Diesel Generator Set
r
OPERATION AND SERVICE
for
69UG15
Generator Set Units
PID UG1450 and Higher
T--343 Rev --
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TABLE OF CONTENTS
PARAGRAPH NUMBER
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Safety--i
GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--i
FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--i
OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--i
MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--i
UNIT LABEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--i
SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--i
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 CONFIGURATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Electronic Governor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Engine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Lube Oil Filter Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 ENGINE SCREW THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.1 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.2 Alternating Current Generator Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 OPERATING CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.2 Control Panel and Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1--1
1--1
1--5
1--5
1--5
1--5
1--5
1--5
1--5
1--5
1--5
1--6
1--6
1--6
1--6
1--7
1.9 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
1.10 ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 GENERATOR SET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 GENERATOR SET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2 Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Post-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4 Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.3 Engine Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.6 Miscellaneous Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--1
2--1
2--2
2--3
2--3
2--3
2--3
2--3
2--4
2--4
3--1
3--1
3--1
3--1
3--2
3--2
3--2
3--3
T--343
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TABLE OF CONTENTS -- Continued
PARAGRAPH NUMBER
Page
3--3
3--4
3--5
4--1
4--1
4--1
4--1
4--1
4--1
4--1
4--1
4--1
4--1
4--4
4--4
4--4
4--4
4--5
4--5
4--5
4--5
4--6
4--6
4--6
4--6
4--7
4--8
4--8
4--9
4--9
3.2 BATTERY CHARGER (SOLID STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 AUTO RE-START OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 PREVENTATIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Servicing Fuel Pump Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 In--Line Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.6 Servicing the Low Coolant Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.7 Servicing Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.8 Servicing Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.9 Servicing Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.10 Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.11 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.12 Replacing the Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.13 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.14 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.15 Servicing Intake Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 SERVICING THE ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Preventative Maintenance and Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Generator Repair/Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.3 Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.4 Generator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 GENERAL GENERATOR SET MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 Maintenance Of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2 Check and Replace Isolators/Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--10
4.7 UNIDRIVE TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--11
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
T--343
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LIST OF ILLUSTRATIONS
FIGURE NUMBER
Page
1--3
1--4
1--5
1--5
1--6
1--7
1--8
1--8
2--1
2--2
4--1
4--4
4--5
4--6
4--6
4--8
4--8
4--9
4--10
4--10
4--11
5--1
5--2
5--3
5--4
5--5
5--6
5--7
Figure 1-1 Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-2 Generator Set -- Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-3 Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-4 Lube Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-5 A--C Generator Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-6 Standard Control Panel and Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-7 Customer Specific Control Panel and Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-8 Auto Restart Control Box and Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-1 Typical Generator Set Mounting - Standard Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-2 Typical Generator Set Mounting - Quick Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-1 Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-2 Low Coolant Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-3 Air Filter (Dry Element Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-4 Air Filter (Oil Bath Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-5 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-6 Rectifier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-7 A-C Generator Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-8 Truss and Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-9 Engine Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-10 Generator Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-11 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-1 Schematic Diagram - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-2 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-3 Schematic Diagram 460 Volt Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-4 Schematic Diagram 230 Volt Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-5 Schematic Diagram - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-6 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-7 Schematic Diagram 460 Volt Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES
TABLE NUMBER
Page
1--2
Table 1-1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 1-2 Auto Restart Preset Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 1-3 Auto Restart Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--9
1--9
Table 1-4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
Table 4-1 Preventative Maintenance Actions and Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--2
T--343
iii
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SAFETY SUMMARY
GENERAL SAFETY NOTICES
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this
manual. They are recommended precautions that must be understood and applied during operation and maintenance
of the equipment covered herein. The general safety notices are presented in the following three sections labeled:
First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions
appearing elsewhere in the manual follows the general safety notices.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.
OPERATING PRECAUTIONS
Always wear safety glasses and hearing protection.
Keep hands, clothing and tools clear of the radiator fan and rotating belts.
No work should be performed on the unit until all circuit breakers and start-stop switches are turned off and the
negative battery terminal has been disconnected..
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the unit and investigate.
MAINTENANCE PRECAUTIONS
Be sure power is turned off and the negative battery cable is disconnected before working on generator set.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with
the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.
In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).
Fuel Tanks present explosion, fire and rupture hazards even if liquid fuel has been drained. Do not attempt any repairs,
especially repairs using flame, welder or torch, unless you have been properly trained and the tank has been emptied
of liquid fuel and fuel vapors and the tank is properly ventilated.
UNIT HAZARD LABEL IDENTIFICATION
To help identify the hazard labels on the Unit and explain the level of awareness each one carries, explanations with
appropriate consequences are provided below:
DANGER
Indicates an immediate hazard which WILL result in severe personal injury or death.
WARNING
Indicates hazards or unsafe conditions which COULD result in severe personal injury or death.
CAUTION
Indicates potential hazards or unsafe practices which COULD result in minor personal injury, product or property
damage.
Safety--i
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SPECIFIC WARNING AND CAUTION STATEMENTS
The statements that follow are applicable to the generator set and appear elsewhere in this manual. These recom-
mended precautions must be understood and applied during operation and maintenance of the equipment covered
herein.
WARNING
CAUTION
Never pour cold water into a hot engine.
Beware of moving poly V-belt, belt driven
components and hot exhaust components.
CAUTION
WARNING
Use only ethylene glycol, anti-freeze (with
inhibitors) in system. Use of glycol by itself
will damage the cooling system.
Under no circumstances should ether or
any other unauthorized starting aids be
used in conjunction with the air intake heat-
er.
CAUTION
WARNING
Never open the radiator cap when the cool-
ant is hot.
Beware of moving poly V-Belt and belt driv-
en components.
WARNING
CAUTION
Always cover the engine inlet tube while the
air cleaner is being serviced.
Beware of pinch points.
WARNING
Do not use gasoline to clean air cleaner
parts.
CAUTION
Do not underfill or overfill the oil bath cups.
Overfilling of cups causes loss of capacity;
underfilling cups causes lack of filtering ef-
ficiency.
WARNING
Do not direct water or steam into the gener-
ator openings. Do not allow any soap and
water solutions to enter the alternator.
CAUTION
WARNING
When trying to restore residual magnetism,
be sure to wear safety glasses and non-con-
ductive gloves. Use an insulated 12 gauge
(or higher) jumper wire. Cut off all but a few
strands from both ends of the jumper wire
to help prevent fusing.
High voltage (dielectric) testing must not be
performed to the machine without first ob-
serving NEMA rules. The insulation of this
generator winding may be safely checked
by using a megger. A high megger reading
indicates good insulation.
CAUTION
CAUTION
The rotor should not be pulled out from the
alternator more than 0.75 inches. Damage
to the bearing and windings may result.
Observe proper polarity when installing the
battery or connecting a battery charger, the
negative battery terminal must be
grounded. Reverse polarity may damage
the charging system. When charging the
battery in unit, isolate the battery by discon-
necting the negative battery terminal first,
then the positive. Once the battery has been
charged, connect the positive battery termi-
nal first, then the negative.
CAUTION
Continued
operation
with
failed
shockmounts may result in engine or gen-
erator damage.
T-343
Safety--ii
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SECTION 1
DESCRIPTION
1.1 INTRODUCTION
The 69UG15 is available as a standard configuration,
with an Auto Restart option or with Auto Restart andLow
Coolant Sensor. The Auto Restart option automatically
restarts the unit in the event of a unit shutdown. Auto
Restart also offers built--in indicators that signal low oil
pressure, high water temperature, overspeed, and
other overcrank conditions.
The Carrier Transicold model 69UG15 under--mounted
diesel--driven generator sets provide electrical power
for all--electric refrigeration units.
The generator set (see Figure 1-1 and Figure 1-2)
consists of a diesel engine direct--connected to an
alternating current generator and mounted in a
structural steel frame. The engine is a vertical in--line,
four cylinder diesel manufactured by Kubota, while the
generator is a 15 kW, brushless, single bearing type
manufactured by Lima. The generator provides a
constant 460 or 230 VAC, three--phase, 60 hertz
electrical supply.
1.2 CONFIGURATION IDENTIFICATION
Generator set identification information is provided on a
label located below the left mounting pad to theleft of the
access service door (front facing). The label provides
the generator set model number, serial number, and
parts identification number (PID). The model number
identifies the overall configuration, while the PID
provides information on specific optional equipment.
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.
Separately bound manuals covering the diesel engine
are also available (see the following chart).
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.
Manual/
Equipment
Covered
V2203--DI
V2203--DI
Type of
Manual
Engine Parts List
Workshop
Form No.
