Carrier 69GL15-114 Operation manual

T-251-04
Models
69GL15-114
69GL15-134

Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221
SERVICE MANUAL
OPERATION AND
DIESEL DRIVEN GENERATOR SET
MODELS
69GL15-114
69GL15-134
Carrier Corporation 1995 DPrinted in U. S. A. 0695

i
TABLE OF CONTENTS
Section Page
1DESCRIPTION 1-1........................................................
1.1 Introduction 1-1...........................................................
1.2 Safety Devices 1-2.........................................................
1.3 Unit Specifications 1-5.....................................................
1.4 Engine Data 1-5...........................................................
1.5 Engine Screw Threads 1-6...................................................
1.6 Lube Oil and Fuel Flow Diagrams 1-6.........................................
1.7 Engine Air System 1-6......................................................
1.8 Operating Controls and Instruments 1-6.......................................
1.8.1 Introduction 1-6..................................................
1.8.2 Control Panel and Related Components 1-6..........................
1.8.3 Protective Devices 1-7.............................................
1.9 Main Alternator (A-C Generator) 1-8.........................................
1.9.1 Principle of Operation 1-8..........................................
1.9.2 A-C Generator (Main Alternator) Circuit Diagram 1-8.................
1.10 Battery Charging Alternator System 1-9.......................................
1.10.1 Introduction 1-9..................................................
1.10.2 Alternator Operation 1-10...........................................
1.10.3 Integral Voltage Regulator Operation (12 volts d-c) 1-10.................
2OPERATION 2-1..........................................................
2.1 Generator Set Installation and Removal 2-1...................................
2.2 Pre-Trip Inspection 2-2.....................................................
2.3 Starting and Stopping Instructions 2-2........................................
2.4 Control Circuit Operation 2-3...............................................
3 TROUBLESHOOTING 3-1.................................................
3.1 Diesel Engine 3-1..........................................................
3.1.1 Engine will not Start 3-1............................................
3.1.2 Engine Starts then Stops 3-1........................................
3.1.3 Starter Motor Malfunction 3-2......................................
3.1.4 Malfunction in the Engine Starting Circuit 3-2.........................
3.1.5 Miscellaneous Engine Troubleshooting 3-2............................
3.2 Alternator (Automotive Type) 3-3............................................
3.3 A-C Brushless Generator (Main Alternator) 3-4................................

ii
TABLE OF CONTENTS (CONTINUED)
Section Page
4SERVICE 4-1.............................................................
4.1 Maintenance Schedule 4-1..................................................
4.1.1 Daily Maintenance 4-1.............................................
4.1.2 First 400 Hour Maintenance 4-1.....................................
4.1.3 Every 1000 Hour Maintenance (Normal Operating Conditions) 4-1.......
4.1.4 Every 3000 to 6000 Hour Maintenance 4-1............................
4.2 Priming the Fuel System 4-2.................................................
4.3 Engine Service and Components 4-2..........................................
4.3.1 Cooling System 4-2................................................
4.3.2 Lube Oil Filters 4-2................................................
4.3.3 Servicing the Fuel Solenoid and Linkage 4-2...........................
4.3.4 Adjusting Engine Speed 4-2.........................................
4.3.5 Engine Air Cleaner 4-3............................................
4.3.6 Servicing Glow Plugs 4-3...........................................
4.3.7 Engine Crankcase Breather 4-3......................................
4.4 Servicing and Adjusting V-belt 4-4............................................
4.4.1 Engine V-belt 4-4.................................................
4.4.2 Alternator V-belt 4-4..............................................
4.5 Servicing the Generator (Main Alternator) 4-4.................................
4.5.1 Preventive Maintenance and Operating Precautions 4-4.................
4.5.2 Installation and Removal 4-6........................................
4.6 Maintenance of Painted Surfaces 4-6.........................................
4.7 Replacing Shockmounts 4-7.................................................
4.7.1 Replacement Criteria 4-7...........................................
4.7.2 Shockmount Replacement 4-7.......................................
4.8 Servicing the Alternator 4-8.................................................
4.8.1 Preliminary Checks and Tests 4-8....................................
4.8.2 Test Tools 4-8.....................................................
4.8.3 Problem Area Determination 4-8....................................
4.8.4 In-Unit Alternator/Regulator Tests 4-8...............................
4.8.5 Alternator Brush Test Procedure 4-10.................................
4.8.6 Slip Ring Servicing 4-10.............................................
4.8.7 Alternator Installation 4-10..........................................
4.9 UnidriveTorqueRequirements 4-11...........................................
5SCHEMATICS 5-1.........................................................
5.1 Introduction 5-1...........................................................

