Diesel Generator Set

OPERATIONS AND SERVICE

MANUAL
For

69UG15
PowerLINE® Series 55 Generator Set Units
PID UG5500 to 5599
EU Stage V Compliant

T-375 Rev A
 OPERATIONS AND SERVICE
MANUAL
For

69UG15
PowerLINE® Series 55 Generator Set Units
PID UG5500 to 5599
EU Stage V Compliant

© Carrier Corporation, 2021 Printed in U. S. A. June 2021

 TABLE OF CONTENTS
PARAGRAPH NUMBER Page

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.2 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.3 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.4 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.5 SPECIFIC HAZARD STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.2 CONFIGURATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.3 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.3.1 Voltage Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4.1 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.2 Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.3 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.4.4 Engine Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.4.5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.5 BATTERY AND BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6 CONTROL PANEL AND CONTROL BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.1 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.2 Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.3 Total Time Meter (TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.4 Ammeter (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.5 Intake Heater Switch (HS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.6 Ignition Switch (IGN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.7 Intake Heater Timer (IHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.8 Starter Solenoid Timer (SST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.7 RECEPTACLE BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
2.8 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
2.9 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1 GENERATOR SET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2 GENERATOR SET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.3 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3.1 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3.2 Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3.3 Post-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.3.4 Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.4 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

i T-375
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.3 Engine Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.1.6 Miscellaneous Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.2 BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.3 ALTERNATING CURRENT (AC) GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.4 ELECTRONIC GOVERNOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.5 VOLTAGE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.6 HIGH VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
SERVICE AND PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.2 PREVENTATIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.3 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.4 ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.4.1 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.4.2 Servicing Fuel Pump Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.4.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.4 In-Line Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.6 Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.7 Servicing Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.8 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.4.9 Replacing the Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.4.10 Servicing Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.4.11 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.4.12 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.4.13 Intake Heater Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.4.14 Intake Heater Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.4.15 Intake Heater Switch (HS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
5.5 SERVICING THE AC GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
5.5.1 Remove and Replace Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
5.6 GENERAL GENERATOR SET MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.6.1 Maintenance of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.6.2 Check and Replace Isolators / Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
5.7 UNIDRIVE TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
INDEX .......................................................................... INDEX–1

T-375 ii
 LIST OF ILLUSTRATIONS
FIGURE NUMBER Page

Figure 2.1 Generator Set ................................................................ 2–1

Figure 2.2 Generator Set Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Figure 2.3 Generator Set Components - Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Figure 2.4 Generator and Engine - Unidrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
Figure 2.5 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Figure 2.6 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Figure 2.7 Electronic Governor Module (EG) ................................................. 2–6
Figure 2.8 Engine Lubrication System ...................................................... 2–7
Figure 2.9 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Figure 2.10 Engine Cooling System ........................................................ 2–9
Figure 2.11 Control Panel and Control Box ................................................. 2–11
Figure 2.12 Receptacle Box ............................................................. 2–12
Figure 3.1 Generator Set Mounting - Standard Mount .......................................... 3–1
Figure 5.1 Mechanical Fuel Pump ......................................................... 5–3
Figure 5.2 Air Cleaner, Dry Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Figure 5.3 Air Cleaner, Oil Bath ........................................................... 5–7
Figure 5.4 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Figure 5.5 Intake Heater ................................................................. 5–8
Figure 5.6 Generator Shaft Keyway ....................................................... 5–10
Figure 5.7 Generator Coupler Bolt ........................................................ 5–11
Figure 5.8 Generator Alignment Bolt ...................................................... 5–11
Figure 5.9 Generator Mounting Bolts ...................................................... 5–12
Figure 5.10 Battery Charger ............................................................. 5–13
Figure 5.11 Generator Shockmounts ...................................................... 5–15
Figure 5.12 Engine Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Figure 5.13 Truss and Isolator ........................................................... 5–16
Figure 5.14 Unidrive Torque Requirements ................................................. 5–17
Figure 6.1 Schematic Legend for 12VDC Circuit .............................................. 6–1
Figure 6.2 Schematic for 12 VDC Control Circuit .............................................. 6–2
Figure 6.3 Schematic High Voltage Circuitry ................................................. 6–3

iii T-375
 LIST OF TABLES
TABLE NUMBER Page

Table 2–1 Safety Devices ............................................................... 2–13

Table 2–2 Fuel Tanks .................................................................. 2–14
Table 2–3 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
Table 2–4 Engine Data ................................................................. 2–14
Table 3–1 Cold Engine Preheat Times ...................................................... 3–3
Table 4–1 Engine Will Not Start ........................................................... 4–1
Table 4–2 Engine Starts Then Stops ....................................................... 4–2
Table 4–3 Engine Will Not Shut Off ........................................................ 4–2
Table 4–4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Table 4–5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
Table 4–6 Miscellaneous Engine Troubleshooting ............................................. 4–3
Table 4–7 Battery Charger (Solid State) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Table 4–8 Alternating Current Generator .................................................... 4–5
Table 4–9 Electronic Governor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Table 4–10 Voltage Controller ............................................................ 4–6
Table 5–1 Preventative Maintenance Actions and Schedule ..................................... 5–1

T-375 iv
 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.
The following general safety notices supplement specific warnings and cautions appearing elsewhere in this man-
ual. They are recommended precautions that must be understood and applied during operation and maintenance
of the equipment covered herein. The general safety notices are presented in the following three sections labeled:
First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions
appearing elsewhere in the manual follows the general safety notices.

1.2 First Aid

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

1.3 Operating Precautions

Always wear safety glasses and hearing protection.
Keep hands, clothing and tools clear of the radiator fan and rotating belts.
Wear appropriate personal protective equipment for the work being undertaken.
No work should be performed on the unit until all circuit breakers and start-stop switches are turned off and the
negative battery terminal has been disconnected.
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the unit and investigate.

1.4 Maintenance Precautions

Be sure power is turned off and the negative battery cable is disconnected before working on generator set.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems
with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.
In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).
Fuel Tanks present explosion, fire, and rupture hazards even if liquid fuel has been drained. Do not attempt any
repairs, especially repairs using flame, welder or torch, unless you have been properly trained and the tank has
been emptied of liquid fuel and fuel vapors and the tank is properly ventilated.

1.5 Specific Hazard Statements

To help identify the hazard labels on the unit and explain the level of awareness each one carries, explanations
with appropriate consequences are provided below:
DANGER - Indicates an immediate hazard which WILL result in severe personal injury or death.
WARNING - Indicates hazards or unsafe conditions which COULD result in severe personal injury or death.
CAUTION - Indicates potential hazards or unsafe practices which COULD result in minor personal injury, product,
or property damage.
The statements that follow are applicable to the generator set and appear elsewhere in this manual. These recom-
mended precautions must be understood and applied during operation and maintenance of the equipment covered
herein.

1–1 T-375
 ! 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 pinch points.

! WARNING
Do not use gasoline to clean air cleaner parts.

! WARNING
Do not direct water or steam into the generator openings. Do not allow any soap and water
solutions to enter the alternator.

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

! CAUTION
Observe proper polarity when installing the battery or connecting a battery charger, the nega-
tive battery terminal must be grounded. Reverse polarity may damage the charging system.
When charging the battery in unit, isolate the battery by disconnecting the negative battery ter-
minal first, then the positive. Once the battery has been charged, connect the positive battery
terminal first, then the negative.

! CAUTION
Never pour cold water into a hot engine.

! CAUTION
Use only ethylene glycol, anti-freeze (with inhibitors) in system. Use of glycol by itself will dam-
age the cooling system.

! CAUTION
Never open the radiator cap when the coolant is hot.

T-375 1–2
 ! 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.

! CAUTION
Continued operation with failed shockmounts may result in engine or generator damage.

1–3 T-375
 SECTION 2
DESCRIPTION

2.1 Introduction
The Carrier Transicold model 69UG15 Series 55 diesel-driven generator set (see Figure 2.1) provides a constant
electrical power supply for all-electric refrigeration units. The 69UG15 is an under-mounted unit secured to the
frame rails of the container trailer chassis.
The generator set consists of a diesel engine directly connected to an alternating current generator and mounted in
a structural steel frame. The engine is a vertical, in-line, four cylinder diesel manufactured by Kubota. The
generator is a 15 kW, permanent, single winding, dual bearing type that supplies nominal 50/60Hz power.
Electrical controls are mounted in a control box with operating controls and gauges mounted on a control panel,
which also serves as the control box cover. The control panel components are protected by a deflector assembly
and a windowed control box door.
The Series 55 model bears the CE mark (Figure 2.1), verification that its 18.5 kW engine complies with Europe’s
Stage V non-road mobile machinery emissions standard, which includes low thresholds for carbon monoxide,
hydrocarbons, particulate matter and nitrogen oxides.

Figure 2.1 Generator Set

1
7

3 4
5
6

1) Standard Mounts 5) Access Door

2) CE Label 6) Control Panel / Control Box
3) Power Cord Receptacle Cover 7) Fuel Tank
4) Unit Nameplate
-----

2–1 T-375
2.2 Configuration Identification
Generator set identification information is provided on a unit nameplate located next to the access service door
(front facing). The label provides the generator set model number, serial number, and parts identification number
(PID). The model number identifies the overall configuration while the PID provides information on specific optional
equipment and differences in detailed parts.

