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Mobile Generator Repair Foreword This manual covers machines with Item Number: 0009258, 0009259, 0009260, 0009261, 0009305, 0009306, 0009310, 0009462, 0009463, 0009464, 0009465, 0009476, 0009477, 0009478 Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it. Basic operating and maintenance procedures are described in the Operator’s Manual supplied with the machine.
Foreword Mobile Generator Repair CALIFORNIA Proposition 65 Warning: Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California WARNING to cause cancer and birth defects or other reproductive harm. Laws Pertaining to Spark Arresters Notice: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels.
Mobile Generator Repair 1. Safety Information 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2. 8 Operating Safety .................................................................................. 9 Service Safety .................................................................................... 10 Operator Safety while using Internal Combustion Engines ................ 12 Towing Safety ..................................................................................... 13 Reporting Trailer Safety Defects ........
Table of Contents 4. Theory of Operation 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5. 45 Introduction ..........................................................................................45 Basic Generator Schematic .................................................................46 Generator Components .......................................................................47 Wiring Diagrams ..................................................................................48 Generator Systems ...........
Mobile Generator Repair 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.28 6.29 7. Table of Contents Probing Plugs and Pins .................................................................... 109 Checking ECM Display and LEDs .................................................... 110 Checking Battery .............................................................................. 111 Checking Power to ECM .......................................................
Table of Contents 7.18 7.19 7.20 7.21 7.22 7.23 8. Mobile Generator Repair Engine Cranks But Does Not Start ....................................................162 Checking Contacts of ECM Preheat Relay .......................................165 Checking Slave Preheat Relay and Wiring .......................................166 Checking Manifold Heater .................................................................167 Checking Fuel Circuit ................................................................
Mobile Generator Repair 9. Table of Contents Output Voltage Troubleshooting 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18 9.19 Wiring Diagrams ............................................................................... 208 “No” Voltage Troubleshooting .......................................................... 214 Checking Main Circuit Breaker .........................................................
Table of Contents 10.18 10.19 10.20 10.21 10.22 Mobile Generator Repair Installing Roof and Center Support Brackets ....................................259 Preparing Unit for Engine/Generator Removal ..................................260 Removing Engine/Generator Assembly ............................................262 Installing Engine/Generator Assembly ..............................................263 Replacing Fuel Tank .........................................................................264 11.
Mobile Generator Repair wc_br0160486enTOC.
Safety Information 1. Mobile Generator Repair Safety Information This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Mobile Generator Repair 1.1 Operating Safety WARNING wc_si000136gb.fm Safety Information Familiarity and proper training are required for the safe operation of equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions contained in both this manual and the engine manual and familiarize yourself with the location and proper use of all controls.
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. 1.1.18 ALWAYS be sure the machine is on a firm, level surface and will not tip, roll, slide, or fall while operating. 1.1.19 ALWAYS remove all tools, cords, and other loose items from generator before starting it. 1.1.
Mobile Generator Repair 1.2.2 Safety Information Ground Connection The generator must be connected to a good earthen ground for proper operating safety! A central “equipment ground” is provided at the customer connection lugs. This point is connected directly to the generator set base. All other system grounds are connected to this central point. Ground the generator in accordance with the standards defined in national, state and local regulations. wc_si000136gb.fm 1.2.
Safety Information 1.3 Operator Safety while using Internal Combustion Engines DANGER wc_si000136gb.fm Mobile Generator Repair Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner's manual and the safety guidelines below. Failure to follow the warnings and safety guidelines could result in severe injury or death. 1.3.1 DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used.
Mobile Generator Repair 1.4 Safety Information Towing Safety Towing a large trailer requires special care. Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. WARNING 1.5 1.4.1 ALWAYS check that the hitch and coupling on the vehicle are rated equal to, or greater than, the trailer's “gross vehicle weight rating” (GVWR). 1.4.2 ALWAYS inspect the hitch and coupling for wear or damage.
Safety Information 1.6 wc_si000136gb.
Mobile Generator Repair wc_si000136gb.
Safety Information Ref. Safety and Operating Labels Label A TOWING INSTRUCTIONS 1. READ OPERATOR'S MANUAL. 2. USE HITCH RATED FRO TRAILER'S "GROSS VEHICLE WEIGHT RATING". 3. SECURELY ATTACH TRAILER TO TOW VEHICLE. 4. ATTACH SAFETY CHAINS USING CROSS PATTERN. 5. ATTACH BREAKDOWN CHAIN TO VEHICLE. 6. CHECK TRAILER LIGHTS. Meaning ABSCHLEPPINSTRUKTIONEN 1. BETRIEBSVORSCHRIFT LESEN. 2. ANHANGEVORRICHTUNG VERWENDEN, DIE DER GESAMTBETRIEBSGEWICHTSKLASSE ENTSPRICHT. 3.
Mobile Generator Repair Ref. Safety Information Label Meaning G Tie-down point H WARNING! To prevent hearing loss, wear hearing protection. Hand injury if entangled in moving belt. Rotating machinery! Do not reach inside with engine running. I WARNING! Hot surface! J Electrical ground. K WARNING! Electric shock will cause serious injury or death. wc_si000136gb.
Safety Information Ref. Mobile Generator Repair Label Meaning L OPERATING INSTRUCTIONS FOR MOBILE GENERATORS BETRIEBSANLEITUNG .. FUR MOBILEAGGREGATE VOR DEM STARTEN 1. BETRIEBSVORSCHRIFT LESEN. .. 2. GERAT WAAGRECHT STELLEN. .. 3. RADER BLOCKIEREN. .. 4. GERAT ERDEN. .. .. 5. STAND ALLER FLUSSIGKEITEN PRUFEN. BEFORE STARTING 1. READ OPERATOR'S MANUAL. 2. LEVEL UNIT. 3. BLOCK WHEELS. 4. GROUND UNIT. 5. CHECK ALL FLUID LEVELS. MANUAL STARTING 1. DISCONNECT ALL EXTERNAL LOADS. 2.
Mobile Generator Repair Ref. Safety Information Label Meaning O WARNING! Generator can automatically start which can cause serious injury. Disconnect battery before servicing. P WARNING! Read and understand the supplied Operator’s Manual before operating this machine. Failure to do so increases the risk of injury to yourself or others. Q WARNING! To reduce the risk of electrical shock, read operator’s manual.
Safety Information Ref. Mobile Generator Repair Label Meaning T WARNING! Disconnect battery before servicing. Read the Operator's Manual.
Mobile Generator Repair 1.8 Safety Information Calling for Service When ordering parts or requesting service information, you will always be asked to specify the model, item number, revision number, and serial number of the unit. You will find this information on the nameplate mounted on or near to the generator’s control panel.
Safety Information Mobile Generator Repair Notes wc_si000136gb.
Mobile Generator Repair 2. Technical Data Technical Data 2.1 Engine Data—G 25 G 25 0009258, 0009462 0009476 Engine Engine make / type Isuzu Model 4LE1PV Number of cylinders 4 Displacement cm3 (in3) Engine speed rpm 2180 (133) 1800 Power @ 1800 rpm continuous/standby kW/Hp Coolant capacity l (qts.) 11.3 (11.9) Oil capacity l (qts.) 8.0 (8.5) Battery 25.7 (34.5) Volts/CCa 12/650 Fuel type Diesel Fuel tank capacity l (gal.) 216 (57) Fuel consumption, continuous load l/hr (gal.
Technical Data 2.2 Mobile Generator Repair Generator Data—G 25 G 25 0009258, 0009462 0009476 Generator Make/Type Marathon / Brushless Model Generator speed 282PSL1540 rpm 1800 Voltage selector switch 3 position AC voltages available 120/240 zig-zag 120/208 low-wye 277/480 Hi-wye Frequency Power factor 60 Hz 1ø 3ø 1.0 0.8 Voltage regulation ±1.00% Insulation class Sound level at 7 m (23 ft.
Mobile Generator Repair 2.3 Technical Data Trailer and Skid Data—G 25 G 25 0009258, 0009462 0009476 Trailer and Skid Dry weight of skid kg (lbs.) 816 (1800) Operating weight of skid kg (lbs.) 984 (2170) Trailer weight kg (lbs.) 181 (400) GVWR kg (lbs.) 1338 (2995) Surge brakes Tires 2.4 Fluid type DOT3 size ST205/75D-15C Dimensions—G 25 in. (mm) 1956 (77) 889 (35) 1321 (52) 1905 (75) 3302 (130) 1448 (57) wc_gr001647 wc_td000147gb.
Technical Data 2.5 Mobile Generator Repair Engine Data—G 50, G 70, G 85 G 50 0009259 Rev. 114 and lower, 0009463, 0009477 G 70 0009260 Rev. 113 and lower, 0009464, 0009478 G 85 0009310 Engine Engine make / type John Deere / 4.5L Model 4045DF150 Number of cylinders 4045TF150 4 Displacement l (in3) Engine speed rpm 4.5 (274.6) 1800 Power @ 1800 rpm continuous/standby kW/Hp Coolant capacity l (qts.) 22.7 (24) Oil capacity l (qts.) 13.5 (14) Battery 52.
Mobile Generator Repair 2.6 Technical Data Generator Data—G 50, G 70, G 85 G 50 0009259 Rev. 114 and lower, 0009463, 0009477 G 70 0009260 Rev. 113 and lower, 0009464, 0009478 G 85 0009310 Generator Make/Type Marathon/ Brushless Model Generator speed 361PSL1648 rpm 3 position AC voltages available 120/240 zig-zag 120/208 low-wye 277/480 Hi-wye Frequency 60 Hz 1ø 3ø 1.0 0.8 Voltage regulation ±1.00% Insulation class Sound level at 7 m (23 ft.
Technical Data 2.7 Mobile Generator Repair Trailer Technical Data—G 50, G 70, G 85 G 50 0009259 Rev. 114 and lower, 0009463, 0009477 G 70 0009260 Rev. 113 and lower, 0009464, 0009478 G 85 0009310 Trailer and Skid Dry weight of skid kg (lbs.) 1550 (3418) 1583 (3490) 1622 (3576) Operating weight of skid kg (lbs.) 1745 (3848) 1778 (3920) 1817 (4006) Trailer weight kg (lbs.) GVWR Surge brakes Tires wc_td000147gb.fm Single axle 442 (975) Tandem axle 499 (1100) kg (lbs.
Mobile Generator Repair 2.8 Technical Data Dimensions—G 50, G 70, G 85 in. (mm) 965 (38) 2438 (96) 1562 (61.5) 2146 (84.5) 3988 (157) 1524 (60) wc_gr001648 wc_td000147gb.
Technical Data 2.9 Mobile Generator Repair Engine Data—G 125, G 160 G 125 0009261 0620067 0620068 G 160 0009306 0620069 0620070 Engine Engine make / type John Deere / 6.8L Model 6068TF275 Number of cylinders 6068HF275 6 Displacement cm3 (in3) 6800 (414) Engine speed rpm Power @ 1800 rpm continuous/standby kW/Hp 123/165 164/220 Coolant capacity l (qts.) 37.8 (40) 24.2 (25.6) Oil capacity l (qts.) 18.9 (20.0) 32.0 (34.
Mobile Generator Repair Technical Data 2.10 Generator Data—G 125, G 160 G 125 0009261 0620067 0620068 G 160 0009306 0620069 0620070 Generator Make/Type Marathon/ Brushless Model Generator speed 362 PSL 1650 363 PSL 1661 1800 rpm Voltage selector switch 3 position AC voltages available 120/240 zig-zag 120/208 low-wye 277/480 Hi-wye Frequency Power factor 60 Hz 1.0 0.8 1ø 3ø Voltage regulation ±1.00% Insulation class Sound level at 7 m (23 ft.
Technical Data Mobile Generator Repair 2.11 Trailer Technical Data—G 125, G 160 G 125 0009261 0620067 0620068 G 160 0009306 0620069 0620070 Trailer and Skid Dry weight of skid kg (lbs.) 2331 (5140) 2400 (5290) Operating weight of skid kg (lbs.) 3139 (6920) 3207 (7070) Trailer weight kg (lbs.) 649 (1430) GVWR kg (lbs.) 4082 (9000) Surge brakes Fluid type Tires size DOT3 7.50x16 2.
Mobile Generator Repair Technical Data 2.13 Isuzu Engine Performance Data Performance data on Isuzu engines are measured at the following standard conditions: • 29.31 inches of mercury dry air pressure • 600 feet altitude • 0 % relative humidity • 77°F air intake temperature • 104°F fuel inlet temperature Refer to the table to estimate the engine power decrease in percent, as environmental factors vary from the standard conditions. MODEL G 12 G 25 wc_td000147gb.fm FUEL TEMP RISE of 1.
Technical Data Mobile Generator Repair 2.14 John Deere Engine Performance Performance data on John Deere engines are measured at the following standard conditions: • 29.31 inches of mercury dry air pressure • 600 feet altitude • 0 % relative humidity • 77°F air intake temperature • 104°F fuel inlet temperature Refer to the table to estimate the engine power decrease in percent, as environmental factors vary from the standard conditions. wc_td000147gb.
Mobile Generator Repair Technical Data 36 34 32 30 26 24 St an db y 22 70 20 G 16 G 50 G 14 12 5, G 16 0 18 85 G 10 85 Pr im e 12 St an db y 70 Pr im e Engine Power Deration (%) 28 G G 8 6 4 2 0 5 (1,5) 6 (1,8) 7 (2,1) 8 (2,4) 9 (2,75) 10 (3,0) 11 (3,3) 12 (3,6) 13 (4,0) 14 (4,3) 15 (4,6) 16 (4,9) 17 (5,2) wc_gr002863 Altitude x 1000 Feet (meter) MODEL FUEL TEMP RISE of 1.
