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

1. l thru 10 are wires from A C generator Figure 5 2 Electrical Wiring Schematic M odel 69G C 15 114 1 Drawing Number 69G C 15 1784 Revision Sheet 2 of 2 5 5 AS 1 D3 6 55 e ee coo pee 6 54 RCRI 5 65 45 Gan TB22 IGN5 6 gt CB3 RCR AUX SET 4 OPGS WTGS RCR2 CB2 1 0 L LOP v com E N GRD TB22 F L OPG Al M IGNI OP6G SM i L FS 25 RCR44 9 51 oh Ke TB2 2 Co GRD A FM E ie f yoy 88 NA GRD 55 10 8 5 4 l Grm Pe Hl CBNC I GP CBI2 l RED POLARITY DOT ALT C ad VR R TB23 GRD 2 LA S GRD s N NS PEP WPP E T510 154 T55 156 LN eae A I GN4 5 ot n RI 52 T3 CBI m RECEPTACLE EE uL 83e 3 T510 6 NC 4 GP cB2 Eolo2 555 o 10o 9 3 2 LR
2. ke U S S E pl 14 e ie p a ke 4 98 T 716 L HI e sP mo Oil Pressure Gauge Voltmeter Gauge Ammeter Gauge Ignition Switch Glow Plug Switch Circuit Breaker CB 1 Circuit Breaker Trip Indicator Frequency Meter Optional Water Temperature Gauge Total Time Meter Circuit Breaker CB 2 Filter Reactor Optional Circuit Breaker CB 3 Run Control Relay RCR Junction Block TB2 Terminal Block TS Terminal Block TB1 Figure 1 3 Control Box and Gauge Panel M odels 69G C 15 134 144 154 174 184 amp 194 1 3 12 UNIT SPECIFICATIONS a Unit Weight Approx Models 69G C 15 104 114 2200 Ib 1000 kg with fuel and battery Models 69G C 15 134 144 154 174 184 amp 194 2260 Ib 1025 kg with fuel and battery b Engine Dry with Accessories 421 Ib 191 kg A C Generator 225 Ib 102 kg d Fuel Tank Draw Models 69G C 15 104 114 70 U S Gallons 265 liter Models 69G C 15 134 144 154 174 184 amp 194 78 U S Gallons 295 liter 13 ENGINE DATA a Bore Stroke CT4 114 V1902 3 35 in 85 mm 3 23 in 82 mm CT4 133 DI V2202 3 43 in 87 mm 3 62 in 92 mm CT4 134 DI V2203
3. AS GPS5 9 coo 6 54 RCR1 IGN5 6 CB3 e 9 WTGG TB23 RCR TB22 5 ono NTGG WTGI o y OPGS WTGS RCR2 03 4 E 3 34 CY s Lor L 16N4 F F ut 4 TB2 GRD TB22 01 5 rs RCR FM 1 TBS TB4 CU 3 SS e CB F V N 6 5 ALT RCRI N GP 5 55 5 a MTGG 21 1 e CBNC BMC GRD GRD y v e CB3 Hiron 1 0 6 5 4 oro L1 6 2 555 e C gt alik TON GPS BA T3 S2R1 RED POLARITY DOT C D DI ALT Sh VR R TB23 GRD 7 Z ue AI TB10 cgi 812 Cp13 GRD A A A O RI S2 T3 RECEPTACLE 1 thru 10 are wires from A C generator Figure 5 1 Electrical Wiring Schematic M odel 69G C 15 104 104 1 amp 114 Drawing Number 69G C 15 1144 Revision A Sheet 2 of 2 5 3 T3 4 460 VOLTS 3 PHASE 32 60 HERTZ R1 GRD
4. CBI LINE LOAD 3 GENERATOR 3 BAT 4 ex DC SS it e e GRD GPS GP RAM Adi sa EUR 7 A 20V 66 8 T gt GP cu ANN 4 D3 RCR HWT t TT LOP Di 10 p f RER TB22 TB23 FS 11 30 0PS 12 b T OP Fe A 2 1p START PIE T3 WT Wy I S S PE 14 Q B CBI N Z 16 Cygne x 55 in T7 LINE SYMBOL DESCRIPTION LINE SYMBOL DESCRIPTION MECHANICAL LINKAGE 10111213 IGN IGNITION SWITCH ENGINE GROUND 10 LOP LOW OIL PRESSURE rh CHASSIS GROUND 16 L1 LIGHT 5 A AMMETER 12 OPG OIL PRESSURE GAUGE 6 ALT ALTERNATOR 12 OPS OIL PRESSURE SENDER 4 BAT BATTERY 911 RCR RUN CONTROL RELAY 3 8 11 16 CB CIRCUIT BREAKER 5 SM STARTER MOTOR 9 10 15 D DIODE 5 17 SS STARTER SOLENOID 1 F FILTER OPTIONAL 11 TB2 TERMINAL BLOCK STUD 2 FM FREQUENCY METER OP 14 TT TOTAL TIME METER TIONAL 1 V VOLTMETER 1 FS FUEL SOLENOID 6 VR VOLTAGE REGULATOR 78 GP GLOW PLUG 13 WTG WATER TEMP GAUGE 7 GPS GLOW PLUG SWITCH 13 WTS WATER TEMP SENDER 9 HWT WATER TEMP SWITCH Figure 5 2 Electrical Wiring Schematic M odel 69G C 15 114 1 Drawing Number 69G C 15 1784 Revision Sheet 1 of 2 5 4
5. Engine Crankcase Breather Mechanical Fuel Pump Open Diode Trio Test 37 Open Regulator Test 37 Open Diode Trio Test 65 Open Regulator Test 65 Alternator Output Test 65 Alternator Brush Assembly 37 Alternator Brush Assembly 65 Rectifier Removal rcti uiw ee n n A C Generator Rectifier Assembly cep uet ede d Sa Asu Shockmount Installation n Clamping Device IndexPin Clamping Device in Closed Position Electrical Wiring Schematic amp Wiring Diagram M odels 69G C 15 104 104 1 amp 114 Electrical Wiring Schematic amp Wiring Diagram M odel 69GC15 114 1 Electrical Wiring Schematic amp Wiring Diagram Models 69G 15 134 144 154 174 amp 194 Electrical Wiring Schematic amp Wiring Diagram M odel 69G C 15 184 184 2 El
6. M odel 69G C 15 184 184 2 Drawing Number 69G C 15 1984 Revision Sheet 1 of 2 5 8 AS D2 p l GP55 9 9 e cB pM D3 6 54 RCR1 jj E OOG TB22 IGN5 6 RCR AUX 4 OPGS WTGS RCR2 CB2 1 2 0 HTGG WTGI p MN L _ L T6N4 N hee S GRD TB22 BE 2224 Al TB15 1814 Uic lis IGNI FM F 0P6G SM AL F E RCR6 L FSG RCR4 51 ol RCR1 S TB2 L GP 5 GRD A FM G rm e 083 55 F V L ALT IN b GP 5 10 5 4 vi is IG T810 CBI2 AL RED POLARITY DOT ALT Di Z OX AS 2 TB23 GRD 5 2 ns N N AIS 4 oc s ius 56 v 5 ed RI S I3 e WT RECEPTACLE ME EI Lit 01888 NC oP 2 555 100 S 3 2 1 D340 RCR6 0 o 1H 56 T54 TBI
7. 3 Keeping forks in pockets on generator set tighten mounting bolt E into container frame on each side of generator set Important Bolts must be tight and retaining pin F must be snapped into position 4 Remove safety chain A before removing forks b Removal WARNING Disconnect power plug before removing generator set 1 Place forks into fork pockets of generator set Attach safety chain A between fork pockets on generator set and fork truck 2 Remove mounting bolt E on each side of generator set 3 Disengage clamps B so handle D is forward and indexing pin C is a vertical position 4 Carefully remove generator set from container 2 1 4 Clamp Mounting 69G C 15 184 A U 5 b Figure 2 4 Clamp on M ounting 69G C 15 184 WARNING To preventinjury the procedures for installation and removal of the generator set given below must be followed NOTE This generator set is equipped with clamps and mounting bolts and can be installed only on containers with matching installation points for the mounting bolts a Installation 1 Place forks into fork pockets of generator set Attach safety chain A between fork pockets on generator set and fork truck Be sure chain A is short enough to retain generator set on forks Adjust each generator set clamp B with handle D forward and indexing pin C in vertical position 2 Move generator set against container and fully engage
8. 3 43 in 87 mm 3 64 in 92 4 mm b Compression Ratio CT4 114 V1902 21 1 CT4 133 DI V2202 20 5 1 CT4 134 DI V2203 20 5 1 Cooling System Capacity 80 5 quarts 7 57 liters includes 1 quart 0 946 liter in coolant recovery bottle Refer to section 4 3 1 Type of Anti F reeze Ethylene G lycol 4 quarts 3 78 liters Water 4 quarts 3 78 liters Use low silicate anti freeze meeting GM specifica tions GM 6038M or equal Water Temperature Safety Switch Setting Opens 230 5 110 3 Resets 200 F 93 C minimum Thermostat Starts to pen 177 to 182 F 80 to 84 C Fully O pen 203 F 95 C d Cylinders Number Four e Displacement CT4 114 V1902 113 57 cu in 1 85 liters CT4 133 DI V2202 133 5 cu in 2 2 liters CT4 134 DI V2203 134 cu in 2 2 liters f FiringOrder 1 3 4 2 g Fuel Winter Diesel No 1 Summer Diesel No 2 h Glow Plug Amperage 7 5 amps per plug at 12 vdc i Horsepower CT4 114 V1902 24 3 hp 1800 rpm CT4 133 DI V2202 32 5 hp 8 1800 rpm CT4 134 DI V2203 33 0 hp 3 1800 rpm j Lubrication System Oil Pressure 40 to 60 psig 3 8 to 5 2 kg cm 9 Oil Pressure Safety Switch Setting Closes 15 psig 2 08 kg cm Capacity 20 U S quarts 18 9 liters Includes 1 U S quart 0 95 liter filter Time between Oil Changes First 400 Hours thereafter every 1000 Hours maximum Oil L evel Indicator Dipstick in oil pan Lube Oil Specification
9. 3 T510 56 NC 4 GP cB2 Eolo2 SSS o 10o 9 211 p3toott Lrers 4olo Z AG N TS6 754 GPS CBC IGN GEN TS5 LINE AOU 3 8 11 16 9 10 15 1 2 TIONAL 1 7 8 7 9 SYMBOL i T3 4 460 VOLTS 3 PHASE 60 HERTZ R1 GRD CB1 LINE AN LOAD A 3 GENERATOR 3 DC 4 55 2 eO s GRD 5 G GPS GP RAM L I 7 A 2 v ANNA 8 T gt GP pg ANN 4 D3 RCR HWT i 5 D 1H2 Ta TT LOP Di 10 e p f RER TB22 TB23 FS 11 SOA POWELL 2 OPS 12 b 10 95 A 2 1p START I 13 WT AA IX 7S Y s 14 C B CBI N Z o ns D x 55 V TTT DESCRIPTION LINE SYMBOL MECHANICAL LINKAGE 10 11 12 13 IGN ENGINE GROUND 10 LOP CHASSIS GROUND 16 L1 AMMETER 12 OPG ALTERNATOR 12 OPS BATTERY 9 11 RCR CIRCUIT BREAKER 5 SM DIODE 5 17 SS FILTER OPTIONAL 11 FREQUENCY METER OP Q 14 TT FUEL SOLENOID 1 V GLOW PLUG 13 WTG GLOW PLUG SWITCH 13 WTS WATER TEMP SWITCH DESCRIPTION IGNITION SWITCH LOW OIL PRESSURE LIGHT OIL PRESSURE GAUGE OIL PRESSURE SENDER RUN CONTROL RELAY STARTER MOTOR STARTER SOLENOID TERMINAL BLOCK STUD TOTAL TIME METER VOLTMETER WATER TEMP GAUGE WATER TEMP SENDER Figure 5 4 Electrical Wiring Schematic
10. 194 Drawing Number 69G C 15 1284 Revision C Sheet 1 of 2 5 6 1 thru 10 lare wires from A C generator Figure 5 3 Electrical Wiring Schematic M odel 69G C 15 134 144 154 174 amp 194 Drawing Number 69G C 15 1284 Revision C Sheet 2 of 2 5 7 AS D2 p 6 95 e se cgo pe D3 GPS4 RCRI p s 3 65 45 G TB22 1GN5 1 6 gt RCR AUX I p3 39 4 OPGS WTGS RCR2 CB2 1 0 WTGG WTGI ex MN 2 Lop E a d LOP N GRD TB22 V F x TB15 TB14 I6N1 eM F 0 SM m EA RCRE RCRI r A FM 55 F V ALT N GP y TS l E Hl GP BAT RED POLARITY DOT gt D1 VR R TB23 GRD r LASG o v GRD 3 2 s N NS Vs ae i T510 54 T55 156 N N A A 16 4 5 oc mm t RI 52 T3 CBI 2 RECEPTACLE CE ui 83e
11. Use a heavy duty lubricating oil conforming to American Petroleum Institute A PI Service Classifica tion CD DS Lube Oil Viscosity Outdoor Temperature Fahrenheit Centigrade SAE Below 32_ 10W or 10W30 32 to 77 F 071025 20 Over 77 F Over 25 300r15W40 14 SAFETY DEVICES Refer to Table 1 2 System components are protected from damage caused by unsafe operating conditions by automatically shutting down the diesel engine when such conditions occur This is accomplished by the safety devices CB 2 HWT or OP These safety devices monitor system operating conditions and open a set of electrical contacts when an unsafe condition occurs O pening one or more of these safety switch contacts will de energize the run control relay This inturn opensa set of RCR contactsto de energize the fuel solenoid De energizing fuel solenoid releases the stop run lever to the STOP position shutting off the fuel supplyto the engine thus stopping the engine The A C generator and the glow plug circuit are protected by circuit breakers listed below but will not shut down the engine if an overload occurs Table 1 2 Safety D evices Unsafe Condition Safety Switch Switch Setting a Engine 1 Low engine lubricating 1 Oil pressure switch 1 Opens below 15 psig oil pressure Automatic reset 1 05 kg cm 2 High engine cooling 2 Water temperature switch 2 Opens above 230 water temperature Automatic reset 5 110 3 C 3
12. 2 3 2 RCR6 o ol S TS6 754 181 GPS IGN GEN TS5 Ned 9 1 thru 10 are wires from A C generator Figure 5 5 Electrical Wiring Diagram M odel 69G 15 184 1 Drawing Number 69G C 15 2044 Revision A Sheet 2 of 2 5 11
13. 4 15 4 16 4 17 4 18 5 1 5 2 5 3 5 4 5 5 Table 1 1 1 2 1 3 LIST OF ILLUSTRATIONS Generator Set Front View Control Box and Gauge Panel odels 696 15 104 amp 114 Control Box and Gauge Panel M odels 69G C 15 134 144 154 174 184 194 Engine ATE CIeaner s s dota tton ent ete nue s RURSUS d Ps kuah ed Lube Oil Flow F el System Diagram sees eme a ee oes E ale P aA E Alternator Schematic Diagram 37 Amp Rectifier Diode Assembly 37 Alternator and Regulator 37 Alternator and Regulator 65 Alternator Schematic Diagram 65 Main Alternator A C Generator A C Generator Circuit Diagram Pin Mounting 69G 15 114 114 1 144 154 Pin Mounting 69GC15 194 0 0 kam kayka sapa a Clamp on M ounting 69G C15 104 134 174 Clamp on M ounting 60 15 184 Fuel Solenoid Assembly Speed Adjustment 2 s REED uel Ran ERES P
