Wacker Neuson G50 User manual

5000189846 05 0911
5000189846
Operator’s Manual
Mobile Generator
G 50
EN

Copyright
notice
© Copyright 2011 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.

G 50 Foreword
wc_tx001048gb.fm 3
Foreword
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.
Machines covered in this manual
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.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
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.
CALIFORNIA
Proposition
65 Warning
Engine 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.
Machine Item Number
G 50 0620710, 0620964, 0620965, 0620966, 5200001317

Foreword G 50
4 wc_tx001048gb.fm
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:
Serious injury hazards to the operator and persons in the work area
Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.

wc_bo5000189846_05TOC.fm 5
Table of ContentsG 50
Foreword 3
1 Safety Information 9
1.1 Signal Words Used in this Manual ....................................................... 9
1.2 Machine Description and Intended Use ............................................. 10
1.3 Operating Safety ................................................................................ 12
1.4 Service Safety .................................................................................... 14
1.5 Operator Safety while using Internal Combustion Engines ................ 16
1.6 Towing Safety ..................................................................................... 17
1.7 Reporting Trailer Safety Defects ........................................................ 17
2 Labels 18
2.1 Label Locations .................................................................................. 18
2.2 Label Meanings .................................................................................. 20
3 Lifting and Transporting 29
3.1 Lifting the Machine ............................................................................. 29
3.2 Towing the Machine ........................................................................... 29
4 Operation 32
4.1 Safety Notices .................................................................................... 32
4.2 CO Alarms .......................................................................................... 32
4.3 Refueling the Machine ........................................................................ 33
4.4 Control Panel ...................................................................................... 34
4.5 Voltage Selector Switch ..................................................................... 36
4.6 Emergency Stop Switch ..................................................................... 37
4.7 Generator Monitoring ......................................................................... 38
4.8 Engine Monitoring .............................................................................. 39
4.9 Engine shutdown faults ...................................................................... 40
4.10 Current Overload Fault ....................................................................... 41
4.11 Event Log ........................................................................................... 41
4.12 Main Line Circuit Breaker ................................................................... 42

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Table of Contents G 50
4.13 Engine Start Switch .............................................................................43
4.14 Voltage Adjustment Rheostat ..............................................................43
4.15 Warning Light ......................................................................................43
4.16 Connection Lugs .................................................................................44
4.17 Grounding the Generator ....................................................................45
4.18 Convenience Receptacles ...................................................................46
4.19 Remote Run Terminal Block ...............................................................46
4.20 Panel Door Interlock Switch ................................................................46
4.21 Terminal Connections .........................................................................47
4.22 Before Starting ....................................................................................48
4.23 Manual Start-Up ..................................................................................48
4.24 Running the Generator ........................................................................51
4.25 Engine Power Correction Factors .......................................................52
4.26 Shutting down the generator ...............................................................52
4.27 Cold Weather Start-Up ........................................................................52
4.28 Automatic/Remote Start-Up ................................................................53
4.29 Remote/Transfer Switch ......................................................................54
5 Using the LCD Panel and Keypad 55
5.1 Navigating the Menus ..........................................................................56
5.2 Entering Passwords ............................................................................58
5.3 Adjusting Screen Contrast ...................................................................59
5.4 Setting the Time or Date .....................................................................60
5.5 Changing User Preferences ................................................................61
5.6 Changing / Disabling Low Fuel Fault ...................................................62
5.7 Changing Cooldown Time ...................................................................63
6 Factory-Installed Options 64
6.1 Engine Block Heater Option ................................................................64
6.2 Electronic Governor .............................................................................65
6.3 Automatic LCD Heat ............................................................................66
6.4 Low Coolant Shutdown .......................................................................67
6.5 Lube Level Maintainer .........................................................................68
6.6 Temperature-Activated Shutters .........................................................69
6.7 Lockable Battery Disconnect ...............................................................69
6.8 Extended Run Tank .............................................................................70
6.9 Battery Charger ...................................................................................70

wc_bo5000189846_05TOC.fm 7
Table of ContentsG 50
6.10 Camlocks ............................................................................................ 71
6.11 Containment System .......................................................................... 72
6.12 Wiring Diagram (Factory-Installed Options) ....................................... 73
6.13 Wiring Diagram Components (Factory-Installed Options) .................. 74
7 Maintenance 75
7.1 Periodic Maintenance Schedule ......................................................... 75
7.2 New Machines .................................................................................... 76
7.3 Resetting the Periodic Maintenance Timer ........................................ 76
7.4 Electronic Control Unit (ECU) ............................................................. 77
7.5 Servicing the Air Cleaner .................................................................... 78
7.6 Engine Oil ........................................................................................... 79
7.7 Checking Engine Coolant ................................................................... 80
7.8 Troubleshooting Automatic Shutdown ................................................ 81
7.9 Maintaining the Trailer ........................................................................ 83
8 Technical Data 84
8.1 Engine ................................................................................................ 84
8.2 Generator ........................................................................................... 85
8.3 Machine ............................................................................................. 85
8.4 Trailer and Skid .................................................................................. 86
8.5 Dimensions ......................................................................................... 88
9 Schematics 89
9.1 Generator and Receptacle Wiring ...................................................... 90
9.2 Generator and Receptacle Wiring Components ................................. 91
9.3 Engine Wiring ..................................................................................... 92
9.4 Engine Wiring Components ................................................................ 93
9.5 Trailer Wiring ...................................................................................... 94
9.6 Trailer Wiring Components ................................................................. 95

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Table of Contents G 50

G 50 Safety Information
wc_si000533gb.fm 9
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 situa-
tion 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.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo 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.
fTo avoid possible death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fTo avoid possible minor or moderate injury from this type of hazard, obey all safety
messages that follow this signal word.

