Wacker Neuson G70 Mobile Generator Operator's Manual
Below you will find brief information for Mobile Generator G70. This manual provides instructions for the safe operation and maintenance of the Wacker Neuson Mobile Generator G70, including safety guidelines, control locations, operating procedures, and maintenance schedules. It covers topics such as machine identification, lifting and transport, machine setup, operation, and troubleshooting, ensuring users can safely utilize this electric power source.
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Operator’s Manual
Mobile Generator
G70
Type
Document
Date
Revision
Language
G70
5100044748
0519
02
EN
Copyright notice
Trademarks
Manufacturer
Original instructions
© Copyright 2019 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.
All trademarks referenced in this manual are the property of their respective owners.
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
This Operator’s Manual presents the original instructions. The original language of this Operator’s Manual is American English.
CALIFORNIA Proposition 65 Warning
CALIFORNIA Proposition 65 Warning
WARNING
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
WARNING
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
WARNING
Cancer and Reproductive Harm - www.P65Warnings.ca.gov.
WARNING
Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.
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CALIFORNIA Proposition 65 Warning Proposition 65 Warning
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G70
Machine Identification
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
G70
Item Number
5100044760 wc_gr015032
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_tx004648en.fm
5
Foreword
Foreword
Mobile Generator
Machine documentation
Expectations for information in this manual
CALIFORNIA
Proposition
65 Warning
Laws pertaining to spark arresters
■ 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.
■ For spare parts information, please see your Wacker Neuson Dealer, or visit the
Wacker Neuson website at http://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.
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.
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.
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CO
DEF
DM
DOC
DTC
EGR
EPA
Mobile Generator 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.
Abbreviations
Abbreviation or
Acronym
ATS
CARB
CDL
CKP
CMP
Definition
Automatic transfer switch
California Air Resource
Board
Commercial driver’s license
Crank position
Camshaft position
ERT
Carbon monoxide
Diesel exhaust fluid
Dosing module
Diesel oxidation catalyst
Diagnostic trouble codes
Exhaust gas recirculation
Environmental Protection
Agency
Extended run tank
Abbreviation or Acronym
L3
LT
MAF
NC
NHTSA
NOx
P/L
PPE
S/N
SCR
SPN
ST
TDG
Definition
Level load logic
Light truck
Mass air flow
Normally closed
National Highway Traffic Safety
Administration
Nitrogen oxides
Pressure limiter
Personal protective equipment
Serial number
Selective catalytic reduction
Suspect parameter number
Special trailer
FMI
GAWR
IBC
Failure mode identifier
Gross axle weight ratings
Intermediate bulk container
TWI
VCW
—
Canadian Transportation of
Dangerous Goods Act
Treadwear indicators
Vehicle capacity weight
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Foreword Mobile Generator
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G70
CALIFORNIA Proposition 65 Warning
Table of Contents
3
Machine Identification
Foreword
1 Safety Information
1.5
1.6
1.7
1.8
1.9
1.1
1.2
1.3
1.4
15
Signal Words Used in this Manual ............................................................. 15
Machine Description and Intended Use ..................................................... 16
Safety Guidelines for Operating the Machine ............................................. 17
Service Safety ............................................................................................ 19
Operator Safety while Using Internal Combustion Engines ....................... 21
Safety Guidelines for Mobile Generators ................................................... 22
Safety Guidelines for Towing the Machine ................................................. 24
Safety Guidelines for Lifting the Machine ................................................... 25
Reporting Safety Defects ........................................................................... 25
2 Label Locations 26
5
6
3 Label Meanings 28
4 Lifting and Transporting
4.1
4.2
4.3
4.4
4.5
4.6
4.7
37
Lifting the Machine ..................................................................................... 37
Before Towing Checklist ............................................................................. 38
Towing the Machine ................................................................................... 39
Preparing the Machine for Transport on a Truck or Trailer ........................ 40
Hazardous Materials Placards ................................................................... 41
Testing the Breakaway System—Hydraulic Surge Brakes ......................... 42
Testing the Breakaway System—Electric Brakes ...................................... 44
5 Machine Setup
5.1
5.2
5.3
5.4
5.5
46
Preparing the Machine for First Use ........................................................... 46
Positioning the Machine ............................................................................. 47
Grounding the Generator ........................................................................... 49
Recommended Fuel ................................................................................... 50
Refueling the Machine—Deep Sea Controller ........................................... 51 wc_bo5100044748_02TOC.fm
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Table of Contents
6 Operation, Control, and Component Locations
6.1
6.2
G70
52
Control and Component Locations ............................................................. 52
Control Panel Components ........................................................................ 53
7 Operation—Deep Sea Controller 54
7.5
7.6
7.7
7.8
7.1
7.2
7.3
7.4
Main Circuit Breaker ................................................................................... 54
Generator Controller Power Switch ............................................................ 55
Function of the Crankcase Pressure Switch (if equipped) ......................... 56
Selecting the Voltage ................................................................................. 58
Deep Sea Controller Buttons/Functions ..................................................... 60
Generator Controller Alarms and Shut-Down Conditions ........................... 62
Before Starting the Machine ....................................................................... 64
Starting and Running the Generator .......................................................... 65
7.9
Stopping the Generator .............................................................................. 67
7.10
Emergency Stop Switch ............................................................................. 68
7.11
Engine and Generator Monitoring .............................................................. 69
8 Working with Deep Sea Controller: DSE 7310 MKII
8.1
8.2
8.3
8.4
70
Introduction ................................................................................................. 70
Navigating the Menus ................................................................................. 71
Adjusting Screen Contrast .......................................................................... 73
How to Reset the Maintenance Timer ........................................................ 74
9 How to Connect Loads—480V
9.1
9.2
9.3
9.4
9.5
9.6
9.7
75
Lug Terminal Connection Diagrams ........................................................... 75
Best Practices for Balancing Loads ............................................................ 76
Connecting 480V, 3-Phase and Single-Phase Loads ................................ 79
Connecting a 240V 3Ø Load and a 240V 1Ø Load .................................... 80
Connecting 240V and 120V Single-Phase Loads ...................................... 81
Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads ........................ 82
Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads ........ 83
10 How to Connect Loads—600V 84
10.1
Lug Terminal Connection Diagrams ........................................................... 84
10.2
Best Practices for Balancing Loads ............................................................ 85
10.3
Connecting a 240V 3Ø Load and a 240V 1Ø Load .................................... 88
10.4
Connecting 240V and 120V Single-Phase Loads ...................................... 89
10.5
Connecting a 208V 3Ø Load and Multiple 120V 1Ø Loads ........................ 90
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G70 Table of Contents
10.6
Connecting a 220–240V 3Ø Load and Multiple 127–133V 1Ø Loads ........ 91
10.7
Connecting 480V, 3-Phase Loads .............................................................. 92
10.8
Connecting 600V, 3-Phase Loads .............................................................. 93
11 Using Remote Start Capabilities 94
11.1
Remote Run Terminal Block ...................................................................... 94
11.2
Remote Transfer Switch ............................................................................. 95
11.3
Preparing for Automatic/Remote Start-Up—Deep Sea .............................. 96
12 Diagnostic Trouble Codes (DTC) 98
12.1
Accessing Engine DTCs using the Deep Sea Controller ........................... 98
12.2
List of Engine Diagnostic Trouble Codes (DTCs) ....................................... 99
13 Factory-Installed Options 117
13.1
600V ......................................................................................................... 117
13.2
Level Load Logic (L3) ............................................................................... 118
13.3
Fuel Filter Heater ...................................................................................... 119
13.4
Quick Oil Change ..................................................................................... 119
13.5
Battery Charger ........................................................................................ 120
13.6
Lockable Battery Disconnect .................................................................... 121
13.7
Camlocks .................................................................................................. 122
13.8
Containment System ................................................................................ 123
13.9
Extended Run Tank (ERT) ....................................................................... 123
13.10
Engine Block Heater ................................................................................. 124
13.11
Low Coolant Shutdown ............................................................................ 125
13.12
Connecting an External Fuel Supply ........................................................ 126
14 Machines with Aftertreatment Exhaust System 127
14.1
How the Aftertreatment Exhaust System Works ...................................... 127
14.2
Filling the DEF Tank ................................................................................. 128
14.3
Shelf Life of Diesel Exhaust Fluid (DEF) .................................................. 130
14.4
Monitoring and Controlling the DEF Level ................................................ 131
14.5
Monitoring DEF Quality ............................................................................ 132
15 General Maintenance 133
15.1
Periodic Maintenance Schedule ............................................................... 133
15.2
Maintaining the Emission Control System ................................................ 134
15.3
Preparing for Maintenance ....................................................................... 134 wc_bo5100044748_02TOC.fm
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Table of Contents G70
15.4
Cleaning the Machine ............................................................................... 134
15.5
Inspecting the Machine ............................................................................ 135
15.6
Maintaining the Trailer .............................................................................. 136
15.7
Checking and Draining the Containment System (if equipped) ................ 137
15.8
Checking the Exhaust System ................................................................. 138
15.9
Maintaining the Battery ............................................................................. 139
15.10
Filling the Radiator ................................................................................... 140
15.11
Replacing the Aftertreatment DEF Dosing Unit Filter (if equipped) .......... 142
15.12
Storage ..................................................................................................... 144
15.13
Machine Disposal and Decommissioning ................................................. 145
16 Engine Maintenance: Kohler KDI 3404 TCR–SCR 146
17 Troubleshooting 149
18 Technical Data: G70 151
18.1
Engine ...................................................................................................... 151
18.2
Generator ................................................................................................. 152
18.3
Machine .................................................................................................... 152
18.4
Trailer and Skid ........................................................................................ 153
18.5
Dimensions ............................................................................................... 154
19 Tire Safety Information 155
20 User’s Information for Transport Canada Fuel Tank 168
21 Emission Control Systems Information and Warranty—Diesel 171
21.1
Emission Control System Background Information .................................. 171
21.2
Limited Defect Warranty for Exhaust Emission Control System .............. 172
21.3
Limited Defect Warranty for Wacker Neuson Emission Control
Systems .................................................................................................... 172
22 General Machine Schematics 175
22.1
Fuses ........................................................................................................ 175
22.2
Trailer Wiring ............................................................................................ 176
22.3
Trailer Wiring Components ....................................................................... 177
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G70 Table of Contents
23 Schematics—Machines with Deep Sea Controller 178
23.1
AC Schematic: G70 480V ........................................................................ 178
23.2
AC Schematic Components: G70 480V ................................................... 179
23.3
AC Schematic: G70 600V ........................................................................ 180
23.4
AC Schematic Components: G70 600V ................................................... 181
23.5
DC Schematic: Deep Sea Control Box ..................................................... 182
23.6
DC Schematic Components: Deep Sea Control Box ............................... 183
23.7
Engine Schematic: Kohler KDI 3404 ........................................................ 184
23.8
Engine Schematic Components: Kohler KDI 3404 ................................... 185
23.9
Engine Schematic: Aftertreatment ............................................................ 186
23.10
Engine Schematic Components: Aftertreatment ...................................... 187 wc_bo5100044748_02TOC.fm
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Table of Contents G70
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Mobile Generator
1 Safety Information
Safety Information
1.1
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.
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Safety Information
1.2
Machine Description and Intended Use
Machine description
Mobile Generator
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.
Intended use 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.
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Mobile Generator
1.3
Safety Guidelines for Operating the Machine
Safety Information
Operator training
Operator qualifications
Application area
Safety devices, controls, and attachments
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.
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, drugs, or prescription drugs
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.
■ Do not operate the machine in areas that contain flammable objects, fuels, or products that produce flammable vapors.
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.
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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.
■ 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 oil, heat transfer fluid (propylene glycol with additives), battery acid, or grease.
Personal protective equipment
(PPE)
After use
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
■ 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 location out of the reach of children.
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Mobile Generator
1.4
Service Safety
Service training
Precautions
Machine modifications
Replacing parts and labels
Safety Information
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 protective 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 untrained or 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.
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.
■ Reinstall the safety devices and guards after repair and maintenance procedures are complete.
When servicing or maintaining the machine:
■ Use only accessories/attachments that are approved by Wacker Neuson.
■ Do not defeat safety devices.
■ Do not modify the machine without the express written approval of Wacker
Neuson.
■ 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.
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Safety Information
Cleaning
Personal protective equipment
(PPE)
Electrical service safety
Mobile Generator
When cleaning and servicing the machine:
■ Keep machine clean and free of debris such as leaves, paper, cartons, etc.
■ Keep labels legible.
■ 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.
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).
■ 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.
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Mobile Generator Safety Information
1.5
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.
Operating safety
Refueling safety
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 items such as exhaust fans or hoses.
When running the engine:
■ Keep the area around the 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.
■ 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.
■ Do not use the machine in areas with risk of explosion or fire.
When refueling the engine:
■ Clean up any spilled fuel immediately.
■ Refill the fuel tank in a well-ventilated area.
■ Reinstall the fuel tank cap after refueling.
■ Use tools specifically meant for refueling (for example, a fuel hose or funnel).
■ Do not smoke.
■ Do not refuel a hot or running engine.
■ Do not refuel the engine near sparks or open flames.
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Safety Information
1.6
Safety Guidelines for Mobile Generators
Mobile Generator
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. 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 poisoning.
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 backup power
Special hazards exist when installing this machine as a backup power supply.
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.
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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
23
Safety Information
1.7
Safety Guidelines for Towing the Machine
Mobile Generator
WARNING
Risk of severe injury or death. Improper trailer condition and towing technique can lead to an accident.
► Obey 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 safety chains are damaged.
■ Do not tow the machine if any of the trailer’s lug nuts are loose or missing.
■ Do not tow the machine if the trailer’s tires have less than 1/16 inch (1.5 mm) of tread.
■ Do not tow the machine if trailer tires are underinflated.
■ Do not tow the machine unless the trailer’s brakes are functioning properly.
■ Do not tow the machine if trailer lighting is not functioning properly.
■ Do not exceed the trailer manufacturer’s speed limitations of 89 km/h (55 mph).
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 a trailer before, practice turning, stopping, and backing up the towing vehicle with the trailer in an area away from traffic. Only drive the towing vehicle with the trailer when you are confident in your ability to do so.
24
wc_tx003567gb_FM10.fm
Mobile Generator
1.8
Safety Guidelines for Lifting the Machine
Safety Information
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 the Technical Data chapter 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
25
Label Locations
2 Label Locations
s b aq g
G70 t m y ap ar u k z ae n ab j h an g aa v w ad a r x g ac g p wc_gr015023
wc_si001112.fm
26
G70 Label Locations af s b af aq ak ak ac t g as c d t g o ao q f aj ah e am t g ag wc_gr015024 wc_si001112.fm
27
c d
Label Meanings
3 Label Meanings
a b e
G70
WARNING
Pressurized contents. Do not open when hot!
WARNING
Lock doors. Access can cause electric shock or injury.
NOTICE
Never change switch position with engine running. Results in damage to machine.
28
WARNING
Electric shock can cause serious injury or death.
DANGER
Asphyxiation hazard.
■ Engines emit carbon monoxide.
■ Do not run the machine indoors or in an enclosed area.
■ Only use OUTSIDE and far away from windows, doors, and vents.
■ Read the Operator’s Manual.
■ No sparks, flames, or burning objects near the machine.
■ Stop the engine before refueling.
■ Use only clean, filtered diesel fuel.
wc_si001113.fm
G70 f g h j k wc_si001113.fm
29
Label Meanings
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
Hot surface
WARNING
Electric shock at cooling fins.
DANGER
Asphyxiation hazard.
■ Engines emit carbon monoxide.
■ Do not run the machine indoors or in an enclosed area.
■ Electric shock and arc flash can cause serious injury or death.
WARNING
Generator can automatically start which can cause serious injury. Disconnect battery before servicing.
o p
Label Meanings G70
WARNING
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.
m n
176186
Improper connection of generator to a buildings electrical system can allow electrical current from the generator to back feed into utility lines. This may result in electrocution of utility workers, fire, or explosion. Connections to a buildings electrical system must be made by a qualified electrician and comply with all applicable laws and electrical codes.
La conexión incorrecta de un generador al sistema eléctrico de un edificio puede conducir a un retorno de la corriente eléctrica desde el generador al sistema de distribución eléctrico publico. Esto puede conducir a la electrocución de los obreros del servicio publico, incendios o explosiones. Sólo un técnico electricista capacitado podrá efectuar conexión al sistema eléctrico del edificio. La conexión eléctrica deberá cumplir con las leyes y códigos eléctricos pertinentes.
Le branchement no conforme du générateur au reseau de distribution eléctrique d'un immeuble peut provoquer la réinjection du courant eléctrique du générateur dans les lignes du reseau public. Ceci peut provoquer une électrocution des employés du service public, un incendie ou une explosion. Les branchements au reseau électrique d'un immeuble doivent
être effectués par un eléctricien qualifié et doivent être conformes à toutes les lois du tous les codes électriques applicables.
WARNING
To reduce the risk of electrical shock and arc flash, read the Operator’s Manual. Improper connection of the generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines.
This may result in electrocution of utility workers, fire, or explosion. Connections to a building’s electrical system must be made by a qualified electrician and comply with all applicable laws and electrical codes.
WARNING
Disconnect battery before servicing.
Read the Operator’s Manual.
30
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.
wc_si001113.fm
G70 q r
Label Meanings
(if equipped)
Battery disconnect must be in “ON” position to start engine.
NOTICE
Do not use the battery disconnect switch while engine is running. Damage to the electrical components may occur.
TOWING INSTRUCTIONS
1. READ OPERATOR'S MANUAL.
2. USE HITCH RATED FRO TRAILER'S
"GROSS VEHICLE WEIGHT RATING".
3. SECURELY ATTACH TRAILER TO TOW
VEHICLE.
4. ATTACH SAFETY CHAINS USING CROSS
PATTERN.
5. ATTACH BREAKDOWN CHAIN TO VEHICLE.
6. CHECK TRAILER LIGHTS.
ABSCHLEPPINSTRUKTIONEN
1. BETRIEBSVORSCHRIFT LESEN.
2. ANHANGEVORRICHTUNG VERWENDEN,
DIE DER GESAMTBETRIEBSGEWICHTSKLASSE
ENTSPRICHT.
3. ANHANGER SICHER AM ZUGFAHRZEUG
BEFESTIGEN.
4. SICHERHEITSKETTEN KREUZWEISE ANBRINGEN.
5. ABREISSKETTE AM FAHRZEUG ANBRINGEN.
6. ANHANGERLEUCHTEN PRUFEN.
INSTRUCCIONES DE REMOLQUE
1. LEA EL MANUAL DEL OPERARIO.
2. UTILICE UN ACOPLE CORRECTAMENTE
CLASIFICADO PARA LA "CLASE DE PESO BUTO"
DEL VEHICULO DEL REMOLQUE.
3. ASEGURESE DE AMARRAR CORRECTAMENTE
EL REMOLQUE AL VEHICULO DE REMOLQUE.
4. FIJE EN CRUZ LAS CADENAS DE SEGURIDAD.
5. FIJE EN EL VEHICULO DE REMOLQUE LA CADENA
DE DESPRENDIMIENTO.
6. CONTROLE LAS LUCES DEL REMOLQUE.
INSTRUCTIONS DE REMORQUAGE
1. LIRE LA NOTICE D'EMPLOI.
2. UTILISER UN GROCHET D'ATTELAGE CONFORME AU
DEBIT NOMINAL DU POIDS BRUT DE VEHICULE DU
TRACTEUR.
3. ATTACHER LA REMORQUE FERMEMENT AU VEHICULE
TRACTEUR.
4. ATTACHER LES CHAINES DE SURETTE EN UTILISANT
UNE METHODE CROISEE.
5. ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE.
6. VERIFIER LES LAMPES DE LA REMORQUE.
NOTICE
Lifting point s
Tie-down point t wc_si001113.fm
31
Label Meanings G70 u v
32
Operator’s Manual must be stored on machine.
Replacement Operator’s Manual can be ordered through your local Wacker Neuson distributor.
wc_si001113.fm
y z aa
G70 w
REMOTE START
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
114897 x ab
Label Meanings
Remote start operation. Read Operator’s
Manual for instructions.
Drain containment system (if equipped).
Operating the main circuit breaker supplies or interrupts power to the customer connection lugs.
Neutral bonded to frame
Generator and receptacle wiring wc_si001113.fm
33
Label Meanings ac ad ae af ag ah
G70
Protecting Our Environment
Fluid containment system
This machine may be covered by one or more patents.
Lug door must be closed for lugs and receptacles to energize.
(Camlock models only)
WARNING
Electric shock can cause serious injury or death.
(Camlock models only)
WARNING
Electric shock and arc flash can cause serious injury or death.
Emission control information.
This equipment has an engine that meets
California Emission Standards under 13 CCR
2423(d) and EPA Emission Standards under 40
CFR 1039.625.
34
wc_si001113.fm
G70 aj ak
SÓLO LÍQUIDO DE ESCAPE DIESEL am
ULSD S15
SOLAMENTE COMBUSTIBLE
DE AZUFRE an
WARNING
Cancer and Reproductive Harm www.P65Warnings.ca.gov
ADVERTENCIA
Cáncer y daño reproductivo www.P65Warnings.ca.gov
AVERTISSEMENT
Cancer ou malformations congénitales www.P65Warnings.ca.gov
5100045462 ao ap
Label Meanings
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.
NOTICE
Diesel exhaust fluid only.
Do not fill the DEF tank with diesel fuel.
NOTICE
Ultra low sulfur fuel only.
Do not fill the diesel tank with DEF.
California Proposition 65 Warning
Cancer and Reproductive Harm - www.P65Warnings.ca.gov.
(if equipped)
Fuel pressure must be tested.
Acceptable range:
-250 mbar minimum
200 mbar maximum
CAUTION
Receptacles not to be used when:
Selector switch set to 208/120V and voltage greater than 228V.
Selector switch set to 480/277V and voltage greater than 457V.
wc_si001113.fm
35
Label Meanings aq ar
Hand grip
Emergency stop
G70
36
wc_si001113.fm
Mobile Generator
4 Lifting and Transporting
Lifting and Transporting
4.1
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.
wc_tx003570gb_FM10.fm
37
Lifting and Transporting
4.2
Before Towing Checklist
Mobile Generator
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 chapter 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
38
Mobile Generator
4.3
Towing the Machine
Lifting and Transporting
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 b
Brakes a a c c wc_gr011430 wc_gr012751
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. wc_tx003570gb_FM10.fm
39
Lifting and Transporting Mobile Generator
4.4
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
40
Mobile Generator
4.5
Hazardous Materials Placards
Overview
Lifting and Transporting
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.
Requirements
Apply the placards wc_gr009231
■ 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.
a. Gradually remove the backing paper and apply the remainder of the placard.
b. Firmly press and smooth the placard into place with a plastic squeegee, stiff cardboard, or a soft cloth.
c. Puncture any air bubbles that may form.
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41
Lifting and Transporting Mobile Generator
4.6
Testing the Breakaway System—Hydraulic Surge Brakes
Requirements ■ Hydraulic reservoir filled
■ Machine parked on a flat surface
When
Procedure
■ Before towing
■ After filling the hydraulic reservoir
Perform the procedure below 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.
a b 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
42
Mobile Generator Lifting and Transporting
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 wc_tx003570gb_FM10.fm
43
Lifting and Transporting Mobile Generator
4.7
Testing the Breakaway System—Electric Brakes
Requirements ■ Voltmeter
■ Battery charger or backup battery (charged)
When
Procedure
■ Before towing
■ Monthly if the machine is not in service
Perform the procedure below 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.
44
wc_tx003570gb_FM10.fm
Mobile Generator Lifting and Transporting
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
F 1000
200
20
2
200m
V
A
VDC VCOM 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. Reinstall the cover to the battery box.
c. Reinstall the breakaway pin (b) into the brake switch.
d. Connect the trailer wiring plug to the tow vehicle.
wc_tx003570gb_FM10.fm
45
Machine Setup
5 Machine Setup
G70
5.1
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. Add fluids as needed and applicable, including fuel, engine oil, hydraulic oil, retardant, and battery acid.
