Operations and Service Manual 69RG15: Diesel Generator Set

Diesel Generator Set
OPERATIONS AND SERVICE

MANUAL
For
69RG15
PowerLINE® Series 55 Generator Set Units
PID RG5500 to 5599
Stage V Compliant
T-377
OPERATIONS AND SERVICE
MANUAL
For
69RG15
PowerLINE® Series 55 Generator Set Units
PID RG5500 to 5599 Stage V Compliant
© Carrier Corporation, 2023 Printed in U. S. A. January 2023

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.3.1 Voltage Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.4.1 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4.2 Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.3 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.4 Engine Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.4.5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.5 BATTERY AND BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6 CONTROL PANEL AND CONTROL BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.1 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.2 Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.3 Total Time Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.4 Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.5 Intake Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.6 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.7 Intake Heater Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.8 Starter Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.7 RECEPTACLE BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.8 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.9 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.1 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.2 Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.3 Post-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.4 Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.2 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1.3 Engine Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5.1.4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
i T-377
5.1.5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5.1.6 Miscellaneous Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.2 BATTERY CHARGER (SOLID STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.3 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4 ELECTRONIC GOVERNOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.5 VOLTAGE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.6 HIGH VOLTAGE CIRCUIT, ELECTRICAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5–6
SERVICE AND PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.2 PREVENTATIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.3 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.4 ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.4.1 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.4.2 Servicing the Fuel Pump Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.4.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.4.4 In-Line Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.4.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.4.6 Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.4.7 Servicing Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.4.8 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.4.9 Replacing the Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.4.10 Servicing the Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.4.11 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
6.4.12 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.4.13 Intake Heater Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.4.14 Intake Heater Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.4.15 Intake Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.5 SERVICING THE AC GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.5.1 Remove and Replace Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.6 GENERAL GENERATOR SET MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.6.1 Maintenance of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.6.2 Checking and Replacing Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.7 UNIDRIVE TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
SCHEMATICS ........................................................................ 7–1
SCHEMATICS PAGE 2 ................................................................. 7–2
SCHEMATICS PAGE 3 ................................................................. 7–3
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
INDEX .......................................................................... INDEX–1
T-377 ii
LIST OF ILLUSTRATIONS
FIGURE NUMBER Page
Figure 2.1 Generator Set ................................................................ 2–1

Figure 2.2 Generator Set Components - Covers Removed ...................................... 2–2
Figure 2.3 Unit Nameplate ............................................................... 2–2
Figure 2.4 Generator and Engine - Unidrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Figure 2.5 Fuel System Diagram .......................................................... 2–4
Figure 2.6 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Figure 2.7 Electronic Governor Module (EG) ................................................. 2–5
Figure 2.8 Engine Lubrication System ...................................................... 2–6
Figure 2.9 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Figure 2.10 Engine Cooling System ........................................................ 2–8
Figure 2.11 Control Panel and Control Box ................................................. 2–10
Figure 2.12 Receptacle Box ............................................................. 2–11
Figure 3.1 Generator Set Mounting - Pin Type with Locking Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Figure 6.1 Battery Cable Routing - Side View ................................................ 6–3
Figure 6.2 Air Cleaner, Dry Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Figure 6.3 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Figure 6.4 Intake Heater ................................................................. 6–8
Figure 6.5 Generator Shaft Keyway ....................................................... 6–10
Figure 6.6 Generator Coupler Bolt ........................................................ 6–10
Figure 6.7 Generator Alignment Bolt ...................................................... 6–11
Figure 6.8 Generator Mounting Bolts ...................................................... 6–11
Figure 6.9 Generator Shockmounts ....................................................... 6–13
Figure 6.10 Engine Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Figure 6.11 Truss and Isolator ........................................................... 6–14
Figure 6.12 Unidrive Torque Requirements ................................................. 6–15
Figure 7.1 Schematic Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Figure 7.2 Schematic 12VDC Control Circuit ................................................. 7–2
Figure 7.3 Schematic High Voltage Circuitry ................................................. 7–3
iii T-377
LIST OF TABLES
TABLE NUMBER Page
Table 2–2 Fuel Tank ................................................................... 2–12

Table 2–1 Safety Devices ............................................................... 2–12
Table 2–4 Engine Data ................................................................ 2–13
Table 2–3 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Table 4–1 Cold Engine Preheat Times ...................................................... 4–2
Table 6–1 Preventative Maintenance Actions and Schedule ..................................... 6–1
T-377 iv
Section 1
Safety Summary
1.1 General Safety Notices
Installation and servicing of generator set equipment can be hazardous due to system belts, radiator fan, and
electrical components. Only trained and qualified service personnel should install, repair, or service generator set
equipment. When working on generator set 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
manual. 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.
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
recommended precautions must be understood and applied during operation and maintenance of the equipment
covered herein.
1–1 T-377
! WARNING
To prevent injury, the procedures provided for installation and removal of the generator set
must be followed carefully.
! WARNING
Disconnect the power plug before removing the generator set.
! 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.
! WARNING
Beware of pinch points.
! WARNING
Do not use gasoline to clean air cleaner parts.
! CAUTION
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.
! 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
damage the cooling system.
! CAUTION
Always cover the engine inlet tube while the air cleaner is being serviced.
T-377 1–2
! CAUTION
When reassembling the air cleaner, make sure the clamp bolt faces out, away from the fuel filter. If
the clamp bolt is assembled facing in, it can contact the fuel filter and cause excessive wear.
! 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.
NOTICE
This generator set is equipped with special pins and mounting bolts and can be installed only
on containers with matching installation points.
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).
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 18 ft-lbs.
NOTICE
Do not attempt to adjust engine speed.
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.
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 back, away from 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.
1–3 T-377
NOTICE
Inspect the generator torsional dampener, bolt, and key as they are removed from the old generator
and installed onto the new generator. Replace any components that are worn or damaged.
NOTICE
Align the torsional dampener and aluminum housing by rotating either one to seat correctly.
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 6.12.
T-377 1–4
Section 2
Description
2.1 Introduction
The Carrier Transicold model 69RG15 Series 55 diesel-driven generator set provides a constant electrical power
supply for all-electric refrigeration units. The 69RG15 is a a clip-on unit (see Figure 2.1, Figure 2.2) mounted to the
front of the container either by pin mounts located on the top channel or by optional clamp mounts located on either
side of the generator set.
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 control box door.
The Series 55 model generator set bears the CE mark, 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 2
2
4 3
7 4
6 5
1) Clamp Mounts (Optional) 5) Access Door