Maintenance 3. Mobile Generator Repair Maintenance 3.1 Periodic Maintenance Schedule The Periodic Maintenance Schedule below lists basic maintenance intervals for the engine and generator. For detailed maintenance procedures on the engine, refer to the engine Operator's Manual.
Mobile Generator Repair 3.2 Maintenance Resetting the Periodic Maintenance Timer After maintenance has been performed on the generator, it is necessary to reset the periodic maintenance timer. • If the periodic maintenance timer is at zero, press the ENG. HRS switch UP and hold for 10 seconds until the “TIME TO SERVICE” resets to 250 hours. • If the service time is greater than zero (maintenance was performed prior to the timer running out) press and hold the ENG. HRS switch UP and hold for 30 seconds.
Maintenance 3.4 Mobile Generator Repair Engine Lubrication John Deere Engines: Check engine oil daily before starting engine. DO NOT operate engine if oil level is below ADD mark on dipstick. Always keep oil level within the crosshatch pattern or “full” mark on dipstick. Change oil after first 100 hours of operation and every 250 hours thereafter. Refer to the engine Operator’s Manual for lubrication specifications. Break-in Service 3.4.1 This engine is factory-filled with John Deere Engine Break-in Oil.
Mobile Generator Repair 3.5 Engine Coolant WARNING 3.6 Maintenance Check the coolant level of the radiator with the engine cold. After initial filling of radiator to 3/4" below bottom of filler neck, maintain proper level in overflow bottle daily. NEVER remove radiator cap or drain plug while engine is hot! Pressurized coolant can cause serious burns. Shut off engine. Only remove radiator cap when it is cool enough to touch with bare hands.
Maintenance 3.7 Mobile Generator Repair Trailer Wiring—G 25, G 50, G 70, G 85 Ref. Description 1 Front right side amber light 2 Front left side amber light 3 Trailer plug 4 Battery 5 Brake solenoid 6 Right rear taillight 7 License plate holder lights 8 Left rear taillight 9 Rear right side red light 10 Rear left side red light Ref.
Mobile Generator Repair Maintenance Standard and Hydraulic Brakes 1 9 B r B r W W G B r W 3 G W 6 7 B r Y B r 7 B r Y B r 2 W 1 0 B r B r W 8 W w c _ g r0 0 0 5 2 2 Electric Brakes 1 9 Br W Br W W R R 3 R G Y Br W R + G Br W 5 6 W Br 7 Br 7 – 4 R W R R R 5 Y Br W Br W Br W 2 wc_tx000504gb.
Maintenance 3.8 Mobile Generator Repair Trailer Wiring—G 125, G 160 Ref. Description 1 Front right side amber light 2 Front left side amber light 3 Trailer plug 4 Battery 5 Brake solenoid 6 Right rear taillight 7 License plate holder lights 8 Left rear taillight 9 Rear right side red light 10 Rear left side red light Ref.
Mobile Generator Repair Maintenance Standard and Hydraulic Brakes 1 9 B r B r W W G 3 G W 6 B r W 7 B r Y B r 7 B r Y B r 2 W B r 1 0 8 B r W W w c _ g r0 0 0 5 2 2 Electric Brakes 1 2 W B r B r W G R 3 G W 5 R R Y R W + B r W 5 R 7 7 B r W R R 5 Y W 5 9 6 B r 4 R B r W B r W 1 0 B r B r 8 W w c _ g r0 0 1 2 2 6 wc_tx000504gb.
Maintenance Mobile Generator Repair Notes wc_tx000504gb.
Mobile Generator Repair 4. Theory of Operation Theory of Operation 4.1 Introduction See Graphic: wc_gr002915 A generator set is a transducer, which means it converts energy from one form (heat) into another (electrical). The two main components of a generator set are the prime mover (engine) and the generator assembly. The engine converts heat into rotating mechanical energy which is then converted by the generator assembly into electrical energy.
Theory of Operation 4.2 Mobile Generator Repair Basic Generator Schematic h f T1 L1 b c d 3-Phase AC out DC in T4 e T7 T10 T12 T11 a T8 T5 L2 T2 3-Phase AC output GND DC in B T9 T6 R T3 L3 g B N F+ 4 F- 3 DC out (exciter field) B Br j AC in (load sensing) 6 B 7 Br i W k l wc_gr002915 Ref. Component Ref.
Mobile Generator Repair 4.3 Theory of Operation Generator Components c Cross section d e b f a i h g Sample rotor assembly a e d g f i wc_gr002916 Ref. Component Ref. Component a Rotating rectifier f Drive disc b Main stator AC output g Exciter rotor (windings) (3 phase) c Main stator (windings) h Exciter stator (field) d Main rotor (field) i Bearing e Cooling fan wc_tx000505gb.
Theory of Operation 4.
Mobile Generator Repair Theory of Operation Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue See Graphic: wc_gr002854 Ref. Description Ref.
Theory of Operation Mobile Generator Repair G 50, G 70, G 85, G 125, G 160 2 44 24 1 13 23 14 16 18 6 6 11 13 9 15 17 5 Br 14 10 12 12 Br 25 13 26 7 7 17 LL LL LL G/Y G/Y G/Y LL G/Y G/Y Br 3 19 T9 Br T7 44 4 Br 6 10 8 B 23 B 24 X G 7 B B Y W 5 4 B B 9 B 21 B 22 X 2 1 B B 9 B 20 B 10 8 B B B B 18 LL Y G 11 W X Y (20) G 11 W CT-1 CT-2 CT-3 L0 T7 T9 L1 L2 L0 L3 B T9 20 T4 B 12 B 1 2 5 6 9 17 13 10 14 18 25 21 22 26 4 3 41 L3 Or
Mobile Generator Repair Theory of Operation Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue See Graphic: wc_gr002917 Ref. Description Ref.
Theory of Operation 4.5 Mobile Generator Repair Generator Systems The generator can be divided into four basic systems: 1) Power Generation and Output. This system includes the generator, voltage selector switch, receptacles, customer connect lugs and circuit breakers. 2) Voltage Regulation. Consisting primarily of the voltage regulator and exciter field winding, this system controls the voltage output of the generator. 3) Engine Start.
Mobile Generator Repair 4.6 Theory of Operation Power Generation & Output See Graphic: wc_gr002915 General Operation The figure shows the basic configuration of the generator. This configuration remains the same for all generator sizes and models. The exciter stator (a) is designed to be the primary source of the generator’s residual magnetism.
Theory of Operation Mobile Generator Repair See Graphic: wc_gr002767 Voltage Selector Switch (VSS) The VSS changes connections between the six main windings to form three different configurations: • High Wye (277/480V 3Ø) • Low Wye (120/208V 3Ø) • Zig-Zag (120/240V 1Ø) The main stator windings connect to one side of the VSS at the terminals. Output leads from the other side of the VSS are directed through the current transformers and then to both the main circuit breaker and the receptacles.
Mobile Generator Repair Theory of Operation G 25/50/70/85/125/160 L1 208 120 T1 T4 High Wye 480 277 T7 20A GFI L1–L2 = 480V L1–N = 277V L2–L3 = 480V L2–N = 277V L3–L1 = 480V L3–N = 277V N T11 T12 T9 T8 T6 T5 T2 T3 L3 L1 T7 208 120 T1 Low Wye T4 T10 N T12 T9 L3 T6 480 277 L–L T5 T8 L2 Zig Zag 208 120 T8 T12 T2 T3 T11 T10 T7 T4 T1 N L3 L1 T5 T9 120V 120V 240V *139/240V *139/240V 120V 120/208V 120/208V or or or *139V *139/240V *139/240V 120V 120/240V N
Theory of Operation Mobile Generator Repair See Graphic: wc_gr002775 Terminal Lugs and Receptacles The main connection lugs, labeled L1, L2, L3, and N are connected through the main circuit breaker (b) and then the voltage selector switch (a) back to the main stator windings. These lugs provide the primary connection points for attachment of outside loads.
Mobile Generator Repair 4.7 Theory of Operation Voltage Regulation See Graphic: wc_gr002776 and wc_gr002777 The Automatic Voltage Regulator (AVR) (a) is an encapsulated electronic control device that is rectangular in shape and located inside the control box on the right side wall. Its function is to maintain constant generator voltage over varying load conditions. The voltage regulator controls generator voltage by sensing AC voltage from the main stator winding at terminals 3 and 4.
Theory of Operation Mobile Generator Repair See Graphic: wc_gr0002778 Regulator Makeup There are eight terminals on the regulator labeled 3, 4, F+, F-, 6, 7, 50 Hz, and 60 Hz. Note: A new replacement regulator comes with a jumper across terminals 6 and 7 which must be removed before the regulator is used. • Terminals 3 and 4 Brown stator wires T7 and T9 are connected to regulator terminals 3 and 4 respectively, for all voltage selector switch positions.
Mobile Generator Repair • Theory of Operation Terminals 50Hz and 60Hz There is an white jumper wire connected (at the factory) to the 60Hz terminal. If 50Hz is required, the jumper will have to be moved to the 50Hz terminal. The position of this jumper tells the regulator where the coarse Under Frequency roll off (U/F) point is. On a 60Hz unit the U/F point is 58Hz. On a 50Hz unit the U/F point is 48Hz.
Theory of Operation Mobile Generator Repair See Graphic: wc_gr002769 Voltage Adjusting Rheostat Generator output voltage can be adjusted using the 2.5k Ohm voltage adjusting rheostat (a). The 2.5k Ohm voltage adjusting rheostat is not part of the voltage regulator. It is connected to the regulator at terminals 6 and 7. The voltage adjustment range is +10% to -10% of the selected voltage. CAUTION: Do not turn the voltage beyond 490VAC; damage to the excitation circuit will occur. 4.7.0.
Mobile Generator Repair 4.8 Theory of Operation Engine Start Battery B+ wires provide 12VDC to the following locations on each generator: • Isuzu-powered generators: starter motor, glow plug relay, starter relay, and terminal strip. • John Deere without Engine Control Unit (ECU): starter motor, starter relay, terminal strip, alternator, and preheat relay. • John Deere with ECU: ECU and terminal strip.
Theory of Operation Mobile Generator Repair In the START/RUN position the ECM preheat relay will energize on the first of the three cranking cycles if coolant temperature (fuel temperature on John Deere powered generators) dictates. The ECM preheat relay supplies 12VDC through gray wire #65 to the glow plug relay on Isuzu-powered generators, intake air heater relay on John Deere (without ECU) powered generators. On John Deere engines with ECU, the ECU controls power to the intake air heater relay.
Mobile Generator Repair 4.9 Theory of Operation ECM Monitoring System Operation The ECM contains a microprocessor that monitors engine safety inputs. It protects the engine by automatically shutting it down in the event of low oil pressure, high coolant temperature, high engine speed, or low engine speed. The ECM is programmed at the factory and does not require any adjustment.
Theory of Operation Mobile Generator Repair The shutdown trip point is approximately 67Hz (2010 rpm) for overspeed and 55Hz (1650 rpm) for underspeed. If engine speed exceeds 67Hz or falls below 55Hz, the ECM opens the fuel relay circuit and stops the engine. Overcrank The frequency signal is also used to determine an overcrank condition.
Mobile Generator Repair Theory of Operation See Graphic: wc_gr002779 Current Transformers Load line current values are provided by three current transformers (CT1, CT2, and CT3). Power lines to the main connection lugs and receptacles run through the current transformers. The current transformers sense line current and send an equivalent voltage to the ECM through the brown, yellow, white, and orange wires connected to plug 3.
ECM Troubleshooting 5. Mobile Generator Repair ECM Troubleshooting 5.1 Normal Boot-up Sequence During the boot-up sequence, the ECM scrolls through several screens before it settles into displaying the run screen. There are two different boot-up sequences depending on size of the generator and options included on the generator. 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.
Mobile Generator Repair ECM Troubleshooting 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 model displayed does not match the model of the generator, call Wacker Service. Initializing G 85 Time to Service 250 Cranking 1 of 3 80 71 P2 75% 0 87 60.0 12.7 Under Frequency Enabled 480 P2 71 75% 0 87 60.0 12.7 Engine Protection Enabled wc_tx000506gb.
ECM Troubleshooting AC Configuration Alt Protection Enabled Rated Volts L to L 480 P2 71 75% 0 87 60.0 12.7 Mobile Generator Repair The ECM displays the AC configuration as determined by the position of the voltage selector switch (VSS). The ECM displays this screen to let the operator know that the alternator protection system has been enabled. The ECM displays the line-to-line voltage. (This screen is shown for 3-phase VSS positions only.
Mobile Generator Repair 5.2 ECM Troubleshooting 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). • Engine Variables The values shown in the lower line of the ECM display are all variables from the engine side of the machine.
ECM Troubleshooting 2 1 481 71 5 Mobile Generator Repair 3 P2 24% 4 0 60.0 87 12.7 6 7 8 wc_gr002944 5.3 ECM Display Screens—Start Switch in Remote Position See Graphic: wc_gr002943 When the start switch is placed in the REMOTE position, the following screens are displayed. 5.3.1 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 Service. 5.3.
Mobile Generator Repair 5.4 ECM Troubleshooting Additional Variables Monitored by the ECM Holding the toggle switch in the HOURS/RESET position allows the operator to view additional variables monitored by the ECM. It also allows the time-to-service countdown timer to be reset. To reset the countdown timer, hold the toggle switch in the HOURS/RESET position for approximately 30 seconds or until all the screens have been scrolled through twice. There are three different sets of additional variables.
