Wacker Neuson G70 User manual

www.wackergroup.com
Mobile Generator
G 50
G 70
G 85
OPERATOR’S MANUAL
0162089en 008
1107
0162089EN

G 50/G 70/G 85 Table of Contents
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1. Foreword 5
2. Safety Information 6
2.1 Operating Safety .................................................................................. 8
2.2 Service Safety .................................................................................... 10
2.3 Operator Safety while using Internal Combustion Engines ................ 11
2.4 Towing Safety ..................................................................................... 12
2.5 Reporting Trailer Safety Defects ........................................................ 13
2.6 Label Location .................................................................................... 14
2.7 Safety and Operating Labels .............................................................. 16
3. Operation 24
3.1 Control Panels .................................................................................... 24
3.2 Generator Monitoring ......................................................................... 26
3.3 Engine Monitoring .............................................................................. 27
3.4 Engine Shutdown Faults .................................................................... 28
3.5 Current Overload Fault ....................................................................... 29
3.6 Application .......................................................................................... 29
3.7 Voltage Selector Switch ..................................................................... 30
3.8 Emergency Stop Switch ..................................................................... 31
3.9 Main Line Circuit Breaker ................................................................... 32
3.10 Engine Start Switch ............................................................................ 33
3.11 Voltage Adjustment Rheostat ............................................................. 33
3.12 Warning Light ..................................................................................... 33
3.13 Connection Lugs ................................................................................ 34
3.14 Ground Connection ............................................................................ 35
3.15 Convenience Receptacles .................................................................. 35
3.16 Remote Run Terminal Block .............................................................. 35
3.17 Panel Door Interlock Switch ............................................................... 35
3.18 Terminal Connections ........................................................................ 36
3.19 Before Starting ................................................................................... 37
3.20 Manual Start-up .................................................................................. 38
3.21 Running the Generator ....................................................................... 40
3.22 Engine Power Correction Factors ...................................................... 40
3.23 Shutting Down Generator ................................................................... 42
3.24 Cold Weather Start-up ........................................................................ 42
3.25 Lifting .................................................................................................. 42
3.26 Overnight Storage .............................................................................. 42
3.27 Long-term Storage ............................................................................. 42

Table of Contents G 50/G 70/G 85
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3.28 Automatic/Remote Start-up .................................................................43
3.29 Remote/Transfer Switch ......................................................................44
3.30 Towing .................................................................................................45
4. Maintenance 47
4.1 Periodic Maintenance Schedule ..........................................................47
4.2 New Machines .....................................................................................48
4.3 Resetting the Periodic Maintenance Timer .........................................48
4.4 Air Cleaner ..........................................................................................49
4.5 Engine Lubrication ...............................................................................50
4.6 Engine Coolant ....................................................................................51
4.7 Trailer Maintenance .............................................................................51
4.8 Troubleshooting Automatic Shutdown .................................................52
4.9 Wire Colors ..........................................................................................53
4.10 Generator and Receptacle Wiring .......................................................54
4.11 Trailer Wiring .......................................................................................60
4.12 G 50/G 70 Engine Wiring ....................................................................62
4.13 G 85 & G 70 w/ECU Engine Wiring .....................................................70
5. Factory-Installed Options 74
5.1 Block Heater ........................................................................................74
5.2 Fuel/Water Separator ..........................................................................75
5.3 Electronic Governor .............................................................................76
5.4 LCD Strip Heater .................................................................................77
5.5 Low Coolant Shutdown .......................................................................78
5.6 Lube Level Maintainer .........................................................................79
5.7 Temperature-Activated Shutters .........................................................80
5.8 Lockable Battery Disconnect ...............................................................80
5.9 Wiring Diagram ....................................................................................82
5.10 Wiring Diagram Components ..............................................................83
5.11 Cam-Lock ............................................................................................84
5.12 Containment System ...........................................................................85
6. Technical Data 86
6.1 Engine Data .........................................................................................86
6.2 Generator Data ....................................................................................88
6.3 Trailer and Skid Data ...........................................................................89
6.4 Dimensions ..........................................................................................90

Foreword
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1 Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker model. For your own safety and protection
from injury, carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.

