0175257en 001
0608
Mobile Generator
G 43
OPERATOR’S MANUAL
0175257EN
G 43 Foreword
Foreword
Machines
covered by
this manual
Machine Item Number
G 43 0620545
Machine
Documentation
Expectations
for
information in
this manual
Copyright
notice
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
If you are missing any of these documents, please contact Wacker Neuson
Corporation to order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson Corporation reserves the right
to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2008 by Wacker Neuson Corporation.
This publication may be reproduced through photocopying by the original
purchaser of the machine. Any other type of reproduction is prohibited without
express written permission from Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson
Corporation represents an infringement of valid copyrights, and violators will be
prosecuted.
Trademarks
All trademarks referenced in this manual are the property of their respective
owners.
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Foreword G 43
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G 43 Table of Contents
Foreword 3
1 Safety Information 7
1.1 Signal Words Found in this Manual ...................................................... 7
1.2 Safety Instructions for Operating the Machine ..................................... 8
1.3 Safety Instructions for Towing ............................................................ 10
1.4 Safety Instructions for Servicing the Machine .................................... 11
1.5 Label Locations .................................................................................. 14
1.6 Label Meanings .................................................................................. 15
2 Transporting, Lifting, and Storing 16
2.1 Transporting ....................................................................................... 16
2.2 Storing ................................................................................................ 16
2.3 Lifting .................................................................................................. 17
3 Operating the Machine 19
3.1 Application .......................................................................................... 19
3.2 Control/Component Locations ............................................................ 20
3.3 Control/Component Descriptions ....................................................... 21
3.4 Control Panel/Microprocessor ............................................................ 22
3.5 Control Panel/Microprocessor Functions ........................................... 22
3.6 Main Control Switch Positions/Functions ........................................... 24
3.7 Preliminary Checklist .......................................................................... 26
3.8 Starting the Generator ........................................................................ 27
3.9 Stopping the Generator ...................................................................... 28
3.10 Connecting Loads to the Terminal Lugs ............................................. 29
3.11 Operating the Generator .................................................................... 30
3.12 Microprocessor Display Screens ........................................................ 31
4 Maintenance 34
4.1 Periodic Maintenance Schedule ......................................................... 34
4.2 Checking the Engine Oil ..................................................................... 35
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Table of Contents G 43
4.3 Changing the Engine Oil .....................................................................36
4.4 Changing Oil Filter ...............................................................................37
4.5 Changing the Fuel Filter ......................................................................38
4.6 Air Cleaner Discharge Valve ...............................................................39
4.7 Cleaning/Changing Air Filter Cartridges ..............................................40
4.8 Checking the Alternator V-Belt ............................................................41
4.9 Lubricating the Trailer ..........................................................................42
4.10 Cleaning the Engine ............................................................................43
4.11 Changing/Tensioning Alternator V-Belt ...............................................44
4.12 Checking/Adjusting Valve Clearances ................................................45
4.13 Checking Battery Electrolyte ...............................................................47
5 Schematics 48
5.1 Power Wiring .......................................................................................48
5.2 Power Wiring Components ..................................................................49
5.3 Engine Wiring ......................................................................................50
5.4 Engine Wiring Components .................................................................51
5.5 Socket Wiring ......................................................................................52
5.6 Socket Wirng Components ..................................................................53
5.7 Control Wiring ......................................................................................54
5.8 Control Wiring Components ................................................................55
6 Basic Troubleshooting 56
7 Technical Data 58
7.1 Machine ...............................................................................................58
7.2 Engine .................................................................................................59
7.3 Dimensions ..........................................................................................60
7.4 Sound Specification .............................................................................61
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50Hz Mobile Generators Safety Information
1 Safety Information
1.1 Signal Words Found in this Manual
This is the safety alert symbol. It is used to alert you to potential personal hazards.
f Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
f Obey all safety messages that follow this symbol to avoid injury or death.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
f Obey all safety messages that follow this symbol to avoid possible injury or
death.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
f Obey all safety messages that follow this symbol to avoid possible minor or
moderate injury.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
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Safety Information 50Hz Mobile Generators
1.2 Safety Instructions for Operating the Machine
DANGER
Electric shock hazard. Backfeed from the generator into the public power distribution system can seriously injure or kill utility workers!
f Connections to a building’s electrical system must be made by a qualified elec-
trician and comply with all applicable laws and electrical codes.
