Wacker Neuson G 25 Operator's Manual
0158596en 013
0709
Mobile Generator
G 25
OPERATOR’S MANUAL
0158596EN
Foreword
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.
This manual provides information and procedures to
safely operate and maintain this Wacker Neuson
model. For your own safety and protection from injury,
carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you
lose this manual or need an additional copy, please
contact Wacker Neuson Corporation. This machine is
built with user safety in mind; however, it can present
hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions
about operating or servicing this equipment, please
contact Wacker Neuson Corporation.
The information contained in this manual was based on
machines in production at the time of publication.
Wacker Neuson Corporation reserves the right to
change any portion of this information without notice.
All rights, especially copying and distribution rights, are
reserved.
Copyright 2009 by Wacker Neuson Corporation.
No part of this publication may be reproduced in any
form or by any means, electronic or mechanical,
including photocopying, without express written
permission from Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized
by Wacker Neuson Corporation represents an
infringement of valid copyrights and will be prosecuted.
We expressly reserve the right to make technical
modifications, even without due notice, which aim at
improving our machines or their safety standards.
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G 25 Table of Contents
Foreword 3
1 Safety Information 7
1.1 Operating Safety .................................................................................. 8
1.2 Service Safety .................................................................................... 10
1.3 Operator Safety while using Internal Combustion Engines ................ 12
1.4 Towing Safety ..................................................................................... 13
1.5 Reporting Trailer Safety Defects ........................................................ 13
1.6 Label Location .................................................................................... 14
1.7 Safety and Operating Labels .............................................................. 16
2 Operation 24
2.1 Control Panels .................................................................................... 24
2.2 Generator Monitoring ......................................................................... 26
2.3 Engine Monitoring .............................................................................. 28
2.4 Engine Shutdown Faults .................................................................... 30
2.5 Current Overload Fault ....................................................................... 31
2.6 Application .......................................................................................... 31
2.7 Voltage Selector Switch ..................................................................... 32
2.8 Emergency Stop Switch ..................................................................... 33
2.9 Main Line Circuit Breaker ................................................................... 34
2.10 Engine Start Switch ............................................................................ 35
2.11 Voltage Adjustment Rheostat ............................................................. 35
2.12 Warning Light ..................................................................................... 35
2.13 Connection Lugs ................................................................................ 36
2.14 Ground Connection ............................................................................ 37
2.15 Convenience Receptacles .................................................................. 37
2.16 Remote Run Terminal Block .............................................................. 37
2.17 Panel Door Interlock Switch ............................................................... 37
2.18 Terminal Connections ........................................................................ 38
2.19 Before Starting ................................................................................... 39
2.20 Manual Start-up .................................................................................. 40
2.21 Running the Generator ....................................................................... 42
2.22 Engine Power Correction Factors ...................................................... 42
2.23 Shutting Down Generator ................................................................... 43
2.24 Cold Weather Start-up ........................................................................ 43
2.25 Lifting .................................................................................................. 43
2.26 Overnight Storage .............................................................................. 43
2.27 Long-term Storage ............................................................................. 43
2.28 Automatic/Remote Start-up ................................................................ 44
2.29 Remote/Transfer Switch ..................................................................... 45
2.30 Towing ................................................................................................ 46
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Table of Contents G 25
3 Maintenance 48
3.1 Periodic Maintenance Schedule ..........................................................48
3.2 New Machines .....................................................................................49
3.3 Resetting the Periodic Maintenance Timer .........................................49
3.4 Air Cleaner ..........................................................................................50
3.5 Engine Lubrication ...............................................................................50
3.6 Engine Coolant ....................................................................................50
3.7 Trailer Maintenance .............................................................................51
3.8 Troubleshooting Automatic Shutdown .................................................52
3.9 Generator and Receptacle Wiring .......................................................54
3.10 Trailer Wiring .......................................................................................60
3.11 Engine Wiring ......................................................................................62
4 Factory-Installed Options 70
4.1 Block Heater ........................................................................................70
4.2 Fuel/Water Separator ..........................................................................71
4.3 Automatic LCD Heat ............................................................................72
4.4 Low Coolant Shutdown .......................................................................73
4.5 Temperature-Activated Shutters .........................................................74
4.6 Lockable Battery Disconnect ...............................................................74
4.7 Extended Run Tank .............................................................................75
4.8 Battery Charger ...................................................................................75
4.9 Cam-Lock ............................................................................................76
4.10 Containment System ...........................................................................77
4.11 Wiring Diagram—Factory-Installed Options ........................................78
4.12 Wiring Diagram Components—Factory-Installed Options ...................79
5 Technical Data 80
5.1 Engine Power Rating ...........................................................................80
5.2 Engine Data Table 1 ............................................................................80
5.3 Engine Data Table 2 ............................................................................81
5.4 Generator Data ....................................................................................82
5.5 Trailer and Skid Data ...........................................................................83
5.6 Dimensions ..........................................................................................84
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G 25 Safety Information
G
1 Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE, and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
DANGER
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
WARNING
CAUTION
WARNIN
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE: Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
Electrocution hazard!
