T-247-05

ModeI
69GC15-164
Carr|er Trans|co|d D|v|s|on, Carr|er Corporat|on, P.O. Box 4805, Syracuse, N.Y. 13221
SERVICE MANUAL
OPERATION AND
DIESEL DRIVEN GENERATOR SET
MODEL
69GC15-164
 Carr|er Corporat|on 1994  Pr|nted |n U. S. A. 1294
i
TABLE OF CONTENTS
Section Page
1 DESCRIPTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 !nìroducìion 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 SaIeìy Ðevices 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 \niì SpeciIicaìions 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 £ngine Ðaìa 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 £ngine Screw Threads 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.ß £ngine Air Sysìem 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Operaìing ConìroÌs And !nsìrumenìs 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.1 !nìroducìion 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.2 ConìroÌ PaneÌ And ReÌaìed Componenìs 14 . . . . . . . . . . . . . . . . . . . . . . .
1.7.3 Proìecìive Ðevices 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Main AÌìernaìor (AC Ceneraìor) 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.1 PrincipÌe OI Operaìion 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.2 AC Ceneraìor (Main AÌìernaìor) Circuiì Ðiagram 1ß . . . . . . . . . . . . . . .
1.9 Baììery Charging Sysìem ß9CC151ß4, 1, 2 1ß . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1O Baììery Charging Sysìem ß9CC151ß43, 4 1ß . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.11 Iube OiÌ And FueÌ FÌow Ðiagrams 1ß . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 OPERATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Ceneraìor Seì !nsìaÌÌaìion And RemovaÌ 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1 Pin Mounìing 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 PreTrip !nspecìion 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Sìarìing And Sìopping !nsìrucìions 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 ConìroÌ Circuiì Operaìion 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TROUBLESHOOTING 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 ÐieseÌ £ngine 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 £ngine WiÌÌ Noì Sìarì 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 £ngine Sìarìs Then Sìops 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.3 Sìarìer Moìor MaÌIuncìion 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.4 MaÌIuncìion !n The £ngine Sìarìing Circuiì 32 . . . . . . . . . . . . . . . . . . . . .
3.1.5 MisceÌÌaneous £ngine TroubÌeshooìing 32 . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Baììery Charger (SoÌid Sìaìe) ß9CC151ß4, 1, 2 33 . . . . . . . . . . . . . . . . . . . . . . .
3.3 Baììery Charger (SoÌid Sìaìe) ß9CC151ß43, 4 33 . . . . . . . . . . . . . . . . . . . . . . . .
3.4 AC BrushÌess Ceneraìor (Main AÌìernaìor) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
TABLE OF CONTENTS {CONTINUED)
Section Page
4 SERVICE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Mainìenance ScheduÌe 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 ÐaiÌy Mainìenance 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Firsì 4OO Hour Mainìenance 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 £very 1OOO Hour Mainìenance (NormaÌ Operaìing Condiìions) 41 . . . .
4.1.4 £very 3OOO To ßOOO Hour Mainìenance 41 . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Priming The FueÌ Sysìem 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 £ngine Service And Componenìs 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 CooÌing Sysìem 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Iube OiÌ FiÌìers 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Servicing The FueÌ SoÌenoid And Iinkage 42 . . . . . . . . . . . . . . . . . . . . . . .
4.3.4 Ad|usìing £ngine Speed 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.5 £ngine Air CÌeaner 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.ß £ngine Crankcase Breaìher 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.7 Servicing CÌow PÌugs 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.8 Servicing FueÌ Pump 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Servicing And Ad|usìing \BeÌì 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Waìer Pump \BeÌì 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Servicing The Ceneraìor (Main AÌìernaìor) 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Prevenìive Mainìenance And Operaìing Precauìions 44 . . . . . . . . . . . . .
4.5.2 !nsìaÌÌaìion And RemovaÌ 4ß . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.ß RepÌacing Shockmounìs 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.ß.1 RepÌacemenì Criìeria 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.ß.2 Shockmounì RepÌacemenì 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Mainìenance OI Painìed SurIaces 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 \nidrive Torque Requiremenìs 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 ELECTRICAL WIRING SCHEMATIC & DIAGRAM 5-1 . . . . . . . . . . . . . . . . . . . . .
5.1 !nìroducìion 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
LIST OF ILLUSTRATIONS
Figure Page
11 Ceneraìor Seì Fronì \iew Wiìh Cover Removed 12 . . . . . . . . . . . . . . . . . . . . . . .
12 ConìroÌ Box And Cauge PaneÌ 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 £ngine Air CÌeaner 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 Main AÌìernaìor (AC Ceneraìor) 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 AC Ceneraìor Circuiì Ðiagram 1ß . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1ß Iube OiÌ FÌow Ðiagram 1ß . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 FueÌ Sysìem Ðiagram 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 FueÌ Sysìem Ðiagram ß9CC151ß43, 4 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 Pin Mounìing 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 FueÌ SoÌenoid AssembÌy 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 Speed Ad|usìmenì 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 Air CÌeaner 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 £ngine Crankcase Breaìher 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 MechanicaÌ FueÌ Pump 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4ß RecìiIier RemovaÌ 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 AC Ceneraìor (RecìiIier AssembÌy) 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 Ðiode Tesìing 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 Shockmounì !nsìaÌÌaìion 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41O \nidrive Torque Requiremenìs 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51 £ÌecìricaÌ Wiring Schemaìic & Ðiagram
(ModeÌs ß9CC151ß4 & ß9CC151ß41) 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52 £ÌecìricaÌ Wiring Schemaìic & Ðiagram
(ModeÌ ß9CC151ß42) 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53 £ÌecìricaÌ Wiring Schemaìic & Ðiagram
(ModeÌ ß9CC151ß43 5ß . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54 £ÌecìricaÌ Wiring Schemaìic & Ðiagram
(ModeÌ ß9CC151ß44) 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES
Table Page
11 ModeÌ Charì 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 SaIeìy Ðevices 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
WARNING
Beware of moving V-Belts and belt driven
components.
This manuaÌ conìains Operaìing Ðaìa, £ÌecìricaÌ
!nIormaìion, and Service !nsìrucìions Ior ìhe dieseÌ
generaìor seì shown in TabÌe 11. (See ÌeIì side oI uniì Ior
seriaÌ/modeÌ number pÌaìe.) SeparaìeÌy bound manuaÌs
covering ìhe CT4134Ð! dieseÌ engine Ior ìhe dieseÌ
driven generaìor seìs are aÌso suppÌied, see charì beÌow.
MANUALl EQUIPMENT TYPE OF
FORM NO. COVERED MANUALlFORM
62-03459 CT4-134-D| Eng|ne Parts L|st
62-03741 CT4-134-D| Workshop Manua|
The dieseÌdriven generaìor seìs are inìended Ior
Ironì mounìing upon a reIrigeraìion uniì. They provide a
consìanì eÌecìricaÌ power suppÌy Ior ìhe operaìion oI an
aÌÌeÌecìric reIrigeraìion uniì.
Iocaìed inside ìhe Irame are ìhe dieseÌ engine, AC
generaìor (main aÌìernaìor), conìroÌ and moniìoring
cabineì, sìarìing baììery, 12 vdc soÌid sìaìe baììery
charger, and oìher necessary accessory componenìs Ior
proper uniì operaìion.
For power, ìhe Carrier TransicoÌd ModeÌ
CT4134Ð!, verìicaÌ inÌine, Iour cyÌinder dieseÌ engine
is used. The engine is equipped wiìh gÌowpÌugs (used as a
sìarìing aid), ¨spinon` Ìube oiÌ and IueÌ IiÌìers Ior easier
IiÌìer changes. AÌÌ reIerences ìo ìhe engine are viewed
Irom ìhe IÌy wheeÌ end.
£ÌecìricaÌ power is generaìed by a Iima 15 KW,
brushÌess, singÌe bearing ACgeneraìor. The generaìor is
coupÌed direcìÌy ìo ìhe engine IÌywheeÌ. The generaìor
provides a consìanì 4ßO vac, 3 phase, ßO herìz eÌecìricaÌ
suppÌy.
The waìer pump and ìhe radiaìor cooÌing Ian are
beÌìdriven Irom ìhe engine crankshaIì sheave.
1.2 SAFETY DEVICES {Refer to Table 1-2)
Sysìem componenìs are proìecìed Irom damage
caused by unsaIe operaìing condiìions by auìomaìicaÌÌy
shuììing down ìhe dieseÌ engine when such condiìions
occur. This is accompÌished by ìhe saIeìy devices CS2,
HWT or !OF. These saIeìy devices moniìor sysìem
operaìing condiìions and open a seì oI eÌecìricaÌ conìacìs
when an unsaIe condiìion occurs. Opening one or more
oI ìhese saIeìy swiìch conìacìs wiÌÌ deenergize ìhe run
conìroÌ reÌay. This, in ìurn, opens a seì oI KCKconìacìs ìo
deenergize ìhe IueÌ soÌenoid.
Ðeenergizing IueÌ soÌenoid reÌeases ìhe sìoprun
Ìever ìo ìhe 5TOF posiìion, shuììing oII ìhe IueÌ suppÌy ìo
ìhe engine, ìhus sìopping ìhe engine.
The AC generaìor and ìhe gÌow pÌug circuiì are
proìecìed by circuiì breakers (Ìisìed beÌow) buì wiÌÌ noì
shuì down ìhe engine iI an overÌoad occurs.
Table 1-1. Model Chart
ModeI No. Engine
CT4-134DI
SoIid State
Battery Charger
DuaI FueI
Gauges
FueI Tank
120 U.S. GaIIons
69GC15-164 X X --- X
69GC15-164-1 X X X X
69GC15-164-2 X X X X
69GC15-164-3 X X X X
69GC15-164-4 X X X X
Table 1-2. Safety Devices
12
Unsafe Condition Safety Switch Switch Setting
a. Engine
1. Low eng|ne |ubr|cat|ng 1. O|| pressure sw|tch (LOP) --- 1. Opens be|ow 15 ps|g
o|| pressure Automat|c reset (1.05 kg/cm)
2. H|gh eng|ne coo||ng 2. Water temperature sw|tch (HWT) --- 2. Opens above 230 
water temperature Automat|c reset 5F (110  3C)
3. Excess|ve current draw 3. C|rcu|t breaker (CB-2) --- 3. Tr|ps at 20 amps
by FS, HWT, L1, OPG, Automat|c reset
WTG, RCR or TT
4. Excess|ve current draw 4. C|rcu|t breaker (CB-4) --- 4. Tr|ps at 30 amps
by battery charger Automat|c reset
b. GIow-PIugs
1. Excess|ve current draw 1. C|rcu|t breaker (CB-3) --- 1. Opens at 45 amps
on g|ow p|ug c|rcu|t Automat|c reset
c. Generator
1. Excess|ve current draw 1. C|rcu|t breaker (CB-1) --- 1. Tr|ps at 25 amps
by generator Manua| reset (460 vac)
1. Fue| Gauge
2. Fue| F|||
3. Battery (BAT)
4. A|r C|eaner
5. Fue| F||ters
6 Battery Charger
(Located on top o| generator
--- 69GC15-164-3, -4)
7. Mu|||er
8. Fue| So|eno|d (FS)
9. Mechan|ca| L||t Pump
10. Fue| B|eed va|ve
11. Rad|ator Cap
12. Contro| Box and Pane|
13. Power Receptac|e
14. Lube O|| D|pst|ck
15. Starter Motor (SM)
16. Rad|ator Over||ow Tank
17. A-C Generator
18. O|| Pressure Sw|tch (LOP)
19. O|| Pressure Gauge
20. Lube O|| F||ter
21. Water Temperature Gauge(WTG)
22. Water Separator
23. Fue| Shut-O|| va|ve
24. Generator Term|na| Box
Figure 1-1. Generator Set --- Front View with Cover Removed
1 2 3 4 5 6 7 8 9 10 2 11
12 13 14 15 16 17,18 19 20 21 22 24 23
13
1. Battery Charger (B)
(Located beh|nd box |or
mode|s 69GC15-164, -1, -2)
2. G|ow P|ug Sw|tch (GPS)
3. |gn|t|on Sw|tch (|GN)
4. C|rcu|t Breaker
Tr|p |nd|cator (L1)
5. Ammeter (A)
6. Tota| T|me Meter (TT)
7. C|rcu|t Breaker (CB-1)
8. C|rcu|t Breaker (CB-2)
9. C|rcu|t Breaker (CB-3)
10. Run Contro| Re|ay (RCR)
11. C|rcu|t Breaker (CB-4)
1
Figure 1-2. Control Box and Gauge Panel
2
3
4
5
6
7
8
9
10
11
1.3 UNIT SPECIFICATIONS
a. Unit Weight Approx.
