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Model 69UG15 - Florens Container Services

1. 4 6 4 5 2 Generator Repair Test Procedures ccc een 4 6 4 5 3 Bearing cece cc rns 4 7 4 5 4 Generator Installation and Removal ssssssssssssssssee een 4 8 4 6 GENERAL GENERATOR SET MAINTENANCE IH 4 8 4 6 1 Maintenance Of Painted Surfaces sssssssssssssssees emen 4 8 4 6 2 Checking And Replacing Shockmounts ssssssssssssseee es 4 8 4 7 SERVICING THE ALTERNATOR ssssssseeeeeeee hee 4 9 4 7 1 Preliminary Checks and Tests cece een 4 9 41 2 T St Io0ls o Lieb imo nt Lupo lee Ma Vistos iav iue nds 4 10 4 7 3 Problem Area Determination 4 10 4 7 4 n Unit Alternator Regulator Tests menn 4 10 4 7 5 Alternator Brush Test 4 11 4 7 6 SlipRing Servicing 4 11 ATI Alternator Installation doro ead weld eee ee ee per E ake ds 4 12 4 8 UNIDRIVE TORQUE REQUIREMENTS ccs 4 12 SCHEMATICS ESI ERA REA ER 5 1 ole INTRODUCTION best nice ecd predia Ursa esu Ion ba ed eed Dad s tue E 5 1 T 266 ii LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 1 1 Generator Set Control Box Road Side nn 1 4 Figure 1 2 Generator Set Top View with Top Frame Members Removed for Clarity 1 5 Figur
2. TNT CONTROL BOX CB5 CIRCUIT BREAKER TO lt gt BATTERY CHARGER If Equipped 4 M j NOTE WHEN PE IS NOT FITTED OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMI NAL STRIP TERMINAL T10 8 6 5 3 2 WINDING LAYOUT Based On Drawings 62 10213 00 Rev D 62 10592 RevA amp 62 10732 Rev Figure 5 7 Schematic Diagram 460 Volt Alternating Current Generator F or Applicability Refer to Table 1 1 T 266 5 8 230V CB4 R1 GENERATOR CIRCUIT BREAKER RECEPTACLE O L1 L2 L3 lt GRD CB5 CIRCUIT BREAKER R2 RECEPTACLE lt gt L1 TO BATTERY CHARGER If Equipped foe L3 2 GRD WINDING LAYOUT Based On Drawings 62 10213 00 Rev D 62 10592 Rev A amp 62 10732 Rev Figure 5 8 Schematic Diagram 230 Volt Alternating Current Generator F or Applicability Refer to Table 1 1 5 9 T 266 A ALTERNATING CURRENT GENERATOR 1 7 4 6 Alternator 1 8 4 9 4 12 Alternator Brush Test 4 11 Alternator R egulator Tests 4 10 Ammeter 1 9 BATTERY CHARGING ALTERNATOR 1 7 BATTERY CHARGING SOLID STATE SYSTEM 1 8 BATTERY SERVICE 4 1 CONFIGURATION IDENTIFICATION 1 1 CONTROL CIRCUIT OPERATION 2 3 Control Panel 1 8 Cooling System 4
3. 1 6 Engine System Jo s ec n t IS C E e f Se S eh 1 6 1 3 2 Lube Oil Filter Arrangement 0 II II nn 1 6 1 3 3 Fuel System EM OPER RE Euer 1 6 1 4 ENGINE SCREW THREADS rh sap heed ERR GUNT DRE ARTI RE 1 6 15 ALTERNATING CURRENT GENERATOR 0c cece e een 1 7 1 5 1 Principle of Operation nii s moie eter pet Ceu e nel o WO IRR Cette die 1 7 1 5 2 Alternating Current Generator Diagram 1 7 1 6 BATTERY CHARGING ALTERNATOR eee 1 7 1 6 Introduction pe Gea act beo npa 1 7 1 6 2 Alternator Operation rre ER Cx Ep Ra eee RACER Cu FLORE OR E ce 1 8 1 6 3 Integral Voltage Regulator Operation 12 volts 1 8 17 BATTERY CHARGING SOLID STATE SYSTEM occ 1 8 18 OPERATING CONTROLS AND INSTRUMENTS ssssessse ee 1 8 1 8 1 Introduction c oov rre E HEU is ier reped 1 8 1 8 2 Control Panel and Related Components 1 8 1 9 SAFETY DEVICES ro rhet vedere cerea out rds a oh tentat en ha leads 1 9 1 10 JNIT SPECIFIGATIONS ux Set tede Ree et ee b lt e etis 1 10 1 11 ENGINE DATA ete ee eee Sy Re XE TC hb BES 1 10 OPERATION isses sive cede Unie kx va we alee s a X CN on ea e EE E e
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6. SERIES STATOR STATOR GENERATOR RECTIFIER ASSEMBLY EXCITER Figure 1 5 A C Generator Circuit Diagram 15 ALTERNATING CURRENT GENERATOR 1 5 1 Principle of Operation The Marathon Alternator Company Lima brushless A C generator 10 Figure 1 2 is self regulated rotating field synchronous unit The generator stator and exciter stator are combined in a common housing The generator field exciter rotor and rotating rectifier assembly are mounted on a common shaft The output of the exciter rotor is applied to the generator field winding through a rotating full wave bridge silicon rectifier unit Allconnections between the exciter stator windings and the generator stator windings internal within the stator housing Only the output power leads are connected at the terminal box located on top of the generator 1 5 2 Alternating Current Generator Diagram Figure 1 5 shows the internal schematic diagram of the generator exciter and rectifier unit The generator is a three phase unit and the exciter stator and exciter rotor also have three phase windings A portion of the exciter stator windings is connected across a tap on the generator stator mnang This exciter shunt winding provides the generator field excitation power required for the generator no load voltage Another portion of the exciter stator windings is conn
7. Operation EN A RU vA Er 69UG15 Diesel Driven Carrier Transicold T 266 Rev H Change 1 20 03 TRANSICOLD o OPERATION AND SERVICE MANUAL DIESEL DRIVEN GENERATOR SET MODEL 69UG 15 Carrier Transicold A member of the United Technologies Corporation family Stock symbol UTX Carrier Transicold Carrier Corporation P O Box 4805 Syracuse N Y 13221U S A 2002Carrier Corporation D Printed in U S A 0602 Carrier A United Technologies Company SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein The general safety notices are presented in the following three sections labeled First Aid Operating Precautions and Maintenance Precautions A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices FIRST AID An injury no matter how slight should never go unattended Always obtain first aid or medical attention immediately OPERATING PRECAUTIONS Always wear safety glasses and hearing protection Keep hands clothing and tools clear of the radiator fan and rotating belts No work should be performed on the unit until all circuit breakers and s
8. 230 VOLT 460 VOLT 7 460 VOLT S Remote With Volt Receptacle meter 13 13 1 Lube Oil Dipstick F ill Cap 9 Starter 2 Mechanical Fuel Pump 10 Air Cleaner 3 Injector Pump 11 Generator Shockmount 4 V Belt 12 Receptacle Box 5 Radiator 13 Receptacle Power Cord E xit 6 Controls See Figure 1 8 14 Circuit Breaker 7 Engine Shockmount Typical 15 Volt Meter Alternate Location 8 Engine Oil Filter Figure 1 1 Generator Set Control Box Road Side T 266 1 4 B o 6 Won S _ eps 1 Fuel Tank 7 Coolant Overflow Bottle 2 Solid State Battery Charger If Equipped 8 Fuel Filter 3 Exhaust Muffler 9 Serial Plate 4 D C Alternator If E quipped 10 Alternating Current Generator 5 Water Temperature S ender 11 AC Generator Connection Box Access 6 Engine 12 Battery Figure 1 2 Generator Set Top View with Top Frame Members Removed for Clarity 1 5 T 266 13 ENGINE The engine is a vertical in line four cylinder diesel which is direct connected to the alternating current generator Information on the major engine systems is provided in the following subparagraphs 1 3 1 Engine Air System The air cleaner Item 10 Figure 1 1 is designed to prolong engine life and performance by preventing dirt and grit from entering the engine and causing excessive wear on all operating parts However the operator is charged
9. Use a heavy duty lubricating oil conforming to American Specification troleum Institute Service Classification CD DS Base Number 8 or above Fahrenheit Centigrade OW SW or 5W20 h Horsepower i Cooling System j Lubrication System 1 11 266 SECTION 2 OPERATION 2 1 GENERATOR SET INSTALLATION AND REMOVAL STANDARD MOUNT The generator set is mounted under the center of the trailer chassis and is easily handled with a fork lift truck capable of handling 2000 poun The fork lift pockets provided are accessible from either side Mounting clamps are designed to be attached to outside I beam flanges only Maximum chassis width is 38 on center a Installation 1 Loosen mounting bolts see Figure 2 1 sufficient to push mounting plates to the outermost position 2 Place forks into fork lift pockets of generator set At tach safety chain between unit and fork truck i 3 Center generator under chassis slide mounting plates fully onto chassis I beams and torque mount CONTAINER FLOOR CROSS BEAMS completion remove safety chain before removing forks of fork lift truck from unit If mounting a generator with power cable secure pow er cable to chassis using tube clamps ing bolts to 80 90 ft lbs 11 1 12 4 mkg Upon If fuel tank is remote connect fuel lines Removal Disconnect power cable at generator if connected Disconnect fuel lines if fuel tank is remote
10. With fork lift in position and safety chain attached slide mounting plates back sufficient to clear chas sis Lower and remove generator REAR OF CHASSIS CHASSIS MOUNTING PLATE GENSET SECTION A Bolt Washer Belleville Washer Spherical Washer Spherical Mounting Plate u ROADSIDE VIEW Generator Frame Tee Nut Roll Pin Chassis I beam Figure 2 1 Generator Set Mounting Standard Mount Change 01 20 03 T 266 2 2 GENERATOR SET INSTALLATION AND REMOVAL QUICK MOUNT The generator set is mounted under the center of the trailer chassis and is easily handled with a fork lift truck capable of handling 2000 pounds The fork lift pockets provided are accessible from either side a Installation 1 Before lifting unit in place loosen the mounting bolts sufficient to bring the clamp to the open position To orient in open position lift nut end of bolt out of slot clamp will fall open 2 Place forks into fork lift pockets of generator Attach safety chain between unit and fork truck 3 Center the generator set in desired position under ch
