G 50 G 70 Operator’s Manual Mobile Generator

G 50 G 70 Operator’s Manual Mobile Generator
Operator’s Manual
Mobile Generator
G 50
G 70
EN
5200018221
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Copyright
notice
© Copyright 2014 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: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original
instructions
This Operator’s Manual presents the original instructions. The original language of this
Operator’s Manual is American English.
Machine Identification
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models below. These instructions have been written expressly by
Wacker Neuson Production Americas LLC and must be followed during installation,
operation, and maintenance of the machines.
Machine
Item Number
G 50
5200001060, 5200001061, 5200001062, 5200001063,
5200001317, 5200006878, 5200008339, 5200014319,
5200014320, 5200014322, 5200014323, 5200017829,
5200017830, 5100014168, 5100014169
G 70
0620646, 0620647, 0620648, 0620711, 5200008340,
5200008341, 5200014463, 5200014464, 5200014465,
5200001318, 5200003220, 5200003973, 5200003974,
5200003975, 5200004151, 5200006879, 5200008342,
5200008343, 5200008344, 5200014463, 5200014464,
5200014465, 5100014190, 5100014191
wc_gr010874
Machine
identification
A nameplate listing the model number, item number, revision number, and serial
number is attached to this machine. The location of the nameplate is shown above.
Serial number
(S/N)
For future reference, record the serial number in the space provided below. You will
need the serial number when requesting parts or service for this machine.
Serial Number:
wc_tx003651gb_FM10.fm
3
Foreword
Foreword
Machine
documentation





Expectations
for
information in
this manual




From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
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 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.
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.
The illustrations, parts, and procedures in this manual refer to Wacker Neuson
factory-installed components. Your machine may vary depending on the
requirements of your specific region.
CALIFORNIA
Proposition
65 Warning
Combustion 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.
4
wc_tx003565gb_FM10.fm
Foreword
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.

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_tx003565gb_FM10.fm
5
Foreword
Notes
6
wc_tx003565gb_FM10.fm
G 50/G 70
Table of Contents
Foreword
1
4
Safety Information
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
13
Signal Words Used in this Manual ..................................................... 13
Machine Description and Intended Use ............................................. 14
Safety Guidelines for Operating the Machine ..................................... 15
Service Safety .................................................................................... 17
Operator Safety while Using Internal Combustion Engines ............... 19
Safety Guidelines for Mobile Generators ........................................... 20
Safety Guidelines for Towing the Machine ......................................... 22
Safety Guidelines for Lifting the Machine ........................................... 23
Reporting Safety Defects ................................................................... 23
2
Label Locations
24
3
Label Meanings
26
4
Lifting and Transporting
35
4.1
4.2
4.3
4.4
4.5
4.6
4.7
5
Machine Setup
5.1
5.2
5.3
5.4
5.5
5.6
6
Lifting the Machine ............................................................................. 35
Before Towing Checklist ..................................................................... 36
Towing the Machine ........................................................................... 37
Preparing the Machine for Transport on a Truck or Trailer ................ 38
Hazardous Materials Placards ........................................................... 39
Testing the Breakaway System (Hydraulic Surge Brakes) ................. 40
Testing the Breakaway System (Electric Brakes) .............................. 42
44
Preparing the Machine for First Use ................................................... 44
Positioning the Machine ..................................................................... 45
Grounding the Generator ................................................................... 47
Recommended Fuel ........................................................................... 48
Refueling the Machine (Basler Controller) ......................................... 49
Refueling the Machine (Deep Sea Controller) .................................... 50
Operation, Control, and Component Locations
6.1
6.2
51
Control / Component Locations .......................................................... 51
Control Panel Components ................................................................ 52
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7
Table of Contents
7
Operation (Basler Controller)
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
8
66
How to Use the Genset Controller LCD and Keypad .......................... 66
Menu Diagram of the Genset Controller ............................................. 67
Menu Diagram Components ............................................................... 68
Using the Metering and Settings Menus ............................................. 69
Logging in to the Genset Controller by Entering the Password .......... 70
Adjusting the LCD Screen Contrast .................................................... 73
Changing the Time/Date Settings ....................................................... 74
Changing the Sender Fail Time Delays .............................................. 75
Changing the Units of Measure .......................................................... 77
Changing the Low Fuel Pre-Alarm Setting ......................................... 79
Changing or Disabling the Low Fuel Alarm Setting ............................ 81
Changing the Cooldown Time Setting ................................................ 83
Changing the Pre-Crank Time Delay (Glow Plug Timer) .................... 85
Changing the Maintenance Interval .................................................... 87
Resetting the Maintenance Interval Pre-Alarm ................................... 89
Resetting a Loss of Voltage Pre-Alarm ............................................... 91
Accessing and Using the Event Log ................................................... 92
Operation (Deep Sea Controller)
9.1
9.2
9.3
9.4
9.5
53
Main Circuit Breaker ........................................................................... 53
Engine Start Switch ............................................................................ 54
Genset Pre-Alarms and Alarms (Shut-Down Conditions) ................... 55
Overcurrent Condition ......................................................................... 56
Using the Lugs and the Convenience Receptacles ............................ 57
Selecting the Voltage .......................................................................... 58
Before Starting the Machine ............................................................... 60
Starting and Running the Machine ..................................................... 61
Stopping the Machine ......................................................................... 63
Emergency Stop Switch ...................................................................... 63
LCD Panel: Monitoring Machine Operation ........................................ 64
Working with Basler Controller
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17
9
G 50/G 70
94
Main Circuit Breaker ........................................................................... 94
Genset Controller Power Switch ......................................................... 95
Selecting the Voltage .......................................................................... 96
Deep Sea Controller Buttons/Functions ............................................. 98
Genset Controller Alarms and Shut-Down Conditions ...................... 100
8
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G 50/G 70
9.6
9.7
9.8
9.9
9.10
Table of Contents
Before Starting the Machine ............................................................. 102
Starting and Running the Generator ................................................ 103
Stopping the Generator .................................................................... 105
Emergency Stop Switch ................................................................... 106
Engine and Generator Monitoring .................................................... 107
10 Working with Deep Sea Controller: DSE 7310
10.1
10.2
10.3
10.4
Introduction ....................................................................................... 108
Navigating the Menus ....................................................................... 109
Adjusting Screen Contrast ................................................................ 111
How to Reset the Maintenance Timer .............................................. 112
11 How to Connect Loads (480V)
11.1
11.2
11.3
11.4
11.5
11.6
11.7
122
Lug Terminal Connection Diagrams ................................................. 122
Best Practices for Balancing Loads .................................................. 123
Connecting a 240V 3Ø Load and a 240V 1Ø Load .......................... 126
Connecting 240V and 120V Single-Phase Loads ............................ 127
Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads .............. 128
Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads 129
Connecting 480V, 3-Phase Loads .................................................... 130
Connecting 600V, 3-Phase Loads .................................................... 131
13 Using Remote Start Capabilities
13.1
13.2
13.3
13.4
113
Lug Terminal Connection Diagrams ................................................. 113
Best Practices for Balancing Loads .................................................. 114
Connecting 480V, 3-Phase and Single-Phase Loads ...................... 117
Connecting a 240V 3Ø Load and a 240V 1Ø Load .......................... 118
Connecting 240V and 120V Single-Phase Loads ............................ 119
Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads .............. 120
Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads 121
12 How to Connect Loads (600V)
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
108
132
Remote Run Terminal Block ............................................................ 132
Remote Transfer Switch ................................................................... 133
Preparing for Automatic/Remote Start-Up (Basler) .......................... 134
Preparing for Automatic/Remote Start-Up (Deep Sea) .................... 135
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9
Table of Contents
G 50/G 70
14 Diagnostic Trouble Codes (DTC)
14.1
14.2
14.3
137
Accessing DTCs with the Basler Controller ...................................... 137
Accessing Engine DTCs using the Deep Sea Controller .................. 138
List of Engine Diagnostic Trouble Codes (DTCs) ............................. 139
15 Factory-Installed Options
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10
15.11
15.12
142
Battery Charger ................................................................................ 142
Lockable Battery Disconnect ............................................................ 143
Camlocks .......................................................................................... 144
Containment System ........................................................................ 145
Extended Run Tank (ERT) ............................................................... 145
Engine Block Heater ......................................................................... 146
Automatic LCD Heat ......................................................................... 146
Low Coolant Shutdown ..................................................................... 147
Temperature-Activated Shutters ....................................................... 148
Positive Air Shutoff Valve ................................................................. 149
Quick-Disconnect Fuel Fittings ......................................................... 150
Lube Level Maintainer ...................................................................... 151
16 General Maintenance
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
16.10
16.11
16.12
152
Periodic Maintenance Schedule ....................................................... 152
Maintaining the Emission Control System ........................................ 152
Preparing for Maintenance ............................................................... 153
Cleaning the Machine ....................................................................... 153
Inspecting the Machine ..................................................................... 154
Maintaining the Trailer ...................................................................... 155
Checking and Draining the Containment System ............................. 156
Checking the Exhaust System .......................................................... 157
Maintaining the Battery ..................................................................... 158
Cleaning the Diesel Particulate Filter (DPF) (if equipped) ................ 159
Storage ............................................................................................. 160
Machine Disposal / Decommissioning .............................................. 161
17 Engine Maintenance: T3 John Deere 4045TF280/290
162
18 Engine Maintenance: T4i John Deere 4045TF290
165
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G 50/G 70
Table of Contents
19 Engine Maintenance: T4i Cummins QSB6.7
168
20 Maintenance Tier 4f Engines: Isuzu
172
21 Troubleshooting
178
22 Technical Data: G 50, T4i John Deere
179
22.1
22.2
22.3
22.4
22.5
Engine .............................................................................................. 179
Generator ......................................................................................... 180
Machine ............................................................................................ 181
Trailer and Skid ................................................................................ 181
Dimensions ....................................................................................... 182
23 Technical Data: G 50, T4f Isuzu
23.1
23.2
23.3
23.4
23.5
Engine .............................................................................................. 183
Generator ......................................................................................... 184
Machine ............................................................................................ 185
Trailer and Skid ................................................................................ 185
Dimensions ....................................................................................... 186
24 Technical Data: G 70, T3 John Deere, 600V
24.1
24.2
24.3
24.4
24.5
187
Engine .............................................................................................. 187
Generator ......................................................................................... 188
Machine ............................................................................................ 188
Trailer ............................................................................................... 189
Dimensions ....................................................................................... 190
25 Technical Data: G 70, T4i Cummins
25.1
25.2
25.3
25.4
25.5
183
191
Engine .............................................................................................. 191
Generator ......................................................................................... 192
Machine ............................................................................................ 192
Trailer and Skid ................................................................................ 193
Dimensions ....................................................................................... 194
Tire Safety Information
195
26 User’s Information for Transport Canada Fuel Tank
wc_bo5200018221_03_FM10TOC.fm
11
207
Table of Contents
G 50/G 70
27 Emission Control Systems Information and Warranty
27.1
27.2
27.3
Emission Control System Background Information ...........................210
Limited Defect Warranty for Exhaust Emission Control System .......211
Limited Defect Warranty for Wacker Neuson Emission Control
Systems .............................................................................................211
28 General Machine Schematics
28.1
28.2
28.3
215
Fuses ...............................................................................................215
Trailer Wiring .....................................................................................216
Trailer Wiring Components ................................................................217
29 Schematics, Machines with Basler Controller
29.1
29.2
29.3
29.4
29.5
29.6
29.7
29.8
29.9
29.10
29.11
29.12
218
AC Schematic: G 50, G 70 ................................................................218
AC Schematic Components: G 50, G 70 ...........................................219
DC Schematic: G 50, T4i John Deere, Basler ...................................220
DC Schematic Components: G 50, T4i John Deere, Basler .............221
DC Schematic: G 50, T4f Isuzu, Basler .............................................222
DC Schematic Components: G 50, T4f Isuzu, Basler .......................223
DC Schematic: G 70, T3 John Deere, Basler ....................................224
DC Schematic Components: G 70, T3 John Deere, Basler ..............225
DC Schematic: G 70, Cummins, Basler ............................................226
DC Schematic Components: G 70, T4i Cummins, Basler .................227
AC Schematic: G 70, John Deere, 600V, Basler ...............................228
AC Schematic Components: G 70, John Deere, 600V, Basler .........229
30 Schematics, Machines with Deep Sea Controller
30.1
30.2
30.3
30.4
30.5
30.6
30.7
30.8
210
230
AC Schematic: G 50, G 70 ................................................................230
Electrical Schematic Components .....................................................231
DC Schematic: G 50, T4i John Deere, Deep Sea .............................232
DC Schematic Components: G 50, T4i John Deere, Deep Sea ........233
DC Schematic: G 70, T3 John Deere, Deep Sea ..............................234
DC Schematic Components: G 70, T3 John Deere, Deep Sea ........235
DC Schematic: G 70, T4i Cummins, Deep Sea ................................236
DC Schematic Components: G 70, T4i Cummins, Deep Sea ...........237
12
wc_bo5200018221_03_FM10TOC.fm
Mobile Generator
1
1.1
Safety Information
Safety Information
Signal Words Used 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.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
► 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.
► To 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.
► To avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
► To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
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.
wc_tx003567gb_FM10.fm
13
Safety Information
1.2
Mobile Generator
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 the 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.
14
wc_tx003567gb_FM10.fm
Mobile Generator
1.3
Safety Information
Safety Guidelines for Operating the Machine
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 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.
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
Application
area
Be aware of the application 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.
■ Identify whether special hazards exist in the application area, such as toxic
gases, or unstable ground conditions, and take appropriate action to eliminate
the special hazards before using the machine.
Be aware of the application area.
■ Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
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
inoperative.
■ Do not modify or defeat the safety devices.
■ Only use accessories or attachments that are approved by Wacker Neuson.
wc_tx003567gb_FM10.fm
15
Safety Information
Safe
operating
practices
Mobile Generator
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.
When operating this machine:
■ Do not operate a machine in need of repair.
■ Do not consume the operating fluids used in this machine. Depending on your
machine model, these operating fluids may include water, wetting agents, fuel
(gasoline, diesel, kerosene, propane, or natural gas), oil, coolant, hydraulic fluid,
heat transfer fluid (propylene glycol with additives), battery acid, or grease.
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
After use
■ Stop the engine when the machine is not being operated.
■ Close the fuel valve on engines equipped with one when the machine is not
being operated.
■ Ensure that the machine will not tip over, roll, slide, or fall when not being
operated.
■ 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.
16
wc_tx003567gb_FM10.fm
Mobile Generator
1.4
Safety Information
Service Safety
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 for additional training if necessary.
When servicing or maintaining this machine:
■ Do not allow improperly trained people to service or maintain the machine.
Personnel servicing or maintaining the machine must be familiar with the
associated 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 operating the machine.
Do not operate the machine with a known problem or deficiency.
■ All repairs and adjustments shall be completed by a qualified technician.
■ Turn off the machine before performing maintenance or making repairs.
■ Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
■ Re-install the safety devices and guards after repair and maintenance
procedures are complete.
Machine
modifications
When servicing or maintaining the machine:
■ Use only accessories/attachments that are approved by Wacker Neuson.
When servicing or maintaining the machine:
■ Do not defeat safety devices.
■ Do not modify the machine without the express written approval of Wacker
Neuson.
Replacing
parts and
labels
■ Replace worn or damaged components.
■ Replace all missing and hard-to-read labels.
■ When replacing electrical components, use components that are identical in
rating and performance to the original components.
■ 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.
Cleaning
When cleaning and servicing the machine:
■ Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
■ Keep the labels legible.
wc_tx003567gb_FM10.fm
17
Safety Information
Mobile Generator
When cleaning the machine:
■ Do not clean the machine while it is running.
■ Never use gasoline or other types of fuels or flammable solvents to clean the
machine. Fumes from fuels and solvents can become explosive.
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).
Electrical
service safety
■ Make sure clothing and shoes are dry, stand on a dry wooden platform or rubber
insulating mat, and use tools with insulated handles when servicing the
machine.
■ 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.
■ Do not pressure wash the control panel, generator end, or any other electrical
components when cleaning the machine.
Cooling
system safety
■ Do not attempt to open the radiator cap while the unit is running or before the
engine has cooled down. Severe burns may result!
■ Engine coolant is toxic to humans and animals. Clean up spills and dispose of
waste engine coolant in accordance with local environmental regulations.
18
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Mobile Generator
1.5
Safety Information
Operator Safety while Using Internal Combustion Engines
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.
► Read 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.
► NEVER operate the machine inside an enclosed area, such as a tunnel, unless
adequate ventilation is provided through such items as exhaust fans or hoses.
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.
■ Re-install the fuel tank cap after refueling.
■ Use suitable tools for refueling (for example, a fuel hose or funnel).
When refueling the engine:
■ Do not smoke.
■ Do not refuel a hot or running engine.
■ Do not refuel the engine near sparks or open flames.
wc_tx003567gb_FM10.fm
19
Safety Information
1.6
Mobile Generator
Safety Guidelines for Mobile Generators
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.
► NEVER 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.
► ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
► Even 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.
► If 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
Electrocution hazard. Machines that generate electric power present special
hazards while the engine is running. These include the risk of electrocution or
severe electrical shock.
► Read and follow the instructions in this Operator’s Manual.
Installing as
Special hazards exist when installing this machine as a backup power supply.
backup power 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.
WARNING
Backfeed from the generator into the public power distribution system can cause
serious injury or death to utility workers!
► 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.
20
wc_tx003567gb_FM10.fm
Mobile Generator
Safety Information
General safety ■ Do not use evaporative starting fluids to start the engine. They are highly
explosive.
■ Do not store items such as excess oil, rags, or tools on top of or inside the
machine. These items are a fire hazard and can restrict cooling air.
■ Ensure that electrical cords attached to the machine are in serviceable condition
without cuts, cracks, or exposed wires.
■ Do not route electrical cords over vibrating or hot parts of the machine.
■ Do not stand on the machine.
■ Do not enclose or cover the machine when it is use, or when it is hot.
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.
wc_tx003567gb_FM10.fm
21
Safety Information
1.7
Mobile Generator
Safety Guidelines for Towing the Machine
WARNING
Risk of severe injury or death. Improper trailer condition and towing technique can
lead to an accident.
► Obey the trailer manufacturer’s instructions and the instructions below to reduce
the risk of an accident.
When towing the machine:
■ Do not tow the machine if the towing vehicle’s hitch or the trailer’s coupler are
damaged.
■ Do not tow the machine if any of the trailer’s lug nuts are missing.
■ Do not tow the machine if the trailer’s tires have less than 1.5 mm (1/16 inch) of
tread.
■ Do not tow the machine unless the trailer’s brakes are functioning properly.
■ Do not exceed the trailer manufacturer’s speed limitations.
When towing the machine:
■ Only tow the machine when the trailer’s lug nuts are properly torqued.
■ Only tow the machine when the trailer’s tires are properly inflated.
■ Only tow the machine when all trailer lights are functioning correctly.
■ Only tow the machine when the trailer’s safety chains are connected to the
towing vehicle in a crisscross pattern.
■ Maintain extra distance between the towing vehicle and other vehicles.
■ Avoid soft shoulders, curbs, and sudden lane changes.
■ Abide by all licensing requirements for your area.
If you have not driven a towing vehicle with trailer before, practice turning,
stopping, and backing up the towing vehicle with trailer in an area away from traffic.
Only drive the towing vehicle with trailer when you are confident in your ability to do
so.
22
wc_tx003567gb_FM10.fm
Mobile Generator
1.8
Safety Information
Safety Guidelines for Lifting the Machine
When lifting the machine:
■ Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any
other type of lifting device used is attached securely and has enough weightbearing capacity to lift or hold the machine safely. See section Technical Data
for machine weight.
■ Remain aware of the location of other people when lifting the machine.
■ Only use the lifting points and tie downs described in the Operator’s Manual.
■ Make sure the transporting vehicle has sufficient load capacity and platform size
to safely transport the machine.
To reduce the possibility of injury:
■ Do not stand under the machine while it is being lifted or moved.
■ Do not get onto the machine while it is being lifted or moved.
1.9
Reporting 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 Neuson.
If NHTSA receives similar complaints, it may open an investigation; and if it finds
that a safety defect exists in a group of trailers, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Wacker Neuson.
To contact NHTSA, you may either contact the Vehicle Safety Hotline toll-free at
1-888-327-4236 (TTY: 1-800-424-9153); go to http://www.safercar.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain other information about your motor vehicle safety from
http://www.safercar.gov
wc_tx003567gb_FM10.fm
23
Label Locations
2
G 50/ G 70
Label Locations
U
B
G
JJ
CC
L
GG
HH
A
X
QH
KK
J
FF
OO
K
DD
P
M1
M2
QQ
EE
NN
Z
MM
XX
G
T
AA
wc_gr007670
24
wc_si000858gb_FM10.fm
G 50/ G 70
Label Locations
U
PP
B
E
UU
JJ
V
V
R
C
D
WW
SS TT
RR
P
G
V
V
Y
O
W
S
F
W
wc_gr007671
wc_si000858gb_FM10.fm
25
Label Meanings
3
G 50 /G 70
Label Meanings
A
WARNING
Pressurized contents. Do not open when hot!
B
WARNING
Lock doors. Access can cause electric shock or
injury.
C
NOTICE
Never change switch position with engine
running. Results in damage to machine.
D
WARNING
Electric shock can cause serious injury or death.
E
DANGER
Asphyxiation hazard.
 Engines emit carbon monoxide.
 Do not run the machine indoors or in an
enclosed area.
 Only use OUTSIDE and far away from
windows, doors, and vents.
 Read the Operator’s Manual.
 No sparks, flames, or burning objects near the
machine.
 Stop the engine before refueling.
 Use only clean, filtered diesel fuel.
26
wc_si000859gb_FM10.fm
G 50 /G 70
Label Meanings
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
CAUTION
Avoid spraying water into generator.
G
WARNING
Hot surface
H
WARNING
Electric shock at cooling fins.
J
DANGER
Asphyxiation hazard.
 Engines emit carbon monoxide.
 Do not run the machine indoors or in an
enclosed area.
 Electric shock and arc flash can cause
serious injury or death.
K
WARNING
Generator can automatically start which can
cause serious injury. Disconnect battery before
servicing.
wc_si000859gb_FM10.fm
27
Label Meanings
G 50 /G 70
L
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.
M1
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.
M2
N
CAUTION
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.
O
WARNING
Disconnect battery before servicing.
Read the Operator’s Manual.
28
wc_si000859gb_FM10.fm
G 50 /G 70
Label Meanings
P
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.
Q
WARNING
Electric shock at cooling fins.
R
WARNING
Hot surface
S
(if equipped)
Battery disconnect must be in “ON” position to
start engine.
NOTICE
Do not use the battery disconnect switch while
engine is running. Damage to the electrical
components may occur.
T
ABSCHLEPPINSTRUKTIONEN
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.
U
wc_si000859gb_FM10.fm
INSTRUCCIONES DE REMOLQUE
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.
NOTICE
Lifting point
29
INSTRUCTIONS DE REMORQUAGE
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.
114894
TOWING INSTRUCTIONS
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.
Label Meanings
G 50 /G 70
V
Tie-down point
W
Electrical ground
X
30
wc_si000859gb_FM10.fm
G 50 /G 70
Label Meanings
Y
Operator’s Manual must be stored on machine.
Replacement Operator’s Manual can be ordered
through your local Wacker Neuson distributor.
Z
Remote start operation. Read Operator’s
Manual for instructions.
AA
CC
Drain containment system.
DD
Operating the main circuit breaker supplies or
interrupts power to the customer connection
lugs.
EE
Neutral bonded to frame
FF
Fuses
Read the Operator’s Manual for machine
information.
1 - Start / Run Circuit
2 - Not used
3 - Not used
4 - Controller
wc_si000859gb_FM10.fm
31
Label Meanings
G 50 /G 70
GG
Generator and receptacle wiring
HH
Engine wiring
JJ
Protecting Our Environment
Fluid containment system
KK
Diagnostic menu navigation
Navigation dans les menus de diagnostic
Navegación por los menús de diagnóstico
MM
This machine may be covered by one or more
patents.
32
wc_si000859gb_FM10.fm
G 50 /G 70
Label Meanings
OO
Remote start operation. Read Operator’s
Manual for instructions.
PP
(if equipped)
NOTICE
Mobile generator must be level for proper
operation of lube level maintainer.
QQ
Lug door must be closed for lugs and
receptacles to energize.
RR
(Camlock models only)
WARNING
Electric shock can cause serious injury or death.
SS
(Camlock models only)
NOTICE
Separate overcurrent protection must be
provided. Do not exceed 400 amps per
receptacle.
TT
(Camlock models only)
WARNING
Electric shock and arc flash can cause serious
injury or death.
wc_si000859gb_FM10.fm
33
Label Meanings
G 50 /G 70
UU
Emission control information.
This equipment has an engine that meets
California Emission Standards under 13 CCR
2423(d) and EPA Emission Standards under 40
CFR 1039.625.
WW
WARNING
Explosion hazard. Do not use evaporative
starting fluids such as ether on this engine. The
engine is equipped with a cold starting aid.
Using evaporative starting fluids can cause an
explosion which can cause engine damage,
personal injury, or death. Read and follow the
engine starting instructions in this Operator's
Manual.
XX
WARNING
Keep all sparks and open flames away from
the battery.
 Wear eye protection.
 Keep away from children.
 Battery acid is poisonous and corrosive.
 Read the Operator’s Manual.
 Explosion hazard.
Dispose of waste batteries in accordance with
local environmental regulations. Battery
contains mercury (Hg), cadmium (Cd), or lead
(Pb).
0183199

