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Summary of Contents for Carrier 69UG15
- Page 1 Diesel Generator Set OPERATIONS AND SERVICE MANUAL 69UG15 Generator Set Units Tier 4i - UG14xx to UG18xx Series T-343 Rev E...
- Page 3 OPERATIONS AND SERVICE MANUAL 69UG15 Generator Set Units Tier 4i - UG14xx to UG18xx Series © Carrier Corporation, 2024 Printed in U. S. A. September 2024...
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Page 5: Table Of Contents
Table of Contents PARAGRAPH NUMBER Page SAFETY SUMMARY ..............1–1 GENERAL SAFETY NOTICES . - Page 6 TROUBLESHOOTING ..............4–1 DIESEL ENGINE .
- Page 7 List of Illustrations FIGURE NUMBER Page Figure 2.1 Generator Set ..............2–3 Figure 2.2 Generator Set −...
- Page 8 List of Tables TABLE NUMBER Page Table 2–1 Model Chart ..............2–2 Table 2–2 Auto Restart Preset Values .
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Page 9: Safety Summary
Section 1 Safety Summary 1.1 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
1.6 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. - Page 11 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.
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Page 13: Description
All references to engine are as viewed from the fly wheel end. 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. -
Page 14: Table 2-1 Model Chart
Table 2–1 Model Chart Model Electrical Wiring Unit Receptacle Box Control Box, 460 Schematic and Mounting Volt Diagram Figures 1400 Series, Single Speed 69UG15−050S−05 UG1450 6.10, 6.11, 6.12 Standard w/Circuit Breaker Standard (Section 3.1.1) UG1451 6.1, 6.2, 6.3 Standard w/Circuit Breaker... -
Page 15: Figure 2.1 Generator Set
Figure 2.1 Generator Set 460 VOLT 1. Mechanical Fuel Pump 11. Air Cleaner 2. Injector Pump 12. Generator Shockmount 3. Engine Speed Sensor 13. Receptacle Box 4. Poly V-Belt 14. Receptacle 5. Radiator 15. Circuit Breaker 6. Controls (See Figure 2.9) 16. -
Page 16: Figure 2.2 Generator Set − Top View (Top Frame Members Removed For Clarity)
Figure 2.2 Generator Set − Top View (Top Frame Members Removed for Clarity) 1. Fuel Tank 8. Fuel Heater (If Equipped) 2. Exhaust Muffler 9. Fuel Filter 3. Solid State Battery Charger 10. Coolant Overflow Bottle 4. Low Coolant Sensor (If Equipped) 11. -
Page 17: Engine
2.3 Engine The engine is a vertical, in-line four cylinder diesel engine, which is direct-connected to the alternating current generator. Information on the major engine systems is provided in the following subparagraphs. NOTE: All threads used on the engine are metric except for the oil drain plug, which is American Standard Pipe Thread (NPT). -
Page 18: Lube Oil Filter Arrangement
2.3.4 Lube Oil Filter Arrangement The engine lubricating oil filter, shown in Figure 2.5, is mounted in a horizontal arrangement. Figure 2.5 Lube Oil 1. Oil Filter (Primary) 2. Oil Pressure Sender 3. Oil Pressure Switch 4. Oil Pan 2.4 Alternating Current Generator 2.4.1 Principle of Operation The Marathon Alternator Company (Lima) brushless alternating current generator, see... -
Page 19: Battery Charging System
Figure 2.6 A-C Generator Circuit Diagram FIELD SHUNT SERIES STATOR GENERATOR STATOR ROTOR RECTIFIER EXCITER ASSEMBLY 2.5 Battery Charging System The solid state battery charger, shown in Figure 2.2, is located to the left of the radiator. The charger is powered by the generator, and this input is protected by a circuit breaker located on the control panel. - Page 20 3. Water Temperature Gauge. See Figure 2.7, Figure 2.8, Figure 2.9 The function of this gauge is to observe water operating temperature. The gauge is connected to the water temperature sender. 4. Water Temperature Sender. See Figure 2.2. This device senses engine water temperature and transmits a signal to the water temperature gauge. 5.
