Contents

Carrier UG1600 Operation Manual PDF

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1 of 72

Summary of Content for Carrier UG1600 Operation Manual PDF

Diesel Generator Set

OPERATION AND SERVICE For

69UG15 Generator Set Units:

PID UG1400 Series PID UG1500 Series PID UG1600 Series PID UG1700 Series PID UG1800 Series PID UG1900 Series

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Carrier Corporation, 2015 Printed in U. S. A. March 2015

OPERATION AND SERVICE For

69UG15 Generator Set Units:

PID UG1400 Series PID UG1500 Series PID UG1600 Series PID UG1700 Series PID UG1800 Series PID UG1900 Series

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TABLE OF CONTENTS PARAGRAPH NUMBER Page

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.2 CONFIGURATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.3.1 Electronic Governor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.3.2 Engine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.3.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.3.4 Lube Oil Filter Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4 ENGINE SCREW THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.5 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.5.1 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.5.2 Alternating Current Generator Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.6 BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.7 OPERATING CONTROLS & INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.7.2 Control Panel and Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.8 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 2.9 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 2.10 ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.1 GENERATOR SET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.2 GENERATOR SET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.3 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.3.1 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.3.2 Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.3.3 Post-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.3.4 Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.4 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 4.1.3 Engine Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 4.1.4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 4.1.5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4.1.6 Miscellaneous Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.2 BATTERY CHARGER (SOLID STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.3 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.4 AUTO RE-START OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.5 DUAL SPEED OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 4.6 ELECTRONIC GOVERNOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SERVICE AND PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.2 PREVENTATIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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5.3 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.4 ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.4.1 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.4.2 Servicing Fuel Pump Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.4.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.4.4 InLine Fuel Strainer (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.4.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.4.6 Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.4.7 Servicing the Low Coolant Sensor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.4.8 Servicing Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.4.9 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.4.10 Replacing the Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.4.11 Servicing Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.4.12 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.4.13 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 5.4.14 Intake Heater Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.4.15 Intake Heater Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.4.16 Intake Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.5 SERVICING THE ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.5.1 Preventative Maintenance and Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.5.2 Generator Repair/Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 5.5.3 Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 5.5.4 Generator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.6 GENERAL GENERATOR SET MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.6.1 Maintenance Of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.6.2 Check and Replace Isolators/Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.7 UNIDRIVE TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510

SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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LIST OF ILLUSTRATIONS FIGURE NUMBER Page

Figure 2.1 Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Figure 2.2 Generator Set Top View (Top Frame Members Removed for Clarity) . . . . . . . . . . . . . . . . . . . . 24 Figure 2.3 Electronic Governor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 2.4 Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 2.5 Lube Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 2.6 A-C Generator Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Figure 2.7 Standard Control Panel and Box With Dual Speed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Figure 2.8 Customer Specific Control Panel and Box With Dual Speed Option . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 2.9 Auto Restart Control Box and Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Figure 3.1 Generator Set Mounting - Standard Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 3.2 Generator Set Mounting - Quick Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 5.1 Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Figure 5.2 Low Coolant Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 5.3 Air Cleaner, Dry Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Figure 5.4 Air Cleaner, Oil Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Figure 5.5 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Figure 5.6 Intake Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Figure 5.7 A-C Generator Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Figure 5.8 Rectifier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Figure 5.9 Truss and Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Figure 5.10 Engine Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Figure 5.11 Generator Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Figure 5.12 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 Figure 6.1 Schematic Diagram - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Figure 6.2 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Figure 6.3 Schematic Diagram 460 Volt Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Figure 6.4 Schematic Diagram - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Figure 6.5 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Figure 6.6 Schematic Diagram 460 Volt Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Figure 6.7 Schematic Diagram - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Figure 6.8 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Figure 6.9 Schematic Diagram 460 Volt Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Figure 6.10 Schematic Diagram - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 Figure 6.11 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611 Figure 6.12 Schematic Diagram 460 Volt Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 612 Figure 6.13 Schematic Diagram - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613 Figure 6.14 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614 Figure 6.15 Schematic Diagram 460 Volt Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 615

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LIST OF TABLES TABLE NUMBER Page

Table 21 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Table 22 Auto Restart Preset Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Table 23 Auto Restart Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Table 24 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Table 41 Miscellaneous Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Table 51 Preventative Maintenance Actions and Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511

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SECTION 1 SAFETY SUMMARY

GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and mainte- nance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cau- tions appearing elsewhere in the manual follows the general safety notices.

FIRST AID An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immedi- ately.

OPERATING PRECAUTIONS Always wear safety glasses and hearing protection. Keep hands, clothing and tools clear of the radiator fan and rotating belts. No work should be performed on the unit until all circuit breakers and start-stop switches are turned off and the negative battery terminal has been disconnected. Always work in pairs. Never work on the equipment alone. In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS Be sure power is turned off and the negative battery cable is disconnected before working on generator set. Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel. In case of electrical fire, open circuit switch and extinguish with CO2 (never use water). Fuel Tanks present explosion, fire and rupture hazards even if liquid fuel has been drained. Do not attempt any repairs, especially repairs using flame, welder or torch, unless you have been properly trained and the tank has been emptied of liquid fuel and fuel vapors and the tank is properly ventilated.

UNIT HAZARD LABEL IDENTIFICATION To help identify the hazard labels on the Unit and explain the level of awareness each one carries, explanations with appropriate consequences are provided below:

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

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

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

T-343 Rev D 12

SPECIFIC HAZARD STATEMENTS The statements that follow are applicable to the generator set and appear elsewhere in this manual. These recom- mended precautions must be understood and applied during operation and maintenance of the equipment covered herein.

WARNING! Beware of moving poly V-belt, belt driven components and hot exhaust components.

WARNING! Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the air intake heater.

WARNING! Beware of moving poly V-Belt and belt driven components.

WARNING! Beware of pinch points.

WARNING! Do not use gasoline to clean air cleaner parts.

WARNING! Do not direct water or steam into the gener- ator openings. Do not allow any soap and water solutions to enter the alternator.

WARNING! High voltage (dielectric) testing must not be performed to the machine without first observing NEMA rules. The insulation of this generator winding may be safely checked by using a megger. A high megger reading indicates good insulation.

CAUTION! Observe proper polarity when installing the battery or connecting a battery char- ger, the negative battery terminal must be grounded. Reverse polarity may damage the charging system. When charging the battery in unit, isolate the battery by dis- connecting the negative battery terminal first, then the positive. Once the battery

has been charged, connect the positive battery terminal first, then the negative.

CAUTION! Never pour cold water into a hot engine.

CAUTION! Use only ethylene glycol, anti-freeze (with inhibitors) in system. Use of glycol by itself will damage the cooling system.

CAUTION! Never open the radiator cap when the coolant is hot.

CAUTION! Always cover the engine inlet tube while the air cleaner is being serviced.

CAUTION! Do not underfill or overfill the oil bath cups. Overfilling of cups causes loss of capacity; underfilling cups causes lack of filtering efficiency.

CAUTION! When trying to restore residual magne- tism, be sure to wear safety glasses and non-conductive gloves. Use an insulated 12 gauge (or higher) jumper wire. Cut off all but a few strands from both ends of the jumper wire to help prevent fusing.

CAUTION! The rotor should not be pulled out from the alternator more than 0.75 inches. Dam- age to the bearing and windings may result.

CAUTION! Continued operation with failed shock- mounts may result in engine or generator damage.

21 T-343 Rev D

SECTION 2 DESCRIPTION

2.1 INTRODUCTION

The Carrier Transicold model 69UG15 under-mounted diesel-driven generator sets provide electrical power for all-electric refrigeration units. The generator set (see Figure 2.1 and Figure 2.2) consists of a diesel engine direct-connected to an alter- nating current generator and mounted in a structural steel frame. The engine is a vertical in-line, four cylin- der diesel manufactured by Kubota, while the genera- tor is a 15 kW, brushless, single bearing type manufactured by Lima. The generator provides a con- stant 460 VAC, three-phase, 60 hertz electrical supply. Electrical controls are mounted in a control box with operating controls and gauges mounted on a control panel, which also serves as the control box cover. The control panel components are protected by a deflector assembly or a windowed control box door. Auxiliary engine equipment consists of the battery, solid state battery charging system, spin-on lube oil filter, fuel filter and other necessary components for proper unit operation. The water pump and the radiator cooling fan are belt-driven from the engine crankshaft. All references to engine are as viewed from the fly wheel end. The 69UG15 is available as a standard configuration, with an Auto Restart option or with Auto Restart and Low Coolant Sensor. The Auto Restart option automat- ically restarts the unit in the event of a unit shutdown. Auto Restart also offers built-in indicators that signal low oil pressure, high water temperature, overspeed, and other overcrank conditions.

Carrier Transicolds Ecodriven dual speed option pro- vides an energy saving alternative to the practice of continuously running the generator at full speed. This speed reduction results in increased fuel economy, reduced carbon footprint, and lowers operating costs.

2.2 CONFIGURATION IDENTIFICATION

Generator set identification information is provided on a label located below the left mounting pad to the left of the access service door (front facing). The label pro- vides the generator set model number, serial number, and parts identification number (PID). The model num- ber identifies the overall configuration while the PID provides information on specific optional equipment and differences in detailed parts. Configuration identification for models covered herein are provided in Table 21. The model number, serial number and PID number must be included when order- ing parts and inquiring about your unit. Separately bound manuals covering the diesel engine are also available (see the following chart). .

Manual/ Form No.

