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

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Operator's Manual
Mobile Generator
G 25
(T4i)
G 25
(T4f)
EN
5200015081
04
0215
5
2
0
0
0
1
5
0
8
1

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Do you have a question about the G 25 and is the answer not in the manual?

Questions and answers

Don Rice
March 17, 2025

How do you stop alarm for power increase

0
1 comments:
Mr. Anderson
March 17, 2025

Press the “Horn Reset” button to silence the audible alarm. Then, remove the fault condition and press “Stop/Reset.”

This answer is automatically generated

0
Mark
July 7, 2025

Where does the trigger power come from to energize the alternator

0

Related Manuals for Wacker Neuson G 25

Summary of Contents for Wacker Neuson G 25

  • Page 1 Operator’s Manual Mobile Generator G 25 (T4i) G 25 (T4f) 5200015081 0215...
  • Page 2 Wacker Neuson Production Americas LLC. Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights. Violators will be prosecuted.

  • Page 3: Machine Identification

    Machine Identification SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models below. These instructions have been written expressly by Wacker Neuson Production Americas LLC and must be followed during installation, operation, and maintenance of the machines. Machine Item Number...

  • Page 4: Foreword

    Use the separate Parts Book supplied with the machine to order replacement  parts. If you are missing any of these documents, please contact Wacker Neuson to  order a replacement or visit www.wackerneuson.com. When ordering parts or requesting service information, be prepared to provide ...
  • Page 5 Serious injury hazards to the operator and persons in the work area  Permanent damage to the machine which will not be covered under warranty  Contact your Wacker Neuson dealer immediately if you have questions about approved or unapproved parts, attachments, or modifications. wc_tx003565gb_FM10.fm...
  • Page 6 Foreword Notes wc_tx003565gb_FM10.fm...

  • Page 7: Table Of Contents

    G 25 Table of Contents Foreword Safety Information Signal Words Used in this Manual ............. 13 Machine Description and Intended Use ..........14 Safety Guidelines for Operating the Machine ........15 Service Safety ..................17 Operator Safety while Using Internal Combustion Engines ....19 Safety Guidelines for Mobile Generators ...........
  • Page 8 Table of Contents G 25 Operation (Basler Controller) Main Circuit Breaker ................54 Engine Start Switch ................55 Genset Pre-Alarms and Alarms (Shut-Down Conditions) ....56 Overcurrent Condition ................. 57 Using the Lugs and the Convenience Receptacles ......58 Selecting the Voltage ................59 Before Starting the Machine ...............
  • Page 9 G 25 Table of Contents Before Starting the Machine ............. 103 Starting and Running the Generator ..........104 Stopping the Generator ..............106 Emergency Stop Switch ..............107 9.10 Engine and Generator Monitoring ............ 108 10 Working with Deep Sea Controller: DSE 7310 10.1...
  • Page 10 Table of Contents G 25 14 Diagnostic Trouble Codes (DTC) 14.1 Accessing DTCs with the Basler Controller ........138 14.2 Accessing Engine DTCs using the Deep Sea Controller ....139 14.3 List of Engine Diagnostic Trouble Codes (DTCs) ......140 15 Factory-Installed Options 15.1...
  • Page 11 AC Schematic Components: ............201 24.3 DC Schematic: G 25, T4i Isuzu, Basler ..........202 24.4 DC Schematic Components: G 25, T4i Isuzu, Basler ...... 203 24.5 DC Schematic: G 25, T4f Isuzu, Basler ..........204 24.6 DC Schematic Components: G 25, T4f Isuzu, Basler ...... 205 24.7...
  • Page 12 G 25 25 Schematics, Machines with Deep Sea Controller 25.1 AC Schematic: ..................208 25.2 AC Schematic Components: ............209 25.3 DC Schematic: G 25, T4i Isuzu, Deep Sea ........210 25.4 DC Schematic Components: G 25, T4i Isuzu, Deep Sea ....211 wc_bo5200015081_03_FM10TOC.fm...

  • Page 13: Safety Information

    Mobile Generator Safety Information Safety Information Signal Words Used in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol.

  • Page 14: Machine Description And Intended Use

    Mobile Generator Machine Description and Intended Use This machine is a mobile electric power source. The Wacker Neuson Mobile Generator consists of a trailer-mounted cabinet containing an electric alternator, a fuel tank, and a diesel engine. A control panel, receptacles, and connection lugs are provided on the side of the cabinet.

  • Page 15: Safety Guidelines For Operating The Machine

    To ensure safe operation of the machine: ■ Do not operate the machine if any safety devices or guards are missing or inoperative. ■ Do not modify or defeat the safety devices. ■ Only use accessories or attachments that are approved by Wacker Neuson. wc_tx003567gb_FM10.fm...
  • Page 16 Safety Information Mobile Generator Safe When operating this machine: operating ■ Remain aware of the machine’s moving parts. Keep hands, feet, and loose practices clothing away from the machine’s moving parts. When operating this machine: ■ Do not operate a machine in need of repair. ■...

  • Page 17: Service Safety

    Machine When servicing or maintaining the machine: modifications ■ Use only accessories/attachments that are approved by Wacker Neuson. When servicing or maintaining the machine: ■ Do not defeat safety devices. ■ Do not modify the machine without the express written approval of Wacker Neuson.
  • Page 18 Safety Information Mobile Generator When cleaning the machine: ■ Do not clean the machine while it is running. ■ Never use gasoline or other types of fuels or flammable solvents to clean the machine. Fumes from fuels and solvents can become explosive. Personal Wear the following Personal Protective Equipment (PPE) while servicing or Protective...

  • Page 19: Operator Safety While Using Internal Combustion Engines

    Mobile Generator Safety Information Operator Safety while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. ► Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below.

  • Page 20: Safety Guidelines For Mobile Generators

    Safety Information Mobile Generator Safety Guidelines for Mobile Generators DANGER Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.
  • Page 21 Mobile Generator Safety Information General safety ■ Do not use evaporative starting fluids to start the engine. They are highly explosive. ■ Do not store items such as excess oil, rags, or tools on top of or inside the machine. These items are a fire hazard and can restrict cooling air. ■...

  • Page 22: Safety Guidelines For Towing The Machine

    Safety Information Mobile Generator Safety Guidelines for Towing the Machine WARNING Risk of severe injury or death. Improper trailer condition and towing technique can lead to an accident. ► Obey the trailer manufacturer’s instructions and the instructions below to reduce the risk of an accident.

  • Page 23: Safety Guidelines For Lifting The Machine

    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. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of trailers, it may order a recall and remedy campaign.

  • Page 24: Label Locations

    Label Locations G 25 Label Locations wc_gr011688 wc_si000835gb_FM10.fm...

  • Page 25: Table Of Contents G

    G 25 Label Locations Ø APAGADO APAGADO ARRET ARRET REMOTE START REMOTE START START / RUN START / RUN FERNSTART FERNSTART START / LAUFEN START / LAUFEN DIAGNOSTICS ARRANQUE REMOTO ARRANQUE REMOTO ARRANQUE / MARCHA ARRANQUE / MARCHA DIAGNOSEN DEMARRAGE A...