62---11335
62---11362
1--1
T-343
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Table 1-1 Model Chart
LEGEND
A1 -- Standard Mount -- (See Figure 2-1)
A2 -- Quick Mount -- (See Figure 2-2)
B1 -- Receptacle Box -- with Circuit Breaker
B2 -- Receptacle Box -- with Circuit Breaker
B3 -- Receptacle Box -- Customer Specific
B4 -- Receptacle Box -- Interlock
C1 -- 460 Volt -- Standard
C2 -- 460 Volt -- with Auto--Restart
C3 -- 460 Volt -- Customer Specific
Electrical Wiring
Unit
Mounting
Receptacle
Box
Schematic and
Model
PID
Control Box
Diagram Figures
UG1450
UG1451
UG1452
UG1453
UG1455
UG1456
UG1457
UG1458
UG1459
UG1460
UG1461
UG1462
UG1463
UG1464
UG1465
UG1466
UG1467
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-5, 5-6, 5-7
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
5-1, 5-2, 5-3, 5-4
A1
A1
A1
A1
A1
A1
A1
A1
A2
A2
A1
A1
A1
A2
A1
A2
A2
B1
B1
B1
B1
B2
B2
B4
B3
B2
B2
B1
B1
B1
B1
B1
B1
B1
C1
C1
C1
C1
C1
C1
C2
C3
C1
C1
C1
C1
C1
C1
C1
C1
C1
69UG15--050S--05
69UG15--050S--06
69UG15--050S--07
69UG15--050S--08
69UG15--050Q--06
69UG15--068S--05
69UG15--068Q--05
69UG15--080S--05
69UG15--080Q--05
T-343
1--2
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5
1
2
3
4
16
15
14
13
12
11
10
9
8
7
6
15
15
15
14
230 VOLT
14
460 VOLT
14
1. Mechanical Fuel Pump
2. Injector Pump
3. Engine Speed Sensor
4. Poly V--Belt
5. Radiator
6. Controls (See Figure 1-6 or Figure 1-8)
7. Engine Oil Filter
9. Lube Oil Dipstick/Fill Cap
10. Starter
11. Air Cleaner
12. Generator Shockmount
13. Receptacle Box
14. Receptacle
15. Circuit Breaker
8. Engine Shockmount (Typical)
16. Air Filter Indicator (if equipped)
Figure 1-1 Generator Set
1--3
T-343
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1
2
3
11
10
4
5
6
9
7
8
1. Fuel Tank
2. Exhaust Muffler
7. Engine
8. Coolant Overflow Bottle
3. Solid State Battery Charger
4. Low Coolant Sensor (If Equipped)
5. Water Temperature Sensor
6. Water Temperature Switch
9. Alternating Current Generator
10. AC Generator Connection Box Access
11. Battery
Figure 1-2 Generator Set -- Top View (Top Frame Members Removed for Clarity)
T-343
1--4
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1.3 ENGINE
2
1
The engine is a vertical, in--line four cylinder diesel
engine, which is direct--connected to the alternating
current generator. Information on the major engine
systems is provided in the following subparagraphs.
1.3.1 Electronic Governor Module
The electronic governor module is a solid state control
module preprogrammed for 1800 RPM. The electronic
governor module, along with the engine speed sensor,
replaced the manual governor in order to provide a
constant engine speed.
3
1.3.2 Engine Air System
The air cleaner (Item 11, Figure 1-1) is designed to
prolong engine life and performance by preventing dirt
and grit from entering the engine and causing excessive
wear on all operating parts. In order for the air filter to
operate properly, the operator must regularly maintain
the air cleaner equipment in accordance with the
instructions provided within this document.
4
1. Oil Filter (Primary)
2. Oil Pressure Sender
3. Oil Pressure Switch
4. Oil Pan
1.3.3 Lube Oil Filter Arrangement
The engine lubricating oil filter is mounted in a horizontal
arrangement and shown in Figure 1-4.
Figure 1-4 Lube Oil
1.3.4 Fuel System
The fuel system is fitted with an in--line pre--filter and a
fuel filter, which also acts as a water separator. The filter
is also fitted with a heater. The fuel system is shown in
Figure 1-3.
1.5 ALTERNATING CURRENT GENERATOR
1.5.1 Principle of Operation
The Marathon Alternator Company (Lima) brushless
AC generator (see Figure 1-2, item 9) is
1.4 ENGINE SCREW THREADS
a
self--regulated, rotating field synchronous unit. The
generator stator and exciter stator are combined in a
common housing. The generator field, exciter rotor, and
rotating rectifier assembly are mounted on a common
shaft. The output of the exciter rotor is applied to the
generator field winding through a rotating, full--wave
bridge, silicon rectifier unit.
All threads used on the engine are metric.
8
All connections between the exciter stator windings and
the generator stator windings are internal within the
stator housing. Only the output power leads are
connected at the terminal box, which is located on top of
the generator.
9
6
1.5.2 Alternating Current Generator Diagram
Figure 1-5 shows the internal schematic diagram of the
generator, exciter, and rectifier unit. The generator is a
three--phase unit, and the exciter stator and exciter rotor
also have three--phase windings. A portion of the exciter
stator windings is connected across a tap on the
generator stator winding. This exciter shunt winding
provides the generator field excitation power required
for the generator no--load voltage. Another portion of the
exciter stator windings is connected in series with the
output of the generator and provides a compounding
excitation characteristic.
5
7
4
2
3
1
1. Fuel Tank
5. Fuel Filter and Water
Separator
6. Injection Pump
8. Fuel Bleed Valve
7. Injector Nozzles
9. Fuel Return Line
2. Fuel Supply Line
3. Inline Fuel Filter
4. Mechanical
Fuel Pump (Engine)
Figure 1-3 Fuel System Diagram
1--5
T-343
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The rotor is, in effect, the secondary of a rotating current
transformer induction frequency converter. The exciter
rotor output voltage is applied to the generator field
windings by a three--phase, full wave rotating silicon
rectifier unit. The response time of the excitation system
is very fast as the exciter stator carries an alternating
current corresponding to the load current that appears
immediately on the exciter primary. An increase in load
current will cause an immediate increase in the exciter
secondary output voltage, which is rectified and applied
to the generator field windings. The inherent
compounding characteristics of the excitation system
provide excellent voltage regulation even under heavy
overload conditions.
1.6 BATTERY CHARGER
The solid state battery charger (see Figure 1-2) is
located to the left of the radiator. The charger is powered
by the generator, and this input is protected by a circuit
breaker located on the control panel. The battery
charger produces
a
tapered charge (25 amps
maximum) and is designed not to overcharge the
battery.
1.7 OPERATING CONTROLS AND
INSTRUMENTS
1.7.1 Introduction
Components required for monitoring and controlling the
unit are located in the control box, on the control panel
(see Figure 1-6) and on the receptacle box (see
Figure 1-1).
FIELD
1.7.2 Control Panel and Related Components
a. Gauges and Senders
SHUNT
1. Oil Pressure Gauge (see Figure 1-6, Figure 1-7,
Figure 1-8)
SERIES
The purpose of this gauge is to observe normal
operating engine oil pressure. Normal oil pressure is 35
to 60 psig (3.3 to 5.2 kg/cm2).
STATOR
2. Oil Pressure Sender (see Figure 1-4)
GENERATOR
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.
STATOR
L
O
A
D
3. Water Temperature Gauge (see Figure 1-6,
Figure 1-7, Figure 1-8)
The function of this gauge is to observe water operating
temperature. The gauge is connected to the water
temperature sender.
4. Water Temperature Sender (see Figure 1-2)
ROTOR
This device senses engine water temperature and
transmits a signal to the water temperature gauge.
5. Low Coolant Sensor (see Figure 1-2)
RECTIFIER
EXCITER
This device senses the coolant level inside the radiator
and will complete a conductive circuit as long as the
probes remain immersed in coolant. When the coolant
level falls below the probes, a signal will be sent to the
auto restart module, shutting down the engine and all
12--volt circuitry.
ASSEMBLY
Figure 1-5 A--C Generator Circuit Diagram
6. Auto Restart Module
CAUTION
Auto start/restart is provided to simplify the start--up
process and provide an automatic restart feature that
will automatically attempt to restart the unit in the event
of shutdown. Four LEDs are used to indicate shutdown
from overcrank, overspeed, low oil pressure, and high
water temperature. A fifth LED is used to indicate the
unit is running. Refer to Table 1-2 for system preset
values.
Observe proper polarity when installing the
battery or connecting a battery charger. The
negative battery terminal must be
grounded. Reverse polarity may damage
the charging system. When charging the
battery in unit, isolate the battery by
disconnecting the negative battery terminal
first, then the positive. Once the battery has
been charged, connect the positive battery
terminal first, then the negative.
The auto restart function will perform a series of six
attempts to restart the unit and make three attempts
within each series. Once the function has completed all
18 attempts, the unit will automatically lock out future
crank attempts. Refer to Table 1-3 for detailed
information on auto restart sequencing.
T-343
1--6
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b. Meters
3. Ignition Switch (IGN)(Auto Restart) (see Figure 1-8)
1. Ammeter (A)
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.
The ammeter (see Figure 1-6, Figure 1-7, Figure 1-8) is
an indicator of the charging system and unit electrical
draw. It indicates the rate of discharge or charge of the
battery. During start up, the intake heater draws
approximately 42 amps.
1.8 SAFETY DEVICES
Safety devices, such as circuit breakers, fuses, and
safety switches, protect system components from
damage.
2. Total Time Meter (TT)
The total time meter (see Figure 1-6, Figure 1-7,
Figure 1-8) calculates the total hours and provides an
accurate readout of accumulated engine running time.
This data can be used to establish the proper periodic
maintenance schedule (refer to Section 4.1).
c. Manual Switches
1. Intake Heater Switch (HS) (see Figure 1-6,
Figure 1-7)
The intake heater switch is of the momentary type.
When held in the PREHEAT position, the switch allows
approximately 42 amps of battery current to flow into the
intake heater, which preheats the air within the intake
manifold and allows the engine to start. After starting the
engine, the intake heater switch should continue to be
held in the ON position for approximately 5 seconds until
the engine has developed enough oil pressure to close
the oil pressure safety switch.
The AC generator, solid state battery charger, fuel
heater, high water temperature, safety relay, total time
meter and intake air heater are protected by circuit
breakers. If a safety device opens and there is an
interruption of electrical current, the electronic governor
module will be de--energized, which will also
de--energize the fuel solenoid, interrupt the fuel flow to
the engine and stop the engine.
In units with auto restart, the engine, engine control
devices, and engine monitoring devices are protected
by the auto restart module, low coolant sensor (if
equipped), circuit breaker, low oil pressure switch, and
high water temperature switch. These safety devices
monitor system operating conditions and open a set of
electrical contacts when an unsafe condition occurs. If a
safety device opens and there is an interruption of
electrical current, the electronic governor module will be
de--energized, which will also de--energize the fuel
solenoid, interrupt the fuel flow to the engine and stop
the engine.
