en Mobile Generator G 32 OPERATOR S MANUAL

Transcription

1 en Mobile Generator G 32 OPERATOR S MANUAL E N

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3 G 32 Foreword Foreword Machines covered by this manual Machine Item Number G Machine Documentation Keep a copy of the Operator s Manual with the machine at all times. Use the separate Parts Book supplied with the machine to order replacement parts. If you are missing any of these documents, please contact Wacker Neuson Corporation to order a replacement or visit 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 Corporation 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 Corporation reserves the right to change any portion of this information without notice. Copyright notice All rights, especially copying and distribution rights, are reserved. Copyright 2008 by Wacker Neuson Corporation. This publication may be reproduced through photocopying by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights, and violators will be prosecuted. Trademarks All trademarks referenced in this manual are the property of their respective owners. wc_tx000897gb.fm 3

4 Foreword G 32 wc_tx000897gb.fm 4

5 G 32 Table of Contents Foreword 3 1 Safety Information Signal Words Found in this Manual Safety Instructions for Operating the Machine Safety Instructions for Towing Safety Instructions for Servicing the Machine Label Locations Label Meanings Transporting, Lifting, and Storing Transporting Storing Lifting Operating the Machine Application Control/Component Locations Control/Component Descriptions Control Panel/Microprocessor Control Panel/Microprocessor Functions Main Control Switch Positions/Functions Preliminary Checklist Starting the Generator Stopping the Generator Connecting Loads to the Terminal Lugs Operating the Generator Microprocessor Display Screens Maintenance Periodic Maintenance Schedule Checking the Engine Oil wc_bo _001toc.fm 5

6 Table of Contents G Changing the Engine Oil Changing Oil Filter Changing the Fuel Filter Air Cleaner Discharge Valve Cleaning/Changing Air Filter Cartridges Checking the Alternator V-Belt Lubricating the Trailer Cleaning the Engine Changing/Tensioning Alternator V-Belt Checking/Adjusting Valve Clearances Checking Battery Electrolyte Schematics Power Wiring Power Wiring Components Engine Wiring Engine Wiring Components Socket Wiring Socket Wirng Components Control Wiring Control Wiring Components Basic Troubleshooting 56 7 Technical Data Machine Engine Dimensions Sound Specification...61 wc_bo _001toc.fm 6

7 50Hz Mobile Generators 1 Safety Information 1.1 Signal Words Found in this Manual Safety Information 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. Obey all safety messages that follow this symbol to avoid injury or death. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. Obey all safety messages that follow this symbol to avoid possible injury or death. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Obey all safety messages that follow this symbol to avoid possible minor or moderate injury. NOTICE: Used without the safety alert symbol, NOTICE indicates a situation which, if not avoided, could result in property damage. Note: Contains additional information important to a procedure. wc_si000271gb.fm 7

8 Safety Information 1.2 Safety Instructions for Operating the Machine 50Hz Mobile Generators DANGER Electric shock hazard. Backfeed from the generator into the public power distribution system can seriously injure or kill 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. 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. Do not use accessories or attachments that are not recommended by Wacker Neuson Corporation. 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 Corporation 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. 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. Wear protective clothing appropriate to the job site when operating the machine. Wear safety glasses when operating this machine. Wear hearing protection when operating this machine. When operating this machine: Do not operate a machine in need of repair. wc_si000271gb.fm 8

9 50Hz Mobile Generators Safety Information Work area Be aware of the work 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. Keep the machine at least one meter (three feet) away from structures, buildings, and other equipment during use. Keep the area immediately surrounding and underneath the machine clean, neat, and free of debris and combustible materials. Make sure that the area overhead is clear of debris that could fall onto or into the machine or exhaust compartment. Make sure the machine is on a firm, level surface and will not tip, roll, slide, or fall while operating. Be aware of the application area. Never operate the machine indoors unless exhaust fumes can be adequately ventilated. Never operate the machine in areas that contain flammable objects, fuels, or products that produce flammable vapors. Never operate the machine if you or the machine are in water. Electrical safety To increase electrical safety while operating this machine, follow the procedures below. Do not operate the generator, or tools attached to the generator, with wet hands. Do not use worn electrical cords. Make certain the machine is well-grounded and securely fastened to a good earthen ground per national and local regulations. Do not overload the generator. The total amperage of the tools and equipment attached to the generator must not exceed the load rating of the generator. Storing the machine 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. wc_si000271gb.fm 9

