Wacker Neuson G 25, T4i, T4f Operator's Manual

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5200015081

Operator’s Manual

Mobile Generator

G 25 (T4i)

G 25 (T4f)

5200015081

04 0215

© Copyright 2015 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.

T ra d emarks

Manufacturer

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

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

wc_gr010874

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 inst allation, operation, and maintenance of the machines.

Machine Item Number

G 25 0620640, 0620641, 062042, 0620709, 0620931,

5200001316, 5200003991, 52000055 57, 5200009370, 5200009371, 5200009372, 52000093 73, 5200009374, 5200009375, 5200009376, 52000093 77, 5200014460, 5200014461, 5200014462, 5100014166, 5100014167

Machine identification

Serial number (S/N)

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.

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:

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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, underst and, 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

Laws pertaining to spark arresters

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.

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.

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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.

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Foreword

Notes

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Table of Contents

Foreword 4

1 Safety Information 13

1.1 Signal Words Used in this Manual ..................................................... 13

1.2 Machine Description and Intended Use ............................................. 14

1.3 Safety Guidelines for Operating the Machine ..................................... 15

1.4 Service Safety .................................................................................... 17

1.5 Operator Safety while Using Internal Combustion Engines ............... 19

1.6 Safety Guidelines for Mobile Generators ........................................... 20

1.7 Safety Guidelines for Towing the Machine ......................................... 22

1.8 Safety Guidelines for Lifting the Machine ........................................... 23

1.9 Reporting Safety Defects ................................................................... 23

2 Label Locations 24

3 Label Meanings 26

4 Lifting and Transporting 36

4.1 Lifting the Machine ............................................................................. 36

4.2 Before Towing Checklist ..................................................................... 37

4.3 Towing the Machine ........................................................................... 38

4.4 Preparing the Machine for Transport on a Truck or Trailer ................ 39

4.5 Hazardous Materials Placards ........................................................... 40

4.6 Testing the Breakaway System (Hydraulic Surge Brakes) ................. 41

4.7 Testing the Breakaway System (Electric Brakes) .............................. 43

5 Machine Setup 45

5.1 Preparing the Machine for First Use ................................................... 45

5.2 Positioning the Machine ..................................................................... 46

5.3 Grounding the Generator ................................................................... 48

5.4 Recommended Fuel ........................................................................... 49

5.5 Refueling the Machine (Basler Controller) ......................................... 50

5.6 Refueling the Machine (Deep Sea Controller) .................................... 51

6 Operation, Control, and Component Locations 52

6.1 Control / Component Locations .......................................................... 52

6.2 Control Panel Components ................................................................ 53

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7 Operation (Basler Controller) 54

7.1 Main Circuit Breaker ...........................................................................54

7.2 Engine Start Switch ............................................................................55

7.3 Genset Pre-Alarms and Alarms (Shut-Down Conditions) ...................56

7.4 Overcurrent Condition .........................................................................57

7.5 Using the Lugs and the Convenience Receptacles ............................58

7.6 Selecting the Voltage ..........................................................................59

7.7 Before Starting the Machine ...............................................................61

7.8 Starting and Running the Machine .....................................................62

7.9 Stopping the Machine .........................................................................64

7.10 Emergency Stop Switch ......................................................................64

7.11 LCD Panel: Monitoring Machine Operation ........................................65

8 Working with Basler Controller 67

8.1 How to Use the Genset Controller LCD and Keypad .......................... 67

8.2 Menu Diagram of the Genset Controller .............................................68

8.3 Menu Diagram Components ...............................................................69

8.4 Using the Metering and Settings Menus .............................................70

8.5 Logging in to the Genset Controller by Entering the Password .......... 71

8.6 Adjusting the LCD Screen Contrast ....................................................74

8.7 Changing the Time/Date Settings .......................................................75

8.8 Changing the Sender Fail Time Delays ..............................................76

8.9 Changing the Units of Measure ..........................................................78

8.10 Changing the Low Fuel Pre-Alarm Setting .........................................80

8.11 Changing or Disabling the Low Fuel Alarm Setting ............................82

8.12 Changing the Cooldown Time Setting ................................................84

8.13 Changing the Pre-Crank Time Delay (Glow Plug Timer) ....................86

8.14 Changing the Maintenance Interval ....................................................88

8.15 Resetting the Maintenance Interval Pre-Alarm ...................................90

8.16 Resetting a Loss of Voltage Pre-Alarm ...............................................92

8.17 Accessing and Using the Event Log ...................................................93

9 Operation (Deep Sea Controller) 95

9.1 Main Circuit Breaker ...........................................................................95

9.2 Genset Controller Power Switch .........................................................96

9.3 Selecting the Voltage ..........................................................................97

9.4 Deep Sea Controller Buttons/Functions .............................................99

9.5 Genset Controller Alarms and Shut-Down Conditions ......................101

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9.6 Before Starting the Machine ............................................................. 103

9.7 Starting and Running the Generator ................................................ 104

9.8 Stopping the Generator .................................................................... 106

9.9 Emergency Stop Switch ................................................................... 107

9.10 Engine and Generator Monitoring .................................................... 108

Table of Contents

10 Working with Deep Sea Controller: DSE 7310 109

10.1 Introduction ....................................................................................... 109

10.2 Navigating the Menus ....................................................................... 110

10.3 Adjusting Screen Contrast ................................................................ 112

10.4 How to Reset the Maintenance Timer .............................................. 113

11 How to Connect Loads (480V) 114

11.1 Lug Terminal Connection Diagrams ................................................. 114

11.2 Best Practices for Balancing Loads .................................................. 115

11.3 Connecting 480V, 3-Phase and Single-Phase Loads ...................... 118

11.4 Connecting a 240V 3Ø Load and a 240V 1Ø Load .......................... 119

11.5 Connecting 240V and 120V Single-Phase Loads ............................ 120

11.6 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads .............. 121

11.7 Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads 122

12 How to Connect Loads (600V) 123

12.1 Lug Terminal Connection Diagrams ................................................. 123

12.2 Best Practices for Balancing Loads .................................................. 124

12.3 Connecting a 240V 3Ø Load and a 240V 1Ø Load .......................... 127

12.4 Connecting 240V and 120V Single-Phase Loads ............................ 128

12.5 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads .............. 129

12.6 Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads 130

12.7 Connecting 480V, 3-Phase Loads .................................................... 131

12.8 Connecting 600V, 3-Phase Loads .................................................... 132

13 Using Remote Start Capabilities 133

13.1 Remote Run Terminal Block ............................................................ 133

13.2 Remote Transfer Switch ................................................................... 134

13.3 Preparing for Automatic/Remote Start-Up (Basler) .......................... 135

13.4 Preparing for Automatic/Remote Start-Up (Deep Sea) .................... 136

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14 Diagnostic Trouble Codes (DTC) 138