Equipment Covered

Type of Manual

62-11335 V2203-DI Engine Part List

62-11362 V2203-DI Workshop

T-343 Rev D 22

Table 21 Model Chart

Model PID Electrical Wiring Schematic and

Diagram Figures

Unit Mounting

Receptacle Box Control Box, 460 Volt

1400 Series, Single Speed

69UG15050S05 UG1450 6.10, 6.11, 6.12 Standard (Figure 3.1)

w/Circuit Breaker Standard

UG1451 6.1, 6.2, 6.3 Standard w/Circuit Breaker Standard

UG1452 6.10, 6.11, 6.12 Standard w/Circuit Breaker Standard

UG1453 6.10, 6.11, 6.12 Standard w/Circuit Breaker Standard

69UG15050S06 UG1455 6.10, 6.11, 6.12 Standard w/Circuit Breaker Standard

UG1456 6.1, 6.2, 6.3 Standard w/Circuit Breaker Standard

69UG15050S07 UG1457 6.4, 6.5, 6.6 Standard w/Interlock Auto-Restart

69UG15050S08 UG1458 6.1, 6.2, 6.3 Standard Customer Specific Customer Specific

69UG15050Q06 UG1459 6.10, 6.11, 6.12 Quick (Figure 3.2)

w/Circuit Breaker Standard

UG1460 6.1, 6.2, 6.3 Quick w/Circuit Breaker Standard

69UG15068S05 UG1461 6.10, 6.11, 6.12 Standard w/Circuit Breaker Standard

UG1462 6.1, 6.2, 6.3 Standard w/Circuit Breaker Standard

UG1463 6.10, 6.11, 6.12 Standard w/Circuit Breaker Standard

69UG15068Q05 UG1464 6.10, 6.11, 6.12 Quick w/Circuit Breaker Standard

69UG15080S05 UG1465 6.10, 6.11, 6.12 Standard w/Circuit Breaker Standard

69UG15080Q05 UG1466 6.10, 6.11, 6.12 Quick w/Circuit Breaker Standard

UG1467 6.1, 6.2, 6.3 Quick w/Circuit Breaker Standard

69UG15068S06 UG1468 6.7, 6.8, 6.9 Standard w/Circuit Breaker Auto-Restart

1500 Series, Dual Speed, W/Fuel Warmer

69UG15050S05 UG1550 6.10, 6.11, 6.12 Standard w/Circuit Breaker 2-Speed

69UG15050S08 UG1558 6.13, 6.14, 6.15 Standard Customer Specific Customer Specific

69UG15068S05 UG1573 6.10, 6.11, 6.12 Standard w/Circuit Breaker 2-Speed

69UG15050S05 UG1572 6.10, 6.11, 6.12 Standard w/Circuit Breaker/ Drain

2-Speed

1600 Series, Dual Speed Provision, W/Fuel Heater

69UG15050S05 UG1651 6.10, 6.11, 6.12 Standard w/Circuit Breaker 2-Speed (prov)

69UG15050S08 UG1658 6.10, 6.14, 6.15 Standard Customer Specific Customer Specific

69UG15068S05 UG1661 6.10, 6.11, 6.12 Standard w/Circuit Breaker 2-Speed (prov)

69UG15068Q05 UG1664 6.10, 6.11, 6.12 Quick w/Circuit Breaker 2-Speed (prov)

69UG15050S05 UG1669 6.10, 6.11, 6.12 Standard w/Circuit Breaker 2-Speed (prov)

69UG15068S05 UG1670 6.10, 6.11, 6.12 Standard w/Circuit Breaker/ Drain

2-Speed (prov)

69UG15050S05 UG1671 6.10, 6.11, 6.12 Standard w/Circuit Breaker/ Drain

2-Speed (prov)

69UG15050S05 UG1672 6.10, 6.11, 6.12 Standard w/Circuit Breaker/ Drain

2-Speed (prov)

23 T-343 Rev D

Figure 2.1 Generator Set

1. Mechanical Fuel Pump 2. Injector Pump 3. Engine Speed Sensor 4. Poly V-Belt 5. Radiator 6. Controls (See Figure 2.9) 7. Engine Oil Filter 8. Engine Shockmount (Typical) 9. Lube Oil Dipstick/Fill Cap 10. Starter

11. Air Cleaner 12. Generator Shockmount 13. Receptacle Box 14. Receptacle 15. Circuit Breaker 16. Air Filter Indicator (if equipped) 17. Air Filter Pre-Cleaner (if equipped) 18. Intake Heater (IH) 19. Fuel Warmer (if equipped)

- - - - -

15

9

2 41

5

68 710112113

14

460 VOLT

15

14

3

16 17

15

14

19 18

T-343 Rev D 24

Figure 2.2 Generator Set Top View (Top Frame Members Removed for Clarity)

1. Fuel Tank 2. Exhaust Muffler 3. Solid State Battery Charger 4. Low Coolant Sensor (If Equipped) 5. Water Temperature Sensor 6. Water Temperature Switch 7. Engine

8. Fuel Heater (If Equipped) 9. Fuel Filter 10. Coolant Overflow Bottle 11. Alternating Current Generator 12. AC Generator Connection Box Access 13. Battery

- - - - -

1

13

12

11

10

7

6

5

4

2

3

89

25 T-343 Rev D

2.3 ENGINE

The engine is a vertical, in-line four cylinder diesel engine, which is direct-connected to the alternating current generator. Information on the major engine sys- tems is provided in the following subparagraphs.

2.3.1 Electronic Governor Module The electronic governor module (EG) is a solid state control module preprogrammed for 1800 RPM high speed and 1500 RPM low speed operation. The elec- tronic governor module, along with the engine speed sensor, replaced the manual governor in order to pro- vide constant and economical engine speed. The unit has an LED which may be used to diagnose failures within the electronic speed control system, refer to Section 4.6 for additional troubleshooting infor- mation on diagnosing failures.

Figure 2.3 Electronic Governor Module

2.3.2 Engine Air System The air cleaner (Figure 2.1) is designed to prolong engine life and performance by preventing dirt and grit from entering the engine and causing excessive wear on all operating parts. In order for the air filter to oper- ate properly, the operator must regularly maintain the air cleaner equipment in accordance with the instruc- tions provided within this document.

2.3.3 Fuel System The fuel system is fitted with an in-line fuel strainer and a fuel filter, which also acts as a water separator. The fuel system is shown in Figure 2.4. There are two fuel heating / warming options: The fuel heater system is located in the fuel filter, and uses a 12 volt heater to heat fuel as it passes through the fuel filter, see Figure 2.2.

The fuel warming system is a mechanical system that warms fuel by passing it through a heat exchanger that is warmed with engine coolant, see Figure 2.1.

Figure 2.4 Fuel System Diagram

2.3.4 Lube Oil Filter Arrangement The engine lubricating oil filter is mounted in a horizon- tal arrangement and shown in Figure 2.5.

Figure 2.5 Lube Oil

LED

Fuel Tank

In Line Fuel Strainer

Mechanical Lift Pump

Fuel Filter

Fuel Warmer (optional)

Injector Nozzles

Injection Pump

Bleed Valve

1 2

3

4

1. Oil Filter (Primary) 2. Oil Pressure Sender 3. Oil Pressure Switch 4. Oil Pan

T-343 Rev D 26

2.4 ENGINE SCREW THREADS

All threads used on the engine are metric except for the oil drain plug, which is American Standard Pipe Thread (NPT).

2.5 ALTERNATING CURRENT GENERATOR

2.5.1 Principle of Operation The Marathon Alternator Company (Lima) brushless alternating current generator (see Figure 2.2, item 11) is a self-regulated, rotating field synchronous unit. The generator stator and exciter stator are combined in a common housing. The generator field, exciter rotor, and rotating rectifier assembly are mounted on a com- mon shaft. The output of the exciter rotor is applied to the generator field winding through a rotating, full-wave bridge, silicon rectifier unit. All connections between the exciter stator windings and generator stator windings are internal within the stator housing. Only the output power leads are con- nected at the terminal box, which is located on top of the generator.

Figure 2.6 A-C Generator Circuit Diagram

2.5.2 Alternating Current Generator Diagram Figure 2.6 shows the internal schematic diagram of the generator, exciter, and rectifier unit. The generator is a three-phase unit, 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 generator no-load voltage. Another portion of exciter stator windings is connected in series with the output of the generator and provides a compounding excitation characteristic. The rotor is, in effect, the secondary of a rotating cur- rent transformer induction frequency converter. The exciter rotor output voltage is applied to the generator field windings by a three-phase, full wave rotating sili- con rectifier unit. The response time of the excitation system is very fast as the exciter stator carries an alter- nating current corresponding to the load current that appears immediately on the exciter primary. An increase in load current will cause an immediate increase in the exciter secondary output voltage, which is rectified and applied to the generator field windings. The inherent compounding characteristics of the exci- tation system provide excellent voltage regulation even under heavy overload conditions.

2.6 BATTERY CHARGING SYSTEM

The solid state battery charger (see Figure 2.2) is located to the left of the radiator. The charger is pow- ered by the generator, and this input is protected by a circuit breaker located on the control panel. The battery charger produces a tapered charge (25 amps maxi- mum) and is designed not to overcharge the battery.

CAUTION! Observe proper polarity when installing the battery or connecting a battery char- ger. The negative battery terminal must be grounded. Reverse polarity may dam- age the charging system. When charging the battery in unit, isolate the battery by disconnecting the negative battery termi- nal first, then the positive. Once the bat- tery has been charged, connect the positive battery terminal first, then the negative.

FIELD

STATORGENERATOR

SHUNT

SERIES

L O A D

ROTOR

EXCITERRECTIFIER ASSEMBLY

STATOR

27 T-343 Rev D

2.7 OPERATING CONTROLS & INSTRUMENTS

2.7.1 Introduction Components required for monitoring and controlling the unit are located in the control box, on the control panel (see Figure 2.1, item 6) and on the receptacle box (see Figure 2.1, item13).

2.7.2 Control Panel and Related Components a. Gauges and Senders

1. Oil Pressure Gauge (see Figure 2.7, Figure 2.8, Figure 2.9) The purpose of this gauge is to observe normal operating engine oil pressure. Normal oil pres- sure is 35 to 60 psig (3.3 to 5.2 kg/cm2).

2. Oil Pressure Sender (see Figure 2.5) This device senses engine lube oil pressure and transmits a signal to the oil pressure gauge. The oil pressure sender is located on the oil filter housing.

3. Water Temperature Gauge (see Figure 2.7, Figure 2.8, Figure 2.9) The function of this gauge is to observe water operating temperature. The gauge is connected to the water temperature sender.

4. Water Temperature Sender (see Figure 2.2) This device senses engine water temperature and transmits a signal to the water temperature gauge.

5. Low Coolant Sensor (see Figure 2.2) This device senses the coolant level inside the radiator and will complete a conductive circuit as long as the probes remain immersed in coolant. When the coolant level falls below the probes, a signal will be sent to the auto restart module, shutting down the engine and all 12volt cir- cuitry.

6. Auto Restart Module Auto start/restart is provided to simplify the start- up process and provide an automatic restart feature that will automatically attempt to restart the unit in the event of shutdown. Four LEDs are used to indicate shutdown from overcrank, over- speed, low oil pressure, and high water tem- perature. A fifth LED is used to indicate the unit is running (see Figure 2.9). Refer to Table 22 for system preset values. The auto restart function will perform a series of six attempts to restart the unit and make three attempts within each series. Once the function has completed all 18 attempts, the unit will auto- matically lock out future crank attempts. Refer to Table 23 for detailed information on auto restart sequencing.

b. Meters

1. Ammeter (A) The ammeter (see Figure 2.7, Figure 2.8, Fig- ure 2.9) is an indicator of the charging system and unit electrical draw. It indicates the rate of discharge or charge of the battery. During start up, the intake heater draws approximately 42 amps.

2. Total Time Meter (TT) The total time meter (see Figure 2.7, Figure 2.8, Figure 2.9) calculates the total hours and provides an accurate readout of accumulated engine running time. This data can be used to establish the proper periodic maintenance schedule (refer to Section 5.1).

c. Manual Switches

1. Intake Heater Switch (HS) (see Figure 2.7, Fig- ure 2.8) The intake heater switch is of the momentary type. When held in the PREHEAT position, the switch allows approximately 42 amps of battery current to flow into the intake heater, which pre- heats the air within the intake manifold and allows the engine to start. After starting the engine, the intake heater switch should continue to be held in the ON position for approximately 5 seconds until the engine has developed enough oil pressure to close the oil pressure safety switch.

