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Wacker Neuson G 230 Operator'S Manual Download Page 240

Schematics, Machines with Deep Sea Controller

G 230 / G 240

240                                    

                                

wc_tx003750gb_FM10.fm

27.5

DC Schematic: G 230 Cummins T4i

5200006818_02

CUMMINS J1939

CONNECTOR

A J1939+

B J1939-

C SHIELD

16 PIN CUMMINS

OEM CONNECTOR

 

A

+24V ECM POWER

F

+24V SERVICE LINK

H

KEYSWITCH

E

STARTER SOLENOID

B

THROTTLE INPUT

M

FAN SPEED SIG.

P

FAN SPEED RETURN

S

AIR HTR RETURN

R

AIR HEATER SIG.

J

-24V ECM POWER

K

DATA LINK RETURN

CUMMINS CONNECTOR

'C7'

1

SENSOR SUPPLY

2

SIGNAL

3

SENSOR RETURN

21 PIN CUMMINS

AFTERTREATMENT

CONNECTOR

3

OEM SENSOR RTN

4

DPF DELTA P

5

DPF OUT PRESSURE

2

OEM SENSOR SUPPLY

7

DOC OUTLET TEMP

1

TEMP RETURN

8

DOC INLET TEMP

6

DPF OUTLET TEMP

CUMMINS CONNECTOR

'C12'

1

PRESSURE

2

SENSOR SUPPLY

3

TEMPERATURE

4

SENSOR RETURN

AIR CLEANER

TBAP SENSOR

1

2

3 

4

COOLANT

LEVEL

SENSOR

A

B

C

DPF

PRESSURE

SENSOR

CONNECTOR

 

1

2

3

4

DPF

TEMPERATURE

SENSOR

CONNECTOR

1

2

3

4

A

B

C

INTAKE HEATER

48

10A
FUSE

18

101

102

STARTER
RELAY

47

46

WHT

BOND TO
FRONT
PANEL
DOOR

GROUND TO 
ENCLOSURE
BOX, LARGE 
STUD (1/2")

 RED
2/0 AWG

L0

BOND BAR

GRD

L3

L2

RED

12 AWG

L1

ORG

ORG

45

MECHANICAL LUGS

YEL

WHT

YEL

BLK

FUEL LEVEL

62

87

95

18

50

53

RED

53

BAT+     2

60

REMOTE START  60

PLUG 1

POWER & 

OUTPUTS

62

SENDER COM  15

FUEL LEVEL   19

64

63

34

PLUG 3 CANBUS

 ELECTRONIC CONTROL UNIT

ORG

60

45

GRN
NO

ORG

50

44

YEL

ORG

48

46

64

RED
NC

RED
NC

EMERGENCY
STOP 
SWITCH

RED

RED

BAT -    1

80

85

BREAKER  61
TRIPPED

PLUG 2

SENSOR INPUTS

TRIP BREAKER  11

PREALARM  10

PLUG 6

CONTACT INPUTS

ALARM   9

49

GROUND TO 
ENCLOSURE
BOX SMALL 
STUD (M8)

START

FUEL

HOUR
METER

RED

WHT/VIO

YEL

VIO

81

91

86

95

90

92

81

BLK

BLK

BLK

BLU

7.5A
FUSE

B+

CAN L    26

CAN H    25

SCR    27

63

34

GRN

YEL

SHIELD

BLK

2/0 AWG

YEL

BLK

86

97

BLU

RED

98

87

98

RED

SHUNT
TRIP
RELAY

99

BLK

120 OHM

67

68

IDLE  64

GROUND TO 
ENCLOSURE
BOX SMALL 
STUD (M8)

101

INTAKE 
HEATER
RELAY

BLK

4 AWG

YEL BLK

 RED
2/0 AWG

20A
FUSE

5A
FUSE

1A
FUSE

B-

150A FUSE

BLACK
4 AWG

RED

12 AWG

BLK

103

BLK

103

105

106

102

110

105

110

106

107

104

104

BLK

12 AWG

BLK

YEL

BLK

4 AWG

RED

RED

RED

107

108

108

RED

12 AWG

109

109

RED

12 AWG

RED

12 AWG

VIO

112

BLK

111

111

VIO

112

GRN

YEL

SHIELD

113

RED

10 AWG

89

89

GRN/YEL

BLK PAIR

2 AWG

BLU

BLU/WHT

80

BLK

10 AWG

63

YEL

99

VIO

ORG

44

44

78

79

GRN/YEL

29

27

28

BLK

RED

BLU

REGEN LIGHT 8

119

ORG

REGENERATION  65

115

WHT

117

WHT

116

120

BLK

119

118

117

TOGGLE
SWITCH

LIGHT

113

  SWITCH

DISCONNECT

  BATTERY

MODELS

ON SOME

NOT USED

BLK

10 AWG

3

5

4

TOGGLE
SWITCH

85

BLU

BLU

44

BLK

BLK

118

90

VIO

VIO

RED

TOGGLE
SWITCH

115

WHT/VIO

GRN

YEL

SHIELD

VIO

BLK

GROUND 7

59

BLK

59

92

116

-

+

SHUNT

MAIN
BREAKER

87

85

30

86

-

+

SEE AC SCHEMATIC
FOR LUG DOOR
SWITCH N.C. WIRING

NOT USED ON
SOME MODELS

REMOTE
START

STARTER 
MOTOR

1

2

3

4

5

6

7

8

9

10

11

12

13

14

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

15

Summary of Contents for G 230

Page 1: ...5000186930 09 0215 5 0 0 0 1 8 6 9 3 0 Operator s Manual Mobile Generator G 230 G 240 EN ...

Page 2: ... distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights Violators will be prosecuted Trademarks All trademarks referenced in this manual are the property of their respective owners Manufacturer Wacker Neuson Production Americas LLC N92W15000 Anthony Avenue Menomonee Falls WI 53051 U S A Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 ...

Page 3: ...ing the model number item number revision number and serial number is attached to this machine The location of the nameplate is shown above Serial number S N For future reference record the serial number in the space provided below You will need the serial number when requesting parts or service for this machine Machine Item Number Machine Item Number G 230 5200010141 5200010142 5200010143 5000620...

Page 4: ...rformance or safety standards of its machines The information contained in this manual is based on machines manufactured up until the time of publication Wacker Neuson reserves the right to change any portion of this information without notice The illustrations parts and procedures in this manual refer to Wacker Neuson factory installed components Your machine may vary depending on the requirement...

Page 5: ...son service center according to written instructions published by Wacker Neuson Unapproved parts attachments and modifications are those that do not meet the approved criteria Unapproved parts attachments or modifications may have the following consequences Serious injury hazards to the operator and persons in the work area Permanent damage to the machine which will not be covered under warranty C...

Page 6: ...Foreword 6 wc_tx003565gb_FM10 fm Notes ...

Page 7: ... 2 Label Locations 24 3 Label Meanings 26 4 Lifting and Transporting 36 4 1 Lifting the Machine 36 4 2 Before Towing Checklist 37 4 3 Towing the Machine 38 4 4 Preparing the Machine for Transport on a Truck or Trailer 39 4 5 Hazardous Materials Placards 40 4 6 Testing the Breakaway System Hydraulic Surge Brakes 41 4 7 Testing the Breakaway System Electric Brakes 43 5 Machine Setup 45 5 1 Preparing...

Page 8: ... Diagram of the Genset Controller 70 8 3 Menu Diagram Components 71 8 4 Using the Metering and Settings Menus 72 8 5 Logging in to the Genset Controller by Entering the Password 73 8 6 Adjusting the LCD Screen Contrast 76 8 7 Changing the Time Date Settings 77 8 8 Changing the Sender Fail Time Delays 78 8 9 Changing the Units of Measure 80 8 10 Changing the Low Fuel Pre Alarm Setting 82 8 11 Chang...

Page 9: ...ractices for Balancing Loads 118 11 3 Connecting 480V 3 Phase and Single Phase Loads 120 11 4 Connecting a 240V 3Ø Load and a 240V 1Ø Load 121 11 5 Connecting a 220 240V 3Ø Load and Multiple 127 133V 1Ø Loads 122 11 6 Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads 123 12 Using Remote Start Capabilities 124 12 1 Remote Run Terminal Block 124 12 2 Remote Transfer Switch 125 12 3 Preparing for ...

Page 10: ...58 15 4 Monitoring and Control of the DEF Level 159 15 5 Monitoring DEF Quality 160 15 6 Conditioning the Aftertreatment Exhaust System if equipped 161 16 General Maintenance 162 16 1 Periodic Maintenance Schedule 162 16 2 Maintaining the Emission Control System 163 16 3 Preparing for Maintenance 163 16 4 Cleaning the Machine 163 16 5 Inspecting the Machine 164 16 6 Maintaining the Trailer 165 16 ...

Page 11: ...3 22 1 Engine G 230 T4f 193 22 2 Engine G 230 T4i 194 22 3 Generator 195 22 4 Trailer and Skid 196 22 5 Dimensions 197 Tire Safety Information 198 23 User s Information for Transport Canada Fuel Tank 210 24 Emission Control Systems Information and Warranty Diesel 213 24 1 Emission Control System Background Information 213 24 2 Limited Defect Warranty for Exhaust Emission Control System 214 24 3 Li...

Page 12: ...ctrical Schematic Components 233 26 15 Cummins Engine Relays and Fuses 234 26 16 Cummins Engine Relays and Fuses 235 27 Schematics Machines with Deep Sea Controller 236 27 1 AC Schematic G 230 G 240 236 27 2 Electrical Schematic Components G 230 G 240 237 27 3 DC Schematic G 240 John Deere Tier 3 238 27 4 DC Schematic Components G 240 John Deere Tier 3 239 27 5 DC Schematic G 230 Cummins T4i 240 2...

Page 13: ...o potential personal hazards Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury To avoid death or serious injury from this type of hazard obey all safety mes sages that follow this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious i...

Page 14: ...h the generator output Overloading the generator with a load that draws excessive power during either continuous running or start up Operating the generator in a manner that is inconsistent with all federal state and local codes and regulations Using the machine as a ladder support or work surface Using the machine to carry or transport passengers or equipment Using the machine to tow other machin...

Page 15: ...or drugs Application area Be aware of the application area Keep unauthorized personnel children and pets away from the machine Remain aware of changing positions and the movement of other equipment and personnel in the application area job site Identify whether special hazards exist in the application area such as toxic gases or unstable ground conditions and take appropriate action to eliminate t...

Page 16: ...t hydraulic fluid heat transfer fluid propylene glycol with additives battery acid or grease Personal Protective Equipment PPE Wear the following Personal Protective Equipment PPE while operating this machine Close fitting work clothes that do not hinder movement Safety glasses with side shields Hearing protection Safety toed footwear After use Stop the engine when the machine is not being operate...

Page 17: ...d adjustments shall be completed by a qualified technician Turn off the machine before performing maintenance or making repairs Remain aware of the machine s moving parts Keep hands feet and loose clothing away from the machine s moving parts Re install the safety devices and guards after repair and maintenance procedures are complete Machine modifications When servicing or maintaining the machine...

Page 18: ...ack long hair Remove all jewelry including rings Electrical service safety Make sure clothing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles when servicing the machine 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 pressure wash ...

Page 19: ...pill and wipe the machine dry before starting Refueling safety When refueling the engine Clean up any spilled fuel immediately Refill the fuel tank in a well ventilated area Re install the fuel tank cap after refueling Use suitable tools for refueling for example a fuel hose or funnel When refueling the engine Do not smoke Do not refuel a hot or running engine Do not refuel the engine near sparks ...

Page 20: ...exhaust you could be breathing CO NEVER use a generator inside homes garages crawlspaces or other partly enclosed areas Deadly levels of carbon monoxide can build up in these areas Using a fan or opening windows and doors does NOT supply enough fresh air ONLY use a generator outside and far away from windows doors and vents These openings can pull in generator exhaust Even when you use a generator...

Page 21: ... cuts cracks or exposed wires Do not route electrical cords over vibrating or hot parts of the machine Do not stand on the machine Do not enclose or cover the machine when it is use or when it is hot 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 di...

Page 22: ...s are properly inflated Only tow the machine when all trailer lights are functioning correctly Only tow the machine when the trailer s safety chains are connected to the towing vehicle in a crisscross pattern Maintain extra distance between the towing vehicle and other vehicles Avoid soft shoulders curbs and sudden lane changes Abide by all licensing requirements for your area If you have not driv...

Page 23: ...g lifted or moved Do not get onto the machine while it is being lifted or moved 1 9 Reporting 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 If NHTSA receives similar complaints it may open an investigation a...

Page 24: ... SOLAMENTE COMBUSTIBLE DE ULTRABAJO CONTENIDO DE AZUFRE 5200020535 DEF SEULEMENT CARBURANT DE SOUFRE ULTRA BAS ULTRA LOW SULFUR FUEL ONLY DIESEL XX YY o o o o RR QQ K XX DIESEL 5200020534 SÓLO LÍQUIDO DE ESCAPE DIESEL SEULEMENT FLUIDE O ÉCHAPPEMENT DIESEL DIESEL EXHAUST FLUID ONLY DEF wc_gr011523 NN ...

