G 230 G 240 Operator’s Manual Mobile Generator

G 230 G 240 Operator’s Manual Mobile Generator
Operator’s Manual
Mobile Generator
G 230
G 240
EN
5000186930
5
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0
09
1
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0215
6
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Copyright notice
© Copyright 2015 by Wacker Neuson Production Americas LLC
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 Production Americas LLC.
Any type of reproduction or distribution not authorized by Wacker
Neuson Production Americas LLC 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 Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original instructions
This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.
Machine Identification
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models below. These instructions have been written expressly by
Wacker Neuson Production Americas LLC and must be followed during installation,
operation, and maintenance of the machines.
Machine
Item Number
Machine
Item Number
G 230
5200010141
5200010142
5200010143
5000620881
5000620882
5000620883
5200007862
5100015614
G 240
5000620661
5000620662
5000620663
5200001323
5200003162
5200006904
5200025556
wc_gr010208
Machine
identification
A nameplate listing the model number, item number, revision number, and serial
number is attached to this machine. The location of the nameplate is shown above.
Serial number
(S/N)
For future reference, record the serial number in the space provided below. You will
need the serial number when requesting parts or service for this machine.
Serial Number:
wc_tx003616gb_FM10.fm
3
Foreword
Foreword
Machine
documentation





Expectations
for
information in
this manual




From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
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 any of these documents, please contact Wacker Neuson to
order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change
any portion of this information without notice.
The illustrations, parts, and procedures in this manual refer to Wacker Neuson
factory-installed components. Your machine may vary depending on the
requirements of your specific region.
CALIFORNIA
Proposition
65 Warning
Combustion exhaust, some of its constituents, and certain vehicle 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.
4
wc_tx003565gb_FM10.fm
Foreword
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:

Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.

Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.

Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:

Serious injury hazards to the operator and persons in the work area

Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.
wc_tx003565gb_FM10.fm
5
Foreword
Notes
6
wc_tx003565gb_FM10.fm
G 230 / G 240
Table of Contents
Foreword
1
4
Safety Information
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
13
Signal Words Used in this Manual ..................................................... 13
Machine Description and Intended Use ............................................. 14
Safety Guidelines for Operating the Machine ..................................... 15
Service Safety .................................................................................... 17
Operator Safety while Using Internal Combustion Engines ............... 19
Safety Guidelines for Mobile Generators ........................................... 20
Safety Guidelines for Towing the Machine ......................................... 22
Safety Guidelines for Lifting the Machine ........................................... 23
Reporting Safety Defects ................................................................... 23
2
Label Locations
24
3
Label Meanings
26
4
Lifting and Transporting
36
4.1
4.2
4.3
4.4
4.5
4.6
4.7
5
Machine Setup
5.1
5.2
5.3
5.4
5.5
5.6
6
Lifting the Machine ............................................................................. 36
Before Towing Checklist ..................................................................... 37
Towing the Machine ........................................................................... 38
Preparing the Machine for Transport on a Truck or Trailer ................ 39
Hazardous Materials Placards ........................................................... 40
Testing the Breakaway System (Hydraulic Surge Brakes) ................. 41
Testing the Breakaway System (Electric Brakes) .............................. 43
45
Preparing the Machine for First Use ................................................... 45
Positioning the Machine ..................................................................... 46
Grounding the Generator ................................................................... 48
Recommended Fuel ........................................................................... 49
Refueling the Machine (Basler Controller) ......................................... 50
Refueling the Machine (Deep Sea Controller) .................................... 51
Operation, Control, and Component Locations
6.1
52
Control / Component Locations .......................................................... 52
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Table of Contents
7
Operation (Basler Controller)
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
8
69
How to Use the Genset Controller LCD and Keypad .......................... 69
Menu Diagram of the Genset Controller ............................................. 70
Menu Diagram Components ............................................................... 71
Using the Metering and Settings Menus ............................................. 72
Logging in to the Genset Controller by Entering the Password .......... 73
Adjusting the LCD Screen Contrast .................................................... 76
Changing the Time/Date Settings ....................................................... 77
Changing the Sender Fail Time Delays .............................................. 78
Changing the Units of Measure .......................................................... 80
Changing the Low Fuel Pre-Alarm Setting ......................................... 82
Changing or Disabling the Low Fuel Alarm Setting ............................ 84
Changing the Cooldown Time Setting ................................................ 86
Changing the Pre-Crank Time Delay (Glow Plug Timer) .................... 88
Changing the Maintenance Interval .................................................... 90
Resetting the Maintenance Interval Pre-Alarm ................................... 92
Resetting a Loss of Voltage Pre-Alarm ............................................... 94
Accessing and Using the Event Log ................................................... 95
Operation (Deep Sea Controller)
9.1
9.2
9.3
54
Main Circuit Breaker ........................................................................... 54
Engine Start Switch ............................................................................ 55
Genset Pre-Alarms and Alarms (Shut-Down Conditions) ................... 56
Overcurrent Condition ......................................................................... 57
Idle Switch .......................................................................................... 57
Diesel Particulate Filter (DPF) ............................................................ 58
Using the Lugs and the Convenience Receptacles ............................ 59
Selecting the Voltage .......................................................................... 60
Before Starting the Machine ............................................................... 63
Starting and Running the Generator ................................................... 64
Stopping the Machine ......................................................................... 66
Emergency Stop Switch ...................................................................... 66
LCD Panel: Monitoring Machine Operation ........................................ 67
Working with Basler Controller
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17
9
G 230 / G 240
97
Main Circuit Breaker ........................................................................... 97
Genset Controller Power Switch ......................................................... 98
Selecting the Voltage .......................................................................... 99
8
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G 230 / G 240
9.4
9.5
9.6
9.7
9.8
9.9
9.10
Table of Contents
Deep Sea Controller Buttons/Functions ........................................... 102
Genset Controller Alarms and Shut-Down Conditions ..................... 104
Before Starting the Machine ............................................................. 106
Starting and Running the Generator ................................................ 107
Stopping the Generator .................................................................... 109
Emergency Stop Switch ................................................................... 110
Engine and Generator Monitoring .................................................... 111
10 Working with Deep Sea Controller: DSE 7310
10.1
10.2
10.3
10.4
Introduction ....................................................................................... 112
Navigating the Menus ....................................................................... 113
Adjusting Screen Contrast ................................................................ 115
How to Reset the Maintenance Timer .............................................. 116
11 How to Connect Loads
11.1
11.2
11.3
11.4
11.5
11.6
117
Lug Terminal Connection Diagrams ................................................. 117
Best Practices for Balancing Loads .................................................. 118
Connecting 480V, 3-Phase and Single-Phase Loads ...................... 120
Connecting a 240V 3Ø Load and a 240V 1Ø Load .......................... 121
Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads 122
Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads .............. 123
12 Using Remote Start Capabilities
12.1
12.2
12.3
12.4
129
Accessing DTCs with the Basler Controller ...................................... 129
Accessing Engine DTCs using the Deep Sea Controller ................. 130
List of Engine Diagnostic Trouble Codes (DTCs) ............................. 131
14 Factory-Installed Options
14.1
14.2
14.3
124
Remote Run Terminal Block ............................................................ 124
Remote Transfer Switch ................................................................... 125
Preparing for Automatic/Remote Start-Up (Basler) .......................... 126
Preparing for Automatic/Remote Start-Up (Deep Sea) .................... 127
13 Diagnostic Trouble Codes (DTC)
13.1
13.2
13.3
112
145
Battery Charger ................................................................................ 145
Lockable Battery Disconnect ............................................................ 146
Camlocks .......................................................................................... 147
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9
Table of Contents
14.4
14.5
14.6
14.7
14.8
14.9
14.10
14.11
14.12
G 230 / G 240
Containment System ........................................................................ 148
Extended Run Tank (ERT) ............................................................... 148
Engine Block Heater ......................................................................... 149
Automatic LCD Heat ......................................................................... 149
Low Coolant Shutdown ..................................................................... 150
Temperature-Activated Shutters ....................................................... 151
Positive Air Shutoff Valve ................................................................. 152
Quick-Disconnect Fuel Fittings ......................................................... 153
Lube Level Maintainer ...................................................................... 154
15 Machines with Aftertreatment Exhaust System
15.1
15.2
15.3
15.4
15.5
15.6
How the Aftertreatment Exhaust System Works ............................... 155
Filling the DEF Tank ......................................................................... 156
Shelf Life of Diesel Exhaust Fluid (DEF) .......................................... 158
Monitoring and Control of the DEF Level .......................................... 159
Monitoring DEF Quality ..................................................................... 160
Conditioning the Aftertreatment Exhaust System (if equipped) ........ 161
16 General Maintenance
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
16.10
16.11
16.12
16.13
16.14
155
162
Periodic Maintenance Schedule ....................................................... 162
Maintaining the Emission Control System ........................................ 163
Preparing for Maintenance ............................................................... 163
Cleaning the Machine ....................................................................... 163
Inspecting the Machine ..................................................................... 164
Maintaining the Trailer ...................................................................... 165
Checking and Draining the Containment System ............................. 166
Checking the Exhaust System .......................................................... 167
Maintaining the Battery ..................................................................... 168
Cleaning the Diesel Particulate Filter (DPF) (if equipped) ................ 169
Filling the Radiator ............................................................................ 170
Replacing the Aftertreatment DEF Dosing Unit Filter ....................... 172
Storage ............................................................................................. 174
Machine Disposal / Decommissioning .............................................. 175
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wc_bo5000186930_09_FM10TOC.fm
G 230 / G 240
Table of Contents
17 Engine Maintenance:
John Deere 4045TF285/HF285 6068HF285
176
18 Engine Maintenance: T4i Cummins QSB6.7
181
19 Engine Maintenance: T4F Cummins QSB7-G9
185
20 Troubleshooting
189
21 Technical Data — G 240
190
21.1
21.2
21.3
21.4
Engine .............................................................................................. 190
Generator ......................................................................................... 191
Trailer and Skid ................................................................................ 191
Dimensions ....................................................................................... 192
22 Technical Data — G 230
22.1
22.2
22.3
22.4
22.5
193
Engine: G 230 T4f ............................................................................ 193
Engine: G 230 T4i ............................................................................ 194
Generator ......................................................................................... 195
Trailer and Skid ................................................................................ 196
Dimensions ....................................................................................... 197
Tire Safety Information
198
23 User’s Information for Transport Canada Fuel Tank
210
24 Emission Control Systems Information and Warranty—Diesel 213
24.1
24.2
24.3
Emission Control System Background Information .......................... 213
Limited Defect Warranty for Exhaust Emission Control System ....... 214
Limited Defect Warranty for Wacker Neuson Emission Control
Systems ............................................................................................ 214
25 General Machine Schematics
25.1
25.2
25.3
217
Fuses .............................................................................................. 217
Trailer Wiring .................................................................................... 218
Trailer Wiring Components ............................................................... 219
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11
Table of Contents
G 230 / G 240
26 Schematics, Machines with Basler Controller
26.1
26.2
26.3
26.4
26.5
26.6
26.7
26.8
26.9
26.10
26.11
26.12
26.13
26.14
26.15
26.16
220
AC Schematic: G 230/G 240 .............................................................220
AC Schematic Components: G 230/G 240 ........................................221
DC Schematic: G 240 John Deere Tier 3 ..........................................222
DC Schematic Components: G 240 Tier 3 ........................................223
DC Schematic: G230 Cummins T4i ..................................................224
DC Schematic Components: G 230 T4i ............................................225
DC Schematic: G230 Cummins T4f ..................................................226
DC Schematic Components: G 230 Cummins T4f ............................227
DC Electrical Schematic Section A: G 230 Cummins T4f .................228
Electrical Schematic Components .....................................................229
DC Electrical Schematic Section B: G 230 Cummins T4f .................230
Electrical Schematic Components .....................................................231
DC Electrical Schematic Section C: G 230 Cummins T4f .................232
Electrical Schematic Components .....................................................233
Cummins Engine Relays and Fuses .................................................234
Cummins Engine Relays and Fuses .................................................235
27 Schematics, Machines with Deep Sea Controller
27.1
27.2
27.3
27.4
27.5
27.6
27.7
27.8
27.9
27.10
27.11
27.12
27.13
27.14
27.15
27.16
236
AC Schematic: G 230 / G 240 ...........................................................236
Electrical Schematic Components: G 230 / G 240 ............................237
DC Schematic: G 240 John Deere Tier 3 ..........................................238
DC Schematic Components: G 240 John Deere Tier 3 ....................239
DC Schematic: G 230 Cummins T4i .................................................240
DC Schematic Components: G 230 Cummins T4i ............................241
DC Schematic: G 230 Cummins T4f .................................................242
DC Schematic Components: G 230 Cummins T4f ............................243
DC Electrical Schematic Section A: G 230 Cummins T4f .................244
Electrical Schematic Components .....................................................245
DC Electrical Schematic Section B: G 230 Cummins T4f .................246
Electrical Schematic Components .....................................................247
DC Electrical Schematic Section C: G 230 Cummins T4f .................248
Electrical Schematic Components .....................................................249
Cummins Engine Relays and Fuses .................................................250
Cummins Engine Relays and Fuses .................................................251
12
wc_bo5000186930_09_FM10TOC.fm
Mobile Generator
1
1.1
Safety Information
Safety Information
Signal Words Used in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE
signal words 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 hazards.
► Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
► To avoid death or serious injury from this type of hazard, obey all safety messages that follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
► To avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
► To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
wc_tx003567gb_FM10.fm
13
Safety Information
1.2
Mobile Generator
Machine Description and Intended Use
This machine is a mobile electric power source. The Wacker Neuson Mobile
Generator consists of a trailer-mounted cabinet containing an electric alternator, a
fuel tank, and a diesel engine. A control panel, receptacles, and connection lugs
are provided on the side of the cabinet. As the engine runs, the generator converts
mechanical energy into electric power. The operator connects loads to the electric
power receptacles and connection lugs.
This machine is intended for the purpose of supplying electrical power to
connected loads. Refer to the product specifications for the output voltage and
frequency of this generator, and for the maximum output power limit of this
generator.
This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons in the area. Machine
damage caused by misuse is not covered under warranty.
The following are some examples of misuse:
■ Connecting a load that has voltage and frequency requirements that are
incompatible with the generator output
■ Overloading the generator with a load that draws excessive power during either
continuous running or start-up
■ Operating the generator in a manner that is inconsistent with all federal, state
and local codes and regulations
■ Using the machine as a ladder, support, or work surface
■ Using the machine to carry or transport passengers or equipment
■ Using the machine to tow other machines
■ Operating the machine outside of factory specifications
■ Operating the machine in a manner inconsistent with all warnings found on the
machine and in the Operator’s Manual
This machine has been designed and built in accordance with the latest global
safety standards. It has been carefully engineered to eliminate hazards as far as
practicable and to increase operator safety through protective guards and labeling.
However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:
■ Heat, noise, exhaust, and carbon monoxide from the engine
■ Fire hazards from improper refueling techniques
■ Fuel and its fumes
■ Electric shock and arc flash
■ Personal injury from improper lifting the trailer tongue
■ Typical hazards related to towing a trailer on roads and highways
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.
14
wc_tx003567gb_FM10.fm
Mobile Generator
1.3
Safety Information
Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
■ Read and understand the operating instructions contained in all manuals
delivered with the machine.
■ Familiarize yourself with the location and proper use of all controls and safety
devices.
■ Contact Wacker Neuson for additional training if necessary.
When operating this machine:
■ Do not allow improperly trained people to operate the machine. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Operator
qualifications
Only trained personnel are permitted to start, operate, and shut down the machine.
They also must meet the following qualifications:
■ have received instruction on how to properly use the machine
■ are familiar with required safety devices
The machine must not be accessed or operated by:
■ children
■ people impaired by alcohol or drugs
Application
area
Be aware of the application area.
■ Keep unauthorized personnel, children, and pets away from the machine.
■ Remain aware of changing positions and the movement of other equipment and
personnel in the application area/job site.
■ Identify whether special hazards exist in the application area, such as toxic
gases, or unstable ground conditions, and take appropriate action to eliminate
the special hazards before using the machine.
Be aware of the application area.
■ Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
Safety
devices,
controls, and
attachments
Only operate the machine when:
■ All safety devices and guards are in place and in working order.
■ All controls operate correctly.
■ The machine is set up correctly according to the instructions in the Operator’s
Manual.
■ The machine is clean.
■ The machine’s labels are legible.
To ensure safe operation of the machine:
■ Do not operate the machine if any safety devices or guards are missing or
inoperative.
■ Do not modify or defeat the safety devices.
■ Only use accessories or attachments that are approved by Wacker Neuson.
wc_tx003567gb_FM10.fm
15
Safety Information
Safe
operating
practices
Mobile Generator
When operating this machine:
■ Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
When operating this machine:
■ Do not operate a machine in need of repair.
■ Do not consume the operating fluids used in this machine. Depending on your
machine model, these operating fluids may include water, wetting agents, fuel
(gasoline, diesel, kerosene, propane, or natural gas), oil, coolant, hydraulic fluid,
heat transfer fluid (propylene glycol with additives), battery acid, or grease.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
■ Close-fitting work clothes that do not hinder movement
■ Safety glasses with side shields
■ Hearing protection
■ Safety-toed footwear
After use
■ Stop the engine when the machine is not being operated.
■ Close the fuel valve on engines equipped with one when the machine is not
being operated.
■ Ensure that the machine will not tip over, roll, slide, or fall when not being
operated.
■ 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.
16
wc_tx003567gb_FM10.fm
Mobile Generator
1.4
Safety Information
Service Safety
Service
training
Before servicing or maintaining the machine:
■ Read and understand the instructions contained in all manuals delivered with
the machine.
■ Familiarize yourself with the location and proper use of all controls and safety
devices.
■ Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
■ Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
■ Do not allow improperly trained people to service or maintain the machine.
Personnel servicing or maintaining the machine must be familiar with the
associated potential risks and hazards.
Precautions
Follow the precautions below when servicing or maintaining the machine.
■ Read and understand the service procedures before performing any service to
the machine.
■ All adjustments and repairs must be completed before operating the machine.
Do not operate the machine with a known problem or deficiency.
■ All repairs and adjustments shall be completed by a qualified technician.
■ Turn off the machine before performing maintenance or making repairs.
■ Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
■ Re-install the safety devices and guards after repair and maintenance
procedures are complete.
Machine
modifications
When servicing or maintaining the machine:
■ Use only accessories/attachments that are approved by Wacker Neuson.
When servicing or maintaining the machine:
■ Do not defeat safety devices.
■ Do not modify the machine without the express written approval of Wacker
Neuson.
Replacing
parts and
labels
■ Replace worn or damaged components.
■ Replace all missing and hard-to-read labels.
■ When replacing electrical components, use components that are identical in
rating and performance to the original components.
■ When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.
Cleaning
When cleaning and servicing the machine:
■ Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
■ Keep the labels legible.
wc_tx003567gb_FM10.fm
17
Safety Information
Mobile Generator
When cleaning the machine:
■ Do not clean the machine while it is running.
■ Never use gasoline or other types of fuels or flammable solvents to clean the
machine. Fumes from fuels and solvents can become explosive.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:
■ Close-fitting work clothes that do not hinder movement
■ Safety glasses with side shields
■ Hearing protection
■ Safety-toed footwear
In addition, before servicing or maintaining the machine:
■ Tie back long hair.
■ Remove all jewelry (including rings).
Electrical
service safety
■ Make sure clothing and shoes are dry, stand on a dry wooden platform or rubber
insulating mat, and use tools with insulated handles when servicing the
machine.
■ 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.
■ Do not pressure wash the control panel, generator end, or any other electrical
components when cleaning the machine.
Cooling
system safety
■ Do not attempt to open the radiator cap while the unit is running or before the
engine has cooled down. Severe burns may result!
■ Engine coolant is toxic to humans and animals. Clean up spills and dispose of
waste engine coolant in accordance with local environmental regulations.
18
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Mobile Generator
1.5
Safety Information
Operator Safety while Using Internal Combustion Engines
WARNING
Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety standards could result in severe injury or
death.
► Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
Exhaust gas from the engine contains carbon monoxide, a deadly poison.
Exposure to carbon monoxide can kill you in minutes.
► NEVER operate the machine inside an enclosed area, such as a tunnel, unless
adequate ventilation is provided through such items as exhaust fans or hoses.
Operating
safety
When running the engine:
■ Keep the area around exhaust pipe free of flammable materials.
■ Check the fuel lines and the fuel tank for leaks and cracks before starting the
engine. Do not run the machine if fuel leaks are present or the fuel lines are
loose.
When running the engine:
■ Do not smoke while operating the machine.
■ Do not run the engine near sparks or open flames.
■ Do not touch the engine or muffler while the engine is running or immediately
after it has been turned off.
■ Do not operate a machine when its fuel cap is loose or missing.
■ Do not start the engine if fuel has spilled or a fuel odor is present. Move the
machine away from the spill and wipe the machine dry before starting.
Refueling
safety
When refueling the engine:
■ Clean up any spilled fuel immediately.
■ Refill the fuel tank in a well-ventilated area.
■ Re-install the fuel tank cap after refueling.
■ Use suitable tools for refueling (for example, a fuel hose or funnel).
When refueling the engine:
■ Do not smoke.
■ Do not refuel a hot or running engine.
■ Do not refuel the engine near sparks or open flames.
wc_tx003567gb_FM10.fm
19
Safety Information
1.6
Mobile Generator
Safety Guidelines for Mobile Generators
DANGER
Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot
see or smell. If you can smell the generator exhaust, you are breathing CO. But
even if you cannot smell the exhaust, you could be breathing CO.
► NEVER use a generator inside homes, garages, crawlspaces, or other partly
enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Using a fan or opening windows and doors does NOT supply enough fresh air.
► ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
► Even when you use a generator correctly, CO may leak into the home. ALWAYS
use a battery-powered or battery-backup CO alarm in the home.
► If you start to feel sick, dizzy, or weak after the generator has been running,
move to fresh air RIGHT AWAY. See a doctor. You could have carbon monoxide
poison.
WARNING
Electrocution hazard. Machines that generate electric power present special
hazards while the engine is running. These include the risk of electrocution or
severe electrical shock.
► Read and follow the instructions in this Operator’s Manual.
Installing as
Special hazards exist when installing this machine as a backup power supply.
backup power 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.
WARNING
Backfeed from the generator into the public power distribution system can cause
serious injury or death to utility workers!
► 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.
20
wc_tx003567gb_FM10.fm
Mobile Generator
Safety Information
General safety ■ Do not use evaporative starting fluids to start the engine. They are highly
explosive.
■ Do not store items such as excess oil, rags, or tools on top of or inside the
machine. These items are a fire hazard and can restrict cooling air.
■ Ensure that electrical cords attached to the machine are in serviceable condition
without cuts, cracks, or exposed wires.
■ Do not route electrical cords over vibrating or hot parts of the machine.
■ Do not stand on the machine.
■ Do not enclose or cover the machine when it is use, or when it is hot.
Ground
connection
The generator must be connected to a good earthen ground for proper operating
safety.
A central “equipment ground” is provided at the customer connection lugs. This
point is connected directly to the generator set base. All other system grounds are
connected to this central point. Ground the generator in accordance with the
standards defined in national, state, and local regulations.
wc_tx003567gb_FM10.fm
21
Safety Information
1.7
Mobile Generator
Safety Guidelines for Towing the Machine
WARNING
Risk of severe injury or death. Improper trailer condition and towing technique can
lead to an accident.
► Obey the trailer manufacturer’s instructions and the instructions below to reduce
the risk of an accident.
When towing the machine:
■ Do not tow the machine if the towing vehicle’s hitch or the trailer’s coupler are
damaged.
■ Do not tow the machine if any of the trailer’s lug nuts are missing.
■ Do not tow the machine if the trailer’s tires have less than 1.5 mm (1/16 inch) of
tread.
■ Do not tow the machine unless the trailer’s brakes are functioning properly.
■ Do not exceed the trailer manufacturer’s speed limitations.
When towing the machine:
■ Only tow the machine when the trailer’s lug nuts are properly torqued.
■ Only tow the machine when the trailer’s tires are properly inflated.
■ Only tow the machine when all trailer lights are functioning correctly.
■ Only tow the machine when the trailer’s safety chains are connected to the
towing vehicle in a crisscross pattern.
■ Maintain extra distance between the towing vehicle and other vehicles.
■ Avoid soft shoulders, curbs, and sudden lane changes.
■ Abide by all licensing requirements for your area.
If you have not driven a towing vehicle with trailer before, practice turning,
stopping, and backing up the towing vehicle with trailer in an area away from traffic.
Only drive the towing vehicle with trailer when you are confident in your ability to do
so.
22
wc_tx003567gb_FM10.fm
Mobile Generator
1.8
Safety Information
Safety Guidelines for Lifting the Machine
When lifting the machine:
■ Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any
other type of lifting device used is attached securely and has enough weightbearing capacity to lift or hold the machine safely. See section Technical Data
for machine weight.
■ Remain aware of the location of other people when lifting the machine.
■ Only use the lifting points and tie-downs described in the Operator’s Manual.
■ Make sure the transporting vehicle has sufficient load capacity and platform size
to safely transport the machine.
To reduce the possibility of injury:
■ Do not stand under the machine while it is being lifted or moved.
■ Do not get onto the machine while it is being lifted or moved.
1.9
Reporting 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.
If NHTSA receives similar complaints, it may open an investigation; and if it finds
that a safety defect exists in a group of trailers, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Wacker Neuson.
To contact NHTSA, you may either contact the Vehicle Safety Hotline toll-free at
1-888-327-4236 (TTY: 1-800-424-9153); go to http://www.safercar.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain other information about your motor vehicle safety from
http://www.safercar.gov
wc_tx003567gb_FM10.fm
23
Label Locations
2
Mobile Generator
Label Locations

