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Repair Manual Mobile Generator

1. IRC a ea d US npo 5 A HIH J A y noa a Les 343990 NHOr r PE A 9 HE 7 l AS A i A la sv H SL L 6l BI Jm y us sv Y ni EL O z sa ou All ol ba A diy 10 u Y ee q 6G 8 9 AIM ZO pz1 JO 09 6 pS UM gge pz pL 19 190 Do oz lOve lg SCE ew A va BL G MI 0 n Sp sy gt Aon ee ee JO MD tu KI T 1 S cc OOO 4 TE TT ye A Ooo OM O Oto SQHO E 0338 mooo LS S cb be 118 gb fm wc_td000214 G 85 Technical Data Engine Wiring Components John Deere with ECU Description Plug 1 engine sender inputs Description Battery Plug 2 engine start run outputs ECM 10A fuse Main circuit breaker 3 phase lugs Starter relay Shunt trip coil Starter Emergency stop switch Alternator Engine Control Module ECM B terminal block Safety interlock switch System 10A fuse Remote start terminals o CO NI OD oO AJ Wy PP Fuel level sender System 30A fuse Harness connector o Intake heater CAN bus connector h h Slave preheat relay Mechanical lugs 3 phase Diagnostic connector ECU harness connector
2. p E oe E a o IT CI ____ er e N 3 a jm ere be dk OO Ree win El ae e a Va 9 T RE AR RAR 2 sal Zum E pas eal los E Nate o i Ei N lt a fall i ae ssl ll 1111 17 uh ss la H Mig y ME To Ih ro ST oles lt j PIES lt L 2 E ax r h J k a ale ALA P sele eTa ih venni nl PE AE O i i p i ala sini 5 gt 2335 29 BOM REV ae IL ii ap 0009369 124 MIL LL 0009459 133 32 0620003 129 12 wc_td000214gb fm 122 G 85 mb See Graphic wc_gr004692 Description Lug door safety interlock switch Technical Data Description Voltage Selector Switch VSS Mechanical lugs Generator Plug 3 current transformer inputs Automatic Voltage Regulator AVR Plug 4 line voltage inputs Voltage adjustment rheostat Shunt Terminal block 120V 20A GFI receptacle Exciter rotor windings 120V breaker Exciter stator winding 240V 50A breaker Rotor O NIOJ om BR OJN 240V 30A breaker 240V 50A receptacle Rectifier diodes Main rotor winding 240V 30A receptacle Main stator windings Engine Control Module ECM Bus bar Auxiliary winding Main breaker Stator Terminal strip ECM Plug 3 Wires EC
3. lt gt OF 0 A HZ The display shows the amount of time left until service on the machine is required To reset the timer to 250 hours Time to Service hold the Hours Reset toggle switch in the up position until 250 all the screens have been scrolled through twice ml 6 1 2 Some ECMs include this message A Hz FOR SALES AND SERVICE CONTACT Sal OF E Some ECMs include this message V A HZ YOUR LOCAL WACKER DEALER KEE Y Ned a n 30 wc_tx000713gb fm Mobile Generator ECM Background Information The display shows the status of the oil pressure sender y y A Hz If the oil pressure sender has failed the time of the failure Oil Pressure Sender will be displayed The time of the failure will be included OK in the display until the generator has been shut down and oe Cbg OF remains shutdown for a period of approximately two min utes V 0 A HZ The display shows the status of the engine coolant tem perature sender If the coolant temperature sender has Water Temp Sender failed the time of the failure will be displayed The time of OK the failure will be included in the display until the genera Qe Gb OF Ei tor has been shut down and remains shutdown for a period of approximately two min
4. we le Re stato N de ref Rev 0009369 lt 123 0009459 lt 128 A DI 0620003 lt 132 DIO Re stato 0009369 gt 124 0009459 gt 129 0620003 gt 133 Re stato wc_gr004668es 2 Disconnect the voltage adjusting rheostat from the automatic voltage regulator AVR 3 Loosen the rheostat s locknut 4 Measure the resistances of the rheostat across the entire range of its travel Does the voltage adjusting rheostat have a range of at least 5 145k Ohms 5 95k for 100k Ohm pots Yes No Your reading Continue The voltage adjusting rheostat has failed replace it 5 Check each wire to ground unpainted surface on door Does each wire measure OPEN or OL to ground Yes No Your reading The voltage adjusting The voltage adjusting rheostat is OK rheostat has failed replace it 6 Reconnect the voltage adjusting rheostat 7 Tighten the rheostat s locknut The voltage adjusting rheostat has now been checked Continue with Checking the Auxi liary Winding 72 Mobile Generator Output Voltage Troubleshooting 8 5 Checking the Auxiliary Winding Prerequisites Procedure wc_tx000726gb fm Generator shut down Follow the procedures below to check the auxiliary winding 1 Open the large hinged panel and locate the Automatic Vo
5. The display shows the value of the alarm setting for low Y A HZ fuel level If the ECM sees that the fuel level is less than Fault sellings 5 for longer than 5 seconds the ECM will shut down 5 Sec O lt 5 the generator PON Si EA we_tx000713gb fm 33 Ww VACKER ECM Background Information Mobile Generator The display shows the status of the battery When the battery voltage is within its normal range 12 15V the V A HZ 12 Volt Battery ECM displays the voltage value in 1 10V increments on Status is Normal the run screen PO ET The display shows the battery low voltage prealarm set V A ting When the ECM detects that battery voltage is less Prealarm Setting Level lt 12 0 V than 12V the battery voltage reading on the run screen will blink The display shows the battery high voltage prealarm set ting When the ECM detects that battery voltage is greater than 15V the battery voltage reading on the run screen will blink v A Hz Prealarm Setting Level gt 15 0 V 2 Dam Qe lt G 85 9305 G 125 G160 John Deere Engines with ECU ECM Display Description V 0 A HZ John Deere engine diagnostic codes SPN Suspect Parameter Number SPN FMI 100 01 FMI Failure Mode Identifier The ten most recent codes will be displayed
6. Violet 947 HC terminal R N A H2 Gray 428 Fuel temp sensor H3 Orange 463 Manifold Air Temp MAT sensor Ji Gray 418 Gray 448 Yellow 914C Engine crank sensor Sensor return Black 050C J2 3 Ground K Red 022 10A fuse Brown 911C White 439 wc_td000214gb fm Sensor excitation 5V HC terminal K N A K2 Brown 491 K3 White 429 121 Fuel control solenoid Air heater relay Technical Data G 85 lt P o pa SI L SD o N O N 5 Has N N 2 o TIE a mM gt S om ESTA sa 100 0000007 O ire e mmm N mms LO H N il 1 00 o PTO ei Ron li i i a To pera ert H o a GROUND GENERATOR HOUSINGTO FRAME
7. Does each wire measure OPEN or OL to ground Yes No Your reading Continue Remove the vent cover from the generator and check the generator for damage 4 Measure the resistance across the blue and the yellow wires Is 10 6 12 0 Ohms measured Yes No Your reading Continue Remove the vent cover from the generator and check the generator for damage then continue 5 Remove the vent cover from the generator to expose the rotor 6 Measure the continuity between the blue wire and the rotor Also measure between the yellow wire and the rotor Does each wire measure OPEN or OL to the rotor Yes No Your reading The excitor stator is OK The exciter stator has failed Call Wacker Neuson Service 7 Reconnect the wiring and re install the vent cover The auxiliary winding has now been checked Continue with Checking the AVR Sensing Wires 74 Mobile Generator Output Voltage Troubleshooting 8 7 Checking the AVR Sensing Wires Prerequisites m Generator shut down Procedure Follow the procedure below to check the AVR sensing wires 1 Open the large hinged panel and locate the Engine Control Module ECM and the Auto matic Voltage Regulator AVR Bus bar asa Liftejia N B R Ree Ae Black ery Y l n a va Vos bobel 7a 6 ska 4A 3 2 DI amp AVR x e HZ STABVOL wc_gr003694 2
8. Engine Wiring Components John Deere with ECU Description Plug 1 engine sender inputs Description Battery Plug 2 engine start run outputs ECM 10A fuse Main circuit breaker 3 phase lugs Starter relay Shunt trip coil Starter Emergency stop switch Alternator Engine Control Module ECM B terminal block Safety interlock switch System 10A fuse Remote start terminals o CO NI OD oO AJ Wy PP Fuel level sender System 30A fuse Harness connector o Intake heater CAN bus connector h h Slave preheat relay Mechanical lugs 3 phase Diagnostic connector ECU harness connector Start switch ECM Plug 1 Wires Hour meter switch ECM Plug 2 Wires Wire Description Gr 61 Emergency stop Wire Description Battery for relays W L 56 Oil pressure sender Crank 12V output Or 60 Remote start Run Fuel 12V output W V 62 Fuel level Remote annunciator NA B 59 Battery Remote annunciator NA R 53 Battery for ECM board Wire Colors Black Red Y Yellow Or Orange Green Tan Br Brown Pr Purple wc_td000214gb fm Blue Violet Cl Clear Sh Shield Pink White Gr Gray LL Light blue 117 918z0015 om G 85
9. Reference Numbers Repair procedures contain reference numbers enclosed in parentheses These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings They are included to aid the mechanic in identifying parts and assembling components Weight Block See Graphic wc_gr000843 The weight block symbol gives an approximate weight measurement to aid the mechanic when lifting hoisting larger components 250 kg 550 Ibs wc_gr000843 wc_tx000575gb fm WACKER 83 Y NEUSON Disassembly Assembly Mobile Generator 9 5 Removing the Roof See Graphic wc_gr003320 This procedure requires an appropriate crane capable of lifting 227 kg 500 lbs y 9 5 1 Disconnect the battery 9 5 2 Remove the doors a 9 5 3 Remove the front and rear access panels b and c 9 5 4 Remove the screws that secure the roof to the side panels d 9 5 5 Remove the screws that secure the control panel enclosure e to the lifting structure f 9 5 6 Remove the screws that secure the door latch g to the lifting structure and remove the door latch 9 5 7 Remove the screws that secure the lifting structure to the frame 9 5 8 Using an appropriate crane or hoist lift the roof h by the lifting eye off of the frame WACKER 84 wc_tx000575gb fm NEUSON Mobile Generator Disassembly Assembly wc_gr003320 uu q WACKER c_tx000575gb f 85 Y NEUSON Disassembl
10. Start switch ECM Plug 1 Wires Hour meter switch ECM Plug 2 Wires Wire Description Gr 61 Emergency stop Wire Description Battery for relays W L 56 Oil pressure sender Crank 12V output Or 60 Remote start Run Fuel 12V output W V 62 Fuel level Remote annunciator NA B 59 Battery Remote annunciator NA R 53 Battery for ECM board Wire Colors Black Red Y Yellow Or Orange Green Tan Br Brown Pr Purple wc_td000214gb fm Blue Violet Cl Clear Sh Shield Pink White Gr Gray LL Light blue 119 G 85 Technical Data ing Diagram If 6 ECU Wi 10 21820016 om Se c80 0SO AEN Ty 0 9320 an 34330 NHOP y Lvv e I VIN 8LV 120 gb fm wc_td000214 G 85 10 7 ECU Harness Connector See Graphic wc_gr002817 Wire Color Destination Wire Color Green 905 Technical Data Destination CAN bus Red 012C Harness Connector HC terminal G Orange 493 Fuel control solenoid Violet 467 Oil pressure sensor Brown 461 Colant temp sensor Yellow 904 CAN bus Violet 447 Engine crank sensor W L 474 ECM Gray 918 HC terminal N N A Orange 473 HC terminal H N A
11. When applying sealants follow instructions on container The sealants listed are recommended for use on Wacker Neuson equipment TYPE PART NO Europe COLOR USAGE SIZE Loctite 496 Clear Instant adhesive for bonding rubber 52676 10z Hernon 110 metal and plastics general purpose Omnifit Sicomet 7000 For gaps up to 0 15 mm 0 006 Read caution instructions before using Temp range 54 to 82 C 65 to 180 F Loctite Primer T Aerosol Fast curing primer for threadlocking 2006124 6 oz Hernon Primer 10 Spray retaining and sealing compounds Must Omnifit VC Activator be used with stainless steel hardware Recommended for use with gasket sealants Torque Values Torque Values Metric Fasteners DIN TORQUE VALUES Based on Bolt Size and Hardness WRENCH SIZE 100000 OC Li 8 8 10 9 12 9 Size Nm ft Ib Nm ft Ib Nm ft lb Metric Inch Metric Inch M3 1 2 11 1 6 14 2 1 19 5 5 7 32 2 5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 si M5 6 0 53 8 5 6 10 7 8 5116 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 190 140 230 169 22 7 8 12 M16 210 155 295 217 355 262 24 15 16 14 M18 290 214 405 298 485 357 27 1 1 16 14 M20 410 302 580 427 690 508 30 1 1 4 17 1 ft lb 1 357 Nm in lb 1 inch
12. E The display shows in psi fuel pressure The display shows in gallons per hour GPH the rate at which fuel is being consumed 95 F Manifold Temp The display shows in F the temperature of the engine intake manifold wc_tx00071 3gb fm WACKER 35 W NEUSON ECM Background Information Mobile Generator 4 6 Voltage Display Errors See Graphic wc_gr003308 Single Phase Display Mode When operating in the single phase 120 240V position line to line voltage will be displayed under P2 240V Line to neutral voltage 120V will be displayed under P1 and P3 This is the normal single phase display mode Three Phase Display Mode When operating in either three phase position 208 120V or 480 277V the line to line voltage will be displayed under P1 P2 and P3 of the ECM For example in the 480 277V position with the control panel rheostat adjusted correctly voltage values will read 480V on all three phases P1 480 P2 480 and P3 480 In the 208 120V position voltage values will read 208V on all three phases P1 208 P2 208 and P3 208 e If leg 2 L2 voltage drops below 50V the ECM is programmed to switch to its single phase mode and stay there until the operator corrects the condition Two common causes for this condition are 1 starting the generator with the connection lug door open and then closing it with the engine still running 2
13. Is there continuity Yes No The emergency stop switch is OK The emergency stop switch has failed replace it 7 Re install the key latch to the lug door The emergency stop switch has now been checked Continue with Checking the Lug Door Switch 69 Output Voltage Troubleshooting Mobile Generator 8 2 Checking the Lug Door Switch Prerequisites Procedure wc_tx000726gb fm Generator shut down Follow the procedure below to check the lug door switch 1 Open the large hinged panel Remove the key latch from the lug door and place in the slot of the lug door switch NOTICE Never place anything but the key into the slot of the lug door switch 2 Disconnect the blue and blue white wires of the lug door switch Also disconnect the orange wires orange and orange white wires on older machines of the lug door switch 3 Check for continuity between the blue and blue white wires Is there continuity Yes ___ No Continue The lug door switch has failed replace it 4 Remove the key from the lug door switch 5 Check for continuity between the blue and blue white wires Is there continuity Yes No The lug door switch has failed replace it Reconnect the blue and blue white wires then continue 6 Check for continuity between the orange wires orange and orange white wires on older machines Is there continuity Yes No Continue The lug door switch has failed replace it 7 Pla
14. True Power kW Reactive power and true power are always represented 90 from each other In the power right triangle the angle formed by the hypot enuse apparent power and the adjacent side true power is referred to as theta 8 Theta is derived from the separation in the sine waves of voltage and current In inductive circuits current lags the voltage due to such factors as coil length coil material and frequency From trigonometry the cosine of Y adjacent side hypotenuse Since cosine and power factor are calculated in the same manner power factor is often referred to as cosine cos B Single phase receptacles are tapped off the legs in a manner that keeps the generator balanced That is voltage supplies to the various single phase outlets originate from different legs of the generator L1 and L3 not from the same leg When tapping single phase loads from the lugs care must be taken so that the generator does not become unbalanced Attach equal loads to each leg if you are running the generator in this manner 21 Electrical Testing Techniques Mobile Generator 3 Electrical Testing Techniques 3 1 Checking Continuity Conduct continuity tests when the engine is shut down When checking continuity use the Ohm setting on your multimeter Place a lead of the multimeter on one end of the wiring or component and the other lead on the opposite end If your meter reads OL or OPEN there is no cont
