Carrier 69GC15-114 Operation Manual PDF

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Summary of Content for Carrier 69GC15-114 Operation Manual PDF

T-235-07

Models 69GC15-104 114/134/144 154/174/184 & 194

Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221

SERVICE MANUAL OPERATION AND

DIESEL DRIVEN GENERATOR SET

MODELS 69GC15-104 114/134/144

154/174/184 & 194

Carrier Corporation 1995 D Printed in U. S. A. 0195

i

TABLE OF CONTENTS Section Page

1 DESCRIPTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Unit Specifications 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Engine Data 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Safety Devices 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Engine Screw Threads 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Engine Air System 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Operating Controls and Instruments 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.1 Introduction 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2 Control Panel and Related Components 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.3 Protective Devices 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 Lube Oil and Fuel Flow Diagrams 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Battery Charging Alternator System 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9.1 Introduction --- 37 Amp 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9.2 Alternator Operation --- 37 Amp 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9.3 Voltage Regulator Operation (12 volts d-c) --- 37 Amp 1-7. . . . . . . . . . . . . . . 1.9.4 Introduction --- 65 Amp 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9.5 Alternator Operation --- 65 Amp 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9.6 Integral Voltage Regulator Operation (12 volts d-c) --- 65 Amp 1-9. . . . . . . .

1.10 Main Alternator (A-C Generator) 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1 Principle of Operation 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2 A-C Generator (Main Alternator) Circuit Diagram 1-10. . . . . . . . . . . . . . . . .

2 OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Generator Set Installation and Removal 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Pin Mounting --- 69GC15-114, -114-1, -144, -154 2-2. . . . . . . . . . . . . . . . . . . . 2.1.2 Pin Mounting --- 69GC15-194 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3 Clamp Mounting --- 69GC15-104, -134, -174 2-4. . . . . . . . . . . . . . . . . . . . . . . . 2.1.4 Clamp Mounting --- 69GC15-184 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Pre-trip Inspection 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Starting and Stopping Instructions 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Control Circuit Operation 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 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 Starter Motor Malfunction 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.4 Malfunction in the Engine Starting Circuit 3-2. . . . . . . . . . . . . . . . . . . . . . . . . 3.1.5 Miscellaneous Engine Troubleshooting 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Alternator (Automotive Type) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 A-C Brushless Generator (Main Alternator) 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

TABLE OF CONTENTS (CONTINUED)

4 SERVICE 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Maintenance Schedule 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Priming the Fuel System 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Engine Service and Components 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Cooling System 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Lube Oil Filters 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 Servicing the Fuel Solenoid and Linkage 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.4 Adjusting Engine Speed 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.5 Engine Air Cleaner 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.6 Engine Crankcase Breather 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.7 Servicing Glow Plugs 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.8 Servicing Fuel Pump 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Servicing the Alternator 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Preliminary Checks and Tests 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.2 Test Tools 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.3 Problem Area Determination 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.4 In-Unit Alternator/Regulator Tests 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.5 Alternator Brush Test Procedure --- 37 AMP 4-7. . . . . . . . . . . . . . . . . . . . . . . 4.4.6 Alternator Brush Test Procedure --- 65 AMP 4-7. . . . . . . . . . . . . . . . . . . . . . . 4.4.7 Slip Ring Servicing 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.8 Alternator Installation 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Servicing and Adjusting V-belt 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 Water Pump V-Belt 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.2 Alternator V-Belt 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Servicing the Generator (Main Alternator) 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 Preventive Maintenance and Operating Precautions 4-8. . . . . . . . . . . . . . . . . 4.6.2 Installation and Removal 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Replacing Shockmounts 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1 Replacement Criteria 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.2 Shockmount Replacement 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Maintenance of Painted Surfaces 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 Replacing Index Pin or Adjusting Clamping Device 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . 5 ELECTRICAL WIRING SCHEMATIC & DIAGRAM 5-1 5.1 Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii/iv

LIST OF ILLUSTRATIONS

Figure Page

1-1 Generator Set --- Front View --- Typical 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Control Box and Gauge Panel (Models 69GC15-104 & -114) 1-3. . . . . . . . . . . . . . . 1-3 Control Box and Gauge Panel (Models 69GC15-134, -144, -154, -174, -184, -194) 1-3 1-4 Engine Air Cleaner 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Lube Oil Flow Diagram 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Fuel System Diagram 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Alternator Schematic Diagram --- 37 Amp 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Rectifier Diode Assembly --- 37 Amp 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Alternator and Regulator --- 37 Amp 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Alternator and Regulator --- 65 Amp 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Alternator Schematic Diagram --- 65 Amp 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Main Alternator (A-C Generator) 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 A-C Generator Circuit Diagram 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 Pin Mounting --- 69GC15-114, -114-1, -144, -154 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Pin Mounting --- 69GC15-194 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Clamp-on Mounting --- 69GC15-104, -134, -174 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Clamp-on Mounting --- 69GC15-184 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 Fuel Solenoid Assembly 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Speed Adjustment 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Air Cleaner 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Engine Crankcase Breather 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Mechanical Fuel Pump 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Open Diode-Trio Test --- 37 Amp 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Open Regulator Test --- 37 Amp 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Open Diode-Trio Test --- 65 Amp 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Open Regulator Test --- 65 Amp 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Alternator Output Test --- 65 Amp 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Alternator Brush Assembly --- 37 Amp 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Alternator Brush Assembly --- 65 Amp 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Rectifier Removal 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 A-C Generator (Rectifier Assembly) 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Diode Testing 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Shockmount Installation 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Clamping Device and Index Pin 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Clamping Device in Closed Position 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 Electrical Wiring Schematic & Wiring Diagram --- (Models 69GC15-104, -104-1 & -114) 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 Electrical Wiring Schematic & Wiring Diagram --- (Model 69GC15-114-1) 5-4. . . . 5-3 Electrical Wiring Schematic & Wiring Diagram ---

(Models 69GC15-134, -144, -154, -174 & -194) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Electrical Wiring Schematic & Wiring Diagram --- (Model 69GC15-184, -184-2) 5-8 5-5 Electrical Wiring Schematic & Wiring Diagram --- (Model 69GC15-184-1) 5-10. . . .

LIST OF TABLES

Table Page

1-1 Model Chart 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Safety Devices 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Alternator and Manuals 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

SECTION 1

DESCRIPTION

1.1 INTRODUCTION

WARNING Beware of moving V-Belts and belt driven components.

This manual contains Operating Data, Electrical Information, and Service Instructions for the diesel generator sets shown in Table 1-1. Separately bound manuals covering the diesel engines for the diesel-driven generator sets are also supplied, see chart below.

MANUAL FORM

NO.

EQUIPMENT COVERED

TYPE OF MANUAL/FORM

62-03459 CT4-114/ 133-DI/134-DI

Engine Parts List

62-03461 CT4-114 Workshop Manual 62-03707 CT4-133-DI Workshop Manual 62-03741 CT4-134-DI Workshop Manual

The diesel-driven generator sets are intended for front mounting upon a refrigeration unit. They provide a constant electrical power supply for the operation of an all-electric refrigeration unit. (See left side of unit for serial/model number plate.)

Located inside the frame are the diesel engine, A-C generator (main alternator), control and monitoring cabinet, starting battery, 12 vdc battery charging alterna- tor, regulator and other necessary accessory components for proper unit operation.

For power, either Carrier Transicold Model CT4-114, CT4-133-DI, or CT4-134-DI (See Model Chart), vertical in-line, four cylinder diesel engines are used. The engine is equipped with glow plugs (used as a starting aid), spin-on lube and fuel oil filters for easier filter changes.

Electrical power is generated by a Lima 15 KW, brushless, single bearing A-C generator. The generator is coupled directly to the engine flywheel. The generator provides a constant 460 vac, 3 phase, 60 hertz electrical supply.

The 12 vdc battery charging alternator is belt-driven from the generator drive shaft sheave. The water pump and the radiator cooling fan are belt-driven from the engine crankshaft sheave.

Table 1-1. Model Chart

Model No. Fuel Tank (U.S. Gallons)

Control Box Engine Alternator Unit

70 78 Fig 1-2

Fig 1-3

CT4-114 CT4-133-DI CT4-134-DI 37 Amp

65 Amp

Mounting

69GC15-104 X X X X Clamp 69GC15-104-1 X X X X Clamp 69GC15-114 X X X X Pin 69GC15-114-1 X X X X Pin 69GC15-134 X X X X Clamp 69GC15-144 X X X X Pin 69GC15-154 X X X X Pin 69GC15-174 X X X X Clamp 69GC15-184 X X X X Clamp 69GC15-184-1 X X X X Clamp 69GC15-184-2 X X X X Clamp 69GC15-194 X X X X Pin

1-2

1 2 3 4 5 6 7 8 9 10

1112131415161718

19

1. Control Box and Panel 2. Alternator (Battery Charging) 3. Air Cleaner 4. Lube Oil Filter 5. Fuel Filters 6. Fuel Solenoid 7. Mechanical Lift Pump

8. Fuel Bleed Valve 9. Radiator Cap

10. Radiator Overflow Tank 11. Fuel Fill 12. Fuel Gauge 13. Oil Pressure Safety Switch 14. Lube Oil Dipstick

15. Starter Motor 16. A-C Generator 17. Battery 18. Power Receptacle

(Located behind Control Box) 19. Clamping Device (Optional)

Figure 1-1. Generator Set --- Front View --- Typical

1-3

1

2

3

4

5

6

7

8

9

10

1. Oil Pressure Gauge 2. Voltmeter Gauge 3. Ammeter Gauge 4. Circuit Breaker

Trip Indicator 5. Ignition Switch 6. Glow Plug Switch 7. Circuit Breaker (CB-1) 8. Frequency Meter (Optional) 9. Water Temperature Gauge

10. Total Time Meter 11. Circuit Breaker (CB-2) 12. Filter Reactor (Optional) 13. Circuit Breaker (CB-3) 14. Run Control Relay (RCR) 15. Junction Block (TB2) 16. Terminal Block (TB1)

TB1

11

12

13 14

15

16

Figure 1-2. Control Box and Gauge Panel (Models 69GC15-104 & -114)

1. Oil Pressure Gauge 2. Voltmeter Gauge 3. Ammeter Gauge 4. Ignition Switch 5. Glow Plug Switch 6. Circuit Breaker (CB-1) 7. Circuit Breaker

Trip Indicator 8. Frequency Meter (Optional) 9. Water Temperature Gauge

10. Total Time Meter 11. Circuit Breaker (CB-2) 12. Filter Reactor (Optional) 13. Circuit Breaker (CB-3) 14. Run Control Relay (RCR) 15. Junction Block (TB2) 16. Terminal Block (TS) 17. Terminal Block (TB1)

1

2

3

4

5

6

7

8

9

10

11

12

13 14

15

16

17

TS

TB1

Figure 1-3. Control Box and Gauge Panel (Models 69GC15---134, -144, -154, -174, -184 & -194)

