Diesel Generator Set r OPERATION AND SERVICE for 69UG15 Generator Set Units PID UG1450 and Higher T--343 Rev --
OPERATION AND SERVICE MANUAL DIESEL DRIVEN GENERATOR SET MODEL 69UG15
TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--i GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--i FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS - Continued PARAGRAPH NUMBER Page 3.2 BATTERY CHARGER (SOLID STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3 3.3 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4 3.4 AUTO RE-START OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5 SERVICE AND PREVENTIVE MAINTENANCE . .
LIST OF ILLUSTRATIONS FIGURE NUMBER Figure 1-1 Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-2 Generator Set -- Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1-3 Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions.
SPECIFIC WARNING AND CAUTION STATEMENTS 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. WARNING CAUTION Never pour cold water into a hot engine. Beware of moving poly V-belt, belt driven components and hot exhaust components. CAUTION WARNING Use only ethylene glycol, anti-freeze (with inhibitors) in system.
SECTION 1 DESCRIPTION The 69UG15 is available as a standard configuration, with an Auto Restart option or with Auto Restart and Low Coolant Sensor. The Auto Restart option automatically restarts the unit in the event of a unit shutdown. Auto Restart also offers built--in indicators that signal low oil pressure, high water temperature, overspeed, and other overcrank conditions. 1.
Table 1-1 Model Chart LEGEND A1 A2 B1 B2 B3 ------ Standard Mount -- (See Figure 2-1) B4 Quick Mount -- (See Figure 2-2) C1 Receptacle Box -- with Circuit Breaker C2 Receptacle Box -- with Circuit Breaker C3 Receptacle Box -- Customer Specific Electrical Wiring Schematic and PID Model Diagram Figures UG1450 5-1, 5-2, 5-3, 5-4 UG1451 5-1, 5-2, 5-3, 5-4 69UG15--050S--05 UG1452 5-1, 5-2, 5-3, 5-4 UG1453 5-1, 5-2, 5-3, 5-4 UG1455 5-1, 5-2, 5-3, 5-4 69UG15--050S--06 UG1456 5-1, 5-2, 5-3, 5-4 69UG15--050S--07 U
5 1 3 2 4 16 15 14 13 12 11 15 10 9 8 7 6 15 15 230 VOLT 460 VOLT 14 1. 2. 3. 4. 5. 6. 7. 8. 14 14 Mechanical Fuel Pump Injector Pump Engine Speed Sensor Poly V--Belt Radiator Controls (See Figure 1-6 or Figure 1-8) Engine Oil Filter Engine Shockmount (Typical) 9. 10. 11. 12. 13. 14. 15. 16.
1 2 3 11 4 10 5 6 9 7 8 1. 2. 3. 4. 5. 6. Fuel Tank Exhaust Muffler Solid State Battery Charger Low Coolant Sensor (If Equipped) Water Temperature Sensor Water Temperature Switch 7. 8. 9. 10. 11.
1.3 ENGINE 3 4 1. 2. 3. 4. 1.5 ALTERNATING CURRENT GENERATOR 1.5.1 Principle of Operation The Marathon Alternator Company (Lima) brushless AC generator (see Figure 1-2, item 9) is a self--regulated, rotating field synchronous unit. The generator stator and exciter stator are combined in a common housing. The generator field, exciter rotor, and rotating rectifier assembly are mounted on a common shaft.
The rotor is, in effect, the secondary of a rotating current transformer induction frequency converter. The exciter rotor output voltage is applied to the generator field windings by a three--phase, full wave rotating silicon rectifier unit. The response time of the excitation system is very fast as the exciter stator carries an alternating current corresponding to the load current that appears immediately on the exciter primary.
3. Ignition Switch (IGN)(Auto Restart) (see Figure 1-8) The ignition switch is of the maintained contact type to be used in the RUN/OFF positions. When switched to the RUN position, it energizes the control module, which in turn controls all functions of the genset. 1.8 SAFETY DEVICES Safety devices, such as circuit breakers, fuses, and safety switches, protect system components from damage.
CONTROL PANEL CONTROL BOX 3 2 11 10 1 4 5 12 9 6 7 8 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Total Time Meter Water Temperature Gauge Oil Pressure Gauge Ammeter Intake Air Heater Switch Ignition Switch Battery Charger Fuse or Circuit Breaker (CB5) Ground Studs Safety Relay Intake Heater Relay Intake Heater Timer Circuit Breaker (CB2) Circuit Breaker (CB3) Figure 1-7 Customer Specific Control Panel and Box CONTROL PANEL 3 4 CONTROL BOX 5 13 14 2 1 6 12 7 11 8 10 9 9.
Table 1-2 Auto Restart Preset Values Indicator Preset Value Description Overspeed 2100 RPM Overspeed is the point at which the unit will signal for shutdown Crank Disconnect 700 RPM Crank Disconnect is the point at which the auto restart module senses the engine has started and will disengage the starter Shutdown Lockout Delay 15 seconds The oil pressure and water temperature inputs are ignored during this 15 second delay (after start up) Intake Heater Delay 30 seconds preheat 3 minutes posthea
Table 1-3 Auto Restart Sequencing (Continued) Series Attempt Number 4 5 6 T-343 Intake Heater Energized in Seconds 30 30 30 Fuel Solenoid Engaged X X X Engine Engine Crank Rest Duration Duration (Seconds) (Seconds) Up To 15 Up To 15 Up To 15 Engine Status 25 If the engine starts: a. Run sequence begins. If the engine fails to start: a. Intake heater will de--energize. b. Fuel solenoid will de--energize. c. Crank output will de--energize. d. Overcrank LED will flash four times.
Table 1-4 Safety Devices Unsafe Condition Low engine lubricating oil pressure High engine cooling water temperature Low coolant Excessive current draw by the safety relay, fuel heater, water temperature gauge, oil pressure gauge or total time meter Excessive current draw by the electronic governor module Safety Switch ENGINE Low oil pressure switch (LOP) -Automatic reset Water temperature switch (HWT) -Automatic reset Low coolant sensor Automatic reset Switch Setting Opens below 18 psig (1.
1.10 ENGINE DATA (Continued) Oil Pressure Safety Switch Setting Opens Capacity 18 psig (1.27 kg/cm2) Engine -- 16.0 US quarts (15.1 liters), includes standard filter. 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 Oil Level Indicator 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 f.
SECTION 2 OPERATION completion, remove safety chain before removing forks of fork lift truck from unit. 2.1 GENERATOR SET INSTALLATION The generator set is mounted under the center of the trailer chassis and is easily handled with a fork lift truck capable of handling 2,000 pounds. The fork lift pockets provided are accessible from either side. Mounting clamps are designed to be attached to outside I-beam flanges only. Maximum chassis width is 38 inches on center. a. Standard Mount 1.
CONTAINER FLOOR CROSS I ---BEAMS REAR OF CHASSIS A A FORK LIFT POCKET ROADSIDE VIEW 5 6 4 7 2 8 3 1 VIEW A - A 1. 2. 3. 4. Angle Assembly, Clamp Washer, Spherical, Male Washer, Spherical, Female Bolt 5. 6. 7. 8. Washer, Spherical, Belleville Roll Pin Nut, Hex, 3/4-10 Frame Assembly Figure 2-2 Typical Generator Set Mounting - Quick Mount 2.2 GENERATOR SET REMOVAL b. Quick Mount a. Standard Mount 1. Disconnect power cable to generator (if connected). 2.
2.3 STARTING AND STOPPING INSTRUCTIONS NOTE 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 paragraph 1.2). 2.3.1 Pre-Start Inspection a.
The ignition switch (IGN) will be released. The intake air heater switch (IH) will be held for 5 seconds, then released after the IGN switch is realeased. 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. b.
SECTION 3 TROUBLESHOOTING CONDITION POSSIBLE CAUSE REMEDY/ REFERENCE SECTION 3.1 DIESEL ENGINE 3.1.
CONDITION POSSIBLE CAUSE REMEDY/ REFERENCE SECTION 3.1.
CONDITION POSSIBLE CAUSE REMEDY/ REFERENCE SECTION 3.1.6 Miscellaneous Engine Troubleshooting Loss of power Restriction in air cleaner Air in fuel system Air vent restricted Restricted fuel lines Fuel injection pump is bad Injector(s) bad or incorrect type used Incorrect fuel injection pump timing Incorrect valve timing Poor compression Section 4.4.13 Section 4.4.
CONDITION POSSIBLE CAUSE REMEDY/ REFERENCE SECTION 3.2 BATTERY CHARGER (SOLID STATE) (CONTINUED) Open input circuit breaker Charger is not receiving AC input Reset Using a voltmeter, confirm charger is receiving correct (230v) AC voltage. If not, check input connections. Charger output is not connected to 12 volt battery Check output wiring connections to battery. Charger is bad Replace Low output voltage measured across charger output Battery not connected to charger.
CONDITION POSSIBLE CAUSE REMEDY/ REFERENCE SECTION 3.3 ALTERNATING CURRENT GENERATOR (CONTINUED) Overheating Generator overloaded Clogged ventilating screens High temperature surrounding generator Insufficient air circulation Unbalanced load Dry bearing Check Clean Section 4.4.5 Section 4.5.1 Balance Section 4.5.1/ 4.5.3 Bad bearing Section 4.5.1/ 4.5.3 Section 4.5.1/ 4.5.3 Section 4.5.4/ Replace Section 4.5.
CONDITION POSSIBLE CAUSE REMEDY/ REFERENCE SECTION 3.4 AUTO RE-START OPTION (CONTINUED) Engine starts, but shuts down from over speed Electronic governor module is bad Replace Engine cranks, but will not start Electronic governor module is bad See 3.1.1 Replace See 3.1.1 Engine starts, but shuts down on low oil See 3.1.2 See 3.1.2 Engine starts, but shuts down on high water temperature See 3.1.6 See 3.1.
SECTION 4 SERVICE AND PREVENTIVE MAINTENANCE 3. Turn filter (item 3) counter-clockwise and remove. Check and clean. 4. To install, reverse steps 1 through 3. 4.1 INTRODUCTION This section covers service for the generator set and general engine service. Refer to the Kubota engine workshop manual, Section 1.1, for other engine servicing. 5 WARNING 3 Beware of moving V-belt and belt driven components. 1 4.
T-343 4--2 Perform at Pre-Trip Inspection X 1.10.f. 4.4.9 1.10.j. 3. Check engine lubrication oil level, add as required 4. Check poly V-Belt for fraying or cracks and proper tension, adjust as required 5. Check radiator hoses for leaks, check coolant level and 50/50 mixture 1.10.h. 10.Check intake heater amperage X X 19.Verify operation of engine protective devices 4.7 17.Tighten engine and generator mounting bolts X X X 4.4.10 16.
4--3 T-343 X X X See Engine Manual See Engine Manual See Engine Manual 4.5.1 26.Check starter condition 27.Check engine compression 28.Check and adjust injector nozzles 29.Perform generator maintenance X X X X 31.Listen for abnormal bearing noise 32.Check fuel lines, lube oil lines and filters for leaks 33.Check exhaust system for leaks 34.Check with voltmeter. Generator output should be 490 volts AC +/-- 10 volts (engine, 1800 RPM) with a nominal frequency of 60Hz +/- 0.
4. Run engine 6 to 12 hours and drain system while warm. Rinse system three times after it has cooled down. Refill system with water. 4. Reconnect the harness and refill the radiator to proper level. 4.4.7 Servicing Low Oil Pressure Switch 1. Remove harness connection from low oil pressure switch (LOP). 2. Remove pressure switch from engine. 3. Apply Teflon thread sealer to threads of new low oil pressure switch. 4. Install new low oil pressure switch. 5.
4.4.10 Lube Oil Filter The primary oil filter is located near the radiator fan (see Figure 1-4). 1. After warming up the engine, stop engine, remove drain plug from oil reservoir and drain engine lube oil. 2. Replace filters. Lightly oil gasket on filter before installing. 3. Add lube oil (Refer to paragraph 1.10.f). 4. Warm up engine and check for leaks. 4.4.11 Engine Speed The engine speed is electronically controlled. DO NOT ATTEMPT TO ADJUST ENGINE SPEED. 4.4.12 Replacing the Engine Speed Sensor 1.
CAUTION Do not underfill or overfill the oil bath cups. Overfilling of cups causes loss of capacity; underfilling cups causes lack of filtering efficiency. 4 1 2 3 5 1 1. Screw 2. Breather Cover 3. Bleed Hole 2 Figure 4-5 Engine Crankcase Breather 3 4.4.15 Servicing Intake Heater 1. Remove harness connection from heater. 2. Remove intake transition mounting hardware. 3. Remove intake transition, heater and both gaskets. 4. Clean old gasket material off the transition and manifold mounting services.
Should the generator fail to build up voltage after being disassembled for any reason, a momentary short-circuit of any two generator leads (L1, L2 and L3) while generator is running should be sufficient to correct this condition. b. Generator Windings (Drying) WARNING Do not direct water or steam into the generator openings. Do not allow any soap and water solutions to enter the alternator. CAUTION When trying to restore residual magnetism, be sure to wear safety glasses and non-conductive gloves.
3. Remove the two cap screws that secure each diode assembly to the exiter. Once this procedure is complete, the diode assemblies are free for removal. 4. A forward diode should have a low resistance when the + of an ohm meter is connected to the exciter rotor lead connection (anode) and the - to the diode bridge (cathode), and a high resistance when the polarity of the ohmmeter is reversed. 5.
The generator is a single bearing type, which means the shaft end of the rotor floats. Before installing the generator, rotate shaft and check if bearing rotates. 1. Brush anti-seize lubricant (lube-plate) on the face of flywheel. 2. Move generator into position and line up with the holes on housing and flywheel. If required, turn crankshaft to align threaded holes in flywheel with generator drive disc mounting holes. 5.
4.6.2 Check and Replace Isolators/Shockmounts a. Replacement Criteria c. 1. 2. 3. Generator Shockmount Replacement Use the two lift eyes to lift and support the engine. Remove shockmount hardware. Raise the generator just enough to remove the shockmounts (Figure 4-10 item 7). 4. Install new shockmounts. 5. Lower the engine enough to assemble hardware as shown and torque. Refer to paragraph 4.7 for torque values. 6. Remove chains from the lift eyes.
4.7 UNIDRIVE TORQUE REQUIREMENTS NOTES SST is an abbreviation for 300 Series Corrosion Resistant Steel. 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 4-11.
SECTION 5 SCHEMATICS 5.1 INTRODUCTION This section contains the 12-volt DC control circuit schematics, the 460 volt alternating current generator schematic and the 230 volt alternating current generator schematic. To identify the schematics applicable to your PID number refer to Table 1-1.
IH Based On Drawings 62-11411-00 Rev62-11414-00 Rev Figure 5-2 Schematic Diagram (For Applicability, Refer to Table 1-1) T-343 5--2
NOTE: WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMINAL STRIP TERMINAL T10.
Based On Drawings 62-11411-00 Rev62-11414-00 Rev Figure 5-4 Schematic Diagram 230 Volt Alternating Current Generator (For Applicability, Refer to Table 1-1) T-343 5--4
Based On Drawing 62-11413-00 Rev A Figure 5-5 Schematic Diagram - Legend (Applies to Figures 5-6, 5-7) 5--5 T-343
Based On Drawing 62-11413-00 Rev A Figure 5-6 Schematic Diagram (For Applicability, Refer to Table 1-1) T-343 5--6
Based On Drawing 62-11413-00 Rev A Figure 5-7 Schematic Diagram 460 Volt Alternating Current Generator (For Applicability, Refer to Table 1-1) 5--7 T-343
INDEX A F AC Generator Description, 1--5 First Aid, Safety--i Air Filter Indicator, 4--5 Fuel Filter, 4--1 Ammeter, 1--7 Fuel Pump Filter Service, 4--1 Auto Restart Module, 1--6 Fuel System, 1--5 Auto Restart Preset Values, 1--9 G Auto Restart Sequencing, 1--9 Gauges and Senders, 1--6 B Generator Principle of Operation, 1--5 Generator Removal and Installation, 4--8 Battery Charger, 1--6 Generator Repair, 4--7 Battery Service, 4--1 Generator Service, 4--6 Bearing Replacement, 4--8 Gener
INDEX (Continued) O S Safety Devices, 1--7 Oil Air Filter, 4--5 Operating Controls and Instruments, 1--6 Operating Precautions, Safety--i Safety Notices, Safety--i Safety Summary, Safety--i Schematics, 5--1 Sequence of Operation, 2--4 Servicing Intake Heater, 4--6 Starting Insturctions, 2--3 Stopping Instructions, 2--3 P Poly V--Belt Service, 4--4 Post--Start Inspection, 2--3 T Torque Requirements, 4--11 Total Time Meter, 1--7 Troubleshooting, 3--1 Pre--Start Inspection, 2--3 Preventative Maintenance
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