2. Ignition Switch (IGN) (see Figure 1-6, Figure 1-7)
The ignition switch is of the momentary type to be used
in the OFF/ON/START positions. When held in the
START (ignition) position, it energizes the starter motor
solenoid, which in turn allows the starter motor to crank
the engine. The switch is released to the RUN position
once the engine has started.
De--energizing the fuel solenoid shuts off the fuel supply
to the engine; thus stopping the engine. Safety device
specifications are provided in Table 1-4.
CONTROL
PANEL
CONTROL
BOX
12
13
3
2
11
4
1
5
6
7
10
9
8
1. Total Time Meter
8. Ground Studs
2. Water Temperature Gauge
3. Oil Pressure Gauge
4. Ammeter
5. Intake Air Heater Switch
6. Ignition Switch
9. Circuit Breaker (CB2)
10. Circuit Breaker (CB3)
11. Intake Heater Relay
12. Safety Relay
13. Intake Heater Timer
7. Battery Charger Circuit Breaker (CB5)
Figure 1-6 Standard Control Panel and Box
1--7
T-343
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CONTROL
PANEL
CONTROL
BOX
3
2
1
11
12
10
4
5
9
6
7
8
13
1. Total Time Meter
8. Ground Studs
2. Water Temperature Gauge
3. Oil Pressure Gauge
4. Ammeter
9. Safety Relay
10. Intake Heater Relay
11. Intake Heater Timer
12. Circuit Breaker (CB2)
13. Circuit Breaker (CB3)
5. Intake Air Heater Switch
6. Ignition Switch
7. Battery Charger Fuse
or Circuit Breaker (CB5)
Figure 1-7 Customer Specific Control Panel and Box
CONTROL
PANEL
CONTROL
BOX
4
3
2
5
13
14
6
12
1
15
16
7
11
8
10
9
1. Total Time Meter
9. Battery Charger Fuse
2. Engine Start Alarm (Buzzer)
3. Water Temperature Gauge
4. Auto Restart Module
5. Oil Pressure Gauge
6. Ammeter
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)
7. Engine Start/Intake Heater
Energized Light
8. Ignition Switch
16. Circuit Breaker (CB3)
Figure 1-8 Auto Restart Control Box and Panel
T-343
1--8
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Table 1-2 Auto Restart Preset Values
Preset Value Description
Indicator
Overspeed
2100 RPM
Overspeed is the point at which the unit will signal for shutdown
Crank Disconnect is the point at which the auto restart module
senses the engine has started and will disengage the starter
Crank Disconnect
700 RPM
Shutdown Lockout
Delay
The oil pressure and water temperature inputs are ignored during
this 15 second delay (after start up)
15 seconds
The delay is used during start up. The intake heater delay begins
timing after the auto restart module signal is received. During the
entire delay, the intake heater circuit will be energized, an indicator
light will be illuminated, and an alarm will sound. When the delay
expires, the unit will crank.
30 seconds
preheat
3 minutes
postheat
Intake Heater Delay
Crank Attempts
A series of six attempts with three attempts in each series
(total of 18 attempts)
18 attempts
Table 1-3 Auto Restart Sequencing
*Engine crank and rest is repeated three times each series unless the engine starts.
Intake
Engine
Crank
Engine
Rest
Heater
Series
Fuel
Attempt Energized Solenoid
Engine Status
Duration
Duration
in
Number
Engaged
(Seconds) (Seconds)
Seconds
If the engine starts:
a. Run sequence begins
b. Intake heater remains energized for 3
minutes
If the engine fails to start:
1
30
X
Up To 15
25
a. Intake heater will de--energize.
b. Fuel solenoid will de--energize.
c. Crank output will de--energize.
d. Overcrank LED will flash once. Wait two
seconds and repeat.
e. Unit will rest 30 minutes and proceed to
the next series.
If the engine starts:
a. Run sequence begins.
b. Intake heater remains energized for 3
minutes.
If the engine fails to start:
2
30
X
Up To 15
25
a. Intake heater will de--energize.
b. Fuel solenoid will de--energize.
c. Crank output will de--energize.
d. Overcrank LED will flash twice. Wait two
seconds and repeat.
e. Unit will rest 30 minutes and proceed to
the next series.
If the engine starts:
a. Run sequence begins.
If the engine fails to start:
a. Intake heater will de--energize.
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.
3
30
X
Up To 15
25
1--9
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Table 1-3 Auto Restart Sequencing (Continued)
Intake
Heater
Engine
Crank
Engine
Rest
Series
Fuel
Attempt Energized Solenoid
Engine Status
Duration
Duration
in
Number
Engaged
(Seconds) (Seconds)
Seconds
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.
4
30
30
30
X
Up To 15
Up To 15
Up To 15
25
25
25
e. Unit will rest five hours and proceed to
the next series.
If the engine starts:
a. Run sequence begins.
If the engine fails to start:
a. Intake heater will de--energize.
b. Fuel solenoid will de--energize.
c. Crank output will de--energize.
d. Overcrank LED will flash five times. Wait
two seconds and repeat.
e. Unit will rest five hours and proceed to
the next series.
5
X
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.
6
X
T-343
1--10
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Table 1-4 Safety Devices
Unsafe Condition
Safety Switch
ENGINE
Switch Setting
Low oil pressure switch (LOP) --
Automatic reset
Opens below 18 psig
(1.27 kg/cm2)
Low engine lubricating oil pressure
High engine cooling water temperature
Low coolant
Water temperature switch (HWT) --
Automatic reset
Opens at 230F (110C)
Low coolant sensor
Automatic reset
Opens with a loss of 32
ounces of coolant
Excessive current draw by the safety re-
lay, fuel heater, water temperature gauge,
oil pressure gauge or total time meter
Excessive current draw by the electronic
governor module
Circuit breaker (CB--2) --
Automatic reset
Trips at 30 amps
Trips at 10 amps
Fuse 1, 2, 3
INTAKE HEATER
Excessive current draw on intake heater
circuit
Circuit breaker (CB--3) --
Automatic reset
Opens at 50 amps
BATTERY CHARGER
Excessive current draw on 230 volt feed
circuit
Circuit breaker (CB--5) -- Manual reset Opens at 3 amps
GENERATOR
Circuit breaker (CB--1, 460 volt) --
Manual reset
Trips at 26 amps
(460 VAC)
Excessive current draw by load
Circuit breaker (CB--4, 230 volt) --
Manual reset
Trips at 48 amps
(230 VAC)
1.9 UNIT SPECIFICATIONS
Nominal Tank Sizes
Fill Capacity
Draw Capacity
52 gallons
(256 liters)
50 gallons*
(246 liters)
50 Gallon Steel
52 gallons
(256 liters)
50 gallons*
(246 liters)
50 Gallon Aluminum
a. Fuel Tanks
67.5 gallons
(197 liters)
65 gallons*
(189 liters)
65 Gallon Steel
85 gallons
(322 liters)
80 gallons*
(303 liters)
80 Gallon Aluminum
*Allows for DOT required 5% vapor space
Battery
63 lb (28.6 kg)
Generator (A--C)
280 lb (127 kg)
434 lb (197 kg) Approximate
1555 lb (705.3 kg)
Engine (Dry) -- without Accessories
Unit (with 50 gal steel tank, dry)
Unit (with 50 gal aluminum tank, dry)
Unit (with 65 gal steel tank, dry)
Unit (with 80 gal aluminum tank, dry)
b. Weights
1485 lb (673.6 kg)
1580 lb (716.7 kg)
1545 lb (700.8 kg)
1.10 ENGINE DATA
a. Bore/Stroke
3.26 in. (38 mm) / 4.03 in. (102.4 mm)
b. Compression Ratio
c. Cylinders (Number)
d. Displacement
21.5 : 1
Four
135.2 cubic inches (2.22 liters)
1--3--4--2
e. Firing Order
1--11
T-343
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1.10 ENGINE DATA (Continued)
Oil Pressure Safety
Switch Setting
Opens
18 psig (1.27 kg/cm2)
Capacity
Engine -- 16.0 US quarts (15.1 liters), includes standard filter.
Dipstick in oil pan or fill cap
NOTE
To check oil level on engines with the dipstick mounted in the
fill cap, remove the cap and wipe the dipstick clean. Insert the
cap back onto the oil fill tube, then remove to check level. It is
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.
Oil Level Indicator
f. Lubrication System
Use a heavy duty lubricating oil conforming to American Pe-
troleum Institute (API) Service Classification CG, CH or CI,
Base Number 10 or above.
Lube Oil
Specification
Outdoor Temperature
Fahrenheit
0F to 45F
Centigrade
--18C to 7C
SAE
10W30
Lube Oil Viscosity
45F and above
7C and above
10W30 or 15W40
Winter
Diesel No. 1
Summer
Diesel No. 2
g. Fuel and Fuel Heater
Thermostat (FHT)
FHT
Close on temperature fall @ 45+/-- 6.5F Open on temperature rise @ 75+/-- 6.5 F
Power Consumption: 150 Watts @ +/-- 10% at 14 VDC
42 amps at 12 VDC
h. Intake Heater Amperage
i. Horsepower
27 HP @ 1800 RPM at 3000 feet above sea level.
32 HP @ 1800 RPM at sea level.
6 U.S. quarts (5.68 liters) -- includes 1 quart (0.95 liter) in
coolant recovery bottle. (Refer to section 4.4.5)
Capacity
The cooling system may be factory charged with a 50/50 mix
of ethylene glycol and water. This mixture provides protection
Anti--Freeze:
to --34F (--37C). For replacement, use a low silicate anti--
Conventional
freeze meeting GM specifications GM 6038M or equal. Again,
a 50/50 mix is recommended.
