Wacker Neuson G 150 User manual

Mobile Generator
G 150
G 180
G 240
OPERATOR’S MANUAL
0171953en 003
0709
0171953EN

G 150 / 180 / 240 Foreword
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Foreword
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.
If you are missing either of these documents, please contact Wacker Neuson
Corporation to order a replacement or visit www.wackerneuson.com.
Contact Wacker Neuson Product Support for information on servicing and
repairing the machine.
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 Corporation 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 Corporation reserves the right to
change any portion of this information without notice.
Copyright
notice
All rights, especially copying and distribution rights, are reserved.
Copyright June 29, 2009 by Wacker Neuson Corporation.
This publication may be reproduced through photocopying by the original
purchaser of the machine. Any other type of reproduction is prohibited without
express written permission from Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson
Corporation represents an infringement of valid copyrights, and violators will be
prosecuted.
CALIFORNIA
Proposition
65 Warning:
Diesel 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.
Trademarks All trademarks referenced in this manual are the property of their respective
owners.

Foreword G 150 / 180 / 240
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G 150 / 180 / 240 Table of Contents
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Foreword 3
1 Safety Information 7
1.1 Signal Words Found in this Manual ...................................................... 7
1.2 Safety Guidelines for Operating the Machine ....................................... 8
1.3 Operator Safety While Using Internal Combustion Engines ................. 9
1.4 Towing Safety ..................................................................................... 10
1.5 Guidelines for Service Safety ............................................................. 10
1.6 Label Locations .................................................................................. 12
1.7 Safety and Warning Labels ................................................................ 14
1.8 Informational Labels ........................................................................... 17
2 Operation 21
2.1 Application .......................................................................................... 21
2.2 Control Panel ...................................................................................... 22
2.3 Normal Boot-up Sequence ................................................................. 24
2.4 Generator monitoring ......................................................................... 26
2.5 Engine Monitoring .............................................................................. 27
2.6 Engine Shutdown Faults .................................................................... 28
2.7 Current Overload Fault ....................................................................... 29
2.8 Warning Light ..................................................................................... 30
2.9 Voltage Selector ................................................................................. 31
2.10 Emergency stop switch ...................................................................... 32
2.11 Main line circuit breaker ..................................................................... 33
2.12 Engine start switch ............................................................................. 34
2.13 Adjusting voltage with the rheostat ..................................................... 35
2.14 Connection Lugs ................................................................................ 36
2.15 Ground connection ............................................................................. 36
2.16 Convenience receptacles ................................................................... 37
2.17 Remote run terminal block ................................................................. 38
2.18 Voltage selector label ......................................................................... 39
2.19 Before starting .................................................................................... 40
2.20 Manual start-up .................................................................................. 41
2.21 Running the generator ........................................................................ 43
2.22 Engine power correction factors ......................................................... 44
2.23 Racor® Filter ...................................................................................... 45
2.24 Shutting off the generator ................................................................... 45
2.25 Cold weather start-up ......................................................................... 46
2.26 Lifting .................................................................................................. 46
2.27 Overnight storage ............................................................................... 46

G 150 / 180 / 240 Table of Contents
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2.28 Long-term storage .............................................................................. 46
2.29 Automatic/remote start-up .................................................................. 47
2.30 Remote/transfer switch ....................................................................... 48
2.31 Towing ................................................................................................ 49
3 Maintenance 51
3.1 Periodic Maintenance Schedule ......................................................... 51
3.2 Breaking In New Machines ................................................................. 52
3.3 Resetting the Periodic Maintenance Timer ........................................ 52
3.4 Replacing the Air Filter Element ......................................................... 53
3.5 Replacing the Racor® Filter Element ................................................. 54
3.6 Lubricating the Engine ........................................................................ 55
3.7 Checking the Engine Coolant Level ................................................... 56
3.8 Maintaining the Trailer ........................................................................ 57
4 Factory-Installed Options 58
4.1 Block Heater ....................................................................................... 58
4.2 LCD Strip Heater ................................................................................ 59
4.3 Low Coolant Shutdown ...................................................................... 60
4.4 Lube Level Maintainer ........................................................................ 61
4.5 Temperature-Activated Shutters ........................................................ 62
4.6 Lockable Battery Disconnect .............................................................. 62
5 Schematics 64
5.1 DC Schematic (G 150 / G 180 / G 240) .............................................. 64
5.2 DC Schematic Components ............................................................... 65
5.3 AC Schematic (G 150 / G 180) ........................................................... 66
5.4 AC Schematic Components (G 150 / G 180) ..................................... 67
5.5 AC Schematic (G 240) ....................................................................... 68
5.6 AC Schematic Components (G 240) .................................................. 69
6 Technical Data 70
6.1 Engine ................................................................................................ 70
6.2 Generator Data ................................................................................... 71
6.3 Trailer and Skid Data .......................................................................... 72
6.4 Dimensions ......................................................................................... 73

G 150 / 180 / 240 Safety Information
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1 Safety Information
1.1 Signal Words Found in this Manual
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
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.
fObey all safety messages that follow this symbol to avoid injury or death.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
fObey all safety messages that follow this symbol to avoid possible injury or
death.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fObey all safety messages that follow this symbol to avoid possible minor or
moderate injury.

