Wacker Neuson G240 User manual

5000186930 02 0511

5000186930

Operator’s Manual

Mobile Generator

G 240

Copyright notice

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.

Manufacturer’s

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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