The cooling system may be factory charged with a 50/50 mix
of extended life coolant (ELC) and deionized water. This mix-
ture provides protection to --34F (--37C). For replacement,
Anti--Freeze:
with extended life coolant (ELC) meeting GM specification
Extended Life
j. Cooling System
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.
Opens
Resets
230 +/-- 5F (110 +/-- 3C)
200F (93C) -- minimum
Water Temperature
Safety Switch
Setting
Starts to open
Fully open
Opens
177 to 182F (80 to 84C)
203F (95C)
Loss of 32 ounces of coolant or more
Refilling of radiator to proper level
Thermostat
Low Coolant
Sensor
Closes
k. Lubrication System
Oil Pressure
35 to 60 psig (3.3 to 5.2 kg/cm@)
T-343
1--12
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SECTION 2
OPERATION
2.1 GENERATOR SET INSTALLATION
completion, remove safety chain before removing
forks of fork lift truck from unit.
b. Quick Mount
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. Loosen mounting bolts (see Figure 2-2) sufficient to
bring clamp to open position. To orient in open posi-
tion, lift nut end of bolt out of slot. Clamp will fall open.
2. Place forks into fork lift pockets of generator. Attach
safety chain between unit and fork truck.
a. Standard Mount
3. Center the generator set in desired position under
chassis.
1. Loosen mounting bolts (see Figure 2-1) sufficient to
push mounting plates to the outermost position.
4. Lift clamp (item 1) in place, ensuring bolt (item 4) is
secured in slot.
2. Place forks into fork lift pockets of generator set. At-
tach safety chain between unit and fork truck.
5. Tighten bolt to 55 - 65 ft-lbs (7.6 - 9.0 mkg).
3. Center generator under chassis slide mounting
plates fully onto chassis I-beams and torque mount-
ing bolts to 80 - 90 ft-lbs (11.1 - 12.4 mkg). Upon
6. Upon completion, remove safety chain before re-
moving forks of fork lift truck from unit.
CONTAINER FLOOR CROSS I---BEAMS
A
REAR OF CHASSIS
A
FORK LIFT POCKET
ROADSIDE VIEW
1
2
3
5
7
6
4
8
SECTION A - A
1. Bolt
5. Washer, Belleville
6. Washer, Spherical, Female
7. Tee Nut
2. Washer, Spherical, Male
3. Mounting Plate
4. Generator Frame
8. Roll Pin
Figure 2-1 Typical Generator Set Mounting - Standard Mount
2--1
T-343
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CONTAINER FLOOR CROSS I---BEAMS
REAR OF CHASSIS
A
A
FORK LIFT POCKET
ROADSIDE VIEW
5
6
4
7
2
8
3
1
VIEW A - A
1. Angle Assembly, Clamp
2. Washer, Spherical, Male
3. Washer, Spherical, Female
4. Bolt
5. Washer, Spherical, Belleville
6. Roll Pin
7. Nut, Hex, 3/4-10
8. Frame Assembly
Figure 2-2 Typical Generator Set Mounting - Quick Mount
2.2 GENERATOR SET REMOVAL
b. Quick Mount
a. Standard Mount
1. Disconnect power cable to unit (if connected).
1. Disconnect power cable to generator (if connected).
2. With fork lift in position and safety chain attached,
loosen mounting bolts, and lift end of bolts out of slot
to orient clamps to open position.
2. With fork lift in position and safety chain attached,
slide mounting plates back sufficiently to clear chas-
sis.
3. Lower and remove generator.
2--2
T-343
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2.3 STARTING AND STOPPING INSTRUCTIONS
2.3.1 Pre-Start Inspection
NOTE
Piston rings in engines that have operated less
than 100 hours may not be fully seated. This
may lead to the possibility of oil seepage from
the exhaust pipe. To properly seat the rings, op-
erate the engine under full load for aperiod of 24
hours. If the condition persists, check valve
clearance when the engine is cold. (Refer to en-
gine workshop manual listed in paragraph 1.2).
a. Check engine lubrication and fuel filters, oil lines, and
connections for leaks. If required, tighten connec-
tions and/or replace gaskets.
b. Check engine lubricating oil level. (Refer to para-
graph 1.10, table entry f.)
c. Check poly V-belt for fraying or cracks and proper ten-
sion. (Refer to paragraph 4.4.9).
a. Standard Units
1. Hold intake heater switch (see Figure 1-6) in the
PREHEAT position. Suggested hold times for a cold
engine are as follows:
d. Check radiator hoses for leaks and check radiator
coolant level. (Refer to paragraph 1.10, table entry j.)
e. Check radiator coil and generator air intake screen for
cleanliness. If required, clean using compressed air,
reversing the normal air flow.
COLD ENGINE PREHEAT TIMES
Ambient Temperature
78 F/ 26 C
Time
5 seconds
f. Check air cleaner for cleanliness and clean if neces-
sary. (Refer to paragraph 4.4.13.)
32 F to 78 F
(0 C to 26 C)
10 seconds
20 seconds
30 seconds
g. Check in--line fuel filter and clean if necessary. (Refer
to paragraph 4.4.4.)
18 F to 32 F
(--8 C to 26 C)
h. Drain water from fuel tank sump and filter bowl.
Below 18 F/-8 C
i. Fill fuel tank with diesel fuel. (Refer to paragraph1.10,
table entry g.)
2. With the intake heater switch held in the PREHEAT
position, place the ignition switch in the START posi-
tion.
j. Check air intake heater amperage. (Refer to para-
graph 1.10, table entry h.)
3. After the engine has started, continue to hold the in-
take heater switch in the PREHEAT position until the
engine develops sufficient oil pressure to close the
k. Check battery terminals for cleanliness and secure-
ness. If required, clean, then coat with a battery termi-
nal sealant.
oil pressure safety switch (approximately
5
seconds). When released, the intake heater switch
will automatically return to the OFF position and the
heater will remain energized for 3 minutes.
l. Check, and if required, tighten all electrical connec-
tions.
m.Check, and if required, tighten all hardware (brack-
ets, etc.).
b. Units with Auto Start
1. Place the Ignition switch (IGN) in the RUN position.
n. Ensure that the main generator set circuit breaker is
off (CB-1 for 460 volt units or CB4 for 230 volt units).
Connect power cable to refrigeration unit and pro-
ceed to paragraph 2.3.2.
2. If the low coolant sensor (LCS) is immersed in cool-
ant, the auto restart module will energize the heater
for 30 seconds and the safety buzzer will sound. Af-
ter the 30 second delay, the unit will attempt to start.
2.3.2 Starting Instructions
2.3.3 Post-Start Inspection
a. Turn on CB-1 for 460 volt units or CB4 for 230 volt
units.
WARNING
b. Check generator output with a voltmeter. In the no
load condition, output should be at 490 (+/- 10%)
volts with 1800 engine RPM. Place generator set
main circuit breaker in the ON position. Start refrig-
eration unit.
Beware of moving poly V-belt, belt driven
components and hot exhaust components.
c. Run engine 10 minutes (check total time meter op-
eration).
d. Listen for abnormal bearing noise (AC generator).
e. Check fuel lines, lube oil lines, and filters for leaks.
f. Check exhaust system for leaks.
WARNING
Under no circumstances should ether or
any other unauthorized starting aids be
used in conjunction with the air intake heat-
er.
2.3.4 Stopping Instructions
Place the ignition switch in the OFF position.
2--3
T-343
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2.4 CONTROL CIRCUIT OPERATION
The ignition switch (IGN) will be released. The intake air
heater switch (IH) will be held for 5 seconds, then
released after the IGN switch is realeased. When the
START switch is released, the starter will be
disengaged.
WARNING
With the engine running, the battery charger provides
DC power to operate the control system and charge the
battery.
Beware of moving poly V-Belt and belt driv-
en components.
b. Units with Auto Start
2.4.1 Sequence of Operation
When the ignition switch is placed in the RUN position,
12-volt DC power is applied to the low coolant sensor
(LCS) and the auto restart module simultaneously. If the
coolant level is below the sensor, all the indicator lights
on the auto restart module will blink once and the LCS
will open the contacts on the low coolant relay,
de-energizing the unit’s 12-volt DC circuitry. If the
coolant level is above the sensor, the auto restart
module will maintain power and all lights on the module
will illuminate. As the module performs its self test, the
lights will go out individually.
a. Standard Units
With the intake heater switch (IH) held in the ON
position, current flows through the ammeter to the
intake heater. While heater is on, the ammeter will show
a 40--amp draw.
A second set of contacts also energizes the safety relay
(S).
If the high water temperature switch (HWT) opens to
break the safety relay ground connection, the safety
relay will not energize, and the engine will not start,
After the self test is complete, the module will energize
the intake heater and sound the audible alarm warning,
indicating that the unit has been powered on and will
start. The 30--second delay starts at this time. When the
30--second delay expires, power will be applied to the
electronic governor and the engine attempts to crank for
15 seconds.
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, intakeheater relay (IHR)
and to the heater, while simultaneously powering the
electronic governor module (EG), fuel solenoid (FS),
and engine speed sensor (ESS).
When the engine starts, the intake heater will remain
energized for 3 minutes; during this time, the
engine/intake heater light and alarm will be energized,
the shutdown/lockout time delay of 15 seconds will
begin counting, and the starter will be disengaged.
During the shutdown/lockout time delay at start up, the
auto restart module will disregard the signals to the oil
pressure and engine temperature inputs, and the Run
sequence will begin (see Restart Procedure). If engine
does not start, refer to Table 1.3 for auto restart
sequencing.
