Wacker Neuson G 85 Repair Manual
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Wacker Neuson G 85 Repair Manual

Wacker Neuson G 85 Repair Manual

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

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Summary of Contents for Wacker Neuson G 85

  • Page 1 Repair Manual Mobile Generator G 85 0171726en 0809...
  • Page 2 This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights. Violators will be prosecuted. Trademarks All trademarks referenced in this manual are the property of their respective owners.
  • Page 3 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.
  • Page 4 No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission from Wacker Neuson Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights, and violators will be prosecuted.

  • Page 5: Table Of Contents

    MG Repair Table of Contents Safety Information Operating Safety ................10 Service Safety ..................12 Operator Safety while using Internal Combustion Engines ....13 Towing Safety ..................14 Reporting Trailer Safety Defects ............14 Theory of Operation Basic Schematic ................. 15 Introduction ..................
  • Page 6 Table of Contents MG Repair ECM/Sensor Troubleshooting Checking Power to the ECM ...............44 Checking Outgoing Power From the ECM ..........47 Checking Temperature Sender ............48 Fuel Sender Failure and Low Fuel Fault ..........50 Calibrating ECM Voltage Display ............51 Calibrating ECM AC Amperage Display ..........52 Calibrating ECM AC Frequency Display ..........53 Calibrating ECM DC Display ...............54 Checking the ECM CAN BUS Circuit ..........55...
  • Page 7 Replacing the Emergency Stop Switch (newer) ....... 103 9.15 Replacing the Diodes ............... 105 9.16 Replacing the Voltage Selector Switch (VSS) ........107 9.17 G 50, G 70, G 85 VSS Wiring ............109 10 Technical Data 10.1 Engine Data ..................110 10.2 Generator Data ................. 111 10.3...
  • Page 8 Table of Contents MG Repair wc_br0171726en_004TOC.fm...

  • Page 9: Safety Information

    This machine is built with user safety in mind; however, like any electrical device it can present serious hazards if improperly operated and serviced. Follow instructions carefully! Should questions arise during operation or service of this equipment, contact Wacker Neuson Corporation. wc_si000356gb.fm...

  • Page 10: Operating Safety

    Safety Information G 85 Operating Safety Familiarity and proper training are required for the safe operation of the machine. Machines operated improperly or by untrained personnel can be hazardous. Read the operating instructions contained in this WARNING manual and the engine manual, and familiarize yourself with the location and proper use of all controls.
  • Page 11 G 85 Safety Information 1.1.17 ALWAYS keep the area immediately surrounding and underneath the machine clean, neat, and free of debris and combustible materials. Make sure that the area overhead is clear of debris that could fall onto or into the machine or exhaust compartment.

  • Page 12: Service Safety

    Safety Information G 85 Service Safety A poorly maintained machine can become a safety hazard! In order for the machine to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. WARNING 1.2.1 NEVER perform even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down.

  • Page 13: Operator Safety While Using Internal Combustion Engines

    G 85 Safety Information 1.2.11 ALWAYS remain aware of moving parts and keep hands, feet, and loose clothing away from the moving parts of the machine. 1.2.12 ALWAYS replace all guards, fasten doors, and make sure all safety devices operate properly after making repairs or servicing the equipment.

  • Page 14: Towing Safety

    National Highway Traffic Safety Administration (NHTSA) in addition to notifying Wacker Neuson Corporation. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

  • Page 15: Theory Of Operation

    Mobile Generator Theory of Operation Theory of Operation Basic Schematic 3-Phase AC out DC in 3-Phase – AC output – AC in DC out (exciter field) AC sensing 5B 7 5A 6 5 4A 4 3A 3 2 1 wc_gr003643 HZ STAB VOLT Ref.

  • Page 16: Introduction

    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).
  • Page 17 Mobile Generator Theory of Operation wc_gr003303 wc_tx001077gb.fm...

  • Page 18: Terminology

    Theory of Operation Mobile Generator Terminology See Graphic: wc_gr003315 To understand the terms “phase”, “leg”, “line-to-line”, and “line-to- neutral”, review the following information. • The main stator (a) consists of three separate groups of windings. These groups of windings are referred to as legs. The legs are labeled L1, L2, and L3.
  • Page 19 Mobile Generator Theory of Operation High Wye Low Wye (480V) (208V) (277V) (120V) 0˚ 45˚ 90˚ 135˚ 180˚ N1–S1 N2–S2 0˚ 45˚ 90˚ 135˚ 180˚ 0˚ 45˚ 90˚ 135˚ 180˚ 225˚ 270˚ 315˚ 360˚ 120˚ 120˚ 1 Hz 1 Rev wc_gr003315 wc_tx001077gb.fm...
  • Page 20 Theory of Operation Mobile Generator • Since the legs are mechanically 120° apart, as the rotor spins, time elapses between the moment when one leg reaches its largest volt- age potential and the moment when the next leg reaches its largest voltage potential.
  • Page 21 Mobile Generator Theory of Operation • Wacker Neuson generators are designed to accommodate various loads and multiple power factors. Power factor is the relationship between power supplied to the load (referred to as apparent power in kVA) and true power (power used by the load (kW). It is expressed mathematically by the equation: power factor = true power ÷...