Safety
devices,
controls, and
attachments
Operator
training
Only operate the machine when:
All safety devices and guards are in place and in working order.
All controls operate correctly.
The machine is set up correctly according to the instructions in the Operator’s
Manual.
The machine is clean.
The machine’s labels are legible.
To ensure safe operation of the machine:
Do not operate the machine if any safety devices or guards are missing or inop-
erative.
Do not modify or defeat the safety devices.
Do not use accessories or attachments that are not recommended by Wacker
Neuson Corporation.
Before operating the machine:
Read and understand the operating instructions contained in all manuals
delivered with the machine.
Familiarize yourself with the location and proper use of all controls and safety
devices.
Contact Wacker Neuson Corporation for additional training if necessary.
When operating this machine:
Do not allow improperly trained people to operate the machine. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Safe
operating
practices
When operating this machine:
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
Wear protective clothing appropriate to the job site when operating the
machine.
Wear safety glasses when operating this machine.
Wear hearing protection when operating this machine.
When operating this machine:
Do not operate a machine in need of repair.
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50Hz Mobile Generators Safety Information
Work area
Be aware of the work area.
Keep unauthorized personnel, children, and pets away from the machine.
Remain aware of changing positions and the movement of other equipment
and personnel in the application area/job site.
Keep the machine at least one meter (three feet) away from structures, build-
ings, and other equipment during use.
Keep the area immediately surrounding and underneath the machine clean,
neat, and free of debris and combustible materials. Make sure that the area
overhead is clear of debris that could fall onto or into the machine or exhaust
compartment.
Make sure the machine is on a firm, level surface and will not tip, roll, slide, or
fall while operating.
Be aware of the application area.
Never operate the machine indoors unless exhaust fumes can be adequately
ventilated.
Never operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
Never operate the machine if you or the machine are in water.
Electrical
safety
Storing the
machine
To increase electrical safety while operating this machine, follow the procedures
below.
Do not operate the generator, or tools attached to the generator, with wet
hands.
Do not use worn electrical cords.
Make certain the machine is well-grounded and securely fastened to a good
earthen ground per national and local regulations.
Do not overload the generator. The total amperage of the tools and equipment
attached to the generator must not exceed the load rating of the generator.
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.
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Safety Information 50Hz Mobile Generators
1.3 Safety Instructions for Towing
WARNING
Towing a trailer requires special care. To reduce the possibility of an accident:
f Both the trailer and the vehicle must be in good working condition.
f The trailer and the vehicle must be securely fastened to each other.
Hitch and
coupling
Tires and
wheels
Brakes and
lights
To reduce the possibility of an accident, perform the following before towing.
Check that the hitch and coupling on the vehicle are rated equal to, or greater
than, the trailer's “gross vehicle weight rating” (GVWR).
Inspect the hitch and coupling for wear or damage. DO NOT tow the trailer
using defective parts.
Make sure the coupling is securely fastened to the vehicle.
Connect the safety chains.
Connect the breakaway cable safety hook to the bumper or rear of the vehicle.
Do not attach it to the hitch.
To reduce the possibility of an accident, perform the following before towing.
Check the condition, tread wear, and air pressure of the trailer tires. Replace
worn tires.
Check that the wheel lug nuts are tight and that none are missing.
To reduce the possibility of an accident, perform the following before towing.
Test the brake linkage on the trailer and the brakes on the towing vehicle.
Make sure directional and trailer lights are connected and working properly.
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50Hz Mobile Generators Safety Information
1.4 Safety Instructions for Servicing the Machine
WARNING
A poorly maintained machine can be a personal injury hazard.
f Follow the Periodic Maintenance schedule in this Operator’s Manual.
f Repair or replace any damaged or defective components immediately.
Service
training
Precautions
Safe servicing
practices
Before servicing or maintaining the machine:
Read and understand the instructions contained in all manuals delivered with
the machine.
Familiarize yourself with the location and proper use of all controls and safety
devices.
Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
Contact Wacker Neuson Corporation for additional training if necessary.
When servicing or maintaining this machine:
Do not allow improperly trained people to service or maintain the machine. Per-
sonnel servicing or maintaining the machine must be familiar with the associated potential risks and hazards.
Follow the precautions below when servicing or maintaining the machine.
Read and understand the service procedures before performing any service to
the machine.
All adjustments and repairs must be completed before operation. Do not oper-
ate the machine with a known problem or deficiency.
