genset ops manual 69ug15

7/14/2019 Genset Ops Manual 69UG15

http://slidepdf.com/reader/full/genset-ops-manual-69ug15 1/51 T-266RevHChange 1/20/03

Carrier TransicoldDiesel DrivenGenerator Set

Operation& Service

Model 69UG15


http://slidepdf.com/reader/full/genset-ops-manual-69ug15 2/51

OPERATION AND SERVICE MANUALDIESEL DRIVEN GENERATOR SET

MODEL69UG15

2002Carrier Corporation D Printedin U. S. A. 0602

Carrier Transicold, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221 U. S. A.

Carrier TransicoldA member of the United Technologies Corporation family. Stock symbol UTX.



Safety--i T-266

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in thismanual. They arerecommendedprecautions thatmustbeunderstood andappliedduringoperation andmaintenanceof the equipment covered herein. The general safety notices are presented in the following three sections labeledFirst Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautionsappearing elsewhere in the manual follows the general safety notices.

FIRST AIDAn injury, no matter howslight, shouldnever go unattended. Always obtain first aid or medical attentionimmediately

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 thenegative 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.

Donotbypass anyelectricalsafetydevices, e.g. bridgingan overload,orusinganysortofjumperwires. Problems withthe 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).

FuelTanks presentexplosion,fire andrupture hazards evenifliquidfuelhasbeendrained. Donotattemptanyrepairsespeciallyrepairs usingflame, welder or torch, unless you haveenproperlytrainedand the tank has been emptied oliquid fuel and fuel vapors and the tank is properly ventilated.

UNIT LABEL IDENTIFICATION

To helpidentifythe hazard labels onthe Unit and explainthe level of awareness each one carries, explanations withappropriate 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 oproperty damage.

SPECIFIC WARNING ANDCAUTION STATEMENTS

The statements that fol low are appli cable to the gener ator set and appear elsewhere i n this manual. These recom

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

herein.

WARNING

Do not use gasoline to clean air cleaner parts.

WARNINGBeware of moving V-belt, belt driven components and hotexhaust components.

WARNING

Underno circumstances shouldetheroranyotherunauthorizedstartingaids beusedinconjunctionwith the glow plugs.



Safety--ii T-266

WARNING

Donotdirectwateror steaminto thegeneratoropenings. Donotallowanysoapand watersolutionsto enter the alternator.

WARNING

Highvoltage(dielectric)testingmustnotbe performedto themachinewithoutfirstobservingNEMArules. The insulation of this generator winding may be safely checked by using a megger. A highmegger reading indicates good insulation.

CAUTIONObserveproperpolaritywheninstalling thebatteryorconnectingabatterycharger,thenegativebat-tery terminal mustbegrounded.Reversepolaritymaydamagethecharging system. Whenchargingthe battery in unit, isolate the battery by disconnecting the negativebattery terminal first, then thepositive.Oncethebatteryhasbeen charged,connectthepositivebatteryterminalfirst,thentheneg-ative.

CAUTION

ThegeneratorsetcircuitbreakermustbeintheONposition inordertosupplypowerto therefrigera-tion unit.

CAUTION

Never pour cold water into a hot engine.

CAUTION

Use only ethylene glycol, anti-freeze (with inhibitors) in system as glycol by itself will damage thecooling system.

CAUTION

Always cover the engineinlet tube while theair cleaner is being serviced.

CAUTION

Do not underfill or overfill the cups. Overfilling of cups means loss of capacity and underfillingmeans lack of filtering efficiency.

CAUTION

Continued operation with failed shockmounts may result in engine or generator damage.

CAUTION

Therotorshouldnotbepulled outfromthealternatormorethan 0.75inches. Damageto thebearingand windings may result.



i T--266

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

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

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

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

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

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

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

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

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

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

1.3 ENGINE 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Engine Air System 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2 Lube Oil Filter Arrangement 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3 Fuel System 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 ENGINE SCREW THREADS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 ALTERNATING CURRENT GENERATOR 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.1 Principle of Operation 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5.2 Alternating Current Generator Diagram 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 BATTERY CHARGING -- ALTERNATOR 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.1 Introduction 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.2 Alternator Operation 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.3 Integral Voltage Regulator Operation (12 volts d-c) 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 BATTERY CHARGING -- SOLID STATE SYSTEM 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 OPERATING CONTROLS AND INSTRUMENTS 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8.1 Introduction 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8.2 Control Panel and Related Components 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9 SAFETY DEVICES 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10 UNIT SPECIFICATIONS 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.11 ENGINE DATA 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.1 GE NERATOR S ET INSTALLATION AND REMOVAL -- S TANDARD MOUNT 2-1. . . . . . . . . . . . . . . . .

2.2 GENERATOR SET INSTALLATION AND REMOVAL -- QUICK MOUNT 2-2. . . . . . . . . . . . . . . . . . . . . .

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

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

2.3.2 Starting Insturctions 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.3.4 Stopping Instructions 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 CONTROL CIRCUIT OPERATION 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Sequence Of Operation (Units using Figure 5-2) 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 Sequence Of Operation (Units using Figure 5-6) 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



ii T--266

TABLE OF CONTENTS -- Continued

PARAGRAPH NUMBER Page

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

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

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

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

3.1.3 Engine Will Not Shut Off 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3.1.6 Miscellaneous Engine Troubleshooting 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 BATTERY CHARGING ALTERNATOR 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.4 ALTERNATING CURRENT GENERATOR 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

4.2 PREVENTIVE MAINTENANCE SCHEDULE 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.4 ENGINE SERVICE AND COMPONENTS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.1 Priming The Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

4.4.4 Cooling System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.5 Servicing And Adjusting V-belt 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.6 Lube Oil Filter 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.7 Adjusting Engine Speed 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.8 Engine Air Cleaner 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.9 Engine Crankcase Breather 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.10 Servicing Glow Plugs 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.5.1 Preventive Maintenance and Operating P recautions 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.2 Generator Repair/Test Procedures 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.3 Bearing Replacement 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.6 GENERAL GENERATOR SET MAINTENANCE 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Maintenance Of Painted Surfaces 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.2 Checking And Replacing Shockmounts 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 SERVICING THE ALTERNATOR 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Preliminary Checks and Tests 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2 Test Tools 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.3 Problem Area Determination 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.4 In-Unit Alternator/Regulator Tests 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.5 Alternator Brush Test Procedure 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.6 Slip Ring Servicing 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.7 Alternator Installation 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 UNIDRIVE TORQUE REQUIREMENTS 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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



iii T--266

LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

Figure 1-1. Generator Set -- Control Box (Road) Side 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1-2. Generator Set -- Top View with Top Frame Members Removed for Clarity 1-5. . . . . . . . . . . . . . . . . .

Figure 1-3. Fuel System Diagram 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1-4. Lube Oil 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1-5. A-C Generator Circuit Diagram 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1-6. Alternator and Regulator 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1-7. Alternator Schematic Diagram 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1-8. Control Box and Panel 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Figure 4-2. Engine Speed Adjustment 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-3. Air Filter 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Figure 4-5. A-C Generator Rectifier Assembly 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-6. Rectifier Removal 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-7. Engine Shockmounts 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-8. Generator Shockmounts 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-9. Open Diode-Trio Test 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-10. Open Regulator Test 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-11. Alternator Output Test 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-12. Alternator Brush Assembly 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-13. Unidrive Torque Requirements 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 5-1 Schematic Diagram 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .








LIST OF TABLES

TABLE NUMBER Page

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

Table 1-2. Safety Devices 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4-1 Preventative Maintenance Actions and Schedule 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-1 T-266

SECTION1

DESCRIPTION

1.1 INTRODUCTION

The carrier Transicold model 69UG15 under-mounteddiesel-driven generator sets serve to provide electricalpower for all-electric refrigeration units.

The generator set (see Figure 1-1 and Figure 1-2)consist of a diesel engine direct connected to analternating current generator and mounted in astructural steel frame. The engine is a vertical in--line,four cylinder diesel manufactured by Kubota while thegenerator is a 15 KW, brushless, single bearing typemanufactured by Lima. The generator provides aconstant 460 or 230 vac, 3 phase, 60 hertz electricalsupply.

Electrical controls are mounted in a control box withoperating controls and gauges mounted on a controlpanel (which alsoserves as the control box cover). Thecontrol panel components are protected by a deflectorassembly or a windowed control box door.

Auxiliary engine equipment consists of the startingbattery, battery charging system (alternator or solidstate), glowplugs (used as a startingaid), “spin-on”lube

oil and fuel filters (for easier filter changes) and othernecessary components for proper unit operation. Thewater pump and the radiator cooling fan are belt-drivenfromthe engine crankshaft. All references toengine areas viewed from the fly wheel end.

1.2 CONFIGURATION IDENTIFICATION

Generator setidentificationinformationis providedonaplate located inside the engine inspection door (see

Figure 1-2). The plate provides the generator setmodenumber, serial number and parts identification numbe(PID). The model number identifies the overaconfiguration while the PID provides information onspecific optional equipment and differences in detailedparts. Configuration identification for models coveredherein are provided in Table 1-1. The model numberserial number and PID number mustbe included when

ordering parts and inquiring about your unit.Separately bound manuals covering the diesel engineand Auto Restart Option are also available, see thefollowingchart. Note, all referencedengines have beenassembled using the two piece oil pan

Manual/FormNo.

EquipmentCovered

Type of Manual

62-03741* CT4-134-DI-B Workshop

62-03459* CT4-134-DI-B Engine Parts List

62-10301** CT4-134-DI Workshop

62-10295** CT4-134-DI Engine Parts List

62-10411 Auto Restart Supplement*Prior to Serial Number XA0001** Starting with Serial Number XA0001

Table 1-1. Model ChartLEGEND

A1 -- 50 Gallon Integral Tank (Side Fill -- Steel)A2 -- 50 Gallon Integral Tank (Top Fill -- Steel)

A3 -- 65 Gallon Integral Tank (Steel)A4 -- 50 Gallon Remote Tank (Steel)A5 -- 75 Gallon Remote Tank (Steel)A6 -- 50 Gallon Remote Tank (Aluminium)

B1 -- 460 VoltB2 -- 230 Volt

C1 -- No Voltmeter, Blank-Off PlateC2 -- With Voltmeter (Greenband)

Model PIDElectrical Wiring

Schematic andDiagram Figures

Fuel Tank Voltage Voltmeter

69UG15-111-1 UG0249 5-1, 5-2, 5-4 A2 B2 C2

UG0026 5-1, 5-2, 5-3 A1 B1 C1

UG0030 5-1, 5-2, 5-3 A1 B1 C2

UG0031 5-1, 5-2, 5-3 A1 B1 C1

UG0045 5-1, 5-2, 5-3 A1 B1 C2

UG0048 5-1, 5-2, 5-3 A1 B1 C2UG0052 5-1, 5-2, 5-3, 5-4 A1 B1/B2 C2

69 15-121-2UG0077 5-1, 5-2, 5-3 A1 B1 C2

UG0100 5-1, 5-2, 5-3 A1 B1 C2

UG0128 5-1, 5-2, 5-3 A2 B1 C2

UG0195 5-1, 5-2, 5-3 A2 B1 C2

UG0227 5-1, 5-2, 5-3 A2 B1 C2

UG0276 5-1, 5-2, 5-3 A2 B1 C1



1-2 T-266

Table 1-1. Model Chart -- Continued




UG0025 5-1, 5-2, 5-3 A1 B1 C169UG15-121-3

UG0034 5-1, 5-2, 5-3 A1 B1 C1

UG0063 5-1, 5-2, 5-3 A1 B1 C2

69UG15-121-5 UG0149 5-1, 5-2, 5-3 A2 B1 C2

UG0221 5-1, 5-2, 5-3 A2 B1 C2

69UG15-121-7 UG0164 5-1, 5-2, 5-3 A2 B1 C1

UG0155 5-1, 5-2, 5-3 A2 B1 C169UG15-121-8

UG0196 5-1, 5-2, 5-3 A2 B1 C1

69UG15-211-1 UG0172 5-1, 5-2, 5-4 A2 B2 C2

UG0049 5-1, 5-2, 5-3 A1 B1 C2

UG0114 5-1, 5-2, 5-3 A1 B1 C2

69UG15-221-2 UG0130 5-1, 5-2, 5-3 A1 B1 C2

UG0148 5-1, 5-2, 5-3 A1 B1 C2

UG0217 5-1, 5-2, 5-3 A2 B1 C2

69UG15-221-3 UG0229 5-1, 5-2, 5-3, 5-4 A2 B1/B2 C2

69UG15-221-4 UG0256 5-1, 5-2, 5-3 A2 B1 C269UG15-321-1 UG0248 5-1, 5-2, 5-3 A5 B1 C2

69UG15-321-2 UG0179 5-1, 5-2, 5-3 A5 B1 C2

UG0203 5-1, 5-2, 5-3 A6 B1 C169UG15-321-5

UG0291 5-1, 5-2, 5-3 A6 B1 C1

69UG15-421-1 UG0255 5-1, 5-2, 5-3 A3 B1 C2

69UG15-521-8 UG0234 5-1, 5-2, 5-3 A3 B1 C1

NOTE: In early 1998, Carrier Transicold began implementing a new model numbering system. The followingmodels use this new system.

