries, such as in Ger-
many, at the collection points of public waste management organizations (e.g.
municipal collection stations). If there are any doubts, information regarding the
different methods of disposal for B2B electronic devices for each country can be
obtained from the sales location, so that the disposal takes place in accordance
with the valid statutory provisions. There are also some notes to follow in the sa-
les contract or in the general Terms and Conditions of the sales location.

For customers in other countries

It is recommended that you do not dispose of the machine in normal household
waste but rather in a separate, environmentally friendly collection facility. Natio-
nal laws also may, under certain circumstances, prescribe the separate disposal
of electrical and electronic products. Correct disposal of this machine in accor-
dance with current national guidelines must be assured.

100_0000_0004.fm 37
11 Technical data

11 Technical data

11.1 GV 2500

Designation Unit GV 2500A GV 2500A

Item number 0009345 0009350

Peak performance (LTP) kW 2.1 2.1

Continuous (prime) power kW 2.1 2.1

output (COP)

Net installed power (PRP) kW 2.0 2.0

Length mm 623 623

Width mm 409 409

Height mm 500 500

Weight kg 41 41

Operating weight kg 46 46

Generator model NSM K80C NSM K80C

Insulation class H H

Output current 1~ A 10.0 10.0

Output frequency Hz 50 50

Power factor cos 0.9 0.9

Nominal speed rpm 3,000 3,000

Phases ~ 1 1

Type of mains Protective breaker Protective breaker

Total harmonic distortion % 6 6

(THD)

Start-up behavior (ICC) In 3-4 3-4

Tank capacity l 11.0 11.0

Main fuse A 12 12

Available voltages 1~ V 230 230

Plug receptacles Model F: 230V 16A 1~ Model E: 230V 16A 1~

CEE7/4 CEE7/5

38 100_0402_td_0005.fm
 11 Technical data

Designation Unit GV 2500A GV 2500A

Plug receptacles Quantity 2 2

Design class G1 G1

Protection rating IP23 IP23

Operating temperature °C -15 – +40 -15 – +40

range

Max. operating height m NN 1,500 1,500

Sound pressure level LpA * dB(A) 68.0 68.0

Standards DIN EN ISO 11201

Measured sound power

level Lwa dB(A) 95 95

Guaranteed dB(A) 96 96

Standards 2000/14/EC

* Measured at 7meter's distance.

100_0402_td_0005.fm 39
11 Technical data

11.2 Combustion engine

Designation

Manufacturer Honda

Type of engine GX160T1-VPM6

Combustion method Four-cycle

Cooling Air cooling

Cylinders 1

Displacement cm3 163

Max. slanting position ° 20

Fuel type Gasoline

Fuel consumption l/h 0.9

Mixture preparation Carburetor

Tank capacity l 11.0

Oil specification SAE 10W-40

Max. oil filling l 0.6

Max. performance kW 2.9

RPM rpm 3,600

Standards SAE J1349

Rated power kW 2.5

Nominal speed rpm 3,000

Standards SAE J1349

Exhaust limit values CARB, EPA, EU

Spark plug type NGK BPR-6 ES

Spark plug air gap mm 0.7

Starter type Recoil starter

40 100_0402_td_0005.fm
 12 Glossary

12 Glossary
Class rating
The class rating according to DIN EN 61140 specifies the safety measures for
electrical equipment to avoid electrocution. There are four class ratings:

Class rating Meaning

0 No special protection apart from the basic insulation.

No grounded conductor.
Plug connection without grounded conductor contact.

I Connection of all conductive housing components to the

grounded conductor.
Plug connection with grounded conductor contact.

II Reinforced or double insulation (protective insulation).

No connection to the grounded conductor.
Plug connection without grounded conductor contact.

III Machines are operated on protective low voltage

(< 50 V).
Connection to the grounded conductor is not necessary.
Plug connection without grounded conductor contact.

100_0000_0005.fm 41
12 Glossary

Protection class IP
The protection class according to DIN EN 60529 indicates the suitability of elec-
trical equipment for use in certain ambient conditions as well as the protection
against risks.
The protection class is specified by an IP code according to DIN EN 60529.

Code Meaning 1st number:

Protection against touching hazardous parts.
Protection against permeating foreign objects.
0 Not protected against contact.
Not protected against foreign bodies.
1 Protected against contact with the back of the hand.
Protected against large foreign objects with diameter > 50 mm (1.9 in).
2 Protected against contact with one finger.
Protected against medium-sized foreign objects (diameter > 12.5 mm
(0.5 in)).
3 Protected against touch with a tool (diameter > 2.5 mm (0.01 in)).
Protected against small foreign objects with (diameter > 2.5 mm (0.01 in)).
4 Protected against touch with a wire (diameter > 1 mm (0.03 in)).
Protected against granular foreign objects (diameter > 1 mm (0.03 in)).
5 Protected against contact.
Protected against dust depositing inside.
6 Completely protected against any contact.
Protected from dust.

Code Meaning 2nd number:

Protection against permeating water
0 Not protected against permeating water.
1 Protected against water dropping vertically.
2 Protected against diagonally falling water (15° angle).
3 Protected against spray (60° angle).
4 Protected against spraying water from all directions.
5 Protected against water jets (nozzle) from any angle.
6 Protected against strong water jets (overflow).
7 Protected from temporary immersion in water.
8 Protected from ongoing immersion in water.

42 100_0000_0005.fm
 13 Diagram

13 Diagram

13.1 GV 2500A - Wiring diagram

Ref. Description Ref. Description

1 Main stator windings 5 Diode
2 Auxiliary winding 6 Surge absorber
3 Capacitor 7 Circuit breaker
4 Rotor windings 8 Plug receptacle 230V, 16 A

Color chart

B Black V Purple Or Orange

G Green W White Pr Purple

L Blue Y Yellow Sh Casing

P Pink Br Brown LL Light blue

R Red Cl Clear G/Y Green/Yellow

T Light brown Gr Gray

100_0402_ew_0003.fm 43
13 Diagram

44 100_0402_ew_0003.fm
 EC declaration of conformity
Manufacturer
Wacker Neuson Produktion GmbH & Co. KG, Preussenstrasse 41, 80809 Munich
This declaration of conformity is issued under the sole responsibility of the manufacturer.
Product

Product GV 2500A
Product type Generator

Product function Electricity generation

Item number 0009345 0009350

Net installed power 2,1 kW 2,1 kW

Measured sound power level 95 dB(A) 95 dB(A)

Guaranteed sound power level 96 dB(A) 96 dB(A)

Conformity assessment procedure

According to 2000/14/EC (2006-06), enclosure VIII.
Appointed body
SNCH Société Nationale de Certification et ’Homologation, L-1852 Luxembourg (NB 0499)
Guidelines and standards
We hereby declare that this product meets the relevant provisions and requirements of the following guidelines
and standards:
2006/42/EC (2009-10), 2014/35/EU (2014-02), 2000/14/EC (2006-06), 2014/30/EU (2014-02), 2011/65/EU
(2015-03)
Authorized representative for technical documents
Robert Räthsel,
Wacker Neuson Produktion GmbH & Co. KG, Preussenstrasse 41, 80809 Munich

Munich, 20.04.2016

Helmut Bauer
Managing Director

Translation of the original Declaration of Conformity