Wacker Neuson G 85 Repair Manual Download Page 3 | Manualshive

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Mobile Generator Repair

Foreword

3

Operating / Parts Information

You must be familiar with the operation of this machine before you
attempt to troubleshoot or repair it. Basic operating and maintenance
procedures are described in the Operator’s Manual supplied with the
machine. Keep a copy of the Operator’s Manual with the machine at all
times. Use the separate Parts Book supplied with the machine to order
replacement parts. If you are missing either of the documents, please
contact Wacker Neuson Corporation to order a replacement.

Damage caused by misuse or neglect of the unit should be brought to
the attention of the operator to prevent similar occurrences from
happening in the future.

This manual provides information and procedures to safely repair and
maintain the above Wacker Neuson model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions described in this manual. The information contained in this
manual is based on machines manufactured up to the time of
publication. Wacker Neuson Corporation reserves the right to change
any portion of this information without notice.

This manual covers machines with Item Number:

0009369, 0009459, 0620003

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Summary of Contents for G 85

Page 1: ...Repair Manual Mobile Generator G 85 0171726en 004 0809 0 1 7 1 7 2 6 E N ...

Page 2: ...xpress written permission from Wacker Neuson Corporation Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights Violators will be prosecuted Trademarks All trademarks referenced in this manual are the property of their respective owners Manufacturer Wacker Neuson Corporation N92W15000 Anthony Avenue Menomonee Falls WI 530...

Page 3: ...oration to order a replacement Damage caused by misuse or neglect of the unit should be brought to the attention of the operator to prevent similar occurrences from happening in the future This manual provides information and procedures to safely repair and maintain the above Wacker Neuson model s For your own safety and protection from injury carefully read understand and observe all instructions...

Page 4: ...d and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator All rights especially copying and distribution rights are reserved Copyright 2009 by Wacker Neuson Corporation No part of this publication may be reproduced in any form or by any means electronic or...

Page 5: ...ues 22 3 1 Checking Continuity 22 3 2 Checking Resistance 22 3 3 Checking Voltage 22 3 4 Probing ECM Plugs and Pins 23 4 ECM Background Information 24 4 1 ECM Handling Precaution 24 4 2 Normal Boot up Sequence 25 4 3 Display Variables and Values 28 4 4 ECM Display Screens Start Switch in Remote Position 29 4 5 Additional Variables Monitored by the ECM 30 4 6 Voltage Display Errors 36 4 7 ECM Autom...

Page 6: ...Engines With ECU 59 6 1 John Deere Engines With ECU Background 59 6 2 Locations of Engine Electrical Components 60 6 3 Engine Electrical Components 61 7 Engine Starting Troubleshooting 62 7 1 Checking the Fuses 62 7 2 Checking the Engine Control Module ECM 63 7 3 Checking the Emergency Stop Switch 64 7 4 Checking the Starter Relay 65 7 5 Checking the Starter Solenoid 66 7 6 Checking the Intake Hea...

Page 7: ...ight Block 84 9 5 Removing the Roof 85 9 6 Preparing Unit for Generator Removal 87 9 7 Replacing the Generator 89 9 8 Removing the AVR 91 9 9 Installing the AVR 92 9 10 Removing the Engine 95 9 11 Installing the Engine 97 9 12 Replacing the Fuel Tank 99 9 13 Replacing the Emergency Stop Switch older 101 9 14 Replacing the Emergency Stop Switch newer 103 9 15 Replacing the Diodes 105 9 16 Replacing...

Page 8: ...Table of Contents MG Repair wc_br0171726en_004TOC fm 8 ...

Page 9: ... Used without the safety alert symbol NOTICE indicates a situation which if not avoided could result in property damage Note Contains additional information important to a procedure Electrocution hazard Electrocution or severe electrical shock hazards are present throughout the generator any time the engine is running Read all safety notes contained in this section before operating or servicing th...

Page 10: ...hed to the generator must not exceed the load rating of the generator 1 1 7 NEVER allow untrained personnel to operate or service the generator The generator set should be set up by a certified electrician 1 1 8 NEVER operate generator in standing water 1 1 9 NEVER touch the hot engine exhaust or generator components Burns will result 1 1 10 NEVER start a machine in need of repair 1 1 11 Use the e...

Page 11: ...l and local regulations BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS Improper connection of generator to a building s electrical system can allow electrical current from the generator to backfeed into utility lines This may result in electrocution of utility workers fire or explosion Connections to a building s electrica...

Page 12: ...stomer connection lugs This point is connected directly to the generator set base All other system grounds are connected to this central point Ground the generator in accordance with the standards defined in national state and local regulations 1 2 3 DO NOT attempt to open the radiator cap while the unit is running or before the engine has cooled down Severe burns may result 1 2 4 DO NOT allow wat...

Page 13: ...people in the area when lifting the machine 1 3 Operator Safety while using Internal Combustion Engines Internal combustion engines present special hazards during operation and fueling Read and follow the warning instructions in the engine owner s manual and the safety guidelines below Failure to follow the warnings and safety standards could result in severe injury or death 1 3 1 Do not run engin...

Page 14: ...hat will be used for towing 1 4 8 ALWAYS make sure directional and trailer lights are connected and working properly 1 4 9 ALWAYS check that the lug nuts holding the wheels are tight and that none are missing 1 5 Reporting Trailer Safety Defects If you believe your trailer has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traff...

Page 15: ...c Exciter rotor winding i Auxiliary winding d Rotating rectifier diodes j Voltage adjusting rheostat e Main rotor winding k Lug door switch f Main stator windings l Stator assembly VOLT T1 T5 T9 T2 N T7 T10 T3 T6 T11 T4 T8 T12 L1 L2 L3 wc_gr003643 3 Phase AC out 3 Phase AC output DC out exciter field AC sensing AC in DC in L Y a c d b e f l h g j i k B R G Y L B W GND L W L R 5C AMP HZ STAB 5B 7 5...

