Repair Manual

Mobile Generator

G 70

0175252en 004 0709

0 1 7 5 2 5 2 E N
Copyright © Copyright 2009 by Wacker Neuson Corporation.
notice All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Corporation
represents an infringement of valid copyrights. Violators will be prosecuted.

Trademarks All trademarks referenced in this manual are the property of their respective owners.

Manufacturer Wacker Neuson Corporation

N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
Mobile Generator Repair Foreword

This manual covers machines with Item Number:

0620350, 0620351, 0620352, 0620708

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. Keep a copy of the Operator’s Manual with the machine at all
times. Use the separate Parts Book supplied with the machine to order
replacement parts. If you are missing either of the documents, please
contact Wacker Neuson Corporation to order a replacement.

Damage caused by misuse or neglect of the unit should be brought to

the attention of the operator to prevent similar occurrences from
happening in the future.

This manual provides information and procedures to safely repair and

maintain the above Wacker Neuson model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions described in this manual. The information contained in this
manual is based on machines manufactured up to the time of
publication. Wacker Neuson Corporation reserves the right to change
any portion of this information without notice.

3
Foreword Mobile Generator Repair

CALIFORNIA
Proposition 65 Warning:
Diesel engine exhaust, some of its constituents, and certain vehicle
WARNING
components contain or emit chemicals known to the State of California
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. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.

All rights, especially copying and distribution rights, are reserved.

Copyright 2009 by Wacker Neuson Corporation

No part of this publication may be reproduced in any form or by any

means, electronic or mechanical, including photocopying, without
express written permission from Wacker Neuson Corporation.

Any type of reproduction or distribution not authorized by Wacker

Neuson Corporation represents an infringement of valid copyrights,
and violators will be prosecuted. We expressly reserve the right to
make technical modifications, even without due notice, which aim at
improving our machines or their safety standards.

4
G 70 Table of Contents
1 Safety Information 9

1.1 Operating Safety ................................................................................ 10

1.2 Service Safety .................................................................................... 12
1.3 Operator Safety while using Internal Combustion Engines ................ 14
1.4 Towing Safety ..................................................................................... 15

2 Theory of Operation 16

2.1 Basic Schematic ................................................................................. 16

2.2 Introduction ......................................................................................... 17
2.3 Terminology ........................................................................................ 19

3 Electrical Testing Techniques 23

3.1 Checking Continuity ........................................................................... 23

3.2 Checking Resistance .......................................................................... 23
3.3 Checking Voltage ............................................................................... 23
3.4 Probing ECM Plugs and Pins ............................................................. 24

4 ECM Background Information 25

4.1 ECM Handling Precaution .................................................................. 25

4.2 Normal Boot-up Sequence ................................................................. 26
4.3 Display Variables and Values ............................................................. 28
4.4 ECM Display Screens—Start Switch in Remote Position ................... 29
4.5 Additional Variables Monitored by the ECM ....................................... 30
4.6 Voltage Display Errors ........................................................................ 32
4.7 ECM Automatic Engine Shutdown Conditions ................................... 34
4.8 ECM Wire Numbering & Colors .......................................................... 35
4.9 Removing and Installing the ECM ...................................................... 36

5 ECM/Sensor Troubleshooting 38

5.1 Checking Power to the ECM .............................................................. 39

5.2 Checking Outgoing Power From the ECM ......................................... 41

5
Table of Contents G 70
5.3 Fuel Sender Failure and Low Fuel Fault .............................................42
5.4 Calibrating ECM Voltage Display ........................................................44
5.5 Calibrating ECM AC Amperage Display ..............................................46
5.6 Calibrating ECM AC Frequency Display .............................................47
5.7 Calibrating ECM DC Display ...............................................................48
5.8 Checking the ECM CAN BUS Circuit ..................................................49
5.9 ECM Plugs and Pins ...........................................................................50
5.10 Checking the Main Circuit Breaker ......................................................51

6 John Deere Engines with ECU 53

6.1 John Deere Engines With ECU—Background ....................................53

6.2 Locations of Engine Electrical Components ........................................54

7 Troubleshooting Engine Start System 55

7.1 Checking Fuses ...................................................................................55

7.2 Checking the Engine Control Module (ECM) ......................................57
7.3 Checking the Emergency Stop Switch ................................................59
7.4 Checking the Starter Relay .................................................................61
7.5 Checking the Starter Solenoid .............................................................62
7.6 Checking the Intake Air Heater Relay .................................................63
7.7 Checking the Main Circuit Breaker ......................................................64

8 Output Voltage Troubleshooting 66

8.1 Where to Start .....................................................................................66

8.2 Checking the Emergency Stop Switch ................................................67
8.3 Checking the Lug Door Switch ............................................................68
8.4 Checking the Main Circuit Breaker ......................................................70
8.5 Checking the Voltage Adjusting Rheostat ...........................................72
8.6 Checking the Auxiliary Winding ...........................................................73
8.7 Checking the Exciter Stator .................................................................74
8.8 Checking the AVR Sensing/Power Wires ............................................75
8.9 Flashing the Generator (checking the excitation system) ...................77
8.10 Checking Stator Windings at the Lugs ................................................78
8.11 Checking the Rectifier Diodes .............................................................79
8.12 Checking the Main Rotor Winding .......................................................80

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G 70 Table of Contents
8.13 Checking the Exciter Rotor Winding ................................................... 81
8.14 Checking Stator Windings at the Generator ....................................... 82

9 Disassembly and Assembly 83

9.1 Tools Required for Disassembly/Assembly Procedures ..................... 83

9.2 Information Regarding Replacement Parts ........................................ 83
9.3 Information Regarding Reference Numbers ....................................... 83
9.4 Removing the Roof ............................................................................. 84
9.5 Removing the Voltage Selector Switch .............................................. 86
9.6 Installing the Voltage Selector Switch ................................................ 87
9.7 Removing the Generator .................................................................... 88
9.8 Installing the Generator ...................................................................... 90
9.9 Removing the AVR ............................................................................. 93
9.10 Installing the AVR Prerequisites ......................................................... 94

10 Schematics 98

10.1 Engine Wiring Diagram—John Deere with ECU ................................ 98

10.2 Engine Wiring Components—John Deere with ECU ......................... 99
10.3 Generator Wiring Diagram ............................................................... 100
10.4 Generator Wiring Components ......................................................... 101

11 Technical Data 102

11.1 Engine Data ...................................................................................... 102

11.2 Generator Data ................................................................................. 103
11.3 Trailer and Skid Data ........................................................................ 104
11.4 Dimensions ....................................................................................... 105

7
Table of Contents G 70
Notes

wc_br0175252en_004TOC.fm 8
G 70 Safety Information
1 Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE, 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.

DANGER indicates a hazardous situation which, if not avoided, will

result in death or serious injury.
DANGER

WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.
WARNING

CAUTION indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.
CAUTION
NOTICE: Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.

Note: Contains additional information important to a procedure.

Electrocution hazard!
Electrocution or severe electrical shock hazards are present
throughout the generator any time the engine is running! Read all
WARNING
safety notes contained in this section before operating or servicing this
equipment.
No one except a trained electrician, familiar with this equipment,
should attempt repairs to the generator! Test procedures which require
that the generator be running must be performed using extreme
caution.
This machine is built with user safety in mind; however, like any
electrical device it can present serious hazards if improperly operated
and serviced. Follow instructions carefully! Should questions arise
during operation or service of this equipment, contact Wacker Neuson
Corporation.

wc_si000353gb.fm 9
Safety Information G 70
1.1 Operating Safety

Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be hazardous. Read the operating instructions contained in this
WARNING manual and the engine manual, and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
1.1.1 NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
1.1.2 NEVER place flammable material or liquids near the generator.
1.1.3 NEVER operate the generator, or tools attached to the generator, with
wet hands.
1.1.4 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
1.1.5 NEVER operate the machine indoors unless exhaust fumes can be
adequately ventilated.
1.1.6 NEVER overload the generator. The total amperage of the tools and
equipment attached to the generator must not exceed the load rating
of the generator.
1.1.7 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a certified electrician.
1.1.8 NEVER operate generator in standing water.
1.1.9 NEVER touch the hot engine, exhaust, or generator components.
Burns will result.
1.1.10 NEVER start a machine in need of repair.
1.1.11 Use the emergency stop button only in an actual emergency. DO NOT
restart the engine until the cause of the trouble has been determined
and fixed.
1.1.12 Wear hearing protection when operating equipment.
1.1.13 ALWAYS follow starting and stopping instructions described in this
manual. Know how to operate and stop generator before starting it.
1.1.14 ALWAYS make a walk-around inspection of the generator set before
starting it. Open side doors and visually inspect engine compartment
for obvious damage or the presence of foreign objects which might
affect operation.
1.1.15 ALWAYS keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
1.1.16 Store the machine properly when it is not being used. The machine
should be stored in a clean, dry location out of the reach of children.

wc_si000353gb.fm 10
G 70 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 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 the
generator before starting it.
1.1.20 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER
DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR
DEATH TO UTILITY WORKERS!
DANGER
Improper connection of generator to a building’s electrical system can
allow electrical current from the generator to backfeed into utility lines.
This may result in electrocution of utility workers, fire, or explosion.
Connections to a building’s electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical
codes.
If connected to a building’s electrical system the generator must meet
the power, voltage, and frequency requirements of the equipment in
the building. Differences in power, voltage, and frequency
requirements may exist and improper connection may lead to
equipment damage, fire, and personal injury or death.

wc_si000353gb.fm 11
Safety Information G 70
1.2 Service Safety

A poorly maintained machine can become a safety hazard! In order

for the machine to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
WARNING

1.2.1 NEVER perform even routine service (oil/filter changes, cleaning,

etc.) unless all electrical components are shut down. Before
servicing this machine, make sure the engine start switch is turned to
off “O”, the circuit breakers are open (off), the emergency stop switch
is closed (pushed in), and the negative terminal on battery is
disconnected. Attach a “DO NOT START” sign to the control panel.
This will notify everyone that the unit is being serviced and will reduce
the chance of someone inadvertently trying to start the unit. If the unit
is connected to a remote start or transfer switch, make sure the remote
switch is also off and tagged.
1.2.2 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.
1.2.3 DO NOT attempt to open the radiator cap while the unit is running or
before the engine has cooled down. Severe burns may result!
1.2.4 DO NOT allow water to accumulate around the base of the machine.
If water is present, move the machine and allow the machine to dry
before servicing.
1.2.5 DO NOT service the machine if your clothing or skin is wet.
1.2.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
1.2.7 Do not modify the machine without the express written approval of the
manufacturer.
1.2.8 DO NOT pressure wash the control panel, generator end, or any other
electrical components when cleaning the machine. Never allow water
to accumulate around the base of the generator set. If water is present,
DO NOT service!
1.2.9 ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.2.10 ALWAYS let the engine cool before transporting or servicing the
machine.

wc_si000353gb.fm 12
G 70 Safety Information
1.2.11 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the machine.
1.2.12 ALWAYS replace all guards, fasten doors, and make sure all safety
devices operate properly after making repairs or servicing the
equipment.
1.2.13 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
1.2.14 Keep the machine clean and labels legible. Replace all missing and
hard-to-read labels. Labels provide important operating instructions
and warn of dangers and hazards.
1.2.15 ALWAYS check all external fasteners at regular intervals.
1.2.16 ALWAYS make sure slings, chains, hooks, ramps, jacks, and other
types of lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people in the area when lifting the
machine.

wc_si000353gb.fm 13
Safety Information G 70
1.3 Operator Safety while using Internal Combustion Engines

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
WARNING warnings and safety standards 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.
1.3.2 Do not fill or drain the fuel tank near an open flame, while smoking, or
while the engine is running.
1.3.3 Do not refuel a hot or running engine.
1.3.4 Refill the fuel tank in a well-ventilated area.
1.3.5 Do not touch or lean against hot exhaust pipes.
1.3.6 Replace the fuel tank cap after refueling.
1.3.7 Do not start the engine if fuel has spilled or a fuel odor is present. Move
the generator away from the spill and wipe the generator dry before
starting.
1.3.8 Do not remove the radiator cap when the engine is running or hot. The
radiator fluid is hot and under pressure and may cause severe burns!

wc_si000353gb.fm 14
G 70 Safety Information
1.4 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

