Carrier 69Ug15 Users Manual Cover

69UG15 to the manual e0f9d579-1031-4b0d-8e88-a340f85d578b

2015-01-24

: Carrier Carrier-69Ug15-Users-Manual-310983 carrier-69ug15-users-manual-310983 carrier pdf

Open the PDF directly: View PDF .
Page Count: 50

Diesel Generator Set

T--343 Rev --

OPERATION AND SERVICE

for

69UG15

Generator Set Units

PID UG1450 and Higher

OPERATION AND SERVICE MANUAL

DIESEL DRIVEN GENERATOR SET

MODEL

69UG15

iT--343

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

SAFETY SUMMARY Safety--i....................................................................

GENERAL SAFETY NOTICES Safety--i............................................................

FIRST AID Safety--i.............................................................................

OPERATING PRECAUTIONS Safety--i............................................................

MAINTENANCE PRECAUTIONS Safety--i..........................................................

UNIT LABEL IDENTIFICATION Safety--i...........................................................

SPECIFIC WARNING AND CAUTION STATEMENTS Safety--i........................................

DESCRIPTION 1--1...............................................................................

1.1 INTRODUCTION 1--1.....................................................................

1.2 CONFIGURATION IDENTIFICATION 1--1...................................................

1.3 ENGINE 1--5.............................................................................

1.3.1 Electronic Governor Module 1--5........................................................

1.3.2 Engine Air System 1--5................................................................

1.3.3 Lube Oil Filter Arrangement 1--5........................................................

1.3.4 Fuel System 1--5......................................................................

1.4 ENGINE SCREW THREADS 1--5...........................................................

1.5 ALTERNATING CURRENT GENERATOR 1--5...............................................

1.5.1 Principle of Operation 1--5..............................................................

1.5.2 Alternating Current Generator Diagram 1--5...............................................

1.6 BATTERY CHARGER 1--6.................................................................

1.7 OPERATING CONTROLS AND INSTRUMENTS 1--6.........................................

1.7.1 Introduction 1--6......................................................................

1.7.2 Control Panel and Related Components 1--6..............................................

1.8 SAFETY DEVICES 1--7...................................................................

1.9 UNIT SPECIFICATIONS 1--11...............................................................

1.10 ENGINE DATA 1--11.......................................................................

OPERATION 2--1.................................................................................

2.1 GENERATOR SET INSTALLATION 2--1.....................................................

2.2 GENERATOR SET REMOVAL 2--2.........................................................

2.3 STARTING AND STOPPING INSTRUCTIONS 2--3...........................................

2.3.1 Pre-Start Inspection 2--3...............................................................

2.3.2 Starting Instructions 2--3...............................................................

2.3.3 Post-Start Inspection 2--3..............................................................

2.3.4 Stopping Instructions 2--3..............................................................

2.4 CONTROL CIRCUIT OPERATION 2--4......................................................

2.4.1 Sequence of Operation 2--4............................................................

TROUBLESHOOTING 3--1.........................................................................

3.1 DIESEL ENGINE 3--1.....................................................................

3.1.1 Engine Will Not Start 3--1..............................................................

3.1.2 Engine Starts Then Stops 3--1..........................................................

3.1.3 Engine Will Not Shut Off 3--2...........................................................

3.1.4 Starter Motor Malfunction 3--2..........................................................

3.1.5 Malfunction In The Engine Starting Circuit 3--2............................................

3.1.6 Miscellaneous Engine Troubleshooting 3--3...............................................

T--343

TABLE OF CONTENTS -- Continued

PARAGRAPH NUMBER Page

3.2 BATTERY CHARGER (SOLID STATE) 3--3..................................................

3.3 ALTERNATING CURRENT GENERATOR 3--4...............................................

3.4 AUTO RE-START OPTION 3--5............................................................

SERVICE AND PREVENTIVE MAINTENANCE 4--1...................................................

4.1 INTRODUCTION 4--1.....................................................................

4.2 PREVENTATIVE MAINTENANCE SCHEDULE 4--1...........................................

4.3 BATTERY SERVICE 4--1..................................................................

4.4 ENGINE SERVICE AND COMPONENTS 4--1................................................

4.4.1 Bleeding the Fuel System 4--1..........................................................

4.4.2 Servicing Fuel Pump Internal Filter 4--1..................................................

4.4.3 Fuel Filter 4--1........................................................................

4.4.4 In--Line Fuel Filter 4--1.................................................................

4.4.5 Cooling System 4--1...................................................................

4.4.6 Servicing the Low Coolant Sensor 4--4...................................................

4.4.7 Servicing Low Oil Pressure Switch 4--4...................................................

4.4.8 Servicing Heater Switch 4--4............................................................

4.4.9 Servicing Poly V-belt 4--4..............................................................

4.4.10 Lube Oil Filter 4--5....................................................................

4.4.11 Engine Speed 4--5....................................................................

4.4.12 Replacing the Engine Speed Sensor 4--5.................................................

4.4.13 Engine Air Cleaner 4--5................................................................

4.4.14 Engine Crankcase Breather 4--6........................................................

4.4.15 Servicing Intake Heater 4--6............................................................

4.5 SERVICING THE ALTERNATING CURRENT GENERATOR 4--6...............................

4.5.1 Preventative Maintenance and Operating Precautions 4--6..................................

4.5.2 Generator Repair/Test Procedures 4--7...................................................

4.5.3 Bearing Replacement 4--8..............................................................

4.5.4 Generator Removal and Installation 4--8..................................................

4.6 GENERAL GENERATOR SET MAINTENANCE 4--9..........................................

4.6.1 Maintenance Of Painted Surfaces 4--9...................................................

4.6.2 Check and Replace Isolators/Shockmounts 4--10...........................................

4.7 UNIDRIVE TORQUE REQUIREMENTS 4--11.................................................

SCHEMATICS 5--1................................................................................

5.1 INTRODUCTION 5--1.....................................................................

iii T--343

LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

Figure 1-1 Generator Set 1--3......................................................................

Figure 1-2 Generator Set -- Top View 1--4............................................................

Figure 1-3 Fuel System Diagram 1--5...............................................................

Figure 1-4 Lube Oil 1--5...........................................................................

Figure 1-5 A--C Generator Circuit Diagram 1--6.......................................................

Figure 1-6 Standard Control Panel and Box 1--7......................................................

Figure 1-7 Customer Specific Control Panel and Box 1--8..............................................

Figure 1-8 Auto Restart Control Box and Panel 1--8...................................................

Figure 2-1 Typical Generator Set Mounting - Standard Mount 2--1......................................

Figure 2-2 Typical Generator Set Mounting - Quick Mount 2--2.........................................

Figure 4-1 Mechanical Fuel Pump 4--1..............................................................

Figure 4-2 Low Coolant Sensor 4--4.................................................................

Figure 4-3 Air Filter (Dry Element Type) 4--5.........................................................

Figure 4-4 Air Filter (Oil Bath Type) 4--6.............................................................

Figure 4-5 Engine Crankcase Breather 4--6..........................................................

Figure 4-6 Rectifier Removal 4--8...................................................................

Figure 4-7 A-C Generator Rectifier Assembly 4--8....................................................

Figure 4-8 Truss and Isolator 4--9...................................................................

Figure 4-9 Engine Shockmounts 4--10................................................................

Figure 4-10 Generator Shockmounts 4--10............................................................

Figure 4-11 Unidrive Torque Requirements 4--11.......................................................

Figure 5-1 Schematic Diagram - Legend 5--1.........................................................

Figure 5-2 Schematic Diagram 5--2.................................................................

Figure 5-3 Schematic Diagram 460 Volt Alternating Current Generator 5--3...............................

Figure 5-4 Schematic Diagram 230 Volt Alternating Current Generator 5--4..............................

Figure 5-5 Schematic Diagram - Legend 5--5.........................................................

Figure 5-6 Schematic Diagram 5--6.................................................................

Figure 5-7 Schematic Diagram 460 Volt Alternating Current Generator 5--7...............................

LIST OF TABLES

TABLE NUMBER Page

Table 1-1 Model Chart 1--2.........................................................................

Table 1-2 Auto Restart Preset Values 1--9............................................................

Table 1-3 Auto Restart Sequencing 1--9..............................................................

Table 1-4 Safety Devices 1--11.......................................................................

Table 4-1 Preventative Maintenance Actions and Schedule 4--2..........................................

Safety--i T-343

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this

manual. They are recommended precautions that must be understood and applied during operation and maintenance

of the equipment covered herein. The general safety notices are presented in the following three sections labeled:

First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions

appearing elsewhere in the manual follows the general safety notices.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

OPERATING PRECAUTIONS

Always wear safety glasses and hearing protection.

Keep hands, clothing and tools clear of the radiator fan and rotating belts.

No work should be performed on the unit until all circuit breakers and start-stop switches are turned off and the

negative battery terminal has been disconnected..

Always work in pairs. Never work on the equipment alone.

In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS

Be sure power is turned off and the negative battery cable is disconnected before working on generator set.

Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with

the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.

In case of electrical fire, open circuit switch and extinguish with CO2(never use water).

Fuel Tanks present explosion, fire and rupture hazards even if liquid fuel has been drained. Do not attempt any repairs,

especially repairs using flame, welder or torch, unless you have been properly trained and the tank has been emptied

of liquid fuel and fuel vapors and the tank is properly ventilated.

UNIT HAZARD LABEL IDENTIFICATION

To help identify the hazard labels on the Unit and explain the level of awareness each one carries, explanations with

appropriate consequences are provided below:

DANGER

Indicates an immediate hazard which WILL result in severe personal injury or death.

WARNING

Indicates hazards or unsafe conditions which COULD result in severe personal injury or death.

CAUTION

Indicates potential hazards or unsafe practices which COULD result in minor personal injury, product or property

damage.

Safety--iiT-343

SPECIFIC WARNING AND CAUTION STATEMENTS

The statements that follow are applicable to the generator set and appear elsewhere in this manual. These recom-

mended precautions must be understood and applied during operation and maintenance of the equipment covered

herein.

WARNING

Beware of moving poly V-belt, belt driven

components and hot exhaust components.

WARNING

Under no circumstances should ether or

any other unauthorized starting aids be

used in conjunction with the air intake heat-

er.

WARNING

Beware of moving poly V-Belt and belt driv-

en components.

WARNING

Beware of pinch points.

WARNING

Do not use gasoline to clean air cleaner

parts.

WARNING

Do not direct water or steam into the gener-

ator openings. Do not allow any soap and

water solutions to enter the alternator.

WARNING

High voltage (dielectric) testing must not be

performed to the machine without first ob-

serving NEMA rules. The insulation of this

generator winding may be safely checked

by using a megger. A high megger reading

indicates good insulation.

CAUTION

Observe proper polarity when installing the

battery or connecting a battery charger, the

negative battery terminal must be

grounded. Reverse polarity may damage

the charging system. When charging the

battery in unit, isolate the battery by discon-

necting the negative battery terminal first,

then the positive. Once the battery has been

charged, connect the positive battery termi-

nal first, then the negative.

CAUTION

Never pour cold water into a hot engine.