1-4

1.2 UNIT SPECIFICATIONS a. Unit Weight Approx.

Models 69GC15-104 & 114: 2200 lb (1000 kg) with fuel and battery Models 69GC15-134, 144, 154, 174, 184 & 194: 2260 lb (1025 kg) with fuel and battery

b. Engine (Dry) --- with Accessories 421 lb (191 kg)

c. A-C Generator 225 lb (102 kg)

d. Fuel Tank Draw Models 69GC15-104 & 114: 70 U.S. Gallons (265 liter) Models 69GC15-134, 144, 154, 174, 184 & 194: 78 U.S. Gallons (295 liter)

1.3 ENGINE DATA a. Bore/Stroke

CT4-114 (V1902): 3.35 in. (85 mm) /3.23 in. (82 mm) CT4-133-DI (V2202): 3.43 in. (87 mm) /3.62 in. (92 mm) CT4-134-DI (V2203): 3.43 in. (87 mm) /3.64 in. (92.4 mm)

b. Compression Ratio CT4-114 (V1902): 21:1 CT4-133-DI (V2202): 20.5:1 CT4-134-DI (V2203): 20.5:1

c. Cooling System Capacity: 8 U.S. quarts (7.57 liters)--- includes 1 quart

(0.946 liter) in coolant recovery bottle. (Refer to section 4.3.1)

Type of Anti-Freeze: Ethylene Glycol 4 quarts (3.78 liters) Water 4 quarts (3.78 liters) Use a low silicate anti-freeze meeting GM specifica-

tions GM 6038M or equal. Water Temperature Safety Switch Setting: Opens 230 5_F (110 3_C) Resets 200_F (93_C) --- minimum Thermostat: Starts to Open 177 to 182_F (80 to 84_C) Fully Open 203_F (95_C)

d. Cylinders (Number) Four

e. Displacement CT4-114 (V1902): 113.57 cu. in. (1.85 liters) CT4-133-DI (V2202): 133.5 cu. in. (2.2 liters) CT4-134-DI (V2203): 134 cu. in. (2.2 liters)

f. Firing Order 1-3-4-2

g. Fuel Winter: Diesel No. 1 Summer: Diesel No. 2

h. Glow Plug Amperage 7.5 amps per plug at 12 vdc

i. Horsepower CT4-114 (V1902): 24.3 hp @ 1800 rpm CT4-133-DI (V2202): 32.5 hp @ 1800 rpm CT4-134-DI (V2203): 33.0 hp @ 1800 rpm

j. Lubrication System Oil Pressure: 40 to 60 psig (3.8 to 5.2 kg/cm@) Oil Pressure Safety Switch Setting Closes: 15 psig (2.08 kg/cm@) Capacity: 20 U.S. quarts (18.9 liters)

(Includes 1 U.S. quart = 0.95 liter filter) Time between Oil Changes:

First 400 Hours, thereafter every 1000 Hours (maximum)

Oil Level Indicator: Dipstick in oil pan Lube Oil Specification: Use a heavy duty lubricating oil conforming to

American Petroleum Institute (API) Service Classifica- tion CD (DS)

Lube Oil Viscosity: Outdoor Temperature

Fahrenheit Centigrade SAE

Below 32_ 0_C 10W or 10W30 32_ to 77_F 0_ to 25_C 20 Over 77_F Over +25_C 30 or 15W40

1.4 SAFETY DEVICES (Refer to Table 1-2) System components are protected from damage

caused by unsafe operating conditions by automatically shutting down the diesel engine when such conditions occur. This is accomplished by the safety devices CB-2, HWT or OP. These safety devices monitor system operating conditions and open a set of electrical contacts when an unsafe condition occurs. Opening one or more of these safety switch contacts will de-energize the run control relay. This, in turn, opens a set of RCR contacts to de-energize the fuel solenoid.

De-energizing fuel solenoid releases the stop-run lever to the STOP position, shutting off the fuel supply to the engine; thus stopping the engine.

The A-C generator and the glow plug circuit are protected by circuit breakers (listed below) but will not shut down the engine if an overload occurs.

1-5

Table 1-2. Safety Devices

Unsafe Condition Safety Switch Switch Setting

a. Engine 1. Low engine lubricating 1. Oil pressure switch --- 1. Opens below 15 psig

oil pressure Automatic reset (1.05 kg/cm@)

2. High engine cooling 2. Water temperature switch --- 2. Opens above 230 water temperature Automatic reset 5_F (110 3_C)

3. Excessive current draw 3. Circuit breaker (CB-2) --- 3. Trips at 20 amps by FS, HWT, L1, OPG, Automatic reset WTG, RCR or TT

b. Glow-Plugs 1. Excessive current draw 1. Circuit breaker (CB-3) --- 1. Opens at 45 amps

on glow plug circuit Automatic reset

c. Generator 1. Excessive current draw 1. Circuit breaker (CB-1) --- 1. Trips at 25 amps

by generator Manual reset (460 vac)

1.5 ENGINE SCREW THREADS

All threads used on the Model CT4-114/133-DI engines are metric except the oil drain plug which is American Standard Pipe Thread (NPT).

1.6 ENGINE AIR SYSTEM

Clean air is supplied to the engine through the air cleaner. (See Figure 1-4). The air is necessary for complete combustion and scavenging of the exhaust gases. As the engine piston goes through the intake stroke, the piston draws clean fresh air down into the cylinder for the compression and power strokes. As the engine goes through its exhaust stroke, the upward movement of the piston forces the hot exhaust gases out of the cylinders through the exhaust valves and the exhaust manifold. If the air filter is allowed to become dirty, the operation of the engine would be impaired. Blow-by gases from the diesel engine crankcase are introduced in the air intake manifold through the crankcase breather. Therefore, the filter must be kept clean and air restriction reduced to a minimum. A dry type air cleaner is used with this unit. Air passes through the screen where dirt or dust in the air is removed before it enters the engine. As the dust and dirt accumulate, the filter should be changed periodically. If the filter is not changed, it will be blocked so that it cannot effectively remove the dirt and dust from the air passing over the screens. The air cleaner is equipped with Vacuator TM

Valve which continuously expel dust and moisture. On cleaners equipped with dust cup, the cup is emptied as dust accumulates. a. Pre-cleaner

The illustration shows a fin which gives high-speed rotation to the intake air, and separates a large portion of the dust from the air by centrifugal action. The plastic fin, the element, and the gasket are vital parts of the cleaner and are designed into a single replaceable assembly. This

design feature assures continued high performance of the cleaner.

1

2

3

1. Pre-Cleaner 2. Ejected Dust 3. Duralife Filter

Figure 1-4. Engine Air Cleaner

b. Ejected dust The dust is swept through a slot in the baffle and

collected in the dust cup or Vacuator TM Valve body. c. Duralife filter

The small portion of the dust remaining in the pre-cleaned air is removed by the Duralife element. The element is chemically-treated and oven-cured for resis- tance to oil and water. Perforated steel supports the

1-6

element inside and out and, together with rigid metal end caps, provides structural rigidity to this vital part of the cleaner. The element can be cleaned for re-use by one of several recommended processes. (Refer to section 4.3.5.)

1.7 OPERATING CONTROLS AND INSTRUMENTS

1.7.1 Introduction

Components required for monitoring and controlling the unit are located in the control box and control panel. (See Figure 1-2 or Figure 1-3)

The water temperature safety switch (HWT) is located near the thermostat housing.

1.7.2 Control Panel and Related Components (See Figure 1-2 or Figure 1-3)

a. A-C Voltmeter

The a-c voltmeter is a sealed and ruggedized device indicating the line-to-line voltage output from the main alternator on a scale of 0 to 600 volts. When the unit has an output of 460 vac, the indicating needle will be in the green band. (Refer to section 4.3.4) b. Total Time Meter

This meter designates 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. Frequency Meter and Interference Filter ---

Optional

The meter and filter are used to monitor the hertz of the A-C generator output. This meter will read 60 hz, when the correct engine speed is obtained. (Refer to section 4.3.4) d. Ammeter

The ammeter indicates the rate of discharge or charge of the battery charging system composed of the battery, battery charging alternator and the voltage regulator. e. Gauges and Senders

1. Oil Pressure Gauge

The purpose of this gauge is to observe normal operating engine oil pressure. Normal oil pressure is 40 to 60 psig (2.8 to 4.2 kg/cm@).

2. Oil Pressure Sender

This sensing device senses engine lube oil pressure and transmits a signal to the oil pressure gauge. The oil pressure sensor is located in the oil line near the oil pressure switch.

3. Water Temperature Gauge

The function of this gauge is to observe water operating temperature (180 to 205_F = 82 to 94_C). The gauge is connected to a water temperature sensing device.

4. Water Temperature Sender

This sensing device senses engine water temperature and transmits a signal to the water temperature gauge.

The water temperature sender is located on the top, front, right side of the engine below the HWT switch.

f. Indicator Light

1. Circuit Breaker Trip Light

This light (red) may be checked (unit not running) by placing the circuit breaker (CB-1) in the off position and at the same time moving the ignition switch to the run position. When the circuit breaker is in the off position, a set of contacts close to complete a circuit to the light.

If the unit is running and the circuit breaker trips, the light will illuminate to signal the operator of a malfunc- tion with the generator.

g. Switches

1. Glow Plug Switch

The glow plug switch (momentary contact type), when held in the UP position (pre-heat), permits battery current (approximately 7.5 amps per plug at 12 vdc) to flow to the glow plugs in the engine to pre-heat the combustion chambers. The glow plugs are located under the fuel injectors. When starting engine, it is necessary to continue to hold the glow plug switch in the UP position until the engine has developed sufficient oil pressure to close the oil pressure safety switch.

2. Ignition Switch

The ignition switch (momentary contact type in the start position), when held in the START (ignition) position energizes the starter motor solenoid which in turn allows the starter motor to crank.

1.7.3 Protective Devices a. Oil Pressure Switch

This switch, set to open below 15 psig (1.05 kg/cm@) will automatically stop the engine upon loss of oil pressure. This switch is located on the right side of the engine. (See Figure 1-1) When the switch opens, the run control relay (RCR) coil is de-energized and the RCR contacts open to de-energize the fuel solenoid (FS); thus stopping the engine.

b. High Water Temperature Switch

This switch, set to open at 230 5_F (110 3_C), will automatically stop the engine upon high water temperature. The switch is located near the thermostat housing. When the switch opens, the run control relay (RCR) coil is de-energized and the RCR contacts open to de-energize the fuel solenoid (FS); thus stopping the engine.

c. A-C Generator Circuit Breaker (CB-1)

This device trips at 25 amps to protect the A-C generator (main alternator) from excessive current (amperage) draw. When the circuit breaker trips, the generator power output to the refrigeration unit ceases. The diesel engine will continue to run (with normal engine operation), but the voltmeter will indicate no output and the circuit breaker indicator light will be illuminated.

1-7

d. Circuit Breaker (CB-2)

The circuit breaker is located in the control box. This device prevents excessive current draw by the compo- nents FS, HWT, L1, OPG, RCR, WTG, and TT. The circuit breaker opens at 20 amps and will automatically reset.

e. Circuit Breaker (CB-3)

The circuit breaker is located above CB-2 in the control box. This device prevents excessive current draw by the glow plug circuitry. The circuit breaker opens at 45 amps and will reset automatically.