Figure 2.2 Generator Set Components

6
5
1 9

3 11

4
8
7

10

1) Fuel Tank 7) Engine Air Cleaner

2) Battery 8) Fuel Filter / Water Separator
3) Battery Charger 9) Oil Filter
4) AC Generator 10) Receptacle Box
5) Engine 11) Control Panel and Control Box
6) Exhaust Muffler
-----

T-375 2–2
 Figure 2.3 Generator Set Components - Top View

6
3

5 12

11

10
7 8 9

1) Fuel Tank 7) Air Cleaner

2) Battery 8) Fuel Filter / Water Separator
3) Battery Charger 9) Oil Filter
4) AC Generator 10) Receptacle Box
5) Engine 11) Control Panel and Control Box
6) Exhaust Muffler 12) Radiator
-----

2–3 T-375
2.3 Alternating Current Generator
The Alternating Current (AC) Generator (see Figure 2.4) bolts directly to the engine and supplies nominal 50/60Hz
power depending on the load requirement.
Generator sets will start at 50Hz. Once the unit is running, the voltage controller will read the voltage output of the
generator and adjust accordingly to keep the voltage within ISO limits. As the Container becomes loaded, voltage
drops and current increases, causing the generator set to adjust speed based on power demand and ambient
conditions. The unit will typically run at 50Hz and vary generator output via winding selection. The speed change to
60 Hz will typically occur when the ambient temperature is high and the unit is heavily loaded.

2.3.1 Voltage Controller

The Voltage Controller (VC) maintains ISO voltage via two-speed and single winding control. It is used to regulate
voltage in order to keep the generator output within ISO limits (see Table 2–3). The Voltage Controller and Voltage
Controller fuses (VCF1 and VCF2) are located in the receptacle box (see Figure 2.12).

2.4 Engine
The engine (see Figure 2.4) is a vertical, in-line four cylinder diesel engine, model V2203-DI, that is directly
connected to the AC generator. The diesel engine takes air, compresses it and then injects fuel into the
compressed air. The heat of the compressed air ignites the fuel spontaneously.

Separately bound manuals covering the diesel engine are available:

• 62-10865, V2203-DI Engine Workshop
• 62-11695, V2203-DI Parts List

Figure 2.4 Generator and Engine - Unidrive Assembly

2 5

1) Generator 4) Engine Shockmount

2) Generator Shockmount 5) Starter
3) Engine 6) Poly V-Belt
-----

T-375 2–4
2.4.1 Engine Fuel System
The engine fuel system (see Figure 2.5) is a closed circuit that injects a precise amount of atomized fuel into the
engine cylinders.
A mechanical lift pump initially transfers fuel at low pressure from the fuel tank and through the fuel shutoff valve.
Fuel exits the lift pump and is pushed into the fuel filter / water separator to remove water and finer particles. An
optional in-line fuel strainer can be used prior to the fuel filter / water separator to trap large particles. The fuel filter
/ water separator also contains a 12-volt fuel heater to heat the fuel. Low pressure fuel then enters the injection
pump, where it is compressed to higher pressures and distributed to individual fuel lines that supply an injector
nozzle for each cylinder. The injector nozzles spray atomized fuel into the combustion chamber based on the tim-
ing of the injector pump. Any excess fuel in the nozzles not used for combustion is sent back to the fuel tank.

Figure 2.5 Engine Fuel System

6
Fuel Tank Supply / Return

7
2 3 4

4 7

2 6

Fuel Tank Supply / Return

5
3
1

1) Fuel Tank 5) Injection Pump

2) In-Line Fuel Strainer (option) 6) Injector Nozzles (4)
3) Mechanical Lift Pump 7) Manual Fuel Bleed Valve
4) Fuel Filter / Water Separator
-----

2–5 T-375
The engine requires all air to be removed the system in order to run at optimal performance. The fuel system
contains a fuel pump primer on the mechanical lift pump and an air bleed screw after the injection pump, if bleeding
air from the system is required.
The engine fuel tank (see Figure 2.6) is available in 50 and 65 gallon capacity, with 50 gallon standard.

Figure 2.6 Fuel Tank

2 3

1) Cap 3) Vent
2) Gauge 4) Fuel Lines
-----

2.4.2 Electronic Governor

The electronic governor controls the speed of the engine by using an Electronic Governor Module (EG), Fuel
Solenoid (FS) and an Engine Speed Sensor (ESS).
The EG (see Figure 2.7) is a solid state control module pre-programmed for 1800 RPM high speed and 1500 RPM
low speed operation. The EG receives an input signal from the ESS of the current RPM and compares this to a
preset value. The EG sends a correction signal to the FS to maintain the proper RPMs.
The EG is mounted in the control box and has an LED which may assist in diagnosing failures within the electronic
speed control system. See Section 4.4 for additional troubleshooting information.

Figure 2.7 Electronic Governor Module (EG)

LED

T-375 2–6
2.4.3 Engine Lubrication System
The engine lubrication system (see Figure 2.8) keeps the engine running smoothly, providing a supply of lubricat-
ing oil to the various moving parts in the engine. The main function is to enable the formation of a film of oil
between moving parts, to reduce friction and wear.
The engine lubricating oil filter is mounted in a horizontal arrangement. The Oil Pressure Sender (OPS), located at
the oil filter housing, senses lube oil pressure and transmits a signal to the Oil Pressure Gauge located on the con-
trol panel (see Figure 2.11). The Low Oil Pressure (LOP) switch opens when engine lubricating oil pressure is
observed below 1.27 kg/cm.

Figure 2.8 Engine Lubrication System

4
1

1) Oil Filter 3) Low Oil Pressure (LOP) Switch

2) Oil Pressure Sender (OPS) 4) Oil Dipstick / Fill Cap
-----

2–7 T-375
2.4.4 Engine Air Cleaner System
The engine air cleaner system (see Figure 2.9) utilizes a filter element to filter the engine intake air. The air cleaner
is designed to effectively remove contaminants from the air stream, resulting in prolonged engine life and reduced
wear on all engine operating parts. When a dry element air filter is utilized, an air filter indicator is mounted on the
air filter body to indicate when the filter element needs to be replaced.
Air exits the air cleaner and then enters the air intake heater (IH), which heats the air before it enters the engine cyl-
inder. This is done to help engine starting in cold temperatures.

Figure 2.9 Engine Air Cleaner

Dry Element Oil Bath

5
5
4 4
3

3 5

1) Air Cleaner, Dry Element 4) Air Inlet Hose

2) Air Cleaner, Oil Bath 5) Air Intake Heater (IH)
3) Air Filter Indicator
-----

T-375 2–8
2.4.5 Engine Cooling System
The engine cooling system (see Figure 2.10) uses extended life coolant and a radiator to keep the engine from
overheating. The radiator transfers the heat from the engine coolant to the surrounding air. The water pump and
the radiator cooling fan are belt-driven from the engine crankshaft. The High Water Temperature Switch (HWT) and
Water Temperature Sender (WTS) monitor and regulate cooling water temperature.

Figure 2.10 Engine Cooling System

4, 5

1) Radiator Assembly 4) High Water Temperature Switch (HWT)

2) Radiator Fill Cap 5) Water Temperature Sender (WTS)
3) Coolant Recovery Bottle
-----

2–9 T-375
2.5 Battery and Battery Charging System
The battery provides 12 VDC power to the starter motor. It also provides the initial voltage for the Intake Heater
until the unit starts.
The solid state battery charger is located in front of the battery. The battery charger is powered by the generator,
and this input is protected by fuses located in the receptacle box. The battery charger produces a tapered charge
(40 amps maximum) and is designed not to overcharge the battery.

! CAUTION
Observe proper polarity when installing the battery or connecting a battery charger. The nega-
tive battery terminal must be grounded. Reverse polarity may damage the charging system.
When charging the battery in unit, isolate the battery by disconnecting the negative battery ter-
minal first, then the positive. Once the battery has been charged, connect the positive battery
terminal first, then the negative.

2.6 Control Panel and Control Box Components

The control panel and control box (see Figure 2.11) contain components required for monitoring and controlling the
Genset unit.

2.6.1 Water Temperature Gauge

The Water Temperature Gauge observes water operating temperature. Once the unit has achieved normal running
temperature, the coolant temperature is between 82 - 96°C. The Water Temperature Sensor senses engine water
temperature and transmits a signal to the Water Temperature Gauge.

2.6.2 Oil Pressure Gauge

The Oil Pressure Gauge observes normal operating engine oil pressure. Normal oil pressure is 3.3 to 5.2 kg/cm2.
The Oil Pressure Sender (see Figure 2.8), located at the oil filter housing, senses lube oil pressure and transmits a
signal to the Oil Pressure Gauge.

2.6.3 Total Time Meter (TT)

The Total Time Meter (TT) calculates the total hours the unit has been running, which provides an accurate readout
of accumulated engine running time. This data can be used to establish proper maintenance schedules (refer to
Table 5–1).

2.6.4 Ammeter (A)

The Ammeter indicates the rate of charge or discharge of the battery charging system. The battery charging
system is composed of the battery and the battery charger, either solid state or alternator. During start up, the
intake heater draws approximately 42 amps.

2.6.5 Intake Heater Switch (HS)

The Intake Heater Switch (HS) is a momentary switch. When held in the PREHEAT position, the switch allows
approximately 42 amps of battery current to flow into the intake heater, which preheats the air within the intake
manifold and allows the engine to start. After starting the engine, the intake heater switch should continue to be
held in the ON position for approximately 5 seconds until the engine has developed enough oil pressure to close
the oil pressure safety switch.

2.6.6 Ignition Switch (IGN)

The Ignition Switch (IGN) is a momentary switch that has OFF/ON/START positions. When held in the START
(ignition) position, it energizes the starter motor solenoid, which in turn allows the starter motor to crank the engine.
The switch is released to the RUN position once the engine has started.

2.6.7 Intake Heater Timer (IHT)

The Intake Heater Timer (IHT) continues to supply power to the intake heater for 3 minutes after initial start-up.

