Wacker Neuson G 50 Manual de reparación

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Pagina 1 - REPAIR MANUAL

www.wackergroup.comMobile GeneratorsG 25 G 50 G 70G 85G 125G 160 REPAIR MANUAL0160486en 0011005 en0160486EN

Pagina 2

Table of Contents Mobile Generator Repairwc_br0160486enTOC.fm 610.18 Installing Roof and Center Support Brackets ...

Pagina 3 - Operating / Parts Information

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 963 Orange Voltage line input L3 at volt selector #284 Yellow Voltage line input L2 at vol

Pagina 4

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 97G 125/160 Control ModulePlug 1: Engine Sender Inputs (12-pin connector)3 White/Blue Cran

Pagina 5 - 3. Maintenance 36

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 985.13 Sender Resistance Graphs5.13.1 Fuel Sender a = shutdown point, 5%b = full, 104%5.1

Pagina 6 - 5. ECM Troubleshooting 66

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 995.13.3 Temperature Sender a = approximate normal operating temperatureb = approximate s

Pagina 7

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 1005.14 Checking Magnetic PickupSee Graphic: wc_gr002114 The magnetic pickup is a magnet

Pagina 8

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1016. Isuzu Engine Troubleshooting6.1 Isuzu Engine BackgroundSee Graphic: wc_gr00

Pagina 9

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1026.2 Engine Wiring Diagram—IsuzuThis schematic will be referred to throughout t

Pagina 10

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1036.3 Engine Wiring Components—Isuzu Ref. Component Ref. Component1 Plug 1 —

Pagina 11

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1046.4 Engine Electrical Component Locations—Isuzu wc_gr002834654832121316149710

Pagina 12 - 1. Safety Information

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1056.5 Engine Electrical Components—IsuzuSee Graphic: wc_gr002834 6.6 Troubles

Pagina 13 - 1.1 Operating Safety

Mobile Generator Repair Table of Contentswc_br0160486enTOC.fm 7

Pagina 14 - 1.2 Service Safety

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1066.7 Engine Troubleshooting—IsuzuEngine TroubleshootingFlowchart 1AIsuzuPull th

Pagina 15

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 107* Battery voltageapproximately 12VEngine TroubleshootingFlowchart 1BIsuzuSee F

Pagina 16

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 108wc_gr002850NoIs 12VDC*measured at terminal86?Ye sNoIs 12VDC*measured at termin

Pagina 17 - 1.4 Towing Safety

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1096.8 Checking Wire ContinuityWhen checking the continuity of a wire, use the Oh

Pagina 18 - 1.6 Label Locations

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1106.10 Checking ECM Display and LEDsSee Graphic: wc_gr002835 After placing the

Pagina 19

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 111 6.11 Checking BatteryThe ECM display may or may not be blank when battery vo

Pagina 20 - INSTRUCTIONS DE REMORQUAGE

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1126.12 Checking Power to ECM See Graphic: wc_gr002833 and wc_gr002836 6.12.1 Pl

Pagina 21

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 113wc_gr002836481211109871232563144567362514321121110 9 8 7654321121110 9 8 76543

Pagina 22 - 1 1 5 0 9 6

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1146.13 Checking Contacts of ECM Crank RelaySee Graphic: wc_gr002833 and wc_gr002

Pagina 23 - DISTANCE

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1156.14 Checking ECM 10A FuseSee Graphic: wc_gr001987 The 10A fuse is found in t

Pagina 24 - L1 L2 L3

Safety Information Mobile Generator Repairwc_si000136gb.fm 81. Safety InformationThis manual contains DANGER, WARNING, CAUTION, and NOTEcallouts which

Pagina 25 - 1.8 Calling for Service

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1166.15 Checking Coil of Starter Relay and WiringSee Graphic: wc_gr002833 and wc_

Pagina 26

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1176.16 Checking Diode Across Relay/Solenoid Coil See Graphic: wc_gr002803 The g

Pagina 27 - 2.1 Engine Data—G 25

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1186.17 Checking Contacts of Starter RelaySee Graphic: wc_gr002922 The starter r

Pagina 28 - 2.2 Generator Data—G 25

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1196.18 Engine Cranks But Does Not Start—IsuzuCheck continuity of black wire #13

Pagina 29 - 2.4 Dimensions—G 25

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 120Replace fuel pump.If there is 12VDC* at the fuel pump and the engine still doe

Pagina 30

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 121 Engine TroubleshootingFlowchart 1FIsuzuwc_gr002840* Battery voltageapproxima

Pagina 31

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 122 Engine TroubleshootingFlowchart 1GIsuzuwc_gr002853NoDoes the plunger spring

Pagina 32

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 123 Engine TroubleshootingFlowchart 1HIsuzuwc_gr002851NoIs 12VDC*measured?Ye sNo

Pagina 33

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1246.19 Checking Power to Glow PlugsSee Graphic: wc_gr002833 and wc_gr002841 6.1

Pagina 34 - 2.9 Engine Data—G 125, G 160

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1256.20 Checking Glow PlugsSee Graphic: wc_gr002033 6.20.1 Remove the glow plug

Pagina 35

Mobile Generator Repair Safety Informationwc_si000136gb.fm 91.1 Operating SafetyFamiliarity and proper training are required for the safe operation of

