Wacker Neuson G 43, Operator'S Manual

Page 1: ...Mobile Generator G 43 OPERATOR S MANUAL 0175257en 001 0608 0 1 7 5 2 5 7 E N...

Page 2: ......

Page 3: ...l 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...

Page 4: ...Foreword G 43 wc_tx000898gb fm 4...

Page 5: ...2 2 Storing 16 2 3 Lifting 17 3 Operating the Machine 19 3 1 Application 19 3 2 Control Component Locations 20 3 3 Control Component Descriptions 21 3 4 Control Panel Microprocessor 22 3 5 Control Pan...

Page 6: ...eaning the Engine 43 4 11 Changing Tensioning Alternator V Belt 44 4 12 Checking Adjusting Valve Clearances 45 4 13 Checking Battery Electrolyte 47 5 Schematics 48 5 1 Power Wiring 48 5 2 Power Wiring...

Page 7: ...messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury f Obey all safety messages that follow this symbol to avoid i...

Page 8: ...lf 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 traine...

Page 9: ...ware 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 tha...

Page 10: ...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 traile...

Page 11: ...ice procedures before performing any service to the machine All adjustments and repairs must be completed before operation Do not oper ate the machine with a known problem or deficiency Safe servicing...

Page 12: ...pen 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 coo...

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

Page 14: ...Safety Information 50Hz Mobile Generators wc_si000271gb fm 14 1 5 Label Locations a b c wc_gr005209...

Page 15: ..._si000271gb fm 15 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 d Internal fuel tank connect...

Page 16: ...ne only use transport vehicles with enough weight bearing capacity for both the generator and the trailer See section Technical Data Secure the generator and the trailer to the transport vehicle 2 2 S...

Page 17: ...ifting 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 li...

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

Page 19: ...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 supp...

Page 20: ...Operating the Machine 50Hz Mobile Generators wc_tx000884gb fm 20 3 2 Control Component Locations a b c d e f g h m p i j k l wc_gr005210...

Page 21: ...j Socket 380V 16A 3P N CEE IEC309 c Microprocessor The microprocessor controls the operation of the generator k Socket 380V 32A 3P N CEE IEC309 d 3 phase voltage lugs Connection point for 400V 3 loads...

Page 22: ...ys 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 c...

Page 23: ...e supply of voltage to the end con sumer g Start button Pressing this button starts the engine when the main control switch is in the MANUAL START position p Down arrow button Pressing this button scr...

Page 24: ...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...

Page 25: ...CG are open MANUAL START With the control switch in this position The engine will start when the START push button is pressed The microprocessor is programmed to moni tor engine functions and generat...

Page 26: ...enerator 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 th...

Page 27: ...he 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...

Page 28: ...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...

Page 29: ...ow the procedure below when connecting to the terminal lugs 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 t...

Page 30: ...ion 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 appr...

Page 31: ...ery is disconnected This screen shows the number of starting occurrences and the number of failed starting attempts This screen shows the status of any outputs setup by the installation engineers This...

Page 32: ...ase and another This screen shows frequency voltage and current on phase 1 This screen shows the programmed values of the differ ential protection system This screen shows the day date and year It res...

Page 33: ...This screen shows the power factor phase displace ment angle between voltage and current COS For inductive loads L 0 xx for capacitive loads C 0 xx This screen shows generator power apparent power kVA...

Page 34: ...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 c...

Page 35: ...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...

Page 36: ...in the oil into the oil tray Note Collect store and dispose of all used oil and filters in accordance with cur rent environmental protection regulations 3 Attach a new seal ring to the drain plug 4 In...

Page 37: ...of all used oil and filters in accordance with cur rent 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 Insta...

Page 38: ...ur rent 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...

Page 39: ...very 3 months Procedure 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 dis charge slot as indicated by...

Page 40: ...ow 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...

Page 41: ...lace 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 spr...

Page 42: ...dure Follow the procedure below to lubricate the trailer 1 Grease the drawbar 1 in the area of the bellows 2 Grease the bearing bushing through the grease nipple 2 on the housing and the cartridge 3 G...

Page 43: ...nator starter gover nor 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 all...

Page 44: ...e 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 n...

Page 45: ...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 va...

Page 46: ...e 6 5 To adjust clearance loosen locknut 4 6 Adjust set screw 5 so that correct clearance is established See section Tech nical Data 7 Tighten locknut 4 8 Rotate crankshaft 360 9 Check adjust clearanc...

Page 47: ...esters 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...

Page 48: ...Schematics 50Hz Mobile Generators wc_tx000886gb fm 48 5 Schematics 5 1 Power Wiring...

Page 49: ...50Hz Mobile Generators Schematics wc_tx000886gb fm 49 5 2 Power Wiring Components Components Connection for 230V III AC Connection for 230V III AC Circuit breaker Load Genset To control board...

Page 50: ...Schematics 50Hz Mobile Generators wc_tx000886gb fm 50 5 3 Engine Wiring...

Page 51: ...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...

Page 52: ...Schematics 50Hz Mobile Generators wc_tx000886gb fm 52 5 5 Socket Wiring...

Page 53: ...50Hz Mobile Generators Schematics wc_tx000886gb fm 53 5 6 Socket Wirng Components Components Main circuit breaker DIFF differential breaker...

Page 54: ...Schematics 50Hz Mobile Generators wc_tx000886gb fm 54 5 7 Control Wiring...

Page 55: ...onents 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 Emergenc...

Page 56: ...ON Triggered switch Short cir cuit or earth fault Call for service Reduce load Check circuits downstream by checking faults in equip ment and or connection cables Low oil pressure Low oil level Clogge...

Page 57: ...50Hz Mobile Generators Basic Troubleshooting wc_tx000896gb fm 57...

Page 58: ...41 3 Standby power kVA 43 4 AC Voltage 1 phase V 230 AC Voltage 3 phase V 400 Frequency Hz 50 Power factor Cos 0 8 Fuel capacity l 78 Run time continuous load h 8 3 Working weight w o trailer kg 1021...

Page 59: ...z Model BF4M 2011 Prime rating power at rated speed kW 36 4 1500 rpm Operating Speed rpm 1500 Cooling system type Oil with radiator Speed rpm 1500 Displacement cc 3110 Cylinders no 4 Aspiration type T...

Page 60: ...Technical Data G 43 wc_td000277gb fm 60 7 3 Dimensions...

Page 61: ...1 7 4 Sound Specification The required sound specification Paragraph 1 7 4 f of 89 392 EEC Machinery Directive is guaranteed sound power level LWA 89 dB A This sound value was determined according to...

Page 62: ......

Page 63: ...ype number 0620543 0620544 0620545 0620546 0620547 Absolute installed power kVA 20 8 30 4 41 3 58 7 74 3 Conformity assess ment procedure At the following test center Measured sound power level Guaran...

Page 64: ......

Page 65: ...0 Fax 49 0 89 3 54 02 3 90 Wacker Neuson Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Skyline Tower Suite 23...