5. Move the machine to its operating location.
6. Connect component parts not already attached.
Safety information
CO alarms
■ Do not exceed the power output of the generator. Damage to tools or generator will occur. Refer to chapter 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.
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.
46
wc_tx004640en.fm
G70
5.2
Positioning the Machine
WARNING
Fire hazard. Do not move the machine while it is running.
► Shut down the machine before moving or repositioning it.
Machine Setup
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.
■ The machine does not block traffic.
■ The machine is not close to any combustible material or flammable vapor.
■ All of the machine’s access doors/panels may be accessed.
■ The area overhead is clear of debris that could fall onto or into the machine or exhaust compartment.
■ 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.
wc_tx004640en.fm
47
Machine Setup
Procedure
Continued from the previous page.
Perform the procedure below to position the machine.
1. Place the machine on solid, stable, and level ground.
G70 a wc_gr009186
2. For machines with trailers, install chocks (a) under the wheels.
48
wc_tx004640en.fm
G70
5.3
Grounding the Generator
External grounding
Machine Setup
A ground connection is located at the customer connection terminal lugs.
Internal grounding 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 that must be observed.
■ In some areas, generators are required to be registered with local utility companies.
■ 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.
wc_tx004640en.fm
49
Machine Setup
5.4
Recommended Fuel
Low temperatures cause diesel fuel to gel. Always use the proper fuel for the conditions. Follow the guidelines in the table below.
G70
Lowest expected ambient temperature
Above freezing
> 0°C (32°F)
Below freezing
< 0°C (32°F)
Recommended fuel
#2 diesel plus additives
Winter-blend diesel
1
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.
50
wc_tx004640en.fm
G70
5.5
Refueling the Machine—Deep Sea Controller
Requirements ■ Engine stopped
■ Machine/fuel tank level with the ground
■ Remote switch disconnected from the remote run terminal
■ Fresh, clean fuel supply
Machine Setup
Procedure Perform the procedure below to refuel the machine.
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 generator controller power switch in the ON position and wait for the
Deep Sea controller to boot up.
3. Press the right arrow button to navigate to the “Engine” screen.
STOP
DSE
DEEP SEA ELECTRONICS
DSE 7310
STOP oo
Auto
Mode wc_gr011443
4. Use the up or down arrow button 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.
wc_tx004640en.fm
6. Reinstall the fuel cap.
7. Place the generator controller power switch in the OFF position.
51
e r q
Operation, Control, and Component Locations
6 Operation, Control, and Component Locations
6.1
Control and Component Locations
c
V Ø A HZ
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
STOP a b f g d h
REMOTE START
FERNSTART
ARRANQUE REMOTO
START / LAUFEN
ARRANQUE / MARCHA j k n l p m o wc_gr011689
wc_tx003635gb_FM10.fm
52
Operation, Control, and Component Locations t s s wc_gr011690
6.2
Control Panel Components
Ref.
Description
Main circuit breaker a h j f g d e b c k
Voltage adjustment rheostat
Generator controller
Idle switch (high and low) (if equipped)
Ground connection point
Pre-alarm/shutdown LED
Engine start switch
Hour meter
Circuit breaker (240V, 20A or 50A)
Circuit breaker (120V, 20A) wc_tx003635gb_FM10.fm
53
s t q r o p m n
Ref.
Description l
Twist-lock receptacle
(2) 240 VAC, 50A optional:
(2) 240 VAC 20A, (1) 240 VAC 50A
GFCI receptacle (120 VAC, 20A)
Remote run terminal block
Emergency stop switch
Lug door interlock switch u
Bond bar
Terminal lugs
Voltage selector switch
Fuse box
Manual conditioning switch for aftertreatment exhaust system
Operation—Deep Sea Controller
7 Operation—Deep Sea Controller
G 70 (600V)
7.1
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 / LAUFEN
ARRANQUE / MARCHA
AUS
APAGADO
STOP
ARRANQUE / MARCHA ARRANQUE / MARCHA START / LAUFEN START / LAUFEN
DEMARRER / MARCHE DEMARRER / MARCHE
AUS AUS
ARRET ARRET APAGADO APAGADO
Functions
ME
R GE NC
Y
S T O P wc_gr011444
■ 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.
wc_tx004641en.fm
54
G 70 (600V) Operation—Deep Sea Controller
7.2
Generator Controller Power Switch
Description The generator controller power switch (a) is a two-position switch: ON and OFF.
a
DSE 7310 MKII
STOP
Function
Position
ON
OFF wc_gr014855
Function
When set to this position:
■ Power is supplied to the generator controller.
■ The generator controller boots up and sets itself to the Stop/Reset mode—the engine is ready to be started.
When set to this position, power to the generator controller is disconnected.
LCD Screen
“Generator at Rest” followed by the status screens that scroll.
Blank screen (off) wc_tx004641en.fm
55
Operation—Deep Sea Controller G 70 (600V)
7.3
Function of the Crankcase Pressure Switch (if equipped)
Function The crankcase pressure switch is a normally closed (NC) switch. Its purpose is to keep the engine from damage due to high pressure build-up inside the crankcase.
If the vent hose becomes clogged because of ice forming inside of it, pressure builds within the crankcase. This pressure could damage the engine. The crankcase pressure switch prevents damage to the engine by shutting down the engine in the event of high pressure.
a
Operation wc_gr015060
When the crankcase pressure switch (a) senses high pressure (>5 psi):
■ the crankcase pressure switch opens which informs the controller a high pressure condition exists
■ the controller sends a shut down message to the engine
■ the machine shuts down
■ the following message appears on the controller’s LCD display
Deep Sea
DSE
DEEP SEA ELECTRONICS
Crankcase Pressure High
DSE 7310
STOP wc_gr014853
This procedure continues on the next page.
56
wc_tx004641en.fm
G 70 (600V)
Procedure
Operation—Deep Sea Controller
Continued from the previous page.
To rectify the condition, clear the vent hose of all obstructions.
1. Remove the insulation that covers the vent hose. a wc_gr015072
2. Remove the vent hose (a) .
3. Thaw and drain the vent hose.
4. Clean the vent hose.
5. Reinstall the vent hose.
6. Reinstall the insulation.
wc_tx004641en.fm
57
Operation—Deep Sea Controller
7.4
Selecting the Voltage
Location
G 70 (600V)
One of two types of voltage selector switch—either three-position (a) or fourposition (b) —is mounted to the machine near the lugs.
NUR NIEDRIGEN SCHWEFELKRAFTSTOFF ODER ULTRANIEDRIGEN SCHWEFELKRAFTSTOFF.
SOLAMENTE COMBUSTIBLE DE BAJO CONTENIDO DE AZUFREO COMBUSTIBLE DE
ULTRABAJO CONTENIDO DE AZUFRE.
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
346/600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø a b wc_gr011503
WARNING
Electric shock hazard. High voltage is present inside the voltage selector switch enclosure when the engine is running.
► Do not open the voltage selector switch enclosure unless the engine is stopped.
Selecting the voltage
The chart below lists the ranges of voltages available in each of the switch positions. Select the desired voltage by rotating the handle of the voltage selector switch. Then, use the voltage adjustment rheostat to set the exact voltage you require. The voltage is displayed on the LCD panel.
Switch position
120/240 VAC 1Ø
208/240 VAC 3Ø
120/139 VAC 1Ø
277/480 VAC 3Ø
346/600 VAC 3Ø 1
3Ø at lugs
(L–L–L)
—
190–240
1Ø at lugs
(L–N)
Range of Voltages Available
1Ø at lugs
(L-L)
1Ø at twist lock
L-N (120V) L-L (240V)
110–125
110–139
220–250
190–240
110–125
110–139
220–250
190–240
1Ø at GFCI
110–125
110–139
380–480
540–600
220–277
—
2
1
Not available on all models.
2
Not available on 600V models.
190–240 2
—
110–139 2
—
190–240 2
—
110–139 2
—
NOTICE: Do not change the position of the voltage selector switch while the engine is running. Doing so can cause arcing which can damage the voltage selector switch and the generator windings.
This procedure continues on the next page.
wc_tx004641en.fm
58
G 70 (600V)
Using the rheostat
Operation—Deep Sea Controller
Continued from the previous page.
The voltage adjustment rheostat (c) is used to fine-tune the voltage as needed while the machine is running.
c
V Ø A HZ
DIAGNOSEN DIAGNOSTICS
DIAGNOSTICOS
DIAGNOSTICS
042563
APAGADO APAGADO AUS AUS
ARRET ARRET
ARRANQUE REMOTO ARRANQUE REMOTO
DISTANCE DISTANCE DEMARRAGE A DEMARRAGE A
ARRANQUE / MARCHA ARRANQUE / MARCHA START / LAUFEN START / LAUFEN
DEMARRER / MARCHE DEMARRER / MARCHE
V
Ø A HZ
DIAGNOSTICS
DIAGNOSEN
AUS AUS
ARRET ARRET APAGADO APAGADO
ARRANQUE REMOTO ARRANQUE REMOTO
DISTANCE DISTANCE DEMARRAGE A DEMARRAGE A
START / LAUFEN START / LAUFEN
DEMARRER / MARCHE DEMARRER / MARCHE ARRANQUE / MARCHA ARRANQUE / MARCHA
E R GE NC
M
S T O P wc_gr011502
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.
Switch Position
208 VAC 3Ø
120 VAC 1Ø
277/480 VAC 3Ø
346/600 VAC 3Ø 3
3Ø Voltage
(L-L-L)
208
220
240
480
460
600
540
Corresponding 1Ø voltage
Twist lock receptacle
L-L (240V)
208
L-N (120V)
120
120V GFCI
120
220
240
240
230
125
139 1
139 1
133 2
—
125
139 1
139 1
133 2
1
Do not use receptacle with this voltage.
2
Voltage may be too high for some tools and equipment. Check tool/equipment specifications.
3
Not available on all models.
wc_tx004641en.fm
59
Operation—Deep Sea Controller
7.5
Deep Sea Controller Buttons/Functions
e d c b a
DSE
DEEP SEA ELECTRONIC S
STOP
G 70 (600V) m f g h j n o p q r s t wc_gr014856
Ref.
Button/function a Right arrow button (right / forward) b c
Up arrow button
Down arrow button d e f
Left arrow button (left / backward)
Check mark button (enter / accept)
This button is used when navigating through the generator controller menus.
Press this button to accept a new value or menu item.
Alarm indicator
Illuminates during a fault condition that has stopped the engine.
g h j m n
Warning indicator
Illuminates during a non-critical alarm condition. Note: non critical alarm conditions may lead to shut-down conditions.
Main breaker open indicator
Illuminates whenever the main circuit breaker is open.
Low speed active indicator
Illuminates when the engine idle speed is set to low idle (if equipped).
Load button (not used)
Gen-Set button (not used)
wc_tx004641en.fm
60
G 70 (600V) Operation—Deep Sea Controller
Ref.
Button/function o Stop / Reset
Pressing this button:
■
■
Sets the generator controller into its Stop/Reset mode
Clears any alarm conditions for which the triggering criteria have been rectified. p q r
Manual mode
Pressing this button:
■ Sets the generator controller to the Manual mode
In Manual mode, the generator can be started and operated.
(not used) s
Auto mode
Pressing this button:
■ Sets the generator controller to the Auto mode
In Auto mode, the generator can only be started and operated by a remote switch.
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) t Start
Pressing this button in Manual mode:
■ Starts the engine
Pressing this button in Stop/Reset mode:
■ Provides a keyswitch to the engine ECU for 10 minutes wc_tx004641en.fm
61
Operation—Deep Sea Controller G 70 (600V)
7.6
Generator Controller Alarms and Shut-Down Conditions
Background The generator controller monitors variables of engine and machine function. The generator controller has two types of alarms: warning alarms and shut-down alarms. The generator controller also monitors for electrical trip conditions.
Warning alarms
Shut-down 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.
Warning alarms include:
■ Low fuel level
■ High coolant temperature
■ Low oil pressure
■ Time to maintenance
DSE
DEEP SEA ELECTRONICS
DSE 7310 MKII
STOP a wc_gr014857
During a warning alarm condition, the LCD panel displays the type of warning alarm, the warning LED (a) 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 are latching alarms and stop the generator. Shut-down alarms include:
■ High coolant temperature
■ Low oil pressure
■ Overspeed/Underspeed
■ Overcrank
■ Low coolant level (if equipped)
■ Overcurrent
DSE
DEEP SEA ELECTRONICS
DSE 7310 MKII
STOP b c
During a shut-down alarm condition, the
LCD panel displays the type of alarm, the wc_gr014858
LEDs (b , c) 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”.
This procedure continues on the next page.
wc_tx004641en.fm
62
G 70 (600V) Operation—Deep Sea Controller
Continued from the previous page.
Variable
Fuel level
Coolant temp.
Normal
>15%
85°C ±8
Warning
15%
>105°C
Oil pressure
Overspeed
Underspeed
Overcrank
60–80 psi
60 Hz
60 Hz
—
Time to maintain 500 hours
Coolant level Above sender —
20 psi
—
—
—
0 hours
Shutdown
—
>108°C: Main circuit breaker trip, followed by a
5-minute cooldown and then engine shutdown
>110°C:
Immediate engine shutdown
15 psi
66 Hz
54 Hz
After 3 attempts
—
Below sender
To Reset
Fill fuel tank. Press “Stop/Reset”.
Reduce electrical load, open a door to allow more cooling air, and add coolant. Press “Stop/Reset”.
Add engine oil. Press “Stop/Reset”.
Press “Stop/Reset”.
Press “Stop/Reset”.
Press “Stop/Reset”.
See How to Reset the Maintenance
Timer .
Add coolant. Press “Stop/Reset”.
Electrical trips Electrical trips are latching type alarms that trip the main circuit breaker. During an electrical trip, the LEDs (b , c) illuminate, an audible alarm sounds, and the Start Engine Cool Down timer starts.
The engine stops when the timer reaches 0.
These electrical trips are often, though not always, electrical load issues that occur independent of the engine.
DSE
DEEP SEA ELECTRONICS b
DSE 7310 MKII c
STOP wc_gr014859
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.
wc_tx004641en.fm
63
Operation—Deep Sea Controller
7.7
Before Starting the Machine
G 70 (600V)
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.
Exterior checks
Internal checks
Before putting the generator into service, perform each item on the following checklist.
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.
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.
64
wc_tx004641en.fm
G 70 (600V) Operation—Deep Sea Controller
7.8
Starting and Running the Generator
Procedure
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 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 generator controller power switch (a) to the ON “I” position.
a
DSE 7310 MKII
STOP
Display d b c wc_gr014860
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.
Preheating
Meaning / Description
The engine is heating.
Crank attempt The engine is attempting to start.
This procedure continues on the next page.
wc_tx004641en.fm
65
Operation—Deep Sea Controller G 70 (600V)
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 generator 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
Safety on delay
Meaning / Description
The generator controller is determining system status.
Safety On Delay
Generator Available
Engine Oil Pressure
Generator available
Engine oil pressure
The generator is operating and ready for service.
Displays the engine oil pressure.
Engine Coolant Temp.
DEF Tank Level
Engine coolant temp.
DEF Tank Level
Engine battery voltage
Displays engine coolant temperature.
Displays the percentage of remaining DEF in the tank.
Displays the battery voltage.
Engine Battery Voltage
Engine Fuel Level
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 7310 MKII
STOP wc_gr014854
11.Turn on (close) the appropriate circuit breakers for your load.
66
wc_tx004641en.fm
G 70 (600V)
7.9
Stopping the Generator
Operation—Deep Sea Controller
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 a minimum of five minutes to allow it to cool down.
5. Press the Stop/Reset “O” button (a) to start the cool down/shut off timer. The engine shuts off automatically when the timer expires.
Note: To bypass the timer and shut off the engine immediately, press the Stop/
Reset “O” button a second time.
b
DSE 7310 MKII
STOP a
6. Set the generator controller power switch (b) to the OFF “O” position.
wc_gr014861 wc_tx004641en.fm
67
Operation—Deep Sea Controller
7.10
Emergency Stop Switch
Location
G 70 (600V)
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 MKII
STOP
Operation
E
M
ERGENC
Y a
S TO P b wc_gr014862
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 sounds.
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.
68
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G 70 (600V) Operation—Deep Sea Controller
7.11
Engine and Generator Monitoring
Description
Generator Available
L-N
L-L
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 .
277 V 0 A
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
V
V wc_gr009842
Displays the percentage of fuel remaining in the fuel tank
Engine Fuel Level
66
% wc_gr009843
Engine Oil Pressure
4.14
bar
60 psi
4.14
kPa wc_gr009844
Engine Coolant Temp.
o
C o
F wc_gr009845
Displays the engine oil pressure (if equipped)
Displays the current temperature of the engine coolant wc_tx004641en.fm
69
Working with Deep Sea Controller: DSE 7310 MKII
8 Working with Deep Sea Controller: DSE 7310 MKII
8.1
Introduction
.
During normal operation, the generator controller displays current information on machine performance and operating status. The keypad (a) provides access to additional monitoring functions through a series of menus displayed on the LCD panel (b) . You can also use the keypad to change certain machine settings if desired.
b d c a
DSE 7310 MKII
STOP f e wc_gr014863
1. The various monitoring and configuration menus can be accessed by pressing the right arrow button (c) .
2. To select items on a menu, use the up/down arrow buttons (d , e) to scroll through the available options.
3. To return to a previous menu screen, press the left arrow button (f) .
4. To exit menu navigation and return to LCD panel monitoring status, press the left or right arrow button (f , c) to return to the “Status” page.
70
wc_tx003611gb_FM10.fm
Working with Deep Sea Controller: DSE 7310 MKII
8.2
Navigating the Menus
The graphic below serves as a navigational aid when accessing the various menus of the generator controller. See the accompanying table for information about the menu items.
Note: The specific order and quantity of screens may vary by model.
.
ECU DTCs* Event Log
Summary
Screen
Engine
Speed
Gen Voltage
(L-N)
Coolant
Temp
Coolant
Temp
Battery
Voltage
Run
Time
Gen Load
(kVAr) wc_tx003611gb_FM10.fm
71
Working with Deep Sea Controller: DSE 7310 MKII
Menu Item
About
Active Config
Alarms
—
Can Bus Information
—
ECU DTCs
Description
Module information
Menu Item
—
Generator configuration Gen Load (h)
Alarms active Gen Load (%)
— Gen Load (kVA)
Can Bus information Gen Load (kVAr)
— Gen Load (kW)
Engine Diagnostic
Trouble Codes
Gen Load (Total %)
Description
—
Generator load kVArh
Generator load Percent
Generator load kVA
Generator load kVAr
Engine Engine info Gen Load (Total kVA)
Generator load kW
Generator load total percent
Generator load total kVA
Generator load total kW Engine Battery Voltage Battery and alternator voltage
—
Engine Coolant Temp
Engine Link
Engine Oil Pressure
Engine Run Time
Engine Speed
Event Log
—
Fuel Level
Gen Current
Gen Earth Current
Gen Frequency
—
Gen Load (Total kW)
Gen Phase Sequence Generator phase sequence
Generator power factor Coolant temperature in
°C and °F
Gen Power Factor
Engine link info
Engine oil pressure in
Bar, PSI, and kPa
Accumulated time in hours
Gen Power Factor (Avg) Generator average power factor
Gen Voltage (L-L) Generator voltage line to line
Gen Voltage (L-N)
Generator
Generator voltage line to neutral
Generator info Engine RPM
List of past events
—
Maintenance Alarm
(Hold “O” to reset)
Serial Port
Status Percentage of fuel remaining in the tank
Generator current amps Summary Screen
Generator earth current amps
—
Generator frequency
(Hz)
—
Hours until maintenance warning
Serial part information
Status information
Main summary screen
—
—
72
wc_tx003611gb_FM10.fm
Working with Deep Sea Controller: DSE 7310 MKII
8.3
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 (a) by pressing and holding the check mark button (b) on the keypad.
b DSE
DEEP SEA ELECTRONICS
DSE 7310 MKII
STOP a wc_gr014864
2. Wait a few seconds for the “Contrast” screen to appear, or use up/down arrow buttons to navigate to the “Contrast” screen. Then, press the check mark button.
The contrast value will start flashing.
c
STOP d wc_gr014865
3. Press the up/down arrow buttons (c , d) 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 generator controller returns to the “Status” screen.
wc_tx003611gb_FM10.fm
73
Working with Deep Sea Controller: DSE 7310 MKII
8.4
How to Reset the Maintenance Timer
Background The maintenance timer is preset to 500 hours. When the maintenance timer times out, the generator 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 MKII
STOP
DSE 7310 MKII
STOP
DSE
DEEP SEA ELECTRONICS
DSE 7310 MKII
STOP
DSE
DSE 7310 MKII
STOP a wc_gr014866
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.
74
wc_tx003611gb_FM10.fm
Mobile Generator
9 How to Connect Loads—480V
How to Connect Loads—480V
The information in this chapter on how to connect loads applies to machines with maximum capabilities of up to 480V.
This chapter does not apply to machines with maximum capabilities of up to 600V.
9.1
Lug Terminal Connection Diagrams
High Wye
240V
Low Wye
240V
Zig Zag wc_tx003581gb_FM10.fm
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
75
or
139V
139V
139V
240V
240V
240V
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø wc_gr010197
How to Connect Loads—480V
9.2
Best Practices for Balancing Loads
Mobile Generator
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.
1Ø Situations For 1Ø situations (voltage selector switch in the 208/240V position)
Unbalanced loads can be detected by observing the generator controller LCD panel. If an unbalanced load condition exists, there will be a significant difference
(over 10%) in both voltage and amperage between the legs.
Observe the amp draw on L1 and L3.
Note: Basler controller screens are shown. For Deep Sea controller machines, see chapter Working with Deep Sea Controller: DSE 7310 MKII for the corresponding parameters.
1Ø ZIG-ZAG
Observe L1 and L3
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
120 L1 10 60 120 L3 12 60
100% 175 60 13 100% 175 60 13 wc_gr011280-480V
If an unbalanced load condition is detected, stop the engine and reconnect the loads so that loads (amp draw) are more equally distributed between the legs (L1 and L3)—for example, if a heavy load and a light load are connected to L1, but only a light load is connected to L3. Reconnect the loads so that the heavy load is connected to L1, and the two lighter loads are connected to L3. Redistributing the loads will equalize the voltage for each leg and allow for better performance from the equipment connected to the generator.
Reconnect the loads as necessary to provide the most equal amp draw between
L1 and L3.
This procedure continues on the next page.
wc_tx003581gb_FM10.fm
76
Mobile Generator
Continued from the previous page.
How to Connect Loads—480V
3Ø Situations When combining 1Ø loads with 3Ø loads (voltage selector switch in 208/240V position), unbalanced loads can be detected by observing the generator 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
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
208 P1 21 60 208 P2 27 60 208 P3 24 60
100% 175 60 13 100% 175 60 13 100% 175 60 13 wc_gr011281-480V
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.
With voltage selected to 208/240 L1 L2 L3 N GND
120/240V
1Ø
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.
LOAD 1
LOAD 3
HOT HOT HOT
LOAD 2 wc_gr011282-480V
This procedure continues on the next page.
wc_tx003581gb_FM10.fm
77
How to Connect Loads—480V
Continued from the previous page.
Using the receptacles
Mobile Generator
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 in to the same duplex receptacle, plug the first load in to one of the duplex receptacles. Then, plug the second load in to the other duplex receptacle.
Additional loads can be plugged in to 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 in to the same duplex receptacle of the distribution panel, plug the first load in to one of the duplex receptacles. Then, plug the second load in to a different duplex receptacle of the distribution box.
LOAD 1
LOAD 2 wc_gr011321
78
wc_tx003581gb_FM10.fm
Mobile Generator How to Connect Loads—480V
9.3
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. Turn the voltage selector switch to the 277/480 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.