Pagina 36

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1266.21 Checking Glow Plug Relay and WiringSee Graphic: wc_gr002833 and wc_gr0028

Pagina 37

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1276.22 Checking Contacts of ECM Preheat RelaySee Graphic: wc_gr002833 and wc_gr0

Pagina 38

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1286.23 Checking Power to and Operation of Fuel PumpSee Graphic: wc_gr002833 and

Pagina 39 - G 70 Standby

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 129wc_gr002842abdec

Pagina 40 - 3. Maintenance

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1306.24 Isuzu Fuel SolenoidSee Graphic: wc_gr002833, wc_gr002844, and wc_gr002031

Pagina 41

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 131wc_gr002844a

Pagina 42 - 3.4 Engine Lubrication

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1326.25 Checking Fuel SolenoidSee Graphic: wc_gr002833 and wc_gr0028526.25.1 Chec

Pagina 43 - 3.6 Trailer Maintenance

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 133 wc_gr002852dgcbaef

Pagina 44

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1346.26 Checking Coil of Fuel Pump RelaySee Graphic: wc_gr002843 6.26.1 Place th

Pagina 45 - Electric Brakes

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 135481211109871232563144567362514321wc_gr002843P1P2aacab86853087

Pagina 46

Safety Information Mobile Generator Repairwc_si000136gb.fm 101.1.17 ALWAYS keep the area immediately surrounding and underneath themachine clean, neat

Pagina 47

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1366.27 Checking Contacts of ECM Fuel RelaySee Graphic: wc_gr002833 and wc_gr0028

Pagina 48

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 1376.28 Checking Contacts of Fuel Pump Relay See Graphic: wc_gr002833 and wc_gr00

Pagina 49 - 4.1 Introduction

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 1386.29 General Engine Troubleshooting—IsuzuSymptom Problem SolutionEngine does n

Pagina 50

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 139Engine hard to start or will not startEngine starting under load Place all cir

Pagina 51

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 140Engine runs irregularly or stalls frequentlyLow coolant temperature Remove and

Pagina 52 - 4.4 Wiring Diagrams

Mobile Generator Repair Isuzu Engine Troubleshootingwc_tx000507gb.fm 141Engine emits black smoke. Improper fuel type Use proper fuel.Clogged or dirty

Pagina 53

Isuzu Engine Troubleshooting Mobile Generator Repairwc_tx000507gb.fm 142Notes

Pagina 54

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 1437. John Deere Engines without ECU7.1 John Deere Engine BackgroundSee Graphic

Pagina 55

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1447.2 Engine Wiring Diagram—John Deere without ECUThis schematic will be refer

Pagina 56

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 1457.3 Engine Wiring Components—John Deere without ECUSee Graphic: wc_gr002827

Pagina 57

Mobile Generator Repair Safety Informationwc_si000136gb.fm 111.2.2 Ground ConnectionThe generator must be connected to a good earthen ground forprope

Pagina 58

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1467.4 Locations of Engine Electrical Components wc_gr0027981172345141915221

Pagina 59 - High Wye

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 1477.5 Engine Electrical ComponentsSee Graphic: wc_gr002798 7.6 Troubleshooting

Pagina 60

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1487.7 Engine Troubleshooting—John Deere without ECUwc_gr002811Check position o

Pagina 61 - MARATHON

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 149wc_gr002831* Battery voltage;approximately 12V.Engine TroubleshootingFlowcha

Pagina 62

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 150Engine TroubleshootingFlowchart 2CJohn Deere without ECUEngine does not Cran

Pagina 63

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 1517.8 Checking Wiring ContinuityWhen checking the continuity of a wire, use th

Pagina 64

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1527.10 Checking ECM Display and LEDsSee Graphic: wc_gr002799 After placing th

Pagina 65 - 4.8 Engine Start

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 153 7.11 Checking BatteryThe ECM display may or may not be blank when the batt

Pagina 66

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1547.12 Checking Power to ECMSee Graphic: wc_gr002827 and wc_gr002800 7.12.1 P

Pagina 67 - 4.9 ECM Monitoring System

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 155wc_gr002800481211109871232563144567362514321121110 9 8 7654321121110 9 8 765

Pagina 68

Safety Information Mobile Generator Repairwc_si000136gb.fm 121.3 Operator Safety while using Internal Combustion EnginesInternal combustion engines pr

Pagina 69

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1567.13 Checking Contacts of ECM Crank RelaySee Graphic: wc_gr002827 and wc_gr0

Pagina 70 - 5.1 Normal Boot-up Sequence

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 1577.14 Checking ECM 10A FuseSee Graphic: wc_gr002802 The 10A fuse is found in

Pagina 71

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1587.15 Checking Diode Across Relay/Solenoid Coil See Graphic: wc_gr002803 The

Pagina 72

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 159 wc_gr002803ecadb

Pagina 73

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1607.16 Checking Coil of Starter Relay and WiringSee Graphic: wc_gr002827 and w

Pagina 74 - 71 24% 87 12.7

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 1617.17 Checking Contacts of Starter Relay and WiringSee Graphic: wc_gr002827 a

Pagina 75

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1627.18 Engine Cranks But Does Not StartEngine TroubleshootingFlowchart 2DJohn

Pagina 76

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 163Replace preheat relay.NoIs 12VDC*measured at terminal30?Ye sCheck for 12VDC*