14. a volt higher or lower due to ambient temperature variations b If the alternator output voltage does not fall within the proper range the alternator should be removed for further inspection and tests Refer to Prestolite manu al 4 45 Alternator Brush Test Procedure 37 AMP a Removing Brush Set Itmaybeadvantageousto remove the alternator from the unit Refer to section 4 4 8 1 Remove wiring to alternator three wires and then remove four screws securing regulator to alternator 2 Slowly pull regulator away from alternator and disconnect green wire from brush assembly R emove two screws securing brush assembly to brush cavity 3 Check slip rings for carbon build up 4 Check brush assembly for chipped or oil on brushes Remaining brush length should be at least 3 16 inch 4 8 mm long b Brush Continuity Check 37 AMP Using a 12 vdc test lamp or ohmmeter test brush assembly for continuity and insulation as shown R emove brush assembly if necessary CONTINUITY CHECK Continuity Ato C OK Continuity DtoE OK No Circuit CtoE OK NEGATIVE GROUND Figure 4 11 Alternator Brush Assembly 37 Amp 4 4 6 Alternator Brush Test Procedure 65 AMP NOTE Before performingtest removal of back cover is required To remove disconnect wires from terminals extending through back cover Remove two screws securing back cover to rear housing and remove cover a Removing Brush Set 1 Remove two lockn
15. clamps into mating holes in container corner castings allowing clamp boss to settle on bottom of corner casting Rotate indexing pin C to horizontal position and lock handle D on both clamps Important Clamping device handle D must be drawn back and handle pin snapped into position and safety pins installed 2 4 3 Keeping forks in pockets on generator set tighten mounting bolt E into container frame on each side of generator set Important Bolts must be tight and retaining plate F must be locked into position 4 Remove safety chain A before removing forks b Removal WARNING Disconnect power plug before removing generator set 1 Place forks into fork pockets of generator set Attach safety chain A between fork pockets on generator set and fork truck 2 Release retaining plate F from locking bracket on each side of generator set 3 Remove mounting bolt E on each side of generator set 4 Disengage clamps B so handle D is forward and indexing pin C is a vertical position 5 Carefully remove generator set from container 2 2 PRE TRIP INSPECTION a Before Starting Generator Set 1 Check engine lubrication and fuel oil filter cases oil lines and connections for leaks Tighten connections and or replace gaskets 2 Check engine lubrication oil level Refer to section 1 3 3 Check engine V Belt for proper tension fraying or cracks Adjust belt or replace Refer to section 4 5 4 Chec
16. shown in Figure 4 7 see above note a After jumper addition the test lamp should now be illuminated with switch ON and engine stopped thus indicating an open regulator If lamp is still not on check bulb and harness If lamp is still not on an open field circuit brushes slip rings etc isindicated the alterna tor must be removed for repair b Ifthelampisnowilluminated with switch ON and engine stopped run engine with no loads Voltmeter should indicate 15 0 volts or greater If voltageislessthan 15 0 volts the alternator is defective diodes etc 4 5 Test No 3 Alternator Output Test 37 AMP CONDITIONS Engine running after voltmeter is connected as shown in Figure 4 7 Start unit and run engine with load With the unit operating placing a load on charging circuit check for nominal system output voltage of between 13 8 14 8 volts for a properly operating charging system Voltages may vary afewtenthsof a volt higher or lower dueto ambient temperature variations If thealternator output voltages does not fall within the proper range the alternator should be disassembled for further inspection and tests Refer to Prestolite manual TOGGLE 12vdc SWITCH BATTERY TEST LAMP EXCITATION OUTPUT 13 75 14 75V RED T BATTERY Figure 4 7 Open Regulator Test 37 Amp Test No 1 Open Diode Trio Test 65 AM P CONDITIONS Start run stop switch SRS inRUN position and engine stop
17. the four 4 mounting boltsand movethe solenoid toward the lever until it shuts off Tighten the mounting bolts 4 3 4 Adjusting Engine Speed The engine speed operates at 1820 to 1840 rpm no load 1710 rpm with load Two methods to check engine speeds are a With the engine stopped place a mark white paintfor example on the crankshaft sheave Start engine and verify engine speed by using a Strobette model 964 Strobetachometer Carrier Transicold Part No 07 00206 b With the engine stopped the second method of checking engine speed is by using a frequency hertz meter Attach one lead to CB 1 terminal 1 Section 5 electrical schematics and the other to chassis ground Start engine and 60 5 hertz will be 1820 rpm and 61 3 hertz will be 1840 rpm no load 1 Speed Lever 2 Nut B 3 Capscrew B Figure 4 2 Speed Adjustment To Increase Speed Loosen jam nut B Turn capscrew B clockwise until correct speed is achieved then tighten jam nut B and check engine speed To Decrease Speed Loosen jam nut B Turn capscrew B counter clockwise until correct speed is achieved then tighten jam nut B and check engine speed 4 3 5 EngineAir Cleaner a Inspection The air cleaner should be inspected constantly for leaks A damaged air cleaner or hose can seriously effect the performance and life of the engine The following simple service steps are easily made while the engine is being servi
18. 3 1 3 Starter Motor Malfunction 3 2 3 1 4 M alfunction in the Engine Starting Circuit 3 2 3 1 5 Miscellaneous Engine Troubleshooting 3 2 3 2 Alternator Automotive Type 3 3 3 3 A C Brushless Generator Main Alternator 3 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 5 1 SERVICE Fee E ates ia ae ER NR sate M aintenance Schedule 2 eer eH ER a aaa Priming the Fuel System fiia mn Engine Service and lt 4 9 1 Cooling System REIR LER EUR a 4 3 2 Qil FICE Si a 4 3 3 Servicing the Fuel Solenoid and 4 3 4 Adjusting Engine 4 3 5 Engine Cleaner u onreine de ead ae Reate Pac e rn 4 3 6 Engine Crankcase 4 3 7 Servicing GOW PIUQS eR asus 4 3 8 Servicing Fuel PUMP s cc n an Servicing the Alternator r mn 4 4 1 Preliminary Checks and Tests 4 4 2 Ing Et eet athena tan Pagans 4 4 3 Problem Area D
19. 7 1 9 3 Voltage Regulator peration 12 volts d c 37 1 7 1 9 4 Introduction 65 mm 1 8 1 9 5 Alternator Operation 65 AMP 1 8 1 9 6 Integral Voltage Regulator Operation 12 volts d c 65 1 9 1 10 Main Alternator A C Generator 0 ccc Hn 1 9 1101 Principle of Operation cao ea 1 9 110 2 A C Generator M ain Alternator Circuit Diagram 1 10 OPERATION pa CE RO VUE E 2 1 21 Generator Set Installation and Removal 2 1 2 1 1 Pin Mounting 69G 15 114 114 1 144 154 2 2 2 1 2 Pin Mounting 696 15 194 2 3 2 1 3 Clamp M ounting 69G C 15 104 134 174 2 4 2 14 Clamp M ounting 696C15 184 2 5 2 2 Pr strip TTispectlOn e i ah e Ve eoe ed c re d 2 5 2 3 Starting and Stopping Instructions n 2 5 24 Control CircultO perathon 5 a eue to reti sehe rn ttn Set euh Ch ied kaq 2 6 3 TROUBLESHOOTING un cece cece cece cece mH nnn 3 1 3 1 wear ant oki 3 1 3 1 1 Engine Will eee inate eed es thas ee es 3 1 3 1 2 Engine Starts Then Stops 3 1
20. CRG Mo oll Z AG N TS6 754 TBI 6 5 CBC IGN GEN TS5 S 7 T3 4 E s 1 HERTZ RI GRD 2 LINE TwN1 A LOAD MA 3 2 GENERATOR 3 VT DC 4 55 2 it e D GRD GPS GP a 7 AX av E CAUTO Tre 6 AAA 45A D3 RCR HWT A Me 15 IGN gt vs 89 OFF dps s RUN 22 TB23 wp s 12 b E 0P 2 14 START Ex 13 WTC ve I S N ges 14 1 ig C Ne iE 55 in 77 LINE SYMBOL DESCRIPTION LINE SYMBOL DESCRIPTION E E MECHANICAL LINKAGE 10111213 IGN IGNITION SWITCH ENGINE GROUND 10 LOP LOW OIL PRESSURE rh CHASSIS GROUND 16 L1 LIGHT 5 A AMMETER 12 OPG OIL PRESSURE GAUGE 6 ALT ALTERNATOR 12 OPS OIL PRESSURE SENDER 4 BAT BATTERY 911 RCR RUN CONTROL RELAY 3 8 11 16 CB CIRCUIT BREAKER 5 SM STARTER MOTOR 9 10 15 D DIODE 5 17 SS STARTER SOLENOID 1 F FILTER OPTIONAL 11 TB2 TERMINAL BLOCK STUD 2 FM FREQUENCY METER OP 14 TT TOTAL TIME METER TIONAL 1 V VOLTMETER 11 FS FUEL SOLENOID 6 VR VOLTAGE REGULATOR 7 8 GP GLOW PLUG 13 WTG WATER TEMP GAUGE 7 GPS GLOW PLUG SWITCH 13 WTS WATER TEMP SENDER 9 HWT WATER TEMP SWITCH Figure 5 3 Electrical Wiring Schematic M odel 69G C 15 134 144 154 174 amp
21. D 4 LINE TN LOAD 3 v P BAT 4 _ 2 DC 55 o 01 KO VR 5 B GRD Xf L1 OPS 3 6295 Cy i6 WTS IGN cel 55 5 2 1V start x Iu OFF D2 13 cgo Wh ws RUN TB22 FS 5 6114 15 Be OEE Lop RCR HWT 16 CB3 GPS D3 1 2 TL GUTO NE 17 45 s v 18 GP Q 65 7 LINE SYMBOL DESCRIPTION LINE SYMBOL DESCRIPTION MECHANICAL LINKAGE 1 121314 IGN IGNITION SWITCH ri ENGINE GROUND 15 LOP LOW OIL PRESSURE CHASSIS GROUND 8 L1 LIGHT 5 A AMMETER 9 OPG OIL PRESSURE GAUGE 7 ALT ALTERNATOR 9 OPS OIL PRESSURE SENDER 4 BAT BATTERY 14 15 RCR RUN CONTROL RELAY 3 8 13 16 CB CIRCUIT BREAKER 5 SM STARTER MOTOR 6 1317 D DIODE 5 11 SS STARTER SOLENOID 1 F FILTER OPTIONAL 3 14 TB2 TERMINAL BLOCK STUD 2 FM FREQUENCY METER OP 12 TT TOTAL TIME METER TIONAL 1 V VOLTMETER 14 FS FUEL SOLENOID 6 VR VOLTAGE REGULATOR 18 GP GLOW PLUG 10 WTG WATER TEMP GAUGE 16 GPS GLOW PLUG SWITCH 10 WTS WATER TEMP SENDER 15 HWT WATER TEMP SWITCH Figure 5 1 Electrical Wiring Schematic M odel 69G C 15 104 104 1 amp 114 Drawing Number 69G C 15 1144 Revision A Sheet 1 of 2 5 2 D2 CB3 D3
22. Excessive current draw 3 Circuit breaker CB 2 3 Trips at 20 amps by FS HWT L1 OPG WTG RCR or TT b Glow Plugs 1 Excessive current draw 1 on glow plug circuit c Generator 1 Excessive current draw 1 by generator 15 ENGINE SCREW THREADS All threads used on the Model CT4 114 133 DI engines are metric except the oil drain plug which is A merican Standard Pipe Thread NPT 16 ENGINE AIR SYSTEM Clean air is supplied to the engine through the air cleaner See Figure 1 4 The air is necessary for complete combustion and scavenging of the exhaust gases As the engine piston goes through the intake stroke the piston draws clean fresh air down into the cylinder for the compression and power strokes As the engine goes through its exhaust stroke the upward movement of the piston forces the hot exhaust gases out of the cylinders through the exhaust valves and the exhaust manifold If the air filter is allowed to become dirty the operation of the engine would be impaired Blow by gases from the diesel engine crankcase are introduced in the air intake manifold through the crankcase breather Therefore the filter must be kept clean and air restriction reduced to a minimum A dry type air cleaner is used with this unit A ir passes through the screen where dirt or dust in the air is removed before it entersthe engine A sthe dust and dirt accumulate the filter should be changed periodically If the filter is not chang
23. R STARTER SOLENOID TERMINAL BLOCK STUD TOTAL TIME METER VOLTMETER WATER TEMP GAUGE WATER TEMP SENDER Figure 5 5 Electrical Wiring Schematic M odel 69G C 15 184 1 AS D2 p 6 55 oe pes GPS4 RCR1 E Pere TB22 IGN5 6 RCR AUX 35 4 OPGS WTGS RCR2 CB2 1 2 L Lop 2 0 TS b op GRD TB22 F OPGI AI TB15 TB14 pi ls IGNI FM F OPGG an FS RCR6 L RCR4DP 2 GPS1 pu ae 080 ol RCRI 8 1 Lop RO FM UNS 55 SS F V emp 22 P ALT FT 1 1016 5 4 9191919 Ill CBNC I 6P PA 12 BAT Ses CBL RED POLARITY DOT Di AEN O OX AS 23 o GRD 3 1 SS s Jae T510 754 155 156 0 ae TOR ITB22 v 5 o4 5 coURL S2 13 CBI 7 m RECEPTACLE CEE TORGE aF NC 4 1 SP cB2 olo2 sss 10