11. Alternator Brush Assembly ssssssssssssss een 4 11 Figure 4 13 Unidrive Torque Requirements ssssssssss emen 4 13 Figure 5 1 Schematic Diagram hee 5 2 Figure 5 2 Schematic Diagram ex ce ye nete e Erkennen hae Gea eee AC 5 3 Figure 5 3 Schematic Diagram rh 5 4 Figure 5 4 Schematic Diagram hee enn 5 5 Figure 5 5 Schematic Diagram ssssssssssssse eee hee eee 5 6 Figure 5 6 Schematic Diagram sssssssssssssee eee hee 5 7 Figure 5 7 Schematic Diagram epi 5 8 Figure 5 8 Schematic Diagram 6 ents 5 9 LIST OF TABLES TABLE NUMBER Page Table 1 T Model Chart i da es Ce eet EA a bk dba Ce S etd es ll 1 1 Table 1 2 Safety Devices See Rr che ede DR E ERE VR RE OR ERI RR RE ike 1 10 Table 4 1 Preventative Maintenance Actions and 5 4 2 iii T 266 SECTION 1 DESCRIPTION 11 INTRODUCTION The carrier Transicold model 69UG15 under mounted diesel driven generator sets serve to provide electrical power for all electric refrigeration units The generator set See Figure 1 1 and Figure 1 2 consist of a diesel engine direct connected to an alternating current generator and mounted in a structural steel frame The engine is a vertical in line four cylinder diesel manufactured by Kubota while the generator is a 15 KW
12. B REG UVPER NOT ATTACHED Figure 4 9 Open Diode Trio Test Test No 1 TOGGLE SWITCH 12 vdc TEST LAMP BATTERY TOGGLE SWITCH 12 vdc TEST LAMP AC TAP POS OUTPUT B INTEGRAL TIO OIL PRESSURE RE SWITCH OR TO OIL PRESSURE SWITCH OR TOGGLE SWITCH BATTERY TOGGLE SWITCH INTEGRAL REGULATOR INDICATION Figure 4 11 Alternator Output Test BATTERY VOLTAGE Test No 3 BATTERY VOLTAGE 4 7 5 Alternator Brush Test Procedure WITH TEST LAMP OFF J UMPER ATTACHED NOTE T310 SVO TS Before performing test removal of back cover is required To remove disconnect wires from terminals extending through back cover Figure 4 10 Open Regulator Test Remove two screws securing back cover to Test No 2 rear housing and remove cover a Removing Brush Set 1 Remove two locknuts securing brush holder and remove brush assembly 2 Check brush assembly for cracked chipped or oil soaked brushes Remaining brush length should be at least 3 16 inch 4 76 mm long 3 Check slip rings for carbon build up 4 Using a 12 vdc test lamp or ohmmeter test brush assembly for continuity and insulation see Figure 4 12 Replace brush assembly if necessary b Brush Continuity Check Using a 12 vdc test lamp or ohmmeter test brush assembly for continuity and insula
13. graph 1 11 table entry j c Check V belt for fraying or cracks and proper tension Refer to paragraph 4 4 5 d Check radiator hoses for leaks and check radiator coolant level Refer to paragraph 1 11 table entry i e Check radiator coil and generator air intake screen for cleanliness 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 Fillfueltank with dieselfuel Referto paragraph 1 11 table entry f i Check glow plug amperage Refer to paragraph 1 11 table entry g j Check battery terminals for cleanliness and secure ness If required clean then coat with a battery termi nal sealant k Check and if required tighten all electrical connec tions C s and if required tighten all hardware brackets etc m Ensure the main generator set circuit breaker CB 1 for 460 volt units or CB4 for 230 volt units Connect power cable to refrigeration unitand proceed to para 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 or any other unauthorized starting aids be used in conjunction with the glow plugs NOTE Piston rings in engines that have operated less than 100 hours may not be fully seated This may lea
14. 1 D DESCRIPTION 1 1 Diode Testing 4 7 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 INDEX F FIRST AID Safety i Fuel Filter 4 1 Fuel Pump 4 1 Fuel System 1 6 4 1 G Gauges 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 Ignition Switch 1 9 Insulation Testing 4 7 INTRODUCTION 1 1 L Lube Oil Filter 1 6 4 4 M MAINTENANCE PRECAUTIONS Safety i Manual Switches 1 9 Meters 1 9 Model Chart 1 1 OPERATING CONTROLS AND INSTRUMENTS 1 8 OPERATING PRECAUTIONS Safety i OPERATION 2 1 Post Start Inspection 2 3 Pre Start Inspection 2 3 PREVENTIVE MAINTENANCE SCHEDULE 4 1 Index 1 T 266 INDEX Continued S T SAFETY DEVICES 1 9 TORQUE REQUIREMENTS 4 12 SAFETY NOTICES Safety i Total Time Meter 1 9 SAFETY SUMMARY Safety i TROUBLESHOOTING 3 1 SCHEMATICS 5 1 SERVICE AND PREVENTIVE MAINTENANCE 4 1 V Shockmounts 4 8 STARTING AND STOPPING 2 3 V belt 4 4 Starting Insturctions 2 3 Voltage Regulator 1 8 Stopping Instructions 2 3 Voltmeter 1 9 1266 Index 2
15. 1 6 Miscellaneous Engine Troubleshooting 3 2 3 2 BATTERY CHARGING ALTERNATOR ccc cee hee 3 3 3 3 BATTERY CHARGER SOLID STATE REA nad 3 3 3 4 ALTERNATING CURRENT GENERATOR cece eet nee 3 4 SERVICE AND PREVENTIVE MAINTENANCE n nnn 4 1 AT INTRODUCTION 2c Rete eoe ten ect oC EE OR Meat eR ette 4 1 42 PREVENTIVE MAINTENANCE SCHEDULE Hn 4 1 4 3 BADEERYS SERVICE Beer ahaa PESE 4 1 4 4 ENGINE SERVICE AND COMPONENTS ee 4 1 4 4 1 Priming The Fuel System rmm 4 1 4 4 2 Servicing Fuel Pump Internal Filter eens 4 1 4 4 3 Fuel Fite Viens Gas Vea Gar 4 1 4 44 SYSTEMS oni sme e ent doi tees ad cute oe Gat ad wee od 4 1 4 4 5 Servicing And Adjusting V belt mnn 4 4 4 4 6 Cube OI E Iter redet op PRI ERR Ep rep gd tr Et 4 4 4 4 7 Adjusting Engine Speed erre raea a a E e E A Ih nn 4 4 448A Engine Air Cleaner AERE Taoa aa taal aida aa 4 4 4 4 9 Engine Crankcase Breather cece ccs 4 5 4 4 10 Servicing Glow Plugs hh 4 5 4 5 SERVICING THE ALTERNATING CURRENT GENERATOR 4 6 4 5 1 Preventive Maintenance and Operating Precautions
16. CEN WE weet qa VO a RA wees 2 1 2 1 GENERATOR SET INSTALLATION AND REMOVAL STANDARD MOUNT 2 1 22 GENERATOR SET INSTALLATION AND REMOVAL QUICK 2 2 2 3 STARTING AND STOPPING INSTRUCTIONS sssseeeeee I menn 2 3 2 3 1 P re Start Inspection icu ohh ee eh eee ec ea uel LR e BE DURER GET en 2 3 2 32 Starting INSturctiOns arana S uev REPRE RE PREND E ha e Rr d 2 3 2 3 3 Post StartInspectiofi 2 Lom ue pA MPG gale tine Pers e uU MET pA UR Rl eau 2 3 2 3 4 Stopping Instructions iot eee cet d v ER ee el ides YER ER ERR VR Recens 2 3 2 4 CONTROL CIRCUIT OPERATION ssssssssse nm I IH ree 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 T 266 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page TROUBLESHOOTING E ER ce a ee eed ad ea eee ate aS 3 1 3 DIESEL ENGINE ipsnm eats Shak Gb Gaede Tad GAR 3 1 Engine Start i2 root Er bt eec dat A eee ded A at 3 1 3 1 2 Enine Starts Then Stops ile eene RR eee DR ECKE e E e XR 3 1 313 Engine hub OM o Lv pter Lev bees Aaa yeaa eae 3 1 3 1 4 Starter Motor Malfunction 0 eH 3 2 3 1 5 Malfunction In The Engine Starting Circuit 0 eee eee 3 2 3
17. brushless single bearing type manufactured by Lima The generator provides a constant 460 or 230 vac 3 phase 60 hertz electrical supply Electrical controls are mounted in a control box with operating controls and gauges mounted on a control panel which also serves as the control box cover The control panel components are protected by a deflector assembly or a windowed control box door Auxiliary engine equipment consists of the starting battery battery charging system alternator or solid state glow plugs used as a Starting aid spin on lube oil and fuel filters for easier filter changes and other necessary components for proper unit operation The water pump and the radiator cooling fan are belt driven from the engine crankshaft All references to engine are as viewed from the fly wheel end 12 CONFIGURATION IDENTIFICATION Generator set identification information is provided on a plate located inside the engine inspection door see Figure 1 2 The plate provides the generator set model number serial number and parts identification number PID The model number identifies the overall configuration while the PID provides information on specific optional equipment and differences in detailed parts Configuration identification for models covered herein are provided in Table 1 1 The model number serial number and PID number must be included when ordering parts and inquiring about your unit Separately bound manual
18. for the glow plugs is 28 9 to 36 2 ft lb 4 0 to 5 0 mkg T 266 Checking for a Defective Glow Plug a Method 1 Place an ammeter or clip on ammeter in series with each glow plug and energize the plugs Each plug should show 7 to 10 amps draw b Method 2 Disconnect the wire connection to the plug and test the resistance from the plug to a ground on the rs block The reading should be 0 7 to 1 2 ohms if the plug is good 4 5 SERVICING THE ALTERNATING CURRENT GENERATOR 4 5 1 Preventive Maintenance and Operating Precautions Costly repairs and down time can usually be prevented by operating electrical equipment under conditions which are compatible with those at which the equipment was designed Follow the instructions outlined below to insure maximum efficiency of the electrical equipment a Cooling Keep all cooling parts clean DO NOT EXCEED TEMPERATURE RISE OF 80 C 176 F ABOVE A 40 C 104 F AMBIENT This ensures that the NEMA Class F insulation will not be damaged DO NOT EXCEED RATED LOAD except as specified for the equipment OPERATE GENERATOR AT RATED SPEED Failure to operate generators at rated load or speed will cause overheating and possible damage to windings due to over voltage or current b Generator Windings Drying WARNING Do not direct water or steam into the generator openings Do notallow any soap and water solutions to enter the alternator WARNING High voltage dielectric testing mustnot