Page 25: ...wc_tx003568gb_FM10 fm 25 Mobile Generator Label Locations wc_gr009229 UU G H J R GG V V WW FF R A KK H ...

Page 26: ...strado antes de Lea y entienda el Manual de Operación suministrado antes de operar esta máquina Si no lo hace incrementará el riesgo de operar esta máquina Si no lo hace incrementará el riesgo de lesionarse o lesionar a otros lesionarse o lesionar a otros 176103 176103 Read and understand the supplied Operator s Manual before Read and understand the supplied Operator s Manual before operating this...

Page 27: ...s Do not open when hot WARNING Hand injury if entangled in moving belt WARNING Rotating machinery Do not reach inside machine with engine running DIESEL 119050 119050 STOP STOP PELIGRO DANGER DANGER Evite de rociar agua Evite de rociar agua en el generador en el generador 176300 176300 Eviter de pulveriser Eviter de pulveriser de l eau dans le de l eau dans le générateur générateur AVIS AVIS AVERT...

Page 28: ... cause serious injury which can cause serious injury Disconnect battery before Disconnect battery before servicing servicing Generateur peut demarrer Generateur peut demarrer automatiquement resultant en des automatiquement resultant en des accidents de personne Deconnecter accidents de personne Deconnecter batterie avant tout entretien batterie avant tout entretien Generador puede arrancar Genera...

Page 29: ...rt switch to OFF position 2 Set engine start switch to OFF position OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS FOR MOBILE GENERATORS FOR MOBILE GENERATORS INSTRUCTIONS D OPERATION INSTRUCTIONS D OPERATION DU GENERATEUR MOBILE DU GENERATEUR MOBILE Antes del arranque Antes del arranque 1 Lea el Manual de Operación 1 Lea el Manual de Operación 2 Nivele la unidad 2 Nivele la unidad 3 Coloque cuñas ...

Page 30: ...s W Neutral bonded to frame 178683 178683 STOP STOP WARNING ADVERTENCIA AVERTISSEMENT WARNING ADVERTENCIA AVERTISSEMENT 114886 114886 176213 176213 L2 L2 L1 L1 L3 L3 NEUTRAL BONDED TO FRAME NEUTRAL BONDED TO FRAME CONDUCTOR NEUTRO CONECTADO AL CHASIS CONDUCTOR NEUTRO CONECTADO AL CHASIS NULL LEITER AM RAHMEN ANGESCHLOSSEN NULL LEITER AM RAHMEN ANGESCHLOSSEN CONDUCTEUR NEUTRE MIS A LA MASSE CONDUCT...

Page 31: ... court circuit Risque d électrocution et d arc de court circuit aux ailettes de refroidissement aux ailettes de refroidissement Peligro de choque eléctrico y arco voltaico de Peligro de choque eléctrico y arco voltaico de cortocircuito en las aletas de refrigeración cortocircuito en las aletas de refrigeración Electric shock and arc flash hazard at cooling fins Electric shock and arc flash hazard ...

Page 32: ...on 480 227V et la tension est plus haute que 457V Le commutateur selecteur est dans la position 480 227V et la tension est plus haute que 457V El interruptor de seleccion de voltaje esta en la posicion 208 120V y el voltaje es mayor de 228V El interruptor de seleccion de voltaje esta en la posicion 208 120V y el voltaje es mayor de 228V El interruptor de seleccion de voltaje esta en la posicion 48...

Page 33: ...E DES DOMMAGES AUX COMPOSANTS TANDIS QUE LE MOTEUR TOURNE DES DOMMAGES AUX COMPOSANTS ELECTRIQUES PEUVENT SE PRODUIRE ELECTRIQUES PEUVENT SE PRODUIRE DO NOT USE THE BATTERY DISCONNECT SWITCH WHILE ENGINE IS DO NOT USE THE BATTERY DISCONNECT SWITCH WHILE ENGINE IS RUNNING DAMAGE TO THE ELECTRICAL COMPONENTS MAY OCCUR RUNNING DAMAGE TO THE ELECTRICAL COMPONENTS MAY OCCUR BATTERIETRENNSCHALTER NICHT ...

Page 34: ...ALVULA DEL SOLAMENTE CIERRE LA VALVULA DEL TANQUE DURANTE EL TRANSPORTE TANQUE DURANTE EL TRANSPORTE BIS TANKOBERSEITE MIT NUR MOTOROL BIS TANKOBERSEITE MIT NUR MOTOROL FULLEN TANKVENTIL WAHREND DES FULLEN TANKVENTIL WAHREND DES TRANSPORTS SCHLIESSEN TRANSPORTS SCHLIESSEN Lug door must be closed for lugs and receptacles to energize La puerta de conexiones debe estar cerrada para que las La porte d...

Page 35: ...ERTENCIA WARNING WARNING Système de 24 volts Ne pas Système de 24 volts Ne pas connecter à système de 12 volts connecter à système de 12 volts 24 volt system Do not connect to 12 24 volt system Do not connect to 12 volt system volt system Sistema de 24 voltios No conecte al Sistema de 24 voltios No conecte al sistema de 12 voltios sistema de 12 voltios AVIS AVIS NOTICE NOTICE AVISO AVISO 520000810...

Page 36: ...m the procedure below to lift the machine 1 Attach the lifting devices and equipment to the lifting eye Do not attach lifting devices to any other part of the machine 2 Lift the machine a small distance 3 Check for stability If necessary lower the machine reposition the lifting devices and lift the machine a small distance again 4 Continue lifting the machine only when it is stable wc_gr011429 WAR...

Page 37: ...hat all lug nuts are in place and are properly torqued Check the tread wear of the tires Check that the tires are inflated to the proper pressure Trailer preparation Check that all doors and access panels are closed and latched Check that outriggers if applicable are retracted Check local regulations regarding hazardous materials placards If applicable install the appropriate placards Trailer oper...

Page 38: ...wing be sure to check licensing requirements Drivers towing trailers may be required to carry a commercial driver s license CDL Check your local and state licensing regulations before towing the generator Coupler maintenance A film of grease on the coupler will extend coupler life and eliminate squeaking Wipe the coupler clean and apply fresh grease each time the trailer is towed Towing safety Whe...

Page 39: ...er are chocked during the loading process Check that the transport vehicle or trailer is clean and free of grease oil ice and other loose material If the machine is mounted to a trailer check that the jackstand or other transport block piece of wood or other similar material is available to support the trailer tongue during transporting Do not use the machine s trailer jack to support the trailer ...

Page 40: ...ions see application step 2 below Mild soap or detergent Fresh clean warm water supply Isopropyl rubbing alcohol lacquer thinner or mineral spirits Soft clean dry cloths Plastic squeegee or stiff cardboard Apply the Placards Four placards have been provided with this machine one for each side one for the front and one for the back To apply the placards do the following 1 Clean the placard mounting...

Page 41: ...cle so that it pulls on the breakaway cord until the emergency lever reaches its second notch b and locks into the ON position 4 Connect the machine trailer to the tow vehicle via the hitch 5 Attempt to tow the machine trailer at a very slow speed less than 5 mph When activated a properly working breakaway system will cause substantial drag on the trailer wheels and may even cause the trailer whee...

Page 42: ...g Continued from the previous page 7 Stop the tow vehicle 8 Release the brake by simultaneously pulling on the breakaway cord and prying the locking spring with a screwdriver c or pry bar Result The procedure to test the breakaway system is now complete wc_gr008510 c ...

Page 43: ...nnect the machine trailer to the tow vehicle 2 Disconnect the trailer wiring plug a from the tow vehicle 3 Pull the breakaway pin b out of the brake switch c to activate the brakes and attempt to tow the machine trailer at a very slow speed less than 5 mph When activated a properly working breakaway system will cause substantial drag on the trailer wheels and may even cause the trailer wheels to l...

Page 44: ...eplace or recharge the breakaway battery 6 If 12 14 VDC was measured but the brakes did not function there is a wiring or mechanical fault with the brakes Repair any faults before towing 7 If the brakes function properly a Reconnect the wires to the breakaway battery b Re install the cover to the battery box c Re install the breakaway pin b into the brake switch d Connect the trailer wiring plug t...

Page 45: ...standby or substitute power supply make sure the voltage and phase rotation of the line connections match those of the utility lines Failure to match phase rotation and voltage may cause equipment connected to the generator to operate incorrectly This could create unsafe operating conditions Do not exceed the rated current limit of any receptacle The bonding bar between the ground connections must...

Page 46: ...ill not enter nearby structures so that the machine does not block traffic so that the machine is not close to any combustible material or flammable vapor so that all of the machine s access doors panels may be accessed so that the area overhead is clear of debris that could fall onto or into the machine or exhaust compartment so that the machine is on a firm level surface and will not tip roll sl...

Page 47: ...d from the previous page Procedure Perform the following procedure to position the machine 1 Place the machine on solid stable and level ground 2 For machines with trailers install chocks a under the wheels Result The machine is now properly positioned wc_gr009186 a ...

Page 48: ...jurisdiction over electrical compliance If the generator is used at a construction site there may be additional regulations which must be observed In some areas generators are required to be registered with local utility companies Internal grounding The exposed conductive noncurrent carrying components that could become energized e g fuel tank engine generator housing control panel enclosure and t...

Page 49: ...e engine owner s manual NOTICE Consult the engine owner s manual regarding the use of biodiesel fuel in this machine Some biodiesel blends may clog the fuel system or gel at cold ambient temperatures sooner than petroleum based diesel Lowest expected ambient temperature Recommended fuel1 Above freezing 0 C 32 F 2 diesel plus additives Below freezing 0 C 32 F Winter blend diesel CAUTION Fire hazard...

Page 50: ...r left corner of the LCD screen 4 Fill the fuel tank until the fuel level reaches 100 5 Re install the fuel cap 6 Place the engine start switch in the OFF position Result The procedure to refuel the machine is now complete WARNING Fire hazard Fuel and its vapors are extremely flammable Burning fuel can cause severe burns Keep all sources of ignition away from the machine while refueling Refuel onl...

Page 51: ...uel tank until the fuel level reaches 100 6 Re install the fuel cap 7 Place the genset controller power switch in the OFF position WARNING Fire hazard Fuel and its vapors are extremely flammable Burning fuel can cause severe burns Keep all sources of ignition away from the machine while refueling Refuel only when the machine is outdoors Clean up spilled fuel immediately wc_gr011443 o o AUTO AUTO D...

Page 52: ...LAUFEN ARRANQUE MARCHA ARRANQUE MARCHA DEMARRER MARCHE DEMARRER MARCHE START RUN START RUN AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF REMOTE START REMOTE START FERNSTART FERNSTART ARRANQUE REMOTO ARRANQUE REMOTO DEMARRAGE A DEMARRAGE A DISTANCE DISTANCE START LAUFEN START LAUFEN ARRANQUE MARCHA ARRANQUE MARCHA DEMARRER MARCHE DEMARRER MARCHE START RUN START RUN A Ø HZ V DIAGNOSTICS DIAGNOSEN DIAG...

Page 53: ...switch and indicator or Manual conditioning switch for aftertreatment exhaust system q Interlock switch lug panel door switch e Genset controller Basler or Deep Sea r Customer connection terminal lugs f Engine start switch or genset power switch s Ground connection h Circuit breaker 240V 50 Amp t Bond bar j Idle switch high and low if equipped u Customer connection terminal lugs door k Circuit bre...

Page 54: ...er to the convenience receptacles NOTICE Before shutting down the generator or performing any service to the generator make sure the main circuit breaker is in the OFF position wc_gr011444 a AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF START LAUFEN START LAUFEN ARRANQUE MARCHA ARRANQUE MARCHA DEMARRER MARCHE DEMARRER MARCHE START RUN START RUN E MERGENC Y S T O P AUS AUS APAGADO APAGADO ARRET ARRET...

Page 55: ...TART RUN a wc_gr011436 Position Function LCD Screen REMOTE START This position is used when the generator is being operated as a stand by power supply and it is connected to a remote switch The generator is in stand by mode and will not start until the remote switch is activated closed READY screen START RUN This is the normal start and run position When set to this position power is supplied to t...

Page 56: ...alarm the LED b illuminates continuously and the machine is shut down A Ø HZ V DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS R Basler AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF REMOTE START REMOTE START FERNSTART FERNSTART ARRANQUE REMOTO ARRANQUE REMOTO DEMARRAGE A DEMARRAGE A DISTANCE DISTANCE START LAUFEN START LAUFEN ARRANQUE MARCHA ARRANQUE MARCHA DEMARRER MARCHE DEMARRER MARCHE START RUN S...

Page 57: ...tart switch It is a two position switch Low Idle turtle and Rated Speed rabbit The idle switch allows the operator to select the speed of the engine at start up Starting the engine at low idle is recommended when operating this machine in extremely cold weather Otherwise the engine can be started at rated speed NOTICE Disconnect all loads from the engine before starting at low idle AUS AUS APAGADO...

