Wacker Neuson G 240 User manual

5000186930 09 0215
5000186930
Operator’s Manual
Mobile Generator
G 230
G 240
EN

Copyright notice © Copyright 2015 by Wacker Neuson Production Americas LLC
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the
machine. Any other type of reproduction is prohibited without express
written permission from Wacker Neuson Production Americas LLC.
Any type of reproduction or distribution not authorized by Wacker
Neuson Production Americas LLC represents an infringement of valid
copyrights. Violators will be prosecuted.
Trademarks All trademarks referenced in this manual are the property of their
respective owners.
Manufacturer Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: [phone] · Fax: [phone] · Tel: [phone]
www.wackerneuson.com
Original instructions This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.

wc_tx003616gb_FM10.fm 3
Machine Identification
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models below. These instructions have been written expressly by
Wacker Neuson Production Americas LLC and must be followed during installation,
operation, and maintenance of the machines.
Machine
identification
A nameplate listing the model number, item number, revision number, and serial
number is attached to this machine. The location of the nameplate is shown above.
Serial number
(S/N)
For future reference, record the serial number in the space provided below. You will
need the serial number when requesting parts or service for this machine.
Machine Item Number Machine Item Number
G 230 5200010141
5200010142
5200010143
5000620881
5000620882
5000620883
5200007862
5100015614
G 240 5000620661
5000620662
5000620663
5200001323
5200003162
5200006904
5200025556
wc_gr010208
Serial Number:

Foreword
4 wc_tx003565gb_FM10.fm
Foreword
Machine
documentation
From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
If you are missing any of these documents, please contact Wacker Neuson to
order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change
any portion of this information without notice.
The illustrations, parts, and procedures in this manual refer to Wacker Neuson
factory-installed components. Your machine may vary depending on the
requirements of your specific region.
CALIFORNIA
Proposition
65 Warning
Combustion exhaust, some of its constituents, and certain vehicle components
contain or emit chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
Laws
pertaining to
spark
arresters
NOTICE: State Health Safety Codes and Public Resources Codes specify that in
certain locations spark arresters be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed to prevent accidental
discharge of sparks or flames from the engine exhaust. Spark arresters are
qualified and rated by the United States Forest Service for this purpose. In order to
comply with local laws regarding spark arresters, consult the engine distributor or
the local Health and Safety Administrator.

Foreword
wc_tx003565gb_FM10.fm 5
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
Approved parts or attachments are those either manufacturedor provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:
Serious injury hazards to the operator and persons in the work area
Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.

Foreword
6 wc_tx003565gb_FM10.fm
Notes

Table of Contents
G 230 / G 240
wc_bo5000186930_09_FM10TOC.fm 7
Foreword 4
1 Safety Information 13
1.1 Signal Words Used in this Manual ..................................................... 13
1.2 Machine Description and Intended Use ............................................. 14
1.3 Safety Guidelines for Operating the Machine ..................................... 15
1.4 Service Safety .................................................................................... 17
1.5 Operator Safety while Using Internal Combustion Engines ............... 19
1.6 Safety Guidelines for Mobile Generators ........................................... 20
1.7 Safety Guidelines for Towing the Machine ......................................... 22
1.8 Safety Guidelines for Lifting the Machine ........................................... 23
1.9 Reporting Safety Defects ................................................................... 23
2 Label Locations 24
3 Label Meanings 26
4 Lifting and Transporting 36
4.1 Lifting the Machine ............................................................................. 36
4.2 Before Towing Checklist ..................................................................... 37
4.3 Towing the Machine ........................................................................... 38
4.4 Preparing the Machine for Transport on a Truck or Trailer ................ 39
4.5 Hazardous Materials Placards ........................................................... 40
4.6 Testing the Breakaway System (Hydraulic Surge Brakes) ................. 41
4.7 Testing the Breakaway System (Electric Brakes) .............................. 43
5 Machine Setup 45
5.1 Preparing the Machine for First Use ................................................... 45
5.2 Positioning the Machine ..................................................................... 46
5.3 Grounding the Generator ................................................................... 48
5.4 Recommended Fuel ........................................................................... 49
5.5 Refueling the Machine (Basler Controller) ......................................... 50
5.6 Refueling the Machine (Deep Sea Controller) .................................... 51
6 Operation, Control, and Component Locations 52
6.1 Control / Component Locations .......................................................... 52