10 Safety Information 50Hz Mobile Generators 1.3 Safety Instructions for Towing WARNING Towing a trailer requires special care. To reduce the possibility of an accident: Both the trailer and the vehicle must be in good working condition. The trailer and the vehicle must be securely fastened to each other. Hitch and coupling To reduce the possibility of an accident, perform the following before towing. Check that the hitch and coupling on the vehicle are rated equal to, or greater than, the trailer's gross vehicle weight rating (GVWR). Inspect the hitch and coupling for wear or damage. DO NOT tow the trailer using defective parts. Make sure the coupling is securely fastened to the vehicle. Connect the safety chains. Connect the breakaway cable safety hook to the bumper or rear of the vehicle. Do not attach it to the hitch. Tires and wheels To reduce the possibility of an accident, perform the following before towing. Check the condition, tread wear, and air pressure of the trailer tires. Replace worn tires. Check that the wheel lug nuts are tight and that none are missing. Brakes and lights To reduce the possibility of an accident, perform the following before towing. Test the brake linkage on the trailer and the brakes on the towing vehicle. Make sure directional and trailer lights are connected and working properly. wc_si000271gb.fm 10

11 50Hz Mobile Generators 1.4 Safety Instructions for Servicing the Machine Safety Information WARNING A poorly maintained machine can be a personal injury hazard. Follow the Periodic Maintenance schedule in this Operator s Manual. Repair or replace any damaged or defective components immediately. 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 Corporation 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 Safe servicing practices Machine modifications Follow the precautions below 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 operation. Do not operate the machine with a known problem or deficiency. When servicing and maintaining this machine: Be aware of the machine s moving parts. Keep hands, feet, and loose clothing away from the machine s moving parts. Wear protective clothing appropriate to the job. Wear safety glasses. Wear hearing protection if required. Re-install the safety devices and guards after repairs and maintenance. When servicing or maintaining the machine: Use only accessories/attachments recommended by Wacker Neuson Corporation. When servicing or maintaining the machine: Do not defeat the safety devices. Do not modify the machine without the express written approval of Wacker Neuson Corporation. wc_si000271gb.fm 11

12 Safety Information 50Hz Mobile Generators Replacing parts and labels Replace worn or damaged components. Use only spare parts recommended by Wacker Neuson Corporation. Replace all missing and hard-to-read labels. When replacing electrical components, use components that are identical in rating and performance as the original components. Before servicing Lifting and transporting Complete the following procedures before servicing the machine. Turn off the machine. Open the circuit breakers ( OFF ). Disconnect the battery. Attach a DO NOT START sign to the control panel. Make sure that the remote start or transfer switch (if used) is also off and tagged. Let the engine cool. When lifting the machine: Make sure slings, chains, hooks, ramps, jacks and other types of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. Be aware of the location of other people when lifting the machine. To reduce the possibility of injury: Do not stand under the machine while it is being hoisted or moved. Do not get onto the machine while it is being hoisted or moved. wc_si000271gb.fm 12

13 50Hz Mobile Generators Notes Safety Information wc_si000271gb.fm 13

14 Safety Information 1.5 Label Locations 50Hz Mobile Generators a b c wc_gr wc_si000271gb.fm 14

15 50Hz Mobile Generators Safety Information 1.6 Label Meanings Ref. Label Definition a Attention! Work with hood closed b WARNING! Electric shock will cause serious injury or death. c Electrical ground GND d Internal fuel tank connection External fuel tank connection wc_si000271gb.fm 15

16 Transporting, Lifting, and Storing 50Hz Mobile Generators 2 Transporting, Lifting, and Storing 2.1 Transporting 2.2 Storing When transporting the machine, only use transport vehicles with enough weightbearing capacity for both the generator and the trailer. See section Technical Data. Secure the generator and the trailer to the transport vehicle. When storing the machine for more than 30 days: Drain the fuel tank. Change the engine oil. Disconnect the battery. Clean the machine. Cover the machine. wc_tx000895gb.fm 16

17 50Hz Mobile Generators 2.3 Lifting Transporting, Lifting, and Storing Prerequisites Engine shut down Appropriate lifting equipment (see section Technical Data for weights) Procedure Follow the procedure below to lift the machine. WARNING Crush hazard. The weight of the machine may crush you if the lifting equipment fails. Crushing may cause severe injury or death. Only use lifting equipment with enough lifting capacity to support the weight of the machine and the trailer. 1. Turn off the engine. 2. Disconnect all loads. 3. Secure all doors in the closed position. 4. Connect an appropriate crane to the lifting eye (a) and lift the machine as needed. A fork truck may also be used. Use the fork lift pockets (b) in the frame of the machine. WARNING Crush hazard. The weight of the machine may crush you if the lifting equipment fails. Crushing may cause severe injury or death. Do not stand underneath the machine when it is being lifted. wc_tx000895gb.fm 17

18 Transporting, Lifting, and Storing Notes 50Hz Mobile Generators wc_tx000895gb.fm 18

19 50Hz Mobile Generators 3 Operating the Machine 3.1 Application Operating the Machine Generator application This machine is a heavy-duty, compact, sound-attenuated generator designed to provide single and three-phase power for construction, commercial, and industrial applications where reliable power is needed.. Safety notices Do not exceed the power output of the generator. Damage to tools or generator will occur. Refer to Technical Data. When using the generator as a standby or substitute power supply, make sure the voltage and phase rotation of the line connections match those of the mains 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. wc_tx000884gb.fm 19