Page 58: ...otect the environment by removing soot from the engine exhaust Function Sustained operation of the generator under load heats the DPF to a temperature high enough to burn accumulated soot As long as a minimum internal temperature is maintained this process passive regeneration will occur automatically Passive regeneration is controlled by the Electronic Control Unit ECU on the engine wc_gr010593 a...

Page 59: ... by their own circuit breakers j k Power to the convenience receptacle circuit breakers is available any time the engine is running even with the main circuit breaker OFF open Note Graphic is representative only Your machine may vary Lug door interlock switch The lug door interlock switch p is located behind the lug door The lug door interlock switch is a safety device When the lug door is opened ...

Page 60: ...oltages available in both of the selector positions The voltage is displayed on the LCD panel This procedure continues on the next page WARNING Electric shock and arc flash hazard High voltage is present at the voltage selector while the engine is running Do not open the access door while the engine is running Do not change the position of the voltage selector while the engine is running wc_gr0103...

Page 61: ...g the voltage To select the voltage 1 Remove the screws b 2 Move the plate c to the desired position 3 Re install the screws Torque the screws to 40 Nm 29 5 ft lbs This procedure continues on the next page 40Nm 29 5 Ft Lbs L3 N 277V L1 L2 480V L2 N 277V L1 N 277V L3 L1 480V L2 L3 480V L1 1 2 N 4 3 8 L L 12 5 6 L N L2 10 L3 9 7 11 L L L2 N 120V L1 L2 208V L3 N 120V L1 N 120V L2 L3 L1 208V L2 L3 208...

Page 62: ...ase outlets As the 3 phase voltage increases so does the single phase voltage NOTICE Do not use the GFCI or twist lock receptacle 120V when the 1Ø voltage is above 135V Damage to the receptacle and the tools connected to it may occur 1 Do not use receptacle with this voltage 2 Voltage may be too high for some tools and equipment Check tool equipment specifications Switch Position 3Ø Voltage L L L ...

Page 63: ...radiator or around the fan Make sure the exhaust compartment is clean with nothing touching the muffler or exhaust pipes Pre operation checks Read and understand the engine owner s manual Check local regulations and NEC standards for electrical connections Determine voltage needs obtain proper cable and equipment to meet the needs Follow local regulations and NEC standards Make sure that the gener...

Page 64: ...hase voltage and frequency may cause equipment connected to the generator to operate incorrectly When using the generator as a stand by or substitute power supply make sure the phase voltage and frequency of the generator matches that of the utility lines or of any other power source normally used wc_gr011540 A Ø HZ V R Basler DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS AUS AUS APAGADO APAGADO ...

Page 65: ...he engine start switch to the START RUN position After displaying INITIALIZING and NOT IN AUTO the LCD panel will display START DELAY followed by CRANKING as the engine begins its crank cycle The crank cycle calls for the engine to crank for 15 seconds then rest for 10 seconds This cycle will repeat three times in an attempt to start the engine If the engine does not start within three attempts th...

Page 66: ... located as shown and can be accessed with the panel doors closed Function Activate the emergency stop switch by pushing the red button Pushing the emergency stop switch turns off opens the main circuit breaker cuts power to the fuel solenoid stops the engine causes Alarm Active Emergency Stop to appear on the LCD display The emergency stop switch will remain activated until the button is pulled o...

Page 67: ...unning This procedure continues on the next page wc_gr010202 Generator Engine Symbol Meaning Description V Volts Displays the value of the AC output voltage being produced by the generator Ø Phase Displays the leg or phase currently being monitored In three phase mode the display toggles between P1 P2 and P3 In single phase mode the display toggles between L1 L3 and L L A Amps Displays the value o...

Page 68: ...h is set to REMOTE START or RUN START Symbol Meaning Description Fuel level Indicates relative fuel level in the fuel tank Temperature Displays temperature of engine coolant Oil pressure Displays engine oil pressure between 0 100 psi Normal operating pressure 60 80 psi Battery voltage Displays real time battery voltage while the machine is operating Actual battery voltage is displayed when the eng...

Page 69: ...d it can be accessed for further submenus To do so press the right arrow button 1 To return to a previous screen press the left arrow button 4 To exit menu navigation and return to monitoring status or the READY screen press and hold the left arrow button To access a setting in order to change it press the check mark button 5 To cancel an operation press the X reset button 6 Normal screens The mac...

Page 70: ...n Alarm Configuration Alarms Alarms System Parameters System Parameters System Settings System Settings Crank Settings Crank Settings Alarm Status Alarm Status Alarms Alarms Pre Alarms Pre Alarms Status Status Inputs Inputs Outputs Outputs Conf Elements Conf Elements Conf Prot Status Conf Prot Status Event Log Event Log J1939 Data J1939 Data J1939 Engine Config J1939 Engine Config J1939 Active DTC...

Page 71: ...ded Run Time Bus V Bus voltage Low Fuel Level Communications Main Menu Conf Elements Configurable elements Maintenance Reset Conf Prot Status Configurable protection status Metering Configure Date Time Oil Pressure Coolant Level Outputs Coolant Temp PF Power factor Cooldown Time Power Crank Settings Pre Alarms Cumulative Programmable Inputs Cumulative Info RPM Rotations per minute Detailed Data Ru...

Page 72: ...menu are read only They cannot be changed except for HRS to MAINTENANCE parameter which can be reset SETTINGS menus SETTINGS menus give detailed information regarding genset controller configuration Use the menu diagram of the genset controller as a guide for navigating the menus There are a limited number of parameters under the SETTINGS menus that may be changed by the user These parameters are ...

Page 73: ...password by the genset controller at the parameter you want to change The default password in either case is OP It is set at the factory It is the only password available and it cannot be changed Once you are logged in you will remain logged in until you log out the machine is turned off or if you press the check mark button inadvertently This usually happens when attempting to change a locked par...

Page 74: ...acter Use the up down arrow buttons to change the A to O Then press the right arrow button to move the cursor to the next position 5 Use the up down buttons to select P Then press the check mark button The screen below appears You are now logged in and have the ability to change parameter settings Do not re enter the password even though it is requested instead navigate to the parameter you would ...

Page 75: ... A will appear The word EDIT will be displayed Whenever EDIT is displayed it means that you are able to change the parameter Use the up down arrow buttons to change the setting Then press the check mark button to accept the new value Note If the genset controller displays the screen B it means that the parameter cannot be changed by the operator Do not re enter the password even though you are req...

Page 76: ...AIN MENU 2 Using the up down arrow buttons 2 3 highlight SETTINGS Then press the right arrow button 3 Highlight GENERAL SETTINGS Then press the right arrow button 1 4 Highlight FRONT PANEL HMI Then press the right arrow button 5 Highlight LCD CONTRAST Then press the check mark button 5 6 If you are not logged in enter the password OP Press the check mark button 7 Using the up down arrow buttons ch...

Page 77: ...the up down arrow buttons 2 3 highlight SETTINGS Then press the right arrow button 3 Highlight GENERAL SETTINGS Then press the right arrow button 1 4 Highlight CONFIGURE DATE TIME Then press the right arrow button 5 Highlight the setting you want change Then press the check mark button 5 6 If you are not logged in enter the password OP Press the check mark button 7 Using the up down arrow buttons ...

Page 78: ... time delay period This is the amount of time that the genset controller must experience the failure before the failure will be seen on the LCD display These failure time delay periods may be changed The table below lists the failure time delay periods the allowable range and their factory settings Procedure Perform the procedure below to change a fail time delay 1 Press the right arrow button 1 t...

Page 79: ... to change Then press the right arrow button 6 Highlight ACTIVATN DELAY or TIME DELAY Then press the check mark button 5 7 If you are not logged in enter the password OP Press the check mark button 8 Using the up down arrow buttons change the value as desired Press the check mark button when finished 9 Exit by pressing the left arrow button 4 three times or until the LCD displays the SETTINGS menu...

Page 80: ...e set to English imperial or metric Procedure Perform the procedure below to set the units of measure 1 Press the right arrow button 1 to access the MAIN MENU 2 Using the up down arrow buttons 2 3 highlight SETTINGS Then press the right arrow button 3 Highlight SYSTEM PARAMS Then press the right arrow button 4 Highlight SYSTEM SETTINGS Then press the right arrow button 5 Highlight the SYSTEM UNITS...

Page 81: ...d from the previous page 8 Exit by pressing the left arrow button 4 twice or until the LCD displays the SETTINGS menu Then scroll to LOGOUT and press the check mark button Press the left arrow button so that the READY screen appears Result The units of measure have now been changed ...

Page 82: ...et controller is the percentage of fuel remaining in the fuel tank The range allowed by the genset controller is 10 100 Procedure Perform the procedure below to change the low fuel pre alarm setting 1 Press the right arrow button 1 to access the MAIN MENU 2 Using the up down arrow buttons 2 3 highlight SETTINGS Then press the right arrow button 3 Highlight ALARM CONFIGURATION Then press the right ...

Page 83: ...change the value as desired Press the check mark button when finished 9 Exit by pressing the left arrow button 4 three times or until the LCD displays the SETTINGS menu Then scroll to LOGOUT and press the check mark button Press the left arrow button so that the READY screen appears Result The low fuel pre alarm setting has now been changed ...

Page 84: ...owed by the genset controller is 0 100 Notes Do not set the low fuel alarm to a value greater than that of the low fuel pre alarm Doing so will nullify the function of the low fuel pre alarm Setting the low fuel alarm below 5 in effect disables the low fuel alarm The genset controller will not shut down the machine The machine will shut down when all fuel is consumed 5 is the lowest value the LCD ...

Page 85: ...en press the right arrow button 5 Highlight the THRESHOLD Then press the check mark button 5 6 If you are not logged in enter the password OP Press the check mark button 7 Using the up down arrow buttons change the value as desired Press the check mark button when finished 8 Exit by pressing the left arrow button 4 three times or until the LCD displays the SETTINGS menu Then scroll to LOGOUT and p...

Page 86: ... timer The function of the cooldown timer is to run the engine at no load after a period of being run at load It is used in conjunction with the remote start system The cooldown timer activates when the machine is no longer receiving a remote run signal This timer is factory set to zero 0 minutes The cooldown time can be changed if desired Procedure Perform the procedure below to change the cooldo...

Page 87: ...ou are not logged in enter the password OP Press the check mark button 7 Using the up down arrow buttons change the value as desired Press the check mark button when finished 8 Exit by pressing the left arrow button 4 twice or until the LCD displays the SETTINGS menu Then scroll to LOGOUT and press the check mark button Press the left arrow button so that the READY screen appears Result The cooldo...

Page 88: ... The genset controller includes a pre crank time delay This is the time the glow plugs will be on before the engine starts to crank The factory setting is 5 seconds The pre crank time delay can be changed if desired NOTICE Do not set the glow plug timer to a value of more than 10 Damage to the glow plugs may occur Procedure Perform the procedure below to change the pre crank time delay 1 Press the...

Page 89: ...you are not logged in enter the password OP Press the check mark button 7 Using the up down arrow buttons change the value as desired Press the check mark button when finished 8 Exit by pressing the left arrow button 4 twice or until the LCD displays the SETTINGS menu Then scroll to LOGOUT and press the check mark button Press the left arrow button until the READY screen appears Result The pre cra...

Page 90: ...ART position Background The maintenance interval is the time in hours scheduled between critical maintenance tasks such as changing the engine oil The amount of time may be changed if desired The factory setting is 250 Note Refer to the Periodic Maintenance Schedule in the Operator s Manual for timing of all scheduled maintenance tasks Procedure Perform the procedure below to change the maintenanc...

Page 91: ...ighlight the THRESHOLD Then press the check mark button 5 7 If you are not logged in enter the password OP Press the check mark button 8 Using the up down arrow buttons change the value as desired Press the check mark button when finished 9 Exit by pressing the left arrow button 4 three times or until the LCD displays the SETTINGS menu Then scroll to LOGOUT and press the check mark button Press th...

Page 92: ...yed and the red LED flashes The maintenance interval pre alarm may be reset by using either of two different methods 1 by holding the X reset button while the MAINT INTERVAL pre alarm screen is being displayed or 2 through the METERING menu Both methods are described below Procedure Perform the procedure below to reset the maintenance interval pre alarm 1 With the PRE ALARM ACTIVE screen showing p...

Page 93: ...n press the right arrow button 5 Using the up down arrow buttons highlight ENGINE Then press the right arrow button 6 Highlight HRS TO MAINT Then press and hold the X reset button for 10 20 seconds This will clear the pre alarm and reset the maintenance interval timer back to 250 or the value it is currently set to 7 Exit by repeatedly pressing the left arrow button until the READY screen appears ...

Page 94: ...h During a loss of voltage pre alarm the LCD will display the screens below To reset the loss of voltage pre alarm simply close the lug door If the voltage does not return to normal further troubleshooting will be needed Note The loss of voltage pre alarm will only occur when the voltage selector switch is in the 120 240 position The condition will still exist if in a 3 phase mode but the pre alar...

Page 95: ...bring up the MAIN menu 2 Highlight METERING Then press the right arrow button 3 Highlight ALARMS STATUS Then press the right arrow button 4 Highlight EVENT LOG Then press the right arrow button The LCD displays the events of the event log Events with the suffix A are alarm conditions Events with the suffix P are pre alarm conditions The events are LCD Screen Meaning OVERCRANK A Overcrank pre alarm...

