Wacker Neuson G230 User manual

Operator’s Manual

Mobile Generator

G230

G240

Type G230, G240

Document 5000186930

Date 0918

Revision 10

Language

EN

5000186930

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.

CALIFORNIA Proposition 65 Warning

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3

CALIFORNIA Proposition 65 Warning

WARNING

The engine exhaust from this product contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

WARNING

Diesel engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth defects, and other reproductive harm.

WARNING

Cancer and Reproductive Harm -

www.P65Warnings.ca.gov.

WARNING

Batteries, battery posts, terminals and related accessories contain lead and lead

compounds, and other chemicals known to the State of California to cause cancer

and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

CALIFORNIA Proposition 65 Warning

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Notes

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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 G50 / G70

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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.

■ For spare parts information, please see your Wacker Neuson Dealer, or visit the

Wacker Neuson website at http://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.

G50 / G70 Foreword

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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.

Foreword G50 / G70

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Notes

Table of Contents

G 230 / G 240

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CALIFORNIA Proposition 65 Warning 3

Foreword 6

1 Safety Information 17

1.1 Signal Words Used in this Manual ..................................................... 17

1.2 Machine Description and Intended Use ............................................. 18

1.3 Safety Guidelines for Operating the Machine ..................................... 19

1.4 Service Safety .................................................................................... 21

1.5 Operator Safety while Using Internal Combustion Engines ............... 23

1.6 Safety Guidelines for Mobile Generators ........................................... 24

1.7 Safety Guidelines for Towing the Machine ......................................... 26

1.8 Safety Guidelines for Lifting the Machine ........................................... 27

1.9 Reporting Safety Defects ................................................................... 27

2 Label Locations 28

3 Label Meanings 30

4 Lifting and Transporting 41

4.1 Lifting the Machine ............................................................................. 41

4.2 Before Towing Checklist ..................................................................... 42

4.3 Towing the Machine ........................................................................... 43

4.4 Preparing the Machine for Transport on a Truck or Trailer ................ 44

4.5 Hazardous Materials Placards ........................................................... 45

4.6 Testing the Breakaway System—Hydraulic Surge Brakes ................. 46

4.7 Testing the Breakaway System—Electric Brakes .............................. 48

5 Machine Setup 50

5.1 Preparing the Machine for First Use ................................................... 50

5.2 Positioning the Machine ..................................................................... 51

5.3 Grounding the Generator ................................................................... 53

5.4 Recommended Fuel ........................................................................... 54

5.5 Refueling the Machine—Basler Controller ......................................... 55

5.6 Refueling the Machine—Deep Sea Controller ................................... 56

Table of Contents

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6 Operation, Control, and Component Locations 57

6.1 Control and Component Locations ..................................................... 57

7 Operation—Basler Controller 59

7.1 Main Circuit Breaker ........................................................................... 59

7.2 Engine Start Switch ............................................................................ 60

7.3 Generator Pre-Alarms and Alarms (Shut-Down Conditions) .............. 61

7.4 Overcurrent Condition ......................................................................... 62

7.5 Idle Switch .......................................................................................... 62

7.6 Diesel Particulate Filter (DPF) ............................................................ 63

7.7 Using the Lugs and the Convenience Receptacles ............................ 64

7.8 Selecting the Voltage .......................................................................... 65

7.9 Before Starting the Machine ............................................................... 68

7.10 Starting and Running the Generator ................................................... 69

7.11 Stopping the Machine ......................................................................... 71

7.12 Emergency Stop Switch ...................................................................... 71

7.13 LCD Panel: Monitoring Machine Operation ........................................ 72

8 Working with Basler Controller 74

8.1 How to Use the Generator Controller LCD and Keypad ..................... 74

8.2 Menu Diagram of the Generator Controller ........................................ 75

8.3 Menu Diagram Components ............................................................... 76

8.4 Using the Metering and Settings Menus ............................................. 77

8.5 Logging in to the Generator Controller by Entering the Password ..... 78

8.6 Adjusting the LCD Screen Contrast .................................................... 81

8.7 Changing the Time/Date Settings ....................................................... 82

8.8 Changing the Sender Fail Time Delays .............................................. 83

8.9 Changing the Units of Measure .......................................................... 85

8.10 Changing the Low Fuel Pre-Alarm Setting ......................................... 87

8.11 Changing or Disabling the Low Fuel Alarm Setting ............................ 89

8.12 Changing the Cooldown Time Setting ................................................ 91

8.13 Changing the Pre-Crank Time Delay (Glow Plug Timer) .................... 93

8.14 Changing the Maintenance Interval .................................................... 95

8.15 Resetting the Maintenance Interval Pre-Alarm ................................... 97

8.16 Resetting a Loss of Voltage Pre-Alarm ............................................... 99

8.17 Accessing and Using the Event Log ................................................. 100

Table of Contents

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9 Operation—Deep Sea Controller 102