Page 16: ...ary element a rotor rotating element a voltage regulator voltage control device and a rectifier assembly current control device The rotor can function as either the magnetic field or the winding Likewise the stator can function as either the magnetic field or the winding depending on the application In Wacker Neuson generators there are two stators a and b and a single rotor assembly c The rotor a...

Page 17: ...Mobile Generator Theory of Operation wc_tx001077gb fm 17 wc_gr003303 c a a d e f b c b d e ...

Page 18: ...osest to 90 is the point where the magnetic field is the strongest i e at either pole The lines of flux c of the main rotor s magnetic field are as shown When the windings of the stator cut these lines of flux voltage is induced in them The amount of induced voltage is greatest at the position where the stator winding is perpendicular to the lines of flux i e when the rotor is in such a posi tion ...

Page 19: ...10 T11 L3 L1 L L 480V L L 208V T4 T3 T2 T1 N L1 T2 L2 L N T5 T8 T6 T1 L N 277V 120V T4 L3 T11 T3 45 90 135 180 0 225 270 315 360 L1 L1 L3 L2 N 1 N 2 S 2 S 1 L3 L2 L1 N 1 N 2 S 2 S 1 N 1 N 2 S 2 S 1 N 1 N 2 S 2 S 1 L3 L2 L1 N1 N2 S2 S1 L3 L2 L1 0 N 1 N 2 S 2 S 1 L3 L2 L1 90 N 1 N 2 S 2 S 1 L3 L2 L1 180 45 N1 N2 S2 S1 S1 L3 L2 L1 135 120 120 d N1 S1 N2 S2 ...

Page 20: ...317 Thus 277V 203V 480V which is the maximum voltage available from the generator In the low wye configuration the largest usable voltage potential in any leg is 120V adding the 73 of any second leg 88V yields the maxi mum voltage potential for the low wye configuration 208V Any measurement between the end of a leg and neutral is know as line to neutral L N voltage Any measurement between the end ...

Page 21: ...s illustrated in the power right triangle below Reactive power and true power are always represented 90 from each other In the power right triangle the angle formed by the hypot enuse apparent power and the adjacent side true power is referred to as theta Theta is derived from the separation in the sine waves of voltage and current In inductive circuits current lags the voltage due to such factors...

Page 22: ...y and must be repaired or replaced 3 2 Checking Resistance Conduct resistance checks when the engine is shut down Use the Ohm setting on your multimeter Conduct resistance checks when the machine is as close to 21 C 70 F as possible Higher temperatures can affect resistance values Most digital multimeters have some internal resistance To obtain your multimeter s internal resistance simply cross th...

Page 23: ...priate extension a to the positive probe on your multimeter Slide the positive probe into the plug along the wire of the pin to be tested Use care when testing this way so you don t damage the wire plug or ECM Find a suitable ground on the machine s frame for the negative probe b of your multimeter wc_gr002926 4 8 121110 9 8 7 1 2 3 2 5 6 3 1 4 4 5 6 7 3 6 2 5 1 4 3 2 1 a b ...

Page 24: ... 4 1 ECM Handling Precaution See Graphic wc_gr003355 NOTICE Use care when working on or around the ECM The ECM may be damaged or it may malfunction if it is accidentally hit by your hand or a tool Do not touch the pins a of the ECM because the AC board of the ECM may malfunction wc_gr003355 a ...

Page 25: ...0 G 85 9310 ECM Display Description Start of the boot up sequence The ECM shows that the glow plugs are on The LED near the stop icon also illu minates Note that the glow plugs are only on during the first of the three starting cycles The ECM displays this screen when the starter is crank ing the engine The ECM displays the countdown time in hours until the next scheduled service The timer starts ...

Page 26: ...en during the first cranking cycle The ECM displays this screen as soon as the engine starts Note that some of the values such as voltage may not be up to their running values at this stage of the sequence The ECM displays this screen to let the operator know that the under frequency system engine speed has been enabled At this point in the sequence the ECM displays running values The ECM displays...

Page 27: ...int the ECM displays the run screen and the values for the main generator variables voltage phase leg amperage hertz For generators with engines that include ECUs the Hz reading will be 60 0 For all others the reading will be 61 5 The ECM will also display the values for the main engine variables oil pressure fuel tank quantity engine temperature and battery voltage Note The ECM display scrolls th...

Page 28: ... display blinks on and off it signifies that the variable temperature fuel capacity etc is in a pre alarm state For example the value for the temperature reading will blink when the temperature of the generator is below 23 C 74 F This simply signifies that the manifold heater or glow plugs will be energized to aid in engine starting The fuel capacity reading will blink when it is below 25 This tel...

Page 29: ...itializing The ECM display reads Initializing and shows the model of the generator If the model displayed does not match the model of the generator call Wacker Neuson Service 4 4 2 Unit in Auto The ECM displays Unit in Auto and the values for oil pressure percentage of fuel remaining engine temperature and voltage of the battery wc_gr002944 481 P2 0 60 0 71 24 87 12 7 1 5 6 7 8 2 3 4 Initializing ...

Page 30: ...eather packages or custom features and those with the John Deere engine that includes the electronic Engine Control Unit ECU All three sets of additional variables are listed below along with typical no load values Note The values from your generator may differ slightly from those shown here G 25 G 50 G 70 G 85 9310 Standard Models ECM Display Description The display shows the amount of time in 1 ...

Page 31: ...isplay shows the total time in 1 10 hour incre ments that the engine has been run New machines or machines with new ECMs will read 0 0 or No Data because the engine has not been run for more than 1 10 of an hour The display shows the amount of time left until service on the machine is required To reset the timer to 250 hours hold the Hours Reset toggle switch in the up position until all the scree...

Page 32: ...d If the ECM detects that the engine speed is less than 55 Hz for longer than 15 seconds the ECM will shut down the generator The display shows the value of the fault setting for over speed If the ECM detects that the engine speed is more than 67 Hz for longer than 15 seconds the ECM will shut down the generator The display shows the status of the engine oil pressure sender If the oil pressure sen...