Page 96: ...ST TIME FIRST ENG HRS LAST ENG HRS DETAILS Most recent event To find the alarm event that has occurred most recently 1 Scroll to each alarm event and record the time it occurred 2 Compare the dates and times of all alarm events The one with the most current date and time is the most recent GEN TEST LOADED Generator test loaded MAINT INTERVAL P Maintenance interval pre alarm LOW COOL LEVEL A Low co...

Page 97: ...ower to the convenience receptacles NOTICE Before shutting down the generator or performing any service to the generator make sure the main circuit breaker is in the OFF position wc_gr011444 a AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF START LAUFEN START LAUFEN ARRANQUE MARCHA ARRANQUE MARCHA DEMARRER MARCHE DEMARRER MARCHE START RUN START RUN E MERGENC Y S T O P AUS AUS APAGADO APAGADO ARRET ARR...

Page 98: ...OFF OFF ON ON a DSE 7310 STOP wc_gr011478 Position Function LCD Screen ON When set to this position Power is supplied to the genset control ler The genset controller boots up and sets itself to the Stop Reset mode the engine is ready to be started Generator at Rest followed by the status screens that scroll OFF When set to this position power to the genset controller is disconnected Blank screen o...

Page 99: ...voltages available in both of the selector positions The voltage is displayed on the LCD panel This procedure continues on the next page WARNING Electric shock and arc flash hazard High voltage is present at the voltage selector while the engine is running Do not open the access door while the engine is running Do not change the position of the voltage selector while the engine is running wc_gr010...

Page 100: ...ing the voltage To select the voltage 1 Remove the screws b 2 Move the plate c to the desired position 3 Re install the screws Torque the screws to 40 Nm 29 5 ft lbs This procedure continues on the next page 40Nm 29 5 Ft Lbs L3 N 277V L1 L2 480V L2 N 277V L1 N 277V L3 L1 480V L2 L3 480V L1 1 2 N 4 3 8 L L 12 5 6 L N L2 10 L3 9 7 11 L L L2 N 120V L1 L2 208V L3 N 120V L1 N 120V L2 L3 L1 208V L2 L3 2...

Page 101: ...hase outlets As the 3 phase voltage increases so does the single phase voltage NOTICE Do not use the GFCI or twist lock receptacle 120V when the 1Ø voltage is above 135V Damage to the receptacle and the tools connected to it may occur 1 Do not use receptacle with this voltage 2 Voltage may be too high for some tools and equipment Check tool equipment specifications Switch Position 3Ø Voltage L L L...

Page 102: ...ing indicator Illuminates during a non critical alarm condition Note non critical alarm conditions may lead to shut down conditions 8 Main breaker open indicator Illuminates whenever the main circuit breaker is open 9 Low speed active indicator Illuminates when the engine idle speed is set to low idle if equipped 10 Load button not used 11 Gen Set button not used AUT AUTO O DEEP SEA ELECTRONIC DEE...

Page 103: ...to the Manual mode In Manual mode the generator can be started and operated 14 not used 15 Auto mode Pressing this button Sets the genset controller to the Auto mode In Auto mode the generator can only be started and operated by a remote switch 16 Lamp test horn reset Pressing this button Silences the audible alarm Illuminates all of the LEDs as a lamp test feature push and hold to perform test 17...

Page 104: ... button to silence the audible alarm Shut down alarms Shut down alarms are latching alarms and stop the generator Shut down alarms include Low fuel level High coolant temperature Low oil pressure Overspeed Underspeed Overcrank Low coolant level if equipped Overcurrent During a shut down alarm condition the LCD panel displays the type of alarm the LEDs 6 8 illuminate an audible alarm sounds and the...

Page 105: ...larms that stop the engine During an electrical trip the LEDs 6 8 illuminate an audible alarm sounds and the machine is shut down Press the Horn Reset button to silence the audible alarm Remove the fault condition then press Stop Reset to enable the engine to be restarted wc_gr011492 DSE DEEP SEA ELECTRONICS DSE 7310 8 6 STOP ...

Page 106: ... radiator or around the fan Make sure the exhaust compartment is clean with nothing touching the muffler or exhaust pipes Pre operation checks Read and understand the engine owner s manual Check local regulations and NEC standards for electrical connections Determine voltage needs obtain proper cable and equipment to meet the needs Follow local regulations and NEC standards Make sure that the gene...

Page 107: ...ON I position 5 Press the Manual mode button b 6 Press the Start I button c The LCD panel displays several screens as the start up sequence begins This procedure continues on the next page CAUTION Possibility of injury or equipment damage Failure to match phase voltage and frequency may cause equipment connected to the generator to operate incorrectly When using the generator as a stand by or subs...

Page 108: ...arts the LCD panel displays the following screens 9 Allow the engine to warm before closing the main circuit breaker 10 Check the voltage displayed on the LCD panel Adjust the voltage as needed using the voltage adjustment rheostat See topic Selecting the Voltage 11 Turn on close the appropriate circuit breakers for your load Display Meaning Description Safety on delay The genset controller is det...

Page 109: ... any hazards by turning off devices such as pumps heaters or lights that may need to be kept on Procedure Perform the procedure below to stop the generator 1 Remove all loads from the generator 2 Open set to OFF O the convenience circuit breakers 3 Open set to OFF O the main circuit breaker 4 Let the engine run for approximately 5 minutes to allow it to cool down 5 Press the Stop Reset O button a ...

Page 110: ...er Open LED illuminates The engine stops The LCD panel b displays a flashing Emergency Stop message The Alarm LED illuminates and an audible alarm will sound To silence the audible alarm press the Horn Reset button on the keypad The flashing message and illuminated LED will remain visible until the emergency stop switch is deactivated To deactivate the emergency stop switch pull the red button out...

Page 111: ...at no load output amperage will display a 0 Hertz Hz Displays output frequency This gauge should read approximately 60 Hz under a no load condition If the frequency is too high check the engine rpm Displays the available voltage of the battery Displays the percentage of fuel remaining in the fuel tank Displays the engine oil pressure if equipped Displays the current temperature of the engine coola...

Page 112: ...ayed on the LCD panel f You can also use the keypad to change certain machine settings if desired 1 The various monitoring and configuration menus can be accessed by pressing the right arrow button 1 2 To select items on a menu use the up down arrow buttons 2 3 to scroll through the available options 3 To return to a previous menu screen press the left arrow button 4 4 To exit menu navigation and ...

Page 113: ... Screen Engine Engine Battery Battery Voltage Voltage Gen Current Gen Current Engine Engine Battery Battery Voltage Voltage Engine Engine Run Run Time Time Gen Earth Gen Earth Current Current Fuel Level Fuel Level Fuel Fuel Level Level Gen Load Gen Load kW kW Maintenance Maintenance Alarm Hold Alarm Hold O to reset O to reset Gen Load Gen Load Total kW Total kW Engine Engine Link Link Gen Load Gen...

Page 114: ...d Total kW Gen Phase Sequence Generator Phase Sequence Engine Coolant Temp Coolant Temperature in C and F Gen Power Factor Generator Power Factor Engine Link Engine Link Info Gen Power Factor Avg Generator Average Power Factor Engine Oil Pressure Engine Oil Pressure in Bar PSI and kPa Gen Voltage L L Generator Voltage Line to Line Engine Run Time Accumulated Time in Hours Gen Voltage L N Generator...

Page 115: ...r or use up down arrow keys to navigate to the Contrast screen Then press the check mark button The contrast value will start flashing 3 Press the up down arrow buttons to change the contrast percentage as desired When the screen contrast reaches a comfortable viewing level press the check mark button to accept the choice 4 Exit by pressing and holding the check mark button until the genset contro...

Page 116: ...e audible alarm Procedure Perform the procedure below to reset the maintenance timer 1 From the Status menu press the right arrow button to reach the Engine menu 2 Using the up and down arrow buttons navigate to the Maintenance alarm 1 screen 3 Press the Stop Reset button a The timer will return to 500 hours DEEP SEA ELECTRONICS DSE DSE wc_gr011508 DEEP SEA ELECTRONICS DSE a DSE 7310 DSE 7310 DSE ...

Page 117: ...fm 117 Mobile Generator How to Connect Loads 11 How to Connect Loads 11 1 Lug Terminal Connection Diagrams For machines with capabilities up to 480V wc_gr011542 High Wye Low Wye 139V 139V 139V or 240V 240V 240V 240V 240V ...

Page 118: ...the genset controller LCD panel If an unbalanced load condition exists there will be a significant difference in both voltage and amperage between the phases Observe the amp draw on P1 P2 and P3 If an unbalanced load is detected stop the engine and reconnect the loads so that loads amp draw are more equally distributed This will also help equalize the voltage for each phase When connecting multipl...

Page 119: ...dditional loads can be plugged into either duplex receptacle When using the 240V twist lock receptacle and a distribution box instead of plugging both loads into the same duplex receptacle of the distribution panel plug the first load into one of the duplex receptacles Then plug the second load into a different duplex receptacle of the distribution box L1 L2 L3 N GND Use L1 as hot for first load U...

Page 120: ...es from the load as shown 4 Close the lug door 5 Start the machine and fine tune the voltage as necessary using the voltage adjustment rheostat Note Graphic is representative only Your machine may vary WARNING Electric shock hazard High voltage can cause serious injury or death Connections must be made by a qualified electrician wc_gr011545 480V 3Ø HOT HOT HOT GN 480V 3Ø TRANSFORMER HOT HOT HOT GN...

Page 121: ...onnect the wires from the load as shown 4 Close the lug door 5 Start the machine and fine tune the voltage as necessary using the voltage adjustment rheostat Note Graphic is representative only Your machine may vary WARNING Electric shock hazard High voltage can cause serious injury or death Connections must be made by a qualified electrician 240V 3Ø HOT HOT HOT GN 139V 240V 3Ø 240V 240V 139V 139V...

Page 122: ...te Graphic is representative only Your machine may vary WARNING Electric shock hazard High voltage can cause serious injury or death Connections must be made by a qualified electrician When connecting multiple 120V loads Use L1 as hot for first load Use L3 as hot for second load Use L2 as hot for third load Balance the load Fine tune the voltage so that both the 3 phase load and the single phase l...

Page 123: ...chine 5 Fine tune the voltage as necessary using the voltage adjustment rheostat Note Graphic is representative only Your machine may vary WARNING Electric shock hazard High voltage can cause serious injury or death Connections must be made by a qualified electrician wc_gr011549 208 L L 120 L N 120V 120V 208V 208V 120V 120V 120V 208V 240V 3Ø 208V 3Ø 120V 1Ø 120V 1Ø TO GND LUG HOT HOT HOT GN WH Whe...

Page 124: ...er start switch If a transfer switch is installed the generator can be used as a stand by power supply When connecting an Automatic Transfer Switch ATS or other remote switch Limit the distance between the remote run terminal block and the remote switch to 1 219 m 4 000 ft max Use twisted 22 gauge wire or heavier Do not run the wire for the remote switch in the same conduit as current carrying wir...

Page 125: ... instructions and warning labels supplied with the switch WARNING Electrocution hazard Failure to isolate the generator from the utility s electrical distribution system could cause output from the generator to backfeed into the utility lines and cause injury or death to utility workers When the generator is used as a stand by power supply it must be equipped with a device which isolates it from t...

Page 126: ... voltage selector switch to the correct voltage position 4 Set the engine start switch to the REMOTE START position 5 Set the main line circuit breaker to ON 6 Secure the generator by closing and locking all doors The generator is now ready for remote starting Maintaining battery charge If the generator is to be used as a stand by power supply provisions must be made to maintain the charge of the ...

Page 127: ...it for the engine to crank start and run If the engine cranks the remote start circuit is functioning e Press the Stop Reset O button d to stop the engine f Remove the jumper wire from the remote run terminals after testing is complete This procedure continues on the next page wc_gr011501 c d b STOP CAUTION Possibility of accidental equipment start up If the contacts on any remote switch linked to...

Page 128: ...button 5 Secure the generator by closing and locking all doors The generator is now ready for automatic starting Maintaining battery charge If the generator is to be used as a stand by power supply provisions must be made to maintain the battery charge This can be done either by attaching a battery charger to the battery or by starting the generator manually and running the engine periodically to ...

Page 129: ...elow to access Diagnostic Trouble Codes 1 At the READY screen press the right arrow button 1 to bring up the MAIN menu 2 Highlight METERING Then press the right arrow button 3 Highlight ALARMS STATUS Then press the right arrow button 4 Highlight J1939 ACTIVE DTC Then press the right arrow button 5 Highlight a DTC Then press the check mark button 5 Note To access a past DTC highlight J1939 PREV DTC...

Page 130: ...lert will show on the LCD panel display A DTC is a two part code consisting of a Suspect Parameter Number SPN and a Failure Mode Identifier FMI Procedure Perform the procedure below to access the Diagnostic Trouble Codes 1 From the status menu press the right arrow key to navigate through engine Generator Alarms to ECU DTCs 2 Use the up and down arrow keys to scroll through the DTCs Note The Deep ...