240 L-L
139 L-N
480V 3Ø
139V 139V
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
480V 480V
480V
277V
277V
277V
HOT HOT HOT GN HOT HOT HOT WH GN wc_tx003581gb_FM10.fm
480V 3Ø
79
480V 3Ø TRANSFORMER wc_gr011437
How to Connect Loads—480V Mobile Generator
9.4
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. Turn the voltage selector switch to the 208/240 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.
240 L-L
139 L-N
240V 3Ø
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
139V 139V
240V 240V
240V
139V
139V
139V
HOT HOT HOT
GN
240V 3Ø
240V 1Ø wc_gr011438-480V
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80
Mobile Generator How to Connect Loads—480V
9.5
Connecting 240V and 120V Single-Phase Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
Background Single-phase loads may be connected at the lugs by connecting the load “line to line” or by connecting the load “line to neutral”. Line-to-line connections use two
“hots” and ground; line-to-neutral connections use one “hot”, neutral, and ground.
Procedure 1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 120/240V 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
240 L-L
120 L-N
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø
120V 120V wc_tx003581gb_FM10.fm
240V
120V
120V
Balance the load
When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
HOT HOT
GN
TO "N" LUG
TO GND LUG
120V 1Ø
240V 1Ø
81
120V 1Ø wc_gr011440-480V
How to Connect Loads—480V Mobile Generator
9.6
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. Turn the voltage selector switch to the 208/240 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.
208 L-L
120 L-N
208V 3Ø
277/480V
3Ø
3Ø
1Ø
120/240V
1Ø 120V 120V
208V 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
208V 3Ø
82
120V 1Ø 120V 1Ø wc_gr011441-480V
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Mobile Generator How to Connect Loads—480V
9.7
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. Turn the voltage selector switch to the 208/240 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.
220–240V 3Ø
277/480V
3Ø
!
127–
139V
220–240 L-L
127–139 L-N
!
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.
Fine-tune the voltage
Fine-tune the voltage so that both the 3-phase load and the single-phase loads operate properly.
HOT HOT HOT
WH
GN GN
TO
GROUND
LUG
220–240V 3Ø 127–139V 1Ø 127–133V 1Ø wc_gr011442-480V wc_tx003581gb_FM10.fm
83
How to Connect Loads—600V
10 How to Connect Loads—600V
Mobile Generator
The information in this chapter on how to connect loads applies to machines with maximum capabilities up to 600V.
This chapter does not apply to machines with maximum capabilities of only 480V.
10.1
Lug Terminal Connection Diagrams
wc_gr011347
High Wye
5
6
7
9
10
11
12
8 2
1 4
3
L1-N = 346V
L2-N = 346V
L3-N = 346V
L1-L2 = 600V
L2-L3 = 600V
L3-L1 = 600V
600V
3Ø
277/480V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
3Ø Zig Zag
9
4
6
5
10
8
3
7
11
12
2
1
Low Wye
240V
9
10
6
5
8
7
11
12
4
2
1
3
6 1
5
8 3
2
7
4
10 9
12 11
L1-N = 277V
L2-N = 277V
L3-N = 277V
L1-L2 = 480V
L2-L3 = 480V
L3-L1 = 480V
600V
3Ø
277/480V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø or
139V
139V
139V
240V
240V
240V
277/480V
3Ø
600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
600V
3Ø
277/480V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
1Ø Zig Zag
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84
Mobile Generator How to Connect Loads—600V
10.2
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.
Note: When in the 600V mode, single phase power is not available.
1Ø Situations For 1Ø situations (voltage selector switch in the 208/240V position)
Unbalanced loads can be detected by observing the generator controller LCD panel. If an unbalanced load condition exists, there will be a significant difference
(over 10%) in both voltage and amperage between the legs.
Observe the amp draw on L1 and L3.
Note: Basler controller screens are shown. For Deep Sea controller machines, see chapter Working with Deep Sea Controller: DSE 7310 MKII for the corresponding parameters.
1Ø ZIG-ZAG
Observe L1 and L3
277/480V
3Ø
346/600V
3Ø
208/240V 3 Ø
120/139V 1 Ø
120/240V
1Ø
120 L1 10 60 120 L3 12 60
100% 175 60 13 100% 175 60 13 wc_gr011280-600V
If an unbalanced load condition is detected, stop the engine and reconnect the loads so that loads (amp draw) are more equally distributed between the legs (L1 and L3)—for example, if a heavy load and a light load are connected to L1, but only a light load is connected to L3. Reconnect the loads so that the heavy load is connected to L1, and the two lighter loads are connected to L3. Redistributing the loads will equalize the voltage for each leg and allow for better performance from the equipment connected to the generator.
Reconnect the loads as necessary to provide the most equal amp draw between
L1 and L3.
This procedure continues on the next page.
wc_tx003683gb_FM10.fm
85
How to Connect Loads—600V Mobile Generator
Continued from the previous page.
3Ø Situations When combining 1Ø loads with 3Ø loads (voltage selector switch in 208/240V position), unbalanced loads can be detected by observing the generator 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
277/480V
3Ø
346/600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
208 P1 21 60 208 P2 27 60 208 P3 24 60
100% 175 60 13 100% 175 60 13 100% 175 60 13 wc_gr011281-600V
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.
With voltage selected to 208/240 L1 L2 L3 N GND
346/600V
3Ø
208/240V 3Ø
120/139V 1Ø
120/240V
1Ø
HOT 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.
LOAD 1 LOAD 2
LOAD 3 wc_gr011282-600V
This procedure continues on the next page.
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86
Mobile Generator
Continued from the previous page.
How to Connect Loads—600V
Using the receptacles
This information applies whether the machine is running in 3Ø or in 1Ø.
Note: When in the 600V mode, single phase power is not available.
When connecting two loads to the duplex receptacles, instead of plugging both loads in to the same duplex receptacle, plug the first load in to one of the duplex receptacles. Then, plug the second load in to the other duplex receptacle.
Additional loads can be plugged in to 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 in to the same duplex receptacle of the distribution panel, plug the first load in to one of the duplex receptacles. Then, plug the second load in to a different duplex receptacle of the distribution box.
LOAD 1
LOAD 2 wc_gr011321 wc_tx003683gb_FM10.fm
87
How to Connect Loads—600V Mobile Generator
10.3
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. Turn the voltage selector switch to the 208/240 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.
240 L-L
139 L-N
240V 3Ø
277/480V
3Ø
208/240V 3 Ø
120/139V 1Ø
120/240V
1Ø
139V 139V
240V 240V
240V
139V
139V
139V
HOT HOT HOT
GN
240V 3Ø
240V 1Ø wc_gr011438-600V
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88
Mobile Generator How to Connect Loads—600V
10.4
Connecting 240V and 120V Single-Phase Loads
WARNING
Electric shock hazard. High voltage can cause serious injury or death.
► Connections must be made by a qualified electrician.
Background Single-phase loads may be connected at the lugs by connecting the load “line to line” or by connecting the load “line to neutral”. Line-to-line connections use two
“hots” and ground; line-to-neutral connections use one “hot”, neutral, and ground.
Procedure 1. Stop the engine and turn the main circuit breaker off.
2. Turn the voltage selector switch to the 120/240V 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
240 L-L
120 L-N
277/480V
3Ø
346/600V
3Ø
208/240V 3 Ø
120/139V 1Ø
120/240V
1Ø 120V 120V wc_tx003683gb_FM10.fm
240V
120V
120V
Balance the load
When connecting multiple 120V loads:
Use L1 as "hot" for first load.
Use L3 as "hot" for second load.
HOT HOT
GN
TO "N" LUG
TO GND LUG
120V 1Ø
240V 1Ø
89
120V 1Ø wc_gr011440-600V
How to Connect Loads—600V Mobile Generator
10.5
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. Turn the voltage selector switch to the 208/240 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.
208 L-L
120 L-N
208V 3Ø
277/480V
3Ø
208/240V 3 Ø
120/139V 1Ø
120/240V
1Ø
120V 120V
208V 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
208V 3Ø
90
120V 1Ø 120V 1Ø wc_gr011441-600V
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Mobile Generator How to Connect Loads—600V
10.6
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. Turn the voltage selector switch to the 208/240 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.
220–240V 3Ø
277/480V
3Ø
600V
3Ø
208/240V 3 Ø
120/139V 1Ø
120/240V
1Ø
!
127–
139V
220–240 L-L
127–139 L-N
!
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.
Fine-tune the voltage
Fine-tune the voltage so that both the 3-phase load and the single-phase loads operate properly.
HOT HOT HOT
WH
GN GN
TO
GROUND
LUG
220–240V 3Ø 127–139V 1Ø 127–133V 1Ø wc_gr011442-600V wc_tx003683gb_FM10.fm
91
How to Connect Loads—600V
10.7
Connecting 480V, 3-Phase Loads
Mobile Generator
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. Turn the voltage selector switch to the 277/480 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.
480V 3Ø
277/480V
3Ø
600V
3Ø
208/240V 3 Ø
120/139V 1 Ø
120/240V
1Ø
480V 480V
480V
277V
277V
277V
HOT HOT HOT GN HOT HOT HOT WH GN transformateur transformador
480V 3Ø
92
480V 3Ø TRANSFORMER wc_gr011843
wc_tx003683gb_FM10.fm
Mobile Generator
10.8
Connecting 600V, 3-Phase Loads
How to Connect Loads—600V
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. Turn the voltage selector switch to the 600 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.
600V 3Ø
277/480V
3Ø
600V
3Ø
208/240V 3 Ø
120/139V 1 Ø
120/240V
1Ø
600V 600V
600V
346V
346V
346V
600 P3 24 60
100% 175 0 13
HOT HOT HOT GN HOT HOT HOT WH GN transformateur transformador wc_tx003683gb_FM10.fm
600V 3Ø
93
600V 3Ø TRANSFORMER wc_gr011356
Using Remote Start Capabilities
11 Using Remote Start Capabilities
Mobile Generator
11.1
Remote Run Terminal Block
Location The remote run terminal block (a) is located as shown.
Note: Graphic is representative only. Your machine may vary.
a
V Ø A HZ
DIAGNOSTICS
DIAGNOSEN
DIAGNOSTICOS
DIAGNOSTICS
4,000 ft
1,219 m
ERGENC
Y
S TO P
ATS
Description wc_gr010366
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).
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94
Mobile Generator
11.2
Remote Transfer Switch
Using Remote Start Capabilities
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.
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95
Using Remote Start Capabilities Mobile Generator
11.3
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
Procedure d c 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.
1. Before using the AUTO mode, perform 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.
0 0 5 6 3 2
REMOTE START
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
AUS
APAGADO
START / LAUFEN
ARRANQUE / MARCHA a b. Set the generator controller power switch (b) to the ON position.
c. Press the AUTO mode button (c) . d. Wait for the engine to crank, start, and run. If the engine cranks, the remote start circuit is functioning.
wc_gr010206 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.
This procedure continues on the next page.
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96
Mobile Generator Using Remote Start Capabilities
Continued from the previous page.
2. Leave the generator 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 battery charge
If the generator is to be used as a stand-by power supply, provisions must be made 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.
wc_tx003610gb_FM10.fm
97
Diagnostic Trouble Codes (DTC)
12 Diagnostic Trouble Codes (DTC)
G70
12.1
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 button to navigate through
“engine”, “Generator”, “Alarms”, to “ECU DTCs”.
STOP wc_gr011701
2. Use the up and down arrow buttons 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.
98
wc_tx004647en.fm
G70 Diagnostic Trouble Codes (DTC)
12.2
List of Engine Diagnostic Trouble Codes (DTCs)
84
84
84
91
51
51
51
51
29
29
51
51
28
28
28
28
Failure Code
SPN FMI
1 1
27 7
Name
DFC_DCUNotPro grammed
EGRFPD
91
91
94
94
96
96
97
100
102
Description
Not Programmed DCU detected
2
1
3
4
2
3
6
3
4
8
2
2
5
8
9
6
7
3
4
3
4
3
4
PTOPH
PTOPL
20 PTOP2H
21 PTOP2L
ACCP2H
ACCP2L
ITHRPREH
ITHRPREL
DCMOC
ITHRS
ITHRCURR
ITHRCURAVE
SPDSG
SPDL
SPDH
DFC_ComAPP1S
AE
ACCP1H
ACCP1L
BSSCV
DRSCV
FLEVH
FLEVL
WGTHR
POILDN
PIMP1
Exhaust gas recirculation (EGR) feedback/position sensor/ dynamic range failure (for CAN)
Accelerator pedal for ASC (PTO) sensor signal too high
Accelerator pedal for ASC (PTO) sensor signal too low
Accelerator pedal for ASC (PTO) sensor 2 signal too high
Accelerator pedal for ASC (PTO) sensor 2 signal too low
Accelerator pedal sensor No.2 signal too high
Accelerator pedal sensor No.2 signal too low
Intake throttle position signal too high
Intake throttle position signal too low
Intake throttle motor driver circuit invalid
Intake throttle stick fault
Intake throttle current fault
Intake throttle average duty fault
Vehicle speed sensor signal invalid
Vehicle speed sensor input open/short
Vehicle speed sensor frequency too high
Invalid data received from accelerator pedal module
Accelerator pedal sensor No.1 signal too high
Accelerator pedal sensor No.1 signal too low
SCV(+) output short to BATT; SCV(-) output short to BATT
SCV(+) output open load/short to GND; SCV(-) output open load/ short to GND; SCV coil open/short
Fuel level sensor signal too high
Fuel level sensor signal too low
Water in fuel filter failure
Engine oil pressure down
Boost pressure sensor performance invalid wc_tx004647en.fm
99
Diagnostic Trouble Codes (DTC) G70
157
157
157
157
157
157
105
105
107
107
107
108
132
156
156
157
110
110
132
132
Failure Code
SPN
102
FMI
2
102
102
105
108
108
110
110
110
3
4
2
2
3
3
4
4
2
Name
DFC_ComEngBP
SAE
PIMH
PIML
DFC_ComInManT empSAE
THAH
THAL
AFC
PAFDFH
PAFDFL
DFC_ComEnvPS
AE
0
2
3
4
2
2
3
3
4
4
2
MAFL
PLVHIRP
14 PLACT
0 PCEX3
PATMH
PATML
THWOT
THWP
DFC_ComCEngD sTSAE
THWH
THWL
MAFP
MAFH
3
4
1
2
PCUND
PCO
PCH
PCL
9 PCP
14 PCONOX
Description
Turbocharger/supercharger boost system performance
Boost pressure sensor signal too high
Boost pressure sensor signal too low
Intake air temperature sensor 1 circuit range/performance bank 1
Air temperature sensor signal too high
Air temperature sensor signal too low
Air filter clogging error
Air filter differential pressure sensor signal too high
Air filter differential pressure sensor signal too low
Barometric pressure too low
Atmosphere pressure sensor signal too high
Atmosphere pressure sensor signal too low
Coolant temperature exceeds upper limit
Coolant temperature sensor performance invalid
Engine coolant flow low/performance
Coolant temperature sensor signal too high
Coolant temperature sensor signal too low
MAF (mass air flow) sensor performance invalid
MAF (mass air flow) sensor signal too high
MAF (mass air flow) sensor signal too low
Multiple high rail pressure error/engine stall after PLV opening
P/L (pressure limiter) activated
C/Rail pressure exceeds high upper limit 3
C/Rail pressure falls below the control limit of the target pressure
PC sensor offset diagnosis
C/Rail pressure sensor signal too high
C/Rail pressure sensor signal too low
C/Rail pressure sensor signal keeping the middle range
PC sensor offset diagnosis for NOX requirement
wc_tx004647en.fm
100
G70 Diagnostic Trouble Codes (DTC)
Failure Code
SPN FMI
157
157
157
157
167
167
168
168
168
168
168
168
168
168
168
171
171
171
171
171
172
172
174
15
16
20
31
1
Name
PCEX1
PCEX2
PCOH
PCOVR
OCHG
Description
31 LCHG
3
4
2
0
1
DFC_BattUHi
DFC_BattULo
3
3
VBBH
DFC_BattUSRCM ax
VBBL 4
4 DFC_BattUSRCMi n
14 DFC_DevLibBattU
HiLo
16 DFC_DevLibBattU
Hi
18 DFC_DevLibBattU
Lo
0 DFC_EnvTVDPlau sMax
1
2
DFC_EnvTVDPlau sMin
DFC_EnvTDynPla us
3
4
DFC_EnvTSRCM ax
DFC_EnvTSRCMi n
THAIH
THAIL
DFC_ComFuelTS
AE
C/Rail pressure exceeds high upper limit 1
C/Rail pressure exceeds high upper limit 2
PC sensor high offset
C/Rail pressure control cannot achieve target fuel
Capacitor charge-up circuit malfunction injector (excessive charge)
Capacitor charge-up circuit malfunction injector (insufficient charge)
System voltage unstable
System voltage low
Vehicle system voltage too high (> 16V)
System voltage high
Vehicle system voltage too low (< 8V)
System voltage low
Manufacturer controlled DTC
Manufacturer controlled DTC
Manufacturer controlled DTC
Ambient air temperature sensor circuit "A" intermittent/erratic
Ambient air temperature sensor circuit "A" intermittent/erratic
Ambient air temperature sensor circuit "A" intermittent/erratic
Ambient air temperature sensor circuit "A" high
Ambient air temperature sensor circuit "A" low
Air temperature (MAF side) sensor signal too high
Air temperature (MAF side) sensor signal too low
Fuel temperature sensor "A" circuit range/performance wc_tx004647en.fm
101
Diagnostic Trouble Codes (DTC) G70
190
249
249
430
430
430
512
1084
1127
1127
1349
1382
1382
1393
637
637
1083
1083
598
604
626
626
Failure Code
SPN FMI
174
174
190
190
190
0
2
3
4
2
513
544
4
5
2
8
3
9
2
2
Name
THFH
THFL
NEOR
NEGUM
DFC_ComNEngS
AE
NEGNON
NEPUM
NENOP
STSWBT
STARELGD
STARELBT
DFC_ComDrvDem
TrqSAE
DFC_ComActEng
TrqSAE
Description
Fuel temperature (with pump) sensor signal too high
Fuel temperature (with pump) sensor signal too low
Engine overrun
Crankshaft and camshaft synchronous error
Ignition/distributor engine speed input circuit range/performance
Crank position e camshaft position sensor no pulse
Crank position (CKP) sensor performance invalid
Crank position (CKP) sensor no pulse
Starter switch short to BATT
Starter relay short to GND
Starter relay short to battery
Invalid data received
Invalid data received
2
3
4
2
2
2
8
DFC_ComRefEng
TrqSAE
CLSW
NEUTSW
GRELBT
GRELGD
GPUM
GNOP
Invalid data received
Clutch switch circuit malfunction (manual transmission only)
Neutral switch circuit malfunction (manual transmission only)
Glow relay output short to BATT
Glow relay output open load/short to GND
Camshaft position (CMP) sensor performance invalid
Camshaft position (CMP) sensor no pulse
19 CANB1 CAN1 node error
31 CANOPENGENU CAN bus-line open from general unit
1
2
19 CANB2
0 TBOPH
TBOPL
IPMPSTDYNOT
CAN2 node error
Boost pressure sensor exceeds upper limit
Boost pressure sensor exceeds lower limit
Pump learning uncompleted
0 FIPRES2
16 FIPRES1
2 ANGSPD1
Fuel filter diagnosis level 2
Fuel filter diagnosis level 1
Engine angle speed error1 (injector#1)
wc_tx004647en.fm
102
G70 Diagnostic Trouble Codes (DTC)
1639
1639
1639
1639
1639
1675
1761
1762
1762
2570
2791
2791
2791
2791
2791
2791
Failure Code
SPN FMI
1393
1394
1394
1395
5
2
5
2
1395
1396
1396
1397
5
3
5
2
1397
1397
1562
1683
Name Description
4
5
NCTWV1
ANGSPD2
NCTWV2
ANGSPD3
NCTWV3
ANGSPD4
NCTWV4
BSTWV1
GSTWV1
NCCOM1
TWV1 output open load injector coil open
Engine angle speed error2 (injector#2)
TWV2 output open load injector coil open
Engine angle speed error3 (injector#3)
TWV3 output open load injector coil open
Engine angle speed error4 (injector#4)
TWV4 output open load injector coil open
COM1 TWV drive sistem output short to BATT TWV1or3 output short to BATT
COM1 TWV drive sistem output short to GND TWV1or3 output short to GND
COM1 TWV drive sistem output open load both TWV1 and TWV3 open load
Not Programmed DCU detected 14 DFC_DCUNotPro grammed
3
4
CFANHBT
CFANHGD
5
6
CFANLBT
CFANLGD
31 EFAN
2 DFC_ComEngSta
ModeSAE
2 DFC_ComPWRM ngSAE
Coolant fan high speed relay short to battery
Coolant fan high speed relay short to GND
Coolant fan low speed relay short to battery
Coolant fan low speed relay short to GND
Electric fan open load/short to GND/short to battery
Invalid data received
Charging system voltage
2
3
2
2
4
7
2
3
DFC_SigUTnkLvl Manufacturer controlled DTC
PHYDH Hydraulic pressure sensor signal too high
4 PHYDL
19 CANOPENDCU
Hydraulic pressure sensor signal too low
DCU-ECU bus open
EGRFB
EGRMOC
EGRNTNR
LEGRH
LEGRL
EGRVI
EGR feedback error
EGR motor drive circuit invalid
EGR no transmission/not received failure (for CAN)
EGR lift sensor signal too high
EGR lift sensor signal too low
EGR valve stick/initialization failure (for CAN) wc_tx004647en.fm
103
Diagnostic Trouble Codes (DTC) G70
2802
2802
2802
2802
2802
3031
Failure Code
SPN
2791
FMI
13
Name
EGRCLEAN
2791
2791
2802
3031
3031
3031
3031
3031
3031
3031
3031
3031