1.4.1 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. DO NOT
tow the trailer using defective parts.
1.4.3 ALWAYS make sure the coupling is securely fastened to the vehicle.
1.4.4 ALWAYS check the tires on the trailer for tread wear, inflation, and
condition. Replace worn tires.
1.4.5 ALWAYS connect the safety chains.
1.4.6 ALWAYS connect the breakaway cable safety hook to the bumper or
rear of the vehicle. DO NOT attach it to the hitch.
1.4.7 ALWAYS test the surge brakes on the trailer and the brakes on the
vehicle that will be used for towing.
1.4.8 ALWAYS make sure directional and trailer lights are connected and
working properly.
1.4.9 ALWAYS check that the lug nuts holding the wheels are tight and that
none are missing.
1.4.10 Reporting Trailer Safety Defects
If you believe your trailer has a defect which could cause a crash or
could cause injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to
notifying Wacker Neuson Corporation.
If NHTSA receives similar complaints, it may open an investigation;
and if it finds that a safety defect exists in a group of vehicles, it may
order a recall and remedy campaign. However, NHTSA cannot
become involved in individual problems between you, your dealer, or
Wacker Neuson Corporation.
To contact NHTSA, you may either contact the Auto Safety Hotline toll-
free at 1-800-424-9393 (or 366-0129 in Washington DC area),
www.nhtsa.com, or write to NHTSA, U.S. Department of
Transportation, 400 7th Street SW, (NSA-11), Washington, DC 20590.
You can also obtain other information about motor vehicle safety from
the Auto Safety Hotline.

wc_si000353gb.fm 15
Theory of Operation Mobile Generator
2 Theory of Operation

2.1 Basic Schematic

l
T1 L1
b
c 3-Phase AC out d T2 T3 h
DC in
+

T4
a e i T7
L2
T12 T8 T6 T5
3-Phase
–
T11
f AC output
T10
Y L
+ –
AC in L/W L R
k T9 L3
DC out (exciter field)

AC sensing

B R G Y L N
n/a n/a
5C 5B 7 5A 6 5 4A 4 3A 3 2 1
B W GND

j g
AMP HZ STAB VOLT wc_gr003643

Ref. Component Ref. Component

a Exciter stator winding g Automatic Voltage Regulator
(AVR)
b Rotor assembly h Main circuit breaker
c Exciter rotor winding i Auxiliary winding
d Rotating rectifier (diodes) j Voltage adjusting rheostat
e Main rotor winding k Lug door switch
f Main stator windings l Stator assembly

wc_tx001077gb.fm 16
Mobile Generator Theory of Operation
2.2 Introduction

See Graphic: wc_gr003303

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. The generator does so through the principle of
electromagnetic induction. This principle states that when a coil of wire
(also known as a winding) is passed through a magnetic field, a
voltage is induced in the winding. The amount of voltage depends on
three factors: 1) the speed of the coil cutting through the magnetic field
(it does not matter which is moving—either the magnetic field or the
winding); 2) the strength of the magnetic field; and 3) the amount of
turns of wire in the winding. The principle also works in reverse; that is,
if voltage and current are present in a coil of wire, a magnetic field is
produced. It is important to understand this basic theory to understand
how the generator functions.

The typical brushless generator assembly consists of a stator

(stationary element), a rotor (rotating element), a voltage regulator
(voltage control device), and a rectifier assembly (current control
device). The rotor can function as either the magnetic field or the
winding. Likewise, the stator can function as either the magnetic field
or the winding, depending on the application. In Wacker Neuson
generators there are two stators (a and b) and a single rotor assembly
(c). The rotor assembly is made up of two halves—the exciter (d) and
the main (e). Three windings make up the exciter half and a single
winding makes up the main rotor half. There are three distinct stator
windings—the exciter, the main, and the auxiliary. The exciter stator
winding (a) is a stand-alone winding. The main and auxiliary windings
are housed within the large stator housing (b).

The exciter stator is the generator’s source of residual magnetism. As

the engine spins, the exciter rotor portion of the rotor assembly spins
inside the exciter stator, an AC voltage is induced in the exciter rotor.
This AC voltage is rectified into DC by the diodes (f) connected to the
rotor assembly. The DC voltage flows through the main rotor winding,
creating a magnetic field. Voltage is then induced in the main stator
windings and the auxiliary winding. The voltage induced in the main
stator windings provides the voltage to the lugs and the receptacles.
The voltage induced in the auxiliary winding is used to power the
voltage regulator.

wc_tx001077gb.fm 17
Theory of Operation Mobile Generator

b
a
e

c
f

e
d

wc_gr003303

wc_tx001077gb.fm 18
Mobile Generator Theory of Operation
2.3 Terminology
See Graphic: wc_gr003315
To understand the terms “phase”, “leg”, “line-to-line”, and “line-to-
neutral”, review the following information.
• The main stator (a) consists of three separate groups of windings.
These groups of windings are referred to as legs. The legs are labeled
L1, L2, and L3. Each leg includes two individual windings. The ends of
these windings are labeled T1, T2, T3, and so on, up to T12.
• Each individual winding has the same resistance (0.2 Ohms). The
voltage selector switch determines how the windings are connected—
in series or parallel. In series, the total voltage of a leg is equal to the
sum of the voltages induced across both windings. In parallel, the total
voltage of a leg is equal to the voltage induced across either winding
(only one).
• Each leg (L1, L2, and L3) is physically 120° from each other.
• The main rotor (b) functions as a rotating magnetic field. It has four
poles, two of which function as North and the other two as South.
• “Flux” is a term used to describe the amount of magnetic field in a
given area. The term “lines of flux” refers to the direction of the attrac-
tion of the magnetic fields—North to South. The point where these
lines of flux are closest to 90° is the point where the magnetic field is
the strongest, i.e., at either pole. The lines of flux (c) of the main
rotor’s magnetic field are as shown. When the windings of the stator
cut these lines of flux, voltage is induced in them. The amount of
induced voltage is greatest at the position where the stator winding is
perpendicular to the lines of flux, i.e., when the rotor is in such a posi-
tion that the windings of a leg are centered over one of the four mag-
netic poles.
• When the two windings of each leg are connected in series, this is the
high-wye configuration (e). The voltage induced in this configuration is
277V per leg. When the two windings of each leg are wired in parallel,
this is the low-wye configuration (f). The voltage induced in this con-
figuration is 139V per leg. (It is adjusted to a usable 120V by the con-
trol panel rheostat.)
• The amount of voltage induced in each leg over time can be graphed.
This graph yields a sine wave (d). It represents the repeating event
(cycle) of the induced positive voltage of the North pole followed by
the induced negative voltage of the South pole. Since the rotor has
four magnetic poles, this cycle occurs twice per revolution of the rotor.
• The engine spins the rotor at 1800 rpm which equals 30 revolutions
per second (rps) (1800 ÷ 60 = 30). The number of revolutions per sec-
ond multiplied by the cycles per revolution (cpr) equals the cycles per
second (Hertz). Thus, 30 rps x 2 cpr = 60 Hz.

wc_tx001077gb.fm 19
Theory of Operation Mobile Generator

L1
High Wye T1 Low Wye L1
L1
e T2 f
T3 T1
T3 a
L-L
T4 (480V) T4 T2 L-L
(208V)
N T8 N T6
T11 T7 T11 T5
T10 L2 T8
L3 T6
T9 T5 L3 L2
L-N L-N L3 L2
(277V) (120V)

c L1

b
N1

N1

N1
S2

S2

S2
N2

N2

N2
S1

S1

S1
L3 L2

0˚ 45˚ 90˚ 135˚ 180˚

L1 L1 L1 L1 L1
S1
N1

S1
N2
N1

S1
S2

N1

N2

N1
S2
S1

S2

N1
S2
N2

N2
S1

S2
L3 L2 L3 N2 L2 L3 L2 L3 L2 L3 L2

N1–S1 N2–S2
0˚ 45˚ 90˚ 135˚ 180˚
0˚ 45˚ 90˚ 135˚ 180˚ 225˚ 270˚ 315˚ 360˚

d
L2

L1 L1

L3

120˚ 120˚

1 Hz

1 Rev
wc_gr003315

wc_tx001077gb.fm 20
Mobile Generator Theory of Operation

• Since the legs are mechanically 120° apart, as the rotor spins, time
elapses between the moment when one leg reaches its largest volt-
age potential and the moment when the next leg reaches its largest
voltage potential. Thus, no two legs reach their largest voltage poten-
tial at the same moment in time, and their corresponding sine waves
are 120° apart. In other words, the voltages induced in each leg are
120° out of phase with each other.
• Although the largest amount of voltage induced in any single leg in the
high-wye configuration is 277V, the voltage induced in a second leg
(either of the other two legs) at that same moment can be tapped and
combined with the 277V of the first leg to create the maximum voltage
available from the generator. The amount of voltage in the second leg
is less than its largest potential because of the position of the rotor’s
magnetic field—it is less than perpendicular to the second leg. The
amount of voltage induced is approximately 73% (203V) of its poten-
tial (see graphic wc_gr003317). Thus, 277V + 203V = 480V, which is
the maximum voltage available from the generator. In the low-wye
configuration, the largest usable voltage potential in any leg is 120V;
adding the 73% of any second leg (88V), yields the maximum voltage
potential for the low-wye configuration—208V.
• Any measurement between the end of a leg and neutral is know as
line-to-neutral (L-N) voltage. Any measurement between the end of
one leg to the end of another leg is known as line-to-line (L-L) voltage.
Any combination of L-N or L-L voltages are 120° out of phase with
each other. For example, L1–N is out of phase with L2–N; L2–N with
L3–N; L3–N with L1–N. Likewise, L1–L2 is out of phase with L2–L3;
L2–L3 with L3–L1; and L2–L3 with L1–L2.
• A three-phase event exists when a three-phase load is attached to the
generator. The three-phase load uses both the voltage and current
from each phase produced by the generator simultaneously. Positive
current produced by the voltage from each leg flows to corresponding
legs of the load.

Sine 60 = 0.866 Sine 60 = 0.866

30˚ Sine 60 = a/277 30˚ Sine 60 = a/120
a 0.866 = a/277 a 0.866 = a/120
277 277 x 0.866 = (a/277) x 277 120 120 x 0.866 = (a/120) x 120
240 = a 104 = a
120˚
60˚ 2(a) 2(a) = 480 120˚
60˚ 2(a) 2(a) = 208
60˚ 60˚
120˚ 120˚
480 – 277 = 203 208 – 120 = 88
203/277 = 0.73 = 73% 88/120 = 0.73 = 73%

wc_gr003317

wc_tx001077gb.fm 21
Theory of Operation Mobile Generator

• Wacker Neuson generators are designed to accommodate various

loads and multiple power factors. Power factor is the relationship
between power supplied to the load (referred to as apparent power in
kVA) and true power (power used by the load (kW). It is expressed
mathematically by the equation: power factor = true power ÷ apparent
power. The power factor is determined by the type of load—inductive
or resistive. In resistive loads, such as heaters, the power factor is typ-
ically 1. In inductive loads, such as motors and transformers, the
power factor is always less than 1. In inductive loads, a portion of the
supplied power is converted to a magnetic field and not used by the
load. This unused power is known as reactive power. The relationship
between apparent power, true power, and reactive power is illustrated
in the power right triangle below.

Reactive power and true power are always represented 90° from each
other. In the power right triangle, the angle formed by the hypotenuse
(apparent power) and the adjacent side (true power) is referred to as
theta ( ). Theta is derived from the separation in the sine waves of
voltage and current. In inductive circuits, current lags the voltage due
to such factors as coil length, coil material, and frequency. From trigo-
nometry, the cosine of = adjacent side ÷ hypotenuse. Since cosine
and power factor are calculated in the same manner, power factor is
often referred to as cosine (cos ).
• Single-phase receptacles are tapped off the legs in a manner that
keeps the generator balanced. That is, voltage supplies to the various
single-phase outlets originate from different legs of the generator (L1
and L3), not from the same leg. When tapping single-phase loads
from the lugs, care must be taken so that the generator does not
become unbalanced. Attach equal loads to each leg if you are running
the generator in this manner.

wc_tx001077gb.fm 22
Mobile Generator Electrical Testing Techniques
3 Electrical Testing Techniques

3.1 Checking Continuity

Conduct continuity tests when the engine is shut down.

When checking continuity, use the Ohm setting on your multimeter.
Place a lead of the multimeter on one end of the wiring or component
and the other lead on the opposite end. If your meter reads “OL” or
“OPEN”, there is no continuity and the wiring or component must be
repaired or replaced.
Note: Some multimeters also have an audio signal setting for
determining continuity. This setting may also be used.
• If your meter reads less than 1.0 Ohm, or the audio signal
sounds, the wiring or component has continuity and should be
OK.
• If your meter reads more than 1.0 Ohm, the wiring is faulty and
must be repaired or replaced.

3.2 Checking Resistance

Conduct resistance checks when the engine is shut down.

Use the Ohm setting on your multimeter.
Conduct resistance checks when the machine is as close to 21°C
(70°F) as possible. Higher temperatures can affect resistance values.
Most digital multimeters have some internal resistance. To obtain your
multimeter’s internal resistance, simply cross the two leads of your
multimeter and read the display. When conducting a resistance check,
subtract your multimeter’s internal resistance from the value you
measure to obtain the true resistance of the component you are
checking.

3.3 Checking Voltage

Conduct voltage checks when the engine is running.

