Wacker Neuson G110 User manual

Category
Power generators
Type
User manual

This manual is also suitable for

Operator’s Manual
Mobile Generator
G50 (60 Hz)
G70 (60 Hz)
G110 (60 Hz)
Type G50, G70, G110
Document 5100027594
Date 0619
Revision 03
Language EN
5100027594
Copyright notice
© Copyright 2019 by Wacker Neuson Máquinas Ltda
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 Máquinas Ltda.
Any type of reproduction or distribution not authorized by Wacker
Neuson Máquinas Ltda 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 Máquinas Ltda
Rod Dom Pedro I (SP65), Km 104
Itatiba - São Paulo - Cep 13.251-705 - Brasil
Tel: +55 11 3183 0222
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
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G50 / G70 / G110 Foreword
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Foreword
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models below. These instructions have been written expressly by
Wacker Neuson Máquinas Ltda 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
documentation
From this point forward in this documentation, Wacker Neuson Máquinas Ltda
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.
Machine Item Number
G50 5100022008, 5100022009
G70 5100022040, 5100022041
G110 5100022042, 5100022043
wc_gr013581
5100022507
FABRICADO
NO BRASIL
Altitude máx. acima do nível do mar (m)
Fator de potência
Fase ( )
Número de série
Número de referência
Revisão
Temperatura máx. do ambiente (C)
Corrente nominal (A)
Frequência nominal (Hz)
Mês/ano de fabricação
Tensão nominal (V)
Potência-Prime (kW/kVA)
Massa (kg)
Tipo/Modelo
Serial Number:
Foreword G50 / G70 / G110
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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.
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.
Table of Contents
G50 / G70 / G110
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CALIFORNIA Proposition 65 Warning 3
Foreword 5
1 Safety Information 11
1.1 Signal Words Used in this Manual ..............................................................11
1.2 Machine Description and Intended Use ......................................................12
1.3 Safety Guidelines for Operating the Machine ..............................................13
1.4 Service Safety .............................................................................................15
1.5 Operator Safety while Using Internal Combustion Engines ........................17
1.6 Safety Guidelines for Mobile Generators ....................................................18
1.7 Safety Guidelines for Lifting the Machine ....................................................19
2 Labels 20
2.1 Label Locations ...........................................................................................20
2.2 Label Meanings ........................................................................................... 22
3 Lifting and Transporting 29
3.1 Lifting the Machine ...................................................................................... 29
3.2 Preparing the Machine for Transport on a Truck or Trailer .........................30
4 Machine Setup 31
4.1 Preparing the Machine for First Use ............................................................31
4.2 Positioning the Machine ..............................................................................32
4.3 Grounding the Generator ............................................................................33
4.4 Recommended Fuel ....................................................................................33
4.5 Refueling the Machine (Deep Sea Controller 7310) ....................................34
4.6 Refueling the Machine (Deep Sea Controller 4510) ....................................35
5 Operation, Control, and Component Locations 36
5.1 Control and Component Locations ..............................................................36
5.2 Control Panel Components .........................................................................37
6 Operation (Deep Sea Controller: DSE 7310) 38
6.1 Generator Controller Power Switch .............................................................38
6.2 Deep Sea Controller Buttons/Functions ......................................................39
Table of Contents
G50 / G70 / G110
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6.3 Generator Controller Alarms and Shut-Down Conditions ........................... 41
6.4 Using the Lugs and the Convenience Receptacles (if equipped) ............... 42
6.5 Selecting the Voltage .................................................................................. 43
6.6 Before Starting the Machine ....................................................................... 45
6.7 Starting and Running the Generator ........................................................... 46
6.8 Stopping the Generator ............................................................................... 48
6.9 Emergency Stop Switch .............................................................................. 49
7 Working with Deep Sea Controller: DSE 7310 50
7.1 Introduction ................................................................................................. 50
7.2 Adjusting Screen Contrast .......................................................................... 51
7.3 Changing the Language .............................................................................. 52
7.4 How to Reset the Maintenance Timer ......................................................... 53
8 Operation (Deep Sea Controller: DSE 4510) 54
8.1 Deep Sea Controller Buttons/Functions ...................................................... 54
8.2 Generator Controller Alarms and Shut-Down Conditions ........................... 55
8.3 Before Starting the Machine ....................................................................... 56
8.4 Starting and Running the Generator ........................................................... 57
8.5 Stopping the Generator ............................................................................... 58
8.6 Emergency Stop Switch .............................................................................. 59
9 Working with Deep Sea Controller: DSE 4510 60
9.1 Introduction ................................................................................................. 60
9.2 Accessing the Event Log ............................................................................ 60
9.3 How to Reset the Maintenance Timer ......................................................... 61
10 How to Connect Loads 62
10.1 Lug Terminal Connection Diagrams ........................................................... 62
10.2 Best Practices for Balancing Loads ............................................................ 63
10.3 Connecting 440V, 3-Phase and Single-Phase Loads ................................. 64
10.4 Connecting a 220V 3Ø Load and a 220V 1Ø Load .................................... 65
10.5 Connecting a 220V 3Ø Load and Multiple 127V 1Ø Loads ........................ 66
Table of Contents
G50 / G70 / G110
wc_bo5100027594_03TOC.fm
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11 Using Remote Start Capabilities 67
11.1 Remote Run Terminal Block ....................................................................... 67
11.2 Remote Transfer Switch ..............................................................................68
11.3 Preparing for Automatic/Remote Start-Up (Deep Sea) ...............................69
12 General Maintenance 71
12.1 Periodic Maintenance Schedule ..................................................................71
12.2 Preparing for Maintenance ..........................................................................72
12.3 Cleaning the Machine .................................................................................. 72
12.4 Inspecting the Machine ...............................................................................73
12.5 Checking and Draining the Containment System ........................................74
12.6 Checking the Exhaust System ....................................................................75
12.7 Maintaining the Battery ................................................................................76
12.8 Storage ........................................................................................................ 77
12.9 Machine Disposal and Decommissioning ....................................................78
13 Engine Maintenance: Perkins 1104A-44G / 1104A-44TG1 79
14 Engine Maintenance: Perkins 81
15 Troubleshooting 83
16 Technical Data 84
16.1 Engine .........................................................................................................84
16.2 Generator ....................................................................................................85
16.3 Dimensions ..................................................................................................86
17 Schematics—Machines with Deep Sea Controller 87
17.1 Fuses ...........................................................................................................87
17.2 AC Schematic: G50 / G70 / G110 ...............................................................88
17.3 Electrical Schematic Components: G50 / G70 / G110 ................................89
17.4 DC Schematic: G50 / G70 / G110 (DSE 7310) ...........................................90
17.5 DC Schematic Components: G50 / G70 / G110 (DSE 7310) ......................91
17.6 DC Schematic: G50 / G70 / G110 (DSE 4510) ...........................................92
17.7 DC Schematic Components: G50 / G70 / G110 (DSE 4510) ......................93
Table of Contents
G50 / G70 / G110
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G150 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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12
Safety Information G150
1.2 Machine Description and Intended Use
This machine is a mobile electric power source. The Wacker Neuson Mobile
Generator consists of a cabinet containing an electric alternator, a fuel tank, and a
diesel engine. A control panel, receptacles (if equipped), 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 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
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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G150 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 G150
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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15
G150 Safety Information
1.4 Service Safety
Service
training
Before servicing or maintaining the machine:
Read and understand the instructions contained in all manuals delivered with
the machine.
Familiarize yourself with the location and proper use of all controls and
protective devices.
Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
Do not allow untrained or improperly trained people to service or maintain the
machine. Personnel servicing or maintaining the machine must be familiar with
the associated potential risks and hazards.
Precautions
When servicing or maintaining the machine:
Read and understand the service procedures before performing any service to
the machine.
All adjustments and repairs must be completed before operating the machine.
Do not operate the machine with a known problem or deficiency.
All repairs and adjustments shall be completed by a qualified technician.
Turn off the machine before performing maintenance or making repairs.
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
Reinstall the safety devices and guards after repair and maintenance
procedures are complete.
Machine
modifications
When servicing or maintaining the machine:
Use only accessories/attachments that are approved by Wacker Neuson.
Do not defeat safety devices.
Do not modify the machine without the express written approval of Wacker
Neuson.
Replacing
parts and
labels
Replace worn or damaged components.
Replace all missing and hard-to-read labels.
When replacing electrical components, use components that are identical in
rating and performance to the original components.
When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.
wc_si000998gb_FM10.fm
16
Safety Information G150
Cleaning
When cleaning and servicing the machine:
Keep machine clean and free of debris such as leaves, paper, cartons, etc.
Keep labels legible.
Do not clean the machine while it is running.
Never use gasoline or other types of fuels or flammable solvents to clean the
machine. Fumes from fuels and solvents can become explosive.
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).
Electrical
service safety
Make sure clothing and shoes are dry, stand on a dry wooden platform or rubber
insulating mat, and use tools with insulated handles when servicing the
machine.
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.
Do not pressure wash the control panel, generator end, or any other electrical
components when cleaning the machine.
Cooling
system safety
Do not attempt to open the radiator cap while the unit is running or before the
engine has cooled down. Severe burns may result!
Engine coolant is toxic to humans and animals. Clean up spills and dispose of
waste engine coolant in accordance with local environmental regulations.
wc_si000998gb_FM10.fm
17
G150 Safety Information
1.5 Operator Safety while Using Internal Combustion Engines
Operating
safety
When running the engine:
Keep the area around the 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.
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.
Do not use the machine in areas with risk of explosion or fire.
Refueling
safety
When refueling the engine:
Clean up any spilled fuel immediately.
Refill the fuel tank in a well-ventilated area.
Reinstall the fuel tank cap after refueling.
Use tools specifically meant for refueling (for example, a fuel hose or funnel).
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.
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.
Exposure to carbon monoxide can kill you in minutes.
NEVER operate the machine inside an enclosed area, such as a tunnel, unless
adequate ventilation is provided through items such as exhaust fans or hoses.
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18
Safety Information G150
1.6 Safety Guidelines for Mobile Generators
Installing as
backup power
Special hazards exist when installing this machine as a backup power supply.
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.
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.
DANGER
Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot
see or smell. If you can smell the generator exhaust, you are breathing CO. Even if
you cannot smell the exhaust, you could be breathing CO.
NEVER use a generator inside homes, garages, crawlspaces, or other partly
enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Using a fan or opening windows and doors does NOT supply enough fresh air.
ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the home. ALWAYS
use a battery-powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running,
move to fresh air RIGHT AWAY. See a doctor. You could have carbon monoxide
poisoning.
WARNING
Electrocution hazard. Machines that generate electric power present special
hazards while the engine is running. These include the risk of electrocution or
severe electrical shock.
Read and follow the instructions in this Operator’s Manual.
WARNING
Backfeed from the generator into the public power distribution system can cause
serious injury or death to utility workers!
Connections to a building’s electrical system must be made by a qualified
electrician and comply with all applicable laws and electrical codes.
wc_si000998gb_FM10.fm
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G150 Safety Information
General safety
Do not use evaporative starting fluids to start the engine. They are highly
explosive.
Do not store items such as excess oil, rags, or tools on top of or inside the
machine. These items are a fire hazard and can restrict cooling air.
Ensure that electrical cords attached to the machine are in serviceable condition
without cuts, cracks, or exposed wires.
Do not route electrical cords over vibrating or hot parts of the machine.
Do not stand on the machine.
Do not enclose or cover the machine when it is use, or when it is hot.
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.
1.7 Safety Guidelines for Lifting the Machine
When lifting the machine:
Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any
other type of lifting device used is attached securely and has enough weight-
bearing capacity to lift or hold the machine safely. See the Technical Data
chapter for machine weight.
Remain aware of the location of other people when lifting the machine.
Only use the lifting points and tie-downs described in the Operator’s Manual.
Make sure the transporting vehicle has sufficient load capacity and platform size
to safely transport the machine.
To reduce the possibility of injury:
Do not stand under the machine while it is being lifted or moved.
Do not get onto the machine while it is being lifted or moved.
20 wc_si000999gb_FM10.fm
Mobile Generator
Labels
2 Labels
2.1 Label Locations
wc_gr013529
B
C
D
F
H
J
K
M
O
S
T
V
W
X
Y
Z
A
D
C
AA
BB
O
JJ
HH
GG
FF
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Wacker Neuson G110 User manual

Category
Power generators
Type
User manual
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