Wacker Neuson G 240 Operator'S Manual Download

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5000186930

0215

Operator’s Manual

Mobile Generator

G 230
G 240

Summary of Contents for G 240

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...

Page 3: ...ng 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 numb...

Page 4: ...formance 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...

Page 5: ...on 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 attachme...

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...

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 LC...

Page 9: ...Practices for Balancing Loads 118 11 3 Connecting 480V 3 Phase and Single Phase Loads 120 11 4 Connecting a 240V 3 Load and a 240V 1 Load 121 11 5 Connecting a 220 240V 3 Load and Multiple 127 133V 1...

Page 10: ...8 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 Maintena...

Page 11: ...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 2...

Page 12: ...trical 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 23...

Page 13: ...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...

Page 14: ...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 fe...

Page 15: ...r 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...

Page 16: ...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...

Page 17: ...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 clot...

Page 18: ...ck 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 hand...

Page 19: ...ill 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 ca...

Page 20: ...xhaust 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 openi...

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 G...

Page 22: ...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...

Page 23: ...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...

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 S LO L QUIDO...

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: ...istrado antes de Lea y entienda el Manual de Operaci n suministrado antes de operar esta m quina Si no lo hace incrementar el riesgo de operar esta m quina Si no lo hace incrementar el riesgo de lesio...

Page 27: ...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 Ev...

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...

Page 29: ...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...

Page 30: ...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 BON...

Page 31: ...court circuit Risque d lectrocution et d arc de court circuit aux ailettes de refroidissement aux ailettes de refroidissement Peligro de choque el ctrico y arco voltaico de Peligro de choque el ctrico...

Page 32: ...n 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...

Page 33: ...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 ENGI...

Page 34: ...VALVULA 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...

Page 35: ...DVERTENCIA WARNING WARNING Syst me de 24 volts Ne pas Syst me de 24 volts Ne pas connecter syst me de 12 volts connecter syst me de 12 volts 24 volt system Do not connect to 12 24 volt system Do not c...

Page 36: ...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 distanc...

Page 37: ...at 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 pan...

Page 38: ...ing 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 genera...

Page 39: ...r 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...

Page 40: ...ons 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 cardb...

Page 41: ...le 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 t...

Page 42: ...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 pr...

Page 43: ...nect 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 t...

Page 44: ...place 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 brake...

Page 45: ...tandby 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 conn...

Page 46: ...ll 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 pane...

Page 47: ...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 w...

Page 48: ...urisdiction 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...

Page 49: ...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 s...

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 m...

Page 51: ...el 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 Burnin...

Page 52: ...AUFEN 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 ARRA...

Page 53: ...witch 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...

Page 54: ...r 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 AP...

Page 55: ...ART 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 generat...

Page 56: ...alarm the LED b illuminates continuously and the machine is shut down A HZ V DIAGNOSTICS DIAGNOSEN DIAGNOSTICOS DIAGNOSTICS R Basler AUS AUS APAGADO APAGADO ARRET ARRET OFF OFF REMOTE START REMOTE ST...

Page 57: ...start 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 rec...

Page 58: ...tect 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...

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 represent...

Page 60: ...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 pre...

Page 61: ...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 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 1 voltage is above 135V Damage to the receptacle and the...

Page 63: ...adiator 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 r...

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 frequ...

Page 65: ...e 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...

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 circui...

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 Phase Displ...

Page 68: ...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 engin...

Page 69: ...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...

Page 70: ...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 Statu...

Page 71: ...ed 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...

Page 72: ...enu 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 Us...

Page 73: ...assword 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...

Page 74: ...cter 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...

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 mar...

Page 76: ...IN 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 pre...

Page 77: ...he 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...

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 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 U...

Page 80: ...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 high...

Page 81: ...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 s...

Page 82: ...t 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...

Page 83: ...hange 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...

Page 84: ...wed 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 th...

Page 85: ...n 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 butto...

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 th...

Page 87: ...u 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 lef...

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 chan...

Page 89: ...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 le...

Page 90: ...RT 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 facto...

Page 91: ...ghlight 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 Pres...

Page 92: ...ed 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 d...

Page 93: ...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 Thi...

Page 94: ...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 troubleshoo...

Page 95: ...ring 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...

Page 96: ...T 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...

Page 97: ...wer 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...

Page 98: ...FF 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 Sto...

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 pr...

Page 100: ...ng 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 nex...

Page 101: ...phase 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 1 voltage is above 135V Damage to the receptacle and t...

Page 102: ...ng 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 b...

Page 103: ...o 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...

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 Overs...

Page 105: ...arms 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 fau...

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...

Page 107: ...N 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 Poss...

Page 108: ...rts 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 t...

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...

Page 110: ...r 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...

Page 111: ...t 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 Dis...

Page 112: ...yed 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...

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 Leve...

Page 114: ...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 Gener...