Use the Volt setting on your multimeter. To prevent damage to your
instrument, start with the highest scale available on your multimeter.
Adjust to a lower scale as readings dictate.
Use extreme caution when checking voltage to reduce the risk of
electric shock.

wc_tx000699gb.fm 23
Electrical Testing Techniques Mobile Generator
3.4 Probing ECM Plugs and Pins

See Graphic: wc_gr002926

To measure the voltage at an ECM pin, attach an appropriate
extension (a) to the positive probe on your multimeter. Slide the
positive probe into the plug along the wire of the pin to be tested. Use
care when testing this way so you don’t damage the wire, plug, or
ECM. Find a suitable ground on the machine’s frame for the negative
probe (b) of your multimeter.

654
321 43
21

12 1110 9
6 5 4 3 87 8765
21 43 2 1
a

wc_gr002926

24 wc_tx000699gb.fm
Mobile Generator Repair ECM Background Information
4 ECM Background Information

4.1 ECM Handling Precaution

See Graphic:wc_gr003355
NOTICE: Use care when working on or around the ECM. The ECM
may be damaged or it may malfunction if it is accidentally hit by your
hand or a tool. Do not touch the pins (a) of the ECM because the AC
board of the ECM may malfunction.

wc_gr003355

wc_tx001066gb.fm 25
ECM Background Information Mobile Generator Repair
4.2 Normal Boot-up Sequence

During the boot-up sequence, the ECM scrolls through several

screens before it settles into displaying the run screen.
G 70, G 85, G 120

ECM Display Description

Start of the boot-up sequence. The ECM display reads
“Initializing” and shows the model of the generator. If the
Initializing model displayed does not match the model of the gener-
G 85 ator, call Wacker Neuson Service.

The ECM displays the countdown time until the next

scheduled service. The timer starts at 250 and counts
Time to Service down to 0.
250

The ECM displays this screen during the first cranking

cycle.
Cranking 1 of 3

The ECM displays this screen as soon as the engine

starts. Note that some of the values such as voltage, may
80 P2 0 60.0 not be up to their running values at this stage of the
71 75% 87 12.7 sequence.

The ECM displays this screen to let the operator know

that the under frequency system (engine speed) has
Under Frequency been enabled.
Enabled

At this point in the sequence, the ECM displays running

values.
480 P2 0 60.0
71 75% 87 12.7

wc_tx001066gb.fm 26
Mobile Generator Repair ECM Background Information
The ECM displays this screen to let the operator know
that the engine protection system has been enabled.
Engine Protection
Enabled

The ECM displays the AC configuration as determined

by the position of the voltage selector switch (VSS).
AC Configuration

The ECM displays this screen to let the operator know

that the alternator protection system has been enabled.
Alt Protection
Enabled

The ECM displays the line-to-line voltage. (This screen is

shown for 3-phase VSS positions only.)
Rated Volts L to L

At this point, the ECM displays the run screen and the
values for the main generator variables: voltage, phase*
480 P2 0 60.0 (leg), amperage, hertz. (For generators with engines that
71 75% 87 12.7 include ECUs, the Hz reading will be 60.0. For all others
the reading will be 61.5.) The ECM will also display the
values for the main engine variables: oil pressure, fuel
tank quantity, engine temperature, and battery voltage.

*Note: The ECM display scrolls through each phase (P1,

P2, P3) if in the 3-phase mode, or L1, L3, and L1 + L3 if
in the single-phase mode.

wc_tx001066gb.fm 27
ECM Background Information Mobile Generator Repair
4.3 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. They are:
(5) engine oil pressure (psi)
(6) fuel tank quantity (shown in percentage of capacity)
(7) engine temperature (°F)
(8) battery voltage (V)

• Blinking Values
When a value on the ECM display blinks on and off, it signifies that the
variable (temperature, fuel capacity, etc.) is in a pre-alarm state. For
example, the value for the temperature reading will blink when the
temperature of the generator is below 23°C (74°F). This simply
signifies that the manifold heater (or glow plugs) will be energized to
aid in engine starting. The fuel capacity reading will blink when it is
below 25%. This tells the operator that the generator will be requiring
fuel soon. See Section Additional Variables Monitored by the ECM.
Note: If your generator has a block heater, the temperature reading
should not blink. If it does, check the block heater to make sure it is
functioning properly.

• ND (No Data), 0 (zero), or Blank Values

When a value on the ECM display reads ND, 0 (zero), or is blank, it
signifies that there is no data available for the variable.

wc_tx001066gb.fm 28
Mobile Generator Repair ECM Background Information

1 2 3 4

481 P2 0 60.0
71 24% 87 12.7

5 6 7 8
wc_gr002944

4.4 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.
4.4.1 “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 Neuson Service.
4.4.2 “Unit in Auto”
The ECM displays “Unit in Auto” and the values for oil pressure,
percentage of fuel remaining, engine temperature, and voltage of the
battery.

1 2
Initializing Unit in Auto
G85 0 50% 74 12.7

wc_gr002943

wc_tx001066gb.fm 29
ECM Background Information Mobile Generator Repair
4.5 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
scrolled through twice. Note: The values from your generator may
differ slightly from those shown here.

ECM Display Description

John Deere engine diagnostic codes.
SPN = Suspect Parameter Number.
SPN.FMI 100.01 FMI = Failure Mode Identifier.
The ten most recent codes will be displayed from most
current to least current. See the John Deere Engine
Manual for details.
The display shows total time, in 1/10 hour increments,
that the engine has been run. New machines, or
Engine Hours machines with new ECMs, will read “No Data” because
1.9 the engine has not been run for more than 1/10 of an
hour.

The display shows the amount of time left until service on

the machine is required. To reset the timer to 250 hours,
Time to Service hold the Hours/Reset toggle switch in the up position
250 until all the screens have scrolled through twice.

The display shows the amount the throttle is open at the

current point in time.
Throttle
10%

The display shows the present load on the engine. For

no load conditions (generator not powering any outside
Load @RPM tools or equipment) the display will read 15%.
15%

wc_tx001066gb.fm 30
Mobile Generator Repair ECM Background Information
The display shows the percentage of total engine torque
being used.
Engine Torque
60%

The display shows, in °F, the temperature of the fuel.

Fuel Temperature
86° F

The display shows, in psi, the fuel pressure.

Fuel Pressure
147

The display shows, in gallons per hour (GPH), the rate at

which fuel is being consumed.
Fuel Rate
0.9 GPH

The display shows, in °F, the temperature of the engine

intake manifold.
Manifold Temp
95°F

wc_tx001066gb.fm 31
ECM Background Information Mobile Generator Repair
4.6 Voltage Display Errors

See Graphic: wc_gr003308

• Single-Phase Display Mode
When operating in the single-phase 120/240V position, line-to-line
voltage will be displayed under P2 (240V). Line-to-neutral voltage
(120V) will be displayed under P1 and P3. This is the normal single-
phase display mode.
• Three-Phase Display Mode
When operating in either three-phase position (208/120V or 480/
277V), the line-to-line voltage will be displayed under P1, P2 and P3 of
the ECM. For example, in the 480/277V position, with the control panel
rheostat adjusted correctly, voltage values will read 480V on all three
phases: P1=480, P2=480, and P3=480. In the 208/120V position,
voltage values will read 208V on all three phases: P1=208, P2=208,
and P3=208.
• If leg 2 (L2) voltage drops below 50V, the ECM is programmed to
switch to its single-phase mode and stay there until the operator
corrects the condition. Two common causes for this condition are:
1) starting the generator with the connection lug door open and
then closing it with the engine still running; 2) starting the genera-
tor in its single-phase position (120/240V), then switching it to a
three-phase position (208/120V or 480/277V) without turning the
generator off first. Both instances will cause the ECM to display a
less than line-to-neutral voltage for P1 and P2, and full line-to-line
voltage for P3. For example, in the 480/277V position P 1 and P2
will read approximately 190V while P3 will read 480V. The volt-
age values displayed in this mode can lead one to conclude that
the generator is not running correctly, when actually it is fine; the
system just needs to be reset. To correct/reset the condition: stop
the engine, make sure the lug door is closed, and then restart the
engine. Allow the generator to cycle through the phases several
times to develop the maximum voltage.
• When in the three-phase mode, if any one of the legs (L1, L2, or
L3) drops out, two of the three phases will automatically also drop
out. For example, if leg 1 drops out, there can be no L1–L2 (P1)
voltage, nor can there be L3–L1 (P3) voltage. (The values dis-
played under P1 and P2 will be residual voltage for the legs them-
selves, not line-to-line voltage. Residual voltage is approximately
36V.) The voltage displayed under P3 will be L2 line-to-neutral
voltage. This condition is known as single-phasing. It is a sign
there is a problem with the generator.

wc_tx001066gb.fm 32
Mobile Generator Repair ECM Background Information
• Engine Hour Switch in Locked Position
Another possible display error can occur when starting the machine
with the engine hour switch (a) in the down (locked) position. This
position is normally used to lock the display onto a single leg and to
prevent the display from scrolling through volt and amp values for all
three legs.

On some generators, starting the engine with the switch in the down
(locked) position will reverse the display for volts and amps. To correct
the display, return the engine hour switch to its unlocked (scroll)
position.

To ensure the correct voltage display, make sure:

• The connection lug door is closed and latched before starting the
engine.
• The voltage selection switch is in its correct position prior to start-
ing the engine.
• The engine hour switch is in its unlocked (center) position.

wc_gr003308

wc_tx001066gb.fm 33
ECM Background Information Mobile Generator Repair
4.7 ECM Automatic Engine Shutdown Conditions

The engine protection system includes two automatic shutdown

conditions: engine overcrank and low fuel. The ECM will also shut
down the engine if an over-current condition exists.

When the ECM has shut down the unit due to one of the faults, the
ECM will display the fault and other pertinent information to aid in
diagnosing the problem. RECORD ALL THE INFORMATION LISTED
on the display, then refer to the following sections to diagnose and
rectify the problem.

When the engine has shut down due to something outside the control
of the ECM, the ECM will display “ENGINE STOPPED”.

Fault Pre-alarm setpoint Shutdown setpoint

Overcrank n/a After third attempt
Fuel level 15% 5%

wc_tx001066gb.fm 34
Mobile Generator Repair ECM Background Information
4.8 ECM Wire Numbering & Colors

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 Plug 1 Wires ECM Plug 2 Wires

Pin Wire Description Pin Wire Description

10 Gr/61 Emergency stop 5 R/18 Battery + (for relays)

3 W/L/56 Cold crank delay 1 Y/63 Crank (12V output)
9 Or/60 Remote start 2 V/64 Run/Fuel (12V output)
12 W/V/62 Fuel level 3 73 Remote annunciator (NA)
8 B/59 Battery – 4 75 Remote annunciator (NA)
7 R/53 Battery + (for ECM board) - - ---

wc_tx001066gb.fm 35
ECM Background Information Mobile Generator Repair
4.9 Removing and Installing the ECM

See Graphic: wc_gr003316

Removal:
4.9.1 Remove the nut securing the hour meter switch (a) and the nut
securing the start switch (b) to the panel.
4.9.2 Disconnect the four harness plugs (e).
4.9.3 Remove the three red wires (d) from the start switch. Remove the start
switch, the hour meter switch, and the ECM from the panel.
Note: Replacement ECMs include start and hour meter switches.
4.9.4 Remove the screws (c) securing the ECM to the panel.

Installation:
4.9.5 Secure the ECM to the panel with screws (c).
4.9.6 Secure the hour meter (a) and the start switch (b) to the control panel.
4.9.7 Reconnect the four harness plugs (e).
4.9.8 Re-install the three red wires (d) to the start switch.

e e
c
c
b

a
d

wc_gr003316

wc_tx001066gb.fm 36
Mobile Generator Repair ECM Background Information
Notes

wc_tx001066gb.fm 37
ECM/Sensor Troubleshooting G 70
5 ECM/Sensor Troubleshooting
This chapter of the manual provides procedures to:
„ Check power to the ECM

„ Check outgoing power from the ECM

„ Check the fuel sender and low fuel fault

„ Calibrate the ECM voltage display

„ Calibrate the AC amperage display

„ Calibrate the ECM AC frequency display

„ Calibrate the ECM DC display

„ Check the ECM can bus circuit

wc_tx000956gb.fm 38
G 70 ECM/Sensor Troubleshooting
5.1 Checking Power to the ECM
Prerequisites „ Fully-charged (12+ Volts) battery
„ Cable running between battery and starter relay is in good conditon and connec-
tions are good.

Procedure Follow the procedure below to check incoming power to the ECM.
1. Check the voltage between red wire #51 at B+ terminal strip and ground.

Is at least 9.8 VDC measured?

Yes ____ No ____ Your reading
Continue. Check red wire #51 and all wiring between B+
terminal strip and the battery.

2. Check voltage between red wire #49 at START/RUN switch and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____ Your reading
Continue. Repair red wire #49.