24. TRANSICOLD Diesel Driven Generator Set 114 134 144 154 174 184 amp 194 LLI OF ef LH Oc TRANSICOLD OPERATION AND SERVICE MANUAL DIESEL DRIVEN GENERATOR SET MODELS 69GC 15 104 114 134 144 154 174 184 amp 194 R UNITED DMA TECHNOLOGIES JCARRIER TRANSICOLD Carrier Transicold Division Carrier Corporation P O Box 4805 Syracuse N Y 13221 Carrier Corporation 1995 D Printed in U S A 0195 TABLE OF CONTENTS Section Page 1 DESCRIPTION bs da ke e WR DE da 1 1 11 lintFod ctlon i mete er ei eheu pep ead setae 1 1 1 2 Unit Specifications e cen Q 1 4 1 3 Engine Data stis teas h uka ratae fav 1 4 14 Safety DEVICES UR 1 4 15 ENGINE SCrEW Threads d er ence Rt 1 5 1 6 Engine ATE Systemi u etos Edi e ee ge ec rec a 1 5 1 7 Operating Controls and Instruments ne 1 6 1 7 1 Oni i ed UR 1 6 1 7 2 Control Panel and Related Components 1 6 1 7 3 Protective Devices uyu up cette nnn 1 6 1 8 Lube Oil and Fuel Flow 1 1 7 1 9 Battery Charging Alternator System 1 7 1 9 1 Introduction 37 AMP 1 7 1 9 2 Alternator Operation 37 1
25. Theuse of stud guides two in bell housing 5 16 18 x2 19 and two in the flywheel 3 8 24 x 2 1 2 19 will make installation easier These studs should have a square or hex design on the end opposite the threads This is necessary to remove studs after generator is installed 1 Remove screen coveringfrom shaft end of genera tor and brush anti seize lubricant Iube plate on the face of flywheel 2 Move generator with hoist into position and line up with the studs on housing and flywheel Turn crankshaft with large wrench to align flywheel with generator if necessary NOTE t may be necessary to apply pressure under the cooling fan to align the generator with the flywheel counterbore 3 Start the 3 8 24 bolts by hand through the disc plate and into the flywheel 4 Secure two of the housing bolts 5 16 18 to draw the mating flanges together 5 Remove studs and secure remaining bolts and washers The 5 16 18 bolts six are to be torqued to a valueof15 2ft lb 2 0 3mkg The 3 8 24 bolts five to be torqued 25 2 16 3 0 3mkg NOTE Install new gaskets one between generator and junction box and the other between box and cover when installing junction box 6 Install screen cover mounting bolts power junc tion box and wiring Torque generator mounting bolts 5 8 11 to a value of 70 ft Ib 9 68 mkg 47 REPLACING SHOCKMOUNTS The engine and generator use different style shock mounts and hold d
26. al Fuel Pump 4 4 SERVICING THE ALTERNATOR 4 4 1 Preliminary Checks and Tests NOTE Before starting the actual electrical test procedure the charging system battery and wiring should be checked to eliminate possible problem areas Figurel 9 37 Amp or Figure 1 10 65 A mp identifiestheterminalson the rear of the alternator a Check the condition and adjustment of belts 1 Check belt adjustment Refer to section 4 5 2 Replace any worn or glazed belts b Check to see that all terminals connectors and plugs are clean and tight 1 Loose or corroded connections cause high resistance and this could cause overcharging under charging or damage to the charging system 2 Badly corroded battery cables could prevent the battery from reaching a fully charged condition C Check battery condition and charge if necessary A low or discharged battery may cause false or misleading readings when conducting in unit tests 4 4 2 Test Tools A list of the following tools is provided to perform tests on the alternator and its components a Volt ohm meter b Single pole single throw switch 12 vdc lamp d Insulated 12 gauge stranded wire e Alligator clamp terminals 4 4 3 Problem Area Determination CONDITIONS Engine running for all tests unless otherwise specified a Battery Undercharged 1 Perform open diode trio test Refer to section 4 4 4 2 Perform regulator tests R efer to section 4 4 4 If regulator is al
27. ce and the inside of the L hook shaft to ensure that the generator set is tightly secured to the container To adjust or replace L hook shaft do the following 1 Rotate index pin 90 and drive the pin out of the L shaft 2 Rotate the L shaft and the piston will rotate inside ofthe cylinder When thetwo holesin the cylinder assembly line up insert drift pin 3 Place large wrench on the L shaft and turn counter clockwise to remove Turning clockwise de creasesthe dimension between the cylinder head and the inside of the L hook shaft 4 Grease shaft with NEVER SEEZ after installing new shaft 5 The clamping device is equipped with two grease fittings and should be greased annually and as required with NEVER SEEZ M ake surethe clamp assembly isin the lower position before greasing CAUTION When replacing complete clamping device apply thread sealer L ocktite h brown in color to the mounting bolts and torque bolts to a value of 50 to 60 ft Ibs 7 6 to 8 2 mkg 1 65 inch 16 51 n 4 1 Clamp in Closed Position 2 U Hook shaft 3 Grease Fitting 4 Index Pin in Lock Position 5 Grease Fitting 6 Spring Latch 7 Latch Pin 8 Retaining Pin Figure 4 18 Clamping Device in Closed Position 4 12 SECTION 5 SCHEMATICS 5 1 INTRODUCTION This section contains Electrical Wiring Schematics and Diagrams covering the M odels listed in Table 1 1 The following general safety notices supp
28. ced in the field The simple service steps are as follows 1 Watch all connections for mechanical tightness Be sure cleaner outlet pipe is not fractured 4 3 2 If cleaner has been dented or damaged check all connections immediately 3 In case of leakage and if adjustment does not correct the trouble replace necessary parts or gaskets Swelled or distorted gaskets must always be renewed b Service Procedure 1 Empty dust cover as required Check to see that the vacuator is not inverted damaged or plugged 2 Stop the engine remove and clean the dust cap Remove the dirty element from the air cleaner Install new filter and tighten wing nut securely 3 Install dust cover makingsureitseals 360 around the air cleaner body Check all connections between the air cleaner and the engineto be certain that they aretight and leak free 1 BodyAssembly 4 2 Primary Element 5 3 Clamp E J 1 Dust Cap Vacuator Figure 4 3 Air Cleaner 4 3 6 Engine Crankcase Breather Both engines use a closed type breather with the breather line attached to the cylinder head cover See Figure 4 4 Cylinder Head Cover 5 Breather Oil Shield Breather Cover 6 Capscrew Breather Element 7 Breather Assembly Plate 8 O Ring Figure 4 4 E ngine Crankcase Breather The breather assembly should be cleaned once a year or at every 3000 hours maintenanc
29. ch is released to the RUN position Releasing glow plug switch de energizes the glow plugs Total time meter is energized simultaneously with the fuel solenoid With the engine running the belt driven alternator provides 12 volt d c power to operate the control system and charge the battery 3 1 DIESEL ENGINE INDICATION TROUBLE 3 L1 Engine Will Not Start a Starter motor will not crank or low cranking speed b Starter motor cranks but engine fails to start c Starter cranks engages but dies after a few seconds 3 1 2 Engine Starts Then Stops a Engine stops after several rotations SECTION 3 TROUBLESHOOTING POSSIBLE CAUSES Battery insufficiently charged Battery terminal post or Battery defective Bad electrical connections at starter Starter motor malfunctions Starter motor solenoid defective Open starting circuit Incorrect grade of lubricating oil No fuel in tank Air in fuel system Water in fuel system Plugged fuel filters Faulty fuel control operation Run control relay Glow plug s defective Plugged fuel lines to injector s Engine lube oil too heavy Voltage drop in starter cable s No fuel in tank Faulty fuel control operation Fuel filter s restricted Air cleaner or hose restricted Safety device open Open wiring circuit to run solenoid Fuel solenoid linkage disconnected Oil pressure switch defective Fuel supply restricted Leak in fuel system Injector nozzle s defectiv
30. coil 34 REFERENCE SECTION 4 6 1 Check 4 6 2 4 6 1 4 6 2 4 6 2 4 6 2 4 3 4 Check Tighten 4 6 2 4 3 4 Engine M anual Tighten 4 6 1 4 3 4 Check Clean 4 3 1 4 3 1 Balance 4 6 1 4 6 1 4 6 1 4 6 2 4 6 2 Check ground to frame 4 6 2 SECTION 4 SERVICE Thissection coversserviceforthe generator set and some engine servicingonly R efer to the Kubota engine workshop manual for other engine servicing Refer to chart in section 1 1 41 MAINTENANCE SCHEDULE Unit ON OFF a Daily Maintenance X X X Beware of moving V Belts and belt driven components b First 400 Hour Maintenance X X X X X 1 2 3 4 WARNING Operation Pre Trip Inspection before starting Pre Trip Inspection after starting Check total time meter Pre Trip Inspection before starting Change lube oil and filter Pre Trip Inspection after starting Check total time meter Every 1000 Hour Maintenance Normal O perating Conditions X X gt gt gt gt gt gt 1 t 43 50 NJ Complete 400 Hour M aintenance Tighten engine and generator mounting bolts Tighten all electrical connections in control box Clean air cleaner check hose and connections Check water pump bearing end play Check alternator slip rings and brushes Replace fuel filter d Every 3000 to 6000 Hour Maintenance X X gt 1 w Complete a 400 and 1000 H our M aintenance Clean cra
31. control and monitoring cabinet starting battery 12 vdc battery charging alterna tor regulator and other necessary accessory components for proper unit operation For power either Carrier Transicold M odel CT 4 114 CT 4 133 DI or CT4 134 DI See odel Chart vertical in line four cylinder diesel engines are used The engine is equipped with glow plugs used as a starting aid spin on lube and fuel oil filters for easier filter changes Electrical power is generated by a Lima 15 KW brushless single bearingA C generator The generator is coupled directly to the engine flywheel The generator provides a constant 460 vac 3 phase 60 hertz electrical supply The 12 vdc battery charging alternator is belt driven from the generator drive shaft sheave The water pump and the radiator cooling fan are belt driven from the engine crankshaft sheave Table 1 1 M odel Chart Model No Fuel Tank Control Box Engine U S Gallons 70 78 Fig Fig CT4 114 0 4 133 CT4 134 DI 12 13 X X 69GC15 104 69GC15 104 1 69GC15 114 69GC15 114 1 69GC15 134 69GC15 144 69GC15 154 69GC15 174 69GC15 184 69GC15 184 1 69GC15 184 2 69GC15 194 gt gt x gt x gt gt gt lt lt gt lt gt 1 1 Alternator Unit 37 65 Mounting Amp Amp py UN DUIS a Control Box and Panel 8 Alternator Battery Charging 9 Air Cleaner 10 Lube Oil Filter 11 Fuel Filters 12 F