CAUTION

Use only ethylene glycol, anti-freeze (with

inhibitors) in system. Use of glycol by itself

will damage the cooling system.

CAUTION

Never open the radiator cap when the cool-

ant is hot.

CAUTION

Always cover the engine inlet tube while the

air cleaner is being serviced.

CAUTION

Do not underfill or overfill the oil bath cups.

Overfilling of cups causes loss of capacity;

underfilling cups causes lack of filtering ef-

ficiency.

CAUTION

When trying to restore residual magnetism,

be sure to wear safety glasses and non-con-

ductive gloves. Use an insulated 12 gauge

(or higher) jumper wire. Cut off all but a few

strands from both ends of the jumper wire

to help prevent fusing.

CAUTION

The rotor should not be pulled out from the

alternator more than 0.75 inches. Damage

to the bearing and windings may result.

CAUTION

Continued operation with failed

shockmounts may result in engine or gen-

erator damage.

1--1 T-343

SECTION 1

DESCRIPTION

1.1 INTRODUCTION

The Carrier Transicold model 69UG15 under--mounted

diesel--driven generator sets provide electrical power

for all--electric refrigeration units.

The generator set (see Figure 1-1 and Figure 1-2)

consists of a diesel engine direct--connected to an

alternating current generator and mounted in a

structural steel frame. The engine is a vertical in--line,

four cylinder diesel manufactured by Kubota, while the

generator is a 15 kW, brushless, single bearing type

manufactured by Lima. The generator provides a

constant 460 or 230 VAC, three--phase, 60 hertz

electrical supply.

Electrical controls are mounted in a control box with

operating controls and gauges mounted on a control

panel, which also serves as the control box cover. The

control panel components are protected by a deflector

assembly or a windowed control box door.

Auxiliary engine equipment consists of the battery, solid

state battery charging system, “spin--on” lube oil filter,

fuel filter and other necessary components for proper

unit operation. The water pump and the radiator cooling

fan are belt--driven from the engine crankshaft. All

references to engine are as viewed from the fly wheel

end.

The 69UG15 is available as a standard configuration,

with an Auto Restart option or with Auto Restart and Low

Coolant Sensor. The Auto Restart option automatically

restarts the unit in the event of a unit shutdown. Auto

Restart also offers built--in indicators that signal low oil

pressure, high water temperature, overspeed, and

other overcrank conditions.

1.2 CONFIGURATION IDENTIFICATION

Generator set identification information is provided on a

label located below the left mounting pad to the left of the

access service door (front facing). The label provides

the generator set model number, serial number, and

parts identification number (PID). The model number

identifies the overall configuration, while the PID

provides information on specific optional equipment.

Separately bound manuals covering the diesel engine

are also available (see the following chart).

Manual/

Form No.

Equipment

Covered

Type of

Manual

62---11335 V2203--DI Engine Parts List

62---11362 V2203--DI Workshop

1--2T-343

Table 1-1 Model Chart

LEGEND

A1 -- Standard Mount -- (See Figure 2-1)

A2 -- Quick Mount -- (See Figure 2-2)

B1 -- Receptacle Box -- with Circuit Breaker

B2 -- Receptacle Box -- with Circuit Breaker

B3 -- Receptacle Box -- Customer Specific

B4 -- Receptacle Box -- Interlock

C1 -- 460 Volt -- Standard

C2 -- 460 Volt -- with Auto--Restart

C3 -- 460 Volt -- Customer Specific

Model PID

Electrical Wiring

Schematic and

Diagram Figures

Unit

Mounting

Receptacle

Box Control Box

69UG15--050S--05

UG1450 5-1, 5-2, 5-3, 5-4 A1 B1 C1

UG1451 5-1, 5-2, 5-3, 5-4 A1 B1 C1

UG1452 5-1, 5-2, 5-3, 5-4 A1 B1 C1

UG1453 5-1, 5-2, 5-3, 5-4 A1 B1 C1

69UG15--050S--06 UG1455 5-1, 5-2, 5-3, 5-4 A1 B2 C1

UG1456 5-1, 5-2, 5-3, 5-4 A1 B2 C1

69UG15--050S--07 UG1457 5-5, 5-6, 5-7 A1 B4 C2

69UG15--050S--08 UG1458 5-1, 5-2, 5-3, 5-4 A1 B3 C3

69UG15--050Q--06 UG1459 5-1, 5-2, 5-3, 5-4 A2 B2 C1

UG1460 5-1, 5-2, 5-3, 5-4 A2 B2 C1

69UG15--068S--05

UG1461 5-1, 5-2, 5-3, 5-4 A1 B1 C1

UG1462 5-1, 5-2, 5-3, 5-4 A1 B1 C1

UG1463 5-1, 5-2, 5-3, 5-4 A1 B1 C1

69UG15--068Q--05 UG1464 5-1, 5-2, 5-3, 5-4 A2 B1 C1

69UG15--080S--05 UG1465 5-1, 5-2, 5-3, 5-4 A1 B1 C1

69UG15--080Q--05 UG1466 5-1, 5-2, 5-3, 5-4 A2 B1 C1

UG1467 5-1, 5-2, 5-3, 5-4 A2 B1 C1

1--3 T-343

214

6871012 1113

230 VOLT 460 VOLT

14 14

1. Mechanical Fuel Pump

2. Injector Pump

3. Engine Speed Sensor

4. Poly V--Belt

5. Radiator

6. Controls (See Figure 1-6 or Figure 1-8)

7. Engine Oil Filter

8. Engine Shockmount (Typical)

9. Lube Oil Dipstick/Fill Cap

10. Starter

11. Air Cleaner

12. Generator Shockmount

13. Receptacle Box

14. Receptacle

15. Circuit Breaker

16. Air Filter Indicator (if equipped)

Figure 1-1 Generator Set

1--4T-343

1. Fuel Tank

2. Exhaust Muffler

3. Solid State Battery Charger

4. Low Coolant Sensor (If Equipped)

5. Water Temperature Sensor

6. Water Temperature Switch

7. Engine

8. Coolant Overflow Bottle

9. Alternating Current Generator

10. AC Generator Connection Box Access

11. Battery

Figure 1-2 Generator Set -- Top View (Top Frame Members Removed for Clarity)

1--5 T-343

1.3 ENGINE

The engine is a vertical, in--line four cylinder diesel

engine, which is direct--connected to the alternating

current generator. Information on the major engine

systems is provided in the following subparagraphs.

1.3.1 Electronic Governor Module

The electronic governor module is a solid state control

module preprogrammed for 1800 RPM. The electronic

governor module, along with the engine speed sensor,

replaced the manual governor in order to provide a

constant engine speed.

1.3.2 Engine Air System

The air cleaner (Item 11, Figure 1-1) is designed to

prolong engine life and performance by preventing dirt

and grit from entering the engine and causing excessive

wear on all operating parts. In order for the air filter to

operate properly, the operator must regularly maintain

the air cleaner equipment in accordance with the

instructions provided within this document.

1.3.3 Lube Oil Filter Arrangement

The engine lubricating oil filter is mounted in a horizontal

arrangement and shown in Figure 1-4.

1.3.4 Fuel System

The fuel system is fitted with an in--line pre--filter and a

fuel filter, which also acts as a water separator. The filter

is also fitted with a heater. The fuel system is shown in

Figure 1-3.

1.4 ENGINE SCREW THREADS

All threads used on the engine are metric.

1. Fuel Tank

2. Fuel Supply Line

3. Inline Fuel Filter

4. Mechanical

Fuel Pump (Engine)

5. Fuel Filter and Water

Separator

6. Injection Pump

8. Fuel Bleed Valve

7. Injector Nozzles

9. Fuel Return Line

Figure 1-3 Fuel System Diagram

1. Oil Filter (Primary)

2. Oil Pressure Sender

3. Oil Pressure Switch

4. Oil Pan

Figure 1-4 Lube Oil

1.5 ALTERNATING CURRENT GENERATOR

1.5.1 Principle of Operation

The Marathon Alternator Company (Lima) brushless

AC generator (see Figure 1-2, item 9) is a

self--regulated, rotating field synchronous unit. The

generator stator and exciter stator are combined in a

common housing. The generator field, exciter rotor, and

rotating rectifier assembly are mounted on a common

shaft. The output of the exciter rotor is applied to the

generator field winding through a rotating, full--wave

bridge, silicon rectifier unit.

All connections between the exciter stator windings and

the generator stator windings are internal within the

stator housing. Only the output power leads are

connected at the terminal box, which is located on top of

the generator.

1.5.2 Alternating Current Generator Diagram

Figure 1-5 shows the internal schematic diagram of the

generator, exciter, and rectifier unit. The generator is a

three--phase unit, and the exciter stator and exciter rotor

also have three--phase windings. A portion of the exciter

stator windings is connected across a tap on the

generator stator winding. This exciter shunt winding

provides the generator field excitation power required

for the generator no--load voltage. Another portion of the

exciter stator windings is connected in series with the

output of the generator and provides a compounding

excitation characteristic.

1--6T-343

The rotor is, in effect, the secondary of a rotating current

transformer induction frequency converter. The exciter

rotor output voltage is applied to the generator field

windings by a three--phase, full wave rotating silicon

rectifier unit. The response time of the excitation system

is very fast as the exciter stator carries an alternating

current corresponding to the load current that appears

immediately on the exciter primary. An increase in load

current will cause an immediate increase in the exciter

secondary output voltage, which is rectified and applied

to the generator field windings. The inherent

compounding characteristics of the excitation system

provide excellent voltage regulation even under heavy

overload conditions.

FIELD

STATOR

GENERATOR

SHUNT

SERIES

ROTOR

EXCITER

RECTIFIER

ASSEMBLY

STATOR

Figure 1-5 A--C Generator Circuit Diagram

CAUTION

Observe proper polarity when installing the

battery or connecting a battery charger. The

negative battery terminal must be

grounded. Reverse polarity may damage

the charging system. When charging the

battery in unit, isolate the battery by

disconnecting the negative battery terminal

first, then the positive. Once the battery has

been charged, connect the positive battery

terminal first, then the negative.

1.6 BATTERY CHARGER

The solid state battery charger (see Figure 1-2) is

located to the left of the radiator. The charger is powered

by the generator, and this input is protected by a circuit

breaker located on the control panel. The battery

charger produces a tapered charge (25 amps

maximum) and is designed not to overcharge the

battery.

1.7 OPERATING CONTROLS AND

INSTRUMENTS

1.7.1 Introduction

Components required for monitoring and controlling the

unit are located in the control box, on the control panel

(see Figure 1-6) and on the receptacle box (see

Figure 1-1).

1.7.2 Control Panel and Related Components

a. Gauges and Senders

1. Oil Pressure Gauge (see Figure 1-6, Figure 1-7,

Figure 1-8)

The purpose of this gauge is to observe normal

operating engine oil pressure. Normal oil pressure is 35

to 60 psig (3.3 to 5.2 kg/cm2).

2. Oil Pressure Sender (see Figure 1-4)

This device senses engine lube oil pressure and

transmits a signal to the oil pressure gauge. The oil

pressure sender is located on the oil filter housing.

