Wacker Neuson 0620649 Operator'S Manual Download

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5000185616

0911

5 0 0 0 1 8 5 6 1 6

Operator’s Manual

Mobile Generator

G 100

G 120

Summary of Contents for 0620649

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 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 ...

Page 3: ...derstand 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 infor...

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 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 question...

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

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

Page 7: ...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 Panel 36 4 3 Main Line Circuit Breaker 38 4 4 Engine Start Switch 39 4 5 Warning Light 40 4 6 Voltage Selector Switch 41 4 7 Voltage Selector Label 42 4 8 Adjusting Voltage with the Rheostat 43 4 9 Emer...

Page 8: ...tomatic 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 or Date 66 5 5 Changing User Preferences 67 5 6 Changing Disabling Low Fuel Fault 68 5 7 Changing Cooldown Time 69 6 Factory Installed Options 70 6 1 Block Heater 70 6 2 Automatic LCD Heat 71 6 3 Lo...

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 Technical Data 86 9 1 Engine 86 9 2 Generator 87 9 3 Trailer and Skid 88 9 4 Dimensions 89 10 Schematics 91 10 1 Engine Wiring 92 10 2 Engine Wiring Components 93 10 3 Electrical Schematic 94 10 4 El...

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

Page 11: ...e 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 symbol It is used to alert you to potential personal hazards f Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or ...

Page 12: ...ns 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 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 g...

Page 13: ...e 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 1 3 1 Do not operate the generator when open containers of fuel paint or other flammable liquids are near 1 3 2 Do not place flammable material or liquids near the generator ...

Page 14: ...ials 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 slide or fall while operating 1 3 19 Remove all tools cords and other loose items from the generator before starting it 1 3 20 Make sure the machine is well grounded and securely fastened to a good ear...

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 ventilated area Replace the fuel tank cap after refueling 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 pres...

Page 16: ...e 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 condition Replace worn tires Check that the lug nuts holding the wheels are tight and that none are missing Brakes and lights Before towing follow the instructions below to ensure that the brakes and li...

Page 17: ...o 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 transfer switch make sure the remote switch is also off and tagged 1 6 2 Ground Connection The generator must be connected to a good earthen ground for proper operating safety A central equipment gro...

Page 18: ...oose 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 equipment 1 6 12 Keep the machine clean and labels legible Replace all missing and hard to read labels Labels provide important operating instructions and warn of dangers and hazards 1 6 13 Check all exte...

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 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 ...

Page 20: ...isque 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 existe el peligro de una descarga electrica o de lesiones personales de una descarga electrica o de lesiones personales Peligro Arco voltaico de cortocircuito Peligro Arco voltaico de cortocircuito A...

Page 21: ...tion 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 yourself and others D NOTICE Never change switch position with engine running Results in damage to machine E WARNING Electric shock and arc flash can cause serious injury or death ...

Page 22: ...To 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 generator H WARNING Hot surface I WARNING Hot surface J WARNING To prevent hearing loss wear hearing protection when operating the machine WARNING Pressurized contents Do not open when hot WARNING Han...

Page 23: ...sk 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 utility lines This may result in electrocution of utility workers fire or explosion Connections to a building s electrical system must be made by a qualified electrician and comply with all applicable...

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 Manual for instructions ...

Page 25: ...ED 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 ANNUNCIATOR COMMON 51 PREALARM 53 PLUG 4 E STOP CANBUS CONTACT OUTPUTS E STOP 46 ALARM 52 BAT 55 49 GROUND TO ENCLOSURE BOX STUD START FUEL PRE HEAT HOUR METER 93 BLK RED WHT VIO YEL VIO GRY TAN WHT TAN 81 ...

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 indoors Electric shock and arc flash will cause serious injury or death DD NOTICE Receptacles not used when Selector switch set to 208 120V and voltage greater than 228V Selector switch set to 480 2...

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 effect at the time of manufacture The label includes the Vehicle Identification Number VIN for the trailer KK Trailer Wiring G Right brake light and directional Y Left brake light and directional Br Tail...

Page 28: ...t 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 operation of lube level maintainer OO Fill to top with engine oil only Close tank valve during transport ...

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 WARNING Electric shock can cause serious injury or death UU Camlock models only NOTICE Separate overcurrent protection must be provided Do not exceed 400 amps per receptacle ...