15. With the main circuit breaker in the OFF position check for continuity between L1 of the main circuit breaker and Lug 1 Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for any of the checks Yes No The main circuit breaker has failed The main circuit breaker is functioning replace it properly 7 Reconnect the yellow Y wire The main circuit breaker has now been checked 68 Mobile Generator Output Voltage Troubleshooting 8 Output Voltage Troubleshooting 8 1 Checking the Emergency Stop Switch Prerequisites Procedure wc_tx000726gb fm Generator shut down Follow the procedure below to check the emergency stop switch 1 Open the large hinged panel Remove the key latch from the lug door and place it in the slot of the lug door switch NOTICE Never place anything but the key into the slot of the lug door switch 2 Place the emergency stop switch in the de activated out position 3 Check the connections of the wiring to the emergency stop switch Make sure all con nections are tight 4 Check continuity across red wire 20 and yellow wire 45 at the switch Old push twist style New push pull style wc_gr003691 Is there continuity Yes No Continue The emergency stop switch has failed replace it 5 Place the emergency stop switch in the activated in position 6 Check continuity across red wire 20 and yellow wire 45 at the switch
16. 25 4 mm Torque Values Torque Values continued Inch Fasteners SAE yq SAE 5 SAE 8 EA Size Nm ft Ib Nm ft Ib Nm ft Ib Metric Inch Metric Inch No 4 0 7 6 1 0 14 1 4 12 5 5 1 4 3 32 No 6 1 4 12 1 9 17 2 4 21 8 5 16 7 64 No 8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 No 10 3 6 32 5 1 45 6 8 60 3 8 _ 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 _ 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8 _ 3 8 1 2 77 57 109 80 142 105 19 3 4 3 8 9 16 111 82 156 115 214 158 13 16 5 8 152 112 216 159 265 195 24 15 16 1 2 3 4 271 200 383 282 479 353 1 1 8 _ 5 8 1 ft lb 1 357 Nm in lb 1inch 25 4 mm Wacker Neuson SE gt PreufenstraBe 41 D 80809 M nchen gt Tel 49 0 89 3 5402 0 Fax 49 0 89 3 54 02 390 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 Neuson Limited Room 1701 03 amp 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
17. 3 Wires ECM Plug 4 Wires Wire Description Wire Description Ammeter line input CT3 Voltage line input L3 at volt selector 28 Ammeter input CT com mon Voltage line input L2 at volt selector 20 Ammeter line input CT2 Voltage line input L1 at volt selector 3 Ammeter line input CT1 wc_td000214gb fm Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of S plus a number S and should be used where indicated Threadlocking compounds normally break down at temperatures above 175 C 350 F If a screw or bolt is hard to remove heat it using a small propane torch to break down the sealant When applying sealants follow instructions on container The sealants listed are recommended for use on Wacker Neuson equipment TYPE PART NO Europe COLOR USAGE SIZE Loctite 222 Purple Low strength for locking threads smaller 73287 10 ml Hernon 420 than 6 mm 1 4 Omnifit 1150 50M Hand tool removable Temp range 54 to 149 C 65 to 300 F Loctite 243 Blue Medium strength for locking threads 29311 5 ml Hernon 423 larger than 6 mm 1 4 17380 50 ml Omnifit 1350 100M Hand tool removable Temp range 54 to 149 C 65 to 300 F Loctite 271 277 Red High strength for all threads up to 25 mm 29312 5 ml Hernon 427 1 26685 10 ml Omnifit 1550
18. 4045TF275 Number of cylinders Displacement Engine speed 1800 Power 1800 rpm 84 2 113 Coolant capacity 22 7 24 Oil capacity qts 15 15 9 Battery dc 12 720 12 1000 Fuel type Diesel Fuel tank capacity gal 337 89 Fuel consumption hr gal continuous load hr 21 2 5 6 Running time Hours continuous load 19 wc_td000214gb fm 1 1 2 G 85 10 2 Generator Data Item Number Technical Data G 85 0009369 0009459 0620003 Generator Make Type Mecc Alte Brushless Model ECO32 3L 4 Generator speed 1800 Voltage selector switch AC voltages available 3 position 120 240 zig zag 120 208 low wye 277 480 Hi wye Frequency Power factor Voltage regulation 60 Hz Insulation class H Sound level at 7 m 23 ft 69 AC receptacles 19 120 GFI duplex 2 duplex 3 twist lock 2 20 19 120 240 V twist lock 1 30A 2 50A Standby Output Continuous Output 74 92 Main breaker wc_td000214gb fm 113 Technical Data G 85 10 3 Trailer and Skid Data Item Number G 85 G 85 0009369 0009459 0620003 Trailer and Skid Dry weight of skid kg Ibs f 1580 3484 1621 3574 Operating weight of kg Ibs skid Trailer weight kg Ibs 1868 4120 1909 4210 Single axle 442 975 Tandem axle 499 1100 kg Ibs Single axle 2304 5080 Tandem axle 2722 6000 Surge
19. ECM Plugs and Pins See Graphic wc_gr002926 To measure the voltage at an ECM pin attach an appropriate extension a to the positive probe on your multimeter Slide the positive probe into the plug along the wire of the pin to be tested Use care when testing this way so you don t damage the wire plug or ECM Find a suitable ground on the machine s frame for the negative probe b of your multimeter wc_gr002926 wc_tx000699gb fm Si Y NEG SA ECM Background Information Mobile Generator 4 ECM Background Information 4 1 ECM Handling Precaution See Graphic wc_gr003355 NOTICE Use care when working on or around the ECM The ECM may be damaged or it may malfunction if it is accidentally hit by your hand or a tool Do not touch the pins a of the ECM because the AC board of the ECM may malfunction wc_gr003355 MESSE R 24 wc_tx000713gb fm Mobile Generator ECM Background Information 4 2 Normal Boot up Sequence During the boot up sequence the ECM scrolls through several screens before it settles into displaying the run screen There are two different boot up sequences depending on size of the generator and options included on the generator Both of the boot up sequences are listed below When checking the boot up sequence of your generator be sure you are checking the one that matches your generator G 25 G 50 G 70 G 85 9310 ECM Display Description Start of the boot up sequence The ECM shows
20. Generator 8 8 Flashing the Generator checking the excitation system Prerequisites m Source of 12VDC Procedure Follow the procedure below to flash the generator 1 Open the large hinged panel and locate the Automatic Voltage Regulator AVR yellow wc_gr003695 2 Disconnect all the wires from the AVR except the rheostat wires and the white jumper wire 3 Connect a multimeter set to the 500VAC or higher scale to the green and black wires WARNING Electric shock hazard High voltage exists between the green and black wires when the engine is running Electric shock can cause injury or death Do not touch the green and black wires 4 Start the engine Then connect the blue wire to the ground lug and the yellow wire to the B terminal strip NOTICE Do not connect the wires to the machine without the engine running Damage to the winding may occur 5 Check the multimeter for the voltage measured across the green and black wires Is 320 50V measured 170 25V on 0009369 rev 100 105 0009459 rev 100 105 0620003 rev 100 106 Yes No Your reading The excitation system is Check the exciter rotor win functioning properly ding See Checking the Continue Exciter Rotor Winding 6 Shut down the generator Then reconnect all the wires to the AVR 7 Start the engine and check the function of the generator Doe
21. Sender Status is Normal CW Si The display shows the status of the speed sender If the speed sender has failed the time of the failure will be dis played The time of the failure will be included in the dis play until the generator has been shut down and remains shutdown for a period of approximately two minutes At that time the ECM clears itself V A HZ 60 0 Hz Nominal No Teeth 14 a Di The display shows the number of teeth on the flywheel which are measured by the magnetic pickup The num ber of teeth differs between Isuzu engines 136 and John Deere engines 142 V A HZ Prealarm Setting 1s lt 55 0 Hz SEC IE The display shows the value of the prealarm setting for under speed If the ECM detects that the engine speed is less than 55 Hz for longer than 1 second the Hz reading on the run screen will start to blink VIOLA Hz Fault Setting 15s lt 55 0 Hz Si The display shows the value of the fault setting for under speed If the ECM detects that the engine speed is less than 55 Hz for longer than 15 seconds the ECM will shut down the generator VI A Hz Fault Setting 1s gt 67 0 Hz se lt SE Par V A Oil Pres Sender Status is Normal KE URS The display shows the value of the fault se
22. Yes No Continue The main circuit breaker has failed replace it 5 With the main circuit breaker in the ON position check for continuity continuity equals 0 0 1 0 Ohms between L1 of the main circuit breaker and Lug Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for each check Yes No Your readings Continue The main circuit breaker has failed replace it 6 With the main circuit breaker in the OFF position check for continuity between L1 of the main circuit breaker and Lug 1 Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for any of the checks Yes No The main circuit breaker has failed The main circuit breaker is functioning replace it properly 7 Reconnect the yellow Y wire The main circuit breaker has now been checked 56 Mobile Generator ECM Sensor Troubleshooting 5 11 ECM Plugs and Pins wc_gr003988 ECM Plug 1 Wires ECM Plug 2 Wires Wire Description i Wire Description Gr 61 Emergency stop Battery for relays W L 56 Oil pressure sender Crank 12V output Or 60 Remote start Run Fuel 12V output W V 62 Fuel level Remote annunciator NA B 59 Battery Remote annunciator NA R 53 Battery for ECM board wc_tx000723gb fm 5 7 ECM Sensor Troubleshooting Mobile Generator Notes wc_tx000723gb fm 58 M
23. brakes Fluid type DOT3 Tires size ST225 75D 15D wc_td000214gb fm 114 G 85 10 4 Dimensions Technical Data mm inches G F wc_gr006389 Machine A B Cc D E F G G 85 965 1970 1703 3923 2445 1346 1475 38 77 5 67 154 5 96 3 53 58 wc_td000214gb fm 115 66970015 om G 85 circadiano Sesta niase 4 US npo 3 no Ai AHH 2 noa i E a Les 34330 NHOf invi Lisi r Lei pati les 9 Hre i ae di n ws a les A a SL x SUI v Hag ev Y N lt 1 gt 61 Lu _g H m Y ls ev Y ni EL S Q rz oz Y Al ol pa z amp k un 0 Ly Y ee e g 6G e 9 O S NM ZO zt 5 _ 40 09 8 15 eS l LARA J M 9G L 6 Pz p D 19 L9 o amp a D c AI o JO 9 gt E Tt Oe DI oc AON A c SS ae rec LU DIM S w Oto sy A I Eee eee eres ce QOO co Rd si 5 S N EA A A 4 a A zy Z oOo 0 O A PANADE p MO e E 116 gb fm wc_td000214 G 85 Technical Data
24. least 9 8V measured Yes _ No Your reading Continue Repair red wire 49 7 Place the START RUN switch in the ON position 8 Check the voltage between red wire 53 at START RUN switch and ground Is at least 9 8V measured Yes No Your reading Continue Replace the START RUN switch This procedure continues on the next page wc_tx000723gb fm 4 5 ECM Sensor Troubleshooting Continued from the previous page Mobile Generator 9 Check the voltage between ECM pin 7 plug 1 red wire 53 and pin 8 plug 1 black wire 59 Is at least 9 8V measured Yes No Your reading Continue Repair red wire 53 10 Check the voltage between ECM pin 5 plug 2 red wire 18 and ground Is at least 9 8V measured fuse box and B terminal strip Repair the wiring as needed Yes No Your reading Power tothe ECM Check continuity of red wire 18 between ECM is OK and fuse box Also check red wire 48 between Incoming power to the ECM has now been checked wc_tx000723gb fm 46 Mobile Generator ECM Sensor Troubleshooting 5 2 Checking Outgoing Power From the ECM Prerequisites Fully charged 12 Volts battery m Atleast 9 8VDC incoing power to ECM on red wires 18 and 53 Procedure Follow the procedure below to check the outgoing power from the ECM 1 Open the control panel and locate the ECM V64 Y63
25. starting the genera tor in its single phase position 120 240V then switching it to a three phase position 208 120V or 480 277V without turning the generator off first Both instances will cause the ECM to display a less than line to neutral voltage for P1 and P2 and full line to line voltage for P3 For example in the 480 277V position P 1 and P2 will read approximately 190V while P3 will read 480V The volt age values displayed in this mode can lead one to conclude that the generator is not running correctly when actually it is fine the system just needs to be reset To correct reset the condition stop the engine make sure the lug door is closed and then restart the engine Allow the generator to cycle through the phases several times to develop the maximum voltage e When in the three phase mode if any one of the legs L1 L2 or L3 drops out two of the three phases will automatically also drop out For example if leg 1 drops out there can be no L1 L2 P1 voltage nor can there be L3 L1 P3 voltage The values dis played under P1 and P2 will be residual voltage for the legs them selves not line to line voltage Residual voltage is approximately 36V The voltage displayed under P3 will be L2 line to neutral voltage This condition is known as single phasing It is a sign there is a problem with the generator y WACKER NEUSON 36 wc_tx000713gb fm Mobile Generator ECM Background Information Engine Hour Switc
26. table below All values are in Ohms valli post Lin L2 N L3 N Li L2 L243 L1 L3 Ideal 0 2 0 2 0 2 0 4 0 4 0 4 Your reading Are your readings approximately equal to the ideal measurements Yes No The main stator win 1 Clean the voltage selector switch with contact cleaner eng ana e eda 2 Check the windings at the generator OK See Checking Stator Windings at the Voltage Selector Switch The stator windings have now been checked at the lugs Continue with Checking the Recti fier Diodes 77 Output Voltage Troubleshooting Mobile Generator 8 10 Checking the Rectifier Diodes Thread in Style Prerequisites m Generator shut down Procedure Follow the procedures below to check the rectifier diodes 1 Remove the rear baffle from the machine wc_gr003811 Remove the cover from the generator Remove the screws that secure the bearing carrier to the stator Disconnect the blue and yellow wires from the AVR Using a puller pull the bearing carrier exciter stator from the stator housing Disconnect the diode s lead from the terminal Note the rubber washer isolating the lead from the diode plate DIA WIN wc_gr003815 7 Using the diode scale on your multimeter check each diode between the diode s lead and the diode plate Reverse the probes of your meter and check the diode again Each diode should conduct in one direction and not in the other Your m
27. that the A glow plugs are on The LED near the stop icon also illu Glow Plugs minates Note that the glow plugs are only on during the On first of the three starting cycles lt The ECM displays this screen when the starter is crank ing the engine The ECM displays the countdown time in hours until the 250 next scheduled service The timer starts at 250 and Time to Service counts down to 0 FOM lt At this point the ECM displays the running values of the V generator 480 71 P2 0 61 5 Note The ECM display scrolls through each phase P1 75 87 12 7 P2 P3 if in the 3 phase mode or L1 L3 and L1 L3 if de OF ES in the single phase mode wc_tx000713gb fm WACKER 25 W NEUSON ECM Background Information Mobile Generator G 85 9305 G 125 G 160 ECM Display Description A Initializing G 85 Start of the boot up sequence The ECM display reads Initializing and shows the model of the generator If the model displayed does not match the model of the gener ator call Wacker Neuson Service Time to Service 250 OEEC UE A Cranking 1 of 3 The ECM displays the countdown time until the next scheduled service The timer starts