32. disconnect the alternator and exciter rotor leads as shown in Figure 4 13 3 Remove the three hold down cap screws which secure the rectifier assembly to its adapter Once this procedure is complete the rectifier assembly is free for removal Follow the testing procedures outlined in section 4 6 1 After the rectifier assembly has been repaired or replaced reverse the procedure as stated above being careful that all lead connections are tight and that set screws are locked with L octite Loctite Corporation 1 Exciter Rotor Lead 2 Alternator Rotor Lead Figure 4 14 A C Generator Rectifier Assembly d Testing Diodes With An Ohmmeter A A Cc C RED LETTERING BLACK LETTERING R After Number Forward Reverse Polarity Polarity Diode Diode A Anode C Cathode Figure 4 15 Diode Testing 1 Remove the diode from the circuit Do not press body out of heat sink Disconnect the lead Do not use excessive heat in unsoldering the lead 2 A good diode should have a low resistance when the of an ohm meter is connected to the anode and the to the cathode and a high resistance when the polarity of the ohmmeter is reversed See Figure 4 15 If both resistances are high or both are low then the diode is defective and should be replaced 4 9 e Rotor Damage The damper bars of the generator prevent excessive hunting when AC generators are operated in parallel D amper bars because they m
33. e Injection pump defective 31 REFERENCE SECTION Charge Check Correct 3 1 3 Engine M anual 3 14 1 3 13 4 2 Drain Sump Replace 4 3 3 4 3 3 4 3 7 E ngine M anual 1 3 Check 13 4 3 3 Replace 4 3 5 14 Check 4 3 3 Replace Engine M anual E ngine M anual Engine M anual Engine M anual INDICATION TROUBLE 3 1 3 Starter M otor M alfunction a Starter motor will not crank or turns slowly b Starter motor turns but pinion does not engage C Starter motor does not disengage after switch has been released d Pinion does not disengage after engine is running a No power to starter motor solenoid b Fuel solenoid does not energize or does not remain energized 3 L5 Miscellaneous E ngine Troubleshooting a Loss of power POSSIBLE CAUSES Battery insufficiently charged Battery cable connections loose or oxidized Battery cables defective Starter brushes shorted out Starter brushes hang up defective or have no contact Starter solenoid damaged Ignition switch defective Engine lube oil too heavy Pinion or ring gear obstructed or worn Ignition switch defective Starter motor solenoid defective D efective starter 3 L4 Malfunction In the Engine Starting Circuit Battery defective Loose electrical connections Battery defective Loose electrical connections Water temperature safety switch open Oil pressure switch defective Run control relay defective Fue
34. e interval whichever comes first 4 3 7 Servicing Glow Plugs The glow plugs are parallel connected and when energized draw 7 5 amps at 12 vdc When servicing the glow plugisto be fitted into the cylinder head to prevent damage to the glow plug Torque value for the glow plugsis 28 9 to 36 2 ft lb 4 0 to 5 0 mkg Checking for a D efective Glow Plug a One method isto remove the injector and then energize the glow plug The glowing tip may then be observed b Another method is to place an ammeter or clip on ammeter in series with each glow plug and energize the plugs Each plug if good should show amperage draw 4 3 8 Servicing Fuel Pump a Mechanical Pump See Figure 4 5 D ue to foreign particlesin the fuel and waxasa result of using the wrong grade of fuel or untreated fuel in cold weather the fuel filter may become plugged or restricted The filter must be cleaned on a regular schedule such as unit pre trip or when the oil and fuel filters are changed Refer to section 4 1 1 Turn nut counter clockwise to loosen and re move item 1 2 Remove banjo fitting item 2 and let it hang loose making sure to keep copper rings item 4 for re placement 3 Turn filter item 3 counter clockwise and re move Check and clean 4 To install reverse steps 1 through 3 E eg Le 1 Nut 2 Banjo 3 Filter 4 Copper Rings Figure 4 5 Mechanic
35. e output Figure 1 7 Alternator Schematic Diagram 37 Amp Both mounting studs have amp potential Heat sink Diodes Figure 1 8 Rectifier Diode Assembly 37 Amp 1 8 1 Excitation 6 Output Terminal 2 White Wire 7 Regulator Terminal 3 Black Wire 8 Red Wire 4 Negative Terminal 9 Regulator 5 Capacitor Figure 1 9 Alternator and Regulator 37 Amp 1 9 4 Introduction 65 Amp The mechanical construction of the alternator differs from the D C generator in that the field rotates and the armature generating windings are stationary T he field current necessary to control the output of the alternator is supplied from the solid state regulator T his integral voltage regulator which incorporates an IC all silicone semiconductor and thick film construction controls the current feed to the field via the brushes and rotor slip rings Two completely sealed ball bearings support the rotor in the front and rear housing CAUTION Observeproper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator 1 9 5 Alternator Operation 65 Amp The alternator converts mechanical and magnetic energy to alternating current A C and vo
36. ect current voltage of approximately 20 volts to any two generator leads L1 L2 and L3 while generator is running D o not make a positive connection but rather touch the leads together until the generator voltage begins to rise and then remove It is suggested that a 30 ampere fuse be inserted in the circuit to prevent any damage in case the build up voltage is not removed quickly enough Reflash field if generator output voltage does not build up 4 6 2 Installation and Removal a Removing the Generator 1 Remove ground wire from frame of generator set 2 Remove generator leads from power junction box then remove four 1 4 20 x 1 2 thread cutting screws securing box to generator 3 Remove screen from coupling end of generator 4 Remove five 3 8 24 x 3 4 hex head screws and washers securing generator disc to engine flywheel A socket brazed to a flexible shaft and an offset wrench are required to remove the bolts Turn bolts counter clock wise with offset wrench to start then use flexible shaft and socket assembly for removal of bolts 5 Remove six 5 16 18 x 1 1 4 bolts and washers that secure generator to engine housing Two boltsare 5 16 18 1 1 2 19 Secure bracket 6 Remove mounting foot hardware then remove generator b Installing the G enerator The generator is a single bearing type which means the shaft end of the rotor floats Before installing generator rotate shaft and check if bearing rotates
37. ectrical Wiring Schematic amp Wiring Diagram odel 696 15 184 1 LIST OF TABLES Model Chal zs c utr rp mI tera m bk id no RE Dubia Safely D vices ots te puyta dire ut stehe ss Alternator and Manuals iii iv Page 1 2 1 3 1 3 1 5 1 7 1 7 1 8 1 8 1 9 1 9 1 10 2 1 2 2 2 4 4 2 4 3 4 3 4 4 4 5 4 6 4 6 4 7 4 7 4 8 4 9 4 9 4 11 4 12 4 12 5 2 5 4 5 6 5 8 5 1 Page 1 1 1 5 1 7 SECTION 1 DESCRIPTION 11 INTRODUCTION WARNING Beware of moving V Belts and belt driven components This manual contains Operating Data Electrical Information and Service Instructions for the diesel generator sets shown in Table 1 1 Separately bound manuals coveringthe diesel enginesfor the diesel driven generator sets are also supplied see chart below EQUIPMENT COVERED CT4 114 133 DI 134 DI MANUAL FORM NO 62 03459 TYPE OF MANUAL FORM Engine Parts List 62 03461 Workshop Manual Workshop Manual Workshop Manual CT4 114 62 03707 CT4 133 Dl 62 03741 CT4 134 Dl The diesel driven generator sets are intended for front mounting upon a refrigeration unit They providea constant electrical power supply for the operation of an all electric refrigeration unit See left side of unit for serial model number plate Located inside the frame are the diesel engine A C generator main alternator
38. ed it will be blocked so that it cannot effectively remove the dirt and dust from the air passing over the screens The air cleaner is equipped with Vacuator Valve which continuously expel dust and moisture On cleaners equipped with dust cup the cup is emptied as dust accumulates a Pre cleaner The illustration shows a fin which gives high speed rotation to the intake air and separatesa large portion of the dustfromthe air by centrifugal action T he plasticfin the element and the gasket are vital parts of the cleaner and are designed into a single replaceable assembly T his Circuit breaker CB 3 1 Automatic reset Circuit breaker CB 1 1 Manual reset 1 5 Automatic reset Opens at 45 amps Trips at 25 amps 460 vac design feature assures continued high performance of the cleaner 1 Pre Cleaner 2 Ejected Dust 3 Duralife Filter Figure 1 4 Engine Air Cleaner b Ejected dust The dust is swept through a slot in the baffle and collected in the dust cup or Vacuator Valve body c Duralife filter The small portion of the dust remaining in the pre cleaned air is removed by the D uralife element The element is chemically treated and oven cured for resis tance to oil and water Perforated steel supports the element inside and out and together with rigid metal end Caps provides structural rigidity to this vital part of the cleaner The element can be cleaned for re use by one of severa
39. efrigeration unit ceases The diesel engine will continue to run with normal engine operation but the voltmeter will indicate no output and the circuit breaker indicator light will be illuminated d Circuit Breaker CB 2 The circuit breaker is located in the control box This device prevents excessive current draw by the compo nents FS HWT L1 OPG RCR WTG and TT The circuit breaker opens at 20 amps and will automatically reset e Circuit Breaker CB 3 The circuit breaker is located above CB 2 in the control box This device prevents excessive current draw by the glow plug circuitry T he circuit breaker opens at 45 amps and will reset automatically 18 LUBE OIL AND FUEL FLOW DIAGRAMS 4 Oil Pressure Sender 5 Oil Pressure Switch 6 Engine Block Oil Connections 1 Engine Block 2 Oil Pan 3 Full Flow Filter Figure 1 5 Lube Oil Flow Diagram 1 1 Fuel Tank 7 Injector Nozzles 2 Fuel Supply Line 8 Fuel Bleed Valve 3 Fuel Return Line 9 Injection Pump 4 Fuel Warmer 10 Primary Filter 5 FuelLeak Off Line 11 Mechanical Lift 6 Secondary Filter Pump Figure 1 6 Fuel System Diagram 1 7 19 BATTERY CHARGING ALTERNATOR SYSTEM Table 1 3 Alternator and M anuals Prestolite Prestolite Amps Alternator No Manual No 8MR2050F 25 51 amp 25 51A 37 8EM2012NA 25 197 65 It is recommended that the applicable manual see Table 1 3 be obtained from Prestolite Electric 7585 Empire Drive P O Box 6210 Fl
40. etermination 4 4 4 In U nit Alternator Regulator Tests 4 4 5 Alternator Brush Test Procedure 37 AMP 4 4 6 Alternator Brush Test Procedure 65AMP 4 4 7 Slip Ring Serviclng etu ue ee s 4 4 8 Alternator Installation Servicing and Adjusting V belt e 4 5 1 Water Pump V B elE ev laya d te e RES Le Wahl 4 5 2 Alternator V Belt u L ald aae een RU eR NICE asss Servicing the Generator M ain Alternator 4 6 1 Preventive M aintenance and Operating Precautions 4 6 2 Installation and Replacing Shockmounts PSU ended 4 7 1 Replacement 4 7 2 Shockmount Replacement Maintenance of Painted Surfaces Replacing Index Pin or Adjusting Clamping Device ELECTRICAL WIRING SCHEMATIC amp DIAGRAM EERO GU CE ON rice mechan et Fal antowan a TABLE OF CONTENTS CONTINUED 4 1 Figure 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 2 1 2 2 2 3 2 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14