Electrocution or severe electrical shock hazards are present
throughout the generator any time the engine is running! Read all
safety notes contained in this section before operating or servicing this
equipment.
No one except a trained electrician, familiar with this equipment,
should attempt repairs to the generator! Test procedures which require
that the generator be running must be performed using extreme
caution.
This machine is built with user safety in mind; however, like any
electrical device it can present serious hazards if improperly operated
and serviced. Follow instructions carefully! Should questions arise
during operation or service of this equipment, contact Wacker Neuson
Corporation.
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Safety Information G 25
1.1 Operating Safety
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be hazardous. Read the operating instructions contained in this
WARNING
1.1.1 NEVER operate the generator when open containers of fuel, paint, or
1.1.2 NEVER place flammable material or liquids near the generator.
1.1.3 NEVER operate the generator, or tools attached to the generator, with
1.1.4 NEVER use worn electrical cords. Severe electrical shock and
1.1.5 NEVER operate the machine indoors unless exhaust fumes can be
manual and the engine manual, and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
other flammable liquids are near.
wet hands.
equipment damage may result.
adequately ventilated.
1.1.6 NEVER overload the generator. The total amperage of the tools and
equipment attached to the generator must not exceed the load rating
of the generator.
1.1.7 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a certified electrician.
1.1.8 NEVER operate generator in standing water.
1.1.9 NEVER touch the hot engine, exhaust, or generator components.
Burns will result.
1.1.10 NEVER start a machine in need of repair.
1.1.11 Use the emergency stop button only in an actual emergency. DO NOT
restart the engine until the cause of the trouble has been determined
and fixed.
1.1.12 Wear hearing protection when operating equipment.
1.1.13 ALWAYS follow starting and stopping instructions described in this
manual. Know how to operate and stop generator before starting it.
1.1.14 ALWAYS make a walk-around inspection of the generator set before
starting it. Open side doors and visually inspect engine compartment
for obvious damage or the presence of foreign objects which might
affect operation.
1.1.15 ALWAYS keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
1.1.16 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.
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G 25 Safety Information
1.1.17 ALWAYS keep the area immediately surrounding and underneath the
machine clean, neat, and free of debris and combustible materials.
Make sure that the area overhead is clear of debris that could fall onto
or into the machine or exhaust compartment.
1.1.18 Be sure the machine is on a firm, level surface and will not tip, roll,
slide, or fall while operating.
1.1.19 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
1.1.20 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER
DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR
DEATH TO UTILITY WORKERS!
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.
Connections to a building’s electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical
codes.
If connected to a building’s electrical system the generator must meet
the power, voltage, and frequency requirements of the equipment in
the building. Differences in power, voltage, and frequency
requirements may exist and improper connection may lead to
equipment damage, fire, and personal injury or death.
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Safety Information G 25
1.2 Service Safety
A poorly maintained machine can become a safety hazard! In order
for the machine to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
WARNING
1.2.1 NEVER perform even routine service (oil/filter changes, cleaning,
etc.) unless all electrical components are shut down. Before
servicing this machine, make sure the engine start switch is turned to
off “O”, the circuit breakers are open (off), the emergency stop switch
is closed (pushed in), and the negative terminal on battery is
disconnected. Attach a “DO NOT START” sign to the control panel.
