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Wacker Neuson
Portable Generator
G 85
Wacker Neuson G 85 Repair Manual
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Wacker Neuson SE · Preußenstraße 41 ·
D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fa
x: +49 - (0)89-3 54 02-390
Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9
007
· Tel. : (262) 255-0500 · Fax: (262) 25
5-0
550 · 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, Kowlo
on, Hongkong.
Tel: (852) 3605 5360, Fax: (852) 2758 0032
129
Table of Contents
Default Chapter
5
Table of Contents
5
1 Safety Information
9
Operating Safety
10
Service Safety
12
Operator Safety While Using Internal Combustion Engines
13
Towing Safety
14
Reporting Trailer Safety Defects
14
2 Theory of Operation
15
Basic Schematic
15
Introduction
16
Terminology
18
3 Electrical Testing Techniques
22
Checking Continuity
22
Checking Resistance
22
Checking Voltage
22
Probing ECM Plugs and Pins
23
4 ECM Background Information
24
ECM Handling Precaution
24
Normal Boot-Up Sequence
25
Display Variables and Values
28
ECM Display Screens-Start Switch in Remote Position
29
Additional Variables Monitored by the ECM
30
Voltage Display Errors
36
ECM Automatic Engine Shutdown Conditions
38
ECM Circuit Boards
39
Control Wiring Numbering & Colors
40
Removing and Installing the ECM
43
5 Ecm/Sensor Troubleshooting
44
Checking Power to the ECM
44
Checking Outgoing Power from the ECM
47
Checking Temperature Sender
48
Fuel Sender Failure and Low Fuel Fault
50
Calibrating ECM Voltage Display
51
Calibrating ECM AC Amperage Display
52
Calibrating ECM AC Frequency Display
53
Calibrating ECM DC Display
54
Checking the ECM CAN BUS Circuit
55
Checking the Main Circuit Breaker
56
ECM Plugs and Pins
57
6 John Deere Engines with ECU
59
John Deere Engines with ECU Background
59
Locations of Engine Electrical Components
60
Engine Electrical Components
61
7 Engine Starting Troubleshooting
62
Checking the Fuses
62
Checking the Engine Control Module (ECM)
63
Checking the Emergency Stop Switch
64
Checking the Starter Relay
65
Checking the Starter Solenoid
66
Checking the Intake Heater Relay
67
Checking the Main Circuit Breaker
68
8 Output Voltage Troubleshooting
69
Checking the Emergency Stop Switch
69
Checking the Lug Door Switch
70
Checking the Main Circuit Breaker
71
Checking the Voltage Adjusting Rheostat
72
Checking the Auxiliary Winding
73
Checking the Exciter Stator
74
Checking the AVR Sensing Wires
75
Flashing the Generator (Checking the Excitation System)
76
Checking Stator Windings at the Lugs
77
Checking the Rectifier Diodes-Thread-In Style
78
Checking the Rectifier Diodes-Solder-In Style
79
Checking the Main Rotor Winding
80
Checking the Exciter Rotor Winding
81
Checking Stator Windings at the Voltage Selector Switch
82
9 Disassembly/Assembly Procedures
83
Tools
83
Ordering Parts
83
Reference Numbers ( )
83
Weight Block
83
Removing the Roof
84
Preparing Unit for Generator Removal
86
Replacing the Generator
88
Removing the AVR
90
Installing the AVR
91
Removing the Engine
96
Installing the Engine
98
Replacing the Fuel Tank
100
Replacing the Emergency Stop Switch (Older)
102
Replacing the Emergency Stop Switch (Newer)
104
Replacing the Diodes
106
Replacing the Voltage Selector Switch (VSS)
108
G 50, G 70, G 85 VSS Wiring
110
10 Technical Data
112
Engine Data
112
Generator Data
113
Trailer and Skid Data
114
Dimensions
115
Engine Wiring Diagram-John Deere with ECU
116
ECU Wiring Diagram
120
ECU Harness Connector
121
Generator Wiring Diagram
122
Torque Values
128
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Wacker Neuson G 85 Specifications
General
Brand
Wacker Neuson
Model
G 85
Category
Portable Generator
Language
English
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