iii/iv
LIST OF ILLUSTRATIONS
Figure Page
1-1 Generator Set --- Control Box Side 1-3........................................
1-2 Generator Set --- Top View 1-3...............................................
1-3 Control Box and Panel 1-4..................................................
1-4 Lube Oil Flow Diagram 1-6.................................................
1-5 Fuel System Diagram 1-6...................................................
1-6 Main Alternator (A-C Generator) 1-8.........................................
1-7 A-C Generator Circuit Diagram 1-8..........................................
1-8 Alternator and Regulator 1-9................................................
1-9 Alternator Schematic Diagram 1-10...........................................
2-1 Generator Set Mounting 2-1.................................................
4-1 Fuel Solenoid Assembly 4-2.................................................
4-2 Air Filter 4-3..............................................................
4-3 Rectifier Removal 4-4......................................................
4-4 A-C Generator (Rectifier Assembly) 4-5.......................................
4-5 Diode Testing 4-5..........................................................
4-6 Engine Shockmounts 4-7....................................................
4-7 Generator Shockmounts 4-7.................................................
4-8 Open Diode-Trio Test 4-8...................................................
4-9 Open Regulator Test 4-9....................................................
4-10 Alternator Output Test 4-9..................................................
4-11 Alternator Brush Assembly 4-10..............................................
4-12 Unidrive Torque Requirements 4-11...........................................
5-1 Electrical Wiring Schematic & Wiring Diagram --- (Models 69GL15-114, -1 & -2) 5-2......
5-2 Electrical Wiring Schematic & Wiring Diagram --- (Models 69GL15-134, -1, -2 & -4) 5-6...
LIST OF TABLES
Table Page
1-1 Model Chart 1-1...........................................................
1-2 Safety Devices 1-2.........................................................
1-3 Alternator and Manual 1-9..................................................

1-1
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
WARNING
Beware of moving V-Belts and belt driven
components.
This manual contains Operating Data, Electrical
Information, and Service Instructions for the diesel
generator sets shown in Table 1-1. (See Figure 1-1 for
location of serial/model number plate.)
Separately bound manuals covering the Deutz
F3L912W diesel engine for the diesel-driven generator
sets are also supplied, see chart below.
MANUAL/
FORM NO. EQUIPMENT
COVERED TYPE OF MANUAL/FORM
291-1842 F3L912W Workshop
62-02383 F3L912W Engine Parts List
The undermounted diesel-driven generator sets
provide a constant electrical power supply for an
all-electric refrigeration unit.
Located inside the frame are the diesel engine, A-C
generator (main alternator), control and monitoring
cabinet,startingbattery,batterychargingalternator,and
other necessary accessory components for proper unit
operation.
Forpower,the DeutzF3L912Wverticalin-line,three
cylinder diesel engine is used. The engine is equipped
withglowplugs(usedasastartingaid)and“spin-on”lube
andfueloilfiltersforeasierfilterchanges.Allreferences
to engines are viewed from the blower end.
Electrical power is generated by a Lima 15 KW,
brushless,singlebearingA-C generator.The generatoris
coupled directly to the engine flywheel. The generator
provides a constant 460/230 vac, 3 phase, 60 hertz
electrical supply.
The engine air cooling blower and alternator are
belt-driven from the engine crankshaft sheave.
The air cooling blower fan belt is automatically
tensionedby the idlerpully and protected by the fan belt
switch.
Table 1-1. Model Chart
Model
Number Integral Fuel
Tank 50 U.S.
Gallons
Integral Fuel
Tank 65 U.S.
Gallons 65 Amp
Alternator Dual Voltage Engine
(Deutz)
F3L912W Fuel
Warmer
69GL15-114 X--- XAX---
69GL15-114-1 X--- XXXX
69GL15-114-2 --- --- XXXX
69GL15-134 X--- XXXX
69GL15-134-1 --- XXXXX
69GL15-134-2 --- X X --- X X
69GL15-134-4 --- X X --- X X
A --- Provision for dual voltage.

