Wacker Neuson G 14 User manual

5000185676 004 0111
5000185676
Operator’s Manual
Mobile Generator
G 14

Copyright notice © Copyright 2011 by Wacker Neuson Production Americas LLC
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the
machine. Any other type of reproduction is prohibited without express
written permission from 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.
Trademarks All trademarks referenced in this manual are the property of their
respective owners.
Manufacturer Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: [phone] · Fax: [phone] · Tel: [phone]
www.wackerneuson.com
Original instructions This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.

G 14 Foreword
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Foreword
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models listed below. These instructions must be followed during
installation and maintenance of the generator (and battery, if equipped).
Machines
covered in
this manual
Machine
documentation
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
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
the machine model number, item number, revision number, and serial number.
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance 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 portion of this information without notice.
CALIFORNIA
Proposition
65 Warning
Engine exhaust, some of its constituents, and certain vehicle components, contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Laws
pertaining to
spark
arresters
NOTICE: State Health Safety Codes and Public Resources Codes specify that in
certain locations spark arresters be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed to prevent accidental
discharge of sparks or flames from the engine exhaust. Spark arresters are
qualified and rated by the United States Forest Service for this purpose. In order to
comply with local laws regarding spark arresters, consult the engine distributor or
the local Health and Safety Administrator.
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
Machine Item Number
G 14 0620689

Foreword G 14
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Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:
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_bo0176741en_004TOC.fm 5
Table of ContentsG 14
Foreword 3
1 Safety Information 7
1.1 Signal Words Found in this Manual ...................................................... 7
1.2 Machine Description and Intended Use ............................................... 8
1.3 Safety Guidelines for Operating the Machine ....................................... 9
1.4 Operator Safety while Using Internal Combustion Engines ............... 12
1.5 Towing Safety ..................................................................................... 13
1.6 Guidelines for Service Safety ............................................................. 13
1.7 Label Locations .................................................................................. 15
1.8 Label Meanings .................................................................................. 17
2 Initial Setup and Overview 25
2.1 Application .......................................................................................... 25
2.2 Included With the Machine ................................................................. 26
2.3 Control Panel ...................................................................................... 28
2.4 Battery ................................................................................................ 30
2.5 Fueling the Machine ........................................................................... 31
2.6 Generator Monitoring ......................................................................... 32
2.7 Engine Monitoring .............................................................................. 33
2.8 Convenience Receptacles .................................................................. 34
2.9 Emergency Stop Switch ..................................................................... 35
2.10 Main Line Circuit Breaker ................................................................... 36
2.11 Thermal Overload Relay .................................................................... 37
2.12 Connection Lugs ................................................................................ 37
2.13 Voltage Output ................................................................................... 38
2.14 Ground Connection ............................................................................ 38
2.15 Before Starting ................................................................................... 39
3 Transportation, Lifting, and Storage 40
3.1 Towing ................................................................................................ 40
3.2 Lifting .................................................................................................. 41
3.3 Storing the Generator ......................................................................... 41

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Table of Contents G 14
4 Operation 42
4.1 Breaking In New Machines ..................................................................42
4.2 Starting the Generator .........................................................................42
4.3 Operating the Generator .....................................................................43
4.4 Engine Shutdown Faults .....................................................................44
4.5 Stopping the Generator .......................................................................46
4.6 Emergency Shutdown Procedure ........................................................46
4.7 Operating in Cold Weather ..................................................................46
5 Maintenance 47
5.1 Periodic Maintenance Schedule ..........................................................47
5.2 Checking Fuses ...................................................................................48
5.3 Maintaining the Air Cleaner .................................................................49
5.4 Checking the Engine Oil ......................................................................50
5.5 Changing the Engine Oil and Filter .....................................................51
5.6 Checking the Engine Coolant Level ....................................................53
5.7 Replacing the Coolant .........................................................................54
5.8 Replacing the Fuel Filter Element .......................................................55
5.9 Bleeding Air From the Fuel System .....................................................56
5.10 Cleaning the Water Separator .............................................................57
5.11 Maintaining the Trailer .........................................................................58
5.12 Troubleshooting ...................................................................................59
6 Technical Data 61
6.1 Engine .................................................................................................61
6.2 Generator Data ....................................................................................62
6.3 Trailer and Skid Data ...........................................................................63
6.4 Dimensions ..........................................................................................63
7 Schematics 64
7.1 DC Schematic .....................................................................................64
7.2 AC Schematic ......................................................................................66