  • Page 22: Electrical Testing Techniques

    Electrical Testing Techniques Mobile Generator Electrical Testing Techniques Checking Continuity Conduct continuity tests when the engine is shut down. When checking continuity, use the Ohm setting on your multimeter. Place a lead of the multimeter on one end of the wiring or component and the other lead on the opposite end.

  • Page 23: Probing Ecm Plugs And Pins

    Mobile Generator Electrical Testing Techniques Probing ECM Plugs and Pins See Graphic: wc_gr002926 To measure the voltage at an ECM pin, attach an appropriate extension (a) to the positive probe on your multimeter. Slide the positive probe into the plug along the wire of the pin to be tested. Use care when testing this way so you don’t damage the wire, plug, or ECM.

  • Page 24: Ecm Background Information

    ECM Background Information Mobile Generator ECM Background Information 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.

  • Page 25: Normal Boot-Up Sequence

    Both of the boot-up sequences are listed below. When checking the boot-up sequence of your generator, be sure you are checking the one that matches your generator. G 25, G 50, G 70, G 85 (9310) ECM Display Description Start of the boot-up sequence.
  • Page 26 ECM Background Information Mobile Generator G 85 (9305), G 125, G 160 ECM Display Description Start of the boot-up sequence. The ECM display reads “Initializing” and shows the model of the generator. If the Initializing model displayed does not match the model of the gener- G 85 ator, call Wacker Neuson Service.
  • Page 27 Mobile Generator ECM Background Information The ECM displays the AC configuration as determined by the position of the voltage selector switch (VSS). AC Configuration The ECM displays this screen to let the operator know that the alternator protection system has been enabled. Alt Protection Enabled The ECM displays the line-to-line voltage.

  • Page 28: Display Variables And Values

    ECM Background Information Mobile Generator Display Variables and Values See Graphic: wc_gr002944 • Generator Variables The values shown in the top line of the ECM display are all variables from the generator side of the machine. They are: (1) voltage (V) (2) phase (Ø) (or leg for single phase) (3) amperage (A) (4) frequency (Hz)

  • Page 29: Ecm Display Screens-Start Switch In Remote Position

    “Initializing” The ECM display reads “Initializing” and shows the model of the generator. If the model displayed does not match the model of the generator, call Wacker 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.

  • Page 30: Additional Variables Monitored By The Ecm

    Engine Control Unit (ECU). All three sets of additional variables are listed below, along with typical no load values. Note: The values from your generator may differ slightly from those shown here. G 25, G 50, G 70, G 85 (9310) Standard Models ECM Display Description The display shows the amount of time, in 1/10 hour seg- ments, that the engine has been running.
  • Page 31 G 25, G 50, G 85 (9310) Cold Weather and Custom Generators ECM Display Description The display shows the total time, in 1/10 hour incre- ments, that the engine has been run.
  • Page 32 ECM Background Information Mobile Generator The display shows the status of the speed sender. If the speed sender has failed, the time of the failure will be dis- Speed Sender played. The time of the failure will be included in the dis- Status is Normal play until the generator has been shut down and remains shutdown for a period of approximately two minutes.
  • Page 33 Mobile Generator ECM Background Information The display shows the value of the fault setting for low oil pressure. If the ECM detects that the engine oil pressure Fault Settings is less than 15 psi for longer than 15 seconds, the ECM 5 Sec @ <...
  • Page 34 Prealarm Setting greater than 15V, the battery voltage reading on the run Level > 15.0 V screen will blink. G 85 (9305), G 125, G160 John Deere Engines with ECU ECM Display Description John Deere engine diagnostic codes. SPN = Suspect Parameter Number FMI = Failure Mode Identifier.
  • Page 35 Mobile Generator ECM Background Information The display shows the present load on the engine. For no load conditions (generator not powering any outside tools Load @RPM or equipment) the display will read 15%. The display shows the percentage of total engine torque being used.

  • Page 36: Voltage Display Errors

    ECM Background Information Mobile Generator Voltage Display Errors See Graphic: wc_gr003308 • Single-Phase Display Mode When operating in the single-phase 120/240V position, line-to-line voltage will be displayed under P2 (240V). Line-to-neutral voltage (120V) will be displayed under P1 and P3. This is the normal single- phase display mode.
  • Page 37 Mobile Generator ECM Background Information • Engine Hour Switch in Locked Position Another possible display error can occur when starting the machine with the engine hour switch (a) in the down (locked) position. This position is normally used to lock the display onto a single leg and to prevent the display from scrolling through volt and amp values for all three legs.