34
wc_si000859gb_FM10.fm
Mobile Generator
4
4.1
Lifting and Transporting
Lifting and Transporting
Lifting the Machine
Requirements
■ Lifting equipment (crane, hoist, or fork truck) capable of supporting the
machine’s weight
■ Lifting devices (hooks, chains, and shackles) capable of supporting the
machine’s weight
■ Engine stopped
Lifting the
machine
A lifting eye is used for lifting the machine.
wc_gr011429
Perform the procedure below to lift the machine.
1. Attach the lifting devices and equipment to the lifting eye. Do not attach lifting
devices to any other part of the machine.
2. Lift the machine a small distance.
WARNING
Crushing hazard. An unstable machine may cause the lifting devices and
equipment to fail. You may be crushed if the lifting devices and equipment fail.
► Check for stability before continuing.
3. Check for stability. If necessary, lower the machine, reposition the lifting devices,
and lift the machine a small distance again.
4. Continue lifting the machine only when it is stable.
wc_tx003570gb_FM10.fm
35
Lifting and Transporting
4.2
Mobile Generator
Before Towing Checklist
Before towing the machine, check the licensing requirements for trailers in your
area. Also check the following items:
Towing vehicle
 Check that the towing vehicle is rated to tow the load.
 Check that the towing vehicle is in serviceable condition.
 Do any necessary service/maintenance on the towing vehicle.
Hitch and coupler
 Check that the towing vehicle and hitch have a rating equal to or greater than
the GVWR of the machine. See Technical Data.
 Check that the hitch of the towing vehicle and coupler of the trailer are compatible.
 Check the condition of both the coupler and the hitch.
 Check that all fasteners on the coupler are tight.
 Check that the coupler has fresh grease applied to it.
Wheels
 Check that wheel chocks are available at the work site.
 Check that all lug nuts are in place and are properly torqued.
 Check the tread wear of the tires.
 Check that the tires are inflated to the proper pressure.
Trailer preparation
 Check that all doors and access panels are closed and latched.
 Check that outriggers (if applicable) are retracted.
 Check local regulations regarding hazardous materials placards. If applicable,
install the appropriate placards.
Trailer operation
 Check that the trailer jacks are in the traveling (horizontal) position.
 Check that the directional and running lights on the trailer function correctly.
 Check that the safety chains of the trailer are connected to the towing vehicle
using a crisscross pattern.
 Check the operation of the trailer brakes by braking the towing vehicle at a slow
speed. Both the vehicle and the trailer must brake smoothly. If the trailer pushes,
check the fluid level in the surge brakes or the operation of the electric brakes.
 Check that the trailer’s breakaway cable (if applicable) is attached to the towing
vehicle.
 Test the function of the breakaway system (if applicable).
36
wc_tx003570gb_FM10.fm
Mobile Generator
4.3
Lifting and Transporting
Towing the Machine
Background
The generator’s trailer is equipped with brakes (surge or electric), safety chains (a),
lights, and a coupler (pintle or ball-type) (b).
b
a
c
wc_gr011430
Brakes
Only use the brakes as designed.
■ The breakaway cable (c) is not a parking brake and should not be used as one.
Licensing
requirements
■ In most states, large trailers must be registered and licensed by the State
Department of Transportation. Before towing, be sure to check licensing
requirements.
■ Drivers towing trailers may be required to carry a commercial driver’s license
(CDL). Check your local and state licensing regulations before towing the
generator.
Coupler
maintenance
■ A film of grease on the coupler will extend coupler life and eliminate squeaking.
Wipe the coupler clean and apply fresh grease each time the trailer is towed.
Towing safety
■ When towing, maintain extra space between vehicles and avoid soft shoulders,
curbs and sudden lane changes. If you have not pulled a trailer before, practice
turning, stopping, and backing up in an area away from heavy traffic.
■ Do not exceed 55 mph when towing a trailer.
wc_tx003570gb_FM10.fm
37
Lifting and Transporting
4.4
Mobile Generator
Preparing the Machine for Transport on a Truck or Trailer
Requirements
■ Machine stopped
■ Flatbed truck or trailer capable of supporting the machine’s weight
■ Chains, hooks, or straps capable of supporting the machine’s weight
WARNING
Crushing hazard. Improperly securing the machine can lead to a crushing hazard.
► Use only the designated tie-down points to secure the machine to a truck or
trailer.
Checklist
Before transporting the machine, check the following items:
Machine
 Check that all accessories are securely stored within the machine.
 Check that all doors and access panels of the machine are closed.
 Check that all electrical supplies are disconnected from the machine.
 For machines with external fuel supplies, check that all fuel supplies are
disconnected from the machine.
 For machines with generators, check that the generator is shut down.
Loading and transporting equipment
 Check that the transport vehicle or trailer can support the weight of the machine.
 Check that the transport vehicle or trailer is wide enough to support the
machine.
 Check that the wheels of the transport vehicle or trailer are chocked during the
loading process.
 Check that the transport vehicle or trailer is clean and free of grease, oil, ice,
and other loose material.
 If the machine is mounted to a trailer, check that the jackstand or other transport
block (piece of wood or other similar material) is available to support the trailer
tongue during transporting. Do not use the machine’s trailer jack to support the
trailer tongue during transporting.
 Check that any ramps used in the loading process:
■ Can support the weight of the machine.
■ Are clean and free of grease, oil, ice, and other loose material.
■ Are securely connected to the transport vehicle or trailer.
■ Are of sufficient length to keep the loading angle 15° or less.
In addition:
 Check that the loading area is flat and the ground is stable.
 Check the overall height of the machine once it is loaded on the truck or trailer.
 Plan your travel route so there will be adequate clearance for overpasses, road
signs, buildings, etc.
 Check local regulations regarding transporting and obey these regulations.
38
wc_tx003570gb_FM10.fm
Mobile Generator
4.5
Lifting and Transporting
Hazardous Materials Placards
Overview
Hazardous materials placards may have been provided with your machine.
Transport Canada, and the Canadian Transportation of Dangerous Goods Act,
require that these hazardous materials placards be permanently applied to certain
machines if they are to be transported or towed on Canadian roads.
Contact Transport Canada if you have questions about driver’s licensing
requirements for transporting machines that bear hazardous materials placard, or
questions about other restrictions for use of this machine
Note: The owner/operator of this machine is responsible for applying the placards.
Use the procedure described below.
wc_gr009231
Requirements
Apply the
Placards
■ Placard mounting surfaces and surrounding ambient temperature should be
at least 10°C (50°F). In colder conditions, see application step 2 below.
■ Mild soap or detergent
■ Fresh, clean, warm water supply
■ Isopropyl (rubbing) alcohol, lacquer thinner, or mineral spirits
■ Soft, clean, dry cloths
■ Plastic squeegee or stiff cardboard
Four placards have been provided with this machine—one for each side, one for
the front, and one for the back.
To apply the placards, do the following.
1. Clean the placard mounting surfaces with mild soap and water. Dry thoroughly.
2. Use isopropyl (rubbing) alcohol to clean the placard mounting surfaces if:
■ they, and the surrounding ambient temperature, are below 10°C (50°F)
■ the placard mounting surfaces are covered with grease and oil.
3. Peel about 2 cm (1 in.) of backing paper from the top of the placard. Fold the
backing paper away from the placard.
4. Apply the top of the placard to the mounting surface. Gradually remove the
backing paper and apply the remainder of the placard. Firmly press and smooth
the placard into place with a plastic squeegee, stiff cardboard, or a soft cloth.
Puncture any air bubbles that may form.
wc_tx003570gb_FM10.fm
39
Lifting and Transporting
4.6
Mobile Generator
Testing the Breakaway System (Hydraulic Surge Brakes)
Requirements
■ Hydraulic reservoir filled
■ Machine parked on a flat surface
When
Test the breakaway system:
■ Before towing
■ After filling the hydraulic reservoir
Procedure
Perform the following procedure to test the breakaway system.
1. Position the machine/trailer on a flat surface.
2. Connect the breakaway cable (a) to the tow vehicle. Do not connect the
machine/trailer to the tow vehicle via the hitch.
b
a
wc_gr008509
wc_gr008508
3. Slowly move the tow vehicle so that it pulls on the breakaway cord until the
emergency lever reaches its second notch (b) and locks into the ON position.
4. Connect the machine/trailer to the tow vehicle via the hitch.
5. Attempt to tow the machine/trailer at a very slow speed (less than 5 mph). When
activated, a properly working breakaway system will cause substantial drag on
the trailer wheels and may even cause the trailer wheels to lock.
WARNING
Personal injury hazard. A faulty breakaway system may lead to an accident and
personal injury if the machine/trailer breaks away.
► Do not tow the machine/trailer if the breakaway system is faulty.
6. If the brakes did not function, repair any faults before towing.
This procedure continues on the next page.
40
wc_tx003570gb_FM10.fm
Mobile Generator
Lifting and Transporting
Continued from the previous page.
7. Stop the tow vehicle.
8. Release the brake by simultaneously pulling on the breakaway cord and prying
the locking spring with a screwdriver (c) or pry bar.
c
wc_gr008510
Result
The procedure to test the breakaway system is now complete.
wc_tx003570gb_FM10.fm
41
Lifting and Transporting
4.7
Mobile Generator
Testing the Breakaway System (Electric Brakes)
Requirements
■ Voltmeter
■ Battery charger or backup battery (charged)
When
Test the breakaway system:
■ Before towing
■ Monthly if the machine is not in service
Procedure
Perform the following procedure to test the breakaway system.
NOTICE: Disconnect the trailer wiring plug from the tow vehicle before testing.
Failure to do so will result in severe damage to the electronic brake control.
1. Connect the machine/trailer to the tow vehicle.
2. Disconnect the trailer wiring plug (a) from the tow vehicle.
c
b
a
wc_gr008513
wc_gr008514
3. Pull the breakaway pin (b) out of the brake switch (c) (to activate the brakes)
and attempt to tow the machine/trailer at a very slow speed (less than 5 mph).
When activated, a properly working breakaway system will cause substantial
drag on the trailer wheels and may even cause the trailer wheels to lock.
4. Stop the tow vehicle.
WARNING
Personal injury hazard. A faulty breakaway system may lead to an accident and
personal injury if the machine/trailer breaks away.
► Do not tow the machine/trailer if the breakaway system is faulty.
This procedure continues on the next page.
42
wc_tx003570gb_FM10.fm
Mobile Generator
Lifting and Transporting
Continued from the previous page.
5. If the brakes did not function, check the voltage of the breakaway battery.
To do so:
a. Remove the cover of the battery box.
b. Remove the wires connected to the breakaway battery (d).
c. Measure the voltage. If 12–14 VDC is not measured, replace or recharge the
breakaway battery.
d
1000
F
200
20
V
2
200m
A
VDC
V-
COM
wc_gr008515
6. If 12–14 VDC was measured but the brakes did not function, there is a wiring or
mechanical fault with the brakes. Repair any faults before towing.
7. If the brakes function properly:
a. Reconnect the wires to the breakaway battery.
b. Re-install the cover to the battery box.
c. Re-install the breakaway pin (b) into the brake switch.
d. Connect the trailer wiring plug to the tow vehicle.
Result
The procedure to test the breakaway system is now complete.
wc_tx003570gb_FM10.fm
43
Machine Setup
5
5.1
Mobile Generator
Machine Setup
Preparing the Machine for First Use
1. Make sure all loose packaging materials have been removed from the machine.
2. Check the machine and its components for damage. If there is visible damage,
do not operate the machine! Contact your Wacker Neuson dealer immediately
for assistance.
3. Take inventory of all items included with the machine and verify that all loose
components and fasteners are accounted for.
4. Attach component parts not already attached.
5. Add fluids as needed and applicable, including fuel, engine oil, and battery acid.
6. Move the machine to its operating location.
Safety
information
■ 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 utility
lines. Failure to match phase rotation and voltage may cause equipment
connected to the generator to operate incorrectly! This could create unsafe
operating conditions.
■ Do not exceed the rated current limit of any receptacle.
■ The bonding bar between the ground connections must remain in place at all
times unless a qualified electrician determines otherwise.
CO Alarms
Because this machine produces carbon monoxide (CO), Wacker Neuson
recommends that CO alarms be installed in all structures in close proximity to the
machine. CO alarms provide an extra measure of protection against this poison
that you cannot see or smell.
Install battery-operated CO alarms or plug-in CO alarms with battery backup,
according to the manufacturer’s instructions. CO alarms should be certified to the
requirements of the latest safety standards (UL 2034, IAS 6-96, or CSA 6.19.01).
Test the CO alarm batteries monthly.
44
wc_tx003572gb_FM10.fm
Mobile Generator
5.2
Machine Setup
Positioning the Machine
WARNING
Fire hazard. Do not move the machine while it is running.
► Shut down the machine before moving or repositioning it.
WARNING
Fire hazard. Machines positioned on a hill or an incline may slide, break away or
roll over.
► Do not position the machine on a hill or an incline.
WARNING
Explosion and fire hazard. Risk of severe injury or death.
► Do not operate the machine near flammable vapors, fuels, or combustibles.
CO Alarms
Because this machine produces carbon monoxide (CO), Wacker Neuson
recommends that CO alarms be installed in all structures in close proximity to the
machine. CO alarms provide an extra measure of protection against this poison
that you cannot see or smell.
Install battery-operated CO alarms or plug-in CO alarms with battery backup,
according to the manufacturer’s instructions. CO alarms should be certified to the
requirements of the latest safety standards (UL 2034, IAS 6-96, or CSA 6.19.01).
Test the CO alarm batteries monthly.
Requirements
Position the machine:
■ so that engine exhaust will not enter nearby structures.
■ so that the machine does not block traffic.
■ so that the machine is not close to any combustible material or flammable vapor.
■ so that all of the machine’s access doors/panels may be accessed.
■ so that the area overhead is clear of debris that could fall onto or into the
machine or exhaust compartment.
■ so that the machine is on a firm, level surface and will not tip, roll, slide, or fall
while operating.
This procedure continues on the next page.
wc_tx003572gb_FM10.fm
45
Machine Setup
Mobile Generator
Continued from the previous page.
Procedure
Perform the following procedure to position the machine.
1. Place the machine on solid, stable, and level ground.
a
wc_gr009186
2. For machines with trailers, install chocks (a) under the wheels.
Result
The machine is now properly positioned.
46
wc_tx003572gb_FM10.fm
Mobile Generator
5.3
Machine Setup
Grounding the Generator
Location
A ground connection is located at the customer connection terminal lugs.
wc_gr011524
Function
This ground connection is used for electrically grounding the generator when
necessary to comply with the National Electrical Code and other federal, state, and
local regulations. For grounding requirements in your area, consult with a qualified
electrician, electrical inspector, or local agency having jurisdiction over electrical
compliance.
■ If the generator is used at a construction site, there may be additional
regulations which must be observed.
■ In some areas, generators are required to be registered with local utility
companies.
wc_tx003572gb_FM10.fm
47
Machine Setup
5.4
Mobile Generator
Recommended Fuel
Low temperatures cause diesel fuel to gel. Always use the proper fuel for the
conditions. Follow the guidelines in the table below.
Lowest expected ambient
temperature
Recommended fuel1
Above freezing
< 0°C (32°F)
#2 diesel plus additives
Below freezing
> 0°C (32°F)
Winter-blend diesel
1
Your engine may require ultra low sulfur fuel. Consult the engine owner’s manual.
NOTICE: Consult the engine owner’s manual regarding the use of biodiesel fuel in
this machine. Some biodiesel blends may clog the fuel system or gel at cold
ambient temperatures sooner than petroleum-based diesel.
CAUTION
Fire hazard.
► Do not use gasoline, crankcase oil, or any oil containing gasoline.
48
wc_tx003572gb_FM10.fm
Mobile Generator
5.5
Machine Setup
Refueling the Machine (Basler Controller)
Requirements
■
■
■
■
■
Procedure
Perform the procedure below to refuel the machine.
Machine shut down
Engine cool
Machine/fuel tank level with the ground
Remote switch disconnected from the remote run terminal
Fresh, clean fuel supply
WARNING
Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause
severe burns.
► Keep all sources of ignition away from the machine while refueling.
► Refuel only when the machine is outdoors.
► Clean up spilled fuel immediately.
1. Remove the fuel cap.
2. Place the engine start switch (a) in the REMOTE START position.
V
Ø
A
HZ
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
a
R
wc_gr008413
3. The fuel level (in percentage of the fuel tank capacity) will be displayed in the
lower left corner of the LCD screen.
4. Fill the fuel tank until the fuel level reaches 100%.
CAUTION
Fire and health hazard. Fuel expands when heated. Expanding fuel in an over-filled
tank can lead to spills and leaks.
► Do not overfill the fuel tank.
5. Re-install the fuel cap.
6. Place the engine start switch in the OFF position.
Result
The procedure to refuel the machine is now complete.
wc_tx003572gb_FM10.fm
49
Machine Setup
5.6
Mobile Generator
Refueling the Machine (Deep Sea Controller)
Requirements
■
■
■
■
Procedure
Perform the procedure below to refuel the machine.
Engine stopped
Machine/fuel tank level with the ground
Remote switch disconnected from the remote run terminal
Fresh, clean fuel supply
WARNING
Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause
severe burns.
► Keep all sources of ignition away from the machine while refueling.
► Refuel only when the machine is outdoors.
► Clean up spilled fuel immediately.
1. Remove the fuel cap.
2. Place the genset controller power switch in the ON position and wait for the
Deep Sea controller to boot up.
3. Press the right arrow key to navigate to the “Engine” screen.
DSE
DSE
DEEP SEA ELECTRONICS
Gener
Gene
ratorAvai
Availab
labl
le
e