NN
o
wc_gr011523
ww
AA

o
K XX
OO
RR
QQ
UU
DIESEL
ULTRA LOW SULFUR
FUEL ONLY
SOLAMENTE COMBUSTIBLE DE
ULTRABAJO CONTENIDO DE AZUFRE
SEULEMENT CARBURANT DE
SOUFRE ULTRA BAS
DEF
5200020535
DEF
DIESEL EXHAUST
FLUID ONLY
SEULEMENT FLUIDE
O'ÉCHAPPEMENT DIESEL
SÓLO LÍQUIDO DE
ESCAPE DIESEL
DIESEL
XX
YY
5200020534
wc_gr011525
24
wc_tx003568gb_FM10.fm
Mobile Generator
Label Locations
FF
GG
R
A
R
KK
VV
J
H
H
UU
WW
G
wc_gr009229
wc_tx003568gb_FM10.fm
25
Label Meanings
3
Mobile Generator
Label Meanings
A
WARNING
Lock doors. Access can cause electric shock,
arc flash, or injury. Read the Operator’s Manual
for more information.
WARNING
Lock doors. Access can cause electric shock, arc flash or injury.
ADVERTENCIA
Cierre las puertas. Ya que de otro modo existe el peligro de un choque eléctrico,
arco voltaico de cortocircuito, o de heridas personales.
AVERTISSEMENT
Fermer les portes d'acces ou il pourrait en résulter risque d'électrocution, arc de
court-circuit, ou des blessures.
176289
B
WARNING
Pressurized contents. Do not open when hot!
WARNING
ADVERTENCIA
AVERTISSEMENT
110164
C
Read and understand the supplied Operator’s
Manual before operating the machine. Failure
to do so increases the risk of injury to yourself
and others.
WARNING
Read and understand the supplied Operator's Manual before
operating this machine. Failure to do so increases the risk of
injury to yourself and others.
ADVERTENCIA
Lea y entienda el Manual de Operación suministrado antes de
operar esta máquina. Si no lo hace, incrementará el riesgo de
lesionarse o lesionar a otros.
AVERTISSEMENT
Avant d'utiliser cette machine, lire attentivement et assimiler
la Notice d'Emploi. Dans le cas contraire, le risque de se blesser
ou de blesser les autres augmente.
176103
D
NOTICE
Never change switch position with engine
running. Results in damage to machine.
NOTICE
Never change switch position with
engine running.
Results in damage to machine.
STOP
AVISO
Nunca cambie la posicion del interruptor
al estar marchando el motor. Ya que ésto
podría conducir a daños en el equipo.
208
120
480
277
AVIS
240
120
Ne jamais changer la position de
l'interrupteur pendant que le moteur est
en marche. Il pourrait en résulter risque
de dommages a'la machine.
176228
E
WARNING
Electric shock and arc flash can cause serious
injury or death.
WARNING
Electric shock and arc flash can cause
serious injury or death.
ADVERTENCIA
Choque eléctrico y arco voltaico de cortocircuito
pueden causar heridas personales o muerte.
AVERTISSEMENT
Électrochoc et arc de court-circuit peuvent
résulter en blessures graves ou mort.
176285
26
wc_tx003569gb_FM10.fm
Mobile Generator
Label Meanings
F
DANGER
Asphyxiation hazard. Do not run the machine
indoors or in an enclosed area without
adequate ventilation. Read the Operator’s
Manual for instructions. No sparks, flames, or
burning objects near machine. Stop the engine
before adding fuel. Use only diesel fuel.
DANGER
STOP
DIESEL
PELIGRO
DANGER
119050
G
WARNING
To prevent hearing loss, wear hearing
protection.
Hand injury if entangled in moving belt.
Rotating machinery! Do not reach inside with
engine running.
WARNING
Hot surface!
NOTICE
Avoid spraying water into generator.
WARNING
ADVERTENCIA
WARNING
AVERTISSEMENT
ADVERTENCIA
AVERTISSEMENT
NOTICE
Avoid spraying water
into generator.
AVISO
Evite de rociar agua
en el generador
AVIS
Eviter de pulveriser
de l'eau dans le
générateur.
176300
H
WARNING
WARNING
Hot surface
WARNING
ADVERTENCIA
AVERTISSEMENT
ADVERTENCIA
AVERTISSEMENT
114885
117038
J
WARNING
To prevent hearing loss, wear hearing
protection when operating the machine.
WARNING
Pressurized contents. Do not open when hot!
WARNING
Hand injury if entangled in moving belt.
WARNING
Rotating machinery! Do not reach inside
machine with engine running.
WARNING
ADVERTENCIA
AVERTISSEMENT
164721
wc_tx003569gb_FM10.fm
27
Label Meanings
Mobile Generator
K
WARNING
Disconnect battery before servicing.
Read the Operator’s Manual.
WARNING
ADVERTENCIA
AVERTISSEMENT
114891
L
WARNING
Generator can automatically start which can
cause serious injury. Disconnect battery before
servicing.
WARNING
Generator can automatically start
which can cause serious injury.
Disconnect battery before
servicing.
ADVERTENCIA
Generador puede arrancar
automaticamente y causar lesiones
personales. Desconecte la bateria
antes de prestar servicio.
AVERTISSEMENT
Generateur peut demarrer
automatiquement resultant en des
accidents de personne. Deconnecter
batterie avant tout entretien.
176184
N
Voltage selector label
O
DANGER
GEFAHR
PELIGRO
DANGER
Danger of asphyxiation! Do not operate this
machine indoors. Electric shock and arc flash
will cause serious injury or death.
DANGER
117993
28
wc_tx003569gb_FM10.fm
Mobile Generator
Label Meanings
P
OPERATING INSTRUCTIONS
FOR MOBILE GENERATORS
INSTRUCCIONES PARA LA PUESTA EN
MARCHA DE GENERADORES MOVILES
Before starting
1. Read Operator's Manual.
2. Level unit.
3. Block wheels.
4. Ground unit.
5. Check all fluid levels.
Antes del arranque
1. Lea el Manual de Operación.
2. Nivele la unidad.
3. Coloque cuñas debajo de las ruedas.
4. Conecte la unidad a tierra.
5. Controle todos los liquídos.
Manual starting
1. Disconnect all external loads.
2. Set voltage selector switch.
3. Lock voltage selector switch.
4. Set emergency stop button to "ON" position.
5. Set engine start switch to "START/RUN" position.
6. Engine will make 3 attempts to start.
Arranque manual
1. Desconecte todas las cargas externas.
2. Ajuste la llave selectora de voltaje.
3. Bloquee la llave selectora de voltaje.
4. Ponga a la posición "ON" el botón de parada
de emergencia.
5. Ponga a la posición "ARRANQUE/MARCHA" el
interruptor de arranque del motor.
6. El motor intentará arrancar 3 veces.
Remote start
1. See Operator's Manual.
Arranque remoto
1. Vea el Manual de Operación.
Stopping
1. Turn off all circuit breakers.
2. Set engine start switch to "OFF" position.
Detencion de motor
1. Apague todos los interruptores de circuito.
2. Ponga a la posición "OFF" el interruptor de arranque
del motor.
INSTRUCTIONS D'OPERATION
DU GENERATEUR MOBILE
Avant le demarrage
1. Lire la Notice d'Emploi.
2. Niveler la machine.
3. Bloquer les roues avec cales de roues.
4. Mettre à terre la machine.
5. Vérifier le niveau de tous les fluides.
Operator's Manual must be stored on machine.
A replacement Operator's Manual can be
ordered through Wacker Neuson or online at
www.wackerneuson.com.
Démorrage à la main
1. Déconnecter tous les regimes externes.
2. Régler le commutateur des tensions d'alimentation.
3. Serrer le commutateur des tensions d'alimentation.
4. Placer le bouton d'arret d'urgence à la position "ON".
5. Placer l'interrupteur de démarrage du moteur à la
position "DEMARRAGE/MARCHE".
6. Le moteur s'essayera de démarrer 3 fois.
Démarrage a distance
1. Lire la Notice d'Emploi.
El Manual de Operación debe ser retenido en la
máquina. Contacte a Wacker Neuson para un
ejemplar adicional o ponga una orden en linea en
www.wackerneuson.com.
La Notice d'Emploi doit être munie sur la machine.
Contacter Wacker Neuson pour commander un
exemplaire supplémentaire ou commander en
ligne chez www.wackerneuson.com.
Arrêt
1. Éteindre tous les coupe-circuits.
2. Placer l'interrupteur de démarrage du moteur à la
position "OFF"
176286
Q
Operator’s Manual must be stored on machine.
Replacement Operator’s Manual can be
ordered through your local Wacker Neuson
distributor.
0158787
R
Tie-down point
113726
wc_tx003569gb_FM10.fm
29
Label Meanings
S
Mobile Generator
WARNING
Stop engine. Electrical hazard. Read
Operator’s Manual.
WARNING / ADVERTENCIA / AVERTISSEMENT
STOP
178683
T
Electrical ground
114886
U
NOTICE
Lifting point
V
Operating the main circuit breaker supplies or
interrupts power to the customer connection
lugs.
L1 L2 L3
176213
W
Neutral bonded to frame
NEUTRAL BONDED TO FRAME
NULL-LEITER AM RAHMEN ANGESCHLOSSEN
CONDUCTOR NEUTRO CONECTADO AL CHASIS
CONDUCTEUR NEUTRE MIS A LA MASSE
DU CHASSIS
116662
30
wc_tx003569gb_FM10.fm
Mobile Generator
Label Meanings
X
Engine wiring
12
INTAKE HEATER
PLUG 1
POWER & SENSOR INPUTS
RED
10AWG
GROUND
1
BAT -
2
BAT+
3
NOT USED ON SOME MODELS
BLK
59
12
BLK
80
8
RED
53
FUEL
9
62
8
BLK
3
11
90
13
14
90
BLK
81
11
TOGGLE
SWITCH
BLK
23
27
50
84
83
GRN
29
84
GRN/YEL
92
RED
ALTERNA
RED
RED
15
YEL
63
92
RED
VIO
51
RED
HOUR
METER
91
VIO
48 95 51
A
J
D
B
U
A
J
D
B
U
BLK
2/0 AWG
ORG
YEL BLK
56
95
48
94
63
NOT USED ON
SOME MODELS
14
18
94
64
50
11
7.5A
FUSE
BLK
BLU
85
30
49
18
10A
FUSE
START
FUEL
80
BLK
2/0 AWG
BATTERY
DISCONNECT
SWITCH
STARTER
RELAY
60
28
RUN MODE
RELAY
ENGINE OUTPUTS
GROUND TO
ENGINE BLOCK
BLK
RED
10AWG
83 82
WHT/BLU
56
REMOTE START
MODE
BREAKER
TRIPPED
GROUND TO
ENCLOSURE
BOX STUD
RED
49
GROUND TO
ENCLOSURE
BOX STUD
START DELAY
(PRE-HEAT)
REMOTE START
RED
10AWG
52 53 RED
82
59
PLUG 2
CONTACT INPUTS
13
65
RELAY
62
WHT/VIO
BLK
SENDER COM
ELECTRONIC CONTROL UNIT
GRY
8
FUEL LEVEL
START
RED
4 AWG
ORG
RED
10AWG
RED
2/0 AWG
B+
RED
WHT
ORG
RED
BLK
BLK
RED
DASHED LINES ARE PART OF ENGINE HARNESS
ENGINE ECU
20 2
PRE
HEAT
34
VIO
RED
96
34
98
61
60
ORG
GRY
46
61
47
93
67
CAN L
53
ORG
2
44
46
97
GRN/YEL
YEL
MECHANICAL LUGS
SHIELD
50
52
REMO
STA
93
GRN
49
ALARM
GRN
NO
RED
NC
120 OHM
48
68
CAN H
SHIELD
REMOTE ANNUNCIATOR
COMMON
51
PREALARM
RED
NC
64
GRY
L1
BLU
73
75
74
TAN/WHT
TAN
L2
BOND BAR
L
L0
46
GRD
47
ORN
97
ORG
44
85
TAN
45
YEL
45
BAT+
TRIP BREAKER
55
96
RED
56
86
BLU
86
99
8
SHUNT
TRIP
RELAY
GROUND TO
ENCLOSURE
BOX STUD
NOT
USED
8
BLK
BOND TO
FRONT
PANEL
DOOR
YEL
YEL
8
3
MAI
BREA
20
98
RED
GROUND TO
ENCLOSURE
BOX STUD
SHU
PLUG 4
E-STOP, CANBUS & CONTACT OUTPUTS
EMERGENCY
STOP
SWITCH
E-STOP
E-STOP
WHT
BLK
WHT
177860
47
Y
Generator and receptacle wiring
Z
WARNING
Electric shock at cooling fins.
WARNING
Electric shock and arc flash hazard at cooling fins.
ADVERTENCIA
Peligro de choque eléctrico y arco voltaico de
cortocircuito en las aletas de refrigeración.
AVERTISSEMENT
Risque d'électrocution et d'arc de court-circuit
aux ailettes de refroidissement.
176284
AA
(if equipped)
MENU NAVIGATION
Status
Engine
Generator
Summary
Screen
Engine
Speed
Gen Voltage
(L-N)
Engine Oil
Pressure
Engine
Oil
Pressure
Gen Voltage
(L-L)
Engine
Coolant
Temp
Engine
Coolant
Temp
Gen
Frequency
Summary
Screen
Engine
Battery
Voltage
Gen Current
Engine
Battery
Voltage
Engine
Run
Time
Gen Earth
Current
Fuel Level
Fuel
Level
Gen Load
(kW)
Maintenance
Alarm [Hold
"O" to reset]
Gen Load
(Total kW)
Engine
Link*
Gen Load
(%)
Can Bus
Information*
Gen Load
(Total %)
Alarms
ECU DTCs*
Event Log
Serial Port
About
Graphical navigation aid for Deep Sea
controller
Gen Load
(kVA)
Gen Load
(Total kVA)
Gen Power
Factor
UP
Gen Power
Factor (Avg)
Gen Load
(kVAr)
FORWARD
BACK
Gen Load
(Total kVAr)
DOWN
Gen Load (h)
Gen Phase
Sequence
Active Config
Active Config
*Not Available on Some Models
5200007881
BB
This machine may be covered by one or more
patents.
U.S.PAT.Nos.: 6012285, 6471476,
D416858, D454357 OTHER U.S. AND
FOREIGN PATENTS PENDING
UTILITY 159116
wc_tx003569gb_FM10.fm
31
Label Meanings
Mobile Generator
CC
Stop engine.
STOP
178682
DD
Remote start operation. Read Operator’s
Manual for instructions.
REMOTE START
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
114897
EE
NOTICE
Receptacles not used when:
Selector switch set to 208/120V and voltage
greater than 228V.
Selector switch set to 480/277V and voltage
greater than 457V.
NOTICE
Receptacles not used when:
Selector switch set to 208/120V and voltage greater than 228V.
Selector switch set to 480/277V and voltage greater than 457V.
HINWEIS
Steckdosen nicht verwenden wenn:
Wahlschalter auf 208/120V eingestellt ist, und Spannung hoher als 228V ist.
Wahlschalter auf 480/277V eingestellt ist, und Spannung hoher als 457V ist.
AVISO
Los receptaculos no deben utilizarse cuando:
El interruptor de seleccion de voltaje esta en la posicion 208/120V y el voltaje es mayor de 228V.
El interruptor de seleccion de voltaje esta en la posicion 480/277V y el voltaje es mayor de 457V.
AVIS
Ne pas utiliser les prises de courant si:
Le commutateur selecteur est dans la position 208/120V et la tension est plus haute que 228V.
Le commutateur selecteur est dans la position 480/227V et la tension est plus haute que 457V.
176188
FF
Handhold
176230
GG
Protecting Our Environment
Fluid containment system
(if equipped)
32
wc_tx003569gb_FM10.fm
Mobile Generator
Label Meanings
HH
(on trailer, if equipped)
Certification Label (VIN Number)
Also attached to each unit is a Certification
Label. This label specifies that the trailer
conforms with all Federal Motor Vehicle
Standards in effect at the time of manufacture.
The label includes the Vehicle Identification
Number (VIN) for the trailer.
JJ
(on trailer, if equipped)
Trailer Wiring
G - Right brake light and directional
Y - Left brake light and directional
Br - Tail, side, and license plate lights
W - Ground
L - Electric brakes
B - Battery charge
KK
DO NOT USE THE BATTERY DISCONNECT SWITCH WHILE ENGINE IS
RUNNING. DAMAGE TO THE ELECTRICAL COMPONENTS MAY OCCUR.
BATTERIETRENNSCHALTER MUSS IN
DER "ON" STELLUNG SEIN,
UM MOTOR ZU STARTEN.
INTERRUPTOR DE DESCONEXION DE
LA BATERIA DEBE ESTAR EN LA
" ON" POSICION PARA ARRANCAR
EL MOTOR.
COMMUTATEUR DE LA BATTERIE
DOIT ETRE DANS LA "ON"
POSITION POUR DEMARRER
LE MOTEUR.
(if equipped)
NOTICE
BATTERY DISCONNECT MUST BE IN
"ON" POSITION TO START ENGINE.
Battery disconnect must be in “ON” position to
start engine.
HINWEIS
..
..
BATTERIETRENNSCHALTER
NICHT BENUTZEN, WAHREND MOTOR LAUFT!
..
BESCHADIGUNG DER ELEKTRISCHEN BESTANDTEILE KANN AUFTRETEN.
AVISO
NO UTILICE EL INTERRUPTOR DE LA DESCONEXION DE LA BATERIA
MIENTRAS QUE EL MOTOR ESTA FUNCIONANDO. DANOS A LOS
COMPONENTES ELECTRICOS PUEDEN OCURRIR.
NOTICE
Do not use the battery disconnect switch while
engine is running. Damage to the electrical
components may occur.
AVIS
N UTILISER PAS LE COMMUTATEUR DE DEBRANCHEMENT DE BATTERIE
TANDIS QUE LE MOTEUR TOURNE. DES DOMMAGES AUX COMPOSANTS
ELECTRIQUES PEUVENT SE PRODUIRE.
173394
LL
FUSES
FUSIBLES
FUSIBLES
FUSES
FUSIBLES
FUSIBLES
161200
187140
wc_tx003569gb_FM10.fm
Fuses
33
Label Meanings
Mobile Generator
MM
(if equipped)
NOTICE
Mobile generator must be level for proper
operation of lube level maintainer.
NOTICE
Mobile Generator must be level for proper
operation of lube level maintainer.
AVIS
Groupe Electrogene doit etre de niveau pour
le bon fonctionnement du regulateur
de lubrifiant.
AVISO
Generador Movil debe ser plano para el
correcto funcionamiento del mantenedor de
nivel de lubricacion.
189843
NN
(if equipped)
Fill to top with engine oil only. Close tank valve
during transport.
FILL TO TOP WITH ENGINE OIL ONLY.
CLOSE TANK VALVE DURING TRANSPORT.
..
BIS
.. TANKOBERSEITE MIT .NUR
. MOTOROL
FULLEN. TANKVENTIL WAHREND DES
TRANSPORTS SCHLIESSEN.
LLENE A LA CIMA CON ACEITE DE MOTOR
SOLAMENTE. CIERRE LA VALVULA DEL
TANQUE DURANTE EL TRANSPORTE.
REMPLIR AU DESSUS DE
MOTEURS SEULEMENT. FERMER LA
SOUPAPE DE RESERVOIR PENDANT
LE TRANSPORT.
OO
Lug door must be closed for lugs and
receptacles to energize.
Lug door must be closed for lugs and receptacles to energize.
La puerta de conexiones debe estar cerrada para que las
conexiones y los tomacorrientes exciten.
La porte de cosses terminales doit être fermée pour que les
cosses terminales et les prises de courant puissent amorcer.
QQ
(Camlock models only)
WARNING
ELECTRIC SHOCK CAN CAUSE SERIOUS
INJURY OR DEATH.
WARNING
Electric shock can cause serious injury or
death.
WARNUNG
HOCHSPANNUNG! VERLETZUNGS-ODER
LEBENSGEFAHR MOEGLICH!
ADVERTENCIA
CHOQUE ELECTRICO PUEDE CAUSAR HERIDAS PERSONALES
O MUERTE.
AVERTISSEMENT
ELECTROCHOC PEUT RESULTER EN BLESSURES OU MORT!
114899
RR
(Camlock models only)
Separate overcurrent protection might be provided. Do not exceed 400 amps per receptacle
Protección adicional contra sobrecorriente debe ser suministrado. No exceder los 400 amperlos por tomacorriente.
Protection supplémentaire contre surintensité doit être fournie. Ne pas dépasser 400 ampères par prise de courant.
5200000525
34
NOTICE
Separate overcurrent protection must be
provided. Do not exceed 400 amps per
receptacle.
wc_tx003569gb_FM10.fm
Mobile Generator
Label Meanings
TT
Notification of California emissions compliance
UU
Ultra low sulfur fuel only
VV
WARNING
ADVERTENCIA
AVERTISSEMENT
5200005890
WARNING
Explosion hazard.
■ Do not use evaporative starting fluids such as ether on this engine.
■ The engine is equipped with a cold starting aid. Using evaporative starting fluids can cause an
explosion which can cause engine damage, personal injury, or death.
■ Read and follow the engine starting instructions in this Operator's Manual.
WW
NOTICE
24 volt system. Do not connect to 12 volt
system.
NOTICE
24 volt system. Do not connect to 12
volt system.
AVISO
Sistema de 24 voltios. No conecte al
sistema de 12 voltios.
AVIS
Système de 24 volts. Ne pas
connecter à système de 12 volts.
5200008104
XX
Diesel exhaust fluid only.
Do not fill the DEF tank with diesel fuel.
DIESEL EXHAUST
FLUID ONLY
SEULEMENT FLUIDE
O'ÉCHAPPEMENT DIESEL
SÓLO LÍQUIDO DE
ESCAPE DIESEL
DEF
DIESEL
5200020534
YY
Ultra low sulfur fuel only.
Do not fill the diesel tank with DEF.
ULTRA LOW SULFUR
FUEL ONLY
SOLAMENTE COMBUSTIBLE
DE ULTRABAJO CONTENIDO
DE AZUFRE
DIESEL
SEULEMENT CARBURANT
DE SOUFRE ULTRA BAS
DEF
5200020535
wc_tx003569gb_FM10.fm
35
Lifting and Transporting
4
4.1
Mobile Generator
Lifting and Transporting
Lifting the Machine
Requirements
■ Lifting equipment (crane, hoist, or fork truck) capable of supporting the
machine’s weight
■ Lifting devices (hooks, chains, and shackles) capable of supporting the
machine’s weight
■ Engine stopped
Lifting the
machine
A lifting eye is used for lifting the machine.
wc_gr011429
Perform the procedure below to lift the machine.
1. Attach the lifting devices and equipment to the lifting eye. Do not attach lifting
devices to any other part of the machine.
2. Lift the machine a small distance.
WARNING
Crushing hazard. An unstable machine may cause the lifting devices and
equipment to fail. You may be crushed if the lifting devices and equipment fail.
► Check for stability before continuing.
3. Check for stability. If necessary, lower the machine, reposition the lifting devices,
and lift the machine a small distance again.
4. Continue lifting the machine only when it is stable.
36
wc_tx003570gb_FM10.fm
Mobile Generator
4.2
Lifting and Transporting
Before Towing Checklist
Before towing the machine, check the licensing requirements for trailers in your
area. Also check the following items:
Towing vehicle
 Check that the towing vehicle is rated to tow the load.
 Check that the towing vehicle is in serviceable condition.
 Do any necessary service/maintenance on the towing vehicle.
Hitch and coupler
 Check that the towing vehicle and hitch have a rating equal to or greater than
the GVWR of the machine. See Technical Data.
 Check that the hitch of the towing vehicle and coupler of the trailer are compatible.
 Check the condition of both the coupler and the hitch.
 Check that all fasteners on the coupler are tight.
 Check that the coupler has fresh grease applied to it.
Wheels
 Check that wheel chocks are available at the work site.
 Check that all lug nuts are in place and are properly torqued.
 Check the tread wear of the tires.
 Check that the tires are inflated to the proper pressure.
Trailer preparation
 Check that all doors and access panels are closed and latched.
 Check that outriggers (if applicable) are retracted.
 Check local regulations regarding hazardous materials placards. If applicable,
install the appropriate placards.
Trailer operation
 Check that the trailer jacks are in the traveling (horizontal) position.
 Check that the directional and running lights on the trailer function correctly.
 Check that the safety chains of the trailer are connected to the towing vehicle
using a crisscross pattern.
 Check the operation of the trailer brakes by braking the towing vehicle at a slow
speed. Both the vehicle and the trailer must brake smoothly. If the trailer pushes,
check the fluid level in the surge brakes or the operation of the electric brakes.
 Check that the trailer’s breakaway cable (if applicable) is attached to the towing
vehicle.
 Test the function of the breakaway system (if applicable).
wc_tx003570gb_FM10.fm
37
Lifting and Transporting
4.3
Mobile Generator
Towing the Machine
Background
The generator’s trailer is equipped with brakes (surge or electric), safety chains (a),
lights, and a coupler (pintle or ball-type) (b).
b
a
c
wc_gr011430
Brakes
Only use the brakes as designed.
■ The breakaway cable (c) is not a parking brake and should not be used as one.
Licensing
requirements
■ In most states, large trailers must be registered and licensed by the State
Department of Transportation. Before towing, be sure to check licensing
requirements.
■ Drivers towing trailers may be required to carry a commercial driver’s license
(CDL). Check your local and state licensing regulations before towing the
generator.
Coupler
maintenance
■ A film of grease on the coupler will extend coupler life and eliminate squeaking.
Wipe the coupler clean and apply fresh grease each time the trailer is towed.
Towing safety
■ When towing, maintain extra space between vehicles and avoid soft shoulders,
curbs and sudden lane changes. If you have not pulled a trailer before, practice
turning, stopping, and backing up in an area away from heavy traffic.
■ Do not exceed 55 mph when towing a trailer.
38
wc_tx003570gb_FM10.fm
Mobile Generator
4.4
Lifting and Transporting
Preparing the Machine for Transport on a Truck or Trailer
Requirements
■ Machine stopped
■ Flatbed truck or trailer capable of supporting the machine’s weight
■ Chains, hooks, or straps capable of supporting the machine’s weight
WARNING
Crushing hazard. Improperly securing the machine can lead to a crushing hazard.
► Use only the designated tie-down points to secure the machine to a truck or
trailer.
Checklist
Before transporting the machine, check the following items:
Machine
 Check that all accessories are securely stored within the machine.
 Check that all doors and access panels of the machine are closed.
 Check that all electrical supplies are disconnected from the machine.
 For machines with external fuel supplies, check that all fuel supplies are
disconnected from the machine.
 For machines with generators, check that the generator is shut down.
Loading and transporting equipment
 Check that the transport vehicle or trailer can support the weight of the machine.
 Check that the transport vehicle or trailer is wide enough to support the
machine.
 Check that the wheels of the transport vehicle or trailer are chocked during the
loading process.
 Check that the transport vehicle or trailer is clean and free of grease, oil, ice,
and other loose material.
 If the machine is mounted to a trailer, check that the jackstand or other transport
block (piece of wood or other similar material) is available to support the trailer
tongue during transporting. Do not use the machine’s trailer jack to support the
trailer tongue during transporting.
 Check that any ramps used in the loading process:
■ Can support the weight of the machine.
■ Are clean and free of grease, oil, ice, and other loose material.
■ Are securely connected to the transport vehicle or trailer.
■ Are of sufficient length to keep the loading angle 15° or less.
In addition:
 Check that the loading area is flat and the ground is stable.
 Check the overall height of the machine once it is loaded on the truck or trailer.
 Plan your travel route so there will be adequate clearance for overpasses, road
signs, buildings, etc.
 Check local regulations regarding transporting and obey these regulations.
wc_tx003570gb_FM10.fm
39
Lifting and Transporting
4.5
Mobile Generator
Hazardous Materials Placards
Overview
Hazardous materials placards may have been provided with your machine.
Transport Canada, and the Canadian Transportation of Dangerous Goods Act,
require that these hazardous materials placards be permanently applied to certain
machines if they are to be transported or towed on Canadian roads.
Contact Transport Canada if you have questions about driver’s licensing
requirements for transporting machines that bear hazardous materials placard, or
questions about other restrictions for use of this machine
Note: The owner/operator of this machine is responsible for applying the placards.
Use the procedure described below.
wc_gr009231
Requirements
Apply the
Placards
■ Placard mounting surfaces and surrounding ambient temperature should be
at least 10°C (50°F). In colder conditions, see application step 2 below.
■ Mild soap or detergent
■ Fresh, clean, warm water supply
■ Isopropyl (rubbing) alcohol, lacquer thinner, or mineral spirits
■ Soft, clean, dry cloths
■ Plastic squeegee or stiff cardboard
Four placards have been provided with this machine—one for each side, one for
the front, and one for the back.
To apply the placards, do the following.
1. Clean the placard mounting surfaces with mild soap and water. Dry thoroughly.
2. Use isopropyl (rubbing) alcohol to clean the placard mounting surfaces if:
■ they, and the surrounding ambient temperature, are below 10°C (50°F)
■ the placard mounting surfaces are covered with grease and oil.
3. Peel about 2 cm (1 in.) of backing paper from the top of the placard. Fold the
backing paper away from the placard.
4. Apply the top of the placard to the mounting surface. Gradually remove the
backing paper and apply the remainder of the placard. Firmly press and smooth
the placard into place with a plastic squeegee, stiff cardboard, or a soft cloth.
Puncture any air bubbles that may form.
40
wc_tx003570gb_FM10.fm
Mobile Generator
4.6
Lifting and Transporting
Testing the Breakaway System (Hydraulic Surge Brakes)
Requirements
■ Hydraulic reservoir filled
■ Machine parked on a flat surface
When
Test the breakaway system:
■ Before towing
■ After filling the hydraulic reservoir
Procedure
Perform the following procedure to test the breakaway system.
1. Position the machine/trailer on a flat surface.
2. Connect the breakaway cable (a) to the tow vehicle. Do not connect the
machine/trailer to the tow vehicle via the hitch.
b
a
wc_gr008509
wc_gr008508
3. Slowly move the tow vehicle so that it pulls on the breakaway cord until the
emergency lever reaches its second notch (b) and locks into the ON position.
4. Connect the machine/trailer to the tow vehicle via the hitch.
5. Attempt to tow the machine/trailer at a very slow speed (less than 5 mph). When
activated, a properly working breakaway system will cause substantial drag on
the trailer wheels and may even cause the trailer wheels to lock.
WARNING
Personal injury hazard. A faulty breakaway system may lead to an accident and
personal injury if the machine/trailer breaks away.
► Do not tow the machine/trailer if the breakaway system is faulty.
6. If the brakes did not function, repair any faults before towing.
This procedure continues on the next page.
wc_tx003570gb_FM10.fm
41
Lifting and Transporting
Mobile Generator
Continued from the previous page.
7. Stop the tow vehicle.
8. Release the brake by simultaneously pulling on the breakaway cord and prying
the locking spring with a screwdriver (c) or pry bar.
c
wc_gr008510
Result
The procedure to test the breakaway system is now complete.
42
wc_tx003570gb_FM10.fm
Mobile Generator
4.7
Lifting and Transporting
Testing the Breakaway System (Electric Brakes)
Requirements
■ Voltmeter
■ Battery charger or backup battery (charged)
When
Test the breakaway system:
■ Before towing
■ Monthly if the machine is not in service
Procedure
Perform the following procedure to test the breakaway system.
NOTICE: Disconnect the trailer wiring plug from the tow vehicle before testing.
Failure to do so will result in severe damage to the electronic brake control.
1. Connect the machine/trailer to the tow vehicle.
2. Disconnect the trailer wiring plug (a) from the tow vehicle.
c
b
a
wc_gr008513
wc_gr008514
3. Pull the breakaway pin (b) out of the brake switch (c) (to activate the brakes)
and attempt to tow the machine/trailer at a very slow speed (less than 5 mph).
When activated, a properly working breakaway system will cause substantial
drag on the trailer wheels and may even cause the trailer wheels to lock.
4. Stop the tow vehicle.
WARNING
Personal injury hazard. A faulty breakaway system may lead to an accident and
personal injury if the machine/trailer breaks away.
► Do not tow the machine/trailer if the breakaway system is faulty.
This procedure continues on the next page.
wc_tx003570gb_FM10.fm
43
Lifting and Transporting
Mobile Generator
Continued from the previous page.
5. If the brakes did not function, check the voltage of the breakaway battery.
To do so:
a. Remove the cover of the battery box.
b. Remove the wires connected to the breakaway battery (d).
c. Measure the voltage. If 12–14 VDC is not measured, replace or recharge the
breakaway battery.
d
1000
F
200
20
V
2
200m
A
VDC
V-
COM
wc_gr008515
6. If 12–14 VDC was measured but the brakes did not function, there is a wiring or
mechanical fault with the brakes. Repair any faults before towing.
7. If the brakes function properly:
a. Reconnect the wires to the breakaway battery.
b. Re-install the cover to the battery box.
c. Re-install the breakaway pin (b) into the brake switch.
d. Connect the trailer wiring plug to the tow vehicle.
Result
The procedure to test the breakaway system is now complete.
44
wc_tx003570gb_FM10.fm
Mobile Generator
5
5.1
Machine Setup
Machine Setup
Preparing the Machine for First Use
1. Make sure all loose packaging materials have been removed from the machine.
2. Check the machine and its components for damage. If there is visible damage,
do not operate the machine! Contact your Wacker Neuson dealer immediately
for assistance.
3. Take inventory of all items included with the machine and verify that all loose
components and fasteners are accounted for.
4. Attach component parts not already attached.
5. Add fluids as needed and applicable, including fuel, engine oil, and battery acid.
6. Move the machine to its operating location.
Safety
information
■ Do not exceed the power output of the generator. Damage to tools or generator
will occur. Refer to Technical Data.
■ When using the generator as a standby or substitute power supply, make sure
the voltage and phase rotation of the line connections match those of the utility
lines. Failure to match phase rotation and voltage may cause equipment
connected to the generator to operate incorrectly! This could create unsafe
operating conditions.
■ Do not exceed the rated current limit of any receptacle.
■ The bonding bar between the ground connections must remain in place at all
times unless a qualified electrician determines otherwise.
CO Alarms
Because this machine produces carbon monoxide (CO), Wacker Neuson
recommends that CO alarms be installed in all structures in close proximity to the
machine. CO alarms provide an extra measure of protection against this poison
that you cannot see or smell.
Install battery-operated CO alarms or plug-in CO alarms with battery backup,
according to the manufacturer’s instructions. CO alarms should be certified to the
requirements of the latest safety standards (UL 2034, IAS 6-96, or CSA 6.19.01).
Test the CO alarm batteries monthly.
wc_tx003572gb_FM10.fm
45
Machine Setup
5.2
Mobile Generator
Positioning the Machine
WARNING
Fire hazard. Do not move the machine while it is running.
► Shut down the machine before moving or repositioning it.
WARNING
Fire hazard. Machines positioned on a hill or an incline may slide, break away or
roll over.
► Do not position the machine on a hill or an incline.
WARNING
Explosion and fire hazard. Risk of severe injury or death.
► Do not operate the machine near flammable vapors, fuels, or combustibles.
CO Alarms
Because this machine produces carbon monoxide (CO), Wacker Neuson
recommends that CO alarms be installed in all structures in close proximity to the
machine. CO alarms provide an extra measure of protection against this poison
that you cannot see or smell.
Install battery-operated CO alarms or plug-in CO alarms with battery backup,
according to the manufacturer’s instructions. CO alarms should be certified to the
requirements of the latest safety standards (UL 2034, IAS 6-96, or CSA 6.19.01).
Test the CO alarm batteries monthly.
Requirements
Position the machine:
■ so that engine exhaust will not enter nearby structures.
■ so that the machine does not block traffic.
■ so that the machine is not close to any combustible material or flammable vapor.
■ so that all of the machine’s access doors/panels may be accessed.
■ so that the area overhead is clear of debris that could fall onto or into the
machine or exhaust compartment.
■ so that the machine is on a firm, level surface and will not tip, roll, slide, or fall
while operating.
This procedure continues on the next page.
46
wc_tx003572gb_FM10.fm
Mobile Generator
Machine Setup
Continued from the previous page.
Procedure
Perform the following procedure to position the machine.
1. Place the machine on solid, stable, and level ground.
a
wc_gr009186
2. For machines with trailers, install chocks (a) under the wheels.
Result
The machine is now properly positioned.
wc_tx003572gb_FM10.fm
47
Machine Setup
5.3
Mobile Generator
Grounding the Generator
External
grounding
A ground connection is located at the customer connection terminal lugs.
wc_gr011524
This ground connection is used for electrically grounding the generator when
necessary to comply with the National Electrical Code and other federal, state, and
local regulations. For grounding requirements in your area, consult with a qualified
electrician, electrical inspector, or local agency having jurisdiction over electrical
compliance.
■ If the generator is used at a construction site, there may be additional
regulations which must be observed.
■ In some areas, generators are required to be registered with local utility
companies.
Internal
grounding
■ The exposed, conductive, noncurrent-carrying components that could become
energized (e.g., fuel tank, engine, generator housing, control panel, enclosure,
and trailer) are bonded (connected) to the machine’s frame.
■ The grounding wires of the machine’s power outputs (receptacles, lugs, and
camlocks) are bonded (connected) to the machine’s frame.
■ The neutral of the generator stator winding is bonded (connected) to the
machine’s frame.
48
wc_tx003572gb_FM10.fm
Mobile Generator
5.4
Machine Setup
Recommended Fuel
Low temperatures cause diesel fuel to gel. Always use the proper fuel for the
conditions. Follow the guidelines in the table below.
Lowest expected ambient
temperature
Recommended fuel1
Above freezing
< 0°C (32°F)
#2 diesel plus additives
Below freezing
> 0°C (32°F)
Winter-blend diesel
1
Your engine may require ultra low sulfur fuel. Consult the engine owner’s manual.
NOTICE: Consult the engine owner’s manual regarding the use of biodiesel fuel in
this machine. Some biodiesel blends may clog the fuel system or gel at cold
ambient temperatures sooner than petroleum-based diesel.
CAUTION
Fire hazard.
► Do not use gasoline, crankcase oil, or any oil containing gasoline.
wc_tx003572gb_FM10.fm
49
Machine Setup
5.5
Mobile Generator
Refueling the Machine (Basler Controller)
Requirements
■
■
■
■
■
Procedure
Perform the procedure below to refuel the machine.
Machine shut down
Engine cool
Machine/fuel tank level with the ground
Remote switch disconnected from the remote run terminal
Fresh, clean fuel supply
WARNING
Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause
severe burns.
► Keep all sources of ignition away from the machine while refueling.
► Refuel only when the machine is outdoors.
► Clean up spilled fuel immediately.
1. Remove the fuel cap.
2. Place the engine start switch (a) in the REMOTE START position.
V
Ø
A
HZ
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
a
R
wc_gr008413
3. The fuel level (in percentage of the fuel tank capacity) will be displayed in the
lower left corner of the LCD screen.
4. Fill the fuel tank until the fuel level reaches 100%.
CAUTION
Fire and health hazard. Fuel expands when heated. Expanding fuel in an over-filled
tank can lead to spills and leaks.
► Do not overfill the fuel tank.
5. Re-install the fuel cap.
6. Place the engine start switch in the OFF position.
Result
The procedure to refuel the machine is now complete.
50
wc_tx003572gb_FM10.fm
Mobile Generator
5.6
Machine Setup
Refueling the Machine (Deep Sea Controller)
Requirements
■
■
■
■
Procedure
Perform the procedure below to refuel the machine.
Engine stopped
Machine/fuel tank level with the ground
Remote switch disconnected from the remote run terminal
Fresh, clean fuel supply
WARNING
Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause
severe burns.
► Keep all sources of ignition away from the machine while refueling.
► Refuel only when the machine is outdoors.
► Clean up spilled fuel immediately.
1. Remove the fuel cap.
2. Place the genset controller power switch in the ON position and wait for the
Deep Sea controller to boot up.
3. Press the right arrow key to navigate to the “Engine” screen.
DSE
DSE
DEEP SEA ELECTRONICS
DSE 7310
DSE 7310
Gener
Gene
ratorAvai
Availab
labl
le
e

DEEP SEA ELECTRONICS
STOP
L-N
L-N
0V
0 AA
L-L
L-L
0V
0.0 HzH
0 kW
kW
---- pf
pf
STOP
Open
Open
Close
Close
Load
Gen-Set
o
Stop/Reset
AUTO
Manual
Mode
Auto
Mode
Lamp Test
Horn Reset
Start
wc_gr011443
4. Use the up or down arrow key to navigate to the “Engine Fuel Level” screen.
The fuel level (in percentage of the fuel tank capacity) will be displayed.
Note: The “Engine Fuel Level” screen will revert back to status screen after three
minutes of inactivity.
5. Fill the fuel tank until the fuel level reaches 100%.
CAUTION
Fire and health hazard. Fuel expands when heated. Expanding fuel in an over-filled
tank can lead to spills and leaks.
► Do not overfill the fuel tank.
6. Re-install the fuel cap.
7. Place the genset controller power switch in the OFF position.
wc_tx003572gb_FM10.fm
51
Operation, Control, and Component Locations
6
Operation, Control, and Component Locations
6.1
Control / Component Locations
V
Ø
A
e
HZ
STOP
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
START / RUN
OFF
f
AUS
APAGADO
ARRET
c
j
d
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
AUS
APAGADO
ARRET
v
OFF
AUS
APAGADO
ARRET
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
a
b
V
Ø
A
HZ
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
R
o
k
h
p
m
n
u
52
wc_gr011509
wc_tx003617gb_FM10.fm
Operation, Control, and Component Locations
w
q
t
s
r
wc_gr011534
Ref.
Description
Ref.
Description
a
Main circuit breaker
n
GFI receptacle
(120 VAC, 20 Amp)
b
Voltage adjustment rheostat
o
Remote run terminal block
c
Hour meter
p
Emergency stop switch
d
(If equipped)
Diesel Particulate Filter (DPF) switch and
indicator
or
Manual conditioning switch for
aftertreatment exhaust system
q
Interlock switch (lug panel door switch)
e
Genset controller (Basler or Deep Sea)
r
Customer connection terminal lugs
f
Engine start switch or genset power switch
s
Ground connection
h
Circuit breaker (240V, 50 Amp)
t
Bond bar
j
Idle switch (high and low) (if equipped)
u
Customer connection terminal lugs door
k
Circuit breaker (120V, 20 Amp)
v
Voltage selector access door
m
Twist-lock receptacle
(120/240 VAC, 50 Amp)
w
Voltage selector switch
wc_tx003617gb_FM10.fm
53
Operation (Basler Controller)
7
7.1
Mobile Generator
Operation (Basler Controller)
Main Circuit Breaker
Location
Various styles of main circuit breakers may be found on Wacker Neuson Mobile
generators. The main circuit breaker (a) is located on the control panel.
Note: Graphic is representative only. Your machine may vary.
a
STOP
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
AUS
APAGADO
ARRET
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
AUS
APAGADO
ARRET
ME
R GE NC
Y
E
STOP
S TOP
wc_gr011444
Functions
■ The main circuit breaker interrupts power from the voltage selector switch to the
terminal lugs.
■ The main circuit breaker does not interrupt power to the convenience
receptacles.
WARNING
Electric shock hazard. High voltage is present inside the control panel while the
engine is running.
► Do not open the control panel unless the engine is stopped.
NOTICE: Before shutting down the generator or performing any service to the
generator, make sure the main circuit breaker is in the OFF position.
54
wc_tx003618gb_FM10.fm
Mobile Generator
7.2
Operation (Basler Controller)
Engine Start Switch
Description
The engine start switch (a) is a three-position switch: “REMOTE START”, “OFF”,
and “START/RUN”.
a
OFF
AUS
APAGADO
ARRET
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
wc_gr011436
Function
Position
Function
LCD Screen
REMOTE START
This position is used when the generator is
being operated as a stand-by power supply, and
it is connected to a remote switch. The
generator is in stand-by mode and will not start
until the remote switch is activated (closed).
READY screen
START/RUN
This is the normal start and run position. When
set to this position, power is supplied to the
genset controller which immediately launches
the start-up sequence.
As a precaution, be prepared for engine startup
anytime the engine start switch is in the
REMOTE START position.
Monitoring
screen
OFF
Power to the genset controller is disconnected.
Blank screen (off)
wc_tx003618gb_FM10.fm
55
Operation (Basler Controller)
7.3
Mobile Generator
Genset Pre-Alarms and Alarms (Shut-Down Conditions)
Background
The genset controller monitors variables of engine and machine function. The
genset controller is programmed to signal pre-alarm conditions, and to shut down
the machine when an alarm condition exists.
Pre-alarms
Pre-alarm conditions are:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Time to maintenance
During a pre-alarm condition, the LCD panel (a) displays the type of pre-alarm, and
the LED (b) flashes. The machine is not shut down.
Alarms/
shutdowns
Shut-down conditions are:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Overspeed/Underspeed
■ Overcrank
■ Low coolant level (if equipped)
■ Overcurrent
During an alarm condition, the LCD panel (a) displays the type of alarm, the LED
(b) illuminates continuously, and the machine is shut down.
V
Ø
A
HZ
042563
V
OFF
AUS
APAGADO
ARRET
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
Ø
A
HZ
a
R
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
Basler
R G E NC
ME
Y
E
b
R
S TOP
wc_gr010359
Variable
Normal
Pre-Alarm
Alarm
To Reset
Fuel level
>15%
15%
5%
Fill fuel tank. Toggle start switch.
Coolant temp
85°C±8
105°C
115°C
Add coolant. Toggle start switch.
Oil pressure
60–80 psi
20 psi
15 psi
Add engine oil. Toggle start switch.
Overspeed
60 Hz
—
66 Hz
Toggle start switch.
Underspeed
60 Hz
—
54 Hz
Toggle start switch.
Overcrank
—
—
After 3 attempts
Toggle start switch.
Time to maintain
250 hours
0 hours
—
Reset genset controller.
Coolant level
Above sender
—
Below sender
Add coolant. Toggle start switch.
56
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Mobile Generator
7.4
Operation (Basler Controller)
Overcurrent Condition
Along with engine functions, the genset controller continuously monitors the
current load in each leg. The values for current overload are programmed into the
ECM at the factory and are different for each generator size.
a
b
V
Ø
A
HZ
042563
OFF
AUS
APAGADO
ARRET
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
R
wc_gr010360
When an overcurrent condition is sensed in any leg, the pre-alarm/shutdown LED
(b) flashes and the LCD displays OVERCURRENT.
If the overcurrent condition persists, the main circuit breaker (a) opens and the
LCD screen changes to OVRLOAD - SET BRKR. This indicates an overload fault.
To clear the overload fault, reset the main circuit breaker. Failing to reset the main
circuit breaker within 5 minutes will cause the machine to shut down. The LCD
screen will then change to OVERLOAD.
7.5
Idle Switch
Location and
description
If equipped, the idle switch (x) is located at the left side of the engine start switch. It
is a two-position switch: Low Idle (turtle), and Rated Speed (rabbit).
x
OFF
AUS
APAGADO
ARRET
V
Ø
A
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
HZ
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
R
wc_gr009225
The idle switch allows the operator to select the speed of the engine at start-up.
Starting the engine at low idle is recommended when operating this machine in
extremely cold weather. Otherwise, the engine can be started at rated speed.
NOTICE: Disconnect all loads from the engine before starting at low idle.
wc_tx003618gb_FM10.fm
57
Operation (Basler Controller)
7.6
Mobile Generator
Diesel Particulate Filter (DPF)
Overview
The machine may be equipped with a Diesel Particulate Filter (DPF). The DPF (a)
helps to protect the environment by removing soot from the engine exhaust.
a
wc_gr010593
Function
Sustained operation of the generator under load heats the DPF to a temperature
high enough to burn accumulated soot. As long as a minimum internal temperature
is maintained, this process (“passive regeneration”) will occur automatically.
Passive regeneration is controlled by the Electronic Control Unit (ECU) on the
engine.
58
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Mobile Generator
7.7
Operation (Basler Controller)
Using the Lugs and the Convenience Receptacles
Overview
Loads can be connected to the genset in two different ways:
1. At the connection lugs (r).
Located as shown, behind the lug door, the connection lugs serve as connection
points for cables.
2. At the convenience receptacles:
■ 120V/240V twist-lock receptacles (l)
■ 120V GFCI duplex receptacles (m)
Note: The convenience receptacles are not protected by the main circuit breaker.
They are protected by their own circuit breakers (j, k). Power to the convenience
receptacle circuit breakers is available any time the engine is running, even with
the main circuit breaker OFF (open).
Note: Graphic is representative only. Your machine may vary.
j
k
p
r
j
m
l
wc_gr011537
Lug door
interlock
switch
The lug door interlock switch (p) is located behind the lug door. The lug door
interlock switch is a safety device. When the lug door is opened, the lug door
interlock switch trips the main circuit breaker.
Note: The lug door interlock switch does NOT interrupt power to the convenience
receptacles. However, the switch does stop excitation at the generator. The result
is significantly reduced voltage at the convenience receptacles.
wc_tx003618gb_FM10.fm
59
Operation (Basler Controller)
7.8
Mobile Generator
Selecting the Voltage
Background
Selecting the voltage is a two-step process. First, select the voltage using the
voltage selector. Then, use the voltage adjustment rheostat to fine-tune the voltage
to your exact requirements.
Location
The voltage selector (a) is located behind the access door in the upper half of the
control box.
WARNING
Electric shock and arc flash hazard. High voltage is present at the voltage selector
while the engine is running.
► Do not open the access door while the engine is running.
► Do not change the position of the voltage selector while the engine is running.
a
wc_gr010389
Voltage
ranges
The chart below lists the ranges of voltages available in both of the selector
positions. The voltage is displayed on the LCD panel.
Range of Voltages Available
Switch position
3Ø at lugs
(L–L–L)
1Ø at lugs
(L–N)
1Ø at lugs
(L-L)
1Ø at twist lock
1Ø at GFCI
L-N (120V)
L-L (240V)
240 VAC
190–240
110–139
190–240
110–139
190–240
110–139
480 VAC
380–480
220–277
190–240
110–139
190–240
110–139
This procedure continues on the next page.
60
wc_tx003618gb_FM10.fm
Mobile Generator
Operation (Basler Controller)
Continued from the previous page.
Description
The voltage selector mechanically changes the connections between the generator
output leads and the terminal lugs on the generator.
c
b
= 40Nm (29.5 Ft Lbs)
L1
L1
1
4
2
N
12
11
L3
1
3
10
L1-N = 120V
L2-N = 120V
L-L
6
5
8
9
7
L2
3
L3-N = 120V
L1-L2= 208V
L2-L3= 208V
L3-L1= 208V
L1-N = 277V
L2-N = 277V
2
L-L
4
12
11
L3
10
9
L-N
N
8
7
L2
6
L3-N = 277V
L1-L2= 480V
L2-L3= 480V
L3-L1= 480V
5
L-N
wc_gr010390
Selecting the
voltage
To select the voltage:
1. Remove the screws (b).
2. Move the plate (c) to the desired position.
3. Re-install the screws. Torque the screws to 40 Nm (29.5 ft.lbs.).
This procedure continues on the next page.
wc_tx003618gb_FM10.fm
61
Operation (Basler Controller)
Mobile Generator
Continued from the previous page.
Using the
rheostat
The voltage adjustment rheostat (d) is used to fine-tune the voltage as needed
while the machine is running.
d
wc_gr010391
Care must be taken when using the voltage adjustment rheostat because adjusting
the voltage for 3-phase operation affects the voltage available at the single-phase
outlets. As the 3-phase voltage increases, so does the single-phase voltage.
NOTICE: Do not use the GFCI or twist-lock receptacle (120V) when the 1Ø voltage
is above 135V. Damage to the receptacle and the tools connected to it may occur.
Corresponding 1Ø voltage
Switch Position
3Ø Voltage
(L-L-L)
Twist lock receptacle
L-L (240V)
240 VAC
480 VAC
L-N (120V)
120V GFCI
208
208
120
120
220
220
125
125
240
240
139
1
1391
480
240
1391
1391
460
230
1332
1332
1 Do
not use receptacle with this voltage.
Voltage may be too high for some tools and equipment. Check tool/equipment specifications.
2
62
wc_tx003618gb_FM10.fm
Mobile Generator
7.9
Operation (Basler Controller)
Before Starting the Machine
WARNING
Personal injury hazard. Failure to follow the listed procedures may cause injury to
personnel or damage to the generator.
► Make sure that all persons setting up the generator are certified or fully trained
on the installation of the generator.
Before putting the generator into service, perform each item on the following
checklist.
Exterior
checks
 Check for damage that may have occurred during towing or travel to the jobsite.
Repair any damage.
 Make sure that the generator is level.
 Chock the trailer wheels.
Internal
checks
 Check engine oil, coolant, and fuel levels—fill as required.
 Check the fan belt and hoses on the engine for loose connections or fraying—
tighten or replace belts and hoses as required.
 Remove any debris that has lodged in vents, near the radiator, or around the
fan.
 Make sure the exhaust compartment is clean, with nothing touching the muffler
or exhaust pipes.
Pre-operation
checks
 Read and understand the engine owner’s manual.
 Check local regulations and NEC standards for electrical connections.
 Determine voltage needs; obtain proper cable and equipment to meet the
needs. Follow local regulations and NEC standards.
 Make sure that the generator is grounded to a good earthen ground per local
regulations and NEC standards.
 Review and follow the safety instructions found in the front of this Operator’s
Manual.
wc_tx003618gb_FM10.fm
63
Operation (Basler Controller)
7.10
Mobile Generator
Starting and Running the Generator
CAUTION
Possibility of injury or equipment damage. Failure to match phase, voltage, and
frequency may cause equipment connected to the generator to operate incorrectly.
► When using the generator as a stand-by or substitute power supply, make sure
the phase, voltage, and frequency of the generator matches that of the utility
lines or of any other power source normally used.
Perform the procedure below to start and run the machine.
1. Set the engine start switch (a) to the OFF position.
Note: Graphic is representative only. Your machine may vary.
e
g
b
OFF
AUS
APAGADO
ARRET
REMOTE START
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
V
Ø
A
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
HZ
OFFF
OF
AUS
AU
S
APAGADO
APAGADO
ARRETT
ARRE
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
REMOTE START
START
START / RU
RUN
N
FERNSTARTT
FERNSTAR
ARRANQUE REMOTO
REMOTO
DEMARRAGE A
DISTANCE
DISTANC
E
START / LAUFE
LAUFEN
N
ARRANQUE / MARCHA
MARCHA
DEMARRER / MARCHE
MARCHE
Basler
Preliminary
R
a
c d
f
wc_gr011540
2. Set the main circuit breaker (b) to OFF.
3. Set the convenience receptacle circuit breakers (c, d) to OFF.
4. Turn off all loads.
5. Check position of the voltage selector switch (e) and make sure it is set for the
desired voltage output. Lock the voltage selector switch in place if desired.
6. If equipped, set the idle switch (g) to the low speed position (turtle).
This procedure continues on the next page.
64
wc_tx003618gb_FM10.fm
Mobile Generator
Operation (Basler Controller)
Continued from the previous page.
7. Connect the load to the lugs and/or to the convenience receptacles.
8. Check the operation of the genset controller.
a. Set the engine start switch to REMOTE START. The LCD panel momentarily
displays INITIALIZING followed by READY. Engine information is also
displayed. Check the fuel level and battery voltage. Add fuel and/or charge
the battery if needed. If the LCD display does not power up, check battery
voltage and connections.
b. With the READY screen showing, press the emergency stop button (f). The
LCD panel displays EMERGENCY STOP, and the pre-alarm/alarm LED
illuminates. If the LCD does not display EMERGENCY STOP, do not
continue. Contact a Wacker Neuson dealer for assistance. Pull out the
emergency stop button after verifying the display.
c. Set the engine start switch to OFF.
Starting
9. Start the engine by setting the engine start switch to the START/RUN position.
After displaying INITIALIZING and NOT IN AUTO, the LCD panel will display
START DELAY followed by CRANKING as the engine begins its crank cycle. The
crank cycle calls for the engine to crank for 15 seconds, then rest for 10 seconds.
This cycle will repeat three times in an attempt to start the engine.
If the engine does not start within three attempts, the genset controller stops the
crank cycle and OVERCRANK is displayed on the LCD panel.
To repeat the crank cycle, set the start switch to OFF, then back to START/RUN.
10.If equipped, set the idle switch to the operating speed position (rabbit).
Upon startup
Upon engine startup, the LCD displays the monitoring screen. Run the engine for a
few minutes to allow it to warm before turning on (closing) any circuit breakers.
Note: Leave the engine start switch (a) in the START/RUN position while the
generator is operating.
wc_gr010195
11.Check the voltage on the monitoring screen and adjust it as needed using the
voltage adjustment rheostat. See topic Selecting the Voltage.
12.Turn on (close) the appropriate circuit breakers for your load.
wc_tx003618gb_FM10.fm
65
Operation (Basler Controller)
7.11
Mobile Generator
Stopping the Machine
Check with other personnel on the jobsite and let them know that power is being
turned off. Make sure that the power shutdown will not create any hazards by
turning off devices such as pumps, heaters, or lights that may need to be kept on.
1. Turn off all loads connected to the generator.
2. Set the main circuit breaker to OFF.
3. Set the convenience receptacle circuit breakers to OFF.
4. Let the engine run for approximately ten minutes to cool it down.
5. Move the engine start switch to the OFF position.
7.12
Emergency Stop Switch
The emergency stop switch (a) is the red button located as shown, and can be
accessed with the panel doors closed.
ERGENC
M
Y
E
Location
a
ALARM ACTIVE
TO VIEW
EMERGENCY STOP
wc_gr010365
Function
Activate the emergency stop switch by pushing the red button. Pushing the
emergency stop switch:
■ turns off (opens) the main circuit breaker
■ cuts power to the fuel solenoid
■ stops the engine
■ causes “Alarm Active: Emergency Stop” to appear on the LCD display
The emergency stop switch will remain activated until the button is pulled out.
NOTICE: Do not use the emergency stop switch to shut down the generator during
normal operation. The emergency stop switch is intended for use only in an actual
emergency situation where the generator must be stopped immediately.
To shut down the generator during normal operation, turn off (open) the main circuit
breaker and then move the engine start switch to the OFF position.
66
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Mobile Generator
7.13
Operation (Basler Controller)
LCD Panel: Monitoring Machine Operation
Overview
Generator and engine information is continuously monitored and displayed on the
LCD panel. The upper line displays generator information. The lower line displays
engine information.
Generator
Engine
wc_gr010202
Generator
information
The upper line of the LCD panel shows the voltage, phase, amperage, and
frequency of the electric power being generated. The information is shown only
when the engine is running.
Symbol
Meaning
Description
V
Volts
Displays the value of the AC output voltage being
produced by the generator.
Ø
Phase
Displays the leg or phase currently being monitored. In
three-phase mode, the display toggles between P1, P2,
and P3. In single-phase mode, the display toggles
between L1, L3, and L-L.
A
Amps
Displays the value of the AC output amperage
produced by the generator. If the generator is operating
at no load, output amperage will be zero (0).
Frequency in
Hertz
Displays the value of the output frequency. This display
will read approximately 61.5 Hz under a no-load
condition and approximately 60 Hz under load.
HZ
This procedure continues on the next page.
wc_tx003618gb_FM10.fm
67
Operation (Basler Controller)
Mobile Generator
Continued from the previous page.
Engine
information
The lower line of the LCD panel shows fuel level, temperature, oil pressure, and
battery voltage. The information is shown when the engine start switch is set to
REMOTE START or RUN/START.
Symbol
Meaning
Description
Fuel level
Indicates relative fuel level in the fuel tank
Temperature
Displays temperature of engine coolant
Oil pressure
Displays engine oil pressure between 0–100 psi
Normal operating pressure = 60–80 psi
Battery voltage
Displays real-time battery voltage while the machine
is operating
Actual battery voltage is displayed when the engine
switch is set to REMOTE START and the generator
is in standby mode.
68
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Mobile Generator
8
Working with Basler Controller
Working with Basler Controller
8.1
How to Use the Genset Controller LCD and Keypad
Basics
The LCD (a) is used to display information regarding machine performance and
operating status. The keypad (b) is used to maneuver through the various menus
of the genset controller. The keypad is also used to enter and change values of
machine settings.
b
a
2
4
5
1
6
3
wc_gr010130
Actions of the
buttons
To scroll through the options within a menu, use the up/down arrow buttons (2, 3).
When an option on a menu is highlighted, it can be accessed for further submenus.
To do so, press the right arrow button (1).
To return to a previous screen, press the left arrow button (4).
To exit menu navigation and return to monitoring status (or the READY screen),
press and hold the left arrow button.
To access a setting in order to change it, press the check mark button (5).
To cancel an operation, press the “X” reset button (6).
Normal
screens
The machine must be running, or the start switch set to REMOTE START position,
for the genset to be on and active. Sample screens of normal operation are shown
below.
Genset monitoring status
READY screen
This screen is displayed
when the machine is running.
This screen is displayed when the
start switch is in REMOTE START.
wc_gr010144
wc_tx003229gb_FM10.fm
69
Working with Basler Controller
8.2
Mobile Generator
Menu Diagram of the Genset Controller
The various menus of the genset controller are divided into two main categories:
METERING and SETTINGS. Access to the METERING menu and to the
SETTINGS menu is done through the MAIN MENU. To access the MAIN MENU
from either the monitoring screen or the READY screen, press the right arrow
button.
Note: Graphic is representative only. Your machine may vary.
.
Main Menu
Metering
Metering
Settings
Engine
Generator
Power
Run Statistics
Alarm-Status
Engine
Oil Pressure
Coolant Temp
Battery Volt
RPM
Speed Source
Fuel Level
Engine Load
Coolant Level*
Total Run Time
Hrs to Maintenance
DEF Tank Level*
DIAGNOSTIC MENU
NAVIGATION
UP
BACK
FORWARD
Generator
Voltages
Frequency
Amps
Bus V
Bus Frequency
Synchronizer
Max Vector Shift
Max ROCOF
ROCOF
DOWN
Power
kW
kVA
kVAR
PF
Run Statistics
Cumulative
Session
Alarm-Status
Alarms
Pre-Alarms
Status
Inputs
Outputs
Conf Elements
Conf Prot Status
Event Log
J1939 Data*
J1939 Engine Config*
J1939 Active DTC*
J1939 Previous DTC*
General Settings
Front Panel HMI
Configure Date/Time
Cumulative
Cumulative Info
Total Run Time
Loaded Run Time
Unloaded Run Time
Detailed Data
Session
Session Info
Total Run Time
Loaded Run Time
Unloaded Run Time
Detailed Data
Detailed Data
Front Panel HMI
LCD Contrast
Language
Settings
System Settings
General Settings
Communications
Sys Parameters
Programmable Inputs
Alarm Config
Generator Protection
Breaker Management
Bias Control
Enter Password
System Parameters
System Settings
Crank Settings
System Units
Maintenance Reset
Crank Settings
Cooldown Time
Alarm Configuration
Alarms
Alarms
Low Fuel Level
* NOT AVAILABLE ON SOME MODELS
wc_gr007618
70
wc_tx003229gb_FM10.fm
Mobile Generator
8.3
Working with Basler Controller
Menu Diagram Components
.
Menu Item
Description
Menu Item
Description
Alarm Config
Alarm configuration
J1939 Active DTC
Diagnostic Trouble
Codes
Alarm Configuration
—
J1939 Data
—
Alarms
—
J1939 Engine Config
Engine configuration
Alarm–Status
—
J1939 Previous DTC
Diagnostic Trouble
Codes
Amps
—
kVA
Kilovolt-amps
Back
—
kVAR
Kilovolt-amps Reactive
Battery Volt
—
kW
Kilowatts
Bias Control
—
Language
—
Breaker Management
—
LCD Contrast
Liquid Crystal Display
Bus Frequency
—
Loaded Run Time
—
Bus V
Bus voltage
Low Fuel Level
—
Communications
—
Main Menu
—
Conf Elements
Configurable elements
Maintenance Reset
—
Conf Prot Status
Configurable protection
status
Metering
—
Configure Date/Time
—
Oil Pressure
—
Coolant Level
—
Outputs
—
Coolant Temp
—
PF
Power factor
Cooldown Time
—
Power
—
Crank Settings
—
Pre-Alarms
—
Cumulative
—
Programmable Inputs
—
Cumulative Info
—
RPM
Rotations per minute
Detailed Data
—
Run Statistics
—
Diagnostic Menu Navigation
—
Session
—
Down
—
Session Info
—
Engine
—
Settings
—
Engine Load
—
Speed Source
—
Enter Password
—
Status
—
Event Log
—
Synchronizer
—
Forward
—
Sys Parameters
System parameters
Frequency
—
System Settings
—
Front Panel HMI
Human-Machine
Interface
System Units
—
Fuel Level
—
Total Run Time
—
General Settings
—
Unloaded Run Time
—
wc_tx003229gb_FM10.fm
71
Working with Basler Controller
Mobile Generator
Menu Item
Description
Menu Item
Description
Generator
—
Up
—
Generator Protection
—
Voltages
—
Hrs to Maintenance
Hours to maintenance
—
—
Inputs
—
—
—
8.4
Using the Metering and Settings Menus
Background
The various menus of the genset controller are divided into two main categories:
METERING, and SETTINGS. Access to the METERING menu and to the
SETTINGS menu is done through the MAIN MENU.
METERING
menus
METERING menus give detailed information regarding engine status and
generator performance. The machine must be running for many of the parameters
to be active. Use the menu diagram of the genset controller as a guide for
navigating the menus.
Parameters under the METERING menu are read-only. They cannot be changed,
except for HRS to MAINTENANCE parameter, which can be reset.
SETTINGS
menus
SETTINGS menus give detailed information regarding genset controller
configuration. Use the menu diagram of the genset controller as a guide for
navigating the menus.
There are a limited number of parameters under the SETTINGS menus that may
be changed by the user. These parameters are:
 LCD screen contrast
 Time and date
 Sender fail time delays
 Units of measure (imperial or metric)
 Low fuel pre-alarm level
 Low fuel alarm level
 Cooldown time
 Pre-crank time delay
 Maintenance interval
Procedures for changing these parameters are included in this manual.
72
wc_tx003229gb_FM10.fm
Mobile Generator
8.5
Working with Basler Controller
Logging in to the Genset Controller by Entering the Password
Precaution
Only change parameters when the READY screen is displayed (start switch in the
REMOTE START position).
Password
In order to change the parameters under the settings menu, you must be “logged
in” to the genset controller. There are two displays where you can log in to the
genset controller: 1) at the “ENTER PASSWORD” display under SETTINGS; or 2)
when prompted for the password by the genset controller at the parameter you
want to change.
The default password, in either case, is “OP”. It is set at the factory. It is the only
password available, and it cannot be changed.
Once you are logged in, you will remain logged in until:
 you log out,
 the machine is turned off,
 or if you press the check mark button inadvertently. This usually happens when
attempting to change a locked parameter.
At ENTER
PASSWORD
To log in to the genset controller at the ENTER PASSWORD display, do the
following:
1. Press the right arrow button (1) to enter the main menu.
wc_gr010119
2. Use the up/down arrow buttons (2, 3) to highlight SETTINGS. Then, press the
right arrow button.
This procedure continues on the next page.
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Mobile Generator
Continued from the previous page.
3. Using the up/down arrow buttons, scroll through the setting parameters until
ENTER PASSWORD is highlighted. Then, press the check mark button (5).
4. The password entry screen appears with a letter “A” as the default character.
Use the up/down arrow buttons to change the “A” to “O”. Then, press the right
arrow button to move the cursor to the next position.
5. Use the up/down buttons to select “P”. Then, press the check mark button.
The screen below appears. You are now logged in and have the ability to change
parameter settings. Do not re-enter the password even though it is requested;
instead, navigate to the parameter you would like to change. You may, however,
log out if desired. To do so, navigate to LOGOUT and press the check mark button.
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Mobile Generator
At the
PASSWORD
prompt
Working with Basler Controller
To log in when prompted to enter the password, do the following:
1. The password entry screen appears with a letter “A” as the default character.
Use the up/down arrow buttons to change the “A” to “O”. Then, press the right
arrow button to move the cursor to the next position.
2. Use the up/down arrow buttons to select “P”. Then, press the check mark
button.
3. A screen for the parameter, similar to that shown below left (A), will appear. The
word “~~EDIT~~” will be displayed. Whenever “~~EDIT~~” is displayed, it
means that you are able to change the parameter. Use the up/down arrow
buttons to change the setting. Then, press the check mark button to accept the
new value.
wc_gr010128
Note: If the genset controller displays the screen (B), it means that the parameter
cannot be changed by the operator. Do not re-enter the password even though you
are requested to do so; instead, press the “X” button to cancel the operation and
return to the previous screen. If you do re-enter the password (by pressing the
check mark button), you will be logged out. In such cases, turn the machine off,
then back on again, and restart the procedure from the beginning.
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8.6
Mobile Generator
Adjusting the LCD Screen Contrast
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Procedure
Perform the procedure below to adjust the LCD screen contrast.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight GENERAL SETTINGS. Then, press the right arrow button (1).
4. Highlight FRONT PANEL HMI. Then, press the right arrow button.
5. Highlight LCD CONTRAST. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the contrast value as desired. Press
the check mark button when finished.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button until the READY screen appears.
Result
The screen contrast has now been adjusted.
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8.7
Working with Basler Controller
Changing the Time/Date Settings
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Procedure
Perform the procedure below to change the time and date.
1. Press the right arrow button (1) to access the MAIN MENU.
wc_gr010133
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight GENERAL SETTINGS. Then, press the right arrow button (1).
4. Highlight CONFIGURE DATE/TIME. Then, press the right arrow button.
5. Highlight the setting you want change. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button so that the READY screen appears.
Result
The date/time settings have now been changed.
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Working with Basler Controller
8.8
Mobile Generator
Changing the Sender Fail Time Delays
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller or connections to a remote
start switch may cause the machine to start unexpectedly. Be prepared for the
engine to start even with the engine start switch in the REMOTE START position.


