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List of Figures FIGURE NUMBER Page Figure 2.1 Label with Generator Set Identification ..........2–1 Figure 2.2 Generator Set UniDrive View (PIDs prior to UG 2019) .
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List of Tables TABLE NUMBER Page Table 2–2 Auto Restart Sequencing ............2–14 Table 2–1 Auto Restart Preset Values .
Section 1 Safety Summary 1.1 General Safety Notices Installation and servicing of Genset equipment can be hazardous due to system belts, radiator fan, and electrical components. Only trained and qualified service personnel should install, repair, or service Genset equipment. When working on Genset equipment, observe all potential Danger, Warning and Caution hazards, including those shown below and on hazard labels attached to the unit.
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WARNING Beware of moving poly V-belt, belt driven components and hot exhaust components. WARNING Under no circumstances should ether or any other unauthorized starting aids be used in con- junction with the air intake heater. WARNING Beware of moving poly V-Belt and belt driven components. WARNING Beware of pinch points.
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CAUTION Never open the radiator cap when the coolant is hot. CAUTION Always cover the engine inlet tube while the air cleaner is being serviced. CAUTION Do not underfill or overfill the oil bath cups. Overfilling of cups causes loss of capacity; under- filling cups causes lack of filtering efficiency.
The 69UG15 is available as a standard configuration, with an Auto Restart option or with Auto Restart and Low Coolant Sensor. The Auto Restart option automatically restarts the unit in the event of a unit shutdown. Auto Restart also offers built-in indicators that signal low oil pressure, high water temperature, overspeed, and other overcrank conditions.
Figure 2.6 Generator Set Top View (PIDs prior to UG2019) 1) Fuel Tank 8) Coolant Overflow Bottle 2) Muffler 9) Intake Air Heater 3) Water Temperature Switch 10) Air Cleaner 4) Water Temperature Sensor 11) Receptacle Box 5) Low Coolant Sensor 12) Generator 6) Radiator 13) Battery Charger...
Figure 2.7 Generator Set Top View (PIDs UG2019 and Up) 1) Fuel Tank 8) Coolant Overflow Bottle 2) Muffler 9) Intake Air Heater 3) Water Temperature Switch 10) Air Cleaner 4) Water Temperature Sensor 11) Receptacle Box 5) Low Coolant Sensor 12) Generator 6) Radiator 13) Battery Charger...
2.3 Engine The engine is a vertical, in-line four cylinder diesel engine, which is directly connected to the alternating current generator. Information on the major engine systems is provided in the following sub-paragraphs. Auxiliary engine equipment consists of the battery, solid state battery charging system, “spin-on” lube oil filter, fuel filter and other necessary components for proper unit operation.
2.3.3 Engine Air System The air cleaner is designed to prolong engine life and performance by preventing dirt and grit from entering the engine and causing excessive wear on all operating parts. In order for the air filter to operate properly, the operator must regularly maintain the air cleaner equipment in accordance with the instructions provided within this document.
2.7.1 Oil Pressure Gauge The Oil Pressure Gauge, shown in Figure 2.11 Figure 2.12, observes normal operating engine oil pressure. Normal oil pressure is 35 to 60 psig (3.3 to 5.2 kg/cm2). The Oil Pressure Sender, shown in Figure 2.10, is located at the oil filter housing and senses lube oil pressure and transmits a signal to the Oil Pressure Gauge.
Figure 2.11 Control Panel and Control Box, Standard Control Panel Control Box INTAKE AIR HEATER IGNITION Mounted to back of box 1) Water Temperature Gauge 9) Intake Heater Relay (HR) 2) Oil Pressure Gauge 10) Circuit Breaker (CB2) 3) Total Time Meter (TT) 11) Circuit Breaker (CB3) 4) Ammeter (A) 12) Circuit Breaker (CB4)
Figure 2.12 Control Panel and Control Box, Auto Restart Control Panel Control Box ENGINE RUNNING OVERCRANK OVERSPEED HIGH TEMPERATURE LOW OIL PRESSURE CB2 CB3 ENGINE START LIGHT INTAKE AIR HEATER IGNITION Mounted to back of 1) Auto Restart Module 9) Safety Relay (S) 2) Water Temperature Gauge 10) Starter Relay (SR) 3) Oil Pressure Gauge...