2) Pin Mounts 6) Control Box / Control Panel
3) Unit Nameplate (Model, Serial, PID) 7) Fuel Gauge
4) Fuel Cap
-----
2–1 T-377
Figure 2.2 Generator Set Components - Covers Removed
4 5 6
3 7
14
13 8
12 9
11
10
1) AC Generator 8) Radiator
2) Receptacle Box 9) Oil Filter
3) Battery Charger 10) Coolant Recovery Bottle
4) Voltage Controller 11) Fuel Tank
5) Engine 12) Fuel Filter / Water Separator
6) Exhaust Muffler 13) Engine Air Cleaner
7) Battery 14) Control Panel and Control Box
-----
2.2 Configuration Identification

Generator set identification information is provided on a unit nameplate located on the side of the unit. 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 2.3 Unit Nameplate
T-377 2–2
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 (see Section 2.3.1) 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 60Hz 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 regulates 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 Engine Parts List
Figure 2.4 Generator and Engine - Unidrive Assembly
3
6
1
2 5 4
1) Generator 4) Engine Shockmount

2) Generator Shockmount 5) Starter
3) Engine 6) Poly V-Belt
-----
2–3 T-377
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. 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 removes water and finer particles and includes a 12-volt baldwin fuel
heater. Low pressure fuel then enters the injection pump, where it is compressed to higher pressures and
distributed to individual fuel lines that supply each cylinder’s injector nozzle. The nozzles spray atomized fuel into
the combustion chamber based on the timing of the injector pump. Any excess fuel in the nozzles not used for
combustion is sent back to the fuel tank.
Figure 2.5 Fuel System Diagram
9 2
1
8
7
9
5 6
4
1
1) Fuel Tank 6) Injection Pump

2) Fuel Tank Supply with Shutoff Valve 7) Injector Nozzles (4)
3) In-Line Fuel Strainer (option) 8) Manual Fuel Bleed Valve
4) Mechanical Lift Pump 9) Fuel Tank Return
5) Fuel Filter / Water Separator
-----
T-377 2–4
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 120 gallon capacity.
Figure 2.6 Fuel Tank
2.4.2 Electronic Governor

The electronic governor controls the speed of the engine by using an electronic governor (EG) module, fuel
solenoid (FS) and engine speed sensor (ESS).
The electronic governor (EG) module (see Figure 2.7) is a solid state control module pre-programmed for 1800
RPM high speed operation and 1500 RPM low speed operation. It receives an input signal from the engine speed
sensor (ESS) of the current RPM and compares this to a preset value. The electronic governor (EG) module sends
a correction signal to the fuel solenoid (FS) to maintain the proper RPMs.
The electronic governor (EG) module is mounted in the control box and has an LED which may assist in
diagnosing failures within the electronic speed control system. See Section 5.4 for additional troubleshooting
information.
Figure 2.7 Electronic Governor Module (EG)
LED
2–5 T-377
2.4.3 Engine Lubrication System
The engine lubrication system (see Figure 2.8) supplies lubricating 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 (OPG) located on
the control 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
1
4
1) Oil Filter 3) Low Oil Pressure (LOP) Switch

2) Oil Pressure Sender (OPS) 4) Oil Dipstick / Fill Cap
-----
T-377 2–6
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
effectively removes contaminants from the air stream, resulting in prolonged engine life and reduced wear on all
operating engine 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.
As air exits the air cleaner, it passes through the air intake heater (IH) and then enters the engine cylinder. This is
done to help the engine start in cold temperatures.
Figure 2.9 Engine Air Cleaner
3 4
2 4
1) Air Cleaner, Dry Element 3) Air Inlet Hose

2) Air Filter Indicator 4) Air Intake Heater
-----
2–7 T-377
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
3
1
4
5
3
1) Radiator assembly 4) High Water Temperature Switch (HWT)

2) Radiator fill cap 5) Water Temperature Sender (WTS)
3) Coolant recovery bottle
-----
T-377 2–8
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 (IH)
until the unit starts. The solid state 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. See Figure 2.2 for location of components.
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
generator set unit.
2.6.1 Water Temperature Gauge

The water temperature gauge (WTG) observes water operating temperature. Once the unit has achieved normal
running temperature, the coolant temperature is between 82 - 96°C. The high water temperature (HWT) switch
senses engine water temperature and transmits a signal to the water temperature gauge (WTG).
2.6.2 Oil Pressure Gauge

The oil pressure gauge (OPG) observes normal operating engine oil pressure. Normal oil pressure is 3.3 to 5.2 kg/
cm2. The oil pressure sender (OPS) (see Figure 2.8), located at the oil filter housing, senses lube oil pressure and
transmits a signal to the oil pressure gauge (OPG).
2.6.3 Total Time Meter

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 6–1).
2.6.4 Ammeter
The ammeter (A) 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 (IH) draws approximately 42 amps.
2.6.5 Intake Heater Switch

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

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

The intake heater timer (IHT) continues to supply power to the intake heater (IH) for 3 minutes after initial start-up.
2.6.8 Starter Solenoid Timer

