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Summary of Contents for Carrier RG2059 Series
- Page 1 Diesel Generator Set OPERATIONS AND SERVICE 69RG15 Generator Set Units RG2059 to RG2100 Series T-361 Rev F 09/19...
- Page 3 OPERATIONS AND SERVICE 69RG15 Generator Set Units RG2059 to RG2100 Series © Carrier Corporation, 2019 Printed in U. S. A. September 2019...
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Page 5: Table Of Contents
TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY SUMMARY ..............1–1 GENERAL SAFETY NOTICES . - Page 6 BATTERY CHARGER (SOLID STATE) ..........4–4 ALTERNATING CURRENT GENERATOR .
- Page 7 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2.1 Generator Set ..............2–2 Figure 2.2 Generator Set - Top Cover Removed .
- Page 8 LIST OF TABLES TABLE NUMBER Page Table 2–1 Model Chart ..............2–1 Table 2–2 Auto Restart Preset Values .
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Page 9: Safety Summary
SECTION 1 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 mainte- nance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions. -
Page 10: Specific Hazard Statements
SPECIFIC HAZARD STATEMENTS The statements that follow are applicable to the generator set and appear elsewhere in this manual. These recom- mended precautions must be understood and applied during operation and maintenance of the equipment covered herein. WARNING To prevent injury, the procedures provided for installation and removal of the generator set must be followed carefully. - Page 11 WARNING High voltage (dielectric) testing must not be performed to the machine without first observing NEMA rules. The insulation of this generator winding may be safely checked by using a meg- ger. A high megger reading indicates good insulation. CAUTION Observe proper polarity when installing the battery or connecting a battery charger, the nega- tive battery terminal must be grounded.
- Page 12 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. Although the generator drive gear and fly wheel adapter plate will normally keep the generator coupled to the engine, even without the bolts, it is safest to remove the lower generator bolts first, in case the generator shifts and falls during bolt removal.
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Page 13: Description
Carrier Transicold’s Ecodriven dual speed option provides an energy saving alternative to the practice of continu- ously running the generator at full speed. This speed reduction results in increased fuel economy, reduced carbon footprint, and lowers operating costs. -
Page 14: Figure 2.1 Generator Set
Figure 2.1 Generator Set Mounting Clamp Mounting Pin (Optional) Mounting Clamp (Optional) Radiator Cap Fuel Cap Fuel Cap Unit Model, Serial &PID Plate Fuel Gauge (Either Side) Control Box Access Door Figure 2.2 Generator Set - Top Cover Removed Engine Exhaust Muffler Intake Heater (IH) Water Temp Sender... -
Page 15: Engine
ENGINE The engine is a vertical, in-line four cylinder diesel engine that is directly connected to the alternating current gen- erator. Information on the major engine systems is provided in the remainder of this chapter. 2.3.1 Electronic Governor Module The electronic governor module (EG) is a solid state control module preprogrammed for 1800 RPM high speed and 1500 RPM low speed operation. -
Page 16: Lube Oil Filter Arrangement
2.3.4 Lube Oil Filter Arrangement The engine lubricating oil filter is mounted in a horizontal arrangement and is shown in Figure 2.5. Figure 2.5 Lube Oil Oil Pressure Sender Oil Filter (Primary) Oil Pressure Switch Oil Pan ENGINE SCREW THREADS All threads on the engine are metric, except for the oil drain plug which is American Standard Pipe Thread (NPT). - Page 17 Figure 2.5) b. Oil Pressure Sender (see This device senses engine lube oil pressure and transmits a signal to the oil pressure gauge. The oil pressure sender is located on the oil filter housing. c. Water Temperature Gauge (see Figure 2.6 Figure 2.7) The function of this gauge is to observe water operating temperature.