  • Page 38: Ecm Automatic Engine Shutdown Conditions

    ECM Background Information Mobile Generator ECM Automatic Engine Shutdown Conditions The engine protection system includes six automatic shutdown conditions: low oil pressure, high coolant temperature, engine underspeed/overspeed, engine overcrank, low fuel. The ECM will also shut down the engine if an over-current condition exists. When the ECM has shut down the unit due to one of the faults, the ECM will display the fault and other pertinent information to aid in diagnosing the problem.

  • Page 39: Ecm Circuit Boards

    Mobile Generator ECM Background Information ECM Circuit Boards 6 5 4 6 5 4 12 11 10 9 8 7 12 1110 9 8 7 8 7 6 5 6 5 4 3 2 1 4 3 2 1 12 1110 9 8 7 8 7 6 5 6 5 4 3 2 1 4 3 2 1...

  • Page 40: Control Wiring Numbering & Colors

    ECM Background Information Mobile Generator Control Wiring Numbering & Colors See Graphic: wc_gr002924 Generator and control wires are marked and color coded to assist in tracing line connections and troubleshooting. The charts below list wire labels and colors followed by a description of their use. G 25 Control Module Plug 1: Engine Sender Inputs (12-pin connector) Black...
  • Page 41 Mobile Generator ECM Background Information Orange Voltage line input L3 at volt selector #28 Yellow Voltage line input L2 at volt selector #20 G 50/70/85 Control Module Plug 1: Engine Sender Inputs (12-pin connector) Black Magnetic pickup Clear, shield Magnetic pickup White-Black Oil pressure sender Yellow...
  • Page 42 ECM Background Information Mobile Generator G 125/160 Control Module Plug 1: Engine Sender Inputs (12-pin connector) White-Blue Crank delay, preheat Run/Off/Auto switch, +12V (positive) Black 12VDC supply, - ground (negative) Orange Remote start contacts Gray Emergency stop pushbutton White-Violet Fuel level sender Plug 2: Engine Start Input/Outputs (8-pin connector) Yellow Out;...

  • Page 43: Removing And Installing The Ecm

    Mobile Generator ECM Background Information 4.10 Removing and Installing the ECM See Graphic: wc_gr003316 Removal: 4.10.1 Remove the nut securing the hour meter switch (a) and the nut securing the start switch (b) to the panel. 4.10.2 Disconnect the four harness plugs (e). 4.10.3 Remove the three red wires (d) from the start switch.

  • Page 44: Ecm/Sensor Troubleshooting

    ECM/Sensor Troubleshooting Mobile Generator ECM/Sensor Troubleshooting 5.1 Checking Power to the ECM Prerequisites Fully-charged (12+ Volts) battery Procedure Follow the procedure below to check the fuses. 1. Locate the 10A and 30A fuses near the John Deere Engine Control Unit (ECU). wc_gr003735 2.
  • Page 45 Mobile Generator ECM/Sensor Troubleshooting Continued from the previous page. 5. Check the voltage between red wire #51 at B+ terminal strip and ground. Is at least 9.8V measured? Yes ____ No ____ Your reading Continue Repair red wire #51. 6. Check voltage between red wire #49 at START/RUN switch and ground. Is at least 9.8V measured? Yes ____ No ____...
  • Page 46 ECM/Sensor Troubleshooting Mobile Generator Continued from the previous page. 9. Check the voltage between ECM pin 7 plug 1 (red wire #53) and pin 8 plug 1 (black wire #59). Plug 1 Plug 2 B 59 R 53 R 18 wc_gr004000 Is at least 9.8V measured? Yes ____...

  • Page 47: Checking Outgoing Power From The Ecm

    Is at least 9.8V measured? Yes ____ No ____ Your reading Coninue The ECM has failed. Call Wacker Neuson Service. 4. Check the voltage between pin 2 plug 2 (violet wire #64) and ground. Is at least 9.8V measured? Yes ____...

  • Page 48: Checking Temperature Sender

    Your reading Repair yellow wire #57; then The ECM has failed. continue. Call Wacker Neuson Service. 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?
  • Page 49 13.Find the voltage measured in the chart below. Does the voltage measured reflect the engine temperature? Yes____ No____ The temperature sender is OK; the ECM The temperature sender has failed; may have failed. Call Wacker Neuson replace it. Service. The temperature sender has now been checked. wc_tx000723gb.fm...

  • Page 50: Fuel Sender Failure And Low Fuel Fault

    Repair W/V wire #62; then The ECM has failed. continue. Call Wacker Neuson Service. 8. Measure the resistance between the fuel sender and ground. 9. Find the resistance measured in the chart below. Does the resistance measured reflect the actual fuel level in the tank?