20 Operating the Machine 3.2 Control/Component Locations 50Hz Mobile Generators a b c d e f p m l k j i h g wc_gr wc_tx000884gb.fm 20

21 50Hz Mobile Generators 3.3 Control/Component Descriptions Operating the Machine Ref. Description Ref. Description a Emergency stop switch Pressing this push button stops the generator immediately. When pressed, the LCD display reads: ALARM EMERGENCY. To release the emergency status, place the main control switch in the LOCK position, then turn and pull out the emergency stop switch. i Socket 220V, 16A, 1P +N CEE/IEC309 b c d e f g h Main circuit breaker The main circuit breaker controls voltage to both the lugs and to the individual circuit breakers. Microprocessor The microprocessor controls the operation of the generator. 3-phase voltage lugs Connection point for 400V, 3Ø loads. Alternator MeccAlte alternator (generator) Engine Deutz Grounding stake The grounding stake is used to connect the machine to earthen ground. Socket 250V, 16A, 1P + N Shuko j k l m n o p Socket 380V, 16A, 3P +N CEE/IEC309 Socket 380V, 32A, 3P +N CEE/IEC309 Socket 380V, 63A, 3P +N CEE/IEC309 Individual circuit breaker panel Each socket has its own individual circuit breaker. Battery cut-off switch This switch disconnects the battery from the engine and the microprocessor. External fuel tank connection point and control valves Engine protection switch This switch controls battery power to the engine and the microprocessor. wc_tx000884gb.fm 21

22 Operating the Machine 3.4 Control Panel/Microprocessor 50Hz Mobile Generators a b c q p o n CR d ENTER CG e m l k j i h g f r 3.5 Control Panel/Microprocessor Functions Ref. Description Ref. Description a LCD display The microprocessor displays the various functions and alarms of the generator in this window. j Charging system LED This LED illuminates when the charging system is active. This LED will flash when there is a problem with the charging system. b Reset button Pressing this button once silences the audible alarm. Pressing it again resets the microprocessor. k Alternator LED This LED illuminates when the alternator is active. This LED will flash when there is a problem with the alternator. wc_tx000884gb.fm 22

23 50Hz Mobile Generators Operating the Machine Ref. Description Ref. Description c Main control switch l Trip LED This LED illuminates when the main breaker has tripped. d e f g h i Microprocessor status LED This LED flashes when the microprocessor is computing a function. Fuel pump button Pressing this button activates the auxiliary fuel pump. This switch is only used with an optional auxiliary fuel tank which is not offered on this machine. Stop button Pressing this button stops the engine. Start button Pressing this button starts the engine when the main control switch is in the MANUAL START position. Engine protection LED This LED illuminates when the engine protection system is active. This LED will flash when there is a problem with the engine. Battery LED This LED illuminates when the battery is charged. This LED will flash when there is a problem with the battery. m Mains LED This LED illuminates when the mains is connected and supplying voltage. n CR Contact LED This LED illuminates when contacts CR are closed signifying that the Mains is the source supply of voltage to the end consumer. o CG Contact LED This LED illuminates when contacts CG are closed signifying that the generator is the source supply of voltage to the end consumer. p Down arrow button ( ) Pressing this button scrolls backward through the screens of the LCD display. q Up arrow button (+) Pressing this button scrolls forward through the screens of the LCD display. r Engine Protection Switch This switch connects battery power to the microprocessor. The microprocessor then monitors: high water temperature, low oil pressure, overspeed, battery charger failure, low fuel level, and a general programmable alarm. Once the unit detects the alarm, it will stop the engine after a certain time, programmed internally and not changeable. wc_tx000884gb.fm 23

24 Operating the Machine 3.6 Main Control Switch Positions/Functions 50Hz Mobile Generators Position AUTOMATIC TEST AUTOMATIC RUNNING LOCKED ENGINE Description With the control switch in this position: The engine will start automatically. The microprocessor will test the function of the generator systems. The results of the tests are displayed on LCD screens. Scroll through the LCD screens by using the arrow keys. The tests do not require the mains supply to be disconnected from the end consumer. With the control switch in this position: The engine will start automatically if the machine is not connected to a mains supply. The microprocessor is programmed to route power (CR closed) from the mains supply to the end consumer (utility) unless a problem with the mains supply is detected. At such a time, the microprocessor starts the generator and routes power (CG closed, CR open) from the generator to the end consumer. At the point where the mains supply is again stable, the microprocessor closes contacts CR and opens contacts CG. The engine will run for approximately 1 minute to allow it to cool. With the control switch in this position: The engine will not start. Power to all generator systems is disconnected. The mains supply is the sole source of power to the end consumer if connected. wc_tx000884gb.fm 24

