Wacker Neuson G240 User manual

Category
Power generators
Type
User manual

This manual is also suitable for

5000186930 02 0511
5000186930
Operator’s Manual
Mobile Generator
G 240
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: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original instructions
This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.
G 240 Foreword
wc_tx001691gb.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.
Manufacturers
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
Machine Item Number
G 240 0620661, 0620662, 0620663, 0620881
Foreword G 240
4 wc_tx001691gb.fm
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_bo5000186930en_01TOC.fm 5
Table of ContentsG 240
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 Safety Guidelines for Operating the Machine ..................................... 12
1.4 Operator Safety while Using Internal Combustion Engines ............... 14
1.5 Towing Safety ..................................................................................... 15
1.6 Service Safety .................................................................................... 16
2 Labels 18
2.1 Label Locations .................................................................................. 18
2.2 Label Meanings .................................................................................. 20
3 Lifting and Transporting 28
3.1 Lifting the Machine ............................................................................. 28
3.2 Towing the Machine ........................................................................... 28
4 Operation 30
4.1 Control Panel ...................................................................................... 31
4.2 Control panel with open access doors ............................................... 32
4.3 Main Line Circuit Breaker ................................................................... 33
4.4 Engine Start Switch ............................................................................ 34
4.5 Warning Light ..................................................................................... 35
4.6 Voltage Selector Switch ..................................................................... 36
4.7 Voltage Selector Label ....................................................................... 37
4.8 Voltage Adjustment Rheostat ............................................................. 37
4.9 Emergency Stop Switch ..................................................................... 38
4.10 Grounding the Generator ................................................................... 39
4.11 Connection Lugs ................................................................................ 40
4.12 Convenience Receptacles .................................................................. 41
4.13 Before Starting ................................................................................... 42
6 wc_bo5000186930en_01TOC.fm
Table of Contents G 240
4.14 Manual Start-Up ..................................................................................43
4.15 Operation .............................................................................................45
4.16 Generator Monitoring ..........................................................................46
4.17 Engine Monitoring ...............................................................................47
4.18 Engine Power Correction Factors .......................................................48
4.19 Engine Shutdown Faults .....................................................................49
4.20 Current Overload Fault ........................................................................50
4.21 Event Log ............................................................................................50
4.22 Stopping the Generator .......................................................................50
4.23 Racor® Crankcase Filter .....................................................................51
4.24 Cold Weather Start-Up ........................................................................52
4.25 Remote Run Terminal Block ...............................................................52
4.26 Automatic/Remote Start-Up ................................................................53
4.27 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 Maintenance 64
6.1 Periodic Maintenance Schedule ..........................................................64
6.2 Break-in Period ....................................................................................65
6.3 Resetting the Periodic Maintenance Timer .........................................65
6.4 Replacing the Air Filter Element ..........................................................66
6.5 Replacing the Racor® Filter Element ..................................................67
6.6 Engine Oil ............................................................................................68
6.7 Checking Engine Coolant ....................................................................69
6.8 Maintaining the Trailer .........................................................................70
6.9 Storage ................................................................................................71
wc_bo5000186930en_01TOC.fm 7
Table of ContentsG 240
7 Factory Installed Options 72
7.1 Block Heater ....................................................................................... 72
7.2 Automatic LCD Heat ........................................................................... 73
7.3 Low Coolant Shutdown ...................................................................... 74
7.4 Lube Level Maintainer ........................................................................ 75
7.5 Temperature-Activated Shutters ........................................................ 76