3031
3217
3218
3219
14
31
9
EGRBM
EGRT
ABNQR
11 QRERR
12 MCPU
13 QRNOT
14 FROM
31 SCPU
0 DFC_UTnkTPhys
RngHi
1
2
DFC_UTnkTPhys
RngLo
DFC_ComDefTank
TSAE
2
3
4
5
DFC_UTnkTInvld
Data
DFC_UTnkTSRC
Max
DFC_UTnkTSRC
Min
DFC_UTnkTSCB
OL
Description
EGR Cleaning failure (valve stuck open/poppet much lower than normal)
EGR battery/motor failure (for CAN)
EGR valve temperature failure (for CAN)
QR definition error (definition concerning QR correction is not right)
QR data error
CPU fault; main CPU fault
QR data is not written
Check sum error - flash area
CPU fault; watchdog IC fault
Reductant tank temperature sensor circuit range/performance
Reductant tank temperature sensor circuit range/performance
Lost communication with ECM/PCM "A"
Reductant level sensor "A" circuit range/performance
Reductant tank temperature sensor circuit high
Reductant tank temperature sensor circuit low
Reductant temperature sensor circuit high
6 DFC_UTnkTSCG Reductant temperature sensor circuit low
10 DFC_UTnkTTout Reductant temperature sensor circuit range/performance
Reductant tank temperature/fuel temperature correlation 16 DFC_UTnkTVDPl ausTempMax
18 DFC_UTnkTVDPl ausTempMin
2 DFC_ComO2NoM
CatDsSAE
Reductant tank temperature/fuel temperature correlation
Invalid data received from NOx sensor "A"
2
2
DFC_ComSensPw rNoMCatDsSAE
DFC_ComSensTe mpNoMCatDsSAE
Invalid data received from NOx sensor "A"
Invalid data received from NOx sensor "A"
wc_tx004647en.fm
104
G70 Diagnostic Trouble Codes (DTC)
Failure Code
SPN
3220
FMI
2
3220
3221
3226
3227
3228
3229
3230
3231
3236
3241
3241
3241
3241
3241
3241
3251
3256
3275
Name Description
2
2
2
2
2
2
2
2
DFC_ComNOxNo
MCatDsSAE
DFC_ComSensN
OxNoMCatDsSAE
DFC_ComSensO2
NoMCatDsSAE
DFC_ComNOxNo
Cat2DsSAE
DFC_ComO2NoC at2DsSAE
DFC_ComSensPw rRngNoCat2DsSA
E
DFC_ComSensTe mpNoCat2DsSAE
DFC_ComSensN
OxStabNoCat2Ds
SAE
DFC_ComSensO2
StabNoCat2DsSA
E
Invalid data received from NOx sensor "A"
Invalid data received from NOx sensor "A"
Invalid data received from NOx sensor "A"
Invalid data received from NOx sensor "B"
Invalid data received from NOx sensor "B"
Invalid data received from NOx sensor "B"
Invalid data received from NOx sensor "B"
Invalid data received from NOx sensor "B"
Invalid data received from NOx sensor "B"
2
0
0
1
DFC_ComEGSAE EGR system performance
DFC_SCRPODPla usUCatUsTMax
SCR NOx catalyst inlet temperature too high
Exhaust gas temperature sensor circuit bank 1 sensor 2 DFC_UCatUsTPh ysRngHi
DFC_SCRPODPla usUCatUsTMin
SCR NOx catalyst inlet temperature too low
Exhaust gas temperature sensor circuit bank 1 sensor 2 1
3
DFC_UCatUsTPh ysRngLo
DFC_UCatUsTSR
CMax
4 DFC_UCatUsTSR
CMin
DPFC 0
13 DFC_HegnMntgPl ausS1B1
13 DFC_HegnMntgPl ausS2B1
Exhaust gas temperature sensor circuit high bank 1 sensor 2
Exhaust gas temperature sensor circuit low bank 1 sensor 2
DPF filter clog
NOx sensor 1/2 correlation bank 1
NOx sensor 1/2 correlation bank 1 wc_tx004647en.fm
105
Diagnostic Trouble Codes (DTC) G70
3509
3509
3510
3510
3510
3515
Failure Code
SPN FMI
3349
3349
3349
3361
3361
3361
Name
2
9
10 TSC1RC
3 DFC_UDosVlvSC
HS
5
TSC1CS
TSC1TMERR
7
DFC_UDosVlvSC
BOLHS
DFC_SCRPODPla usUDosVlv
3361
3362
3
4
3
4
12 DFC_UDosVlvOvr
Temp
4 DFC_UDosVlvSC
GOLLS
VCC1H
VCC1L
VCC2H
VCC2L
3515
3515
3515
3515
3515
3515
3515
3516
13 DFC_SSp2Mon
2 DFC_UrQlSnsrTIn vldData
3
4
DFC_UrQlSnsrTS
RCMax
DFC_UrQlSnsrTS
RCMin
5
6
DFC_UrQlSnsrTS
CBOL
DFC_UrQlSnsrTS
CG
10 DFC_UrQlSnsrTTo ut
16 DFC_SCRPODUr
TankTPlausMax
18 DFC_SCRPODUr
TankTPlausMin
0 DFC_SCRPODUr
QlyDetnAbslt
Description
TSC1 checksum test
TSC1 time out error
TSC1 rolling count test
Reductant injection valve circuit range/performance bank 1 unit 1
Reductant injection valve circuit range/performance bank 1 unit 1
Reductant injection valve circuit range/performance bank 1 unit 1
Reductant injection valve circuit range/performance bank 1 unit 1
Reductant injection valve circuit range/performance bank 1 unit 1
Battery 5V reference 1 circuit high (5V power supply for sensor)
Battery 5V reference 1 circuit low (5V power supply for sensor)
Battery 5V reference 2 circuit high (5V power supply for sensor)
Battery 5V reference 2 circuit low (5V power supply for sensor)
Sensor reference voltage "B" circuit range/performance
Reductant quality performance
Reductant quality sensor circuit range/performance
Reductant quality sensor circuit range/performance
Reductant quality sensor circuit range/performance
Reductant quality sensor circuit range/performance
Reductant quality performance
Reductant control module internal temperature sensor range/ performance
Reductant control module internal temperature sensor range/ performance
Reductant quality sensor circuit range/performance
wc_tx004647en.fm
106
G70 Diagnostic Trouble Codes (DTC)
Failure Code
SPN
3516
FMI
10
Name
DFC_UrQlSnsrStu ck
3516
3521
18 DFC_SCRPODUr
QlyDetnEfc
2 DFC_UrQlSnsrInvl dData
3521 3
3521
3521
3521
4
5
6
DFC_UrQlSnsrSR
CMax
DFC_UrQlSnsrSR
CMin
DFC_UrQlSnsrSC
BOL
DFC_UrQlSnsrSC
G
3521
3521
3521
3521
3521
3532
3532
3532
9
9
DFC_ComA1DEFI
TO
DFC_UrQlSnsrPpt yDetn
10 DFC_UrQlSnsrTou t
12 DFC_ComA1DEFI
DLC
19 DFC_UrQlSnsrNot
Avl
2 DFC_UTnkLvlInvld
Data
3
4
DFC_UTnkLvlSRC
Max
DFC_UTnkLvlSRC
Min
3532
3532
3532
4082
4082
Description
Reductant quality performance
Reductant quality sensor circuit range/performance
Reductant quality performance
Reductant quality sensor circuit range/performance
Reductant quality sensor circuit range/performance
Reductant quality sensor circuit range/performance
Reductant quality sensor circuit range/performance
Lost communication with ECM/PCM "A"
Reductant quality performance
Reductant quality performance
Invalid data received
Reductant quality performance
Reductant level sensor "A" circuit range/performance
Reductant level sensor "A" circuit high
Reductant level sensor "A" circuit low
5
6
DFC_UTnkLvlSCB
OL
DFC_UTnkLvlSC
G
Reductant level sensor "A" circuit high
Reductant level sensor "A" circuit low
10 DFC_UTnkLvlTout Reductant level sensor "A" circuit range/performance
3 ELPUMPBT Electric lift pump relay short to battery
4 ELPUMPGD Electric lift pump relay short to GND wc_tx004647en.fm
107
Diagnostic Trouble Codes (DTC)
Failure Code
SPN
4340
FMI
2
4340
4340
4340
4340
Name Description
3
4
DFC_UHtrPLLoad
FbPlaus
DFC_UHtrPLSCB
DFC_UHtrPLSCG
5 DFC_UHtrPLOL
12 DFC_UHtrPLOvrT emp
Exhaust aftertreatment fuel injector "B" control circuit/open
Reductant heater "B" control circuit high
Reductant heater "B" control circuit low
Reductant heater "B" control circuit/open
Reductant heater "B" control circuit performance
4340
4342
4342
4342
4342
4342
4344
13 DFC_UHCEnfShO ffWiEmp
2 DFC_UHtrBLLoad
FbPlaus
Reductant heater "B" control circuit performance
Exhaust aftertreatment fuel injector "B" control circuit/open
3
4
5
2
DFC_UHtrBLSCB Reductant heater "A" control circuit high
DFC_UHtrBLSCG Reductant heater "A" control circuit low
DFC_UHtrBLOL
12 DFC_UHtrBLOvrT emp
DFC_UHtrSLLoad
FbPlaus
Reductant heater "A" control circuit/open
Reductant heater "A" control circuit performance
Reductant heater "C" control circuit performance
4344
4344
4344
4344
4353
4353
4353
4357
4357
4374
4374
3
4
5
DFC_UHtrSLSCB Reductant heater "C" control circuit high
DFC_UHtrSLSCG Reductant heater "C" control circuit low
DFC_UHtrSLOL
12 DFC_UHtrSLOvrT emp
Reductant heater "C" control circuit/open
Reductant heater "C" control circuit performance
3
5
DFC_UHtrSMSCB Reductant metering unit heater control circuit high
DFC_UHtrSMOL Reductant metering unit heater control circuit/open
Reductant metering unit heater control circuit performance 12 DFC_UHtrSMOvrT emp
4 DFC_UHCMonCir c3ScgOrOpenLoa dErr
Reductant heater "A" control circuit low
5 Reductant heater "A" control circuit/open
3
4
DFC_UHCMonCir c3OpenLoadErr
DFC_SRCMaxUP mpP
DFC_SRCMinUP mpP
Reductant pressure sensor circuit high
Reductant pressure sensor circuit low
G70
wc_tx004647en.fm
108
G70 Diagnostic Trouble Codes (DTC)
Failure Code
SPN
4440
FMI
0
4440
4440
4440
4440
4440
4440
5026
5026
5027
5028
5029
5030
5031
5031
5034
5035
5036
2
3
4
Name
DFC_UPmpMotN
DvtPerm
DFC_UPmpMotCo mRxFail
DFC_UPmpMotS
CB
DFC_UPmpMotS
CG
2
2
2 DFC_HegnHtrRdn
S1B1
12 DFC_HegnHtrAvlS
1B1
2 DFC_ComNOxCor
PresLamCat2DsS
AE
2
DFC_ComNOxNO
2CorDsSAE
DFC_ComNOxNH
3CorDsSAE
2
DFC_ComNOxCor
PresNOxCat2DsS
AE
DFC_ComNOxNO
2CorCat2DsSAE
Description
Reductant pump "A" control performance/stuck off
Reductant pump "A" control circuit/open
Reductant pump "A" control circuit high
Reductant pump "A" control circuit low
5
12
DFC_UPmpMotOL Reductant pump "A" control circuit/open
DFC_UPmpMotOv rTemp
Reductant pump "A" control performance/stuck off
Reductant pump "A" control performance/stuck off 16 DFC_UPmpMotN
Dvt
0 DFC_HegnOutOfR ngDiagNoxMaxS1
B1
NOx sensor circuit high bank 1 sensor 1
1 NOx sensor circuit low bank 1 sensor 1
2
2
DFC_HegnOutOfR ngDiagNoxMinS1
B1
DFC_ComNOxCor
PresLamDsSAE
DFC_ComNOxCor
PresNOxDsSAE
Invalid data received from NOx sensor "A"
Invalid data received from NOx sensor "A"
Invalid data received from NOx sensor "A"
Invalid data received from NH3 sensor
NOx sensor heater sense circuit range/performance bank 1 sensor 1
NOx sensor heater sense circuit range/performance bank 1 sensor 1
Invalid data received from NOx sensor "B"
Invalid data received from NOx sensor "B"
Invalid data received from NOx sensor "B" wc_tx004647en.fm
109
Diagnostic Trouble Codes (DTC)
Failure Code
SPN
5037
FMI
2
5045
5045
5137
5137
Name Description
2
3
4
DFC_ComNOxNH
3CorCat2DsSAE
DFC_HegnHtrRdn
S2B1
12 DFC_HegnHtrAvlS
2B1
Invalid data received from NH3 sensor
NOx sensor heater control circuit range/performance bank 1 sensor 2
NOx sensor heater control circuit range/performance bank 1 sensor 2
DFC_UHtrTnkSCB Reductant tank heater control circuit high
DFC_UHtrTnkSC
G
Reductant tank heater control circuit low
5137
5137
5461
5461
5
12
DFC_UHtrTnkOL Reductant tank heater control circuit/open
DFC_UHtrTnkOvr
Temp
Reductant tank heater control circuit performance
Manufacturer controlled DTC 31 DFC_SCRCatDes oxDmd
31 DFC_SCRCatDes oxEom
Manufacturer controlled DTC
5491
5491
5713
3
4
2
5713
5714
5716
5717
5717
5717
2
2
2
2
5
6
DFC_ARlySCB_1 Actuator supply voltage "B" circuit high
DFC_ARlySCG_1 Actuator supply voltage "B" circuit low
DFC_ComNOxSn srATO1SelfDiagS
AE
Invalid data received from NOx sensor "B"
NOx sensor circuit bank 1 sensor 1 DFC_HegnSnsrSi gRdnS1B1
DFC_ComNOxSn srSelfDiagSAE
DFC_HegnSnsrSi gRdnS2B1
DFC_ComNOxSn srATO1SelfDiagFi nalResSAE
DFC_HegnOpCirS
1B1
DFC_HegnShCirS
1B1
Invalid data received from NOx sensor "A"
NOx sensor circuit bank 1 sensor 2
Invalid data received from NOx sensor "B"
NOx sensor circuit bank 1 sensor 1
NOx sensor circuit bank 1 sensor 1
5718
5720
2
5
DFC_ComNOxSn srATI1SelfDiagFin alResSAE
DFC_HegnOpCirS
2B1
Invalid data received from NOx sensor "A"
NOx sensor circuit range/performance bank 1 sensor 1
G70
wc_tx004647en.fm
110
G70 Diagnostic Trouble Codes (DTC)
Failure Code
SPN
5720
FMI
6
5838
5839
5840
5841
5842
6875
6875
6875
6875
6876
7069
7069
7540
7540
7561
7561
31
31
31
31
31
Name
DFC_HegnShCirS
2B1
MDFC5
MDFC2
MDFC3
MDFC1
MDFC4
Description
NOx sensor circuit bank 1 sensor 2
Merged DFC failure of assigned group 5—impeded EGR valve
Merged DFC failure of assigned group 2—absence of dosing
Merged DFC failure of assigned group 3 —low reagent consumption
Merged DFC failure of assigned group 1—poor reagent quality
Merged DFC failure of assigned group 4—tampering of monitoring system
Reductant pressure too high
3
4
3
4
4
0
1
DFC_SCRMonMet
CtlOvrPresErr
DFC_SCRMonMet
CtlUndrPresErr
10 DFC_SCRMonPre sBuildUpErr
13 DFC_SCRMonOvr
PresErr
1 DFC_UPmpPPhys
RngLo
5
Reductant pressure too low
Reductant pressure sensor circuit range/performance
Reductant pressure too high
Reductant pressure sensor circuit low
DFC_ARlySCB_2 Actuator supply voltage "C" circuit high
DFC_ARlySCG_2 Actuator supply voltage "C" circuit low
DFC_ARlySCB_3 Actuator supply voltage "D" circuit high
DFC_ARlySCG_3 Actuator supply voltage "D" circuit low
Reductant heater "B" control circuit low DFC_UHCMonCir c4ScgOrOpenLoa dErr
DFC_UHCMonCir c4OpenLoadErr
Reductant heater "B" control circuit/open
7562
7562
7563
7597
7606
4
5
3
DFC_UHCMonCir c5ScgOrOpenLoa dErr
DFC_UHCMonCir c5OpenLoadErr
DFC_UHCMonSc bErr
Reductant heater "C" control circuit low
Reductant heater "C" control circuit/open
Reductant heater "B" control circuit performance
2
31
DFC_ComTotSAE Lost communication with fuel injector control module
DFC_UDCRdcAg
Rmn
Reductant level too low wc_tx004647en.fm
111
Diagnostic Trouble Codes (DTC) G70
Failure Code
SPN
7607
FMI
0
516096
516096
516096
516097
516097
516097
Name Description
9
DFC_SCRPODMo nTnkT
CANOPENPROS
CRT2
Reductant tank temperature sensor circuit range/performance
PROSCRT2 open (time out) error
2
9
9
12
DFC_ComAMBTO Ambient air temperature sensor circuit "A"
DFC_ComAMBDL
C
Ambient air temperature sensor circuit "A"
ECSCS
ECSTMERR
ECS checksum test
ECS time out error
516097
516097
516098
516099
516100
9 DFC_ComAT1I1T
O
10 ECSRC
Invalid data received from NOx sensor "A"
12 DFC_ComAT1I1D
LC
ECS rolling count test
Invalid data received from NOx sensor "A"
31 CANOPENPTODE CAN bus-line open from PTODE
31 CANOPENPTO CAN bus-line open from PTO
9 DFC_ComAT1IGC
2TO
Invalid data received from NOx sensor "A"
516100
516101
516101
516103
516104
516104
516105
516105
516106
516107
31 CANOPENINNOX CAN bus-line open from NOx unit bus line
9 DFC_ComAT1O1
TO
Invalid data received from NOx sensor "B"
Invalid data received from NOx sensor "B" 12 DFC_ComAT1O1
DLC
9 DFC_ComAT1OG
C2TO
Invalid data received from NOx sensor "B"
Vehicle communication bus A performance 12 DFC_ComCILBus
OffNodeA
12 DFC_ComCILErrP asNodeA
12 DFC_ComCILBus
OffNodeB
12 DFC_ComCILErrP asNodeB
2 DFC_ComDM19D sAck
9 DFC_ComDM19D sBAM2PKTTO
Vehicle communication bus A performance
Vehicle communication bus B performance
Vehicle communication bus B performance
Invalid data received
Lost communication with ECM/PCM "A"
wc_tx004647en.fm
112
G70 Diagnostic Trouble Codes (DTC)
Failure Code
SPN
516108
FMI
9
516109
516110
516111
516112
516113
516114
516115
516116
516117
516123
516124
516125
516126
516127
516128
516129
516131
516132
Name
9
9
2
9
9
9
9
DFC_ComDM19D sBAMTO
DFC_ComDM19D sPKT2PKTTO
DFC_ComDM19D sTO
DFC_ComDM19U sAck
DFC_ComDM19U sBAM2PKTTO
DFC_ComDM19U sBAMTO
DFC_ComDM19U sPKT2PKTTO
DFC_ComDM19U sTO
9
9
9
9
DFC_ComDM1EC
UBAM2PCKTO
DFC_ComDM1EC
UPCK2PCKTO
DFC_ComDM1EC
UTO
DFC_ComEC1BA
M2PKTTO
9
9
DFC_ComEC1BA
MTO
DFC_ComEC1PK
T2PKTTO
12 DFC_ComEEC1D
LC
9 DFC_ComEEC1T
O
12 DFC_ComEEC2D
LC
12 DFC_ComEEC3D
LC
9 DFC_ComEEC3T
O
Description
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Invalid data received
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Invalid data received from ECM/PCM "A"
Invalid data received from ECM/PCM "A"
Invalid data received from ECM/PCM "A"
Invalid data received from ECM/PCM "A"
Lost communication with ECM/PCM "A" wc_tx004647en.fm
113
Diagnostic Trouble Codes (DTC)
Failure Code
SPN
516133
FMI
12
Name
DFC_ComEOIDL
C
516134
516137
516138
516141
516142
516144
9
12
Description
Invalid data received from ECM/PCM "A"
DFC_ComEOITO Lost communication with ECM/PCM "A"
DFC_ComET1DL
C
Invalid data received from ECM/PCM "A"
9 DFC_ComET1TO Lost communication with ECM/PCM "A"
12 DFC_ComIC1DLC Invalid data received from ECM/PCM "A"
516155
516156
9
9
DFC_ComIC1TO Lost communication with ECM/PCM "A"
DFC_ComNOxSe nsGlbReqTxTO
Lost communication with NOx sensor "A"
Invalid data received from ECM/PCM "A" 12 DFC_ComPROSC
R2DLC
9 DFC_ComPROSC
R2TO
Lost communication with ECM/PCM "A"
516159 Invalid data received from ECM/PCM "A"
516160
516165
516167
516168
516190
12 DFC_ComPROSC
R5DLC
9 DFC_ComPROSC
R5TO
9 DFC_ComTDTO
14 DFC_EEPRdErr
Lost communication with ECM/PCM "A"
Lost communication with ECM/PCM "A"
Internal control module EEPROM error
Internal control module EEPROM error
NOx sensor circuit bank 1 sensor 1
516193
516194
14 DFC_EEPWrErr
12 DFC_HegnWireDi agS1B1
12 DFC_MoCComErr
Cnt
12 DFC_MoCComSP
I
Internal control module main processor performance
Internal control module main processor performance
516195
516196
516197
516214
12 DFC_MoCROMErr
XPg
12 DFC_MRlyErlyOp ng
13 DFC_MRlyStk
Internal control module monitoring processor performance
Reductant control module power relay de-energized performance—too early
Reductant control module power relay de-energized performance—too late
Control module processor
516218
12 DFC_Pmd_PeriMo n
0 DFC_SCRChkAda pMax
NOx exceedance—root cause unknown
G70
wc_tx004647en.fm
114
G70 Diagnostic Trouble Codes (DTC)
Failure Code
SPN
516218
FMI
1
516224
516225
516226
516227
516228
516229
516230
516231
516231
516232
516233
516234
516235
516236
516237
516241
516242
516243
516244
516245
516245
Name Description
2
2
2
0
0
2
2
DFC_SCRChkAda pMin
DFC_SCRMonDet
ModeBLPlaus
DFC_SCRMonDet
ModePresChk
DFC_SCRMonDet
ModePresStab
DFC_SCRPODFil
Full
DFC_SCRPODLe akDetnNoDos
DFC_SCRPODPla usUCatUsTStat
DFC_SCRPODPR ednErr
NOx exceedence—root cause unknown
Reductant pressure sensor circuit range/performance
Reductant pressure sensor circuit range/performance
Reductant pressure sensor circuit range/performance
Reductant system performance bank 1
Reductant system performance bank 1
Manufacturer controlled DTC
Reductant pressure sensor circuit range/performance
0
1
DFC_SCRPODPS nsrPlausHi
DFC_SCRPODPS nsrPlausLo
10 DFC_SCRPODSM
Htr
10 DFC_SCRPODSM
HtrT
2 DFC_SCRPODSM
HtrTCldStrt
Reductant pressure sensor circuit high
Reductant pressure sensor circuit low
Reductant heater "B" control circuit performance
Reductant heater "B" control circuit performance
Reductant heater "B" control circuit performance
10 DFC_SCRPODSM
2
T
DFC_SCRPODSM
TCldStrt
Reductant metering unit temperature sensor circuit range/ performance
Reductant metering unit temperature sensor circuit range/ performance
Reductant tank temperature sensor circuit intermittent/erratic 10 DFC_SCRPODTn kTempResp
14 DFC_SWReset_0 Internal control module main processor performance
14 DFC_SWReset_1 Internal control module main processor performance
3
4
14 DFC_SWReset_2 Internal control module main processor performance
4 DFC_T15SysProt Ignition coil primary/secondary circuit/open
DFC_UHtrRlySCB
DFC_UHtrRlySCG
Reductant heater "D" control circuit low
Reductant heater "D" control circuit high wc_tx004647en.fm
115
Diagnostic Trouble Codes (DTC)
Failure Code
SPN FMI
516245
516245
516246
Name
5
3
DFC_UHtrRlyOL
12 DFC_UHtrRlyOvrT emp
DFC_UrBackFlow
PmpSCB
516246
516246
516246
516247
516253
516253
516254
4
5
12 DFC_UrBackFlow
PmpOT
12 DFC_HegnWireDi agS2B1
0 DFC_UPmpMotrat dcPmpMax
1
DFC_UrBackFlow
PmpSCG
DFC_UrBackFlow
PmpOL
0
DFC_UPmpMotrat dcPmpMin
DFC_UPmpMotrat
HTMax
516254
516255
516255
516256
516256
516259
516260
516261
1
0
1
0
DFC_UPmpMotrat
HTMin
DFC_UPmpMotrat nPmpMax
DFC_UPmpMotrat nPmpMin
DFC_UPmpMotrat
SMTMax
1 DFC_UPmpMotrat
SMTMin
12 DFC_ComAT1T1I
DLC
9 DFC_ComAT1T1I
TO
0 DFC_DStgyHCLd
CritMax
Description
Reductant heater "D" control circuit/open
Reductant heater "D" control circuit performance
Reductant purge control valve "A" circuit high
Reductant purge control valve "A" circuit low
Reductant purge control valve "A" circuit /open
Reductant purge control valve "A" performance
NOx sensor circuit range/performance bank 1 sensor 1
Reductant metering unit heater control circuit performance
Reductant metering unit heater control circuit performance
Reductant metering unit heater control circuit performance
Reductant metering unit heater control circuit performance
Reductant pump "A" control performance/stuck off
Reductant pump "A" control performance/stuck off
Reductant metering unit temperature sensor circuit range/ performance
Reductant metering unit temperature sensor circuit range/ performance
Invalid data received
Lost communication with ECM/PCM "A"
Manufacturer controlled DTC
G70
wc_tx004647en.fm
116
G70
13 Factory-Installed Options
Factory-Installed Options
13.1
600V
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, 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.
Machines with the 600V option include a four-position switch on the controller used for selecting voltage. See Selecting the Voltage for instructions on how to use the voltage selector switch. See How to Connect Loads—600V for instructions on how to connect loads on machines with maximum capabilities up to 600V.
wc_tx004645.fm
117
Factory-Installed Options
13.2
Level Load Logic (L3)
G70
The Level Load Logic (L3) option applies load to the engine to heat coolant, reducing the chance of wet stacking.