Page 33: ...igh engine temperature If the ECM detects that the engine temperature is greater than 239 F 221 F on Isuzu engines for longer than 5 seconds the ECM will shut down the generator The display shows the status of the fuel sender If the fuel sender has failed the time of the failure will be displayed The time of the failure will be included in the display until the generator has been shut down and rem...

Page 34: ...Deere engine diagnostic codes SPN Suspect Parameter Number FMI Failure Mode Identifier The ten most recent codes will be displayed from most current to least current See the John Deere Engine Manual for details The display shows total time in 1 10 hour increments that the engine has been run New machines or machines with new ECMs will read No Data because the engine has not been run for more than ...

Page 35: ... The display shows the percentage of total engine torque being used The display shows in F the temperature of the fuel The display shows in psi fuel pressure The display shows in gallons per hour GPH the rate at which fuel is being consumed The display shows in F the temperature of the engine intake manifold Load RPM 15 Engine Torque 60 Fuel Temperature 86 F Fuel Pressure 147 Fuel Rate 0 9 GPH Man...

Page 36: ... genera tor in its single phase position 120 240V then switching it to a three phase position 208 120V or 480 277V without turning the generator off first Both instances will cause the ECM to display a less than line to neutral voltage for P1 and P2 and full line to line voltage for P3 For example in the 480 277V position P 1 and P2 will read approximately 190V while P3 will read 480V The volt age...

Page 37: ... through volt and amp values for all three legs On some generators starting the engine with the switch in the down locked position will reverse the display for volts and amps To correct the display return the engine hour switch to its unlocked scroll position To ensure the correct voltage display make sure The connection lug door is closed and latched before starting the engine The voltage selecti...

Page 38: ... ECM will display the fault and other pertinent information to aid in diagnosing the problem RECORD ALL THE INFORMATION LISTED on the display then refer to the following sections to diagnose and rectify the problem When the engine has shut down due to something outside the control of the ECM the ECM will display ENGINE STOPPED Fault Pre alarm setpoint Shutdown setpoint Low oil pressure 20 psi 15 p...

Page 39: ...el relay e Preheat relay P1 Power and engine sensing P2 Power to crank fuel and fault prealarm closures P3 AC Amps connection to current transformers P4 AC Volts connection to voltage selector switch a b wc_gr002924 4 8 121110 9 8 7 1 2 3 2 5 6 3 1 4 4 5 6 7 3 6 2 5 1 4 3 2 1 121110 9 8 7 6 5 4 3 2 1 121110 9 8 7 6 5 4 3 2 1 6 5 4 1 2 3 6 5 4 1 2 3 4 3 1 2 4 3 1 2 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 P...

Page 40: ...emperature sender 7 Red Run Off Auto switch 12V positive 8 Black 12VDC supply ground negative 10 Orange Remote start contacts 11 Red Emergency stop pushbutton 12 White Violet Fuel level sender Plug 2 Engine Start Inputs Outputs 8 pin connector 1 Yellow Red Out 12VDC to starter relay 2 Violet Out 12VDC to E stop switch 5 Red In 12VDC from B through 10A fuse 7 Red In 12VDC from B 8 Green Out 12VDC t...

Page 41: ...ncy stop pushbutton 12 White Violet Fuel level sender Plug 2 Engine Start Input Outputs 8 pin connector 1 Yellow Out 12VDC to starter relay 2 Violet Out 12VDC to E stop switch 5 Red In 12VDC from starter relay B through 10A fuse 7 Red In 12VDC from starter relay B 8 Green Out 12VDC to air intake heater relay Plug 3 Current Transformer Inputs 6 pin connector 1 White Ammeter line input CT common 2 B...

Page 42: ...ug 2 Engine Start Input Outputs 8 pin connector 1 Yellow Out 12VDC to starter relay 2 Violet Out 12VDC to E stop switch 5 Red In 12VDC from starter relay B through 10A fuse Plug 3 Current Transformer Inputs 6 pin connector 1 White Ammeter line input CT common 2 Brown Ammeter line input CT1 4 Orange Ammeter line input CT3 5 Yellow Ammeter line input CT2 Plug 4 Line Voltage Inputs 4 pin connector 2 ...

Page 43: ... the three red wires d from the start switch Remove the start switch the hour meter switch and the ECM from the panel Note Replacement ECMs include start and hour meter switches 4 10 4 Remove the screws c securing the ECM to the panel Installation 4 10 5 Secure the ECM to the panel with screws c 4 10 6 Secure the hour meter a and the start switch b to the control panel 4 10 7 Reconnect the four ha...

Page 44: ...Check the condition of the 30A fuse Is the fuse OK 4 Check the condition of the ECM 10A fuse Is the fuse OK This procedure continues on the next page Yes ____ No ____ Continue Replace the fuse with one of the same size and rating Yes ____ No ____ Continue Check the function of the main circuit breaker The shunt of the main circuit breaker is most likely the cause of a fuse failure See section 5 10...

Page 45: ...9 at START RUN switch and ground Is at least 9 8V measured 7 Place the START RUN switch in the ON position 8 Check the voltage between red wire 53 at START RUN switch and ground Is at least 9 8V measured This procedure continues on the next page Yes ____ No ____ Your reading Continue Repair red wire 51 Yes ____ No ____ Your reading Continue Repair red wire 49 Yes ____ No ____ Your reading Continue...

Page 46: ...ltage between ECM pin 5 plug 2 red wire 18 and ground Is at least 9 8V measured Incoming power to the ECM has now been checked Yes ____ No ____ Your reading Continue Repair red wire 53 Yes ____ No ____ Your reading Power to the ECM is OK Check continuity of red wire 18 between ECM and fuse box Also check red wire 48 between fuse box and B terminal strip Repair the wiring as needed wc_gr004000 ECM ...