1.8 LUBE OIL AND FUEL FLOW DIAGRAMS

1

2

3

4

5

6

1. Engine Block 4. Oil Pressure Sender 2. Oil Pan 5. Oil Pressure Switch 3. Full Flow Filter 6. Engine Block Oil Connections

Figure 1-5. Lube Oil Flow Diagram

1 Fuel Tank 2 Fuel Supply Line 3 Fuel Return Line 4 Fuel Warmer 5 Fuel Leak-Off Line 6 Secondary Filter

7 Injector Nozzles 8 Fuel Bleed Valve 9 Injection Pump

10 Primary Filter 11 Mechanical Lift

Pump

1

2

3

4

5

7

8

9

6

10

11

Figure 1-6. Fuel System Diagram

1.9 BATTERY CHARGING ALTERNATOR SYSTEM

Table 1-3. Alternator and Manuals

Prestolite Prestolite Amps Alternator No. Manual No.

8MR2050F 25-51 & 25-51A 37 8EM2012NA 25-197 65

It is recommended that the applicable manual (see Table 1-3) be obtained from Prestolite Electric, 7585 Empire Drive, P.O. Box 6210, Florence, Kentucky, 41042, U.S.A., for complete overhaul and service information of the alternator, and regulator, if required. 1.9.1 Introduction --- 37 Amp

The mechanical construction of the alternator differs from the D-C generator in that the field rotates and the (armature) generating windings are stationary. The field current necessary to control the output of the alternator is supplied from the regulator. The regulator controls the current feed to the field via the brushes and rotor slip rings.

Two completely sealed ball bearings support the rotor in the front and rear housing.

CAUTION Observe proper polarity when installing battery, negative battery terminal must be grounded. Reverse polarity will destroy the rectifier diodes in alternator. As a precautionary measure, disconnect positive battery terminal when charging battery in unit. Connecting charger in reverse will destroy the rectifier diodes in alternator.

1.9.2 Alternator Operation --- 37 Amp The alternator converts mechanical and magnetic

energy to A-C (Alternating Current) and voltage, by the rotation of an electromagnetic field (rotor) inside a three phase stator assembly. The alternating current and voltage is changed to direct current and voltage, by passing A-C energy through a three phase, full-wave rectifier system. Generally, six silicon rectifier diodes are used. (See Figure 1-7)

Since diodes pass direct current in only one direction, their arrangement in the alternator eliminates the need for a cutout relay in the voltage regulator. The individual rectifier diodes, three positive and three negative, are assembled in two temperature dissipating heat sinks. The heat sinks placed in the alternator with threaded studs also serve as circuit terminals. (See Figure 1-8)

Maximum charging current is limited by the design and connections in the stator assembly, eliminating the need for a current regulating relay in the voltage regulator. 1.9.3 Voltage Regulator Operation

(12 volts d-c) --- 37 Amp The regulator is an all-electronic, transistorized

device. No mechanical contacts or relays are used to perform the voltage regulation of the alternator system.

1-8

The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit. The system is temperature compensated to permit the ideal charging rate at all temperatures.

The regulator is an electronic switching device. (See Figure 1-9) It senses the voltage appearing at the auxiliary terminal of the alternator and supplies the necessary field current for maintaining the system voltage at the output terminal. The output current is determined by the load.

1 2

3 4

5

6

7

8

9

10

+

1. Regulator terminal 6. Negative diode 2. Trio diode assembly assembly 3. Positive output 7. Delta stator 4. Positive diode 8. Field

assembly (rotor winding) 5. Rectifier diode 9. Rotor

connecting lead 10. Negative output

Figure 1-7. Alternator Schematic Diagram --- 37 Amp

Diodes

Heat sink Both mounting studs have potential

Figure 1-8. Rectifier Diode Assembly --- 37 Amp

1

2

3

4

5

6

7

8

9

1. Excitation 6. Output Terminal 2. White Wire 7. Regulator Terminal 3. Black Wire 8. Red Wire 4. Negative Terminal 9. Regulator 5. Capacitor

Figure 1-9. Alternator and Regulator --- 37 Amp

1.9.4 Introduction --- 65 Amp The mechanical construction of the alternator differs

from the D-C generator in that the field rotates and the (armature) generating windings are stationary. The field current necessary to control the output of the alternator is supplied from the solid-state regulator. This integral voltage regulator, which incorporates an IC, all silicone semiconductor and thick-film construction, controls the current feed to the field via the brushes and rotor slip rings.

Two completely sealed ball bearings support the rotor in the front and rear housing.

CAUTION Observe proper polarity when installing battery, negative battery terminal must be grounded. Reverse polarity will destroy the rectifier diodes in alternator. As a precautionary measure, disconnect positive battery terminal when charging battery in unit. Connecting charger in reverse will destroy the rectifier diodes in alternator.

1.9.5 Alternator Operation --- 65 Amp The alternator converts mechanical and magnetic

energy to alternating current (A.C.) and voltage, by the rotation of an electromagnetic field (rotor) inside a three phase stator assembly. The alternating current and voltage is changed to direct current and voltage, by passing A.C. energy through a three phase,full-wave rectifier system system. Six silicon rectifier diodes are used. (See Figure 1-11)

1-9

1.9.6 Integral Voltage Regulator Operation (12 volts d-c) --- 65 Amp

The regulator is an all-electronic, transistorized device. No mechanical contacts or relays are used to perform the voltage regulation of the alternator system. The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit. The system is temperature compensated to permit the ideal charging rate at all temperatures.

The regulator is an electronic switching device. (See Figure 1-10) It senses the voltage appearing at the auxiliary terminal of the alternator and supplies the necessary field current for maintaining the system voltage at the output terminal. The output current is determined by the load.

1 2

3

4

5

6

7

1. AC Tap 2. Back Cover 3. Positive Output(B+) 4. Integral Regulator

5. Excite 6. Ground 7. 12vdc Test Lamp

Terminal (D+) Figure 1-10. Alternator and Regulator --- 65 Amp

Figure 1-11. Alternator Schematic Diagram---65Amp

1. 12vdc Test Lamp Terminal (D+)

2. Diode Trio 3. Positive Out

put (B+) 4. Rectifier

5. Ground 6. AC Tap 7. Rotor (Field) 8. Stator 9. Integral Regulator

10. Excite

1 2 3

4

5

6

7

8

9

10

1.10 MAIN ALTERNATOR (A-C GENERATOR)

LIMA

Figure 1-12. Main Alternator (A-C Generator) 1.10.1 Principle of Operation

The MAC (Lima) brushless A-C generator is a self-regulated, rotating field synchronous unit with the rotor having a salient pole construction with amortisseur windings. 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, silicone rectifier unit.

The exciter pole pieces contain residual magnetism, setting up lines of force across the air gap to the exciter armature. When the exciter armature begins to rotate a voltage is induced and current flow is initiated in the exciter armature AC windings. This voltage is fed to the rotating rectifier assembly, rectified and fed to the alternator field coils. This DC voltage is sufficient to magnetize the laminated alternator field which will set up lines of force across the air gap to the alternator stator. As the generator rotor rotates a voltage will be induced and current will flow in the alternator stator windings and to the output circuit.

All connections between the exciter stator windings and the generator stator windings are internally con- nected within the stator housing. Only the output power leads of the generator unit are brought out to the generator terminal box.

1-10

1.10.2 A-C Generator (Main Alternator) Circuit Diagram

Figure 1-13 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 genera- tor 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 char- acteristic.

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 silicone rectifier unit. The response time of the excitation system is very fast since the exciter stator carries an alternating current corresponding to the load current which 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

STATORGENERATOR

SHUNT

SERIES

L O A D

ROTOR

EXCITER RECTIFIER ASSEMBLY

STATOR

Figure 1-13 A-C. Generator Circuit Diagram

2-1

SECTION 2

OPERATION

2.1 GENERATOR SET INSTALLATION AND REMOVAL

2.1.1 Pin Mounting --- 69GC15-114, -114-1, -144, -154

Figure 2-1. Pin Mounting --- 69GC15-114, -114-1, -144, -154

WARNING

To prevent injury, the procedures for installation and removal of the generator set given below must be followed.

NOTE

This generator set is equipped with special pins and mounting bolts and can be installed only on containers with matching installation points.

a. Installation:

1. Place forks into fork pickets of generator set. Attach safety chain A between fork pockets on generator set and fork truck. Be sure chain A is short enough to retain generator set on forks.

2. Line up generator set with refrigeration unit and container. Raise generator set until top of set is several inches above top edge of container. Move generator set against container and lower into position.

Important --- Two pins B must be fully engaged in mating holes in container.

3. Keep forks in pockets on generator set and tighten mounting bolt C on each side of generator set into container frame.

Important --- Bolts must be tight and retaining pin D must be snapped into position.

4. Remove safety chain A before removing forks.

b. Removal:

WARNING

Disconnect power plug before removing generator set.

1. Move forks into fork pockets on generator set. Attach safety chain A between fork pockets on generator set and fork truck.

2. Remove mounting bolt C on each side of generator set.

3. Raise generator set several inches to disengage pins B from mating holes and remove from container.

2-2

2.1.2 Pin Mounting --- 69GC15-194

A

A

B

D C

D

C

Figure 2-2. Pin Mounting --- 69GC15-194

WARNING

To prevent injury, the procedures for installation and removal of the generator set given below must be followed.

NOTE

This generator set is equipped with special pins and mounting bolts and can be installed only on containers with matching installation points.

a. Installation:

12. Place forks into fork pockets of generator set. Attach safety chain (A) between fork pockets on genera- tor set and fork truck. Be sure chain (A) is short enough to retain generator set on forks.

13. Line up generator set with refrigeration unit and container. Raise generator set until top of set is several inches above top edge of container. Move generator set against container and lower into position.

Important --- Two pins (B) must be fully engaged in mating holes in container.

14. Keep forks in pockets on generator set and tighten mounting bolt (C) on each side of generator set into container frame.

Important --- Bolts must be tight and retaining plate (D) must be locked into position.

15. Remove safety chain (A) before removing forks.

b. Removal: WARNING

Disconnect power plug before removing generator set.

1. Move forks into fork pockets on generator set. Attach safety chain (A) between fork pockets on genera- tor set and fork truck.

2. Release retaining plate (D) from locking brack- et on each side of generator set.

3. Remove mounting bolt (C) on each side of generator set.

4. Raise generator set several inches to disengage pins (B) from mating holes and remove from container.

2-3

2.1.3 Clamp Mounting --- 69GC15-104, -134, -174

Figure 2-3. Clamp-on Mounting --- 69GC15-104, -134, -174

WARNING

To prevent injury, the procedures for installation and removal of the generator set given below must be followed.

NOTE

This generator set is equipped with clamps and mounting bolts and can be installed only on containers with matching installation points for the mounting bolts.

a. Installation:

1. Place forks into fork pockets of generator set. Attach safety chain A between fork pockets on generator set and fork truck. Be sure chain A is short enough to retain generator set on forks. Adjust each generator set clamp B with handle D forward and indexing pin C in vertical position.

2. Move generator set against container and fully engage clamps into mating holes in container corner castings, allowing clamp boss to settle on bottom of corner casting. Rotate indexing pin C to horizontal position and lock handle D on both clamps.

Important --- Clamping device handle D must be drawn back and handle pin snapped into position and safety pins installed.