25 50Hz Mobile Generators Position MANUAL MAINS MANUAL START MANUAL GEN SET Description Operating the Machine With the control switch in this position: The engine will not start even if the START push button is pressed. The microprocessor is programmed to always use the mains as the supply for the end consumer. The mains contacts (CR) are closed. The generator contacts (CG) are open. With the control switch in this position: The engine will start when the START push button is pressed. The microprocessor is programmed to monitor engine functions and generator output. With the control switch in this position: The engine will not start even if the START push button is pressed. The microprocessor is programmed to always use the generator as the supply for the end consumer (utility). The mains supply contacts (CR) are open. The generator contacts (CG) are closed. wc_tx000884gb.fm 25

26 Operating the Machine 3.7 Preliminary Checklist 50Hz Mobile Generators Prerequisites Machine on a flat, horizontal surface Wheels of trailer chocked Procedure Have a certified electrician set up the generator. Complete the following preliminary checks before putting the generator into service. 1. Make a walk-around inspection of the generator. Open side doors and visually inspect engine compartment for obvious damage or the presence of foreign objects which might affect operation. 2. Fill the engine cooling system with coolant. See the engine manual. 3. Check and fill the engine sump with oil. See the engine manual. 4. Check the engine air filter. 5. Check the fuel level. Fill the fuel tank if necessary. 6. Remove the grounding stake (a) from the machine and drive it into the ground. 7. Connect the cable form the grounding stake to the machine at the grounding location (b). 8. Connect the battery. wc_tx000884gb.fm 26

27 ENTER CR CG 50Hz Mobile Generators 3.8 Starting the Generator Operating the Machine Prerequisites Machine on a flat, horizontal surface Wheels of trailer chocked Procedure Follow the procedure below to start the generator. 1. Disconnect all loads from the generator. 2. Place the battery cut-off switch (n) in the ON position. 3. Place the fuel valves (o) in the appropriate OPEN position. 4. Place the control switch in the MANUAL START position. 5. Turn the ENGINE PROTECTION switch to the ON position (1). 6. Press the START push button. Release the START push button when the engine starts. NOTICE: Do not hold the START push button depressed for more than 20 seconds. Damage to the starter may occur. Allow 30 second of cooling time between starting attempts. wc_tx000884gb.fm 27

28 ENTER CR CG Operating the Machine 3.9 Stopping the Generator 50Hz Mobile Generators Prerequisites All tools disconnected from generator Wheels of trailer chocked Procedure Follow the procedure below to stop the generator. 1. Disconnect all tools from the generator. 2. Place the main circuit breaker and the individual circuit breakers in the OFF position. 3. Allow the engine to run 2 3 minutes to cool down. 4. Press the STOP push button. 5. Turn the ENGINE PROTECTION switch to the OFF position (0). 6. Place the control switch in the LOCKED ENGINE position. 7. Place the battery cut-off switch (l) in the OFF position. If storing the machine, see section Transporting, Lifting, and Storing. wc_tx000884gb.fm 28

29 50Hz Mobile Generators 3.10 Connecting Loads to the Terminal Lugs Operating the Machine Prerequisites Engine shut down Wheels of trailer chocked The appropriate qualifications and training mandated by the country where the generator will be installed. If you do not have the appropriate qualifications, do not continue with this procedure. Procedure Follow the procedure below when connecting to the terminal lugs. WARNING Electric shock hazard. High voltage exists at the terminal lugs when the engine is running. Electric shock can cause severe injury or death. Do not attempt to connect cables to the terminal lugs while the engine is running. 1. Shut down the engine. 2. Place the main circuit breaker in the OFF position. 3. Remove the screw that secures the terminal lug door (a). 4. Open the terminal lug door. 5. Connect the cables to the terminal lugs. 6. Close the terminal lug door. 7. Secure the cables with the latching device (b). wc_tx000884gb.fm 29

30 Operating the Machine 3.11 Operating the Generator 50Hz Mobile Generators Prerequisites All preliminary checks made Wheels of trailer chocked Procedure Follow the procedure below when operating the generator. WARNING Electric shock hazard. High voltage exists at the terminal lugs when the engine is running. Electric shock can cause severe injury or death. Do not attempt to connect cables to the terminal lugs while the engine is running. 1. Place the main circuit breaker (a) and the individual circuit breakers (b) in the OFF position. 2. Connect the cables to terminal lugs if the load requires this type of connection. 3. Start the engine. 4. Place the main circuit breaker in the ON position. 5. Connect loads as required using the appropriate socket(s). 6. Place the individual circuit breakers in the ON positions as needed. wc_tx000884gb.fm 30

