Model

69GC15-164

T-247-05
 OPERATION AND
SERVICE MANUAL
DIESEL DRIVEN GENERATOR SET

MODEL
69GC15-164

Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221
 Carrier Corporation 1994 D Printed in U. S. A. 1294
 TABLE OF CONTENTS

Section Page

1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 Engine Screw Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Engine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Operating Controls And Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7.2 Control Panel And Related Components . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7.3 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.8 Main Alternator (A-C Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.8.1 Principle Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.8.2 A-C Generator (Main Alternator) Circuit Diagram . . . . . . . . . . . . . . . 1-6
1.9 Battery Charging System --- 69GC15-164, -1, -2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.10 Battery Charging System --- 69GC15-164-3, -4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.11 Lube Oil And Fuel Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Generator Set Installation And Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Pin Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Pre-Trip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Starting And Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Control Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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 Battery Charger (Solid State) --- 69GC15-164, -1, -2 . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Battery Charger (Solid State) --- 69GC15-164-3, -4 . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 A-C Brushless Generator (Main Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

i
 TABLE OF CONTENTS (CONTINUED)

Section Page

4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.5 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.6 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.7 Servicing Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.8 Servicing Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 Servicing And Adjusting V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4.1 Water Pump 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 Replacing Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6.1 Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6.2 Shockmount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7 Maintenance Of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.8 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

5 ELECTRICAL WIRING SCHEMATIC & DIAGRAM . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

ii
 LIST OF ILLUSTRATIONS

Figure Page
1-1 Generator Set --- Front View With Cover Removed . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Control Box And Gauge Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-4 Main Alternator (A-C Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-5 A-C Generator Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-6 Lube Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-7 Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-8 Fuel System Diagram --- 69GC15-164-3, -4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2-1 Pin Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
4-1 Fuel Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-4 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-5 Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-6 Rectifier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-7 A-C Generator (Rectifier Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-8 Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-9 Shockmount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-10 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

5-1 Electrical Wiring Schematic & Diagram ---

(Models 69GC15-164 & 69GC15-164-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Electrical Wiring Schematic & Diagram ---
(Model 69GC15-164-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 Electrical Wiring Schematic & Diagram ---
(Model 69GC15-164-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4 Electrical Wiring Schematic & Diagram ---
(Model 69GC15-164-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

LIST OF TABLES

Table Page
1-1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

iii
 SECTION 1
DESCRIPTION
1.1 INTRODUCTION starting aid), “spin-on” lube oil and fuel filters for easier
WARNING filter changes. All references to the engine are viewed
from the fly wheel end.
Beware of moving V-Belts and belt driven
components. Electrical power is generated by a Lima 15 KW,
brushless, single bearing A-C generator. The generator is
This manual contains Operating Data, Electrical
coupled directly to the engine flywheel. The generator
Information, and Service Instructions for the diesel
provides a constant 460 vac, 3 phase, 60 hertz electrical
generator set shown in Table 1-1. (See left side of unit for
supply.
serial/model number plate.) Separately bound manuals
covering the CT4-134-DI diesel engine for the diesel- The water pump and the radiator cooling fan are
driven generator sets are also supplied, see chart below. belt-driven from the engine crankshaft sheave.

MANUAL/ EQUIPMENT TYPE OF 1.2 SAFETY DEVICES (Refer to Table 1-2)

FORM NO. COVERED MANUAL/FORM System components are protected from damage
caused by unsafe operating conditions by automatically
62-03459 CT4-134-DI Engine Parts List
shutting down the diesel engine when such conditions
62-03741 CT4-134-DI Workshop Manual
occur. This is accomplished by the safety devices CB-2,
The diesel-driven generator sets are intended for HWT or LOP. These safety devices monitor system
front mounting upon a refrigeration unit. They provide a operating conditions and open a set of electrical contacts
constant electrical power supply for the operation of an when an unsafe condition occurs. Opening one or more
all-electric refrigeration unit. of these safety switch contacts will de-energize the run
control relay. This, in turn, opens a set of RCR contacts to
Located inside the frame are the diesel engine, A-C
de-energize the fuel solenoid.
generator (main alternator), control and monitoring
cabinet, starting battery, 12 vdc solid state battery De-energizing fuel solenoid releases the stop-run
charger, and other necessary accessory components for lever to the STOP position, shutting off the fuel supply to
proper unit operation. the engine; thus stopping the engine.
For power, the Carrier Transicold Model The A-C generator and the glow plug circuit are
CT4-134-DI, vertical in-line, four cylinder diesel engine protected by circuit breakers (listed below) but will not
is used. The engine is equipped with glow plugs (used as a shut down the engine if an overload occurs.

Table 1-1. Model Chart

Model No. Engine Solid State Dual Fuel Fuel Tank
CT4-134DI Battery Charger Gauges 120 U.S. Gallons
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

1-1
 Unsafe Condition Safety Switch Switch Setting
a. Engine
1. Low engine lubricating 1. Oil pressure switch (LOP) --- 1. Opens below 15 psig
oil pressure Automatic reset (1.05 kg/cm@)
2. High engine cooling 2. Water temperature switch (HWT) --- 2. Opens above 230 ¦
water temperature Automatic reset 5_F (110 ¦ 3_C)
3. Excessive current draw 3. Circuit breaker (CB-2) --- 3. Trips at 20 amps
by FS, HWT, L1, OPG, Automatic reset
WTG, RCR or TT
4. Excessive current draw 4. Circuit breaker (CB-4) --- 4. Trips at 30 amps
by battery charger Automatic reset
b. Glow-Plugs
1. Excessive current draw 1. Circuit breaker (CB-3) --- 1. Opens at 45 amps
on glow plug circuit Automatic reset
c. Generator
1. Excessive current draw 1. Circuit breaker (CB-1) --- 1. Trips at 25 amps
by generator Manual reset (460 vac)

1 2 3 4 5 6 7 8 9 10 11 2

24 23 22 21 20 19 17,18 16 15 14 13 12

1. Fuel Gauge 8. Fuel Solenoid (FS) 17. A-C Generator

2. Fuel Fill 9. Mechanical Lift Pump 18. Oil Pressure Switch (LOP)
3. Battery (BAT) 10. Fuel Bleed Valve 19. Oil Pressure Gauge
4. Air Cleaner 11. Radiator Cap 20. Lube Oil Filter
5. Fuel Filters 12. Control Box and Panel 21. Water Temperature Gauge(WTG)
6 Battery Charger 13. Power Receptacle 22. Water Separator
(Located on top of generator 14. Lube Oil Dipstick 23. Fuel Shut-Off Valve
--- 69GC15-164-3, -4) 15. Starter Motor (SM) 24. Generator Terminal Box
7. Muffler 16. Radiator Overflow Tank
Figure 1-1. Generator Set --- Front View with Cover Removed