2ß9O Ìb (1223 kg) wiìh IueÌ and baììery
b. Engine {Dry) --- with Accessories
421 Ìb (191 kg)
c. A-C Generator
225 Ìb (1O2 kg)
d. Fuel Tank Capacity
!IquId: 12ß \.S. CaÌÌons (477 Ìiìer)
!raw: 119.5 \.S. CaÌÌons (452.4 Ìiìer)
1.4 ENGINE DATA
a. Bore/Stroke
CT4134!1 ]122û3):
3.43 in. (87 mm) /3.ß4 in. (92.4 mm)
b. Compression Ratio
CT4134!1 ]122û3):
2O.5:1
c. Cooling System
Ca¡arIì):
8 \.S. quarìs (7.57 Ìiìers) incÌudes 1 quarì
(O.94ß Ìiìer) in cooÌanì recovery boììÌe.
(ReIer ìo secìion 4.3.1)
T)¡r oI AnìI!rrrzr:
£ìhyÌene CÌycoÌ 4 quarìs (3.78 Ìiìers)
Waìer 4 quarìs (3.78 Ìiìers)
\se a Ìow siÌicaìe anìiIreeze meeìing CM
speciIicaìions CM ßO38M or equaÌ.
Waìrr Trm¡rraìurr 5wIìrÞ 5rììIng:
Opens 23O 5F (11O 3C)
Reseìs 2OOF (93C) minimum
TÞrrmo·ìaì:
Sìarìs ìo Open 177 ìo 182F (8O ìo 84C)
FuÌÌy Open 2O3F (95C)
d. Cylinders {Number)
Four
e. Displacement
CT4134!1 ]122û3):
134 cu. in. (2.2 Ìiìers)
f. Firing Order
1342
g. Fuel
WInìrr: ÐieseÌ No. 1
5ummrr: ÐieseÌ No. 2
h. Glow Plug Amperage
7.5 amps per pÌug aì 12 vdc
i. Horsepower
CT4134!1 ]122û3):
33.O hp @ 18OO rpm
j. Lubrication System
OII Frr··urr:
4O ìo ßO psig (3.8 ìo 5.2 kg/cm)
OII Frr··urr 5wIìrÞ 5rììIng CIo·r·:
15 psig (2.O8 kg/cm)
Ca¡arIì):
2O \.S. quarìs (18.9 Ìiìers)
TImr Irìwrrn OII CÞangr·:
Firsì 4OO Hours, ìhereaIìer every 1OOO Hours
(maximum)
14
OII !r+rI 1ndIraìor:
Ðipsìick in oiÌ pan
!uIr OII 5¡rrIIIraìIon:
\se a heavy duìy Ìubricaìing oiÌ conIorming ìo
American PeìroÌeum !nsìiìuìe (AP!) Service CÌassiIica
ìion CÐ (ÐS).
!uIr OII 1I·ro·Iì):
Outdoor Temperature
Fahrenheit Centigrade SAE
Be|ow 32 0C 10W or 10W30
32 to 77F 0 to 25C 20
Over 77F Over ÷25C 30 or 15W40
1.5 ENGINE SCREW THREADS
AÌÌ ìhreads used on ìheModeÌ CT4134Ð! engine
are meìric excepì ìhe oiÌ drain pÌug which is American
Sìandard Pipe Thread (NPT).
1.0 ENGINE AIR SYSTEM
1
2
3
1. Pre-C|eaner
2. Ejected Dust
3. Dura|||e F||ter
Figure 1-3. Engine Air Cleaner
CÌean air is suppÌied ìo ìhe engine ìhrough ìhe air
cÌeaner. (See Figure 13) The air is necessary Ior
compÌeìe combusìion and scavenging oI ìhe exhausì
gases. As ìhe engine pisìon goes ìhrough ìhe inìake
sìroke, ìhe pisìon draws cÌean Iresh air down inìo ìhe
cyÌinder Ior ìhe compression and power sìrokes. As ìhe
engine goes ìhrough iìs exhausì sìroke, ìhe upward
movemenì oI ìhe pisìon Iorces ìhe hoì exhausì gases ouì
oI ìhe cyÌinders ìhrough ìhe exhausì vaÌves and ìhe
exhausì maniIoÌd. !I ìhe air IiÌìer is aÌÌowed ìo become
dirìy, ìhe operaìion oI ìhe engine wouÌd be impaired.
BÌowby gases Irom ìhe dieseÌ engine crankcase are
inìroduced in ìhe air inìake maniIoÌd ìhrough ìhe
crankcase breaìher. ThereIore, ìhe IiÌìer musì be kepì
cÌean and air resìricìion reduced ìo a minimum. A dry
ìype air cÌeaner is used wiìh ìhis uniì. Air passes ìhrough
ìhe screen where dirì or dusì in ìhe air is removed beIore
iì enìers ìhe engine. As ìhe dusì and dirì accumuÌaìe, ìhe
IiÌìer shouÌd be changed periodicaÌÌy. !I ìhe IiÌìer is noì
changed, iì wiÌÌ be bÌocked so ìhaì iì cannoì eIIecìiveÌy
remove ìhe dirì and dusì Irom ìhe air passing over ìhe
screens. The air cÌeaner is equipped wiìh \acuaìor
TM
\aÌve which conìinuousÌy expeÌ dusì and moisìure. On
cÌeaners equipped wiìh dusì cup, ìhe cup is empìied as
dusì accumuÌaìes.
a. Pre-cleaner
The iÌÌusìraìion shows a Iin which gives highspeed
roìaìion ìo ìhe inìake air, and separaìes a Ìarge porìionoI
ìhe dusì Iromìhe air by cenìriIugaÌ acìion. The pÌasìic Iin,
ìhe eÌemenì, and ìhe gaskeì are viìaÌ parìs oI ìhe cÌeaner
and are designed inìo a singÌe repÌaceabÌe assembÌy. This
design Ieaìure assures conìinued high perIormance oI
ìhe cÌeaner.
b. Ejected dust
The dusì is swepì ìhrough a sÌoì in ìhe baIIÌe and
coÌÌecìed in ìhe dusì cup or \acuaìor
TM
\aÌve body.
c. Duralife filter
The smaÌÌ porìion oI ìhe dusì remaining in ìhe
precÌeaned air is removed by ìhe ÐuraÌiIe eÌemenì. The
eÌemenì is chemicaÌÌyìreaìed and ovencured Ior resis
ìance ìo oiÌ and waìer. PerIoraìed sìeeÌ supporìs ìhe
eÌemenì inside and ouì and, ìogeìher wiìh rigid meìaÌ end
caps, provides sìrucìuraÌ rigidiìy ìo ìhis viìaÌ parì oI ìhe
cÌeaner. The eÌemenì can be cÌeaned Ior reuse by one oI
severaÌ recommended processes. (ReIer ìo secìion 4.3.5)
1.7 OPERATING CONTROLS AND
INSTRUMENTS
1.7.1 Introduction
Mosì componenìs required Ior moniìoring and con
ìroÌÌing ìhe uniì are Ìocaìed in ìhe conìroÌ box and conìroÌ
paneÌ, ìhe remaining componenìs and ìheir Ìocaìions are
aÌso described beÌow.
1.7.2 Control Panel and Related Components
a. Gauges and Senders
1. Ammrìrr ]A)
The ammeìer indicaìes ìheraìe oI discharge or charge
oI ìhe baììery charging sysìem composed oI ìhe baììery
and ìhe soÌid sìaìe baììery charger. (See Figure 12)
2. OII Frr··urr Caugr
The purpose oI ìhis gauge is ìo observe normaÌ
operaìingengineoiÌ pressure. NormaÌ oiÌ pressureis 4Oìo
ßO psig (2.8 ìo 4.2 kg/cm). (See Figure 11)
3. Waìrr Trm¡rraìurr Caugr ]WTC)
The Iuncìion oI ìhis gauge is ìo observe waìer
operaìing ìemperaìure (18O ìo 2O5F=82 ìo 94C). The
gauge is connecìed ìo a waìer ìemperaìure sensing
device. !I ìhe gauge or sender IaiÌs, boìh musì be repÌaced
(kiì avaiÌabÌe). (See Figure 11)
4. Waìrr Trm¡rraìurr 5rndrr
This sensing device senses engine waìer ìemperaìure
and ìransmiìs a signaÌ ìo ìhe waìer ìemperaìure gauge.
The waìer ìemperaìure sender is Ìocaìed on ìhe ìop,
Ironì, righì side oI ìhe enginebeÌowìheHWTswiìch. The
waìer ìemperaìure gauge and sender boìh musì be
repÌaced iI eiìher componenì IaiÌs (kiì avaiÌabÌe).
15
b. Indicator Light
1. CIrruIì SrraIrr TrI¡ !IgÞì ]!1)
This Ìighì (red) may be checked (uniì noì running) by
pÌacing ìhe circuiì breaker (CB1) in ìhe oII posiìion and
aì ìhe same ìime moving ìhe igniìion swiìch ìo ìhe run
posiìion. When ìhe circuiì breaker is in ìhe oII posiìion, a
seì oI conìacìs cÌose ìo compÌeìe a circuiì ìo ìhe Ìighì.
!I ìhe uniì is running and ìhe circuiì breaker ìrips, ìhe
Ìighì wiÌÌ iÌÌuminaìe ìo signaÌ ìhe operaìor oI a maÌIunc
ìion wiìh ìhe generaìor. (See Figure 12)
c. Meter
1. ToìaI TImr Mrìrr ]TT)
This meìer designaìes ìhe ìoìaÌ hours and provides an
accuraìe readouì oI accumuÌaìed engine running ìime. This
daìa can be used ìo esìabÌish ìhe proper periodic mainìe
nance scheduÌe. (ReIer ìo secìion 4.1) (See Figure 12)
d. Switches
1. CIow FIug 5wIìrÞ ]CF5)
The gÌowpÌug swiìch (momenìary conìacì ìype), when
heÌd in ìhe \P posiìion (preheaì), permiìs baììery
currenì (approximaìeÌy 7.5 amps per pÌug aì 12 vdc) ìo
IÌow ìo ìhe gÌow pÌugs in ìhe engine ìo preheaì ìhe
combusìion chambers. The gÌow pÌugs are Ìocaìed under
ìhe IueÌ in|ecìors. When sìarìing engine, iì is necessary ìo
conìinue ìo hoÌd ìhe gÌow pÌug swiìch in ìhe \P posiìion
unìiÌ ìhe engine has deveÌoped suIIicienì oiÌ pressure ìo
cÌose ìhe oiÌ pressure saIeìy swiìch. (See Figure 12)
2. 1gnIìIon 5wIìrÞ ]1CA)
The igniìion swiìch (momenìary conìacì ìype in ìhe
sìarì posiìion), when heÌd in ìhe START (igniìion)
posiìion energizes ìhe sìarìer moìor soÌenoid which in
ìurn aÌÌows ìhe sìarìer moìor ìo crank. (See Figure 12)
1.7.3 Protective Devices
a. Circuit Breakers
1. AC Crnrraìor CIrruIì SrraIrr ]CS1)
This device ìrips aì 25 amps ìo proìecì ìhe AC
generaìor (main aÌìernaìor) Irom excessive currenì
(amperage) draw. When ìhe circuiì breaker ìrips, ìhe
generaìor power ouìpuì ìo ìhe reIrigeraìion uniì ceases.