3. Place the START/RUN switch in the ON position.

4. Check the voltage between red wire #53 at START/RUN switch and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____ Your reading
Continue. Replace the START/RUN switch.

This procedure continues on the next page.

wc_tx000956gb.fm 39
ECM/Sensor Troubleshooting G 70
Continued from the previous page.
5. Check the voltage between ECM pin 7 plug 1 (red wire #53) and pin 8 plug 1
(black wire #59).

Is at least 9.8 VDC measured?

Yes ____ No ____ Your reading
Continue. Repair red wire #53 and/or black wire #59.

6. Open the engine compartment and locate the 10A fuse.

Is the 10A fuse OK?
Yes ____ No ____
Continue. Replace the fuse with one of the same size and rating.
Check the function of the main circuit breaker. The shunt of
the main circuit breaker is most likely the cause of a fuse failure.
See Section 5.10 Checking the Main Circuit Breaker.

7. Check the voltage between ECM pin 5 plug 2 (red wire #18) and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____ Your reading
Power to the ECM Check continuity of red wire #18 between ECM
is OK. and fuse box. Also check red wire #48 between
fuse box and B+ terminal strip. Repair the wiring
as needed.

Incoming power to the ECM has now been checked.

wc_tx000956gb.fm 40
G 70 ECM/Sensor Troubleshooting
5.2 Checking Outgoing Power From the ECM
Prerequisites „ Fully-charged (12+ Volts) battery
„ At least 9.8 VDC incoming power to ECM on red wires #18 and #53

Procedure Follow the procedure below to check the outgoing power from the ECM.
1. Open the control panel and locate the ECM.

2. Place the START/RUN switch in the ON position.

3. Check the voltage between pin 1 plug 2 (yellow wire #63) and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____ Your reading
Continue. The ECM has failed.
Call Wacker Neuson Service.

4. Check the voltage between pin 2 plug 2 (violet wire #64) and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____
Outgoing power from the ECM is OK. The ECM has failed.

Outgoing power from the ECM has now been checked.

wc_tx000956gb.fm 41
ECM/Sensor Troubleshooting G 70
5.3 Fuel Sender Failure and Low Fuel Fault
Prerequisites „ Fuel in fuel tank
„ Fully-charged battery

Procedure Follow the procedure below to check the ECM and fuel sender.
1. Open the large hinged panel and locate the fuel sender.

2. Disconnect white/violet (W/V) wire #62 from the fuel sender.

3. With the START/RUN switch in the ON position, measure the voltage between
W/V wire #62 and ground.
Is at least 4.8 VDC measured?
Yes ____ No ____ Your reading
Go to step 8. Continue.

4. Open the control panel and locate the ECM.

5. With the START/RUN switch in the ON position, measure the voltage between
ECM plug 1 pin 12 (W/V wire #62) and ground.
Is at least 4.8 VDC measured?
Yes ____ No ____ Your reading
Repair W/V wire #62; then The ECM has failed.
continue.

6. With the START/RUN switch in the OFF position, measure the resistance
between the fuel sender and ground.

This procedure continues on the next page.

wc_tx000956gb.fm 42
G 70 ECM/Sensor Troubleshooting
Continued from the previous page.
7. Find the resistance measured in the chart below.

Does the resistance measured reflect the actual fuel level in the tank?
Yes ____ No ____
The fuel sender is OK; the ECM has failed. The fuel sender has failed; replace it.
Call Wacker Neuson Service.

8. Reconnect W/V wire #62.

The ECM and fuel sender have now been checked.

wc_tx000956gb.fm 43
ECM/Sensor Troubleshooting G 70
5.4 Calibrating ECM Voltage Display
Prerequisites Functioning generator

Procedure Follow the procedure below to calibrate the ECM voltage display.
1. Open the large hinged panel. Remove the “key” (latch) from the lug door and
place it in the slot of the lug door switch. NOTICE: Never place anything but the
key into the slot of the lug door switch.

2. Close the large hinged panel.

3. Place the START/RUN switch in the ON position so that the engine starts.

WARNING
Electric shock hazard. High voltage exists at the lugs when the engine is running.
Electric shock can cause injury or death.
f Do not touch the lugs when the engine is running.

4. Open the lug door.

5. With a multimeter, measure the AC voltage between lug 1 and lug 2.

6. Compare the reading on the multimeter with that on the ECM.

Are the readings within 2 Volts?

Yes ____ No ____ Your reading

No adjustment is necessary. Continue.

This procedure continues on the next page.

wc_tx000956gb.fm 44
G 70 ECM/Sensor Troubleshooting
Continued from the previous page.
7. Open the control panel and locate the VOLTS ADJ pot on the ECM.

WARNING
Electric shock hazard. High voltage exists at the cooling fins of the Automatic Volt-
age Regulator (AVR) when the engine is running. Electric shock can cause severe
injury or death.
f Do not touch the AVR when the engine is running.

8. Adjust the VOLTS ADJ pot until the ECM reads the same as the voltage mea-
sured at the lugs.
9. Re-install the key to the door switch and close the control panel.

The ECM voltage has now been calibrated.

wc_tx000956gb.fm 45
ECM/Sensor Troubleshooting G 70
5.5 Calibrating ECM AC Amperage Display
Prerequisites „ Functioning generator
„ Ammeter
„ 25A or greater load

Procedure Follow the procedure below to calibrate the ECM amperage display.
1. Attach a 25A or greater load to the lugs.
2. Place the START/RUN switch in the ON position so that the engine starts.
3. Close the main circuit breaker.
4. Attach a clamp-style ammeter to one of the lines connected to the lugs.
5. Observe the ECM display as it cycles through the amperage values for each leg. Place
the hour meter switch into the down position when the ECM displays an amperage
value.

6. Compare the Amp reading on the ammeter with that on the ECM display.
Are the readings within 0.5 Amps?
Yes ____ No ____ Your reading
No adjustment is necessary. Continue.

7. Open the control panel and locate the AMPS ADJ pot.

WARNING
Electric shock hazard. High voltage exists at the cooling fins of the Automatic Voltage
Regulator (AVR) when the engine is running. Electric shock can cause severe injury or
death.
f Do not touch the AVR when the engine is running.

8. Adjust the AMPS ADJ pot until the ECM reads the same as the amperage mea-
sured by the ammeter.
9. Close the control panel.

The ECM amperage display has now been calibrated.

wc_tx000956gb.fm 46
G 70 ECM/Sensor Troubleshooting
5.6 Calibrating ECM AC Frequency Display
Prerequisites Functioning generator

Procedure Follow the procedure below to calibrate the ECM AC frequency display.
Note: Recalibrate only if your unit is off by more than 5 Hz.
1. Start the generator. Using a tachometer or vibrotach, adjust the engine speed to
1800 rpm or 60 Hz.
2. Open the control panel to gain access to the ECM. Monitor the ECM display
panel as adjustments are made.

WARNING
Electric shock hazard. High voltage exists at the cooling fins of the Automatic Volt-
age Regulator (AVR) when the engine is running. Electric shock can cause injury or
death.
f Do not touch the AVR when the engine is running.

3. Locate the AC frequency push button. Hold the AC frequency push button in
until the ECM display reads 60 Hz.
4. Set the engine no-load speed to 1850 rpm.

The ECM AC frequency has now been calibrated.

wc_tx000956gb.fm 47
ECM/Sensor Troubleshooting G 70
5.7 Calibrating ECM DC Display
Prerequisites Functioning generator

Procedure Follow the procedure below to calibrate the ECM DC voltage (12V battery) display.
1. Measure the voltage across the machine’s 12V battery using a multimeter.
Note: This procedure works best when the battery voltage measures 12.6 VDC.
2. Place the start switch in the REMOTE START position.
3. Open the control panel to gain access to the ECM.
4. Slide the number 2, Dual-In-line Package (DIP) switch to the ON position and
then back to the OFF position. This resets the DC voltage display.

The ECM DC voltage display is now calibrated.

wc_tx000956gb.fm 48
G 70 ECM/Sensor Troubleshooting
5.8 Checking the ECM CAN BUS Circuit
Prerequisites „ Generator shut down
„ ECM turned off

Procedure Follow the procedure below to check the ECM CAN BUS circuit.
1. Open the control panel.
2. Disconnect the CAN BUS connector.

3. Measure the resistance across terminals A and B of the connector.

Is approximately 120 ohms measured?
Yes ____ No ____
The CAN BUS circuit is OK. The CAN BUS circuit has failed.
Replace the ECM.

4. Reconnect the CAN BUS connector.

5. Close the control panel.

The ECM CAN BUS circuit has now been checked.

wc_tx000956gb.fm 49
ECM/Sensor Troubleshooting G 70
5.9 ECM Plugs and Pins

ECM Plug 1 Wires ECM Plug 2 Wires

Pin Wire Description Pin Wire Description

10 Gr/61 Emergency stop 5 R/18 Battery + (for relays)

3 W/L/56 Cold crank delay 1 Y/63 Crank (12V output)
9 Or/60 Remote start 2 V/64 Run/Fuel (12V output)
12 W/V/62 Fuel level 3 73 Remote annunciator (NA)
8 B/59 Battery – 4 75 Remote annunciator (NA)
7 R/53 Battery + (for ECM board) - - ---

wc_tx000956gb.fm 50
G 70 ECM/Sensor Troubleshooting
5.10 Checking the Main Circuit Breaker
Prerequisites „ Fully-charged battery
„ Emergency stop switch in disengaged (out) position
„ Engine shut down

Procedure Follow the procedure below to check the main circuit breaker.

WARNING
Electric shock hazard. High voltage exists at the lugs with the engine running. High
voltage can cause severe injury or death.
f Do not conduct this test with the engine running.

1. Remove the “key” (latch) (a) from the lug door and place in the slot of the lug
door switch. NOTICE: Do not place anything but the key into the slot of the lug
door switch.

2. Place the main circuit breaker in the ON position.

Does the main circuit breaker stay in the ON position?
Yes ____ No ____
Continue. The main circuit breaker has failed; replace it.

3. With the main circuit breaker in the ON position, remove the key from the lug
door switch.
Does the main circuit breaker trip?
Yes ____ No ____
Continue with step 6. Continue.

4. Disconnect the yellow wire of the main circuit breaker from the two yellow wires.

This procedure continues on the next page.

wc_tx000956gb.fm 51
ECM/Sensor Troubleshooting G 70
Continued from the previous page.
5. Measure the voltage between the two yellow wires and ground.

Is at least 9.8 VDC measured?

Yes ____ No ____
The main circuit bre- Check condition/connection of yellow wire between the main cir-
aker has failed; cuit breaker and the terminal strip. There must be more than
replace it. 9.8 VDC between the wire and ground. When voltage exists,
repeat step 4.

6. Place the key into the lug door switch.

7. With the main circuit breaker in the ON position, check for continuity (continuity
equals 0.0–1.0 Ohms) between L1 of the main circuit breaker and Lug 1. Also
check between L2 and Lug 2, and L3 and Lug 3.

Is there continuity for each check?

Yes ____ No ____ Your reading
Continue. The main circuit breaker has
failed; replace it. ____; _____; _____

8. With the main circuit breaker in the OFF position, check for continuity between
L1 of the main circuit breaker and Lug 1. Also check between L2 and Lug 2, and
L3 and Lug 3.
Is there continuity for any of the checks?
Yes ____ No ____
The main circuit breaker has failed; The main circuit breaker is functioning pro-
replace it. perly.

9. Reconnect the yellow (Y) wires and lug door key.

The main circuit breaker has now been checked.

wc_tx000956gb.fm 52
Mobile Generator Repair John Deere Engines with ECU
6 John Deere Engines with ECU

6.1 John Deere Engines With ECU—Background

John Deere engines with electronic control systems are used on

Wacker Neuson generator models G 70, G 85, and G 120. The
electronic control system consists of:
• Engine Control Unit (ECU): the computer which controls fuel and
the ignition system.
• The following sensors: oil pressure, coolant temperature, fuel
temperature, manifold air temperature, crank position, and
speed.
• Fuel pump control solenoid.
• Manifold air heater.
The electronic control system serves as a governor by controlling the
fuel to the engine. It does so by controlling the engine’s injection pump
control valve through a proportional solenoid. In doing so, fuel is
delivered according to engine conditions, in precise amounts, and at
the precise time in relation to piston position.
The ECU communicates with the Engine Control Module (ECM)
mounted to the generator’s control panel 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). Diagnostic tools available from John Deere
can plug into the CAN bus to assist in troubleshooting the operation of
the engine. The ECM controls the engine up through engine start
(cranking). Once started, the ECU controls the running of the engine.
The ECU has diagnostic abilities and shares engine diagnostic
information through codes which are displayed on the ECM display
screen. These diagnostic codes are referred to as “SPN/FMI” codes:
Suspect Parameter Number (SPN) and Failure Mode Identifier (FMI).
SPN/FMI codes are conveyed in a two-part code number. The SPN
typically contains between two and four digits and is the first number
of the code. The FMI contains one or two digits and is the second
number of the code. For example, if the ECM displays “SPN/FMI 100.
4”, The SPN “100” indicates a condition with the engine oil. FMI “4”
indicates that the engine oil pressure input voltage is lower than the
sensor’s specification—a condition associated with a disconnected oil
pressure sensor. There are many such SPN/FMI codes. See the John
Deere service manual for more information.

wc_tx001067gb.fm 53
John Deere Engines with ECU Mobile Generator Repair
6.2 Locations of Engine Electrical Components

4
3
1
6

2 5

wc_gr005886

Ref. Component Ref. Component

1 Main circuit breaker 5 Starter motor
2 Engine Control Module (ECM) 6 Starter relay
3 Slave preheat relay 7 Engine Control Unit (ECU)
4 Manifold heater 8 Fuel pump assembly

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G 70 Troubleshooting Engine Start System
7 Troubleshooting Engine Start System
7.1 Checking Fuses
Prerequisites „ Battery voltage measuring 11–13 VDC

Procedure Follow the procedure below to check the fuses.