G 14 Safety Information
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1 Safety Information
1.1 Signal Words Found 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.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo avoid death or serious injury from this type of hazard, obey all safety messages that
follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
fTo avoid possible death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fTo avoid possible minor or moderate injury from this type of hazard, obey all safety mes-
sages that follow this signal word.

Safety Information G 14
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1.2 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. As the engine runs, the generator converts
mechanical energy into electric power. The operator connects loads to the electric
power receptacles and connection lugs.
This machine is intended for the purpose of supplying electrical power to
connected loads. Refer to the product specifications for the output voltage and
frequency of this generator, and for the maximum output power limit of this
generator.
This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons in the area. Machine
damage caused by misuse is not covered under warranty.
The following are some examples of misuse:
Connecting a load that has voltage and frequency requirements that are
incompatible with 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 federal, state
and local codes and regulations
Using the machine as a ladder, support, or work surface
Using the machine to carry or transport passengers or equipment
Using the machine to tow other machines
Operating the machine outside of factory specifications
Operating machine in a manner inconsistent with all warnings found on the
machine and in the Operator’s Manual
This machine has been designed and built in accordance with the latest global
safety standards. It has been carefully engineered to eliminate hazards as far as
practicable and to increase operator safety through protective guards and labeling.
However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:
Heat, noise, exhaust, and carbon monoxide from the engine
Fire hazards from improper refueling techniques
Fuel and its fumes
Electric shock and arc flash
Personal injury from improper lifting the trailer tongue
Typical hazards related to towing a trailer on roads and highways
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.

G 14 Safety Information
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1.3 Safety Guidelines for Operating the Machine
Operator
qualifications
Only trained personnel are permitted to start, operate, and shut down the machine.
They also must meet the following qualifications:
have received instruction on how to properly use the machine
are familiar with required safety devices
The machine must not be accessed or operated by:
children
people impaired by alcohol or drugs
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
Before
starting the
machine
Before starting this machine:
Have a certified electrician set up the generator set. Do not allow untrained
personnel to operate or service the generator.
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.
fNEVER 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 opening windows and doors does NOT supply enough fresh air.
fONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
fEven when you use a generator correctly, CO may leak into the home. ALWAYS
use a battery-powered or battery-backup CO alarm in the home.
fIf you start to feel sick, dizzy, or weak after the generator has been running,
move to fresh air RIGHT AWAY. See a doctor. You could have carbon monoxide
poison.
WARNING
Machines operated improperly or by untrained personnel can be hazardous.
fRead the operating instructions contained in both this Operator’s Manual and
the engine operator’s manual.
fFamiliarize yourself with the location and proper use of all controls.
fInexperienced operators should receive instruction from someone familiar with
the machine before being allowed to operate it.