The system turns On when the following conditions occur:
■ The generator’s frequency is greater than 58 Hz for at least 30s.
■ The generator’s kW Load is less than 30% of the machine rating.
■ The engine coolant temperature is less than 85°C.
The system turns Off when the following conditions occur:
■ The generator’s frequency is less than 55 Hz.
■ The generator’s kW Load is greater than 35% of the machine rating.
■ The engine coolant temperature is greater than 90°C.
When one of the Off Conditions is true, the system remains off until all three of the
On conditions are true again.
wc_gr015076
118
wc_tx004645.fm
G70
13.3
Fuel Filter Heater
Factory-Installed Options
The fuel filter heater option consists of a wrap to cover the fuel filter, a thermostat, and a wiring harness connected to the machine’s main wiring harness. This option helps prevent diesel fuel from gelling in the filter. The fuel filter heater turns on in temperatures below 45°F (7°C). The operator can also adjust the temperature using a knob.
13.4
Quick Oil Change
The quick oil change option:
■ Purges the engine oil filter before removal
■ Evacuates the engine oil from the sump directly to waste containment
■ Refills clean oil into the engine through the new oil filter wc_gr015077 wc_tx004645.fm
119
wc_gr015075
Factory-Installed Options
13.5
Battery Charger
G70
An optional battery charger (a) 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.
Note: Graphic is representative only. Your machine may vary.
a a wc_gr012952
120
wc_tx004645.fm
G70
13.6
Lockable Battery Disconnect
Factory-Installed Options
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.
Note: Graphic is representative only. Your machine may vary.
wc_gr012953
NOTICE: Do not use the battery disconnect switch while the engine is running.
Damage to electrical components may occur.
wc_tx004645.fm
121
Factory-Installed Options
13.7
Camlocks
G70
A second optional outlet panel features camlock connectors for easy tool changes.
Each connector is protected by a spring-loaded cover.
wc_gr012954
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.
122
wc_tx004645.fm
G70
13.8
Containment System
Factory-Installed Options
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_gr012955
13.9
Extended Run Tank (ERT)
An extended run (fuel) tank (a) 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.
a wc_gr012957 wc_tx004645.fm
123
Factory-Installed Options
13.10 Engine Block Heater
G70
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.
Note: Graphic is representative only. Your machine may vary.
a b wc_gr012967
124
wc_tx004645.fm
G70
13.11 Low Coolant Shutdown
Factory-Installed Options
Background 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.
Note: Graphic is representative only. Your machine may vary.
b a
Function wc_gr012960
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.
wc_tx004645.fm
125
Factory-Installed Options
13.12 Connecting an External Fuel Supply
Background Quick-disconnect fuel fittings allow an external fuel supply to be connected.
G70
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 (Supply is 1/2 in. and return is
3/8 in.)
Procedure Perform the procedure below to connect the external fuel supply.
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.
1. Connect the external feed hose at the external feed hose fitting (a) .
2. Connect the external return hose at the external return hose fitting (b) .
a b wc_gr013026
3. Move the fuel valve handle (e) from the up position (c) for internal fuel supply to the down position (d) for external fuel supply.
Note: Graphic is representative only. Your machine may vary.
e
126
c d wc_gr013027
wc_tx004645.fm
G70 Machines with Aftertreatment Exhaust System
14 Machines with Aftertreatment Exhaust System
14.1
How the Aftertreatment Exhaust System Works
Background Many Wacker Neuson generators with Tier 4f engines use an aftertreatment exhaust system to reduce emissions. There are six 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 (NO x
■ Heating Valve
) emissions.
This valve controls the flow of coolant from the engine’s cooling system to the
DEF tank.
■ 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.
■ Dosing Module (DM)
A DM is an electronic unit that injects a precise amount of DEF into the mixing pipe between the DOC and SCR sections of the exhaust can.
Note: The SCR, DOC, and DM are combined as one unit.
How it works ► The exhaust is first treated by the DOC.
► Exhaust (NO x
) emissions flow through the DOC into the mixing pipe.
► The dosing module supplies DEF to the mixing pipe.
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 Tank
Heating Valve
DEF Supply
Module
Dosing Module
DOC SCR
Mixing Pipe
Interaction wc_tx004642en.fm
wc_gr012291
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
127
Machines with Aftertreatment Exhaust System
14.2
Filling the DEF Tank
G70
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 Some DEF nozzles have magnetic lockouts. If such a magnetic interface is encountered, insert a DEF mis-filling prevention device in the DEF tank filling neck to unlock the nozzle.
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 (a) .
a wc_gr015078
This procedure continues on the next page.
128
wc_tx004642en.fm
G70 Machines with Aftertreatment Exhaust System
Continued from the previous page.
2. Set the engine start switch (b) 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.
DEF Tank Level
100 %
REMOTE START
FERNSTART
ARRANQUE REMOTO
DEMARRAGE A
DISTANCE
OFF
AUS
APAGADO
ARRET
START / RUN
START / LAUFEN
ARRANQUE / MARCHA
DEMARRER / MARCHE b wc_gr015079
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 key switch is on.
4. Fill the DEF tank until the DEF level reaches 100%.
5. Reinstall the DEF cap.
6. Place the engine start switch in the OFF position.
wc_tx004642en.fm
129
Machines with Aftertreatment Exhaust System
14.3
Shelf Life of Diesel Exhaust Fluid (DEF)
G70
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
≤ 10°C (≤ 50°F)
≤ 25°C (≤ 77°F)
≤ 30°C (≤ 86°F)
≤ 35°C (≤ 95°F)
≥35°C (≥95°F)
Minimum shelf life (months)
36
18
12
6
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.
130
wc_tx004642en.fm
G70 Machines with Aftertreatment Exhaust System
14.4
Monitoring and Controlling the DEF Level
The diesel exhaust fluid (DEF) level is monitored by the generator 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 generator 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.
SCR-DEF Lamps
DEF Level
≥ 15%
15–5%
5%
Controller Message
No message
Low DEF pre-alarm
Low DEF alarm wc_gr015080
Controller / Machine Response
Normal screen / normal operation
■ Normal operation
■ Warning light flashes
■ Main circuit breaker opens
■ Engine runs for 5 minutes to cool down, then shuts down
■ Engine alarm light turns on solid wc_tx004642en.fm
131
Machines with Aftertreatment Exhaust System
14.5
Monitoring DEF Quality
G70
The quality of Diesel Exhaust Fluid (DEF) is monitored by the generator 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 generator controller displays messages alerting the operator as to the condition of the DEF quality. See table below.
ECU Amber
Warning
DEF Quality / Malfunction
No issues detected
Issue detected
3 hours after issue is detected*
10 minutes after previous malfunction
Controller Message
No message
ECU amber warning
SCR inducement**
SCR inducement shutdown wc_gr015080
Controller / Machine Response
Normal screen / normal operation
■
■
■
Warning light blinks
ECU amber warning
Specific engine DTC
■
■
Main circuit breaker opens
Engine runs for 10 minutes to cool down
■
■
Engine stops running***
Engine alarm light turns on solid
* The 3-hour timer is for one DTC. Multiple DTCs may reduce the running time by one half hour for each DTC (i.e. 2 DTCs
= 1.5 hours, 3 DTCs = 1 hour, etc.).
** Before an SCR inducement occurs, if the fault is cleared, normal operation resumes. If a second fault occurs within 40 hours of engine run time, the timer resumes where it left off.
After an SCR inducement occurs, if the fault is cleared, normal operation resumes. If a second fault occurs within 40 hours of engine run time, the engine will immediately re-enter SCR inducement.
After 40 hours of engine run time with no faults, the SCR inducement timer will reset to “0”.
*** Multiple restarts are permitted to help diagnose issues. The main breaker cannot be reset until the fault is cleared.
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G70
15 General Maintenance
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.
15.1
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.
Check exhaust system.
Drain containment system.
(if equipped)
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
(if equipped)
1
At least monthly.
2
Every 2000 hours or 2 years.
3
Every 4500 hours or 3 years.
Weekly
50 hours or 2 weeks
250 hours
600 hours or 12 months
Other
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General Maintenance
15.2
Maintaining the Emission Control System
G70
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.
15.3
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.
Set the start switch to OFF.
Open the circuit breakers (set 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.
15.4
Cleaning the Machine
When As needed
Suggested cleaning materials
Cleaning the interior
■ 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.
Clean the interior of the machine.
Check the fluid level in the containment system (if equipped) and drain if necessary. See topic Checking and Draining the Containment System .
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.
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G70
15.5
Inspecting the Machine
When Daily
Overview
External inspection
Internal inspection
General Maintenance
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.
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
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 wc_tx004649en.fm
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General Maintenance
15.6
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.
G70
Wheels
Axle Hubs
Brakes
■ Check that lug nuts holding wheels are tight.
■ Replace any missing lug nuts immediately.
■ Grease axle hubs using a good wheel-bearing grease.
■ 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.
136
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G70 General Maintenance
15.7
Checking and Draining the Containment System (if equipped)
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. Reinstall the drain plug.
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General Maintenance
15.8
Checking the Exhaust System
When Check the exhaust system weekly before operating the machine.
G70
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 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 b a e d e b c wc_gr015062
2. Inspect the exhaust pipes (a) , coolant lines (b) , supply module (c) , SCR canister (d) , and clamps (e) , 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.
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G70
15.9
Maintaining the Battery
General Maintenance
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
Battery connections
Maintaining battery condition
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.
To connect the battery:
1. Place all electrical switches in the OFF position.
2. Connect the red positive (+) battery cable to the battery.
3. 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.
■ 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.
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General Maintenance
15.10 Filling the Radiator
When Every 6000 hours
G70
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 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
3.5 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.
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140
G70
Important
General Maintenance
Continued from the previous page.
7. Reinstall 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 concentration of silicates which can damage the engine and cooling system.
Use an OAT coolant in this engine. Refer to the engine owner’s manual for more information.
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General Maintenance G70
15.11 Replacing the Aftertreatment DEF Dosing Unit Filter (if equipped)
When Replace the aftertreatment Diesel Exhaust Fluid (DEF) dosing unit filter every 500 hours or 12 months.
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.
Procedure
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.
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.
142
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G70
Installation
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.
1. Insert the equalizing element into the new filter.
2. Insert the filter assembly into the aftertreatment dosing unit.
3. Reinstall the filter cap and tighten it to 20 Nm (14.8 ft. lbs.).
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General Maintenance
15.12 Storage
G70
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
Perform 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 the 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. Exposed rubber items should be protected from the weather. Either cover them or use a protectant.
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G70
15.13 Machine Disposal and Decommissioning
General Maintenance
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
Disposal
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.
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.
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Engine Maintenance: Kohler KDI 3404 TCR–SCR
16 Engine Maintenance: Kohler KDI 3404 TCR–SCR
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.
146
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Engine Maintenance: Kohler KDI 3404 TCR–SCR
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.
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Engine Maintenance: Kohler KDI 3404 TCR–SCR
148
wc_tx004646en.fm
Mobile Generator
17 Troubleshooting
Troubleshooting
Problem
Engine does not start
Engine tries to start but stops
Cause
Battery discharged
Battery connections corroded
Blown fuse
Defective starter
No fuel
Clogged fuel filter
Fuel circuit failure
Remedy
Charge battery.
Clean battery connections.
Replace fuse.
Replace starter.
Fill tank with fuel.
Bleed fuel lines.
Replace fuel filter.
Check fuel lines.
No generator output
Lug door open at engine start (Deep Sea only)
Main circuit breaker open
Lug door open (Basler only)
Low oil pressure
High coolant temperature
Low oil level
Clogged oil filter
Overload
Low coolant level
Low oil level
Clogged oil filter
Engine emits black smoke Clogged air filter
Overload
High oil level
Close lug doors before starting the engine.
Close main circuit breaker.
Close lug door.
Fill engine sump with oil.
Replace oil filter.
Reduce load.
Fill with coolant.
Fill sump with oil.
Replace oil filter.
Clean/replace air filter cartridges.
Reduce load.
Remove excess oil.
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Troubleshooting
This page is intentionally left blank.
150
wc_tx001197gb_FM10.fm
G70
18 Technical Data: G70
Technical Data: G70
18.1
Engine
Engine Power Rating
Net power rating per ISO 3046. Actual power output may vary due to conditions of specific use.
Machine: G70
Engine
Engine make
Model
Emissions
Number of cylinders
Displacement
Operating speed
Rated standby power
Coolant capacity
Oil capacity
Battery
Fuel type
1
Fuel tank capacity
Fuel consumption, prime load
Run time at 100% prime load
2
Run time at 75% prime load
2
Run time at 50% prime load
2
Run time at 25% prime load
2
L (in
3 rpm kW (Hp)
L (qt)
L (qt)
Volts/CCa
L (gal)
)
L/hr (gal/hr)
Hours
Hours
Hours
Hours
Kohler
KDI3404 TCR-SCR
Tier IV final
4
3.36 (205)
1800
81 (109)
20.3 (21.5)
15 (15.8)
12 / 1000
No. 1/No. 2 diesel
Ultra low sulfur fuel only
424 (112)
16 (4.2)
25.2
32
47.1
74.7
1
The use of #6 diesel fuel is not recommended.
2 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.
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Technical Data: G70
18.2
Generator
Machine
Make/Type
Model
Prime rating
Voltage selector switch
AC voltages available
Frequency
Power factor
Voltage regulation
Insulation class
G70 kVA
Hz
1ø
3ø
G70 (standard)
Generator
G70 (600V)
Mecc Alte / Brushless / 4 pole
ECP32-3L/4
120/240 1Ø zig-zag
120, 127, 139, 240, 254, 277
3Ø: 90
1Ø: 48
3 position
120/240 1Ø zig-zag
120, 127, 139, 240, 254, 277, 346
120/208 3Ø low-wye
240/480 3Ø hi-wye
208, 220, 240, 416, 440, 480
60
1.0
0.8
120/208 3Ø low-wye
240/480/600 3Ø hi-wye
208, 220, 240, 416, 440, 480, 600
±1.00%
H
18.3
Machine
Machine
Sound level at 7 m (23 ft.)
AC receptacles
Standby Output
Prime Output
G70 (standard)
Machine db(A)
G70 (600V)
68
(2) 120V, 20A, GFI duplex
(3) 120/240V, 50A twist-lock
63/79 61/77 kW/ kVA kW/ kVA
A
58/72
250
56/70
Main breaker
wc_td000741.fm
152
G70
18.4
Trailer and Skid
Technical Data: G70
G70
Dry weight of skid
Operating weight of skid
Trailer weight
Operating weight on trailer
Surge brakes
Tires
Trailer and Skid kg (lb) kg (lb) kg (lb) kg (lb)
Fluid type size
1701 (3750)
2050 (4510)
399 (880)
2450 (5390)
DOT3
ST225/75D15 wc_td000741.fm
153
Technical Data: G70
18.5
Dimensions
A
E
G70
F
G
B
C
Machine
G70 Skid
G70 Trailer mm
(in.) mm
(in.)
A
965
(38)
—
D wc_gr006389
B
—
2162
(85)
C
—
1715
(67.5)
D
—
4064
(160)
E
2451
(96.5)
—
F
1476
(58.1)
—
G
1605
(63.2)
—
154
wc_td000741.fm
Tire Safety Information
19 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.
wc_tx003108gb_FM10.fm
155
Tire Safety Information
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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. T RAILERS 10,000 P OUNDS GVWR OR L ESS
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,QIRUPDWLRQ3ODFDUG attached DGMDFHQWWRRUQHDUWKHWUDLOHU¶V9,1
(Certification) label at the left front of the trailer.
1.1.2. T RAILERS O VER 10,000 P OUNDS GVWR (N OTE : T HESE 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.
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.
6 7(36)25 ' (7(50,1,1* & 255(&7 / 2$' / ,0,7 ± 7 2: 9 (+,&/(
1.
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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¶VPDQXDOWRGHWHUPLQHKRZWKLVZHLJKWWUDQVIHUU educes the available cargo and luggage capacity of your vehicle.
* /266$5< 2 ) 7 ,5( 7 (50,12/2*<
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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). wc_tx003108gb_FM10.fm
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Tire Safety Information
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
The downward force applied to the 5 th
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. wc_tx003108gb_FM10.fm
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Tire Safety Information
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¶VGHVLJQDWLRQIRUD rim 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 a QGOXJJDJHORDGSOXVNLORJUDPVOEVWLPHVWKHYHKLFOH¶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. T
IRE
S
AFETY
- E
VERYTHING
R
IDES
O
N
I
T
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:
Help protect you and others from avoidable breakdowns and accidents
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 wc_tx003108gb_FM10.fm
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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. F INDING Y OUR V EHICLE ' S R ECOMMENDED T IRE P RESSURE AND L OAD L IMITS
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. U NDERSTANDING T IRE P RESSURE AND L OAD L IMITS
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. C HECKING T IRE P RESSURE
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. S TEPS FOR M AINTAINING P ROPER T IRE P RESSURE
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. T IRE S IZE
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. T IRE T READ
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. T IRE B ALANCE AND W HEEL A LIGNMENT
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. T IRE R EPAIR
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. T IRE F UNDAMENTALS
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. wc_tx003108gb_FM10.fm
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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". wc_tx003108gb_FM10.fm
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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. T
IRE
S
AFETY
T
IPS
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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Tire Safety Information
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User’s Information for Transport Canada Fuel Tank
20 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.
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User’s Information for Transport Canada Fuel Tank wc_tx003111gb_FM10.fm
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User’s Information for Transport Canada Fuel Tank
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Emission Control Systems Information and Warranty—Diesel
21 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.
21.1
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.
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Emission Control Systems Information and Warranty—Diesel
21.2
Limited Defect Warranty for Exhaust Emission Control System
See the supplied engine owner’s manual for the applicable emission warranty statement.
21.3
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 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.
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.
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
Air handling system and associated plumbing
Exhaust system (upstream of last after treatment device)
Components
Charge air cooler
Charge air cooler plumbing
Exhaust gas piping from turbocharger out to the last after treatment device
wc_tx003113gb_FM10.fm
172
Emission Control Systems Information and Warranty—Diesel
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.
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. wc_tx003113gb_FM10.fm
173
Emission Control Systems Information and Warranty—Diesel
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.
174
wc_tx003113gb_FM10.fm
Mobile Generator
22 General Machine Schematics
22.1
Fuses
Kohler Engine Harness
F303
5A
F308
5A
F302
20A
F305
5A
F301
30A
F304
30A
86
87
RELAY
K310
30
85
86
87
RELAY
K306
30
85
86
87
RELAY
K304
30
85
86
87
RELAY
K302
30
85
86
87
RELAY
K309
30
85
86
87
RELAY
K305
30
85
86
87
RELAY
K303
30
85
86
87
RELAY
K301
30
85 wc_gr015139
K302
K303
K304
K305
K306
K309
K310
Ref.
F301
F302
F303
F304
F305
F308
K301
Description
Aftertreatment supply
ECU switched power
ECU constant B+
Starter relay supply
EGR valve supply
Lift pump supply
NOx sensor
Hose heater power
Hose heater 1
Hose heater 2
Hose heater 3
ECU switched power
Lift pump
Fuel filter heater option wc_tx004650en.fm
175
General Machine Schematics
Deep Sea Control Box Harness
F103
5A
F106
30A
F109
5A
F112
10A
F151
10A
F102
5A
F105
10A
F108
10A
F111
30A
F115
5A
D102
F101
3A
F104
3A
F107
2A
F110
10A
F113
2A
D101
86
87
RELAY
K151
30
85
86
87
RELAY
K102
30
85
86
87
RELAY
K101
30
85 wc_gr015140
Ref.
F101
F102
F103
F104
F105
F106
F107
F108
F109
F110
Description
Telematics run signal
Auxiliary keyswitch
ECM keyswitch
Heater/auxiliary
DSE control power
Engine DCU/ECU supply
Sensor supply
Keyswitch/start relays
Fan controller
Fuel heater option
Ref.
F111
F112
F113
F115
D101
D102
K101
K102
K103
K151
Description
Keyswitch supply
Telematics/diagnostics supply
Telematics auto signal
Work light
L3 option supply
Shunt trip output diode
Breaker shunt trip diode
Keyswitch relay
Shunt trip relay
L3 option relay
General Machine Schematics
22.2
Trailer Wiring
Standard and Hydraulic Brakes
1
3
2
10
9
Mobile Generator
6
7
7
8
Electric Brakes
1
Br W
G
Y
Br
W
R
3
R
R
R
R
W
4
+ –
2
Br W
9
Br W
W
R
5
W
R
5
G
Br
W
6
Br
7
Br 7
Y
Br
W
8
10
Br W wc_gr000523
176 wc_tx004650en.fm
Mobile Generator
22.3
Trailer Wiring Components
8
9
10
6
7
4
5
Ref.
Description
1 Front right side amber light
2
3
Front left side amber light
Trailer plug
Battery
Brake solenoid
Right tail light
License plate holder lights
Left tail light
Rear right side red light
Rear left side red light
G
W
R
Y
Ref.
Wire Colors
B Black
Br Brown
L Blue
Red
Yellow
Green
White
Rear Lights
Ground
Tail light
—
Brake light
—
—
—
Side Lights
Ground
—
—
Power
—
—
—
Harness
Battery charge
Tail, side, and license plate
—
Electric brakes
Left brake light and directional
Right brake light and directional
Ground wc_tx004650en.fm
177
General Machine Schematics
Schematics—Machines with Deep Sea Controller
23 Schematics—Machines with Deep Sea Controller
23.1
AC Schematic: G70 480V
4
CAMLOCK OPTION
11
DC CONTROL WIRING
LOCATED ON DC SCHEMATIC
DS104 - PLUG 4
RELAY C/D & VOLTAGE SENSING
NC RELAY C1
NC RELAY C2
NO RELAY D1
NO RELAY D2
L1 VOLTAGE SENSING
L2 VOLTAGE SENSING
L3 VOLTAGE SENSING
N VOLTAGE SENSING
DS105 - PLUG 5
CURRENT SENSING
34
35
36
37
30
31
32
33
L1 CURRENT SENSING
L2 CURRENT SENSING
L3 CURRENT SENSING
-
CURRENT SENSING COM
-
42
43
44
45
46
47
780 RD/WH 16 AWG
779 BU 16 AWG
742 BR 16 AWG
743 YL 16 AWG
741 OR 16 AWG
740 WH 16 AWG
737 BR 16 AWG
738 YL 16 AWG
739 OR 16 AWG
736 WH 16 AWG
278 BK 16 AWG
1 2
NOTE:
WIRES 278
AND 279 ARE
PART OF DC
CONTROL BOX
HARNESS.
CR705
779 BU 16 AWG 279 BU/WH 16 AWG
[N1]
ADJUSTABLE
TRIP MAIN
CIRCUIT
BREAKER. SET
PER
MACHINE
RATING.
