Wacker Neuson G 25 Generator Set

⚠ Fire hazard. Ensure quick-disconnect fittings are seated and hoses are not kinked.

1. Connect the external feed hose at the external feed hose fitting.
2. Connect the external return hose at the external return hose fitting.
3. Move the fuel valve handle from the up position for internal supply to the down position for external supply.

⚠ Fire hazard. Do not move the machine while it is running.

⚠ Do not position the machine on a hill or an incline.

Tools: Wheel chocks

1. Place the machine on solid, stable, and level ground.
2. For machines with trailers, install chocks under the wheels.

Tools: Soft cloths, Plastic squeegee

1. Clean placard mounting surfaces with mild soap and water; dry.
2. Use isopropyl alcohol if below 10°C (50°F) or greasy.
3. Peel about 2 cm of backing paper from the top.
4. Apply top of placard, gradually remove backing, press smooth.

Tools: Plastic cloth, Collection container, Pipe sealant

1. Open the access door on the side of the machine.
2. Check the fluid level in the containment system.
3. If fluid has accumulated, drain the containment system.
4. Place a plastic cloth and collection container beneath the machine.
5. Remove the drain plug and drain fluid.
6. Apply pipe sealant to the drain plug and re-install.

1. Open the access door on the curb side of the machine.
2. Inspect exhaust pipes and muffler for cracks, holes, burned insulation, loose clamps, soot.
3. Start the engine and listen for excessive noise, rumbling, whine, or rattling.
4. Repair or replace faulty components before returning to service.

⚠ Burn hazard. Do not touch engine, DPF, or exhaust pipe while operating.

1. Start the engine at low idle speed.
2. Move the manual regeneration switch to the on position and hold for five seconds.
3. Release the switch.
4. Regeneration runs; engine speed increases to about 1000 rpm.
5. Engine returns to low idle (about 750 rpm) when complete.

⚠ Burn hazard. Check coolant level only after engine is shut down and cool.

1. Open the access cover on the roof.
2. Slowly rotate radiator cap counterclockwise to release pressure; remove.
3. Add coolant at about 1.5 gallons per minute for 6 minutes.
4. Wait 10 minutes, then fill at about 1.5 gallons per minute for 3:30 minutes or until full.
5. Run machine under 50% load for about 15 minutes until coolant exceeds 190°F.
6. Inspect radiator cap and seal; clean or replace if necessary.
7. Re-install the radiator cap.

⚠ DEF contains urea. Do not get in eyes.

⚠ Do not disconnect the DEF line while under low pressure.

Tools: Strap wrench or filter wrench, Warm water, Clean cloth, Container

1. Remove the filter cap.
2. Remove the filter equalizing element.
3. Use the disposable filter tool to remove the filter element.
4. Clean the filter cap and threads with warm water and a clean cloth.
5. Insert the equalizing element into the new filter.
6. Insert the filter assembly into the aftertreatment dosing unit.
7. Re-install the filter cap and torque to 20 Nm (14.8 ft.lbs.).

⚠ Disconnect trailer wiring plug before testing; damage to electronic brake control.

Tools: Voltmeter, Battery charger or backup battery

1. Connect machine/trailer to tow vehicle.
2. Disconnect trailer wiring plug from tow vehicle.
3. Pull breakaway pin out of brake switch and tow at less than 5 mph.
4. Stop the tow vehicle.
5. Check breakaway battery voltage; replace or recharge if not 12–14 VDC.
6. Repair wiring/mechanical faults if brakes did not function.
7. Reconnect wires, re-install cover and breakaway pin, reconnect plug.

⚠ Personal injury hazard if breakaway system is faulty.

Tools: Screwdriver or pry bar

1. Position machine/trailer on a flat surface.
2. Connect breakaway cable to tow vehicle, not via hitch.
3. Slowly move tow vehicle until emergency lever locks into ON.
4. Connect machine/trailer to tow vehicle via hitch.
5. Attempt to tow at less than 5 mph; check for drag.
6. Repair faults if brakes did not function.
7. Stop the tow vehicle.
8. Release brake by pulling breakaway cord and prying locking spring.

⚠ Crushing hazard. Check for stability before continuing.

Tools: Lifting equipment, Hooks, chains, shackles

1. Attach lifting devices and equipment to the lifting eye.
2. Lift the machine a small distance.
3. Check for stability; reposition if necessary.
4. Continue lifting only when stable.

⚠ Be prepared for engine startup in REMOTE START position.

Tools: Jumper wire (minimum 16-gauge insulated)

1. Perform a manual start to verify the LCD panel; check fuel and battery.
2. Attach a jumper wire between the two remote run terminals.
3. Set engine start switch to REMOTE START.
4. Wait for engine to crank, start, and run.
5. Move engine start switch to OFF to stop.
6. Remove jumper wire.
7. Set voltage selector switch to correct position.
8. Set engine start switch to REMOTE START.
9. Set main line circuit breaker to ON.
10. Secure generator by closing and locking all doors.