  • Page 51: Calibrating Ecm Voltage Display

    Mobile Generator ECM/Sensor Troubleshooting 5.5 Calibrating ECM Voltage Display Prerequisites Functioning generator Procedure Follow the procedure below to calibrate the ECM voltage display. 1. Open the large hinged panel. Remove the “key” (latch) from the lug door and place it in the slot of the lug door switch.

  • Page 52: Calibrating Ecm Ac Amperage Display

    ECM/Sensor Troubleshooting Mobile Generator 5.6 Calibrating ECM AC Amperage Display Prerequisites Functioning generator Ammeter 25A or greater load Procedure Follow the procedure below to calibrate the ECM amperage display. 1. Attach a 25A or greater load to the lugs. 2. Place the START/RUN switch in the ON position so that the engine starts. 3.

  • Page 53: Calibrating Ecm Ac Frequency Display

    Mobile Generator ECM/Sensor Troubleshooting 5.7 Calibrating ECM AC Frequency Display Prerequisites Functioning generator Procedure Follow the procedure below to calibrate the ECM AC frequency display. Note: Recalibrate only if your unit is off by more than 5 Hz. 1. Start the generator. Using a tachometer or vibrotach, adjust the engine speed to 1800 rpm or 60 Hz.

  • Page 54: Calibrating Ecm Dc Display

    ECM/Sensor Troubleshooting Mobile Generator 5.8 Calibrating ECM DC Display Prerequisites Functioning generator Procedure Follow the procedure below to calibrate the ECM DC voltage (12V battery) display. 1. Measure the voltage across the machine’s 12V battery using a multimeter. Note: This procedure works best when the battery voltage measures 12.6 VDC.

  • Page 55: Checking The Ecm Can Bus Circuit

    Mobile Generator ECM/Sensor Troubleshooting 5.9 Checking the ECM CAN BUS Circuit Prerequisites Generator shut down ECM turned off Procedure Follow the procedure below to check the ECM CAN BUS circuit. 1. Open the control panel. 2. Disconnect the CAN BUS connector. 3.

  • Page 56: Checking The Main Circuit Breaker

    ECM/Sensor Troubleshooting Mobile Generator 5.10 Checking the Main Circuit Breaker Prerequisites Fully-charged battery Emergency stop switch in disengaged (out) position. Procedure Follow the procedure below to check the main circuit breaker. As a reminder, place a check mark next to the answer that applies. 1.

  • Page 57: Ecm Plugs And Pins

    Mobile Generator ECM/Sensor Troubleshooting 5.11 ECM Plugs and Pins 6 5 4 Plug 3 Plug 4 12 11 10 9 6 5 4 8 7 6 3 2 1 4 3 2 Plug 1 Plug 2 wc_gr003988 ECM Plug 1 Wires ECM Plug 2 Wires Wire Description...
  • Page 58 ECM/Sensor Troubleshooting Mobile Generator Notes wc_tx000723gb.fm...

  • Page 59: John Deere Engines With Ecu

    John Deere Engines With ECU John Deere Engines With ECU Background The Tier II John Deere engines with electronic control systems are used on Wacker Neuson generator models G 85, G 125, and G 160. The electronic control system consists of: •...

  • Page 60: Locations Of Engine Electrical Components

    John Deere Engines With ECU Mobile Generator Locations of Engine Electrical Components wc_gr003343 wc_tx000698gb.fm...

  • Page 61: Engine Electrical Components

    Mobile Generator John Deere Engines With ECU Engine Electrical Components See Graphic: wc_gr003343 Ref. Component Ref. Component Main circuit breaker Starter relay Engine Control Module (ECM) Oil pressure sensor Alternator Engine Control Unit (ECU) Slave preheat relay Crank position sensor Manifold air temperature sensor Fuel pump assembly Manifold heater...

  • Page 62: Engine Starting Troubleshooting

    Engine Starting Troubleshooting G 85 Engine Starting Troubleshooting 7.1 Checking the Fuses Fully-charged (12+ Volts) battery Prerequisites Follow the procedure below to check the fuses. Procedure 1. Locate the 10A and 30A fuses near the John Deere Engine Control Unit (ECU).

  • Page 63: Checking The Engine Control Module (Ecm)

    #63 and ground during cranking. Is there at least 9.8VDC measured in each case? Yes____ No____ The ECM is OK. The ECM has failed. Call Wacker Neuson Service. The ECM has now been checked. Continue with Checking the Emergency Stop Switch. wc_tx000678gb.fm...