3. Keeping forks in pockets on generator set, tighten mounting bolt E into container frame on each side of generator set.

Important --- Bolts must be tight and retaining pin F must be snapped into position.

4. Remove safety chain A before removing forks.

b. Removal:

WARNING

Disconnect power plug before removing generator set.

1. Place forks into fork pockets of generator set. Attach safety chain A between fork pockets on generator set and fork truck.

2. Remove mounting bolt E on each side of generator set.

3. Disengage clamps B so handle D is forward and indexing pin C is in a vertical position.

4. Carefully remove generator set from container.

2-4

2.1.4 Clamp Mounting --- 69GC15-184

E E F F

Figure 2-4. Clamp-on Mounting --- 69GC15-184

WARNING

To prevent injury, the procedures for installation and removal of the generator set given below must be followed.

NOTE

This generator set is equipped with clamps and mounting bolts and can be installed only on containers with matching installation points for the mounting bolts.

a. Installation:

1. Place forks into fork pockets of generator set. Attach safety chain A between fork pockets on generator set and fork truck. Be sure chain A is short enough to retain generator set on forks. Adjust each generator set clamp B with handle D forward and indexing pin C in vertical position.

2. Move generator set against container and fully engage clamps into mating holes in container corner castings, allowing clamp boss to settle on bottom of corner casting. Rotate indexing pin C to horizontal position and lock handle D on both clamps.

Important --- Clamping device handle D must be drawn back and handle pin snapped into position and safety pins installed.

3. Keeping forks in pockets on generator set, tighten mounting bolt E into container frame on each side of generator set.

Important --- Bolts must be tight and retaining plate F must be locked into position.

4. Remove safety chain A before removing forks.

b. Removal:

WARNING

Disconnect power plug before removing generator set.

1. Place forks into fork pockets of generator set. Attach safety chain A between fork pockets on generator set and fork truck.

2. Release retaining plate F from locking bracket on each side of generator set.

3. Remove mounting bolt E on each side of generator set.

4. Disengage clamps B so handle D is forward and indexing pin C is in a vertical position.

5. Carefully remove generator set from container.

2-5

2.2 PRE-TRIP INSPECTION a. Before Starting Generator Set

1. Check engine lubrication and fuel oil filter cases, oil lines, and connections for leaks. (Tighten connections and/or replace gaskets)

2. Check engine lubrication oil level. (Refer to section 1.3)

3. Check engine V-Belt for proper tension, fraying or cracks. Adjust belt or replace. (Refer to section 4.5)

4. Check radiator hoses for leaks and check radiator coolant level. (Add pre-mixed 50/50 antifreeze- water as required.) (Refer to section 1.3)

5. Check radiator coil and generator air intake screen for cleanliness. (Clean using compressed air, reversing the normal air flow.)

6. Check air cleaner for cleanliness and clean if necessary. (Refer to section 4.3.5)

7. Drain water from fuel tank sump.

8. Fill fuel tank with diesel fuel. (Refer to section 1.3)

9. Check battery terminals for cleanliness and securement. (Clean and coat with a mineral type grease.)

10. Check for loose electrical connections.

11. Grease Fuel Solenoid plunger. (Use P/N 07-00245-00.)

12. Check glow plug amperage. (Refer to section 1.3)

13. Connect power cable to refrigeration unit. Start genset as detailed in section 2.3 and then turn refrigera- tion unit on to check operation. (Refer to section b.)

b. After Starting Generator Set

1. Refer to section 2.3 for starting and stopping instructions.

2. Check voltmeter. Should be 460 volts a-c ( 5% no load). Volt meter indicating needle should be pointing to high side of green band (1820 to 1840 rpm, no load) (1710 rpm, with load).

3. Check total time meter operation. (Run engine 10 minutes)

4. Listen for abnormal bearing noise. (12 vdc alternator and main alternator)

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

6. Check radiator and hoses for leaks.

7. Check exhaust system for leaks.

8. Check operation of indicator light. (Refer to section 1.7.2)

2.3 STARTING AND STOPPING INSTRUCTIONS

a. Starting Instructions

WARNING

Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the glow plugs.

NOTE

When starting the engine, it is necessary to continue to hold the glow plug switch in the UP position until the engine develops sufficient oil pressure to close the oil pressure safety switch, energizing and completing all circuits for unit operation.

1. Hold glow plug switch in the UP position for 30 seconds. (See Figure 1-2 or Figure 1-3)

NOTE

Below 0_F, hold glow plug switch for two minutes, release switch for 30 seconds and again hold glow plug switch for two minutes. If engine does not start after 10 seconds cranking, wait for 30 seconds before repeating starting procedure.

2. With glow plug switch held in the UP position, push the ignition switch to the START position.

3. After engine has started, continue to hold the glow plug switch in the UP position until the oil pressure safety switch closes (when engine develops sufficient oil pressure). The glow plug switch will automatically be in the OFF position when released.

b. Stopping Instructions

1. Push ignition switch to the OFF position.

2-6

2.4 CONTROL CIRCUIT OPERATION

WARNING

Beware of moving V-Belts and belt driven components.

CAUTION The generator set circuit breaker must be in the ON position in order to supply power to the refrigeration unit.

When the glow plug switch is held in the pre-heat position, current flows to the glow plugs. The glow plugs (starting aids) provide a source of heat to pre-heat the combustion chamber during start-up. Power also flows to the run control relay which energizes, and closes the RCR contacts. From the relay RCR, power flows through the high water temperature switch to ground.

In order to start engine, hold the glow plug switch in the UP position for the recommended time as detailed in section 2.3 and then hold the ignition (Start-Run-Off) switch in the START position. With ignition switch in the

START position, starter solenoid is energized closing starter motor contactor contacts (SS), which energizes starter motor. The starter motor turns over the engine resulting in pumping fuel to the engine cylinders by the injection pump. This fuel is ignited by heat of compres- sion; thus starting the engine. Also, run control relay is energized at the same time to close a set of contacts and completes a circuit to the fuel solenoid.

When the engine has developed sufficient oil pres- sure, oil pressure safety switch contacts close to maintain a circuit to the run control relay. Energizing this relay closes (RCR) contacts providing a circuit to keep the fuel run solenoid energized as long as the safety switch contacts remain closed. The glow plug switch is then released and the ignition switch is released to the RUN position. Releasing glow plug switch de-energizes the glow plugs.

Total time meter is energized simultaneously with the fuel solenoid.

With the engine running, the belt-driven alternator provides 12-volt d-c power to operate the control system and charge the battery.

3-1

SECTION 3

TROUBLESHOOTING

3.1 DIESEL ENGINE

INDICATION/ REFERENCE TROUBLE POSSIBLE CAUSES SECTION

3.1.1 Engine Will Not Start

a. Starter motor Battery insufficiently charged Charge will not crank or low Battery terminal post or Battery defective Check cranking speed.

Bad electrical connections at starter Correct Starter motor malfunctions 3.1.3 Starter motor solenoid defective Engine Manual Open starting circuit 3.1.4 Incorrect grade of lubricating oil 1.3

b. Starter motor No fuel in tank 1.3 cranks but engine Air in fuel system 4.2 fails to start Water in fuel system Drain Sump

Plugged fuel filters Replace Faulty fuel control operation 4.3.3 Run control relay 4.3.3 Glow plug(s) defective 4.3.7 Plugged fuel lines to injector(s) Engine Manual

c. Starter cranks, Engine lube oil too heavy 1.3 engages but dies Voltage drop in starter cable(s) Check after a few seconds

3.1.2 Engine Starts Then Stops

a. Engine stops No fuel in tank 1.3 after several Faulty fuel control operation 4.3.3 rotations Fuel filter(s) restricted Replace

Air cleaner or hose restricted 4.3.5 Safety device open 1.4 Open wiring circuit to run solenoid Check Fuel solenoid linkage disconnected 4.3.3 Oil pressure switch defective Replace Fuel supply restricted Engine Manual Leak in fuel system Engine Manual Injector nozzle(s) defective Engine Manual Injection pump defective Engine Manual

3-2

INDICATION/ REFERENCE TROUBLE POSSIBLE CAUSES SECTION

3.1.3 Starter Motor Malfunction

a. Starter motor Battery insufficiently charged Charge will not crank or Battery cable connections loose or oxidized Check turns slowly

Battery cables defective Replace Starter brushes shorted out Engine Manual 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 1.3

b. Starter motor Pinion or ring gear obstructed or worn Engine Manual turns but pinion does not engage

c. Starter motor Ignition switch defective Replace does not disengage Starter motor solenoid defective Engine Manual after switch has been released

d. Pinion does not Defective starter Engine Manual disengage after engine is running

3.1.4 Malfunction In the Engine Starting Circuit

a. No power to Battery defective Correct starter motor Loose electrical connections Tighten solenoid

b. Fuel solenoid Battery defective Correct does not energize or Loose electrical connections Tighten does not remain Water temperature safety switch open 1.4 energized Oil pressure switch defective Replace

Run control relay defective 4.3.3 Fuel solenoid defective 4.3.3 Ignition switch defective Replace

3.1.5 Miscellaneous Engine Troubleshooting

a. Loss of power Restriction in air cleaner 4.3.5 Air in fuel system 4.2 Air vent in fuel cap restricted Clean Restricted fuel lines Engine Manual Defective fuel injection pump Engine Manual Defective injector(s) or incorrect type Engine Manual Incorrect fuel injection pump timing Engine Manual Incorrect valve timing Engine Manual Poor compression Engine Manual

3-3

INDICATION/ REFERENCE TROUBLE POSSIBLE CAUSES SECTION

3.1.5 Miscellaneous Engine Troubleshooting (continued)

b. Vibration Engine shockmounts defective Replace Poor compression Engine Manual Fuel solenoid or linkage 4.3.3

c. Overheating Restriction in air cleaner 4.3.5 Exhaust pipe restriction Remove Restriction in water jacket Check Loose water pump V-Belt 4.5 Restriction in radiator 4.3.1 Coolant level too low 1.3 Defective thermostat Engine Manual Defective water pump Engine Manual

d. Excessive crankcase pressure Plugged crankcase breather line 4.3.6

3.2 ALTERNATOR (AUTOMOTIVE TYPE)

Battery Undercharged Defective cables, dirty battery posts or corroded terminals 4.4.1

Loose or broken belt 4.5 Worn or broken brushes 4.4.5 or 4.4.6 Defective alternator system 4.4.4 Defective wire harness Replace Broken brush 4.4.5 or 4.4.6 Defective alternator Replace

Battery Overcharged Defective alternator system Check -excessive use of water. Voltmeter indicates greater than 14.5 volts (connected across battery with no load) with engine idling.