The dieseÌ engine wiÌÌ conìinue ìo run (wiìh normaÌ
engine operaìion), buì ìhe voÌìmeìer wiÌÌ indicaìe no
ouìpuì and ìhe circuiì breaker indicaìor Ìighì wiÌÌ be
iÌÌuminaìed. (See Figure 12)
2. CIrruIì SrraIrr ]CS2)
The circuiì breaker is Ìocaìed in ìhe righìhand
boììom corner oI ìhe conìroÌ box. This device prevenìs
excessive currenì draw by ìhe componenìs FS, HWT, I1,
OPC, RCR, WTC, and TT. The circuiì breaker opens aì
2O amps and wiÌÌ auìomaìicaÌÌy reseì.
3. CIrruIì SrraIrr ]CS3)
The circuiì breaker is Ìocaìed above CB2 in ìhe
conìroÌ box. This device prevenìs excessive currenì draw
by ìhe gÌowpÌug circuiìry. The circuiì breaker opens aì 45
amps and wiÌÌ reseì auìomaìicaÌÌy.
4. CIrruIì SrraIrr ]CS4) ]69CC1J164, 1, 2)
The circuiì breaker is Ìocaìed above ìhe run conìroÌ
reÌay in ìhe conìroÌ box. This device prevenìs excessive
currenì draw by ìhe baììery charging ìransIormer Ìine
voÌìage. The circuiì breaker opens aì 3O amps and wiÌÌ
reseì auìomaìicaÌÌy.
b. Switches
1. OII Frr··urr 5wIìrÞ ]!OF)
This swiìch, seì ìo open beÌow 15 psig (1.O5 kg/cm)
wiÌÌ auìomaìicaÌÌy sìop ìhe engine upon Ìoss oI oiÌ
pressure. This swiìch is Ìocaìed above ìhe oiÌ IiÌìer. (See
Figure 11) When ìhe swiìch opens, ìhe run conìroÌ reÌay
(RCR) coiÌ is deenergized andìhe RCRconìacìs openìo
deenergize ìhe IueÌ soÌenoid (FS), ìhus sìopping ìhe
engine.
2. Waìrr Trm¡rraìurr 5wIìrÞ ]HWT)
This swiìch, seì ìo open aì 23O  5F (11O  3C),
wiÌÌ auìomaìicaÌÌy sìop ìhe engine upon high waìer
ìemperaìure. The swiìch is Ìocaìed near ìhe ìhermosìaì
housing. When ìhe swiìch opens, ìhe run conìroÌ reÌay
(RCR) coiÌ is deenergized andìhe RCRconìacìs openìo
deenergize ìhe IueÌ soÌenoid (FS), ìhus sìopping ìhe
engine.
1.8 MAIN ALTERNATOR
{A-C GENERATOR)
LIMA
Figure 1-4. Main Alternator {A-C Generator)
1.8.1 Principle of Operation
The MAC (Iima) brushÌess AC generaìor is a
seÌIreguÌaìed, roìaìing IieÌd synchronous uniì wiìh ìhe
roìor having a saÌienì poÌe consìrucìion wiìh amorìisseur
windings. The generaìor sìaìor and exciìer sìaìor are
combined in a common housing. The generaìor IieÌd,
exciìer roìor and roìaìing recìiIier assembÌy are mounìed
on a common shaIì. The ouìpuì oI ìhe exciìer roìor is
appÌied ìo ìhe generaìor IieÌd winding ìhrough a roìaìing,
IuÌÌwave bridge, siÌicone recìiIier uniì.
The exciìer poÌe pieces conìain residuaÌ magneìism,
seììing up Ìines oI Iorce across ìhe air gap ìo ìhe exciìer
armaìure. When ìhe exciìer armaìure begins ìo roìaìe a
voÌìage is induced and currenì IÌow is iniìiaìed in ìhe
exciìer armaìure AC windings. This voÌìage is Ied ìo ìhe
roìaìing recìiIier assembÌy, recìiIied and Ied ìo ìhe
aÌìernaìor IieÌd coiÌs. This ÐC voÌìage is suIIicienì ìo
magneìize ìhe Ìaminaìed aÌìernaìor IieÌd whichwiÌÌ seì up
Ìines oI Iorceacross ìheair gapìo ìheaÌìernaìor sìaìor. As
ìhe generaìor roìor roìaìes a voÌìage wiÌÌ be induced and
currenì wiÌÌ IÌow in ìhe aÌìernaìor sìaìor windings and ìo
ìhe ouìpuì circuiì.
AÌÌ connecìions beìween ìhe exciìer sìaìor windings
and ìhe generaìor sìaìor windings are inìernaÌÌy con
necìed wiìhin ìhe sìaìor housing. OnÌy ìhe ouìpuì power
Ìeads oI ìhe generaìor uniì are broughì ouì ìo ìhe
generaìor ìerminaÌ box.
1ß
1.8.2 A-C Generator {Main Alternator)
Circuit Diagram
FIELD
STATOR
GENERATOR
SHUNT
SERIES
L
O
A
D
ROTOR
EXCITER
RECTIFIER
ASSEMBLY
STATOR
Figure 1-5. A-C Generator Circuit Diagram
Figure 15 shows ìhe inìernaÌ schemaìic diagram oI
ìhe generaìor, exciìer and recìiIier uniì. The generaìor is
a ìhree phase uniì and ìhe exciìer sìaìor and exciìer roìor
aÌso have ìhree phase windings. A porìion oI ìhe exciìer
sìaìor windings is connecìed across a ìapon ìhegeneraìor
sìaìor winding. This exciìer shunì winding provides ìhe
generaìor IieÌd exciìaìion power required Ior ìhe genera
ìor no Ìoad voÌìage. Anoìher porìion oI ìhe exciìer sìaìor
windings is connecìed in series wiìh ìhe ouìpuì oI ìhe
generaìor and provides a compounding exciìaìion char
acìerisìic.
The roìor is, in eIIecì, ìhe secondary oI a roìaìing
currenì ìransIormer inducìion Irequency converìer. The
exciìer roìor ouìpuì voÌìage is appÌied ìo ìhe generaìor
IieÌd windings by a ìhree phase IuÌÌ wave roìaìing siÌicone
recìiIier uniì. The response ìime oI ìhe exciìaìion sysìem
is very Iasì since ìhe exciìer sìaìor carries an aÌìernaìing
currenì corresponding ìo ìhe Ìoad currenì which appears
immediaìeÌy on ìhe exciìer primary. An increase in Ìoad
currenì wiÌÌ cause an immediaìe increase in ìhe exciìer
secondary ouìpuì voÌìagewhichis recìiIiedand appÌiedìo
ìhe generaìor IieÌd windings. The inherenì compounding
characìerisìics oI ìhe exciìaìion sysìem provide exceÌÌenì
voÌìage reguÌaìioneven under heavy overÌoadcondiìions.
1.0 Battery Charging System --- 00GC15-104, -1, -2
The soÌid sìaìe baììery charging sysìem is Ìocaìed on
ìhe conìroÌ box, see Figure 12. This baììery charging
sysìem consisìs oI ìwo secìions, Iirsì, a 1718 voÌì
ìransIormer, ìhaì is powered by ìhe I!MA generaìor.
Second, is a soÌid sìaìe voÌìage reguÌaìor ìhaì recìiIies ìhe
inpuì voÌìage and conìroÌs ìhe ouìpuì voÌìage Ior opìi
mum charging. The baììery charger has a maximum
charge raìe oI 2O amps and is designed noì ìo over charge
ìhe baììery.
1.10 Battery Charging System --- 00GC15-104-3, -4
On modeÌs ß9CC151ß43 and ß9CC151ß44, ìhe
soÌid sìaìe baììery charger is Ìocaìed on ìop oI ìhe
generaìor, nexì ìo ìhe air cÌeaner (see Figure 11). The
charger is powered by ìhe Iima generaìor and ìhis inpuì
is proìecìed by a 3 amp Iuse Ìocaìed on ìhe generaìor
|uncìion box. The baììery charger has a maximumcharge
raìe oI 25 amps and is designed noì ìo overcharge ìhe
baììery.
CAUTION
Observe proper polarity when installing the
battery, the negative battery terminal must be
grounded. Reverse polarity will destroy the
rectifier diodes in the generator sets solid state
battery charging system if a battery charger is
connected in reverse. As a precautionary
measure isolate the battery from the unit as
follows: disconnect negative battery terminal
first, then the positive battery terminal when
charging battery in unit. Once the battery has
been fully charged, connect the positive battery
terminal first, then the negative battery
terminal. NEVER jump start the battery when
its mounted in the unit, this will destroy the
components of the generator sets battery
charger.
1.11 LUBE OIL AND FUEL FLOW
DIAGRAMS
1. Fu|| ||ow o|| |||ter
2. Eng|ne b|ock o||
pump connect|ons
3. O|| pressure gauge
4. O|| pressure sw|tch
1
2
3 4
Figure 1-0. Lube Oil Flow Diagram
17
1. Fue| Tank
2. Fue| Return L|ne
3. |njector Nozz|es
4. |nject|on Pump
5. Fue| F||ters
6. Fue| Warmer
7. Mechan|ca| Pump
8. Stra|ner
9. Water Separator
10. Shut-O|| va|ve
11. Fue| Supp|y L|ne
Figure 1-7. Fuel System Diagram
1 2
3
4
5 6
7 8 9 10 11
1. Fue| Tank
2. Fue| Return L|ne
3. |njector Nozz|es
4. |nject|on Pump
5. Fue| F||ters
6. Mechan|ca| Pump
7. Shut-O|| va|ve
8. Fue| Supp|y L|ne
Figure 1-8. Fuel System Diagram --- 00GC15-104-3, -4
1 2
3
4
5
6
7
8
21
SECTION 2
OPERATION
2.1 GENERATOR SET INSTALLATION AND REMOVAL
2.1.1 Pin mounting
A
A
B
D
C
D
C
Figure 2-1. Pin Mounting
WARNING
To prevent injury, the procedures for installation
and removal of the generator set given below
must be followed.
NOTE
This generaìor seì is equipped wiìh speciaÌ pins
and mounìing boÌìs and can be insìaÌÌed onÌy on
conìainers wiìh maìching insìaÌÌaìion poinìs.
a. Installation:
1. PÌace Iorks inìo Iork pockeìs oI generaìor seì.
Aììach saIeìy chain {A) beìween Iork pockeìs on genera
ìor seì and Iork ìruck. Be sure chain {A) is shorì enough
ìo reìain generaìor seì on Iorks.
2. Iine up generaìor seì wiìh reIrigeraìion uniì
and conìainer. Raise generaìor seì unìiÌ ìop oI seì is
severaÌ inches above ìop edge oI conìainer. Move
generaìor seì againsì conìainer and Ìower inìo posiìion.
1m¡orìanì Two ¡In· {B) mu·ì Ir IuII) rngagrd In
maìIng ÞoIr· In ronìaInrr.
3. Keep Iorks in pockeìs on generaìor seì and
ìighìen mounìing boÌì {C) on each side oI generaìor seì
inìo conìainer Irame.