1. Locate the 10A and 30A fuses.

2. Check the condition of the 30A fuse. (Note: If the ECM display is blank when the
START/RUN switch is in the ON position, the 30A fuse is most likely blown.)
Is the fuse OK?
Yes____ No____
Continue. Replace the fuse with one of the same size and rating.
Check the function of the main circuit breaker. The shunt of
the main circuit breaker is most likely the cause of a fuse failure.
See Section 7.7 Checking the Main Circuit Breaker.

3. Check the condition of the 10A fuse.

Is the fuse OK?
Yes____ No____
Continue. Replace the fuse with one of the same size and rating.

This procedure continues on the next page.

wc_tx000957gb.fm 55
Troubleshooting Engine Start System G 70
Continued from the previous page.
4. Check the condition of the ECM 10A fuse.

Is the fuse OK?

Yes____ No____
The fuse is OK. Replace the fuse with one of the same size and rating.

The fuses have now been checked. Continue with Section 7.2 Checking the ECM.

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G 70 Troubleshooting Engine Start System
7.2 Checking the Engine Control Module (ECM)
Prerequisites Battery voltage measuring 11–13 VDC

Procedure Follow the procedure below to check the ECM.

1. Open the control panel and locate the ECM.
.

Plug 1 Plug 2

R
V
R Y

2. Place the START/RUN switch in the ON position.

Does the ECM boot up and do the FUEL (a) and CRANK (b) LEDs illuminate?
Yes____ No____
Go to step 6. Continue.

3. Check connections of battery cables. Also check battery voltage.

Is the battery voltage 11–13 VDC?
Yes____ No____ Your reading
Continue. Charge the battery.

4. Locate Plug 1. Measure the voltage between red wire #53 of the plug and
ground.
Is at least 9.8V measured?
Yes____ No____ Your reading
Continue. Repair or replace wire #53.

5. Locate Plug 2. Measure the voltage between red wire #18 and ground during
cranking.
Is at least 9.8 VDC measured?
Yes____ No____ Your reading
Continue. Repair or replace wire #18.

This procedure continues on the next page.

wc_tx000957gb.fm 57
Troubleshooting Engine Start System G 70
Continued from the previous page.
6. Locate Plug 2. Measure the voltage between violet wire #64 and ground. Also
measure the voltage between yellow wire #63 and ground during cranking.
Is there at least 9.8 VDC measured in each case?
Yes____ No____
The ECM is OK. The ECM has failed; replace it.

The ECM has now been checked. Continue with Section 7.3 Checking the
Emergency Stop Switch.

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G 70 Troubleshooting Engine Start System
7.3 Checking the Emergency Stop Switch
Prerequisites Battery voltage measuring 11–13 VDC

Procedure Follow the procedure below to check the emergency stop switch.
1. Remove the rear panel from the machine to access the emergency stop switch
(a).

2. Check the connections of the wiring to the emergency stop switch. Make sure all
connections are tight.
Note: If wire #61 is shorted to ground, the machine will not start and the LCD dis-
play will read “EMERGENCY STOP”.
3. Place the START/RUN switch in the ON position.
4. Place the emergency stop switch in the de-activated (out) position.
5. Measure the voltage between violet wire #64 (at the switch) and ground.
#46 #79 #46
#45 #45
#79
#44
#44
V #34
V #34

#64
V #64
V
#61 #20
#61 #20

wc_gr005181
Is at least 9.8 VDC measured?
Yes____ No____ Your reading
Continue. Repair violet wire #64.

This procedure continues on the next page.

wc_tx000957gb.fm 59
Troubleshooting Engine Start System G 70
Continued from the previous page.
6. Measure the voltage between violet wire #34 (at the switch) and ground.
Is at least 9.8 VDC measured?
Yes____ No____ Your reading
Continue. The emergency stop switch
has failed; replace it.

7. Place the emergency stop switch in the activated position (push it in).
8. Check for voltage between violet wire #34 (at the switch) and ground.
Is any voltage measured?
Yes ____ No ____ Your reading
The emergency stop switch The emergency stop switch
has failed; replace it. is OK.

The emergency stop switch has now been checked. Continue with Section 7.4
Checking the Starter Relay.

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G 70 Troubleshooting Engine Start System
7.4 Checking the Starter Relay
Prerequisites Battery voltage measuring 11–13 VDC

Procedure Follow the procedure below to check the starter relay.

1. Locate the starter relay.

2. Check the voltage between the red wire #50 and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____ Your reading
Continue. Repair or replace red wire #50.

3. Place the START/RUN switch in the ON position.

4. Measure the voltage between red wire #422 and ground during cranking.
Is at least 9.8VDC measured?
Yes ____ No ____ Your reading
Continue. Repair or replace red wire #422.

5. Check the connection to ground of both black wires.

Is there a path to ground?
Yes ____ No ____ Your reading
Continue. Repair or replace both black wires.

6. Place the START/RUN switch in the ON position.

7. Measure the voltage between the red wire (R) running to the starter solenoid
and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____ Your reading
The starter relay is OK. The starter relay has failed;
replace it.

The starter relay has now been checked. Continue with Section 7.5 Checking the
Starter Solenoid.

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Troubleshooting Engine Start System G 70
7.5 Checking the Starter Solenoid
Prerequisites Battery voltage measuring 11–13 VDC

Procedure Follow the procedure below to check the starter solenoid.

1. Locate the starter (a) and the starter solenoid.

2. Check the connection of the large red wire.

3. Measure the voltage between the large red wire and ground.
Is at least 9.8 VDC measured?
Yes____ No____ Your reading
Continue. Repair or replace the large red wire.

4. Place the START/RUN switch in the ON position. Measure the voltage between
the small red wire and ground during the cranking cycle.
Is at least 9.8 VDC measured?
Yes____ No____ Your reading
Continue. Repair or replace small red wire.

5. If at least 9.8 VDC is present at the starter and at the starter solenoid, the
engine should crank. If the engine does not crank, the starter motor has failed.
Replace the starter motor.

The starter solenoid has now been checked. Continue with Section 7.6 Checking
the Intake Air Heater Relay.

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G 70 Troubleshooting Engine Start System
7.6 Checking the Intake Air Heater Relay
Prerequisites Battery voltage measuring 11–13 VDC

Procedure Follow the procedure below to check the intake air heater relay.
1. Locate the intake air heater relay.

2. Measure the voltage between terminal 30 (red wire #11) of the intake air heater
relay and ground.
Is at least 9.8 VDC measured?
Yes____ No____ Your reading
Continue. Repair or replace red wire #11.

3. Place the START/RUN switch in the ON position.

4. Measure the voltage between terminal 86 (grey wire #65) and ground during the
preheat cycle. Note: This cycle only lasts a few seconds.
Is at least 9.8 VDC measured?
Yes____ No____ Your reading
Continue. Repair or replace grey wire #65.

5. Check the connection to ground of black wire #13 at terminal 85.

Is there a path to ground?
Yes____ No____ Your reading
Continue. Repair or replace wire #13.

6. Place the START/RUN switch in the ON position.

7. Measure the voltage between terminal 87 (red wire #12) and ground.
Is at least 9.8 VDC measured?
Yes____ No____ Your reading
The intake air heater relay is The intake air heater relay
OK. has failed; replace it.

The intake air heater relay has now been checked.

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Troubleshooting Engine Start System G 70
7.7 Checking the Main Circuit Breaker
Prerequisites „ Fully-charged battery
„ Emergency stop switch in disengaged (out) position
„ Engine shut down

Procedure Follow the procedure below to check the main circuit breaker.

WARNING
Electric shock hazard. High voltage exists at the lugs with the engine running. High
voltage can cause severe injury or death.
f Do not conduct this test with the engine running.

1. Remove the “key” (latch) (a) from the lug door and place in the slot of the lug
door switch. NOTICE: Do not place anything but the key into the slot of the lug
door switch.

2. Place the main circuit breaker in the ON position.

Does the main circuit breaker stay in the ON position?
Yes ____ No ____
Continue. The main circuit breaker has failed; replace it.

3. With the main circuit breaker in the ON position, remove the key from the lug
door switch.
Does the main circuit breaker trip?
Yes ____ No ____
Continue with step 6. Continue.

4. Disconnect the yellow wire of the main circuit breaker from the two yellow wires.

This procedure continues on the next page.

wc_tx000957gb.fm 64
G 70 Troubleshooting Engine Start System
Continued from the previous page.
5. Measure the voltage between the two yellow wires and ground.

Is at least 9.8 VDC measured?

Yes ____ No ____
The main circuit Check condition/connection of yellow wire between the main
breaker has failed; circuit breaker and the terminal strip. There must be more than
replace it. 9.8 VDC between the wire and ground. When voltage exists,
repeat step 4.

6. Place the key into the lug door switch.

7. With the main circuit breaker in the ON position, check for continuity (continuity
equals 0.0–1.0 Ohms) between L1 of the main circuit breaker and Lug 1. Also
check between L2 and Lug 2, and L3 and Lug 3.

Is there continuity for each check?

Yes ____ No ____ Your reading
Continue. The main circuit breaker has
failed; replace it. ____; _____; _____

8. With the main circuit breaker in the OFF position, check for continuity between
L1 of the main circuit breaker and Lug 1. Also check between L2 and Lug 2, and
L3 and Lug 3.
Is there continuity for any of the checks?
Yes ____ No ____
The main circuit breaker has failed; The main circuit breaker is functioning
replace it. properly.

9. Reconnect the yellow (Y) wires and lug door key.

The main circuit breaker has now been checked.

wc_tx000957gb.fm 65
Output Voltage Troubleshooting G 70
8 Output Voltage Troubleshooting
8.1 Where to Start
Background Complete the troubleshooting procedures in the sequence below. Once the
problem has been found, repair the machine and try it again. It is not necessary to
perform all procedures once the problem has been diagnosed and repaired.

Sequence
Step Task
1. Check the emergency stop switch.
See Section 8.2 Checking the Emergency Stop Switch.
2. Check the lug door switch.
See Section 8.3 Checking the Lug Door Switch.
3. Check the main circuit breaker.
See Section 8.4 Checking the Main Circuit Breaker.
4. Check the voltage adjusting rheostat.
See Section 8.5 Checking the Voltage Adjusting Rheostat.
5. Check the auxiliary winding.
See Section 8.6 Checking the Auxiliary Winding.
6. Check the exciter stator.
See Section 8.7 Checking the Exciter Stator.
7. Check the AVR sensing wires.
See Section 8.8 Checking the AVR Sensing Wires.

8. Flash the generator.

See Section 8.9 Flashing the Generator.
9. Check the stator windings at the Lugs.
See Section 8.10 Checking the Stator Windings at the lugs.
10. Check the rectifier diodes.
See Section 8.11 Checking the Rectifier Diodes.
11. Check the main rotor winding.
See Section 8.12 Checking the Main Rotor Winding.
12. Check the exciter rotor winding.
See Section 8.13 Checking the Exciter Rotor Winding.
13. Check the stator windings at the generator.
See Section 8.14 Checking the Stator Windings at the
Generator.

wc_tx000958gb.fm 66
G 70 Output Voltage Troubleshooting
8.2 Checking the Emergency Stop Switch
Prerequisites Generator shut down

Procedure Follow the procedure below to check the emergency stop switch.
1. Open the large hinged panel. Locate the emergency stop switch (a).

2. Place the emergency stop switch in the de-activated (out) position.

3. Check the connections of the wiring to the emergency stop switch. Make sure all
connections are tight.
4. Measure the voltage between red wire #20 and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____
Continue. Check condition/connection of red wire #20 to terminal strip.

5. Measure the voltage between yellow #45 and ground.

Is any voltage measured?
Yes ____ No ____
The emergency stop switch has failed; replace it. Continue.