Battery charges at idle, but Slipping belt 4.5 discharges under load conditions. Alternator defective Prestolite Manual

3-4

3.3 A-C BRUSHLESS GENERATOR (MAIN ALTERNATOR)

INDICATION/ REFERENCE TROUBLE POSSIBLE CAUSES SECTION

No voltage Loss of residual magnetism in exciter field 4.6.1 Circuit breaker tripped Check Open in stator windings 4.6.2 Open or short in rotating rectifiers 4.6.1 Short circuited 4.6.2 Open in alternator field 4.6.2 Shorted exciter armature 4.6.2

Low voltage Low engine speed 4.3.4 Excessive load Check High resistance connections --- connections

warm or hot Tighten Shorted field 4.6.2

Fluctuating voltage Fluctuating speed 4.3.4 (May be indicated by Irregular speed of engine Engine Manual flickering lights) Loose terminal or load connections Tighten

Defective bearing causing uneven air gap 4.6.1

High voltage Excessive engine speed 4.3.4

Overheating Generator overloaded Check Clogged ventilating screens Clean High temperature surrounding generator 4.3.1 Insufficient circulation 4.3.1 Unbalanced load Balance Dry bearing 4.6.1

Mechanical Noise Defective bearing 4.6.1 Rotor scrubbing on stator 4.6.1 Loose laminations 4.6.2 Loose or misaligned coupling 4.6.2

Generator frame Static charge Check ground produces shock to frame when touched Grounded armature of field coil 4.6.2

4-1

SECTION 4

SERVICE

This section covers service for the generator set and some engine servicing only. Refer to the Kubota engine workshop manual for other engine servicing. (Refer to chart in section 1.1)

WARNING Beware of moving V-Belts and belt driven components.

4.1 MAINTENANCE SCHEDULE

Unit Operation Reference ON/OFF Section

a. Daily Maintenance X 1. Pre-Trip Inspection --- before starting 2.2

X 2. Pre-Trip Inspection --- after starting 2.2 X 3. Check total time meter Run 10

minutes

b. First 400 Hour Maintenance

X 1. Pre-Trip Inspection --- before starting 2.2 X X 2. Change lube oil and filter 4.3.2 X 3. Pre-Trip Inspection --- after starting 2.2 X 4. Check total time meter Run 10

minutes

c. Every 1000 Hour Maintenance (Normal Operating Conditions) X X 1. Complete 400 Hour Maintenance 4.1.b.

X 2. Tighten engine and generator mounting bolts 4.7 X 3. Tighten all electrical connections in control box Tighten X 4. Clean air cleaner, check hose and connections 4.3.5 X 5. Check water pump bearing end play None X 6. Check alternator slip rings and brushes 4.4.4 X 7. Replace fuel filter 4.3.8

d. Every 3000 to 6000 Hour Maintenance X X 1. Complete a 400 and 1000 Hour Maintenance 4.1.b. &

4.1.c. X 2. Clean crankcase breather 4.3.6

X X 3. Clean and flush cooling system 4.3.1 X 4. Check starter condition Engine

Manual X X 5. Check engine compression Engine

Manual X 6. Check and adjust injector nozzles Engine

Manual X 7. Replace V-Belt 4.5

4-2

4.2 PRIMING THE FUEL SYSTEM The unit is equipped with a mechanical fuel lift pump,

it is mounted on the engine next to the injection pump.(Also, refer to section 4.3.8) This pump has a manual plunger for bleeding fuel when the fuel tank has been run dry.

Since the unit employs a closed fuel circuit, it is recommended to use the following steps:

1. Turn bleed valve (Red) counter-clockwise until fully opened (see Figure 1-1 or Figure 1-6).

2. Turn the top of the manual plunger counter-clock- wise to unlock it. (See Figure 1-1) Then, rapidly hand pump the manual plunger until a positive pressure (resistance) is felt, which will indicate fuel flow.

3. Depress and turn the top of the manual plunger clockwise to lock in place.

4. Start engine. (Refer to section 2.3) 5. When engine is running properly, turn bleed valve

clockwise until fully closed.

4.3 ENGINE SERVICE AND COMPONENTS 4.3.1 Cooling System

The radiator, externally and internally, must be clean for adequate cooling. The fan belt must be adjusted periodically to provide maximum air flow. (Refer to section 4.5)

Do the following to service the cooling system:

a. Remove all foreign material from the radiator coil by reversing the normal air flow (Force air in through the front of the radiator and discharge through the radiator toward the engine.) Compressed air or water may be used as a cleaning agent. It may be necessary to use warm water mixed with any good commercial dishwasher detergent. Rinse coil(s) with fresh water if a detergent is used.

b. Drain coolant completely by opening drain-cock and removing radiator cap.

CAUTION

Use only ethylene glycol, anti-freeze (with inhibitors) in system as glycol by itself will damage the cooling system. Always add pre-mixed 50/50 anti-freeze and water to radiator/engine. Never exceed more than a 50% concentration of anti-freeze. Use a low silicate anti-freeze meeting GM specifications GM 6038M or equal.

c. Close drain-cock and fill system with clean, untreated water to which three to five percent of an alkaline based radiator cleaner should be added; six ounces --- dry = 151 grams to one gallon (3.8 litre) of water.

d. Run engine 6 to 12 hours and drain system while warm. Rinse system three times after it has cooled down. Refill system with water.

e. Run engine to operating temperature. Drain system again and fill with treated water/anti-freeze. (See Caution note and refer to section 1.3.c.) NEVER POUR

COLD WATER INTO A HOT ENGINE, however hot water can always be added to a cold engine. 4.3.2 Lube Oil Filters

The full flow filter is located near the run solenoid as shown in Figure 1-1.

After warming up the engine, stop engine, remove drain plug from oil reservoir and drain engine lube oil. Lightly oil gasket on filter before installing.

Replace filters and add lube oil. (Refer to section 1.3) Warm up engine and check for leaks. 4.3.3 Servicing the Fuel Solenoid and Linkage

1

2

3

4

5 6

RUN CONTROL LEVER

2.47 (6.27cm.)

(8.18cm.) 3.22

ENERGIZED

DE-ENERGIZED

1. Solenoid 4. Clip 2. Solenoid Bracket 5. Linkage Rod 3. Spring 6. Boot

Figure 4-1. Fuel Solenoid Assembly

NOTE Periodically grease (P/N 07-00245-00) Fuel Solenoid plunger.

a. Remove spring linkage from injection pump run lever (item 3, Figure 4-1).

b. Disconnect wiring to solenoid. Remove clip (item 4) from linkage rod (item 5). Remove mounting hardware from solenoid and then remove solenoid.

c. Install new solenoid and mounting hardware, connect wiring. Place ignition (Start-Run-Off) switch in the START position to energize solenoid. Check ener- gized dimension as shown in Figure 4-1. Turn switch OFF. Check de-energized dimension. If energized dimension needs adjusting, loosen solenoid mounting bolts and move solenoid.

4-3

d. Energize solenoid and check clearance.

e. If the engine does not shut off when the fuel solenoid is de-energized, loosen the four (4) mounting bolts and move the solenoid toward the lever until it shuts off. Tighten the mounting bolts.

4.3.4 Adjusting Engine Speed

The engine speed operates at 1820 to 1840 rpm (no load), 1710 rpm (with load).

Two methods to check engine speeds are:

a. With the engine stopped, place a mark (white paint for example) on the crankshaft sheave. Start engine and verify engine speed by using a Strobette-model 964 (Strobetachometer), Carrier Transicold Part No. 07-00206.

b. With the engine stopped, the second method of checking engine speed is by using a frequency (hertz) meter. Attach one lead to CB-1 terminal 1, Section 5, electrical schematics, and the other to chassis ground. Start engine and 60.5 hertz will be 1820 rpm and 61.3 hertz will be 1840 rpm (no load).

1

2

3

1. Speed Lever 2. Jam Nut B 3. Capscrew B

Figure 4-2. Speed Adjustment

To Increase Speed:

Loosen jam nut B. Turn capscrew B clockwise until correct speed is achieved, then tighten jam nut B and check engine speed.

To Decrease Speed: Loosen jam nut B. Turn capscrew B counter-

clockwise until correct speed is achieved, then tighten jam nut B and check engine speed.

4.3.5 Engine Air Cleaner a. Inspection

The air cleaner should be inspected constantly for leaks. A damaged air cleaner or hose can seriously effect the performance and life of the engine. The following simple service steps are easily made while the engine is being serviced in the field.

The simple service steps are as follows:

1. Watch all connections for mechanical tightness. Be sure cleaner outlet pipe is not fractured.

2. If cleaner has been dented or damaged, check all connections immediately.

3. In case of leakage and if adjustment does not correct the trouble, replace necessary parts or gaskets. Swelled or distorted gaskets must always be renewed.

b. Service Procedure

1. Empty dust cover as required. Check to see that the vacuator is not inverted, damaged or plugged.

2. Stop the engine, remove and clean the dust cap. Remove the dirty element from the air cleaner. Install new filter and tighten wing nut securely.

3. Install dust cover, making sure it seals 360_ around the air cleaner body. Check all connections between the air cleaner and the engine to be certain that they are tight and leak-free.

1234 5

1. Body Assembly 2. Primary Element 3. Clamp

4. Dust Cap 5. Vacuator

Figure 4-3. Air Cleaner

4.3.6 Engine Crankcase Breather

Both engines use a closed type breather with the breather line attached to the cylinder head cover. (See Figure 4-4)

2 3 4 5 6

1

8

7

1. Cylinder Head Cover 5. Breather Oil Shield 2. Breather Cover 6. Capscrew 3. Breather Element 7. Breather Assembly 4. Plate 8. O-Ring

Figure 4-4. Engine Crankcase Breather

The breather assembly should be cleaned once a year or at every 3000 hours maintenance interval (whichever comes first).

4-4

4.3.7 Servicing Glow Plugs

The glow plugs are parallel connected and when energized, draw 7.5 amps at 12 vdc. When servicing, the glow plug is to be fitted into the cylinder head to prevent damage to the glow plug.

Torque value for the glow plugs is 28.9 to 36.2 ft-lb (4.0 to 5.0 mkg).

Checking for a Defective Glow Plug:

a. One method is to remove the injector and then energize the glow plug. The glowing tip may then be observed.

b. Another method is to place an ammeter (or clip-on ammeter) in series with each glow plug and energize the plugs. Each plug (if good) should show amperage draw.

4.3.8 Servicing Fuel Pump

a. Mechanical Pump (See Figure 4-5)

Due to foreign particles in the fuel and wax as a result of using the wrong grade of fuel or untreated fuel in cold weather, the fuel filter may become plugged or restricted. The filter must be cleaned on a regular schedule such as unit pre-trip or when the oil and fuel filters are changed. (Refer to section 4.1)

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

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 re- move. Check and clean.

4. To install reverse steps 1 through 3.

12

3

1

4

1. Nut 2. Banjo

3. Filter 4. Copper Rings

Figure 4-5. Mechanical Fuel Pump

4.4 SERVICING THE ALTERNATOR 4.4.1 Preliminary Checks and Tests

NOTE Before starting the actual electrical test procedure, the charging system, battery and wiring should be checked to eliminate possible problem areas. Figure 1-9 (37 Amp) or Figure 1-10 (65 Amp) identifies the terminals on the rear of the alternator.

a. Check the condition and adjustment of belts. 1. Check belt adjustment. (Refer to section 4.5) 2. Replace any worn or glazed belts.

b. Check to see that all terminals, connectors and plugs are clean and tight.

1. Loose or corroded connections cause high resistance and this could cause overcharging, under- charging or damage to the charging system.

2. Badly corroded battery cables could prevent the battery from reaching a fully charged condition.

c. Check battery condition and charge if necessary. A low or discharged battery may cause false or misleading readings when conducting in-unit tests.