The starter motor turns over the engine resulting in
pumping of fuel to the engine cylinders by the injection
pump. This fuel is ignited by heat of compression; thus
starting the engine. When the engine has developed
sufficient oil pressure, the low oil pressure switch
contacts close to maintain power to the safety relay.
Once the engine has started, the intake heater will
remain energized for 3 minutes.
2--4
T-343
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SECTION 3
TROUBLESHOOTING
REMEDY/
REFERENCE
SECTION
CONDITION
POSSIBLE CAUSE
3.1 DIESEL ENGINE
3.1.1 Engine Will Not Start
Battery insufficiently charged
Battery terminal post or battery defective
Electrical connections at starter are bad
Starter motor malfunctions
Starter motor solenoid defective
Open starting circuit
Charge
Check
Correct
See 3.1.4
Engine Manual
See 3.1.5
Section 1.10.f.
Starter motor will not crank or low
cranking speed
Incorrect grade of lubricating oil
No fuel in tank
Sections
1.9/1.10.g
Air inside the fuel system
Water inside the fuel system
Plugged fuel filters
Section 4.4.1
Drain Sump
Replace
Air intake heater is bad
Low oil / Oil pressure switch defective
Faulty heater switch
Plugged fuel lines to injector(s)
Mechanical lift fuel pump malfunction
Fuses F1, F2, F3, F4 are bad
Loose or no connection between wire harness and
electronic governor
Section 4.4.15
Section 4.4.7
Section 4.4.8
Engine Manual
Engine Manual
Check/ replace
Check/correct
Starter motor cranks, but fails to
start
Engine lube oil too heavy
Voltage drop in starter cable(s)
Section 1.10.f.
Check
Starter cranks and engages, but
dies after a few seconds
3.1.2 Engine Starts Then Stops
No fuel in tank
Sections
1.9/1.10.g
Fuel heater switch not held long enough
Fuel filter restricted
Hold switch
Replace
Air cleaner or hose restricted
Engine crankcase breather or hose restricted
Safety device open
Open wiring circuit to fuel solenoid
Fuel solenoid defective
Section 4.4.13
Section 4.4.14
Section 1.8
Check
Engine stops after a few rotations
Replace
Fuel supply restricted
Sections 1.10.g,
4.4.2, and 4.4.3
Mechanical lift fuel pump malfunction
Low oil / Oil pressure switch defective
Leak in fuel system
Engine Manual
Section 4.4.7
Check
Injector nozzle(s) defective
Injection pump defective
Generator internal overloads open
Engine Manual
Engine Manual
Table 1-4
T-343
3--1
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REMEDY/
REFERENCE
SECTION
CONDITION
POSSIBLE CAUSE
3.1.3 Engine Will Not Shut Off
Engine will not shut off
Loose ground connection
Improperly seated fuel solenoid
Clean/Tighten
Correct
3.1.4 Starter Motor Malfunction
Battery insufficiently charged
Battery cable connections loose or oxidized
Battery cables defective
Charge
Check/Replace
Check/Replace
Engine Manual
Starter brushes shorted out
Starter motor will not crank or turns
slowly
Starter brushes hang up, defective or have no contact Engine Manual
Starter solenoid damaged
Ignition switch defective
Engine lube oil too heavy
Engine Manual
Replace
Section 1.10.f.
Starter motor turns, but pinion does Pinion or ring gear obstructed or worn
not engage
Engine Manual
Ignition switch is bad
Starter motor solenoid is bad
Check/Replace
Engine Manual
Starter motor does not disengage
after switch has been released
Pinion does not disengage after
engine is running
Starter is bad
Engine Manual
3.1.5 Malfunction In The Engine Starting Circuit
Battery defective
Loose electrical connections
Correct
Tighten
No power to starter motor solenoid
Battery defective
Correct
Loose electrical connections
Oil pressure switch defective
Water temperature safety switch open
Fuel solenoid defective
Intake heater switch is bad
Electronic governor module is bad
Tighten
Section 1.8
Section 1.8
Engine Manual
Fuel solenoid does not energize or
does not remain energized
Check
(Engine Manual)
Replace
(Section 4.4.15)
Check/Replace
Intake heater switch is bad
Timer is bad
Heater element is bad
Heater relay is bad
Section 4.4.15
Section 4.4.15
Section 4.4.15
Section 4.4.15
Intake heater does not energize
T-343
3--2
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REMEDY/
REFERENCE
SECTION
CONDITION
POSSIBLE CAUSE
3.1.6 Miscellaneous Engine Troubleshooting
Restriction in air cleaner
Air in fuel system
Air vent restricted
Section 4.4.13
Section 4.4.1
Clean
Restricted fuel lines
Engine Manual
Engine Manual
Engine Manual
Engine Manual
Engine Manual
Engine Manual
Loss of power
Fuel injection pump is bad
Injector(s) bad or incorrect type used
Incorrect fuel injection pump timing
Incorrect valve timing
Poor compression
Engine shockmounts are bad
Poor compression
Replace
Engine Manual
Vibration
Restriction in air cleaner
Exhaust pipe restriction
Restriction in water jacket
Restriction in radiator
Coolant level too low
Loose water pump/alternator poly V-belt
Thermostat is bad
Section 4.4.13
Remove
Engine Manual
Section 4.4.5
Section 1.10.j.
Section 4.4.9
Engine Manual
Engine Manual
Overheating
Water pump is bad
Excessive crankcase pressure
Plugged crankcase breather line
Section 4.4.14
3.2 BATTERY CHARGER (SOLID STATE)
Short in 12-volt wiring causing overload of charger
Locate and
remove short or
replace charger
Circuit breaker trips when charger is
turned on
Circuit breaker trips repeatedly,
even when not connected
Internal short
Replace charger
Bad cell in battery
Test battery for
defect according
to battery
manufacturer’s
instructions
Charger does not taper back after
charging for a few minutes
Replace
Charger is bad
T-343
3--3
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REMEDY/
REFERENCE
SECTION
CONDITION
POSSIBLE CAUSE
3.2 BATTERY CHARGER (SOLID STATE) (CONTINUED)
Open input circuit breaker
Reset
Charger is not receiving AC input
Using a voltme-
ter, confirm
charger is receiv-
ing correct (230v)
AC voltage. If not,
check input
Charger does not charge
connections.
Charger output is not connected to 12 volt battery
Check output
wiring connec-
tions to battery.
Replace
Charger is bad
Battery not connected to charger. It is normal to
measure 12 volts or less across charger output with
no battery connected
Check charging
leads from
charger to battery
Low output voltage measured
across charger output
Reverse polarity connection to
battery has caused charger to stop
charging
Internal DC fuse blown and possible damage to
current carrying components
Replace
3.3 ALTERNATING CURRENT GENERATOR
Loss of residual magnetism in exciter field
Section 4.5.2.a.
Check
Section 4.5.4/
Replace
Circuit breaker tripped
Open in stator windings
Section 4.5.1.c.
Section 4.5.4/
Replace
Open or short in rotating rectifiers
Short circuited
No voltage
Section 4.5.4/
Replace
Section 4.5.4/
Replace
Open in alternator field
Shorted exciter armature
Low engine speed
Excessive load
Section 4.4.11
Check
High resistance connections - connections are
warm or hot
Shorted field
Tighten
Low voltage
Section 4.5.4/
Replace
Fluctuating speed
Irregular speed of engine
Loose terminal or load connections
Bad bearing causing uneven air gap
Section 4.4.11
Engine Manual
Tighten
Section 4.5.1/
4.5.3
Fluctuating voltage (May be indi-
cated by flickering lights)
High voltage
Excessive engine speed
Section 4.4.11
T-343
3--4
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REMEDY/
REFERENCE
SECTION
CONDITION
POSSIBLE CAUSE
3.3 ALTERNATING CURRENT GENERATOR (CONTINUED)
Generator overloaded
Check
Clogged ventilating screens
Clean
High temperature surrounding generator
Section 4.4.5
Section 4.5.1
Balance
Section 4.5.1/
4.5.3
Overheating
Insufficient air circulation
Unbalanced load
Dry bearing
Bad bearing
Section 4.5.1/
4.5.3
Rotor scrubbing on stator
Loose laminations
Section 4.5.1/
4.5.3
Section 4.5.4/
Replace
Mechanical Noise
Loose or misaligned coupling
Static charge
Section 4.5.4
Check ground to
frame
Section 4.5.4/
Replace
Generator frame produces shock
when touched
Grounded armature of field coil
3.4 AUTO RE-START OPTION
Wait 30 seconds for intake heater to be activated
Coolant level below the low coolant sensor
Relay defective
Wait
1.10.j.
Check/Replace
Ignition switch defective
Check/Replace
Switch
3 amp Fuse is bad
Check and
When the Ignition switch is placed in
the RUN position, nothing happens--
no lights illuminate
Replace Fuse
Loose connector on module
Auto restart module is bad
Tighten
connector
Check for 12
volts at Pin 4/
Replace module
Miswired connectors
Check/Correct
wiring
No voltage at Pin 2 of the connector
Check Starter Solenoid
Auto restart module is bad
Trace/Correct
See 3.1.1
Replace module
Alarm sounds, but engine does not
crank
Speed Sensor wiring loose
Speed Sensor is bad
Auto restart module is bad
Check/Correct
Replace
Replace module
Engine starts, but the starter does
not disengage
T-343
3--5
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REMEDY/
REFERENCE
SECTION
CONDITION
POSSIBLE CAUSE
3.4 AUTO RE-START OPTION (CONTINUED)
Engine starts, but shuts down from
over speed
Electronic governor module is bad
Replace
Electronic governor module is bad
See 3.1.1
Replace
See 3.1.1
Engine cranks, but will not start
Engine starts, but shuts down on
low oil
See 3.1.2
See 3.1.2
See 3.1.6
See 3.1.6
Engine starts, but shuts down on
high water temperature
T-343
3--6
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SECTION 4
SERVICE AND PREVENTIVE MAINTENANCE
4.1 INTRODUCTION
3. Turn filter (item 3) counter-clockwise and remove.
Check and clean.