19. product or property damage SPECIFIC WARNING AND CAUTION STATEMENTS The statements that follow are applicable to the generator set and appear elsewhere in this manual These recom mended precautions must be understood and applied during operation and maintenance of the equipment covered herein WARNING Do not use gasoline to clean air cleaner parts WARNING Beware of moving V belt belt driven components and hot exhaust components WARNING Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the glow plugs Safety i T 266 WARNING Do not direct water or steam into the generator openings Do not allow any soap and water solutions to enter the alternator WARNING High voltage dielectric testing must not be performed to the machine without first observing NEMA rules The insulation of this generator winding may be safely checked by using a megger A high megger reading indicates good insulation CAUTION Observe proper polarity when installing the battery or connecting a battery charger the negative bat tery terminal must be grounded Reverse polarity may damage the charging system When charging the battery in unit isolate the battery by disconnecting the negative battery terminal first then the positive Once the battery has been charged connect the positive battery terminal first then the neg ative CAUTION The generator set circuit breaker mustbe in the ON position in o
20. the new filter with fuel lightly oil gasket with lube oil and replace by hand 4 4 4 Cooling System The radiator must be clean externally and internally for adequate cooling The fan belt must be adjusted periodically to provide maximum air flow refer to paragraph 4 4 5 To service the cooling system do the following a Remove all foreign material from the radiator coil by reversing the normal air flow Compressed air or wa ter may be usedas a cleaning agent Itmay be neces sary to use warm water mixed with any good commer cial dishwasher detergent Rinse coil s with fresh water if a detergent is used b Drain coolant completely by opening drain cock and removing radiator cap CAUTION Never pour cold water into a hot engine Close drain cock and fill system with clean untreated water to which three to five percent of an alkaline base radiator cleaner should be added six ounces dry 2 151 grams to one gallon 3 8 liter of water T 266 ees Suonipuoo uoneJjedo eq lt quenbaJJ Gop ON 29U 2 TZ 3ndino e6ejeduuy 10jeuuay v Ayd OZ O QUOD ui suon euuo e21029J 3 6 qeuas pue auibu 3 ST Joy 4 jeugegu dun 3jr1 Jen 4 je rueu e u ue9 2 7 T AION 995 IIO 483 Weg
21. 11 1 e Run engine to operating temperature Drain system again and fill with treated water anti freeze See above Caution note and refer to paragraph 1 11 1 4 4 5 Servicing And Adjusting V belt WARNING Beware of moving V belt and belt driven components NOTE Frayed cracked or worn V belt must be replaced After installing a new belt it is advisable to check the adjustment after running the unit for three or four hours This is to allow for the initial stretch which is common on new belts Once this initial stretch has taken place the belt should be checked at regular intervals The V belt is driven by a sheave on the engine crankshaft Its three functions are 1 drive the alternator if equipped 2 drive the radiator fan and 3 to drive the water pump To replace or adjust the belt do the following a Replacing the V Belt 1 Depending on equipment supplied loosen the alternator adjustment arm pivot bolt or the idler pivot bolt 2 Replace belt and adjust tension in accordance with the following step b Adjusting Tension 1 Check belt tension correct tension is 40 45 pounds on the Burroughs gauge Carrier Transicold P N 07 00203 Use hand force only on the alternator to tighten belt Do not use pry bar or excessive force as it may cause alternator housing damage 2 When belt is at correct tension tighten pivot bolt 4 4 6 Lube Oil Filter The primary oil filter is located near the radiator fan whi
22. A Continued Diesel No 1 Diesel No 2 f Fuel and Fuel Heater FHT Thermostat 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 7 5 amps per plug at 12 vdc 28 hp 1800 rpm at 3000 feet above sea level 33 hp 1800 rpm at sea level 6 U S quarts 5 68 liters includes 1 quart 0 95 liter in coolant recovery bottle Refer to section 4 4 4 Anti Freeze Type For optimum performance and protection the cooling system is factory charged with a 50 50 mix of ethylene glycol and wa ter This mixture provides protection to 34 F 37 C For replacement use a low sillcate anti freeze meeting GM speci GM 6038M or equal Again 50 50 mix 15 recom mended Water Temperature Opens 200 93 C minimum Thermostat Oil Pressure Safe ty Switch S etting 15 psig 2 08 kg cm Opens Engine 17 2 U S quarts 16 3 liters includes standard filter Oil Level Indicator Dipstick in oil pan or fill cap NOTE To check oil level on engines with the dip stick mounted in the fill cap remove the cap and wipe the dipstick clean Insert the cap back onto the oil fill tube then remove to check level It is not necessary to screw the cap back into the fill tube when level DO 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
23. ION 3 1 4 Starter Motor Malfunction Battery insufficiently charged Charge Battery cable connections loose or oxidized Chec Battery cables defective Replace Starter motor will not crank or turns Starter brushes shorted out Engine M anual Starter brushes hang up defective or have no contact Engine M anual Starter solenoid damaged Engine M anual Ignition switch defective R eplace Engine lube oil too heavy 1 11 Starter motor turns but pinion does Pinion or ring gear obstructed or worn Engine M anual not engage Starter motor does not disengage af Ignition switch defective Replace ter switch has been released Starter motor solenoid defective Engine M anual Pinion does not disengage after en Defective starter Engine M anual gine is running 3 1 5 Malfunction In The Engine Starting Circuit Battery defective Correct No power to starter motor solenoid Loose electrical connections Tighten Battery defective Loose electrical connections Fuel solenoid does not energize or Oil pressure switch defective does not remain energized Water temperature safety switch open 1 9 Fuel solenoid defective Engine M anual Ignition switch defective Replace 3 1 6 Miscellaneous Engine Troubleshooting Restriction in air cleaner Air in fuel system 4 4 1 Air vent restricted Clean Restricted fuel lines Engine M anual Loss of power Defective fuel injection pump Engine M anual Defective injector s or incorrect type Engine M anual Incorrect
24. NERATOR TERMINAL GLOW PLUG GLOW PLUG SWITCH HIGH WATER TEMPERATURE SWITCH IGNITION SWITCH LOW OIL PRESSURE SWITCH OIL PRESSURE GAUGE OIL PRESSURE SENDER SAFETY RELAY STARTER MOTOR STARTER SOLENOID TIME METER VOLTAGE REGULATOR WATER TEMPERATURE GAUGE WATER TEMPERATURE SENDER Based On Drawings 62 10213 00 Rev D 62 10592 RevA amp 62 10732 Rev Figure 5 5 Schematic Diagram Legend Applies to Figure 5 6 T 266 5 6 12VDC CONTROL CIRCUIT BAT 12V DC FEIN ie AN GP 83 aux A SOA CAUTO CB2 AUX CAUTO ALTERNATOR OPTION D4 Bn BC BLK RED GRN woe 6710 OR BS oN S o 6T GTB BATTERY CHARGER OPTION Based On Drawings 62 10213 00 Rev D 62 10592 RevA amp 62 10732 Rev Figure 5 6 Schematic Diagram For Applicability Refer to Table 1 1 5 7 T 266 460 R1 10 4 GENERATOR CIRCUIT BREAKER RECEPTACLE SO CABLE lt lt 2 lt GRD SEE NOTE FROM FRAME PE PHYSICAL EARTH If Equipped S LS S L
25. TAT FUEL HEATER FUEL SOLENOID FUEL SOLENOID HOLD FUEL SOLENOID PULL GLOW PLUG GLOW PLUG SWITCH HEATER RELAY HIGH WATER TEMPERATURE SWITCH IGNITION SWITCH LOW OIL PRESSURE SWITCH OIL PRESSURE GAUGE OIL PRESSURE SENDER SAFETY RELAY STARTER MOTOR STARTER SOLENOID TERMINAL BLOCK WATER TEMPERATURE GAUGE WATER TEMPERATURE SENDER Based On Drawing 62 02678 RevA Figure 5 1 Schematic Diagram Legend Applies to Figure 5 2 T 266 5 2 12VDC CONTROL CIRCUIT 12V DC BAT EIN 11 BATTERY CHARGER OPTION BLK RED GRN D4 B A CAC RED BC A ALTERNATOR OPTION A D4 A 30 87 o gt 30 87 FHT FH CB2 UG0291 DOES NOT LM AUX HAVE FHT BAT 30A CAUTO HWT 85 86 gn NOTE In 1997 early production units were retrofitted to move the low oil pressure switch from the wiring feeding terminal board terminal TB 4 to the wiring feeding the safety relay If servicing a unitthatis not wired as shown above the unit should be retrofitted Contact Carrier Service Engineering Based On Drawings 62 10008 00 Rev A amp 62 0009 00 Rev A Figu
26. assis CONTAINER FLOOR CROSS BEAMS 92 Ww N e C Lift clamp item 1 in place ensuring bolt item 4 is secured in slot Tighten bolt to 55 65 ft lbs 7 6 9 0 Upon completion remove safety chain before re moving forks of fork lift truck from unit Removal Disconnect power cable to unit if connected Disconnect fuel lines if fuel tank is remote With fork lift in position and safety chain attached loosen mounting bolts and lift end of bolts out of slot to orient clamps to open position Lower and remove generator REAR OF CHASSIS FORK LIFT POCKET Angle Assembly Clamp Washer Spherical Washer Spherical Bolt Washer Spherical Belleville ARNE ROADSIDE VIEW Frame Assembly Roll Pin Nut Hex 3 4 10 Chassis I beam Figure 2 2 Generator Set Mounting Quick Mount Change 01 20 03 T 266 2 2 2 3 STARTING AND STOPPING INSTRUCTIONS 2 3 1 Pre Start Inspection a Check engine lubrication and fuel filters oil lines and connections for leaks If required tighten connec tions and or replace gaskets b Check engine lubricating oil level Refer to para