This will notify everyone that the unit is being serviced and will reduce
the chance of someone inadvertently trying to start the unit. If the unit
is connected to a remote start or transfer switch, make sure the remote
switch is also off and tagged.
1.2.2 Ground Connection
The generator must be connected to a good earthen ground for
proper operating safety!
A central “equipment ground” is provided at the customer connection
lugs. This point is connected directly to the generator set base. All
other system grounds are connected to this central point. Ground the
generator in accordance with the standards defined in national, state,
and local regulations.
1.2.3 DO NOT attempt to open the radiator cap while the unit is running or
before the engine has cooled down. Severe burns may result!
1.2.4 DO NOT allow water to accumulate around the base of the machine.
If water is present, move the machine and allow the machine to dry
before servicing.
1.2.5 DO NOT service the machine if your clothing or skin is wet.
1.2.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
1.2.7 Do not modify the machine without the express written approval of the
manufacturer.
1.2.8 DO NOT pressure wash the control panel, generator end, or any other
electrical components when cleaning the machine. Never allow water
to accumulate around the base of the generator set. If water is present,
DO NOT service!
1.2.9 ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.2.10 ALWAYS let the engine cool before transporting or servicing the
machine.
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G 25 Safety Information
1.2.11 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the machine.
1.2.12 ALWAYS replace all guards, fasten doors, and make sure all safety
devices operate properly after making repairs or servicing the
equipment.
1.2.13 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
1.2.14 Keep the machine clean and labels legible. Replace all missing and
hard-to-read labels. Labels provide important operating instructions
and warn of dangers and hazards.
1.2.15 ALWAYS check all external fasteners at regular intervals.
1.2.16 ALWAYS make sure slings, chains, hooks, ramps, jacks, and other
types of lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people in the area when lifting the
machine.
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Safety Information G 25
1.3 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
WARNING
1.3.1 Do not run engine indoors or in an area with poor ventilation unless
1.3.2 Do not fill or drain the fuel tank near an open flame, while smoking, or
1.3.3 Do not refuel a hot or running engine.
1.3.4 Refill the fuel tank in a well-ventilated area.
1.3.5 Do not touch or lean against hot exhaust pipes.
1.3.6 Replace the fuel tank cap after refueling.
1.3.7 Do not start the engine if fuel has spilled or a fuel odor is present. Move
warnings and safety standards could result in severe injury or death.
exhaust hoses are used.
while the engine is running.
the generator away from the spill and wipe the generator dry before
starting.
1.3.8 Do not remove the radiator cap when the engine is running or hot. The
radiator fluid is hot and under pressure and may cause severe burns!
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G 25 Safety Information
1.4 Towing Safety
Towing a large trailer requires special care. Both the trailer and vehicle
must be in good condition and securely fastened to each other to
reduce the possibility of an accident.
WARNING
1.4.1 ALWAYS check that the hitch and coupling on the vehicle are rated
equal to, or greater than, the trailer’s “gross vehicle weight rating”
(GVWR).
1.4.2 ALWAYS inspect the hitch and coupling for wear or damage. DO NOT
tow the trailer using defective parts.
1.4.3 ALWAYS make sure the coupling is securely fastened to the vehicle.
1.4.4 ALWAYS check the tires on the trailer for tread wear, inflation, and
condition. Replace worn tires.
1.4.5 ALWAYS connect the safety chains.
1.4.6 ALWAYS connect the breakaway cable safety hook to the bumper or
rear of the vehicle. DO NOT attach it to the hitch.
1.4.7 ALWAYS test the surge brakes on the trailer and the brakes on the
vehicle that will be used for towing.
1.4.8 ALWAYS make sure directional and trailer lights are connected and
working properly.
1.4.9 ALWAYS check that the lug nuts holding the wheels are tight and that
none are missing.
1.5 Reporting Trailer Safety Defects
If you believe your trailer has a defect which could cause a crash or
could cause injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to
notifying Wacker Neuson Corporation.
If NHTSA receives similar complaints, it may open an investigation;
and if it finds that a safety defect exists in a group of vehicles, it may
order a recall and remedy campaign. However, NHTSA cannot
become involved in individual problems between you, your dealer, or
Wacker Neuson Corporation.