3. Water Temperature Gauge (see Figure 1-6,

Figure 1-7, Figure 1-8)

The function of this gauge is to observe water operating

temperature. The gauge is connected to the water

temperature sender.

4. Water Temperature Sender (see Figure 1-2)

This device senses engine water temperature and

transmits a signal to the water temperature gauge.

5. Low Coolant Sensor (see Figure 1-2)

This device senses the coolant level inside the radiator

and will complete a conductive circuit as long as the

probes remain immersed in coolant. When the coolant

level falls below the probes, a signal will be sent to the

auto restart module, shutting down the engine and all

12--volt circuitry.

6. Auto Restart Module

Auto start/restart is provided to simplify the start--up

process and provide an automatic restart feature that

will automatically attempt to restart the unit in the event

of shutdown. Four LEDs are used to indicate shutdown

from overcrank, overspeed, low oil pressure, and high

water temperature. A fifth LED is used to indicate the

unit is running. Refer to Table 1-2 for system preset

values.

The auto restart function will perform a series of six

attempts to restart the unit and make three attempts

within each series. Once the function has completed all

18 attempts, the unit will automatically lock out future

crank attempts. Refer to Table 1-3 for detailed

information on auto restart sequencing.

1--7 T-343

b. Meters

1. Ammeter (A)

The ammeter (see Figure 1-6, Figure 1-7, Figure 1-8) is

an indicator of the charging system and unit electrical

draw. It indicates the rate of discharge or charge of the

battery. During start up, the intake heater draws

approximately 42 amps.

2. Total Time Meter (TT)

The total time meter (see Figure 1-6, Figure 1-7,

Figure 1-8) calculates the total hours and provides an

accurate readout of accumulated engine running time.

This data can be used to establish the proper periodic

maintenance schedule (refer to Section 4.1).

c. Manual Switches

1. Intake Heater Switch (HS) (see Figure 1-6,

Figure 1-7)

The intake heater switch is of the momentary type.

When held in the PREHEAT position, the switch allows

approximately 42 amps of battery current to flow into the

intake heater, which preheats the air within the intake

manifold and allows the engine to start. After starting the

engine, the intake heater switch should continue to be

held in the ON position for approximately 5 seconds until

the engine has developed enough oil pressure to close

the oil pressure safety switch.

2. Ignition Switch (IGN) (see Figure 1-6, Figure 1-7)

The ignition switch is of the momentary type to be used

in the OFF/ON/START positions. When held in the

START (ignition) position, it energizes the starter motor

solenoid, which in turn allows the starter motor to crank

the engine. The switch is released to the RUN position

once the engine has started.

3. Ignition Switch (IGN)(Auto Restart) (see Figure 1-8)

The ignition switch is of the maintained contact type to

be used in the RUN/OFF positions. When switched to

the RUN position, it energizes the control module, which

in turn controls all functions of the genset.

1.8 SAFETY DEVICES

Safety devices, such as circuit breakers, fuses, and

safety switches, protect system components from

damage.

The AC generator, solid state battery charger, fuel

heater, high water temperature, safety relay, total time

meter and intake air heater are protected by circuit

breakers. If a safety device opens and there is an

interruption of electrical current, the electronic governor

module will be de--energized, which will also

de--energize the fuel solenoid, interrupt the fuel flow to

the engine and stop the engine.

In units with auto restart, the engine, engine control

devices, and engine monitoring devices are protected

by the auto restart module, low coolant sensor (if

equipped), circuit breaker, low oil pressure switch, and

high water temperature switch. These safety devices

monitor system operating conditions and open a set of

electrical contacts when an unsafe condition occurs. If a

safety device opens and there is an interruption of

electrical current, the electronic governor module will be

de--energized, which will also de--energize the fuel

solenoid, interrupt the fuel flow to the engine and stop

the engine.

De--energizing the fuel solenoid shuts off the fuel supply

to the engine; thus stopping the engine. Safety device

specifications are provided in Table 1-4.

CONTROL

BOX

CONTROL

PANEL

1. Total Time Meter

2. Water Temperature Gauge

3. Oil Pressure Gauge

4. Ammeter

5. Intake Air Heater Switch

6. Ignition Switch

7. Battery Charger Circuit Breaker (CB5)

8. Ground Studs

9. Circuit Breaker (CB2)

10. Circuit Breaker (CB3)

11. Intake Heater Relay

12. Safety Relay

13. Intake Heater Timer

Figure 1-6 Standard Control Panel and Box

1--8T-343

CONTROL

BOX

CONTROL

PANEL

1. Total Time Meter

2. Water Temperature Gauge

3. Oil Pressure Gauge

4. Ammeter

5. Intake Air Heater Switch

6. Ignition Switch

7. Battery Charger Fuse

or Circuit Breaker (CB5)

8. Ground Studs

9. Safety Relay

10. Intake Heater Relay

11. Intake Heater Timer

12. Circuit Breaker (CB2)

13. Circuit Breaker (CB3)

Figure 1-7 Customer Specific Control Panel and Box

CONTROL

BOX

CONTROL

PANEL

11 16

1. Total Time Meter

2. Engine Start Alarm (Buzzer)

3. Water Temperature Gauge

4. Auto Restart Module

5. Oil Pressure Gauge

6. Ammeter

7. Engine Start/Intake Heater

Energized Light

8. Ignition Switch

9. Battery Charger Fuse

or Circuit Breaker (CB5)

10. Ground Studs

11. Circuit Breaker (CB2)

12. Starter Relay (SR)

13. Low Coolant Relay (LR)

14. Intake Heater Relay (HR)

15. Safety Relay (S)

16. Circuit Breaker (CB3)

Figure 1-8 Auto Restart Control Box and Panel

1--9 T-343

Table 1-2 Auto Restart Preset Values

Indicator Preset Value Description

Overspeed 2100 RPM Overspeed is the point at which the unit will signal for shutdown

Crank Disconnect 700 RPM Crank Disconnect is the point at which the auto restart module

senses the engine has started and will disengage the starter

Shutdown Lockout

Delay 15 seconds The oil pressure and water temperature inputs are ignored during

this 15 second delay (after start up)

Intake Heater Delay

30 seconds

preheat

3 minutes

postheat

The delay is used during start up. The intake heater delay begins

timing after the auto restart module signal is received. During the

entire delay, the intake heater circuit will be energized, an indicator

light will be illuminated, and an alarm will sound. When the delay

expires, the unit will crank.

Crank Attempts 18 attempts A series of six attempts with three attempts in each series

(total of 18 attempts)

Table 1-3 Auto Restart Sequencing

*Engine crank and rest is repeated three times each series unless the engine starts.

Series

Attempt

Number

Intake

Heater

Energized

Seconds

Fuel

Solenoid

Engaged

Engine

Crank

Duration

(Seconds)

Engine

Rest

Duration

(Seconds)

Engine Status

130 XUp To 15 25

If the engine starts:

a. Run sequence begins

b. Intake heater remains energized for 3

minutes

If the engine fails to start:

a. Intake heater will de--energize.

b. Fuel solenoid will de--energize.

c. Crank output will de--energize.

d. Overcrank LED will flash once. Wait two

seconds and repeat.

e. Unit will rest 30 minutes and proceed to

the next series.

230 XUp To 15 25

If the engine starts:

a. Run sequence begins.

b. Intake heater remains energized for 3

minutes.

If the engine fails to start:

a. Intake heater will de--energize.

b. Fuel solenoid will de--energize.

c. Crank output will de--energize.

d. Overcrank LED will flash twice. Wait two

seconds and repeat.

e. Unit will rest 30 minutes and proceed to

the next series.

330 XUp To 15 25

If the engine starts:

a. Run sequence begins.

If the engine fails to start:

a. Intake heater will de--energize.

b. Fuel solenoid will de--energize.

c. Crank output will de--energize.

d. Overcrank LED will flash three times.

Wait two seconds and repeat.

e. Unit will rest five hours and proceed to

the next series.

1--10T-343

Table 1-3 Auto Restart Sequencing (Continued)

Series

Attempt

Number

Intake

Heater

Energized

Seconds

Fuel

Solenoid

Engaged

Engine

Crank

Duration

(Seconds)

Engine

Rest

Duration

(Seconds)

Engine Status

430 XUp To 15 25

If the engine starts:

a. Run sequence begins.

If the engine fails to start:

a. Intake heater will de--energize.

b. Fuel solenoid will de--energize.

c. Crank output will de--energize.

d. Overcrank LED will flash four times. Wait

two seconds and repeat.

e. Unit will rest five hours and proceed to

the next series.

530 XUp To 15 25

If the engine starts:

a. Run sequence begins.

If the engine fails to start:

a. Intake heater will de--energize.

b. Fuel solenoid will de--energize.

c. Crank output will de--energize.

d. Overcrank LED will flash five times. Wait

two seconds and repeat.

e. Unit will rest five hours and proceed to

the next series.

630 XUp To 15 25

If the engine starts:

a. Run sequence begins.

If the engine fails to start:

a. Intake heater will de--energize.

b. Fuel solenoid will de--energize.

c. Crank output will de--energize.

d. Overcrank LED will illuminate solid and

lock out future crank attempts.

e. To reset, turn unit power switch OFF and

back ON.

1--11 T-343

Table 1-4 Safety Devices

Unsafe Condition Safety Switch Switch Setting

ENGINE

Low engine lubricating oil pressure Low oil pressure switch (LOP) --

Automatic reset

Opens below 18 psig

(1.27 kg/cm2)

High engine cooling water temperature Water temperature switch (HWT) --

Automatic reset Opens at 230F (110C)

Low coolant Low coolant sensor

Automatic reset

Opens with a loss of 32

ounces of coolant

Excessive current draw by the safety re-

lay, fuel heater, water temperature gauge,

oil pressure gauge or total time meter

Circuit breaker (CB--2) --

Automatic reset Trips at 30 amps

Excessive current draw by the electronic

governor module Fuse 1, 2, 3 Trips at 10 amps

INTAKE HEATER

Excessive current draw on intake heater

circuit

Circuit breaker (CB--3) --

Automatic reset Opens at 50 amps

BATTERY CHARGER

Excessive current draw on 230 volt feed

circuit Circuit breaker (CB--5) -- Manual reset Opens at 3 amps

GENERATOR

Excessive current draw by load

Circuit breaker (CB--1, 460 volt) --

Manual reset

Trips at 26 amps

(460 VAC)

Circuit breaker (CB--4, 230 volt) --

Manual reset

Trips at 48 amps

(230 VAC)

1.9 UNIT SPECIFICATIONS

a. Fuel Tanks

Nominal Tank Sizes Fill Capacity Draw Capacity

50 Gallon Steel 52 gallons

(256 liters)

50 gallons*

(246 liters)

50 Gallon Aluminum 52 gallons

(256 liters)

50 gallons*

(246 liters)

65 Gallon Steel 67.5 gallons

(197 liters)

65 gallons*

(189 liters)

80 Gallon Aluminum 85 gallons

(322 liters)

80 gallons*

(303 liters)

*Allows for DOT required 5% vapor space

b. Weights

Battery 63 lb (28.6 kg)

Generator (A--C) 280 lb (127 kg)

Engine (Dry) -- without Accessories 434 lb (197 kg) Approximate

Unit (with 50 gal steel tank, dry) 1555 lb (705.3 kg)

Unit (with 50 gal aluminum tank, dry) 1485 lb (673.6 kg)

Unit (with 65 gal steel tank, dry) 1580 lb (716.7 kg)

Unit (with 80 gal aluminum tank, dry) 1545 lb (700.8 kg)

1.10 ENGINE DATA

a. Bore/Stroke 3.26 in. (38 mm) / 4.03 in. (102.4 mm)

b. Compression Ratio 21.5 : 1

c. Cylinders (Number) Four

d. Displacement 135.2 cubic inches (2.22 liters)

e. Firing Order 1--3--4--2

1--12T-343

1.10 ENGINE DATA (Continued)

f. Lubrication System

Oil Pressure Safety

Switch Setting

Opens

18 psig (1.27 kg/cm2)

Capacity Engine -- 16.0 US quarts (15.1 liters), includes standard filter.

Oil Level Indicator

Dipstick in oil pan or fill cap

NOTE

To check oil level on engines with the dipstick mounted in the

fill cap, remove the cap and wipe the dipstick clean. Insert the

cap back onto the oil fill tube, then remove to check level. It is

not necessary to screw the cap back into the fill tube when

checking level. DO NOT add oil if level is within the “safe”

range. If needed, add oil to bring level within the “safe” range.

Screw cap fully into fill tube after checking level.

Lube Oil

Specification

Use a heavy duty lubricating oil conforming to American Pe-

troleum Institute (API) Service Classification CG, CH or CI,

Base Number 10 or above.

Lube Oil Viscosity

Outdoor Temperature

Fahrenheit Centigrade SAE

0F to 45F --18C to 7C 10W30

45F and above 7C and above 10W30 or 15W40

g. Fuel and Fuel Heater

Thermostat (FHT)

Winter Summer

Diesel No. 1 Diesel No. 2

FHT

Close on temperature fall @ 45+/-- 6.5F Open on temperature rise @ 75+/-- 6.5 F

Power Consumption: 150 Watts @ +/-- 10% at 14 VDC

h. Intake Heater Amperage 42 amps at 12 VDC

i. Horsepower 27 HP @ 1800 RPM at 3000 feet above sea level.

32 HP @ 1800 RPM at sea level.

j. Cooling System

Capacity 6 U.S. quarts (5.68 liters) -- includes 1 quart (0.95 liter) in

coolant recovery bottle. (Refer to section 4.4.5)

Anti--Freeze:

Conventional

The cooling system may be factory charged with a 50/50 mix

of ethylene glycol and water. This mixture provides protection

to --34F (--37C). For replacement, use a low silicate anti--

freeze meeting GM specifications GM 6038M or equal. Again,

a 50/50 mix is recommended.

Anti--Freeze:

Extended Life

The cooling system may be factory charged with a 50/50 mix

of extended life coolant (ELC) and deionized water. This mix-

ture provides protection to --34F (--37C). For replacement,

with extended life coolant (ELC) meeting GM specification

GM6277M and deionized water. Again, a 50/50 mix is recom-

mended. Extended life coolant is red or orange in color.

DO NOT mix with conventional coolant.

Water Temperature

Safety Switch

Setting

Opens 230 +/-- 5F (110 +/-- 3C)

Resets 200F (93C) -- minimum

Thermostat Starts to open 177 to 182F (80 to 84C)

Fully open 203F (95C)

Low Coolant

Sensor

Opens

Closes

Loss of 32 ounces of coolant or more

Refilling of radiator to proper level

k. Lubrication System Oil Pressure 35 to 60 psig (3.3 to 5.2 kg/cm@)

2--1 T-343

SECTION 2

OPERATION

2.1 GENERATOR SET INSTALLATION

The generator set is mounted under the center of the

trailer chassis and is easily handled with a fork lift truck

capable of handling 2,000 pounds. The fork lift pockets

provided are accessible from either side. Mounting

clamps are designed to be attached to outside I-beam

flanges only. Maximum chassis width is 38 inches on

center.

a. Standard Mount

1. Loosen mounting bolts (see Figure 2-1) sufficient to

push mounting plates to the outermost position.

2. Place forks into fork lift pockets of generator set. At-

tach safety chain between unit and fork truck.

3. Center generator under chassis slide mounting

plates fully onto chassis I-beams and torque mount-

ing bolts to 80 - 90 ft-lbs (11.1 - 12.4 mkg). Upon

completion, remove safety chain before removing

forks of fork lift truck from unit.

b. Quick Mount

1. Loosen mounting bolts (see Figure 2-2) sufficient to

bring clamp to open position. To orient in open posi-

tion, lift nut end of bolt out of slot. Clamp will fall open.

2. Place forks into fork lift pockets of generator. Attach

safety chain between unit and fork truck.

3. Center the generator set in desired position under

chassis.

4. Lift clamp (item 1) in place, ensuring bolt (item 4) is

secured in slot.

5. Tighten bolt to 55 - 65 ft-lbs (7.6 - 9.0 mkg).

6. Upon completion, remove safety chain before re-

moving forks of fork lift truck from unit.

REAR OF CHASSIS

SECTION A - A

ROADSIDE VIEW

FORK LIFT POCKET

CONTAINER FLOOR CROSS I --- BEAMS

1. Bolt

2. Washer, Spherical, Male

3. Mounting Plate

4. Generator Frame

5. Washer, Belleville

6. Washer, Spherical, Female

7. Tee Nut

8. Roll Pin

Figure 2-1 Typical Generator Set Mounting - Standard Mount

2--2

T-343

REAR OF CHASSIS

ROADSIDE VIEW

CONTAINER FLOOR CROSS I --- BEAMS

FORK LIFT POCKET

VIEW A - A

1. Angle Assembly, Clamp

2. Washer, Spherical, Male

3. Washer, Spherical, Female

4. Bolt

5. Washer, Spherical, Belleville

6. Roll Pin

7. Nut, Hex, 3/4-10

8. Frame Assembly

Figure 2-2 Typical Generator Set Mounting - Quick Mount

2.2 GENERATOR SET REMOVAL

a. Standard Mount

1. Disconnect power cable to generator (if connected).

2. With fork lift in position and safety chain attached,

slide mounting plates back sufficiently to clear chas-

sis.

3. Lower and remove generator.

b. Quick Mount

1. Disconnect power cable to unit (if connected).

2. With fork lift in position and safety chain attached,

loosen mounting bolts, and lift end of bolts out of slot

to orient clamps to open position.

2--3 T-343

2.3 STARTING AND STOPPING INSTRUCTIONS

2.3.1 Pre-Start Inspection

a. Check engine lubrication and fuel filters, oil lines, and

connections for leaks. If required, tighten connec-

tions and/or replace gaskets.

b. Check engine lubricating oil level. (Refer to para-

graph 1.10, table entry f.)

c. Check poly V-belt for fraying or cracks and proper ten-

sion. (Refer to paragraph 4.4.9).

d. Check radiator hoses for leaks and check radiator

coolant level. (Refer to paragraph 1.10, table entry j.)

e. Check radiator coil and generator air intake screen for

cleanliness. If required, clean using compressed air,

reversing the normal air flow.

f. Check air cleaner for cleanliness and clean if neces-

sary. (Refer to paragraph 4.4.13.)

g. Check in--line fuel filter and clean if necessary. (Refer

to paragraph 4.4.4.)

h. Drain water from fuel tank sump and filter bowl.

i. Fill fuel tank with diesel fuel. (Refer to paragraph 1.10,

table entry g.)

j. Check air intake heater amperage. (Refer to para-

graph 1.10, table entry h.)

k. Check battery terminals for cleanliness and secure-

ness. If required, clean, then coat with a battery termi-

nal sealant.

l. Check, and if required, tighten all electrical connec-

tions.

m.Check, and if required, tighten all hardware (brack-

ets, etc.).

n. Ensure that the main generator set circuit breaker is

off (CB-1 for 460 volt units or CB4 for 230 volt units).

Connect power cable to refrigeration unit and pro-

ceed to paragraph 2.3.2.

2.3.2 Starting Instructions

WARNING

Beware of moving poly V-belt, belt driven

components and hot exhaust components.

WARNING

Under no circumstances should ether or

any other unauthorized starting aids be

used in conjunction with the air intake heat-

er.

NOTE

Piston rings in engines that have operated less

than 100 hours may not be fully seated. This

may lead to the possibility of oil seepage from

the exhaust pipe. To properly seat the rings, op-

erate the engine under full load for a period of 24

hours. If the condition persists, check valve

clearance when the engine is cold. (Refer to en-

gine workshop manual listed in paragraph 1.2).

a. Standard Units

1. Hold intake heater switch (see Figure 1-6) in the

PREHEAT position. Suggested hold times for a cold

engine are as follows:

COLD ENGINE PREHEAT TIMES

Ambient Temperature Time

78 F/ 26 C 5 seconds

32Fto78F

(0Cto26C)

10 seconds

18Fto32F

(--8Cto26C)

20 seconds

Below18F/-8C 30 seconds

2. With the intake heater switch held in the PREHEAT

position, place the ignition switch in the START posi-

tion.

3. After the engine has started, continue to hold the in-

take heater switch in the PREHEAT position until the

engine develops sufficient oil pressure to close the

oil pressure safety switch (approximately 5

seconds). When released, the intake heater switch

will automatically return to the OFF position and the

heater will remain energized for 3 minutes.

b. Units with Auto Start

1. Place the Ignition switch (IGN) in the RUN position.

2. If the low coolant sensor (LCS) is immersed in cool-

ant, the auto restart module will energize the heater

for 30 seconds and the safety buzzer will sound. Af-

ter the 30 second delay, the unit will attempt to start.

2.3.3 Post-Start Inspection

a. Turn on CB-1 for 460 volt units or CB4 for 230 volt

units.

b. Check generator output with a voltmeter. In the no

load condition, output should be at 490 (+/- 10%)

volts with 1800 engine RPM. Place generator set

main circuit breaker in the ON position. Start refrig-

eration unit.

c. Run engine 10 minutes (check total time meter op-

eration).

d. Listen for abnormal bearing noise (AC generator).

e. Check fuel lines, lube oil lines, and filters for leaks.

f. Check exhaust system for leaks.

2.3.4 Stopping Instructions

Place the ignition switch in the OFF position.

2--4

T-343

2.4 CONTROL CIRCUIT OPERATION

WARNING

Beware of moving poly V-Belt and belt driv-

en components.

2.4.1 Sequence of Operation

a. Standard Units

With the intake heater switch (IH) held in the ON

position, current flows through the ammeter to the

intake heater. While heater is on, the ammeter will show

a 40--amp draw.

A second set of contacts also energizes the safety relay

(S).

If the high water temperature switch (HWT) opens to

break the safety relay ground connection, the safety

relay will not energize, and the engine will not start,

To start the engine, the ignition switch (IGN) is held in

the START position. With the switch in the START

position, current flows to the start solenoid (SS), through

the SS contacts to the starter motor (SM). Current then

flows to the intake heater timer, intake heater relay (IHR)

and to the heater, while simultaneously powering the

electronic governor module (EG), fuel solenoid (FS),

and engine speed sensor (ESS).

The starter motor turns over the engine resulting in

pumping of fuel to the engine cylinders by the injection

pump. This fuel is ignited by heat of compression; thus

starting the engine. When the engine has developed

sufficient oil pressure, the low oil pressure switch

contacts close to maintain power to the safety relay.

Once the engine has started, the intake heater will

remain energized for 3 minutes.

The ignition switch (IGN) will be released. The intake air

heater switch (IH) will be held for 5 seconds, then

released after the IGN switch is realeased. When the

START switch is released, the starter will be

disengaged.

With the engine running, the battery charger provides

DC power to operate the control system and charge the

battery.

b. Units with Auto Start

When the ignition switch is placed in the RUN position,

12-volt DC power is applied to the low coolant sensor

(LCS) and the auto restart module simultaneously. If the

coolant level is below the sensor, all the indicator lights

on the auto restart module will blink once and the LCS

will open the contacts on the low coolant relay,

de-energizing the unit’s 12-volt DC circuitry. If the

coolant level is above the sensor, the auto restart

module will maintain power and all lights on the module

will illuminate. As the module performs its self test, the

lights will go out individually.

After the self test is complete, the module will energize

the intake heater and sound the audible alarm warning,

indicating that the unit has been powered on and will

start. The 30--second delay starts at this time. When the

30--second delay expires, power will be applied to the

electronic governor and the engine attempts to crank for

15 seconds.

When the engine starts, the intake heater will remain

energized for 3 minutes; during this time, the

engine/intake heater light and alarm will be energized,

the shutdown/lockout time delay of 15 seconds will

begin counting, and the starter will be disengaged.

During the shutdown/lockout time delay at start up, the

auto restart module will disregard the signals to the oil

pressure and engine temperature inputs, and the Run

sequence will begin (see Restart Procedure). If engine

does not start, refer to Table 1.3 for auto restart

sequencing.

3--1 T-343

SECTION 3

TROUBLESHOOTING

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

3.1 DIESEL ENGINE

3.1.1 Engine Will Not Start

Starter motor will not crank or low

cranking speed

Battery insufficiently charged

Battery terminal post or battery defective

Electrical connections at starter are bad

Starter motor malfunctions

Starter motor solenoid defective

Open starting circuit

Incorrect grade of lubricating oil

Charge

Check

Correct

See 3.1.4

Engine Manual

See 3.1.5

Section 1.10.f.

Starter motor cranks, but fails to

start

No fuel in tank

Air inside the fuel system

Water inside the fuel system

Plugged fuel filters

Air intake heater is bad

Low oil / Oil pressure switch defective

Faulty heater switch

Plugged fuel lines to injector(s)

Mechanical lift fuel pump malfunction

Fuses F1, F2, F3, F4 are bad

Loose or no connection between wire harness and

electronic governor

Sections

1.9/1.10.g

Section 4.4.1

Drain Sump

Replace

Section 4.4.15

Section 4.4.7

Section 4.4.8

Engine Manual

Check/ replace

Check/correct

Starter cranks and engages, but

dies after a few seconds

Engine lube oil too heavy

Voltage drop in starter cable(s)

Section 1.10.f.

Check

3.1.2 Engine Starts Then Stops

Engine stops after a few rotations

No fuel in tank

Fuel heater switch not held long enough

Fuel filter restricted

Air cleaner or hose restricted

Engine crankcase breather or hose restricted

Safety device open

Open wiring circuit to fuel solenoid

Fuel solenoid defective

Fuel supply restricted

Mechanical lift fuel pump malfunction

Low oil / Oil pressure switch defective

Leak in fuel system

Injector nozzle(s) defective

Injection pump defective

Generator internal overloads open

Sections

1.9/1.10.g

Hold switch

Replace

Section 4.4.13

Section 4.4.14

Section 1.8

Check

Replace

Sections 1.10.g,

4.4.2, and 4.4.3

Engine Manual

Section 4.4.7

Check

Engine Manual

Table 1-4

3--2

T-343

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

3.1.3 Engine Will Not Shut Off

Engine will not shut off Loose ground connection

Improperly seated fuel solenoid

Clean/Tighten

Correct

3.1.4 Starter Motor Malfunction

Starter motor will not crank or turns

slowly

Battery insufficiently charged

Battery cable connections loose or oxidized

Battery cables defective

Starter brushes shorted out

Starter brushes hang up, defective or have no contact

Starter solenoid damaged

Ignition switch defective

Engine lube oil too heavy

Charge

Check/Replace

Engine Manual

Replace

Section 1.10.f.

Starter motor turns, but pinion does

not engage

Pinion or ring gear obstructed or worn Engine Manual

Starter motor does not disengage

after switch has been released

Ignition switch is bad

Starter motor solenoid is bad

Check/Replace

Engine Manual

Pinion does not disengage after

engine is running

Starter is bad Engine Manual

3.1.5 Malfunction In The Engine Starting Circuit

No power to starter motor solenoid Battery defective

Loose electrical connections

Correct

Tighten

Fuel solenoid does not energize or

does not remain energized

Battery defective

Loose electrical connections

Oil pressure switch defective

Water temperature safety switch open

Fuel solenoid defective

Intake heater switch is bad

Electronic governor module is bad

Correct

Tighten

Section 1.8

Engine Manual

Check

(Engine Manual)

Replace

(Section 4.4.15)

Check/Replace

Intake heater does not energize

Intake heater switch is bad

Timer is bad

Heater element is bad

Heater relay is bad

Section 4.4.15

3--3 T-343

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

3.1.6 Miscellaneous Engine Troubleshooting

Loss of power

Restriction in air cleaner

Air in fuel system

Air vent restricted

Restricted fuel lines

Fuel injection pump is bad

Injector(s) bad or incorrect type used

Incorrect fuel injection pump timing

Incorrect valve timing

Poor compression

Section 4.4.13

Section 4.4.1

Clean

Engine Manual

Vibration Engine shockmounts are bad

Poor compression

Replace

Engine Manual

Overheating

Restriction in air cleaner

Exhaust pipe restriction

Restriction in water jacket

Restriction in radiator

Coolant level too low

Loose water pump/alternator poly V-belt

Thermostat is bad

Water pump is bad

Section 4.4.13

Remove

Engine Manual

Section 4.4.5

Section 1.10.j.

Section 4.4.9

Engine Manual

Excessive crankcase pressure Plugged crankcase breather line Section 4.4.14

3.2 BATTERY CHARGER (SOLID STATE)

Circuit breaker trips when charger is

turned on

Short in 12-volt wiring causing overload of charger Locate and

remove short or

replace charger

Circuit breaker trips repeatedly,

even when not connected

Internal short Replace charger

Charger does not taper back after

charging for a few minutes

Bad cell in battery

Charger is bad

Test battery for

defect according

to battery

manufacturer’s

instructions

Replace

3--4

T-343

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

3.2 BATTERY CHARGER (SOLID STATE) (CONTINUED)

Charger does not charge

Open input circuit breaker

Charger is not receiving AC input

Charger output is not connected to 12 volt battery

Charger is bad

Reset

Using a voltme-

ter, confirm

charger is receiv-

ing correct (230v)

AC voltage. If not,

check input

connections.

Check output

wiring connec-

tions to battery.

Replace

Low output voltage measured

across charger output

Battery not connected to charger. It is normal to

measure 12 volts or less across charger output with

no battery connected

Check charging

leads from

charger to battery

Reverse polarity connection to

battery has caused charger to stop

charging

Internal DC fuse blown and possible damage to

current carrying components

Replace

3.3 ALTERNATING CURRENT GENERATOR

No voltage

Loss of residual magnetism in exciter field

Circuit breaker tripped

Open in stator windings

Open or short in rotating rectifiers

Short circuited

Open in alternator field

Shorted exciter armature

Section 4.5.2.a.

Check

Section 4.5.4/

Replace

Section 4.5.1.c.

Section 4.5.4/

Replace

Section 4.5.4/

Replace

Section 4.5.4/

Replace

Low voltage

Low engine speed

Excessive load

High resistance connections - connections are

warm or hot

Shorted field

Section 4.4.11

Check

Tighten

Section 4.5.4/

Replace

Fluctuating voltage (May be indi-

cated by flickering lights)

Fluctuating speed

Irregular speed of engine

Loose terminal or load connections

Bad bearing causing uneven air gap

Section 4.4.11

Engine Manual

Tighten

Section 4.5.1/

4.5.3

High voltage Excessive engine speed Section 4.4.11

3--5 T-343

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

3.3 ALTERNATING CURRENT GENERATOR (CONTINUED)

Overheating

Generator overloaded

Clogged ventilating screens

High temperature surrounding generator

Insufficient air circulation

Unbalanced load

Dry bearing

Check

Clean

Section 4.4.5

Section 4.5.1

Balance

Section 4.5.1/

4.5.3

Mechanical Noise

Bad bearing

Rotor scrubbing on stator

Loose laminations

Loose or misaligned coupling

Section 4.5.1/

4.5.3

Section 4.5.1/

4.5.3

Section 4.5.4/

Replace

Section 4.5.4

Generator frame produces shock

when touched

Static charge

Grounded armature of field coil

Check ground to

frame

Section 4.5.4/

Replace

3.4 AUTO RE-START OPTION

When the Ignition switch is placed in

the RUN position, nothing happens--

no lights illuminate

Wait 30 seconds for intake heater to be activated

Coolant level below the low coolant sensor

Relay defective

Ignition switch defective

3 amp Fuse is bad

Loose connector on module

Auto restart module is bad

Miswired connectors

Wait

1.10.j.

Check/Replace

Switch

Check and

Replace Fuse

Tighten

connector

Check for 12

volts at Pin 4/

Replace module

Check/Correct

wiring

Alarm sounds, but engine does not

crank

No voltage at Pin 2 of the connector

Check Starter Solenoid

Auto restart module is bad

Trace/Correct

See 3.1.1

Replace module

Engine starts, but the starter does

not disengage

Speed Sensor wiring loose

Speed Sensor is bad

Auto restart module is bad

Check/Correct

Replace

Replace module

3--6

T-343

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

3.4 AUTO RE-START OPTION (CONTINUED)

Engine starts, but shuts down from

over speed

Electronic governor module is bad Replace

Engine cranks, but will not start Electronic governor module is bad

See 3.1.1

Replace

See 3.1.1

Engine starts, but shuts down on

low oil

See 3.1.2 See 3.1.2

Engine starts, but shuts down on

high water temperature

See 3.1.6 See 3.1.6

4--1 T-343

SECTION 4

SERVICE AND PREVENTIVE MAINTENANCE

4.1 INTRODUCTION

This section covers service for the generator set and

general engine service. Refer to the Kubota engine

workshop manual, Section 1.1, for other engine

servicing.

WARNING

Beware of moving V-belt and belt driven

components.

4.2 PREVENTATIVE MAINTENANCE SCHEDULE

A tabular listing of the recommended preventative

maintenance activities and schedule is provided in

Table 4-1.

4.3 BATTERY SERVICE

When replacing the battery, determine whether the unit

was supplied with a mat in the battery tray. If so

equipped, the mat must also be replaced.

4.4 ENGINE SERVICE AND COMPONENTS

4.4.1 Bleeding the Fuel System

The unit is equipped with a mechanical fuel lift pump,

mounted on the engine next to the injection pump. The

fuel system is a closed circuit, which will require

bleeding if loss of fuel has occurred. To fill and bleed the

system, do the following:

1. Turn fuel bleed valve (Red, see Figure 1-3) counter-

clockwise until fully opened.

2. Turn the top of the manual priming pump (see

Figure 4-1) counter-clockwise to unlock it, and then

rapidly hand pump the manual plunger until a posi-

tive pressure (resistance) is felt. This will indicate

fuel flow.

3. Depress and turn the top of the manual priming

pumpclockwisetolockinplace.

4. Start engine. (Refer to section 2.3).

5. When engine is running properly, turn fuel bleed

valve clockwise until fully closed.

4.4.2 Servicing Fuel Pump Internal Filter

The internal fuel filter may become plugged or restricted

with foreign particles or wax, which can develop if the

wrong grade of fuel is used or untreated fuel is used in

cold weather, contaminating the fuel. If the internal filter

is plugged, the engine will lose power. Therefore, the

filter must be cleaned on a regular basis. The quality of

the fuel will affect the filter cleaning schedule (refer to

section 4.2).

1. Turn nut (item 1) counter-clockwise to loosen and re-

move.

2. Remove banjo fitting (item 2) and let it hang loose,

making sure to keep copper rings (item 4) for re-

placement.

3. Turn filter (item 3) counter-clockwise and remove.

Check and clean.

4. To install, reverse steps 1 through 3.

1. Nut

2. Banjo

3. Filter

4. Copper Rings

5. Manual Priming Pump

Figure 4-1 Mechanical Fuel Pump

4.4.3 Fuel Filter

The full flow filter is located on the generator set frame

(see Figure 1-3).

To renew, remove the nut on top of filter housing, then

remove the bowl housing and filter element. Install new

filter element. Lightly oil new gasket with lube oil and

replace. Reassemble housing.

4.4.4 In--Line Fuel Filter

Loosen bowl by turning counter--clockwise. To renew,

remove in--line fuel strainer, check and clean, and

replace.

4.4.5 Cooling System

To ensure adequate cooling, the radiator must be clean,

externally and internally. To service the cooling system,

do the following:

1. Remove all foreign material from the radiator coil by

reversing the normal air flow. Compressed air or wa-

ter may be used as a cleaning agent. It may be nec-

essary to use warm water mixed with any good com-

mercial dishwasher detergent. If a detergent is used,

rinse coil(s) with fresh water.

2. Drain coolant completely by opening drain cock and

removing radiator cap.

CAUTION

Never pour cold water into a hot engine.

3. Close drain cock and fill system with clean, untreated

water to which between 3% and 5% of an alkaline

base radiator cleaner should be added; six ounces

(dry) = 151 grams to one gallon (3.8 liter) of water.

4--2T-343

Table 4-1 Preventative Maintenance Actions and Schedule

Description of Procedure Reference

Paragraph

Perform

Pre-Trip

Inspection

Standard Service

Interval Units

Extended

Service

Interval

Units*

Every

1000

Hours

Annually

or Every

3000 Hours

Annually

or Every

3000 Hours

For Pre-Trip inspection, perform items 1 through 15; for “After Start-up” checks, perform items 32 through 36.

1. Check (In Place) engine/generator shockmounts for cracks, cuts, abrasion or flaring X

2. Check engine lubrication, fuel filter, and connections for leaks X X X

3. Check engine lubrication oil level, add as required 1.10.f. X X X

4. Check poly V-Belt for fraying or cracks and proper tension, adjust as required 4.4.9 X X X

5. Check radiator hoses for leaks, check coolant level and 50/50 mixture 1.10.j. X X X

6. Check radiator coil and generator air intake for cleanliness

(Clean using compressed air, reversing air flow direction) X X X

7. Check air cleaner

7a. Oil bath air filter: Check for cleanliness and clean filter body and internal mesh.

Change oil every 250 hours 4.4.13.d. X X X

7b. Dry element air filter with indicator: Check for cleanliness and clean/replace

as air filter indicator indicates 4.4.13.c. X X X

8. Drain water from fuel tank sump and fuel filter bowl X X X

9. Fill fuel tank with diesel fuel; check fuel gauge operation 1.10.g. X X X

10.Check intake heater amperage 1.10.h. X X X

11. Check battery terminals for tightness and cleanliness. Clean and coat terminals with

battery terminal sealant X X X

12.Check for dirty/loose electrical connections, frayed cables/wires and cracked insulation X X X

13.Tighten all hardware (brackets, etc.) X X X

14.Clean oil bath air filter body and internal mesh (See Note 2) 4.4.13 X X

15.Clean mechanical fuel lift pump internal filter 4.4.2 X X X

16.Change lubricating oil and filter(s) (See Note 1) 4.4.10 X X

17.Tighten engine and generator mounting bolts 4.7 X X

18.Tighten all electrical connections in the control box X X

19.Verify operation of engine protective devices X X

4--3 T-343

Table 4-1 Preventative Maintenance Actions and Schedule (Continued)

Description of Procedure Reference

Paragraph

Perform

Pre-Trip

Inspection

Standard Service

Interval Units

Extended

Service

Interval

Units

Every

1000

Hours

Annually

or Every

3000 Hours

Annually

or Every

3000 Hours

20.Check water pump bearing end play See Engine

Manual X X

21.Change fuel filter 4.4.3 X X

22.Clean crankcase breather 4.4.14 X X

23.Remove and check engine/generator shockmounts for cracks, cuts, splits, abrasion or flaring 4.6.2 X X

24.Check and, if required, replace poly V-Belt 4.4.9 X X

25.Clean and flush coolant system 4.4.5 XSeeNote3

26.Check starter condition See Engine

Manual X X

27.Check engine compression See Engine

Manual X X

28.Check and adjust injector nozzles See Engine

Manual X X

29.Perform generator maintenance 4.5.1 X X

After Starting Generator Set, perform the following:

30.Check total time meter operation (Allow engine to run for 10 minutes) X

31.Listen for abnormal bearing noise X

32.Check fuel lines, lube oil lines and filters for leaks X

33.Check exhaust system for leaks X

34.Check with voltmeter. Generator output should be 490 volts AC +/-- 10 volts

(engine, 1800 RPM) with a nominal frequency of 60Hz +/- 0.1%

Turn refrigeration unit on and check generator 1800 RPM minimum under full load (15 kW)

NOTES:

1. 500 hour interval in extreme operation conditions

2. 250 hour interval in extreme operation conditions

3. Four years or 4000 hours if unit is factory charged with long life (red/orange) coolant

4--4T--343

4. Run engine 6 to 12 hours and drain system while

warm. Rinse system three times after it has cooled

down. Refill system with water.

CAUTION

Use only ethylene glycol, anti-freeze (with

inhibitors) in system. Use of glycol by itself

will damage the cooling system (Refer to

paragraph 1.10.j.).

5. Run engine to operating temperature. Drain system

again and fill with treated water/anti-freeze (see

above Caution note).

4.4.6 Servicing the Low Coolant Sensor

a. Testing the Low Coolant Sensor (LCS)

1. Verify the coolant level is correct.

2. Verify the wiring to the sensor is correct.

3. Check voltage (12.5 to 13.5 VDC) to the B terminal

with the ignition switch on (see Figure 4-2).

4. Check continuity between terminals A and C (see

Figure 4-2) while 12 VDC is applied to terminal B.

5. Drain the coolant from the system to below the level

of the coolant sensor and remove the sensor as

described in Section 4.4.6.b., steps 1 and 2 below.

6. With the sensor removed from the radiator and 12

VDC applied to terminal B, the circuit between

terminals A and C should be open.

Figure 4-2 Low Coolant Sensor

CAUTION

Never open the radiator cap when the

coolant is hot.

b. Replacing the Low Coolant Sensor (LCS)

1. Loosen the radiator drain pet cock and drain coolant

to a point below the sensor into an approved

container.

2. Unplug the harness and remove sensor from

radiator header.

3. Apply Teflon thread tape or thread sealer to the LCS

threads and install sensor.

4. Reconnect the harness and refill the radiator to

proper level.

4.4.7 Servicing Low Oil Pressure Switch

1. Remove harness connection from low oil pressure

switch (LOP).

2. Remove pressure switch from engine.

3. Apply Teflon thread sealer to threads of new low oil

pressure switch.

4. Install new low oil pressure switch.

5. Reconnect harness connection to low oil pressure

switch.

4.4.8 Servicing Heater Switch

1. Remove control box cover.

2. Remove all connections going to heater switch (HS).

3. Remove heater switch from control box.

4. Install new heater switch.

5. Reconnect wire harness connections to switch.

6. Confirm that wires are connected to correct

terminals.

7. Reinstall control box cover.

4.4.9 Servicing Poly V-belt

WARNING

Beware of moving poly V-belt and belt

driven components.

WARNING

Beware of pinch points.

NOTE

A frayed, cracked or worn poly V-belt must be

replaced. After installing a new belt, check the

adjustment after running the unit for three or

four hours. This will allow for the initial stretch,

which is common on new belts. Once this initial

stretch has taken place, the belt should be

checked at regular intervals.

The poly V-belt is driven by a sheave on the engine

crankshaft. Its two functions are: (1) to drive the radiator

fan and (2) to drive the water pump.

To replace the poly V-belt, perform the following steps:

1. Using the proper size socket, slowly rotate the crank

on the crank pulley nut. At the same time, use a flat,

blunt object to guide the belt off the crank pulley

towards radiator. Be careful not to damage grooves

on the pulley.

2. Replace the poly V-Belt by positioning the belt on the

water pump pulley, and while rotating the engine (as

in step 1), use a flat, blunt object to guide the belt

onto the crank pulley. Be careful not to damage

grooves on the pulley or belt.

4--5 T-343

4.4.10 Lube Oil Filter

The primary oil filter is located near the radiator fan

(see Figure 1-4).

1. After warming up the engine, stop engine, remove

drain plug from oil reservoir and drain engine lube oil.

2. Replace filters. Lightly oil gasket on filter before

installing.

3. Add lube oil (Refer to paragraph 1.10.f).

4. Warm up engine and check for leaks.

4.4.11 Engine Speed

The engine speed is electronically controlled. DO NOT

ATTEMPT TO ADJUST ENGINE SPEED.

4.4.12 Replacing the Engine Speed Sensor

1. Disconnect the plug to the sensor.

2. Remove the bolt securing the sensor to the housing.

3. Remove the sensor from the housing.

4. Clean the recess in the housing to ensure that the

sensor seats properly when re-installed.

5. Re-install by sensor, replace the securing bolt and

connect the plug to the sensor.

4.4.13 Engine Air Cleaner

a. Inspection

The dry element or oil bath air cleaner should be

inspected regularly for leaks. A damaged air cleaner or

hose can seriously affect the performance and life of the

engine. The air cleaner is designed to effectively

remove contaminants from the air stream entering the

engine. An excessive accumulation of these

contaminants in the air cleaner will impair its operation.

Therefore, a service schedule must be set up and

followed.

1. Check all connections for mechanical tightness. Be

sure the air cleaner outlet pipe is not fractured.

2. In case of leakage and if adjustment does not correct

the trouble, replace necessary parts or gaskets.

Swollen or distorted gaskets must always be

replaced.

b. Air Filter Indicator

The air filter indicator is mounted on the unit frame and

connected to the engine air intake. Its function is to

indicate when the air cleaner element requires

replacing. In operation: When a plugged air cleaner

decreases intake manifold pressure to 500 mm (20”)

WG, the indicator moves to the red line. The air cleaner

element should be replaced and the indicator reset by

pressing the reset button.

c. ServiceProcedure(DryElement)

1. Stop the engine, remove air cleaner and install a

new element. Refer to Figure 4-3.

1. Air Outlet

2. Air Cleaner Body

3. Air Inlet

4. Cap Clamp

5. Air Filter Indicator

Figure 4-3 Air Filter (Dry Element Type)

d. Service Procedure (Oil Type)

Inspect the oil cup (see Figure 4-4) at regular intervals.

Initially, inspect daily or as often as conditions require.

Never allow more than 1/2 inch (12.7 mm) of dirt deposit

in the cup. More than 1/2 inch accumulation could result

in oil and dirt carrying over into the engine, causing

accelerated engine wear. Heavily contaminated oil will

not allow the air cleaner to function properly.

CAUTION

Always cover the engine inlet tube while the

air cleaner is being serviced.

Stop the engine and remove the oil cup from the air

cleaner. Dispose of the oil in an environmentally safe

manner. Remove the inner cup from the oil cup and

clean both cups.

Reassemble and fill both oil cups to the indicated level

with oil specified in paragraph 1.10.f.

4--6T--343

CAUTION

Do not underfill or overfill the oil bath cups.

Overfilling of cups causes loss of capacity;

underfilling cups causes lack of filtering

efficiency.

1. Air Inlet Hood

2. Air Cleaner Body

3. Cap Clamp

4. Inner Oil Cup

5. Gasket

6. Oil Cup

Figure 4-4 Air Filter (Oil Bath Type)

e. Service - Body Assembly

The lower portion of the air cleaner should be inspected

each time the oil cup is inspected or serviced. If there is

any sign of contaminant buildup or plugging, the body

assembly should be removed and back flushed.

At least once a year or at regular engine service periods,

remove the entire air cleaner and perform the following:

1. Remove oil cups. Check and clean center tube.

WARNING

Do not use gasoline to clean air cleaner

parts.

2. Pump solvent through the air outlet with sufficient

force and volume to produce a hard, even stream out

of the bottom of the body assembly. Reverse flush

until all foreign material is removed.

4.4.14 Engine Crankcase Breather

The engine uses a closed type breather with the

breather line attached to the cylinder head cover (see

Figure 4-5). It is not necessary to dissemble valve style

elements for cleaning. However, the bleed hole should

be checked to ensure it is free of obstruction. Check

once a year or at every 3,000 hours maintenance

interval, whichever comes first.

1. Scre

2. Breather Cover

3. Bleed Hole

4. Breather

alve

5. Breather Tube

Figure 4-5 Engine Crankcase Breather

4.4.15 Servicing Intake Heater

1. Remove harness connection from heater.

2. Remove intake transition mounting hardware.

3. Remove intake transition, heater and both gaskets.

4. Clean old gasket material off the transition and

manifold mounting services.

5. Install new heater with a new gasket on either side.

6. Assemble transition to heater and torque mounting

hardware (refer to the engine manual for torque

values).

7. Reconnect harness to heater connection point.

8. Coat stud on heater with protective coating.

4.5 SERVICING THE ALTERNATING CURRENT

GENERATOR

4.5.1 Preventative Maintenance and

Operating Precautions

Costly repairs and down time can usually be prevented

by operating electrical equipment under conditions that

are compatible with those under which the equipment

was designed. Follow the instructions outlined below to

insure maximum efficiency of the electrical equipment.

a. Cooling

Keep all cooling parts clean. DO NOT EXCEED

TEMPERATURE RISE OF 80C (176F) ABOVE A 40C

(104F) AMBIENT. This ensures that the NEMA Class

“F” insulation will not be damaged. DO NOT EXCEED

RATED LOAD except as specified for the equipment.

OPERATE GENERATOR AT RATED SPEED. Failure

to operate generators at rated load or speed will cause

overheating and possible damage to windings due to

over voltage or current.

4--7 T-343

b. Generator Windings (Drying)

WARNING

Do not direct water or steam into the

generator openings. Do not allow any soap

and water solutions to enter the alternator.

WARNING

High voltage (dielectric) testing must not be

performed to the machine without first

observing NEMA rules. The insulation of

this generator winding may be safely

checked by using a megger. A high megger

reading indicates good insulation.

Generators that have been in transit, recently steam

cleaned or in storage for long periods may be subjected

to extreme temperature and moisture changes. This

can cause excessive condensation, and the generator

windings should be thoroughly dried out before bringing

the generator up to full nameplate voltage. If this

precaution is not taken, serious damage to the

generator can result. The following steps should be

taken to effectively dry the generator windings:

1. Dry windings by placing generator in drying oven or

hot room, or dry with warm air blower directed

through windings.

2. If the generator has been operated and is being

placed into storage for any period of time, a P.D.

George #11127 type air-dry fungus resistant varnish

should be applied.

The finest insulation job can be very quickly broken

down by carelessly applying high voltage to windings in

a moisture saturated condition. Failure to follow these

guidelines could easily cause a breakdown, making it

necessary to return the generator to the factory for

repair.

c. Rotor Damage

If a rotor becomes defective, it should be returned to the

factory with full nameplate data. To repair a rotor, the

special tooling and technique of the factory are

necessary and essential. Should a failure occur, Carrier

Transicold should be notified immediately and steps will

be taken to return the generator for service.

d. Terminal Strip Cleaning

Open terminal box. Remove dust and debris, and clean

terminal strip with wire brush. Reapply protective

coating.

4.5.2 Generator Repair/Test Procedures

a. Restoring Residual Magnetism

The direct current (DC) necessary to magnetize the

alternator field is obtained from the exciter. Initially, upon

starting the generator, current flow and voltage are

induced into the exciter armature by the magnetic lines

of force set up by the residual magnetism of the exciter

field poles.

Residual magnetism of the exciter field poles may be

lost or weakened by a strong neutralizing magnetic field

from any source, or if the generator is not operated for a

long period of time.

Should the generator fail to build up voltage after being

disassembled for any reason, a momentary short-circuit

of any two generator leads (L1, L2 and L3) while

generator is running should be sufficient to correct this

condition.

CAUTION

When trying to restore residual magnetism,

be sure to wear safety glasses and

non-conductive gloves. Use an insulated 12

gauge (or higher) jumper wire. Cutoff all but

a few strands from both ends of the jumper

wire to help prevent fusing.

As an alternate method, apply either an alternating

current or a direct current voltage of approximately 20

volts to any two generator leads (L1, L2 and L3) while

generator is running. Do not make a positive

connection, but rather touch the leads together until the

generator voltage begins to rise, then remove. Insert a

30 ampere fuse into the circuit to prevent any damage in

case the build-up voltage is not removed quickly

enough. Reflash field if generator output voltage does

not build up.

b. Winding Insulation Testing

Continuity test results for the stator winding tests are

provided in the following table:

Wire

Pair Ohm* Wire

Pair Ohm*

T10-T1 IT1-T8 IT4-T5 I

T10-T2 IT1-T9 IT4-T6 I

T10-T3 IT2-T3 IT4-T7 I

T10-T4 IT2-T4 IT4-T8 I

T10-T5 IT2-T5 0T4-T9 I

T10-T6 IT2-T6 IT5-T6 I

T10-T7 0T2-T7 IT5-T7 I

T10-T8 0T2-T8 IT5-T8 I

T10-T9 0T2-T9 IT5-T9 I

T1-T2 IT3-T4 IT6-T7 I

T1-T3 IT3-T5 IT6-T8 I

T1-T4 0T3-T6 0T6-T9 I

T1-T5 IT3-T7 IT7-T8 0

T1-T6 IT3-T8 IT7-T9 0

T1-T7 IT3-T9 IT8-T9 0

* 0 = no resistance (closed circuit) & I = infinite resistance (open circuit)

4--8T--343

c. Diode Testing

The rectifier diode assemblies can be tested, and if

damaged, replaced. Over current, over voltage, over

speed, or reverse currents can damage the assembly or

diodes. To remove the diode assemblies and perform

diode testing, do the following:

1. Remove the bearing cover by removing the four bolts

(see Figure 4-6). Both the bearing and diode

assemblies will be visible.

a. Rectifier Flange

b. Rectifier Assembly

c. Rectifier Bolt

d. Bearin

Cover

e. Bearing Cover Bolt

f. Bearing

g. Bearing Cover Flange

Figure 4-6 Rectifier Removal

2. Mark and disconnect the alternator rotor wires at the

rectifier screw terminals. Note that the terminals are

marked with red paint for the forward diode assembly

and black for the reverse diode assembly. Mark and

disconnect the exciter leads from the double spade

terminals (see Figure 4-7).

a. Diode Assembly

b. Diode Bridge

c. Exciter Rotor Lead Connection

d. Alternator Rotor Lead Connection

Figure 4-7 A-C Generator Rectifier Assembly

3. Remove the two cap screws that secure each diode

assembly to the exiter. Once this procedure is

complete, the diode assemblies are free for removal.

4. A forward diode should have a low resistance when

the + of an ohm meter is connected to the exciter

rotor lead connection (anode) and the - to the diode

bridge (cathode), and a high resistance when the

polarity of the ohmmeter is reversed.

5. A reverse diode should have a high resistance when

the + of an ohm meter is connected to the exciter

rotor lead connection (anode) and the - to the diode

bridge (cathode), and a low resistance when the

polarity of the ohmmeter is reversed.

6. If both resistances are high or both are low, the diode

is defective and the diode assembly should be

replaced.

4.5.3 Bearing Replacement

When operated under normal conditions,

factory--lubricated shielded bearings will normally

provide years of trouble--free service. Excessive

bearing load and adverse environment conditions will

greatly shorten bearing life. To remove the bearings, do

the following:

1. Remove bearing cover (See Figure 4-6).

2. Remove bearing with a bearing or wheel puller.

3. Install new bearing. Ball bearings are pre-lubricated

and require no additional lubrication for the life of the

bearing.

4. Coat mating surface of bearing cover flange with

anti-corrosion compound (Tef-Gel, Carrier Part

Number 02-00083-00). Replace bearing cover.

4.5.4 Generator Removal and Installation

a. Removing the Generator

1. Remove covers and ground wire from frame of

generator set.

2. Remove connection box cover and disconnect

power leads.

3. Remove screen cover and generator exhaust baffle

from coupling end of generator.

4. Remove the six 8mm hex head bolts and washers

that secure the generator drive disc to the engine

flywheel. Turn bolts counter-clockwise with offset

wrench to start, then use flexible shaft and socket

assembly for removal of bolts.

5. Remove the twelve 3/8 inch hex head cap screws

and washers that secure generator frame to engine

flywheel housing.

6. Remove the four 5/8 inch bolts that secure the

generator mounting feet to the shockmount bracket,

then remove generator.

b. Installing the Generator

NOTE

For torque values refer to paragraph 4.7.

4--9 T-343

The generator is a single bearing type, which means the

shaft end of the rotor floats. Before installing the

generator, rotate shaft and check if bearing rotates.

1. Brush anti-seize lubricant (lube-plate) on the face of

flywheel.

2. Move generator into position and line up with the

holes on housing and flywheel. If required, turn

crankshaft to align threaded holes in flywheel with

generator drive disc mounting holes.

CAUTION

The rotor should not be pulled out from the

alternator more than 0.75 inches. Damage

to the bearing and windings may result.

3. Start the 8mm bolts (by hand) through the disc plate

and into the flywheel. Once alignment is made

torque the six bolts.

4. Secure two of the housing bolts (3/8 inch) on the top

and bottom of the generator housing to draw the

mating flanges together.

5. Secure the remaining bolts and washers (3/8 inch);

torque the 12 bolts in a staggered pattern.

6. Install and torque generator mounting bracket bolts

(5/8 inch). Install screen cover, generator exhaust

baffle, power leads, ground wiring and generator

cover. Install new gasket when installing generator

connection box cover.

4.6 GENERAL GENERATOR SET MAINTENANCE

4.6.1 Maintenance Of Painted Surfaces

The unit is protected against the corrosive atmosphere

in which it normally operates by a special paint system.

However, if the paint system is damaged, the base

metal can corrode. If the paint system is scratched or

damaged, do the following:

a. Clean area to bare metal using a wire brush, emery

paper or equivalent cleaning method.

b. Immediately following cleaning, spray or brush on a

zinc rich primer.

c. After the primer has dried, spray or brush on finish

coat of paint to match original unit color.

UNIDRIVE

TRUSS

FRAME

1. Bolt

2. Lock Washer

3. Flat Washer

4. Heat Shield

5. Isolator

6. Locknut

7. Nutplate

Figure 4-8 Truss and Isolator

4--10T--343

4.6.2 Check and Replace Isolators/Shockmounts

a. Replacement Criteria

CAUTION

Continued operation with failed

shockmounts may result in engine or

generator damage.

When a shockmount has been cut, split, abraded or has

flared due to normal deterioration, it must be replaced.

Damage to the mounts may not be visible when installed

and under load from the component. To correctly

inspect shockmounts, they must be removed.

b. Engine Isolator/Shockmount Replacement

1. Use the two lift eyes to lift and support the engine.

2. Remove truss, unidrive isolator and all hardware as

shown in Figure 4-9, if equipped.

3. Remove all hardware as shown in Figure 4-9.

4. Raise the engine just enough to remove the

shockmounts (Figure 4-9 item 4).

5. Install new shockmounts.

NOTE

For torque values refer to paragraph 4.7.

6. Lower the engine enough to assemble hardware as

shown and torque per paragraph 4.7.

7. Remove chains from the lift eyes.

ENGINE

FRAME

1. Bolt

2. Lock Washer

3. Snubbing Washer

4. Shockmount

5. Flat Washer

Figure 4-9 Engine Shockmounts

c. Generator Shockmount Replacement

1. Use the two lift eyes to lift and support the engine.

2. Remove shockmount hardware.

3. Raise the generator just enough to remove the

shockmounts (Figure 4-10 item 7).

4. Install new shockmounts.

5. Lower the engine enough to assemble hardware as

shown and torque. Refer to paragraph 4.7 for torque

values.

6. Remove chains from the lift eyes.

GENERATOR

FRAME

INSTALL MOUNT

WITH LARGE

FLARE AT TOP

FRAME

1. Scre

(5/8)

2. Mounting Base

3 Flat Washer (5/8)

4. Locknut (5/8)

5. Locknut (1/2)

6. Flat Washer (1/2)

7. Shockmount

8. Support Plate

9. Snubbing Washer

10. Screw (1/2)

11. Screw (3/8)

12. Flat Washer (3/8)

13. Locknut (3/8)

Figure 4-10 Generator Shockmounts

4--11 T-343

4.7 UNIDRIVE TORQUE REQUIREMENTS

Extensive damage may occur if the proper hardware is

not used and/or proper procedures are not followed

when working with the unidrive assembly. Periodic

inspection of hardware and bolt torque is recommended

to ensure the integrity of the unidrive.

Torque value and hardware requirements for unidrive

assembly are provided in Figure 4-11.

NOTES

SST is an abbreviation for 300 Series Corrosion

Resistant Steel.

Loctite #242 or an equivalent product should be

used on ALL hardware shown in Figure 4-11.

UNIDRIVE - SECTIONAL VIEW

ENGINE & GENERATOR SHOCKMOUNTS/ISOLATORS -TOPVIEW

ENGINE MOUNT - RIGHT SIDE VIEW

Engine Flywheel

Generator Disc Drive

3/8-16 x 1-1/2 lg - SST

(12 Req’d) 25 ft-lb (3.46 mkg)

1/2-13 x 3-1/2 lg - SST

(2 Req’d) 75 ft-lb (10.37 mkg)

5/8-18 x 2.00 lg - SST

(4 Req’d) 91--95 ft-lb (1.58--13.13 mkg)

3/8-16 x 1 lg - SST

(4 Req’d) 25 ft-lb (3.46 mkg)

M8x15MMlg-SST

(6 Req’d) 19 ft-lb (2.49 mkg)

5/8-11 x 4.00 lg - SST

(2 Req’d) 90 ft-lb (9.68 mkg)

M8 X 1-1/4 lg - STL

(4 Req’d) 11 ft-lb (1.5 mkg)

Nut, Self Lock 3/8-16 - SST

(2 Req’d) 30--39 ft-lb (4.15--5.39 mkg)

3/8-16 X 1-1/4 lg - SST

(4 Req’d) 30--39 ft-lb (4.15--5.39 mkg)

TRUSS AND ISOLATOR

Figure 4-11 Unidrive Torque Requirements

5--1 T-343

SECTION 5

SCHEMATICS

5.1 INTRODUCTION

This section contains the 12-volt DC control circuit schematics, the 460 volt alternating current generator schematic

and the 230 volt alternating current generator schematic. To identify the schematics applicable to your PID number

refertoTable1-1.

Based On Drawings 62-11411-00 Rev-

62-11414-00 Rev -

Figure 5-1 Schematic Diagram - Legend

(Applies to Figures 5-2 thru 5-4)

5--2

T-343

Based On Drawings 62-11411-00 Rev-

62-11414-00 Rev -

Figure 5-2 Schematic Diagram

(For Applicability, Refer to Table 1-1)

5--3 T-343

NOTE:

WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES

ARE CONNECTED DIRECTLY AT GENERATOR TERMI-

NAL STRIP TERMINAL T10.

Based On Drawings 62-11411-00 Rev-

62-11414-00 Rev -

Figure 5-3 Schematic Diagram 460 Volt Alternating Current Generator

(For Applicability, Refer to Table 1-1)

5--4

T-343

Based On Drawings 62-11411-00 Rev-

62-11414-00 Rev -

Figure 5-4 Schematic Diagram 230 Volt Alternating Current Generator

(For Applicability, Refer to Table 1-1)

5--5 T-343

Based On Drawing 62-11413-00 Rev A

Figure 5-5 Schematic Diagram - Legend

(Applies to Figures 5-6, 5-7)

5--6

T-343

Based On Drawing 62-11413-00 Rev A

Figure 5-6 Schematic Diagram

(For Applicability, Refer to Table 1-1)

5--7 T-343

Based On Drawing 62-11413-00 Rev A

Figure 5-7 Schematic Diagram 460 Volt Alternating Current Generator

(For Applicability, Refer to Table 1-1)

Index--1 T-343

INDEX

AC Generator Description, 1--5

Air Filter Indicator, 4--5

Ammeter, 1--7

Auto Restart Module, 1--6

Auto Restart Preset Values, 1--9

Auto Restart Sequencing, 1--9

Battery Charger, 1--6

Battery Service, 4--1

Bearing Replacement, 4--8

Bleeding the Fuel System, 4--1

Control Circuit Operation, 2--4

Control Panel, 1--6

Cooling System, 4--1

Diode Testing, 4--8

Dry Element Air Filter, 4--5

Electronic Governor Module, 1--5

Engine Air Cleaner, 4--5

Engine Air System, 1--5

Engine Crankcase Breather, 4--6

Engine Data, 1--11

Engine Description, 1--5

Engine Isolator/Shockmount Replacement, 4--10

Engine Screw Threads, 1--5

Engine Service, 4--1

Engine Speed, 4--5

Engine Speed Sensor Replacement, 4--5

FirstAid,Safety--i

Fuel Filter, 4--1

Fuel Pump Filter Service, 4--1

Fuel System, 1--5

Gauges and Senders, 1--6

Generator Principle of Operation, 1--5

Generator Removal and Installation, 4--8

Generator Repair, 4--7

Generator Service, 4--6

Generator Set Installation, 2--1

Generator Set Removal, 2--2

Generator Test Procedures, 4--7

Generator Windings, 4--7

Hazard Label Identification, Safety--i

Heater Switch Service, 4--4

Ignition Switch, 1--7

In--Line Fuel Filter, 4--1

Insulation Testing, 4--7

Intake Heater Switch, 1--7

Low Coolant Sensor, 1--6

Low Coolant Sensor Service, 4--4

Low Oil Pressure Switch Service, 4--4

Lube Oil Filter, 1--5, 4--5

Maintenance Precautions, Safety--i

Manual Switches, 1--7

Meters, 1--7

Model Chart, 1--2

Index--2

T-343

INDEX (Continued)

Oil Air Filter, 4--5

Operating Controls and Instruments, 1--6

Operating Precautions, Safety--i

Poly V--Belt Service, 4--4

Post--Start Inspection, 2--3

Pre--Start Inspection, 2--3

Preventative Maintenance and

Operating Precautions , 4--6

Preventative Maintenance Schedule, 4--1, 4--2

Safety Devices, 1--7

Safety Notices, Safety--i

Safety Summary, Safety--i

Schematics, 5--1

Sequence of Operation, 2--4

Servicing Intake Heater, 4--6

Starting Insturctions, 2--3

Stopping Instructions, 2--3

Torque Requirements, 4--11

Total Time Meter, 1--7

Troubleshooting, 3--1

Unit Introduction, 1--1

Unit Specifications, 1--11

Carrier Transicold Division,

Carrier Corporation

Container Products Group

P.O. Box 4805

Syracuse, N.Y. 13221 U.S A

www.carrier.transicold.com

A member of the United Technologies Corporation family. Stock symbol UTX

Carrier 69Ug15 Users Manual Cover

69UG15 to the manual e0f9d579-1031-4b0d-8e88-a340f85d578b

Navigation menu

Versions of this User Manual:

Views

Navigation