UG0351 5-1, 5-2, 5-3 A2 B1 C1

UG0413 5-1, 5-2, 5-3 A2 B1 C2

69UG15-050Q-01 UG0497 5-5, 5-6, 5-7 A2 B1 C2UG0524 5-5, 5-6, 5-7 A2 B1 C2

UG0560 5-5, 5-6, 5-7 A2 B1 C2

UG0426 5-5, 5-6, 5-7 A2 B1 C169 15-050 -02

UG0688 5-5, 5-6, 5-7 A2 B1 C1

UG0427 5-5, 5-6,5-7 A6 B1 C1

UG0458 5-5, 5-6, 5-7 A6 B1 C169UG15-050R-01

UG0513 5-5, 5-6, 5-7 A6 B1 C1

UG0555 5-5, 5-6, 5-7 A6 B1 C1



1-3 T-266

Table 1-1. Model Chart -- Continued




UG0350 5-1, 5-2, 5-3 A2 B1 C2

UG0444 5-5, 5-6, 5-7 A2 B1 C1

UG0464 5-5, 5-6, 5-7 A2 B1 C1

UG0467 5-5, 5-6, 5-7 A2 B1 C2

UG0472 5-5, 5-6, 5-7 A2 B1 C1

UG0519 5-5, 5-6, 5-7 A2 B1 C1

UG0557 5-5, 5-6, 5-7 A2 B1 C169UG15-050S-01

UG0558 5-5, 5-6, 5-7 A2 B1 C2

UG0559 5-5, 5-6, 5-7 A2 B1 C1

UG0571 5-5, 5-6, 5-7 A2 B1 C2

UG0584 5-5, 5-6, 5-8 A2 B2 C1

UG0609 5-5, 5-6, 5-8 A2 B2 C1

UG0648 5-5,5-6, 5-7 A2 B1 C1

UG0695 5-5,5-6, 5-7 A2 B1 C1

69UG15-050S-02 UG0678 5-5, 5-6, 5-7 A2 B1 C1

69UG15-050S-20 UG0732 5-5, 5-6, 5-7 A2 B1 C1UG0342 5-1, 5-2, 5-3 A3 B1 C1

69 15-068 -01UG0601 5-5, 5-6, 5-7 A3 B1 C1

UG0443 5-5, 5-6, 5-7 A3 B1 C1

UG0463 5-5, 5-6, 5-7 A3 B1 C1

UG0556 5-5, 5-6, 5-7 A3 B1 C2

69UG15-068S-01 UG0598 5-5, 5-6, 5-7 A3 B1 C1

UG0645 5-5, 5-6, 5-7 A3 B1 C1

UG0694 5-5, 5-6, 5-7 A3 B1 C1

UG0837 5-5, 5-6, 5-7 A3 B1 C1



1-4 T-266

14

1

32 4

5

678911 1012

13

12 -- ALTERNATE RECEPTACLE BOX ARRANGEMENTS

230 VOLT 460 VOLT(RemoteReceptacle)

460 VOLT(With Volt-meter)

141414

1313 13

15

1. Lube Oil Dipstick/Fill Cap2. Mechanical Fuel Pump3. Injector Pump4. V-Belt5. Radiator6. Controls (See Figure 1-8)7. Engine Shockmount (Typical)8. Engine Oil Filter

9. S tarter10. Air Cleaner11. Generator Shockmount12. Receptacle Box13. Receptacle / Power Cord Exit14. Circuit Breaker15. Volt Meter (Alternate Location)

Figure 1-1. Generator Set -- Control Box (Road) Side



1-5 T-266

11

1

2

3

4

6

789

10

12

5

1. Fuel Tank2. Solid State Battery Charger (If Equipped)3. Exhaust Muffler4. D.C. Alternator (If Equipped)5. Water Temperature Sender6. Engine

7. Coolant Overflow Bottle8. F uel Filter9. S erial Plate

10. Alternating Current Generator11. AC Generator Connection Box Access12. Battery

Figure1-2. Generator Set -- Top View with Top Frame Members Removed for Clarity



1-6 T-266

1.3 ENGINE

Theengine is a verticalin--line four cylinderdiesel whichis direct connected to the alternating currentgenerator.Information on the major engine systems is provided inthe following subparagraphs.

1.3.1 Engine Air System

The air cleaner (Item 10, Figure 1-1) is designed toprolong engine life and performance by preventing dirtandgritfromentering the engine andcausingexcessivewear on all operating parts. However, the operator ischarged with the responsibility of providing the aircleaner equipment with regular maintenance inaccordance with the instructions.

1.3.2 Lube Oil Filter Arrangement

The engine lubricating oil filter may be mounted in ahorizontal or vertical arrangement. Also, an additionalby--pass filter may be supplied. Flow through theby--pass filter is fromthe standardfilter withreturntotheoil pan. Filter arrangements are shown in Figure 1-4.

1.3.3 Fuel System

Thefuelsystemis fittedwith a filterwhich also acts as awater separator. The filter may also be fitted with anoptional heater. The fuel systemis shown in Figure 1-3

1.4 ENGINE SCREWTHREADS

All threads used on the engine are metric except the oildrain plug which is American Standard P ipe Thread(NPT).

1

2

3

4

5

6

7

8

1. F uel Tank

2. Fuel Supply Line3. MechanicalFuel Pump (Engine)

4. Fuel Filter & Water

Separator

5. Injection Pump6. Injector Nozzles7. Fuel Bleed Valve8. Fuel Return Line

Figure 1-3. Fuel SystemDiagram

1

2

3

HORIZONTALARRANGEMENT

VERTICAL

ARRANGEMENT

1

2

3

4

7

6 5

BY--PASSARRANGEMENT(If Equipped)

1. Oil Pressure Switch2. Oil Pressure Sender3. Oil Filter (Primary)4. By--P ass Oil Supply

5. By--P ass Oil Filter6. Oil Pan7. By--P ass Oil Return

Figure 1-4. Lube Oil



1-7 T-266

FIELD

STATORGENERATOR

SHUNT

SERIES

LOAD

ROTOR

EXCITERRECTIFIERASSEMBLY

STATOR

Figure 1-5. A-C Generator Circuit Diagram

1.5 ALTERNATING CURRENT GENERATOR

1.5.1 Principle of Operation

The Marathon Alternator Company (Lima) brushlessA-C generator (10, Figure 1-2) is a self-regulated,rotating field synchronous unit. The generator stator

and exciter stator are combined in a common housing. The generator field, exciter rotor and rotating rectifierassembly are mounted on a common shaft. The outputof the exciter rotor is applied to the generator fieldwinding through a rotating, full-wave bridge, siliconrectifier unit.

All connections betweenthe exciterstator windings andthe generator stator windings internal within the statorhousing. Onlythe outputpower leads are connected atthe terminal box, located on top of the generator.

1.5.2 Alternating Current Generator Diagram

Figure 1-5shows the internal schematic diagramof thegenerator, exciter and rectifier unit. The generator is athree phase unitand the exciter stator and exciter rotor

alsohavethree phase windings. A portion of theexciterstator windings is connected across a tap on thegenerator stator winding. This exciter shunt windingprovides the generator field excitation power requiredforthe generator no-loadvoltage.Anotherportionof theexciter stator windings is connected in series with theoutput of the generator and provides a compoundingexcitation characteristic.

Therotoris, ineffect, the secondaryofa rotatingcurrenttransformer induction frequency converter. The exciterrotor output voltage is applied to the generator fieldwindings by a three phase full wave rotating silicon

rectifierunit. The responsetime ofthe excitationsystemis veryfastsincethe exciter statorcarries analternatingcurrentcorrespondingtothe loadcurrentwhichappearsimmediately on the exciter primary. An increase in loadcurrent will cause an immediate increase in the excitesecondary output voltage which is rectified andappliedto the generator field windings. The inherencompounding characteristics of the excitation systemprovide excellent voltage regulation even under heavyoverload conditions.

12

3

4

5

6

7

1. AC Tap2. Back Cover3. Positive Output(B+)4. Integral Regulator

5. Excite6. Ground7. 12 vdc Test Lamp

Terminal (D+)

1.6 BATTERY CHARGING -- ALTERNATOR

CAUTION

Observeproperpolaritywhen installingthebattery or connectingabattery charger, thenegative battery terminal must begrounded. Reverse polarity may damagethe charging system. When charging thebattery in unit, isolate the battery bydisconnectingthenegativebatteryterminalfirst,thenthepositive.Oncethebatteryhasbeen charged,connectthe positivebatteryterminal first, then the negative.

1.6.1 Introduction

The mechanical construction of the alternator differsfrom the DC generator in that the field rotates and the(armature)generatingwindings arestationary. The fieldcurrent necessaryto controlthe output of the alternatois supplied from the solid-state regulator. This integravoltageregulatorcontrols the currentfeedtothe fieldviathe brushes and rotor slip rings. (See Figure 1-6)

Two completelysealedballbearings supportthe rotorinthe front and rear housing.

1.6.2 Alternator Operation



1-8 T-266

The alternator converts mechanical and magneticenergy to alternating current (A.C.) and voltage, bytherotationof an electromagnetic field (rotor)insidea threephase stator assembly. The voltage is changed to DCvoltage, bypassing A.C. energythrougha three phase,full-wave rectifier system. Six silicon rectifier diodes areused (see Figure 1-7).

Figure 1-6. Alternator and Regulator

1

2

3

4

5

6

7

8

9

10

1. 12vdc Test Lamp Terminal (D+)(Not connected)

2. Diode Trio3. Positive Output(B+)4. Rectifier

5. Ground6. AC Tap7. Rotor (Field)8. Stator9. Integral Regulator

10. Excite

Figure 1-7. Alternator Schematic Diagram

1.6.3 Integral Voltage Regulator Operation(12 volts d-c)

The regulator is anall-electronic, transistorizeddevice.No mechanical contacts or relays are used to performthe voltage regulation of the alternator system. Theelectronic circuitry shouldneverrequireadjustmentandthe solid state active elements used have provedreliable enough to warrant a sealed unit. The systemistemperature compensated to permit the ideal chargingrate at all temperatures.