27. be performed to the machine without first observing NEMA rules The insulation of this generator winding may be safely checked by using a megger A high megger reading indicates good insulation Generators that have been in transit recently steam cleaned or in storage for long periods may be subjected to extreme temperature and moisture changes This can cause excessive condensation and the generator windings should be thoroughly dried out before bringing the generator up to full nameplate voltage If this precaution is not taken serious damage to the generator can result The following steps should be taken to effectively dry the generator windings 1 Dry windings by placing generator in drying oven or hotroom or dry with warm air blower directed through windings 2 If the generator has been operated and is being placed into storage for any period of time a P D George 11127 type air dry fungus resistant varnish should be applied The finest insulation job can be very quickly broken down by carelessly applying high voltage to windings in a moisture saturated condition Failure to follow these T 266 4 6 cause a breakdown making it guide lines could easil he generator to the factory for necessary to return t repair c Rotor Damage If a rotor becomes defective itshould be returned to the factory with full nameplate data To repair a rotor the special tooling and technique of the factory are necessary and essent
28. d and back flushed Atleast once a year or atregular engine service periods remove the entire air cleaner and perform the following 1 Remove oil cups Check and clean center tube WARNING Do not use gasoline to clean air cleaner parts 2 Pump solvent through the air outlet with sufficient force and volume to produce a hard even stream out the bottom of the body assembly Reverse flush until all foreign material is removed 4 5 4 4 9 Engine Crankcase Breather The engine uses a closed type breather with the breather line attached to the cylinder head cover See Figure 4 4 Element style breather assemblies should be brushed clean Itis notnecessary to dissemble valve style elements for cleaning However the bleed hole should be checked to ensure it is free of obstruction Check once a year or at every 3000 hours maintenance interval whichever comes first ELEMENT STYLE PRIOR TO PID UG0457 1 Cylinder Head Cover 5 Breather Oil Shield 2 Breather Cover 6 Capscrew 3 Breather Element 7 Breather Assembly 4 Plate 8 O Ring VALVE STYLE STARTING WITH PID UG0457 1 Screw 4 Breather Valve 2 Breather Cover 5 Breather Tube 3 Bleed Hole Figure 4 4 Engine Crankcase Breather 4 4 10 Servicing Glow Plugs The glow plugs are parallel connected and when energized each plug draws 7 5 amps at 12 vdc When servicing the glow plug is to be hand fitted into the cylinder head to prevent thread damage Torque value
29. d to the possibility of oil seepage outthe exhaust pipe To properly seat the rings oper ate the engine under full load for a period of 24 hours If condition persists check valve clear ance when engine is cold Refer to engine workshop 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 2 3 COLD ENGINE GLOW TIMES b With glow plug switch held in the PREHEAT position place the ignition switch in the START position c After engine has started continue to hold the glow plug switch in the PREHEAT position until the engine develops sufficient oil pressure to close the oil pres sure safety switch When released the glow plug switch will automatically return to the OFF position 2 3 3 Post Start Inspection a Check generator output with a voltmeter In the no load condition output should be at rated output of 460 10 or 230 volts a c 5 with 1820 to 1840 engine RPM Place generator set main circuit breaker in the ON position Start refrigeration unit and check generator 1710 rpm b ies REMIS meter operation run engine 10 min utes C Listen for abnormal bearing noise A C generator d Check fuel lines lube oil lines and filters for leaks e Check exhaust system for leaks 2 3 4 Stopping Instructions Place the ignition switch in the OFF position 2 4 CONTROL CIRCUIT OPERATION WARNING Beware of
30. e 1 6 1 Introduction The mechanical construction of the alternator differs from the DC generator in that the field rotates and the armature generating windings are stationary The field current necessary to control the output of the alternator is supplied from the solid state regulator This integral voltage regulator controls the currentfeed to the field via the brushes and rotor slip rings See Figure 1 6 Two completely sealed ball bearings support the rotor in the front and rear housing 1 6 2 Alternator Operation T 266 The alternator converts mechanical and magnetic energy to alternating current A C and voltage by the rotation of an electromagnetic field rotor inside a three phase stator assembly The voltage is changed to DC voltage by passing A C energy through a three phase full wave rectifier system Six silicon rectifier diodes are used see Figure 1 7 Figure 1 6 Alternator and Regulator 1 12vdc Test Lamp 5 Ground Terminal D 6 AC Tap Not connected 7 Rotor Field 2 Diode Trio 8 Stator 3 Positive Output B 9 Integral Regulator 4 Rectifier 10 Excite Figure 1 7 Alternator Schematic Diagram 1 6 3 Integral Voltage Regulator Operation 12 volts d c 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 stat
31. e Torque value and hardware requirements for unidrive assembly are provided in Figure 4 13 NOTES SST is anabbreviation for 300 Series Corrosion Resistant Steel Loctite 4242 oran equivalent product should be used on ALL hardware shown on this page T 266 T 266 1 2 13 x 3 1 2 Ig SST 2 Req d 90 ft lb 12 44 mkg JOR Ve 9 J 5 8 18 x 2 00 lg SST 4 Req d 25 ft lb 3 46 mkg ENGINE amp GENERATOR SHOCKIVDUNTS TOP MEW Engine Flywheel 3 8 16 x 1 1 2 lg SST 12 Req d 25 ft Ib 3 46 mkg N t M8 x 15MM lg SST 6 Req d 19 ft Ib 2 49 mkg Generator Disc Drive UNIDRIVE SECTIONAL VIEW 5 8 18 x 4 00 or 4 50 Ig SST 2 Req d 90 ft lb 9 68 mkg ENGINE MOUNT RIGHT SIDE VEW Figure 4 13 Unidrive Torque Requirements 4 14 SECTION 5 SCHEMATICS 5 1 INTRODUCTION This section contains the 12 volt DC control circuit schematics the 460 volt alternating current generator schematic and the 230 volt alternating current generator schematic To identify the schematics applicable to your model and PID number refer to Table 1 1 5 1 T 266 LEG OPTIONAL ENGINE GROUND CHASSIS GROUND AMMETER ALTERNATOR AUXILIARY CONTACTS BATTERY CHARGER BATTERY CIRCUIT BREAKER DIODE FUSE 3 AMP FUEL HEATER THERMOS
32. e 1 3 Fuel System Diagram alesti erene ata r e a nn 1 6 Figure 1 4 Lube Oil ee ERE e Ie DER er dx etc Maayan ee X CORR E RO RP E one 1 6 Figure 1 5 A C Generator Circuit Diagram nn 1 7 Figure 1 6 Alternator and Regulator eee 1 8 Figure 1 7 Alternator Schematic Diagram sssssessssss een 1 8 Figure 1 8 Control Box and Panel 1 9 Figure 2 1 Generator Set Mounting Standard Mount 8 2 1 Figure 2 2 Generator Set Mounting Quick Mount nn 2 2 Figure 4 1 Mechanical Fuel Pump 2 00 ccc eee mh 4 1 Figure 4 2 Engine Speed Adjustment eee en 4 4 Figure 4 3 a rua soe rtt be Rye md ROC Ded genet et Et dot e ee RON tei yet 4 5 Figure 4 4 Engine Crankcase Breather 4 5 Figure 4 5 A C Generator Rectifier Assembly 4 7 Figure 4 6 Rectifier Removals evo eua rtt eter t US DRE Wat ee ae eae eee St 4 7 Figure 4 7 Engine Shockmounts 4 9 Figure 4 8 Generator Shockmounts sssssssssssssesss eee 4 9 Figure 4 9 Open Diode Trio Test Hn 4 10 Figure 4 10 Open Regulator Test Rm 4 11 Figure 4 11 Alternator Output Test n nmn 4 11 Figure 4 12
33. e 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 It senses the voltage appearing atthe 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 CAUTION Observe proper polarity when installing the battery or connecting a battery charger the T 266 negative battery terminal must grounded Reverse polarity may damage the charging system When charging the battery in unit isolate the battery by disconnecting the negative battery terminal first then the positive Once the battery has been charged connectthe positive battery terminal first then the negative 17 BATTERY CHARGING SOLID STATE SYSTEM The solid state battery charger see Figure 1 2 is located to the left of the radiator The charger is powered by the generator and this input is protected by a circuit breaker located on the control panel The battery charger produces a tapered charge 25 and is designed not to overcharge the battery 18 OPERATING CONTROLS AND INSTRUMENTS 1 8 1 Introduction Components required for monitoring and controlling the unit are located in the control box on the control panel see Figure 1 8 and on the receptacle box see Figu