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.
2–9 T-377
Figure 2.11 Control Panel and Control Box
Control Panel Control Box
1 2 13
14
15
3 7
4
12
9
11
10 8
16
5
6
Mounted to
back of box
1) Water Temperature Gauge (WTG) 9) Intake Heater Relay (HR)

2) Oil Pressure Gauge (OPG) 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)
-----
T-377 2–10
2.7 Receptacle Box Components
The Receptacle box (see Figure 2.12) contains 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.
2–11 T-377
Table 2–1 Safety Devices
Engine
Unsafe Condition: Low engine lubricating oil pressure.
Safety Switch Low oil pressure (LOP) switch - Automatic reset
Switch Setting Opens below 1.27 kg/cm
Unsafe Condition: High engine cooling water temperature.
Safety Switch High water temperature (HWT) switch - 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)
Intake Heater
Unsafe Condition: Excessive current draw on intake heater circuit
Battery Charger
Unsafe Condition: Excessive current draw on 12 volt supply circuit.
Unsafe Condition: Excessive current draw on 460 volt feed circuit
Safety Switch Fuse BCF3
Generator
Unsafe Condition: Excessive current draw by load
Safety Switch Circuit breaker (CB-1, 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
2.9 Unit Specifications
Table 2–2 Fuel Tank

Capacity: Nominal tank size: 120 gallon
Fill capacity: 120 gallon
Draw capacity: 119 gallon (Allows for DOT required 5% vapor space)
Unit Weight: Engine (Dry) without accessories: 851 kg approximate
T-377 2–12
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: 54-00378-20
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
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
Lubrication System: Oil pressure: 3.3 to 5.2 kg/cm
Oil pressure safety switch setting opens: 1.27 kg/cm2
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:
For outdoor temperatures (-18°C to 7°C): SAE: 10W30 or Mobile Delvac 1*
For outdoor temperatures (above 7°C): 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
Fuel, Summer: Diesel No. 2
FHT, Winter: Close on temperature fall @ 7.2 + 3.6°C
FHT, Summer: Open on temperature rise @ 23.8 + 3.6°C
Power consumption: 150 Watts @ + 10% at 14 VDC
Diesel fuel specification type and percentage of 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.%
2–13 T-377
Table 2–4 Engine Data (Continued)
Intake Heater: Amperage - 42 amps at 12 VDC
Resistance (cold) - Approximately 0.3 ohms
Horsepower: 24.8 HP @ 1800 RPM at sea level. (SAE J1995 Gross Power Rating)
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 at 110 + 3°C
Resets at 93°C - minimum
Thermostat:
Starts to open at 80 to 84°C
Fully open at 95°C
Low coolant sensor:
Opens at loss of 907g of coolant or more
Closes at refilling of radiator to proper level
T-377 2–14
Section 3
Installation
! WARNING
To prevent injury, the procedures provided for installation and removal of the generator set
must be followed carefully.
! WARNING
Disconnect the power plug before removing the generator set.
NOTICE
This generator set is equipped with special pins and mounting bolts and can be installed only
on containers with matching installation points.
Figure 3.1 Generator Set Mounting - Pin Type with Locking Bracket
1
2
A B
3 4 A
A
D
C
C
G D
3.1 Installation
1. Place forks into the fork pockets of the generator set. Attach the safety chain (A) between fork pockets on
the generator set and fork truck. Be sure the chain (A) is short enough to retain the generator set on the
forks.
2. Line up the generator set with the refrigeration unit and container. Raise the generator set until the top is
several inches above the top edge of the container. Move the generator set against the container and lower
into position. Ensure the two pins (B) are fully engaged in the mating holes in the container.
3. Keep forks in the pockets on the generator set and tighten mounting bolt (C) on each side of the generator
set into the container frame. Torque mounting bolts to 17.3 + 3.5 mkg. Ensure the locking brackets (D) are
locked into position so as to capture bolt heads (C) and prevent turning.
4. Upon completion, remove the safety chain (A) before removing the forks of the fork truck from the unit.
3–1 T-377
3.2 Removal
1. Move the forks into the fork pockets on the generator set. Attach the safety chain (A) between fork pockets
on the generator set and fork truck.
2. Release the locking brackets (D) on each side of the generator set.
3. Remove the mounting bolt (C) on each side of the generator set and tighten into the threaded hole (E).
4. Raise the generator set several inches to disengage the pins (B) from the mating holes and remove from
container.
T-377 3–2
Section 4
Operation
4.1 Starting and Stopping Instructions

4.1.1 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 the engine lubricating oil level (see Table 2–4).
3. Check the poly V-belt for fraying or cracks and proper tension (see Section 6.4.10).
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 6.4.11).
7. Check the in-line fuel strainer and clean if necessary (see Section 6.4.4).
8. Drain water from the fuel filter bowl.
9. Fill the fuel tank with diesel fuel (see Table 2–4).
10. Check the air intake heater (IH) amperage (see Table 2–4).
11. Check the 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 that the main generator set circuit breaker (CB1) is in the OFF position. Connect the power cable to
the refrigeration unit and proceed to Section 4.1.2 for starting instructions.
4.1.2 Starting Instructions

Before start up, both the generator set circuit breaker (CB1) and the refrigerated unit should be OFF. After start up,
the generator set 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
! 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).
4–1 T-377
Procedure:
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 generator set receptacle.
3. Hold the intake heater switch (HS) in the PREHEAT position (see Figure 2.11) in the PREHEAT position.
Suggested hold times for a cold engine are listed in the following table:
Table 4–1 Cold Engine Preheat Times

Ambient Temperature Time
26°C 5 seconds
0°C to 26°C 10 seconds
-8°C 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.
4.1.3 Post-Start Inspection

1. Allow the generator set 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 and check total time meter operation.
6. Listen for abnormal bearing noise from the AC generator.
7. Check the fuel lines, lube oil lines, and filters for leaks.
8. Check the exhaust system for leaks.
4.1.4 Stopping Instructions

