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Wacker Neuson G70, Operator'S Manual

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Wacker Neuson G70 Operator'S Manual Download Page 70

Maintenance

G 50/G 70/G 85

wc_tx000484gb.fm

70

4.13 G 85 & G 70 w/ECU Engine Wiring

Engine

Wires

BOM

Revision

See Graphic:

Revision

See Graphic:

0009369

124 & higher

wc_gr004614

123 & lower

wc_gr002616

0009459

133 & higher

wc_gr004614

132 & lower

wc_gr002616

0620003

129 & higher

wc_gr004614

128 & lower

wc_gr002616

0620350

wc_gr004614

0620351

wc_gr004614

0620352

wc_gr004614

Ref.

Description

Ref.

Description

1

Safety interlock switch

11

Intake heater relay

2

Mechanical lugs

12

Plug 2 - engine start outputs

3

Main circuit breaker

13

Run/off/auto switch

4

Shunt

14

Battery

5

Emergency Stop switch

15

10A fuse

6

Engine control module

16

Starter relay

7

Plug 1 - engine sender inputs

17

Starter

8

Remote start contacts

18

Alternator

9

Fuel level sender

19

Terminal block

10

Intake heater

Ref.

Description

Ref.

Description

18

B

62

Fuel Level

53

B

63

Crank

56

Cold Crank Delay

64

Run/Fuel

59

Battery -

73

Remote Annunciator

60

Remote Start

75

Remote Annunciator

61

E-Stop

Wire Colors

B

Black

R

Red

Y

Yellow

Or

Orange

G

Green

T

Tan

Br

Brown

Pr

Purple

L

Blue

V

Violet

Cl

Clear

Sh

Shield

P

Pink

W

White

Gr

Gray

LL

Light blue

Summary of Contents for G70

Page 1: ...www wackergroup com Mobile Generator G 50 G 70 G 85 OPERATOR S MANUAL 0162089en 008 1107 0 1 6 2 0 8 9 E N...

Page 2: ......

Page 3: ...rent Overload Fault 29 3 6 Application 29 3 7 Voltage Selector Switch 30 3 8 Emergency Stop Switch 31 3 9 Main Line Circuit Breaker 32 3 10 Engine Start Switch 33 3 11 Voltage Adjustment Rheostat 33 3...

Page 4: ...lors 53 4 10 Generator and Receptacle Wiring 54 4 11 Trailer Wiring 60 4 12 G 50 G 70 Engine Wiring 62 4 13 G 85 G 70 w ECU Engine Wiring 70 5 Factory Installed Options 74 5 1 Block Heater 74 5 2 Fuel...

Page 5: ...quipment please contact Wacker Corporation The information contained in this manual was based on machines in production at the time of publication Wacker Corporation reserves the right to change any p...

Page 6: ...ult in death or serious injury CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Used without the safety alert symbol NOTICE indicates a haza...

Page 7: ...e is built with user safety in mind however like any electrical device it can present serious hazards if improperly operated and serviced Follow instructions carefully Should questions arise during op...

Page 8: ...hed to the generator must not exceed the load rating of the generator 2 1 7 NEVER allow untrained personnel to operate or service the generator The generator set should be set up by a certified electr...

Page 9: ...national 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...

Page 10: ...at the customer connection lugs This point is connected directly to the generator set base All other system grounds are connected to this central point Ground the generator in accordance with the sta...

Page 11: ...people in the area when lifting the machine 2 3 Operator Safety while using Internal Combustion Engines Internal combustion engines present special hazards during operation and fueling Read and follo...

Page 12: ...the trailer using defective parts 2 4 3 ALWAYS make sure the coupling is securely fastened to the vehicle 2 4 4 ALWAYS check the tires on the trailer for tread wear inflation and condition Replace wo...

Page 13: ...pen an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between yo...

Page 14: ...Safety Information G 50 G 70 G 85 wc_si000158gb fm 14 2 6 Label Location...

Page 15: ...G 50 G 70 G 85 Safety Information wc_si000158gb fm 15...