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: ...for 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 securely to the lifting eye 3 2 Towing the Machine Provided equipment The generator trailer is equipped with brakes lights and coupler connection Prerequisites Before towing the generator Check that ...

Page 32: ...by 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 operation of the electric brakes Licensing requirements In most states large trailers must be registered and licensed by the State Department of Transportation Before towing be sure to check licensi...

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

Page 34: ...standby 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 connected to the generator to operate incorrectly This could create unsafe operating conditions Do not exceed the rated current limit of any receptacle The bonding bar between the ground connections must...

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 refueling f Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner Static electricity can ignite the fuel or fuel vapors f Refuel only when the machine is outdoors f Clean...

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 Ø HZ V R Basler DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSEN DIAGNOSEN DIAGNOSTICOS DIAGNOSTICOS DIAGNOSTICS DIAGNOSTICS 6 5 1 2 4 3 ...

Page 37: ...ction 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 Circuit breaker 120V 20 Amp two 3 Down arrow button m Twist lock receptacle 120 240 VAC 50 Amp three 4 Left arrow key left backward n GFI receptacle 120 VAC 20 Amp two 5 Check mark button enter accept...

Page 38: ...y 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 these receptacles are powered even with the main breaker in the off O position f To turn off power to receptacles open the individual circuit breakers provided for each wc_gr005693 WARNING Possibility...

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 solenoid is disconnected Note When set in the REMOTE START or START RUN position the engine start switch applies battery power to the control module to turn on the LCD panel and also energizes the eng...

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 topic Navigating the Menus A Ø HZ V R Basler DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF REMOTE START REMOTE START FERNSTART FERNSTART ARRANQUE REMOTO ARRAN...

Page 41: ...eration 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 This allows the voltage setting to be locked in place to prevent unauthorized personnel from changing the voltage selection To lock the voltage selector switch in position push the locking mechanism up a...

Page 42: ...ock 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 receptacles will not be cut wc_gr005696 WARNING Hazardous voltage Improperly connected terminals can cause severe electrical shock burns or death f All connections to the terminals must be made by a qualifie...

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 solenoid and results in the engine shutting down The switch will remain activated until the button is pulled out NOTICE Press the emergency stop button only in the case of an actual emergency where the gener...

Page 44: ...achment 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 wrench to tighten the cable connections in place wc_gr005694 WARNING Electrocution hazard High voltage is present inside the hinged terminal door when the generator is operating f Do not open the hing...

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 having jurisdiction over electrical compliance If the generator is used at a construction site there may be additional regulations which must be observed In some areas generators are required to be ...

Page 46: ...ytime the generator is running even with the main line circuit breaker open Operating notes When the voltage selector switch is in the 480V 3Ø position voltage at the duplex receptacles is 139V and voltage at the 50A receptacles is 139 240V When the voltage selector switch is in the 208V 3Ø position voltage at the 30 50A receptacles is 120 208V When the voltage selector switch is in the 208V 3Ø po...

Page 47: ...ler 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 required make sure that the generator is grounded to a good earthen ground per local regulations and NEC standards check that all electrical connections were made in compliance with local regulations...

Page 48: ...EMERGENCY 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 After displaying INITIALIZING and NOT IN AUTO sequence the LCD display will read START DELAY followed by CRANKING as the engine begins its crank cycle The normal cycle is for the engine to crank for 12...

Page 49: ... 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 3Ø 277 480 3Ø 120 240 A Ø HZ V R Basler DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF REMOTE START REMOTE START FERNSTART FERNSTART ARRANQUE REMOTO ARRANQUE REMOTO DEMARRAGE A DEMARRAGE A DISTANCE DISTANCE START LAUFEN S...

Page 50: ...phase 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 Ø HZ V R Basler DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF REMOTE START REMOTE START FERNSTART FERNSTART ARRANQUE REMOTO ARRANQUE REMOTO DEMARRAGE A DEMARRAGE A DIS...

Page 51: ...put 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 Ø HZ V 208 P1 24 61 5 85 175 78 14 3 A Ø HZ V READY 100 175 0 13 2 ...

Page 52: ...es 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 high BATTERY Measures engine starting battery voltage Normal reading is 13 5 14 5V Check engine charging system if voltage falls sig nificantly outside this range Actual battery voltage is displayed wh...