14.1 Accessing DTCs with the Basler Controller ......................................138

14.2 Accessing Engine DTCs using the Deep Sea Controller ..................139

14.3 List of Engine Diagnostic Trouble Codes (DTCs) .............................140

15 Factory-Installed Options 143

15.1 Battery Charger ................................................................................143

15.2 Lockable Battery Disconnect ............................................................144

15.3 Camlocks ..........................................................................................145

15.4 Containment System ........................................................................146

15.5 Extended Run Tank (ERT) ...............................................................146

15.6 Engine Block Heater .........................................................................147

15.7 Automatic LCD Heat .........................................................................147

15.8 Low Coolant Shutdown .....................................................................148

15.9 Temperature-Activated Shutters .......................................................149

15.10 Positive Air Shutoff Valve .................................................................150

15.11 Quick-Disconnect Fuel Fittings .........................................................151

15.12 Lube Level Maintainer ......................................................................152

16 General Maintenance 153

16.1 Periodic Maintenance Schedule .......................................................153

16.2 Maintaining the Emission Control System ........................................153

16.3 Preparing for Maintenance ...............................................................154

16.4 Cleaning the Machine .......................................................................154

16.5 Inspecting the Machine .....................................................................155

16.6 Maintaining the Trailer ......................................................................156

16.7 Checking and Draining the Containment System .............................157

16.8 Checking the Exhaust System ..........................................................158

16.9 Maintaining the Battery .....................................................................159

16.10 Cleaning the Diesel Particulate Filter (DPF) (if equipped) ................ 160

16.11 Storage .............................................................................................161

16.12 Machine Disposal / Decommissioning ..............................................162

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Table of Contents

17 Maintenance Tier 4i Engines: Isuzu 163

18 Maintenance Tier 4f Engines: Isuzu 166

19 Troubleshooting 172

20 Technical Data 173

20.1 Engine .............................................................................................. 173

20.2 Generator ......................................................................................... 175

20.3 Trailer and Skid ................................................................................ 176

20.4 Dimensions ....................................................................................... 177

Tire Safety Information 178

21 User’s Information for Transport Canada Fuel Tank 190

22 Emission Control Systems Information and Warranty 193

22.1 Emission Control System Background Information .......................... 193

22.2 Limited Defect Warranty for Exhaust Emission Control System ....... 194

22.3 Limited Defect Warranty for Wacker Neuson Emission Control

Systems ............................................................................................ 194

23 General Machine Schematics 197

23.1 Fuses .............................................................................................. 197

23.2 Trailer Wiring .................................................................................... 198

23.3 Trailer Wiring Components ............................................................... 199

24 Schematics, Machines with Basler Controller 200

24.1 AC Schematic: ................................................................................. 200

24.2 AC Schematic Components: ........................................................... 201

24.3 DC Schematic: G 25, T4i Isuzu, Basler ............................................ 202

24.4 DC Schematic Components: G 25, T4i Isuzu, Basler ...................... 203

24.5 DC Schematic: G 25, T4f Isuzu, Basler ............................................ 204

24.6 DC Schematic Components: G 25, T4f Isuzu, Basler ...................... 205

24.7 AC Schematic: G25, Isuzu, 600V, Basler ......................................... 206

24.8 AC Schematic Components: G 25, Isuzu, 600V, Basler .................. 207

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Table of Contents

25 Schematics, Machines with Deep Sea Controller 208

25.1 AC Schematic: ..................................................................................208

25.2 AC Schematic Components: ............................................................209

25.3 DC Schematic: G 25, T4i Isuzu, Deep Sea .......................................210

25.4 DC Schematic Components: G 25, T4i Isuzu, Deep Sea ..................211

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Mobile Generator

1 Safety Information

1.1 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 mes-

sages that follow this signal word.

Safety Information

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,

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.

obey all

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Safety Information

1.2 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

Mobile Generator

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 rema in even after protective measures have been t aken. 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.

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Mobile Generator

1.3 Safety Guidelines for Operating the Machine

Safety Information

Operator training

Operator qualifications

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.

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

Safety devices, controls, and attachments

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.

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.

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Safety Information

Mobile Generator

Safe operating practices

Personal Protective Equipment (PPE)

After use

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), o il, coolant, hydraulic fluid, heat transfer fluid (propylene glycol with additives), battery acid, or grease.

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

■ 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.

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Mobile Generator

1.4 Service Safety

Safety Information

Service training

Precautions

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.

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

Replacing parts and labels

Cleaning

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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

■ Replace worn or damaged components.

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

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

■ When replacement parts are required for this machine, use only Wacker

When cleaning and servicing the machine:

■ Keep the machine clean and free of debris such as leaves, paper, cartons, etc.

■ Keep the labels legible.

Neuson.

rating and performance to the original components.

Neuson replacement parts or those p arts equivalent to the original in a ll types of specifications, such as physical dimensions, type, strength, and material.

Safety Information

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.

Mobile Generator

Personal Protective Equipment (PPE)

Electrical service safety

Cooling system safety

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).

■ Make sure clothing and shoes are dry , st and on a dry wooden plat form 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.

■ 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.

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Mobile Generator

Safety Information

1.5 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

Refueling 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.

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.

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Safety Information

1.6 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. ALWA YS

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 AW AY. See a doctor. You could have carbon monoxide poison.