2. Ignition Switch (IGN) (see Figure 2.7, Figure 2.8, Figure 2.9) The ignition switch is of the momentary type to be used in the OFF/ON/START positions. When held in the START (ignition) position, it ener- gizes the starter motor solenoid, which in turn allows the starter motor to crank the engine. The switch is released to the RUN position once the engine has started.

3. Ignition Switch (IGN)(Auto Restart) (Figure 2.9) The ignition switch is of the maintained contact type to be used in the RUN/OFF positions. When switched to the RUN position, it energizes the control module, which in turn controls all functions of the genset.

4. Operating Mode Switch (Figure 2.7, Figure 2.8) The Operating Mode (Dual Speed) switch is of the maintained contact type to be used in the ECONOMY/POWER positions. When switched to the ECONOMY position, it energizes the dual speed timer control module, which signals the programmed electronic governor module (EG) to reduce engine speed from 1800 RPM to 1500 RPM after a period of two (2) hours.

T-343 Rev D 28

b. Timers

1. Intake Heater Timer (IHT) The Intake Heater Timer continues to supply power to the intake heater for 3 minutes after ini- tial start-up.

2. Dual Speed Timer (DT) The Dual Speed Timer provides power to the electronic governor module for a 2 hour period to maintain initial high speed operation.

Figure 2.7 Standard Control Panel and Box With Dual Speed Option

1. Total Time Meter 2. Water Temperature Gauge 3. Oil Pressure Gauge 4. Ammeter 5. Intake Heater Switch 6. Ignition Switch 7. Dual Speed Switch (If Equipped) 8. Battery Charger Circuit Breaker (CB5)

9. Ground Studs 10. Circuit Breaker (CB2) 11. Circuit Breaker (CB3) 12. Intake Heater Relay 13. Safety Relay 14. Dual Speed Timer (If Equipped) 15. Intake Heater Timer

- - - - -

CONTROL BOX

CONTROL PANEL

1

8

7

6

5

4

3 2

14

9

10

11

12

13 15

29 T-343 Rev D

Figure 2.8 Customer Specific Control Panel and Box With Dual Speed Option

1. Total Time Meter 2. Water Temperature Gauge 3. Oil Pressure Gauge 4. Ammeter 5. Intake Heater Switch 6. Ignition Switch 7. Dual Speed Switch (If Equipped) 8. Battery Charger Fuse or Circuit Breaker (CB5)

9. Ground Studs 10. Safety Relay 11. Intake Heater Relay 12. Dual Speed Timer (If Equipped) 13. Intake Heater Timer 14. Circuit Breaker (CB2) 15. Circuit Breaker (CB3)

- - - - -

CONTROL BOX

CONTROL PANEL 12

10 14

13

15

9

11 1

8

7

6

5

4

32

T-343 Rev D 210

Figure 2.9 Auto Restart Control Box and Panel

1. Total Time Meter 2. Engine Start Alarm (Buzzer) 3. Water Temperature Gauge 4. Auto Restart Module 5. Oil Pressure Gauge 6. Ammeter 7. Engine Start/Intake Heater Energized Light 8. Ignition Switch 9. Battery Charger Fuse or Circuit Breaker (CB5)

10. Ground Studs 11. Circuit Breaker (CB2) 12. Starter Relay (SR) 13. Low Coolant Relay (LR) 14. Intake Heater Relay (HR) 15. Safety Relay (S) 16. Circuit Breaker (CB3) 17. Speed Control Module

- - - - -

CONTROL BOX

CONTROL PANEL

10

13

11 16

1512

9

8

6

5

2

7

4

143

1 17

Table 22 Auto Restart Preset Values

Indicator Preset Value Description

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

Crank Disconnect 700 RPM Crank Disconnect is the point at which the auto restart module senses the engine has started and will disengage the starter

Shutdown Lockout Delay 15 seconds The oil pressure and water temperature inputs are ignored during this 15 second delay (after start up)

Intake Heater Delay 30 seconds preheat 3 minutes postheat

The delay is used during start up. The intake heater delay be- gins timing after the auto restart module signal is received. During the entire delay, the intake heater circuit will be ener- gized, an indicator light will be illuminated, and an alarm will sound. When the delay expires, the unit will crank.

Crank Attempts 18 attempts A series of six attempts with three attempts in each series (total of 18 attempts), refer to Table 23, Auto Restart Sequencing.

211 T-343 Rev D

Table 23 Auto Restart Sequencing *Engine crank and rest is repeated three times each series unless the engine starts.

Series Attempt Number

Intake Heater

Energized in

Seconds

Fuel Solenoid Engaged

Engine Crank

Duration (Seconds)

Engine Rest

Duration (Seconds)

Engine Status

1 30 X Up To 15 25

If the engine starts: a. Run sequence begins b. Intake heater remains energized for 3 min- utes If the engine fails to start: a. Intake heater will de-energize. b. Fuel solenoid will de-energize. c. Crank output will de-energize. d. Overcrank LED will flash once. Wait two sec- onds and repeat. e. Unit will rest 30 minutes and proceed to the next series.

2 30 X Up To 15 25

If the engine starts: a. Run sequence begins. b. Intake heater remains energized for 3 min- utes. If the engine fails to start: a. Intake heater will de-energize. b. Fuel solenoid will de-energize. c. Crank output will de-energize. d. Overcrank LED will flash twice. Wait two sec- onds and repeat. e. Unit will rest 30 minutes and proceed to the next series.

3 30 X Up To 15 25

If the engine starts: a. Run sequence begins. If the engine fails to start: a. Intake heater will de-energize. b. Fuel solenoid will de-energize. c. Crank output will de-energize. d. Overcrank LED will flash three times. Wait two seconds and repeat. e. Unit will rest five hours and proceed to the next series.

4 30 X Up To 15 25

If the engine starts: a. Run sequence begins. If the engine fails to start: a. Intake heater will de-energize. b. Fuel solenoid will de-energize. c. Crank output will de-energize. d. Overcrank LED will flash four times. Wait two seconds and repeat. e. Unit will rest five hours and proceed to the next series.

T-343 Rev D 212

5 30 X Up To 15 25

If the engine starts: a. Run sequence begins. If the engine fails to start: a. Intake heater will de-energize. b. Fuel solenoid will de-energize. c. Crank output will de-energize. d. Overcrank LED will flash five times. Wait two seconds and repeat. e. Unit will rest five hours and proceed to the next series.

6 30 X Up To 15 25

If the engine starts: a. Run sequence begins. If the engine fails to start: a. Intake heater will de-energize. b. Fuel solenoid will de-energize. c. Crank output will de-energize. d. Overcrank LED will illuminate solid and lock out future crank attempts. e. To reset, turn unit power switch OFF and back ON.

Table 23 Auto Restart Sequencing *Engine crank and rest is repeated three times each series unless the engine starts.

Series Attempt Number

Intake Heater

Energized in

Seconds

Fuel Solenoid Engaged

Engine Crank

Duration (Seconds)

Engine Rest

Duration (Seconds)

Engine Status

213 T-343 Rev D

2.8 SAFETY DEVICES

Safety devices, such as circuit breakers, fuses, and safety switches, protect system components from dam- age. The AC generator, solid state battery charger, fuel heater, high water temperature, safety relay, total time meter and intake heater are protected by circuit break- ers. If a safety device opens and there is an interrup- tion of electrical current, the electronic governor module will be de-energized, which will also de-ener- gize the fuel solenoid, interrupt the fuel flow to the engine and stop the engine.

In units with auto restart, the engine, engine control devices, and engine monitoring devices are protected by the auto restart module, low coolant sensor (if equipped), circuit breaker, low oil pressure switch, and high water temperature switch. These safety devices monitor system operating conditions and open a set of electrical contacts when an unsafe condition occurs. If a safety device opens and there is an interruption of electrical current, the electronic governor module will be de-energized, which will also de-energize the fuel solenoid, interrupt the fuel flow to the engine and stop the engine. De-energizing the fuel solenoid shuts off the fuel sup- ply to the engine; thus stopping the engine. Safety device specifications are provided in Table 24.

Table 24 Safety Devices

Unsafe Condition Safety Switch Switch Setting

ENGINE

Low engine lubricating oil pressure Low oil pressure switch (LOP) - Au- tomatic reset

Opens below 18 psig (1.27 kg/cm2)

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

Opens at 230F (110C)

Low coolant Low coolant sensor Automatic reset

Opens with a loss of 32 ounc- es of coolant

Excessive current draw by the safety relay, fuel heater, water temperature gauge, oil pressure gauge or total time meter

Circuit breaker (CB2) - Automatic reset

Trips at 30 amps

Excessive current draw by the electronic governor module

Fuse 1, 2, 3 Trips at 10 amps

INTAKE HEATER

Excessive current draw on intake heater cir- cuit

Circuit breaker (CB3) - Automatic reset

Opens at 50 amps

BATTERY CHARGER

Excessive current draw on 230 volt feed cir- cuit

Circuit breaker (CB5) - Manual reset Opens at 3 amps

GENERATOR

Excessive current draw by load Circuit breaker (CB1, 460 volt) - Manual reset

Trips at 26 amps (460 VAC)

T-343 Rev D 214

2.9 UNIT SPECIFICATIONS

*Allows for DOT required 5% vapor space

2.10 ENGINE DATA

a. Fuel Tanks

Nominal Tank Sizes Fill Capacity Draw Capacity

50 Gallon Steel 52 gallons (197 liters) 50 gallons* (189 liters)

50 Gallon Aluminum 52 gallons (197 liters) 50 gallons* (189 liters)

65 Gallon Steel 67.5 gallons (256 liters) 65 gallons* (246 liters)

80 Gallon Aluminum 85 gallons (322 liters) 80 gallons* (303 liters)

b. Weights

Battery 63 lb (28.6 kg)

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

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

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

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

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

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

a. Bore /Stroke 3.26 in. (83 mm) / 4.03 in. (102.4 mm)

b. Compression Ratio 21.5 : 1

c. Cylinders (Number) Four

d. Displacement 135.2 cubic inches (2.22 liters) (2216 cm3)

e. Firing Order 1342

215 T-343 Rev D

f. Lubrication System Oil Pressure Safety Switch Setting Opens

18 psig (1.27 kg/cm2)

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

Oil Level Indicator Dipstick in oil pan or fill cap

NOTICE To check oil level on engines with the dip- stick mounted in the fill cap, remove the cap and wipe the dipstick clean. Insert the cap back onto the oil f i l l tube, then remove to check level. It is not necessary to screw the cap back into the fill tube when checking level. DO NOT add oil if level is within the safe range. If needed, add oil to bring level within the safe range. Screw cap fully into fill tube after checking level.

Lube Oil Specification Use a heavy duty lubricating oil conforming to American Petro- leum Institute (API) Service Classification CG, CH or CI, Base Number 10 or above.

