Wacker Neuson G 100 Page 19 Operator'S Manual Download

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G 100 / G 120

Labels

wc_si000546gb.fm

Labels

2.1

Label Locations

A, Z

M, N

wc_gr006134

DIESEL

STOP

PELIGRO
DANGER

GEFAHR

DANGER

WARNING

WARNUNG

Lock doors. Access can cause electric shock or injury.
Arc flash hazard!

Turen schliessen! Zugang kann elektrischen Schlag oder
Verletzung verursachen. Gefahr: Kurzschlusslichtbogen!

Fermer les portes d'acces ou il pourrait en resulter
risque d'electrocution ou accidents de personne.
Danger: Arco de court-circuit!

AVERTISSEMENT

ADVERTENCIA

Cierre las puertas. Ya que de orto modo existe el peligro
de una descarga electrica o de lesiones personales.
Peligro: Arco voltaico de cortocircuito!

DIAGNOSTICS

DIAGNOSEN

DIAGNOSTICOS

DIAGNOSTICS

Summary of Contents for G 100

Page 1: ...5000185616 04 0911 5 0 0 0 1 8 5 6 1 6 Operator s Manual Mobile Generator G 100 G 120 EN...

Page 2: ...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...

Page 3: ...erstand 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 sta...

Page 4: ...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...

Page 5: ...G 100 G 120 Foreword wc_tx000994gb fm 5...

Page 6: ...Foreword G 100 G 120 6 wc_tx000994gb fm...

Page 7: ...2 Labels 19 2 1 Label Locations 19 2 2 Label Meanings 21 3 Lifting and Transporting 31 3 1 Lifting the Machine 31 3 2 Towing the Machine 31 4 Operation 34 4 1 Refueling the Machine 35 4 2 Control Pan...

Page 8: ...omatic Remote Start Up 59 4 26 Remote Transfer Switch 60 5 Using the LCD Panel and Keypad 61 5 1 Navigating the Menus 62 5 2 Entering Passwords 64 5 3 Adjusting Screen Contrast 65 5 4 Setting the Time...

Page 9: ...7 5 Replacing the Racor Filter Element if equipped 80 7 6 Lubricating the Engine 81 7 7 Checking the Engine Coolant Level 82 7 8 Maintaining the Trailer 83 7 9 Storage 84 8 Basic Troubleshooting 85 9...

Page 10: ...10 wc_bo5000185616_04TOC fm Table of Contents G 100 G 120...

Page 11: ...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 is the safety alert symb...

Page 12: ...s 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...

Page 13: ...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 protect...

Page 14: ...als Make sure that the area overhead is clear of debris that could fall onto or into the machine or exhaust compartment 1 3 18 Make sure the machine is on a firm level surface and will not tip roll sl...

Page 15: ...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 ve...

Page 16: ...vehicle hitch Tires and wheels Before towing follow the instructions below to ensure that the tires and wheels are ready for use Check the tires on the trailer for tread wear proper inflation and con...

Page 17: ...the control panel This will notify everyone that the unit is being serviced and will reduce the chance of someone inadvertently trying to start the unit If the unit is connected to a remote start or...

Page 18: ...ose clothing away from the moving parts of the generator and engine 1 6 11 Replace all guards fasten doors and make sure all safety devices operate properly after making repairs or servicing the equip...

Page 19: ...Arc flash hazard Turen schliessen Zugang kann elektrischen Schlag oder Verletzung verursachen Gefahr Kurzschlusslichtbogen Fermer les portes d acces ou il pourrait en resulter risque d electrocution o...

Page 20: ...sque d electrocution ou accidents de personne Danger Arco de court circuit Danger Arco de court circuit Cierre las puertas Ya que de orto modo existe el peligro Cierre las puertas Ya que de orto modo...

Page 21: ...ion B WARNING Pressurized contents Do not open when hot C WARNING Read and understand the supplied Operator s Manual before operating the machine Failure to do so increases the risk of injury to yours...