Mobile Generator

Installing as backup power

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.

Special hazards exist when installing this machine as a backup power supply. 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 elec-

trician 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 connectio n may lead to equipment damage, fire, and personal injury or death.

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Mobile Generator

Safety Information

General safety

Ground connection

■ 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.

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.

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Safety Information

1.7 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.

Mobile Generator

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.

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Mobile Generator

1.8 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 cap acity 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

Safety Information

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

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Label Locations G 25

wc_gr011688

2 Label Locations

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wc_gr011684

Basler

DIAGNOSTICS

DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS

AUSAUS APAGADOAPAGADO ARRETARRET

OFFOFF

REMOTE STARTREMOTE START

FERNSTARTFERNSTART

ARRANQUE REMOTOARRANQUE REMOTO

DEMARRAGE A DEMARRAGE A DISTANCEDISTANCE

START / LAUFENSTART / LAUFEN ARRANQUE / MARCHAARRANQUE / MARCHA DEMARRER / MARCHEDEMARRER / MARCHE

START / RUNSTART / RUN

T4i

T4f

J J

JT J

SS TT

AAMM

Z S V R N

G 25 Label Locations

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Label Meanings G 25

INSTRUCCIONES DE REMOLQUEINSTRUCCIONES DE REMOLQUE

1.LEA EL MANUAL DEL OPERARIO.1.LEA EL MANUAL DEL OPERARIO.

2.UTILICE UN ACOPLE CORRECTAMENTE 2.UTILICE UN ACOPLE CORRECTAMENTE CLASIFICADO PARA LA "CLASE DE PESO CLASIFICADO PARA LA "CLASE DE PESO BRUTO" DEL VEHICULO DEL REMOLQUE. BRUTO" DEL VEHICULO DEL REMOLQUE.

3.ASEGURESE DE AMARRAR CORRECTAMENTE EL 3.ASEGURESE DE AMARRAR CORRECTAMENTE EL REMOLQUE AL VEHICULO DE REMOLQUE. REMOLQUE AL VEHICULO DE REMOLQUE.

4.FIJE EN CRUZ LAS CADENAS DE SEGURIDAD.4.FIJE EN CRUZ LAS CADENAS DE SEGURIDAD.

5.FIJE EN EL VEHICULO DE REMOLQUE 5.FIJE EN EL VEHICULO DE REMOLQUE LA CADENA DE DESPRENDIMIENTO. LA CADENA DE DESPRENDIMIENTO.

6.CONTROLE LAS LUCES DEL REMOLQUE.6.CONTROLE LAS LUCES DEL REMOLQUE.

1.READ OPERATOR'S MANUAL. 1.READ OPERATOR'S MANUAL.

2.USE HITCH RATED FOR TRAILER'S 2.USE HITCH RATED FOR TRAILER'S "GROSS VEHICLE WEIGHT RATING". "GROSS VEHICLE WEIGHT RATING".

3.SECURELY ATTACH TRAILER TO TOW VEHICLE.3.SECURELY ATTACH TRAILER TO TOW VEHICLE.

4.ATTACH SAFETY CHAINS USING CROSS 4.ATTACH SAFETY CHAINS USING CROSS PATTERN. PATTERN.

5.ATTACH BREAKDOWN CHAIN TO VEHICLE.5.ATTACH BREAKDOWN CHAIN TO VEHICLE.

6.CHECK TRAILER LIGHTS.6.CHECK TRAILER LIGHTS.

TOWING INSTRUCTIONSTOWING INSTRUCTIONS ABSCHLEPPINSTRUKTIONENABSCHLEPPINSTRUKTIONEN

1.BETRIEBSVORSCHRIFT LESEN.1.BETRIEBSVORSCHRIFT LESEN.

2.ANHANGEVORRICHTUNG VERWENDEN, 2.ANHANGEVORRICHTUNG VERWENDEN, DIE DER GESAMTBETRIEBSGEWICHTSKLASSE DIE DER GESAMTBETRIEBSGEWICHTSKLASSE ENTSPRICHT. ENTSPRICHT.

3.ANHANGER SICHER AM ZUGFAHRZEUG 3.ANHANGER SICHER AM ZUGFAHRZEUG BEFESTIGEN. BEFESTIGEN.

4.SICHERHEITSKETTEN KREUZWEISE ANBRINGEN.4.SICHERHEITSKETTEN KREUZWEISE ANBRINGEN.

5.ABREISSKETTE AM FAHRZEUG ANBRINGEN.5.ABREISSKETTE AM FAHRZEUG ANBRINGEN.

6.ANHANGERLEUCHTEN PRUFEN.6.ANHANGERLEUCHTEN PRUFEN.

....

INSTRUCTIONS DE REMORQUAGEINSTRUCTIONS DE REMORQUAGE

1.LIRE LA NOTICE D'EMPLOI.1.LIRE LA NOTICE D'EMPLOI.

2.UTILISER UN CROCHET D'ATTELAGE CONFORME2.UTILISER UN CROCHET D'ATTELAGE CONFORME AU DEBIT NOMINAL DU POIDS BRUT DE AU DEBIT NOMINAL DU POIDS BRUT DE VEHICULE DU VEHICULE TRACTEUR. VEHICULE DU VEHICULE TRACTEUR.

3.ATTACHER LA REMORQUE FERMEMENT AU 3.ATTACHER LA REMORQUE FERMEMENT AU VEHICULE TRACTEUR. VEHICULE TRACTEUR.

4.ATTACHER LES CHAINES DE SURETE EN 4.ATTACHER LES CHAINES DE SURETE EN UTILISANT UNE METHODE CROISEE. UTILISANT UNE METHODE CROISEE.

5.ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE.5.ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE.

6.VERIFIER LES LAMPES DE LA REMORQUE.6.VERIFIER LES LAMPES DE LA REMORQUE.

117960117960

3 Label Meanings

(on trailer , if equipped)

B WARNING

Pressurized contents. Do not open when hot!

C WARNING

Lock doors. Access can cause electric shock or injury.

