Operator’s Manual

Mobile Generator

G50

Machine Type G50

Material Number 5100064538 / 3300031571
Version 02
Date 02/2023 5100064538
Language [en-US]
Imprint
Publisher and copyright holder:
Wacker Neuson America Corporation
N92W15000 Anthony Ave
Menomonee Falls, WI 53051, USA
www.wackerneuson.us
Original operator’s manual
All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable
worldwide.
This document may be used by the recipient only for the designated purpose. It may in no way be duplicated or
translated in any other language, in whole or in part, without prior permission in writing from the manufacturer.
Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of
Wacker Neuson America Corporation.
Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecu-
tion.
Wacker Neuson America Corporation reserves the right to change its products and their technical specifications
for further technical development at any time without any claim to changes to machines already delivered. The in-
formation in the technical documentation supplied with the product applies in each case.
The machine on the cover is for illustration purposes only and may therefore have special equipment (options).
Wacker Neuson America Corporation, responsibility for errors or omissions not accepted, printed in USA
Copyright © 2023
California Proposition 65 Warning

WARNING
The engine exhaust from this product contains chemicals known to
the State of California to cause cancer, birth defects, or other repro-
ductive harm.

WARNING
Diesel engine exhaust and some of its constituents are known to the
State of California to cause cancer, birth defects, and other reproduc-
tive harm.

WARNING
Cancer and Reproductive Harm
www.P65Warnings.ca.gov

WARNING
Batteries, battery posts, terminals and related accessories contain
lead and lead compounds, and other chemicals known to the State of
California to cause cancer and birth defects or other reproductive
harm. WASH HANDS AFTER HANDLING.
This page is intentionally left blank.
 Table of Contents

Table of Contents
1 Foreword
1.1 Machine Identification ............................................................................................................................ 8
1.2 Machine Documentation ........................................................................................................................ 8
1.3 Expectations for Information in This Manual .......................................................................................... 9
1.4 California Proposition 65 Warning ......................................................................................................... 9
1.5 Laws Pertaining to Spark Arresters ....................................................................................................... 9
1.6 Manufacturer’s Approval ........................................................................................................................ 9
1.7 Abbreviations ....................................................................................................................................... 10

2 Usage
2.1 Intended Use........................................................................................................................................ 11
2.2 Unintended Use ................................................................................................................................... 11
2.3 Residual Risks ..................................................................................................................................... 12

3 Safety
3.1 Signal Words Used in This Manual ...................................................................................................... 13
3.2 Safety Guidelines for Operating the Machine ...................................................................................... 13
3.3 Safety Guidelines for Maintenance ...................................................................................................... 14
3.4 Safety Guidelines for Using Internal Combustion Engines .................................................................. 16
3.5 Safety Guidelines for Mobile Generators ............................................................................................. 17
3.6 Reporting Safety Defects ..................................................................................................................... 18

4 Description of the Machine

4.1 Machine Description ............................................................................................................................ 20
4.2 Controls and Components ................................................................................................................... 20
4.3 Overview of the Labels ........................................................................................................................ 23
4.4 Safety Label Meanings ........................................................................................................................ 27
4.5 Information Label Meanings................................................................................................................. 34

5 Transportation
5.1 Safety Guidelines for Lifting and Transporting ..................................................................................... 38
5.2 Lifting the Machine ............................................................................................................................... 38
5.3 Before Towing Checklist ...................................................................................................................... 39
5.4 Towing the Machine ............................................................................................................................. 40
5.5 Preparing the Machine for Transport on a Truck or Trailer .................................................................. 40
5.6 Hazardous Materials Placard ............................................................................................................... 41
5.7 Testing the Breakaway System—Hydraulic Surge Brakes .................................................................. 42
5.8 Testing the Breakaway System—Electric Brakes ................................................................................ 43

6 Commissioning
6.1 Preparing the Machine for First Use .................................................................................................... 45
6.2 Installing the Trailer Tongue ................................................................................................................ 45

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6.3 Positioning the Machine ....................................................................................................................... 46

6.4 Grounding the Machine........................................................................................................................ 47
6.5 Recommended Fuel............................................................................................................................. 48
6.6 Refueling the Machine—Deep Sea Controller ..................................................................................... 49

7 Operation
7.1 Main Circuit Breaker ............................................................................................................................ 51
7.2 Deep Sea Controller ............................................................................................................................ 51
7.3 Working with Deep Sea Controller ....................................................................................................... 66
7.4 How to Connect Loads—480V............................................................................................................. 70
7.5 How to Connect Loads—600V............................................................................................................. 80
7.6 Using Remote Start Capabilities .......................................................................................................... 89
7.7 Wet Stacking ........................................................................................................................................ 94

8 Accessories
8.1 Overview .............................................................................................................................................. 95
8.2 Lockable Battery Disconnect ............................................................................................................... 95
8.3 600V Capability .................................................................................................................................... 95
8.4 Battery Charger.................................................................................................................................... 95
8.5 Fuel Filter Heater ................................................................................................................................. 96
8.6 Quick Oil Change ................................................................................................................................. 96
8.7 Containment System............................................................................................................................ 97
8.8 Camlocks ............................................................................................................................................. 98
8.9 Engine Block Heater ............................................................................................................................ 99
8.10 Low Coolant Shutdown ........................................................................................................................ 99
8.11 External Fuel Supply Connection....................................................................................................... 100
8.12 Level Load Logic (L3) ........................................................................................................................ 100

9 Maintenance
9.1 General Maintenance......................................................................................................................... 102
9.2 Preparing for Maintenance................................................................................................................. 102
9.3 Maintenance Table ............................................................................................................................ 102
9.4 Inspecting the Machine ...................................................................................................................... 103
9.5 Checking and Cleaning the Radiator ................................................................................................. 103
9.6 Maintaining the Fuel Filter.................................................................................................................. 104
9.7 Maintaining the Trailer ....................................................................................................................... 105
9.8 Engine Oil Viscosity ........................................................................................................................... 106
9.9 Checking the Engine Oil .................................................................................................................... 107
9.10 Checking the Exhaust System ........................................................................................................... 108
9.11 Checking and Draining the Containment System (if equipped) ......................................................... 109
9.12 Servicing the Air Cleaner ................................................................................................................... 110
9.13 Cleaning the Machine ........................................................................................................................ 110

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9.14 Maintaining the Battery ...................................................................................................................... 111

9.15 Changing the Engine Oil and Filter .................................................................................................... 112
9.16 Maintaining the Emission Control System ......................................................................................... 114
9.17 Filling the Radiator ............................................................................................................................. 115
9.18 Coolant............................................................................................................................................... 116

10 Troubleshooting
10.1 Troubleshooting ................................................................................................................................. 117
10.2 Diagnostic Trouble Codes.................................................................................................................. 117

11 Storage
11.1 Long-Term Storage ............................................................................................................................ 123

12 Decommissioning

13 Technical Data
13.1 Engine ................................................................................................................................................ 126
13.2 Generator ........................................................................................................................................... 126
13.3 Machine ............................................................................................................................................. 127
13.4 Trailer and Skid .................................................................................................................................. 127
13.5 Dimensions ........................................................................................................................................ 128

14 Tire Safety Information

14.1 Tire Safety Information....................................................................................................................... 129
14.2 Tire Safety Information Section Descriptions ..................................................................................... 129
14.3 Steps for Determining Correct Load Limit—Trailer ............................................................................ 130
14.4 Steps for Determining Correct Load Limit—Tow Vehicle................................................................... 131
14.5 Glossary of Tire Terminology ............................................................................................................. 132
14.6 Tire Safety—Everything Rides on It ................................................................................................... 136
14.7 Safety First—Basic Tire Maintenance................................................................................................ 137
14.8 Tire Safety Tips .................................................................................................................................. 143

15 Emission Control System Information and Warranty

15.1 Emission Control System Background Information............................................................................ 144
15.2 Limited Defect Warranty for Exhaust Emission Control System ........................................................ 144
15.3 Limited Defect Warranty for Wacker Neuson Emission Control Systems.......................................... 145

Index .............................................................................................................................................................. 148

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Foreword
1.1 Machine Identification

1 Foreword

1.1 Machine Identification

Save these instructions
This manual contains important instructions for the machine models below.
These instructions have been written expressly by Wacker Neuson America
Corporation and must be followed during installation, operation, and mainte-
nance of the machines.
The following machines and variants/options are described:

Machine Item Number

G50 5100052254

Machine identification
A nameplate listing the model number, item number, revision, and serial
number is attached to this machine. The location of the nameplate is shown
below.

Fig. 1: Nameplate location

Serial number (S/N)

For future reference, record the serial number in the space provided below.
You will need the serial number when requesting parts or service for this ma-
chine.

Serial number:

1.2 Machine Documentation

Keep a copy of the operator’s manual with the machine at all times.
From this point forward in this documentation, Wacker Neuson America Cor-
poration will be referred to as Wacker Neuson or the manufacturer.

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 Foreword
Expectations for Information in This Manual 1.3

For spare parts information, please see your Wacker Neuson dealer, or visit
the Wacker Neuson website at http://www.wackerneuson.com/.
1
When ordering parts or requesting service information, be prepared to pro-
vide the machine model number, item number, and serial number.

1.3 Expectations for Information in This Manual

This manual provides information and procedures to safely operate and
maintain this machine. For your own safety and to reduce the risk of injury,
carefully read, understand, and observe all instructions described in this
manual.
The manufacturer expressly reserves the right to make technical modifica-
tions, even without notice, which improve the performance or safety stan-
dards of its machines.
The information contained in this manual is based on machines manufac-
tured up until the time of publication. The manufacturer reserves the right to
change any portion of this information without notice.
The illustrations, parts, and procedures in this manual refer to the manufac-
turer’s factory-installed components. Your machine may vary depending on
the requirements of your specific region.

1.4 California Proposition 65 Warning

Combustion exhaust, some of its constituents, and certain vehicle compo-
nents contain or emit chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.

1.5 Laws Pertaining to Spark Arresters

State Health Safety Codes and Public Resources Codes specify that in cer-
tain locations spark arresters be used on internal combustion engines that
use hydrocarbon fuels. A spark arrester is a device designed to prevent acci-
dental discharge of sparks or flames from the engine exhaust. Spark ar-
resters 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.

1.6 Manufacturer’s Approval

This manual contains references to approved parts, attachments, and modi-
fications. The following definitions apply:
• Approved parts or attachments are those either manufactured or pro-
vided by the manufacturer.
• Approved modifications are those performed by an authorized service
center according to written instructions published by the manufacturer.
• Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:

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Foreword
1.7 Abbreviations

• Serious injury hazards to the operator and persons in the work area
• Permanent damage to the machine which will not be covered under war-
ranty
Contact your dealer immediately if you have questions about approved or
unapproved parts, attachments, or modifications.

1.7 Abbreviations

Acronym Definition Acronym Definition

CAN Controller area network CARB California Air Resource Board
CDL Commercial driver’s license CO Carbon monoxide
CPU Central processing unit DTC Diagnostic trouble code
ECU Engine control unit EGR Exhaust gas recirculation
EPA Environmental protection agency GAWR Gross axle weight rating
GFCI Ground fault circuit interrupter GVWR Gross vehicle weight rating
Hz Hertz IBC Intermediate bulk container
kVA Kilovolt-ampere kW Kilowatt
L3 Level load logic NATM National association of trailer manufacturers
NHTSA National highway traffic safety administra- PPE Personal protective equipment
tion
S/N Serial number VAC Volts alternating current
VIN Vehicle identification number — —

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 Usage
Intended Use 2.1

2 Usage

2.1 Intended Use

This machine is a mobile electric power source. The Wacker Neuson Mobile 2
Generator consists of a trailer-mounted cabinet containing an electric alter-
nator, 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.

2.2 Unintended Use

This machine has been designed and built strictly for the intended use de-
scribed 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
• 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

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Usage
2.3 Residual Risks

2.3 Residual Risks

WARNING
Serious injury or death hazard
Improper operation of the machine can result in serious injury or death. Be-
fore operating this machine, make sure to:
► Read and understand the operator’s manual.
► Read and understand all labels on the machine.
► Have training in the safe and proper use of the machine.
► Follow all applicable laws and regulations that pertain to this machine.

This machine has been designed and built in accordance with the latest
global safety standards. It has been carefully engineered to eliminate haz-
ards as far as practicable and to increase operator safety through protective
guards and labeling.
However, some risks may remain even after protective measures have been
taken. They are called residual risks. On this machine, they may include ex-
posure 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 techniques
• Typical hazards related to towing a trailer on roads and highways
To protect yourself and others, make sure you thoroughly read and under-
stand the safety information presented in this manual before operating the
machine.

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 Safety
Signal Words Used in This Manual 3.1

3 Safety

3.1 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 per-
sonal injury, damage to the equipment, or improper service.
3
DANGER
DANGER indicates a hazardous situation which, if not avoided, will re-
sult in death or serious injury.
► To avoid death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
► To avoid possible death or serious injury from this type of hazard, obey
all safety messages that follow this signal word.

CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
► To avoid possible minor or moderate injury from this type of hazard,
obey all safety messages that follow this signal word.

NOTICE
NOTICE identifies a situation that causes damage if it is not observed.
► To avoid possible damage from this type of hazard, obey all safety mes-
sages that follow this signal word.

Note: A Note contains additional information important to a procedure.

3.2 Safety Guidelines for Operating the Machine

Operator and service training and knowledge
Before operating, maintaining, or servicing the machine:
• Familiarize yourself with the location and proper use of all controls and
safety devices.
• Know the rules for the jobsite.
• Contact Wacker Neuson for additional training if necessary.

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Safety
3.3 Safety Guidelines for Maintenance

Operator and service qualifications

Only trained personnel are permitted to start, operate, and shut down the
machine. They also must meet the following qualifications:
• Have received instruction on how to properly use the machine
• Are familiar with required safety devices
The machine must not be accessed or operated by:
• Children
• People impaired by alcohol or drugs

Application area
Be aware of the application area.
• Remain aware of changing positions and the movement of other equip-
ment and personnel in the application area/jobsite.
• 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.
• Do not operate the machine in areas that contain flammable objects, fu-
els, or products that produce flammable vapors.

Personal protective equipment (PPE)

Wear the following personal protective equipment (PPE) while operating this
machine:
• Close-fitting work clothes that do not hinder movement
• Safety glasses with side shields
• Hearing protection
• Safety-toed footwear
Tie back long hair and remove all jewelry (including rings).

After use
• Stop the engine when the machine is not being operated.
• Close the fuel valve, if equipped, when machine is not being operated.
• Ensure that the machine will not tip over, roll, slide, or fall when not being
operated.
• Store the machine in a clean, dry location out of the reach of children.

3.3 Safety Guidelines for Maintenance

Before servicing or maintaining the machine, see Safety Guidelines for Op-
erating the Machine on page 13.

Precautions
Follow the precautions below when servicing or maintaining the machine.

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 Safety
Safety Guidelines for Maintenance 3.3

• Read and understand the service procedures before performing any ser-
vice to the machine.
• Personnel servicing or maintaining the machine must be familiar with the
associated potential risks and hazards.
• 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.
3
Machine modifications
When servicing or maintaining the machine:
• Use only accessories/attachments that are approved by Wacker Neuson.
• Do not defeat safety devices.
• Do not modify the machine without the express written approval of
Wacker Neuson.

Replacing parts and labels

• Replace worn or damaged components.
• Replace all missing and hard-to-read labels.
• When replacing electrical components, use components that are identi-
cal in rating and performance to the original components.
• When replacement parts are required for this machine, use only
Wacker Neuson replacement parts or those parts equivalent to the origi-
nal in all types of specifications, such as physical dimensions, type,
strength, and material.

Cleaning
When cleaning and servicing the machine:
• Keep the machine clean and free of debris such as leaves, paper, car-
tons, etc.
• Keep the labels legible.
• 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.

Electrical service safety

• Make sure clothing and shoes are dry, stand on a dry wooden platform
or rubber insulating mat, and use tools with insulated handles when ser-
vicing the machine.
• Do not allow water to accumulate around the base of the machine. If wa-
ter 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.

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Safety
3.4 Safety Guidelines for Using Internal Combustion Engines

Cooling system safety

• Do not attempt to open the radiator cap while the unit is running or be-
fore the engine has cooled down. Severe burns may result!
• Engine coolant is toxic to humans and animals. Clean up spills and dis-
pose of waste engine coolant in accordance with local environmental
regulations.

3.4 Safety Guidelines for Using Internal Combustion Engines

DANGER
Poisoning hazard
Exhaust gas contains carbon monoxide, a deadly poison.
► 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.

WARNING
Personal injury hazard
Failure to follow the warnings and safety standards during operation and fu-
eling could result in severe injury or death.
► Read and follow the warning instructions in the engine owner’s manual
and the safety guidelines below.

Running the engine

• Keep the area around the 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.
• 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 immedi-
ately 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 start-
ing.
• Do not use the machine in areas with a risk of explosion or fire.

Refueling safety
• Clean up any spilled fuel immediately.
• Refill the fuel tank in a well-ventilated area.
• Replace the fuel tank cap after refueling.

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 Safety
Safety Guidelines for Mobile Generators 3.5

• Use suitable tools for refueling (for example, a fuel hose or funnel).
• Do not smoke.
• Do not refuel a hot or running engine.
• Do not refuel the engine near sparks or open flames.

3.5 Safety Guidelines for Mobile Generators

3

DANGER
Carbon monoxide hazard
Using this machine indoors can kill you in minutes. Exhaust gas contains
carbon monoxide (CO). This is a deadly poison you cannot see or smell. If
you can smell the exhaust, you are breathing CO. Even if you cannot smell
the exhaust, you could still be breathing CO.
► Never operate the machine inside an enclosed area, such as a home,
tunnel, or garage unless it is vented properly.
► Only use the machine outside and far away from windows, doors, and
vents. These openings can pull in exhaust gas.
► Always use a battery-powered or battery-backup CO alarm in nearby
structures. Even when you use the machine correctly, CO may leak into
nearby structures.
► If you start to feel sick, dizzy, or weak after the machine has been run-
ning, move to fresh air IMMEDIATELY. See a doctor. You could have
carbon monoxide poisoning.

WARNING
Electrocution hazard
Generators present special hazards during operation and servicing. These
include the risk of electrocution or severe electrical shock. Failure to follow
the safety information below can result in severe injury or death.
► Read and follow the safety instructions in this operator’s manual.
► Contact the generator manufacturer for additional information regarding
the generator.

WARNING
Injury hazard
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 quali-
fied electrician and comply with all applicable laws and electrical codes.

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Safety
3.6 Reporting Safety Defects

Installing as backup power

Special hazards exist when installing this machine as a backup power sup-
ply. Improper connection of the mobile 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.
If connected to a building’s electrical system, the generator must meet the
power, voltage, and frequency requirements of the equipment in the building.
Differences in power, voltage, and frequency requirements may exist and
improper connection may lead to equipment damage, fire, and personal in-
jury or death.

General safety
• Do not use evaporative starting fluids to start the engine. They are highly
explosive.
• Do not store items such as excess oil, rags, or tools on top of or inside
the machine. These items are a fire hazard and can restrict cooling air.
• Ensure that electrical cords attached to the machine are in serviceable
condition without cuts, cracks, or exposed wires.
• Do not route electrical cords over vibrating or hot parts of the machine.
• Do not stand on the machine.
• Do not enclose or cover the machine when it is use, or when it is hot.

Ground connection
The mobile 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 mobile generator in
accordance with the standards defined in national, state, and local regula-
tions.

3.6 Reporting Safety Defects

If you believe your trailer has a defect which could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Wacker Neu-
son.
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 individ-
ual 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.safer-
car.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590

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 Safety
Reporting Safety Defects 3.6

You can also obtain other information about your motor vehicle safety from
http://www.safercar.gov

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Description of the Machine
4.1 Machine Description

4 Description of the Machine

4.1 Machine Description

This machine is a mobile electric power source. The Wacker Neuson Mobile
Generator consists of a trailer-mounted cabinet containing an electric alter-
nator, 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.

4.2 Controls and Components

7 3

1 2 4
6

17 18

14
16 15
8

12
9
5
10

13

11
Fig. 2: Control and component locations

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 Description of the Machine
Controls and Components 4.2

19 4

Fig. 3: Fuse boxes

20

Fig. 4: Voltage selector switch

Ref Component Ref Component

1 Main circuit breaker 2 Voltage adjustment rheostat
3 Mobile generator controller 4 Main power switch
5 Ground connection point 6 Pre-alarm/shutdown LED
7 Hour meter 8 Circuit breaker (120V or 240V, 50A)
9 Circuit breaker (120V, 20A) 10 Twist-lock receptacle (2) 240 VAC, 50A

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Description of the Machine
4.2 Controls and Components

Ref Component Ref Component

11 GFCI receptacle (120 VAC, 20A) 12 Remote run terminal block
13 Emergency stop switch 14 Lug door interlock switch
15 Bond bar 16 Terminal lugs
17 Convenience light 18 Convenience light switch
19 Fuse box 20 Voltage selector switch

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 Description of the Machine
Overview of the Labels 4.3

4.3 Overview of the Labels

WARNING

ADVERTENCIA
AVERTISSEMENT

114885

4
158787

WARNING

Lock doors. Access can cause electric shock, arc flash or injury.

ADVERTENCIA
Cierre las puertas. Ya que de otro modo existe el peligro de un choque eléctrico,
arco voltaico de cortocircuito, o de heridas personales.

AVERTISSEMENT
Fermer les portes d'acces ou il pourrait en résulter risque d'électrocution, arc de
court-circuit, ou des blessures.

176289

OPERATING INSTRUCTIONS INSTRUCCIONES PARA LA PUESTA EN

FOR MOBILE GENERATORS MARCHA DE GENERADORES MOVILES
Before starting Antes del arranque
1. Read Operator's Manual. 1. Lea el Manual de Operación.
2. Level unit. 2. Nivele la unidad.
3. Block wheels. 3. Coloque cuñas debajo de las ruedas.
4. Ground unit. 4. Conecte la unidad a tierra.
5. Check all fluid levels. 5. Controle todos los liquídos.

Manual starting Arranque manual

1. Disconnect all external loads. 1. Desconecte todas las cargas externas.
2. Set voltage selector switch. 2. Ajuste la llave selectora de voltaje.
3. Lock voltage selector switch. 3. Bloquee la llave selectora de voltaje.
4. Set emergency stop button to "ON" position. 4. Ponga a la posición "ON" el botón de parada
5. Set engine start switch to "START/RUN" position. de emergencia.
6. Engine will make 3 attempts to start. 5. Ponga a la posición "ARRANQUE/MARCHA" el
interruptor de arranque del motor.
Remote start 6. El motor intentará arrancar 3 veces.
1. See Operator's Manual.
Arranque remoto
Stopping 1. Vea el Manual de Operación.
1. Turn off all circuit breakers.
2. Set engine start switch to "OFF" position. Detencion de motor
1. Apague todos los interruptores de circuito.
2. Ponga a la posición "OFF" el interruptor de arranque
del motor.

INSTRUCTIONS D'OPERATION
DU GENERATEUR MOBILE
Avant le demarrage

160604
1. Lire la Notice d'Emploi. Operator's Manual must be stored on machine.
2. Niveler la machine. A replacement Operator's Manual can be
3. Bloquer les roues avec cales de roues. ordered through Wacker Neuson or online at
4. Mettre à terre la machine.
5. Vérifier le niveau de tous les fluides.
www.wackerneuson.com.