1-2
1.2 SAFETY DEVICES (Refer to Table 1-2.)
System components are protected from damage
caused by unsafe operating conditions by automatically
shutting down the diesel engine when such conditions
occur. This is accomplished by the safety devices FBS,
LOP or OTS. These safety devices monitor system
operatingconditionsandopenasetofelectricalcontacts
when an unsafe condition occurs. Opening one or more
of these safety switch contacts will de-energize the fuel
solenoid.
De-energizing fuel solenoid releases the stop-run
lever to the STOPposition,shuttingoffthefuelsupplyto
the engine; thus stopping the engine.
The A-C generator and the glow plug circuit are
protected by circuit breakers (listed below) but will not
shut down the engine if an overload occurs.
Table 1-2. Safety Devices
Unsafe Condition Safety Switch Switch Setting
a. Engine
1. Broken fan belt 1. Fan belt switch (FBS) 1. Trips when belt breaks
2. Excessive current draw by FS, 2. Circuit breaker (CB-2) --- 2. Trips at 20 amps
FH,S,SSorTT Automaticreset
3. Low engine lubricating 3. Oil pressure switch (LOP) --- 3. Opens below 26 psig
oil pressure Automatic reset (1.83 kg/cm@)
4. High oil temperature 4. Oil temperature switch (OTS) --- 4. Closes at 266 _F
Automatic reset (130_C)
b. Glow Plugs
1. Excessive current draw 1. Circuit breaker (CB-3) --- 1. Trips at 50 amps
on glow plug circuit Automatic reset
c. Generator
1. Excessive current draw 1. Circuit breaker (CB-1) --- 1. Trips at 26 amps
by generator Manual reset (460 vac)
2. Excessive current draw 2. Circuit breaker (CB-4) --- 2. Trips at 48 amps
by generator Manual reset (230 vac)

1-3
1. Control Box and Panel
2. Serial/Model Number Plate
3. Oil Pressure Gauge
4. Power Receptacle
5. Fuel Tank
6. Engine Shockmount
7. Fuel Bleed Valve
8. Fuel Warmer
9. Engine
10. Lube Oil Dipstick/Fill Cap
11. Fuel Solenoid
12. Engine Oil Filter
13. Generator Shockmount
Figure 1-1. Generator Set --- Control Box Side
1. Fuel Filters
2. A-C Generator
3. Starter Motor (Location)
4. Engine Oil Breather
5. Muffler Exhaust Pipe
6. Alternator
7. Alternator Belt
8. Battery
9. Air Cleaner
10. Fan Belt
11. Blower Fan
12. Muffler (Location)
Figure 1-2. Generator Set --- Top View
123
5678910111213
12345678
91011
12
4

1-4
Figure 1-3. Control Box and Panel
1. Glow Plug Indicator (GPI)
2. Glow Plug Switch (GPS)
3. Ignition Switch (IGN)
4. Ammeter (A)
5. Total Time Meter (TT)
6. Circuit Breaker ---
230 vac (CB4)
7. Circuit Breaker Trip Light
8. Circuit Breaker ---
460 vac (CB1)
9. Voltage Selector
10. Terminal Block (TB)
11. Circuit Breaker (CB3)
12. Circuit Breaker (CB2)
13. Run Relay (RR)
14. Heat Relay (HR)
GLOW
PLUG
PREHEAT
OFF OFF
IGN
STAR
TRUN
DANGER
HIGH
VOLT-
AGE
CB TRIP
460V CB
AMP HOURS
VS
230V CB
OFF 460
V
230
V
1
2345
6789
10
11121314