ECM Troubleshooting Mobile Generator Repair Oil Pressure Sender OK The display shows the status of the oil pressure sender. If the oil pressure sender has failed, the time of the failure will be displayed. The time of the failure will be included in the display until the generator has been shut down and remains shutdown for a period of approximately two minutes. Water Temp Sender OK The display shows the status of the engine coolant temperature sender.
Mobile Generator Repair Speed Sender Status is Normal ECM Troubleshooting The display shows the status of the speed sender. If the speed sender has failed, the time of the failure will be displayed. The time of the failure will be included in the display until the generator has been shut down and remains shutdown for a period of approximately two minutes. At that time the ECM clears itself. 60.0 Hz Nominal No.
ECM Troubleshooting Fault Settings 5 Sec @ < 15 psi Service Time Reset to 250 Hrs Prealarm Setting Level < 70 F Mobile Generator Repair The display shows the value of the fault setting for low oil pressure. If the ECM detects that the engine oil pressure is less than 15 psi for longer than 15 seconds, the ECM will shut down the generator. The display shows this screen if the time to service timer has been reset to 250 hours.
Mobile Generator Repair ECM Troubleshooting 12 Volt Battery Status is Normal The display shows the status of the battery. When the battery voltage is within its “normal” range, 12 –15V, the ECM displays the voltage value in 1/10V increments on the run screen. Prealarm Setting Level < 12.0 V The display shows the battery low-voltage prealarm setting. When the ECM detects that battery voltage is less than 12V, the battery voltage reading on the run screen will blink. Prealarm Setting Level > 15.
ECM Troubleshooting Load @RPM 15% Engine Torque 60% Mobile Generator Repair The display shows the present load on the engine. For no load conditions (generator not powering any outside tools or equipment) the display will read 15%. The display shows the percentage of total engine torque being used. The display shows, in °F, the temperature of the fuel. Fuel Temperature 86° F The display shows, in psi, fuel pressure. Fuel Pressure 147 Fuel Rate 0.9 GPH Manifold Temp 95°F wc_tx000506gb.
Mobile Generator Repair 5.5 ECM Troubleshooting CAN Bus Code Screen For John Deere engines with electronic control (G 85, G 125, G160), the Engine Control Unit (ECU) communicates with the Engine Control Module (ECM) through a Controller Area Network (CAN). The wiring between the controllers forms a bus (physical electrical interface where many devices share the same electrical connections).
ECM Troubleshooting 5.6 Mobile Generator Repair Voltage Display Errors See Graphic: wc_gr002770 • Single Phase Display Mode The ECM is programmed to display line-to-line voltage values for both three-phase voltage selector switch positions. For example, if the voltage selector switch is in the 277/480V position, voltage values will read 480V on all three legs. However, when operating in the single phase 120/240V position, line-to-line voltage will only be displayed for leg 2 (240V).
Mobile Generator Repair • ECM Troubleshooting Engine Hour Switch in Locked Position Another possible display error can occur when starting the machine with the engine hour switch (a) in its down or 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. On some generators, starting the engine with the switch in its locked (down) position will reverse the display for volts and amps.
ECM Troubleshooting 5.7 Mobile Generator Repair ECM Automatic Engine Shutdown Conditions The engine protection system includes six automatic shutdown conditions: low oil pressure, high coolant temperature, engine under/ 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 you in diagnosing the problem.
Mobile Generator Repair ECM Troubleshooting If the pressure gauge reads differently than the ECM, there is a problem with the sender or the ECM. 5.7.1.4 With a multimeter, check the continuity of the wire between the sender and the ECM. If the resistance measures “OL”, “OPEN”, or more than 1 Ohm, replace the wire. 5.7.1.5 Clean buildup from the end of the sender and check the sender’s resistance. A functioning sender will measure 240±10 Ohms outside of the engine.
ECM Troubleshooting 5.7.2 Mobile Generator Repair High Coolant Temperature Fault FAULT HIGH ENGINE TEMPERATURE 255 See Graphic: wc_gr001982, wc_gr001983, and wc_gr002083 When the ECM display reads “FAULT HIGH ENGINE TEMPERATURE” or similar, it signifies that engine coolant temperature has risen above safe levels. The temperature at which the ECM will shut down the engine is 239°F (115°C) for John Deere engines, 221°F (105°C) for Isuzu engines.
Mobile Generator Repair ECM Troubleshooting 5.7.2.4 Check the function of the ECM by attaching varying loads of resistance on one end of the temperature sender wiring and the other end to ground. This can be done by attaching varying resistors or through a potentiometer (an extra voltage adjustment rheostat similar to the one mounted on the control panel may be used.) Calibrate the rheostat by attaching the leads of a multimeter to it and turning the rheostat’s adjusting knob.
ECM Troubleshooting 5.7.3 Mobile Generator Repair Overspeed/Underspeed Shutdown Fault FAULT UNDERSPEED FAULT OVERSPEED See Graphic: wc_gr001984 and wc_gr002780 When the ECM display reads “FAULT OVERSPEED” or similar, it indicates that the engine speed exceeded approximately 2130 rpm (118% of its rated speed of 1800 rpm) and the ECM has automatically shut down the engine.
Mobile Generator Repair 5.7.4 ECM Troubleshooting Overcrank Shutdown Fault FAULT OVERCRANK To rectify an overcrank condition, carry out the engine troubleshooting procedures found in this manual. Note: An overcrank condition can occur even when the engine does not crank. This happens if a failure in one of the relays prevents the engine from cranking, allowing the ECM to time out. To reset the ECM, turn the start switch to OFF, then back to START/RUN, and retry starting the engine.
ECM Troubleshooting 5.7.5 Mobile Generator Repair Low Fuel Shutdown Fault FAULT LOW FUEL See Graphic: wc_gr002084 A low fuel fault condition will be displayed when the fuel level drops to 5% of capacity and the ECM has shut down the engine. This fault condition prevents the fuel lines from running completely dry and avoids the need to bleed the lines when the tank is refilled. To diagnose and rectify fault: 5.7.5.1 With a multimeter, check the continuity of the wire between the sender and the ECM.
Mobile Generator Repair 5.7.6 ECM Troubleshooting Over Current Shutdown Fault FAULT OVERLOAD Along with engine functions, the ECM continuously monitors the current load in each leg. The values for current overload are programmed into the ECM at the factory and are different for each generator size. When an overload condition is sensed in any leg, the engine will shut down and the ECM displays “FAULT OVERLOAD” or similar.
ECM Troubleshooting 5.8 Mobile Generator Repair Sender Failures Oil Sender Failure SPN PREALARM Check Diagnostic If one of the sensors should malfunction or become shorted to ground, the ECM LCD will display a message similar to one of those shown above. The yellow caution LED on the front of the control panel will also illuminate. The value for the variable may go blank. Check the wiring to the sensor and the sensor before using the generator. 5.
Mobile Generator Repair ECM Troubleshooting a 208 L1 b c d wc_gr002771 wc_tx000506gb.
ECM Troubleshooting Mobile Generator Repair See Graphic: wc_gr002772 5.9.2 To recalibrate the ECM AC amperage display: 5.9.2.1 Start the generator and place one of the receptacle circuit breakers in the ON position. Plug in a load of 10A or greater on G12 and G25 models; 20A or greater on G50 and larger models. Or, connect an appropriately-sized load bank to the generator. Attach a clamp-type ammeter to one of the load wires (not more than one load wire or your readings will be inaccurate). 5.9.2.
Mobile Generator Repair ECM Troubleshooting See Graphic: wc_gr002795 5.9.3 To recalibrate the ECM AC frequency (Hz) display: Note: Recalibrate only if your unit is off by more than 5Hz. 5.9.3.1 Start the generator. Using a tachometer or vibrotach, adjust the engine speed to 1800 rpm or 60Hz. 5.9.3.2 Open the control panel to gain access to the ECM. Monitor the ECM display panel as adjustments are made. 5.9.3.3 Locate the AC frequency push button (a).
ECM Troubleshooting Mobile Generator Repair See Graphic: wc_gr002796 and wc_gr002971 Isuzu and John Deere engines without ECU 5.9.4 To recalibrate ECM DC voltage (12V battery) display: 5.9.4.1 Start the generator. Open the control panel to gain access to the ECM. Monitor the ECM display panel as adjustments are made. 5.9.4.2 Using a multimeter, measure the voltage across the 12V machine battery.
Mobile Generator Repair ECM Troubleshooting 5.10 Removing and Installing the ECM See Graphic: wc_gr002797 Removal: 5.10.1 Remove the nut securing the hour meter switch (a) and the nut securing the start switch (b) to the panel. 5.10.2 Remove the screws (c) securing the ECM to the panel. 5.10.3 Disconnect the four harness plugs (e). 5.10.4 Remove the three red wires (d) from the start switch. Remove the start switch, hour meter switch, and the ECM from the panel.
ECM Troubleshooting Mobile Generator Repair 5.11 ECM Circuit Boards a a 4 3 2 1 6 5 4 3 2 1 654 321 P3 b b P4 4 3 2 1 6 5 4 3 2 1 12 1110 9 8 7 6 5 4 3 2 1 43 21 12 1110 9 6 5 4 3 87 21 8 7 6 5 4 3 2 1 e 8765 43 2 1 c P1 12 1110 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 d P2 wc_gr002924 Note: Your machine’s ECM board may differ slightly from the one pictured. Ref. wc_tx000506gb.
Mobile Generator Repair ECM Troubleshooting 5.12 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.
ECM Troubleshooting Mobile Generator Repair 3 Orange Voltage line input L3 at volt selector #28 4 Yellow Voltage line input L2 at volt selector #20 G 50/70/85 Control Module Plug 1: Engine Sender Inputs (12-pin connector) 1 Black Magnetic pickup 2 Clear, shield Magnetic pickup 3 White/Black Oil pressure sender 5 Yellow Water temperature sender 7 Red Run/Off/Auto switch, +12V (positive) 8 Black 12VDC supply, - ground (negative) 10 Orange Remote start contacts 11 Green Emergency
Mobile Generator Repair ECM Troubleshooting G 125/160 Control Module Plug 1: Engine Sender Inputs (12-pin connector) 3 White/Blue Crank delay, preheat 5 - - 7 Red Run/Off/Auto switch, +12V (positive) 8 Black 12VDC supply, - ground (negative) 9 Orange Remote start contacts 10 Gray Emergency stop pushbutton 12 White/Violet Fuel level sender Plug 2: Engine Start Input/Outputs (8-pin connector) 1 Yellow Out; 12VDC to starter relay 2 Violet Out; 12VDC to E-stop switch 5 Red In; 12V
ECM Troubleshooting Mobile Generator Repair 5.13 Sender Resistance Graphs 5.13.1 Fuel Sender 300 250 a 230 200 Ohm 150 100 33 50 b 0 0 20 40 60 80 100 5 120 104 Fuel Level % wc_gr002081 a = shutdown point, 5% b = full, 104% 5.13.2 Oil Sender 300 250 Ohm 200 a 175 150 b 100 50 0 0 20 40 15 60 80 PSI a = shutdown point, 175 psi (12 bar) b = normal operating pressure, 50 psi (3.4 bar) wc_tx000506gb.
Mobile Generator Repair 5.13.3 ECM Troubleshooting Temperature Sender 1000 800 Ohm 600 400 200 100 0 a 50 100 150 ˚F a = approximate normal operating temperature b = approximate shut down temperature wc_tx000506gb.
ECM Troubleshooting Mobile Generator Repair 5.14 Checking Magnetic Pickup See Graphic: wc_gr002114 The magnetic pickup is a magnet with a coil of wire wrapped around it. It sends an AC signal to the ECM when the engine turns. The ECM determines rpm by counting the AC voltage sine waves generated every time a flywheel tooth passes underneath the magnetic pickup. When the ECM sees that the engine has reached 100 rpm, the ECM discontinues cranking the starter motor. wc_tx000506gb.fm 5.14.
Mobile Generator Repair 6. Isuzu Engine Troubleshooting Isuzu Engine Troubleshooting 6.1 Isuzu Engine Background See Graphic: wc_gr002003 The Isuzu engines use individual cylinder glow plugs as a starting aid. An electric fuel lift pump and an electro-mechanical fuel solenoid are used for engine run/stop control. The glow plugs are located near the top of the engine, and protrude into each cylinder, one per cylinder.
Isuzu Engine Troubleshooting 6.2 Mobile Generator Repair Engine Wiring Diagram—Isuzu This schematic will be referred to throughout this chapter.
Mobile Generator Repair 6.3 Ref. Isuzu Engine Troubleshooting Engine Wiring Components—Isuzu Component Ref.
Isuzu Engine Troubleshooting 6.4 Mobile Generator Repair Engine Electrical Component Locations—Isuzu 11 19 5 4 8 3 10 7 6 9 2 12 18 17 13 15 wc_gr002834 wc_tx000507gb.
Mobile Generator Repair 6.5 Isuzu Engine Troubleshooting Engine Electrical Components—Isuzu See Graphic: wc_gr002834 Ref. Component Ref.
Isuzu Engine Troubleshooting 6.7 Mobile Generator Repair Engine Troubleshooting—Isuzu Engine Does Not Crank Engine Troubleshooting Check position of emergency stop switch. Is the switch in the correct position? Flowchart 1A Isuzu Pull the switch out. No * Battery voltage approximately 12V Yes Checking ECM Display and LEDs Place the start switch in the START/RUN position. Is the ECM illuminated? Yes Does the ECM boot up and are the LEDs lit? No Repair or replace ECM.
Mobile Generator Repair Isuzu Engine Troubleshooting Engine Troubleshooting Flowchart 1B Isuzu Engine does not Crank Continued from Flowchart 1A * Battery voltage approximately 12V Checking contacts of ECM crank relay Check for 12VDC at red wire #18 at ECM pin 5, plug 2. Is there 12VDC* on red wire #18? Yes No Repair or replace ECM. Check for 12VDC at yellow wire #63 at ECM pin 1, plug 2.