2.6.8 Starter Solenoid Timer (SST)

The Starter Solenoid Timer (SST) limits the amount of time that the starter can be engaged to 15 seconds. If the
starter is manually engaged for more than 15 seconds, power will be cut to the starter. Once power has been
removed, the starter can again be engaged for up to 15 seconds.

T-375 2–10
 Figure 2.11 Control Panel and Control Box

Control Panel Control Box

13
7 SST

1
2 8
14
9 IHT

HR S SSR
3
4
11
CB4 12

10
CB2 CB3
16
RUN

OFF OFF
INTAKE AIR HEATER IGNITION

5 6

15

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)
5) Intake Heater Switch (HS) 13) Starter Solenoid Timer (SST)
6) Ignition Switch (IGN) 14) Intake Heater Timer (IHT)
7) Starter Solenoid Relay (SSR) 15) Ground Studs
8) Safety Relay (S) 16) Electronic Governor Module (EG)
-----

2–11 T-375
2.7 Receptacle Box Components
The Receptacle box (see Figure 2.12) contain components required for monitoring and controlling the Genset unit.

Figure 2.12 Receptacle Box

1 2 5 6 7 2

3 4 3

1) Access Cover 5) Voltage Controller Fuse (VCF1)

2) Circuit Breaker (CB1) Genset 6) Voltage Controller Fuse (VCF2)
3) Receptacle 7) Battery Charger Fuse BCF3
4) Voltage Controller (VC)
-----

2.8 Safety Devices

Safety devices, such as circuit breakers, fuses, and safety switches protect system components from damage.
The AC generator, solid state battery charger, fuel heater, high water temperature, safety relay, total time meter
and intake heater are protected by circuit breakers. If a safety device opens and there is an interruption of electrical
current, the electronic governor module will be de-energized, which will also de-energize the fuel solenoid, interrupt
the fuel flow to the engine and stop the engine.
Safety device specifications are provided in Table 2–1.

T-375 2–12
 Table 2–1 Safety Devices

Engine
Unsafe Condition: Low engine lubricating oil pressure
Safety Switch Low Oil Pressure Switch (LOP) - Automatic reset
Switch Setting Opens below 1.27 kg/cm
Unsafe Condition: High engine cooling water temperature
Safety Switch Water temperature switch (HWT) - Automatic reset
Switch Setting Opens at 110°C
Unsafe Condition: Excessive current draw by the safety relay, fuel heater, water temperature gauge, oil
pressure gauge or total time meter
Safety Switch Circuit breaker (CB-2) - Automatic reset
Switch Setting Trips at 30 amps
Unsafe Condition: Excessive current draw by the electronic governor module
Safety Switch Fuse 1, 2, 3 (replace)
Switch Setting Trips at 10 amps
Intake Heater
Unsafe Condition: Excessive current draw on intake heater circuit
Safety Switch Circuit breaker (CB-3) - Automatic reset
Switch Setting Trips at 50 amps
Battery Charger
Unsafe Condition: Excessive current draw on 12 volt supply circuit.
Safety Switch Circuit breaker (CB-4) - Automatic reset
Switch Setting Trips at 50 amps
Unsafe Condition: Excessive current draw on 460 volt feed circuit
Safety Switch Fuses BCF3
Switch Setting Trips at 5 amps
Generator
Unsafe Condition: Excessive current draw by load
Safety Switch Circuit breaker (CB1, 460 volt) - Manual reset
Switch Setting Trips at 26 amps (460 vac)
Voltage Controller
Unsafe Condition: Excessive current draw on 460 volt feed circuit
Safety Switch Fuses VCF1, VCF2
Switch Setting Trips at 5 amps

2–13 T-375
2.9 Unit Specifications

Table 2–2 Fuel Tanks

Capacity: 50 Gallon Steel Fill Capacity: 197 liters
Draw Capacity: 189 liters
50 Gallon Aluminum Fill Capacity: 197 liters
Draw Capacity: 189 liters
65 Gallon Steel Fill Capacity: 256 liters
Draw Capacity: 246 liters
Unit Weights (with 50 Gallon Steel 729.8 kg
tank, dry):
50 Gallon Aluminum 698.1 kg
65 Gallon Steel 741.2 kg

Table 2–3 Generator

Output: 15 KW, 18.75 KVA, 0.8 pf KW
Output Voltage: 400-500 VAC @ 60 hz
360-460 VAC @ 50 hz
Speed: 1800 RPM @ 60 hz
1500 RPM @ 50 hz
Weight: 121 kg
Part Number: 54-00738-20

Table 2–4 Engine Data

Bore / Stroke: 83 mm / 102.4 mm

Compression Ratio: 22.0 to 1

Cylinders (Number): Four

Displacement: 2.22 liters (2216 cm3)

Firing Order: 1-3-4-2

Screw Threads: All threads are metric, except for the oil drain plug which is American Standard Pipe
Thread (NPT).

Weight (Dry): 199 kg approximate

T-375 2–14
 Table 2–4 Engine Data
Lubrication System: Oil Pressure 3.3 to 5.2 kg/cm

Oil Pressure Safety Switch 1.27 kg/cm2

Setting Opens

Capacity Engine - 14.2 liters, includes standard filter.

Oil Level Indicator Dipstick in oil pan or fill cap.

NOTE:
To check oil level on engines with the dipstick
mounted in the fill cap, remove the cap and wipe
the dipstick clean. Insert the cap back onto the oil
fill tube, then remove to check level. It is not
necessary to screw the cap back into the fill tube
when checking level. DO NOT add oil if level is
within the “safe” range. If needed, add oil to bring
level within the “safe” range. Screw cap fully into
fill tube after checking level.

Lube Oil Specification Use a heavy duty lubricating oil conforming to

American Petroleum Institute (API) Service
Classification CF or better.

Lube Oil Viscosity Outdoor Temperature

Centigrade: -18°C to 7°C

SAE: 10W30 or Mobile Delvac 1*

Centigrade: 7°C and above

SAE: 10W30 or 15W40 or Mobile Delvac 1*

* Mobile Delvac 1, 5W-40 or 15W-40 is the only

approved synthetic oil.

Fuel and Fuel Heater Thermostat (FHT):

Fuel Winter Diesel No. 2 with winter blends

Summer Diesel No. 2

FHT Winter Close on temperature fall @ 7.2 +/- 3.6°C

Summer Open on temperature rise @ 23.8 +/- 3.6°C

Power Consumption: 150 Watts @ +/- 10% at 14 VDC

Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.
Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the
use of ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas.
Therefore, please use No.2-D S15 diesel fuel. Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%

Intake Heater: Amperage - 42 amps at 12 VDC

Resistance (cold) - Approx. 0.3 ohms

Horsepower: 24.8 HP @ 1800 RPM at sea level. (SAE J1995 Gross Power Rating)

2–15 T-375
 Table 2–4 Engine Data
Cooling System: Capacity 5.68 liters - includes 0.95 liter in coolant recovery
bottle.

Anti-Freeze: Extended Life The cooling system is factory charged with a 50/
50 mix of extended life coolant (ELC) and
deionized water. This mixture provides protection
to -37°C. For replacement, use Shell Rotella ELC
Nitrite Free Pre-Diluted 50/50 antifreeze /
coolant.

Water Temperature Safety Switch Setting:

Opens 110 +/- 3°C

Resets 93°C - minimum

Thermostat:

Starts to open 80 to 84°C

Fully open 95°C

Low Coolant Sensor:

Opens Loss of 907g of coolant or more

Closes Refilling of radiator to proper level

T-375 2–16
 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 907 kg. The fork lift pockets provided are accessible from either side. Mounting clamps are
designed to be attached to outside I-beam flanges only. Maximum chassis width is 97 cm on center.
1. Loosen the mounting bolts (see Figure 3.1) enough to push the mounting plates to the outermost position.
2. Place forks into the fork lift pockets of the generator set. Attach the safety chain between the unit and fork truck.
3. Center the generator under the chassis slide mounting plates fully onto the chassis I-beams and torque
mounting bolts to 11.1 - 12.4 m-kg. Upon completion, remove the safety chain before removing forks of fork
lift truck from the unit.

3.2 Generator Set Removal

1. Disconnect power cable to generator (if connected).
2. With fork lift in position and safety chain attached, slide mounting plates back sufficiently to clear chassis.
3. Lower and remove generator.

Figure 3.1 Generator Set Mounting - Standard Mount

1 2

3 Road Side View 3

8
4
9
5
10

11
6

7
View A-A

1) Container Floor Cross I-Beam 7) Roll Pin

2) Rear of Chassis 8) Bolt
3) Fork Lift Pocket 9) Washer, Spherical, Male
4) Washer, Belleville 10) Mounting Plate
5) Washer, Spherical, Female 11) Generator Frame
6) Tee Nut
-----

3–1 T-375
3.3 Starting and Stopping Instructions
3.3.1 Pre-Start Inspection
1. Check engine lubrication and fuel filters, oil lines, and connections for leaks. If required, tighten connections
and / or replace gaskets.
2. Check engine lubricating oil level (see Table 2–4).
3. Check the poly V-belt for fraying or cracks and proper tension (see Section 5.4.10).
4. Check the radiator hoses for leaks and check radiator coolant level (see Table 2–4).
5. Check the radiator coil and generator air intake screen for cleanliness. If required, clean using compressed
air, reversing the normal air flow.
6. Check the air cleaner for cleanliness and clean if necessary (see Section 5.4.11).
7. Check the in-line fuel strainer and clean if necessary (see Section 5.4.4).
8. Drain water from the fuel tank sump and filter bowl.
9. Fill the fuel tank with diesel fuel (see Table 2–4).
10. Check the air intake heater amperage (see Table 2–4).
11. Check battery terminals for cleanliness and secureness. If required, clean, then coat with a battery terminal
sealant.
12. Check, and if required, tighten all electrical connections.
13. Check, and if required, tighten all hardware (brackets, etc.).
14. Ensure the main generator set Circuit Breaker (CB1) is in the OFF position. Connect power cable to
refrigeration unit and proceed to Starting Instructions (see Section 3.3.2).