  • Page 64: Checking The Emergency Stop Switch

    Engine Starting Troubleshooting G 85 7.3 Checking the Emergency Stop Switch Prerequisites Generator shut down Battery voltage measuring 11–13VDC Procedure Follow the procedure below to check the emergency stop switch. 1. Place the emergency stop switch in the de-activated (out) position.

  • Page 65: Checking The Starter Relay

    G 85 Engine Starting Troubleshooting 7.4 Checking the Starter Relay Prerequisites Battery voltage measuring 11–13VDC Procedure Follow the procedure below to check the starter relay. 1. Locate the starter relay. Intake heater relay Gr 65 R 11 B 14 R 12...

  • Page 66: Checking The Starter Solenoid

    Engine Starting Troubleshooting G 85 7.5 Checking the Starter Solenoid Prerequisites Battery voltage measuring 11–13VDC Procedure Follow the procedure below to check the starter solenoid. 1. Locate the starter and the starter solenoid. Starter wc_gr003724 2. Check the connection of the large red wire.

  • Page 67: Checking The Intake Heater Relay

    G 85 Engine Starting Troubleshooting 7.6 Checking the Intake Heater Relay Prerequisites Battery voltage measuring 11–13VDC Procedure Follow the procedure below to check the intake heater relay. 1. Locate the intake heater relay. Intake heater relay Gr 65 R 11...

  • Page 68: Checking The Main Circuit Breaker

    Engine Starting Troubleshooting G 85 7.7 Checking the Main Circuit Breaker Fully-charged battery Prerequisites Emergency stop switch in disengaged (out) position. Follow the procedure below to check the main circuit breaker. As a reminder, place Procedure a check mark next to the answer that applies.

  • Page 69: Output Voltage Troubleshooting

    Mobile Generator Output Voltage Troubleshooting Output Voltage Troubleshooting 8.1 Checking the Emergency Stop Switch Prerequisites Generator shut down Procedure Follow the procedure below to check the emergency stop switch. 1. Open the large hinged panel. Remove the "key" (latch) from the lug door and place it in the slot of the lug door switch.

  • Page 70: Checking The Lug Door Switch

    Output Voltage Troubleshooting Mobile Generator 8.2 Checking the Lug Door Switch Prerequisites Generator shut down Procedure Follow the procedure below to check the lug door switch. 1. Open the large hinged panel. Remove the "key" (latch) from the lug door and place in the slot of the lug door switch.

  • Page 71: Checking The Main Circuit Breaker

    Mobile Generator Output Voltage Troubleshooting 8.3 Checking the Main Circuit Breaker Prerequisites Fully-charged battery Emergency stop switch in disengaged (out) position. Procedure Follow the procedure below to check the main circuit breaker. As a reminder, place a check mark next to the answer that applies. 1.

  • Page 72: Checking The Voltage Adjusting Rheostat

    Output Voltage Troubleshooting Mobile Generator 8.4 Checking the Voltage Adjusting Rheostat Prerequisites Generator shut down Procedure Follow the procedure below to check the voltage adjusting rheostat. 1. Open the control panel and locate the voltage adjusting rheostat. 4A 4 3A 3 2 1 0009369 >124 0009459 >129 0620003 >133...

  • Page 73: Checking The Auxiliary Winding

    Mobile Generator Output Voltage Troubleshooting 8.5 Checking the Auxiliary Winding Prerequisites Generator shut down Procedure Follow the procedures below to check the auxiliary winding. 1. Open the large hinged panel and locate the Automatic Voltage Regulator (AVR). Blue 1000 200m 5B 7 5A 6 5 4A 4 3A 3 2 1 HZ STAB VOLT...

  • Page 74: Checking The Exciter Stator

    Your reading The excitor stator The exciter stator has failed. is OK. Call Wacker Neuson Service. 7. Reconnect the wiring, and re-install the vent cover. The auxiliary winding has now been checked. Continue with Checking the AVR Sensing Wires. wc_tx000726gb.fm...

  • Page 75: Checking The Avr Sensing Wires

    Mobile Generator Output Voltage Troubleshooting 8.7 Checking the AVR Sensing Wires Prerequisites Generator shut down Procedure Follow the procedure below to check the AVR sensing wires. 1. Open the large hinged panel and locate the Engine Control Module (ECM) and the Auto- matic Voltage Regulator (AVR).

  • Page 76: Flashing The Generator (Checking The Excitation System)

    Output Voltage Troubleshooting Mobile Generator 8.8 Flashing the Generator (checking the excitation system) Prerequisites Source of 12VDC Procedure Follow the procedure below to flash the generator. 1. Open the large hinged panel and locate the Automatic Voltage Regulator (AVR). 1000 200m 2.

  • Page 77: Checking Stator Windings At The Lugs

    Mobile Generator Output Voltage Troubleshooting 8.9 Checking Stator Windings at the Lugs Prerequisites Generator shut down Two alligator clips each connected to 12 inches of 14-gauge wire Procedure Follow the procedure below to check the stator windings at the lugs. 1.