31 50Hz Mobile Generators 3.12 Microprocessor Display Screens Operating the Machine The following screens appear when the control switch is placed in the TEST position. Scroll through the screens using the control panel arrow keys. GEN. I1 32 I2 0 I3 0 GEN. V1N V2N V3N GEN. V12 V23 V GEN. V HZ 50.1 I1 32 This screen shows the amp draw (load) on each individual phase. This screen shows the voltage between each phase and neutral. This screen shows the voltage between one phase and another. This screen shows frequency, voltage, and current on phase 1. DIF RET 0.00 (0.30)A 0.3)S This screen shows the programmed values of the differential protection system. MON 18:02:05 This screen shows the day, date, and year. It resets each time the battery is disconnected. STARTING 135 FAILED STARTING 1 This screen shows the number of starting occurrences and the number of failed starting attempts. OUT ABC This screen shows the status of any outputs setup by the installation engineers. IN ABCD This screen shows the status of any inputs setup by the installation engineers. HOUR-METER 4 h 7m 40S 1500RPM LC 92% PO 4.4bar TM 83 C This is the hour meter display. This screen shows: engine rpm, fuel percentage (LC); oil pressure (PO); engine temperature (TM). BATTERY CHARGER 27.2V 1.4A GEN. KWh This screen shows battery voltage and amp draw. This screen shows the supplied voltage from the genset in kilowatt hours. wc_tx000884gb.fm 31

32 Operating the Machine GEN. COS. L 1.00 FREQ 50.0HZ 50Hz Mobile Generators This screen shows the power factor phase displacement angle between voltage and current (COS.). For inductive loads: L 0.xx; for capacitive loads: C 0.xx. GEN. 7KVA 0KVAr 7KW This screen shows generator power: apparent kva, actual kw, and reactive kvar. The following screens appear when the control switch is placed in the TEST position while the generator is connected to the mains supply. Scroll through the screens using the control panel arrow keys. MAIN 7KVA 0KVAr 7KW This screen shows the amp draw (load) on each individual phase. MAIN V1N V2N V3N MAIN V12 V23 V MAIN V HZ 50.0 I1 22 This screen shows the voltage between each phase and neutral. This screen shows the voltage between one phase and another. This screen shows frequency, voltage, and current on phase 1. DIF RET 0.00 (0.30)A 0.3)S This screen shows the programmed values of the differential protection system. MON 18:02:05 This screen shows the day, date, and year. It resets each time the battery is disconnected. STARTING 135 FAILED STARTING 1 This screen shows the number of starting occurrences and the number of failed starting attempts. OUT ABC This screen shows the status of any outputs setup by the installation engineers. IN ABCD This screen shows the status of any inputs setup by the installation engineers. HOUR-METER 4 h 7m 40S 1500RPM LC 92% PO 4.4bar TM 83 C This is the hour meter display. This screen shows: engine rpm, fuel percentage (LC); oil pressure (PO); engine temperature (TM). wc_tx000884gb.fm 32

33 50Hz Mobile Generators BATTERY CHARGER 27.2V 1.4A MAIN COS. L 1.00 FREQ 50.0HZ Operating the Machine This screen shows battery voltage and amp draw. This screen shows the power factor phase displacement angle between voltage and current (COS.). For inductive loads: L 0.xx; for capacitive loads: C 0.xx. MAIN 7KVA 0KVAr 7KW This screen shows generator power: apparent power kva; actual power kw; reactive power kvar. wc_tx000884gb.fm 33

34 Maintenance 4 Maintenance 4.1 Periodic Maintenance Schedule 50Hz Mobile Generators Refer to the Deutz engine manual for detailed information on maintaining the engine. Interval* (hours of service) (10) (250) (500) (1000) (2000) (6000) Item Task Daily 3 months 6 months Yearly 2 years 6 years Air cleaner Check Battery connections Check Engine lube oil level** Check Fuel level Check Air cleaner discharge valve Clean Air cleaner filter cartridge Clean Alternator V-belt Check Battery electrolyte level Check Air cleaner valve Clean Air cleaner filter cartridge Clean Battery electrolyte density Check Engine Clean Engine oil and filter Change Fuel filter Replace Trailer Lubricate Valve clearances Check/ adjust Air cleaner safety cartridge Change Alternator V-belt Change Engine Partial overhaul * Use whichever comes first, calendar time or service hours. ** Change engine oil and filter after first 50 hours of operation. wc_tx000885gb.fm 34

35 50Hz Mobile Generators 4.2 Checking the Engine Oil Maintenance Prerequisites Machine on a level surface Engine off When Procedure Every 10 hours of service or daily Follow the procedure below to check the engine oil. 1. Clean around the dipstick (a). 2. Remove the dipstick and wipe it clean. 3. Re-insert the dipstick and check the oil level. Maintain the oil level between the MAX and MIN marks on the dipstick. 4. Remove the oil filler cap and add oil as needed. See Technical Data for oil type and amount. NOTICE: Do not overfill the machine with oil. Engine damage may result. Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 35