Safety Information G 150 / 180 / 240
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1.2 Safety Guidelines for Operating the Machine
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.
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.
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.
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
electrician 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 150 / 180 / 240 Safety Information
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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.
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.
1.3 Operator Safety While Using Internal Combustion Engines
1. Do not run engine indoors or in an area with poor ventilation unless exhaust
hoses are used.
2. Do not fill or drain the fuel tank near an open flame, while smoking, or while the
engine is running.
3. Do not refuel a hot or running engine.
4. Refill the fuel tank in a well-ventilated area.
5. Do not touch or lean against hot exhaust pipes.
6. Replace the fuel tank cap after refueling.
7. Do not start the engine if fuel has spilled or a fuel odor is present. Move the gen-
erator away from the spill and wipe the generator dry before starting.
8. Do not remove the radiator cap when the engine is running or hot. The radiator
fluid is hot and under pressure and may cause severe burns!
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.

Safety Information G 150 / 180 / 240
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1.4 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 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, 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.
1.5 Guidelines for Service Safety
Prerequisites Before servicing this machine:
Stop the engine.
If the engine has an electric starter, isconnect 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.
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.
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 150 / 180 / 240 Safety Information
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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
Replace worn or damaged components.
Use only spare parts recommended by Wacker Neuson.
Keep the fuel lines in serviceable condition. Leaking fuel and flames 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.

Safety Information G 150 / 180 / 240
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1.6 Label Locations

G 150 / 180 / 240 Safety Information
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wc_gr005517
G
H
J
R
GG
FF
RA
HK

Safety Information G 150 / 180 / 240
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1.7 Safety and Warning Labels
Ref. Label Definition
A WARNING!
Lock doors. Access can cause electric
shock, arc flash, or injury.
B WARNING!
Pressurized contents. Do not open when hot!
CWARNING!
Read and understand the supplied
Operator’s Manual before operating the
machine. Failure to do so increases the risk
of injury to yourself or others.
DNOTICE
Never change switch position with engine
running. Results in damage to machine.
E WARNING!
Electric shock and arc flash can cause
serious injury or death.

G 150 / 180 / 240 Safety Information
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FDANGER!
Asphyxiation hazard. Read the Operator’s
Manual for instructions. No sparks, flames,
or burning objects near machine. Stop the
engine before adding fuel. Use only diesel
fuel.
G 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.
H WARNING!
Hot surface!
J WARNING!
To prevent hearing loss, wear hearing
protection when operating the machine.
WARNING!
Pressurized contents. Do not open when hot!
WARNING!
Hand injury if entangled in moving belt.
WARNING!
Rotating machinery! Do not reach inside
machine with engine running.
K WARNING!
Disconnect battery before servicing.
Read the Operator’s Manual.
Ref. Label Definition

Safety Information G 150 / 180 / 240
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L WARNING!
Generator can automatically start which can
cause serious injury. Disconnect battery
before servicing.
ODANGER!
Electric shock will cause serious injury or
death. Danger of asphyxiation!
SWARNING
Stop engine. Electrical hazard. Read
Operator’s Manual.
ZWARNING
Electric shock at cooling fins.
CC Stop engine.
Ref. Label Definition

G 150 / 180 / 240 Safety Information
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1.8 Informational Labels
Ref. Label Definition
N Voltage selector label
P
Q Operator’s Manual must be stored on
machine. Replacement Operator’s Manual
can be ordered through your local Wacker
Neuson distributor.
G 240 G 150 / G180
= 40Nm (29.5 Ft Lbs)
L3-N= 277V
L1-L2=480V
L2-N= 277V
L1-N= 277V
L3-L1=480V
L2-L3=480V
L1
1
2
N
4
3
8
L-L
12
5
6
L-N
L2
10
L3
9
7
11
L-L
L2-N= 120V
L1-L2=208V
L3-N= 120V
L1-N= 120V
L2
L3-L1=208V
L2-L3=208V
5
2
6
1
N
4
12
3
11
L1
9
L3
10 8
7
L-N

Safety Information G 150 / 180 / 240
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R Tie-down point.
T Electrical ground
UCAUTION
Lifting point.
V Operating the main circuit breaker supplies
or interrupts power to the customer
connection lugs.
W Neutral bonded to frame
X Engine wiring
Ref. Label Definition

G 150 / 180 / 240 Safety Information
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Y
G 240
G 150 / G 180
AA A nameplate listing the model number, item
number, revision number, and serial number
is attached to each unit. Please record the
information found on this plate so it will be
available should the nameplate become lost
or damaged. When ordering parts or
requesting service information, you will
always be asked to specify the model
number, item number, revision number, and
serial number of the unit.
BB This machine may be covered by one or
more patents.
DD Remote start operation. Read Operator’s
Manual for instructions.
EE NOTICE
Receptacles not used when:
Selector switch set to 208/120V and voltage
greater than 228V.
Selector switch set to 480/277V and voltage
greater than 457V.
Ref. Label Definition
UTILITY 159116
UTILITY 159116
U.S.PAT.Nos.: 6012285, 6471476,
U.S.PAT.Nos.: 6012285, 6471476,
D416858, D454357 OTHER U.S. AND
D416858, D454357 OTHER U.S. AND
FOREIGN PATENTS PENDING
FOREIGN PATENTS PENDING

Safety Information G 150 / 180 / 240
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FF Hand hold
GG Protecting Our Environment
Fluid containment system
(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. The label includes the Vehicle
Identification Number (VIN) for the trailer.
Trailer Wiring
G - Right brake light and directional
Y - Left brake light and directional
Br - Tail, side, and license plate lights
W - Ground
L - Electric brakes
B - Battery charge
(if equipped)
CAUTION: Do not use battery
disconnect switch while engine is
running. Damage to electrical
components may occur.
Ref. Label Definition