Background
There are five senders/sensors monitored by the genset controller. Each has its
own failure-time-delay period. This is the amount of time that the genset controller
must experience the failure before the failure will be seen on the LCD display.
These failure-time-delay periods may be changed. The table below lists the failuretime-delay periods, the allowable range, and their factory settings.
Failure Time Delay
Procedure
Range
Factory Setting
Coolant temperature sender
0 to 30 min
5 min
Oil pressure sender
0 to 300 sec
10 sec
Fuel level sender
0 to 300 sec
10 sec
Voltage sensor
0 to 300 sec
15 sec
Speed sender
0 to 300 sec
300 sec
Perform the procedure below to change a fail time delay.
1. Press the right arrow button (1) to access the MAIN MENU.
wc_gr010134
This procedure continues on the next page.
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Working with Basler Controller
Continued from the previous page.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight ALARM CONFIGURATION. Then, press the right arrow button.
4. Highlight SENDER FAIL. Then, press the right arrow button.
5. Highlight the sender or sensor you want to change. Then, press the right arrow
button.
6. Highlight ACTIVATN DELAY or TIME DELAY. Then, press the check mark
button (5).
7. If you are not logged in, enter the password “OP”. Press the check mark button.
8. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
9. Exit by pressing the left arrow button (4) three times or until the LCD displays
the SETTINGS menu. Then, scroll to LOGOUT and press the check mark
button. Press the left arrow button so that the READY screen appears.
Result
The fail time delay has now been changed.
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Working with Basler Controller
8.9
Mobile Generator
Changing the Units of Measure
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
Genset controller units of measure may be set to English (imperial) or metric.
Procedure
Perform the procedure below to set the units of measure.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight SYSTEM PARAMS. Then, press the right arrow button.
4. Highlight SYSTEM SETTINGS. Then, press the right arrow button.
5. Highlight the SYSTEM UNITS. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
This procedure continues on the next page.
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Working with Basler Controller
Continued from the previous page.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button so that the READY screen appears.
Result
The units of measure have now been changed.
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8.10
Mobile Generator
Changing the Low Fuel Pre-Alarm Setting
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The low fuel pre-alarm setting may be changed if desired. The value shown by the
genset controller is the percentage of fuel remaining in the fuel tank. The range
allowed by the genset controller is 10–100.
Procedure
Perform the procedure below to change the low fuel pre-alarm setting.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight ALARM CONFIGURATION. Then, press the right arrow button.
4. Highlight PRE-ALARMS. Then, press the right arrow button.
5. Highlight the LOW FUEL LEVEL. Then, press the right arrow button.
6. Highlight the THRESHOLD. Then, press the check mark button (5).
7. If you are not logged in, enter the password “OP”. Press the check mark button.
This procedure continues on the next page.
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Working with Basler Controller
Continued from the previous page.
8. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
9. Exit by pressing the left arrow button (4) three times or until the LCD displays
the SETTINGS menu. Then, scroll to LOGOUT and press the check mark
button. Press the left arrow button so that the READY screen appears.
Result
The low fuel pre-alarm setting has now been changed.
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8.11
Mobile Generator
Changing or Disabling the Low Fuel Alarm Setting
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
Notes
The LCD panel displays, in percentage, how much fuel is in the fuel tank. The low
fuel alarm shutdown is set at the factory to activate at 6%. This value may be
changed if desired. For example, you may wish to reduce the low fuel alarm setting
so that the machine operates for a longer period of time or until virtually all fuel is
consumed before the genset controller shuts down the machine for lack of fuel.
The range allowed by the genset controller is 0–100%.
 Do not set the low fuel alarm to a value greater than that of the low fuel prealarm. Doing so will nullify the function of the low fuel pre-alarm.
 Setting the low fuel alarm below 5, in effect, disables the low fuel alarm. The
genset controller will not shut down the machine. The machine will shut down
when all fuel is consumed.
 “5” is the lowest value the LCD will display.
NOTICE: If the low fuel alarm is set below 5, it is possible to run the fuel so low that
air will be drawn into the engine. The fuel system may then need to be bled before
it will start and run.
Approximate run time (at 100% prime load) gained with low fuel alarm set to 0%.
Machine
Procedure
Fuel Use gal/hr
Time Gained hr
G 25
1.8
3.7
G 25 ERT
1.8
4.2
G 50
3.4
3.0
G 50 ERT
3.4
3.8
G 70
4.9
2.1
G 70 ERT
4.9
2.6
G 100
6.2
3.3
G 120
7.44
2.7
G 150
8.85
3.4
G 180
10.8
2.7
G 240
13.5
2.1
Perform the procedure below to change the low fuel alarm setting.
1. Press the right arrow button (1) to access the MAIN MENU.
This procedure continues on the next page.
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Working with Basler Controller
Continued from the previous page.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.Highlight ALARM CONFIG. Then, press the right arrow
button.
3. Highlight ALARMS. Then, press the right arrow button.
4. Highlight the LOW FUEL LEVEL. Then, press the right arrow button.
5. Highlight the THRESHOLD. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
8. Exit by pressing the left arrow button (4) three times or until the LCD displays
the SETTINGS menu. Then, scroll to LOGOUT and press the check mark
button. Press the left arrow button so that the READY screen appears.
Result
The low fuel alarm setting has now been changed.
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8.12
Mobile Generator
Changing the Cooldown Time Setting
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The genset controller includes a cooldown timer. The function of the cooldown
timer is to run the engine at no load after a period of being run at load. It is used in
conjunction with the remote start system. The cooldown timer activates when the
machine is no longer receiving a remote run signal. This timer is factory set to zero
(0) minutes. The cooldown time can be changed if desired.
Procedure
Perform the procedure below to change the cooldown time setting.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight SYSTEM PARAMS. Then, press the right arrow button.
This procedure continues on the next page.
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Continued from the previous page.
4. Highlight CRANK SETTINGS. Then, press the right arrow button.
5. Highlight COOLDOWN TIME. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button so that the READY screen appears.
Result
The cooldown time setting has now been changed.
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8.13
Mobile Generator
Changing the Pre-Crank Time Delay (Glow Plug Timer)
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The genset controller includes a pre-crank time delay. This is the time the glow
plugs will be on before the engine starts to crank. The factory setting is 5 seconds.
The pre-crank time delay can be changed if desired.
NOTICE: Do not set the glow plug timer to a value of more than 10. Damage to the
glow plugs may occur.
Procedure
Perform the procedure below to change the pre-crank time delay.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
3. Highlight SYSTEM PARAMS. Then, press the right arrow button.
This procedure continues on the next page.
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Continued from the previous page.
4. Highlight CRANK SETTINGS. Then, press the right arrow button.
5. Highlight PRECRANK DELY. Then, press the check mark button (5).
6. If you are not logged in, enter the password “OP”. Press the check mark button.
7. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
8. Exit by pressing the left arrow button (4) twice or until the LCD displays the
SETTINGS menu. Then, scroll to LOGOUT and press the check mark button.
Press the left arrow button until the READY screen appears.
Result
The pre-crank time delay has now been changed.
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8.14
Mobile Generator
Changing the Maintenance Interval
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The maintenance interval is the time, in hours, scheduled between critical
maintenance tasks (such as, changing the engine oil). The amount of time may be
changed if desired. The factory setting is 250.
Note: Refer to the Periodic Maintenance Schedule in the Operator’s Manual for
timing of all scheduled maintenance tasks.
Procedure
Perform the procedure below to change the maintenance interval.
1. Press the right arrow button (1) to access the MAIN MENU.
2. Using the up/down arrow buttons (2, 3) highlight SETTINGS. Then, press the
right arrow button.
This procedure continues on the next page.
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Working with Basler Controller
Continued from the previous page.
3. Highlight ALARM CONFIGURATION. Then, press the right arrow button.
4. Highlight PRE-ALARMS. Then, press the right arrow button.
5. Highlight the MAINTENANCE INTERVAL. Then, press the right arrow button.
6. Highlight the THRESHOLD. Then, press the check mark button (5).
7. If you are not logged in, enter the password “OP”. Press the check mark button.
8. Using the up/down arrow buttons, change the value as desired. Press the check
mark button when finished.
9. Exit by pressing the left arrow button (4) three times or until the LCD displays
the SETTINGS menu. Then, scroll to LOGOUT and press the check mark
button. Press the left arrow button so that the READY screen appears.
Result
The maintenance interval has now been changed.
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Working with Basler Controller
8.15
Mobile Generator
Resetting the Maintenance Interval Pre-Alarm
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
When the MAINT INTERVAL pre-alarm is active, the PRE-ALARM ACTIVE screen
is displayed and the red LED flashes.
The maintenance interval pre-alarm may be reset by using either of two different
methods: 1) by holding the “X” reset button while the MAINT INTERVAL pre-alarm
screen is being displayed, or 2) through the METERING menu. Both methods are
described below.
Procedure
Perform the procedure below to reset the maintenance interval pre-alarm.
1. With the PRE-ALARM ACTIVE screen showing, press and hold the “X” reset
button (6) for 10–20 seconds. This will clear the pre-alarm and reset the
maintenance interval timer back to 250 (or the value it is currently set to).
If that method is unsuccessful, continue.
2. Press the right arrow button (1) to access the PRE-ALARMS menu.
This procedure continues on the next page.
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Continued from the previous page.
3. With the PRE-ALARMS screen showing (MAINT INTERVAL highlighted), press
the left arrow button (4) three times.
4. Using the up/down arrow buttons highlight METERING. Then, press the right
arrow button.
5. Using the up/down arrow buttons highlight ENGINE. Then, press the right arrow
button.
6. Highlight HRS TO MAINT. Then, press and hold the “X” reset button for 10–20
seconds. This will clear the pre-alarm and reset the maintenance interval timer
back to 250 (or the value it is currently set to).
7. Exit by repeatedly pressing the left arrow button until the READY screen
appears.
Result
The maintenance interval interval pre-alarm has now been reset.
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8.16
Mobile Generator
Resetting a Loss of Voltage Pre-Alarm
Background
The loss of voltage pre-alarm condition occurs most often because of an open lug
door switch. During a loss of voltage pre-alarm, the LCD will display the screens
below.
To reset the loss of voltage pre-alarm, simply close the lug door. If the voltage does
not return to normal, further troubleshooting will be needed.
Note: The loss of voltage pre-alarm will only occur when the voltage selector
switch is in the 120/240 position. The condition will still exist if in a 3-phase mode,
but the pre-alarm will not activate.
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8.17
Working with Basler Controller
Accessing and Using the Event Log
Requirements
Machine stopped
Start switch in REMOTE START
Note: Internal programming of the genset controller, or closed connections to a
remote start switch, may cause the machine to start unexpectedly. Be prepared for
the engine to start even with the engine start switch in the REMOTE START
position.


Background
The event log allows the technician to review recent events of the machine
including pre-alarm and alarm (shut-down) conditions. The event log can aid the
technician in diagnosing machine problems.
Note: Before accessing the event log, check the date and time of the genset
controller. The date and times listed in the event log will be relative to the date and
time setting of the genset controller.
Procedure
Perform the procedure below to access the event log.
1. At the READY screen, press the right arrow button to bring up the MAIN menu.
2. Highlight METERING. Then, press the right arrow button.
3. Highlight ALARMS-STATUS. Then, press the right arrow button.
4. Highlight EVENT LOG. Then, press the right arrow button.
The LCD displays the events of the event log. Events with the suffix “A” are alarm
conditions. Events with the suffix “P” are pre-alarm conditions. The events are:
LCD Screen
Meaning
OVERCRANK A
Overcrank pre-alarm
ENGINE RUNNING
Engine running
PROT SHUTDOWN
Protective shutdown
EMERGENCY STOP A
Emergency stop alarm
ATS INPUT CLOSED
Automatic transfer switch input closed
NORM SHUTDOWN
Normal shutdown
FUEL LEVL SENDR FAIL P
Fuel level sender failure pre-alarm
FUEL LEVL SENDR FAIL A
Fuel level sender failure alarm
LOW FUEL LEVEL P
Low fuel level pre-alarm
LOW FUEL LEVEL A
Low fuel level alarm
OVER VOLTAGE P
Over voltage pre-alarm
OVER CURRENT P
Over current pre-alarm
LOW OIL PRES A
Low oil pressure alarm
LOSS OF VOLT P
Loss of voltage pre-alarm
LOSS OF VOLT
Loss of voltage
LOW OIL PRES P
Low oil pressure pre-alarm
LOW BATT VOLT P
Low battery voltage pre-alarm
OIL SNDR FAIL P
Oil sender failure pre-alarm
OIL SNDR FAIL
Oil sender failure
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Mobile Generator
LCD Screen
Meaning
GEN TEST LOADED
Generator test loaded
MAINT INTERVAL P
Maintenance interval pre-alarm
LOW COOL LEVEL A
Low coolant level alarm
5. Highlight the event of interest. Then, press the right arrow button.
Details of the event appear: They are:
 ACTIVE
 OCCURENCE COUNT
 FIRST DATE
 FIRST TIME
 LAST DATE
 LAST TIME
 FIRST ENG HRS
 LAST ENG HRS
 DETAILS
Most recent
event
To find the alarm event that has occurred most recently:
1. Scroll to each alarm event and record the time it occurred.
2. Compare the dates and times of all alarm events. The one with the most current
date and time is the most recent.
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9
9.1
Operation (Deep Sea Controller)
Operation (Deep Sea Controller)
Main Circuit Breaker
Location
Various styles of main circuit breakers may be found on Wacker Neuson Mobile
generators. The main circuit breaker (a) is located on the control panel.
Note: Graphic is representative only. Your machine may vary.
a
STOP
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
AUS
APAGADO
ARRET
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
OFF
AUS
APAGADO
ARRET
ME
R GE NC
Y
E
STOP
S TOP
wc_gr011444
Functions
■ The main circuit breaker interrupts power from the voltage selector switch to the
terminal lugs.
■ The main circuit breaker does not interrupt power to the convenience
receptacles.
WARNING
Electric shock hazard. High voltage is present inside the control panel while the
engine is running.
► Do not open the control panel unless the engine is stopped.
NOTICE: Before shutting down the generator or performing any service to the
generator, make sure the main circuit breaker is in the OFF position.
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Operation (Deep Sea Controller)
9.2
Mobile Generator
Genset Controller Power Switch
Description
The genset controller power switch (a) is a two-position switch: ON and OFF.
a
ON
DSE 7310
STOP
OFF
wc_gr011478
Function
Position
Function
LCD Screen
ON
When set to this position:
■ Power is supplied to the genset controller.
■ The genset controller boots up and sets
itself to the Stop/Reset mode—the
engine is ready to be started.
“Generator at Rest” followed
by the status screens that
scroll.
OFF
When set to this position, power to the
genset controller is disconnected.
Blank screen (off)
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9.3
Operation (Deep Sea Controller)
Selecting the Voltage
Background
Selecting the voltage is a two-step process. First, select the voltage using the
voltage selector. Then, use the voltage adjustment rheostat to fine-tune the voltage
to your exact requirements.
Location
The voltage selector (a) is located behind the access door in the upper half of the
control box.
WARNING
Electric shock and arc flash hazard. High voltage is present at the voltage selector
while the engine is running.
► Do not open the access door while the engine is running.
► Do not change the position of the voltage selector while the engine is running.
a
wc_gr010389
Voltage
ranges
The chart below lists the ranges of voltages available in both of the selector
positions. The voltage is displayed on the LCD panel.
Range of Voltages Available
Switch position
3Ø at lugs
(L–L–L)
1Ø at lugs
(L–N)
1Ø at lugs
(L-L)
L-N (120V)
L-L (240V)
240 VAC
190–240
110–139
190–240
110–139
190–240
110–139
480 VAC
380–480
220–277
190–240
110–139
190–240
110–139
This procedure continues on the next page.
wc_tx003619gb_FM10.fm
99
1Ø at twist lock
1Ø at GFCI
Operation (Deep Sea Controller)
Mobile Generator
Continued from the previous page.
Description
The voltage selector mechanically changes the connections between the generator
output leads and the terminal lugs on the generator.
c
b
= 40Nm (29.5 Ft Lbs)
L1
L1
1
4
2
N
12
11
L3
1
3
10
L1-N = 120V
L2-N = 120V
L-L
6
5
8
9
7
L2
3
L3-N = 120V
L1-L2= 208V
L2-L3= 208V
L3-L1= 208V
L1-N = 277V
L2-N = 277V
2
L-L
4
12
11
L3
10
9
L-N
N
8
7
L2
6
L3-N = 277V
L1-L2= 480V
L2-L3= 480V
L3-L1= 480V
5
L-N
wc_gr010390
Selecting the
voltage
To select the voltage:
1. Remove the screws (b).
2. Move the plate (c) to the desired position.
3. Re-install the screws. Torque the screws to 40 Nm (29.5 ft.lbs.).
This procedure continues on the next page.
100
wc_tx003619gb_FM10.fm
Mobile Generator
Operation (Deep Sea Controller)
Continued from the previous page.
Using the
rheostat
The voltage adjustment rheostat (d) is used to fine-tune the voltage as needed
while the machine is running.
d
wc_gr010391
Care must be taken when using the voltage adjustment rheostat because adjusting
the voltage for 3-phase operation affects the voltage available at the single-phase
outlets. As the 3-phase voltage increases, so does the single-phase voltage.
NOTICE: Do not use the GFCI or twist-lock receptacle (120V) when the 1Ø voltage
is above 135V. Damage to the receptacle and the tools connected to it may occur.
Corresponding 1Ø voltage
Switch Position
3Ø Voltage
(L-L-L)
Twist lock receptacle
L-L (240V)
240 VAC
480 VAC
L-N (120V)
120V GFCI
208
208
120
120
220
220
125
125
240
240
139
1
1391
480
240
1391
1391
460
230
1332
1332
1 Do
not use receptacle with this voltage.
Voltage may be too high for some tools and equipment. Check tool/equipment specifications.
2
wc_tx003619gb_FM10.fm
101
Operation (Deep Sea Controller)
9.4
Mobile Generator
Deep Sea Controller Buttons/Functions
2
5
1
4
DSE
DEEP SEA ELECTRONICS
ELECTRONICS
6
DSE 731
7310
0
7
STOP
8
3
9
Open
Open
Close
Close
Load
Gen-Set
10
11
AUTO
AUT
O
Stop/Reset
12
Manual
Mode
13
Lamp Test
est
Horn Reset
Auto
Mode
14
15
Start
16
17
wc_gr011485
Ref.
Button/function
1
Right arrow button (right / forward)
2
Up arrow button
3
Down arrow button
4
Left arrow button (left / backward)
5
Check mark button (enter / accept)
This button is used when navigating through the genset controller menus.
Press this button to accept a new value or menu item.
6
Alarm indicator
Illuminates during a fault condition that has stopped the engine.
7
Warning indicator
Illuminates during a non-critical alarm condition. Note: non critical alarm
conditions may lead to shut-down conditions.
8
Main breaker open indicator
Illuminates whenever the main circuit breaker is open.
9
Low speed active indicator
Illuminates when the engine idle speed is set to low idle (if equipped).
10
Load button (not used)
11
Gen-Set button (not used)
102
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Mobile Generator
Ref.
wc_tx003619gb_FM10.fm
Operation (Deep Sea Controller)
Button/function
12
Stop / Reset
Pressing this button:
■ Sets the genset controller into its Stop/Reset mode
■ Clears any alarm conditions for which the triggering criteria have been rectified.
13
Manual mode
Pressing this button:
■ Sets the genset controller to the Manual mode
In Manual mode, the generator can be started and operated.
14
(not used)
15
Auto mode
Pressing this button:
■ Sets the genset controller to the Auto mode
In Auto mode, the generator can only be started and operated by a remote
switch.
16
Lamp test / horn reset
Pressing this button:
■ Silences the audible alarm
■ Illuminates all of the LEDs as a lamp test feature (push and hold to perform
test)
17
Start
Pressing this button:
■ Starts the engine
This button is only active in Manual mode.
103
Operation (Deep Sea Controller)
9.5
Mobile Generator
Genset Controller Alarms and Shut-Down Conditions
Background
The genset controller monitors variables of engine and machine function. The
genset controller has two types of alarms: warning alarms and shut-down alarms.
The genset controller also monitors for electrical trip conditions.
Warning
alarms
Warnings are non-critical alarm
conditions that do not affect the operation
of the generator system. They serve to
draw the operator’s attention to an
undesirable condition. Warning alarms
are self-resetting when the fault condition
is removed.
DSE
DEEP SEA ELECTRONICS
DSE 7310
STOP
Warning alarms include:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Time to maintenance
7
wc_gr011490
During a warning alarm condition, the LCD panel displays the type of warning
alarm, the warning LED (7) illuminates, and an audible alarm sounds. The machine
is not shut down. Press the “Horn Reset” button to silence the audible alarm.
Shut-down
alarms
Shut-down alarms are latching alarms
and stop the generator. Shut-down
alarms include:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Overspeed/Underspeed
■ Overcrank
■ Low coolant level (if equipped)
■ Overcurrent
DSE
DEEP SEA ELECTRONICS
DSE 7310
STOP
6
8
wc_gr011491
During a shut-down alarm condition, the
LCD panel displays the type of alarm, the LEDs (6, 8) illuminate, an audible alarm
sounds, and the machine is shut down. Press the “Horn Reset” button to silence
the audible alarm. Remove the fault condition, then press “Stop/Reset”.
Variable
Normal
Warning
Shutdown
To Reset
Fuel level
>15%
15%
—
Fill fuel tank. Press “Stop/Reset”.
Coolant temp.
85°C±8
105°C
115°C
Add coolant. Press “Stop/Reset”.
Oil pressure
60–80 psi
20 psi
15 psi
Add engine oil. Press “Stop/Reset”.
Overspeed
60 Hz
—
66 Hz
Press “Stop/Reset”.
Underspeed
60 Hz
—
54 Hz
Press “Stop/Reset”.
Overcrank
—
—
After 3 attempts
Press “Stop/Reset”.
Time to maintain
500 hours
0 hours
—
Reset genset controller.
Coolant level
Above sender
—
Below sender
Add coolant. Press “Stop/Reset”.
104
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Operation (Deep Sea Controller)
Electrical trips Electrical trips are latching type alarms
that stop the engine.
During an electrical trip, the LEDs (6, 8)
illuminate, an audible alarm sounds, and
the machine is shut down.
Press the “Horn Reset” button to silence
the audible alarm. Remove the fault
condition, then press “Stop/Reset” to
enable the engine to be restarted.
DSE
DEEP SEA ELECTRONICS
DSE 7310
STOP
6
8
wc_gr011492
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105
Operation (Deep Sea Controller)
9.6
Mobile Generator
Before Starting the Machine
WARNING
Personal injury hazard. Failure to follow the listed procedures may cause injury to
personnel or damage to the generator.
► Make sure that all persons setting up the generator are certified or fully trained
on the installation of the generator.
Before putting the generator into service, perform each item on the following
checklist.
Exterior
checks
 Check for damage that may have occurred during towing or travel to the jobsite.
Repair any damage.
 Make sure that the generator is level.
 Chock the trailer wheels.
Internal
checks
 Check engine oil, coolant, and fuel levels—fill as required.
 Check the fan belt and hoses on the engine for loose connections or fraying—
tighten or replace belts and hoses as required.
 Remove any debris that has lodged in vents, near the radiator, or around the
fan.
 Make sure the exhaust compartment is clean, with nothing touching the muffler
or exhaust pipes.
Pre-operation
checks
 Read and understand the engine owner’s manual.
 Check local regulations and NEC standards for electrical connections.
 Determine voltage needs; obtain proper cable and equipment to meet the
needs. Follow local regulations and NEC standards.
 Make sure that the generator is grounded to a good earthen ground per local
regulations and NEC standards.
 Review and follow the safety instructions found in the front of this Operator’s
Manual.
106
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9.7
Operation (Deep Sea Controller)
Starting and Running the Generator
CAUTION
Possibility of injury or equipment damage. Failure to match phase, voltage, and
frequency may cause equipment connected to the generator to operate incorrectly.
► When using the generator as a stand-by or substitute power supply, make sure
the phase, voltage, and frequency of the generator matches that of the utility
lines or of any other power source normally used.
Procedure
Perform the procedure below to start the generator.
1. Check the position of the voltage selector and make sure that it is set for the
desired voltage output. Lock the voltage selector in place.
2. Set the main circuit breaker to the OFF “O” position.
3. Set the convenience receptacle circuit breakers to the OFF “O” position.
4. Set the genset controller power switch (a) to the ON “I” position.
a
STOP
d
c
b
wc_gr011488
5. Press the “Manual mode” button (b).
6. Press the “Start” “I” button (c).
The LCD panel displays several screens as the start-up sequence begins.
Display
Meaning / Description
Preheating
The engine is heating.
Crank attempt
The engine is attempting to start.
This procedure continues on the next page.
wc_tx003619gb_FM10.fm
107
Operation (Deep Sea Controller)
Mobile Generator
Continued from the previous page.
7. The engine will crank. During a normal cycle, the engine cranks for 12 seconds
and rests for 12 seconds. This cycle will repeat three times.
Note: If the engine does not start within the normal cycle, the genset controller will
shut down the engine. “Failed to start” will display on the LCD.
► To repeat the crank cycle, press the Stop/Reset “O” button (d) to reset the
engine control model. Allow the starter motor to cool between start-up attempts.
8. After the engine starts, the LCD panel displays the following screens.
Display
Meaning / Description
Safety on delay
The genset controller is
determining system status.
Generator available
The generator is operating and
ready for service.
Engine oil pressure
Displays the engine oil pressure
Engine coolant temp.
Displays engine coolant
temperature
Engine battery voltage
Displays the battery voltage
Engine fuel level
Displays the percentage of
remaining fuel
9. Allow the engine to warm before closing the main circuit breaker.
10.Check the voltage displayed on the LCD panel. Adjust the voltage as needed
using the voltage adjustment rheostat. See topic Selecting the Voltage.
DSE
DEEP SEA ELECTRONICS
DSE 7320
STOP
wc_gr011499
11.Turn on (close) the appropriate circuit breakers for your load.
108
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9.8
Operation (Deep Sea Controller)
Stopping the Generator
Requirements
Before stopping the generator:
■ Check with other personnel on the jobsite and let them know that power is being
turned off.
■ Make sure that the power shutdown will not create any hazards by turning off
devices such as pumps, heaters, or lights that may need to be kept on.
Procedure
Perform the procedure below to stop the generator.
1. Remove all loads from the generator.
2. Open (set to OFF “O”) the convenience circuit breakers.
3. Open (set to OFF “O”) the main circuit breaker.
4. Let the engine run for approximately 5 minutes to allow it to cool down.
5. Press the Stop / Reset “O” button (a).
b
STOP
a
wc_gr011500
6. Set the genset controller power switch (b) to the OFF “O” position.
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109
Operation (Deep Sea Controller)
9.9
Mobile Generator
Emergency Stop Switch
Location
The emergency stop switch is the red button (a) located to the left of the control
panel. The button can be accessed with the panel doors closed. It is electrically
isolated from the switch and also from the rest of the metering panel.
DSE
DEEP SEA ELECTRONICS
DSE 7310
a
ERGENC
M
Y
E
STOP
S TO P
b
wc_gr009857
Operation
Activate the emergency stop switch by pressing the red button. This results in the
following actions:
■ The main breaker opens.
■ The “Main Breaker Open” LED illuminates.
■ The engine stops.
■ The LCD panel (b) displays a flashing “Emergency Stop” message.
■ The “Alarm” LED illuminates, and an audible alarm will sound.
To silence the audible alarm, press the Horn Reset button on the keypad. The
flashing message and illuminated LED will remain visible until the emergency stop
switch is deactivated.
To deactivate the emergency stop switch, pull the red button out.
NOTICE: Press the emergency stop button only in the case of an actual
emergency where the generator must be stopped immediately! In all other
instances, open the main line circuit breaker and then press the off button.
110
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Mobile Generator
9.10
Operation (Deep Sea Controller)
Engine and Generator Monitoring
Description
Engine and generator information is displayed on the LCD panel and scrolls
continuously while the generator is operating.
For more information on the Deep Sea controller, see chapter Working with the
Deep Sea Controller.
Generator Available
L-N
277 V
0 A
L-L
480 V
59.9 Hz
0 kW
--- pf
wc_gr009841
Volts “V”- Displays the AC output voltage being produced by
the generator.
Amps “A” - Displays the AC output amperage produced by the
generator. If the generator is operating at no-load, output
amperage will display a 0.
Hertz “Hz” - Displays output frequency. This gauge should
read approximately 60 Hz under a no-load condition. If the
frequency is too high, check the engine rpm
Displays the available voltage of the battery
Engine Battery Voltage
Battery
Charge Alt
25.5 V
0.0 V
wc_gr009842
Displays the percentage of fuel remaining in the fuel tank.
Engine Fuel Level
66 %
wc_gr009843
Displays the engine oil pressure (if equipped)
Engine Oil Pressure
4.14
60
4.14
bar
psi
kPa
wc_gr009844
Displays the current temperature of the engine coolant
Engine Coolant Temp.
16 oC
60 oF
wc_gr009845
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Working with Deep Sea Controller: DSE 7310
10 Working with Deep Sea Controller: DSE 7310
10.1
Introduction
During normal operation, the genset controller displays current information on
machine performance and operating status. The keypad (e) provides access to
additional monitoring functions through a series of menus displayed on the LCD
panel (f). You can also use the keypad to change certain machine settings if
desired.
.
f
1
2
e
DSE 7310
STOP
4
5
3
wc_gr011504
1. The various monitoring and configuration menus can be accessed by pressing
the right arrow button (1).
2. To select items on a menu, use the up/down arrow buttons (2, 3) to scroll
through the available options.
3. To return to a previous menu screen, press the left arrow button (4).
4. To exit menu navigation and return to LCD panel monitoring status, press the
left or right arrow button (1, 4) to return to the “Status” page.
112
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Working with Deep Sea Controller: DSE 7310
10.2
Navigating the Menus
The graphic below serves as a navigational aid when accessing the various menus
of the genset controller. See the accompanying table for information about the
menu items.
.
MENU NAVIGATION
Status
Engine
Generator
Summary
Screen
Engine
Speed
Gen Voltage
(L-N)
Engine Oil
Pressure
Engine
Oil
Pressure
Gen Voltage
(L-L)
Engine
Coolant
Temp
Engine
Coolant
Temp
Gen
Frequency
Summary
Screen
Engine
Battery
Voltage
Gen Current
Engine
Battery
Voltage
Engine
Run
Time
Gen Earth
Current
Fuel Level
Fuel
Level
Gen Load
(kW)
Maintenance
Alarm [Hold
"O" to reset]
Gen Load
(Total kW)
Engine
Link*
Gen Load
(%)
Can Bus
Information*
Gen Load
(Total %)
Alarms
ECU DTCs*
Event Log
Serial Port
About
Gen Load
(kVA)
Gen Load
(Total kVA)
Gen Power
Factor
UP
Gen Power
Factor (Avg)
Gen Load
(kVAr)
FORWARD
BACK
Gen Load
(Total kVAr)
DOWN
Gen Load (h)
Gen Phase
Sequence
Active Config
*Not Available on Some Models
Active Config
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113
Working with Deep Sea Controller: DSE 7310
Menu Item
Description
Menu Item
Description
About
Module Information
—
—
Active Config
Generator Configuration
Gen Load (h)
Generator Load kVArh
Alarms
Alarms Active
Gen Load (%)
Generator Load Percent
—
—
Gen Load (kVA)
Generator Load kVA
Can Bus Information
Can Bus Information
Gen Load (kVAr)
Generator Load kVAr
—
—
Gen Load (kW)
Generator Load kW
ECU DTCs
Engine Diagnostic
Trouble Codes
Gen Load (Total %)
Generator Load Total
Percent
Engine
Engine Info
Gen Load (Total kVA)
Generator Load Total
kVA
Engine Battery Voltage
Battery and Alternator
Voltage
Gen Load (Total kW)
Generator Load Total
kW
—
—
Gen Phase Sequence
Generator Phase
Sequence
Engine Coolant Temp
Coolant Temperature in
°C and °F
Gen Power Factor
Generator Power Factor
Engine Link
Engine Link Info
Gen Power Factor (Avg)
Generator Average
Power Factor
Engine Oil Pressure
Engine Oil Pressure in
Bar, PSI, and kPa
Gen Voltage (L-L)
Generator Voltage Line
to Line
Engine Run Time
Accumulated Time in
Hours
Gen Voltage (L-N)
Generator Voltage Line
to Neutral
Engine Speed
Engine RPM
Generator
Generator Info
Event Log
List of Past Events
Maintenance Alarm
(Hold “O” to reset)
Hours until
Maintenance Warning
—
—
Serial Port
Serial Part Info
Fuel Level
Percentage of Fuel
Remaining in the Tank
Status
Status Information
Gen Current
Generator Current
Amps
Summary Screen
Main Summary Screen
Gen Earth Current
Generator Earth
Current Amps
—
—
Gen Frequency
Generator Frequency
(Hz)
—
—
114
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Working with Deep Sea Controller: DSE 7310
10.3
Adjusting Screen Contrast
Overview
The contrast of the LCD display can be adjusted to suit the operator’s preference.
Procedure
Perform the procedure below to adjust the screen contrast.
1. Access the “Editor—Display” menu on the LCD panel (f) by pressing and
holding the check mark button (5) on the keypad.
DEEP SEA ELECTRONICS
DSE
5
DSE 7310
STOP

f
wc_gr009802
2. Wait a few seconds for the “Contrast” screen to appear, or use up/down arrow
keys to navigate to the “Contrast” screen. Then, press the check mark button.
The contrast value will start flashing.
2
DSE
DS
E
DEEP SEA ELECTRONICS
ELECTRONICS
DSE 7310
STOP