  • Page 26: Label Meanings

    Label Meanings G 25 Label Meanings (on trailer, if equipped) TOWING INSTRUCTIONS TOWING INSTRUCTIONS ABSCHLEPPINSTRUKTIONEN ABSCHLEPPINSTRUKTIONEN INSTRUCCIONES DE REMOLQUE INSTRUCCIONES DE REMOLQUE INSTRUCTIONS DE REMORQUAGE INSTRUCTIONS DE REMORQUAGE 1.LEA EL MANUAL DEL OPERARIO. 1.LEA EL MANUAL DEL OPERARIO. 1.LIRE LA NOTICE D'EMPLOI.
  • Page 27 G 25 Label Meanings DANGER Asphyxiation hazard. Do not run the machine indoors or in an enclosed area without adequate ventilation. 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.
  • Page 28 Label Meanings G 25 Electrical ground WARNING Electric shock and arc flash can cause serious injury or death. wc_tx003634gb_FM10.fm...
  • Page 29 G 25 Label Meanings Operator’s Manual must be stored on machine. Replacement Operator’s Manual can be ordered through your local Wacker Neuson distributor. wc_sy0158787 wc_sy0160602 wc_tx003634gb_FM10.fm...
  • Page 30 Label Meanings G 25 WARNING! Operation of this equipment may create sparks WARNING that can start fires around dry vegetation. A spark Operation of This Equipment May Create Sparks That Can Start Fires Around Dry arrestor may be required. The operator should Vegetation.
  • Page 31 G 25 Label Meanings WARNING Disconnect battery before servicing. Read the Operator’s Manual. (on trailer, if equipped) Drain containment system. 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.
  • Page 32 Label Meanings G 25 Operating the main circuit breaker supplies or interrupts power to the customer connection lugs. Neutral bonded to frame Fuses Read the Operator’s Manual for machine information. WARNING Electric shock at cooling fins. Generator and receptacle wiring...
  • Page 33 G 25 Label Meanings Engine wiring WARNING Hot surface (if equipped) Battery disconnect must be in “ON” position to start engine. NOTICE Do not use the battery disconnect switch while engine is running. Damage to the electrical components may occur.
  • Page 34 Label Meanings G 25 Diagnostic menu navigation This machine may be covered by one or more patents. (on trailer, if equipped) (On trailer, if equipped) 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.
  • Page 35 G 25 Label Meanings (Camlock models only) NOTICE Separate overcurrent protection must be provided. Do not exceed 400 amps per receptacle. (Camlock models only) WARNING Electric shock and arc flash can cause serious injury or death. WARNING Explosion hazard. Do not use evaporative starting fluids such as ether on this engine.

  • Page 36: Lifting And Transporting

    Lifting and Transporting Mobile Generator Lifting and Transporting Lifting the Machine ■ Lifting equipment (crane, hoist, or fork truck) capable of supporting the Requirements machine’s weight ■ Lifting devices (hooks, chains, and shackles) capable of supporting the machine’s weight ■ Engine stopped Lifting the A lifting eye is used for lifting the machine.

  • Page 37: Before Towing Checklist

    Mobile Generator Lifting and Transporting Before Towing Checklist Before towing the machine, check the licensing requirements for trailers in your area. Also check the following items: Towing vehicle  Check that the towing vehicle is rated to tow the load. ...

  • Page 38: Towing The Machine

    Lifting and Transporting Mobile Generator Towing the Machine Background The generator’s trailer is equipped with brakes (surge or electric), safety chains (a), lights, and a coupler (pintle or ball-type) (b). wc_gr011430 Brakes Only use the brakes as designed. ■ The breakaway cable (c) is not a parking brake and should not be used as one. ■...

  • Page 39: Preparing The Machine For Transport On A Truck Or Trailer

    Mobile Generator Lifting and Transporting Preparing the Machine for Transport on a Truck or Trailer ■ Machine stopped Requirements ■ Flatbed truck or trailer capable of supporting the machine’s weight ■ Chains, hooks, or straps capable of supporting the machine’s weight WARNING Crushing hazard.

  • Page 40: Hazardous Materials Placards

    Lifting and Transporting Mobile Generator Hazardous Materials Placards Overview Hazardous materials placards may have been provided with your machine. Transport Canada, and the Canadian Transportation of Dangerous Goods Act, require that these hazardous materials placards be permanently applied to certain machines if they are to be transported or towed on Canadian roads.

  • Page 41: Testing The Breakaway System (Hydraulic Surge Brakes)

    Mobile Generator Lifting and Transporting Testing the Breakaway System (Hydraulic Surge Brakes) ■ Hydraulic reservoir filled Requirements ■ Machine parked on a flat surface When Test the breakaway system: ■ Before towing ■ After filling the hydraulic reservoir Procedure Perform the following procedure to test the breakaway system. 1.
  • Page 42 Lifting and Transporting Mobile Generator Continued from the previous page. 7. Stop the tow vehicle. 8. Release the brake by simultaneously pulling on the breakaway cord and prying the locking spring with a screwdriver (c) or pry bar. wc_gr008510 Result The procedure to test the breakaway system is now complete.

  • Page 43: Testing The Breakaway System (Electric Brakes)

    Mobile Generator Lifting and Transporting Testing the Breakaway System (Electric Brakes) ■ Voltmeter Requirements ■ Battery charger or backup battery (charged) When Test the breakaway system: ■ Before towing ■ Monthly if the machine is not in service Procedure Perform the following procedure to test the breakaway system. NOTICE: Disconnect the trailer wiring plug from the tow vehicle before testing.
  • Page 44 Lifting and Transporting Mobile Generator Continued from the previous page. 5. If the brakes did not function, check the voltage of the breakaway battery. To do so: a. Remove the cover of the battery box. b. Remove the wires connected to the breakaway battery (d). c.

  • Page 45: Machine Setup

    1. Make sure all loose packaging materials have been removed from the machine. 2. Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance.

  • Page 46: Positioning The Machine

    ► Do not operate the machine near flammable vapors, fuels, or combustibles. CO Alarms Because this machine produces carbon monoxide (CO), Wacker Neuson recommends that CO alarms be installed in all structures in close proximity to the machine. CO alarms provide an extra measure of protection against this poison that you cannot see or smell.
  • Page 47 Mobile Generator Machine Setup Continued from the previous page. Procedure Perform the following procedure to position the machine. 1. Place the machine on solid, stable, and level ground. wc_gr009186 2. For machines with trailers, install chocks (a) under the wheels. Result The machine is now properly positioned.

  • Page 48: Grounding The Generator

    Machine Setup Mobile Generator Grounding the Generator Location A ground connection is located at the customer connection terminal lugs. wc_gr011524 Function This ground connection is used for electrically grounding the generator when necessary to comply with the National Electrical Code and other federal, state, and local regulations.

  • Page 49: Recommended Fuel

    Mobile Generator Machine Setup Recommended Fuel Low temperatures cause diesel fuel to gel. Always use the proper fuel for the conditions. Follow the guidelines in the table below. Lowest expected ambient Recommended fuel temperature Above freezing #2 diesel plus additives <...

  • Page 50: Refueling The Machine (Basler Controller)

    Machine Setup Mobile Generator Refueling the Machine (Basler Controller) ■ Machine shut down Requirements ■ Engine cool ■ Machine/fuel tank level with the ground ■ Remote switch disconnected from the remote run terminal ■ Fresh, clean fuel supply Procedure Perform the procedure below to refuel the machine. WARNING Fire hazard.

  • Page 51: Refueling The Machine (Deep Sea Controller)

    Mobile Generator Machine Setup Refueling the Machine (Deep Sea Controller) ■ Engine stopped Requirements ■ Machine/fuel tank level with the ground ■ Remote switch disconnected from the remote run terminal ■ Fresh, clean fuel supply Procedure Perform the procedure below to refuel the machine. WARNING Fire hazard.

  • Page 52: Operation, Control, And Component Locations

    Operation, Control, and Component Locations Operation, Control, and Component Locations Control / Component Locations Ø STOP DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS WARNING WARNING 0 0 5 6 3 APAGADO APAGADO ARRET ARRET REMOTE START REMOTE START START / RUN START / RUN FERNSTART FERNSTART START / LAUFEN...

