Wacker Neuson G240 User manual

Category
Power generators
Type
User manual

This manual is also suitable for

Operator’s Manual
Mobile Generator
G230
G240
Type G230, G240
Document 5000186930
Date 0119
Revision 11
Language
EN
5000186930
Copyright notice
© Copyright 2019 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.
wc_tx004643en.fm 3
CALIFORNIA Proposition 65 Warning
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 Proposition 65 Warning
4 wc_tx004643en.fm
Notes
wc_tx003616gb_FM10.fm
5
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
G230 5200010141
5200010142
5200010143
5000620881
5000620882
5000620883
5200007862
5100015614
5100045190
5100045596
5100045597
G240 5000620661
5000620662
5000620663
5200001323
5200003162
5200006904
5200025556
wc_gr010208
Serial Number:
Foreword Mobile Generator
6 wc_tx003565gb_FM10.fm
Foreword
Machine
documentation
â–  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.
â–  For spare parts information, please see your Wacker Neuson Dealer, or visit the
Wacker Neuson website at http://www.wackerneuson.com/.
â–  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
â–  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.
â–  Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
â–  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.
â–  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.
Mobile Generator Foreword
wc_tx003565gb_FM10.fm 7
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
â–  Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
â–  Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
â–  Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:
â–  Serious injury hazards to the operator and persons in the work area
â–  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.
Abbreviations
Abbreviation or
Acronym
Definition
Abbreviation
or Acronym
Definition
ATS Automatic transfer switch L3 Level load logic
CARB California Air Resource
Board
LT Light truck
CDL Commercial driver’s license MAF Mass air flow
CKP Crank position NC Normally closed
CMP Camshaft position NHTSA National Highway Traffic Safety
Administration
CO Carbon monoxide NOx Nitrogen oxides
DEF Diesel exhaust fluid P/L Pressure limiter
DM Dosing module PPE Personal protective equipment
DOC Diesel oxidation catalyst S/N Serial number
DTC Diagnostic trouble codes SCR Selective catalytic reduction
EGR Exhaust gas recirculation SPN Suspect parameter number
EPA Environmental Protection
Agency
ST Special trailer
ERT Extended run tank TDG Canadian Transportation of
Dangerous Goods Act
FMI Failure mode identifier TWI Treadwear indicators
GAWR Gross axle weight ratings VCW Vehicle capacity weight
IBC Intermediate bulk container — —
Foreword Mobile Generator
8 wc_tx003565gb_FM10.fm
Notes
Table of Contents
G150 / G180
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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
G150 / G180
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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 ......................................... 86
8.11 Changing or Disabling the Low Fuel Alarm Setting ............................ 88
8.12 Changing the Cooldown Time Setting ................................................ 90
8.13 Changing the Pre-Crank Time Delay (Glow Plug Timer) .................... 92
8.14 Changing the Maintenance Interval .................................................... 94
8.15 Resetting the Maintenance Interval Pre-Alarm ................................... 96
8.16 Resetting a Loss of Voltage Pre-Alarm ............................................... 98
8.17 Accessing and Using the Event Log ................................................... 99
Table of Contents
G150 / G180
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9 Operation—Deep Sea Controller 101
9.1 Main Circuit Breaker ......................................................................... 101
9.2 Generator Controller Power Switch .................................................. 102
9.3 Selecting the Voltage ....................................................................... 103
9.4 Deep Sea Controller Buttons/Functions ........................................... 106
9.5 Generator Controller Alarms and Shut-Down Conditions ................. 108
9.6 Before Starting the Machine ............................................................. 110
9.7 Starting and Running the Generator ................................................ 111
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—Deep Sea .................... 131
13 Diagnostic Trouble Codes (DTC) 133
13.1 Accessing DTCs with the Basler Controller ...................................... 133
13.2 Accessing Engine DTCs using the Deep Sea Controller ................. 134
13.3 List of Engine Diagnostic Trouble Codes (DTCs) ............................. 135
Table of Contents
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14 Factory-Installed Options 148
14.1 Battery Charger ................................................................................ 148
14.2 Lockable Battery Disconnect ............................................................ 149
14.3 Camlocks .......................................................................................... 150
14.4 Containment System ........................................................................ 151
14.5 Extended Run Tank (ERT) ............................................................... 151
14.6 Engine Block Heater ......................................................................... 152
14.7 Cold-Weather Thermostat ................................................................ 153
14.8 Low Coolant Shutdown ..................................................................... 154