Safety Information G 14
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Make a walk-around inspection of the generator set before starting it. Open
side doors and visually inspect engine compartment for obvious damage or the
presence of foreign objects which might affect operation.
Follow starting and stopping instructions described in this manual. Know how to
operate and stop the generator before starting it.
Do not start a machine in need of repair.
Make sure the machine is on a firm, level surface and will not tip, roll, slide, or
fall while operating.
Remove all tools, cords, and other loose items from the generator before
starting it.
Electrical
safety
To increase electrical safety while operating this machine:
Do not operate the generator, or tools attached to the generator, with wet hands.
Do not use worn electrical cords. Severe electrical shock and equipment
damage may result.
Do not operate generator in standing water.
Make certain the machine is well-grounded and securely fastened to a good
earthen ground per national and local regulations.
Do not overload the generator. The total amperage of the tools and equipment
attached to the generator must not exceed the load rating of the generator.
Generator
vibration
Generators vibrate in normal use. During and after the use of the generator, inspect
the generator as well as extension cords and power supply cords connected to it
for damage from vibration.
Have damaged items repaired or replaced as necessary.
Do not use plugs or or cords that show signs of damage such as broken or
cracked insulation or damaged blades.
Operating
safety
To increase operating safety while running this machine:
Do not operate the generator when open containers of fuel, paint, or other
flammable liquids are in the vicinity of the generator.
Do not place flammable material or liquids near the generator.
Do not operate the machine indoors unless exhaust fumes can be adequately
ventilated.
Do not touch the hot engine, exhaust, or generator components. Burns will
result.
WARNING
Backfeed from the generator into the public power distribution system can seriously
injure or kill utility workers!
fImproper connection of generator to a building’s electrical system can allow
electrical current from the generator to backfeed into utility lines. This may result
in electrocution of utility workers, fire, or explosion.
fConnections to a building’s electrical system must be made by a qualified elec-
trician and comply with all applicable laws and electrical codes.
fIf connected to a building’s electrical system, the generator must meet the
power, voltage, and frequency requirements of the equipment in the building.

G 14 Safety Information
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Do not use the emergency stop button except in case of an actual emergency.
Do not restart the engine until the cause of the trouble has been determined and
fixed.
Always do the following:
Wear hearing protection when operating equipment.
Keep the machine at least one meter (three feet) away from structures,
buildings, and other equipment during use.
Keep the area immediately surrounding and underneath the machine clean,
neat, and free of debris and combustible materials. Make sure that the area
overhead is clear of debris that could fall onto or into the machine or exhaust
compartment.
Storing the
machine
Store the machine properly when it is not being used. The machine should be
stored in a clean, dry location out of the reach of children.

Safety Information G 14
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1.4 Operator Safety while Using Internal Combustion Engines
Operating
safety
When running the engine:
Keep the area around exhaust pipe free of flammable materials.
 Check the fuel lines and the fuel tank for leaks and cracks before starting the engine.
Do not run the machine if fuel leaks are present or the fuel lines are loose.
When running the engine:
Do not smoke while operating the machine.
Do not run the engine near sparks or open flames.
Do not touch the engine or muffler while the engine is running or immediately
after it has been turned off.
Do not operate a machine when its fuel cap is loose or missing.
Do not start the engine if fuel has spilled or a fuel odor is present. Move the
machine away from the spill 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.
Replace the fuel tank cap after refueling.
Do not smoke.
Do not refuel a hot or running engine.
Do not refuel the engine near sparks or open flames.
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.
fRead and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
Exhaust gas from the engine contains carbon monoxide, a deadly poison.
Exposure to carbon monoxide can kill you in minutes.
fNEVER operate the machine inside an enclosed area, such as a tunnel, unless
adequate ventilation is provided through such items as exhaust fans or hoses.

G 14 Safety Information
wc_si000337gb.fm 13
1.5 Towing Safety
Hitch and
coupling
Before towing, follow the instructions below to ensure that the hitch and coupling
are ready for use.
Check that the hitch and coupling on the vehicle are rated equal to, or greater
than, the trailer’s Gross Vehicle Weight Rating (GVWR).
Inspect the hitch and coupling for wear or damage. DO NOT tow the trailer
using defective parts.
Make sure the coupling is securely fastened to the vehicle.
Connect the safety chains.
Connect the breakaway cable safety hook to the bumper or rear of the vehicle.
Do not attach the breakaway cable to the vehicle hitch.
Tires and
wheels
Before towing, follow the instructions below to ensure that the tires and wheels are
ready for use.
Check the tires on the trailer for tread wear, proper inflation, and condition.
Replace worn tires.
Check that the lug nuts holding the wheels are tight and that none are missing.
Brakes and
lights
Before towing, follow the instructions below to ensure that the brakes and lights are
ready for use.
Test the surge brakes on the trailer.
Test the brakes on the vehicle that will be used for towing.
Make sure directional and trailer lights are connected and working properly.
1.6 Guidelines for Service Safety
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
In addition, before servicing or maintaining the machine:
Tie back long hair.
Remove all jewelry (including rings).