Lube Oil Viscosity (Outdoor Temperature)

Fahrenheit: 0F to 45F Centigrade: -18C to 7C SAE: 10W30

Fahrenheit: 45F and above Centigrade: 7C and above SAE: 10W30 or 15W40

g. Fuel and Fuel Heater Thermostat (FHT)

Winter Summer

Diesel No. 1 Diesel No. 2

FHT

Close on temperature fall @ 45+/ 6.5F

Open on temperature rise @ 75+/ 6.5F

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

h. Fuel Warmer Coolant Temperature

i. Intake Heater Amperage - 42 amps at 12 VDC

Resistance (cold) - Approx. 0.3 ohms

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

32 HP @ 1800 RPM at sea level.

T-343 Rev D 216

k. Cooling System Capacity 6 U.S. quarts (5.68 liters) - includes 1 quart (0.95 liter) in cool- ant recovery bottle. (Refer to Section 5.4.5)

Anti-Freeze: Conventional The cooling system may be factory charged with a 50/50 mix of ethylene glycol and water. This mixture provides protection to -34F (-37C). For replacement, use a low silicate anti-freeze meeting GM specifications GM 6038M or equal. Again, a 50/50 mix is recommended.

Anti-Freeze: Extended Life The cooling system may be factory charged with a 50/50 mix of extended life coolant (ELC) and deionized water. This mix- ture provides protection to -34F (-37C). For replacement, with extended life coolant (ELC) meeting GM specification GM6277M and deionized water. Again, a 50/50 mix is recom- mended. Extended life coolant is red or orange in color. DO NOT mix with conventional coolant.

Water Temperature Safety Switch Setting

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

Resets 200F (93C) - minimum

Thermostat:

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

Fully open 203F (95C)

Low Coolant Sensor:

Opens Loss of 32 ounces of coolant or more

Closes Refilling of radiator to proper level

l. Lubrication System Oil Pressure 35 to 60 psig (3.3 to 5.2 kg/cm2)

m. Electrical Generator 460 VAC (+/ 10%) @ 60 hz

31 T-343 Rev D

SECTION 3 OPERATION

3.1 GENERATOR SET INSTALLATION

The generator set is mounted under the center of the trailer chassis and is easily handled with a fork lift truck capable of handling 2,000 pounds. The fork lift pockets provided are accessible from either side. Mounting clamps are designed to be attached to outside I-beam flanges only. Maximum chassis width is 38 inches on center.

1. Standard Mount

a. Loosen mounting bolts (see Figure 3.1) suffi- cient to push mounting plates to the outer- most position.

b. Place forks into fork lift pockets of generator set. Attach safety chain between unit and fork truck.

c. Center generator under chassis slide mount- ing plates fully onto chassis I-beams and torque mounting bolts to 80 - 90 ft-lbs (11.1 -

12.4 m-kg). Upon completion, remove safety chain before removing forks of fork lift truck from unit.

2. Quick Mount

a. Loosen mounting bolts (see Figure 3.2) suffi- cient to bring clamp to open position. To ori- ent in open position, lift nut end of bolt out of slot. Clamp will fall open.

b. Place forks into fork lift pockets of generator. Attach safety chain between unit and fork truck.

c. Center the generator set in desired position under chassis.

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

e. Tighten bolt to 55 - 65 ft-lbs (7.6 - 9.0 m-kg). f. Upon completion, remove safety chain before

removing forks of fork lift truck from unit.

Figure 3.1 Generator Set Mounting - Standard Mount

1. Fuel Tank 2. Exhaust Muffler 3. Solid State Battery Charger 4. Low Coolant Sensor (If Equipped) 5. Water Temperature Sensor 6. Water Temperature Switch 7. Engine

8. Fuel Heater (If Equipped) 9. Fuel Filter 10. Coolant Overflow Bottle 11. Alternating Current Generator 12. AC Generator Connection Box Access 13. Battery

- - - - -

2

6 3

4

REAR OF CHASSIS

SECTION A A

ROADSIDE VIEW

7

8

A

A

FORK LIFT POCKET

1

5

CONTAINER FLOOR CROSS I-BEAMS

T-343 Rev D 32

Figure 3.2 Generator Set Mounting - Quick Mount

1. Angle Assembly, Clamp 2. Washer, Spherical, Male 3. Washer, Spherical, Female 4. Bolt

5. Washer, Spherical, Belleville 6. Roll Pin 7. Nut, Hex, 3/4-10 8. Frame Assembly

- - - - -

3.2 GENERATOR SET REMOVAL

1. Standard Mount

a. Disconnect power cable to generator (if con- nected).

b. With fork lift in position and safety chain attached, slide mounting plates back suffi- ciently to clear chassis.

c. Lower and remove generator.

2. Quick Mount

a. Disconnect power cable to unit (if con- nected).

b. With fork lift in position and safety chain attached, loosen mounting bolts, and lift end of bolts out of slot to orient clamps to open position.

1

2

3

4

5

8

6

7

REAR OF CHASSIS

ROADSIDE VIEW

CONTAINER FLOOR CROSS I-BEAMS

FORK LIFT POCKET

A

A

VIEW A - A

33 T-343 Rev D

3.3 STARTING AND STOPPING INSTRUCTIONS

3.3.1 Pre-Start Inspection

1. Check engine lubrication and fuel filters, oil lines, and connections for leaks. If required, tighten connections and/or replace gaskets.

2. Check engine lubricating oil level. (Refer to Sec- tion 2.10, table entry f.)

3. Check poly V-belt for fraying or cracks and proper tension. (Refer to Section 5.4.11.)

4. Check radiator hoses for leaks and check radia- tor coolant level. (Refer to Section 2.10, table entry k.)

5. Check radiator coil and generator air intake screen for cleanliness. If required, clean using compressed air, reversing the normal air flow.

6. Check air cleaner for cleanliness and clean if necessary. (Refer to Section 5.4.12.)

7. Check in-line fuel strainer and clean if neces- sary. (Refer to Section 5.4.4.)

8. Drain water from fuel tank sump and filter bowl. 9. Fill fuel tank with diesel fuel. (Refer to Section

2.10, table entry g.) 10. Check air intake heater amperage. (Refer to

Section 2.10, table entry i.) 11. Check battery terminals for cleanliness and

secureness. If required, clean, then coat with a battery terminal sealant.

12. Check, and if required, tighten all electrical con- nections.

13. Check, and if required, tighten all hardware (brackets, etc.).

14. Ensure the main generator set circuit breaker (CB1) is in the OFF position. Connect power cable to refrigeration unit and proceed to Sec- tion 3.3.2.

3.3.2 Starting Instructions Before start up, both the Genset circuit breaker (CB1) and the refrigerated unit should be OFF. After start up, the Genset unit should be run for at least two minutes to allow the power source to stabilize before supplying power to the refrigerated unit. This will eliminate the potential of any cold start transient spikes from reach- ing the refrigerated unit. Cold start transient spikes can potentially cause nuisance over voltage alarms on refrigerated units that are sensitive to electrical spikes or transients.

WARNING! Beware of moving poly V-belt, belt driven components and hot exhaust compo- nents.

WARNING! Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the air intake heater.

NOTICE Piston rings in engines that have oper- ated less than 100 hours may not be fully seated. This may lead to the possibility of oil seepage from the exhaust pipe. To properly seat the rings, operate the engine under full load for a period of 24 hours. If the condition persists, check valve clearance when the engine is cold. (Refer to engine workshop manual listed in Section 2.2.)

1. Standard Units a. Make sure that CB-1 is in the OFF position. b. Hook up the 460 volt cable from the refriger-

ated unit to the Genset receptacle. c. Hold intake heater switch (see Figure 2.7) in

the PREHEAT position. Suggested hold times for a cold engine are as follows:

d. With the intake heater switch held in the PREHEAT position, place the ignition switch in the START position.

e. After the engine has started, continue to hold the intake heater switch in the PREHEAT position until the engine develops sufficient oil pressure to close the oil pressure safety switch (approximately 5 seconds). When released, the intake heater switch will auto- matically return to the OFF position and the heater will remain energized for 3 minutes.

2. Units with Auto Start a. Make sure that CB-1 is in the OFF position. b. Hook up the 460 volt cable from the refriger-

ated unit to the Genset receptacle. c. Place the Ignition switch (IGN) in the RUN

position.

COLD ENGINE PREHEAT TIMES

Ambient Temperature Time

78F/26C 5 seconds

32F to 78F (0 to 26C) 10 seconds

18F to 32F (-8 to 26C) 20 seconds

Below 18F/-8C 30 seconds

T-343 Rev D 34

d. If the low coolant sensor (LCS) is immersed in coolant, the auto restart module will ener- gize the heater for 30 seconds and the safety buzzer will sound. After the 30 second delay, the unit will attempt to start.

3.3.3 Post-Start Inspection

1. Allow the Genset unit to run for at least 2 min- utes.

2. Turn on CB-1 for 460 volt units. 3. Check generator output with a voltmeter. In the

no load condition, output should be at 490 (+/- 15 volts) with 1800 engine RPM.

4. Start refrigeration unit. 5. Run engine 10 minutes (check total time meter

operation). 6. Listen for abnormal bearing noise (AC genera-

tor). 7. Check fuel lines, lube oil lines, and filters for

leaks. 8. Check exhaust system for leaks.

3.3.4 Stopping Instructions

1. Place CB-1 in the OFF position. 2. Place the ignition switch in the OFF position.

3.4 SEQUENCE OF OPERATION

WARNING! Beware of moving poly V-Belt and belt driven components.

1. Standard Units: With the intake heater switch (HS) held in the ON position, current flows through the ammeter to the intake heater. While the heater is on, the ammeter will show a 42-amp draw. A second set of contacts also energizes the safety relay (S). If the high water temperature switch (HWT) opens to break the safety relay ground connec- tion, the safety relay will not energize, and the engine will not start. To start the engine, the ignition switch (IGN) is held in the START position. With the switch in the START position, current flows to the start solenoid (SS), through the SS contacts to the starter motor (SM). Current then flows to the intake heater timer, intake heater relay (HR) and to the heater, while simultaneously powering the electronic governor module (EG), fuel solenoid (FS), and engine speed sensor (ESS).

The starter motor turns over the engine resulting in pumping of fuel to the engine cylinders by the injection pump. This fuel is ignited by heat of compression; thus starting the engine. When the engine has developed sufficient oil pressure, the low oil pressure switch (LOP) contacts close to maintain power to the safety relay (S). Once the engine has started, the intake heater (IH) will remain energized for 3 minutes. The ignition switch (IGN) will be released. The intake heater switch (HS) will be held for 5 sec- onds, then released after the ignition switch is released. When the START switch is released, the starter will be disengaged. With the engine running, the battery charger pro- vides DC power to operate the control system and charge the battery.