34. ected in series with the output of the generator and provides a compounding excitation characteristic The rotor is in effect the secondary ofa rotating current transformer induction frequency converter The exciter rotor output voltage is applied to the generator field windings by a three phase full wave rotating silicon 1 7 rectifier unit The response time ofthe 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 field windings inherent compounding characteristics of the excitation system provide excellent voltage regulation even under heavy overload conditions 1 AC Tap 2 Back Cover 3 Positive Output B 4 Integral Regulator 5 Excite 6 Ground 7 12 Test Lamp Terminal D 16 BATTERY CHARGING ALTERNATOR CAUTION Observe proper polarity when installing the battery or connecting a battery charger the negative battery terminal must be grounded Reverse polarity may damage the charging system When charging the battery in unit isolate the battery by disconnecting the negative battery terminal first then the positive Once the battery has been charged connectthe positive battery terminal first then the negativ
35. er Part Number 02 00083 00 Replace bearing cover 1 Rectifier Flange 2 Rectifier Assembly 3 Rectifier Bolt 4 Bearing Cover 5 Bearing Cover Bolt 6 Bearing 7 Bearing Cover Flange Figure 4 6 Rectifier Removal 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 peeve connection box cover disconnect power eads 3 Remove screen cover and generator exhaust baffle from coupling end of generator 4 Remove six 8mm hex head bolts and washers securing the generator drive disc to the engine flywheel Turn bolts counter clockwise with offset wrench to start then use flexible shaft and socket assembly for removal of bolts 5 Remove twelve 3 8 inch hex head capscrews and washers that secure generator frame to engine flywheel housing 6 Remove four 5 8 inch bolts that secure the generator mounting feet to the shock mount bracket then remove generator b Installing the Generator NOTE For torque values refer to paragraph 4 8 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 1 Brush anti seize lubricant lube plate on the face of flywheel 2 Move generator into position and line up with the holes on housing and flywheel If required turn crankshaft to align threaded holes in flywheel with generator drive d
36. erminal post or battery defective Chec B ad electrical connections at starter Correct Starter motor malfunctions 3 1 4 Starter motor solenoid defective Engine M anual Open starting circuit 3 1 4 Incorrect grade of lubricating oil 1 11 No fuel in tank 1 10 1 11 9 Air in fuel system 4 4 1 Water in fuel system Drain Sump Starter motor cranks but fails to start Plugged fuel filters Replace Glow plug s defective 4 4 10 Plugged fuel lines to injector s Engine M anual M echanical lift fuel pump malfunction Engine M anual Starter motor will not crank or low cranking speed Starter cranks engages but dies after Engine lube oil too heavy 1 11 a few seconds Voltage drop in starter cable s Check 3 1 2 Engine Starts Then Stops No fuel in tank 1 10 1 11 9 Fuel filter restricted Replace Air cleaner or hose restricted 4 4 8 Safety device open Open wiring circuit to fuel solenoid Fuel solenoid Replace Engine stops after a few rotations Fuel supply restricted 1 11 9 4 2 echanical lift fuel pump malfunction Engine M anual Oil pressure switch defective Replace Leak in fuel system Check Injector nozzle s defective Engine M anual Injection pump defective Engine M anual Generator internal overloads open Table 1 2 3 1 3 Engine Will Not Shut Off Loose ground connection Clean amp Tighten Engine will not shut off Improperly seated fuel solenoid Correct 3 1 T 266 REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECT
37. ests the charging system battery and wiring should be checked to eliminate problem areas Figure 1 6 identifies the terminals on rear of the alternator a Check the condition of the V belt 4 9 GENERATOR Q Ui V lt 12 13 INSTALL MOUNT WITH LARGE FLARE AT TOP 7 8 Screw 5 8 8 Spacer Mounting Base 9 Snubbing Washer Flat Washer 5 8 10 Screw 1 2 Locknut 5 8 11 Screw 3 8 Locknut 1 2 12 Flat Washer 3 8 Flat Washer 1 2 13 Locknut 3 8 Shockmount Figure 4 8 Generator Shockmounts 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 2 are clean tight Loose or corroded connections cause high resistance and this could cause overcharging undercharging or damage to the charging system 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 T 266 4 7 2 Test Tools The following tools are required to perform tests on the alternator and its components 1 Volt ohm meter 2 Single pole single throw switch 3 12 vdc lamp 4 Insulated 12 gauge stranded wire 5 Alligator clamp terminals 4 7 3 Problem Area D
38. etermination Suggested test sequence for battery undercharge and battery overcharge are as follows a Battery Undercharged 1 Perform open diode trio test Refer to paragraph 4 7 4 Test No 1 2 Perform regulator tests Refer to paragraph 4 7 4 Test No 2 If the working the cause is probably an open field circuit and the 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 paragraph 4 7 4 Test No 3 2 Regulator shorted Replace regulator 4 7 4 In Unit Alternator Regulator Tests Test No 1 Open Diode Trio Test CONDITIONS Start run stop switch SRS in RUN position and engine stopped after proper hook up is made and test leads connected No electrical loads a With jumper not attached Check for battery voltage atterminal A and for 1 5 to 3 0 volts atterminal B see Figure 4 9 b Add jumper J U1 between terminals A and B Start engine and run with no load Ifthe testlamp now goes off and charging voltage is present at terminal A more than battery voltage the diode trio is open Alternator should be removed for repair If the voltmeter indication is not in this range remove the jumper and proceed to the regulator test test no 2 Test No 2 Open Regulator Test CONDITIONS Engine stopped start run stop switch in the RUN position and voltmeter set up as shown in Figu
39. ety contacts energizes the run winding of the fuel solenoid A thermostat FHT internal to the fuel filter head closes to energizes the fuel heater FH at cold fuel temperatures The starter motor turns over the engine resulting in pumping of fuel to the engine cylinders by the injection pump This fuel is ignited by heat of compression thus starting the engine When the engine has developed sufficient oil pressure the low oil pressure switch contacts close to maintain the circuit to the safety relay Once the engine has started the ignition switch is released to the RUN position The glow plug switch is then released Releasing the glow plug switch de energizes the glow plugs while releasing the ignition switch de energizes the starter motor With the engine running the battery charger or alternator provides DC power to operate the control system and charge the battery T 266 2 4 2 4 2 Sequence Of Operation Units using Figure 5 6 With the glow plug switch GPS held in the pre heat position current flows to the glow plugs GP second set of contacts also energizes the safety relay S The safety relay will not energize and the engine will not start if the high water temperature switch HWT opens to break the safety relay ground connection To start the engine the ignition switch IGN is held in the START position With the switch in the START position current flows to the startsolenoid SS throug
40. fuel injection pump timing Engine M anual Incorrect valve timing Engine M anual Poor compression Engine M anual TNT Engine shockmounts defective Replace Restriction in air cleaner 4 4 8 Exhaust pipe restriction Remove Restriction in water jacket Engine M anual Restriction in radiator 4 4 4 Coolant level too low Loose water pump alternator V belt 4 45 Defective thermostat Engine M anual Defective water pump Engine M anual Overheating T 266 3 2 CONDITION POSSIBLE CAUSE 3 2 BATTERY CHARGING ALTERNATOR Defective cables dirty battery posts or corroded terminals Loose or broken belt Worn or broken brushes Defective alternator system Defective wire harness Broken brush Defective alternator Battery undercharged Battery Overcharged excessive use Defective alternator system of water Voltmeter indicates greater than 14 5 volts connected across battery with no load with engine running Battery charges with engine runnin no load but discharges under loa conditions Slipping belt Alternator defective 3 3 BATTERY CHARGER SOLID STATE Short in 12 volt wiring causing Input fuse blows when charger is overload of charger turned on Input fuse blows repeatedly even when not connected Bad cell in battery Charger does not taper back after charging for a few minutes Defective charger input circuit breaker Charger is not receiving AC input Charger does not charge Charger
41. ge Glow Plug S witch Ignition S witch PRESENT DESIGN CONTROL PANEL Battery Charger Fuse or Circuit Breaker CB5 Total Time Meter Volt Meter Water Temperature Gauge Figure 1 8 Control Box and Panel b Meters 1 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 provides information 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 hours and provides an accurate readout of accumulated engine running time This data can be used to establish the proper periodic maintenance schedule Refer to section 4 1 3 Voltmeter V Optional The A C voltmeter see Figure 1 1 or Figure 1 8 is a sealed device indicating the line to line voltage output from the A C generator When the unithas an output of 460 vac or 230 vac if so optioned the indicating needle will be in the green band Refer to section 4 4 7 c Manual Switches 1 Glow Plug Switch GPS see Figure 1 8 The glow plug switch is ofthe momentary type and when held in the PREHEAT position permits battery current 1 9 approximately 30 amps to flow to the glow plugs and preheat the combustion chambers The glow plugs are located underthe fuel injectors When starting engine it is necessary to continue to hold t