Pagina 77

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 164 Engine TroubleshootingFlowchart 2FJohn Deere without ECUwc_gr002921Move

Pagina 78

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 1657.19 Checking Contacts of ECM Preheat RelaySee Graphic: wc_gr002928 The E

Pagina 79

Mobile Generator Repair Safety Informationwc_si000136gb.fm 131.4 Towing SafetyTowing a large trailer requires special care. Both the trailer and vehic

Pagina 80

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1667.20 Checking Slave Preheat Relay and WiringSee Graphic: wc_gr002827 and wc_

Pagina 81 - 5.5 CAN Bus Code Screen

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 1677.21 Checking Manifold HeaterSee Graphic: wc_gr002808 The manifold heater (

Pagina 82 - 5.6 Voltage Display Errors

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1687.22 Checking Fuel CircuitSee Graphic: wc_gr002827 and wc_gr002809 The fuel

Pagina 83

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 169 cbd481211109871232563144567362514321wc_gr002809aafae1387

Pagina 84

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 1707.23 General Engine Troubleshooting—John DeereSymptom Problem SolutionEngine

Pagina 85

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 171Engine knocks Low engine oil level Add oil to engine crank-case.Injection pu

Pagina 86 - TEMPERATURE 255

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 172Turbo charger not function-ing (Turbocharge engines only).See authorized dea

Pagina 87

Mobile Generator Repair John Deere Engines without ECUwc_tx000508gb.fm 173Engine overheats Engine overloaded Reduce load.Low coolant level Fill radiat

Pagina 88

John Deere Engines without ECU Mobile Generator Repairwc_tx000508gb.fm 174Notes

Pagina 89

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1758. John Deere Engines with ECU8.1 John Deere Engine BackgroundThe (tier II) Jo

Pagina 90

Safety Information Mobile Generator Repairwc_si000136gb.fm 141.6 Label Locations

Pagina 91

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1768.2 Engine Wiring Diagram—John Deere with ECU87412050D42242908205021222220K3G2K

Pagina 92 - 5.9 Recalibrating the ECM

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1778.3 Engine Wiring Components—John Deere with ECU Ref. Description Ref. Descr

Pagina 93

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1788.4 ECU Wiring Diagram A1 A2 A3B1 B2 B3C1 C2 C3D1 D2 D3E1 E2 E3F1 F2 F3G1 G2 G

Pagina 94

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1798.5 ECU Harness Connector See Graphic: wc_gr002817 8.6 Sensors and Components

Pagina 95

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1808.7 Locations of Engine Electrical Components wc_gr002812123456789101615111314

Pagina 96

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1818.8 Engine Electrical ComponentsSee Graphic: wc_gr002812 8.9 Troubleshooting F

Pagina 97

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1828.10 Engine Troubleshooting—John Deere with ECUwc_gr002819Engine Troubleshootin

Pagina 98

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 183wc_gr002823Engine does not CrankContinued from Flowchart 2G* Battery voltageapp

Pagina 99

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 184wc_gr002824Engine TroubleshootingFlowchart 2IJohn Deere with ECUContinued from

Pagina 100

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1858.11 Checking Wiring ContinuityWhen checking the continuity of a wire, use the

Pagina 101

Mobile Generator Repair Safety Informationwc_si000136gb.fm 15

Pagina 102 - Fuel Level %

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1868.13 Checking ECM Display and LEDsSee Graphic: wc_gr0002813 8.13.1 Remove the

Pagina 103 - 5.13.3 Temperature Sender

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1878.14 Checking System 10A & 30A FusesSee Graphic: wc_gr002820There are two f

Pagina 104 - 5.14 Checking Magnetic Pickup

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1888.16 Checking Power to ECM and Start SwitchSee Graphic: wc_gr002816 and wc_gr00

Pagina 105 - 6.1 Isuzu Engine Background

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 189wc_gr002814481211109871232563144567362514321bP1P2acaEaEaBaBJOHN DEERE sideWACKE

Pagina 106

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1908.17 Checking Contacts of ECM Crank RelaySee Graphic: wc_gr002816 and wc_gr0028

Pagina 107

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1918.18 Checking ECM 10A FuseSee Graphic: wc_gr002802 The 10A fuse is found in th

Pagina 108

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1928.19 Checking Relay Coil DiodesSee Graphic: wc_gr002803 The glow plug relay (a

Pagina 109

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 193 wc_gr002803ecadb

Pagina 110 - Flowchart 1A

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1948.20 Checking Coil of Starter Relay and WiringSee Graphic: wc_gr0002816 and wc_

Pagina 111 - Flowchart 1B

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 195wc_gr002804481211109871232563144567362514321P1P2aaabacadaDJOHN DEERE side WACKE

Pagina 113

Safety Information Mobile Generator Repairwc_si000136gb.fm 161.7 Safety and Operating LabelsRef. Label MeaningAB WARNING! Pressurized contents. Do no

Pagina 114

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 1968.21 Checking Contacts of Starter Relay and WiringSee Graphic: wc_gr002805 and

Pagina 115 - 6.11 Checking Battery

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1978.22 Engine Cranks But Does Not Start—John Deere with ECUReplace preheat relay.