Page 131: ... Error in frequency pulse width or period of any frequency or PWM signal is outside its predetermined limits 9 ABNORMAL UPDATE RATE Update rate of parameter is abnormal 10 DATA RT OF CHG ERR Rate of change of data is abnormal 11 FAILURE CAUSE UNKNOWN String indicating failure cause is unknown 12 BAD INTELLIGNT DEVICE Engine ECU is reporting that an intelligent device or component failure has been ...

Page 132: ...pressure parameter 100 1 ENG OIL PRESS LO LO Engine Oil Pressure is below the LOW LOW threshold 100 3 Oil Prs Snsr Volt HI Oil Pressure Sensor Input Voltage High 100 4 Oil Prs Snsr Volt LO Oil Pressure Sensor Input Voltage Low 100 17 ENG OIL PRESS LO Engine Oil Pressure is below the LOW threshold 100 18 Oil Prs Snsr Volt MLO Oil Pressure Sensor Input Voltage Moderately Low 100 31 Oil Pressure INVL...

Page 133: ...ure is below the LOW threshold 110 0 ENG COOLNT TMP HI HI Engine Coolant Temperature is above the HIGH HIGH threshold 110 3 Cool Tmp Sns Volt HI Coolant Temp Sensor Input Voltage High 110 4 Cool Tmp Sns Volt LO Coolant Temp Sensor Input Voltage Low 110 15 ENG COOLANT TEMP HI Engine Coolant Temperature is above the HIGH threshold 110 16 Cool Temp MHI Coolant Temp Sensor Input Moderately High 110 17...

Page 134: ... panel for Display of J1939 Parameter 188 17 SPEED AT IDLE LO Metering string for ECU trouble code metering indicates Engine Idle speed is below the LOW threshold 189 0 Engine Spd DERATE Engine Speed Derate 190 0 Engine OvrSpd EXTRM Engine Overspeed Extreme 190 1 ENGINE SPEED LOW Engine speed is below the LOW threshold 190 16 Engine OvrSpd MODRT Engine Overspeed Moderate 190 17 SPEED AT IDLE LO En...

Page 135: ...Sensor Input Pattern Error 637 2 Crank Pos Sns Noisy Crank Position Input Noise 637 5 Crank Pos Sns Curr LO Crank Position Sensor Current Low 637 6 Crank Pos Sns Curr HI Crank Position Sensor Current High 637 7 Crnk Pmp Pos Tmg OOS Crank Pump Position Timing Moderately Out of Sync 637 8 Crank Pos Sns MSNG Crank Position Missing 637 10 Crank Pos Sns In ERR Crank Position Input Pattern Error 639 J19...

Page 136: ...Part Number Invalid 654 5 Cyl 4 EUI Ckt OPEN Cylinder 4 EUI Circuit Open 654 6 Cyl 4 EUI Ckt SHORT Cylinder 4 EUI Circuit Shorted 654 7 Cyl 4 EUI Ckt MECH FL Cylinder 4 EUI Circuit Mechanical Failure 654 13 Cyl 4 EUI QR INVLD Cylinder 4 EUI Circuit QR Code Invalid 654 CYLINDER 4 INJECTOR Caption String for Cylinder 4 Injector 655 2 Cyl 5 EUI PN INVLD Cylinder 5 EUI Part Number Invalid 655 5 Cyl 5 ...

Page 137: ...n String for Cylinder 19 Injector 670 CYLINDER 20 INJECTOR Caption String for Cylinder 20 Injector 671 CYLINDER 21 INJECTOR Caption String for Cylinder 21 Injector 672 CYLINDER 22 INJECTOR Caption String for Cylinder 22 Injector 673 CYLINDER 23 INJECTOR Caption String for Cylinder 23 Injector 674 CYLINDER 24 INJECTOR Caption String for Cylinder 24 Injector 676 ENG GLOW PLUG RELAY Caption String fo...

Page 138: ... String for Engine Brake Output 1 1074 ENG EXHAUST BRAKE OUT Caption String for Engine Exhaust Brake Output 1075 5 Fuel TR Pump Curr LO Fuel Transfer Pump Current Low 1075 6 Fuel TR Pump Curr HI Fuel Transfer Pump Current High 1075 12 Fuel TR Pump ERR Fuel Transfer Pump Error 1079 SENSOR SUPPLY VOLTS 1 Caption String for Sensor Supply Voltage 1 1080 3 Snsr Supp 1 Volt LO Sensor Supply 1 Voltage Lo...

Page 139: ...MISFIRE CYLINDER 2 Caption String for Misfire detected on a single engine cylinder 1325 MISFIRE CYLINDER 3 Caption String for Misfire detected on a single engine cylinder 1326 MISFIRE CYLINDER 4 Caption String for Misfire detected on a single engine cylinder 1327 MISFIRE CYLINDER 5 Caption String for Misfire detected on a single engine cylinder 1328 MISFIRE CYLINDER 6 Caption String for Misfire de...

Page 140: ...3 MISFIRE CYLINDER 21 Caption String for Misfire detected on a single engine cylinder 1344 MISFIRE CYLINDER 22 Caption String for Misfire detected on a single engine cylinder 1345 MISFIRE CYLINDER 23 Caption String for Misfire detected on a single engine cylinder 1346 MISFIRE CYLINDER 24 Caption String for Misfire detected on a single engine cylinder 1347 3 Pump Ctrl Vlv Curr HI Pump Control Valve...

Page 141: ... Temp Moderately High 2634 POWER RELAY Caption String for main Power Relay 2659 2 EGR Flo Tmp MISMATCH Exhaust Gas Recirculation Flow Temp Mis match 2659 15 EGR Flo Rt High Exhaust Gas Recirculation Flow Rate High Least Severe 2659 17 EGR Flo Rt LO Exhaust Gas Recirculation Flow Rate Low Least Severe 2790 16 Trbo Cmp Out Tmp HI Turbo Compressor Outlet Temp Moderately High 2791 2 EGR Vlv Pos Invld ...

Page 142: ...ANBus Message 523222 TC01 CAN MSG Caption String for CANBus Message 523238 SWTOUT CAN MSG Caption String for CANBus Message 523239 DECV1 CAN MSG Caption String for CANBus Message 523240 FUNMODCTL CAN MSG Caption String for CANBus Message 523350 CYL BANK 1 INJECTORS Caption String for Cylinder Bank 1 Injectors 523351 CYL BANK 1 INJECTORS Caption String for Cylinder Bank 1 Injectors 523352 CYL BANK ...

Page 143: ... 523566 INJECTN PERIOD CYL 6 Caption String for Single Cylinder Injection Period 523567 INJECTN PERIOD CYL 7 Caption String for Single Cylinder Injection Period 523568 INJECTN PERIOD CYL 8 Caption String for Single Cylinder Injection Period 523600 ECU ERROR String for Diagnostic Trouble Code Indicating ECU Error 523601 ECU ERROR String for Diagnostic Trouble Code Indicating ECU Error 523602 FAN SP...

Page 144: ...ng for Diagnostic Trouble Code Indicating ECU Error 523613 RAIL PRESSURE Caption String for Rail Pressure 523615 METERING UNIT VALVE Caption String for Metering Unit Valve 523617 ECU ERROR String for Diagnostic Trouble Code Indicating ECU Error Failure Code String Displayed Description SPN FMI ...

Page 145: ... have this information available when contacting Wacker Neuson Corporation The illustrations shown in this chapter represent typical installations The factory installed options on your machine may look different 14 1 Battery Charger An optional battery charger maintains the battery at peak power while the machine is turned off Use of a battery charger is recommended when the generator is not opera...

Page 146: ...ts the battery A padlock not included securely locks the switch in the OFF position If equipped the battery disconnect switch is mounted to the upper skid beneath the access door on either the right or left side of the machine NOTICE Do not use the battery disconnect switch while the engine is running Damage to electrical components may occur wc_gr010552 ...

Page 147: ...atures camlock connectors for easy tool changes Each connector is protected by a spring loaded cover NOTICE Separate overcurrent protection must be provided Do not exceed 400 amps per receptacle WARNING Electric shock hazard Do not operate this machine with defective or missing guards doors or pro tective interlocks ...

Page 148: ...10 of the fluid contained in the machine 14 5 Extended Run Tank ERT An extended run fuel tank provides extended run time under a continuous full load The long run time eliminates the need for daily refueling saving money on fuel deliveries The tank is fully fluid contained and is ideal for remote or weekend running of equipment such as dewatering submersible pumps wc_gr002647 a wc_gr006179 ...

Page 149: ...heater draws power from the panel control module and is active only when the panel control module is powered An optional thermostat a can be installed if the machine is to be used in extremely cold weather The thermostat automatically powers the panel control module when the temperature drops to approximately 30 C 22 F This activates the heater to prevent damage to the LCD panel It is important to...

Page 150: ...s If after the ten seconds coolant levels are still sensed as being low the ECM shuts down the engine The ECM will then display LOW COOL LEVEL Allow the engine to cool before adding additional coolant If it is necessary to open the radiator only do so with the engine off and only when coolant is cool enough to touch with bare hands Slowly loosen the radiator cap to relieve pressure first before re...

Page 151: ...The shutters are designed to keep the engine compartment warm thus increasing engine temperature during cold weather operation The shutters are activated through a wax pellet actuator b that is connected to the generator s cooling system As radiator coolant warms the wax pellet actuator engages a linkage c that opens the shutters As the coolant cools the shutters close ...

Page 152: ... air is drawn into the engine Pressing the emergency stop switch alone will not stop a runaway engine Some models include a positive air shutoff valve a Activating the positive air shutoff valve blocks the flow of air into the engine intake and stops the engine from running Operation To activate the positive air shutoff valve pull the T handle b located next to the voltage selector switch The valv...

Page 153: ...xternal return hose c through the access port a on the curb side of the machine 2 Disconnect the internal feed hose d at the tank fitting and connect the internal feed hose to the external supply hose 3 Disconnect the internal return hose e from the tank fitting and connect it to the external return hose c Result The external fuel supply is now connected wc_gr009257 wc_gr009257 a b c d e WARNING F...

Page 154: ...s oil level is the same as that measured by the engine dipstick A float inside the valve detects low oil levels and opens the valve to supply the needed oil The system is wired to the ECM and includes a low oil shutdown in case the oil in the reservoir is depleted Operation If the engine shuts down due to low oil the ECM will display LOW OIL LEVEL Fill the engine and the additional oil reservoir w...

Page 155: ...arbons and organic diesel particulates Decomposition Reactor Tube DRT A DRT is a tube between the DOC and the SCR into which the DEF is introduced dosed into the exhaust stream How it works The exhaust is first treated by the DOC Exhaust NOx emissions flow through the DOC into the DRT DEF is injected into the DRT The amount and frequency is controlled by the DEF supply module The DEF vaporizes and...

Page 156: ...zzles that meet the ISO 22241 4 standard This system also allows for automatic shut off Notices Do not put Diesel fuel or any other liquid besides DEF into the DEF tank The DEF freezes crystallizes at 11 F 12 C Do not overfill the DEF tank DEF expands when frozen Expanding DEF can cause machine damage DEF may be corrosive on certain materials copper brass Clean up any spilled DEF immediately Proce...

Page 157: ...display the increasing DEF level while the engine is running 4 Fill the DEF tank until the DEF level reaches 100 5 Re install the DEF cap 6 Place the engine start switch in the OFF position 0 0 READY 100 0 0 P2 13 0 25 3 63 A Ø HZ V R Basler DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF REMOTE START REMOTE START FERNSTART FERNSTART ARRANQUE REMOTO ARRAN...

Page 158: ...e DEF manufacturer for detailed information NOTICE Only use equipment that is clearly specified for handling DEF Do not use any hoses or pumps that do not specifically identify being compatible with the brand of DEF being used as DEF can be a corrosive liquid to certain metals and can dissolve minerals from hoses and plastic fittings Always read and understand all information from the DEF manufact...

Page 159: ... trips Machine runs for 10 minutes then shuts down During shutdown the LED is on solid and the LCD screen shows LOW DEF SHUTDOWN The machine may be restarted without adding any DEF but will only run for 10 minutes before the genset controller shuts down the machine Only the convenience receptacles are available 0 DEF PRESVR INDUCMT Same as above plus the engine s SEVERE INDUCMT timer starts 30 min...

Page 160: ...re the genset controller shuts down the machine Only the convenience receptacles are available 165 minutes after issue detected DEF PRESVR INDUCMT Same as above 180 minutes after issue detected DEF SEVERE INDUCMT After 180 minutes of run time with a DEF quality issue the engine shuts itself down This is the first of four shutdowns allowed by the engine Note The genset controller s 10 minute run ti...

Page 161: ...out and the conditioning process will begin The engine speed will gradually increase to about 1100 rpm while the machine is in conditioning mode When conditioning is complete the engine speed will return to low idle about 900 rpm Note The conditioning process may continue for up to one hour depending on ambient conditions and the amount of DEF crystals inside the DRT NOTICE To prevent machine dama...