Page 47: ...ate the ECM 2 Place the START RUN switch in the ON position 3 Check the voltage between pin 1 plug 2 yellow wire 63 and ground Is at least 9 8V measured 4 Check the voltage between pin 2 plug 2 violet wire 64 and ground Is at least 9 8V measured Outgoing power from the ECM has now been checked Yes ____ No ____ Your reading Coninue The ECM has failed Call Wacker Neuson Service Yes ____ No ____ Your...

Page 48: ... at least 4 8 VDC measured 5 Open the control panel and locate the ECM 6 Place the START RUN switch in the ON position 7 Measure the voltage between ECM plug 1 pin 5 and ground Is at least 4 8 VDC measured 8 Measure the resistance between the sender and ground 9 Find the resistance measured in the chart below Does the resistance measured reflect the engine temperature This procedure continues on t...

Page 49: ...rt the engine 12 Measure the voltage between the sender and ground 13 Find the voltage measured in the chart below Does the voltage measured reflect the engine temperature The temperature sender has now been checked Yes____ No____ The temperature sender is OK the ECM may have failed Call Wacker Neuson Service The temperature sender has failed replace it ...

Page 50: ...TART RUN switch in the ON position 7 Measure the voltage between ECM plug 1 pin 12 W V wire 62 and ground Is at least 4 8 VDC measured 8 Measure the resistance between the fuel sender and ground 9 Find the resistance measured in the chart below Does the resistance measured reflect the actual fuel level in the tank 10 Reconnect W V wire 62 The ECM and fuel sender have now been checked Yes____ No___...

Page 51: ...s when the engine is run ning Electric shock can cause injury or death Do not touch the lugs 4 Open the lug door 5 With a multimeter measure the AC voltage between lug 1 and lug 2 6 Compare the reading on the multimeter with that on the ECM Are the readings within 2 Volts 7 Open the control panel and locate the VOLTS ADJ pot on the ECM WARNING Electric shock hazard High voltage exists at the cooli...

Page 52: ...h the amperage values for each leg Place the hour meter switch into the down position when the ECM displays an amperage value 6 Compare the Amp reading on the ammeter with that on the ECM display Are the readings within 0 5 Amps 7 Open the control panel and locate the AMPS ADJ pot WARNING Electric shock hazard High voltage exists at the cooling fins of the Automatic Voltage Regulator AVR when the ...

Page 53: ...st the engine speed to 1800 rpm or 60 Hz 2 Open the control panel to gain access to the ECM Monitor the ECM display panel as adjustments are made WARNING Electric shock hazard High voltage exists at the cooling fins of the Automatic Voltage Regulator AVR when the engine is running Electric shock can cause injury or death Do not touch the AVR 3 Locate the AC frequency push button Hold the AC freque...

Page 54: ...e the voltage across the machine s 12V battery using a multimeter Note This procedure works best when the battery voltage measures 12 6 VDC 2 Place the start switch in the REMOTE START position 3 Open the control panel to gain access to the ECM 4 Slide the number 2 Dual In line Package DIP switch to the ON position and then back to the OFF position This resets the DC voltage display The ECM DC vol...

Page 55: ...to check the ECM CAN BUS circuit 1 Open the control panel 2 Disconnect the CAN BUS connector 3 Measure the resistance across terminals A and B of the connector Is approximately 120 ohms measured 4 Reconnect the CAN BUS connector 5 Close the control panel The ECM CAN BUS circuit has now been checked Yes ____ No ____ The CAN BUS circuit is OK The CAN BUS circuit has failed Replace the ECM ...

Page 56: ...n 5 With the main circuit breaker in the ON position check for continuity continuity equals 0 0 1 0 Ohms between L1 of the main circuit breaker and Lug Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for each check 6 With the main circuit breaker in the OFF position check for continuity between L1 of the main circuit breaker and Lug 1 Also check between L2 and Lug 2 and L3 and...

Page 57: ...ug 4 wc_gr003988 AC Plug 3 ECM Plug 1 Wires ECM Plug 2 Wires Pin Wire Description Pin Wire Description 10 Gr 61 Emergency stop 5 R 18 Battery for relays 3 W L 56 Oil pressure sender 1 Y 63 Crank 12V output 9 Or 60 Remote start 2 V 64 Run Fuel 12V output 12 W V 62 Fuel level 3 73 Remote annunciator NA 8 B 59 Battery 4 75 Remote annunciator NA 7 R 53 Battery for ECM board ...

Page 58: ...ECM Sensor Troubleshooting Mobile Generator wc_tx000723gb fm 58 Notes ...

Page 59: ...etwork CAN The wiring between the controllers forms a bus physical electrical interface where many devices share the same electrical connections Diagnostic tools available from John Deere can plug into the CAN bus to assist in troubleshooting the operation of the engine The ECM controls the engine up through engine start cranking Once started the ECU controls the running of the engine The ECU has ...

Page 60: ...John Deere Engines With ECU Mobile Generator wc_tx000698gb fm 60 6 2 Locations of Engine Electrical Components wc_gr003343 1 2 5 6 10 16 15 11 13 14 12 3 4 7 8 9 ...

Page 61: ...t breaker 9 Starter relay 2 Engine Control Module ECM 10 Oil pressure sensor 3 Alternator 11 Engine Control Unit ECU 4 Slave preheat relay 12 Crank position sensor 5 Manifold air temperature sensor 13 Fuel pump assembly 6 Manifold heater 14 Coolant temperature sensor 7 Starter motor 15 Fuel temperature sensor 8 Starter motor solenoid 16 Fuel pump control solenoid ...

Page 62: ... Check the condition of the 30A fuse Is the fuse OK 4 Check the condition of the ECM 10A fuse Is the fuse OK The fuses have now been checked Yes ____ No ____ Continue Replace the fuse with one of the same size and rating Yes ____ No ____ Continue Check the function of the main circuit breaker The shunt of the main circuit breaker is most likely the cause of a fuse failure See Section 7 7 Checking ...