41. extreme temperature and moisture changes This can cause excessive con densation and the generator windings should be thor oughly dried out before bringingthe generator up to full nameplate voltage If this precaution isnot taken serious damage to the generator can result The following steps should be taken to effectively dry the generator windings 1 a Place generator in drying oven or hot room b Dry with warm air blower directed through windings 2 8 the generator has been operated and then put into storage for any period of time a PD George 11127 type air dry fungus resistant varnish should be applied Experience hasshown that it isnecessary to take these precautions in locations such as seaboard installations and other highly humid areas Some installations will be in atmospheres that are much more corrosive than others A little precautions along the lines outlined here could eliminate an unnecessary repair job Each generator was subjected to a standard NEMA insulation test which means 1000 volts plus twice the highest voltage for which the generator is rated was impressed between the winding and frame machines are insulated with a high safety factor for the class of insulation used The latest and newest in insulation and baking techniques are used The finest insulation job can be very quickly broken down by carelessly applying high voltage to windings in a moisture saturated condition M ishandling
42. gram 65Amp 1 9 110 MAIN ALTERNATOR A C GENERATOR Figure 1 12 Main Alternator A C Generator 1 10 1 Principle of O peration The MAC Lima brushless A C generator is a self regulated rotating field synchronous unit with the rotor having a salient pole construction with amortisseur windings The generator stator and exciter stator are combined in a common housing The generator field exciter rotor and rotating rectifier assembly are mounted on a common shaft The output of the exciter rotor is applied to the generator field windingthrough a rotating full wave bridge silicone rectifier unit The exciter pole pieces contain residual magnetism setting up lines of force across the air gap to the exciter armature W hen the exciter armature begins to rotate a voltage is induced and current flow is initiated in the exciter armature AC windings This voltage is fed to the rotating rectifier assembly rectified and fed to the alternator field coils This DC voltage is sufficient to magnetize the laminated alternator field which will set up lines of force acrossthe air gap to the alternator stator A s the generator rotor rotates a voltage will be induced and current will flow in the alternator stator windings and to the output circuit All connections between the exciter stator windings and the generator stator windings are internally con nected within the stator housing Only the output power leads of the generator unit are broug
43. he alternator eliminates the need for a cutout relay in the voltage regulator T he individual rectifier diodes three positive and three negative are assembled in two temperature dissipating heat sinks T he heat sinks placed in the alternator with threaded studs also serve as circuit terminals See Figure 1 8 M aximum charging current is limited by the design and connections in the stator assembly eliminating the need for a current regulating relay in the voltage regulator 1 9 3 Voltage Regulator O peration 12 volts d c 37 Amp The regulator is an all electronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures The regulator is an electronic switching device See Figure 1 9 It senses the voltage appearing at the auxiliary terminal of the alternator and supplies the necessary field current for maintaining the system voltage at the output terminal The output current is determined by the load 1 Regulator terminal Negative diode 2 Trio diode assembly assembly 3 Positive output 7 Delta stator 4 Positive diode 8 Field assembly rotor winding 5 Rectifier diode 9 Rotor connecting lead 10 Negativ
44. he alternator pivot bolt and capscrew on adjustment arm 2 Replace belt U se hand force only on alternator to tighten belt D o not use pry bar or excessive force as it may cause bearing failure the alternator When belt is tight tighten the alternator bolts 3 Check belt tension correct specifications are 40 45 Ibs on the Burroughs gauge Carrier Transicold P N 07 00203 4 6 SERVICING THE GENERATOR MAIN ALTERNATOR 4 6 1 Preventive M aintenance and Operating Precautions Costly repairs and down time can usually be pre vented by operating electrical equipment under condi tions which are compatible with those at which the equipment was designed to operate Follow the instruc tions outlined below to ensure maximum efficiency of the electrical equipment a Cooling Keep all cooling parts clean and make certain sufficient room isleft on all sides for a plentiful supply of fresh coolant air flow DO NOT EXCEED TEMPERA TURE RISE AS SHOWN FOR 80 C 176 ABOVE 40 104 AMBIENT Thisensuresthat theinsulation NEMA Class F will not be damaged DO NOT EXCEED RATED LOAD except as specified for the equipment OPERATE GENERATOR AT RATED SPEED Failure to operate generators at rated load or speed will cause overheating and possible damage to windings due to over voltage or current b Bearing Replacement Factory lubricated shielded bearings will normally provide several years of trouble free service when ope
45. ht out to the generator terminal box 1 10 2 A C Generator Main Alternator Circuit Diagram Figure 1 13 shows the internal schematic diagram of the generator exciter and rectifier unit The generator is athree phase unit and the exciter stator and exciter rotor also have three phase windings A portion of the exciter stator windingsisconnected acrossatap on the generator stator winding This exciter shunt winding provides the generator field excitation power required for the genera tor no load voltage A nother portion of the exciter stator windings is connected in series with the output of the generator and provides a compounding excitation char acteristic The rotor is in effect the secondary of a rotating current transformer induction frequency converter The exciter rotor output voltage is applied to the generator field windings by a three phase full wave rotating silicone rectifier unit The responsetime of the excitation system is very fast since the exciter stator carries an alternating current corresponding to the load current which appears immediately on the exciter primary An increase in load current will cause an immediate increase in the exciter secondary output voltage which is rectified and applied to the generator field windings The inherent compounding characteristics of the excitation system provide excellent voltage regulation even under heavy overload conditions 1 10 RECTIFIER ASSEMBLY l EXCITER I Fig
46. in thisrespect can easily cause a breakdown making it necessary to return the generator to the factory for repair and consequent expense and loss of time WARNING High voltage dielectric testing must not be performed to the machine without first observing NEMA rules The insulation of this generator winding may be safely checked by using a megger A high megger reading indicates low insulation leakage g Restoring Residual M agnetism The direct current DC necessary to magnetize the alternator field is obtained from the exciter Initially upon starting the generator current flow and voltage are induced into the exciter armature by the magnetic lines of force set up by the residual magnetism of the exciter field poles Residual magnetism of the exciter field poles may be lost or weakened by a strong neutralizing magnetic field from any source or if the generator is not operated for a long period of time WARNING When trying to restore residual magnetism be sure to wear leather gloves and use a fused insulated 12 gauge or larger jumper wire Cut off all but a few strands from both ends of the jumper wire Should the generator fail to build up voltage after being disassembled for any reason a momentary short circuit of any two generator leads L1 L2 and L3 while generator is running should be sufficient to correct this condition If not an alternate method may be used A pply either an alternating current or a dir
47. k pockets on generator set and fork truck 2 Remove mounting bolt C on each side of generator set 3 Raise generator set several inches to disengage pins B from mating holes and remove from container 2 1 2 Pin Mounting 69GC 15 194 Figure 2 2 Pin Mounting 69G C 15 194 WARNING To preventinjury the procedures for installation and removal of the generator set given below must be followed NOTE This generator set is equipped with special pins and mounting bolts and can be installed only on containers with matching installation points a Installation 12 Place forks into fork pockets of generator set Attach safety chain A between fork pockets on genera tor set and fork truck Be sure chain A is short enough to retain generator set on forks 13 Line up generator set with refrigeration unit and container Raise generator set until top of set is several inches above top edge of container Move generator set against container and lower into position Important Two pins B must be fully engaged in mating holes in container 2 2 14 Keep forks in pockets on generator set and tighten mounting bolt C on each side of generator set into container frame Important Bolts must be tight and retaining plate D must be locked into position 15 Removesafetychain A before removingforks b Removal WARNING Disconnect power plug before removing generator set 1 Move forks into f
48. k radiator hoses for leaks and check radiator coolant level Add pre mixed 50 50 antifreeze water as required Refer to section 1 3 5 Check radiator coil and generator air intake screen for cleanliness Clean using compressed air reversing the normal air flow 6 Check air cleaner for cleanliness and clean if necessary Refer to section 4 3 5 7 Drain water from fuel tank sump 8 Fill fuel tank with diesel fuel Refer to section 1 3 9 Check battery terminals for cleanliness and securement Clean and coat with a mineral type grease 10 Check for loose electrical connections 1l GreaseFuel Solenoid plunger U se P N 07 00245 00 12 Check glow plug amperage Refer to section 1 3 13 Connectpower cableto refrigeration unit Start genset as detailed in section 2 3 and then turn refrigera tion unit on to check operation Refer to section b b After Starting Generator Set 1 Refer to section 2 3 for starting and stopping instructions 2 Check voltmeter Should be 460 voltsa c 5 no load Volt meter indicating needle should be pointing to high side of green band 1820 to 1840 rpm no load 1710 rpm with load 3 Check total time meter operation Run engine 10 minutes 2 5 4 Listen for abnormal bearing noise 12 vdc alternator and main alternator 5 Check fuel lines lube oil lines and filters for leaks 6 Check radiator and hoses for leaks 7 Check exhaust system for lea