7.6 Lockable Battery Disconnect .............................................................. 76
7.7 Camlocks ............................................................................................ 77
8 Basic Troubleshooting 78
9 Technical Data 79
9.1 Engine ................................................................................................ 79
9.2 Generator ........................................................................................... 80
9.3 Trailer and Skid .................................................................................. 80
9.4 Dimensions ......................................................................................... 81
10 Schematics 83
10.1 Engine Wiring ..................................................................................... 84
10.2 Engine Wiring Components ................................................................ 85
10.3 Electrical Schematic ........................................................................... 86
10.4 Electrical Schematic Components ...................................................... 87
8 wc_bo5000186930en_01TOC.fm
Table of Contents G 240
G 240 Safety Information
wc_si000549gb.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
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.
f Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
f
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.
f
To 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.
f
To avoid possible minor or moderate injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
Safety Information G 240
10 wc_si000549gb.fm
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 240 Safety Information
wc_si000549gb.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.
Safety Information G 240
12 wc_si000549gb.fm
1.3 Safety Guidelines for Operating the Machine
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 240 Safety Information
wc_si000549gb.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 240
14 wc_si000549gb.fm
1.4 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.
f 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. Expo-
sure to carbon monoxide can kill you in minutes.
f 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.
G 240 Safety Information
wc_si000549gb.fm 15
1.5 Towing Safety
Hitch and coupling
Before towing, follow the instructions below to ensure that the hitch
and coupling are ready for use.
Check that the hitch and coupling on the vehicle are rated equal
to, or greater than, the trailer’s Gross Vehicle Weight Rating
(GVWR).
Inspect the hitch and coupling for wear or damage. DO NOT tow
the trailer using defective parts.
Make sure the coupling is securely fastened to the vehicle.
Connect the safety chains.
Connect the breakaway cable safety hook to the bumper or rear
of the vehicle. Do not attach the breakaway cable to the vehicle
hitch.
Tires and wheels
Before towing, follow the instructions below to ensure that the tires
and wheels are ready for use.
Check the tires on the trailer for tread wear, proper inflation, and
condition. Replace worn tires.
Check that the lug nuts holding the wheels are tight and that none
are missing.
Brakes and lights
Before towing, follow the instructions below to ensure that the brakes
and lights are ready for use.
Test the surge brakes on the trailer.
Test the brakes on the vehicle that will be used for towing.
Make sure directional and trailer lights are connected and
working properly.
WARNING
Towing a large trailer requires special care. To reduce the possibility of an accident:
f Both the trailer and vehicle must be in good condition.
f The trailer and the vehicle must be securely fastened to each other.
Safety Information G 240
16 wc_si000549gb.fm
1.6 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).
1.6.1 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.
1.6.2 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.
1.6.3 Do not attempt to open the radiator cap while the unit is running or
before the engine has cooled down. Severe burns may result!
1.6.4 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.
1.6.5 Do not service the machine if your clothing or skin is wet.
1.6.6 Do not allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the
electrical components of this equipment.
WARNING
G 240 Safety Information
wc_si000549gb.fm 17
1.6.7 Do not modify the machine without the express written approval of the
manufacturer.
1.6.8 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!
1.6.9 Allow the engine to cool before performing any service work on the
machine.
1.6.10 Remain aware of moving parts and keep hands, feet, and loose
clothing away from the moving parts of the generator and engine.
1.6.11 Replace all guards, fasten doors, and make sure all safety devices
operate properly after making repairs or servicing the equipment.
1.6.12 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.
1.6.13 Check all external fasteners at regular intervals.
1.6.14 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.
Labels G 240
18 wc_si000548gb.fm
2Labels
2.1 Label Locations
OO
R
Basler
RR
QQ
SS
G 240 Labels
wc_si000548gb.fm 19
wc_gr005517
G
H
J
R
GG
FF
R
AKK
HK
Labels G 240
20 wc_si000548gb.fm
2.2 Label Meanings
A WARNING!
Lock doors. Access can cause electric
shock, arc flash, or injury. Read the
Operator’s Manual for more information.
B WARNING!
Pressurized contents. Do not open when hot!
CWARNING!
Read and understand the supplied
Operator’s Manual before operating the
machine. Failure to do so increases the risk
of injury to yourself and others.
DNOTICE
Never change switch position with engine
running. Results in damage to machine.
E WARNING!
Electric shock and arc flash can cause
serious injury or death.
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Wacker Neuson G240 User manual

Category
Power generators
Type
User manual
This manual is also suitable for

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