Démorrage à la main El Manual de Operación debe ser retenido en la

1. Déconnecter tous les regimes externes. máquina. Contacte a Wacker Neuson para un
2. Régler le commutateur des tensions d'alimentation.
3. Serrer le commutateur des tensions d'alimentation. ejemplar adicional o ponga una orden en linea en
4. Placer le bouton d'arret d'urgence à la position "ON". www.wackerneuson.com.
5. Placer l'interrupteur de démarrage du moteur à la
position "DEMARRAGE/MARCHE". La Notice d'Emploi doit être munie sur la machine.
6. Le moteur s'essayera de démarrer 3 fois.
Contacter Wacker Neuson pour commander un
Démarrage a distance exemplaire supplémentaire ou commander en
1. Lire la Notice d'Emploi. ligne chez www.wackerneuson.com.
Arrêt
1. Éteindre tous les coupe-circuits.
2. Placer l'interrupteur de démarrage du moteur à la
position "OFF"

176286

Fig. 5: Labels overview 1

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Description of the Machine
4.3 Overview of the Labels

WARNING WARNING WARNING

DANGER
PELIGRO
Electric shock and arc flash can cause DANGER
Electric shock and arc flash hazard at cooling fins.
serious injury or death.
ADVERTENCIA ADVERTENCIA
Peligro de choque eléctrico y arco voltaico de
Generator can automatically start Choque eléctrico y arco voltaico de cortocircuito
cortocircuito en las aletas de refrigeración.
which can cause serious injury. pueden causar heridas personales o muerte.
Disconnect battery before
AVERTISSEMENT AVERTISSEMENT 5000158965
servicing.
WARNING
ADVERTENCIA Électrochoc et arc de court-circuit peuvent Risque d'électrocution et d'arc de court-circuit Cancer and Reproductive Harm
Generador puede arrancar aux ailettes de refroidissement.
automaticamente y causar lesiones résulter en blessures graves ou mort. www.P65Warnings.ca.gov
personales. Desconecte la bateria
antes de prestar servicio. 176285 176284 ADVERTENCIA
AVERTISSEMENT 5000183403 5200006899
Cáncer y daño reproductivo
Generateur peut demarrer www.P65Warnings.ca.gov
automatiquement resultant en des
accidents de personne. Deconnecter
batterie avant tout entretien. AVERTISSEMENT
176184
Cancer ou malformations
congénitales
www.P65Warnings.ca.gov
5100045462

WARNING
Electric shock and arc flash can cause
serious injury or death.
ADVERTENCIA
Choque eléctrico y arco voltaico de cortocircuito
pueden causar heridas personales o muerte.
5000158788
AVERTISSEMENT
Électrochoc et arc de court-circuit peuvent
résulter en blessures graves ou mort.
176285

REMOTE START
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE

L1 L2 L3
114893

114897

120 V
AUX INPUT

WARNING
Improper connection of generator to a buildings electrical system can allow electrical current
NEUTRAL BONDED TO FRAME
from the generator to back feed into utility lines. This may result in electrocution of utility
workers, fire, or explosion. Connections to a buildings electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical codes.

ADVERTENCIA
La conexión incorrecta de un generador al sistema eléctrico de un edificio puede conducir a
CONDUCTOR NEUTRO CONECTADO AL CHASIS
un retorno de la corriente eléctrica desde el generador al sistema de distribución eléctrico
publico. Esto puede conducir a la electrocución de los obreros del servicio publico,
NOTICE
incendios o explosiones. Sólo un técnico electricista capacitado podrá efectuar conexión al
sistema eléctrico del edificio. La conexión eléctrica deberá cumplir con las leyes y códigos
eléctricos pertinentes.
Receptacles not used when:
Selector switch set to 208/120V and voltage greater than 228V.
CONDUCTEUR NEUTRE MIS A LA MASSE
ADVERTISSEMENT 5100060327
Selector switch set to 480/277V and voltage greater than 457V.
DU CHASSIS
Le branchement no conforme du générateur au reseau de distribution eléctrique d'un
immeuble peut provoquer la réinjection du courant eléctrique du générateur dans les lignes
du reseau public. Ceci peut provoquer une électrocution des employés du service public, un
AVISO
incendie ou une explosion. Les branchements au reseau électrique d'un immeuble doivent
être effectués par un eléctricien qualifié et doivent être conformes à toutes les lois du tous
Los receptáculos no deben utilizarse cuando:
El interruptor de selección de voltaje está en la posición 208/120V y el voltaje es mayor de 228V.
5000116662
les codes électriques applicables. El interruptor de selección de voltaje está en la posición 480/277V y el voltaje es mayor de 457V.
176186
AVIS
Ne pas utiliser les prises de courant si:
Le commutateur selecteur est dans la position 208/120V et la tension est plus haute que 228V.
Le commutateur selecteur est dans la position 480/227V et la tension est plus haute que 457V.
5000176188

2000534743

1452 kg
(3200 LBS)

5100052624

1452 kg
(3200 LBS)
5100060341

5100060341

Fig. 6: Labels overview 2

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 Description of the Machine
Overview of the Labels 4.3

WARNING
ADVERTENCIA
AVERTISSEMENT
5200005890

WARNING
ADVERTENCIA
AVERTISSEMENT
WARNING
WARNING Electric shock and arc flash can cause
serious injury or death.
ADVERTENCIA
Choque eléctrico y arco voltaico de cortocircuito
pueden causar heridas personales o muerte.

AVERTISSEMENT
Électrochoc et arc de court-circuit peuvent
résulter en blessures graves ou mort.

ADVERTENCIA 176285

AVERTISSEMENT

114885 179282 164721

5100058317

Fig. 7: Labels overview 3

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Description of the Machine
4.3 Overview of the Labels

2000508787

WARNING
ADVERTENCIA
AVERTISSEMENT
WARNING 1

3 4 85 lb-ft
ADVERTENCIA 115 Nm

AVERTISSEMENT 5 2

5100031252 5100060334

WARNING
ADVERTENCIA
AVERTISSEMENT
WARNING 1
85 lb-ft
ADVERTENCIA 3 4
115 Nm

AVERTISSEMENT 5 2

5100031251
5100031166

Fig. 8: Labels overview 4

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 Description of the Machine
Safety Label Meanings 4.4

4.4 Safety Label Meanings

DANGER DANGER
PELIGRO
DANGER Asphyxiation hazard
• Engines emit carbon monoxide.
• Do not run the machine indoors or in an enclosed area.
• Electric shock and arc flash can cause serious injury or death.

5000183403

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.

WARNING
Read and understand the supplied operator’s manual before operating this
machine. Failure to do so increases the risk of injury to yourself or others.

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Description of the Machine
4.4 Safety Label Meanings

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!

NOTICE
Avoid spraying water into generator.

WARNING
Personal injury hazards
• To prevent hearing loss, wear hearing protection when operating the
machine.
• Pressurized contents. Do not open when hot.
• Hand injury if entangled in moving belt.
• Rotating machinery. Do not reach inside machine when the engine is
running.
WARNING
ADVERTENCIA
AVERTISSEMENT

164721

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 Description of the Machine
Safety Label Meanings 4.4

WARNING
Personal injury hazards
• To prevent hearing loss, wear hearing protection when operating the
machine.
• Hand injury if entangled in moving belt.
• Rotating machinery. Do not reach inside machine when the engine is
running.

179282

WARNING
Explosion hazard
Pressurized contents. Do not open when hot.

5100052624

WARNING
WARNING
Hot surface hazard

ADVERTENCIA
AVERTISSEMENT

114885

WARNING WARNING
Electric shock and arc flash can cause
serious injury or death. Personal injury hazard
ADVERTENCIA
Choque eléctrico y arco voltaico de cortocircuito Electric shock and arc flash can cause serious injury or death.
pueden causar heridas personales o muerte.

AVERTISSEMENT
Électrochoc et arc de court-circuit peuvent
résulter en blessures graves ou mort.
176285

WARNING ADVERTENCIA
AVERTISSEMENT

5100069090

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Description of the Machine
4.4 Safety Label Meanings

WARNING WARNING
Electric shock and arc flash hazard at cooling fins.
ADVERTENCIA Electric shock and arc flash hazard at cooling fins.
Peligro de choque eléctrico y arco voltaico de
cortocircuito en las aletas de refrigeración.
AVERTISSEMENT
Risque d'électrocution et d'arc de court-circuit
aux ailettes de refroidissement.

176284

WARNING
Improper connection of generator to a buildings electrical system can allow electrical current
WARNING
from the generator to back feed into utility lines. This may result in electrocution of utility
workers, fire, or explosion. Connections to a buildings electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical codes.

ADVERTENCIA
Improper connection of the generator to a building’s electrical system can
La conexión incorrecta de un generador al sistema eléctrico de un edificio puede conducir a
un retorno de la corriente eléctrica desde el generador al sistema de distribución eléctrico
publico. Esto puede conducir a la electrocución de los obreros del servicio publico,
incendios o explosiones. Sólo un técnico electricista capacitado podrá efectuar conexión al
allow electrical current from the generator to backfeed into utility lines. This
sistema eléctrico del edificio. La conexión eléctrica deberá cumplir con las leyes y códigos
eléctricos pertinentes. may result in electrocution of utility workers, fire, or explosion. Connections
ADVERTISSEMENT
Le branchement no conforme du générateur au reseau de distribution eléctrique d'un
immeuble peut provoquer la réinjection du courant eléctrique du générateur dans les lignes
du reseau public. Ceci peut provoquer une électrocution des employés du service public, un
to a building’s electrical system must be made by a qualified electrician and
incendie ou une explosion. Les branchements au reseau électrique d'un immeuble doivent
être effectués par un eléctricien qualifié et doivent être conformes à toutes les lois du tous
les codes électriques applicables. comply with all applicable laws and electrical codes.
176186

WARNING WARNING
Lock doors. Access can cause electric shock, arc flash, or injury. Read the
operator’s manual for more information.
Lock doors. Access can cause electric shock, arc flash or injury.

ADVERTENCIA
Cierre las puertas. Ya que de otro modo existe el peligro de un choque eléctrico,
arco voltaico de cortocircuito, o de heridas personales.

AVERTISSEMENT
Fermer les portes d'acces ou il pourrait en résulter risque d'électrocution, arc de
court-circuit, ou des blessures.

176289

WARNING WARNING
ADVERTENCIA
AVERTISSEMENT Explosion hazard (diesel machines)
5200005890
• Do not use evaporative starting fluids such as ether on this engine.
• The engine is equipped with a cold starting aid. Using evaporative start-
ing fluids can cause an explosion which can cause engine damage, per-
sonal injury, or death.
• Read and follow the engine starting instructions in this operator's man-
ual.

WARNING WARNING
Generator can automatically start which can cause serious injury. Discon-
nect battery before servicing.
Generator can automatically start
which can cause serious injury.
Disconnect battery before
servicing.
ADVERTENCIA
Generador puede arrancar
automaticamente y causar lesiones
personales. Desconecte la bateria
antes de prestar servicio.
AVERTISSEMENT
Generateur peut demarrer
automatiquement resultant en des
accidents de personne. Deconnecter
batterie avant tout entretien.

176184

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 Description of the Machine
Safety Label Meanings 4.4

WARNING
Tire, wheel, or lug nut failure can cause loss of control. Before towing, you
must CHECK:
1. Tire pressure and tread.
2. Tires and wheels for damage.
3. Lug nuts for tightness. For new and remounted wheels, retighten lug
nuts at the first 10, 25, and 50 miles of driving.

WARNING
4
Trailer can roll if it comes loose. Electric safety brake applies when cable
pulls pin out of switch box.
1. PULL hard to get pin out of switch box.
2. CHECK brake by PULLING TRAILER with tow vehicle.
3. ATTACH pin CABLE to tow vehicle so pin will be pulled out if trailer
separates.
4. Promptly REPLACE pin in switch box.

WARNING
Trailer can roll if it comes loose. Safety brake applies when chain pulls
brake lever.
1. ATTACH brake CHAIN securely to tow vehicle so lever will be pulled if
trailer separates.
2. CHECK brake fluid level.
3. DO NOT TOW trailer if brake fluid is NOT FULL.

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Description of the Machine
4.4 Safety Label Meanings

WARNING
(On trailer, if equipped)

5100031251
Uncoupling will cause trailer to come loose from tow vehicle. You must:
1. Check that ball load rating is same as or greater than coupler load rat-
ing.
2. Check that ball size is same as coupler.
5100060334

3. Close coupler clamp on ball.

4. Lift coupler upwards to test that it will not separate from ball.
5. Lock coupler clamp with pin or padlock.

WARNING
(On trailer, if equipped)
Always use safety chains. Chains hold trailer if connection fails. You must:
1. Cross chains underneath coupler.
2. Allow slack for trailer to turn.
3. Attach chain hooks securely to tow vehicle.

WARNING WARNING
ADVERTENCIA
AVERTISSEMENT
WARNING 1
(On trailer, if equipped)
3 4 85 lb-ft
ADVERTENCIA 115 Nm

AVERTISSEMENT 5 2
Lights can prevent trailer from being hit by other vehicles. You must:
5100031252

WARNING
1. Connect trailer and two vehicle electrical connectors.
ADVERTENCIA
AVERTISSEMENT
2. Check all lights: tail lights, turn signals, and brake lights.
WARNING 1
85 lb-ft
ADVERTENCIA 3 4
115 Nm

5100031166
AVERTISSEMENT 5 2
3. Do not tow if lights are not working.

WARNING
Tire, wheel, or lug nut failure can cause loss of control. Before towing, you
must check:
1. Tire pressure and tread.
2. Tires and wheels for damage.
3. Lug nuts for tightness. Lug nuts should be tightened to 85 ft. lbs. For
new and remounted wheels, tighten lug nuts at the first 10, 25, and
50 miles of driving.

WARNING
(On trailer, if equipped)
2000508787

The breakaway cable activates the trailer’s hydraulic brakes.

Check the hydraulic fluid level.
Do not tow if the hydraulic fluid is not at the proper level.

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 Description of the Machine
Safety Label Meanings 4.4

WARNING WARNING
Cancer and Reproductive Harm
www.P65Warnings.ca.gov
ADVERTENCIA
California Proposition 65 Warning
Cáncer y daño reproductivo
www.P65Warnings.ca.gov
AVERTISSEMENT
Cancer and Reproductive Harm
Cancer ou malformations
congénitales
www.P65Warnings.ca.gov www.P65Warnings.ca.gov
5100045462

NOTICE
Ultra low sulfur fuel only (diesel machines).

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

NOTICE NOTICE
Receptacles not used when:
Selector switch set to 208/120V and voltage greater than 228V.
Selector switch set to 480/277V and voltage greater than 457V.
Receptacles not used when:
AVISO
Los receptáculos no deben utilizarse cuando:
El interruptor de selección de voltaje está en la posición 208/120V y el voltaje es mayor de 228V.
El interruptor de selección de voltaje está en la posición 480/277V y el voltaje es mayor de 457V. Selector switch set to 208/120V and voltage greater than 228V.
AVIS
Ne pas utiliser les prises de courant si:
Le commutateur selecteur est dans la position 208/120V et la tension est plus haute que 228V.
Le commutateur selecteur est dans la position 480/227V et la tension est plus haute que 457V.
Selector switch set to 480/277V and voltage greater than 457V.
5000176188

NOTICE
Do not use the battery disconnect switch while engine is running. Damage
to the electrical components may occur.
Battery disconnect must be in ON position to start engine.

5100058317

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Description of the Machine
4.5 Information Label Meanings

4.5 Information Label Meanings

Operating instructions
Before starting
• Read Operator’s Manual.
• Level unit.
• Block wheels.
• Ground unit.
• Check all fluid levels.
Manual starting
176286
• Turn off all circuit breakers.
• Set to correct voltage.
• Start engine. See Operator’s Manual.
• Engine will make 3 attempts to start.
Remote start
• See Operator’s Manual.
Stopping
• Turn off all circuit breakers.
• Stop engine. See Operator’s Manual.

Operator’s manual must be stored on machine. Replacement operator’s

manual can be ordered through your local Wacker Neuson distributor.

158787

MANUFACTURED BY/FABRIQUÉ PAR:

DATE: GVWR/PNBV:
COLD INFL. PRESS./PRESS.
DE GONF À FROID
(on trailer, if equipped)
GAWR/PNBE (ALL AXLES) TIRE/PNEU RIM/JANTE KPA (PSI/LPC) SGL/DUAL

THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN
MOTOR VEHICLE SAETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE. /CE
VÉHICULE EST CONFORME À TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU
Certification label (VIN)
RÉGLEMENT SUR LA SÉCURITÉ DES VÉHICULES AUTOMOBILES DU CANADA EN VIGUEUR À LA
DATE DE SA FABRICATION.
THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY
STANDARDS (FMVSS) IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE 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
V.I.N./N.I.V. TYPE/TYPE DE VEHICULE:

time of manufacture. The label includes the vehicle identification number

(VIN) for the trailer.

174993

Lug door must be closed for lugs and receptacles to energize.

(if equipped)
Drain location for containment skid.

160604

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 Description of the Machine
Information Label Meanings 4.5

Protecting Our Environment

Fluid containment system
(if equipped)

Lifting point

1452 kg
(3200 LBS)
4

5100060341

Operating the main circuit breaker supplies or interrupts power to the cus-
tomer connection lugs.

L1 L2 L3
114893

Neutral bonded to frame

NEUTRAL BONDED TO FRAME

CONDUCTOR NEUTRO CONECTADO AL CHASIS

CONDUCTEUR NEUTRE MIS A LA MASSE

DU CHASSIS
5000116662

Remote start. Read operator’s manual for instructions.

REMOTE START
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE

114897

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Description of the Machine
4.5 Information Label Meanings

Tie-down point

Emergency stop

External plug
120 V 120V, auxiliary input

AUX INPUT
Breaker designations

5100060327

Camlocks
2000534743

ON / OFF

5200006899

Reading light ON / OFF

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 Description of the Machine
Information Label Meanings 4.5

Receptacle designations

5000158965

Rheostat control

5000158788

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37
Transportation
5.1 Safety Guidelines for Lifting and Transporting

5 Transportation

5.1 Safety Guidelines for Lifting and Transporting

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. For ma-
chine weight, see Dimensions on page 128.
• 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 man-
ual.
• Make sure the transporting vehicle has sufficient load capacity and plat-
form 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.

5.2 Lifting the Machine

WARNING
Crushing hazard
An unstable machine may cause the lifting device to fail. You may be
crushed if the lifting device fails.
► Check for machine stability before continuing.

Requirements
• Lifting equipment (crane, hoist, or fork truck) capable of supporting the
machine’s weight.
• Lifting devices (hooks, chains, and shackles) capable of supporting the
machine’s weight.
• Engine stopped.

Procedure
A lifting eye (1) is used for lifting the machine.
1
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.
3. Check for stability. If necessary, lower the machine, reposition the lift-
ing devices, and lift the machine a small distance again.
Fig. 9: Lifting eye
4. Continue lifting the machine only when it is stable.

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 Transportation
Before Towing Checklist 5.3

5.3 Before Towing Checklist

Before towing the machine, check the licensing requirements for trailers in
your area. Also, check the following items:

Towing vehicle
• The towing vehicle is rated to tow the load.
• The towing vehicle is in serviceable condition.
• Do any necessary service/maintenance on the towing vehicle.

Hitch and coupler

• The towing vehicle and hitch have a rating equal to or greater than the
gross vehicle weight rating (GVWR) of the machine. For further informa-
tion, see Trailer and Skid on page 127. 5
• The hitch of the towing vehicle and coupler of the trailer are compatible.
• Check the condition of both the coupler and the hitch.
• All fasteners on the coupler are tight.
• The coupler has fresh grease applied to it.

Wheels
• Wheel chocks are available at the work site.
• All lug nuts are in place and are properly torqued.
• Check the tread wear of the tires. Do not tow the machine if the trailer’s
tires have less than 1.5 mm (1/16 in.) of tread.
• The tires are inflated to the proper pressure.

Trailer preparation
• All doors and access panels are closed and latched.
• The outriggers (if applicable) are retracted.
• Check local regulations regarding hazardous materials placards. If appli-
cable, install the appropriate placards.

Trailer operation
• The trailer jacks are in the travel (horizontal) position.
• The directional and running lights on the trailer function correctly.
• The safety chains of the trailer are connected to the towing vehicle using
a crisscross pattern.
• Check the operation of the trailer brakes by braking the towing vehicle at
a slow speed. Both the vehicle and the trailer must brake smoothly. If the
trailer pushes, check the fluid level in the surge brakes or the operation
of the electric brakes.
• The trailer’s breakaway cable (if applicable) is attached to the towing ve-
hicle.
• Test the function of the breakaway system (if applicable).

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Transportation
5.4 Towing the Machine

5.4 Towing the Machine

Overview
The mobile generator’s trailer is equipped with brakes (surge or electric),
2 safety chains (1), lights, and a coupler (pintle or ball-type) (3).
Only use the brakes as designed.
The breakaway cable (2) is not a parking brake and should not be used as
1 one.

3 Licensing requirements
Fig. 10: Safety chains, breakaway • In most states, large trailers must be registered and licensed by the
cable, and coupler State Department of Transportation. Before towing, be sure to check li-
censing requirements.
• Drivers towing trailers may be required to carry a commercial driver’s li-
cense (CDL). Check your local and state licensing regulations before
towing the mobile generator.

Coupler maintenance
• A film of grease on the coupler extends coupler life and eliminates
squeaking. Wipe the coupler clean and apply fresh grease each time the
trailer is towed.

5.5 Preparing the Machine for Transport on a Truck or Trailer

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.

Requirements
• Machine stopped.
• Flatbed truck or trailer capable of supporting the machine’s weight.
• Chains, hooks, or straps capable of supporting the machine’s weight.

Checklist
Before transporting the machine, check the following items:
Machine
• All doors and access panels of the machine are closed.
• All electrical connections are disconnected from the machine.
• The machine is shut down.
• The tower is completely lowered.
• The outriggers are in the travel position.

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 Transportation
Hazardous Materials Placard 5.6

• The outrigger bars and jacks are locked in place.

• The tongue jack is in the travel position.
Loading and transporting equipment
• The transport vehicle or trailer can support the weight of the machine.
• The wheels of the transport vehicle or trailer are chocked during the
loading process.
• The transport vehicle or trailer is clean and free of grease, oil, ice, and
other loose material.
• The machine’s trailer jack is not used to support the trailer tongue during
transporting.
• Check that any ramps used in the loading process:
– Can support the weight of the machine.
5
– 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:
• Make sure the loading area is flat and the ground is stable.
• Check the overall height of the machine once loaded. Plan your travel
route so that there will be adequate clearance for overpasses, road
signs, buildings, etc.
• Check local regulations regarding transporting and obey these regula-
tions.

5.6 Hazardous Materials Placard

Note: The owner/operator of this machine may be responsible for applying
the placard. Use the procedure described below.

Overview
Hazardous materials placards may have been provided with your machine.
Transport Canada, and the Canadian Transportation of Dangerous Goods
Act, require that these hazardous materials placards be permanently applied
to certain machines if they are to be transported or towed on Canadian
roads.
Contact Transport Canada if you have questions about driver’s licensing re-
quirements for transporting machines that bear hazardous materials placard,
or questions about other restrictions for use of this machine.

Requirements
• The placard mounting surface 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

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Transportation
5.7 Testing the Breakaway System—Hydraulic Surge Brakes

• Soft, clean, dry cloths

• Plastic squeegee or stiff cardboard

Applying the placard

Follow the procedure below to apply the placard to the machine in the loca-
tion shown in the illustration.
1. Clean the placard mounting surface with mild soap and water. Dry
thoroughly.
2. Use isopropyl (rubbing) alcohol to clean the placard mounting surface
if:
Fig. 11: Position to apply the placard ð It, and the surrounding ambient temperature, are below 10°C (50°F).
ð The placard mounting surface is 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.
ð Gradually remove the backing paper and apply the remainder of the
placard.
ð Firmly press and smooth the placard into place with a plastic
squeegee, stiff cardboard, or a soft cloth.
ð Puncture any air bubbles that may form.

5.7 Testing the Breakaway System—Hydraulic Surge Brakes

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.

When
• Before towing
• After filling the hydraulic reservoir

Requirements
• Hydraulic reservoir filled
• Machine parked on a flat surface

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 Transportation
Testing the Breakaway System—Electric Brakes 5.8

Procedure
2
1. Check the breakaway cable (1) for damage.
1
2. Make sure the indicator bead and clip are in place as follows:
ð The clip should be just inside the actuator (2).
ð The bead should be just behind the clip.