  • Page 78: Checking The Rectifier Diodes-Thread-In Style

    Does each diode check OK? The diodes are OK. Replace all diodes. Call Wacker Neuson Service. 8. Reconnect the AVR. 9. Reconnect the diodes. Be sure to include the washer when reconnecting the diode lead. The rectifier diodes have now been checked. Continue with Checking the Main Rotor Win- ding.

  • Page 79: Checking The Rectifier Diodes-Solder-In Style

    Does each diode check OK? The diodes are OK. Replace all diodes. Call Wacker Neuson Service. The rectifier diodes have now been checked. Continue with Checking the Main Rotor Win- ding. Note: If moving on to the next test, leave the generator disassembled.

  • Page 80: Checking The Main Rotor Winding

    Yes____ No____ Your reading Continue The main rotor winding has failed. Call Wacker Neuson Service. 8. Check each wire for short (path) to the rotor shaft. Does each wire measure “OPEN” or “OL” to the rotor shaft? Yes____ No____ Your reading The main rotor The main rotor winding has failed.

  • Page 81: Checking The Exciter Rotor Winding

    Your reading The main rotor The main rotor winding has failed. winding is OK. Call Wacker Neuson Service. 10.Reassemble the generator components. The exciter rotor winding has now been checked. Continue with Checking Stator Windings at the Voltage Selector Switch.

  • Page 82: Checking Stator Windings At The Voltage Selector Switch

    Call the lugs, the VSS has failed; replace it. Wacker Neuson Service. 5. Reconnect the wires and reinstall the generator components. The main stator windings have now been checked.

  • Page 83: Disassembly/Assembly Procedures

    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.

  • Page 84: Removing The Roof

    Disassembly/Assembly Mobile Generator Removing the Roof See Graphic: wc_gr003320 This procedure requires an appropriate crane capable of lifting 227 kg (500 lbs.). 9.5.1 Disconnect the battery. 9.5.2 Remove the doors (a). 9.5.3 Remove the front and rear access panels (b and c). 9.5.4 Remove the screws that secure the roof to the side panels (d).
  • Page 85 Mobile Generator Disassembly/Assembly wc_gr003320 wc_tx000575gb.fm...

  • Page 86: Preparing Unit For Generator Removal

    Disassembly/Assembly Mobile Generator Preparing Unit for Generator Removal See Graphic: wc_gr003321 9.6.1 Remove the roof. See section Removing Roof. 9.6.2 Remove the screws that secure the air filter assembly and set the air filter assembly off to the side. 9.6.3 Remove the cover to the VSS box.
  • Page 87 Mobile Generator Disassembly/Assembly wc_gr003321 wc_tx000575gb.fm...

  • Page 88: Replacing The Generator

    Disassembly/Assembly Mobile Generator Replacing the Generator See Graphic: wc_gr003322 This procedure requires an appropriate crane capable of lifting 365 kg (800 lbs.). Removal: 9.7.1 See section Preparing Unit for Generator Removal. 9.7.2 Remove the screens (a) from both sides of the generator housing. 9.7.3 Remove the screws (b) that secure the shock mounts to the frame.
  • Page 89 Mobile Generator Disassembly/Assembly G 25 G 50, G 70, G 85 G 50, G 70, G 85 G 25 wc_gr003322 wc_tx000575gb.fm...

  • Page 90: Removing The Avr

    Disassembly/Assembly Mobile Generator Removing the AVR Prerequisites Machine shut down Procedure Follow the procedure below to remove the Automatic Voltage Regulator (AVR). 9.8.1 Remove the screws that secure the large access panel and open the large access panel. 9.8.2 Make note of the wires connected to the AVR 9.8.3 Disconnect the wires.

  • Page 91: Installing The Avr

    Mobile Generator Disassembly/Assembly Installing the AVR Prerequisites • Machine shut down • Multimeter Procedure Follow the procedure below to install and set the Automatic Voltage Regulator (AVR). 9.9.1 Check the function of the voltage adjusting rheostat. See section Checking the Voltage Adjusting Rheostat 9.9.2 Mount the AVR to the machine with the two screws.
  • Page 92 Disassembly/Assembly Mobile Generator Continued from the previous page. WARNING Electric shock hazard. Voltage exists at the cooling fins of the AVR when the engine is running. Electric shock can cause severe injury or death. Never touch the cooling fins when the engine is running. 9.9.5 Place the voltage selector switch in the 208/120V position.
  • Page 93 Mobile Generator Disassembly/Assembly Continued from the previous page. 9.9.11 Check the voltage between Lug 1 and Lug 2 with a multimeter. 9.9.12 Adjust the VOLT pot of the AVR until 250 VAC is measured between Lug 1 and Lug 2.Test the consistency by checking the voltage across Lug 1 and Lug 2, Lug 2 and Lug 3, Lug 3 and Lug 1.
  • Page 94 Disassembly/Assembly Mobile Generator Continued from the previous page. 9.9.17 Check the consistency between the voltage measured at the lugs by the multimeter and that shown on the ECM display. If the ECM display is off by more than 2%, adjust the VOLT pot on the ECM so that the ECM display matches the reading on the multimeter.
  • Page 95 Mobile Generator Disassembly/Assembly Notes wc_tx000575gb.fm...

