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Wacker Neuson G 25, Operator'S Manual, Page: 155 / 214

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Wacker Neuson G 25 Operator'S Manual Download Page 155

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155

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 
inspection

Perform an external inspection of the machine. Check for:

External damage (dents, cracks, broken door latches, etc.) 

Loose or missing fasteners

Loose or missing parts

Fluid leaks

Restricted air flow in the exhaust compartment

Problems with the trailer—refer to topic 

Maintaining the Trailer

Internal 
inspection

Open the access doors on both sides of the machine. Check for:

Damage to control panel, switches, or customer connections

Loose or missing fasteners

Loose or missing parts

Loose or damaged hoses

Fluid leaks 

Rags, containers, or other debris inside the cabinet

 

Summary of Contents for G 25

Page 1: ...5200015081 04 0215 5 2 0 0 0 1 5 0 8 1 Operator s Manual Mobile Generator G 25 T4i G 25 T4f EN...

Page 2: ...distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights Violators will be prosecuted Trademarks All trademarks referenced in this manual are...

Page 3: ...number item number revision number and serial number is attached to this machine The location of the nameplate is shown above Serial number S N For future reference record the serial number in the sp...

Page 4: ...formance or safety standards of its machines The information contained in this manual is based on machines manufactured up until the time of publication Wacker Neuson reserves the right to change any...

Page 5: ...on service center according to written instructions published by Wacker Neuson Unapproved parts attachments and modifications are those that do not meet the approved criteria Unapproved parts attachme...

Page 6: ...Foreword 6 wc_tx003565gb_FM10 fm Notes...

Page 7: ...4 3 Label Meanings 26 4 Lifting and Transporting 36 4 1 Lifting the Machine 36 4 2 Before Towing Checklist 37 4 3 Towing the Machine 38 4 4 Preparing the Machine for Transport on a Truck or Trailer 39...

Page 8: ...ring and Settings Menus 70 8 5 Logging in to the Genset Controller by Entering the Password 71 8 6 Adjusting the LCD Screen Contrast 74 8 7 Changing the Time Date Settings 75 8 8 Changing the Sender F...

Page 9: ...d 119 11 5 Connecting 240V and 120V Single Phase Loads 120 11 6 Connecting a 208V 3 Load and Multiple 120V 1 Loads 121 11 7 Connecting a 220 240V 3 Load and Multiple 127 133V 1 Loads 122 12 How to Con...

Page 10: ...t 147 15 8 Low Coolant Shutdown 148 15 9 Temperature Activated Shutters 149 15 10 Positive Air Shutoff Valve 150 15 11 Quick Disconnect Fuel Fittings 151 15 12 Lube Level Maintainer 152 16 General Mai...

Page 11: ...93 22 2 Limited Defect Warranty for Exhaust Emission Control System 194 22 3 Limited Defect Warranty for Wacker Neuson Emission Control Systems 194 23 General Machine Schematics 197 23 1 Fuses 197 23...

Page 12: ...15081_03_FM10TOC fm 12 25 Schematics Machines with Deep Sea Controller 208 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 Compon...

Page 13: ...potential personal hazards Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury To avoid death or...

Page 14: ...the generator output Overloading the generator with a load that draws excessive power during either continuous running or start up Operating the generator in a manner that is inconsistent with all fe...

Page 15: ...r drugs Application area Be aware of the application area Keep unauthorized personnel children and pets away from the machine Remain aware of changing positions and the movement of other equipment and...

Page 16: ...hydraulic fluid heat transfer fluid propylene glycol with additives battery acid or grease Personal Protective Equipment PPE Wear the following Personal Protective Equipment PPE while operating this...

Page 17: ...adjustments shall be completed by a qualified technician Turn off the machine before performing maintenance or making repairs Remain aware of the machine s moving parts Keep hands feet and loose clot...

Page 18: ...ck long hair Remove all jewelry including rings Electrical service safety Make sure clothing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated hand...

Page 19: ...ill and wipe the machine dry before starting Refueling safety When refueling the engine Clean up any spilled fuel immediately Refill the fuel tank in a well ventilated area Re install the fuel tank ca...

Page 20: ...xhaust you could be breathing CO NEVER use a generator inside homes garages crawlspaces or other partly enclosed areas Deadly levels of carbon monoxide can build up in these areas Using a fan or openi...

Page 21: ...cuts cracks or exposed wires Do not route electrical cords over vibrating or hot parts of the machine Do not stand on the machine Do not enclose or cover the machine when it is use or when it is hot G...

Page 22: ...are properly inflated Only tow the machine when all trailer lights are functioning correctly Only tow the machine when the trailer s safety chains are connected to the towing vehicle in a crisscross...

Page 23: ...lifted or moved Do not get onto the machine while it is being lifted or moved 1 9 Reporting Safety Defects If you believe your trailer has a defect which could cause a crash or could cause injury or...

Page 24: ...wc_si000835gb_FM10 fm 24 Label Locations G 25 2 Label Locations G G GG JJ C H F VV EE K E W D X wc_gr011688...