When servicing and maintaining this machine:
Be aware of the machine’s moving parts. Keep hands, feet, and loose clothing
away from the machine’s moving parts.
Wear protective clothing appropriate to the job.
Wear safety glasses.
Wear hearing protection if required.
Re-install the safety devices and guards after repairs and maintenance.
Machine
modifications
When servicing or maintaining the machine:
Use only accessories/attachments recommended by Wacker Neuson Corpora-
tion.
When servicing or maintaining the machine:
Do not defeat the safety devices.
Do not modify the machine without the express written approval of Wacker
Neuson Corporation.
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Safety Information 50Hz Mobile Generators
Replacing
parts and
labels
Before
servicing
Lifting and
transporting
Replace worn or damaged components.
Use only spare parts recommended by Wacker Neuson Corporation.
Replace all missing and hard-to-read labels.
When replacing electrical components, use components that are identical in
rating and performance as the original components.
Complete the following procedures before servicing the machine.
Turn off the machine.
Open the circuit breakers (“OFF”).
Disconnect the battery.
Attach a “DO NOT START” sign to the control panel.
Make sure that the remote start or transfer switch (if used) is also off and
tagged.
Let the engine cool.
When lifting the machine:
Make sure slings, chains, hooks, ramps, jacks and other types of lifting devices
are attached securely and have enough weight-bearing capacity to lift or hold
the machine safely.
Be aware of the location of other people when lifting the machine.
To reduce the possibility of injury:
Do not stand under the machine while it is being hoisted or moved.
Do not get onto the machine while it is being hoisted or moved.
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50Hz Mobile Generators Safety Information
Notes
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Safety Information 50Hz Mobile Generators
1.5 Label Locations
a
b
c
wc_gr005209
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50Hz Mobile Generators Safety Information
1.6 Label Meanings
Ref. Label Definition
a
b
Attention! Work with hood closed
WARNING!
Electric shock will cause serious
injury or death.
c
GND
d
88897
Electrical ground
Internal fuel tank connection
External fuel tank connection
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Transporting, Lifting, and Storing 50Hz Mobile Generators
2 Transporting, Lifting, and Storing
2.1 Transporting
When transporting the machine, only use transport vehicles with enough weightbearing capacity for both the generator and the trailer. See section Technical Data.
Secure the generator and the trailer to the transport vehicle.
2.2 Storing
When storing the machine for more than 30 days:
Drain the fuel tank.
Change the engine oil.
Disconnect the battery.
Clean the machine.
Cover the machine.
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50Hz Mobile Generators Transporting, Lifting, and Storing
2.3 Lifting
Prerequisites
Procedure
Engine shut down
Appropriate lifting equipment (see section Technical Data for weights)
Follow the procedure below to lift the machine.
WARNING
Crush hazard. The weight of the machine may crush you if the lifting equipment
fails. Crushing may cause severe injury or death.
f Only use lifting equipment with enough lifting capacity to support the weight of
the machine and the trailer.
1. Turn off the engine.
2. Disconnect all loads.
3. Secure all doors in the closed position.
4. Connect an appropriate crane to the lifting eye (a) and lift the machine as
needed. A fork truck may also be used. Use the fork lift pockets (b) in the frame
of the machine.
WARNING
Crush hazard. The weight of the machine may crush you if the lifting equipment
fails. Crushing may cause severe injury or death.
f Do not stand underneath the machine when it is being lifted.
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Transporting, Lifting, and Storing 50Hz Mobile Generators
Notes
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50Hz Mobile Generators Operating the Machine
3 Operating the Machine
3.1 Application
Generator
application
Safety notices
This machine is a heavy-duty, compact, sound-attenuated generator designed to
provide single and three-phase power for construction, commercial, and industrial
applications where reliable power is needed.
.
Do not exceed the power output of the generator. Damage to tools or generator
will occur. Refer to Technical Data.
When using the generator as a standby or substitute power supply, make sure
the voltage and phase rotation of the line connections match those of the mains
lines. Failure to match phase rotation and voltage may cause equipment connected to the generator to operate incorrectly! This could create unsafe operating conditions.
Do not exceed the rated current limit of any receptacle.
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Operating the Machine 50Hz Mobile Generators
3.2 Control/Component Locations
a
b c d e f
p
m
j
l
k
h
i
g
wc_gr005210
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