Pagina 116 - 6.12 Checking Power to ECM

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 198 Engine TroubleshootingFlowchart 2KJohn Deerewc_gr002822Place the start swit

Pagina 117

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 1998.23 Checking Slave Preheat Relay and WiringSee Graphic: wc_gr002816 and wc_gr0

Pagina 118

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 2008.24 Checking Manifold HeaterSee Graphic: wc_gr002808 The manifold heater (e)

Pagina 119 - 6.14 Checking ECM 10A Fuse

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 2018.25 Checking Contacts of ECM Fuel RelaySee Graphic: wc_gr002927In order for th

Pagina 120

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 2028.26 Checking Power to ECUSee Graphic: wc_gr002816 and wc_gr002826 Be sure the

Pagina 121

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 203 A1 A2 A3B1 B2 B3C1 C2 C3D1 D2 D3E1 E2 E3F1 F2 F3G1 G2 G3H1 H2 H3J1 J2 J3K1

Pagina 122

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 2048.27 General Engine Troubleshooting—John Deere with ECUSymptom Problem Solution

Pagina 123 - Flowchart 1D

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 205Engine knocks Low engine oil level Add oil to engine crank-case.Injection pump

Pagina 124 - Flowchart 1E

Mobile Generator Repair Safety Informationwc_si000136gb.fm 17G Tie-down pointH WARNING! To prevent hearing loss, wear hearing protection.Hand injury i

Pagina 125 - Flowchart 1F

John Deere Engines with ECU Mobile Generator Repairwc_tx000515gb.fm 206Turbo charger not function-ing (Turbocharge engines only).See authorized dealer

Pagina 126 - Flowchart 1G

Mobile Generator Repair John Deere Engines with ECUwc_tx000515gb.fm 207Engine overheats Engine overloaded Reduce load.Low coolant level Fill radiator

Pagina 127 - Flowchart 1H

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2089. Output Voltage Troubleshooting9.1 Wiring Diagrams G 25

Pagina 128 - Schematic wc_gr002833 detail

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 209See Graphic: wc_gr002854 Ref. Description Ref. Description1 Lug safety limi

Pagina 129 - 6.20 Checking Glow Plugs

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 210 G 50, G 70, G 85, G 125w c _ g r 0 0 0 5 2 4T 6T 8T 1 1T 1 0T 7F +T 1 2T 3

Pagina 130

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 211See Graphic: wc_gr000524 Ref. Description Ref. Description1. Lug safety lim

Pagina 131

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 212G 160

Pagina 132

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 213See Graphic: wc_gr000895 Ref. Description Ref. Description1 Lug safety li

Pagina 133

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2149.2 “No” Voltage Troubleshooting (Zero (0.0) Volts measured

Pagina 134 - 6.24 Isuzu Fuel Solenoid

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 215Make all necessary repairs then retry generator. If there is still no voltag

Pagina 135

Safety Information Mobile Generator Repairwc_si000136gb.fm 18LMN DANGER! Electric shock will cause serious injury or death. Danger of asphyxiation!Re

Pagina 136 - 6.25 Checking Fuel Solenoid

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 216wc_gr002862Is 240V+measured at terminals3 and 4? NoDo all 3windings measure

Pagina 137

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 2179.3 Checking Main Circuit BreakerSee Graphic: wc_gr002855 Electric shock ha

Pagina 138

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2189.4 Checking Circuit Breaker and Function of Voltage SelectorSwitchSee Graph

Pagina 139

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 219 L2L1–NL3–NT8T2T11T32625761021181316T6T9T12L3L1T10T7T4T1L2–Nwc_gr002856Key:

Pagina 140

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2209.5 Replacing Voltage Selector Switch (VSS)See Graphic: wc_gr002123 and wc_g

Pagina 141

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 221 T7 L0T11T8 T6T7 T2 L2 L32618 226T1010 1424 8 16 2412 2820YOr2618 226 10 14

Pagina 142

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2229.6 Checking Exciter Stator WindingSee Graphic: wc_gr002103 9.6.1 Remove ex

Pagina 143

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 223 9.7 Accessing the Rotor Bearing, Diodes, and Rotor WindingSee Graphic: wc_

Pagina 144

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2249.8 Checking Generator/Excitation System(Including Manual Excitation/Flashin

Pagina 145

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 225If your meter shows no continuity between brown wires 3 and 4 withthe interl

Pagina 146

Mobile Generator Repair Safety Informationwc_si000136gb.fm 19O WARNING! Generator can automatically start which can cause serious injury. Disconnect b

Pagina 147

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 226External battery excitation/flashing proceduresSee Graphic: wc_gr001951 The

Pagina 148

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 227VOLTSTABU/Fwc_gr00195160 Hz50 Hz4 Br6 B7 WF- BF+ B3 Br

Pagina 149

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2289.9 Checking Lug Door SwitchSee Graphic: wc_gr002110There are two sets of co

Pagina 150

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 229

Pagina 151

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2309.10 Replacing and Resetting the Automatic Voltage Regulator(AVR)See Graphic

Pagina 152 - John Deere without EC

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 231wc_gr002858ab43F+F-c

Pagina 153 - Flowchart 2B

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2329.11 Checking Exciter Rotor WindingSee Graphic: wc_gr002106 Note: For clari

Pagina 154 - John Deere without ECU

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 2339.12 Checking Rectifier DiodesSee Graphic: wc_gr002104 Note: For clarity, t