Page 162: ...very 4500 hours or 3 years WARNING A poorly maintained machine can malfunction causing injuries or permanent damage to the machine Keep the machine in safe operating condition by performing periodic mainte nance and making repairs as needed Daily Weekly 50 hours or 2 weeks 250 hours 600 hours or 12 months Other Conduct visual walk around inspection Check exhaust system Drain containment system Ser...

Page 163: ...ircuit breakers move to the OFF position Close the emergency stop switch push in Disconnect the negative terminal on the battery Attach a DO NOT START sign to the control panel If the unit is connected to a remote start or transfer switch make sure the remote switch is also off and tagged 16 4 Cleaning the Machine When As needed Suggested cleaning materials Compressed air Clean water supply Mild d...

Page 164: ...rnal inspection of the machine Check for External damage dents cracks broken door latches etc Loose or missing fasteners Loose or missing parts Fluid leaks Restricted air flow in the exhaust compartment Problems with the trailer refer to topic Maintaining the Trailer Internal inspection Open the access doors on both sides of the machine Check for Damage to control panel switches or customer connec...

Page 165: ...any missing lug nuts immediately Axle Hubs Grease axle hubs using a good wheel bearing grease Brakes Check operation of brakes before each trip Check level of brake fluid in actuator at front of trailer at regular intervals Fill brake fluid to approximately 1 inch below top of reservoir using DOT 3 heavy duty brake fluid Tighten filler plug securely Note If fluid level has fallen too low bleed bra...

Page 166: ...s cool to the touch Machine is on a level surface Plastic cloth and a container of sufficient volume to collect drained fluid Note Collect store and dispose of drained fluid in accordance with current environmental protection regulations Procedure Perform the procedure below to check and drain the containment system 1 Open the access door on the side of the machine 2 Check the fluid level in the c...

Page 167: ... is stopped Exhaust pipes and muffler are cool to the touch Procedure Perform the following procedure to check the exhaust system 1 Open the access door on the curb side of the machine 2 Inspect the exhaust pipes a and muffler b looking for Cracks or holes Burned or missing insulation Loose or missing clamps Black soot deposits especially around welds and joints 3 Start the engine Listen carefully...

Page 168: ...onnections To connect the battery 1 Connect the red positive battery cable to the battery 2 Connect the black negative battery cable to the battery To disconnect the battery 1 Stop the engine 2 Place all electrical switches in the OFF position 3 Disconnect the black negative battery cable from the battery 4 Disconnect the red positive battery cable from the battery Maintaining battery condition Fo...

Page 169: ...speed 2 Move the manual regeneration switch c to the on position and hold it for five seconds The DPF indicator will go out and the regeneration process will begin 3 Release the switch The engine speed will gradually increase to about 1000 rpm while the machine is in regeneration mode When regeneration is complete the engine speed will return to low idle about 750 rpm Note The regeneration process...

Page 170: ...pproximately 1 5 gallons per minute for 6 minutes 4 Wait 10 minutes Then fill at a rate of approximately 1 5 gallons per minute for 3 30 minutes or until full 5 Run the machine under a 50 load for approximately 15 minutes until the coolant temperature exceeds 190 F 6 Inspect the radiator cap and cap seal for damage Clean the radiator cap or replace if necessary This procedure continues on the next...

Page 171: ...tal coolant additives MUST be used year round Automotive type coolants do not contain the correct coolant additives to protect heavy duty diesel engines They often contain a high concentation of silicates which can damage the engine and cooling system Important Use a long life ethylene glycol coolant in this engine Refer to the engine owner s manual for more information ...

Page 172: ...e residual DEF liquid that may be in the filter housing Dispose of the DEF in accordance with the environment protection legislation 1 Remove the filter cap a This procedure continues on the next page WARNING Personal injury hazard DEF contains urea Do not get the substance in your eyes In case of contact immediately flush eyes with large amounts of water for a minium of 15 minutes WARNING The DEF...

Page 173: ...lter tool will make a click sound This indicates that the filter element is properly engaged 4 Clean the filter cap and threads with warm water and a clean cloth Note Inspect the filter cap for cracks or leaks If the threads are damaged replace the filter cap Installation 1 Insert the equalizing element into the new filter 2 Insert the filter assembly into the aftertreatment dosing unit 3 Re insta...

Page 174: ... fuel After completing the procedures listed above fill the fuel tank completely and add a high quality stabilizer to the fuel Choose a stabilizer that includes cleaning agents and additives designed to coat protect the cylinder walls Make sure the stabilizer you use is compatible with the fuel in your area fuel type grade and temperature range Do not add extra alcohol to fuels which already conta...

Page 175: ...ollow local safety and environmental regulations pertaining to the disposal of construction equipment Preparation Perform the following tasks to prepare the machine for disposal Move the machine to a protected location where it will not pose any safety hazards and cannot be accessed by unauthorized individuals Ensure that the machine cannot be operated from the time of final shutdown to disposal D...

Page 176: ...rom the engine owner s manual For additional information see the engine owner s manual NOTICE The standard oil change interval on Wacker Neuson Mobile Generators is 250 hours To meet the 500 hour extended interval period listed above certain requirements must be met including engine drain pan diesel fuel engine oil and fuel filter used See the John Deere operator s manual that came with your engin...

Page 177: ...ate viscosity based on the expected outside air temperature See the table below WARNING Most used liquids from this machine such as oil gasoline grease etc contain small amounts of materials that can cause cancer and other health problems if inhaled ingested or left in contact with skin for prolonged periods of time Take steps to avoid inhaling or ingesting used liquids Wash skin thoroughly after ...

Page 178: ...wc_tx003849gb_FM10 fm 178 Engine Maintenance John Deere 4045TF285 HF285 6068HF285 770051 ...

Page 179: ...wc_tx003849gb_FM10 fm 179 Engine Maintenance John Deere 4045TF285 HF285 6068HF285 770052 ...

Page 180: ...wc_tx003849gb_FM10 fm 180 Engine Maintenance John Deere 4045TF285 HF285 6068HF285 770048 ...

Page 181: ...oil of appropriate viscosity based on the expected outside air temperature See the table below WARNING Most used liquids from this machine such as oil gasoline grease etc contain small amounts of materials that can cause cancer and other health problems if inhaled ingested or left in contact with skin for prolonged periods of time Take steps to avoid inhaling or ingesting used liquids Wash skin th...

Page 182: ...s Engine Oil Recommendation Bulletin 3810340 While the preferred viscosity grade is 15W 40 lower viscosity multigrade oils can be used in colder climates See the accompanying chart Any viscosity grade lower than 15W 40 must still meet CES 20081 Synthetic engine oils API Group III and Group IV basestocks are recommended for use in Cummins engines operation in ambient temperature conditions consiste...

Page 183: ...gb_FM10 fm 183 Engine Maintenance T4i Cummins QSB6 7 The engine maintenance schedule s in this chapter are reproduced from the engine owner s manual For additional information see the engine owner s manual 770015 ...

Page 184: ...wc_tx003663gb_FM10 fm 184 Engine Maintenance T4i Cummins QSB6 7 770016 ...

Page 185: ... oil of appropriate viscosity based on the expected outside air temperature See the table below WARNING Most used liquids from this machine such as oil gasoline grease etc contain small amounts of materials that can cause cancer and other health problems if inhaled ingested or left in contact with skin for prolonged periods of time Take steps to avoid inhaling or ingesting used liquids Wash skin t...

Page 186: ...ns Engine Oil Recommendation Bulletin 3810340 While the preferred viscosity grade is 15W 40 lower viscosity multigrade oils can be used in colder climates See the accompanying chart Any viscosity grade lower than 15W 40 must still meet CES 20081 Synthetic engine oils API Group III and Group IV basestocks are recommended for use in Cummins engines operation in ambient temperature conditions consist...

Page 187: ...and Reservoirs Drain Coolant Level Check Fuel Water Separator Drain Lubricating Oil Level Check Aftertreatment Exhaust Piping Check Dust Ejection Valve Check Diesel Exhaust Fluid DEF Level Check Maintenance Procedures at 250 Hours or 3 Months Air Cleaner Restriction Check Charge Air Piping Check Charge Air Cooler Check Radiator Hoses Check Air Intake Piping Check Radiator Check Maintenance Procedu...

Page 188: ...nd corrosion protection Supplemental coolant additive SCA is essential for liner pitting and scaling protection 3 The service interval is 2 years 4 Follow the manufacturers recommended maintenance procedures for the starter alternator batteries electrical components engine brake exhaust brake charge air cooler radiator air compressor air cleaner refrigerant compressor and fan clutch 5 Reset valve ...

Page 189: ...l tank with fuel Bleed fuel lines Replace fuel filter Check fuel lines No generator output Main circuit breaker open Lug door open Close main circuit breaker Close lug door Low oil pressure Low oil level Clogged oil filter Fill engine sump with oil Replace oil filter High coolant temperature Overload Low coolant level Low oil level Clogged oil filter Reduce load Fill with coolant Fill sump with oi...

Page 190: ...chine for more information 2 The use of 6 diesel fuel is not recommended Item No G 240 Engine Engine make John Deere 6 8L Engine model 6068HF485 Number of cylinders 6 Displacement cm in 6800 415 Operating speed rpm 1800 Rated standby power 1800 rpm kW Hp 235 315 Coolant capacity L qt 28 8 30 4 Oil capacity L qt 32 5 34 3 Battery V ccA 12 950 Fuel type type Clean filtered 1 or 2 diesel2 Fuel tank c...

Page 191: ...cy 60 Hz Power factor 1Ø 3Ø 1 0 0 8 Voltage regulation 1 00 Insulation class H Sound level at 7 m 23 ft dB A 72 AC receptacles 2 duplex 3 twist lock 1Ø 120 GFI duplex Amps 2 20A 1Ø 120 240 V twist lock Amps 3 50A Standby output kW kVA 210 262 Prime output kW kVA 191 238 Main breaker Amps 700 Item No G 240 Trailer Dry weight of skid kg lb 3044 6714 Operating weight of skid kg lb 4351 9594 Trailer w...

Page 192: ...0 G 240 21 4 Dimensions G 240 Item Number 0620661 5200001323 0602662 0620663 5200006904 a mm in 3353 132 0 3353 132 0 b 1384 54 5 1384 54 5 c 1829 72 0 1918 72 0 d 2146 84 5 2146 84 5 e 2591 102 2591 102 f 5055 199 5055 199 wc_gr011550 b d f a c e ...

Page 193: ...ne make Cummins Engine model QSB7 G9 Number of cylinders 6 Displacement cm in 6 700 409 Operating speed rpm 1 800 Rated standby power 1800 rpm kW hp 234 314 Coolant capacity L qt 61 7 65 2 Engine oil type 15W 40 multigrade low ash CES 20081 API CJ 4 SL or equivalent Oil capacity L qt 17 5 18 5 Battery V ccA 2 x 12 1000 Fuel type type Ultra low sulfur fuel Clean filtered 1 or 2 diesel2 Fuel tank ca...

Page 194: ... recommended Machine G 230 Engine make Cummins Engine model QSB7 G6 Number of cylinders 6 Displacement cm in 6700 409 Operating speed rpm 1800 Rated standby power 1800 rpm kW hp 234 314 Coolant capacity L qt 36 38 5 Engine oil type 15W 40 multigrade low ash CES 20081 API CJ 4 SL or equivalent Oil capacity L qt 17 5 18 5 Battery V ccA 24 950 Fuel type type Ultra low sulfur fuel Clean filtered 1 or ...

Page 195: ...e panel AC voltages available 1Ø V 3Ø V 120 127 139 240 254 277 208 220 240 416 440 480 Frequency 60 Hz Power factor 1Ø 3Ø 1 0 0 8 Voltage regulation 1 00 Insulation class H Sound level at 7 m 23 ft dB A 72 AC receptacles 2 duplex 3 twist lock 1Ø 120 GFI duplex Amps 2 20A 1Ø 120 240 V twist lock Amps 3 50A Standby output kW kVA 202 253 Prime output kW kVA 184 230 Main breaker Amps 700 ...

Page 196: ...230 G 230 22 4 Trailer and Skid Machine G 230 Dry weight of skid kg lb 2856 6340 Operating weight of skid kg lb 4163 4220 Trailer weight without generator kg lb 641 1414 GVWR kg lb 5455 12 000 Surge brakes Fluid type Dot 3 Tires size 7 50 x 16E ...

Page 197: ...2882 0620883 5200010141 5200010142 a mm in 3353 132 0 3353 132 0 3353 132 0 3353 132 0 b 1321 52 0 1384 54 5 1321 52 0 1384 54 5 c 1893 74 5 1918 72 0 1943 76 5 1968 77 5 d 2146 84 5 2146 84 5 2146 84 5 2146 84 5 e 2655 104 5 2655 104 5 2705 106 5 2705 106 5 f 5055 199 5055 199 5055 199 5055 199 wc_gr011550 b d f a c e ...

Page 198: ...on Federal Regulation 49 CFR 575 requires trailer manufacturers to include certain tire information in the owner s manuals for the trailers they manufacture This regulation requires that the information be in the English language This chapter includes all the information required by Federal Regulation 49 CFR 575 ...