Isuzu Engine Troubleshooting Mobile Generator Repair Engine does not crank Continued from Flowchart 1B Engine Troubleshooting Checking coil of starter relay and wiring Flowchart 1C Isuzu * Battery voltage approximately 12V Place starter switch in the START/RUN position. During cranking, check for 12VDC* at terminal 86 of starter relay. Is 12VDC* measured at terminal 86? No Check continuity of yellow wire #63 between ECM pin 1, plug 2 and relay terminal 86. Repair wire as required.
Mobile Generator Repair 6.8 Isuzu Engine Troubleshooting Checking Wire Continuity When checking the continuity of a wire, use the Ohms scale on your checking instrument (multimeter). A reading of less than one Ohm means the wire has continuity and should be OK. A reading over one Ohm usually means that the wire or connectors are corroded and should be repaired or replaced. A reading of “OL” or “OPEN” means the wire is broken and there is no continuity. In such cases, repair or replace the wire. 6.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.10 Checking ECM Display and LEDs See Graphic: wc_gr002835 After placing the start switch in the START/RUN position, the ECM goes through a boot-up sequence. On early machines the ECM displays “Preheating”, then “Cranking”. Later model machines display “Initializing...”, “Time to Service”, and then “Cranking _ of 3”. During the preheat cycle (heater activation), the LED (b) near the stop sign illuminates.
Mobile Generator Repair Isuzu Engine Troubleshooting b a c wc_gr002835 6.11 Checking Battery The ECM display may or may not be blank when battery voltage is less than 12V. During such a condition, the battery may be charged enough to light the display, but not enough to fully crank the starter. wc_tx000507gb.fm 6.11.1 Check that battery cable connections are tight. 6.11.2 Check battery terminals for corrosion. Clean the terminals if necessary.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.12 Checking Power to ECM See Graphic: wc_gr002833 and wc_gr002836 6.12.1 6.12.2 6.12.3 6.12.4 6.12.5 6.12.6 6.12.7 6.12.8 wc_tx000507gb.fm Place the start switch (6) in the START/RUN position and check for 12VDC (battery voltage approximately 12V) between red wire #53 at ECM pin 7, plug 1 and ground. • If 12VDC is measured, the ECM is receiving power. Go to step 8. • If 12VDC is not measured, continue.
Mobile Generator Repair 6 5 4 3 2 1 P3 Isuzu Engine Troubleshooting 4 3 2 1 654 321 P4 4 3 2 1 6 5 4 3 2 1 12 1110 9 8 7 6 5 4 3 2 1 43 21 12 1110 9 6 5 4 3 87 21 8765 43 2 1 8 7 6 5 4 3 2 1 P1 12 1110 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 P2 b a c e d wc_gr002836 wc_tx000507gb.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.13 Checking Contacts of ECM Crank Relay See Graphic: wc_gr002833 and wc_gr002829 When the start switch is placed in the START/RUN position, the ECM crank relay (c) energizes. The ECM crank relay supplies 12VDC through yellow wire #63 to energize the starter relay (14). 6.13.1 6.13.2 6.13.3 6.13.4 6.13.5 Check for 12VDC (battery voltage approximately 12V) between red wire #18 at pin 5, plug 2 and ground.
Mobile Generator Repair Isuzu Engine Troubleshooting 6.14 Checking ECM 10A Fuse See Graphic: wc_gr001987 The 10A fuse is found in the control compartment on G25 models (a). It is found in the engine compartment on all other models (b). There is 12VDC fed through this fuse to the ECM fuel and crank relay contacts via ECM pin 5, plug 2. If the fuse repeatedly blows, it is a sign that there is a short in the wires to/from the ECM, a diode is faulty, or the fuel or starter relay is shorted. 6.14.1 6.14.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.15 Checking Coil of Starter Relay and Wiring See Graphic: wc_gr002833 and wc_gr002848 6.15.1 6.15.2 6.15.3 Place the start switch in the START/RUN position. During the cranking cycle, check for 12VDC (battery voltage approximately 12V) between yellow wire #63 at terminal 86 of the starter relay (a) (16) and ground. • If 12VDC is measured, the starter relay is receiving power. • If 12VDC is not measured, continue.
Mobile Generator Repair Isuzu Engine Troubleshooting 6.16 Checking Diode Across Relay/Solenoid Coil See Graphic: wc_gr002803 The glow plug relay (a) and the fuel solenoid (b) on Isuzu powered generators, and the starter relay (c) (and fuel solenoid (d) on John Deere engines without the Engine Control Unit (ECU)), all have a diode (e) similar to the one pictured connected across the coil. The diodes are encapsulated in rubber.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.17 Checking Contacts of Starter Relay See Graphic: wc_gr002922 The starter relay coil and its wiring must be functioning properly before checking the starter relay contacts. See section Checking Coil of Starter Relay and Wiring. 6.17.1 6.17.2 6.17.3 Check for 12VDC (battery voltage approximately 12V) between the red wire at terminal 30 of the starter relay (a) and ground.
Mobile Generator Repair Isuzu Engine Troubleshooting 6.18 Engine Cranks But Does Not Start—Isuzu Engine Cranks but does not Start Engine Troubleshooting Flowchart 1D Isuzu Check fuel system: fuel supply, filter, condition of tank, and hoses. * Battery voltage approximately 12V Checking Power to Glow Plugs Place start switch in START/RUN position. Check red wire #12 for 12VDC* during preheat cycle. Checking Glow Plugs Is 12VDC* measured? Yes Place start switch in the OFF position.
Isuzu Engine Troubleshooting Engine Cranks but does not Start Continued from Flowchart 1D Mobile Generator Repair Engine Troubleshooting Flowchart 1E Isuzu Checking fuel pump and power to fuel pump * Battery voltage approximately 12V Check 10A fuse to fuel pump. Replace fuse as needed. Check for 12VDC* at the fuel pump. Is there 12VDC*at fuel pump? No See Flowchart 1H Yes Check continuity of black wire from pump to ground. Does the black wire have continuity? No Repair/replace wire as needed.
Mobile Generator Repair Isuzu Engine Troubleshooting Engine Troubleshooting Flowchart 1F Isuzu Engine Cranks but does not Start Continued from Flowchart 1E * Battery voltage approximately 12V Checking solenoid hold-in voltage. Check 25A fuse to fuel pump. Replace fuse as needed. Disconnect the fuel solenoid at the connector. Check for 12VDC* between red wire #28 and ground during the cranking cycle. Is 12VDC* measured? Check continuity of red wire #28. Repair/replace wire as needed.
Isuzu Engine Troubleshooting Mobile Generator Repair Engine Troubleshooting Engine Cranks but does not Start Continued from Flowchart 1F Flowchart 1G Isuzu Checking fuel solenoid. Place the start switch in the OFF position. Allow the machine to cool. Remove the fuel solenoid from the injection pump and perform the following: * Battery voltage approximately 12V Check for free plunger movement by pushing the plunger into the solenoid and allowing it to spring back.
Mobile Generator Repair Isuzu Engine Troubleshooting Engine Troubleshooting Flowchart 1H Isuzu Engine Cranks but does not Start Continued from Flowchart 1E * Battery voltage approximately 12V Checking coil of fuel pump relay Check for 12VDC* during cranking period on violet wire #34 at terminal 86 of the fuel pump relay. Is 12VDC* measured? No Check continuity of violet wires #64 and #34 from ECM pin 2, plug 2 through emergency stop switch to terminal 86 of fuel pump relay.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.19 Checking Power to Glow Plugs See Graphic: wc_gr002833 and wc_gr002841 6.19.1 Place the start switch in the START/RUN position. Check for 12VDC between red wire #12 (a) at the glow plug(s) (b) and ground during the preheat cycle. 6.19.2 • If 12VDC is measured, the glow plugs are receiving power; go to step 3. • If 12VDC is not measured, continue. Place the start switch in the OFF position.
Mobile Generator Repair Isuzu Engine Troubleshooting 6.20 Checking Glow Plugs See Graphic: wc_gr002033 6.20.1 WARNING 6.20.2 Remove the glow plug from the engine. Burn hazard. Glow plugs can reach temperatures up to 1200°F (649°C). Do not touch the element of the glow plug. Be extremely careful when testing the glow plug. Using 10-gauge wire, apply 12VDC to the glow plug—positive on the upper portion and ground the base. If the glow plug does not heat (glow) within five seconds, replace the glow plug.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.21 Checking Glow Plug Relay and Wiring See Graphic: wc_gr002833 and wc_gr002838 The glow plug relay (a) is the chrome “can-style” relay located inside the engine compartment. 6.21.1 Check power to the coil of the relay by measuring voltage (battery voltage approximately 12V) between terminal CP and ground during the preheat cycle. • If 12VDC is not measured, check the continuity of gray wire #65 between terminal CP and ECM pin 8, plug 2.
Mobile Generator Repair Isuzu Engine Troubleshooting 6.22 Checking Contacts of ECM Preheat Relay See Graphic: wc_gr002833 and wc_gr002936 The ECM includes an onboard preheat relay (a) which is located on on the lower board, behind the crank and fuel relays. To test the function of its contacts carry out the following procedure: 6.22.1 6.22.2 Probe ECM pin 7, plug 2 (b) at red wire #17 for 12VDC (battery voltage approximately 12V). Measure between red wire #17 to pin 7, plug 2 and ground.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.23 Checking Power to and Operation of Fuel Pump See Graphic: wc_gr002833 and wc_gr002842 The 12VDC fuel pump (8) (d) is shaped like a small in-line fuel filter and is gold in color. It is located on the “clean” side of the fuel filter and fastened to the side of the engine. The 12VDC fuel pump pulls fuel up from the storage tank, through the fuel filter, and then pushes it into the injection pump. wc_tx000507gb.fm 6.23.
Mobile Generator Repair Isuzu Engine Troubleshooting e a d c b wc_gr002842 wc_tx000507gb.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.24 Isuzu Fuel Solenoid See Graphic: wc_gr002833, wc_gr002844, and wc_gr002031 The fuel solenoid (a) is a gold-colored, cylinder-shaped electromechanical device that moves a fuel control lever inside the injection pump. It is fastened to the side of the injection pump housing. When energized, the solenoid plunger overcomes a spring and is drawn into the solenoid magnetically.
Mobile Generator Repair Isuzu Engine Troubleshooting a wc_gr002844 wc_tx000507gb.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.25 Checking Fuel Solenoid See Graphic: wc_gr002833 and wc_gr002852 6.25.1 Check the 25A fuse (11) (d). Replace the fuse if it is blown. 6.25.2 Place the start switch in the START/RUN position and check for 12VDC (battery voltage approximately 12V) between red wire #28 at the fuel solenoid plug and ground. Also check the continuity of the solenoid plug (f). Repair/replace the wiring or plug as needed. 6.25.
Mobile Generator Repair e a Isuzu Engine Troubleshooting c f g b d wc_gr002852 wc_tx000507gb.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.26 Checking Coil of Fuel Pump Relay See Graphic: wc_gr002843 6.26.1 6.26.2 6.26.3 6.26.4 6.26.5 6.26.6 wc_tx000507gb.fm Place the start switch in the START/RUN position and check for 12VDC (battery voltage approximately 12V) during the cranking cycle between violet wire #34 at terminal 86 of the fuel pump relay (a) and ground. • If 12VDC is not measured, go to step 3.
Mobile Generator Repair Isuzu Engine Troubleshooting 654 321 a 12 1110 9 6 5 4 3 87 21 85 30 86 P1 43 21 8765 43 2 1 P2 a b 87 c a wc_gr002843 wc_tx000507gb.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.27 Checking Contacts of ECM Fuel Relay See Graphic: wc_gr002833 and wc_gr002864 The ECM has an on-board fuel relay (a) which controls power to the coil of the fuel pump relay (15) (b). When energized, the fuel pump relay switches 12VDC through a 10A fuse (10) (c) to the fuel pump (d). 6.27.1 Place the start switch in the START/RUN position and probe pin 2, plug 2 for 12VDC (battery voltage approximately 12V). Measure between pin 2, plug 2 and ground.
Mobile Generator Repair Isuzu Engine Troubleshooting 6.28 Checking Contacts of Fuel Pump Relay See Graphic: wc_gr002833 and wc_gr002842 6.28.1 6.28.2 Check for 12VDC (battery voltage approximately 12V) between terminal 30 of the fuel pump relay (15) (a) and ground. • If 12VDC is not measured, check the continuity of red wire #31 from terminal 30 of the fuel pump relay to B+ terminal of the glow plug relay (14) (b). Repair/replace the wire as needed.
Isuzu Engine Troubleshooting Mobile Generator Repair 6.29 General Engine Troubleshooting—Isuzu Symptom Problem Solution Engine does not crank Discharged battery Recharge or replace battery. Defective battery cable connections Replace or repair cables. Defective starter and/or wiring Repair or replace starter and wiring. Exhaust restricted Check and correct exhaust restriction. Fuel filter plugged or full of water Replace fuel filter or drain water from filter.
Mobile Generator Repair Isuzu Engine Troubleshooting Symptom Problem Solution Engine hard to start or will not start Engine starting under load Place all circuit breakers in OFF positions. No fuel Check fuel tank and hoses. Air in fuel line Bleed fuel line. Cold weather Use cold weather starting aids. Crankcase oil too heavy Use oil of proper viscosity. Improper fuel type Use proper fuel type for operating conditions.