3
wc_gr009850
3. Press the up/down arrow buttons to change the contrast percentage as desired.
When the screen contrast reaches a comfortable viewing level, press the check
mark button to accept the choice.
4. Exit by pressing and holding the check mark button until the genset controller
returns to the “Status” screen.
Result
The screen contrast has now been changed.
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Working with Deep Sea Controller: DSE 7310
10.4
How to Reset the Maintenance Timer
Background
The maintenance timer is preset to 500 hours. When the maintenance timer times
out, the genset controller sounds the audible alarm.
Procedure
Perform the procedure below to reset the maintenance timer.
1. From the “Status” menu, press the right arrow button to reach the “Engine”
menu.
DSE
DEEP SEA ELECTRONICS
DSE 7310
STOP
DSE 7310
STOP
DSE
DEEP SEA ELECTRONICS
DSE 7310
STOP
DSE
DSE 7310
STOP
a
wc_gr011508
2. Using the up and down arrow buttons, navigate to the “Maintenance alarm 1”
screen.
3. Press the “Stop/Reset” button (a). The timer will return to 500 hours.
116
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Mobile Generator
How to Connect Loads
11 How to Connect Loads
11.1
Lug Terminal Connection Diagrams
For machines with capabilities up to 480V
High Wye
240V
Low Wye
240V
or
139V
139V
139V
240V
240V
240V
wc_gr011542
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How to Connect Loads
11.2
Mobile Generator
Best Practices for Balancing Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
Background
Three-phase (3Ø) loads are, by their nature, balanced. It is when single-phase
(1Ø) loads are combined with existing 3Ø loads that an unbalanced condition can
occur. Dedicated 1Ø loads may also be unbalanced if the loads are not equally
distributed between the legs (L1 and L3) of the generator.
The sensing wires of the generator’s voltage regulator are connected to L1 and L3.
Having the loads balanced between L1 and L3 allows the generator to provide
voltage that is more consistent with the voltage needs of the equipment connected
to it.
3Ø Situations
When combining 1Ø loads with 3Ø loads (voltage selector switch in 208/240V
position), unbalanced loads can be detected by observing the genset controller
LCD panel. If an unbalanced load condition exists, there will be a significant
difference in both voltage and amperage between the phases.
Observe the amp draw on P1, P2, and P3.
3Ø LOW WYE
Observe P1, P2, P3
208 P1
24
100% 175 60
60
13
208 P2
24
100% 175 60
60
13
208 P3
24
60
100% 175 60
13
wc_gr011543
If an unbalanced load is detected, stop the engine and reconnect the loads so that
loads (amp draw) are more equally distributed. This will also help equalize the
voltage for each phase.
When connecting multiple 120V 1Ø loads to the lugs while in 208/240V 3Ø mode,
use L1 as “hot” for the first load (or heaviest load). Use L3 as “hot” for the second
load (or next heaviest load), and use L2 as “hot” for the third load (lightest load). If
additional loads are to be connected, repeat the connection sequence L1, L3, and
then L2.
This procedure continues on the next page.
118
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Mobile Generator
How to Connect Loads
Continued from the previous page.
L1 L2 L3 N GND
With voltage selected to 240
HOT HOT
When connecting multiple 120V 1Ø loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.
HOT
LOAD 1
LOAD 2
LOAD 3
wc_gr011544
Using the
receptacles
This information applies whether the
machine is running in 3Ø or in 1Ø.
When connecting two loads to the duplex
receptacles, instead of plugging both
loads into the same duplex receptacle,
plug the first load into one of the duplex
receptacles. Then, plug the second load
into the other duplex receptacle.
Additional loads can be plugged into
either duplex receptacle.
LOAD 2
LOAD 1
wc_gr011320
When using the 240V twist-lock
receptacle and a distribution box, instead
of plugging both loads into the same
duplex receptacle of the distribution
panel, plug the first load into one of the
duplex receptacles. Then, plug the
second load into a different duplex
receptacle of the distribution box.
LOAD 1
LOAD 2
wc_gr011321
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How to Connect Loads
11.3
Mobile Generator
Connecting 480V, 3-Phase and Single-Phase Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Set the voltage selector switch to the 480V position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the voltage
adjustment rheostat.
Note: Graphic is representative only. Your machine may vary.
240 L-L
139 L-N
480V 3Ø
139V
480V
139V
480V
480V
277V
277V
277V
HOT HOT HOT
GN
HOT HOT HOT
480V 3Ø
WH
480V 3Ø
GN
TRANSFORMER
wc_gr011545
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Mobile Generator
11.4
How to Connect Loads
Connecting a 240V 3Ø Load and a 240V 1Ø Load
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Set the voltage selector switch to the 240V position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door.
5. Start the machine and fine-tune the voltage as necessary using the voltage
adjustment rheostat.
Note: Graphic is representative only. Your machine may vary.
240 L-L
139 L-N
240V 3Ø
139V
139V
240V
240V
240V
139V
139V
139V
HOT HOT HOT
240V 3Ø
GN
240V 1Ø
wc_gr011546
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How to Connect Loads
11.5
Mobile Generator
Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Set the voltage selector switch to the 240V position.
3. Open the lug door and connect the wires from the load(s) as shown.
4. Close the lug door and start the machine.
5. Fine-tune the voltage as necessary using the voltage adjustment rheostat.
Note: Graphic is representative only. Your machine may vary.
220–240 L-L
127–139 L-N
240V 3Ø
!
!
127–
139V
127–
139V
220–
240V
220–
240V
220–240V
127–139V
127–139V
127–139V
Balance the load
When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.
HOT
HOT
HOT
WH
GN
GN
Fine-tune the voltage
Fine-tune the voltage so that
both the 3-phase load and
the single-phase loads
operate properly.
TO
GROUND
LUG
127–139V 1Ø
220–240V 3Ø
127–133V 1Ø
wc_gr011548
122
wc_tx003620gb_FM10.fm
Mobile Generator
11.6
How to Connect Loads
Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
1. Stop the engine and turn the main circuit breaker off.
2. Set the voltage selector switch to the 240V position.
3. Open the lug door and connect the wires from the load as shown.
4. Close the lug door and start the machine.
5. Fine-tune the voltage as necessary using the voltage adjustment rheostat.
Note: Graphic is representative only. Your machine may vary.
208 L-L
120 L-N
240V 3Ø
120V
208V
120V
208V
208V
120V
120V
120V
Balance the load
When connecting multiple
120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
Use L2 as "hot" for third load.
HOT
HOT
HOT
WH
GN
TO GND
LUG
120V 1Ø
208V 3Ø
120V 1Ø
wc_gr011549
wc_tx003620gb_FM10.fm
123
Using Remote Start Capabilities
Mobile Generator
12 Using Remote Start Capabilities
12.1
Remote Run Terminal Block
Location
The remote run terminal block (a) is located as shown.
Note: Graphic is representative only. Your machine may vary.
V
Ø
A
a
HZ
R
ERGENC
M
Y
E
Basler
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
S TO P
4,000 ft
1,219 m
ATS
wc_gr010366
Description
The remote run terminal block provides connection points for the installation of a
remotely located transfer/start switch. If a transfer switch is installed, the generator
can be used as a stand-by power supply.
When connecting an Automatic Transfer Switch (ATS) or other remote switch:
■ Limit the distance between the remote run terminal block and the remote switch
to 1,219 m (4,000 ft) max.
■ Use twisted, 22-gauge wire or heavier.
■ Do not run the wire for the remote switch in the same conduit as current carrying
wire.
■ Do not run a voltage to the contacts (these are dry contacts).
124
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Mobile Generator
12.2
Using Remote Start Capabilities
Remote Transfer Switch
Background
A remote transfer switch is designed to transfer electrical loads from the normal
power source (utility) to the emergency power source (generator) when normal
voltage falls below a prescribed level.
The remote transfer switch automatically returns the load back to the normal
source when power is restored back to operating levels.
WARNING
Electrocution hazard. Failure to isolate the generator from the utility’s electrical
distribution system could cause output from the generator to backfeed into the
utility lines and cause injury or death to utility workers!
► When the generator is used as a stand-by power supply, it must be equipped
with a device which isolates it from the utility’s distribution system.
► An isolation device is also required if the generator is being used as a backup to
some other type of power supply system.
Precautions
■ Installation of a remote transfer switch or other type of remote starting device is
the responsibility of the generator user.
■ Installation of such devices must be performed by a qualified electrician
following all directions supplied by the manufacturer of the switch.
■ If attaching the generator to a power supply normally serviced by a utility
company, notify the utility company and check local and state regulations.
■ Familiarize yourself with all instructions and warning labels supplied with the
switch.
CAUTION
Possibility of injury or equipment damage. Failure to match phase rotation and
voltage may cause equipment connected to the generator to operate incorrectly.
► When using the generator as a stand-by or substitute power supply, make sure
the voltage and phase rotation of the line connections match those of the utility
lines or of any other power source normally used.
DANGER
Electrocution hazard. Lethal voltage is always present in the transfer switch once it
has been properly installed.
► Disconnect power before servicing the transfer switch.
wc_tx003610gb_FM10.fm
125
Using Remote Start Capabilities
12.3
Mobile Generator
Preparing for Automatic/Remote Start-Up (Basler)
Background
When the engine start switch is in the REMOTE START position, the generator can
be started remotely through a automatic transfer switch or other type of remote
start switch.
CAUTION
Possibility of unexpected machine startup. If the contacts on a remote switch
connected to the generator are closed, the machine could start unexpectedly when
the engine start switch is set to the REMOTE START position.
► Be prepared for engine startup anytime the engine start switch is in the
REMOTE START position.
► Before placing the engine start switch in the REMOTE START position, verify
that the contacts on any remote/transfer switch connected to the generator are
OFF (OPEN).
Procedure
Before operating the machine in the remote start mode, do the following:
1. Perform a manual start to verify that the LCD panel is operating correctly. Refer
to topics Before Starting and Starting and Running the Machine.
a. Check the fuel level and add fuel as needed.
b. Check the battery voltage. Charge the battery if needed.
2. Check the operation of the remote
start circuit:
a. Attach a short jumper wire (a)
(minimum 16-gauge insulated)
between the two terminals on the
remote run terminal block. The
jumper wire completes the circuit
which initializes the genset
controller start sequence.
b. Set the engine start switch to the
REMOTE START position.
c. Wait for the engine to crank, start,
and run.
d. Move the engine start switch to OFF to stop the engine.
e. Remove the jumper wire from the remote run terminals.
a
005632
OFF
AUS
APAGADO
ARRET
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
50A
20A
wc_gr010206
3. Set the voltage selector switch to the correct voltage position.
4. Set the engine start switch to the REMOTE START position.
5. Set the main line circuit breaker to ON.
6. Secure the generator by closing and locking all doors.
The generator is now ready for remote starting.
Maintaining
If the generator is to be used as a stand-by power supply, provisions must be made
battery charge to maintain the charge of the battery. This can be done either by attaching a battery
charger to the battery or by starting and running the engine periodically.
126
wc_tx003610gb_FM10.fm
Mobile Generator
12.4
Using Remote Start Capabilities
Preparing for Automatic/Remote Start-Up (Deep Sea)
Background
In AUTO mode, the generator can be started remotely, either through a transfer
switch or some other type of remote start switch. AUTO mode is the normal setting
when using the generator as a stand-by power supply.
b
STOP
c
d
wc_gr011501
CAUTION
Possibility of accidental equipment start-up. If the contacts on any remote switch
linked to the generator are closed, the generator could start unexpectedly when the
AUTO mode button is pressed.
► Before pressing the AUTO mode button, verify that the contacts on any remote
switch linked to the generator are OPEN.
Procedure
1. Before using the AUTO mode, perform
a
a check of the auto start-up circuit. To
do so:
a. Attach a short jumper wire (a)
(minimum 16-gauge insulated)
between the two terminals on the
remote run terminal block. The
jumper wire applies a ground to the
ECM to complete the start circuit.
b. Set the genset controller power
switch (b) to the ON position.
c. Press the AUTO mode button (c).
wc_gr010206
d. Wait for the engine to crank, start,
and run. If the engine cranks, the remote start circuit is functioning.
e. Press the Stop/Reset “O” button (d) to stop the engine.
f. Remove the jumper wire from the remote run terminals after testing is
complete.
005632
OFF
AUS
APAGADO
ARRET
50A
20A
This procedure continues on the next page.
wc_tx003610gb_FM10.fm
127
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
Using Remote Start Capabilities
Mobile Generator
Continued from the previous page.
2. Leave the genset controller power switch in the ON position.
3. Close the main circuit breaker.
4. Press the AUTO mode button.
5. Secure the generator by closing and locking all doors.
The generator is now ready for automatic starting.
Maintaining
If the generator is to be used as a stand-by power supply, provisions must be made
battery charge to maintain the battery charge. This can be done either by attaching a battery
charger to the battery or by starting the generator manually and running the engine
periodically to maintain the battery charge.
128
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Mobile Generator
Diagnostic Trouble Codes (DTC)
13 Diagnostic Trouble Codes (DTC)
13.1
Accessing DTCs with the Basler Controller
Background
This machine may include an engine that has self-diagnostic capabilities. These
engines communicate issues with the engine through Diagnostic Trouble Codes
(DTCs). When a DTC is present, an alert will show on the LCD panel display. A
DTC is a two part code consisting of a Suspect Parameter Number (SPN), and a
Failure Mode Identifier (FMI).
Procedure
Perform the procedure below to access Diagnostic Trouble Codes.
1. At the READY screen, press the right arrow button (1) to bring up the MAIN
menu.
2
4
READY
100% 175
5
13.4
MAIN MENU
1
3
6
J1939 ACTIVE DTC
1/1 SPN FMI OC
100 4
1
METERING
SETTINGS
METERING
CLEAR DTCs
ENGINE
GENERATOR
POWER
RUN STATISTICS
ALARMS-STATUS
DIAGNOSTICS
1
NO
ALARMS-STATUS
EVENT
J1939
J1939
J1939
J1939
LOG
1
DATA
ENGINE CONFIG
ACTIVE DTC
1
PREV DTC
0
wc_gr011382
2. Highlight METERING. Then, press the right arrow button.
3. Highlight ALARMS-STATUS. Then, press the right arrow button.
4. Highlight J1939 ACTIVE DTC. Then, press the right arrow button.
5. Highlight a DTC. Then, press the check mark button (5).
Note: To access a past DTC, highlight J1939 PREV DTC. Then, press the right
arrow button.
wc_tx003548gb_FM10.fm
129
Diagnostic Trouble Codes (DTC)
13.2
Mobile Generator
Accessing Engine DTCs using the Deep Sea Controller
Background
This machine may include an engine that has self-diagnostic capabilities. These
engines communicate issues with the engine through Diagnostic Trouble Codes
(DTCs). When a DTC is present, an alert will show on the LCD panel display. A
DTC is a two part code consisting of a Suspect Parameter Number (SPN), and a
Failure Mode Identifier (FMI).
Procedure
Perform the procedure below to access the Diagnostic Trouble Codes.
1. From the “status” menu, press the right arrow key to navigate through “engine”,
“Generator”, “Alarms”, to “ECU DTCs”.
.
STOP
wc_gr011701
2. Use the up and down arrow keys to scroll through the DTCs.
Note: The Deep Sea Controller will list the most current DTC first, followed by the
any other DTCs in order of their occurrence.
130
wc_tx003548gb_FM10.fm
Mobile Generator
13.3
Diagnostic Trouble Codes (DTC)
List of Engine Diagnostic Trouble Codes (DTCs)
Failure Code
String Displayed
Description
SPN
FMI
—
0
DATA HI MOST SEVERE
Data is higher than expected at the most severe
level
—
1
DATA LO MOST SEVERE
Data is lower than expected at the most severe
level
—
2
DATA ERRATIC OR BAD
Data is erratic, intermittent, or incorrect
—
3
VOLTS HI OR SHORTED
Measured voltage is higher than expected or
shorted to a high source
—
4
VOLTS LO OR SHORTED
Measured voltage is lower than expected or
shorted to a low source
—
5
CURRENT LO OR OPEN
Measured current is lower than expected or the
circuit is open
—
6
CURRENT HI OR SHORTED
Measured current is higher than expected or
shorted
—
7
MECHANICAL SYSTM ERR
Mechanical system error
—
8
FREQ OR PWM ERROR
Error in frequency, pulse width or period of any
frequency or PWM signal
is outside its predetermined limits
—
9
ABNORMAL UPDATE RATE
Update rate of parameter is abnormal
—
10
DATA RT OF CHG ERR
Rate of change of data is abnormal
—
11
FAILURE CAUSE UNKNOWN
String indicating failure cause is unknown
—
12
BAD INTELLIGNT DEVICE
Engine ECU is reporting that an intelligent
device or component failure
has been detected
—
13
OUT OF CALIBRATION
Device or parameter is out of calibration
—
14
CONSULT ENG MFG DATA
User should consult engine manufacturer's data
28
3
Throttle Volt HI
Throttle Voltage High
28
4
Throttle Volt LO
Throttle Voltage Low
28
14
Throttle Volt OOR
Throttle Input Voltage Out of Range
29
3
Throttle Volt HI
Throttle Voltage High
29
4
Throttle Volt LO
Throttle Voltage Low
29
14
Throttle Volt OOR
Throttle Input Voltage Out of Range
29
#
ACCEL PEDAL 2 POSITN
Caption string for accelerator pedal 2 position
52
15
INTERCOOLER TEMP HI
Engine Intercooler Temperature is above the
HIGH threshold
wc_tx003548gb_FM10.fm
131
Diagnostic Trouble Codes (DTC)
Mobile Generator
Failure Code
String Displayed
Description
SPN
FMI
91
3
Thr Pos Sns Volt HI
Throttle Position Sensor Input Voltage (High)
91
4
Thr Pos Sns Volt LO
Throttle Position Sensor Input Voltage (Low)
91
14
Thr Pos Sns Volt OOR
Throttle Voltage (Out of Range)
94
1
FUEL DELIV PRS LO LO
Engine Fuel Delivery Pressure is below the
LOW LOW
threshold
94
3
Fuel Pmp Prs Volt HI
Fuel Pump Pressure Input Voltage (High)
94
4
Fuel Pmp Prs Volt LO
Fuel Pump Pressure Input Voltage (Low)
94
17
Fuel Pressure LO
Fuel Supply Pressure (Low Least Severe)
97
3
Water In Fl Volt HI
Water In Fuel Signal Voltage High
97
4
Water In Fl Volt LO
Water In Fuel Signal Voltage Low
97
16
Water in Fuel
Water In Fuel Detected
98
#
ENG OIL LEVEL
Caption used on front panel for Display of J1939
Parameter
99
#
OIL FILTER DIFF PRESS
Caption string for oil filter differential pressure
parameter
100
1
ENG OIL PRESS LO LO
Engine Oil Pressure is below the LOW LOW
threshold
100
3
Oil Prs Snsr Volt HI
Oil Pressure Sensor Input Voltage (High)
100
4
Oil Prs Snsr Volt LO
Oil Pressure Sensor Input Voltage (Low)
100
17
ENG OIL PRESS LO
Engine Oil Pressure is below the LOW threshold
100
18
Oil Prs Snsr Volt MLO
Oil Pressure Sensor Input Voltage (Moderately
Low)
100
31
Oil Pressure INVLD
Oil Pressure (Invalid)
101
#
CRANKCASE PRESSURE
Caption string for crankcase pressure
102
2
Manifld Air Prs INVD
Manifold Air Pressure Invalid
102
3
Mnfld AirP SnsVlt HI
Manifold Air Pressure Sensor Input Voltage High
102
4
Mnfld AirP SnsVlt LO
Manifold Air Pressure Sensor Input Voltage Low
103
0
Trbo Overspd Severe
Turbo Overspeed (Most Severe)
103
2
Trbo Speed MisMatch
Turbo Speed (Mismatch)
103
5
Trbo Spd Sns Curr LO
Turbo Speed Sensor Current (Low)
103
6
Trbo Spd Sns Curr HI
Turbo Speed Sensor Current (High)
103
8
Trbo Speed INVLD
Turbo Speed (Invalid)
103
31
Trbo Speed MISSING
Turbo Speed (Missing)
132
wc_tx003548gb_FM10.fm
Mobile Generator
Diagnostic Trouble Codes (DTC)
Failure Code
String Displayed
SPN
Description
FMI
105
0
EGR Mixed Air Tmp HI
Exhaust Gas Recirculation Mixed Air High
(Least Severe)
105
3
EGR Air Temp Vlt HI
Exhaust Gas Recirculation Mixed Air Temp Voltage (High)
105
4
EGR Air Temp Vlt LO
Exhaust Gas Recirculation Mixed Air Temp Voltage (Low)
105
15
EGR Mixed Air Tmp HI
Exhaust Gas Recirculation Mixed Air High
(Least Severe)
105
16
EGR MxdAir Tmp MHI
Exhaust Gas Recirculation Mixed Air Temp
(Moderately High)
107
0
Air Filt Restricted
Air Filter Restriction (High)
108
2
Barometrc Prs INVLD
Barometric Pressure (Invalid)
108
31
Barometrc Prs ERR
Barometric Pressure (Error)
109
1
ENG COOLNT PRS LO LO
Engine Coolant Pressure is below the LOW
LOW threshold
109
17
ENG COOLANT PRS LO
Engine Coolant Pressure is below the LOW
threshold
110
0
ENG COOLNT TMP HI HI
Engine Coolant Temperature is above the HIGH
HIGH
threshold
110
3
Cool Tmp Sns Volt HI
Coolant Temp Sensor Input Voltage (High)
110
4
Cool Tmp Sns Volt LO
Coolant Temp Sensor Input Voltage (Low)
110
15
ENG COOLANT TEMP HI
Engine Coolant Temperature is above the HIGH
threshold
110
16
Cool Temp MHI
Coolant Temp Sensor Input (Moderately High)
110
17
Cool Temp LO
Coolant Temp Sensor Input (Low Least Severe)
111
1
Coolnt Lvl LO
Coolant Level (Low)
111
17
ENG COOLANT LVL LO
Engine Coolant Level is below the LOW threshold
111
#
LOW COOL LEVEL
Low Coolant Level string used in event log and/
or Alarm and
Prealarm annunciation
157
3
Fuel Rail Prs Vlt HI
Fuel Rail Pressure Input Voltage (High)
157
4
Fuel Rail Prs Vlt LO
Fuel Rail Pressure Input Voltage (Low)
157
10
Fuel Rail Prs LOSS
Fuel Rail Pressure Loss Detected
157
17
Fuel Rl Prs NOT DEV
Fuel Rail Pressure Not Developed
wc_tx003548gb_FM10.fm
133
Diagnostic Trouble Codes (DTC)
Mobile Generator
Failure Code
String Displayed
SPN
Description
FMI
158
0
KSW BATT VOLTS HI HI
Key Switch Battery Potential is above the HIGH
HIGH threshold
158
1
KSW BATT VOLTS LO LO
Key Switch Battery Potential is below the LOW
LOW threshold
158
15
KSW BATT VOLTS HI
Key Switch Battery Potential is above the HIGH
threshold
158
17
KSW BATT VOLTS LO
Key Switch Battery Potential is below the LOW
threshold
168
#
LOW BATT VOLT
Low Battery Voltage string used in event log
and/or Alarm and
Prealarm annunciation
174
0
Fuel Temp EXT HI
Fuel Temp (Extremely High)
174
3
Fuel Tmp Sns Volt HI
Fuel Temp Sensor Input Voltage (High)
174
4
Fuel Tmp Sns Volt LO
Fuel Temp Sensor Input Voltage (Low)
174
16
Fuel Temp MHI
Fuel Temp (Moderately High)
175
#
ENG OIL TEMP
Caption used on front panel for Display of J1939
Parameter
188
17
SPEED AT IDLE LO
Metering string for ECU trouble code metering
indicates Engine
Idle speed is below the LOW threshold
189
0
Engine Spd DERATE
Engine Speed Derate
190
0
Engine OvrSpd EXTRM
Engine Overspeed (Extreme)
190
1
ENGINE SPEED LOW
Engine speed is below the LOW threshold
190
16
Engine OvrSpd MODRT
Engine Overspeed (Moderate)
190
17
SPEED AT IDLE LO
Engine Idle speed is below the LOW threshold
190
#
ENGINE SPEED
Caption used on front panel for Display of J1939
Parameter
237
2
VIN Data MisMatch
VIN Data Mismatch with other controllers
412
0
EGR Temp EXT HI
Exhaust Gas Recirculation Temp (Extremely
High)
412
3
EGR Temp In Vlt HI
Exhaust Gas Recirculation Temp Input Voltage
(High)
412
4
EGR Temp In Vlt LO
Exhaust Gas Recirculation Temp Input Voltage
(Low)
412
16
EGR Temp MHI
Exhaust Gas Recirculation Temp (Moderately
High)
520
#
RETARDER % TORQUE
Caption string for retarder % torque
134
wc_tx003548gb_FM10.fm
Mobile Generator
Diagnostic Trouble Codes (DTC)
Failure Code
String Displayed
SPN
Description
FMI
563
#
ABS ACTIVE
Caption String for Antilock Brake System (ABS)
active
611
3
Inj Short to PWR
Injector Wiring Shorted to Power
611
4
Inj Short to GND
Injector Wiring Shorted to Ground
624
#
DIAGNOSTIC LAMP
Caption String for Diagnostic Lamp
627
1
Inj Spply Vlt Problm
Injector Supply Voltage Problem
627
16
ECU Power Volt HI
ECU Power High Voltage
627
18
ECU Power Volt LO
ECU Power Low Voltage
627
13
ECU ERROR
ECU Error
630
#
ECU INTERNAL ERROR
Caption string for ECU Internal Error
636
2
Pump Pos Sns Noisy
Pump Position Sensor Input Noise
636
5
Pump Pos Sns Curr LO
Pump Position Sensor Current (Low)
636
6
Pump Pos Sns Curr HI
Pump Position Sensor Current (High)
636
8
Pump Pos Sns In MSNG
Pump Position Sensor Input Missing
636
10
Pump Pos Sns In ERR
Pump Position Sensor Input Pattern Error
637
2
Crank Pos Sns Noisy
Crank Position Input Noise
637
5
Crank Pos Sns Curr LO
Crank Position Sensor Current (Low)
637
6
Crank Pos Sns Curr HI
Crank Position Sensor Current (High)
637
7
Crnk/Pmp Pos Tmg OOS
Crank/Pump Position Timing Moderately Out of
Sync
637
8
Crank Pos Sns MSNG
Crank Position Missing
637
10
Crank Pos Sns In ERR
Crank Position Input Pattern Error
639
#
J1939 NETWORK 1
Caption String for J1939 Network number 1
641
4
Trbo Actuator ERR
Turbo Actuator Error
641
12
ECU/Trbo Comm ERR
ECU/Turbo Communication Error
641
13
TrboAct Lrnd Val ERR
Turbo Actuator Learned Value Error
641
16
Trbo Act Temp MHI
Turbo Actuator Temp (Moderately High)
651
2
Cyl 1 EUI PN INVLD
Cylinder #1 EUI Part Number (Invalid)
651
5
Cyl 1 EUI Ckt OPEN
Cylinder #1 EUI Circuit (Open)
651
6
Cyl 1 EUI Ckt SHORT
Cylinder #1 EUI Circuit (Shorted)
651
7
Cyl 1 EUI Ckt MECH FL
Cylinder #1 EUI Circuit (Mechanical Failure)
651
13
Cyl 1 EUI QR INVLD
Cylinder #1 EUI Circuit QR Code (Invalid)
wc_tx003548gb_FM10.fm
135
Diagnostic Trouble Codes (DTC)
Mobile Generator
Failure Code
String Displayed
SPN
Description
FMI
651
#
CYLINDER 1 INJECTOR
Caption String for Cylinder 1 Injector
652
2
Cyl 2 EUI PN INVLD
Cylinder #2 EUI Part Number (Invalid)
652
5
Cyl 2 EUI Ckt OPEN
Cylinder #2 EUI Circuit (Open)
652
6
Cyl 2 EUI Ckt SHORT
Cylinder #2 EUI Circuit (Shorted)
652
7
Cyl 2 EUI Ckt MECH FL
Cylinder #2 EUI Circuit (Mechanical Failure)
652
13
Cyl 2 EUI QR INVLD
Cylinder #2 EUI Circuit QR Code (Invalid)
652
#
CYLINDER 2 INJECTOR
Caption String for Cylinder 2 Injector
653
2
Cyl 3 EUI PN INVLD
Cylinder #3 EUI Part Number (Invalid)
653
5
Cyl 3 EUI Ckt OPEN
Cylinder #3 EUI Circuit (Open)
653
6
Cyl 3 EUI Ckt SHORT
Cylinder #3 EUI Circuit (Shorted)
653
7
Cyl 3 EUI Ckt MECH FL
Cylinder #3 EUI Circuit (Mechanical Failure)
653
13
Cyl 3 EUI QR INVLD
Cylinder #3 EUI Circuit QR Code (Invalid)
653
#
CYLINDER 3 INJECTOR
Caption String for Cylinder 3 Injector
654
2
Cyl 4 EUI PN INVLD
Cylinder #4 EUI Part Number (Invalid)
654
5
Cyl 4 EUI Ckt OPEN
Cylinder #4 EUI Circuit (Open)
654
6
Cyl 4 EUI Ckt SHORT
Cylinder #4 EUI Circuit (Shorted)
654
7
Cyl 4 EUI Ckt MECH FL
Cylinder #4 EUI Circuit (Mechanical Failure)
654
13
Cyl 4 EUI QR INVLD
Cylinder #4 EUI Circuit QR Code (Invalid)
654
#
CYLINDER 4 INJECTOR
Caption String for Cylinder 4 Injector
655
2
Cyl 5 EUI PN INVLD
Cylinder #5 EUI Part Number (Invalid)
655
5
Cyl 5 EUI Ckt OPEN
Cylinder #5 EUI Circuit (Open)
655
6
Cyl 5 EUI Ckt SHORT
Cylinder #5 EUI Circuit (Shorted)
655
7
Cyl 5 EUI Ckt MECH FL
Cylinder #5 EUI Circuit (Mechanical Failure)
655
13
Cyl 5 EUI QR INVLD
Cylinder #5 EUI Circuit QR Code (Invalid)
655
#
CYLINDER 5 INJECTOR
Caption String for Cylinder 5 Injector
656
2
Cyl 6 EUI PN INVLD
Cylinder #6 EUI Part Number (Invalid)
656
5
Cyl 6 EUI Ckt OPEN
Cylinder #6 EUI Circuit (Open)
656
6
Cyl 6 EUI Ckt SHORT
Cylinder #6 EUI Circuit (Shorted)
656
7
Cyl 6 EUI Ckt MECH FL
Cylinder #6 EUI Circuit (Mechanical Failure)
656
13
Cyl 6 EUI QR INVLD
Cylinder #6 EUI Circuit QR Code (Invalid)
656
#
CYLINDER 6 INJECTOR
Caption String for Cylinder 6 Injector
136
wc_tx003548gb_FM10.fm
Mobile Generator
Diagnostic Trouble Codes (DTC)
Failure Code
String Displayed
SPN
Description
FMI
657
#
CYLINDER 7 INJECTOR
Caption String for Cylinder 7 Injector
658
#
CYLINDER 8 INJECTOR
Caption String for Cylinder 8 Injector
659
#
CYLINDER 9 INJECTOR
Caption String for Cylinder 9 Injector
660
#
CYLINDER 10 INJECTOR
Caption String for Cylinder 10 Injector
661
#
CYLINDER 11 INJECTOR
Caption String for Cylinder 11 Injector
662
#
CYLINDER 12 INJECTOR
Caption String for Cylinder 12 Injector
663
#
CYLINDER 13 INJECTOR
Caption String for Cylinder 13 Injector
664
#
CYLINDER 14 INJECTOR
Caption String for Cylinder 14 Injector
665
#
CYLINDER 15 INJECTOR
Caption String for Cylinder 15 Injector
666
#
CYLINDER 16 INJECTOR
Caption String for Cylinder 16 Injector
667
#
CYLINDER 17 INJECTOR
Caption String for Cylinder 17Injector
668
#
CYLINDER 18 INJECTOR
Caption String for Cylinder 18 Injector
669
#
CYLINDER 19 INJECTOR
Caption String for Cylinder 19 Injector
670
#
CYLINDER 20 INJECTOR
Caption String for Cylinder 20 Injector
671
#
CYLINDER 21 INJECTOR
Caption String for Cylinder 21 Injector
672
#
CYLINDER 22 INJECTOR
Caption String for Cylinder 22 Injector
673
#
CYLINDER 23 INJECTOR
Caption String for Cylinder 23 Injector
674
#
CYLINDER 24 INJECTOR
Caption String for Cylinder 24 Injector
676
#
ENG GLOW PLUG RELAY
Caption String for Engine Glow Plug Relay
677
#
ENGINE START RELAY
Caption String for Engine Start Relay
701
#
AUX I/O 1
Caption String for Auxiliary I/O 1
702
#
AUX I/O 2
Caption String for Auxiliary I/O 2
703
#
AUX I/O 3
Caption String for Auxiliary I/O 3
704
#
AUX I/O 4
Caption String for Auxiliary I/O 4
705
#
AUX I/O 5
Caption String for Auxiliary I/O 5
706
#
AUX I/O 6
Caption String for Auxiliary I/O 6
707
#
AUX I/O 7
Caption String for Auxiliary I/O 7
708
#
AUX I/O 8
Caption String for Auxiliary I/O 8
709
#
AUX I/O 9
Caption String for Auxiliary I/O 9
710
#
AUX I/O 10
Caption String for Auxiliary I/O 10
711
#
AUX I/O 11
Caption String for Auxiliary I/O 11
wc_tx003548gb_FM10.fm
137
Diagnostic Trouble Codes (DTC)
Mobile Generator
Failure Code
String Displayed
SPN
Description
FMI
712
#
AUX I/O 12
Caption String for Auxiliary I/O 12
713
#
AUX I/O 13
Caption String for Auxiliary I/O 13
714
#
AUX I/O 14
Caption String for Auxiliary I/O 14
715
#
AUX I/O 15
Caption String for Auxiliary I/O 15
716
#
AUX I/O 16
Caption String for Auxiliary I/O 16
898
2
REQ SPD DATA ERRATIC
Speed Demand Data is erratic
898
9
Spd/Trq Msg INVLD
Vehicle Speed/Torque Message Invalid
898
#
ENGINE REQSTED SPEED
Caption String for Engine Requested Speed
923
#
PWM OUTPUT
Caption String for Engine PWM Output
970
2
Aux Eng SD SW INVLD
Auxiliary Engine Shutdown Switch (Invalid)
970
31
Aux Eng SD SW ACTV
Auxiliary Engine Shutdown Switch Active
971
31
Eng Derate SW ACTV
External Engine Derate Switch Active
975
#
FAN SPEED
Caption String for Engine Fan Speed
1072
#
ENG BRAKE OUTPUT 1
Caption String for Engine Brake Output 1
1074
#
ENG EXHAUST BRAKE OUT
Caption String for Engine Exhaust Brake Output
1075
5
Fuel TR Pump Curr LO
Fuel Transfer Pump Current (Low)
1075
6
Fuel TR Pump Curr HI
Fuel Transfer Pump Current (High)
1075
12
Fuel TR Pump ERR
Fuel Transfer Pump (Error)
1079
#
SENSOR SUPPLY VOLTS 1
Caption String for Sensor Supply Voltage 1
1080
3
Snsr Supp 1 Volt LO
Sensor Supply 1 Voltage (Low)
1080
4
Snsr Supp 1 Volt HI
Sensor Supply 1 Voltage (High)
1080
#
SENSOR SUPPLY VOLTS 2
Caption String for Sensor Supply Voltage 2
1081
#
ENG WAIT TO START LMP
Caption String for Engine Wait to Start Lamp
1109
31
Eng Shutdown WARNING
Engine Shutdown Warning
1109
#
EPS SHUTDN APPROACHG
Caption String for indication that Engine Protective System
Shutdown Is Approaching
1110
31
Eng Prot Shutdown
Engine Protection Shutdown
1136
0
ECU Temp EXT HI
ECU Temperature (Extremely High)
1136
15
ENG ECU TEMP HI
ECU Temperature has exceeded the HIGH level
1136
16
ECU Temp MHI
ECU Temperature (Moderately High)
138
wc_tx003548gb_FM10.fm
Mobile Generator
Diagnostic Trouble Codes (DTC)
Failure Code
String Displayed
SPN
Description
FMI
1172
3
Trbo Cmp Tmp Volt HI
Turbo Compressor Inlet Temp Input Voltage
(High)
1172
4
Trbo Cmp Tmp Volt LO
Turbo Compressor Inlet Temp Input Voltage
(Low)
1172
16
Trbo Cmp In Tmp MHI
Turbo Compressor Inlet Temp (Moderately High)
1180
0
Trbo Trbn Tmp EXT HI
Turbo Turbine Inlet Temp (Extremely High)
1180
16
Trbo Trbn In Tmp MHI
Turbo Turbine Inlet Temp (Moderately High)
1231
#
J1939 NETWORK 2
Caption String for J1939 Network number 2
1235
#
J1939 NETWORK 3
Caption String for J1939 Network number 3
1237
#
ENG SHUTDN ORIDE SW
Caption String for Engine Shutdown Override
Switch
1322
#
MULTI CYL MISFIRE
Caption String for Misfire detected on multiple
engine cylinders
1323
#
MISFIRE CYLINDER 1
Caption String for Misfire detected on a single
engine cylinder
1324
#
MISFIRE CYLINDER 2
Caption String for Misfire detected on a single
engine cylinder
1325
#
MISFIRE CYLINDER 3
Caption String for Misfire detected on a single
engine cylinder
1326
#
MISFIRE CYLINDER 4
Caption String for Misfire detected on a single
engine cylinder
1327
#
MISFIRE CYLINDER 5
Caption String for Misfire detected on a single
engine cylinder
1328
#
MISFIRE CYLINDER 6
Caption String for Misfire detected on a single
engine cylinder
1329
#
MISFIRE CYLINDER 7
Caption String for Misfire detected on a single
engine cylinder
1330
#
MISFIRE CYLINDER 8
Caption String for Misfire detected on a single
engine cylinder
1331
#
MISFIRE CYLINDER 9
Caption String for Misfire detected on a single
engine cylinder
1332
#
MISFIRE CYLINDER 10
Caption String for Misfire detected on a single
engine cylinder
1333
#
MISFIRE CYLINDER 11
Caption String for Misfire detected on a single
engine cylinder
1334
#
MISFIRE CYLINDER 12
Caption String for Misfire detected on a single
engine cylinder
wc_tx003548gb_FM10.fm
139
Diagnostic Trouble Codes (DTC)
Mobile Generator
Failure Code
String Displayed
SPN
Description
FMI
1335
#
MISFIRE CYLINDER 13
Caption String for Misfire detected on a single
engine cylinder
1336
#
MISFIRE CYLINDER 14
Caption String for Misfire detected on a single
engine cylinder
1337
#
MISFIRE CYLINDER 15
Caption String for Misfire detected on a single
engine cylinder
1338
#
MISFIRE CYLINDER 16
Caption String for Misfire detected on a single
engine cylinder
1339
#
MISFIRE CYLINDER 17
Caption String for Misfire detected on a single
engine cylinder
1340
#
MISFIRE CYLINDER 18
Caption String for Misfire detected on a single
engine cylinder
1341
#
MISFIRE CYLINDER 19
Caption String for Misfire detected on a single
engine cylinder
1342
#
MISFIRE CYLINDER 20
Caption String for Misfire detected on a single
engine cylinder
1343
#
MISFIRE CYLINDER 21
Caption String for Misfire detected on a single
engine cylinder
1344
#
MISFIRE CYLINDER 22
Caption String for Misfire detected on a single
engine cylinder
1345
#
MISFIRE CYLINDER 23
Caption String for Misfire detected on a single
engine cylinder
1346
#
MISFIRE CYLINDER 24
Caption String for Misfire detected on a single
engine cylinder
1347
3
Pump Ctrl Vlv Curr HI
Pump Control Valve Current (High)
1347
5
Pmp Ctrl Vlv C MSMCH
Pump Control Valve Current (Mismatch)
1347
7
Fuel Rl Prs Ctrl ERR
Fuel Rail Pressure Control (Error)
1569
31
Fuel Derate
Fuel Derate
1638
#
HYDRAULIC TEMP
Caption String for Hydraulic Temperature
1639
1
Fan Speed Zero
Fan Speed Detected (Zero)
1639
16
Fan Speed HI
Fan Speed Detected (High)
1639
18
Fan Speed LO
Fan Speed Detected (Low)
2000
13
Security Violation
Security Violation
2005
9
TSC CAN Msg NT RCV
TSC CAN Message Not Received
2030
9
AC Clutch Msg NT RCV
A/C Clutch Status CAN Message Not Received
140
wc_tx003548gb_FM10.fm
Mobile Generator
Diagnostic Trouble Codes (DTC)
Failure Code
String Displayed
SPN
Description
FMI
2071
9
Tr Oil Can Msg NT RCV
Trans. Oil, Tier Size, Vehicle Speed CAN Message Not
Received
2629
0
TRBO 1 OUT TMP HI HI
Turbocharger 1 outlet pressure is above the
HIGH HIGH
threshold
2629
15
TURBO 1 OUT TMP HI
Turbocharger 1 outlet pressure is above the
HIGH threshold
2630
0
EGR FrAir Tmp EXT HI
Exhaust Gas Recirculation Fresh Air Temp
(Extremely High)
2630
3
EGR FrAir Tmp Vlt HI
Exhaust Gas Recirculation Fresh Air Temp Input
Voltage (High)
2630
4
EGR FrAir Tmp Vlt LO
Exhaust Gas Recirculation Fresh Air Temp Input
Voltage (Low)
2630
15
EGR FrAir Tmp HI
Exhaust Gas Recirculation Fresh Air Temp
(High Least Severe)
2630
16
EGR FrAir Tmp MHI
Exhaust Gas Recirculation Fresh Air Temp
(Moderately High)
2634
#
POWER RELAY
Caption String for main Power Relay
2659
2
EGR Flo/Tmp MISMATCH
Exhaust Gas Recirculation Flow/Temp Mismatch
2659
15
EGR Flo Rt High
Exhaust Gas Recirculation Flow Rate (High
Least Severe)
2659
17
EGR Flo Rt LO
Exhaust Gas Recirculation Flow Rate (Low
Least Severe)
2790
16
Trbo Cmp Out Tmp HI
Turbo Compressor Outlet Temp (Moderately
High)
2791
2
EGR Vlv Pos Invld
Exhaust Gas Recirculation Valve Position
Invalid
2791
3
EGRVlv Pos In Vlt HI
Exhaust Gas Recirculation Valve Position Input
Voltage (High)
2791
4
EGRVlv Pos In Vlt LO
Exhaust Gas Recirculation Valve Position Input
Voltage (Low)
2791
13
EGR Vlv Control ERR
Exhaust Gas Recirculation Valve Control Error
2791
31
EGR Valve Cal ERR
Exhaust Gas Recirculation Valve Calibration
Error
2791
#
EGR VALVE CONTROL
Caption String for EGR Valve Control
2795
7
Trbo Act Pos MSMATCH
Turbo Actuator Position Mismatch
wc_tx003548gb_FM10.fm
141
Diagnostic Trouble Codes (DTC)
Mobile Generator
Failure Code
String Displayed
SPN
Description
FMI
3719
0
DPF SOOT LVL EXT HI
String for Diagnostic Trouble Code Indicating
Diesel Particulate
Filter Soot Level High - Most Severe Level
3719
15
DPF SOOT LVL HI
String for Diagnostic Trouble Code Indicating
Diesel Particulate
Filter Soot Level High - Least Severe Level
3719
16
DPF SOOT LVL MOD HI
String for Diagnostic Trouble Code Indicating
Diesel Particulate
Filter Soot Level High - Moderately Severe
Level
520837
1
STARTER SPEED LO LO
Starter Speed is below the LOW LOW threshold
820838
1
RUN UP SPEED LO LO
Run Up Speed is below the LOW LOW threshold
522192
12
MTU ENGINE BAD
Component failure of the MTU engine control
ECU
523212
#
ENGPRT CAN MSG
Caption String for CANBus Message
523216
#
PREHTENCMD CAN MSG
Caption String for CANBus Message
523218
#
RxCCVS CAN MSG
Caption String for CANBus Message
523222
#
TC01 CAN MSG
Caption String for CANBus Message
523238
#
SWTOUT CAN MSG
Caption String for CANBus Message
523239
#
DECV1 CAN MSG
Caption String for CANBus Message
523240
#
FUNMODCTL CAN MSG
Caption String for CANBus Message
523350
#
CYL BANK 1 INJECTORS
Caption String for Cylinder Bank 1 Injectors
523351
#
CYL BANK 1 INJECTORS
Caption String for Cylinder Bank 1 Injectors
523352
#
CYL BANK 2 INJECTORS
Caption String for Cylinder Bank 2 Injectors
523353
#
CYL BANK 2 INJECTORS
Caption String for Cylinder Bank 2 Injectors
523354
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
523355
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
523370
#
RAIL PRESSURE
Caption String for Rail Pressure
523420
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
523450
#
MULTI STATE SWITCH 1
Caption String for Multi State Switch 1
523451
#
MULTI STATE SWITCH 2
Caption String for Multi State Switch 2
523452
#
MULTI STATE SWITCH 3
Caption String for Multi State Switch 3
142
wc_tx003548gb_FM10.fm
Mobile Generator
Diagnostic Trouble Codes (DTC)
Failure Code
String Displayed
SPN
Description
FMI
523470
#
RAIL PRESSURE LMT VLV
Caption String for Rail Pressure Limit Valve
523490
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
523500
#
CAN MSG TIMEOUT
Caption String indicating Can Message Timeout
has occurred
523550
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
523561
#
INJECTN PERIOD CYL 1
Caption String for Single Cylinder Injection
Period
523562
#
INJECTN PERIOD CYL 2
Caption String for Single Cylinder Injection
Period
523563
#
INJECTN PERIOD CYL 3
Caption String for Single Cylinder Injection
Period
523564
#
INJECTN PERIOD CYL 4
Caption String for Single Cylinder Injection
Period
523565
#
INJECTN PERIOD CYL 5
Caption String for Single Cylinder Injection
Period
523566
#
INJECTN PERIOD CYL 6
Caption String for Single Cylinder Injection
Period
523567
#
INJECTN PERIOD CYL 7
Caption String for Single Cylinder Injection
Period
523568
#
INJECTN PERIOD CYL 8
Caption String for Single Cylinder Injection
Period
523600
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
523601
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
523602
#
FAN SPEED
Caption String for Engine Fan Speed
523604
#
RXENGTMP CAN MSG
Caption String for CANBus Message
523605
#
TSC1-AE MSG MISSING
Caption String for CANBus Message
523606
#
TSC1-AR MSG MISSING
Caption String for CANBus Message
523607
#
TSC1-DE MSG MISSING
Caption String for CANBus Message
523608
#
TSC1-DR MSG MISSING
Caption String for CANBus Message
523609
#
TSC1-PE MSG MISSING
Caption String for CANBus Message
523610
#
TSC1-VE MSG MISSING
Caption String for CANBus Message
523611
#
TSC1-VR MSG MISSING
Caption String for CANBus Message
wc_tx003548gb_FM10.fm
143
Diagnostic Trouble Codes (DTC)
Mobile Generator
Failure Code
String Displayed
SPN
Description
FMI
523612
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
523613
#
RAIL PRESSURE
Caption String for Rail Pressure
523615
#
METERING UNIT VALVE
Caption String for Metering Unit Valve
523617
#
ECU ERROR
String for Diagnostic Trouble Code Indicating
ECU Error
144
wc_tx003548gb_FM10.fm
Mobile Generator
Factory-Installed Options
14 Factory-Installed Options
This machine may be equipped with one or more of the following factory-installed
options. To verify if any of these options are installed on your machine, contact
Wacker Neuson Corporation at 1-800-770-0957. A nameplate listing the Model
Number, Item Number, Revision, and Serial Number is attached to each unit.
Please have this information available when contacting Wacker Neuson
Corporation.
The illustrations shown in this chapter represent typical installations. The factoryinstalled options on your machine may look different.
14.1
Battery Charger
An optional battery charger maintains the battery at peak power while the machine
is turned off. Use of a battery charger is recommended when the generator is not
operated on a regular basis. The battery charger prevents voltage drain and
reduces the possibility of having to jump-start the engine after long periods of
inactivity. Plug the cord into a 120V power supply.
wc_gr005779
wc_tx003612gb_FM10.fm
145
Factory-Installed Options
14.2
Mobile Generator
Lockable Battery Disconnect
A lockable ON/OFF switch is available which disconnects the battery. A padlock
(not included) securely locks the switch in the OFF position. If equipped, the battery
disconnect switch is mounted to the upper skid beneath the access door on either
the right or left side of the machine.
wc_gr010552
NOTICE: Do not use the battery disconnect switch while the engine is running.
Damage to electrical components may occur.
146
wc_tx003612gb_FM10.fm
Mobile Generator
14.3
Factory-Installed Options
Camlocks
A second optional outlet panel features camlock connectors for easy tool changes.
Each connector is protected by a spring-loaded cover.
NOTICE: Separate overcurrent protection must be provided. Do not exceed 400
amps per receptacle.
WARNING
Electric shock hazard.
► Do not operate this machine with defective or missing guards, doors, or protective interlocks.
wc_tx003612gb_FM10.fm
147
Factory-Installed Options
14.4
Mobile Generator
Containment System
Overspills and leaks are captured in the containment system (a). The containment
system holds over 110% of the fluid contained in the machine.
a
wc_gr002647
14.5
Extended Run Tank (ERT)
An extended run (fuel) tank provides extended run time under a continuous full
load. The long run time eliminates the need for daily refueling, saving money on
fuel deliveries. The tank is fully fluid-contained and is ideal for remote or weekend
running of equipment such as dewatering submersible pumps.
wc_gr006179
148
wc_tx003612gb_FM10.fm
Mobile Generator
14.6
Factory-Installed Options
Engine Block Heater
The engine block heater option includes a block heater (a) with a cord (b). The
function of the block heater is to heat the engine coolant/engine block to improve
cold-weather engine starting. Plug the cord into a 120V power supply.
14.7
Automatic LCD Heat
To improve the performance of the LCD panel in cold weather, the LCD panel
control module is equipped with an LCD heater. The heater draws power from the
panel control module and is active only when the panel control module is powered.
An optional thermostat (a) can be installed if the machine is to be used in extremely
cold weather. The thermostat automatically powers the panel control module when
the temperature drops to approximately -30°C (-22° F). This activates the heater to
prevent damage to the LCD panel.
a
wc_gr010554
It is important to note that the panel control module draws a small amount of power
from the battery when turned on—even when the machine is not running. If the
battery should fail, the heater will also fail. Be sure to keep the battery charged
when the generator is not in use.
wc_tx003612gb_FM10.fm
149
Factory-Installed Options
14.8
Mobile Generator
Low Coolant Shutdown
Description
The low-coolant shutdown system consists of an electronic sensor that monitors
coolant level. The sensor (a) is mounted to the radiator and wired into the ECM.
The sensor probe (b) is submerged in radiator coolant.
Function
If the probe senses no coolant, it sends a signal to the ECM. The ECM program
includes a 10-second timer to protect from nuisance shutdowns. If after the ten
seconds coolant levels are still sensed as being low, the ECM shuts down the
engine. The ECM will then display “LOW COOL LEVEL”. Allow the engine to cool
before adding additional coolant.
WARNING
Burn hazard. Pressurized coolant is very hot and can cause serious burns.
► Do not remove the radiator cap while the engine is hot.
If it is necessary to open the radiator, only do so with the engine off, and only when
coolant is cool enough to touch with bare hands. Slowly loosen the radiator cap to
relieve pressure first, before removing it completely.
Note: The sensor may be disabled by unplugging the wire harness. This action will
not shut down the machine.
150
wc_tx003612gb_FM10.fm
Mobile Generator
14.9
Factory-Installed Options
Temperature-Activated Shutters
The shutters (a) are mounted to the top of the generator enclosure.
The shutters are designed to keep the engine compartment warm, thus increasing
engine temperature during cold weather operation. The shutters are activated
through a wax-pellet actuator (b) that is connected to the generator's cooling
system. As radiator coolant warms, the wax-pellet actuator engages a linkage (c)
that opens the shutters. As the coolant cools, the shutters close.
wc_tx003612gb_FM10.fm
151
Factory-Installed Options
Mobile Generator
14.10 Positive Air Shutoff Valve
Description
Diesel engines may occasionally continue to run even after the machine has been
turned off. This “runaway” condition occurs when combustible intake air is drawn
into the engine. Pressing the emergency stop switch alone will not stop a runaway
engine.
Some models include a positive air shutoff valve (a). Activating the positive air
shutoff valve blocks the flow of air into the engine intake and stops the engine from
running.
a
b
wc_gr010205
Operation
To activate the positive air shutoff valve, pull the T-handle (b) located next to the
voltage selector switch. The valve will reset automatically after activation.
152
wc_tx003612gb_FM10.fm
Mobile Generator
Factory-Installed Options
14.11 Quick-Disconnect Fuel Fittings
Quick-disconnect fuel fittings allow an external fuel supply to be connected to the
engine.
Requirements
■ Engine stopped and cool to the touch
■ Fuel supply and return hoses with compatible quick-disconnect fittings
Note: Required fitting size is ISO 7241-1-Series B (3/8 in.)
Procedure
Perform the following procedure to connect the external fuel supply.
1. Feed the external supply hose (b) and the external return hose (c) through the
access port (a) on the curb side of the machine.
e
a
d
c
b
wc_gr009257
2. Disconnect the internal feed hose (d) at the tank fitting, and connect the internal
feed hose to the external supply hose.
3. Disconnect the internal return hose (e) from the tank fitting, and connect it to the
external return hose (c).
Result
The external fuel supply is now connected.
WARNING
Fire hazard. Improper connections or damaged hoses may leak flammable fuel.
► Ensure that all quick-disconnect fittings are properly seated before operating
the machine.
► Make sure that fuel hoses are not kinked. Ensure that the hoses will not touch
or rest upon hot surfaces while the machine is operating.
wc_tx003612gb_FM10.fm
153
Factory-Installed Options
Mobile Generator
14.12 Lube Level Maintainer
Description
The lube level maintainer system protects the engine from low oil levels by
providing an additional 6-quart oil reservoir. Oil from the reservoir is gravity-fed
from the oil reservoir (a) through the control valve (b) and into the engine oil pan as
needed.
The valve includes a sightglass (c) through which the oil level can be seen. This oil
level is the same as that measured by the engine dipstick. A float inside the valve
detects low oil levels and opens the valve to supply the needed oil. The system is
wired to the ECM and includes a low oil shutdown in case the oil in the reservoir is
depleted.
Operation
If the engine shuts down due to low oil, the ECM will display “LOW OIL LEVEL”. Fill
the engine and the additional oil reservoir with oil before placing the generator back
into service.
NOTICE: To prevent overfilling the engine with oil, place the shutoff valve (d) in the
closed position when moving or towing the generator. Once the generator is in
position, open the valve.
154
wc_tx003612gb_FM10.fm
Machines with Aftertreatment Exhaust System
15 Machines with Aftertreatment Exhaust System
15.1
How the Aftertreatment Exhaust System Works
Background
Many Wacker Neuson Generators with Tier 4 engines use an aftertreatment
exhaust system to reduce emissions. There are five main components to the
system:
■ Heat
■ Diesel Exhaust Fluid (DEF)
DEF is a urea-based chemical reactant designed specifically for use in SCR
systems to reduce nitrogen oxides (NOx) emissions.
■ Selective Catalytic Reduction (SCR) system
An SCR is a catalytic converter which houses a catalyst made of base metal
oxides (such as titanium, vanadium, and tungsten oxides).
■ Diesel Oxidation Catalyst (DOC)
A DOC is a catalytic converter that oxides pollutants such as carbon monoxide,
hydrocarbons, and organic diesel particulates.
■ Decomposition Reactor Tube (DRT)
A DRT is a tube between the DOC and the SCR into which the DEF is
introduced (dosed) into the exhaust stream.
How it works
► The exhaust is first treated by the DOC.
► Exhaust (NOx) emissions flow through the DOC into the DRT.
► DEF is injected into the DRT.
The amount and frequency is controlled by the DEF supply module.
► The DEF vaporizes and decomposes to form ammonia and carbon dioxide.
Within the SCR catalyst, the NOx are catalytically reduced by the ammonia into
water and nitrogen. These are then released through the exhaust elbow.
DEF Supply
Module
DEF Tank
DOC
SCR
DRT
wc_gr012291
Interaction
The system requires very little interaction by the operator. Items that require
attention are:
■ DEF tank—refill as required
■ DEF supply module filter—change every 4500 hours
■ Manual regeneration—a manual regeneration of the system may be necessary
if the engine is unable to complete an automatic regeneration cycle.
wc_tx003871gb_FM10.fm
155
Machines with Aftertreatment Exhaust System
15.2
Filling the DEF Tank
Requirements
■ Machine level with the ground
■ Remote switch disconnected from the remote run terminal
■ Fresh Diesel Exhaust Fluid (DEF)—also known as Aqueous Urea Solution 32%
(AUS32)—manufactured to the standards of ISO 22241.
Background
The DEF refilling interface on this machine meets ISO 22241-4. The inlet includes
a magnetic ring that opens filler nozzles that meet the ISO 22241-4 standard. This
system also allows for automatic shut-off.
Notices
■ Do not put Diesel fuel or any other liquid besides DEF into the DEF tank.
■ The DEF freezes (crystallizes) at 11°F (-12°C). Do not overfill the DEF tank.
DEF expands when frozen. Expanding DEF can cause machine damage.
■ DEF may be corrosive on certain materials (copper, brass). Clean up any spilled
DEF immediately.
CAUTION
Personal injury hazard. DEF is a skin and eye irritant.
► Wear eye and hand protection when using DEF.
Procedure
Perform the procedure below to fill the DEF tank.
1. Remove the DEF tank cap (b).
b
wc_gr012293
This procedure continues on the next page.
156
wc_tx003871gb_FM10.fm
Machines with Aftertreatment Exhaust System
Continued from the previous page.
2. Set the engine start switch (a) to the REMOTE START position. The DEF level
(in percentage of the DEF tank capacity) is displayed on the left side of the LCD
screen.
0
P2
0
V
0.0
Ø
A
HZ
OFF
100%
AUS
APAGADO
ARRET
READY
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
63
0 25.3
Basler
13%
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
a
R
wc_gr012292
3. Start the engine by setting the engine start switch to the START/RUN position.
Note: The controller will only display the increasing DEF level while the engine is
running.
4. Fill the DEF tank until the DEF level reaches 100%.
5. Re-install the DEF cap.
6. Place the engine start switch in the OFF position.
wc_tx003871gb_FM10.fm
157
Machines with Aftertreatment Exhaust System
15.3
Shelf Life of Diesel Exhaust Fluid (DEF)
The shelf life of DEF is a function of temperature and the amount of exposure to
sunlight. Certain conditions can degrade the solution to a point where it will no
longer meet the standards.
Recommended shelf life of DEF is listed in the table below. See the DEF
manufacturer for detailed information.
Temperature range
Minimum shelf life (months)
≤ 10°C
≤ 50°F
36
≤ 25°C
≤ 77°C
18
≤ 30°C
≤ 86°C
12
≤ 35°C
≤ 95°C
6
≥35°C
≥95°C
Check before use
NOTICE: Only use equipment that is clearly specified for handling DEF. Do not use
any hoses or pumps that do not specifically identify being compatible with the
brand of DEF being used, as DEF can be a corrosive liquid to certain metals and
can dissolve minerals from hoses and plastic fittings. Always read and understand
all information from the DEF manufacturer regarding storage and transfer of the
DEF.
158
wc_tx003871gb_FM10.fm
Machines with Aftertreatment Exhaust System
15.4
Monitoring and Control of the DEF Level
The Diesel Exhaust Fluid (DEF) level is monitored by the genset controller. In
normal operation, the DEF level (in percentage of the DEF tank capacity) is
displayed on the left side of the LCD screen. When the DEF tank begins to empty,
the genset controller displays messages alerting the operator of the condition of
the DEF supply. See table below.
Refilling the DEF tank before the DEF level reaches 2.5% avoids DEF-levelrelated engine shutdowns.
DEF INDUCEMENT
wc_gr012296
DEF Level
Controller Message
Controller / Machine Response
≥ 10%
No message
Normal screen / normal operation
2.5–10%
DEF WARNING
■ Normal operation.
■ LED flashes.
0–2.5%
DEF INDUCEMENT
■ Main circuit breaker trips.
■ Machine runs for 10 minutes, then shuts down.
■ During shutdown the LED is on solid and the LCD screen
shows LOW DEF SHUTDOWN.
The machine may be restarted without adding any DEF, but
will only run for 10 minutes before the genset controller
shuts down the machine. Only the convenience receptacles
are available.
0%
DEF PRESVR INDUCMT
Same as above plus the engine’s SEVERE INDUCMT timer
starts.
30 minutes
after 0%
DEF SEVERE INDUCMT
■ After 30 minutes of run time with 0% DEF, the engine
wc_tx003871gb_FM10.fm
shuts itself down. This is the first of four shutdowns
allowed by the engine.
Note: The genset controller’s 10-minute run time limitation
is still active within the 30-minute engine run time limit.
Thus, up to three restarts by the genset controller are
possible within the 30-minute engine-controlled run time.
■ The engine will allow four such shutdowns to occur. On the
fourth shutdown, the engine controller will lock out the
engine. The engine can only be unlocked by a Cummins
service technician.
159
Machines with Aftertreatment Exhaust System
15.5
Monitoring DEF Quality
The quality of Diesel Exhaust Fluid (DEF) is monitored by the genset controller.
When the DEF quality begins to deteriorate (or something other than DEF is put
into the DEF tank, or the sensor is disconnected/malfunctioning), the genset
controller displays messages alerting the operator as to the condition of the DEF
quality. See table below.
DEF WARNING
wc_gr012297
DEF Quality
/malfunction
Controller Message
Controller / Machine Response
No issues detected
No message
Normal screen / normal operation
Issue detected
DEF WARNING
■ Normal operation.
■ LED flashes.
The SEVERE INDUCMT timer starts.
90 minutes after
issue is detected
DEF INDUCEMENT
■ Main circuit breaker trips.
■ Machine runs for 10 minutes, then shuts down. LED on
solid.
The machine may be restarted, but will only run for 10
minutes before the genset controller shuts down the
machine. Only the convenience receptacles are available.
165 minutes after
issue detected
DEF PRESVR INDUCMT
Same as above.
180 minutes after
issue detected
DEF SEVERE INDUCMT
■ After 180 minutes of run time with a DEF quality issue,
the engine shuts itself down. This is the first of four
shutdowns allowed by the engine.
Note: The genset controller’s 10-minute run time
limitation is still active within the 180-minute engine run
time limit. Thus, up to seventeen restarts by the genset
controller are possible within the 180-minute engine
controlled run time.
■ The engine may be restarted, but the run time is
lessened to 30 minutes. At the 30-minute mark, the
engine shuts itself down. This is the second of four
allowed shutdowns. The genset controller’s 10-minute
run time limitation is still active. Thus, up to three
restarts by the genset controller are possible within the
30-minute engine controlled run time limit. On the fourth
shutdown, the engine controller will lock out the engine.
The engine can only be unlocked by a Cummins service
technician.
160
wc_tx003871gb_FM10.fm
Machines with Aftertreatment Exhaust System
15.6
Conditioning the Aftertreatment Exhaust System (if equipped)
Overview
Sustained operation of the generator under load heats the Selective Catalytic
Reduction (SCR) system to a temperature high enough to burn accumulated Diesel
Exhaust Fluid (DEF) crystals. This conditioning process normally occurs
automatically.
DEF crystals may fill the Decomposition Reactor Tube (DRT) if the engine runs at
idle for long periods with no load. An indicator (a) on the control panel illuminates
when a conditioning is needed.
a
b
OFF
AUS
APAGADO
ARRET
V
Ø
A
REMOTE START
START / RUN
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE
HZ
wc_gr012298
WARNING
Burn hazard. The engine, SCR components, and exhaust elbow become very hot
during operation.
► Do not touch the engine, the SCR components, or exhaust elbow while the
machine is operating. Wait for these components to cool before touching them.
Procedure
Perform the procedure below to condition the SCR system.
1. Start the engine at low idle speed.
2. Move the manual conditioning switch (b) to the “ON” position and hold it for five
seconds, then release the switch. The indicator will go out and the conditioning
process will begin.
The engine speed will gradually increase to about 1100 rpm while the machine is in
conditioning mode. When conditioning is complete, the engine speed will return to
low idle (about 900 rpm).
Note: The conditioning process may continue for up to one hour depending on
ambient conditions and the amount of DEF crystals inside the DRT.
NOTICE: To prevent machine damage, perform a manual conditioning as soon as
the indicator illuminates.
wc_tx003871gb_FM10.fm
161
General Maintenance
Mobile Generator
16 General Maintenance
WARNING
A poorly maintained machine can malfunction, causing injuries or permanent
damage to the machine.
► Keep the machine in safe operating condition by performing periodic maintenance and making repairs as needed.
16.1
Periodic Maintenance Schedule
The table below lists basic machine maintenance. Tasks designated with check
marks may be performed by the operator. Tasks designated with square bullet
points require special training and equipment.
Daily
Conduct visual walk-around
inspection.
Weekly
50
hours
or 2
weeks
250
hours
600
hours
or 12
months
Other