Page 16: ...IEBSVORSCHRIFT LESEN 2 ANHANGEVORRICHTUNG VERWENDEN DIE DER GESAMTBETRIEBSGEWICHTSKLASSE ENTSPRICHT 3 ANHANGER SICHER AM ZUGFAHRZEUG BEFESTIGEN 4 SICHERHEITSKETTEN KREUZWEISE ANBRINGEN 5 ABREISSKETTE...

Page 17: ...fore adding fuel Use only diesel fuel G Tie down point H WARNING To prevent hearing loss wear hearing protection Hand injury if entangled in moving belt Rotating machinery Do not reach inside with eng...

Page 18: ...58gb fm 18 L M Operator s Manual must be stored on machine Replacement Operator s Manual can be ordered through your local Wacker distributor N DANGER Electric shock will cause serious injury or death...

Page 19: ...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 bui...

Page 20: ...g W A R N I N G A D V E R T I S S E M E N T A D V E R T E N C I A W A R N U N G POUR REMORQUE G FEUX DE STOP ET DE DIRECTION D Y FEUX DE STOP ET DE DIRECTION G Br FEUX D ARRIERE DE POSITION ET DE PLAQ...

Page 21: ...fm 21 Z Neutral bonded to frame AA Fuses Read the operator s manual for machine information 1 Controller 2 Not used 3 Not used 4 Not used BB WARNING Electric shock at cooling fins CC G 50 G 70 G 85 Ge...

Page 22: ...item number revision number and serial number is attached to each unit Please record the information found on this plate so it will be available should the nameplate become lost or damaged When order...

Page 23: ...LECTRICAL COMPONENTS MAY OCCUR RUNNING DAMAGE TO THE ELECTRICAL COMPONENTS MAY OCCUR BATTERIETRENNSCHALTER NICHT BENUTZEN WAHREND MOTOR LAUFT BATTERIETRENNSCHALTER NICHT BENUTZEN WAHREND MOTOR LAUFT B...

Page 24: ...Operation G 50 G 70 G 85 wc_tx000483gb fm 24 3 Operation 3 1 Control Panels...

Page 25: ...k Receptacle 120 240 VAC 30 Amp c Shutdown LED n GFI Receptacle 120 VAC 20 Amp two d Pre alarm LED o Remote Run Terminal Block e LCD Panel p Emergency Stop Switch f Engine Start Switch q Interlock Swi...

Page 26: ...the display from scrolling press the ENG HRS switch down Volts V Displays the AC output voltage being produced by the generator Phase Indicates which phase is currently being displayed Amps A Displays...

Page 27: ...gauge measures the engine starting battery voltage A normal reading is 13 5 14 5V If the gauge falls much below or above these values the engine charging system should be checked With the engine swit...

Page 28: ...er FMI Failure Mode Identifier Indicates that the engine speed exceeded approximately 2000 rpm 110 of its rated speed of 1800 rpm and the ECM has auto matically shut the engine down An overcrank fault...

Page 29: ...ons where reliable power is needed NOTICE Do not exceed the power output of the generator Damage to tools or generator will occur Refer to Technical Data When using the generator as a standby or subst...

Page 30: ...r to Section Voltage Adjustment Rheostat 277 480 VAC 3 Voltage ranges are selected by rotating the handle on the switch to the desired voltage The switch is equipped with a locking mechanism This allo...

Page 31: ...shing the red button in Pushing the emergency stop switch opens the main circuit breaker and the fuel solenoid and results in the engine shutting down The switch will remain in until the button is rot...

Page 32: ...or or performing any service to the generator unit make sure the main circuit breaker is in the off O position NOTICE The convenience receptacles are not connected through the main line circuit breake...

Page 33: ...including the fuel solenoid is disconnected 3 11 Voltage Adjustment Rheostat See Graphic wc_gr002611 Just left of the controller display window is the voltage adjustment rheostat b Use the rheostat to...