28. the ON position Does the ECM boot up and do the FUEL amp CRANK LEDs illuminate Yes No Go to step 6 Continue 3 Check connections of battery cables Also check battery voltage Is the battery voltage 12 2V Yes No Your reading Continue Charge the battery 4 Locate Plug 1 Check the voltage between red wire 53 of the plug and ground Is at least 9 8V measured Yes No Your reading Continue Repair or replace wire 53 5 Locate Plug 2 Check voltage between red wire 18 and ground during cranking Is at least 9 8V measured Yes No Your reading Continue Repair or replace wire 15 6 Locate Plug 2 Check the voltage between violet wire 64 and ground Also check the voltage between yellow wire 63 and ground during cranking Is there at least 9 8VDC measured in each case Yes No The ECM is OK The ECM has failed Call Wacker Neuson Service The ECM has now been checked Continue with Checking the Emergency Stop Switch 63 Engine Starting Troubleshooting G 85 7 3 Checking the Emergency Stop Switch Prerequisites Procedure wc_tx000678gb fm Generator shut down m Battery voltage measuring 11 13VDC Follow the procedure below to check the emergency stop switch 1 Place the emergency stop switch in the de activated out position 2 Place the START RUN switch in the ON position 3 Check the connections of the wiring to the emergency stop switch Make s
29. the VOLT pot a on the new AVR counterclockwise as far as possible wc_gr004584 This procedure continues on the next page we_tx000575gb fm 91 w VACKER Disassembly Assembly Mobile Generator Continued from the previous page WARNING Electric shock hazard Voltage exists at the cooling fins of the AVR when the engine is running Electric shock can cause severe injury or death gt Never touch the cooling fins when the engine is running 9 9 5 Place the voltage selector switch in the 208 120V position 9 9 6 Never adjust the AVR voltage pot with the voltage selector switch in any other position Damage to the generator may occur 9 9 7 Loosen the lock nut and adjust the voltage adjusting rheostat c clockwise as far as possible els y i vu wc_gr004585 wc_gr004587 9 9 8 Open the large hinged panel Remove the key latch from the lug door and place it in the slot of the lug door switch NOTICE Never place anything but the key into the slot of the lug door switch 9 9 9 Place the main circuit breaker in the ON position WARNING Electric shock hazard High voltage exists at the lugs when the engine is running High voltage can kill or cause severe injury gt Never touch the lugs when the engine is running 9 9 10 Start the machine NOTICE Shut down the machine immediate
30. the negative terminal on battery is disconnected Attach a DO NOT START sign to 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 Ground Connection The generator must be connected to a good earthen ground for proper operating safety A central equipment ground is provided at the customer connection lugs This point is connected directly to the generator set base All other system grounds are connected to this central point Ground the generator in accordance with the standards defined in national state and local regulations DO NOT attempt to open the radiator cap while the unit is running or before the engine has cooled down Severe burns may result DO NOT allow water to accumulate around the base of the machine If water is present move the machine and allow the machine to dry before servicing DO NOT service the machine if your clothing or skin is wet DO NOT allow untrained personnel to service this equipment Only trained electrical technicians should be allowed to service the electrical components of this equipment Do not modify the machine without the express written approval of the manufacturer DO NOT pressure wash the control panel generator end or any other electrical components when cle
31. wc_gr004001 2 Place the START RUN switch in the ON position 3 Check the voltage between pin 1 plug 2 yellow wire 63 and ground Is at least 9 8V measured Yes No Your reading Coninue The ECM has failed Call Wacker Neuson Service 4 Check the voltage between pin 2 plug 2 violet wire 64 and ground Is at least 9 8V measured Yes No Your reading Outgoing power from the The ECM has failed ECM is OK Call Wacker Neuson Service Outgoing power from the ECM has now been checked wc_tx000723gb fm 4 7 ECM Sensor Troubleshooting Mobile Generator 5 3 Checking Temperature Sender Prerequisites Procedure wc_tx000723gb fm Fully charged battery Follow the procedure below to check the ECM and the temperature sender 1 Openthe large hinged panel and locate the temperature sender Y ST e Temperature i sender wc_gr003981 2 Disconnect yellow wire 57 from the temperature sender 3 Place the START RUN switch in the ON position 4 Measure the voltage between yellow wire 57 and ground Is at least 4 8 VDC measured Yes No _ Your reading Go to step 8 Continue 5 Open the control panel and locate the ECM 6 Place the START RUN switch in the ON position 7 Measure the voltage between ECM plug 1 pin 5 and ground Is at least 4 8 VDC measured Yes No Your reading Repair yellow wire 457 then The ECM has failed continue Call Wacke
32. 0 Disconnect the fuel return line e 9 10 11 Remove the fan guard f 9 10 12 Disconnect the ground strap g from the engine 9 10 13 Disconnect the engine from the frame by removing the screws that secure the shock mounts 9 10 14 Using as appropriate hoist or crane lift the engine up and out of the frame WACKER 96 wc_tx000575gb fm NEUSON Mobile Generator Disassembly Assembly wc_gr003351 Ju a WACKER c_tx000575gb f 97 NEUSON Disassembly Assembly Mobile Generator 9 11 Installing the Engine See Graphic wc_gr003352 9 11 1 This procedure requires an appropriate crane capable of lifting 1000 kg 2200 Ibs Using as appropriate hoist or crane lower the engine into the frame y 9 11 2 Secure the engine to the frame with the screws that secure the shock mounts 9 11 3 Connect the ground strap g to the engine 9 11 4 Install the fan guard f 9 11 5 Connect the fuel return line e 9 11 6 Connect the exhaust pipe d to the engine Tighten the clamp at the muffler 9 11 7 Connect the radiator hoses c to the engine 9 11 8 Fill the radiator with coolant 9 11 9 Using an appropriate hoist or crane lower the control panel enclosure onto the frame 9 11 10 Connect and the fuel line b to the fuel filter 9 11 11 Connect the wiring harness a to the engine Secure the harness as necessary with wire ties 9 11 12 Install the battery 9 11 13 Install the generator See section Replacing the G
33. 220M Heat parts before disassembly 73285 50 ml Temp range 54 to 149 C 65 to 300 F Loctite 290 Green Medium to high strength for locking 28824 5 ml Hernon 431 preassembled threads and for sealing 25316 10 ml Omnifit 1710 230LL weld porosity wicking Gaps up to 0 13 mm 0 005 Temp range 54 to 149 C 65 to 300 F Loctite 609 Green Medium strength retaining compound for 29314 5 ml Hernon 822 slip or press fit of shafts bearings gears Omnifit 1730 230L pulleys etc Gaps up to 0 13 mm 0 005 Temp range 54 to 149 C 65 to 300 F Loctite 545 Brown Hydraulic sealant 79356 50 ml Hernon 947 Temp range 54 to 149 C 65 to 300 F Omnifit 1150 50M Loctite 592 White Pipe sealant with Teflon for moderate 26695 6 ml Hernon 920 pressures 73289 50 ml Omnifit 790 Temp range 54 to 149 C 65 to 300 F Loctite 515 Purple Form in place gasket for flexible joints 70735 50 ml Hernon 910 Fills gaps up to 1 3 mm 0 05 Omnifit 10 Temp range 54 to 149 C 65 to 300 F Threadlockers and Sealants Threadlockers and Sealants continued Threadlocking adhesives and sealants are specified throughout this manual by a notation of S plus a number S and should be used where indicated Threadlocking compounds normally break down at temperatures above 175 C 350 F If a screw or bolt is hard to remove heat it using a small propane torch to break down the sealant
34. Disconnect the 4 pin connector it has 3 wires from the ECM 3 Remove the green and black wires from the AVR 4 Measure the resistance across the green and black wires Is 0 2 1 0 Ohms measured Yes No Your reading Continue Remove the vent cover from the generator and check the generator for damage 5 Measure the resistance between the green wire and the ground lug Also check between the black wire and the ground lug Is 0 2 1 0 Ohms measured Yes No Your reading Continue Remove the vent cover from the generator and check the generator for damage 6 Remove the bus bar between the neutral lug and the ground lug 7 Measure the continuity between the green wire and the ground lug Also check between the black wire and the ground lug Does each wire measure OPEN or OL to the ground lug Yes No Your reading The sensing wires Remove the vent cover from the generator and are OK check the generator for damage 8 Reconnect the 4 pin connector and the green and black wires to the AVR NOTICE NEVER run the generator when the green and black wires are disconnec ted from the AVR and all other wires are connected to the AVR Damage to the gen erator will occur 9 Reconnect the bus bar DO NOT run the generator with the bus bar disconnected The AVR sensing wires have now been checked Continue with Flashing the Generator wc_tx000726gb fm 75 Output Voltage Troubleshooting Mobile
35. HE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS Improper connection of 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 laws and electrical codes If connected to a building s electrical system the generator must meet the power voltage and frequency requirements of the equipment in the building Differences in power voltage and frequency requirements may exist and improper connection may lead to equipment damage fire and personal injury or death 11 Safety Information G 85 1 2 wc_si000356gb fm Service Safety A WARNING 1 2 1 1 2 2 1 2 3 1 2 4 1 2 5 1 2 6 1 2 7 1 2 8 1 2 9 1 2 10 A poorly maintained machine can become a safety hazard In order for the machine to operate safely and properly over a long period of time periodic maintenance and occasional repairs are necessary NEVER perform even routine service oil filter changes cleaning etc unless all electrical components are shut down Before servicing this machine make sure the engine start switch is turned to off O the circuit breakers are open off the emergency stop switch is closed pushed in and
36. M Plug 4 Wires Wire Description Wire Description Ammeter line input CT3 Voltage line input L3 at volt selector 28 Ammeter input CT com mon Voltage line input L2 at volt selector 20 Ammeter line input CT2 Voltage line input L1 at volt selector 3 Ammeter line input CT1 wc_td000214gb fm G 85 Technical Data 967 0016 om duly 062 98 9 dwy 9zz 02 9 dwy 321 099 ON NM TT 1488 Cer O O ow 33 222 Oso moo 100 128 0620003 124 gb fm wc_td000214 G 85 mb See Graphic wc_gr003296 Description Lug door safety interlock switch Technical Data Description Voltage Selector Switch VSS Mechanical lugs Generator Plug 3 current transformer inputs Automatic Voltage Regulator AVR Plug 4 line voltage inputs Voltage adjustment rheostat Shunt Terminal block 120V 20A GFI receptacle Exciter rotor windings 120V breaker Exciter stator winding 240V 50A breaker Rotor O NIOJ om BR OJN 240V 30A breaker 240V 50A receptacle Rectifier diodes Main rotor winding 240V 30A receptacle Main stator windings Engine Control Module ECM Bus bar Auxiliary winding Main breaker Stator Terminal strip ECM Plug
37. Mobile Generator G 85 0171726en 004 0809 0 7 1 7 6 N 1 2 E Copyright notice Trademarks Manufacturer Copyright 2009 by Wacker Neuson Corporation All rights including copying and distribution rights are reserved This publication may be photocopied by the original purchaser of the machine Any other type of reproduction is prohibited without express written permission from Wacker Neuson Corporation Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights Violators will be prosecuted All trademarks referenced in this manual are the property of their respective owners Wacker Neuson Corporation N92W15000 Anthony Avenue Menomonee Falls WI 53051 U S A Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Mobile Generator Repair Foreword This manual covers machines with Item Number 0009369 0009459 0620003 Operating Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it Basic operating and maintenance procedures are described in the Operator s Manual supplied with the machine 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 either of the documents please contact Wacker Neuson Corporation to order a
38. No The main stator windings are OK If there is a difference between the readings taken here and those taken at the lugs the VSS has failed replace it 5 Reconnect the wires and reinstall the generator components The main stator windings have now been checked 82 The main stator win dings have failed Call Wacker Neuson Service Mobile Generator Disassembly Assembly 9 Disassembly Assembly 9 1 9 2 9 3 9 4 Tools Because all possible problems encountered while repairing the machine cannot be anticipated it is up to the mechanic to use common sense and good judgement in tool selection The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate Before substituting another tool or procedure you should be satisfied that neither personal injury nor damage to the component will result Ordering Parts The repair procedures contained in this manual do not include part numbers For parts replacement information refer to the Parts Book originally supplied with the machine If the original Parts Book has been lost a replacement may be ordered from Wacker Neuson Corporation When ordering a replacement Parts Book please list the model number item number revision level and serial number of the machine Parts Books are also available on the Wacker Neuson Corporation Web site See www wackerneuson com Enter the site as a visitor
39. S box 9 16 11 Connect the wiring to the VSS 9 16 12 Reinstall the cover a of the VSS box and the air filter Y WACKER NEUSON 1 08 wc_tx000575gb fm Mobile Generator Disassembly Assembly Ora Tis IN 0 wc_gr003284 we_tx000575gb fm 109 Y VACKER Disassembly Assembly Mobile Generator 9 17 G50 G 70 G 85 VSS Wiring Gen Gen l TS TS E T6 Y ni a E m 1 5 9 13 17 2il 25 a NA 9 23 2 3 7 11 15 1 7 a T12 L2 AVR to Automatic Voltage Regulator ECM to Engine Control Module a cg Gen TB TB Gen from generator TB to terminal block R1 T7 on older TB to terminal block R2 T9 on older Gen Gen TS Lug TS TS to terminal strip E CB to main circuit breaker N O N N i 00 ar A si o o o EP N My 28 24 20 164121 8 4 al El L2 T5 Or CB TS Gen G ECM Y I TB AVR lella ali wc_gr003928 WACKER 1 10 000575gb f Y NEUSON eS Mobile Generator Disassembly Assembly Notes we_tx000575gb fm 111 Y SN Technical Data G 85 10 Technical Data 10 1 Engine Data Item Number G 85 0009369 G 85 0009459 0620003 rev 115 amp 0620003 rev 114 amp above lower Engine make type John Deere 4 5L Model
40. Starter motor Fuel temperature sensor Starter motor solenoid 16 Fuel pump control solenoid wc_tx000698gb fm 6 1 Engine Starting Troubleshooting G 85 7 Engine Starting Troubleshooting 7 1 Checking the Fuses Prerequisites Procedure wc_tx000678gb fm Fully charged 12 Volts battery Follow the procedure below to check the fuses 1 Locate the 10A and 30A fuses near the John Deere Engine Control Unit ECU wc_gr003735 2 Check the condition of the 10A fuse Is the fuse OK Yes No Continue Replace the fuse with one of the same size and rating 3 Check the condition of the 30A fuse Is the fuse OK Yes No Continue Check the function of the main circuit breaker The shunt of the main circuit breaker is most likely the cause of a fuse failure See Section 7 7 Checking the Main Circuit Breaker 4 Check the condition of the ECM 10A fuse wc_gr003913 Is the fuse OK Yes No The fuses are OK Replace the fuse with one of the same size and rating The fuses have now been checked 62 G 85 Engine Starting Troubleshooting 7 2 Checking the Engine Control Module ECM Prerequisites Procedure wc_tx000678gb fm Generator shut down Follow the procedure below to check the ECM 1 Open the control panel and locate the ECM Pr 10A ECM wc_gr003720 2 Place the START RUN switch in