DEEP SEA ELECTRONICS
DSE 7310
DSE 7310
Alarm
Warning
L-N
L-N
0V
0 AA
L-L
L-L
0V
0.0 HzH
Main Breaker Open
0 kW
kW
---- pf
pf
Low Speed Active
Alarm
Warning
Open
Open
Close
Close
Load
Gen-Set
Main Breaker Open
o
Stop/Reset
AUTO
Manual
Mode
Auto
Mode
Lamp Test
Horn Reset
Low Speed Active
Start
wc_gr011443
4. Use the up or down arrow key to navigate to the “Engine Fuel Level” screen.
The fuel level (in percentage of the fuel tank capacity) will be displayed.
Note: The “Engine Fuel Level” screen will revert back to status screen after three
minutes of inactivity.
5. Fill the fuel tank until the fuel level reaches 100%.
CAUTION
Fire and health hazard. Fuel expands when heated. Expanding fuel in an over-filled
tank can lead to spills and leaks.
► Do not overfill the fuel tank.
6. Re-install the fuel cap.
7. Place the genset controller power switch in the OFF position.
50
wc_tx003572gb_FM10.fm
Operation, Control, and Component Locations
6
Operation, Control, and Component Locations
6.1
Control / Component Locations
V
Ø
A
c
HZ
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
a
b
f
g
d
WARNING
0 0 5 62 3
h
OFF
AUS
APAGADO
ARRET
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
j
L1 L2 L3
e
50A
20A
k
r
n
l
q
p
m
o
wc_gr011689
wc_tx003635gb_FM10.fm
51
Operation, Control, and Component Locations
t
s
s
wc_gr011690
6.2
Control Panel Components
Ref.
a
Description
Ref.
Main circuit breaker
l
Description
Twist-lock receptacle
(120/240 VAC, 50 Amp)
(1) 30 Amp optional
b
Voltage adjustment rheostat
m
GFI receptacle (120 VAC, 20 Amp)
c
Genset controller (Basler or Deep Sea)
n
Remote run terminal block
d
Idle switch (high and low) (if equipped)
o
Emergency stop switch
e
Ground connection point
p
Lug door interlock switch
f
Pre-alarm/shutdown LED
q
Bond bar
g
Engine start switch
r
Terminal lugs
h
Hour meter
s
Voltage selector switch
j
Circuit breaker (240V, 50 Amp)
t
Fuse box
k
Circuit breaker (120V, 20 Amp)
—
52
—
wc_tx003635gb_FM10.fm
Mobile Generator
7
7.1
Operation (Basler Controller)
Operation (Basler Controller)
Main Circuit Breaker
Location
Various styles of main circuit breakers may be found on Wacker Neuson Mobile
generators. The main circuit breaker (a) is located on the control panel.
Note: Graphic is representative only. Your machine may vary.
a
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
AUS
APAGADO
ARRET
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
ME
R GE NC
Y
E
AUS
APAGADO
ARRET
S TOP
wc_gr011444
Functions
■ The main circuit breaker interrupts power from the voltage selector switch to the
terminal lugs.
■ The main circuit breaker does not interrupt power to the convenience
receptacles.
WARNING
Electric shock hazard. High voltage is present inside the control panel while the
engine is running.
► Do not open the control panel unless the engine is stopped.
NOTICE: Before shutting down the generator or performing any service to the
generator, make sure the main circuit breaker is in the OFF position.
wc_tx003579gb_FM10.fm
53
Operation (Basler Controller)
7.2
Mobile Generator
Engine Start Switch
Description
The engine start switch (a) is a three-position switch: “REMOTE START”, “OFF”,
and “START/RUN”.
a
OFF
AUS
APAGADO
ARRET
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
wc_gr011436
Function
Position
Function
LCD Screen
REMOTE START
This position is used when the generator is
being operated as a stand-by power supply, and
it is connected to a remote switch. The
generator is in stand-by mode and will not start
until the remote switch is activated (closed).
READY screen
START/RUN
This is the normal start and run position. When
set to this position, power is supplied to the
genset controller which immediately launches
the start-up sequence.
As a precaution, be prepared for engine startup
anytime the engine start switch is in the
REMOTE START position.
Monitoring
screen
OFF
Power to the genset controller is disconnected.
Blank screen (off)
54
wc_tx003579gb_FM10.fm
Mobile Generator
7.3
Operation (Basler Controller)
Genset Pre-Alarms and Alarms (Shut-Down Conditions)
Background
The genset controller monitors variables of engine and machine function. The
genset controller is programmed to signal pre-alarm conditions, and to shut down
the machine when an alarm condition exists.
Pre-alarms
Pre-alarm conditions are:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Time to maintenance
During a pre-alarm condition, the LCD panel (a) displays the type of pre-alarm, and
the LED (b) flashes. The machine is not shut down.
Shut-down conditions are:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Overspeed/Underspeed
■ Overcrank
■ Low coolant level (if equipped)
■ Overcurrent
■ Low oil level (option)1
1
V
Ø
A
HZ
a
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
b
Basler
Alarms/
shutdowns
R
wc_gr011837
Not used with Isuzu engine.
During an alarm condition, the LCD
panel (a) displays the type of alarm, the LED (b) illuminates continuously, and the
machine is shut down.
Variable
Normal
Pre-Alarm
Alarm
To Reset
Fuel level
>15%
15%
5%
Fill fuel tank. Toggle start switch.
Coolant temp
85°C±8
105°C
115°C
Add coolant. Toggle start switch.
Oil pressure
60–80 psi
20 psi
15 psi
Add engine oil. Toggle start switch.
Overspeed
60 Hz
—
66 Hz
Toggle start switch.
Underspeed
60 Hz
—
54 Hz
Toggle start switch.
Overcrank
—
—
After 3 attempts
Toggle start switch.
Time to maintain
250 hours
0 hours
—
Reset genset controller.
Coolant level
Above sender
—
Below sender
Add coolant. Toggle start switch.
wc_tx003579gb_FM10.fm
55
Operation (Basler Controller)
Overcurrent Condition
Along with engine functions, the genset controller continuously monitors the
current load in each leg. The values for current overload are programmed into the
ECM at the factory and are different for each generator size.
a
b
V
Ø
A
HZ
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
Basler
7.4
Mobile Generator
R
wc_gr010360
When an overcurrent condition is sensed in any leg, the pre-alarm/shutdown LED
(b) flashes and the LCD displays OVERCURRENT.
If the overcurrent condition persists, the main circuit breaker (a) opens and the
LCD screen changes to OVRLOAD - SET BRKR. This indicates an overload fault.
To clear the overload fault, reset the main circuit breaker. Failing to reset the main
circuit breaker within 5 minutes will cause the machine to shut down. The LCD
screen will then change to OVERLOAD.
56
wc_tx003579gb_FM10.fm
Mobile Generator
7.5
Operation (Basler Controller)
Using the Lugs and the Convenience Receptacles
Overview
Loads can be connected to the genset in two different ways:
1. At the connection lugs (r).
Located as shown, behind the lug door, the connection lugs serve as connection
points for cables.
2. At the convenience receptacles:
■ 120V/240V twist-lock receptacles (l)
■ 120V GFCI duplex receptacles (m)
Note: The convenience receptacles are not protected by the main circuit breaker.
They are protected by their own circuit breakers (j, k). Power to the convenience
receptacle circuit breakers is available any time the engine is running, even with
the main circuit breaker OFF (open).
Note: Graphic is representative only. Your machine may vary.
V
Ø
A
HZ
042563
OFF
AUS
APAGADO
ARRET
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
j
R
k
r
p
ERGENC
M
Y
E
l
S TO P
m
wc_gr010361
Lug door
interlock
switch
The lug door interlock switch (p) is located behind the lug door. The lug door
interlock switch is a safety device. When the lug door is opened, the lug door
interlock switch trips the main circuit breaker.
Note: The lug door interlock switch does NOT interrupt power to the convenience
receptacles. However, the switch does stop excitation at the generator. The result
is significantly reduced voltage at the convenience receptacles.
wc_tx003579gb_FM10.fm
57
Operation (Basler Controller)
7.6
Mobile Generator
Selecting the Voltage
Location
One of two types of voltage selector switch—either three-position (a) or fourposition (b)—is mounted to the machine near the lugs.
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE
ULTRABAJO CONTENIDO DE AZUFRE.
STOP
!
DIESEL
177416
NUR NIEDRIGEN SCHWEFELKRAFTSTOFF ODER ULTRANIEDRIGEN SCHWEFELKRAFTSTOFF.
DANGER
GEFAHR
PELIGRO
DANGER
277/480V
3Ø
346/600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
!
a
b
wc_gr011503
WARNING
Electric shock hazard. High voltage is present inside the voltage selector switch
enclosure when the engine is running.
► Do not open the voltage selector switch enclosure unless the engine is stopped.
Selecting the
voltage
The chart below lists the ranges of voltages available in each of the switch
positions. Select the desired voltage by rotating the handle of the voltage selector
switch. Then, use the voltage adjustment rheostat to set the exact voltage you
require. The voltage is displayed on the LCD panel.
Range of Voltages Available
Switch position
3Ø at lugs
(L–L–L)
1Ø at lugs
(L–N)
1Ø at lugs
(L-L)
1Ø at twist lock
L-N (120V)
L-L (240V)
1Ø at GFCI
120/240 VAC 1Ø
—
110–125
220–250
110–125
220–250
110–125
208/240 VAC 3Ø
120/139 VAC 1Ø
190–240
110–139
190–240
110–139
190–240
110–139
277/480 VAC 3Ø
380–480
220–2772
190–2402
110–1392
190–2402
110–1392
346/600 VAC 3Ø1
540–600
—
—
—
—
—
1 Not
2 Not
available on all models.
available on 600V models.
NOTICE: Do not change the position of the voltage selector switch while the
engine is running. Doing so can cause arcing which can damage the voltage
selector switch and the generator windings.
58
wc_tx003579gb_FM10.fm
Mobile Generator
Using the
rheostat
Operation (Basler Controller)
The voltage adjustment rheostat (c) is used to fine-tune the voltage as needed
while the machine is running.
c
OFF
AUS
APAGADO
ARRET
V
V
Ø
A
HZ
Ø
A
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
HZ
042563
OFF
AUS
APAGADO
ARRET
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
Basler
REMOTE START
R
E R G E NC
M
Y
E
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
R
S TOP
wc_gr011502
Care must be taken when using the voltage adjustment rheostat because adjusting
the voltage for 3-phase operation affects the voltage available at the single-phase
outlets. As the 3-phase voltage increases, so does the single-phase voltage.
NOTICE: Do not use the GFCI or twist-lock receptacle (120V) when the 1Ø voltage
is above 135V. Damage to the receptacle and the tools connected to it may occur.
Switch Position
208 VAC 3Ø
120 VAC 1Ø
277/480 VAC 3Ø
346/600 VAC 3Ø3
3Ø Voltage
(L-L-L)
Corresponding 1Ø voltage
Twist lock receptacle
L-L (240V)
L-N (120V)
120V GFCI
208
208
120
120
220
220
125
125
240
240
139
1
1391
480
240
1391
1391
460
230
1332
1332
600
540
1 Do
not use receptacle with this voltage.
may be too high for some tools and equipment. Check tool/equipment specifications.
3
Not available on all models.
2Voltage
wc_tx003579gb_FM10.fm
59
Operation (Basler Controller)
7.7
Mobile Generator
Before Starting the Machine
WARNING
Personal injury hazard. Failure to follow the listed procedures may cause injury to
personnel or damage to the generator.
► Make sure that all persons setting up the generator are certified or fully trained
on the installation of the generator.
Before putting the generator into service, perform each item on the following
checklist.
Exterior
checks
 Check for damage that may have occurred during towing or travel to the jobsite.
Repair any damage.
 Make sure that the generator is level.
 Chock the trailer wheels.
Internal
checks
 Check engine oil, coolant, and fuel levels—fill as required.
 Check the fan belt and hoses on the engine for loose connections or fraying—
tighten or replace belts and hoses as required.
 Remove any debris that has lodged in vents, near the radiator, or around the
fan.
 Make sure the exhaust compartment is clean, with nothing touching the muffler
or exhaust pipes.
Pre-operation
checks
 Read and understand the engine owner’s manual.
 Check local regulations and NEC standards for electrical connections.
 Determine voltage needs; obtain proper cable and equipment to meet the
needs. Follow local regulations and NEC standards.
 Make sure that the generator is grounded to a good earthen ground per local
regulations and NEC standards.
 Review and follow the safety instructions found in the front of this Operator’s
Manual.
60
wc_tx003579gb_FM10.fm
Mobile Generator
7.8
Operation (Basler Controller)
Starting and Running the Machine
CAUTION
Possibility of injury or equipment damage. Failure to match phase, voltage, and
frequency may cause equipment connected to the generator to operate incorrectly.
► When using the generator as a stand-by or substitute power supply, make sure
the phase, voltage, and frequency of the generator matches that of the utility
lines or of any other power source normally used.
Preliminary
Perform the procedure below to start and run the machine.
1. Set the engine start switch (a) to the OFF position.
Note: Graphic is representative only. Your machine may vary.
d
208/240V 3Ø
120/139V 1Ø
277/480V
3Ø
V
Ø
A
HZ
042563
120/240V
1Ø
346/600V
3Ø
OFFF
OF
AUS
AU
S
APAGADO
APAGADO
ARRETT
ARRE
b
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
REMOTE START
START
START / RUN
RUN
FERNSTARTT
FERNSTAR
ARRANQUE REMOTO
REMOTO
DEMARRAGE A
DISTANCE
DISTANC
E
START / LAUFE
LAUFEN
N
ARRANQUE / MARCHA
MARCHA
DEMARRER / MARCHE
MARCHE
e
R
OFFF
OF
AUS
AU
S
APAGADO
APAGADO
ARRETT
ARRE
REMOTE START
START
START / RUN
RUN
FERNSTARTT
FERNSTAR
ARRANQUE REMOTO
REMOTO
DEMARRAGE A
DISTANCE
DISTANC
E
START / LAUFEN
LAUFEN
ARRANQUE / MARCHA
MARCHA
DEMARRER / MARCHE
MARCHE
a
c
f
wc_gr011279
2. Set the main circuit breaker (b) to OFF.
3. Set the convenience receptacle circuit breakers (c, d) to OFF.
4. Turn off all loads.
5. Check position of the voltage selector switch (e) and make sure it is set for the
desired voltage output. Lock the voltage selector switch in place if desired.
This procedure continues on the next page.
wc_tx003579gb_FM10.fm
61
Operation (Basler Controller)
Mobile Generator
Continued from the previous page.
6. Connect the load to the lugs and/or to the convenience receptacles.
7. Check the operation of the genset controller.
a. Set the engine start switch to REMOTE START. The LCD panel momentarily
displays INITIALIZING followed by READY. Engine information is also
displayed. Check the fuel level and battery voltage. Add fuel and/or charge
the battery if needed. If the LCD display does not power up, check battery
voltage and connections.
b. With the READY screen showing, press the emergency stop button (f). The
LCD panel displays EMERGENCY STOP, and the pre-alarm/alarm LED
illuminates. If the LCD does not display EMERGENCY STOP, do not
continue. Contact a Wacker Neuson dealer for assistance. Pull out the
emergency stop button after verifying the display.
c. Set the engine start switch to OFF.
Starting
8. Start the engine by setting the engine start switch to the START/RUN position.
After displaying INITIALIZING and NOT IN AUTO, the LCD panel will display
START DELAY followed by CRANKING as the engine begins its crank cycle. The
crank cycle calls for the engine to crank for 10 seconds, then rest for 10 seconds.
This cycle will repeat three times in an attempt to start the engine.
If the engine does not start within three attempts, the genset controller stops the
crank cycle and OVERCRANK is displayed on the LCD panel.
9. To repeat the crank cycle, set the start switch to OFF, then back to START/RUN.
Upon startup
Upon engine startup, the LCD displays the monitoring screen. Run the engine for a
few minutes to allow it to warm before turning on (closing) any circuit breakers.
Note: Leave the engine start switch (a) in the START/RUN position while the
generator is operating.
wc_gr010195
10.Check the voltage on the monitoring screen and adjust it as needed using the
voltage adjustment rheostat. See topic Selecting the Voltage.
11.Turn on (close) the appropriate circuit breakers for your load.
62
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7.9
Operation (Basler Controller)
Stopping the Machine
Check with other personnel on the jobsite and let them know that power is being
turned off. Make sure that the power shutdown will not create any hazards by
turning off devices such as pumps, heaters, or lights that may need to be kept on.
1. Turn off all loads connected to the generator.
2. Set the main circuit breaker to OFF.
3. Set the convenience receptacle circuit breakers to OFF.
4. Let the engine run for approximately five minutes to cool it down.
5. Move the engine start switch to the OFF position.
7.10
Emergency Stop Switch
The emergency stop switch (a) is the red button located as shown, and can be
accessed with the panel doors closed.
ERGENC
M
Y
E
Location
a
ALARM ACTIVE
TO VIEW
EMERGENCY STOP
Function
wc_gr010365
Activate the emergency stop switch by pushing the red button. Pushing the
emergency stop switch:
■ turns off (opens) the main circuit breaker
■ cuts power to the fuel solenoid
■ stops the engine
■ causes “Alarm Active: Emergency Stop” to appear on the LCD display
The emergency stop switch will remain activated until the button is pulled out.
NOTICE: Do not use the emergency stop switch to shut down the generator during
normal operation. The emergency stop switch is intended for use only in an actual
emergency situation where the generator must be stopped immediately.
To shut down the generator during normal operation, turn off (open) the main circuit
breaker and then move the engine start switch to the OFF position.
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7.11
Mobile Generator
LCD Panel: Monitoring Machine Operation
Overview
Generator and engine information is continuously monitored and displayed on the
LCD panel. The upper line displays generator information. The lower line displays
engine information.
Generator
Engine
wc_gr010202
Generator
information
The upper line of the LCD panel shows the voltage, phase, amperage, and
frequency of the electric power being generated. The information is shown only
when the engine is running.
Symbol
Meaning
Description
V
Volts
Displays the value of the AC output voltage being
produced by the generator.
Ø
Phase
Displays the leg or phase currently being monitored. In
three-phase mode, the display toggles between P1, P2,
and P3. In single-phase mode, the display toggles
between L1, L3, and L-L.
A
Amps
Displays the value of the AC output amperage
produced by the generator. If the generator is operating
at no load, output amperage will be zero (0).
Frequency in
Hertz
Displays the value of the output frequency.
For tier 3 engines, this display will read approximately
61.5 Hz under a no-load condition and approximately
60 Hz under load.
For tier 4 engines, this display will read approximately
60.0 Hz under no-load and loaded conditions.
HZ
This procedure continues on the next page.
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Operation (Basler Controller)
Continued from the previous page.
Engine
information
The lower line of the LCD panel shows fuel level, temperature, oil pressure, and
battery voltage. The information is shown when the engine start switch is set to
REMOTE START or RUN/START.
Symbol
Meaning
Description
Fuel level
Indicates relative fuel level in the fuel tank
Temperature
Displays temperature of engine coolant
Oil pressure
Displays engine oil pressure between 0–100 psi
Normal operating pressure = 50–80 psi
Battery voltage
Displays real-time battery voltage while the machine
is operating
Actual battery voltage is displayed when the engine
switch is set to REMOTE START and the generator
is in standby mode.
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8
Mobile Generator
Working with Basler Controller
8.1
How to Use the Genset Controller LCD and Keypad
Basics
The LCD (a) is used to display information regarding machine performance and
operating status. The keypad (b) is used to maneuver through the various menus
of the genset controller. The keypad is also used to enter and change values of
machine settings.
b
a
2
4
5
1
6
3
wc_gr010130
Actions of the
buttons
To scroll through the options within a menu, use the up/down arrow buttons (2, 3).
When an option on a menu is highlighted, it can be accessed for further submenus.
To do so, press the right arrow button (1).
To return to a previous screen, press the left arrow button (4).
To exit menu navigation and return to monitoring status (or the READY screen),
press and hold the left arrow button.
To access a setting in order to change it, press the check mark button (5).
To cancel an operation, press the “X” reset button (6).
Normal
screens
The machine must be running, or the start switch set to REMOTE START position,
for the genset to be on and active. Sample screens of normal operation are shown
below.
Genset monitoring status
READY screen
This screen is displayed
when the machine is running.
This screen is displayed when the
start switch is in REMOTE START.
wc_gr010144
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8.2
Working with Basler Controller
Menu Diagram of the Genset Controller
The various menus of the genset controller are divided into two main categories:
METERING and SETTINGS. Access to the METERING menu and to the
SETTINGS menu is done through the MAIN MENU. To access the MAIN MENU
from either the monitoring screen or the READY screen, press the right arrow
button.
Note: Graphic is representative only. Your machine may vary.
.
Metering
Engine
Oil Pressure
Coolant Temp
Metering
Settings
DIAGNOSTIC MENU
NAVIGATION
UP
Fuel Level
Engine Load
Coolant Level*
Total Run Time
BACK
FORWARD
Generator
DOWN
Bus V
Bus Frequency
Synchronizer
Cumulative
kVAR
Detailed Data
Unloaded Run Time
Session
Session
Alarm-Status
Session Info
Total Run Time
Loaded Run Time
Unloaded Run Time
Alarms
Pre-Alarms
Status
Inputs
Detailed Data
Event Log
J1939 Engine Config*
J1939 Active DTC*
J1939 Previous DTC*
General Settings
Front Panel HMI
Settings
General Settings
Communications
Generator Protection
Breaker Management
Bias Control
Enter Password
Crank Settings
* NOT AVAILABLE ON SOME MODELS
wc_gr007618
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8.3
Mobile Generator
Menu Diagram Components
.
Menu Item
Description
Menu Item
Description
Alarm Config
Alarm configuration
J1939 Active DTC
Diagnostic Trouble
Codes
Alarm Configuration
—
J1939 Data
—
Alarms
—
J1939 Engine Config
Engine configuration
Alarm–Status
—
J1939 Previous DTC
Diagnostic Trouble
Codes
Amps
—
kVA
Kilovolt-amps
Back
—
kVAR
Kilovolt-amps Reactive
Battery Volt
—
kW
Kilowatts
Bias Control
—
Language
—
Breaker Management
—
LCD Contrast
Liquid Crystal Display
Bus Frequency
—
Loaded Run Time
—
Bus V
Bus voltage
Low Fuel Level
—
Communications
—
Main Menu
—
Conf Elements
Configurable elements
Maintenance Reset
—
Conf Prot Status
Configurable protection
status
Metering
—
Configure Date/Time
—
Oil Pressure
—
Coolant Level
—
Outputs
—
Coolant Temp
—
PF
Power factor
Cooldown Time
—
Power
—
Crank Settings
—
Pre-Alarms
—
Cumulative
—
Programmable Inputs
—
Cumulative Info
—
RPM
Rotations per minute
Detailed Data
—
Run Statistics
—
Diagnostic Menu Navigation
—
Session
—
Down
—
Session Info
—
Engine
—
Settings
—
Engine Load
—
Speed Source
—
Enter Password
—
Status
—
Event Log
—
Synchronizer
—
Forward
—
Sys Parameters
System parameters
Frequency
—
System Settings
—
Front Panel HMI
Human-Machine
Interface
System Units
—
Fuel Level
—
Total Run Time
—
General Settings
—
Unloaded Run Time
—
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Working with Basler Controller
Menu Item
Description
Menu Item
Description
Generator
—
Up
—
Generator Protection
—
Voltages
—
Hrs to Maintenance
Hours to maintenance
—
—
Inputs
—
—
—
8.4
Using the Metering and Settings Menus
Background
The various menus of the genset controller are divided into two main categories:
METERING, and SETTINGS. Access to the METERING menu and to the
SETTINGS menu is done through the MAIN MENU.
METERING
menus
METERING menus give detailed information regarding engine status and
generator performance. The machine must be running for many of the parameters
to be active. Use the menu diagram of the genset controller as a guide for
navigating the menus.
Parameters under the METERING menu are read-only. They cannot be changed,
except for HRS to MAINTENANCE parameter, which can be reset.
SETTINGS
menus
SETTINGS menus give detailed information regarding genset controller
configuration. Use the menu diagram of the genset controller as a guide for
navigating the menus.
There are a limited number of parameters under the SETTINGS menus that may
be changed by the user. These parameters are:
 LCD screen contrast
 Time and date
 Sender fail time delays
 Units of measure (imperial or metric)
 Low fuel pre-alarm level
 Low fuel alarm level
 Cooldown time
 Pre-crank time delay
 Maintenance interval
Procedures for changing these parameters are included in this manual.
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8.5
Mobile Generator
Logging in to the Genset Controller by Entering the Password
Precaution
Only change parameters when the READY screen is displayed (start switch in the
REMOTE START position).
Password
In order to change the parameters under the settings menu, you must be “logged
in” to the genset controller. There are two displays where you can log in to the
genset controller: 1) at the “ENTER PASSWORD” display under SETTINGS; or 2)
when prompted for the password by the genset controller at the parameter you
want to change.
The default password, in either case, is “OP”. It is set at the factory. It is the only
password available, and it cannot be changed.
Once you are logged in, you will remain logged in until:
 you log out,
 the machine is turned off,
 or if you press the check mark button inadvertently. This usually happens when
attempting to change a locked parameter.
At ENTER
PASSWORD
To log in to the genset controller at the ENTER PASSWORD display, do the
following:
1. Press the right arrow button (1) to enter the main menu.
wc_gr010119
2. Use the up/down arrow buttons (2, 3) to highlight SETTINGS. Then, press the
right arrow button.
This procedure continues on the next page.
70
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Working with Basler Controller
Continued from the previous page.
3. Using the up/down arrow buttons, scroll through the setting parameters until
ENTER PASSWORD is highlighted. Then, press the check mark button (5).
4. The password entry screen appears with a letter “A” as the default character.
Use the up/down arrow buttons to change the “A” to “O”. Then, press the right
arrow button to move the cursor to the next position.
5. Use the up/down buttons to select “P”. Then, press the check mark button.
The screen below appears. You are now logged in and have the ability to change
parameter settings. Do not re-enter the password even though it is requested;
instead, navigate to the parameter you would like to change. You may, however,
log out if desired. To do so, navigate to LOGOUT and press the check mark button.
wc_gr010122
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At the
PASSWORD
prompt
Mobile Generator
To log in when prompted to enter the password, do the following:
1. The password entry screen appears with a letter “A” as the default character.
Use the up/down arrow buttons to change the “A” to “O”. Then, press the right
arrow button to move the cursor to the next position.
2. Use the up/down arrow buttons to select “P”. Then, press the check mark
button.
3. A screen for the parameter, similar to that shown below left (A), will appear. The
word “~~EDIT~~” will be displayed. Whenever “~~EDIT~~” is displayed, it
means that you are able to change the parameter. Use the up/down arrow
buttons to change the setting. Then, press the check mark button to accept the
new value.
wc_gr010128
Note: If the genset controller displays the screen (B), it means that the parameter
cannot be changed by the operator. Do not re-enter the password even though you
are requested to do so; instead, press the “X” button to cancel the operation and
return to the previous screen. If you do re-enter the password (by pressing the
check mark button), you will be logged out. In such cases, turn the machine off,
then back on again, and restart the procedure from the beginning.
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8.6
Working with Basler Controller
Adjusting the LCD Screen Contrast
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Procedure
Perform the procedure below to adjust the LCD screen contrast.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight GENERAL SETTINGS. Then, press the right arrow button (1).
4. Highlight FRONT PANEL HMI. Then, press the right arrow button.
5. Highlight LCD CONTRAST. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the contrast value as desired. Press
the check mark button when finished.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button until the READY screen appears.
Result
The screen contrast has now been adjusted.
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8.7
Mobile Generator
Changing the Time/Date Settings
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Procedure
Perform the procedure below to change the time and date.
1. Press the right arrow button (1) to access the MAIN MENU.
wc_gr010133
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight GENERAL SETTINGS. Then, press the right arrow button (1).
4. Highlight CONFIGURE DATE/TIME. Then, press the right arrow button.
5. Highlight the setting you want change. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button so that the READY screen appears.
Result
The date/time settings have now been changed.
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8.8
Working with Basler Controller
Changing the Sender Fail Time Delays
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller or connections to a remote
start switch may cause the machine to start unexpectedly. Be prepared for the
engine to start even with the engine start switch in the REMOTE START position.