  • Page 53: Control Panel Components

    Operation, Control, and Component Locations wc_gr011690 Control Panel Components Ref. Description Ref. Description Main circuit breaker Twist-lock receptacle (2) 240 VAC, 50A optional: (2) 240 VAC 20A, (1) 240 VAC 50A Voltage adjustment rheostat GFI receptacle (120 VAC, 20A) Genset controller (Basler or Deep Sea) Remote run terminal block Idle switch (high and low) (if equipped) Emergency stop switch...

  • Page 54: Operation (Basler Controller)

    Operation (Basler Controller) Main Circuit Breaker Location Various styles of main circuit breakers may be found on Wacker Neuson Mobile generators. The main circuit breaker (a) is located on the control panel. Note: Graphic is representative only. Your machine may vary.

  • Page 55: Engine Start Switch

    Mobile Generator Operation (Basler Controller) Engine Start Switch Description The engine start switch (a) is a three-position switch: “REMOTE START”, “OFF”, and “START/RUN”. APAGADO APAGADO ARRET ARRET REMOTE START REMOTE START START / RUN START / RUN START / LAUFEN START / LAUFEN FERNSTART FERNSTART...

  • Page 56: Genset Pre-Alarms And Alarms (Shut-Down Conditions)

    Operation (Basler Controller) Mobile Generator Genset Pre-Alarms and Alarms (Shut-Down Conditions) Background The genset controller monitors variables of engine and machine function. The genset controller is programmed to signal pre-alarm conditions, and to shut down the machine when an alarm condition exists. Pre-alarms Pre-alarm conditions are: ■...

  • Page 57: Overcurrent Condition

    Mobile Generator Operation (Basler Controller) Overcurrent Condition Along with engine functions, the genset controller continuously monitors the current load in each leg. The values for current overload are programmed into the ECM at the factory and are different for each generator size. Ø...

  • Page 58: Using The Lugs And The Convenience Receptacles

    Operation (Basler Controller) Mobile Generator Using the Lugs and the Convenience Receptacles Overview Loads can be connected to the genset in two different ways: 1. At the connection lugs (r). Located as shown, behind the lug door, the connection lugs serve as connection points for cables.

  • Page 59: Selecting The Voltage

    Mobile Generator Operation (Basler Controller) Selecting the Voltage Location One of two types of voltage selector switch—either three-position (a) or four- position (b)—is mounted to the machine near the lugs. 3Ø 1Ø 277/480V 208/240V 3 Ø 3Ø 120/139V 1 Ø 120/240V 277/480V 3Ø...
  • Page 60 Operation (Basler Controller) Mobile Generator Using the The voltage adjustment rheostat (c) is used to fine-tune the voltage as needed rheostat while the machine is running. APAGADO APAGADO ARRET ARRET REMOTE START REMOTE START START / RUN START / RUN FERNSTART FERNSTART START / LAUFEN...

  • Page 61: Before Starting The Machine

    Mobile Generator Operation (Basler Controller) Before Starting the Machine WARNING Personal injury hazard. Failure to follow the listed procedures may cause injury to personnel or damage to the generator. ► Make sure that all persons setting up the generator are certified or fully trained on the installation of the generator.

  • Page 62: Starting And Running The Machine

    Operation (Basler Controller) Mobile Generator Starting and Running the Machine CAUTION Possibility of injury or equipment damage. Failure to match phase, voltage, and frequency may cause equipment connected to the generator to operate incorrectly. ► When using the generator as a stand-by or substitute power supply, make sure the phase, voltage, and frequency of the generator matches that of the utility lines or of any other power source normally used.
  • Page 63 LCD panel displays EMERGENCY STOP, and the pre-alarm/alarm LED illuminates. If the LCD does not display EMERGENCY STOP, do not continue. Contact a Wacker Neuson dealer for assistance. Pull out the emergency stop button after verifying the display. c. Set the engine start switch to OFF.

  • Page 64: Stopping The Machine

    Operation (Basler Controller) Mobile Generator Stopping the Machine 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. 1.

  • Page 65: Lcd Panel: Monitoring Machine Operation

    Mobile Generator Operation (Basler Controller) 7.11 LCD Panel: Monitoring Machine Operation Overview Generator and engine information is continuously monitored and displayed on the LCD panel. The upper line displays generator information. The lower line displays engine information. Generator Engine wc_gr010202 Generator The upper line of the LCD panel shows the voltage, phase, amperage, and information...
  • Page 66 Operation (Basler Controller) Mobile Generator Continued from the previous page. Engine The lower line of the LCD panel shows fuel level, temperature, oil pressure, and information battery voltage. The information is shown when the engine start switch is set to RUN/START.

  • Page 67: Working With Basler Controller

    Mobile Generator Working with Basler Controller Working with Basler Controller How to Use the Genset Controller LCD and Keypad Basics The LCD (a) is used to display information regarding machine performance and operating status. The keypad (b) is used to maneuver through the various menus of the genset controller.

  • Page 68: Menu Diagram Of The Genset Controller

    Working with Basler Controller Mobile Generator Menu Diagram of the Genset Controller The various menus of the genset controller are divided into two main categories: METERING and SETTINGS. Access to the METERING menu and to the SETTINGS menu is done through the MAIN MENU. To access the MAIN MENU from either the monitoring screen or the READY screen, press the right arrow button.

  • Page 69: Menu Diagram Components

    Mobile Generator Working with Basler Controller Menu Diagram Components Menu Item Description Menu Item Description Alarm Config J1939 Active DTC Alarm configuration Diagnostic Trouble Codes Alarm Configuration J1939 Data — — Alarms J1939 Engine Config — Engine configuration Alarm–Status J1939 Previous DTC —...

  • Page 70: Using The Metering And Settings Menus

    Working with Basler Controller Mobile Generator Menu Item Description Menu Item Description Generator — — Generator Protection Voltages — — Hrs to Maintenance — Hours to maintenance — Inputs — — — Using the Metering and Settings Menus Background The various menus of the genset controller are divided into two main categories: METERING, and SETTINGS.

  • Page 71: Logging In To The Genset Controller By Entering The Password

    Mobile Generator Working with Basler Controller Logging in to the Genset Controller by Entering the Password Precaution Only change parameters when the READY screen is displayed (start switch in the REMOTE START position). Password In order to change the parameters under the settings menu, you must be “logged in”...
  • Page 72 Working with Basler Controller Mobile Generator Continued from the previous page. 3. Using the up/down arrow buttons, scroll through the setting parameters until ENTER PASSWORD is highlighted. Then, press the check mark button (5). 4. The password entry screen appears with a letter “A” as the default character. Use the up/down arrow buttons to change the “A”...
  • Page 73 Mobile Generator Working with Basler Controller At the To log in when prompted to enter the password, do the following: PASSWORD 1. The password entry screen appears with a letter “A” as the default character. prompt Use the up/down arrow buttons to change the “A” to “O”. Then, press the right arrow button to move the cursor to the next position.

  • Page 74: Adjusting The Lcd Screen Contrast

    Working with Basler Controller Mobile Generator Adjusting the LCD Screen Contrast Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.

  • Page 75: Changing The Time/Date Settings

    Mobile Generator Working with Basler Controller Changing the Time/Date Settings Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.

  • Page 76: Changing The Sender Fail Time Delays

    Working with Basler Controller Mobile Generator Changing the Sender Fail Time Delays Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller or connections to a remote start switch may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.
  • Page 77 Mobile Generator Working with Basler Controller Continued from the previous page. 2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the right arrow button. 3. Highlight ALARM CONFIGURATION. Then, press the right arrow button. 4. Highlight SENDER FAIL. Then, press the right arrow button. 5.