49. ks 8 Check operation of indicator light Refer to section 1 7 2 23 STARTING AND STOPPING INSTRUCTIONS a Starting Instructions WARNING Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the glow plugs NOTE When starting the engine it is necessary to continue to hold the glow plug switch in the UP position until the engine develops sufficient oil pressure to close the oil pressure safety switch energizing and completing all circuits for unit operation 1 Hold glow plug switch in the UP position for 30 seconds See Figure 1 2 or Figure 1 3 NOTE Below 0 F hold glow plug switch for two minutes release switch for 30 seconds and again hold glow plug switch for two minutes If engine does not start after 10 seconds cranking wait for 30 seconds before repeating starting procedure 2 With glow plug switch held in the UP position push the ignition switch to the START position 3 After engine has started continue to hold the glow plug switch in the UP position until the oil pressure safety switch closes when engine develops sufficient oil pressure The glow plug switch will automatically be in the OFF position when released b Stopping Instructions 1 Push ignition switch to the OFF position 24 CONTROL CIRCUIT OPERATION WARNING Beware of moving V Belts and belt driven components CAUTION Thegenerator set circuit breaker must be in the ON p
50. l recommended processes R efer to section 4 3 5 17 OPERATING CONTROLS AND INSTRUMENTS 1 7 1 Introduction Components required for monitoring and controlling the unit are located in the control box and control panel See Figure 1 2 or Figure 1 3 The water temperature safety switch HWT is located near the thermostat housing 1 7 2 Control Panel and Related Components See Figure 1 2 or Figure 1 3 a A C Voltmeter The a c voltmeter is a sealed and ruggedized device indicating the line to line voltage output from the main alternator on a scale of Oto 600 volts When the unit has an output of 460 vac the indicating needle will be in the green band Refer to section 4 3 4 b Total Time M eter This meter designatesthe total hoursand providesan accurate readout of accumulated engine running time This data can be used to establish the proper periodic maintenance schedule Refer to section 4 1 c Frequency Meter and Interference Filter Optional The meter and filter are used to monitor the hertz of the A C generator output This meter will read 60 hz when the correct engine speed is obtained Refer to section 4 3 4 d Ammeter The ammeter indicates the rate of discharge or charge of the battery charging system composed of the battery battery charging alternator and the voltage regulator e Gauges and Senders 1 Oil Pressure G auge The purpose of this gauge is to observe normal operating engine oil pres
51. l solenoid defective Ignition switch defective Restriction in air cleaner Air in fuel system Air vent in fuel cap restricted Restricted fuel lines D efective fuel injection pump D efective injector s or incorrect type Incorrect fuel injection pump timing Incorrect valve timing Poor compression 32 REFERENCE SECTION Charge Check Replace Engine M anual Engine M anual Engine M anual Replace 1 3 Engine M anual Replace Engine M anual Engine M anual Correct Tighten Correct Tighten 14 Replace 4 3 3 4 3 3 Replace 4 3 5 4 2 Clean Engine M anual Engine M anual Engine M anual Engine M anual Engine M anual Engine M anual INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 L5 Miscellaneous E ngine Troubleshooting continued b Vibration Engine shockmounts defective Replace Poor compression Fuel solenoid or linkage Engine M anual 4 3 3 C Overheating Restriction in air cleaner 4 3 5 Exhaust pipe restriction Remove Restriction in water jacket Check Loose water pump V Belt 4 5 Restriction in radiator 4 3 1 Coolant level too low 1 3 d Excessive crankcase D efective thermostat D efective water pump Engine M anual Engine M anual pressure Plugged crankcase breather line 4 3 6 3 2 ALTERNATOR AUTOMOTIVE TYPE Battery U ndercharged D efective cables dirty battery posts or corroded terminals 4 4 1 Loose or broken belt 4 5 Worn or broken brushes 4 4 5 or 4 4 6 D efective al
52. lement the specific warnings and cautions appearing elsewhere in this manual T hey are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein WARNING Electrical power is generated bya Lima 15 KW A C generator The generator provides a constant 460 or 230 vac 3 phase 60 hertz electrical supply WARNING Beware of moving V Belts and belt driven components WARNING Before servicing unit make sure the unit circuit breaker CB1 and the start stop switch are in the OFF position Also disconnect power plug and cable Make sure the power plug s are clean and dry before connecting to any power receptacle WARNING High voltage dielectric testing must not be performed to the machine withoutfirst observing NE M A rules The insulation of this generator winding may be safely checked by using a megger A high megger reading indicates low insulation leakage CAUTION Thegenerator set circuit breaker must bein theON position in order to supply power tothe refrigeration unit CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator 5 1 T3 4 460 VOLTS 3 PHASE 32 60 HERTZ R1 GR
53. lt GPS CBC IGN GEN TSS 1 SE 1 thru 10 are wires from A C generator Figure 5 4 Electrical Wiring Diagram M odel 69G C 15 184 184 2 Drawing Number 69G C 15 1984 Revision Sheet 2 of 2 5 9 LINE ROU 3 8 11 16 9 10 15 1 2 TIONAL 1 78 7 SYMBOL gt I T3 pe 1 60 HERTZ RI GRD 2 CBI LINE N1 LOAD A 3 2 GENERATOR Ny 3 4 4 L12V DC SS Eu D GRD GPS AVV WD P ANV k EE AUTO To 6 uU 45A 4 D3 RCR HWT I 2 wa Pl 10 ICN mum T 89 OFF or T RUN TB22 TB23 FS 11 AUTO ela V 20A 4 Sylloge 0 5 12 b I OP Fe 2 14 START a 13 WT vis I S 14 C m B CBI N Z K T SS 1N 7 DESCRIPTION LINE SYMBOL MECHANICAL LINKAGE 9 HWT ENGINE GROUND 10111213 IGN CHASSIS GROUND 10 LOP AMMETER 16 L1 ALTERNATOR 12 OPG BATTERY 12 OPS CIRCUIT BREAKER 911 RCR DIODE 5 SM FILTER OPTIONAL 5 17 SS FREQUENCY METER OP 1 TB2 14 TT FUEL SOLENOID 1 V GLOW PLUG 13 WTG GLOW PLUG SWITCH 13 WTS Drawing Number 69G C 15 2044 Revision A Sheet 1 of 2 5 10 DESCRIPTION WATER TEMP SWITCH IGNITION SWITCH LOW OIL PRESSURE LIGHT OIL PRESSURE GAUGE OIL PRESSURE SENDER RUN CONTROL RELAY STARTER MOTO
54. ltage by the rotation of an electromagneticfield rotor inside athree phase stator assembly The alternating current and voltage is changed to direct current and voltage by passing A C energy through a three phase full wave rectifier system system Six silicon rectifier diodes are used See Figure 1 11 1 9 6 Integral Voltage Regulator O peration 12 volts d c 65 Amp The regulator is an all electronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures The regulator is an electronic switching device See Figure 1 10 It senses the voltage appearing at the auxiliary terminal of the alternator and supplies the necessary field current for maintaining the system voltage at the output terminal The output current is determined by the load 1 AC Tap 5 Excite 2 Back Cover 6 Ground 3 Positive Output B 7 12vdc Test Lamp 4 Integral Regulator Terminal D Figure 1 10 Alternator and Regulator 65 Amp 1 12vdc Test Lamp 5 Ground Terminal D 6 AC Tap 2 Diode Trio 7 Rotor Field 3 Positive Out 8 Stator put B 9 Integral Regulator 4 Rectifier 10 Excite Figure 1 11 Alternator Schematic Dia
55. metal can corrode In order to protect the unit from the highly corrosive sea atmosphere or if the protective paint system is scratched or damaged 1 Cleanareato bare metal usinga wire brush emery paper or equivalent cleaning method 2 Immediately following cleaning spray or brush on a zinc rich primer 3 Aftertheprimer hasdried spray or brush on finish coat of paint to match original unit color 49 REPLACING INDEX PIN OR ADJUSTING CLAMPING DEVICE 65 inch 16 51 mm 6 5 7 1 Handle 5 Chamfer 2 Cylinder 6 L Hook Shaft 3 Index Pin 7 Insert Drift Pin Here 4 Crown 8 Spring Clip Figure 4 17 Clamping Device and Index Pin a Replacing Index Pin See Figure 4 17 If necessary to replacea damaged pin in the L shaft do the following 1 Simultaneously release spring clip and lift handle to open the clamping device L shaft 2 Withawrench placed on the L portion of thebar rotate the L hook 90 in either direction 3 With a drift pin or punch 3 8 2 9 5 mm diameter or smaller drive remaining portion of pin outof the bar 4 Rotate L hook 90 to original position 5 Drive new pin in place with crown end up 6 If necessary to replace spring clip remove two Socket head screws and install new spring clip b Adjusting Clamping Device See Figure 4 18 The clamping device L hook shaft see Figure 4 18 must be 65 inch 21 32 16 51 mm between the head of clamping devi
56. nkcase breather Clean and flush cooling system Check starter condition Check engine compression Check and adjust injector nozzles Replace V Belt 4 1 Reference Section 2 2 2 2 Run 10 minutes 2 2 4 3 2 2 2 Run 10 minutes 4 1 b 4 7 Tighten 4 3 5 None 4 4 4 4 3 8 4 1 b amp 4 1 c 4 3 6 4 3 1 Engine M anual Engine M anual Engine M anual 4 5 4 2 PRIMING THE FUEL SYSTEM Theunitisequipped with a mechanical fuel lift pump it is mounted on the engine next to the injection pump Also refer to section 4 3 8 This pump has a manual plunger for bleeding fuel when the fuel tank has been run dry Since the unit employs a closed fuel circuit it is recommended to use the following steps 1 Turn bleed valve Red counter clockwise until fully opened see Figure 1 1 or Figure 1 6 2 Turnthetop of the manual plunger counter clock wise to unlock it See Figure 1 1 Then rapidly hand pump the manual plunger until a positive pressure resistance is felt which will indicate fuel flow 3 Depress and turn the top of the manual plunger clockwise to lock in place 4 Start engine Refer to section 2 3 5 When engineisrunning properly turn bleed valve clockwise until fully closed 4 3 ENGINE SERVICE AND COMPONENTS 4 3 1 Cooling System The radiator externally and internally must be clean for adequate cooling The fan belt must be adjusted periodically to provide maximum air flow Refer
57. old engine 4 3 2 Lube Oil Filters The full flow filter is located near the run solenoid as shown in Figure 1 1 After warming up the engine stop engine remove drain plug from oil reservoir and drain engine lube oil Lightly oil gasket on filter before installing Replace filters and add lube oil Refer to section 1 3 Warm up engine and check for leaks 4 3 3 Servicing the Fuel Solenoid and Linkage O ENERGIZED DE ENERGIZED 2 47 6 27cm 3 22 8 18cm 1 Solenoid 4 Clip 2 Solenoid Bracket 5 Linkage Rod 3 Spring 6 Boot Figure 4 1 Fuel Solenoid Assembly NOTE Periodically grease P N 07 00245 00 Fuel Solenoid plunger a Remove spring linkage from injection pump run lever item 3 Figure 4 1 b Disconnect wiring to solenoid Remove clip item 4 from linkage rod item 5 Remove mountinghardware from solenoid and then remove solenoid c Install new solenoid and mounting hardware connect wiring Place ignition Start Run Off switch in the START position to energize solenoid Check ener gized dimension asshown Figure 4 1 Turn switch OFF Check de energized dimension If energized dimension needs adjusting loosen solenoid mounting bolts and move solenoid 4 2 d Energize solenoid and check clearance e If the engine does not shut off when the fuel solenoid is de energized loosen