41. aning the machine Never allow water to accumulate around the base of the generator set If water is present DO NOT service ALWAYS replace the safety devices and guards after repairs and maintenance ALWAYS let the engine cool before transporting or servicing the machine 12 G 85 1 3 wc_si000356gb fm 1 2 11 1 2 12 1 2 13 1 2 14 1 2 15 1 2 16 Safety Information ALWAYS remain aware of moving parts and keep hands feet and loose clothing away from the moving parts of the machine ALWAYS replace all guards fasten doors and make sure all safety devices operate properly after making repairs or servicing the equipment ALWAYS keep hands feet and loose clothing away from the moving parts on the generator and engine 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 ALWAYS check all external fasteners at regular intervals ALWAYS 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 Always remain aware of the location of other people in the area when lifting the machine Operator Safety while using Internal Combustion Engines A Internal combustion engines present special hazards during operation and fueling Read and follow the warning instructions in the eng
42. at 250 and counts down to 0 The ECM displays this screen during the first cranking cycle 80 P2 60 0 71 75 87 12 7 Qe OIE E The ECM displays this screen as soon as the engine starts Note that some of the values such as voltage may not be up to their running values at this stage of the sequence v A Hz Under Frequency Enabled e lt b OF V A HZ 480 P2 O 60 0 71 75 87 12 7 The ECM displays this screen to let the operator know that the under frequency system engine speed has been enabled At this point in the sequence the ECM displays running values VIOLA Hz Engine Protection Enabled The ECM displays this screen to let the operator know that the engine protection system has been enabled WACKER NEUSON 26 wc_tx000713gb fm Mobile Generator ECM Background Information The ECM displays the AC configuration as determined by Li A me the position of the voltage selector switch VSS AC Configuration Qe lt OF The ECM displays this screen to let the operator know that the alternator protection system has been enabled VIOLA Hz Alt Protection Enabled 4 Gi The ECM displays the line to line voltage This screen is i y A ne shown for 3 phase VSS pos
43. ce the key into the lug door switch 8 Check for continuity between the orange wires orange and orange white wires on older machines Is there continuity Yes No The lug door switch has failed replace it The lug door switch is OK 9 Reconnect the blue and blue white wires to the lug door switch Also reconnect the orange wires orange and orange white wires on older machines 10 Re install the key latch to the lug door Note eave key disconnected if moving to the next check The lug door switch has now been checked Continue with Checking the Main Circuit Brea ker 70 Mobile Generator Output Voltage Troubleshooting 8 3 Checking the Main Circuit Breaker Prerequisites Procedure wc_tx000726gb fm a Fully charged battery m Emergency stop switch in disengaged out position Follow the procedure below to check the main circuit breaker As a reminder place a check mark next to the answer that applies 1 With the lug door closed place the main circuit breaker in the ON position Does the main circuit breaker stay in the ON position Yes No Continue The main circuit breaker has failed replace it 2 With the main circuit breaker in the ON position open the lug door Does the main circuit breaker trip Yes No Continue The main circuit breaker has failed replace it 3 Open the large hinged panel and disconnect the yellow Y wire leading to the shunt of the main circ
44. ck wire 14 Is there a path to ground Yes No Your reading Continue Repair or replace wire 050D or wire 14 6 Place the START RUN switch in the ON position 7 Check the voltage between the red wire running to the starter solenoid and ground Is at least 9 8VDC measured Yes No Your reading The starter relay is OK The starter relay has failed replace it The starter relay has now been checked Continue with Checking the Starter Solenoid wc_tx000678gb fm 6 5 Engine Starting Troubleshooting G 85 7 5 Checking the Starter Solenoid Prerequisites Procedure wc_tx000678gb fm m Battery voltage measuring 11 13VDC Follow the procedure below to check the starter solenoid 1 Locate the starter and the starter solenoid wc_gr003724 2 Check the connection of the large red wire 3 Check the voltage between the large red wire and ground Is at least 9 8VDC measured Yes No Your reading Continue Repair or replace the large red wire 4 Place the START RUN switch in the ON position Check voltage between the small red wire and ground during the cranking cycle Is at least 9 8VDC measured Yes No Your reading Continue Repair or replace small red wire 5 If at least 9 8VDC is present at the starter and at the starter solenoid the engine should crank If the engine does not crank the starter motor has failed Replace the starter motor The starter solenoid has no
45. d to the start switch wc_tx000713gb fm WACKER a3 NEUSON ECM Sensor Troubleshooting Mobile Generator 5 ECM Sensor Troubleshooting 5 1 Checking Power to the ECM Prerequisites Fully charged 12 Volts battery Procedure Follow the procedure below to check the fuses 1 Locate the 10A and 30A fuses near the John Deere Engine Control Unit ECU wc_gr003735 2 Check the condition of the 10A fuse Is the fuse OK Yes No_ Continue Replace the fuse with one of the same size and rating 3 Check the condition of the 30A fuse Is the fuse OK Yes No Continue Check the function of the main circuit breaker The shunt of the main circuit breaker is most likely the cause of a fuse failure See section 5 10 Checking the Main Circuit Breaker 4 Check the condition of the ECM 10A fuse wc_gr003913 Is the fuse OK Yes No The fuses are OK Replace the fuse with one of the same size and rating This procedure continues on the next page wc_tx000723gb fm 44 Mobile Generator ECM Sensor Troubleshooting Continued from the previous page 5 Check the voltage between red wire 51 at B terminal strip and ground B TERMINAL STRIP R 51 START RUN SWITCH wc_gr003997 Is at least 9 8V measured Yes No Your reading Continue Repair red wire 51 6 Check voltage between red wire 49 at START RUN switch and ground Is at
46. display panel as adjustments are made WARNING Electric shock hazard High voltage exists at the cooling fins of the Automatic Voltage Regulator AVR when the engine is running Electric shock can cause injury or death Do not touch the AVR wc_gr004012 3 Locate the AC frequency push button Hold the AC frequency push button in until the ECM display reads 60 Hz 4 Set the engine no load speed to 1850 rpm The ECM AC frequency has now been calibrated wc_tx000723gb fm 5 3 ECM Sensor Troubleshooting Mobile Generator 5 8 Calibrating ECM DC Display Prerequisites Functioning generator Procedure Follow the procedure below to calibrate the ECM DC voltage 12V battery display wc_gr003996 1 Measure the voltage across the machine s 12V battery using a multimeter Note This procedure works best when the battery voltage measures 12 6 VDC 2 Place the start switch in the REMOTE START position 3 Open the control panel to gain access to the ECM 4 Slide the number 2 Dual In line Package DIP switch to the ON position and then back to the OFF position This resets the DC voltage display The ECM DC voltage display is now calibrated wc_tx000723gb fm 54 Mobile Generator ECM Sensor Troubleshooting 5 9 Checking the ECM CAN BUS Circuit Prerequisites Generator shut down ECM turned off Procedure Follow the procedure below to check the ECM CAN BUS circuit 1 Open the control panel 2 Disconnect the CAN BUS c
47. e Prealarm Setting Level lt 70F EL US A engine temperature is less than 70 F the engine temper ature reading on the run screen will blink V 0 A The display shows the value of the prealarm setting for high engine temperature If the ECM detects that the Prealarm Setting engine temperature is greater than 234 F 218 F on Level gt 234 F Isuzu engines the engine temperature reading on the de GE S run screen will blink V 0 A The display shows the value of the fault setting for high engine temperature If the ECM detects that the engine Fault Setting temperature is greater than 239 F 221 F on Isuzu 5secO gt 234F engines for longer than 5 seconds the ECM will shut Qe CM OF ES down the generator The display shows the status of the fuel sender If the fuel sender has failed the time of the failure will be displayed V A HZ Fuel Sender The time of the failure will be included in the display until Status is Normal the generator has been shut down and remains shut oe Gb OF Fa down for a period of approximately two minutes The display shows the value of the prealarm setting for low fuel level If the ECM sees that the fuel level has V A HZ Prealarm Selling dropped below 25 the fuel level reading on the run Level lt 25 di screen will start to blink Y lt OF E
48. e main circuit breaker 4 Attach a clamp style ammeter to one of the lines connected to the lugs 5 Observe the ECM display as it cycles through the amperage values for each leg Place the hour meter switch into the down position when the ECM displays an amperage value wc_gr003938 6 Compare the Amp reading on the ammeter with that on the ECM display Are the readings within 0 5 Amps Yes No Your reading No adjustment is necessary Continue 7 Open the control panel and locate the AMPS ADJ pot WARNING Electric shock hazard High voltage exists at the cooling fins of the Automatic Voltage Regulator AVR when the engine is running Electric shock can cause injury or death Do not touch the AVR 8 Adjust the AMPS ADJ pot until the ECM reads the same as the amperage measured by the ammeter 9 Close the control panel The ECM amperage display has now been calibrated wc_tx000723gb fm 52 Mobile Generator ECM Sensor Troubleshooting 5 7 Calibrating ECM AC Frequency Display Prerequisites Functioning generator Procedure Follow the procedure below to calibrate the ECM AC frequency display Note Recalibrate only if your unit is off by more than 5 Hz 1 Start the generator Using a tachometer or vibrotach adjust the engine speed to 1800 rpm or 60 Hz 2 Open the control panel to gain access to the ECM Monitor the ECM
49. e safety alert symbol It is used to alert you to potential A symbol to avoid possible injury or death DANGER indicates a hazardous situation which if not avoided will result in death or serious injury DANGER WARNING indicates a hazardous situation which if not avoided could result in death or serious injury WARNING CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury CAUTION 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 Electrocution hazard Electrocution or severe electrical shock hazards are present throughout the generator any time the engine is running Read all safety notes contained in this section before operating or servicing this equipment No one except a trained electrician familiar with this equipment should attempt repairs to the generator Test procedures which require that the generator be running must be performed using extreme caution This machine is built with user safety in mind however like any electrical device it can present serious hazards if improperly operated and serviced Follow instructions carefully Should questions arise during operation or service of this equipment contact Wacker Neuson Corporation WARNING we_si000356gb fm 9 Safety Information G 85 1 1 wc_si000356gb f
50. e the rubber washer f onto the pushbutton portion of the switch then insert the pushbutton through the door 9 14 5 Align the washer so that the tab g is 180 from the notch h in the door Slide the washer onto the pushbutton so that the tab of the washer fits in the groove i of the pushbutton Secure the pushbutton with the locking nut d 9 14 6 Reconnect the wiring to the contact block 9 14 7 Attach the contact block to the pushbutton and slide the locking tab a to the locked position WACKER 1 04 wc_tx000575gb fm NEUSON Mobile Generator Disassembly Assembly 79 64 Gr 61 wc_gr003677 e WACKER c_tx000575gb f 105 NEUSON Disassembly Assembly Mobile Generator 9 15 Replacing the Diodes Prerequisites e Solder Flux core 60 40 e Soldering iron lt 10 Watts e Heat sink putty or two alligator clips to act as heat sinks e Epoxy Procedure Follow the procedure below to replace the diodes 9 15 1 Remove the rear access panel a from the machine wc_gr005153 9 15 2 Remove the cover b from the generator 9 15 3 Rotate the engine until a diode c is accessible VIA ALT NC groo5 1 54 9 15 4 Cut the diode wires near the diode and remove the diode from the holder d 9 15 5 Do not remove the existing old wires i clean them instead This procedure continues on the next page w SN 106 we_tx000575gb fm Mobile Generator Disassembly Assembl
51. ed 79 Output Voltage Troubleshooting Mobile Generator 8 12 Checking the Main Rotor Winding Prerequisites m Generator shut down Procedure Follow the procedure below to check the main rotor winding 1 Remove the rear baffle from the machine wc_gr00381 1 Remove the cover from the generator Remove the screws that secure the bearing carrier to the stator Disconnect the blue and yellow wires from the AVR Using a puller pull the bearing carrier exciter stator from the stator housing Disconnect the wires to the main rotor winding One is marked with a red tag and the other is marked with a blue tag DIA WIN nouveau 7 Measure the resistance across the two wires Is 1 4 3 Ohms measured Yes No Your reading Continue The main rotor winding has failed Call Wacker Neuson Service 8 Check each wire for short path to the rotor shaft Does each wire measure OPEN or OL to the rotor shaft Yes No Your reading The main rotor The main rotor winding has failed winding is OK Call Wacker Neuson Service The main rotor winding has now been checked Continue with Checking the Exciter Rotor Winding Note If moving on to the next test leave the generator disassembled wc_tx000726gb fm 80 Mobile Generator Output Voltage Troubleshooting 8 13 Checking the Exciter Rotor Winding Prerequisites Procedure wc_tx000726gb fm Generator shut down Follow the proc
52. ed by the generator assembly into electrical energy The generator does so through the principle of electromagnetic induction This principle states that when a coil of wire also Known as a winding is passed through a magnetic field a voltage is induced in the winding The amount of voltage depends on three factors 1 the speed of the coil cutting through the magnetic field it does not matter which is moving either the magnetic field or the winding 2 the strength of the magnetic field and 3 the amount of turns of wire in the winding The principle also works in reverse that is if voltage and current are present in a coil of wire a magnetic field is produced It is important to understand this basic theory to understand how the generator functions The typical brushless generator assembly consists of a stator stationary element a rotor rotating element a voltage regulator voltage control device and a rectifier assembly current control device The rotor can function as either the magnetic field or the winding Likewise the stator can function as either the magnetic field or the winding depending on the application In Wacker Neuson generators there are two stators a and b and a single rotor assembly c The rotor assembly is made up of two halves the exciter d and the main e Three windings make up the exciter half and a single winding makes up the main rotor half There are three distinct stator windings the excite