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Page 21: Figure 2.7 Standard Control Panel And Box With Dual Speed Option
Figure 2.7 Standard Control Panel and Box With Dual Speed Option CONTROL CONTROL PANEL 1. Total Time Meter 9. Ground Studs 2. Water Temperature Gauge 10. Circuit Breaker (CB2) 3. Oil Pressure Gauge 11. Circuit Breaker (CB3) 4. Ammeter 12. Intake Heater Relay 5. -
Page 22: Figure 2.9 Auto Restart Control Box And Panel
Figure 2.9 Auto Restart Control Box and Panel CONTROL CONTROL PANEL 1. Total Time Meter 10. Ground Studs 2. Engine Start Alarm (Buzzer) 11. Circuit Breaker (CB2) 3. Water Temperature Gauge 12. Starter Relay (SR) 4. Auto Restart Module 13. Low Coolant Relay (LR) 5. - Page 23 Table 2–3 Auto Restart Sequencing *Engine crank and rest is repeated three times each series unless the engine starts. Series Intake Fuel Engine Engine Engine Status Attempt Heater Solenoid Crank Rest Number Energized Engaged Duration Duration (Seconds) (Seconds) Seconds If the engine starts: a.
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Page 24: Safety Devices
Table 2–3 Auto Restart Sequencing *Engine crank and rest is repeated three times each series unless the engine starts. Series Intake Fuel Engine Engine Engine Status Attempt Heater Solenoid Crank Rest Number Energized Engaged Duration Duration (Seconds) (Seconds) Seconds If the engine starts: a. -
Page 25: Unit Specifications
Table 2–4 Safety Devices Unsafe Condition Safety Switch Switch Setting Engine Excessive current draw by the safety relay, Circuit breaker (CB−2) - Automatic Trips at 30 amps fuel heater, water temperature gauge, oil reset pressure gauge or total time meter Excessive current draw by the electronic Fuse 1, 2, 3 Trips at 10 amps... - Page 26 f. Lubrication System Oil Pressure Safety Switch Set- 18 psig (1.27 kg/cm ting Opens Capacity Engine - 16.0 US quarts (15.1 liters), includes standard filter. Oil Level Indicator Dipstick in oil pan or fill cap To check oil level on engines with the dip- stick mounted in the fill cap, remove the cap and wipe the dipstick clean.
- Page 27 k. Cooling System Capacity 6 U.S. quarts (5.68 liters) - includes 1 quart (0.95 liter) in coolant recovery bottle. (Refer to Section 5.4.5) Anti-Freeze: Conventional The cooling system may be factory charged with a 50/50 mix of ethylene glycol and water. This mixture provides protection to -34F (-37C).
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Page 29: Operation
Figure 3.1, to ensure all items are not damaged and in place. It is recommended to use Carrier provided hardware. NOTE: Mounting bolts are Grade 5 steel with 3/4-10 UNC-2A threads. 2. Loosen the mounting bolts enough to push the mounting plates to the outermost position. - Page 30 5. Lift the forks up so that both sides of the generator set mounts are touching the chassis I-beam. Chassis I-Beam Chassis I-Beam Generator Set 6. Slide the mounting plates fully onto the chassis I-beams and torque mounting bolts to a minimum of 200 ft- lbs (271 Nm), in a cross pattern.