1-2
 5
11
1 6

10

7 9
2
3
4
8

1. Battery Charger (B) 7. Circuit Breaker (CB-1)

(Located behind box for 4. Circuit Breaker 8. Circuit Breaker (CB-2)
models 69GC15-164, -1, -2) Trip Indicator (L1) 9. Circuit Breaker (CB-3)
2. Glow Plug Switch (GPS) 5. Ammeter (A) 10. Run Control Relay (RCR)
3. Ignition Switch (IGN) 6. Total Time Meter (TT) 11. Circuit Breaker (CB-4)
Figure 1-2. Control Box and Gauge Panel
1.3 UNIT SPECIFICATIONS Water Temperature Switch Setting:
a. Unit Weight Approx. Opens 230 ¦ 5_F (110 ¦ 3_C)
Resets 200_F (93_C) --- minimum
2690 lb (1223 kg) with fuel and battery
Thermostat:
b. Engine (Dry) --- with Accessories Starts to Open 177 to 182_F (80 to 84_C)
421 lb (191 kg) Fully Open 203_F (95_C)
c. A-C Generator d. Cylinders (Number)
Four
225 lb (102 kg)
e. Displacement
d. Fuel Tank Capacity
CT4-134-DI (V2203):
Liquid: 126 U.S. Gallons (477 liter) 134 cu. in. (2.2 liters)
Draw: 119.5 U.S. Gallons (452.4 liter) f. Firing Order
1.4 ENGINE DATA 1-3-4-2
g. Fuel
a. Bore/Stroke
Winter: Diesel No. 1
CT4-134-DI (V2203): Summer: Diesel No. 2
3.43 in. (87 mm) /3.64 in. (92.4 mm) h. Glow Plug Amperage
b. Compression Ratio 7.5 amps per plug at 12 vdc
CT4-134-DI (V2203): i. Horsepower
CT4-134-DI (V2203):
20.5:1
33.0 hp @ 1800 rpm
c. Cooling System
j. Lubrication System
Capacity: Oil Pressure:
8 U.S. quarts (7.57 liters) --- includes 1 quart 40 to 60 psig (3.8 to 5.2 kg/cm@)
(0.946 liter) in coolant recovery bottle. Oil Pressure Switch Setting Closes:
(Refer to section 4.3.1)
15 psig (2.08 kg/cm@)
Type of Anti-Freeze: Capacity:
Ethylene Glycol 4 quarts (3.78 liters) 20 U.S. quarts (18.9 liters)
Water 4 quarts (3.78 liters) Time between Oil Changes:
Use a low silicate anti-freeze meeting GM First 400 Hours, thereafter every 1000 Hours
specifications GM 6038M or equal. (maximum)

1-3
 Oil Level Indicator: the screen where dirt or dust in the air is removed before
Dipstick in oil pan it enters the engine. As the dust and dirt accumulate, the
filter should be changed periodically. If the filter is not
Lube Oil Specification:
changed, it will be blocked so that it cannot effectively
Use a heavy duty lubricating oil conforming to remove the dirt and dust from the air passing over the
American Petroleum Institute (API) Service Classifica- TM
tion CD (DS). screens. The air cleaner is equipped with Vacuator
Valve which continuously expel dust and moisture. On
Lube Oil Viscosity: cleaners equipped with dust cup, the cup is emptied as
Outdoor Temperature dust accumulates.
a. Pre-cleaner
Fahrenheit Centigrade SAE The illustration shows a fin which gives high-speed
rotation to the intake air, and separates a large portion of
Below 32_ 0_C 10W or 10W30 the dust from the air by centrifugal action. The plastic fin,
32_ to 77_F 0_ to 25_C 20 the element, and the gasket are vital parts of the cleaner
Over 77_F Over +25_C 30 or 15W40 and are designed into a single replaceable assembly. This
design feature assures continued high performance of
1.5 ENGINE SCREW THREADS the cleaner.
All threads used on the Model CT4-134-DI engine b. Ejected dust
are metric except the oil drain plug which is American The dust is swept through a slot in the baffle and
Standard Pipe Thread (NPT).
collected in the dust cup or Vacuator TM Valve body.
1.6 ENGINE AIR SYSTEM
c. Duralife filter
The small portion of the dust remaining in the
pre-cleaned air is removed by the Duralife element. The
element is chemically-treated and oven-cured for resis-
tance to oil and water. Perforated steel supports the
element inside and out and, together with rigid metal end
caps, provides structural rigidity to this vital part of the
cleaner. The element can be cleaned for re-use by one of
1 several recommended processes. (Refer to section 4.3.5)
1.7 OPERATING CONTROLS AND
INSTRUMENTS
1.7.1 Introduction
2 Most components required for monitoring and con-
trolling the unit are located in the control box and control
panel, the remaining components and their locations are
3 also described below.
1.7.2 Control Panel and Related Components
a. Gauges and Senders
1. Ammeter (A)
The ammeter indicates the rate of discharge or charge
1. Pre-Cleaner of the battery charging system composed of the battery
2. Ejected Dust and the solid state battery charger. (See Figure 1-2)
3. Duralife Filter 2. Oil Pressure Gauge
Figure 1-3. Engine Air Cleaner The purpose of this gauge is to observe normal
Clean air is supplied to the engine through the air operating engine oil pressure. Normal oil pressure is 40 to
cleaner. (See Figure 1-3) The air is necessary for 60 psig (2.8 to 4.2 kg/cm@). (See Figure 1-1)
complete combustion and scavenging of the exhaust 3. Water Temperature Gauge (WTG)
gases. As the engine piston goes through the intake
The function of this gauge is to observe water
stroke, the piston draws clean fresh air down into the
operating temperature (180 to 205_F = 82 to 94_C). The
cylinder for the compression and power strokes. As the
gauge is connected to a water temperature sensing
engine goes through its exhaust stroke, the upward
device. If the gauge or sender fails, both must be replaced
movement of the piston forces the hot exhaust gases out
(kit available). (See Figure 1-1)
of the cylinders through the exhaust valves and the
exhaust manifold. If the air filter is allowed to become 4. Water Temperature Sender
dirty, the operation of the engine would be impaired. This sensing device senses engine water temperature
Blow-by gases from the diesel engine crankcase are and transmits a signal to the water temperature gauge.
introduced in the air intake manifold through the The water temperature sender is located on the top,
crankcase breather. Therefore, the filter must be kept front, right side of the engine below the HWT switch. The
clean and air restriction reduced to a minimum. A dry water temperature gauge and sender both must be
type air cleaner is used with this unit. Air passes through replaced if either component fails (kit available).