3.3.2 Starting Instructions

Before start up, both the Genset Circuit Breaker (CB1) and the refrigerated unit should be OFF. After start up, the
Genset unit should be run for at least two minutes to allow the power source to stabilize before supplying power to
the refrigerated unit. This will eliminate the potential of any cold start transient spikes from reaching the refrigerated
unit. Cold start transient spikes can potentially cause nuisance over voltage alarms on refrigerated units that are
sensitive to electrical spikes or transients.

! 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
conjunction with the air intake heater.

NOTICE
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. (Refer to engine workshop manual listed in Section 2.4).
1. Make sure that Circuit Breaker CB-1 is in the OFF position.
2. Hook up the 460 volt cable from the refrigerated unit to the Genset receptacle.
3. Hold the Intake Heater Switch (HS) in the PREHEAT position (see Figure 2.11). Suggested hold times for a
cold engine are listed in the following table:

T-375 3–2
 Table 3–1 Cold Engine Preheat Times
Ambient Temperature Time
26°C 5 seconds
0° to 26°C 10 seconds
-8° to 26°C 20 seconds
Below -8°C 30 seconds

4. With the Intake Heater Switch (HS) held in the PREHEAT position, place the Ignition Switch (IGN) in the
START position.
5. After the engine has started, continue to hold the Intake Heater Switch (HS) in the PREHEAT position until
the engine develops sufficient oil pressure to close the Oil Pressure Safety Switch (approximately 5
seconds). When released, the Intake Heater Switch (HS) will automatically return to the OFF position and the
heater will remain energized for 3 minutes.

3.3.3 Post-Start Inspection

1. Allow the Genset unit to run for at least 2 minutes.
2. Turn on Circuit Breaker CB-1.
3. Check generator output with a volt meter. Voltage output at start up with no load at 50Hz operation should be
1500 RPM, 360-460 VAC. Voltage output may vary and fall with ISO specifications based on ambient (see
Table 2–3).
4. Start the refrigeration unit.
5. Run the engine for 10 minutes (check total time meter operation).
6. Listen for abnormal bearing noise (AC generator).
7. Check the fuel lines, lube oil lines, and filters for leaks.
8. Check the exhaust system for leaks.

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

With the Intake Heater Switch (HS) held in the ON position, current flows through the ammeter to the Intake Heater
(IH). While the heater is on, the ammeter will show a 42-amp draw.
A second set of contacts also energizes the Safety Relay (S).
If the High Water Temperature Switch (HWT) opens to break the safety relay ground connection, the Safety Relay
(S) will not energize, and the engine will not start.
To start the engine, the Ignition Switch (IGN) is held in the START position. With the switch in the START position,
current flows to the Starter Solenoid (SS), through the SS contacts to the Starter Motor (SM). Current then flows to
the Intake Heater Timer (IHT), Intake Heater Relay (HR) and to the heater, while simultaneously powering the
Electronic Governor Module (EG), Fuel Solenoid (FS), and Engine Speed Sensor (ESS).
The Starter Motor (SM) turns over the engine resulting in pumping of fuel to the engine cylinders by the injection
pump. This fuel is ignited by heat of compression; thus starting the engine. When the engine has developed
sufficient oil pressure, the Low Oil Pressure Switch (LOP) contacts close to maintain power to the Safety Relay (S).
Once the engine has started, the Intake Heater (IH) will remain energized for 3 minutes.
The Ignition Switch (IGN) will be released. The Intake Heater Switch (HS) will be held for 5 seconds, then released
after the Ignition Switch (IGN) is released. When the START switch is released, the starter will be disengaged.
With the engine running, the battery charger provides DC power to operate the control system and charge the
battery.

3–3 T-375
 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

Starter motor malfunctions Section 4.1.4

Starter motor solenoid defective Engine Manual

Open starting circuit Section 4.1.5

Incorrect grade of lubricating oil Table 2–4

Fuse F5 is bad Replace

Starter motor cranks, but fails No fuel in tank Table 2–4

to start
Air inside the fuel system Section 5.4.1

Water inside the fuel system Drain Sump

Plugged fuel filters Replace

Air intake heater is bad Section 5.4.13

Low oil / oil pressure switch defective Section 5.4.7

Faulty heater switch Section 5.4.14

Plugged fuel lines to injector(s) Engine Manual

Mechanical lift fuel pump malfunction Engine Manual

Fuses F1, F2, F3, F4 are bad Check / Replace

Loose or no connection between wire Check / Correct

harness and Electronic Governor Module
(EG)

Starter cranks and engages, Engine lube oil too heavy Section Table 2–4
but dies after a few seconds
Voltage drop in starter cable(s) Check

4–1 T-375
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 Table 2–4

rotations
Intake heater switch not held long enough Hold switch

Fuel filter restricted Replace

Air cleaner or hose restricted Section 5.4.11

Engine crankcase breather or hose restricted Section 5.4.12

Safety device open Section 2.8

Open wiring circuit to fuel solenoid Check

Fuel solenoid defective Replace

Fuel supply restricted Table 2–4, Section 5.4.2, and

Section 5.4.3

Mechanical lift fuel pump malfunction Engine Manual

Low oil / low oil pressure switch defective Section 5.4.7

Leak in fuel system Check

Injector nozzle(s) defective Engine Manual

Injection pump defective Engine Manual

Generator internal overloads open Table 2–3

4.1.3 Engine Will Not Shut Off

Table 4–3 Engine Will Not Shut Off

Condition Possible Cause Remedy / Reference Section

Engine will not shut off Loose ground connection Clean / Tighten

Improperly seated fuel solenoid Correct

4.1.4 Starter Motor Malfunction

Table 4–4 Starter Motor Malfunction
Condition Possible Cause Remedy / Reference Section

Starter motor will not crank or Battery insufficiently charged Charge

turns slowly
Battery cable connections loose or oxidized Check / Replace

Battery cables defective Check / Replace

Starter brushes shorted out Engine Manual

Starter brushes hang up, defective or have Engine Manual

no contact

Starter solenoid damaged Engine Manual

Ignition switch defective Replace

Engine lube oil too heavy Table 2–4

T-375 4–2
 Table 4–4 Starter Motor Malfunction

Condition Possible Cause Remedy / Reference Section

Starter motor turns, but pinion Pinion or ring gear obstructed or worn Engine Manual
does not engage

Starter motor does not Ignition switch is bad Check / Replace

disengage after switch has
been released Starter motor solenoid is bad Engine Manual

Pinion does not disengage Starter is bad Engine Manual

after engine is running

4.1.5 Malfunction In The Engine Starting Circuit

Table 4–5 Malfunction In The Engine Starting Circuit

Condition Possible Cause Remedy / Reference Section
No power to starter motor Battery defective Correct
solenoid
Loose electrical connections Tighten
Fuel solenoid does not Battery defective Correct
energize or does not remain
Loose electrical connections Tighten
energized
Oil pressure switch defective Section 5.4.7
Water temperature safety switch open Section 5.4.5
Fuel solenoid defective Engine Manual
Intake heater switch is bad Check (Engine Manual)
Electronic Governor Module (EG) is bad Replace (Section 5.4.14)
Check / Replace
Intake heater does not Intake heater switch is bad Section 5.4.14
energize
Timer is bad Section 5.4.14
Heater element is bad Section 5.4.14
Heater relay is bad Section 5.4.14

4.1.6 Miscellaneous Engine Troubleshooting

Table 4–6 Miscellaneous Engine Troubleshooting
Condition Possible Cause Remedy / Reference Section

Loss of power Restriction in air cleaner Section 5.4.11

Air in fuel system Section 5.4.1

Air vent restricted Clean

Restricted fuel lines Engine Manual

Fuel injection pump is bad Engine Manual

Injector(s) bad or incorrect type used Engine Manual

Incorrect fuel injection pump timing Engine Manual

Incorrect valve timing Engine Manual

Poor compression Engine Manual

4–3 T-375
 Table 4–6 Miscellaneous Engine Troubleshooting

Condition Possible Cause Remedy / Reference Section

Vibration Engine shockmounts are bad Replace

Poor compression Engine Manual

Overheating Restriction in air cleaner Section 5.4.11

Exhaust pipe restriction Remove

Restriction in water jacket Engine Manual

Restriction in radiator Section 5.4.5

Coolant level too low Table 2–4

Loose water pump/alternator poly V-belt Section 5.4.10

Thermostat is bad Engine Manual

Water pump is bad Engine Manual

Excessive crankcase pressure Plugged crankcase breather line Section 5.4.12

4.2 Battery Charger

Table 4–7 Battery Charger (Solid State)

Condition Possible Cause Remedy / Reference Section

CB4 trips when charger is Short in 12-volt wiring causing overload of Locate and remove short or
turned on charger replace charger

Circuit breaker trips Internal short Replace charger

repeatedly, even when not
connected

Charger does not taper back Bad cell in battery Test battery for defect according to
after charging for a few battery manufacturer’s instructions
minutes
Charger is bad Replace

Charger does not charge Open BCF3 Replace

Charger is not receiving AC input Use voltmeter to confirm charger is
receiving 360-500 VAC. If not,
check input connections/fuses.

Charger output is not connected to 12 volt Check output wiring connections to

battery battery.

Charger is bad Replace

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

Reverse polarity connection to Internal DC fuse blown and possible Replace

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

T-375 4–4
4.3 Alternating Current (AC) 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

Contactor not engaged Replace

Low voltage Low engine speed Section 5.4.8

High resistance connections, connections Tighten

are warm or hot

Loss of rotor magnetism Replace

Fluctuating voltage (May be Fluctuating speed Section 5.4.8

indicated by flickering lights)
Irregular speed of engine Engine Manual

Loose terminal or load connections Tighten

Bad bearing causing uneven air gap Replace

High voltage Excessive engine speed Section 5.4.8

Overheating Generator overloaded Check

Clogged vents/baffles Check / Clean

High temperature surrounding generator Section 5.4.5

Insufficient air circulation or recirculation Check / Clean

Unbalanced load Balance

Dry bearing Replace

Mechanical Noise Bad bearing Replace

Rotor rubbing on stator Replace

Loose laminations Replace

Generator frame produces Static charge Check ground to frame

shock when touched
Grounded armature of field coil Replace

4–5 T-375
4.4 Electronic Governor Module

Table 4–9 Electronic Governor Modules

Fault LED flash code Possible Cause

Engine Over Speed: more than One Long–One Short ESS or mechanical engine problem
2,530 RPM

Actuator Wiring Disconnection. Two Long–One Short Short ESS or wiring problem
No signal from ESS for 2 seconds
after RPM is greater than 1,000
RPM for 10 seconds, OR for 5
seconds while engine cranking
(no voltage at EG pin 18).

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 than Two Long–Seven Short EG or alternator problem

26V.

4.5 Voltage Controller

The voltage controller has one green indicator light and one yellow indicator light. When the green light is illumi-
nated, it means that the voltage controller is receiving power. During normal operations the yellow light is continu-
ously blinking at a one Hz rate. If there is a problem then the yellow light will blink at various rates depending upon
the fault. Refer to the chart below to determine the fault.

Table 4–10 Voltage Controller

Green LED Fault Possible Cause / Remedy

LED not illuminated No power to the voltage controller Contactor failed

Check line side power on

contactors

Yellow LED flash Code Fault Possible Cause / Remedy

One Long–Three Short Over Voltage Error Engine speed, check

One Long–Four Short Under Voltage Error Engine speed, check

4.6 High Voltage Circuit

Electrical troubleshooting for high voltage control circuit

! WARNING
Before proceeding with the troubleshooting, make sure to follow your company’s standard
safety procedures for working with electrical components.

T-375 4–6
 Item Checks Potential Cause

Receptacle (R) Check output voltage at Receptacle R (L1- Faulty Receptacle (Replace)
L2, L2-L3, L1-L3) (50Hz: 360 - 460 VAC,
and 60Hz: 400 - 500 VAC)

High Voltage Wires (from Check if wires/terminals are connected Loose connections (Tighten)
Circuit Breaker to Receptacle) (Check Continuity for each leg)

Circuit Breaker (CB) Test the output power from Circuit Breaker Faulty Circuit Breaker (Replace),
CB (21-22, 22-23, 21-23) Circuit Breaker (CB) is in the OFF
position
Verify Circuit Breaker (CB) is in the ON
position

Test the input power to the Circuit Breaker

CB (11-12, 12-13, 11-13)

Voltage Controller (VC) and Verify VCF1 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 VCF2 Fuse is not blown (Check Blown Fuse (Replace)

Continuity for each leg across fuse, outside
of circuit; inside of circuit if not running)

Verify Voltage Controller has power Faulty Voltage Controller, Loose

(powered by high voltage) - verify green connections, Faulty Generator
light is illuminated (Replace and tighten)

Verify Voltage Controller has green light One Long–Two Short = Voltage
illuminated and yellow light flashing at 1 Hz Controller Fault (Failed voltage
(Yellow light flashing sequence other than controller, replace)
at 1 Hz indicates a fault condition)
One Long–Three Short = Over
Voltage Error (Engine speed,
check)

One Long–Four Short = Under

Voltage Error (Engine speed,
check)

One Long–Five Short = Hot Start

Error (Reset power to the unit)

One Long–Six Short = Voltage

Controller Fault (Failed voltage
controller, replace)

One Long–Seven Short = Voltage

Controller Fault (Failed voltage
controller, replace)

Verify that the Connectors to the Voltage Check if the connectors are pushed
Controller are secured (Snapped in place in all the way
and do not easily pull out)
Remove connectors and inspect
terminal pin insertion depth (all the
same)
Check to see if wires/terminals are
connected (Check)

4–7 T-375
 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 62-10865, Section 1.1, for additional engine servicing.

! WARNING
Beware of moving poly V-belt, belt driven components and hot exhaust components.

5.2 Preventative Maintenance Schedule

A tabular listing of the recommended preventative maintenance activities and schedule is provided in Table 5–1.
Table 5–1 Preventative Maintenance Actions and Schedule
Perform Perform Perform
Manual
Procedure During every 2000 every 4000
Reference
Pre-Trip1 hrs service2 hrs service3
1. Check (in place) engine / generator shockmounts for cracks, cuts, Section X X
abrasion or flaring 5.6.2
2. Check engine lubrication oil and fuel lines, filters and connections - X X X
for leaks.
3. Check engine lubrication oil level, add as required. Section X
4. Check Poly V-belt for fraying or cracking, replace as required. Section X X X
5.4.10
5. Check radiator hoses for leaks. - X X X
6. Check coolant level add 50/50 mix as required. Section X X X
7. Check radiator coil and generator air intake for cleanliness. Section X X X
5.4.5
8. Check Air Cleaner: X X X
For Dry element air cleaner: Section X X X
Check for cleanliness and clean / replace as filter indicator indicates 5.4.11
9. Drain Water from fuel tank sump. - X X X
10. Drain Water from fuel filter bowl. - X X X
11. Fill fuel tank with diesel fuel, check fuel gauge operation. - X X X
12. Check intake heater amperage. Section X X X
5.4.14
13. Check battery terminals for tightness and cleanliness. - X X X
14. Check for dirty loose electrical connections, frayed cables and - X X X
cracked insulation.
15. Check and tighten as required all hardware, brackets etc. - X X X
16. Clean mechanical fuel lift pump internal filter. Section X X
5.4.2
17. Change in line fuel strainer (option). Section X X
5.4.4
18. Clean and coat terminals with battery terminal sealant. - X X
19. Change lubricating oil and filters (See NOTES) Section X X
5.4.6

5–1 T-375
 Table 5–1 Preventative Maintenance Actions and Schedule
Perform Perform Perform
Manual
Procedure During every 2000 every 4000
Reference
Pre-Trip1 hrs service2 hrs service3
20. Tighten engine and generator mounting bolts. Section X X
5.6.2
21. Tighten all electrical connections in control box. - X X
22. Check water pump bearing end play. Engine X X
Manual
23. Change fuel filter. Section X X
5.4.3
24. Check crankcase breather. Section X X
5.4.12
25. Remove and check engine / generator shockmounts for cracks, Section X X
cuts, abrasion or flaring. 5.6.2
26. Clean and flush coolant system. Section X
5.4.5
27. Check starter condition. Engine X X
Manual
28. Check engine compression. Engine X X
Manual
29. Check and adjust injector nozzles. Engine X X
Manual
30. Perform generator maintenance. Section 5.6 X X
31. Check total time meter operation (allow engine to run 10 minutes). - X X X
32. Listen for abnormal noises. - X X X
33. Check fuel, lubricating oil and radiator coolant lines, connections - X X X
and filters for leaks.
34. Check exhaust system for leaks. - X X X
35. Check with voltmeter. Generator output should be 490 volts, +/- Section 5.6 X X X
15 volts (engine, 1800 rpm) with a nominal frequency of 60Hz.
36. Turn refrigeration unit on and check generator 1800 rpm under full Section 5.6 X X X
load.
37. Verify operation of safety devices. Section 2.8 X X

NOTICE
Units have mineral oil installed from the factory - change lubricating oil and filters after the first
2000 hours of service or at the end of the first year, whichever comes first.
Oil changes after the first 2000 hour service, or 1 year:
• If using mineral oil, oil changes should continue every 2000 hours of service or every 1 year, whichever
comes first.
• If using specified synthetic lubricating oil and OEM extended life oil filter, oil changes should be completed
every 4000 hours of service, or every two years, whichever comes first.
1 Pre-trip maintenance checks should be carried out prior to any use of the unit (1-15 and 31-36).
2
2000 hour maintenance checks should be carried out annually or every 2000 hours, whichever comes first.
3 4000 hour maintenance checks should be carried out every two years or every 4000 hours, whichever comes first.

T-375 5–2
5.3 Battery Service
When replacing the battery, determine whether the unit was supplied with a mat in the battery tray. If so equipped,
the mat must also be replaced.

5.4 Engine Service and Components

The unit is equipped with a mechanical fuel pump (see Figure 5.1) mounted on the engine next to the injection pump.

Figure 5.1 Mechanical Fuel Pump

6
2
3 4

1) Manual Priming Pump 4) Copper Rings

2) Banjo 5) Filter
3) Nut 6) Nut
-----

5.4.1 Bleeding the Fuel System

The fuel system is a closed circuit which will require bleeding if loss of fuel has occurred. To fill and bleed the
system, do the following:
1. Turn the (red) fuel bleed valve (see Figure 2.5) counterclockwise until fully opened.
2. Turn the top of the manual priming pump counter-clockwise to unlock it, and then hand pump the manual
plunger until a positive pressure (resistance) is felt. This will indicate fuel flow.
3. Depress and turn the top of the manual priming pump clockwise to lock in place.
4. Start the engine (see Section 2.4).
5. When the engine is running properly, turn the fuel bleed valve clockwise until fully closed.

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. Therefore, the filter must be cleaned on a regular basis. The quality of the fuel
will affect the filter cleaning schedule (see Section 5.2).
1. Turn the nut counter-clockwise to loosen and remove.
2. Remove the banjo fitting and let it hang loose.
3. Turn the filter counter-clockwise and remove. Check and clean.
4. To install, reverse steps 1 through 3.

5–3 T-375
5.4.3 Fuel Filter
The fuel filter is located on the generator set frame (see Figure 2.5).
1. To replace the fuel filter, loosen and remove the filter housing.
2. Lightly oil new gasket with lube oil.
3. Replace the filter.

NOTICE
If the generator set is equipped with the fuel filter bowl assembly, when replacing the fuel filter,
a new fuel filter O-ring should be oiled and replaced, and then the clear bowl should also be
tightened to 24 N-m.

5.4.4 In-Line Fuel Strainer

1. Loosen bowl by turning counter-clockwise.
2. To renew, remove in-line fuel strainer. Check and clean, and replace.

5.4.5 Cooling System

To ensure adequate cooling, the radiator must be clean, externally and internally. To service the cooling system, do
the following:
1. Remove all foreign material from the radiator coil by reversing the normal air flow. 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. If a detergent is used, rinse coil(s) with fresh water.
2. Drain coolant completely by opening the drain cock and removing the radiator cap.

! CAUTION
Never pour cold water into a hot engine.
3. Close the drain cock and fill the system with clean, untreated water to which between 3% and 5% of an
alkaline base radiator cleaner should be added; 170 grams (dry) = 151 grams to 3.8 liter of water.
4. Run the engine 6 to 12 hours and drain the system while warm. Rinse the system three times after it has
cooled down. Refill the system with water.

! CAUTION
Use only ethylene glycol, anti-freeze (with inhibitors) in the system. Use of glycol by itself will
damage the cooling system.

5. Run the engine to operating temperature. Drain the system again and fill with treated water / anti-freeze
(see above Caution statement).

5.4.6 Lube Oil Filter

The primary oil filter is located near the radiator fan (see Figure 2.10).
1. After warming up the engine, stop the engine, remove the drain plug from the oil reservoir and drain engine
lube oil.
2. Replace filters. Lightly oil the gasket on filter before installing.
3. Add lube oil (see Table 2–4).
4. Warm up the engine and check for leaks.
5.4.7 Servicing Low Oil Pressure Switch
1. Remove the harness connection from the Low Oil Pressure Switch (LOP).
2. Remove the pressure switch from the engine.

T-375 5–4
 3. Apply Teflon thread sealer to the threads of the new LOP switch.
4. Install the new LOP switch.
5. Reconnect harness connection to the low oil pressure switch.

5.4.8 Engine Speed

1. The engine speed is electronically controlled.

NOTICE
Do not attempt to adjust engine speed.

5.4.9 Replacing the Engine Speed Sensor

1. Disconnect the plug to the sensor.
2. Remove the bolt securing the sensor to the housing.
3. Remove the sensor from the housing.
4. Clean the recess in the housing to ensure that the sensor seats properly when re-installed.
5. Re-install the sensor, replace the securing bolt and connect the plug to the sensor.

5.4.10 Servicing Poly V-belt

! WARNING
Beware of moving poly V-belt and belt driven components.

! WARNING
Beware of pinch points.

NOTICE
A frayed, cracked or worn poly V-belt must be replaced. After installing a new belt, check the
adjustment after running the unit for three or four hours. This will allow for the initial stretch,
which is common on new belts. Once this initial stretch has taken place, the belt should be
checked at regular intervals.
The poly V-belt is driven by a sheave on the engine crankshaft. Its two functions are: (1) to drive the radiator fan
and (2) to drive the water pump. To replace the poly V-belt, perform the following steps:
1. Using the proper size socket, slowly rotate the crank on the crank pulley nut. At the same time, use a flat,
blunt object to guide the belt off the crank pulley towards radiator. Be careful not to damage grooves on the
pulley.
2. Replace the poly V-Belt by positioning the belt on the water pump pulley, and while rotating the engine (as in
step 1.), use a flat, blunt object to guide the belt onto the crank pulley. Be careful not to damage grooves on
the pulley or belt.

5.4.11 Engine Air Cleaner

The dry element engine air cleaner uses a dry element filter (see Figure 5.2) to filter the engine intake air. The oil
bath air cleaner option uses an oil cup instead of the dry element filter (see Figure 5.3).
The engine air cleaner should be inspected regularly for leaks (see Figure 2.5). A damaged air cleaner or hose
can seriously affect the performance and life of the engine. The air cleaner is designed to effectively remove
contaminants from the air stream entering the engine. An excessive accumulation of contaminants in the air
cleaner will impair its operation. Therefore, a service schedule must be set up and followed.

5–5 T-375
 1. Check all connections for mechanical tightness. Be sure the air cleaner outlet pipe is not fractured.
2. In case of leakage, if adjustment does not correct the problem, replace necessary parts or gaskets. Swollen
or distorted gaskets must always be replaced.

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 WG, the indicator moves to the red line. The air
cleaner element should be replaced and the indicator reset by pressing the reset button.

Air Cleaner, Dry Element Service

See Figure 5.2 for this procedure.
1. Stop the engine and open the cap clamps to remove air cleaner bottom cap.
2. Remove the air filter element from the air cleaner body.
3. Install the new element, secure the bottom cap with the cap clamps.

Figure 5.2 Air Cleaner, Dry Element

1 5

4 6

1) Air Outlet 4) Cap Clamp

2) Air Cleaner Body 5) Air Outlet
3) Air Inlet 6) Air Filter Indicator
-----
Air Cleaner, Oil Bath Service
See Figure 5.3 for this procedure.
The oil cup should be inspected during pretrip, before each trip. Never allow more than 12.7 mm of dirt deposit in
the cup. More than 12.7 mm accumulation could result in oil and dirt carrying over into the engine, causing
accelerated engine wear. Heavily contaminated oil will not allow the air cleaner to function properly.

! CAUTION
Always cover the engine inlet tube while the air cleaner is being serviced.

1. Stop the engine and remove the oil cup from the air cleaner. Dispose of the oil in an environmentally safe
manner.
2. Remove the inner oil cup from the oil cup and clean both cups.
3. Reassemble and fill both oil cups to the indicated level with oil specified in Table 2–4.

T-375 5–6
 ! CAUTION
Do not underfill or overfill the oil bath cups. Overfilling cups causes loss of capacity; underfill-
ing cups causes lack of filtering efficiency.

Figure 5.3 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.
At least once a year, or at regular engine service intervals, remove the entire air cleaner and perform the following
cleaning procedure:
1. Remove oil cup. Check and clean center tube.

! WARNING
Do not use gasoline to clean air cleaner parts.

2. Pump solvent through the air outlet with sufficient force and volume to produce a hard, even stream out of
the bottom of the body assembly. Reverse flush until all foreign material is removed.

5–7 T-375
5.4.12 Engine Crankcase Breather
The engine uses a closed type breather (see Figure 5.4) with the breather line attached to the cylinder head cover.
It is not necessary to disassemble valve style elements for cleaning. However, the bleed hole should be checked
for obstructions. Check once a year or at every 4,000 hours maintenance interval, whichever comes first.

Figure 5.4 Engine Crankcase Breather

1
4
2
5
3

1) Screw 4) Breather Cover

2) Breather Valve 5) Bleed Hole
3) Breather Tube
-----

5.4.13 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.

Figure 5.5 Intake Heater

1) Positive Terminal 2) Heater Body

-----

5.4.14 Intake Heater Service

1. Remove the harness connection from the heater.
2. Remove the intake transition mounting hardware.
3. Remove the intake transition, heater and both gaskets.
4. Clean the old gasket material off the transition and manifold mounting services.

T-375 5–8
 5. Install the new heater with a new gasket on either side.
6. Assemble transition to heater and torque mounting hardware (refer to engine manual for torque values).
7. Reconnect the harness to heater connection point.
8. Coat the stud on the heater with protective coating.

5.4.15 Intake Heater Switch (HS)

1. Remove the control box cover.
2. Remove all connections going to the Heater Switch (HS).
3. Remove the Heater Switch (HS) from the control box.
4. Install the new Heater Switch (HS).
5. Reconnect the wire harness connections to the switch.
6. Confirm wires are connected to the correct terminals.
7. Reinstall the control box cover.

5.5 Servicing the AC Generator

5.5.1 Remove and Replace Procedure
The only serviceable parts on the generator are the torsional dampener, key, fan, and fan cover. If there is a
problem with the generator, it should be replaced using the following procedure.
For Unidrive torque requirements, see Section 5.7.
Procedure:
1. Remove the unit top and side panels in order to access the generator.
2. Disconnect the battery.

! CAUTION
Observe proper polarity when installing the battery or connecting a battery charger, the nega-
tive battery terminal must be grounded. Reverse polarity may damage the charging system.
When charging the battery in unit, isolate the battery by disconnecting the negative battery ter-
minal first, then the positive. Once the battery has been charged, connect the positive battery
terminal first, then the negative.
3. Remove the truss assembly center nuts and nut plate.
4. Remove the truss side bolts / washers and spacers (2), and remove the truss.
5. Remove the 3/8” bolt / washer that secures the wire harnesses and fuel lines to the top of the generator.
Move the wire harnesses and fuel lines out of the way.
6. Remove the 1/4” bolts / washers (4) that secure the battery charger bracket to the unit frame. This will allow
you to access the cables on the bottom of the battery charger.
7. Mark and disconnect the cables on the battery charger and remove the battery charger assembly from the
unit.
8. Remove the bolts / washers (6) that secure the receptacle box to the unit. Wire-tie the receptacle box to the
side of the unit so that the receptacle box is not hanging by the cables.
9. Remove the tape on the wire harness and cut the wires (5) that connect the receptacle box to the generator.
Make sure to cut the wires on the receptacle box side of the current butt splices.
10. Remove the bolts / washers (2) that secure the generator support plate to the two generator shockmounts.
11. Remove the bolts / washers (3) that secure the lower radiator access panel (on the other side of the unit) in
order to access the engine shockmounts.

5–9 T-375
 12. Back off about 25mm, but do not remove the engine shockmount bolts. This will allow the engine / generator
to be slightly lifted off of the unit frame.

NOTICE
The generator / engine must be slightly lifted off of the unit frame in order to provide enough
clearance for the generator support plate to slide away from the unit frame.
13. Using the lifting lugs on the top of the generator, lift the generator / engine several inches so that the
generator support plate will clear the unit frame allowing the entire generator assembly to be removed.
14. Place several support beams under the engine and then lower the generator / engine onto the beams. Make
sure that the generator support plate is lifted high enough to allow for the removal of the generator
assembly, but not so high that the fan hits the radiator coil.
15. Starting with the lower bolts, remove the 3/8”-16 bolts / washers (12) that secure the generator to the
engine.

NOTICE
Although the generator torsional dampener and flywheel 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. Lift the generator assembly (generator & support plate) off of the unit frame and lower it onto a stable work
surface.

NOTICE
Inspect the generator torsional dampener, bolt, and key as they will have to be removed from the old
generator and installed onto the new generator. Replace these components if they are worn or
damaged.
17. Remove the generator torsional coupler bolt / washer and pull off the torsional dampener.
18. Place the torsional dampener on the new generator shaft.
19. Insert the key into the keyway of the generator shaft. See Figure 5.6.

Figure 5.6 Generator Shaft Keyway

T-375 5–10
20. Apply Loctite 262 to the generator coupler bolt. Install with washer and torque to 38 N-m (28 ft-lbs). See Figure
5.7.

NOTE
In order to torque generator torsional dampener gear bolt, use a strap wrench or similar device to
secure the dampener while torquing the bolt.

Figure 5.7 Generator Coupler Bolt

21. Remove the generator support plate from the old generator and install it onto the new generator.
22. With the torsional dampener and support plate installed on the new generator, lift and position the generator
so that the generator mounting holes (12) are lined up with the engine mounting holes.
23. Insert two generator alignment bolts (2 1/2”) to temporarily align / secure the generator to the engine.
Tighten the bolts enough so that the torsional dampener on the generator is touching the aluminum housing
on the engine. Do not over tighten the alignment bolts, as they will bottom out on the engine bell housing.
See Figure 5.8.

NOTICE
Align the torsional dampener and aluminum housing by rotating either one to seat correctly.

Figure 5.8 Generator Alignment Bolt

5–11 T-375
 24. Once aligned, push the generator to fully seat the torsional dampener into the aluminum housing of the
flywheel adaptor plate.
25. With the torsional dampener seated into the aluminum housing, the alignment bolts (2) can be removed, and
the generator mounting bolts (12) can be reinstalled. Torque to 34 Nm (25 ft-lb). Install several mounting
bolts to secure the generator before removing the alignment bolts. See Figure 5.9.

NOTE
Although the torsional dampener and mating surface of the generator will generally keep the generator
coupled to the engine, even with all of the bolts removed, it is safest to start installation of the top
generator bolts first, just in case the generator shifts.

Figure 5.9 Generator Mounting Bolts

26. With all of the generator mounting bolts secured, use the lift to raise the generator / engine in order to
remove the support blocks under the engine.
27. Place the generator support plate mounting bolts (2) down into the generator support plate in order to line up
the mounting bolt holes with the shockmounts.
28. Ensure that the large washers placed on the shockmounts and slowly lower the generator / engine so that
the generator support plate holes line up with the shockmount holes.
29. Remove the generator support plate bolts and install the bolts / large washers from the bottom of the
shockmounts through the generator support plate. Secure the bolts (2) with nuts, torque to 102 Nm (75 ft-lb).
30. Tighten the engine shockmount bolts, torque to 122 Nm (90 ft-lb).
31. Replace the lower radiator access panel and secure with bolts / washers (3).
32. Re-secure the battery charger cables to the bottom of the battery charger.
33. Observe proper polarity when installing the battery or connecting a battery charger, the negative battery terminal
must be grounded. Reverse polarity may damage the charging system. When charging the battery in unit, isolate
the battery by disconnecting the negative battery terminal first, then the positive. Once the battery has been
charged, connect the positive battery terminal first, then the negative.

T-375 5–12
 Figure 5.10 Battery Charger

1) AC Wiring from Generator 2) DC Wiring to 12v Battery

Red (+), Black (-)
-----
34. Re-secure the battery charger assembly to the unit frame.
35. Cut the wire-tie supporting the receptacle box to the unit frame and re-secure the receptacle box to the unit
frame using bolts and washers (6). Make sure the receptacle wires are pulled through the access port in the
frame and ensure that they will be accessible to splice with the generator wires.
36. Place two pieces of heat shrink tubing (1 large, 1 small) over each receptacle box wire.
37. Connect and butt splice the receptacle box harness wires with the new generator wires.
38. For each of the other five wires, heat shrink the small tubing first, and then the large tubing to ensure a
watertight seal.
39. Neatly tape all wires together.
40. Replace and secure the wire harnesses onto the top of the generator, secure with the bolt.
41. Replace the truss and the truss brackets, secure the sides with the mounting bolts (2). See Figure 5.13.

NOTE
Installing the two back truss bolts first allows the truss assembly to be pulled forward slightly, making it
easier to install the two front truss bolts.

42. Secure the center of the truss to the isolator by installing the nuts (2) and nut plate (1).
43. Connect the battery.
44. Re-install the top and side panel covers.

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. Clean area to bare metal using a wire brush, emery paper or equivalent cleaning method.
2. Immediately following cleaning, spray or brush on a zinc rich primer.
3. After the primer has dried, spray or brush on finish coat of paint to match original unit color.

5–13 T-375
5.6.2 Check and Replace Isolators / Shockmounts

! CAUTION
Continued operation with failed shockmounts may result in engine or generator damage. When
a shockmount has been cut, split, abraded or has flared due to normal deterioration, it must be
replaced. Damage to the mounts may not be visible when installed and under load from the
component. To correctly inspect shockmounts, they must be removed.

Engine Isolator / Shockmount Replacement

1. Use the two lift eyes to lift and support the engine.
2. Remove truss, unidrive isolator and all hardware as shown in Figure 5.13.
3. Remove all hardware as shown in Figure 5.12.
4. Raise the engine just enough to remove the shockmounts as shown in Figure 5.12.
5. Install new shockmounts.
6. Lower the engine enough to assemble hardware as shown and torque per Section 5.7.
7. Remove chains from the lift eyes.

Generator Shockmount Replacement

1. Use the two lift eyes to lift and support the engine.
2. Remove shockmount hardware.
3. Raise the generator just enough to remove the shockmounts as shown in Figure 5.11.
4. Install new shockmounts.
5. Lower the engine enough to assemble hardware as shown and torque. See Section 5.7 for torque values.
6. Remove chains from the lift eyes.

T-375 5–14
 Figure 5.11 Generator Shockmounts

11
1
12

2 13

3
14

15

16

17
5
6 18
4 7
19

Install Mount 20
with Large Flare
8 at Top
21
9
10 22

1) Generator 12) Flat Washer (5/8)

2) Locknut (5/8) 13) Mounting Base
3) Flat Washer (5/8) 14) Locknut (1/2)
4) Support Plate 15) Flat Washer (1/2)
5) Screw (3/8) 16) Flat Washer (5/8)
6) Flat Washer (3/8) 17) Screw (5/8)
7) Shockmount 18) Snubbing Washer
8) Shockmount 19) Screw (1/2)
9) Support Plate 20) Frame
10) Frame 21) Flat Washer (3/8)
11) Locknut (5/8) 22) Locknut (3/8)
-----

5–15 T-375
 Figure 5.12 Engine Shockmounts

1
7

1) Shockmount 5) Snubbing Washer

2) Snubbing Washer 6) Shockmount
3) Bolt 7) Flat Washer
4) Lock Washer
-----

Figure 5.13 Truss and Isolator

2 7
10

11
8
5

9
6

1) Truss 7) Locknut
2) Bolt 8) Heat Shield
3) Lock Washer 9) Isolator
4) Flat Washer 10) Nutplate
5) Frame 11) Truss
6) Unidrive
-----

T-375 5–16
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 5.14.

NOTICE
SST is an abbreviation for 300 Series Corrosion Resistant Steel. Loctite #242 or an equivalent
product should be used on ALL hardware shown in Figure 5.14.

Figure 5.14 Unidrive Torque Requirements

M8 x 50 mm Allen
(6 req’d ) 25.76 Nm (19 ft-lb)
Truss and Isolator

3/8 x 1.5 lg - SST 3/8-16 x 1-1/4 lg - SST

(12 req’d) 33.90 Nm (25 ft-lb) (4 req’d) 40.67-52.88 Nm
(30-39 ft-lb)

M8 x 1-1/4 lg - STL
(4 req’d) 14.91 Nm (11 ft-lb)

Nut, Self Lock 3/8-16 - SST

(2 req’d) 40.67-52.88 Nm (30-39 ft-lb)

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

(2 req’d) 101.69 Nm (75 ft-lb)

5/8-18 x 2.00 lg - SST 3/8-16 x 1 lg - SST

(4 req’d) 123.38 - 128.80 Nm (4 req’d) 33.90 Nm (25 ft-lb)
(91-95 ft-lb)

Torsional Dampener

3/8-24 x 1.00
(1 req’d) 37.96 Nm (28 ft-lb)

5/8-11 x 4.00 lg - SST

(2 req’d) 122.02 Nm (90 ft-lb)

5–17 T-375
 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 Legend for 12VDC Circuit

6–1 T-375
 Figure 6.2 Schematic for 12 VDC Control Circuit

12 VDC Control Circuit

T-375 6–2
 Figure 6.3 Schematic High Voltage Circuitry

Receptacle Box

High Voltage Circuitry

6–3 T-375
 SECTION 7
EU DECLARATION OF CONFORMITY

Serial Number/Seriennummer /Serienummer:

–
Manufacturing
Date/Herstellungsdatum/Fremstillingsdato :

EU Declaration of Conformity
EU-Konformitätserklärung / EU Overensstemmelseserklæring

We, manufacturer: Carrier Transicold

Wir, der Hersteller / Vi, fabrikant: 700 Olympic Dr
Athens, GA 30601

Declare, under our sole responsibility, that the UG Generator Set Unit:
Erklären, eigenverantwortlich, dass Generatoraggregat Einheit / Erklærer, som eneansvarlige, at Generator sæt enhed:
Models(Modelle/ Modellerne) :
69UG15-068S-55
69UG15-050S-55

are in conformity with the provisions of the following European Directives:

in Übereinstimmung mit den Bestimmungen der folgenden europäischen Richtlinien ist /er i overensstemmelse med bestemmelserne i følgende europæiske direktiver:

x Machinery Directive 2006/42/EC following Annex VIII

Maschinenrichtlinie 2006/42/EC, folgender Anhang VIII / Maskindirektiv 2006/42/EF, tillæg VIII
x Electromagnetic Compatibility Directive 2014/30/EU following Annex II
Richtlinie zur elektromagnetischen Verträglichkeit 2014/30/EU, folgender Anhang II / Elektromagnetisk Kompatibilitetsdirektiv 2014/30/EU, tillæg II
x Noise Directive 2000/14/EC following Annex III
Schallschutzrichtlinie 2000/14/EG folgender Anhang III / Støjdirektiv 2000/14/EF, tillæg III

The following Harmonized Standards were applied for this equipment:

Folgende harmonisierte Normen wurden für diese Geräte angewendet/ Følgende harmoniserede standarder blev anvendt til dette udstyr:

Machinery Directive EMC Directive Noise Directive

Maschinenrichtlinie/ EMV Richtlinie/ Schallschutzrichtlinie/
Maskindirektiv EMC direktiv Støjdirektiv
EN ISO 12100:2010 EN 61000-6-4:2007 EN 3744:1995
EN 60204-1:2006 EN 61000-6-2:2005 EN 8528-01:1993
EN 13857:2008 EN 55011:2009 Lwa 99.0 dB

The following technical standard was applied for this equipment/Folgende technische Norm wurde für diese Geräte angewendet// Følgende Tekniske standarder blev anvendt til dette
udstyr: ISO 1496-2:2018

Person established in Europe authorized to compile a copy of the Technical File:

In Europa ansässige Person, die berechtigt ist, eine Kopie der technischen Dokumentation zu erstellen/ Ansvarlig person i Europa udpeget til at udarbejde en kopi af den tekniske fil:

Shaun Bretherton
Service Engineering Manager of CTL Rotterdam
Pittsburgstraat 21 3047 BL Rotterdam, Netherlands

Nader Awwad, Engineering Director Date

Carrier Transicold
P.O. Box 4805
Syracuse, New York 13221, USA
(Authorized person to sign declaration on behalf of the manufacturer)
(Person, die zur Unterzeichnung der Erklärung im Namen des Herstellers berechtigt ist/ Bemyndiget person skal underskrive på vejne af fabrikanten)

Carrier Transicold Division, Carrier Corporation Part no./Teilenr : 62-10144-126 Rev A

P.O. Box 4805 Syracuse, New York 13221 USA English/Deutsch/Dansk

T-375 7-1
 INDEX

A Engine Fuel System 2–5

Engine Fuel System, Bleed 5–3
AC Generator 2–1, 2–4
Engine Fuel System, Fuel Filter / Water Separator 2–5
AC Generator Service 5–9
Engine Fuel System, Fuel Filter Replace 5–4
AC Generator Troubleshooting 4–5
Engine Fuel System, Fuel Pump Internal Filter Service
Ammeter 2–10
5–3
Engine Fuel System, Fuel Solenoid (FS) 2–6
B
Engine Fuel System, Fuel Tank Specifications 2–14
Battery 2–10 Engine Fuel System, Injection Pump 2–5
Battery Charger 2–10 Engine Fuel System, Injector Nozzles 2–5
Battery Charger Troubleshooting 4–4 Engine Fuel System, In-Line Fuel Strainer 2–5
Battery Charging System 2–10 Engine Fuel System, In-Line Strainer Replace 5–4
Battery Service 5–3 Engine Fuel System, Mechanical Lift Pump 2–5
Engine Lube System 2–7
C Engine Lube System Location and Components 2–7
CE mark 2–1 Engine Lube System, Low Oil Pressure (LOP) Switch
CE verification 2–1 2–7
Circuit Breaker (CB1) 3–2 Engine Lube System, Oil Filter Replace 5–4
Configuration Identification 2–2 Engine Lube System, Oil Pressure Sender (OPS) 2–7
Control Panel 2–10 Engine Lube System, Oil Pressure Switch Service 5–4
Engine Service 5–3
E Engine Shockmounts 5–16
Electronic Governor Module (EG) 2–6, 2–10 Engine Speed Sensor (ESS) 2–6
Electronic Governor Module (EG) Operation 3–3 Engine Speed Sensor (ESS) Operation 3–3
Electronic Governor Module (EG) Troubleshooting 4–6 Engine Speed Sensor (ESS) Replace 5–5
Engine 2–1, 2–4 Engine Speed Service 5–5
Engine Air Cleaner 2–8 Engine Troubleshooting 4–1
Engine Air Cleaner Location and Components 2–8
Engine Air Cleaner Service 5–5
F
Engine Air Cleaner, Air Filter Indicator 2–8 First Aid 1–1
Engine Air Cleaner, Air Filter Indicator Service 5–6 Fuel Solenoid (FS) Operation 3–3
Engine Air Cleaner, Body Service 5–7
Engine Air Cleaner, Dry Element Air Filter 2–8 G
Engine Air Cleaner, Dry Element Service 5–6 General Safety Notices 1–1
Engine Air Cleaner, Intake Heater (IH) 2–8 Generator Set Components 2–2
Engine Air Cleaner, Intake Heater (IH) Switch Service Generator Set Components - Top View 2–3
5–9 Generator Set General Maintenance 5–13
Engine Air Cleaner, Intake Heater (IH) Test 5–8 Generator Set Identification 2–2
Engine Air Cleaner, Oil Bath Service 5–6 Generator Set Installation 3–1
Engine Cooling System 2–9 Generator Set Removal 3–1
Engine Cooling System Location and Components 2–9
Engine Cooling System Service 5–4 H
Engine Cooling System, High Water Temperature
High Voltage Circuit Troubleshooting 4–6
Switch (HWT) 2–9
Engine Cooling System, Radiator 2–9
I
Engine Cooling System, Water Temperature Sender
(WTS) 2–9 Ignition Switch (IGN) 2–10
Engine Crankcase Breather Service 5–8 Ignition Switch (IGN) Operation 3–3
Engine Data 2–14 Intake Heater Relay (HR) Operation 3–3
Engine Data Specifications 2–14 Intake Heater Switch (HS) 2–10

Index–1 T-375
Intake Heater Timer (IHT) 2–10 Schematic Diagram 6–2
Intake Heater Timer (IHT) Operation 3–3 Schematic Diagram - Legend 6–1
Isolators/Shockmounts Check and Replace 5–14 Schematic High Voltage Circuitry 6–3
Schematics 6–1
L Sequence of Operation 3–3
Low Oil Pressure Switch (LOP) Operation 3–3 Standard Mount Mounting 3–1
Starter Motor (SM) Operation 3–3
M Starter Solenoid (SS) Operation 3–3
Starter Solenoid Timer (SST) 2–10
Maintenance Precautions 1–1
Starting and Stopping Instructions 3–2
O Starting Instructions 3–2
Stopping Instructions 3–3
Oil Pressure Gauge 2–7, 2–10
Operating Precautions 1–1 T
P Total Time Meter (TT) 2–10
Truss and Isolator 5–16
Painted Surfaces 5–13
Poly V-belt Service 5–5 U
Post-Start Inspection 3–3
Unidrive Assembly Components 2–4
Pre-Start Inspection 3–2
UniDrive Torque Requirements 5–17
Preventative Maintenance Schedule 5–1
Unit Nameplate 2–2
R Unit Specifications 2–14

Receptacle Box 2–12 V

S Voltage Controller (VC) 2–4, 2–12

Safety Devices 2–12 W

Safety Relay (S) Operation 3–3
Water Temperature Gauge 2–10
Safety Summary 1–1

T-375 Index–2
 Carrier Transicold Division,
Carrier Corporation
P.O. Box 4805
Syracuse, NY 13221 USA

https://www.carrier.com/container-refrigeration