Table of Contents G 230 / G 240
wc_bo5000186930_09_FM10TOC.fm
8
7 Operation (Basler Controller) 54
7.1 Main Circuit Breaker ...........................................................................54
7.2 Engine Start Switch ............................................................................55
7.3 Genset Pre-Alarms and Alarms (Shut-Down Conditions) ...................56
7.4 Overcurrent Condition .........................................................................57
7.5 Idle Switch ..........................................................................................57
7.6 Diesel Particulate Filter (DPF) ............................................................58
7.7 Using the Lugs and the Convenience Receptacles ............................59
7.8 Selecting the Voltage ..........................................................................60
7.9 Before Starting the Machine ...............................................................63
7.10 Starting and Running the Generator ...................................................64
7.11 Stopping the Machine .........................................................................66
7.12 Emergency Stop Switch ......................................................................66
7.13 LCD Panel: Monitoring Machine Operation ........................................67
8 Working with Basler Controller 69
8.1 How to Use the Genset Controller LCD and Keypad ..........................69
8.2 Menu Diagram of the Genset Controller .............................................70
8.3 Menu Diagram Components ...............................................................71
8.4 Using the Metering and Settings Menus .............................................72
8.5 Logging in to the Genset Controller by Entering the Password ..........73
8.6 Adjusting the LCD Screen Contrast ....................................................76
8.7 Changing the Time/Date Settings .......................................................77
8.8 Changing the Sender Fail Time Delays ..............................................78
8.9 Changing the Units of Measure ..........................................................80
8.10 Changing the Low Fuel Pre-Alarm Setting .........................................82
8.11 Changing or Disabling the Low Fuel Alarm Setting ............................84
8.12 Changing the Cooldown Time Setting ................................................86
8.13 Changing the Pre-Crank Time Delay (Glow Plug Timer) ....................88
8.14 Changing the Maintenance Interval ....................................................90
8.15 Resetting the Maintenance Interval Pre-Alarm ...................................92
8.16 Resetting a Loss of Voltage Pre-Alarm ...............................................94
8.17 Accessing and Using the Event Log ...................................................95
9 Operation (Deep Sea Controller) 97
9.1 Main Circuit Breaker ...........................................................................97
9.2 Genset Controller Power Switch .........................................................98
9.3 Selecting the Voltage ..........................................................................99

Table of Contents
G 230 / G 240
wc_bo5000186930_09_FM10TOC.fm 9
9.4 Deep Sea Controller Buttons/Functions ........................................... 102
9.5 Genset Controller Alarms and Shut-Down Conditions ..................... 104
9.6 Before Starting the Machine ............................................................. 106
9.7 Starting and Running the Generator ................................................ 107
9.8 Stopping the Generator .................................................................... 109
9.9 Emergency Stop Switch ................................................................... 110
9.10 Engine and Generator Monitoring .................................................... 111
10 Working with Deep Sea Controller: DSE 7310 112
10.1 Introduction ....................................................................................... 112
10.2 Navigating the Menus ....................................................................... 113
10.3 Adjusting Screen Contrast ................................................................ 115
10.4 How to Reset the Maintenance Timer .............................................. 116
11 How to Connect Loads 117
11.1 Lug Terminal Connection Diagrams ................................................. 117
11.2 Best Practices for Balancing Loads .................................................. 118
11.3 Connecting 480V, 3-Phase and Single-Phase Loads ...................... 120
11.4 Connecting a 240V 3Ø Load and a 240V 1Ø Load .......................... 121
11.5 Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads 122
11.6 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads .............. 123
12 Using Remote Start Capabilities 124
12.1 Remote Run Terminal Block ............................................................ 124
12.2 Remote Transfer Switch ................................................................... 125
12.3 Preparing for Automatic/Remote Start-Up (Basler) .......................... 126
12.4 Preparing for Automatic/Remote Start-Up (Deep Sea) .................... 127
13 Diagnostic Trouble Codes (DTC) 129
13.1 Accessing DTCs with the Basler Controller ...................................... 129
13.2 Accessing Engine DTCs using the Deep Sea Controller ................. 130
13.3 List of Engine Diagnostic Trouble Codes (DTCs) ............................. 131
14 Factory-Installed Options 145
14.1 Battery Charger ................................................................................ 145
14.2 Lockable Battery Disconnect ............................................................ 146
14.3 Camlocks .......................................................................................... 147