WARNING
Towing a large trailer requires special care. To reduce the possibility of an accident:
fBoth the trailer and vehicle must be in good condition.
fThe trailer and the vehicle must be securely fastened to each other.

Safety Information G 14
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Prerequisites Before servicing this machine:
Stop the engine.
If the engine has an electric starter, disconnect the negative terminal on the
battery.
Attach a “DO NOT START” sign to the machine. This will notify everyone that
the machine is being serviced and will reduce the chance of someone
inadvertently trying to start the machine.
Ground
connection
The generator must be connected to a good earthen ground for proper
operating safety!
Ground the generator in accordance with the standards defined in national,
state, and local regulations.
Personal
injury
avoidance
Let the engine and muffler cool before transporting or servicing the machine.
Do not service the machine if your clothing or skin is wet.
Do not allow untrained personnel to service this machine. Only trained electrical
technicians should be allowed to service the electrical components of this
machine.
Service safety Do not modify the machine without the express written approval of the
manufacturer.
Do not allow water to accumulate around the base of the machine. If water is
present, move the machine and allow the machine to dry before servicing.
When cleaning the unit, do not pressure wash the control panel or any other
electrical components.
..
Replacing
parts and
labels
When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.
Keep the fuel lines in serviceable condition. Leaking fuel and fumes are
extremely explosive!
Replace all missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
Check all external fasteners at regular intervals.
WARNING
A poorly maintained machine can be a personal injury hazard.
fFollow the Periodic Maintenance schedule in this Operator’s Manual.
fRepair or replace any damaged or defective components immediately.

G 14 Labels
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2 Labels
2.1 Label Locations

Labels G 14
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G 14 Labels
wc_si000563gb.fm 17
2.2 Label Meanings
A WARNING!
Lock doors. Access can cause electric
shock, arc flash, or injury. Read the
Operator’s Manual for more information.
B WARNING!
Pressurized contents. Do not open when hot!
C WARNING!
Read and understand the supplied
Operator’s Manual before operating the
machine. Failure to do so increases the risk
of injury to yourself and others.
D WARNING!
Electric shock and arc flash can cause
serious injury or death.
EDANGER!
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.

Labels G 14
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F WARNING!
To prevent hearing loss, wear hearing
protection.
Hand injury if entangled in moving belt.
Rotating machinery! Do not reach inside
with engine running.
WARNING!
Hot surface!
NOTICE
Avoid spraying water into generator.
GWARNING!
Hot surface!
HWARNING!
To prevent hearing loss, wear hearing
protection when operating the machine.
WARNING!
Pressurized contents. Do not open when hot!
WARNING!
Hand injury if entangled in moving belt.
WARNING!
Rotating machinery! Do not reach inside
machine with engine running.
J WARNING!
Disconnect battery before servicing.
Read the Operator’s Manual.

G 14 Labels
wc_si000563gb.fm 19
K WARNING!
To reduce the risk of electrical shock and arc
flash, read the Operator’s Manual. Improper
connection of the generator to a building’s
electrical system can allow electrical current
from the generator to backfeed into utility
lines. This may result in electrocution of
utility workers, fire, or explosion.
Connections to a building’s electrical system
must be made by a qualified electrician and
comply with all applicable laws and electrical
codes.
LDANGER
Using a generator indoors CAN KILL YOU IN
MINUTES. Generator exhaust contains
carbon monoxide. This is a poison you
cannot see or smell.
NEVER use inside a home or garage, EVEN
IF doors and windows are open.
Only use OUTSIDE and away from windows,
doors, and vents.
Avoid other generator hazards. READ
MANUAL BEFORE USE.

Labels G 14
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M
N Operator’s Manual must be stored on
machine. Replacement Operator’s Manual
can be ordered through your local Wacker
Neuson distributor.
O Tie-down point.