Fig. 12: Breakaway cable and actua-

tor

3. If the clip is broken and the bead is outside the actuator, or if the trailer
seems difficult to tow, reset the cable as follows: 5

ð Slide the coupler (3) forward and push up on the pushrod release
bracket (4) to allow the bead to retract into the actuator.
3 4
Fig. 13: Coupler and pushrod re-
lease bracket

5.8 Testing the Breakaway System—Electric Brakes

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.

NOTICE
Testing the breakaway system with the wiring plug connected may cause
damage to the electronic brake control.
► Disconnect the trailer wiring plug from the tow vehicle before testing.

When
• Before towing
• Monthly if the machine is not in service

Requirements
• Voltmeter
• Battery charger or backup battery (charged)

Procedure
1. Connect the machine/trailer to the tow vehicle.

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Transportation
5.8 Testing the Breakaway System—Electric Brakes

2. Disconnect the trailer wiring plug (1) from the tow vehicle.

Fig. 14: Trailer wiring plug and brake switch

3. Pull the breakaway pin (2) out of the brake switch (3) (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 sys-
tem causes substantial drag on the trailer wheels and may even cause
the trailer wheels to lock.
4. Stop the tow vehicle.
5. If the brakes did not function, check the voltage of the breakaway bat-
tery. To do so:
ð Remove the cover of the battery box.
ð Remove the wires connected to the breakaway battery (4).
4
ð Measure the voltage. If 12–14 VDC is not measured, replace or
recharge the breakaway battery.
6. If 12–14 VDC was measured but the brakes did not function, there is a
F 1000
200
20
2
V
200m
wiring or mechanical fault with the brakes. Repair any faults before
A
towing.
V- COM

VDC 7. If the brakes function properly:

wc_gr008515 ð Reconnect the wires to the breakaway battery.
Fig. 15: Breakaway battery ð Install the cover on the battery box.
ð Install the breakaway pin (2) into the brake switch.
ð Connect the trailer wiring plug to the tow vehicle.

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 Commissioning
Preparing the Machine for First Use 6.1

6 Commissioning

6.1 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. Add fluids as needed and applicable, including fuel, engine oil, hy-
draulic oil, retardant, and battery acid.
5. Move the machine to its operating location.
6. Connect component parts not already attached. 6

Safety information
• Do not exceed the power output of the generator. Damage to tools or
generator will occur. For further information, see Generator on page 126.
• 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.

6.2 Installing the Trailer Tongue

CAUTION
Pinching and crushing hazard
To avoid possible injury, keep fingers away from the pivot point when lower-
ing or raising the trailer tongue.

Overview
The trailer tongue folds to save space, mainly during the shipping process.
Perform the following procedure to lower the tongue. If desired, reverse the
procedure to raise the tongue for shipping or storage purposes.

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Commissioning
6.3 Positioning the Machine

Procedure

2 1. Swing the trailer jack (1) down and raise the jack to move the foldable
portion (2) of the trailer tongue about 2 in. (5.08 cm) off the ground.
5
2. While supporting the foldable portion of the trailer tongue, remove the
lower nuts (3), washers, and bolts (4).
1 4
3. Loosen, but do not remove, the top nut (5) and bolt securing the trailer
4 3 tongue.

Fig. 16: Trailer tongue in raised posi-

tion

4. Carefully rotate the foldable portion of the trailer tongue down.

6 8 5. Install the shorter bolt (6), nut (7), and washer in the position shown.
6. Install the longer bolt (8), nut (9), and washer in the position shown.
7. Tighten all hardware to a range of 160 – 180 Nm (118 – 132 ft. lbs.).

7 9

Fig. 17: Trailer tongue in lowered po-

sition

6.3 Positioning the Machine

DANGER
Asphyxiation hazard
Exhaust gas from the machine contains carbon monoxide, a deadly poison
you cannot see or smell. Exposure to carbon monoxide can kill you in min-
utes.
► Position the machine so that exhaust will not enter any nearby struc-
tures.

WARNING
Fire hazard
Do not move the machine while it is running.
► Shut down the machine before moving or repositioning it.

WARNING
Tipping 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.

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 Commissioning
Grounding the Machine 6.4

WARNING
Explosion and fire hazard
Risk of severe injury or death.
► Do not operate the machine near flammable vapors, fuels, or com-
bustibles.

Requirements
Position the machine so that:
• The machine exhaust will not enter nearby structures.
• The machine does not block traffic.
• The machine is not near any combustible material or flammable vapor.
• All of the machine’s access doors/panels may be accessed.
• The area overhead is clear of debris that could fall onto or into the ma- 6
chine or exhaust compartment.
• The machine is on a firm, level surface and will not tip, roll, slide, or fall
while operating.

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

1 wc_gr009186

Fig. 18: Wheel chocks

6.4 Grounding the Machine

1 1

wc_gr011524
Fig. 19: Grounding lugs

External grounding
A ground connection (1) is located at the customer connection terminal lugs.

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Commissioning
6.5 Recommended Fuel

Function
This ground connection is used for electrically grounding the machine when
necessary to comply with the National Electrical Code and other federal,
state, and local regulations. For grounding requirements in your area, con-
sult with a qualified electrician, electrical inspector, or local agency having ju-
risdiction over electrical compliance.
• If the mobile generator is used at a construction site, there may be addi-
tional regulations that must be observed.
• In some areas, mobile generators are required to be registered with local
utility companies.

Internal grounding
• The exposed, conductive, noncurrent-carrying components that could
become energized (for example, fuel tank, engine, generator housing,
control panel, enclosure, and trailer) are bonded (connected) to the ma-
chine’s frame.
• The grounding wires of the machine’s power outputs (receptacles) are
bonded (connected) to the machine’s frame.
• The neutral of the generator stator winding is bonded (connected) to the
machine’s frame.

6.5 Recommended Fuel

CAUTION
Fire hazard
Gasoline and oil are extremely flammable.
► Do not use gasoline, crankcase oil, or any oil containing gasoline to fill
the fuel tank.

NOTICE
Using biodiesel fuel may damage the engine.
► 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.

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

Lowest Expected Ambient Temperature Recommended Fuel1)

Above freezing > 0 °C (32 °F) #2 diesel plus additives
Below freezing < 0 °C (32 °F) Winter-blend diesel
1) Your engine may require ultra low sulfur fuel. Consult the engine owner’s manual.

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 Commissioning
Refueling the Machine—Deep Sea Controller 6.6

6.6 Refueling the Machine—Deep Sea Controller

WARNING
Fire and explosion hazard
Fuel and its vapors are extremely flammable and can be explosive. Burning
fuel can cause severe burns.
► Keep all sources of ignition away from the machine while refueling.
► Store fuel containers in a well-ventilated area, away from any com-
bustible materials or sources of ignition.
► Refuel only when the machine is outdoors.
► Clean up spilled fuel immediately.
► Do not smoke while refueling.
► To prevent static electricity buildup when transferring the fuel from the
pump to the container, place the fuel container on the ground. Hold the 6
hose nozzle firmly against the side of the container while filling it.

CAUTION
Fire and health hazard
Fuel expands when heated. Expanding fuel in an over-filled tank can lead to
spills and leaks.
► Do not fill the fuel tank completely.

Requirements
• Machine shut down
• Engine cool
• Machine/fuel tank level with the ground
• Remote switch disconnected from the remote run terminal
• Fresh, clean fuel supply

Procedure
1. Remove the fuel cap.
2. Place the controller Power switch in the ON position and wait for the
controller to boot up.
3. Press the right arrow button to navigate to the Engine screen.

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Commissioning
6.6 Refueling the Machine—Deep Sea Controller

DSE
DEEP SEA ELECTRONICS DSE 7310

DSE
DEEP SEA ELECTRONICS DSE 7310

Generator Available STOP

ü L-N 0V 0A
STOP
L-L 0V 0.0 Hz
0 kW --- pf

Open Open
Load Gen-Set
Close Close

o
Stop/Reset
AUTO

Lamp Test Start

Manual Auto
Mode Mode Horn Reset

wc_gr011443
Fig. 20: Engine Fuel Level screen

4. Use the up or down arrow button to navigate to the Engine Fuel Level
screen. The fuel level (in percentage of the fuel tank capacity) is dis-
played.
Note: The Engine Fuel Level screen reverts back to the Status screen
after three minutes of inactivity.
5. Fill the fuel tank until the fuel level reaches 100%.
6. Install the fuel cap.
7. Place the mobile generator controller power switch in the OFF position.

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 Operation
Main Circuit Breaker 7.1

7 Operation

7.1 Main Circuit Breaker

WARNING
Electric shock hazard
High voltage is present inside the control panel while the engine is running.
Opening the control panel may cause electric shocks.
► Do not open the control panel unless the engine is stopped.

NOTICE
Leaving the main circuit breaker in the ON position may cause damage.
► Before shutting down the generator or performing any service to the
generator, make sure the main circuit breaker is in the OFF position.

Note: Graphic is representative only. Your machine may vary. 7

Location
Various styles of main circuit breakers may be found on Wacker Neuson mo-
bile generators. The main circuit breaker (1) is located on the control panel.
1
Functions
• The main circuit breaker interrupts power from the voltage selector
switch to the terminal lugs.
• The main circuit breaker does not interrupt power to the convenience re-
ceptacles.
Fig. 21: Main circuit breaker

7.2 Deep Sea Controller

7.2.1 Mobile Generator Controller Power Switch

Note: Graphic is representative only. Your machine may vary.

Description
The mobile generator controller power switch (1) is a two-position switch: ON
and OFF.

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Operation
7.2 Deep Sea Controller

ON

DSE 7310 MKII

STOP

OFF

wc_gr014855
Fig. 22: Power switch

Function

Position Function LCD Screen

ON • Power is supplied to the mobile generator controller. “Generator at Rest” fol-
• The mobile generator controller boots up and sets itself to the Stop/Reset lowed by the status
mode—the engine is ready to be started. screens that scroll.

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

7.2.2 Function of the Crankcase Pressure Switch (Optional)

Function
The crankcase pressure switch is a normally closed (NC) switch. Its purpose
is to keep the engine from damage due to high pressure build-up inside the
crankcase. If the vent hose becomes clogged because of ice forming inside
of it, pressure builds within the crankcase. This pressure could damage the
engine. The crankcase pressure switch prevents damage to the engine by
shutting down the engine in the event of high pressure.

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 Operation
Deep Sea Controller 7.2

Operation

Fig. 23: Crankcase pressure switch 7

When the crankcase pressure switch (1) senses high pressure:
• The crankcase pressure switch opens, which informs the controller a
high pressure condition exists.
• The controller sends a shutdown message to the engine.
• The machine shuts down.
• “Crankcase Pressure High” appears on the controller’s LCD display.

Deep Sea

DSE
DEEP SEA ELECTRONICS DSE 7310

Crankcase Pressure High STOP

Fig. 24: Crankcase Pressure High message

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Operation
7.2 Deep Sea Controller

Procedure
To rectify a high crankcase pressure condition, clear the vent hose of all ob-
structions.
1. If applicable, remove the insulation that covers the vent hose.
2 2. Remove the vent hose (2).

Fig. 25: Vent hose

Fig. 26: Vent hose

3. Thaw and drain the vent hose.

4. Clean the vent hose.
5. Install the vent hose.
6. If applicable, install the insulation.

7.2.3 Selecting the Voltage

WARNING
Electric shock hazard
High voltage is present inside the control panel while the engine is running.
Opening the control panel may cause electric shocks.
► Do not open the control panel unless the engine is stopped.

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 Operation
Deep Sea Controller 7.2

NOTICE
Changing the voltage selector switch position while the engine is running
may cause arcing, which may damage the switch and the generator wind-
ings.
► Do not change the voltage selector switch position while the engine is
running.

NOTICE
Using receptacles when the voltage is too high may cause damage to the re-
ceptacles and the tools connected to the receptacles.
► Do not use the GFCI or twist-lock receptacle (120V) when the 1Ø volt-
age is above 135V.

Note: Graphic is representative only. Your machine may vary.

Location
7
One of two types of voltage selector switch—either three-position (1) or four-
position (2)—is mounted to the machine near the lugs.

3Ø
1Ø 277/480V 208/240V 3Ø
3Ø 120/139V 1Ø
277/480V 120/240V
3Ø 1Ø
346/600V 120/240V
NUR NIEDRIGEN SCHWEFELKRAFTSTOFF ODER ULTRANIEDRIGEN SCHWEFELKRAFTSTOFF.

SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE

ULTRABAJO CONTENIDO DE AZUFRE.
177416

STOP
DIESEL
DANGER
GEFAHR
PELIGRO
DANGER
3Ø 1Ø
! !

1 2

wc_gr011503
Fig. 27: Three- and four-position selector switches

Selecting the voltage

The chart below lists the ranges of voltages available in each of the switch
positions. Select the desired voltage by rotating the handle of the voltage se-
lector switch. Then, use the voltage adjustment rheostat to set the exact volt-
age you require. The voltage is displayed on the LCD panel.

Range of Voltages Available

3Ø at Lugs 1Ø at Lugs 1Ø at Lugs 1Ø at Twist Lock
Switch position (L–L–L) (L–N) (L-L) 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

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Operation
7.2 Deep Sea Controller

Range of Voltages Available

3Ø at Lugs 1Ø at Lugs 1Ø at Lugs 1Ø at Twist Lock
Switch position (L–L–L) (L–N) (L-L) L-N (120V) L-L (240V) 1Ø at GFCI
1) 1) 1) 1)
277/480 VAC 3Ø 380 – 480 220 – 277 380 - 480 110 – 139 190 – 240 110 – 1391)
346/600 VAC 3Ø2) 540 – 600 310 - 347 — — — —
1) Not available on 600V models.
2) Not available on all models.

Using the rheostat

The voltage adjustment rheostat (1) is used to fine-tune the voltage as
needed while the machine is running.
1
Care must be taken when using the voltage adjustment rheostat because
adjusting the voltage for three-phase operation affects the voltage available
at the single-phase outlets. As the three-phase voltage increases, so does
the single-phase voltage.

Corresponding 1Ø Voltage
Fig. 28: Voltage adjustment rheostat 3Ø Voltage Twist Lock Receptacle
Switch Position (L-L-L) L-L (240V) L-N (120V) 120V GFCI
208 VAC 3Ø 208 208 120 120
120 VAC 1Ø 220 220 125 125
1)
240 240 139 1391)
277/480 VAC 3Ø 480 240 1391) 1391)
460 230 1332) 1332)
346/600 VAC 3Ø3) 600 —
540
1) Do not use receptacle with this voltage.
2) Voltage may be too high for some tools and equipment. Check tool/equipment specifications.
3) Not available on all models.

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 Operation
Deep Sea Controller 7.2

7.2.4 Deep Sea Controller Buttons / Functions

2 1
5 6

4
7
DSE
DEEP SEA ELECTRONICS DSE 7310 MKII

STOP 8
3
9

10
11

AUTO

12 13 14 15 16 17

wc_gr014856
Fig. 29: Controller button functions

Ref Button / Indicator Function

1 Right arrow button (right/forward) —
2 Up arrow button —
3 Down arrow button —
4 Left arrow button (left/backward) —
5 Check mark button (enter/accept) This is used when navigating through the mobile generator controller
menus.
Press this button to accept a new value or menu item.
6 Alarm indicator This illuminates during a fault condition that has stopped the engine.
7 Warning indicator This illuminates during a non-critical alarm condition. Note: non-critical
alarm conditions may lead to shut-down conditions.
8 Main breaker open indicator This illuminates whenever the main circuit breaker is open.
9 Low speed active indicator This illuminates when the engine idle speed is set to low idle (if
equipped).
10 Load button (not used) —
11 Gen-Set button (not used) —

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Operation
7.2 Deep Sea Controller

Ref Button / Indicator Function

12 Stop/Reset Pressing this button:
• Sets the mobile generator 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 mobile generator controller to the Manual
mode
In Manual mode, the mobile generator can be started and operated.
14 (not used) —
15 Auto mode Pressing this button sets the mobile generator controller to the Auto
mode
In Auto mode, the mobile 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 in Manual mode:
• Starts the engine
Pressing this button in Stop/Reset mode:
• Provides a keyswitch to the engine control unit ( ECU) for 10 minutes

7.2.5 Generator Controller Alarms and Shut-down Conditions

Overview
The mobile generator controller monitors variables of engine and machine
function. The mobile generator controller has two types of alarms: warning
alarms and shut-down alarms. The mobile generator controller also monitors
for electrical trip conditions.

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 Operation
Deep Sea Controller 7.2

Warning alarms
DSE
DEEP SEA ELECTRONICS DSE 7310 MKII

Warnings are non-critical alarm conditions that do not affect the operation of
STOP

the mobile generator system. They serve to draw the operator’s attention to
an undesirable condition. Warning alarms are self-resetting when the fault
condition is removed.
Warning alarms include:
1
• Low fuel level
wc_gr014857
Fig. 30: Warning LED • High coolant temperature
• Overspeed/Underspeed
• Time to maintenance
• Air filter differential pressure
• kW overload
• Oil pressure CAN data invalid
• Increase load
During a warning alarm condition, the LCD panel displays the type of warn-
ing alarm, the warning LED (1) illuminates, and an audible alarm sounds.
The machine is not shut down. Press the Horn Reset button to silence the
audible alarm. 7

DEEP SEA ELECTRONICS

Shut-down alarms
DSE DSE 7310 MKII

STOP
Shut-down alarms are latching alarms and stop the machine. Shut-down
alarms include:
• High coolant temperature
• Low oil pressure
1 2
• Overspeed/Underspeed
wc_gr014858
Fig. 31: Warning LEDs
• Overcrank
• Low coolant level (if equipped)
• Overcurrent
• Crankcase pressure high
• Auto-sense fail
– This occurs when the controller cannot determine the voltage selec-
tor switch position. The controller reads the voltage on all three legs
and uses that to determine which mode the machine is in. Based on
the start-up voltages, it enables the voltage, kW ratings, and protec-
tions specific to that mode. If the voltage is too high, low, or uneven
between the three phases, it triggers this alarm and shuts down the
machine. Make sure that during startup (within 10 seconds of reach-
ing rated speed for the first time), the L-N and L-L voltages of all
three phases are close to their intended operational values for that
voltage mode.
During a shut-down alarm condition, the LCD panel displays the type of
alarm, the LEDs (1 and 2) illuminate, an audible alarm sounds, and the ma-
chine is shut down. Press the Horn Reset button to silence the audible
alarm. Remove the fault condition, then press Stop/Reset.

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Operation
7.2 Deep Sea Controller

Variable Normal Warning Shutdown To Reset

Fuel level >15% 15% — Fill fuel tank. Press “Stop/
Reset.”
Coolant temp. 85°C ±8 105°C 110°C Add coolant. Press “Stop/
Reset.”
Oil pressure Pressure while — No pressure while engine Add engine oil. Press
engine running; running; switch closed “Stop/Reset.”
switch open
Overspeed 60 Hz 63 Hz 66 Hz Press “Stop/Reset.”
Underspeed 60 Hz 57 Hz 54 Hz Press “Stop/Reset.”
Overcrank — — After 1 attempt Press “Stop/Reset.”
Time to maintain 500 hours 0 hours — Reset controller.
Coolant level Above sender — Below sender Add coolant. Press “Stop/
Reset.”
Air filter differen- <4.00 kPA 4 – 5 kPA >5 kPA Clean/replace intake filter.
tial pressure Press “Stop/Reset.”
kW overload Reduce load below 99%
3Ø <100% 100-110% for <1 hour 100-110% for >1 hour before time limit is
reached
1Ø <100% N/A 100%
Increase load >30% engine load <30% engine load — Increase load

Electrical trips
DSE
DEEP SEA ELECTRONICS DSE 7310 MKII

Electrical trips are latching type alarms that trip the main circuit breaker.
STOP

During an electrical trip, the LEDs (1 and 2) illuminate, an audible alarm

sounds, and a cooldown timer starts. The engine stops when the timer
reaches 0.
These electrical trips are often, though not always, electrical load issues
1 2
that occur independent of the engine.
wc_gr014859
Fig. 32: Warning LEDs Press the Horn Reset button to silence the audible alarm. Remove the fault
condition, then press Stop/Reset to enable the engine to be restarted.

7.2.6 Before Starting the Machine

WARNING
Personal injury hazard
Failure to follow listed procedures may cause injury to personnel or damage
to the machine.
► Make sure that all persons setting up the machine are certified or fully
trained on the installation of the machine.

Before putting the mobile generator into service, perform each item on the
following checklist.

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 Operation
Deep Sea Controller 7.2

Exterior checks
• Check for damage that may have occurred during towing or travel to the
jobsite. Repair any damage.
• Make sure that the mobile generator is level.
• Chock the trailer wheels.

Internal checks
• Check engine oil, coolant, and fuel levels—fill as required.
• Check the fan belt and hoses on the engine for loose connections or
fraying—tighten or replace belts and hoses as required.
• Remove any debris that has lodged in vents, near the radiator, or around
the fan.
• Make sure the exhaust compartment is clean, with nothing touching the
muffler or exhaust pipes.

Pre-operation checks
• Read and understand the engine owner’s manual.
• Check local regulations and NEC standards for electrical connections. 7
• Determine voltage needs; obtain proper cable and equipment to meet
the needs. Follow local regulations and NEC standards.
• Make sure that the mobile 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 opera-
tor’s manual.

7.2.7 Starting and Running the Mobile Generator

CAUTION
Personal injury or machine damage hazard
Failure to match phase, voltage, and frequency may cause equipment con-
nected to the mobile generator to operate incorrectly.
► When using the mobile generator as a stand-by or substitute power sup-
ply, make sure the phase, voltage, and frequency of the mobile genera-
tor matches that of the utility lines or of any other power source normally
used.

Notes:
• If the engine does not start within the normal cycle, the mobile generator
controller shuts down the engine. “Failed to start” displays on the LCD.
– To repeat the crank cycle, press the Stop/Reset (O) button (4) to re-
set the engine control module. Allow the starter motor to cool be-
tween start-up attempts.
• Do not open the lug door or change the low idle switch during the first
15 seconds after the engine is started.

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Operation
7.2 Deep Sea Controller

• On machines equipped with a low idle switch, starting in low idle mode
delays voltage configuration sensing until the machine is brought up to
rated speed the first time after a start. The lug door must be closed be-
fore the low idle switch is turned off.
• The lug door interlock switch does NOT interrupt power to the conve-
nience receptacles. However, the switch does stop excitation at the gen-
erator. The result is significantly reduced voltage at the convenience re-
ceptacles.

Procedure
1. Check the position of the voltage selector switch and make sure that it
is set for the desired voltage output. Lock the voltage selector switch in
place.
2. Set the main circuit breaker to the OFF (O) position.
3. Set the convenience receptacle circuit breakers to the OFF position.
4. Set the mobile generator controller power switch (1) to the ON (I) posi-
tion.

DSE 7310 MKII

STOP

4 2 3 wc_gr014860
Fig. 33: Power switch, Manual Mode button, Start button, Stop/Reset button

5. Verify that the lug door is closed.

6. Press the Manual Mode button (2).
7. Press the Start (I) button (3).
The LCD panel displays the Preheating and then Crank Attempt
screens as the start-up sequence begins. (See the table at the end of
this section for screen meanings/descriptions.)
The engine cranks. During a normal cycle, the engine cranks for
12 seconds.
After the engine starts, the LCD panel displays screens in the following
order (see the table at the end of this section for screen meanings/de-
scriptions):
8. Press the Start (I) button (3).
The LCD panel displays the Preheating and then Crank Attempt
screens as the start-up sequence begins. (See the table at the end of
this section for screen meanings/descriptions.)
The engine cranks. During a normal cycle, the engine cranks for
12 seconds and rests for 12 seconds. This cycle repeats 3 times.
To repeat the crank cycle, press the Stop/Reset (O) button to reset the
engine control module. Allow the starter motor to cool between start-up
attempts.