1m¡orìanì SoIì· mu·ì Ir ìIgÞì and rrìaInIng ¡Iaìr {D)
mu·ì Ir IorIrd Inìo ¡o·IìIon.
4. Remove saIeìy chain {A) beIore removingIorks.
b. Removal:
WARNING
Disconnect power plug before removing generator
set.
1. Move Iorks inìo Iork pockeìs on generaìor seì.
Aììach saIeìy chain {A) beìween Iork pockeìs on genera
ìor seì and Iork ìruck.
2. ReÌease reìaining pÌaìe {D) Irom Ìocking brack
eì on each side oI generaìor seì.
3. Remove mounìing boÌì {C) on each side oI
generaìor seì.
4. Raise generaìor seì severaÌ inches ìo disengage
pins {B) Irom maìing hoÌes and remove Irom conìainer.
2.2 PRE-TRIP INSPECTION
a. Before Starting Generator Set
1. Check engine Ìubricaìion and IueÌ oiÌ IiÌìer
cases, oiÌ Ìines, and connecìions Ior Ìeaks.
(Tighìen connecìions and/or repÌace gaskeìs)
2. Check engine Ìubricaìion oiÌ ÌeveÌ.
(ReIer ìo secìion 1.4.|.)
3. Check engine \BeÌì Ior proper ìension, Iraying
or cracks. Ad|usì beÌì or repÌace.
(ReIer ìo secìion 4.4)
4. Check radiaìor hoses Ior Ìeaks and check
radiaìor cooÌanì ÌeveÌ. (Add premixed 5O/5O anìiIreeze
waìer as required.) ReIer ìo secìion 1.4.c.
5. Check radiaìor coiÌ and generaìor air inìake
screen Ior cÌeanÌiness. (CÌean using compressed air,
reversing ìhe normaÌ air IÌow.)
ß. Check air cÌeaner Ior cÌeanÌiness and cÌean iI
necessary. (ReIer ìo secìion 4.3.5)
7. Ðrain waìer Irom IueÌ ìank sump.
8. FiÌÌ IueÌ ìank wiìh dieseÌ IueÌ.
(ReIer ìo secìion 1.4.g.)
9. Check gÌow pÌug amperage.
(ReIer ìo secìion 1.4.h.)
1O. Check baììery ìerminaÌs Ior cÌeanÌiness and
secureness. (CÌean and coaì wiìh a mineraÌ ìype grease.)
11. Check Ior Ìoose eÌecìricaÌ connecìions.
22
12. Connecì power cabÌe ìo reIrigeraìion uniì. Sìarì
genseì as deìaiÌed in secìion 2.3 and ìhen ìurn reIrigera
ìion uniì on ìo check operaìion.
(ReIer ìo secìion 2.2.b.)
13. Crease FueÌ SoÌenoid pÌunger.
(\se P/N O7OO245OO.)
b. After Starting Generator Set
1. ReIer ìo secìion 2.3 Ior sìarìing and sìopping
insìrucìions.
2. Check ìoìaÌ ìime meìer operaìion.
(Run engine 1O minuìes)
3. Iisìen Ior abnormaÌ bearing noise.
(Main aÌìernaìor)
4. Check IueÌ Ìines, Ìube oiÌ Ìines and IiÌìers Ior
Ìeaks.
5. Check radiaìor and hoses Ior Ìeaks.
ß. Check exhausì sysìem Ior Ìeaks.
7. Check operaìion oI indicaìor Ìighì.
(ReIer ìo secìion 1.7.2.c.)
2.3 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 sìarìing ìhe engine, iì is necessary ìo
conìinue ìo hoÌd ìhe gÌow pÌug swiìch in ìhe \P
posiìion unìiÌ ìhe engine deveÌops suIIicienì oiÌ
pressure ìo cÌose ìhe oiÌ pressure saIeìy swiìch,
energizing and compÌeìing aÌÌ circuiìs Ior uniì
operaìion.
1. HoÌd gÌow pÌug swiìch in ìhe \P posiìion Ior 3O
seconds. (See Figure 12)
NOTE
BeÌow OF, hoÌd gÌow pÌug swiìch Ior ìwo
minuìes, reÌease swiìch Ior 3O seconds and again
hoÌd gÌow pÌug swiìch Ior ìwo minuìes. !I engine
does noì sìarì aIìer 1O seconds cranking, waiì Ior
3O seconds beIore repeaìing sìarìing procedure.
2. Wiìh gÌow pÌug swiìch heÌd in ìhe !F posiìion,
push ìhe igniìion swiìch ìo ìhe 5TAKT posiìion.
3. AIìer engine has sìarìed, conìinue ìo hoÌd ìhe
gÌow pÌug swiìch in ìhe !F posiìion unìiÌ ìhe oiÌ pressure
saIeìy swiìch cÌoses (when engine deveÌops suIIicienì oiÌ
pressure). The gÌow pÌug swiìch wiÌÌ auìomaìicaÌÌy be in
ìhe O!! posiìion when reÌeased.
NOTE
Aì ìhis poinì, observe ìhe ammeìer reading
which shouÌd be posiìive. !I ìhe reading is
negaìive or neuìraÌ, ìhis is an indicaìion oI
improper charging (reIer ìo secìion 3.2).
4. CompÌeìe preìrip inspecìion.
(ReIer ìo secìion 2.2.b.)
b. Stopping Instructions
1. Push igniìion swiìch ìo ìhe O!! posiìion.
2.4 CONTROL CIRCUIT OPERATION
WARNING
Beware of moving V-Belts and belt driven
components.
CAUTION
The generator set circuit breaker must be in the
ON position in order to supply power to the
refrigeration unit.
When ìhe gÌow pÌug swiìch is heÌd in ìhe preheaì
posiìion, currenì IÌows ìo ìhe gÌow pÌugs. The gÌow pÌugs
(sìarìing aids) provide a source oI heaì ìo preheaì ìhe
combusìion chamber during sìarìup. Power aÌso IÌows ìo
ìhe run conìroÌ reÌay which energizes, and cÌoses ìhe KCK
conìacìs. From ìhe reÌay KCK, power IÌows ìhrough ìhe
high waìer ìemperaìure swiìch ìo ground.
!n order ìo sìarì engine, hoÌd ìhe gÌow pÌug swiìch in
ìhe \Pposiìion Ior ìhe recommended ìime as deìaiÌed in
secìion 2.3.a. and ìhen hoÌd ìhe igniìion (SìarìRunOII)
swiìch in ìhe 5TAKT posiìion. Wiìh igniìion swiìch in ìhe
5TAKT posiìion, sìarìer soÌenoid is energized cÌosing
sìarìer moìor conìacìor conìacìs (SS), which energizes
sìarìer moìor. The sìarìer moìor ìurns over ìhe engine
resuÌìing in pumping IueÌ ìo ìhe engine cyÌinders by ìhe
in|ecìion pump. This IueÌ is igniìed by heaì oI compres
sion, ìhus sìarìing ìhe engine. AÌso, run conìroÌ reÌay is
energized aì ìhe same ìime ìo cÌose a seì oI conìacìs and
compÌeìes a circuiì ìo ìhe IueÌ soÌenoid.
When ìhe engine has deveÌoped suIIicienì oiÌ pres
sure, oiÌ pressure saIeìy swiìch conìacìs cÌose ìo mainìain
a circuiì ìo ìhe run conìroÌ reÌay. £nergizing ìhis reÌay
cÌoses (RCR) conìacìs providing a circuiì ìo keep ìhe IueÌ
run soÌenoid energized as Ìong as ìhe saIeìy swiìch
conìacìs remain cÌosed. The gÌow pÌug swiìch is ìhen
reÌeased and ìhe igniìion swiìch is reÌeased ìo ìhe K!A
posiìion. ReÌeasing gÌow pÌug swiìch deenergizes ìhe
gÌow pÌugs.
ToìaÌ ìime meìer is energized simuÌìaneousÌy wiìh ìhe
IueÌ soÌenoid.
Wiìh ìhe engine running, ìhe soÌid sìaìe baììery
charger provides 12voÌì dc power ìo operaìe ìhe conìroÌ
sysìem and charge ìhe baììery.
31
SECTION 3
TROUBLESHOOTING
3.1 DIESEL ENGINE
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
3.1.1 Engine Will Not Start
a. Sìarìer moìor Baììery insuIIicienìÌy charged Charge
wiÌÌ noì crank or Ìow Baììery ìerminaÌ posì or Baììery deIecìive Check
cranking speed. Baììery charger assembÌy deIecìive RepÌace
Bad eÌecìricaÌ connecìions aì sìarìer Correcì
Sìarìer moìor maÌIuncìions 3.1.3
Sìarìer moìor soÌenoid deIecìive £ngine ManuaÌ
Open sìarìing circuiì 3.1.4
!ncorrecì grade oI Ìubricaìing oiÌ
CÌosed IueÌ shuìoII vaÌve Open
b. Sìarìer moìor No IueÌ in ìank 1.4.g.
cranks buì engine Air in IueÌ sysìem 4.2
IaiÌs ìo sìarì Waìer in IueÌ sysìem Ðrain Sump
PÌugged IueÌ IiÌìers RepÌace
FauÌìy IueÌ conìroÌ operaìion 4.3.3
Run conìroÌ reÌay 4.3.3
CÌow pÌug(s) deIecìive 4.3.7
PÌugged IueÌ Ìines ìo in|ecìor(s) £ngine ManuaÌ
c. Sìarìer cranks, £ngine Ìube oiÌ ìoo heavy 1.4.|.
engages buì dies \oÌìage drop in sìarìer cabÌe(s) Check
aIìer a Iew seconds
3.1.2 Engine Starts Then Stops
a. £ngine sìops No IueÌ in ìank 1.4.g.
aIìer severaÌ FauÌìy IueÌ conìroÌ operaìion 4.3.3
roìaìions FueÌ IiÌìer(s) resìricìed RepÌace
Air cÌeaner or hose resìricìed 4.3.5
SaIeìy device open 1.2
Open wiring circuiì ìo run soÌenoid Check
FueÌ soÌenoid Ìinkage disconnecìed 4.3.3
OiÌ pressure swiìch deIecìive RepÌace
CÌosed IueÌ shuìoII vaÌve Open
FueÌ suppÌy resìricìed £ngine ManuaÌ
Ieak in IueÌ sysìem £ngine ManuaÌ
!n|ecìor nozzÌe(s) deIecìive £ngine ManuaÌ
!n|ecìion pump deIecìive £ngine ManuaÌ
32
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
3.1.3 Starter Motor Malfunction
a. Sìarìer moìor Baììery insuIIicienìÌy charged Charge
wiÌÌ noì crank or Baììery cabÌe connecìions Ìoose or oxidized Check
ìurns sÌowÌy Baììery charger assembÌy deIecìive RepÌace
Baììery cabÌes deIecìive RepÌace
Sìarìer brushes shorìed ouì £ngine ManuaÌ
Sìarìer brushes hang up, deIecìive or
have no conìacì £ngine ManuaÌ
Sìarìer soÌenoid damaged £ngine ManuaÌ
!gniìion swiìch deIecìive RepÌace
£ngine Ìube oiÌ ìoo heavy 1.4.|.