Background
There are five senders/sensors monitored by the genset controller. Each has its
own failure-time-delay period. This is the amount of time that the genset controller
must experience the failure before the failure will be seen on the LCD display.
These failure-time-delay periods may be changed. The table below lists the failuretime-delay periods, the allowable range, and their factory settings.
Failure Time Delay
Procedure
Range
Factory Setting
Coolant temperature sender
0 to 30 min
5 min
Oil pressure sender
0 to 300 sec
10 sec
Fuel level sender
0 to 300 sec
10 sec
Voltage sensor
0 to 300 sec
15 sec
Speed sender
0 to 300 sec
300 sec
Perform the procedure below to change a fail time delay.
1. Press the right arrow button (1) to access the MAIN MENU.
wc_gr010134
This procedure continues on the next page.
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Continued from the previous page.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight ALARM CONFIGURATION. Then, press the right arrow button.
4. Highlight SENDER FAIL. Then, press the right arrow button.
5. Highlight the sender or sensor you want to change. Then, press the right arrow
button.
6. Highlight ACTIVATN DELAY or TIME DELAY. Then, press the check mark
button (5).
7. If you are not logged in, enter the password “OP”. Press the check mark button.
8. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
9. Exit by pressing the left arrow button (4) three times or until the LCD displays
the SETTINGS menu. Then, scroll to LOGOUT and press the check mark
button. Press the left arrow button so that the READY screen appears.
Result
The fail time delay has now been changed.
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8.9
Working with Basler Controller
Changing the Units of Measure
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
Genset controller units of measure may be set to English (imperial) or metric.
Procedure
Perform the procedure below to set the units of measure.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight SYSTEM PARAMS. Then, press the right arrow button.
4. Highlight SYSTEM SETTINGS. Then, press the right arrow button.
5. Highlight the SYSTEM UNITS. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
This procedure continues on the next page.
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Continued from the previous page.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button so that the READY screen appears.
Result
The units of measure have now been changed.
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8.10
Working with Basler Controller
Changing the Low Fuel Pre-Alarm Setting
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The low fuel pre-alarm setting may be changed if desired. The value shown by the
genset controller is the percentage of fuel remaining in the fuel tank. The range
allowed by the genset controller is 10–100.
Procedure
Perform the procedure below to change the low fuel pre-alarm setting.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight ALARM CONFIGURATION. Then, press the right arrow button.
4. Highlight PRE-ALARMS. Then, press the right arrow button.
5. Highlight the LOW FUEL LEVEL. Then, press the right arrow button.
6. Highlight the THRESHOLD. Then, press the check mark button (5).
7. If you are not logged in, enter the password “OP”. Press the check mark button.
This procedure continues on the next page.
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Continued from the previous page.
8. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
9. Exit by pressing the left arrow button (4) three times or until the LCD displays
the SETTINGS menu. Then, scroll to LOGOUT and press the check mark
button. Press the left arrow button so that the READY screen appears.
Result
The low fuel pre-alarm setting has now been changed.
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8.11
Working with Basler Controller
Changing or Disabling the Low Fuel Alarm Setting
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
Notes
The LCD panel displays, in percentage, how much fuel is in the fuel tank. The low
fuel alarm shutdown is set at the factory to activate at 6%. This value may be
changed if desired. For example, you may wish to reduce the low fuel alarm setting
so that the machine operates for a longer period of time or until virtually all fuel is
consumed before the genset controller shuts down the machine for lack of fuel.
The range allowed by the genset controller is 0–100%.
 Do not set the low fuel alarm to a value greater than that of the low fuel prealarm. Doing so will nullify the function of the low fuel pre-alarm.
 Setting the low fuel alarm below 5, in effect, disables the low fuel alarm. The
genset controller will not shut down the machine. The machine will shut down
when all fuel is consumed.
 “5” is the lowest value the LCD will display.
NOTICE: If the low fuel alarm is set below 5, it is possible to run the fuel so low that
air will be drawn into the engine. The fuel system may then need to be bled before
it will start and run.
Approximate run time (at 100% prime load) gained with low fuel alarm set to 0%.
Machine
Procedure
Fuel Use gal/hr
Time Gained hr
G 25
1.8
3.7
G 25 ERT
1.8
4.2
G 50
3.4
3.0
G 50 ERT
3.4
3.8
G 70
4.9
2.1
G 70 ERT
4.9
2.6
G 100
6.2
3.3
G 120
7.44
2.7
G 150
8.85
3.4
G 180
10.8
2.7
G 240
13.5
2.1
Perform the procedure below to change the low fuel alarm setting.
1. Press the right arrow button (1) to access the MAIN MENU.
This procedure continues on the next page.
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Continued from the previous page.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.Highlight ALARM CONFIG. Then, press the right arrow
button.
3. Highlight ALARMS. Then, press the right arrow button.
4. Highlight the LOW FUEL LEVEL. Then, press the right arrow button.
5. Highlight the THRESHOLD. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
8. Exit by pressing the left arrow button (4) three times or until the LCD displays
the SETTINGS menu. Then, scroll to LOGOUT and press the check mark
button. Press the left arrow button so that the READY screen appears.
Result
The low fuel alarm setting has now been changed.
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8.12
Working with Basler Controller
Changing the Cooldown Time Setting
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The genset controller includes a cooldown timer. The function of the cooldown
timer is to run the engine at no load after a period of being run at load. It is used in
conjunction with the remote start system. The cooldown timer activates when the
machine is no longer receiving a remote run signal. This timer is factory set to zero
(0) minutes. The cooldown time can be changed if desired.
Procedure
Perform the procedure below to change the cooldown time setting.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight SYSTEM PARAMS. Then, press the right arrow button.
This procedure continues on the next page.
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Continued from the previous page.
4. Highlight CRANK SETTINGS. Then, press the right arrow button.
5. Highlight COOLDOWN TIME. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button so that the READY screen appears.
Result
The cooldown time setting has now been changed.
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8.13
Working with Basler Controller
Changing the Pre-Crank Time Delay (Glow Plug Timer)
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The genset controller includes a pre-crank time delay. This is the time the glow
plugs will be on before the engine starts to crank. The factory setting is 5 seconds.
The pre-crank time delay can be changed if desired.
NOTICE: Do not set the glow plug timer to a value of more than 10. Damage to the
glow plugs may occur.
Procedure
Perform the procedure below to change the pre-crank time delay.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight SYSTEM PARAMS. Then, press the right arrow button.
This procedure continues on the next page.
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Continued from the previous page.
4. Highlight CRANK SETTINGS. Then, press the right arrow button.
5. Highlight PRECRANK DELY. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button until the READY screen appears.
Result
The pre-crank time delay has now been changed.
86
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Mobile Generator
8.14
Working with Basler Controller
Changing the Maintenance Interval
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The maintenance interval is the time, in hours, scheduled between critical
maintenance tasks (such as, changing the engine oil). The amount of time may be
changed if desired. The factory setting is 250.
Note: Refer to the Periodic Maintenance Schedule in the Operator’s Manual for
timing of all scheduled maintenance tasks.
Procedure
Perform the procedure below to change the maintenance interval.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
This procedure continues on the next page.
wc_tx003229gb_FM10.fm
87
Working with Basler Controller
Mobile Generator
Continued from the previous page.
3. Highlight ALARM CONFIGURATION. Then, press the right arrow button.
4. Highlight PRE-ALARMS. Then, press the right arrow button.
5. Highlight the MAINTENANCE INTERVAL. Then, press the right arrow button.
6. Highlight the THRESHOLD. Then, press the check mark button (5).
7. If you are not logged in, enter the password “OP”. Press the check mark button.
8. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
9. Exit by pressing the left arrow button (4) three times or until the LCD displays
the SETTINGS menu. Then, scroll to LOGOUT and press the check mark
button. Press the left arrow button so that the READY screen appears.
Result
The maintenance interval has now been changed.
88
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Mobile Generator
8.15
Working with Basler Controller
Resetting the Maintenance Interval Pre-Alarm
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
When the MAINT INTERVAL pre-alarm is active, the PRE-ALARM ACTIVE screen
is displayed and the red LED flashes.
The maintenance interval pre-alarm may be reset by using either of two different
methods: 1) by holding the “X” reset button while the MAINT INTERVAL pre-alarm
screen is being displayed, or 2) through the METERING menu. Both methods are
described below.
Procedure
Perform the procedure below to reset the maintenance interval pre-alarm.
1. With the PRE-ALARM ACTIVE screen showing, press and hold the “X” reset
button (6) for 10–20 seconds. This will clear the pre-alarm and reset the
maintenance interval timer back to 250 (or the value it is currently set to).
If that method is unsuccessful, continue.
2. Press the right arrow button (1) to access the PRE-ALARMS menu.
This procedure continues on the next page.
wc_tx003229gb_FM10.fm
89
Working with Basler Controller
Mobile Generator
Continued from the previous page.
3. With the PRE-ALARMS screen showing (MAINT INTERVAL highlighted), press
the left arrow button (4) three times.
4. Using the up/down arrow buttons highlight METERING. Then, press the right
arrow button.
5. Using the up/down arrow buttons highlight ENGINE. Then, press the right arrow
button.
6. Highlight HRS TO MAINT. Then, press and hold the “X” reset button for 10–20
seconds. This will clear the pre-alarm and reset the maintenance interval timer
back to 250 (or the value it is currently set to).
7. Exit by repeatedly pressing the left arrow button until the READY screen
appears.
Result
The maintenance interval interval pre-alarm has now been reset.
90
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8.16
Working with Basler Controller
Resetting a Loss of Voltage Pre-Alarm
Background
The loss of voltage pre-alarm condition occurs most often because of an open lug
door switch. During a loss of voltage pre-alarm, the LCD will display the screens
below.
To reset the loss of voltage pre-alarm, simply close the lug door. If the voltage does
not return to normal, further troubleshooting will be needed.
Note: The loss of voltage pre-alarm will only occur when the voltage selector
switch is in the 120/240 position. The condition will still exist if in a 3-phase mode,
but the pre-alarm will not activate.
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91
Working with Basler Controller
8.17
Mobile Generator
Accessing and Using the Event Log
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The event log allows the technician to review recent events of the machine
including pre-alarm and alarm (shut-down) conditions. The event log can aid the
technician in diagnosing machine problems.
Note: Before accessing the event log, check the date and time of the genset
controller. The date and times listed in the event log will be relative to the date and
time setting of the genset controller.
Procedure
Perform the procedure below to access the event log.
1. At the READY screen, press the right arrow button to bring up the MAIN menu.
2. Highlight METERING. Then, press the right arrow button.
3. Highlight ALARMS-STATUS. Then, press the right arrow button.
4. Highlight EVENT LOG. Then, press the right arrow button.
The LCD displays the events of the event log. Events with the suffix “A” are alarm
conditions. Events with the suffix “P” are pre-alarm conditions. The events are:
LCD Screen
Meaning
OVERCRANK A
Overcrank pre-alarm
ENGINE RUNNING
Engine running
PROT SHUTDOWN
Protective shutdown
EMERGENCY STOP A
Emergency stop alarm
ATS INPUT CLOSED
Automatic transfer switch input closed
NORM SHUTDOWN
Normal shutdown
FUEL LEVL SENDR FAIL P
Fuel level sender failure pre-alarm
FUEL LEVL SENDR FAIL A
Fuel level sender failure alarm
LOW FUEL LEVEL P
Low fuel level pre-alarm
LOW FUEL LEVEL A
Low fuel level alarm
OVER VOLTAGE P
Over voltage pre-alarm
OVER CURRENT P
Over current pre-alarm
LOW OIL PRES A
Low oil pressure alarm
LOSS OF VOLT P
Loss of voltage pre-alarm
LOSS OF VOLT
Loss of voltage
LOW OIL PRES P
Low oil pressure pre-alarm
LOW BATT VOLT P
Low battery voltage pre-alarm
OIL SNDR FAIL P
Oil sender failure pre-alarm
OIL SNDR FAIL
Oil sender failure
92
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Mobile Generator
Working with Basler Controller
LCD Screen
Meaning
GEN TEST LOADED
Generator test loaded
MAINT INTERVAL P
Maintenance interval pre-alarm
LOW COOL LEVEL A
Low coolant level alarm
5. Highlight the event of interest. Then, press the right arrow button.
Details of the event appear: They are:
 ACTIVE
 OCCURENCE COUNT
 FIRST DATE
 FIRST TIME
 LAST DATE
 LAST TIME
 FIRST ENG HRS
 LAST ENG HRS
 DETAILS
Most recent
event
To find the alarm event that has occurred most recently:
1. Scroll to each alarm event and record the time it occurred.
2. Compare the dates and times of all alarm events. The one with the most current
date and time is the most recent.
wc_tx003229gb_FM10.fm
93
Operation (Deep Sea Controller)
9
9.1
Mobile Generator
Operation (Deep Sea Controller)
Main Circuit Breaker
Location
Various styles of main circuit breakers may be found on Wacker Neuson Mobile
generators. The main circuit breaker (a) is located on the control panel.
Note: Graphic is representative only. Your machine may vary.
a
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
AUS
APAGADO
ARRET
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
ME
R GE NC
Y
E
AUS
APAGADO
ARRET
S TOP
wc_gr011444
Functions
■ The main circuit breaker interrupts power from the voltage selector switch to the
terminal lugs.
■ The main circuit breaker does not interrupt power to the convenience
receptacles.
WARNING
Electric shock hazard. High voltage is present inside the control panel while the
engine is running.
► Do not open the control panel unless the engine is stopped.
NOTICE: Before shutting down the generator or performing any service to the
generator, make sure the main circuit breaker is in the OFF position.
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9.2
Operation (Deep Sea Controller)
Genset Controller Power Switch
Description
The genset controller power switch (a) is a two-position switch: ON and OFF.
a
ON
OFF
wc_gr011478
Function
Position
ON
Function
LCD Screen
When set to this position:
“Generator at Rest” followed
by the status screens that
scroll.
■ Power is supplied to the genset
controller.
■ The genset controller boots up and sets
itself to the Stop/Reset mode—the
engine is ready to be started.
OFF
wc_tx003580gb_FM10.fm
When set to this position, power to the
genset controller is disconnected.
95
Blank screen (off)
Operation (Deep Sea Controller)
9.3
Mobile Generator
Selecting the Voltage
Location
One of two types of voltage selector switch—either three-position (a) or fourposition (b)—is mounted to the machine near the lugs.
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE
ULTRABAJO CONTENIDO DE AZUFRE.
STOP
!
DIESEL
177416
NUR NIEDRIGEN SCHWEFELKRAFTSTOFF ODER ULTRANIEDRIGEN SCHWEFELKRAFTSTOFF.
DANGER
GEFAHR
PELIGRO
DANGER
277/480V
3Ø
346/600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
!
a
b
wc_gr011503
WARNING
Electric shock hazard. High voltage is present inside the voltage selector switch
enclosure when the engine is running.
► Do not open the voltage selector switch enclosure unless the engine is stopped.
Selecting the
voltage
The chart below lists the ranges of voltages available in each of the switch
positions. Select the desired voltage by rotating the handle of the voltage selector
switch. Then, use the voltage adjustment rheostat to set the exact voltage you
require. The voltage is displayed on the LCD panel.
Range of Voltages Available
Switch position
3Ø at lugs
(L–L–L)
1Ø at lugs
(L–N)
1Ø at lugs
(L-L)
1Ø at twist lock
L-N (120V)
L-L (240V)
1Ø at GFCI
120/240 VAC 1Ø
—
110–125
220–250
110–125
220–250
110–125
208/240 VAC 3Ø
120/139 VAC 1Ø
190–240
110–139
190–240
110–139
190–240
110–139
277/480 VAC 3Ø
380–480
220–2772
190–2402
110–1392
190–2402
110–1392
346/600 VAC 3Ø1
540–600
—
—
—
—
—
1 Not
2 Not
available on all models.
available on 600V models.
NOTICE: Do not change the position of the voltage selector switch while the
engine is running. Doing so can cause arcing which can damage the voltage
selector switch and the generator windings.
96
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Mobile Generator
Using the
rheostat
Operation (Deep Sea Controller)
The voltage adjustment rheostat (c) is used to fine-tune the voltage as needed
while the machine is running.
c
OFF
AUS
APAGADO
ARRET
V
V
Ø
A
HZ
Ø
A
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
HZ
042563
OFF
AUS
APAGADO
ARRET
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
Basler
REMOTE START
R
E R G E NC
M
Y
E
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
R
S TOP
wc_gr011502
Care must be taken when using the voltage adjustment rheostat because adjusting
the voltage for 3-phase operation affects the voltage available at the single-phase
outlets. As the 3-phase voltage increases, so does the single-phase voltage.
NOTICE: Do not use the GFCI or twist-lock receptacle (120V) when the 1Ø voltage
is above 135V. Damage to the receptacle and the tools connected to it may occur.
Switch Position
208 VAC 3Ø
120 VAC 1Ø
277/480 VAC 3Ø
346/600 VAC 3Ø3
3Ø Voltage
(L-L-L)
Corresponding 1Ø voltage
Twist lock receptacle
L-L (240V)
L-N (120V)
120V GFCI
208
208
120
120
220
220
125
125
240
240
139
1
1391
480
240
1391
1391
460
230
1332
1332
600
540
1 Do
not use receptacle with this voltage.
may be too high for some tools and equipment. Check tool/equipment specifications.
3
Not available on all models.
2Voltage
wc_tx003580gb_FM10.fm
97
Operation (Deep Sea Controller)
9.4
Mobile Generator
Deep Sea Controller Buttons/Functions
2
5
1
4
DSE
DEEP SEA ELECTRONICS
ELECTRONICS
6
DSE 731
7310
0
7
Alarm
Warning
arning
8
Main Breaker Open
3
Low Speed Active
9
Open
Open
Close
Close
Load
Gen-Set
10
11
AUTO
AUT
O
Stop/Reset
12
Manual
Mode
13
Lamp Test
est
Horn Reset
Auto
Mode
14
15
Start
16
17
wc_gr011485
Ref.
Button/function
1
Right arrow button (right / forward)
2
Up arrow button
3
Down arrow button
4
Left arrow button (left / backward)
5
Check mark button (enter / accept)
This button is used when navigating through the genset controller menus.
Press this button to accept a new value or menu item.
6
Alarm indicator
Illuminates during a fault condition that has stopped the engine.
7
Warning indicator
Illuminates during a non-critical alarm condition. Note: non critical alarm
conditions may lead to shut-down conditions.
8
Main breaker open indicator
Illuminates whenever the main circuit breaker is open.
9
Low speed active indicator
Illuminates when the engine idle speed is set to low idle (if equipped).
10
Load button (not used)
11
Gen-Set button (not used)
98
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Mobile Generator
Ref.
wc_tx003580gb_FM10.fm
Operation (Deep Sea Controller)
Button/function
12
Stop / Reset
Pressing this button:
■ Sets the genset controller into its Stop/Reset mode
■ Clears any alarm conditions for which the triggering criteria have been
rectified.
13
Manual mode
Pressing this button:
■ Sets the genset controller to the Manual mode
In Manual mode, the generator can be started and operated.
14
(not used)
15
Auto mode
Pressing this button:
■ Sets the genset controller to the Auto mode
In Auto mode, the generator can only be started and operated by a remote
switch.
16
Lamp test / horn reset
Pressing this button:
■ Silences the audible alarm
■ Illuminates all of the LEDs as a lamp test feature (push and hold to perform
test)
17
Start
Pressing this button:
■ Starts the engine
This button is only active in Manual mode.
99
Operation (Deep Sea Controller)
9.5
Mobile Generator
Genset Controller Alarms and Shut-Down Conditions
Background
The genset controller monitors variables of engine and machine function. The
genset controller has two types of alarms: warning alarms and shut-down alarms.
The genset controller also monitors for electrical trip conditions.
Warning
alarms
Warnings are non-critical alarm
conditions that do not affect the operation
of the generator system. They serve to
draw the operator’s attention to an
undesirable condition. Warning alarms
are self-resetting when the fault condition
is removed.
DSE
DEEP SEA ELECTRONICS
DSE 7310
Alarm
Warning
Main Breaker Open
Low Speed Active
Warning alarms include:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Time to maintenance
7
wc_gr011490
During a warning alarm condition, the LCD panel displays the type of warning
alarm, the warning LED (7) illuminates, and an audible alarm sounds. The machine
is not shut down. Press the “Horn Reset” button to silence the audible alarm.
Shut-down
alarms
Shut-down alarms are latching alarms
and stop the generator. Shut-down
alarms include:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Overspeed/Underspeed
■ Overcrank
■ Low coolant level (if equipped)
■ Overcurrent
DSE
DEEP SEA ELECTRONICS
DSE 7310
Alarm
Warning
Main Breaker Open
Low Speed Active
6
8
wc_gr011491
During a shut-down alarm condition, the
LCD panel displays the type of alarm, the LEDs (6, 8) illuminate, an audible alarm
sounds, and the machine is shut down. Press the “Horn Reset” button to silence
the audible alarm. Remove the fault condition, then press “Stop/Reset”.
Variable
Normal
Warning
Shutdown
To Reset
Fuel level
>15%
15%
—
Fill fuel tank. Press “Stop/Reset”.
Coolant temp.
85°C±8
105°C
115°C
Add coolant. Press “Stop/Reset”.
Oil pressure
60–80 psi
20 psi
15 psi
Add engine oil. Press “Stop/Reset”.
Overspeed
60 Hz
—
66 Hz
Press “Stop/Reset”.
Underspeed
60 Hz
—
54 Hz
Press “Stop/Reset”.
Overcrank
—
—
After 3 attempts
Press “Stop/Reset”.
Time to maintain
500 hours
0 hours
—
Reset genset controller.
Coolant level
Above sender
—
Below sender
Add coolant. Press “Stop/Reset”.
100
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Mobile Generator
Operation (Deep Sea Controller)
Electrical trips Electrical trips are latching type alarms
that stop the engine.
During an electrical trip, the LEDs (6, 8)
illuminate, an audible alarm sounds, and
the machine is shut down.
DSE
DEEP SEA ELECTRONICS
DSE 7310
Alarm
Warning
Main Breaker Open
Press the “Horn Reset” button to silence
the audible alarm. Remove the fault
condition, then press “Stop/Reset” to
enable the engine to be restarted.
Low Speed Active
6
8
wc_gr011492
wc_tx003580gb_FM10.fm
101
Operation (Deep Sea Controller)
9.6
Mobile Generator
Before Starting the Machine
WARNING
Personal injury hazard. Failure to follow the listed procedures may cause injury to
personnel or damage to the generator.
► Make sure that all persons setting up the generator are certified or fully trained
on the installation of the generator.
Before putting the generator into service, perform each item on the following
checklist.
Exterior
checks
 Check for damage that may have occurred during towing or travel to the jobsite.
Repair any damage.
 Make sure that the generator is level.
 Chock the trailer wheels.
Internal
checks
 Check engine oil, coolant, and fuel levels—fill as required.
 Check the fan belt and hoses on the engine for loose connections or fraying—
tighten or replace belts and hoses as required.
 Remove any debris that has lodged in vents, near the radiator, or around the
fan.
 Make sure the exhaust compartment is clean, with nothing touching the muffler
or exhaust pipes.
Pre-operation
checks
 Read and understand the engine owner’s manual.
 Check local regulations and NEC standards for electrical connections.
 Determine voltage needs; obtain proper cable and equipment to meet the
needs. Follow local regulations and NEC standards.
 Make sure that the generator is grounded to a good earthen ground per local
regulations and NEC standards.
 Review and follow the safety instructions found in the front of this Operator’s
Manual.
102
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9.7
Operation (Deep Sea Controller)
Starting and Running the Generator
CAUTION
Possibility of injury or equipment damage. Failure to match phase, voltage, and
frequency may cause equipment connected to the generator to operate incorrectly.
► When using the generator as a stand-by or substitute power supply, make sure
the phase, voltage, and frequency of the generator matches that of the utility
lines or of any other power source normally used.
Procedure
Perform the procedure below to start the generator.
1. Check the position of the voltage selector and make sure that it is set for the
desired voltage output. Lock the voltage selector in place.
2. Set the main circuit breaker to the OFF “O” position.
3. Set the convenience receptacle circuit breakers to the OFF “O” position.
4. Set the genset controller power switch (a) to the ON “I” position.
a
d
c
b
wc_gr011488
5. Press the “Manual mode” button (b).
6. Press the “Start” “I” button (c).
The LCD panel displays several screens as the start-up sequence begins.
Display
Meaning / Description
Preheating
The engine is heating.
Crank attempt
The engine is attempting to start.
This procedure continues on the next page.
wc_tx003580gb_FM10.fm
103
Operation (Deep Sea Controller)
Mobile Generator
Continued from the previous page.
7. The engine will crank. During a normal cycle, the engine cranks for 12 seconds
and rests for 12 seconds. This cycle will repeat three times.
Note: If the engine does not start within the normal cycle, the genset controller will
shut down the engine. “Failed to start” will display on the LCD.
► To repeat the crank cycle, press the Stop/Reset “O” button (d) to reset the
engine control model. Allow the starter motor to cool between start-up attempts.
8. After the engine starts, the LCD panel displays the following screens.
Display
Meaning / Description
Safety on delay
The genset controller is
determining system status.
Generator available
The generator is operating and
ready for service.
Engine oil pressure
Displays the engine oil pressure
Engine coolant temp.
Displays engine coolant
temperature
Engine battery voltage
Displays the battery voltage
Engine fuel level
Displays the percentage of
remaining fuel
9. Allow the engine to warm before closing the main circuit breaker.
10.Check the voltage displayed on the LCD panel. Adjust the voltage as needed
using the voltage adjustment rheostat. See topic Selecting the Voltage.
DSE
DEEP SEA ELECTRONICS
DSE 7320
Alarm
Warning
Main Breaker Open
Low Speed Active
wc_gr011499
11.Turn on (close) the appropriate circuit breakers for your load.
104
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Mobile Generator
9.8
Operation (Deep Sea Controller)
Stopping the Generator
Requirements
Before stopping the generator:
■ Check with other personnel on the jobsite and let them know that power is being
turned off.
■ Make sure that the power shutdown will not create any hazards by turning off
devices such as pumps, heaters, or lights that may need to be kept on.
Procedure
Perform the procedure below to stop the generator.
1. Remove all loads from the generator.
2. Open (set to OFF “O”) the convenience circuit breakers.
3. Open (set to OFF “O”) the main circuit breaker.
4. Let the engine run for approximately 5 minutes to allow it to cool down.
5. Press the Stop / Reset “O” button (a).
b
a
wc_gr011500
6. Set the genset controller power switch (b) to the OFF “O” position.
wc_tx003580gb_FM10.fm
105
Operation (Deep Sea Controller)
9.9
Mobile Generator
Emergency Stop Switch
Location
The emergency stop switch is the red button (a) located to the left of the control
panel. The button can be accessed with the panel doors closed. It is electrically
isolated from the switch and also from the rest of the metering panel.
DSE
DEEP SEA ELECTRONICS
DSE 7310
Alarm
Warning
Main Breaker Open
a
Y
E
Low Speed Active
ERGENC
M
b
S TO P
wc_gr009857
Operation
Activate the emergency stop switch by pressing the red button. This results in the
following actions:
■ The main breaker opens.
■ The “Main Breaker Open” LED illuminates.
■ The engine stops.
■ The LCD panel (b) displays a flashing “Emergency Stop” message.
■ The “Alarm” LED illuminates, and an audible alarm will sound.
To silence the audible alarm, press the Horn Reset button on the keypad. The
flashing message and illuminated LED will remain visible until the emergency stop
switch is deactivated.
To deactivate the emergency stop switch, pull the red button out.
NOTICE: Press the emergency stop button only in the case of an actual
emergency where the generator must be stopped immediately! In all other
instances, open the main line circuit breaker and then press the off button.
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Mobile Generator
9.10
Operation (Deep Sea Controller)
Engine and Generator Monitoring
Description
Engine and generator information is displayed on the LCD panel and scrolls
continuously while the generator is operating.
For more information on the Deep Sea controller, see chapter Working with the
Deep Sea Controller.
Generator Available
L-N
277 V
0 A
L-L
480 V
59.9 Hz
0 kW
--- pf
wc_gr009841
Volts “V”- Displays the AC output voltage being produced by
the generator.
Amps “A” - Displays the AC output amperage produced by the
generator. If the generator is operating at no-load, output
amperage will display a 0.
Hertz “Hz” - Displays output frequency. This gauge should
read approximately 60 Hz under a no-load condition. If the
frequency is too high, check the engine rpm
Displays the available voltage of the battery
Engine Battery Voltage
Battery
Charge Alt
25.5 V
0.0 V
wc_gr009842
Displays the percentage of fuel remaining in the fuel tank.
Engine Fuel Level
66 %
wc_gr009843
Displays the engine oil pressure
Engine Oil Pressure
4.14
60
4.14
bar
psi
kPa
wc_gr009844
Displays the current temperature of the engine coolant
Engine Coolant Temp.
16 oC
60 oF
wc_gr009845
wc_tx003580gb_FM10.fm
107
Working with Deep Sea Controller: DSE 7310
10 Working with Deep Sea Controller: DSE 7310
10.1
Introduction
During normal operation, the genset controller displays current information on
machine performance and operating status. The keypad (e) provides access to
additional monitoring functions through a series of menus displayed on the LCD
panel (f). You can also use the keypad to change certain machine settings if
desired.
.
f
1
2
e
DSE 7310
4
5
3
wc_gr011504
1. The various monitoring and configuration menus can be accessed by pressing
the right arrow button (1).
2. To select items on a menu, use the up/down arrow buttons (2, 3) to scroll
through the available options.
3. To return to a previous menu screen, press the left arrow button (4).
4. To exit menu navigation and return to LCD panel monitoring status, press the
left or right arrow button (1, 4) to return to the “Status” page.
108
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Working with Deep Sea Controller: DSE 7310
10.2
Navigating the Menus
The graphic below serves as a navigational aid when accessing the various menus
of the genset controller. See the accompanying table for information about the
menu items.
.
MENU NAVIGATION
Status
Engine
Generator
Summary
Screen
Engine
Speed
Gen Voltage
(L-N)
Engine Oil
Pressure
Engine
Oil
Pressure
Gen Voltage
(L-L)
Engine
Coolant
Temp
Engine
Coolant
Temp
Gen
Frequency
Summary
Screen
Engine
Battery
Voltage
Gen Current
Engine
Battery
Voltage
Engine
Run
Time
Gen Earth
Current
Fuel Level
Fuel
Level
Gen Load
(kW)
Maintenance
Alarm [Hold
"O" to reset]
Gen Load
(Total kW)
Engine
Link*
Gen Load
(%)
Can Bus
Information*
Gen Load
(Total %)
Alarms
ECU DTCs*
Event Log
Serial Port
Schedule
Gen Load
(kVA)
Gen Load
(Total kVA)
Gen Power
Factor
UP
Gen Power
Factor (Avg)
Gen Load
(kVAr)
FORWARD
BACK
Gen Load
(Total kVAr)
DOWN
Gen Load (h)
Gen Phase
Sequence
Active Config
Active Config
wc_tx003611gb_FM10.fm
*Not Available on Some Models
109
About
Working with Deep Sea Controller: DSE 7310
Menu Item
Description
Menu Item
Description
About
Module Information
—
—
Active Config
Generator Configuration
Gen Load (h)
Generator Load kVArh
Alarms
Alarms Active
Gen Load (%)
Generator Load Percent
—
—
Gen Load (kVA)
Generator Load kVA
Can Bus Information
Can Bus Information
Gen Load (kVAr)
Generator Load kVAr
—
—
Gen Load (kW)
Generator Load kW
ECU DTCs
Engine Diagnostic
Trouble Codes
Gen Load (Total %)
Generator Load Total
Percent
Engine
Engine Info
Gen Load (Total kVA)
Generator Load Total
kVA
Engine Battery Voltage
Battery and Alternator
Voltage
Gen Load (Total kW)
Generator Load Total
kW
—
—
Gen Phase Sequence
Generator Phase
Sequence
Engine Coolant Temp
Coolant Temperature in
°C and °F
Gen Power Factor
Generator Power Factor
Engine Link
Engine Link Info
Gen Power Factor (Avg)
Generator Average
Power Factor
Engine Oil Pressure
Engine Oil Pressure in
Bar, PSI, and kPa
Gen Voltage (L-L)
Generator Voltage Line
to Line
Engine Run Time
Accumulated Time in
Hours
Gen Voltage (L-N)
Generator Voltage Line
to Neutral
Engine Speed
Engine RPM
Generator
Generator Info
Event Log
List of Past Events
Maintenance Alarm
(Hold “O” to reset)
Hours until
Maintenance Warning
—
—
Serial Port
Serial Part Info
Fuel Level
Percentage of Fuel
Remaining in the Tank
Status
Status Information
Gen Current
Generator Current
Amps
Summary Screen
Main Summary Screen
Gen Earth Current
Generator Earth
Current Amps
—
—
Gen Frequency
Generator Frequency
(Hz)
—
—
110
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Working with Deep Sea Controller: DSE 7310
10.3
Adjusting Screen Contrast
Overview
The contrast of the LCD display can be adjusted to suit the operator’s preference.
Procedure
Perform the procedure below to adjust the screen contrast.
1. Access the “Editor—Display” menu on the LCD panel (f) by pressing and
holding the check mark button (5) on the keypad.
5
DSE
DEEP SEA ELECTRONICS
DSE 7310
Alarm

Warning
Main Breaker Open
Low Speed Active
f
wc_gr009802
2. Wait a few seconds for the “Contrast” screen to appear, or use up/down arrow
keys to navigate to the “Contrast” screen. Then, press the check mark button.
The contrast value will start flashing.
2
DSE
DEEP SEA ELECTRONICS
Editor
Edit
or— —Di
Displa
splay
y