Page 63: ...8V measured 5 Locate Plug 2 Check voltage between red wire 18 and ground during cranking Is at least 9 8V measured 6 Locate Plug 2 Check the voltage between violet wire 64 and ground Also check the voltage between yellow wire 63 and ground during cranking Is there at least 9 8VDC measured in each case The ECM has now been checked Continue with Checking the Emergency Stop Switch Yes____ No____ Go t...

Page 64: ...he voltage between violet wire 64 and ground at the switch Is at least 9 8 VDC measured 5 Check the voltage between violet wire 34 and ground at the switch Is at least 9 8VDC measured The emergency stop switch has now been checked Continue with Checking the Starter Relay Yes____ No____ Your reading Continue The emergency stop switch has failed replace it Yes____ No____ Your reading The emergency s...

Page 65: ...ion to ground of black wire 050D and black wire 14 Is there a path to ground 6 Place the START RUN switch in the ON position 7 Check the voltage between the red wire running to the starter solenoid and ground Is at least 9 8VDC measured The starter relay has now been checked Continue with Checking the Starter Solenoid Yes____ No____ Your reading Continue Repair or replace the red wire Yes____ No__...

Page 66: ...Place the START RUN switch in the ON position Check voltage between the small red wire and ground during the cranking cycle Is at least 9 8VDC measured 5 If at least 9 8VDC is present at the starter and at the starter solenoid the engine should crank If the engine does not crank the starter motor has failed Replace the starter motor The starter solenoid has now been checked Continue with Checking ...

Page 67: ... least 9 8VDC measured 5 Check the connection to ground of black wire 14 at terminal 85 Is there a path to ground 6 Place the START RUN switch in the ON position 7 Check the voltage between terminal 87 red wire 12 and ground Is at least 9 8VDC measured The intake heater relay has now been checked Yes____ No____ Your reading Continue Repair or replace red wire 11 Yes____ No____ Your reading Continu...

Page 68: ...With the main circuit breaker in the ON position check for continuity continuity equals 0 0 1 0 Ohms between L1 of the main circuit breaker and Lug Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for each check 6 With the main circuit breaker in the OFF position check for continuity between L1 of the main circuit breaker and Lug 1 Also check between L2 and Lug 2 and L3 and Lug...

Page 69: ...the wiring to the emergency stop switch Make sure all con nections are tight 4 Check continuity across red wire 20 and yellow wire 45 at the switch Is there continuity 5 Place the emergency stop switch in the activated in position 6 Check continuity across red wire 20 and yellow wire 45 at the switch Is there continuity 7 Re install the key latch to the lug door The emergency stop switch has now b...

Page 70: ...there continuity 6 Check for continuity between the orange wires orange and orange white wires on older machines Is there continuity 7 Place the key into the lug door switch 8 Check for continuity between the orange wires orange and orange white wires on older machines Is there continuity 9 Reconnect the blue and blue white wires to the lug door switch Also reconnect the orange wires orange and or...

Page 71: ...breaker in the ON position check for continuity continuity equals 0 0 1 0 Ohms between L1 of the main circuit breaker and Lug Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity for each check 6 With the main circuit breaker in the OFF position check for continuity between L1 of the main circuit breaker and Lug 1 Also check between L2 and Lug 2 and L3 and Lug 3 Is there continuity...

Page 72: ...e range of its travel Does the voltage adjusting rheostat have a range of at least 5 145k Ohms 5 95k for 100k Ohm pots 5 Check each wire to ground unpainted surface on door Does each wire measure OPEN or OL to ground 6 Reconnect the voltage adjusting rheostat 7 Tighten the rheostat s locknut The voltage adjusting rheostat has now been checked Continue with Checking the Auxi liary Winding Yes____ N...

Page 73: ...ss the two red wires Is 1 7 2 7 Ohms measured 5 Check each red wire for continuity to ground Does each wire measure OPEN or OL to ground 6 Reconnect the wiring The auxiliary winding has now been checked Continue with Checking the Exciter Stator Yes____ No____ Your reading Continue Remove the vent cover from the generator and check the generator for damage Yes____ No____ Your reading Auxiliary wind...

Page 74: ...ity between the blue wire and the rotor Also measure between the yellow wire and the rotor Does each wire measure OPEN or OL to the rotor 7 Reconnect the wiring and re install the vent cover The auxiliary winding has now been checked Continue with Checking the AVR Sensing Wires Yes____ No____ Your reading Continue Remove the vent cover from the generator and check the generator for damage Yes____ ...

Page 75: ...between the black wire and the ground lug Does each wire measure OPEN or OL to the ground lug 8 Reconnect the 4 pin connector and the green and black wires to the AVR NOTICE NEVER run the generator when the green and black wires are disconnec ted from the AVR and all other wires are connected to the AVR Damage to the gen erator will occur 9 Reconnect the bus bar DO NOT run the generator with the b...

Page 76: ...n connect the blue wire to the ground lug and the yellow wire to the B terminal strip NOTICE Do not connect the wires to the machine without the engine running Damage to the winding may occur 5 Check the multimeter for the voltage measured across the green and black wires Is 320 50V measured 170 25V on 0009369 rev 100 105 0009459 rev 100 105 0620003 rev 100 106 6 Shut down the generator Then recon...

Page 77: ...e resistance between Lug 2 and the neutral lug and lug 3 and the neutral lug Enter these values in the table below 5 Measure the resistance between Lug 1 and Lug 2 Lug 1 and Lug 3 and Lug 2 and Lug 3 Enter these values into the table below All values are in Ohms Are your readings approximately equal to the ideal measurements The stator windings have now been checked at the lugs Continue with Check...