b. Sìarìer moìor Pinion or ring gear obsìrucìed or worn £ngine ManuaÌ
ìurns buì pinion
does noì engage
c. Sìarìer moìor !gniìion swiìch deIecìive RepÌace
does noì disengage Sìarìer moìor soÌenoid deIecìive £ngine ManuaÌ
aIìer swiìch has
been reÌeased
d. Pinion does noì ÐeIecìive sìarìer £ngine ManuaÌ
disengage aIìer
engine is running
3.1.4 Malfunction In the Engine Starting Circuit
a. No power ìo Baììery deIecìive Correcì
sìarìer moìor Ioose eÌecìricaÌ connecìions Tighìen
soÌenoid
b. FueÌ soÌenoid Baììery deIecìive Correcì
does noì energize or Ioose eÌecìricaÌ connecìions Tighìen
does noì remain Waìer ìemperaìure saIeìy swiìch open 1.2
energized OiÌ pressure swiìch deIecìive RepÌace
Run conìroÌ reÌay deIecìive 4.3.3
FueÌ soÌenoid deIecìive 4.3.3
!gniìion swiìch deIecìive RepÌace
3.1.5 Miscellaneous Engine Troubleshooting
a. Ioss oI power Resìricìion in air cÌeaner 4.3.5
Air in IueÌ sysìem 4.2
Air venì in IueÌ cap resìricìed CÌean
Resìricìed IueÌ Ìines £ngine ManuaÌ
ÐeIecìive IueÌ in|ecìion pump £ngine ManuaÌ
ÐeIecìive in|ecìor(s) or incorrecì ìype £ngine ManuaÌ
!ncorrecì IueÌ in|ecìion pump ìiming £ngine ManuaÌ
!ncorrecì vaÌve ìiming £ngine ManuaÌ
Poor compression £ngine ManuaÌ
33
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
3.1.5 Miscellaneous Engine Troubleshooting {continued)
b. \ibraìion £ngine shockmounìs deIecìive RepÌace
Poor compression £ngine ManuaÌ
FueÌ soÌenoid or Ìinkage 4.3.3
c. Overheaìing Resìricìion in air cÌeaner 4.3.5
£xhausì pipe resìricìion Remove
Resìricìion in waìer |ackeì Check
Ioose waìer pump \BeÌì 4.4
Resìricìion in radiaìor 4.3.1
CooÌanì ÌeveÌ ìoo Ìow 1.4.c.
ÐeIecìive ìhermosìaì £ngine ManuaÌ
ÐeIecìive waìer pump £ngine ManuaÌ
d. £xcessive crankcase
pressure PÌugged crankcase breaìher Ìine 4.3.ß
3.2 BATTERY CHARGER {SOLID STATE) --- 00GC15-104, -1, -2
Baììery \ndercharged ÐeIecìive cabÌes, dirìy baììery posìs or
corroded ìerminaÌs RepÌace/CÌean
ÐeIecìive ìransIormer
or baììery charger
(Ammeìer indicaìes negaìive) RepÌace
Baììery Overcharged ÐeIecìive baììery charger sysìem Check
excessive use oI waìer.
\oÌìmeìer indicaìes greaìer
ìhan 14.5 voÌìs (connecìed
across baììery wiìh no Ìoad)
wiìh engine idÌing.
3.3 BATTERY CHARGER {SOLID STATE) --- 00GC15-104-3, -4
a. !npuì Iuse/breaker bÌows when Shorì in 12 voÌì wiring causing Iocaìe and
charger is ìurned on overÌoad oI charger remove shorì
b. !npuì Iuse/breaker bÌows repeaìedÌy, !nìernaÌ shorì RepÌace
even wiìh no baììery connecìed
c. Charger does noì ìaper back Bad ceÌÌ in baììery Tesì baììery Ior
in charge deIecì according
ìo baììery
manuIacìurer`s
insìrucìions
ÐeIecìive charger RepÌace
d. Charger does noì charge BÌown inpuì Iuse/breaker RepÌace Iuse
Charger is noì receiving AC inpuì \sing a voÌìmeìer,
conIirm charger is
receiving correcì
AC voÌìage. !I noì
check inpuì
connecìions.
34
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
3.3 BATTERY CHARGER {SOLID STATE) --- 00GC15-104-3, -4 {continued)
Charger`s ouìpuì is noì connecìed Check ouìpuì
ìo 12 voÌì baììery wiring connecìions
ìo baììery.
ÐeIecìive charger RepÌace
e. Iow ouìpuì voÌìage measured Baììery noì connecìed ìo charger. !ì is Check charging
across charger ouìpuì normaÌ ìo measure 12 voÌìs or Ìess across Ìeads Irom charger
charger ouìpuì wiìh no baììery connecìed ìo baììery
I. Reverse poÌariìy connecìion ìo !nìernaÌ ÐC Iuse bÌown and possibÌe RepÌace
baììery has caused charger ìo damage ìo currenì carrying componenìs
sìop charging
3.4 A-C BRUSHLESS GENERATOR {MAIN ALTERNATOR)
No voÌìage Ioss oI residuaÌ magneìism in exciìer IieÌd 4.5.1.g.
Circuiì breaker ìripped Check
Open in sìaìor windings 4.5.2
Open or shorì in roìaìing recìiIiers 4.5.1.c
Shorì circuiìed 4.5.2
Open in aÌìernaìor IieÌd 4.5.2
Shorìed exciìer armaìure 4.5.2
Iow voÌìage Iow engine speed 4.3.4
£xcessive Ìoad Check
High resisìance connecìions connecìions
warm or hoì Tighìen
Shorìed IieÌd 4.5.2
FÌucìuaìing voÌìage FÌucìuaìing speed 4.3.4
(May be indicaìed by !rreguÌar speed oI engine £ngine ManuaÌ
IÌickering Ìighìs) Ioose ìerminaÌ or Ìoad connecìions Tighìen
ÐeIecìive bearing causing uneven air gap 4.5.1.b.
High voÌìage £xcessive engine speed 4.3.4
Overheaìing Ceneraìor overÌoaded Check
CÌogged venìiÌaìing screens CÌean
High ìemperaìure surrounding generaìor 4.3.1
!nsuIIicienì circuÌaìion 4.3.1
\nbaÌanced Ìoad BaÌance
Ðry bearing 4.5.1
MechanicaÌ Noise ÐeIecìive bearing 4.5.1
Roìor scrubbing on sìaìor 4.5.1
Ioose Ìaminaìions 4.5.2
Ioose or misaÌigned coupÌing 4.5.2
Ceneraìor Irame Sìaìic charge Check ground
produces shock ìo Irame
when ìouched Crounded armaìure oI IieÌd coiÌ 4.5.2
41
SECTION 4
SERVICE
This secìioncovers serviceIor ìhegeneraìor seì andsomeengine servicingonÌy. ReIer ìo ìheKuboìa engineworkshop
manuaÌ Ior oìher engine servicing. (ReIer ìo charì in secìion 1.1)
WARNING
Beware of moving V-Belts and belt driven components.
4.1 MAINTENANCE SCHEDULE
Unit Operation Reference
ON/OFF Section
4.1.1 Daily Maintenance
X 1. PreTrip !nspecìion beIore sìarìing 2.2.a.
X 2. PreTrip !nspecìion aIìer sìarìing 2.2.b.
X 3. Check ìoìaÌ ìime meìer Run 1O
minuìes
4.1.2 First 400 Hour Maintenance
X 1. PreTrip !nspecìion beIore sìarìing 2.2.a.
X X 2. Change Ìube oiÌ and IiÌìer 4.3.2
X 3. PreTrip !nspecìion aIìer sìarìing 2.2.b.
X 4. Check ìoìaÌ ìime meìer Run 1O
minuìes
4.1.3 Every 1000 Hour Maintenance {Normal Operating Conditions)
X X 1. CompÌeìe 4OO Hour Mainìenance 4.1.2
X 2. Tighìen engine and generaìor mounìing boÌìs 4.ß
X 3. Tighìen aÌÌ eÌecìricaÌ connecìions in ìerminaÌ/conìroÌ box Tighìen
X 4. CÌean air cÌeaner, check hose and connecìions 4.3.5
X 5. Check waìer pump bearing end pÌay None
X ß. Check baììery charger assembÌy amperage ouìpuì None
X 7. Check mechanicaÌ IueÌ ÌiIì pump IiÌìer 4.3.8
X 8. CÌean screen in IueÌ sìrainer None
4.1.4 Every 3000 to 0000 Hour Maintenance
X X 1. CompÌeìe a 4OO and 1OOO Hour Mainìenance 4.1.2 &
4.1.3
X 2. CÌean crankcase breaìher 4.3.ß
X X 3. CÌean and IÌush cooÌing sysìem 4.3.1
X 4. Check sìarìer condiìion £ngine
ManuaÌ
X X 5. Check engine compression £ngine
ManuaÌ
X ß. Check and ad|usì in|ecìor nozzÌes £ngine
ManuaÌ
X 7. RepÌace \BeÌì 4.4
42
4.2 PRIMING THE FUEL SYSTEM
The uniì is equipped wiìh a mechanicaÌ IueÌ ÌiIì pump,
iì is mounìed on ìhe engine nexì ìo ìhe in|ecìion pump.
(AÌso, reIer ìo secìion 4.3.8) This pump has a manuaÌ
pÌunger Ior bÌeeding IueÌ when ìhe IueÌ ìank has been run
dry.
Since ìhe uniì empÌoys a cÌosed IueÌ circuiì, iì is
recommended ìo use ìhe IoÌÌowing sìeps:
1. Turn bÌeed vaÌve (Red) counìercÌockwise unìiÌ
IuÌÌy opened (see Figure 11).
2. Turn ìhe ìop oI ìhe manuaÌ pÌunger counìercÌock
wise ìo unÌock iì. (See Figure 11) Then, rapidÌy hand
pump ìhe manuaÌ pÌunger unìiÌ a posiìive pressure
(resisìance) is IeÌì, which wiÌÌ indicaìe IueÌ IÌow.
3. Ðepress and ìurn ìhe ìop oI ìhe manuaÌ pÌunger
cÌockwise ìo Ìock in pÌace.
4. Sìarì engine. (ReIer ìo secìion 2.3)
5. When engine is running properÌy, ìurn bÌeed vaÌve
cÌockwise unìiÌ IuÌÌy cÌosed.
4.3 ENGINE SERVICE AND COMPONENTS
4.3.1 Cooling System
The radiaìor, exìernaÌÌy and inìernaÌÌy, musì be cÌean
Ior adequaìe cooÌing. The Ian beÌì musì be ad|usìed
periodicaÌÌy ìo provide maximum air IÌow. (ReIer ìo
secìion 4.4)
!o ìÞr IoIIowIng ìo ·rr+Irr ìÞr rooIIng ·)·ìrm:
a. Remove aÌÌ Ioreign maìeriaÌ Iromìhe radiaìor coiÌ
by reversing ìhe normaÌ air IÌow (Force air in ìhru ìhe
Ironì oI ìhe radiaìor and discharge ìhru ìhe radiaìor
ìoward ìhe engine.) Compressed air or waìer may be
used as a cÌeaning agenì. !ì may be necessary ìo use warm
waìer mixed wiìh any good commerciaÌ dishwasher
deìergenì. Rinse coiÌ(s) wiìh Iresh waìer iI a deìergenì is
used.
b. Ðrain cooÌanì compÌeìeÌy by opening draincock
and removing radiaìor 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 0038M or equal.
c. CÌose draincock and IiÌÌ sysìem wiìh cÌean,
unìreaìed waìer ìo which ìhree ìo Iive percenì oI an
aÌkaÌine base radiaìor cÌeaner shouÌd be added, six
ounces dry = 151 grams ìo one gaÌÌon (3.8 Ìiìer) oI
waìer.
d. Run engine ß ìo 12 hours and drain sysìem whiÌe
warm. Rinse sysìemìhree ìimes aIìer iì has cooÌed down.
ReIiÌÌ sysìem wiìh waìer.
e. Run engine ìo operaìing ìemperaìure. Ðrain
sysìem again and IiÌÌ wiìh ìreaìed waìer/anìiIreeze. (See
Cauìion noìe and reIer ìo secìion 1.4.c.) A!1!K FO!K
CO!! WAT!K 1ATO A HOT !AC1A!, however hoì
waìer can aÌways be added ìo a coÌd engine.