DSE 7310
Alarm
Warning
Contras
Contr
ast
t
55 %
3
Main Breaker Open
Low Speed Active
wc_gr009850
3. Press the up/down arrow buttons to change the contrast percentage as desired.
When the screen contrast reaches a comfortable viewing level, press the check
mark button to accept the choice.
4. Exit by pressing and holding the check mark button until the genset controller
returns to the “Status” screen.
Result
The screen contrast has now been changed.
wc_tx003611gb_FM10.fm
111
Working with Deep Sea Controller: DSE 7310
10.4
How to Reset the Maintenance Timer
Background
The maintenance timer is preset to 500 hours. When the maintenance timer times
out, the genset controller sounds the audible alarm.
Procedure
Perform the procedure below to reset the maintenance timer.
1. From the “Status” menu, press the right arrow button to reach the “Engine”
menu.
DSE
DEEP SEA ELECTRONICS
DSE 7310
Alarm
DSE 7310
Warning
Main Breaker Open
Low Speed Active
DSE
DEEP SEA ELECTRONICS
DSE 7310
Alarm
Warning
Main Breaker Open
Low Speed Active
DSE
DSE 7310
Alarm
Warning
Main Breaker Open
Low Speed Active
a
wc_gr011508
2. Using the up and down arrow buttons, navigate to the “Maintenance alarm 1”
screen.
3. Press the “Stop/Reset” button (a). The timer will return to 500 hours.
112
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Mobile Generator
How to Connect Loads (480V)
11 How to Connect Loads (480V)
The information in this chapter on how to connect loads applies to machines with
maximum capabilities of up to 480V.
This chapter does not apply to machines with maximum capabilities of up to 600V.
11.1
Lug Terminal Connection Diagrams
High Wye
3Ø
1Ø
120/240V
1Ø
277/480V
3Ø
240V
Low Wye
240V
or
139V
139V
139V
240V
240V
240V
3Ø
1Ø
277/480V
3Ø
277/480V
3Ø
120/240V
1Ø
3Ø
1Ø
120/240V
1Ø
Zig Zag
wc_gr010197
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113
How to Connect Loads (480V)
11.2
Mobile Generator
Best Practices for Balancing Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
Background
Three-phase (3Ø) loads are, by their nature, balanced. It is when single-phase
(1Ø) loads are combined with existing 3Ø loads that an unbalanced condition can
occur. Dedicated 1Ø loads may also be unbalanced if the loads are not equally
distributed between the legs (L1 and L3) of the generator.
The sensing wires of the generator’s voltage regulator are connected to L1 and L3.
Having the loads balanced between L1 and L3 allows the generator to provide
voltage that is more consistent with the voltage needs of the equipment connected
to it.
Note: When in the 600V mode, single phase power is not available.
1Ø Situations
For 1Ø situations (voltage selector switch in the 208/240V position)
Unbalanced loads can be detected by observing the genset controller LCD panel. If
an unbalanced load condition exists, there will be a significant difference (over
10%) in both voltage and amperage between the legs.
Observe the amp draw on L1 and L3.
1Ø ZIG-ZAG
Observe L1 and L3
120 L1 12
277/480V
3Ø
346/600V
3Ø
60
120 L3 12
60
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
100% 175 60 13
100% 175 60 13
wc_gr011280
If an unbalanced load condition is detected, stop the engine and reconnect the
loads so that loads (amp draw) are more equally distributed between the legs (L1
and L3)—for example, if a heavy load and a light load are connected to L1, but only
a light load is connected to L3. Reconnect the loads so that the heavy load is
connected to L1, and the two lighter loads are connected to L3. Redistributing the
loads will equalize the voltage for each leg and allow for better performance from
the equipment connected to the generator.
Reconnect the loads as necessary to provide the most equal amp draw between
L1 and L3.
This procedure continues on the next page.
114
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Mobile Generator
How to Connect Loads (480V)
Continued from the previous page.
3Ø Situations
When combining 1Ø loads with 3Ø loads (voltage selector switch in 208/240V
position), unbalanced loads can be detected by observing the genset controller
LCD panel. If an unbalanced load condition exists, there will be a significant
difference in both voltage and amperage between the phases.
Observe the amp draw on P1, P2, and P3.
277/480V
3Ø
3Ø LOW WYE
346/600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
Observe P1, P2, P3
208 P1 24
60
100% 175 60 13
208 P2 24
60
208 P3 24
100% 175 60 13
60
100% 175 60 13
wc_gr011281
If an unbalanced load is detected, stop the engine and reconnect the loads so that
loads (amp draw) are more equally distributed. This will also help equalize the
voltage for each phase.
When connecting multiple 120V 1Ø loads to the lugs while in 208/240V 3Ø mode,
use L1 as “hot” for the first load (or heaviest load). Use L3 as “hot” for the second
load (or next heaviest load), and use L2 as “hot” for the third load (lightest load). If
additional loads are to be connected, repeat the connection sequence L1, L3, and
then L2.
With voltage selected to 208/240
277/480V
3Ø
346/600V
3Ø
L1 L2 L3 N GND
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
HOT HOT
When connecting multiple 120V 1Ø loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
LOAD 1
Use L2 as "hot" for third load.
HOT
LOAD 2
LOAD 3
wc_gr011282
This procedure continues on the next page.
wc_tx003581gb_FM10.fm
115
How to Connect Loads (480V)
Mobile Generator
Continued from the previous page.
Using the
receptacles
This information applies whether the machine is running in 3Ø or in 1Ø.
Note: When in the 600V mode, single phase power is not available.
When connecting two loads to the duplex receptacles, instead of plugging both
loads in to the same duplex receptacle, plug the first load in to one of the duplex
receptacles. Then, plug the second load in to the other duplex receptacle.
Additional loads can be plugged in to either duplex receptacle.
LOAD 2
LOAD 1
wc_gr011320
When using the 240V twist-lock receptacle and a distribution box, instead of
plugging both loads in to the same duplex receptacle of the distribution panel, plug
the first load in to one of the duplex receptacles. Then, plug the second load in to a
different duplex receptacle of the distribution box.
LOAD 1
LOAD 2
wc_gr011321
116
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Mobile Generator
11.3
How to Connect Loads (480V)
Connecting 480V, 3-Phase and Single-Phase Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 277/480 position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the voltage
adjustment rheostat.
240 L-L
139 L-N
480V 3Ø
277/480V
3Ø
139V
3Ø
1Ø
120/240V
1Ø
480V
277/480V
3Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
139V
480V
480V
120/240V
1Ø
277V
277V
277V
HOT HOT HOT
GN
HOT HOT HOT
480V 3Ø
WH
480V 3Ø
GN
TRANSFORMER
wc_gr011437
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117
How to Connect Loads (480V)
11.4
Mobile Generator
Connecting a 240V 3Ø Load and a 240V 1Ø Load
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 208/240 position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the voltage
adjustment rheostat.
240 L-L
139 L-N
240V 3Ø
3Ø
1Ø
277/480V
3Ø
120/240V
1Ø
240V
277/480V
3Ø
600V
3Ø
139V
139V
240V
240V
208/240V 3Ø
120/139V 1Ø
139V
120/240V
1Ø
139V
139V
HOT HOT HOT
240V 3Ø
GN
240V 1Ø
wc_gr011438
118
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Mobile Generator
11.5
How to Connect Loads (480V)
Connecting 240V and 120V Single-Phase Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
Background
Single-phase loads may be connected at the lugs by connecting the load “line to
line” or by connecting the load “line to neutral”. Line-to-line connections use two
“hots” and ground; line-to-neutral connections use one “hot”, neutral, and ground.
Procedure
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 120/240V position.
3. Open the lug door and connect the wires from the load(s) as shown.
4. Close the lug door and start the machine.
5. Fine-tune the voltage as necessary using the voltage adjustment rheostat
.
240 L-L
120 L-N
3Ø
1Ø
120/240V
1Ø
277/480V
3Ø
120V
277/480V
3Ø
346/600V
3Ø
120V
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
240V
120V
120V
Balance the load
When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
GN
HOT
HOT
TO "N" LUG
TO GND LUG
120V 1Ø
120V 1Ø
240V 1Ø
wc gr011440
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119
How to Connect Loads (480V)
11.6
Mobile Generator
Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 208/240 position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door and start the machine.
5. Fine-tune the voltage as necessary using the voltage adjustment rheostat.
208V 3Ø
208 L-L
120 L-N
3Ø
1Ø
277/480V
3Ø
120/240V
1Ø
120V
208V
277/480V
3Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
120V
208V
208V
120V
120/240V
1Ø
120V
120V
Balance the load
When connecting multiple
120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.
HOT
HOT
HOT
WH
GN
TO GND
LUG
120V 1Ø
208V 3Ø
120V 1Ø
wc_gr011441
120
wc_tx003581gb_FM10.fm
Mobile Generator
11.7
How to Connect Loads (480V)
Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 208/240 position.
3. Open the lug door and connect the wires from the load(s) as shown.
4. Close the lug door and start the machine.
5. Fine-tune the voltage as necessary using the voltage adjustment rheostat.
220–240V 3Ø
220–240 L-L
127–139 L-N
3Ø
1Ø
277/480V
3Ø
!
120/240V
1Ø
!
127–
139V
127–
139V
220–
240V
277/480V
3Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
220–
240V
220–240V
120/240V
1Ø
127–139V
127–139V
127–139V
Balance the load
When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.
HOT
HOT
HOT
WH
GN
GN
Fine-tune the voltage
Fine-tune the voltage so that
both the 3-phase load and
the single-phase loads
operate properly.
TO
GROUND
LUG
127–139V 1Ø
220–240V 3Ø
127–133V 1Ø
wc_gr011442
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121
How to Connect Loads (600V)
Mobile Generator
12 How to Connect Loads (600V)
The information in this chapter on how to connect loads applies to machines with
maximum capabilities up to 600V.
This chapter does not apply to machines with maximum capabilities of only 480V.
12.1
Lug Terminal Connection Diagrams
wc_gr011347
9
High Wye
10
11
L1-N = 346V
L2-N = 346V
L3-N = 346V
L1-L2 = 600V
L2-L3 = 600V
L3-L1 = 600V
12
8
2
7
6
1
4
3
5
3Ø Zig Zag
9
10
8
7
11
4
3
12
6
2
1
L1-N = 277V
L2-N = 277V
L3-N = 277V
L1-L2 = 480V
L2-L3 = 480V
L3-L1 = 480V
208/240V 3Ø
120/139V 1Ø
277/480V
3Ø
120/240V
1Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
277/480V
3Ø
120/240V
1Ø
600V
3Ø
5
Low Wye
240V
9
11
10
12
or
6
2
1
5
4
8
277/480V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
600V
3Ø
3
7
6
1
2
5
139V
139V
139V
240V
240V
240V
8
7
3
10
277/480V
3Ø
9
4
600V
3Ø
12
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
11
1Ø Zig Zag
122
wc_tx003683gb_FM10.fm
Mobile Generator
12.2
How to Connect Loads (600V)
Best Practices for Balancing Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
Background
Three-phase (3Ø) loads are, by their nature, balanced. It is when single-phase
(1Ø) loads are combined with existing 3Ø loads that an unbalanced condition can
occur. Dedicated 1Ø loads may also be unbalanced if the loads are not equally
distributed between the legs (L1 and L3) of the generator.
The sensing wires of the generator’s voltage regulator are connected to L1 and L3.
Having the loads balanced between L1 and L3 allows the generator to provide
voltage that is more consistent with the voltage needs of the equipment connected
to it.
Note: When in the 600V mode, single phase power is not available.
1Ø Situations
For 1Ø situations (voltage selector switch in the 208/240V position)
Unbalanced loads can be detected by observing the genset controller LCD panel. If
an unbalanced load condition exists, there will be a significant difference (over
10%) in both voltage and amperage between the legs.
Observe the amp draw on L1 and L3.
1Ø ZIG-ZAG
Observe L1 and L3
120 L1 12
277/480V
3Ø
346/600V
3Ø
60
120 L3 12
60
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
100% 175 60 13
100% 175 60 13
wc_gr011280
If an unbalanced load condition is detected, stop the engine and reconnect the
loads so that loads (amp draw) are more equally distributed between the legs (L1
and L3)—for example, if a heavy load and a light load are connected to L1, but only
a light load is connected to L3. Reconnect the loads so that the heavy load is
connected to L1, and the two lighter loads are connected to L3. Redistributing the
loads will equalize the voltage for each leg and allow for better performance from
the equipment connected to the generator.
Reconnect the loads as necessary to provide the most equal amp draw between
L1 and L3.
This procedure continues on the next page.
wc_tx003683gb_FM10.fm
123
How to Connect Loads (600V)
Mobile Generator
Continued from the previous page.
3Ø Situations
When combining 1Ø loads with 3Ø loads (voltage selector switch in 208/240V
position), unbalanced loads can be detected by observing the genset controller
LCD panel. If an unbalanced load condition exists, there will be a significant
difference in both voltage and amperage between the phases.
Observe the amp draw on P1, P2, and P3.
277/480V
3Ø
3Ø LOW WYE
346/600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
Observe P1, P2, P3
208 P1 24
60
100% 175 60 13
208 P2 24
60
208 P3 24
100% 175 60 13
60
100% 175 60 13
wc_gr011281
If an unbalanced load is detected, stop the engine and reconnect the loads so that
loads (amp draw) are more equally distributed. This will also help equalize the
voltage for each phase.
When connecting multiple 120V 1Ø loads to the lugs while in 208/240V 3Ø mode,
use L1 as “hot” for the first load (or heaviest load). Use L3 as “hot” for the second
load (or next heaviest load), and use L2 as “hot” for the third load (lightest load). If
additional loads are to be connected, repeat the connection sequence L1, L3, and
then L2.
With voltage selected to 208/240
277/480V
3Ø
346/600V
3Ø
L1 L2 L3 N GND
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
HOT HOT
When connecting multiple 120V 1Ø loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
LOAD 1
Use L2 as "hot" for third load.
HOT
LOAD 2
LOAD 3
wc_gr011282
This procedure continues on the next page.
124
wc_tx003683gb_FM10.fm
Mobile Generator
How to Connect Loads (600V)
Continued from the previous page.
Using the
receptacles
This information applies whether the machine is running in 3Ø or in 1Ø.
Note: When in the 600V mode, single phase power is not available.
When connecting two loads to the duplex receptacles, instead of plugging both
loads in to the same duplex receptacle, plug the first load in to one of the duplex
receptacles. Then, plug the second load in to the other duplex receptacle.
Additional loads can be plugged in to either duplex receptacle.
LOAD 2
LOAD 1
wc_gr011320
When using the 240V twist-lock receptacle and a distribution box, instead of
plugging both loads in to the same duplex receptacle of the distribution panel, plug
the first load in to one of the duplex receptacles. Then, plug the second load in to a
different duplex receptacle of the distribution box.
LOAD 1
LOAD 2
wc_gr011321
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125
How to Connect Loads (600V)
12.3
Mobile Generator
Connecting a 240V 3Ø Load and a 240V 1Ø Load
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 208/240 position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the voltage
adjustment rheostat.
240 L-L
139 L-N
240V 3Ø
3Ø
1Ø
277/480V
3Ø
120/240V
1Ø
240V
277/480V
3Ø
600V
3Ø
139V
139V
240V
240V
208/240V 3Ø
120/139V 1Ø
139V
120/240V
1Ø
139V
139V
HOT HOT HOT
240V 3Ø
GN
240V 1Ø
wc_gr011438
126
wc_tx003683gb_FM10.fm
Mobile Generator
12.4
How to Connect Loads (600V)
Connecting 240V and 120V Single-Phase Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
Background
Single-phase loads may be connected at the lugs by connecting the load “line to
line” or by connecting the load “line to neutral”. Line-to-line connections use two
“hots” and ground; line-to-neutral connections use one “hot”, neutral, and ground.
Procedure
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 120/240V position.
3. Open the lug door and connect the wires from the load(s) as shown.
4. Close the lug door and start the machine.
5. Fine-tune the voltage as necessary using the voltage adjustment rheostat
.
240 L-L
120 L-N
3Ø
1Ø
120/240V
1Ø
277/480V
3Ø
120V
277/480V
3Ø
346/600V
3Ø
120V
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
240V
120V
120V
Balance the load
When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
GN
HOT
HOT
TO "N" LUG
TO GND LUG
120V 1Ø
120V 1Ø
240V 1Ø
wc gr011440
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127
How to Connect Loads (600V)
12.5
Mobile Generator
Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 208/240 position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door and start the machine.
5. Fine-tune the voltage as necessary using the voltage adjustment rheostat.
208V 3Ø
208 L-L
120 L-N
3Ø
1Ø
277/480V
3Ø
120/240V
1Ø
120V
208V
277/480V
3Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
120V
208V
208V
120V
120/240V
1Ø
120V
120V
Balance the load
When connecting multiple
120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.
HOT
HOT
HOT
WH
GN
TO GND
LUG
120V 1Ø
208V 3Ø
120V 1Ø
wc_gr011441
128
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Mobile Generator
12.6
How to Connect Loads (600V)
Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 208/240 position.
3. Open the lug door and connect the wires from the load(s) as shown.
4. Close the lug door and start the machine.
5. Fine-tune the voltage as necessary using the voltage adjustment rheostat.
220–240V 3Ø
220–240 L-L
127–139 L-N
3Ø
1Ø
277/480V
3Ø
!
120/240V
1Ø
!
127–
139V
127–
139V
220–
240V
277/480V
3Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
220–
240V
220–240V
120/240V
1Ø
127–139V
127–139V
127–139V
Balance the load
When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.
HOT
HOT
HOT
WH
GN
GN
Fine-tune the voltage
Fine-tune the voltage so that
both the 3-phase load and
the single-phase loads
operate properly.
TO
GROUND
LUG
127–139V 1Ø
220–240V 3Ø
127–133V 1Ø
wc_gr011442
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129
How to Connect Loads (600V)
12.7
Mobile Generator
Connecting 480V, 3-Phase Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 277/480 position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the voltage
adjustment rheostat.
480V 3Ø
277/480V
3Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
480V
480V
480V
277V
277V
277V
HOT HOT HOT
GN
HOT HOT HOT
WH
GN
transformateur
transformador
480V 3Ø
480V 3Ø
TRANSFORMER
wc_gr011843
130
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Mobile Generator
12.8
How to Connect Loads (600V)
Connecting 600V, 3-Phase Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 600 position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the voltage
adjustment rheostat.
600V 3Ø
277/480V
3Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
600V
600V
600V
600 P3
24
60
100% 175 0
13
346V
346V
346V
HOT HOT HOT
GN
HOT HOT HOT
WH
GN
transformateur
transformador
600V 3Ø
600V 3Ø
TRANSFORMER
wc_gr011356
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131
Using Remote Start Capabilities
Mobile Generator
13 Using Remote Start Capabilities
13.1
Remote Run Terminal Block
Location
The remote run terminal block (a) is located as shown.
Note: Graphic is representative only. Your machine may vary.
V
Ø
A
a
HZ
R
ERGENC
M
Y
E
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
S TO P
4,000 ft
1,219 m
ATS
wc_gr010366
Description
The remote run terminal block provides connection points for the installation of a
remotely located transfer/start switch. If a transfer switch is installed, the generator
can be used as a stand-by power supply.
When connecting an Automatic Transfer Switch (ATS) or other remote switch:
■ Limit the distance between the remote run terminal block and the remote switch
to 1,219 m (4,000 ft) max.
■ Use twisted, 22-gauge wire or heavier.
■ Do not run the wire for the remote switch in the same conduit as current carrying
wire.
■ Do not run a voltage to the contacts (these are dry contacts).
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13.2
Using Remote Start Capabilities
Remote Transfer Switch
Background
A remote transfer switch is designed to transfer electrical loads from the normal
power source (utility) to the emergency power source (generator) when normal
voltage falls below a prescribed level.
The remote transfer switch automatically returns the load back to the normal
source when power is restored back to operating levels.
WARNING
Electrocution hazard. Failure to isolate the generator from the utility’s electrical
distribution system could cause output from the generator to backfeed into the
utility lines and cause injury or death to utility workers!
► When the generator is used as a stand-by power supply, it must be equipped
with a device which isolates it from the utility’s distribution system.
► An isolation device is also required if the generator is being used as a backup to
some other type of power supply system.
Precautions
■ Installation of a remote transfer switch or other type of remote starting device is
the responsibility of the generator user.
■ Installation of such devices must be performed by a qualified electrician
following all directions supplied by the manufacturer of the switch.
■ If attaching the generator to a power supply normally serviced by a utility
company, notify the utility company and check local and state regulations.
■ Familiarize yourself with all instructions and warning labels supplied with the
switch.
CAUTION
Possibility of injury or equipment damage. Failure to match phase rotation and
voltage may cause equipment connected to the generator to operate incorrectly.
► When using the generator as a stand-by or substitute power supply, make sure
the voltage and phase rotation of the line connections match those of the utility
lines or of any other power source normally used.
DANGER
Electrocution hazard. Lethal voltage is always present in the transfer switch once it
has been properly installed.
► Disconnect power before servicing the transfer switch.
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133
Using Remote Start Capabilities
13.3
Mobile Generator
Preparing for Automatic/Remote Start-Up (Basler)
Background
When the engine start switch is in the REMOTE START position, the generator can
be started remotely through a automatic transfer switch or other type of remote
start switch.
CAUTION
Possibility of unexpected machine startup. If the contacts on a remote switch
connected to the generator are closed, the machine could start unexpectedly when
the engine start switch is set to the REMOTE START position.
► Be prepared for engine startup anytime the engine start switch is in the
REMOTE START position.
► Before placing the engine start switch in the REMOTE START position, verify
that the contacts on any remote/transfer switch connected to the generator are
OFF (OPEN).
Procedure
Before operating the machine in the remote start mode, do the following:
1. Perform a manual start to verify that the LCD panel is operating correctly. Refer
to topics Before Starting and Starting and Running the Machine.
a. Check the fuel level and add fuel as needed.
b. Check the battery voltage. Charge the battery if needed.
2. Check the operation of the remote
start circuit:
a. Attach a short jumper wire (a)
(minimum 16-gauge insulated)
between the two terminals on the
remote run terminal block. The
jumper wire completes the circuit
which initializes the genset
controller start sequence.
b. Set the engine start switch to the
REMOTE START position.
c. Wait for the engine to crank, start,
and run.
d. Move the engine start switch to OFF to stop the engine.
e. Remove the jumper wire from the remote run terminals.
a
005632
OFF
AUS
APAGADO
ARRET
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
50A
20A
wc_gr010206
3. Set the voltage selector switch to the correct voltage position.
4. Set the engine start switch to the REMOTE START position.
5. Set the main line circuit breaker to ON.
6. Secure the generator by closing and locking all doors.
The generator is now ready for remote starting.
Maintaining
If the generator is to be used as a stand-by power supply, provisions must be made
battery charge to maintain the charge of the battery. This can be done either by attaching a battery
charger to the battery or by starting and running the engine periodically.
134
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Mobile Generator
13.4
Using Remote Start Capabilities
Preparing for Automatic/Remote Start-Up (Deep Sea)
Background
In AUTO mode, the generator can be started remotely, either through a transfer
switch or some other type of remote start switch. AUTO mode is the normal setting
when using the generator as a stand-by power supply.
b
c
d
wc_gr011501
CAUTION
Possibility of accidental equipment start-up. If the contacts on any remote switch
linked to the generator are closed, the generator could start unexpectedly when the
AUTO mode button is pressed.
► Before pressing the AUTO mode button, verify that the contacts on any remote
switch linked to the generator are OPEN.
Procedure
1. Before using the AUTO mode, perform
a
a check of the auto start-up circuit. To
do so:
a. Attach a short jumper wire (a)
(minimum 16-gauge insulated)
between the two terminals on the
remote run terminal block. The
jumper wire applies a ground to the
ECM to complete the start circuit.
b. Set the genset controller power
switch (b) to the ON position.
c. Press the AUTO mode button (c).
wc_gr010206
d. Wait for the engine to crank, start,
and run. If the engine cranks, the remote start circuit is functioning.
e. Press the Stop/Reset “O” button (d) to stop the engine.
f. Remove the jumper wire from the remote run terminals after testing is
complete.
005632
OFF
AUS
APAGADO
ARRET
50A
20A
This procedure continues on the next page.
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135
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
Using Remote Start Capabilities
Mobile Generator
Continued from the previous page.
2. Leave the genset controller power switch in the ON position.
3. Close the main circuit breaker.
4. Press the AUTO mode button.
5. Secure the generator by closing and locking all doors.
The generator is now ready for automatic starting.
Maintaining
If the generator is to be used as a stand-by power supply, provisions must be made
battery charge to maintain the battery charge. This can be done either by attaching a battery
charger to the battery or by starting the generator manually and running the engine
periodically to maintain the battery charge.
136
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Mobile Generator
Diagnostic Trouble Codes (DTC)
14 Diagnostic Trouble Codes (DTC)
14.1
Accessing DTCs with the Basler Controller
Background
This machine may include an engine that has self-diagnostic capabilities. These
engines communicate issues with the engine through Diagnostic Trouble Codes
(DTCs). When a DTC is present, an alert will show on the LCD panel display. A
DTC is a two part code consisting of a Suspect Parameter Number (SPN), and a
Failure Mode Identifier (FMI).
Procedure
Perform the procedure below to access Diagnostic Trouble Codes.
1. At the READY screen, press the right arrow button (1) to bring up the MAIN
menu.
2
4
READY
100% 175
5
13.4
MAIN MENU
1
3
6
J1939 ACTIVE DTC
1/1 SPN FMI OC
100 4
1
METERING
SETTINGS
METERING
CLEAR DTCs
ENGINE
GENERATOR
POWER
RUN STATISTICS
ALARMS-STATUS
DIAGNOSTICS
1
NO
ALARMS-STATUS
EVENT
J1939
J1939
J1939
J1939
LOG
1
DATA
ENGINE CONFIG
ACTIVE DTC
1
PREV DTC
0
wc_gr011382
2. Highlight METERING. Then, press the right arrow button.
3. Highlight ALARMS-STATUS. Then, press the right arrow button.
4. Highlight J1939 ACTIVE DTC. Then, press the right arrow button.
5. Highlight a DTC. Then, press the check mark button (5).
Note: To access a past DTC, highlight J1939 PREV DTC. Then, press the right
arrow button.
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137
Diagnostic Trouble Codes (DTC)
14.2
Mobile Generator
Accessing Engine DTCs using the Deep Sea Controller
Background
This machine may include an engine that has self-diagnostic capabilities. These
engines communicate issues with the engine through Diagnostic Trouble Codes
(DTCs). When a DTC is present, an alert will show on the LCD panel display. A
DTC is a two part code consisting of a Suspect Parameter Number (SPN), and a
Failure Mode Identifier (FMI).
Procedure
Perform the procedure below to access the Diagnostic Trouble Codes.
1. From the “status” menu, press the right arrow key to navigate through “engine”,
“Generator”, “Alarms”, to “ECU DTCs”.
.
wc_gr011701
2. Use the up and down arrow keys to scroll through the DTCs.
Note: The Deep Sea Controller will list the most current DTC first, followed by the
any other DTCs in order of their occurrence.
138
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Mobile Generator
14.3
Diagnostic Trouble Codes (DTC)
List of Engine Diagnostic Trouble Codes (DTCs)
Failure Code
SPN-FMI
Failure Type
100-1
Engine oil press drop
100-3
Engine oil press sensor malfunction (high voltage)
100-4
Engine oil press sensor malfunction (low voltage)
102-3
Boost pressure sensor malfunction (high voltage)
102-4
Boost pressure sensor malfunction (low voltage)
105-3
Boost temp sensor malfunction (high voltage)
105-4
Boost temp sensor malfunction (low voltage)
108-3
Baro press sensor malfunction (high voltage)
108-4
Baro press sensor malfunction (low voltage)
110-0
Over heat
110-3
Water temp sensor malfunction (high voltage)
110-4
Water temp sensor malfunction (low voltage)
157-3
Common rail press sensor malfunction (high voltage)
157-4
Common rail press sensor malfunction (low voltage)
157-15
Common rail pressure malfunction (pump over pressure feed)
158-3
Battery system high voltage malfunction
172-3
Intake air temp sensor malfunction (high voltage)
172-4
Intake air temp sensor malfunction (low voltage)
174-3
Fuel temp sensor malfunction (high voltage)
174-4
Fuel temp sensor malfunction (low voltage)
190-0
Over run
628-2
ROM malfunction
633-7
Pressure limiter open
636-2
Cam sensor malfunction (no signal)
636-7
Cam sensor phase shifting
639-2
CAN time-out malfunction
639-19
CAN Bus malfunction
651-5
Injection nozzle # 1 driving system disconnection
652-5
Injection nozzle # 2 driving system disconnection
653-5
Injection nozzle # 3 driving system disconnection
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139
Diagnostic Trouble Codes (DTC)
Mobile Generator
Failure Code
SPN-FMI
Failure Type
654-5
Injection nozzle # 4 driving system disconnection
676-5
Glow relay malfunction
677-5
Starter cut relay malfunction
723-2
Crank sensor malfunction (no signal)
723-8
Crank sensor malfunction (abnormal signal)
1077-2
CPU malfunction
1079-2
5V power supply 1 voltage malfunction
1080-2
5V power supply 2 voltage malfunction
1131-3
Manifold temp sensor malfunction (high voltage)
1131-4
Manifold temp sensor malfunction (low voltage)
1239-1
Common rail pressure down (No pump pressure feed)
1239-17
Common rail pressure down (pump pressure feed insufficient)
1347-3
SCV driving system + B short
1347-4
SCV driving system disconnection, GND short
1485-5
Main relay system malfunction (not connected)
1485-6
Main relay system malfunction (not disconnected)
10001-2
EGR position sensor malfunction
10001-13
EGR zero-point learning malfunction
10002-2
EGR valve control malfunction
10003-2
Injection nozzle common 1 driving system malfunction
10004-2
Injection nozzle common 2 driving system malfunction
10005-1
Charge circuit malfunction (bank 1)
10006-1
Charge circuit malfunction (bank 2)
10007-2
CPU monitoring IC malfunction
10008-2
A/D conversion malfunction
10009-2
5V power supply 3 voltage malfunction
10010-2
5V power supply 4 voltage malfunction
10013-2
EEPROM malfunction
10032-2
QR code malfunction
10033-2
RAM malfunction
10045-2
ADIC malfunction
10046-2
SWITCH-IC 1 internal malfunction
140
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Mobile Generator
Diagnostic Trouble Codes (DTC)
Failure Code
SPN-FMI
Failure Type
10048-2
SWITCH-IC 1 communicate malfunction
10050-2
Injector IC malfunction
10051-2
Injector IC communicate malfunction
10052-2
Injector IC check sum malfunction
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141
Factory-Installed Options
Mobile Generator
15 Factory-Installed Options
This machine may be equipped with one or more of the following factory-installed
options. To verify if any of these options are installed on your machine, contact
Wacker Neuson Corporation at 1-800-770-0957. A nameplate listing the Model
Number, Item Number, Revision, and Serial Number is attached to each unit.
Please have this information available when contacting Wacker Neuson
Corporation.
The illustrations shown in this chapter represent typical installations. The factoryinstalled options on your machine may look different.
15.1
Battery Charger
An optional battery charger maintains the battery at peak power while the machine
is turned off. Use of a battery charger is recommended when the generator is not
operated on a regular basis. The battery charger prevents voltage drain and
reduces the possibility of having to jump-start the engine after long periods of
inactivity. Plug the cord into a 120V power supply.
wc_gr005779
142
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Mobile Generator
15.2
Factory-Installed Options
Lockable Battery Disconnect
A lockable ON/OFF switch is available which disconnects the battery. A padlock
(not included) securely locks the switch in the OFF position. If equipped, the battery
disconnect switch is mounted to the upper skid beneath the access door on either
the right or left side of the machine.
wc_gr010552
NOTICE: Do not use the battery disconnect switch while the engine is running.
Damage to electrical components may occur.
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143
Factory-Installed Options
15.3
Mobile Generator
Camlocks
A second optional outlet panel features camlock connectors for easy tool changes.
Each connector is protected by a spring-loaded cover.
NOTICE: Separate overcurrent protection must be provided. Do not exceed 400
amps per receptacle.
WARNING
Electric shock hazard.
► Do not operate this machine with defective or missing guards, doors, or protective interlocks.
144
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Mobile Generator
15.4
Factory-Installed Options
Containment System
Overspills and leaks are captured in the containment system (a). The containment
system holds over 110% of the fluid contained in the machine.
a
wc_gr002647
The containment system should be checked every 50 hours or 2 weeks and
drained when necessary. If fluid is found in the containment tank, trace the cause of
the leak and correct.
Note: In the interests of environmental protection, place impermeable sheeting and
a container under the machine to collect the liquid which drains off. Dispose of this
liquid in accordance with environmental protection legislation.
15.5
Extended Run Tank (ERT)
An extended run (fuel) tank provides extended run time under a continuous full
load. The long run time eliminates the need for daily refueling, saving money on
fuel deliveries. The tank is fully fluid-contained and is ideal for remote or weekend
running of equipment such as dewatering submersible pumps.
wc_gr006179
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145
Factory-Installed Options
15.6
Mobile Generator
Engine Block Heater
The engine block heater option includes a block heater (a) with a cord (b). The
function of the block heater is to heat the engine coolant/engine block to improve
cold-weather engine starting. Plug the cord into a 120V power supply.
15.7
Automatic LCD Heat
To improve the performance of the LCD panel in cold weather, the LCD panel
control module is equipped with an LCD heater. The heater draws power from the
panel control module and is active only when the panel control module is powered.
An optional thermostat (a) can be installed if the machine is to be used in extremely
cold weather. The thermostat automatically powers the panel control module when
the temperature drops to approximately -30°C (-22° F). This activates the heater to
prevent damage to the LCD panel.
a
wc_gr010554
It is important to note that the panel control module draws a small amount of power
from the battery when turned on—even when the machine is not running. If the
battery should fail, the heater will also fail. Be sure to keep the battery charged
when the generator is not in use.
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Mobile Generator
15.8
Factory-Installed Options
Low Coolant Shutdown
Description
The low-coolant shutdown system consists of an electronic sensor that monitors
coolant level. The sensor (a) is mounted to the radiator and wired into the ECM.
The sensor probe (b) is submerged in radiator coolant.
Function
If the probe senses no coolant, it sends a signal to the ECM. The ECM program
includes a 10-second timer to protect from nuisance shutdowns. If after the ten
seconds coolant levels are still sensed as being low, the ECM shuts down the
engine. The ECM will then display “LOW COOL LEVEL”. Allow the engine to cool
before adding additional coolant.
WARNING
Burn hazard. Pressurized coolant is very hot and can cause serious burns.
► Do not remove the radiator cap while the engine is hot.
If it is necessary to open the radiator, only do so with the engine off, and only when
coolant is cool enough to touch with bare hands. Slowly loosen the radiator cap to
relieve pressure first, before removing it completely.
Note: The sensor may be disabled by unplugging the wire harness. This action will
not shut down the machine.
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147
Factory-Installed Options
15.9
Mobile Generator
Temperature-Activated Shutters
The shutters (a) are mounted to the top of the generator enclosure.
The shutters are designed to keep the engine compartment warm, thus increasing
engine temperature during cold weather operation. The shutters are activated
through a wax-pellet actuator (b) that is connected to the generator's cooling
system. As radiator coolant warms, the wax-pellet actuator engages a linkage (c)
that opens the shutters. As the coolant cools, the shutters close.
148
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Mobile Generator
Factory-Installed Options
15.10 Positive Air Shutoff Valve
Description
Diesel engines may occasionally continue to run even after the machine has been
turned off. This “runaway” condition occurs when combustible intake air is drawn
into the engine. Pressing the emergency stop switch alone will not stop a runaway
engine.
Some models include a positive air shutoff valve (a). Activating the positive air
shutoff valve blocks the flow of air into the engine intake and stops the engine from
running.
a
b
wc_gr010205
Operation
To activate the positive air shutoff valve, pull the T-handle (b) located next to the
voltage selector switch. The valve will reset automatically after activation.
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149
Factory-Installed Options
Mobile Generator
15.11 Quick-Disconnect Fuel Fittings
Quick-disconnect fuel fittings allow an external fuel supply to be connected to the
engine.
Requirements
■ Engine stopped and cool to the touch
■ Fuel supply and return hoses with compatible quick-disconnect fittings
Note: Required fitting size is ISO 7241-1-Series B (3/8 in.)
Procedure
Perform the following procedure to connect the external fuel supply.
1. Feed the external supply hose (b) and the external return hose (c) through the
access port (a) on the curb side of the machine.
e
a
d
c
b
wc_gr009257
2. Disconnect the internal feed hose (d) at the tank fitting, and connect the internal
feed hose to the external supply hose.
3. Disconnect the internal return hose (e) from the tank fitting, and connect it to the
external return hose (c).
Result
The external fuel supply is now connected.
WARNING
Fire hazard. Improper connections or damaged hoses may leak flammable fuel.
► Ensure that all quick-disconnect fittings are properly seated before operating
the machine.
► Make sure that fuel hoses are not kinked. Ensure that the hoses will not touch
or rest upon hot surfaces while the machine is operating.
150
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Mobile Generator
Factory-Installed Options
15.12 Lube Level Maintainer
Description
The lube level maintainer system protects the engine from low oil levels by
providing an additional 6-quart oil reservoir. Oil from the reservoir is gravity-fed
from the oil reservoir (a) through the control valve (b) and into the engine oil pan as
needed.
The valve includes a sightglass (c) through which the oil level can be seen. This oil
level is the same as that measured by the engine dipstick. A float inside the valve
detects low oil levels and opens the valve to supply the needed oil. The system is
wired to the ECM and includes a low oil shutdown in case the oil in the reservoir is
depleted.
Operation
If the engine shuts down due to low oil, the ECM will display “LOW OIL LEVEL”. Fill
the engine and the additional oil reservoir with oil before placing the generator back
into service.
NOTICE: To prevent overfilling the engine with oil, place the shutoff valve (d) in the
closed position when moving or towing the generator. Once the generator is in
position, open the valve.
wc_tx003612gb_FM10.fm
151
General Maintenance
Mobile Generator
16 General Maintenance
WARNING
A poorly maintained machine can malfunction, causing injuries or permanent
damage to the machine.
► Keep the machine in safe operating condition by performing periodic maintenance and making repairs as needed.
16.1
Periodic Maintenance Schedule
The table below lists basic machine maintenance. Tasks designated with check
marks may be performed by the operator. Tasks designated with square bullet
points require special training and equipment.
Daily
Conduct visual walk-around inspection.