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Page 31: Quick Mount Installation
NOTE: It is important to ensure the forklift is removed when checking torque on the genset. Keeping the forklift installed can cause a false torque reading due to the forks holding the unit down, possibly resulting in the unit not being properly secured to the chassis. If the genset is removed for PM or service, it is recommended that the hardware be sprayed with a rust inhibiting lubricant prior to re-installation. -
Page 32: Generator Set Removal
3.2 Generator Set Removal 1. Disconnect the power cable to the generator set (if connected). 2. For Standard Mount: With a fork lift in position and safety chain attached, slide the mounting plates back sufficiently to clear the chassis. For Quick Mount: With fork lift in position and safety chain attached, loosen mounting bolts, and lift end of bolts out of slot to orient clamps to open position. -
Page 33: Post-Start Inspection
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. -
Page 34: Stopping Instructions
3.3.4 Stopping Instructions 1. Place CB-1 in the OFF position. 2. Place the ignition switch in the OFF position. 3.4 Sequence of Operation WARNING Beware of moving poly V-belt, belt driven components and hot exhaust components. 3.4.1 Standard Units With the intake heater switch (HS) held in the ON position, current flows through the ammeter to the intake heater. While the heater is on, the ammeter will show a 42-amp draw. -
Page 35: Troubleshooting
Section 4 Troubleshooting 4.1 Diesel Engine 4.1.1 Engine Will Not Start Condition Possible Cause Remedy / Reference Battery insufficiently charged Charge Battery terminal post or battery defective Check Electrical connections at starter are bad Correct Starter motor will not crank or Starter motor malfunctions Section 4.1.4 low cranking speed... - Page 36 4.1.3 Engine Starts Then Stops Condition Possible Cause Remedy / Reference No fuel in tank Section 2.8 Section 2.9 Intake heater switch not held long enough Hold switch Fuel filter restricted Replace Air cleaner or hose restricted Section 5.4.12 Engine crankcase breather or hose restricted Section 5.4.13 Safety device open Section 2.7...
- Page 37 4.1.5 Malfunction In The Engine Starting Circuit Condition Possible Cause Remedy / Reference Battery defective Correct No power to starter motor solenoid Loose electrical connections Tighten Battery defective Correct Loose electrical connections Tighten Oil pressure switch defective Section 2.7 Fuel solenoid does not Water temperature safety switch open Section 2.7 energize or does not remain...
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Page 38: Battery Charger (Solid State)
4.2 Battery Charger (Solid State) Condition Possible Cause Remedy / Reference Circuit breaker trips when Locate and remove short or Short in 12-volt wiring causing overload of charger charger is turned on replace charger Circuit breaker trips repeatedly, Internal short Replace charger even when not connected Test battery for defect... -
Page 39: Auto Re-Start Option
Condition Possible Cause Remedy / Reference Fluctuating speed Section 5.4.9 Irregular speed of engine Engine Manual Fluctuating voltage (May be Loose terminal or load connections Tighten indicated by flickering lights) Section 5.5.1 Section Bad bearing causing uneven air gap 5.5.3 High voltage Excessive engine speed Section 5.4.9... -
Page 40: Dual Speed Option
Condition Possible Cause Remedy / Reference Electronic Governor Module (EG) is bad. See Engine cranks, but will not start Replace / Section 4.1.1 Section 4.1.1 Engine starts, but shuts down Section 4.1.3 Section 4.1.3 on low oil Engine starts, but shuts down Section 4.1.6 Section 4.1.6 on high water temperature... -
Page 41: Service And Preventative Maintenance
Section 5 Service And Preventative Maintenance 5.1 Introduction This section covers service for the generator set and general engine service. Refer to the Kubota engine workshop manual, Section 2.1, for additional engine servicing. WARNING Beware of moving V-belt and belt driven components. 5.2 Preventative Maintenance Schedule A tabular listing of the recommended preventative maintenance activities and schedule is provided in Table... -