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 Engine power correction factors Model Fuel temp rise of 1 C 1 8 F Air temp rise of 12 C 10 F Relative humidity rise of 10 Altitude rise of 305 m 1000 ft above 3050 m 10 000 ft Altitude rise of 305 m ...

Page 54: ...ECM 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 the generator due to an overcrank condition LOW FUEL A low fuel fault condition will be displayed when the fuel tank drops to 5 and the ECM has shut the engine down This fault condition prevents the ...

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 OVERLOAD 4 20 Event Log The control module contains an event log that records the first and last occurrences of pre alarms and alarms See Using the LCD and Keypad for instructions on how to access the event...

Page 56: ...f 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 main line circuit breaker 3 Let engine run for approximately 5 minutes to allow it to cool down 4 Move engine start switch to the off O position ...

Page 57: ...intake 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 Filter heater Your crankcase filter may be equipped with a thermostatically controlled heating system as shown in the illustration on the right This system prevents water vapor from condensing and freezi...

Page 58: ...n 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 for installation of a remote start switch When it is connected to a transfer switch it allows the generator to be used as a stand by power supply Connections When connecting a remote start switch or...

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 complete 3 Secure the generator by closing and locking all doors 4 Set the engine start switch to REMOTE START and close the main line circuit breaker The generator is now ready for automatic starting M...

Page 60: ...ls 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 utility lines and cause injury or death to utility workers f When the generator is used as a standby power supply it must be equipped with a device which isolates it from the utility s distribution sys...

Page 61: ...e 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 select items on a menu use the up down arrow buttons 2 3 to scroll through the available options When the desired option is highlighted as shown above press the right arrow button to access the menu for t...

Page 62: ...Level 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 Inputs Event Log J1939 Engine Config J1939 Active DTC J1939 Previous DTC Session kVAR Generator Bus V Bus Frequency Synchronizer Session Session Info Total Run Time Loaded Run Time Unloaded Run Time C...

Page 63: ...nu 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 Cooldown Time Power Crank Settings Pre Alarms Cumulative Programmable Inputs Cumulative Info RPM Rotations per minute Detailed Data Run Statistics Diagnostic Menu Navigation Session Down Session Info En...

Page 64: ...pears 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 button 1 to enter the character and move to the next position 5 2 3 Use the up down buttons to select the next character in the password and press the right arrow button Continue selecting and enter...

Page 65: ...n 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 Select FRONT PANEL HMI Press the right arrow button 5 3 5 Select LCD CONTRAST Press the right arrow button 5 3 6 If necessary enter your password See Entering Passwords for more information 5 3 7 Use the ...

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 DATE TIME Press the right arrow button 5 4 5 Select the item to change Press the check mark button 5 5 4 6 If necessary enter your password See Entering Passwords for more information 5 4 7 Use the up d...

Page 67: ...right 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 default Press the check mark button 5 5 8 Exit by repeatedly pressing the left arrow until the LCD panel display returns to monitoring status Changing System Language Many of the default English monitorin...

Page 68: ...three 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 ALARMS Press the right arrow button 5 6 5 Select LOW FUEL LEVEL Press the right arrow button 5 6 6 Select THRESHOLD Press the check mark 5 5 6 7 Enter your password See Entering Passwords for more i...

Page 69: ...w 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 Select CRANK SETTINGS Press the right arrow button 5 7 5 Select COOLDOWN TIME Press the check mark button 5 5 7 6 If necessary enter your password See Entering Passwords for more information 5 7 7 Use th...

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 typical installations The factory installed options on your machine may look different 6 1 Block Heater The engine block heater option includes a block heater a with a cord b The function of the block hea...

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 activates the heater to prevent damage to the LCD panel It is important to note that the panel control module draws a small amount of power from the battery when turned on even when the machine is not runn...

Page 72: ...n 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 necessary to open the radiator only do so with the engine off and only when coolant is cool enough to touch with bare hands Slowly loosen the radiator cap to relieve pressure first before removing it complet...

Page 73: ...evel 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 oil shutdown in case the oil in the reservoir is depleted If the engine shuts down due to low oil the ECM will display LOW OIL LEVEL Fill the engine and the additional oil reservoir with oil before pl...

Page 74: ...s 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 switch is available which disconnects the battery A padlock not included securely locks the switch in the OFF position If equipped the battery disconnect switch is mounted to the upper skid beneath t...