53. edure below to check the exciter rotor winding 1 Remove the rear baffle from the machine wc_gr003811 2 Remove the cover from the generator 3 Remove the screws that secure the bearing carrier to the stator 4 Disconnect the blue and yellow wires from the AVR 5 Using a puller pull the bearing carrier exciter stator from the stator housing 6 On older machines remove the exciter rotor leads from the diode plates The three exciter rotor leads are connected to the diode plates in between each pair of diodes Or remove the diode plates completely to access the exciter rotor leads wc_gr003709 7 On newer machines the location of the three exciter rotor leads is also in between each pair of diodes 8 Measure the resistance across each lead and the other two leads one lead at a time Is 0 3 1 0 Ohms measured in each case Yes No Your readings The exciter rotor has failed Call Wacker Neuson Service The exciter rotor windings are OK 9 Check each lead for short path to the rotor shaft Does each lead measure OPEN or OL to the rotor shaft Yes No Your reading The main rotor The main rotor winding has failed winding is OK Call Wacker Neuson Service 10 Reassemble the generator components The exciter rotor winding has now been checked Continue with Checking Stator Windings at the Voltage Selector Switch 81 Output Voltage Troubleshooti
54. eeaeeeeeeeseeeeneeeeeeeeeneaaaaes 84 9 4 WelghtBIOCK silla is 84 9 5 Removing the ROO cara aan 85 9 6 Preparing Unit for Generator Removal 87 9 7 Replacing the Generator acia a ea ania 89 9 8 REMOVINGHNC AVR strano ail ciali 91 9 9 Installing the AMA te AO 92 9 10 Removing the Engine lt ida 95 9 11 Installing the Engine aa 97 9 12 Replacing the Fuel Tank ii 99 9 13 Replacing the Emergency Stop Switch older 101 9 14 Replacing the Emergency Stop Switch newer 103 9 15 Replacing the Diodes i 105 9 16 Replacing the Voltage Selector Switch VSS 0oooococcncccccccccccccanannnnos 107 9 17 G50 G 70 G 85 VSS Wiring inline 109 10 Technical Data 110 10 1 A ah ad ili lire ts ia aa le a ee elec 110 10 2 Generator Data mesias rc 111 10 3 Trailer and Skid Data crea lidia aaa 112 10 4 DIMENSIONS creer 113 10 5 Engine Wiring Diagram John Deere with ECU 114 10 6 ECU Wiring Diagram dodo 118 10 7 ECU Harness GONnecior stola aaa ea 119 10 8 Generator Wiring Diagram i 120 Table of Contents MG Repair G 85 Safety Information 1 Safety Information This manual contains DANGER WARNING CAUTION NOTICE and NOTE callouts which must be followed to reduce the possibility of personal injury damage to the equipment or improper service personal injury hazards Obey all safety messages that follow this This is th
55. eens Start Switch in Remote Position 29 4 5 Additional Variables Monitored by the ECM 30 4 6 Voltage Display EMmovs escu leleine 36 4 7 ECM Automatic Engine Shutdown Conditions no 38 4 8 ECM Circuit BoardS sa ieee aN cal do oo ii liu ese 39 4 9 Control Wiring Numbering amp Colors 40 4 10 Removing and Installing the ECM 43 Table of Contents MG Repair 5 ECM Sensor Troubleshooting 44 5 1 Checking Power to the ECM cl ii 44 5 2 Checking Outgoing Power From the ECM n 47 5 3 Checking Temperature Sender 48 5 4 Fuel Sender Failure and Low Fuel Fault 50 5 5 Calibrating ECM Voltage Display cnn 51 5 6 Calibrating ECM AC Amperage Display in 52 5 7 Calibrating ECM AC Frequency Display 53 5 8 Calibrating ECM DC Display i 54 5 9 Checking the ECM CAN BUS Circuit 55 5 10 Checking the Main Circuit Breaker ii 56 5 11 ECM PIUGS and PINS colla 57 6 John Deere Engines With ECU 59 6 1 John Deere Engines With ECU Background 59 6 2 Locations of Engine Electrical Components 60 6 3 Engine Electrical Components nenene 61 7 Engine Starting Troubleshooting 62 7 1 a iaia i 62 7 2 Checking the Engine Control Module ECM 63 7 3 Checking the Emerg
56. ency Stop Switch 64 7 4 Checking the Starter Relay ivi 65 7 5 Checking the Starter Solenoid 66 7 6 Checking the Intake Heater Relay oooooocccconoocccccccnnoconanccccnncnnnnannnnnnos 67 7 7 Checking the Main Circuit Breaker ii 68 8 Output Voltage Troubleshooting 69 8 1 Checking the Emergency Stop Switch 69 8 2 Checking the Lug Door Switch ii 70 8 3 Checking the Main Circuit Breaker ooooooocccnnnnnnnccccnnnccnnconnccccnnnnnnannnnnos 71 8 4 Checking the Voltage Adjusting Rheostat n 72 8 5 Checking the Auxiliary Winding 73 8 6 Checking the Exciter Stator rs iria 74 MG Repair Table of Contents 8 7 Checking the AVR Sensing Wires 75 8 8 Flashing the Generator checking the excitation system 76 8 9 Checking Stator Windings at the LUGS ooooccccccccccncccccccccconanananinininanns 77 8 10 Checking the Rectifier Diodes Thread in Style 78 8 11 Checking the Rectifier Diodes Solder in Style 79 8 12 Checking the Main Rotor Winding i 80 8 13 Checking the Exciter Rotor Winding i 81 8 14 Checking Stator Windings at the Voltage Selector Switch 82 9 Disassembly Assembly Procedures 84 9 1 POOS as heres ot ahaa ta eto lori 84 9 2 OrdsiMg alc dic ae 84 9 3 Reference Numbers ccceeeeeeeeeeeeeeeeeeee
57. ency Stop Switch older 9 13 1 9 13 2 9 13 3 9 13 4 9 13 5 9 13 6 9 13 7 9 13 8 Turn off the generator before replacing the emergency stop switch Removal Slide the locking tab a to the unlock position and pull the switch off the pushbutton Label and disconnect the wiring from the switch Remove the locking nut b and washer Remove the screws c that secure the pushbutton and remove the pushbutton Installation Slide the pushbutton portion through the door Note Position the pushbutton with TOP marking facing up Secure the pushbutton with screws c Attach washer and locking nut b Reconnect the wiring Attach the switch to the pushbutton and slide the locking tab a to the locked position y WACKER NEUSON 1 02 wc_tx000575gb fm Mobile Generator Disassembly Assembly 6 wc_gr003286 Nn 9 WACKER c_tx000575gb f 103 NEUSON Disassembly Assembly Mobile Generator 9 14 Replacing the Emergency Stop Switch newer See Graphic wc_gr003677 Turn off the generator and disconnect the battery before replacing the emergency stop switch y Removal 9 14 1 Slide the locking tab a to the unlock position and pull the contact block b off the pushbutton c portion of the switch 9 14 2 Label and disconnect the wiring from the contact block 9 14 3 Remove the locking nut d and washer e and remove the pushbutton portion of the switch Installation 9 14 4 Slid
58. enerator 9 11 14 Install the roof WACKER 98 wc_tx000575gb fm NEUSON Mobile Generator Disassembly Assembly es ea o i pu j El a ZA e A Z A I Z i y AJ i we_gr003352 wc_tx000575gb fm 9 9 WACKER NEUSON Disassembly Assembly Mobile Generator 9 12 Replacing the Fuel Tank See Graphic wc_gr003350 This procedure requires a crane or hoist capable of lifting 1900 kgs 2000 Ibs y Removal 9 12 1 Disconnect the fuel hoses and the fuel sender wiring 9 12 2 Remove the screws that secure the upper frame assembly a to the lower frame skid b 9 12 3 Using an appropriate crane or hoist lift the upper frame assembly off the lower frame assembly 9 12 4 Remove the screws that secure the fuel tank c to the lower frame assembly 9 12 5 Using an appropriate crane or hoist lift the fuel tank from the lower frame assembly Installation 9 12 6 Using an appropriate crane or hoist lower the fuel tank into the lower frame assembly 9 12 7 Secure the fuel tank c to the lower frame assembly 9 12 8 Using an appropriate crane or hoist lower the upper frame assembly onto the lower frame assembly 9 12 9 Secure the upper frame assembly a to the lower frame skid b WACKER 1 00 wc_tx000575gb fm NEUSON Mobile Generator Disassembly Assembly wc_gr003350 we_tx000575gb fm 101 wi Negrar Disassembly Assembly Mobile Generator 9 13 Replacing the Emerg
59. ent exists when a three phase load is attached to the generator The three phase load uses both the voltage and current from each phase produced by the generator simultaneously Positive current produced by the voltage from each leg flows to corresponding legs of the load Sine 60 0 866 Sine 60 0 866 Sine 60 a 277 30 Sine 60 a 120 0 866 a 277 0 866 a 120 277 x 0 866 a 277 x 277 120 120 x 0 866 a 120 x 120 240 a 104 a 2 a 480 a 2 a 208 gt 208 120 88 88 120 0 73 73 wc_gr003317 20 Mobile Generator Theory of Operation wc_tx001077gb fm Wacker Neuson generators are designed to accommodate various loads and multiple power factors Power factor is the relationship between power supplied to the load referred to as apparent power in kVA and true power power used by the load kW It is expressed mathematically by the equation power factor true power apparent power The power factor is determined by the type of load inductive or resistive In resistive loads such as heaters the power factor is typically 1 In inductive loads such as motors and transformers the power factor is always less than 1 In inductive loads a portion of the supplied power is converted to a magnetic field and not used by the load This unused power is known as reactive power The relationship between apparent power true power and reactive power is illustrated in the power right triangle below
60. ergency DO NOT restart the engine until the cause of the trouble has been determined and fixed Wear hearing protection when operating equipment ALWAYS follow starting and stopping instructions described in this manual Know how to operate and stop generator before starting it ALWAYS make a walk around inspection of the generator set before starting it Open side doors and visually inspect engine compartment for obvious damage or the presence of foreign objects which might affect operation ALWAYS keep the machine at least one meter three feet away from structures buildings and other equipment during use 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 10 G 85 wc_si000356gb fm 1 1 17 1 1 18 1 1 19 1 1 20 DANGER Safety Information ALWAYS 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 Be sure the machine is on a firm level surface and will not tip roll slide or fall while operating ALWAYS remove all tools cords and other loose items from the generator before starting it ALWAYS make certain the machine is well grounded and securely fastened to a good earthen ground per national and local regulations BACKFEED FROM T
61. eter should read 0 4 0 5V in the direction that conducts Does each diode check OK Yes No The diodes are OK Replace all diodes Call Wacker Neuson Service 8 Reconnect the AVR 9 Reconnect the diodes Be sure to include the washer when reconnecting the diode lead The rectifier diodes have now been checked Continue with Checking the Main Rotor Win ding Note f moving on to the next test leave the generator disassembled wc_tx000726gb fm 78 Mobile Generator Output Voltage Troubleshooting 8 11 Checking the Rectifier Diodes Solder in Style Prerequisites Procedure wc_tx000726gb fm Generator shut down Follow the procedures below to check the rectifier diodes 1 Remove the rear baffle a from the machine wc_gr005153 2 Remove the cover b from the generator 3 Rotate the engine to access the diodes 4 Using the diode scale on your multimeter place the meter leads near the diode one on either side Reverse the probes of your meter and check the diode again wc_gr005168 Each diode should conduct in one direction and not in the other Your meter should read 0 4 0 5V in the direction that conducts Does each diode check OK Yes No The diodes are OK Replace all diodes Call Wacker Neuson Service The rectifier diodes have now been checked Continue with Checking the Main Rotor Win ding Note If moving on to the next test leave the generator disassembl
62. from most oO M OF E current to least current See the John Deere Engine Manual for details The display shows total time in 1 10 hour increments a that the engine has been run New machines or Engine Hours machines with new ECMs will read No Data because 1 9 the engine has not been run for more than 1 10 of an OF E hour The display shows the amount of time left until service on the machine is required To reset the timer to 250 hours A Time to Service hold the Hours Reset toggle switch in the up position until 250 l all the screens have been scrolled through twice Qe The display shows the amount the throttle is open at the Current point in time Throttle 10 gt Ned SE ri 34 wc_tx000713gb fm Mobile Generator ECM Background Information The display shows the present load on the engine For no 147 Fuel Pressure Y y A Hiz load conditions generator not powering any outside tools Da Saia or equipment the display will read 15 Qe OF V A HZ The display shows the percentage of total engine torque being used Engine Torque 60 Qe M GF FA V 0 A HZ The display shows in F the temperature of the fuel Fuel Temperature 86 F FOA lt
63. gnostic abilities and shares engine diagnostic information through codes which are displayed on the ECM display screen These diagnostic codes are referred to as SPN FMI codes Suspect Parameter Number SPN and Failure Mode Identifier FMI SPN FMI codes are conveyed in a two part code number The SPN typically contains between two and four digits and is the first number of the code The FMI contains one or two digits and is the second number of the code For example if the ECM displays SPN FMI 100 4 The SPN 100 indicates a condition with the engine oil FMI 4 indicates that the engine oil pressure input voltage is lower than the sensor s specification a condition associated with a disconnected oil pressure sensor There are many such SPN FMI codes See the John Deere service manual for more information 59 John Deere Engines With ECU Mobile Generator 6 2 Locations of Engine Electrical Components wc_gr003343 wc_tx000698gb fm 60 Mobile Generator John Deere Engines With ECU 6 3 Engine Electrical Components See Graphic wc_gr003343 Component Component Main circuit breaker Starter relay Engine Control Module ECM Oil pressure sensor Alternator Engine Control Unit ECU Slave preheat relay Crank position sensor Manifold air temperature sensor Fuel pump assembly Manifold heater Coolant temperature sensor
64. h in Locked Position Another possible display error can occur when starting the machine with the engine hour switch a in the down locked position This position is normally used to lock the display onto a single leg and to prevent the display from scrolling through volt and amp values for all three legs On some generators starting the engine with the switch in the down locked position will reverse the display for volts and amps To correct the display return the engine hour switch to its unlocked scroll position To ensure the correct voltage display make sure e The connection lug door is closed and latched before starting the engine e The voltage selection switch is in its correct position prior to start ing the engine The engine hour switch is in its unlocked center position wc_gr003308 wc_tx000713gb fm WACKER 37 W NEUSON Mobile Generator ECM Automatic Engine Shutdown Conditions ECM Background Information 4 7 The engine protection system includes six automatic shutdown conditions low oil pressure high coolant temperature engine underspeed overspeed engine overcrank low fuel The ECM will also shut down the engine if an over current condition exists When the ECM has shut down the unit due to one of the faults the ECM will display the fault and other pertinent information to a
65. he trailer using defective parts ALWAYS make sure the coupling is securely fastened to the vehicle ALWAYS check the tires on the trailer for tread wear inflation and condition Replace worn tires ALWAYS connect the safety chains ALWAYS connect the breakaway cable safety hook to the bumper or rear of the vehicle DO NOT attach it to the hitch ALWAYS test the surge brakes on the trailer and the brakes on the vehicle that will be used for towing ALWAYS make sure directional and trailer lights are connected and working properly ALWAYS check that the lug nuts holding the wheels are tight and that none are missing Reporting Trailer Safety Defects If you believe your trailer has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Wacker Neuson Corporation If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Wacker Neuson Corporation To contact NHTSA you may either contact the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0129 in Washington DC area www nhtsa com or write to NHTSA U S Department of Transportation 400 7th Street SW NSA 11 Washington DC 20590 You ca