Page 42: Servicing Fuel Pump Internal Filter
5.4.2 Servicing 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. -
Page 43: Servicing The Low Coolant Sensor (Option)
1. After warming up the engine, stop the engine. Remove the drain plug from the oil reservoir and drain engine lube oil. 2. Replace filters. Lightly oil the gasket on the filter before installing. 3. Add lube oil. See Section 2.9. -
Page 44: Replacing The Engine Speed Sensor
5.4.10 Replacing the Engine Speed Sensor 1. Disconnect the plug to the sensor. See Figure 2.1. 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. -
Page 45: Figure 5.3 Air Cleaner, Dry Element
2. Remove the air filter element from the air cleaner body. 3. Install the new element, secure the bottom cap with the cap clamps. Figure 5.3 Air Cleaner, Dry Element 1. Air Outlet 4. Cap Clamp 2. Air Cleaner Body 5. -
Page 46: Engine Crankcase Breather
Figure 5.4 Air Cleaner, Oil Bath 1. Air Inlet Hood 4. Inner Oil Cup 2. Air Cleaner Body 5. Gasket 3. Cap Clamp 6. Oil Cup d. 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. -
Page 47: Intake Heater Test
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. -
Page 48: Generator Repair/Test Procedures
If a rotor becomes defective, it should be returned to the factory with full nameplate data. To repair a rotor, the special tooling and technique of the factory are necessary and essential. Should a failure occur, Carrier Transicold should be notified immediately and steps will be taken to return the generator for service. -
Page 49: Figure 5.7 A-C Generator Rectifier Assembly
b. Winding Insulation Testing Continuity test results for the stator winding tests are provided in the following table: Wire Ohm* Wire Ohm* Wire Ohm* Pair Pair Pair T10-T1 T1-T8 T4-T5 T10-T2 T1-T9 T4-T6 T10-T3 T2-T3 T4-T7 T10-T4 T2-T4 T4-T8 T10-T5 T2-T5 T4-T9 T10-T6... -
Page 50: Bearing Replacement
3. Install new bearing. Ball bearings are pre-lubricated and require no additional lubrication for the life of the bearing. 4. Coat mating surface of bearing cover flange with anti-corrosion compound (Tef-Gel, Carrier Part Number 02-00083-00). 5. Replace bearing cover and mylar gasket. -
Page 51: General Generator Set Maintenance
5. Remove the twelve 3/8 inch hex head cap screws and washers that secure generator frame to engine flywheel housing. 6. Remove the four 5/8 inch bolts that secure the generator mounting feet to the shockmount bracket, then remove generator. b. -
Page 52: Check And Replace Isolators/Shockmounts
5.6.2 Check and Replace Isolators/Shockmounts a. Replacement Criteria 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. -
Page 53: Unidrive Torque Requirements
Figure 5.11 Generator Shockmounts GENERATOR INSTALL MOUNT WITH LARGE FLARE AT TOP FRAME FRAME 1. Screw (5/8) 8. Support Plate 2. Mounting Base 9. Snubbing Washer 3 Flat Washer (5/8) 10. Screw (1/2) 4. Locknut (5/8) 11. Screw (3/8) 5. Locknut (1/2) 12. -
Page 54: Figure 5.12 Unidrive Torque Requirements
Figure 5.12 Unidrive Torque Requirements ENGINE & GENERATOR SHOCKMOUNTS/ I SOLATORS ‐ TOP VIEW 1/2-13 x 3-1/2 lg - SST (2 Req’d) 75 ft-lb (10.37 mkg) TRUSS AND ISOLATOR 3/8-16 X 1-1/4 lg - SST M8 X 1-1/4 lg - STL (4 Req’d) 11 ft-lb (1.5 mkg) Nut, Self Lock 3/8-16 - SST 3/8-16 x 1 lg - SST... -
Page 55: Table 5-1 Preventative Maintenance Actions And Schedule
Table 5–1 Preventative Maintenance Actions and Schedule Extended Standard Service Service Interval Units Interval Perform at Reference Units* Description of Procedure Pre-Trip Paragraph Inspection Annually Annually Every 1000 or Every or Every Hours 3000 Hours 3000 Hours For Pre-Trip inspection, perform items 1 through 15; for “After Start-up” checks, perform items 32 through 36. 1. - Page 56 Table 5–1 Preventative Maintenance Actions and Schedule Extended Standard Service Service Interval Units Interval Perform at Reference Units* Description of Procedure Pre-Trip Paragraph Inspection Annually Annually Every 1000 or Every or Every Hours 3000 Hours 3000 Hours 23. Remove and check engine/generator shockmounts Section 5.6.2 for cracks, cuts, splits, abrasion or flaring 24.