The regulator is an electronic switching device. Itsenses the voltageappearingatthe auxiliaryterminal of the alternator and supplies the necessary field currentfor maintaining the system voltage at the outputterminal. The output current is determined by the load.

CAUTION

Observeproperpolaritywhen installingthebatteryor connecting abatterycharger, the

negative battery terminal must begrounded. Reverse polarity may damagethe charging system. When charging thebattery in unit, isolate the battery bydisconnectingthenegativebatteryterminalfirst,thenthepositive. Oncethebatteryhasbeen charged, connectthe positivebatteryterminal first, then the negative.

1.7 BATTERY CHARGING -- SOLID STATESYSTEM

The solid state battery charger (see Figure 1-2) islocatedtothe leftofthe radiator. The chargeris poweredby the generator and this inputis protected by a circuitbreaker located on the control panel. The batterycharger produces a tapered charge (25 ampsmaximum) and is designed not to overcharge thebattery.

1.8 OPERATING CONTROLS ANDINSTRUMENTS

1.8.1 Introduction

Components required for monitoring andcontrollingtheunit are located in the control box, on the control panel(see Figure 1-8) and on the receptacle box (seeFigure 1-1).

1.8.2 Control Panel and Related Components

a. Gauges and Senders

1 Oil Pressure Gauge (see Figure 1-8)

The purpose of this gauge is to observe normaloperating engineoil pressure. Normal oil pressure is 35to 60 psig (3.3 to 5.2 kg/cm@).

2 Oil Pressure Sender

This device (see Figure 1-4) senses engine lube oilpressure and transmits a signal to the oil pressure

gauge.The oilpressure senderis locatedonthe primaryoil filter housing.

3 Water Temperature Gauge (see Figure 1-8)

Thefunctionofthis gauge is to observe wateroperatingtemperature. The gauge is connected to the watertemperature sender.

4 Water Temperature Sender

This sensing device (see Figure 1-2) senses enginewater temperature and transmits a signal to the watertemperature gauge. The water temperature sender islocatedonthe top, left-handside ofthe enginebelowtheHWT switch.



1-9 T-266

1. Terminal Block (If Equipped)2. Rectifier (If Equipped)3. Low Voltage Harness4. Ground Studs5. Circuit Breaker (CB3)6. Circuit Breaker (CB2)

7. Heater Relay (If Equipped8. Safety Relay9. Oil Pressure Gauge

10. Ammeter11. Glow Plug Switch12. Ignition Switch

13. Battery Charger Fuseor Circuit Breaker (CB5)

14. Total Time Meter15. Volt Meter16. Water Temperature

Gauge

CONTROL BOXCONTROL PANEL

161

2

3

4

5

6

7

8

9

10

11

1214

15

13

9

10

11

12

13

16

1414

14

PREVIOUS DESIGN PRESENT DESIGN

Figure 1-8. Control Box and Panel

b. Meters1 Ammeter (A)

The ammeter (see Figure 1-8) indicates the rate of discharge or charge of the battery. It is an indicator of charging system function. Also, the ammeter providesinformation on glow plug condition. During operation,each plug draws approximately 7.5 amp.

2 Total Time Meter (TT)

This meter (see Figure 1-8) designates the total hoursand provides an accurate readout of accumulatedenginerunning time. This data canbeused to establishthe proper periodic maintenance schedule. (Refer tosection 4.1.)

3. Voltmeter (V) -- Optional

The A-C voltmeter (see Figure 1-1 or Figure 1-8) is asealed device indicating the line-to-line voltage outputfromtheA--C generator. When the unithas an output of 460vac(or230vacifso optioned), the indicatingneedlewill be in the green band. (Refer to section 4.4.7.)

c. Manual Switches

1 Glow Plug Switch (GPS) (see Figure 1-8)

Theglowplugswitchis ofthe momentarytype andwhenheld in the PREHEAT position, permits battery current

(approximately 30 amps) to flow to the glow plugs andpreheatthe combustion chambers. The glow plugs arelocated under the fuel injectors. Whenstartingengine, iis necessary to continue to hold the glowplug switch inthe UP positionuntil the enginehas developedsufficienoil pressure to close the oil pressure safety switch.

2 Ignition Switch (IGN) (see Figure 1-8)

The ignition switch is of the momentary type in theSTART position), when held in the START (ignitionposition it energizes the starter motor solenoid which inturn allows the starter motor to crank the engine. Theswitch is released to the RUN position once the enginehas started.

1.9 SAFETY DEVICESSystem components are protected from damagecaused by unsafe operating conditions by safetydevices including circuit breakers, fuses and safetyswitches.

The A -C generator and the glow plug circuit areprotected by circuit breakers which will open onexcessive current draw to interrupt the componenelectrical circuit. The battery charger is protected in thesame manner but the protectivedevice may be a circubreaker or a fuse.



1-10 T-266

The engine, engine control devices and enginemonitoring devices are protected bya circuit breaker, alow oil pressure switch and a high water temperatureswitch. These safety devices monitor systemoperatingconditions and opena setof electricalcontacts when an

unsafe conditionoccurs. Openingone or more of thesesafetyswitchcontacts will de-energize the fuelsolenoid.

De-energizing the fuel solenoidshuts offthe fuel supplyto the engine; thus stopping the engine. Safety devicespecifications are provided in Table 1-2.

Table 1-2. Safety Devices

Unsafe Condition Safety Switch Switch SettingENGINE

Low engine lubricating oil pressure Low oil pressure switch (LOP) -- Auto-matic reset Opens below 15 psig(1.05 kg/cm@)

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

Opens at 230 _ F (110 _ C)

Excessive current draw by the fuel sole-noid, fuel heater, water temperaturegauge, oil pressure gauge or total timemeter.

Circuit breaker (CB-2) --Automatic reset

Trips at 30 amps

GLOWPLUGS

Excessive current draw on glow plug cir-cuit.

Circuit breaker (CB-3) --Automatic reset

Opens at 50 amps

BATTERY CHARGER

Excessive current draw on 230 volt feed

circuit.

Circuit breaker (CB-5) --

Automatic reset or fuse

Opens at 3 amps

GENERATOR

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

Trips at 26 amps(460 vac)

Excessive current draw by loadCircuit breaker (CB-4, 230 volt) --Manual reset

Trips at 48 amps(230 vac)

1.10 UNIT SPECIFICATIONS

Nominal Tank Sizes Fill Capacity DrawCapacity

50 Gallon (Integral) S teel 57.6 Gallon 50 Gallon*

65 Gallon (Integral) S teel 67.5 Gallon 65 Gallon*a. Fuel Tanks

55 Gallon (Remote) Steel -- 50 Gallon

55 Gallon (Remote) Aluminum -- 50 Gallon

85 Gallon (Remote) Steel -- 80 Gallon*Allows for DOT required 5% vapor space

Battery 52 lb (23.6 kg)

Generator (A-C) 285 lb (129 kg)b. Weights

Engine (Dry) -- without Accessories 418 lb (189.5 kg) Approximate

Unit (with integral 50 gal tank, dry) 1370 lb (621 kg)

1.11 ENGINE DATA

a. Bore/Stroke 3.43 in. (87 mm) / 3.64 in. (92.4 mm)

b. Compression Ratio 20.5 : 1c. Cylinders (Number) Four

d. Displacement 134 cubic inches (2.2 liters)

e. Firing Order 1-3-4-2



1-11 T-266

1.11 ENGINE DATA (Continued)

Winter Summer

Diesel No. 1 Diesel No. 2. Fuel and Fuel Heater FHT

Close on temperature fall @ 45±6.5 °F Open on temperature rise @ 75±6.5 °F

Power Consumption: 140--165 Watts @ 12--15.5 vdc

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

28 hp @ 1800 rpm at 3000 feet above sea level.

h. Horsepower 33 hp @ 1800 rpm at sea level.

Capacity 6 U.S. quarts (5.68 liters) -- includes 1 quart (0.95 liter) incoolant recovery bottle. (Refer to section 4.4.4)

i. Cooling System

Anti-Freeze Type For optimumperformance and protection, the cooling systemis factory charged with a 50/50 mix of ethylene glycol and wa-ter. This mixture provides protection to --34 _ F (--37 _ C). Forreplacement, use a low silicate anti-freeze meeting GM speci-fications GM 6038M or equal. Again, a 50/50 mix is recom-mended.

Water Temperature Opens 230 ¦ 5 _ F (110 ¦ 3 _ C)a ety wtc

Setting Resets 200 _ F (93 _ C) -- minimum

Thermostat S tarts to open 177 to 182 _ F (80 to 84 _ C)

Fully open 203 _ F (95 _ C)

Oil P ressure 35 to 60 psig (3.3 to 5.2 kg/cm@)

Oil Pressure Safe-ty Switch SettingOpens

15 psig (2.08 kg/cm@)

Capacity Engine -- 17.2 U.S. quarts (16.3 liters) includes standard filter.

j. Lubrication System

Oil Level Indicator Dipstick in oil pan or fill cap

NOTE

To check oil level on engines with the dip stick mounted in thefill cap, remove the cap and wipe the dipstick clean. Insert thecap back onto the oil fill tube then remove to check level. It isnot necessary to screw the cap back into the fill tube when

checking level. DO NOT add oil if level is within the “safe”range. If needed, add oil to bring level within the “safe” range.Screw cap fully into fill tube after checking level.

Lube OilSpecification

Use a heavy duty lubricating oil conforming to American Pe-troleumInstitute (API) Service Classification CD (DS), BaseNumber 8 or above.

Outdoor Temperature

Fahrenheit Centigrade SAE

Below --20 _ F Below --29 _ C 0W, 5W or 5W20u e scos ty

--20 _ to 32 _ F --29 _ to 0 _ C 10W or 10W30

32 _ to 77 _ F 0 _ to 25 _ C 20W or 15W40

Over 77 _ F Over +25 _ C 30W or 15W40



2-1 T-266

Change 01/20/03

SECTION 2

OPERATION

2.1 GENERATOR SET INSTALLATION ANDREMOVAL -- STANDARD MOUNT

The generator set is mounted under the center of thetrailer chassis and is easily handled with a fork lifttruckcapable of handling 2000 pounds. The fork lift pocketsprovided are accessible from either side. Mounting

clamps are designed to be attached to outside 1 beamflanges only. Maximumchassis width is 38” oncenter.

a. Installation

1 Loosen mounting bolts (see Figure 2-1) sufficienttopush mounting plates to the outermost position

2 Place forks into forkliftpockets of generator set. At-tach safety chain between unit and fork truck.

3 Center generator under chassis slide mountingplates fullyonto chassis I--beams andtorquemount-

ing bolts to 80 --- 90 ft-lbs ( 11.1 --- 12.4 mkg). Uponcompletion, remove safety chain before removingforks of fork lift truck from unit.

4. If mounting a generator with power cable, secure power cable to chassis using tube clamps.

5. If fuel tank is remote, connect fuel lines.b. Removal

1 Disconnect power cable atgenerator (if connected)

2 Disconnect fuel lines (if fuel tank is remote).

3 With fork lift in position and safety chain attachedslide mounting plates back sufficient to clear chassis.

4 Lower and remove generator.

1

2

3

4

5

6

9

REAR OF CHASSIS

CHASSIS MOUNTING PLATE

GENSET

SECTION A -- A EXPLODED VIEW

ROADSIDE VIEW

CONTAINER FLOOR CROSS “I” BEAMS

7

8

A

A

FORK LIFT POCKET

1

2


A

1. Bolt2. Washer, Belleville3. Washer, Spherical4. Washer, Spherical5. Mounting Plate

6. Generator Frame7. Tee Nut8. Roll Pin9. Chassis I-beam

Figure 2-1. Generator SetMounting -- Standard Mount



2-2 T-266

Change 01/20/03

2.2 GENERATOR SET INSTALLATION ANDREMOVAL -- QUICK MOUNT

The generator set is mounted under the center of thetrailer chassis and is easily handled with a fork lift truckcapable of handling 2000 pounds. The fork lift pocketsprovided are accessible from either side.

a. Installation

1 Before lifting unit in place loosen the mounting boltssufficient to bring the clamp to the open position. Toorientin openposition, liftnut end of boltout of slot,clamp will fall open.