To contact NHTSA, you may either contact the Auto Safety Hotline tollfree at 1-800-424-9393 (or 366-0129 in Washington DC area),
www.nhtsa.com, or write to NHTSA, U.S. Department of
Transportation, 400 7th Street SW, (NSA-11), Washington, DC 20590.
You can also obtain other information about motor vehicle safety from
the Auto Safety Hotline.
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Safety Information G 25
1.6 Label Location
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G 25 Safety Information
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Safety Information G 25
1.7 Safety and Operating Labels
Ref. Label Meaning
A
TOWING INSTRUCTIONS ABSCHLEPPINSTRUKTIONEN INSTRUCCIONES DE REMOLQUE
1. READ OPERATOR'S MANUAL.
2. USE HITCH RATED FRO TRAILER'S
"GROSS VEHICLE WEIGHT RATING".
3. SECURELY ATTACH TRAILER TO TOW
VEHICLE.
4. ATTACH SAFETY CHAINS USING CROSS
PATTERN.
5. ATTACH BREAKDOWN CHAIN TO VEHICLE.
6. CHECK TRAILER LIGHTS.
1. BETRIEBSVORSCHRIFT LESEN.
2. ANHANGEVORRICHTUNG VERWENDEN,
DIE DER GESAMTBETRIEBSGEWICHTSKLASSE
ENTSPRICHT.
3. ANHANGER SICHER AM ZUGFAHRZEUG
BEFESTIGEN.
4. SICHERHEITSKETTEN KREUZWEISE ANBRINGEN.
5. ABREISSKETTE AM FAHRZEUG ANBRINGEN.
6. ANHANGERLEUCHTEN PRUFEN.
1. LEA EL MANUAL DEL OPERARIO.
2. UTILICE UN ACOPLE CORRECTAMENTE
CLASIFICADO PARA LA "CLASE DE PESO BUTO"
DEL VEHICULO DEL REMOLQUE.
3. ASEGURESE DE AMARRAR CORRECTAMENTE
EL REMOLQUE AL VEHICULO DE REMOLQUE.
4. FIJE EN CRUZ LAS CADENAS DE SEGURIDA D.
5. FIJE EN EL VEHICULO DE REMOLQUE LA CA DENA
DE DESPRENDIMIENTO.
6. CONTROLE LAS LUCES DEL REMOLQUE.
B WARNING!
Pressurized contents. Do not open when
hot!
C WARNING!
Lock doors. Access can cause electric
shock or injury.
D CAUTION
Lifting point.
INSTRUCTIONS DE REMORQUAGE
1. LIRE LA NOTICE D'EMPLOI.
2. UTILISER UN GROCHET D'ATTELAGE CONFORME AU
DEBIT NOMINAL DU POIDS BRUT DE VEHICULE DU
TRACTEUR.
3. ATTACHER LA REMORQUE FERMEMENT AU VEHICULE
TRACTEUR.
4. ATTACHER LES CHAINES DE SURETTE EN UTILISANT
UNE METHODE CROISEE.
5. ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE.
6. VERIFIER LES LAMPES DE LA REMORQUE.
114894
E NOTICE
Never change switch position with engine
running. Results in damage to machine.
WARNING!
Electric shock can cause serious injury or
death.
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G 25 Safety Information
Ref. Label Meaning
F DANGER!
Asphyxiation hazard. Read the Operator’s Manual for instructions. No sparks,
flames, or burning objects near machine.
Stop the engine before adding fuel. Use
only diesel fuel.
G Tie-down point.
H WARNING!
To prevent hearing loss, wear hearing
protection.
Hand injury if entangled in moving belt.
Rotating machinery! Do not reach inside
with engine running.
WARNING!
Hot surface!
CAUTION!
Avoid spraying water into generator.
I WARNING!
Hot surface!
J Electrical ground
K WARNING!
Electric shock can cause serious injury or
death.
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Safety Information G 25
Ref. Label Meaning
L
M Operator’s Manual must be stored on
N DANGER!
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machine. Replacement Operator’s Manual can be ordered through your local
Wacker Neuson distributor.
Electric shock will cause serious injury or
death. Danger of asphyxiation!
G 25 Safety Information
Ref. Label Meaning
O WARNING!