42. h the SS contacts to the starter motor SM and to the pull in winding of the fuel solenoid FS Also asecond setof contacts energizes the oil pressure gauge OPG water temperature gauge WTG the total time meter TT and the run winding of the fuel solenoid Also at this time power flows to the fuel heater thermostat FHT or on systems fitted with a heater relay the heater relay HR is energized Energizing HR provides a circuit to the fuel heater thermostat The thermostat internal to the fuel filter head energizes the fuel heater FH atcold fuel temperatures The starter motor turns over the engine resulting in pumping of fuel to the engine cylinders by the injection pump This fuel is ignited by heat of compression thus starting the engine When the engine has developed sufficient oil pressure the low oil pressure switch contacts close to maintain power to the safety relay Once the engine has started the ignition switch is released to the RUN position The glow plug switch is then released Releasing the glow plug switch de energizes the glow plugs while releasing the ignition switch de energizes the starter motor With the engine running the battery charger or alternator provides DC power to operate the control system and charge the battery SECTION 3 TROUBLESHOOTING 3 1 DIESEL ENGINE REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECTION 3 1 1 Engine Will Not Start Battery insufficiently charged Charge Battery t
43. he glow plug switch in the UP position until the ome has developed sufficient oil 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 the START position when held in the START ignition position it energizes the starter motor solenoid which in turn allows the starter motor to crank the engine The switch is released to the RUN position once the engine has started 19 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by safety devices including circuit breakers fuses and safety switches The A C generator and the glow plug circuit are protected by circuit breakers which will open on excessive current draw to interrupt the component electrical circuit The battery charger is protected in the same manner butthe protective device may be a circuit breaker or a fuse T 266 The engine engine control devices and engine unsafe condition occurs Opening one or more of these monitoring devices are protected by a circuit breaker a safety switch contacts will de energize the fuel solenoid low oil pressure switch and a high water temperature De energizing the fuel solenoid shuts off the fuel supply switch These safety devices monitor system operating e conditions and open a setof electrical contacts when an pa Safely device Table 1 2 Safety Devices Unsafe Condition Safety Switch Switch Set
44. ial Should a failure occur Carrier Transicold should be notified immediately and steps will be taken to return the generator for service d Terminal Strip Cleaning Open Terminal Box Remove dustand debris and clean terminal strip with wire brush Reapply protective coating 4 5 2 Generator Repair Test Procedures a Restoring Residual Magnetism The direct current DC necessary to magnetize the alternator field is obtained from the exciter Initially upon Starting the generator current flow and voltage are induced into the exciter armature by the magnetic lines of force set up by the residual magnetism of the exciter field poles Residual magnetism of the exciter field poles may be lost or weakened by a strong neutralizing magnetic field from any source or ifthe generator is not operated fora long period of time 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 NOTE When trying to restore residual magnetism be sure to wear safety glasses non conductive gloves Use an insulated 12 gauge or higher jumper wire Cut off all but a few strands from both ends ofthe jumper wire to help ensure fusing does not take place As an alternate method apply either an alternating current or a direct current voltage of approximately 20 volts to any t
45. isc mounting holes CAUTION The rotor should not be pulled out from the alternator more than 0 75 inches Damage to the bearing and windings may result 3 Startthe 8mm bolts by hand through the disc plate and into the flywheel Once alignment is made torque bolts six 4 Secure two of the housing bolts 3 8 on the top and bottom of the generator housing to draw the mating flanges together 5 Secure remaining bolts and washers 3 8 and torque 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 generator cover Install new gasket when installing generator connection box cover T 266 4 8 4 6 GENERAL GENERATOR SET MAINTENANCE 4 6 1 Maintenance Of Painted Surfaces The unit is protected against the corrosive atmosphere in which it normally operates by a special paint system However should the paint system be damaged the base metal can corrode If the paintsystem is scratched or damaged do the following a Clean area to bare metal using a wire brush emery paper or equivalent cleaning method b Immediately following cleaning spray or brush ona zinc rich primer c After the primer has dried spray or brush on finish coat of paint to match original unit color 4 6 2 Checking And Replacing Shockmounts a Replacement Criteria CAUTION Continued operation with failed shock
46. l charts Continued Schematic an Fuel Tank Voltage Voltmeter Diagram Figures ai 690615 121 5 suenins 112 060196 915253 A 8 C 6615201 0602 515254 A 82 C Ucow9 515253 Ar 8 c2 6900152212 69UG1532L8 060239 515253 A3 81 Cl NOTE In 1998 Carrier Transicold a new model numbering system The following models s use this new system 69UG 15 0500 01 555657 m a o 060426 55 5657 A sm PN UG088 55 5657 A2 1 i UG0427 55 5 6 5 7 UG0458 55 5 6 5 7 enero ON f TUGO 55 5 6 5 7 060555__ 5 5 5 6 5 7 266 1 2 Table 1 1 Model Chart Continued Schematic an Fuel Tank Voltage Voltmeter Diagram Figures C2 cI c1 C2 C2 c1 c1 c1 cI c1 69UG15 0685 01 1 3 T 266 4 14 14
47. le the by pass filter is located on the generator set frame see Figure 1 4 After warming up the engine stop engine remove drain plug from oil reservoir and drain engine lube oil Replace filters Lightly oil gasket on filter before installing Add lube oil Refer to paragraph 1 11 j Warm up engine and check for leaks 4 4 7 Adjusting Engine Speed The engine is to ores at 1820 to 1840 rpm no load 1710 rpm with full load To check the engine speed do the following T 266 4 4 a With the engine stopped place a mark white paint for example on the crankshaft sheave Start engine and verify engine ed 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 capscrew clockwise 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 capscrew counter clockwise until correct speed is achieved then tighten jam nut and recheck engine speed 1 Speed Lever 2 Nut 3 Capscrew Figure 4 2 Engine Speed Adjustment 4 4 8 Engine Air Cleaner a Inspection The oil bath air cleaner should be inspected routinely for leaks A damaged air cleaner or hose can seriously affectthe performance and life of the engine To inspect the air cleaner do the following 1 Check all connections for mechanical tightness Be sure outlet pipe i
48. lunger see Figure 4 1 counter clockwise to unlock it then rapidly hand pump the manual plunger until a positive pressure resistance is felt which will indicate fuel flow c Depress and turn the top of the manual plunger clock wise to lock in place d Start engine Refer to section 2 3 e When engine is running propery turn bleed valve clockwise until fully closed 4 4 2 Servicing Fuel Pump Internal Filter Due to foreign particles in the fuel and wax as a result of using the wrong grade of fuel or untreated fuel in cold weather the internal fuel filter may become plugged or restricted and the engine will loose capacity The filter must be cleaned on a regular schedule Quality of fuel will effect filter cleaning schedule refer to section 4 2 a Turn nut item 1 counter clockwise to loosen and re move b Remove banjo fitting item 2 and let it hang loose making sure to keep copper rings item 4 for re placement 4 1 c Turn filter item 3 counter clockwise and remove Check and clean d To install reverse steps 1 through 3 1 Nut 4 Copper Rings 2 Banjo 5 Manual Priming Pump 3 Filter Figure 4 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 filter with a filter wrench pre fill