Safety Information G 50/G 70/G 85
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2. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE:Used without the safety alert symbol, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
Danger of Electrocution!
Danger of electrocution or severe electrical shock is present
throughout the generator any time the engine is running! Read all
safety notes contained in this section before operating or servicing this
equipment.
No one except a trained electrician, familiar with this equipment,
should attempt repairs to the generator! Test procedures which require
that the generator be running must be performed using extreme
caution.
DANGER
WARNING
CAUTION
DANGER

G 50/G 70/G 85 Safety Information
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This machine is built with user safety in mind; however, like any
electrical device it can present serious hazards if improperly operated
and serviced. Follow instructions carefully! Should questions arise
during operation or service of this equipment, contact Wacker
Corporation.

Safety Information G 50/G 70/G 85
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2.1 Operating Safety
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
this manual and the Engine Manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
2.1.1 NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
2.1.2 NEVER place flammable material or liquids near the generator.
2.1.3 NEVER operate the generator, or tools attached to the generator, with
wet hands.
2.1.4 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
2.1.5 NEVER operate the machine indoors unless exhaust fumes can be
adequately ventilated.
2.1.6 NEVER overload the generator. The total amperage of the tools and
equipment attached to the generator must not exceed the load rating
of the generator.
2.1.7 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a certified electrician.
2.1.8 NEVER operate generator in standing water.
2.1.9 NEVER touch the hot engine, exhaust, or generator components.
Burns will result.
2.1.10 NEVER start a unit in need of repair.
2.1.11 Use the emergency stop button only in an actual emergency. DO NOT
restart the engine until the cause of the trouble has been determined
and fixed.
2.1.12 ALWAYS wear hearing protection when operating equipment.
2.1.13 ALWAYS follow starting and stopping instructions described in this
manual. Know how to operate and stop generator before starting it.
2.1.14 ALWAYS 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.
2.1.15 ALWAYS keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
2.1.16 ALWAYS 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.
WARNING

G 50/G 70/G 85 Safety Information
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2.1.17 ALWAYS keep the area immediately surrounding and underneath the
machine clean, neat, and free of debris and combustible materials.
Make sure that the area overhead is clear of debris that could fall onto
or into the machine or exhaust compartment.
2.1.18 ALWAYS be sure the machine is on a firm, level surface and will not
tip, roll, slide, or fall while operating.
2.1.19 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
2.1.20 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER
DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR
DEATH TO UTILITY WORKERS!
Improper 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.
Connections to a building’s electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical
codes.
If connected to a building’s electrical system the generator must meet
the power, voltage, and frequency requirements of the equipment in
the building. Differences in power, voltage, and frequency
requirements may exist and improper connection may lead to
equipment damage, fire, and personal injury or death.
DANGER

Safety Information G 50/G 70/G 85
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2.2 Service Safety
A poorly maintained machine can become a safety hazard! In order
for the machine to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
2.2.1 NEVER perform even routine service (oil/filter changes, cleaning,
etc.) unless all electrical components are shut down. Before
servicing this machine, make sure the engine start switch is turned to
off “O”, the circuit breakers are open (off), the emergency stop switch
is closed (pushed in), and the negative terminal on battery is
disconnected. Attach a “DO NOT START” sign to the control panel.
This will notify everyone that the unit is being serviced and will reduce
the chance of someone inadvertently trying to start the unit. If the unit
is connected to a remote start or transfer switch, make sure the remote
switch is also off and tagged.
2.2.2 Ground Connection
The generator must be connected to a good earthen ground for
proper operating safety!
A central “equipment ground” is provided at the customer connection
lugs. This point is connected directly to the generator set base. All
other system grounds are connected to this central point. Ground the
generator in accordance with the standards defined in national, state
and local regulations.
2.2.3 DO NOT attempt to open the radiator cap while the unit is running or
before the engine has cooled down. Severe burns may result!
2.2.4 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.
2.2.5 DO NOT service the machine if your clothing or skin is wet.
2.2.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
2.2.7 DO NOT modify the machine without the express written approval of
the manufacturer.
2.2.8 DO NOT pressure wash the control panel, generator end, or any other
electrical components when cleaning the unit. Never allow water to
accumulate around the base of the generator set. If water is present,
DO NOT service!
2.2.9 ALWAYS replace the safety devices and guards after repairs and
maintenance.
2.2.10 ALWAYS let the engine cool before transporting or servicing it.
WARNING