Isuzu Engine Troubleshooting Mobile Generator Repair Symptom Problem Solution Engine runs irregularly or stalls frequently Low coolant temperature Remove and check thermostat. Clogged fuel filter Replace fuel filter element. Water, dirt, or air in fuel system Drain, flush, fill, and bleed system. Dirty or faulty injection nozzles Have authorized servicing dealer or engine distributor check injectors. Engine overloaded Reduce load. Intake air restriction Service air cleaner.
Mobile Generator Repair Isuzu Engine Troubleshooting Symptom Problem Solution Engine emits black smoke. Improper fuel type Use proper fuel. Clogged or dirty air cleaner Service air cleaner. Engine overheats Engine overloaded Reduce load. Injection nozzles dirty See authorized dealer or distributor. Engine out of time See authorized dealer or distributor. Engine overloaded Reduce load. Low coolant level Fill radiator to proper level.
Isuzu Engine Troubleshooting Notes wc_tx000507gb.
Mobile Generator Repair 7. John Deere Engines without ECU John Deere Engines without ECU 7.1 John Deere Engine Background See Graphic: wc_gr002004 The John Deere engines used on generator models G 50, G 70, and G 85 (item 0009310) do not include an electronic Engine Control Unit (ECU). These engines use a mechanical fuel pump, an intake air heater as a starting aid, and an internal electric fuel valve for engine run/stop control.
John Deere Engines without ECU 7.2 Mobile Generator Repair Engine Wiring Diagram—John Deere without ECU CP SO 144 SI 19 2 LL Y V Br 1 24 Or 6G R Y LL 6 wc_tx000508gb.fm CG 13 87 wc_gr002827 This schematic will be referred to throughout this chapter.
Mobile Generator Repair 7.3 John Deere Engines without ECU Engine Wiring Components—John Deere without ECU See Graphic: wc_gr002827 Ref. Description Ref.
John Deere Engines without ECU 7.4 Mobile Generator Repair Locations of Engine Electrical Components 22 16 15 23 21 20 25 19 7 6 5 11 24 14 wc_tx000508gb.
Mobile Generator Repair 7.5 John Deere Engines without ECU Engine Electrical Components See Graphic: wc_gr002798 Ref. Component Ref. Component 4 Magnetic pickup 19 Battery 5 Oil pressure sender 20 10 A fuse 6 Coolant temperature sender 21 Starter relay 7 Main circuit breaker 22 Starter 11 Engine Control Module (ECM) 23 Alternator 14 Fuel level sender 24 Fuel solenoid 15 Intake manifold heater 25 Diodes 16 Slave preheat relay 7.
John Deere Engines without ECU 7.7 Mobile Generator Repair Engine Troubleshooting—John Deere without ECU Engine does not Crank Engine Troubleshooting Check position of emergency stop switch. Is the switch in the correct position? Pull the switch out. Flowchart 2A John Deere without ECU * Battery voltage; approximately 12V. Yes Checking ECM Display and LEDs Place the start switch in the START/RUN position.
Mobile Generator Repair John Deere Engines without ECU Engine Troubleshooting Flowchart 2B John Deere without ECU Engine does not Crank Continued from Flowchart 1A * Battery voltage; approximately 12V. Checking contacts of ECM crank relay Check for 12VDC at red wire #18 at ECM pin 5, plug 2. Is there 12VDC* on red wire #18? Yes No Repair or replace ECM. Check for 12VDC at yellow wire #63 at ECM pin 1, plug 2.
John Deere Engines without ECU Continued from Flowchart 2B Engine does not Crank Checking coil of starter relay and wiring Mobile Generator Repair Engine Troubleshooting Flowchart 2C John Deere without ECU Place starter switch in the START position. During cranking, check for 12VDC* at terminal CP of starter relay. Is 12VDC* measured at terminal CP? No * Battery voltage approximately 12V Check continuity of yellow wire #63 between ECM pin 1, plug 2 and relay terminal "CP". Repair wire as required.
Mobile Generator Repair 7.8 John Deere Engines without ECU Checking Wiring Continuity When checking the continuity of a wire, use the Ohms scale on your checking instrument (multimeter). A reading of less than one Ohm means the wire has continuity and should be OK. A reading over one Ohm usually means that the wire or connectors are corroded and should be repaired or replaced. A reading of “OL” or “OPEN” means the wire is broken and there is no continuity. In such cases, repair or replace the wire. 7.
John Deere Engines without ECU Mobile Generator Repair 7.10 Checking ECM Display and LEDs See Graphic: wc_gr002799 After placing the start switch in the START/RUN position, the ECM goes through a boot-up sequence. On early machines the ECM displays “Preheating”, then “Cranking”. Later model machines display “Initializing...”, “Time to Service”, and then “Cranking _ of 3”. During the preheat cycle (heater activation), the LED (b) near the stop sign illuminates.
Mobile Generator Repair a John Deere Engines without ECU b c wc_gr002799 7.11 Checking Battery The ECM display may or may not be blank when the battery voltage is less than 12V. During such a condition, the battery may be charged enough to light the display, but not enough to fully crank the starter. 7.11.1 Check that the battery cable connections are tight. 7.11.2 Check the battery terminals for corrosion. Clean the terminals if necessary.
John Deere Engines without ECU Mobile Generator Repair 7.12 Checking Power to ECM See Graphic: wc_gr002827 and wc_gr002800 7.12.1 7.12.2 7.12.3 7.12.4 7.12.5 7.12.6 7.12.7 7.12.8 wc_tx000508gb.fm Place the start switch (16) in the START/RUN position and check for 12VDC (battery voltage approximately 12V) between red wire #53 at pin 7, plug 1 and ground. • If 12VDC is measured, the ECM is receiving power. Go to step 8. • If 12VDC is not measured, continue.
Mobile Generator Repair 6 5 4 3 2 1 P3 John Deere Engines without ECU 4 3 2 1 654 321 P4 4 3 2 1 6 5 4 3 2 1 12 1110 9 8 7 6 5 4 3 2 1 12 1110 9 6 5 4 3 87 21 43 21 8765 43 2 1 8 7 6 5 4 3 2 1 P1 12 1110 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 P2 b a d c wc_gr002800 wc_tx000508gb.
John Deere Engines without ECU Mobile Generator Repair 7.13 Checking Contacts of ECM Crank Relay See Graphic: wc_gr002827 and wc_gr002829 When the start switch is placed in the START/RUN position, the ECM crank relay (c) energizes. The ECM crank relay supplies 12VDC through yellow wire #63 to energize the starter relay (14). 7.13.1 7.13.2 7.13.3 7.13.4 7.13.5 Check for 12VDC (battery voltage approximately 12V) between red wire #18 at pin 5, plug 2 and ground.
Mobile Generator Repair John Deere Engines without ECU 7.14 Checking ECM 10A Fuse See Graphic: wc_gr002802 The 10A fuse is found in the control compartment on G25 models (a). It is found in the engine compartment on all other models (b). There is 12VDC fed through this fuse to the ECM fuel and crank relay contacts via ECM pin 5, plug 2. If the fuse repeatedly blows, it is a sign that there is a short in the wires to/from the ECM, a diode is faulty, or the fuel or starter relay is shorted. 7.14.1 7.14.
John Deere Engines without ECU Mobile Generator Repair 7.15 Checking Diode Across Relay/Solenoid Coil See Graphic: wc_gr002803 The glow plug relay (a) and the fuel solenoid (b) on Isuzu powered generators, and the starter relay (c) (and fuel solenoid (d) on John Deere engines without the Engine Control Unit (ECU)), all have a diode (e) similar to the one pictured connected across the coil. The diodes are encapsulated in rubber.
Mobile Generator Repair John Deere Engines without ECU b a c d e wc_gr002803 wc_tx000508gb.
John Deere Engines without ECU Mobile Generator Repair 7.16 Checking Coil of Starter Relay and Wiring See Graphic: wc_gr002827 and wc_gr002865 7.16.1 Disconnect the wiring from the starter relay (16) terminals CP (a) and CG (b) and check the resistance across terminals CP and CG. 7.16.2 6 5 4 3 87 21 P1 • If 100±10% is measured, continue. • If 12VDC is measured, the coil of the starter relay is receiving power. Go to step 4. • If 12VDC is not measured, continue.
Mobile Generator Repair John Deere Engines without ECU 7.17 Checking Contacts of Starter Relay and Wiring See Graphic: wc_gr002827 and wc_gr002805 The starter relay coil and its wiring must be functioning properly before checking the starter relay contacts. See section Checking Starter Relay Coil and Wiring. 7.17.1 7.17.2 7.17.3 Check for 12VDC (battery voltage approximately 12V) between the red wire #51 at terminal B+ (SI) (a) of the starter relay and ground.
John Deere Engines without ECU Mobile Generator Repair 7.18 Engine Cranks But Does Not Start Engine Cranks But Does Not Start Engine Troubleshooting Flowchart 2D John Deere without ECU Check fuel system: fuel supply, filter, condition of tank, and hoses. * Battery voltage approximately 12V Checking contacts of ECM preheat relay Check for 12VDC* on red wire #17 to ECM pin 7, plug 2.
Mobile Generator Repair John Deere Engines without ECU Engine Troubleshooting Flowchart 2E John Deere without ECU Engine Cranks but does not Start Continued from Flowchart 2D * Battery voltage approximately 12V Checking Slave Preheat Relay and Wiring With the start switch in the START position, check for 12VDC* on gray wire #65 at terminal 86 of the slave preheat relay during the preheat cycle.
John Deere Engines without ECU Engine Cranks but does not Start Continued from Flowchart 2E Checking Manifold Heater Mobile Generator Repair Engine Troubleshooting Flowchart 2F John Deere without ECU Place start switch in STOP position. Remove red wire #12 from heater terminal. Check resistance between heater terminal and ground. Does the heater have continuity? No * Battery voltage; approximately 12V. Replace the manifold heater. Yes Checking Fuel Circuit Repair or replace the ECM.
Mobile Generator Repair John Deere Engines without ECU 7.19 Checking Contacts of ECM Preheat Relay See Graphic: wc_gr002928 The ECM includes an onboard preheat relay (a) which is located on on the lower board, behind the crank and fuel relays. To test the function of its contacts carry out the following procedure: 7.19.1 7.19.2 Probe ECM pin 7, plug 2 (b) at red wire #17 for 12VDC (battery voltage approximately 12V). Measure between red wire #17 to pin 7, plug 2 and ground.
John Deere Engines without ECU Mobile Generator Repair 7.20 Checking Slave Preheat Relay and Wiring See Graphic: wc_gr002827 and wc_gr002807 The slave preheat relay (14) (a) is located inside the engine compartment. To check the slave preheat relay, carry out the following procedures: 7.20.1 Check power to the coil of the slave preheat relay by measuring voltage (battery voltage approximately 12V) between terminal 86 and ground during the preheat cycle.
Mobile Generator Repair John Deere Engines without ECU 7.21 Checking Manifold Heater See Graphic: wc_gr002808 The manifold heater (e) is located in line with the intake air supply. WARNING 7.21.1 Disconnect red wire #12 (c) from the manifold heater. Check the continuity of red wire #12 between the manifold heater and terminal 87 of the slave preheat relay. Repair/replace the wire as needed. 7.21.
John Deere Engines without ECU Mobile Generator Repair 7.22 Checking Fuel Circuit See Graphic: wc_gr002827 and wc_gr002809 The fuel solenoid valve (22) (b) is located inside, near the top of the injection pump. When it is energized, fuel flows to the injection nozzles; when de-energized, fuel flow ceases and the engine stops quickly. There is a single violet wire which supplies power to the fuel solenoid valve.
Mobile Generator Repair John Deere Engines without ECU c d b a 654 321 12 1110 9 6 5 4 3 87 21 43 21 af 8765 43 2 1 e a wc_gr002809 13 87 wc_tx000508gb.
John Deere Engines without ECU Mobile Generator Repair 7.23 General Engine Troubleshooting—John Deere Symptom Problem Solution Engine cranks but will not start Exhaust restricted Check and correct exhaust restriction. Fuel filter plugged or full of water Replace fuel filter or drain water from filter. Injection pump not getting fuel or air in fuel system Check fuel flow at supply pump or bleed fuel system.
Mobile Generator Repair John Deere Engines without ECU Symptom Problem Solution Engine knocks Low engine oil level Add oil to engine crankcase. Injection pump out of time See authorized service dealer or distributor. Low coolant temperature Remove and check thermostat. Engine overheating See “Engine overheats” symptom in this chart. Low coolant temperature Remove and check thermostat. Clogged fuel filter Replace fuel filter element.
John Deere Engines without ECU Symptom Engine emits white smoke Engine emits black smoke wc_tx000508gb.fm Mobile Generator Repair Problem Solution Turbo charger not functioning (Turbocharge engines only). See authorized dealer or distributor. Leaking exhaust manifold gasket. See authorized dealer or distributor. Defective aneroid control line. See authorized dealer or distributor. Restricted fuel hose Clean or replace fuel hose. Improper fuel type Use proper fuel.
Mobile Generator Repair John Deere Engines without ECU Symptom Problem Solution Engine overheats Engine overloaded Reduce load. Low coolant level Fill radiator to proper level. Check radiator and hoses for loose connections and leaks. Faulty radiator cap See authorized dealer or distributor. Stretched poly-vee belt or defective belt tensioner Check automatic belt tensioner and check belts for stretching. Replace belts as required. Low engine oil level Check oil level. Add oil as required.
John Deere Engines without ECU Notes wc_tx000508gb.
Mobile Generator Repair 8. John Deere Engines with ECU John Deere Engines with ECU 8.1 John Deere Engine Background The (tier II) John Deere engines with electronic control systems are used on Wacker generator models G 85 (BOM 9305), G 125, and G 160. The electronic control system consists of: • Engine Control Unit (ECU); the computer which controls fuel, and the ignition system.