Check exhaust system.


Drain containment system.
Service the battery.

Clean the machine inside and
out.


Grease axle.
Check brake fluid level in
trailer.1

Fill the radiator.2

Replace the aftertreatment
DEF dosing unit filter.3

1At
least monthly.
Every 2000 hours or 2 years.
3Every 4500 hours or 3 years.
2
162
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Mobile Generator
16.2
General Maintenance
Maintaining the Emission Control System
For machines sold in North America:
Normal maintenance, replacement, or repair of emission control devices and
systems may be performed by any repair establishment or individual; however,
warranty repairs must be performed by a dealer/service center authorized by
Wacker Neuson. The use of service parts that are not equivalent in performance
and durability to authorized parts may impair the effectiveness of the emission
control system and may have a bearing on the outcome of a warranty claim.
16.3
Preparing for Maintenance
Do not perform even routine service (oil/filter changes, cleaning, etc.) unless all
electrical components are shut down. Use the checklist below to prepare this
machine for maintenance.
 Move the start switch to “OFF”.
 Open the circuit breakers (move to the “OFF” position).
 Close the emergency stop switch (push in).
 Disconnect the negative terminal on the battery.
 Attach a “DO NOT START” sign to the control panel.
 If the unit is connected to a remote start or transfer switch, make sure the
remote switch is also off and tagged.
16.4
Cleaning the Machine
When
As needed
Suggested
cleaning
materials
■
■
■
■
Compressed air
Clean water supply
Mild detergent
Clean, dry cloths
NOTICE: Do not use a pressure washer to clean this machine. Pressurized water
can severely damage the generator and sensitive electronic components.
Cleaning the
interior
Clean the interior of the machine.
 Check the fluid level in the containment skid (if equipped) and drain if necessary.
See “Checking / Draining the Containment Skid.”
 Remove rags, containers, or other debris from the cabinet. Nothing should be
stored inside the machine.
 Remove leaves and twigs from the exhaust compartment.
 Wipe interior surfaces clean of oil, dust, and dirt.
Cleaning the
exterior
Clean the exterior of the machine with clean water and a mild detergent.
wc_tx003614gb_FM10.fm
163
General Maintenance
16.5
Mobile Generator
Inspecting the Machine
When
Daily
Overview
Inspect the machine before each use. A thorough inspection will help to identify
mechanical faults or potentially unsafe operating conditions. Correct these
problems before operating the machine.
External
inspection
Perform an external inspection of the machine. Check for:
 External damage (dents, cracks, broken door latches, etc.)
 Loose or missing fasteners
 Loose or missing parts
 Fluid leaks
 Restricted air flow in the exhaust compartment
 Problems with the trailer—refer to topic Maintaining the Trailer
Internal
inspection
Open the access doors on both sides of the machine. Check for:
 Damage to control panel, switches, or customer connections
 Loose or missing fasteners
 Loose or missing parts
 Loose or damaged hoses
 Fluid leaks
 Rags, containers, or other debris inside the cabinet
164
wc_tx003614gb_FM10.fm
Mobile Generator
16.6
General Maintenance
Maintaining the Trailer
Tires
■ Keep tires inflated to the proper pressure as shown on the tire sidewall.
■ Check tread periodically for wear.
■ Replace tires as required.
Wheels
■ Check that lug nuts holding wheels are tight.
■ Replace any missing lug nuts immediately.
Axle Hubs
■ Grease axle hubs using a good wheel-bearing grease.
Brakes
■ Check operation of brakes before each trip.
■ Check level of brake fluid in actuator at front of trailer at regular intervals.
■ Fill brake fluid to approximately 1 inch below top of reservoir using DOT-3
heavy-duty brake fluid.
■ Tighten filler plug securely.
Note: If fluid level has fallen too low, bleed brake lines to remove any air trapped in
lines. Then fill to proper level with clean brake fluid.
wc_tx003614gb_FM10.fm
165
General Maintenance
16.7
Mobile Generator
Checking and Draining the Containment System
When
Check and drain the containment system every 50 hours.
Overview
Certain machines are equipped with a containment system. The containment
system protects the environment by collecting fluid leaks (fuel, coolant, or oil)
which might otherwise contaminate the soil.
NOTICE: It is important to check the containment system regularly. A large amount
of fluid collected in a 24-hour period indicates a significant leak.
Requirements
■ Machine stopped and engine is cool to the touch
■ Machine is on a level surface
■ Plastic cloth and a container of sufficient volume to collect drained fluid
Note: Collect, store, and dispose of drained fluid in accordance with current
environmental protection regulations.
Procedure
Perform the procedure below to check and drain the containment system.
1. Open the access door on the side of the machine.
2. Check the fluid level in the containment system.
3. If fluid has accumulated, drain the containment system.
a. Place a plastic cloth and a collection container beneath the machine.
b. Remove the drain plug (a). Drain accumulated fluid into a suitable container.
a
wc_gr012332
c. Apply pipe sealant to the drain plug.
d. Re-install the drain plug.
Result
The containment system has now been checked and drained.
166
wc_tx003614gb_FM10.fm
Mobile Generator
16.8
General Maintenance
Checking the Exhaust System
When
Check the exhaust system weekly before operating the machine.
Background
A leaky exhaust system will adversely affect machine operation. Symptoms include
increased noise and visible soot deposits. Leaking exhaust can also ignite
surrounding materials and pipe insulation, causing a fire.
Requirements
■ Engine is stopped
■ Exhaust pipes and muffler are cool to the touch
Procedure
Perform the following procedure to check the exhaust system.
1. Open the access door on the curb side of the machine.
a
a
b
a
wc_gr009917
2.




Inspect the exhaust pipes (a) and muffler (b), looking for:
Cracks or holes
Burned or missing insulation
Loose or missing clamps
Black soot deposits, especially around welds and joints
3.