36 Maintenance 4.3 Changing the Engine Oil 50Hz Mobile Generators Prerequisites Machine on a level surface Engine off Engine oil warm approximately 80 C (176 F) Oil tray Drain plug seal ring When Procedure Every 1000 hours of service or yearly Follow the procedure below to change the engine oil. 1. Place the oil tray underneath the engine. CAUTION Burn hazard. Hot engine oil can cause burns. Avoid touching the hot oil. 2. Remove the drain plug and drain the oil into the oil tray. Note: Collect, store and dispose of all used oil and filters in accordance with current environmental protection regulations. 3. Attach a new seal ring to the drain plug. 4. Install the drain plug into the engine. 5. Remove the oil filler cap and add oil as needed. See section Technical Data for type and quantity. NOTICE: Do not overfill the machine with oil. Engine damage may occur. wc_gr Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 36

37 50Hz Mobile Generators 4.4 Changing Oil Filter Maintenance Prerequisites Machine on a level surface Engine off Engine oil warm approximately 80 C (176 F) New oil filter When Procedure Every 1000 hours of service or yearly Follow the procedure below to change the oil filter. 1. Place the oil tray underneath the engine. CAUTION Burn hazard. Hot engine oil can cause burns. Avoid touching the hot oil. 2. Remove the oil filter. Catch any dripping oil. Note: Collect, store and dispose of all used oil and filters in accordance with current environmental protection regulations. 3. Clean the filter housing base. 4. Apply a thin coat of engine oil to the seal of the new oil filter. 5. Install the new filter cartridge and tighten by hand. When the seal contacts the base, tighten the filter cartridge an additional 1/2 turn. 6. Start and run the engine for a few minutes, then switch off the engine. 7. Check the oil level. Add oil as needed. Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 37

38 Maintenance 4.5 Changing the Fuel Filter 50Hz Mobile Generators Prerequisites Engine off New fuel filter When Procedure Every 1000 hours of service or yearly Follow the procedure below to change the oil filter. 1. Close the fuel shut-off valve(s). WARNING Fire hazard. Diesel fuel is flammable. Fire can cause severe burns. Keep flames and smoking materials away from the fuel system. 2. Remove the fuel filter. Clean up any spilled fuel. Note: Collect, store and dispose of all used fuel and filters in accordance with current environmental protection regulations. 3. Clean the filter housing base. 4. Apply a thin coat of engine oil or diesel fuel to the seal of the new fuel filter. 5. Install the new filter cartridge and tighten by hand. When the seal contacts the base, tighten the filter cartridge an additional 1/2 turn. 6. Open the fuel shut-off valve(s). 7. Start the engine and check for leaks. Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 38

39 50Hz Mobile Generators 4.6 Air Cleaner Discharge Valve Maintenance Prerequisites Engine off Machine cool When Procedure Every 250 hours of service or every 3 months Follow the procedure below to empty the air cleaner discharge valve. 1. Empty the air cleaner discharge valve (1) by pressing apart the lips of the discharge slot as indicated by the arrows. 2. Remove any caked dirt by pressing together section of valve. Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 39

40 Maintenance 50Hz Mobile Generators 4.7 Cleaning/Changing Air Filter Cartridges Prerequisites Engine off Source of compressed air When Procedure Every 500 hours of service or every 6 months (safety cartridge: 2 years) Follow the procedure below to clean/change the air filter cartridges. 1. Unclip the fasteners (1). 2. Remove hood (2). 3. Remove cartridge (3). 4. Clean cartridge (3) with compressed air, blowing from inside to outside. 5. Do not clean safety cartridge (4). Instead, replace it every 2 years. Remove nut (5) to remove safety cartridge. 6. Re-install cartridge (3). 7. Re-install hood (2). Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 40

41 50Hz Mobile Generators 4.8 Checking the Alternator V-Belt Maintenance Prerequisites Engine off Tension gauge When Procedure Every 250 hours of service or every 3 months Follow the procedure below to check the alternator V-belt. 1. Run the engine under load for 15 minutes. Then, turn engine off. 2. Visually inspect the alternator V-belt for damage. 3. Place indicator arm (1) into the gauge. 4. Position the gauge (3) on the alternator V-belt midway between the pulleys. 5. Push slowly on the black pad (4) at right angles to the alternator V-belt (2) until the spring is heard or felt to trigger. 6. Carefully remove the gauge without altering the position of indicator arm (1). 7. Read the value where black indicator arm (1) intersects scale (5). See section Technical Data for setting. 8. Retension the alternator V-belt and measure again if necessary. Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 41

42 Maintenance 4.9 Lubricating the Trailer 50Hz Mobile Generators Prerequisites Engine off Trailer chocked Multi-purpose grease to DIN KTA 3K4 When Procedure Every 10,000 15,000 km of service or yearly Follow the procedure below to lubricate the trailer. 1. Grease the drawbar (1) in the area of the bellows. wc_gr Grease the bearing bushing through the grease nipple (2) on the housing and the cartridge. 3. Grease the pivot bolt (3) of the overrun lever and the handbrake levers through the grease nipple. 4. Grease the end of the brake rod end fitting (4). 5. Oil the joints of the spring cylinder in the handbrake lever (5). wc_tx000885gb.fm 42