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Page 18: Figure 2.6 Control Box Standard
Figure 2.6 Control Box Standard Control Panel Water Temp Gauge Oil Pressure Gauge Total Time Meter Ammeter Ignition Switch Intake Heater Switch Control Box (Front View with Cover Removed) S t a r t e r S o l e n o i d Timer (SST) G r o u n d S t r a p... -
Page 19: Figure 2.7 Control Box And Panel With Auto Restart
Figure 2.7 Control Box and Panel With Auto Restart Control Panel Water Temp Gauge Oil Pressure Gauge E ngine St art A larm (Buzzer) Total Time Meter Ammeter Ignition Switch Auto Restart Module Engine Start/ Intake Heater Energized Light Control Box (Front View with Cover Removed) Intake Heater G ro u n d S t r a p Relay (HR) -
Page 20: Table 2-2 Auto Restart Preset Values
Table 2–2 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. - Page 21 Table 2–3 Auto Restart Sequencing (Continued) Series Attempt Number Engine Status: If the engine starts: Intake Heater Energized 1. Run sequence begins. in Seconds If the engine fails to start: Fuel Solenoid Engaged 1. Intake heater will de-energize. 2. Fuel solenoid will de-energize. Engine Crank Duration Up to 15 3.
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Page 22: Safety Devices
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, inter- rupt the fuel flow to the engine and stop the engine. -
Page 23: 2.10 Unit Specifications
Table 2–4 Safety Devices GENERATOR Unsafe Excessive current draw by load Condition: Safety Switch Circuit breaker (CB-1, 460 volt) - Manual reset Switch Setting Trips at 26 amps (460 vac) VOTLAGE CONTROLLER Unsafe Excessive current draw on 460 volt feed circuit Condition: Safety Switch Fuses VCF1, VCF2, VCF6, VCF7 (replace) - Page 24 Table 2–6 Engine Data (Continued) Lubrication System: Oil Pressure Safety Switch Set- 18 psig (1.27 kg/cm ting Opens Capacity Engine − 15.0 US quarts (14.2 liters), includes stan- dard filter. Oil Level Indicator Dipstick in oil pan or fill cap To check oil level on engines with the d ip sti ck mou nte d i n the fi ll cap , remove the cap and wipe the dipstick...
- Page 25 Table 2–6 Engine Data (Continued) Cooling System: Capacity 6 U.S. quarts (5.68 liters) - includes 1 quart (0.95 li- ter) in coolant recovery bottle. (Refer to Section 5.5.5) Anti-Freeze: Extended Life The cooling system is factory charged with a 50/50 mix of extended life coolant (ELC) and deionized water.
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Page 27: Operation
SECTION 3 OPERATION GENERATOR SET INSTALL AND REMOVE - PIN TYPE WITH LOCKING BRACKET Figure 3.1 Generator Set Mounting - Pin Type with Locking Bracket 62- 02899- 04 Rev D WARNING To prevent injury, the procedures provided for installation and removal of the generator set must be followed carefully. -
Page 28: Removal
3.1.2 Removal WARNING Disconnect power plug before removing generator set. 1. Move forks into fork pockets on generator set. Attach safety chain (A) between fork pockets on generator set and fork truck. 2. Release locking brackets (D) on each side of generator set. 3. -
Page 29: Installation
3.2.1 Installation 1. Place forks into fork pockets of generator set. Attach safety chain (A) between fork pockets on generator set and fork truck. Be sure chain (A) is short enough to retain generator set on forks. Ensure that generator set clamps (B) are in the unlocked position and actuating handle (C) in the horizontal position. -
Page 30: Starting Instructions
8. Drain water from fuel filter bowl. 9. Fill fuel tank with diesel fuel. (Refer to Section 2.11, Fuel and Fuel Heater Thermostat (FHT).) 10. Check intake heater amperage. (Refer to Section 2.11, Intake Heater.) 11. Check battery terminals for cleanliness and secureness. If required, clean, then coat with a battery terminal sealant. -
Page 31: Post-Start Inspection
4. With the intake heater switch held in the PREHEAT position, place the ignition switch in the START position. 5. After the engine has started, continue to hold the intake heater switch 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 will automatically return to the OFF position and the heater will remain energized for 3 minutes. - Page 32 Once the engine has started and the start switch has been released, the starter motor will stop cranking and the intake heater will remain energized for 3 minutes. With the engine running, the battery charger provides DC power to operate the control system and charge the battery. Units with Auto Restart When the ignition switch is placed in the RUN position, 12-volt DC power is applied to the auto restart module.
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Page 33: Troubleshooting
SECTION 4 TROUBLESHOOTING DIESEL ENGINE 4.1.1 Engine Will Not Start Table 4–1 Engine Will Not Start Condition Possible Cause Remedy/Reference Section Starter motor will not crank or Battery insufficiently charged Charge low cranking speed Battery terminal post or battery defective Check Electrical connections at starter are bad Correct... -
Page 34: Engine Starts Then Stops
4.1.2 Engine Starts Then Stops Table 4–2 Engine Starts Then Stops Condition Possible Cause Remedy/Reference Section Section 2.10/Section 2.11. Engine stops after a few No fuel in tank rotations Intake heater switch not held long enough Hold switch Fuel filter restricted Replace Section 5.5.11 Air cleaner or hose restricted... -
Page 35: Malfunction In The Engine Starting Circuit
Table 4–4 Starter Motor Malfunction (Continued) Condition Possible Cause Remedy/Reference Section Starter motor turns, but pinion Pinion or ring gear obstructed or worn Engine Manual does not engage Starter motor does Ignition switch is bad Check/Replace disengage after switch has Starter motor solenoid is bad Engine Manual been released... -
Page 36: Miscellaneous Engine Troubleshooting
4.1.6 Miscellaneous Engine Troubleshooting Table 4–6 Miscellaneous Engine Troubleshooting Condition Possible Cause Remedy/Reference Section Loss of power Restriction in air cleaner Section 5.5.11 Air in fuel system Section 5.5.11 Air vent restricted Clean Restricted fuel lines Engine Manual Fuel injection pump is bad Engine Manual Injector(s) bad or incorrect type used Engine Manual... -
Page 37: Alternating Current Generator
Table 4–7 Battery Charger (Solid State) Condition Possible Cause Remedy/Reference Section Charger does not charge Open BCF3, BCF4, or BCF5 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... -
Page 38: Auto Re-Start Option
Table 4–8 Alternating Current Generator Condition Possible Cause Remedy/Reference Section Mechanical Noise Bad bearing Replace Rotor rubbing on stator Replace Loose laminations Replace Loose or misaligned coupling Check drive gear Generator frame produces Static charge Check ground to frame shock when touched AUTO RE-START OPTION Table 4–9 Auto Re-Start Option Condition... -
Page 39: Electronic Governor Module
ELECTRONIC GOVERNOR MODULE Table 4–10 Electronic Governor Modules Fault LED flash code Possible Cause Engine Over Speed: more than One Long - One Short ESS or mechanical engine problem 2,530 RPM Actuator Wiring Disconnection. Two Long - One Short Short ESS or wiring problem No signal from ESS for 2 seconds after RPM is greater than... -
Page 41: Service And Preventative Maintenance
SECTION 5 SERVICE AND PREVENTATIVE MAINTENANCE INTRODUCTION This section covers service for the generator set and general engine service. Refer to the Kubota engine workshop Section 2.1) for other engine servicing. manual (refer to WARNING Beware of moving poly V-belt and belt driven components. PREVENTATIVE MAINTENANCE SCHEDULE Table 5–1. -
Page 42: Battery Charger Service
BATTERY CHARGER SERVICE PIDs prior to RG2059 are equipped with a battery charger mounted on the generator. If so equipped, when replac- ing the battery charger ensure the cables are NOT touching anything to prevent the wire chaffing with the following: 1. -
Page 43: Engine Service And Components
Figure 5.4 Battery Harness (PIDs prior to RG2059) Minimum of 0.25 in Minimum of 0.25 in (6.4mm) from Edge (6.4mm) from Edge ENGINE SERVICE AND COMPONENTS 5.5.1 Bleeding the Fuel System The unit is equipped with a mechanical fuel lift pump, mounted on the engine next to the injection pump. The fuel system is a closed circuit which will require bleeding if loss of fuel has occurred. -
Page 44: Fuel Filter
Figure 5.5 Mechanical fuel Pump Hand Priming Pump Filter Copper Rings Banjo 5.5.3 Fuel Filter The fuel filter is located on the generator set unidrive assembly (see Figure 2.2). To replace the fuel filter, loosen and remove the filter housing. Lightly oil new gasket with lube oil and replace the filter. 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. -
Page 45: Lube Oil Filter
5. Run engine to operating temperature. Drain system again and fill with treated water/anti-freeze. (See above Section 2.11.) Caution note and refer to 5.5.6 Lube Oil Filter The oil filter is located near the radiator fan (see Figure 2.5). 1. After warming up the engine, stop engine, remove drain plug from oil reservoir and drain engine lube oil. 2. -
Page 46: Engine Air Cleaner
The poly V-belt is driven by a sheave on the engine crankshaft. Its two functions are to: • drive the radiator fan • drive the water pump To replace the poly V-belt, perform the following steps: 1. Using the proper size socket, slowly rotate the crank on the crank pulley nut. At the same time, use a flat, blunt object to guide the belt off the crank pulley towards radiator. -
Page 47: Engine Crankcase Breather
Air Cleaner, Oil Bath Service Procedure The oil cup should be inspected during pretrip, before each trip. Never allow more than 1/2 inch (12.7 mm) of dirt deposit in the cup. More than 1/2 inch accumulation could result in oil and dirt carrying over into the engine, caus- ing accelerated engine wear. -
Page 48: Intake Heater Test
Figure 5.8 Engine Crankcase Breather Screw Breather Valve Breather Cover Breather Tube Bleed Hole 5.5.13 Intake Heater Test 1. Disconnect the lead from the heater terminal (positive). 2. Measure the resistance between the heater positive terminal and the heater body. 3. -
Page 49: Intake Heater Switch
5.5.15 Intake Heater Switch 1. Remove control box cover. 2. Remove all connections going to heater switch (HS). 3. Remove heater switch from control box. 4. Install new heater switch. 5. Reconnect wire harness connections to switch. 6. Confirm wires are connected to correct terminals. 7. -
Page 50: Figure 5.10 Drive Gear
13. Remove the bolt/washer (1) that secures the ground wire to the generator. 14. Back off (about 1”), but do not remove the engine shock mount bolts. This will allow the engine/generator to be slightly lifted off of the unit frame. 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. -
Page 51: Figure 5.11 Generator Unit
Figure 5.11 Generator Unit Voltage Controller Battery Charger Air Intake Port (hose not shown) Channel Assembly Fly Wheel Generator Generator Shock Mount Inspection Port 21. Place the key into the slot on the drive shaft of the new generator, and install the drive gear over the drive shaft and key. - Page 52 27. With the generator drive gear pressed against the coupling on the fly wheel adaptor plate, use the screw- driver to slowly rotate the fly wheel. Use a flashlight to observe the generator drive gear as you rotate the fly wheel.
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Page 53: General Generator Set Maintenance
Figure 5.12 Battery Charger (PIDs Prior to RG2059) Output - Output + Ground Power Cable Figure 5.13 Battery Charger (PIDs RG2059 and Up) AC Wiring from Generator DC Wiring to 12v Battery Red (+) Black (-) 43. Replace the voltage controller cables and secure the voltage controller to the channel assembly using the 1/ 4”... -
Page 54: Figure 5.14 Snubber Hardware
When a shockmount has been cut, split, abraded or has flared due to normal deterioration, it must be replaced. Damage to the mounts may not be visible when installed and under load from the component. To correctly inspect shockmounts, they must be removed. Engine Shockmount Replacement NOTE Refer to... -
Page 55: Unidrive Torque Requirements
Figure 5.15 Engine Shockmounts Screw (5/8) Lock Washer (5/8) Flat Washer (5/8) Snubbing Washer ENGINE Shockmount FRAME 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. -
Page 56: Figure 5.16 Generator Shockmounts
Figure 5.16 Generator Shockmounts Lock-nut (5/8) GENERATOR Plain Washer (5/8) Screw (1/2) Mounting Base Screw (3/8) Plain Washer (3/8) Plain Washer (5/8) Flat Washer (1/2) Lock Washer (1/2) Flat Washer Shockmount Plain Washer (3/8) Lock-nut (3/8) Screw (5/8) INSTALL MOUNT WITH LARGER FLARE AT TOP AS SHOWN Shockmount Mounting Base... -
Page 57: Figure 5.17 Unidrive Torque Requirements
Figure 5.17 Unidrive Torque Requirements ENGINE & GENERATOR ENGINE MOUNT SHOCKMOUNTS 3/8-16 x 1-1/4 lg - SST 5/8-18 x 2.25 lg - SST 31 + 3.7 ft.-lb (42.03Nm) 92.5 + 9.2 ft.-lb (125.41Nm) 1/2-13 x 3 lg - SST 5/8-11 x 4.00lg - SST 75 + 9.4 ft.-lb (101.69Nm) 92.5 + 9.2 ft-lb (125.41Nm) UNIDRIVE... -
Page 58: Table 5-1 Preventative Maintenance Actions And Schedule
Table 5–1 Preventative Maintenance Actions and Schedule Every Every Manual During 2000 4000 Procedure Reference Pre-Trip hours of hours of service service Section 1. Check (in place) Engine/Generator shock mounts for 5.7.2 cracks, cuts, abrasion or flaring 2. Check engine lubrication oil and fuel lines, filters and con- nections for leaks. - Page 59 Table 5–1 Preventative Maintenance Actions and Schedule (Continued) Every Every Manual During 2000 4000 Procedure Reference Pre-Trip hours of hours of service service 22.Check water pump bearing end play. Engine Manual 23.Change fuel filter. Section 5.5.3 24.Check crankcase breather. Section 5.5.12 25.Remove and check engine/generator shock mounts for Section...
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Page 61: Schematics
SECTION 6 SCHEMATICS INTRODUCTION This section contains the 12 volt DC control circuit schematics and the 460 volt alternating current schematics. Figure 6.1 Schematic Legend (PIDs prior to RG2059) Based on Drawing 62-11741- 00 6–1 T-361... -
Page 62: Figure 6.2 Schematic 12Vdc Control Circuit (Pids Prior To Rg2059)
SECTION 6 SCHEMATICS PAGE 2 Figure 6.2 Schematic 12VDC Control Circuit (PIDs prior to RG2059) 12VDC CONTROL CIRCUIT Based on Drawing 62-11741- 00 T-361 6–2... -
Page 63: Schematics
SECTION 6 SCHEMATICS PAGE 3 Figure 6.3 Schematic 460 Volt Alternating Current Generator (PIDs prior to RG2059) 460V HIGH VOLTAGE CIRCUITRY 6–3 T-361... -
Page 64: Figure 6.4 Schematic Legend (Pids Rg2059 And Up)
SECTION 6 SCHEMATICS PAGE 4 Figure 6.4 Schematic Legend (PIDs RG2059 and Up) Based on Drawing 62-11910-00 T-361 6–4... -
Page 65: Schematics
SECTION 6 SCHEMATICS PAGE 5 Figure 6.5 Schematic 12VDC Control Circuit (PIDs RG2059 and Up) 12VDC CONTROL CIRCUIT Based on Drawing 62-11910-00 6–5 T-361... -
Page 66: Schematics
SECTION 6 SCHEMATICS PAGE 6 Figure 6.6 Schematic High Voltage Circuitry - 7 Wire Generator (PID RG2059) 460V HIGH VOLTAGE CIRCUITRY T-361 6–6... -
Page 67: Schematics
SECTION 6 SCHEMATICS PAGE 7 Figure 6.7 Schematic High Voltage Circuitry - 8 Wire Generator (PIDs RG2060 and Up) 460V HIGH VOLTAGE CIRCUITRY 6–7 T-361... -
Page 69: Index
INDEX Numerics 460 Volt Alternating Current Generator 6–3 6–6 General 1–1 General Safety Notices 1–1 Generator 5–9 Air Cleaner Body 5–7 Air Cleaner, Dry Element 5–6 Air Cleaner, Oil Bath 5–7 Hazard Label 1–1 Air Filter Indicator 5–6 Alternating Current Generator 2–4 4–5 5–9 Ammeter 2–5... - Page 70 Total Time Meter 2–5 Troubleshooting 4–1 Safety 1–1 Safety Devices 2–10 Schematic Diagram 6–2 6–3 6–6 Unidrive Torque 5–15 Sequence of Operation 3–5 Unit 1–1 Servicing Fuel Pump Internal Filter 5–3 Specific Hazard Statements 1–2 Starter Motor Malfunction 4–2 Starter Timer 2–5 Voltage Controller 2–4 4–7 Starting and Stopping Instructions 3–3...
- Page 72 Carrier Transicold Division, Carrier Corporation A part of UTC Building & Industrial Systems, a business unit of United P.O. Box 4805 Technologies Corporation. Stock symbol UTX. Syracuse, NY 13221 USA Original Instructions www.carrier.transicold.com...
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