Page 78: ...rubber washer isolating the lead from the diode plate 7 Using the diode scale on your multimeter check each diode between the diode s lead and the diode plate Reverse the probes of your meter and check the diode again Each diode should conduct in one direction and not in the other Your meter should read 0 4 0 5V in the direction that conducts Does each diode check OK 8 Reconnect the AVR 9 Reconnec...

Page 79: ...odes 4 Using the diode scale on your multimeter place the meter leads near the diode one on either side Reverse the probes of your meter and check the diode again Each diode should conduct in one direction and not in the other Your meter should read 0 4 0 5V in the direction that conducts Does each diode check OK The rectifier diodes have now been checked Continue with Checking the Main Rotor Win ...

Page 80: ...t the wires to the main rotor winding One is marked with a red tag and the other is marked with a blue tag 7 Measure the resistance across the two wires Is 1 4 3 Ohms measured 8 Check each wire for short path to the rotor shaft Does each wire measure OPEN or OL to the rotor shaft The main rotor winding has now been checked Continue with Checking the Exciter Rotor Winding Note If moving on to the n...

Page 81: ...e the diode plates completely to access the exciter rotor leads 7 On newer machines the location of the three exciter rotor leads is also in between each pair of diodes 8 Measure the resistance across each lead and the other two leads one lead at a time Is 0 3 1 0 Ohms measured in each case 9 Check each lead for short path to the rotor shaft Does each lead measure OPEN or OL to the rotor shaft 10 ...

Page 82: ...Reconnect the wires and reinstall the generator components The main stator windings have now been checked wc_gr003928 T2 T6 T11 L0 N L1 T12 L2 1 5 9 13 17 21 25 3 Br 7 11 15 19 23 27 26 22 18 14 10 6 2 28 24 20 16 12 8 4 L3 L2 T10 T7 N T3 Or ECM ECM ECM TB TB TB TS TS Gen Gen Gen CB Gen TS TS Lug CB TS T5 Gen Gen Y N AVR to Automatic Voltage Regulator ECM to Engine Control Module Gen from generato...

Page 83: ... Parts Book originally supplied with the machine If the original Parts Book has been lost a replacement may be ordered from Wacker Neuson Corporation When ordering a replacement Parts Book please list the model number item number revision level and serial number of the machine Parts Books are also available on the Wacker Neuson Corporation Web site See www wackerneuson com Enter the site as a visi...

Page 84: ...t and rear access panels b and c 9 5 4 Remove the screws that secure the roof to the side panels d 9 5 5 Remove the screws that secure the control panel enclosure e to the lifting structure f 9 5 6 Remove the screws that secure the door latch g to the lifting structure and remove the door latch 9 5 7 Remove the screws that secure the lifting structure to the frame 9 5 8 Using an appropriate crane ...

Page 85: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 85 c h b d d e f g a wc_gr003320 a ...

Page 86: ...e blue from term 1 yellow from term 3 blue white from term 3A green from term 4 red from term 5 and black from term 5C Cut the wire ties that secure the wires 9 6 9 Disconnect the other AVR wires f red wire from the lighter gauge blue wire blue white wire at the connector to the lighter gauge blue white wire 9 6 10 Cut the wire tie then disconnect the connector g holding wire L1 to wire 1 from the...

Page 87: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 87 wc_gr003321 a f e j i h b c d g ...

Page 88: ...lex plates by turning the generator fan 9 7 6 Remove the screws d that secure the generator to the engine 9 7 7 Using an appropriate crane or hoist lift the generator up and away from the engine Installation 9 7 8 Position the generator into the frame 9 7 9 Using Loctite 231 or equivalent on the screws d secure the generator to the engine Torque the screws to 69Nm 50 ft lbs 9 7 10 Using Loctite 23...

Page 89: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 89 wc_gr003322 a b c c d d G 25 G 50 G 70 G 85 a G 50 G 70 G 85 G 25 ...

Page 90: ...w to remove the Automatic Voltage Regulator AVR 9 8 1 Remove the screws that secure the large access panel a and open the large access panel 9 8 2 Make note of the wires connected to the AVR b 9 8 3 Disconnect the wires 9 8 4 Remove the screws that secure the AVR and remove the AVR from the machine The procedure to remove the AVR is now complete ...

Page 91: ... Check the function of the voltage adjusting rheostat See section Checking the Voltage Adjusting Rheostat 9 9 2 Mount the AVR b to the machine with the two screws 9 9 3 Reconnect the wires to the AVR 9 9 4 Adjust the VOLT pot a on the new AVR counterclockwise as far as possible This procedure continues on the next page VOLT B R G Y L L W 5C AMP HZ STAB 5B 7 5A 6 5 4A 4 3A 3 2 1 n a n a V W 5C5B 7 ...

Page 92: ...he key into the slot of the lug door switch 9 9 9 Place the main circuit breaker in the ON position 9 9 10 Start the machine NOTICE Shut down the machine immediately if any load change in engine rpm on the generator is sensed A change in engine rpm indicates incorrect wiring Check the wiring This procedure continues on the next page WARNING Electric shock hazard Voltage exists at the cooling fins ...

Page 93: ...voltage between each lug and Neutral Approximately 139V should be measured 9 9 13 Shut down the machine Change the voltage selector switch to the 480 277 position 9 9 14 Start the machine 9 9 15 Measure the voltage between Lug 1 and Lug 2 Adjust the voltage adjusting rheostat until 480V is measured Tighten the lock nut 9 9 16 Test the consistency of the voltage by checking across Lug 1 and Lug 2 L...

Page 94: ...e ECM display is off by more than 2 adjust the VOLT pot on the ECM so that the ECM display matches the reading on the multimeter NOTICE Only adjust the ECM pot when the voltage selector switch is in the 480 277V position 9 9 18 Shut down the machine 9 9 19 Re install the key latch to the lug door 9 9 20 Close the large access panel and secure it with two screws The procedure to install and set the...

Page 95: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 95 Notes ...