Start the engine. Listen carefully for:
Excessive noise
Rumbling
High-pitched whine
Rattling
Repair or replace faulty components before putting the machine back into service.
Result
The exhaust system has now been checked.
wc_tx003614gb_FM10.fm
167
General Maintenance
16.9
Mobile Generator
Maintaining the Battery
WARNING
Explosion hazard. Batteries can emit explosive hydrogen gas.
► Keep all sparks and flames away from the battery.
► Do not short-circuit battery posts.
Safety
precautions
Observe the following safety precautions to prevent serious damage to the
electrical system.
■ Do not disconnect the battery while the machine is running.
■ Do not attempt to run the machine without a battery.
■ Do not attempt to jump-start the machine.
■ In the event that the machine has a discharged battery, either replace the
battery with a fully charged battery or charge the battery using an appropriate
battery charger.
■ Dispose of waste batteries in accordance with local environmental regulations.
Battery
connections
To connect the battery:
1. Connect the red positive (+) battery cable to the battery.
2. Connect the black negative (-) battery cable to the battery.
To disconnect the battery:
1. Stop the engine.
2. Place all electrical switches in the OFF position.
3. Disconnect the black negative (-) battery cable from the battery.
4. Disconnect the red positive (+) battery cable from the battery.
Maintaining
battery
condition
■ Follow the battery manufacturer’s maintenance recommendations.
■ Keep battery terminals clean and connections tight.
■ When necessary, tighten the cables and grease the cable clamps with
petroleum jelly.
■ Maintain the battery at full charge to improve cold weather starting.
168
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Mobile Generator
General Maintenance
16.10 Cleaning the Diesel Particulate Filter (DPF) (if equipped)
Overview
Sustained operation of the generator under load heats the DPF to a temperature
high enough to burn accumulated soot. This cleaning process (passive
regeneration) normally occurs automatically.
Soot may fill the DPF (a) when the engine runs at idle for long periods with no load.
An indicator (b) on the control panel illuminates when the DPF is full of soot. The
operator must then either increase the load on the engine, or perform a manual
regeneration to clean the DPF.
a
b
V
c
Ø
wc_gr009226
WARNING
Burn hazard. The engine, DPF and exhaust pipe become very hot during operation.
► Do not touch the engine, DPF, or exhaust pipe while the machine is operating.
Wait for these components to cool before touching them.
Manual
regeneration
If the DPF indicator illuminates, follow the steps below to perform an manual
regeneration.
1. Start the engine at low idle speed.
2. Move the manual regeneration switch (c) to the “on” position and hold it for five
seconds. The DPF indicator will go out and the regeneration process will begin.
3. Release the switch.
The engine speed will gradually increase to about 1000 rpm while the machine is in
regeneration mode. When regeneration is complete, the engine speed will return to
low idle (about 750 rpm).
Note: The regeneration process may continue for up to one hour depending on
ambient conditions and the amount of soot inside the DPF.
NOTICE: The DPF may be permanently damaged if the machine continues to
operate with accumulated soot inside the DPF. Perform a manual regeneration as
soon as possible after the indicator illuminates.
wc_tx003614gb_FM10.fm
169
General Maintenance
Mobile Generator
16.11 Filling the Radiator
When
Every 2000 hours or 2 years
Requirements
■ Machine shut down
■ Engine cool to touch
■ Fresh coolant (as needed)
Procedure
Perform the procedure below to fill the radiator.
WARNING
Burn hazard. Engine coolant is hot and under pressure at operating temperature.
► Check the coolant level only after the engine has been shut down and is cool.
1. Open the access cover on the roof (a).
b
a
WARNUNG
WARNING
ADVERTENCIA
wc_gr012631
WARNING
Burn hazard. Coolant can contain alkali.
► Avoid coolant contact with skin and eyes.
2. Slowly rotate the radiator cap (b) counterclockwise to release any remaining
system pressure. Unscrew and remove the radiator cap after the pressure has
been release.
3. Add coolant by filling at a rate of approximately 1.5 gallons per minute for 6
minutes.
4. Wait 10 minutes. Then, fill at a rate of approximately 1.5 gallons per minute for
3:30 minutes or until full.
5. Run the machine under a 50% load for approximately 15 minutes until the
coolant temperature exceeds 190°F.
6. Inspect the radiator cap and cap seal for damage. Clean the radiator cap or
replace if necessary.
This procedure continues on the next page.
170
wc_tx003614gb_FM10.fm
Mobile Generator
General Maintenance
Continued from the previous page.
7. Re-install the radiator cap.
NOTICE: Solutions of antifreeze and supplemental coolant additives MUST be
used year-round. Automotive-type coolants do not contain the correct coolant
additives to protect heavy-duty diesel engines. They often contain a high
concentation of silicates which can damage the engine and cooling system.
Important
Use a long-life ethylene glycol coolant in this engine. Refer to the engine owner’s
manual for more information.
wc_tx003614gb_FM10.fm
171
General Maintenance
Mobile Generator
16.12 Replacing the Aftertreatment DEF Dosing Unit Filter
When
Replace the aftertreatment Diesel Exhaust Fluid (DEF) dosing unit filter every 4500
hours or 3 years.
Requirements
■
■
■
■
■
■
Machine stopped
Replacement filter element
Strap wrench or filter wrench
Warm water
Clean cloth
Container of suitable size to collect residual DEF in filter housing
WARNING
Personal injury hazard. DEF contains urea. Do not get the substance in your eyes.
► In case of contact, immediately flush eyes with large amounts of water for a
minium of 15 minutes.
WARNING
The DEF line connecting the aftertreatment DEF dosing unit to the aftertreatment
DEF dosing valve is under low pressure and should not be disconnected while the
engine is running or before the system has completed the purge process after
engine shutdown. Disconnecting the DEF line while under low pressure could
cause DEF to spray.
► Do not disconnect the DEF line while under low pressure.
Procedure
Perform the procedure below to replace the aftertreatment DEF dosing unit filter.
Note: In the interests of the environment protection, place a container under the
filter cap to collect the residual DEF liquid that may be in the filter housing. Dispose
of the DEF in accordance with the environment protection legislation.
1. Remove the filter cap (a).
c
a
d
b
wc_gr012300
This procedure continues on the next page.
172
wc_tx003614gb_FM10.fm
Mobile Generator
General Maintenance
Continued from the previous page.
2. Remove the filter equalizing element (b).
3. Use the disposable filter tool (c) to aid in removing the filter element (d). Use the
appropriate end of the tool, depending on the color of the plastic on the filter.
Note: The disposable filter tool will make a “click” sound. This indicates that the
filter element is properly engaged.
4. Clean the filter cap and threads with warm water and a clean cloth.
Note: Inspect the filter cap for cracks or leaks. If the threads are damaged, replace
the filter cap.
Installation
1. Insert the equalizing element into the new filter.
2. Insert the filter assembly into the aftertreatment dosing unit.
3. Re-install the filter cap and torque it to 20 Nm (14.8 ft.lbs.).
Result
The aftertreatment DEF dosing unit filter has now been replaced.
wc_tx003614gb_FM10.fm
173
General Maintenance
Mobile Generator
16.13 Storage
Introduction
Extended storage of equipment requires preventive maintenance. Performing
these steps helps to preserve machine components and ensures the machine will
be ready for future use. While not all of these steps necessarily apply to this
machine, the basic procedures remain the same.
When
Prepare your machine for extended storage if it will not be operated for 30 days or
more.
Preparing for
storage
Follow the procedures below to prepare your machine for storage.
■ Complete any needed repairs.
■ Replenish or change oils (engine, exciter, hydraulic, and gearcase) per the
intervals specified in the Scheduled Maintenance table.
■ Grease all fittings and, if applicable, repack bearings.
■ Inspect engine coolant. Replace coolant if it appears cloudy, is more than two
seasons old, or does not meet the average lowest temperature for your area.
■ If your machine has an engine equipped with a fuel valve, start the engine, close
the fuel valve, and run the engine until it stops.
■ Consult the engine owner’s manual for instructions on preparing the engine for
storage.
Stabilizing the
fuel
After completing the procedures listed above, fill the fuel tank completely and add a
high-quality stabilizer to the fuel.
■ Choose a stabilizer that includes cleaning agents and additives designed to
coat/protect the cylinder walls.
■ Make sure the stabilizer you use is compatible with the fuel in your area, fuel
type, grade and temperature range. Do not add extra alcohol to fuels which
already contain it (for example, E10).
■ For engines with diesel fuel, use a stabilizer with a biocide to restrict or prevent
bacteria and fungus growth.
■ Add the correct amount of stabilizer per the manufacturer’s recommendations.
Storing the
machine
Perform these remaining steps to store your machine.
■ Wash the machine and allow it to dry.
■ Move the machine to a clean, dry, secure storage location. Block or chock
wheels to prevent machine movement.
■ Use touch-up paint as needed to protect exposed metal against rust.
■ If the machine has a battery, either remove or disconnect it.
NOTICE: Allowing the battery to freeze or completely discharge is likely to cause
permanent damage. Periodically charge the battery while the machine is not in
use. In cold climates, store and charge the battery indoors or in a warm location.
■ Cover the machine. Tires and other exposed rubber items should be protected
from the weather. Either cover them or use a readily available protectant.
174
wc_tx003614gb_FM10.fm
Mobile Generator
General Maintenance
16.14 Machine Disposal / Decommissioning
Introduction
This machine must be properly decommissioned at the end of its service life.
Responsible disposal of recyclable components, such as plastic and metal,
ensures that these materials can be reused—conserving landfill space and
valuable natural resources.
Responsible disposal also prevents toxic chemicals and materials from harming
the environment. The operating fluids in this machine, including fuel, engine oil,
and grease, may be considered hazardous waste in many areas. Before
decommissioning this machine, read and follow local safety and environmental
regulations pertaining to the disposal of construction equipment.
Preparation
Perform the following tasks to prepare the machine for disposal.
 Move the machine to a protected location where it will not pose any safety
hazards and cannot be accessed by unauthorized individuals.
 Ensure that the machine cannot be operated from the time of final shutdown to
disposal.
 Drain all fluids, including fuel, engine oil, and coolant.
 Seal any fluid leaks.
Disposal
Perform the following tasks to dispose of the machine.
 Disassemble the machine and separate all parts by material type.
 Dispose of recyclable parts as specified by local regulations.
 Dispose of all non-hazardous components that cannot be recycled.
 Dispose of waste fuel, oil, and grease in accordance with local environmental
protection regulations.
wc_tx003614gb_FM10.fm
175
Engine Maintenance: John Deere 4045TF285/HF285 6068HF285
17 Engine Maintenance: John Deere 4045TF285/HF285 6068HF285
The engine maintenance schedule(s) in this chapter are reproduced from the
engine owner’s manual. For additional information, see the engine owner’s
manual.
770050
NOTICE: The standard oil change interval on Wacker Neuson Mobile Generators
is 250 hours. To meet the 500-hour extended interval period listed above, certain
requirements must be met including: engine drain pan, diesel fuel, engine oil, and
fuel filter used. See the John Deere operator’s manual that came with your engine.
176
wc_tx003849gb_FM10.fm
Engine Maintenance: John Deere 4045TF285/HF285 6068HF285
The viscosity of the engine oil is an important factor when determining the correct
engine oil to use in your machine. Use an engine oil of appropriate viscosity based
on the expected outside air temperature. See the table below.
WARNING
Most used liquids from this machine such as oil, gasoline, grease, etc., contain
small amounts of materials that can cause cancer and other health problems if
inhaled, ingested, or left in contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.
770046
wc_tx003849gb_FM10.fm
177
Engine Maintenance: John Deere 4045TF285/HF285 6068HF285
770051
178
wc_tx003849gb_FM10.fm
Engine Maintenance: John Deere 4045TF285/HF285 6068HF285
770052
wc_tx003849gb_FM10.fm
179
Engine Maintenance: John Deere 4045TF285/HF285 6068HF285
770048
180
wc_tx003849gb_FM10.fm
Engine Maintenance: T4i Cummins QSB6.7
18 Engine Maintenance: T4i Cummins QSB6.7
The viscosity of the engine oil is an important factor when determining the correct
engine oil to use in your machine. Use an engine oil of appropriate viscosity based
on the expected outside air temperature. See the table below.
WARNING
Most used liquids from this machine such as oil, gasoline, grease, etc., contain
small amounts of materials that can cause cancer and other health problems if
inhaled, ingested, or left in contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.
wc_tx003663gb_FM10.fm
181
Engine Maintenance: T4i Cummins QSB6.7
Oil Viscosity
The primary Cummins Inc. recommendation is for the use of 15W-40 multigrade.
lubricating oil for normal operation at ambient temperatures above -15°C [5°F]. The use
of multigrade oil reduces deposit formation, improves engine cranking in low
temperature conditions, and increases engine durability by maintaining lubrication
during high temperature operating conditions. Since multigrade oils have been shown
to provide approximately 30 percent lower oil consumption than monograde oils, it is
important to use multigrade oils, to be certain the engine will meet applicable emissions
requirements.
Use of "synthetic engine oils" (those made with API group 3 or group 4 base stocks) is
permitted, subject to the same performance and viscosity limitations of petroleum
(mineral) based engine oils. The same oil change intervals that are applied to
petroleum (mineral) based engine oils must be applied to synthetic oils.
For further details and discussion of engine lubrication oils for Cummins® engines,
refer to the latest revision of Cummins® Engine Oil Recommendation, Bulletin
3810340.
While the preferred viscosity grade is 15W-40, lower viscosity multigrade oils can be
used in colder climates. See the accompanying chart. Any viscosity grade lower than
15W-40 must still meet CES 20081.
Synthetic engine oils, API Group III and Group IV basestocks, are recommended for
use in Cummins® engines operation in ambient temperature conditions consistently
below -25°C [-13°F]. Synthetic 0W-30 oils that meet the requirements of API Group III
or Group IV basestocks, can be used in operations where the ambient temperature
never exceeds 0°C [32°F]. Multi viscosity oils rated 0W-30 do not offer the same level
of protection against fuel dilution as do higher multigrade oils. Higher cylinder wear can
be experienced when using 0W-30 oils in high-load situations.
As these oils have directionally thinner oil films than 15W-40 oils, top-quality
Fleetguard® filters must be used above 20°C [70°F]. Some oil suppliers might claim
better fuel economy for these oils. Cummins Inc. can neither approve nor disapprove
any product not manufactured by Cummins Inc. These claims are between the
customer and the oil supplier. Obtain a commitment from the oil supplier that the oil will
give satisfactory performance in Cummins® engines, or do not use the oil.
770035
182
wc_tx003663gb_FM10.fm
Engine Maintenance: T4i Cummins QSB6.7
The engine maintenance schedule(s) in this chapter are reproduced from the
engine owner’s manual. For additional information, see the engine owner’s
manual.
770015
wc_tx003663gb_FM10.fm
183
Engine Maintenance: T4i Cummins QSB6.7
770016
184
wc_tx003663gb_FM10.fm
Engine Maintenance: T4F Cummins QSB7-G9
19 Engine Maintenance: T4F Cummins QSB7-G9
The viscosity of the engine oil is an important factor when determining the correct
engine oil to use in your machine. Use an engine oil of appropriate viscosity based
on the expected outside air temperature. See the table below.
WARNING
Most used liquids from this machine such as oil, gasoline, grease, etc., contain
small amounts of materials that can cause cancer and other health problems if
inhaled, ingested, or left in contact with skin for prolonged periods of time.
► Take steps to avoid inhaling or ingesting used liquids.
► Wash skin thoroughly after exposure to used liquids.
wc_tx003751gb_FM10.fm
185
Engine Maintenance: T4F Cummins QSB7-G9
Oil Viscosity
The primary Cummins Inc. recommendation is for the use of 15W-40 multigrade.
lubricating oil for normal operation at ambient temperatures above -15°C [5°F]. The use
of multigrade oil reduces deposit formation, improves engine cranking in low
temperature conditions, and increases engine durability by maintaining lubrication
during high temperature operating conditions. Since multigrade oils have been shown
to provide approximately 30 percent lower oil consumption than monograde oils, it is
important to use multigrade oils, to be certain the engine will meet applicable emissions
requirements.
Use of "synthetic engine oils" (those made with API group 3 or group 4 base stocks) is
permitted, subject to the same performance and viscosity limitations of petroleum
(mineral) based engine oils. The same oil change intervals that are applied to
petroleum (mineral) based engine oils must be applied to synthetic oils.
For further details and discussion of engine lubrication oils for Cummins® engines,
refer to the latest revision of Cummins® Engine Oil Recommendation, Bulletin
3810340.
While the preferred viscosity grade is 15W-40, lower viscosity multigrade oils can be
used in colder climates. See the accompanying chart. Any viscosity grade lower than
15W-40 must still meet CES 20081.
Synthetic engine oils, API Group III and Group IV basestocks, are recommended for
use in Cummins® engines operation in ambient temperature conditions consistently
below -25°C [-13°F]. Synthetic 0W-30 oils that meet the requirements of API Group III
or Group IV basestocks, can be used in operations where the ambient temperature
never exceeds 0°C [32°F]. Multi viscosity oils rated 0W-30 do not offer the same level
of protection against fuel dilution as do higher multigrade oils. Higher cylinder wear can
be experienced when using 0W-30 oils in high-load situations.
As these oils have directionally thinner oil films than 15W-40 oils, top-quality
Fleetguard® filters must be used above 20°C [70°F]. Some oil suppliers might claim
better fuel economy for these oils. Cummins Inc. can neither approve nor disapprove
any product not manufactured by Cummins Inc. These claims are between the
customer and the oil supplier. Obtain a commitment from the oil supplier that the oil will
give satisfactory performance in Cummins® engines, or do not use the oil.
770035
186
wc_tx003751gb_FM10.fm
Engine Maintenance: T4F Cummins QSB7-G9
The engine maintenance schedule(s) in this chapter are reproduced from the
engine owner’s manual. For additional information, see the engine owner’s
manual.
Maintenance Schedule
Perform maintenance at whichever interval occurs first. At each scheduled
maintenance interval, perform all previous maintenance checks that are due for
scheduled maintenance.
Maintenance Procedures at Daily Interval
•
•
•
•
•
•
•
•
•
•
Air Intake Piping - Check
Fan, Cooling - Inspect for Reuse
Crankcase Breather Tube - Check
Air Tanks and Reservoirs - Drain
Coolant Level - Check
Fuel-Water Separator - Drain
Lubricating Oil Level - Check
Aftertreatment Exhaust Piping - Check
Dust Ejection Valve - Check
Diesel Exhaust Fluid (DEF) Level - Check
Maintenance Procedures at 250 Hours or 3 Months
•
•
•
•
•
•
Air Cleaner Restriction - Check
Charge-Air Piping - Check
Charge-Air Cooler - Check
Radiator Hoses - Check
Air Intake Piping - Check
Radiator - Check
Maintenance Procedures at 500 Hours or 6 Months
• Fuel Filter (Spin-On Type) - Change
• Lubricating Oil and Filters - Change
6
1, 7
• Engine Coolant Antifreeze - Check 2
• Batteries - Check
4
4
• Battery Cables and Connections - Check
• Radiator Pressure Cap - Inspect for Reuse
Maintenance Procedures at 1000 Hours or 1 Year
• Drive Belt, Cooling Fan - Check
• Cooling Fan Belt Tensioner - Check
770036
wc_tx003751gb_FM10.fm
187
Engine Maintenance: T4F Cummins QSB7-G9
Maintenance Procedures at 2000 Hours
• Crankcase Ventilation Filter - Change
Maintenance Procedures at 2000 Hours or 2 Years
8
• Cooling System - Flush
• Vibration Damper, Rubber - Check
3
• Vibration Damper, Viscous - Check
• Air Compressor Discharge Lines - Maintenance Check
• Engine Steam Cleaning - Clean
Maintenance Procedures at 4500 Hours or 3 Years
• Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter - Change
Maintenance Procedures at 5000 Hours or 4 Years
• Overhead Set - Adjust
5
1. Cummins Inc. requires the use of a high quality, heavy duty engine oil. Use the
following procedure for lubrication oil and recommendations. Refer to Procedure
018-003 in Section V.
2. Service interval is every oil change or 500 hours, or 6 months, whichever occurs
first. Use the following procedure for coolant specifications and
recommendations. Refer to Procedure 018-004 in Section V. The change interval
is 2 years. Antifreeze is essential for freeze, overheat, and corrosion protection.
Supplemental coolant additive (SCA) is essential for liner pitting and scaling.
protection.
3. The service interval is 2 years.
4. Follow the manufacturers' recommended maintenance procedures for the starter.
alternator, batteries, electrical components, engine brake, exhaust brake,
charge-air cooler, radiator, air compressor, air cleaner, refrigerant compressor,
and fan clutch.
5. Reset valve lash, if needed, to nominal specifications. Refer to Procedure 018015 in Section V.
6. Replace the suction-side and the pressure-side fuel filters at the same time.
7. For standby generator sets, the recommended change interval is 250 hours or
every 12 months, whichever occurs first. For primary or continuous rated
generator sets the interval is 500 hours or every 12 months, whichever occurs
first.
8. This cooling system requirement to Flush at this scheduled maintenance
includes: Drain, Flush, and Fill.
Use the following procedure for fuel recommendations and specifications
information. Refer to Procedure 018-002 in Section V.
Maintain the correct oil and filter change intervals. It is a vital factor in preserving the
integrity of an engine. Filters must be changed when the oil is changed.
770037
188
wc_tx003751gb_FM10.fm
Mobile Generators
Troubleshooting
20 Troubleshooting
Problem
Cause
Remedy
Engine doesn’t start
Battery discharged
Battery connections
corroded
Blown fuse
Defective starter
Charge battery.
Clean battery connections.
No fuel
Clogged fuel filter
Fuel circuit failure
Fill tank with fuel.
Bleed fuel lines.
Replace fuel filter.
Check fuel lines.
No generator output
Main circuit breaker open
Lug door open
Close main circuit breaker.
Close lug door.
Low oil pressure
Low oil level
Clogged oil filter
Fill engine sump with oil.
Replace oil filter.
High coolant temperature
Overload
Low coolant level
Low oil level
Clogged oil filter
Reduce load.
Fill with coolant.
Fill sump with oil.
Replace oil filter.
Engine emits black smoke
Clogged air filter
Clean/replace air filter
cartridges.
Reduce load.
Remove excess oil.
Engine tries to start but
stops
Overload
High oil level
wc_tx001197gb_FM10.fm
189
Replace fuse.
Replace starter.
Technical Data — G 240
G 240
21 Technical Data — G 240
21.1
Engine
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 No.
G 240
Engine
Engine make
John Deere 6.8L
Engine model
6068HF485
Number of cylinders
6
Displacement
cm³ (in³)
Operating speed
rpm
Rated standby power
@ 1800 rpm
6800 (415)
1800
kW (Hp)
235 (315)
Coolant capacity
L (qt)
28.8 (30.4)
Oil capacity
L (qt)
32.5 (34.3)
Battery
V/ccA
12 / 950
Fuel type
Fuel tank capacity
Fuel consumption @ prime load
type
Clean, filtered #1 or
#2 diesel2
l (gal)
1430 (378)
l (gal)/hr
51.1 (13.5)
Run time at 100% prime load1
Hr
26.3
Run time at 75% prime load1
Hr
35.0
Run time at 50% prime load1
Hr
49.8
Run time at 25% prime load1
Hr
92.1
1
Run times are based on useable fuel volume, not on fuel tank capacity. “Useable fuel volume”
does not include fuel remaining in the tank after a low fuel shutdown.
See “Refueling the Machine” for more information.
2
The use of #6 diesel fuel is not recommended.
190
wc_td000424gb_FM10.fm
G 240
21.2
Technical Data — G 240
Generator
Item No.
G 240
Generator
Make/Type
Mecc Alte
Model
Generator speed
ECO38-3SN/4
rpm
1800
Voltage selector
AC voltages available
2 position reconnectable panel
1Ø (V)
3Ø (V)
120, 127, 139, 240, 254, 277
208, 220, 240, 416, 440, 480
Frequency
60 Hz
Power factor
1Ø
3Ø
1.0
0.8
Voltage regulation
±1.00%
Insulation class
Sound level at 7 m (23 ft.)
H
dB(A)
72
AC receptacles
21.3
2 duplex, 3 twist-lock
1Ø 120 GFI duplex
Amps
2-20A
1Ø 120/240 V twist lock
Amps
3–50A
Standby output
kW/kVA
210/262
Prime output
kW/kVA
191/238
Main breaker
Amps
700
Trailer and Skid
Item No.
G 240
Trailer
Dry weight of skid
kg (lb)
3044 (6714)
Operating weight of skid
kg (lb)
4351 (9594)
Trailer weight without generator
kg (lb)
641 (1414)
GVWR
kg (lb)
5455 (12,000)
Surge brakes
Fluid type
Tires
wc_td000424gb_FM10.fm
size
191
Dot 3
7.50 x 16E
Technical Data — G 240
21.4
G 240
Dimensions
G 240
0620661
5200001323
0602662
0620663
5200006904
3353 (132.0)
3353 (132.0)
b
1384 (54.5)
1384 (54.5)
c
1829 (72.0)
1918 (72.0)
d
2146 (84.5)
2146 (84.5)
e
2591 (102)
2591 (102)
f
5055 (199)
5055 (199)
Item Number
a
mm (in.)
a
c
e
f
b
d
192
wc_gr011550
wc_td000424gb_FM10.fm
G 230
Technical Data — G 230
22 Technical Data — G 230
22.1
Engine: G 230 T4f
Engine Power Rating
Net power rating per ISO 3046. Actual power output may vary due to conditions of
specific use.
Machine
G 230
Engine make
Cummins
Engine model
QSB7-G9
Number of cylinders
6
Displacement
cm³ (in³)
Operating speed
rpm
Rated standby power
@ 1800 rpm
6,700 (409)
1,800
kW (hp)
234 (314)
L (qt)
61.7 (65.2)
type
15W-40 multigrade, low ash
CES-20081 (API CJ-4/SL)
or equivalent
Oil capacity
L (qt)
17.5 (18.5)
Battery
V/ccA
2 x 12 / 1000
Coolant capacity
Engine oil
Fuel type
type
Fuel tank capacity
Fuel consumption @ prime load
Ultra-low sulfur fuel
Clean, filtered #1 or #2 diesel2
L (gal)
1,444 (381)
L (gal)/hr
51.1 (13.6)
Run time at 100% prime load1
hr
26.1
Run time at 75% prime load1
hr
33.9
Run time at 50% prime load1
hr
47.3
Run time at 25% prime load1
hr
75.1
DEF type
type
DEF tank capacity
DEF consumption @ prime load
DEF run time at 100% prime load3
1
AUS 32
L (gal)
37.4 (142)
L (gal)/hr
1.55 (0.54)
hours
65.9
Run times are based on useable fuel volume, not on fuel tank capacity. “Usable fuel volume”
does not include fuel remaining in the tank after a low fuel shutdown.
See “Refueling the Machine” for more information.
2
The use of #6 diesel fuel is not recommended.
3 Run times are based on useable DEF volume, not on DEF tank capacity.
wc_td000527gb_FM10.fm
193
Technical Data — G 230
22.2
G 230
Engine: G 230 T4i
Engine Power Rating
Net power rating per ISO 3046. Actual power output may vary due to conditions of
specific use.
Machine
G 230
Engine make
Cummins
Engine model
QSB7-G6
Number of cylinders
6
Displacement
cm³ (in³)
Operating speed
rpm
Rated standby power
@ 1800 rpm
6700 (409)
1800
kW (hp)
234 (314)
L (qt)
36 (38.5)
type
15W-40 multigrade, low ash
CES-20081 (API CJ-4/SL)
or equivalent
Oil capacity
L (qt)
17.5 (18.5)
Battery
V/ccA
24 / 950
Coolant capacity
Engine oil
Fuel type
type
Fuel tank capacity
Fuel consumption @ prime load
Ultra-low sulfur fuel
Clean, filtered #1 or
#2 diesel**
L (gal)
1430 (378)
L (gal)/hr
51.1 (13.5)
Run time at 100% prime load *
hr
25.7
Run time at 75% prime load *
hr
33.8
Run time at 50% prime load *
hr
49.3
Run time at 25% prime load *
hr
82.6
* Run times are based on useable fuel volume, not on fuel tank capacity. “Useable fuel volume”
does not include fuel remaining in the tank after a low fuel shutdown.
See “Refueling the Machine” for more information.
** The use of #6 diesel fuel is not recommended.
194
wc_td000527gb_FM10.fm
G 230
22.3
Technical Data — G 230
Generator
Item No.
G 230
Make/Type
Mecc Alte
Model
ECO38-3SN/4
Generator speed
rpm
Voltage selector
AC voltages available
1800
2-position reconnectable panel
1Ø (V)
3Ø (V)
Frequency
120, 127, 139, 240, 254, 277
208, 220, 240, 416, 440, 480
60 Hz
Power factor
1Ø
3Ø
Voltage regulation
1.0
0.8
±1.00%
Insulation class
H
Sound level at 7 m (23 ft.)
dB(A)
AC receptacles
72
2 duplex, 3 twist-lock
1Ø 120 GFI duplex
Amps
2-20A
1Ø 120/240 V twist lock
Amps
3–50A
Standby output
kW/kVA
202/253
Prime output
kW/kVA
184/230
Main breaker
Amps
wc_td000527gb_FM10.fm
195
700
Technical Data — G 230
22.4
G 230
Trailer and Skid
Machine
G 230
Dry weight of skid
kg (lb)
2856 (6340)
Operating weight of skid
kg (lb)
4163 (4220)
Trailer weight without generator
kg (lb)
641 (1414)
GVWR
kg (lb)
5455 (12,000)
Surge brakes
Fluid type
Tires
size
196
Dot 3
7.50 x 16E
wc_td000527gb_FM10.fm
G 230
22.5
Technical Data — G 230
Dimensions
G 230 T4i
G 230 T4f
0620881
5200007862
0602882
0620883
5200010141
5200010142
3353 (132.0)
3353 (132.0)
3353 (132.0)
3353 (132.0)
b
1321 (52.0)
1384 (54.5)
1321 (52.0)
1384 (54.5)
c
1893 (74.5)
1918 (72.0)
1943 (76.5)
1968 (77.5)
d
2146 (84.5)
2146 (84.5)
2146 (84.5)
2146 (84.5)
e
2655 (104.5)
2655 (104.5)
2705 (106.5)
2705 (106.5)
f
5055 (199)
5055 (199)
5055 (199)
5055 (199)
Machine
a
mm (in.)
a
c
e
f
b
d
wc_td000527gb_FM10.fm
197
wc_gr011550
Tire Safety Information
Tire Safety Information
Introduction to Tire Safety Information
Federal Regulation 49 CFR 575 requires trailer manufacturers to include certain
tire information in the owner’s manuals for the trailers they manufacture. This
regulation requires that the information be in the English language. This chapter
includes all the information required by Federal Regulation 49 CFR 575.
198
wc_tx003108gb_FM10.fm
Tire Safety Information
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ILOOHGSURSDQHFRQWDLQHUVLVFRQVLGHUHGSDUWRIWKHZHLJKWRIWKHWUDLOHUEHIRUHLWLVORDGHGZLWKFDUJRDQGLVQRWFRQVLGHUHG
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VRDVQRWWRRYHUORDGWKHYHKLFOH8QGHUVWDQGLQJWKLVIOH[LELOLW\ZLOODOORZ\RXWKHRZQHUWRPDNHFKRLFHVWKDWILW\RXU
WUDYHOQHHGV
:KHQORDGLQJ\RXUFDUJREHVXUHLWLVGLVWULEXWHGHYHQO\WRSUHYHQWRYHUORDGLQJIURQWWREDFNDQGVLGHWRVLGH+HDY\
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WLUH7KHEHVWZD\WRNQRZWKHDFWXDOZHLJKWRIWKHYHKLFOHLVWRZHLJKLWDWDSXEOLFVFDOH7DONWR\RXUGHDOHUWRGLVFXVV
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Tire Safety Information
Excessive loads and/or underinflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation
can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that
enables a tire to support the load, so proper inflation is critical. The proper air pressure may be found on the
certification/VIN label and/or on the Tire Placard. This value should never exceed the maximum cold inflation pressure
stamped on the tire.
1.1.1. TRAILERS 10,000 POUNDS GVWR OR LESS
Tire and Loading Information Placard – Figure 1-1
1. /RFDWHWKHVWDWHPHQW³7KHZHLJKWRIFDUJRVKRXOG QHYHUH[FHHG;;;NJRU;;;OEV´RQ\RXUYHKLFOH¶V
placard. See figure 1-1.
2. This figure equals the available amount of cargo and luggage load capacity.
3. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not
safely exceed the available cargo and luggage load capacity.
7KHWUDLOHU¶VSODFDUGUHIHUVWRWKH7LUH,QIRUPDWLRQ3ODFDUGattached DGMDFHQWWRRUQHDUWKHWUDLOHU¶V9,1
(Certification) label at the left front of the trailer.
1.1.2. TRAILERS OVER 10,000 POUNDS GVWR (NOTE: THESE TRAILERS ARE NOT REQUIRED TO HAVE A TIRE
INFORMATION PLACARD ON THE VEHICLE)
1. Determine the empty weight of your trailer by weighing the trailer using a public scale or other means.
This step does not have to be repeated.
2. Locate the *9:5*URVV9HKLFOH:HLJKW5DWLQJRIWKHWUDLOHURQ\RXUWUDLOHU¶V9,1&HUWLILFDWLRQODEHO
3. Subtract the empty weight of your trailer from the GVWR stated on the VIN label. That weight is the
maximum available cargo capacity of the trailer and may not be safely exceeded.
67(36)25 '(7(50,1,1*&255(&7/2$'/,0,7±72:9(+,&/(
1. /RFDWHWKHVWDWHPHQW³7KHFRPELQHGZHLJKWRIRFFXSDQWVDQGFDUJRVKRXOGQHYHUH[FHHG;;;OEV´RQ
\RXUYHKLFOH¶VSODFDUG
2. Determine the combined weight of the driver and passengers who will be riding in your vehicle.
3. Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds.
4. 7KHUHVXOWLQJILJXUHHTXDOVWKHDYDLODEOHDPRXQWRIFDUJRDQGOXJJDJHFDSDFLW\)RUH[DPSOHLIWKH³;;;´
amount equals 1400 lbs. and there will be five 150 lb. passengers in your vehicle, the amount of available
cargo and luggage capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).
5. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not
safely exceed the available cargo and luggage capacity calculated in Step # 4.
6. If your vehicle will be towing a trailer, load from your trailer will be transferred to your vehicle. Consult the
WRZYHKLFOH¶VPDQXDOWRGHWHUPLQHKRZWKLVZHLJKWWUDQVIHUUeduces the available cargo and luggage
capacity of your vehicle.
*/266$5< 2)7,5(7(50,12/2*<
$FFHVVRU\ZHLJKW
The combined weight (in excess of those standard items which may be replaced) of automatic transmission,
power steering, power brakes, power windows, power seats, radio and heater, to the extent that these items
are available as factory-installed equipment (whether installed or not).
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Bead
The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the
rim.
Bead separation
This is the breakdown of the bond between components in the bead.
Bias ply tire
A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less
than 90 degrees to the centerline of the tread.
Carcass
The tire structure, except tread and sidewall rubber which, when inflated, bears the load.
Chunking
The breaking away of pieces of the tread or sidewall.
Cold inflation pressure
The pressure in the tire before you drive.
Cord
The strands forming the plies in the tire.
Cord separation
The parting of cords from adjacent rubber compounds.
Cracking
Any parting within the tread, sidewall, or inner liner of the tire extending to cord material.
CT
A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges
pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the
rim flanges inside the air cavity of the tire.
Curb weight
The weight of a motor vehicle with standard equipment including the maximum capacity of fuel, oil, and
coolant, and, if so equipped, air conditioning and additional weight optional engine.
Extra load tire
A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard
tire.
Groove
The space between two adjacent tread ribs.
Gross Axle Weight Rating
The maximum weight that any axle can support, as published on the Certification / VIN label on the front left
side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached
to the towing vehicle.
Gross Vehicle Weight Rating
The maximum weight of the fully loaded trailer, as published on the Certification / VIN label. Actual weight
determined by weighing trailer on a public scale, without being attached to the towing vehicle.
Hitch Weight
The downward force exerted on the hitch ball by the trailer coupler.
Innerliner
The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire.
Innerliner separation
The parting of the innerliner from cord material in the carcass.
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Tire Safety Information
Intended outboard sidewall
The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name
molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing
sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a
vehicle.
Light truck (LT) tire
A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose
passenger vehicles.
Load rating
The maximum load that a tire is rated to carry for a given inflation pressure.
Maximum load rating
The load rating for a tire at the maximum permissible inflation pressure for that tire.
Maximum permissible inflation pressure
The maximum cold inflation pressure to which a tire may be inflated.
Maximum loaded vehicle weight
The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight.
Measuring rim
The rim on which a tire is fitted for physical dimension requirements.
Pin Weight
th
The downward force applied to the 5 wheel or gooseneck ball, by the trailer kingpin or gooseneck coupler.
Non-pneumatic rim
A mechanical device which, when a non-pneumatic tire assembly incorporates a wheel, supports the tire, and
attaches, either integrally or separably, to the wheel center member and upon which the tire is attached.
Non-pneumatic spare tire assembly
A non-pneumatic tire assembly intended for temporary use in place of one of the pneumatic tires and rims that
are fitted to a passenger car in compliance with the requirements of this standard.
Non-pneumatic tire
A mechanical device which transmits, either directly or through a wheel or wheel center member, the vertical
load and tractive forces from the roadway to the vehicle, generates the tractive forces that provide the
directional control of the vehicle and does not rely on the containment of any gas or fluid for providing those
functions.
Non-pneumatic tire assembly
A non-pneumatic tire, alone or in combination with a wheel or wheel center member, which can be mounted on
a vehicle.
Normal occupant weight
This means 68 kilograms (150 lbs.) times the number of occupants specified in the second column of Table I
of 49 CFR 571.110.
Occupant distribution
The distribution of occupants in a vehicle as specified in the third column of Table I of 49 CFR 571.110.
Open splice
Any parting at any junction of tread, sidewall, or innerliner that extends to cord material.
Outer diameter
The overall diameter of an inflated new tire.
Overall width
The linear distance between the exteriors of the sidewalls of an inflated tire, including elevations due to
labeling, decorations, or protective bands or ribs.
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Ply
A layer of rubber-coated parallel cords.
Ply separation
A parting of rubber compound between adjacent plies.
Pneumatic tire
A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an
automotive wheel, provides the traction and contains the gas or fluid that sustains the load.
Production options weight
The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in
excess of those standard items which they replace, not previously considered in curb weight or accessory
weight, including heavy duty brakes, ride levelers, roof rack, heavy duty battery, and special trim.
Radial ply tire
A pneumatic tire in which the ply cords that extend to the beads are laid at substantially 90 degrees to the
centerline of the tread.
Recommended inflation pressure
This is the inflation pressure provided by the vehicle manufacturer on the Tire Information label and on the
Certification / VIN tag.
Reinforced tire
A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard
tire.
Rim
A metal support for a tire or a tire and tube assembly upon which the tire beads are seated.
Rim diameter
This means the nominal diameter of the bead seat.
Rim size designation
This means the rim diameter and width.
Rim type designation
7KLVPHDQVWKHLQGXVWU\RIPDQXIDFWXUHU¶VGHVLJQDWLRQIRUDrim by style or code.
Rim width
This means the nominal distance between rim flanges.
Section width
The linear distance between the exteriors of the sidewalls of an inflated tire, excluding elevations due to
labeling, decoration, or protective bands.
Sidewall
That portion of a tire between the tread and bead.
Sidewall separation
The parting of the rubber compound from the cord material in the sidewall.
Special Trailer (ST) tire
The "ST" is an indication the tire is for trailer use only.
Test rim
The rim on which a tire is fitted for testing, and may be any rim listed as appropriate for use with that tire.
Tread
That portion of a tire that comes into contact with the road.
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Tire Safety Information
Tread rib
A tread section running circumferentially around a tire.
Tread separation
Pulling away of the tread from the tire carcass.
Treadwear indicators (TWI)
The projections within the principal grooves designed to give a visual indication of the degrees of wear of the
tread.
Vehicle capacity weight
The rated cargo aQGOXJJDJHORDGSOXVNLORJUDPVOEVWLPHVWKHYHKLFOH¶VGHVLJQDWHGVHDWLQJFDSDFLW\
Vehicle maximum load on the tire
The load on an individual tire that is determined by distributing to each axle its share of the maximum loaded
vehicle weight and dividing by two.
Vehicle normal load on the tire
The load on an individual tire that is determined by distributing to each axle its share of the curb weight,
accessory weight, and normal occupant weight (distributed in accordance with Table I of CRF 49 571.110) and
dividing by 2.
Weather side
The surface area of the rim not covered by the inflated tire.
Wheel center member
In the case of a non-pneumatic tire assembly incorporating a wheel, a mechanical device which attaches,
either integrally or separably, to the non-pneumatic rim and provides the connection between the nonpneumatic rim and the vehicle; or, in the case of a non-pneumatic tire assembly not incorporating a wheel, a
mechanical device which attaches, either integrally or separably, to the non-pneumatic tire and provides the
connection between tire and the vehicle.
Wheel-holding fixture
The fixture used to hold the wheel and tire assembly securely during testing.
1.4. TIRE SAFETY - EVERYTHING RIDES ON IT
The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that
discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It
can be obtained and downloaded from NHTSA, free of charge, from the following web site:
http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.html
Studies of tire safety show that maintaining proper tire pressure, observing tire and vehicle load limits (not
carrying more weight in your vehicle than your tires or vehicle can safely handle), avoiding road hazards, and
inspecting tires for cuts, slashes, and other irregularities are the most important things you can do to avoid tire
failure, such as tread separation or blowout and flat tires. These actions, along with other care and
maintenance activities, can also:
Improve vehicle handling
Help protect you and others from avoidable breakdowns and accidents
Improve fuel economy
Increase the life of your tires.
This booklet presents a comprehensive overview of tire safety, including information on the following topics:
Basic tire maintenance
Uniform Tire Quality Grading System
Fundamental characteristics of tires
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Tire Safety Information
Tire safety tips.
Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the
time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire
failure.
6$)(7<),567±%$6,&7,5(0 $,17(1$1&(
Properly maintained tires improve the steering, stopping, traction, and load-carrying capability of your vehicle.
Underinflated tires and overloaded vehicles are a major cause of tire failure. Therefore, as mentioned above,
to avoid flat tires and other types of tire failure, you should maintain proper tire pressure, observe tire and
vehicle load limits, avoid road hazards, and regularly inspect your tires.
1.5.1. FINDING YOUR VEHICLE 'S RECOMMENDED TIRE PRESSURE AND L OAD LIMITS
Tire information placards and vehicle certification labels contain information on tires and load limits. These
labels indicate the vehicle manufacturer's information including:
Recommended tire size
Recommended tire inflation pressure
Vehicle capacity weight (VCW±the maximum occupant and cargo weight a vehicle is designed to carry)
Front and rear gross axle weight ratings (GAWR± the maximum weight the axle systems are designed to
carry).
Both placards and certification labels are permanently attached to the trailer near the left front.
1.5.2. UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS
Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the
overall performance of the vehicle. The tire inflation pressure is a number that indicates the amount of air
pressure± measured in pounds per square inch (psi)±a tire requires to be properly inflated. (You will also find
this number on the vehicle information placard expressed in kilopascals (kpa), which is the metric measure
used internationally.)
Manufacturers of passenger vehicles and light trucks determine this number based on the vehicle's design
load limit, that is, the greatest amount of weight a vehicle can safely carry and the vehicle's tire size. The
proper tire pressure for your vehicle is referred to as the "recommended cold inflation pressure." (As you will
read below, it is difficult to obtain the recommended tire pressure if your tires are not cold.)
Because tires are designed to be used on more than one type of vehicle, tire manufacturers list the "maximum
permissible inflation pressure" on the tire sidewall. This number is the greatest amount of air pressure that
should ever be put in the tire under normal driving conditions.
1.5.3. CHECKING TIRE PRESSURE
It is important to check your vehicle's tire pressure at least once a month for the following reasons:
Most tires may naturally lose air over time.
Tires can lose air suddenly if you drive over a pothole or other object or if you strike the curb when
parking.
With radial tires, it is usually not possible to determine underinflation by visual inspection.
For convenience, purchase a tire pressure gauge to keep in your vehicle. Gauges can be purchased at tire
dealerships, auto supply stores, and other retail outlets.
The recommended tire inflation pressure that vehicle manufacturers provide reflects the proper psi when a tire
is cold. The term cold does not relate to the outside temperature. Rather, a cold tire is one that has not been
driven on for at least three hours. When you drive, your tires get warmer, causing the air pressure within them
to increase. Therefore, to get an accurate tire pressure reading, you must measure tire pressure when the tires
are cold or compensate for the extra pressure in warm tires.
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Tire Safety Information
1.5.4. STEPS FOR MAINTAINING PROPER TIRE PRESSURE
Step 1: Locate the recommended tire pressure on the vehicle's tire information placard, certification
label, or in the owner's manual.
Step 2: Record the tire pressure of all tires.
Step 3: If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the
tire valve stem with the edge of your tire gauge until you get to the correct pressure.
Step 4: If the tire pressure is too low, note the difference between the measured tire pressure and the
correct tire pressure. These "missing" pounds of pressure are what you will need to add.
Step 5: At a service station, add the missing pounds of air pressure to each tire that is underinflated.
Step 6: Check all the tires to make sure they have the same air pressure (except in cases in which the
front and rear tires are supposed to have different amounts of pressure).
If you have been driving your vehicle and think that a tire is underinflated, fill it to the recommended cold
inflation pressure indicated on your vehicle's tire information placard or certification label. While your tire may
still be slightly underinflated due to the extra pounds of pressure in the warm tire, it is safer to drive with air
pressure that is slightly lower than the vehicle manufacturer's recommended cold inflation pressure than to
drive with a significantly underinflated tire. Since this is a temporary fix, don't forget to recheck and adjust the
tire's pressure when you can obtain a cold reading.
1.5.5. TIRE SIZE
To maintain tire safety, purchase new tires that are the same size as the vehicle's original tires or another size
recommended by the manufacturer. Look at the tire information placard, the owner's manual, or the sidewall of
the tire you are replacing to find this information. If you have any doubt about the correct size to choose,
consult with the tire dealer.
1.5.6. TIRE TREAD
The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding,
especially when the road is wet or icy. In general, tires are not safe and should be replaced when the tread is
worn down to 1/16 of an inch. Tires have built-in treadwear indicators that let you know when it is time to
replace your tires. These indicators are raised sections spaced intermittently in the bottom of the tread
grooves. When they appear "even" with the outside of the tread, it is time to replace your tires. Another method
for checking tread depth is to place a penny in the tread with Lincoln's head upside down and facing you. If
you can see the top of Lincoln's head, you are ready for new tires.
1.5.7. TIRE BALANCE AND WHEEL ALIGNMENT
To avoid vibration or shaking of the vehicle when a tire rotates, the tire must be properly balanced. This
balance is achieved by positioning weights on the wheel to counterbalance heavy spots on the wheel-and-tire
assembly. A wheel alignment adjusts the angles of the wheels so that they are positioned correctly relative to
the vehicle's frame. This adjustment maximizes the life of your tires. These adjustments require special
equipment and should be performed by a qualified technician.
1.5.8. TIRE REPAIR
The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that
surrounds the puncture hole. Punctures through the tread can be repaired if they are not too large, but
punctures to the sidewall should not be repaired. Tires must be removed from the rim to be properly inspected
before being plugged and patched.
1.5.9. TIRE FUNDAMENTALS
Federal law requires tire manufacturers to place standardized information on the sidewall of all tires. This
information identifies and describes the fundamental characteristics of the tire and also provides a tire
identification number for safety standard certification and in case of a recall.
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Tire Safety Information
1.5.9.1. Information on Passenger Vehicle Tires
Please refer to the diagram below.
P
The "P" indicates the tire is for passenger vehicles.
Next number
This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In
general, the larger the number, the wider the tire.
Next number
This two-digit number, known as the aspect ratio, gives the tire's ratio of height to width. Numbers of 70 or
lower indicate a short sidewall for improved steering response and better overall handling on dry pavement.
R
The "R" stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years.
Next number
This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to
purchase new tires to match the new wheel diameter.
Next number
This two- or three-digit number is the tire's load index. It is a measurement of how much weight each tire can
support. You may find this information in your owner's manual. If not, contact a local tire dealer. Note: You may
not find this information on all tires because it is not required by law.
M+S
The "M+S" or "M/S" indicates that the tire has some mud and snow capability. Most radial tires have these
markings; hence, they have some mud and snow capability.
Speed Rating
The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time. The
ratings range from 99 miles per hour (mph) to 186 mph. These ratings are listed below. Note: You may not find
this information on all tires because it is not required by law.
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Tire Safety Information
Tire Safety Information
Letter Rating
Q
R
S
T
U
H
V
W
Y
Speed Rating
99 mph
106 mph
112 mph
118 mph
124 mph
130 mph
149 mph
168* mph
186* mph
* For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use the letters ZR.
For those with a maximum speed capability over 186 mph, tire manufacturers always use the letters ZR.
U.S. DOT Tire Identification Number
This begins with the letters "DOT" and indicates that the tire meets all federal standards. The next two
numbers or letters are the plant code where it was manufactured, and the last four numbers represent the
week and year the tire was built. For example, the numbers 3197 means the 31st week of 1997. The other
numbers are marketing codes used at the manufacturer's discretion. This information is used to contact
consumers if a tire defect requires a recall.
Tire Ply Composition and Materials Used
The number of plies indicates the number of layers of rubber-coated fabric in the tire. In general, the greater
the number of plies, the more weight a tire can support. Tire manufacturers also must indicate the materials in
the tire, which include steel, nylon, polyester, and others.
Maximum Load Rating
This number indicates the maximum load in kilograms and pounds that can be carried by the tire.
Maximum Permissible Inflation Pressure
This number is the greatest amount of air pressure that should ever be put in the tire under normal driving
conditions.
1.5.9.2. UTQGS Information
Treadwear Number
This number indicates the tire's wear rate. The higher the treadwear number is, the longer it should take for the
tread to wear down. For example, a tire graded 400 should last twice as long as a tire graded 200.
Traction Letter
This letter indicates a tire's ability to stop on wet pavement. A higher graded tire should allow you to stop your
car on wet roads in a shorter distance than a tire with a lower grade. Traction is graded from highest to lowest
as "AA","A", "B", and "C".
Temperature Letter
This letter indicates a tire's resistance to heat. The temperature grade is for a tire that is inflated properly and
not overloaded. Excessive speed, underinflation or excessive loading, either separately or in combination, can
cause heat build-up and possible tire failure. From highest to lowest, a tire's resistance to heat is graded as
"A", "B", or "C".
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Tire Safety Information
1.5.9.3. Additional Information on Light Truck Tires
Please refer to the following diagram.
Tires for light trucks have other markings besides those found on the sidewalls of passenger tires.
LT
The "LT" indicates the tire is for light trucks or trailers.
ST
An "ST" is an indication the tire is for trailer use only.
Max. Load Dual kg (lbs) at kPa (psi) Cold
This information indicates the maximum load and tire pressure when the tire is used as a dual, that is,
when four tires are put on each rear axle (a total of six or more tires on the vehicle).
Max. Load Single kg (lbs) at kPa (psi) Cold
This information indicates the maximum load and tire pressure when the tire is used as a single.
Load Range
This information identifies the tire's load-carrying capabilities and its inflation limits.
1.6. TIRE SAFETY TIPS
Preventing Tire Damage
Slow down if you have to go over a pothole or other object in the road.
Do not run over curbs or other foreign objects in the roadway, and try not to strike the curb when
parking.
Tire Safety Checklist
Check tire pressure regularly (at least once a month), including the spare.
Inspect tires for uneven wear patterns on the tread, cracks, foreign objects, or other signs of wear or
trauma.
Remove bits of glass and foreign objects wedged in the tread.
Make sure your tire valves have valve caps.
Check tire pressure before going on a long trip.
Do not overload your vehicle. Check the Tire Information and Loading Placard or 8VHU¶V0DQXDO for the
maximum recommended load for the vehicle.
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209
User’s Information for Transport Canada Fuel Tank
23 User’s Information for Transport Canada Fuel Tank
Note: The following information applies ONLY to machines equipped with a
Transport Canada fuel tank. This type of fuel tank is required for machines
transported on Canadian roads. Contact your Wacker Neuson dealer if you are
unsure about whether or not your machine is approved for use in Canada.
Description
The fuel tank, or Intermediate Bulk Container (IBC), on this machine was designed
for the storage and transportation of diesel fuel when mounted on a mobile electric
power source as a sub-base tank.
The fuel tank was manufactured using ductile steel which meets or exceeds United
Nations specifications (eg. CGSB 43-146-2002 in Canada). It has been tested and
certified as UN Standard Mobile IBC, 31A/Y Packing Group II and III. This is an
international standard recognized by the Canadian Transportation of Dangerous
Goods Act (TDG), and it applies to tanks either made in Canada or imported (TDG
Regs. 5.6(b)).
The fuel tank is equipped with a pressure / vacuum relief venting device set to 2 psi
(14 kPa) pressure and 0.25 psi (1.75 kPa) vacuum.
General
requirements
■ Do not fill above 95% maximum capacity of the fuel tank.
■ All valves and plugs must be closed while the machine is being transported.
Placarding
requirements
Immediately after the fuel tank is filled (fully or partially) with flammable liquids, UN
Placards / Transport of Dangerous Goods Decals / Placards of Flammable Liquids
(Transport Canada - Product Identification Decals) must be installed prior to
moving the machine in any manner. This is a requirement of Transport Canada.
Refer to “Hazardous Materials Placards” in the Operation chapter for instructions
on how to install the placards.
Maintaining
the fuel tank
■ The fuel tank must not be lifted or moved with any fuel inside. Drain the fuel tank
completely and remove external hardware before relocating the tank for
inspection or maintenance.
■ Do not drill into, or weld anything onto, the fuel tank.
■ Inspect the exterior paint annually for chips or scratches. Repair any damage
using compatible paint.
■ Replacement of damaged components or parts must be of the same
specification or equivalent. Replacement parts can be obtained directly from
Wacker Neuson or from an authorized Wacker Neuson service center.
Compulsory
inspections
Transport of Dangerous Goods / Transport Canada regulations require the fuel
tank to be leak tested and inspected every 5 years (60 months) at a certified facility.
A list of testing facilities in Canada certified to perform leak tests and inspections
can be found at the Transport Canada website:
http://www.tc.gc.ca/tdg/containers/ibc_leak/ibcleak.asp
The following pages contain forms for you to record tank inspection and testing
results. Copy the pages as needed.
210
wc_tx003111gb_FM10.fm
User’s Information for Transport Canada Fuel Tank
wc_tx003111gb_FM10.fm
211
User’s Information for Transport Canada Fuel Tank
212
wc_tx003111gb_FM10.fm
Emission Control Systems Information and Warranty—Diesel
24 Emission Control Systems Information and Warranty—Diesel
The Emission Control Warranty and associated information is valid only for the
U.S.A., its territories, and Canada.
24.1
Emission Control System Background Information
Introduction
Wacker Neuson engines/equipment must conform with applicable Environmental
Protection Agency (EPA) and California Air Resource Board (CARB) emissions
regulations. These regulations require that manufacturers warrant the emission
control systems for defects in materials and workmanship.
Furthermore, EPA and CARB regulations require all manufacturers to furnish
written instructions describing how to operate and maintain the engines/equipment
including the emission control systems. This information is provided with all
Wacker Neuson engines/equipment at the time of purchase.
Exhaust Emissions
The combustion process produces carbon monoxide, oxides of nitrogen, and
hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important
because, under certain conditions, they react to form photochemical smog when
subjected to sunlight. Carbon monoxide does not react in the same way, but it is
toxic.
Problems that may affect Emissions
If any of the following symptoms arise, have the engine/equipment inspected and
repaired by a Wacker Neuson dealer/service center.
 Hard starting or stalling after starting
 Rough idling
 Misfiring or backfiring under load
 Afterburning (backfiring)
 Presence of black exhaust smoke during operation
 High fuel consumption
Tampering and Altering
Tampering with or altering the emission control system may increase emissions
beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny
a warranty claim. Among those acts that constitute tampering are:
 Removing or altering of any part of the air intake, fuel, or exhaust systems.
 Altering or defeating the speed-adjusting mechanism causing the engine to
operate outside its design parameters.
wc_tx003113gb_FM10.fm
213
Emission Control Systems Information and Warranty—Diesel
24.2
Limited Defect Warranty for Exhaust Emission Control System
See the supplied engine owner’s manual for the applicable emission warranty
statement.
24.3
Limited Defect Warranty for Wacker Neuson Emission Control
Systems
The Emission Control Warranty is valid only for the U.S.A., its territories, and
Canada.
Wacker Neuson Sales Americas, LLC, N92 W15000 Anthony Avenue,
Menomonee Falls, WI 53051, (hereinafter “Wacker Neuson”) warrants to the initial
retail purchaser and each subsequent owner, that this engine/equipment, including
all parts of its emission control system, have been designed, built, and equipped to
conform at the time of initial sale to all applicable evaporative emission regulations
of the U.S. Environmental Protection Agency (EPA) and the California Air
Resources Board (CARB), and that the engine/equipment is free of defects in
materials and workmanship which would cause this engine/equipment to fail to
conform to EPA regulations during its warranty period.
Wacker Neuson is also liable for damages to other engine/equipment components
caused by a failure of any warranted parts during the warranty period.
Limited Defect Warranty Period for Wacker Neuson Emission Control
Systems
The warranty period for this engine/equipment begins on the date of sale to the
initial purchaser and continues for a period of five years or 3000 hours of operation
(whichever comes first). For the warranty terms for your specific engine/equipment,
visit wackerneuson.com.
Any implied warranties are limited to the duration of this written warranty.
What is covered
Wacker Neuson recommends the use of genuine Wacker Neuson parts, or the
equivalent, whenever maintenance is performed. The use of replacement parts not
equivalent to the original parts may impair the effectiveness of the engine/
equipment emission controls systems. If such a replacement part is used in the
repair or maintenance of the engine/equipment, assure yourself that such part is
warranted by its manufacturer to be equivalent to the parts offered by Wacker
Neuson in performance and durability. Furthermore, if such a replacement part is
used in the repair or maintenance of the engine/equipment, and an authorized
Wacker Neuson dealer/service center determines it is defective or causes a failure
of a warranted part, the claim for repair of the engine/equipment may be denied. If
the part in question is not related to the reason the engine/equipment requires
repair, the claim will not be denied.
214
wc_tx003113gb_FM10.fm
Emission Control Systems Information and Warranty—Diesel
For the components listed in the following table, an authorized Wacker Neuson
dealer/service center will, at no cost to you, make the necessary diagnosis, repair,
or replacement necessary to ensure that the engine/equipment complies with the
applicable EPA regulations. All defective parts replaced under this warranty
become property of Wacker Neuson.
System Covered
Components
Air handling system and associated
plumbing
Charge air cooler
Exhaust system (upstream of last
aftertreatment
Exhaust gas piping from turbocharger out
to the last aftertreatment device
Charge air cooler plumbing
What is not covered