66. id in diagnosing the problem RECORD ALL THE INFORMATION LISTED on the display then refer to the following sections to diagnose and rectify the problem When the engine has shut down due to something outside the control of the ECM the ECM will display ENGINE STOPPED Shutdown setpoint Pre alarm setpoint Low oil pressure 20 psi 15 psi High coolant temperature 100 C 211 F Isuzu 112 C 234 F John Deere 105 C 221 F Isuzu 115 C 239 F John Deere Underspeed n a 55 Hz 1650 rpm Overspeed Overcrank n a 67 Hz 2010 rpm After third attempt Fuel level 5 WACKER W NEUSON 38 wc_tx000713gb fm Mobile Generator 4 8 ECM Circuit Boards Pa EEE M LL 7 Lem Y 3 P OF 129110918 gt 6 5 4 3 2 211 7 3 LIL DVD LD AZZ P1 Ly y COME 8 7 6 5 V po le s aJs e 1 Y aisil ECM Background Information wc_gr002924 Note Your machine s ECM board may differ slightly from the one pictured Description AC board Engine board Crank relay Fuel relay Preheat relay Power and engine sensing Power to crank fuel and fault prealarm closures AC Amps connection to current transformers AC Volts connection to voltage selector switch wc_tx000713gb fm WACKER 39 NEUSON ECM Background Information Mobile Generator 4 9 Control Wiring Nu
67. ine owner s manual and the safety guidelines below Failure to follow the WARNING warnings and safety standards could result in severe injury or death 1 3 1 1 3 2 1 3 3 1 3 4 1 3 5 1 3 6 1 3 7 1 3 8 Do not run engine indoors or in an area with poor ventilation unless exhaust hoses are used Do not fill or drain the fuel tank near an open flame while smoking or while the engine is running Do not refuel a hot or running engine Refill the fuel tank in a well ventilated area Do not touch or lean against hot exhaust pipes Replace the fuel tank cap after refueling Do not start the engine if fuel has spilled or a fuel odor is present Move the generator away from the spill and wipe the generator dry before starting Do not remove the radiator cap when the engine is running or hot The radiator fluid is hot and under pressure and may cause severe burns 13 Safety Information G 85 1 4 1 5 wc_si000356gb fm Towing Safety A WARNING 1 4 1 1 4 2 1 4 3 1 4 4 1 4 5 1 4 6 1 4 7 1 4 8 1 4 9 Towing a large trailer requires special care Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident ALWAYS check that the hitch and coupling on the vehicle are rated equal to or greater than the trailer s gross vehicle weight rating GVWR ALWAYS inspect the hitch and coupling for wear or damage DO NOT tow t
68. inistrator All rights especially copying and distribution rights are reserved Copyright 2009 by Wacker Neuson Corporation No part of this publication may be reproduced in any form or by any means electronic or mechanical including photocopying 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 We expressly reserve the right to make technical modifications even without due notice which aim at improving our machines or their safety standards MG Repair Table of Contents 1 Safety Information 9 1 1 Operating Safety sceniche bi alal salito 10 1 2 A neren ennn n 12 1 3 Operator Safety while using Internal Combustion Engines 13 1 4 TOWINgisaleyiassc orale lisina 14 1 5 Reporting Trailer Safety Defects 14 2 Theory of Operation 15 2 1 Basic SCNEMAlIC aaa dios 15 2 2 os A aah te att ie 16 2 3 ESTAN ai oa tia Apiro anna 18 3 Electrical Testing Techniques 22 3 1 Checking COMMUN sd loa 22 3 2 Checking Resistance i 22 3 3 Checking Voltage aa ani 22 3 4 Probing ECM Plugs and Pins sai lhi 23 4 ECM Background Information 24 4 1 EGM Randig Precaulioni a Selena are 24 4 2 Normal Boot up Sequence i i 25 4 3 Display Variables and Valles cesiones rli rnsiolacania 28 4 4 ECM Display Scr
69. inuity and the wiring or component must be repaired or replaced Note Some multimeters also have an audio signal setting for determining continuity This setting may also be used e If your meter reads less than 1 0 Ohm or the audio signal sounds the wiring or component has continuity and should be OK e If your meter reads more than 1 0 Ohm the wiring is faulty and must be repaired or replaced 3 2 Checking Resistance Conduct resistance checks when the engine is shut down Use the Ohm setting on your multimeter Conduct resistance checks when the machine is as close to 21 C 70 F as possible Higher temperatures can affect resistance values Most digital multimeters have some internal resistance To obtain your multimeter s internal resistance simply cross the two leads of your multimeter and read the display When conducting a resistance check subtract your multimeter s internal resistance from the value you measure to obtain the true resistance of the component you are checking 3 3 Checking Voltage Conduct voltage checks when the engine is running Use the Volt setting on your multimeter To prevent damage to your instrument start with the highest scale available on your multimeter Adjust to a lower scale as readings dictate Use extreme caution when checking voltage to reduce the risk of electric shock Y WACKER NEUSON 22 wc_tx000699gb fm Mobile Generator Electrical Testing Techniques 3 4 Probing
70. itions only Rated Volts L to L e lt V 0 HZ At this point the ECM displays the run screen and the values for the main generator variables voltage phase 480 P2 0 60 0 leg amperage hertz For generators with engines that 71 75 87 12 7 include ECUs the Hz reading will be 60 0 For all others ole OF the reading will be 61 5 The ECM will also display the values for the main engine variables oil pressure fuel tank quantity engine temperature and battery voltage Note The ECM display scrolls through each phase P1 P2 P3 if in the 3 phase mode or L1 L3 and L1 L3 if in the single phase mode we_tx000713gb fm 27 Ww VACKER ECM Background Information Mobile Generator 4 3 Display Variables and Values See Graphic wc_gr002944 e Generator Variables The values shown in the top line of the ECM display are all variables from the generator side of the machine They are 1 voltage V 2 phase 2 or leg for single phase 3 amperage A 4 frequency Hz Engine Variables The values shown in the lower line of the ECM display are all variables from the engine side of the machine They are 5 engine oil pressure psi 6 fuel tank quantity shown in percentage of capacity 7 engine temperature F 8 battery voltage V e Blinking Values When a value on the ECM display blinks on and off it signifies that the va
71. ltage Regulator AVR wc_gr003692 2 Disconnect the red wire from the AVR 3 Disconnect the red wire from the blue wire of the lug door switch 4 Measure the resistances across the two red wires Is 1 7 2 7 Ohms measured Yes No Your reading Continue Remove the vent cover from the generator and check the generator for damage 5 Check each red wire for continuity to ground Does each wire measure OPEN or OL to ground Yes No Your reading Auxiliary winding Remove the vent cover from the generator and is OK check the generator for damage 6 Reconnect the wiring The auxiliary winding has now been checked Continue with Checking the Exciter Stator 73 Output Voltage Troubleshooting Mobile Generator 8 6 Checking the Exciter Stator Prerequisites Procedure wc_tx000726gb fm Generator shut down Follow the procedure below to check the exciter stator 1 Openthe large hinged panel and locate the Automatic Voltage Regulator AVR 2 Blue L A Blue L 2 Yellow Y 7 i Cos Via L When ry N low Y DA AVR DO AY JJe i ME STARVOLI wc_gr003693 2 Disconnect the blue and yellow wires from the AVR 3 Measure the continuity between the blue wire and ground Also measure between the yellow wire and ground
72. ly if any load change in engine rpm on the generator is sensed A change in engine rpm indicates incorrect wiring Check the wiring This procedure continues on the next page Y SN 92 wc_tx000575gb fm Mobile Generator Disassembly Assembly Continued from the previous page 9 9 11 Check the voltage between Lug 1 and Lug 2 with a multimeter Lsjtejes O a a a I O ES 9 9 12 9 9 13 9 9 14 9 9 15 9 9 16 wc_gr004590 Adjust the VOLT pot of the AVR until 250 VAC is measured between Lug 1 and Lug 2 Test the consistency by checking the voltage across Lug 1 and Lug 2 Lug 2 and Lug 3 Lug 3 and Lug 1 Then check the voltage between each lug and Neutral Approximately 139V should be measured Shut down the machine Change the voltage selector switch to the 480 277 position Start the machine Measure the voltage between Lug 1 and Lug 2 Adjust the voltage adjusting rheostat until 480V is measured Tighten the lock nut Test the consistency of the voltage by checking across Lug 1 and Lug 2 Lug 2 and Lug 3 Lug 3 and Lug 1 Then check the voltage between each lug and Neutral Approximately 277V should be measured This procedure continues on the next page wc_tx000575gb fm WACKER 93 W NEUSON Disassembly Assembly Mobile Generator Continued from the previous page 9 9 17 Check the consistency between the voltage
73. m Operating Safety A Familiarity and proper training are required for the safe operation of the machine Machines operated improperly or by untrained personnel can be hazardous Read the operating instructions contained in this WARNING manual and the engine manual and familiarize yourself with the 1 1 8 1 1 9 1 1 10 1 1 11 1 1 12 1 1 13 location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the machine before being allowed to operate it NEVER operate the generator when open containers of fuel paint or other flammable liquids are near NEVER place flammable material or liquids near the generator NEVER operate the generator or tools attached to the generator with wet hands NEVER use worn electrical cords Severe electrical shock and equipment damage may result NEVER operate the machine indoors unless exhaust fumes can be adequately ventilated NEVER overload the generator The total amperage of the tools and equipment attached to the generator must not exceed the load rating of the generator NEVER allow untrained personnel to operate or service the generator The generator set should be set up by a certified electrician NEVER operate generator in standing water NEVER touch the hot engine exhaust or generator components Burns will result NEVER start a machine in need of repair Use the emergency stop button only in an actual em
74. mbering amp Colors See Graphic wc_gr002924 Generator and control wires are marked and color coded to assist in tracing line connections and troubleshooting The charts below list wire labels and colors followed by a description of their use G 25 Control Module Plug 1 Engine Sender Inputs 12 pin connector Black Magnetic pickup Clear shield Magnetic pickup White Blue Oil pressure sender Yellow Water temperature sender Red Run Off Auto switch 12V positive Black 12VDC supply ground negative Orange Remote start contacts Red Emergency stop pushbutton White Violet Fuel level sender Plug 2 Engine Start Inputs Outputs 8 pin connector Yellow Red Out 12VDC to starter relay Violet Out 12VDC to E stop switch In 12VDC from B through 10A fuse In 12VDC from B Out 12VDC to glow plug relay urrent Transformer Inputs 6 pin connector White Ammeter line input CT common Brown Ammeter line input CT 1 Orange Ammeter line input CT3 Yellow Ammeter line input CT2 Plug 4 Line Voltage Inputs 4 pin connector 2 Brown Voltage line input L1 at volt selector 3 WY Ned SEN 40 wc_tx000713gb fm Mobile Generator ECM Background Information 3 Orange Voltage line input L3 at volt selector 28 4 Yellow Voltage line input L2 at volt selector 20 Plug 1 Engine Sender Inputs 12 pin connector Black Magnetic pick
75. measured at the lugs by the multimeter and that shown on the ECM display If the ECM display is off by more than 2 adjust the VOLT pot on the ECM so that the ECM display matches the reading on the multimeter NOTICE Only adjust the ECM pot when the voltage selector switch is in the 480 277V position wc_gr004589 9 9 18 Shut down the machine 9 9 19 Re install the key latch to the lug door 9 9 20 Close the large access panel and secure it with two screws The procedure to install and set the AVR is now complete WACKER nae Y NEUSON 94 c_tx000575gb f Mobile Generator Disassembly Assembly Notes we_tx000575gb fm 95 Y VACKER Disassembly Assembly Mobile Generator 9 10 Removing the Engine See Graphic wc_gr003351 This procedure requires an appropriate crane capable of lifting 1000 kg 2200 Ibs y 9 10 1 Remove the roof See section Removing the Roof 9 10 2 Remove the generator See section Removing the Generator 9 10 3 Remove the battery 9 10 4 Disconnect the wiring harness a from the engine 9 10 5 Disconnect and plug the fuel line b at the fuel filter 9 10 6 Using an appropriate hoist or crane lift the control panel enclosure from the frame 9 10 7 Drain the radiator 9 10 8 Disconnect the radiator hoses c from the engine 9 10 9 Disconnect the exhaust pipe d from the engine Loosen the clamp at the muffler and rotate the exhaust pipe away from the engine 9 10 1
76. n Circuit Breaker Prerequisites Procedure wc_tx000678gb fm a Fully charged battery m Emergency stop switch in disengaged out position Follow the procedure below to check the main circuit breaker As a reminder place a check mark next to the answer that applies 1 With the lug door closed place the main circuit breaker in the ON position Does the main circuit breaker stay in the ON position Yes No Continue The main circuit breaker has failed replace it 2 With the main circuit breaker in the ON position open the lug door Does the main circuit breaker trip Yes No Continue The main circuit breaker has failed replace it 3 Open the large hinged panel and disconnect the yellow Y wire leading to the shunt of the main circuit breaker 4 Place the main circuit breaker in the ON position Does the main circuit breaker stay in the ON position Yes No Continue The main circuit breaker has failed replace it 5 With the main circuit breaker in the ON position check for continuity continuity equals 0 0 1 0 Ohms between L1 of the main circuit breaker and Lug Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for each check Yes No Your readings Continue The main circuit breaker has failed replace it i 6
77. n also obtain other information about motor vehicle safety from the Auto Safety Hotline 14 Mobile Generator Theory of Operation 2 Theory of Operation 2 1 Basic Schematic a N ius C 3 Phase AC out d DC in A i Edel a 1 T4 T7 ehi YY Ve ez I va TARA ee ae L2 3 Ph La 4 Tii f AC ioni A L3 lt Im ll 5 5 ll I x dali D en ME Co PE J e A n Lello Bcbel 7 sA 6 skal a jaa 32 1 a i Eee g AMP HZ ISTABIVOLTI wc_gr003643 Component Component Exciter stator winding Automatic Voltage Regulator AVR Rotor assembly Main circuit breaker Exciter rotor winding i Auxiliary winding Rotating rectifier diodes j Voltage adjusting rheostat Main rotor winding Lug door switch Main stator windings Stator assembly wc_tx001077gb fm 1 5 Theory of Operation Mobile Generator 2 2 we_tx001077gb fm Introduction See Graphic wc_gr003303 A generator set is a transducer which means it converts energy from one form heat into another electrical The two main components of a generator set are the prime mover engine and the generator assembly The engine converts heat into rotating mechanical energy which is then convert