Page 25: ...RET ARRET OFF OFF REMOTE START REMOTE START FERNSTART FERNSTART ARRANQUE REMOTO ARRANQUE REMOTO DEMARRAGE A DEMARRAGE A DISTANCE DISTANCE START LAUFEN START LAUFEN ARRANQUE MARCHA ARRANQUE MARCHA DEMA...

Page 26: ...USING CROSS 4 ATTACH SAFETY CHAINS USING CROSS PATTERN PATTERN 5 ATTACH BREAKDOWN CHAIN TO VEHICLE 5 ATTACH BREAKDOWN CHAIN TO VEHICLE 6 CHECK TRAILER LIGHTS 6 CHECK TRAILER LIGHTS TOWING INSTRUCTION...

Page 27: ...structions No sparks flames or burning objects near machine Stop the engine before adding fuel Use only diesel fuel G Tie down point H WARNING To prevent hearing loss wear hearing protection Hand inju...

Page 28: ...wc_tx003634gb_FM10 fm 28 Label Meanings G 25 J Electrical ground K WARNING Electric shock and arc flash can cause serious injury or death L...

Page 29: ...x003634gb_FM10 fm 29 G 25 Label Meanings L M Operator s Manual must be stored on machine Replacement Operator s Manual can be ordered through your local Wacker Neuson distributor wc_sy0158787 wc_sy016...

Page 30: ...llow electrical current from the generator to backfeed into utility lines This may result in electrocution of utility workers fire or explosion Connections to a building s electrical system must be ma...

Page 31: ...ual U on trailer if equipped W Drain containment system X WARNING To prevent hearing loss wear hearing protection when operating the machine WARNING Pressurized contents Do not open when hot WARNING H...

Page 32: ...ing the main circuit breaker supplies or interrupts power to the customer connection lugs Z Neutral bonded to frame AA Fuses Read the Operator s Manual for machine information BB WARNING Electric shoc...

Page 33: ...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 GG Low sulfur...

Page 34: ...so attached to each unit is a Certification Label This label specifies that the trailer conforms with all Federal Motor Vehicle Standards in effect at the time of manufacture The label includes the Ve...

Page 35: ...e personal injury or death Read and follow the engine starting instructions in this Operator s Manual V V WARNING Keep all sparks and open flames away from the battery Wear eye protection Keep away fr...

Page 36: ...the procedure below to lift the machine 1 Attach the lifting devices and equipment to the lifting eye Do not attach lifting devices to any other part of the machine 2 Lift the machine a small distanc...

Page 37: ...at all lug nuts are in place and are properly torqued Check the tread wear of the tires Check that the tires are inflated to the proper pressure Trailer preparation Check that all doors and access pan...

Page 38: ...ing be sure to check licensing requirements Drivers towing trailers may be required to carry a commercial driver s license CDL Check your local and state licensing regulations before towing the genera...

Page 39: ...r are chocked during the loading process Check that the transport vehicle or trailer is clean and free of grease oil ice and other loose material If the machine is mounted to a trailer check that the...

Page 40: ...ons see application step 2 below Mild soap or detergent Fresh clean warm water supply Isopropyl rubbing alcohol lacquer thinner or mineral spirits Soft clean dry cloths Plastic squeegee or stiff cardb...

Page 41: ...le so that it pulls on the breakaway cord until the emergency lever reaches its second notch b and locks into the ON position 4 Connect the machine trailer to the tow vehicle via the hitch 5 Attempt t...

Page 42: ...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 Result The pr...

Page 43: ...nect the machine trailer to the tow vehicle 2 Disconnect the trailer wiring plug a from the tow vehicle 3 Pull the breakaway pin b out of the brake switch c to activate the brakes and attempt to tow t...

Page 44: ...place or recharge the breakaway battery 6 If 12 14 VDC was measured but the brakes did not function there is a wiring or mechanical fault with the brakes Repair any faults before towing 7 If the brake...

Page 45: ...tandby or substitute power supply make sure the voltage and phase rotation of the line connections match those of the utility lines Failure to match phase rotation and voltage may cause equipment conn...

Page 46: ...ll not enter nearby structures so that the machine does not block traffic so that the machine is not close to any combustible material or flammable vapor so that all of the machine s access doors pane...

Page 47: ...from the previous page Procedure Perform the following procedure to position the machine 1 Place the machine on solid stable and level ground 2 For machines with trailers install chocks a under the w...

Page 48: ...ary to comply with the National Electrical Code and other federal state and local regulations For grounding requirements in your area consult with a qualified electrician electrical inspector or local...

Page 49: ...engine owner s manual NOTICE Consult the engine owner s manual regarding the use of biodiesel fuel in this machine Some biodiesel blends may clog the fuel system or gel at cold ambient temperatures s...

Page 50: ...r left corner of the LCD screen 4 Fill the fuel tank until the fuel level reaches 100 5 Re install the fuel cap 6 Place the engine start switch in the OFF position Result The procedure to refuel the m...

Page 51: ...Place the genset controller power switch in the OFF position WARNING Fire hazard Fuel and its vapors are extremely flammable Burning fuel can cause severe burns Keep all sources of ignition away from...

Page 52: ...0 0 5 6 3 2 wc_gr011689 m o p q r e n l a b f g h j k AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF REMOTE START REMOTE START FERNSTART FERNSTART ARRANQUE REMOTO ARRANQUE REMOTO DEMARRAGE A DEMARRAGE A...