Generator can automatically start which
can cause serious injury. Disconnect battery before servicing.
P WARNING!
Read and understand the supplied Operator’s Manual before operating the
machine. Failure to do so increases the
risk of injury to yourself or others.
Q 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.
R Remote start operation. Read Operator’s
S CAUTION!
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Manual for instructions.
Receptacles not to be used when:
Selector switch set to 208/120V and voltage greater than 228V.
Selector switch set to 480/277V and voltage greater than 457V.
Safety Information G 25
Ref. Label Meaning
T WARNING!
Disconnect battery before servicing.
Read the Operator’s Manual.
U
V Operator’s Manual must be stored on
machine. Replacement Operator’s Manual can be ordered through your local
Wacker Neuson distributor.
W Drain containment system.
X WARNING!
To prevent hearing loss, wear hearing
protection when operating the machine.
WARNING!
Pressurized contents. Do not open when
hot!
WARNING!
Hand injury if entangled in moving belt.
WARNING!
Rotating machinery! Do not reach inside
machine with engine running.
Y Operating the main circuit breaker sup-
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plies or interrupts power to the customer
connection lugs.
G 25 Safety Information
Ref. Label Meaning
Z Neutral bonded to frame
AA Fuses
Read the Operator’s Manual for machine
information.
1 - Fuel Solenoid
2 - Fuel Pump
3 - Controller
4 - Not Used
BB WARNING!
Electric shock at cooling fins.
CC G 25 Generator and Receptacle Wiring
DD G 25 Engine Wiring
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Safety Information G 25
Ref. Label Meaning
EE WARNING!
Hot surface!
FF (if equipped)
CAUTION: Do not use battery disconnect
switch while engine is running. Damage
to electrical components may occur.
GG Low sulfur fuel or ultra low sulfur fuel
only.
HH
JJ
WARNING
Lock doors. Access can cause electric
shock, arc flash, or injury.
Protecting Our Environment
Fluid containment system
(if equipped)
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G 25 Safety Information
Ref. Label Meaning
\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. When
ordering parts or requesting service information, you will always be asked to specify the model number, item number,
revision number, and serial number of
the unit.
This machine may be covered by one or
more patents.
Certification Label (VIN Number)
Also attached to each unit is a Certification Label. This label specifies that the
trailer conforms with all Federal Motor
Vehicle Standards in effect at the time of
manufacture. The label includes the Vehicle Identification Number (VIN) for the
trailer.
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Operation G 25
2. Operation
2.1 Control Panels
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G
E
R
N
E
C
M
Y
E
S
P
T
O
G 25 Operation
Ref. Description Ref. Description
a Main Circuit Breaker l Twist-Lock Receptacle
(120/240 VAC, 50Amp)
b Voltage Adjustment Rheostat m Twist-Lock Receptacle
(120/240 VAC, 30 Amp)
c Shutdown LED n GFI Receptacle
(120 VAC, 20 Amp) - two
d Pre-alarm LED o Remote Run Terminal Block
e LCD Panel p Emergency Stop Switch
f Engine Start Switch q Interlock Switch
g Engine Hours Switch r Customer Connection Terminal Lugs
h Circuit Breaker
s Ground Connection
(240V, 50 Amp)
j Circuit Breaker
t Bond bar
(240V, 30 Amp)
k Circuit Breaker (120V, 20
Amp) - two
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Operation G 25
2.2 Generator Monitoring
Generator information is displayed on the top line of the LCD panel and
is scrolled continuously while the generator is operating, to show the
voltage, amperage and frequency of each phase.
Note: To prevent the display from scrolling, press the engine hours
switch down.
Volts “V”- Displays the AC output voltage being produced by the
generator.
Phase “Ø” - Indicates which leg is currently being displayed.
Amps “A” - Displays the AC output amperage produced by the
generator. If the generator is operating at no-load, output amperage
will display a 0.
Hertz “Hz” - Displays output frequency. This gauge should read
approximately 61.5 Hz under a no-load condition. If the frequency is
too high, check the engine rpm.
208 1 24 61.5
78 85% 175 14.3
UNIT IN AUTO
Ø 100% 85 13.2
Sample display with engine running.
Sample display in “Auto” mode.
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