Safety Information G 50
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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 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

G 50 Safety Information
wc_si000533gb.fm 11
• 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.
Electrocution hazard!
Electrocution or severe electrical shock hazards are present
throughout the generator any time the engine is running! Read all
safety notes contained in this section before operating or servicing this
equipment.
No one except a trained electrician, familiar with this equipment,
should attempt repairs to the generator! Test procedures which require
that the generator be running must be performed using extreme
caution.
This machine is built with user safety in mind; however, like any
electrical device it can present serious hazards if improperly operated
and serviced. Follow instructions carefully! Should questions arise
during operation or service of this equipment, contact Wacker Neuson
Corporation.
WARNIN
G

Safety Information G 50
12 wc_si000533gb.fm
1.3 Operating Safety
Familiarity and proper training are required for the safe operation of
the machine. Machines operated improperly or by untrained
personnel can be dangerous. Read the operating instructions
contained in both this manual and the engine manual and familiarize
yourself with the location and proper use of all controls. Inexperienced
operators should receive instruction from someone familiar with the
machine before being allowed to operate 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
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
1.3.1 Do not operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
1.3.2 Do not place flammable material or liquids near the generator.
1.3.3 Do not operate the generator, or tools attached to the generator, with
wet hands.
1.3.4 Do not use worn electrical cords. Severe electrical shock and
equipment damage may result.
1.3.5 Do not operate the machine indoors unless exhaust fumes can be
adequately ventilated.
1.3.6 Do not overload the generator. The total amperage of the tools and
equipment attached to the generator must not exceed the load rating
of the generator.
1.3.7 Do not allow untrained personnel to operate or service the generator.
The generator set should be set up by a certified electrician.
1.3.8 Do not operate generator in standing water.
1.3.9 Do not touch the hot engine, exhaust, or generator components.
Burns will result.
WARNING

G 50 Safety Information
wc_si000533gb.fm 13
1.3.10 Do not start a machine in need of repair.
1.3.11 Use the emergency stop button only in an actual emergency. Do not
restart the engine until the cause of the trouble has been determined
and fixed.
1.3.12 Wear hearing protection when operating equipment.
1.3.13 Follow starting and stopping instructions described in this manual.
Know how to operate and stop generator before starting it.
1.3.14 Make a walk-around inspection of the generator set before starting it.
Open side doors and visually inspect engine compartment for obvious
damage or the presence of foreign objects which might affect
operation.
1.3.15 Keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
1.3.16 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.
1.3.17 Keep the area immediately surrounding and underneath the machine
clean, neat, and free of debris and combustible materials. Make sure
that the area overhead is clear of debris that could fall onto or into the
machine or exhaust compartment.
1.3.18 Make sure the machine is on a firm, level surface and will not tip, roll,
slide, or fall while operating.
1.3.19 Remove all tools, cords, and other loose items from the generator
before starting it.
1.3.20 Make sure the machine is well-grounded and securely fastened to a
good earthen ground per national and local regulations.
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER
DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR
DEATH TO UTILITY WORKERS!
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.
Connections to a building’s electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical
codes.
If connected to a building’s electrical system, the generator must meet
the power, voltage, and frequency requirements of the equipment in
the building. Differences in power, voltage, and frequency
requirements may exist and improper connection may lead to
equipment damage, fire, and personal injury or death.
WARNING

Safety Information G 50
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1.4 Service Safety
A poorly maintained machine can become a safety hazard! In order
for the machine to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
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).
1.4.1 Do not perform even routine service (oil/filter changes, cleaning,
etc.) unless all electrical components are shut down. Before
servicing this machine, make sure the engine start switch is turned to
off “O”, the circuit breakers are open (off), the emergency stop switch
is closed (pushed in), and the negative terminal on battery is
disconnected. Attach a “DO NOT START” sign to the control panel.
This will notify everyone that the unit is being serviced and will reduce
the chance of someone inadvertently trying to start the unit. If the unit
is connected to a remote start or transfer switch, make sure the
remote switch is also off and tagged.
1.4.2 Ground Connection
The generator must be connected to a good earthen ground for
proper operating safety!
A central “equipment ground” is provided at the customer connection
lugs. This point is connected directly to the generator set base. All
other system grounds are connected to this central point. Ground the
generator in accordance with the standards defined in national, state,
and local regulations.
1.4.3 Do not attempt to open the radiator cap while the unit is running or
before the engine has cooled down. Severe burns may result!
1.4.4 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.
1.4.5 Do not service the machine if your clothing or skin is wet.
WARNING

