Carrier 69UG15 manual

Diesel Gener ator Set T - - 343 Rev - - OPERA TIO N AND SER VICE for 69UG15 Gener ator Set Unit s PID UG1450 and Higher r[...]

OPERA TION AND SER VICE MANUAL DIESEL DR IVEN GENER A T O R SET MODEL 69UG15[...]

i T - - 343 T ABLE OF CONTENTS P ARAG RAPH NUMBE R Page SAFE TY SU MMAR Y Safety- - i .................................................................... GENE RAL S AFETY NOTIC ES Safe ty- -i ............................................................ FIRST A ID Safe ty- -i .........................................................................[...]

ii T - - 343 T A BLE OF CON TEN TS - - Continued P ARAG RAPH NUMBE R Page 3.2 BA TTER Y CHARGER (SOLID ST A TE) 3- - 3 .................................................. 3.3 AL T ERNA TING CURRENT G ENE RA TOR 3- - 4 ............................................... 3.4 AUTO RE-ST ART OPTION 3- - 5 ....................................................[...]

iii T - - 343 LIS T OF ILLU STR A TI ONS FI GURE NUM BER Page Figur e 1-1 Gener ator Set 1- - 3 ...................................................................... Figur e 1-2 Gener ator Set - - T op V iew 1- - 4 ............................................................ Figur e 1-3 Fuel S yst em Diagram 1- - 5 ................................[...]

Safe ty- - i T -343 SA FETY S UMMA R Y GENE RAL SAF ET Y NOT ICE S The f ollowing general saf ety notices supplement t he spec ific war nings and caut ions appear ing elsewhere in t his manual. They are recommended pr ecautions that must be underst ood and applied during operat ion and maintenance of t he equipment cover ed herein. The gener al saf[...]

Safe ty- - i i T -343 SPECIF IC WARNING AND CAUTI ON ST A TEMENT S The statements that follow ar e applic able to t he gene rator set and appear elsewher e in this manual. These r ec om- mended pr ecautions must be understood and applie d during operation and maintenanc e of the equipment cove r e d her ein. W ARNI NG Be war e of moving poly V - be[...]

1- - 1 T -343 SECTI ON 1 DESCRIPTION 1.1 I NTRO DUCTI O N The Car rier Transicold model 69UG 15 under - - mounted diesel - - dr iven generat or s ets provide elect ric al power for all - - electr ic ref rigerat ion unit s. The gener ator s et ( see Figur e 1-1 and Figure 1-2) consis ts of a diesel engine direct - - connect ed to an alter nating cur[...]

1- - 2 T -343 T able 1- 1 Model Cha rt LEGEN D A1 - - Standar d Mount - - (See F igure 2-1) A2 - - Quick Mount - - (See F igure 2- 2) B1 - - Receptac le Box - - wit h Circuit Break er B2 - - Receptac le Box - - wit h Circuit Break er B3 - - Receptac le Box - - Cust omer Specif ic B4 - - Receptac le Box - - I nter lock C1 - - 460 Volt - - St andard [...]

1- - 3 T -343 15 9 2 14 5 6 87 10 12 1 1 13 14 230 VOL T 460 VOL T 15 15 14 14 3 15 14 16 1. Mechanic al Fuel P ump 2. Injec tor P ump 3. Engine Speed S ensor 4. Poly V - - Belt 5. Radiator 6. Contr ols (S ee Figur e 1-6 or F igure 1-8) 7. Engine O il Filt er 8. Engine Shoc kmount (Typical) 9. Lube Oil Dips tic k/F ill Cap 10. Star ter 1 1. Air Cle[...]

1- - 4 T -343 1 11 10 9 8 7 6 5 4 2 3 1. Fuel T ank 2. Exhaus t Muffler 3. Solid St at e Batt ery Charger 4. Low Coolant Sensor (If E quipped) 5. Water T emper ature S ensor 6. Water T emper ature S witc h 7. Engine 8. Coolant O ver flow Bot t le 9. Alt ernat ing Current G enerator 10. AC Generat or Connect ion Box A cces s 1 1. Batte ry Fi gu re 1[...]