43 50Hz Mobile Generators 4.10 Cleaning the Engine Maintenance Prerequisites Engine off Engine cool When Procedure Every 1000 hours of service or yearly Follow the procedure below to clean the engine. 1. Cover electric/electrical components and connection: alternator, starter, governor, solenoid. 2. Blow compressed air through the engine stating with the exhaust side. Take care not to damage cooling fins of cooling system. 3. Cold water jet or steam cleaning is allowed. Limit pressure to 60 bar and temperature to 90 C. 4. Remove the covering from electric/electrical components installed in step Start engine and allow remaining water to evaporate. Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 43

44 Maintenance 50Hz Mobile Generators 4.11 Changing/Tensioning Alternator V-Belt Prerequisites Engine off New alternator V-belt When Procedure Every 2000 hours of service or every 2 years Follow the procedure below to change/tension the alternator V-belt. 1. Loosen the screws (1), (2), and (3). 2. Rotate the alternator (4) downward until the alternator V-belt can be removed. Remove the alternator V-belt. 3. Install the new alternator V-belt. 4. Rotate the alternator upward by turning screw (3). 5. Check alternator V-belt tension. 6. Tighten the screws (1), (2), and (3). Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 44

45 50Hz Mobile Generators 4.12 Checking/Adjusting Valve Clearances Prerequisites Engine off and cool Cylinder head gasket Feeler gauges Maintenance When Every 1000 hours of service or yearly Procedure Follow the procedure below to check/adjust the valve clearances. 1. Turn the crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Position 1 of diagram below. 2. Adjust the valves marked in black in position 1 of diagram. 3. Remove the cylinder head cover. This procedure continues on the next page. wc_tx000885gb.fm 45

46 Maintenance Continued from the previous page. 50Hz Mobile Generators 4. Check valve clearance (1) between rocker arm/tappet contact face (2) and valve stem (3) with the feeler gauge (6). 5. To adjust clearance, loosen locknut (4). 6. Adjust set screw (5) so that correct clearance is established. See section Technical Data. 7. Tighten locknut (4). 8. Rotate crankshaft Check/adjust clearances of valves marked in black in position 2 of diagram. 10.Re-install cylinder head cover with new gasket. Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 46

47 50Hz Mobile Generators 4.13 Checking Battery Electrolyte Maintenance Prerequisites Engine off & cool Distilled water When Procedure Every 250 hours of service or every 3 months Follow the procedure below to check the battery electrolyte. 1. Disconnect the battery. WARNING Burn hazard. Battery acid is caustic. It can cause severe burns. Do not touch battery acid with your bare hands. 2. Remove the sealing caps (1). If testers (2) are present, the electrolyte should reach the base of the testers. If testers are not present, the electrolyte should be 10 15mm above the plates of the battery. 3. Add distilled water as needed to obtain the correct electrolyte level. 4. Measure the electrolyte density with a commercial hydrometer. Electrolyte density kg/l Charge status Normal Well charged 1.20 Semi-charged, re-charge 1.12 Discharged, immediately charge 5. Re-install the sealing caps (1). Note: Refer to the Deutz engine manual for detailed information on maintaining the engine. wc_tx000885gb.fm 47

48 Schematics 5 Schematics 5.1 Power Wiring 50Hz Mobile Generators wc_tx000886gb.fm 48

49 50Hz Mobile Generators 5.2 Power Wiring Components Schematics Components (+) Connection for 230V III AC (++) Connection for 230V III AC Circuit breaker Load Genset To control board wc_tx000886gb.fm 49

50 Schematics 5.3 Engine Wiring 50Hz Mobile Generators wc_tx000886gb.fm 50

51 50Hz Mobile Generators 5.4 Engine Wiring Components Schematics Components + Battery Battery Alarm EXT. (External) alarm Start Fuel solenoid EXT. (External) alarm relay Low oil pressure Charge alternator D+ High coolant temperature High oil temperature Low fuel level Low water level (standard Deutz 1012) Fuel level Engine temperature (only Deutz 1012) Engine rpm Start pre-heat RES. (resistor) Start preheat relay wc_tx000886gb.fm 51

52 Schematics 5.5 Socket Wiring 50Hz Mobile Generators wc_tx000886gb.fm 52

53 50Hz Mobile Generators 5.6 Socket Wirng Components Schematics Components Main circuit breaker DIFF. (differential) breaker wc_tx000886gb.fm 53