Page 53: ...VAC 50A b Voltage adjustment rheostat m GFI receptacle 120 VAC 20A c Genset controller Basler or Deep Sea n Remote run terminal block d Idle switch high and low if equipped o Emergency stop switch e G...

Page 54: ...power to the convenience receptacles NOTICE Before shutting down the generator or performing any service to the generator make sure the main circuit breaker is in the OFF position wc_gr011444 a AUS A...

Page 55: ...ART RUN a wc_gr011436 Position Function LCD Screen REMOTE START This position is used when the generator is being operated as a stand by power supply and it is connected to a remote switch The generat...

Page 56: ...ure Low oil pressure Overspeed Underspeed Overcrank Low coolant level if equipped Overcurrent Low oil level option 1 1 Not used with Isuzu engine During an alarm condition the LCD panel a displays the...

Page 57: ...nt condition is sensed in any leg the pre alarm shutdown LED b flashes and the LCD displays OVERCURRENT If the overcurrent condition persists the main circuit breaker a opens and the LCD screen change...

Page 58: ...Graphic is representative only Your machine may vary Lug door interlock switch The lug door interlock switch p is located behind the lug door The lug door interlock switch is a safety device When the...

Page 59: ...IESEL SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE ULTRABAJO CONTENIDO DE AZUFRE ULTRABAJO CONTENIDO DE AZUFRE NU...

Page 60: ...osition 3 Voltage L L L Corresponding 1 voltage Twist lock receptacle L L 240V L N 120V 120V GFCI 208 VAC 3 120 VAC 1 208 208 120 120 220 220 125 125 240 240 1391 1391 277 480 VAC 3 480 240 1391 1391...

Page 61: ...adiator or around the fan Make sure the exhaust compartment is clean with nothing touching the muffler or exhaust pipes Pre operation checks Read and understand the engine owner s manual Check local r...

Page 62: ...r 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...

Page 63: ...ing 8 Start the engine by setting the engine start switch to the START RUN position After displaying INITIALIZING and NOT IN AUTO the LCD panel will display START DELAY followed by CRANKING as the eng...

Page 64: ...located as shown and can be accessed with the panel doors closed Function Activate the emergency stop switch by pushing the red button Pushing the emergency stop switch turns off opens the main circui...

Page 65: ...Generator Engine Symbol Meaning Description V Volts Displays the value of the AC output voltage being produced by the generator Phase Displays the leg or phase currently being monitored In three phas...

Page 66: ...is set to REMOTE START or RUN START Symbol Meaning Description Fuel level Indicates relative fuel level in the fuel tank Temperature Displays temperature of engine coolant Oil pressure Displays engin...

Page 67: ...it can be accessed for further submenus To do so press the right arrow button 1 To return to a previous screen press the left arrow button 4 To exit menu navigation and return to monitoring status or...

Page 68: ...y vary Metering Settings Metering Engine Oil Pressure Coolant Temp Fuel Level Engine Load Coolant Level Total Run Time Settings General Settings Communications Generator Protection Breaker Management...

Page 69: ...ed Run Time Bus V Bus voltage Low Fuel Level Communications Main Menu Conf Elements Configurable elements Maintenance Reset Conf Prot Status Configurable protection status Metering Configure Date Time...

Page 70: ...enu are read only They cannot be changed except for HRS to MAINTENANCE parameter which can be reset SETTINGS menus SETTINGS menus give detailed information regarding genset controller configuration Us...

Page 71: ...assword by the genset controller at the parameter you want to change The default password in either case is OP It is set at the factory It is the only password available and it cannot be changed Once...

Page 72: ...cter 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 5 Use the up down buttons to select P Then press the check mark button...

Page 73: ...A will appear The word EDIT will be displayed Whenever EDIT is displayed it means that you are able to change the parameter Use the up down arrow buttons to change the setting Then press the check mar...

Page 74: ...IN MENU 2 Using the up down arrow buttons 2 3 highlight SETTINGS Then press the right arrow button 3 Highlight GENERAL SETTINGS Then press the right arrow button 1 4 Highlight FRONT PANEL HMI Then pre...

Page 75: ...he up down arrow buttons 2 3 highlight SETTINGS Then press the right arrow button 3 Highlight GENERAL SETTINGS Then press the right arrow button 1 4 Highlight CONFIGURE DATE TIME Then press the right...

Page 76: ...time delay period This is the amount of time that the genset controller must experience the failure before the failure will be seen on the LCD display These failure time delay periods may be changed T...

Page 77: ...to change Then press the right arrow button 6 Highlight ACTIVATN DELAY or TIME DELAY Then press the check mark button 5 7 If you are not logged in enter the password OP Press the check mark button 8 U...

Page 78: ...set to English imperial or metric Procedure Perform the procedure below to set the units of measure 1 Press the right arrow button 1 to access the MAIN MENU 2 Using the up down arrow buttons 2 3 high...

Page 79: ...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 s...

Page 80: ...t controller is the percentage of fuel remaining in the fuel tank The range allowed by the genset controller is 10 100 Procedure Perform the procedure below to change the low fuel pre alarm setting 1...