Check exhaust system.

50
hours
or 2
weeks
250
hours
Other

Drain containment system.
Service the battery.

Clean the machine inside and out.


Grease axle.

Check brake fluid level in trailer at least monthly.
16.2
600
hours
or 12
months
Maintaining the Emission Control System
For machines sold in North America:
Normal maintenance, replacement, or repair of emission control devices and
systems may be performed by any repair establishment or individual; however,
warranty repairs must be performed by a dealer/service center authorized by
Wacker Neuson. The use of service parts that are not equivalent in performance
and durability to authorized parts may impair the effectiveness of the emission
control system and may have a bearing on the outcome of a warranty claim.
152
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Mobile Generator
16.3
General Maintenance
Preparing for Maintenance
Do not perform even routine service (oil/filter changes, cleaning, etc.) unless all
electrical components are shut down. Use the checklist below to prepare this
machine for maintenance.
 Move the start switch to “OFF”.
 Open the circuit breakers (move to the “OFF” position).
 Close the emergency stop switch (push in).
 Disconnect the negative terminal on the battery.
 Attach a “DO NOT START” sign to the control panel.
 If the unit is connected to a remote start or transfer switch, make sure the
remote switch is also off and tagged.
16.4
Cleaning the Machine
When
As needed
Suggested
cleaning
materials
■
■
■
■
Compressed air
Clean water supply
Mild detergent
Clean, dry cloths
NOTICE: Do not use a pressure washer to clean this machine. Pressurized water
can severely damage the generator and sensitive electronic components.
Cleaning the
interior
Clean the interior of the machine.
 Check the fluid level in the containment skid (if equipped) and drain if necessary.
See “Checking / Draining the Containment Skid.”
 Remove rags, containers, or other debris from the cabinet. Nothing should be
stored inside the machine.
 Remove leaves and twigs from the exhaust compartment.
 Wipe interior surfaces clean of oil, dust, and dirt.
Cleaning the
exterior
Clean the exterior of the machine with clean water and a mild detergent.
wc_tx003614gb_FM10.fm
153
General Maintenance
16.5
Mobile Generator
Inspecting the Machine
When
Daily
Overview
Inspect the machine before each use. A thorough inspection will help to identify
mechanical faults or potentially unsafe operating conditions. Correct these
problems before operating the machine.
External
inspection
Perform an external inspection of the machine. Check for:
 External damage (dents, cracks, broken door latches, etc.)
 Loose or missing fasteners
 Loose or missing parts
 Fluid leaks
 Restricted air flow in the exhaust compartment
 Problems with the trailer—refer to topic Maintaining the Trailer
Internal
inspection
Open the access doors on both sides of the machine. Check for:
 Damage to control panel, switches, or customer connections
 Loose or missing fasteners
 Loose or missing parts
 Loose or damaged hoses
 Fluid leaks
 Rags, containers, or other debris inside the cabinet
154
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Mobile Generator
16.6
General Maintenance
Maintaining the Trailer
Tires
■ Keep tires inflated to the proper pressure as shown on the tire sidewall.
■ Check tread periodically for wear.
■ Replace tires as required.
Wheels
■ Check that lug nuts holding wheels are tight.
■ Replace any missing lug nuts immediately.
Axle Hubs
■ Grease axle hubs using a good wheel-bearing grease.
Brakes
■ Check operation of brakes before each trip.
■ Check level of brake fluid in actuator at front of trailer at regular intervals.
■ Fill brake fluid to approximately 1 inch below top of reservoir using DOT-3
heavy-duty brake fluid.
■ Tighten filler plug securely.
Note: If fluid level has fallen too low, bleed brake lines to remove any air trapped in
lines. Then fill to proper level with clean brake fluid.
wc_tx003614gb_FM10.fm
155
General Maintenance
16.7
Mobile Generator
Checking and Draining the Containment System
When
Daily
Overview
Certain machines are equipped with a containment system. The containment
system protects the environment by collecting fluid leaks (fuel, coolant, or oil)
which might otherwise contaminate the soil.
NOTICE: It is important to check the containment system daily. A large amount of
fluid collected in a 24-hour period indicates a significant leak.
Requirements
■ Machine stopped and engine is cool to the touch
■ Machine is on a level surface
■ Plastic cloth and a container of sufficient volume to collect drained fluid
Note: Collect, store, and dispose of drained fluid in accordance with current
environmental protection regulations.
Procedure
Perform the procedure below to check and drain the containment system.
1. Open an access door on either side of the machine. The containment system
(a) surrounds the fuel tank (b).
b
a
c
wc_gr009227
2. Check the fluid level in the containment system.
3. If fluid has accumulated, drain the containment system.
a. Place a plastic cloth and a collection container beneath the machine.
b. Remove the drain plug (c) and gasket. Drain accumulated fluid into a suitable
container.
c. Inspect the gasket and replace if necessary.
d. Re-install the drain plug and gasket.
Result
The containment system has now been checked and drained.
156
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16.8
General Maintenance
Checking the Exhaust System
When
Check the exhaust system daily before operating the machine.
Background
A leaky exhaust system will adversely affect machine operation. Symptoms include
increased noise, visible soot deposits, and carbon monoxide emission. Leaking
exhaust can also ignite surrounding materials and pipe insulation, causing a fire.
DANGER
Asphyxiation hazard. A leaky exhaust system emits carbon monoxide. This is a
poison that you cannot see or smell.
► Do not operate the machine until exhaust leaks have been repaired.
Requirements
■ Engine is stopped
■ Exhaust pipes and muffler are cool to the touch
Procedure
Perform the following procedure to check the exhaust system.
1. Open the access door on the curb side of the machine.
a
a
b
a
wc_gr009917
2.




Inspect the exhaust pipes (a) and muffler (b), looking for:
Cracks or holes
Burned or missing insulation
Loose or missing clamps
Black soot deposits, especially around welds and joints
3.