1-4
b. Indicator Light current draw by the battery charging transformer line
1. Circuit Breaker Trip Light (L1) voltage. The circuit breaker opens at 30 amps and will
reset automatically.
This light (red) may be checked (unit not running) by
placing the circuit breaker (CB-1) in the off position and b. Switches
at the same time moving the ignition switch to the run 1. Oil Pressure Switch (LOP)
position. When the circuit breaker is in the off position, a This switch, set to open below 15 psig (1.05 kg/cm@)
set of contacts close to complete a circuit to the light. will automatically stop the engine upon loss of oil
If the unit is running and the circuit breaker trips, the pressure. This switch is located above the oil filter. (See
light will illuminate to signal the operator of a malfunc- Figure 1-1) When the switch opens, the run control relay
tion with the generator. (See Figure 1-2) (RCR) coil is de-energized and the RCR contacts open to
de-energize the fuel solenoid (FS); thus stopping the
c. Meter
engine.
1. Total Time Meter (TT)
2. Water Temperature Switch (HWT)
This meter designates the total hours and provides an
accurate readout of accumulated engine running time. This This switch, set to open at 230 ¦ 5_F (110 ¦ 3_C),
data can be used to establish the proper periodic mainte- will automatically stop the engine upon high water
nance schedule. (Refer to section 4.1) (See Figure 1-2) temperature. The switch is located near the thermostat
housing. When the switch opens, the run control relay
d. Switches (RCR) coil is de-energized and the RCR contacts open to
1. Glow Plug Switch (GPS) de-energize the fuel solenoid (FS); thus stopping the
The glow plug switch (momentary contact type), when engine.
held in the UP position (pre-heat), permits battery 1.8 MAIN ALTERNATOR
current (approximately 7.5 amps per plug at 12 vdc) to (A-C GENERATOR)
flow to the glow plugs in the engine to pre-heat the
combustion chambers. The glow plugs are located under
the fuel injectors. When starting engine, it is necessary to
continue to hold the glow plug switch in the UP position
until the engine has developed sufficient oil pressure to LIMA
close the oil pressure safety switch. (See Figure 1-2)
2. Ignition Switch (IGN)
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. (See Figure 1-2) Figure 1-4. Main Alternator (A-C Generator)
1.7.3 Protective Devices 1.8.1 Principle of Operation
a. Circuit Breakers The MAC (Lima) brushless A-C generator is a
1. A-C Generator Circuit Breaker (CB-1) self-regulated, rotating field synchronous unit with the
rotor having a salient pole construction with amortisseur
This device trips at 25 amps to protect the A-C windings. The generator stator and exciter stator are
generator (main alternator) from excessive current combined in a common housing. The generator field,
(amperage) draw. When the circuit breaker trips, the exciter rotor and rotating rectifier assembly are mounted
generator power output to the refrigeration unit ceases. on a common shaft. The output of the exciter rotor is
The diesel engine will continue to run (with normal applied to the generator field winding through a rotating,
engine operation), but the voltmeter will indicate no full-wave bridge, silicone rectifier unit.
output and the circuit breaker indicator light will be
illuminated. (See Figure 1-2) The exciter pole pieces contain residual magnetism,
setting up lines of force across the air gap to the exciter
2. Circuit Breaker (CB-2) armature. When the exciter armature begins to rotate a
The circuit breaker is located in the right-hand voltage is induced and current flow is initiated in the
bottom corner of the control box. This device prevents exciter armature AC windings. This voltage is fed to the
excessive current draw by the components FS, HWT, L1, rotating rectifier assembly, rectified and fed to the
OPG, RCR, WTG, and TT. The circuit breaker opens at alternator field coils. This DC voltage is sufficient to
20 amps and will automatically reset. magnetize the laminated alternator field which will set up
3. Circuit Breaker (CB-3) lines of force across the air gap to the alternator stator. As
the generator rotor rotates a voltage will be induced and
The circuit breaker is located above CB-2 in the current will flow in the alternator stator windings and to
control box. This device prevents excessive current draw the output circuit.
by the glow plug circuitry. The circuit breaker opens at 45
amps and will reset automatically. All connections between the exciter stator windings
and the generator stator windings are internally con-
4. Circuit Breaker (CB-4) (69GC15-164, -1, -2) nected within the stator housing. Only the output power
The circuit breaker is located above the run control leads of the generator unit are brought out to the
relay in the control box. This device prevents excessive generator terminal box.

1-5
1.8.2 A-C Generator (Main Alternator) 1.9 Battery Charging System --- 69GC15-164, -1, -2
Circuit Diagram
The solid state battery charging system is located on
the control box, see Figure 1-2. This battery charging
FIELD
system consists of two sections; first, a 17---18 volt
transformer, that is powered by the LIMA generator.
Second, is a solid state voltage regulator that rectifies the
SHUNT input voltage and controls the output voltage for opti-
mum charging. The battery charger has a maximum
charge rate of 20 amps and is designed not to over charge
the battery.
SERIES
1.10 Battery Charging System --- 69GC15-164-3, -4
STATOR On models 69GC15-164-3 and 69GC15-164-4, the
solid state battery charger is located on top of the
GENERATOR STATOR generator, next to the air cleaner (see Figure 1-1). The
L charger is powered by the Lima generator and this input
O is protected by a 3 amp fuse located on the generator
A junction box. The battery charger has a maximum charge
D rate of 25 amps and is designed not to overcharge the
battery.
CAUTION
Observe proper polarity when installing the
ROTOR battery, the negative battery terminal must be
grounded. Reverse polarity will destroy the
rectifier diodes in the generator sets solid state
RECTIFIER EXCITER battery charging system if a battery charger is
ASSEMBLY
connected in reverse. As a precautionary
measure isolate the battery from the unit as
follows: disconnect negative battery terminal
Figure 1-5. A-C Generator Circuit Diagram first, then the positive battery terminal when
charging battery in unit. Once the battery has
Figure 1-5 shows the internal schematic diagram of
been fully charged, connect the positive battery
the generator, exciter and rectifier unit. The generator is
terminal first, then the negative battery
a three phase unit and the exciter stator and exciter rotor
terminal. NEVER jump start the battery when
also have three phase windings. A portion of the exciter
its mounted in the unit, this will destroy the
stator windings is connected across a tap on the generator
components of the generator sets battery
stator winding. This exciter shunt winding provides the
charger.
generator field excitation power required for the genera-
tor no load voltage. Another portion of the exciter stator 1.11 LUBE OIL AND FUEL FLOW
windings is connected in series with the output of the DIAGRAMS
generator and provides a compounding excitation char-
acteristic.
The rotor is, in effect, the secondary of a rotating
current transformer induction frequency converter. The
exciter rotor output voltage is applied to the generator 1
field windings by a three phase full wave rotating silicone 2
rectifier unit. The response time of the excitation system
4 3
is very fast since the exciter stator carries an alternating
current corresponding to the load current which appears
immediately on the exciter primary. An increase in load
current will cause an immediate increase in the exciter 1. Full flow oil filter 3. Oil pressure gauge
secondary output voltage which is rectified and applied to 2. Engine block oil 4. Oil pressure switch
the generator field windings. The inherent compounding pump connections
characteristics of the excitation system provide excellent
voltage regulation even under heavy overload conditions. Figure 1-6. Lube Oil Flow Diagram

1-6
 3 3
4 4
1 2 5 6 1 2 5

11 10 9 8 7 8 6
7

1. Fuel Tank 7. Mechanical Pump 1. Fuel Tank 5. Fuel Filters

2. Fuel Return Line 8. Strainer 2. Fuel Return Line 6. Mechanical Pump
3. Injector Nozzles 9. Water Separator 3. Injector Nozzles 7. Shut-Off Valve
4. Injection Pump 10. Shut-Off Valve 4. Injection Pump 8. Fuel Supply Line
5. Fuel Filters 11. Fuel Supply Line
6. Fuel Warmer Figure 1-8. Fuel System Diagram --- 69GC15-164-3, -4

Figure 1-7. Fuel System Diagram

1-7
 SECTION 2
OPERATION
2.1 GENERATOR SET INSTALLATION AND REMOVAL
2.1.1 Pin mounting

D D
C C
A

Figure 2-1. Pin Mounting

WARNING 2. Release retaining plate (D) from locking brack-
To prevent injury, the procedures for installation et on each side of generator set.
and removal of the generator set given below 3. Remove mounting bolt (C) on each side of
must be followed. generator set.
NOTE 4. Raise generator set several inches to disengage
This generator set is equipped with special pins pins (B) from mating holes and remove from container.
and mounting bolts and can be installed only on 2.2 PRE-TRIP INSPECTION
containers with matching installation points. a. Before Starting Generator Set
a. Installation: 1. Check engine lubrication and fuel oil filter
1. Place forks into fork pockets of generator set. cases, oil lines, and connections for leaks.
Attach safety chain (A) between fork pockets on genera- (Tighten connections and/or replace gaskets)
tor set and fork truck. Be sure chain (A) is short enough 2. Check engine lubrication oil level.
to retain generator set on forks. (Refer to section 1.4.j.)
2. Line up generator set with refrigeration unit 3. Check engine V-Belt for proper tension, fraying
and container. Raise generator set until top of set is or cracks. Adjust belt or replace.
several inches above top edge of container. Move (Refer to section 4.4)
generator set against container and lower into position.
4. Check radiator hoses for leaks and check
Important --- Two pins (B) must be fully engaged in radiator coolant level. (Add pre-mixed 50/50 antifreeze-
mating holes in container. water as required.) Refer to section 1.4.c.
3. Keep forks in pockets on generator set and 5. Check radiator coil and generator air intake
tighten mounting bolt (C) on each side of generator set screen for cleanliness. (Clean using compressed air,
into container frame. reversing the normal air flow.)
Important --- Bolts must be tight and retaining plate (D) 6. Check air cleaner for cleanliness and clean if
must be locked into position. necessary. (Refer to section 4.3.5)
4. Remove safety chain (A) before removing forks. 7. Drain water from fuel tank sump.
b. Removal: 8. Fill fuel tank with diesel fuel.
WARNING (Refer to section 1.4.g.)