4.3.2 Lube Oil Filters
The IuÌÌ IÌow IiÌìer is Ìocaìed near ìhe run soÌenoid as
shown in Figure 11.
AIìer warming up ìhe engine, sìop engine, remove
drain pÌug Irom oiÌ reservoir and drain engine Ìube oiÌ.
IighìÌy oiÌ gaskeì on IiÌìer beIore insìaÌÌing.
RepÌace IiÌìers and add Ìube oiÌ. (ReIer ìo secìion
1.4.|.) Warm up engine and check Ior Ìeaks.
4.3.3 Servicing the Fuel Solenoid and Linkage
2.47
(6.27cm.)
(8.18cm.)
3.22
ENERGIZED
DE-ENERGIZED
1
2
3
4
5
6
RUN
CONTROL
LEVER
1. So|eno|d
2. So|eno|d Bracket
3. Spr|ng
4. C||p
5. L|nkage Rod
6. Boot
Figure 4-1. Fuel Solenoid Assembly
NOTE
PeriodicaÌÌy grease (P/N O7OO245OO) FueÌ
SoÌenoid pÌunger.
a. Remove spring Ìinkage Irom in|ecìion pump run
Ìever (iìem 3, Figure 41).
b. Ðisconnecì wiring ìo soÌenoid. Remove cÌip (iìem 4)
Irom Ìinkage rod (iìem 5). Remove mounìing hardware
Irom soÌenoid and ìhen remove soÌenoid.
c. !nsìaÌÌ new soÌenoid and mounìing hardware,
connecì wiring. PÌace igniìion (SìarìRunOII) swiìch in
ìhe START posiìion ìo energize soÌenoid. Check ener
gizeddimensionas shownin Figure 41. Turn swiìchOFF.
Check deenergized dimension. !I energized dimension
needs ad|usìing, Ìoosen soÌenoid mounìing boÌìs and
move soÌenoid.
43
d. £nergize soÌenoid and check cÌearance.
e. !I ìhe engine does noì shuì oII when ìhe IueÌ
soÌenoid is deenergized, Ìoosen ìhe Iour (4) mounìing
boÌìs and move ìhe soÌenoid ìoward ìhe Ìever unìiÌ iì shuìs
oII. Tighìen ìhe mounìing boÌìs.
4.3.4 Adjusting Engine Speed
The engine speed operaìes aì 182O ìo 184O rpm (no
Ìoad), 171O rpm (wiìh Ìoad).
Two mrìÞod· ìo rÞrrI rngInr ·¡rrd· arr:
a. Wiìh ìhe engine sìopped, pÌace a mark (whiìe
painì Ior exampÌe) on ìhe crankshaIì sheave. Sìarì engine
and veriIy engine speed by using a SìrobeììemodeÌ 9ß4
(Sìrobeìachomeìer), Carrier TransicoÌd Parì No.
O7OO2Oß.
b. Wiìh ìhe engine sìopped, ìhe second meìhod oI
checking engine speed is by using a Irequency (herìz)
meìer. Aììach one Ìead ìo CB1 ìerminaÌ 1, Figures
51/52, eÌecìricaÌ schemaìics, and ìhe oìher ìo chassis
ground. Sìarì engine and ßO.5 herìz wiÌÌ be 182O rpm and
ß1.3 herìz wiÌÌ be 184O rpm (no Ìoad).
1
2
3
1. Speed Lever
2. Jam Nut "B"
3. Capscrew "B"
Figure 4-2. Speed Adjustment
To 1nrrra·r 5¡rrd:
Ioosen |am nuì ¨B.` Turn capscrew ¨B` cÌockwise
unìiÌ correcì speed is achieved, ìhen ìighìen |am nuì ¨B`
and check engine speed.
To !rrrra·r 5¡rrd:
Ioosen |am nuì ¨B.` Turn capscrew ¨B` counìer
cÌockwise unìiÌ correcì speed is achieved, ìhen ìighìen
|am nuì ¨B` and check engine speed.
4.3.5 Engine Air Cleaner
a. Inspection
The air cÌeaner shouÌd be inspecìed consìanìÌy Ior
Ìeaks. A damaged air cÌeaner or hose can seriousÌy aIIecì
ìhe perIormance and ÌiIe oI ìhe engine. The IoÌÌowing
simpÌe service sìeps are easiÌy made whiÌe ìhe engine is
being serviced in ìhe IieÌd.
TÞr ·Im¡Ir ·rr+Irr ·ìr¡· arr a· IoIIow·:
1. Waìch aÌÌ connecìions Ior mechanicaÌ ìighìness.
Be sure cÌeaner ouìÌeì pipe is noì Iracìured.
2. !I cÌeaner has been denìed or damaged, check aÌÌ
connecìions immediaìeÌy.
3. !n case oI Ìeakage and iI ad|usìmenì does noì
correcì ìhe ìroubÌe, repÌace necessary parìs or gaskeìs.
5wrIIrd or dI·ìorìrd ga·Irì· mu·ì aIwa)· Ir rrnrwrd.
b. Service Procedure
1. £mpìy dusì cover as required. Check ìo see ìhaì
ìhe \acuaìor is noì inverìed, damaged or pÌugged.
2. Sìop ìhe engine, remove and cÌean ìhe dusì cap.
Remove ìhe dirìy eÌemenì Irom ìhe air cÌeaner. !nsìaÌÌ
new IiÌìer and ìighìen wing nuì secureÌy.
3. !nsìaÌÌ dusì cover, makingsure iì seaÌs 3ßOaround
ìhe air cÌeaner body. Check aÌÌ connecìions beìween ìhe
air cÌeaner and ìhe engine ìo be cerìain ìhaì ìhey are ìighì
and ÌeakIree.
1 2 3 4
5
1. Body Assemb|y
2. Pr|mary E|ement
3. C|amp
4. Dust Cap
5. vacuator
Figure 4-3. Air Cleaner
4.3.0 Engine Crankcase Breather
Boìh engines use a cÌosed ìype breaìher wiìh ìhe
breaìher Ìine aììached ìo ìhe cyÌinder head cover. (See
Figure 44)
2
3
4
5
6
1
8
7
1. Cy||nder Head Cover
2. Breather Cover
3. Breather E|ement
4. P|ate
5. Breather O|| Sh|e|d
6. Capscrew
7. Breather Assemb|y
8. O-R|ng
Figure 4-4. Engine Crankcase Breather
The breaìher assembÌy shouÌd be cÌeaned once a year
or aì every 3OOO hours mainìenance inìervaÌ (whichever
comes Iirsì).
4.3.7 Servicing Glow Plugs
The gÌow pÌugs are paraÌÌeÌ connecìed and when
energized, draw 7.5 amps aì 12 vdc. When servicing, ìhe
gÌow pÌug is ìo be Iiììed inìo ìhe cyÌinder head ìo prevenì
damage ìo ìhe gÌow pÌug.
44
Torque vaÌue Ior ìhe gÌowpÌugs is 28.9 ìo3ß.2 IìÌb(4.O
ìo 5.O mkg).
CÞrrIIng Ior a !rIrrìI+r CIow FIug:
a. One meìhod is ìo remove ìhe in|ecìor and ìhen
energize ìhe gÌow pÌug. The gÌowing ìip may ìhen be
observed.
b. Anoìher meìhod is ìo pÌace an ammeìer (or
cÌipon ammeìer) in series wiìh each gÌow pÌug and
energize ìhe pÌugs. £ach pÌug (iI good) shouÌd show
amperage draw.
4.3.8 Servicing Fuel Pump
a. Mechanical Pump {See Figure 4-5)
Ðue ìo Ioreign parìicÌes inìhe IueÌ and wax as a resuÌì
oI using ìhe wrong grade oI IueÌ or unìreaìed IueÌ in coÌd
weaìher. The IueÌ IiÌìer may become pÌugged or re
sìricìed, and ìhe engine wiÌÌ Ìoose capaciìy. The IiÌìer
musì be cÌeaned on a reguÌar scheduÌe such as uniì pre
ìrip or when ìhe oiÌ and IueÌ IiÌìers are changed (reIer ìo
secìion 4.1).
1. Turn nuì counìercÌockwise ìo Ìoosen and re
move (iìem 1).
2. Remove ban|o Iiììing (iìem 2) and Ìeì iì hang
Ìoose, making sure ìo keep copper rings (iìem 4) Ior re
pÌacemenì.
3. Turn IiÌìer (iìem 3) counìercÌockwise and re
move. Check and cÌean.
4. To insìaÌÌ reverse sìeps 1 ìhrough 3.
1
2
3
1
4
1. Nut
2. Banjo
3. F||ter
4. Copper R|ngs
Figure 4-5. Mechanical Fuel Pump
4.4 SERVICING AND ADJUSTING V-BELT
WARNING
Beware of moving V-Belts and belt driven
components.
NOTE
Frayed, cracked or worn \BeÌìs musì be
repÌaced. AIìer insìaÌÌing a new beÌì, iì is
advisabÌe ìo check ìhe ad|usìmenì aIìer running
ìhe uniì Ior ìhree or Iour hours. This is ìo aÌÌow
Ior ìhe iniìiaÌ sìreìch which is common on new
beÌìs. Once ìhis iniìiaÌ sìreìch has ìaken pÌaceìhe
beÌì may be checked aì reguÌar inìervaÌs.
4.4.1 Water Pump V-Belt
The waìer pump \BeÌì is driven by a sheave on ìhe
engine crankshaIì. Ad|usìmenì is achieved by aÌìering
posiìion oI ìhe idÌer puÌÌey.
a. Replacing the V-Belt
1. Ioosen ìhe idÌer brackeì pivoì boÌì.
2. RepÌace beÌì. \se hand Iorce onÌy on idÌer puÌÌey
ìo ìighìen beÌì. !o noì u·r ¡r) Iar or rxrr··I+r Iorrr a· Iì
ma) rau·r waìrr ¡um¡ IrarIng· ìo IaII. When beÌì is ìighì,
ìighìen idÌer brackeì pivoì boÌì.
3. Check beÌì ìension, correcì speciIicaìions are
4O45 Ìbs. on ìhe Burroughs gauge Carrier TransicoÌd P/N
O7OO2O3.
4.5 SERVICING THE GENERATOR
{MAIN ALTERNATOR)
4.5.1 Preventive Maintenance and
Operating Precautions
CosìÌy repairs and down ìime can usuaÌÌy be pre
venìed by operaìing eÌecìricaÌ equipmenì under condi
ìions which are compaìibÌe wiìh ìhose aì which ìhe
equipmenì was designed ìo operaìe. FoÌÌow ìhe insìruc
ìions ouìÌined beÌowìo insure maximumeIIiciency oI ìhe
eÌecìricaÌ equipmenì.
a. Cooling
Keep aÌÌ cooÌing parìs cÌean and make cerìain
suIIicienì room is ÌeIì on aÌÌ sides Ior a pÌenìiIuÌ suppÌy oI
Iresh cooÌanì air IÌow. !O AOT !XC!!! T!MF!KA
T!K! K15! A5 5HOWA !OK SûC ]176!) ASO1! A
4ûC]1û4!) AMS1!AT. This ensures ìhaì ìheinsuÌaìion
N£MA CÌass ¨F` wiÌÌ noì be damaged. !O AOT
!XC!!! KAT!! !OA! excepì as speciIied Ior ìhe
equipmenì. OF!KAT! C!A!KATOK AT KAT!!