Table of Contents G 230 / G 240
wc_bo5000186930_09_FM10TOC.fm
10
14.4 Containment System ........................................................................148
14.5 Extended Run Tank (ERT) ...............................................................148
14.6 Engine Block Heater .........................................................................149
14.7 Automatic LCD Heat .........................................................................149
14.8 Low Coolant Shutdown .....................................................................150
14.9 Temperature-Activated Shutters .......................................................151
14.10 Positive Air Shutoff Valve .................................................................152
14.11 Quick-Disconnect Fuel Fittings .........................................................153
14.12 Lube Level Maintainer ......................................................................154
15 Machines with Aftertreatment Exhaust System 155
15.1 How the Aftertreatment Exhaust System Works ...............................155
15.2 Filling the DEF Tank .........................................................................156
15.3 Shelf Life of Diesel Exhaust Fluid (DEF) ..........................................158
15.4 Monitoring and Control of the DEF Level ..........................................159
15.5 Monitoring DEF Quality .....................................................................160
15.6 Conditioning the Aftertreatment Exhaust System (if equipped) ........161
16 General Maintenance 162
16.1 Periodic Maintenance Schedule .......................................................162
16.2 Maintaining the Emission Control System ........................................163
16.3 Preparing for Maintenance ...............................................................163
16.4 Cleaning the Machine .......................................................................163
16.5 Inspecting the Machine .....................................................................164
16.6 Maintaining the Trailer ......................................................................165
16.7 Checking and Draining the Containment System .............................166
16.8 Checking the Exhaust System ..........................................................167
16.9 Maintaining the Battery .....................................................................168
16.10 Cleaning the Diesel Particulate Filter (DPF) (if equipped) ................169
16.11 Filling the Radiator ............................................................................170
16.12 Replacing the Aftertreatment DEF Dosing Unit Filter .......................172
16.13 Storage .............................................................................................174
16.14 Machine Disposal / Decommissioning ..............................................175

Table of Contents
G 230 / G 240
wc_bo5000186930_09_FM10TOC.fm 11
17 Engine Maintenance:
John Deere 4045TF285/HF285 6068HF285 176
18 Engine Maintenance: T4i Cummins QSB6.7 181
19 Engine Maintenance: T4F Cummins QSB7-G9 185
20 Troubleshooting 189
21 Technical Data — G 240 190
21.1 Engine .............................................................................................. 190
21.2 Generator ......................................................................................... 191
21.3 Trailer and Skid ................................................................................ 191
21.4 Dimensions ....................................................................................... 192
22 Technical Data — G 230 193
22.1 Engine: G 230 T4f ............................................................................ 193
22.2 Engine: G 230 T4i ............................................................................ 194
22.3 Generator ......................................................................................... 195
22.4 Trailer and Skid ................................................................................ 196
22.5 Dimensions ....................................................................................... 197
Tire Safety Information 198
23 User’s Information for Transport Canada Fuel Tank 210
24 Emission Control Systems Information and Warranty—Diesel 213
24.1 Emission Control System Background Information .......................... 213
24.2 Limited Defect Warranty for Exhaust Emission Control System ....... 214
24.3 Limited Defect Warranty for Wacker Neuson Emission Control
Systems ............................................................................................ 214
25 General Machine Schematics 217
25.1 Fuses .............................................................................................. 217
25.2 Trailer Wiring .................................................................................... 218
25.3 Trailer Wiring Components ............................................................... 219