Disconnect power plug before removing generator 9. Check glow plug amperage.
set. (Refer to section 1.4.h.)
10. Check battery terminals for cleanliness and
1. Move forks into fork pockets on generator set.
secureness. (Clean and coat with a mineral type grease.)
Attach safety chain (A) between fork pockets on genera-
tor set and fork truck. 11. Check for loose electrical connections.

2-1
 12. Connect power cable to refrigeration unit. Start NOTE
genset as detailed in section 2.3 and then turn refrigera- At this point, observe the ammeter reading
tion unit on to check operation. which should be positive. If the reading is
(Refer to section 2.2.b.) negative or neutral, this is an indication of
13. Grease Fuel Solenoid plunger. improper charging (refer to section 3.2).
(Use P/N 07-00245-00.) 4. Complete pre-trip inspection.
b. After Starting Generator Set (Refer to section 2.2.b.)
1. Refer to section 2.3 for starting and stopping b. Stopping Instructions
instructions.
1. Push ignition switch to the OFF position.
2. Check total time meter operation.
(Run engine 10 minutes) 2.4 CONTROL CIRCUIT OPERATION
WARNING
3. Listen for abnormal bearing noise.
(Main alternator) Beware of moving V-Belts and belt driven
components.
4. Check fuel lines, lube oil lines and filters for
leaks. CAUTION
5. Check radiator and hoses for leaks. The generator set circuit breaker must be in the
ON position in order to supply power to the
6. Check exhaust system for leaks. refrigeration unit.
7. Check operation of indicator light.
When the glow plug switch is held in the pre-heat
(Refer to section 1.7.2.c.)
position, current flows to the glow plugs. The glow plugs
2.3 STARTING AND STOPPING (starting aids) provide a source of heat to pre-heat the
INSTRUCTIONS combustion chamber during start-up. Power also flows to
a. Starting Instructions the run control relay which energizes, and closes the RCR
contacts. From the relay RCR, power flows through the
WARNING high water temperature switch to ground.
Under no circumstances should ether or any
In order to start engine, hold the glow plug switch in
other unauthorized starting aids be used in
the UP position for the recommended time as detailed in
conjunction with the glow plugs.
section 2.3.a. and then hold the ignition (Start-Run-Off)
NOTE switch in the START position. With ignition switch in the
When starting the engine, it is necessary to START position, starter solenoid is energized closing
continue to hold the glow plug switch in the UP starter motor contactor contacts (SS), which energizes
position until the engine develops sufficient oil starter motor. The starter motor turns over the engine
pressure to close the oil pressure safety switch, resulting in pumping fuel to the engine cylinders by the
energizing and completing all circuits for unit injection pump. This fuel is ignited by heat of compres-
operation. sion; thus starting the engine. Also, run control relay is
energized at the same time to close a set of contacts and
1. Hold glow plug switch in the UP position for 30 completes a circuit to the fuel solenoid.
seconds. (See Figure 1-2)
When the engine has developed sufficient oil pres-
NOTE sure, oil pressure safety switch contacts close to maintain
Below 0_F, hold glow plug switch for two a circuit to the run control relay. Energizing this relay
minutes, release switch for 30 seconds and again closes (RCR) contacts providing a circuit to keep the fuel
hold glow plug switch for two minutes. If engine run solenoid energized as long as the safety switch
does not start after 10 seconds cranking, wait for contacts remain closed. The glow plug switch is then
30 seconds before repeating starting procedure. released and the ignition switch is released to the RUN
position. Releasing glow plug switch de-energizes the
2. With glow plug switch held in the UP position, glow plugs.
push the ignition switch to the START position.
Total time meter is energized simultaneously with the
3. After engine has started, continue to hold the
fuel solenoid.
glow plug switch in the UP position until the oil pressure
safety switch closes (when engine develops sufficient oil With the engine running, the solid state battery
pressure). The glow plug switch will automatically be in charger provides 12-volt d-c power to operate the control
the OFF position when released. system and charge the battery.

2-2
 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. Battery charger assembly defective Replace
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
Closed fuel shut-off valve Open

b. Starter motor No fuel in tank 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
Run control relay 4.3.3
Glow plug(s) defective 4.3.7
Plugged fuel lines to injector(s) 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 1.4.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 run solenoid Check
Fuel solenoid linkage disconnected 4.3.3
Oil pressure switch defective Replace
Closed fuel shut-off valve Open
Fuel supply restricted Engine Manual
Leak in fuel system Engine Manual
Injector nozzle(s) defective Engine Manual
Injection pump defective Engine Manual

3-1
 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 charger assembly defective Replace
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 Water temperature safety switch open 1.2
energized Oil pressure switch defective Replace
Run control relay defective 4.3.3
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 in fuel cap restricted Clean
Restricted fuel lines Engine Manual
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

3-2
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION

3.1.5 Miscellaneous Engine Troubleshooting (continued)

b. Vibration Engine shockmounts defective Replace

Poor compression Engine Manual
Fuel solenoid or linkage 4.3.3

c. Overheating Restriction in air cleaner 4.3.5

Exhaust pipe restriction Remove
Restriction in water jacket Check
Loose water pump V-Belt 4.4
Restriction in radiator 4.3.1
Coolant level too low 1.4.c.
Defective thermostat Engine Manual
Defective water pump Engine Manual

d. Excessive crankcase
pressure Plugged crankcase breather line 4.3.6

3.2 BATTERY CHARGER (SOLID STATE) --- 69GC15-164, -1, -2

Battery Undercharged Defective cables, dirty battery posts or

corroded terminals Replace/Clean
Defective transformer
or battery charger
(Ammeter indicates negative) Replace

Battery Overcharged Defective battery charger system Check

--- excessive use of water.
Voltmeter indicates greater
than 14.5 volts (connected
across battery with no load)
with engine idling.

3.3 BATTERY CHARGER (SOLID STATE) --- 69GC15-164-3, -4

a. Input fuse/breaker blows when Short in 12 volt wiring causing Locate and
charger is turned on overload of charger remove short

b. Input fuse/breaker blows repeatedly, Internal short Replace

even with no battery connected

c. Charger does not taper back Bad cell in battery Test battery for
in charge defect according
to battery
manufacturer’s
instructions
Defective charger Replace

d. Charger does not charge Blown input fuse/breaker Replace fuse

Charger is not receiving AC input Using a voltmeter,
confirm charger is
receiving correct
AC voltage. If not
check input
connections.

3-3
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION

3.3 BATTERY CHARGER (SOLID STATE) --- 69GC15-164-3, -4 (continued)

Charger’s output is not connected Check output
to 12 volt battery wiring connections
to battery.
Defective charger Replace

e. Low output voltage measured Battery not connected to charger. It is Check charging
across charger output normal to measure 12 volts or less across leads from charger
charger output with no battery connected to battery

f. Reverse polarity connection to Internal DC fuse blown and possible Replace

battery has caused charger to damage to current carrying components
stop charging

3.4 A-C BRUSHLESS GENERATOR (MAIN ALTERNATOR)

No voltage Loss of residual magnetism in exciter field 4.5.1.g.
Circuit breaker tripped Check
Open in stator windings 4.5.2
Open or short in rotating rectifiers 4.5.1.c
Short circuited 4.5.2
Open in alternator field 4.5.2
Shorted exciter armature 4.5.2

Low voltage Low engine speed 4.3.4

Excessive load Check
High resistance connections --- connections
warm or hot Tighten
Shorted field 4.5.2

Fluctuating voltage Fluctuating speed 4.3.4

(May be indicated by Irregular speed of engine Engine Manual
flickering lights) Loose terminal or load connections Tighten
Defective bearing causing uneven air gap 4.5.1.b.

High voltage Excessive engine speed 4.3.4

Overheating Generator overloaded Check

Clogged ventilating screens Clean
High temperature surrounding generator 4.3.1
Insufficient circulation 4.3.1
Unbalanced load Balance
Dry bearing 4.5.1

Mechanical Noise Defective bearing 4.5.1

Rotor scrubbing on stator 4.5.1
Loose laminations 4.5.2
Loose or misaligned coupling 4.5.2

Generator frame Static charge Check ground

produces shock to frame
when touched Grounded armature of field coil 4.5.2

3-4
 SECTION 4
SERVICE

This section covers service for the generator set and some engine servicing only. Refer to the Kubota engine workshop
manual for other engine servicing. (Refer to chart in section 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. Pre-Trip Inspection --- before starting 2.2.a.
X 2. Pre-Trip Inspection --- after starting 2.2.b.
X 3. Check total time meter Run 10
minutes
4.1.2 First 400 Hour Maintenance
X 1. Pre-Trip Inspection --- before starting 2.2.a.
X X 2. Change lube oil and filter 4.3.2
X 3. Pre-Trip Inspection --- after starting 2.2.b.
X 4. Check total time meter Run 10
minutes
4.1.3 Every 1000 Hour Maintenance (Normal Operating Conditions)
X X 1. Complete 400 Hour Maintenance 4.1.2
X 2. Tighten engine and generator mounting bolts 4.6
X 3. Tighten all electrical connections in terminal/control box Tighten
X 4. Clean air cleaner, check hose and connections 4.3.5
X 5. Check water pump bearing end play None
X 6. Check battery charger assembly amperage output None
X 7. Check mechanical fuel lift pump filter 4.3.8
X 8. Clean screen in fuel strainer None
4.1.4 Every 3000 to 6000 Hour Maintenance
X X 1. Complete a 400 and 1000 Hour Maintenance 4.1.2 &
4.1.3
X 2. Clean crankcase breather 4.3.6
X X 3. Clean and flush cooling system 4.3.1
X 4. Check starter condition Engine
Manual
X X 5. Check engine compression Engine
Manual
X 6. Check and adjust injector nozzles Engine
Manual
X 7. Replace V-Belt 4.4

4-1
4.2 PRIMING THE FUEL SYSTEM COLD WATER INTO A HOT ENGINE, however hot
The unit is equipped with a mechanical fuel lift pump, water can always be added to a cold engine.
it is mounted on the engine next to the injection pump. 4.3.2 Lube Oil Filters
(Also, refer to section 4.3.8) This pump has a manual The full flow filter is located near the run solenoid as
plunger for bleeding fuel when the fuel tank has been run shown in Figure 1-1.
dry.
After warming up the engine, stop engine, remove
Since the unit employs a closed fuel circuit, it is drain plug from oil reservoir and drain engine lube oil.
recommended to use the following steps: Lightly oil gasket on filter before installing.
1. Turn bleed valve (Red) counter-clockwise until Replace filters and add lube oil. (Refer to section
fully opened (see Figure 1-1). 1.4.j.) Warm up engine and check for leaks.
2. Turn the top of the manual plunger counter-clock- 4.3.3 Servicing the Fuel Solenoid and Linkage
wise to unlock it. (See Figure 1-1) Then, rapidly hand
pump the manual plunger until a positive pressure 2
(resistance) is felt, which will indicate fuel flow.
3. Depress and turn the top of the manual plunger
clockwise to lock in place. 1
3
4. Start engine. (Refer to section 2.3)
5. When engine is running properly, turn bleed valve
clockwise until fully closed.
4.3 ENGINE SERVICE AND COMPONENTS
4
4.3.1 Cooling System 6
The radiator, externally and internally, must be clean 5 RUN
CONTROL
for adequate cooling. The fan belt must be adjusted LEVER
periodically to provide maximum air flow. (Refer to
section 4.4)
Do the following to service the cooling system:
a. Remove all foreign material from the radiator coil
by reversing the normal air flow (Force air in thru the
front of the radiator and discharge thru the radiator
toward the engine.) Compressed air or water may be
used as a cleaning agent. It may be necessary to use warm
water mixed with any good commercial dishwasher
detergent. Rinse coil(s) with fresh water if a detergent is
used.
ENERGIZED 2.47
b. Drain coolant completely by opening drain-cock (6.27cm.)
and removing radiator cap. DE-ENERGIZED 3.22
(8.18cm.)
CAUTION
1. Solenoid 4. Clip
Use only ethylene glycol, anti-freeze (with 2. Solenoid Bracket 5. Linkage Rod
inhibitors) in system as glycol by itself will 3. Spring 6. Boot
damage the cooling system.
Always add pre-mixed 50/50 anti-freeze and Figure 4-1. Fuel Solenoid Assembly
water to radiator/engine. Never exceed more NOTE
than a 50% concentration of anti-freeze. Use a
low silicate anti-freeze meeting GM Periodically grease (P/N 07-00245-00) Fuel
specifications GM 6038M or equal. Solenoid plunger.
a. Remove spring linkage from injection pump run
c. Close drain-cock and fill system with clean, lever (item 3, Figure 4-1).
untreated water to which three to five percent of an
alkaline base radiator cleaner should be added; six b. Disconnect wiring to solenoid. Remove clip (item 4)
ounces --- dry = 151 grams to one gallon (3.8 liter) of from linkage rod (item 5). Remove mounting hardware
water. from solenoid and then remove solenoid.
d. Run engine 6 to 12 hours and drain system while c. Install new solenoid and mounting hardware,
warm. Rinse system three times after it has cooled down. connect wiring. Place ignition (Start-Run-Off) switch in
Refill system with water. the START position to energize solenoid. Check ener-
gized dimension as shown in Figure 4-1. Turn switch OFF.
e. Run engine to operating temperature. Drain Check de-energized dimension. If energized dimension
system again and fill with treated water/anti-freeze. (See needs adjusting, loosen solenoid mounting bolts and
Caution note and refer to section 1.4.c.) NEVER POUR move solenoid.

4-2
 d. Energize solenoid and check clearance. 3. In case of leakage and if adjustment does not
correct the trouble, replace necessary parts or gaskets.
e. If the engine does not shut off when the fuel
Swelled or distorted gaskets must always be renewed.
solenoid is de-energized, loosen the four (4) mounting
bolts and move the solenoid toward the lever until it shuts b. Service Procedure
off. Tighten the mounting bolts. 1. Empty dust cover as required. Check to see that
4.3.4 Adjusting Engine Speed the Vacuator is not inverted, damaged or plugged.
The engine speed operates at 1820 to 1840 rpm (no 2. Stop the engine, remove and clean the dust cap.
load), 1710 rpm (with load). Remove the dirty element from the air cleaner. Install
new filter and tighten wing nut securely.
Two methods to check engine speeds are: 3. Install dust cover, making sure it seals 360_ around
a. With the engine stopped, place a mark (white the air cleaner body. Check all connections between the
paint for example) on the crankshaft sheave. Start engine air cleaner and the engine to be certain that they are tight
and verify engine speed by using a Strobette-model 964 and leak-free.
(Strobetachometer), Carrier Transicold Part No.
07-00206.
b. With the engine stopped, the second method of
checking engine speed is by using a frequency (hertz)
meter. Attach one lead to CB-1 terminal 1, Figures
5-1/5-2, electrical schematics, and the other to chassis
ground. Start engine and 60.5 hertz will be 1820 rpm and
61.3 hertz will be 1840 rpm (no load). 4 3 2 1
5

1. Body Assembly 4. Dust Cap

1 2. Primary Element 5. Vacuator
3. Clamp
Figure 4-3. Air Cleaner
4.3.6 Engine Crankcase Breather
2 Both engines use a closed type breather with the
breather line attached to the cylinder head cover. (See
Figure 4-4)
3 7

1. Speed Lever
2. Jam Nut “B” 8
3. Capscrew “B”
Figure 4-2. Speed Adjustment
To Increase Speed:
Loosen jam nut “B.” Turn capscrew “B” clockwise
until correct speed is achieved, then tighten jam nut “B”
and check engine speed. 1
To Decrease Speed: 2
Loosen jam nut “B.” Turn capscrew “B” counter- 3
clockwise until correct speed is achieved, then tighten 4
5
jam nut “B” and check engine speed.
6
4.3.5 Engine Air Cleaner 1. Cylinder Head Cover 5. Breather Oil Shield
a. Inspection 2. Breather Cover 6. Capscrew
3. Breather Element 7. Breather Assembly
The air cleaner should be inspected constantly for 4. Plate 8. O-Ring
leaks. A damaged air cleaner or hose can seriously affect
the performance and life of the engine. The following Figure 4-4. Engine Crankcase Breather
simple service steps are easily made while the engine is The breather assembly should be cleaned once a year
being serviced in the field. or at every 3000 hours maintenance interval (whichever
comes first).
The simple service steps are as follows:
4.3.7 Servicing Glow Plugs
1. Watch all connections for mechanical tightness.
The glow plugs are parallel connected and when
Be sure cleaner outlet pipe is not fractured.
energized, draw 7.5 amps at 12 vdc. When servicing, the
2. If cleaner has been dented or damaged, check all glow plug is to be fitted into the cylinder head to prevent
connections immediately. damage to the glow plug.

4-3
 Torque value for the glow plugs is 28.9 to 36.2 ft-lb (4.0 4.4 SERVICING AND ADJUSTING V-BELT
to 5.0 mkg). WARNING
Beware of moving V-Belts and belt driven
Checking for a Defective Glow Plug: components.

NOTE
a. One method is to remove the injector and then
energize the glow plug. The glowing tip may then be Frayed, cracked or worn V-Belts must be
observed. replaced. After installing a new belt, it is
advisable to check the adjustment after running
the unit for three or four hours. This is to allow
b. Another method is to place an ammeter (or for the initial stretch which is common on new
clip-on ammeter) in series with each glow plug and belts. Once this initial stretch has taken place the
energize the plugs. Each plug (if good) should show belt may be checked at regular intervals.
amperage draw.
4.4.1 Water Pump V-Belt
4.3.8 Servicing Fuel Pump The water pump V-Belt is driven by a sheave on the
engine crankshaft. Adjustment is achieved by altering
a. Mechanical Pump (See Figure 4-5) position of the idler pulley.
a. Replacing the V-Belt
Due to foreign particles in the fuel and wax as a result
of using the wrong grade of fuel or untreated fuel in cold 1. Loosen the idler bracket pivot bolt.
weather. The fuel filter may become plugged or re- 2. Replace belt. Use hand force only on idler pulley
stricted, and the engine will loose capacity. The filter to tighten belt. Do not use pry bar or excessive force as it
must be cleaned on a regular schedule such as unit pre- may cause water pump bearings to fail. When belt is tight,
trip or when the oil and fuel filters are changed (refer to tighten idler bracket pivot bolt.
section 4.1). 3. Check belt tension, correct specifications are
40-45 lbs. on the Burroughs gauge Carrier Transicold P/N
1. Turn nut counter-clockwise to loosen and re- 07-00203.
move (item 1). 4.5 SERVICING THE GENERATOR
(MAIN ALTERNATOR)
2. Remove banjo fitting (item 2) and let it hang 4.5.1 Preventive Maintenance and
Operating Precautions
loose, making sure to keep copper rings (item 4) for re-
placement. Costly repairs and down time can usually be pre-
vented by operating electrical equipment under condi-
tions which are compatible with those at which the
3. Turn filter (item 3) counter-clockwise and re- equipment was designed to operate. Follow the instruc-
move. Check and clean. tions outlined below to insure maximum efficiency of the
electrical equipment.
4. To install reverse steps 1 through 3. a. Cooling
Keep all cooling parts clean and make certain
sufficient room is left on all sides for a plentiful supply of
fresh coolant air flow. DO NOT EXCEED TEMPERA-
TURE RISE AS SHOWN FOR 80_C (176_F) ABOVE A
40_C (104_F) AMBIENT. This ensures that the insulation
3 NEMA Class “F” will not be damaged. DO NOT
EXCEED RATED LOAD except as specified for the
equipment. OPERATE GENERATOR AT RATED
SPEED. Failure to operate generators at rated load or
speed will cause overheating and possible damage to
1 windings due to over voltage or current.
b. Bearing Replacement
Factory lubricated shielded bearings will normally
4 provide several years of trouble free service when
2 1 operated under normal conditions. Excessive bearing
load and adverse environment conditions will greatly
1. Nut shorten bearing life. Should bearing failure occur,
2. Banjo bearings can be replaced. ALWAYS REPLACE WITH
3. Filter THE SAME TYPE BEARING AS INSTALLED AT THE
4. Copper Rings FACTORY. CHECK PARTS LIST FOR PART NUMBER.
Figure 4-5. Mechanical Fuel Pump Include generator serial number when ordering bearings.

4-4
 Do the following to remove bearing:
1. Remove bearing cap. (See Figure 4-6) 2 2
2. Remove bearing with the use of a bearing or wheel
puller.
3. Install new bearing. Ball bearings on Lima genera-
tors are pre-lubricated and require no further lubrication
for the life of the bearing.
4. Replace end cap. 1

1. Exciter Rotor Lead

2. Alternator Rotor Lead
Figure 4-7. A-C Generator (Rectifier Assembly)
d. Testing Diodes With An Ohmmeter
3 1. Remove the diode from the circuit. Do not press
2 body out of heat sink. Disconnect the lead. Do not use
excessive heat in unsoldering the lead.
4 2. A good diode should have a low resistance when
1 the + of an ohm meter is connected to the anode and the
--- to the cathode, and a high resistance when the polarity
1. Bolt 4. Rotating Diode of the ohmmeter is reversed. (See Figure 4-8)
2. Bearing Cap Bridge If both resistances are high or both are low, then the
3. Bearing diode is defective and should be replaced.
A A C C
Figure 4-6. Rectifier Removal

c. Rotating Diode Bridge (Rectifier Assembly)

Replacement
RED LETTERING BLACK LETTERING
The rotating diode bridge can be removed and “R” After Number
replaced. Overcurrent, overvoltage, overspeed, or re- Forward Reverse
Polarity Polarity
verse currents can cause damage to the assembly or any of Diode Diode
the component parts. The rotating diode bridge may be A (+) = Anode C (---) = Cathode
removed through the bearing cap on the rear of the
generator. (See Figure 4-6 and Figure 4-7) Figure 4-8. Diode Testing
e. Rotor Damage
1. Remove the bearing cap by removing the four
bolts shown in Figure 4-6 and both the bearing and The damper bars of the generator prevent excessive
rectifier assembly will be visible. hunting when AC generators are operated in parallel.
Damper bars, because they must have a low electrical
2. Use a bearing puller to remove the bearing from resistance and are subjected to extreme centrifugal
main shaft being careful to locate the puller on the inner forces, must be mechanically secure and permanent.
race of the bearing to avoid bearing damage. Once the Consequently, they are welded to end plates completely
bearing is free, it is then necessary to disconnect the covering the field.
alternator and exciter rotor leads as shown in Figure 4-6. All rotors are static and dynamically balanced to a
high degree on precision machines to assure minimum
3. Remove the three hold-down cap screws which vibration. They will, therefore, remain dynamically stable
secure the rectifier assembly to its adapter. Once this at speed well beyond the synchronous speed of the
procedure is complete the rectifier assembly is free for generator. The rotors on generators are, however,
removal. subjected to extreme centrifugal forces which can in-
crease beyond safe operating limits at overspeed. There-
Follow the testing procedures outlined in section
fore, the prime mover should be adequately governed to
4.5.1.d.
prevent overspeed.
After the rectifier assembly has been repaired or Damage to the rotor can also occur due to overheat-
replaced, reverse the procedure as stated above, being ing which can be caused by the air flow being restricted
careful that all lead connections are tight and that set from dust or other foreign objects collecting in the air
screws are locked with Loctite. (Loctite Corporation) passage.

4-5
 If a rotor becomes defective, it should be returned to g. Restoring Residual Magnetism
the factory with full nameplate data, because the rotor NOTE
coils are enclosed in welded squirrel case winding. To
repair a rotor the special tooling and technique of the When trying to restore residual magnetism, be
factory is necessary and essential. Should a failure occur, sure to wear leather gloves and use an insulated
Carrier Transicold should be notified immediately and 12 gauge (or higher) jumper wire. Cut-off a few
steps will be taken to get the generator back into service strands from both ends of the jumper wire to
with the least expense; and more important, to determine ensure fusing does not take place.
the cause of the failure and take steps to prevent a The direct current (DC) necessary to magnetize the
recurrence. alternator field is obtained from the exciter. Initially,
upon starting the generator, current flow and voltage are
f. Generator Windings (Drying)
induced into the exciter armature by the magnetic lines of
force set up by the residual magnetism of the exciter field
Generators that have been in transit or storage for poles.
long periods may be subjected to extreme temperature
and moisture changes. This can cause excessive con- Residual magnetism of the exciter field poles may be
densation, and the generator windings should be thor- lost or weakened by a strong neutralizing magnetic field
oughly dried out before bringing the generator up to full from any source, or if the generator is not operated for a
nameplate voltage. If this precaution is not taken, serious long period of time.
damage to the generator can result. The following steps Should the generator fail to build up voltage after
should be taken to effectively dry the generator windings: being disassembled for any reason, a momentary short-
circuit of any two generator leads (L1, L2 and L3 while
1. (a)Place generator in drying oven or hot room. generator is running) should be sufficient to correct this
condition. If not, an alternate method may be used.
Apply either an alternating current or a direct current
(b)Dry with warm air blower directed through
windings. voltage of approximately 20 volts to any two generator
leads (L1, L2 and L3 while generator is running). Do not
make a positive connection but rather touch the leads
2. (a)If the generator has been operated and then together until the generator voltage begins to rise and
put into storage for any period of time, a P.D. George then remove. It is suggested that a 30 ampere fuse be
#11127 type air-dry fungus resistant varnish should be inserted in the circuit to prevent any damage in case the
applied. build-up voltage is not removed quickly enough.
Reflash field if generator output voltage does not
Experience has shown that it is necessary to take these build up.
precautions in locations such as seaboard installations
and other highly humid areas. Some installations will be 4.5.2 Installation and Removal
in atmospheres that are much more corrosive than a. Removing the Generator
others. A little precautions along the lines outlined here 1. Remove generator set cover assembly and genera-
could eliminate an unnecessary repair job. tor ground wire.
2. Remove generator leads from terminal box, and
Each generator was subjected to a standard NEMA all electrical wires from generator and engine. Then
insulation test, which means 1000 volts plus twice the remove four 1/4-20 x 1.00 lg screws securing terminal box
highest voltage for which the generator is rated was to generator.
impressed between the winding and frame. All machines
are insulated with a high safety factor for the class of 3. Drain radiator, then disconnect all air/coolant
insulation used. The latest and newest in insulation and hoses from generator and engine. Remove fan.
baking techniques are used. 4. Separate flex exhaust pipe from muffler.
5. Remove mounting foot hardware from generator,
The finest insulation job can be very quickly broken and engine mounting brackets from frame.
down by carelessly applying high voltage to windings in a
moisture saturated condition. Mishandling in this respect 6. Place slings around generator and engine. Raise
can easily cause a breakdown, making it necessary to both up enough to clear approximately two inches, then
return the generator to the factory for repair, and swing engine out first and bring entire assembly straight
consequent expense and loss of time. out.
7. Remove necessary mounting brackets (battery,
WARNING fuel, ect.). Remove generator screen from coupling end
of generator.
High voltage (dielectric) testing must not be
performed to the machine without first 8. Remove four 5/16-18 x 1-1/2 screws and two
observing NEMA rules. The insulation of this 5/16-18 x 1-1/4 screws securing the engine fly wheel
generator winding may be safely checked by housing to the generator flange.
using a megger. A high megger reading indicates 9. Remove five 3/8-24 x 3/4 screws securing generator
low insulation leakage. disc to engine flywheel. (A socket brazed to a flexible

4-6
shaft and an offset wrench are required to remove the 4.6.2 Shockmount Replacement
bolts.) Turn bolts counter-clockwise with offset wrench to a. Engine
start, then use flexible shaft and socket assembly for
removal of bolts. 1. Remove the two 1/2-13 x 3-1/2 inch long capscrews.
(Loctite has been applied to these bolts.) Place sling or
b. Installing the Generator
other device around engine (near oil reservoir) and
NOTE slowly raise the engine enough to remove the engine
For torque values refer to section 4.8. mounting shockmounts. (The fan may have to be rotated
to prevent striking the fan shroud.)
The generator is a single bearing type which means 2. Install shockmounts and flat washers as shown in
the shaft end of the rotor floats. Before installing Figure 4-9.
generator, rotate shaft and check if bearing rotates.
3. Apply Loctite EV (purple in color) to threads of
The use of stud guides, two in bell housing (5/16-18 x 2 bolts.
lg) and two in the flywheel (3/8-24 x 2-1/2 lg) will make
installation easier. These studs should have a square or 4. Lower engine, and torque shockmount bolts.
hex design on the end opposite the threads. This is b. Generator
necessary to remove studs after generator is installed. 1. Remove the four 1/2-13 x 3-1/4 inch long caps-
1. Remove screen covering from shaft end of genera- crews. (Loctite has been applied to these bolts.) Place
tor and brush anti-seize lubricant (lube-plate) on the face sling or other device around generator, slowly raise
of flywheel. enough to replace shockmounts.

2. Move generator (with hoist) into position with 2. Install shockmounts and flat washers as shown in
engine and line up with the studs on housing and Figure 4-9.
flywheel. Turn crankshaft (with large wrench) to align
3. Apply Loctite EV (purple in color) to threads of
flywheel with generator, if necessary.
bolts.
NOTE
4. Lower generator and torque shockmount bolts.
It may be necessary to apply pressure under the
cooling fan shaft to align the generator with the
flywheel counterbore.
FLAT WASH- BOLT
3. Start the 3/8-24 bolts (by hand) through the disc ER
ENGINE OR
plate and into the flywheel. Once alignment is made SHOCK-
remove studs and torque bolts (five). GENERATOR MOUNT
4. Secure two of the housing bolts (5/16-18) to draw MOUNTING
the mating flanges together. SHOCK-
5. Remove studs and secure remaining bolts and FRAM MOUNT
FLAT WASH-
washers 5/16-18 (four) and torque bolts (six). E ER
6. To install reverse steps 1 through 7 in section
4.5.2.a..
NUT
NOTE
Figure 4-9. Shockmount Installation
Install new gaskets (one between generator and
terminal box and the other between box and 4.7 MAINTENANCE OF PAINTED
cover) when installing terminal box. SURFACES
The unit is protected by a special paint system against
7. Torque generator/engine mounting bolts (six). the corrosive atmosphere in which it normally operates.
4.6 REPLACING SHOCKMOUNTS However, should the paint system be damaged, the base
metal can corrode. In order to protect the unit from the
NOTE
highly corrosive sea atmosphere or if the protective paint
For torque values refer to section 4.8. system is scratched or damaged:
1. Clean area to bare metal using a wire brush, emery
The engine and generator use different style shock-
paper or equivalent cleaning method.
mounts and hold down hardware.
4.6.1 Replacement Criteria 2. Immediately following cleaning, spray or brush on
a zinc rich primer.
When the neoprene shockmount has been cut, split,
abraded or has flared due to wear from bolts and normal 3. After the primer has dried, spray or brush on finish
deterioration. coat of paint to match original unit color.

4-7
4.8 UNIDRIVE TORQUE REQUIREMENTS The figures below show the torque value, size
Extensive damage may occur if the proper and grade of the hardware to be used when
hardware and procedures are not followed. Period- assembling the unidrive assembly.
ic inspection of hardware and bolt torque is NOTE
recommended to ensure the integrity of the uni- SST is an abbreviation for; 300 Series
drive. Corrosion Resistant Steel.

LIMA

M10 x 1.25 x 20 mm
(1 Req’d) 43 ft-lb (5.95 mkg)

1/2-13 x 3-1/4 lg - SST

M12 x 1.25 x 25 mm
(4 Req’d) 42 ft-lb (5.81
(3 Req’d) 65 ft-lb (8.99
mkg)
GENERATOR SHOCKMOUNTS - SIDE VIEW mkg)
ENGINE MOUNT - RIGHT SIDE VIEW

M12 x 1.25 x 25 mm
(4 Req’d) 65 ft-lb (8.99
1/2-13 x 3-1/2 lg - SST mkg)
(2 Req’d) 42 ft-lb (5.81
mkg) ENGINE MOUNT - LEFT SIDE VIEW

3/8-24 x 3/4 lg
Engine Flywheel (5 Req’d) 25 ft-lb (3.46
mkg)
ENGINE SHOCKMOUNTS - BACK VIEW
Generator Disc Drive

5/16-18 x 1-1/4 lg
(2 Req’d) 15 ft-lb (2.07 5/16-18 x 1-1/2 lg
mkg) (4 Req’d) 15 ft-lb (2.07
mkg)
UNIDRIVE - SECTIONAL VIEW
Figure 4-10. Unidrive Torque Requirements

4-8
 SECTION 5

SCHEMATICS

5.1 INTRODUCTION

This section contains Electrical Wiring Schematics and Diagrams covering the Models listed in Table 1-1. The
following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They
are recommended precautions that must be understood and applied during operation and maintenance of the
equipment covered herein.

WARNING

Electrical power is generated by a Lima 15 KW, A-C generator. The generator provides a constant 460 or 230 vac,
3 phase, 60 hertz electrical supply.

WARNING

Beware of moving V-Belts and belt driven components.

WARNING

Before servicing unit, make sure the unit circuit breaker (CB1) and the start-stop switch are in the OFF
position. Also disconnect power plug and cable.
Make sure the power plug(s) are clean and dry before connecting to any power receptacle.

WARNING

High voltage (dielectric) testing must not be performed to the machine without first observing NEMA rules. The
insulation of this generator winding may be safely checked by using a megger. A high megger reading indicates
low insulation leakage.

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.

5-1
LINE SYMBOL DESCRIPTION LINE SYMBOL DESCRIPTION
MECHANICAL LINKAGE 10,11,12,13 IGN IGNITION SWITCH
ENGINE GROUND 8 L1 CB TRIPPED (INDR. LIGHT)
CHASSIS GROUND 14 LOP LOW OIL PRESSURE
6 A AMMETER 13,14 RR RUN CONTROL RELAY
7 B BATTERY CHARGER 5 SM STARTER MOTOR
4 BAT BATTERY 5,10 SS STARTER SOLENOID
3,8,13,14 CB CIRCUIT BREAKER 2,3 TB TERMINAL BLOCK
12,15 D DIODE 1 TR TRANSFORMER
13 FS FUEL SOLENOID 11 TT TOTAL TIME METER
16,17 GP GLOW PLUG 9 WTG WATER TEMP. GAUGE
15,16,17 GPS GLOW PLUG SWITCH 9 WTS WATER TEMP. SENDER
14 HWT WATER TEMP. SWITCH

Figure 5-1. Electrical Wiring Schematic & Diagram --- Models 69GC15-164 & 69GC15-164-1
Drawing Numbers 69GC15-1824-RA & 69GC15-1954-R-
(Sheet 1 of 2)

5-2
 1 thru 10 are wires from A-C generator

Figure 5-1. Electrical Wiring Schematic & Diagram --- Models 69GC15-164 & 69GC15-164-1
Drawing Number 69GC15-1814-RB
(Sheet 2 of 2)

5-3
Figure 5-2. Electrical Wiring Schematic & Diagram --- Model 69GC15-164-2
(Sheet 1 of 2)

5-4
Figure 5-2. Electrical Wiring Schematic & Diagram --- Model 69GC15-164-2
(Sheet 2 of 2)

5-5
Figure 5-3. Electrical Wiring Schematic & Diagram --- Model 69GC15-164-3
(Sheet 1 of 2)

5-6
Figure 5-3. Electrical Wiring Schematic & Diagram --- Model 69GC15-164-3
(Sheet 2 of 2)

5-7
Figure 5-4. Electrical Wiring Schematic & Diagram --- Model 69GC15-164-4
(Sheet 1 of 2)

5-8
Figure 5-4. Electrical Wiring Schematic & Diagram --- Model 69GC15-164-4
(Sheet 2 of 2)

5-9