Page 34: ...el like the one shown in section Terminal Connections is attached to the inside of the terminal door It shows the correct terminal connections for selected voltages Connections to the lugs should be m...

Page 35: ...selector switch is in the 480 V 3 position voltage at the duplex receptacles is 139 V and voltage at the 30 50 A receptacles is 139 240 V When the voltage selector switch is in the 208 V 3 position vo...

Page 36: ...stem can allow electrical current from the generator to backfeed into utility lines This may result in electrocution of utility workers fire or explosion Connections to a building s electrical system...

Page 37: ...ck to make sure no debris has lodged in vents near radiator or around fan Check to make sure that the exhaust compartment is clean and nothing is touching the muffler or exhaust pipes Check that gener...

Page 38: ...and convenience receptacle circuit breakers to off O This will disconnect all loads from the generator 3 20 4 Move Engine Start Switch f to REMOTE START to check operation of engine control module The...

Page 39: ...sure battery charging system oil pressure and engine temperature readings are within normal ranges 3 20 8 Check that AC voltage is correct Voltage can be fine adjusted by turning the voltage adjustme...

Page 40: ...art Switch f in the REMOTE START position verify that the contacts on any remote switch linked to the generator set are OPEN This will prevent the generator from immediately starting when the Engine S...

Page 41: ...eration wc_tx000483gb fm 41 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 7 8 9 10 11 12 13 14 15 16 17 18 2 1 2 4 2 75 3 0 3 3 3 6 4 0 4 3 4 6 4 9 5 2 5 5 wc_gr001227 Altitude x 1000 Feet Engin...

Page 42: ...ly activate the cold starting aid when the temperature is low enough and will display AIR INTAKE HEATER during the time the cold starting aid is activated 3 25 Lifting A central lifting eye is located...

Page 43: ...ing panel is operating correctly Refer to Section Before Starting and Manual Start up sections in this manual 3 28 2 If a check of auto start up circuit is desired attach a short jumper wire minimum 1...

Page 44: ...of remote starting device is the responsibility of the generator user Installation of such devices must be performed by a qualified electrician following all directions supplied by the manufacturer of...

Page 45: ...e coupling and safety chains have failed The breakaway cable is not a parking brake and should not be used as one 3 30 7 Check that all fasteners on the coupling are secure 3 30 8 Check the tread wear...

Page 46: ...Operation G 50 G 70 G 85 wc_tx000483gb fm 46 w c _ g r 0 0 0 5 1 0 a d c b...

Page 47: ...containment system Service the battery Change engine oil and replace oil filter Clean unit inside and out Check air intake hoses connections and system Replace fuel filter element Check automatic belt...

Page 48: ...After maintenance has been performed on the generator it is necessary to reset the periodic maintenance timer If the periodic maintenance timer is at zero press the ENG HRS switch UP and hold for 10 s...

Page 49: ...a new air filter cartridge then Re install the end cover making sure that the dust cap e is clean and is pointing downward Periodically make sure the inlet pipe f is free from obstructions Check all c...

Page 50: ...reak in oil 4 5 2 If the engine has significant operating time at light load or makeup oil is required in the first 100 hour period a longer break in period may be required In these situations an addi...

Page 51: ...t heavy duty diesel engines They often contain a high concentration of silicates which can damage the engine and cooling system Refer to engine Operator s Manual for coolant recommendations 4 7 Traile...

Page 52: ...4 8 3 If oil level is good start engine and verify loss of oil pressure Shut down engine immediately if oil pressure value does not read at least 15 psi within 5 seconds Check the oil pressure shutdow...

Page 53: ...problems Low Fuel Level Shutdown 4 8 1 Check fuel level Note Warning light will come on when fuel level drops below 25 Engine will shut down only when level drops below 5 4 8 2 Check for leaks in fuel...

Page 54: ...6 126 wc_gr003171 105 lower wc_gr002614 0620002 129 higher wc_gr004692 106 128 wc_gr003171 105 lower wc_gr002614 0620003 129 higher wc_gr004692 107 128 wc_gr003171 106 lower wc_gr002614 0620350 wc_gr0...