9.1 Main Circuit Breaker ......................................................................... 102

9.2 Generator Controller Power Switch .................................................. 103

9.3 Selecting the Voltage ....................................................................... 104

9.4 Deep Sea Controller Buttons/Functions ........................................... 107

9.5 Generator Controller Alarms and Shut-Down Conditions ................. 109

9.6 Before Starting the Machine ............................................................. 111

9.7 Starting and Running the Generator ................................................ 112

9.8 Stopping the Generator .................................................................... 114

9.9 Emergency Stop Switch ................................................................... 115

9.10 Engine and Generator Monitoring .................................................... 116

10 Working with Deep Sea Controller: DSE 7310 MKII 117

10.1 Introduction ....................................................................................... 117

10.2 Navigating the Menus ....................................................................... 118

10.3 Adjusting Screen Contrast ................................................................ 120

10.4 How to Reset the Maintenance Timer .............................................. 121

11 How to Connect Loads 122

11.1 Lug Terminal Connection Diagrams ................................................. 122

11.2 Best Practices for Balancing Loads .................................................. 123

11.3 Connecting 480V, 3-Phase and Single-Phase Loads ...................... 125

11.4 Connecting a 240V 3Ø Load and a 240V 1Ø Load .......................... 126

11.5 Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads 127

11.6 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads .............. 128

12 Using Remote Start Capabilities 129

12.1 Remote Run Terminal Block ............................................................ 129

12.2 Remote Transfer Switch ................................................................... 130

12.3 Preparing for Automatic/Remote Start-Up—Basler .......................... 131

12.4 Preparing for Automatic/Remote Start-Up—Deep Sea .................... 132

13 Diagnostic Trouble Codes (DTC) 134

13.1 Accessing DTCs with the Basler Controller ...................................... 134

13.2 Accessing Engine DTCs using the Deep Sea Controller ................. 135

13.3 List of Engine Diagnostic Trouble Codes (DTCs) ............................. 136

Table of Contents

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14 Factory-Installed Options 150

14.1 Battery Charger ................................................................................ 150

14.2 Lockable Battery Disconnect ............................................................ 151

14.3 Camlocks .......................................................................................... 152

14.4 Containment System ........................................................................ 153

14.5 Extended Run Tank (ERT) ............................................................... 153

14.6 Engine Block Heater ......................................................................... 154

14.7 Cold-Weather Thermostat ................................................................ 155

14.8 Low Coolant Shutdown ..................................................................... 156

14.9 Temperature-Activated Shutters ....................................................... 157

14.10 Positive Air Shutoff Valve ................................................................. 158

14.11 Connecting an External Fuel Supply ................................................ 159

14.12 Lube Level Maintainer ...................................................................... 160

15 Machines with Aftertreatment Exhaust System 161

15.1 How the Aftertreatment Exhaust System Works ............................... 161

15.2 Filling the DEF Tank ......................................................................... 162

15.3 Shelf Life of Diesel Exhaust Fluid (DEF) .......................................... 164

15.4 Monitoring and Control of the DEF Level .......................................... 165

15.5 Monitoring DEF Quality ..................................................................... 166

15.6 Conditioning the Aftertreatment Exhaust System (if equipped) ........ 167

16 General Maintenance 168

16.1 Periodic Maintenance Schedule ....................................................... 168

16.2 Maintaining the Emission Control System ........................................ 169

16.3 Preparing for Maintenance ............................................................... 169

16.4 Cleaning the Machine ....................................................................... 169

16.5 Inspecting the Machine ..................................................................... 170

16.6 Maintaining the Trailer ...................................................................... 171

16.7 Checking and Draining the Containment System (if equipped) ........ 172

16.8 Checking the Exhaust System .......................................................... 173

16.9 Maintaining the Battery ..................................................................... 174

16.10 Filling the Radiator ............................................................................ 175

16.11 Replacing the Aftertreatment DEF Dosing Unit Filter (if equipped) .. 177

16.12 Storage ............................................................................................. 179

16.13 Machine Disposal and Decommissioning ......................................... 180

Table of Contents

G 230 / G 240

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17 Engine Maintenance: John Deere 4045TF285/HF285 6068HF285 181

