Wacker Neuson G78 User manual

0175259en 002 0110

0175259EN

Operator’s Manual

Mobile Generator

G 78

Copyright

notice

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 Corporation.

Any type of reproduction or distribution not authorized by Wacker Neuson Corporation

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 Corporation

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

Translated

instructions

This Operator’s Manual presents a translation of the original instructions. The original

language of this Operator’s Manual is American English.

G 78 Foreword

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Foreword

Machines

covered by

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.

 If you are missing any of these documents, please contact Wacker Neuson

Corporation 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 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.

 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.

Trademarks

All trademarks referenced in this manual are the property of their respective

owners.

Machine Item Number

G 78 0620547

Foreword G 78

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G 78 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 Instructions for Operating the Machine ..................................... 8

1.3 Safety Instructions for Towing ............................................................ 10

1.4 Safety Instructions for Servicing the Machine .................................... 11

1.5 Label Locations .................................................................................. 14

1.6 Label Meanings .................................................................................. 15

2 Transporting, Lifting, and Storing 16

2.1 Transporting ....................................................................................... 16

2.2 Storing ................................................................................................ 16

2.3 Lifting .................................................................................................. 17

3 Operating the Machine 19

3.1 Application .......................................................................................... 19

3.2 Control/Component Locations ............................................................ 20

3.3 Control/Component Descriptions ....................................................... 21

3.4 Control Panel/Microprocessor ............................................................ 22

3.5 Control Panel/Microprocessor Functions ........................................... 22

3.6 Main Control Switch Positions/Functions ........................................... 24

3.7 Preliminary Checklist .......................................................................... 26

3.8 Starting the Generator ........................................................................ 27

3.9 Stopping the Generator ...................................................................... 28

3.10 Connecting Loads to the Terminal Lugs ............................................. 29

3.11 Operating the Generator .................................................................... 30

3.12 Microprocessor Display Screens ........................................................ 31

4 Maintenance 34

4.1 Periodic Maintenance Schedule ......................................................... 34

4.2 Checking the Engine Oil ..................................................................... 35

Table of Contents G 78

wc_bo0175259_001TOC.fm 6

4.3 Changing the Engine Oil .....................................................................36

4.4 Changing Oil Filter ...............................................................................37

4.5 Changing the Fuel Filter ......................................................................38

4.6 Air Cleaner Discharge Valve ...............................................................39

4.7 Cleaning/Changing Air Filter Cartridges ..............................................40

4.8 Checking the Alternator V-Belt ............................................................41

4.9 Lubricating the Trailer ..........................................................................42

4.10 Cleaning the Engine ............................................................................43

4.11 Changing/Tensioning Alternator V-Belt ...............................................44

4.12 Checking/Adjusting Valve Clearances ................................................45

4.13 Checking Battery Electrolyte ...............................................................47

5 Schematics 48

5.1 Power Wiring .......................................................................................48

5.2 Power Wiring Components ..................................................................49

5.3 Engine Wiring ......................................................................................50

5.4 Engine Wiring Components .................................................................51

5.5 Socket Wiring ......................................................................................52

5.6 Socket Wirng Components ..................................................................53

5.7 Control Wiring ......................................................................................54

5.8 Control Wiring Components ................................................................55

6 Basic Troubleshooting 56

7 Technical Data 58

7.1 Machine ...............................................................................................58

7.2 Engine .................................................................................................59

7.3 Dimensions ..........................................................................................60

7.4 Sound Power .......................................................................................61

50Hz Mobile Generators 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.

f 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.

f Obey 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.

f Obey 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.

f Obey all safety messages that follow this symbol to avoid possible minor or

moderate injury.

Safety Information 50Hz Mobile Generators

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1.2 Safety Instructions for Operating the Machine

Safety

devices,

controls, and

attachments

Only operate the machine when:

 All safety devices and guards are in place and in working order.

 All controls operate correctly.

 The machine is set up correctly according to the instructions in the Operator’s

Manual.

 The machine is clean.

 The machine’s labels are legible.

To ensure safe operation of the machine:

 Do not operate the machine if any safety devices or guards are missing or inop-

erative.