1- - 5 T -343 1.3 EN GINE The engine is a v ert ical, in - - line four c ylinder dies el engine, which is direct - - connect ed to t he alter nating curr ent generat or . Inf ormat ion on the major engine systems is provided in th e following s ubparagraphs. 1.3 .1 E lec tronic Gov er nor Module The elect ronic governor module is a s olid st ate co[...]

1- - 6 T -343 The r otor is , in eff ect, t he secondary of a rot ating current tr ansfor mer induction frequenc y conv erter. T he exc iter rot or output voltage is applied to t he generator f ield windings by a t hree - - phase, f ull wave rot ating silicon rectif ier unit. T he r esponse t ime of the excitat ion system is ve ry fa st as th e ex [...]

1- - 7 T -343 b. Meters 1. Ammeter (A) The ammet er ( see F igure 1-6, F igure 1-7, F igure 1-8) is an in dicator of the charg ing system and u nit electrica l draw . I t indicat es t he rat e of dis charge or charge of t he batt ery . During st art up, t he intak e heater dr aws approxim ately 42 am ps. 2. T otal Time Meter (T T) The t otal t ime [...]

1- - 8 T -343 CONTROL BO X CONTROL PA N E L 3 4 5 6 7 2 1 12 9 8 11 10 13 1. T ot al T ime Met er 2. Water T emper ature G auge 3. Oil P ress ure G auge 4. Ammeter 5. Int ake Air Heat er Swit ch 6. Ignit ion Swit ch 7. Bat ter y Charger Fus e or Circuit B reaker ( CB5) 8. Gr ound St uds 9. Safe ty Re la y 10. Intake Heat er Relay 1 1. Int ake Heat [...]

1- - 9 T -343 T able 1 -2 Auto Restart P reset V alu es Indica tor Preset V alu e Descrip ti on Ov erspeed 2100 RPM Over speed is t he point at which t he unit will signal f or shut down Crank Dis connect 700 RPM Crank Dis connect is t he point at which t he auto r est art m odule senses the engine has s tar ted and will dis engage the st art er Sh[...]

1- - 10 T -343 T able 1- 3 Auto Re st ar t Seque ncing (Cont inued) Series Attem pt Numb er In take Heater Energized in Se conds Fuel Solenoid Enga ged Engine Crank Durati o n (Se conds ) Engine Rest Durati o n (Se conds ) Engine St atus 4 30 X Up T o 15 25 If the engine s tar ts: a. Run sequenc e begins. If the engine f ails t o st art : a. I ntak[...]

1- - 1 1 T-343 T able 1 -4 Safety Devi ces Uns afe C ondition Safety Switch Switc h Set ting ENGIN E Low engine lubricat ing oil press ure Low o il pressu re switch (LOP) - - Auto ma tic re se t Opens below 18 psig (1.27 kg/cm 2 ) High engine cooling wat er tem perat ure W ater tem peratur e swit ch (HW T) - - Auto ma tic re se t Opens at 230F (1 1[...]

1- - 12 T -343 1.10 ENG INE DA T A (Cont inued) f. Lubricat ion Syst em Oil Pr ess ure S afe ty Switc h Set ting Opens 18 psig (1. 27 kg/ cm 2 ) Capacity E ngine - - 16.0 US quar ts (15. 1 liter s), includes s tandar d filt er . Oil Lev el Indicat or Dipstic k in oil pan or f ill cap NOT E T o chec k oil level on engines wit h t he dipstic k mount [...]

2- - 1 T -343 SECTI ON 2 OPER A TION 2.1 G ENERA TOR SET INST ALLA TION The gener ator s et is m ounted under t he cent er of t he trailer chassis and is easily handled wit h a for k lift t ruck capable of handling 2, 000 pounds. The for k lift pock ets provided ar e access ible f rom eit her s ide. Mount ing clamps ar e designed t o be at t ached [...]

2- - 2 T -343 1 2 3 4 5 8 6 7 REAR OF CHASSIS ROADSIDE VIEW CONT AI NER FL OOR CROS S I - - - BEA MS FORK LI F T POCK ET A A VIEW A - A 1. Angle Ass embly , Clamp 2. W asher , Spheric al, Male 3. W asher , Spheric al, Fem ale 4. Bolt 5. W asher , Spheric al, Belleville 6. Roll Pin 7. Nut, Hex, 3/ 4-10 8. Fr ame Ass embly Figure 2- 2 T ypic al Gene [...]

2- - 3 T -343 2.3 S T ART I NG AND STOPPI NG INS TRUCT IO NS 2.3. 1 Pre -Start In sp ectio n a. Check engine lubr icat ion and fuel f ilter s, oil lines, and connect ions for leaks. I f requir ed, tight en connec- tions and/or replace gas kets . b. Check engine lubric ating oil level. (Ref er t o para- graph 1. 10, t able entr y f. ) c. Check poly [...]

2- - 4 T -343 2.4 CO NTRO L CI RCUIT O PERA TIO N W ARNI NG Be war e of m oving poly V- B elt a nd belt driv- en c ompone nts . 2.4 .1 S eque nce of Oper at ion a. St andard Unit s Wit h t he int ake heat er s witc h (IH) held in t he ON position, c urrent f lows t hrough t he amm eter to t he intake heat er . W hile heat er is on, the ammet er wil[...]

3- - 1 T -343 SECTI ON 3 TROUBLESHOOTING CONDI TI ON POS SI BLE CAUSE REMEDY / REFE RENCE SECTION 3.1 DIESEL ENGI NE 3.1 .1 E ngine Will Not Star t Star ter m otor will not cr ank or low crank ing speed Batt ery ins ufficient ly charged Batt ery t erm inal post or batt ery def ect ive Elect rical c onnect ions at s tar ter ar e bad Star ter m otor [...]

3- - 2 T -343 CONDI TI ON POS SI BLE CAUSE REMEDY / REFE RENCE SECTION 3.1 .3 E ngine Will Not Shut Of f Engine will not shut off Loose ground c onnection Im properly s eated f uel solenoid Clean/Tighten Corre ct 3.1.4 Star ter Motor Malfunctio n Star ter m otor will not cr ank or tur ns slowly Batt ery ins ufficient ly charged Batt ery cable conne[...]

3- - 3 T -343 CONDI TI ON POS SI BLE CAUSE REMEDY / REFE RENCE SECTION 3.1 .6 M isc ella neous Engine T roubles hooting Loss of power Restr ict ion in air cleaner Air in fuel system Air vent res tric ted Restr ict ed fuel lines Fuel injec tion pump is bad Inject or( s) bad or incorr ect t ype us ed Incor rect f uel injection pum p tim ing Incorrect[...]

3- - 4 T -343 CONDI TI ON POS SI BLE CAUSE REMEDY / REFE RENCE SECTION 3.2 BA TTER Y CHARG ER (SO L ID ST A T E) (CO NT INUED) Charger does not c harge Open input circ uit breaker Charger is not r eceiving AC input Charger out put is not c onnect ed to 12 volt bat tery Charger is bad Rese t Using a volt me- ter, confirm charger is r eceiv- ing co r[...]

3- - 5 T -343 CONDI TI ON POS SI BLE CAUSE REMEDY / REFE RENCE SECTION 3.3 AL TERNA TING CURRENT GE NERA TOR ( CONT INUE D) Over heating Gener ator over loaded Clogged ventilat ing sc reens High tem peratur e surr ounding generator Insuff icient air c irculat ion Unbalanced load Dry bearing Check Clean Sec tio n 4.4 .5 Sec tio n 4.5 .1 Balance Sec [...]

3- - 6 T -343 CONDI TI ON POS SI BLE CAUSE REMEDY / REFE RENCE SECTION 3.4 AUTO RE -ST ART O PT IO N (CONT I NUED) Engine st art s, but shut s down f rom over speed Elect ronic gover nor module is bad Replace Engine cranks , but will not start Elect ronic gover nor module is bad See 3 .1.1 Replace See 3 .1.1 Engine st art s, but shut s down on low [...]

4- - 1 T -343 SECTI ON 4 SERVICE AND PREVENTIVE M AINT ENANCE 4.1 I NTRO DUCTI O N This sec tion c overs ser vice f or the gener ator s et and general engine ser vice. Refer to the K ubota engine works hop manual, S ect ion 1.1, f or ot her engine servic ing. W ARNI NG Beware of mo vi ng V-bel t and b el t dri ven com ponent s. 4.2 PREVENT A TI VE [...]

4- - 2 T -343 T able 4 -1 Prevent ative M ain ten ance Act io ns an d Sch edu le Descrip ti on o f Proced u re Refer ence Paragr aph Perf orm at Pre- T r ip Inspect ion Standard Serv ice Inter va l Unit s Ex tende d Service In terval Uni ts* Every 1000 Hour s Annuall y or Every 3000 H ours Annuall y or Every 3000 Hours For Pr e-T rip inspec tion, p[...]

4- - 3 T -343 T able 4 -1 Prevent ative M ain ten ance Act io ns an d Sch edu le ( Con ti nu ed) Descrip ti on o f Proced u re Refer ence Paragr aph Perf orm at Pre- T r ip Inspect ion Standard Serv ice Inter va l Unit s Ex tende d Service In terval Uni ts Every 1000 Hour s Annuall y or Every 3000 Hours Annuall y or Every 3000 Hours 20. Check wat e[...]

4- - 4 T - - 343 4. Run engine 6 t o 12 hour s and drain syst em while warm. Rinse syste m three times after it has cool ed dow n. Refill system with water . CAUTI ON Use on ly et hyl ene g l ycol , an ti - freeze ( wi th in hi b ito rs) i n system. Use of g lyco l by it self will dama ge the cooling system (Ref er to par agr aph 1 .10 .j.). 5. Run[...]

4- - 5 T -343 4.4 .10 Lube Oil Filter The pri mary oil f ilt er is locat ed near t he radiat or f an (see Figu re 1-4). 1. A ft er warm ing up the engine, s top engine, r emove drain plug f rom oil r eservoir and drain engine lube oil. 2. Replac e filters . Lightly oil gas ket on f ilter bef ore installing. 3. A dd lube oil (Refer to par agraph 1. [...]

4- - 6 T - - 343 CAUTI ON Do not unde rf ill or over fill the oil bath c ups. Ove rfilling of cups ca use s loss of ca pac ity ; under filling cups ca use s la ck of f ilter ing effi cien cy . 1 2 3 4 5 6 1. Air I nlet Hood 2. Air Cleaner Body 3. Cap Clamp 4. Inner Oil Cup 5. Gasket 6. Oil Cup Figure 4- 4 Air Filt er (Oil Ba th T ype) e. Service - [...]

4- - 7 T -343 b. Gener ator Windings ( Dry ing) W ARNI NG Do not d irect water or ste am into the gene ra tor ope nings . Do not a llow any soa p and wat er sol u tio n s to enter t he altern ato r . W ARNI NG Hig h vol tag e (di elect ric) testi ng mu st n o t be per form ed to the ma chine wit hout firs t obse rv ing NEMA rule s. The insulat ion [...]

4- - 8 T - - 343 c. Di od e T estin g The r ectif ier diode as semblies c an be tes ted, and if damaged, replac ed. Over cur rent , over v oltage, ov er speed, or reverse c urrent s can damage the assembly or diodes. T o remov e the diode assemblies and perfor m diode test ing, do the f ollowing: 1. Rem ove the bear ing cover by rem oving the four [...]

4- - 9 T -343 The gener ator is a single bearing t ype, which m eans the shaft end of the rot or f loat s. B efor e installing the generat or , rot ate s haft and check if bear ing rot ates . 1. B rush ant i-seiz e lubricant (lube- plate) on the f ace of fly wheel. 2. M ove generat or int o pos ition and line up wit h the holes on housing and f lyw[...]

4- - 10 T - - 343 4.6 .2 Chec k and Re plac e Isola tors /Shoc km ounts a. Rep lacemen t Cri teria CAUTI ON Continue d oper at ion with faile d shoc km ounts ma y re s ult in engine or gen erato r damag e. When a s hockmount has been c ut, split, abraded or has flar ed due to norm al deteriorat ion, it mus t be replaced. Damage t o the mount s m ay[...]

4- - 1 1 T-343 4.7 UNI DRIV E TORQUE RE QUI REME NTS Ext ensive dam age m ay occ ur if the proper hardwar e is not used and/ or proper pr ocedures are not followed when working wit h the unidr ive ass embly . Periodic inspect ion of har dware and bolt tor que is recommended to ensur e the int egrit y of the unidr ive. T orque v alue and hardware re[...]

5- - 1 T -343 SECTI ON 5 SCHEMA TICS 5.1 I NTRO DUCTI O N This s ect ion contains t he 12-volt DC cont rol cir cuit s chemat ics, t he 460 volt alternating c urrent generator sc hemat ic and the 230 volt alternat ing curr ent gener ator schemat ic. T o ident ify the s chemat ics applic able to your PID number r e f e rt oT a b l e1 - 1 . Based O n [...]

5- - 2 T -343 Based O n Drawings 62-1 141 1- 00 Rev- 62-1 1414- 00 Rev - IH Figure 5- 2 Sc hem atic D iagr am (F or Applicabilit y , Refer t o T able 1-1)[...]

5- - 3 T -343 NOTE: WHEN PE IS NOT FIT TED, OUT PUT GROUND WIRES ARE CONNECTED DI RECTL Y A T GENERA TOR TE RMI- NAL STRIP TER MINAL T10. Based O n Drawings 62-1 141 1- 00 Rev- 62-1 1414- 00 Rev - Figure 5- 3 Sc hem atic D iagr am 4 60 V olt Alte rna ting Curr ent Gene ra tor (F or Applicabilit y , Refer t o T able 1-1)[...]

5- - 4 T -343 Based O n Drawings 62-1 141 1- 00 Rev- 62-1 1414- 00 Rev - Figure 5- 4 Sc hem atic D iagr am 23 0 V olt A lter nat ing Curr ent Gene ra tor (F or Applicabilit y , Refer t o T able 1-1)[...]

5- - 5 T -343 Based On Drawing 62-1 1413-00 Rev A Figure 5- 5 Sc hem atic D iagr am - Le gend (Applies t o Figures 5- 6, 5-7)[...]

5- - 6 T -343 Based O n Drawing 62-1 1413-00 Rev A Figure 5- 6 Sc hem atic D iagr am (F or Applicabilit y , Refer t o T able 1-1)[...]

5- - 7 T -343 Based On Drawing 62-1 1413-00 Rev A Figure 5- 7 Sc hem atic D iagr am 4 60 V olt Alte rna ting Curr ent Gene ra tor (F or Applicabilit y , Refer t o T able 1-1)[...]

Index - - 1 T -343 INDEX A AC Gener ator Descr iption, 1 - - 5 Air Filt er I ndicator, 4- - 5 Ammeter , 1- - 7 Auto Rest art Module, 1 - - 6 Auto Rest art Pr eset V alues, 1- - 9 Auto Rest art Sequenc ing, 1- - 9 B Batt ery Char ger , 1 - - 6 Battery Service , 4 - - 1 Bearing Replac ement, 4 - - 8 Bleeding t he Fuel Sy st em, 4 - - 1 C Control Circ[...]

Index - - 2 T -343 INDEX (Continued) O Oil Air Filt er , 4 - - 5 Oper ating Cont rols and I nst rument s, 1 - - 6 Oper ating Pr ecaut ions, S afet y - - i P Poly V- - Belt Se rvice, 4- - 4 Post - - Star t Ins pection, 2 - - 3 Pre- - Start In sp ecti on , 2- - 3 Prev entat ive Maint enance and Oper ating Pr ecaut ions , 4 - - 6 Prev entat ive Maint [...]

© 2008 Carrier Corporat ion D Printed in U. S. A. 0908 Carrier Transicold Division, Carrier Corporation Container Products Group P .O. Box 4805 Syracuse, N.Y . 13221 U. S A www .carrier .transicold.com A member of the United T echnologies Corporation family . Stock symbol UTX[...]