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 Operation
Deep Sea Controller 7.2

After the engine starts, the LCD panel displays screens in the following
order (see the table at the end of this section for screen meanings/de-
scriptions):
ð Safety on Delay
ð Generator Available
ð Engine Oil Pressure
ð Engine Coolant Temperature
ð Engine Battery Voltage
ð Engine Fuel Level
9. Allow the engine to warm before closing the main circuit breaker.
10. Check the voltage displayed on the LCD panel.
11. Adjust the voltage as needed using the voltage adjustment rheostat.
For more information, see Selecting the Voltage on page 54.
12. Turn on (close) the appropriate circuit breakers for your load.

DEEP SEA ELECTRONICS

DSE DSE 7310 MKII
7

STOP

wc_gr014854
Fig. 34: Checking the voltage displayed

Screen Title Meaning/Description

Preheating The engine is heating.
Crank attempt The engine is attempting to start.
Safety on delay The mobile generator controller is determining system status.
Generator available The mobile generator is operating and ready for service.
Engine oil pressure Displays the engine oil pressure.
Engine coolant temperature Displays engine coolant temperature.
Engine battery voltage Displays the battery voltage.
Engine fuel level Displays the percentage of remaining fuel.

7.2.8 Stopping the Mobile Generator

Requirements
Before stopping the mobile generator:
• Check with other personnel on the jobsite and let them know that power
is being turned off.
• Make sure that the power shutdown will not create any hazards by turn-
ing off devices such as pumps, heaters, or lights that may need to be
kept on.

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Operation
7.2 Deep Sea Controller

Procedure
1. Remove all loads from the mobile generator by turning off any con-
nected equipment.
2. Set the convenience circuit breakers to OFF (O).
3. Set the main circuit breaker to OFF (O).
4. Press the Stop/Reset (O) button (1) to start the cool down/shut off
timer. The engine shuts off automatically when the timer expires.
Note: To bypass the timer and shut off the engine immediately, press
the Stop/Reset button a second time.

2 1
DSE 7310 MKII

STOP

wc_gr014861
Fig. 35: Stop/Reset button and power switch

5. Set the mobile generator controller power switch (2) to the OFF (O) po-
sition.

7.2.9 Emergency Stop Switch

NOTICE
The Emergency Stop switch is intended for use only in an actual emergency
situation where the mobile generator must be stopped immediately.
► Do not use the Emergency Stop switch to shut down the mobile genera-
tor during normal operation.

Location
The Emergency Stop switch is the red button (1) located to the right of the
control panel. The button can be accessed with the panel doors closed. It is
electrically isolated from the switch and also from the rest of the metering
panel.

2
DSE
DEEP SEA ELECTRONICS DSE 7310 MKII

STOP

ERGENC
M
E

S TO P

wc_gr014862
Fig. 36: Emergency stop switch and LCD panel

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 Operation
Deep Sea Controller 7.2

Operation
Activate the Emergency Stop switch by pressing the red button. This results
in the following actions:
• The main breaker opens.
• The Main Breaker Open LED illuminates.
• The engine stops.
• The LCD panel (2) displays a flashing Emergency Stop message.
• The Alarm LED illuminates, and an audible alarm sounds.
To silence the audible alarm, press the Horn Reset button on the keypad.
The flashing message and illuminated LED remains visible until the Emer-
gency Stop switch is deactivated.
To deactivate the Emergency Stop switch, pull the red button out.

7.2.10 Engine and Generator Monitoring

Description
Engine and generator information is displayed on the LCD panel and scrolls
continuously while the mobile generator is operating. 7

For more information on the Deep Sea controller, see Working with Deep
Sea Controller on page 66.

Volts “V” - Displays the AC output voltage being produced by the

Generator Available generator
L-N 277 V 0A Amps “A”- Displays the AC output amperage produced by the gen-
erator. If the generator is operating at no-load, output amperage dis-
L-L 480 V 59.9 Hz plays a 0.
0 kW --- pf Hertz “Hz”- Displays output frequency. This gauge should read ap-
proximately 60 Hz under a no-load condition. If the frequency is too
wc_gr009841 high, check the engine rpm.

Kilowatts “kW” - Displays the power output being produced in kilo-

watts
Power factor “pf” - Displays the ratio of kW to kVA
Displays the available DC voltage of the battery
Engine Battery Voltage

Battery 25.5 V
Charge Alt 0.0 V

wc_gr009842

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Operation
7.3 Working with Deep Sea Controller

Displays the percentage of fuel remaining in the fuel tank

Engine Fuel Level

66 %

wc_gr009843

Displays the engine oil pressure (if equipped)

Engine Oil Pressure

4.14 bar
60 psi
4.14 kPa
wc_gr009844

Displays the current temperature of the engine coolant

Engine Coolant Temp.

16 oC

60 oF

wc_gr009845

7.3 Working with Deep Sea Controller

7.3.1 Introduction
During normal operation, the mobile generator controller displays current in-
formation on machine performance and operating status. The keypad (1)
provides access to additional monitoring functions through a series of menus
displayed on the LCD panel (2). You can also use the keypad to change cer-
tain machine settings if desired.

4 1
DSE 7310 MKII 2
STOP

6
5
wc_gr014863

Fig. 37: Deep Sea controller buttons

1. The various monitoring and configuration menus can be accessed by

pressing the right arrow button (3).

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 Operation
Working with Deep Sea Controller 7.3

2. To select items on a menu, use the up/down arrow buttons (4 and 5) to

scroll through the available options.
3. To return to a previous menu screen, press the left arrow button (6).
4. To exit menu navigation and return to LCD panel monitoring status,
press the left or right arrow button (6 and 3) to return to the Status
page.

7.3.2 Navigating the Menus

The following graphic serves as a navigational aid when accessing the vari-
ous menus of the mobile generator controller. See the accompanying table
for information about the menu items.
Note: The specific order and quantity of screens may vary by model.

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Operation
7.3 Working with Deep Sea Controller

MENU NAVIGATION

Status Engine Generator Alarms ECU DTCs* Event Log Serial Port About
Summary Engine Gen Voltage
Screen Speed (L-N)

Engine
Engine Oil Gen Voltage
Oil
Pressure (L-L)
Pressure
Engine Engine
Gen
Coolant Coolant
Frequency
Temp Temp
Engine
Summary
Battery Gen Current
Screen
Voltage
Engine Engine
Gen Earth
Battery Run
Current
Voltage Time

Fuel Gen Load

Fuel Level
Level (kW)

Maintenance
Gen Load
Alarm [Hold
(Total kW)
"O" to reset]

Engine Gen Load

Link* (%)

Can Bus Gen Load

Information* (Total %)

Gen Load
(kVA)

Gen Load
(Total kVA)

Gen Power
Factor UP

Gen Power
Factor (Avg)

Gen Load BACK FORWARD

(kVAr)

Gen Load
(Total kVAr)
DOWN
Gen Load (h)

Gen Phase
Sequence

Active Config

Active Config *Not Available on Some Models

Fig. 38: Deep Sea controller menu navigation

Menu Item Description Menu Item Description

About Module information — —
Active Config Generator configuration Gen Load (h) Generator load kVArh
Alarms Alarms active Gen Load (%) Generator load percentage
— — Gen Load (kVA) Generator load kVA

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 Operation
Working with Deep Sea Controller 7.3

Menu Item Description Menu Item Description

CAN Bus Information CAN bus information Gen Load (kVAr) Generator load (kVAr)
— — Gen Load (kW) Generator load kW
ECU DTCs Engine diagnostic trouble codes Gen Load (Total %) Generator load total percentage
Engine Engine information Gen Load (Total kVA) Generator load total kVA
Engine Battery Volt- Battery and alternator voltage Gen Load (Total kW) Generator load total kW
age
— — Gen Phase Sequence Generator phase sequence
Engine Coolant Coolant temperature in °C and °F Gen Power Factor Generator power factor
Temp
Engine Link Engine link information Gen Power Factor Generator average power factor
(Avg)
Engine Oil Pressure Engine oil pressure in bar, PSI, Gen Voltage (L-L) Generator voltage line to line
and kPa
Engine Run Time Accumulated time in hours Gen Voltage (L-N) Generator voltage line to neutral
Engine Speed Engine rpm Generator Generator information
Event Log List of past events Maintenance Alarm Hours until maintenance warning
(Hold “O” to reset) 7
— — Serial port Serial port information
Fuel Level Percentage of fuel remaining in Status Status information
the tank
Gen Current Generator current amps Summary Screen Main Summary screen
Gen Earth Current Generator earth current amps — —
Gen Frequency Generator frequency (Hz) — —

7.3.3 Adjusting Screen Contrast

Overview
The contrast of the LCD display can be adjusted to suit the operator’s prefer-
ence.

Procedure
DSE
DEEP SEA ELECTRONICS DSE 7310 MKII


STOP

1. Access the Editor—Display menu on the LCD panel (1) by pressing

and holding the check mark button (2) on the keypad.
wc_gr014864
2. Wait a few seconds for the Contrast screen to appear, or use up/down
2 1 arrow buttons to navigate to the Contrast screen. Then, press the
check mark button. The contrast value starts flashing.

DEEP SEA ELECTRONICS

3. Press the up/down arrow buttons (3) and (4) to change the contrast
DSE DSE 7310 MKII

STOP
percentage as desired. When the screen contrast reaches a comfort-
 able viewing level, press the check mark button to accept the choice.
4. Exit by pressing and holding the check mark button until the mobile
wc_gr014865

3 4 generator controller returns to the Status screen.

Fig. 39: LCD panel and buttons

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 Operation
7.4 How to Connect Loads—480V

7.3.4 How to Reset the Maintenance Timer

Overview
The maintenance timer is preset to 500 hours. When the maintenance timer
times out, the mobile generator controller sounds the audible alarm.

NICS DSE 7310 MKII

Procedure
STOP

Note: For menu navigation reference, see Navigating the Menus on page
DSE 7310 MKII

STOP

67.
NICS DSE 7310 MKII

STOP

1. From the Status menu, press the right arrow button to reach the En-
gine menu.
DSE 7310 MKII

STOP
2. Using the up and down arrow buttons, navigate to the Maintenance
Alarm 1 screen.
1 3. Press the Stop/Reset button (1).
wc_gr014866
ð The timer returns to 500 hours.
Fig. 40: Stop/Reset button

7.4 How to Connect Loads—480V

The information in this section on how to connect loads applies to machines
with maximum capabilities of up to 480V.
This section does not apply to machines with maximum capabilities of up to
600V.

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 Operation
How to Connect Loads—480V 7.4

7.4.1 Lug Terminal Connection Diagram

High Wye
3Ø
1Ø
277/480V 120/240V
3Ø 1Ø
240V

Low Wye
139V 3Ø
1Ø
139V 277/480V 120/240V
208V or 240V 3Ø 1Ø
139V
or
240V
240V
240V

3Ø
1Ø
277/480V 120/240V
3Ø 1Ø

Zig Zag
wc_gr010197
Fig. 41: Lug terminal connection diagram

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Operation
7.4 How to Connect Loads—480V

7.4.2 Best Practices for Balancing Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

Overview
Three-phase loads are, by their nature, balanced. It is when single-phase
loads are combined with existing three-phase loads that an unbalanced con-
dition can occur. Dedicated single-phase loads may also be unbalanced if
the loads are not equally distributed between the legs (L1 and L3) of the mo-
bile generator.
The sensing wires of the generator’s voltage regulator are connected to L1
and L3. Having the loads balanced between L1 and L3 allows the generator
to provide voltage that is more consistent with the voltage needs of the
equipment connected to it.

Single-phase situations
DEEP SEA ELECTRONICS

For single-phase situations (voltage selector switch in the 208/240V posi-

DSE DSE 7310 MKII

STOP

tion), unbalanced loads can be detected by observing the mobile generator

controller LCD panel. If an unbalanced load condition exists, there is a signif-
icant difference (over 10%) in both voltage and amperage between the legs.
Observe the amp draw on L1 and L3.
AUTO

If an unbalanced load condition is detected, stop the engine and reconnect

the loads so that loads (amp draw) are more equally distributed between the
Fig. 42: Observing the amp draw on
L1 and L3 legs (L1 and L3)—for example, if a heavy load and a light load are con-
nected to L1, but only a light load is connected to L3. Reconnect the loads
so that the heavy load is connected to L1, and the two lighter loads are con-
nected to L3. Redistributing the loads equalizes the voltage for each leg and
allows for better performance from the equipment connected to the mobile
generator.
Reconnect the loads as necessary to provide the most equal amp draw be-
tween L1 and L3.
Observe the amp draw on L1, L2, and L3.

Three-phase situations
When combining single-phase loads with three-phase loads (voltage selec-
DSE
DEEP SEA ELECTRONICS DSE 7310 MKII

STOP

tor switch in 208/240V position), unbalanced loads can be detected by ob-

serving the mobile generator controller LCD panel. If an unbalanced load
condition exists, there is a significant difference in both voltage and amper-
age between the phases.
AUTO
If an unbalanced load is detected, stop the engine and reconnect the loads
so that loads (amp draw) are more equally distributed. This also helps equal-
ize the voltage for each phase.
Fig. 43: Observing the amp draw on
L1, L2, and L3

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 Operation
How to Connect Loads—480V 7.4

When connecting multiple 120V single-phase loads to the lugs while in

208/240V three-phase mode, use L1 as “hot” for the first load (or heaviest
load). Use L3 as “hot” for the second load (or next heaviest load), and use
L2 as “hot” for the third load (lightest load). If additional loads are to be con-
nected, repeat the connection sequence L1, L3, and then L2.

With voltage selected to 208/240 L1 L2 L3 N GND

3Ø
1Ø
277/480V 120/240V
3Ø 1Ø

HOT HOT HOT

When connecting multiple 120V 1Ø loads:

Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load. LOAD 1 LOAD 2

LOAD 3

wc_gr011282-480V
Fig. 44: Connection sequence

Using the receptacles

This information applies whether the machine is running in three-phase or in
single-phase. 7
LOAD 2 When connecting two loads to the duplex receptacles, instead of plugging
both loads in to the same duplex receptacle, plug the first load in to one of
LOAD 1
the duplex receptacles. Then, plug the second load in to the other duplex
receptacle. Additional loads can be plugged in to either duplex receptacle.

wc_gr011320
Fig. 45: Using the receptacles in
three-phase or in single-phase

When using the 240V twist-lock receptacle and a distribution box, instead of
plugging both loads in to the same duplex receptacle of the distribution
panel, plug the first load in to one of the duplex receptacles. Then, plug the
second load in to a different duplex receptacle of the distribution box.

LOAD 1

LOAD 2
wc_gr011321
Fig. 46: Using the receptacles with a
240V twist-lock receptacle and a dis-
tribution box

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Operation
7.4 How to Connect Loads—480V

7.4.3 Connecting 480V Three-phase and Single-phase Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.
240 L-L
139 L-N
480V 3Ø
139V 139V
3Ø
1Ø
277/480V 120/240V
3Ø 1Ø

480V 480V

480V

277V
277V
277V

HOT HOT HOT GN HOT HOT HOT WH GN

480V 3Ø 480V 3Ø TRANSFORMER

wc_gr011437
Fig. 47: Connecting 480V three-phase and single-phase loads

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 Operation
How to Connect Loads—480V 7.4

7.4.4 Connecting a 240V Three-phase Load and a 240V Single-phase Load

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.
240 L-L
139 L-N
240V 3Ø
3Ø
1Ø 7
277/480V 120/240V
3Ø 1Ø 139V 139V

240V 240V

240V

139V
139V
139V

HOT HOT HOT GN

240V 3Ø
240V 1Ø

wc_gr011438-480V

Fig. 48: Connecting a 240V three-phase load and 240V single-phase loads

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Operation
7.4 How to Connect Loads—480V

7.4.5 Connecting 240V and 120V Single-phase Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

Overview
Single-phase loads may be connected at the lugs by connecting the load
“line to line” or by connecting the load “line to neutral.” Line-to-line connec-
tions use two “hots” and ground; line-to-neutral connections use one “hot,”
neutral, and ground.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.

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 Operation
How to Connect Loads—480V 7.4

240 L-L
120 L-N
3Ø
1Ø
277/480V 120/240V
3Ø 1Ø
120V 120V

240V

120V

120V

Balance the load

When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
GN
HOT HOT

TO "N" LUG
TO GND LUG 7

120V 1Ø 120V 1Ø

240V 1Ø

wc_gr011440-480V
Fig. 49: Connecting 240V and 120V single-phase loads

7.4.6 Connecting a 208V Three-phase and Multiple 120V Single-phase Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.

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Operation
7.4 How to Connect Loads—480V

208 L-L
208V 3Ø 120 L-N

3Ø
1Ø
277/480V 120/240V
3Ø 1Ø 120V 120V

208V 208V

208V

120V
120V
120V

Balance the load

When connecting multiple
120V loads: HOT HOT HOT WH GN
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.

TO GND
LUG

208V 3Ø 120V 1Ø 120V 1Ø

wc_gr011441-480V
Fig. 50: Connecting a 208V three-phase and multiple 120V single-phase loads

7.4.7 Connecting a 220–240V Three-phase and Multiple 127–133V Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.

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 Operation
How to Connect Loads—480V 7.4

220–240V 3Ø 220–240 L-L

127–139 L-N
3Ø
1Ø
277/480V 120/240V
3Ø 1Ø ! !
127– 127–
139V 139V

220– 220–
240V 240V

220–240V

127–139V
127–139V
127–139V

Balance the load

When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load. WH
HOT HOT HOT
GN GN
Use L2 as "hot" for third load.

Fine-tune the voltage

Fine-tune the voltage so that
both the 3-phase load and
the single-phase loads 7
operate properly.

TO
GROUND
LUG

220–240V 3Ø 127–139V 1Ø 127–133V 1Ø

wc_gr011442-480V
Fig. 51: Connecting a 220-240V three-phase and multiple127-133V loads

7.4.8 Connecting 480V Three-phase Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.

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Operation
7.5 How to Connect Loads—600V

480V 3Ø

277/480V 208/240V 3Ø
3Ø 120/139V 1Ø

600V 120/240V
3Ø 1Ø

480V 480V

480V

277V
277V
277V

HOT HOT HOT GN HOT HOT HOT WH GN

transformateur
transformador

480V 3Ø 480V 3Ø TRANSFORMER

wc_gr011843
Fig. 52: Connecting 480V three-phase loads

7.5 How to Connect Loads—600V

The information in this chapter on how to connect loads applies to machines
with maximum capabilities of up to 600V.
This section does not apply to machines with maximum capabilities of only
480V.

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 Operation
How to Connect Loads—600V 7.5

7.5.1 Lug Terminal Connection Diagram

wc_gr011347
High Wye 9

10
11
L1-N = 346V
12 L2-N = 346V 277/480V 208/240V 3Ø
3Ø 120/139V 1Ø
L3-N = 346V
8 2 600V 120/240V
L1-L2 = 600V 3Ø 1Ø
7 1
6 4 L2-L3 = 600V
5 3 L3-L1 = 600V

3Ø Zig Zag
9
10
L1-N = 277V
8 277/480V 208/240V 3Ø
L2-N = 277V 3Ø 120/139V 1Ø

7 L3-N = 277V 600V 120/240V

3Ø 1Ø
L1-L2 = 480V
11 L2-L3 = 480V
4 3 1 7
2 L3-L1 = 480V
6 12

Low Wye
9 11 139V
277/480V 208/240V 3Ø
139V 3Ø 120/139V 1Ø
208V or 240V 10 12 139V 600V 120/240V
or 3Ø 1Ø
240V
6 2
1 240V
5
8 4 240V
7 3

6 1
2 277/480V 208/240V 3Ø
5 3 10 9 3Ø 120/139V 1Ø
8
7 4 600V 120/240V
3Ø 1Ø
12 11

1Ø Zig Zag
Fig. 53: Lug terminal connection diagram

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Operation
7.5 How to Connect Loads—600V

7.5.2 Best Practices for Balancing Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

Note: When in the 600V mode, single-phase power is not available.

Overview
Three-phase loads are, by their nature, balanced. It is when single-phase
loads are combined with existing three-phase loads that an unbalanced con-
dition can occur. Dedicated single-phase loads may also be unbalanced if
the loads are not equally distributed between the legs (L1 and L3) of the mo-
bile generator.
The sensing wires of the generator’s voltage regulator are connected to L1
and L3. Having the loads balanced between L1 and L3 allows the generator
to provide voltage that is more consistent with the voltage needs of the
equipment connected to it.

Single-phase situations
For single-phase situations (voltage selector switch in the 208/240V posi-
tion), unbalanced loads can be detected by observing the mobile generator
controller LCD panel. If an unbalanced load condition exists, there is a signif-
icant difference (over 10%) in both voltage and amperage between the legs.
Observe the amp draw on L1 and L3.
If an unbalanced load condition is detected, stop the engine and reconnect
DSE
DEEP SEA ELECTRONICS DSE 7310 MKII
the loads so that loads (amp draw) are more equally distributed between the
legs (L1 and L3)—for example, if a heavy load and a light load are con-
STOP

nected to L1, but only a light load is connected to L3. Reconnect the loads
so that the heavy load is connected to L1, and the two lighter loads are con-
nected to L3. Redistributing the loads equalizes the voltage for each leg and
AUTO
allows for better performance from the equipment connected to the mobile
generator.
Fig. 54: Observing the amp draw on Reconnect the loads as necessary to provide the most equal amp draw be-
L1 and L3 tween L1 and L3.

Three-phase situations
When combining single-phase loads with three-phase loads (voltage selec-
tor switch in 208/240V position), unbalanced loads can be detected by ob-
serving the mobile generator controller LCD panel. If an unbalanced load
condition exists, there is a significant difference in both voltage and amper-
age between the phases.
Observe the amp draw on L1, L2, and L3.

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 Operation
How to Connect Loads—600V 7.5

If an unbalanced load is detected, stop the engine and reconnect the loads
DSE
DEEP SEA ELECTRONICS DSE 7310 MKII so that loads (amp draw) are more equally distributed. This also helps equal-
STOP

ize the voltage for each phase.

When connecting multiple 120V single-phase loads to the lugs while in
208/240V three-phase mode, use L1 as “hot” for the first load (or heaviest
load). Use L3 as “hot” for the second load (or next heaviest load), and use
L2 as “hot” for the third load (lightest load). If additional loads are to be con-
AUTO

nected, repeat the connection sequence L1, L3, and then L2.

Fig. 55: Observing the amp draw on With voltage selected to 208/240 L1 L2 L3 N GND

L1, L2, and L3 277/480V

3Ø
208/240V 3Ø
120/139V 1Ø

346/600V 120/240V
3Ø 1Ø

HOT HOT HOT

When connecting multiple 120V 1Ø loads:

Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load. LOAD 1 LOAD 2

LOAD 3

wc_gr011282-600V
Fig. 56: Connection sequence
7
Using the receptacles
This information applies whether the machine is running in three-phase or in
single-phase.
LOAD 2 When connecting two loads to the duplex receptacles, instead of plugging
both loads in to the same duplex receptacle, plug the first load in to one of
LOAD 1
the duplex receptacles. Then, plug the second load in to the other duplex
receptacle. Additional loads can be plugged in to either duplex receptacle.

wc_gr011320
Fig. 57: Using the receptacles in
three-phase or in single-phase

When using the 240V twist-lock receptacle and a distribution box, instead of
plugging both loads in to the same duplex receptacle of the distribution
panel, plug the first load in to one of the duplex receptacles. Then, plug the
second load in to a different duplex receptacle of the distribution box.

LOAD 1

LOAD 2
wc_gr011321
Fig. 58: Using the receptacles with a
240V twist-lock receptacle and a dis-
tribution box

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Operation
7.5 How to Connect Loads—600V

7.5.3 Connecting a 240V Three-phase Load and a 240V Single-phase Load

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.
240 L-L
139 L-N
240V 3Ø

277/480V 208/240V 3Ø
3Ø 120/139V 1Ø 139V 139V
600V 120/240V
3Ø 1Ø

240V 240V

240V

139V
139V
139V

HOT HOT HOT GN

240V 3Ø
240V 1Ø

wc_gr011438-600V
Fig. 59: Connecting a 240V three-phase and a 240V single-phase load

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 Operation
How to Connect Loads—600V 7.5

7.5.4 Connecting 240V and 120V Single-phase Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

Overview
Single-phase loads may be connected at the lugs by connecting the load
“line to line” or by connecting the load “line to neutral.” Line-to-line connec-
tions use two “hots” and ground; line-to-neutral connections use one “hot,”
neutral, and ground.
1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door. 7

5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.