176 ECM LL Y V 26 23 R Br Or 6G R Y LL Wacker side 22 J D B A E G F U V 429 23 F C A H J 24 G E D SO CG SI 422 wc_tx000515gb.fm B 050D 14 21 20 14 050 J3 K1 K2 K3 J1 J2 H1 H2 H3 G1 G2 G3 F1 F2 F3 E1 E2 E3 D1 D2 D3 C1 C2 C3 B1 B2 B3 A1 A2 A3 25 G1 F1 K3 G2 J2 K1 A2 wc_gr002816 JOHN DEERE ECU 8.
Mobile Generator Repair 8.3 Ref. John Deere Engines with ECU Engine Wiring Components—John Deere with ECU Description Ref.
wc_tx000515gb.fm 178 n J3 K1 K2 K3 J1 J2 H1 H2 H3 G1 G2 G3 F1 F2 F3 E1 E2 E3 D1 D2 D3 C1 C2 C3 B1 B2 B3 A1 A2 A3 448 447 461 l k c 914D 428 412 914E JOHN DEERE ECU h d 914F m 463 b j a f 012C between A2 and G 022C to K1 911 467 914B 493 491 429 050G 012D 002D g 022A to B F G H A E D 082 e C J B D B A E G 050 F + U V wc_gr002817 – 8.
Mobile Generator Repair 8.5 John Deere Engines with ECU ECU Harness Connector See Graphic: wc_gr002817 Ref.
John Deere Engines with ECU 8.7 Mobile Generator Repair Locations of Engine Electrical Components 3 1 2 4 5 6 14 7 15 8 16 13 9 10 11 12 wc_gr002812 wc_tx000515gb.
Mobile Generator Repair 8.8 John Deere Engines with ECU Engine Electrical Components See Graphic: wc_gr002812 Ref. Component Ref.
John Deere Engines with ECU Mobile Generator Repair 8.10 Engine Troubleshooting—John Deere with ECU Engine Does Not Crank Engine Troubleshooting Flowchart 2G John Deere with ECU Check position of emergency stop switch. Is the switch in the correct position? * Battery voltage approximately 12V Pull the switch out. Yes See Flowchart 1B Checking ECM Display and LEDs Place the start switch in the START/RUN position.
Mobile Generator Repair John Deere Engines with ECU Engine Troubleshooting Flowchart 2H John Deere with ECU Engine does not Crank Continued from Flowchart 2G * Battery voltage approximately 12V Checking contacts of ECM crank relay Check for 12VDC at red wire #18 at ECM pin 5, plug 2. Is there 12VDC* on red wire #18? Yes No Repair or replace ECM. Check for 12VDC at yellow wire #63 at ECM pin 1, plug 2.
John Deere Engines with ECU Mobile Generator Repair Engine Troubleshooting Engine does not Crank Continued from Flowchart 2H Flowchart 2I John Deere with ECU * Battery voltage approximately 12V Checking coil of starter relay and wiring Place starter switch in the START/RUN position. During cranking, check for 12VDC* at terminal CP of starter relay. Is 12VDC* measured at terminal CP? No Yes Check continuity of black wire #14 from starter relay terminal CG to ground.
Mobile Generator Repair John Deere Engines with ECU 8.11 Checking Wiring Continuity When checking the continuity of a wire, use the Ohms scale on your checking instrument (multimeter). A reading of less than one Ohm means the wire has continuity and should be OK. A reading over one Ohm usually means that the wire or connectors are corroded and should be repaired or replaced. A reading of “OL” or “OPEN” means the wire is broken and there is no continuity. In such cases, repair or replace the wire. 8.
John Deere Engines with ECU Mobile Generator Repair 8.13 Checking ECM Display and LEDs See Graphic: wc_gr0002813 8.13.1 Remove the three screws (a) securing the control panel and open the panel. 8.13.2 Check general condition of all ECM connectors (plugs) and wiring. Look for burn marks, melting, and signs of damage; repair or replace as necessary. 8.13.3 Place the start switch in the “START/RUN” position. 8.13.
Mobile Generator Repair John Deere Engines with ECU 8.14 Checking System 10A & 30A Fuses See Graphic: wc_gr002820 There are two fuses in the wiring from the battery that protect the electrical system. Both fuses are located near the ECU; the 30A fuse (a) (21) is the first, the 10A fuse (b) (20) the second. To check the fuses, remove the connector cover which protects the fuse. Replace the fuse if it is blown. If the fuse repeatedly blows, it is a sign of a short in the wiring.
John Deere Engines with ECU Mobile Generator Repair 8.16 Checking Power to ECM and Start Switch See Graphic: wc_gr002816 and wc_gr002814 8.16.1 8.16.2 8.16.3 8.16.4 8.16.5 8.16.6 8.16.7 wc_tx000515gb.fm Disconnect plug 1 from the ECM. Place the start switch (13) in the START/RUN position and check for 12VDC (battery voltage approximately 12V) between red wire #53 at pin 7, plug 1 and ground. • If 12VDC is measured, the ECM is receiving power. • If 12VDC is not measured, continue.
Mobile Generator Repair 654 321 John Deere Engines with ECU 43 21 12 1110 9 6 5 4 3 87 21 P1 8765 43 2 1 P2 a A1 A2 A3 a d B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 b J3 c a K1 K2 K3 a B a B a E a E WACKER side JOHN DEERE side wc_gr002814 wc_tx000515gb.
John Deere Engines with ECU Mobile Generator Repair 8.17 Checking Contacts of ECM Crank Relay See Graphic: wc_gr002816 and wc_gr002830 When the start switch is placed in the START/RUN position, the ECM crank relay (c) energizes. The ECM crank relay supplies 12VDC through yellow wire #63 to energize the starter relay (14). 8.17.1 8.17.2 8.17.3 8.17.4 8.17.5 Check for 12VDC (battery voltage approximately 12V) between red wire #18 at pin 5, plug 2 and ground.
Mobile Generator Repair John Deere Engines with ECU 8.18 Checking ECM 10A Fuse See Graphic: wc_gr002802 The 10A fuse is found in the control compartment on G25 models (a). It is found in the engine compartment on all other models (b). There is 12VDC fed through this fuse to the ECM fuel and crank relay contacts via ECM pin 5, plug 2. If the fuse repeatedly blows, it is a sign that there is a short in the wires to/from the ECM, a diode is faulty, or the fuel or starter relay is shorted. 8.18.1 8.18.
John Deere Engines with ECU Mobile Generator Repair 8.19 Checking Relay Coil Diodes See Graphic: wc_gr002803 The glow plug relay (a) and the fuel solenoid (b) on Isuzu powered generators, and the starter relay (c) (and fuel solenoid (d) on John Deere engines without the Engine Control Unit (ECU)), all have a diode (e) similar to the one pictured connected across the coil. The diodes are encapsulated in rubber.
Mobile Generator Repair John Deere Engines with ECU b a c d e wc_gr002803 wc_tx000515gb.
John Deere Engines with ECU Mobile Generator Repair 8.20 Checking Coil of Starter Relay and Wiring See Graphic: wc_gr0002816 and wc_gr002804 8.20.1 8.20.2 8.20.3 8.20.4 wc_tx000515gb.fm Disconnect the wiring from the starter relay (16) terminals CP (a) and CG (b) and check the resistance across terminals CP and CG. • If 100±10% Ohms is not measured, replace the starter relay. • If 100±10% Ohms is measured, continue. Place the start switch in the START/RUN position.
Mobile Generator Repair John Deere Engines with ECU 654 321 c a 43 21 12 1110 9 6 5 4 3 87 21 8765 43 2 1 a b a P1 P2 a d a D a D JOHN DEERE side WACKER side wc_gr002804 wc_tx000515gb.
John Deere Engines with ECU Mobile Generator Repair 8.21 Checking Contacts of Starter Relay and Wiring See Graphic: wc_gr002805 and wc_gr002816 8.21.1 8.21.2 8.21.3 8.21.4 Check for 12VDC (battery voltage approximately 12V) between terminal B+ SI (a) of the starter relay and ground. • If 12VDC is not measured, check the continuity of the red wire from terminal B+ of the starter relay to terminal B+ of the starter motor. Also check the continuity of the red wire from the starter motor to the battery.
Mobile Generator Repair John Deere Engines with ECU 8.22 Engine Cranks But Does Not Start—John Deere with ECU Engine Cranks But Does Not Start Engine Troubleshooting Check fuel system: fuel supply, filter, condition of tank, and hoses. Flowchart 2J John Deere with ECU Checking Slave Preheat Relay and Wiring * Battery voltage approximately 12V Preheat relay checks only apply when the generator is cold: approximately 15˚C (60˚F) and lower.
John Deere Engines with ECU Mobile Generator Repair Engine Cranks but does not Start Continued from Flowchart 2J Engine Troubleshooting Flowchart 2K John Deere Checking Manifold Heater Place start switch in STOP position. Remove red wire from heater terminal. Check resistance between heater terminal and ground. * Battery voltage approximately 12V Does the heater have resistance? No Replace the intake manifold heater. Repair or replace the wire.
Mobile Generator Repair John Deere Engines with ECU 8.23 Checking Slave Preheat Relay and Wiring See Graphic: wc_gr002816 and wc_gr002825 8.23.1 8.23.2 8.23.3 8.23.4 Place the start switch in the START/RUN position and check for 12VDC (battery voltage approximately 12V) between gray wire #65 at slave preheat relay (a) terminal 86 and ground.
John Deere Engines with ECU Mobile Generator Repair 8.24 Checking Manifold Heater See Graphic: wc_gr002808 The manifold heater (e) is located in line with the intake air supply. WARNING 8.24.1 Disconnect red wire #12 (c) from the manifold heater. Check the continuity of red wire #12 between the manifold heater and terminal 87 of the slave preheat relay. Repair/replace the wire as needed. 8.24.
Mobile Generator Repair John Deere Engines with ECU 8.25 Checking Contacts of ECM Fuel Relay See Graphic: wc_gr002927 In order for the ECM fuel relay to energize, the ECM must be receiving power. If the engine cranks, the ECM is receiving power. If the engine does not crank, see section Checking ECM 10A Fuse. The engine’s ECU receives control power through the ECM fuel relay.
John Deere Engines with ECU Mobile Generator Repair 8.26 Checking Power to ECU See Graphic: wc_gr002816 and wc_gr002826 Be sure the ECM fuel relay contact circuit is functioning. See section Checking Contacts of ECM Fuel Relay. 8.26.1 Remove the ECU harness connector (a). 8.26.2 Place the start switch in the REMOTE START position. 8.26.3 Check for 12VDC (battery voltage approximately 12V) between terminal A2 of the ECU harness connector and ground. 8.26.4 8.26.5 8.26.
Mobile Generator Repair John Deere Engines with ECU A1 A2 A3 B1 B2 B3 a b C1 C2 C3 D1 D2 D3 E1 E2 E3 a F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 a G a G JOHN DEERE side WACKER side a d c a wc_gr002826 wc_tx000515gb.
John Deere Engines with ECU Mobile Generator Repair 8.27 General Engine Troubleshooting—John Deere with ECU Symptom Problem Solution Engine cranks but will not start Exhaust restricted Check and correct exhaust restriction. Fuel filter plugged or full of water Replace fuel filter or drain water from filter. Injection pump not getting fuel or air in fuel system Check fuel flow at supply pump or bleed fuel system.
Mobile Generator Repair John Deere Engines with ECU Symptom Problem Solution Engine knocks Low engine oil level Add oil to engine crankcase. Injection pump out of time See authorized service dealer or distributor. Low coolant temperature Remove and check thermostat. Engine overheating See “Engine overheats” symptom in this chart. Low coolant temperature Remove and check thermostat. Clogged fuel filter Replace fuel filter element.
John Deere Engines with ECU Symptom Engine emits white smoke Engine emits black smoke wc_tx000515gb.fm Mobile Generator Repair Problem Solution Turbo charger not functioning (Turbocharge engines only). See authorized dealer or distributor. Leaking exhaust manifold gasket. See authorized dealer or distributor. Defective aneroid control line. See authorized dealer or distributor. Restricted fuel hose Clean or replace fuel hose. Improper fuel type Use proper fuel.
Mobile Generator Repair John Deere Engines with ECU Symptom Problem Solution Engine overheats Engine overloaded Reduce load. Low coolant level Fill radiator to proper level. Check radiator and hoses for loose connections and leaks. Faulty radiator cap See authorized dealer or distributor. Stretched poly-vee belt or defective belt tensioner Check automatic belt tensioner and check belts for stretching. Replace belts as required. Low engine oil level Check oil level. Add oil as required.
Output Voltage Troubleshooting 9. Mobile Generator Repair Output Voltage Troubleshooting 9.
Mobile Generator Repair Output Voltage Troubleshooting See Graphic: wc_gr002854 Ref. Description Ref.
Output Voltage Troubleshooting Mobile Generator Repair G 50, G 70, G 85, G 125 2 2 4 1 L 1 L 2 L 3 L 0 3 2 3 4 B r 6 6 5 7 7 B r L L L L L L L L L L G /Y G /Y G /Y G /Y G /Y B r 1 9 B B B L 0 1 0 B B 9 B B B 89 B C T -3 B 98 B T 7 C T -2 B B B B C T -1 1 0 B r T 9 1 1 B B 2 0 T 4 B T 5 B 1 5 1 2 1 3 L 3 3 1 L 2 4 L 1 2 C T 3 C T C T 2 C T 1 4 1 5 2 6 1 5 2 T 9 9 1 0 6 1 3 1 4 1 7 1 8 2 1 2 2 2 5 2 6 T 9 T 6 T 8 T 1 1 T 1 0 T 7 T 1 T 1 2 O Y B r
Mobile Generator Repair Output Voltage Troubleshooting See Graphic: wc_gr000524 Ref. Description Ref. Description 1. Lug safety limit switch 11. 240V 30A receptacle 2. Mechanical lugs 12. Engine Control Module (ECM) 3. Buss bar 13. Plug 4 - line voltage inputs 4. Main breaker 14. Plug 3 - current transformer inputs 5. Shunt 15. Voltage selector switch 6. 120V 20A GFI receptacle 16. Generator 7. 120V breaker 17. Voltage regulator 8. 240V 50A breaker 18.