Page 81: ...hange 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 Then scroll to LOGOUT and press...

Page 82: ...wed by the genset controller is 0 100 Notes Do not set the low fuel alarm to a value greater than that of the low fuel pre alarm Doing so will nullify the function of the low fuel pre alarm Setting th...

Page 83: ...n press the right arrow button 5 Highlight the THRESHOLD Then press the check mark button 5 6 If you are not logged in enter the password OP Press the check mark button 7 Using the up down arrow butto...

Page 84: ...timer The function of the cooldown timer is to run the engine at no load after a period of being run at load It is used in conjunction with the remote start system The cooldown timer activates when th...

Page 85: ...u are not logged in enter the password OP Press the check mark button 7 Using the up down arrow buttons change the value as desired Press the check mark button when finished 8 Exit by pressing the lef...

Page 86: ...The genset controller includes a pre crank time delay This is the time the glow plugs will be on before the engine starts to crank The factory setting is 5 seconds The pre crank time delay can be chan...

Page 87: ...ou are not logged in enter the password OP Press the check mark button 7 Using the up down arrow buttons change the value as desired Press the check mark button when finished 8 Exit by pressing the le...

Page 88: ...RT position Background The maintenance interval is the time in hours scheduled between critical maintenance tasks such as changing the engine oil The amount of time may be changed if desired The facto...

Page 89: ...ghlight the THRESHOLD Then press the check mark button 5 7 If you are not logged in enter the password OP Press the check mark button 8 Using the up down arrow buttons change the value as desired Pres...

Page 90: ...ed and the red LED flashes The maintenance interval pre alarm may be reset by using either of two different methods 1 by holding the X reset button while the MAINT INTERVAL pre alarm screen is being d...

Page 91: ...press the right arrow button 5 Using the up down arrow buttons highlight ENGINE Then press the right arrow button 6 Highlight HRS TO MAINT Then press and hold the X reset button for 10 20 seconds Thi...

Page 92: ...During a loss of voltage pre alarm the LCD will display the screens below To reset the loss of voltage pre alarm simply close the lug door If the voltage does not return to normal further troubleshoo...

Page 93: ...ring up the MAIN menu 2 Highlight METERING Then press the right arrow button 3 Highlight ALARMS STATUS Then press the right arrow button 4 Highlight EVENT LOG Then press the right arrow button The LCD...

Page 94: ...T TIME FIRST ENG HRS LAST ENG HRS DETAILS Most recent event To find the alarm event that has occurred most recently 1 Scroll to each alarm event and record the time it occurred 2 Compare the dates and...

Page 95: ...pt power to the convenience receptacles NOTICE Before shutting down the generator or performing any service to the generator make sure the main circuit breaker is in the OFF position wc_gr011444 a AUS...

Page 96: ...nction OFF OFF ON ON a wc_gr011478 Position Function LCD Screen ON When set to this position Power is supplied to the genset controller The genset controller boots up and sets itself to the Stop Reset...

Page 97: ...DIESEL SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE ULTRABAJO CONTENIDO DE AZUFRE ULTRABAJO CONTENIDO DE AZUFRE N...

Page 98: ...Position 3 Voltage L L L Corresponding 1 voltage Twist lock receptacle L L 240V L N 120V 120V GFCI 208 VAC 3 120 VAC 1 208 208 120 120 220 220 125 125 240 240 1391 1391 277 480 VAC 3 480 240 1391 1391...

Page 99: ...alarm condition Note non critical alarm conditions may lead to shut down conditions 8 Main breaker open indicator Illuminates whenever the main circuit breaker is open 9 Low speed active indicator Il...

Page 100: ...o the Manual mode In Manual mode the generator can be started and operated 14 not used 15 Auto mode Pressing this button Sets the genset controller to the Auto mode In Auto mode the generator can only...

Page 101: ...n alarms Shut down alarms are latching alarms and stop the generator Shut down alarms include Low fuel level High coolant temperature Low oil pressure Overspeed Underspeed Overcrank Low coolant level...

Page 102: ...ine During an electrical trip the LEDs 6 8 illuminate an audible alarm sounds and the machine is shut down Press the Horn Reset button to silence the audible alarm Remove the fault condition then pres...

Page 103: ...radiator or around the fan Make sure the exhaust compartment is clean with nothing touching the muffler or exhaust pipes Pre operation checks Read and understand the engine owner s manual Check local...

Page 104: ...e ON I position 5 Press the Manual mode button b 6 Press the Start I button c The LCD panel displays several screens as the start up sequence begins This procedure continues on the next page CAUTION P...

Page 105: ...lays the following screens 9 Allow the engine to warm before closing the main circuit breaker 10 Check the voltage displayed on the LCD panel Adjust the voltage as needed using the voltage adjustment...

Page 106: ...e any hazards by turning off devices such as pumps heaters or lights that may need to be kept on Procedure Perform the procedure below to stop the generator 1 Remove all loads from the generator 2 Ope...

Page 107: ...The engine stops The LCD panel b displays a flashing Emergency Stop message The Alarm LED illuminates and an audible alarm will sound To silence the audible alarm press the Horn Reset button on the k...

