Wacker Neuson G50 User manual

Category
Power generators
Type
User manual

This manual is also suitable for

Operator’s Manual
Mobile Generator
G50
G70
Type G50, G70
Document 5200018221
Date
0918
Revision 06
Language EN
5200018221
Copyright notice
© Copyright 2018 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.
CALIFORNIA Proposition 65 Warning
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CALIFORNIA Proposition 65 Warning
WARNING
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
WARNING
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
WARNING
Cancer and Reproductive Harm -
www.P65Warnings.ca.gov.
WARNING
Batteries, battery posts, terminals and related accessories contain lead and lead
compounds, and other chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.
CALIFORNIA Proposition 65 Warning
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Notes
Mobile Generator Machine Identification
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Machine Identification
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models below. These instructions have been written expressly by
Wacker Neuson Production Americas LLC and must be followed during installation,
operation, and maintenance of the machines.
Machine
identification
A nameplate listing the model number, item number, revision number, and serial
number is attached to this machine. The location of the nameplate is shown above.
Serial number
(S/N)
For future reference, record the serial number in the space provided below. You will
need the serial number when requesting parts or service for this machine.
Machine Item Number
G50 5200001060, 5200001061, 5200001062, 5200001063,
5200001317, 5200006878, 5200008339, 5200014319,
5200014320, 5200014322, 5200014323, 5200017829,
5200017830, 5100014168, 5100014169
G70 5000620646, 5000620647, 5000620648, 5000620711,
5200008340, 5200008341, 5200001318, 5200003220,
5200003973, 5200003974, 5200003975, 5200004151,
5200006879, 5200008342, 5200008343, 5200008344,
5200014463, 5200014464, 5200014465, 5100014190,
5100014191
wc_gr010874
Serial Number:
Foreword G50 / G70
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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.
G50 / G70 Foreword
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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.
Foreword G50 / G70
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Notes
Table of Contents
Mobile Generator
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CALIFORNIA Proposition 65 Warning 3
Machine Identification 5
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 40
4.1 Lifting the Machine ..................................................................................... 40
4.2 Before Towing Checklist ............................................................................. 41
4.3 Towing the Machine ................................................................................... 42
4.4 Preparing the Machine for Transport on a Truck or Trailer ........................ 43
4.5 Hazardous Materials Placards ................................................................... 44
4.6 Testing the Breakaway System—Hydraulic Surge Brakes ......................... 45
4.7 Testing the Breakaway System—Electric Brakes ...................................... 47
5 Machine Setup 49
5.1 Preparing the Machine for First Use ........................................................... 49
5.2 Positioning the Machine ............................................................................. 50
5.3 Grounding the Generator ........................................................................... 52
5.4 Recommended Fuel ................................................................................... 53
5.5 Refueling the Machine—Basler Controller ................................................. 54
5.6 Refueling the Machine—Deep Sea Controller ........................................... 55
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6 Operation, Control, and Component Locations 56
6.1 Control and Component Locations ............................................................. 56
6.2 Control Panel Components ........................................................................ 57
7 Operation—Basler Controller 58
7.1 Main Circuit Breaker ................................................................................... 58
7.2 Engine Start Switch .................................................................................... 60
7.3 Generator Pre-Alarms and Alarms (Shut-Down Conditions) ...................... 61
7.4 Overcurrent Condition ................................................................................ 62
7.5 Function of the Crankcase Pressure Switch (if equipped) ......................... 63
7.6 Using the Lugs and the Convenience Receptacles ................................... 65
7.7 Selecting the Voltage ................................................................................. 66
7.8 Before Starting the Machine ....................................................................... 68
7.9 Starting and Running the Machine ............................................................. 69
7.10 Stopping the Machine ................................................................................ 72
7.11 Emergency Stop Switch ............................................................................. 72
7.12 LCD Panel: Monitoring Machine Operation ................................................ 73
8 Working with Basler Controller 75
8.1 How to Use the Generator Controller LCD and Keypad ............................ 75
8.2 Menu Diagram of the Generator Controller ................................................ 76
8.3 Menu Diagram Components ...................................................................... 77
8.4 Using the Metering and Settings Menus .................................................... 78
8.5 Logging in to the Generator Controller by Entering the Password ............. 79
8.6 Adjusting the LCD Screen Contrast ........................................................... 82
8.7 Changing the Time/Date Settings .............................................................. 83
8.8 Changing the Sender Fail Time Delays ..................................................... 84
8.9 Changing the Units of Measure .................................................................. 86
8.10 Changing the Low Fuel Pre-Alarm Setting ................................................. 88
8.11 Changing or Disabling the Low Fuel Alarm Setting .................................... 90
8.12 Changing the Cooldown Time Setting ........................................................ 92
8.13 Changing the Pre-Crank Time Delay (Glow Plug Timer) ........................... 94
8.14 Changing the Maintenance Interval ........................................................... 96
8.15 Resetting the Maintenance Interval Pre-Alarm .......................................... 98
8.16 Resetting a Loss of Voltage Pre-Alarm .................................................... 100