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Operation
7.5 How to Connect Loads—600V

240 L-L
120 L-N
277/480V 208/240V 3Ø
3Ø 120/139V 1Ø

346/600V 120/240V
3Ø 1Ø
120V 120V

240V

120V

120V

Balance the load

When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
GN
HOT HOT

TO "N" LUG
TO GND LUG

120V 1Ø 120V 1Ø

240V 1Ø

wc_gr011440-600V
Fig. 60: Connecting 240V and 120V single-phase loads

7.5.5 Connecting a 208V Three-phase and Multiple 120V Single-phase Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.

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 Operation
How to Connect Loads—600V 7.5

208 L-L
208V 3Ø 120 L-N

277/480V 208/240V 3Ø
3Ø 120/139V 1Ø
120V 120V
600V 120/240V
3Ø 1Ø

208V 208V

208V

120V
120V
120V

Balance the load

When connecting multiple
120V loads: HOT HOT HOT WH GN
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.

TO GND
LUG

208V 3Ø 120V 1Ø 120V 1Ø

wc_gr011441-600V
Fig. 61: Connecting a 208V three-phase and multiple120V single-phase loads

7.5.6 Connecting a 220–240V Three-phase and Multiple 127–133V Single-phase Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.

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Operation
7.5 How to Connect Loads—600V

220–240V 3Ø 220–240 L-L

127–139 L-N

277/480V
3Ø
208/240V 3Ø
120/139V 1Ø
! !
600V 120/240V 127– 127–
3Ø 1Ø 139V 139V

220– 220–
240V 240V

220–240V

127–139V
127–139V
127–139V

Balance the load

When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load. WH
HOT HOT HOT
GN GN
Use L2 as "hot" for third load.

Fine-tune the voltage

Fine-tune the voltage so that
both the 3-phase load and
the single-phase loads
operate properly.

TO
GROUND
LUG

220–240V 3Ø 127–139V 1Ø 127–133V 1Ø

wc_gr011442-600V
Fig. 62: Connecting a 220–240V three-phase and multiple 127–133V loads

7.5.7 Connecting 600V Three-phase Loads

WARNING
Electric shock hazard
High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.

1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the displayed position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the
voltage adjustment rheostat.

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 Operation
Using Remote Start Capabilities 7.6

600V 3Ø

277/480V 208/240V 3Ø
3Ø 120/139V 1Ø

600V 120/240V
3Ø 1Ø

600V 600V

600V
600 P3 24 60

346V
346V
100% 175 0 13
346V

HOT HOT HOT GN HOT HOT HOT WH GN

transformateur
transformador

600V 3Ø 600V 3Ø TRANSFORMER

wc_gr011356
Fig. 63: Connecting 600V three-phase loads

7.6 Using Remote Start Capabilities

7.6.1 Remote Run Terminal Block

Note: Graphic is representative only. Your machine may vary.
The remote run terminal block (1) is located as shown.

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Operation
7.6 Using Remote Start Capabilities

042563

OFF
AUS
APAGADO
ARRET
1
REMOTE START START / RUN
FERNSTART START / LAUFEN
ARRANQUE REMOTO ARRANQUE / MARCHA
DEMARRAGE A DEMARRER / MARCHE
DISTANCE

ERGENC
M

Y
S TO P

4,000 ft
1,219 m

ATS

wc_gr010366

Fig. 64: Remote run terminal block

Description
The remote run terminal block provides connection points for the installation
of a remotely located transfer/start switch. If a transfer switch is installed, the
mobile generator can be used as a stand-by power supply.
When connecting an automatic transfer switch (ATS) or other remote switch:
• Limit the distance between the remote run terminal block and the remote
switch to 1,219 m (4,000 ft) max.
• Use twisted, 22-gauge wire or heavier.
• Do not run the wire for the remote switch in the same conduit as current
carrying wire.
• Do not run a voltage to the contacts (these are dry contacts).

7.6.2 Remote Transfer Switch

DANGER
Electrocution hazard
Lethal voltage is always present in the transfer switch once it has been prop-
erly installed.
► Disconnect power before servicing the transfer switch.

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 Operation
Using Remote Start Capabilities 7.6

WARNING
Personal injury or equipment damage hazard
Failure to match phase rotation and voltage may cause equipment con-
nected to the mobile generator to operate incorrectly.
► When using the mobile generator as a stand-by or substitute power sup-
ply, make sure the voltage and phase rotation of the line connections
match those of the utility lines or of any other power source normally
used.

WARNING
Electrocution hazard
Failure to isolate the mobile generator from the utility’s electrical distribution
system could cause output from the generator to backfeed into the utility
lines and cause injury oder death to utility workers.
► When the mobile generator is used as a stand-by power supply, it must
be equipped with a device which isolates it from the utility’s distribution 7
system.
► An isolation device is also required if the mobile generator is being used
as a backup to some other type of power supply system.

Overview
A remote transfer switch is designed to transfer electrical loads from the nor-
mal power source (utility) to the emergency power source (mobile generator)
when normal voltage falls below a prescribed level.
The remote transfer switch automatically returns the load back to the normal
source when power is restored back to operating levels.

Precautions
• Installation of a remote transfer switch or other type of remote starting
device is the responsibility of the mobile generator user.
• Installation of such devices must be performed by a qualified electrician
following all directions supplied by the manufacturer of the switch.
• If attaching the mobile generator to a power supply normally serviced by
a utility company, notify the utility company and check local and state
regulations.
• Familiarize yourself with all instructions and warning labels supplied with
the switch.

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Operation
7.6 Using Remote Start Capabilities

7.6.3 Preparing for Automatic/Remote Start-up

WARNING
Personal injury hazard
If the contacts on any remote switch linked to the mobile generator are
closed, the mobile generator could start unexpectedly when the Auto Mode
button is pressed.
► Before pressing the Auto Mode button, verify that the contacts on any
remote switch linked to the mobile generator are open.

Overview
In Auto mode, the mobile generator can be started remotely, either through a
transfer switch or some other type of remote start switch. Auto mode is the
normal setting when using the mobile generator as a stand-by power supply.

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 Operation
Using Remote Start Capabilities 7.6

1 Procedure

005632
1. Before using the Auto mode, perform a check of the auto start-up cir-
cuit. To do so:
OFF
AUS
APAGADO
ARRET

REMOTE START START / RUN

FERNSTART START / LAUFEN
ARRANQUE REMOTO ARRANQUE / MARCHA
DEMARRAGE A DEMARRER / MARCHE
DISTANCE

50A

20A ð Attach a short jumper wire (1) (minimum 16-gauge insulated) be-
tween the two terminals on the remote run terminal block. The
jumper wire applies a ground to the ECM to complete the start cir-
cuit.
wc_gr010206 ð Set the mobile generator controller power switch (2) to the ON posi-
tion.
Fig. 65: Jumper wire
ð Press the Auto Mode button (3).
ð Wait for the engine to crank, start, and run. If the engine cranks, the
remote start circuit is functioning.
ð Press the Stop/Reset button (4) to stop the engine.
ð Remove the jumper wire from the remote run terminals after testing
is complete.

7
STOP

4 3 wc_gr011501

Fig. 66: Power switch, Auto Mode button, and Stop/Reset button

2. Leave the mobile generator controller power switch in the ON position.

3. Close the main circuit breaker.
4. Press the Auto Mode button.
5. Secure the mobile generator by closing and locking all doors.
ð The mobile generator is now ready for automatic starting.

Maintaining battery charge

If the mobile generator is to be used as a stand-by power supply, provisions
must be made to maintain the battery charge. This can be done either by at-
taching a battery charger to the battery or by starting the mobile generator
manually and running the engine periodically to maintain the battery charge.

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Operation
7.7 Wet Stacking

7.7 Wet Stacking

Overview
Wet stacking is the buildup of unburned diesel fuel, moisture, and carbon
particles in the exhaust system of the machine. This occurs when diesel fuel
is not completely burned off during use, and a black, oily residue accumu-
lates in the exhaust system due to operating the machine at a light load for
extended periods of time.
Wet stacking can lead to reduced engine performance, pollution, premature
engine wear, and permanent engine damage.

Prevention
• Use the right sized machine for the needs of the job.
• Follow the maintenance schedule.
• Load the machine greater than 30% of the engine rating.
• Run the machine a few minutes per week at the operational temperature.
• Have the machine regularly serviced by an experienced service techni-
cian.

Solution
• Have the machine serviced by an experienced service technician.
• Operate the machine at a load of about 75–80% of the machine’s name-
plate rating for a few hours to raise the exhaust temperature high enough
to clean out the exhaust system.

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 Accessories
Overview 8.1

8 Accessories

8.1 Overview
This machine may be equipped with one or more of the following factory-in-
stalled options. To verify if any of these options are installed on your ma-
chine, contact Wacker Neuson America Corporation at 1-800-770-0957. A
nameplate listing the model number, item number, and serial number is at-
tached to each unit. Please have this information available when contacting
Wacker Neuson America Corporation.
The illustrations shown in this chapter represent typical installations. The
factory-installed options on your machine may look different.
This machine comes standard with a 650 CCA battery. For colder weather
climates, Wacker Neuson recommends the larger (1,000 CCA) battery. Oth-
erwise, the machine may have difficulty starting.

8.2 Lockable Battery Disconnect

NOTICE
Power interruption while the engine is running may cause damage to electri-
cal components. 8
► Do not use the battery disconnect switch while the engine is running.

Note: Graphic is representative only. Your machine may vary.

A lockable ON/OFF switch is available which disconnects the battery. A pad-
lock (not included) securely locks the switch in the OFF position. If equipped,
the battery disconnect switch is mounted to the upper skid beneath the ac-
cess door on either side of the machine.

Fig. 67: Lockable battery disconnect

8.3 600V Capability

Machines with the 600V option include a four-position switch on the con-
troller used for selecting voltage. For instructions on how to use the voltage
selector switch, see Selecting the Voltage on page 54. For instructions on
how to connect loads on machines with maximum capabilities up to 600V,
see How to Connect Loads—600V on page 80.

8.4 Battery Charger

Note: Graphic is representative only. Your machine may vary.

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Accessories
8.5 Fuel Filter Heater

An optional battery charger (1) maintains the battery at peak power while the
machine is turned off. Use of a battery charger is recommended when the
1 mobile generator is not operated on a regular basis. The battery charger pre-
vents voltage drain and reduces the possibility of having to jump-start the
engine after long periods of inactivity. Plug the cord into a 120V power sup-
ply.

Fig. 68: Battery charger

8.5 Fuel Filter Heater

The fuel filter heater option consists of a wrap to cover the fuel filter, a ther-
mostat, and a wiring harness connected to the machine’s main wiring har-
ness. This option helps prevent diesel fuel from gelling in the filter. The fuel
filter heater turns on in temperatures below 45°F (7°C). The operator can
also adjust the temperature using a knob.

Fig. 69: Fuel filter heater location

8.6 Quick Oil Change

The quick oil change option evacuates the engine oil from the sump directly
to waste containment.

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 Accessories
Containment System 8.7

Fig. 70: Quick oil change location

8
8.7 Containment System
Overspills and leaks are captured in the containment system (1). The con-
tainment system holds over 110% of the fluid contained in the machine.
Note: This is a standard feature on G50 models.

Fig. 71: Containment system

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Accessories
8.8 Camlocks

8.8 Camlocks

WARNING
Electric shock hazard
Operating the machine with defective or missing safety devices may cause
serious electrical shocks.
► Do not operate this machine with defective or missing guards, doors, or
protective interlocks.

NOTICE
Damage to electrical components may occur without proper protection.
► Provide separate overcurrent protection.
► Do not exceed 400 amps per receptacle.

A second optional outlet panel features camlock connectors for easy tool
changes. Each connector is protected by a spring-loaded cover.

Fig. 72: Camlocks

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 Accessories
Engine Block Heater 8.9

8.9 Engine Block Heater

Note: Graphic is representative only. Your machine may vary.
The engine block heater option includes a block heater (1) with a cord (2).
The function of the block heater is to heat the engine coolant/engine block to
1 improve cold-weather engine starting. Plug the cord into a 120V power sup-
ply.

Fig. 73: Engine block heater

8.10 Low Coolant Shutdown

WARNING
Burn hazard
Engine coolant is hot and under pressure at operating temperature. It can
cause severe personal injury.
► Check the engine coolant level only after the engine has been shut
down and is cool. 8
► Do not add engine coolant directly to the radiator when hot.
► Check the coolant level at the reserve tank and add coolant as needed.
► Wear eye protection when handling the engine coolant.
► Tighten the radiator cap securely after checking the radiator. Steam can
escape during engine operation if the cap is loose.

Note: Graphic is representative only. Your machine may vary.

Overview
1
The low-coolant shutdown system consists of an electronic sensor that moni-
tors coolant level. The sensor (1) is mounted to the radiator and wired into
the ECM. The sensor probe is submerged in radiator coolant.
Note: The sensor may be disabled by unplugging the wire harness. This ac-
tion does not shut down the machine.

Function
If the probe senses no coolant, it sends a signal to the ECM. The ECM pro-
Fig. 74: Low coolant sensor gram includes a 2-second timer to protect from nuisance shutdowns. If after
the two seconds coolant levels are still sensed as being low, the ECM shuts
down the engine. The ECM then displays “LOW COOLANT LEVEL.” Allow
the engine to cool before adding additional coolant.
If it is necessary to open the radiator, only do so with the engine off, and only
when coolant is cool enough to touch with bare hands. Slowly loosen the ra-
diator cap to relieve pressure first, before removing it completely.

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Accessories
8.11 External Fuel Supply Connection

8.11 External Fuel Supply Connection

WARNING
Fire hazard
Improper connections or damaged hoses may leak flammable fuel.
► Ensure that all quick-disconnect fittings are properly seated before oper-
ating the machine.
► Make sure that fuel hoses are not kinked. Ensure that the hoses will not
touch or rest upon hot surfaces while the machine is operating.

Note: Graphic is representative only. Your machine may vary.

Requirements
• Engine stopped and cool to the touch
• Fuel supply and return hoses with compatible quick-disconnect fittings

Overview
Quick-disconnect fuel fittings allow an external fuel supply to be connected.
Note: The required fitting size is ISO 7241-1-Series B. The supply is 1/2 in.
and the return is 3/8 in.

Procedure

1 2 1. Connect the external feed hose at the external feed hose fitting (1).
2. Connect the external return hose at the external return hose fitting (2).

Fig. 75: Hose fittings

3. Move the fuel valve handle (3) from the down position for internal fuel
3 supply to the up position for external fuel supply.
Note: When connected to an external tank, there is a required fuel pressure
of -250 to 200 mbar. This pressure is measured at a point 100 to 200 mm
(4 to 8 in.) before the high pressure fuel pump inlet.

Fig. 76: External fuel supply handle

8.12 Level Load Logic (L3)

The Level Load Logic (L3) option applies load to the engine to heat coolant,
reducing the chance of wet stacking.
The system turns on when the following conditions occur:

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 Accessories
Level Load Logic (L3) 8.12

• The generator’s frequency is between 58 and 62 Hz for at least 30 sec-

onds.
• The generator’s kW load is less than 40% of the machine rating for at
least 5 seconds.
• The engine coolant temperature is less than 95°C for at least 5 seconds.
The system turns off when the following conditions occur:
• The generator’s frequency is less than 55 Hz or greater than 65 Hz.
• The generator’s kW load is greater than 45% of the machine rating.
• The engine coolant temperature is greater than 100°C.
When one of the Off conditions is true, the system remains off until all three
of the On conditions are true again.
Note: The L3 is limited to one activation every 10 minutes to prevent exces-
sive wear on the clutch. However, once activated, it can run indefinitely or
disengage at any time.

Fig. 77: Level load logic (L3) location

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Maintenance
9.1 General Maintenance

9 Maintenance

9.1 General Maintenance

WARNING
Injury and machine damage hazard
A poorly maintained machine can malfunction, causing injuries or permanent
damage to the machine.
► Keep the machine in safe operating condition by performing periodic
maintenance and making repairs as needed.

9.2 Preparing for Maintenance

Do not perform even routine service (oil/filter changes, cleaning, etc.) unless
all electrical components are shut down. Use the checklist below to prepare
this machine for maintenance:
• Set the start switch to OFF.
• Open the circuit breakers (set to the OFF position).
• Close the Emergency Stop switch (push in).
• Disconnect the negative terminal on the battery.
• Attach a “DO NOT START” sign to the control panel.
• If the unit is connected to a remote start or transfer switch, make sure
the remote switch is also off and tagged.

9.3 Maintenance Table

Maintenance cycle Personnel For further information
Daily Operating personnel [► 103] Inspecting the Machine
[► 103] Checking and Cleaning the Radiator
[► 104] Maintaining the Fuel Filter
[► 105] Maintaining the Trailer
[► 107] Checking the Engine Oil
Every week Operating personnel [► 108] Checking the Exhaust System
Every month Operating personnel [► 43] Testing the Breakaway System—Electric
Brakes
50 hours Operating personnel [► 109] Checking and Draining the Containment Sys-
tem (if equipped)
250 hours Operating personnel [► 110] Servicing the Air Cleaner
[► 110] Cleaning the Machine
[► 111] Maintaining the Battery
500 hours Operating personnel [► 112] Changing the Engine Oil and Filter
6000 hours Maintenance personnel [► 115] Filling the Radiator

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 Maintenance
Inspecting the Machine 9.4

9.4 Inspecting the Machine

When
Every 10 hours or daily

Overview
Inspect the machine before each use. A thorough inspection helps to identify
mechanical faults or potentially unsafe operating conditions. Correct these
problems before operating the machine.

External inspection
Perform an external inspection of the machine. Check for:
• External damage (dents, cracks, broken door latches, etc.)
• Loose or missing fasteners
• Loose or missing parts
• Cut or worn insulation on electrical cords
• Damaged light fixtures or lamps
• Fluid leaks
• Restricted air flow at the engine exhaust
• Problems with the trailer (if equipped, see Maintaining the Trailer on
page 105)

Internal inspection 9
Open the access doors on both sides of the machine. Check for:
• Damage to control panels, switches, or convenience receptacles
• Loose or missing fasteners
• Loose or missing parts
• Loose or damaged hoses
• Fluid leaks
• Rags, containers, or other debris inside the cabinet

9.5 Checking and Cleaning the Radiator

CAUTION
Personal injury hazard
Using compressed air or high-pressure water may cause eye injuries due to
flying debris, dust, and steam.
► Wear eye protection when using compressed air or high-pressure water.

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Maintenance
9.6 Maintaining the Fuel Filter

NOTICE
Cleaning the radiator improperly will damage the radiator fins.
► Do not use high-pressure water or compressed air at a pressure greater
than 28 psi (193 kPa).
► Do not use a wire brush.

When
Daily

Requirements
• Machine shut down and engine cool to the touch
• Compressed air

Procedure
1 1. Inspect the radiator for damage and any excessive dirt and debris. If
there is no damage and the radiator is clean, no further action is neces-
sary. Otherwise, continue with this procedure.
2. Use compressed air to clean loose particles from the radiator.
3. Clear any obstructions from the exhaust screen (1) on the top of the
machine.

Fig. 78: Exhaust screen

9.6 Maintaining the Fuel Filter

Environment
Use a suitable container to collect, store, and dispose of drained fluids and
lubricants in accordance with current environmental protection regulations.

When
• Drain the water separator daily.
• Change the fuel filter every 500 hours.

Requirements
• Machine shut down and secure
• Replacement water separator
• Container of sufficient volume to collect drained fluid
• Filter wrench

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 Maintenance
Maintaining the Trailer 9.7

Overview
The engine utilizes a pre-filter attached to the lift pump and a fuel filter with a
water separator element that removes water from the fuel supply. As fuel
flows through the water separator element, removed water is collected within
the fuel filter canister.

Draining the water separator

The fuel filter (1) is located in the engine compartment.
1. Place a collection container beneath the water separator drain
hose (2).
6
2. Loosen the wing nut (3) at the bottom of the water separator without re-
1 moving it.

2 3 3. Drain any water present.

4. Tighten the wing nut.
Fig. 79: Fuel filter, drain hose, and
wing nut Replacing the pre-filter
Note: Do not fill the new fuel filter with fuel.
1. Remove the pre-filter using an appropriate filter wrench.
2. Install the new pre-filter.

Replacing the water separator

1. Disconnect the water presence sensor (4) cable. 9
5 2. Remove the water presence sensor from the fuel filter.
3. Loosen the cartridge with an appropriate filter wrench.
4. Lubricate the O-ring (5) at the top of the new fuel filter with some petro-
leum jelly or some clean diesel fuel.
3 4 5. Tighten the water presence sensor onto the new fuel filter, tightening to
wc_gr015021 a torque of 5 Nm (44 in. lbs.).
Fig. 80: Water presence sensor, O- 6. Install the new fuel filter (with water separator) using the filter wrench,
ring, and wing nut tightening to a torque of 17 Nm (13 ft. lbs.).
7. Connect the cable of the water presence sensor.
8. To fill the fuel filter with fuel, press the priming button (6) repeatedly un-
til it becomes stiff.

9.7 Maintaining the Trailer

When
Daily

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Maintenance
9.8 Engine Oil Viscosity

Tires
• Keep tires inflated to the proper pressure as shown on the tire sidewall.
• Check tread periodically for wear.
• Replace tires as required.

Wheels
• Check that lug nuts holding wheels are tight.
• Replace any missing lug nuts immediately.

Axle hubs
• Grease axle hubs using a good wheel-bearing grease.

Brakes
Note: If the fluid level has fallen too low, bleed the brake lines to remove any
air trapped in the lines. Then, fill to the proper level with clean brake fluid.
• Check operation of brakes before each trip.
• Check level of brake fluid in actuator at front of trailer at regular intervals.
• Fill brake fluid to approximately 1 inch below top of reservoir using
DOT-3 heavy-duty brake fluid.
• Tighten filler plug securely.

9.8 Engine Oil Viscosity

WARNING
Health hazard
Most used liquids from this machine contain small amounts of materials that
can cause cancer and other health problems if inhaled, ingested, or left in
contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.

The viscosity of the engine oil is an important factor when determining the
correct engine oil to use in your machine. Use an engine oil of appropriate
viscosity based on the expected outside air temperature.
Refer to the following table when choosing engine oil:

Item Specification
Oil Viscosity ≥ -25°C 10W40
Oil Viscosity < -25°C 5W30
Oil Capacity 11.5 L (12.2 qt)
Refer to the engine owner’s manual for more information.

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 Maintenance
Checking the Engine Oil 9.9

9.9 Checking the Engine Oil

WARNING
Health hazard
Most used liquids from this machine contain small amounts of materials that
can cause cancer and other health problems if inhaled, ingested, or left in
contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.

NOTICE
Engine damage can occur if the oil level is too high or if the incorrect oil is
used.
► Oil must be removed from the engine if the oil level is above the max
line.
► Use only the recommended oil.

NOTICE
Prevent dirt and debris from contaminating the engine oil. Carefully clean the
oil cap, dipstick, and the surrounding area before removing the cap. 9

Do not mix different types of engine oil. This can adversely affect the lubri-
cating properties of the engine oil.

Environment
Use a suitable container to collect, store, and dispose of drained fluids and
lubricants in accordance with current environmental protection regulations.

When
Every 10 hours or daily

Requirements
• Machine on a level surface
• Machine shut down for several minutes
• Recommended oil (for oil specifications, see Engine Oil Viscosity on
page 106)
• A clean cloth

Overview
Maintaining the appropriate engine oil prevents excessive wear of the en-
gine.