D NOTICE

Lifting point

E NOTICE

Never change switch position with engine running. Results in damage to machine.

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G 25 Label Meanings

113726

F DANGER

Asphyxiation hazard. Do not run the machine indoors or in an enclosed area without adequate ventilation. Read the Operator’s Manual for instructions. No sparks, flames, or burning objects near machine. Stop the engine before adding fuel. Use only diesel fuel.

G Tie-down point

113726

H 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.

I WARNING

Hot surface

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Label Meanings G 25

J Electrical ground

K WARNING

Electric shock and arc flash can cause serious injury or death.

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G 25 Label Meanings

M Operator’s Manual must be stored on machine.

Replacement Operator’s Manual can be ordered through your local Wacker Neuson distr ibutor.

wc_sy0158787

wc_sy0160602

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Label Meanings G 25

AND

N WARNING!

Operation of this equipment may create sparks

Operation of This Equipment May Create Sparks That Can Start Fires Around Dry Vegetation. A Spark Arrestor May be Required. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements.

WARNING

Per CAL. PRC. CODE

P Read and understand the supplied Operator’s

Q1 WARNING

that can start fires around dry vegetation. A sp ark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.

Manual before operating the machine. Failure to do so increases the risk of injury to yourself and others.

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.

Q2 Voltage selector label

R Remote start operation. Read Operator’s Manual

for instructions.

S 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.

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G 25 Label Meanings

T WARNING

Disconnect battery before servicing. Read the Operator’s Manual.

(on trailer, if equipped)

W Drain containment system.

X 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.

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Label Meanings G 25

Y Operating the main circuit breaker supplies or

interrupts power to the customer connection lugs.

Z Neutral bonded to frame

AA Fuses

Read the Operator’s Manual for machine information.

BB WARNING

CC Generator and receptacle wiring

Electric shock at cooling fins.

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G 25 Label Meanings

DD Engine wiring

EE WARNING

Hot surface

FF (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.

GG Low sulfur fuel or ultra low sulfur fuel only.

JJ Protecting Our Environment

Fluid containment system

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Label Meanings G 25

KK Diagnostic menu navigation

MM This machine may be covered by one or more

patents.

QQ (Camlock models only)

RR (Camlock models only)

(on trailer , if equipped)

(On trailer, if equipped) Certification Label (VIN Number)

Also attached to each unit is a Certification Label. This label specifies that the trailer conforms with all Federal Motor Vehicle Standards in effect at the time of manufacture. The label includes the Vehicle Identification Number (VIN) for the trailer.

Lug door must be closed for lugs and recept acles to energize.

WARNING Electric shock can cause serious injury or death.

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G 25 Label Meanings

0183199

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.

UU 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.

V V WARNING

 Keep all sparks and open flames away from

the battery.

 Wear eye protection.  Keep away from children.

0183199

 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).

WW WARNING

Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrester may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.

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Lifting and Transporting

4 Lifting and Transporting

4.1 Lifting the Machine

Mobile Generator

Requirements

Lifting the machine

■ 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

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.

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Mobile Generator

4.2 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.

Lifting and Transporting

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 brakin g 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 tha t the trailer’s breakaway cable (if applicable) is attached to the towin g

vehicle.

 Test the function of the breakaway system (if applicable).

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Lifting and Transporting

wc_gr011430

4.3 Towing the Machine

Mobile Generator

Background

Brakes

Licensing requirements

The generator’s trailer is equipped with brakes (surge or electric), safety chains (a), lights, and a coupler (pintle or ball-type) (b).

Only use the brakes as designed.

■ The breakaway cable (c) is not a parking brake and should not be used as one.

■ 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

Towing safety

■ 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.

■ 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

Mobile Generator

Lifting and Transporting

4.4 Preparing the Machine for Transport on a Truck or Trailer

Requirements

Checklist

■ 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.

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 t hat the transport vehicle or trailer can sup port 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.

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Lifting and Transporting

4.5 Hazardous Materials Placards

Mobile Generator

Overview

Requirements

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

■ 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

Apply the Placards

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.

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Mobile Generator

wc_gr008509

Lifting and Transporting

4.6 Testing the Breakaway System (Hydraulic Surge Brakes)

Requirements

When

Procedure

■ Hydraulic reservoir filled

■ Machine parked on a flat surface

Test the breakaway system:

■ Before towing

■ After filling the hydraulic reservoir

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.

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.

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Lifting and Transporting

wc_gr008510

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.

Mobile Generator

Result

The procedure to test the breakaway system is now complete.

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Mobile Generator

wc_gr008513

Lifting and Transporting

4.7 Testing the Breakaway System (Electric Brakes)

Requirements

When

Procedure

■ Voltmeter

■ Battery charger or backup battery (charged)

Test the breakaway system:

■ Before towing

■ Monthly if the machine is not in service

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.

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.

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Lifting and Transporting

wc_gr008515

VDC

1000

200

2 200m

V- COM

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.

Mobile Generator

Result

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.

The procedure to test the breakaway system is now complete.

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Mobile Generator

5Machine Setup

5.1 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.

Machine Setup

Safety information

CO Alarms

■ 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.

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.

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Machine Setup

5.2 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.

Mobile Generator

CO Alarms

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.

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Mobile Generator

Continued from the previous page.

Machine Setup

Procedure

Result

Perform the following procedure to position the machine.

1. Place the machine on solid, stable, and level ground.

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2. For machines with trailers, install chocks (a) under the wheels.

The machine is now properly positioned.

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Machine Setup

wc_gr011524

5.3 Grounding the Generator

Mobile Generator

Location

Function

A ground connection is located at the customer connection terminal lugs.

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.

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Mobile Generator

5.4 Recommended Fuel

Low temperatures cause diesel fuel to gel. Always use the proper fuel for the conditions. Follow the guidelines in the table below.

Machine Setup

Lowest expected ambient

temperature

Above freezing < 0°C (32°F)

Below freezing > 0°C (32°F)

Your engine may require ultra low sulfur fuel. Consult the engine owner’s manual.