Page 55: ...5 15 L3 L3 2 0 2 0 2 0 2 0 L1 L1 L2 L2 2 0 2 0 SHUNT SHUNT L LUG SAFETY LUG SAFETY LIMIT LIMIT SWITCH SWITCH MAIN BRKR MAIN BRKR L W L W CT 2 CT 2 CT 1 CT 1 PAIR BLK 4 GA PAIR BLK 4 GA PAIR BLK 4 GA P...

Page 56: ...05 lower wc_gr002614 0620002 129 higher wc_gr004692 106 128 wc_gr003171 105 lower wc_gr002614 0620003 129 higher wc_gr004692 107 128 wc_gr003171 106 lower wc_gr002614 0620350 wc_gr004692 0620351 wc_gr...

Page 57: ...G 50 G 70 G 85 Maintenance wc_tx000484gb fm 57...

Page 58: ...05 lower wc_gr002614 0620002 129 higher wc_gr004692 106 128 wc_gr003171 105 lower wc_gr002614 0620003 129 higher wc_gr004692 107 128 wc_gr003171 106 lower wc_gr002614 0620350 wc_gr004692 0620351 wc_gr...

Page 59: ...G 50 G 70 G 85 Maintenance wc_tx000484gb fm 59...

Page 60: ...r taillight 7 License plate holder lights 8 Left rear taillight 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 ch...

Page 61: ...G 50 G 70 G 85 Maintenance wc_tx000484gb fm 61 Standard and Hydraulic Brakes Electric Brakes 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 62: ...2 129 higher wc_gr004613 110 128 wc_gr003218 109 wc_gr003172 108 lower wc_gr002615 Ref Description Ref Description 1 Safety interlock switch 12 Plug 2 engine start outputs 2 Mechanical lugs 13 Run off...

Page 63: ...57 61 61 10 10 55 55 55 55 54 54 2 1 B 2 20 20 TERM TERM BLOCK BLOCK 17 17 10 A FUSE 10 A FUSE 48 48 51 51 49 49 53 53 88 OIL PRESSURE 88 OIL PRESSURE TOGGLE TOGGLE SWITCH SWITCH 18 18 52 52 52 52 49...

Page 64: ..._gr004613 110 128 wc_gr003218 109 wc_gr003172 108 lower wc_gr002615 Ref Description Ref Description 1 Safety interlock switch 12 Plug 2 engine start outputs 2 Mechanical lugs 13 Run off auto switch 3...

Page 65: ...G 50 G 70 G 85 Maintenance wc_tx000484gb fm 65 G 50 G 70 Engine Wiring...

Page 66: ..._gr004613 110 128 wc_gr003218 109 wc_gr003172 108 lower wc_gr002615 Ref Description Ref Description 1 Safety interlock switch 12 Plug 2 engine start outputs 2 Mechanical lugs 13 Run off auto switch 3...

Page 67: ...G 50 G 70 G 85 Maintenance wc_tx000484gb fm 67 G 50 G 70 Engine Wiring...

Page 68: ..._gr004613 110 128 wc_gr003218 109 wc_gr003172 108 lower wc_gr002615 Ref Description Ref Description 1 Safety interlock switch 12 Plug 2 engine start outputs 2 Mechanical lugs 13 Run off auto switch 3...

Page 69: ...G 50 G 70 G 85 Maintenance wc_tx000484gb fm 69 G 50 G 70 Engine Wiring...

Page 70: ...lugs 12 Plug 2 engine start outputs 3 Main circuit breaker 13 Run off auto switch 4 Shunt 14 Battery 5 Emergency Stop switch 15 10A fuse 6 Engine control module 16 Starter relay 7 Plug 1 engine sende...