Pagina 155 - 7.9 Probing Plugs and Pins

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2349.13 Checking Main Rotor WindingSee Graphic: wc_gr002107 Note: For clarity,

Pagina 156

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 235

Pagina 157 - 7.11 Checking Battery

Safety Information Mobile Generator Repairwc_si000136gb.fm 20T WARNING! Disconnect battery before servicing.Read the Operator's Manual.UA namepla

Pagina 158 - 7.12 Checking Power to ECM

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2369.14 Replacing Rotor Bearing, Diode Ring, and Exciter Rotor See Graphic: wc_

Pagina 159

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 237

Pagina 160

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2389.15 Low* Voltage Troubleshooting (*Greater than 1; usually 30–40)Ye sVer

Pagina 161 - 7.14 Checking ECM 10A Fuse

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 239Low Voltage TroubleshootingFlowchart 4CContinued from Flowchart 4Bwc_gr00286

Pagina 162

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 240See Flowchart 4Cwc_gr003009Are the diodes functioning properly?NoReplace six

Pagina 163

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 2419.16 Verifying VoltageSee Graphic: wc_gr001979 Electric shock hazard. This

Pagina 164

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 2429.17 Checking Main Stator WindingSee Graphic: wc_gr002108 9.17.1 Remove the

Pagina 165

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 2439.18 Generator Produces High Voltage TroubleshootingHigh Voltage Troubleshoo

Pagina 166 - Flowchart 2D

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 244wc_gr003010Check function ofvoltage selector switch.Replace the voltageselec

Pagina 167 - Flowchart 2E

Mobile Generator Repair Output Voltage Troubleshootingwc_tx000509gb.fm 2459.19 Replacing Emergency Stop SwitchSee Graphic: wc_gr002087 Removal:9.19.1

Pagina 168 - Flowchart 2F

Mobile Generator Repair Safety Informationwc_si000136gb.fm 211.8 Calling for ServiceWhen ordering parts or requesting service information, you will al

Pagina 169

Output Voltage Troubleshooting Mobile Generator Repairwc_tx000509gb.fm 246Notes

Pagina 170

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 24710. Disassembly/Assembly Procedures10.1 ToolsBecause all possible problems

Pagina 171

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 24810.5 Exhaust System Exploded View—G 25Ref. Component Ref. Component1 Horizo

Pagina 172 - 7.22 Checking Fuel Circuit

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 24910.6 Removing Exhaust System—G 25See Graphic: wc_gr002055 10.6.1 Shut dow

Pagina 173

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 25010.8 Exhaust System Exploded View—G 50, G 70, G 85 Ref. Component Ref. Com

Pagina 174

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 25110.9 Removing Exhaust System—G 50, G 70, G 85See Graphic: wc_gr002041 and w

Pagina 175

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 25210.10 Installing Exhaust System—G 50, G 70, G 85See Graphic: wc_gr002042

Pagina 176

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 25310.11 Exhaust System Exploded View—G 125, G 160 10.12 Removing Exhaust Sys

Pagina 177

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 25410.13 Installing Exhaust System—G 125, G 160See Graphic: wc_gr002056 10.13

Pagina 178

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 25510.14 Preparing Unit for Generator RemovalSee Graphic: wc_gr002043 10.14.1

Pagina 179

Safety Information Mobile Generator Repairwc_si000136gb.fm 22Notes

Pagina 180 - Wacker side

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 25610.15 Removing GeneratorSee Graphic: wc_gr002044 10.15.1 On John Deere-pow

Pagina 181

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 25710.16 Installing GeneratorSee Graphic: wc_gr002049 10.16.1 To aid in assem

Pagina 182 - 8.4 ECU Wiring Diagram

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 25810.17 Removing Roof and Center Support BracketsSee Graphic: wc_gr002046 10

Pagina 183 - 8.6 Sensors and Components

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 25910.18 Installing Roof and Center Support BracketsSee Graphic: wc_gr002046

Pagina 184

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 26010.19 Preparing Unit for Engine/Generator Removal See Graphic: wc_gr002045

Pagina 185

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 261 wc_gr002045acdbjiefgh

Pagina 186 - John Deere with ECU

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 26210.20 Removing Engine/Generator AssemblySee Graphic: wc_gr002047 10.20.1 U

Pagina 187 - John Deere with EC

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 26310.21 Installing Engine/Generator AssemblySee Graphic: wc_gr002047 10.21.1

Pagina 188 - Flowchart 2I

Disassembly/Assembly Procedures Mobile Generator Repairwc_tx000510gb.fm 26410.22 Replacing Fuel TankSee Graphic: wc_gr002125 Removal:10.22.1 Remove t

Pagina 189 - 8.12 Probing Plugs and Pins

Mobile Generator Repair Disassembly/Assembly Procedureswc_tx000510gb.fm 265

Pagina 190

Mobile Generator Repair Technical Datawc_td000147gb.fm 232. Technical Data2.1 Engine Data—G 25G 250009258, 00094620009476EngineEngine make / typeIsuzu

Pagina 191 - 8.15 Checking Battery

Factory-Installed Options Mobile Generatorswc_tx000524gb.fm 26611. Factory-Installed OptionsThis machine may be equipped with one or more of the follo