This section covers service for the generator set and
general engine service. Refer to the Kubota engine
workshop manual, Section 1.1, for other engine
servicing.
4. To install, reverse steps 1 through 3.
5
3
1
WARNING
Beware of moving V-belt and belt driven
components.
4.2 PREVENTATIVE MAINTENANCE SCHEDULE
A tabular listing of the recommended preventative
maintenance activities and schedule is provided in
Table 4-1.
4
1
4.3 BATTERY SERVICE
2
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.
1. Nut
2. Banjo
3. Filter
4. Copper Rings
5. Manual Priming Pump
4.4 ENGINE SERVICE AND COMPONENTS
4.4.1 Bleeding the Fuel System
Figure 4-1 Mechanical Fuel Pump
4.4.3 Fuel Filter
The unit is equipped with a mechanical fuel lift pump,
mounted on the engine next to the injection pump. The
fuel system is a closed circuit, which will require
bleeding if loss of fuel has occurred. To fill and bleed the
system, do the following:
The full flow filter is located on the generator set frame
(see Figure 1-3).
To renew, remove the nut on top of filter housing, then
remove the bowl housing and filter element. Install new
filter element. Lightly oil new gasket with lube oil and
replace. Reassemble housing.
1. Turn fuel bleed valve (Red, see Figure 1-3) counter-
clockwise until fully opened.
4.4.4 In--Line Fuel Filter
2. Turn the top of the manual priming pump (see
Figure 4-1) counter-clockwise to unlock it, and then
rapidly hand pump the manual plunger until a posi-
tive pressure (resistance) is felt. This will indicate
fuel flow.
Loosen bowl by turning counter--clockwise. To renew,
remove in--line fuel strainer, check and clean, and
replace.
4.4.5 Cooling System
To ensure adequate cooling, the radiator must be clean,
externally and internally. To service the cooling system,
do the following:
3. Depress and turn the top of the manual priming
pump clockwise to lock in place.
4. Start engine. (Refer to section 2.3).
1. Remove all foreign material from the radiator coil by
reversing the normal air flow. Compressed air or wa-
ter may be used as a cleaning agent. It may be nec-
essary to use warm water mixed with any good com-
mercial dishwasher detergent. If a detergent is used,
rinse coil(s) with fresh water.
5. When engine is running properly, turn fuel bleed
valve clockwise until fully closed.
4.4.2 Servicing Fuel Pump Internal Filter
The internal fuel filter may become plugged or restricted
with foreign particles or wax, which can develop if the
wrong grade of fuel is used or untreated fuel is used in
cold weather, contaminating the fuel. If the internal filter
is plugged, the engine will lose power. Therefore, the
filter must be cleaned on a regular basis. The quality of
the fuel will affect the filter cleaning schedule (refer to
section 4.2).
2. Drain coolant completely by opening drain cock and
removing radiator cap.
CAUTION
Never pour cold water into a hot engine.
1. Turn nut (item 1) counter-clockwise to loosen and re-
move.
3. Close drain cock and fill systemwith clean, untreated
water to which between 3% and 5% of an alkaline
base radiator cleaner should be added; six ounces
(dry) = 151 grams to one gallon (3.8 liter) of water.
2. Remove banjo fitting (item 2) and let it hang loose,
making sure to keep copper rings (item 4) for re-
placement.
4--1
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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.
4. Reconnect the harness and refill the radiator to
proper level.
4.4.7 Servicing Low Oil Pressure Switch
1. Remove harness connection from low oil pressure
switch (LOP).
CAUTION
2. Remove pressure switch from engine.
Use only ethylene glycol, anti-freeze (with
inhibitors) in system. Use of glycol by itself
will damage the cooling system (Refer to
paragraph 1.10.j.).
3. Apply Teflon thread sealer to threads of new low oil
pressure switch.
4. Install new low oil pressure switch.
5. Reconnect harness connection to low oil pressure
switch.
5. Run engine to operating temperature. Drain system
again and fill with treated water/anti-freeze (see
above Caution note).
4.4.8 Servicing Heater Switch
1. Remove control box cover.
4.4.6 Servicing the Low Coolant Sensor
a. Testing the Low Coolant Sensor (LCS)
1. Verify the coolant level is correct.
2. Remove all connections going to heater switch (HS).
3. Remove heater switch from control box.
4. Install new heater switch.
2. Verify the wiring to the sensor is correct.
5. Reconnect wire harness connections to switch.
3. Check voltage (12.5 to 13.5 VDC) to the B terminal
with the ignition switch on (see Figure 4-2).
6. Confirm that wires are connected to correct
terminals.
4. Check continuity between terminals A and C (see
Figure 4-2) while 12 VDC is applied to terminal B.
7. Reinstall control box cover.
4.4.9 Servicing Poly V-belt
5. Drain the coolant from the system to below the level
of the coolant sensor and remove the sensor as
described in Section 4.4.6.b., steps 1 and 2 below.
WARNING
Beware of moving poly V-belt and belt
driven components.
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.
WARNING
Beware of pinch points.
NOTE
A frayed, cracked or worn poly V-belt must be
replaced. After installing a new belt, check the
adjustment after running the unit for three or
four hours. This will allow for the initial stretch,
which is common on new belts. Once this initial
stretch has taken place, the belt should be
checked at regular intervals.
Figure 4-2 Low Coolant Sensor
CAUTION
Never open the radiator cap when the
coolant is hot.
The poly V-belt is driven by a sheave on the engine
crankshaft. Its two functions are: (1) to drive the radiator
fan and (2) to drive the water pump.
To replace the poly V-belt, perform the following steps:
1. Using the proper size socket, slowly rotate the crank
on the crank pulley nut. At the same time, use a flat,
blunt object to guide the belt off the crank pulley
towards radiator. Be careful not to damage grooves
on the pulley.
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.
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.
3. Apply Teflon thread tape or thread sealer to the LCS
threads and install sensor.
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4.4.10 Lube Oil Filter
c. Service Procedure (Dry Element)
The primary oil filter is located near the radiator fan
(see Figure 1-4).
1. Stop the engine, remove air cleaner and install a
new element. Refer to Figure 4-3.
1. After warming up the engine, stop engine, remove
drain plug from oil reservoir and drain engine lube oil.
1
1
2. Replace filters. Lightly oil gasket on filter before
installing.
2
3
3. Add lube oil (Refer to paragraph 1.10.f).
4. Warm up engine and check for leaks.
4.4.11 Engine Speed
The engine speed is electronically controlled. DO NOT
ATTEMPT TO ADJUST ENGINE SPEED.
5
4
4.4.12 Replacing the Engine Speed Sensor
1. Disconnect the plug to the sensor.
2. Remove the bolt securing the sensor to the housing.
3. Remove the sensor from the housing.
4. Clean the recess in the housing to ensure that the
sensor seats properly when re-installed.
1. Air Outlet
2. Air Cleaner Body
3. Air Inlet
4. Cap Clamp
5. Air Filter Indicator
5. Re-install by sensor, replace the securing bolt and
connect the plug to the sensor.
Figure 4-3 Air Filter (Dry Element Type)
4.4.13 Engine Air Cleaner
d. Service Procedure (Oil Type)
a. Inspection
Inspect the oil cup (see Figure 4-4) at regular intervals.
Initially, inspect daily or as often as conditions require.
Never allow more than 1/2 inch (12.7 mm) of dirt deposit
in the cup. More than 1/2 inch accumulation could result
in oil and dirt carrying over into the engine, causing
accelerated engine wear. Heavily contaminated oil will
not allow the air cleaner to function properly.
The dry element or oil bath air cleaner should be
inspected regularly for leaks. A damaged air cleaner or
hose can seriously affect the performance and life of the
engine. The air cleaner is designed to effectively
remove contaminants from the air stream entering the
engine. An excessive accumulation of these
contaminants in the air cleaner will impair its operation.
Therefore, a service schedule must be set up and
followed.
CAUTION
Always cover the engine inlet tube while the
air cleaner is being serviced.
1. Check all connections for mechanical tightness. Be
sure the air cleaner outlet pipe is not fractured.
2. In case of leakage and if adjustment does not correct
the trouble, replace necessary parts or gaskets.
Swollen or distorted gaskets must always be
replaced.
Stop the engine and remove the oil cup from the air
cleaner. Dispose of the oil in an environmentally safe
manner. Remove the inner cup from the oil cup and
clean both cups.
b. Air Filter Indicator
The air filter indicator is mounted on the unit frame and
connected to the engine air intake. Its function is to
indicate when the air cleaner element requires
replacing. In operation: When a plugged air cleaner
decreases intake manifold pressure to 500 mm (20”)
WG, the indicator moves to the red line. The air cleaner
element should be replaced and the indicator reset by
pressing the reset button.
Reassemble and fill both oil cups to the indicated level
with oil specified in paragraph 1.10.f.
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CAUTION
Do not underfill or overfill the oil bath cups.
Overfilling of cups causes loss of capacity;
underfilling cups causes lack of filtering
efficiency.