3
L1 L2 L3
N
(L0)
L1 L2
[N3] [N3] [N3]
L3
BOND BAR
N
(L0)
G
[N4]
5
GROUND TO
ENCLOSURE
BOX STUD
[N2]
[N2]
[N2] [N2]
[N2]
[N2]
[N2]
[N2]
737 BR 16 AWG
735 WH 16 AWG
738 YL 16 AWG
736 WH 16 AWG
739 OR 16 AWG
734 WH 16 AWG
G
10
12
SW701
PHASE SWITCH
HIGH WYE
LOW WYE
ZIG-ZAG
T2
1
2
R1
[N5]
742
BR
L1
[N2]
3
T12
7
4 8
5 9 13
[N2]
17
6
740 WH
N (L0)
[N2]
10
T6
14
T7
18
N (L0) [N2]
21 25
22
T10
26
11
T5
L2
[N2]
15
12
19 23
R2 [N5]
27
16 20
L2 [N2]
24
741 OR
28
L3 [N2]
743 YL
Mobile Generator
[N5][N5]
[N5][N5]
[N5][N5]
[N5]
[N5]
278 BK 16 AWG RD – STATOR AUX [Z2]
709 GN/YL 10 AWG
710 GN/YL 10 AWG
711 GN/YL 10 AWG
708 BK 10 AWG
705 BK 10 AWG
703 BR 14 AWG
702 BK 10 AWG
714 LB 10 AWG
715 LB 10 AWG
716 LB 10 AWG
724 BK
10 AWG
X G
723 BK
10 AWG Y
240VAC 50A
RECEPTACLE
726 BR 14 AWG
W
704 BK 10 AWG
701 BK 10 AWG
722 BK
10 AWG
X G
721 BK
10 AWG Y
240VAC 50A
RECEPTACLE
W
725 BR 14 AWG
8
9
720 BK
10 AWG
719 BK
10 AWG
X G
Y
240VAC 50A
RECEPTACLE
W
717 GN/YL 14 AWG
718 GN/YL 14 AWG
LINE GND
TEST
RESET
N/C LOAD
120VAC 20A
GFI RECEPTACLE
LINE GND
TEST
RESET
N/C LOAD
120VAC 20A
GFI RECEPTACLE
T3
[N2]
A
13 TB701 - TERMINAL BLOCK
SUPPLIED WITH GENERATOR
B
R2 [N5]
[N2]
T11
AMP.
Hz STAB
REG. TYPE: DSR
10k Ω
VOLT
6 POT-701
VOLTAGE ADJUST
POTENTIOMETER
VT – SIGNAL
WH – COM
COM
CR701 - AVR
COMMON
A.P.O.
COMMON
50/60 Hz
COMMON
VEXT/PEXT
AUX/NEUTRAL
AUX/NEUTRAL
H_PHASE
H_PHASE
F_PHASE
F_PHASE
AUX/EXC +
AUX/EXC +
EXC -
15
10
9
8
14
13
12
11
3
2
1
5
4
7
6
7
60 Hz
JUMPER
WH – COM
VT – SIGNAL
BK – SENSING [11]
RD – STATOR AUX [Z1]
GN – SENSING [3]
780 RD/WH 16 AWG
YL – EXC [+]
BU – EXC [-]
14
GENERATOR
CONTROL
WIRE
BUNDLE
BU
[-]
YL
[+]
BK
[11]
GN
[3]
RD
[Z1]
RD
[Z2]
BK – SENSING [11]
GN – SENSING [3]
15
GENERATOR
(ALTERNATOR)
17
YL [+]
EXCITER
T11
T4
T1
T9
T8
T3
16
BK – SENSING [11]
GN – SENSING [3]
NOTE:
GN AND BK SENSING WIRES
RUN WITH T3 AND T11
ALONG ENTIRE LENGTH
18 ROTATING COMPONENTS
RECTIFIE R
19 20
MAIN FIELD
1 3 5 7 9 11 RD
L2 [N2]
L2 [N2]
L1
E
L2
G
N
L3 [N2]
T9
L3
F
L2
H
N
T4
T8
BU [-]
STATOR
GROUND
GENERAT
OR
HOUSING
TO
FRAME
26
25
ROTOR
24
T2
T7
T12
T10
T6
T5
MAIN
ROTOR
23
2 4 6 8 10 12
22
STATOR
MAIN
WINDINGS
21
STATOR
AUX
WINDING
RD
27
HIGH WYE
L-N = 277v
L-L = 480v
L3
9
11
10
2
L1
1
3
4
12
N 8
7
6
5
L2
L-N
L-L
LOW WYE
L-N = 120v
L-L = 208v
3
4
L1
11
12
N
1
2
L3 9
10
6
8
L-N
7
5
L2
L-L
L3
9
10
11
12 5
L-N
7
6
L-L
8
N
ZIG-ZAG
L-N = 120v
L-L = 240v
2 1
4
L-N
3
L1 wc_gr015134
178
Mobile Generator
23.2
AC Schematic Components: G70 480V
Ref.
Description
1
Note: Wires 278 and 279 are part of the
DC control box harness.
4
5
2
3
6
7
Lug door safety interlock switch
Mechanical lugs
Camlock option
Ground to enclosure box stud
Voltage adjust potentiometer
CR701—AVR
Common
A.P.O.
Common
50/60 Hz
Common
Vext/pext
Auxiliary/neutral
Auxiliary/neutral
H_phase
H_phase
F_phase
8
9
10
11
F_phase
Aux/exc +
Aux/exc +
Exc -
Receptacles
Circuit breakers
Current transformers
Deep Sea 73xx MKII Electronic Control
Module
DC control wiring located on DC schematic
DS104—plug 4 relay C/D and voltage sensing
NC relay C1
NC relay C2
25
26
27
28
21
22
23
17
18
19
20
24
12
13
14
15
16
Ref.
11
Description
NO relay D1
NO relay D2
L1 voltage sensing
L2 voltage sensing
L3 voltage sensing
N voltage sensing
DS105—plug 5 current sensing
L1 current sensing
L2 current sensing
L3 current sensing
—
Current sensing com
—
Phase switch
Terminal block supplied with generator
Generator control wire bundle
Generator winding wires to terminal block
Green and black sensing wires physically run with T1 and T11.
Generator (alternator)
Rotating components
Rectifier
Main field
Stator auxiliary winding
Stator main windings
Main rotor
Rotor
Stator
Ground generator housing to frame
Generator winding wires to phase switch
Adjustable trip main circuit breaker. Set per machine rating.
Schematics—Machines with Deep Sea Controller
Generator specific sizing/ratings
N1 Main breaker rating
N1
N3
Main power conductor
CB-lug phase conductor
N4
N5
Ground lug conductor
Convenience receptacle phase conductor
BLK
GRN
BLU
Black
Green
Blue
G50
175A
1x black #4 AWG
2x black #4 AWG
G70
225A
2x black #6 AWG
1x black #6 AWG
RED Red
TAN Tan
VIO Violet
Wire Colors
WHT White
YEL Yellow
GRY Gray
ORG
BRN
PNK
Orange
Brown
Pink wc_tx004651en.fm
179
Schematics—Machines with Deep Sea Controller
23.3
AC Schematic: G70 600V
4
CAMLOCK OPTION
278 BK
16 AWG
1 2
NOTE:
WIRES 278 AND
279 ARE PART
OF DC CONTROL
BOX HARNESS.
279 BU/WH 16 AWG
CR705
28
[N1]
ADJUSTABLE
TRIP MAIN
CIRCUIT
BREAKER. SET
PER MACHINE
RATING.
779 BU 16 AWG
3
L1
L1
L2
L2
L3
L3
[N3] [N3] [N3]
[N2]
[N2]
[N2]
[N2]
[N2]
[N2]
11
DC CONTROL WIRING
LOCATED ON DC SCHEMATIC
DS104 - PLUG 4
RELAY C/D & VOLTAGE SENSING
NC RELAY C1
NC RELAY C2
NO RELAY D1
NO RELAY D2
L1 VOLTAGE SENSING
L2 VOLTAGE SENSING
L3 VOLTAGE SENSING
N VOLTAGE SENSING
DS105 - PLUG 5
CURRENT SENSING
L1 CURRENT SENSING
L2 CURRENT SENSING
L3 CURRENT SENSING
-
CURRENT SENSING COM
-
34
35
36
30
31
32
33
37
42
43
44
45
46
47
780 RD/WH 16 AWG
779 BU 16 AWG
742 BR 16 AWG
743 YL 16 AWG
741 OR 16 AWG
740 WH 16 AWG
737 BR 16 AWG
738 YL 16 AWG
739 OR 16 AWG
736 WH 16 AWG
743 YL 16 AWG
L2 [N2]
N (L0) [N2]
12
SW701
PHASE SWITCH
HIGH WYE
3P ZIG-ZAG
LOW WYE
ZIG-ZAG
1
2
5
6
9
10
T10
13
14
17
18
21
T8
22
25
26
T3
T6
N
(L0)
BOND
N
BAR
(L0)
G
[N4]
29
T7
30
G
737 BR 16 AWG
33
34
GROUND TO
ENCLOSURE
BOX STUD
37
N (L0) [N2]
N (L0) [N2]
738 YL 16 AWG
735 WH 16 AWG
736 WH 16 AWG
734 WH 16 AWG
740 WH 16 AWG
741 OR 16 AWG
38
T4
42
5
739 OR 16 AWG
742 BR 16 AWG
41
T1
GN - SENSING [1/3]
45
46
10
G [N5]
G [N5]
N (L0) [N5]
N (L0) [N5]
R2 [N5]
R2 [N5]
R1 [N5]
R1 [N5]
CT-3
CURRENT
TRANSFORMER
T11
BK - SENSING [11]
708 BK 10 AWG
705 BK 10 AWG
703 BR 14 AWG
702 BK 10 AWG
707 BK 10 AWG
706 BR 14 AWG
704 BK 10 AWG
701 BK 10 AWG
717 GN/YL 14 AWG
711 GN/YL 10 AWG 718 GN/YL 14 AWG
709 GN/YL 10 AWG 710 GN/YL 10 AWG
713 LB 14 AWG
712 LB 14 AWG
714 LB 10 AWG
715 LB 10 AWG
716 LB 10 AWG
724 BK
10 AWG
X G
723 BK
10 AWG Y
240VAC 50A
RECEPTACLE
726 BR 14 AWG
W
LINE
TEST
RESET
GND
N/C LOAD
120VAC 20A
GFI RECEPTACLE
9
722 BK
10 AWG
719 BK
10 AWG
X G
721 BK
10 AWG Y
240VAC 50A
RECEPTACLE
W
725 BR 14 AWG 8
720 BK
10 AWG
X G
Y
240VAC 50A
RECEPTACLE
W
LINE
TEST
RESET
GND
N/C LOAD
120VAC 20A
GFI RECEPTACLE
13
A
TB701 - TERMINAL BLOCK
SUPPLIED WITH GENERATOR
B
T9
L1 [N2]
R2 / 45
C
L1 [N2]
T9 / 15 / 48
L2 [N2]
L2 [N2]
E
L2
G
T5
L3 [N2]
L3 [N2]
T5 / L3
R1 / 47
D
L1 [N2]
L1 [N2]
L1
F
L2 [N2]
L2 [N2]
1 / 40
H
L3 [N2]
L3 [N2]
27 / 46
15
6
POT-701
VOLTAGE
ADJUST
POTENTIOME
TER
REG. TYPE SR7-2G
T5
T9
120kΩ
VT – SIGNAL
WH – COM
GREEN GN – SENSING [1/3]
CONNECT NEAR AVR
2G R7E S TYP REG.
5 C
5 B
5 A
4 A
3 A
7
CR701 - AVR
COMMON
COMMON
EXT POT.
COMMON
50/60 Hz
COMMON
REG SENS V
REG SENS V
EXC+/SUPPLY
EXC+/SUPPLY
SUP JMP <160V
EXC-
4
3A
3
2
1
5A
6
5
4A
5C
5B
7
BK – SENSING [11]
60 Hz
JUMPER
RD – STATOR AUX [Z1]
GREEN
780 RD/WH 16 AWG
YL – EXC [+]
BU – EXC [-]
Mobile Generator
RD – STATOR AUX [Z2]
CONNECT NEAR AVR
14
GENERATOR
CONTROL
WIRE
BUNDLE BU
[-]
YL
[+]
BK
[11]
GN
[1/3]
RD
[Z1]
RD
[Z2]
3 7 11 15 19 23 27 31 35 39 43 47
13
I
N (L0) [N2]
N(L0) / 7
K
TB702 - TERMINAL BLOCK
SUPPLIED WITH GENERATOR
[N2]
-
M
[N2]
3 / 23
O
N (L0) [N2]
N (L0) [N2]
21 / 36 / 41
L
N (L0) [N2]
N (L0) [N2]
11 / 20
N
32 / 44
[N2]
[N2]
P
-
4
T2
8
T12
12 16 20 24 28 32 36 40 44 48
N (L0) [N2]
N (L0) [N2]
HIGH WYE
L-N = 347v
L-L = 600v
AVR = 300v
L1
9
11
10
4
L2
3
1
2
N
12
8
7
6
5
L3
L-N
L-L
L2 [N2]
L1
3P ZIG-ZAG
L-N = 277v
L-L = 480v
AVR = 277v
10
8
9
L-N
1
L2
3
7
N
11
12
6
4
5
L3
2
L-L
LOW WYE
L-N = 120v / 137v
L-L = 208v / 240v
AVR = 208v / 240v
11
L1
1
L2
3
9
12
2 4
10
N
6
8
7
L-N
5
L3
L-L
L3
7
5
8
6 1
L-N
3
2
L-L
4
N
ZIG-ZAG
L-N = 120v
L-L = 240v
AVR = 208v
12 11
L1
10
L-N
9
GENERATOR
(ALTERNATOR)
17
YL [+]
EXCITER
18
ROTATING COMPONENTS
RECTIFIER
19 20
MAIN FIELD
1 3 5 7 9 11 RD
26
GROUND
GENERATOR
HOUSING TO
FRAME
BU [-]
STATOR
25
27
ROTOR
24
23
MAIN
ROTOR
2 4 6 8 10 12
22
STATOR
MAIN
WINDINGS
T3
T1
T2
T4
T8
T11
T6
T10
BK - SENSING [11]
T7
GN - SENSING [1/3]
T12
NOTE:
GREEN AND BLACK SENSING WIRES PHYSICALLY RUN WITH T3 AND T11
ALONG ENTIRE LENGTH.
GREEN ELECTRICALLY CONNECTED TO T1 AT SELECTOR SWITCH.
BLACK ELECTRICALLY CONNECTED TO T11 AT SELECTOR SWITCH.
16
RD
21
STATOR
AUX
WINDING wc_gr015135
180
Mobile Generator
23.4
AC Schematic Components: G70 600V
Ref.
Description
1
Note: Wires 278 and 279 are part of the
DC control box harness.
4
5
2
3
6
7
Lug door safety interlock switch
Mechanical lugs
Camlock option
Ground to enclosure box stud
Voltage adjust potentiometer
CR701—AVR
Common
A.P.O.
Common
50/60 Hz
Common
Vext/pext
Auxiliary/neutral
Auxiliary/neutral
H_phase
H_phase
F_phase
8
9
10
11
F_phase
Aux/exc +
Aux/exc +
Exc -
Receptacles
Circuit breakers
Current transformers
Deep Sea 73xx MKII Electronic Control
Module
DC control wiring located on DC schematic
DS104—plug 4 relay C/D and voltage sensing
NC relay C1
NC relay C2
25
26
27
28
21
22
23
17
18
19
20
24
12
13
14
15
16
Ref.
11
Description
NO relay D1
NO relay D2
L1 voltage sensing
L2 voltage sensing
L3 voltage sensing
N voltage sensing
DS105—plug 5 current sensing
L1 current sensing
L2 current sensing
L3 current sensing
—
Current sensing com
—
Phase switch
Terminal block supplied with generator
Generator control wire bundle
Generator winding wires to terminal block
Green and black sensing wires physically run with T1 and T11.
Generator (alternator)
Rotating components
Rectifier
Main field
Stator auxiliary winding
Stator main windings
Main rotor
Rotor
Stator
Ground generator housing to frame
Generator winding wires to phase switch
Adjustable trip main circuit breaker. Set per machine rating.
Schematics—Machines with Deep Sea Controller
Generator specific sizing/ratings
N1 Main breaker rating
N1
N3
Main power conductor
CB-lug phase conductor
N4
N5
Ground lug conductor
Convenience receptacle phase conductor
BLK
GRN
BLU
Black
Green
Blue
RED Red
TAN Tan
VIO Violet
Wire Colors
WHT White
YEL Yellow
GRY Gray
G50
175A
1x black #4 AWG
2x black #4 AWG
G70
225A
2x black #6 AWG
1x black #6 AWG
ORG
BRN
PNK
Orange
Brown
Pink wc_tx004651en.fm
181
Schematics—Machines with Deep Sea Controller
22.4
DC Schematic: Deep Sea Control Box
1
CR102 - PANEL MOUNT
BULKHEAD RECEPTACLE
(EXTERNAL TELEMATICS OPTION)
BATTERY (+)
BATTERY (-)
RUN SIGNAL
CAN LOW (J1939 -)
CAN HI (J1939 +)
MODBUS RS485 ‘A+’
MODBUS RS485 ‘B-’
UTILIZATION (AUTO)
3
4
5
6
1
2
7
8
2 3
CR104
4-POSITION
DEUTCH RECPT.
CR105
4-POSITION
DEUTCH PLUG
175 RD 16 AWG
177 BK 16 AWG
179 VT 16 AWG
180 GN 16 AWG 176 BU 16 AWG
189 YL 16 AWG
198 WH/VT 16 AWG
199 WH/GY 16 AWG
3
CR106
4-POSITION
DEUTCH
PLUG
160 RD 16 AWG
162 BK 16 AWG
164 VT 16 AWG
216 BU 16 AWG
GN 20 AWG
YL 20 AWG
SHIELD
SP107
190 WH/VT 16 AWG
191 WH/GY 16 AWG
CR107
4-POSITION
DEUTCH
RECPT.
2
14
15
16
18
19
20
DS101 - PLUG 1
POWER AND OUTPUTS
BAT (-)
BAT (+)
E-STOP INPUT
KEYSWITCH OUT (FUEL)
START SIGNAL OUT
DC ALT EXCITATION
-
DIGITAL OUTPUT E
DIGITAL OUTPUT F
DIGITAL OUTPUT G
DIGITAL OUTPUT H
DIGITAL OUTPUT I
DIGITAL OUTPUT J
DS102 - PLUG 2
ANALOG SENSOR INPUTS
SENSOR COMMON
ANALOG SENSOR A
ANALOG SENSOR B
ANALOG SENSOR C
ANALOG SENSOR D
ANALOG SENSOR E
ANALOG SENSOR F
DS103 - PLUG 3
MAG PICKUP AND CANBUS
MAG PICKUP +
MAG PICKUP -
MAG PICKUP SHIELD
J1939 CAN (+)
J1939 CAN (-)
J1939 CAN SHIELD
DSENET B
DSENET A
DSENET SHIELD
DS104 - PLUG 4
RELAY C/D & VOLTAGE SENSING
NC RELAY C1
NC RELAY C2
NO RELAY D1
NO RELAY D2
L1 VOLTAGE SENSING
L2 VOLTAGE SENSING
L3 VOLTAGE SENSING
N VOLTAGE SENSING
30
31
32
33
34
35
36
37
25
26
27
28
29
21
22
23
24
17
18
19
20
14
15
16
10
11
12
13
6
7
8
9
3
4
5
1
2
DS105 - PLUG 5
CURRENT SENSING
L1 CURRENT SENSING
L2 CURRENT SENSING
L3 CURRENT SENSING
-
CURRENT SENSING COM
-
DS106 - PLUG 6
DIGITAL INPUTS
DIGITAL INPUT A
DIGITAL INPUT B
DIGITAL INPUT C
DIGITAL INPUT D
DIGITAL INPUT E
DIGITAL INPUT F
DIGITAL INPUT G
DIGITAL INPUT H
DS107 - PLUG 7
MODBUS RS485
RS485 – ‘SCR’
RS485 – ‘B-’
RS485 – ‘A+’
-
-
-
42
43
44
45
46
47
56
57
58
-
-
-
48
49
50
51
52
53
54
55
101 BK 16 AWG
102 BU 16 AWG
105 RD 16 AWG
106 VT 16 AWG
100 BU 16 AWG
168 BU 18 AWG
107 BU 16 AWG
111 BU 16 AWG
169 BU 16 AWG
134 BU 16 AWG
120 BK 16 AWG
115 BU 16 AWG
118 BU 16 AWG
103 BU 16 AWG
17
116 BU 16 AWG
117 BU 16 AWG
119 BU 18 AWG
121 BU 16 AWG
122 BU 16 AWG
123 BU 18 AWG
F113 - 2A FUSE
YL 20 AWG
GN 20 AWG
SHIELD
SP108
21
CR103 - DIAGNOSTIC CONNECTOR
9-PIN DEUTSCH
DATALINK RETURN (-)
DATALINK B+
CAN HI (J1939 +)
CAN LOW (J1939 -)
CAN SHIELD
-
-
ISO 15765 CAN1-H
ISO 15765 CAN1-L
(KOHLER)
(KOHLER)
G
H
J
C
D
E
F
A
B
191 WH/GY 16 AWG
190 WH/VT 16 AWG
211 WH/GY 16 AWG
210 WH/VT 16 AWG
CR108
3-POSITION DEUTCH RECPT.
163 BK 16 AWG
161 RD 16 AWG
YL 20 AWG
GN 20 AWG
SHIELD
SHIELD
WH 20 AWG
BK 20 AWG
Mobile Generator
SP105
159 RD 16 AWG
F101 - 3A FUSE
181 VT 16 AWG
SP112
13
SW101
POWER
TOGGLE
104 RD 16 AWG
SP104
167 BK 16 AWG
124 BU 16 AWG
F112 - 10A FUSE
154 RD 16 AWG
4 L3 COMPONENTS
F151 - 10A FUSE
132 RD 16 AWG 133 RD 16 AWG
30
K151
L3 RELAY
87
86 85
134 BU 16 AWG
135 BU 16 AWG
131 BK 16 AWG
12
SW102
IDLE
TOGGLE
121 BU 16 AWG
SP103
171 BK 16 AWG
174 BK 16 AWG 170 BK 16 AWG
173 BK 16 AWG
129 VT 16 AWG
HR101
HOURMETER
10 SW103
REGEN
TOGGLE
11
INSTALL REGEN LIGHT
AND TOGGLE SWITCH
IF REQUIRED.
SECURE LOOSE WIRE
ENDS IF REGEN
LIGHT/SWITCH IS
NOT REQUIRED.
9
172 BK 16 AWG
107 BU 16 AWG
168 BU 18 AWG
LT103
REGEN
LIGHT
8
LT104
WORK
LIGHT
WH
7
BR
108 BU
16 AWG
197 BK
16 AWG
SP102
195 BU
16 AWG
110 BU 16 AWG
120 BK 16 AWG
115 BU 16 AWG
100 BU 16 AWG
118 BU 16 AWG 103 BU 16 AWG
119 BU 18 AWG
123 BU 18 AWG
6
SW104
WORK LT
TOGGLE
196 BU 16 AWG
109 RD 12 AWG
113 RD 10 AWG
192 VT 14 AWG
112 VT 16 AWG
135 BU 16 AWG
YL 20 AWG
GN 20 AWG
SHIELD
128 RD 16 AWG
154 RD 16 AWG
126 VT 16 AWG
115 BU 16 AWG
103 BU 16 AWG
120 BK 16 AWG
118 BU 16 AWG
178 VT 16 AWG
119 BU 18 AWG
127 BU 16 AWG
123 BU 18 AWG
196 BU 16 AWG
100 BU 16 AWG
WH 20 AWG
BK 20 AWG
200 VT 16 AWG
110 BU 16 AWG
168 BU 18 AWG
16
16
16
16
16
16
16
16
16
16
20
SIZE
12
12
12
12
16
16
16
16
20
16
16
20
20
16
16
20
16
20
14
15
16
17
18
10
11
12
13
4
5
6
7
8
9
#
1
2
3
19
20
21
22
23
24
25
26
27
28
29
FUNCTION
B+ FUSEBLOCK (30A)
CONTROL BOX BATTERY SUPPLY B (+)
KEYSWITCH FUSEBLOCK (5A)
-
KEYSWITCH FUSEBLOCK (5A)
L3 RELAY OUTPUT
J1939 (+)
J1939 (-)
J1939 SHIELD
B+ FUSEBLOCK (2A)
TELEMATICS/DIAGNOSTIC B+ (10A)
KEYSW VIA RELAY D (3A)
PIN 18 ANALOG INPUT D (FUEL SENDER)
PIN 20 ANALOG INPUT F
CONTROLLER ANALOG COMMON
PIN 19 ANALOG INPUT E
KEYSWITCH FUSEBLOCK (5A)
PIN 51 DIGITAL INPUT D
PIN 53 DIGITAL INPUT F
PIN 54 DIGITAL INPUT G
WORK LIGHT SWITCH (5A)
PIN 5 START COMMAND OUTPUT
ISO 15765 CAN1-H (KOHLER)
ISO 15765 CAN1-L (KOHLER)
-
KEYSWITCH FUSEBLOCK (10A)
-
PIN 8 DIGITAL OUTPUT
ALTERNATOR D+
5
SP101
127 BU 16 AWG
122 BU
16 AWG
36
116 BU 16 AWG
192 VT
14 AWG
112 VT
16 AWG
126 VT
16 AWG
182 VT
14 AWG
183 VT
16 AWG
184 VT
16 AWG
TS102
REMOTE START
TERMINALS
158 BK 16 AWG
22
104 RD
16 AWG
109 RD
12 AWG
128 RD
16 AWG
140 RD
16 AWG
185 RD
16 AWG
186 RD
12 AWG
187 RD
16 AWG
188 RD
16 AWG
153 RD
12 AWG
193 RD
16 AWG
113 RD
10 AWG
166 VT 16 AWG
165 VT 16 AWG
156 VT 12 AWG
106 VT 16 AWG
35
K101
KEYSWITCH RELAY
30
86
87
155 RD 12 AWG
85
157 BK 16 AWG
194 RD 16 AWG
101 BK 16 AWG
23 GROUND TO
ENCLOSURE BOX
REAR STUD (M8)
ST101
178 VT 16 AWG
111 BU
16 AWG
D101 SHUNT
TRIP
OUTPUT DIODE
34
200 VT 16 AWG
SP106
138 RD
16 AWG
SP110
141 RD 16 AWG
37
SW110 EMERGENCY STOP SWITCH
RD NC
144 RD
16 AWG
38
114 BU 16 AWG
143 RD 16 AWG
137 BU
16 AWG
GN NO
K102
SHUNT TRIP
30 RELAY 87
86 85
33
142 RD
16 AWG RD
149 BK 16 AWG
152 BK 10 AWG
ST104
24
BRAIDED GROUND STRAP
GROUND
TO
CONTROL
BOX SIDE
STUD
INSIDE
BOX
ST102
25
GROUND
TO
CONTROL
BOX DOOR
STUD
26
NC
105 RD
16 AWG
40
LUG DOOR N.C. SWITCH WIRING
LOCATED ON AC SCHEMATIC
WIRES END IN DISCONNECTS AT AVR.