Page 115: ...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 percentag...

Page 116: ...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 n...

Page 117: ...m 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...

Page 118: ...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 un...

Page 119: ...itional 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 distri...

Page 120: ...res 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 va...

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 m...

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...

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...

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 betwee...

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 gen...

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 locki...

Page 127: ...t 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 t...

Page 128: ...utton 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 pro...

Page 129: ...low 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 T...

Page 130: ...ert 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 Diagn...

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 ch...

Page 132: ...ressure 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...

Page 133: ...re 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 Sn...

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 D...

Page 135: ...ensor 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 H...

Page 136: ...art 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 6...

Page 137: ...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 Stri...

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 T...

Page 139: ...ISFIRE 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 Captio...

Page 140: ...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 C...

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 Fl...

Page 142: ...NBus 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 M...

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 Stri...

Page 144: ...g 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 D...

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...

Page 146: ...s 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...

Page 147: ...tures 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 WARNIN...

Page 148: ...0 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 ref...

Page 149: ...eater 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 wea...

Page 150: ...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...

Page 151: ...he 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 connect...

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...

Page 153: ...ternal 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...

Page 154: ...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...

Page 155: ...rbons 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...

Page 156: ...zles 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...

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...

Page 158: ...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 th...

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 fo...

Page 160: ...e 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 SEV...

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 ret...

Page 162: ...ery 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 ma...

Page 163: ...rcuit 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...

Page 164: ...nal 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 compartmen...

Page 165: ...ny 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 traile...

Page 166: ...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...

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 ex...

Page 168: ...nnections 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 a...

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 spee...

Page 170: ...proximately 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 appr...

Page 171: ...al 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 silica...

Page 172: ...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...

Page 173: ...ter 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...

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 t...

Page 175: ...llow 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 p...

Page 176: ...om 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 exten...

Page 177: ...te 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 c...

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: ...il 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 mater...

Page 182: ...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...

Page 183: ...b_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 ma...

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 mate...

Page 186: ...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...

Page 187: ...nd 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 Mainte...

Page 188: ...d 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 proc...

Page 189: ...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 lev...

Page 190: ...hine 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 Operat...

Page 191: ...cy 60 Hz Power factor 1 3 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 1 120 GFI duplex Amps 2 20A 1 120 240 V twist lock Am...

Page 192: ...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 1...

Page 193: ...e 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 t...

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 capacit...

Page 195: ...ble panel AC voltages available 1 V 3 V 120 127 139 240 254 277 208 220 240 416 440 480 Frequency 60 Hz Power factor 1 3 1 0 0 8 Voltage regulation 1 00 Insulation class H Sound level at 7 m 23 ft dB...

Page 196: ...30 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 br...

Page 197: ...882 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...

Page 198: ...n 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 informatio...

Page 199: ...RUZDUG KDOI RI WKH OHIW URDG VLGH RI WKH XQLW 7KLV FHUWLILFDWLRQ 9 1 ODEHO ZLOO LQGLFDWH WKH WUDLOHU V URVV 9HKLFOH HLJKW 5DWLQJ 9 5 7KLV LV WKH PRVW ZHLJKW WKH IXOO ORDGHG WUDLOHU FDQ ZHLJK W ZLOO DO...

Page 200: ...ted 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 t...

Page 201: ...side 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...

Page 202: ...orporates 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 as...

Page 203: ...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 met...

Page 204: ...ating 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 use...

Page 205: ...lated 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 truc...

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...

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...

Page 208: ...ire 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 a...

Page 209: ...d 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...

Page 210: ...sported 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 Transp...

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: ...missions 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 reac...

Page 214: ...arts 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 purcha...

Page 215: ...is 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 Owne...

Page 216: ...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 o...

Page 217: ...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 2...

Page 218: ...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...

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 Groun...

Page 220: ...chines 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...

Page 221: ...tor 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 Excite...

Page 222: ...ER 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...

Page 223: ...s 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...

Page 224: ...7 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 SMAL...

Page 225: ...al 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...

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 TR...

Page 227: ...et 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...

Page 228: ...OR 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 9...

Page 229: ...mote 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...

Page 230: ...OL 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...

Page 231: ...or 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 monit...

Page 232: ...C 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 L...

Page 233: ...tertreatment 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 hos...

Page 234: ...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...

Page 235: ...xhaust 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...

Page 236: ...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...

Page 237: ...ge 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 windi...

Page 238: ...cs 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...

Page 239: ...set 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 str...

Page 240: ...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 S...

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 sole...

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 R...

Page 243: ...ctive 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 Intak...

Page 244: ...OUND 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 ENCLOSU...

Page 245: ...act 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...

Page 246: ...R 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 INT...

Page 247: ...ion 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 Di...

Page 248: ...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 BACKFLO...

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...

Page 250: ...CTOR 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 C...

Page 251: ...st 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...

Page 252: ......

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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 G...

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