1-5
1.3 UNIT SPECIFICATIONS
a. Fuel Tanks
Standard:
50 Gallon (Integral) Steel
65 Gallon (Integral) Steel
Optional:
75 Gallon (Remote) Aluminum or Steel
110 Gallon (Remote) Steel
b. Weights
Battery:
52 lb (23.6 kg)
Generator (A-C):
285 lb (129 kg)
Engine (Dry) --- without Accessories:
595.25 lb (270 kg) Approx.
Fuel Tank (50 gallon) --- Dry:
100 lb (45 kg)
Fuel Tank (65 gallon) --- Dry:
130 lb (59 kg)
Fuel Tank (75 gallon) --- Dry:
190 lb (86 kg)
Fuel Tank (110 gallon) --- Dry:
225 lb (102 kg)
Unit (Genset):
1975 lb (898 kg)
1.4 ENGINE DATA
a. Bore/Stroke
3.94 in. (100mm) /4.72 in. (120 mm)
b. Compression Ratio
19 : 1
c. Cooling System
V-belt driven fan
d. Cylinders (Number)
Three
e. Displacement
172.45 cubic inches (2826 cubic cm)
f. Firing Order
1-2-3
g. Fuel
Winter: Diesel No. 1
Summer: Diesel No. 2
h. Glow Plug Amperage
10 amps per plug at 12 vdc
i. Horsepower
33.5 hp @ 1800 rpm
j. Lubrication System
Oil Pressure:
40 to 60 psig (3.8 to 5.2 kg/cm@)
Oil Pressure Safety Switch Setting Opens:
26 psig (1.83 kg/cm@)
Oil Temperature Safety Switch Setting Opens:
266 _F (130 _C)
Capacity:
Engine --- 21.13 U.S. quarts (20 liters)
Optional:
Fill-Max Filter --- 10 U.S. quarts (9.46 liters)
Time between Oil Changes:
First 400 Hours, thereafter every 1000 Hours
(maximum)
Oil Level Indicator:
Dipstick in oil pan
Lube Oil Specification:
Use a heavy duty lubricating oil conforming to
American Petroleum Institute (API) Service
Classification CD (DS)
Lube Oil Viscosity:
Outdoor Temperature
Fahrenheit Centigrade SAE
Below 32_0_C 10W or 10W30
32_to 77_F0_to 25_C20
Over 77_FOver+25_C 30 or 15W40

1-6
1.5 ENGINE SCREW THREADS
Allthreads used on the engines are metric except the
oil drain plug which is American Standard Pipe Thread
(NPT).
1.6 LUBE OIL AND FUEL FLOW DIAGRAMS
1
2
3
4
5
1. Engine Block
2. Engine Block Oil Connection
3. Oil Pan
4. Oil Pressure Gauge
5. Oil Pressure Switch
Figure 1-4. Lube Oil Flow Diagram
1. Fuel Tank
2. Fuel Supply Line
3. Fuel Warmer
(Optional)
4. Fuel Strainer
(Optional)
5. Mechanical
Fuel Pump
6. Fuel Return Line
7. Primary Filter
8. Secondary Filter
9. Injector Nozzles
10. Fuel Bleed Valve
11. Injection Pump
1
2
3
45
6
7
8
9
10
11
Figure 1-5. Fuel System Diagram
1.7 ENGINE AIR SYSTEM
The air cleaner is put on the engine to prolong its life
andperformancebypreventingdirt andgrit fromgetting
into the engine causing excessive wear on all operating
parts.However,the operatoris ofnecessity chargedwith
the responsibility of giving the air cleaner equipment
regular and constant attention in accordance with the
instructions.
Clean air is supplied to the engine through the air
cleaner (see Figure 1-2). The air is necessary for
complete combustion and scavenging of the exhaust
gases. As the engine piston goes through the intake
stroke, the piston draws clean fresh air down into the
cylinder for the compression and power strokes. As the
engine goes through its exhaust stroke, the upward
movement of the piston forces the hot exhaust gases out
of the cylinders through the exhaust valves and the
exhaust manifold. If the air filter is allowed to become
dirty, the operation of the engine would be impaired.
1.8 OPERATING CONTROLS AND
INSTRUMENTS
1.8.1 Introduction
Componentsrequiredformonitoringandcontrolling
the unit are located in the control box and control panel
(see Figure 1-3).
1.8.2 Control Panel and Related Components
(see Figure 1-3)
a. Gauges
1. Ammeter Gauge
Theammeterindicatestherateofdischargeorcharge
of the battery charging system composed of the battery
and battery charging alternator.
2. Oil Pressure Gauge
The gauge is located next to the control box (see
Figure 1-1). Its purpose is to observe normal operating
engine pressure. Normaloil pressure is 40 to60 psig(3.8
to 5.2 kg/cm@).
3. Total Time Meter
Thismeterdesignatesthetotalhoursandprovidesan
accurate readout of accumulated engine running time.
This data can be used to establish the proper periodic
maintenance schedule. (Refer to section 4.1.)
b. Indicators
1. Circuit Breaker Trip Light
This indicator light (red) may be checked (unit not
running) by placing the circuit breaker (CB-1) in the off
position and at the same time moving the ignition switch
to the runposition. Whenthe circuit breakers(CB-1for
460 vacor CB-4 for230vac) is in the off position, a set of
contacts close to complete a circuit to the light.
If the unit is running andthe circuit breaker trips, the
light will illuminate to signal the operator of a
malfunction with the generator.