Start the engine. Listen carefully for:
Excessive noise
Rumbling
High-pitched whine
Rattling
Repair or replace faulty components before putting the machine back into service.
Result
The exhaust system has now been checked.
wc_tx003614gb_FM10.fm
157
General Maintenance
16.9
Mobile Generator
Maintaining the Battery
WARNING
Explosion hazard. Batteries can emit explosive hydrogen gas.
► Keep all sparks and flames away from the battery.
► Do not short-circuit battery posts.
Safety
precautions
Observe the following safety precautions to prevent serious damage to the
electrical system.
■ Do not disconnect the battery while the machine is running.
■ Do not attempt to run the machine without a battery.
■ Do not attempt to jump-start the machine.
■ In the event that the machine has a discharged battery, either replace the
battery with a fully charged battery or charge the battery using an appropriate
battery charger.
■ Dispose of waste batteries in accordance with local environmental regulations.
Battery
connections
To connect the battery:
1. Connect the red positive (+) battery cable to the battery.
2. Connect the black negative (-) battery cable to the battery.
To disconnect the battery:
1. Stop the engine.
2. Place all electrical switches in the OFF position.
3. Disconnect the black negative (-) battery cable from the battery.
4. Disconnect the red positive (+) battery cable from the battery.
Maintaining
battery
condition
■ Follow the battery manufacturer’s maintenance recommendations.
■ Keep battery terminals clean and connections tight.
■ When necessary, tighten the cables and grease the cable clamps with
petroleum jelly.
■ Maintain the battery at full charge to improve cold weather starting.
158
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Mobile Generator
General Maintenance
16.10 Cleaning the Diesel Particulate Filter (DPF) (if equipped)
Overview
Sustained operation of the generator under load heats the DPF to a temperature
high enough to burn accumulated soot. This cleaning process (passive
regeneration) normally occurs automatically.
Soot may fill the DPF (a) when the engine runs at idle for long periods with no load.
An indicator (b) on the control panel illuminates when the DPF is full of soot. The
operator must then either increase the load on the engine, or perform a manual
regeneration to clean the DPF.
a
b
V
c
Ø
wc_gr009226
WARNING
Burn hazard. The engine, DPF and exhaust pipe become very hot during operation.
► Do not touch the engine, DPF, or exhaust pipe while the machine is operating.
Wait for these components to cool before touching them.
Manual
regeneration
If the DPF indicator illuminates, follow the steps below to perform an manual
regeneration.
1. Start the engine at low idle speed.
2. Move the manual regeneration switch (c) to the “on” position and hold it for five
seconds. The DPF indicator will go out and the regeneration process will begin.
3. Release the switch.
The engine speed will gradually increase to about 1000 rpm while the machine is in
regeneration mode. When regeneration is complete, the engine speed will return to
low idle (about 750 rpm).
Note: The regeneration process may continue for up to one hour depending on
ambient conditions and the amount of soot inside the DPF.
NOTICE: The DPF may be permanently damaged if the machine continues to
operate with accumulated soot inside the DPF. Perform a manual regeneration as
soon as possible after the indicator illuminates.
wc_tx003614gb_FM10.fm
159
General Maintenance
Mobile Generator
16.11 Storage
Introduction
Extended storage of equipment requires preventive maintenance. Performing
these steps helps to preserve machine components and ensures the machine will
be ready for future use. While not all of these steps necessarily apply to this
machine, the basic procedures remain the same.
When
Prepare your machine for extended storage if it will not be operated for 30 days or
more.
Preparing for
storage
Follow the procedures below to prepare your machine for storage.
■ Complete any needed repairs.
■ Replenish or change oils (engine, exciter, hydraulic, and gearcase) per the
intervals specified in the Scheduled Maintenance table.
■ Grease all fittings and, if applicable, repack bearings.
■ Inspect engine coolant. Replace coolant if it appears cloudy, is more than two
seasons old, or does not meet the average lowest temperature for your area.
■ If your machine has an engine equipped with a fuel valve, start the engine, close
the fuel valve, and run the engine until it stops.
■ Consult the engine owner’s manual for instructions on preparing the engine for
storage.
Stabilizing the
fuel
After completing the procedures listed above, fill the fuel tank completely and add a
high-quality stabilizer to the fuel.
■ Choose a stabilizer that includes cleaning agents and additives designed to
coat/protect the cylinder walls.
■ Make sure the stabilizer you use is compatible with the fuel in your area, fuel
type, grade and temperature range. Do not add extra alcohol to fuels which
already contain it (for example, E10).
■ For engines with diesel fuel, use a stabilizer with a biocide to restrict or prevent
bacteria and fungus growth.
■ Add the correct amount of stabilizer per the manufacturer’s recommendations.
Storing the
machine
Perform these remaining steps to store your machine.
■ Wash the machine and allow it to dry.
■ Move the machine to a clean, dry, secure storage location. Block or chock
wheels to prevent machine movement.
■ Use touch-up paint as needed to protect exposed metal against rust.
■ If the machine has a battery, either remove or disconnect it.
NOTICE: Allowing the battery to freeze or completely discharge is likely to cause
permanent damage. Periodically charge the battery while the machine is not in
use. In cold climates, store and charge the battery indoors or in a warm location.
■ Cover the machine. Tires and other exposed rubber items should be protected
from the weather. Either cover them or use a readily available protectant.
160
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Mobile Generator
General Maintenance
16.12 Machine Disposal / Decommissioning
Introduction
This machine must be properly decommissioned at the end of its service life.
Responsible disposal of recyclable components, such as plastic and metal,
ensures that these materials can be reused—conserving landfill space and
valuable natural resources.
Responsible disposal also prevents toxic chemicals and materials from harming
the environment. The operating fluids in this machine, including fuel, engine oil,
and grease, may be considered hazardous waste in many areas. Before
decommissioning this machine, read and follow local safety and environmental
regulations pertaining to the disposal of construction equipment.
Preparation
Perform the following tasks to prepare the machine for disposal.
 Move the machine to a protected location where it will not pose any safety
hazards and cannot be accessed by unauthorized individuals.
 Ensure that the machine cannot be operated from the time of final shutdown to
disposal.
 Drain all fluids, including fuel, engine oil, and coolant.
 Seal any fluid leaks.
Disposal
Perform the following tasks to dispose of the machine.
 Disassemble the machine and separate all parts by material type.
 Dispose of recyclable parts as specified by local regulations.
 Dispose of all non-hazardous components that cannot be recycled.
 Dispose of waste fuel, oil, and grease in accordance with local environmental
protection regulations.
wc_tx003614gb_FM10.fm
161
Engine Maintenance: T3 John Deere 4045TF280/290
17 Engine Maintenance: T3 John Deere 4045TF280/290
The viscosity of the engine oil is an important factor when determining the correct
engine oil to use in your machine. Use an engine oil of appropriate viscosity based
on the expected outside air temperature. See the table below.
WARNING
Most used liquids from this machine such as oil, gasoline, grease, etc., contain
small amounts of materials that can cause cancer and other health problems if
inhaled, ingested, or left in contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.
162
wc_tx003664gb_FM10.fm
Engine Maintenance: T3 John Deere 4045TF280/290
770019
wc_tx003664gb_FM10.fm
163
Engine Maintenance: T3 John Deere 4045TF280/290
The engine maintenance schedule(s) in this chapter are reproduced from the
engine owner’s manual. For additional information, see the engine owner’s
manual.
770018
164
wc_tx003664gb_FM10.fm
Engine Maintenance: T4i John Deere 4045TF290
18 Engine Maintenance: T4i John Deere 4045TF290
The viscosity of the engine oil is an important factor when determining the correct
engine oil to use in your machine. Use an engine oil of appropriate viscosity based
on the expected outside air temperature. See the table below.
WARNING
Most used liquids from this machine such as oil, gasoline, grease, etc., contain
small amounts of materials that can cause cancer and other health problems if
inhaled, ingested, or left in contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.
wc_tx003665gb_FM10.fm
165
Engine Maintenance: T4i John Deere 4045TF290
770019
166
wc_tx003665gb_FM10.fm
Engine Maintenance: T4i John Deere 4045TF290
The engine maintenance schedule(s) in this chapter are reproduced from the
engine owner’s manual. For additional information, see the engine owner’s
manual.
770018
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167
Engine Maintenance: T4i Cummins QSB6.7
19 Engine Maintenance: T4i Cummins QSB6.7
The viscosity of the engine oil is an important factor when determining the correct
engine oil to use in your machine. Use an engine oil of appropriate viscosity based
on the expected outside air temperature. See the table below.
WARNING
Most used liquids from this machine such as oil, gasoline, grease, etc., contain
small amounts of materials that can cause cancer and other health problems if
inhaled, ingested, or left in contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.
168
wc_tx003663gb_FM10.fm
Engine Maintenance: T4i Cummins QSB6.7
Oil Viscosity
The primary Cummins Inc. recommendation is for the use of 15W-40 multigrade.
lubricating oil for normal operation at ambient temperatures above -15°C [5°F]. The use
of multigrade oil reduces deposit formation, improves engine cranking in low
temperature conditions, and increases engine durability by maintaining lubrication
during high temperature operating conditions. Since multigrade oils have been shown
to provide approximately 30 percent lower oil consumption than monograde oils, it is
important to use multigrade oils, to be certain the engine will meet applicable emissions
requirements.
Use of "synthetic engine oils" (those made with API group 3 or group 4 base stocks) is
permitted, subject to the same performance and viscosity limitations of petroleum
(mineral) based engine oils. The same oil change intervals that are applied to
petroleum (mineral) based engine oils must be applied to synthetic oils.
For further details and discussion of engine lubrication oils for Cummins® engines,
refer to the latest revision of Cummins® Engine Oil Recommendation, Bulletin
3810340.
While the preferred viscosity grade is 15W-40, lower viscosity multigrade oils can be
used in colder climates. See the accompanying chart. Any viscosity grade lower than
15W-40 must still meet CES 20081.
Synthetic engine oils, API Group III and Group IV basestocks, are recommended for
use in Cummins® engines operation in ambient temperature conditions consistently
below -25°C [-13°F]. Synthetic 0W-30 oils that meet the requirements of API Group III
or Group IV basestocks, can be used in operations where the ambient temperature
never exceeds 0°C [32°F]. Multi viscosity oils rated 0W-30 do not offer the same level
of protection against fuel dilution as do higher multigrade oils. Higher cylinder wear can
be experienced when using 0W-30 oils in high-load situations.
As these oils have directionally thinner oil films than 15W-40 oils, top-quality
Fleetguard® filters must be used above 20°C [70°F]. Some oil suppliers might claim
better fuel economy for these oils. Cummins Inc. can neither approve nor disapprove
any product not manufactured by Cummins Inc. These claims are between the
customer and the oil supplier. Obtain a commitment from the oil supplier that the oil will
give satisfactory performance in Cummins® engines, or do not use the oil.
770035
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169
Engine Maintenance: T4i Cummins QSB6.7
The engine maintenance schedule(s) in this chapter are reproduced from the
engine owner’s manual. For additional information, see the engine owner’s
manual.
770015
170
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Engine Maintenance: T4i Cummins QSB6.7
770016
wc_tx003663gb_FM10.fm
171
Maintenance Tier 4f Engines: Isuzu
20 Maintenance Tier 4f Engines: Isuzu
The viscosity of the engine oil is an important factor when determining the correct
engine oil to use in your machine. Use an engine oil of appropriate viscosity based
on the expected outside air temperature. See the table below.
WARNING
Most used liquids from this machine such as oil, gasoline, grease, etc., contain
small amounts of materials that can cause cancer and other health problems if
inhaled, ingested, or left in contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.
-30°C
(-22°F)
-15°C
(5°F)
30°C
(86°F)
SAE 10W-30
SAE 10W-40
SAE 15W-40
wc_gr011764
172
wc_tx003642gb_FM10.fm
Maintenance Tier 4f Engines: Isuzu
The engine maintenance schedule(s) in this chapter are reproduced from the
engine owner’s manual. For additional information, see the engine owner’s
manual.
770001
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173
Maintenance Tier 4f Engines: Isuzu
770006
174
wc_tx003642gb_FM10.fm
Maintenance Tier 4f Engines: Isuzu
770007
wc_tx003642gb_FM10.fm
175
Maintenance Tier 4f Engines: Isuzu
770008
770009
176
wc_tx003642gb_FM10.fm
Maintenance Tier 4f Engines: Isuzu
770010
wc_tx003642gb_FM10.fm
177
Troubleshooting
Mobile Generators
21 Troubleshooting
Problem
Cause
Remedy
Engine doesn’t start
Battery discharged
Battery connections
corroded
Blown fuse
Defective starter
Charge battery.
Clean battery connections.
No fuel
Clogged fuel filter
Fuel circuit failure
Fill tank with fuel.
Bleed fuel lines.
Replace fuel filter.
Check fuel lines.
No generator output
Main circuit breaker open
Lug door open
Close main circuit breaker.
Close lug door.
Low oil pressure
Low oil level
Clogged oil filter
Fill engine sump with oil.
Replace oil filter.
High coolant temperature
Overload
Low coolant level
Low oil level
Clogged oil filter
Reduce load.
Fill with coolant.
Fill sump with oil.
Replace oil filter.
Engine emits black smoke
Clogged air filter
Clean/replace air filter
cartridges.
Reduce load.
Remove excess oil.
Engine tries to start but
stops
Overload
High oil level
178
Replace fuse.
Replace starter.
wc_tx001197gb_FM10.fm
Mobile Generator
Technical Data: G 50, T4i John Deere
22 Technical Data: G 50, T4i John Deere
22.1
Engine
Engine Power Rating
Gross standby power rating per ISO 8528-1 and SAE J1995. Actual power output
may vary due to conditions of specific use.
Item Number:
G 50
5200001060
G 50
5200001061
5200001062
G 50 ERT
5200001063
Engine
Engine make
John Deere
Model
4045TF290
Emissions
Tier IVi
Number of cylinders
4
Displacement
4.5 (275)
L (in3)
Operating speed
rpm
Rated standby power @ 1800 rpm
1800
kW (hp)
55 (74)
Coolant capacity
L (qt)
18.9 (20)
Oil capacity
L (qt)
15 (15.9)
Battery
Volts/CCa
Fuel type
12/750
12/950
12/750
#2 ultra low sulfur diesel **
Fuel tank capacity
L (gal)
Fuel consumption, prime load
318 (84)
L/hr (gph)
1195 (315.6)
12.9 (3.4)
Run time at 100% prime load *
hr
21.6
89.7
Run time at 75% prime load *
hr
27.2
113.1
Run time at 50% prime load *
hr
38.4
159.5
Run time at 25% prime load *
hr
64.5
268.2
* Run times are based on useable fuel volume, not on fuel tank capacity. “Useable fuel volume”
does not include fuel remaining in the tank after a low fuel shutdown.
See “Refueling the Machine” for more information.
** For operation in freezing temperatures, winterized fuel should be used. See the engine
owner’s manual.
wc_td000462gb_FM10.fm
179
Technical Data: G 50, T4i John Deere
22.2
Mobile Generator
Generator
G 50
Model:
G 50 ERT
Generator
Make/Type
Mecc Alte / Brushless / 4 pole
Model
Prime rating
ECO32-1L/4
3Ø: 60
1Ø: 34
kVA
Voltage selector switch
3 position
AC voltages available
120/240 1Ø zig-zag
120, 127, 139, 240, 254, 277
120/208 3Ø low-wye
277/480 3Ø hi-wye
208, 220, 240, 416, 440, 460, 480
Frequency
Hz
60
Power factor
1ø
3ø
1.0
0.8
Voltage regulation
±1.00%
Insulation class
H
180
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Mobile Generator
22.3
Technical Data: G 50, T4i John Deere
Machine
G 50
Model:
G 50 ERT
Machine
Sound level at 7 m (23 ft.)
67
dB(A)
AC receptacles
(2) 120V, 20A, GFI duplex
(3) 120/240V, 50A twist-lock
Standby Output
kW/
kVA
43/54
Prime Output
kW/
kVA
39/49
Main breaker
Amps
22.4
175
Trailer and Skid
G 50
Standard
G 50
Custom &
Cold Weather
G 50 ERT
MGT 2
MGT 2
MGT 3.1
Trailer and Skid
Trailer model
Dry weight of skid
kg (lbs.)
1442 (3178)
1482 (3268)
1746 (3849)
Operating weight of skid
kg (lbs.)
1716 (3783)
1757 (3873)
2776 (6121)
Trailer weight
kg (lbs.)
Operating weight on trailer
kg (lbs.)
Surge brakes
Tires
wc_td000462gb_FM10.fm
399 (880)
2115 (4663)
Fluid type
621 (1370)
2156 (4753)
3398 (7491)
DOT3
size
ST225/75D-15
181
7.5 x 16E
Technical Data: G 50, T4i John Deere
22.5
Mobile Generator
Dimensions
mm (in.)
E
A
F
B
D
C
wc_gr006389
Machine
A
B
C
D
E
F
G
G 50 Skid
965
(38)
—
—
—
2445
(96.25)
1346
(53)
1476
(58.1)
—
2032
(80)
1715
(67.5)
4064
(160)
—
—
—
G 50 ERT
Skid
1156
(45.5)
—
—
—
2794
(110)
1816
(71.5)
1946
(76.6)
G 50 ERT
Trailer
—
2464
(97)
2032
(80)
4470
(176)
—
—
—
G 50 Trailer
G
182
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Mobile Generator
Technical Data: G 50, T4f Isuzu
23 Technical Data: G 50, T4f Isuzu
23.1
Engine
Engine Power Rating
Net standby power rating per ISO 8528-1 and SAE J1349. Actual power output
may vary due to conditions of specific use.
G 50
5200014319
Item Number:
G 50
5200014320
5200014322
G 50 ERT
5200014223
Engine
Engine make
Isuzu
Model
4LE2X
Emissions
Tier IV
Number of cylinders
Displacement
Operating speed
Rated standby power @ 1800 rpm
4
2.18 (133)
L (in3)
rpm
1800
kW (hp)
49 (66)
Coolant capacity
L (qt)
15.1 (16)
Oil capacity
L (qt)
10.4 (11)
Battery
Volts/ccA
Fuel type
Fuel tank capacity
Fuel consumption, prime load
Run time at 100% prime load *
12/750
12/950
12/750
#2 ultra low sulfur diesel **
L (gal)
318 (84)
L/hr (gph)
hr
1195 (315.6)
12.6 (3.3)
22.1
91.8
* Run times are based on useable fuel volume, not on fuel tank capacity. “Useable fuel volume” does not include fuel remaining in the tank after a low fuel shutdown.
See “Refueling the Machine” for more information.
** For operation in freezing temperatures, winterized fuel should be used. See the engine owner’s manual.
wc_td000617gb_FM10.fm
183
Technical Data: G 50, T4f Isuzu
23.2
Mobile Generator
Generator
G 50
Model:
G 50 ERT
Generator
Make/Type
Mecc Alte / Brushless / 4 pole
Model
Prime rating
ECO32-1L/4
3Ø: 60
1Ø: 34
kVA
Voltage selector switch
3 position
AC voltages available
120/240 1Ø zig-zag
120, 127, 139, 240, 254, 277
120/208 3Ø low-wye
277/480 3Ø hi-wye
208, 220, 240, 416, 440, 460, 480
Frequency
Hz
60
Power factor
1ø
3ø
1.0
0.8
Voltage regulation
±1.00%
Insulation class
H
184
wc_td000617gb_FM10.fm
Mobile Generator
23.3
Technical Data: G 50, T4f Isuzu
Machine
Model:
G 50
G 50 ERT
Machine
Sound level at 7 m (23 ft.)
dB(A)
AC receptacles
23.4
68
(2) 120V, 20A, GFI duplex
(3) 120/240V, 50A twist-lock
Standby Output
kW/
kVA
42/53
Prime Output
kW/
kVA
38/48
Main breaker
Amps
175
Trailer and Skid
G 50
Standard
G 50
Custom &
Cold Weather
G 50 ERT
MGT 2
MGT 2
MGT 3.1
Trailer and Skid
Trailer model
Dry weight of skid
kg (lbs.)
1262 (2783)
1303 (2873)
1566 (3454)
Operating weight of skid
kg (lbs.)
1537 (3388)
1578 (3478)
2597 (5726)
Trailer weight
kg (lbs.)
Operating weight on trailer
kg (lbs.)
Surge brakes
Tires
wc_td000617gb_FM10.fm
399 (880)
1936 (4268)
Fluid type
621 (1370)
1977 (4359)
3218 (7094)
DOT3
size
ST225/75D-15
185
7.5 x 16E
Technical Data: G 50, T4f Isuzu
23.5
Mobile Generator
Dimensions
mm (in.)
E
A
F
B
D
C
wc_gr006389
Machine
A
B
C
D
E
F
G
G 50 Skid
965
(38)
—
—
—
2445
(96.25)
1346
(53)
1476
(58.1)
—
2032
(80)
1715
(67.5)
4064
(160)
—
—
—
G 50 ERT
Skid
1156
(45.5)
—
—
—
2794
(110)
1816
(71.5)
1946
(76.6)
G 50 ERT
Trailer
—
2464
(97)
2032
(80)
4470
(176)
—
—
—
G 50 Trailer
G
186
wc_td000617gb_FM10.fm
Mobile Generator
Technical Data: G 70, T3 John Deere, 600V
24 Technical Data: G 70, T3 John Deere, 600V
Engine Power Rating
Gross standby power rating per ISO 8528-1 and SAE J1995. Actual power output
may vary due to conditions of specific use.
24.1
Engine
Machine
G 70
5200014463
Engine
Engine make
John Deere
Model
4045TF285
Emissions
Tier 3
Number of cylinders
4
L (in.3)
Displacement
Operating speed
rpm
Rated standby power @ 1800 rpm
kW (hp)
4.5 (275)
1800
74 (99)
Coolant capacity
L (qt)
18.9 (20)
Oil capacity
L (qt)
15 (15.9)
Battery
Volts/
CCa
12/750
Fuel type1
No. 2 diesel
Fuel tank capacity
L (gal)
318 (84)
Fuel consumption, prime load
L/hr
(gal/hr)
18.7 (4.9)
Run time at 100% prime load2
hr
15.3
Run time at 75% prime load2
hr
19.5
Run time at 50% prime load2
hr
28.4
Run time at 25% prime load2
hr
49.5
1
The use of #6 diesel fuel is not recommended.
times are based on useable fuel volume, not on fuel tank capacity. “Useable fuel volume”
does not include fuel remaining in the tank after a low fuel shutdown.
See “Refueling the Machine” for more information.
2Run
wc_td000583gb_Fm10.fm
187
Technical Data: G 70, T3 John Deere, 600V
24.2
Mobile Generator
Generator
Machine
G 70
Generator
Make/Type
Mecc Alte / Brushless / 4 pole
Model
ECO32-3L/4
Prime rating
kVA
3Ø: 78
1Ø: 39
Voltage selector switch
4 position
AC voltages available
120/240 1Ø zig-zag
120, 127, 139, 240, 254, 277
120/208 3Ø low-wye
277/480 3Ø hi-wye
208, 220, 240, 416, 440, 460, 480
3Ø zig-zag
600
Frequency
Hz
60
Power factor
1ø
3ø
1.0
0.8
Voltage regulation
±1.00%
Insulation class
24.3
H
Machine
Machine
G 70
Machine
Sound level at 7 m (23 ft.)
db(A)
AC receptacles
68
(2) 120V, 20A, GFI duplex
(3) 120/240V, 50A twist-lock
Standby Output
kW/
kVA
61.8/77.2
Prime Output
kW/
kVA
56.2/70.2
Main breaker
A
188
225
wc_td000583gb_Fm10.fm
Mobile Generator
24.4
Technical Data: G 70, T3 John Deere, 600V
Trailer
G 70 600V
5200014463
Trailer and Skid
Dry weight of skid
kg (lb)
1571 (3464)
Operating weight of skid
kg (lb)
1845 (4069)
Trailer weight
kg (lb)
399 (880)
Operating weight on trailer
kg (lb)
2244 (4949)
Surge brakes
Fluid type
Tires
wc_td000583gb_Fm10.fm
size
189
DOT3
ST205/75D-15C
Technical Data: G 70, T3 John Deere, 600V
24.5
Mobile Generator
Dimensions
E
A
G
F
B
D
C
wc_gr006389
mm (in.)
Machine
A
B
C
D
E
F
G
G 70 Skid
0620646
965 (38)
—
—
—
2445
(96.25)
1346 (53)
1475 (58)
G 70 Trailer
0620646
—
2032 (80)
1715
(67.5)
4064
(160)
—
—
—
G 70 Skid
0620647
0620648
965 (38)
—
—
—
2445
(96.25)
1435
(56.5)
1476
(58.1)
G 70 Trailer
0620647
0620648
5200001318
—
2032 (80)
1715
(67.5)
4064
(160)
—
—
—
G 70 ERT Skid
0620711
1156
(45.5)
—
—
—
2794
(110)
1816
(71.5)
1943
(76.5)
G 70 ERT Trailer
0620711
—
2464 (97)
2032 (80)
4470
(176)
—
—
—
190
wc_td000583gb_Fm10.fm
Mobile Generator
Technical Data: G 70, T4i Cummins
25 Technical Data: G 70, T4i Cummins
25.1
Engine
Engine Power Rating
Net power rating per ISO 3046. Actual power output may vary due to conditions of
specific use.
G 70
Standard
Machine:
G 70
CW / custom
G 70
ERT
Engine
Engine make
Cummins
Model
QSB5-G7
Emissions
Tier 4i
Number of cylinders
4
l (in3)
Displacement
Operating speed
4.5 (272)
rpm
Rated standby power @ 1800 rpm
1800
kW (Hp)
86 (115)
Coolant capacity
l (qts.)
18 (19)
Oil capacity
l (qts.)
14.5 (15.3)
Volts/CCa
2 x 12 / 750
Battery
Fuel type1
No. 2 diesel
Ultra low sulfur fuel only
Fuel tank capacity
l (gal.)
318 (84)
1195 (315.6)
Fuel consumption, prime load
l/hr (gal./hr)
Run time at 100% prime load2
Hours
15.8
65.7
Run time at 75% prime load2
Hours
19.4
80.8
Run time at 50% prime load2
Hours
25.1
104.3
Run time at 25% prime load2
Hours
35.1
145.9
1The
17.4 (4.6)
use of #6 diesel fuel is not recommended.
times are based on useable fuel volume, not on fuel tank capacity. “Useable fuel volume”
does not include fuel remaining in the tank after a low fuel shutdown.
See “Refueling the Machine” for more information.
2Run
wc_td000558gb_FM10.fm
191
Technical Data: G 70, T4i Cummins
25.2
Mobile Generator
Generator
Machine
G 70
G 70 ERT
Generator
Make/Type
Mecc Alte / Brushless / 4 pole
Model
ECO32-3L/4
Prime rating
kVA
3Ø: 84
1Ø: 46
Voltage selector switch
3 position
AC voltages available
120/240 1Ø zig-zag
120, 127, 139, 240, 254, 277
120/208 3Ø low-wye
277/480 3Ø hi-wye
208, 220, 240, 416, 440, 460, 480
Frequency
Hz
60
Power factor
1ø
3ø
1.0
0.8
Voltage regulation
±1.00%
Insulation class
25.3
H
Machine
Machine
G 70
G 70 ERT
Machine
Sound level at 7 m (23 ft.)
db(A)
AC receptacles
68
(2) 120V, 20A, GFI duplex
(2) 120/240V, 50A twist-lock
(1) 120/240V, 30A twist-lock
Standby Output
kW/
kVA
63/79
Prime Output
kW/
kVA
58/72
Main breaker
A
192
225
wc_td000558gb_FM10.fm
Mobile Generator
25.4
Technical Data: G 70, T4i Cummins
Trailer and Skid
G 70
Standard
G 70
CW / Custom
G 70
ERT
Trailer and Skid
Dry weight of skid
kg (lbs.)
1592 (3510)
1633 (3600)
1893 (4174)
Operating weight of skid
kg (lbs.)
1866 (4115)
1907 (4205)
2167 (4779)
Trailer weight
kg (lbs.)
Operating weight on trailer
kg (lbs.)
Surge brakes
Tires
wc_td000558gb_FM10.fm
Fluid type
size
193
399 (880)
2265 (4995)
2306 (5085)
DOT3
ST205/75D-15C
621 (1370)
2799 (6149)
Technical Data: G 70, T4i Cummins
25.5
Mobile Generator
Dimensions
E
A
F
B
G
D
C
wc_gr006389
mm (in.)
Machine
A
B
C
D
E
F
G
G 70 Skid
965 (38)
—
—
—
2445
(96.25)
1346
(53)
1475
(58)
G 70 Trailer
—
2032
(80)
1715
(67.5)
4064
(160)
—
—
—
G 70 Skid
965 (38)
—
—
—
2445
(96.25)
1435
(56.5)
1476
(58.1)
G 70 Trailer
—
2032
(80)
1715
(67.5)
4064
(160)
—
—
—
G 70 ERT Skid
1156
(45.5)
—
—
—
2794
(110)
1816
(71.5)
1943
(76.5)
G 70 ERT Trailer
—
2464
(97)
2032
(80)
4470
(176)
—
—
—
194
wc_td000558gb_FM10.fm
Tire Safety Information
Tire Safety Information
Introduction to Tire Safety Information
Federal Regulation 49 CFR 575 requires trailer manufacturers to include certain
tire information in the owner’s manuals for the trailers they manufacture. This
regulation requires that the information be in the English language. This chapter
includes all the information required by Federal Regulation 49 CFR 575.
wc_tx003108gb_FM10.fm
195
Tire Safety Information
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196
wc_tx003108gb_FM10.fm
Tire Safety Information
Excessive loads and/or underinflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation
can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that
enables a tire to support the load, so proper inflation is critical. The proper air pressure may be found on the
certification/VIN label and/or on the Tire Placard. This value should never exceed the maximum cold inflation pressure
stamped on the tire.
1.1.1. TRAILERS 10,000 POUNDS GVWR OR LESS
Tire and Loading Information Placard – Figure 1-1
1. /RFDWHWKHVWDWHPHQW³7KHZHLJKWRIFDUJRVKRXOG QHYHUH[FHHG;;;NJRU;;;OEV´RQ\RXUYHKLFOH¶V
placard. See figure 1-1.
2. This figure equals the available amount of cargo and luggage load capacity.
3. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not
safely exceed the available cargo and luggage load capacity.
7KHWUDLOHU¶VSODFDUGUHIHUVWRWKH7LUH,QIRUPDWLRQ3ODFDUGattached DGMDFHQWWRRUQHDUWKHWUDLOHU¶V9,1
(Certification) label at the left front of the trailer.
1.1.2. TRAILERS OVER 10,000 POUNDS GVWR (NOTE: THESE TRAILERS ARE NOT REQUIRED TO HAVE A TIRE
INFORMATION PLACARD ON THE VEHICLE)
1. Determine the empty weight of your trailer by weighing the trailer using a public scale or other means.
This step does not have to be repeated.
2. Locate the *9:5*URVV9HKLFOH:HLJKW5DWLQJRIWKHWUDLOHURQ\RXUWUDLOHU¶V9,1&HUWLILFDWLRQODEHO
3. Subtract the empty weight of your trailer from the GVWR stated on the VIN label. That weight is the
maximum available cargo capacity of the trailer and may not be safely exceeded.
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\RXUYHKLFOH¶VSODFDUG
2. Determine the combined weight of the driver and passengers who will be riding in your vehicle.
3. Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds.
4. 7KHUHVXOWLQJILJXUHHTXDOVWKHDYDLODEOHDPRXQWRIFDUJRDQGOXJJDJHFDSDFLW\)RUH[DPSOHLIWKH³;;;´
amount equals 1400 lbs. and there will be five 150 lb. passengers in your vehicle, the amount of available
cargo and luggage capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).
5. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not
safely exceed the available cargo and luggage capacity calculated in Step # 4.
6. If your vehicle will be towing a trailer, load from your trailer will be transferred to your vehicle. Consult the
WRZYHKLFOH¶VPDQXDOWRGHWHUPLQHKRZWKLVZHLJKWWUDQVIHUUeduces the available cargo and luggage
capacity of your vehicle.
*/266$5< 2)7,5(7(50,12/2*<
$FFHVVRU\ZHLJKW
The combined weight (in excess of those standard items which may be replaced) of automatic transmission,
power steering, power brakes, power windows, power seats, radio and heater, to the extent that these items
are available as factory-installed equipment (whether installed or not).
wc_tx003108gb_FM10.fm
197
Tire Safety Information
Bead
The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the
rim.
Bead separation
This is the breakdown of the bond between components in the bead.
Bias ply tire
A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less
than 90 degrees to the centerline of the tread.
Carcass
The tire structure, except tread and sidewall rubber which, when inflated, bears the load.
Chunking
The breaking away of pieces of the tread or sidewall.
Cold inflation pressure
The pressure in the tire before you drive.
Cord
The strands forming the plies in the tire.
Cord separation
The parting of cords from adjacent rubber compounds.
Cracking
Any parting within the tread, sidewall, or inner liner of the tire extending to cord material.
CT
A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges
pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the
rim flanges inside the air cavity of the tire.
Curb weight
The weight of a motor vehicle with standard equipment including the maximum capacity of fuel, oil, and
coolant, and, if so equipped, air conditioning and additional weight optional engine.
Extra load tire
A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard
tire.
Groove
The space between two adjacent tread ribs.
Gross Axle Weight Rating
The maximum weight that any axle can support, as published on the Certification / VIN label on the front left
side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached
to the towing vehicle.
Gross Vehicle Weight Rating
The maximum weight of the fully loaded trailer, as published on the Certification / VIN label. Actual weight
determined by weighing trailer on a public scale, without being attached to the towing vehicle.
Hitch Weight
The downward force exerted on the hitch ball by the trailer coupler.
Innerliner
The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire.
Innerliner separation
The parting of the innerliner from cord material in the carcass.
198
wc_tx003108gb_FM10.fm
Tire Safety Information
Intended outboard sidewall
The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name
molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing
sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a
vehicle.
Light truck (LT) tire
A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose
passenger vehicles.
Load rating
The maximum load that a tire is rated to carry for a given inflation pressure.
Maximum load rating
The load rating for a tire at the maximum permissible inflation pressure for that tire.
Maximum permissible inflation pressure
The maximum cold inflation pressure to which a tire may be inflated.
Maximum loaded vehicle weight
The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight.
Measuring rim
The rim on which a tire is fitted for physical dimension requirements.
Pin Weight
th
The downward force applied to the 5 wheel or gooseneck ball, by the trailer kingpin or gooseneck coupler.
Non-pneumatic rim
A mechanical device which, when a non-pneumatic tire assembly incorporates a wheel, supports the tire, and
attaches, either integrally or separably, to the wheel center member and upon which the tire is attached.
Non-pneumatic spare tire assembly
A non-pneumatic tire assembly intended for temporary use in place of one of the pneumatic tires and rims that
are fitted to a passenger car in compliance with the requirements of this standard.
Non-pneumatic tire
A mechanical device which transmits, either directly or through a wheel or wheel center member, the vertical
load and tractive forces from the roadway to the vehicle, generates the tractive forces that provide the
directional control of the vehicle and does not rely on the containment of any gas or fluid for providing those
functions.
Non-pneumatic tire assembly
A non-pneumatic tire, alone or in combination with a wheel or wheel center member, which can be mounted on
a vehicle.
Normal occupant weight
This means 68 kilograms (150 lbs.) times the number of occupants specified in the second column of Table I
of 49 CFR 571.110.
Occupant distribution
The distribution of occupants in a vehicle as specified in the third column of Table I of 49 CFR 571.110.
Open splice
Any parting at any junction of tread, sidewall, or innerliner that extends to cord material.
Outer diameter
The overall diameter of an inflated new tire.
Overall width
The linear distance between the exteriors of the sidewalls of an inflated tire, including elevations due to
labeling, decorations, or protective bands or ribs.
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Tire Safety Information
Ply
A layer of rubber-coated parallel cords.
Ply separation
A parting of rubber compound between adjacent plies.
Pneumatic tire
A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an
automotive wheel, provides the traction and contains the gas or fluid that sustains the load.
Production options weight
The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in
excess of those standard items which they replace, not previously considered in curb weight or accessory
weight, including heavy duty brakes, ride levelers, roof rack, heavy duty battery, and special trim.
Radial ply tire
A pneumatic tire in which the ply cords that extend to the beads are laid at substantially 90 degrees to the
centerline of the tread.
Recommended inflation pressure
This is the inflation pressure provided by the vehicle manufacturer on the Tire Information label and on the
Certification / VIN tag.
Reinforced tire
A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard
tire.
Rim
A metal support for a tire or a tire and tube assembly upon which the tire beads are seated.
Rim diameter
This means the nominal diameter of the bead seat.
Rim size designation
This means the rim diameter and width.
Rim type designation
7KLVPHDQVWKHLQGXVWU\RIPDQXIDFWXUHU¶VGHVLJQDWLRQIRUDrim by style or code.
Rim width
This means the nominal distance between rim flanges.
Section width
The linear distance between the exteriors of the sidewalls of an inflated tire, excluding elevations due to
labeling, decoration, or protective bands.
Sidewall
That portion of a tire between the tread and bead.
Sidewall separation
The parting of the rubber compound from the cord material in the sidewall.
Special Trailer (ST) tire
The "ST" is an indication the tire is for trailer use only.
Test rim
The rim on which a tire is fitted for testing, and may be any rim listed as appropriate for use with that tire.
Tread
That portion of a tire that comes into contact with the road.
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Tire Safety Information
Tread rib
A tread section running circumferentially around a tire.
Tread separation
Pulling away of the tread from the tire carcass.
Treadwear indicators (TWI)
The projections within the principal grooves designed to give a visual indication of the degrees of wear of the
tread.
Vehicle capacity weight
The rated cargo aQGOXJJDJHORDGSOXVNLORJUDPVOEVWLPHVWKHYHKLFOH¶VGHVLJQDWHGVHDWLQJFDSDFLW\
Vehicle maximum load on the tire
The load on an individual tire that is determined by distributing to each axle its share of the maximum loaded
vehicle weight and dividing by two.
Vehicle normal load on the tire
The load on an individual tire that is determined by distributing to each axle its share of the curb weight,
accessory weight, and normal occupant weight (distributed in accordance with Table I of CRF 49 571.110) and
dividing by 2.
Weather side
The surface area of the rim not covered by the inflated tire.
Wheel center member
In the case of a non-pneumatic tire assembly incorporating a wheel, a mechanical device which attaches,
either integrally or separably, to the non-pneumatic rim and provides the connection between the nonpneumatic rim and the vehicle; or, in the case of a non-pneumatic tire assembly not incorporating a wheel, a
mechanical device which attaches, either integrally or separably, to the non-pneumatic tire and provides the
connection between tire and the vehicle.
Wheel-holding fixture
The fixture used to hold the wheel and tire assembly securely during testing.
1.4. TIRE SAFETY - EVERYTHING RIDES ON IT
The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that
discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It
can be obtained and downloaded from NHTSA, free of charge, from the following web site:
http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.html
Studies of tire safety show that maintaining proper tire pressure, observing tire and vehicle load limits (not
carrying more weight in your vehicle than your tires or vehicle can safely handle), avoiding road hazards, and
inspecting tires for cuts, slashes, and other irregularities are the most important things you can do to avoid tire
failure, such as tread separation or blowout and flat tires. These actions, along with other care and
maintenance activities, can also:
Improve vehicle handling
Help protect you and others from avoidable breakdowns and accidents
Improve fuel economy
Increase the life of your tires.
This booklet presents a comprehensive overview of tire safety, including information on the following topics:
Basic tire maintenance
Uniform Tire Quality Grading System
Fundamental characteristics of tires
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Tire Safety Information
Tire safety tips.
Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the
time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire
failure.
6$)(7<),567±%$6,&7,5(0 $,17(1$1&(
Properly maintained tires improve the steering, stopping, traction, and load-carrying capability of your vehicle.
Underinflated tires and overloaded vehicles are a major cause of tire failure. Therefore, as mentioned above,
to avoid flat tires and other types of tire failure, you should maintain proper tire pressure, observe tire and
vehicle load limits, avoid road hazards, and regularly inspect your tires.
1.5.1. FINDING YOUR VEHICLE 'S RECOMMENDED TIRE PRESSURE AND L OAD LIMITS
Tire information placards and vehicle certification labels contain information on tires and load limits. These
labels indicate the vehicle manufacturer's information including:
Recommended tire size
Recommended tire inflation pressure
Vehicle capacity weight (VCW±the maximum occupant and cargo weight a vehicle is designed to carry)
Front and rear gross axle weight ratings (GAWR± the maximum weight the axle systems are designed to
carry).
Both placards and certification labels are permanently attached to the trailer near the left front.
1.5.2. UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS
Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the
overall performance of the vehicle. The tire inflation pressure is a number that indicates the amount of air
pressure± measured in pounds per square inch (psi)±a tire requires to be properly inflated. (You will also find
this number on the vehicle information placard expressed in kilopascals (kpa), which is the metric measure
used internationally.)
Manufacturers of passenger vehicles and light trucks determine this number based on the vehicle's design
load limit, that is, the greatest amount of weight a vehicle can safely carry and the vehicle's tire size. The
proper tire pressure for your vehicle is referred to as the "recommended cold inflation pressure." (As you will
read below, it is difficult to obtain the recommended tire pressure if your tires are not cold.)
Because tires are designed to be used on more than one type of vehicle, tire manufacturers list the "maximum
permissible inflation pressure" on the tire sidewall. This number is the greatest amount of air pressure that
should ever be put in the tire under normal driving conditions.
1.5.3. CHECKING TIRE PRESSURE
It is important to check your vehicle's tire pressure at least once a month for the following reasons:
Most tires may naturally lose air over time.
Tires can lose air suddenly if you drive over a pothole or other object or if you strike the curb when
parking.
With radial tires, it is usually not possible to determine underinflation by visual inspection.
For convenience, purchase a tire pressure gauge to keep in your vehicle. Gauges can be purchased at tire
dealerships, auto supply stores, and other retail outlets.
The recommended tire inflation pressure that vehicle manufacturers provide reflects the proper psi when a tire
is cold. The term cold does not relate to the outside temperature. Rather, a cold tire is one that has not been
driven on for at least three hours. When you drive, your tires get warmer, causing the air pressure within them
to increase. Therefore, to get an accurate tire pressure reading, you must measure tire pressure when the tires
are cold or compensate for the extra pressure in warm tires.
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Tire Safety Information
1.5.4. STEPS FOR MAINTAINING PROPER TIRE PRESSURE
Step 1: Locate the recommended tire pressure on the vehicle's tire information placard, certification
label, or in the owner's manual.
Step 2: Record the tire pressure of all tires.
Step 3: If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the
tire valve stem with the edge of your tire gauge until you get to the correct pressure.
Step 4: If the tire pressure is too low, note the difference between the measured tire pressure and the
correct tire pressure. These "missing" pounds of pressure are what you will need to add.
Step 5: At a service station, add the missing pounds of air pressure to each tire that is underinflated.
Step 6: Check all the tires to make sure they have the same air pressure (except in cases in which the
front and rear tires are supposed to have different amounts of pressure).
If you have been driving your vehicle and think that a tire is underinflated, fill it to the recommended cold
inflation pressure indicated on your vehicle's tire information placard or certification label. While your tire may
still be slightly underinflated due to the extra pounds of pressure in the warm tire, it is safer to drive with air
pressure that is slightly lower than the vehicle manufacturer's recommended cold inflation pressure than to
drive with a significantly underinflated tire. Since this is a temporary fix, don't forget to recheck and adjust the
tire's pressure when you can obtain a cold reading.
1.5.5. TIRE SIZE
To maintain tire safety, purchase new tires that are the same size as the vehicle's original tires or another size
recommended by the manufacturer. Look at the tire information placard, the owner's manual, or the sidewall of
the tire you are replacing to find this information. If you have any doubt about the correct size to choose,
consult with the tire dealer.
1.5.6. TIRE TREAD
The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding,
especially when the road is wet or icy. In general, tires are not safe and should be replaced when the tread is
worn down to 1/16 of an inch. Tires have built-in treadwear indicators that let you know when it is time to
replace your tires. These indicators are raised sections spaced intermittently in the bottom of the tread
grooves. When they appear "even" with the outside of the tread, it is time to replace your tires. Another method
for checking tread depth is to place a penny in the tread with Lincoln's head upside down and facing you. If
you can see the top of Lincoln's head, you are ready for new tires.
1.5.7. TIRE BALANCE AND WHEEL ALIGNMENT
To avoid vibration or shaking of the vehicle when a tire rotates, the tire must be properly balanced. This
balance is achieved by positioning weights on the wheel to counterbalance heavy spots on the wheel-and-tire
assembly. A wheel alignment adjusts the angles of the wheels so that they are positioned correctly relative to
the vehicle's frame. This adjustment maximizes the life of your tires. These adjustments require special
equipment and should be performed by a qualified technician.
1.5.8. TIRE REPAIR
The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that
surrounds the puncture hole. Punctures through the tread can be repaired if they are not too large, but
punctures to the sidewall should not be repaired. Tires must be removed from the rim to be properly inspected
before being plugged and patched.
1.5.9. TIRE FUNDAMENTALS
Federal law requires tire manufacturers to place standardized information on the sidewall of all tires. This
information identifies and describes the fundamental characteristics of the tire and also provides a tire
identification number for safety standard certification and in case of a recall.
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Tire Safety Information
1.5.9.1. Information on Passenger Vehicle Tires
Please refer to the diagram below.
P
The "P" indicates the tire is for passenger vehicles.
Next number
This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In
general, the larger the number, the wider the tire.
Next number
This two-digit number, known as the aspect ratio, gives the tire's ratio of height to width. Numbers of 70 or
lower indicate a short sidewall for improved steering response and better overall handling on dry pavement.
R
The "R" stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years.
Next number
This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to
purchase new tires to match the new wheel diameter.
Next number
This two- or three-digit number is the tire's load index. It is a measurement of how much weight each tire can
support. You may find this information in your owner's manual. If not, contact a local tire dealer. Note: You may
not find this information on all tires because it is not required by law.
M+S
The "M+S" or "M/S" indicates that the tire has some mud and snow capability. Most radial tires have these
markings; hence, they have some mud and snow capability.
Speed Rating
The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time. The
ratings range from 99 miles per hour (mph) to 186 mph. These ratings are listed below. Note: You may not find
this information on all tires because it is not required by law.
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Tire Safety Information
Tire Safety Information
Letter Rating
Q
R
S
T
U
H
V
W
Y
Speed Rating
99 mph
106 mph
112 mph
118 mph
124 mph
130 mph
149 mph
168* mph
186* mph
* For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use the letters ZR.
For those with a maximum speed capability over 186 mph, tire manufacturers always use the letters ZR.
U.S. DOT Tire Identification Number
This begins with the letters "DOT" and indicates that the tire meets all federal standards. The next two
numbers or letters are the plant code where it was manufactured, and the last four numbers represent the
week and year the tire was built. For example, the numbers 3197 means the 31st week of 1997. The other
numbers are marketing codes used at the manufacturer's discretion. This information is used to contact
consumers if a tire defect requires a recall.
Tire Ply Composition and Materials Used
The number of plies indicates the number of layers of rubber-coated fabric in the tire. In general, the greater
the number of plies, the more weight a tire can support. Tire manufacturers also must indicate the materials in
the tire, which include steel, nylon, polyester, and others.
Maximum Load Rating
This number indicates the maximum load in kilograms and pounds that can be carried by the tire.
Maximum Permissible Inflation Pressure
This number is the greatest amount of air pressure that should ever be put in the tire under normal driving
conditions.
1.5.9.2. UTQGS Information
Treadwear Number
This number indicates the tire's wear rate. The higher the treadwear number is, the longer it should take for the
tread to wear down. For example, a tire graded 400 should last twice as long as a tire graded 200.
Traction Letter
This letter indicates a tire's ability to stop on wet pavement. A higher graded tire should allow you to stop your
car on wet roads in a shorter distance than a tire with a lower grade. Traction is graded from highest to lowest
as "AA","A", "B", and "C".
Temperature Letter
This letter indicates a tire's resistance to heat. The temperature grade is for a tire that is inflated properly and
not overloaded. Excessive speed, underinflation or excessive loading, either separately or in combination, can
cause heat build-up and possible tire failure. From highest to lowest, a tire's resistance to heat is graded as
"A", "B", or "C".
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Tire Safety Information
1.5.9.3. Additional Information on Light Truck Tires
Please refer to the following diagram.
Tires for light trucks have other markings besides those found on the sidewalls of passenger tires.
LT
The "LT" indicates the tire is for light trucks or trailers.
ST
An "ST" is an indication the tire is for trailer use only.
Max. Load Dual kg (lbs) at kPa (psi) Cold
This information indicates the maximum load and tire pressure when the tire is used as a dual, that is,
when four tires are put on each rear axle (a total of six or more tires on the vehicle).
Max. Load Single kg (lbs) at kPa (psi) Cold
This information indicates the maximum load and tire pressure when the tire is used as a single.
Load Range
This information identifies the tire's load-carrying capabilities and its inflation limits.
1.6. TIRE SAFETY TIPS
Preventing Tire Damage
Slow down if you have to go over a pothole or other object in the road.
Do not run over curbs or other foreign objects in the roadway, and try not to strike the curb when
parking.
Tire Safety Checklist
Check tire pressure regularly (at least once a month), including the spare.
Inspect tires for uneven wear patterns on the tread, cracks, foreign objects, or other signs of wear or
trauma.
Remove bits of glass and foreign objects wedged in the tread.
Make sure your tire valves have valve caps.
Check tire pressure before going on a long trip.
Do not overload your vehicle. Check the Tire Information and Loading Placard or 8VHU¶V0DQXDO for the
maximum recommended load for the vehicle.
206
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User’s Information for Transport Canada Fuel Tank
26 User’s Information for Transport Canada Fuel Tank
Note: The following information applies ONLY to machines equipped with a
Transport Canada fuel tank. This type of fuel tank is required for machines
transported on Canadian roads. Contact your Wacker Neuson dealer if you are
unsure about whether or not your machine is approved for use in Canada.
Description
The fuel tank, or Intermediate Bulk Container (IBC), on this machine was designed
for the storage and transportation of diesel fuel when mounted on a mobile electric
power source as a sub-base tank.
The fuel tank was manufactured using ductile steel which meets or exceeds United
Nations specifications (eg. CGSB 43-146-2002 in Canada). It has been tested and
certified as UN Standard Mobile IBC, 31A/Y Packing Group II and III. This is an
international standard recognized by the Canadian Transportation of Dangerous
Goods Act (TDG), and it applies to tanks either made in Canada or imported (TDG
Regs. 5.6(b)).
The fuel tank is equipped with a pressure / vacuum relief venting device set to 2 psi
(14 kPa) pressure and 0.25 psi (1.75 kPa) vacuum.
General
requirements
■ Do not fill above 95% maximum capacity of the fuel tank.
■ All valves and plugs must be closed while the machine is being transported.
Placarding
requirements
Immediately after the fuel tank is filled (fully or partially) with flammable liquids, UN
Placards / Transport of Dangerous Goods Decals / Placards of Flammable Liquids
(Transport Canada - Product Identification Decals) must be installed prior to
moving the machine in any manner. This is a requirement of Transport Canada.
Refer to “Hazardous Materials Placards” in the Operation chapter for instructions
on how to install the placards.
Maintaining
the fuel tank
■ The fuel tank must not be lifted or moved with any fuel inside. Drain the fuel tank
completely and remove external hardware before relocating the tank for
inspection or maintenance.
■ Do not drill into, or weld anything onto, the fuel tank.
■ Inspect the exterior paint annually for chips or scratches. Repair any damage
using compatible paint.
■ Replacement of damaged components or parts must be of the same
specification or equivalent. Replacement parts can be obtained directly from
Wacker Neuson or from an authorized Wacker Neuson service center.
Compulsory
inspections
Transport of Dangerous Goods / Transport Canada regulations require the fuel
tank to be leak tested and inspected every 5 years (60 months) at a certified facility.
A list of testing facilities in Canada certified to perform leak tests and inspections
can be found at the Transport Canada website:
http://www.tc.gc.ca/tdg/containers/ibc_leak/ibcleak.asp
The following pages contain forms for you to record tank inspection and testing
results. Copy the pages as needed.
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User’s Information for Transport Canada Fuel Tank
208
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User’s Information for Transport Canada Fuel Tank
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209
Emission Control Systems Information and Warranty
27 Emission Control Systems Information and Warranty
The Emission Control Warranty and associated information is valid only for the
U.S.A., its territories, and Canada.
27.1
Emission Control System Background Information
Introduction
Wacker Neuson engines/equipment must conform with applicable Environmental
Protection Agency (EPA) and California Air Resource Board (CARB) emissions
regulations. These regulations require that manufacturers warrant the emission
control systems for defects in materials and workmanship.
Furthermore, EPA and CARB regulations require all manufacturers to furnish
written instructions describing how to operate and maintain the engines/equipment
including the emission control systems. This information is provided with all
Wacker Neuson engines/equipment at the time of purchase.
Exhaust Emissions
The combustion process produces carbon monoxide, oxides of nitrogen, and
hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important
because, under certain conditions, they react to form photochemical smog when
subjected to sunlight. Carbon monoxide does not react in the same way, but it is
toxic.
Problems that may affect Emissions
If any of the following symptoms arise, have the engine/equipment inspected and
repaired by a Wacker Neuson dealer/service center.
 Hard starting or stalling after starting
 Rough idling
 Misfiring or backfiring under load
 Afterburning (backfiring)
 Presence of black exhaust smoke during operation
 High fuel consumption
Tampering and Altering
Tampering with or altering the emission control system may increase emissions
beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny
a warranty claim. Among those acts that constitute tampering are:
 Removing or altering of any part of the air intake, fuel, or exhaust systems.
 Altering or defeating the speed-adjusting mechanism causing the engine to
operate outside its design parameters.
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Emission Control Systems Information and Warranty
27.2
Limited Defect Warranty for Exhaust Emission Control System
See the supplied engine owner’s manual for the applicable emission warranty
statement.
27.3
Limited Defect Warranty for Wacker Neuson Emission Control
Systems
The Emission Control Warranty is valid only for the U.S.A., its territories, and
Canada.
Wacker Neuson Sales Americas, LLC, N92 W15000 Anthony Avenue,
Menomonee Falls, WI 53051, (hereinafter “Wacker Neuson”) warrants to the initial
retail purchaser and each subsequent owner, that this engine/equipment, including
all parts of its emission control system, have been designed, built, and equipped to
conform at the time of initial sale to all applicable evaporative emission regulations
of the U.S. Environmental Protection Agency (EPA) and the California Air
Resources Board (CARB), and that the engine/equipment is free of defects in
materials and workmanship which would cause this engine/equipment to fail to
conform to EPA regulations during its warranty period.
Wacker Neuson is also liable for damages to other engine/equipment components
caused by a failure of any warranted parts during the warranty period.
Limited Defect Warranty Period for Wacker Neuson Emission Control
Systems
The warranty period for this engine/equipment begins on the date of sale to the
initial purchaser and continues for a period of five years or 3000 hours of operation
(whichever comes first). For the warranty terms for your specific engine/equipment,
visit wackerneuson.com.
Any implied warranties are limited to the duration of this written warranty.
What is covered
Wacker Neuson recommends the use of genuine Wacker Neuson parts, or the
equivalent, whenever maintenance is performed. The use of replacement parts not
equivalent to the original parts may impair the effectiveness of the engine/
equipment emission controls systems. If such a replacement part is used in the
repair or maintenance of the engine/equipment, assure yourself that such part is
warranted by its manufacturer to be equivalent to the parts offered by Wacker
Neuson in performance and durability. Furthermore, if such a replacement part is
used in the repair or maintenance of the engine/equipment, and an authorized
Wacker Neuson dealer/service center determines it is defective or causes a failure
of a warranted part, the claim for repair of the engine/equipment may be denied. If
the part in question is not related to the reason the engine/equipment requires
repair, the claim will not be denied.
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211
Emission Control Systems Information and Warranty
For the components listed in the following table, an authorized Wacker Neuson
dealer/service center will, at no cost to you, make the necessary diagnosis, repair,
or replacement necessary to ensure that the engine/equipment complies with the
applicable EPA regulations. All defective parts replaced under this warranty
become property of Wacker Neuson.
System Covered
Components
Air handling system and associated
plumbing
Charge air cooler
Exhaust system (upstream of last
aftertreatment
Exhaust gas piping from turbocharger out
to the last aftertreatment device
Charge air cooler plumbing
What is not covered