Page 22: ...o prevent hearing loss wear hearing protection Hand injury if entangled in moving belt Rotating machinery Do not reach inside with engine running WARNING Hot surface NOTICE Avoid spraying water into g...

Page 23: ...k of electrical shock and arc flash read the Operator s Manual Improper connection of the generator to a building s electrical system can allow electrical current from the generator to backfeed into u...

Page 24: ...wc_si000546gb fm P Q QA Operator s Manual must be stored on machine Replacement Operator s Manual can be ordered through your local Wacker Neuson distributor R Remote start operation Read Operator s M...

Page 25: ...D NC RED NC EMERGENCY STOP SWITCH VIO RED RED RED RED 10AWG GRN YEL BAT 2 80 83 84 85 RUN MODE 29 REMOTE START 28 MODE BREAKER 30 TRIPPED PLUG 2 CONTACT INPUTS TRIP BREAKER 56 E STOP 47 REMOTE ANNUNCI...

Page 26: ...to specify the model number item number revision number and serial number of the unit BB This machine may be covered by one or more patents CC DANGER Danger of asphyxiation Do not operate this machine...

Page 27: ...system if equipped JJ Certification Label VIN Number Also attached to each unit is a Certification Label This label specifies that the trailer conforms with all Federal Motor Vehicle Standards in effe...

Page 28: ...engine NOTICE Do not use the battery disconnect switch while engine is running Damage to the electrical components may occur MM Fuses NN if equipped NOTICE Mobile generator must be level for proper o...

Page 29: ...or neutral Starting in gear kills This label appears on the John Deere engine but does not apply to this machine SS Lug door must be closed for lugs and receptacles to energize TT Camlock models only...

Page 30: ...Labels G 100 G 120 30 wc_si000546gb fm VV Camlock models only WARNING Electric shock and arc flash can cause serious injury or death...

Page 31: ...or such work Lifting the generator A central lifting eye is located at the top of the generator and is attached to a lifting frame inside the housing When lifting the generator attach a hook or sling...

Page 32: ...y braking the vehicle at a slow speed before entering traffic Both the vehicle and the trailer should brake smoothly If the trailer seems to be pushing check the fluid level in the surge brakes or the...

Page 33: ...G 100 G 120 Lifting and Transporting wc_tx001191gb fm 33 Notes...

Page 34: ...tandby or substitute power supply make sure the voltage and phase rotation of the line connections match those of the utility lines Failure to match phase rotation and voltage may cause equipment conn...

Page 35: ...to refuel the machine is now complete WARNING Fire hazard Fuel and its vapors are extremely flammable Burning fuel can cause severe burns f Keep all sources of ignition away from the machine while ref...

Page 36: ...fm 4 2 Control Panel wc_gr006136 m n u p v a c f b e g d o h k q r s t A HZ V R Basler DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSEN DIAGNOSEN DIAGNOSTICOS DIAGNOSTI...

Page 37: ...tion terminal lugs door f Engine start switch v Voltage selector switch g Keypad not required for operation 1 Right arrow button right forward h Circuit breaker 240V 50 Amp three 2 Up arrow button k C...

Page 38: ...service to the generator unit make sure the main line circuit breaker is in the off O position NOTICE The convenience receptacles are not connected through the main line circuit breaker As a result t...

Page 39: ...switch immediately launches the engine start cycle and activates the starter motor to crank the engine Off O position In the off O position power to the engine s electrical system including the fuel...

Page 40: ...ine pre alarms Fuel Level 15 High Temperature 226 F Low Oil Pressure 20 psi Time to Service 250 hours Diagnostic Table Codes Active Engine Diagnostic Table Codes DTCs can be viewed in the menu See top...

Page 41: ...Operation Select the voltage range by rotating the handle on the voltage selector switch to the desired voltage Locking the voltage selector The voltage selector is equipped with a locking mechanism T...