6. Place the emergency stop switch in the activated (in) position.

7. Measure the voltage between yellow #45 and ground.
Is at least 9.8 VDC measured?
Yes ____ No ____
The emergency stop switch is OK. The emergency stop switch has failed;
replace it.

The emergency stop switch has now been checked. Continue with Section 8.3
Checking the Lug Door Switch.

wc_tx000958gb.fm 67
Output Voltage Troubleshooting G 70
8.3 Checking the Lug Door Switch
Prerequisites Generator shut down

Procedure Follow the procedure below to check the lug door switch.
1. Open the large hinged panel. Remove the “key” (latch) (a) from the lug door and
place in the slot of the lug door switch. NOTICE: Do not place anything but the
key into the slot of the lug door switch.

a
wc_gr005482
2. Disconnect the blue wire and the orange wires of the lug door switch.
Disconnect the blue/white wire at the AVR.
3. With the key in the lug door switch, check for continuity between the blue wire
and blue/white wire.
Is there continuity?
Yes ____ No ____
Continue. The lug door switch has failed; replace it.

4. Remove the key from the lug door switch.

5. Check for continuity between the blue wire and the blue/white wire.
Is there continuity?
Yes ____ No ____
The lug door switch has failed; replace it. Reconnect the blue and blue/white wires;
then continue.

6. Check for continuity between the orange wires.

Is there continuity?
Yes ____ No ____
Continue. The lug door switch has failed; replace it.

This procedure continues on the next page.

wc_tx000958gb.fm 68
G 70 Output Voltage Troubleshooting
Continued from the previous page.
7. Place the key into the lug door switch.
8. Check for continuity between the orange wires.
Is there continuity?
Yes ____ No ____
The lug door switch has failed; replace it. The lug door switch is OK.

9. Reconnect the wiring.

10.Re-install the key (latch) to the lug door unless moving on to the next test.

The lug door switch has now been checked. Continue with Section 8.4 Checking
the Main Circuit Breaker.

wc_tx000958gb.fm 69
Output Voltage Troubleshooting G 70
8.4 Checking the Main Circuit Breaker
Prerequisites „ Fully-charged battery
„ Emergency stop switch in disengaged (out) position.
„ Engine shut down.

Procedure Follow the procedure below to check the main circuit breaker.

WARNING
Electric shock hazard. High voltage exists at the lugs with the engine running. High
voltage can cause severe injury or death.
f Do not conduct this test with the engine running.

1. Remove the “key” (latch) (a) from the lug door and place in the slot of the lug
door switch. NOTICE: Do not place anything but the key into the slot of the lug
door switch.

2. Place the main circuit breaker in the ON position.

Does the main circuit breaker stay in the ON position?
Yes ____ No ____
Continue. The main circuit breaker has failed; replace it.

3. With the main circuit breaker in the ON position, remove the key from the lug
door switch.
Does the main circuit breaker trip?
Yes ____ No ____
Continue with step 6. Continue.

4. Disconnect the yellow wire of the main circuit breaker from the two yellow wires.

This procedure continues on the next page.

wc_tx000958gb.fm 70
G 70 Output Voltage Troubleshooting
Continued from the previous page.
5. Measure the voltage between the two yellow wires and ground.

Is at least 9.8 VDC measured?

Yes ____ No ____
The main circuit Check condition/connection of yellow wire between the main
breaker has failed; circuit breaker and the terminal strip. There must be more than
replace it. 9.8 VDC between the wire and ground. When voltage exists,
repeat step 4.

6. Place the key into the lug door switch.

7. With the main circuit breaker in the ON position, check for continuity (continuity
equals 0.0–1.0 Ohms) between L1 of the main circuit breaker and Lug 1. Also
check between L2 and Lug 2, and L3 and Lug 3.

Is there continuity for each check?

Yes ____ No ____ Your reading
Continue. The main circuit breaker has
failed; replace it. ____; _____; _____

8. With the main circuit breaker in the OFF position, check for continuity between
L1 of the main circuit breaker and Lug 1. Also check between L2 and Lug 2, and
L3 and Lug 3.
Is there continuity for any of the checks?
Yes ____ No ____
The main circuit breaker has failed; The main circuit breaker is functioning
replace it. properly.

9. Reconnect the yellow (Y) wires and lug door key.

The main circuit breaker has now been checked. Continue with Section 8.5
Checking the Voltage Adjusting Rheostat.

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Output Voltage Troubleshooting G 70
8.5 Checking the Voltage Adjusting Rheostat
Prerequisites Generator shut down

Procedure Follow the procedure below to check the voltage adjusting rheostat.
1. Open the control panel and locate the voltage adjusting rheostat.

2. Disconnect the voltage adjusting rheostat from the Automatic Voltage Regulator
(AVR).
3. Loosen the rheostat’s locknut.
4. Measure the resistances of the rheostat across the entire range of its travel.
Does the voltage adjusting rheostat have a range of at least 5–145k ohms?
Yes ____ No ____ Your reading
Continue. The voltage adjusting rheostat has failed;
replace it.

5. Check each wire (violet & white) to ground (unpainted surface on door).
Does each wire measure “OPEN” or “OL” to ground?
Yes ____ No ____ Your reading
The voltage adjusting The voltage adjusting
rheostat is OK. rheostat has failed;
replace it.

6. Reconnect the voltage adjusting rheostat to the AVR.

7. Tighten the rheostat’s locknut.

The voltage adjusting rheostat has now been checked. Continue with Section 8.6
Checking the Auxiliary Winding.

wc_tx000958gb.fm 72
G 70 Output Voltage Troubleshooting
8.6 Checking the Auxiliary Winding
Prerequisites Generator shut down

Procedure Follow the procedures below to check the auxiliary winding.

1. Open the large hinged panel and locate the Automatic Voltage Regulator (AVR).

2. Disconnect the red wire from the AVR.

3. Disconnect the red wire from the blue wire of the lug door switch.
4. Measure the resistances across the two red wires.
Is 1.4–2.7 Ohms measured?
Yes ____ No ____ Your reading
Continue. Remove the vent cover from the generator and
check the generator for damage.

5. Check each red wire for continuity to ground.

Does each wire measure “OPEN” or “OL” to ground?
Yes ____ No ____ Your reading
Auxiliary winding Remove the vent cover from the generator and
is OK check the generator for damage.

6. Reconnect the wiring.

The auxiliary winding has now been checked. Continue with Section 8.7 Checking
the Exciter Stator.

wc_tx000958gb.fm 73
Output Voltage Troubleshooting G 70
8.7 Checking the Exciter Stator
Prerequisites Generator shut down

Procedure Follow the procedure below to check the exciter stator.

1. Open the large hinged panel and locate the Automatic Voltage Regulator (AVR).

2. Disconnect the blue and yellow wires from the AVR.

3. Measure the continuity between the blue wire and ground. Also measure
between the yellow wire and ground.
Does each wire measure “OPEN” or “OL” to ground?
Yes ____ No ____ Your reading
Continue. Remove the vent cover from the generator and
check the generator for damage.

4. Measure the resistance across the blue and the yellow wires.
Is 10.6–12.0 Ohms measured?
Yes ____ No ____ Your reading
Continue. Remove the vent cover from the generator and
check the generator for damage; then continue.

5. Remove the vent cover from the generator to expose the rotor.
6. Measure the continuity between the blue wire and the rotor. Also measure
between the yellow wire and the rotor.
Does each wire measure “OPEN” or “OL” to the rotor?
Yes ____ No ____ Your reading
The exciter stator is OK. The exciter stator has failed.

7. Reconnect the wiring, and re-install the vent cover.

The exciter stator has now been checked.

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G 70 Output Voltage Troubleshooting
8.8 Checking the AVR Sensing/Power Wires
Prerequisites Generator shut down

Procedure Follow the procedure below to check the AVR sensing/power wires.
1. Open the large hinged panel and locate the Engine Control Module (ECM) and
the Automatic Voltage Regulator (AVR).

2. Disconnect the 4-pin connector (it has 3 wires) from the ECM.
3. Remove the green and black wires from the AVR.
4. Measure the resistance across the green and black wires.
Is 0.2–1.0 Ohms measured?
Yes ____ No ____ Your reading
Continue. Remove the vent cover from the generator and
check the generator for damage.

5. Measure the resistance between the green wire and the ground lug. Also check
between the black wire and the ground lug.
Is 0.2–1.0 Ohms measured?
Yes ____ No ____ Your reading
Continue. Remove the vent cover from the generator and
check the generator for damage.

6. Remove the bus bar between the neutral lug and the ground lug.
7. Measure the continuity between the green wire and the ground lug. Also check
between the black wire and the ground lug.
Does each wire measure “OPEN” or “OL” to the ground lug?
Yes ____ No ____ Your reading
The sensing wires Remove the vent cover from the generator and
are OK. check the generator for damage.

This procedure continues on the next page.

wc_tx000958gb.fm 75
Output Voltage Troubleshooting G 70
Continued from the previous page.
8. Reconnect the 4-pin connector and the green and black wires to the AVR.
NOTICE: NEVER run the generator when the green and black wires are
disconnected from the AVR and all other wires are connected to the AVR.
Damage to the generator will occur.
9. Reconnect the bus bar. DO NOT run the generator with the bus bar disconnected.

The AVR sensing wires have now been checked. Continue with Section 8.9
Flashing the Generator.

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G 70 Output Voltage Troubleshooting
8.9 Flashing the Generator (checking the excitation system)
Prerequisites Source of 12 VDC

Procedure Follow the procedure below to flash the generator.

1. Open the large hinged panel and locate the Automatic Voltage Regulator (AVR).

1000
F 200
20
V
2
200m

V- COM

2. Disconnect all the wires from the AVR except the rheostat wires and the white
jumper wire.
3. Connect a multimeter (set to the 500 VAC (or higher) scale) to the green and
black wires.

WARNING
Electric shock hazard. High voltage exists between the green and black wires when
the engine is running. Electric shock can cause injury or death
f Do not touch the green and black wires when the engine is running.

4. Start the engine. Then, connect the blue wire to the ground lug and the yellow
wire to the B+ terminal strip. NOTICE: Only connect the wires to the machine
when the engine is running. Otherwise, damage to the winding may occur.
5. Measure the voltage across the green and black wires.
Is 270–320 VAC measured?
Yes ____ No ____ Your reading
The excitation system is Check the exciter rotor
functioning properly. winding. See Checking the
Continue. Exciter Rotor Winding.

6. Shut down the generator. Then, reconnect all the wires to the AVR.
7. Start the engine and check the function of the generator.
Does the generator now function properly?
Yes ____ No ____
The generator is OK. The AVR has failed; replace it.

The excitation system has now been checked. Continue with Section 8.10
Checking the Stator Windings at the Lugs.

wc_tx000958gb.fm 77
Output Voltage Troubleshooting G 70
8.10 Checking Stator Windings at the Lugs
Prerequisites „ Generator shut down
„ Two alligator clips; each connected to 12 inches of 14-gauge wire

Procedure Follow the procedure below to check the stator windings at the lugs.
1. Place the voltage selector switch in the 480/277 position.
2. Open the lug door. Connect the alligator clips/wires to Lug 1 and to the neutral
lug (N).
3. Close the lug door and place the main circuit breaker in the ON (closed)
position.
4. Measure the resistance between Lug 1 and the neutral lug. Enter the reading in
the table below. Also measure the resistance between Lug 2 and the neutral lug,
and lug 3 and the neutral lug. Enter these values in the table below.

1000
F 200
20
V F 1000
200 V
20
2 2
200m 200m

A A

V- COM V- COM

wc_gr005496
5. Measure the resistance between Lug 1 and Lug 2; Lug 1 and Lug 3; and Lug 2
and Lug 3. Enter these values into the table below. All values are in Ohms.
480/277 posi-
L1–N L2–N L3–N L1–L2 L2–L3 L1–L3
tion

Ideal 0.1 0.1 0.1 0.2 0.2 0.2

Your reading

Are your readings approximately equal to the ideal measurements?

Yes ____ No ____
The main stator 1. Clean the voltage selector switch with contact cleaner.
windings and the
2. Check the windings at the generator. See Checking Stator
voltage selector
switch are OK. Windings at the Voltage Selector Switch.

The stator windings have now been checked at the lugs. Continue with Section
8.11 Checking the Rectifier Diodes.

wc_tx000958gb.fm 78
G 70 Output Voltage Troubleshooting
8.11 Checking the Rectifier Diodes
Prerequisites Generator shut down

Procedure Follow the procedures below to check the rectifier diodes.

1. Remove the rear baffle (a) from the machine.

2. Remove the cover (b) from the generator.

3. Rotate the engine to access the diodes.
4. Using the diode scale on your multimeter, place the meter leads near the diode,
one on either side. Reverse the probes of your meter and check the diode
again.