Page 71: ...SS OR OR 2 OR OR 45 45 Y 44 44 Y 79 79 LL LL 60 60 44 44 45 45 Y OR OR 20 20 G NO NO 46 46 G Y G Y V 61 61 34 34 G NO NO R NC NC 64 64 R NC NC W B 61 61 10 10 2 1 2 Y OR OR R 51 51 R 20 20 53 53 R 48...

Page 72: ...ngine start outputs 3 Main circuit breaker 13 Run off auto switch 4 Shunt 14 Battery 5 Emergency Stop switch 15 10A fuse 6 Engine control module 16 Starter relay 7 Plug 1 engine sender inputs 17 Start...

Page 73: ...G 50 G 70 G 85 Maintenance wc_tx000484gb fm 73...

Page 74: ...oration at 1 800 770 0957 A nameplate listing the Model Number Item Number Revision and Serial Number is attached to each unit Please have this information available when contacting WACKER Corporation...

Page 75: ...th Isuzu engines Empty the separator water bowl a as needed by opening the water bowl drain b The separator element should be changed each time the fuel filter is changed approximately every 600 hours...

Page 76: ...onsists of an electronic module a or b and an electronic actuator c or d The module senses rotation of the flywheel then sends a signal to the electronic actuator that governs the fuel injection syste...

Page 77: ...tance of the coiled element of the heater is sensed by the thermostat The resistance of the element changes with temperature At approximately 30 C the resistance value triggers the thermostat to send...

Page 78: ...hutdowns If after the ten seconds coolant levels are still sensed as being low the ECM shuts down the engine The ECM will then display the FAULT LOW WATER LEVEL Allow the engine to cool before adding...

Page 79: ...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...

Page 80: ...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 5 8 Lockable Battery Disconnect See Graphic wc_g...

Page 81: ...Mobile Generators Factory Installed Options wc_tx000380gb fm 81 Notes...

Page 82: ...ack R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue 80 12V 87 88 R 80 91 89 R B 87 Or 86 R R R B R 82 83 85 81 83 G B...

Page 83: ...n Ref Description 1 Thermostat module 7 Positive air shutoff solenoid actuator 2 Terminal block 8 Auxiliary relay terminals 3 1 Amp fuse 9 Plug 1 engine sensor inputs 4 Water level sensor 10 Electroni...

Page 84: ...fm 84 5 11 Cam Lock See Graphic wc_gr002584 A second optional outlet panel features cam lock connectors u for easy tool changes The door is equipped with an interlock switch q When the door is opened...

Page 85: ...tained in the machine The containment system should be checked every 50 hours or 2 weeks and drained when necessary If fluid is found in the containment tank trace the cause of the leak and correct No...

Page 86: ...4 5L Model 4045DF270 4045TF270 4045TF285 4045TF275 Number of cylinders 4 Displacement l in3 4 5 274 6 Engine speed rpm 1800 Power 1800 rpm kW Hp 50 67 74 5 100 74 99 84 2 113 Coolant capacity l qts 22...

Page 87: ...TF275 Number of cylinders 4 Displacement l in3 4 5 274 6 Engine speed rpm 1800 Power 1800 rpm kW Hp 50 67 74 5 100 74 99 84 2 113 Coolant capacity l qts 22 7 24 22 7 24 26 5 28 22 7 24 Oil capacity l...

Page 88: ...Generator speed rpm 1800 Voltage selector switch 3 position AC voltages available 120 240 zig zag 120 208 low wye 277 480 Hi wye Frequency 60 Hz Power factor 1 3 1 0 0 8 Voltage regulation 1 00 Insula...

Page 89: ...railer and Skid Dry weight of skid kg lbs 1432 3157 1473 3247 1509 3328 1550 3418 1608 3544 1648 3634 1580 3484 1621 3574 Operating weight of skid kg lbs 1720 3793 1761 3883 1798 3964 1839 4054 1896 4...

Page 90: ...Technical Data G50 G 70 G 85 90 6 4 Dimensions mm inches...

Page 91: ......

Page 92: ...02 0 Fax 49 0 89 3 54 02 3 90 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Skyline Tower Suite 2303 2...

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