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Page 57: Schematics
Section 6 Schematics 6.1 Introduction This section contains the 12-volt DC control circuit schematics and the 460 volt alternating current generator sche- matics. To identify the schematics applicable to your PID number refer to Table 2–1. Figure 6.1 Schematic Diagram - Legend (Applies to Figure 6.2 thru... -
Page 58: Figure 6.2 Schematic Diagram
Figure 6.2 Schematic Diagram (For Applicability, Refer to Table 2–1) T-343 6–2... -
Page 59: Figure 6.3 Schematic Diagram 460 Volt Alternating Current Generator
Figure 6.3 Schematic Diagram 460 Volt Alternating Current Generator (For Applicability, Refer to Table 2–1) 6–3 T-343... -
Page 60: Figure 6.4 Schematic Diagram - Legend
Figure 6.4 Schematic Diagram - Legend (Applies to Figure 6.5 thru Figure 6.6) T-343 6–4... -
Page 61: Figure 6.5 Schematic Diagram
Figure 6.5 Schematic Diagram (For Applicability, Refer to Table 2–1) 6–5 T-343... -
Page 62: Figure 6.6 Schematic Diagram 460 Volt Alternating Current Generator
Figure 6.6 Schematic Diagram 460 Volt Alternating Current Generator (For Applicability, Refer to Table 2–1) T-343 6–6... -
Page 63: Figure 6.7 Schematic Diagram - Legend
Figure 6.7 Schematic Diagram - Legend (Applies to Figure 6.8 thru Figure 6.9) 6–7 T-343... -
Page 64: Figure 6.8 Schematic Diagram
Figure 6.8 Schematic Diagram (For Applicability, Refer to Table 2–1) T-343 6–8... -
Page 65: Figure 6.9 Schematic Diagram 460 Volt Alternating Current Generator
Figure 6.9 Schematic Diagram 460 Volt Alternating Current Generator NOTE: WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY GENERATOR TERMINAL STRIP TERMINAL T10. (For Applicability, Refer to Table 2–1) 6–9 T-343... -
Page 66: Figure 6.10 Schematic Diagram - Legend
Figure 6.10 Schematic Diagram - Legend (Applies to Figure 6.11 thru Figure 6.12) T-343 6–10... -
Page 67: Figure 6.11 Schematic Diagram
Figure 6.11 Schematic Diagram (For Applicability, Refer to Table 2–1) 6–11 T-343... -
Page 68: Figure 6.12 Schematic Diagram 460 Volt Alternating Current Generator
Figure 6.12 Schematic Diagram 460 Volt Alternating Current Generator NOTE: WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY GENERATOR TERMINAL STRIP TERMINAL T10. (For Applicability, Refer to Table 2–1) T-343 6–12... -
Page 69: Figure 6.13 Schematic Diagram - Legend
Figure 6.13 Schematic Diagram - Legend (Applies to Figure 6.14 thru Figure 6.15) 6–13 T-343... -
Page 70: Figure 6.14 Schematic Diagram
Figure 6.14 Schematic Diagram (For Applicability, Refer to Table 2–1) T-343 6–14... -
Page 71: Figure 6.15 Schematic Diagram 460 Volt Alternating Current Generator
Figure 6.15 Schematic Diagram 460 Volt Alternating Current Generator NOTE: WHEN PE IS NOT FITTED, OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY GENERATOR TERMINAL STRIP TERMINAL T10. (For Applicability, Refer to Table 2–1) 6–15 T-343... -
Page 73: Index
Index Air Cleaner Body 5–6 Heater Test 5–7 Air Cleaner, Dry Element 5–4 Air Cleaner, Oil Bath Service 5–5 Instruments 2–7 Air Filter Indicator 5–4 Intake Heater 5–7 Alternating Current Generator 2–6 Intake Heater Switch 5–7 Alternating Current Generator Troubleshooting 4–4 Isolators/Shockmounts 5–12 Auto Re-Start Option 4–5 Auto Re-Start Option Troubleshooting 4–5... - Page 76 Carrier Transicold Division, Carrier Corporation P.O. Box 4805 Syracuse, NY 13221 USA https://www.carrier.com/container-refrigeration...
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