SP113
27
139 BU
16 AWG
147 BU
16 AWG
SP109
148 BU
16 AWG
145 BU 16 AWG
146 BK 16 AWG
151 BK 16 AWG
117 BU 16 AWG
150 BU 16 AWG
136 BK 16 AWG
130 BK 16 AWG
31
1
C2
CB101
MAIN BREAKER
AUX
SHUNT
4
2
C1
L1 CABLE
L2 CABLE
L3 CABLE
278 BK
16 AWG
BLUE
39
SW120
LUG DOOR SAFETY
INTERLOCK SWITCH
11 12
279 BU/WH
16 AWG
BU/
WH
33
ORAN
GE
29
MECHANICAL
34
ORAN
GE
L2
L1 CABLE
L2 CABLE
32
L3
BOND
BAR
L0
L3 CABLE
N CABLE
L1 CABLE
GRD
L2 CABLE
L3 CABLE
GROUND CABLE
30
27
28 wc_gr015136
182
Mobile Generator
23.5
DC Schematic Components: Deep Sea Control Box
Ref.
Description
1
CR102—Panel mount bulkhead receptacle (external telematics option)
Battery (+)
Battery (-)
Run signal
CAN low (J1939 -)
2
CAN high (J1939 +)
Modbus RS485 A+
Modbus RS486 B-
Utilization (auto)
Four-position Deutch receptacle
Four-position Deutch plug
3
4
5
L3 components
CR101—Control panel bulkhead
B+ fuse block (30A)
Control box battery supply B (+)
Keyswitch fuseblock (5A)
—
Keyswitch fuseblock (5A)
L3 relay output
J1939 (+)
J1939 (-)
J1939 shield
B+ fuseblock (2A)
Telematics/diagnostic B+ (10A)
Keyswitch via relay D (3A)
Pin 18 analog input D (fuel sender)
Pin 15 analog input A
Controller analog common
Pin 20 analog input F
Keyswitch fuseblock (5A)
Pin 51 digital input D
Pin 53 digital input F
Pin 54 digital input G
Work light switch (5A)
Pin 5 star command output
Analog sensor D
Ref.
5
Description
ISO 15765 CAN1-H (Kohler)
6
7
8
9
ISO 15765 CAN1-L (Kohler)
—
Keyswitch fuseblock (10A)
—
Pin 8 digital output
Alternator D+
Work light toggle
Work light
Regen light
Install regen light and toggle switch if required. Secure loose wire ends if regen light/switch is not required.
10
11
12
13
Regen toggle
Hour meter
Idle toggle
Power toggle
Deep Sea 73xx MKII Electronic Control Module
14 DS101—plug 1 power and outputs
Battery (-)
Battery (+)
15
19
Emergency stop input
Keyswitch out (fuel)
Start signal out
DC alt excitation
—
Digital output E
Digital output F
Digital output G
Digital output H
Digital output I
Digital output J
DS102—plug 2 analog sensor inputs
Sensor common
Analog sensor A
Analog sensor B
Analog sensor C
Digital input F wc_tx004651en.fm
183
Schematics—Machines with Deep Sea Controller
Ref.
Description
15 Analog sensor E
Analog sensor F
16 DS103—plug 3 mag pickup and CANbus
Mag pickup +
Mag pickup -
Mag pickup shield
J1939 CAN (+)
J1939 CAN (-)
J1939 CAN shield
DSENET B
DSENET A
DSENET shield
Wiring for voltage and current sensing located on
AC schematic
17
DS104—plug 4 relay C/D and voltage sensing
NC relay C1
NC relay C2
NO relay D1
NO relay D2
L1 voltage sensing
L2 voltage sensing
L3 voltage sensing
N voltage sensing
18
19
DS105—plug 5 current sensing
L1 current sensing
L2 current sensing
L3 current sensing
—
Current sensing com
—
DS106—plug 6 digital inputs
Digital input A
Digital input B
Digital input C
Digital input D
36
37
38
39
30
31
32
33
34
35
26
27
28
29
22
23
24
25
40
Ref.
19
20
21
Description
Digital input G
Digital input H
Digital input E
DS107—plug 7 Modbus RS485
RS485—SCR
RS485—B-
RS485—A+
CR103—diagnostic connector 9-pin
Deutsch
Datalink return (-)
Datalink B+
CAN high (J1939 +)
CAN low (J1939 -)
CAN shield
ISO 15765 CAN1-H
ISO 15765 CAN1-L
Remote start terminals
Ground to enclosure box rear stud
Braided ground strap
Ground to control box side stud inside box
Ground to control box stud
See AC schematic
Bond bar
Mechanical lugs
Ground cable
Main breaker
Shunt
Breaker shunt trip diode
Shunt trip output diode
Keyswitch relay
Terminal strip jumper—one end for keyswitch jumper, other end for B+
Emergency stop switch
Shunt trip relay
Lug door safety interlock switch
Lug door N.C. switch wiring located on AC schematic. Wires end in disconnects at
AVR.
Schematics—Machines with Deep Sea Controller
23.6
Engine Schematic: Kohler KDI 3404
1
FUNCTION
DCU POWER SUPPLY B+
CONTROL BOX BATTERY SUPPLY
DCU KEYSWITCH
-
ECU KEYSWITCH
L3 RELAY OUTPUT
J1939 (+)
J1939 (-)
J1939 SHIELD
COOLANT SENSOR SUPPLY B+
TELEMATICS / DIAGNOSTIC (B+)
KEYSWITCH OPTION (3A)
FUEL SENDER SIGNAL
ANALOG INPUT OPTION
CONTROLLER ANALOG COMMON
ANALOG INPUT OPTION
FAN CONTROLLER KEYSWITCH
LOW COOLANT LEVEL SENSOR SIGNAL
GRID HEATER LAMP SIGNAL
CRANKCASE PSI SW SIGNAL
CONTROL BOX WORK LT SW OUTPUT
STARTER RELAY COMMAND
ISO 15765 CAN1 -H
ISO 15765 CAN1 -L
-
KEYSWITCH OPTION (10A)
-
DIGITAL OUTPUT OPTION
ALTERNATOR D+
16
20
20
16
16
20
16
20
16
20
16
20
16
16
16
16
16
16
16
SIZE
16
16
16
16
12
12
12
12
16
16
#
3
4
5
6
1
2
9
10
7
8
17
18
19
20
21
11
12
13
14
15
16
22
23
24
25
26
27
28
29
309 RD 12 AWG
313 RD 10 AWG
392 VT 14 AWG
312 VT 16 AWG
335 BU 16 AWG
YL 20 AWG
GN 20 AWG
SHIELD
428 RD 16 AWG
454 RD 16 AWG
326 VT 18 AWG
315 BU 16 AWG
317 BU 18 AWG
320 BK 16 AWG
378 VT 16 AWG
419 BU 18 AWG
427 BU 16 AWG
323 BU 18 AWG
396 BU 16 AWG
300 BU 16 AWG
400 VT 16 AWG
WH 20 AWG
BK 20 AWG
SHIELD
418 BK 16 AWG
428 RD 16 AWG
419 BU 18 AWG
CR304
A
B
C
D
2
SN302
COOLANT LEVEL
SENSOR
396 BU 16 AWG
397 BK 16 AWG
CR380 CR381
496 BU 16 AWG
GROUND TO
CONTROL BOX
SIDE STUD
OUTSIDE BOX
8
(-)
(+)
(S)
9
3
LT381
OPT. WORK LIGHT
335 BU 16 AWG
336 BK 16 AWG
321 VT 18 AWG
375 BK 18 AWG
317 BU 18 AWG
SN304
AIR PRESSURE
DIFFERENTIAL SENSOR s s
5
4
SP329
368 BU 18 AWG
378 VT 16 AWG
376 BK 16 AWG
YL 20 AWG
GN 20 AWG
SHIELD
K310
FUEL FILTER
HEATER RELAY
31 381 BK 18 AWG
382 BU 18 AWG
383 BU 18 AWG
406 BU 18 AWG
400 VT 16 AWG
326 VT 18 AWG
325 BK 16 AWG
391 VT 16 AWG
CR385
FUEL FILTER
HEATER PLUG
CR386
FUEL FILTER
HEATER RECPT.
30
412 VT 16 AWG
413 BK 16 AWG
414 VT 18 AWG
415 BU 18 AWG
SP317
29
H301 - FUEL FILTER
HEATER OPTION
398 BK 18 AWG
28
CABINET THERMOSTAT
NC TEMP SWITCH
RD 10 AWG
RD 10 AWG
RD 10 AWG
SP318 SP319
SP312
399 BK 16 AWG
27
RD 2/0 AWG
B+ CABLE ASSEMBLY
23
STARTER
SOLENOID
STARTER
MOTOR
24
KDI ENGINE HARNESS
FROM CR310-G2
22
21
RD 6 AWG
ALTERNATOR
CABLE
ASSEMBLY
KDI ENGINE
HARNESS
FROM CR310-D8
20
(B+) AND (B-) CABLE ASSEMBLIES
EACH INCLUDE (3) 10 AWG TAPS FOR
SYSTEM WIRING. BOTH SUPPLIED
SEPARATELY FROM ENGINE HARNESS.
19
26
SW380 - BATTERY
DISCONNECT OPTION B+ CABLE AND 10 AWG TAPS
DIRECT TO BATTERY
IF OPTION NOT PRESENT
25
12V BATTERY
404 RD 16 AWG
F307
INLINE FUSE – 80A
313 RD 10 AWG
403 RD 10 AWG
SP307
307 RD 10 AWG
SP324
F304
FUSE – 30A
SP325
377 BK 18 AWG
384 BU 18 AWG
BK 10 AWG
SP320
BK 10 AWG
SP321
BK 10 AWG
SP322
GROUND
TO SIDE
OF ENGINE
BLOCK
18
32
K307
STARTER RELAY
-
409 BK 10 AWG
410 BK 10 AWG
411 BK 10 AWG
BK 2/0 AWG
GROUND CABLE ASSEMBLY
314 RD 12 AWG
341 VT 18 AWG
17
402 RD 10 AWG
SP306
306 RD 12 AWG
305 RD 8 AWG
SP326
F306
INLINE FUSE – 50A
SP327
319 RD 8 AWG
343 VT 18 AWG
35
K309
LIFT PUMP RELAY
SP309
SP310
SP311
407 RD
16 AWG
318 BK 12 AWG
320 BK 16 AWG
316 BK 16 AWG
405 BK 18 AWG
328 BK 14 AWG
362 BK 12 AWG
363 BK 12 AWG
354 BK 12 AWG
355 BK 12 AWG
373 BK 16 AWG
10
454 RD 16 AWG
CR388 TELEMATICS
BATTERY DISCONNECT
BYPASS REPLACES CR307
IF OPTIONAL BATTERY
DISCONNECT PRESENT.
16
353 BU 12 AWG
352 BU 18 AWG
K308
GRID HEATER RELAY
33
349 RD 8 AWG
351 BU 18 AWG
34
H302 KOHLER
GRID HEATER
401 RD
10 AWG
SP305 302 RD
12 AWG
SP315
329 RD 16 AWG
303 RD 12 AWG
F308
FUSE – 5A
F302
FUSE – 20A
357 RD 16 AWG
337 RD 12 AWG
SP328
339 RD 12 AWG
338 RD 18 AWG
36
K306
ECU SWITCHED
POWER RELAY
340 VT 12 AWG
342 VT 18 AWG
344 VT 16 AWG
345 VT 12 AWG
350 BU 18 AWG
F305
FUSE – 5A
359 BU 16 AWG
371 BU 18 AWG
346 VT 16 AWG
301 RD
12 AWG
F303
FUSE – 5A
F301
FUSE – 30A
304 RD 16 AWG
308 RD 12 AWG
SP323
311 RD 14 AWG
380 VT 18 AWG
37
K301
NOx SENSOR RELAY
327 RD 16 AWG
389 VT 14 AWG
361 BK 18 AWG
K304
HOSE HEATER 2 RELAY
310 RD 12 AWG
379 VT 18 AWG
K302
HOSE HEATER
POWER RELAY
390 BU 12 AWG
385 BU 18 AWG
393 BU 16 AWG
374 VT 18 AWG
K303
HOSE HEATER 1 RELAY
360 BK 16 AWG
386 BU 18 AWG
394 BU 16 AWG
372 VT 18 AWG
358 BK 16 AWG
387 BU 18 AWG
315 BU 16 AWG
323 BU 18 AWG
CR309
322 BK 18 AWG
11
12
6
CR312 KOHLER
“WATER IN FUEL” SWITCH
CR313 KOHLER DIRTY
AIR FILTER SWITCH
324 BK 18 AWG
395 BU 16 AWG
370 VT 18 AWG
K305
HOSE HEATER 3 RELAY
356 BK 16 AWG
388 BU 18 AWG
1
2
312 VT 16 AWG
392 VT 14 AWG
309 RD 12 AWG
427 BU 16 AWG
300 BU 16 AWG
368 BU 18 AWG
SN303
CRANKCASE PRESSURE
SWITCH
1
2
331 BK 18 AWG
332 BK 18 AWG
330 BK 16 AWG
15
7
333 BU 18 AWG
334 BU 18 AWG
38
SP313
369 VT 18 AWG
184
Mobile Generator
13
312 VT 16 AWG
YL 20 AWG
GN 20 AWG
SHIELD
BK 20 AWG
WH 20 AWG
SHIELD
322 BK 18 AWG
321 VT 18 AWG
300 BU 16 AWG
368 BU 18 AWG
353 BU 12 AWG
352 BU 18 AWG
427 BU 16 AWG
351 BU 18 AWG
371 BU 18 AWG
333 BU 18 AWG
334 BU 18 AWG
330 BK 16 AWG
346 VT 16 AWG
SP308
362 BK 12 AWG
363 BK 12 AWG
350 BU 18 AWG
327 RD 16 AWG
347 VT 12 AWG
364 BU 22 AWG
365 BK 22 AWG
366 BK 22 AWG
367 BU 22 AWG
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
367 BU 22 AWG
366 BK 22 AWG
348 VT 22 AWG
365 BK 22 AWG
364 BU 22 AWG
3
4
5
1
2 CR311
KOHLER
MASS AIR FLOW
CONNECTOR
14
YL 20 AWG
GN 20 AWG
SHIELD
369 VT 18 AWG
385 BU 18 AWG
BK 20 AWG
WH 20 AWG
SHIELD
354 BK 12 AWG
388 BU 18 AWG
390 BU 12 AWG
387 BU 18 AWG
392 VT 14 AWG
386 BU 18 AWG
309 RD 12 AWG
395 BU 16 AWG
389 VT 14 AWG
394 BU 16 AWG
393 BU 16 AWG
9
10
11
12
13
6
7
8
PIN
1
2
3
4
5
14
15
16
17
18
19
FUNCTION
J1939 (+) CAN2-H
J1939 (-) CAN2-L
-
HOSE RELAY POWER RELAY (86)
HOSE RELAY POWER RELAY (85)
ISO 15765 CAN1-L
ISO 15765 CAN1-H
DCU BATTERY GND REF
HOSE HEATER 3 RELAY (85)
HOSE RELAY POWER RELAY (87)
HOSE HEATER 2 RELAY (85)
DCU IGNITION SWITCH
HOSE HEATER 1 RELAY (85)
DCU POWER SUPPLY (12V B+)
HOSE HEATER 3 RELAY (30)
NOx SENSOR RELAY (87)
HOSE HEATER 2 RELAY (30)
-
HOSE HEATER 1 RELAY (30)
NOM
SZ mm 2 AWG
16 0.75
18
16 0.75
18
16 0.75
18
16
16
0.75
18
0.75
18
16 0.75
18
16
12
0.75
18
4 12
16
12
0.75
18
2.5
14
16 0.75
18
12
16
2.5
14
0.75
18
12 4 12
16
12
0.75
18
2.5
14
16 0.75
18
12
16
2.5
14
0.75
18
39 wc_gr015137
Mobile Generator
23.7
Engine Schematic Components: Kohler KDI 3404
2
3
4
Ref.
Description
1 CR301—Control panel bulkhead plug
DCU power supply B+
Control box battery supply
DCU keyswitch
—
ECU keyswitch
L3 relay output
J1939 (+)
J1939 (-)
J1939 shield
Coolant sensor supply B+
Telematics/diagnostic (B+)
Keyswitch option (3A)
Fuel sender signal
Analog input option
Controller analog common
Analog input option
Fan controller keyswitch
Low coolant level sensor signal
Grid heater lamp signal
Crankcase PSI SW signal
Control box work light SW output
Starter relay command
ISO 15765 CAN1-H
ISO 15765 CAN1-L
—
Keyswitch option (10A)
5
6
B8
—
Digital output option
Alternator D+
Coolant level sensor
Optional work light
L3 system option
System power
System ground
Air pressure differential sensor
Fuel level sender
Grid heater indicator lamp low side driver
Ref.
7
8
9
10
11
12
13
B3
B1
C10
D8
PIN
D7
D1
D2
G2
B6
28
Description
Crankcase pressure switch
Ground to control box side stud outside box
Di+ fan controller
CR351 [C1: ECU connector]
Power supply (+)
Power ground (-)
J1939 CAN_H (+)
J1939 CAN_L (-)
Configurable input 1
Configurable input 2
CR352 [C2: clutch connector]
Sensor power supply return (-)
5VDC sensor power supply
Clutch fan speed feedback
Configurable input 3
Clutch coil output return (-)
Clutch coil output (+)
CR353 fan clutch connector
Hall effect sensor (-)
Hall effect sensor (+)
Digital fan speed output
Not used
Solenoid return
Solenoid pwm in
CR312—Kohler water in fuel switch
CR313—Kohler dirty air filter switch
CR310—Kohler vehicle connector (ECU) all other pins optional/not required
Function
Ignition input
J1939 (+) CAN2-H
J1939 (-) CAN2-L
SA1—GND—5V sensor ground ref
SA1—5V 1—sensor 5v supply
12V command to ECU (starter motor)
Alternator D+ terminal
Starter motor command (relay power in)
Starter motor relay low side driver
Cabinet thermostat NC temperature switch wc_tx004651en.fm
185
Schematics—Machines with Deep Sea Controller
Ref.
Description
F12
Grid heater relay low side driver
(optional)
E11 Lift pump relay low side driver
E9 Water in fuel switch input
E2
Dirty air filter switch input (open/ground)
20
21
22
23
24
D9
C7
D3
14
15
C9
C8
G1
B5
C11 EGR valve ground ref
C12 EGR valve power supply (12V input)
A1
A2
Main ground reference
Signal ground reference
Main relay command low side driver
Main power supply (B+)
Main relay power supply (switched)
Air mass flow sensor
16
Air mass flow sensor ground ref
Air mass temperature sensor ground ref
Air mass temperature sensor
CR311 Kohler mass air flow connector
CR314—fuel lift pump
System ground
System power
CR388 telematics battery disconnect bypass replaces CR307 if optional battery disconnect is present.
17
18
19
25
26
27
Ground cable assembly
Ground to side of engine block
B+ and B- cable assemblies each include three 10 AWG taps for system wiring.
Both are supplied separately from the engine harness.
KDI engine harness from CR310-D8
Alternator
Alternator cable assembly
Starter solenoid
KDI engine harness from CR310-G2
B+ cable and 10 AWG taps direct to battery if option is not present.
Battery disconnect option
B+ cable assembly
Ref.