5F!!!. FaiÌure ìo operaìe generaìors aì raìed Ìoad or
speed wiÌÌ cause overheaìing and possibÌe damage ìo
windings due ìo over voÌìage or currenì.
b. Bearing Replacement
Facìory Ìubricaìed shieÌded bearings wiÌÌ normaÌÌy
provide severaÌ years oI ìroubÌe Iree service when
operaìed under normaÌ condiìions. £xcessive bearing
Ìoad and adverse environmenì condiìions wiÌÌ greaìÌy
shorìen bearing ÌiIe. ShouÌd bearing IaiÌure occur,
bearings can be repÌaced. A!WAY5 K!F!AC! W1TH
TH! 5AM! TYF! S!AK1AC A5 1A5TA!!!! AT TH!
!ACTOKY. CH!CXFAKT5 !15T!OKFAKTA!MS!K.
!ncÌude generaìor seriaÌ number when ordering bearings.
45
!o ìÞr IoIIowIng ìo rrmo+r IrarIng:
1. Remove bearing cap. (See Figure 4ß)
2. Remove bearing wiìh ìhe use oI a bearing or wheeÌ
puÌÌer.
3. !nsìaÌÌ newbearing. BaÌÌ bearings on Iima genera
ìors are preÌubricaìed and require no Iurìher Ìubricaìion
Ior ìhe ÌiIe oI ìhe bearing.
4. RepÌace end cap.
2
1
3
4
1. Bo|t
2. Bear|ng Cap
3. Bear|ng
4. Rotat|ng D|ode
Br|dge
Figure 4-0. Rectifier Removal
c. Rotating Diode Bridge {Rectifier Assembly)
Replacement
The roìaìing diode bridge can be removed and
repÌaced. Overcurrenì, overvoÌìage, overspeed, or re
verse currenìs can causedamage ìoìhe assembÌy or any oI
ìhe componenì parìs. The roìaìing diode bridge may be
removed ìhrough ìhe bearing cap on ìhe rear oI ìhe
generaìor. (See Figure 4ß and Figure 47)
1. Remove ìhe bearing cap by removing ìhe Iour
boÌìs shown in Figure 4ß and boìh ìhe bearing and
recìiIier assembÌy wiÌÌ be visibÌe.
2. \se a bearing puÌÌer ìo remove ìhe bearing Irom
main shaIì being careIuÌ ìo Ìocaìe ìhe puÌÌer on ìhe inner
race oI ìhe bearing ìo avoid bearing damage. Once ìhe
bearing is Iree, iì is ìhen necessary ìo disconnecì ìhe
aÌìernaìor and exciìer roìor Ìeads as shown in Figure 4ß.
3. Remove ìhe ìhree hoÌddown cap screws which
secure ìhe recìiIier assembÌy ìo iìs adapìer. Once ìhis
procedure is compÌeìe ìhe recìiIier assembÌy is Iree Ior
removaÌ.
FoÌÌow ìhe ìesìing procedures ouìÌined in secìion
4.5.1.d.
AIìer ìhe recìiIier assembÌy has been repaired or
repÌaced, reverse ìhe procedure as sìaìed above, being
careIuÌ ìhaì aÌÌ Ìead connecìions are ìighì and ìhaì seì
screws are Ìocked wiìh Iocìiìe. (Iocìiìe Corporaìion)
2
2
1
1
1. Exc|ter Rotor Lead
2. A|ternator Rotor Lead
Figure 4-7. A-C Generator {Rectifier Assembly)
d. Testing Diodes With An Ohmmeter
1. Remove ìhe diode Irom ìhe circuiì. Ðo noì press
body ouì oI heaì sink. Ðisconnecì ìhe Ìead. Ðo noì use
excessive heaì in unsoÌdering ìhe Ìead.
2. A good diode shouÌd have a Ìow resisìance when
ìhe ÷oI an ohmmeìer is connecìed ìo ìhe anode and ìhe
ìo ìhe caìhode, and a high resisìance when ìhe poÌariìy
oI ìhe ohmmeìer is reversed. (See Figure 48)
!I boìh resisìances are high or boìh are Ìow, ìhen ìhe
diode is deIecìive and shouÌd be repÌaced.
A A C C
RED LETTER|NG BLACK LETTER|NG
"R" A|ter Number
Forward Reverse
Po|ar|ty Po|ar|ty
D|ode D|ode
A (÷) = Anode C (---) = Cathode
Figure 4-8. Diode Testing
e. Rotor Damage
The damper bars oI ìhe generaìor prevenì excessive
hunìing when AC generaìors are operaìed in paraÌÌeÌ.
Ðamper bars, because ìhey musì have a Ìow eÌecìricaÌ
resisìance and are sub|ecìed ìo exìreme cenìriIugaÌ
Iorces, musì be mechanicaÌÌy secure and permanenì.
ConsequenìÌy, ìhey are weÌded ìo end pÌaìes compÌeìeÌy
covering ìhe IieÌd.
AÌÌ roìors are sìaìic and dynamicaÌÌy baÌanced ìo a
high degree on precision machines ìo assure minimum
vibraìion. They wiÌÌ, ìhereIore, remain dynamicaÌÌy sìabÌe
aì speed weÌÌ beyond ìhe synchronous speed oI ìhe
generaìor. The roìors on generaìors are, however,
sub|ecìed ìo exìreme cenìriIugaÌ Iorces which can in
crease beyond saIe operaìing Ìimiìs aì overspeed. There
Iore, ìhe prime mover shouÌd be adequaìeÌy governed ìo
prevenì overspeed.
Ðamage ìo ìhe roìor can aÌso occur due ìo overheaì
ing which can be caused by ìhe air IÌow being resìricìed
Irom dusì or oìher Ioreign ob|ecìs coÌÌecìing in ìhe air
passage.
4ß
!I a roìor becomes deIecìive, iì shouÌd be reìurned ìo
ìhe Iacìory wiìh IuÌÌ namepÌaìe daìa, because ìhe roìor
coiÌs are encÌosed in weÌded squirreÌ case winding. To
repair a roìor ìhe speciaÌ ìooÌing and ìechnique oI ìhe
Iacìory is necessary and essenìiaÌ. ShouÌd a IaiÌure occur,
Carrier TransicoÌd shouÌd be noìiIied immediaìeÌy and
sìeps wiÌÌ be ìaken ìo geì ìhe generaìor back inìo service
wiìh ìhe Ìeasì expense, and moreimporìanì, ìodeìermine
ìhe cause oI ìhe IaiÌure and ìake sìeps ìo prevenì a
recurrence.
f. Generator Windings {Drying)
Ceneraìors ìhaì have been in ìransiì or sìorage Ior
Ìong periods may be sub|ecìed ìo exìreme ìemperaìure
and moisìure changes. This can cause excessive con
densaìion, and ìhe generaìor windings shouÌd be ìhor
oughÌy dried ouì beIore bringing ìhe generaìor up ìo IuÌÌ
namepÌaìe voÌìage. !I ìhis precauìion is noì ìaken, serious
damage ìo ìhe generaìor can resuÌì. The IoÌÌowing sìeps
shouÌd be ìaken ìo eIIecìiveÌy dry ìhe generaìor windings:
1. (a)PÌace generaìor in drying oven or hoì room.
(b)Ðry wiìh warm air bÌower direcìed ìhrough
windings.
2. (a)!I ìhe generaìor has been operaìed and ìhen
puì inìo sìorage Ior any period oI ìime, a P.Ð. Ceorge
¬11127 ìype airdry Iungus resisìanì varnish shouÌd be
appÌied.
£xperiencehas shownìhaì iì is necessary ìo ìakeìhese
precauìions in Ìocaìions such as seaboard insìaÌÌaìions
and oìher highÌy humid areas. Some insìaÌÌaìions wiÌÌ be
in aìmospheres ìhaì are much more corrosive ìhan
oìhers. A ÌiììÌe precauìions aÌong ìhe Ìines ouìÌined here
couÌd eÌiminaìe an unnecessary repair |ob.
£ach generaìor was sub|ecìed ìo a sìandard N£MA
insuÌaìion ìesì, which means 1OOO voÌìs pÌus ìwice ìhe
highesì voÌìage Ior which ìhe generaìor is raìed was
impressed beìween ìhe winding and Irame. AÌÌ machines
are insuÌaìed wiìh a high saIeìy Iacìor Ior ìhe cÌass oI
insuÌaìion used. The Ìaìesì and newesì in insuÌaìion and
baking ìechniques are used.
The Iinesì insuÌaìion |ob can be very quickÌy broken
down by careÌessÌy appÌying high voÌìage ìo windings in a
moisìuresaìuraìedcondiìion. MishandÌingin ìhis respecì
can easiÌy cause a breakdown, making iì necessary ìo
reìurn ìhe generaìor ìo ìhe Iacìory Ior repair, and
consequenì expense and Ìoss oI ìime.
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. Ahigh megger reading indicates
low insulation leakage.
g. Restoring Residual Magnetism
NOTE
When ìrying ìo resìore residuaÌ magneìism, be
sure ìo wear Ìeaìher gÌoves and use an insuÌaìed
12 gauge (or higher) |umper wire. CuìoII a Iew
sìrands Irom boìh ends oI ìhe |umper wire ìo
ensure Iusing does noì ìake pÌace.
The direcì currenì (ÐC) necessary ìo magneìize ìhe
aÌìernaìor IieÌd is obìained Irom ìhe exciìer. !niìiaÌÌy,
upon sìarìing ìhe generaìor, currenì IÌowand voÌìage are
inducedinìo ìheexciìer armaìureby ìhemagneìic Ìines oI
Iorce seì up by ìhe residuaÌ magneìismoI ìhe exciìer IieÌd
poÌes.
ResiduaÌ magneìism oI ìhe exciìer IieÌd poÌes may be
Ìosì or weakened by a sìrong neuìraÌizing magneìic IieÌd
Irom any source, or iI ìhe generaìor is noì operaìed Ior a
Ìong period oI ìime.
ShouÌd ìhe generaìor IaiÌ ìo buiÌd up voÌìage aIìer
being disassembÌed Ior any reason, a momenìary shorì
circuiì oI any ìwo generaìor Ìeads (I1, I2 and I3 whiÌe
generaìor is running) shouÌd be suIIicienì ìo correcì ìhis
condiìion. !I noì, an aÌìernaìe meìhod may be used.
AppÌy eiìher an aÌìernaìing currenì or a direcì currenì
voÌìage oI approximaìeÌy 2O voÌìs ìo any ìwo generaìor
Ìeads (I1, I2 and I3 whiÌe generaìor is running). Ðo noì
make a posiìive connecìion buì raìher ìouch ìhe Ìeads
ìogeìher unìiÌ ìhe generaìor voÌìage begins ìo rise and
ìhen remove. !ì is suggesìed ìhaì a 3O ampere Iuse be
inserìed in ìhe circuiì ìo prevenì any damage in case ìhe
buiÌdup voÌìage is noì removed quickÌy enough.
ReIÌash IieÌd iI generaìor ouìpuì voÌìage does noì
buiÌd up.
4.5.2 Installation and Removal
a. Removing the Generator
1. Remove generaìor seì cover assembÌy and genera
ìor ground wire.
2. Remove generaìor Ìeads Irom ìerminaÌ box, and
aÌÌ eÌecìricaÌ wires Irom generaìor and engine. Then
remove Iour 1/42O x 1.OO Ìg screws securing ìerminaÌ box
ìo generaìor.
3. Ðrain radiaìor, ìhen disconnecì aÌÌ air/cooÌanì
hoses Irom generaìor and engine. Remove Ian.
4. Separaìe IÌex exhausì pipe Irom muIIÌer.
5. Remove mounìing Iooì hardware Iromgeneraìor,
and engine mounìing brackeìs Irom Irame.
ß. PÌace sÌings around generaìor and engine. Raise
boìh up enough ìo cÌear approximaìeÌy ìwo inches, ìhen
swing engine ouì Iirsì and bring enìire assembÌy sìraighì
ouì.
7. Remove necessary mounìing brackeìs (baììery,
IueÌ, ecì.). Remove generaìor screen Irom coupÌing end
oI generaìor.
8. Remove Iour 5/1ß18 x 11/2 screws and ìwo
5/1ß18 x 11/4 screws securing ìhe engine IÌy wheeÌ
housing ìo ìhe generaìor IÌange.
9. Remove Iive 3/824x 3/4screws securinggeneraìor
disc ìo engine IÌywheeÌ. (A sockeì brazed ìo a IÌexibÌe
47
shaIì and an oIIseì wrench are required ìo remove ìhe
boÌìs.) Turn boÌìs counìercÌockwise wiìh oIIseì wrench ìo
sìarì, ìhen use IÌexibÌe shaIì and sockeì assembÌy Ior
removaÌ oI boÌìs.
b. Installing the Generator
NOTE
For ìorque vaÌues reIer ìo secìion 4.8.
The generaìor is a singÌe bearing ìype which means
ìhe shaIì end oI ìhe roìor IÌoaìs. BeIore insìaÌÌing
generaìor, roìaìe shaIì and check iI bearing roìaìes.
The use oI sìud guides, ìwo in beÌÌ housing (5/1ß18 x 2
Ìg) and ìwo in ìhe IÌywheeÌ (3/824 x 21/2 Ìg) wiÌÌ make
insìaÌÌaìion easier. These sìuds shouÌd have a square or
hex design on ìhe end opposiìe ìhe ìhreads. This is
necessary ìo remove sìuds aIìer generaìor is insìaÌÌed.
1. Remove screen covering IromshaIì end oI genera
ìor and brush anìiseize Ìubricanì (ÌubepÌaìe) on ìhe Iace
oI IÌywheeÌ.
2. Move generaìor (wiìh hoisì) inìo posiìion wiìh
engine and Ìine up wiìh ìhe sìuds on housing and
IÌywheeÌ. Turn crankshaIì (wiìh Ìarge wrench) ìo aÌign
IÌywheeÌ wiìh generaìor, iI necessary.
NOTE
!ì may be necessary ìo appÌy pressure under ìhe
cooÌing Ian shaIì ìo aÌign ìhe generaìor wiìh ìhe
IÌywheeÌ counìerbore.
3. Sìarì ìhe 3/824 boÌìs (by hand) ìhrough ìhe disc
pÌaìe and inìo ìhe IÌywheeÌ. Once aÌignmenì is made
remove sìuds and ìorque boÌìs (Iive).
4. Secure ìwo oI ìhe housing boÌìs (5/1ß18) ìo draw
ìhe maìing IÌanges ìogeìher.
5. Remove sìuds and secure remaining boÌìs and
washers 5/1ß18 (Iour) and ìorque boÌìs (six).
ß. To insìaÌÌ reverse sìeps 1 ìhrough 7 in secìion
4.5.2.a..
NOTE
!nsìaÌÌ new gaskeìs (one beìween generaìor and
ìerminaÌ box and ìhe oìher beìween box and
cover) when insìaÌÌing ìerminaÌ box.
7. Torque generaìor/engine mounìing boÌìs (six).
4.0 REPLACING SHOCKMOUNTS
NOTE
For ìorque vaÌues reIer ìo secìion 4.8.
The engine and generaìor use diIIerenì sìyÌe shock
mounìs and hoÌd down hardware.
4.0.1 Replacement Criteria
When ìhe neoprene shockmounì has been cuì, spÌiì,
abraded or has IÌared due ìo wear Irom boÌìs and normaÌ
deìerioraìion.
4.0.2 Shockmount Replacement
a. Engine
1. Remove ìheìwo 1/213x 31/2inch Ìongcapscrews.
(Iocìiìe has been appÌied ìo ìhese boÌìs.) PÌace sÌing or
oìher device around engine (near oiÌ reservoir) and
sÌowÌy raise ìhe engine enough ìo remove ìhe engine
mounìing shockmounìs. (The Ian may have ìo be roìaìed
ìo prevenì sìriking ìhe Ian shroud.)
2. !nsìaÌÌ shockmounìs and IÌaì washers as shown in
Figure 49.
3. AppÌy Iocìiìe £\ (purpÌe in coÌor) ìo ìhreads oI
boÌìs.
4. Iower engine, and ìorque shockmounì boÌìs.
b. Generator
1. Remove ìhe Iour 1/213 x 31/4 inch Ìong caps
crews. (Iocìiìe has been appÌied ìo ìhese boÌìs.) PÌace
sÌing or oìher device around generaìor, sÌowÌy raise
enough ìo repÌace shockmounìs.
2. !nsìaÌÌ shockmounìs and IÌaì washers as shown in
Figure 49.
3. AppÌy Iocìiìe £\ (purpÌe in coÌor) ìo ìhreads oI
boÌìs.
4. Iower generaìor and ìorque shockmounì boÌìs.
SHOCK-
MOUNT
FLAT WASH-
ER
FRAM
E
ENGINE OR
GENERATOR
MOUNTING
NUT
BOLT
FLAT WASH-
ER
SHOCK-
MOUNT
Figure 4-0. Shockmount Installation
4.7 MAINTENANCE OF PAINTED
SURFACES
The uniì is proìecìed by a speciaÌ painì sysìemagainsì
ìhe corrosive aìmosphere in which iì normaÌÌy operaìes.
However, shouÌd ìhe painì sysìem be damaged, ìhe base
meìaÌ can corrode. !n order ìo proìecì ìhe uniì Irom ìhe
highÌy corrosive sea aìmosphere or iI ìhe proìecìive painì
sysìem is scraìched or damaged:
1. CÌean area ìo bare meìaÌ using a wire brush, emery
paper or equivaÌenì cÌeaning meìhod.
2. !mmediaìeÌy IoÌÌowing cÌeaning, spray or brush on
a zinc rich primer.
3. AIìer ìheprimer has dried, spray or brush onIinish
coaì oI painì ìo maìch originaÌ uniì coÌor.
48
Figure 4-10. Unidrive Torque Requirements
The Iigures beÌow show ìhe ìorque vaÌue, size
and grade oI ìhe hardware ìo be used when
assembÌing ìhe unidrive assembÌy.
£xìensive damage may occur iI ìhe proper
hardware and procedures are noì IoÌÌowed. Period
ic inspecìion oI hardware and boÌì ìorque is
recommended ìo ensure ìhe inìegriìy oI ìhe uni
drive.
4.8 UNIDRIVE TORQUE REQUIREMENTS
UNIDRIVE -- SECTIONAL VIEW
GENERATOR SHOCKMOUNTS -- SIDE VIEW
ENGINE MOUNT -- LEFT SIDE VIEW
ENGINE MOUNT -- RIGHT SIDE VIEW
ENGINE SHOCKMOUNTS -- BACK VIEW
Fngine IÌywheeÌ
Cenerator Disc Drive
3/824 x 3/4 Ìg
(5 Req´d) 25 ItÌb (3.4ß
mkg)
5/1ß18 x 11/4 Ìg
(2 Req´d) 15 ItÌb (2.O7
mkg)
1/213 x 31/2 Ìg SST
(2 Req´d) 42 ItÌb (5.81
mkg)
M1O x 1.25 x 2O mm
(1 Req´d) 43 ItÌb (5.95 mkg)
M12 x 1.25 x 25 mm
(3 Req´d) ß5 ItÌb (8.99
mkg)
M12 x 1.25 x 25 mm
(4 Req´d) ß5 ItÌb (8.99
mkg)
NOTE
SST is an abbreviaìion Ior, 3OO Series
Corrosion Resisìanì SìeeÌ.
LIMA
1/213 x 31/4 Ìg SST
(4 Req´d) 42 ItÌb (5.81
mkg)
5/1ß18 x 11/2 Ìg
(4 Req´d) 15 ItÌb (2.O7
mkg)
51
SECTION 5
SCHEMATICS
5.1 INTRODUCTION
This secìion conìains £ÌecìricaÌ Wiring Schemaìics and Ðiagrams covering ìhe ModeÌs Ìisìed in TabÌe 11. The
IoÌÌowing generaÌ saIeìy noìices suppÌemenì ìhe speciIic warnings andcauìions appearingeÌsewhere inìhis manuaÌ. They
are recommended precauìions ìhaì musì be undersìood and appÌied during operaìion and mainìenance oI ìhe
equipmenì covered herein.
WARNING
Electrical power is generatedby a Lima 15 KW, A-Cgenerator. The generator provides a constant 400or 230vac,
3 phase, 00 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
Highvoltage {dielectric) testing must not be performedto the machine without first observingNEMArules. The
insulation of this generator winding may be safely checked by using a megger. A high megger reading indicates
low insulation leakage.
CAUTION
The generator set circuit breaker must be in the ON position in order to supply power to the refrigeration unit.
CAUTION
Observe proper polarity when installing the battery, the negative battery terminal must be grounded. Reverse
polarity will destroy the rectifier diodes in the generator sets solid state battery charging system if a battery
charger is connected in reverse. As a precautionary measure isolate the battery from the unit as follows:
disconnect negative battery terminal first, then the positive battery terminal when charging battery in unit.
Once the battery has been fully charged, connect the positive battery terminal first, then the negative battery
terminal. NEVER jump start the battery when its mounted in the unit, this will destroy the components of the
generator sets battery charger.
52
MFCHANICAL LINKACF
FNCINF CROUND
CHASSIS CROUND
ß A AMMFTFR
7 B BATTFRY CHARCFR
4 BAT BATTFRY
3,8,13,14 CB CIRCUIT BRFAKFR
12,15 D DIODF
13 IS IUFL SOLFNOID
1ß,17 CP CLOW PLUC
15,1ß,17 CPS CLOW PLUC SWITCH
14 HWT WATFR TFMP. SWITCH
1O,11,12,13 ICN ICNITION SWITCH
8 L1 CB TRIPPFD (INDR. LICHT)
14 LOP LOW OIL PRFSSURF
13,14 RR RUN CONTROL RFLAY
5 SM STARTFR MOTOR
5,1O SS STARTFR SOLFNOID
2,3 TB TFRMINAL BLOCK
1 TR TRANSIORMFR
11 TT TOTAL TIMF MFTFR
9 WTC WATFR TFMP. CAUCF
9 WTS WATFR TFMP. SFNDFR
LINE SYMBOL LINE SYMBOL DESCRIPTION DESCRIPTION
Figure 5-1. Electrical Wiring Schematic & Diagram --- Models 00GC15-104 & 00GC15-104-1
Drawing Numbers 00GC15-1824-RA & 00GC15-1054-R-
{Sheet 1 of 2)
53
1 thru 10 are w|res |rom A-C generator
Figure 5-1. Electrical Wiring Schematic & Diagram --- Models 00GC15-104 & 00GC15-104-1
Drawing Number 00GC15-1814-RB
{Sheet 2 of 2)
54
Figure 5-2. Electrical Wiring Schematic & Diagram --- Model 00GC15-104-2
{Sheet 1 of 2)
55
Figure 5-2. Electrical Wiring Schematic & Diagram --- Model 00GC15-104-2
{Sheet 2 of 2)
5ß
Figure 5-3. Electrical Wiring Schematic & Diagram --- Model 00GC15-104-3
{Sheet 1 of 2)
57
Figure 5-3. Electrical Wiring Schematic & Diagram --- Model 00GC15-104-3
{Sheet 2 of 2)
58
Figure 5-4. Electrical Wiring Schematic & Diagram --- Model 00GC15-104-4
{Sheet 1 of 2)
59
Figure 5-4. Electrical Wiring Schematic & Diagram --- Model 00GC15-104-4
{Sheet 2 of 2)