  • Page 78: Changing The Units Of Measure

    Working with Basler Controller Mobile Generator Changing the Units of Measure Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.
  • Page 79 Mobile Generator Working with Basler Controller Continued from the previous page. 8. Exit by pressing the left arrow button (4) twice or until the LCD displays the SETTINGS menu. Then, scroll to LOGOUT and press the check mark button. Press the left arrow button so that the READY screen appears. Result The units of measure have now been changed.

  • Page 80: Changing The Low Fuel Pre-Alarm Setting

    Working with Basler Controller Mobile Generator 8.10 Changing the Low Fuel Pre-Alarm Setting Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.
  • Page 81 Mobile Generator Working with Basler Controller Continued from the previous page. 8. Using the up/down arrow buttons, change the value as desired. Press the check mark button when finished. 9. Exit by pressing the left arrow button (4) three times or until the LCD displays the SETTINGS menu.

  • Page 82: Changing Or Disabling The Low Fuel Alarm Setting

    Approximate run time (at 100% prime load) gained with low fuel alarm set to 0%. Machine Fuel Use gal/hr Time Gained hr G 25 G 25 ERT G 50 G 50 ERT G 70 G 70 ERT G 100 G 120 7.44...
  • Page 83 Mobile Generator Working with Basler Controller Continued from the previous page. 2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the right arrow button.Highlight ALARM CONFIG. Then, press the right arrow button. 3. Highlight ALARMS. Then, press the right arrow button. 4.

  • Page 84: Changing The Cooldown Time Setting

    Working with Basler Controller Mobile Generator 8.12 Changing the Cooldown Time Setting Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.
  • Page 85 Mobile Generator Working with Basler Controller Continued from the previous page. 4. Highlight CRANK SETTINGS. Then, press the right arrow button. 5. Highlight COOLDOWN TIME. Then, press the check mark button (5). 6. If you are not logged in, enter the password “OP”. Press the check mark button. 7.

  • Page 86: Changing The Pre-Crank Time Delay (Glow Plug Timer)

    Working with Basler Controller Mobile Generator 8.13 Changing the Pre-Crank Time Delay (Glow Plug Timer) Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.
  • Page 87 Mobile Generator Working with Basler Controller Continued from the previous page. 4. Highlight CRANK SETTINGS. Then, press the right arrow button. 5. Highlight PRECRANK DELY. Then, press the check mark button (5). 6. If you are not logged in, enter the password “OP”. Press the check mark button. 7.

  • Page 88: Changing The Maintenance Interval

    Working with Basler Controller Mobile Generator 8.14 Changing the Maintenance Interval Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.
  • Page 89 Mobile Generator Working with Basler Controller Continued from the previous page. 3. Highlight ALARM CONFIGURATION. Then, press the right arrow button. 4. Highlight PRE-ALARMS. Then, press the right arrow button. 5. Highlight the MAINTENANCE INTERVAL. Then, press the right arrow button. 6.

  • Page 90: Resetting The Maintenance Interval Pre-Alarm

    Working with Basler Controller Mobile Generator 8.15 Resetting the Maintenance Interval Pre-Alarm Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.
  • Page 91 Mobile Generator Working with Basler Controller Continued from the previous page. 3. With the PRE-ALARMS screen showing (MAINT INTERVAL highlighted), press the left arrow button (4) three times. 4. Using the up/down arrow buttons highlight METERING. Then, press the right arrow button.

  • Page 92: Resetting A Loss Of Voltage Pre-Alarm

    Working with Basler Controller Mobile Generator 8.16 Resetting a Loss of Voltage Pre-Alarm Background The loss of voltage pre-alarm condition occurs most often because of an open lug door switch. During a loss of voltage pre-alarm, the LCD will display the screens below.

  • Page 93: Accessing And Using The Event Log

    Mobile Generator Working with Basler Controller 8.17 Accessing and Using the Event Log Requirements Machine stopped  Start switch in REMOTE START  Note: Internal programming of the genset controller, or closed connections to a remote start switch, may cause the machine to start unexpectedly. Be prepared for the engine to start even with the engine start switch in the REMOTE START position.
  • Page 94 Working with Basler Controller Mobile Generator LCD Screen Meaning GEN TEST LOADED Generator test loaded MAINT INTERVAL P Maintenance interval pre-alarm LOW COOL LEVEL A Low coolant level alarm 5. Highlight the event of interest. Then, press the right arrow button. Details of the event appear: They are: ACTIVE ...

  • Page 95: Operation (Deep Sea Controller)

    Operation (Deep Sea Controller) Main Circuit Breaker Location Various styles of main circuit breakers may be found on Wacker Neuson Mobile generators. The main circuit breaker (a) is located on the control panel. Note: Graphic is representative only. Your machine may vary.

  • Page 96: Genset Controller Power Switch

    Operation (Deep Sea Controller) Mobile Generator Genset Controller Power Switch Description The genset controller power switch (a) is a two-position switch: ON and OFF. wc_gr011478 Function Position Function LCD Screen When set to this position: “Generator at Rest” followed ■ Power is supplied to the genset by the status screens that controller.

  • Page 97: Selecting The Voltage

    Mobile Generator Operation (Deep Sea Controller) Selecting the Voltage Location One of two types of voltage selector switch—either three-position (a) or four- position (b)—is mounted to the machine near the lugs. 3Ø 1Ø 277/480V 208/240V 3 Ø 3Ø 120/139V 1 Ø 120/240V 277/480V 3Ø...
  • Page 98 Operation (Deep Sea Controller) Mobile Generator Using the The voltage adjustment rheostat (c) is used to fine-tune the voltage as needed rheostat while the machine is running. APAGADO APAGADO ARRET ARRET REMOTE START REMOTE START START / RUN START / RUN FERNSTART FERNSTART START / LAUFEN...

  • Page 99: Deep Sea Controller Buttons/Functions

    Mobile Generator Operation (Deep Sea Controller) Deep Sea Controller Buttons/Functions DEEP SEA ELECTRONIC DEEP SEA ELECTRONICS S DSE 731 DSE 7310 0 Alarm Alarm Warning arning Main Breaker Open Main Breaker Open Low Speed Low Speed Active Active Open Open Open Open Load...
  • Page 100 Operation (Deep Sea Controller) Mobile Generator Ref. Button/function Stop / Reset Pressing this button: ■ Sets the genset controller into its Stop/Reset mode ■ Clears any alarm conditions for which the triggering criteria have been rectified. Manual mode Pressing this button: ■...

  • Page 101: Genset Controller Alarms And Shut-Down Conditions

    Mobile Generator Operation (Deep Sea Controller) Genset Controller Alarms and Shut-Down Conditions Background The genset controller monitors variables of engine and machine function. The genset controller has two types of alarms: warning alarms and shut-down alarms. The genset controller also monitors for electrical trip conditions. Warning Warnings are non-critical alarm alarms...
  • Page 102 Operation (Deep Sea Controller) Mobile Generator Electrical trips Electrical trips are latching type alarms that stop the engine. During an electrical trip, the LEDs (6, 8) DEEP SEA ELECTRONICS illuminate, an audible alarm sounds, and DSE 7310 the machine is shut down. Alarm Warning Main Breaker Open...

  • Page 103: Before Starting The Machine

    Mobile Generator Operation (Deep Sea Controller) Before Starting the Machine WARNING Personal injury hazard. Failure to follow the listed procedures may cause injury to personnel or damage to the generator. ► Make sure that all persons setting up the generator are certified or fully trained on the installation of the generator.

  • Page 104: Starting And Running The Generator

    Operation (Deep Sea Controller) Mobile Generator Starting and Running the Generator CAUTION Possibility of injury or equipment damage. Failure to match phase, voltage, and frequency may cause equipment connected to the generator to operate incorrectly. ► When using the generator as a stand-by or substitute power supply, make sure the phase, voltage, and frequency of the generator matches that of the utility lines or of any other power source normally used.
  • Page 105 Mobile Generator Operation (Deep Sea Controller) Continued from the previous page. 7. The engine will crank. During a normal cycle, the engine cranks for 12 seconds and rests for 12 seconds. This cycle will repeat three times. Note: If the engine does not start within the normal cycle, the genset controller will shut down the engine.