1
2
3
4
5
1
1. Screw
2. Breather Cover
3. Bleed Hole
4. Breather Valve
5. Breather Tube
2
3
Figure 4-5 Engine Crankcase Breather
4.4.15 Servicing Intake Heater
1. Remove harness connection from heater.
2. Remove intake transition mounting hardware.
3. Remove intake transition, heater and both gaskets.
4
5
6
4. Clean old gasket material off the transition and
manifold mounting services.
1. Air Inlet Hood
2. Air Cleaner Body
3. Cap Clamp
4. Inner Oil Cup
5. Gasket
6. Oil Cup
5. Install new heater with a new gasket on either side.
6. Assemble transition to heater and torque mounting
hardware (refer to the engine manual for torque
values).
Figure 4-4 Air Filter (Oil Bath Type)
e. Service - Body Assembly
7. Reconnect harness to heater connection point.
8. Coat stud on heater with protective coating.
The lower portion of the air cleaner should be inspected
each time the oil cup is inspected or serviced. If there is
any sign of contaminant buildup or plugging, the body
assembly should be removed and back flushed.
4.5 SERVICING THE ALTERNATING CURRENT
GENERATOR
4.5.1 Preventative Maintenance and
At least once a year or at regular engine service periods,
remove the entire air cleaner and perform the following:
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.
1. Remove oil cups. Check and clean center tube.
WARNING
a. Cooling
Do not use gasoline to clean air cleaner
parts.
Keep all cooling parts clean. DO NOT EXCEED
TEMPERATURE RISE OF 80C (176F) ABOVE A 40C
(104F) AMBIENT. This ensures that the NEMA Class
“F” insulation will not be damaged. DO NOT EXCEED
RATED LOAD except as specified for the equipment.
OPERATE GENERATOR AT RATED SPEED. Failure
to operate generators at rated load or speed will cause
overheating and possible damage to windings due to
over voltage or current.
2. Pump solvent through the air outlet with sufficient
force and volume to produce a hard, even stream out
of the bottom of the body assembly. Reverse flush
until all foreign material is removed.
4.4.14 Engine Crankcase Breather
The engine uses a closed type breather with the
breather line attached to the cylinder head cover (see
Figure 4-5). It is not necessary to dissemble valve style
elements for cleaning. However, the bleed hole should
be checked to ensure it is free of obstruction. Check
once a year or at every 3,000 hours maintenance
interval, whichever comes first.
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b. Generator Windings (Drying)
Should the generator fail to build up voltage after being
disassembled for any reason, a momentary short-circuit
of any two generator leads (L1, L2 and L3) while
generator is running should be sufficient to correct this
condition.
WARNING
Do not direct water or steam into the
generator openings. Do not allow any soap
and water solutions to enter the alternator.
CAUTION
When trying to restore residual magnetism,
be sure to wear safety glasses and
non-conductive gloves. Use an insulated 12
gauge (or higher) jumper wire. Cutoff all but
a few strands from both ends of the jumper
wire to help prevent fusing.
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.
As an alternate method, apply either an alternating
current or a direct current voltage of approximately 20
volts to any two generator leads (L1, L2 and L3) while
generator is running. Do not make a positive
connection, but rather touch the leads together until the
generator voltage begins to rise, then remove. Insert a
30 ampere fuse into the circuit to prevent any damage in
case the build-up voltage is not removed quickly
enough. Reflash field if generator output voltage does
not build up.
Generators that have been in transit, recently steam
cleaned or in storage for long periods may be subjected
to extreme temperature and moisture changes. This
can cause excessive condensation, and the generator
windings should be thoroughly dried out before bringing
the generator up to full nameplate voltage. If this
precaution is not taken, serious damage to the
generator can result. The following steps should be
taken to effectively dry the generator windings:
b. Winding Insulation Testing
Continuity test results for the stator winding tests are
provided in the following table:
1. Dry windings by placing generator in drying oven or
hot room, or dry with warm air blower directed
through windings.
Wire
Pair
Wire
Pair
Wire
Pair
Ohm*
Ohm*
Ohm*
2. If the generator has been operated and is being
placed into storage for any period of time, a P.D.
George #11127 type air-dry fungus resistant varnish
should be applied.
T10-T1
T10-T2
T10-T3
T10-T4
T10-T5
T10-T6
T10-T7
T10-T8
T10-T9
T1-T2
I
I
I
I
I
T1-T8
T1-T9
T2-T3
T2-T4
T2-T5
T2-T6
T2-T7
T2-T8
T2-T9
T3-T4
T3-T5
T3-T6
T3-T7
T3-T8
T3-T9
I
I
I
I
0
I
I
I
I
I
I
0
I
I
I
T4-T5
T4-T6
T4-T7
T4-T8
T4-T9
T5-T6
T5-T7
T5-T8
T5-T9
T6-T7
T6-T8
T6-T9
T7-T8
T7-T9
T8-T9
I
I
I
I
I
I
I
I
I
I
I
I
0
0
0
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.
I
0
0
0
I
I
0
I
c. Rotor Damage
If a rotor becomes defective, it should be returned to the
factory with full nameplate data. To repair a rotor, the
special tooling and technique of the factory are
necessary and essential. Should a failure occur, Carrier
Transicold should be notified immediately and steps will
be taken to return the generator for service.
T1-T3
T1-T4
T1-T5
T1-T6
d. Terminal Strip Cleaning
I
I
Open terminal box. Remove dust and debris, and clean
terminal strip with wire brush. Reapply protective
coating.
T1-T7
* 0 = no resistance (closed circuit) & I = infinite resistance (open circuit)
4.5.2 Generator Repair/Test Procedures
a. Restoring Residual Magnetism
The direct current (DC) necessary to magnetize the
alternator field is obtained from the exciter. Initially, upon
starting the generator, current flow and voltage are
induced into the exciter armature by the magnetic lines
of force set up by the residual magnetism of the exciter
field poles.
Residual magnetism of the exciter field poles may be
lost or weakened by a strong neutralizing magnetic field
from any source, or if the generator is not operated for a
long period of time.
T-343
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c. Diode Testing
3. Remove the two cap screws that secure each diode
assembly to the exiter. Once this procedure is
complete, the diode assemblies are free for removal.
The rectifier diode assemblies can be tested, and if
damaged, replaced. Over current, over voltage, over
speed, or reverse currents can damage the assembly or
diodes. To remove the diode assemblies and perform
diode testing, do the following:
4. A forward diode should have a low resistance when
the + of an ohm meter is connected to the exciter
rotor lead connection (anode) and the - to the diode
bridge (cathode), and a high resistance when the
polarity of the ohmmeter is reversed.
1. Remove the bearing cover by removingthe four bolts
(see Figure 4-6). Both the bearing and diode
assemblies will be visible.
5. A reverse diode should have a high resistance when
the + of an ohm meter is connected to the exciter
rotor lead connection (anode) and the - to the diode
bridge (cathode), and a low resistance when the
polarity of the ohmmeter is reversed.
a.
b.
6. If both resistances are high or both are low, the diode
is defective and the diode assembly should be
replaced.
c.
d.
4.5.3 Bearing Replacement
When
operated
under
normal
conditions,
factory--lubricated shielded bearings will normally
provide years of trouble--free service. Excessive
bearing load and adverse environment conditions will
greatly shorten bearing life. To remove the bearings, do
the following:
g.
f.
e.
1. Remove bearing cover (See Figure 4-6).
2. Remove bearing with a bearing or wheel puller.
a. Rectifier Flange
b. Rectifier Assembly
c. Rectifier Bolt
e. Bearing Cover Bolt
f. Bearing
g. Bearing Cover Flange
3. Install new bearing. Ball bearings are pre-lubricated
and require no additional lubrication for the life of the
bearing.
d. Bearing Cover
Figure 4-6 Rectifier Removal
4. Coat mating surface of bearing cover flange with
anti-corrosion compound (Tef-Gel, Carrier Part
Number 02-00083-00). Replace bearing cover.
4.5.4 Generator Removal and Installation
2. Mark and disconnect the alternator rotor wires at the
rectifier screw terminals. Note that the terminals are
marked with red paint for theforward diodeassembly
and black for the reverse diode assembly. Mark and
disconnect the exciter leads from the double spade
terminals (see Figure 4-7).
a. Removing the Generator
1. Remove covers and ground wire from frame of
generator set.
a.
a.
2. Remove connection box cover and disconnect
power leads.
b.
3. Remove screen cover and generator exhaust baffle
from coupling end of generator.
d.
4. Remove the six 8mm hex head bolts and washers
that secure the generator drive disc to the engine
flywheel. Turn bolts counter-clockwise with offset
wrench to start, then use flexible shaft and socket
assembly for removal of bolts.
c.
5. Remove the twelve 3/8 inch hex head cap screws
and washers that secure generator frame to engine
flywheel housing.
b.
d.
6. Remove the four 5/8 inch bolts that secure the
generator mounting feet to the shockmount bracket,
then remove generator.
a. Diode Assembly
b. Diode Bridge
c. Exciter Rotor Lead Connection
d. Alternator Rotor Lead Connection
b. Installing the Generator
NOTE
For torque values refer to paragraph 4.7.
Figure 4-7 A-C Generator Rectifier Assembly
T--343
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The generator is a single bearing type, which means the
shaft end of the rotor floats. Before installing the
generator, rotate shaft and check if bearing rotates.
1. Brush anti-seize lubricant (lube-plate) on the face of
flywheel.
2. Move generator into position and line up with the
holes on housing and flywheel. If required, turn
crankshaft to align threaded holes in flywheel with
generator drive disc mounting holes.
5. Secure the remaining bolts and washers (3/8 inch);
torque the 12 bolts in a staggered pattern.
6. Install and torque generator mounting bracket bolts
(5/8 inch). Install screen cover, generator exhaust
baffle, power leads, ground wiring and generator
cover. Install new gasket when installing generator
connection box cover.