8.17 Accessing and Using the Event Log ........................................................ 101
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Mobile Generator
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9 Operation—Deep Sea Controller 103
9.1 Main Circuit Breaker ................................................................................. 103
9.2 Generator Controller Power Switch .......................................................... 104
9.3 Function of the Crankcase Pressure Switch (if equipped) ....................... 105
9.4 Selecting the Voltage ............................................................................... 107
9.5 Deep Sea Controller Buttons/Functions ................................................... 109
9.6 Generator Controller Alarms and Shut-Down Conditions ......................... 111
9.7 Before Starting the Machine ..................................................................... 113
9.8 Starting and Running the Generator ........................................................ 114
9.9 Stopping the Generator ............................................................................ 116
9.10 Emergency Stop Switch ........................................................................... 117
9.11 Engine and Generator Monitoring ............................................................ 118
10 Working with Deep Sea Controller: DSE 7310 MKII 119
10.1 Introduction ............................................................................................... 119
10.2 Navigating the Menus ............................................................................... 120
10.3 Adjusting Screen Contrast ........................................................................ 122
10.4 How to Reset the Maintenance Timer ...................................................... 123
11 How to Connect Loads—480V 124
11.1 Lug Terminal Connection Diagrams ......................................................... 124
11.2 Best Practices for Balancing Loads .......................................................... 125
11.3 Connecting 480V, 3-Phase and Single-Phase Loads .............................. 128
11.4 Connecting a 240V 3Ø Load and a 240V 1Ø Load .................................. 129
11.5 Connecting 240V and 120V Single-Phase Loads .................................... 130
11.6 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads ...................... 131
11.7 Connecting a 220–240V 3Ø Load and Multiple 127–133V
1Ø Loads .................................................................................................. 132
12 How to Connect Loads—600V 133
12.1 Lug Terminal Connection Diagrams ......................................................... 133
12.2 Best Practices for Balancing Loads .......................................................... 134
12.3 Connecting a 240V 3Ø Load and a 240V 1Ø Load .................................. 137
12.4 Connecting 240V and 120V Single-Phase Loads .................................... 138
12.5 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads ...................... 139
12.6 Connecting a 220–240V 3Ø Load and Multiple 127–133V
1Ø Loads .................................................................................................. 140
12.7 Connecting 480V, 3-Phase Loads ............................................................ 141
12.8 Connecting 600V, 3-Phase Loads ............................................................ 142
Table of Contents
Mobile Generator
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13 Using Remote Start Capabilities 143
13.1 Remote Run Terminal Block .................................................................... 143
13.2 Remote Transfer Switch ........................................................................... 144
13.3 Preparing for Automatic/Remote Start-Up—Basler .................................. 145
13.4 Preparing for Automatic/Remote Start-Up—Deep Sea ............................ 146
14 Diagnostic Trouble Codes (DTC) 148
14.1 Accessing DTCs with the Basler Controller .............................................. 148
14.2 Accessing Engine DTCs using the Deep Sea Controller ......................... 149
14.3 List of Engine Diagnostic Trouble Codes (DTCs) ..................................... 150
15 Factory-Installed Options 164
15.1 Battery Charger ........................................................................................ 164
15.2 Lockable Battery Disconnect .................................................................... 165
15.3 Camlocks .................................................................................................. 166
15.4 Containment System ................................................................................ 167
15.5 Extended Run Tank (ERT) ....................................................................... 167
15.6 Engine Block Heater ................................................................................. 168
15.7 Cold-Weather Thermostat ........................................................................ 169
15.8 Low Coolant Shutdown ............................................................................ 170
15.9 Temperature-Activated Shutters .............................................................. 171
15.10 Positive Air Shutoff Valve ......................................................................... 172
15.11 Connecting an External Fuel Supply ........................................................ 173
15.12 Lube Level Maintainer .............................................................................. 174
16 Machines with Aftertreatment Exhaust System 175
16.1 How the Aftertreatment Exhaust System Works ...................................... 175
16.2 Filling the DEF Tank ................................................................................. 176
16.3 Shelf Life of Diesel Exhaust Fluid (DEF) .................................................. 178
16.4 Monitoring and Control of the DEF Level ................................................. 179
16.5 Monitoring DEF Quality ............................................................................ 180
17 General Maintenance 181
17.1 Periodic Maintenance Schedule ............................................................... 181
17.2 Maintaining the Emission Control System ................................................ 182
17.3 Preparing for Maintenance ....................................................................... 182
17.4 Cleaning the Machine ............................................................................... 182
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17.5 Inspecting the Machine ............................................................................ 183
17.6 Maintaining the Trailer .............................................................................. 184
17.7 Checking and Draining the Containment System (if equipped) ................ 185
17.8 Checking the Exhaust System ................................................................. 186