Pagina 192

Mobile Generators Factory-Installed Optionswc_tx000524gb.fm 26711.2 Fuel/Water Separator See Graphic: wc_gr001705The fuel/water separator separates wa

Pagina 193

Factory-Installed Options Mobile Generatorswc_tx000524gb.fm 26811.3 Electronic GovernorSee Graphic: wc_gr001714, wc_gr001715, wc_gr001716, wc_gr001717

Pagina 194

Mobile Generators Factory-Installed Optionswc_tx000524gb.fm 269

Pagina 195 - 8.18 Checking ECM 10A Fuse

Factory-Installed Options Mobile Generatorswc_tx000524gb.fm 27011.4 Schematic—Isuzu Engine with Electronic Governor2728+-112ClShW/LOrBBW/VYRYRVRRRGrVR

Pagina 196

Mobile Generators Factory-Installed Optionswc_tx000524gb.fm 27111.5 Components—Isuzu Engine with Electronic Governor Ref. Component Ref. Component1

Pagina 197

Factory-Installed Options Mobile Generatorswc_tx000524gb.fm 27211.6 Schematic—John Deere Engine with Electronic Governor13252487SICPCGSOwc_gr002939196

Pagina 198

Mobile Generators Factory-Installed Optionswc_tx000524gb.fm 27311.7 Components—John Deere Engine with Electronic GovernorRef. Description Ref. Descrip

Pagina 199

Factory-Installed Options Mobile Generatorswc_tx000524gb.fm 27411.8 LCD Strip HeaterSee Graphic: wc_gr001723, wc_gr001724The LCD strip heater option i

Pagina 200

Mobile Generators Factory-Installed Optionswc_tx000524gb.fm 27511.9 Low Coolant ShutdownSee Graphic: wc_gr001708The low-coolant shutdown system consis

Pagina 201 - Flowchart 2J

Technical Data Mobile Generator Repairwc_td000147gb.fm 242.2 Generator Data—G 25G 250009258, 00094620009476GeneratorMake/TypeMarathon / BrushlessModel

Pagina 202 - John Deere

Factory-Installed Options Mobile Generatorswc_tx000524gb.fm 27611.10 Lube Level MaintainerSee Graphic: wc_gr001711, wc_gr001712, wc_gr001713The lube l

Pagina 203

Mobile Generators Factory-Installed Optionswc_tx000524gb.fm 27711.11 Temperature-Activated ShuttersSee Graphic: wc_gr001706, wc_gr001707The shutters (

Pagina 204

Factory-Installed Options Mobile Generatorswc_tx000524gb.fm 27811.12 Schematic—Temperature-Activated Shutters Wire ColorsB Black R Red Y Yellow Or

Pagina 205

Mobile Generators Factory-Installed Optionswc_tx000524gb.fm 27911.13 Components—Temperature-Activated ShuttersSee Graphic: wc_gr003174 Ref Descript

Pagina 206 - 8.26 Checking Power to ECU

Factory-Installed Options Mobile Generatorswc_tx000524gb.fm 280

Pagina 207

Threadlockers and SealantsThreadlockers and SealantsThreadlocking adhesives and sealants are specified throughout thismanual by a notation of “S” plus

Pagina 208

Threadlockers and SealantsThreadlockers and Sealants (continued)Threadlocking adhesives and sealants are specified throughout this manual by a notatio

Pagina 209

Torque ValuesTorque ValuesMetric Fasteners (DIN)TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZESize Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric I

Pagina 210

Torque ValuesTorque Values (continued)Inch Fasteners (SAE)Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric InchNo.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/

Pagina 212 - 9.1 Wiring Diagrams

Mobile Generator Repair Technical Datawc_td000147gb.fm 252.3 Trailer and Skid Data—G 252.4 Dimensions—G 25in. (mm)G 250009258, 00094620009476Trailer a

Pagina 213

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax:

Pagina 214 - G 50, G 70, G 85, G 125

Mobile Generator Repair Forewordwc_tx000420gb.fm iOperating / Parts InformationYou must be familiar with the operation of this machine before youattem

Pagina 215

Technical Data Mobile Generator Repairwc_td000147gb.fm 262.5 Engine Data—G 50, G 70, G 85 G 500009259Rev. 114and lower,0009463,0009477G 700009260Re

Pagina 216

Mobile Generator Repair Technical Datawc_td000147gb.fm 272.6 Generator Data—G 50, G 70, G 85G 500009259Rev. 114and lower,0009463,0009477G 700009260Rev

Pagina 217

Technical Data Mobile Generator Repairwc_td000147gb.fm 282.7 Trailer Technical Data—G 50, G 70, G 85G 500009259Rev. 114and lower,0009463,0009477G 7000

Pagina 218 - Flowchart 3A

Mobile Generator Repair Technical Datawc_td000147gb.fm 292.8 Dimensions—G 50, G 70, G 85in. (mm) 2438 (96)965 (38)1524 (60)3988 (157)wc_gr0016482146

Pagina 219 - Flowchart 3B

Technical Data Mobile Generator Repairwc_td000147gb.fm 302.9 Engine Data—G 125, G 160G 125000926106200670620068G 160000930606200690620070EngineEngine

Pagina 220 - Flowchart 3C

Mobile Generator Repair Technical Datawc_td000147gb.fm 312.10 Generator Data—G 125, G 160G 125000926106200670620068G 160000930606200690620070Generator

