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Carrier 69UG15 User's Manual

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1. 1 Total Time Meter 9 Battery Charger Fuse 2 Engine Start Alarm Buzzer or Circuit Breaker CB5 3 Water Temperature Gauge 10 Ground Studs 4 Auto Restart Module 11 Circuit Breaker CB2 5 Oil Pressure Gauge 12 Starter Relay SR 6 Ammeter 13 Low Coolant Relay LR 7 Engine Start Intake Heater 14 Intake Heater Relay HR Energized Light 15 Safety Relay S 8 Ignition Switch 16 Circuit Breaker CB3 Figure 1 8 Auto Restart Control Box and Panel T 343 1 8 Table 1 2 Auto Restart Preset Values Indicator Preset Value Description 2100 RPM Overspeed is the point at which the unit will signal for shutdown Crank Disconnect is the point at which the auto restart module Crank Disconnect 700 RPM senses the engine has started and will disengage the starter Shutdown Lockout 15 seconds The oil pressure and water temperature inputs are ignored during Delay this 15 second delay after start up 30 seconds The delay is used during start up The intake heater delay begins preheat timing after the auto restart module signal is received During the entire delay the intake heater circuit will energized an indicator 3 minutes light will be illuminated and an alarm will sound When the delay postheat expires the unit will crank Crank Attempts 18 attempts total of f with three attempts in each series Table 1 3 Aut
2. OID GAUGE SENDER Based On Drawing 62 11413 00 RevA Figure 5 5 Schematic Diagram Legend Applies to Figures 5 6 5 7 5 5 T 343 CB3 BAT AUX SOA 30 87 AUTO 1 ES CB2 BAT A AUX 0 CAUTO Based On Drawing 62 11413 00 RevA Figure 5 6 Schematic Diagram For Applicability Refer to Table 1 1 T 343 5 6 460V G C ERATOR CIRCUIT o N O I AA g p qp CO O J WINDING LAYOUT Based On Drawing 62 11413 00 RevA Figure 5 7 Schematic Diagram 460 Volt Alternating Current Generator For Applicability Refer to Table 1 1 5 7 T 343 A 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 B Battery Charger 1 6 B
3. 90 00 8883 4 2 iii 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 a
4. eens 1 5 1 5 2 Alternating Current Generator Diagram sh 1 5 1 6 BATTERY CHARGER a a e TET 1 6 1 7 OPERATING CONTROLS AND INSTRUMENTS 1 6 1 751 mirod ction sea a AA RA ta Se Se ee 1 6 1 7 2 Control Panel and Related Components ete 1 6 1 8 SAFETY DEVICES xin ee A tee a Beste dps 1 7 19 UNIT SPECIFICATIONS ek baht ae ee pad ee ee ee ce ee eS 1 11 1210 ENGINEDATA 2n na AR Ga ut Ene pee eL e Da e bet vs 1 11 OPERATION DET 2 1 2 1 GENERATOR SET INSTALLATION m 2 1 2 2 GENERATOR SET REMOVAL i s a psd tirita ratios res de 2 2 2 3 STARTING AND STOPPING INSTRUCTIONS sssssss eese nen 2 3 2 3 1 Pre Start Inspection ouo e ea da Y Rer TR S Re iR a 2 3 2 9 2 Starting Instructions irene dar 2 3 23 3 POSt Start INSPSCHON acie eas Hew ewes cade eas Bade PER Seas Satie eas a EE 2 3 2 3 4 Stopping Instructions 00 kay yy kay mre 2 3 2 4 CONTROL CIRCUIT OPERATION yoo n mn 2 4 2 4 1 Sequence of Operation lo 000 ananena ananena 2 4 TROUBLESHOOTING ayan oo DB LI EET LE ales EL 3 1 31 DIESEL ENGINE 23530 a a UA Uu NE Me aspe i lias cn 3 1 3 1 1 Engine Will Not Start na A e mh 3
5. 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 pump clockwise to lock in place Start engine Refer to section 2 3 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 Tum 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
6. Carrier J Diesel Generator Set 2 OPERATION AND SERVICE for 69UG15 Generator Set Units PID UG1450 and Higher T 343 Rev TRANSICOLD r OPERATION AND SERVICE MANUAL DIESEL DRIVEN GENERATOR SET MODEL 69UG15 TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY SUMMARY a S ba DE f Safety i GENERAL SAFETY NOTICES ene hn Safety i FIRSTAID cidad ia cs gira dees Safety i OPERATING PRECAUTIONS ssh hs Safety i MAINTENANCE PRECAUTIONS yol Safety i UNIT EABEE IDENTIEIGATION rori 7 RR Lala eh AS we CPG Safety i SPECIFIC WARNING AND CAUTION STATEMENTS Safety i a A a etal wie cance eee DER ere a 1 1 14 INTRODUCTION cuina ia Us b ERD OU PEERS ELEEY 1 1 1 2 CONFIGURATION IDENTIFICATION m RII I e m rh 1 1 1 9 ENGINE ob 000000 000000 00 x dnte 1 5 1 3 1 Electronic Governor Module yo 9 Ul s rm 1 5 1 3 2 Engine AI SYStOM cde theese ceed when ies een eed whos te WEN EN LIdg deeper ded 1 5 1 9 3 Lube Oil Filter Arrangement 1 5 1 3 4 FUE System ooo Rn 1 5 1 4 ENGINE SCREW THREADS hn 1 5 1 5 ALTERNATING CURRENT GENERATOR 1 5 1 5 4 Principle of Operation
7. ROADSIDE VIEW S 4 1 Angle Assembiy Clamp VVasher Spherical Male VVasher Spherical Female Bolt VVasher Spherical Belleville Roll Pin Nut Hex 3 4 10 Frame Assembly CONDO Figure 2 2 Typical Generator Set Mounting Quick Mount 2 2 GENERATOR SET REMOVAL a Standard Mount b Quick Mount 1 Disconnect power cable to generator if connected 1 Disconnect power cable to unit if connected 2 With fork lift in position and safety chain attached 2 With fork lift in position and safety chain attached slide mounting plates back sufficiently to clear chas loosen mounting bolts and lift end of bolts out of slot sis to orient clamps to open position 3 Lower and remove generator T 343 2 2 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 Check engine lubricating oil level Refer to para graph 1 10 table entry f o Check poly V belt for fraying or cracks and proper ten sion Refer to paragraph 4 4 9 Check radiator hoses for leaks and check radiator coolant level Refer to paragraph 1 10 table entry j o Check radiator coil and generator ai
8. gt gt R RELAY H EMP SWITCH SWITCH ER ER TIM ESS SW E GAUG E SEND EARTH A GD CO o N gt w A gt gt 3 7 2 1 2 1 4 6 5 6 8 8 6 2 2 3 4 7 S 1 5 9 9 5 2 1 4 2 2 1 1 XS 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 1 T 343 12VDC CONTROL CIRCUIT CB2 BAT AUX 30A AUTO Based On Dravvings 62 11411 00 Rev 62 11414 00 Rev Figure 5 2 Schematic Diagram For Applicability Refer to Table 1 1 T 343 5 2 G C ERATOR CIRCUI O T1 O N O GJ I FROM FRAME R PE NOTE WHEN PE
9. m not necessary to screw the cap back into the fill tube when f Lubrication System 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 Use a heavy duty lubricating oil conforming to American Pe Specification troleum Institute API Service Classification CG CH or Cl p Base Number 10 or above Fahrenheit Centigrade Pinter Summe 8 g Fuel and Fuel Heater Thermostat FHT FAT 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 Lu 27 HP 1800 RPM at 3000 feet above sea level M nid 32 HP 1800 RPM at sea level Capa 6 U S quarts 5 68 liters includes 1 quart 0 95 liter in pacity coolant recovery bottle Refer to section 4 4 5 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 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
10. 66 syea 10 S lli pue s uli ro qni saul f n 4994 ze esiou DBuueeq jeuuouqe 40 4918 Le seinuiuu OL 104 uni 01 euiBue AO V uoreJado 1942W auum e101 OF 19S 10 e 19U95 Hues 193v suds s no eoueuejureui Joyelaueb WIOLISd 62 s lzzou 4o o lul 1snfpe pue 82 uoissaJduuoo euiDue Ze uonipuoo 5 9c wajs s juejoos usn j pue uea 9 Gz Weg A Ajod ase dal y pue pz Sx98J9 JO Sjunouuxoous 101e1eueD euiDue xoeuo pue e ouleH 22 JeujeoJq eseoxueJo uea zc 1944 f n 12 pue Buueeq duund 19949 02 Jo uondu s q p nunuo2 lnp u s pue suonoy eo ueueo1ure y 9AI EUSASId L t IALL T 343 4 8 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 44 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 switc
11. Series Heater Fuel Attempt Energized Solenoid Number in Engaged Seconds Engine Engine Crank Rest Duration Duration Seconds Seconds Engine Status 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 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 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 T 343 1 10 Table 1 4 Safety Devices Unsafe Condition Safety Switch Switch Setting Low oil pressure switch LOP Opens below 18 psig Automatic reset 1 27 kg cm Water temperature switch HWT Low coolant sensor Opens with a loss of 32 Low coolant Automatic reset ounces of coolant Excessive current draw by the s
12. 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 CONDITION 3 1 DIESEL ENGINE 3 1 1 Engine Will Not Start Starter motor will not crank or low cranking speed Starter motor cranks but fails to start Starter cranks and engages but dies after a few seconds 3 1 2 Engine Starts Then Stops Engine stops after a few rotations SECTION 3 TROUBLESHOOTING POSSIBLE CAUSE 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 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 F
13. 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 44 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 UNIDRIVE 1 Bolt 2 Lock Washer 3 Flat Washer 4 Heat Shield 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 dama
14. a 50 50 mix is recom mended Extended life coolant is red or orange in color DO NOT mix with conventional coolant Water Temperature 230 5F 110 3C Safety Switch Oil Level Indicator Anti Freeze Conventional Anti Freeze j Cooling System Extended Life Setting 200F 93C minimum Thermostat 177 to 182F 80 to 84C r Fully open 203F 95C Lovv Coolant Opens Loss of 32 ounces of coolant or more Sensor Closes Refilling of radiator to proper level k Lubrication System 35 to 60 psig 3 3 to 5 2 kg cm T 343 1 12 2 1 SECTION 2 OPERATION 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 l beam flanges only Maximum chassis width is 38 inches on center a Standard Mount 1 2 PODZ Loosen mounting bolts see Figure 2 1 sufficient to push mounting plates to the outermost position Place forks into fork lift pockets of generator set At tach safety chain between unit and fork truck Center generator under chassis slide mounting plates fully onto chassis l 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 Quick Mount Loosen mounti
15. 1 3 1 2 Engine Starts Then Stops LL ehh 3 1 3 1 3 Engine Will Not Shut Off lo 0000 eyy kay yaaa ayyy ka 3 2 3 1 4 Starter Motor Malfunction ya ayyy ka ayyy yaa ayyy yaa ii 3 2 3 1 5 Malfunction In The Engine Starting Circuit 3 2 3 1 6 Miscellaneous Engine Troubleshooting eee ka kk 3 3 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 3 2 BATTERY CHARGER SOLID STATE tenets 3 3 3 3 ALTERNATING CURRENT GENERATOR 0 8 3 4 3 4 AUTO RE START OPTION ez D cok aie hae her use Dep Gale EI eal uber ERG Brae b ue 3 5 SERVICE AND PREVENTIVE MAINTENANCE 4 1 41 INTRODUCTION lt een 00 hand hate aoe ee e ee ee den 4 1 4 2 PREVENTATIVE MAINTENANCE SCHEDULE ees en 4 1 4 5 BATTERY SERVICE EON Pee eau x beoe e x apa es 4 1 4 4 ENGINE SERVICE AND COMPONENTS mn 4 1 4 4 1 Bleeding the Fuel System hh n 4 1 4 4 2 Servicing Fuel Pump Internal Filter 90 eee ia 4 1 4 43 Fuel Filter ror onr ER A Sais a eae B RUR ee e epic mega 4 1 4 4 4 In Line Fuel Filter ete t hn 4 1 4 4 5 Cooling System si deh
16. 3 1 4 ENGINE SCREW THREADS All threads used on the engine are metric Fuel Tank Fuel Supply Line Inline Fuel Filter Mechanical Fuel Pump Engine 5 Fuel Filter and Water Separator Injection Pump Fuel Bleed Valve Injector Nozzles Fuel Return Line RON 6 8 7 9 Figure 1 3 Fuel System Diagram 1 5 2 a 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
17. 8 Figure 4 7 A C Generator Rectifier Assembly nett sa yl la 4 8 Figure 4 8 Truss and ISolator balks ayi Sl D lke s SUL SiC Ne 4 9 Figure 4 9 Engine Shockmounts ooo 4 10 Figure 4 10 Generator Shockmounts oo ola ey ayyy ka nn 4 10 Figure 4 11 Unidrive Torque Requirements l kk a kk 4 11 Figure 5 1 Schematic Diagram Legend e ly iii 5 1 Figure 5 2 Schematic Diagram eese mn 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 9 e n 5 5 Figure 5 6 Schematic Diagram 00 eese mn 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 hn 1 2 Table 1 2 Auto Restart Preset Values mm 1 9 Table 1 3 Auto Restart Sequencing emn 1 9 1 Devices eR a ee DEA ee ee E LEER 1 11 Table 4 1 Preventative Maintenance Actions and Schedule
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19. IS NOT FITTED OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMI NAL STRIP TERMINAL T10 AJ C M FROM GENERATOR M CONTROL HOUSING GRD STUD O co WINDING LAYOUT 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 3 T 343 LION CB4 CIRCUIT BR WINDING LAYOUT 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 T 343 5 4 O 1 j 3 4 9 g 3 7 3 8 3 8 5 2 02 02 0 d s O f RELAY SWITCH NJ SOR oWITCH AY AUGE ND AJ 4
20. Post Start Inspection 2 3 Pre Start Inspection 2 3 Preventative Maintenance and Operating Precautions 4 6 Preventative Maintenance Schedule 4 1 4 2 T 343 S 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 T Torque Requirements 4 11 Total Time Meter 1 7 Troubleshooting 3 1 U Unit Introduction 1 1 Unit Specifications 1 11 Index 2 Z Carrier A United Technologies Company Carrier Transicold Division Carrier Corporation Container Products Group P O Box 4805 Syracuse N Y 13221 U SA www carrier transicold com A member of the United Technologies Corporation family Stock symbol UTX TRANSICOLD 2008 Carrier Corporation e Printed in U S A 0908
21. aaa A va D m e cria 4 1 4 4 6 Servicing the Low Coolant Sensor 4 4 4 4 7 Servicing Low Oil Pressure Switch oo aaeeea 4 4 4 4 8 Servicing Heater Switch 00 ern 4 4 4 4 9 Servicing Poly V belt 000 eem rh 4 4 4 4 10 Lube Oil Filter rojo ee ee ie lg ee i ee Xe tid aot 4 5 4 4 11 Engine Speed eo ebore Ueber R eds aber av 4 5 4 4 12 Replacing the Engine Speed Sensor eee tenes 4 5 4 4 13 Engine Air Cleaner 0 00 escent ete ene hn 4 5 4 4 14 Engine Crankcase Breather oo 00 oy n 4 6 4 4 15 Servicing Intake Heater 9000000 ya hh 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 0 cece ete 4 7 4 5 3 Bearing Replacement 44 oer ev ce ELDER ee See ee ER TEE meee a eee 4 8 4 5 4 Generator Removal and Installation 9000 eens 4 8 4 6 GENERAL GENERATOR SET MAINTENANCE 4 9 4 6 1 Maintenance Of Painted Surfaces ocococccccccocncnnc es 4 9 4 6 2 Check and Replace Isolators Shockmounts vo lo eee teen eet eens 4 10 4 7 UNIDRIVE TORQUE REQUIREMENTS ee
22. and diode assemblies will be visible e Bearing Cover Bolt f Bearing g Bearing Cover Flange a Rectifier Flange b Rectifier Assembly c Rectifier Bolt d Bearing Cover Figure 4 6 Rectifier Removal 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 T 343 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 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 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 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 W
23. 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 T 343 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
24. 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 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 CONTROL PANEL see Figure 1 6 SO OFF SOT Tota
25. for re placement 4 5 3 Turn filter item 3 counter clockwise and remove Check and clean 4 To install reverse steps 1 through 3 1 Nut 4 Copper Rings 2 Banjo 5 Manual Priming Pump 3 Filter 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 Drain coolant completely by opening drain cock and removing radiator cap 44 CAUTION Never pour cold water into a hot engine 3 Close drain cock and fill sys
26. 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 T 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 STATOR GENERATOR STATOR RECTIFIER EXCITER ASSEMBLY Figure 1 5 A C Generator Circuit Diagram 44 CAUTION Observe proper polarity when installing the battery or connecting a battery charger T
27. 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 2 Service Procedure Dry Element 1 Stop the engine remove air cleaner and install a new element Refer to Figure 4 3 1 Air Outlet 4 Cap Clamp 2 Air Cleaner Body 5 Air Filter Indicator 3 Air Inlet 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 inthe 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 44 CAUTION Always coverthe engine inlettube 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 environ
28. 362 V2203 DI VVorkshop T 343 Table 1 1 Model Chart LEGEND A1 Standard Mount See Figure 2 1 B4 Receptacle Box Interlock A2 Quick Mount See Figure 2 2 C1 460 Volt Standard B1 Receptacle Box with Circuit Breaker C2 460 Volt vvith Auto Restart B2 Receptacle Box with Circuit Breaker C3 460 Volt Customer Specific B3 Receptacle Box Customer Specific Electrical VViring Schematic and R Control Box Diagram Figures UG1450 5 1 5 2 5 3 5 4 UG1451 5 1 5 2 5 3 5 4 69UG15 050S 05 69UG15 0688 05 69UG15 080Q 05 7557 5 1 5 2 5 3 5 4 m UG1467 5 1 5 2 5 3 5 4 T 343 1 2 15 o bo 15 230 VOLT 460 VOLT 1 Mechanical Fuel Pump 9 Lube Oil Dipstick Fill Cap 2 Injector Pump 10 Starter 3 Engine Speed Sensor 11 Air Cleaner 4 Poly V Belt 12 Generator Shockmount 5 Radiator 13 Receptacle Box 6 Controls See Figure 1 6 or Figure 1 8 14 Receptacle 7 Engine Oil Filter 15 Circuit Breaker 8 Engine Shockmount Typical 16 Air Filter Indicator if equipped Figure 1 1 Generator Set 1 3 T 343 1 Fuel Tank 7 Engine 2 Exhaust Muffler 8 Coolant Overflow Bottle 3 Solid State Battery Charger 9 Alternating Current Generator 4 Low Co
29. M Place generator set main circuit breaker in the ON position Start refrig eration unit 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 b C T 343 2 4 CONTROL CIRCUIT OPERATION 44 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
30. SHOCKMOUNTS ISOLATORS TOP VIEW 1 2 13 x 3 1 2 lg SST 2 Req d 75 ft lb 10 37 mkg 3 8 16 x 1 lg SST 4 Req d 25 ft lb 3 46 mkg 5 8 18 x 2 00 lg SST 4 Req d 91 95 ft lb 1 58 13 13 mkg TRUSS AND ISOLATOR 3 8 16 X 1 1 4 Ig SST 4 Req d 30 39 ft lb 4 15 5 39 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 ENGINE MOUNT RIGHT SIDE VIEW 5 8 11 x 4 00 Ig UNIDRIVE SECTIONAL VIEW Engine Flywheel 3 8 16 x 1 1 2 lg SST 12 Req d 25 ft lb 3 46 mkg M8 x 15 MM Ig SST 6 Req d 19 ft lb 2 49 mkg Generator Disc Drive S 2 Req d 90 ft lb 9 68 mkg Figure 4 11 Unidrive Torque Requirements 4 11 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 refer to Table 1 1 Zo gt Ul gt Fr 4 T N 0 A gt samc ERNOR MODULE ENSOR NJ n n mmm o gt ERMOSTAT
31. 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 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 78 F 250 32 F to 78 F 10 seconds 0 C to 26 C 18 F to 32 F 20 seconds 8 C to 26 C Below 18 F 8 C With the intake heater switch held in the PREHEAT position placethe ignition switch in the START posi tion 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 Units with Auto Start 1 Place the Ignition switch IGN in the RUN position 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 2 3 3 Post Start Inspection a Turn on CB 1 for 460 volt units or CB4 for 230 volt units Check generator output with a voltmeter In the no load condition output should be at 490 10 volts with 1800 engine RP
32. afety re dS lay fuel heater water temperature gauge RUE be ds 2 oil pressure gauge or total time meter Excessive current draw by the electronic governor module Low engine lubricating oil pressure High engine cooling water temperature Trips at 30 amps Fuse 1 2 3 Trips at 10 amps INTAKE HEATER Excessive current draw on intake heater Circuit breaker CB 3 circuit Automatic reset BATTERY CHARGER Opens at 50 amps Excessive current draw on 230 volt feed circuit Circuit breaker CB 5 Manual reset Opens at 3 amps GENERATOR Circuit breaker CB 1 460 volt Trips at 26 amps E 2 d Manual reset 460 VAC AERSBIVELGHITORT GERM SOS Circuit breaker CB 4 230 volt Trips at 48 amps Manual reset 230 VAC 1 9 UNIT SPECIFICATIONS a Fuel Tanks 4941 197 kg Approximate b Weights 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 d Displacement 135 2 cubic inches 2 22 liters e Firing Order 1 3 4 2 1 11 T 343 1 10 ENGINE DATA Continued Oil Pressure Safety Switch Setting 18 psig 1 27 kg cm Opens Engine 16 0 US quarts 15 1 liters includes standard filter 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
33. 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 circuitto 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 Hi EE AE ROS O OS SEAS iii Hs fea US MSC B T O LUNG E ss E priors 0 T 1577 Em T Tm T TeT7 T TS T IL T T6787 TTTS er ILL T T8786 T TTT 0 Pret 1 T7879 T T979 9 7 O noresistance closed circuit 8 1 infinite resistance open circuit T 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
34. ater switch from control box Install new heater switch Reconnect wire harness connections to switch Confirm that wires are connected to correct terminals 7 Reinstall control box cover 4 4 9 Servicing Poly V belt 2 3 4 5 oak WN 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 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 4 10 Lube Oil Filter The primary oil filter is located near the ra
35. attery Service 4 1 Bearing Replacement 4 8 Bleeding the Fuel System 4 1 C Control Circuit Operation 2 4 Control Panel 1 6 Cooling System 4 1 D Diode Testing 4 8 Dry Element Air Filter 4 5 E 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 INDEX F First Aid Safety i Fuel Filter 4 1 Fuel Pump Filter Service 4 1 Fuel System 1 5 G 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 H 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 L 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 1 T 343 INDEX Continued O Oil Air Filter 4 5 Operating Controls and Instruments 1 6 Operating Precautions Safety i P Poly V Belt Service 4 4
36. aulty 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 Engine lube oil too heavy Voltage drop in starter cable s 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 REMEDY REFERENCE SECTION Charge Check Correct See 3 1 4 Engine Manual See 3 1 5 Section 1 10 f 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 Engine Manual Check replace Check correct Section 1 10 f Check 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 Engine Manual Table 1 4 T 343 REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECTION 3 1 3 Engine Will Not Shut Off Endi ROR SHUR Loose ground connection Clean Tighten Improperly seated fuel solenoid Correct 3 1 4 Starter Mot
37. ction 4 5 4 Replace Section 4 5 4 Replace Section 4 4 11 Check Tighten Section 4 5 4 Replace Section 4 4 11 Engine Manual Tighten Section 4 5 1 4 5 3 Section 4 4 11 3 3 ALTERNATING CURRENT GENERATOR CONTINUED REMEDY REFERENCE SECTION CONDITION POSSIBLE CAUSE Overheating Mechanical Noise Generator frame produces shock when touched Generator overloaded Clogged ventilating screens High temperature surrounding generator Insufficient air circulation Unbalanced load Dry bearing Bad bearing Rotor scrubbing on stator Loose laminations Loose or misaligned coupling Static charge Grounded armature of field coil Check Clean Section 4 4 5 Section 4 5 1 Balance Section 4 5 1 4 5 3 Section 4 5 1 4 5 3 Section 4 5 1 4 5 3 Section 4 5 4 Replace Section 4 5 4 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 1107 Check Replace 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
38. diator fan see Figure 1 4 1 After warming up the engine stop engine remove drain plug from oil reservoir and drain engine lube oil 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 Re install by sensor replace the securing bolt and connect the plug to the sensor 4 4 13 Engine Air Cleaner a Inspection 2 5 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 Incase of leakage and if adjustment does not correct the trouble replace necessary parts or gaskets Swollen
39. 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 3 5 Check Correct Replace Replace module 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 T 343 See 3 1 6 3 6 See 3 1 6 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
40. e T 343 3 2 CONDITION POSSIBLE CAUSE REFERENCE SECTION Restriction in air cleaner Section 4 4 13 Air in fuel system Section 4 4 1 Air vent restricted Clean Restricted fuel lines Engine Manual Loss of power Fuel injection pump is bad Engine Manual Injector s bad or incorrect type used Engine Manual Incorrect fuel injection pump timing Engine Manual Incorrect valve timing Engine Manual Poor compression Engine Manual Vibrati Engine shockmounts are bad Replace Poor compression Engine Manual Restriction in air cleaner Section 4 4 13 Exhaust pipe restriction Remove Restriction in water jacket Engine Manual Restriction in radiator Section 4 4 5 Coolant level too low Section 1 10 j Loose water pump alternator poly V belt Section 4 4 9 Thermostat is bad Engine Manual Water pump is bad Engine Manual Plugged crankcase breather line Section 4 4 14 Overheating 3 2 BATTERY CHARGER SOLID STATE Short in 12 volt wiring causing overload of charger Locate and remove short or replace charger Circuit breaker trips repeatedly Internal short Replace charger even when not connected Bad cell in battery T battery for defect according Charger does not taper back after to battery charging for a few minutes manufacturer s instructions Charger is bad Replace Circuit breaker trips when charger is turned on 3 3 T 343 CONDITION POSSIBLE CAUSE 3 2 BATTERY CHARGER SOLID STATE CONTINUED Charger does not charge L
41. eck once a year or at every 3 000 hours maintenance interval whichever comes first T 343 1 Screw 4 Breather Valve 2 Breather Cover 5 Breather Tube 3 Bleed Hole 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 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
42. 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 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
43. ged 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 ona zinc rich primer c After the primer has dried spray or brush on finish coat of paint to match original unit color 5 Isolator 6 Locknut 7 Nutplate Figure 4 8 Truss and Isolator T 343 4 6 2 Check and Replace Isolators Shockmounts a Replacement Criteria Generator Shockmount Replacement Use the two lift eyes to lift and support the engine Remove shockmount hardware A CAUTION Raise the generator just enough to remove the shockmounts Figure 4 10 item 7 Install new shockmounts Continued operation with failed Lower the engine enough to assemble hardware as shockmounts may result in engine or shown and torque Refer to paragraph 4 7 for torque nerator damage values generatordamag 6 Remove chains from the lift eyes os 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 GENERATOR 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 sh
44. h on see Figure 4 2 Check continuity between terminals A and C see Figure 4 2 while 12 VDC is applied to terminal B 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 With the sensor removed from the radiator and 12 VDC applied to terminal B the circuit between terminals A and C should be open PIN YELLOW WIRE SIGNAL PIN B RED WIRE POWER PIN A BLACK WIRE GROUND Figure 4 2 Low Coolant Sensor 44 CAUTION Never open the radiator cap when the coolant is hot Replacing the Low Coolant Sensor LCS 1 Loosenthe radiator drain pet cock and drain coolant to a point below the sensor into an approved container Unplug the harness and remove sensor from radiator header Apply Teflon thread tape or thread sealer to the LCS threads and install sensor T 343 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 Remove pressure switch from engine Apply Teflon thread sealer to threads of new low oil pressure switch Install new low oil pressure switch Reconnect harness connection to low oil pressure switch 4 4 8 Servicing Heater Switch Remove control box cover Remove all connections going to heater switch HS Remove he
45. he negative battery terminal must be grounded Reverse polarity may damage the charging system When charging the battery in unit isolate the battery by disconnectingthe negative battery terminal first then the positive Once the battery has been charged connect the positive battery terminal first then the negative T 343 1 6 1 6 BATTERY CHARGER The solid state battery charger see Figure 1 2 is located tothe left ofthe 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 cm 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
46. hen operated under normal conditions factory lubricated shielded bearings vvill normally provide years of trouble free service Excessive bearing load and adverse environment conditions vvill 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 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 Remove connection box cover and disconnect power leads Remove screen cover and generator exhaust baffle from coupling end of generator 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 Remove the twelve 3 8 inch hex head cap screws and washers that secure generator frame to engine flywheel housing Remove the four 5 8 inch bolts that secure the generator mounting feet to the shockmount bracket then remove generator Installing the Generator NOTE For torque values refer to paragraph 4 7
47. hn 4 11 SCHEMATICS u 2 oe A A eet anata decade ae 5 1 5 1 INTRODUCTION 223 oops ci beh epu EN eke EI EE domed 5 1 T 343 i LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 1 1 Generator Seti cross bep E RE eu bees BE take a a e 1 3 Figure 1 2 Generator Set Top View 0 ccc enn eee eens 1 4 Figure 1 3 Fuel System Diagram ee eee eee eee 1 5 Figure 1 4 UDS MD Tc 1 5 Figure 1 5 A C Generator Circuit Diagram 1 6 Figure 1 6 Standard Control Panel and Box een 1 7 Figure 1 7 Customer Specific Control Panel and Box 0 0 cece eect eee eee 1 8 Figure 1 8 Auto Restart Control Box and Panel LL eens 1 8 Figure 2 1 Typical Generator Set Mounting Standard Mount 8 2 1 Figure 2 2 Typical Generator Set Mounting Quick Mount 2 2 2 Figure 4 1 Mechanical Fuel Pump e m mr 4 1 Figure 4 2 Low Coolant Sensor LLL ees hh 4 4 Figure 4 3 Air Filter Dry Element Type oo IIIA rn 4 5 Figure 4 4 Air Filter Oil Bath Type 99000 ayyy ka HH rn 4 6 Figure 4 5 Engine Crankcase Breather ooo eee eee eens 4 6 Figure 4 6 Rectifier Removal 90000 ya ayyy ka ayy yy mnn 4
48. ily 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 44 CAUTION When trying to restore residual magnetism be sure to wear safety glasses
49. l Time Meter Water Temperature Gauge Oil Pressure Gauge Ammeter Intake Air Heater Switch Ignition Switch Battery Charger Circuit Breaker CB5 NOOR WDD 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 Ifa safety device opens and there is an interruption of electrical current the electronic govern
50. mentally 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 T 343 44 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 4 Inner Oil Cup 2 Air Cleaner Body 5 Gasket 3 Cap Clamp 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 AX 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 Ch
51. nel 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 oll 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 1 1 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 ona 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 Equipment Type of Form No Covered Manual 62 11335 V2203 DI Engine Parts List 62 11
52. ng 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 Place forks into fork lift pockets of generator Attach safety chain between unit and fork truck Center the generator set in desired position under chassis Lift clamp item 1 in place ensuring bolt item 4 is secured in slot Tighten bolt to 55 65 ft lbs 7 6 9 0 mkg Upon completion remove safety chain before re moving forks of fork lift truck from unit REAR OF CHASSIS FORK LIFT POCKET SECTIONA A 5 6 7 8 Figure 2 1 Typical Generator Set Mounting Standard Mount Bolt Washer Spherical Male Mounting Plate Generator Frame Washer Belleville Washer Spherical Female Tee Nut Roll Pin T 343 CONTAINER FLOOR CROSS 1 BEAMS REAR OF CHASSIS FORK LIFT POCKET
53. ny necessary repairs performed by qualified service personnel In case of electrical fire open circuit switch and extinguish with CO 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 4h DANGER Indicates an immediate hazard which WILL result in severe personal injury or death WA TE Indicates hazards or unsafe conditions which COULD result in severe personal injury or death 44 CAUTION Indicates potential hazards or unsafe practices which COULD result in minor personal injury product or property damage Safety i T 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 unautho
54. o Restart Sequencing Engine crank and rest is repeated three times each series unless the engine starts Intake Heater Delay Intake Series Heater Fuel Attempt Energized Solenoid Number in Engaged Seconds If the engine starts a Run sequence begins b Intake heater remains energized for 3 minutes If the engine fails to start 1 30 x Up To 15 25 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 Engine Engine Crank Rest Duration Duration Seconds Seconds Engine Status If the engine starts a Run sequence begins b Intake heater remains energized for 3 minutes If the engine fails to start 2 30 x Up To 15 25 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 If the engine starts a Run sequence begins If the engine fails to start a Intake heater will de energize 3 30 X Up To 15 25 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 9 T 343 Table 1 3 Auto Restart Sequencing Continued Intake
55. olant Sensor If Equipped 10 AC Generator Connection Box Access 5 Water Temperature Sensor 11 Battery 6 Water Temperature Switch Figure 1 2 Generator Set Top View Top Frame Members Removed for Clarity T 343 1 4 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
56. or Malfunction Battery insufficiently charged Charge Battery cable connections loose or oxidized Check Replace Battery cables defective Check Replace Starter motor will not crank or turns Starter brushes shorted out Engine Manual slowly Starter brushes hang up defective or have no contact Engine Manual Starter solenoid damaged Engine Manual Ignition switch defective Replace Engine lube oil too heavy Section 1 10 f Starter motor turns but pinion does Pinion or ring gear obstructed or worn Engine Manual not engage Starter motor does not disengage Ignition switch is bad Check Replace after switch has been released Starter motor solenoid is bad Engine Manual Pinion does not disengage after Starter is bad Engine Manual engine is running 3 1 5 Malfunction In The Engine Starting Circuit N Battery defective Correct 0000 Loose electrical connections Tighten Battery defective Correct Loose electrical connections Tighten Oil pressure svvitch defective Section 1 8 Water temperature safety switch open Section 1 8 Fuel solenoid does not energize or Fuel solenoid defective Engine Manual does not remain energized nee Intake heater switch is bad Check Engine Manual Electronic governor module is bad Replace Section 4 4 15 Check Replace Intake heater switch is bad Section 4 4 15 Timer is bad Section 4 4 15 Heater element is bad Section 4 4 15 Heater relay is bad Section 4 4 15 Intake heater does not energiz
57. or 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 12 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 T 343 CONTROL CONTROL PANEL 5 5 BOX o 1 Total Time Meter 8 Ground Studs 2 VVater Temperature Gauge 9 Safety Relay 3 Oil Pressure Gauge 10 Intake Heater Relay 4 Ammeter 11 Intake Heater Timer 5 Intake Air Heater Switch 12 Circuit Breaker CB2 6 Ignition Switch 13 Circuit Breaker CB3 7 Battery Charger Fuse or Circuit Breaker CB5 Figure 1 7 Customer Specific Control Panel and Box CONTROL CONTROL PANEL BOX 3
58. ow output voltage measured across charger output Reverse polarity connection to battery has caused charger to stop charging Open input circuit breaker Charger is not receiving AC input Charger output is not connected to 12 volt battery Charger is bad Battery not connected to charger It is normal to measure 12 volts or less across charger output with no battery connected Internal DC fuse blown and possible damage to current carrying components 3 3 ALTERNATING CURRENT GENERATOR No voltage Low voltage Fluctuating voltage May be indi cated by flickering lights High voltage T 343 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 Low engine speed Excessive load High resistance connections connections are warm or hot Shorted field Fluctuating speed Irregular speed of engine Loose terminal or load connections Bad bearing causing uneven air gap Excessive engine speed 3 4 REMEDY REFERENCE SECTION 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 Check charging leads from charger to battery Replace Section 4 5 2 a Check Section 4 5 4 Replace Section 4 5 1 c Section 4 5 4 Replace Se
59. own 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 INSTALL MOUNT WITH LARGE FLARE AT TOP FA SN 7 m 1 Screvv 5 8 8 Support Plate 2 Mounting Base 9 Snubbing VVasher 3 Flat VVasher 5 8 10 Screvv 1 2 4 Locknut 5 8 11 Screw 3 8 5 Locknut 1 2 12 Flat Washer 3 8 6 Flat Washer 1 2 13 Locknut 3 8 7 Shockmount Figure 4 10 Generator Shockmounts 1 Bolt 4 Shockmount 2 Lock Washer 5 Flat Washer 3 Snubbing Washer Figure 4 9 Engine Shockmounts T 343 4 10 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 ENGINE amp GENERATOR
60. r 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 Check in line fuel filter and clean if necessary Refer to paragraph 4 4 4 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 Check battery terminals for cleanliness and secure ness If required clean then coat with a battery termi nal sealant 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 44 WARNING Beware of moving poly V belt belt driven components and hot exhaust components AX 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
61. rized starting aids be used in conjunction with the air intake heat o r 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 44 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 44 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 T 343 Safety ii 44 CAUTION Never pour cold water into a hot engine 44 CAUTION Use only ethylene glycol anti freeze with inhibitors in system Use of glycol by itself will damage the cooling system 44 CAUTION Never open the radiator cap when the cool o 3 r3 a 44 CAUTION Always cover the engine inle
62. t tube while the air cleaner is being serviced 44 CAUTION Do not underfill or overfill the oil bath cups Overfilling of cups causes loss of capacity underfilling cups causes lack of filtering ef zh 9 o o lt 44 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 44 CAUTION The rotor should not be pulled out from the alternator more than 0 75 inches Damage to the bearing and windings may result 44 CAUTION Continued operation with failed shockmounts may result in engine or gen erator damage 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 pa
63. tem 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 T 343 SaJIA9p oAn9910Jd euiBue jo uoejedo JISA 61 00 0J1UOO ay Ul suonoeuuoo 26211109 je us1yBI gr syoq Bununouu pue uazuBi 7L ajon ees s Jeyy pue jo Buneougni abueyo 9r JOY peuajur duund yy jeorueyoau 0 z amp 10N S ysau jeujeyur pue Apog d lili Are yq io ueej vL 91e sjexoeJq eewpueu je ueiufi El uone nsui pexoeJo pue saeJiM se qeo paes suonoeuuoo jea esooj Auip 104 499u29 ZL juejeos jeuiuJa UA S EU ULI 800 pue ugay sseuiueejo pue sseujyBn 104 seule Aq neq Y29049 LE ebeladwe sayeay aye ul 499y OL uoneJedo a6ne6 jan y v jan jeselp uw qUe eni 114 Imoq f n pue duuns que jaen WO ureJq Sojeoipul Jojeoipul Jay se eoe deJ uee o pue ssaulueajo JO YOOUD JOJeoIpul ui 19414 Jre jueuie e Aug qz sinoy oGz fue e io aBueyo Useui eusa ul pue Apog H lli uee o pue sseui uee o JO 499U2 H T 1e Yq O ez Jeueep re Y99040 uonoeuip MO re SA A L re pessejduuoo Buisn ueoj o SS UIIUP T JO exe1ur Jre JoJelauaB pue 109 JOjeIpeJ YOSUD eJnjxiul QG OG pue juejoo9 sXeo 10 S SOU Jo1elpeJ se 1sn pe uorsua pue sx9e19 Jo Bui ea 10J yeg
64. will cause overheating and possible damage to windings due to over voltage or current a b Generator Windings Drying 44 WARNING Do not direct water or steam into the generator openings Do not allow any soap and water solutions to enter the alternator 44 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 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 eas

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