Each diode should conduct in one direction and not in the other. Your meter should
read 0.4–0.5V in the direction that conducts.
Does each diode check OK?
Yes No
The diodes are OK. Replace all diodes.
Call Wacker Service.

The rectifier diodes have now been checked. Continue with Section 8.12 Checking
the Main Rotor Winding. Note: If moving on to the next test, leave the generator
disassembled.

wc_tx000958gb.fm 79
Output Voltage Troubleshooting G 70
8.12 Checking the Main Rotor Winding
Prerequisites Generator shut down

Procedure Follow the procedure below to check the main rotor winding.
1. Remove the rear baffle from the machine.

wc_gr003811

2. Remove the cover from the generator.

3. Remove the screws that secure the bearing carrier to the stator.
4. Disconnect the blue and yellow wires from the AVR.
5. Using a puller, pull the bearing carrier/exciter stator from the stator housing.
6. Disconnect the wires to the main rotor winding. One is marked with a red tag
and the other is marked with a blue tag.

7. Measure the resistance across the two wires.

Is 1.4–3 Ohms measured?
Yes ____ No ____ Your reading
Continue. The main rotor winding has failed.
Call Wacker Service.

8. Check each wire for short (path) to the rotor shaft.

Does each wire measure “OPEN” or “OL” to the rotor shaft?
Yes ____ No ____ Your reading
The main rotor The main rotor winding has failed.
winding is OK. Call Wacker Service.

The main rotor winding has now been checked. Continue with Section 8.13 Checking the
Exciter Rotor Winding. Note: If moving on to the next test, leave the generator disassem-
bled.

wc_tx000958gb.fm 80
G 70 Output Voltage Troubleshooting
8.13 Checking the Exciter Rotor Winding
Prerequisites Generator shut down

Procedure Follow the procedure below to check the exciter rotor winding.
1. Remove the rear baffle from the machine.

wc_gr003811

2. Remove the cover from the generator.

3. Remove the screws that secure the bearing carrier to the stator.
4. Disconnect the blue and yellow wires from the AVR.
5. Using a puller, pull the bearing carrier/exciter stator from the stator housing.
6. Locate the three exciter rotor leads in between each pair of diodes.

wc_gr005099
7. Measure the resistance across each lead and the other two leads (one lead at a
time).
Is 0.3–1.0 Ohms measured in each case?
Yes ____ No ____ Your reading
The exciter rotor windings The exciter rotor has failed.
are OK. _____; _____; _____

8. Check each lead for short (path) to the rotor shaft.

Does each lead measure “OPEN” or “OL” to the rotor shaft?
Yes ____ No ____ Your reading
The main rotor winding is OK. The main rotor winding has failed.

9. Reassemble the generator components.

The exciter rotor winding has now been checked. Continue with Section 8.13
Checking Stator Windings at the Generator.

wc_tx000958gb.fm 81
Output Voltage Troubleshooting G 70
8.14 Checking Stator Windings at the Generator
Prerequisites Generator shut down

Procedure Follow the procedure below to check the main stator windings at the generator.
1. Remove the cover from the Voltage Selector Switch (VSS).

Gen Gen TS TS

T2 L0
T6 N T11

1 5 9 13 17 21 25

3 7 11 15 19 23 27

L1 T12 L2

Br Gen TS TB**
ECM CB
Gen Gen TS Lug TS
T10 T7 N N T3

26 22 18 14 10 6 2

28 24 20 16 12 8 4

L3 L2 T5

Or CB TS Gen
ECM Y TB*
ECM wc_gr005494

AVR = to Automatic Voltage Regulator TB* = to terminal block R1 (T7 on older)

ECM = to Engine Control Module TB**= to terminal block R2 (T9 on older)
Gen = from generator TS = to terminal strip
CB = to main circuit breaker

2. Note the positions and labels of all wires connected to the VSS (T2, T3, T4 etc.).
3. Check the resistance across each pair of wires for each winding (T1–T2, T3–T4
and so on). Note: T1, T3, T4, T9, and T11 are located at the terminal strip.
T1–T2 T3–T4 T5–T6 T7–T8 T9–T10 T11–T12

Your reading

Do all six stator windings measure approximately 0.2 Ohms?

Yes ____ No ____
The main stator windings are OK. If there is a difference The main stator
between the readings taken here and those taken at the lugs, windings have failed.
the VSS has failed; replace it.

4. Reconnect the wires and re-install the generator components.

The main stator windings have now been checked.

wc_tx000958gb.fm 82
G 70 Disassembly and Assembly
9 Disassembly and Assembly
9.1 Tools Required for Disassembly/Assembly Procedures
„ It is up to the mechanic to use common sense and good judgment in tool
selection to reduce the risk of injury while repairing the machine.
„ In cases where a special tool is required, the special tool is listed in the
prerequisite section of the procedure.
„ Before substituting another tool or procedure from those recommended in this
manual, the mechanic must be satisfied that neither personal injury nor damage
to the machine will result due to the substitution.

9.2 Information Regarding Replacement Parts

„ The repair procedures contained in this manual do not include part numbers.
„ For replacement parts information, refer to the Parts Book originally supplied
with the machine.
„ If the original Parts Book has been lost, a replacement may be ordered from
Wacker Neuson Corporation.
„ When ordering a replacement Parts Book, please list the model number, item
number, revision level, and serial number of the machine.
„ Parts Books are also available on the Wacker Neuson Corporation Web site.
See www.wackerneuson.com. Enter the site as a visitor.

9.3 Information Regarding Reference Numbers

Repair procedures contain reference numbers enclosed in parentheses ( ). These
numbers refer to the item numbers shown on the assembly drawings and other
detailed drawings. They are included to aid the mechanic in identifying parts and
assembling components.

wc_tx001068gb.fm 83
Disassembly and Assembly G 70
9.4 Removing the Roof
Prerequisites „ Machine shut down
„ Crane capable of lifting 227 kg (500 lb)

Procedure Follow the procedure below to remove the roof.

1. Disconnect the battery.
2. Remove the doors (a).

3. Remove the front and rear access panels (b and c).

4. Remove the screws that secure the roof to the side panels (d).
5. Remove the screws that secure the control panel enclosure (e) to the lifting
structure (f).
6. Remove the screws that secure the door latch (g) to the lifting structure and
remove the door latch.

This procedure continues on the next page.

wc_tx001068gb.fm 84
G 70 Disassembly and Assembly
Continued from the previous page.
7. Remove the screws that secure the lifting structure to the frame.
8. Using an appropriate crane or hoist, lift the roof (h), by the lifting eye, off of the
machine.

The procedure is now complete.

wc_tx001068gb.fm 85
Disassembly and Assembly G 70
9.5 Removing the Voltage Selector Switch
Prerequisites „ Machine shut down
„ Engine cool

Removal Follow the procedure below to remove the Voltage Selector Switch (VSS).

WARNING
Electric shock hazard. High voltage exists inside at voltage selector switch when
the engine is running. High voltage can cause severe injury or death.
f Shut down the generator before performing this procedure.

9. Remove the air cleaner assembly.

10.Remove the cover (a) from the voltage selector switch box.

c d

wc_gr005890
11.Remove the switch handle (b), locking ring (c), and face plate (d).
12.Label, then disconnect all the wires attached to the VSS (e).

e
f

wc_gr005897
13.Remove the mounting plate (f).
14.Remove the VSS (e) and support plate (g) from the box.
15.Remove the support plate from the VSS.

The procedure is now complete.

wc_tx001068gb.fm 86
G 70 Disassembly and Assembly
9.6 Installing the Voltage Selector Switch
Prerequisites „ Machine shut down
„ New Voltage Selector Switch (VSS)

Procedure Follow the procedure below to install the Voltage Selector Switch (VSS).

WARNING
Electric shock hazard. High voltage exists inside at voltage selector switch when
the engine is running. High voltage can cause severe injury or death.
f Shut down the machine before performing this procedure.

1. Attach the support plate (g) to the VSS (e).

e
f

wc_gr005897
2. Secure the VSS and support plate to the box.
3. Install the mounting plate (f).
4. Connect the wires to the VSS (e).

c d

wc_gr005890
5. Install the switch handle (b), locking ring (c), and face plate (d).
6. Install the cover (a) to the voltage selector switch box.
7. Install the air cleaner assembly.

The procedure is now complete.

wc_tx001068gb.fm 87
Disassembly and Assembly G 70
9.7 Removing the Generator
Prerequisites „ Roof removed
„ Crane capable of lifting 227 kg (500 lb)

Procedure Follow the procedure below to remove the generator.

1. Remove the voltage selector switch. See Section 9.5 Removing the Voltage
Selector Switch.
2. Label, then disconnect all wires from the terminal strip (a).

3. Remove the lower bracket (b) of the voltage selector switch box.
4. Remove the screen (c) from the generator.

5. Place suitable blocks (j) underneath the engine to support it.

Note: For clarity, the blocks are shown with the generator already removed.

This procedure continues on the next page.

wc_tx001068gb.fm 88
G 70 Disassembly and Assembly
Continued from the previous page.
6. Remove the screws (d) that secure the generator flex plates to the engine fly-
wheel.

7. Remove the secews (e) that secure the generator housing to the engine bell
housing.
8. Disconnect the ground strap (f).

9. Remove the screws that secure the shock mount (g) to the frame.
10.Using an appropriate crane or hoist, lift the generator out of the machine.

The procedure is now complete.

wc_tx001068gb.fm 89
Disassembly and Assembly G 70
9.8 Installing the Generator
Prerequisites „ Crane capable of lifting 227 kg (500 lb)
„ Loctite® 243 or equivalent
„ Two 3/8-16 x 3-inch threaded studs
„ Three M10x30 threaded studs

Procedure Follow the procedure below to install the generator.

1. Outside of the machine, secure the shock mounts (g) to the generator housing.
Torque the screws to 86 Nm (63 ft.lbs.).

2. Clean all paint from the mating surface (x) of the generator housing.
3. Install two 3/8-16 x 3-inch studs (h) into the engine flywheel 180° away from
each other.

4. Install three M10x30 studs (i) into the engine bell housing at 120° intervals.
5. Using an appropriate crane or hoist, lower the generator into the machine. Slide
the flex discs of the generator over the 3/8-16 studs. Use the studs to guide the
generator into position.

This procedure continues on the next page.

wc_tx001068gb.fm 90
G 70 Disassembly and Assembly
Continued from the previous page.
6. Using Loctite 243 on screws (d), secure the generator flex plates to the engine
flywheel. Remove the 3/8-16 studs. Torque the screws to 45 Nm (33 ft.lbs.).

7. Using Loctite 243 on screws (e), secure the generator housing to the engine bell
housing. Remove the M10 studs. Torque the screws to 86 Nm (45 ft.lbs.).
8. Secure the shock mount (g) to the frame.

9. Connect the ground strap (f).

10.Install the lower bracket (b) of the voltage selector switch box.

11.Connect the appropriate wires to the terminal strip (a).

This procedure continues on the next page.

wc_tx001068gb.fm 91
Disassembly and Assembly G 70
Continued from the previous page.
12.Install the screen (c).

13.Re-install the voltage selector switch. See section Installing the Voltage Selec-
tor Switch.

The procedure is now complete.

wc_tx001068gb.fm 92
G 70 Disassembly and Assembly
9.9 Removing the AVR
Prerequisites Machine shut down

Procedure Follow the procedure below to remove the Automatic Voltage Regulator (AVR).
1. Remove the screws that secure the large access panel (a) and open the large
access panel.

2. Make note of the wires connected to the AVR (b).

3. Disconnect the wires.

4. Remove the screws that secure the AVR and remove the AVR from the
machine.

The procedure to remove the AVR is now complete.

wc_tx001068gb.fm 93
Disassembly and Assembly G 70
9.10 Installing the AVR Prerequisites
„ Machine shut down
„ Multimeter

Procedure Follow the procedure below to install and set the Automatic Voltage Regulator
(AVR).
1. Check the function of the voltage adjusting rheostat. See section Checking the
Voltage Adjusting Rheostat.
2. Mount the AVR (b) to the machine with the two screws.
L/W
5C 5B 7
B W
B R G Y L

n/a n/a
5C 5B 7 5A 6 5 4A 4 3A 3 2 1

5C 5B 7
V W

AMP HZ STAB VOLT

wc_gr004583

3. Reconnect the wires to the AVR.

4. Adjust the VOLT pot (a) on the new AVR counterclockwise as far as possible.

This procedure continues on the next page.

wc_tx001068gb.fm 94
G 70 Disassembly and Assembly
Continued from the previous page.

WARNING Electric shock hazard. Voltage exists at the cooling fins of the AVR
when the engine is running. Electric shock can cause severe injury or death.
f Never touch the cooling fins when the engine is running.