Output Voltage Troubleshooting G 160 wc_tx000509gb.
Mobile Generator Repair Output Voltage Troubleshooting See Graphic: wc_gr000895 Ref. Description Ref.
Output Voltage Troubleshooting 9.2 Mobile Generator Repair “No” Voltage Troubleshooting (Zero (0.0) Volts measured on multimeter) Check position of circuit breaker. Is the circuit breaker in the "ON" (closed) position? No Place the circuit breaker in the "ON" (closed) position. Yes No Voltage Troubleshooting Flowchart 3A Checking main circuit breaker Does the main circuit breaker have continuity? No Replace the main circuit breaker.
Mobile Generator Repair Output Voltage Troubleshooting No Voltage Troubleshooting Flowchart 3B Continued from Flowchart 3A Checking generator/excitation system · Check function of lug door switch. Do brown wires at AVR have continuity? · Check continuity of wire at #3 from AVR to lug door switch and then from switch toT7 lug in control box. No · Check continuitywire at #4 to T9 lug in control box. Yes · Check for 0.20 Ohms resistance between T7 and T9 lugs in control box.
Output Voltage Troubleshooting Mobile Generator Repair No Voltage Troubleshooting Flowchart 3C Continued from Flowchart 3B Excite generator with a 12V battery on F+ and F-. Check for 240V (or more) on brown wires 3 and 4. Is 240V+ measured at terminals 3 and 4? Yes Replacing and Resetting the Automatic Voltage Regulator No Reconnect the AVR and retry generator. Does generator work? Checking condition of exciter rotor winding Check condition of exciter rotor winding. No Do all 3 windings measure 0.
Mobile Generator Repair 9.3 Output Voltage Troubleshooting Checking Main Circuit Breaker See Graphic: wc_gr002855 Electric shock hazard. Turn off the generator before conducting this test. WARNING 9.3.1 Open the control panel and place the main circuit breaker in the “ON” (closed) position. 9.3.2 Check the main circuit breaker for continuity—on all three legs. If the main circuit breaker has no continuity when in the “ON” position, replace it. wc_gr002855 wc_tx000509gb.
Output Voltage Troubleshooting Mobile Generator Repair 9.4 Checking Circuit Breaker and Function of Voltage Selector Switch See Graphic: wc_gr002856 wc_tx000509gb.fm 9.4.1 Turn off the generator. 9.4.2 Place the voltage selector switch (VSS) in the 480V/277V position. 9.4.3 Open the control panel. Measure the resistance from each leg to neutral: L1–N, L2–N, and L3–N. Do so by measuring resistance across each wire connected to the top of the main circuit breaker to neutral lug.
Mobile Generator Repair Output Voltage Troubleshooting 2 1 3 4 6 6 5 7 7 1 9 1 0 8 1 0 8 Key: T# = generator wire ends # = VSS terminal 1 1 9 L1 B T1 2 0 T4 1 2 1 2 1 3 T10 T3 1 4 T9 26 1 5 T11 18 13 T2 1 3 1 4 1 7 1 8 2 1 2 2 2 5 2 6 T 9 L2–N 8 1 1 1 2 1 5 1 6 1 9 2 0 2 3 2 4 1 6 F + FF-F + 2 7 2 8 T 3 L2 T 2 1 8 wc_gr002856 wc_tx000509gb.
Output Voltage Troubleshooting 9.5 Mobile Generator Repair Replacing Voltage Selector Switch (VSS) See Graphic: wc_gr002123 and wc_gr002124 Removal: 9.5.1 Place the engine start switch in the “O” (OFF) position and push in the emergency stop button. 9.5.2 Remove the rear enclosure panel to expose the generator. Remove the cover of the voltage selector switch box. 9.5.3 Label if necessary, then remove all the wires connected to the voltage selector switch. 9.5.
Mobile Generator Repair Output Voltage Troubleshooting Wires T7 L0 T11 T10 2 6 T8 10 14 T6 18 22 26 Even Numbered Terminals 4 8 12 20 T2 L2 24 28 L3 Or Y Jumpers 6 4 10 8 14 12 18 16 22 24 20 Wires T9 T9 L0 T5 T4 25 21 17 13 9 5 1 27 23 19 15 11 7 3 T12 L1 26 28 j1 j2 Black jumper 20 to 15 2 Black jumper 12 to 17 Black jumper 10 to 21 T7 16 j1 T9 L2 Br j2 Jumpers 25 21 17 13 9 5 1 27 23 19 15 11 7 3 Odd Numbered Terminals wc_
Output Voltage Troubleshooting 9.6 Mobile Generator Repair Checking Exciter Stator Winding See Graphic: wc_gr002103 9.6.1 Remove exciter stator wires F+ and F- from the voltage regulator and check continuity between wires. There should be approximately 23 (0.0 +0.5) Ohms resistance between F+ and F-, and infinite (open) resistance from either wire to ground. If 23 Ohms is read, then the exciter stator is OK. 9.6.
Mobile Generator Repair Output Voltage Troubleshooting G 25 a G 50, G 70, G 85, G 125, & G 160 d c b e f wc_gr002774 9.7 Accessing the Rotor Bearing, Diodes, and Rotor Winding See Graphic: wc_gr002774 wc_tx000509gb.fm 9.7.1 On generators with Isuzu engines, remove screws (a) and nuts securing support cover. Tap the cover with a hammer to open a gap between the cover and the generator housing, then use a screwdriver to pry the cover all the way off the housing. 9.7.
Output Voltage Troubleshooting 9.8 Mobile Generator Repair Checking Generator/Excitation System (Including Manual Excitation/Flashing) See Graphic: wc_gr002857 Field testing of the voltage regulator requires special equipment and is not practical or necessary. By removing the voltage regulator from the circuit and testing the excitation system, one can determine by process of elimination whether the problem lies within the regulator or the excitation system.
Mobile Generator Repair Output Voltage Troubleshooting 1 2 1 4 1 3 If your meter shows no continuity between brown wires 3 and 4 with the interlock switch closed, check the continuity of each wire separately. To do so, open the interlock switch by removing screw (b). Note the brown wire #3 (c) leading to AVR. Check it for continuity. Also check the wire on the opposite side of the interlock switch (d) back to the T7 lug (e) located inside control box, for continuity.
Output Voltage Troubleshooting Mobile Generator Repair External battery excitation/flashing procedures See Graphic: wc_gr001951 The exciter stator core is the main source of the generator's residual magnetism. If it has been subjected to severe vibration during shipping, it may have lost its residual magnetism. To restore residual magnetism, flash the field as described below. To flash the field: 9.8.6 With engine off, disconnect black wires F+ and F-, and brown wires 3 and 4, from the regulator. 9.8.
Mobile Generator Repair Output Voltage Troubleshooting STAB U/F 7 W F- B F+ B 3 Br VOLT 60 Hz 50 Hz 4 Br 6 B wc_gr001951 wc_tx000509gb.
Output Voltage Troubleshooting 9.9 Mobile Generator Repair Checking Lug Door Switch See Graphic: wc_gr002110 There are two sets of contacts in the door switch. The first set is normally open. These contacts open the brown AVR wire #3 to turn off the AVR when the door is opened. The second set is normally closed. These contacts close the yellow shut trip circuit breaker wires to 12V from battery, causing the breaker to open when the door is opened. Electric shock hazard.
Mobile Generator Repair wc_tx000509gb.
Output Voltage Troubleshooting Mobile Generator Repair 9.10 Replacing and Resetting the Automatic Voltage Regulator (AVR) See Graphic: wc_gr002858 Removal: 9.10.1 Place the engine start switch in the “O” (OFF) position and push in the emergency stop button. 9.10.2 Label then disconnect the wires connected to the automatic voltage regulator (AVR). 9.10.3 Remove the screws (a) and remove the AVR. Installation: 9.10.
Mobile Generator Repair b Output Voltage Troubleshooting F- F+ a 4 c 3 wc_gr002858 wc_tx000509gb.
Output Voltage Troubleshooting Mobile Generator Repair 9.11 Checking Exciter Rotor Winding See Graphic: wc_gr002106 Note: For clarity, the rotor is shown removed from generator housing. wc_tx000509gb.fm 9.11.1 Disconnect the three black wires (a) fastened to the diode support brackets. These black wires run to the exciter rotor winding. Arbitrarily label the three black wires “1”, “2”, and “3”. 9.11.2 Measure the resistance across each combination of wires: 1–2, 2–3, and 1–3.
Mobile Generator Repair Output Voltage Troubleshooting 9.12 Checking Rectifier Diodes See Graphic: wc_gr002104 Note: For clarity, the rotor is shown removed from generator housing. wc_tx000509gb.fm 9.12.1 Locate the two threaded studs (b) on the diode ring and remove all wires fastened to them. 9.12.2 Identify the leads from each diode (a). 9.12.3 Set the multimeter to the diode scale. Check that each diode conducts one way and not the other. A functioning diode should read 0.500 ± 0.
Output Voltage Troubleshooting Mobile Generator Repair 9.13 Checking Main Rotor Winding See Graphic: wc_gr002107 Note: For clarity, the rotor is shown removed from generator housing. wc_tx000509gb.fm 9.13.1 Locate two threaded studs (b) on diode ring. Remove all wires fastened to the studs. 9.13.2 Locate the two black wires with yellow insulators that run down motor shaft (a). 9.13.3 Measure the resistance across the wires; it should equal 1.4±0.5 Ohms. If not, replace the generator assembly. 9.
Mobile Generator Repair wc_tx000509gb.
Output Voltage Troubleshooting Mobile Generator Repair 9.14 Replacing Rotor Bearing, Diode Ring, and Exciter Rotor See Graphic: wc_gr002105 Removal: 9.14.1 Using a puller, pull the bearing (a) from the shaft. Heat the bearing if necessary but do not heat it more than 212°F (100°C). 9.14.2 Disconnect the black exciter rotor wires and the main rotor winding wires (black with yellow insulator) from the diode ring (b). 9.14.3 Remove the screws securing the the ring to the collar (c) and remove the ring.
Mobile Generator Repair wc_tx000509gb.
Output Voltage Troubleshooting Mobile Generator Repair 9.15 Low* Voltage Troubleshooting (*Greater than 1; usually 30–40) Check position of voltage selector switch. Make sure it is in the correct position. Check the lug door. Make sure it is shut tight. Check the function of the door switch. If the switch is not functioning properly, replace it. Verifying voltage Verify voltage using a multimeter or voltmeter. Does the ECM voltage match the multimeter? No Recalibrate the ECM voltmeter.
Mobile Generator Repair Output Voltage Troubleshooting Low Voltage Troubleshooting Flowchart 4C Continued from Flowchart 4B Reconnect the AVR and retry generator. Does generator work? No Check the function of the door rheostat. Replace the rheostat. Is the rheostat functioning properly? No Yes Replacing and resetting the automatic voltage regulator Adjust the "Volt" pot on the AVR. Replace the AVR. No Is the voltage correct? Yes Check AVR fuse. Is AVR fuse OK? Yes Replace AVR.
Output Voltage Troubleshooting Mobile Generator Repair Low Voltage Troubleshooting Flowchart 4B Continued from Flowchart 4A Checking generator/excitation system Excite generator with a 12V battery on F+ and F-. Check for 240V (or more) on brown wires 3 and 4. Is 240V+ measured at terminals 3 and 4? Checking rectifier diodes No Check condition of rectifier diodes. Yes Are the diodes functioning properly? See Flowchart 4C No Replace six-diode ring assembly.
Mobile Generator Repair Output Voltage Troubleshooting 9.16 Verifying Voltage See Graphic: wc_gr001979 Electric shock hazard. This test involves live voltages which can cause severe injury or death. Only qualified personnel should conduct this test. WARNING 9.16.1 Shut off the generator. 9.16.2 Open the lug door and defeat the interlock switch. To defeat the interlock switch, remove key latch from hinged door and place it in slot of interlock switch. See section Checking Safety Interlock Switch. 9.
Output Voltage Troubleshooting Mobile Generator Repair 9.17 Checking Main Stator Winding See Graphic: wc_gr002108 wc_tx000509gb.fm 9.17.1 Remove the generator’s rear enclosure panel. 9.17.2 Remove the top and rear covers of the voltage selector switch box. 9.17.3 Carefully label all wires (a) coming from inside the generator housing that are connected to the voltage selector switch. Disconnect the wires from the switch. Note: These wires are recognizable by their cloth-type insulation.
Mobile Generator Repair Output Voltage Troubleshooting 9.18 Generator Produces High Voltage Troubleshooting Check position of voltage selector switch. Is the voltage selector switch (VSS) in the correct position? With engine off, place switch in correct position. No Yes Verifying voltage High Voltage Troubleshooting Flowchart 5A Verify voltage using a multimeter or voltmeter. Does the ECM voltage match the multimeter? No Recalibrate the ECM display. Yes Adjust voltage on door rheostat.