Recommended fuel

#2 diesel plus additives

Winter-blend diesel

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.

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Machine Setup

Basler

DIAGNOSTICS

DIAGNOSEN

DIAGNOSTICOS

DIAGNOSTICS

wc_gr008413

5.5 Refueling the Machine (Basler Controller)

Mobile Generator

Requirements

Procedure

■ Machine shut down

■ Engine cool

■ Machine/fuel tank level with the ground

■ Remote switch disconnected from the remote run terminal

■ Fresh, clean fuel supply

Perform the procedure below to refuel the machine.

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.

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 ove r-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

Mobile Generator

wc_gr011443



AUTOAUTO

DEEP SEA ELECTRONICSDEEP SEA ELECTRONICS

DSE 7310DSE 7310

DSEDSE

OpenOpen CloseClose

Gen-SetGen-Set

OpenOpen CloseClose

LoadLoad

AlarmAlarm

WarningWarning

Main Breaker OpenMain Breaker Open

Low Speed ActiveLow Speed Active

StartStartLamp TestLamp Test

Horn ResetHorn Reset

AutoAuto ModeMode

ManualManual ModeMode

Stop/ResetStop/Reset

Generator Availabl eGenerator Available L-NL-N L-LL-L

0 kW0 kW

0 V0 V 0.0 Hz0.0 Hz

--- pf--- pf

0 V0 V 0 A0 A

DSE

DEEP SEA ELECTRONICS

DSE 7310

Alarm

Warning

Main Breaker Open

Low Speed Active

5.6 Refueling the Machine (Deep Sea Controller)

Machine Setup

Requirements

Procedure

■ Engine stopped

■ Machine/fuel tank level with the ground

■ Remote switch disconnected from the remote run terminal

■ Fresh, clean fuel supply

Perform the procedure below to refuel the machine.

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.

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.

wc_tx003572gb_FM10.fm

6. Re-install the fuel cap.

7. Place the genset controller power switch in the OFF position.

Operation, Control, and Component Locations

L2L2

L1L1

L3L3

WARNINGWARNING

20A20A

50A50A

0 0 5 6 3 2

wc_gr011689

m op

b f

AUSAUS

APAGADOAPAGADO

ARRETARRET

OFFOFF

REMOTE STARTREMOTE START

FERNSTARTFERNSTART

ARRANQUE REMOTOARRANQUE REMOTO

DEMARRAGE A DEMARRAGE A

DISTANCEDISTANCE

START / LAUFENSTART / LAUFEN ARRANQUE / MARCHAARRANQUE / MARCHA DEMARRER / MARCHEDEMARRER / MARCHE

START / RUNSTART / RUN

DIAGNOSTICS

DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS

STOP

6 Operation, Control, and Component Locations

6.1 Control / Component Locations

wc_tx003635gb_FM10.fm

Operation, Control, and Component Locations

wc_gr011690

6.2 Control Panel Components

Ref. Description Ref. Description

Main circuit breaker

b Voltage adjustment rheostat m GFI receptacle (120 VAC, 20A) 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 Vo ltage selector switch

j Circuit breaker (240V, 20A or 50A) t Fuse box k Circuit breaker (120V, 20A) — —

Twist-lock receptacle (2) 240 VAC, 50A

optional:

240 VAC 20A, (1) 240 VAC 50A

(2)

wc_tx003635gb_FM10.fm

Operation (Basler Controller)

AUS APAGADO ARRET

OFF

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

START / RUN

AUS APAGADO ARRET

OFF

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

START / RUN

7 Operation (Basler Controller)

7.1 Main Circuit Breaker

Mobile Generator

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.

START / RUN

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

OFF

AUS APAGADO

START / RUN

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

OFF

AUS APAGADO ARRET

ARRET

Functions

wc_gr011444

■ The main circuit breaker interrupts power from the volt age 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

Mobile Generator

AUS

APAGADO

ARRET

OFF

REMOTE START

FERNSTART

ARRANQUE REMOTO

DEMARRAGE A

DISTANCE

START / LAUFEN

ARRANQUE / MARCHA

DEMARRER / MARCHE

START / RUN

7.2 Engine Start Switch

Operation (Basler Controller)

Description

Function

The engine start switch (a) is a three-position switch: “REMOTE START”, “OFF”, and “START/RUN”.

OFF

AUS

APAGADO

ARRET

REMOTE START

FERNSTART

ARRANQUE REMOTO

DEMARRAGE A

DISTANCE

START / RUN

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

wc_gr011436

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).

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 st artu p anytime the engine start switch is in the REMOTE START position.

READY screen

Monitoring screen

wc_tx003579gb_FM10.fm

OFF Power to the genset controller is disconnected. Blank screen (off)

Operation (Basler Controller)

DIAGNOSTICS

DIAGNOSEN

DIAGNOSTICOS

DIAGNOSTICS

Basler

Mobile Generator

7.3 Genset Pre-Alarms and Alarms (Shut-Down Conditions)

Background

Pre-alarms

Alarms/ shutdowns

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-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, an d 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)

Not used with Isuzu engine.

wc_gr011837

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

Mobile Generator

Basler

DIAGNOSTICS

DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS

wc_gr010360

7.4 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.

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.

Operation (Basler Controller)

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.

wc_tx003579gb_FM10.fm

Operation (Basler Controller)

wc_gr010361

AUSAUS APAGADOAPAGADO ARRETARRET

OFFOFF

REMOTE STARTREMOTE START

FERNSTARTFERNSTART

ARRANQUE REMOTOARRANQUE REMOTO

DEMARRAGE A DEMARRAGE A DISTANCEDISTANCE

START / LAUFENSTART / LAUFEN ARRANQUE / MARCHAARRANQUE / MARCHA DEMARRER / MARCHEDEMARRER / MARCHE

START / RUNSTART / RUN

Basler

DIAGNOSTICS

DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS

042563

Mobile Generator

7.5 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.

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

Mobile Generator

wc_gr011503

277/480V

120/240V

1Ø3Ø

3Ø 1Ø

DIESELDIESEL

SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE ULTRABAJO CONTENIDO DE AZUFRE.ULTRABAJO CONTENIDO DE AZUFRE.