4.6 GENERAL GENERATOR SET MAINTENANCE
4.6.1 Maintenance Of Painted Surfaces
The unit is protected against the corrosive atmosphere
in which it normally operates by a special paint system.
However, if the paint system is damaged, the base
metal can corrode. If the paint system is scratched or
damaged, do the following:
CAUTION
The rotor should not be pulled out from the
alternator more than 0.75 inches. Damage
to the bearing and windings may result.
a. Clean area to bare metal using a wire brush, emery
paper or equivalent cleaning method.
3. Start the 8mm bolts (by hand) through the disc plate
and into the flywheel. Once alignment is made
torque the six bolts.
b. Immediately following cleaning, spray or brush on a
zinc rich primer.
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.
c. After the primer has dried, spray or brush on finish
coat of paint to match original unit color.
TRUSS
1
6
7
1
2
2
3
4
TRUSS
5
FRAME
4
5
UNIDRIVE
1. Bolt
5. Isolator
6. Locknut
7. Nutplate
2. Lock Washer
3. Flat Washer
4. Heat Shield
Figure 4-8 Truss and Isolator
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4.6.2 Check and Replace Isolators/Shockmounts
a. Replacement Criteria
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
CAUTION
shockmounts (Figure 4-10 item 7).
4. Install new shockmounts.
5. Lower the engine enough to assemble hardware as
shown and torque. Refer to paragraph 4.7 for torque
values.
Continued
operation
with
failed
shockmounts may result in engine or
generator damage.
6. Remove chains from the lift eyes.
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.
GENERATOR
4
3
b. Engine Isolator/Shockmount Replacement
1. Use the two lift eyes to lift and support the engine.
4
3
2
5
2. Remove truss, unidrive isolator and all hardware as
shown in Figure 4-9, if equipped.
3. Remove all hardware as shown in Figure 4-9.
6
3
1
4. Raise the engine just enough to remove the
shockmounts (Figure 4-9 item 4).
5. Install new shockmounts.
NOTE
11
8
For torque values refer to paragraph 4.7.
9
12
6. Lower the engine enough to assemble hardware as
shown and torque per paragraph 4.7.
10
7
7. Remove chains from the lift eyes.
ENGINE
INSTALL MOUNT
WITH LARGE
FLARE AT TOP
FRAME
1
12
13
7
8
2
FRAME
3
1. Screw (5/8)
8. Support Plate
2. Mounting Base
3 Flat Washer (5/8)
4. Locknut (5/8)
5. Locknut (1/2)
6. Flat Washer (1/2)
7. Shockmount
9. Snubbing Washer
10. Screw (1/2)
11. Screw (3/8)
12. Flat Washer (3/8)
13. Locknut (3/8)
4
5
FRAME
3
Figure 4-10 Generator Shockmounts
1. Bolt
2. Lock Washer
3. Snubbing Washer
4. Shockmount
5. Flat Washer
Figure 4-9 Engine Shockmounts
T--343
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4.7 UNIDRIVE TORQUE REQUIREMENTS
NOTES
SST is an abbreviation for 300 Series Corrosion
Resistant Steel.
Extensive damage may occur if the proper hardware is
not used and/or proper procedures are not followed
when working with the unidrive assembly. Periodic
inspection of hardware and bolt torque is recommended
to ensure the integrity of the unidrive.
Loctite #242 or an equivalent product should be
used on ALL hardware shown in Figure 4-11.
Torque value and hardware requirements for unidrive
assembly are provided in Figure 4-11.
ENGINE & GENERATOR SHOCKMOUNTS/ISOLATORS - TOP VIEW
1/2-13 x 3-1/2 lg - SST
(2 Req’d) 75 ft-lb (10.37 mkg)
TRUSS AND ISOLATOR
3/8-16 X 1-1/4 lg - SST
(4 Req’d) 30--39 ft-lb (4.15--5.39 mkg)
M8 X 1-1/4 lg - STL
(4 Req’d) 11 ft-lb (1.5 mkg)
Nut, Self Lock 3/8-16 - SST
(2 Req’d) 30--39 ft-lb (4.15--5.39 mkg)
3/8-16 x 1 lg - SST
(4 Req’d) 25 ft-lb (3.46 mkg)
5/8-18 x 2.00 lg - SST
(4 Req’d) 91--95 ft-lb (1.58--13.13 mkg)
ENGINE MOUNT - RIGHT SIDE VIEW
UNIDRIVE - SECTIONAL VIEW
Engine Flywheel
3/8-16 x 1-1/2 lg - SST
(12 Req’d) 25 ft-lb (3.46 mkg)
M8 x 15 MM lg - SST
(6 Req’d) 19 ft-lb (2.49 mkg)
Generator Disc Drive
5/8-11 x 4.00 lg - SST
(2 Req’d) 90 ft-lb (9.68 mkg)
Figure 4-11 Unidrive Torque Requirements
T-343
4--11
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SECTION 5
SCHEMATICS
5.1 INTRODUCTION
This section contains the 12-volt DC control circuit schematics, the 460 volt alternating current generator schematic
and the 230 volt alternating current generator schematic. To identify the schematics applicable to your PID number
refer to Table 1-1.
Based On Drawings 62-11411-00 Rev-
62-11414-00 Rev -
Figure 5-1 Schematic Diagram - Legend
(Applies to Figures 5-2 thru 5-4)
T-343
5--1
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IH
Based On Drawings 62-11411-00 Rev-
62-11414-00 Rev -
Figure 5-2 Schematic Diagram
(For Applicability, Refer to Table 1-1)
T-343
5--2
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NOTE:
WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES
ARE CONNECTED DIRECTLY AT GENERATOR TERMI-
NAL STRIP TERMINAL T10.
Based On Drawings 62-11411-00 Rev-
62-11414-00 Rev -
Figure 5-3 Schematic Diagram 460 Volt Alternating Current Generator
(For Applicability, Refer to Table 1-1)
T-343
5--3
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Based On Drawings 62-11411-00 Rev-
62-11414-00 Rev -
Figure 5-4 Schematic Diagram 230 Volt Alternating Current Generator
(For Applicability, Refer to Table 1-1)
T-343
5--4
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Based On Drawing 62-11413-00 Rev A
Figure 5-5 Schematic Diagram - Legend
(Applies to Figures 5-6, 5-7)
T-343
5--5
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Based On Drawing 62-11413-00 Rev A
Figure 5-6 Schematic Diagram
(For Applicability, Refer to Table 1-1)
T-343
5--6
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Based On Drawing 62-11413-00 Rev A
Figure 5-7 Schematic Diagram 460 Volt Alternating Current Generator
(For Applicability, Refer to Table 1-1)
T-343
5--7
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INDEX
A
F
First Aid, Safety--i
AC Generator Description, 1--5
Fuel Filter, 4--1
Air Filter Indicator, 4--5
Fuel Pump Filter Service, 4--1
Fuel System, 1--5
Ammeter, 1--7
Auto Restart Module, 1--6
Auto Restart Preset Values, 1--9
Auto Restart Sequencing, 1--9
G
Gauges and Senders, 1--6
Generator Principle of Operation, 1--5
Generator Removal and Installation, 4--8
Generator Repair, 4--7
B
Battery Charger, 1--6
Generator Service, 4--6
Battery Service, 4--1
Generator Set Installation, 2--1
Generator Set Removal, 2--2
Generator Test Procedures, 4--7
Generator Windings, 4--7
Bearing Replacement, 4--8
Bleeding the Fuel System, 4--1
C
Control Circuit Operation, 2--4
H
Control Panel, 1--6
Hazard Label Identification, Safety--i
Cooling System, 4--1
Heater Switch Service, 4--4
I
D
Ignition Switch, 1--7
Diode Testing, 4--8
In--Line Fuel Filter, 4--1
Insulation Testing, 4--7
Intake Heater Switch, 1--7
Dry Element Air Filter, 4--5
E
L
Electronic Governor Module, 1--5
Engine Air Cleaner, 4--5
Low Coolant Sensor, 1--6
Engine Air System, 1--5
Low Coolant Sensor Service, 4--4
Low Oil Pressure Switch Service, 4--4
Lube Oil Filter, 1--5, 4--5
Engine Crankcase Breather, 4--6
Engine Data, 1--11
Engine Description, 1--5
Engine Isolator/Shockmount Replacement, 4--10
Engine Screw Threads, 1--5
Engine Service, 4--1
M
Maintenance Precautions, Safety--i
Manual Switches, 1--7
Meters, 1--7
Engine Speed, 4--5
Engine Speed Sensor Replacement, 4--5
Model Chart, 1--2
T-343
Index--1
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INDEX (Continued)
O
S
Safety Devices, 1--7
Oil Air Filter, 4--5
Safety Notices, Safety--i
Safety Summary, Safety--i
Schematics, 5--1
Operating Controls and Instruments, 1--6
Operating Precautions, Safety--i
Sequence of Operation, 2--4
Servicing Intake Heater, 4--6
Starting Insturctions, 2--3
Stopping Instructions, 2--3
P
T
Poly V--Belt Service, 4--4
Post--Start Inspection, 2--3
Pre--Start Inspection, 2--3
Torque Requirements, 4--11
Total Time Meter, 1--7
Troubleshooting, 3--1
U
Preventative Maintenance and
Operating Precautions , 4--6
Unit Introduction, 1--1
Preventative Maintenance Schedule, 4--1, 4--2
Unit Specifications, 1--11
T-343
Index--2
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Carrier Transicold Division,
Carrier Corporation
Container Products Group
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A
A member of the United Technologies Corporation family. Stock symbol UTX
©2008 Carrier Corporation D Printed in U. S. A. 0908
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