2 Place forks into fork liftpockets of generator. Attachsafety chain between unit and fork truck.

3 Center the generator set in desired position underchassis.

4 Lift clamp (item1) in place ensuring bolt (item 4) issecured in slot.

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

6 Upon completion, remove safety chain before re-moving forks of fork lift truck from unit.

b. Removal

1 Disconnect power cable to unit (if connected).

2 Disconnect fuel lines (if fuel tank is remote).3 With fork lift in position and safety chain attached,

loosen mounting bolts and liftend of bolts out of slotto orient clamps to open position.

4 Lower and remove generator.

12

3

4

5

6

7

8

9

REAR OF CHASSIS

ROADSIDE VIEW


FORK LIFT POCKET

A

A

VIEWA -- A

1. Angle Assembly, Clamp2. Washer, Spherical3. Washer, Spherical4. Bolt5. Washer, Spherical, Belleville

6. Frame Assembly7. Roll Pin8. Nut, Hex, 3/4-109. Chassis I-beam

Figure 2-2. Generator Set Mounting -- QuickMount



2-3 T-266

2.3 STARTING AND STOPPING INSTRUCTIONS

2.3.1 Pre-Start Inspection

a. Check engine lubricationand fuel filters, oillines, andconnections for leaks. If required, tighten connec-tions and/or replace gaskets.

b. Check engine lubricating oil level. (Refer to para-graph 1.11, table entry j.)

c. CheckV-beltforfraying or cracks andpropertension.(Refer to paragraph 4.4.5.)

d. Check radiator hoses for leaks and check radiatorcoolantlevel. (Refer toparagraph1.11, table entryi.)

e. Checkradiatorcoilandgeneratorairintakescreenforcleanliness. If required, clean using compressed air,reversing the normal air flow.

f. Check air cleaner for cleanliness and clean if neces-sary. (Refer to paragraph 4.4.8).

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

h. Fillfuel tankwithdieselfuel. (Refertoparagraph1.11,table entry f.)

i. Check glow plug amperage. (Refer to paragraph1.11, table entry g.)

j. Check battery terminals for cleanliness and secure-ness. If required,clean,thencoatwitha batterytermi-nal sealant.

k. Check and if required, tighten all electrical connec-tions.

l. Checkandif required, tighten all hardware(brackets,etc.).

m.Ensure the maingenerator setcircuit breaker (CB--1for 460 volt units or CB4 for 230 volt units). Connectpowercable torefrigerationunitandproceedtopara-graph 2.3.2.

2.3.2 Starting Instructions

WARNING

Beware of moving V-belt, belt driven com-ponents and hot exhaust components.

WARNING

Under no circumstances should ether orany other unauthorized starting aids beused in conjunction with the glow plugs.

NOTE

Piston rings in engines that have operatedless

than 100 hours may not be fully seated. Thismayleadto thepossibilityof oilseepageouttheexhaust pipe. To properly seat the rings, oper-ate the engine under full load for a period of 24hours. If condition persists, check valve clear-ance when engine is cold. (Refer to engineworkshop manual listed in paragraph 1.2.)

a. Hold glow plug switch (See Figure 1-8) in the PRE -HEAT position. Suggested hold times for a cold en-gine are as follows.

COLD ENGINE GLOWTIMES

Ambient Temperature Time

68 _ F/20 _ C 5 seconds

32 _ F/0 _ C 20 seconds

18 _ F/--8 _ C 40 seconds

Below 18 _ F/--8 _ C 1 minute intervals

b. WithglowplugswitchheldinthePREHEAT positionplace the ignition switch in the START position.

c. After engine has started, continue to hold the glowplugswitchintheP REHEAT positionuntil theenginedevelops sufficientoil pressure to close the oil pressure safety switch. When released, the glow plugswitch will automatically return to the OFF position

2.3.3 Post-Start Inspection

a. Check generator output with a voltmeter. In the noload condition, output should be at rated output o460(¦ 10%) or 230 volts a-c (¦ 5%) with 1820 to1840 engine RP M. Place generator set main circuibreaker in the ON position. Start refrigeration unand check generator (1710 rpm).

b. Checktotal time meteroperation(runengine10min

utes).c. Listen for abnormal bearing noise (A--C generator)

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

e. Check exhaust systemfor leaks.

2.3.4 Stopping Instructions

Place the ignition switch in the OFF position.

2.4 CONTROL CIRCUIT OPERATION

WARNING

Beware of moving V-Belt and belt drivencomponents.

2.4.1 Sequence Of Operation (Units using Figure5-2)

NOTE

In 1997, early production units were retrofittedtomovethelowoil pressure switchfromthe wir-ing feeding terminal board terminal TB4 to thewiringfeedingthe safetyrelay. If servicing a unitthatis notwiredas shown inFigure5-2, theunitshould be retrofitted. Contact Carrier ServiceEngineering.

With the glow plug switch (GPS) held in the pre-heaposition, current flows to the glowplugs (GP). A secondset of contacts also energizes the safety relay (S)Energizingthe safetyrelayprovides a potential circuittothe run winding of the fuel solenoid (FS) and to thecontacts of the heater relay (HR). The safety relay winot energize, and the engine will not start, if the highwater temperature switch (HWT) opens to break thesafety relay ground connection.

To start the engine, the ignition switch (IGN) is held inthe START position. With the switch in the STARTposition, current flows to the start solenoid (SS) andthrough the SS contacts to the starter motor (SM) andpull in winding of the fuel solenoid (FS).



2-4 T-266

Also, a second set of contacts provides power toterminal board terminal TB4. FromTB4 power flows tothe oil pressure gauge (OPG), water temperaturegauge, heater relay (HR) and to the safety relaycontacts. Energizing the heater relay provides a circuitto the fuel heater thermostat (FHT) while providingpower to the safety relay contacts energizes the runwinding of the fuel solenoid. A thermostat (FHT),internal to the fuel filter head, closes to energizes thefuel heater (FH) at cold fuel temperatures.

The starter motor turns over the engine resulting in

pumping of fuel to the engine cylinders by the injectionpump. This fuel is ignited by heat of compression; thusstarting the engine. When the engine has developedsufficient oil pressure, the low oil pressure switchcontacts close tomaintain the circuit tothe safety relay.

Once the engine has started, the ignition switch isreleased to the RUN position. The glow plug switch isthen released. Releasing the glow plug switchde-energizes the glow plugs whilereleasing the ignitionswitch de--energizes the starter motor.

With the engine running, the battery charger oralternator provides DC power to operate the controlsystem and charge the battery.

2.4.2 Sequence Of Operation (Units usingFigure 5-6)

With the glow plug switch (GPS) held in the pre-heatposition, current flows to theglowplugs (GP). A secondset of contacts also energizes the safety relay (S).

Thesafetyrelaywillnotenergize,andthe engine will notstart, if the high water temperature switch (HWT) opensto break the safety relay ground connection.

To start the engine, the ignition switch (IGN) is held inthe START position. With the switch in the STARTposition, currentflows tothe startsolenoid(SS),throughthe SS contacts to thestartermotor(SM) and to thepullinwindingof the fuelsolenoid(FS). Also,a secondsetof contacts energizes the oilpressure gauge(OP G), watertemperature gauge (WTG), the total time meter (TT)and the run winding of the fuel solenoid. Also, at thistime, powerflows to thefuel heaterthermostat(FHT) or(on systems fitted with a heater relay) the heater relay(HR) is energized. Energizing HR provides a circuit tothe fuel heater thermostat. The thermostat internal tothe fuel filterheadenergizes thefuel heater(FH) atcoldfuel temperatures.

The starter motor turns over the engine resulting inpumping of fuel to the engine cylinders by the injectionpump. This fuel is ignited by heat of compression; thusstarting the engine. When the engine has developedsufficient oil pressure, the low oil pressure switchcontacts close to maintain power to the safety relay.

Once the engine has started, the ignition switch isreleased to the RUN position. The glow plug switch isthen released. Releasing the glow plug switchde-energizes the glow plugs while releasingthe ignitionswitch de--energizes the starter motor.

With the engine running, the battery charger oralternator provides DC power to operate the controlsystem and charge the battery.



3-1 T-266

SECTION3

TROUBLESHOOTING

3.1 DIESEL ENGINE

CONDITION POSSIBLE CAUSEREMEDY/

REFERENCESECTION

3.1.1 EngineWill Not Start

Starter motor will not crank or lowcrankingspeed

Battery insufficiently chargedBattery terminal post or battery defectiveBad electrical connectionsat starterStarter motor malfunctionsStarter motor solenoid defectiveOpen startingcircuitIncorrect gradeof lubricatingoil

ChargeCheckCorrect3.1.4EngineManual3.1.41.11.j

Starter motor cranks but fails to start

No fuel in tankAir in fuel systemWater in fuel systemPlugged fuel filtersGlow plug(s) defective

Plugged fuel lines to injector(s)Mechanical lift fuel pump malfunction

1.10/1.11.g4.4.1Drain SumpReplace4.4.10

EngineManualEngineManual

Starter cranks, engages but diesafterafew seconds

Enginelubeoil too heavyVoltagedropin starter cable(s)

1.11.jCheck

3.1.2 Engine Starts Then Stops

Enginestops after afew rotations

No fuel in tankFuel filter restrictedAir cleaner or hoserestrictedSafety deviceopenOpen wiring circuit to fuel solenoidFuel solenoid

Fuel supply restrictedMechanical lift fuel pump malfunctionOil pressureswitchdefectiveLeak in fuel systemInjector nozzle(s) defectiveInjection pump defectiveGenerator internal overloadsopen

1.10/1.11.gReplace4.4.81.9CheckReplace

1.11.g/4.2EngineManualReplaceCheckEngineManualEngineManual

Table1-2

3.1.3 EngineWill Not Shut Off

Enginewill notshut off Looseground connectionImproperly seated fuel solenoid

Clean & TightenCorrect



3-2 T-266


REFERENCESECTION

3.1.4 Starter Motor Malfunction

Starter motor will not crank or turnsslowly

Battery insufficiently chargedBattery cableconnections looseor oxidizedBattery cablesdefectiveStarter brushes shorted outStarter brushes hangup, defectiveor havenocontactStarter solenoid damagedIgnition switch defectiveEnginelubeoil too heavy

ChargeCheckReplaceEngineManualEngineManualEngineManualReplace1.11. j

Starter motor turnsbutpinion doesnot engage

Pinion or ring gear obstructed or worn EngineManual

Starter motor does not disengageaf-ter switchhas been released

Ignition switch defectiveStarter motor solenoid defective

ReplaceEngineManual

Piniondoes not disengageafter en-gineis running

Defectivestarter EngineManual

3.1.5 Malfunction In The Engine Starting Circuit

No power tostarter motor solenoid Battery defectiveLooseelectrical connections

Correct Tighten

Fuel solenoid does not energizeordoes not remain energized

Battery defectiveLooseelectrical connectionsOil pressureswitchdefectiveWater temperaturesafety switch openFuel solenoid defectiveIgnition switch defective

Correct Tighten1.91.9EngineManualReplace

3.1.6 Miscellaneous Engine Troubleshooting

Loss of power

Restrictionin air cleaner

Air in fuel systemAir vent restrictedRestricted fuel linesDefective fuel injection pumpDefective injector(s) or incorrect typeIncorrect fuel injectionpump timingIncorrect valvetimingPoor compression

4.4.8

4.4.1CleanEngineManualEngineManualEngineManualEngineManualEngineManualEngineManual

Vibration Engineshockmounts defectivePoor compression

ReplaceEngineManual

Overheating

Restrictionin air cleanerExhaust piperestriction

Restriction in water jacketRestriction in radiatorCoolant level too lowLoosewater pump/alternator V-beltDefective thermostatDefectivewater pump

4.4.8Remove

EngineManual4.4.41.11.i.4.4.5EngineManualEngineManual

Excessivecrankcasepressure Plugged crankcasebreather line 4.4.9



3-3 T-266


REFERENCESECTION

3.2 BATTERY CHARGING ALTERNATOR

Battery undercharged

Defective cables, dirty battery posts orcorroded terminalsLooseor broken beltWorn or broken brushes

Defectivealternator systemDefective wireharnessBroken brushDefectivealternator

Clean4.4.54.7.5

CheckReplace4.7.5Replace

Battery Overcharged --excessive useof water. Voltmeter indicates greaterthan 14.5 volts (connected acrossbattery withno load) withenginerunning.