G 50/G 70/G 85 Safety Information
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2.2.11 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the machine.
2.2.12 ALWAYS replace all guards, fasten doors and make sure all safety
devices operate properly after making repairs or servicing the
equipment.
2.2.13 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
2.2.14 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
2.2.15 ALWAYS check all external fasteners at regular intervals.
2.2.16 ALWAYS make sure slings, chains, hooks, ramps, jacks and other
types of lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people in the area when lifting the
machine.
2.3 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
Owner’s Manual and the safety guidelines below. Failure to follow the
warnings and safety standards could result in severe injury or death.
2.3.1 DO NOT run engine indoors or in an area with poor ventilation unless
exhaust hoses are used.
2.3.2 DO NOT fill or drain the fuel tank near an open flame, while smoking,
or while the engine is running.
2.3.3 DO NOT refuel a hot or running engine.
2.3.4 ALWAYS refill the fuel tank in a well-ventilated area.
2.3.5 DO NOT touch or lean against hot exhaust pipes.
2.3.6 ALWAYS replace the fuel tank cap after refueling.
2.3.7 DO NOT start the engine if fuel has spilled or a fuel odor is present.
Move the generator away from the spill and wipe the generator dry
before starting.
2.3.8 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!
DANGER

Safety Information G 50/G 70/G 85
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2.4 Towing Safety
Towing a large trailer requires special care. Both the trailer and vehicle
must be in good condition and securely fastened to each other to
reduce the possibility of an accident.
2.4.1 ALWAYS check that the hitch and coupling on the vehicle are rated
equal to, or greater than, the trailer's “gross vehicle weight rating”
(GVWR).
2.4.2 ALWAYS inspect the hitch and coupling for wear or damage. DO NOT
tow the trailer using defective parts.
2.4.3 ALWAYS make sure the coupling is securely fastened to the vehicle.
2.4.4 ALWAYS check the tires on the trailer for tread wear, inflation, and
condition. Replace worn tires.
2.4.5 ALWAYS connect the safety chains.
2.4.6 ALWAYS connect the breakaway cable safety hook to the bumper or
rear of the vehicle. DO NOT attach it to the hitch.
2.4.7 ALWAYS test the surge brakes on the trailer and the brakes on the
vehicle that will be used for towing.
2.4.8 ALWAYS make sure directional and trailer lights are connected and
working properly.
2.4.9 ALWAYS check that the lug nuts holding the wheels are tight and that
none are missing.
WARNING

G 50/G 70/G 85 Safety Information
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2.5 Reporting Trailer Safety Defects
If you believe your trailer has a defect which could cause a crash or
could cause injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to
notifying Wacker Corporation.
If NHTSA receives similar complaints, it may open an investigation;
and if it finds that a safety defect exists in a group of vehicles, it may
order a recall and remedy campaign. However, NHTSA cannot
become involved in individual problems between you, your dealer, or
Wacker Corporation.
To contact NHTSA, you may either contact the Auto Safety Hotline toll-
free at 1-800-424-9393 (or 366-0129 in Washington DC area),
www.nhtsa.com, or write to NHTSA, U.S. Department of
Transportation, 400 7th Street SW, (NSA-11), Washington, DC 20590.
You can also obtain other information about motor vehicle safety from
the Auto Safety Hotline.

Safety Information G 50/G 70/G 85
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2.6 Label Location