4.4.2 Test Tools A list of the following tools is provided to perform

tests on the alternator and its components. a. Volt-ohm meter b. Single-pole, single throw switch c. 12 vdc lamp d. Insulated 12 gauge stranded wire e. Alligator clamp terminals

4.4.3 Problem Area Determination CONDITIONS: Engine running for all tests (unless

otherwise specified). a. Battery Undercharged

1. Perform open diode-trio test. (Refer to section 4.4.4)

2. Perform regulator tests. (Refer to section 4.4.4) If regulator is alright, the cause is probably an open field circuit, and alternator must be removed for repair.

3. Further investigation requires alternator removal and repair (diodes). b. Battery Overcharged

1. Perform alternator output test. (Refer to section 4.4.4)

2. Regulator shorted. Replace regulator.

4.4.4 In-Unit Alternator/Regulator Tests Test No. 1 --- Open Diode-Trio Test --- 37 AMP

CONDITIONS: Engine running (after proper hook- up is made and test leads connected) with no electrical loads.

a. Remove regulator from alternator housing (refer to section 4.4.8) leaving leads connected. Add jumper (JUI) between the output and regulator terminals and connect voltmeter as shown in Figure 4-6.

4-5

b. Start engine. If voltmeter now indicates 13.75 to 14.75 volts, the Diode-Trio is open and must be replaced. If the voltmeter indication is not in this range, remove the jumper (JUI) and proceed to the regulator test (Test No. 2).

d

WHITE

BLACK

NEGATIVE

HOUSING GROUND

BATTERY

+ OUTPUT

REG

RED

JU1

OUTPUT

VOLTS AMPS

BLACK

GREATER THAN 15V

RED

12vdc TEST LAMP

d+

TOGGLE SWITCHBATTERY

EXCITATION

Figure 4-6. Open Diode-Trio Test --- 37 Amp

Test No. 2 --- Open Regulator Test --- 37 AMP

NOTE

Before performing test, connect an insulated jumper between regulator and field terminal. Loosely mount regulator to alternator with the two screws for test.

CONDITIONS: Engine running (after proper hook- up is made and test leads connected) with alternator, regulator and voltmeter setup as shown in Figure 4-7, see above note.

a. After jumper addition, the test lamp should now be illuminated, with switch ON and engine stopped, thus indicating an open regulator. If lamp is still not on, check bulb and harness. If lamp is still not on, an open field circuit (brushes, slip-rings, etc.) is indicated, the alterna- tor must be removed for repair.

b. If the lamp is now illuminated (with switch ON and engine stopped), run engine with no loads. Voltmeter should indicate 15.0 volts or greater. If voltage is less than 15.0 volts, the alternator is defective (diodes, etc).

Test No. 3 --- Alternator Output Test --- 37 AMP CONDITIONS: Engine running (after voltmeter is

connected as shown in Figure 4-7). Start unit and run engine with load. With the unit

operating (placing a load on charging circuit) check for nominal system output voltage of between 13.8-14.8 volts for a properly operating charging system. (Voltages may vary a few tenths of a volt, higher or lower, due to ambient temperature variations.) If the alternator output voltages does not fall within the proper range, the alternator should be disassembled for further inspection and tests. (Refer to Prestolite manual).

WHITE

BLACK

NEGATIVE

RED

REG

REG

+ OUTPUT

BATTERY

HOUSING GROUND

JU1

BLACK

OUTPUT

13.75-14.75V

VOLTS AMPS RED

12vdc TEST LAMP

d+

TOGGLE SWITCHBATTERY

EXCITATION d

Figure 4-7. Open Regulator Test --- 37 Amp

Test No. 1 --- Open Diode-Trio Test --- 65 AMP CONDITIONS: Start-run-stop switch (SRS) in RUN

position and engine stopped (after proper hook-up is made and test leads connected). No electrical loads.

a. With jumper not attached. Check for battery voltage at terminal A and for 1.5 to 3.0 volts at terminal B, see Figure 4-8.

b. Add jumper JU1 between terminals A and B. Start engine and run with no load. If the test lamp now goes off, and charging voltage is present at terminal A (more than battery voltage), the diode-trio is open. Alternator should be removed for repair. If the voltmeter indication is not in this range, remove the jumper and proceed to the regulator test (Test No. 2).

4-6

d

12vdc TEST LAMP

d+

TOGGLE SWITCH

BATTERY D+ AC TAP (TACH.)

GROUND

EXCITE

INTEGRAL REGULATOR

POS+ OUTPUT (B+)

BATTERY

BLK

VOLTS

B A

RED

JU1

STEP TEST POINT INDICATION

1

2

3

A (B+)

B (REG)

BATTERY VOLTAGE

1.5 TO 3.0 VOLTS WITH TEST LAMP ON

13.5 TO15.0 VOLTS (JUMPER ATTACHED ENGINE RUNNING)

A (B+)

SENSE TO BATTERY

*

*

* JUMPER NOT ATTACHED

**

**

REMOTE BATTERY SENSE ONLY

(TO OIL PRESSURE SWITCH OR TOGGLE SWITCH )

Figure 4-8. Open Diode-Trio Test --- 65 Amp

Test No. 2 --- Open Regulator Test --- 65 AMP

CONDITIONS: Engine stopped (start-run-stop switch in the RUN position) and voltmeter set-up as shown in Figure 4-9.

NOTE

Before performing test, removal of back cover is required. To remove, disconnect wires from terminals extending through back cover. Remove back cover (two screws) and reconnect all wires.

a. With jumper not attached, check for battery voltage at terminals A and B. Test lamp will be off.

b. Add jumper JU1 between field and ground (see Figure 4-9). If 1.5 to 3.0 volts is present at terminal B and the test lamp is on, the regulator is open. Alternator should be removed for repair.

B A

D+

AC TAP (TACH.)

POS + OUTPUT (B+)

FIELDGROUND

INTEGRAL REGULATOR

EXCITE JU1

BATTERY

VOLTS

BLK

RED

STEP TEST POINT INDICATION

1

2

3

A (B+)

B (REG)

BATTERY VOLTAGE

B (D+)

SENSE TO BATTERY

BATTERY VOLTAGE WITH TEST LAMP OFF

JUMPER ATTACHED. 1.5 TO 3.0 VOLTS. TEST LAMP ON

d

12vdc TEST LAMP

d+

TOGGLE SWITCH

BATTERY

* JUMPER NOT ATTACHED

** REMOTE BATTERY SENSE ONLY

*

*

** (TO OIL PRESSURE SWITCH OR TOGGLE SWITCH )

Figure 4-9. Open Regulator Test --- 65 Amp

Test No. 3 --- Alternator Output Test --- 65 AMP CONDITIONS: Engine running (after voltmeter is

connected as shown in Figure 4-10).

VOLTS

AC TAP (TACH.)

POS+ OUTPUT (B+)

BATTERY

GROUND INTEGRAL REGULATOR

EXCITE

BLK

RED POS + OUTPUT 13.8 TO 14.8V

D+

(TO OIL PRESSURE SWITCH OR TOGGLE SWITCH)

SENSE TO BATTERY

d

12vdc TEST LAMP

d+

TOGGLE SWITCH

BATTERY

** REMOTE BATTERY SENSE ONLY

**

Figure 4-10. Alternator Output Test --- 65 Amp

4-7

a. Start unit and run engine with load. With the unit operating (placing a load on charging circuit) check for nominal system output voltage of between 13.8 --- 14.8 volts for a properly operating charging system. (Voltages may vary a few tenths of a volt, higher or lower, due to ambient temperature variations.)

b. If the alternator output voltage does not fall within the proper range, the alternator should be removed for further inspection and tests. (Refer to Prestolite manu- al.)

4.4.5 Alternator Brush Test Procedure --- 37 AMP a. Removing Brush Set

It may be advantageous to remove the alternator from the unit. (Refer to section 4.4.8)

1. Remove wiring to alternator (three wires) and then remove four screws securing regulator to alternator.

2. Slowly, pull regulator away from alternator and disconnect green wire from brush assembly. Remove two screws securing brush assembly to brush cavity.

3. Check slip rings for carbon build-up. 4. Check brush assembly for chipped or oil on

brushes. Remaining brush length should be at least 3/16 inch (4.8 mm) long. b. Brush Continuity Check --- 37 AMP

Using a 12 vdc test lamp or ohmmeter, test brush assembly for continuity and insulation as shown. Remove brush assembly if necessary.

CONTINUITY CHECK

Continuity A to C OK Continuity D to E OK No Circuit C to E OK

D

E

A

C

NEGATIVE GROUND

Figure 4-11. Alternator Brush Assembly --- 37 Amp

4.4.6 Alternator Brush Test Procedure --- 65 AMP

NOTE

Before performing test, removal of back cover is required. To remove, disconnect wires from terminals extending through back cover. Remove two screws securing back cover to rear housing and remove cover.

a. Removing Brush Set 1. Remove two locknuts securing brush holder and

remove brush assembly.

2. Check brush assembly for cracked, chipped or oil soaked brushes. Remaining brush length should be at least 3/16 inch (4.76 mm) long.

3. Check slip rings for carbon build-up. 4. Using a 12 vdc test lamp or ohmmeter, test brush

assembly for continuity and insulation (see Figure 4-12). Replace brush assembly if necessary. b. Brush Continuity Check --- 65 AMP

Using a 12 vdc test lamp or ohmmeter, test brush assembly for continuity and insulation as shown. Remove brush assembly if necessary.

CONTINUITY CHECK

Continuity A to B OK Continuity C to D OK No Circuit A to C OK No Circuit A to D OK No Circuit B to C OK No Circuit B to D OK

A

D

C

B

Figure 4-12. Alternator Brush Assembly --- 65 Amp

4.4.7 Slip Ring Servicing Clean brush contacting surfaces with fine crocus

cloth. Wipe dust and residue away. If surfaces are worn beyond this restoration, replace

entire rotor assembly. 4.4.8 Alternator Installation

Installation: a. Make sure negative battery terminal is discon-

nected. b. Install alternator to mounting bracket with the

alternator pivot bolt and adjustment arm bolt loosely in position.

c. Place V-Belt on alternator sheave. d. Check the center alignment of the generator

driving pulley and alternator pulley, to ensure proper drive. Pulley misalignment will create excess belt wear and limit alternator bearing life. The center line of the alternator sheave, and the driving sheave must be in line.

e. Pivot alternator to place tension on belt. For correct belt tension refer to section 4.5.2. Tighten pivot and adjustment bolts.

f. Connect wiring to alternator. g. Connect battery cable. Start unit and check for

output per section 4.4.3.

4-8

4.5 SERVICING AND ADJUSTING V-BELT WARNING

Beware of moving V-Belts and belt driven components

NOTE Frayed, cracked or worn V-Belts must be replaced. After installing a new belt, it is advisable to check the adjustment after running the unit for three or four hours. This is to allow for the initial stretch which is common on new belts. Once this initial stretch has taken place the belt may be checked at regular intervals.

4.5.1 Water Pump V-Belt

The water pump V-Belt is driven by a sheave on the engine crankshaft. Adjustment is achieved by altering position of the idler pulley. a. Replacing the V-Belt

1. Loosen the idler bracket pivot bolt.

2. Replace belt. Use hand force only on idler pulley to tighten belt. Do not use pry bar or excessive force as it may cause water pump bearings to fail. When belt is tight, tighten idler bracket pivot bolt.