Pagina 221

Technical Data Mobile Generator Repairwc_td000147gb.fm 322.11 Trailer Technical Data—G 125, G 1602.12 Dimensions—G 125, G 160mm (inches)G 125000926106

Pagina 222

Mobile Generator Repair Technical Datawc_td000147gb.fm 332.13 Isuzu Engine Performance DataPerformance data on Isuzu engines are measured at the follo

Pagina 223 - # = VSS terminal

Technical Data Mobile Generator Repairwc_td000147gb.fm 342.14 John Deere Engine PerformancePerformance data on John Deere engines are measured at thef

Pagina 224

Mobile Generator Repair Technical Datawc_td000147gb.fm 35MODEL FUEL TEMP RISE of 1.8°FAIR TEMP RISE of 10°FALTITUDE RISE of 305 m (1000 ft)RELATIVE HU

Pagina 225 - Black jumper 20 to 15

Foreword Mobile Generator Repairwc_tx000420gb.fm iiCALIFORNIA Proposition 65 Warning:Diesel engine exhaust, some of its constituents, and certain vehi

Pagina 226

Maintenance Mobile Generator Repairwc_tx000504gb.fm 363. Maintenance3.1 Periodic Maintenance ScheduleThe Periodic Maintenance Schedule below lists bas

Pagina 227

Mobile Generator Repair Maintenancewc_tx000504gb.fm 373.2 Resetting the Periodic Maintenance TimerAfter maintenance has been performed on the generato

Pagina 228

Maintenance Mobile Generator Repairwc_tx000504gb.fm 383.4 Engine LubricationJohn Deere Engines:Check engine oil daily before starting engine. DO NOT o

Pagina 229

Mobile Generator Repair Maintenancewc_tx000504gb.fm 393.5 Engine CoolantCheck the coolant level of the radiator with the engine cold. After initialfil

Pagina 230

Maintenance Mobile Generator Repairwc_tx000504gb.fm 403.7 Trailer Wiring—G 25, G 50, G 70, G 85Ref. Description1 Front right side amber light2 Front l

Pagina 231

Mobile Generator Repair Maintenancewc_tx000504gb.fm 41Standard and Hydraulic BrakesElectric Brakesw c _ g r 0 0 0 5 2 2B rB rWWB rWGB rWYB r WB r WYGB

Pagina 232 - 9.9 Checking Lug Door Switch

Maintenance Mobile Generator Repairwc_tx000504gb.fm 423.8 Trailer Wiring—G 125, G 160Ref. Description1 Front right side amber light2 Front left side a

Pagina 233

Mobile Generator Repair Maintenancewc_tx000504gb.fm 43Standard and Hydraulic BrakesElectric Brakesw c _ g r 0 0 0 5 2 2B rB rWWB rWGB rWYB r WB r WYGB

Pagina 234

Maintenance Mobile Generator Repairwc_tx000504gb.fm 44Notes

Pagina 235

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 454. Theory of Operation4.1 IntroductionSee Graphic: wc_gr002915A generator set is a trans

Pagina 236

Mobile Generator Repair Table of Contentswc_br0160486enTOC.fm 11. Safety Information 81.1 Operating Safety ...

Pagina 237

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 464.2 Basic Generator SchematicRef. Component Ref. Componenta Exciter stator g Automatic v

Pagina 238

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 474.3 Generator Components Ref. Component Ref. Componenta Rotating rectifier f Drive disc

Pagina 239

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 48

Pagina 240

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 49 See Graphic: wc_gr002854Wire ColorsB Black R Red Y Yellow Or OrangeG Green T Tan Br Br

Pagina 241

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 50 G 50, G 70, G 85, G 125, G 160

Pagina 242 - Flowchart 4A

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 51 See Graphic: wc_gr002917Wire ColorsB Black R Red Y Yellow Or OrangeG Green T Tan Br Br

Pagina 243 - Flowchart 4C

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 524.5 Generator SystemsThe generator can be divided into four basic systems: 1) Power Gene

Pagina 244 - Flowchart 4B

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 534.6 Power Generation & OutputSee Graphic: wc_gr002915General OperationThe figure sho

Pagina 245 - 9.16 Verifying Voltage

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 54See Graphic: wc_gr002767Voltage Selector Switch (VSS)The VSS changes connections between

Pagina 246

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 55* Do not use GFI receptacles because GFI receptacles are only rated to 135V. Use care wh

Pagina 247 - Flowchart 5A

Table of Contents Mobile Generator Repairwc_br0160486enTOC.fm 24. Theory of Operation 454.1 Introduction ...

Pagina 248 - Flowchart 5B

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 56 See Graphic: wc_gr002775Terminal Lugs and ReceptaclesThe main connection lugs, labeled

Pagina 249

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 574.7 Voltage RegulationSee Graphic: wc_gr002776 and wc_gr002777The Automatic Voltage Regu

Pagina 250

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 58 See Graphic: wc_gr0002778Regulator MakeupThere are eight terminals on the regulator la

Pagina 251 - (550 lbs.)