  • Page 106: Stopping The Generator

    Operation (Deep Sea Controller) Mobile Generator Stopping the Generator Requirements Before stopping the 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 107: Emergency Stop Switch

    Mobile Generator Operation (Deep Sea Controller) Emergency Stop Switch Location The emergency stop switch is the red button (a) located to the left of the control panel. The button can be accessed with the panel doors closed. It is electrically isolated from the switch and also from the rest of the metering panel.

  • Page 108: Engine And Generator Monitoring

    Operation (Deep Sea Controller) Mobile Generator 9.10 Engine and Generator Monitoring Description Engine and generator information is displayed on the LCD panel and scrolls continuously while the generator is operating. For more information on the Deep Sea controller, see chapter Working with the Deep Sea Controller.

  • Page 109: Working With Deep Sea Controller: Dse 7310

    Working with Deep Sea Controller: DSE 7310 10 Working with Deep Sea Controller: DSE 7310 10.1 Introduction During normal operation, the genset controller displays current information on machine performance and operating status. The keypad (e) provides access to additional monitoring functions through a series of menus displayed on the LCD panel (f).

  • Page 110: Navigating The Menus

    Working with Deep Sea Controller: DSE 7310 10.2 Navigating the Menus The graphic below serves as a navigational aid when accessing the various menus of the genset controller. See the accompanying table for information about the menu items. MENU NAVIGATION MENU NAVIGATION Status Status...
  • Page 111 Working with Deep Sea Controller: DSE 7310 Menu Item Description Menu Item Description About — Module Information — Active Config Generator Configuration Gen Load (h) Generator Load kVArh Alarms Gen Load (%) Generator Load Percent Alarms Active — Gen Load (kVA) Generator Load kVA —...

  • Page 112: Adjusting Screen Contrast

    Working with Deep Sea Controller: DSE 7310 10.3 Adjusting Screen Contrast Overview The contrast of the LCD display can be adjusted to suit the operator’s preference. Procedure Perform the procedure below to adjust the screen contrast. 1. Access the “Editor—Display” menu on the LCD panel (f) by pressing and holding the check mark button (5) on the keypad.

  • Page 113: How To Reset The Maintenance Timer

    Working with Deep Sea Controller: DSE 7310 10.4 How to Reset the Maintenance Timer Background The maintenance timer is preset to 500 hours. When the maintenance timer times out, the genset controller sounds the audible alarm. Procedure Perform the procedure below to reset the maintenance timer. 1.

  • Page 114: How To Connect Loads (480V)

    How to Connect Loads (480V) Mobile Generator 11 How to Connect Loads (480V) The information in this chapter on how to connect loads applies to machines with maximum capabilities of up to 480V. This chapter does not apply to machines with maximum capabilities of up to 600V. 11.1 Lug Terminal Connection Diagrams High Wye...

  • Page 115: Best Practices For Balancing Loads

    Mobile Generator How to Connect Loads (480V) 11.2 Best Practices for Balancing Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. Background Three-phase (3Ø) loads are, by their nature, balanced. It is when single-phase (1Ø) loads are combined with existing 3Ø...
  • Page 116 How to Connect Loads (480V) Mobile Generator Continued from the previous page. 3Ø Situations When combining 1Ø loads with 3Ø loads (voltage selector switch in 208/240V position), unbalanced loads can be detected by observing the genset controller LCD panel. If an unbalanced load condition exists, there will be a significant difference in both voltage and amperage between the phases.
  • Page 117 Mobile Generator How to Connect Loads (480V) Continued from the previous page. Using the This information applies whether the machine is running in 3Ø or in 1Ø. receptacles Note: When in the 600V mode, single phase power is not available. When connecting two loads to the duplex receptacles, instead of plugging both loads in to the same duplex receptacle, plug the first load in to one of the duplex receptacles.

  • Page 118: Connecting 480V, 3-Phase And Single-Phase Loads

    How to Connect Loads (480V) Mobile Generator 11.3 Connecting 480V, 3-Phase and Single-Phase Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 119: Connecting A 240V 3Ø Load And A 240V 1Ø Load

    Mobile Generator How to Connect Loads (480V) 11.4 Connecting a 240V 3Ø Load and a 240V 1Ø Load WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 120: Connecting 240V And 120V Single-Phase Loads

    How to Connect Loads (480V) Mobile Generator 11.5 Connecting 240V and 120V Single-Phase Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. Background Single-phase loads may be connected at the lugs by connecting the load “line to line”...

  • Page 121: Connecting A 208V 3Ø Load And Multiple 120V 1Ø Loads

    Mobile Generator How to Connect Loads (480V) 11.6 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 122: Connecting A 220–240V 3Ø Load And Multiple 127–133V 1Ø Loads

    How to Connect Loads (480V) Mobile Generator 11.7 Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 123: How To Connect Loads (600V)

    Mobile Generator How to Connect Loads (600V) 12 How to Connect Loads (600V) The information in this chapter on how to connect loads applies to machines with maximum capabilities up to 600V. This chapter does not apply to machines with maximum capabilities of only 480V. 12.1 Lug Terminal Connection Diagrams wc_gr011347...

  • Page 124: Best Practices For Balancing Loads

    How to Connect Loads (600V) Mobile Generator 12.2 Best Practices for Balancing Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. Background Three-phase (3Ø) loads are, by their nature, balanced. It is when single-phase (1Ø) loads are combined with existing 3Ø...
  • Page 125 Mobile Generator How to Connect Loads (600V) Continued from the previous page. 3Ø Situations When combining 1Ø loads with 3Ø loads (voltage selector switch in 208/240V position), unbalanced loads can be detected by observing the genset controller LCD panel. If an unbalanced load condition exists, there will be a significant difference in both voltage and amperage between the phases.
  • Page 126 How to Connect Loads (600V) Mobile Generator Continued from the previous page. Using the This information applies whether the machine is running in 3Ø or in 1Ø. receptacles Note: When in the 600V mode, single phase power is not available. When connecting two loads to the duplex receptacles, instead of plugging both loads in to the same duplex receptacle, plug the first load in to one of the duplex receptacles.

  • Page 127: Connecting A 240V 3Ø Load And A 240V 1Ø Load

    Mobile Generator How to Connect Loads (600V) 12.3 Connecting a 240V 3Ø Load and a 240V 1Ø Load WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 128: Connecting 240V And 120V Single-Phase Loads

    How to Connect Loads (600V) Mobile Generator 12.4 Connecting 240V and 120V Single-Phase Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. Background Single-phase loads may be connected at the lugs by connecting the load “line to line”...

  • Page 129: Connecting A 208V 3Ø Load And Multiple 120V 1Ø Loads

    Mobile Generator How to Connect Loads (600V) 12.5 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 130: Connecting A 220–240V 3Ø Load And Multiple 127–133V 1Ø Loads

    How to Connect Loads (600V) Mobile Generator 12.6 Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 131: Connecting 480V, 3-Phase Loads

    Mobile Generator How to Connect Loads (600V) 12.7 Connecting 480V, 3-Phase Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 132: Connecting 600V, 3-Phase Loads

    How to Connect Loads (600V) Mobile Generator 12.8 Connecting 600V, 3-Phase Loads WARNING Electric shock hazard. High voltage can cause serious injury or death. ► Connections must be made by a qualified electrician. 1. Stop the engine and turn the main circuit breaker off. 2.

  • Page 133: Using Remote Start Capabilities

    Mobile Generator Using Remote Start Capabilities 13 Using Remote Start Capabilities 13.1 Remote Run Terminal Block Location The remote run terminal block (a) is located as shown. Note: Graphic is representative only. Your machine may vary. Ø DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS 4,000 ft 1,219 m...

  • Page 134: Remote Transfer Switch

    Using Remote Start Capabilities Mobile Generator 13.2 Remote Transfer Switch Background A remote transfer switch is designed to transfer electrical loads from the normal power source (utility) to the emergency power source (generator) when normal voltage falls below a prescribed level. The remote transfer switch automatically returns the load back to the normal source when power is restored back to operating levels.

  • Page 135: Preparing For Automatic/Remote Start-Up (Basler)

    Mobile Generator Using Remote Start Capabilities 13.3 Preparing for Automatic/Remote Start-Up (Basler) Background When the engine start switch is in the REMOTE START position, the generator can be started remotely through a automatic transfer switch or other type of remote start switch.

  • Page 136: Preparing For Automatic/Remote Start-Up (Deep Sea)

    Using Remote Start Capabilities Mobile Generator 13.4 Preparing for Automatic/Remote Start-Up (Deep Sea) Background In AUTO mode, the generator can be started remotely, either through a transfer switch or some other type of remote start switch. AUTO mode is the normal setting when using the generator as a stand-by power supply.
  • Page 137 Mobile Generator Using Remote Start Capabilities Continued from the previous page. 2. Leave the genset controller power switch in the ON position. 3. Close the main circuit breaker. 4. Press the AUTO mode button. 5. Secure the generator by closing and locking all doors. The generator is now ready for automatic starting.

  • Page 138: Diagnostic Trouble Codes (Dtc)

    Diagnostic Trouble Codes (DTC) Mobile Generator 14 Diagnostic Trouble Codes (DTC) 14.1 Accessing DTCs with the Basler Controller Background This machine may include an engine that has self-diagnostic capabilities. These engines communicate issues with the engine through Diagnostic Trouble Codes (DTCs).

  • Page 139: Accessing Engine Dtcs Using The Deep Sea Controller

    Mobile Generator Diagnostic Trouble Codes (DTC) 14.2 Accessing Engine DTCs using the Deep Sea Controller Background This machine may include an engine that has self-diagnostic capabilities. These engines communicate issues with the engine through Diagnostic Trouble Codes (DTCs). When a DTC is present, an alert will show on the LCD panel display. A DTC is a two part code consisting of a Suspect Parameter Number (SPN), and a Failure Mode Identifier (FMI).

  • Page 140: List Of Engine Diagnostic Trouble Codes (Dtcs)

    Diagnostic Trouble Codes (DTC) Mobile Generator 14.3 List of Engine Diagnostic Trouble Codes (DTCs) Failure Code Failure Type SPN-FMI 100-1 Engine oil press drop 100-3 Engine oil press sensor malfunction (high voltage) 100-4 Engine oil press sensor malfunction (low voltage) 102-3 Boost pressure sensor malfunction (high voltage) 102-4...
  • Page 141 Mobile Generator Diagnostic Trouble Codes (DTC) Failure Code Failure Type SPN-FMI 654-5 Injection nozzle # 4 driving system disconnection 676-5 Glow relay malfunction 677-5 Starter cut relay malfunction 723-2 Crank sensor malfunction (no signal) 723-8 Crank sensor malfunction (abnormal signal) 1077-2 CPU malfunction 1079-2...
  • Page 142 Diagnostic Trouble Codes (DTC) Mobile Generator Failure Code Failure Type SPN-FMI 10048-2 SWITCH-IC 1 communicate malfunction 10050-2 Injector IC malfunction 10051-2 Injector IC communicate malfunction 10052-2 Injector IC check sum malfunction wc_tx003548gb_FM10.fm...

  • Page 143: Battery Charger

    This machine may be equipped with one or more of the following 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.

  • Page 144: Lockable Battery Disconnect

    Factory-Installed Options Mobile Generator 15.2 Lockable Battery Disconnect A lockable ON/OFF switch is available which disconnects the battery. A padlock (not included) securely locks the switch in the OFF position. If equipped, the battery disconnect switch is mounted to the upper skid beneath the access door on either the right or left side of the machine.

  • Page 145: Camlocks

    Mobile Generator Factory-Installed Options 15.3 Camlocks A second optional outlet panel features camlock connectors for easy tool changes. Each connector is protected by a spring-loaded cover. NOTICE: Separate overcurrent protection must be provided. Do not exceed 400 amps per receptacle. WARNING Electric shock hazard.

  • Page 146: Containment System

    Factory-Installed Options Mobile Generator 15.4 Containment System Overspills and leaks are captured in the containment system (a). The containment system holds over 110% of the fluid contained in the machine. wc_gr002647 The containment system should be checked every 50 hours or 2 weeks and drained when necessary.

  • Page 147: Engine Block Heater

    Mobile Generator Factory-Installed Options 15.6 Engine Block Heater The engine block heater option includes a block heater (a) with a cord (b). The function of the block heater is to heat the engine coolant/engine block to improve cold-weather engine starting. Plug the cord into a 120V power supply. 15.7 Automatic LCD Heat To improve the performance of the LCD panel in cold weather, the LCD panel...

  • Page 148: Low Coolant Shutdown

    Factory-Installed Options Mobile Generator 15.8 Low Coolant Shutdown Description 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. Function If the probe senses no coolant, it sends a signal to the ECM.

  • Page 149: Temperature-Activated Shutters

    Mobile Generator Factory-Installed Options 15.9 Temperature-Activated Shutters 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 150: Positive Air Shutoff Valve

    Factory-Installed Options Mobile Generator 15.10 Positive Air Shutoff Valve Description Diesel engines may occasionally continue to run even after the machine has been turned off. This “runaway” condition occurs when combustible intake air is drawn into the engine. Pressing the emergency stop switch alone will not stop a runaway engine.

  • Page 151: Quick-Disconnect Fuel Fittings

    Mobile Generator Factory-Installed Options 15.11 Quick-Disconnect Fuel Fittings Quick-disconnect fuel fittings allow an external fuel supply to be connected to the engine. ■ Engine stopped and cool to the touch Requirements ■ Fuel supply and return hoses with compatible quick-disconnect fittings Note: Required fitting size is ISO 7241-1-Series B (3/8 in.) Procedure Perform the following procedure to connect the external fuel supply.

  • Page 152: Lube Level Maintainer

    Factory-Installed Options Mobile Generator 15.12 Lube Level Maintainer Description The lube level maintainer system protects the engine from low oil levels by providing an additional 6-quart oil reservoir. Oil from the reservoir is gravity-fed from the oil reservoir (a) through the control valve (b) and into the engine oil pan as needed.

  • Page 153: General Maintenance

    Wacker Neuson. The use of service parts that are not equivalent in performance and durability to authorized parts may impair the effectiveness of the emission control system and may have a bearing on the outcome of a warranty claim.

  • Page 154: Preparing For Maintenance

    General Maintenance Mobile Generator 16.3 Preparing for Maintenance Do not perform even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down. Use the checklist below to prepare this machine for maintenance.  Move the start switch to “OFF”. ...

  • Page 155: Inspecting The Machine

    Mobile Generator General Maintenance 16.5 Inspecting the Machine When Daily Overview Inspect the machine before each use. A thorough inspection will help to identify mechanical faults or potentially unsafe operating conditions. Correct these problems before operating the machine. External Perform an external inspection of the machine. Check for: inspection ...

  • Page 156: Maintaining The Trailer

    General Maintenance Mobile Generator 16.6 Maintaining the Trailer ■ Keep tires inflated to the proper pressure as shown on the tire sidewall. Tires ■ Check tread periodically for wear. ■ Replace tires as required. ■ Check that lug nuts holding wheels are tight. Wheels ■...

  • Page 157: Checking And Draining The Containment System

    Mobile Generator General Maintenance 16.7 Checking and Draining the Containment System When Daily Overview Certain machines are equipped with a containment system. The containment system protects the environment by collecting fluid leaks (fuel, coolant, or oil) which might otherwise contaminate the soil. NOTICE: It is important to check the containment system daily.

  • Page 158: Checking The Exhaust System

    General Maintenance Mobile Generator 16.8 Checking the Exhaust System When Check the exhaust system daily before operating the machine. Background A leaky exhaust system will adversely affect machine operation. Symptoms include increased noise, visible soot deposits, and carbon monoxide emission. Leaking exhaust can also ignite surrounding materials and pipe insulation, causing a fire.

  • Page 159: Maintaining The Battery

    Mobile Generator General Maintenance 16.9 Maintaining the Battery WARNING Explosion hazard. Batteries can emit explosive hydrogen gas. ► Keep all sparks and flames away from the battery. ► Do not short-circuit battery posts. Safety Observe the following safety precautions to prevent serious damage to the precautions electrical system.

  • Page 160: Cleaning The Diesel Particulate Filter (Dpf) (If Equipped)

    General Maintenance Mobile Generator 16.10 Cleaning the Diesel Particulate Filter (DPF) (if equipped) Overview Sustained operation of the generator under load heats the DPF to a temperature high enough to burn accumulated soot. This cleaning process (passive regeneration) normally occurs automatically. Soot may fill the DPF (a) when the engine runs at idle for long periods with no load.

  • Page 161: Storage

    Mobile Generator General Maintenance 16.11 Storage Introduction Extended storage of equipment requires preventive maintenance. Performing these steps helps to preserve machine components and ensures the machine will be ready for future use. While not all of these steps necessarily apply to this machine, the basic procedures remain the same.

  • Page 162: Machine Disposal / Decommissioning

    General Maintenance Mobile Generator 16.12 Machine Disposal / Decommissioning Introduction This machine must be properly decommissioned at the end of its service life. Responsible disposal of recyclable components, such as plastic and metal, ensures that these materials can be reused—conserving landfill space and valuable natural resources.

  • Page 163: Maintenance Tier 4I Engines: Isuzu

    G 25 Maintenance Tier 4i Engines: Isuzu 17 Maintenance Tier 4i Engines: Isuzu The viscosity of the engine oil is an important factor when determining the correct engine oil to use in your machine. Use an engine oil of appropriate viscosity based on the expected outside air temperature.
  • Page 164 Maintenance Tier 4i Engines: Isuzu G 25 The engine maintenance schedule(s) in this chapter are reproduced from the engine owner’s manual. For additional information, see the engine owner’s manual. wc_tx003641gb_FM10.fm...
  • Page 165 G 25 Maintenance Tier 4i Engines: Isuzu wc_tx003641gb_FM10.fm...

  • Page 166: Maintenance Tier 4F Engines: Isuzu

    Maintenance Tier 4f Engines: Isuzu 18 Maintenance Tier 4f Engines: Isuzu The viscosity of the engine oil is an important factor when determining the correct engine oil to use in your machine. Use an engine oil of appropriate viscosity based on the expected outside air temperature.
  • Page 167 Maintenance Tier 4f Engines: Isuzu The engine maintenance schedule(s) in this chapter are reproduced from the engine owner’s manual. For additional information, see the engine owner’s manual. 770001 wc_tx003642gb_FM10.fm...
  • Page 168 Maintenance Tier 4f Engines: Isuzu 770006 wc_tx003642gb_FM10.fm...
  • Page 169 Maintenance Tier 4f Engines: Isuzu 770007 wc_tx003642gb_FM10.fm...
  • Page 170 Maintenance Tier 4f Engines: Isuzu 770008 770009 wc_tx003642gb_FM10.fm...
  • Page 171 Maintenance Tier 4f Engines: Isuzu 770010 wc_tx003642gb_FM10.fm...

  • Page 172: Troubleshooting

    Troubleshooting Mobile Generators 19 Troubleshooting Problem Cause Remedy Engine doesn’t start Battery discharged Charge battery. Battery connections Clean battery connections. corroded Blown fuse Replace fuse. Defective starter Replace starter. Engine tries to start but No fuel Fill tank with fuel. stops Bleed fuel lines.

  • Page 173: Technical Data

    Engine Engine Power Rating Net standby power rating per ISO 8528-1 and SAE J1349. Actual power output may vary due to conditions of specific use. G 25 G 25 ERT Engine Engine make / type Isuzu Model 4LE2-NYGV, Tier 4 Interim...
  • Page 174 Technical Data G 25 G 25 G 25 ERT Engine Engine make / type Isuzu Model 4LE2-TAGV, Tier 4 Final Number of cylinders Displacement (in. 2179 (133) Engine speed 1800 Power @ 1800 rpm - continuous/ kW (hp) 23.5 (31.5) / 30.0 (40.0)

  • Page 175: Generator

    G 25 Technical Data 20.2 Generator G 25 Machine G 25 ERT Generator Make/Type Mecc Alte / Brushless Model ECO 28-2LN/4 Generator speed 1800 Voltage selector switch 3 position AC voltages available 120/240 zig-zag 120/208 low-wye 277/480 hi-wye Frequency 60 Hz Power factor 1ø...

  • Page 176: Trailer And Skid

    Technical Data G 25 20.3 Trailer and Skid With Tier 4i Isuzu engine Machine G 25 G 25 ERT Trailer and Skid Dry weight of skid kg (lb) 867 (1911) 950 (2094) Operating weight of skid kg (lb) 1,058 (2333)

  • Page 177: Dimensions

    G 25 Technical Data 20.4 Dimensions Ref. G 25 G 25 ERT Dimensions 890 (35) 1620 (69) 2032 (80) 1700 (67) 1945 (76.6) mm (in.) 1130 (44.5) 1384 (54.5) 1260 (49.6) 1514 (59.6) 3922 (154.4) wc_td000584gb_FM10.fm...

  • Page 178: Tire Safety Information

    Tire Safety Information Tire Safety Information Introduction to Tire Safety Information Federal Regulation 49 CFR 575 requires trailer manufacturers to include certain tire information in the owner’s manuals for the trailers they manufacture. This regulation requires that the information be in the English language. This chapter includes all the information required by Federal Regulation 49 CFR 575.
  • Page 179 Tire Safety Information wc_tx003108gb_FM10.fm...
  • Page 180 Tire Safety Information Excessive loads and/or underinflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that enables a tire to support the load, so proper inflation is critical.
  • Page 181 Tire Safety Information Bead The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the rim. Bead separation This is the breakdown of the bond between components in the bead. Bias ply tire A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less than 90 degrees to the centerline of the tread.
  • Page 182 Tire Safety Information Intended outboard sidewall The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle.
  • Page 183 Tire Safety Information A layer of rubber-coated parallel cords. Ply separation A parting of rubber compound between adjacent plies. Pneumatic tire A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an automotive wheel, provides the traction and contains the gas or fluid that sustains the load. Production options weight The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in excess of those standard items which they replace, not previously considered in curb weight or accessory...
  • Page 184 Tire Safety Information Tread rib A tread section running circumferentially around a tire. Tread separation Pulling away of the tread from the tire carcass. Treadwear indicators (TWI) The projections within the principal grooves designed to give a visual indication of the degrees of wear of the tread.
  • Page 185 Tire Safety Information Tire safety tips. Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure.
  • Page 186 Tire Safety Information 1.5.4. S TEPS FOR AINTAINING ROPER RESSURE Step 1: Locate the recommended tire pressure on the vehicle's tire information placard, certification label, or in the owner's manual. Step 2: Record the tire pressure of all tires. Step 3: If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the tire valve stem with the edge of your tire gauge until you get to the correct pressure.
  • Page 187 Tire Safety Information 1.5.9.1. Information on Passenger Vehicle Tires Please refer to the diagram below. The "P" indicates the tire is for passenger vehicles. Next number This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In general, the larger the number, the wider the tire.
  • Page 188 Tire Safety Information Tire Safety Information Letter Rating Speed Rating 99 mph 106 mph 112 mph 118 mph 124 mph 130 mph 149 mph 168* mph 186* mph * For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use the letters ZR. For those with a maximum speed capability over 186 mph, tire manufacturers always use the letters ZR.
  • Page 189 Tire Safety Information 1.5.9.3. Additional Information on Light Truck Tires Please refer to the following diagram. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. The "LT" indicates the tire is for light trucks or trailers. An "ST"...

  • Page 190: User's Information For Transport Canada Fuel Tank

    Note: The following information applies ONLY to machines equipped with a Transport Canada fuel tank. This type of fuel tank is required for machines transported on Canadian roads. Contact your Wacker Neuson dealer if you are unsure about whether or not your machine is approved for use in Canada.
  • Page 191 User’s Information for Transport Canada Fuel Tank wc_tx003111gb_FM10.fm...
  • Page 192 User’s Information for Transport Canada Fuel Tank wc_tx003111gb_FM10.fm...

  • Page 193: Emission Control Systems Information And Warranty

    Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny a warranty claim. Among those acts that constitute tampering are: Removing or altering of any part of the air intake, fuel, or exhaust systems.

  • Page 194: Limited Defect Warranty For Exhaust Emission Control System

    Any implied warranties are limited to the duration of this written warranty. What is covered Wacker Neuson recommends the use of genuine Wacker Neuson parts, or the equivalent, whenever maintenance is performed. The use of replacement parts not equivalent to the original parts may impair the effectiveness of the engine/ equipment emission controls systems.
  • Page 195 Emission Control Systems Information and Warranty For the components listed in the following table, an authorized Wacker Neuson dealer/service center will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine/equipment complies with the applicable EPA regulations.
  • Page 196 For owners located more than 100 miles from an authorized dealer/service center (excluding the states with high-altitude areas as identified in 40 CFR Part 1068, Appendix III), Wacker Neuson will pay for pre-approved shipping costs to and from an authorized Wacker Neuson dealer/service center.

  • Page 197: General Machine Schematics

    Mobile Generator General Machine Schematics 23 General Machine Schematics 23.1 Fuses G 25 T4i Isuzu, Basler G 25 T4f Isuzu, Basler 10A ECM start 10A ECM start 10A Fuel pump 1A Coolant sensor 10A Fuel solenoid 7.5A 7.5A ECM/switch 7.5A 7.5A ECM/switch...

  • Page 198: Trailer Wiring

    General Machine Schematics Mobile Generator 23.2 Trailer Wiring Standard and Hydraulic Brakes Electric Brakes Br W – Br W Br W w c _ g r 0 0 0 5 2 2 wc_gr000523...

  • Page 199: Trailer Wiring Components

    Mobile Generator General Machine Schematics 23.3 Trailer Wiring Components 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 200: Schematics, Machines With Basler Controller

    Schematics, Machines with Basler Controller G 25 24 Schematics, Machines with Basler Controller 24.1 AC Schematic: (POWER) (POWER) MECHANICAL LUGS MECHANICAL LUGS L1 L1 L2 L2 L3 L3 BOND BOND SAFETY SAFETY LIMIT LIMIT 60HZ JUMPER 60HZ JUMPER GROUND TO...

  • Page 201: Ac Schematic Components

    G 25 Schematics, Machines with Basler Controller 24.2 AC Schematic Components: Ref. Description Ref. Description Lug safety limit switch Generator Mechanical lugs Voltage regulator with 4A fuse Plug 3 - current transformer inputs Voltage adjustment rheostat Plug 4 - line voltage inputs...
  • Page 202 Schematics, Machines with Basler Controller G 25 24 Schematics, Machines with Basler Controller 24.1 AC Schematic: GENERATOR (ALTERNATOR) (POWER) POTENTIOMETER VOLTAGE ADJUST MECHANICAL LUGS 120V 120V LUG SAFETY LIMIT BOND RECPT RECPT SWITCH EXCITER 60HZ JUMPER RECTIFIER GROUND TO ENCLOSURE BOX...
  • Page 203 G 25 Schematics, Machines with Basler Controller 24.2 AC Schematic Components: Ref. Description Ref. Description Lug safety limit switch Generator Mechanical lugs Voltage regulator with 4A fuse Plug 3 - line voltage inputs Voltage adjustment rheostat Shunt Terminal block Plug 5 - current transformer inputs...

  • Page 204: Dc Schematic: G 25, T4F Isuzu, Basler

    Schematics, Machines with Basler Controller G 25 24.5 DC Schematic: G 25, T4f Isuzu, Basler wc_gr011726...

  • Page 205: Dc Schematic Components: G 25, T4F Isuzu, Basler

    G 25 Schematics, Machines with Basler Controller 24.6 DC Schematic Components: G 25, T4f Isuzu, Basler Ref. Description Ref. Description Plug 1 - power and engine sender inputs Idle switch Plug 2 - contact inputs Battery disconnect (optional) Electronic control unit (genset controller) Shunt trip relay Plug 4 - E-stop &...

  • Page 206: Ac Schematic: G25, Isuzu, 600V, Basler

    Schematics, Machines with Basler Controller G 25 24.7 AC Schematic: G25, Isuzu, 600V, Basler wc_gr011816...

  • Page 207: Ac Schematic Components: G 25, Isuzu, 600V, Basler

    G 25 Schematics, Machines with Basler Controller 24.8 AC Schematic Components: G 25, Isuzu, 600V, Basler Ref. Description Ref. Description Lug safety limit switch Generator Mechanical lugs Voltage regulator with 4A fuse Plug 3 — line voltage inputs Voltage adjustment rheostat...

  • Page 208: Schematics, Machines With Deep Sea Controller

    Schematics, Machines with Deep Sea Controller G 25 25 Schematics, Machines with Deep Sea Controller 25.1 AC Schematic: (POWER) (POWER) MECHANICAL LUGS L1 L1 L2 L2 L3 L3 BOND BOND SAFETY SAFETY LIMIT LIMIT 60HZ JUMPER 60HZ JUMPER GROUND TO...

  • Page 209: Ac Schematic Components

    G 25 Schematics, Machines with Deep Sea Controller 25.2 AC Schematic Components: Ref. Description Ref. Description Lug safety limit switch Generator Mechanical lugs Voltage regulator with 4A fuse Plug 3 - current transformer inputs Voltage adjustment rheostat Plug 4 - line voltage inputs...

  • Page 210: Dc Schematic: G 25, T4I Isuzu, Deep Sea

    Schematics, Machines with Deep Sea Controller G 25 25.3 DC Schematic: G 25, T4i Isuzu, Deep Sea wc_gr011775...

  • Page 211: Dc Schematic Components: G 25, T4I Isuzu, Deep Sea

    G 25 Schematics, Machines with Deep Sea Controller 25.4 DC Schematic Components: G 25, T4i Isuzu, Deep Sea Ref. Description Ref. Description Plug 1 - power and engine sender inputs Emergency stop switch Plug 2 - contact inputs Remote start terminals...
  • Page 212 Schematics, Machines with Deep Sea Controller G 25 Notes...
  • Page 214 Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · N92W15000 Anthony Ave. · Menomonee Falls, WI 53051 · 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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