  • Page 96: Removing The Engine

    Disassembly/Assembly Mobile Generator 9.10 Removing the Engine See Graphic: wc_gr003351 This procedure requires an appropriate crane capable of lifting 1000 kg (2200 lbs.). 9.10.1 Remove the roof. See section Removing the Roof. 9.10.2 Remove the generator. See section Removing the Generator. 9.10.3 Remove the battery.
  • Page 97 Mobile Generator Disassembly/Assembly wc_gr003351 wc_tx000575gb.fm...

  • Page 98: Installing The Engine

    Disassembly/Assembly Mobile Generator 9.11 Installing the Engine See Graphic: wc_gr003352 This procedure requires an appropriate crane capable of lifting 1000 kg (2200 lbs.). 9.11.1 Using as appropriate hoist or crane, lower the engine into the frame. 9.11.2 Secure the engine to the frame with the screws that secure the shock mounts.
  • Page 99 Mobile Generator Disassembly/Assembly wc_gr003352 wc_tx000575gb.fm...

  • Page 100: Replacing The Fuel Tank

    Disassembly/Assembly Mobile Generator 9.12 Replacing the Fuel Tank See Graphic: wc_gr003350 This procedure requires a crane or hoist capable of lifting 1900 kgs. (2000 lbs.). Removal: 9.12.1 Disconnect the fuel hoses and the fuel sender wiring. 9.12.2 Remove the screws that secure the upper frame assembly (a) to the lower frame (skid) (b).
  • Page 101 Mobile Generator Disassembly/Assembly wc_gr003350 wc_tx000575gb.fm...

  • Page 102: Replacing The Emergency Stop Switch (Older)

    Disassembly/Assembly Mobile Generator 9.13 Replacing the Emergency Stop Switch (older) Turn off the generator before replacing the emergency stop switch. Removal: 9.13.1 Slide the locking tab (a) to the unlock position and pull the switch off the pushbutton. 9.13.2 Label and disconnect the wiring from the switch. 9.13.3 Remove the locking nut (b) and washer.
  • Page 103 Mobile Generator Disassembly/Assembly wc_gr003286 wc_tx000575gb.fm...

  • Page 104: Replacing The Emergency Stop Switch (Newer)

    Disassembly/Assembly Mobile Generator 9.14 Replacing the Emergency Stop Switch (newer) See Graphic: wc_gr003677 Turn off the generator and disconnect the battery before replacing the emergency stop switch. Removal: 9.14.1 Slide the locking tab (a) to the unlock position and pull the contact block (b) off the pushbutton (c) portion of the switch.
  • Page 105 Mobile Generator Disassembly/Assembly wc_tx000575gb.fm...

  • Page 106: Replacing The Diodes

    Disassembly/Assembly Mobile Generator 9.15 Replacing the Diodes Prerequisites • Solder (Flux core 60-40) • Soldering iron (<10 Watts) • Heat sink putty or two alligator clips to act as heat sinks • Epoxy Procedure Follow the procedure below to replace the diodes. 9.15.1 Remove the rear access panel from the machine.
  • Page 107 Mobile Generator Disassembly/Assembly Continued from the previous page. 9.15.6 Add a small amount of epoxy to the diode holder. 9.15.7 Insert the diode into the holder. Red marking faces to the right. 9.15.8 Cut any excess wire from the new diode. 9.15.9 Add heat sinks (alligator clips are shown for this purpose).

  • Page 108: Replacing The Voltage Selector Switch (Vss)

    Disassembly/Assembly Mobile Generator 9.16 Replacing the Voltage Selector Switch (VSS) See Graphic: wc_gr003284 Electric shock hazard. Turn off the generator before replacing the Voltage Selector Switch (VSS). WARNING Removal: 9.16.1 Remove the air filter and the cover of the VSS box (a). 9.16.2 Label and disconnect all the wires attached to the VSS.
  • Page 109 Mobile Generator Disassembly/Assembly wc_gr003284 wc_tx000575gb.fm...