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 59• Terminals 50Hz and 60HzThere is an white jumper wire connected (at the factory) to the

Pagina 252 - 4 Rod 8 Exhaust tail pipe

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 60See Graphic: wc_gr002769Voltage Adjusting RheostatGenerator output voltage can be adjust

Pagina 253

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 614.8 Engine StartBattery B+ wires provide 12VDC to the following locations on eachgenerat

Pagina 254

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 62In the START/RUN position the ECM preheat relay will energize on thefirst of the three c

Pagina 255

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 634.9 ECM Monitoring SystemOperationThe ECM contains a microprocessor that monitors engine

Pagina 256

Theory of Operation Mobile Generator Repairwc_tx000505gb.fm 64The shutdown trip point is approximately 67Hz (2010 rpm) foroverspeed and 55Hz (1650 rpm

Pagina 257

Mobile Generator Repair Theory of Operationwc_tx000505gb.fm 65See Graphic: wc_gr002779 Current TransformersLoad line current values are provided by t

Pagina 258

Mobile Generator Repair Table of Contentswc_br0160486enTOC.fm 36.9 Probing Plugs and Pins ...

Pagina 259

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 665. ECM Troubleshooting5.1 Normal Boot-up SequenceDuring the boot-up sequence, the ECM sc

Pagina 260 - 10.15 Removing Generator

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 67G 85 (9305), G 125, G 160 ECM Display DescriptionStart of the boot-up sequence. The ECM

Pagina 261 - 10.16 Installing Generator

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 68The ECM displays the AC configuration as determined by the position of the voltage selec

Pagina 262

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 695.2 Display Variables and ValuesSee Graphic: wc_gr002944• Generator VariablesThe values

Pagina 263

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 705.3 ECM Display Screens—Start Switch in Remote PositionSee Graphic: wc_gr002943When the

Pagina 264

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 715.4 Additional Variables Monitored by the ECMHolding the toggle switch in the HOURS/RESE

Pagina 265

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 72G 25, G 50, G 85 (9310) Cold Weather and Custom GeneratorsThe display shows the status o

Pagina 266

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 73The display shows the status of the speed sender. If the speed sender has failed, the ti

Pagina 267

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 74The display shows the value of the fault setting for low oil pressure. If the ECM detect

Pagina 268 - 10.22 Replacing Fuel Tank

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 75G 85 (9305), G 125, G160 John Engines with ECUThe display shows the status of the batter

Pagina 269

Table of Contents Mobile Generator Repairwc_br0160486enTOC.fm 47.18 Engine Cranks But Does Not Start ...

Pagina 270 - 11.1 Block Heater

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 76The display shows the present load on the engine. For no load conditions (generator not

Pagina 271 - 11.2 Fuel/Water Separator

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 775.5 CAN Bus Code ScreenFor John Deere engines with electronic control (G 85, G 125, G160

Pagina 272 - 11.3 Electronic Governor

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 785.6 Voltage Display ErrorsSee Graphic: wc_gr002770• Single Phase Display ModeThe ECM is

Pagina 273

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 79• Engine Hour Switch in Locked PositionAnother possible display error can occur when sta

Pagina 274

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 805.7 ECM Automatic Engine Shutdown ConditionsThe engine protection system includes six au

Pagina 275

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 81If the pressure gauge reads differently than the ECM, there is aproblem with the sender

Pagina 276

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 825.7.2 High Coolant Temperature FaultSee Graphic: wc_gr001982, wc_gr001983, and wc_gr0020

Pagina 277

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 835.7.2.4 Check the function of the ECM by attaching varying loads of resistanceon one end

Pagina 278 - 11.8 LCD Strip Heater

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 845.7.3 Overspeed/Underspeed Shutdown FaultSee Graphic: wc_gr001984 and wc_gr002780When t

Pagina 279 - 11.9 Low Coolant Shutdown

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 855.7.4 Overcrank Shutdown Fault To rectify an overcrank condition, carry out the engine

Pagina 280 - 11.10 Lube Level Maintainer

Mobile Generator Repair Table of Contentswc_br0160486enTOC.fm 59. Output Voltage Troubleshooting 2089.1 Wiring Diagrams ...

Pagina 281

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 865.7.5 Low Fuel Shutdown Fault See Graphic: wc_gr002084A low fuel fault condition will b

Pagina 282

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 875.7.6 Over Current Shutdown Fault Along with engine functions, the ECM continuously mo

Pagina 283

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 885.8 Sender Failures If one of the sensors should malfunction or become shorted to groun

Pagina 284

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 89wc_gr002771bac208 L1d

Pagina 285 - Threadlockers and Sealants

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 90See Graphic: wc_gr0027725.9.2 To recalibrate the ECM AC amperage display:5.9.2.1 Start t

Pagina 286

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 91See Graphic: wc_gr002795 5.9.3 To recalibrate the ECM AC frequency (Hz) display:Note: R

Pagina 287 - Torque Values

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 92See Graphic: wc_gr002796 and wc_gr002971Isuzu and John Deere engines without ECU5.9.4 To

Pagina 288

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 935.10 Removing and Installing the ECMSee Graphic: wc_gr002797 Removal:5.10.1 Remove the

Pagina 289

ECM Troubleshooting Mobile Generator Repairwc_tx000506gb.fm 945.11 ECM Circuit Boards Note: Your machine’s ECM board may differ slightly from the one

Pagina 290

Mobile Generator Repair ECM Troubleshootingwc_tx000506gb.fm 955.12 Control Wiring Numbering & ColorsSee Graphic: wc_gr002924Generator and control

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