1-7
2. Glow Plug Indicator
Thiscoilisusedasavisualaidtoassisttheoperatorin
determining when the glow plugs are fully energized.
While holding the glow plug switch in the UP (preheat)
position peer through the small holes on the face of the
indicator. When the coil inside illuminates to a bright
orange this indicates that the combustion chamber is at
the pre-heat stage for ignition.
c. Switches
1. Glow Plug Switch
Theglowplugswitch(momentarycontacttype),when
held in the UP position (pre-heat), permits battery
current (approximately 10 amps per plug at 12 vdc) to
flow to the glow plugs in the engine to pre-heat the
combustion chambers. The glow plugs are located under
thefuelinjectors.Whenstartingengine,itisnecessaryto
continue to hold the glow plug switch in the UP position
until the engine has developed sufficient oil pressure to
close the oil pressure safety switch.
2. Ignition Switch
The ignition switch (momentary contact type in the
start position), when held in the START (ignition)
position energizes the starter motor solenoid which in
turn allows the starter motor to crank.
3. Voltage Selector Switch (Optional)
This switch is used to select either 230 or 460 vac
output. When making a selection the unit must be OFF.
1.8.3 Protective Devices
a. Circuit Breakers
1. A-C Generator Circuit Breaker (CB-1)
This device is located on the control box panel. It
protects the A-C generator (main alternator) from
excessive current (amperage) draw. When the circuit
breaker trips, the generator power output to the
refrigeration unit ceases. The dieselengine willcontinue
to run (with normal engine operation), but a voltmeter
will indicate no output . The circuit breaker trips at 26
amps (460 vac) and must be manually reset.
2. Circuit Breaker (CB-2)
The circuit breaker is located in the control box. This
device prevents excessive current draw by the
componentsFS,FH,HR,S,SSandTT.Thecircuit
breaker opens at 20 amps and will automatically reset.
3. Circuit Breaker (CB-3)
The circuit breaker is located next to CB-2 in the
control box. This device prevents excessive current draw
by the glow plug and fuel pump circuitry. The circuit
breaker opens at 50 amps and will reset automatically.
4. Circuit Breaker (CB-4) (Optional)
This device is located next to CB-1 on the control box
panel. It protects the A-C generator (main alternator)
from excessive current (amperage) draw. When the
circuit breaker trips, the generator power output to the
refrigeration unit ceases. The dieselengine willcontinue
to run (with normal engine operation), but a voltmeter
will indicate no output . The circuit breaker trips at 48
amps (230 vac) and must be manually reset.
b. Switches
1. Fan Belt Switch (FBS)
This switch is activated by the fan belt breaking and
releasing the spring tension on the idler pully, which in
turn swings around to hit the fan belt switch. When this
happensasetofinternalcontactsopentode-energizethe
fuel solenoid (FS); thus stopping the engine.
2. Low Oil Pressure Switch (LOP)
This switch, set to open below 26 psig (1.83 kg/cm@)
will automatically stop the engine upon loss of oil
pressure. This switch is located behind the oil pressure
gauge(seeFigure1-1).Whentheswitchopens,thefuel
solenoid (FS) de-energizes; thus stopping the engine.
3. Oil Temperature Switch (OTS)
This switch, set to close above 266 _F(130 _C)will
automatically stop the engine when a high oil
temperatureisreached.Theswitchislocatedatthetopof
the engine block oil connection (see Figure 1-4). When
theswitchcloses,thesafetyrelay(S)coilisenergizedand
the normally closed (N.C.) safety relay contacts open to
de-energize the fuel solenoid (FS); thus stopping the
engine.