Defective alternator system 4.8

Battery charges with enginerunning(noload), but discharges under loadconditions.

Slipping beltAlternator defective

4.4.54.7.7

3.3 BATTERY CHARGER (SOLID STATE)

Input fuseblowswhen charger isturned on

Short in 12 volt wiring causingoverload of charger

Locateandre-moveshort

Input fuseblows repeatedly, evenwhen notconnected

Internal short Replace

Charger does not taper back aftercharging for afew minutes

Bad cell in battery

Defectivecharger

Test battery fordefect accordingto batterymanufacturer’s

instructionsReplace

Charger does not charge

Open input circuit breakerCharger is notreceivingAC input

Charger outputis not connected to 12volt battery

Defectivecharger

ResetUsingavoltme-ter, confirm charger is receivingcorrect (230v)AC voltage. If nocheck input con-nections.Check outputwiringconnec-tions to battery.

Replace

Low output voltagemeasured acrosscharger output

Battery notconnected to charger. It isnormal to measure12 volts or lessacrosscharger output withno battery connected

Check chargingleadsfromchar-ger to battery

Reversepolarity connectionto bat-tery has caused charger to stopcharging

Internal DC fuseblownand possibledamageto current carryingcomponents

Replace



3-4 T-266


REFERENCESECTION

3.4 ALTERNATING CURRENT GENERATOR

No voltage

Loss of residual magnetismin exciter fieldCircuit breaker trippedOpen in stator windingsOpen or shortin rotatingrectifiersShort circuitedOpen in alternator fieldShorted exciter armature

4.5.1.a.Check4.5.44.5.1.c.4.5.44.5.44.5.4

Low voltage

Low enginespeedExcessiveloadHighresistanceconnections -- connectionswarmor hotShorted field

4.4.7Check

Tighten4.5.4

Fluctuating voltage(May beindi-cated by flickeringlights)

FluctuatingspeedIrregular speed of engineLooseterminal or load connectionsDefective bearingcausinguneven air gap

4.4.7EngineManual

Tighten4.5.1.4.5.3

High voltage Excessiveenginespeed 4.4.7

Overheating

Generator overloadedClogged ventilating screensHightemperaturesurroundinggeneratorInsufficient circulationUnbalanced loadDry bearing

CheckClean4.4.44.4.4Balance4.5.1.4.5.3

Mechanical Noise

DefectivebearingRotor scrubbing onstatorLooselaminationsLooseor misaligned coupling

4.5.1.4.5.34.5.1.4.5.34.5.44.5.4

Generator frameproduces shockwhen touched

Static charge

Groundedarmatureof field coil

Check ground toframe4.5.4



4-1 T-266

SECTION4

SERVICE AND PREVENTIVE MAINTENANCE

4.1 INTRODUCTION

This section covers service for the generator set andgeneral engine servic. Refer to the Kubota engineworkshop manual (refer to section1.1) forother engineservicing.

WARNINGBeware of moving V-belt and belt driven

components.

4.2 PREVENTIVE MAINTENANCE SCHEDULE

A tabular listing of the recommended preventativemaintenance activities and schedule is provided in Table 4-1.

4.3 BATTERY SERVICE

Whenreplacingthe battery, note ifthe unitwas suppliedwith a matt in the battery tray. If so equipped, the mattmust also be replaced.

4.4 ENGINE SERVICE AND COMPONENTS

4.4.1 Priming The Fuel System

The unit is equipped with a mechanical fuel lift pump,mounted on the engine nextto the injection pump. Thefuel systemis a closed circuitwhichwill require bleedingif loss of fuel has occurred. To fill and bleed thesystem,do the following:

a. Turn bleed valve (Red, see Figure 1-3) counter-clockwise until fully opened.

b. Turn the top of the manual plunger (see Figure 4-1)counter-clockwise to unlock it then, rapidly handpump the manual plunger until a positive pressure

(resistance) is felt, which will indicate fuel flow.

c. Depressandturnthe topof the manual plungerclock-wise to lock in place.

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

e. When engine is running properly, turn bleed valveclockwise until fully closed.

4.4.2 Servicing Fuel Pump Internal Filter

Due to foreign particles inthefuel and waxas a resultof using the wrong grade of fuel or untreated fuel in coldweather, the internal fuel filter may become plugged orrestricted and the engine will loose capacity. The filtermust be cleaned on a regular schedule. Quality of fuelwill effect filter cleaning schedule (refer to section 4.2).

a. Turnnut(item1) counter-clockwise toloosen andre-move .

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

c. Turn filter (item 3) counter-clockwise and removeCheck and clean.

d. To install reverse steps 1 through 3.

5

1

2

3

4

1

1. Nut2. Banjo3. Filter

4. Copper Rings5. Manual Priming Pump

Figure4-1. Mechanical Fuel Pump

4.4.3 Fuel Filter

The full flow filter is located on the generator set frame(see Figure 1-2). To renew, remove the filterwith a filtewrench, pre--fill the new filter with fuel, lightly oil gaskewith lube oil and replace by hand.

4.4.4 Cooling System

The radiatormustbe clean, externally and internally, foadequate cooling. The fan belt must be adjustedperiodically to provide maximum air flow (refer toparagraph 4.4.5). To service the coolingsystem, dothefollowing:

a. Remove all foreign material from the radiator coil byreversingthe normal air flow. Compressed air or watermaybeusedas a cleaningagent. Itmaybenecessaryto usewarmwatermixedwithanygoodcommercial dishwasher detergent. Rinse coil(s) with freshwater if a detergent is used.

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

CAUTION

Never pour cold water into a hot engine.

c. Closedrain-cockandfill systemwith clean, untreatedwater to which three to five percent of an alkalinebase radiator cleaner should be added; six ounces(dry) =151 grams to one gallon (3.8 liter) of water.



4-2 T-266

T a b l e 4 - 1 P r e v e n t a t i v e M a i n t e n a n c e A c t i o n s a n

d S c h e d u l e

D e s c r i p t i o n o f P r o c e d u r e

R e f e r e n c e

P a r a g r a p h

P e r f o r m

a t

P r e - - T r i p

I n s p e c t i o n

E

v e r y

1

0 0 0

H

o u r s

A n n u a l l y

o r

E v e r y

3 0 0 0

H o u r s

F o r P r e - - T r i p i n s p e c t i o n p e r f o r m i t e m s 1 t h r o u g h 1 3 t h a n p

e r f o r m “ A f t e r S t a r t - - u p ” c h e c k s , i t e m s 3 2 t h r o u g h 3 6

1 . C h e c k ( I n P l a c e ) E n g i n e / G e n e r a t o r S h o c k m o u n t s f o r C r a c k

s , C u t s , A b r a s i o n o r F l a r i n g

X

2 . C h e c k E n g i n e L u b r i c a t i o n , F u e l F i l t e r , O i l L i n e s a n d C o n n e c

t i o n s f o r L e a k s .

X

X

3 . C h e c k E n g i n e L u b r i c a t i o n O i l L e v e l

1 . 1 1

. j .

X

X

4 . C h e c k V - B e l t f o r F r a y i n g

o r C r a c k s a n d P r o p e r T e n s i o n

4 . 4 . 5

X

X

5 . C h e c k R a d i a t o r H o s e s f o

r L e a k s , C h e c k C o o l a n t L e v e l a n d

5 0 / 5 0 M i x t u r e

1 . 1 1

. i .

X

X

6 . C h e c k R a d i a t o r C o i l a n d

G e n e r a t o r A i r I n t a k e f o r C l e a n l i n e s

s

( C l e a n U s i n g C o m p r e s s e

d A i r , R e v e r s i n g A i r F l o w D i r e c t i o n

)

X

X

7 . C h e c k A i r C l e a n e r f o r C l e a n l i n e s s a n d C l e a n a s N e c e s s a r y

4 . 4 . 8

X

X

8 . D r a i n W a t e r f r o m F u e l T a

n k S u m p a n d F u e l F i l t e r B o w l

X

X

9 . F i l l F u e l T a n k w i t h D i e s e l F u e l

1 . 1 1

. f .

X

X

1 0 . C h e c k G l o w P l u g A m p e r a g e

1 . 1 1

. g .

X

X

1 1 . C h e c k B a t t e r y T e r m i n a l s

f o r T i g h t n e s s a n d C l e a n l i n e s s .

( C l e a n t h e n c o a t w i t h b a t t e r y t e r m i n a l s e a l a n t )

X

X

1 2 . C h e c k f o r L o o s e E l e c t r i c a l C o n n e c t i o n s

X

X

1 3 . T i g h t e n a l l H a r d w a r e ( B r a c k e t s , e t c . )

X

X

1 4 . C h a n g e L u b r i c a t i n g O i l a n d F i l t e r ( s ) ( S e e N o t e )

4 . 4 . 6

X

1 5 . C l e a n A i r F i l t e r B o d y , C h e c k H o s e C o n n e c t i o n s . ( S e e N o t e )

4 . 4 . 8

X

1 6 . C h a n g e O i l B a t h A i r F i l t e

r O i l ( S e e N o t e )

4 . 4 . 8

X

1 7 . C l e a n M e c h a n i c a l F u e l L i f t P u m p I n t e r n a l F i l t e r

4 . 4 . 2

X

1 8 . T i g h t e n E n g i n e a n d G e n e r a t o r M o u n t i n g B o l t s .

4 . 8

X

1 9 . T i g h t e n a l l E l e c t r i c a l C o n n e c t i o n s i n t h e C o n t r o l B o x

X

2 0 . C h e c k B a t t e r y C h a r g i n g A l t e r n a t o r A m p e r a g e O u t p u t

4 . 7

X

2 1 . C h e c k W a t e r P u m p B e a r

i n g E n d P l a y

S e e

E n g i n e

M a n u a l

X

N o t e : M o r e f r e q u e n t i n t e r v a l s

m a y b e n e c e s s a r y i n e x t r e m e o p e

r a t i o n c o n d i t i o n s .