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Maintenance
9.10 Checking the Exhaust System

Procedure
2
1. Open the engine access door.
2. Carefully remove the dipstick (1) and wipe it clean.
1
3. Fully insert the dipstick into the dipstick tube and remove it again to
check the engine oil level.

Fig. 81: Dipstick and oil cap

4. If the engine oil level is between the MIN (3) and MAX (4) marks, the
level is acceptable. Do not add engine oil.
5. If the oil level is below (5) the MIN mark, remove the engine oil cap (2)
5 3 4 and add enough oil to raise the level within the MIN-MAX range.

wc_gr013952 ð Repeat steps 1, 2, and 3 to check engine oil level.

Fig. 82: Dipstick marks ð Install the engine oil cap when the engine oil level is sufficient.
6. Install the dipstick.

9.10 Checking the Exhaust System

When
Weekly

Requirements
• Engine stopped
• Exhaust pipes and muffler cool to the touch

Overview
A leaky exhaust system adversely affects machine operation. Symptoms in-
clude increased noise and visible soot deposits. Leaking exhaust can also
ignite surrounding materials and pipe insulation, causing a fire.

Procedure
1
1. Open the access door on the curb side of the machine.
2. Inspect the exhaust pipes (1) and muffler (2), looking for:
ð Cracks or holes
ð Burned or missing insulation
1 ð Loose or missing clamps
2 ð Black soot deposits, especially around welds and joints
Fig. 83: Exhaust pipes and muffler

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 Maintenance
Checking and Draining the Containment System (if equipped) 9.11

3. Start the engine and listen carefully for:

ð Excessive noise
ð Rumbling
ð High-pitched whine
ð Rattling
4. Repair or replace faulty components before putting the machine back
into service.

9.11 Checking and Draining the Containment System (if equipped)

NOTICE
It is important to check the containment system regularly. A large amount of
fluid collected in a 24-hour period indicates a significant leak.

Environment
Use a suitable container to collect, store, and dispose of drained fluids and
lubricants in accordance with current environmental protection regulations.

When
Every 50 hours 9

Requirements
• Machine stopped and engine is cool to the touch
• Machine is on a level surface
• Plastic cloth and a container of sufficient volume to collect drained fluid

Overview
Certain machines are equipped with a containment system. The containment
system protects the environment by collecting fluid leaks (fuel, coolant, or oil)
which might otherwise contaminate the soil.

Procedure
1. Open the access door on the side of the machine.
1 2. Check the fluid level in the containment system.
3. If fluid has accumulated, drain the containment system.
ð Place a plastic cloth and a collection container beneath the machine.
ð Remove the drain plug (1). Drain accumulated fluid into a suitable
container.

Fig. 84: Drain plug

ð Apply pipe sealant to the drain plug.
ð Install the drain plug.

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Maintenance
9.12 Servicing the Air Cleaner

9.12 Servicing the Air Cleaner

WARNING
Fire hazard
Flammable liquids pose a fire hazard when cleaning.
► Do not use gasoline or other types of low flash point solvents to clean
the air cleaner.

NOTICE
Compressed air can damage air filter elements.
► Do not use compressed air to clean the air filter elements.

When
• Every 250 hours before operating the machine—check the condition of
the elements
• Every 500 hours or as needed—replace the elements

Requirements
• Machine shut down
• Damp cloth

Procedure
5
2
1 If the outer air filter element (1) is excessively dirty, replace it. Replace the
3 inner air filter element (2) every third time the outer air filter element is re-
placed. Check for any signs of leaks or damaged components throughout
this process.
1. Release the latch (3) and remove the cover (4) from the air cleaner
3 housing (5).
4
wc_gr014078
2. Remove the outer air filter element from the air cleaner housing. If nec-
Fig. 85: Air cleaner components
essary, also remove the inner air filter element.
3. Clean the inside of the air cleaner housing components with a damp
cloth.
4. Install the air filter elements.
5. Install the cover and fasten the latch.

9.13 Cleaning the Machine

When
Every 250 hours

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 Maintenance
Maintaining the Battery 9.14

Suggested cleaning materials

• Compressed air
• Clean water supply
• Mild detergent
• Clean, dry cloths

Cleaning the interior

Clean the interior of the machine.
1. Check the fluid level in the containment system (if equipped) and drain
if necessary. For more information, see Checking and Draining the
Containment System (if equipped) on page 109.
2. Remove rags, containers, or other debris from the cabinet. Nothing
should be stored inside the machine.
3. Remove leaves and twigs from the exhaust compartment.
4. Wipe interior surfaces clean of oil, dust, and dirt.

Cleaning the exterior

Clean the exterior of the machine with clean water and a mild detergent.

9.14 Maintaining the Battery

9
WARNING
Explosion hazard
Batteries can emit explosive hydrogen gas.
► Keep all sparks and flames away from the battery.
► Do not short-circuit battery posts.

When
Every 250 hours

Safety precautions
Observe the following safety precautions to prevent serious damage to the
electrical system.
• Do not disconnect the battery while the machine is running.
• Do not attempt to run the machine without a battery.
• Do not attempt to jump-start the machine.
• In the event that the machine has a discharged battery, either replace
the battery with a fully charged battery or charge the battery using an ap-
propriate battery charger.
• Dispose of waste batteries in accordance with local environmental regu-
lations.

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Maintenance
9.15 Changing the Engine Oil and Filter

Battery connections
To connect the battery:
1. Place all electrical switches in the OFF position.
2. Connect the red positive (+) battery cable to the battery.
3. Connect the black negative (-) battery cable to the battery.
To disconnect the battery:
1. Stop the engine.
2. Place all electrical switches in the OFF position.
3. Disconnect the black negative (-) battery cable from the battery.
4. Disconnect the red positive (+) battery cable from the battery.

Maintaining battery condition

• Follow the battery manufacturer’s maintenance recommendations.
• Keep battery terminals clean and connections tight.
• When necessary, tighten the cables and grease the cable clamps with
petroleum jelly.
• Maintain the battery at full charge to improve cold weather starting.

9.15 Changing the Engine Oil and Filter

WARNING
Health hazard
Most used oil contains small amounts of materials that can cause cancer
and other health problems if inhaled, ingested, or left in contact with skin for
prolonged periods of time.
► Take steps to avoid inhaling or ingesting used engine oil.
► Wash skin thoroughly after exposure to used engine oil.

WARNING
Burn hazard
Hot oil draining from the engine can burn.
► Do not touch hot oil.

Environment
Use a suitable container to collect, store, and dispose of drained fluids and
lubricants in accordance with current environmental protection regulations.

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 Maintenance
Changing the Engine Oil and Filter 9.15

When
Every 500 hours of service under normal operating conditions with fluids
meeting the recommended specifications.

Requirements
• Machine on a level surface
• Machine shut down for several minutes
• Engine oil (for oil specifications, see Engine Oil Viscosity on page 106)
• Engine oil filter
• Three O-rings
• Plastic sheet to protect work surface
• Container of sufficient volume to collect drained oil
• Wrenches

Overview
Maintaining the engine oil and filter prevents excessive wear of the engine.

Changing the engine oil (standard)

1
1. Loosen the engine oil cap (1).

Fig. 86: Engine oil cap

2. Loosen the two bolts (2) on the engine oil drain cover.
3 3. Rotate the cover 180°.
4
4. Feed the oil drain hose (3) through the oil drain access hole.
5. Open the drain hose valve on the fitting next to the oil pan.
6. Remove the drain plug (4) and drain the engine oil into an appropriate
2 container placed on a plastic sheet.
7. Install the drain plug.
Fig. 87: Bolts, hose, and plug 8. Feed the oil drain hose back through the oil drain access hole and clip
it into its storage position.
9. Rotate the engine oil drain cover 180° and tighten the bolts.
10. Remove the engine oil cap and add the recommended type and
amount of engine oil (see Checking the Engine Oil on page 107).
11. Install the engine oil cap.

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Maintenance
9.16 Maintaining the Emission Control System

Changing the engine oil (with quick change option)

5
1. Loosen the oil filter head and lift up on the top slightly to crack the
seal (5).
6
2. Attach a suction hose to the quick connect fitting (6) and drain the oil
from the engine.
3. Change the engine oil filter. For further information, see Changing the
Engine Oil Filter on page 114.
Fig. 88: Engine oil cap and quick 4. Replace the oil suction hose with the oil fill hose and add the recom-
change hose mended type and amount of engine oil (see Checking the Engine Oil
on page 107).

9.15.1 Changing the Engine Oil Filter

Changing the engine oil filter

7 1. Loosen the oil filter cap (7) and wait two minutes for the oil to drain
from the filter.

Fig. 89: Oil filter cap

2. Remove the oil filter assembly (8) from the oil filter housing.
8
3. Remove and replace the three O-rings (9).
4. Install a new filter element (10).
5. Install the oil filter assembly to the oil filter housing.
9 6. Tighten the oil filter assembly to 25 Nm (18 ft. lbs.).
10
wc_gr013963
Fig. 90: Filter assembly, O-rings, and
filter element

9.16 Maintaining the Emission Control System

For machines sold in North America:
Normal maintenance, replacement, or repair of emission control devices and
systems may be performed by any repair establishment or individual; how-
ever, warranty repairs must be performed by a dealer/service center autho-
rized by Wacker Neuson. The use of service parts that are not equivalent in
performance and durability to authorized parts may impair the effectiveness
of the emission control system and may have a bearing on the outcome of a
warranty claim.

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 Maintenance
Filling the Radiator 9.17

9.17 Filling the Radiator

WARNING
Burn hazard
Engine coolant is hot and under pressure at operating temperature. It can
cause severe personal injury.
► Check the engine coolant level only after the engine has been shut
down and is cool.
► Do not add engine coolant directly to the radiator when hot.
► Check the coolant level at the reserve tank and add coolant as needed.
► Wear eye protection when handling the engine coolant.
► Tighten the radiator cap securely after checking the radiator. Steam can
escape during engine operation if the cap is loose.

WARNING
Burn hazard
Engine coolant can contain alkali.
► Avoid engine coolant contact with skin and eyes.

9
NOTICE
Automotive-type coolants do not contain the correct coolant additives to pro-
tect heavy-duty diesel engines. They often contain a high concentration of
silicates which can damage the engine and cooling system.
► Use an OAT or HOAT coolant mixed to the appropriate percentage with
distilled water. For further information, see Coolant on page 116.

NOTICE
Use long-life ethylene glycol coolant in this engine. Refer to the engine
owner’s manual for more information.

When
Every 2,000 hours or 2 years

Requirements
• Machine shut down
• Engine cool to touch
• Fresh coolant (as needed)

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Maintenance
9.18 Coolant

Procedure
1. Open the access cover on the roof.

Fig. 91: Radiator cap

ADVERTENCIA
WARNUNG

WARNING

Fig. 92: Access cover and radiator cap

2. Slowly rotate the radiator cap counterclockwise to release any remain-

ing system pressure. Unscrew and remove the radiator cap after the
pressure is released.
3. Add coolant by filling at a rate of approximately 1.5 gallons per minute
for 6 minutes.
4. Wait 10 minutes. Then, fill at a rate of approximately 1.5 gallons per
minute for 3.5 minutes or until full.
5. Run the machine under a 50% load for approximately 15 minutes until
the coolant temperature exceeds 190°F.
6. Inspect the radiator cap and cap seal for damage. Clean the radiator
cap or replace if necessary.
7. Install the radiator cap.

9.18 Coolant
Overview
The coolant is a type of fluid made by mixing distilled water and ethylene gly-
col long life coolant concentrate or propylene glycol long life coolant concen-
trate. Its function is to cool the heat generated by the engine.
Note: If ethylene glycol is used, make sure to use organic acid technology
(OAT) low silicate or hybrid organic acid technology (HOAT) low silicate.

Handling the long-life coolant (LLC)

To prevent the engine damage due to freezing of the coolant and to protect
the cooling system from corrosion, mix the specified long-life coolant (LLC)
and distilled water with an appropriate ratio. See the table below.

Usage Region Outside Temperature LLC Concentration

Warm region (other than the cold region specifications) -12°C (10°F) or above 30%
Cold region (cold region specifications) -30°C (-22°F) or above 50%

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 Troubleshooting
Troubleshooting 10.1

10 Troubleshooting

10.1 Troubleshooting

Problem Cause Remedy

Engine does not start Battery discharged Charge battery.
Battery connections corroded Clean battery connections.
Blown fuse Replace fuse.
Defective starter Replace starter.
Engine tries to start but stops No fuel Fill tank with fuel.
Bleed fuel lines.
Clogged fuel filter Replace fuel filter.
Fuel circuit failure Check fuel lines.
Lug door open at engine start Close lug doors before starting the engine.
No generator output Main circuit breaker open Close main circuit breaker.
Low oil pressure Low oil level Fill engine sump with oil.
Clogged oil filter Replace oil filter.
High coolant temperature Overload Reduce load.
Low coolant level Fill with coolant.
Low oil level Fill sump with oil.
Clogged oil filter Replace oil filter.
Engine emits black smoke Clogged air filter Clean/replace air filter cartridges.
Overload Reduce load.
10
High oil level Remove excess oil.

10.2 Diagnostic Trouble Codes

10.2.1 Accessing Engine DTCs with the Deep Sea Controller

Overview
STOP
This machine may include an engine that has self-diagnostic capabilities.
These engines communicate issues with the engine through diagnostic trou-
ble codes (DTCs). When a DTC is present, an alert shows on the LCD panel
display. A DTC is a two-part code consisting of a suspect parameter number
(SPN), and a failure mode identifier (FMI).
The Deep Sea controller lists the most current DTC first, followed by the any
other DTCs in order of their occurrence.

Fig. 93: Accessing DTCs Procedure

1. From the “Status” menu, press the right arrow button to navigate
through “Engine,” “Generator,” and “Alarms” to “ECU DTCs.”

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Troubleshooting
10.2 Diagnostic Trouble Codes

2. Use the up and down arrow buttons to scroll through the DTCs.
Note: The Deep Sea controller lists the most current DTC first followed
by any other DTCs in order of their occurrence.

10.2.2 General Fault Mode Indicator (FMI) Chart

FMI Description
0 High—most severe (3)
1 Low—most severe (3)
2 Erratic, intermittent, or incorrect
3 Voltage above normal
4 Voltage below normal
5 Current below normal
6 Current above normal
7 Not responding properly
8 Abnormal frequency, pulse width, or period
9 Abnormal update rate
10 Abnormal rate of change
11 Other failure mode
12 Failure
13 Out of calibration
14 Special instruction
15 High—least severe (1)
16 High—moderate severity (2)
17 Low—least severe (1)
18 Low—moderate severity (2)
19 Data error
20 Data drifted high
21 Data drifted low
31 —

10.2.3 List of Engine Diagnostic Trouble Codes

SPN FMI P-code Name Description

27 7 P0400 EGRFPD EGR feedback/position sensor/Dynamic range failure (for CAN)
28 3 P0228 PTOPH Accelerator pedal for ASC (PTO) sensor signal too high
28 4 P0227 PTOPL Accelerator pedal for ASC (PTO) sensor signal too low
28 20 P2123 PTOP2H Accelerator pedal for ASC (PTO) sensor 2 signal too high
28 21 P2122 PTOP2L Accelerator pedal for ASC (PTO) sensor 2 signal too low
28 21 P2122 PTOP2L Accelerator pedal for ASC (PTO) sensor 2 signal too low
29 3 P0223 ACCP2H Accelerator pedal sensor No.2 signal too high
29 4 P0222 ACCP2L Accelerator pedal sensor No.2 signal too low
84 8 P0503 SPDH Vehicle speed sensor frequency too high

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 Troubleshooting
Diagnostic Trouble Codes 10.2

SPN FMI P-code Name Description

84 5 P0502 SPDL Vehicle speed sensor input open/short
84 2 P0501 SPDSG Vehicle speed sensor signal invalid
91 3 P0123 ACCP1H Accelerator pedal sensor No.1 signal too high
91 4 P0122 ACCP1L Accelerator pedal sensor No.1 signal too low
94 3 P0629 BSSCV SCV(+) output short to BATT; SCV(-) output short to BATT
94 6 P0627 DRSCV SCV(+) output open load/short to GND; SCV(-) output open load/short to
GND; SCV coil open/short
96 3 P0463 FLEVH Fuel level sensor signal too high
96 4 P0462 FLEVL Fuel level sensor signal too low
97 2 P2269 WGTHR Water in fuel filter failure
100 1 P0524 POILDN Engine oil pressure low
102 3 P0238 PIMH Boost pressure sensor signal too high
102 4 P0237 PIML Boost pressure sensor signal too low
102 2 P0236 PIMP1 Boost pressure sensor performance invalid
105 3 P0113 THAH Air temperature sensor signal too high
105 4 P0112 THAL Air temperature sensor signal too low
107 2 P2280 AFC Air filter clogging error
107 3 P2280 PAFDFH Air filter differential pressure sensor signal too high
107 4 P2280 PAFDFL Air filter differential pressure sensor signal too low
108 3 P2229 PATMH Atmosphere pressure sensor signal too high
108 4 P2228 PATML Atmosphere pressure sensor signal too low
110 2 P0116 THWP Coolant temperature sensor performance invalid
110 3 P0118 THWH Coolant temperature sensor signal too high
10
110 4 P0117 THWL Coolant temperature sensor signal too low
110 0 P0217 THWOT Coolant temperature exceeds upper limit
156 14 P1219 PLACT P/L (pressure limiter) activated
156 2 P1219 PLVHIRP Multiple high rail pressure error / Engine stall after PLV opening
157 9 P0191 PCP C/Rail press. Sensor signal keeping the middle range
157 2 P0191 PCO PC sensor offset diagnosis (drifted high or low)
157 14 P0191 PCONOX PC sensor offset diagnosis for NOX requirement (drifted high or low)
157 20 P0191 PCOH PC sensor high offset
157 3 P0193 PCH C/Rail pressure sensor signal too high
157 4 P0192 PCL C/Rail pressure sensor signal too low
157 0 P0088 PCEX3 C/Rail pressure exceeds high upper limit3
157 31 P1220 PCOVR C/Rail pressure control cannot achieve target fuel
157 1 P1221 PCUND C/Rail pressure falls below the control limit of the target pressure
157 16 P2293 PCEX2 C/Rail pressure exceeds high upper limit2
157 15 P1217 PCEX1 C/Rail pressure exceeds high upper limit1
167 31 P0611 LCHG Capacitor charge-up circuit malfunction injector (insufficient charge) within
ECU
167 1 P0200 OCHG Capacitor charge-up circuit malfunction injector (excessive charge)

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Troubleshooting
10.2 Diagnostic Trouble Codes

SPN FMI P-code Name Description

168 3 P0563 VBBH Vehicle system voltage too high (> 16 V)
168 4 P0562 VBBL Vehicle system voltage too low (< 8 V)
174 3 P0183 THFH Fuel temperature (with pump) sensor signal too high
174 4 P0182 THFL Fuel temperature (with pump) sensor signal too low
190 9 P0385 NEGNON Crank position and camshaft position sensor no pulse
190 0 P0219 NEOR Engine over speed condition
190 2 P0016 NEGUM Crankshaft and Camshaft synchronous error
249 8 P0337 NENOP Crank position (CKP) sensor no pulse
249 2 P0336 NEPUM Crank position (CKP) sensor performance invalid
430 3 P0615 STSWBT Starter switch short to BATT
430 5 P0617 STARELBT Starter relay short to battery
430 4 P0616 STARELGD Starter relay short to GND
598 2 P0704 CLSW Clutch switch circuit malfunction (manual transmission only)
604 2 P0850 NEUTSW Neutral switch circuit malfunction (manual transmission only)
626 3 P0542 GRELBT Glow relay output short to BATT
626 4 P0541 GRELGD Glow relay output open load/short to GND
637 8 P0342 GNOP Camshaft position (CMP) sensor no pulse
637 2 P0341 GPUM Camshaft position (CMP) sensor performance invalid
1083 31 U0101 CANOPEN- CAN bus-line open from general unit
GENU
1083 19 U0073 CANB1 CAN1 node error
1084 19 U1001 CANB2 CAN2 node error
1127 0 P0234 TBOPH Boost pressure sensor exceeds upper limit
1127 1 P0299 TBOPL Boost pressure sensor exceeds lower limit
1349 2 P268B IPMPSTDYNOT Pump learning uncompleted
1382 16 P1222 FIPRES1 Fuel filter diagnosis level 1
1382 0 P1223 FIPRES2 Fuel filter diagnosis level 2
1393 5 P0201 NCTWV1 Injector1 output open load injector coil open
1393 2 P0263 ANGSPD1 Engine angle speed error 1 (Injector 1)
1394 5 P0205 NCTWV2 Injector 3 output open load injector coil open
1394 2 P0275 ANGSPD2 Engine angle speed error 2 (Injector 3)
1395 5 P0203 NCTWV3 Injector 4 (4cyl engine)/Injector 2 (3cyl engine) output open load injector
coil open
1395 2 P0269 ANGSPD3 Engine angle speed error 3 (Injector 4 (4cyl engine)/Injector 2 (3cyl en-
gine))
1396 5 P0206 NCTWV4 Injector 2 (4cyl engine) output open load injector coil open
1396 2 P0278 ANGSPD4 Engine angle speed error 4 (Injector 2)
1397 3 P2148 BSTWV1 COM1 Injector drive system output short to BATT Injector 1 or
Injector 3 (4cyl engine) / Injector 2 (3cyl engine) output short to BATT
1397 4 P2147 GSTWV1 COM1 Injector drive system output short to GND Injector 1 or
Injector 3 (4cyl engine) / Injector 2 (3cyl engine) output short to GNS

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 Troubleshooting
Diagnostic Trouble Codes 10.2

SPN FMI P-code Name Description

1397 5 P2146 NCCOM1 COM1 Injector drive system output open load both Injector 1 and Injector
4 (4cyl engine) / Injector 2 (3cyl engine) open load
1639 5 P0694 CFANLBT Coolant fan low speed relay short to battery
1639 6 P0693 CFANLGD Coolant fan low speed relay short to GND
1639 3 P0696 CFANHBT Coolant fan high speed relay short to battery
1639 4 P0695 CFANHGD Coolant fan high speed relay short to GND
1639 31 P0480 EFAN Electric fan open load/short to GND/short to battery
1762 3 P0935 PHYDH Hydraulic pressure sensor signal too high
1762 4 P0934 PHYDL Hydraulic pressure sensor signal too low
2791 3 P0406 LEGRH EGR (exhaust gas recirculation) lift sensor signal too high
2791 4 P0405 LEGRL EGR (exhaust gas recirculation) lift sensor signal too low
2791 14 P0404 EGRBM EGR battery/motor failure (for CAN)
2791 2 U0411 EGRNTNR EGR no transmission/not received failure (for CAN)
2791 31 P2425 EGRT EGR valve temperature failure (for CAN)
2791 7 P0488 EGRVI EGR valve stuck/initialization failure (for CAN)
2791 13 P0403 EGRCLEAN EGR Cleaning failure (valve stuck open/poppet much lower than normal)
2791 13 P0403 EGRCLEAN EGR Cleaning failure (valve stuck open/poppet much lower than normal)
2802 13 P1602 QRNOT QR data is not written
2802 11 P0602 QRERR QR data error
2802 9 P1601 ABNQR QR definition error (definition concerning QR correction is not right)
2802 31 P0607 SCPU CPU fault; watchdog IC fault
2802 12 P0606 MCPU CPU fault; main CPU fault
2802 14 P0601 FROM Check sum error - flash area
10
3349 9 U0107 TSC1TMERR TSC1 Time out error
3349 10 U0408 TSC1RC TSC1 Rolling count test
3349 2 U0408 TSC1CS TSC1 Checksum test
3349 9 U0107 TSC1TMERR TSC1 Time out error
3349 10 U0408 TSC1RC TSC1 Rolling count test
3349 2 U0408 TSC1CS TSC1 Checksum test
3509 3 P0643 VCC1H Battery 5V reference 1 circuit high (5V power supply for sensor)
3509 4 P0642 VCC1L Battery 5V reference 1 circuit low (5V power supply for sensor)
3510 3 P0653 VCC2H Battery 5V reference 2 circuit high (5V power supply for sensor)
3510 4 P0652 VCC2L Battery 5V reference 2 circuit low (5V power supply for sensor)
4082 3 P0232 ELPUMPBT Electric lift pump relay short to battery
4082 4 P0231 ELPUMPGD Electric lift pump relay short to GND
4082 4 P0231 ELPUMPGD Electric lift pump relay short to GND

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Troubleshooting
10.2 Diagnostic Trouble Codes

10.2.4 List of Deep Sea Controller Diagnostic Trouble Codes

SPN Warning FMI Shutdown FMI Description

96 17 1 Fuel Level Low
100 17 1 Oil Pressure Low (Analog Sensor)
100 17 1 Oil Pressure Low (Digital Input)
100 2 2 Oil Pressure Sensor Fault
110 15 0 Coolant Temperature High (Analog Sensor)
110 15 0 Coolant Temperature High (Digital Input)
110 2 2 Coolant Temperature Sensor Fault
167 17 1 Charge Alternator Failed
168 15 0 Plant Battery Voltage High
168 17 1 Plant Battery Voltage Low
190 15 0 Overspeed
190 17 1 Underspeed
2436 17 1 Generator Average AC Frequency Under
2436 15 0 SPN Generator Average Line-Line AC RMS Voltage Over
2440 17 1 Generator Average Line-Line AC RMS Voltage Under
2440 15 0 Generator Average Line-Line AC RMS Voltage Over
2444 17 1 Generator Average Line-Neutral AC RMS Voltage Under
2444 15 0 Generator Average Line-Neutral AC RMS Voltage Over
2448 15 0 Generator Average AC RMS Current Over

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 Storage
Long-Term Storage 11.1

11 Storage

11.1 Long-Term Storage

NOTICE
Allowing the battery to freeze or completely discharge is likely to cause per-
manent damage.
► Periodically charge the battery while the machine is not in use.
► In cold climates, store and charge the battery indoors or in a warm loca-
tion.