58. orence Kentucky 41042 U S A for complete overhaul and service information of the alternator and regulator if required 1 9 1 Introduction 37 Amp The mechanical construction of the alternator differs from the D C generator in that the field rotates and the armature generating windings are stationary The field current necessary to control the output of the alternator is supplied from the regulator T he regulator controlsthe current feed to the field via the brushes and rotor slip rings Two completely sealed ball bearings support the rotor in the front and rear housing CAUTION Observeproper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator 1 9 2 Alternator Operation 37 Amp The alternator converts mechanical and magnetic energy to A C Alternating Current and voltage by the rotation of an electromagnetic field rotor inside a three phase stator assembly The alternating current and voltage is changed to direct current and voltage by passing A C energy through a three phase full wave rectifier system G enerally six silicon rectifier diodes are used See Figure 1 7 Since diodes pass direct current in only one direction their arrangement in t
59. ork pockets on generator set Attach safety chain A between fork pockets on genera tor set and fork truck 2 Release retaining plate D from locking brack et on each side of generator set 3 Remove mounting bolt C on each side of generator set 4 Raisegenerator set several inches to disengage pins B from mating holes and remove from container 2 1 3 Clamp Mounting 69G C 15 104 134 174 Figure 2 3 Clamp on M ounting 69GC 15 104 134 174 WARNING To preventinjury the procedures for installation and removal of the generator set given below must be followed NOTE This generator set is equipped with clamps and mounting bolts and can be installed only on containers with matching installation points for the mounting bolts a Installation l Place forks into fork pockets of generator set Attach safety chain A between fork pockets on generator set and fork truck Be sure chain A is short enough to retain generator set on forks Adjust each generator set clamp B with handle D forward and indexing pin C in vertical position 2 Move generator set against container and fully engage clamps into mating holes in container corner castings allowing clamp boss to settle on bottom of corner casting Rotate indexing pin C to horizontal position and lock handle D on both clamps Important Clamping devicehandle D must be drawn back and handle pin snapped into position and safety pins installed 2 3
60. osition in order to supply power to the refrigeration unit When the glow plug switch is held in the pre heat position current flows to the glow plugs The glow plugs starting aids provide a source of heat to pre heat the combustion chamber during start up Power also flowsto therun control relay which energizes and closestheRCR contacts From the relay RCR power flows through the high water temperature switch to ground In order to start engine hold the glow plug switch in the U P position for the recommended time as detailed in section 2 3 and then hold the ignition Start R un O ff switch in the START position With ignition switch in the 2 6 START position starter solenoid is energized closing starter motor contactor contacts SS which energizes starter motor The starter motor turns over the engine resulting in pumping fuel to the engine cylinders by the injection pump This fuel is ignited by heat of compres sion thus starting the engine Also run control relay is energized at the same time to close a set of contacts and completes a circuit to the fuel solenoid When the engine has developed sufficient oil pres sure oil pressure safety switch contacts close to maintain a circuit to the run control relay Energizing this relay closes contactsprovidinga circuit to keep the fuel run solenoid energized as long as the safety switch contacts remain closed The glow plug switch is then released and the ignition swit
61. own hardware 4 7 1 Replacement Criteria When the neoprene shockmount has been cut split abraded or hasflared due to wear from bolts and normal deterioration 4 10 4 7 2 Shockmount Replacement a Engine 1 Remove the two 1 2 13 x 3 inch long capscrews Loctite has been applied to these bolts Place sling or other device under engine near oil reservoir and slowly raise the engine enough to remove the engine mounting shockmounts The fan may have to be rotated to prevent striking the fan shroud 2 Install shockmounts and flat washers as shown in Figure 4 16 3 Apply Loctite EV purple in color to threads of bolts 4 Lower engine secure and torque shockmount bolts to a torque value of 45 2ft Ib 6 2 0 2 mko b Generator 1 Removethetwo 1 2 13 x 3 1 2 inch long capscrews Loctite hasbeen applied to these bolts U singliftingeye in generator slowly raise enough to replace shock mounts 2 Install shockmounts and flat washers as shown in Figure 4 16 3 Apply Loctite EV purple in color to threads of bolts 4 Lower generator secure and torque shockmount bolts to a torque value of 45 2 ft lb 6 2 0 2 FLAT WASHER 5 Figure 4 16 Shockmount Installation FRAME 48 MAINTENANCE OF PAINTED SURFACES Theunitisprotected by a special paint system against the corrosive atmosphere in which it normally operates However should the paint system be damaged the base
62. ped after proper hook up is made and test leads connected No electrical loads a With jumper not attached Check for battery voltage at terminal A and for 1 5 to 3 0 voltsat terminal B see Figure 4 8 b Add jumper JU 1 between terminals A and B Start engine and run with no load If thetest lamp now goesoff and charging voltage is present at terminal A morethan battery voltage the diode trio is open Alternator should be removed for repair If the voltmeter indication isnotinthisrange remove thejumper and proceed to the regulator test Test No 2 TOGGLE 12vdc SWITCH TEST LAMP 4 BATTERY D LX CI POS GROUND OUTPUT INTEGRAL B REGULATOR EXCITE SENSE TO TO OIL PRESSURE BATTERY SWITCH OR TOGGLE SWITCH STEP TEST POINT INDICATION N BATTERY ES A B VOLTAGE 1 5 TO 3 0 VOLTS WITH TEST LAMP ON 13 5 TO 15 0 VOLTS JUMPER ATTACHED ENGINE RUNNING JUMPER NOT ATTACHED REMOTE BATTERY SENSE ONLY Figure 4 8 Open Diode Trio Test 65 Amp Test No 2 Open Regulator Test 65 AMP CONDITIONS Engine stopped start run stop switch in the RUN position and voltmeter set up as shown in Figure 4 9 NOTE Before performingtest removal of back cover is required To remove disconnect wires from terminals extending through back cover Remove back cover two screws and reconnect all wires a With jumper not attached check for bat
63. rated under normal conditions Excessive bearing load and adverse environment conditions will greatly shorten bearing life Should bearing failure occur bearings can be replaced ALWAYS REPLACE WITH THE SAME TYPE BEARING ASINSTALLED AT THE FACTORY CHECK PARTSLIST FOR PART NUMBER Include generator serial number when ordering bearings Do the following to remove bearing 1 Remove bearing cap See Figure 4 13 2 Remove bearing with the use of a bearing or wheel puller 3 Install new bearing Ball bearingson Lima genera torsare pre lubricated and require no further lubrication for the life of the bearing 4 Replace end cap 1 Bolt 2 Bearing Cap 3 Bearing 4 Rotating Diode Bridge Figure 4 13 Rectifier Removal c Rotating Diode Bridge Rectifier Assembly Replacement The rotating diode bridge can be removed and replaced Over current over voltage over speed or reverse currents can cause damage to the assembly or any of the component parts The rotating diode bridge may be removed through the bearing cap on the rear of the generator See Figure 4 13 and Figure 4 14 1 Remove the bearing cap by removing the four bolts shown in Figure 4 13 and both the bearing and rectifier assembly will be visible 2 Usea bearing puller to remove the bearing from main shaft being careful to locate the puller on the inner race of the bearing to avoid bearing damage Once the 4 8 bearing is free it is then necessary to
64. right the cause is probably an open field circuit and alternator must be removed for repair 3 Further investigation requires alternator removal and repair diodes b Battery Overcharged 1 Perform alternator output test Refer to section 4 4 4 2 Regulator shorted R eplace regulator 4 4 4 In Unit Alternator R egulator Tests Test No 1 Open Diode Trio Test 37 AMP CONDITIONS Engine running after proper hook up is made and test leads connected with no electrical loads a Remove regulator from alternator housing refer to section 4 4 8 leaving leads connected Add jumper JUI between the output and regulator terminals and connect voltmeter as shown in Figure 4 6 4 4 b Start engine If voltmeter now indicates 13 75 to 14 75 volts the Diode Trio isopen and must bereplaced If the voltmeter indication isnotinthisrange removethe jumper JUI and proceed to the regulator test Test No 2 TOGGLE 12vdc SWITCH TEST LAMP BATTERY DG EXCITATION NEGATIVE HOUSING GROUND OUTPUT GREATER THAN 15V Figure 4 6 Open Diode Trio Test 37 Amp Test No 2 Open Regulator Test 37 AM P NOTE Before performing test connect an insulated jumper between regulator and field terminal Loosely mount regulator to alternator with the two screws for test CONDITIONS Engine running after proper hook up is made and test leads connected with alternator regulator and voltmeter setup as
65. rs T he glow plugs are located under the fuel injectors W hen starting engine it is necessary to continue to hold the glow plug switch in the U P position until the engine has developed sufficient oil pressure to close the oil pressure safety switch 2 Ignition Switch The ignition switch momentary contact type in the start position when held in the START ignition position energizes the starter motor solenoid which in turn allows the starter motor to crank 1 7 3 Protective Devices a Oil Pressure Switch This switch set to open below 15 psig 1 05 kg cm will automatically stop the engine upon loss of oil pressure T his switch is located on the right side of the engine See Figure 1 1 When the switch opens the run control relay RCR coil is de energized and the RCR contacts open to de energize the fuel solenoid FS thus stopping the engine b High Water Temperature Switch This switch set to open at 230 5 F 110 3 C will automatically stop the engine upon high water temperature The switch is located near the thermostat housing When the switch opens the run control relay RCR coil isde energized and theR CR contacts open to de energize the fuel solenoid FS thus stopping the engine c A C Generator Circuit Breaker CB 1 This device trips at 25 amps to protect the A C generator main alternator from excessive current amperage draw When the circuit breaker trips the generator power output to the r