1-8
1.9 MAIN ALTERNATOR
(A-C GENERATOR)
Figure 1-6. Main Alternator (A-C Generator)
1.9.1 Principle of Operation
The MAC (Lima) brushless A-C generator is a
self-regulated, rotating field synchronous unit with the
rotor having a salient pole construction withamortisseur
windings. The generator stator and exciter stator are
combined in a common housing. The generator field,
exciterrotorandrotatingrectifierassemblyaremounted
on a common shaft. The output of the exciter rotor is
appliedtothegeneratorfieldwindingthrougharotating,
full-wave bridge, silicone rectifier unit.
The exciter pole pieces contain residual magnetism,
setting up lines of force across the air gap to the exciter
armature. When the exciter armature begins to rotate a
voltage is induced and current flow is initiated in the
exciter armature AC windings. This voltage is fed to the
rotating rectifier assembly, rectified and fed to the
alternator field coils. This DC voltage is sufficient to
magnetizethelaminatedalternatorfieldwhichwillsetup
linesofforceacrosstheairgaptothealternatorstator.As
thegenerator rotor rotates avoltage willbe induced and
current will flow in the alternator stator windings and to
the output circuit.
All connections between the exciter stator windings
and the generator stator windings are internally
connected within the stator housing. Only the output
power leads of the generator unit are brought out to the
generator terminal box.
1.9.2 A-C Generator (Main Alternator)
Circuit Diagram
Figure 1-7 shows the internal schematic diagram of
thegenerator,exciterandrectifier unit. The generatoris
athreephaseunitandtheexciterstatorandexciterrotor
also have three phase windings. A portion of the exciter
statorwindingsisconnectedacrossataponthegenerator
stator winding. This exciter shunt winding provides the
generator field excitation power required for the
generatornoloadvoltage.Anotherportionoftheexciter
stator windings is connected in series with the output of
the generator and provides a compounding excitation
characteristic.
The rotor is, in effect, the secondary of a rotating
current transformer induction frequency converter. The
exciter rotor output voltage is applied to the generator
fieldwindingsby athree phase fullwave rotatingsilicone
rectifier unit. The responsetime of the excitationsystem
is very fast since the exciter stator carries an alternating
current corresponding to the load current whichappears
immediately on the exciter primary. An increase in load
current will cause an immediate increase in the exciter
secondaryoutputvoltagewhichisrectifiedandappliedto
thegeneratorfieldwindings.Theinherentcompounding
characteristicsof the excitation system provide excellent
voltageregulationevenunderheavyoverloadconditions.
FIELD
STATOR
GENERATOR
SHUNT
SERIES
L
O
A
D
ROTOR
EXCITER
RECTIFIER
ASSEMBLY
STATOR
Figure 1-7. A-C Generator Circuit Diagram

1-9
1.10 BATTERY CHARGING ALTERNATOR
SYSTEM
1.10.1 Introduction
Table 1-3. Alternator and Manual
Prestolite Prestolite Amps
Alternator No. Manual No.
8EM2012NA 25-197 65
It is recommended that the applicable manual (see
chart above) be obtained from Prestolite Electric, 7585
Empire Drive, P.O. Box 6210, Florence, Kentucky, 41042,
U.S.A.,forcompleteoverhaulandserviceinformationof
the alternator, and regulator, if required.
The mechanical construction of the alternatordiffers
from the d-c generator in that the field rotates and the
(armature)generatingwindings are stationary. Thefield
current necessary to control the output of the alternator
is supplied from the solid-state regulator. This integral
voltage regulator, which incorporates an IC, all silicone
semiconductor and thick-film construction, controls the
current feed to the field via the brushes and rotor slip
rings.
Twocompletelysealedballbearingssupporttherotor
in the front and rear housing.
12
3
4
5
6
7
1. A-C Tap
2. Back Cover
3. Positive Output(B+)
4. Integral Regulator
5. Excite
6. Ground
7. 12vdc Test Lamp
Terminal (D+)
Figure 1-8. Alternator and Regulator
CAUTION
Observeproperpolaritywheninstallingbattery,
negative battery terminal must be grounded.
Reverse polarity will destroy the rectifier diodes
in alternator. As a precautionary measure,
disconnect positive battery terminal when
charging battery in unit. Connecting charger in
reverse will destroy the rectifier diodes in
alternator.

1-10
1.10.2 Alternator Operation
The alternator converts mechanical and magnetic
energy to alternating current (A-C) and voltage, by the
rotationofanelectromagneticfield(rotor)insideathree
phase stator assembly. The alternating current and
voltage is changed to direct current and voltage, by
passing A-C energy through a three phase, full-wave
rectifiersystem.Sixsiliconrectifierdiodesareused.(See
Figure 1-9)
1.10.3 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 state active elements used have proved
reliable enough to warrant a sealed unit. The system is
temperature compensated to permit the ideal charging
rate at all temperatures.
The regulator is an electronic switching device. It
senses the system voltage level and switches the voltage
applied to the field in order to maintain proper system
voltage.
1. 12vdc Test Lamp
Terminal (D+)
2. Diode Trio
3. Positive Output(B+)
4. Rectifier
5. Ground
6. A-C Tap
7. Rotor (Field)
8. Stator
9. Integral Regulator
10. Excite
123
4
5
6
7
8
9
10
Figure 1-9. Alternator Schematic Diagram

2-1
SECTION 2
OPERATION
2.1 GENERATOR SET INSTALLATION AND REMOVAL
1
2
3
4
5
6
7
1. Bolt (1/2-13 x 2-1/2 lg Grade 8)
2. Flat Washer
3. Mounting Clip
4. Genset Mounting Bracket
5. Rectangular Washer
6. Locknut
7. Chassis I-beam
CHASSIS CENTER LINEMOUNTING CLIPS
CHASSIS MOUNTING CLIP
GENSET GENSET BRACKET
SECTIONAL VIEW EXPLODED VIEW
CURBSIDE VIEW
Figure 2-1. Generator Set Mounting
TheGensetcenteredunderthetrailerchassisiseasily
removed with a fork lift truck (Fork lift pockets are
provided) capable of handling 2000 pounds.
NOTES
1. When installing genset, torque mounting
bolts to 85-90 ft-lbs (11.75-12.44 mkg).
2. It is not recommended using original
locknuts for second installation.
a. Installation:
1. Place forks into forklift pocketsof generatorset.
Attach safety chain between unit and fork truck.
2. FollowFigure 2-1forinstallationofgenset.Upon
completion, remove safety chain before removing forks
of fork lift truck from unit.
b. Removal:
1. Disconnect power cable to unit (if connected).
2. Disconnect fuel lines (if fuel tank is remote).
3. With fork lift in position and safety chain
attached remove hardware (see Figure 2-1) and then
remove genset.

2-2
2.2 PRE-TRIP INSPECTION
a. Before Starting Generator Set
1. Check engine lubrication and fuel oil filter cases,
oil lines, and connections for leaks.
(Tighten connections and/or replace gaskets.)
2. Check engine lubrication oil level.
(Refer to section 1.4.j.)
3. Check V-belts for fraying or cracks. (Refer to
section 4.4.)
4. Check engine blower fan for cleanliness.
5. Check air cleaner for cleanliness and clean if
necessary. (Refer to section 4.3.5.)
6. Drainwaterfromprimaryfuelfilterandfueltank
sump.
7. Fill fuel tank with diesel fuel.
(Refer to section 1.4.g.)
8. Check glow plug amperage.
(Refer to section 1.4.h.)
9. Check battery terminals for cleanliness and
securement.(Cleanandcoatwithamineraltypegrease.)
10. Check for loose electrical connections.
11. Tighten all hardware. (Brackets, ect.)
12. Connect power cable to refrigeration unit. Start
genset as detailed in section 2.3 and then turn refrigera-
tion unit ON to check operation.
(Refer to section b.)
b. After Starting Generator Set
1. Refer to section 2.3 for starting and stopping
instructions.
2. Checking with a voltmeter. Generator output
should be 460 volts a-c (¦10% no load).
(1825 rpm, no load) (1800 rpm, with load).
3. Check total time meter operation.
(Run engine 10 minutes.)
4. Listen for abnormal bearing noise.
(Main alternator.)
5. Checkfuellines,lubeoillinesandfiltersforleaks.
6. Check exhaust system for leaks.
2.3 STARTING AND STOPPING
INSTRUCTIONS
a. Starting Instructions
NOTE
On new or not yet broken-in engines there is a
possibility ofoilseepageoutthe mufflerexhaust
pipe. The following is recommended:
1. Avoid prolonged high idle/no load periods
when engine is not broken-in.
2. Apply fullload to engine as soon aspossible
during initial run-in.
3. Check valve clearance when engine is cold.
(Refer to engine workshop manual, see section
1.1)
WARNING
Undernocircumstancesshouldetherorany
other unauthorized starting aids be used in
conjunction with the glow plugs.
NOTE
When starting the engine, it is necessary to
continue to hold the glow plug switch in the UP
position until the engine develops sufficient oil
pressure to close the oil pressure safety switch,
energizing and completing all circuits for unit
operation.
4. Hold glow plug switch in the UP position for 30
seconds. (See Figure 1-3.)
NOTE
Below 0_F, hold glow plug switch for two
minutes, release switchfor 30seconds andagain
hold glow plug switch for two minutes. If engine
doesnotstartafter10secondscranking,wait for
30 seconds before repeating starting procedure.
5. With glow plug switch held in the PREHEAT
position, pushthe ignitionswitch tothe STARTposition.
6. After engine has started, continue to hold the
glow plug switch in the UPposition until the oil pressure
safety switch closes (when engine develops sufficient oil
pressure). The glow plug switch will automatically be in
the OFF position when released.
7. Complete pre-trip inspection.
(Refer to section 2.2.b.)
b. Stopping Instructions
1. Push ignition switch to the OFF position.

2-3
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 the glow plug switch is held in the pre-heat
position, current flows to the glow plugs. The glow plugs
(starting aids) provide a source of heat to pre-heat the
combustion chamber during start-up.
In order to start engine, hold the glow plug switch in
the PREHEAT position for the recommended time as
detailed in section 2.3.a. and then hold the ignition
(Start-Run-Off) switch in the START position. With
ignitionswitch inthe START position, starter solenoid is
energized closing starter motor contactor contacts (SS),
which energizes starter motor. The starter motor turns
over the engine resulting in pumping fuel to the engine
cylinders by the injection pump. This fuel is ignited by
heat of compression; thus starting the engine.
When the engine has developed sufficient oil pres-
sure, oilpressure safety switch contactsclose to maintain
a circuit to the fuel solenoid (FS). The glow plug switch is
then released and the ignition switch is released to the
RUN position. Releasing glow plug switch de-energizes
the glow plugs.
Total time meteris energized simultaneously withthe
fuel solenoid.
With the engine running, the alternator provides
12-volt d-c power to operate the control system and
charge the battery.

3-1
SECTION 3
TROUBLESHOOTING
3.1 DIESEL ENGINE
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
3.1.1 Engine Will Not Start
a. Starter motor Battery insufficiently charged Charge
will not crank or low Battery terminal post or battery defective Check
cranking speed. Bad electrical connections at starter Correct
Starter motor malfunctions 3.1.3
Starter motor solenoid defective Engine Manual
Open starting circuit 3.1.4
Incorrect grade of lubricating oil 1.4.j
b. Starter motor No fuel in tank 1.3/1.4.g
cranks but engine Air in fuel system 4.2
fails to start Water in fuel system Drain Sump
Plugged fuel filters Replace
Faulty fuel control operation 4.3.3
Safety relay Check
Glow plug(s) defective 4.3.6
Plugged fuel lines to injector(s) Engine Manual
Mechanical lift fuel pump malfunction Engine Manual
c. Starter cranks, Engine lube oil too heavy 1.4.j
engages but dies Voltage drop in starter cable(s) Check
after a few seconds
3.1.2 Engine Starts Then Stops
a. Engine stops No fuel in tank 1.3/1.4.g
after several Faulty fuel control operation 4.3.3
rotations Fuel filter(s) restricted Replace
Air cleaner or hose restricted 4.3.5
Safety device open 1.2
Open wiring circuit to fuel solenoid Check
Fuel solenoid linkage disconnected 4.3.3
Fuel supply restricted 1.4.g/4.2
Mechanical lift fuel pump malfunction Engine Manual
Oil pressure switch defective Replace
Leak in fuel system Check
Injector nozzle(s) defective Engine Manual
Injection pump defective Engine Manual

3-2
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
3.1.3 Starter Motor Malfunction
a. Starter motor Battery insufficiently charged Charge
will not crank or Battery cable connections loose or oxidized Check
turns slowly Battery cables defective Replace
Starter brushes shorted out Engine Manual
Starter brushes hang up, defective or
have no contact Engine Manual
Starter solenoid damaged Engine Manual
Ignition switch defective Replace
Engine lube oil too heavy 1.4.j
b. Starter motor Pinion or ring gear obstructed or worn Engine Manual
turns but pinion
does not engage
c. Starter motor Ignition switch defective Replace
does not disengage Starter motor solenoid defective Engine Manual
after switch has
been released
d. Pinion does not Defective starter Engine Manual
disengage after
engine is running
3.1.4 Malfunction In the Engine Starting Circuit
a. No power to Battery defective Correct
starter motor Loose electrical connections Tighten
solenoid
b. Fuel solenoid Battery defective Correct
does not energize or Loose electrical connections Tighten
does not remain Oil pressure switch defective 1.2
energized Safety relay defective Replace
Fuel solenoid defective 4.3.3
Ignition switch defective Replace
3.1.5 Miscellaneous Engine Troubleshooting
a. Loss of power Restriction in air cleaner 4.3.5
Air in fuel system 4.2
Air vent restricted Clean
Restricted fuel lines 1.4.g/4.2
Defective fuel injection pump Engine Manual
Defective injector(s) or incorrect type Engine Manual
Incorrect fuel injection pump timing Engine Manual
Incorrect valve timing Engine Manual
Poor compression Engine Manual