Output Voltage Troubleshooting Mobile Generator Repair High Voltage Troubleshooting Flowchart 5B Continued from Flowchart 5A With the engine off, soak the VSS contacts with quick dry type contact cleaner. Turn switch knob back and forth several times to clean contacts. Dry VSS with compressed air. Is voltage now OK? No Check function of voltage selector switch. Call Wacker Service. Yes Is the voltage selector switch functioning properly? No Replace the voltage selector switch.
Mobile Generator Repair Output Voltage Troubleshooting 9.19 Replacing Emergency Stop Switch See Graphic: wc_gr002087 Removal: 9.19.1 Remove the rear machine enclosure panel. 9.19.2 Remove the two screws (a) securing the protective cover (b). 9.19.3 Disengage the switch connectors (c) from the nut (e). 9.19.4 Loosen the two screws (d) securing the nut (e). Then, twist and pull the nut to remove it. 9.19.5 Pull the knob assembly (f) from the panel. Installation: 9.19.
Output Voltage Troubleshooting Notes wc_tx000509gb.
Mobile Generator Repair Disassembly/Assembly Procedures 10. Disassembly/Assembly Procedures 10.1 Tools Because all possible problems encountered while repairing the equipment cannot be anticipated, it is up to the mechanic to use common sense and good judgement in tool selection. The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate.
Disassembly/Assembly Procedures Mobile Generator Repair 10.5 Exhaust System Exploded View—G 25 G25 5 7 8 6 2 7 1 3 4 1 7 5 G12 wc_gr002055 Ref. Component Ref. Component 1 Horizontal exhaust pipe 5 M8 hardware 2 Top muffler bracket 6 Muffler 3 Bottom muffler bracket 7 Clamp 4 Rod 8 Exhaust tail pipe wc_tx000510gb.
Mobile Generator Repair Disassembly/Assembly Procedures 10.6 Removing Exhaust System—G 25 See Graphic: wc_gr002055 10.6.1 Shut down the machine and allow the the exhaust pipes to cool. 10.6.2 Remove the front panel. 10.6.3 Disconnect the horizontal exhaust pipe (1) from the engine manifold. 10.6.4 Loosen the clamp securing the horizontal exhaust pipe to the muffler (6) and remove the horizontal exhaust pipe. 10.6.
Disassembly/Assembly Procedures Mobile Generator Repair 10.8 Exhaust System Exploded View—G 50, G 70, G 85 7 9 7 6 8 10 7 1 2 5 4 3 wc_gr002041 Ref. Component Ref. Component 1 Horizontal exhaust pipe 6 Muffler 2 Top muffler bracket 7 Clamp 3 Bottom muffler bracket 8 Exhaust tail pipe 4 Rod 9 Vertical exhaust pipe 5 M8 hardware 10 Heat wrap wc_tx000510gb.
Mobile Generator Repair Disassembly/Assembly Procedures 10.9 Removing Exhaust System—G 50, G 70, G 85 See Graphic: wc_gr002041 and wc_gr002042 wc_tx000510gb.fm 10.9.1 Shut down the machine and allow the exhaust pipes to cool. 10.9.2 Remove the front panel. 10.9.3 Remove the clamp (a) securing the horizontal exhaust pipe (b) to the engine exhaust manifold. 10.9.4 Loosen the clamp (c) securing the horizontal exhaust pipe to the vertical exhaust pipe (d). 10.9.
Disassembly/Assembly Procedures Mobile Generator Repair 10.10 Installing Exhaust System—G 50, G 70, G 85 See Graphic: wc_gr002042 10.10.1 Position the horizontal exhaust pipe (b) in the engine exhaust manifold, then across the top of the engine and out the rear of the enclosure. 10.10.2 Position the muffler (g) in the lower muffler bracket. 10.10.3 Slide the clamp over the vertical exhaust pipe and insert the vertical exhaust pipe (h) into the horizontal exhaust pipe.
Mobile Generator Repair Disassembly/Assembly Procedures 10.11 Exhaust System Exploded View—G 125, G 160 4 3 5 3 1 3 2 wc_gr002056 Ref. Component Ref. Component 1 Horizontal exhaust pipe 4 Exhaust tail pipe 2 Muffler 5 Vertical exhaust pipe 3 Clamp 10.12 Removing Exhaust System—G 125, G 160 See Graphic: wc_gr002056 10.12.1 Shut down the machine and allow the exhaust pipes to cool. 10.12.2 Remove the front panel. 10.12.
Disassembly/Assembly Procedures Mobile Generator Repair 10.13 Installing Exhaust System—G 125, G 160 See Graphic: wc_gr002056 10.13.1 Position the muffler (2) in place but do not tighten the hardware. 10.13.2 Secure the exhaust tail pipe (4) to the muffler using the clamp. 10.13.3 Position the vertical exhaust pipe (5) and the clamp on the muffler but do not tighten the clamp. 10.13.4 Secure the horizontal exhaust pipe (1) to the engine manifold. 10.13.
Mobile Generator Repair Disassembly/Assembly Procedures 10.14 Preparing Unit for Generator Removal See Graphic: wc_gr002043 10.14.1 Disconnect the battery. 10.14.2 Remove the doors. To remove the doors, simply pull up on the door at the hinge. 10.14.3 Remove the screws securing the rear panel and remove the panel. 10.14.4 Remove the fill hose (a) and the vent hose (d) from inside the engine compartment. Plug the fuel tank opening. 10.14.5 Remove the ground strap (b). 10.14.
Disassembly/Assembly Procedures Mobile Generator Repair 10.15 Removing Generator See Graphic: wc_gr002044 10.15.1 On John Deere-powered machines, remove the nuts (a) securing the generator to the two shock mounts. On Isuzu-powered machines, remove the nuts (f) securing the generator to the mounting plate. (Remove the mounting plate after the generator has been removed.) 10.15.2 Remove the fan guard (b). 10.15.3 Remove the bolts securing the rotor drive plates (c) to the engine flywheel (d).
Mobile Generator Repair Disassembly/Assembly Procedures 10.16 Installing Generator See Graphic: wc_gr002049 10.16.1 To aid in assembly, insert two M10 guide studs into two of the engine adapter flange holes (a). Isuzu engines already have these studs (e). 10.16.2 Using an appropriate hoist or lifting device, carefully position the generator on the guide studs and shock mounts (b). 10.16.3 Secure the rotor drive plates to the engine flywheel using six 3/8-inch bolts.
Disassembly/Assembly Procedures Mobile Generator Repair 10.17 Removing Roof and Center Support Brackets See Graphic: wc_gr002046 10.17.1 With an appropriate hoist or lifting device, support the roof of the generator by the lifting eye. 10.17.2 Remove the bolts (a) securing the roof to the sides. Also remove the bolts (b) securing the top to the radiator bulkhead. 10.17.3 Remove the bolts (c) securing the control panel (d) to the upright brace (e). 10.17.
Mobile Generator Repair Disassembly/Assembly Procedures 10.18 Installing Roof and Center Support Brackets See Graphic: wc_gr002046 10.18.1 With an appropriate hoist or lifting device, support the roof of the generator by the lifting eye. 10.18.2 With the assistance of a partner, position the top on the unit. 10.18.3 Install the bolts (f) securing the upright braces to the frame. 10.18.4 Install the bolts (c) securing the control panel (d) to the upright brace (e). 10.18.
Disassembly/Assembly Procedures Mobile Generator Repair 10.19 Preparing Unit for Engine/Generator Removal See Graphic: wc_gr002045 10.19.1 Disconnect the battery. 10.19.2 Remove the doors. To remove the doors, simply pull up on the door at the hinge. 10.19.3 Remove the screws securing the front and rear panels and remove the panels. 10.19.4 Remove the roof. See section Removing Roof. 10.19.5 Remove the horizontal exhaust pipe running from the exhaust manifold to the rear of the unit.
Mobile Generator Repair Disassembly/Assembly Procedures a c b d f e j i g h wc_gr002045 wc_tx000510gb.
Disassembly/Assembly Procedures Mobile Generator Repair 10.20 Removing Engine/Generator Assembly See Graphic: wc_gr002047 10.20.1 Using chains attached to the lifting eyes of the engine (a) and the generator (b), support the engine/generator assembly with an appropriate hoist or lifting device. 10.20.2 Remove the screws (c) securing the engine to the engine mounts. 10.20.3 Remove the nuts (d) securing the generator to the shock mounts. 10.20.
Mobile Generator Repair Disassembly/Assembly Procedures 10.21 Installing Engine/Generator Assembly See Graphic: wc_gr002047 10.21.1 Using chains attached to the lifting eyes of the engine (a) and the generator (b), support the engine/generator assembly with an appropriate hoist or lifting device. 10.21.2 With the assistance of a partner, carefully position the engine/ generator assembly on the unit. 10.21.3 Secure the engine to the engine mounts using eight M12 bolts (c). Torque bolts to 63 ft.lbs.
Disassembly/Assembly Procedures Mobile Generator Repair 10.22 Replacing Fuel Tank See Graphic: wc_gr002125 Removal: 10.22.1 Remove the four M16 bolts (a) and nuts securing the skid to the trailer. Using an appropriate lift or hoist, lift the generator/fuel tank assembly from the trailer. 10.22.2 Remove the front and rear enclosure panels for access to bolts. Remove the M8 bolts (b) securing the drip pan (c) to the skid and remove the pan. Set the generator/fuel tank assembly on 4 x 4 beams. 10.22.
Mobile Generator Repair wc_tx000510gb.
Factory-Installed Options Mobile Generators 11. Factory-Installed Options This machine may be equipped with one or more of the following factory-installed options. To verify if any of these options are installed on your machine, contact the WACKER Corporation at 1-800-770-0957. A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit. Please have this information available when contacting WACKER Corporation. 11.
Mobile Generators Factory-Installed Options 11.2 Fuel/Water Separator See Graphic: wc_gr001705 The fuel/water separator separates water from the fuel on models with Isuzu engines. Empty the separator water bowl (a) as needed by opening the water bowl drain (b). The separator element should be changed each time the fuel filter is changed—approximately every 600 hours of operation. To change the element: wc_tx000524gb.fm 11.2.
Factory-Installed Options Mobile Generators 11.3 Electronic Governor See Graphic: wc_gr001714, wc_gr001715, wc_gr001716, wc_gr001717 The electronic governor option consists of an electronic module (a or b) and an electronic actuator (c or d). The module senses rotation of the flywheel, then sends a signal to the electronic actuator that governs the fuel injection system. The system is designed to precisely regulate engine rpm, and thus frequency, to within approximately 0.25%.
Mobile Generators wc_tx000524gb.
Factory-Installed Options Mobile Generators 11.
Mobile Generators Factory-Installed Options 11.5 Components—Isuzu Engine with Electronic Governor Ref. Component Ref.
Factory-Installed Options Mobile Generators 25 CP SO 1 2 272 SI 19 6 Cl B Cl wc_tx000524gb.fm CG 13 87 24 wc_gr002939 B BAT + BAT – ACT ACT MPU + MPU – MPU-SHIELD B V R V B Cl Cl 11.
Mobile Generators Factory-Installed Options 11.7 Components—John Deere Engine with Electronic Governor Ref. Description Ref.
Factory-Installed Options Mobile Generators 11.8 LCD Strip Heater See Graphic: wc_gr001723, wc_gr001724 The LCD strip heater option includes a thermostat module (a) and a clear heater strip that is bonded to the LCD (b) of the ECM. The purpose of the strip heater is to prevent the LCD from being damaged by extremely cold temperatures. The resistance of the coiled element of the heater is sensed by the thermostat. The resistance of the element changes with temperature.
Mobile Generators Factory-Installed Options 11.9 Low Coolant Shutdown See Graphic: wc_gr001708 The low-coolant shutdown system consists of an electronic sensor that monitors coolant level. The sensor (a) is mounted to the radiator and wired into the ECM. The sensor probe (b) is submerged in radiator coolant. If the probe senses no coolant, it sends a signal to the ECM. The ECM program includes a 10-second timer to protect from nuisance shutdowns.
Factory-Installed Options Mobile Generators 11.10 Lube Level Maintainer See Graphic: wc_gr001711, wc_gr001712, wc_gr001713 The lube level maintainer system protects the engine from low oil levels by providing an additional 6-quart oil reservoir. Oil from the reservoir is gravity-fed from the oil reservoir (a) through the control valve (b) and into the engine oil pan as needed. The valve includes a sightglass (c) through which the oil level can be seen.
Mobile Generators Factory-Installed Options 11.11 Temperature-Activated Shutters See Graphic: wc_gr001706, wc_gr001707 The shutters (a) are mounted to the top of the generator enclosure. The shutters are designed to keep the engine compartment warm, thus increasing engine temperature during cold weather operation. The shutters are activated through a wax-pellet actuator (b) that is connected to the generator's cooling system.
Factory-Installed Options Mobile Generators 11.12 Schematic—Temperature-Activated Shutters 1 Or R R R B R 6 R 7 R Bl 82 4 G 83 B 4 84 82 85 83 9 B 81 81 5 80 W 80 NC C NO 8 wc_gr003174 Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue wc_tx000524gb.
Mobile Generators Factory-Installed Options 11.13 Components—Temperature-Activated Shutters See Graphic: wc_gr003174 Ref Description Ref Description 1 Thermostat module 6 Auxiliary relay terminals 2 Terminal block 7 Plug 1, engine sensor inputs 3 1 Amp fuse 8 Electronic control board 4 Water level sensor 9 LCD heater 5 Lube level maintainer low level switch wc_tx000524gb.
Factory-Installed Options wc_tx000524gb.
Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 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 equipment.
Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 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.
Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 10.9 WRENCH SIZE 12.9 Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 – M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 – M5 6.0 *53 8.
Torque Values Torque Values (continued) Inch Fasteners (SAE) Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32 No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64 No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64 No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32 1/4 8.
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel.