2. Units with Auto Start, Low Coolant Sensor: When the ignition switch (IGN) is placed in the RUN position, 12-volt DC power is applied to the low coolant sensor (LCS), if applicable, and the auto restart module simultaneously. If the cool- ant level is below the sensor, all the indicator lights on the auto restart module will blink once and the LCS will open the contacts on the low coolant relay, de-energizing the units 12-volt DC circuitry. If the coolant level is above the sensor, the auto restart module will maintain power and all lights on the module will illuminate. As the auto restart module performs its self test, the lights will go out individually. After the self test is complete, the auto restart module will energize the intake heater and sound the audible alarm warning, indicating that the unit has been powered on and will start. The 30-second delay starts at this time. When the 30-second delay expires, power will be applied to the electronic governor and the engine attempts to crank for 15 seconds. When the engine starts, the intake heater will remain energized for 3 minutes; during this time, the engine/intake heater light and alarm will be energized, the shutdown/lockout time delay of 15 seconds will begin counting, and the starter will be disengaged. During the shutdown/lockout time delay at start up, the auto restart module will disregard the signals to the oil pressure and engine temperature inputs, and the Run sequence will begin. If engine does not start, refer to Table 23 for auto restart sequencing.

3. Units with Dual Speed Option: When the Operating Mode switch is placed in the POWER position, the engine will run continu- ously at 1800 RPM, 60 Hz (normal operating mode).

35 T-343 Rev D

When the Operating Mode switch is placed in the ECONOMY position, 12-volts DC will be sup- plied to the Dual Speed Timer (DT). The timer will pass 12-volts DC to Electronic Governor

Module (EG) via pin #15 after a period of two (2) hours. The power to pin #15 will signal the con- trol logic within the EG to throttle the engine to 1500 RPM, 50 Hz operation.

41 T-343 Rev D

SECTION 4 TROUBLESHOOTING

4.1 DIESEL ENGINE

4.1.1 Engine Will Not Start

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

Starter motor will not crank or low cranking speed

Battery insufficiently charged Charge

Battery terminal post or battery defective Check

Electrical connections at starter are bad Correct

Starter motor malfunctions Section 4.1.4

Starter motor solenoid defective Engine Manual

Open starting circuit Section 4.1.5

Incorrect grade of lubricating oil Section 2.10, f.

Starter motor cranks, but fails to start

No fuel in tank Section 2.9/Section 2.10, g.

Air inside the fuel system Section 5.4.1

Water inside the fuel system Drain Sump

Plugged fuel filters Replace

Air intake heater is bad Section 5.4.15

Low oil / Oil pressure switch defective Section 5.4.8

Faulty heater switch Section 5.4.16

Plugged fuel lines to injector(s) Engine Manual

Mechanical lift fuel pump malfunction Engine Manual

Fuses F1, F2, F3, F4 are bad Check/Replace

Loose or no connection between wire harness and Elec- tronic Governor Module (EG)

Check/Correct

Starter cranks and engages, but dies after a few seconds

Engine lube oil too heavy Section 2.10, f.

Voltage drop in starter cable(s) Check

T-343 Rev D 42

4.1.2 Engine Starts Then Stops

4.1.3 Engine Will Not Shut Off

4.1.4 Starter Motor Malfunction

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

Engine stops after a few rotations

No fuel in tank Section 2.9/Section 2.10, g.

Intake heater switch not held long enough Hold switch

Fuel filter restricted Replace

Air cleaner or hose restricted Section 5.4.12

Engine crankcase breather or hose restricted Section 5.4.13

Safety device open Section 2.8

Open wiring circuit to fuel solenoid Check

Fuel solenoid defective Replace

Fuel supply restricted Section 2.10.g,Section 5.4.2, and Section 5.4.3

Mechanical lift fuel pump malfunction Engine Manual

Low oil / Oil pressure switch defective Section 5.4.8

Leak in fuel system Check

Injector nozzle(s) defective Engine Manual

Injection pump defective Engine Manual

Generator internal overloads open Table 24

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

Engine will not shut off Loose ground connection Clean/Tighten

Improperly seated fuel solenoid Correct

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

Starter motor will not crank or turns slowly

Battery insufficiently charged Charge

Battery cable connections loose or oxidized Check/Replace

Battery cables defective Check/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 Table 2.10, f.

Starter motor turns, but pinion does not engage

Pinion or ring gear obstructed or worn Engine Manual

Starter motor does not disengage after switch has been released

Ignition switch is bad Check/Replace

Starter motor solenoid is bad Engine Manual

Pinion does not disengage after engine is running

Starter is bad Engine Manual

43 T-343 Rev D

4.1.5 Malfunction In The Engine Starting Circuit

4.1.6 Miscellaneous Engine Troubleshooting

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

No power to starter motor solenoid Battery defective Correct

Loose electrical connections Tighten

Fuel solenoid does not energize or does not remain energized

Battery defective Correct

Loose electrical connections Tighten

Oil pressure switch defective Section 2.8

Water temperature safety switch open Section 2.8

Fuel solenoid defective Engine Manual

Intake heater switch is bad Check (Engine Manual)

Electronic Governor Module (EG) is bad Replace (Section 5.4.15) Check/Replace

Intake heater does not energize

Intake heater switch is bad Section 5.4.15

Timer is bad Section 5.4.15

Heater element is bad Section 5.4.15

Heater relay is bad Section 5.4.15

Table 41 Miscellaneous Engine Troubleshooting

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

Loss of power

Restriction in air cleaner Section 5.4.12

Air in fuel system Section 5.4.1

Air vent restricted Clean

Restricted fuel lines Engine Manual

Fuel injection pump is bad Engine Manual

Injector(s) bad or incorrect type used Engine Manual

Incorrect fuel injection pump timing Engine Manual

Incorrect valve timing Engine Manual

Poor compression Engine Manual

Vibration Engine shockmounts are bad Replace

Poor compression Engine Manual

Overheating

Restriction in air cleaner Section 5.4.12

Exhaust pipe restriction Remove

Restriction in water jacket Engine Manual

Restriction in radiator Section 5.4.5

Coolant level too low Section 2.10, k.

Loose water pump/alternator poly V-belt Section 5.4.11

Thermostat is bad Engine Manual

Water pump is bad Engine Manual

Excessive crankcase pressure Plugged crankcase breather line Section 5.4.13

T-343 Rev D 44

4.2 BATTERY CHARGER (SOLID STATE)

4.3 ALTERNATING CURRENT GENERATOR

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

Circuit breaker trips when charger is turned on

Short in 12-volt wiring causing overload of charger Locate and remove short or re- place charger

Circuit breaker trips repeatedly, even when not connected

Internal short Replace charger

Charger does not taper back after charging for a few minutes

Bad cell in battery Test battery for defect accord- ing to battery manufacturers instructions

Charger is bad Replace

Charger does not charge

Open input circuit breaker Reset

Charger is not receiving AC input Using a voltmeter, confirm charger is receiving correct (230v) AC voltage. If not, check input connections.

Charger output is not connected to 12 volt battery Check output wiring connec- tions to battery.

Charger is bad Replace

Low output voltage measured across charger output

Battery not connected to charger. It is normal to measure 12 volts or less across charger output with no battery con- nected

Check charging leads from charger to battery

Reverse polarity connection to bat- tery has caused charger to stop charging

Internal DC fuse blown and possible damage to current carrying components

Replace

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

No voltage

Loss of residual magnetism in exciter field Section 5.5.2.a

Circuit breaker tripped Check

Open in stator windings Section 5.5.4/Replace

Open or short in rotating rectifiers Section 5.5.1.c

Short circuited Section 5.5.4/Replace

Open in alternator field Section 5.5.4/Replace

Shorted exciter armature Section 5.5.4/Replace

Low voltage

Low engine speed Section 5.4.9

Excessive load Check

High resistance connections - connections are warm or hot

Tighten

Shorted field Section 5.5.4/Replace

Fluctuating voltage (May be indi- cated by flickering lights)

Fluctuating speed Section 5.4.9

Irregular speed of engine Engine Manual

Loose terminal or load connections Tighten

Bad bearing causing uneven air gap Section 5.5.1/Section 5.5.3

High voltage Excessive engine speed Section 5.4.9

45 T-343 Rev D

4.4 AUTO RE-START OPTION

Overheating

Generator overloaded Check

Clogged ventilating screens Clean

High temperature surrounding generator Section 5.4.5

Insufficient air circulation Section 5.5.1

Unbalanced load Balance

Dry bearing Section 5.5.1/Section 5.5.3

Mechanical Noise

Bad bearing Section 5.5.1/Section 5.5.3

Rotor scrubbing on stator Section 5.5.1/Section 5.5.3

Loose laminations Section 5.5.4/Replace

Loose or misaligned coupling Section 5.5.4

Generator frame produces shock when touched

Static charge Check ground to frame

Grounded armature of field coil Section 5.5.4/Replace

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

When the Ignition switch is placed in the RUN position, nothing hap- pens - no lights illuminate

Wait 30 seconds for intake heater to be activated Wait

Coolant level below the low coolant sensor Section 2.10, k.

Relay defective Check/Replace

Ignition switch defective Check/Replace Switch

3 amp Fuse is bad Check and Replace Fuse

Loose connector on module Tighten connector

Auto restart module is bad Check for 12 volts at Pin 4/Re- place module

Miswired connectors Check/Correct wiring

Alarm sounds, but engine does not crank

No voltage at Pin 2 of the connector Trace/Correct

Check Starter Solenoid Section 4.1.1

Auto restart module is bad Replace module

Engine starts, but the starter does not disengage

Speed Sensor wiring loose Check/Correct

Speed Sensor is bad Replace

Auto restart module is bad Replace module

Engine starts, but shuts down from over speed

Electronic Governor Module (EG) is bad Replace

Engine cranks, but will not start Electronic Governor Module (EG) is bad. See Section 4.1.1

Replace/Section 4.1.1

Engine starts, but shuts down on low oil

See Section 4.1.2 Section 4.1.2

Engine starts, but shuts down on high water temperature

See Section 4.1.6 Section 4.1.6

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

T-343 Rev D 46

4.5 DUAL SPEED OPTION

4.6 ELECTRONIC GOVERNOR MODULE

CONDITION POSSIBLE CAUSE REMEDY/REFERENCE SECTION

When the Operating Mode switch is placed in the Economy position, nothing happens.

Wait 2 hours for the Dual Speed Timer (DT) to activate the Electronic Governor Module (EG).

Wait

The Dual Speed Timer (DT) is bad. Check for 12 volts at Pin 15/Re- place module

12v is not available to the Dual Speed Timer (DT). Check/Replace Switch

12v is not available to the Operating Mode switch. Check/Correct wiring

FAULT LED FLASH CODE POSSIBLE CAUSE

Engine Over Speed: more than 2,530 RPM One LongOne Short ESS or mechanical engine problem

Actuator Wiring Disconnection. No signal from ESS for 2 sec- onds after RPM is greater than 1,000 RPM for 10 seconds, OR for 5 seconds while engine cranking (no voltage at EG pin 18).

Two LongOne Short Short ESS or wiring problem

Speed Sensor Disconnection. Fuel/speed actuator (FS) wir- ing disconnected or open circuit. Coil Resistance Spec: 2.8 ohm +/- 10%.