 Do not modify or defeat the safety devices.

 Do not use accessories or attachments that are not recommended by Wacker

Neuson Corporation.

Operator

training

Before operating the machine:

 Read and understand the operating instructions contained in all manuals

delivered with the machine.

 Familiarize yourself with the location and proper use of all controls and safety

devices.

 Contact Wacker Neuson Corporation for additional training if necessary.

When operating this machine:

 Do not allow improperly trained people to operate the machine. People

operating the machine must be familiar with the potential risks and hazards

associated with it.

Safe

operating

practices

When operating this machine:

 Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

 Wear protective clothing appropriate to the job site when operating the

machine.

 Wear safety glasses when operating this machine.

 Wear hearing protection when operating this machine.

When operating this machine:

 Do not operate a machine in need of repair.

DANGER

Electric shock hazard. Backfeed from the generator into the public power distribu-

tion system can seriously injure or kill utility workers!

f Connections to a building’s electrical system must be made by a qualified elec-

trician and comply with all applicable laws and electrical codes.

50Hz Mobile Generators Safety Information

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Work area

Be aware of the work area.

 Keep unauthorized personnel, children, and pets away from the machine.

 Remain aware of changing positions and the movement of other equipment

and personnel in the application area/job site.

 Keep the machine at least one meter (three feet) away from structures, build-

ings, 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.

 Make sure the machine is on a firm, level surface and will not tip, roll, slide, or

fall while operating.

Be aware of the application area.

 Never operate the machine indoors unless exhaust fumes can be adequately

ventilated.

 Never operate the machine in areas that contain flammable objects, fuels, or

products that produce flammable vapors.

 Never operate the machine if you or the machine are in water.

Electrical

safety

To increase electrical safety while operating this machine, follow the procedures

below.

 Do not operate the generator, or tools attached to the generator, with wet

hands.

 Do not use worn electrical cords.

 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.

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 50Hz Mobile Generators

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1.3 Safety Instructions for Towing

Hitch and

coupling

To reduce the possibility of an accident, perform the following before towing.

 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 it to the hitch.

Tires and

wheels

To reduce the possibility of an accident, perform the following before towing.

 Check the condition, tread wear, and air pressure of the trailer tires. Replace

worn tires.

 Check that the wheel lug nuts are tight and that none are missing.

Brakes and

lights

To reduce the possibility of an accident, perform the following before towing.

 Test the brake linkage on the trailer and the brakes on the towing vehicle.

 Make sure directional and trailer lights are connected and working properly.

WARNING

Towing a trailer requires special care. To reduce the possibility of an accident:

f Both the trailer and the vehicle must be in good working condition.

f The trailer and the vehicle must be securely fastened to each other.

50Hz Mobile Generators Safety Information

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1.4 Safety Instructions for Servicing the Machine

Service

training

Before servicing or maintaining the machine:

 Read and understand the instructions contained in all manuals delivered with

the machine.

 Familiarize yourself with the location and proper use of all controls and safety

devices.

 Only trained personnel shall troubleshoot or repair problems occurring with the

machine.

 Contact Wacker Neuson Corporation for additional training if necessary.

When servicing or maintaining this machine:

 Do not allow improperly trained people to service or maintain the machine. Per-

sonnel servicing or maintaining the machine must be familiar with the associ-

ated potential risks and hazards.

Precautions

Follow the precautions below when servicing or maintaining the machine.

 Read and understand the service procedures before performing any service to

the machine.

 All adjustments and repairs must be completed before operation. Do not oper-

ate the machine with a known problem or deficiency.

Safe servicing

practices

When servicing and maintaining this machine:

 Be aware of the machine’s moving parts. Keep hands, feet, and loose clothing

away from the machine’s moving parts.

 Wear protective clothing appropriate to the job.

 Wear safety glasses.

 Wear hearing protection if required.

 Re-install the safety devices and guards after repairs and maintenance.

Machine

modifications

When servicing or maintaining the machine:

 Use only accessories/attachments recommended by Wacker Neuson Corpora-

tion.