17.9 Maintaining the Battery ............................................................................. 187
17.10 Cleaning the Diesel Particulate Filter (DPF) (if equipped) ........................ 188
17.11 Filling the Radiator ................................................................................... 189
17.12 Replacing the Aftertreatment DEF Dosing Unit Filter (if equipped) .......... 191
17.13 Storage ..................................................................................................... 193
17.14 Machine Disposal and Decommissioning ................................................. 194
18 Engine Maintenance: John Deere 4045TF285/HF285 6068HF285 195
18.1 Heavy Duty Diesel Engine Coolant .......................................................... 200
19 Engine Maintenance: John Deere 4045TF/280290 4045HF280 201
19.1 Heavy Duty Diesel Engine Coolant .......................................................... 205
20 Engine Maintenance: T4i Cummins QSB6.7 206
20.1 Coolant Recommendations and Specifications ........................................ 209
21 Maintenance Tier 4f Engines: Isuzu 210
21.1 Coolant ..................................................................................................... 215
22 Troubleshooting 216
23 Technical Data: G50, T4i John Deere 217
23.1 Engine ...................................................................................................... 217
23.2 Generator ................................................................................................. 218
23.3 Machine .................................................................................................... 219
23.4 Trailer and Skid ........................................................................................ 219
23.5 Dimensions ............................................................................................... 220
Table of Contents
Mobile Generator
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24 Technical Data: G50, T4f Isuzu 221
24.1 Engine ...................................................................................................... 221
24.2 Generator ................................................................................................. 222
24.3 Machine .................................................................................................... 223
24.4 Trailer and Skid ........................................................................................ 223
24.5 Dimensions ............................................................................................... 224
25 Technical Data: G70, T3 John Deere, 600V 225
25.1 Engine ...................................................................................................... 225
25.2 Generator ................................................................................................. 226
25.3 Machine .................................................................................................... 226
25.4 Trailer ....................................................................................................... 227
25.5 Dimensions ............................................................................................... 228
26 Technical Data: G70, T4i Cummins 229
26.1 Engine ...................................................................................................... 229
26.2 Generator ................................................................................................. 230
26.3 Machine .................................................................................................... 230
26.4 Trailer and Skid ........................................................................................ 231
26.5 Dimensions ............................................................................................... 232
27 Tire Safety Information 233
28 User’s Information for Transport Canada Fuel Tank 245
29 Emission Control Systems Information and Warranty—Diesel 248
29.1 Emission Control System Background Information .................................. 248
29.2 Limited Defect Warranty for Exhaust Emission Control System .............. 249
29.3 Limited Defect Warranty for Wacker Neuson Emission Control
Systems .................................................................................................... 249
30 General Machine Schematics 253
30.1 Fuses ........................................................................................................ 253
30.2 Trailer Wiring ............................................................................................ 254
30.3 Trailer Wiring Components ....................................................................... 255
Table of Contents
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31 Schematics—Machines with Deep Sea Controller 256
31.1 AC Schematic: G50 .................................................................................. 256
31.2 AC Schematic Components: G50 ............................................................ 257
31.3 DC Schematic: G50 .................................................................................. 258
31.4 DC Schematic Components: G50 ............................................................ 259
31.5 AC Schematic: G70 .................................................................................. 260
31.6 AC Schematic Components: G70 ............................................................ 261
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.
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Safety Information Mobile Generator
1.2 Machine Description and Intended Use
Machine
description
This machine is a mobile electric power source. The Wacker Neuson Mobile
Generator consists of a trailer-mounted cabinet containing an electric alternator, a
fuel tank, and a diesel engine. A control panel, receptacles, and connection lugs
are provided on the side of the cabinet. As the engine runs, the generator converts
mechanical energy into electric power. The operator connects loads to the electric
power receptacles and connection lugs.
Intended use
This machine is intended for the purpose of supplying electrical power to
connected loads. Refer to the product specifications for the output voltage and
frequency of this generator, and for the maximum output power limit of this
generator.
This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons in the area. Machine
damage caused by misuse is not covered under warranty.
The following are some examples of misuse:
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.
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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.
Safe
operating
practices
When operating this machine:
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Safety Information Mobile Generator
■ 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 G50 User manual

Category
Power generators
Type
User manual
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