Two LongThree Short FS or wiring problem

EG supply voltage is greater than 26V. Two LongSeven Short EG or alternator problem

51 T-343 Rev D

SECTION 5 SERVICE AND PREVENTATIVE MAINTENANCE

5.1 INTRODUCTION

This section covers service for the generator set and general engine service. Refer to the Kubota engine workshop manual, Section 2.1, for additional engine servicing.

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

5.2 PREVENTATIVE MAINTENANCE SCHEDULE

A tabular listing of the recommended preventative maintenance activities and schedule is provided in Table 51.

5.3 BATTERY SERVICE

When replacing the battery, determine whether the unit was supplied with a mat in the battery tray. If so equipped, the mat must also be replaced.

5.4 ENGINE SERVICE AND COMPONENTS

5.4.1 Bleeding the Fuel System The unit is equipped with a mechanical fuel lift pump mounted on the engine next to the injection pump. The fuel system is a closed circuit which will require bleed- ing if loss of fuel has occurred. To fill and bleed the sys- tem, do the following:

1. Turn fuel bleed valve (Red, see Figure 2.4) counterclockwise until fully opened.

2. Turn the top of the manual priming pump (see Figure 5.1) counter-clockwise to unlock it, and then hand pump the manual plunger until a pos- itive pressure (resistance) is felt. This will indi- cate fuel flow.

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

4. Start engine. (Refer to Section 3.3.)

5. When engine is running properly, turn fuel bleed valve clockwise until fully closed.

5.4.2 Servicing Fuel Pump Internal Filter The internal fuel f i l ter may become plugged or restricted with foreign particles or wax, which can develop if the wrong grade of fuel is used or untreated fuel is used in cold weather, contaminating the fuel. If

the internal filter is plugged, the engine will lose power. Therefore, the filter must be cleaned on a regular basis. The quality of the fuel will affect the filter clean- ing schedule (refer to Section 5.2).

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

2. Remove banjo fitting (item 2) and let it hang loose, making sure to keep copper rings (item 4) for replacement.

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

4. To install, reverse steps 1 through 3.

Figure 5.1 Mechanical Fuel Pump

5.4.3 Fuel Filter The fuel filter is located on the generator set frame (see Figure 2.4). To replace the fuel filter, loosen and remove the filter housing. Lightly oil new gasket with lube oil and replace the filter.

NOTICE If the generator set is equipped with the fuel filter bowl assembly, when replacing the fuel filter, a new fuel filter O-ring should be oiled and replaced, and then the clear bowl should also be tightened to 18 ft-lbs.

5

1

2

3

4

1

1. Nut 2. Banjo 3. Filter

4. Copper Rings 5. Manual Priming Pump

T-343 Rev D 52

5.4.4 InLine Fuel Strainer (Option) Loosen bowl by turning counter-clockwise. To renew, remove in-line fuel strainer, check and clean, and replace.

5.4.5 Cooling System To ensure adequate cooling, the radiator must be clean, externally and internally. To service the cooling system, do the following:

1. Remove all foreign material from the radiator coil by reversing the normal air flow. Com- pressed 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. If a detergent is used, rinse coil(s) with fresh water.

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

CAUTION! Never pour cold water into a hot engine.

3. Close drain cock and fill system with clean, untreated water to which between 3% and 5% of an alkaline base radiator cleaner should be added; six ounces (dry) = 151 grams to one gal- lon (3.8 liter) of water.

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

CAUTION! Use only ethylene glycol, anti-freeze (with inhibitors) in system. Use of glycol by itself will damage the cooling system (Refer to Section 2.10.k).

5. Run engine to operating temperature. Drain sys- tem again and fill with treated water/anti-freeze (see above Caution note).

5.4.6 Lube Oil Filter The primary oil filter is located near the radiator fan (see Figure 2.5).

1. After warming up the engine, stop engine, remove drain plug from oil reservoir and drain engine lube oil.

2. Replace filters. Lightly oil gasket on filter before installing.

3. Add lube oil (Refer to Section 2.10.f).

4. Warm up engine and check for leaks.

5.4.7 Servicing the Low Coolant Sensor (Option)

a. Testing the Low Coolant Sensor (LCS)

1. Verify the coolant level is correct.

2. Verify the wiring to the sensor is correct.

3. Check voltage (12.5 to 13.5 VDC) to the B termi- nal with the ignition switch on (see Figure 5.2).

4. Check continuity between terminals A and C (see Figure 5.2) while 12 VDC is applied to ter- minal B.

5. Drain the coolant from the system to below the level of the coolant sensor and remove the sen- sor as described in Section , steps a and b below.

6. With the sensor removed from the radiator and 12 VDC applied to terminal B, the circuit between terminals A and C should be open.

Figure 5.2 Low Coolant Sensor

CAUTION! Never open the radiator cap when the coolant is hot.

b. Replacing the Low Coolant Sensor (LCS)

1. Loosen the radiator drain pet cock and drain coolant to a point below the sensor into an approved container.

2. Unplug the harness and remove sensor from radiator header.

3. Apply Teflon thread tape or thread sealer to the LCS threads and install sensor.

4. Reconnect the harness and refill the radiator to proper level.

53 T-343 Rev D

5.4.8 Servicing Low Oil Pressure Switch

1. Remove harness connection from low oil pres- sure switch (LOP).

2. Remove pressure switch from engine.

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

4. Install new low oil pressure switch.

5. Reconnect harness connection to low oil pres- sure switch.

5.4.9 Engine Speed The engine speed is electronically controlled. DO NOT ATTEMPT TO ADJUST ENGINE SPEED.

5.4.10 Replacing the Engine Speed Sensor

1. Disconnect the plug to the sensor, (see Figure 2.1).

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

3. Remove the sensor from the housing.

4. Clean the recess in the housing to ensure that the sensor seats properly when re-installed.

5. Re-install the sensor, replace the securing bolt and connect the plug to the sensor.

5.4.11 Servicing Poly V-belt

WARNING! Beware of moving poly V-belt and belt driven components.

WARNING! Beware of pinch points.

NOTICE A frayed, cracked or worn poly V-belt must be replaced. After installing a new belt, check the adjustment after running the unit for three or four hours. This will allow for the initial stretch, which is com- mon on new belts. Once this initial stretch has taken place, the belt should be checked at regular intervals.

The poly V-belt is driven by a sheave on the engine crankshaft. Its two functions are: (1) to drive the radia- tor fan and (2) to drive the water pump.

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

1. Using the proper size socket, slowly rotate the crank on the crank pulley nut. At the same time, use a flat, blunt object to guide the belt off the crank pulley towards radiator. Be careful not to damage grooves on the pulley.

2. Replace the poly V-Belt by positioning the belt on the water pump pulley, and while rotating the engine (as in step 1.), use a flat, blunt object to guide the belt onto the crank pulley. Be careful not to damage grooves on the pulley or belt.

5.4.12 Engine Air Cleaner The dry element engine air cleaner uses a dry element filter (see Figure 5.3) to filter the engine intake air. The oil bath air cleaner option uses an oil cup instead of the dry element filter (see Figure 5.4). The engine air cleaner should be inspected regularly for leaks, (see Figure 2.1). A damaged air cleaner or hose can seriously affect the performance and life of the engine. The air cleaner is designed to effectively remove contaminants from the air stream entering the engine. An excessive accumulation of contaminants in the air cleaner will impair its operation. Therefore, a service schedule must be set up and followed.

1. Check all connections for mechanical tightness. Be sure the air cleaner outlet pipe is not frac- tured.

2. In case of leakage, if adjustment does not cor- rect the problem, replace necessary parts or gaskets. Swollen or distorted gaskets must always be replaced.

a. Air Filter Indicator The air filter indicator, used with the dry element filter, is mounted on the unit frame and connected to the engine air intake. Its function is to indicate when the air cleaner dry element needs to be replaced. In operation: When a plugged air cleaner decreases intake manifold pressure to 500 mm (20) WG, the indicator moves to the red line. The air cleaner element should be replaced and the indicator reset by pressing the reset button.

b. Air Cleaner, Dry Element Service

1. Stop the engine and open the cap clamps (see Figure 5.3) to remove air cleaner bottom cap.

2. Remove the air filter element from the air cleaner body.

3. Install the new element, secure the bottom cap with the cap clamps.

T-343 Rev D 54

Figure 5.3 Air Cleaner, Dry Element

c. Air Cleaner, Oil Bath Service The oil cup should be inspected during pretrip, before each trip. Never allow more than 1/2 inch (12.7 mm) of dirt deposit in the cup. More than 1/2 inch accumulation could result in oil and dirt carrying over into the engine, causing accelerated engine wear. Heavily contami- nated oil will not allow the air cleaner to function prop- erly.

CAUTION! Always cover the engine inlet tube while the air cleaner is being serviced.

1. Stop the engine and remove the oil cup from the air cleaner. Dispose of the oil in an environmen- tally safe manner.

2. Remove the inner oil cup from the oil cup and clean both cups.

3. Reassemble and fill both oil cups to the indi- cated level with oil specified in Section 2.10.f.

CAUTION! Do not underfill or overfill the oil bath cups. Overfilling cups causes loss of capacity; underfilling cups causes lack of filtering efficiency.

Figure 5.4 Air Cleaner, Oil Bath

d. Air Cleaner Body Service The air cleaner body should be inspected each time the oil cup is serviced. If there is any sign of contami- nant buildup or plugging, the air cleaner body should be removed and back flushed. At least once a year, or at regular engine service inter- vals, remove the entire air cleaner and perform the fol- lowing cleaning procedure:

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

WARNING! Do not use gasoline to clean air cleaner parts.

2. Pump solvent through the air outlet with suffi- cient force and volume to produce a hard, even stream out of the bottom of the body assembly. Reverse flush unti l al l foreign material is removed.

5.4.13 Engine Crankcase Breather The engine uses a closed type breather with the breather line attached to the cylinder head cover (see Figure 5.5). It is not necessary to disassemble valve style elements for cleaning. However, the bleed hole should be checked to ensure it is free of obstruction. Check once a year or at every 4,000 hours mainte- nance interval, whichever comes first.

5

4

2

1 1

3

1. Air Outlet 2. Air Cleaner Body 3. Air Inlet

4. Cap Clamp 5. Air Filter Indicator

1

2

3

4 5

6

1. Air Inlet Hood 2. Air Cleaner Body 3. Cap Clamp

4. Inner Oil Cup 5. Gasket 6. Oil Cup

55 T-343 Rev D

Figure 5.5 Engine Crankcase Breather

5.4.14 Intake Heater Test

1. Disconnect the lead from the heater terminal (1).

2. Measure the resistance between the heater positive terminal (1) and the heater body (2).

3. If the resistance is infinity or significantly differ- ent than the specification, resistance (cold) 0.3 ohms, replace the heater.