Page 96: ...t the fuel filter 9 10 6 Using an appropriate hoist or crane lift the control panel enclosure from the frame 9 10 7 Drain the radiator 9 10 8 Disconnect the radiator hoses c from the engine 9 10 9 Disconnect the exhaust pipe d from the engine Loosen the clamp at the muffler and rotate the exhaust pipe away from the engine 9 10 10 Disconnect the fuel return line e 9 10 11 Remove the fan guard f 9 1...

Page 97: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 97 wc_gr003351 a c c e g b d f ...

Page 98: ...11 4 Install the fan guard f 9 11 5 Connect the fuel return line e 9 11 6 Connect the exhaust pipe d to the engine Tighten the clamp at the muffler 9 11 7 Connect the radiator hoses c to the engine 9 11 8 Fill the radiator with coolant 9 11 9 Using an appropriate hoist or crane lower the control panel enclosure onto the frame 9 11 10 Connect and the fuel line b to the fuel filter 9 11 11 Connect t...

Page 99: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 99 wc_gr003352 a c c e g b d f ...

Page 100: ...ane or hoist lift the upper frame assembly off the lower frame assembly 9 12 4 Remove the screws that secure the fuel tank c to the lower frame assembly 9 12 5 Using an appropriate crane or hoist lift the fuel tank from the lower frame assembly Installation 9 12 6 Using an appropriate crane or hoist lower the fuel tank into the lower frame assembly 9 12 7 Secure the fuel tank c to the lower frame ...

Page 101: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 101 a c b b wc_gr003350 ...

Page 102: ...l and disconnect the wiring from the switch 9 13 3 Remove the locking nut b and washer 9 13 4 Remove the screws c that secure the pushbutton and remove the pushbutton Installation 9 13 5 Slide the pushbutton portion through the door Note Position the pushbutton with TOP marking facing up Secure the pushbutton with screws c 9 13 6 Attach washer and locking nut b 9 13 7 Reconnect the wiring 9 13 8 A...

Page 103: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 103 wc_gr003286 a b c ...

Page 104: ...ct block 9 14 3 Remove the locking nut d and washer e and remove the pushbutton portion of the switch Installation 9 14 4 Slide the rubber washer f onto the pushbutton portion of the switch then insert the pushbutton through the door 9 14 5 Align the washer so that the tab g is 180 from the notch h in the door Slide the washer onto the pushbutton so that the tab of the washer fits in the groove i ...

Page 105: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 105 ...

Page 106: ...Epoxy Procedure Follow the procedure below to replace the diodes 9 15 1 Remove the rear access panel a from the machine 9 15 2 Remove the cover b from the generator 9 15 3 Rotate the engine until a diode c is accessible 9 15 4 Cut the diode wires near the diode and remove the diode from the holder d 9 15 5 Do not remove the existing old wires i clean them instead This procedure continues on the ne...

Page 107: ... 15 7 Insert the diode e into the holder Red marking faces to the right 9 15 8 Cut f any excess wire from the new diode 9 15 9 Add heat sinks g alligator clips are shown for this purpose 9 15 10 Solder h the new diode to the existing old wires 9 15 11 Rotate the engine and repeat the soldering procedure for each diode 9 15 12 Reassemble the machine ...

Page 108: ...the VSS 9 16 4 Remove the screws c that secure the front face of the VSS 9 16 5 Remove the screws that secure the mounting bracket d to the VSS box and remove the VSS and mounting bracket from the VSS box 9 16 6 Remove the mounting bracket from the VSS e Installation 9 16 7 Attach the mounting bracket d to the VSS e 9 16 8 Slide the VSS into the VSS box and secure the face plate c with the screws ...

Page 109: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 109 wc_gr003284 b a c d e ...

Page 110: ...15 19 23 27 26 22 18 14 10 6 2 28 24 20 16 12 8 4 L3 L2 T10 T7 N T3 Or ECM ECM ECM TB TB TB TS TS Gen Gen Gen CB Gen TS TS Lug CB TS T5 Gen Gen Y N AVR to Automatic Voltage Regulator ECM to Engine Control Module Gen from generator TB to terminal block R1 T7 on older TB to terminal block R2 T9 on older TS to terminal strip CB to main circuit breaker AVR G ...

Page 111: ...Mobile Generator Disassembly Assembly wc_tx000575gb fm 111 Notes ...

Page 112: ...ake type John Deere 4 5L Model 4045TF275 Number of cylinders 4 Displacement l in3 4 5 274 6 Engine speed rpm 1800 Power 1800 rpm kW Hp 84 2 113 Coolant capacity l qts 22 7 24 Oil capacity l qts 15 15 9 Battery Volts CCA 12 720 12 1000 Fuel type Diesel Fuel tank capacity l gal 337 89 Fuel consumption continuous load l hr gal hr 21 2 5 6 Running time continuous load Hours 16 ...

Page 113: ...ctor switch 3 position AC voltages available 120 240 zig zag 120 208 low wye 277 480 Hi wye Frequency 60 Hz Power factor 1ø 3ø 1 0 0 8 Voltage regulation 1 00 Insulation class H Sound level at 7 m 23 ft dB A 69 AC receptacles 2 duplex 3 twist lock 1ø 120 GFI duplex Amps 2 20 1ø 120 240 V twist lock Amps 1 30A 2 50A Standby Output kW kVA 74 92 Continuous Output kW kVA 67 84 Main breaker Amps 250 ...

Page 114: ...09459 0620003 Trailer and Skid Dry weight of skid kg lbs 1580 3484 1621 3574 Operating weight of skid kg lbs 1868 4120 1909 4210 Trailer weight kg lbs Single axle 442 975 Tandem axle 499 1100 GVWR kg lbs Single axle 2304 5080 Tandem axle 2722 6000 Surge brakes Fluid type DOT3 Tires size ST225 75D 15D ...