14.9 Temperature-Activated Shutters ....................................................... 155
14.10 Positive Air Shutoff Valve ................................................................. 156
14.11 Connecting an External Fuel Supply ................................................ 157
14.12 Lube Level Maintainer ...................................................................... 158
15 Machines with Aftertreatment Exhaust System 159
15.1 How the Aftertreatment Exhaust System Works ............................... 159
15.2 Filling the DEF Tank ......................................................................... 160
15.3 Shelf Life of Diesel Exhaust Fluid (DEF) .......................................... 162
15.4 Monitoring and Control of the DEF Level .......................................... 163
15.5 Monitoring DEF Quality ..................................................................... 164
15.6 Conditioning the Aftertreatment Exhaust System (if equipped) ........ 165
16 General Maintenance 166
16.1 Periodic Maintenance Schedule ....................................................... 166
16.2 Maintaining the Emission Control System ........................................ 167
16.3 Preparing for Maintenance ............................................................... 167
16.4 Cleaning the Machine ....................................................................... 167
16.5 Inspecting the Machine ..................................................................... 168
16.6 Maintaining the Trailer ...................................................................... 169
16.7 Checking and Draining the Containment System (if equipped) ........ 170
16.8 Checking the Exhaust System .......................................................... 171
16.9 Maintaining the Battery ..................................................................... 172
16.10 Filling the Radiator ............................................................................ 173
16.11 Replacing the Aftertreatment DEF Dosing Unit Filter (if equipped) .. 175
16.12 Storage ............................................................................................. 177
16.13 Machine Disposal and Decommissioning ......................................... 178
Table of Contents
G150 / G180
wc_bo5000186930_10TOC.fm
13
17 Engine Maintenance: John Deere 4045TF285/HF285 6068HF285 179
17.1 Heavy Duty Diesel Engine Coolant .................................................. 183
18 Engine Maintenance: T4i Cummins QSB6.7 185
18.1 Coolant Recommendations and Specifications ................................ 188
19 Engine Maintenance: T4F Cummins QSB7-G9 189
20 Troubleshooting 193
21 Technical Data — G 240 194
21.1 Engine .............................................................................................. 194
21.2 Generator ......................................................................................... 195
21.3 Trailer and Skid ................................................................................ 195
21.4 Dimensions ....................................................................................... 196
22 Technical Data — G 230 197
22.1 Engine: G 230 T4f ............................................................................ 197
22.2 Engine: G 230 T4i ............................................................................ 198
22.3 Generator ......................................................................................... 199
22.4 Trailer and Skid ................................................................................ 200
22.5 Dimensions ....................................................................................... 201
23 Tire Safety Information 202
24 User’s Information for Transport Canada Fuel Tank 214
25 Emission Control Systems Information and Warranty—Diesel 217
25.1 Emission Control System Background Information .......................... 217
25.2 Limited Defect Warranty for Exhaust Emission Control System ....... 218
25.3 Limited Defect Warranty for Wacker Neuson Emission Control
Systems ............................................................................................ 218
Table of Contents
G150 / G180
wc_bo5000186930_10TOC.fm
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26 General Machine Schematics 221
26.1 Fuses .................................................................................................221
26.2 Trailer Wiring .....................................................................................222
26.3 Trailer Wiring Components ................................................................223
27 Schematics—Machines with Basler Controller 224
27.1 AC SchematicG 230/G 240 ...............................................................224
27.2 AC Schematic ComponentsG 230/G 240 ..........................................225
27.3 DC Schematic: G 240 John Deere Tier 3 ..........................................226
27.4 DC Schematic Components: G 240 Tier 3 ........................................227
27.5 DC Schematic: G230 Cummins T4i ..................................................228
27.6 DC Schematic Components: G 230 T4i ............................................229
27.7 DC Schematic: G230 Cummins T4f ..................................................230
27.8 DC Schematic Components: G 230 Cummins T4f ............................231
27.9 DC Electrical Schematic Section A: G 230 Cummins T4f .................232
27.10 Electrical Schematic Components .....................................................233
27.11 DC Electrical Schematic Section B: G 230 Cummins T4f .................234