Failures other than those resulting from defects in material or workmanship.
Any systems or parts which are affected or damaged by owner abuse,
tampering, neglect, improper maintenance, misuse, improper fueling,
improper storage, accident and/or collision; the incorporation of, or any use
of, add-on or modified parts, or unsuitable attachments, or the alteration of
any part.
Replacement of expendable maintenance items made in connection with
required maintenance services after the item’s first scheduled replacement
as listed in the maintenance section of the engine/equipment operator’s
manual, such as spark plugs and filters.
Incidental or consequential damages such as loss of time or the use of the
engine/equipment, or any commercial loss due to the failure of the engine/
equipment.
Diagnosis and inspection charges that do not result in warranty-eligible
service being performed.
Any non-authorized replacement part, or malfunction of authorized parts due
to use of-non authorized parts.
Owner’s Warranty Responsibility
The engine/equipment owner, is responsible for the performance of the required
maintenance listed in the Wacker Neuson engine/equipment operator’s manual.
Wacker Neuson recommends that all receipts covering maintenance on the
engine/equipment be retained, but Wacker Neuson cannot deny warranty
coverage solely for the lack of receipts or for the failure to ensure the performance
of all scheduled maintenance.
Normal maintenance, replacement, or repair of emission control devices and
systems may be performed by any repair establishment or individual; however,
warranty repairs must be performed by an authorized Wacker Neuson dealer/
service center.
The engine/equipment must be presented to an authorized Wacker Neuson dealer/
service center as soon as a problem exists. Contact Wacker Neuson Product
Support Department (1-800-770-0957) or visit wackerneuson.com to find a dealer/
service center in your area, or to answer questions regarding warranty rights and
responsibilities.
wc_tx003113gb_FM10.fm
215
Emission Control Systems Information and Warranty—Diesel
How to Make a Claim
In the event that any emission-related part is found to be defective during the
warranty period, you shall notify Wacker Neuson Product Support Department
(1-800-770-0957, or [email protected], or
wackerneuson.com), and you will be advised of the appropriate dealer/service
center where warranty repair can be performed. All repairs qualifying under this
limited warranty must be performed by an authorized Wacker Neuson dealer/
service center.
You must take your Wacker Neuson engine/equipment along with proof of original
purchase date, at your expense, to the authorized Wacker Neuson dealer/service
center during their normal business hours.
For owners located more than 100 miles from an authorized dealer/service center
(excluding the states with high-altitude areas as identified in 40 CFR Part 1068,
Appendix III), Wacker Neuson will pay for pre-approved shipping costs to and from
an authorized Wacker Neuson dealer/service center.
Claims for repair or adjustment found to be caused solely by defects in material or
workmanship will not be denied because the engine/equipment was not properly
maintained and used.
The warranty repairs should be completed in a reasonable amount of time, not to
exceed 30 days.
216
wc_tx003113gb_FM10.fm
Mobile Generator
General Machine Schematics
25 General Machine Schematics
25.1
Fuses
G 25 T4i Isuzu, Basler
#1
G 25 T4f Isuzu, Basler
10A
10A ECM start
#1
#2
10A
10A Fuel pump
#2
#3
10A
10A Fuel solenoid
#3
#4
7.5A
7.5A ECM/switch
#4
#1
10A ECM start
10A
#2
1A Coolant sensor
1A
N/A
7.5A ECM/switch
7.5A
#3
G 150, T3 John Deere, Basler
G 180, T3 John Deere, Basler
#4
7.5A
7.5A ECM/switch
wc_gr011774
#1
G 50, T4i John Deere, Basler
G 50, T4i John Deere, Deep Sea
G 50, T4f Isuzu, Basler
G 70, T3 John Deere, Basler
G 70, T3 John Deere, Deep Sea
10A
10A ECM start
#2
7.5A
7.5A ECM/switch
#3
G 150, T3 John Deere, Deep Sea
G 180, T3 John Deere, Deep Sea
#4
#3
#4
7.5A
7.5A ECM/switch
G 70, T4i Cummins, Basler
10A
#2
1A
10A ECM start
7.5A
7.5A ECM/switch
G 150, T4i Cummins, Basler
G 180, T4i Cummins, Basler
#1
#5
20A
1A Coolant sensor #6
#3
#4
10A ECM start
#2
#1
#1
10A
10A
G 230, T4i Cummins, Basler
10A ECM start
#5
20A
20A Engine ECU
#2
#6
20A Engine ECU
#3
#7
1A
1A Engine diagnostics
N/A
#4
#8
5A
5A Keyswitch
#7
1A
1A Engine diagnostics
#8
5A
5A Keyswitch
7.5A
7.5A ECM/switch
N/A
wc_gr011870
G 230, T4f Cummins, Basler
G 70, Tier 4i Cummins, Deep Sea
#1
#1
10A
10A ECM start
#5
20A
30A
30A Engine ECU
10A Engine diagnostics
#6
10A
N/A
#3
#7
5A
#4
#8
5A
#3
#7
1A
1A Engine diagnostics
#8
5A
5A Keyswitch
7.5A ECM/switch
#5
#2
#6
7.5A
10A ECM start
20A Engine ECU
#2
#4
10A
7.5A
7.5A ECM/switch
5A Keyswitch
(ON/OFF switch)
5A Fuse/relay box
at connector 6
wc_gr012013
wc_gr011826
wc_tx003652gb_FM10.fm
217
General Machine Schematics
25.2
Mobile Generator
Trailer Wiring
Standard and Hydraulic Brakes
Electric Brakes
1
B r
9
B r
W
W
G
W
B r
1
9
Br W
Br W
6
W
R
R
3
W
G
3
7
B r
Y
B r
7
B r
5
6
W
R
G
Y
Br
W
G
Br
W
+
Br
7
Br
7
–
4
R
2
Y
B r
W
1 0
B r
B r
W
W
R
R
R
8
W
5
Y
Br
W
Br W
Br W
2
w c _ g r0 0 0 5 2 2
218
8
10
wc_gr000523
Mobile Generator
25.3
General Machine Schematics
Trailer Wiring Components
Ref.
Ref.
wc_tx003652gb_FM10.fm
Description
1
Front right side amber light
2
Front left side amber light
3
Trailer plug
4
Battery
5
Brake solenoid
6
Right tail light
7
License plate holder lights
8
Left tail light
9
Rear right side red light
10
Rear left side red light
Wire Colors
Rear Lights
Side Lights
Harness
B
BLACK
Ground
Ground
Battery charge
Br
BROWN
Tail light
L
BLUE
R
RED
Y
YELLOW
Left brake light and directional
G
GREEN
Right brake light and directional
W
WHITE
Ground
Tail, side and license plate
Brake light
Power
219
Electric brakes
Schematics, Machines with Basler Controller
G 230 / G 240
26 Schematics, Machines with Basler Controller
26.1
AC Schematic: G 230/G 240
25
7
17
8
8
23
22
6
9
9
12
14
5
24
15
16
13
21
10
20
10
20
10
20
11
4
3
1
CT
6
CT
6
CT
7
CT
7
CT
7
CT
7
3
WHT
WH
T
3
BR
3
YE
CT-CT
36
CT-CT
19
36A
36
A
3
OR
CT-CT
18
2
wc_gr011988
220
wc_tx003749gb_FM10.fm
G 230 / G 240
26.2
Schematics, Machines with Basler Controller
AC Schematic Components: G 230/G 240
Ref.
Description
Ref.
Description
1
Genset controller
14
Exciter
2
Plug 4—line voltage inputs
15
Rectifier
3
Plug 3—current transformer
inputs
16
Rotor main field
4
Voltage selector switch
17
Generator (alternator)
5
Main breaker
18
Stator auxiliary winding
6
Lug safety limit switch
19
Stator main windings
7
Mechanical lugs
20
Receptacle, 240V 50A
8
GFI receptacle, 120V
21
Exciter rotor windings
9
Circuit breaker, 120V 20A
22
Rotor
10
Circuit breaker, 240V 50A
23
Bond bar
11
Voltage adjusting rheostat
24
Shunt
12
Voltage regulator
25
Machine and components
13
Stator
—
—
Wire Colors
wc_tx003749gb_FM10.fm
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
221
Schematics, Machines with Basler Controller
DC Schematic: G 240 John Deere Tier 3
12
RED
10AWG
3
BLK
GROUND 1
59
BAT -
2
80
BLK
BAT+
3
53
RED
22
14
GRY
8
13
65
8
8
FUEL LEVEL 9
62
RELAY
62
WHT/VIO
BLK
3
11
90
BLK
23
12
13
14
90
SENDER COM 11
BLK
81
52
82
RED
10AWG
53 RED
RED
49
59
17
BLK
BLK
RED
10AWG
83 82
8
WHT/BLU
56
START DELAY 23
(PRE-HEAT)
50
92
84
REMOTE START 28
MODE
83
RUN MODE 29
84
GRN/YEL
85
BLU
BREAKER 30
TRIPPED
GRN
49
5
BLK
14
56
95
15
RED
START
63
YEL
63
92
RED
94
VIO
64
VIO
51
RED
6
91
18 95 51
31
ORG
RED
96
98
B
B
U
U
V
V
YEL
ORG
25
BLK
RED
4 AWG
ORG
RED
10AWG
RED
2/0 AWG
B+
RED
WHT
RED
BLK
BLK
2/0 AWG
27
BLK
30
-
RED
29
9 F
G 12 G
34
VIO
61
A 13 A
J 11 J
D 10 D
F
20 2
PRE
HEAT
34
50
11
RED
18
FUEL
28
26
7.5A
FUSE
94
1
24
60
REMOTE START 27
2
80
BLK
2/0 AWG
GROUND TO
ENGINE BLOCK
60
ORG
GRY
16
4
E-STOP 46
61
E-STOP 47
93
RED
NC
93
64
67
15
GRN
NO
RED
NC
46
97
120 OHM
ORG
2
44
GRY
GRN/YEL
GRN
CAN L 48
21
68
CAN H 49
YEL
SHIELD 50
SHIELD
REMOTE ANNUNCIATOR
COMMON 51
73
TAN/WHT
ALARM 52
75
TAN
PREALARM 53
74
TAN
MECHANICAL LUGS
BLU
20
96
RED
TRIP BREAKER 56
86
BLU
L2
BOND BAR
L3
L0
GRD
46
47
ORN
97
BAT+ 55
L1
ORG
44
85
45
YEL
45
7
32
8
86
99
BLK
8
8
NOT
USED ON
YEL
YEL
3
20
19
98
SHU
26.3
G 230 / G 240
WHT
RED
BLK
WHT
47
222
wc_gr011989
wc_tx003749gb_FM10.fm
G 230 / G 240
26.4
Schematics, Machines with Basler Controller
DC Schematic Components: G 240 Tier 3
Ref.
Description
Ref.
Description
1
Electronic control board
17
Toggle switch
2
Engine outputs
18
10A fuse
3
Engine sensor inputs
19
Main breaker
4
Emergency stop, canbus, and
contact outputs
20
Lug door safety switch
5
Fuses
21
Mechanical lugs
6
Hour meter
22
Relay (if equipped)
7
Shunt trip relay
23
Intake heater (if equipped)
8
Contact inputs
24
Starter relay
9
21 position connector
25
Starter
10
Start relay
26
Alternator
11
Alternator / charge
27
12V battery
12
B+ switched
28
Battery disconnect switch
13
Crank delay
29
John Deere engine ECU
14
Fuel level
30
Engine harness
15
Remote start
31
Terminal block
16
Emergency stop switch
32
Resistor (if equipped)
Wire Colors
wc_tx003749gb_FM10.fm
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
223
Schematics, Machines with Basler Controller
DC Schematic: G230 Cummins T4i
BLK
RED
12 AWG
RED
VIO
BAT -
2
80
BLK
BLK
BLK
BAT+
3
56
RED
GROUND 1
59
121
24
36
81
BLK
FUEL LEVEL 9
62
107
WHT/VIO
62
YEL
BLK
103
59
81
SENDER COM 11
55
82
118
GROUND TO
ENCLOSURE
BOX SMALL
STUD (M8)
83
REGENERATION 18
117
WHT
IDLE 21
115
WHT
60
ORG
REMOTE START 28
MODE
83
GRN
RUN MODE 29
84
GRN/YEL
85
BLU
REMOTE START 27
8
BREAKER 30
TRIPPED
RED
12 AWG
RED
109
107
104
RED
12 AWG
YEL
112
BLK
BLK
104
YEL
105
105
84
38
49
88
10A
FUSE
5
37
7.5A
FUSE
20A
FUSE
39
1A
FUSE
5
25
RED
88
108
106
RED
92
RED
91
VIO
6
17
118
9
31
27
-
+
BLK
10 AWG
ORG
98
61
28
RED
10 AWG
SHIELD
E-STOP 47
4
67
93
30
ORG
44
46
97
120 OHM
GRN
CAN L 48
13
YEL
SHIELD 50
SHIELD
REMOTE ANNUNCIATOR
COMMON 51
ALARM 52
TAN/WHT
75
TAN
L1
ORG
BLU/WHT
BLU
REGEN LIGHT 54
74
TAN
119
ORG
BAT+ 55
96
RED
TRIP BREAKER 56
86
BLU
PRESSURE
2
2
SENSOR SUPPLY
3
3
TEMPERATURE
4
4
SENSOR RETURN
L2
L3
L0
26
GRD
33
21
20
A
29
RED
1
SENSOR SUPPLY
B
27
BLU
2
SIGNAL
C
28
BLK
3
SENSOR RETURN
1
3
OEM SENSOR RTN
2
4
DPF DELTA P
3
5
DPF OUT PRESSURE
4
2
OEM SENSOR SUPPLY
1
7
DOC OUTLET TEMP
2
1
TEMP RETURN
3
8
DOC INLET TEMP
4
6
DPF OUTLET TEMP
78
97
PREALARM 53
1
79
BLU
73
1
18
50
68
CAN H 49
44
44
85
ORG
45
44
29
YEL
45
7
32
87
86
99
YEL
YEL
34
GRN/YEL
30
87
BLK PAIR
2 AWG
BLK
85
86
DATA LINK RETURN
14
15
GRN
NO
RED
NC
64
-24V ECM POWER
60
ORG
61
121
GRY
93
AIR HEATER SIG.
111
GRY
E-STOP 46
AIR HTR RETURN
RED
96
34
YEL
113
VIO
FAN SPEED RETURN
B B J1939A A J1939+
C C SHIELD
GRN
113
P
S
R
J
K
BLK
10 AWG
RED
VIO
RED
NC
THROTTLE INPUT
-
73 87 50
2
16
STARTER SOLENOID
111
RED
2/0 AWG
101
106
48 95
BLK
120
KEYSWITCH
BLK
+
RED
12 AWG
108
VIO
119
+24V SERVICE LINK
110
RED
2/0 AWG
11
63
94
BB+
BLACK
4 AWG
34
117
YEL
BLK
2/0 AWG
BLK
12 AWG
BLK
95
110
BLK
4 AWG
5A
FUSE
START
1
BLK
23
BLK
4 AWG
92
RED
64
YEL
VIO
82
94
FUEL
102
A
F
H
E
B
+24V ECM POWER
FAN SPEED SIG.
48
63
112
RED
17
BLK
BLK
TOGGLE
SWITCH
RED
12 AWG
63
22
56 RED
49
116
102
101
90
BLK
3
12
109
103
80
19
98
SHUNT
26.5
G 230 / G 240
35
46
RED
WHT
BLK
47
99
WHT
89
GRN/YEL
89
wc_gr011990
224
wc_tx003749gb_FM10.fm
G 230 / G 240
26.6
Schematics, Machines with Basler Controller
DC Schematic Components: G 230 T4i
Ref.
Description
Ref.
Description
Ref.
Description
Ref.
Description
1
Electronic control board
13
Cummins J3 connector
12
16 pin Cummins OEM connector
30
Air cleaner TBAP sensor
2
Engine outputs
B: J1939 (–)
A: 24V (+) ECM power
31
Terminal block
Start
A: J1939 (+)
F: 24V (+) service link
32
Resistor (if equipped)
Fuel
C: Shield
H: Keyswitch
33
Coolant level sensor
Cummins C12 connector
E: Starter solenoid
34
DPF pressure sensor connector
1: Ground
1: Pressure
B: Throttle input
35
DPF temperature sensor connector
2: Battery (–)
2: Sensor supply
Fan speed signal
36
Fuel level
3: Battery (+)
3: Temperature
P: Fan speed return
37
7.5A fuse
9: Fuel Level
4: Sensor return
S: Air heater return
38
1A fuse
3
4
wc_tx003749gb_FM10.fm
Plug 1—Engine sensor inputs
14
11: Sender com
15
Remote start
R: Air heater signal
39
5A fuse
Plug 4—Emergency stop, canbus, and
contact outputs
16
Emergency stop switch
J: 24V (–) ECM power
—
—
K: Data link return
—
—
46: Emergency stop
17
Toggle switch
47: Emergency stop
18
Bond bar
48: Canbus L
19
Main breaker
49: Canbus H
20
Lug door safety switch
50: Shield
21
Mechanical lugs
51: Remote annunciator common
22
Intake heater relay (if equipped)
52: Alarm
23
Intake heater (if equipped)
53: Pre-alarm
24
Starter relay
54: Regeneration light
25
Starter
55: Battery (+)
26
Cummins C7 connector
Wire Colors
56: Trip breaker
1: Sensor supply
5
Fuses
2: Signal
6
Hour meter
3: Sensor return
7
Shunt trip relay
27
12V battery
8
Plug 2—Contact inputs
28
Battery disconnect switch (if equipped)
18: Regeneration
29
21 pin Cummins after treatment connector
21: Idle
3: OEM sensor return
27: Remote start
4: Diesel particulate filter pressure change
28: Remote start mode
5: Diesel particulate filter out pressure
29: Run mode
2: OEM sensor supply
30: Breaker (tripped)
7: DOC outlet temperature
9
Light
1: Temperature return
10
Start relay
8: DOC inlet temperature
11
150A fuse
9: Diesel particulate filter outlet
temperature
225
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
Schematics, Machines with Basler Controller
26.7
G 230 / G 240
DC Schematic: G230 Cummins T4f
BK
109
RD 18 AWG
BK
BK
BK
56
3
62
BK
25
BK
59
82
118
83
BK
84
BK
85
BK
84
10
88
13
9
49
194
7.5A
FUSE
10A
FUSE
112
204
RD
192
10A
FUSE
30A
FUSE
5A
FUSE
5A
FUSE
95
RD
RD
8
BK
RD
94
RD
117
92
91
BK
33
50
18
EMERGENCY
STOP
SWITCH
34
21
60
RED
NC
-
+
RD
2/0 AWG
110
29
64
30
SHIELD
50
REMOTE ANNUNCIATOR
COMMON 51
ALARM 52
26
YL
79
REGEN LIGHT 54
BAT+
55
TRIP BREAKER 56
50
MECHANICAL LUGS
L1
BK
73
RD
75
BK
74
BK
119
BK
96
RD
86
BK
20 AWG
L2
L0
L3
43
BK
45
99
46
RD
201
BK
47
A
C
J1939+
99
22
46
J1939 -
20 AWG
22
J1939 +
32
COOLANT SENSOR RETURN
35
COOLANT SENSOR SIGNAL
8
SENSOR (+5V) SUPPLY
149 BK 18 AWG
6
DEF SUPPLY MODULE PUMP MODE/TEMPERATURE DRIVER
150 BK 18 AWG
16
DEF PRESSURE SENSOR
151 BK 18 AWG
54
DEF PUMP MOTOR RETURN
152 RD 18 AWG
79
DEF PUMP MOTOR SUPPLY
153 BK 18 AWG
81
DEF REVERTING VALVE
38
DEF PRESSURE LINE HEATER DIAGNOSTIC
39
DEF BACKFLOW LINE HEATER DIAGNOSTIC
40
DEF SUCTION LINE HEATER DIAGNOSTIC
D
J1939-
E
SHIELD
3
DEF LINE HEATERS RELAY CONTROL
162 BK 18 AWG
84
DEF LINE HEATER CURRENT MONITOR (1 OF 2)
163 BK 18 AWG
85
DEF LINE HEATER CURRENT MONITOR (2 OF 2)
7
DEF SUPPLY MODULE RELAY CONTROL
161 BK 18 AWG
164 BK
18 AWG
34
BLK PAIR
2 AWG
BOND TO
FRONT
PANEL
DOOR
BK
BK
89 BK 10 AWG
154 BK 18 AWG
148
RD 18
AWG
SENSOR +5V POWER SUPPLY
2
OEM SENSOR RETURN (-)
4
DEF DRIVER
10
149
DEF INJECTOR PRESSURE SENSOR SIGNAL
3
150
SUPPLY MODULE PUMP RETURN
8
151
DEF PUMP POWER
9
152
DEF REVERTING VALVE
11
153
MAIN
BREAKER
98
BATTERY SUPPLY (-)
20 AWG
160 BK 18 AWG
CUMMINS J26
SUPPLY MODULE CONNECTOR
24
BK
202
RD
BK
BATTERY SUPPLY (-)
73
167 RD
18 AWG
27
43
BK
85
87
+24 V DATALINK
GRD
45
30
52
166 BK 18 AWG
NOT USED ON
SOME MODELS
86
BATTERY SUPPLY (-)
140 BK 18 AWG
159 BK 18 AWG
BK
87
86
SHUNT
TRIP
RELAY
DATALINK RETURN
B
18
AWG
78
85
28
A
BOND BAR
BK
44
51
158 BK 18 AWG
BU/WH
BK
BATTERY SUPPLY (-)
139 BK 18 AWG
165 BK 18 AWG
23
SHIELD
97
PREALARM 53
193
BK
20 AWG
97
BATTERY SUPPLY (-)
50
146 RD 18 AWG
CUMMINS J3
DIAGNOSTIC CONNECTOR
20 AWG
144 BK
53
DEF DOSING INJECTOR LOW
77
DEF DOSING INJECTOR HIGH
57
DEF TANK HEATING VALVE RETURN
82
DEF TANK HEATING VALVE SUPPLY
157 RD 18 AWG
1 RD 18 AWG
155 BK 18 AWG
2 BK 18 AWG
GROUND TO ENCLOSURE
BOX SMALL STUD (M8)
46
200 RD
156 BK 18 AWG
DEF PUMP RETURN
12
BATTERY RETURN (-)
6
168 BK 18 AWG
DEF SUPPLY MODULE 24V B+
5
169 RD 18 AWG
189 RD 10 AWG
190 RD 12 AWG
191 RD 12 AWG
192 BK 12 AWG
SHIELD
1
35
CUMMINS J6
DEF TANK TEMP/QUALITY/
LEVEL SENSORS
2
2
36
CUMMINS J17
DOC INLET/OUTLET
TEMP SENSORS
3
2
37
CUMMINS J10
SCR INLET/OUTLET
TEMP SENSORS
3
2
38
3
2
39
CUMMINS J7B
DOWNSTREAM
SCR NOx SENSOR
3
40
CUMMINS J7A
UPSTREAM DOC
NOx SENSOR
AFTERTREATMENT J1939 (-)
23
AFTERTREATMENT J1939 (+)
22
226
GN 20 AWG
YL 20 AWG
30
CUMMINS J31
DEF INJECTOR
41
CONNECTOR 5
(GRAY)
6C 6A
5A 5C
3
176 BK 18 AWG
4A
177 RD 18 AWG
4B
1
178 BK 18 AWG
4
179 RD 18 AWG
180 BK 18 AWG
4
181 RD 18 AWG
42
1C
1D
4E
2B
4C
2D
4H
4D
1
182 RD 18 AWG
4F
4
183 BK 18 AWG
3A
1
184 RD 18 AWG
4G
4
185 BK 18 AWG
3H
1
186 RD 18 AWG
2
187 BK 18 AWG
SHIELD
CUMMINS CC24B 24 PIN
CROSSOVER CONNECTOR
CONNECTOR 6
(BLACK)
4
1
4
CUMMINS J27
1 DEF TANK HEATING VALVE
199 BK
C
188 BK 10 AWG
GROUND TO
ENCLOSURE
BOX, LARGE
STUD (1/2")
120 OHM
49
194
RD
189
GN
INTAKE AIR RELAY SIGNAL
49
145 BK 18 AWG
147
RD
18 AWG
52
SHIELD
46
120 OHM
75
142 BK 18 AWG
YL
RD
44
105
GN
19
93
143 BK
18 AWG
31
188
120 OHM
68
CAN H
C
CUMMINS J22
COOLANT LEVEL B
SENSOR
A
-
RD
GRN
NO
RED
NC
INTAKE AIR RELAY RETURN
20 AWG
20
+
NOT USED
ON SOME
MODELS
RD
98
61
B+
113
RD
10 AWG
76
141 BK 18 AWG
BK 18 AWG
BK
96
BK
2/0 AWG
RD
2/0 AWG
BATTERY
DISCONNECT
SWITCH
KEY SWITCH
104
104 BK 18 AWG
BK 10 AWG
SHUNT
PLUG 4
E-STOP, CANBUS & CONTACT OUTPUTS
121
BK
93
67
BATTERY SUPPLY (+)
5
138 BK 18 AWG
STARTER
BMOTOR
16
73 87 50
BK
14
61
48
BATTERY SUPPLY (+)
28
WATER IN FUEL SENSOR
136 RD 18 AWG
BK
CAN L
BATTERY SUPPLY (+)
27
205
BK
197
113
47
BATTERY SUPPLY (+)
26
134 RD 18 AWG
137 BK 18 AWG
BK
4 AWG
BK
BK
120
LIGHT
196
195
118
7
E-STOP
25
109 RD 12 AWG
105
101
48 95
TOGGLE
SWITCH
INTAKE HEATER
150A FUSE
108
49
HOUR
METER
BK
119
46
BATTERY SUPPLY (+)
105 BK 18 AWG
203
BK
102
63
FUEL
E-STOP
ECM RETURN
1
112
BK
4 AWG
BK
88
4
62
110 BK 12 AWG
11 12 12
START
RELAY
ENGINE OUTPUTS
RD
18 AWG
92
48
3
RD
12 AWG
104
RD
12 AWG
82
94
64
BK
18 AWG
83
6
109
63
102
206
RD
BK
4 AWG
BK
12 AWG
BK
5
BK
BK
TOGGLE
SWITCH
TOGGLE
SWITCH
BK
18 AWG
BREAKER 30
TRIPPED
60
116
BK
BK
18 AWG
RUN MODE 29
BK
13
131 BK 18 AWG
63
INTAKE
HEATER
RELAY
15
RD
49
195 RD
REMOTE START 28
MODE
BK
115
55 56 RD
RD
12 AWG
REMOTE START 27
117
130 RD 18 AWG
2
132 RD 18 AWG
101
90
RD
12 AWG
103
REGENERATION 18
1
135 RD 18 AWG
81
GROUND TO
ENCLOSURE
BOX SMALL
STUD (M8)
CUMMINS J78
WATER IN FUEL
SENSOR
133 RD 18 AWG
BK
SENDER COM 11
STARTER
RELAY
62
BK
IDLE 21
PLUG 2
CONTACT INPUTS
FUEL LEVEL
81
BK
FUEL LEVEL 9
2
ELECTRONIC CONTROL UNIT
RD
CUMMINS J2 ECU CONNECTOR
48
103
198 BK
12 AWG
BAT+
17
80
2F
2G
2E
2C
2H
1G
3E
1F
1H
CUMMINS CONNECTOR
'JP1'
159
1
1
PRESSURE
AIR CLEANER 2
TBAP SENSOR 3
2
SENSOR SUPPLY
3
TEMPERATURE
4
4
RETURN
160
161
164
165
166
167
1E
1A
51
32
158
2A
1B
3D
CONNECTOR 1
(BLACK)
80
2
CONNECTOR 2 (GRAY)
PLUG 1
POWER & SENSOR INPUTS
121
BAT -
47
B
CONNECTOR 1 (BLACK)
59
AFTERTREATMENT RELAY BOX
1
CONNECTOR 4 (GREEN)
GROUND
CONNECTOR 3 (BLUE
1
170 RD 18 AWG
1
171 BK 18 AWG
2
172 RD 18 AWG
1
173 BK 18 AWG
2
174 RD 18 AWG
1
175 BK 18 AWG
2
CUMMINS J28
DEF PRESSURE LINE
HOSE HEATER
CUMMINS J29
DEF BACKFLOW LINE
HOSE HEATER
CUMMINS J30
DEF SUPPLY LINE
HOSE HEATER
43
44
45
5200014425_s1_02
wc_tx003749gb_FM10.fm
G 230 / G 240
26.8
Schematics, Machines with Basler Controller
DC Schematic Components: G 230 Cummins T4f
Ref.
1
2
Plug 1 - power and engine sender inputs
Plug 2 - contact inputs
Ref.
27
28
Description
Wire Colors
Bond bar
Shunt trip relay
3
Electronic control unit (genset controller)
29
4
Plug 4 - E-stop, CANBUS, contact
outputs
30
5
Idle toggle switch
31
Coolant level sensor
32
Air cleaner Temperature/Pressure Sensor
Connector (TBAP) sensor
6
Remote start / Off / Start/Run switch
Battery disconnect (optional)
120 Ohm resistor
7
Relay - engine outputs
33
Terminal strip
8
Hour meter
34
Cummins supply module connector
35
Cummins Diesel Exhaust Fluid (DEF)
temperature/quality level sensors
36
Cummins Diesel Oxidation Catalyst (DOC)
inlet/outlet temperature sensors
37
Cummins Selective Catalyst Reduction
(SCR) inlet/outlet temperature sensors
38
Cummins upstream Diesel Oxidation
Catalyst (DOC) NOx sensor
39
Cummins downstream Selective Catalyst
Reduction (SCR) Nox sensor
40
Cummins 24 pin crossover connector
41
Cummins Diesel Exhaust Fluid (DEF)
injector
42
Aftertreatment relay box
43
Cummins Diesel Exhaust Fluid (DEF)
pressure line hose heater
44
Cummins Diesel Exhaust Fluid (DEF)
backflow line hose heater
45
Cummins Diesel Exhaust Fluid (DEF)
supply line hose heater
46
Cummins Diesel Exhaust Fluid (DEF) tank
heating valve
47
Cummins Engine Control Unit (ECU)
connector
9
10
11
12
13
14
15
16
17
18
19
20
21
wc_tx003749gb_FM10.fm
Description
30A fuse
10A fuse
10A Fuse
5A Fuse
7.5A fuse
Intake heater
Intake heater relay
150A fuse
Starter relay
Emergency stop switch
Remote start terminals
Battery
Starter motor
22
Shunt
48
Cummins water in fuel sensor
23
Mechanical lugs
49
Toggle switch
24
Main circuit breaker
50
Light
25
Fuel level sender
51
Cummins connector ‘JP1’
26
Lug door interlock switch
52
Cummins diagnostic connector
227
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
Schematics, Machines with Basler Controller
DC Electrical Schematic Section A: G 230 Cummins T4f
GROUND
1
80
BK
BK
BK
56
RD
59
121
BAT -
2
BAT+
3
80
62
BK
62
BK
59
82
118
60
BK
REMOTE START 28
MODE
83
BK
RUN MODE 29
84
BK
85
BK
REMOTE START 27
BREAKER 30
TRIPPED
84
13
10
88
49
7.5A
FUSE
10A
FUSE
112
9
11
30A
FUSE
10A
FUSE
12
192
12
5A
FUSE
5A
FUSE
BK
95
48
RD
RD
88
RD
117
START
RELAY
ENGINE OUTPUTS
194
92
94
63
109
82
BK
12 AWG
BK
83
6
BK
18 AWG
115
BK
BK
TOGGLE
SWITCH
TOGGLE
SWITCH
BK
18 AWG
BK
5
RD
49
116
BK
BK
18 AWG
117
REGENERATION 18
55 56 RD
RD
18 AWG
81
RD
12 AWG
SENDER COM 11
195 RD
PLUG 2
CONTACT INPUTS
90
BK
103
IDLE 21
92
RD
94
91
BK
49
HOUR
METER
FUEL
64
B
63
BK
119
118
196
195
48 95
33
BK
120
LIGHT
108
TOGGLE
SWITCH
8
BK
197
BK
73 87 50
7
50
BK
BK
113
E-STOP
46
E-STOP
47
48
CAN H
49
SHIELD
50
RED
NC
60
98
61
RD
GRN
NO
RED
NC
19
61
93
121
BK
67
CAN L
34
120 OHM
93
64
RD
44
46
30
97
GN
26
68
REMOTE ANNUNCIATOR
COMMON 51
ALARM 52
YL
REGEN LIGHT 54
BAT+
55
TRIP BREAKER 56
23
SHIELD
BK
73
RD
75
BK
74
BK
119
BK
96
RD
86
BK
L2
BOND BAR
L3
L0
GRD
BU/WH
BK
BK
27
78
43
44
85
43
BK
45
BK
45
28
NOT USED ON
SOME MODELS
87
86
99
SHUNT
TRIP
RELAY
202
RD
BK
30
87
BLK PAIR
2 AWG
BK
85
86
A
MECHANICAL LUGS
L1
97
PREALARM 53
50
79
24
MAIN
BREAKER
98
46
RD
201
BK
47
BK
SHUNT
4
EMERGENCY
STOP
SWITCH
RD
96
18
BK
PLUG 4
E-STOP, CANBUS & CONTACT OUTPUTS
3
25
BK
FUEL LEVEL 9
GROUND TO
ENCLOSURE
BOX SMALL
STUD (M8)
2
FUEL LEVEL
81
RD
12 AWG
PLUG 1
POWER & SENSOR INPUTS
1
ELECTRONIC CONTROL UNIT
26.9
G 230 / G 240
22
BOND TO
FRONT
PANEL
DOOR
BK
BK
99
89 BK 10 AWG
228
5200014425_s1_02_A
wc_tx003749gb_FM10.fm
G 230 / G 240
Schematics, Machines with Basler Controller
26.10 Electrical Schematic Components
Ref.
1
Description
Ref.
Description
Plug 1 - power and engine sender inputs
5
Idle toggle switch
Ground
6
Remote start / Off / Start/Run switch
Battery -
7
Relay - engine outputs
Battery +
8
Hour meter
Fuel level
9
30A fuse
Sender common
10
10A fuse
Plug 2 - contact inputs
11
10A fuse
Regeneration
12
5A fuse
Idle
13
7.5A fuse
Remote start
18
Emergency stop switch
Remote start mode
19
Remote start terminals
Run mode
22
Shunt
Breaker tripped
23
Mechanical lugs
3
Electronic control unit (genset controller)
24
Main circuit breaker
4
Plug 4 - E-stop, CANBUS, contact
outputs
25
Emergency stop
26
Lug door interlock switch
Emergency stop
27
Bond bar
2
Canbus low
28
Fuel level sender
Shunt trip relay
Canbus high
30
120 Ohm resistor
Shield
33
Terminal strip
Remote annunciator common
49
Toggle switch
Alarm
50
Light
Prealarm
—
—
Regenerator light
—
—
Battery +
—
—
Trip breaker
—
—
Wire Colors
wc_tx003749gb_FM10.fm
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
229
Schematics, Machines with Basler Controller
G 230 / G 240
26.11 DC Electrical Schematic Section B: G 230 Cummins T4f
BK
109
RD 18 AWG
47
BK
CUMMINS J2 ECU CONNECTOR
103
17
48
STARTER
RELAY
CUMMINS J78
WATER IN FUEL
SENSOR
1
130 RD 18 AWG
13
2
131 BK 18 AWG
62
ECM RETURN
1
BATTERY SUPPLY (+)
25
BATTERY SUPPLY (+)
26
BATTERY SUPPLY (+)
27
BATTERY SUPPLY (+)
28
BATTERY SUPPLY (+)
5
KEY SWITCH
104
76
INTAKE AIR RELAY RETURN
105
75
INTAKE AIR RELAY SIGNAL
49
BATTERY SUPPLY (-)
50
BATTERY SUPPLY (-)
139 BK 18 AWG
51
BATTERY SUPPLY (-)
140 BK 18 AWG
52
BATTERY SUPPLY (-)
73
BATTERY SUPPLY (-)
132 RD 18 AWG
133 RD 18 AWG
102
101
BK
RD
12 AWG
109 RD 12 AWG
134 RD 18 AWG
63
135 RD 18 AWG
15
INTAKE
HEATER
RELAY
136 RD 18 AWG
112
BK
4 AWG
A
205
BK
206
RD
INTAKE HEATER
14
104 BK 18 AWG
105 BK 18 AWG
104
RD
12 AWG
204
RD
137 BK 18 AWG
203
BK
105
138 BK 18 AWG
110 BK 12 AWG
BK
4 AWG
STARTER
MOTOR
102
BK
2/0 AWG
B-
141 BK 18 AWG
21
B+
150A FUSE
BK
4 AWG
RD
2/0 AWG
16
-
20
+
C
CUMMINS J22
COOLANT LEVEL B
SENSOR
A
-
RD
2/0 AWG
110
BK 18 AWG
BATTERY
DISCONNECT
SWITCH
29
143 BK
18 AWG
J1939 -
20 AWG
22
J1939 +
32
COOLANT SENSOR RETURN
35
COOLANT SENSOR SIGNAL
142 BK 18 AWG
145 BK 18 AWG
147
RD
18 AWG
146 RD 18 AWG
31
188
8
SENSOR (+5V) SUPPLY
149 BK 18 AWG
6
DEF SUPPLY MODULE PUMP MODE/TEMPERATURE DRIVER
150 BK 18 AWG
16
DEF PRESSURE SENSOR
151 BK 18 AWG
54
DEF PUMP MOTOR RETURN
152 RD 18 AWG
79
DEF PUMP MOTOR SUPPLY
153 BK 18 AWG
81
DEF REVERTING VALVE
38
DEF PRESSURE LINE HEATER DIAGNOSTIC
39
DEF BACKFLOW LINE HEATER DIAGNOSTIC
40
DEF SUCTION LINE HEATER DIAGNOSTIC
3
DEF LINE HEATERS RELAY CONTROL
162 BK 18 AWG
84
DEF LINE HEATER CURRENT MONITOR (1 OF 2)
163 BK 18 AWG
85
DEF LINE HEATER CURRENT MONITOR (2 OF 2)
7
DEF SUPPLY MODULE RELAY CONTROL
YL
NOT USED
ON SOME
MODELS
SHIELD
194
RD
30
193
BK
120 OHM
20 AWG
189
20 AWG
20 AWG
192 BK
46
GN
113
RD
10 AWG
20 AWG
20 AWG
+
101
WATER IN FUEL SENSOR
52
158 BK 18 AWG
CUMMINS J3
DIAGNOSTIC CONNECTOR
A
DATALINK RETURN
B
+24 V DATALINK
C
159 BK 18 AWG
160 BK 18 AWG
161 BK 18 AWG
J1939+
D
J1939-
E
SHIELD
164 BK
18 AWG
165 BK 18 AWG
53
DEF DOSING INJECTOR LOW
77
DEF DOSING INJECTOR HIGH
154 BK 18 AWG
57
DEF TANK HEATING VALVE RETURN
29 RD
82
DEF TANK HEATING VALVE SUPPLY
166 BK 18 AWG
167 RD
18 AWG
C
B
5200014425_s1_02_B
230
wc_tx003749gb_FM10.fm
G 230 / G 240
Schematics, Machines with Basler Controller
26.12 Electrical Schematic Components
Ref.
Description
14
Intake heater
(Not used)
Intake heater relay
Sensor (+5V) supply
150A Fuse
Diesel Exhaust Fluid (DEF) supply module
pump mode/temperature driver
17
Starter relay
Diesel Exhaust Fluid (DEF) pressure sensor
20
Battery
Diesel Exhaust Fluid (DEF) pump motor return
Starter motor
Diesel Exhaust Fluid (DEF) pump motor
supply
Battery disconnect switch
Diesel Exhaust Fluid (DEF) reverting valve
120 Ohm resistor
Diesel Exhaust Fluid (DEF) pressure line
heater diagnostic
Coolant level sensor
Diesel Exhaust Fluid (DEF) backflow line
heater diagnostic
Cummins Engine Control Unit (ECU)
connector
Diesel Exhaust Fluid (DEF) suction line heater
diagnostic
Water in fuel sensor
Diesel Exhaust Fluid (DEF) line heaters relay
control
ECM return
Diesel Exhaust Fluid (DEF) line heater current
monitor (1 of 2)
Battery supply positive
Diesel Exhaust Fluid (DEF) line heater current
monitor (2 of 2)
Battery supply positive
Diesel Exhaust Fluid (DEF) supply module
relay control
Battery supply positive
Diesel Exhaust Fluid (DEF) dosing injector low
Battery supply positive
Diesel Exhaust Fluid (DEF) dosing injector
high
Battery supply positive
(Not used)
Key switch
Diesel Exhaust Fluid (DEF) tank heating valve
return
Intake air relay return
Diesel Exhaust Fluid (DEF) tank heating valve
supply
15
16
21
29
30
31
47
wc_tx003749gb_FM10.fm
Ref.
Description
Intake air relay signal
48
Cummins water in fuel sensor
Battery supply negative
52
Cummins diagnostic connector
Battery supply negative
Datalink return
Battery supply negative
+24V Datalink
Battery supply negative
J1939+
Battery supply negative
J1939-
J1939-
Shield
J1939+
—
—
Coolant sensor return
—
—
Coolant sensor signal
—
—
Wire Colors
231
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
Schematics, Machines with Basler Controller
G 230 / G 240
26.13 DC Electrical Schematic Section C: G 230 Cummins T4f
C
B
18
AWG
34
148
RD 18
AWG
CUMMINS J26
SUPPLY MODULE CONNECTOR
SENSOR +5V POWER SUPPLY
2
144 BK
OEM SENSOR RETURN (-)
4
DEF DRIVER
10
149
DEF INJECTOR PRESSURE SENSOR SIGNAL
3
150
SUPPLY MODULE PUMP RETURN
8
151
DEF PUMP POWER
9
152
DEF REVERTING VALVE
11
153
DEF PUMP RETURN
12
157 RD 18 AWG
1 RD 18 AWG
155 BK 18 AWG
2 BK 18 AWG
4
CUMMINS J27
1 DEF TANK HEATING VALVE
199 BK
46
200 RD
156 BK 18 AWG
BATTERY RETURN (-)
6
168 BK 18 AWG
DEF SUPPLY MODULE 24V B+
5
169 RD 18 AWG
2
CUMMINS J6
DEF TANK TEMP/QUALITY/
LEVEL SENSORS
36
3
2
37
3
2
38
3
2
39
3
CUMMINS J10
SCR INLET/OUTLET
TEMP SENSORS
CUMMINS J7A
UPSTREAM DOC
NOx SENSOR
CUMMINS J7B
DOWNSTREAM
SCR NOx SENSOR
CUMMINS CC24B 24 PIN
CROSSOVER CONNECTOR
AFTERTREATMENT J1939 (-)
23
AFTERTREATMENT J1939 (+)
22
GN 20 AWG
YL 20 AWG
30
CUMMINS J31
DEF INJECTOR
5A 5C
3
176 BK 18 AWG
4A
177 RD 18 AWG
4B
1
178 BK 18 AWG
4
179 RD 18 AWG
1
4
180 BK 18 AWG
181 RD 18 AWG
2B
4H
4D
4F
183 BK 18 AWG
3A
1
184 RD 18 AWG
4G
4
185 BK 18 AWG
3H
186 RD 18 AWG
187 BK 18 AWG
41
1D
2D
4
2
1C
4E
182 RD 18 AWG
1
42
4C
1
SHIELD
120 OHM
40
CUMMINS J17
DOC INLET/OUTLET
TEMP SENSORS
CONNECTOR 5
(GRAY)
6C 6A
4
CONNECTOR 4 (GREEN)
2
35
CONNECTOR 3 (BLUE
1
CONNECTOR 6
(BLACK)
AFTERTREATMENT RELAY BOX
SHIELD
2F
2G
2E
2C
2H
1G
3E
1F
1H
232
CUMMINS CONNECTOR
'JP1'
32
159
1
1
PRESSURE
AIR CLEANER 2
TBAP SENSOR 3
2
SENSOR SUPPLY
3
TEMPERATURE
4
4
RETURN
160
161
164
165
166
167
170 RD 18 AWG
1E
1A
51
158
2A
1B
3D
CONNECTOR 1
(BLACK)
192 BK 12 AWG
CONNECTOR 2 (GRAY)
190 RD 12 AWG
191 RD 12 AWG
CONNECTOR 1 (BLACK)
189 RD 10 AWG
198 BK
12 AWG
188 BK 10 AWG
171 BK 18 AWG
43
CUMMINS J28
DEF PRESSURE LINE
2
HOSE HEATER
1
44
173 BK 18 AWG
CUMMINS J29
DEF BACKFLOW LINE
2
HOSE HEATER
174 RD 18 AWG
1
175 BK 18 AWG
2
172 RD 18 AWG
1
CUMMINS J30
DEF SUPPLY LINE
HOSE HEATER
45
5200014425_s1_02_C
wc_tx003749gb_FM10.fm
G 230 / G 240
Schematics, Machines with Basler Controller
26.14 Electrical Schematic Components
Ref.
30
Description
Ref.
120 Ohm resistor
Description
38
Cummins upstream Diesel Oxidation
Catalyst (DOC) NOx sensor
32
Air cleaner Temperature/Pressure
Sensor Connector (TBAP) sensor
39
Cummins downstream Selective Catalyst
Reduction (SCR) Nox sensor
34
Cummins supply module connector
40
Cummins 24 pin crossover connector
Sensor +5V power supply
Aftertreatment J1939(-)
OEM sensor return negative
Aftertreatment J1939(+)
Diesel Exhaust Fluid (DEF) driver
41
Diesel Exhaust Fluid (DEF) injector
pressure sensor signal
42
Supply module pump return
Diesel Exhaust Fluid (DEF) pump power
Diesel Exhaust Fluid (DEF) reverting
valve
Diesel Exhaust Fluid (DEF) pump return
Battery return negative
Cummins Diesel Exhaust Fluid (DEF)
injector
Aftertreatment relay box
43
Cummins Diesel Exhaust Fluid (DEF)
pressure line hose heater
44
Cummins Diesel Exhaust Fluid (DEF)
backflow line hose heater
45
Cummins Diesel Exhaust Fluid (DEF)
supply line hose heater
46
Cummins Diesel Exhaust Fluid (DEF) tank
heating valve
51
Cummins connector ‘JP1’
Diesel Exhaust Fluid (DEF) supply
module 24V B+
Pressure
35
Cummins Diesel Exhaust Fluid (DEF)
temperature/quality level sensors
Sensor supply
36
Cummins Diesel Oxidation Catalyst
(DOC) inlet/outlet temperature sensors
Temperature
37
Cummins Selective Catalyst Reduction
(SCR) inlet/outlet temperature sensors
Return
Wire Colors
wc_tx003749gb_FM10.fm
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
233
Schematics, Machines with Basler Controller
G 230 / G 240
26.15 Cummins Engine Relays and Fuses
4
DEF SUPPLY
MODULE RELAY
1
FUSE 1 - 15A
30
87
86
85
6
CONNECTOR 6
+24V BATTERY POSITIVE
KEYSWITCH
AFTERTREATEMENT
7 POWER RELAY
2
6A
FUSE 2 - 10A
6C
+24V BATTERY POSITIVE
5A
6
5
1
3
CUMMINS J2 ECU CONNECTOR - PIN 7
4B
CUMMINS J6 DEF TANK SENSORS - PIN 4
4C
CUMMINS J17 DOC TEMP SENSORS - PIN 4
4F
CUMMINS J7A DOC NOx SENSOR - PIN 1
86
85
4G
CUMMINS J7B SCR NOx SENSOR - PIN 1
4A
CUMMINS J6 DEF TANK SENSORS - PIN 3
4E
CUMMINS J17 DOC TEMP SENSORS - PIN 1
4H
CUMMINS J10 SCR TEMP SENSORS - PIN 1
3A
CUMMINS J7A DOC NOx SENSOR - PIN 4
3H
CUMMINS J7B SCR NOx SENSOR - PIN 4
1D
CUMMINS J26 SUPPLY MODULE CONNECTOR - PIN 6
2H
CUMMINS J2 ECU CONNECTOR - PIN 53
2A
CUMMINS J2 ECU CONNECTOR - PIN 77
3D
CUMMINS J31 DEF INJECTOR - PIN 1
3E
CUMMINS J31 DEF INJECTOR - PIN 2
2B
CUMMINS J2 ECU CONNECTOR - PIN 38
1E
CUMMINS J28 DEF PRESSURE LINE HEATER - PIN 1
30
87
86
85
HEATER RELAY
FUSE 3 - 15A
2C
CUMMINS J10 SCR TEMP SENSORS - PIN 4
9 DEF BACKFLOW LINE
5C
CUMMINS J26 SUPPLY MODULE CONNECTOR - PIN 5
4D
5
-24V BATTERY NEGATIVE
1C
87
HEATER RELAY
3
CONNECTORS 1, 2, 3, AND 4
OUTPUT PINS
30
8 DEF PRESSURE LINE
CONNECTOR 5
11
30
87
2D
CUMMINS J2 ECU CONNECTOR - PIN 39
86
85
1B
CUMMINS J29 DEF BACKFLOW LINE HEATER - PIN 1
2F
CUMMINS J2 ECU CONNECTOR - PIN 40
DEF SUPPLY LINE
10 HEATER RELAY
1F
CUMMINS J30 DEF SUPPLY LINE HEATER - PIN 1
2G
CUMMINS J2 ECU CONNECTOR - PIN 3
30
87
1A
CUMMINS J28 DEF PRESSURE LINE HEATER - PIN 2
86
85
1G
CUMMINS J29 DEF BACKFLOW LINE HEATER - PIN 2
1H
CUMMINS J30 DEF SUPPLY LINE HEATER - PIN 2
2E
CUMMINS J2 ECU CONNECTOR - PINS 84 & 85
2
8
10 9
7
4
wc_gr011996
234
wc_tx003749gb_FM10.fm
G 230 / G 240
Schematics, Machines with Basler Controller
26.16 Cummins Engine Relays and Fuses
Ref.
1
15A fuse 1
Ref.
Description
Cummins Diesel Exhaust Fluid (DEF) tank
sensors - pin 3
10A fuse 2
Cummins Diesel Oxidation Catalyst (DOC)
temperature sensors - pin 1
15A fuse 3
Cummins Selective Catalyst Reduction
(SCR) temperature sensors - pin 1
Diesel Exhaust Fluid (DEF) supply
module relay
