Wacker Neuson G 25 Operator's Manual
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Wacker Neuson G 25 Operator's Manual

Mobile generator
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OPERATOR'S MANUAL
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0158596en
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Mobile Generator
G 25
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Summary of Contents for Wacker Neuson G 25

  • Page 1 0158596en 0709 Mobile Generator G 25 OPERATOR’S MANUAL...

  • Page 3: Foreword

    Foreword This manual provides information and procedures to safely operate and maintain this Wacker Neuson model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual.
  • Page 4 wc_tx000001gb diesel.fm...

  • Page 5: Table Of Contents

    G 25 Table of Contents Foreword Safety Information Operating Safety .................. 8 Service Safety ..................10 Operator Safety while using Internal Combustion Engines ....12 Towing Safety ..................13 Reporting Trailer Safety Defects ............13 Label Location ..................14 Safety and Operating Labels .............. 16 Operation Control Panels ..................
  • Page 6 Table of Contents G 25 Maintenance Periodic Maintenance Schedule ............48 New Machines ..................49 Resetting the Periodic Maintenance Timer .........49 Air Cleaner ..................50 Engine Lubrication ................50 Engine Coolant ..................50 Trailer Maintenance ................51 Troubleshooting Automatic Shutdown ..........52 Generator and Receptacle Wiring ............54 3.10...

  • Page 7: Safety Information

    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. wc_si000137gb.fm...

  • Page 8: Operating Safety

    Safety Information G 25 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 manual and the engine manual, and familiarize yourself with the location and proper use of all controls.
  • Page 9 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.

  • Page 10: Service Safety

    Safety Information G 25 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 NEVER perform even routine service (oil/filter changes, cleaning, 1.2.1...
  • Page 11 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.

  • Page 12: Operator Safety While Using Internal Combustion Engines

    Safety Information G 25 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 warnings and safety standards could result in severe injury or death.

  • Page 13: Towing Safety

    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.

  • Page 14: Label Location

    Safety Information G 25 Label Location wc_si000137gb.fm...
  • Page 15 G 25 Safety Information wc_si000137gb.fm...

  • Page 16: Safety And Operating Labels

    Safety Information G 25 Safety and Operating Labels Ref. Label Meaning TOWING INSTRUCTIONS ABSCHLEPPINSTRUKTIONEN INSTRUCCIONES DE REMOLQUE INSTRUCTIONS DE REMORQUAGE 1. LEA EL MANUAL DEL OPERARIO. 1. LIRE LA NOTICE D'EMPLOI. 1. READ OPERATOR'S MANUAL. 1. BETRIEBSVORSCHRIFT LESEN. 2. UTILICE UN ACOPLE CORRECTAMENTE 2.
  • Page 17 G 25 Safety Information Ref. Label Meaning DANGER! Asphyxiation hazard. Read the Opera- tor’s Manual for instructions. No sparks, flames, or burning objects near machine. Stop the engine before adding fuel. Use only diesel fuel. Tie-down point. WARNING! To prevent hearing loss, wear hearing protection.
  • Page 18 Safety Information G 25 Ref. Label Meaning Operator’s Manual must be stored on machine. Replacement Operator’s Man- ual can be ordered through your local Wacker Neuson distributor. DANGER! Electric shock will cause serious injury or death. Danger of asphyxiation! wc_si000137gb.fm...
  • Page 19 G 25 Safety Information Ref. Label Meaning WARNING! Generator can automatically start which can cause serious injury. Disconnect bat- tery before servicing. WARNING! Read and understand the supplied Oper- ator’s Manual before operating the machine. Failure to do so increases the risk of injury to yourself or others.
  • Page 20 Safety Information G 25 Ref. Label Meaning WARNING! Disconnect battery before servicing. Read the Operator’s Manual. Operator’s Manual must be stored on machine. Replacement Operator’s Man- ual can be ordered through your local Wacker Neuson distributor. Drain containment system. WARNING! To prevent hearing loss, wear hearing protection when operating the machine.
  • Page 21 Fuses Read the Operator’s Manual for machine information. 1 - Fuel Solenoid 2 - Fuel Pump 3 - Controller 4 - Not Used WARNING! Electric shock at cooling fins. G 25 Generator and Receptacle Wiring G 25 Engine Wiring wc_si000137gb.fm...
  • Page 22 Safety Information G 25 Ref. Label Meaning WARNING! Hot surface! (if equipped) CAUTION: Do not use battery disconnect switch while engine is running. Damage to electrical components may occur. Low sulfur fuel or ultra low sulfur fuel only. WARNING Lock doors. Access can cause electric shock, arc flash, or injury.
  • Page 23 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 name- plate become lost or damaged.