3. Check belt tension, correct specifications are 40-45 lbs. on the Burroughs gauge Carrier Transicold P/N 07-00203.

4.5.2 Alternator V-Belt The alternator V-Belt is driven by a sheave on the

generator drive shaft. Adjustment is achieved by pivoting the position of the alternator. a. Replacing the V-Belt

1. Loosen the alternator pivot bolt and capscrew on adjustment arm.

2. Replace belt. Use hand force only on alternator to tighten belt. Do not use pry bar or excessive force as it may cause bearing failure in the alternator. When belt is tight, tighten the alternator bolts.

3. Check belt tension, correct specifications are 40-45 lbs. on the Burroughs gauge Carrier Transicold P/N 07-00203.

4.6 SERVICING THE GENERATOR (MAIN ALTERNATOR)

4.6.1 Preventive Maintenance and Operating Precautions

Costly repairs and down time can usually be pre- vented by operating electrical equipment under condi- tions which are compatible with those at which the equipment was designed to operate. Follow the instruc- tions outlined below to ensure maximum efficiency of the electrical equipment. a. Cooling

Keep all cooling parts clean and make certain sufficient room is left on all sides for a plentiful supply of fresh coolant air flow. DO NOT EXCEED TEMPERA- TURE RISE AS SHOWN FOR 80_C (176_F) ABOVE A

40_C (104_F) AMBIENT. This ensures that the insulation NEMA Class F 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. b. Bearing Replacement

Factory lubricated shielded bearings will normally provide several years of trouble free service when operated under normal conditions. Excessive bearing load and adverse environment conditions will greatly shorten bearing life. Should bearing failure occur, bearings can be replaced. ALWAYS REPLACE WITH THE SAME TYPE BEARING AS INSTALLED AT THE FACTORY. CHECK PARTS LIST FOR PART NUMBER. Include generator serial number when ordering bearings.

Do the following to remove bearing: 1. Remove bearing cap. (See Figure 4-13) 2. Remove bearing with the use of a bearing or wheel

puller. 3. Install new bearing. Ball bearings on Lima genera-

tors are pre-lubricated and require no further lubrication for the life of the bearing.

4. Replace end cap.

2

1

3

4

1. Bolt 3. Bearing 2. Bearing Cap 4. Rotating Diode Bridge

Figure 4-13. Rectifier Removal

c. Rotating Diode Bridge (Rectifier Assembly) Replacement The rotating diode bridge can be removed and

replaced. Over-current, over-voltage, over-speed, or reverse currents can cause damage to the assembly or any of the component parts. The rotating diode bridge may be removed through the bearing cap on the rear of the generator. (See Figure 4-13 and Figure 4-14)

1. Remove the bearing cap by removing the four bolts shown in Figure 4-13 and both the bearing and rectifier assembly will be visible.

2. Use a bearing puller to remove the bearing from main shaft being careful to locate the puller on the inner race of the bearing to avoid bearing damage. Once the

4-9

bearing is free, it is then necessary to disconnect the alternator and exciter rotor leads as shown in Figure 4-13.

3. Remove the three hold-down cap screws which secure the rectifier assembly to its adapter. Once this procedure is complete the rectifier assembly is free for removal.

Follow the testing procedures outlined in section 4.6.1.

After the rectifier assembly has been repaired or replaced, reverse the procedure as stated above, being careful that all lead connections are tight and that set screws are locked with Loctite. (Loctite Corporation)

1

2 2

11

1. Exciter Rotor Lead 2. Alternator Rotor Lead

Figure 4-14. A-C Generator (Rectifier Assembly)

d. Testing Diodes With An Ohmmeter

A A C C

RED LETTERING BLACK LETTERING

R After Number Forward Reverse Polarity Polarity Diode Diode A (+) = Anode C (---) = Cathode

Figure 4-15. Diode Testing

1. Remove the diode from the circuit. Do not press body out of heat sink. Disconnect the lead. Do not use excessive heat in unsoldering the lead.

2. A good diode should have a low resistance when the + of an ohm meter is connected to the anode and the --- to the cathode, and a high resistance when the polarity of the ohmmeter is reversed. (See Figure 4-15)

If both resistances are high or both are low, then the diode is defective and should be replaced.

e. Rotor Damage The damper bars of the generator prevent excessive

hunting when AC generators are operated in parallel. Damper bars, because they must have a low electrical resistance and are subjected to extreme centrifugal forces, must be mechanically secure and permanent. Consequently, they are welded to end plates completely covering the field.

All rotors are static and dynamically balanced to a high degree on precision machines to assure minimum vibration. They will, therefore, remain dynamically stable at speed well beyond the synchronous speed of the generator. The rotors on generators are, however, subjected to extreme centrifugal forces which can in- crease beyond safe operating limits at over-speed. Therefore, the prime mover should be adequately governed to prevent over-speed.

Damage to the rotor can also occur due to overheat- ing which can be caused by the air flow being restricted from dust or other foreign objects collecting in the air passage.

If a rotor becomes defective, it should be returned to the factory with full nameplate data, because the rotor coils are enclosed in welded squirrel case winding. To repair a rotor the special tooling and technique of the factory is necessary and essential. Should a failure occur, Carrier Transicold should be notified immediately and steps will be taken to get the generator back into service with the least expense; and more important, to determine the cause of the failure and take steps to prevent a recurrence. f. Generator Windings (Drying)

Generators that have been in transit or storage for long periods may be subjected to extreme temperature and moisture changes. This can cause excessive con- densation, and the generator windings should be thor- oughly 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. (a)Place generator in drying oven or hot room. (b)Dry with warm air blower directed through

windings. 2. (a)If the generator has been operated and then

put into storage for any period of time, a P.D. George #11127 type air-dry fungus resistant varnish should be applied.

Experience has shown that it is necessary to take these precautions in locations such as seaboard installations and other highly humid areas. Some installations will be in atmospheres that are much more corrosive than others. A little precautions along the lines outlined here could eliminate an unnecessary repair job.

Each generator was subjected to a standard NEMA insulation test, which means 1000 volts plus twice the highest voltage for which the generator is rated was impressed between the winding and frame. All machines are insulated with a high safety factor for the class of insulation used. The latest and newest in insulation and baking techniques are used.

4-10

The finest insulation job can be very quickly broken down by carelessly applying high voltage to windings in a moisture saturated condition. Mishandling in this respect can easily cause a breakdown, making it necessary to return the generator to the factory for repair, and consequent expense and loss of time.

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 low insulation leakage.

g. 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.

WARNING

When trying to restore residual magnetism, be sure to wear leather gloves and use a fused insulated 12 gauge (or larger) jumper wire. Cut off all but a few strands from both ends of the jumper wire.

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. If not, an alternate method may be used. 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 and then remove. It is suggested that a 30 ampere fuse be inserted in 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.

4.6.2 Installation and Removal a. Removing the Generator

1. Remove ground wire from frame of generator set.

2. Remove generator leads from power junction box, then remove four 1/4-20 x 1/2 thread cutting screws securing box to generator.

3. Remove screen from coupling end of generator.

4. Remove five 3/8-24 x 3/4 hex head screws and washers securing generator disc to engine flywheel. (A

socket brazed to a flexible shaft and an offset wrench are required to remove the bolts.) Turn bolts counter-clock- wise with offset wrench to start, then use flexible shaft and socket assembly for removal of bolts.

5. Remove six 5/16-18 x 1-1/4 bolts and washers that secure generator to engine housing. Two bolts are 5/16-18 x 1-1/2 lg. (Secure bracket)

6. Remove mounting foot hardware, then remove generator.

b. Installing the Generator

The generator is a single bearing type which means the shaft end of the rotor floats. Before installing generator, rotate shaft and check if bearing rotates.

The use of stud guides, two in bell housing (5/16-18 x 2 lg) and two in the flywheel (3/8-24 x 2-1/2 lg) will make installation easier. These studs should have a square or hex design on the end opposite the threads. This is necessary to remove studs after generator is installed.

1. Remove screen covering from shaft end of genera- tor and brush anti-seize lubricant (lube-plate) on the face of flywheel.

2. Move generator (with hoist) into position and line up with the studs on housing and flywheel. Turn crankshaft (with large wrench) to align flywheel with generator, if necessary.

NOTE

It may be necessary to apply pressure under the cooling fan to align the generator with the flywheel counterbore.

3. Start the 3/8-24 bolts (by hand) through the disc plate and into the flywheel.

4. Secure two of the housing bolts (5/16-18) to draw the mating flanges together.

5. Remove studs and secure remaining bolts and washers. The 5/16-18 bolts (six) are to be torqued to a value of 15 2 ft-lb (2 0.3 mkg). The 3/8-24 bolts (five) are to be torqued 25 2 ft-lb (3 0.3 mkg).

NOTE

Install new gaskets (one between generator and junction box and the other between box and cover) when installing junction box.

6. Install screen cover, mounting bolts, power junc- tion box and wiring. Torque generator mounting bolts (5/8-11) to a value of 70 ft-lb (9.68 mkg).

4.7 REPLACING SHOCKMOUNTS

The engine and generator use different style shock- mounts and hold down hardware.

4.7.1 Replacement Criteria When the neoprene shockmount has been cut, split,

abraded or has flared due to wear from bolts and normal deterioration.

4-11

4.7.2 Shockmount Replacement

a. Engine

1. Remove the two 1/2-13 x 3 inch long capscrews. (Loctite has been applied to these bolts.) Place sling or other device under engine (near oil reservoir) and slowly raise the engine enough to remove the engine mounting shockmounts. (The fan may have to be rotated to prevent striking the fan shroud.)

2. Install shockmounts and flat washers as shown in Figure 4-16.

3. Apply Loctite EV (purple in color) to threads of bolts.

4. Lower engine, secure, and torque shockmount bolts to a torque value of 45 2 ft-lb (6.2-0.2 mkg).

b. Generator

1. Remove the two 1/2-13 x 3-1/2 inch long capscrews. (Loctite has been applied to these bolts.) Using lifting eye in generator, slowly raise enough to replace shock- mounts.