Table of Contents G 230 / G 240
wc_bo5000186930_09_FM10TOC.fm
12
26 Schematics, Machines with Basler Controller 220
26.1 AC Schematic: G 230/G 240 .............................................................220
26.2 AC Schematic Components: G 230/G 240 ........................................221
26.3 DC Schematic: G 240 John Deere Tier 3 ..........................................222
26.4 DC Schematic Components: G 240 Tier 3 ........................................223
26.5 DC Schematic: G230 Cummins T4i ..................................................224
26.6 DC Schematic Components: G 230 T4i ............................................225
26.7 DC Schematic: G230 Cummins T4f ..................................................226
26.8 DC Schematic Components: G 230 Cummins T4f ............................227
26.9 DC Electrical Schematic Section A: G 230 Cummins T4f .................228
26.10 Electrical Schematic Components .....................................................229
26.11 DC Electrical Schematic Section B: G 230 Cummins T4f .................230
26.12 Electrical Schematic Components .....................................................231
26.13 DC Electrical Schematic Section C: G 230 Cummins T4f .................232
26.14 Electrical Schematic Components .....................................................233
26.15 Cummins Engine Relays and Fuses .................................................234
26.16 Cummins Engine Relays and Fuses .................................................235
27 Schematics, Machines with Deep Sea Controller 236
27.1 AC Schematic: G 230 / G 240 ...........................................................236
27.2 Electrical Schematic Components: G 230 / G 240 ............................237
27.3 DC Schematic: G 240 John Deere Tier 3 ..........................................238
27.4 DC Schematic Components: G 240 John Deere Tier 3 ....................239
27.5 DC Schematic: G 230 Cummins T4i .................................................240
27.6 DC Schematic Components: G 230 Cummins T4i ............................241
27.7 DC Schematic: G 230 Cummins T4f .................................................242
27.8 DC Schematic Components: G 230 Cummins T4f ............................243
27.9 DC Electrical Schematic Section A: G 230 Cummins T4f .................244
27.10 Electrical Schematic Components .....................................................245
27.11 DC Electrical Schematic Section B: G 230 Cummins T4f .................246
27.12 Electrical Schematic Components .....................................................247
27.13 DC Electrical Schematic Section C: G 230 Cummins T4f .................248
27.14 Electrical Schematic Components .....................................................249
27.15 Cummins Engine Relays and Fuses .................................................250
27.16 Cummins Engine Relays and Fuses .................................................251

wc_tx003567gb_FM10.fm 13
Mobile Generator Safety Information
1 Safety Information
1.1 Signal Words Used in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE
signal words which must be followed to reduce the possibility of personal injury,
damage to the equipment, or improper service.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
►Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
►To avoid death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
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.

wc_tx003567gb_FM10.fm
14
Mobile Generator
Safety Information
1.2 Machine Description and Intended Use
This machine is a mobile electric power source. The Wacker Neuson Mobile
Generator consists of a trailer-mounted cabinet containing an electric alternator, a
fuel tank, and a diesel engine. A control panel, receptacles, and connection lugs
are provided on the side of the cabinet. As the engine runs, the generator converts
mechanical energy into electric power. The operator connects loads to the electric
power receptacles and connection lugs.
This machine is intended for the purpose of supplying electrical power to
connected loads. Refer to the product specifications for the output voltage and
frequency of this generator, and for the maximum output power limit of this
generator.
This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons in the area. Machine
damage caused by misuse is not covered under warranty.
The following are some examples of misuse:
■Connecting a load that has voltage and frequency requirements that are
incompatible with the generator output
■Overloading the generator with a load that draws excessive power during either
continuous running or start-up
■Operating the generator in a manner that is inconsistent with all federal, state
and local codes and regulations
■Using the machine as a ladder, support, or work surface
■Using the machine to carry or transport passengers or equipment
■Using the machine to tow other machines
■Operating the machine outside of factory specifications
■Operating the machine in a manner inconsistent with all warnings found on the
machine and in the Operator’s Manual
This machine has been designed and built in accordance with the latest global
safety standards. It has been carefully engineered to eliminate hazards as far as
practicable and to increase operator safety through protective guards and labeling.
However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:
■Heat, noise, exhaust, and carbon monoxide from the engine
■Fire hazards from improper refueling techniques
■Fuel and its fumes
■Electric shock and arc flash
■Personal injury from improper lifting the trailer tongue
■Typical hazards related to towing a trailer on roads and highways
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.