Cummins Diesel Oxidation Catalyst (DOC)
NOx sensor - pin 4
Connector 5
Cummins Selective Catalyst Reduction
(SCR) NOx sensor - pin 4
-24V battery negative
Cummins supply module connector - pin 6
-24V battery positive
Cummins Engine Control Unit (ECU)
connector - pin 53
Connector 6
Cummins Engine Control Unit (ECU)
connector - pin 77
+24V battery positive
Cummins Diesel Exhaust Fluid (DEF)
injector - pin 1
Keyswitch
Cummins Diesel Exhaust Fluid (DEF)
injector - pin 2
Aftertreatment power relay
Cummins Engine Control Unit (ECU)
connector - pin 36
8
Diesel Exhaust Fluid (DEF) pressure line
heater relay
Cummins Diesel Exhaust Fluid (DEF)
pressure line heater - pin 1
9
Diesel Exhaust Fluid (DEF) backflow line
heater relay
Cummins Engine Control Unit (ECU)
connector - pin 39
10
Diesel Exhaust Fluid (DEF) supply line
heater relay
Cummins Engine Control Unit (ECU)
connector - pin 39
Connectors 1, 2, 3, and 4 output pins
Cummins Diesel Exhaust Fluid (DEF)
backflow line heater - pin 1
Cummins supply module connector pine 5
Cummins Engine Control Unit (ECU)
connector - pin 40
Cummins Engine Control Unit (ECU)
connector - pin 7
Cummins Diesel Exhaust Fluid (DEF)
supply line heater - pin 1
Cummins Diesel Exhaust Fluid (DEF)
tank sensors - pin 4
Cummins Engine Control Unit (ECU)
connector - pin 3
Cummins Diesel Oxidation Catalyst
(DOC) temperature sensors - pin 4
Cummins Diesel Exhaust Fluid (DEF)
pressure line heater - pin 2
Cummins Selective Catalyst Reduction
(SCR) temperature sensors - pin 4
Cummins Diesel Exhaust Fluid (DEF)
backflow line heater - pin 2
Cummins Diesel Oxidation Catalyst
(DOC) NOx sensor - pin 1
Cummins Diesel Exhaust Fluid (DEF)
supply line heater - pin 2
Cummins Selective Catalyst Reduction
(SCR) NOx sensor - pin 1
Cummins Engine Control Unit (ECU) - pin
84 & 85
2
3
4
5
6
7
11
wc_tx003749gb_FM10.fm
Description
235
Wire Colors
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
Schematics, Machines with Deep Sea Controller
G 230 / G 240
27 Schematics, Machines with Deep Sea Controller
AC Schematic: G 230 / G 240
19
RED
79 BLU/VV
BLU/WHT
1
6
11
2
120V
GFI
RECPT
L2
L3
N
12
G
17
3
GROUND TO
ENCLOSURE BOX
STUD
PAIR
#2
SHUNT
MAIN
BREAKER
25 BRN
BOND
BAR
78 BLU
7
120V
20A
BRKER
11
9
BLK
6GA
14
15
N
16
6
R1
2
L-L
7
L3
L2
6
10
EXCITER
L1-N = 277V
L2-N = 277V
L3-N = 277V
L1-L2= 480V
L2-L3= 480V
L3-L1= 480V
YEL (+)
(EXCITER)
+
2
240V 50A
20 BLK 10GA
1
BREAKER
19 BLK 10GA
Y
5
240V 50A
22 BLK 10GA
X
4
BREAKER
21 BLK 10GA
Y
8
240V 50A
24 BLK 10GA
X
7
BREAKER
23 BLK 10GA
Y
240V
50A
RCPT
240V
50A
RCPT
24
240V
50A
RCPT
26
G
10
W
ROTOR
MAIN
FIELD
21
8
X
23
BLU (-)
-
10
RECTIFIER
ROTOR
STATOR
53 WHT/ORG
B
16
REG. TYPE UVR 6
G
W
15
G
9
W
14
150K
POTENTIOMETER
VOLTAGE ADJUST
5
9
20
53 WHT/VIO
1
LT BLU 14GA
LT BLU 10GA
LT BLU 10GA
LT BLU 10GA
BRN 14GA
R2
L1
8
52 WHT/BLU
0
13
1
N
51 WHT/BLK
5
4
GRN/YEL 14GA
GRN/YEL 10GA
BRN 14GA
12
7
120V
20A
BRKER
6
2
18
R3
11
22
17
3
3
4
(POWER)
6
120V
GFI
RECPT
26 BRN
L1
(3X) 2 PAIRS #2 BLK
3
RED
GENERATOR
(ALTERNATOR)
16
MECHANICAL LUGS
LUG SAFETY
LIMIT
SWITCH
VIO
WHT
18
L-N
2
N
12
11
10
L3
9
6
5
8
7
L1-N = 120V
L2-N = 120V
L3-N = 120V
L1-L2= 208V
L2-L3= 208V
L3-L1= 208V
BLK 6GA
4
BLK 6GA
1
BLK 6GA
3
L-L
L1
L2
PLUG 5
CURRENT TRANSFORMER
INPUTS
69
36 WHT
37 BRN
X
2
72
75
39 ORN
CT-3
CT1
25
U1
1
CT-2
13
3
1
Y
6
V2
7
36A
CT COM 74
CT3
CT-1
38 YEL
7
5
36B
CT COM 71
CT2
CT2
PAIR #2 BLK
PAIR #2 BLK
PAIR #2 BLK
15
U2
3
CT COM 68
CT1
11
9
5
STATOR
AUX
WINDING
STATOR
MAIN
WINDINGS
Z
10
14
V1
5
PLUG 3
LINE VOLTAGE
INPUTS
12
PAIR #2 BLK
PAIR #2 BLK
CT3
L-N
ELECTRONIC CONTROL BOARD
27.1
N
35
40 WHT
L3
37
41 ORN
L2
39
43 YEL
L1
41
42 BRN
W2
11
2
O
N
4
W1
9
6
4
8
10
12
TERMINATE AT GENERATOR
TERMINAL BLOCK
GROUND GENERATOR
HOUSING TO FRAME
178172_02
236
wc_tx003750gb_FM10.fm
G 230 / G 240
27.2
Schematics, Machines with Deep Sea Controller
Electrical Schematic Components: G 230 / G 240
Ref.
Description
Ref.
Description
1
Lug safety limit switch
14
Auxiliary stator winding
2
Mechanical lugs
15
Voltage selector switch
3
Main circuit breaker
16
Generator
4
Plug 4 - line voltage inputs
17
Voltage regulator with 4A fuse
5
Plug 5 - current transformer inputs
18
Voltage adjustment rheostat
6
120V GFI receptacle
19
Machine and components
7
120V 20A breaker
20
Exciter rotor windings
8
240V 50A breaker
21
Exciter stator winding
9
Shunt
22
Rotor
10
240V 50A receptacle
23
Rectifier (diodes)
11
Bond bar
24
Main rotor winding
12
Genset controller
25
Main stator windings
13
Stator
26
Exciter
Wire Colors
wc_tx003750gb_FM10.fm
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
237
Schematics, Machines with Deep Sea Controller
27.3
G 230 / G 240
DC Schematic: G 240 John Deere Tier 3
J
14
1
15
25
29
4
22
17
11
2
13
10
8
21
20
9
16
18
19
3
7
26
23
6
27
28
12
24
5
wc_gr011793
238
wc_tx003750gb_FM10.fm
G 230 / G 240
27.4
Schematics, Machines with Deep Sea Controller
DC Schematic Components: G 240 John Deere Tier 3
Ref.
Description
Ref.
Description
1
Plug 1 - power and engine sender inputs
16
Engine Control Unit (ECU)
2
Plug 2 - contact inputs
17
Starter relay
3
Plug 3 - CANBUS
18
Emergency stop switch
4
Electronic control unit (genset controller)
19
Remote start terminals
5
Shunt
20
Battery
6
Plug 4 - E-stop, contact outputs
21
Starter motor
7
120 ohm resistor (if equipped)
22
Alternator
8
Hour meter
23
Mechanical lugs
9
Terminal strip
24
Main circuit breaker
10
10A fuse
25
Fuel level sender
11
Battery disconnect (optional)
26
Lug door interlock switch
12
Shunt trip relay
27
Bond bar
13
7.5A fuse
28
Resistor
14
Intake heater
29
ON/OFF toggle switch
15
Heater relay
30
—
Wire Colors
wc_tx003750gb_FM10.fm
BLK
Black
RED
Red
WHT
White
ORG
Orange
GRN
Green
TAN
Tan
YEL
Yellow
—
—
BLU
Blue
VIO
Violet
GRY
Gray
—
—
239
Schematics, Machines with Deep Sea Controller
DC Schematic: G 230 Cummins T4i
BLK
RED
12 AWG
RED
35
VIO
BAT -
1
BAT+
1
2
80
BLK
53
RED
80
PLUG 1
POWER & OUTPUTS
3
64
103
4
34
8
YEL
GROUND 7
REGEN LIGHT 8
BLK
ORG
119
118
BLK
PLUG 2
SENSOR INPUTS
SENDER COM 15
FUEL LEVEL 19
81
BLK
62
116
RED
109
107
BLK
4 AWG
VIO
10
7.5A
FUSE
10A
FUSE
32
34
1A
FUSE
95
108
BLK
4 AWG
5A
FUSE
106
RED
12 AWG
PLUG 3
CANBUS
19
ORG
7
120 OHM
AIR HEATER SIG.
J
-24V ECM POWER
K
DATA LINK RETURN
BLK
+
-
RED
2/0 AWG
11
CUMMINS J1939
CONNECTOR
YEL
A A J1939+
GRN
B B J1939-
SHIELD
C C SHIELD
38 CUMMINS CONNECTOR
37
GRN
'C12'
1
1
PRESSURE
AIR CLEANER 2
TBAP SENSOR 3
2
SENSOR SUPPLY
3
TEMPERATURE
4
4
SENSOR RETURN
SHIELD
SHIELD
27
MECHANICAL LUGS
SEE AC SCHEMATIC
FOR LUG DOOR
SWITCH N.C. WIRING
115
ORG
BLU/WHT
L2
BOND BAR
L3
L0
'C7'
COOLANT
LEVEL
SENSOR
23
BLU
40 CUMMINS CONNECTOR
39
GRD
A
29
RED
1
SENSOR SUPPLY
B
27
BLU
2
SIGNAL
C
28
BLK
3
SENSOR RETURN
78
BLU
44
44
ORG
45
WHT
42
44
YEL
45
WHT
RED
18
48
EMERGENCY
STOP
SWITCH
RED
NC
98
GRN
NO
RED
NC
YEL
YEL
MAIN
BREAKER
BLU
BLU
12
24
46
ORG
85
44
97
BLK
BLK
47
99
87
41
5
89
21 PIN CUMMINS
AFTERTREATMENT
CONNECTOR
3
OEM SENSOR RTN
4
DPF DELTA P
5
DPF OUT PRESSURE
4
2 OEM SENSOR SUPPLY
1
7
DOC OUTLET TEMP
1
TEMP RETURN
8
DOC INLET TEMP
6
DPF OUTLET TEMP
DPF
TEMPERATURE 2
SENSOR
3
CONNECTOR
4
WHT
WHT
99
86
BLK PAIR
2 AWG
GRN/YEL
64
VIO
1
DPF
PRESSURE 2
SENSOR
CONNECTOR 3
NOT USED ON
SOME MODELS
28
SHUNT
117
36
BLK
10 AWG
BLK
10 AWG
46
RED
REGENERATION 65
111
20
-
YEL
50
111
110
NOT USED
ON SOME
MODELS
60
L1
IDLE 64
AIR HTR RETURN
R
ORG
85
FAN SPEED RETURN
S
113
RED
10 AWG
26
BREAKER 61
TRIPPED
P
105
YEL
GRN
60
FAN SPEED SIG.
BLK
12 AWG
BATTERY
DISCONNECT
SWITCH
79
REMOTE START 60
M
104
RED
REMOTE
START
6
THROTTLE INPUT
YEL
B+
101
106
ORG
27
B
BLK
B-
+
VIO
67
STARTER SOLENOID
BLK
2/0 AWG
RED
2/0 AWG
113
SCR
22
BLACK
4 AWG
87 50
25
STARTER
MOTOR
34
9
26
KEYSWITCH
E
110
63
108
CAN H
H
102
14
21
RED
117
18 95
CAN L
INTAKE HEATER
150A FUSE
RED
68
112
BLK
YEL BLK
112
33
20A
FUSE
13
TOGGLE
SWITCH
18
3
+24V SERVICE LINK
104
RED
12 AWG
105
49
48
30
TOGGLE
SWITCH
YEL
RED
118
31
WHT/VIO
RED
12 AWG
TOGGLE
SWITCH
BLK
115
PLUG 6
CONTACT INPUTS
4
GROUND TO
ENCLOSURE
BOX SMALL
STUD (M8)
BLK
BLU
86
53
29
120
PREALARM 10
F
RELAY
116
LIGHT
+24V ECM POWER
103
59
16
63
15 INTAKE
HEATER
92
ALARM 9
2
BLK
BLK
59
119
TRIP BREAKER 11
92
RED
12 AWG
102
101
YEL
HOUR
METER
VIO 91
90
BLK
A
107
STARTER
RELAY
62
VIO
63
START 5
17
FUEL LEVEL
25
90
VIO
WHT/VIO
FUEL
16 PIN CUMMINS
OEM CONNECTOR
109
81
ELECTRONIC CONTROL UNIT
27.5
G 230 / G 240
GRN/YEL
89
GROUND TO
ENCLOSURE
BOX, LARGE
STUD (1/2")
BOND TO
FRONT
PANEL
DOOR
85
86
30
SHUNT
TRIP
RELAY
98
GROUND TO
ENCLOSURE
BOX SMALL
STUD (M8)
5200006818_02
87
RED
240
wc_tx003750gb_FM10.fm
G 230 / G 240
27.6
Schematics, Machines with Deep Sea Controller
DC Schematic Components: G 230 Cummins T4i
Ref.
1
2
3
Description
Ref.
Ref.
22
150A fuse
Battery negative
23
Mechanical lugs
Sensor supply
Battery positive
24
Main circuit breaker
Signal
Fuel
25
Fuel level sender
Sensor return
Start
26
Lug door interlock switch
Ground
27
Bond bar
Diesel Particulate Filter (DPF) pressure
sensor connector
Regeneration light
28
Resistor (if equipped)
Alarm
29
ON/OFF toggle switch
Prealarm
30
Toggle switch (exhaust regenerator)
Trip breaker
31
Toggle switch (low idle)
Plug 2 - sensor inputs
32
20A fuse
Original Equipment Manufacturer (OEM)
sensor return
Sender common
33
1A fuse
Diesel Particulate Filter (DPF) Delta P
Fuel level
34
5A fuse
Plug 3 - CANBUS
35
16 pin Cummins Original Equipment
Manufacturer (OEM) connector
Diesel Particulate Filter (DPF) out
pressure
Selective Catalyst Reduction (SCR)
Electronic control unit (genset controller)
5
Shunt
6
Plug 6 - contact inputs
41
42
21 pin Cummins aftertreatment
connector
Diesel Oxidation Catalyst (DOC) inlet
temperature
Keyswitch
Diesel Particulate Filter (DPF) outlet
temperature
Starter solenoid
Throttle input
—
Fan speed signal
Breaker tripped
Diesel Particulate Filter (DPF)
temperature sensor connector
Temperature return
+24V service link
Remote start
Cummins connector ‘C7’
Original Equipment Manufacturer (OEM)
sensor supply
+24V Electronic Control Module (ECM)
power
CANBUS LOW
4
40
Description
Plug 1 - power and outputs
CANBUS HIGH
—
Fan speed return
Idle
Air heater return
Regeneration
wc_tx003750gb_FM10.fm
Description
Wire Colors
Air heater signal
7
120 ohm resistor (if equipped)
Black
RED
Red
WHT
White
Hour meter
-24V Electronic Control Module (ECM)
power
BLK
8
GRN
Green
TAN
Tan
YEL
Yellow
9
Terminal strip
Data link return
BLU
Blue
VIO
Violet
GRY
Gray
10
10A fuse
Cummins J1939 connector
—
—
—
—
ORG
Orange
11
Battery disconnect (optional)
J1939+
12
Shunt trip relay
J1939-
13
7.5A fuse
Shield
14
Intake heater
15
Intake heater relay
16
Light
17
Starter relay
Pressure
18
Emergency stop switch
Sensor supply
19
Remote start terminals
Temperature
20
Battery
Sensor return
21
Starter motor
36
37
Air cleaner Temperature/Pressure
Sensor (TBAP) sensor
38
Cummins connector ‘C12’
39
Coolant level sensor
241
Schematics, Machines with Deep Sea Controller
DC Schematic: G 230 Cummins T4f
BK
B
109
RD 18 AWG
17
80
1
FUEL LEVEL
81
56
RD
GROUND 7
59
BK
119
BK
BK
118
GROUND TO
ENCLOSURE
BOX SMALL
STUD (M8)
49
TRIP BREAKER 11
BK
86
2
13
10
88
10A
FUSE
RD
10A
FUSE
30A
FUSE
204
RD
192
5A
FUSE
LIGHT
RD
BK
118
HOUR
METER
91
119
120
33
88
98
RED
NC
IDLE 64
REGENERATION 65
BK
115
BAT+
2
BLK
151
RED
NOT USED
ON SOME
MODELS
SHIELD
SEE AC SCHEMATIC
FOR LUG DOOR
SWITCH N.C. WIRING
BK
44
30
28
45
BK
99
86
BK
98
46
201
BK
47
99
BK
A
DATALINK RETURN
B
+24 V DATALINK
52
BATTERY SUPPLY (-)
73
BATTERY SUPPLY (-)
20 AWG
46
J1939 -
20 AWG
22
J1939 +
32
COOLANT SENSOR RETURN
35
COOLANT SENSOR SIGNAL
C
J1939+
D
J1939-
E
SHIELD
SENSOR +5V POWER SUPPLY
2
OEM SENSOR RETURN (-)
4
DEF DRIVER
10
149
DEF INJECTOR PRESSURE SENSOR SIGNAL
3
150
SUPPLY MODULE PUMP RETURN
8
151
DEF PUMP POWER
9
152
DEF REVERTING VALVE
11
153
BOND TO
FRONT
PANEL
DOOR
22
144 BK
DEF SUPPLY MODULE PUMP MODE/TEMPERATURE DRIVER
16
DEF PRESSURE SENSOR
54
DEF PUMP MOTOR RETURN
152 RD 18 AWG
79
DEF PUMP MOTOR SUPPLY
153 BK 18 AWG
81
DEF REVERTING VALVE
38
DEF PRESSURE LINE HEATER DIAGNOSTIC
39
DEF BACKFLOW LINE HEATER DIAGNOSTIC
40
DEF SUCTION LINE HEATER DIAGNOSTIC
3
DEF LINE HEATERS RELAY CONTROL
162 BK 18 AWG
84
DEF LINE HEATER CURRENT MONITOR (1 OF 2)
163 BK 18 AWG
85
DEF LINE HEATER CURRENT MONITOR (2 OF 2)
7
DEF SUPPLY MODULE RELAY CONTROL
154 BK 18 AWG
148
RD 18
AWG
CUMMINS J26
SUPPLY MODULE CONNECTOR
SENSOR (+5V) SUPPLY
6
151 BK 18 AWG
161 BK 18 AWG
164 BK
18 AWG
8
150 BK 18 AWG
160 BK 18 AWG
18
AWG
34
BLK PAIR
2 AWG
53
DEF DOSING INJECTOR LOW
77
DEF DOSING INJECTOR HIGH
57
DEF TANK HEATING VALVE RETURN
82
DEF TANK HEATING VALVE SUPPLY
157 RD 18 AWG
1 RD 18 AWG
155 BK 18 AWG
2 BK 18 AWG
4
CUMMINS J27
1 DEF TANK HEATING VALVE
199 BK
46
200 RD
156 BK 18 AWG
DEF PUMP RETURN
12
BATTERY RETURN (-)
6
168 BK 18 AWG
DEF SUPPLY MODULE 24V B+
5
169 RD 18 AWG
BK
89 BK 10 AWG
C
188 BK 10 AWG
RED
GROUND TO
ENCLOSURE
BOX, LARGE
STUD (1/2")
5A FUSE
GROUND TO ENCLOSURE
BOX SMALL STUD (M8)
NOT USED ON
SOME MODELS
BATTERY SUPPLY (-)
140 BK 18 AWG
167 RD
18 AWG
24
BK
MAIN
BREAKER
51
158 BK 18 AWG
GRD
NOT USED ON
SOME MODELS
202
RD
150
152
L0
L3
27
BK
85
30
BATTERY SUPPLY (-)
139 BK 18 AWG
166 BK 18 AWG
45
19
BATTERY SUPPLY (-)
50
159 BK 18 AWG
BK
REMOTE
START
87
86
SHUNT
TRIP
RELAY
L2
43
60
INTAKE AIR RELAY SIGNAL
49
149 BK 18 AWG
CUMMINS J3
DIAGNOSTIC CONNECTOR
193
BK
20 AWG
BU/WH
BK
75
146 RD 18 AWG
BOND BAR
BK
43
105
165 BK 18 AWG
78
97
KEY SWITCH
145 BK 18 AWG
147
RD
18 AWG
52
194
RD
RED
MECHANICAL LUGS
BATTERY SUPPLY (+)
INTAKE AIR RELAY RETURN
142 BK 18 AWG
YL
189
23
28
76
GN
20 AWG
L1
54
31
RD
79
BK
150
A
120 OHM
RD
1
110
BK
50
BATTERY SUPPLY (+)
20 AWG
143 BK
18 AWG
C
CUMMINS J22
COOLANT LEVEL B
SENSOR
-
151
YL
87
BAT -
+
188
115
26
BK
53
RD
2/0 AWG
97
BK
117
20
20
BATTERY
DISCONNECT
SWITCH
RD
10 AWG
RD
85
85
B+
+
BATTERY SUPPLY (+)
27
104
141 BK 18 AWG
113
SHUNT
PLUG 3
CANBUS
29
GN
6
BREAKER 61
TRIPPED
21
BK 18 AWG
5
44
BK
BK
BK
2/0 AWG
RD
2/0 AWG
26
5
104 BK 18 AWG
20 AWG
BK
60
14
197
SHIELD
27
112
BK 10 AWG
68
25
B-
WATER IN FUEL SENSOR
136 RD 18 AWG
138 BK 18 AWG
STARTER
MOTOR
16
87 50
GRN
NO
RED
NC
120 OHM
26
REMOTE START 60
BATTERY SUPPLY (+)
134 RD 18 AWG
105
BK
4 AWG
113
64
SCR
25
109 RD 12 AWG
137 BK 18 AWG
150A FUSE
RD
18
EMERGENCY
STOP
SWITCH
196
195
TOGGLE
SWITCH
117
INTAKE HEATER
101
TOGGLE
SWITCH
RD
CAN H
BATTERY SUPPLY (+)
105 BK 18 AWG
203
BK
102
108
48 95
49
50
67
ECM RETURN
1
205
BK
206
RD
BK
4 AWG
BK
18 AWG
RD
8
92
CAN L
62
110 BK 12 AWG
5A
FUSE
BK
18 AWG
95
BK
81
62
BK
3
RD
12 AWG
104
RD
12 AWG
112
195 RD
SENDER COM 15
INTAKE
HEATER
RELAY
9 11 12 12
49
7.5A
FUSE
48
FUEL LEVEL 19
131 BK 18 AWG
63
BK
4 AWG
BK
BK
PLUG 6
CONTACT INPUTS
194
109
RD
12 AWG
PLUG 2
SENSOR INPUTS
BK
RD
PREALARM 10
4
2
189 RD 10 AWG
190 RD 12 AWG
198 BK
12 AWG
92
ALARM 9
ELECTRONIC CONTROL UNIT
103
BK
59
TOGGLE
SWITCH
116
REGEN LIGHT 8
TELEMATICS
UNIT
15
BK
BK
12 AWG
7
BK
63
13
191 RD 12 AWG
192 BK 12 AWG
35
CUMMINS J6
DEF TANK TEMP/QUALITY/
LEVEL SENSORS
1
2
2
36
CUMMINS J17
DOC INLET/OUTLET
TEMP SENSORS
3
A
2
37
CUMMINS J10
SCR INLET/OUTLET
TEMP SENSORS
3
3
40
SHIELD
AFTERTREATMENT J1939 (-)
23
AFTERTREATMENT J1939 (+)
22
242
GN 20 AWG
YL 20 AWG
30
5A 5C
3
176 BK 18 AWG
4A
4
177 RD 18 AWG
4B
1
178 BK 18 AWG
4
179 RD 18 AWG
1
180 BK 18 AWG
4
181 RD 18 AWG
2B
4H
4D
183 BK 18 AWG
3A
CUMMINS J7B
DOWNSTREAM
SCR NOx SENSOR
1
184 RD 18 AWG
4G
4
185 BK 18 AWG
3H
1
186 RD 18 AWG
41
187 BK 18 AWG
1D
2D
4
2
1C
4E
4F
CUMMINS J31
DEF INJECTOR
42
4C
182 RD 18 AWG
39
CUMMINS CC24B 24 PIN
CROSSOVER CONNECTOR
CONNECTOR 5
(GRAY)
6C 6A
1
38
2
CONNECTOR 6
(BLACK)
CUMMINS J7A
UPSTREAM DOC
NOx SENSOR
2
3
SHIELD
2F
2G
2E
2C
2H
1G
3E
1F
1H
159
51
1
PRESSURE
AIR CLEANER 2
TBAP SENSOR 3
2
SENSOR SUPPLY
3
TEMPERATURE
4
4
RETURN
160
161
CUMMINS CONNECTOR
'JP1'
1
164
165
166
167
1E
1A
32
158
2A
1B
3D
CONNECTOR 1
(BLACK)
56
BK
18 AWG
5
START
130 RD 18 AWG
135 RD 18 AWG
BK
34
RD
18 AWG
4
RD
12 AWG
PLUG 1
POWER & OUTPUTS
BK
FUEL
102
101
90
CUMMINS J2 ECU CONNECTOR
1
133 RD 18 AWG
62
BK
RD
CONNECTOR 2 (GRAY)
64
47
CUMMINS J78
WATER IN FUEL
SENSOR
132 RD 18 AWG
CONNECTOR 1 (BLACK)
3
25
CONNECTOR 4 (GREEN)
2
BK
STARTER
RELAY
CONNECTOR 3 (BLUE
BAT+
BK
80
1
103
120 OHM
BAT -
48
AFTERTREATMENT RELAY BOX
27.7
G 230 / G 240
170 RD 18 AWG
1
171 BK 18 AWG
2
172 RD 18 AWG
1
173 BK 18 AWG
2
174 RD 18 AWG
1
175 BK 18 AWG
2
CUMMINS J28
DEF PRESSURE LINE
HOSE HEATER
43
CUMMINS J29
DEF BACKFLOW LINE
HOSE HEATER
44
CUMMINS J30
DEF SUPPLY LINE
HOSE HEATER
45
5100015549_s1_01
wc_tx003750gb_FM10.fm
G 230 / G 240
27.8
Schematics, Machines with Deep Sea Controller
DC Schematic Components: G 230 Cummins T4f
Ref.
Ref.
Description
Wire Colors
1
Plug 1 - power and engine sender inputs
29
Battery disconnect (optional)
2
Plug 2 - sender inputs
30
120 Ohm resistor
3
Plug 3 - CANBUS
31
Coolant level sensor
32
Air cleaner Temperature/Pressure Sensor
Connector (TBAP) sensor
4
Electronic control unit (genset controller)
5
Idle toggle switch
33
Terminal strip
6
Plug 6 - contact inputs
34
Cummins supply module connector
35
Cummins Diesel Exhaust Fluid (DEF)
temperature/quality level sensors
36
Cummins Diesel Oxidation Catalyst (DOC)
inlet/outlet temperature sensors
37
Cummins Selective Catalyst Reduction
(SCR) inlet/outlet temperature sensors
38
Cummins upstream Diesel Oxidation
Catalyst (DOC) NOx sensor
39
Cummins downstream Selective Catalyst
Reduction (SCR) Nox sensor
40
Cummins 24 pin crossover connector
41
Cummins Diesel Exhaust Fluid (DEF)
injector
42
Aftertreatment relay box
43
Cummins Diesel Exhaust Fluid (DEF)
pressure line hose heater
44
Cummins Diesel Exhaust Fluid (DEF)
backflow line hose heater
45
Cummins Diesel Exhaust Fluid (DEF) supply
line hose heater
46
Cummins Diesel Exhaust Fluid (DEF) tank
heating valve
47
Cummins Engine Control Unit (ECU)
connector
7
8
9
10
11
12
13
14
15
16
17
18
19
wc_tx003750gb_FM10.fm
Description
Genset power toggle switch
Hour meter
30A fuse
10A fuse
10A Fuse
5A Fuse
7.5A fuse
Intake heater
Intake heater relay
150A fuse
Starter relay
Emergency stop switch
Remote start terminals
20
Battery
48
Cummins water in fuel sensor
21
Starter motor
49
Manual conditioning toggle switch
22
Shunt
50
Light (manual regeneration)
23
Mechanical lugs
51
Cummins connector ‘JP1’
24
Main circuit breaker
52
Cummins diagnostic connector
25
Fuel level sender
53
Telematics unit (not used on some models)
26
Lug door interlock switch
54
5A fuse
27
Bond bar
—
28
Shunt trip relay
—
243
BK
Black
RD
Red
YL
Yellow
OR
Orange
GN
Green
TN
Tan
BR
Brown
PU
Purple
BU
Blue
VIO
Violet
CL
Clear
SH
Shield
PK
Pink
WH
White
GY
Gray
LB
Lt. blue
Schematics, Machines with Deep Sea Controller
DC Electrical Schematic Section A: G 230 Cummins T4f
80
1
FUEL LEVEL
81
RD
3
64
4
34
FUEL
5
START
56
BK
90
RD
BK
56
7
BK
63
BK
TOGGLE
SWITCH
103
BK
59
92
BK
118
116
GROUND 7
REGEN LIGHT 8
59
BK
119
BK
GROUND TO
ENCLOSURE
BOX SMALL
STUD (M8)
49
ALARM 9
TRIP BREAKER 11
BK
86
10A
FUSE
RD
2
13
10
88
112
192
9 11 12 12
49
10A
FUSE
30A
FUSE
7.5A
FUSE
5A
FUSE
5A
FUSE
RD
8
62
FUEL LEVEL 19
92
BK
118
HOUR
METER
91
119
LIGHT
RD
BK
B
195
87 50
RD
113
RD
18
88
98
RED
NC
CAN L
26
CAN H
25
BK
RD
44
97
120 OHM
GN
26
YL
79
68
SCR
SHIELD
27
BK
6
SEE AC SCHEMATIC
FOR LUG DOOR
SWITCH N.C. WIRING
BK
BREAKER 61
TRIPPED
IDLE 64
REGENERATION 65
BK
85
BK
115
BK
44
28
43
99
SHUNT
TRIP
RELAY
BAT BAT+
1
2
150
BLK
151
RED
54
NOT USED ON
SOME MODELS
19
BLK PAIR
2 AWG
BK
30
BK
MAIN
BREAKER
98
46
201
BK
47
99
24
BK
202
RD
150
152
27
43
45
RD
53
BK
85
87
GRD
BK
REMOTE
START
87
86
BK
BOND BAR
L0
L3
BK
45
86
L2
BU/WH
60
BK
BK
117
MECHANICAL LUGS
78
97
85
60
23
L1
BK
REMOTE START 60
50
SHUNT
PLUG 3
CANBUS
67
115
RD
GRN
NO
RED
NC
64
3
5
TOGGLE
SWITCH
33
117
EMERGENCY
STOP
SWITCH
197
TOGGLE
SWITCH
120
50
196
108
48 95
49
BK
18 AWG
BK
81
BK
18 AWG
SENDER COM 15
195 RD
95
48
PLUG 2
SENSOR INPUTS
194
BK
BK
PLUG 6
CONTACT INPUTS
109
RD
12 AWG
4
BK
RD
PREALARM 10
ELECTRONIC CONTROL UNIT
25
62
BK
BK
12 AWG
2
BK
BK
18 AWG
PLUG 1
POWER & OUTPUTS
BAT+
80
RD
18 AWG
1
RD
12 AWG
BAT -
TELEMATICS
UNIT
27.9
G 230 / G 240
BK
BOND TO
FRONT
PANEL
DOOR
22
BK
89 BK 10 AWG
RED
5A FUSE
GROUND TO ENCLOSURE
BOX SMALL STUD (M8)
NOT USED ON
SOME MODELS
A
GROUND TO
ENCLOSURE
BOX, LARGE
STUD (1/2")
5100015549_s1_01_A
244
wc_tx003750gb_FM10.fm
G 230 / G 240
Schematics, Machines with Deep Sea Controller
27.10 Electrical Schematic Components
Ref.
1
Description
Ref.
Description
Plug 1 - power and engine sender inputs
7
Genset power toggle switch
Battery -
8
Hour meter
Battery +
9
30A fuse
Fuel
10
10A fuse
Start
11
10A fuse
Ground
12
5A fuse
Regeneration light
13
7.5A fuse
Alarm
18
Emergency stop switch
Prealarm
19
Remote start terminals
Trip breaker
22
Shunt
Plug 2 - contact inputs
23
Mechanical lugs
Sender communication
24
Main circuit breaker
Fuel level
25
Fuel level sender
Plug 3 - canbus
26
Lug door interlock switch
Canbus low
27
Bond bar
Canbus high
28
Shunt trip relay
Selective Catalyst Reduction (SCR)
33
Terminal strip
4
Electronic control unit (genset controller)
49
Manual conditioning toggle switch
5
Idle toggle switch
50
Light (manual regeneration)
6
Plug 6 - contact inputs
53
Telematics unit
Remote suction
54
5A fuse
Breaker tripped
—
—
Idle
—
—
Regeneration
—
—
2
3
Wire Colors
wc_tx003750gb_FM10.fm
BK
Black
RD
Red
YL
Yellow
OR
Orange
GN
Green
TN
Tan
BR
Brown
PU
Purple
BU
Blue
VIO
Violet
CL
Clear
SH
Shield
PK
Pink
WH
White
GY
Gray
LB
Lt. blue
245
Schematics, Machines with Deep Sea Controller
G 230 / G 240
27.11 DC Electrical Schematic Section B: G 230 Cummins T4f
BK
B
109
RD 18 AWG
47
48
103
17
STARTER
RELAY
CUMMINS J2 ECU CONNECTOR
CUMMINS J78
WATER IN FUEL
SENSOR
1
130 RD 18 AWG
13
2
131 BK 18 AWG
62
ECM RETURN
1
BATTERY SUPPLY (+)
25
BATTERY SUPPLY (+)
132 RD 18 AWG
133 RD 18 AWG
102
101
BK
15
RD
12 AWG
109 RD 12 AWG
134 RD 18 AWG
63
135 RD 18 AWG
INTAKE
HEATER
RELAY
205
BK
206
RD
INTAKE HEATER
14
104 BK 18 AWG
105 BK 18 AWG
104
RD
12 AWG
204
RD
105
A
102
STARTER
MOTOR
BK
4 AWG
20
+
-
+
C
CUMMINS J22
COOLANT LEVEL B
SENSOR
110
A
BK 18 AWG
29
KEY SWITCH
INTAKE AIR RELAY RETURN
105
75
INTAKE AIR RELAY SIGNAL
49
BATTERY SUPPLY (-)
50
BATTERY SUPPLY (-)
51
BATTERY SUPPLY (-)
140 BK 18 AWG
52
BATTERY SUPPLY (-)
73
BATTERY SUPPLY (-)
20 AWG
46
J1939 -
20 AWG
22
J1939 +
32
COOLANT SENSOR RETURN
35
COOLANT SENSOR SIGNAL
8
SENSOR (+5V) SUPPLY
149 BK 18 AWG
6
DEF SUPPLY MODULE PUMP MODE/TEMPERATURE DRIVER
150 BK 18 AWG
16
DEF PRESSURE SENSOR
151 BK 18 AWG
54
DEF PUMP MOTOR RETURN
152 RD 18 AWG
79
DEF PUMP MOTOR SUPPLY
153 BK 18 AWG
81
DEF REVERTING VALVE
38
DEF PRESSURE LINE HEATER DIAGNOSTIC
39
DEF BACKFLOW LINE HEATER DIAGNOSTIC
40
DEF SUCTION LINE HEATER DIAGNOSTIC
20 AWG
20
RD
2/0 AWG
101
31
143 BK
18 AWG
142 BK 18 AWG
145 BK 18 AWG
147
RD
18 AWG
146 RD 18 AWG
188
BATTERY
DISCONNECT
SWITCH
GN
YL
113
NOT USED
ON SOME
MODELS
SHIELD
151
194
RD
30
193
BK
120 OHM
20 AWG
20 AWG
189
BATTERY SUPPLY (+)
139 BK 18 AWG
21
RD
2/0 AWG
28
5
141 BK 18 AWG
B+
150A FUSE
16
BK
2/0 AWG
B-
BATTERY SUPPLY (+)
76
138 BK 18 AWG
110 BK 12 AWG
BK
4 AWG
BATTERY SUPPLY (+)
27
104
137 BK 18 AWG
203
BK
26
136 RD 18 AWG
112
BK
4 AWG
WATER IN FUEL SENSOR
20 AWG
52
158 BK 18 AWG
CUMMINS J3
DIAGNOSTIC CONNECTOR
A
DATALINK RETURN
B
+24 V DATALINK
C
159 BK 18 AWG
160 BK 18 AWG
J1939+
D
J1939-
E
SHIELD
3
DEF LINE HEATERS RELAY CONTROL
162 BK 18 AWG
84
DEF LINE HEATER CURRENT MONITOR (1 OF 2)
163 BK 18 AWG
85
DEF LINE HEATER CURRENT MONITOR (2 OF 2)
7
DEF SUPPLY MODULE RELAY CONTROL
161 BK 18 AWG
164 BK
18 AWG
165 BK 18 AWG
166 BK 18 AWG
167 RD
18 AWG
154 BK 18 AWG
C
53
DEF DOSING INJECTOR LOW
77
DEF DOSING INJECTOR HIGH
57
DEF TANK HEATING VALVE RETURN
82
DEF TANK HEATING VALVE SUPPLY
5100015549_s1_01_B
246
wc_tx003750gb_FM10.fm
G 230 / G 240
Schematics, Machines with Deep Sea Controller
27.12 Electrical Schematic Components
Ref.
Description
14
Intake heater
Coolant sensor return
15
Intake heater relay
Coolant sensor signal
16
150A Fuse
Sensor (+5V) supply
Starter relay
Diesel Exhaust Fluid (DEF) supply module
pump mode/temperature driver
20
Battery
Diesel Exhaust Fluid (DEF) pressure sensor
21
Starter motor
Diesel Exhaust Fluid (DEF) pump motor return
29
Battery disconnect switch (not used on
some models)
Diesel Exhaust Fluid (DEF) pump motor
supply
30
120 Ohm resistor
Diesel Exhaust Fluid (DEF) reverting valve
Coolant level sensor
Diesel Exhaust Fluid (DEF) pressure line
heater diagnostic
Cummins Engine Control Unit (ECU)
connector
Diesel Exhaust Fluid (DEF) backflow line
heater diagnostic
Water in fuel sensor
Diesel Exhaust Fluid (DEF) suction line heater
diagnostic
ECM return
Diesel Exhaust Fluid (DEF) line heaters relay
control
Battery supply positive
Diesel Exhaust Fluid (DEF) line heater current
monitor (1 of 2)
Battery supply positive
Diesel Exhaust Fluid (DEF) line heater current
monitor (2 of 2)
Battery supply positive
Diesel Exhaust Fluid (DEF) supply module
relay control
Battery supply positive
Diesel Exhaust Fluid (DEF) dosing injector low
Battery supply positive
Diesel Exhaust Fluid (DEF) dosing injector
high
Key switch
(Not used)
Intake air relay return
Diesel Exhaust Fluid (DEF) tank heating valve
return
Intake air relay signal
Diesel Exhaust Fluid (DEF) tank heating valve
supply
17
31
47
Description
Battery supply negative
48
Cummins water in fuel sensor
Battery supply negative
52
Cummins diagnostic connector
Battery supply negative
Datalink return
Battery supply negative
+24V Datalink
Battery supply negative
J1939+
J1939-
J1939-
J1939+
Shield
(Not used)
wc_tx003750gb_FM10.fm
Ref.
—
Wire Colors
—
247
BK
Black
RD
Red
YL
Yellow
OR
Orange
GN
Green
TN
Tan
BR
Brown
PU
Purple
BU
Blue
VIO
Violet
CL
Clear
SH
Shield
PK
Pink
WH
White
GY
Gray
LB
Lt. blue
Schematics, Machines with Deep Sea Controller
G 230 / G 240
27.13 DC Electrical Schematic Section C: G 230 Cummins T4f
B
18
AWG
34
148
RD 18
AWG
CUMMINS J26
SUPPLY MODULE CONNECTOR
SENSOR +5V POWER SUPPLY
2
144 BK
OEM SENSOR RETURN (-)
4
DEF DRIVER
10
149
DEF INJECTOR PRESSURE SENSOR SIGNAL
3
150
SUPPLY MODULE PUMP RETURN
8
151
157 RD 18 AWG
1 RD 18 AWG
155 BK 18 AWG
2 BK 18 AWG
4
CUMMINS J27
1 DEF TANK HEATING VALVE
46
199 BK
200 RD
DEF PUMP POWER
9
152
DEF REVERTING VALVE
11
153
DEF PUMP RETURN
12
BATTERY RETURN (-)
6
168 BK 18 AWG
DEF SUPPLY MODULE 24V B+
5
169 RD 18 AWG
156 BK 18 AWG
188 BK 10 AWG
C
189 RD 10 AWG
CONNECTOR 6
(BLACK)
CONNECTOR 5
(GRAY)
6C 6A
5A 5C
35
36
3
2
37
3
2
3
38
2
3
CUMMINS J10
SCR INLET/OUTLET
TEMP SENSORS
4A
4
177 RD 18 AWG
4B
1D
1
178 BK 18 AWG
4E
2B
4
1
4
179 RD 18 AWG
180 BK 18 AWG
181 RD 18 AWG
AFTERTREATMENT J1939 (-)
AFTERTREATMENT J1939 (+)
23
22
GN 20 AWG
YL 20 AWG
30
4C
4H
4D
CUMMINS J7A
UPSTREAM DOC
NOx SENSOR
1
182 RD 18 AWG
4F
4
183 BK 18 AWG
3A
CUMMINS J7B
DOWNSTREAM
SCR NOx SENSOR
1
184 RD 18 AWG
4G
4
185 BK 18 AWG
3H
1
186 RD 18 AWG
2
187 BK 18 AWG
SHIELD
CUMMINS CC24B 24 PIN
CROSSOVER CONNECTOR
120 OHM
40
39
CUMMINS J17
DOC INLET/OUTLET
TEMP SENSORS
176 BK 18 AWG
CUMMINS J31
DEF INJECTOR
41
1C
2D
AFTERTREATMENT RELAY BOX
2
42
3
CONNECTOR 4 (GREEN)
2
CUMMINS J6
DEF TANK TEMP/QUALITY/
LEVEL SENSORS
CONNECTOR 3 (BLUE
1
2F
2G
2E
2C
2H
1E
1A
1G
3E
1F
1H
248
32
159
1
1
PRESSURE
2
AIR CLEANER
TBAP SENSOR 3
2
SENSOR SUPPLY
3
TEMPERATURE
4
4
RETURN
160
161
CUMMINS CONNECTOR
'JP1'
164
165
166
167
2A
1B
3D
51
158
CONNECTOR 2 (GRAY)
SHIELD
CONNECTOR 1 (BLACK)
192 BK 12 AWG
CONNECTOR 1
(BLACK)
198 BK
12 AWG
190 RD 12 AWG
191 RD 12 AWG
170 RD 18 AWG
1
171 BK 18 AWG
2
172 RD 18 AWG
1
173 BK 18 AWG
2
174 RD 18 AWG
1
175 BK 18 AWG
2
CUMMINS J28
DEF PRESSURE LINE
HOSE HEATER
43
CUMMINS J29
DEF BACKFLOW LINE
HOSE HEATER
44
CUMMINS J30
DEF SUPPLY LINE
HOSE HEATER
45
5100015549_s1_01_C
wc_tx003750gb_FM10.fm
G 230 / G 240
Schematics, Machines with Deep Sea Controller
27.14 Electrical Schematic Components
Ref.
30
32
34
Description
120 Ohm resistor
Description
38
Cummins upstream Diesel Oxidation
Catalyst (DOC) NOx sensor
Air cleaner Temperature/Pressure
Sensor Connector (TBAP) sensor
39
Cummins supply module connector
40
Black
RD
Red
YL
Yellow
OR
Orange
Cummins downstream Selective Catalyst
Reduction (SCR) Nox sensor
GN
Green
TN
Tan
BR
Brown
PU
Purple
BU
Blue
VIO
Violet
CL
Clear
SH
Shield
Cummins 24 pin crossover connector
PK
Pink
WH
White
GY
Gray
LB
Lt. blue
Aftertreatment J1939(-)
OEM sensor return negative
Aftertreatment J1939(+)
Diesel Exhaust Fluid (DEF) injector
pressure sensor signal
Supply module pump return
Diesel Exhaust Fluid (DEF) pump power
Diesel Exhaust Fluid (DEF) reverting
valve
Diesel Exhaust Fluid (DEF) pump return
Battery return negative
41
42
Wire Colors
BK
Sensor +5V power supply
Diesel Exhaust Fluid (DEF) driver
wc_tx003750gb_FM10.fm
Ref.
Cummins Diesel Exhaust Fluid (DEF)
injector
Aftertreatment relay box
43
Cummins Diesel Exhaust Fluid (DEF)
pressure line hose heater
44
Cummins Diesel Exhaust Fluid (DEF)
backflow line hose heater
45
Cummins Diesel Exhaust Fluid (DEF) supply
line hose heater
46
Cummins Diesel Exhaust Fluid (DEF) tank
heating valve
51
Cummins connector ‘JP1’
Diesel Exhaust Fluid (DEF) supply
module 24V B+
Pressure
35
Cummins Diesel Exhaust Fluid (DEF)
temperature/quality level sensors
Sensor supply
36
Cummins Diesel Oxidation Catalyst
(DOC) inlet/outlet temperature sensors
Temperature
37
Cummins Selective Catalyst Reduction
(SCR) inlet/outlet temperature sensors
Return
249
Schematics, Machines with Deep Sea Controller
G 230 / G 240
27.15 Cummins Engine Relays and Fuses
4
DEF SUPPLY
MODULE RELAY
1
FUSE 1 - 15A
30
87
86
85
6
CONNECTOR 6
+24V BATTERY POSITIVE
KEYSWITCH
AFTERTREATEMENT
7 POWER RELAY
2
6A
FUSE 2 - 10A
6C
5C
5A
6
5
1
3
4B
CUMMINS J6 DEF TANK SENSORS - PIN 4
4C
CUMMINS J17 DOC TEMP SENSORS - PIN 4
4F
CUMMINS J7A DOC NOx SENSOR - PIN 1
85
4G
CUMMINS J7B SCR NOx SENSOR - PIN 1
4A
CUMMINS J6 DEF TANK SENSORS - PIN 3
4E
CUMMINS J17 DOC TEMP SENSORS - PIN 1
4H
CUMMINS J10 SCR TEMP SENSORS - PIN 1
3A
CUMMINS J7A DOC NOx SENSOR - PIN 4
3H
CUMMINS J7B SCR NOx SENSOR - PIN 4
1D
CUMMINS J26 SUPPLY MODULE CONNECTOR - PIN 6
2H
CUMMINS J2 ECU CONNECTOR - PIN 53
2A
CUMMINS J2 ECU CONNECTOR - PIN 77
3D
CUMMINS J31 DEF INJECTOR - PIN 1
3E
CUMMINS J31 DEF INJECTOR - PIN 2
2B
CUMMINS J2 ECU CONNECTOR - PIN 38
30
87
86
85
1E
CUMMINS J28 DEF PRESSURE LINE HEATER - PIN 1
CUMMINS J2 ECU CONNECTOR - PIN 39
30
87
2D
86
85
1B
CUMMINS J29 DEF BACKFLOW LINE HEATER - PIN 1
2F
CUMMINS J2 ECU CONNECTOR - PIN 40
1F
CUMMINS J30 DEF SUPPLY LINE HEATER - PIN 1
2G
CUMMINS J2 ECU CONNECTOR - PIN 3
DEF SUPPLY LINE
10 HEATER RELAY
2
CUMMINS J2 ECU CONNECTOR - PIN 7
86
HEATER RELAY
FUSE 3 - 15A
2C
CUMMINS J10 SCR TEMP SENSORS - PIN 4
9 DEF BACKFLOW LINE
+24V BATTERY POSITIVE
CUMMINS J26 SUPPLY MODULE CONNECTOR - PIN 5
4D
5
-24V BATTERY NEGATIVE
1C
87
HEATER RELAY
3
CONNECTORS 1, 2, 3, AND 4
OUTPUT PINS
30
8 DEF PRESSURE LINE
CONNECTOR 5
11
30
87
1A
CUMMINS J28 DEF PRESSURE LINE HEATER - PIN 2
86
85
1G
CUMMINS J29 DEF BACKFLOW LINE HEATER - PIN 2
1H
CUMMINS J30 DEF SUPPLY LINE HEATER - PIN 2
2E
CUMMINS J2 ECU CONNECTOR - PINS 84 & 85
8
10 9
7
4
5100015549_s2_01
250
wc_tx003750gb_FM10.fm
G 230 / G 240
Schematics, Machines with Deep Sea Controller
27.16 Cummins Engine Relays and Fuses
Ref.
Ref.
Description
15A fuse 1
Cummins Diesel Exhaust Fluid (DEF) tank
sensors - pin 3
10A fuse 2
Cummins Diesel Oxidation Catalyst (DOC)
temperature sensors - pin 1
15A fuse 3
Cummins Selective Catalyst Reduction
(SCR) temperature sensors - pin 1
Diesel Exhaust Fluid (DEF) supply
module relay
Cummins Diesel Oxidation Catalyst (DOC)
NOx sensor - pin 4
Connector 5
Cummins Selective Catalyst Reduction
(SCR) NOx sensor - pin 4
-24V battery negative
Cummins supply module connector - pin 6
-24V battery positive
Cummins Engine Control Unit (ECU)
connector - pin 53
Connector 6
Cummins Engine Control Unit (ECU)
connector - pin 77
+24V battery positive
Cummins Diesel Exhaust Fluid (DEF)
injector - pin 1
Keyswitch
Cummins Diesel Exhaust Fluid (DEF)
injector - pin 2
Aftertreatment power relay
Cummins Engine Control Unit (ECU)
connector - pin 36
8
Diesel Exhaust Fluid (DEF) pressure line
heater relay
Cummins Diesel Exhaust Fluid (DEF)
pressure line heater - pin 1
9
Diesel Exhaust Fluid (DEF) backflow line
heater relay
Cummins Engine Control Unit (ECU)
connector - pin 39
10
Diesel Exhaust Fluid (DEF) supply line
heater relay
Cummins Engine Control Unit (ECU)
connector - pin 39
Connectors 1, 2, 3, and 4 output pins
Cummins Diesel Exhaust Fluid (DEF)
backflow line heater - pin 1
Cummins supply module connector pine 5
Cummins Engine Control Unit (ECU)
connector - pin 40
Cummins Engine Control Unit (ECU)
connector - pin 7
Cummins Diesel Exhaust Fluid (DEF)
supply line heater - pin 1
Cummins Diesel Exhaust Fluid (DEF)
tank sensors - pin 4
Cummins Engine Control Unit (ECU)
connector - pin 3
Cummins Diesel Oxidation Catalyst
(DOC) temperature sensors - pin 4
Cummins Diesel Exhaust Fluid (DEF)
pressure line heater - pin 2
Cummins Selective Catalyst Reduction
(SCR) temperature sensors - pin 4
Cummins Diesel Exhaust Fluid (DEF)
backflow line heater - pin 2
Cummins Diesel Oxidation Catalyst
(DOC) NOx sensor - pin 1
Cummins Diesel Exhaust Fluid (DEF)
supply line heater - pin 2
Cummins Selective Catalyst Reduction
(SCR) NOx sensor - pin 1
Cummins Engine Control Unit (ECU) - pin
84 & 85
1
2
3
4
5
6
7
11
wc_tx003750gb_FM10.fm
Description
251
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, D-80809 München, Tel.: +49-(0)89-3 54 02-0 Fax: +49 - (0)89-3 54 02-390
Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI 53051
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
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