29
30
35
36
37
38
39
31
32
33
34
Description
Fuel filter heater option
System power
System ground
Fuel filter heater plug/fuel filter heater receptacle
Fuel filter heater relay
Starter relay
Grid heater relay
Kohler grid heater
Lift pump relay
ECU switched power relay
NOx sensor relay
Hose heater relays
CR320—Aftertreatment harness connector
J1939 (+) CAN2-H
J1939 (-) CAN2-L
Hose relay power relay (86)
Hose relay power relay (85)
ISO 15765 CAN1-L
ISO 15765 CAN1-H
DCU battery ground ref
Hose heater 3 relay (85)
Hose relay power relay (87)
Hose heater 2 relay (85)
DCU ignition switch
Hose heater 1 relay (85)
DCU power supply (12V B+)
Hose heater 3 relay (30)
NOx sensor relay (87)
Hose heater 2 relay (30)
—
Hose heater 1 relay (30)
Schematics—Machines with Deep Sea Controller
22.4
Engine Schematic: Aftertreatment
1
2
3
CR850
NOX SENSOR 1 UPSTREAM
FUNCTION PIN
POWER
GROUND
1
2
CAN LO
CAN HI
GND REF (POS)
3
4
5
865 VT 18 AWG
864 BK 18 AWG
GN 20 AWG
YL 20 AWG
SHIELD
863 BK 18 AWG
CR851
NOX SENSOR 2 DNSTREAM
FUNCTION PIN
POWER
GROUND
1
2
CAN LO
CAN HI
GND REF (POS)
3
4
5
862 VT 18 AWG
859 BK 18 AWG
GN 20 AWG
YL 20 AWG
SHIELD
CR852
DEF TANK SENSOR
FUNCTION
POWER
GROUND
CAN LO
CAN HI
PIN
1
2
3
4
861 VT 18 AWG
866 BK 18 AWG
GN 20 AWG
YL 20 AWG
SHIELD
SP812
SP813
SP811
837 BK 16 AWG
860 VT 18 AWG
SP803
892 VT 14 AWG
866 BK 18 AWG
4
5
6
CR856
DEF HOSE HEATER 1
FUNCTION
GND
12V IN
PIN
1
2
842 BU 18 AWG
843 BU 18 AWG
CR857
DEF HOSE HEATER 2
FUNCTION
GND
12V IN
PIN
1
2
845 BU 18 AWG
846 BU 18 AWG
CR858
DEF HOSE HEATER 3
FUNCTION
GND
12V IN
PIN
1
2
848 BU 18 AWG
849 BU 18 AWG
SP810
889 VT 14 AWG
8
CR802
SUPPLY MODULE
FUNCTION
-
PUMP MOTOR PWM
PUMP MOTOR +
PUMP MOTOR GND
REVERTING VALVE +
REVERTING VALVE
-
PRESSURE SENSOR GND
PRESSURE SENSOR SIGNAL
PRESSURE SENSOR +
HEATER
HEATER SIGNAL
5
6
7
8
9
10
11
12
PIN
1
2
3
4
884 BU 18 AWG
883 VT 18 AWG
882 BK 18 AWG
881 VT 18 AWG
880 BU 18 AWG
879 BK 18 AWG
878 BU 18 AWG
877 BU 18 AWG
876 VT 18 AWG
875 BU 18 AWG
SP805
862 VT 18 AWG
865 VT 18 AWG
891 VT 18 AWG
847 BU 18 AWG
844 BU 18 AWG
841 BU 18 AWG
888 BU 18 AWG
887 BU 18 AWG
869 VT 18 AWG
SP806
SP804
842 BU 18 AWG
845 BU 18 AWG
848 BU 18 AWG
SP809
SP808
SP807
893 BU 18 AWG
894 BU 18 AWG
895 BU 18 AWG
890 BU 14 AWG
7
FUNCTION
J1939 (+) CAN2-H
J1939 (-) CAN2-L
-
HOSE RELAY POWER RELAY (86)
HOSE RELAY POWER RELAY (85)
ISO 15765 CAN1-L
ISO 15765 CAN1-H
DCU BATTERY GND REF
HOSE HEATER 3 RELAY (85)
HOSE RELAY POWER RELAY (87)
HOSE HEATER 2 RELAY (85)
DCU IGNITION SWITCH
HOSE HEATER 1 RELAY (85)
DCU POWER SUPPLY (12V B+)
HOSE HEATER 3 RELAY (30)
NOx SENSOR RELAY (87)
HOSE HEATER 2 RELAY (30)
-
HOSE HEATER 1 RELAY (30)
16
12
16
12
16
12
16
12
16
12
16
16
16
16
16
12
NOM
SZ
PIN
16 1
16
16
2
3
4
5
6
7
8
11
12
9
10
13
14
17
18
15
16
19
YL 20 AWG
GN 20 AWG
SHIELD
869 VT 18 AWG
885 BU 18 AWG
BK 20 AWG
WH 20 AWG
SHIELD
854 BK 12 AWG
888 BU 18 AWG
890 BU 14 AWG
887 BU 18 AWG
892 VT 14 AWG
886 BU 18 AWG
899 RD 12 AWG
895 BU 18 AWG
889 VT 14 AWG
894 BU 18 AWG
893 BU 18 AWG
875 BU 18 AWG
876 VT 18 AWG
877 BU 18 AWG
878 BU 18 AWG
879 BK 18 AWG
882 BK 18 AWG
883 VT 18 AWG
884 BU 18 AWG
881 VT 18 AWG
880 BU 18 AWG
854 BK 12 AWG
899 RD 12 AWG
12
SP802
SP801
838 BK 14 AWG
856 BK 14 AWG857 BK 16 AWG
871 RD 14 AWG
874 RD 16 AWG
872 RD 14 AWG
873 RD 16 AWG
CR854
DOSING MODULE VALVE
FUNCTION PIN
GND 1
12V IN 2
853 BU 18 AWG
852 BU 18 AWG
13
CR855
DEF TANK HEATING VALVE
FUNCTION PIN
SUPPLY (POWER) 1
-
-
CONTROL (GND)
2
3
4
851 VT 18 AWG
850 BU 18 AWG
885 BU 18 AWG
886 BU 18 AWG
186
SHIELD
Mobile Generator
839 BU 18 AWG
840 BK 18 AWG
CR859
AMBIENT TEMP SENSOR
PIN FUNCTION
1
2
SIGNAL OUT
GND REF
9
855 BK 14 AWG
856 BK 14 AWG
875 BU 16 AWG
876 VT 16 AWG
871 RD 14 AWG
872 RD 14 AWG
857 BK 16 AWG
840 BK 18 AWG
877 BU 18 AWG
860 VT 18 AWG
847 BU 18 AWG
888 BU 18 AWG
858 BK 16 AWG
839 BU 18 AWG
878 BU 18 AWG
879 BK 18 AWG
891 VT 18 AWG
844 BU 18 AWG
887 BU 18 AWG
874 RD 16 AWG
869 VT 18 AWG
882 BK 18 AWG
883 VT 18 AWG
853 BU 18 AWG
BK 20 AWG
867 BK 18 AWG
SHIELD
GN 20 AWG
YL 20 AWG
841 BU 18 AWG
873 RD 16 AWG
851 VT 18 AWG
884 BU 18 AWG
881 VT 18 AWG
880 BU 18 AWG
852 BU 18 AWG
WH 20 AWG
868 BU 18 AWG
870 BU 18 AWG
850 BU 18 AWG
885 BU 18 AWG
886 BU 18 AWG
89
90
91
82
83
-
92
93
94
79
80
81
76
77
78
71
72
73
74
75
62
63
64
59
60
61
56
57
58
53
54
55
68
69
70
65
66
67
42
-
49
50
51
52
39
40
41
-
22
-
9
-
17
30
31
-
27
28
29
4
5
6
7
8
PIN
1
2
3
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
M
S
S
S
S
S
S
S
S
S
S
TYPE
L
L
L
L
L
L
M
S
S
S
S
S
S
M
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
M
S
S
868 BU 18 AWG
867 BK 18 AWG
PIN
CR853
SCR TEMP SENSOR
FUNCTION
1
2
SIGNAL OUT
GND REF
FUNCTION
BATTERY MINUS 1
BATTERY MINUS 2
SUPPLY MODULE HEATER
SUPPLY MODULE HEATER V+
BATTERY PLUS 1
BATTERY PLUS 2
BATTERY MINUS 3
-
RESERVE ANALOG SENSOR 2 GND
-
RED. AGENT PRESSURE SENSOR SUPPLY
-
TERMINAL 15 SWITCHED B+
-
DEF HOSE HEATER 3 RELAY FEEDBACK
DEF HOSE HEATER 3 RELAY CONTROL
BATTERY MINUS 4
-
RESERVE ANALOG INPUT 2
-
RED. AGENT PRESSURE SENSOR SIGNAL
RED. AGENT PRESSURE SENSOR GND
-
RESERVE FREQUENCY INPUT 1
-
DEF HOSE HEATER 2 RELAY FEEDBACK
DEF HOSE HEATER 2 RELAY CONTROL
BATTERY PLUS 4
-
MAIN RELAY HOSE HEATER SUPPLY
RED. AGENT PUMP MOTOR GND
RED. AGENT PUMP MOTOR SUPPLY +
-
-
RED. AGENT METERING VALVE (LOW-SIDE)
-
DCU CAN 1 LOW
CATALYST TEMP SENSOR 1 GND
-
-
-
DCU CAN 0 LOW
DCU CAN 0 HIGH
DCU CAN 2 TERM. RES. ENABLE JUMPER A
DCU CAN 2 TERM. RES. ENABLE JUMPER B
-
-
-
DEF HOSE HEATER 1 RELAY FEEDBACK
BATTERY PLUS 3
-
RED. AGENT TANK HEATING SUPPLY B+
RED. AGENT PUMP MOTOR CONTROL
RED. AGENT REVERTING VALVE SUPPLY B+
RED. AGENT REVERTING VALVE CONTROL
-
RED. AGENT METERING VALVE (HIGH SIDE)
-
DCU CAN 1 HIGH
CATALYST TEMP SENSOR 1 SIGNAL
-
DCU CAN 1 TERM. RES. ENABLE JUMPER A
DCU CAN 1 TERM. RES. ENABLE JUMPER B
-
RED. AGENT TANK HEATING (LOW SIDE)
HOSE HEATER MAIN RELAY (LOW SIDE)
DEF HOSE HEATER 1 RELAY CONTROL
11
10 wc_gr015138
Mobile Generator
22.4
Engine Schematic Components: Aftertreatment
Ref.
Description
1 NOx sensor 1 upstream
Power
Ground
2
CAN low
CAN high
Ground ref (pos)
NOx sensor 1 downstream
3
Power
Ground
CAN low
CAN high
Ground ref (pos)
DEF tank sensor
Power
Ground
4
5
6
7
CAN low
CAN high
DEF hose heater 1
Ground
12V in
DEF hose heater 2
Ground
12V in
DEF hose heater 3
Ground
12V in
Main engine harness connector
J1939 (+) CAN2-H
J1939 (-) CAN2-L
—
Hose relay power relay (86)
Hose relay power relay (85)
ISO 15765 CAN1-L
ISO 15765 CAN1-H
DCU battery ground ref
Hose heater 3 relay (85)
Hose relay power relay (87)
Hose heater 2 relay (85)
Ref.
7
8
9
10
Description
DCU ignition switch
Hose heater 1 relay (85)
DCU power supply (12V B+)
Hose heater 3 relay (30)
NOx sensor relay (87)
Hose heater 2 relay (30)
—
Hose heater 1 relay (30)
Supply module
—
Pump motor pwm
Pump motor +
Pump motor ground
Reverting valve +
Reverting valve
—
Pressure sensor ground
Pressure sensor signal
Pressure sensor +
Heater
Heater signal
Ambient temperature sensor
Signal out
Ground ref
DCU main connector
1—Battery minus 1
2—Battery minus 2
3—Supply module heater
4—Supply module heater V+
5—Battery plus 1
6—Battery plus 2
7—Battery minus 3
9—Reserve analog sensor 2 ground
17—Red. agent pressure sensor supply
22—Terminal 15 switched B+
27—DEF hose heater 3 relay feedback
28—DEF hose heater 3 relay control
29—Battery minus 4 wc_tx004651en.fm
187
Schematics—Machines with Deep Sea Controller
Ref.
Description
10 31—Reserve analog input 2
39—Red. agent pressure sensor signal
40—Red. agent pressure sensor ground
42—Reserve frequency input 1
49—DEF hose heater 2 relay feedback
50—DEF hose heater 2 relay control
51—Battery plus 4
53—Main relay hose heater supply
54—Red. agent pump motor ground
55—Red. agent pump motor supply +
58—Red. agent metering valve (low side)
60—DCU CAN 1 low
61—Catalyst temperature sensor 1 ground
65—DCU CAN 0 low
66—DCU CAN 0 high
67—DCU CAN 2 term. res. enable jumper A
68—DCU CAN 2 term. res. enable jumper B
72—DEF hose heater 1 relay feedback
73—Battery plus 3
75—Red. agent tank heating supply B+
Ref.
10
11
12
13
Description
76—Red. agent pump motor control
77—Red. agent reverting valve supply B+
78—Red. agent reverting valve control
80—Red. agent metering valve (high side)
82—DCU CAN 1 high
83—Catalyst temperature sensor 1 signal
89—DCU CAN 1 term. res. enable jumper
A
90—DCU CAN 1 term. res. enable jumper
B
92—Red. agent tank heating (low side)
93—Hose heater main relay (low side)
94—DEF hose heater 1 relay control
SCR temperature sensor
Signal out
Ground ref
Dosing module valve
Ground
12V in
DEF tank heating valve
Supply (power)
Control (ground)
Schematics—Machines with Deep Sea Controller
This page is intentionally left blank.
188
Mobile Generator
G70
Numerics
600V . . . . . . . . . . . . . . . . . . . . . . . . 84, 117
A
Aftertreatment exhaust system . . . . . . . 127
Application area . . . . . . . . . . . . . . . . . . . . 17
Attachments . . . . . . . . . . . . . . . . . . . . . . . 17
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Battery disconnect . . . . . . . . . . . . . . . . . 121
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 42, 44
Breakaway system . . . . . . . . . . . . . . 42, 44
C
CALIFORNIA Proposition 65 Warning . . . . 6
California Proposition 65 warning . . . . . . . 3
Camlocks . . . . . . . . . . . . . . . . . . . . . . . . 122
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 20
Components . . . . . . . . . . . . . . . . . . . . . . 52
Connecting loads
480V . . . . . . . . . . . . . . . . . . . . . . . . . 75
600V . . . . . . . . . . . . . . . . . . . . . . . . . 84
Containment system . . . . . . . . . . . 123, 137
Control panel . . . . . . . . . . . . . . . . . . . . . . 53
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . 140
D
Deep Sea controller . . . . . . . . . . . 54, 60, 70
alarms . . . . . . . . . . . . . . . . . . . . . . . . 62
circuit breaker . . . . . . . . . . . . . . . . . . 54
engine . . . . . . . . . . . . . . . . . . . . . . . . 69
maintenance timer . . . . . . . . . . . . . . . 74
menus . . . . . . . . . . . . . . . . . . . . . . . . 71
power switch . . . . . . . . . . . . . . . . . . . 55
remote start . . . . . . . . . . . . . . . . . . . . 96
screen contrast . . . . . . . . . . . . . . . . . 73
DEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
filter . . . . . . . . . . . . . . . . . . . . . . . . . 142
level . . . . . . . . . . . . . . . . . . . . . . . . . 131
quality . . . . . . . . . . . . . . . . . . . . . . . 132
shelf life . . . . . . . . . . . . . . . . . . . . . . 130
tank . . . . . . . . . . . . . . . . . . . . . . . . . 128
Diagnostic Trouble Codes (DTC) . . . 98, 99
Disposal and decommissioning . . . . . . . 145
DM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
DOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
wc_bo5100044748_02IOM.fm
189
Index
E
Emission control system . . . . . . . .134, 171
Engine . . . . . . . . . . . . . . . . . . . . . . .69, 151
maintenance . . . . . . . . . . . . . . . . . . .146
Engine block heater . . . . . . . . . . . . . . . .124
Engine controller
error codes . . . . . . . . . . . . . . . . . . . . .99
Extended run tank (ERT) . . . . . . . . . . . .123
External fuel supply . . . . . . . . . . . . . . . .126
F
Factory-installed options . . . . . . . . . . . .117
600V . . . . . . . . . . . . . . . . . . . . . . . . .117
battery charger . . . . . . . . . . . . . . . . .120
battery disconnect . . . . . . . . . . . . . .121
camlocks . . . . . . . . . . . . . . . . . . . . .122
containment system . . . . . . . . . . . . .123
engine block heater . . . . . . . . . . . . .124
extended run tank (ERT) . . . . . . . . .123
fuel filter heater . . . . . . . . . . . . . . . .119
level load logic . . . . . . . . . . . . . . . . .118
low coolant shutdown . . . . . . . . . . . .125
quick oil change . . . . . . . . . . . . . . . .119
quick-disconnect fuel fittings . . . . . .126
Filter
maintenance . . . . . . . . . . . . . . . . . . .133
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
refueling . . . . . . . . . . . . . . . . . . . . . . .51
stabilizing . . . . . . . . . . . . . . . . . . . . .144
valve . . . . . . . . . . . . . . . . . . . . . . . . . .18
Fuel filter heater . . . . . . . . . . . . . . . . . . .119
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . .175
G
Grounding . . . . . . . . . . . . . . . . . . . . . . . .49
H
Hazardous materials placards . . . . . . . . .41
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . .46
I
Internal combustion engines
operating safety . . . . . . . . . . . . . . . . .21
refueling safety . . . . . . . . . . . . . . . . . .21
L
Labels . . . . . . . . . . . . . . . . . . . . . . . . .17, 19
replacing . . . . . . . . . . . . . . . . . . . . . . .19
Level load logic (L3) . . . . . . . . . . . . . . . .118
Index
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
safety . . . . . . . . . . . . . . . . . . . . . . . . 25
Low coolant shutdown . . . . . . . . . . . . . 125
M
Machine
cleaning . . . . . . . . . . . . . . . . . . . . . . 20
description and intended use . . . . . . 16
dimensions . . . . . . . . . . . . . . . . . . . 154
modifications . . . . . . . . . . . . . . . . . . . 19
storage . . . . . . . . . . . . . . . . . . . . . . 144
storing . . . . . . . . . . . . . . . . . . . . . . . . 18
Machine setup . . . . . . . . . . . . . . . . . . . . 46
positioning . . . . . . . . . . . . . . . . . . . . . 47
Maintenance . . . . . . . . . . . . . . . . . . . . . 133
aftertreatment . . . . . . . . . . . . . . . . . 142
battery . . . . . . . . . . . . . . . . . . . . . . . 139
cleaning . . . . . . . . . . . . . . . . . . . . . 134
containment system . . . . . . . . . . . . 137
emission control system . . . . . . . . . 134
engine . . . . . . . . . . . . . . . . . . . . . . . 146
engine schedule . . . . . . . . . . . . . . . 133
exhaust system . . . . . . . . . . . . . . . . 138
inspection . . . . . . . . . . . . . . . . . . . . 135
preparation . . . . . . . . . . . . . . . . . . . 134
radiator . . . . . . . . . . . . . . . . . . . . . . 140
trailer . . . . . . . . . . . . . . . . . . . . . . . . 136
O
Operation . . . . . . . . . . . . . . . . . . . . . 52, 54
crankcase pressure switch . . . . . . . . 56
emergency stop switch . . . . . . . . . . . 68
first use . . . . . . . . . . . . . . . . . . . . . . . 46
starting . . . . . . . . . . . . . . . . . . . . 64, 65
stopping . . . . . . . . . . . . . . . . . . . . . . 67
Operator
P
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
replacing . . . . . . . . . . . . . . . . . . . . . . 19
Personal protective equipment (PPE) . . . 20
Q
Quick oil change . . . . . . . . . . . . . . . . . . 119
Quick-disconnect fuel fittings . . . . . . . . 126
190
G70
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . 140
Remote start . . . . . . . . . . . . . . . . . . . . . . 94
Remote transfer switch . . . . . . . . . . . . . . 95
S
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
after use . . . . . . . . . . . . . . . . . . . . . . 18
devices, controls, and attachments . . 17
information . . . . . . . . . . . . . . . . . . . . . 15
operating practices . . . . . . . . . . . . . . 18
PPE . . . . . . . . . . . . . . . . . . . . . . . 18, 20
service . . . . . . . . . . . . . . . . . . . . . . . . 19
service safety
signal words . . . . . . . . . . . . . . . . . . . 15
towing . . . . . . . . . . . . . . . . . . . . . . . . 24
Schematics . . . . . . . . . . . . . . . . . . . . . . 175
aftertreatment . . . . . . . . . . . . . 186, 187
Deep Sea controller . . . . . . . . . . . . . 178
engine . . . . . . . . . . . . . . . . . . . 184, 186
trailer . . . . . . . . . . . . . . . . . . . . . . . . 176
SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Spark arresters . . . . . . . . . . . . . . . . . . . . . 6
Storage . . . . . . . . . . . . . . . . . . . . . . 18, 144
T
Technical data . . . . . . . . . . . . . . . . . . . . 151
dimensions . . . . . . . . . . . . . . . . . . . 154
Tire safety . . . . . . . . . . . . . . . . . . . . . . . 155
Towing . . . . . . . . . . . . . . . . . . . . . . . . 38, 39
coupler maintenance . . . . . . . . . . . . . 39
hitch and coupler . . . . . . . . . . . . . . . . 38
safety . . . . . . . . . . . . . . . . . . . . . . . . . 39
Trailer . . . . . . . . . . . . . . . . . . 136, 153, 176
Transport Canada fuel tank . . . . . . . . . . 168
G70
Transport preparation . . . . . . . . . . . . . . . 40
Transporting . . . . . . . . . . . . . . . . . . . . . . 37
Troubleshooting . . . . . . . . . . . . . . . . . . . 149
V
Voltage selector switch . . . . . . . . . . . . . . 58
Index wc_bo5100044748_02IOM.fm
191
Important: For spare parts information, please see your Wacker Neuson Dealer, or visit the
Wacker Neuson website at http://www.wackerneuson.com/.
Wichtig!
Informationen über Ersatzteile erhalten Sie von Ihrem Wacker Neuson Händler oder besuchen Sie die Wacker Neuson Website unter http://www.wackerneuson.com/.
Important : Pour des informations sur les pièces détachées, merci de consulter votre distributeur Wacker Neuson, ou de visiter le site Internet de Wacker Neuson sur http://www.wackerneuson.com/.
Importante : Para saber más sobre las piezas de repuesto, póngase en contacto con su distribuidor de Wacker Neuson o acceda al sitio web de Wacker Neuson en http://www.wackerneuson.com/.
Importante : Per informazioni sui pezzi di ricambio, contattare il rivenditore Wacker Neuson o visitare il sito di Wacker Neuson all’indirizzo www.wackerneuson.com.
Viktigt : För information om reservdelar, kontakta din Wacker Neuson-leverantör eller besök
Wacker Neusons webbplats på http://www.wackerneuson.com/.
Tärkeää : Pyydä varaosatietoja Wacker Neusonin jälleenmyyjältä tai vieraile Wacker Neusonin web-sivustolla osoitteessa http://www.wackerneuson.com/
Viktig : For informasjon om reservedeler, vennligst kontakt din Wacker Neuson-forhandler, eller besøk Wacker Neusons nettside på http://www.wackerneuson.com/.
Vigtigt : Hvis du ønsker oplysninger om reservedele, bedes du kontakte din Wacker Neuson forhandler eller besøg Wacker Neuson websiden på http://www.wackerneuson.com/.
Belangrijk! Neem contact op met uw Wacker Neuson dealer of bezoek de website van Wacker
Neuson op http://www.wackerneuson.com/ voor meer informatie over reserveonderdelen.
Importante : Para obter informações sobre as peças sobresselentes, consulte o seu fornecedor da Wacker Neuson ou aceda ao site Web da Wacker Neuson em http://www.wackerneuson.com
Wa ż ne : W celu uzyskania informacji na temat cz ęś ci zamiennych skontaktuj si ę z przedstawicielem firmy Wacker Neuson lub skorzystaj z witryny internetowej http://wackerneuson.com/.
D ů ležité upozorn ě ní! Pro informace o náhradních dílech, prosím, kontaktujte svého Wacker
Neuson dealera, nebo navštivte webové stránky http://www.wackerneuson.com/.
FONTOS: A pótalkatrészekre vonatkozó információkért kérjük, forduljon Wacker Neuson keresked ő jéhez vagy látogasson el a Wacker Neuson weboldalára a következ ő címen: http://www.wackerneuson.com/.
Важно !
Для ознакомления с информацией о запасных частях , пожалуйста , обратитесь к местному торговому представителю компании Wacker Neuson или посетите веб сайт http://www.wackerneuson.com/.
Σημαντικό : Για πληροφορίες σχετικά με τα ανταλλακτικά , μιλήστε με τον αντιπρόσωπό σας της
Wacker Neuson, ή επισκεφθείτε τον ιστότοπο http://www.wackerneuson.com/.
Važno : Za rezervne dijelove obratite se svom Wacker Neuson prodava č u ili posjetite mrežne stranice tvrtke Wacker Neuson: http://www.wackerneuson.com/.
Önemli : Yedek parça bilgileri için Wacker Neuson Bayinize bak ı n veya Wacker Neuson web sitesini ziyaret edin. http://www.wackerneuson.com/
重要 交換部品の情報については、ワッカーノイソンディーラーにお問い合わせ頂くか、ワッ
カーノイソンウェブサイト http://www.wackerneuson.com/ をご覧ください。
重要 有关备件信息,请咨询您的威克诺森经销商或访问威克诺森网站: http://www.wackerneuson.com/。
Important : Pentru informa ţ ii referitoare la piesele de schimb, v ă rug ă m s ă v ă adresa ţ i distribuitorului Wacker Neuson sau s ă vizita ţ i site-ul web Wacker Neuson la adresa http://www.wackerneuson.com/.
Важно : За информация относно резервни части , моля , обърнете се към местния дилър на Wacker Neuson или посетете уебсайта на Wacker Neuson на адрес http://www.wackerneuson.com/.
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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Key features
- Mobile electric power source
- Diesel engine powered
- Multiple voltage options
- Deep Sea Controller for monitoring and control
- Safety features like emergency stop switch