54 Schematics 5.7 Control Wiring 50Hz Mobile Generators wc_tx000886gb.fm 54

55 50Hz Mobile Generators 5.8 Control Wiring Components Schematics Components Current transformer X1-Connector engine X2-Connector gen set X4- Connector LTS (microprocessor) (**) 230V connection (***) Option: glow plug Alarm Level Circuit board Mains voltage Contact Emergency stop Negative 2 Pin 18 Pin 20 Board Cable to LTS (microprocessor) Alarm Level wc_tx000886gb.fm 55

56 Basic Troubleshooting 6 Basic Troubleshooting 50Hz Mobile Generators Problem Cause Remedy Engine doesn t start Battery discharged Battery connections corroded Defective starter Charge battery. Clean battery connections. Replace starter. Engine tries to start but stops Engine doesn t reach operating speed No generator output Low oil pressure High coolant temperature Engine overspeed Black smoke No fuel Clogged fuel filter Fuel circuit failure Speed regulator failure Fuel circuit failure Speed regulator failure Voltage regulator malfunction Voltage regulator malfunction Overload switch ON Triggered switch. Short circuit or earth fault. Low oil level Clogged oil filter Oil pump failure Alarm failure Overload Low coolant level Clogged oil filter Oil pump failure Speed regulator failure Overload switch ON Alarm failure Fuel circuit failure Clogged air filter Overload High oil level Fill tank with fuel. Replace fuel filter. Check fuel lines. Call for service. Check fuel lines. Call for service. Call for service. Call for service. Reduce load. Check circuits downstream by checking faults in equipment and/or connection cables. Fill engine sump with oil. Replace oil filter. Call for service. Check connections between sensor and panel. If necessary, replace sensor. Reduce load. Fill with coolant. Replace oil filter. Call for service. Call for service. Reduce load. Check connections between sensor and panel. If necessary, replace sensor. Call for service. Clean/replace air filter cartridges. Reduce load. Remove excess oil. wc_tx000896gb.fm 56

57 50Hz Mobile Generators Basic Troubleshooting wc_tx000896gb.fm 57

58 Technical Data G 32 7 Technical Data 7.1 Machine Item number G Prime output kva 30,4 Standby output kva 31,9 Voltage V 400 / 230 Frequency Hz 50 Power factor Cos Ø 0,8 Fuel capacity l 78 Run time (continuous load) h 11,0 Working weight (w/o trailer) kg 1091 Alternator Make/ model MeccAlte / ECO 28 VL Insulation Class H Voltage regulation Model/ type (%) SR7/2 / electronic (± 1%) wc_td000276gb.fm 58

59 G Engine Technical Data Engine Power Rating Net power rating per ISO Actual power output may vary due to conditions of specific use. Engine Type Make Diesel Deutz Model F4M 2011 Prime rating power at rated speed kw 1500 rpm Operating Speed rpm 1500 Cooling system type Oil with radiator Displacement cc 3110 Cylinders no. 4 Aspiration type Natural Governor type Mechanical Battery V/cca 12/680 Electrical system (DC) Volt 12 Oil type (SAE) 20 W 20 Oil quantity l 13 V-belt pretension / tension* N 450 / 350 ± 20 Valve clearance (cold)** mm Inlet: ; outlet: * After engine has been running under load for 15 minutes. ** Engine oil should be less than 80 C. *** Including oil cooler, without oil filter. wc_td000276gb.fm 59

60 Technical Data G Dimensions wc_td000276gb.fm 60

61 G Sound Specification Technical Data The required sound specification, Paragraph f of 89/392/EEC Machinery Directive, is: guaranteed sound power level (LWA) = 89 db(a). This sound value was determined according to ISO 3744 for the sound power level (LWA). wc_td000276gb.fm 61

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63 EC Declaration of Conformity Wacker Construction Equipment AG, Preußenstraße 41, München certifies that the construction machines: Category Mobile Generator Type G 22 G 32 G 43 G 66 G 78 Machine type number Absolute installed power kva 20,8 30,4 41,3 58,7 74,3 fulfill the requirements of the following directives: Conformity assessment procedure At the following test center Measured sound power level Guaranteed sound power level Appendix VIII SNCH Société Nationale de Certification et Homologation 11, route de Luxembourg L-5230 Sandweiler G 22, G 32, G 43 G 66, G 78 G 22, G 32, G 43 G 66, G db(a) 95 db(a) 89 db(a) 96 db(a) 98/37/EC 2004/108/EC 2000/14/EC 2006/95/EC Beierlein Head of product management Dr. Fischer Head of Research and Development

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66 Wacker Construction Equipment AG Preußenstraße 41 D München Tel.: +49-(0) Fax: (0) Wacker Neuson Corporation P.O. Box 9007 Menomonee Falls, WI Tel. : (262) Fax: (262) Tel. : (800) Wacker Asia Pacific Operations Skyline Tower, Suite 2303, 23/F 39 Wang Kwong Road, Kowloon Bay, Hong Kong Tel Fax: