Wacker Neuson G625 User manual

Category
Power generators
Type
User manual
Operator’s Manual
Notice d'emploi
Mobile Generator
Groupe électrogène mobile
G625
Type G625
Document 5100027362
Date 0316
Version 01
Language EN-FR
5100027362
Copyright notice
© Copyright 2016 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 Operators Manual presents the original instructions. The original
language of this Operator’s Manual is American English.
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3
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
G625 5100013899
wc_gr012550
Serial Number:
Foreword
4 wc_tx003956gb_FM10.fm
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.
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
6 wc_tx003956gb_FM10.fm
Notes
Table of Contents
G625
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Foreword 4
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 Towing the Machine ......................................... 20
1.8 Safety Guidelines for Lifting the Machine ........................................... 21
1.9 Reporting Safety Defects ................................................................... 21
2 Labels 22
2.1 Label Locations ................................................................................. 22
2.2 Label Meanings .................................................................................. 24
3 Lifting and Transporting 33
3.1 Lifting the Machine ............................................................................. 33
3.2 Before Towing Checklist ..................................................................... 34
3.3 Towing the Machine ........................................................................... 35
3.4 Preparing the Machine for Transport on a Truck or Trailer ................ 36
3.5 Testing the Breakaway System—Electric Brakes .............................. 37
4 Controls 39
4.1 Control and Component Locations ..................................................... 39
4.2 Component Descriptions .................................................................... 41
4.3 Emergency Stop Switch ..................................................................... 44
4.4 Busbar and Camlock Doors ............................................................... 45
4.5 Main Circuit Breaker ........................................................................... 47
4.6 Remote Run Terminal Block .............................................................. 48
4.7 Remote Transfer Switch ..................................................................... 49
4.8 Test Plug Inputs for Voltage ............................................................... 50
4.9 Battery Charger .................................................................................. 50
4.10 Camlocks ............................................................................................ 51
4.11 Containment System .......................................................................... 51
4.12 Three-Way Fuel Valve Switch ............................................................ 52
4.13 Quick Disconnect Fuel Fittings ........................................................... 52
Table of Contents
G625
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8
4.14 Low-Coolant Shutdown .......................................................................53
4.15 Racor Fuel Filtration System ..............................................................54
4.16 Alternator Anti-Condensation Heater ..................................................54
4.17 Coolant Heater ....................................................................................55
5 Using the DSE 8610 Deep Sea Controller 56
5.1 Deep Sea Controller Buttons and Functions ......................................56
5.2 Navigating the Menus .........................................................................59
5.3 How to Reset the Maintenance Timer ................................................62
5.4 Deep Sea Controller Alarms and Shut-Down Conditions ...................63
5.5 Adjusting Screen Contrast ..................................................................65
6 Machine Setup 66
6.1 Preparing the Machine for First Use ...................................................66
6.2 Positioning the Machine ......................................................................67
6.3 Grounding the Generator ....................................................................69
6.4 Recommended Fuel ...........................................................................70
6.5 Connecting and Using an External Fuel Supply .................................71
6.6 Refueling the Machine ........................................................................72
7 How to Connect Loads 74
7.1 Busbar/Camlock Connections and
Voltage Selector Plate Positions .........................................................74
7.2 Connecting Multiple Generators .........................................................76
7.3 Connecting Two Generators ...............................................................78
7.4 Connecting Three Generators ............................................................80
7.5 Connecting Four Generators ..............................................................82
8 Operation 84
8.1 Modes of Operation ............................................................................84
8.2 Configuring the Generator with the Load Application Switch ..............86
8.3 Assigning Generator Position with the
Multi-Set Communication Switch ........................................................87
8.4 Selecting the Voltage ..........................................................................89
8.5 Before Starting the Machine ...............................................................91
8.6 Operating the Generator — Stand-Alone Manual Mode .....................92
8.7 Operating the Generator — Stand-Alone Auto Mode Remote Start ...97
Table of Contents
G625
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8.8 Operating the Generator — Multiple Gensets Manual Mode ........... 103
8.9 Operating the Generator — Multiple Gensets
Auto Mode Equal Load Share .......................................................... 109
8.10 Operating the Generator — Multiple Gensets
Auto Mode Load Demand ................................................................ 115
8.11 Operating the Generator — Multiple Gensets
Auto Mode Remote Start .................................................................. 123
8.12 Engine and Generator Monitoring .................................................... 131
9 General Maintenance 132
9.1 Periodic Maintenance Schedule ....................................................... 132
9.2 Maintaining the Emission Control System ........................................ 133
9.3 Preparing for Maintenance ............................................................... 133
9.4 Cleaning the Machine ....................................................................... 133
9.5 Inspecting the Machine .................................................................... 134
9.6 Maintaining the Trailer ...................................................................... 135
9.7 Checking and Pumping Out the Containment System ..................... 136
9.8 Checking the Exhaust System ......................................................... 137
9.9 Maintaining the Battery ..................................................................... 138
9.10 Filling the Radiator ........................................................................... 139
9.11 Storage ............................................................................................. 141
9.12 Machine Disposal and Decommissioning ......................................... 142
10 Engine Maintenance: Volvo TAD1642GE 143
11 Troubleshooting 147
11.1 Responding to a Fluid Accumulation Alarm ..................................... 148
12 Technical Data 149
12.1 Engine .............................................................................................. 149
12.2 Generator ......................................................................................... 150
12.3 Trailer and Skid ................................................................................ 151
12.4 Dimensions ....................................................................................... 152
Tire Safety Information 153
Table of Contents
G625
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13 Schematics 165
13.1 Engine Schematic: Volvo TAD1642GE ............................................166
13.2 Schematic Components: Volvo TAD1642GE ...................................167
13.3 Panel Schematic ...............................................................................168
13.4 Schematic Components ....................................................................169
13.5 Panel Schematic Components .........................................................170
13.6 Auxiliary Power Schematic ...............................................................172
13.7 Auxiliary Power Components ............................................................173
13.8 AC Schematic ...................................................................................174
13.9 AC Schematic Components ..............................................................175
13.10 Trailer Wiring ....................................................................................176
13.11 Trailer Wiring Components ...............................................................177
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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.
wc_si000928gb_FM10.fm
12
Mobile Generator
Safety Information
1.2 Machine Description and Intended Use
This machine is a mobile electric power source. The Wacker Neuson Mobile
Generator consists of a trailer-mounted cabinet containing an electric alternator, a
fuel tank, and a diesel engine. A control panel, receptacles, and connection lugs
are provided on the side of the cabinet. Additional connection lugs are provided at
the rear 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 Operators 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 improperly 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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13
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 or 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.
Be aware of the application area.
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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Mobile Generator
Safety Information
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.
When operating this machine:
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 fluid,
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, dry location out of the reach of children.
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Mobile Generator
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 safety
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 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.
Re-install 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.
When servicing or maintaining the machine:
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.
Cleaning
When cleaning and servicing the machine:
Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
Keep the labels legible.
When cleaning the machine:
wc_si000928gb_FM10.fm
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Mobile Generator
Safety Information
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.
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Mobile Generator
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.
When running the engine:
Do not smoke while operating the machine.
Do not run the engine near sparks or open flames.
Do not touch the engine or muffler while the engine is running or immediately
after it has been turned off.
Do not operate a machine when its fuel cap is loose or missing.
Do not start the engine if fuel has spilled or a fuel odor is present. Move the
machine away from the spill and wipe the machine dry before starting.
Refueling
safety
When refueling the engine:
Clean up any spilled fuel immediately.
Refill the fuel tank in a well-ventilated area.
Re-install the fuel tank cap after refueling.
Use suitable tools for refueling (for example, a fuel hose or funnel).
When refueling the engine:
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
Mobile Generator
Safety Information
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.
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Mobile Generator
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.
wc_si000928gb_FM10.fm
20
Mobile Generator
Safety Information
1.7 Safety Guidelines for Towing the Machine
When towing the machine:
Do not tow the machine if the towing vehicle’s hitch or the trailers coupler are
damaged.
Do not tow the machine if any of the trailers lug nuts are missing.
Do not tow the machine if the trailers tires have less than 1/16 inch (1.5 mm) of
tread.
Do not tow the machine unless the trailers brakes are functioning properly.
Do not exceed the trailer manufacturers speed limitations.
When towing the machine:
Only tow the machine when the trailer’s lug nuts are properly torqued.
Only tow the machine when the trailer’s tires are properly inflated.
Only tow the machine when all trailer lights are functioning correctly.
Only tow the machine when the trailer’s safety chains are connected to the
towing vehicle in a crisscross pattern.
Maintain extra distance between the towing vehicle and other vehicles.
Avoid soft shoulders, curbs, and sudden lane changes.
Abide by all licensing requirements for your area.
If you have not driven a towing vehicle with a trailer before, practice turning,
stopping, and backing up the towing vehicle with the trailer in an area away from
traffic. Only drive the towing vehicle with the trailer when you are confident in your
ability to do so.
WARNING
Risk of severe injury or death. Improper trailer condition and towing technique can
lead to an accident.
Obey the trailer manufacturer’s instructions and the instructions below to reduce
the risk of an accident.
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Wacker Neuson G625 User manual

Category
Power generators
Type
User manual

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