When
Prepare your machine for extended storage if it will not be operated for
30 days or more.

Overview
Extended storage of equipment requires preventive maintenance. Perform-
ing these steps helps to preserve machine components and ensures the ma-
chine will be ready for future use. While not all of these steps necessarily ap-
ply to this machine, the basic procedures remain the same.

Preparing for storage

Perform the procedures below to prepare your machine for storage.
• Complete any needed repairs.
• Replenish or change oils (engine, exciter, hydraulic, and gearcase) per
the intervals specified in the Periodic Maintenance Schedule table.
• Grease all fittings and, if applicable, repack bearings.
11
• Inspect engine coolant. Replace coolant if it appears cloudy, is more
than two seasons old, or does not meet the average lowest temperature
for your area.
• If your machine has an engine equipped with a fuel valve, start the en-
gine, close the fuel valve, and run the engine until it stops.
• Consult the engine owner’s manual for instructions on preparing the en-
gine for storage.

Stabilizing the fuel

After completing the procedures listed above, fill the fuel tank completely
and add a high-quality stabilizer to the fuel.
• Choose a stabilizer that includes cleaning agents and additives designed
to coat/protect the cylinder walls.
• Make sure the stabilizer you use is compatible with the fuel in your area,
fuel type, grade, and temperature range. Do not add extra alcohol to fu-
els which already contain it (for example, E10).

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Storage
11.1 Long-Term Storage

• For engines with diesel fuel, use a stabilizer with a biocide to restrict or
prevent bacteria and fungus growth.
• Add the correct amount of stabilizer per the manufacturer’s recommen-
dations.

Storing the machine

Perform these remaining steps to store your machine.
• Wash the machine and allow it to dry.
• Move the machine to a clean, dry, secure storage location. Block or
chock the wheels to prevent machine movement.
• Use touch-up paint as needed to protect exposed metal against rust.
• If the machine has a battery, either remove or disconnect it.
• Cover the machine. Exposed rubber items should be protected from the
weather. Either cover them or use a protectant.

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 Decommissioning
Long-Term Storage 11.1

12 Decommissioning
Overview
This machine must be properly decommissioned at the end of its service life.
Responsible disposal of recyclable components, such as plastic and metal,
ensures that these materials can be reused—conserving landfill space and
valuable natural resources.
Responsible disposal also prevents toxic chemicals and materials from
harming the environment.
The operating fluids in this machine, including fuel, engine oil, and grease,
may be considered hazardous waste in many areas.
Before decommissioning this machine, read and follow local safety and envi-
ronmental regulations pertaining to the disposal of construction equipment.

Preparation
• Move the machine to a protected location where it does not pose any
safety hazards and cannot be accessed by unauthorized individuals.
• Ensure that the machine cannot be operated from the time of final shut-
down to disposal.
• Drain all fluids, including fuel, engine oil, and coolant.
• Seal any fluid leaks.

Disposal
• Disassemble the machine and separate all parts by material type.
• Dispose of recyclable parts as specified by local regulations.
• Dispose of all non-hazardous components that cannot be recycled.
• Dispose of waste fuel, oil, and grease in accordance with local environ-
mental protection regulations.

12

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Technical Data
13.1 Engine

13 Technical Data

13.1 Engine
Engine Power Rating
Gross standby power rating per ISO 8528-1 and SAE J1995. Actual power
output may vary due to conditions of specific use.

Item Units G50

Engine make — Kohler
Model — KDI2504TCR
Emissions — T4
Number of cylinders — 4
3
Displacement L (in ) 2.5 (151.5)
Operating speed rpm 1,800
Rated standby power @ 1800 rpm kW (hp) 54.5 (73.1)
Coolant capacity L (qt) 14.7 (15.5)
Oil capacity L (qt) 11.5 (12.2)
Battery volts / CCA 12 / 650
12 / 1,000
Fuel type — #1 / #2 ultra-low sulfur diesel1)
Fuel tank capacity L (gal) 333 (88)
Fuel consumption, prime load L / hr (gph) 12.5 (3.3)
2)
Run time at 100% prime load hr 25.6
2)
Run time at 75% prime load hr 34.2
2)
Run time at 50% prime load hr 48.5
2)
Run time at 25% prime load hr 74.7
1) The use of #6 diesel fuel is not recommended.
2) Run times are based on useable fuel volume, not on fuel tank capacity. “Useable fuel volume” does not include fuel remaining in the tank af-
ter a low fuel shutdown. For more information, see “Refueling the Machine.”

13.2 Generator

Item Units Standard 600V

Alternator make — Mecc Alte / Brushless with AVR
Alternator model — ECP 32-2S4 C ECP 32-1M4 C
Prime rating kVa 1Ø: 35.5 1Ø: 25.5
3Ø: 54 3Ø: 49
Voltage selector — 3-position switch 4-position switch
AC voltages available — 208, 220, 240, 416, 440, 480 switch- 208, 220, 240, 416, 440, 600 switch-
able able
120, 127, 139, 240, 254, 277 adjustable 120, 127, 139, 240, 254, 277, 346 ad-
voltage justable voltage
Frequency Hz 60

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 Technical Data
Machine 13.3

Item Units Standard 600V

Power factor 1ø 1.0
3ø 0.8
Voltage regulation — ± 1.00%
Insulation class — H

13.3 Machine

Machine Units Standard 600V

Sound level at 7 m (23 ft) dB(A)
Electric fan at 70% 67.1
AC receptacles — (2) 20A, GFI duplex
(3) 50A twist-lock
Standby output kW / kVA 41.8 / 52.4
Prime output kW / kVA 38 / 47.6
Main breaker A 125

13.4 Trailer and Skid

Machine Units G50

Dry weight of skid kg (lb) 963 (2,124)
Operating weight of skid kg (lb) 1,227 (2,705)
Trailer weight kg (lb) 175 (385)
Operating weight on trailer kg (lb) 1,402 (3,090)
Surge brakes Fluid type DOT3
Tires Size ST205 / 75D-15

13

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Technical Data
13.5 Dimensions

13.5 Dimensions
D

F
E

C
Fig. 94: Dimensions

Position Unit G50

A mm (in.) 960 (37.8)
B mm (in.) 1,803 (71)
C mm (in.) 1,480 (58.3)
D mm (in.) 2,073 (81.6)
E mm (in.) 1,156 (45.5)
F mm (in.) 1,286 (50.6)
G mm (in.) 3,525 (138.8)

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 Tire Safety Information
Tire Safety Information 14.1

14 Tire Safety Information

14.1 Tire Safety Information

Introduction to tire safety information
Federal Regulation 49 CFR 575 requires trailer manufacturers to include
certain tire information in the owner’s manuals for the trailers they manufac-
ture. This regulation requires that the information be in the English language.
This chapter includes all the information required by Federal Regulation 49
CFR 575.

14.2 Tire Safety Information Section Descriptions

This portion of the User’s Manual contains tire safety information as required
by 49 CFR 575.6.
Section 1.1 contains “Steps for Determining Correct Load Limit—Trailer.”
Section 1.2 contains “Steps for Determining Correct Load Limit—Tow Vehi-
cle.”
Section 1.3 contains a Glossary of Tire Terminology, including “cold inflation
pressure,” “maximum inflation pressure,” “recommended inflation pressure,”
and other non-technical terms.
Section 1.4 contains information from the NHTSA brochure entitled “Tire
Safety—Everything Rides On It.” This brochure, as well as the preceding
subsections, describes the following items:
• Tire labeling, including a description and explanation of each marking on
the tires, and information about the DOT tire identification number (TIN).
• Recommended tire inflation pressure, including a description and expla-
nation of:
– Cold inflation pressure.
– Vehicle placard and location on the vehicle.
– Adverse safety consequences of under inflation (including tire fail-
ure).
– Measuring and adjusting air pressure for proper inflation.
• Tire care, including maintenance and safety practices.
• Vehicle load limits, including a description and explanation of the follow-
ing items:
– Locating and understanding the load limit information, total load ca- 14
pacity, and cargo capacity.
– Calculating total and cargo capacities with varying seating configura-
tions including quantitative examples showing / illustrating how the
vehicles cargo and luggage capacity decreases as combined num-
ber and size of occupants’ increases. This item is also discussed in
Section 3.
– Determining compatibility of tire and vehicle load capabilities.
– Adverse safety consequences of overloading on handling and stop-
ping on tires.

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Tire Safety Information
14.3 Steps for Determining Correct Load Limit—Trailer

14.3 Steps for Determining Correct Load Limit—Trailer

Determining the load limits of a trailer includes more than understanding the
load limits of the tires alone. On all trailers there is a Federal certification/VIN
label that is located on the forward half of the left (road) side of the unit. This
certification/VIN label indicates the trailer’s Gross Vehicle Weight Rating
(GVWR). This is the most weight the fully loaded trailer can weigh. It also
provides the Gross Axle Weight Rating (GAWR). This is the most a particular
axle can weigh. If there are multiple axles, the GAWR of each axle is pro-
vided.
If your trailer has a GVWR of 10,000 pounds or less, there is a vehicle plac-
ard located in the same location as the certification label described above.
This placard provides tire and loading information. In addition, this placard
shows a statement regarding maximum cargo capacity. Cargo can be added
to the trailer, up to the maximum weight specified on the placard. The com-
bined weight of the cargo is provided as a single number. In any case, re-
member: the total weight of a fully loaded trailer can not exceed the stated
GVWR.
For trailers with living quarters installed, the weight of water and propane
also need to be considered. The weight of fully filled propane containers is
considered part of the weight of the trailer before it is loaded with cargo, and
is not considered part of the disposable cargo load. Water however, is a dis-
posable cargo weight and is treated as such. If there is a fresh water storage
tank of 100 gallons, this tank when filled would weigh about 800 pounds. If
more cargo is being transported, water can be off-loaded to keep the total
amount of cargo added to the vehicle within the limits of the GVWR so as
not to overload the vehicle. Understanding this flexibility allows you, the
owner, to make choices that fit your travel needs.
When loading your cargo, be sure it is distributed evenly to prevent over-
loading front to back and side to side. Heavy items should be placed low and
as close to the axle positions as reasonable. Too many items on one side
may overload a tire. The best way to know the actual weight of the vehicle is
to weigh it at a public scale. Talk to your dealer to discuss the weighing
methods needed to capture the various weights related to the trailer. This
would include the weight empty or unloaded, weights per axle, wheel, hitch
or king-pin, and total weight.
Excessive loads and/or underinflation cause tire overloading and, as a re-
sult, abnormal tire flexing occurs. This situation can generate an excessive
amount of heat within the tire. Excessive heat may lead to tire failure. It is
the air pressure that enables a tire to support the load, so proper inflation is
critical. The proper air pressure may be found on the certification/VIN label
and/or on the tire placard. This value should never exceed the maximum
cold inflation pressure stamped on the tire.

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 Tire Safety Information
Steps for Determining Correct Load Limit—Tow Vehicle 14.4

Trailers 10,000 pounds GVWR or less

Fig. 95: Tire and loading information

1. Locate the statement, “The weight of cargo should never exceed XXX
kg or XXX lbs.,” on your vehicle’s placard. See the graphic above.
2. This figure equals the available amount of cargo and luggage load ca-
pacity.
3. Determine the combined weight of luggage and cargo being loaded on
the vehicle. That weight may not safely exceed the available cargo and
luggage load capacity.
The trailer’s placard refers to the tire information placard attached adjacent
to or near the trailer’s VIN (Certification) label at the left front of the trailer.

Trailers over 10,000 pound GVWR (Note: these trailers are not
required to have a tire information placard on the vehicle)
1. Determine the empty weight of your trailer by weighing the trailer using
a public scale or other means. This step does not have to be repeated.
2. Locate the gross vehicle weight rating (GVWR) of the trailer on your
trailer’s VIN (certification) label.
3. Subtract the empty weight of your trailer from the GVWR stated on the
VIN label. That weight is the maximum available cargo capacity of the
trailer and may not be safely exceeded.

14.4 Steps for Determining Correct Load Limit—Tow Vehicle

1. Locate the statement, “The combined weight of occupants and cargo
should never exceed XXX lbs.,” on your vehicle’s placard. 14
2. Determine the combined weight of the driver and passengers who are
riding in your vehicle.
3. Subtract the combined weight of the driver and passengers from XXX
kilograms or XXX pounds.
4. The resulting figure equals the available amount of cargo and luggage
capacity. For example, if the “XXX” amount equals 1400 lbs. and there
are five 150 lb. passengers in your vehicle, the amount of available
cargo and luggage capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).

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Tire Safety Information
14.5 Glossary of Tire Terminology

5. Determine the combined weight of luggage and cargo being loaded on

the vehicle. That weight may not safely exceed the available cargo and
luggage capacity calculated in Step # 4.
6. If your vehicle is towing a trailer, load from your trailer is transferred to
your vehicle. Consult the tow vehicle’s manual to determine how this
weight transfer reduces the available cargo and luggage capacity of
your vehicle.

14.5 Glossary of Tire Terminology

Accessory weight
The combined weight (in excess of those standard items which may be re-
placed) of automatic transmission, power steering, power brakes, power win-
dows, power seats, radio and heater, to the extent that these items are avail-
able as factory-installed equipment (whether installed or not).
Bead
The part of the tire that is made of steel wires, wrapped or reinforced by ply
cords and that is shaped to fit the rim.
Bead separation
This is the breakdown of the bond between components in the bead.
Bias ply tire
A pneumatic tire in which the ply cords that extend to the beads are laid at
alternate angles substantially less than 90 degrees to the centerline of the
tread.
Carcass
The tire structure, except tread and sidewall rubber which, when inflated,
bears the load.
Chunking
The breaking away of pieces of the tread or sidewall.
Cold inflation pressure
The pressure in the tire before you drive.
Cord
The strands forming the plies in the tire.
Cord separation
The parting of cords from adjacent rubber compounds.
Cracking
Any parting within the tread, sidewall, or inner liner of the tire extending to
cord material.
CT
A pneumatic tire with an inverted flange tire and rim system in which the rim
is designed with rim flanges pointed radially inward and the tire is designed
to fit on the underside of the rim in a manner that encloses the rim flanges
inside the air cavity of the tire.
Curb weight

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 Tire Safety Information
Glossary of Tire Terminology 14.5

The weight of a motor vehicle with standard equipment including the maxi-
mum capacity of fuel, oil, and coolant, and, if so equipped, air conditioning
and additional weight optional engine.
Extra load tire
A tire designed to operate at higher loads and at higher inflation pressures
than the corresponding standard tire.
Groove
The space between two adjacent tread ribs.
Gross axle weight rating
The maximum weight that any axle can support, as published on the Certifi-
cation/VIN label on the front left side of the trailer. Actual weight determined
by weighing each axle on a public scale, with the trailer attached to the tow-
ing vehicle.
Gross vehicle weight rating
The maximum weight of the fully loaded trailer, as published on the Certifica-
tion/VIN label. Actual weight determined by weighing trailer on a public
scale, without being attached to the towing vehicle.
Hitch weight
The downward force exerted on the hitch ball by the trailer coupler.
Innerliner
The layer(s) forming the inside surface of a tubeless tire that contains the in-
flating medium within the tire.
Innerliner separation
The parting of the innerliner from cord material in the carcass.
Intended outboard sidewall
The sidewall that contains a white-wall, bears white lettering or bears manu-
facturer, brand, and/or model name molding that is higher or deeper than the
same molding on the other sidewall of the tire or the outward facing sidewall
of an asymmetrical tire that has a particular side that must always face out-
ward when mounted on a vehicle.
Light truck (LT) tire
A tire designated by its manufacturer as primarily intended for use on light-
weight trucks or multipurpose passenger vehicles.
Load rating
The maximum load that a tire is rated to carry for a given inflation pressure.
Maximum load rating 14
The load rating for a tire at the maximum permissible inflation pressure for
that tire.
Maximum permissible inflation pressure
The maximum cold inflation pressure to which a tire may be inflated.
Maximum loaded vehicle weight
The sum of curb weight, accessory weight, vehicle capacity weight, and pro-
duction options weight.
Measuring rim

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Tire Safety Information
14.5 Glossary of Tire Terminology

The rim on which a tire is fitted for physical dimension requirements.

Non-pneumatic rim
A mechanical device which, when a non-pneumatic tire assembly incorpo-
rates a wheel, supports the tire, and attaches, either integrally or separably,
to the wheel center member and upon which the tire is attached.
Non-pneumatic spare tire assembly
A non-pneumatic tire assembly intended for temporary use in place of one of
the pneumatic tires and rims that are fitted to a passenger car in compliance
with the requirements of this standard.
Non-pneumatic tire
A mechanical device which transmits, either directly or through a wheel or
wheel center member, the vertical load and tractive forces from the roadway
to the vehicle, generates the tractive forces that provide the directional con-
trol of the vehicle and does not rely on the containment of any gas or fluid for
providing those functions.
Non-pneumatic tire assembly
A non-pneumatic tire, alone or in combination with a wheel or wheel center
member, which can be mounted on a vehicle.
Normal occupant weight
This means 68 kg (150 lb) times the number of occupants specified in the
second column of Table I of 49 CFR 571.110.
Occupant distribution
The distribution of occupants in a vehicle as specified in the third column of
Table I of 49 CFR 571.110.
Open splice
Any parting at any junction of tread, sidewall, or innerliner that extends to
cord material.
Outer diameter
The overall diameter of an inflated new tire.
Overall width
The linear distance between the exteriors of the sidewalls of an inflated tire,
including elevations due to labeling, decorations, or protective bands or ribs.
Pin weight
The downward force applied to the 5th wheel or gooseneck ball, by the
trailer kingpin or gooseneck coupler.
Ply
A layer of rubber-coated parallel cords.
Ply separation
A parting of rubber compound between adjacent plies.
Pneumatic tire
A mechanical device made of rubber, chemicals, fabric and steel or other
materials, that, when mounted on an automotive wheel, provides the traction
and contains the gas or fluid that sustains the load.
Production options weight

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 Tire Safety Information
Glossary of Tire Terminology 14.5

The combined weight of those installed regular production options weighing

over 2.3 kg (5 lb) in excess of those standard items which they replace, not
previously considered in curb weight or accessory weight, including heavy
duty brakes, ride levelers, roof rack, heavy duty battery, and special trim.
Radial ply tire
A pneumatic tire in which the ply cords that extend to the beads are laid at
substantially 90 degrees to the centerline of the tread.
Recommended inflation pressure
This is the inflation pressure provided by the vehicle manufacturer on the
Tire Information label and on the Certification/VIN tag.
Reinforced tire
A tire designed to operate at higher loads and at higher inflation pressures
than the corresponding standard tire.
Rim
A metal support for a tire or a tire and tube assembly upon which the tire
beads are seated.
Rim diameter
This means the nominal diameter of the bead seat.
Rim size designation
This means the rim diameter and width.
Rim type designation
This means the industry of manufacturer’s designation for a rim by style or
code.
Rim width
This means the nominal distance between rim flanges.
Section width
The linear distance between the exteriors of the sidewalls of an inflated tire,
excluding elevations due to labeling, decoration, or protective bands.
Sidewall
That portion of a tire between the tread and bead.
Sidewall separation
The parting of the rubber compound from the cord material in the sidewall.
Special trailer (ST) tire
The "ST" is an indication the tire is for trailer use only.
Test rim 14
The rim on which a tire is fitted for testing, and may be any rim listed as ap-
propriate for use with that tire.
Tread
That portion of a tire that comes into contact with the road.
Tread rib
A tread section running circumferentially around a tire.
Tread separation
Pulling away of the tread from the tire carcass.

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14.6 Tire Safety—Everything Rides on It

Treadwear indicators (TWI)

The projections within the principal grooves designed to give a visual indica-
tion of the degrees of wear of the tread.
Vehicle capacity weight
The rated cargo and luggage load plus 68 kg (150 lb) times the vehicle’s
designated seating capacity.
Vehicle maximum load on the tire
The load on an individual tire that is determined by distributing to each axle
its share of the maximum loaded vehicle weight and dividing by two.
Vehicle normal load on the tire
The load on an individual tire that is determined by distributing to each axle
its share of the curb weight, accessory weight, and normal occupant weight
(distributed in accordance with Table I of CRF 49 571.110) and dividing by 2.
Weather side
The surface area of the rim not covered by the inflated tire.
Wheel center member
In the case of a non-pneumatic tire assembly incorporating a wheel, a me-
chanical device which attaches, either integrally or separably, to the non-
pneumatic rim and provides the connection between the nonpneumatic rim
and the vehicle; or, in the case of a non-pneumatic tire assembly not incor-
porating a wheel, a mechanical device which attaches, either integrally or
separably, to the non-pneumatic tire and provides the connection between
tire and the vehicle.
Wheel-holding fixture
The fixture used to hold the wheel and tire assembly securely during testing.

14.6 Tire Safety—Everything Rides on It

The National Traffic Safety Administration (NHTSA) has published a
brochure (DOT HS 809 361) that discusses all aspects of Tire Safety, as re-
quired by CFR 575.6. This brochure is reproduced in part below. It can be
obtained and downloaded from NHTSA, free of charge, from the following
web site:
http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.html
Studies of tire safety show that maintaining proper tire pressure, observing
tire and vehicle load limits (not carrying more weight in your vehicle than
your tires or vehicle can safely handle), avoiding road hazards, and inspect-
ing tires for cuts, slashes, and other irregularities are the most important
things you can do to avoid tire failure, such as tread separation or blowout
and flat tires. These actions, along with other care and maintenance activi-
ties, can also:
• Improve vehicle handling
• Help protect you and others from avoidable breakdowns and accidents
• Improve fuel economy
• Increase the life of your tires.

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 Tire Safety Information
Safety First—Basic Tire Maintenance 14.7

This booklet presents a comprehensive overview of tire safety, including in-

formation on the following topics:
• Basic tire maintenance
• Uniform Tire Quality Grading System
• Fundamental characteristics of tires
• Tire safety tips
Use this information to make tire safety a regular part of your vehicle mainte-
nance routine. Recognize that the time you spend is minimal compared with
the inconvenience and safety consequences of a flat tire or other tire failure

14.7 Safety First—Basic Tire Maintenance

Properly maintained tires improve the steering, stopping, traction, and load-
carrying capability of your vehicle. Underinflated tires and overloaded vehi-
cles are a major cause of tire failure. Therefore, as mentioned above, to
avoid flat tires and other types of tire failure, you should maintain proper tire
pressure, observe tire and vehicle load limits, avoid road hazards, and regu-
larly inspect your tires.

Finding your vehicle’s recommended tire pressure and load

limits
Tire information placards and vehicle certification labels contain information
on tires and load limits. These labels indicate the vehicle manufacturer's in-
formation including:
• Recommended tire size
• Recommended tire inflation pressure
• Vehicle capacity weight (VCW–the maximum occupant and cargo weight
a vehicle is designed to carry)
• Front and rear gross axle weight ratings (GAWR– the maximum weight
the axle systems are designed to carry).
Both placards and certification labels are permanently attached to the trailer
near the left front.

Understanding tire pressure and load limits

Tire inflation pressure is the level of air in the tire that provides it with load-
carrying capacity and affects the overall performance of the vehicle. The tire
inflation pressure is a number that indicates the amount of air pressure–
measured in pounds per square inch (psi)–a tire requires to be properly in-
flated. (You can also find this number on the vehicle information placard ex- 14
pressed in kilopascals (kpa), which is the metric measure used internation-
ally.)

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14.7 Safety First—Basic Tire Maintenance

Manufacturers of passenger vehicles and light trucks determine this number

based on the vehicle's design load limit, that is, the greatest amount of
weight a vehicle can safely carry and the vehicle's tire size. The proper tire
pressure for your vehicle is referred to as the "recommended cold inflation
pressure." (As you will read below, it is difficult to obtain the recommended
tire pressure if your tires are not cold.) Because tires are designed to be
used on more than one type of vehicle, tire manufacturers list the "maximum
permissible inflation pressure" on the tire sidewall. This number is the great-
est amount of air pressure that should ever be put in the tire under normal
driving conditions.

Checking tire pressure

It is important to check your vehicle's tire pressure at least once a month for
the following reasons:
• Most tires may naturally lose air over time.
• Tires can lose air suddenly if you drive over a pothole or other object or if
you strike the curb when parking.
• With radial tires, it is usually not possible to determine underinflation by
visual inspection.
For convenience, purchase a tire pressure gauge to keep in your vehicle.
Gauges can be purchased at tire dealerships, auto supply stores, and other
retail outlets.
The recommended tire inflation pressure that vehicle manufacturers provide
reflects the proper psi when a tire is cold. The term cold does not relate to
the outside temperature. Rather, a cold tire is one that has not been driven
on for at least three hours. When you drive, your tires get warmer, causing
the air pressure within them to increase. Therefore, to get an accurate tire
pressure reading, you must measure tire pressure when the tires are cold or
compensate for the extra pressure in warm tires.

Steps for maintaining proper tire pressure

1. Locate the recommended tire pressure on the vehicle's tire information
placard, certification label, or in the owner's manual.
2. Record the tire pressure of all tires.
3. If the tire pressure is too high in any of the tires, slowly release air by
gently pressing on the tire valve stem with the edge of your tire gauge
until you get to the correct pressure.
4. If the tire pressure is too low, note the difference between the mea-
sured tire pressure and the correct tire pressure. These "missing"
pounds of pressure are what you need to add.
5. At a service station, add the missing pounds of air pressure to each tire
that is underinflated.
6. Check all the tires to make sure they have the same air pressure (ex-
cept in cases in which the front and rear tires are supposed to have dif-
ferent amounts of pressure).

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Safety First—Basic Tire Maintenance 14.7

If you have been driving your vehicle and think that a tire is underinflated, fill
it to the recommended cold inflation pressure indicated on your vehicle's tire
information placard or certification label. While your tire may still be slightly
underinflated due to the extra pounds of pressure in the warm tire, it is safer
to drive with air pressure that is slightly lower than the vehicle manufacturer's
recommended cold inflation pressure than to drive with a significantly under-
inflated tire. Since this is a temporary fix, don't forget to recheck and adjust
the tire's pressure when you can obtain a cold reading.

Tire size
To maintain tire safety, purchase new tires that are the same size as the ve-
hicle's original tires or another size recommended by the manufacturer. Look
at the tire information placard, the owner's manual, or the sidewall of the tire
you are replacing to find this information. If you have any doubt about the
correct size to choose, consult with the tire dealer.

Tire tread
The tire tread provides the gripping action and traction that prevent your ve-
hicle from slipping or sliding, especially when the road is wet or icy. In gen-
eral, tires are not safe and should be replaced when the tread is worn down
to 1/16 of an inch. Tires have built-in treadwear indicators that let you know
when it is time to replace your tires. These indicators are raised sections
spaced intermittently in the bottom of the tread grooves. When they appear
"even" with the outside of the tread, it is time to replace your tires. Another
method for checking tread depth is to place a penny in the tread with Lin-
coln's head upside down and facing you. If you can see the top of Lincoln's
head, you are ready for new tires.

Tire balance and wheel alignment

To avoid vibration or shaking of the vehicle when a tire rotates, the tire must
be properly balanced. This balance is achieved by positioning weights on the
wheel to counterbalance heavy spots on the wheel-and-tire assembly. A
wheel alignment adjusts the angles of the wheels so that they are positioned
correctly relative to the vehicle's frame. This adjustment maximizes the life of
your tires. These adjustments require special equipment and should be per-
formed by a qualified technician.

Tire repair
The proper repair of a punctured tire requires a plug for the hole and a patch
for the area inside the tire that surrounds the puncture hole. Punctures
through the tread can be repaired if they are not too large, but punctures to 14
the sidewall should not be repaired. Tires must be removed from the rim to
be properly inspected before being plugged and patched.

Tire fundamentals
Federal law requires tire manufacturers to place standardized information on
the sidewall of all tires. This information identifies and describes the funda-
mental characteristics of the tire and also provides a tire identification num-
ber for safety standard certification and in case of a recall.

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Tire Safety Information
14.7 Safety First—Basic Tire Maintenance

Information on Passenger Vehicle Tires

Please refer to the diagram below.

Fig. 96: Passenger vehicle tire information

P
The "P" indicates the tire is for passenger vehicles.
Next number
This three-digit number gives the width in millimeters of the tire from sidewall
edge to sidewall edge. In general, the larger the number, the wider the tire.
Next number
This two-digit number, known as the aspect ratio, gives the tire's ratio of
height to width. Numbers of 70 or lower indicate a short sidewall for im-
proved steering response and better overall handling on dry pavement.
R
The "R" stands for radial. Radial ply construction of tires has been the indus-
try standard for the past 20 years.
Next number
This two-digit number is the wheel or rim diameter in inches. If you change
your wheel size, you have to purchase new tires to match the new wheel di-
ameter.
Next number
This two- or three-digit number is the tire's load index. It is a measurement of
how much weight each tire can support. You may find this information in
your owner's manual. If not, contact a local tire dealer. Note: You may not
find this information on all tires because it is not required by law.
M+S

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 Tire Safety Information
Safety First—Basic Tire Maintenance 14.7

The "M+S" or "M/S" indicates that the tire has some mud and snow capabil-
ity. Most radial tires have these markings; hence, they have some mud and
snow capability.
Speed rating
The speed rating denotes the speed at which a tire is designed to be driven
for extended periods of time. The ratings range from 99 miles per hour (mph)
to 186 mph. These ratings are listed below. Note: You may not find this infor-
mation on all tires because it is not required by law.

Letter Rating Speed Rating

Q 99 mph
R 106 mph
S 112 mph
T 118 mph
U 124 mph
H 130 mph
V 149 mph
W 168 mph1)
Y 186 mph2)
1) For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use
the letters ZR.
2) For tires with a maximum speed capability over 186 mph, tire manufacturers always use the
letters ZR.
U.S. DOT tire identification number
This begins with the letters "DOT" and indicates that the tire meets all federal
standards. The next two numbers or letters are the plant code where it was
manufactured, and the last four numbers represent the week and year the
tire was built. For example, the numbers 3197 means the 31st week of 1997.
The other numbers are marketing codes used at the manufacturer's discre-
tion. This information is used to contact consumers if a tire defect requires a
recall.
Tire ply composition and materials used
The number of plies indicates the number of layers of rubber-coated fabric in
the tire. In general, the greater the number of plies, the more weight a tire
can support. Tire manufacturers also must indicate the materials in the tire,
which include steel, nylon, polyester, and others.
Maximum load rating
This number indicates the maximum load in kilograms and pounds that can
be carried by the tire. 14
Maximum permissible inflation pressure
This number is the greatest amount of air pressure that should ever be put in
the tire under normal driving conditions.

UTQGS information
Treadwear number

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Tire Safety Information
14.7 Safety First—Basic Tire Maintenance

This number indicates the tire's wear rate. The higher the treadwear number
is, the longer it should take for the tread to wear down. For example, a tire
graded 400 should last twice as long as a tire graded 200.
Traction letter
This letter indicates a tire's ability to stop on wet pavement. A higher graded
tire should allow you to stop your car on wet roads in a shorter distance than
a tire with a lower grade. Traction is graded from highest to lowest as "AA,"
"A," "B," and "C."
Temperature letter
This letter indicates a tire's resistance to heat. The temperature grade is for
a tire that is inflated properly and not overloaded. Excessive speed, underin-
flation or excessive loading, either separately or in combination, can cause
heat build-up and possible tire failure. From highest to lowest, a tire's resis-
tance to heat is graded as "A," "B," or "C."
Please refer to the following diagram.

Fig. 97: Light truck tire information

Tires for light trucks have other markings besides those found on the side-
walls of passenger tires.
LT
The "LT" indicates the tire is for light trucks or trailers.
ST
An "ST" is an indication the tire is for trailer use only.
Max. load dual kg (lb) at kPa (psi) cold

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 Tire Safety Information
Tire Safety Tips 14.8

This information indicates the maximum load and tire pressure when the tire
is used as a dual, that is, when four tires are put on each rear axle (a total of
six or more tires on the vehicle).
Max. load single kg (lb) at kPa (psi) cold
This information indicates the maximum load and tire pressure when the tire
is used as a single.
Load range
This information identifies the tire's load-carrying capabilities and its inflation
limits.

14.8 Tire Safety Tips

Preventing tire damage
• Slow down if you have to go over a pothole or other object in the road.
• Do not run over curbs or other foreign objects in the roadway, and try not
to strike the curb when parking.

Tire safety checklist

• Check tire pressure regularly (at least once a month), including the
spare.
• Inspect tires for uneven wear patterns on the tread, cracks, foreign ob-
jects, or other signs of wear or trauma.
• Remove bits of glass and foreign objects wedged in the tread.
• Make sure your tire valves have valve caps.
• Check tire pressure before going on a long trip.
• Do not overload your vehicle. Check the Tire Information and Loading
Placard or User’s Manual for the maximum recommended load for the
vehicle.

14

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Emission Control System Information and Warranty
15.1 Emission Control System Background Information

15 Emission Control System Information and Warranty

The Emission Control Warranty and associated information is valid only for
the U.S.A., its territories, and Canada.

15.1 Emission Control System Background Information

Introduction
Wacker Neuson engines/equipment must conform with applicable Environ-
mental Protection Agency (EPA) and California Air Resource Board (CARB)
emissions regulations. These regulations require that manufacturers warrant
the emission control systems for defects in materials and workmanship.
Furthermore, EPA and CARB regulations require all manufacturers to furnish
written instructions describing how to operate and maintain the engines/
equipment including the emission control systems. This information is pro-
vided with all Wacker Neuson engines/equipment at the time of purchase.

Exhaust emissions
The combustion process produces carbon monoxide, oxides of nitrogen, and
hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very impor-
tant because, under certain conditions, they react to form photochemical
smog when subjected to sunlight. Carbon monoxide does not react in the
same way, but it is toxic.

Problems that may affect emissions

If any of the following symptoms arise, have the engine/equipment inspected
and repaired by a Wacker Neuson dealer/service center.
• Hard starting or stalling after starting
• Rough idling
• Misfiring or backfiring under load
• Afterburning (backfiring)
• Presence of black exhaust smoke during operation
• High fuel consumption

Tampering and altering

Tampering with or altering the emission control system may increase emis-
sions beyond the legal limit. If evidence of tampering is found, Wacker Neu-
son may deny a warranty claim. Among those acts that constitute tampering
are:
• Removing or altering of any part of the air intake, fuel, or exhaust sys-
tems.
• Altering or defeating the speed-adjusting mechanism causing the engine
to operate outside its design parameters.

15.2 Limited Defect Warranty for Exhaust Emission Control System

See the supplied engine owner’s manual for the applicable emission war-
ranty statement.

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 Emission Control System Information and Warranty
Limited Defect Warranty for Wacker Neuson Emission Control Systems 15.3

15.3 Limited Defect Warranty for Wacker Neuson Emission Control

Systems
The Emission Control Warranty is valid only for the U.S.A., its territories, and
Canada.
Wacker Neuson America Corporation, N92 W15000 Anthony Avenue,
Menomonee Falls, WI 53051, (hereinafter “Wacker Neuson”) warrants to the
initial retail purchaser and each subsequent owner, that this engine/equip-
ment, including all parts of its emission control system, have been designed,
built, and equipped to conform at the time of initial sale to all applicable
evaporative emission regulations of the U.S. Environmental Protection
Agency (EPA), and that the engine/equipment is free of defects in materials
and workmanship which would cause this engine/equipment to fail to con-
form to EPA regulations during its warranty period.
Wacker Neuson is also liable for damages to other engine/equipment com-
ponents caused by a failure of any warranted parts during the warranty pe-
riod.

What is covered
Wacker Neuson recommends the use of genuine Wacker Neuson parts, or
the equivalent, whenever maintenance is performed. The use of replace-
ment parts not equivalent to the original parts may impair the effectiveness
of the engine/equipment emission controls systems. If such a replacement
part is used in the repair or maintenance of the engine/equipment, assure
yourself that such part is warranted by its manufacturer to be equivalent to
the parts offered by Wacker Neuson in performance and durability. Further-
more, if such a replacement part is used in the repair or maintenance of the
engine/equipment, and an authorized Wacker Neuson dealer/service center
determines it is defective or causes a failure of a warranted part, the claim
for repair of the engine/equipment may be denied. If the part in question is
not related to the reason the engine/equipment requires repair, the claim will
not be denied.
For the components listed in the following table, an authorized Wacker Neu-
son dealer/service center will, at no cost to you, make the necessary diagno-
sis, repair, or replacement necessary to ensure that the engine/equipment
complies with the applicable EPA regulations. All defective parts replaced
under this warranty become property of Wacker Neuson.

System Covered Components

Air handling system and associated Charge air cooler
plumbing Charge air cooler plumbing
Exhaust system (upstream of last af- Exhaust gas piping from tur-
tertreatment device) bocharger out to the last aftertreat-
ment device 15

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Emission Control System Information and Warranty
15.3 Limited Defect Warranty for Wacker Neuson Emission Control Systems

What is not covered

• Failures other than those resulting from defects in material or workman-
ship.
• Any systems or parts which are affected or damaged by owner abuse,
tampering, neglect, improper maintenance, misuse, improper fueling, im-
proper storage, accident and/or collision; the incorporation of, or any use
of, add-on or modified parts, or unsuitable attachments, or the alteration
of any part.
• Replacement of expendable maintenance items made in connection with
required maintenance services after the item’s first scheduled replace-
ment as listed in the maintenance section of the engine/equipment oper-
ator’s manual, such as spark plugs and filters.
• Incidental or consequential damages such as loss of time or the use of
the engine/equipment, or any commercial loss due to the failure of the
engine/equipment.
• Diagnosis and inspection charges that do not result in warranty-eligible
service being performed.
• Any non-authorized replacement part, or malfunction of authorized parts
due to use of-non authorized parts.

Owner’s warranty responsibility

The engine/equipment owner, is responsible for the performance of the re-
quired maintenance listed in the Wacker Neuson engine/equipment opera-
tor’s manual. Wacker Neuson recommends that all receipts covering mainte-
nance on the engine/equipment be retained, but Wacker Neuson cannot
deny warranty coverage solely for the lack of receipts or for the failure to en-
sure the performance of all scheduled maintenance.
Normal maintenance, replacement, or repair of emission control devices and
systems may be performed by any repair establishment or individual; how-
ever, warranty repairs must be performed by an authorized Wacker Neuson
dealer/service center.
The engine/equipment must be presented to an authorized Wacker Neuson
dealer/service center as soon as a problem exists. Contact Wacker Neuson
Product Support Department (1-800-770-0957) or visit wackerneuson.com to
find a dealer/service center in your area, or to answer questions regarding
warranty rights and responsibilities.

How to make a claim

In the event that any emission-related part is found to be defective during the
warranty period, you shall notify Wacker Neuson Product Support Depart-
ment (1-800-770-0957, or [email protected], or wack-
erneuson.com), and you will be advised of the appropriate dealer/service
center where warranty repair can be performed. All repairs qualifying under
this limited warranty must be performed by an authorized Wacker Neuson
dealer/service center.
You must take your Wacker Neuson engine/equipment along with proof of
original purchase date, at your expense, to the authorized Wacker Neuson
dealer/service center during their normal business hours.

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 Emission Control System Information and Warranty
Limited Defect Warranty for Wacker Neuson Emission Control Systems 15.3

For owners located more than 100 miles from an authorized dealer/service
center (excluding the states with high-altitude areas as identified in 40 CFR
Part 1068, Appendix III), Wacker Neuson will pay for pre-approved shipping
costs to and from an authorized Wacker Neuson dealer/service center.
Claims for repair or adjustment found to be caused solely by defects in ma-
terial or workmanship will not be denied because the engine/equipment was
not properly maintained and used.
The warranty repairs should be completed in a reasonable amount of time,
not to exceed 30 days.

15

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Index

Index
A D
Abbreviations........................................................... 10 Deep Sea controller........................................... 21, 66
Accessories adjusting screen contrast.................................... 69
600V capability ................................................... 95 buttons and functions ......................................... 58
battery charger ................................................... 96 menu navigation ................................................. 67
camlocks ............................................................ 98 power switch....................................................... 51
containment system ........................................... 97 resetting the maintenance timer ......................... 70
engine block heater ............................................ 99
external fuel supply .......................................... 100 E
fuel filter heater................................................... 96
level load logic (L3) .......................................... 100 Electric brakes ......................................................... 43
lockable battery disconnect ................................ 95 Electrical
low coolant shutdown ......................................... 99 fuse boxes .......................................................... 21
quick oil change.................................................. 96 grounding................................................ 18, 21, 47
Alarms ............................................................... 58, 68 safety .................................................................. 15
Application area....................................................... 14 Emergency stop switch...................................... 22, 64
Emission control system
information........................................................ 144
B maintenance ..................................................... 114
Balancing loads Engine
480V ................................................................... 72 air cleaner—servicing ....................................... 110
600V ................................................................... 82 block heater ........................................................ 99
Battery changing the oil and filter.................................. 113
charger ............................................................... 96 checking the oil................................................. 107
lockable disconnect ............................................ 95 oil ...................................................................... 106
maintaining ....................................................... 111 oil change—quick option .................................... 96
Brakes oil pressure ................................................... 66, 69
testing electric breakaway system...................... 43 Exhaust
testing hydraulic breakaway system................... 42 checking the system ......................................... 108

C F
Camlocks................................................................. 98 Fuel
Connecting loads external supply ................................................. 100
480V ................................................................... 70 filter................................................................... 104
600V ................................................................... 80 filter heater.......................................................... 96
Containment system percentage remaining................................... 66, 69
checking and draining ...................................... 109 recommended..................................................... 48
Cooling system refueling.............................................................. 49
coolant.............................................................. 116 safety .................................................................. 16
low coolant shutdown ......................................... 99 stabilizing.......................................................... 123
radiator ..................................................... 104, 115 water separator................................................. 105
safety.................................................................. 16
temperature .................................................. 66, 69 G
Crankcase pressure switch ..................................... 52
Grounding................................................................ 47

H
Hazardous materials placard................................... 41

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 Index

I Misuse ..................................................................... 11
Installation as backup power ................................... 18
O
L Operation
main circuit breaker ...................................... 21, 51
Level load logic (L3) .............................................. 100
safety .................................................................. 13
Lifting ....................................................................... 38
trailer................................................................... 39
Safety ................................................................. 38
Operator
qualifications....................................................... 14
M training................................................................ 13
Machine
cleaning .............................................................. 15 P
controls and components ................................... 20
Personal protective equipment ................................ 14
decommissioning.............................................. 125
Preparation
description .......................................................... 20
hitch and coupler ................................................ 39
electrical grounding ............................................ 47
trailer................................................................... 39
identification ......................................................... 8
wheels ................................................................ 39
Inspecting ......................................................... 103
intended use....................................................... 11
labels ............................................................ 15, 23 R
lifting ................................................................... 38 Radiator
modifications ...................................................... 15 checking and cleaning ...................................... 104
nameplate............................................................. 8 filling ................................................................. 115
number ................................................................. 8 Receptacle............................................................... 22
positioning .......................................................... 47 Remote start ............................................................ 89
preparing for first use ......................................... 45 Rheostat .................................................................. 56
refueling.............................................................. 49 Risk
residual risks ...................................................... 12 residual risks....................................................... 12
running ............................................................... 61
serial number........................................................ 8
starting................................................................ 61
S
stopping.............................................................. 63 Safety ...................................................................... 18
storage ............................................................. 123 maintenance ....................................................... 14
unintended use................................................... 11 operational.......................................................... 13
Maintenance refueling.............................................................. 16
battery .............................................................. 111 reporting defects................................................. 18
checking and cleaning the radiator................... 104 signal words and symbols .................................. 13
checking and draining the containment system 109 trailer tires................................. 129, 136, 137, 143
checking the engine oil..................................... 107 Selecting the voltage ............................................... 55
checking the exhaust system ........................... 108 Spark arresters .......................................................... 9
cleaning the machine ....................................... 110 Specifications
coolant.............................................................. 116 coolant .............................................................. 116
emission control system ................................... 114 dimensions ....................................................... 128
filling the radiator .............................................. 115 engine............................................................... 126
fuel filter............................................................ 104 engine oil .......................................................... 106
preparing for ..................................................... 102 generator .......................................................... 127
safety.................................................................. 14 machine ............................................................ 127
servicing the air cleaner ................................... 110 trailer and skid .................................................. 127
timer reset .......................................................... 70
trailer ................................................................ 105 T
trailer coupler...................................................... 40 Tow vehicle
trailer tires......................................................... 137 load limits.......................................................... 131
water separator ................................................ 105

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Index

Towing ..................................................................... 40
checklist.............................................................. 39
Trailer
coupler maintenance .......................................... 40
installing the tongue ........................................... 45
licensing requirements ....................................... 40
load limits ......................................................... 130
maintenance..................................................... 105
operation ............................................................ 39
preparation ......................................................... 39
tire safety information ....................................... 129
trailer tires......................................................... 136
Transporting
Safety ................................................................. 38
Troubleshooting..................................................... 117
accessing diagnostic trouble codes.................. 117
controller diagnostic trouble codes................... 122
engine diagnostic trouble codes................. 69, 121
fault mode indicator chart ................................. 118

V
Voltage
adjustment rheostat...................................... 21, 56
battery .......................................................... 65, 69
generator ............................................................ 65
Selection............................................................. 55
selector switch.............................................. 21, 55

W
Wet stacking ............................................................ 94
Wheels .................................................................... 39

Operator’s Manual | G50 | 5100064538 | 02/2023 | [en-US]

150
 Index

[en-US] | 02/2023 | 5100064538 | G50 | Operator’s Manual

151
Wacker Neuson America
Corporation
N92W15000 Anthony Ave
Menomonee Falls, WI
USA-53051

Tel.: +01 262 255-0500

EMail:
[email protected]
www.wackerneuson.us
Material Number: 5100064538
Language: [en-US]