Page 42: ...ck Switch The customer connection lugs panel access door is equipped with an interlock switch q When the door is opened this switch automatically trips the main circuit breaker Voltage to the receptac...

Page 43: ...lso from the rest of the metering panel Operation Activate the emergency stop switch by pressing the red button Activating the emergency stop switch opens the main circuit breaker and the fuel solenoi...

Page 44: ...chment of outside loads Connecting to the lugs Make connections to the lugs by running the power cables up through the slots in the bottom of the panel and into the lug Use a 5 16 inch or 8 mm Allen w...

Page 45: ...comply with the National Electrical Code and other federal state and local regulations For grounding requirements in your area consult with a qualified electrician electrical inspector or local agency...

Page 46: ...nytime the generator is running even with the main line circuit breaker open Operating notes When the voltage selector switch is in the 480V 3 position voltage at the duplex receptacles is 139V and vo...

Page 47: ...er wheels Internal and pre operation checks check engine oil coolant and fuel levels fill as required check the fan belt and hoses on the engine for loose connections or fraying tighten or replace as...

Page 48: ...MERGENCY STOP Pull out the emergency stop button after verifying the display and return the engine start switch to off O 7 Start engine by moving the engine start switch to the START RUN position 8 Af...

Page 49: ...ng the voltage adjustment rheostat on the metering panel Check frequency The frequency should read 60 Hz wc_gr006140 v p k h f a 120 208 3 277 480 3 120 240 A HZ V R Basler DIAGNOSTICS DIAGNOSEN DIAGN...

Page 50: ...hase mode the display will read L1 L3 or LL Amps A Displays the AC output amperage produced by the generator If the generator is operating at no load output amperage will display a 0 f A HZ V R Basler...

Page 51: ...tput frequency This gauge should read approximately 60 Hz under a no load condition If the frequency is too high check the engine rpm Sample display with engine running Sample display in Auto mode A H...

Page 52: ...s relative fuel level in the fuel tank Engine shuts down automatically at 5 level TEMPERATURE Displays temperature of engine coolant Engine shuts down automatically if coolant tem perature gets too hi...

Page 53: ...25 C 77 F air intake temperature 40 C 104 F fuel inlet temperature Refer to the table below to estimate the engine power decrease in percent as environmental factors vary from the standard conditions...

Page 54: ...CM has automatically shut the engine down OVERCRANK An overcrank fault is displayed when the engine fails to start during three cycles of the normal cranking cycle The ECM has automatically shut down...

Page 55: ...fault 3 To clear the overload fault reset the main circuit breaker Failing to reset the main circuit breaker will cause the machine to shut down after 5 minutes The display will then change to OVERLO...

Page 56: ...Make sure that the power shutdown will not create any hazards by turning off devices such as pumps heaters or lights that may need to be kept on 1 Remove all loads from generator 2 Open turn to off O...

Page 57: ...ntake system The crankcase filter contains a high performance element which should be replaced after every 750 hours of operation See Replacing the Racor Filter Element in the Maintenance chapter Filt...

Page 58: ...Terminal Block Location The remote run terminal block i is located just to the left of the convenience receptacle circuit breakers Description The remote run terminal block provides connection points...

Page 59: ...complete the start circuit Wait for the engine to crank start and run Move the engine start switch to off O to stop the engine Remove the jumper wire from the remote run terminals after testing is com...

Page 60: ...s supplied with the switch WARNING Electrocution hazard Failure to isolate the generator from the utility s electrical distribution system could cause output from the generator to backfeed into the ut...

Page 61: ...certain machine settings if desired 5 0 1 The various monitoring and configuration menus can be accessed by pressing the right arrow button 1 This action brings up the Main Menu screen 5 0 2 To selec...