wc_tx003567gb_FM10.fm 15
Mobile Generator Safety Information
1.3 Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
■Read and understand the operating instructions contained in all manuals
delivered with the machine.
■Familiarize yourself with the location and proper use of all controls and safety
devices.
■Contact Wacker Neuson for additional training if necessary.
When operating this machine:
■Do not allow improperly trained people to operate the machine. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Operator
qualifications
Only trained personnel are permitted to start, operate, and shut down the machine.
They also must meet the following qualifications:
■have received instruction on how to properly use the machine
■are familiar with required safety devices
The machine must not be accessed or operated by:
■children
■people impaired by alcohol or drugs
Application
area
Be aware of the application area.
■Keep unauthorized personnel, children, and pets away from the machine.
■Remain aware of changing positions and the movement of other equipment and
personnel in the application area/job site.
■Identify whether special hazards exist in the application area, such as toxic
gases, or unstable ground conditions, and take appropriate action to eliminate
the special hazards before using the machine.
Be aware of the application area.
■Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
Safety
devices,
controls, and
attachments
Only operate the machine when:
■All safety devices and guards are in place and in working order.
■All controls operate correctly.
■The machine is set up correctly according to the instructions in the Operator’s
Manual.
■The machine is clean.
■The machine’s labels are legible.
To ensure safe operation of the machine:
■Do not operate the machine if any safety devices or guards are missing or
inoperative.
■Do not modify or defeat the safety devices.
■Only use accessories or attachments that are approved by Wacker Neuson.

wc_tx003567gb_FM10.fm
16
Mobile Generator
Safety Information
Safe
operating
practices
When operating this machine:
■Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
When operating this machine:
■Do not operate a machine in need of repair.
■Do not consume the operating fluids used in this machine. Depending on your
machine model, these operating fluids may include water, wetting agents, fuel
(gasoline, diesel, kerosene, propane, or natural gas), oil, coolant, hydraulic fluid,
heat transfer fluid (propylene glycol with additives), battery acid, or grease.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
■Close-fitting work clothes that do not hinder movement
■Safety glasses with side shields
■Hearing protection
■Safety-toed footwear
After use ■Stop the engine when the machine is not being operated.
■Close the fuel valve on engines equipped with one when the machine is not
being operated.
■Ensure that the machine will not tip over, roll, slide, or fall when not being
operated.
■Store the machine properly when it is not being used. The machine should be
stored in a clean, dry location out of the reach of children.

wc_tx003567gb_FM10.fm 17
Mobile Generator Safety Information
1.4 Service Safety
Service
training
Before servicing or maintaining the machine:
■Read and understand the instructions contained in all manuals delivered with
the machine.
■Familiarize yourself with the location and proper use of all controls and safety
devices.
■Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
■Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
■Do not allow improperly trained people to service or maintain the machine.
Personnel servicing or maintaining the machine must be familiar with the
associated potential risks and hazards.
Precautions Follow the precautions below when servicing or maintaining the machine.
■Read and understand the service procedures before performing any service to
the machine.
■All adjustments and repairs must be completed before operating the machine.
Do not operate the machine with a known problem or deficiency.
■All repairs and adjustments shall be completed by a qualified technician.
■Turn off the machine before performing maintenance or making repairs.
■Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
■Re-install the safety devices and guards after repair and maintenance
procedures are complete.
Machine
modifications
When servicing or maintaining the machine:
■Use only accessories/attachments that are approved by Wacker Neuson.
When servicing or maintaining the machine:
■Do not defeat safety devices.
■Do not modify the machine without the express written approval of Wacker
Neuson.
Replacing
parts and
labels
■Replace worn or damaged components.
■Replace all missing and hard-to-read labels.
■When replacing electrical components, use components that are identical in
rating and performance to the original components.
■When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.
Cleaning When cleaning and servicing the machine:
■Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
■Keep the labels legible.