2. Install shockmounts and flat washers as shown in Figure 4-16.

3. Apply Loctite EV (purple in color) to threads of bolts.

4. Lower generator, secure, and torque shockmount bolts to a torque value of 45 2 ft-lb (6.2-0.2 mkg).

SHOCKMOUNT

FLAT WASHER

FRAME

Figure 4-16. Shockmount Installation

4.8 MAINTENANCE OF PAINTED SURFACES

The unit is protected by a special paint system against the corrosive atmosphere in which it normally operates. However, should the paint system be damaged, the base metal can corrode. In order to protect the unit from the highly corrosive sea atmosphere or if the protective paint system is scratched or damaged:

1. Clean area to bare metal using a wire brush, emery paper or equivalent cleaning method.

2. Immediately following cleaning, spray or brush on a zinc rich primer.

3. After the primer has dried, spray or brush on finish coat of paint to match original unit color.

4-12

4.9 REPLACING INDEX PIN OR ADJUSTING CLAMPING DEVICE

1 2

3 4

56 7

8

.65 inch (16.51 mm)

1. Handle 5. Chamfer 2. Cylinder 6. L Hook Shaft 3. Index Pin 7. Insert Drift Pin Here 4. Crown 8. Spring Clip

Figure 4-17. Clamping Device and Index Pin

a. Replacing Index Pin (See Figure 4-17) If necessary to replace a damaged pin in the L shaft, do

the following:

1. Simultaneously release spring clip and lift handle to open the clamping device L shaft.

2. With a wrench placed on the L portion of the bar, rotate the L hook 90_ in either direction.

3. With a drift pin or punch (3/8 = 9.5 mm diameter or smaller), drive remaining portion of pin out of the bar.

4. Rotate L hook 90_ to original position.

5. Drive new pin in place with crown end up.

6. If necessary to replace spring clip, remove two socket head screws and install new spring clip. b. Adjusting Clamping Device (See Figure 4-18)

The clamping device L hook shaft (see Figure 4-18) must be .65 inch (21/32 = 16.51 mm) between the head of clamping device and the inside of the L hook shaft to ensure that the generator set is tightly secured to the container.

To adjust or replace L hook shaft, do the following:

1. Rotate index pin 90_ and drive the pin out of the L shaft.

2. Rotate the L shaft and the piston will rotate inside of the cylinder. When the two holes in the cylinder assembly line up, insert drift pin.

3. Place large wrench on the L shaft and turn counter-clockwise to remove. Turning clockwise de- creases the dimension between the cylinder head and the inside of the L hook shaft.

4. Grease shaft with NEVER SEEZ after installing new shaft.

5. The clamping device is equipped with two grease fittings and should be greased annually and as required with NEVER SEEZ. Make sure the clamp assembly is in the lower position before greasing.

CAUTION

When replacing complete clamping device, apply thread sealer (Locktite h, brown in color) to the mounting bolts and torque bolts to a value of 50 to 60 ft-lbs (7.6 to 8.2 mkg).

1

23456 7

8

.65 inch (16.51 mm)

1. Clamp in Closed Position 5. Grease Fitting 2. L Hook shaft 6. Spring Latch 3. Grease Fitting 7. Latch Pin 4. Index Pin in Lock Position 8. Retaining Pin

Figure 4-18. Clamping Device in Closed Position

5-1

SECTION 5

SCHEMATICS

5.1 INTRODUCTION

This section contains Electrical Wiring Schematics and Diagrams covering the Models listed in Table 1-1. 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.

WARNING

Electrical power is generated by a Lima 15 KW, A-C generator. The generator provides a constant 460 or 230 vac, 3 phase, 60 hertz electrical supply.

WARNING

Beware of moving V-Belts and belt driven components.

WARNING

Before servicing unit, make sure the unit circuit breaker (CB1) and the start-stop switch are in the OFF position. Also disconnect power plug and cable.

Make sure the power plug(s) are clean and dry before connecting to any power receptacle.

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 low insulation leakage.

CAUTION

The generator set circuit breaker must be in the ON position in order to supply power to the refrigeration unit.

CAUTION

Observe proper polarity when installing battery, negative battery terminal must be grounded. Reverse polarity will destroy the rectifier diodes in alternator. As a precautionary measure, disconnect positive battery terminal when charging battery in unit. Connecting charger in reverse will destroy the rectifier diodes in alternator.

5-2

MECHANICAL LINKAGE ENGINE GROUND CHASSIS GROUND

5 A AMMETER 7 ALT ALTERNATOR 4 BAT BATTERY 3,8,13,16 CB CIRCUIT BREAKER 6,13,17 D DIODE 1 F FILTER (OPTIONAL) 2 FM FREQUENCY METER (OP- TIONAL) 14 FS FUEL SOLENOID 18 GP GLOW PLUG 16 GPS GLOW PLUG SWITCH 15 HWT WATER TEMP. SWITCH

11,12,13,14 IGN IGNITION SWITCH 15 LOP LOW OIL PRESSURE 8 L1 LIGHT 9 OPG OIL PRESSURE GAUGE 9 OPS OIL PRESSURE SENDER 14,15 RCR RUN CONTROL RELAY 5 SM STARTER MOTOR 5,11 SS STARTER SOLENOID 3,14 TB2 TERMINAL BLOCK (STUD) 12 TT TOTAL TIME METER 1 V VOLTMETER 6 VR VOLTAGE REGULATOR 10 WTG WATER TEMP. GAUGE 10 WTS WATER TEMP. SENDER

LINE SYMBOLLINE SYMBOL DESCRIPTION DESCRIPTION

Figure 5-1. Electrical Wiring Schematic --- Model 69GC15-104, -104-1 & -114 Drawing Number 69GC15-1144 Revision A (Sheet 1 of 2)

5-3

1 thru 10 are wires from A-C generator

Figure 5-1. Electrical Wiring Schematic --- Model 69GC15-104, -104-1 & -114 Drawing Number 69GC15-1144 Revision A (Sheet 2 of 2)

5-4

MECHANICAL LINKAGE ENGINE GROUND CHASSIS GROUND

5 A AMMETER 6 ALT ALTERNATOR 4 BAT BATTERY 3,8,11,16 CB CIRCUIT BREAKER 9,10,15 D DIODE 1 F FILTER (OPTIONAL) 2 FM FREQUENCY METER (OP- TIONAL) 11 FS FUEL SOLENOID 7,8 GP GLOW PLUG 7 GPS GLOW PLUG SWITCH 9 HWT WATER TEMP. SWITCH

10,11,12,13 IGN IGNITION SWITCH 10 LOP LOW OIL PRESSURE 16 L1 LIGHT 12 OPG OIL PRESSURE GAUGE 12 OPS OIL PRESSURE SENDER 9,11 RCR RUN CONTROL RELAY 5 SM STARTER MOTOR 5,17 SS STARTER SOLENOID 11 TB2 TERMINAL BLOCK (STUD) 14 TT TOTAL TIME METER 1 V VOLTMETER 6 VR VOLTAGE REGULATOR 13 WTG WATER TEMP. GAUGE 13 WTS WATER TEMP. SENDER

LINE SYMBOLLINE SYMBOL DESCRIPTION DESCRIPTION

Figure 5-2. Electrical Wiring Schematic --- Model 69GC15-114-1 Drawing Number 69GC15-1784 Revision --- (Sheet 1 of 2)

5-5

1 thru 10 are wires from A-C generator

Figure 5-2. Electrical Wiring Schematic --- Model 69GC15-114-1 Drawing Number 69GC15-1784 Revision --- (Sheet 2 of 2)

5-6

MECHANICAL LINKAGE ENGINE GROUND CHASSIS GROUND

5 A AMMETER 6 ALT ALTERNATOR 4 BAT BATTERY 3,8,11,16 CB CIRCUIT BREAKER 9,10,15 D DIODE 1 F FILTER (OPTIONAL) 2 FM FREQUENCY METER (OP- TIONAL) 11 FS FUEL SOLENOID 7,8 GP GLOW PLUG 7 GPS GLOW PLUG SWITCH 9 HWT WATER TEMP. SWITCH

10,11,12,13 IGN IGNITION SWITCH 10 LOP LOW OIL PRESSURE 16 L1 LIGHT 12 OPG OIL PRESSURE GAUGE 12 OPS OIL PRESSURE SENDER 9,11 RCR RUN CONTROL RELAY 5 SM STARTER MOTOR 5,17 SS STARTER SOLENOID 11 TB2 TERMINAL BLOCK (STUD) 14 TT TOTAL TIME METER 1 V VOLTMETER 6 VR VOLTAGE REGULATOR 13 WTG WATER TEMP. GAUGE 13 WTS WATER TEMP. SENDER

LINE SYMBOLLINE SYMBOL DESCRIPTION DESCRIPTION

Figure 5-3. Electrical Wiring Schematic --- Model 69GC15-134, -144, -154, -174 & -194 Drawing Number 69GC15-1284 Revision C (Sheet 1 of 2)

5-7

1 thru 10 are wires from A-C generator

Figure 5-3. Electrical Wiring Schematic --- Model 69GC15-134, -144, -154, -174 & -194 Drawing Number 69GC15-1284 Revision C (Sheet 2 of 2)

5-8

MECHANICAL LINKAGE ENGINE GROUND CHASSIS GROUND

5 A AMMETER 6 ALT ALTERNATOR 4 BAT BATTERY 3,8,11,16 CB CIRCUIT BREAKER 9,10,15 D DIODE 1 F FILTER (OPTIONAL) 2 FM FREQUENCY METER (OP- TIONAL) 11 FS FUEL SOLENOID 7,8 GP GLOW PLUG 7 GPS GLOW PLUG SWITCH 9 HWT WATER TEMP. SWITCH

10,11,12,13 IGN IGNITION SWITCH 10 LOP LOW OIL PRESSURE 16 L1 LIGHT 12 OPG OIL PRESSURE GAUGE 12 OPS OIL PRESSURE SENDER 9,11 RCR RUN CONTROL RELAY 5 SM STARTER MOTOR 5,17 SS STARTER SOLENOID 11 TB2 TERMINAL BLOCK (STUD) 14 TT TOTAL TIME METER 1 V VOLTMETER 13 WTG WATER TEMP. GAUGE 13 WTS WATER TEMP. SENDER

LINE SYMBOLLINE SYMBOL DESCRIPTION DESCRIPTION

Figure 5-4. Electrical Wiring Schematic --- Model 69GC15-184, -184-2 Drawing Number 69GC15-1984 Revision ---

(Sheet 1 of 2)

5-9

1 thru 10 are wires from A-C generator

Figure 5-4. Electrical Wiring Diagram --- Model 69GC15-184, -184-2 Drawing Number 69GC15-1984 Revision ---

(Sheet 2 of 2)

5-10

MECHANICAL LINKAGE ENGINE GROUND CHASSIS GROUND

5 A AMMETER 6 ALT ALTERNATOR 4 BAT BATTERY 3,8,11,16 CB CIRCUIT BREAKER 9,10,15 D DIODE 1 F FILTER (OPTIONAL) 2 FM FREQUENCY METER (OP- TIONAL) 11 FS FUEL SOLENOID 7,8 GP GLOW PLUG 7 GPS GLOW PLUG SWITCH

9 HWT WATER TEMP. SWITCH 10,11,12,13 IGN IGNITION SWITCH 10 LOP LOW OIL PRESSURE 16 L1 LIGHT 12 OPG OIL PRESSURE GAUGE 12 OPS OIL PRESSURE SENDER 9,11 RCR RUN CONTROL RELAY 5 SM STARTER MOTOR 5,17 SS STARTER SOLENOID 11 TB2 TERMINAL BLOCK (STUD) 14 TT TOTAL TIME METER 1 V VOLTMETER 13 WTG WATER TEMP. GAUGE 13 WTS WATER TEMP. SENDER

LINE SYMBOLLINE SYMBOL DESCRIPTION DESCRIPTION

Figure 5-5. Electrical Wiring Schematic --- Model 69GC15-184-1 Drawing Number 69GC15-2044 Revision A

(Sheet 1 of 2)

5-11

1 thru 10 are wires from A-C generator

Figure 5-5. Electrical Wiring Diagram --- Model 69GC15-184-1 Drawing Number 6

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