4-3 T-266

T a b l e 4 - 1 P r e v e n t a t i v

e M a i n t e n a n c e A c t i o n s a n d S c h e d u l e ( C o n t i n u e d )

D e s c r i p t i o n o f P r o c e d u r e

R e f e r e n c e

P a r a g r a p h

P e r f o r m

a t

P r e - - T r i p

E

v e r y

1

0 0 0

H

o u r s

A n n u a l l y

o r

E v e r y

3 0 0 0

H o u r s

2 2 . V e r i f y O p e r a t i o n O f E n g i n e P r o t e c t i v e D e v i c e s

X

2 3 . C h a n g e F u e l F i l t e r

4 . 4 . 3

X

2 4 . C l e a n C r a n k c a s e B r e a t h e r

4 . 4 . 9

X

2 5 . R e m o v e a n d C h e c k E n g i n e / G e n e r a t o r S h o c k m o u n t s f o r C r a

c k s , C u t s , S p l i t s , A b r a s i o n o r

F l a r i n g

4 . 6 . 2

X

2 6 . C h e c k a n d I f R e q u i r e d R e p l a c e V - B e l t

4 . 4 . 5

X

2 7 . C l e a n a n d F l u s h C o o l a n t

S y s t e m

4 . 4 . 4

X

2 8 . C h e c k S t a r t e r C o n d i t i o n

S e e

E n g i n e

M a n u a l

X

2 9 . C h e c k E n g i n e C o m p r e s s

i o n

S e e

E n g i n e

M a n u a l

X

3 0 . C h e c k a n d A d j u s t I n j e c t o

r N o z z l e s

S e e

E n g i n e

M a n u a l

X

3 1 . P e r f o r m G e n e r a t o r M a i n t e n a n c e

4 . 5 . 1 .

X

A f t e r S t a r t i n g G e n e r a t o r S e t , p e r f o r m t h e f o

l l o w i n g :

3 2 C h e c k T o t a l T i m e M e t e r O p e r a t i o n ( A l l o w E n g i n e t o R u n 1 0

M i n u t e s )

X

3 3 L i s t e n f o r A b n o r m a l B e a r

i n g N o i s e

X

3 4 C h e c k F u e l L i n e s , L u b e O i l L i n e s a n d F i l t e r s f o r L e a k s .

X

3 5 C h e c k E x h a u s t S y s t e m F

o r L e a k s

X

3 6 C h e c k w i t h v o l t m e t e r . G e

n e r a t o r o u t p u t s h o u l d b e 4 6 7 v o l t s

A C ( + / - - 1 0 % ) n o l o a d

( e n g i n e , 1 8 2 0 - - 1 8 4 0 R P M

) . T u r n r e f r i g e r a t i o n u n i t o n a n d c h

e c k g e n e r a t o r

1 7 1 0 R P M m i n i m u m u n d e r f u l l l o a d ( 4 3 0 v o l t s + / - - 1 0 % )

X



4-4 T-266

d. Run engine 6 to 12 hours and drain system whilewarm. Rinse system three times after it has cooleddown. Refill system with water.

CAUTION

Use only ethylene glycol, anti-freeze (withinhibitors) in systemas glycol by itself willdamage the cooling system. (Refer toparagraph 1.11.i.)

e. Run engine to operating temperature. Drain systemagain and fill with treated water/anti-freeze. (Seeabove Caution note and refer to paragraph 1.11.i.)

4.4.5 Servicing And Adjusting V-belt

WARNING

Beware of moving V-belt and belt drivencomponents

NOTE

Frayed, cracked or worn V-belt must bereplaced. After installing a new belt, it isadvisabletocheckthe adjustmentafterrunning

the unit for three or four hours. This is to allowfor the initial stretch which is common on newbelts. Once this initial stretch has taken place,the beltshould be checked at regularintervals.

The V-belt is driven by a sheave on the enginecrankshaft. Its three functions are: (1) drive thealternator(ifequipped),(2)drive the radiatorfan, and(3)to drive the waterpump. To replaceoradjustthe belt, dothe following:

a. Replacing the V-Belt

1. Depending on equipment supplied, loosen thealternator adjustmentarmpivot bolt or the idlerpivotbolt.

2. Replace belt and adjust tension in accordance withthe following step.

b. Adjusting Tension

1. Check belt tension, correct tensionis 40-45poundson the Burroughs gauge (Carrier Transicold P /N07-00203). Use hand force only on the alternator totightenbelt. Do not use pry bar or excessive force as it may c ause alternator housing damage.

2. When belt is at correct tension, tighten pivot bolt.

4.4.6 Lube Oil Filter

Theprimaryoil filterislocatednearthe radiatorfanwhilethe by--pass filter is located on the generator set frame

(see Figure 1-4).After warming upthe engine, stopengine, removedrainplug from oil reservoir and drain engine lube oil.

Replace filters. Lightly oil gasket on filter beforeinstalling. Add lube oil. (Refer to paragraph 1.11.j.)Warmup engine and check for leaks.

4.4.7 Adjusting Engine Speed

The engine is to operate at1820 to 1840 rpm(no load),1710rpm(with fullload). To checktheengine speed, dothe following:

a. Withthe engine stopped, placea mark(whitepaintforexample) on the crankshaftsheave. Startengineandverify engine speed using a strobe tachometer(Strobette-model 964, Carrier Transicold Part No.07-00206.)

b. To Increase Speed:

Loosen jam nut (see Figure 4-2). Turn capscrewclockwise until correct speed is achieved, then tighten jam nut and recheck engine speed.

c. To Decrease Speed:

Loosen jam nut (see Figure 4-2). Turn capscrewcounter-clockwise until correct speed is achieved, thentighten jam nut and recheck engine speed.

1

3

2

1. Speed Lever2. J am Nut

3. Capscrew

Figure 4-2. Engine Speed Adjustment

4.4.8 Engine Air Cleaner

a. Inspection

Theoil bath air cleanershouldbeinspected routinelyforleaks. A damaged air cleaner or hose can seriously

affectthe performance andlife of the engine. Toinspectthe air cleaner, do the following

1. Check all connections for mechanical tightness. Besure outlet pipe is not fractured.

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

3. In case of leakage, replace necessary parts orgaskets. S welled or distorted gaskets must be replaced.

b. Service -- Oil Cups

Inspectthe oilcups (seeFigure 4-3) atregularintervals.Initially inspect daily or as often as conditions require.Never allowmorethan1/2inch (12.7 mm) of dirtdeposit

inthe cup. More than1/2inch accumulation couldresultin oil and dirt to carry over into the engine causingaccelerated engine wear. Heavily contaminated oil willnot allow the air cleaner to function properly.

CAUTION

Alwayscovertheengineinlettubewhiletheair cleaner is being serviced.

Stop the engine and remove the oil cups from the aircleaner. Dispose of the oil in an environmentally safe



4-5 T-266

manner. Remove the inner cup from the oil cup andclean both cups.

Reassemble and fill both oil cups to the indicated level with oil specified in paragraph 1.11.j.

CAUTION

Do not underfill or overfill the cups.Overfilling of cups means loss of capacityand underfilling means lack of filteringefficiency.

1

2

3

4

5

1. Air Inlet Hood2. Air Cleaner Body3. Cap Clamp

4. Inner Oil Cup5. Oil Cup

Figure4-3. Air Filter

c. Service -- Body Assembly

Thelowerportion ofthe air cleanershouldbe inspectedeachtime theoil cup is inspectedor serviced. If thereis

any sign of contaminant buildup or plugging, the bodyassembly shouldberemoved andback flushed. Atleastoncea year oratregular engineservice periods removethe entire air cleaner and perform the following:

1 Remove oil cups. Check and clean center tube.

WARNING

Do not use gasoline to clean air cleanerparts.

2 Pump solvent through the air outlet with sufficientforce and volume to produce a hard, evenstreamoutthe bottomof the body assembly. Reverse flushuntilall foreign material is removed.

4.4.9 Engine Crankcase Breather

The engine uses a closed type breather with thebreather line attached to the cylinder head cover. (SeeFigure 4-4.) Element style breather assemblies shouldbebrushedclean. It is notnecessaryto dissemble valvestyle elements for cleaning. However the bleed holeshould be checked to ensure it is free of obstructionCheck once a year or atevery 3000hours maintenanceinterval (whichever comes first).

23

456

1

8

7ELEMENT STYLEPRIOR TO PID UG0457

1. Cylinder Head Cover2. Breather Cover3. Breather Element4. Plate

5. Breather Oil Shield6. Capscrew7. Breather Assembly8. O-Ring

VALVE STYLE -- STARTING WITH PID UG0457

1

5

4 3

2

1. Screw2. Breather Cover3. Bleed Hole

4. Breather Valve5. Breather Tube

Figure 4-4. Engine Crankcase Breather

4.4.10 Servicing Glow Plugs

The glow plugs are parallel connected and whenenergized, each plug draws 7.5 amps at 12 vdc. Whenservicing, the glow plug is to be hand fitted into thecylinder head to prevent thread damage.

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



4-6 T-266

Checking for a Defective Glow Plug:

a. Method 1: Place an ammeter (or clip-on ammeter inseries with each glow plug and energize the plugs.Each plug should show 7 to 10 amps draw.

b. Method 2: Disconnectthe wire connectionto theplugand test the resistance from the plug to a ground onthe engine block. The reading should be 0.7 to 1.2ohms if the plug is good.

4.5 SERVICING THE ALTERNATING CURRENT

GENERATOR4.5.1 Preventive Maintenance and

Operating Precautions

Costly repairs and down time canusually be preventedby operating electrical equipment under conditionswhicharecompatible withthose atwhichthe equipmentwas designed. Follow the instructions outlined belowtoinsure maximumefficiency of the electrical equipment.

a. Cooling

Keep all cooling parts clean. D O N O T E XC EE D TE MP E RA TURE RI S E OF 80 _ C (176 _ F ) A B O V E A40 _ C (104 _ F) AMBIENT . This ensures that the NEMAClass “F” insulation will not be damaged. D O N O T

E X CE ED RATE D LOA D except as specified for theequipment. O P ER AT E G E NE RAT OR AT R AT ED SPEED . Failure to operate generators at rated load orspeed will cause overheating and possible damage towindings due to over voltage or current.

b. Generator Windings (Drying)

WARNING

Do not direct water or steam into thegenerator openings. Do notallowany soapand water solutions to enterthe alternator.

WARNING

Highvoltage(dielectric) testingmustnotbeperformed to the machine without firstobserving NEMA rules. The insulation of this generator winding may be safelychecked byusing a megger. A high meggerreading indicates good insulation.

Generators that have been in transit, recently steamcleaned, orinstorageforlong periods maybesubjectedto extreme temperature and moisture changes. Thiscan cause excessive condensation, and the generatorwindings shouldbe thoroughly driedoutbeforebringingthe generator up to full nameplate voltage. If thisprecaution is not taken, serious damage to thegenerator can result. The following steps should be

taken to effectively dry the generator windings:

1 Dry windings by placing generator in drying oven orhotroomor dry withwarmairblower directedthroughwindings.

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

The finest insulation job can be very quickly brokendown bycarelesslyapplyinghigh voltageto windings ina moisture saturated condition. Failure to follow these

guide lines could easily cause a breakdown, making itnecessary to return the generator to the factory forrepair.

c. Rotor Damage

If a rotorbecomes defective, itshouldbereturnedto thefactory with full nameplate data. To repair a rotor, thespecial tooling and technique of the factory arenecessaryandessential. Shoulda failure occur, Carrier Transicoldshouldbe notified immediatelyand steps willbe taken to return the generator for service.

d. Terminal Strip Cleaning

OpenTerminal Box. Removedustanddebris andcleanterminal strip with wire brush. Reapply protectivecoating.

4.5.2 Generator Repair/Test Procedures

a. Restoring Residual Magnetism

The direct current (DC) necessary to magnetize thealternatorfieldis obtainedfromthe exciter. Initially, uponstarting the generator, current flow and voltage areinduced into the exciter armature by the magnetic linesof force setupby the residual magnetismof the exciterfield poles.

Residual magnetism of the exciter field poles may belostor weakened bya strongneutralizingmagnetic fieldfromany source, or ifthe generatoris notoperatedforalong period of time.