Page 115: ...G 85 Technical Data wc_td000214gb fm 115 10 4 Dimensions mm inches Machine A B C D E F G G 85 965 38 1970 77 5 1703 67 3923 154 5 2445 96 3 1346 53 1475 58 wc_gr006389 A B D E F G C ...

Page 116: ...82 050 21 22 22 20 K3 G2 K1 A2 G1 F1 J2 wc_gr004699 JOHN DEERE ECU ECM J B G A D E F U V A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 SI CP CG SO G 23 23 26 24 25 H J B C D E F A 14 14 Wacker side 6 R Br G Y LL Or R LL Y V BOM REV 0009369 124 0009459 133 0620003 129 ...

Page 117: ...2 Harness connector 10 Intake heater 23 CAN bus connector 11 Slave preheat relay 24 Diagnostic connector 12 Mechanical lugs 3 phase 25 ECU harness connector 13 Start switch 26 Hour meter switch ECM Plug 1 Wires ECM Plug 2 Wires Pin Wire Description Pin Wire Description 10 Gr 61 Emergency stop 5 R 18 Battery for relays 3 W L 56 Oil pressure sender 1 Y 63 Crank 12V output 9 Or 60 Remote start 2 V 64...

Page 118: ... G1 F1 J2 wc_gr002816 JOHN DEERE ECU ECM J B G A D E F U V A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 SI CP CG SO G 23 23 26 24 25 H J B C D E F A 14 14 Wacker side 6 R Br G Y LL Or R LL Y V BOM REV 0009369 100 123 0009459 100 132 0620003 100 128 ...

Page 119: ...2 Harness connector 10 Intake heater 23 CAN bus connector 11 Slave preheat relay 24 Diagnostic connector 12 Mechanical lugs 3 phase 25 ECU harness connector 13 Start switch 26 Hour meter switch ECM Plug 1 Wires ECM Plug 2 Wires Pin Wire Description Pin Wire Description 10 Gr 61 Emergency stop 5 R 18 Battery for relays 3 W L 56 Oil pressure sender 1 Y 63 Crank 12V output 9 Or 60 Remote start 2 V 64...

Page 120: ... D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 JOHN DEERE ECU 463 418 N A 050G 012D 002D 914F 429 412 461 914E 428 914D 491 493 467 911 914B 012C between A2 and G 022C to K1 447 448 050 082 J B G A D E F U V wc_gr002817 a b c d e f g h i n j k l m 022A to B G H J B C D E F A ...

Page 121: ...p sensor G1 Yellow 904 CAN bus B2 Violet 447 Engine crank sensor G2 W L 474 ECM B3 Gray 918 HC terminal N N A G3 Orange 473 HC terminal H N A C1 Violet 947 HC terminal R N A H1 C2 H2 C3 Gray 428 Fuel temp sensor H3 D1 Orange 463 Manifold Air Temp MAT sensor J1 Gray 418 N A D2 Gray 448 Engine crank sensor J2 Black 050C Ground D3 Yellow 914C Sensor return J3 E1 K1 Red 022 10A fuse E2 Brown 911C Sens...

Page 122: ...Technical Data G 85 wc_td000214gb fm 122 10 8 Generator Wiring Diagram BOM REV 0009369 124 0009459 133 0620003 129 ...

Page 123: ...r stator winding 8 240V 50A breaker 22 Rotor 9 240V 30A breaker 23 Rectifier diodes 10 240V 50A receptacle 24 Main rotor winding 11 240V 30A receptacle 25 Main stator windings 12 Engine Control Module ECM 26 Auxiliary winding 13 Bus bar 27 Stator 14 Main breaker 28 Terminal strip ECM Plug 3 Wires ECM Plug 4 Wires Pin Wire Description Pin Wire Description 4 Or 39 Ammeter line input CT3 3 Or 41 Volt...

Page 124: ...Technical Data G 85 wc_td000214gb fm 124 wc_gr003296 3 4 13 14 27 28 2 1 4 3 3 2 1 6 5 4 BOM REV 0009369 100 123 0009459 100 132 0620003 100 128 ...

Page 125: ...r stator winding 8 240V 50A breaker 22 Rotor 9 240V 30A breaker 23 Rectifier diodes 10 240V 50A receptacle 24 Main rotor winding 11 240V 30A receptacle 25 Main stator windings 12 Engine Control Module ECM 26 Auxiliary winding 13 Bus bar 27 Stator 14 Main breaker 28 Terminal strip ECM Plug 3 Wires ECM Plug 4 Wires Pin Wire Description Pin Wire Description 4 Or 39 Ammeter line input CT3 3 Or 41 Volt...

Page 126: ...9311 5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 73285 50 ml Loctite 290 Hernon 431 Omnifit 1710 230LL Green Medium to high strength for locking preassembled threads and for sealing weld porosity wicking Gaps up to 0 13 mm 0 005 Temp range 54 to ...

Page 127: ... follow instructions on container The sealants listed are recommended for use on Wacker Neuson equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant adhesive for bonding rubber metal and plastics general purpose For gaps up to 0 15 mm 0 006 Read caution instructions before using Temp range 54 to 82 C 65 to 180 F 52676 1oz Loctite Primer T Hernon P...

Page 128: ... 5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 M5 6 0 53 8 5 6 10 7 8 5 16 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 190 140 230 169 22 7 8 12 M16 210 155 295 217 355 262 24 15 16 14 M18 290 214 405 298 485 357 27 1 1 16 14 M20 410 302 580 427 690 508 30 1 1 4 17 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm 8 8 10 9 12 9 ...

Page 129: ...o 8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 No 10 3 6 32 5 1 45 6 8 60 3 8 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8 3 8 1 2 77 57 109 80 142 105 19 3 4 3 8 9 16 111 82 156 115 214 158 13 16 5 8 152 112 216 159 265 195 24 15 16 1 2 3 4 271 200 383 282 479 353 1 1 8 5 8 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm ...

Page 130: ...02 390 Wacker Neuson Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Neuson Limited Room 1701 03 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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