NUR NIEDRIGEN SCHWEFELKRAFTSTOFF ODER ULTRANIEDRIGEN SCHWEFELKRAFTSTOFF.NUR NIEDRIGEN SCHWEFELKRAFTSTOFF ODER ULTRANIEDRIGEN SCHWEFELKRAFTSTOFF.

STOPSTOP

PELIGROPELIGRO

GEFAHRGEFAHR

DANGERDANGER

177416177416

1Ø

120/240V

208/240V 3

3Ø

277/480V

3Ø

346/600V

120/139V 1

7.6 Selecting the Voltage

Operation (Basler Controller)

Location

Selecting the voltage

One of two types of voltage selector switch—either three-position (a) or fourposition (b)—is mounted to the machine near the lugs.

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.

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

190–240 110–139 190–240 110–139 190–240 110–139

120/139 VAC 1Ø 277/480 VAC 3Ø 380–480 220–277 346/600 VAC 3Ø

540–600 — — — — —

Not available on all models.

Not available on 600V models.

190–240

110–139

190–240

110–139

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.

wc_tx003579gb_FM10.fm

Operation (Basler Controller)

AUSAUS APAGADOAPAGADO ARRETARRET

OFFOFF

REMOTE STARTREMOTE START

FERNSTARTFERNSTART ARRANQUE REMOTOARRANQUE REMOTO DEMARRAGE A DEMARRAGE A

DISTANCEDISTANCE

START / LAUFENSTART / LAUFEN ARRANQUE / MARCHAARRANQUE / MARCHA DEMARRER / MARCHEDEMARRER / MARCHE

START / RUNSTART / RUN

Basler

DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS

042563

wc_gr011502

Basler

DIAGNOSTICS

DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS

AUSAUS APAGADOAPAGADO ARRETARRET

OFFOFF

REMOTE STARTREMOTE START

FERNSTARTFERNSTART ARRANQUE REMOTOARRANQUE REMOTO DEMARRAGE A DEMARRAGE A DISTANCEDISTANCE

START / LAUFENSTART / LAUFEN ARRANQUE / MARCHAARRANQUE / MARCHA DEMARRER / MARCHEDEMARRER / MARCHE

START / RUNSTART / RUN

Mobile Generator

Using the rheostat

The voltage adjustment rheostat (c) is used to fine-tune the voltage as needed while the machine is running.

Care must be taken when using the voltage adjustment rhe ostat 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 vo ltage is above 135V. Damage to the receptacle and the tools connected to it may occur.

Switch Position

208 VAC 3Ø 120 VAC 1Ø

3Ø Voltage (L-L-L)

208 208 120 120 220 220 125 125 240 240

277/480 VAC 3Ø 480 240 139

460 230 133

346/600 VAC 3Ø

600 540

Corresponding 1Ø voltage Twist lock receptacle L-L (240V) L-N (120V) 120V GFCI

139

1 1 2

139 139 133

1 1 2

Do not use receptacle with this voltage.

Voltage may be too high for some tools and equipment. Check tool/equipment specifications.

Not available on all models.

wc_tx003579gb_FM10.fm

Mobile Generator

7.7 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.

Operation (Basler Controller)

Exterior checks

Internal checks

Pre-operation 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.

 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.

 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.

wc_tx003579gb_FM10.fm

Operation (Basler Controller)

wc_gr011279

AUAUSS

APAGADAPAGADOO

ARREARRETT

OFOFFF

REMOTE STARREMOTE STARTT

FERNSTARFERNSTARTT

ARRANQUE REMOTARRANQUE REMOTOO

DEMARRAGE ADEMARRAGE A

DISTANCDISTANCEE

START / LAUFESTART / LAUFENN ARRANQUE / MARCHARRANQUE / MARCHAA DEMARRER / MARCHDEMARRER / MARCHEE

START / RUSTART / RUNN

AUAUSS

APAGADAPAGADOO

ARREARRETT

OFOFFF

REMOTE STARREMOTE STARTT

FERNSTARFERNSTARTT

ARRANQUE REMOTARRANQUE REMOTOO

DEMARRAGE ADEMARRAGE A

DISTANCDISTANCEE

START / LAUFESTART / LAUFENN ARRANQUE / MARCHARRANQUE / MARCHAA DEMARRER / MARCHDEMARRER / MARCHEE

START / RUSTART / RUNN

Basler

DIAGNOSTICS

DIAGNOSEN

DIAGNOSTICOS

DIAGNOSTICS

042563

1Ø

120/240V

3Ø

277/480V

208/240V 3

3Ø

346/600V

120/139V 1

7.8 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.

Mobile Generator

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.

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

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.

Operation (Basler Controller)

Starting

Upon startup

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 ST AR T/RUN.

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.

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.

wc_tx003579gb_FM10.fm

wc_gr010195

Operation (Basler Controller)

ALARM ACTIVEALARM ACTIVE

TO VIEWTO VIEW

EMERGENCY STOPEMERGENCY STOP

wc_gr010365

7.9 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

Mobile Generator

Location

Function

The emergency stop switch (a) is the red button located as shown, and can be accessed with the panel doors closed.

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.

wc_tx003579gb_FM10.fm

Mobile Generator

Operation (Basler Controller)

7.11 LCD Panel: Monitoring Machine Operation

Overview

Generator information

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

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).

HZ 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.

This procedure continues on the next page.

wc_tx003579gb_FM10.fm

Operation (Basler Controller)

Continued from the previous page.

Mobile Generator

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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Mobile Generator Working with Basler Controller

wc_gr010130

8 Working with Basler Controller

8.1 How to Use the Genset Controller LCD and Keypad

Basics

Actions of the buttons

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.

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).

Normal screens

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).