Page 75: ...camlock 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 Electric shock hazard f Do not operate this machine with defective or missing guards doors or protec tive interlocks ...

Page 76: ...t 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 located on the opposite side of the machine Disconnect the internal return hose from the tank fitting and connect it to the external return hose c Result The external fuel supply is now connected wc gr...

Page 77: ...r 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 walkaround inspection 3 Check tire inflation tread wear and lug nuts before towing 3 Check fuel filter 3 Service the battery Change engine oil and replace oil filter Clean unit inside and out Check a...

Page 78: ...while 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 STATISTICS CUMULATIVE CUMULATIVE Resetting from Main Menu The periodic maintenance timer can also be reset from the main menu 1 To access the main menu press the right arrow button 1 on the keypad g No...

Page 79: ...ator 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 cartridge c 10 Insert a new air filter cartridge 11 Re install the end cover making sure that the dust cap is clean and pointing downward 12 Make sure that the intake piping a is fully engaged over the ne...

Page 80: ...resent 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 the bottom of the filter head assembly Note Dispose of the used filter element and O rings in accordance with local envi ronmental protection regulations 5 Install a new O ring on the bottom of the fil...

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 should be used to make up any oil consumed during the break in period During the first 20 hours avoid prolonged periods of no load or sustained maximum load operation If engine is to run for longer than...

Page 82: ...ler 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 round Automotive type coolants do not contain the correct coolant addi tives to protect heavy duty diesel engines They often contain a high concentration of silicates which can damage the engine and...

Page 83: ...g 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 regular intervals Fill brake fluid to approximately 1 inch below top of reservoir using DOT 3 heavy duty brake fluid Tighten filler plug securely Note If fluid level has fallen too low bleed brake lines t...

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 protect the cylinder walls Make sure the stabilizer you use is compatible with the fuel in your area fuel type grade and temperature range Do not add extra alcohol to fuels which already contain it for e...

Page 85: ...k 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 oil filter Oil pump failure Fill engine sump with oil Replace oil filter Call for service High coolant temperature Overload Low coolant level Low oil level Clogged oil filter Reduce load Fill with c...

Page 86: ...l 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 power 1800 rpm kW Hp 99 133 118 158 Coolant capacity l qts 22 5 23 8 Oil capacity l qts 15 15 9 Battery Volts CCA 12 950 Fuel type type Clean filtered 1 or 2 diesel Fuel tank capacity l gal 756 199 8 F...

Page 87: ...zag 277 480 120 208 120 240 AC voltages available 1Ø V 3Ø V 120 127 139 240 254 277 208 220 240 416 440 480 Frequency 60 Hz Power factor 1Ø 3Ø 1 0 0 8 Voltage regulation 1 00 Insulation class H Sound level at 7 m 23 ft dB A 69 70 AC receptacles 2 duplex 3 twist lock 1Ø 120 GFI duplex Amps 2 20A 1Ø 120 240 V twist lock Amps 3 50A Standby output kW kVA 88 110 106 132 Prime output kW kVA 80 100 96 12...

Page 88: ...d 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 4534 9995 Surge brakes Fluid type Dot 3 Tires size 7 50 x 16E ...

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: ...RIP 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 PRE HEAT HEAT 93 93 BLK BLK RED RED WHT VIO WHT VIO YEL YEL VIO VIO GRY GRY TAN WHT TAN WHT TAN TAN 81 81 82 82 82 82 83 83 84 84 94 94 94 94 96 96 96 96 86 86 74 74 95 95 90 90 91 91 92 92 92 92 90 ...

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 Starter 14 Start relay 30 Alternator 15 Alternator charge 31 12V battery 16 B switched 32 Battery disconnect switch 17 Crank delay 33 John Deere engine ECU 18 Fuel level 34 Engine harness 19 Remote start 3...

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 control module 25 Main stator windings 13 Main breaker 26 Auxiliary stator winding 14 Bond bar 27 Stator 15 Voltage selector switch 28 Terminal strip Wire Colors BLK Black RED Red ORN Orange GRN Green...

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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 Grand Century Place 193 Prince Edward Road West Mongkok Kowloon Hongkong Tel 852 3605 5360 Fax 852 2758 0032 ...

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Wacker Neuson 0620649, Operator'S Manual

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