Figure 5.6 Intake Heater

5.4.15 Intake Heater Service

1. Remove harness connection from heater.

2. Remove intake transition mounting hardware.

3. Remove intake transition, heater and both gas- kets.

4. Clean old gasket material off the transition and manifold mounting services.

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

6. Assemble transition to heater and torque mount- ing hardware (refer to engine manual for torque values).

7. Reconnect harness to heater connection point.

8. Coat stud on heater with protective coating.

5.4.16 Intake Heater Switch

1. Remove control box cover.

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

3. Remove heater switch from control box.

4. Install new heater switch.

5. Reconnect wire harness connections to switch.

6. Confirm wires are connected to correct termi- nals.

7. Reinstall control box cover.

5.5 SERVICING THE ALTERNATING CURRENT GENERATOR

5.5.1 Preventative Maintenance and Operating Precautions

Costly repairs and down time can usually be prevented by operating electrical equipment under conditions that are compatible with those under which the equipment was designed. Follow the instructions outlined below to insure maximum efficiency of the electrical equipment.

a. Cooling Keep all cooling parts clean. DO NOT EXCEED TEM- PERATURE RISE OF 80C (176F) ABOVE A 40C (104F) AMBIENT. This ensures that the NEMA Class F insulation will not be damaged. DO NOT EXCEED RATED LOAD except as specified for the equipment. OPERATE GENERATOR AT RATED SPEED. Failure to operate generators at rated load or speed will cause overheating and possible damage to windings due to over voltage or current.

b. Generator Windings (Drying)

WARNING! Do not direct water or steam into the gen- erator openings. Do not allow any soap and water solutions to enter the alterna- tor.

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 meg- ger reading indicates good insulation.

1

5

4 3 2

1. Screw 2. Breather Cover 3. Bleed Hole

4. Breather Valve 5. Breather Tube

1

2

1. Positive Terminal 2. Heater Body

T-343 Rev D 56

Generators that have been in transit, recently steam cleaned or in storage for long periods may be sub- jected to extreme temperature and moisture changes. This can cause excessive condensation, and the gen- erator windings should be thoroughly dried out before bringing the generator up to full nameplate voltage. If this precaution is not taken, serious damage to the generator can result. The following steps should be taken to effectively dry the generator windings:

1. Dry windings by placing generator in drying oven or hot room, or dry with warm air blower directed through windings.

2. If the generator has been operated and is being placed into storage for any period of time, a P.D. George #11127 type air-dry fungus resistant var- nish should be applied.

The finest insulation job can be very quickly broken down by carelessly applying high voltage to windings in a moisture saturated condition. Failure to follow these guidelines could easily cause a breakdown, making it necessary to return the generator to the factory for repair.

c. Rotor Damage If a rotor becomes defective, it should be returned to the factory with full nameplate data. To repair a rotor, the special tooling and technique of the factory are necessary and essential. Should a failure occur, Car- rier Transicold should be notified immediately and steps will be taken to return the generator for service.

d. Terminal Strip Cleaning Open terminal box. Remove dust and debris, and clean terminal strip with wire brush. Reapply protective coat- ing.

5.5.2 Generator Repair/Test Procedures

a. Restoring Residual Magnetism The direct current (DC) necessary to magnetize the alternator field is obtained from the exciter. Initially, upon starting the generator, current flow and voltage are induced into the exciter armature by the magnetic lines of force set up by the residual magnetism of the exciter field poles. Residual magnetism of the exciter field poles may be lost or weakened by a strong neutralizing magnetic field from any source, or if the generator is not oper- ated for a long period of time. Should the generator fail to build up voltage after being disassembled for any reason, a momentary short-cir- cuit of any two generator leads (L1, L2 and L3) while generator is running should be sufficient to correct this condition.

CAUTION! When trying to restore residual magne- tism, be sure to wear safety glasses and non-conductive gloves. Use an insulated 12 gauge (or higher) jumper wire. Cut off all but a few strands from both ends of the jumper wire to help prevent fusing.

As an alternate method, apply either an alternating cur- rent 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 connec- tion, but rather touch the leads together until the gener- ator voltage begins to rise, then remove. Insert a 30 ampere fuse into the circuit to prevent any damage in case the build-up voltage is not removed quickly enough. Reflash field if generator output voltage does not build up.

b. Winding Insulation Testing Continuity test results for the stator winding tests are provided in the following table:

C. Diode Testing The rectifier diode assemblies can be tested, and if damaged, replaced. Over current, over voltage, over speed, or reverse currents can damage the assembly or diodes. To remove the diode assemblies and per- form diode testing, do the following:

Wire Pair

Ohm* Wire Pair

Ohm* Wire Pair

Ohm*

T10-T1 I T1-T8 I T4-T5 I

T10-T2 I T1-T9 I T4-T6 I

T10-T3 I T2-T3 I T4-T7 I

T10-T4 I T2-T4 I T4-T8 I

T10-T5 I T2-T5 0 T4-T9 I

T10-T6 I T2-T6 I T5-T6 I

T10-T7 0 T2-T7 I T5-T7 I

T10-T8 0 T2-T8 I T5-T8 I

T10-T9 0 T2-T9 I T5-T9 I

T1-T2 I T3-T4 I T6-T7 I

T1-T3 I T3-T5 I T6-T8 I

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

T1-T5 I T3-T7 I T7-T8 0

T1-T6 I T3-T8 I T7-T9 0

T1-T7 I T3-T9 I T8-T9 0

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

57 T-343 Rev D

1. Remove the bearing cover by removing the four bolts (see Figure 5.8). Both the bearing and diode assemblies will be visible.

2. Mark and disconnect the alternator rotor wires at the rectifier screw terminals. Note that the termi- nals are marked with red paint for the forward diode assembly and black for the reverse diode assembly. Mark and disconnect the exciter leads from the double spade terminals (see Fig- ure 5.7).

Figure 5.7 A-C Generator Rectifier Assembly

3. Remove the two cap screws that secure each diode assembly to the exciter. Once this proce- dure is complete, the diode assemblies are free for removal.

4. A forward diode should have a low resistance when the + of an ohm meter is connected to the exciter rotor lead connection (anode) and the - to the diode bridge (cathode), and a high resis- tance when the polarity of the ohmmeter is reversed.

5. A reverse diode should have a high resistance when the + of an ohm meter is connected to the exciter rotor lead connection (anode) and the - to the diode bridge (cathode), and a low resis- tance when the polarity of the ohmmeter is reversed.

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

5.5.3 Bearing Replacement When operated under normal conditions, factory-lubri- cated shielded bearings will normally provide years of trouble-free service. Excessive bearing load and adverse environment conditions will greatly shorten bearing life. To remove the bearings, do the following:

1. Remove bearing cover and mylar gasket. (See Figure 5.8).

2. Remove bearing with a bearing or wheel puller.

3. Install new bearing. Ball bearings are pre-lubri- cated and require no additional lubrication for the life of the bearing.

4. Coat mating surface of bearing cover flange with anti-corrosion compound (Tef-Gel, Carrier Part Number 02-00083-00).

5. Replace bearing cover and mylar gasket.

Figure 5.8 Rectifier Removal

a.

d.

c.

b.

a.

b.

d.

a. Diode Assembly b. Diode Bridge c. Exciter Rotor Lead Connection d. Alternator Rotor Lead Connection

a.

h. g.

e.

d.

c. b.

f.

a. Rectifier Flange b. Rectifier Assembly c. Rectifier Bolt d. Bearing Cover

e. Bearing Cover Bolt f. Mylar Gasket g. Bearing h. Bearing Cover Flange

T-343 Rev D 58

5.5.4 Generator Removal and Installation

a. Removing the Generator

1. Remove covers and ground wire from frame of generator set.

2. Remove connection box cover and disconnect power leads.

3. Remove screen cover and generator exhaust baffle from coupling end of generator.

4. Remove the six 8mm hex head bolts and wash- ers that secure the generator drive disc to the engine flywheel. Turn bolts counter-clockwise with offset wrench to start, then use flexible shaft and socket assembly for removal of bolts.

5. Remove the twelve 3/8 inch hex head cap screws and washers that secure generator frame to engine flywheel housing.

6. Remove the four 5/8 inch bolts that secure the generator mounting feet to the shockmount bracket, then remove generator.

b. Installing the Generator

NOTICE For torque values refer to Section 5.7.

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

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

2. Move generator into position and line up with the holes on housing and flywheel. If required, turn crankshaft to align threaded holes in fly- wheel with generator drive disc mounting holes.

CAUTION! The rotor should not be pulled out from the alternator more than 0.75 inches. Damage to the bearing and windings may result.

3. Start the 8mm bolts (by hand) through the disc plate and into the flywheel. Once alignment is made torque the six bolts.

4. Secure two of the housing bolts (3/8 inch) on the top and bottom of the generator housing to draw the mating flanges together.

5. Secure the remaining bolts and washers (3/8 inch); torque the 12 bolts in a staggered pattern.

6. Install and torque generator mounting bracket bolts (5/8 inch). Install screen cover, generator exhaust baffle, power leads, ground wiring and generator cover. Install new gasket when install- ing generator connection box cover.

5.6 GENERAL GENERATOR SET MAINTENANCE

5.6.1 Maintenance Of Painted Surfaces The unit is protected against the corrosive atmosphere in which it normally operates by a special paint system. However, if the paint system is damaged, the base metal can corrode. If the paint system is scratched or damaged, do the following:

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 fin- ish coat of paint to match original unit color.

Figure 5.9 Truss and Isolator

UNIDRIVE

TRUSS

TRUSS

FRAME

1

5

4

7 6

3

2 1

4

5

2

1. Bolt 2. Lock Washer 3. Flat Washer 4. Heat Shield

5. Isolator 6. Locknut 7. Nutplate

59 T-343 Rev D

5.6.2 Check and Replace Isolators/Shock- mounts

a. Replacement Criteria

CAUTION! Continued operation with failed shock- mounts may result in engine or generator damage.

When a shockmount has been cut, split, abraded or has flared due to normal deterioration, it must be replaced. Damage to the mounts may not be visible when installed and under load from the component. To correctly inspect shockmounts, they must be removed.

b. Engine Isolator/Shockmount Replacement

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

2. Remove truss, unidrive isolator and all hardware as shown in Figure 5.9, if equipped.

3. Remove all hardware as shown in Figure 5.11.

4. Raise the engine just enough to remove the shockmounts (Figure 5.11, item 4).

5. Install new shockmounts.

NOTICE For torque values refer to Section 5.7.