27.12 Electrical Schematic Components .....................................................235
27.13 DC Electrical Schematic Section C: G 230 Cummins T4f .................236
27.14 Electrical Schematic Components .....................................................237
27.15 Cummins Engine Relays and Fuses .................................................238
27.16 Cummins Engine Relays and Fuses .................................................239
28 Schematics—Machines with Deep Sea Controller 240
28.1 AC Schematic G 230 / G 240 ............................................................240
28.2 Electrical Schematic Components: G 230 / G 240 ............................241
28.3 DC Schematic: G 240 John Deere Tier 3 ..........................................242
28.4 DC Schematic Components: G 240 John Deere Tier 3 ....................243
28.5 DC Schematic: G 230 Cummins T4i .................................................244
28.6 DC Schematic Components: G 230 Cummins T4i ............................245
28.7 DC Schematic: G 230 Cummins T4f .................................................246
28.8 DC Schematic Components: G 230 Cummins T4f ............................247
28.9 DC Electrical Schematic Section A: G 230 Cummins T4f .................248
28.10 Electrical Schematic Components .....................................................249
28.11 DC Electrical Schematic Section B: G 230 Cummins T4f .................250
Table of Contents
G150 / G180
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15
28.12 Electrical Schematic Components .................................................... 251
28.13 DC Electrical Schematic Section C: G 230 Cummins T4f ................ 252
28.14 Electrical Schematic Components .................................................... 253
28.15 Cummins Engine Relays and Fuses ................................................ 254
28.16 Cummins Engine Relays and Fuses ................................................ 255
Table of Contents
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wc_tx003567gb_FM10.fm
17
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.
â–º 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.
â–º 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.
â–º 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.
â–º To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
wc_tx003567gb_FM10.fm
18
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:
â–  Connecting a load that has voltage and frequency requirements that are
incompatible with the generator output
â–  Overloading the generator with a load that draws excessive power during either
continuous running or start-up
â–  Operating the generator in a manner that is inconsistent with all federal, state
and local codes and regulations
â–  Using the machine as a ladder, support, or work surface
â–  Using the machine to carry or transport passengers or equipment
â–  Using the machine to tow other machines
â–  Operating the machine outside of factory specifications
â–  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:
â–  Heat, noise, exhaust, and carbon monoxide from the engine
â–  Fire hazards from improper refueling techniques
â–  Fuel and its fumes
â–  Electric shock and arc flash
â–  Personal injury from improper lifting the trailer tongue
â–  Typical hazards related to towing a trailer on roads and highways
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.
wc_tx003567gb_FM10.fm
19
Mobile Generator Safety Information
1.3 Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
â–  Read and understand the operating instructions contained in all manuals
delivered with the machine.
â–  Familiarize yourself with the location and proper use of all controls and safety
devices.
â–  Contact Wacker Neuson for additional training if necessary.
When operating this machine:
â–  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:
â–  Have received instruction on how to properly use the machine
â–  Are familiar with required safety devices
The machine must not be accessed or operated by:
â– Children
â–  People impaired by alcohol, drugs, or prescription drugs
Application
area
Be aware of the application area.
â–  Keep unauthorized personnel, children, and pets away from the machine.
â–  Remain aware of changing positions and the movement of other equipment and
personnel in the application area/job site.
â–  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.
â–  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:
â–  All safety devices and guards are in place and in working order.
â–  All controls operate correctly.
■ The machine is set up correctly according to the instructions in the Operator’s
Manual.
â–  The machine is clean.
■ The machine’s labels are legible.
To ensure safe operation of the machine:
â–  Do not operate the machine if any safety devices or guards are missing or
inoperative.
â–  Do not modify or defeat the safety devices.
â–  Only use accessories or attachments that are approved by Wacker Neuson.
wc_tx003567gb_FM10.fm
20
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.
â–  Do not operate a machine in need of repair.
â–  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:
â–  Close-fitting work clothes that do not hinder movement
â–  Safety glasses with side shields
â–  Hearing protection
â–  Safety-toed footwear
After use
â–  Stop the engine when the machine is not being operated.
â–  Close the fuel valve on engines equipped with one when the machine is not
being operated.
â–  Ensure that the machine will not tip over, roll, slide, or fall when not being
operated.
â–  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 G240 User manual

Category
Power generators
Type
User manual
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