  • Page 24: Operation

    Operation G 25 Operation Control Panels wc_tx000137gb.fm...

  • Page 25: Table Of Contents G

    G 25 Operation Ref. Description Ref. Description Main Circuit Breaker Twist-Lock Receptacle (120/240 VAC, 50Amp) Voltage Adjustment Rheostat Twist-Lock Receptacle (120/240 VAC, 30 Amp) Shutdown LED GFI Receptacle (120 VAC, 20 Amp) - two Pre-alarm LED Remote Run Terminal Block...

  • Page 26: Generator Monitoring

    Operation G 25 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.
  • Page 27 G 25 Operation Notes: wc_tx000137gb.fm...

  • Page 28: Engine Monitoring

    Operation G 25 Engine Monitoring With the engine start switch set to “RUN/START” or “REMOTE START”, engine information will be continuously displayed on the bottom line of the LCD panel. - Displays engine oil pressure. The gauge registers oil pressure between 0–100 psi. Normal operating pressure is between 60–80 psi.
  • Page 29 G 25 Operation Sample display of engine hours. RUNNING HOURS 135.2 Sample display of periodic maintenance timer. TIME TO SERVICE 180.2 hrs. Sample display showing engine fault set points. LOP<15 HWT>225 OS>67 wc_tx000137gb.fm...

  • Page 30: Engine Shutdown Faults

    Operation G 25 Engine Shutdown Faults The Engine Control Module (ECM) continuously monitors vital engine functions for six fault conditions. When a fault condition occurs, the engine will shut down and the LCD panel will display the fault causing the shutdown. To reset the ECM and resume operation, return the engine start switch manually to off “O”.

  • Page 31: Current Overload Fault

    G 25 Operation Indicates that the engine speed dropped below 55Hz (1650 rpm) for more than 15 seconds FAULT and the ECM has automatically shut down the UNDERSPEED 53 engine. Current Overload Fault Along with engine functions the ECM continuously monitors the current load in each phase.

  • Page 32: Voltage Selector Switch

    Operation G 25 Voltage Selector Switch See Graphic: wc_gr001682 The voltage selector switch is located in a separate enclosure on the generator on the opposite side of the machine. The selector switch is a three-position switch which mechanically changes the connections between the generator output leads and the terminal lugs on the generator.

  • Page 33: Emergency Stop Switch

    G 25 Operation Emergency Stop Switch See Graphic: wc_gr001677 The emergency stop switch (p) is the red button located below the receptacle panel and can be accessed with the panel doors closed. Activate the emergency stop switch by pushing the red button in.

  • Page 34: Main Line Circuit Breaker

    Operation G 25 Main Line Circuit Breaker See Graphic: wc_gr001683 The main line circuit breaker (c) is located on the control panel. In the off “O” position, the main line circuit breaker interrupts power from the selector switch to the terminal lugs at the bottom of the generator panel.

  • Page 35: Engine Start Switch

    G 25 Operation 2.10 Engine Start Switch See Graphic: wc_gr001683 The engine start switch (f) is a three-position switch: “REMOTE START”, off “O”, and “START/RUN”. The “REMOTE START” position is the normal setting used when using the generator as a back-up power supply connected to a remote switch.

  • Page 36: Connection Lugs

    Operation G 25 2.13 Connection Lugs See Graphic: wc_gr001684 The customer connection lugs (r) are located on left at the bottom of the panel behind a hinged door. The lugs provide connection points for attachment of outside loads. A large label like the one shown in section Terminal Connections is attached to the inside of the terminal door.

  • Page 37: Ground Connection

    G 25 Operation 2.14 Ground Connection See Graphic: wc_gr001684 A ground connection (s) is located next to the terminal lugs. The unit must have this ground lug connected to a good earthen ground for proper operating safety in compliance with NEC and local standards.

  • Page 38: Terminal Connections

    Operation G 25 2.18 Terminal Connections ALL CONNECTIONS TO THE TERMINALS MUST BE MADE BY A TRAINED ELECTRICIAN. BACKFEED FROM THE GENERATOR INTO THE UTILITY’S DISTRIBUTION SYSTEM CAN CAUSE A SERIOUS INJURY OR DEATH TO UTILITY WORKERS! WARNING Improper connection of generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines.