G 50 Safety Information
wc_si000533gb.fm 15
1.4.6 Do not allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the
electrical components of this equipment.
1.4.7 Do not modify the machine without the express written approval of the
manufacturer.
1.4.8 Do not pressure wash the control panel, generator end, or any other
electrical components when cleaning the unit. Never allow water to
accumulate around the base of the generator set. If water is present,
DO NOT service!
1.4.9 Allow the engine to cool before performing any service work on the
machine.
1.4.10 Remain aware of moving parts and keep hands, feet, and loose
clothing away from the moving parts of the generator and engine.
1.4.11 Replace all guards, fasten doors, and make sure all safety devices
operate properly after making repairs or servicing the equipment.
1.4.12 Keep the machine clean and labels legible. Replace all missing and
hard-to-read labels. Labels provide important operating instructions
and warn of dangers and hazards.
1.4.13 Check all external fasteners at regular intervals.
1.4.14 Make sure slings, chains, hooks, ramps, jacks, and other types of
lifting devices are attached securely and have enough weight-bearing
capacity to lift or hold the machine safely. Always remain aware of the
location of other people in the area when lifting the machine.

Safety Information G 50
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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.
• Replace the fuel tank cap after refueling.
• 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.
fRead 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. Expo-
sure to carbon monoxide can kill you in minutes.
fNEVER operate the machine inside an enclosed area, such as a tunnel, unless
adequate ventilation is provided through such items as exhaust fans or hoses.

G 50 Safety Information
wc_si000533gb.fm 17
1.6 Towing Safety
Towing a large trailer requires special care. Both the trailer and vehicle
must be in good condition and securely fastened to each other to
reduce the possibility of an accident.
1.6.1 Verify that the hitch and coupling on the vehicle are rated equal to, or
greater than, the trailer's “gross vehicle weight rating” (GVWR).
1.6.2 Inspect the hitch and coupling for wear or damage. DO NOT tow the
trailer using defective parts.
1.6.3 Make sure the coupling is securely fastened to the vehicle.
1.6.4 Check the tires on the trailer for tread wear, inflation, and condition.
Replace worn tires.
1.6.5 Connect the safety chains.
1.6.6 Connect the breakaway cable safety hook to the bumper or rear of the
vehicle. DO NOT attach it to the hitch.
1.6.7 Test the surge brakes on the trailer and the brakes on the vehicle that
will be used for towing.
1.6.8 Make sure directional and trailer lights are connected and working
properly.
1.6.9 Check that the lug nuts holding the wheels are tight and that none are
missing.
1.7 Reporting Trailer Safety Defects
If you believe your trailer has a defect which could cause a crash or
could cause injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to
notifying Wacker Neuson Corporation.
If NHTSA receives similar complaints, it may open an investigation;
and if it finds that a safety defect exists in a group of vehicles, it may
order a recall and remedy campaign. However, NHTSA cannot
become involved in individual problems between you, your dealer, or
Wacker Neuson Corporation.
To contact NHTSA, you may either contact the Auto Safety Hotline toll-
free at 1-800-424-9393 (or 366-0129 in Washington DC area),
www.nhtsa.com, or write to NHTSA, U.S. Department of
Transportation, 400 7th Street SW, (NSA-11), Washington, DC 20590.
You can also obtain other information about motor vehicle safety from
the Auto Safety Hotline.
WARNING

Labels G 50
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2Labels
2.1 Label Locations
wc_gr007670
AVERTISSEMENT
AVERTISSEMENT
ADVERTENCIA
ADVERTENCIA
WARNING
WARNING
WARNUNG
WARNUNG
114885
114885
AVERTISSEMENT
AVERTISSEMENT
WARNING
WARNING
WARNUNG
WARNUNG
ADVERTENCIA
ADVERTENCIA
P
A
GG
KK
HH
L
CC
UBG
T
AA
JJ
XJ
K
DD
M1
M2
QQ
OO
FF
QH
G
NN
Z
LL MM
EE

G 50 Labels
wc_si000520gb.fm 19
U
JJ
wc_gr007671
V
V
WW
OY
V
P
RC
FS
G
V
D
B
PP
E
UU
RR
SS
TT

Labels G 50
20 wc_si000520gb.fm
2.2 Label Meanings
AWARNING!
Pressurized contents. Do not open when hot!
BWARNING!
Lock doors. Access can cause electric shock or
injury.
CNOTICE
Never change switch position with engine run-
ning. Results in damage to machine.
DWARNING!
Electric shock can cause serious injury or death.
EDANGER!
Asphyxiation hazard.
Engines emit carbon monoxide.
Do not run the machine indoors or in an
enclosed area.
Only use OUTSIDE and far away from win-
dows, doors, and vents.
Read the Operator’s Manual.
No sparks, flames, or burning objects near the
machine.
Stop the engine before refueling.
Use only clean, filtered diesel fuel.