1. Place circuit breaker CB-1 in the OFF position.
2. Place the ignition switch (IGN) in the OFF position.
4.2 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 an approximate 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).
T-377 4–2
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 (LOP) switch contacts close to maintain power to the safety relay (S).
Once the engine has started, the intake heater (IH) will remain energized for three minutes.
The ignition switch (IGN) will be released. The intake heater switch (HS) will be held for five 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.
4–3 T-377
Section 5
Troubleshooting
5.1 Diesel Engine

5.1.1 Engine Will Not Start
Condition Possible Cause Remedy / Reference Section
Starter motor will not crank or Battery is insufficiently charged Charge
low cranking speed Battery terminal post or battery is defective Check
Electrical connections at starter are bad Correct
Starter motor malfunction Section 5.1.4
Starter motor solenoid is defective Engine Manual
Starting circuit is open Section 5.1.5
Lubricating oil is incorrect grade Section 2.9
Fuse F5 is bad Replace
Starter motor cranks, but fails Fuel tank is empty Section 2.9
to start Air inside the fuel system Section 6.4.1
Water inside the fuel system Drain Sump
Fuel filters are plugged Replace
Air intake heater is bad Section 6.4.14
Oil level is low; Oil pressure switch is defective Section 6.4.7
Heater switch is faulty Section 6.4.15
Fuel lines to injector(s) are plugged Engine Manual
Mechanical lift fuel pump malfunction Engine Manual
Fuses F1, F2, F3 are bad Check / replace
Connection between wire harness and Check / correct
Electronic Governor Module (EG) is loose or
bad
Starter cranks and engages, Engine lube oil is too heavy Table 2–4.
but dies after a few seconds Starter cable(s) has voltage drop Check
5.1.2 Engine Starts Then Stops

Engine stops after a few Fuel tank is empty Section 2.9
rotations Intake heater switch is not held long enough Hold switch
Fuel filter is restricted Replace
Air cleaner or hose is restricted Section 6.4.11
Engine crankcase breather or hose is Section 6.4.12
restricted
Safety device is open Section 2.8
5–1 T-377
Engine stops after a few Wiring circuit to fuel solenoid is open Check
rotations Fuel solenoid is defective Replace
Fuel supply is restricted Section 2.9,Section 6.4.2
Mechanical lift fuel pump malfunction Engine Manual
Oil level is low; Oil pressure switch is defective Section 6.4.7
Fuel system has leak Check
Injector nozzle(s) is defective Engine Manual
Injection pump is defective Engine Manual
Generator internal overloads are open Table 2–1
5.1.3 Engine Will Not Shut Off

Engine will not shut off Ground connection is loose Clean / Tighten
Fuel solenoid is improperly seated Correct
5.1.4 Starter Motor Malfunction

Starter motor will not crank or Battery is insufficiently charged Charge
turns slowly Battery cable connections are loose or Check / Replace
oxidized
Battery cables are defective Check / Replace
Starter brushes are shorted out Engine Manual
Starter brushes hang up, defective or have no Engine Manual
contact
Starter solenoid is damaged Engine Manual
Ignition switch is defective Replace
Engine lube oil is too heavy Section 2.9
Starter motor turns, but pinion Pinion or ring gear is obstructed or worn Engine Manual
does not engage
Starter motor does not Ignition switch is bad Check / Replace
disengage after switch has Starter motor solenoid is bad Engine Manual
been released
Pinion does not disengage after Starter is bad Engine Manual
engine is running
5.1.5 Malfunction In The Engine Starting Circuit

No power to starter motor Battery is defective Correct
solenoid Electrical connections are loose Tighten
T-377 5–2
Fuel solenoid does not Battery is defective Correct
energize or does not remain Electrical connections are loose Tighten
energized
Oil pressure switch is defective Section 1.9
Water temperature safety switch is open Section 1.9
Fuel solenoid is defective Engine Manual
Intake heater switch is bad Check (Engine Manual)
Electronic governor module (EG) is bad Check / Replace (Section
6.4.14)
Intake heater does not energize Intake heater switch is bad Section 6.4.14
Timer is bad Section 6.4.14
Heater element is bad Section 6.4.14
Heater relay is bad Section 6.4.14
5.1.6 Miscellaneous Engine Troubleshooting

Loss of power Air cleaner has restriction Section 6.4.11
Fuel system has air in it. Section 6.4.11
Air vent is restricted Clean
Fuel lines are restricted Engine Manual
Fuel injection pump is bad Engine Manual
Injector(s) are bad or incorrect type used Engine Manual
Fuel injection pump timing is incorrect Engine Manual
Valve timing is incorrect Engine Manual
Compression is poor Engine Manual
Vibration Engine shockmounts are bad Replace
Compression is poor Engine Manual
Overheating Air cleaner restriction Section 6.4.11
Exhaust pipe restriction Remove
Water jacket restriction Engine Manual
Radiator restriction Section 6.4.5
Coolant level is too low Section 2.9.
Water pump is loose; alternator poly V-belt is Section 6.4.10
loose
Thermostat is bad Engine Manual
Water pump is bad Engine Manual
Excessive crankcase pressure Crankcase breather line is plugged Section 6.4.12
5–3 T-377
5.2 Battery Charger (Solid State)

CB4 trips when charger is Short in 12-volt wiring causing overload of Locate and remove short or replace
turned on charger charger
Circuit breaker trips repeatedly, Internal short Replace charger
even when not connected
Charger does not taper back Bad cell in battery Test battery for defect according to
after charging for a few minutes battery manufacturer’s instructions
Charger is bad Replace
Charger does not charge BCF3 is open 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 is blown and possible Replace
battery has caused charger to damage to current carrying components
stop charging
5.3 Alternating Current Generator

No voltage Rotor magnetism is lost Replace
Circuit breaker is tripped Check CB1
Open in stator windings Replace
Short circuited Replace
Worn drive gear is stripped Check / Replace
Contactor is not engaged Replace
Low voltage Engine speed is low Section 6.4.12
High resistance connections, connections Tighten
are warm or hot
Rotor magnetism is lost Replace
Fluctuating voltage (May be Speed fluctuating Section 6.4.12
indicated by flickering lights) Engine speed is irregular Engine Manual
Terminal or load connections are loose Tighten
Bad bearing is causing uneven air gap Replace
High voltage Engine speed is excessive Section 6.4.12
T-377 5–4
Overheating Generator is overloaded Check
Vents / baffles are clogged Check / Clean
High temperature surrounding generator Section 6.4.5
Air circulation or recirculation is insufficient Check / Clean
Load is unbalanced Balance
Bearing is dry Replace
Mechanical Noise Bearing is bad Replace
Rotor is rubbing on stator Replace
Laminations are loose Replace
Coupling is loose or misaligned Check drive gear
Generator frame produces Static charge Check ground to frame
shock when touched
5.4 Electronic Governor Module
Fault LED flash code Possible Cause

Engine over speed: more than 2,530 RPM One Long - One Short ESS or mechanical engine problem
Actuator wiring disconnection. No signal from Two Long - One Short Short ESS or wiring problem
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. Fuel / speed Two Long - Three Short FS or wiring problem
actuator (FS) wiring disconnected or open
circuit. Coil resistance spec: 2.8 ohm + 10%.
EG supply voltage is greater than 26V. Two Long - Seven Short EG or alternator problem
5.5 Voltage Controller

The voltage controller has one green indicator light and one yellow indicator light. When the green light is
illuminated, it means that the voltage controller is receiving power. The yellow light only illuminates (flashes) to
indicate that there is a problem.
Green LED Fault Possible Cause / Remedy

LED not illuminated No power to the voltage controller (VC) 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
5–5 T-377
5.6 High Voltage Circuit, Electrical Troubleshooting
! WARNING
Before proceeding with troubleshooting, make sure to follow your company’s standard safety
procedures for working with electrical components.
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. Check Loose connections. Tighten.
Circuit Breaker to continuity for each leg.
Receptacle)
Circuit Breaker (CB) Test the output power from circuit breaker Faulty circuit breaker. Replace.
CB (21-22, 22-23, 21-23).
Verify circuit breaker (CB) is in the ON Circuit breaker (CB) is in the OFF
position. position.
Test the input power to the circuit breaker

CB (11-12, 12-13, 11-13).
Voltage Controller (VC) Verify VCF1 fuse is not blown. Check Blown fuse. Replace.
and 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. This indicates a failed
Yellow light flashing sequence other than voltage controller. Replace.
at 1 Hz indicates a fault condition. One Long / Three Short = over
voltage error. Check engine speed.
One Long / Four Short = under
voltage error. Check engine speed.
One Long / Five Short = hot start
error. Reset power to the unit.
One Long / Six Short = voltage
controller fault. This indicates a failed
voltage controller. Replace.
One Long / Seven Short = voltage
controller fault. This indicates a 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. Very
depth is the same.
Check to see if wires / terminals are
connected.
Section 6
Service and Preventative Maintenance
6.1 Introduction
This section covers service for the generator set and general engine service. Refer to the Kubota engine workshop
manual (see Section 2.1) for other engine servicing.
! WARNING
6.2 Preventative Maintenance Schedule

A tabular listing of the recommended preventative maintenance activities and schedule is provided in Table 6–1.
Table 6–1 Preventative Maintenance Actions and Schedule

Perform Perform
Perform
Manual every every
Procedure during
Reference 2000 hrs 4000 hrs
Pre-Trip1
service2 service3
1. Check (in place) engine / generator shockmounts for cracks, Section X X
cuts, abrasion or flaring. 6.6.2
2. Check engine lubrication oil and fuel lines, filters and - X X X
connections for leaks.
3. Check engine lubrication oil level, add as required. Section 2.9 X
4. Check Poly V-belt for fraying or cracking. Replace as required. Section X X X
6.4.10
5. Check radiator hoses for leaks. - X X X
6. Check coolant level. Add 50/50 mix as required. Section 2.9 X X X
7. Check radiator coil and generator air intake for cleanliness. Section X X X
6.4.5
8. Check Air Cleaner: X X X
For Dry Element air cleaner: Section X X X
Check for cleanliness and replace as filter indicator indicates. 6.4.11
9. Drain water from the fuel tank sump. - X X X
10. Drain water from the fuel filter bowl. - X X X
11. Fill the fuel tank with diesel fuel. Check fuel gauge operation. Section 2.9 X X X
12. Check intake heater amperage. Section X X X
6.4.15
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 the mechanical fuel lift pump internal filter. Section X X
6.4.2
17. Change in the line fuel strainer (option). Section X X
6.4.4
18. Clean and coat terminals with battery terminal sealant. - X X
6–1 T-377
Table 6–1 Preventative Maintenance Actions and Schedule (Continued)
Perform Perform
Perform
Manual every every
Procedure during
Reference 2000 hrs 4000 hrs
Pre-Trip1
service2 service3
19. Change lubricating oil and filters (See NOTES) Section X X
6.4.6
20. Tighten engine and generator mounting bolts. Section X X
6.6.2
21. Tighten all electrical connections in the control box. - X X
22. Check water pump bearing end play. Engine X X
Manual
23. Change the fuel filter. Section X X
6.4.3
24. Check the crankcase breather. Section X X
6.4.12
25. Remove and check engine / generator shockmounts for cracks, Section X X
cuts, abrasion or flaring. 6.6.2
26. Clean and flush the coolant system. Section X
6.4.5
27. Check the starter condition. Engine X X
Manual
28. Check engine compression. Engine X X
Manual
29. Check and adjust the injector nozzles. Engine X X
Manual
30. Perform generator maintenance. Section 6.5 X X
31. Check total time meter operation (allow engine to run 10 - X X X
minutes).
32. Listen for abnormal noises. - X X X
33. Check fuel, lubricating oil and radiator coolant lines, - X X X
connections and filters for leaks.
34. Check exhaust system for leaks. - X X X
35. Check Generator output with a voltmeter, should be 490 volts, Section 6.5 X X X
+ 15 volts (engine, 1800 rpm) with a nominal frequency of 60Hz.
36. Turn the refrigeration unit on and check generator 1800 rpm Section 6.5 X X X
under full load.
37. Verify operation of safety devices. Section 2.8 X X
NOTES ON LUBRICATING OIL AND FILTERS:

• 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 com-
pleted 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-377 6–2
6.3 Battery Service
When replacing the battery, note if the unit was supplied with a mat in the battery tray. If so equipped, the mat must
also be replaced. Orient battery cables approximately as shown in Figure 6.1. When installing cables to battery,
ensure the cables are not touching anything, and are floating in free air.
! CAUTION
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.
Figure 6.1 Battery Cable Routing - Side View
6.4 Engine Service and Components

6.4.1 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 fuel bleed valve (see Figure 2.5) counterclockwise until fully opened.
2. Turn the top of the manual priming pump counterclockwise 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 hand priming pump clockwise to lock in place.
4. Start the engine. See Section 4.1.
5. When the engine is running properly, turn the fuel bleed valve clockwise until fully closed.
6.4.2 Servicing the 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 6.2).
1. Turn the nut counterclockwise to loosen and remove
2. Remove the banjo fitting and let it hang loose.
3. Turn filter counterclockwise and remove. Check and clean.
4. To install, reverse steps 1 through 3.
6–3 T-377
6.4.3 Fuel Filter
The fuel filter is located on the generator set unidrive assembly (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 18 ft-lbs.
6.4.4 In-Line Fuel Strainer

1. Loosen the bowl by turning counter-clockwise.
2. To renew, remove the in-line fuel strainer.
3. Check and clean, and replace.
6.4.5 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. Rinse coil(s) with fresh water if a detergent is used.
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 liters 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 system. Use of glycol by itself will dam-
age the cooling system.
5. Run the engine to operating temperature. Drain the system again and fill with treated water / anti-freeze.
See the above Caution statement.
6.4.6 Lube Oil Filter

The oil filter is located near the radiator fan (see Figure 2.8).
1. After warming up the engine, stop the engine, remove the drain plug from the oil reservoir and drain engine
lube oil.
2. Replace the filters. Lightly oil the gasket on the filter before installing.
3. Add lube oil (see Table 2–4).
4. Warm up the engine and check for leaks.
T-377 6–4
6.4.7 Servicing Low Oil Pressure Switch
1. Remove harness connection from the low oil pressure (LOP) switch.
2. Remove the low oil pressure (LOP) switch from the engine.
3. Apply Teflon thread sealer to all threads of new the new switch.
4. Install the new switch.
5. Reconnect the harness connection to the new switch.
6.4.8 Engine Speed

The engine speed is electronically controlled. There are no adjustments.
NOTICE
Do not attempt to adjust engine speed.
6.4.9 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. Reinstall the sensor, replace the securing bolt and connect the plug to the sensor.
6.4.10 Servicing the Poly V-belt
! WARNING
! 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 the 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.
6–5 T-377
6.4.11 Engine Air Cleaner
The engine air cleaner uses a dry element filter (see Figure 6.2) to filter the engine intake air.
The engine air cleaner should be inspected regularly for leaks (see Figure 2.9). 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.
! CAUTION
Always cover the engine inlet tube while the air cleaner is being serviced.
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 air filter body. Its function is to indicate
when the air cleaner dry element needs to be replaced. In operation, when a plugged air cleaner decreases intake
manifold pressure to 500 mm (20”) WG, the indicator moves to the red line. The air cleaner element should be
replaced and the indicator reset by pressing the reset button.
Air Cleaner, Dry Element Service

Refer to Figure 6.2 for this procedure.
1. Stop the engine and open the cap clamps to remove the air cleaner bottom cap.
2. Remove the air filter element from the air cleaner body.
3. Install the new element, and secure the bottom cap with the cap clamps.
Figure 6.2 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
-----
! CAUTION
When reassembling the air cleaner, make sure the clamp bolt faces out, away from the fuel filter. If
the clamp bolt is assembled facing in, it can contact the fuel filter and cause excessive wear.
T-377 6–6
Air Cleaner Body Service
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. Check and clean the 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.
6.4.12 Engine Crankcase Breather

The engine uses a closed type breather (see Figure 6.3) 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 to
ensure it is free of obstruction. Check once a year or every 4000 hours maintenance interval (whichever comes first).
Figure 6.3 Engine Crankcase Breather
3
2
4
1
5
1) Breather Tube 4) Breather Cover

2) Breather Valve 5) Bleed Hole
3) Screw
-----
6.4.13 Intake Heater Test

Refer to Figure 6.4 for this procedure
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.
6–7 T-377
Figure 6.4 Intake Heater
1) Positive Terminal 2) Heater Body

-----
6.4.14 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.
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.
6.4.15 Intake Heater Switch

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

6.5.1 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 6.7
1. Remove the unit top and side panels in order to access the generator.
2. Disconnect the battery.
3. Remove the truss assembly center nuts and nut plate.
4. Remove the truss side bolts / washers and spacers (2), and remove the truss.
T-377 6–8
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.
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 the unit frame and lower onto a stable work surface.
NOTICE
Inspect the generator torsional dampener, bolt, and key as they are removed from the old generator
and installed onto the new generator. Replace any components that 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 6.5.
6–9 T-377
Figure 6.5 Generator Shaft Keyway
20. Apply Loctite 262 to the generator coupler bolt. Install with washer and torque to 38 N-m (28 ft-lbs). See
Figure 6.6.
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 6.6 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 6.7.
NOTICE
Align the torsional dampener and aluminum housing by rotating either one to seat correctly.
T-377 6–10
Figure 6.7 Generator Alignment Bolt
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 6.8.
Figure 6.8 Generator Mounting Bolts
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 gen-
erator bolts first, just in case the generator shifts.
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).
6–11 T-377
31. Replace the lower radiator access panel and secure with bolts / washers (3).
32. Secure the battery charger cables to the bottom of the battery charger.
! 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.
33. Secure the battery charger assembly to the unit frame.
34. 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.
35. Place two pieces of heat shrink tubing (1 large, 1 small) over each receptacle box wire.
36. Connect and butt splice the receptacle box harness wires with the new generator wires.
37. For each of the other five wires, heat shrink the small tubing first, and then the large tubing to ensure a
watertight seal.
38. Neatly tape all wires together.
39. Replace and secure the wire harnesses onto the top of the generator, secure with the bolt.
40. Replace the truss and the truss brackets, secure the sides with the mounting bolts (2). See Figure 6.11.
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.
41. Secure the center of the truss to the isolator by installing the nuts (2) and nut plate (1).
42. Connect the battery.
43. Re-install the top and side panel covers
6.6 General Generator Set Maintenance

6.6.1 Maintenance of Painted Surfaces
The unit is protected against the corrosive atmosphere in which it normally operates by a special paint system.
However, should the paint system be 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.
6.6.2 Checking and Replacing 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.
T-377 6–12
Generator Shockmount Replacement
1. Use the two lift eyes to lift and support the engine.
2. Remove shockmount hardware, Figure 6.9.
3. Raise the generator just enough to remove the shockmounts.
4. Install new shockmounts.
5. Lower the engine enough to assemble hardware as shown and torque. Refer to Section 6.7 for torque values.
6. Remove chains from the lift eyes.
Figure 6.9 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) Lock-nut (5/8) 13) Mounting Base
3) Flat Washer (5/8) 14) Lockout (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)
-----
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 6.11.
3. Remove all hardware as shown in Figure 6.10.
6–13 T-377
4. Raise the engine just enough to remove the shockmounts.
5. Inspect shockmounts and replace if required.
6. Lower the engine enough to assemble hardware as shown and torque per Section 6.7.
7. Remove chains from the lift eyes.
Figure 6.10 Engine Shockmounts
1
7
1) Shockmount 5) Snubbing Washer

2) Snubbing Washer 6) Shockmount
3) Bolt 7) Flat Washer
4) Lock Washer
-----
Figure 6.11 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-377 6–14
6.7 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
6.12.
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 6.12.
Figure 6.12 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)
3/8-16 x 1 lg - SST
5/8-18 x 2.00 lg - SST
(4 req’d) 33.90 Nm (25 ft-lb)
(4 req’d) 123.38 - 128.80 Nm
(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)
6–15 T-377
SECTION 7
SCHEMATICS
Introduction
This section contains the 12 volt DC control circuit schematics and the 460 volt alternating current schematics.
Figure 7.1 Schematic Legend
7–1 T-377
SECTION 7
SCHEMATICS PAGE 2
Figure 7.2 Schematic 12VDC Control Circuit
T-377 7–2
SECTION 7
SCHEMATICS PAGE 3
Figure 7.3 Schematic High Voltage Circuitry
7–3 T-377
SECTION 8
Serial Number:
__________-__________
Manufacturing Date:
___________
EU Declaration of Conformity
We, manufacturer: Carrier Transicold Pte Ltd
700 Olympic Drive
Athens, GA 30601
Declare, under our sole responsibility, that the RG Generator Set Unit:
Models
69RG15-120W-23 69RG15-120W-55
69RG15-120P-23 69RG15-120P-55
69RG15-120C-23 69RG15-120C-55
are in conformity with the provisions of the following European Directives:

• Machinery Directive 2006/42/EC following Annex VIII
• Electromagnetic Compatibility Directive 2014/30/EU following Annex II
• Noise Directive 2005/88/EC following Annex III
The following Harmonized Standards were applied for this equipment:
Machinery Directive EMC Directive Noise Directive

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 97.0 dB
The following technical standard was applied for this equipment: ISO 1496-2:2018
Person established in Europe authorized to compile a copy of the Technical File:
Shaun Bretherton
Service Engineering Manager of CTL Rotterdam
Waalhaven Oostzijde 85, 3087 BM, Rotterdam
The 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)
8-1 T-377
INDEX
A Engine Fuel System 2–4

Engine Fuel System, Fuel Filter / Water Separator 2–4
AC Generator 2–3
Engine Fuel System, Fuel Tank 2–5
Air Cleaner Body 6–7
Engine Fuel System, Injection Pump 2–4
Air Cleaner, Dry Element 6–6
Engine Fuel System, Injector Nozzles 2–4
Air Filter Indicator 6–6
Engine Fuel System, In-Line Fuel Strainer 2–4
Alternating Current Generator 2–3
Engine Fuel System, Location and Components 2–4
Alternating Current Generator Troubleshooting 5–4
Engine Fuel System, Mechanical Lift Pump 2–4
Engine Lube System 2–6
B Engine Lube System, Location and Components 2–6
Battery 2–9 Engine Lube System, Low Oil Pressure (LOP) 2–6
Battery Charger 2–9 Engine Lube System, Oil Pressure Gauge (OPG) 2–9
Battery Charger (Solid State) Troubleshooting 5–4 Engine Lube System, Oil Pressure Sender (OPS) 2–6
Battery Service 6–3 Engine Service and Components 6–3
Bleeding the Fuel System 6–3 Engine Speed Sensor (ESS) 2–5
Engine Starts Then Stops 5–1
C Engine Will Not Shut Off 5–2
Engine, Description 2–3
CE mark 2–1
Engine, Introduction 2–1
CE verification 2–1
Circuit Breaker Location
CB1 2–11
F
CB2, CB3, CB4 2–10 First Aid 1–1
Configuration Identification 2–2 Fuel Filter 6–3
Control Box Components 2–10 Fuel Solenoid (FS) 2–5
Control Panel Components 2–10 Fuse Location
Cooling System 6–4 VCF1, VCF2, BCF3 2–11
D G
Diesel Engine Troubleshooting 5–1 Generator Set Components 2–1
Generator Set Components - Covers Removed 2–2
E Generator Set Identification 2–2
Electronic Governor Module (EG) 2–5
Electronic Governor Module Troubleshooting 5–5 I
Engine Air Cleaner 2–7 Ignition Switch (IGN) 2–9
Engine Air Cleaner, Air Filter Indicator 2–7 In-Line Fuel Strainer 6–4
Engine Air Cleaner, Air Intake Heater (IH) 2–7 Intake Heater Switch 6–8
Engine Air Cleaner, Dry Element Air Filter 2–7 Intake Heater Switch (HS) 2–9
Engine Air Cleaner, Location and Components 2–7 Intake Heater Test 6–7
Engine Cooling System 2–8 Intake Heater Timer (IHT) 2–9
Engine Cooling System, High Water Temperature Introduction 2–1, 8–1
Switch (HWT) 2–8
Engine Cooling System, Location and Components 2–8
L
Engine Cooling System, Radiator 2–8
Engine Cooling System, Water Temperature Gauge Lube Oil Filter 6–4
(WTG) 2–9
Engine Cooling System, Water Temperature Sender M
(WTS) 2–8
Maintenance Precautions 1–1
Engine Crankcase Breather 6–7
Malfunction In The Engine Starting Circuit 5–2
Index–1 T-377
Miscellaneous Engine Troubleshooting 5–3 Specific Hazard Statements 1–1
Starter Motor Malfunction 5–2
O Starter Solenoid Timer (SST) 2–9
Starting and Stopping Instructions 4–1
Operating Precautions 1–1
Stopping Instructions 4–2
P
T
Painted Surfaces 6–12
Total Time Meter (TT) 2–9
Post-Start Inspection 4–2
Troubleshooting 5–1
Pre-Start Inspection 4–1
Preventative Maintenance Schedule 6–1
U
R Unidrive Assembly Components 2–3
Unidrive Torque 6–15
Receptacle Box 2–11
Unit Nameplate 2–2
Unit Specifications, Engine Data 2–13
S
Unit Specifications, Fuel Tank 2–12
Safety devices 2–11 Unit Specifications, Generator 2–13
Safety Notices 1–1
Schematic Diagram 7–2, 7–3 V
Sequence of Operation 4–2
Voltage Controller (VC) 2–3
Servicing Fuel Pump Internal Filter 6–3
Voltage Controller Troubleshooting 5–5
T-377 Index–2
Carrier Transicold Division,
Carrier Corporation
P.O. Box 4805
Syracuse, NY 13221 USA
https://www.carrier.com/container-refrigeration

Operations and Service Manual 69RG15: Diesel Generator Set

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Diesel Generator Set

OPERATIONS AND SERVICE

© Carrier Corporation, 2023 Printed in U. S. A. January 2023

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

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

Table 2–2 Fuel Tank ................................................................... 2–12

1.2 First Aid

1.3 Operating Precautions

1.4 Maintenance Precautions

1.5 Specific Hazard Statements

Figure 2.1 Generator Set

1) Clamp Mounts (Optional) 5) Access Door

2.2 Configuration Identification

2.3.1 Voltage Controller

Separately bound manuals covering the diesel engine are available:

Figure 2.4 Generator and Engine - Unidrive Assembly

1) Generator 4) Engine Shockmount

Figure 2.5 Fuel System Diagram

1) Fuel Tank 6) Injection Pump

Figure 2.6 Fuel Tank

2.4.2 Electronic Governor

Figure 2.7 Electronic Governor Module (EG)

Figure 2.8 Engine Lubrication System

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

Figure 2.9 Engine Air Cleaner

1) Air Cleaner, Dry Element 3) Air Inlet Hose

Figure 2.10 Engine Cooling System

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

2.6 Control Panel and Control Box Components

2.6.1 Water Temperature Gauge

2.6.2 Oil Pressure Gauge

2.6.3 Total Time Meter

2.6.5 Intake Heater Switch

2.6.6 Ignition Switch

2.6.7 Intake Heater Timer

2.6.8 Starter Solenoid Timer

Control Panel Control Box

1) Water Temperature Gauge (WTG) 9) Intake Heater Relay (HR)

Figure 2.12 Receptacle Box

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

2.8 Safety Devices

Safety device specifications are provided in Table 2–1.

2.9 Unit Specifications

Table 2–2 Fuel Tank

Table 2–4 Engine Data

4.1 Starting and Stopping Instructions

4.1.2 Starting Instructions

Table 4–1 Cold Engine Preheat Times

4.1.3 Post-Start Inspection

4.1.4 Stopping Instructions

4.2 Sequence of Operation

A second set of contacts also energizes the safety relay (S).

5.1 Diesel Engine

5.1.2 Engine Starts Then Stops

5.1.3 Engine Will Not Shut Off

5.1.4 Starter Motor Malfunction

5.1.5 Malfunction In The Engine Starting Circuit

5.1.6 Miscellaneous Engine Troubleshooting

Condition Possible Cause Remedy / Reference Section