Page 62: ...evel Total Run Time Settings General Settings Communications Generator Protection Breaker Management Bias Control Enter Password General Settings Crank Settings Alarm Status Alarms Pre Alarms Status I...

Page 63: ...u Conf Elements Configurable elements Maintenance Reset Conf Prot Status Configurable protection status Metering Configure Date Time Oil Pressure Coolant Level Outputs Coolant Temp PF Power factor Coo...

Page 64: ...ears with a blinking letter A as the default character Use the up down buttons 2 3 to change the A to the correct letter or number 5 2 2 When the correct letter or number appears press the right arrow...

Page 65: ...4 three times to access the main menu 5 3 2 Using the up down arrow buttons 2 3 select SETTINGS and press the right arrow button 5 3 3 Select GENERAL SETTINGS Press the right arrow button 5 3 4 Selec...

Page 66: ...to access the main menu 5 4 2 Using the up down arrow buttons 2 3 select SETTINGS and press the right arrow button 5 4 3 Select GENERAL SETTINGS Press the right arrow button 5 4 4 Select CONFIGURE DAT...

Page 67: ...ight arrow button 5 5 5 Select SYSTEM UNITS Press the check mark button 5 5 5 6 If necessary enter your password See Entering Passwords for more information 5 5 7 Select either METRIC or ENGLISH defau...

Page 68: ...hree times to access the main menu 5 6 2 Using the up down arrow buttons 2 3 select SETTINGS and press the right arrow button 5 6 3 Select ALARM CONFIGURATION Press the right arrow button 5 6 4 Select...

Page 69: ...4 three times to access the main menu 5 7 2 Using the up down arrow buttons 2 3 select SETTINGS and press the right arrow button 5 7 3 Select SYSTEM PARAMETERS Press the right arrow button 5 7 4 Sele...

Page 70: ...Number Item Number Revision and Serial Number is attached to each unit Please have this information available when contacting Wacker Neuson Note The illustrations shown in this chapter represent typic...

Page 71: ...a can be installed if the machine is to be used in extremely cold weather The thermostat automatically powers the panel control module when the temperature drops to approximately 30 C 22 F This activa...

Page 72: ...seconds coolant levels are still sensed as being low the ECM shuts down the engine The ECM will then display LOW COOL LEVEL Allow the engine to cool before adding additional coolant If it is necessar...

Page 73: ...vel is the same as that measured by the engine dipstick A float inside the valve detects low oil levels and opens the valve to supply the needed oil The system is wired to the ECM and includes a low o...

Page 74: ...cooling system As radiator coolant warms the wax pellet actuator engages a linkage c that opens the shutters As the coolant cools the shutters close 6 6 Lockable Battery Disconnect A lockable ON OFF...

Page 75: ...amlock connectors for easy tool changes Each connector is protected by a spring loaded cover NOTICE Separate overcurrent protection must be provided Do not exceed 400 amps per receptacle WARNING Elect...

Page 76: ...a on the curb side of the machine 2 Disconnect the internal feed hose d at the tank fitting and connect the internal feed hose to the external supply hose 3 The internal return hose e not shown is lo...

Page 77: ...2 weeks Every 250 Hrs or 10 weeks Every 600 Hrs or 12 Mo Every 1200 Hrs or 24 Mo Every 2000 Hrs Other Check engine oil and coolant level 3 Check engine air filter gauge air cleaner dust cap 3 Visual...

Page 78: ...hile viewing these menus press and hold the reset button 6 for 10 seconds If pre alarm is active Main screen METERING ALARM STATUS PRE ALARMS If pre alarm is not active METERING ENGINE METERING RUN ST...

Page 79: ...tor of the engine air filter gauge reaches the red line Procedure Follow the procedure below to replace the primary air filter element 9 Remove the end cover d then discard the entire air filter cartr...

Page 80: ...esent inside the canister so use caution to avoid spills 3 Pull the filter element down to remove it 4 Remove the O ring 5 from the top of the filter element end cap 7 Also remove the O ring 6 from th...