66. sheave must be in line e Pivot alternator to place tension on belt For correct belt tension refer to section 4 5 2 Tighten pivot and adjustment bolts f Connect wiring to alternator g Connect battery cable Start unit and check for output per section 4 4 3 4 5 SERVICING AND ADJUSTING V BELT WARNING Beware of moving V Belts and belt driven components NOTE Frayed cracked or worn V Belts must be replaced After installing a new belt it is advisable to check the adjustment after running the unit for three or four hours This is to allow for the initial stretch which is common on new belts O ncethisinitial stretch hastaken placethe belt may be checked at regular intervals 4 5 1 Water Pump V Belt The water pump V Belt is driven by a sheave on the engine crankshaft Adjustment is achieved by altering position of the idler pulley a Replacing the V Belt 1 Loosen the idler bracket pivot bolt 2 Replace belt Use hand force only on idler pulley to tighten belt Do not use pry bar or excessive force as it may cause water pump bearings to fail When belt is tight tighten idler bracket pivot bolt 3 Check belt tension correct specifications are 40 45 Ibs on the Burroughs gauge Carrier Transicold P N 07 00203 4 5 2 Alternator V Belt The alternator V Belt is driven by a sheave on the generator drive shaft A djustment is achieved by pivoting the position of the alternator a Replacing the V Belt 1 Loosen t
67. sure N ormal oil pressureis 40 to 60 psig 2 8 to 4 2 kg cm 2 Oil Pressure Sender This sensing device senses engine lube oil pressure and transmits a signal to the oil pressure gauge The oil pressure sensor is located in the oil line near the oil pressure switch 3 Water Temperature G auge The function of this gauge is to observe water operating temperature 180 to 205 F 82to 94 C The gauge is connected to a water temperature sensing device 4 Water Temperature Sender This sensing device senses engine water temperature and transmits a signal to the water temperature gauge 1 6 The water temperature sender is located on the top front right side of the engine below the HWT switch f Indicator Light l Circuit Breaker Trip Light This light red may be checked unit not running by placing the circuit breaker CB 1 in the off position and at the same time moving the ignition switch to the run position When the circuit breaker isin the off position set of contacts close to complete a circuit to the light If the unit is running and the circuit breaker trips the light will illuminate to signal the operator of a malfunc tion with the generator g Switches 1 Glow Plug Switch The glow plug switch momentary contact type when held in the UP position pre heat permits battery current approximately 7 5 amps per plug at 12 vdc to flow to the glow plugs in the engine to pre heat the combustion chambe
68. ternator system 4 4 4 D efective wire harness Replace Broken brush 4 4 5 or 4 4 6 D efective alternator Replace Battery O vercharged D efective alternator system Check excessive use of water Voltmeter indicates greater than 14 5 volts connected across battery with no load with engine idling Battery charges at idle but Slipping belt 4 5 discharges under load conditions Alternator defective Prestolite M anual 3 3 3 3 A C BRUSHLESS GENERATOR MAIN ALTERNATOR INDICATION TROUBLE No voltage Low voltage Fluctuating voltage M ay be indicated by flickering lights High voltage Overheating M echanical Noise Generator frame produces shock when touched POSSIBLE CAUSES L oss of residual magnetism in exciter field Circuit breaker tripped Open in stator windings Open or short in rotating rectifiers Short circuited Open in alternator field Shorted exciter armature Low engine speed Excessive load High resistance connections connections warm or hot Shorted field Fluctuating speed Irregular speed of engine Loose terminal or load connections D efective bearing causing uneven air gap Excessive engine speed Generator overloaded Clogged ventilating screens High temperature surrounding generator Insufficient circulation U nbalanced load Dry bearing D efective bearing Rotor scrubbing on stator Loose laminations Loose or misaligned coupling Static charge Grounded armature of field
69. tery voltage at terminals A and B Test lamp will be off b Add jumper JU 1 between field and ground see Figure 4 9 If 1 5 to 3 0 volts is present at terminal B and the test lamp is on the regulator is open Alternator should be removed for repair TOGGLE 12vdc AC TAP SWITCH TEST LAMP TACH 4 BATTERY POS OUTPUT T GROUND FIELD INTEGRAL M REGULATOR jul EXCITE TO OIL PRESSURE SENSE TO SWITCH OR BATTERY TOGGLE SWITCH STEP TEST POINT INDICATION BATTERY B VOLTAGE BATTERY VOLTAGE 2 WITH TEST LAMP OFF JUMPER ATTACHED B D 1 5 TO 3 0 VOLTS TESTLAMP ON JUMPER NOT ATTACHED REMOTE BATTERY SENSE ONLY Figure 4 9 Open Regulator Test 65 Amp Test No 3 Alternator Output Test 65 AM P CONDITIONS Engine running after voltmeter is connected as shown in Figure 4 10 TOGGLE 12vdc SWITCH TEST LAMP forem d TACH BATTERY POS xi OUTPUT B GROUND SENSE TO INTEGRAL BATTERY REGULATOR EXCITE TO OIL PRESSURE SWITCH OR TOGGLE SWITCH 4 BATTERY POS OUTPUT 13 8 TO 14 8V REMOTE BATTERY SENSE ONLY Figure 4 10 Alternator Output Test 65 Amp 4 6 a Start unit and run engine with load With the unit operating placing a load on charging circuit check for nominal system output voltage of between 13 8 14 8 volts for a properly operating charging system Voltages may vary a few tenths of
70. to section 4 5 Do thefollowing to service the cooling system a Remove all foreign material from the radiator coil by reversing the normal air flow Force air in through the front of the radiator and discharge through the radiator toward the engine Compressed air or water may be used asa cleaning agent t may be necessary to use warm water mixed with any good commercial dishwasher detergent R inse coil s with fresh water if a detergent is used b Drain coolant completely by opening drain cock and removing radiator cap CAUTION Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to radiator engine Never exceed more than a 50 concentration of anti freeze Use a low silicate anti freeze meeting GM specifications GM 6038M or equal C Close drain cock and fill system with clean untreated water to which three to five percent of an alkaline based radiator cleaner should be added six ounces dry 151 grams to one gallon 3 8 litre of water d Run engine 6 to 12 hours and drain system while warm R inse system three times after it has cooled down Refill system with water e Run engine to operating temperature Drain system again and fill with treated water anti freeze See Caution note and refer to section 1 3 c NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a c
71. uel Solenoid 13 Mechanical Lift Pump 14 Figure 1 1 Generator Set Front View Typical Fuel Bleed Valve Radiator Cap Radiator Overflow Tank Fuel Fill Fuel Gauge Oil Pressure Safety Switch Lube Oil Dipstick 1 2 15 16 17 18 Ime acus Starter Motor A C Generator Battery Power Receptacle Located behind Control Box Clamping Device Optional 1 59 LM Ley o 14 1 Oil Pressure Gauge 2 Voltmeter Gauge 15 3 Amm 4 Circuit Breaker Ammeter Gauge Trip Indicator Ignition Switch Glow Plug Switch Circuit Breaker CB 1 Frequency Meter Optional Water Temperature Gauge Total Time Meter Circuit Breaker CB 2 Filter Reactor Optional Circuit Breaker CB 3 Run Control Relay RCR Junction Block TB2 Terminal Block TB1 Figure 1 2 Control Box and Gauge Panel M odels 69G C 15 104 amp 114 e NR
72. ure 1 13 A C Generator Circuit Diagram SECTION 2 OPERATION 2 1 GENERATOR SET INSTALLATION AND REM OVAL 2 1 1 Pin Mounting 69GC 15 114 114 1 144 154 Figure 2 1 Pin Mounting 69G C 15 114 114 1 144 154 WARNING To preventinjury the procedures for installation and removal of the generator set given below must be followed NOTE This generator set is equipped with special pins and mounting bolts and can be installed only on containers with matching installation points a Installation 1 Place forks into fork pickets of generator set Attach safety chain A between fork pockets on generator set and fork truck Be sure chain A is short enough to retain generator set on forks 2 Line up generator set with refrigeration unit and container Raise generator set until top of set is several inches above top edge of container Move generator set against container and lower into position Important Two pins B must be fully engaged in mating holes in container 2 1 3 Keep forks in pockets on generator set and tighten mounting bolt C on each side of generator set into container frame Important Bolts must be tight and retaining pin D must be snapped into position 4 Remove safety chain A before removing forks b Removal WARNING Disconnect power generator set plug before removing 1 Move forks into fork pockets on generator set Attach safety chain A between for
73. ust have a low electrical resistance and are subjected to extreme centrifugal forces must be mechanically secure and permanent Consequently they are welded to end plates completely covering the field All rotors are static and dynamically balanced to a high degree on precision machines to assure minimum vibration T hey will therefore remain dynamically stable at speed well beyond the synchronous speed of the generator The rotors on generators are however subjected to extreme centrifugal forces which can in crease beyond safe operating limits at over speed Therefore the prime mover should be adequately governed to prevent over speed D amage to the rotor can also occur due to overheat ing which can be caused by the air flow being restricted from dust or other foreign objects collecting in the air passage If arotor becomes defective it should be returned to the factory with full nameplate data because the rotor coils are enclosed in welded squirrel case winding To repair a rotor the special tooling and technique of the factory is necessary and essential Should a failure occur Carrier Transicold should be notified immediately and steps will be taken to get the generator back into service with the least expense and moreimportant to determine the cause of the failure and take steps to prevent a recurrence f Generator Windings Drying Generators that have been in transit or storage for long periods may be subjected to
74. uts securing brush holder and remove brush assembly 4 7 2 Check brush assembly for cracked chipped or oil soaked brushes Remaining brush length should be at least 3 16 inch 4 76 mm long 3 Check slip rings for carbon build up 4 Using a 12 vdc test lamp or ohmmeter test brush assembly for continuity and insulation see Figure 4 12 Replace brush assembly if necessary b Brush Continuity Check 65 AM P Using a 12 vdc test lamp or ohmmeter test brush assembly for continuity and insulation as shown Remove brush assembly if necessary CONTINUITY CHECK Continuity Ato B OK Continuity C to D OK No Circuit Ato C OK No Circuit AtoD OK No Circuit B to C OK No Circuit BtoD OK Figure 4 12 Alternator Brush Assembly 65 Amp 44 7 Slip Ring Servicing Clean brush contacting surfaces with fine crocus cloth Wipe dust and residue away If surfaces are worn beyond this restoration replace entire rotor assembly 4 4 8 Alternator Installation Installation a Make sure negative battery terminal is discon nected b Install alternator to mounting bracket with the alternator pivot bolt and adjustment arm bolt loosely in position c Place V Belt on alternator sheave d Check the center alignment of the generator driving pulley and alternator pulley to ensure proper drive Pulley misalignment will create excess belt wear and limit alternator bearing life The center line of the alternator sheave and the driving

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

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

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