When servicing or maintaining the machine:

 Do not defeat the safety devices.

 Do not modify the machine without the express written approval of Wacker

Neuson Corporation.

WARNING

A poorly maintained machine can be a personal injury hazard.

f Follow the Periodic Maintenance schedule in this Operator’s Manual.

f Repair or replace any damaged or defective components immediately.

Safety Information 50Hz Mobile Generators

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Replacing

parts and

labels

 Replace worn or damaged components.

 Use only spare parts recommended by Wacker Neuson Corporation.

 Replace all missing and hard-to-read labels.

 When replacing electrical components, use components that are identical in

rating and performance as the original components.

Before

servicing

Complete the following procedures before servicing the machine.

 Turn off the machine.

 Open the circuit breakers (“OFF”).

 Disconnect the battery.

 Attach a “DO NOT START” sign to the control panel.

 Make sure that the remote start or transfer switch (if used) is also off and

tagged.

 Let the engine cool.

Lifting and

transporting

When lifting the machine:

 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.

 Be aware of the location of other people when lifting the machine.

To reduce the possibility of injury:

 Do not stand under the machine while it is being hoisted or moved.

 Do not get onto the machine while it is being hoisted or moved.

50Hz Mobile Generators Safety Information

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Notes

Safety Information 50Hz Mobile Generators

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1.5 Label Locations

a

b

c

wc_gr005209

50Hz Mobile Generators Safety Information

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1.6 Label Meanings

Ref. Label Definition

a

Attention! Work with hood closed

b

WARNING!

Electric shock will cause serious

injury or death.

c

Electrical ground

d

Internal fuel tank connection

External fuel tank connection

GND

88897

Transporting, Lifting, and Storing 50Hz Mobile Generators

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2 Transporting, Lifting, and Storing

2.1 Transporting

When transporting the machine, only use transport vehicles with enough weight-

bearing capacity for both the generator and the trailer. See section Technical Data.

Secure the generator and the trailer to the transport vehicle.

2.2 Storing

When storing the machine for more than 30 days:

 Drain the fuel tank.

 Change the engine oil.

 Disconnect the battery.

 Clean the machine.

 Cover the machine.

50Hz Mobile Generators Transporting, Lifting, and Storing

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2.3 Lifting

Prerequisites

 Engine shut down

 Appropriate lifting equipment (see section Technical Data for weights)

Procedure

Follow the procedure below to lift the machine.

1. Turn off the engine.

2. Disconnect all loads.

3. Secure all doors in the closed position.

4. Connect an appropriate crane to the lifting eye (a) and lift the machine as

needed. A fork truck may also be used. Use the fork lift pockets (b) in the frame

of the machine.

WARNING

Crush hazard. The weight of the machine may crush you if the lifting equipment

fails. Crushing may cause severe injury or death.

f Only use lifting equipment with enough lifting capacity to support the weight of

the machine and the trailer.

WARNING

Crush hazard. The weight of the machine may crush you if the lifting equipment

fails. Crushing may cause severe injury or death.

f Do not stand underneath the machine when it is being lifted.

Transporting, Lifting, and Storing 50Hz Mobile Generators

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Notes

50Hz Mobile Generators Operating the Machine

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3 Operating the Machine

3.1 Application

Generator

application

This machine is a heavy-duty, compact, sound-attenuated generator designed to

provide single and three-phase power for construction, commercial, and industrial

applications where reliable power is needed.

.

Safety notices

 Do not exceed the power output of the generator. Damage to tools or generator

will occur. Refer to Technical Data.

 When using the generator as a standby or substitute power supply, make sure

the voltage and phase rotation of the line connections match those of the mains

lines. Failure to match phase rotation and voltage may cause equipment con-

nected to the generator to operate incorrectly! This could create unsafe operat-

ing conditions.

 Do not exceed the rated current limit of any receptacle.

Operating the Machine 50Hz Mobile Generators

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3.2 Control/Component Locations

a

b c d e f

g

h

m

p

i

j

k

l

wc_gr005210

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Wacker Neuson G78 User manual

Wacker Neuson G78 User manual

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