Should the generator fail to build upvoltage after beingdisassembledforanyreason,a momentaryshort-circuitof any two generator leads (L1, L2 and L3) whilegenerator is running should be sufficient to correct thiscondition.

NOTE

When trying to restore residual magnetism, besure to wear safety glasses andnon--conductive gloves. Use an insulated 12gauge (or higher) jumper wire. Cut-off all but afewstrands frombothendsofthe jumperwiretohelp ensure fusing does not take place.

As an alternate method, apply either an alternatingcurrent or a direct current voltage of approximately 20volts to any two generator leads (L1, L2 and L3) whilegenerator is running. Do notmake a positiveconnectionbut rather touch the leads together until the generatorvoltage begins to rise and then remove. It is suggestedthat a 30 ampere fuse be inserted in the circuit toprevent any damage in case the build-up voltage is notremoved quickly enough.

Reflash field if generator output voltage does not buildup.



4-7 T-266

b. Winding Insulation Testing

Continuity test results for the stator winding tests areprovided on the following table.

WirePair

Ohm* WirePair

Ohm* WirePair

Ohm*

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

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

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

T10--T4 I T2--T4 I T4--T8 I T10--T5 I T2--T5 0 T4--T9 I

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

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

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

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

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

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

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

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

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

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

c. Diode Testing.

The rectifier diode assemblies can be tested and if damaged, replaced. Over current, over voltage, overspeed, orreverse currents candamagethe assemblyordiodes. To remove the diode assemblies and performdiode testing do the following:

1. Removethe bearingcoverbyremovingthefourbolts(see Figure 4-6). Both the bearing and diodeassemblies will be visible.

2. Markanddisconnectthe alternator rotor wires attherectifier screwterminals. Note thatthe terminals aremarkedwithredpaintfortheforwarddiodeassemblyand blackfor the reverse diode assembly. Mark anddisconnect the exciter leads fromthe double spadeterminals. (See Figure 4-5.)

3. Remove the two capscrews which secure eachdiodeassembly tothe spider. Once this procedure iscompletethe diodeassemblies arefree for removal.

4. A forward diode should have a low resistance whenthe + of an ohm meter is connected to the exciterrotor lead connection(anode) and the -- to the diodebridge (cathode), and a high resistance when thepolarity of the ohmmeter is reversed.

5. A reverse diode should havea highresistance whenthe + of an ohm meter is connected to the exciterrotor lead connection(anode) and the -- to the diodebridge (cathode), and a low resistance when thepolarity of the ohmmeter is reversed.

6. If both resistances are high orboth are low, then thediode is defective and thediode assembly should bereplaced.

4

1

4

1

3

2

2

1. Diode Assembly2. Diode Bridge3 Exciter Rotor Lead Connection4. Alternator Rotor Lead Connection

Figure4-5. A-C Generator Rectifier Assembly

4.5.3 Bearing Replacement

Factory lubricated shielded bearings will normallyprovide years of trouble free service when operatedunder normal conditions. Excessive bearing load andadverse environment conditions will greatly shortenbearing life. To remove the bearings, do the following:

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

2. Remove bearing with the use of a bearing or wheepuller.

3. Install newbearing. Ball bearings arepre--lubricatedand require no further lubrication for the life of thebearing.

4. Coat mating surface of bearing cover flange withanti--corrosion compound (Tef--Gel, Carrier ParNumber 02--00083--00). Replace bearing cover.

1

5

432

7

6

1. Rectifier Flange2. Rectifier Assembly3. Rectifier Bolt4. Bearing Cover

5. Bearing Cover Bolt6. Bearing7. Bearing Cover Flange

Figure 4-6. Rectifier Removal



4-8 T-266

4.5.4 Generator Installation and Removal

a. Removing the Generator

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

2. Remove connection box cover, disconnect powerleads.

3. Remove screen cover and generator exhaustbafflefrom coupling end of generator.

4. Remove six 8mm hex head bolts and washerssecuring the generator drive disc to the engineflywheel. Turn bolts counter-clockwise with offsetwrench to start, then use flexible shaft and socketassembly for removal of bolts.

5. Remove twelve 3/8 inch hex head capscrews andwashers that secure generator frame to engineflywheel housing.

6. Remove four5/8inchbolts thatsecure the generatormounting feet to the shock mount bracket, thenremove generator.

b. Installing the Generator

NOTE

For torque values refer to paragraph 4.8.

Thegeneratoris a singlebearing type which means theshaftend of the rotor floats. Before installinggenerator,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 theholes on housing and flywheel. If required, turncrankshaft to align threaded holes in flywheel withgenerator drive disc mounting holes.

CAUTION

The rotorshould notbepulled outfromthe

alternator more than 0.75 inches. Damageto the bearing and windings may result.

3. Start the 8mmbolts (by hand) throughthe disc plateand into the flywheel. Once alignment is madetorque bolts (six).

4. Securetwo of thehousing bolts (3/8), onthe topandbottomof the generator housing, todraw the matingflanges together.

5. Secure remaining bolts and washers (3/8) andtorque bolts (twelve)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 generatorcover. Install new gasket when installing generatorconnection box cover.

4.6 GENERAL GENERATOR SET MAINTENANCE

4.6.1 Maintenance Of Painted Surfaces

The unitis protected against the corrosive atmosphereinwhichitnormally operates bya special paint system.However, should the paint system be damaged, thebase metal cancorrode. If thepaintsystemis scratchedor damaged, do the following:

a. Clean area to bare metal using a wire brush, emerypaper or equivalent cleaning method.

b. Immediately following cleaning, spray or brush on azinc rich primer.

c. After the primer has dried, spray or brush on finishcoat of paint to match original unit color.

4.6.2 Checking And Replacing Shockmounts

a. Replacement Criteria

CAUTION

Continued operation with failed shock--mounts may result in engine or generatordamage.

When a shockmounthas beencut, split, abraded orhas

flared due to normal deterioration, it must be replaced.Damageto the mountsmaynotbe visible wheninstalledand under load from the component. To correctlyinspect shockmounts, they must be removed.

b. Engine ShockmountReplacement

NOTE

For torque values refer to paragraph 4.8.

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

2. Remove all hardware as shown in Figure 4-7.

3. Raise the engine just enough to remove theshockmounts (item 3).

4. Install new shockmounts.5. Lower the engine enough to assemble hardware as

shown and torque per paragraph 4.8.

6. Remove chains from the lift eyes.

c. Generator Shockmount Replacement (seeFigure 4-8)

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

2. Remove shockmount hardware, items 5 through 13figure Figure 4-8.

3. Raise the generator just enough to remove theshockmounts (item 7).

4. Install new shockmounts.

5. Lower the engine enough to assemble hardware asshown and torque. Refer toparagraph 4.8fortorquevalues.



4-9 T-266

6. Remove chains from the lift eyes.

PID UG0130 AND HIGHER

PID UG0129 AND LOWER

1

6

5

4

3

2

ENGINE

ENGINE

2

6

5

2

3

FRAME

FRAME

1. Locknut2. Snubbing Washer3. Shockmount

4. Spacer5. Flat Washer6. Screw

Figure 4-7. Engine Shockmounts

1

13

12

11

10

9

8

7

6

5

4

2

GENERATOR

FRAME

3

3

12

INSTALL MOUNT WITHLARGE FLARE AT TOP

FRAME

7

8

1. Screw (5/8)

2. Mounting Base3 Flat Washer (5/8)4. Locknut (5/8)5. Locknut (1/2)6. Flat Washer (1/2)7. Shockmount

8. Spacer

9. Snubbing Washer10. Screw (1/2)11. Screw (3/8)12. Flat Washer (3/8)13. Locknut (3/8)

Figure 4-8. Generator Shockmounts

4.7 SERVICING THE ALTERNATOR

WARNING

Beware of moving V-Belt and belt drivencomponents.

4.7.1 Preliminary Checks and Tests

NOTE

Before starting electrical tests, the chargingsystem, battery and wiring should be checkedto eliminate problem areas. Figure 1-6identifies the terminals on rear of the alternator.

a. Check the condition of the V-belt.

1. Check belt adjustment (refer to paragraph 4.4.5).

2. Replace V-belt if worn or glazed.

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

are clean and tight.1. Loose or corroded connections cause high

resistance and this could cause overchargingundercharging or damage to the charging system.

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

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



4-10 T-266

4.7.2 Test Tools

The following tools are requiredto perform tests onthealternator and its components.

1. Volt-ohmmeter

2. Single-pole, single throw switch

3. 12 vdc lamp

4. Insulated 12 gauge stranded wire

5. Alligator clamp terminals

4.7.3 ProblemArea Determination

Suggested test sequence for battery undercharge andbattery overcharge are as follows:

a. Battery Undercharged

1. Perform open diode-trio test. (Refer to paragraph4.7.4 Test No. 1)

2. Perform regulator tests. (Refer to paragraph 4.7.4 Test No. 2). If the regulator is working, the cause isprobably an open field circuit, and the alternatormust be removed for repair.

3. Further investigation requires alternator removaland repair (diodes).

b. Battery Overcharged1. Perform alternator output test.

(Refer to paragraph 4.7.4, Test No. 3)

2. Regulator shorted. Replace regulator.

4.7.4 In-UnitAlternator/Regulator Tests

Test No. 1 -- Open Diode-Trio Test

CONDITIONS: Start-run-stop switch (SRS) in RUNposition and engine stopped (after proper hook-up ismade and test leads connected). No electrical loads.

a. With jumper not attached. Check for battery voltageatterminalA andfor 1.5 to 3.0volts atterminal B, seeFigure 4-9.

b. Add jumper J U1 between terminals A and B. Startengineand runwithnoload. If thetestlampnowgoesoff, and charging voltage is present at terminal A(more than battery voltage), the diode-trio is open.Alternator should be removed for repair. If thevoltmeter indication is not in this range, remove the jumper and proceed to the regulator test (test no. 2).

Test No. 2 -- Open Regulator Test

CONDITIONS: Enginestopped(start-run-stopswitchinthe RUN position) and voltmeter set-up as shown inFigure 4-10.

NOTE

Before performing test, removal of back cover

is required. To remove, disconnect wires fromterminals extending through back cover.Remove back cover (two screws) andreconnect all wires.

a. Withjumpernotattached,checkforbatteryvoltageatterminals A and B. Test lamp will be off.

b. Add jumper J U1 between field and ground (seeFigure 4-10). If 1.5 to3.0volts is presentatterminalBand the test lamp is on, the regulator is open.Alternator should be removed for repair.

Test No. 3. Alternator Output Test

CONDITIONS: Engine running (after voltmeter isconnected as shown in Figure 4-11).

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

b. If the alternator outputvoltage does not fall within theproper range, the alternator should be removed forfurther inspection and tests. (Refer to Prestolitemanual.)

VOLTS

+ --

d d+

D+

B

A

JU1

12vdcTEST LAMP

TOGGLESWITCH

BATTERY

AC TAP(TACH.)

GROUND

EXCITE

INTEGRALREGULATOR

POS+OUTPUT

(B+)

BATTERY BLACK

RED

STEP TESTPOINT INDICATION

1

2

3

A(B+)

B (REG)

BATTERY VOLTAGE

1.5TO 3.0VOLTSWITH TEST LAMP ON

13.5TO15.0VOLTS(J UMPER ATTACHEDENGINE RUNNING)

A(B+)

*

*

*JUMPERNOTATTACHED

(TO OIL PRESSURESWITCH OR

TOGGLE SWITCH )

+ --

Figure4-9. Open Diode-Trio Test



4-11 T-266

(Test No. 1)

FIELD

JU1

B(D+)

BATTERY VOLTAGEWITH TEST LAMP OFF

J UMPER ATTACHED.1.5TO 3.0VOLTS.TEST LAMP ON

VOLTS

+ --

+ --

d d+

D+

B

A

12 vdc TEST LAMPTOGGLE SWITCH

BATTERY

AC TAP(TACH.)