  • Page 39: Before Starting

    G 25 Operation 2.19 Before Starting Before putting the generator into service, review each item on the following checklist. Because generators are often run for long periods of time unattended, it is important to make sure that the machine is set up properly to reduce possible problems.

  • Page 40: Manual Start-Up

    Operation G 25 2.20 Manual Start-up See Graphic: wc_gr001682, wc_gr001677, wc_gr001683 Before starting the generator set, thoroughly review the pre-start-up checklist in the previous section. Proceed with generator start-up only after checking each item in that section. Thoroughly read and make sure you understand the engine Operator’s Manual supplied with the generator.
  • Page 41 G 25 Operation 2.20.7 After engine starts, allow it to warm up for a few minutes and check readouts on LCD panel. The “TIME TO SERVICE” interval will be displayed. Make sure battery charging system, oil pressure and engine temperature readings are within normal ranges.

  • Page 42: Running The Generator

    Operation G 25 2.21 Running the Generator See Graphic: wc_gr001683 Leave the engine start switch (f) in the “START/RUN” position while the generator is operating. If the generator was started using a remote switch, leave engine start switch in the “REMOTE START” position.

  • Page 43: Shutting Down Generator

    G 25 Operation 2.23 Shutting Down Generator Check with other personnel on the jobsite and let them know that power is being turned off. Make sure that the power shutdown will not create any hazards by turning off devices such as pumps, heaters, or lights that may need to be kept on.

  • Page 44: Automatic/Remote Start-Up

    Operation G 25 2.28 Automatic/Remote Start-up In the “REMOTE START” position the generator can be started remotely, either through a transfer switch or some other type of remote start switch. “REMOTE START” is the normal setting when using the generator as a standby power supply. Before placing the generator in the automatic start-up mode, review the pre-start and manual Start-up sections in this manual and follow procedure below.

  • Page 45: Remote/Transfer Switch

    G 25 Operation 2.29 Remote/Transfer Switch When the generator is used as a stand-by power supply, it must be equipped with a device which isolates it from the utility’s distribution system. WARNING Failure to isolate the generator from the utility’s electrical...

  • Page 46: Towing

    Operation G 25 2.30 Towing See Graphic: wc_gr000510 The generator trailer is equipped with brakes, lights, and coupler connection. Before towing the generator, perform the following: 2.30.1 Check that the towing vehicle and hitch have a rating equal to or greater than the GVWR.
  • Page 47 G 25 Operation wc_tx000137gb.fm...

  • Page 48: Maintenance

    Maintenance G 25 Maintenance Periodic Maintenance Schedule The chart below lists basic machine and engine maintenance. Refer to your engine operator’s manual for additional information on engine maintenance. Daily 50 hr 600 hr 1200 2000 Other or 2 hr or...

  • Page 49: New Machines

    G 25 Maintenance New Machines 3.2.1 Run generator at least 60–100% of continuous load for the first 100 hours. 3.2.2 Change engine oil and replace oil filter after the first 50 hours. Resetting the Periodic Maintenance Timer After maintenance has been performed on the generator, it is necessary to reset the periodic maintenance timer.

  • Page 50: Air Cleaner

    Maintenance G 25 Air Cleaner See Graphic: wc_gr001685 Replace the air filter cartridge (c) when yellow indicator of the engine air filter gauge reaches the red line. To replace the air filter cartridge: • Remove the end cover (d), then discard the entire air filter cartridge.

  • Page 51: Engine Coolant

    G 25 Maintenance Engine Coolant Check the coolant level of the radiator with the engine cold. After initial filling of radiator to 3/4 inch below bottom of filler neck, maintain proper level in overflow bottle daily. NEVER remove radiator cap or drain plug while engine is hot! Pressurized coolant can cause serious burns.

  • Page 52: Troubleshooting Automatic Shutdown

    The generator, however, can also cause problems. Consult a qualified electrician or your nearest Wacker Neuson dealer for possible causes of generator problems. Anytime the generator is down for service, secure it by closing and locking all doors, and hang a "DO NOT RUN"...
  • Page 53 G 25 Maintenance Overspeed or Underspeed Shutdown Restart engine and read the AC frequency meter. Meter should read aproximately 61.5 Hz under no-load condition. If frequency is high, adjust engine rpm for correct frequency (approximately 1850 rpm). Overcrank Shutdown 3.8.1 Check fuel level.