17.1 Heavy Duty Diesel Engine Coolant .................................................. 185

18 Engine Maintenance: T4i Cummins QSB6.7 187

18.1 Coolant Recommendations and Specifications ................................ 190

19 Engine Maintenance: T4F Cummins QSB7-G9 191

20 Troubleshooting 195

21 Technical Data — G 240 196

21.1 Engine .............................................................................................. 196

21.2 Generator ......................................................................................... 197

21.3 Trailer and Skid ................................................................................ 197

21.4 Dimensions ....................................................................................... 198

22 Technical Data — G 230 199

22.1 Engine: G 230 T4f ............................................................................ 199

22.2 Engine: G 230 T4i ............................................................................ 200

22.3 Generator ......................................................................................... 201

22.4 Trailer and Skid ................................................................................ 202

22.5 Dimensions ....................................................................................... 203

23 Tire Safety Information 204

24 User’s Information for Transport Canada Fuel Tank 216

25 Emission Control Systems Information and Warranty—Diesel 219

25.1 Emission Control System Background Information .......................... 219

25.2 Limited Defect Warranty for Exhaust Emission Control System ....... 220

25.3 Limited Defect Warranty for Wacker Neuson Emission Control

Systems ............................................................................................ 220

Table of Contents

G 230 / G 240

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26 General Machine Schematics 223

26.1 Fuses .................................................................................................223

26.2 Trailer Wiring .....................................................................................224

26.3 Trailer Wiring Components ................................................................225

27 Schematics—Machines with Basler Controller 226

27.1 AC SchematicG 230/G 240 ...............................................................226

27.2 AC Schematic ComponentsG 230/G 240 ..........................................227

27.3 DC Schematic: G 240 John Deere Tier 3 ..........................................228

27.4 DC Schematic Components: G 240 Tier 3 ........................................229

27.5 DC Schematic: G230 Cummins T4i ..................................................230

27.6 DC Schematic Components: G 230 T4i ............................................231

27.7 DC Schematic: G230 Cummins T4f ..................................................232

27.8 DC Schematic Components: G 230 Cummins T4f ............................233

27.9 DC Electrical Schematic Section A: G 230 Cummins T4f .................234

27.10 Electrical Schematic Components .....................................................235

27.11 DC Electrical Schematic Section B: G 230 Cummins T4f .................236

27.12 Electrical Schematic Components .....................................................237

27.13 DC Electrical Schematic Section C: G 230 Cummins T4f .................238

27.14 Electrical Schematic Components .....................................................239

27.15 Cummins Engine Relays and Fuses .................................................240

27.16 Cummins Engine Relays and Fuses .................................................241

28 Schematics—Machines with Deep Sea Controller 242

28.1 AC SchematicG 230 / G 240 .............................................................242

28.2 Electrical Schematic Components: G 230 / G 240 ............................243

28.3 DC Schematic: G 240 John Deere Tier 3 ..........................................244

28.4 DC Schematic Components: G 240 John Deere Tier 3 ....................245

28.5 DC Schematic: G 230 Cummins T4i .................................................246

28.6 DC Schematic Components: G 230 Cummins T4i ............................247

28.7 DC Schematic: G 230 Cummins T4f .................................................248

28.8 DC Schematic Components: G 230 Cummins T4f ............................249

28.9 DC Electrical Schematic Section A: G 230 Cummins T4f .................250

28.10 Electrical Schematic Components .....................................................251

28.11 DC Electrical Schematic Section B: G 230 Cummins T4f .................252

Table of Contents

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28.12 Electrical Schematic Components .................................................... 253

28.13 DC Electrical Schematic Section C: G 230 Cummins T4f ................ 254

28.14 Electrical Schematic Components .................................................... 255

28.15 Cummins Engine Relays and Fuses ................................................ 256

28.16 Cummins Engine Relays and Fuses ................................................ 257

Table of Contents

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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

messages that follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in

death or serious injury.

► To avoid possible death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in

minor or moderate injury.

► To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

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Safety Information Mobile Generator

1.2 Machine Description and Intended Use

Machine

description

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.

Intended use

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.

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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, drugs, or prescription 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.

■ 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.

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Safety Information Mobile Generator

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.

■ 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 oil,

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 location out of the reach of children.

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Wacker Neuson G230, G240 User manual

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