Table 2–1 Auto Restart Preset Values Indicator Preset Value Description Overspeed 2100 RPM Overspeed is the point at which the unit will signal for shutdown Crank Disconnect 700 RPM Crank Disconnect is the point at which the auto restart module senses the engine has started and will disengage the starter Shutdown Lockout 15 seconds...
Table 2–2 Auto Restart Sequencing Series Attempt Number Engine Status: If the engine starts: Intake Heater Energized in Seconds 1. Run sequence begins. If the engine fails to start: Fuel Solenoid Engaged 1. Intake heater will de-energize. Engine Crank Duration Up to 15 2.
Section 3 Operation 3.1 Generator Set Installation The generator set is mounted under the center of the trailer chassis and is easily handled with a fork lift truck capable of handling 2,000 pounds. The fork lift pockets provided are accessible from either side. 3.1.1 Standard Mount Installation Mounting clamps, shown in...
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5. Lift the forks up so that both sides of the generator set mounts are touching the chassis I-beam. Chassis I-Beam Chassis I-Beam Generator Set 6. Slide the mounting plates fully onto the chassis I-beams and torque mounting bolts to a minimum of 200 ft- lbs (271 Nm), in a cross pattern.
NOTE: It is important to ensure the forklift is removed when checking torque on the genset. Keeping the forklift installed can cause a false torque reading due to the forks holding the unit down, possibly resulting in the unit not being properly secured to the chassis. If the genset is removed for PM or service, it is recommended that the hardware be sprayed with a rust inhibiting lubricant prior to re-installation.
3.2 Generator Set Removal 1. Disconnect the power cable to the generator (if connected). 2. For Standard Mount: With a fork lift in position and safety chain attached, slide the mounting plates back sufficiently to clear the chassis. For Quick Mount: With fork lift in position and safety chain attached, loosen mounting bolts, and lift end of bolts out of slot to orient clamps to open position 3.
Piston rings in engines that have operated less than 100 hours may not be fully seated. This may lead to the possibility of oil seepage from the exhaust pipe. To properly seat the rings, operate the engine under full load for a period of 24 hours. If the condition persists, check valve clearance when the engine is cold.
3.3.4 Stopping Instructions 1. Place Circuit Breaker CB-1 in the OFF position. 2. Place the Ignition Switch (IGN) in the OFF position. 3.4 Sequence of Operation Warning Beware of moving the poly V-Belt and belt driven components. 1. Standard Units: With the Intake Heater Switch (HS) held in the ON position, current flows through the ammeter to the Intake Heater (IH).
Section 4 Troubleshooting 4.1 Diesel Engine 4.1.1 Engine Will Not Start Table 4–1 Engine Will Not Start Condition Possible Cause Remedy / Reference Section Starter motor will not crank or Battery insufficiently charged Charge low cranking speed Battery terminal post or battery defective Check Electrical connections at starter are bad Correct...
4.1.2 Engine Starts Then Stops Table 4–2 Engine Starts Then Stops Condition Possible Cause Remedy / Reference Section Engine stops after a few No fuel in tank Section 2.9 Section 2.10. rotations Intake heater switch not held long enough Hold switch Fuel filter restricted Replace Air cleaner or hose restricted...
Table 4–4 Starter Motor Malfunction Condition Possible Cause Remedy / Reference Section Starter motor does Ignition switch is bad Check/Replace disengage after switch has Starter motor solenoid is bad Engine Manual been released Pinion does not disengage Starter is bad Engine Manual after engine is running 4.1.5...
Table 4–6 Miscellaneous Engine Troubleshooting Condition Possible Cause Remedy / Reference Section Overheating Restriction in air cleaner Section 5.4.12 Exhaust pipe restriction Remove Restriction in water jacket Engine Manual Restriction in radiator Section 5.4.5 Coolant level too low Section 2.10. Loose water pump/alternator poly V-belt Section 5.4.11 Thermostat is bad...
4.3 Alternating Current Generator Table 4–8 Alternating Current Generator Condition Possible Cause Remedy / Reference Section No voltage Loss of rotor magnetism Replace Circuit breaker tripped Check CB1 Open in stator windings Replace Short circuited Replace Worn drive gear stripped Check/Replace Contactor not engaged Replace...
4.4 Auto Re-Start Option Table 4–9 Auto Re-Start Option Condition Possible Cause Remedy / Reference Section When the Ignition switch is Wait 30 seconds for intake heater to be Wait placed in the RUN position, activated nothing happens- no lights Coolant level below the low coolant sensor 1.10.j illuminate Relay defective...
Table 4–10 Electronic Governor Modules Fault LED flash code Possible Cause Speed Sensor Disconnection. Two Long–Three Short FS or wiring problem Fuel / speed actuator (FS) wiring disconnected or open circuit. Coil Resistance Spec: 2.8 ohm +/- 10%. EG supply voltage is greater Two Long–Seven Short EG or alternator problem than 26V.
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Table 4–13 High Voltage Circuit Item Checks Potential Cause High Voltage Wires (from Check if wires/terminals are connected Loose connections (Tighten) Primary and Boost Contactors (Check Continuity for each leg) to Circuit Breaker, Voltage Controller, Fuse Blocks, Generator, Battery Charger) Primary (P) or Boost (B) Visually verify Primary (P) or Boost (B) Faulty Contactor / Faulty Voltage,...
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Table 4–13 High Voltage Circuit Item Checks Potential Cause Voltage Controller (VC) and Verify VCF6 Fuse is not blown (Check Blown Fuse (Replace) Fuses Continuity for each leg across fuse, outside of circuit; inside of circuit if not running) Verify VCF7 Fuse is not blown (Check Blown Fuse (Replace) Continuity for each leg across fuse, outside of circuit;...
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Table 4–13 High Voltage Circuit Item Checks Potential Cause Primary (P) or Boost (B) Visually verify Primary (P) or Boost (B) Faulty Contactor / Faulty Voltage, Contactor Contactor is energized (wait 10-20 seconds Controller / Faulty, Fuses / Faulty after start-up) Generator (Replace) Test the output voltage from Primary (P) or Boost (B) Contactor (L1-L2, L2-L3, L1-L3)
Section 5 Service and Preventative Maintenance 5.1 Introduction This section covers service for the generator set and general engine service. Refer to the Kubota engine workshop manual, Section 1.1, for additional engine servicing. WARNING Beware of moving V-belt and belt driven components. 5.2 Preventative Maintenance Schedule A tabular listing of the recommended preventative maintenance activities and schedule is provided in Table...
5.4.2 Servicing Fuel Pump Internal Filter The internal fuel filter may become plugged or restricted with foreign particles or wax, which can develop if the wrong grade of fuel is used or untreated fuel is used in cold weather, contaminating the fuel. If the internal filter is plugged, the engine will lose power.
5.4.6 Lube Oil Filter The primary oil filter, shown in Figure 2.10, is located near the radiator fan. 1. After warming up the engine, stop the engine, remove the drain plug from the oil reservoir and drain engine lube oil. 2.
5.4.9 Engine Speed 1. The engine speed is electronically controlled. Do not attempt to adjust engine speed. 5.4.10 Replacing the Engine Speed Sensor 1. Disconnect the plug to the sensor. See Figure 2.2 Figure 2.3. 2. Remove the bolt securing the sensor to the housing. 3.
Air Filter Indicator The air filter indicator, used with the dry element filter, is mounted on the unit frame and connected to the engine air intake. Its function is to indicate when the air cleaner dry element needs to be replaced. In operation: When a plugged air cleaner decreases intake manifold pressure to 500 mm (20”) WG, the indicator moves to the red line.
Figure 5.4 Air Cleaner, Oil Bath 1) Air Inlet Hood 4) Inner Oil Cup 2) Air Cleaner Body 5) Gasket 3) Cap Clamp 6) Oil Cup - - - - - Air Cleaner Body Service The air cleaner body should be inspected each time the oil cup is serviced. If there is any sign of contaminant buildup or plugging, the air cleaner body should be removed and back flushed.
5.4.14 Intake Heater Test 1. Disconnect the lead from the heater terminal. 2. Measure the resistance between the heater positive terminal and the heater body. 3. If the resistance is infinity or significantly different than the specification, resistance (cold) 0.3 ohms, replace the heater.
5.5 Servicing the AC Generator 5.5.1 Remove and Replace Procedure The only serviceable parts on the Generator are the Drive Gear (metal), Key, Fan, and Fan Cover. If there is a problem with the Generator, it should be replaced using the following procedure: For additional torque values refer to Section 5.7.
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Although the generator drive gear and fly wheel adapter plate will normally keep the generator coupled to the engine, even without the bolts, it is safest to remove the lower generator bolts first, in case the generator shifts and falls during bolt removal. 16.
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20. Replace and torque the generator drive gear bolt / washer, torque to 28 +/-2 ft-lbs. In order to torque generator drive gear bolt you will have to use a strap wrench or similar device to secure the gear while you torque the bolt. 21.
5.6 General Generator Set Maintenance 5.6.1 Maintenance of Painted Surfaces The unit is protected against the corrosive atmosphere in which it normally operates by a special paint system. However, if the paint system is damaged, the base metal can corrode. If the paint system is scratched or damaged, do the following: 1.
5.7 Unidrive Torque Requirements Extensive damage may occur if the proper hardware is not used and/or proper procedures are not followed when working with the unidrive assembly. Periodic inspection of hardware and bolt torque is recommended to ensure the integrity of the unidrive. Torque value and hardware requirements for unidrive assembly are provided in Figure 5.15.
Table 5–1 Preventative Maintenance Actions and Schedule Perform Perform Perform Manual Procedure During every 2000 every 4000 Reference Pre-Trip hrs service hrs service 1. Check (in place) Engine/Generator shockmounts for cracks, cuts, Section abrasion or flaring 5.6.2 2. Check engine lubrication oil and fuel lines, filters and connections for leaks.
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Table 5–1 Preventative Maintenance Actions and Schedule Perform Perform Perform Manual Procedure During every 2000 every 4000 Reference Pre-Trip hrs service hrs service 25. Remove and check engine/generator shockmounts for cracks, Section cuts, abrasion or flaring. 5.6.2 26. Clean and flush coolant system. Section 5.4.5 27.
Section 6 Schematics 6.1 Introduction This section contains the 12-volt DC control circuit schematic and the high voltage circuitry schematics. Figure 6.1 Schematic Diagram - Legend (PIDs prior to UG2019) 62-11725-0 6–1 T-360...
Index AC Generator 5–8 Heater Test 5–7 Air Cleaner Body 5–6 High Voltage Circuit 4–7 Air Cleaner, Dry Element 5–5 Air Cleaner, Oil Bath Service 5–5 Air Filter Indicator 5–5 In-Line Fuel Strainer 5–2 Alternating Current Generator 2–9 4–5 Instruments 2–9 Auto Re-Start Option 4–6 Intake Heater 5–7 Intake Heater Switch 5–7...
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Starting Instructions 3–4 Stopping Instructions 3–6 UniDrive Torque Requirements 5–16 Unit Specifications 2–17 Troubleshooting 4–1 Truss and Isolator 5–15 Voltage Controller 2–9 4–7 T-360 Index - 2...
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Carrier Transicold Division, Carrier Corporation P.O. Box 4805 Syracuse, NY 13221 USA https://www.carrier.com/container-refrigeration...
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