  • Page 54: Generator And Receptacle Wiring

    Maintenance G 25 Generator and Receptacle Wiring Revision See Graphic: Revision See Graphic: 0009368 104–123 wc_gr003169 103 & lower wc_gr001686 0009368 124 & higher wc_gr004611 — — 0009466 105–128 wc_gr003169 104 & lower wc_gr001686 0009466 129 & higher wc_gr004611 —...
  • Page 55 G 25 Maintenance wc_tx000197gb.fm...
  • Page 56 Maintenance G 25 Revision See Graphic: Revision See Graphic: 0009368 104–123 wc_gr003169 103 & lower wc_gr001686 0009368 124 & higher wc_gr004611 — — 0009466 105–128 wc_gr003169 104 & lower wc_gr001686 0009466 129 & higher wc_gr004611 — — 0620004 104–127 wc_gr003169 103 &...
  • Page 57 G 25 Maintenance wc_tx000197gb.fm...
  • Page 58 Maintenance G 25 Revision See Graphic: Revision See Graphic: 0009368 104–123 wc_gr003169 103 & lower wc_gr001686 0009368 124 & higher wc_gr004611 — — 0009466 105–128 wc_gr003169 104 & lower wc_gr001686 0009466 129 & higher wc_gr004611 — — 0620004 104–127 wc_gr003169 103 &...
  • Page 59 G 25 Maintenance wc_tx000197gb.fm...

  • Page 60: Trailer Wiring

    Maintenance G 25 3.10 Trailer Wiring Ref. Description Front right side amber light Front left side amber light Trailer plug Battery Brake solenoid Right tail light License plate holder lights Left tail light Rear right side red light Rear left side red light Ref.
  • Page 61 G 25 Maintenance Standard and Hydraulic Brakes Electric Brakes Br W – Br W Br W wc_gr000523 wc_tx000197gb.fm...

  • Page 62: Engine Wiring

    Maintenance G 25 3.11 Engine Wiring Revision See Graphic: Revision See Graphic: Revision See Graphic: 0009368 107–123 wc_gr003217 wc_gr003170 105 & lower wc_gr001687 0009368 124 & higher wc_gr004609 – – – – 0009466 111–128 wc_gr003217 wc_gr003170 109 & lower wc_gr001687 0009466 129 &...
  • Page 63 G 25 Maintenance wc_tx000197gb.fm...
  • Page 64 Maintenance G 25 Revision See Graphic: Revision See Graphic: Revision See Graphic: 0009368 107–123 wc_gr003217 wc_gr003170 105 & lower wc_gr001687 0009368 124 & higher wc_gr004609 – – – – 0009466 111–128 wc_gr003217 wc_gr003170 109 & lower wc_gr001687 0009466 129 & higher wc_gr004609 –...
  • Page 65 G 25 Maintenance wc_tx000197gb.fm...
  • Page 66 Maintenance G 25 Revision See Graphic: Revision See Graphic: Revision See Graphic: 0009368 107–123 wc_gr003217 wc_gr003170 105 & lower wc_gr001687 0009368 124 & higher wc_gr004609 – – – – 0009466 111–128 wc_gr003217 wc_gr003170 109 & lower wc_gr001687 0009466 129 & higher wc_gr004609 –...
  • Page 67 G 25 Maintenance wc_tx000197gb.fm...
  • Page 68 Maintenance G 25 Revision See Graphic: Revision See Graphic: Revision See Graphic: 0009368 107–123 wc_gr003217 wc_gr003170 105 & lower wc_gr001687 0009368 124 & higher wc_gr004609 – – – – 0009466 111–128 wc_gr003217 wc_gr003170 109 & lower wc_gr001687 0009466 129 & higher wc_gr004609 –...
  • Page 69 G 25 Maintenance wc_tx000197gb.fm...

  • Page 70: Factory-Installed Options

    To verify if any of these options are installed on your machine, contact Wacker Neuson Corporation at 1-800-770-0957. A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit. Please have this information available when contacting Wacker Neuson Corporation. Block Heater See Graphic: wc_gr001709 The engine block heater option includes a block heater (a) with a cord (b).

  • Page 71: Fuel/Water Separator

    G 25 Factory-Installed Options Fuel/Water Separator See Graphic: wc_gr001705 The fuel/water separator separates water from the fuel on models with Isuzu engines. Empty the separator water bowl (a) as needed by opening the water bowl drain (b). The separator element should be changed each time the fuel filter is changed—approximately every 600...