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Safety Information G 50/G 70/G 85
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2.7 Safety and Operating Labels
Ref. Label Meaning
A
BWARNING!
Pressurized contents. Do not open when
hot!
CWARNING!
Lock doors. Access can cause electric
shock or injury.
DCAUTION!
Lifting point.
ECAUTION!
Never change switch position with engine
running. Results in damage to machine.
WARNING!
Electric shock will cause serious injury or
death.
INSTRUCTIONS DE REMORQUAGE
TOWING INSTRUCTIONS ABSCHLEPPINSTRUKTIONEN INSTRUCCIONES DE REMOLQUE
1. READ OPERATOR'S MANUAL.
2. USE HITCH RATED FRO TRAILER'S
"GROSS VEHICLE WEIGHT RATING".
3. SECURELY ATTACH TRAILER TO TOW
VEHICLE.
4. ATTACH SAFETY CHAINS USING CROSS
PATTERN.
5. ATTACH BREAKDOWN CHAIN TO VEHICLE.
6. CHECK TRAILER LIGHTS.
1. BETRIEBSVORSCHRIFT LESEN.
2. ANHANGEVORRICHTUNG VERWENDEN,
DIE DER GESAMTBETRIEBSGEWICHTSKLASSE
ENTSPRICHT.
3. ANHANGER SICHER AM ZUGFAHRZEUG
BEFESTIGEN.
4. SICHERHEITSKETTEN KREUZWEISE ANBRINGEN.
5. ABREISSKETTE AM FAHRZEUG ANBRINGEN.
6. ANHANGERLEUCHTEN PRUFEN.
1. LEA EL MANUAL DEL OPERARIO.
2. UTILICE UN ACOPLE CORRECTAMENTE
CLASIFICADO PARA LA "CLASE DE PESO BUTO"
DEL VEHICULO DEL REMOLQUE.
3. ASEGURESE DE AMARRAR CORRECTAMENTE
EL REMOLQUE AL VEHICULO DE REMOLQUE.
4. FIJE EN CRUZ LAS CADENAS DE SEGURIDAD.
5. FIJE EN EL VEHICULO DE REMOLQUE LA CADENA
DE DESPRENDIMIENTO.
6. CONTROLE LAS LUCES DEL REMOLQUE.
1. LIRE LA NOTICE D'EMPLOI.
2. UTILISER UN GROCHET D'ATTELAGE CONFORME AU
DEBIT NOMINAL DU POIDS BRUT DE VEHICULE DU
TRACTEUR.
3. ATTACHER LA REMORQUE FERMEMENT AU VEHICULE
TRACTEUR.
4. ATTACHER LES CHAINES DE SURETTE EN UTILISANT
UNE METHODE CROISEE.
5. ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE.
6. VERIFIER LES LAMPES DE LA REMORQUE.
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G 50/G 70/G 85 Safety Information
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FDANGER!
Asphyxiation hazard. Read the Opera-
tor’s Manual for instructions. No sparks,
flames, or burning objects near machine.
Stop the engine before adding fuel. Use
only diesel fuel.
GTie-down point.
HWARNING!
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!
CAUTION!
Avoid spraying water into generator.
IWARNING!
Hot surface!
JElectrical ground
KWARNING!
Electric shock will cause serious injury or
death.
Ref. Label Meaning

Safety Information G 50/G 70/G 85
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L
MOperator’s Manual must be stored on
machine. Replacement Operator’s
Manual can be ordered through your
local Wacker distributor.
NDANGER!
Electric shock will cause serious injury or
death. Danger of asphyxiation!
Ref. Label Meaning
a

G 50/G 70/G 85 Safety Information
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OWARNING!
Generator can automatically start which
can cause serious injury. Disconnect
battery before servicing.
PWARNING!
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.
QWARNING!
To reduce the risk of electrical shock,
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.
RRemote start operation. Read operator’s
manual for instructions.
SCAUTION!
Receptacles not to be 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 Meaning
REMOTE START
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
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Safety Information G 50/G 70/G 85
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TWARNING!
Disconnect battery before servicing.
Read the Operator's Manual.
U
VOperator’s Manual must be stored on
machine. Replacement Operator’s
Manual can be ordered through your
local Wacker distributor.
WDrain containment system.
XWARNING!
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
with engine running.
YOperating the main circuit breaker
supplies or interrupts power to the
customer connection lugs.
Ref. Label Meaning
W A R N I N G
A D V E R T I S S E M E N T
A D V E R T E N C I A
W A R N U N G
POUR REMORQUE
G - FEUX DE STOP ET DE DIRECTION D
Y - FEUX DE STOP ET DE DIRECTION G
Br -FEUX D'ARRIERE, DE POSITION ET
DE PLAQUE D'IMMATRICULATION
W - MISE A TERRE
L - FREINS ELECTRIQUES
B - CHARGE DE LA BATTERIE
G - RECHTES BREMSLICHT UND BLINKER
Y - LINKES BREMSLICHT UND BLINKER
Br -SCHLUSS-, SEITEN- UND
KENNZEICHENLEUCHTE
W - ERDUNG
L - ELEKTRISCHE BREMSE
B - BATTERIE-LADUNG
ANHÄNGER-VERDRAHTUNG
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
DE REMOLQUE
G - LUZ FRENO Y GIRO DERECHA
Y - LUZ FRENO Y GIRO IZQUIERDA
Br -LUZ TRASERA, LATERAL Y PLACA
DE MATRICULA
W - TIERRA
L - FRENOS ELECTRICOS
B - CARGA BATERIA
115681
DISPOSITION DES CABLESCANALISATION ELECTRICA
L1 L2 L3
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