GROUND

EXCITE

INTEGRALREGULATOR

POS+

OUTPUT(B+)

BATTERY BLACK

RED

STEP TESTPOINT INDICATION

1

2

3

A(B+)

B(REG)

BATTERY VOLTAGE*

*

*JUMPERNOTATTACHED


TOGGLE SWITCH )

Figure 4-10. Open Regulator Test(Test No. 2)

GROUND

INTEGRALREGULATORVOLTS

+ --

D+

13.8TO14.8VPOS +OUTPUT

AC TAP(TACH.)

POS+OUTPUT

(B+)

BATTERY

EXCITE

BLACK

RED


TOGGLE SWITCH)

+ --

d d+

TOGGLE SWITCH

BATTERY

12 vdc TEST LAMP

Figure 4-11.AlternatorOutputTest(Test No. 3)

4.7.5 Alternator Brush Test Procedure

NOTE

Before performing test, removal of back coveris required. To remove, disconnect wires fromterminals extending through back cover.Remove two screws securing back cover torear housing and remove cover.

a. Removing Brush Set

1. Remove two locknuts securing brush holder andremove brush assembly.

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

3. Check slip rings for carbon build-up.

4. Using a 12 vdc test lamp or ohmmeter, test brushassembly for continuity and insulation (seeFigure 4-12). Replace brushassembly if necessary

b. Brush Continuity Check

Using a 12 vdc test lamp or ohmmeter, test brushassembly for continuity and insulation as shown

Remove brush assembly if necessary.



4-12 T-266

A

D

C

B

CONTINUITY CHECK

Continuity

Continuity C to D OK

A to B OK

No Circuit

No Circuit A to D OK

A to C OK

No Circuit

No Circuit B to D OK

B to C OK

Figure 4-12. Alternator Brush Assembly

4.7.6 Slip Ring Servicing

Clean brush contacting surfaces with fine crocus cloth.Wipe dust and residue away.

If surfaces are worn beyond this restoration, replaceentire rotor assembly.



4-13 T-266

4.7.7 Alternator Installation

a. Make surenegative batteryterminal is disconnected.

b. Install alternator to mounting bracket with thealternator pivot bolt and adjustment armbolt looselyin position.

c. Place V-belt on alternator sheave.

d. Check the center alignment of the generator drivingpulley and alternator pulley, to ensure proper drive.Pulley misalignment will create excess belt wear and

limit alternator bearing life. The center line of thealternator sheave and the driving sheave must be inline.

e. Pivot alternator to place tension on belt. For correctbelt tension see paragraph 4.4.5. Tighten pivot andadjustment bolts.

f. Connect wiring to alternator.

g. Connectbatterycable. Startunitandcheckforoutpuper paragraph 4.7.4, Test No.3.

4.8 UNIDRIVE TORQUE REQUIREMENTS

Extensive damage may occur if the proper hardware isnot used and/or proper procedures are not followedwhen working with the unidrive assembly. Periodicinspectionof hardware andbolttorqueis recommendedto ensure the integrity of the unidrive.

Torque value and hardware requirements for unidrive

assembly are provided in Figure 4-13.

NOTES

SST is anabbreviationfor300 Series CorrosionResistant Steel.

Loctite#242 oranequivalentproductshouldbeused on ALL hardware shown on this page.



4-14 T-266

UNIDRIVE - SECTIONALVIEW

ENGINE&GENERATORSHOCKMOUNTS- TOPVIEW

ENGINEMOUNT- RIGHTSIDE VIEW

Engine Flywheel

Generator Disc Drive

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

1/2-13 x 3-1/2lg -- SST(2Req’d)90ft-lb (12.44 mkg)

5/8-18 x 2.00 lg -- SST(4Req’d)70ft-lb (9.68 mkg)3/8-16 x 1-1/4lg -- SST

(4Req’d)25ft-lb (3.46 mkg)

M8 x 15MM lg -- SST(6Req’d)19ft-lb (2.49 mkg)

5/8-18 x 4.00 or 4.50 lg -- SST(2Req’d) 90ft-lb (9.68 mkg)

Figure 4-13. Unidrive Torque Requirements



5-1 T-266

SECTION5

SCHEMATICS

5.1 INTRODUCTION

This section contains the 12 volt DC control circuit schematics, the 460 volt alternating current generator schematicandthe 230voltalternatingcurrentgeneratorschematic. Toidentifythe schematics applicabletoyourmodel andPIDnumber refer to Table 1-1.



5-2 T-266

Based On Drawing 62-02678 Rev A

OPTIONAL

ENGINE GROUND

CHASSIS GROUND

3 A AMMETER

5 ALT ALTERNATOR

8,10 AUX AUXILIARY CONTACTS

4 BC BATTERY CHARGER

1 BAT BATTERY

3,8,11 CB CIRCUIT BREAKER

4,5,6,8 D DIODE3 F FUSE, 3 AMP

3 FHT FUEL HEATER THERMOSTAT

12 FH FUEL HEATER

10 FS FUEL SOLENOID

10 FSA FUEL SOLENOID -- HOLD

10 FSB FUEL SOLENOID -- PULL

7 GP GLOW PLUG

7 GPS GLOW PLUG SWITCH

8,12 HR HEATER RELAY

15 HWT HIGH WATER TEMP ERATURE SWITCH

10 IGN IGNITION SWITCH

11 LOP LOW OIL PRESSURE SWITCH

13 OPG OIL PRESSURE GAUGE

13 OPS OIL PRESSURE SENDER

9,15 S SAFETY RELAY

2 SM STARTER MOTOR

2,16 SS STARTER SOLENOID

3,8 TB TERMINAL BLOCK

14 WTG WATER TEMP ERATURE GAUGE

14 WTS WATER TEMP ERATURE SENDER

Figure 5-1 Schematic Diagram

-- Legend -- (Applies to Figure 5-2)



5-3 T-266

Based On Drawings 62-10008-00 Rev A & 62--0009--00 Rev A

ALTERNATOR OP TION

BATTERY CHARGEROPTION

NOTE

In 1997, early production units were retrofitted to move the low oil pressure switch fromthe wiring feedingterminal boardterminal TB4 tothe wiringfeedingthe safetyrelay. If servicinga unitthatis notwiredas shownabove, the unit should be retrofitted. Contact Carrier Service Engineering.

CB5 or F

UG0291 DOES NOTHAVE FHT


(For Applicability, Refer to Table 1-1)



5-4 T-266


460 Volt Alternating Current Generator (For Applicability, Refer to Table 1-1)



5-5 T-266


230Volt Alternating Current Generator (For Applicability, Refer to Table 1-1)



5-6 T-266

Based On Drawings 62-10213-00 Rev D, 62--10592 Rev A & 62--10732 Rev --

OPTIONAL

ENGINE GROUND

CHASSIS GROUND

2 A AMMETER11 ALT ALTERNATOR

12 BC BATTERY CHARGER

2 BAT BATTERY

4,8,13 CB CIRCUIT BREAKER

5,11,12 D DIODE

7 FHT FUEL HEATER THERMOSTAT

7 FH FUEL HEATER

6 FS FUEL SOLENOID

6 FSA FUEL SOLENOID -- HOLD

6 FSB FUEL SOLENOID -- PULL

13,14 GT GENERATOR TERMINAL

3,4 GP GLOW PLUG4,5 GPS GLOW P LUG SWITCH

5 HWT HIGH WATER TEMP ERATURE SWITCH

7,8 IGN IGNITION SWITCH

5 LOP LOW OIL PRESSURE SWITCH

8 OPG OIL PRESSURE GAUGE

8 OPS OIL PRESSURE SENDER

5,6 S SAFETY RELAY

2 SM STARTER MOTOR

2,9 SS STARTER SOLENOID

10 TT TIME METER

11 VR VOLTAGE REGULATOR

9 WTG WATER TEMPERATURE GAUGE9 WTS WATER TEMPERATURE SENDER


-- Legend -- Applies to Figure 5-6



5-7 T-266

ALTERNATOR OP TION

BATTERY CHARGER OPTION


ORREDOR

WHITE


(For Applicability, Refer to Table 1-1)



5-8 T-266

TOBATTERY CHARGER

(If Equipped)

GENERATOR C IR CUIT BR EAKE R R EC EPTAC LE

R1CB1CB1

WINDING LAYOUT

VOLT

METER

CB5CIRCUIT BREAKER

10 -- 4SO CABLE


FROM FRAME

FROM CONTROLBOX

SEE NOTE

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

PEPHYSICAL EARTH

(If Equipped)





5-9 T-266

TOBATTERY CHARGER

(If Equipped)

GENERATOR CIRCUIT BREAKERR1

RECEPTACLE

CB5CIRCUIT BREAKER

CB4 R1RECEPTACLE

R2RECEPTACLE

WINDING LAYOUT

VOLTMETER

Based On Drawings 62-10213-00 Rev D, 62--10592 Rev A & 62--10732 Rev -





Index-1 T-266

INDEX

A

ALTERNATING CURRENT GENERATOR, 1-7, 4-6

Alternator, 1-8, 4-9, 4-12

Alternator Brush Test, 4-11

Alternator/Regulator Tests, 4-10

Ammeter, 1-9

B

BATTERY CHARGING -- ALTERNATOR , 1-7

BATTERY CHARGING -- SOLID STATE SY STEM,1-8

BATTERY SERVICE, 4-1

C

CONFIGURATION IDENTIFICATION, 1-1

CONTROL CIRCUIT OPERATION, 2-3

Control Panel, 1-8

Cooling System, 4-1

D

DESCRIPTION, 1-1

Diode Testing, 4-7

E

ENGINE, 1-6

Engine Air Cleaner , 4-4

Engine Air System, 1-6

Engine Crankcase Breather, 4-5

ENGINE SCREW THREADS, 1-6

ENGINE SERVICE, 4-1

Engine Speed, 4-4

FFIRST AID, Safety--i

Fuel Filter, 4-1

Fuel Pump, 4-1

Fuel System, 1-6, 4-1

GGauges and Senders, 1-8

Generator Repair, 4-6

GENERATOR SET INSTALLATION AND REMOVAL,2-1, 2-2

Generator Test Procedures, 4-6

Glow Plug Switch, 1-9

Glow Plugs, 4-5

IIgnition Switch, 1-9

Insulation Testing, 4-7

INTRODUCTION , 1-1

LLube Oil Filter, 1-6, 4-4

MMAINTENANCE PRECAUTIONS, Safety--i

Manual Switches, 1-9

Meters, 1-9

Model Chart, 1-1

O

OPERATING CONTROLS AND INSTRUMENTS, 1-8OPERATING P RECAUTIONS, Safety--i

OPERATION, 2-1

PPost--Start Inspection, 2-3

Pre--Start Inspection, 2-3

PREVENTIVE MAINTENANCE SCHEDULE, 4-1



INDEX -- Continued

SSAFETY DEVICES, 1-9

SAFETY NOTICE S, Safety--i

SAF ETY SUMMARY, Safety--i

SCHEMATICS, 5-1

SERVICE AND PREVENTIVE MAINTENANCE, 4-1

Shockmounts , 4-8

STARTING AND STOPP ING, 2-3

Starting Insturctions, 2-3

Stopping Instructions, 2-3

T TORQUE REQUIREMENTS, 4-12

Total Time Meter, 1-9

TROUBLESHOOTING, 3-1

VV--belt, 4-4

Voltage Regulator, 1-8

Voltmeter, 1-9

genset ops manual 69ug15

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