  • Page 72: Automatic Lcd Heat

    Factory-Installed Options G 25 Automatic LCD Heat See Graphic: wc_gr001723, wc_gr001724 To improve the performance of the LCD panel in cold weather, the LCD panel control module is equipped with an LCD heater. The heater draws power from the panel control module and is active only when the panel control module is powered.

  • Page 73: Low Coolant Shutdown

    G 25 Factory-Installed Options Low Coolant Shutdown See Graphic: wc_gr001708 The low-coolant shutdown system consists of an electronic sensor that monitors coolant level. The sensor (a) is mounted to the radiator and wired into the ECM. The sensor probe (b) is submerged in radiator coolant.

  • Page 74: Temperature-Activated Shutters

    Factory-Installed Options G 25 Temperature-Activated Shutters See Graphic: wc_gr005770, wc_gr001707 The shutters (a) are mounted to the top of the generator enclosure. The shutters are designed to keep the engine compartment warm, thus increasing engine temperature during cold weather operation. The shutters are activated through a wax-pellet actuator (b) that is connected to the generator's cooling system.

  • Page 75: Extended Run Tank

    G 25 Factory-Installed Options Extended Run Tank An extended run, 135-gallon fuel tank provides a 70-hour run time under a continuous full load. The long run time eliminates the need for daily refueling, saving money on fuel deliveries. The tank is fully fluid- contained and is ideal for remote or weekend running of equipment such as dewatering submersible pumps.

  • Page 76: Cam-Lock

    Factory-Installed Options G 25 Cam-Lock See Graphic: wc_gr002584 A second optional outlet panel features camlock connectors (u) for easy tool changes. The door is equipped with an interlock switch (q). When the door is opened this switch automatically trips the main circuit breaker.

  • Page 77: Containment System

    G 25 Factory-Installed Options 4.10 Containment System See Graphic: wc_gr002647 Overspills and leaks are captured in the containment system. The containment system holds over 110% of the fluid contained in the machine. The containment system should be checked every 50 hours or 2 weeks and drained when necessary.

  • Page 78: Wiring Diagram-Factory-Installed Options

    Factory-Installed Options G 25 4.11 Wiring Diagram—Factory-Installed Options Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Light blue wc_tx000853gb.fm...

  • Page 79: Wiring Diagram Components-Factory-Installed Options

    G 25 Factory-Installed Options 4.12 Wiring Diagram Components—Factory-Installed Options See Graphic: wc_gr001868 Description Description Thermostat module Positive air shutoff solenoid actuator Terminal block Auxiliary relay terminals 1 Amp fuse Plug 1, engine sensor inputs Water level sensor Electronic control board...

  • Page 80: Technical Data

    Technical Data G 25 Technical Data Engine Power Rating Engine Power Rating Gross standby power rating per ISO 8528-1 and SAE J1995. Actual power output may vary due to conditions of specific use. Engine Data Table 1 G 25 G 25 0009368, 0009466, 0620004 Rev.

  • Page 81: Engine Data Table 2

    G 25 Technical Data Engine Data Table 2 G 25 G 25 G 25 0620344 0620345 0620706 0620346 Engine Engine make / type Isuzu Model 4LE2-NYGV, Tier 4 Number of cylinders Displacement 2179 (133) Engine speed 1800 Rated standby power kW(Hp) 26.4 (35.4)

  • Page 82: Generator Data

    Technical Data G 25 Generator Data G 25 0009368 Rev.127 & higher 0009466 Rev.131 & higher 0009368 Rev.126 & lower 0620004 Rev.130 & higher 0009466 Rev.131 & lower 0620344 0620004 Rev.130 & lower 0620345 0620346 0620706 Generator Make/Type Mecc Alte / Brushless...

  • Page 83: Trailer And Skid Data

    G 25 Technical Data Trailer and Skid Data G 25 0009368 Rev.127 & higher 0009368 0009466 Rev.126 & lower Rev.131 & higher 0009466 0620004 0620706 Rev.131 & lower Rev.130 & higher 0620004 0620344 Rev.130 & lower 0620345 0620346 Trailer and Skid Dry weight of skid kg (lbs.)

  • Page 84: Dimensions

    Technical Data G 25 Dimensions mm (in.) G 25 G 25 0620344 0620346 0620345 0620706 Dimensions—mm (in.) 890 (35) 1620 (69) 1700 (67) 1945 (76.6) 1130 (44.5) 1514 (59.6) 1260 (49.6) 1644 (64.9) 3920 (154.5) wc_td000139gb.fm...
  • Page 86 Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.

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