5. Place the voltage selector switch in the 208/120V position.

6. Never adjust the AVR voltage pot with the voltage selector switch in any other
position. Damage to the generator may occur.
7. Loosen the lock nut and adjust the voltage adjusting rheostat (c) clockwise as
far as possible.

wc_gr004587

8. Open the large hinged panel. Remove the “key” (latch) from the lug door and
place it in the slot of the lug door switch. NOTICE: Never place anything but the
key into the slot of the lug door switch.
9. Place the main circuit breaker in the ON position.

WARNING! Electric shock hazard. High voltage exists at the lugs when the engine
is running. High voltage can kill or cause severe injury.
f Never touch the lugs when the engine is running.

10.Start the machine.

NOTICE: Shut down the machine immediately if any load (change in engine rpm)
on the generator is sensed. A change in engine rpm indicates incorrect wiring.
Check the wiring.

This procedure continues on the next page.

wc_tx001068gb.fm 95
Disassembly and Assembly G 70
Continued from the previous page.
11.Check the voltage between Lug 1 and Lug 2 with a multimeter.

12.Adjust the VOLT pot of the AVR until 250 VAC is measured between Lug 1 and
Lug 2.Test the consistency by checking the voltage across Lug 1 and Lug 2,
Lug 2 and Lug 3, Lug 3 and Lug 1. Then, check the voltage between each lug
and Neutral. Approximately 139V should be measured.
13.Shut down the machine. Change the voltage selector switch to the 480/277
position.
14.Start the machine.
15.Measure the voltage between Lug 1 and Lug 2. Adjust the voltage adjusting
rheostat until 480V is measured. Tighten the lock nut.
16.Test the consistency of the voltage by checking across Lug 1 and Lug 2, Lug 2
and Lug 3, Lug 3 and Lug 1. Then, check the voltage between each lug and
Neutral. Approximately 277V should be measured.

This procedure continues on the next page.

wc_tx001068gb.fm 96
G 70 Disassembly and Assembly
Continued from the previous page.
17.Check the consistency between the voltage measured at the lugs by the
multimeter and that shown on the ECM display. If the ECM display is off by more
than 2%, adjust the VOLT pot on the ECM so that the ECM display matches the
reading on the multimeter.
NOTICE: Only adjust the ECM pot when the voltage selector switch is in the
480/277V position.

18.Shut down the machine.

19.Re-install the “key” (latch) to the lug door.
20.Close the large access panel and secure it with two screws.

The procedure to install and set the AVR is now complete.

wc_tx001068gb.fm 97
wc_tx000945gb.fm
87
Schematics
10 Schematics

14

SI SO
14
CP CG

98
429
082

R Or R
6G Y
Br LL 20

ECM
412
050

422
050D

21
K3
G2
J2
K1
A2 JOHN DEERE
ECU
G1
10.1 Engine Wiring Diagram—John Deere with ECU

F1
V
A1 A2 A3

B1 B2 B3
Y
23 C1 C2 C3

D1 D2 D3
J
E1 E2 E3
LL
26 B G 25
V E D
22 F C
A F F1 F2 F3
A B
U 23 J G1 G2 G3
E G
D H
H1 H2 H3

J1 J2 J3
Wacker side 24 K1 K2 K3
wc_gr004699
G 70
G 70 Schematics
10.2 Engine Wiring Components—John Deere with ECU

Ref. Description Ref. Description

1 Plug 1 — engine sender inputs 14 Battery

2 Plug 2 — engine start/run outputs 15 ECM 10A fuse
3 Main circuit breaker (3-phase lugs) 16 Starter relay
4 Shunt trip coil 17 Starter
5 Emergency stop switch 18 Alternator
6 Engine Control Module (ECM) 19 B+ terminal block
7 Safety interlock switch 20 System 10A fuse
8 Remote start terminals 21 System 30A fuse
9 Fuel level sender 22 Harness connector
10 Intake heater 23 CAN bus connector
11 Slave preheat relay 24 Diagnostic connector
12 Mechanical lugs (3 phase) 25 ECU harness connector
13 Start switch 26 Hour meter switch

ECM Plug 1 Wires ECM Plug 2 Wires

Pin Wire Description Pin Wire Description

10 Gr/61 Emergency stop 5 R/18 Battery + (for relays)

3 W/L/56 Oil pressure sender 1 Y/63 Crank (12V output)
9 Or/60 Remote start 2 V/64 Run/Fuel (12V output)
12 W/V/62 Fuel level 3 73 Remote annunciator (NA)
8 B/59 Battery – 4 75 Remote annunciator (NA)
7 R/53 Battery + (for ECM board) - - ---

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_tx000945gb.fm 99
Schematics G 70
10.3 Generator Wiring Diagram

wc_tx000945gb.fm 100
G 70 Schematics
10.4 Generator Wiring Components

Ref. Description Ref. Description

1 Lug door (safety interlock) switch 15 Voltage Selector Switch (VSS)
2 Mechanical lugs 16 Generator
3 Plug 3 - current transformer inputs 17 Automatic Voltage Regulator (AVR)
4 Plug 4 - line voltage inputs 18 Voltage adjustment rheostat
5 Shunt 19 Terminal block
6 120V 20A GFI receptacle 20 Exciter rotor windings
7 120V breaker 21 Exciter stator winding
8 240V 50A breaker 22 Rotor
9 240V 30A breaker 23 Rectifier (diodes)
10 240V 50A receptacle 24 Main rotor winding
11 240V 30A receptacle 25 Main stator windings
12 Engine Control Module (ECM) 26 Auxiliary winding
13 Bus bar 27 Stator
14 Main breaker 28 Terminal strip

ECM Plug 3 Wires ECM Plug 4 Wires

Pin Wire Description Pin Wire Description

4 Or Ammeter line input CT3 3 Or Voltage line input L3 at volt

39 41 selector #28
1 W Ammeter input CT com- 4 Y Voltage line input L2 at volt
36 mon 43 selector #20
5 Y Ammeter line input CT2 2 Br Voltage line input L1 at volt
38 42 selector #3
2 Br Ammeter line input CT1 - - ---
37

wc_tx000945gb.fm 101
Technical Data G 70
11 Technical Data

11.1 Engine Data

Engine Power Rating

Gross standby power rating per ISO 8528-1 and SAE J1995. Actual
power output may vary due to conditions of specific use.

Item Number: G 70
G 70
0620350
0620351
0620352
0620708

Engine
Engine make / type John Deere / 4.5L John Deere / 4.5L
Model 4045TF285 4045TF285
Number of cylinders 4 4
Displacement L (in3) 4.5 (274.6) 4.5 (274.6)
Engine speed rpm 1800 1800
Power @ 1800 rpm kW/hp 74/99 74/99
Coolant capacity L (qts.) 26.5 (28) 26.5 (28)
Oil capacity L (qts.) 15 (15.9) 15 (15.9)
Battery Volts/
12/720 12/1000
ccA

Fuel type Diesel Diesel

Fuel tank capacity L (gal) 337 (89) 337 (89)
Fuel consumption, L/hr
(gph) 18.7 (4.9) 18.7 (4.9)
continuous load
Running time, Hr
18.2 18.2
continuous load

wc_td000267gb.fm 102
G 70 Technical Data
11.2 Generator Data

Item Number: G 70
0620350
0620351
0620352
0620708

Generator
Make/Type Mecc Alte / brushless

Model ECO32-3L/4
Generator speed rpm 1800
Voltage selector switch 3-position
AC voltages 120/240 zig-zag
available 120/208 low-wye
277/480 Hi-wye
Frequency 60 Hz
Power factor 1ø 1.0
3ø 0.8
Voltage regulation ±1.00%
Insulation class H
Sound level at 7 m dB(A)
68
(23 ft.)
AC receptacles 2 duplex, 3 twist-lock
1ø 120 GFI duplex Amps 2-20
1ø 120/240 V twist lock Amps 1-30A 2-50A
Standby Output kW/kVA 63/79
Continuous Output kW/kVA 58/72
Main breaker Amps 225

wc_td000267gb.fm 103
Technical Data G 70
11.3 Trailer and Skid Data

Item Number: G 70
G 70
0620351
0620350
0620352

Trailer and Skid

Dry weight of skid kg (lbs) 1608 1648
(3544) (3634)
Operating weight kg (lbs) 1896 1937
of skid (4180) (4270)
Trailer weight kg (lbs)
Single axle 442 (975)
Tandem axle 499 (1100)
GVWR kg (lbs)
Single axle 2304 (5080)
Tandem axle 2722 (6000)
Surge brakes Fluid DOT3
type
Tires size ST225/75D-15D

Item Number: G 70 ERT 0620708

Trailer and Skid

Dry weight of skid kg (lb) 1872 (4128)
Operating weight of skid kg (lb) 2938 (6478)
Trailer weight kg (lb) 605 (1334)
GVWR kg (lb) 4534 (9995)
Surge brakes Fluid type DOT 3
Tires size 7.50 x 16E

wc_td000267gb.fm 104
G 70 Technical Data
11.4 Dimensions
mm (inches)

A E

G
F
B

D
C wc_gr006389

Machine A B C D E F G
G 70 965 1970 1703 3923 2445 1346 1475
(38) (77.5) (67) (154.5) (96.3) (53) (58)
G 70 ERT 1156 2477 2032 4470 2794 1816 1943
(45.5) (97.5) (80) (176) (110) (71.5) (76.5)

wc_td000267gb.fm 105
 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 Neuson equipment.

TYPE PART NO. –

( ) = Europe COLOR USAGE SIZE
Loctite 222 Purple Low strength, for locking threads smaller 73287 - 10 ml
Hernon 420 than 6 mm (1/4”).
Omnifit 1150 (50M) Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 243 Blue Medium strength, for locking threads 29311 - .5 ml
Hernon 423 larger than 6 mm (1/4”). 17380 - 50 ml
Omnifit 1350 (100M) Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 271/277 Red High strength, for all threads up to 25 mm 29312 - .5 ml
Hernon 427 (1”). 26685 - 10 ml
Omnifit 1550 (220M) Heat parts before disassembly. 73285 - 50 ml
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 290 Green Medium to high strength, for locking 28824 - .5 ml
Hernon 431 preassembled threads and for sealing 25316 - 10 ml
Omnifit 1710 (230LL) weld porosity (wicking).
Gaps up to 0.13 mm (0.005”)
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 609 Green Medium strength retaining compound for 29314 - .5 ml
Hernon 822 slip or press fit of shafts, bearings, gears,
Omnifit 1730 (230L) pulleys, etc.
Gaps up to 0.13 mm (0.005”)
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 545 Brown Hydraulic sealant 79356 - 50 ml
Hernon 947 Temp. range: -54 to 149°C (-65 to 300°F)
Omnifit 1150 (50M)
Loctite 592 White Pipe sealant with Teflon for moderate 26695 - 6 ml
Hernon 920 pressures. 73289 - 50 ml
Omnifit 790 Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 515 Purple Form-in-place gasket for flexible joints. 70735 - 50 ml
Hernon 910 Fills gaps up to 1.3 mm (0.05”)
Omnifit 10 Temp. range: -54 to 149°C (-65 to 300°F)
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. The sealants
listed are recommended for use on Wacker Neuson equipment.

TYPE PART NO. –

( ) = Europe COLOR USAGE SIZE
Loctite 496 Clear Instant adhesive for bonding rubber, 52676 - 1oz.
Hernon 110 metal and plastics; general purpose.
Omnifit Sicomet 7000 For gaps up to 0.15 mm (0.006”)
Read caution instructions before using.
Temp. range: -54 to 82°C (-65 to 180°F)
Loctite Primer T Aerosol Fast curing primer for threadlocking, 2006124-6 oz.
Hernon Primer 10 Spray retaining and sealing compounds. Must
Omnifit VC Activator be used with stainless steel hardware.
Recommended for use with gasket
sealants.
 Torque Values
Torque Values

Metric Fasteners (DIN)

TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE

8.8 10.9 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 8.5 6 10 7 8 5/16 4 –
M6 10 7 14 10 17 13 10 – 5 –
M8 25 18 35 26 41 30 13 1/2 6 –
M10 49 36 69 51 83 61 17 11/16 8 –
M12 86 63 120 88 145 107 19 3/4 10 –
M14 135 99 190 140 230 169 22 7/8 12 –
M16 210 155 295 217 355 262 24 15/16 14 –
M18 290 214 405 298 485 357 27 1-1/16 14 –
M20 410 302 580 427 690 508 30 1-1/4 17 –

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

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 8.1 6 12 9 16 12 – 7/16 – 3/32

5/16 18 13 26 19 33 24 13 1/2 – 1/4

3/8 31 23 45 33 58 43 – 9/16 – 5/16

7/16 50 37 71 52 94 69 16 5/8 – 3/8

1/2 77 57 109 80 142 105 19 3/4 – 3/8

9/16 111 82 156 115 214 158 – 13/16 – –

5/8 152 112 216 159 265 195 24 15/16 – 1/2

3/4 271 200 383 282 479 353 – 1-1/8 – 5/8

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390
Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
Tel: (852) 3605 5360, Fax: (852) 2758 0032