78. n the ON position 4 Measure the voltage between W V wire 62 and ground Is at least 4 8 VDC measured Yes No Your reading Go to step 8 Continue 5 Open the control panel and locate the ECM 6 Place the START RUN switch in the ON position 7 Measure the voltage between ECM plug 1 pin 12 W V wire 62 and ground Is at least 4 8 VDC measured Yes No Your reading Repair W V wire 62 then The ECM has failed continue Call Wacker Neuson Service 8 Measure the resistance between the fuel sender and ground 9 Find the resistance measured in the chart below 300 250 200 150 Ohms 100 50 o 510 20 30 40 50 60 70 80 90 100 110 Fuel wc_gr003966 Does the resistance measured reflect the actual fuel level in the tank Yes No The fuel sender is OK the ECM has failed The fuel sender has failed replace it Call Wacker Neuson Service 10 Reconnect W V wire 62 The ECM and fuel sender have now been checked wc_tx000723gb fm 50 Mobile Generator ECM Sensor Troubleshooting 5 5 Calibrating ECM Voltage Display Prerequisites Functioning generator Procedure Follow the procedure below to calibrate the ECM voltage display 1 Open the large hinged panel Remove the key latch from the lug door and place it in the slot of the lug door switch NOTICE Never place anything but the key into the slot of
79. ng 8 14 Checking Stator Windings at the Voltage Selector Switch Prerequisites Procedure wc_tx000726gb fm Generator shut down Mobile Generator 1 Follow the procedure below to check the main stator windings at the generator 2 Remove the cover from the Voltage Selector Switch VSS ECM 3 Note the positions and labels of all wires connected to the VSS T2 T3 T4 etc AVR to Automatic Voltage Regulator ECM to Engine Control Module Gen from generator TB to terminal block R1 T7 on older TB to terminal block R2 T9 on older TS to terminal strip CB to main circuit breaker 1 i Gen Gen I TS TS I T2 T6 LO E i 5 DO oO I i 5 Pay 17 21 25 I rs re e e lea le I I Qi Dj I 3 Py A rw 2 7 5 7 I I E a i L1 L2 B ni eM CB Gen TB TB I I Gen I I I I 26 I I l ES I I l ES I I 28 I J I I it I Or CB I I wc gr003928 4 Check the resistance across each pair of wires for each winding T1 T2 T3 T4 and so on up to T11 T12 Note 77 T4 T8 and T9 are located at the terminal strip T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12 Your readings Do all six stator windings measure approximately 0 2 Ohms Yes
80. obile Generator John Deere Engines With ECU 6 John Deere Engines With ECU 6 1 wc_tx000698gb fm John Deere Engines With ECU Background The Tier Il John Deere engines with electronic control systems are used on Wacker Neuson generator models G 85 G 125 and G 160 The electronic control system consists of Engine Control Unit ECU the computer which controls fuel and the ignition system e The following sensors oil pressure coolant temperature fuel temperature manifold air temperature crank position and speed e Fuel pump control solenoid e Manifold air heater The electronic control system serves as a governor by controlling the fuel to the engine It does so by controlling the engine s injection pump control valve through a proportional solenoid In doing so fuel is delivered according to engine conditions in precise amounts and at the precise time in relation to piston position The ECU communicates with the Engine Control Module ECM mounted to the generator s control panel through a Controller Area Network CAN The wiring between the controllers forms a bus physical electrical interface where many devices share the same electrical connections Diagnostic tools available from John Deere can plug into the CAN bus to assist in troubleshooting the operation of the engine The ECM controls the engine up through engine start cranking Once started the ECU controls the running of the engine The ECU has dia
81. onnector wc_gr005297 3 Measure the resistance across terminals A and B of the connector Is approximately 120 ohms measured Yes No The CAN BUS circuit is OK The CAN BUS circuit has failed Replace the ECM 4 Reconnect the CAN BUS connector 5 Close the control panel The ECM CAN BUS circuit has now been checked wc_tx000723gb fm 5 5 ECM Sensor Troubleshooting Mobile Generator 5 10 Checking the Main Circuit Breaker Prerequisites Procedure wc_tx000723gb fm a Fully charged battery m Emergency stop switch in disengaged out position Follow the procedure below to check the main circuit breaker As a reminder place a check mark next to the answer that applies 1 With the lug door closed place the main circuit breaker in the ON position Does the main circuit breaker stay in the ON position Yes No Continue The main circuit breaker has failed replace it 2 With the main circuit breaker in the ON position open the lug door Does the main circuit breaker trip Yes No Continue The main circuit breaker has failed replace it 3 Open the large hinged panel and disconnect the yellow Y wire leading to the shunt of the main circuit breaker 4 Place the main circuit breaker in the ON position Does the main circuit breaker stay in the ON position
82. ponding sine waves are 120 apart In other words the voltages induced in each leg are 120 out of phase with each other Although the largest amount of voltage induced in any single leg in the high wye configuration is 277V the voltage induced in a second leg either of the other two legs at that same moment can be tapped and combined with the 277V of the first leg to create the maximum voltage available from the generator The amount of voltage in the second leg is less than its largest potential because of the position of the rotor s magnetic field it is less than perpendicular to the second leg The amount of voltage induced is approximately 73 203V of its potential see graphic wc_gr003317 Thus 277V 203V 480V which is the maximum voltage available from the generator In the low wye configuration the largest usable voltage potential in any leg is 120V adding the 73 of any second leg 88V yields the maxi mum voltage potential for the low wye configuration 208V Any measurement between the end of a leg and neutral is know as line to neutral L N voltage Any measurement between the end of one leg to the end of another leg is known as line to line L L voltage Any combination of L N or L L voltages are 120 out of phase with each other For example L1 N is out of phase with L2 N L2 N with L3 N L3 N with L1 N Likewise L1 L2 is out of phase with L2 L3 L2 L3 with L3 L1 and L2 L3 with L1 L2 A three phase ev
83. r the main and the auxiliary The exciter stator winding a is a stand alone winding The main and auxiliary windings are housed within the large stator housing b The exciter stator is the generator s source of residual magnetism As the engine spins the exciter rotor portion of the rotor assembly spins inside the exciter stator an AC voltage is induced in the exciter rotor This AC voltage is rectified into DC by the diodes f connected to the rotor assembly The DC voltage flows through the main rotor winding creating a magnetic field Voltage is then induced in the main stator windings and the auxiliary winding The voltage induced in the main stator windings provides the voltage to the lugs and the receptacles The voltage induced in the auxiliary winding is used to power the voltage regulator 16 Mobile Generator Theory of Operation wc_gr003303 wc_tx001077gb fm 1 7 Theory of Operation Mobile Generator 2 3 Terminology See Graphic wc_gr003315 wc_tx001077gb fm a a To understand the terms phase leg line to line and line to neutral review the following information The main stator a consists of three separate groups of windings These groups of windings are referred to as legs The legs are labeled L1 L2 and L3 Each leg includes two individual windings The ends of these windings are labeled T1 T2 T3 and so on up to T12 Each individual winding has the same
84. r Neuson Service 8 Measure the resistance between the sender and ground 9 Find the resistance measured in the chart below 1000 800 Ohm 600 400 200 1002 s eassessasaseaaia a i b o F wc_gr002093 Does the resistance measured reflect the engine temperature Yes No Continue The temperature sender has failed replace it This procedure continues on the next page 48 Mobile Generator ECM Sensor Troubleshooting wc_tx000723gb fm Continued from previous page 10 Reconnect yellow wire 57 to the temperature sender 11 Start the engine 12 Measure the voltage between the sender and ground 13 Find the voltage measured in the chart below 5 Volts N 0 0 50 100 150 200 250 o F wc_gr003967 Does the voltage measured reflect the engine temperature Yes No The temperature sender is OK the ECM The temperature sender has failed may have failed Call Wacker Neuson replace it Service The temperature sender has now been checked 49 ECM Sensor Troubleshooting Mobile Generator 5 4 Fuel Sender Failure and Low Fuel Fault Prerequisites Fuel in fuel tank Procedure Follow the procedure below to check the ECM and fuel sender 1 Open the large hinged panel and locate the fuel sender wc_gr003934 2 Disconnect white violet W V wire 62 from the fuel sender 3 Place the START RUN switch i
85. rallel this is the low wye configuration f The voltage induced in this con figuration is 139V per leg It is adjusted to a usable 120V by the con trol panel rheostat The amount of voltage induced in each leg over time can be graphed This graph yields a sine wave d It represents the repeating event cycle of the induced positive voltage of the North pole followed by the induced negative voltage of the South pole Since the rotor has four magnetic poles this cycle occurs twice per revolution of the rotor The engine spins the rotor at 1800 rpm which equals 30 revolutions per second rps 1800 60 30 The number of revolutions per sec ond multiplied by the cycles per revolution cpr equals the cycles per second Hertz Thus 30 rps x 2 cpr 60 Hz 18 Mobile Generator L1 High Wye LI 480V Low Wye wc_tx001077gb fm Theory of Operation LI L3 I 120 gt 150 19 wc_gr003315 Theory of Operation Mobile Generator we_tx001077gb fm Y 480 277 203 203 277 0 73 73 Since the legs are mechanically 120 apart as the rotor spins time elapses between the moment when one leg reaches its largest volt age potential and the moment when the next leg reaches its largest voltage potential Thus no two legs reach their largest voltage poten tial at the same moment in time and their corres
86. replacement Damage caused by misuse or neglect of the unit should be brought to the attention of the operator to prevent similar occurrences from happening in the future This manual provides information and procedures to safely repair and maintain the above Wacker Neuson model s For your own safety and protection from injury carefully read understand and observe all instructions described in this manual The information contained in this manual is based on machines manufactured up to the time of publication Wacker Neuson Corporation reserves the right to change any portion of this information without notice Foreword WARNIN Mobile Generator Repair CALIFORNIA Proposition 65 Warning Diesel engine exhaust some of its constituents and certain vehicle q components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Laws Pertaining to Spark Arresters Notice State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Adm
87. resistance 0 2 Ohms The voltage selector switch determines how the windings are connected in series or parallel In series the total voltage of a leg is equal to the sum of the voltages induced across both windings In parallel the total voltage of a leg is equal to the voltage induced across either winding only one Each leg L1 L2 and L3 is physically 120 from each other The main rotor b functions as a rotating magnetic field It has four poles two of which function as North and the other two as South Flux is a term used to describe the amount of magnetic field in a given area The term lines of flux refers to the direction of the attrac tion of the magnetic fields North to South The point where these lines of flux are closest to 90 is the point where the magnetic field is the strongest i e at either pole The lines of flux c of the main rotor s magnetic field are as shown When the windings of the stator cut these lines of flux voltage is induced in them The amount of induced voltage is greatest at the position where the stator winding is perpendicular to the lines of flux i e when the rotor is in such a posi tion that the windings of a leg are centered over one of the four mag netic poles When the two windings of each leg are connected in series this is the high wye configuration e The voltage induced in this configuration is 277V per leg When the two windings of each leg are wired in pa
88. riable temperature fuel capacity etc is in a pre alarm state For example the value for the temperature reading will blink when the temperature of the generator is below 23 C 74 F This simply signifies that the manifold heater or glow plugs will be energized to aid in engine starting The fuel capacity reading will blink when it is below 25 This tells the operator that the generator will be requiring fuel soon See Section Additional Variables Monitored by the ECM Note f your generator has a block heater the temperature reading should not blink If it does check the block heater to make sure it is functioning properly ND No Data 0 zero or Blank Values When a value on the ECM display reads ND 0 zero or is blank it signifies that there is no data available for the variable y WACKER NEUSON 28 wc_tx000713gb fm Mobile Generator ECM Background Information 1 2 3 4 WT 2 l a A 481 P2 0 60 0 QT O eE 8 71 24 87 12 7 i pos n T ee De Tea OF LS 20 5 6 7 8 EN wc_gr002944 4 4 ECM Display Screens Start Switch in Remote Position See Graphic wc_gr002943 When the start switch is placed in the REMOTE position the following screens are displayed 4 4 1 Initializing The ECM display reads Initializing and shows the model of the generator If the model displayed does not match the model of the generator call Wacker Ne
89. s the generator now function properly Yes No The generator should be OK The AVR has failed replace it The excitation system has now been checked Continue with Checking the Stator Windings at the Lugs wc_tx000726gb fm 76 Mobile Generator Output Voltage Troubleshooting 8 9 Checking Stator Windings at the Lugs Prerequisites Procedure wc_tx000726gb fm m Generator shut down Two alligator clips each connected to 12 inches of 14 gauge wire Follow the procedure below to check the stator windings at the lugs 1 Place the voltage selector switch in the 480 277 position 2 Open the lug door Connect the alligator clips wires to Lug 1 and to the neutral lug N 3 Close the lug door and place the main circuit breaker in the ON closed position 4 Measure the resistance between Lug 1 and the neutral lug Enter the reading in the table below Also measure the resistance between Lug 2 and the neutral lug and lug 3 and the neutral lug Enter these values in the table below z ZOO WH ele wc_gr003931 5 Measure the resistance between Lug 1 and Lug 2 Lug 1 and Lug 3 and Lug 2 and Lug 3 Enter these values into the
90. te Violet Yellow Fuel level sender in connector Out 12VDC to starter relay Violet Out 12VDC to E stop switch Red In 12VDC from starter relay B through 10A fuse Plug 3 C urrent Transformer Inputs 6 pin connector White Ammeter line input CT common Brown Ammeter line input CT 1 Orange Yellow Ammeter line input CT3 Ammeter line input CT2 ne Voltage Inputs 4 pin connector Brown Voltage line input L1 at volt selector 3 Orange Voltage line input L3 at volt selector 28 Yellow Voltage line input L2 at volt selector 20 WACKER W NEUSON 42 wc_tx000713gb fm Mobile Generator ECM Background Information 4 10 Removing and Installing the ECM See Graphic wc_gr003316 4 10 1 4 10 2 4 10 3 4 10 4 4 10 5 4 10 6 4 10 7 4 10 8 Removal Remove the nut securing the hour meter switch a and the nut securing the start switch b to the panel Disconnect the four harness plugs e Remove the three red wires d from the start switch Remove the start switch the hour meter switch and the ECM from the panel Note Replacement ECMs include start and hour meter switches Remove the screws c securing the ECM to the panel Installation Secure the ECM to the panel with screws c Secure the hour meter a and the start switch b to the control panel Reconnect the four harness plugs e Re install the three red wires
91. tely 90 to obtain access to the generator Support the control panel enclosure in this position WACKER 86 wc_tx000575gb fm NEUSON Mobile Generator Disassembly Assembly wc_gr003321 ui WACKER c_tx000575gb f 87 NEUSON Disassembly Assembly Mobile Generator 9 7 Replacing the Generator See Graphic wc_gr003322 9 7 1 9 7 2 9 7 3 9 7 4 9 7 5 9 7 6 9 7 7 9 7 8 9 7 9 9 7 10 9 7 11 9 7 12 9 7 13 9 7 14 This procedure requires an appropriate crane capable of lifting 365 kg 800 Ibs Removal See section Preparing Unit for Generator Removal Remove the screens a from both sides of the generator housing Remove the screws b that secure the shock mounts to the frame Support the engine from underneath and the generator from above Remove the screws c that mount the flex plates to the engine Reposition the flex plates by turning the generator fan Remove the screws d that secure the generator to the engine Using an appropriate crane or hoist lift the generator up and away from the engine Installation Position the generator into the frame Using Loctite 231 or equivalent on the screws d secure the generator to the engine Torque the screws to 69Nm 50 ft lbs Using Loctite 231 or equivalent on screws c secure the flex plates to the engine Torque the screws to 45 Nm 33 ft lbs 35Nm 25 ft lbs on G 25 models Using screws b secure the shock mounts to the frame Sec
92. the lug door switch 2 Close the large hinged panel 3 Place the START RUN switch in the ON position so that the engine starts WARNING Electric shock hazard High voltage exists at the lugs when the engine is run ning Electric shock can cause injury or death Do not touch the lugs 4 Open the lug door 5 With a multimeter measure the AC voltage between lug 1 and lug 2 wc_gr003937 6 Compare the reading on the multimeter with that on the ECM Are the readings within 2 Volts Yes No Your reading No adjustment is necessary Continue 7 Open the control panel and locate the VOLTS ADJ pot on the ECM WARNING Electric shock hazard High voltage exists at the cooling fins of the AVR when the engine is running Electric shock can cause injury or death Do not touch the AVR 8 Adjust the VOLTS ADJ pot until the ECM reads the same as the voltage measured at the lugs 9 Re install the key to the door switch and close the control panel The ECM voltage has now been calibrated wc_tx000723gb fm 5 1 ECM Sensor Troubleshooting Mobile Generator 5 6 Calibrating ECM AC Amperage Display Prerequisites Functioning generator Ammeter 25A or greater load Procedure Follow the procedure below to calibrate the ECM amperage display 1 Attach a 25A or greater load to the lugs 2 Place the START RUN switch in the ON position so that the engine starts 3 Close th
93. tting for over speed If the ECM detects that the engine speed is more than 67 Hz for longer than 15 seconds the ECM will shut down the generator The display shows the status of the engine oil pressure sender If the oil pressure sender has failed the time of the failure will be displayed The time of the failure will be included in the display until the generator has been shut down and remains shutdown for a period of approxi mately 2 minutes A Hz Prealarm Setting Level lt 20 psi olde Gy Sl The display shows the value of the prealarm setting for low oil pressure If the ECM detects that the engine oil pressure is less than 20 psi the engine oil pressure read ing on the run screen will start to blink WACKER NEUSON 32 wc_tx000713gb fm Mobile Generator ECM Background Information The display shows the value of the fault setting for low oil x A mg pressure If the ECM detects that the engine oil pressure Fault Settings is less than 15 psi for longer than 15 seconds the ECM 5 Sec lt 15 psi will shut down the generator Ye OF The display shows this screen if the time to service timer has been reset to 250 hours V BD A HZ Service Time Reset to 250 Hrs 4 Gi The display shows the value of the prealarm setting for y A ne low engine temperature If the ECM detects that th
94. uit breaker 4 Place the main circuit breaker in the ON position Does the main circuit breaker stay in the ON position Yes No Continue The main circuit breaker has failed replace it 5 With the main circuit breaker in the ON position check for continuity continuity equals 0 0 1 0 Ohms between L1 of the main circuit breaker and Lug Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for each check Yes No Your readings Continue The main circuit breaker has failed replace it I 6 With the main circuit breaker in the OFF position check for continuity between L1 of the main circuit breaker and Lug 1 Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for any of the checks Yes No The main circuit breaker has failed replace The main circuit breaker is functioning pro it perly 7 Reconnect the yellow Y wire The main circuit breaker has now been checked Continue with Checking the Voltage Adjusting Rheostat 71 Output Voltage Troubleshooting Mobile Generator 8 4 Checking the Voltage Adjusting Rheostat Prerequisites Procedure wc_tx000726gb fm Generator shut down Follow the procedure below to check the voltage adjusting rheostat 1 Open the control panel and locate the voltage adjusting rheostat
95. up Clear shield Magnetic pickup White Black Oil pressure sender Yellow Water temperature sender Red Run Off Auto switch 12V positive Black 12VDC supply ground negative Orange Remote start contacts Green Emergency stop pushbutton White Violet Plug 2 Engine Start Input Outputs 8 p Fuel level sender in connector Yellow Out 12VDC to starter relay Violet Out 12VDC to E stop switch Red In 12VDC from starter relay B through 10A fuse Red In 12VDC from starter relay B Green Out 12VDC to air intake heater relay urrent Transformer Inputs 6 pin connector White Ammeter line input CT common Brown Ammeter line input CT 1 Orange Ammeter line input CT3 Yellow Brown Ammeter line input CT2 ne Voltage Inputs 4 pin connector Voltage line input L1 at volt selector 3 Orange Voltage line input L3 at volt selector 28 Yellow Voltage line input L2 at volt selector 20 wc_tx000713gb fm WACKER 41 W NEUSON ECM Background Information Mobile Generator G 125 160 Control Module Plug 1 Engine Sender Inputs 12 pin connector White Blue Crank delay preheat Red Run Off Auto switch 12V positive Black 12VDC supply ground negative Orange Remote start contacts Gray Emergency stop pushbutton Whi
96. ure all con nections are tight 4 Check the voltage between violet wire 64 and ground at the switch 5 foe a O 2 D o gt Le vieux style par pouss e torsion Le nouveau style sym trique Is at least 9 8 VDC measured Yes No Your reading Continue The emergency stop switch has failed replace it 5 Check the voltage between violet wire 34 and ground at the switch Is at least 9 8VDC measured Yes No Your reading The emergency stop switch The emergency stop switch is not the problem has failed replace it The emergency stop switch has now been checked Continue with Checking the Starter Relay 64 G 85 Engine Starting Troubleshooting 7 4 Checking the Starter Relay Prerequisites Battery voltage measuring 11 13VDC Procedure Follow the procedure below to check the starter relay 1 Locate the starter relay Intake heater relay Gr 6577 R 50 Starter R425 relay B050D R wc_gr003912 2 Check the voltage between the red wire running from the starter to the starter relay and ground Is at least 9 8VDC measured Yes No __ Your reading Continue Repair or replace the red wire 3 Place the START RUN switch in the ON position 4 Check the voltage between red wire 422 and ground during cranking Is at least 9 8VDC measured Yes No Your reading Continue Repair or replace wire 422 5 Check the connection to ground of black wire 050D and bla
97. ure the screens a to both sides of the generator housing Reconnect all wiring Reinstall the control panel enclosure and the roof A WACKER NEUSON 88 wc_tx000575gb fm Mobile Generator Disassembly Assembly wc_gr003322 wc_tx000575gb fm 89 Ww WACKE Disassembly Assembly Mobile Generator 9 8 Removing the AVR Prerequisites Machine shut down Procedure Follow the procedure below to remove the Automatic Voltage Regulator AVR 9 8 1 Remove the screws that secure the large access panel a and open the large access panel eee Da wc_gr004605 wc_gr004581 9 8 2 Make note of the wires connected to the AVR b CAN ORE Ke 9 8 3 Disconnect the wires 9 8 4 Remove the screws that secure the AVR and remove the AVR from the machine The procedure to remove the AVR is now complete WACKER nae Y NEUSON 90 c_tx000575gb f Mobile Generator Disassembly Assembly 9 9 Installing the AVR Prerequisites e Machine shut down Multimeter Procedure Follow the procedure below to install and set the Automatic Voltage Regulator AVR 9 9 1 Check the function of the voltage adjusting rheostat See section Checking the Voltage Adjusting Rheostat 9 9 2 Mount the AVR b to the machine with the two screws wc_gr004605 wc_gr004583 9 9 3 Reconnect the wires to the AVR 9 9 4 Adjust
98. uson Service 4 4 2 Unit in Auto The ECM displays Unit in Auto and the values for oil pressure percentage of fuel remaining engine temperature and voltage of the battery 1 OLA 2 OLA Initializing G85 Unit in Auto 50 74 12 7 lt il SE wc_gr002943 SE we_tx000713gb fm 29 Y VACKER ECM Background Information Mobile Generator 4 5 Additional Variables Monitored by the ECM Holding the toggle switch in the HOURS RESET position allows the operator to view additional variables monitored by the ECM It also allows the time to service countdown timer to be reset To reset the countdown timer hold the toggle switch in the HOURS RESET position for approximately 30 seconds or until all the screens have been scrolled through twice There are three different sets of additional variables Each of the following categories of generators has its own unique set standard those generators with cold weather packages or custom features and those with the John Deere engine that includes the electronic Engine Control Unit ECU All three sets of additional variables are listed below along with typical no load values Note The values from your generator may differ slightly from those shown here G 25 G 50 G 70 G 85 9310 Standard Models ECM Display Description The display shows the amount of time in 1 10 hour seg A ments that the engine has been running Running Time 0 6
99. utes G 25 G 50 G 85 9310 Cold Weather and Custom Generators Description The display shows the total time in 1 10 hour incre ments that the engine has been run New machines or machines with new ECMs will read 0 0 or No Data because the engine has not been run for more than 1 10 of an hour The display shows the amount of time left until service on the machine is required To reset the timer to 250 hours hold the Hours Reset toggle switch in the up position until all the screens have been scrolled through twice The display shows the date and job number data regard ing the ECM manufacture ECM Display v A Hz Running Time 0 1 Hours se KE Di ea A HZ Time to Service 250 0 Hours Qh OF A HZ SW Rev x x x date Job No 123456 O Oi Si EI v A Hz AC Configuration Qe lt V A HZ Alt Protection Enabled e OF The display shows the AC configuration as determined by the position of the Voltage Selector Switch VSS If the machine is not running the display reads Unknown The ECM displays this screen to let the operator know that the alternator protection system has been enabled or disabled wc_tx000713gb fm WACKER 31 NEUSON Wy ECM Background Information Mobile Generator V A HZ Speed
100. w been checked Continue with Checking the Intake Heater Relay 66 G 85 Engine Starting Troubleshooting 7 6 Checking the Intake Heater Relay Prerequisites Battery voltage measuring 11 13VDC Procedure Follow the procedure below to check the intake heater relay 1 Locate the intake heater relay Intake heater relay 30 86 Gr 65 gt ee Be 85 R11 R 12 B14 OH R50 SANS A Tp Ga Starter R 422 Y A relay BosoD R wc_gr003912 2 Check the voltage between terminal 30 red wire 11 of the intake heater relay and ground Is at least 9 8VDC measured Yes No Your reading Continue Repair or replace red wire 11 3 Place the START RUN switch in the ON position 4 Check the voltage between terminal 86 grey wire 65 and ground during cranking Is at least 9 8VDC measured Yes No Your reading Continue Repair or replace grey wire 65 5 Check the connection to ground of black wire 14 at terminal 85 Is there a path to ground Yes No __ Your reading Continue Repair or replace wire 14 6 Place the START RUN switch in the ON position 7 Check the voltage between terminal 87 red wire 12 and ground Is at least 9 8VDC measured Yes No The intake heater relay is The intake heater relay has OK failed replace it Your reading The intake heater relay has now been checked wc_tx000678gb fm 6 7 Engine Starting Troubleshooting G 85 7 7 Checking the Mai
101. y Continued from the previous page 9 15 6 Adda small amount of epoxy to the diode holder 9 15 7 Insert the diode e into the holder Red marking faces to the right wc_gr005155 9 15 8 Cut f any excess wire from the new diode si 15 9 Addheat sinks g alligator clips are shown for nis salini wc_gr005156 9 15 10 Solder h the new diode to the existing old wires 9 15 11 Rotate the engine and repeat the soldering procedure for each diode 9 15 12 Reassemble the machine wc_tx000575gb fm 1 07 SN Disassembly Assembly Mobile Generator 9 16 Replacing the Voltage Selector Switch VSS See Graphic wc_gr003284 WARNING 9 16 1 9 16 2 9 16 3 9 16 4 9 16 5 9 16 6 9 16 7 9 16 8 9 16 9 Electric shock hazard Turn off the generator before replacing the Voltage Selector Switch VSS Removal Remove the air filter and the cover of the VSS box a Label and disconnect all the wires attached to the VSS Remove the switch handle b from the VSS Remove the screws c that secure the front face of the VSS Remove the screws that secure the mounting bracket d to the VSS box and remove the VSS and mounting bracket from the VSS box Remove the mounting bracket from the VSS e Installation Attach the mounting bracket d to the VSS e Slide the VSS into the VSS box and secure the face plate c with the screws Attach the switch handle b 9 16 10 Secure the mounting bracket to the VS
102. y Assembly Mobile Generator 9 6 Preparing Unit for Generator Removal See Graphic wc_gr003321 y 9 6 1 Remove the roof See section Removing Roof 9 6 2 Remove the screws that secure the air filter assembly and set the air filter assembly off to the side 9 6 3 Remove the cover to the VSS box 9 6 4 Cut the wire tie a that secures the wiring to the engine 9 6 5 Disconnect the ground strap b between the generator and the frame 9 6 6 Disconnect the ground strap c between the engine and the control panel enclosure 9 6 7 Disconnect the fuel line d from the fuel filter 9 6 8 Disconnect the wires from the Automatic Voltage Regulator AVR e blue from term 1 yellow from term 3 blue white from term 3A green from term 4 red from term 5 and black from term 5C Cut the wire ties that secure the wires 9 6 9 Disconnect the other AVR wires f red wire from the lighter gauge blue wire blue white wire at the connector to the lighter gauge blue white wire 9 6 10 Cut the wire tie then disconnect the connector g holding wire L1 to wire 1 from the generator Also cut the wire tie and disconnect the connector holding wire L3 to wire 9 from the generator 9 6 11 Cut the wire ties h that secure the rest of the generator wires 9 6 12 Disconnect the generator wires from the VSS 9 6 13 Remove the screws that secure the door hinges i and remove the hinges 9 6 14 Lift and rotate the control panel enclosure j approxima

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