Page 108: ...ting at no load output amperage will display a 0 Hertz Hz Displays output frequency This gauge should read approximately 60 Hz under a no load condition If the frequency is too high check the engine r...

Page 109: ...layed on the LCD panel f You can also use the keypad to change certain machine settings if desired 1 The various monitoring and configuration menus can be accessed by pressing the right arrow button 1...

Page 110: ...y Screen Screen Engine Engine Battery Battery Voltage Voltage Gen Current Gen Current Engine Engine Battery Battery Voltage Voltage Engine Engine Run Run Time Time Gen Earth Gen Earth Current Current...

Page 111: ...Total kW Gen Phase Sequence Generator Phase Sequence Engine Coolant Temp Coolant Temperature in C and F Gen Power Factor Generator Power Factor Engine Link Engine Link Info Gen Power Factor Avg Gener...

Page 112: ...rast value will start flashing 3 Press the up down arrow buttons to change the contrast percentage as desired When the screen contrast reaches a comfortable viewing level press the check mark button t...

Page 113: ...he maintenance timer 1 From the Status menu press the right arrow button to reach the Engine menu 2 Using the up and down arrow buttons navigate to the Maintenance alarm 1 screen 3 Press the Stop Rese...

Page 114: ...ct 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 277 480V 120...

Page 115: ...nced load condition exists there will be a significant difference over 10 in both voltage and amperage between the legs Observe the amp draw on L1 and L3 If an unbalanced load condition is detected st...

Page 116: ...ase When connecting multiple 120V 1 loads to the lugs while in 208 240V 3 mode use L1 as hot for the first load or heaviest load Use L3 as hot for the second load or next heaviest load and use L2 as h...

Page 117: ...ame duplex receptacle plug the first load in to one of the duplex receptacles Then plug the second load in to the other duplex receptacle Additional loads can be plugged in to either duplex receptacle...

Page 118: ...rom the load as shown 4 Close the lug door 5 Start the machine and fine tune the voltage as necessary using the voltage adjustment rheostat WARNING Electric shock hazard High voltage can cause serious...

Page 119: ...t the wires from the load as shown 4 Close the lug door 5 Start the machine and fine tune the voltage as necessary using the voltage adjustment rheostat WARNING Electric shock hazard High voltage can...

Page 120: ...lector switch to the 120 240V position 3 Open the lug door and connect the wires from the load s as shown 4 Close the lug door and start the machine 5 Fine tune the voltage as necessary using the volt...

Page 121: ...5 Fine tune the voltage as necessary using the voltage adjustment rheostat WARNING Electric shock hazard High voltage can cause serious injury or death Connections must be made by a qualified electri...

Page 122: ...lectric shock hazard High voltage can cause serious injury or death Connections must be made by a qualified electrician When connecting multiple 120V loads Use L1 as hot for first load Use L3 as hot f...

Page 123: ...s wc_gr011347 1 Zig Zag 3 Zig Zag Low Wye 139V 139V 139V or 240V 240V 240V High Wye 240V 1 120 240V 3 277 480V 208 240V 3 3 600V 120 139V 1 1 120 240V 3 277 480V 208 240V 3 3 600V 120 139V 1 1 120 240...

Page 124: ...nced load condition exists there will be a significant difference over 10 in both voltage and amperage between the legs Observe the amp draw on L1 and L3 If an unbalanced load condition is detected st...

Page 125: ...ase When connecting multiple 120V 1 loads to the lugs while in 208 240V 3 mode use L1 as hot for the first load or heaviest load Use L3 as hot for the second load or next heaviest load and use L2 as h...

Page 126: ...ame duplex receptacle plug the first load in to one of the duplex receptacles Then plug the second load in to the other duplex receptacle Additional loads can be plugged in to either duplex receptacle...

Page 127: ...t the wires from the load as shown 4 Close the lug door 5 Start the machine and fine tune the voltage as necessary using the voltage adjustment rheostat WARNING Electric shock hazard High voltage can...

Page 128: ...lector switch to the 120 240V position 3 Open the lug door and connect the wires from the load s as shown 4 Close the lug door and start the machine 5 Fine tune the voltage as necessary using the volt...

Page 129: ...5 Fine tune the voltage as necessary using the voltage adjustment rheostat WARNING Electric shock hazard High voltage can cause serious injury or death Connections must be made by a qualified electri...

Page 130: ...lectric shock hazard High voltage can cause serious injury or death Connections must be made by a qualified electrician When connecting multiple 120V loads Use L1 as hot for first load Use L3 as hot f...

Page 131: ...s from the load as shown 4 Close the lug door 5 Start the machine and fine tune the voltage as necessary using the voltage adjustment rheostat WARNING Electric shock hazard High voltage can cause seri...

Page 132: ...as shown 4 Close the lug door 5 Start the machine and fine tune the voltage as necessary using the voltage adjustment rheostat WARNING Electric shock hazard High voltage can cause serious injury or d...

Page 133: ...er start switch If a transfer switch is installed the generator can be used as a stand by power supply When connecting an Automatic Transfer Switch ATS or other remote switch Limit the distance betwee...

Page 134: ...instructions and warning labels supplied with the switch WARNING Electrocution hazard Failure to isolate the generator from the utility s electrical distribution system could cause output from the gen...

Page 135: ...voltage selector switch to the correct voltage position 4 Set the engine start switch to the REMOTE START position 5 Set the main line circuit breaker to ON 6 Secure the generator by closing and locki...

Page 136: ...d Wait for the engine to crank start and run If the engine cranks the remote start circuit is functioning e Press the Stop Reset O button d to stop the engine f Remove the jumper wire from the remote...

Page 137: ...utton 5 Secure the generator by closing and locking all doors The generator is now ready for automatic starting Maintaining battery charge If the generator is to be used as a stand by power supply pro...

Page 138: ...low to access Diagnostic Trouble Codes 1 At the READY screen press the right arrow button 1 to bring up the MAIN menu 2 Highlight METERING Then press the right arrow button 3 Highlight ALARMS STATUS T...

Page 139: ...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 Procedure Perform the procedure below to access the Dia...

Page 140: ...n high voltage 110 4 Water temp sensor malfunction low voltage 157 3 Common rail press sensor malfunction high voltage 157 4 Common rail press sensor malfunction low voltage 157 15 Common rail pressur...

Page 141: ...tem B short 1347 4 SCV driving system disconnection GND short 1485 5 Main relay system malfunction not connected 1485 6 Main relay system malfunction not disconnected 10001 2 EGR position sensor malfu...

Page 142: ...enerator Diagnostic Trouble Codes DTC 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...

Page 143: ...have this information available when contacting Wacker Neuson Corporation The illustrations shown in this chapter represent typical installations The factory installed options on your machine may look...

Page 144: ...s 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...

Page 145: ...tures 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 WARNIN...

Page 146: ...and correct Note In the interests of environmental protection place impermeable sheeting and a container under the machine to collect the liquid which drains off Dispose of this liquid in accordance...

Page 147: ...eater draws power from the panel control module and is active only when the panel control module is powered An optional thermostat a can be installed if the machine is to be used in extremely cold wea...

Page 148: ...If after the ten seconds coolant levels are still sensed as being low the ECM shuts down the engine The ECM will then display LOW COOL LEVEL Allow the engine to cool before adding additional coolant...

Page 149: ...he 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 connect...

Page 150: ...air is drawn into the engine Pressing the emergency stop switch alone will not stop a runaway engine Some models include a positive air shutoff valve a Activating the positive air shutoff valve blocks...

Page 151: ...ternal return hose c through the access port a on the curb side of the machine 2 Disconnect the internal feed hose d at the tank fitting and connect the internal feed hose to the external supply hose...

Page 152: ...oil level is the same as that measured by the engine dipstick A float inside the valve detects low oil levels and opens the valve to supply the needed oil The system is wired to the ECM and includes...

Page 153: ...t be performed by a dealer service center authorized by Wacker Neuson The use of service parts that are not equivalent in performance and durability to authorized parts may impair the effectiveness of...

Page 154: ...s also off and tagged 16 4 Cleaning the Machine When As needed Suggested cleaning materials Compressed air Clean water supply Mild detergent Clean dry cloths NOTICE Do not use a pressure washer to cle...

Page 155: ...nal inspection of the machine Check for External damage dents cracks broken door latches etc Loose or missing fasteners Loose or missing parts Fluid leaks Restricted air flow in the exhaust compartmen...

Page 156: ...ny missing lug nuts immediately Axle Hubs Grease axle hubs using a good wheel bearing grease Brakes Check operation of brakes before each trip Check level of brake fluid in actuator at front of traile...

Page 157: ...container of sufficient volume to collect drained fluid Note Collect store and dispose of drained fluid in accordance with current environmental protection regulations Procedure Perform the procedure...

Page 158: ...following procedure to check the exhaust system 1 Open the access door on the curb side of the machine 2 Inspect the exhaust pipes a and muffler b looking for Cracks or holes Burned or missing insula...

Page 159: ...nnections To connect the battery 1 Connect the red positive battery cable to the battery 2 Connect the black negative battery cable to the battery To disconnect the battery 1 Stop the engine 2 Place a...

Page 160: ...speed 2 Move the manual regeneration switch c to the on position and hold it for five seconds The DPF indicator will go out and the regeneration process will begin 3 Release the switch The engine spee...

Page 161: ...fuel After completing the procedures listed above fill the fuel tank completely and add a high quality stabilizer to the fuel Choose a stabilizer that includes cleaning agents and additives designed t...

Page 162: ...llow local safety and environmental regulations pertaining to the disposal of construction equipment Preparation Perform the following tasks to prepare the machine for disposal Move the machine to a p...

Page 163: ...ee the table below WARNING Most used liquids from this machine such as oil gasoline grease etc contain small amounts of materials that can cause cancer and other health problems if inhaled ingested or...

Page 164: ...b_FM10 fm 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 m...

Page 165: ...wc_tx003641gb_FM10 fm 165 G 25 Maintenance Tier 4i Engines Isuzu 770012...

Page 166: ...expected outside air temperature See the table below WARNING Most used liquids from this machine such as oil gasoline grease etc contain small amounts of materials that can cause cancer and other heal...

Page 167: ...2gb_FM10 fm 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 manu...

Page 168: ...wc_tx003642gb_FM10 fm 168 Maintenance Tier 4f Engines Isuzu 770006...