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Page 200: ...ated 2 Locate the 9 5 URVV 9HKLFOH HLJKW 5DWLQJ RI WKH WUDLOHU RQ RXU WUDLOHU V 9 1 HUWLILFDWLRQ ODEHO 3 Subtract the empty weight of your trailer from the GVWR stated on the VIN label That weight is the maximum available cargo capacity of the trailer and may not be safely exceeded 67 36 25 7 50 1 1 255 7 2 0 7 72 9 1 RFDWH WKH VWDWHPHQW 7KH FRPELQHG ZHLJKW RI RFFXSDQWV DQG FDUJR VKRXOG QHYHU H FH...

Page 201: ...rside of the rim in a manner that encloses the rim flanges inside the air cavity of the tire Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel oil and coolant and if so equipped air conditioning and additional weight optional engine Extra load tire A tire designed to operate at higher loads and at higher inflation pressures than the correspond...

Page 202: ...corporates a wheel supports the tire and attaches either integrally or separably to the wheel center member and upon which the tire is attached Non pneumatic spare tire assembly A non pneumatic tire assembly intended for temporary use in place of one of the pneumatic tires and rims that are fitted to a passenger car in compliance with the requirements of this standard Non pneumatic tire A mechanic...

Page 203: ...n the Tire Information label and on the Certification VIN tag Reinforced tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire Rim A metal support for a tire or a tire and tube assembly upon which the tire beads are seated Rim diameter This means the nominal diameter of the bead seat Rim size designation This means the rim diameter a...

Page 204: ...rating a wheel a mechanical device which attaches either integrally or separably to the non pneumatic tire and provides the connection between tire and the vehicle Wheel holding fixture The fixture used to hold the wheel and tire assembly securely during testing 1 4 TIRE SAFETY EVERYTHING RIDES ON IT The National Traffic Safety Administration NHTSA has published a brochure DOT HS 809 361 that disc...

Page 205: ...flated You will also find this number on the vehicle information placard expressed in kilopascals kpa which is the metric measure used internationally Manufacturers of passenger vehicles and light trucks determine this number based on the vehicle s design load limit that is the greatest amount of weight a vehicle can safely carry and the vehicle s tire size The proper tire pressure for your vehicl...

Page 206: ... If you have any doubt about the correct size to choose consult with the tire dealer 1 5 6 TIRE TREAD The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding especially when the road is wet or icy In general tires are not safe and should be replaced when the tread is worn down to 1 16 of an inch Tires have built in treadwear indicators that let y...

Page 207: ... two digit number is the wheel or rim diameter in inches If you change your wheel size you will have to purchase new tires to match the new wheel diameter Next number This two or three digit number is the tire s load index It is a measurement of how much weight each tire can support You may find this information in your owner s manual If not contact a local tire dealer Note You may not find this i...

Page 208: ...tire can support Tire manufacturers also must indicate the materials in the tire which include steel nylon polyester and others Maximum Load Rating This number indicates the maximum load in kilograms and pounds that can be carried by the tire Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions...

Page 209: ...nd tire pressure when the tire is used as a single Load Range This information identifies the tire s load carrying capabilities and its inflation limits 1 6 TIRE SAFETY TIPS Preventing Tire Damage Slow down if you have to go over a pothole or other object in the road Do not run over curbs or other foreign objects in the roadway and try not to strike the curb when parking Tire Safety Checklist Chec...

Page 210: ...nsported Placarding requirements Immediately after the fuel tank is filled fully or partially with flammable liquids UN Placards Transport of Dangerous Goods Decals Placards of Flammable Liquids Transport Canada Product Identification Decals must be installed prior to moving the machine in any manner This is a requirement of Transport Canada Refer to Hazardous Materials Placards in the Operation c...

Page 211: ...wc_tx003111gb_FM10 fm 211 User s Information for Transport Canada Fuel Tank ...

Page 212: ...wc_tx003111gb_FM10 fm 212 User s Information for Transport Canada Fuel Tank ...

Page 213: ...Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Problems that may affect Emissions If any of the following symptoms arise have t...

Page 214: ...parts during the warranty period Limited Defect Warranty Period for Wacker Neuson Emission Control Systems The warranty period for this engine equipment begins on the date of sale to the initial purchaser and continues for a period of five years or 3000 hours of operation whichever comes first For the warranty terms for your specific engine equipment visit wackerneuson com Any implied warranties a...

Page 215: ...sis and inspection charges that do not result in warranty eligible service being performed Any non authorized replacement part or malfunction of authorized parts due to use of non authorized parts Owner s Warranty Responsibility The engine equipment owner is responsible for the performance of the required maintenance listed in the Wacker Neuson engine equipment operator s manual Wacker Neuson reco...

Page 216: ...u must take your Wacker Neuson engine equipment along with proof of original purchase date at your expense to the authorized Wacker Neuson dealer service center during their normal business hours For owners located more than 100 miles from an authorized dealer service center excluding the states with high altitude areas as identified in 40 CFR Part 1068 Appendix III Wacker Neuson will pay for pre ...

Page 217: ...a 1 2 3 4 7 5A ECM switch 7 5A G 150 T3 John Deere Basler G 180 T3 John Deere Basler 10A ECM start 1 2 3 4 5 6 7 8 7 5A ECM switch 7 5A 10A 1A Engine diagnostics 20A Engine ECU N A 5A Keyswitch 5A 1A 20A wc_gr011870 10A ECM start 1 2 3 4 7 5A ECM switch 7 5A 10A G 150 T3 John Deere Deep Sea G 180 T3 John Deere Deep Sea G 150 T4i Cummins Basler G 180 T4i Cummins Basler G 230 T4i Cummins Basler 10A ...

Page 218: ...r Wiring Standard and Hydraulic Brakes Electric Brakes w c _ g r 0 0 0 5 2 2 B r B r W W B r W G B r W Y B r W B r W Y G B r W 1 9 8 6 2 1 0 3 B r B r 7 7 3 G Y Br W R R R Br W R W W W W Br Br Br Br Br Br W wc_gr000523 Y W G R W R R 1 4 5 5 2 9 6 8 7 7 10 Br W ...

Page 219: ... solenoid 6 Right tail light 7 License plate holder lights 8 Left tail light 9 Rear right side red light 10 Rear left side red light Ref Wire Colors Rear Lights Side Lights Harness B BLACK Ground Ground Battery charge Br BROWN Tail light Tail side and license plate L BLUE R RED Brake light Power Electric brakes Y YELLOW Left brake light and directional G GREEN Right brake light and directional W W...

Page 220: ...achines with Basler Controller 26 1 AC Schematic G 230 G 240 wc_gr011988 CT CT 3 36 6 CT CT 36 36A A CT CT 3 3 3 3 O OR R WH WHT T 3 3 3 3 B BR R Y YE E 6 6 6 6 7 7 7 7 7 7 7 7 C CT T C CT T C CT T CT CT CT CT CT CT 1 2 6 3 5 4 7 8 10 12 14 13 15 18 17 20 23 24 25 21 19 22 16 8 9 9 11 10 10 20 20 ...

Page 221: ...ctor switch 17 Generator alternator 5 Main breaker 18 Stator auxiliary winding 6 Lug safety limit switch 19 Stator main windings 7 Mechanical lugs 20 Receptacle 240V 50A 8 GFI receptacle 120V 21 Exciter rotor windings 9 Circuit breaker 120V 20A 22 Rotor 10 Circuit breaker 240V 50A 23 Bond bar 11 Voltage adjusting rheostat 24 Shunt 12 Voltage regulator 25 Machine and components 13 Stator Wire Color...

Page 222: ...KER 30 TRIPPED TRIPPED TRIP BREAKER 56 TRIP BREAKER 56 E STOP 47 E STOP 47 REMOTE ANNUNCIATOR REMOTE ANNUNCIATOR COMMON 51 COMMON 51 PREALARM 53 PREALARM 53 E STOP 46 E STOP 46 ALARM 52 ALARM 52 BAT 55 BAT 55 49 49 START START FUEL FUEL PRE PRE HEAT HEAT 93 93 BLK BLK RED RED WHT VIO WHT VIO YEL YEL VIO VIO GRY GRY TAN WHT TAN WHT TAN TAN 81 81 82 82 82 82 83 83 84 84 94 94 94 94 96 96 96 96 86 86...

Page 223: ...es 21 Mechanical lugs 6 Hour meter 22 Relay if equipped 7 Shunt trip relay 23 Intake heater if equipped 8 Contact inputs 24 Starter relay 9 21 position connector 25 Starter 10 Start relay 26 Alternator 11 Alternator charge 27 12V battery 12 B switched 28 Battery disconnect switch 13 Crank delay 29 John Deere engine ECU 14 Fuel level 30 Engine harness 15 Remote start 31 Terminal block 16 Emergency ...

Page 224: ...47 E STOP 47 REMOTE ANNUNCIATOR REMOTE ANNUNCIATOR COMMON 51 COMMON 51 PREALARM 53 PREALARM 53 E STOP 46 E STOP 46 ALARM 52 ALARM 52 BAT 55 BAT 55 49 49 GROUND TO GROUND TO ENCLOSURE ENCLOSURE BOX SMALL BOX SMALL STUD M8 STUD M8 START START FUEL FUEL 93 93 BLK BLK RED RED WHT VIO WHT VIO YEL YEL VIO VIO GRY GRY TAN WHT TAN WHT TAN TAN 81 81 82 82 82 82 83 83 84 84 94 94 94 94 96 96 96 96 86 86 74 ...

Page 225: ...nal 6 Hour meter 3 Sensor return 7 Shunt trip relay 27 12V battery 8 Plug 2 Contact inputs 28 Battery disconnect switch if equipped 18 Regeneration 29 21 pin Cummins after treatment connector 21 Idle 3 OEM sensor return 27 Remote start 4 Diesel particulate filter pressure change 28 Remote start mode 5 Diesel particulate filter out pressure 29 Run mode 2 OEM sensor supply 30 Breaker tripped 7 DOC o...

Page 226: ... ENGINE OUTPUTS ELECTRONIC CONTROL UNIT BK 60 45 44 GRN NO RD 50 44 BK BK 34 61 46 93 64 RED NC RED NC EMERGENCY STOP SWITCH BK RD RD RD BAT 2 80 83 84 85 RUN MODE 29 REMOTE START 28 MODE BREAKER 30 TRIPPED PLUG 2 CONTACT INPUTS TRIP BREAKER 56 E STOP 47 REMOTE ANNUNCIATOR COMMON 51 PREALARM 53 PLUG 4 E STOP CANBUS CONTACT OUTPUTS E STOP 46 ALARM 52 BAT 55 49 GROUND TO ENCLOSURE BOX SMALL STUD M8 ...

Page 227: ...let outlet temperature sensors 12 5A Fuse 38 Cummins upstream Diesel Oxidation Catalyst DOC NOx sensor 13 7 5A fuse 39 Cummins downstream Selective Catalyst Reduction SCR Nox sensor 14 Intake heater 40 Cummins 24 pin crossover connector 15 Intake heater relay 41 Cummins Diesel Exhaust Fluid DEF injector 16 150A fuse 42 Aftertreatment relay box 17 Starter relay 43 Cummins Diesel Exhaust Fluid DEF p...

Page 228: ...TOR COMMON 51 PREALARM 53 PLUG 4 E STOP CANBUS CONTACT OUTPUTS E STOP 46 ALARM 52 BAT 55 49 GROUND TO ENCLOSURE BOX SMALL STUD M8 START FUEL HOUR METER 93 BK RD BK BK BK BK RD BK 81 82 82 83 84 94 94 96 96 86 74 95 90 91 92 92 81 BK BK BK BK BK BK BK BK BK RD RD BK BK BK 7 5A FUSE CAN L 48 CAN H 49 SHIELD 50 63 GN YL SHIELD 97 86 85 97 BK RD 98 87 98 RD SHUNT TRIP RELAY 99 BK 120 OHM 67 68 IDLE 21...

Page 229: ...emote start 18 Emergency stop switch Remote start mode 19 Remote start terminals Run mode 22 Shunt Breaker tripped 23 Mechanical lugs 3 Electronic control unit genset controller 24 Main circuit breaker 4 Plug 4 E stop CANBUS contact outputs 25 Fuel level sender Emergency stop 26 Lug door interlock switch Emergency stop 27 Bond bar Canbus low 28 Shunt trip relay Canbus high 30 120 Ohm resistor Shie...

Page 230: ...ROL 53 DEF DOSING INJECTOR LOW 77 DEF DOSING INJECTOR HIGH 57 DEF TANK HEATING VALVE RETURN 82 DEF TANK HEATING VALVE SUPPLY CUMMINS J3 DIAGNOSTIC CONNECTOR A DATALINK RETURN B 24 V DATALINK C J1939 D J1939 E SHIELD INTAKE HEATER 101 102 STARTER RELAY RD 2 0 AWG RD 12 AWG B BK 2 0 AWG 206 RD 205 BK 101 INTAKE HEATER RELAY BK 4 AWG 204 RD 203 BK RD 2 0 AWG STARTER MOTOR B 150A FUSE BK 4 AWG RD 12 A...