wc_tx003567gb_FM10.fm
18
Mobile Generator
Safety Information
When cleaning the machine:
■Do not clean the machine while it is running.
■Never use gasoline or other types of fuels or flammable solvents to clean the
machine. Fumes from fuels and solvents can become explosive.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:
■Close-fitting work clothes that do not hinder movement
■Safety glasses with side shields
■Hearing protection
■Safety-toed footwear
In addition, before servicing or maintaining the machine:
■Tie back long hair.
■Remove all jewelry (including rings).
Electrical
service safety
■Make sure clothing and shoes are dry, stand on a dry wooden platform or rubber
insulating mat, and use tools with insulated handles when servicing the
machine.
■Do not allow water to accumulate around the base of the machine. If water is
present, move the machine and allow the machine to dry before servicing.
■Do not pressure wash the control panel, generator end, or any other electrical
components when cleaning the machine.
Cooling
system safety
■Do not attempt to open the radiator cap while the unit is running or before the
engine has cooled down. Severe burns may result!
■Engine coolant is toxic to humans and animals. Clean up spills and dispose of
waste engine coolant in accordance with local environmental regulations.

wc_tx003567gb_FM10.fm 19
Mobile Generator Safety Information
1.5 Operator Safety while Using Internal Combustion Engines
Operating
safety
When running the engine:
■Keep the area around exhaust pipe free of flammable materials.
■Check the fuel lines and the fuel tank for leaks and cracks before starting the
engine. Do not run the machine if fuel leaks are present or the fuel lines are
loose.
When running the engine:
■Do not smoke while operating the machine.
■Do not run the engine near sparks or open flames.
■Do not touch the engine or muffler while the engine is running or immediately
after it has been turned off.
■Do not operate a machine when its fuel cap is loose or missing.
■Do not start the engine if fuel has spilled or a fuel odor is present. Move the
machine away from the spill and wipe the machine dry before starting.
Refueling
safety
When refueling the engine:
■Clean up any spilled fuel immediately.
■Refill the fuel tank in a well-ventilated area.
■Re-install the fuel tank cap after refueling.
■Use suitable tools for refueling (for example, a fuel hose or funnel).
When refueling the engine:
■Do not smoke.
■Do not refuel a hot or running engine.
■Do not refuel the engine near sparks or open flames.
WARNING
Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety standards could result in severe injury or
death.
►Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
Exhaust gas from the engine contains carbon monoxide, a deadly poison.
Exposure to carbon monoxide can kill you in minutes.
►NEVER operate the machine inside an enclosed area, such as a tunnel, unless
adequate ventilation is provided through such items as exhaust fans or hoses.

wc_tx003567gb_FM10.fm
20
Mobile Generator
Safety Information
1.6 Safety Guidelines for Mobile Generators
Installing as
backup power
Special hazards exist when installing this machine as a backup power supply.
Improper connection of generator to a building’s electrical system can allow
electrical current from the generator to backfeed into utility lines. This may result in
electrocution of utility workers, fire, or explosion.
If connected to a building’s electrical system, the generator must meet the power,
voltage, and frequency requirements of the equipment in the building. Differences
in power, voltage, and frequency requirements may exist and improper connection
may lead to equipment damage, fire, and personal injury or death.
DANGER
Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot
see or smell. If you can smell the generator exhaust, you are breathing CO. But
even if you cannot smell the exhaust, you could be breathing CO.
►NEVER use a generator inside homes, garages, crawlspaces, or other partly
enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Using a fan or opening windows and doors does NOT supply enough fresh air.
►ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
►Even when you use a generator correctly, CO may leak into the home. ALWAYS
use a battery-powered or battery-backup CO alarm in the home.
►If you start to feel sick, dizzy, or weak after the generator has been running,
move to fresh air RIGHT AWAY. See a doctor. You could have carbon monoxide
poison.
WARNING
Electrocution hazard. Machines that generate electric power present special
hazards while the engine is running. These include the risk of electrocution or
severe electrical shock.
►Read and follow the instructions in this Operator’s Manual.
WARNING
Backfeed from the generator into the public power distribution system can cause
serious injury or death to utility workers!
►Connections to a building’s electrical system must be made by a qualified elec-
trician and comply with all applicable laws and electrical codes.