Failures other than those resulting from defects in material or workmanship.
Any systems or parts which are affected or damaged by owner abuse,
tampering, neglect, improper maintenance, misuse, improper fueling,
improper storage, accident and/or collision; the incorporation of, or any use
of, add-on or modified parts, or unsuitable attachments, or the alteration of
any part.
Replacement of expendable maintenance items made in connection with
required maintenance services after the item’s first scheduled replacement
as listed in the maintenance section of the engine/equipment operator’s
manual, such as spark plugs and filters.
Incidental or consequential damages such as loss of time or the use of the
engine/equipment, or any commercial loss due to the failure of the engine/
equipment.
Diagnosis and inspection charges that do not result in warranty-eligible
service being performed.
Any non-authorized replacement part, or malfunction of authorized parts due
to use of-non authorized parts.
Owner’s Warranty Responsibility
The engine/equipment owner, is responsible for the performance of the required
maintenance listed in the Wacker Neuson engine/equipment operator’s manual.
Wacker Neuson recommends that all receipts covering maintenance on the
engine/equipment be retained, but Wacker Neuson cannot deny warranty
coverage solely for the lack of receipts or for the failure to ensure the performance
of all scheduled maintenance.
Normal maintenance, replacement, or repair of emission control devices and
systems may be performed by any repair establishment or individual; however,
warranty repairs must be performed by an authorized Wacker Neuson dealer/
service center.
The engine/equipment must be presented to an authorized Wacker Neuson dealer/
service center as soon as a problem exists. Contact Wacker Neuson Product
Support Department (1-800-770-0957) or visit wackerneuson.com to find a dealer/
service center in your area, or to answer questions regarding warranty rights and
responsibilities.
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Emission Control Systems Information and Warranty
How to Make a Claim
In the event that any emission-related part is found to be defective during the
warranty period, you shall notify Wacker Neuson Product Support Department
(1-800-770-0957, or [email protected], or
wackerneuson.com), and you will be advised of the appropriate dealer/service
center where warranty repair can be performed. All repairs qualifying under this
limited warranty must be performed by an authorized Wacker Neuson dealer/
service center.
You must take your Wacker Neuson engine/equipment along with proof of original
purchase date, at your expense, to the authorized Wacker Neuson dealer/service
center during their normal business hours.
For owners located more than 100 miles from an authorized dealer/service center
(excluding the states with high-altitude areas as identified in 40 CFR Part 1068,
Appendix III), Wacker Neuson will pay for pre-approved shipping costs to and from
an authorized Wacker Neuson dealer/service center.
Claims for repair or adjustment found to be caused solely by defects in material or
workmanship will not be denied because the engine/equipment was not properly
maintained and used.
The warranty repairs should be completed in a reasonable amount of time, not to
exceed 30 days.
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Emission Control Systems Information and Warranty
214
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Mobile Generator
General Machine Schematics
28 General Machine Schematics
28.1
Fuses
G 25 T4i Isuzu, Basler
#1
G 25 T4f Isuzu, Basler
10A
10A ECM start
#1
#2
10A
10A Fuel pump
#2
#3
10A
10A Fuel solenoid
#3
#4
7.5A
7.5A ECM/switch
#4
#1
10A ECM start
10A
#2
1A Coolant sensor
1A
N/A
7.5A ECM/switch
7.5A
#3
G 150, T3 John Deere, Basler
G 180, T3 John Deere, Basler
#4
7.5A
7.5A ECM/switch
wc_gr011774
#1
G 50, T4i John Deere, Basler
G 50, T4i John Deere, Deep Sea
G 50, T4f Isuzu, Basler
G 70, T3 John Deere, Basler
G 70, T3 John Deere, Deep Sea
10A
10A ECM start
#2
7.5A
7.5A ECM/switch
#3
G 150, T3 John Deere, Deep Sea
G 180, T3 John Deere, Deep Sea
#4
#3
#4
7.5A
7.5A ECM/switch
G 70, T4i Cummins, Basler
10A
#2
1A
10A ECM start
7.5A
7.5A ECM/switch
G 150, T4i Cummins, Basler
G 180, T4i Cummins, Basler
#1
#5
20A
1A Coolant sensor #6
#3
#4
10A ECM start
#2
#1
#1
10A
10A
G 230, T4i Cummins, Basler
10A ECM start
#5
20A
20A Engine ECU
#2
#6
20A Engine ECU
#3
#7
1A
1A Engine diagnostics
N/A
#4
#8
5A
5A Keyswitch
#7
1A
1A Engine diagnostics
#8
5A
5A Keyswitch
7.5A
7.5A ECM/switch
N/A
wc_gr011870
G 230, T4f Cummins, Basler
G 70, Tier 4i Cummins, Deep Sea
#1
#1
10A
10A ECM start
#5
20A
30A
30A Engine ECU
10A Engine diagnostics
#6
10A
N/A
#3
#7
5A
#4
#8
5A
#3
#7
1A
1A Engine diagnostics
#8
5A
5A Keyswitch
7.5A ECM/switch
#5
#2
#6
7.5A
10A ECM start
20A Engine ECU
#2
#4
10A
7.5A
7.5A ECM/switch
5A Keyswitch
(ON/OFF switch)
5A Fuse/relay box
at connector 6
wc_gr012013
wc_gr011826
wc_tx003652gb_FM10.fm
215
General Machine Schematics
28.2
Mobile Generator
Trailer Wiring
Standard and Hydraulic Brakes
Electric Brakes
1
B r
9
B r
W
W
G
W
B r
1
9
Br W
Br W
6
W
R
R
3
W
G
3
7
B r
Y
B r
7
B r
5
6
W
R
G
Y
Br
W
G
Br
W
+
Br
7
Br
7
–
4
R
2
Y
B r
W
1 0
B r
B r
W
W
R
R
R
8
W
5
Y
Br
W
Br W
Br W
2
w c _ g r0 0 0 5 2 2
216
8
10
wc_gr000523
Mobile Generator
28.3
General Machine Schematics
Trailer Wiring Components
Ref.
Ref.
wc_tx003652gb_FM10.fm
Description
1
Front right side amber light
2
Front left side amber light
3
Trailer plug
4
Battery
5
Brake solenoid
6
Right tail light
7
License plate holder lights
8
Left tail light
9
Rear right side red light
10
Rear left side red light
Wire Colors
Rear Lights
Side Lights
Harness
B
BLACK
Ground
Ground
Battery charge
Br
BROWN
Tail light
L
BLUE
R
RED
Y
YELLOW
Left brake light and directional
G
GREEN
Right brake light and directional
W
WHITE
Ground
Tail, side and license plate
Brake light
Power
217
Electric brakes
Schematics, Machines with Basler Controller
G 50/G 70
29 Schematics, Machines with Basler Controller
29.1
AC Schematic: G 50, G 70
30
2
1
6
18
6
14
16
22
28
7
13
7
4
8
10
21
17
20
23
24
29
10
8
19
12
27
5
26
15
25
3
wc_gr011782
218
G 50/G 70
29.2
Schematics, Machines with Basler Controller
AC Schematic Components: G 50, G 70
Ref.
Description
Ref.
Description
1
Lug safety limit switch
17
Voltage regulator with 4A fuse
2
Mechanical lugs
18
Voltage adjustment rheostat
3
Plug 3 — line voltage inputs
19
Terminal block
4
Shunt
20
Exciter rotor windings
5
Plug 4 — current transformer inputs
21
Exciter stator winding
6
120V GFI receptacle
22
Rotor
7
120V 20A breaker
23
Rectifier (diodes)
8
240V 50A breaker
24
Main rotor winding
10
240V 50A receptacle
(240V, 30A optional)
25
Main stator windings
12
Genset controller
26
Auxiliary stator winding
13
Main breaker
27
Stator
14
Bus bar (bond bar)
28
Exciter
15
Voltage selector switch
29
Ammeters
16
Generator
30
Machine and components
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003661gb_FM10.fm
219
Schematics, Machines with Basler Controller
29.3
G 50/G 70
DC Schematic: G 50, T4i John Deere, Basler
1
30
25
5
6
2
12
10
13
14
17
15
8
9
33
7
3
11
21
22
19
18
20
26
23
4
29
27
31
28
24
wc_gr011785
220
G 50/G 70
29.4
Schematics, Machines with Basler Controller
DC Schematic Components: G 50, T4i John Deere, Basler
Ref.
Description
Ref.
Description
1
Plug 1 - power and engine sender inputs
17
Starter relay
2
Plug 2 - contact inputs
18
Emergency stop switch
3
Plug 3 - AC line volts and tachometer
19
Remote start terminals
4
Plug 4 - E-stop & contact outputs
20
Battery
5
Water temperature sender
21
Starter motor
6
Remote start / Off / Start/Run switch
22
Alternator
7
Relay - engine outputs
23
Mechanical lugs
8
Hour meter
24
Main circuit breaker
9
Throttle solenoid
25
Fuel level sender
10
10A fuse
26
Lug door interlock switch
11
Electronic control unit (genset controller)
27
Bond bar
12
Magnetic pickup
28
Shunt trip relay
13
7.5A fuse
29
Battery disconnect (optional)
14
Intake heater
30
Oil pressure sender
15
Intake heater relay
31
Shunt
16
Terminal strip
32
—
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003661gb_FM10.fm
221
Schematics, Machines with Basler Controller
29.5
G 50/G 70
DC Schematic: G 50, T4f Isuzu, Basler
1
5
3
25
14
6
2
9
10
22
13
7
12
8
18
21
19
20
4
15
11
16
24
23
17
16
wc_gr011726
222
G 50/G 70
29.6
Schematics, Machines with Basler Controller
DC Schematic Components: G 50, T4f Isuzu, Basler
Ref.
Description
Ref.
Description
1
Plug 1 - power and engine sender inputs
14
Idle switch
2
Plug 2 - contact inputs
15
Battery disconnect (optional)
3
Electronic control unit (genset controller)
16
Shunt trip relay
4
Plug 4 - E-stop & contact outputs
17
Bond bar
5
Water temperature sender
18
Emergency stop switch
6
Remote start / Off / Start/Run switch
19
Remote start terminals
7
Relay - engine outputs
20
Battery
8
Hour meter
21
Starter motor
9
1A fuse
22
Engine connector
10
10A fuse
23
Mechanical lugs
11
Lug door interlock switch
24
Main circuit breaker
12
Terminal strip
25
Fuel level sender
13
7.5A fuse
—
—
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003661gb_FM10.fm
223
Schematics, Machines with Basler Controller
29.7
G 50/G 70
DC Schematic: G 70, T3 John Deere, Basler
3
1
14
25
15
6
2
10
11
17
13
21
8
7
18
9
22
20
16
19
4
27
26
23
12
28
24
5
wc_gr011786
224
G 50/G 70
29.8
Schematics, Machines with Basler Controller
DC Schematic Components: G 70, T3 John Deere, Basler
Ref.
Description
Ref.
Description
1
Plug 1 - power and engine sender inputs
15
Intake heater relay
2
Plug 2 - contact inputs
16
Engine Control Unit (ECU)
3
Electronic control unit (genset controller)
17
Starter relay
4
Plug 4 - E-stop, CANBUS and contact
outputs
18
Emergency stop switch
5
Shunt
19
Remote start terminals
6
Remote start / Off / Start/Run switch
20
Battery
7
Relay - engine outputs
21
Starter motor
8
Hour meter
22
Alternator
9
Terminal strip
23
Mechanical lugs
10
10A fuse
24
Main circuit breaker
11
Battery disconnect (optional)
25
Fuel level sender
12
Shunt trip relay
26
Lug door interlock switch
13
7.5A fuse
27
Bond bar
14
Intake heater
28
Resistor (if equipped)
Wire Colors
BLK
Black
RED
Red
WHT
White
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003661gb_FM10.fm
ORG
Orange
225
Schematics, Machines with Basler Controller
29.9
G 50/G 70
DC Schematic: G 70, Cummins, Basler
1
17
25
15
14
3
6
5
2
21
9
7
18
4
12
16
13
10
8
11
29
33
20
19
31
30
26
28
23
27
32
22
24
wc_gr011791
226
G 50/G 70
Schematics, Machines with Basler Controller
29.10 DC Schematic Components: G 70, T4i Cummins, Basler
Ref.
Description
Ref.
Description
1
Plug 1 - power and engine sender inputs
18
Emergency stop switch
2
Plug 2 - contact inputs
19
Remote start terminals
3
Electronic control unit (genset controller)
20
Battery
4
Plug 4 - E-stop, CANBUS, contact
outputs
21
Starter motor
5
Idle toggle switch
22
Shunt
6
Remote start / Off / Start/Run switch
23
Mechanical lugs
7
Relay - engine outputs
24
Main circuit breaker
8
Hour meter
25
Fuel level sender
9
20A fuse
26
Lug door interlock switch
10
10A fuse
27
Bond bar
11
1A Fuse
28
Shunt trip relay
12
5A Fuse
29
Battery disconnect (optional)
13
7.5A fuse
30
120 Ohm resistor
14
Intake heater
31
Coolant level sensor
15
Intake heater relay
32
Air cleaner sensor
16
250A fuse
33
Terminal strip
17
Starter relay
34
—
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003661gb_FM10.fm
227
Schematics, Machines with Basler Controller
G 50/G 70
29.11 AC Schematic: G 70, John Deere, 600V, Basler
30
2
1
6
6
16
18
14
22
28
17
13
7
7
4
21
8
20
23
24
9
11
19
29
5
12
25
15
3
26
27
10
wc_gr011816
228
G 50/G 70
Schematics, Machines with Basler Controller
29.12 AC Schematic Components: G 70, John Deere, 600V, Basler
Ref.
Description
Ref.
Description
1
Lug safety limit switch
16
Generator
2
Mechanical lugs
17
Voltage regulator with 4A fuse
3
Plug 3 — line voltage inputs
18
Voltage adjustment rheostat
4
Shunt
19
Terminal block (2)
5
Plug 5 — current transformer inputs
20
Exciter rotor windings
6
120V GFI receptacle
21
Exciter stator winding
7
120V 20A breaker
22
Rotor
8
240V 50A breaker
23
Rectifier (diodes)
9
240V 50A receptacle
24
Main rotor winding
10
Fuse box
25
Main stator windings
11
Terminal block (1)
26
Auxiliary stator winding
12
Genset controller
27
Stator
13
Main breaker
28
Exciter
14
Bus bar (bond bar)
29
Ammeters
15
Voltage selector switch
30
Machine and components
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003661gb_FM10.fm
229
Schematics, Machines with Deep Sea Controller
G 50/G 70
30 Schematics, Machines with Deep Sea Controller
30.1
AC Schematic: G 50, G 70
30
2
1
6
18
6
14
16
22
28
7
13
7
4
8
10
21
17
20
23
24
29
10
8
19
12
27
5
26
15
25
3
wc_gr011913
230
G 50/G 70
30.2
Schematics, Machines with Deep Sea Controller
Electrical Schematic Components
Ref.
Description
Ref.
Description
1
Lug safety limit switch
17
Voltage regulator with 4A fuse
2
Mechanical lugs
18
Voltage adjustment rheostat
3
Plug 3 — line voltage inputs
19
Terminal block
4
Shunt
20
Exciter rotor windings
5
Plug 4 — current transformer inputs
21
Exciter stator winding
6
120V GFI receptacle
22
Rotor
7
120V 20A breaker
23
Rectifier (diodes)
8
240V 50A breaker
24
Main rotor winding
10
240V 50A receptacle
(240V, 30A optional)
25
Main stator windings
12
Genset controller
26
Auxiliary stator winding
13
Main breaker
27
Stator
14
Bus bar (bond bar)
28
Exciter
15
Voltage selector switch
29
Ammeters
16
Generator
30
Machine and components
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003662gb_FM10.fm
231
Schematics, Machines with Deep Sea Controller
30.3
G 50/G 70
DC Schematic: G 50, T4i John Deere, Deep Sea
1
31
25
8
14
7
10
13
4
2
5
12
17
16
15
11
3
21
18
19
22
20
6
26
28
24
23
27
29
30
wc_gr011792
232
G 50/G 70
30.4
Schematics, Machines with Deep Sea Controller
DC Schematic Components: G 50, T4i John Deere, Deep Sea
Ref.
Description
Ref.
Description
1
Plug 1 - power and engine sender inputs
17
Starter relay
2
Plug 2 - contact inputs
18
Emergency stop switch
3
Plug 3 - tachometer
19
Remote start terminals
4
Electronic control unit (genset controller)
20
Battery
5
Water temperature sender
21
Starter motor
6
Plug 6 - Contact inputs
22
Alternator
7
Relay - engine outputs
23
Mechanical lugs
8
Hour meter
24
Main circuit breaker
9
Fuel pump
25
Fuel level sender
10
10A fuse
26
Lug door interlock switch
11
Terminal strip
27
Bond bar
12
Magnetic pickup
28
Shunt trip relay
13
7.5A fuse
29
Battery disconnect (optional)
14
Intake heater
30
Shunt
15
Intake heater relay
31
ON/OFF toggle switch
16
Fuel solenoid
32
—
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003662gb_FM10.fm
233
Schematics, Machines with Deep Sea Controller
30.5
G 50/G 70
DC Schematic: G 70, T3 John Deere, Deep Sea
14
1
15
25
29
4
22
17
2
13
10
8
11
21
20
9
16
18
19
3
7
26
23
6
27
28
12
24
5
wc_gr011793
234
G 50/G 70
30.6
Schematics, Machines with Deep Sea Controller
DC Schematic Components: G 70, T3 John Deere, Deep Sea
Ref.
Description
Ref.
Description
1
Plug 1 - power and engine sender inputs
16
Engine Control Unit (ECU)
2
Plug 2 - contact inputs
17
Starter relay
3
Plug 3 - CANBUS
18
Emergency stop switch
4
Electronic control unit (genset controller)
19
Remote start terminals
5
Shunt
20
Battery
6
Plug 4 - E-stop, contact outputs
21
Starter motor
7
120 ohm resistor (if equipped)
22
Alternator
8
Hour meter
23
Mechanical lugs
9
Terminal strip
24
Main circuit breaker
10
10A fuse
25
Fuel level sender
11
Battery disconnect (optional)
26
Lug door interlock switch
12
Shunt trip relay
27
Bond bar
13
7.5A fuse
28
Resistor
14
Intake heater
29
ON/OFF toggle switch
15
Heater relay
30
—
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003662gb_FM10.fm
235
Schematics, Machines with Deep Sea Controller
30.7
G 50/G 70
DC Schematic: G 70, T4i Cummins, Deep Sea
17
25
1
15
14
11
4
2
21
20
9
30
31
32
13
29
10
8
33
21
18
3
26
6
23
27
19
24
28
12
wc_gr011794
236
G 50/G 70
30.8
Schematics, Machines with Deep Sea Controller
DC Schematic Components: G 70, T4i Cummins, Deep Sea
Ref.
Description
Ref.
Description
1
Plug 1 - power and engine sender inputs
19
Remote start terminals
2
Plug 2 - sensor inputs
20
20A fuse
3
Plug 3 - CANBUS
21
Starter motor
4
Electronic control unit (genset controller)
22
Battery
5
Water temperature sender
23
Mechanical lugs
6
Plug 6 - contact inputs
24
Main circuit breaker
7
Relay - engine outputs
25
Fuel level sender
8
Hour meter
26
Lug door interlock switch
9
Idle toggle switch
27
Bond bar
10
10A fuse
28
Shunt trip relay
11
ON/OFF toggle switch
29
Battery disconnect (optional)
12
Shunt
30
1A fuse
13
7.5A fuse
31
5A fuse
14
Intake heater
32
150A fuse
15
Intake heater relay
33
Terminal strip
16
Fuel relay
34
—
17
Starter relay
35
Coolant level sensor
18
Emergency stop switch
36
Air cleaner sensor
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
wc_tx003662gb_FM10.fm
237
Schematics, Machines with Deep Sea Controller
G 50/G 70
Notes
238
Wacker Neuson SE
·
Preußenstraße 41
· D-80809 München
· Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390
Wacker Neuson Corporation · N92W15000 Anthony Ave. · Menomonee Falls, WI 53051 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 ·Tel. : (800) 770-0957
Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
Tel: (852) 3605 5360, Fax: (852) 2758 0032
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