49. mounts may result in engine or generator damage When shockmounthas been cut split abraded orhas flared due to normal deterioration it must be replaced Damage to the mounts may notbe visible when installed and under load from the opon n To correctly inspect shockmounts they must be removed b Engine Shockmount Replacement 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 the shockmounts 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 see Figure 4 8 1 Use the two lift eyes to lift and support the engine 2 Remove shockmount hardware items 5 through 13 figure Figure 4 8 3 Raise the generator just enough to remove the shockmounts item 7 4 Install new shockmounts 5 Lower the engine enough to assemble hardware as e and torque Referto paragraph 4 8 fortorque values 6 Remove chains from the lift eyes PID UG0130 AND HIGHER 1 Locknut 4 Spacer 2 Snubbing Washer 5 Flat Washer 3 Shockmount 6 Screw Figure 4 7 Engine Shockmounts 4 7 SERVICING THE ALTERNATOR WARNING Beware of moving V Belt and belt driven components 4 7 1 Preliminary Checks and Tests NOTE Before starting electrical t
50. moving V Belt and belt driven components 2 4 1 Of Operation Units using Figure NOTE In 1997 early production units were retrofitted to move the low oil pressure switch from the wir ing feeding terminal board terminal TB4 to the wiring feeding the safety relay If servicing a unit thatis not wired as shown in Figure 5 2 the unit should be retrofitted Contact Carrier Service Engineering With the glow plug switch GPS held in the pre heat position current flows to the glow plugs GP A second set of contacts also energizes the safety relay S Energizing the safety relay provides a potential circuitto the run winding of the fuel solenoid FS and to the contacts of the heater relay HR The safety relay will not energize and the engine will not start if the high water temperature switch HWT opens to break the safety relay ground connection To start the engine the ignition switch IGN is held in the START position With the switch in the START position current flows to the start solenoid SS and through the SS contacts to the starter motor SM and pull in winding of the fuel solenoid FS T 266 Also a second set of contacts provides power to terminal board terminal TB4 From TB4 power flows to the oil E gauge OPG water temperature gauge heater relay THR and to the safety relay contacts Energizing the heater relay provides a circuit to the fuel heater thermostat FHT while providing power to the saf
51. output is not connected to 12 volt battery Defective charger Battery not connected to charger It is normal to measure 12 volts or less across charger output with no battery connected Low output voltage measured across charger output Reverse polarity connection to bat tery has caused charger to stop charging Internal DC fuse blown and possible damage to current carrying components 3 3 REMEDY REFERENCE SECTION Locate and re move short Internal short Test battery for defect according to battery manufacturer s instructions Replace Reset Using a voltme ter confirm char ger is receiving correct 230v AC voltage If not check input con nections Check output wiring connec tions to battery Replace Check charging leads from char ger to battery Replace T 266 REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECTION 3 4 ALTERNATING CURRENT GENERATOR No voltage Low voltage Fluctuating voltage M ay be indi cated by flickering lights M echanical Noise Generator frame produces shock when touched T 266 Loss 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 Engine M anual Loo
52. rder to supply power to the refrigera 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 the cooling system CAUTION Always cover the engine inlet tube while the air cleaner is being serviced CAUTION Do not underfill or overfill the cups Overfilling of cups means loss of capacity and underfilling means lack of filtering efficiency CAUTION Continued operation with failed shockmounts may result in engine or generator damage CAUTION The rotor should not be pulled out from the alternator more than 0 75 inches Damage to the bearing and windings may result T 266 S afety ii TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY SUMMARY awn asd e Veo Ree E RO ER aie Safety i GENERALI SAFETY NOTIGES eR MPa em S afety FIRST AID tee Ga CB EI NEEDS Safety i OPERATING PRECAUTIONS erc Me bete Safety i MAINTENANCE PRECAUTIONS nea esee Hehe Safety i SPECIFIC WARNING AND CAUTION STATEMENTS sssssssess e nnn Safety i DESCRIPTION rro tei eR ine v DECANO I oC UR CUR CR US E A 1 1 Id UINTRODUCTION ekbenvRi quer Erbe ev p DER CE paa CEDE EE DUREE 1 1 12 CONFIGURATION IDENTIFICATION Ihe 1 1 L3 ENGINE ec ettam en tte bsc eame Daas
53. re 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 normal operating engine oil pressure Normal oil pressure is 35 to 60 psig 3 3 to 5 2 kg cm 2 Oil Pressure Sender This device see Figure 1 4 senses engine lube oil pressure and transmits a signal to the oil pressure gauge The oil pressure sender is located on the primary oil filter housing 3 Water Temperature Gauge see Figure 1 8 The function of this gauge is to observe water operating temperature The gauge is connected to the water temperature sender 4 Water Temperature Sender This sensing device see Figure 1 2 senses engine water temperature and transmits a signal to the water temperature gauge The water temperature sender is located on the top left hand side ofthe engine below the HWT switch P 9 16 10 oof n 12 11 12 9 13 13 Pa wT fen CONTROL BOX 1 Terminal Block If Equipped 2 Rectifier If Equipped 3 Low Voltage Harness 4 Ground Studs 5 Circuit Breaker CB3 6 Circuit Breaker CB2 7 8 9 10 Ammeter 11 12 PREMOUS DESIGN Heater Relay If Equipped Safety Relay Oil Pressure Gau
54. re 4 10 NOTE Before performing test removal of back cover is required To remove disconnect wires from terminals extending through back cover Remove back cover two screws and reconnect all wires T 266 a With jumper not attached check for battery voltage at terminals A and B Test lamp will be off b Add jumper JU1 between field and ground see Figure 4 10 If 1 5 to 3 0 volts is presentatterminal B and 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 is connected as shown in Figure 4 11 a Start unit and run engine with load With the unit operating placing a load on charging circuit check for nominal system output voltage of between 13 8 14 8 volts for a properly operating charging system Voltages may vary a few tenths of a volt higher or lower due to ambient temperature variations 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 manual o TOGGLE SWITCH TESTI LAMP lt a q q BATTERY AC TAP TACH EXCITE TO OIL PRESSURE SWITCH OR TOGGLE SWITCH INDICATION BATTERY AB VOLTAGE 1 5 TO 3 0 VOLTS WITH TEST LAMP ON 13 5 T0 15 0 VOLTS AB J UMPER ATTACHED ENGINE RUNNING
55. re 5 2 Schematic Diagram For Applicability Refer to Table 1 1 5 3 T 266 460V G CBI R1 GENERATOR CIRCUIT BREAKE CRECEPTACLE TERMINAL BLOCK EN C CONNECTOR oto a2 6 WINDING LAYOUT Figure 5 3 Schematic Diagram 460 Volt Alternating Current Generator For Applicability Refer to Table 1 1 T 266 5 4 230V G R GENERATOR CIRCUIT BREAKER RECEPTACLE pA Sg x A R2 RECEPTACLE CTERMINAL BLOCK CONNECTOR TB oo 10 Sm 6 8 6 5 3 2 WINDING LAYOUT Figure 5 4 Schematic Diagram 230 Volt Alternating Current Generator F or Applicability Refer to Table 1 1 5 5 T 266 LEGEND OPTIONAL ENGINE GROUND CHASSIS GROUND AMMETER 11 ALTERNATOR 12 BATTERY CHARGER 2 BATTERY 4 8 13 CIRCUIT BREAKER 5 11 12 DIODE FUEL HEATER THERMOSTAT FUEL HEATER FUEL SOLENOID FUEL SOLENOID HOLD FUEL SOLENOID PULL GE
56. s covering the diesel engine and Auto Restart Option are also available see the following chart Note all referenced engines have been assembled using the two piece oil pan Equipment Type o Manual 62 03741 CT4 134 DI B Workshop 62 03459 CT4 134 DI B Engine Parts List Manual Form No Covered 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 Chart LEGEND Al 50 Gallon Integral Tank Side Fill Steel Bl 460 Volt A2 50Gallon Integral Tank Top Fill Steel B2 230 Volt A3 65Gallon Integral Tank Steel A4 50 Gallon Remote Tank Steel C1 No Voltmeter Blank Off Plate A5 75 Gallon Remote Tank Steel C2 With Voltmeter Greenband 50 Gallon Remote Tank Aluminium Electrical Wirin Schematic an Diagram Figures Fuel Tank Voltage Voltmeter A2 B2 C2 suc UG0MS 915254 A gt 050026 915253 8 060030 5152 53 t2 060031 5152353 Al Bi 0600 5152 53 060648 5152 53 Bi 0600 5152 53 06018 5152 53 A2 060195 5152 53 060277 5192253 1 1 B1 Bl Bl Bl Bl Cl C2 C1 C2 C2 Al Al Al Al A2 A2 A2 Bl Bl Bl Bl C2 C2 C2 C2 T 266 Table 1 1 Mede
57. s not fractured 2 If cleaner has been dented or damaged check all connections immediately 3 In case of leakage replace necessary parts or gaskets Swelled or distorted gaskets must be replaced b Service Oil Cups Inspectthe oil cups see Figure 4 3 atregular intervals Initially inspect daily or as often as conditions require Never allow more than 1 2 inch 12 7 mm of dirt deposit in the cup More than 1 2 inch accumulation could result in oil and dirt to carry over into the engine causing accelerated engine wear Heavily contaminated oil will not allow the air cleaner to function properly CAUTION Always cover the engine inlettube while the air cleaner is being serviced Stop the engine and remove the oil cups from the air cleaner Dispose of the oil in an environmentally safe manner Remove the inner cup from the oil cup and clean both cups Reassemble and fill both oil cups to the indicated level with oil specified in paragraph 1 11 CAUTION Do not underfill or overfill the cups Overfilling of cups means loss of capacity and underfilling means lack of filtering efficiency 1 Air Inlet Hood 2 Air Cleaner Body 3 Cap Clamp 4 Inner Oil Cup 5 Oil Cup Figure 4 3 Air Filter c Service Body Assembly The lower portion of the air cleaner should be inspected each time the oil cup is inspected or serviced If there is any sign of contaminant buildup or plugging the body assembly should be remove