Page 169: ...wc_tx003642gb_FM10 fm 169 Maintenance Tier 4f Engines Isuzu 770007...

Page 170: ...wc_tx003642gb_FM10 fm 170 Maintenance Tier 4f Engines Isuzu 770008 770009...

Page 171: ...wc_tx003642gb_FM10 fm 171 Maintenance Tier 4f Engines Isuzu 770010...

Page 172: ...tank with fuel Bleed fuel lines Replace fuel filter Check fuel lines No generator output Main circuit breaker open Lug door open Close main circuit breaker Close lug door Low oil pressure Low oil lev...

Page 173: ...efueling the Machine for more information 2 The use of 6 diesel fuel is not recommended G 25 G 25 ERT Engine Engine make type Isuzu Model 4LE2 NYGV Tier 4 Interim Number of cylinders 4 Displacement cm...

Page 174: ...Engine Engine make type Isuzu Model 4LE2 TAGV Tier 4 Final Number of cylinders 4 Displacement cm3 in 3 2179 133 Engine speed rpm 1800 Power 1800 rpm continuous standby kW hp 23 5 31 5 30 0 40 0 Coolan...

Page 175: ...h 3 position AC voltages available 120 240 zig zag 120 208 low wye 277 480 hi wye Frequency 60 Hz Power factor 1 3 1 0 0 8 Voltage regulation 1 00 Insulation class H Sound level at 7 m 23 ft db A 65 A...

Page 176: ...weight of skid kg lb 1 058 2333 1 372 3026 Trailer weight kg lb 182 400 290 640 GVWR kg lb 1 338 2 995 Surge brakes fluid type DOT3 Tires size ST205 75D 15C Machine G 25 G 25 ERT Trailer and Skid Dry...

Page 177: ...584gb_FM10 fm 177 G 25 Technical Data 20 4 Dimensions Ref G 25 G 25 ERT Dimensions A mm in 890 35 B 1620 69 2032 80 C 1700 67 D 1945 76 6 E 1130 44 5 1384 54 5 F 1260 49 6 1514 59 6 G 3922 154 4 A D E...

Page 178: ...n 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 informatio...

Page 179: ...RUZDUG KDOI RI WKH OHIW URDG VLGH RI WKH XQLW 7KLV FHUWLILFDWLRQ 9 1 ODEHO ZLOO LQGLFDWH WKH WUDLOHU V URVV 9HKLFOH HLJKW 5DWLQJ 9 5 7KLV LV WKH PRVW ZHLJKW WKH IXOO ORDGHG WUDLOHU FDQ ZHLJK W ZLOO DO...

Page 180: ...ted 2 Locate the 9 5 URVV 9HKLFOH HLJKW 5DWLQJ RI WKH WUDLOHU RQ RXU WUDLOHU V 9 1 HUWLILFDWLRQ ODEHO 3 Subtract the empty weight of your trailer from the GVWR stated on the VIN label That weight is t...

Page 181: ...side of the rim in a manner that encloses the rim flanges inside the air cavity of the tire Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel oil...

Page 182: ...orporates a wheel supports the tire and attaches either integrally or separably to the wheel center member and upon which the tire is attached Non pneumatic spare tire assembly A non pneumatic tire as...

Page 183: ...the Tire Information label and on the Certification VIN tag Reinforced tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire Rim A met...

Page 184: ...ating a wheel a mechanical device which attaches either integrally or separably to the non pneumatic tire and provides the connection between tire and the vehicle Wheel holding fixture The fixture use...

Page 185: ...lated You will also find this number on the vehicle information placard expressed in kilopascals kpa which is the metric measure used internationally Manufacturers of passenger vehicles and light truc...

Page 186: ...If you have any doubt about the correct size to choose consult with the tire dealer 1 5 6 TIRE TREAD The tire tread provides the gripping action and traction that prevent your vehicle from slipping or...

Page 187: ...two digit number is the wheel or rim diameter in inches If you change your wheel size you will have to purchase new tires to match the new wheel diameter Next number This two or three digit number is...

Page 188: ...ire can support Tire manufacturers also must indicate the materials in the tire which include steel nylon polyester and others Maximum Load Rating This number indicates the maximum load in kilograms a...

Page 189: ...d tire pressure when the tire is used as a single Load Range This information identifies the tire s load carrying capabilities and its inflation limits 1 6 TIRE SAFETY TIPS Preventing Tire Damage Slow...

Page 190: ...sported Placarding requirements Immediately after the fuel tank is filled fully or partially with flammable liquids UN Placards Transport of Dangerous Goods Decals Placards of Flammable Liquids Transp...

Page 191: ...wc_tx003111gb_FM10 fm 191 User s Information for Transport Canada Fuel Tank...

Page 192: ...wc_tx003111gb_FM10 fm 192 User s Information for Transport Canada Fuel Tank...

Page 193: ...s The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to fo...

Page 194: ...s during the warranty period Limited Defect Warranty Period for Wacker Neuson Emission Control Systems The warranty period for this engine equipment begins on the date of sale to the initial purchaser...

Page 195: ...nd inspection charges that do not result in warranty eligible service being performed Any non authorized replacement part or malfunction of authorized parts due to use of non authorized parts Owner s...