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

wc_tx003229gb_FM10.fm

Working with Basler Controller

Metering

Settings

Metering

Engine

Oil Pressure

Coolant Temp

Fuel Level

Engine Load

Coolant Level*

Total Run Time

Settings

General Settings

Communications

Generator Protection

Breaker Management

Bias Control

Enter Password

General Settings

Crank Settings

Alarm-Status

Alarms

Pre-Alarms

Status

Inputs

Event Log

J1939 Engine Config*

J1939 Active DTC*

J1939 Previous DTC*

Session

Generator

Bus V

Bus Frequency

Synchronizer

Session

Session Info

Total Run Time

Loaded Run Time

Unloaded Run Time

Cumulative

Unloaded Run Time

Front Panel HMI

Detailed Data

* NOT AVAILABLE ON SOME MODELS

wc_gr007618

8.2 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.

Mobile Generator

wc_tx003229gb_FM10.fm

Mobile Generator Working with Basler Controller

8.3 Menu Diagram Components

Menu Item Description Menu Item Description

Alarm Config

Alarm Configuration Alarms Alarm–Status

Amps Back Battery Volt Bias Control Breaker Management Bus Frequency Bus V Communications Conf Elements Conf Prot Status

Configure Date/Time Coolant Level Coolant Temp Cooldown Time Crank Settings Cumulative Cumulative Info Detailed Data Diagnostic Menu Navi-

gation Down Engine

En Enter Password Event Log Forward Frequency Front Panel HMI

Fuel Level General Settings

gine

Load

Alarm configuration

— — —

— — — — — — Bus voltage — Configurable elements Configurable protection

status — — — — — — — — —

— — — — — — — Human-Machine

Interface — —

J1939 Active DTC

J1939 Data J1939 Engine Config J1939 Previous DTC

kVA kVAR kW Language LCD Contrast Loaded Run Time Low Fuel Level Main Menu Maintenance Reset Metering

Oil Pressure Outputs PF Power Pre-Alarms Programmable Inputs RPM Run Statistics Session

Session Info Settings Speed Source Status Synchronizer Sys Parameters System Settings System Units

Total Run Time Unloaded Run Time

Diagnostic Trouble Codes

— Engine configuration Diagnostic Trouble

Codes Kilovolt-amps Kilovolt-amps Reactive Kilowatts — Liquid Crystal Display — — — — —

— — Power factor — — — Rotations per minute — —

— — — — — System parameters — —

— —

wc_tx003229gb_FM10.fm

Working with Basler Controller

Menu Item Description Menu Item Description

Generator Generator Protection Hrs to Maintenance Inputs

— — Hours to maintenance —

Up Voltages — —

Mobile Generator

— — — —

8.4 Using the Metering and Settings Menus

Background

METERING menus

SETTINGS menus

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 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 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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Mobile Generator Working with Basler Controller

wc_gr010119

8.5 Logging in to the Genset Controller by Entering the Password

Precaution

Password

At ENTER PASSWORD

Only change parameters when the READY screen is displayed (start switch in the REMOTE START position).

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.

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.

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.

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Working with Basler Controller

wc_gr010122

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.

Mobile Generator

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.

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Mobile Generator Working with Basler Controller

wc_gr010128

At the PASSWORD prompt

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 tha t shown below lef t (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.

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 p assword 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 Adjusting the LCD Screen Contrast

Mobile Generator

Requirements

Procedure

 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.

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 Changing the Time/Date Settings

Requirements

Procedure

 Machine stopped  Start switch in REMOTE START

Perform the procedure below to change the time and date.

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 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

wc_tx003229gb_FM10.fm

The date/time settings have now been changed.

Working with Basler Controller

8.8 Changing the Sender Fail Time Delays

Mobile Generator

Requirements

Background

Procedure

 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.

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 list s the fa ilu retime-delay periods, the allowable range, and their factory settings.

Failure Time Delay 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.

This procedure continues on the next page.

wc_gr010134

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Mobile Generator Working with Basler Controller

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 Changing the Units of Measure

Mobile Generator

Requirements

Background

Procedure

 Machine stopped  Start switch in REMOTE START

Genset controller units of measure may be set to English (imperial) or metric.

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 de sired. Press the check mark button when finished.

This procedure continues on the next page.

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Continued from the previous page.

Result

The units of measure have now been changed.

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Working with Basler Controller

8.10 Changing the Low Fuel Pre-Alarm Setting

Mobile Generator

Requirements

Background

Procedure

 Machine stopped  Start switch in REMOTE START

The low fuel pre-alarm setting may be changed if desired. The value shown b y the genset controller is the percentage of fuel remaining in the fuel tank. The range allowed by the genset controller is 10–100.

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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Mobile Generator Working with Basler Controller

Continued from the previous page.

8. Using the up/down arrow buttons, change the value as desired. Press the check mark button when finished.

Result

The low fuel pre-alarm setting has now been changed.

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Mobile Generator

8.11 Changing or Disabling the Low Fuel Alarm Setting

Requirements

Background

Notes

 Machine stopped  Start switch in REMOTE START

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 pre-

alarm. 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 belo w 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.

Procedure

Approximate run time (at 100% prime load) gained with low fuel alarm set to 0%.

Machine 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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Mobile Generator Working with Basler Controller

Continued from the previous page.

Result

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.

The low fuel alarm setting has now been changed.

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8.12 Changing the Cooldown Time Setting

Mobile Generator

Requirements

Background

Procedure

 Machine stopped  Start switch in REMOTE START

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.

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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Mobile Generator Working with Basler Controller

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.

Result

The cooldown time setting has now been changed.

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Working with Basler Controller

Mobile Generator

8.13 Changing the Pre-Crank Time Delay (Glow Plug Timer)

Requirements

Background

Procedure

 Machine stopped  Start switch in REMOTE START

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.

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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Mobile Generator Working with Basler Controller

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.

Result

The pre-crank time delay has now been changed.

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Working with Basler Controller

8.14 Changing the Maintenance Interval

Mobile Generator

Requirements

Background

Procedure

 Machine stopped  Start switch in REMOTE START

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.

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.

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Mobile Generator Working with Basler Controller

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.

Result

The maintenance interval has now been changed.

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8.15 Resetting the Maintenance Interval Pre-Alarm

Mobile Generator

Requirements

Background

Procedure

 Machine stopped  Start switch in REMOTE START

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.