Page 231: ...sor Diesel Exhaust Fluid DEF line heaters relay control ECM return Diesel Exhaust Fluid DEF line heater current monitor 1 of 2 Battery supply positive Diesel Exhaust Fluid DEF line heater current monitor 2 of 2 Battery supply positive Diesel Exhaust Fluid DEF supply module relay control Battery supply positive Diesel Exhaust Fluid DEF dosing injector low Battery supply positive Diesel Exhaust Flui...

Page 232: ...OC INLET OUTLET TEMP SENSORS 1 3 4 2 CUMMINS J7A UPSTREAM DOC NOx SENSOR 1 3 4 2 CUMMINS J10 SCR INLET OUTLET TEMP SENSORS 1 3 4 1 CUMMINS J29 DEF BACKFLOW LINE HOSE HEATER 2 1 CUMMINS J30 DEF SUPPLY LINE HOSE HEATER 2 1 CUMMINS J28 DEF PRESSURE LINE HOSE HEATER 2 4 CUMMINS J27 DEF TANK HEATING VALVE 1 155 BK 18 AWG 157 RD 18 AWG 156 BK 18 AWG 168 BK 18 AWG 153 152 151 150 149 18 AWG 148 RD 18 AWG...

Page 233: ...ftertreatment relay box Supply module pump return 43 Cummins Diesel Exhaust Fluid DEF pressure line hose heater Diesel Exhaust Fluid DEF pump power 44 Cummins Diesel Exhaust Fluid DEF backflow line hose heater Diesel Exhaust Fluid DEF reverting valve 45 Cummins Diesel Exhaust Fluid DEF supply line hose heater Diesel Exhaust Fluid DEF pump return 46 Cummins Diesel Exhaust Fluid DEF tank heating val...

Page 234: ...NECTOR PIN 53 2A CUMMINS J2 ECU CONNECTOR PIN 77 3D CUMMINS J31 DEF INJECTOR PIN 1 3E CUMMINS J31 DEF INJECTOR PIN 2 2B CUMMINS J2 ECU CONNECTOR PIN 38 1E CUMMINS J28 DEF PRESSURE LINE HEATER PIN 1 2D CUMMINS J2 ECU CONNECTOR PIN 39 1B CUMMINS J29 DEF BACKFLOW LINE HEATER PIN 1 2F CUMMINS J2 ECU CONNECTOR PIN 40 1F CUMMINS J30 DEF SUPPLY LINE HEATER PIN 1 2G CUMMINS J2 ECU CONNECTOR PIN 3 1A CUMMI...

Page 235: ...Exhaust Fluid DEF pressure line heater pin 1 9 Diesel Exhaust Fluid DEF backflow line heater relay Cummins Engine Control Unit ECU connector pin 39 10 Diesel Exhaust Fluid DEF supply line heater relay Cummins Engine Control Unit ECU connector pin 39 11 Connectors 1 2 3 and 4 output pins Cummins Diesel Exhaust Fluid DEF backflow line heater pin 1 Cummins supply module connector pine 5 Cummins Engin...

Page 236: ...1 5 8 10 12 4 2 6 CT1 CT2 CT3 STATOR MAIN WINDINGS PAIR 2 W Y G X W G Y X G W X Y R3 R2 R1 L1 N 277V L2 N 277V L3 N 277V L1 L2 480V L2 L3 480V L3 L1 480V 3 4 N L1 2 1 L2 6 5 7 L1 1 3 9 L3 10 11 8 12 U1 1 U2 3 Y 6 Z 10 V2 7 X 2 W1 9 O N W2 11 V1 5 2 6 N 7 5 L2 8 4 10 L3 11 9 12 L1 N 120V L2 N 120V L3 N 120V L1 L2 208V L2 L3 208V L3 L1 208V 16 10 240V 50A RCPT 15 9 240V 50A RCPT 240V 50A RCPT 14 178...

Page 237: ...age inputs 17 Voltage regulator with 4A fuse 5 Plug 5 current transformer inputs 18 Voltage adjustment rheostat 6 120V GFI receptacle 19 Machine and components 7 120V 20A breaker 20 Exciter rotor windings 8 240V 50A breaker 21 Exciter stator winding 9 Shunt 22 Rotor 10 240V 50A receptacle 23 Rectifier diodes 11 Bond bar 24 Main rotor winding 12 Genset controller 25 Main stator windings 13 Stator 2...

Page 238: ...ics Machines with Deep Sea Controller G 230 G 240 238 wc_tx003750gb_FM10 fm 27 3 DC Schematic G 240 John Deere Tier 3 J wc_gr011793 1 2 4 5 3 12 7 8 9 10 13 29 25 11 14 15 16 17 18 28 24 19 23 27 26 20 21 22 6 ...

Page 239: ...nset controller 19 Remote start terminals 5 Shunt 20 Battery 6 Plug 4 E stop contact outputs 21 Starter motor 7 120 ohm resistor if equipped 22 Alternator 8 Hour meter 23 Mechanical lugs 9 Terminal strip 24 Main circuit breaker 10 10A fuse 25 Fuel level sender 11 Battery disconnect optional 26 Lug door interlock switch 12 Shunt trip relay 27 Bond bar 13 7 5A fuse 28 Resistor 14 Intake heater 29 ON...

Page 240: ...4 YEL ORG 48 46 64 RED NC RED NC EMERGENCY STOP SWITCH RED RED BAT 1 80 85 BREAKER 61 TRIPPED PLUG 2 SENSOR INPUTS TRIP BREAKER 11 PREALARM 10 PLUG 6 CONTACT INPUTS ALARM 9 49 GROUND TO ENCLOSURE BOX SMALL STUD M8 START FUEL HOUR METER RED WHT VIO YEL VIO 81 91 86 95 90 92 81 BLK BLK BLK BLU 7 5A FUSE B CAN L 26 CAN H 25 SCR 27 63 34 GRN YEL SHIELD BLK 2 0 AWG YEL BLK 86 97 BLU RED 98 87 98 RED SH...

Page 241: ... Toggle switch low idle 32 20A fuse 33 1A fuse 34 5A fuse 35 16 pin Cummins Original Equipment Manufacturer OEM connector 24V Electronic Control Module ECM power 24V service link Keyswitch Starter solenoid Throttle input Fan speed signal Fan speed return Air heater return Air heater signal 24V Electronic Control Module ECM power Data link return 36 Cummins J1939 connector J1939 J1939 Shield 37 Air...

Page 242: ... 18 AWG RD 2 0 AWG GN YL SHIELD BK 18 AWG 188 110 189 151 RED RD 2 0 AWG B BK 2 0 AWG 101 B BK 4 AWG 105 RD 10 AWG BK 10 AWG 113 102 RD 12 AWG BK 4 AWG 150A FUSE BK 12 AWG INTAKE HEATER INTAKE HEATER RELAY 204 RD BK 104 BK 4 AWG 101 102 STARTER RELAY 206 RD 205 BK 203 RD 12 AWG 103 63 BK 110 BK 12 AWG 104 BK 18 AWG 105 BK 18 AWG 155 BK 18 AWG 157 RD 18 AWG 200 RD 199 BK 4 CUMMINS J27 DEF TANK HEAT...

Page 243: ...ective Catalyst Reduction SCR Nox sensor 12 5A Fuse 40 Cummins 24 pin crossover connector 13 7 5A fuse 41 Cummins Diesel Exhaust Fluid DEF injector 14 Intake heater 42 Aftertreatment relay box 15 Intake heater relay 43 Cummins Diesel Exhaust Fluid DEF pressure line hose heater 16 150A fuse 44 Cummins Diesel Exhaust Fluid DEF backflow line hose heater 17 Starter relay 45 Cummins Diesel Exhaust Flui...

Page 244: ...ROUND TO ENCLOSURE BOX SMALL STUD M8 BK BK 86 85 97 BK 99 BK BK 45 60 45 44 BK BK 43 43 78 BK BK SHUNT 89 BK 10 AWG L3 L2 L1 RD MECHANICAL LUGS 50 BK BU WH 79 BOND TO FRONT PANEL DOOR GROUND TO ENCLOSURE BOX LARGE STUD 1 2 L0 BOND BAR GRD BLK PAIR 2 AWG BK 12 AWG HOUR METER 91 92 BK BK 120 BK 119 LIGHT 87 95 48 50 GRN NO 88 64 RED NC RED NC EMERGENCY STOP SWITCH RD RD RD 97 RD 98 108 BK 118 117 RD...

Page 245: ...tact inputs 23 Mechanical lugs Sender communication 24 Main circuit breaker Fuel level 25 Fuel level sender 3 Plug 3 canbus 26 Lug door interlock switch Canbus low 27 Bond bar Canbus high 28 Shunt trip relay Selective Catalyst Reduction SCR 33 Terminal strip 4 Electronic control unit genset controller 49 Manual conditioning toggle switch 5 Idle toggle switch 50 Light manual regeneration 6 Plug 6 c...

Page 246: ...ER CURRENT MONITOR 1 OF 2 85 DEF LINE HEATER CURRENT MONITOR 2 OF 2 7 DEF SUPPLY MODULE RELAY CONTROL 53 DEF DOSING INJECTOR LOW 77 DEF DOSING INJECTOR HIGH BATTERY SUPPLY BATTERY SUPPLY KEY SWITCH INTAKE AIR RELAY RETURN INTAKE AIR RELAY SIGNAL BATTERY SUPPLY BATTERY SUPPLY 51 BATTERY SUPPLY 52 BATTERY SUPPLY 73 BATTERY SUPPLY 46 J1939 22 J1939 32 COOLANT SENSOR RETURN 35 COOLANT SENSOR SIGNAL 8 ...

Page 247: ...tion line heater diagnostic ECM return Diesel Exhaust Fluid DEF line heaters relay control Battery supply positive Diesel Exhaust Fluid DEF line heater current monitor 1 of 2 Battery supply positive Diesel Exhaust Fluid DEF line heater current monitor 2 of 2 Battery supply positive Diesel Exhaust Fluid DEF supply module relay control Battery supply positive Diesel Exhaust Fluid DEF dosing injector...

Page 248: ...D 2F 2G 4D 2E 2C 4F 2H 3A 2A 158 159 160 164 161 167 166 165 4H 4G 1E 3H 1A 1B 3D 1G 3E 1F 1H 171 BK 18 AWG 173 BK 18 AWG 175 BK 18 AWG 170 RD 18 AWG 172 RD 18 AWG 174 RD 18 AWG CUMMINS J29 DEF BACKFLOW LINE HOSE HEATER CUMMINS J30 DEF SUPPLY LINE HOSE HEATER CUMMINS J28 DEF PRESSURE LINE HOSE HEATER 1 2 1 2 1 2 AIR CLEANER TBAP SENSOR 1 2 3 4 1 PRESSURE 2 SENSOR SUPPLY 3 TEMPERATURE 4 RETURN CUMM...

Page 249: ... Supply module pump return 43 Cummins Diesel Exhaust Fluid DEF pressure line hose heater Diesel Exhaust Fluid DEF pump power 44 Cummins Diesel Exhaust Fluid DEF backflow line hose heater Diesel Exhaust Fluid DEF reverting valve 45 Cummins Diesel Exhaust Fluid DEF supply line hose heater Diesel Exhaust Fluid DEF pump return 46 Cummins Diesel Exhaust Fluid DEF tank heating valve Battery return negat...

Page 250: ...ECTOR PIN 53 2A CUMMINS J2 ECU CONNECTOR PIN 77 3D CUMMINS J31 DEF INJECTOR PIN 1 3E CUMMINS J31 DEF INJECTOR PIN 2 2B CUMMINS J2 ECU CONNECTOR PIN 38 1E CUMMINS J28 DEF PRESSURE LINE HEATER PIN 1 2D CUMMINS J2 ECU CONNECTOR PIN 39 1B CUMMINS J29 DEF BACKFLOW LINE HEATER PIN 1 2F CUMMINS J2 ECU CONNECTOR PIN 40 1F CUMMINS J30 DEF SUPPLY LINE HEATER PIN 1 2G CUMMINS J2 ECU CONNECTOR PIN 3 1A CUMMIN...

Page 251: ...ust Fluid DEF pressure line heater relay Cummins Diesel Exhaust Fluid DEF pressure line heater pin 1 9 Diesel Exhaust Fluid DEF backflow line heater relay Cummins Engine Control Unit ECU connector pin 39 10 Diesel Exhaust Fluid DEF supply line heater relay Cummins Engine Control Unit ECU connector pin 39 11 Connectors 1 2 3 and 4 output pins Cummins Diesel Exhaust Fluid DEF backflow line heater pi...

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Page 254: ... 02 390 Wacker Neuson Production Americas LLC N92W15000 Anthony Ave Menomonee Falls WI 53051 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Neuson Limited Room 1701 03 1717 20 17 F Tower 1 Grand Century Place 193 Prince Edward Road West Mongkok Kowloon Hongkong Tel 852 3605 5360 Fax 852 2758 0032 ...

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