Page 81: ...change of John Deere Engine Break In Oil and a new John Deere oil filter NOTICE Do not add more oil until the oil level is BELOW the ADD mark on the dipstick John Deere Engine Break In Oil TY22041 sho...

Page 82: ...er cap seal for damage Clean the radiator filler cap or replace it if necessary 5 Re install the radiator filler cap NOTICE Solutions of antifreeze and supplemental coolant additives MUST be used year...

Page 83: ...lug nuts immediately Axle Hubs Grease axle hubs using a good wheel bearing grease Brakes Check operation of brakes before each trip Check level of brake fluid in actuator at front of trailer at regul...

Page 84: ...completing the procedures listed above fill the fuel tank completely and add a high quality stabilizer to the fuel Choose a stabilizer that includes cleaning agents and additives designed to coat prot...

Page 85: ...fuel lines No generator output Main circuit breaker open Lug door open Voltage regulator malfunc tion Close main circuit breaker Close lug door Call for service Low oil pressure Low oil level Clogged...

Page 86: ...fuel is not recommended Item No G 100 G 120 Engine Engine make John Deere 4 5L Engine model 4045HF285 Emissions Tier 3 Number of cylinders 4 Displacement cm in 4500 275 Engine speed rpm 1800 Rated po...

Page 87: ...zag 277 480 120 208 120 240 AC voltages available 1 V 3 V 120 127 139 240 254 277 208 220 240 416 440 480 Frequency 60 Hz Power factor 1 3 1 0 0 8 Voltage regulation 1 00 Insulation class H Sound leve...

Page 88: ...Skid Item No G 100 G 120 Generator Dry weight no trailer kg lbs 2131 4699 2143 4725 Operating weight no trailer kg lbs 2783 6137 2795 6163 Trailer weight without generator kg lbs 621 1370 GVWR kg lbs...

Page 89: ...G 100 G 120 Technical Data wc_td000298gb fm 89 9 4 Dimensions G 100 G 120 a mm in 2784 110 0 b 1143 45 0 c 1727 68 0 wc_gr005086 b a c...

Page 90: ...Technical Data G 100 G 120 90 wc_td000298gb fm Notes...

Page 91: ...G 100 G 120 Schematics wc_tx000998gb fm 91 10 Schematics This page is intentionally left blank...

Page 92: ...IP BREAKER 56 E STOP 47 E STOP 47 REMOTE ANNUNCIATOR REMOTE ANNUNCIATOR COMMON 51 COMMON 51 PREALARM 53 PREALARM 53 E STOP 46 E STOP 46 ALARM 52 ALARM 52 BAT 55 BAT 55 49 49 START START FUEL FUEL PRE...

Page 93: ...Lug door safety switch 5 Fuses 25 Mechanical lugs 6 Hour meter 26 Relay if equipped 7 Shunt trip relay 27 Intake heater if equipped 8 Contact inputs 28 Starter relay 13 21 position connector 29 Starte...

Page 94: ...Schematics G 100 G 120 94 10 3 Electrical Schematic 36 36 CT CT CT CT CT CT OR OR WHT WHT BR BR Y 6 6 7 7 7 7 PLUG 5 PLUG 5 CURRENT CURRENT TRANSFORMER TRANSFORMER CT CT CT CT C CT CT CT CT CT CT...

Page 95: ...line voltage inputs 19 Terminal block 5 Shunt 20 Exciter 6 120V 20A GFI receptacle 21 Stator 7 120V breaker 22 Rotor 8 240V 50A breaker 23 Rectifier 10 240V 50A receptacle 24 Rotor winding 12 Engine c...

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Page 98: ...02 390 Wacker Neuson Production Americas LLC N92W15000 Anthony Ave Menomonee Falls WI 53051 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Neuson Limited Room 1701 03 1717 20 17 F Tower 1 G...

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