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.

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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.

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8.16 Resetting a Loss of Voltage Pre-Alarm

Mobile Generator

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 volt age 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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8.17 Accessing and Using the Event Log

Requirements

Background

Procedure

 Machine stopped  Start switch in REMOTE START

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 an d time setting of the genset controller.

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 Protec tive 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

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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

Mobile Generator

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 e vents. Th e one with the most current date and time is the most recent.

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Mobile Generator

AUS

APAGADO

ARRET

OFF

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

START / RUN

AUS APAGADO ARRET

OFF

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

START / RUN

9 Operation (Deep Sea Controller)

9.1 Main Circuit Breaker

Operation (Deep Sea Controller)

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.

START / RUN

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

OFF

AUS

APAGADO

START / RUN

START / LAUFEN ARRANQUE / MARCHA DEMARRER / MARCHE

OFF

AUS APAGADO ARRET

ARRET

Functions

wc_gr011444

■ The main circuit breaker interrupts power from the volt age se lector 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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Operation (Deep Sea Controller)

OFFOFF

ONON

wc_gr011478

9.2 Genset Controller Power Switch

Mobile Generator

Description

Function

The genset controller power switch (a) is a two-position switch: ON and OFF.

Position Function LCD Screen

ON When set to this position:

■ Power is supp lie d to th e genset

controller.

■ The genset controller boots up and sets

itself to the Stop/Reset mode—the engine is ready to be started.

“Generator at Rest” followed by the status screens that scroll.

OFF When set to this position, power to the

genset controller is disconnected.

Blank screen (off)

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Mobile Generator

wc_gr011503

277/480V

120/240V

1Ø3Ø

3Ø 1Ø

DIESELDIESEL

SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE ULTRABAJO CONTENIDO DE AZUFRE.ULTRABAJO CONTENIDO DE AZUFRE.

NUR NIEDRIGEN SCHWEFELKRAFTSTOFF ODER ULTRANIEDRIGEN SCHWEFELKRAFTSTOFF.NUR NIEDRIGEN SCHWEFELKRAFTSTOFF ODER ULTRANIEDRIGEN SCHWEFELKRAFTSTOFF.

STOPSTOP

PELIGROPELIGRO

GEFAHRGEFAHR

DANGERDANGER

177416177416

1Ø

120/240V

208/240V 3

3Ø

277/480V

3Ø

346/600V

120/139V 1

9.3 Selecting the Voltage

Operation (Deep Sea Controller)

Location

Selecting the voltage

One of two types of voltage selector switch—either three-position (a) or fourposition (b)—is mounted to the machine near the lugs.

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.

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

190–240 110–139 190–240 110–139 190–240 110–139

120/139 VAC 1Ø 277/480 VAC 3Ø 380–480 220–277 346/600 VAC 3Ø

540–600 — — — — —

Not available on all models.

Not available on 600V models.

190–240

110–139

190–240

110–139

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.

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Operation (Deep Sea Controller)

AUSAUS APAGADOAPAGADO ARRETARRET

OFFOFF

REMOTE STARTREMOTE START

FERNSTARTFERNSTART ARRANQUE REMOTOARRANQUE REMOTO DEMARRAGE A DEMARRAGE A

DISTANCEDISTANCE

START / LAUFENSTART / LAUFEN ARRANQUE / MARCHAARRANQUE / MARCHA DEMARRER / MARCHEDEMARRER / MARCHE

START / RUNSTART / RUN

Basler

DIAGNOSTICS DIAGNOSEN

DIAGNOSTICOS

DIAGNOSTICS

042563

wc_gr011502

Basler

DIAGNOSTICS

DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS

AUSAUS APAGADOAPAGADO ARRETARRET

OFFOFF

REMOTE STARTREMOTE START

FERNSTARTFERNSTART ARRANQUE REMOTOARRANQUE REMOTO DEMARRAGE A DEMARRAGE A DISTANCEDISTANCE

START / LAUFENSTART / LAUFEN ARRANQUE / MARCHAARRANQUE / MARCHA DEMARRER / MARCHEDEMARRER / MARCHE

START / RUNSTART / RUN

Mobile Generator

Using the rheostat

The voltage adjustment rheostat (c) is used to fine-tune the voltage as needed while the machine is running.

NOTICE: Do not use the GFCI or twist-lock receptacle (120V) when the 1Ø vo ltage is above 135V. Damage to the receptacle and the tools connected to it may occur.

Switch Position

208 VAC 3Ø 120 VAC 1Ø

3Ø Voltage (L-L-L)

208 208 120 120 220 220 125 125 240 240

277/480 VAC 3Ø 480 240 139

460 230 133

346/600 VAC 3Ø

600 540

Corresponding 1Ø voltage Twist lock receptacle L-L (240V) L-N (120V) 120V GFCI

139

1 1 2

139 139 133

1 1 2

Do not use receptacle with this voltage.

Voltage may be too high for some tools and equipment. Check tool/equipment specifications.

Not available on all models.

wc_tx003580gb_FM10.fm

Mobile Generator

AUTAUTOO

DEEP SEA ELECTRONICDEEP SEA ELECTRONICSS

DSE 731DSE 73100

DSE

OpenOpen CloseClose

Gen-SetGen-Set

OpenOpen CloseClose

LoadLoad

AlarmAlarm

Warningarning

Main Breaker OpenMain Breaker Open

Low SpeedLow Speed ActiveActive

StartStartLampLamp Testest

Horn ResetHorn Reset

AutoAuto ModeMode

ManualManual

ModeMode

Stop/ResetStop/Reset

12 13 14 15 16 17

wc_gr011485

Operation (Deep Sea Controller)

9.4 Deep Sea Controller Buttons/Functions

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 mar k but to n (e nt er / acce pt)

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)

wc_tx003580gb_FM10.fm

Operation (Deep Sea Controller)

Ref. 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.

Mobile Generator

100

wc_tx003580gb_FM10.fm

Wacker Neuson G 25, T4i, T4f Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual