TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY SUMMARY ..............1–1 GENERAL SAFETY NOTICES .
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ELECTRONIC GOVERNOR MODULE ..........4–7 VOLTAGE CONTROLLER .
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LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2.1 Unit View, UniDrive (PIDs prior to UG 2019) ......... 2–2 Figure 2.2 Unit View, UniDrive (PIDs UG2019 and Up) .
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LIST OF TABLES TABLE NUMBER Page Table 2–1 Auto Restart Preset Values ........... . . 2–12 Table 2–2 Auto Restart Sequencing .
SECTION 1 SAFETY SUMMARY GENERAL SAFETY NOTICES Installation and servicing of Genset equipment can be hazardous due to system belts, radiator fan, and electrical components. Only trained and qualified service personnel should install, repair, or service Genset equipment. When working on Genset equipment, observe all potential Danger, Warning and Caution hazards, including those shown below and on hazard labels attached to the unit.
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 Beware of moving poly V-belt, belt driven components and hot exhaust components. WARNING Under no circumstances should ether or any other unauthorized starting aids be used in con- junction with the air intake heater.
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CAUTION Use only ethylene glycol, anti-freeze (with inhibitors) in system. Use of glycol by itself will dam- age the cooling system. CAUTION Never open the radiator cap when the coolant is hot. CAUTION Always cover the engine inlet tube while the air cleaner is being serviced. CAUTION Do not underfill or overfill the oil bath cups.
SECTION 2 DESCRIPTION GENERAL SAFETY NOTICES The Carrier Transicold model 69UG15 under-mounted diesel-driven generator sets provide electrical power for all- electric refrigeration units. The generator set (see Figure 2.2, Figure 2.4 Figure 2.6) consists of a diesel engine direct-connected to an alternating current generator and mounted in a structural steel frame.
Figure 2.3 Unit View, Front (PIDs prior to UG2019) Fuel Tank Water Temperature Water Temperature Switch Intake Air Heater Sensor Radiator Battery Battery Charger Generator Receptacle Air Cleaner Fuel Filter/ Fuel Heater Coolant Controls Circuit Breaker Receptacle Overflow Bottle T-360 2–4...
Figure 2.4 Unit View, Front (PIDs UG2019 and Up) Water Temperature Water Temperature Intake Air Heater Fuel Tank Sensor Switch Radiator Battery Battery Charger Generator Receptacle Coolant Overflow Bottle Controls Air Cleaner Receptacle C i r c u i t Fuel Filter/ Breaker Fuel Heater...
Figure 2.5 Unit View, Top (PIDs prior to UG2019) Muffler Fuel Tank Water Temp. Switch Water Temp. Sensor Battery Low Coolant Senor Battery Charger Generator Receptacle Box C o o l a n t Radiator Overflow Bottle Intake Air Air Cleaner Fuel Filter/Fuel Heater Heater T-360...
Figure 2.6 Unit View, Top (PIDs UG2019 and Up) Muffler Fuel Tank Water Temp. Switch Water Temp. Sensor Low Coolant Battery Sensor Battery Charger Generator Receptacle Box C o o l a n t Radiator Overflow Bottle Air Cleaner Intake Air Heater Fuel Filter/Fuel Heater 2–7 T-360...
ENGINE The engine is a vertical, in-line four cylinder diesel engine, which is directly connected to the alternating current generator. Information on the major engine systems is provided in the following sub-paragraphs. 2.3.1 Electronic Governor Module The electronic governor module (EG) is a solid state control module pre-programmed for 1800 RPM high speed and 1500 RPM low speed operation.
Figure 2.9 Lube Oil Oil Pressure Sender Oil Filter (Primary) Oil Pressure Switch Oil Pan 2.3.5 Engine Screw Threads All threads used on the engine are metric except for the oil drain plug, which is American Standard Pipe Thread (NPT). ALTERNATING CURRENT GENERATOR The generator is directly bolted to the engine and supplies nominal 50/60Hz power depending on the load requirement.
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c. Water Temperature Gauge (see Figure 2.10) The function of this gauge is to observe water operating temperature. The gauge is connected to the water temperature sensor. d. Water Temperature Sensor (see Figure 2.6) This device senses engine water temperature and transmits a signal to the water temperature gauge. e.
Figure 2.10 Control Panel and Box, Standard CONTROL PANEL CONTROL BOX Starter Solenoid Timer Oil Pressure Gauge Water Temperature (SST) Gauge Starter Solenoid Relay (SSR) Safety Relay (S) Intake Heater Intake Heater Relay (HR) Timer (IHT) Total Time Meter Circuit Breaker Ammeter (CB3) Circuit Breaker...
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Series Attempt Number Engine Status: If the engine starts: Intake Heater Energized (Seconds) 30 1. Run sequence begins 2. Intake heater remains energized for 3 minutes Fuel Solenoid Engaged If the engine fails to start: Engine Crank Duration (Seconds) Up to 15 1.
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.
SECTION 3 OPERATION GENERATOR SET INSTALLATION The generator set is mounted under the center of the trailer chassis and is easily handled with a fork lift truck capa- ble 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.
5. Check radiator coil and generator air intake screen for cleanliness. If required, clean using compressed air, reversing the normal air flow. 6. Check air cleaner for cleanliness and clean if necessary. (Refer to Section 5.4.12.) 7. Check in-line fuel strainer and clean if necessary. (Refer to Section 5.4.4.) 8.
d. With the intake heater switch held in the PREHEAT position, place the ignition switch in the START position. e. 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.
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2. Units with Auto Start, Low Coolant Sensor: When the ignition switch (IGN) is placed in the RUN position, 12-volt DC power is applied to the low coolant sensor (LCS), if applicable, and the auto restart module simultaneously. If the coolant level is below the sen- sor, all the indicator lights on the auto restart module will blink once and the LCS will open the contacts on the low coolant relay, de-energizing the unit’s 12-volt DC circuitry.
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...
4.1.2 Engine Starts Then Stops Table 4–2 Engine Starts Then Stops Condition Possible Cause Remedy/Reference Section Engine stops after a few rota- No fuel in tank Section 2.9/Section 2.10. tions Intake heater switch not held long enough Hold switch Fuel filter restricted Replace Air cleaner or hose restricted Section 5.4.12...
4.1.4 Starter Motor Malfunction Table 4–4 Starter Motor Malfunction Condition Possible Cause Remedy/Reference Section Starter motor will not crank or Battery insufficiently charged Charge turns slowly Battery cable connections loose or oxidized Check/Replace Battery cables defective Check/Replace Starter brushes shorted out Engine Manual Starter brushes hang up, defective or have Engine Manual...
4.1.6 Miscellaneous Engine Troubleshooting Table 4–6 Miscellaneous Engine Troubleshooting Condition Possible Cause Remedy/Reference Section Loss of power Restriction in air cleaner Section 5.4.12 Air in fuel system Section 5.4.1 Air vent restricted Clean Restricted fuel lines Engine Manual Fuel injection pump is bad Engine Manual Injector(s) bad or incorrect type used Engine Manual...
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...
Table 4–9 Auto Re-Start Option Condition Possible Cause Remedy/Reference Section Engine cranks, but will not start Electronic Governor Module (EG) is bad Replace Section 4.1.1 Section 4.1.1 Engine starts, but shuts down Section 4.1.2 Section 4.1.2 on low oil Engine starts, but shuts down Section 4.1.6 Section 4.1.6 on high water temperature...
HIGH VOLTAGE CIRCUIT Electrical troubleshooting for high voltage control circuit WARNING Before proceeding with the troubleshooting, make sure to follow your company’s standard safety procedures for working with electrical components. 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)
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ITEM CHECKS POTENTIAL CAUSE Voltage Controller (VC) and Verify VCF6 Fuse is not blown (Check Con- Blown Fuse (Replace) Fuses tinuity for each leg across fuse, outside of circuit; inside of circuit if not running) Verify VCF7 Fuse is not blown (Check Con- Blown Fuse (Replace) tinuity for each leg across fuse, outside of circuit;...
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ITEM CHECKS POTENTIAL CAUSE Primary (P) or Boost (B) Con- Visually verify Primary (P) or Boost (B) Faulty Contactor/Faulty Voltage tactor Contactor is energized (wait 10-20 seconds Controller/Faulty Fuses/Faulty after start-up) Generator (Replace) Test the output voltage from Primary (P) or Boost (B) Contactor (L1-L2, L2-L3, L1-L3) (50Hz: 360 - 460 VAC, and 60Hz: 400 - 500 VAC)
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 manual, Section 1.1, for additional engine servicing. WARNING Beware of moving V-belt and belt driven components. PREVENTATIVE MAINTENANCE SCHEDULE A tabular listing of the recommended preventative maintenance activities and schedule is provided in Table...
Figure 5.1 Mechanical Fuel Pump Manual Priming Pump Filter Banjo Copper Rings 5.4.3 Fuel Filter The fuel filter is located on the generator set frame (see Figure 2.8). To replace the fuel filter, loosen and remove the filter housing. Lightly oil new gasket with lube oil and replace the filter.
5.4.6 Lube Oil Filter The primary oil filter is located near the radiator fan (see Figure 2.9). 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.
5.4.9 Engine Speed The engine speed is electronically controlled. DO NOT ATTEMPT TO ADJUST ENGINE SPEED. 5.4.10 Replacing the Engine Speed Sensor 1. Disconnect the plug to the sensor, (see Figure 2.2). 2. Remove the bolt securing the sensor to the housing. 3.
Air Filter Indicator The air filter indicator, used with the dry element filter, is mounted on the unit frame and connected to the engine air intake. Its function is to indicate when the air cleaner dry element needs to be replaced. In operation: When a plugged air cleaner decreases intake manifold pressure to 500 mm (20”) WG, the indicator moves to the red line.
Figure 5.4 Air Cleaner, Oil Bath Air Inlet Hood Air Cleaner Body Cap Clamp Inner Oil Cup Gasket Oil Cup Air Cleaner Body Service The air cleaner body should be inspected each time the oil cup is serviced. If there is any sign of contaminant buildup or plugging, the air cleaner body should be removed and back flushed.
5.4.14 Intake Heater Test 1. Disconnect the lead from the heater terminal (1). 2. Measure the resistance between the heater positive terminal (1) and the heater body (2). 3. If the resistance is infinity or significantly different than the specification, resistance (cold) 0.3 ohms, replace the heater.
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1. Remove the unit top and side panels in order to access the generator. 2. Disconnect the battery. CAUTION Observe proper polarity when installing the battery or connecting a battery charger, the nega- tive battery terminal must be grounded. Reverse polarity may damage the charging system. When charging the battery in unit, isolate the battery by disconnecting the negative battery ter- minal first, then the positive.
Figure 5.7 Drive Gear Drive Gear Washer Bolt 17. Remove the generator drive gear bolt/washer. 18. Use a gear puller to remove the drive gear and key from the generator drive shaft. 19. 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.
Figure 5.9 Generator R/R (PIDs UG2019 and Up) Battery Battery Charger Wire Harness Bolt Generator Generator Support Engine Shock Mount P l a t e M o n i t o r i n g Bolt Bolt Fly Wheel Inspection Port Generator Shock Mount 20.
Although the drive gear and mating surface of the generator will generally keep the generator coupled to the engine, even with all of the bolts removed, it is safest to start installation of the top generator bolts first, just in case the generator shifts. 30.
37. Re-secure the battery charger assembly to the unit frame. 38. 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.
f. Lower the engine enough to assemble hardware as shown and torque per Section 5.7. g. Remove chains from the lift eyes. 3. Generator Shockmount Replacement a. Use the two lift eyes to lift and support the engine. b. Remove shockmount hardware. c.
UNIDRIVE TORQUE REQUIREMENTS Extensive damage may occur if the proper hardware is not used and/or proper procedures are not followed when working with the unidrive assembly. Periodic inspection of hardware and bolt torque is recommended to ensure the integrity of the unidrive. Torque value and hardware requirements for unidrive assembly are provided in Figure 5.15.
Table 5–1 Preventative Maintenance Actions and Schedule Perform Perform Manual Perform every every Procedure Refer- During 2000 4000 ence Pre-Trip hours of hours of service service 1. Check (in place) Engine/Generator shock mounts for cracks, cuts, Section abrasion or flaring 5.6.2 2.
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Table 5–1 Preventative Maintenance Actions and Schedule Perform Perform Manual Perform every every Procedure Refer- During 2000 4000 ence Pre-Trip hours of hours of service service 23. Change fuel filter. Section 5.4.3 24. Check crankcase breather. Section 5.4.13 25. Remove and check engine/generator shock mounts for cracks, Section cuts, abrasion or flaring.
SECTION 6 SCHEMATICS INTRODUCTION This section contains the 12-volt DC control circuit schematic and the high voltage circuitry schematics. Figure 6.1 Schematic Diagram - Legend (PIDs prior to UG2019) 62-11725-0 6–1 T-360...
INDEX AC Generator 5–7 Heater Test 5–7 Air Cleaner Body 5–6 High Voltage Circuit 4–8 Air Cleaner, Dry Element 5–5 Air Cleaner, Oil Bath Service 5–5 Air Filter Indicator 5–5 In-Line Fuel Strainer 5–2 Alternating Current Generator 2–9 4–5 Instruments 2–9 Auto Re-Start Option 4–6 Intake Heater 5–7 Intake Heater Switch 5–7...
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Specific Hazard Statements 1–2 Standard Mount 3–1 UniDrive 2–3 Starter Motor Malfunction 4–3 UniDrive Torque Requirements 5–15 Starting and Stopping Instructions 3–2 Unit Hazard Label Identification 1–1 Starting Instructions 3–3 Unit Specifications 2–16 Stopping Instructions 3–4 Voltage Controller 2–9 4–7 Troubleshooting 4–1 Truss and Isolator 5–14 T-360...
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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...