58. se terminal or load connections Tighten Defective bearing causing uneven air gap 4 5 1 4 5 3 Generator overloaded Clogged ventilating screens High temperature surrounding generator Insufficient circulation A Unbalanced load Balance Dry bearing 4 5 1 4 5 3 Defective bearing Rotor scrubbing on stator Loose laminations Loose or misaligned coupling Static charge Grounded armature of field coil 3 4 SECTION 4 SERVICE AND PREVENTIVE MAINTENANCE 4 1 INTRODUCTION This section covers service for the generator set and general engine servic Refer to the Kubota engine workshop manual refer to section 1 1 for other engine servicing WARNING Beware of moving V belt and belt driven components 4 2 PREVENTIVE MAINTENANCE SCHEDULE A tabular listing of the recommended preventative activities and schedule is provided in able 4 1 4 3 BATTERY SERVICE When replacing the battery note if the unit was supplied with a matt in the battery tray If so equipped the matt must 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 next to the injection pump The fuel system is a closed circuit which will require bleeding if loss of fuel has occurred To fill and bleed the system do the following bleed valve Red see Figure 1 3 counter clockwise until fully opened b Turn the top of the manual p
59. tart stop switches are turned off and the negative battery terminal has been disconnected Always work in pairs Never work on the equipment alone In case of severe vibration or unusual noise stop the unit and investigate MAINTENANCE PRECAUTIONS Be sure power is turned off and the negative battery cable is disconnected before working on generator set Do notbypass any electrical safety devices e g bridging an overload orusing any sortof jumper wires P roblems with the system should be diagnosed and any necessary repairs performed by qualified service personnel In case of electrical fire open circuit switch and extinguish with gt never use water Fuel Tanks present explosion fire and rupture hazards even if liquid fuel has been drained Do notattemptany repairs especially repairs using flame welder or torch unless you haveen properly trained and the tank has been emptied of liquid fuel and fuel vapors and the tank is properly ventilated UNIT LABEL IDENTIFICATION To help identify the hazard labels on the Unit and explain the level of awareness each one carries explanations with appropriate consequences are provided below DANGER indicates an immediate hazard which WILL result in severe personal injury or death WARNING indicates hazards or unsafe conditions which COULD result in severe personal injury or death CAUTION indicates potential hazards or unsafe practices which COULD result in minor personal injury
60. ting Low engine lubricating oil pressure switch Auto Cos kac psig High engine cooling water temperature Water temperature switch HWT Au tomato Opens at 230 F 110 C Excessive current draw by the fuel sole noid fuel heater water temperature Circuit breaker CB 2 gauge oil pressure gauge or total time Automatic reset meter Trips at 30 amps GLOW PLUGS Excessive current draw on glow plug cir Circuit breaker CB 3 BATTERY CHARGER Excessive current draw on 230 volt feed Circuit breaker CB 5 GENERATOR Circuit breaker CB 1 460 volt Trips at 26 amps E ed diat Manual reset 460 vac Circuit breaker 4 230 volt Trips at 48 amps Manual reset 230 vac 1 10 UNIT SPECIFICATIONS Nominal Tank Sizes Fill Capacity Draw Capacity 50 Gallon Integral Steel 57 6 Gallon 50 Gallon a Fuel Tanks 55 Gallon Remotej 56 55 Gallon Remote Aluminum _ 85 Gallon Remote see 80Gallon _ on Allows for DOT require Batery BEIGE Generator A C 285 lb 129 kg 2 a Engine Dry without Accessories 418 Ib 189 5 kg Approximate Unit with integral 50 gal tank dry 1370 Ib 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 1 Cylinders Number d Displacement 134 cubic inches 2 2 liters e Firing Order 1 3 4 2 T 266 1 10 1 11 ENGINE DAT
61. tion as shown Remove brush assembly if necessary 4 11 T 266 Continuity Continuity No Circuit No Circuit No Circuit No Circuit CONTINUITY CHECK 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 replace entire rotor assembly T 266 4 7 7 Alternator Installation a b Make sure negative battery terminal is disconnected Install alternator to mounting bracket with the alternator pivot bolt and adjustment arm bolt loosely in position Place V belt on alternator sheave 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 sheave and the driving sheave must be in ine Pivot alternator to place tension on belt For correct belt tension see paragraph 4 4 5 Tighten pivot and adjustment bolts Connect wiring to alternator g Connect battery cable Start unit and check for output per paragraph 4 7 4 Test No 3 4 8 UNIDRIVE TORQUE REQUIREMENTS Extensive damage may occur if the proper hardware is not used and or proper procedures are not followed when working with the unidrive assembly Periodic inspection of hardware and bolt torque is recommended to ensure the integrity of the unidriv
62. val 4 A forward diode should have a low resistance when the of an ohm meter is connected to the exciter rotor lead connection anode and the to the diode bridge cathode and a high resistance when the polarity of the ohmmeter is reversed 5 reverse diode should have a high resistance when the of an ohm meter is connected to the exciter rotor lead connection anode and the to the diode bridge cathode and a low resistance when the polarity of the ohmmeter is reversed 6 If both resistances are high or both are low then the diode is defective and the diode assembly should be replaced EE eae EN ii Sm E Eg ssl 4 7 1 Diode Assembly 2 Diode Bridge 3 Exciter Rotor Lead Connection 4 Alternator Rotor Lead Connection Figure 4 5 A C Generator Rectifier Assembly 4 5 3 Bearing Replacement Factory lubricated shielded bearings will normally provide years of trouble free service when operated under normal conditions Excessive bearing load and adverse environment conditions will greatly shorten bearing life To remove the bearings do the following 1 Remove bearing cover See Figure 4 6 2 bearing with the use of a bearing or wheel puller 3 Install new bearing Ball bearings are pre lubricated and require no further lubrication for the life of the bearing 4 Coat mating surface of bearing cover flange with anti corrosion compound Tef Gel Carri
63. with the responsibility of providing the air cleaner equipment with regular maintenance accordance with the instructions 1 3 2 Lube Oil Filter Arrangement The engine lubricating oil filter may be mounted in a horizontal or vertical arrangement Also an additional by pass filter may be supplied Flow through the by pass filter is from the standard filter with return to the oil pan Filter arrangements are shown in Figure 1 4 1 3 3 Fuel System The fuel system is fitted with a filter which also acts as a water separator The filter may also be fitted with an 1 Fuel Tank Separator optional heater The fuel system is shown in Figure 1 3 2 Fuel Supply Line 5 Injection Pump 14 ENGINE SCREW THREADS 3 Mechanical 6 Injector Nozzles Fuel Pump Engine 7 Fuel Bleed Valve All threads used on the engine are metric except the oil 4 Fuel Filter amp Water 8 Fuel Return Line Nee which is American Standard Pipe Thread NPT Figure 1 3 Fuel System Diagram HORIZONTAL ARRANGEMENT Joa BY PASS ARRANGEMENT If Equipped ae 5 VERTICAL ARRANGEMENT 1 Oil Pressure Switch 5 By Pass Oil Filter 2 Oil Pressure Sender 6 Oil Pan 3 Oil Filter Primary 7 By Pass Oil Return 4 By Pass Oil Supply Figure 1 4 Lube Oil T 266 1 6
64. wo generator leads L1 L2 and L3 while generator is running Do not make a positive connection but rather touch the leads together until the generator voltage begins to rise and then remove It is suggested that a 30 ampere fuse be inserted in the circuit to prevent any damage in case the build up voltage is not removed quickly enough Reflash field if generator output voltage does not build up b Winding Insulation Testing Continuity test results for the stator winding tests are provided on the following table T5 T6 TTS Infinite 0 no resistance closed circuit amp resistance open circuit c Diode Testing The rectifier diode assemblies can be tested and if damaged replaced Over current over voltage over speed or reverse currents can damage the assembly or diodes To remove the diode assemblies and perform diode testing do the following 1 Remove the bearing cover by removing the four bolts see Figure 4 6 Both the bearing and diode assemblies will be visible 2 Mark and disconnect the alternator rotor wires atthe rectifier screw terminals Note that the terminals are marked with red paint for the forward diode assembly and black for the reverse diode assembly Mark and disconnect the exciter leads from the double spade terminals See Figure 4 5 3 Remove the two capscrews which secure each diode assembly to the spider Once this procedure is complete the diode assemblies are free for remo

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