Page 196: ...t take your Wacker Neuson engine equipment along with proof of original purchase date at your expense to the authorized Wacker Neuson dealer service center during their normal business hours For owner...

Page 197: ...A 5 6 7 8 1A Engine diagnostics 20A Engine ECU N A 5A Keyswitch 5A 1A 20A wc_gr011826 G 70 Tier 4i Cummins Deep Sea 1 2 3 4 7 5A ECM switch 7 5A G 150 T3 John Deere Basler G 180 T3 John Deere Basler 1...

Page 198: ...Wiring Standard and Hydraulic Brakes Electric Brakes w c _ g r 0 0 0 5 2 2 B r B r W W B r W G B r W Y B r W B r W Y G B r W 1 9 8 6 2 1 0 3 B r B r 7 7 3 G Y Br W R R R Br W R W W W W Br Br Br Br Br...

Page 199: ...solenoid 6 Right tail light 7 License plate holder lights 8 Left tail light 9 Rear right side red light 10 Rear left side red light Ref Wire Colors Rear Lights Side Lights Harness B BLACK Ground Groun...

Page 200: ...L 14GA 12 GRN YEL 14GA 12 GRN YEL 14GA 10 GRN YEL 10GA 10 GRN YEL 10GA 11 GRN YEL 10GA 11 GRN YEL 10GA 4 BLK 10GA 4 BLK 10GA 8 BLK 10GA 8 BLK 10GA 7 BLK 10GA 7 BLK 10GA 5 BLK 10GA 5 BLK 10GA L2 L2 L1...

Page 201: ...minal block 5 Shunt 20 Exciter rotor windings 6 120V GFI receptacle 21 Exciter stator winding 7 120V 20A breaker 22 Rotor 8 240V 50A breaker 23 Rectifier diodes 8a 240V 20A breaker optional 10 240V 50...

Page 202: ...SAFETY LIMIT SWITCH BLU 18 AWG BLU W 18 AWG CT 2 CT 1 PAIR BLK 10GA PAIR BLK 10GA L3 MECHANICAL LUGS 6GA CT 3 T4 T7 T3 T8 T12 T10 21 22 T6 13 17 18 9 10 14 T11 25 26 L0 PAIR BLK 10GA T2 5 1 6 2 L1 3 J...

Page 203: ...sformer inputs 20 Exciter rotor windings 6 120V GFI receptacle 21 Exciter stator winding 7 120V 20A breaker 22 Rotor 8 240V 50A breaker 23 Rectifier diodes 9 240V 20A breaker optional 24 Main rotor wi...

Page 204: ...Schematics Machines with Basler Controller G 25 204 24 5 DC Schematic G 25 T4f Isuzu Basler 1 5 6 14 7 8 10 9 13 18 19 22 4 12 25 20 21 11 23 24 15 16 17 16 2 3 wc_gr011726...

Page 205: ...Shunt trip relay 4 Plug 4 E stop contact outputs 17 Bond bar 5 Water temperature sender 18 Emergency stop switch 6 Remote start Off Start Run switch 19 Remote start terminals 7 Relay engine outputs 20...

Page 206: ...Schematics Machines with Basler Controller G 25 206 24 7 AC Schematic G25 Isuzu 600V Basler wc_gr011816 1 2 6 14 6 18 30 16 24 23 20 21 17 7 7 11 26 25 15 27 19 8 9 4 29 10 13 3 5 12 28 22...

Page 207: ...urrent transformer inputs 20 Exciter rotor windings 6 120V GFI receptacle 21 Exciter stator winding 7 120V 20A breaker 22 Rotor 8 240V 50A breaker 23 Rectifier diodes 9 240V 50A receptacle 24 Main rot...

Page 208: ...U 10GA 16 LT BLU 10GA 18 LT BLU 14GA 18 LT BLU 14GA 17 LT BLU 14GA 17 LT BLU 14GA 13 GRN YEL 14GA 13 GRN YEL 14GA 12 GRN YEL 14GA 12 GRN YEL 14GA 10 GRN YEL 10GA 10 GRN YEL 10GA 11 GRN YEL 10GA 11 GRN...

Page 209: ...rminal block 5 Shunt 20 Exciter rotor windings 6 120V GFI receptacle 21 Exciter stator winding 7 120V 20A breaker 22 Rotor 8 240V 50A breaker 23 Rectifier diodes 8a 240V 20A breaker optional 10 240V 5...

Page 210: ...Schematics Machines with Deep Sea Controller G 25 210 25 3 DC Schematic G 25 T4i Isuzu Deep Sea wc_gr011775 1 2 3 7 4 5 18 19 33 20 29 21 22 23 26 27 28 24 34 6 25 9 14 15 16 17 10 12 31 32 13 8...

Page 211: ...otor 5 Water temperature sender 22 Alternator 6 ON OFF toggle switch 23 Mechanical lugs 7 Relay engine outputs 24 Main circuit breaker 8 Hour meter 25 Fuel level sender 9 Fuel pump 26 Lug door interlo...

Page 212: ...Schematics Machines with Deep Sea Controller G 25 212 Notes...

Page 213: ......

Page 214: ...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 Pl...

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