  • Page 110: G 50, G 70, G 85 Vss Wiring

    Disassembly/Assembly Mobile Generator 9.17 G 50, G 70, G 85 VSS Wiring AVR = to Automatic Voltage Regulator ECM = to Engine Control Module TB** Gen = from generator TB* = to terminal block R1 (T7 on older) TB**= to terminal block R2 (T9 on older)
  • Page 111 Mobile Generator Disassembly/Assembly Notes wc_tx000575gb.fm...

  • Page 112: Technical Data

    Technical Data G 85 10 Technical Data 10.1 Engine Data Item Number: G 85 0009369 G 85 0009459 0620003 rev 115 & 0620003 rev 114 & above lower Engine Engine make / type John Deere / 4.5L Model 4045TF275 Number of cylinders Displacement 4.5 (274.6)

  • Page 113: Generator Data

    G 85 Technical Data 10.2 Generator Data Item Number: G 85 0009369 0009459 0620003 Generator Make/Type Mecc Alte / Brushless Model ECO32-3L/4 Generator speed 1800 Voltage selector 3 position switch AC voltages 120/240 zig-zag available 120/208 low-wye 277/480 Hi-wye Frequency...

  • Page 114: Trailer And Skid Data

    Technical Data G 85 10.3 Trailer and Skid Data Item Number: G 85 G 85 0009369 0009459 0620003 Trailer and Skid Dry weight of skid kg (lbs.) 1580 (3484) 1621 (3574) Operating weight of kg (lbs.) 1868 (4120) 1909 (4210)

  • Page 115: Dimensions

    G 85 Technical Data 10.4 Dimensions mm (inches) wc_gr006389 Machine G 85 1970 1703 3923 2445 1346 1475 (38) (77.5) (67) (154.5) (96.3) (53) (58) wc_td000214gb.fm...

  • Page 116: Engine Wiring Diagram-John Deere With Ecu

    Technical Data G 85 10.5 Engine Wiring Diagram—John Deere with ECU 0009369 124+ 0009459 133+ 0620003 129+ wc_td000214gb.fm...
  • Page 117 G 85 Technical Data Engine Wiring Components—John Deere with ECU Ref. Description Ref. Description Plug 1 — engine sender inputs Battery Plug 2 — engine start/run outputs ECM 10A fuse Main circuit breaker (3-phase lugs) Starter relay Shunt trip coil...
  • Page 118 Technical Data G 85 0009369 100–123 0009459 100–132 0620003 100–128 wc_td000214gb.fm...
  • Page 119 G 85 Technical Data Engine Wiring Components—John Deere with ECU Ref. Description Ref. Description Plug 1 — engine sender inputs Battery Plug 2 — engine start/run outputs ECM 10A fuse Main circuit breaker (3-phase lugs) Starter relay Shunt trip coil...

  • Page 120: Ecu Wiring Diagram

    Technical Data G 85 10.6 ECU Wiring Diagram wc_td000214gb.fm...

  • Page 121: Ecu Harness Connector

    G 85 Technical Data 10.7 ECU Harness Connector See Graphic: wc_gr002817 Ref. Wire Color/# Destination Ref. Wire Color/# Destination Green/905 CAN bus Red/012C Harness Connector (HC) terminal G Orange/493 Fuel control solenoid Violet/467 Oil pressure sensor Brown/461 Colant temp sensor...

  • Page 122: Generator Wiring Diagram

    Technical Data G 85 10.8 Generator Wiring Diagram 0009369 124+ 0009459 133+ 0620003 129+ wc_td000214gb.fm...
  • Page 123 G 85 Technical Data See Graphic: wc_gr004692 Ref. Description Ref. Description Lug door (safety interlock) switch Voltage Selector Switch (VSS) Mechanical lugs Generator Plug 3 - current transformer inputs Automatic Voltage Regulator (AVR) Plug 4 - line voltage inputs Voltage adjustment rheostat...
  • Page 124 Technical Data G 85 0009369 100–123 0009459 100–132 0620003 100–128 wc_td000214gb.fm...
  • Page 125 G 85 Technical Data See Graphic: wc_gr003296 Ref. Description Ref. Description Lug door (safety interlock) switch Voltage Selector Switch (VSS) Mechanical lugs Generator Plug 3 - current transformer inputs Automatic Voltage Regulator (AVR) Plug 4 - line voltage inputs Voltage adjustment rheostat...
  • Page 126 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson equipment. TYPE PART NO. –...
  • Page 127 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson equipment. TYPE PART NO. –...

  • Page 128: Torque Values

    Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE 10.9 12.9 Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch 7/32 – 9/32 – 5/16 – – – – 11/16 – – – 15/16 –...
  • Page 129 Torque Values Torque Values (continued) Inch Fasteners (SAE) Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch No.4 – 3/32 No.6 5/16 – 7/64 No.8 11/32 – 9/64 No.10 – – 5/32 – 7/16 – 3/32 5/16 – – 9/16 – 5/16 7/16 –...
  • Page 130 Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.

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