6. Lower the engine enough to assemble hardware as shown and torque per Section 5.7.

7. Remove chains from the lift eyes.

Figure 5.10 Engine Shockmounts

c. Generator Shockmount Replacement

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

2. Remove shockmount hardware.

3. Raise the generator just enough to remove the shockmounts (Figure 5.11, item 7).

4. Install new shockmounts.

5. Lower the engine enough to assemble hardware as shown and torque. Refer to Section 5.7 for torque values.

6. Remove chains from the lift eyes.

Figure 5.11 Generator Shockmounts

ENGINE

FRAME

1

3

4 5

2

3

1. Bolt 2. Lock Washer 3. Snubbing Washer

4. Shockmount 5. Flat Washer

1

13

12

11

10 9

8

7

6 5

4 2

GENERATOR

FRAME

3

3

12

INSTALL MOUNT WITH LARGE FLARE AT TOP

FRAME

7 8

34

1. Screw (5/8) 2. Mounting Base 3 Flat Washer (5/8) 4. Locknut (5/8) 5. Locknut (1/2) 6. Flat Washer (1/2) 7. Shockmount

8. Support Plate 9. Snubbing Washer

10. Screw (1/2) 11. Screw (3/8) 12. Flat Washer (3/8) 13. Locknut (3/8)

T-343 Rev D 510

5.7 UNIDRIVE TORQUE REQUIREMENTS

Extensive damage may occur if the proper hardware is not used and/or proper procedures are not followed when working with the unidrive assembly. Periodic inspection of hardware and bolt torque is recom- mended to ensure the integrity of the unidrive. Torque value and hardware requirements for unidrive assembly are provided in Figure 5.12.

NOTICE SST is an abbreviation for 300 Series Cor- rosion Resistant Steel. Loctite #242 or an equivalent product should be used on ALL hardware shown in Figure 5.12.

Figure 5.12 Unidrive Torque Requirements

UNIDRIVE SECTIONAL VIEW

ENGINE & GENERATOR SHOCKMOUNTS/ISOLATORS TOP VIEW

ENGINE MOUNT RIGHT SIDE VIEW

Engine Flywheel

Generator Disc Drive

3/8-16 x 1-1/2 lg - SST (12 Reqd) 25 ft-lb (3.46 mkg)

1/2-13 x 3-1/2 lg - SST (2 Reqd) 75 ft-lb (10.37 mkg)

5/8-18 x 2.00 lg - SST )

3/8-16 x 1 lg - SST (4 Reqd) 25 ft-lb (3.46 mkg)

M8 x 15 MM lg - SST (6 Reqd) 19 ft-lb (2.49 mkg)

5/8-11 x 4.00 lg - SST (2 Reqd) 90 ft-lb (9.68 mkg)

M8 X 1-1/4 lg - STL (4 Reqd) 11 ft-lb (1.5 mkg)

Nut, Self Lock 3/8-16 - SST )

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

TRUSS AND ISOLATOR

511 T-343 Rev D

Table 51 Preventative Maintenance Actions and Schedule

Description of Procedure Reference Paragraph

Perform at Pre-Trip

Inspection

Standard Service Interval Units

Extended Service Interval Units*

Every 1000 Hours

Annually or Every

3000 Hours

Annually or Every

3000 Hours

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

1. Check (in place) Engine/Generator shock mounts for cracks, cuts, abrasion or flaring

X

2. Check engine lubrication, fuel filter, and connec- tions for leaks

X X X

3. Check engine lubrication oil level, add as required Section 2.10.f X X X

4. Check poly V-Belt for fraying or cracks Section 5.4.11

X X X

5. Check radiator hoses for leaks/check coolant level and 50/50 mixture

Section 2.10.k

X X X

6. Check radiator coil and generator air intake for cleanliness (Clean using compressed air, reversing air flow direction)

X X X

7. Check Air Cleaner

For Oil bath air filter: Check for cleanliness and clean fil- ter body and internal mesh. Change oil every 250 hours

Section 5.4.12

X X X

For Dry element air filter with indicator: Check for clean- liness and clean/replace as air filter indicator indicates

Section 5.4.12

X X X

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

9. Fill fuel tank with diesel fuel; check fuel gauge operation.

Section 2.10.g

X X X

10. Check intake heater amperage Section 2.10.i X X X

11. Check battery terminals for tightness and cleanli- ness. Clean and coat terminals with battery termi- nal sealant

X X X

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

X X X

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

14. Clean oil bath air filter body and internal mesh2 Section 5.4.12

X X

15. Clean mechanical fuel lift pump internal filter Section 5.4.2 X X X

16. Change lubricating oil and filter(s)1 Section 5.4.6 X X

17. Tighten engine and generator mounting bolts Section 5.7 X X

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

19. Verify operation of engine protective devices X X

20. Check water pump bearing end play See Engine Manual

X X

21. Change fuel filter Section 5.4.3 X X

22. Clean crankcase breather Section 5.4.13

X X

T-343 Rev D 512

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

Section 5.6.2 X X

24. Check and, if required, replace poly V-Belt Section 5.4.11

X X

25. Clean and flush coolant system Section 5.4.5 X X Note 3

26. Check starter condition See Engine Manual

X X

27. Check engine compression See Engine Manual

X X

28. Check and adjust injector nozzles See Engine Manual

X X

29. Perform generator maintenance Section 5.5.1 X X

After Starting Generator Set, perform the following:

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

X

31. Listen for abnormal bearing noise X

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

33. Check exhaust system for leaks X

34. Check with voltmeter. Generator output should be 490 volts AC +/- 15volts (engine, 1800 RPM) with a nominal frequency of 60 Hz +/- 0.1% Turn refrigeration unit on and check generator 1800 RPM minimum under full load (15 kW)

X

NOTES: 1. 500 hour interval in extreme operation conditions 2. 250 hour interval in extreme operation conditions 3. Four years or 4000 hours if unit is factory charged with long life (red/orange) coolant

Table 51 Preventative Maintenance Actions and Schedule

Description of Procedure Reference Paragraph

Perform at Pre-Trip

Inspection

Standard Service Interval Units

Extended Service Interval Units*

Every 1000 Hours

Annually or Every

3000 Hours

Annually or Every

3000 Hours

61 T-343 Rev D

SECTION 6 SCHEMATICS

6.1 INTRODUCTION

This section contains the 12-volt DC control circuit schematics and the 460 volt alternating current generator sche- matics. To identify the schematics applicable to your PID number refer to Table 21.

Figure 6.1 Schematic Diagram - Legend

(Applies to Figure 6.2 thru Figure 6.3)

Based On Drawing 62-11411-00 Rev-

T-343 Rev D 62

Figure 6.2 Schematic Diagram

(For Applicability, Refer to Table 21)

Based On Drawing 62-11411-00 Rev

IH

63 T-343 Rev D

Figure 6.3 Schematic Diagram 460 Volt Alternating Current Generator

(For Applicability, Refer to Table 21)

NOTE: WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMI- NAL STRIP TERMINAL T10.

Based On Drawing 62-11411-00 Rev

T-343 Rev D 64

Figure 6.4 Schematic Diagram - Legend

(Applies to Figure 6.5 thru Figure 6.6)

Based On Drawing 62-11413-00 Rev A

65 T-343 Rev D

Figure 6.5 Schematic Diagram

(For Applicability, Refer to Table 21)

Based On Drawing 62-11413-00 Rev A

T-343 Rev D 66

Figure 6.6 Schematic Diagram 460 Volt Alternating Current Generator

(For Applicability, Refer to Table 21)

Based On Drawing 62-11413-00 Rev A

67 T-343 Rev D

Figure 6.7 Schematic Diagram - Legend

(Applies to Figure 6.8 thru Figure 6.9)

Based On Drawing 62-11466-00 Rev B

T-343 Rev D 68

Figure 6.8 Schematic Diagram

(For Applicability, Refer to Table 21)

Based On Drawing 62-11466-00 Rev B

69 T-343 Rev D

Figure 6.9 Schematic Diagram 460 Volt Alternating Current Generator

(For Applicability, Refer to Table 21)

NOTE: WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMINAL STRIP TERMINAL T10.

Based On Drawings 62-11466-00 Rev- B

T-343 Rev D 610

Figure 6.10 Schematic Diagram - Legend

(Applies to Figure 6.11 thru Figure 6.12)

Based On Drawing 62-11438-00 Rev D

611 T-343 Rev D

Figure 6.11 Schematic Diagram

(For Applicability, Refer to Table 21)

Based On Drawing 62-11438-00 Rev D

T-343 Rev D 612

Figure 6.12 Schematic Diagram 460 Volt Alternating Current Generator

(For Applicability, Refer to Table 21)

NOTE: WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMINAL STRIP TERMINAL T10.

Based On Drawing 62-11438 Rev D

613 T-343 Rev D

Figure 6.13 Schematic Diagram - Legend

(Applies to Figure 6.14 thru Figure 6.15)

Based On Drawing 62-11441-00 Rev D

T-343 Rev D 614

Figure 6.14 Schematic Diagram

(For Applicability, Refer to Table 21)

Based On Drawing 62-11441-00 Rev D

615 T-343 Rev D

Figure 6.15 Schematic Diagram 460 Volt Alternating Current Generator

(For Applicability, Refer to Table 21)

NOTE: WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMINAL STRIP TERMINAL T10.

Based On Drawing 62-11441 Rev D

Index1 T-343 Rev D

INDEX

A AC Generator 55 Air Cleaner Body 54 Air Cleaner, Dry Element 53 Air Cleaner, Oil Bath Service 54 Air Filter Indicator 53 ALTERNATING CURRENT GENERATOR 44 Alternating Current Generator 26, 44 AUTO RE-START OPTION 45 Auto Re-Start Option 45

B BATTERY CHARGER (SOLID STATE) 44 Battery Charger (Solid State) 44 Battery Charging System 26

C Configuration Identification 21 Control Panel 27

D Description 21, 31 Diesel Engine 41 Dual Speed Option 46

E ELECTRONIC GOVERNOR MODULE 46 Electronic Governor Module 25, 46 Engine Air Cleaner 53 Engine Air System 25 Engine Crankcase Breather 54 Engine Data 214 Engine Screw Threads 26 Engine Speed 53 Engine Speed Sensor 53 Engine Starts Then Stops 42 Engine Will Not Shut Off 42 Engine Will Not Start 41

F First Aid 11

G General Generator Set Maintenance 58 General Safety Notices 11 Generator Set Installation 31 Generator Set Removal 32

H Heater Test 55

I Instruments 27 Intake Heater 55 Intake Heater Switch 55 Isolators/Shockmounts 59

L Low Coolant Sensor 52 Lube Oil Filter 52 Lube Oil Filter Arrangement 25

M Maintenance Precautions 11 Malfunction In The Engine Starting Circuit 43 Miscellaneous Engine Troubleshooting 43

O Oil Pressure Switch 53 Operating Controls 27 Operating Precautions 11

P Painted Surfaces 58 Poly V-belt 53 Post-Start Inspection 34 Pre-Start Inspection 33 Preventative Maintenance Actions and Schedule 511

Q Quick Mount 32

S Safety Devices 213 Safety Summary 11 Schematic Diagram 62 Schematic Diagram - Legend 61 Schematics 61 Sequence of Operation Warning 34 Specific Hazard Statements 12 Standard Mount 31 Starter Motor Malfunction 42 Starting and Stopping Instructions 33 Starting Instructions 33 Stopping Instructions 34

T-343 Rev D Index2

T Troubleshooting 41

U Unidrive Torque Requirements 510

Unit Hazard Label Identification 11 Unit Specifications 214

V VOLTAGE CONTROLLER 46

A member of the United Technologies Corporation. Stock symbol UTX

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