Carrier TRANSICOLD 69UG15 Series Operation And Service Download

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Diesel Generator Set

−

343 Rev B

OPERATION AND SERVICE

for

69UG15

Generator Set Units:

PID UG1400 Series
PID UG1500 Series
PID UG1600 Series

Summary of Contents for TRANSICOLD 69UG15 Series

Page 1: ...Diesel Generator Set T 343 Rev B OPERATION AND SERVICE for 69UG15 Generator Set Units PID UG1400 Series PID UG1500 Series PID UG1600 Series r ...

Page 2: ...OPERATION AND SERVICE MANUAL DIESEL DRIVEN GENERATOR SET MODEL 69UG15 ...

Page 3: ...il Filter Arrangement 1 5 1 4 ENGINE SCREW THREADS 1 6 1 5 ALTERNATING CURRENT GENERATOR 1 6 1 5 1 Principle of Operation 1 6 1 5 2 Alternating Current Generator Diagram 1 6 1 6 BATTERY CHARGING SYSTEM 1 6 1 7 OPERATING CONTROLS INSTRUMENTS 1 7 1 7 1 Introduction 1 7 1 7 2 Control Panel and Related Components 1 7 1 8 SAFETY DEVICES 1 12 1 9 UNIT SPECIFICATIONS 1 13 1 10 ENGINE DATA 1 13 OPERATION ...

Page 4: ...mp Internal Filter 4 1 4 4 3 Fuel Filter 4 1 4 4 4 In Line Fuel Strainer Option 4 1 4 4 5 Cooling System 4 1 4 4 6 Lube Oil Filter 4 2 4 4 7 Servicing the Low Coolant Sensor Option 4 2 4 4 8 Servicing Low Oil Pressure Switch 4 2 4 4 9 Engine Speed 4 2 4 4 10 Replacing the Engine Speed Sensor 4 2 4 4 11 Servicing Poly V belt 4 3 4 4 12 Engine Air Cleaner 4 3 4 4 13 Engine Crankcase Breather 4 4 4 4...

Page 5: ...9 Truss and Isolator 4 7 Figure 4 10 Engine Shockmounts 4 8 Figure 4 11 Generator Shockmounts 4 8 Figure 4 12 Unidrive Torque Requirements 4 9 Figure 5 1 Schematic Diagram Legend 5 1 Figure 5 2 Schematic Diagram 5 2 Figure 5 3 Schematic Diagram 460 Volt Alternating Current Generator 5 3 Figure 5 4 Schematic Diagram Legend 5 4 Figure 5 5 Schematic Diagram 5 5 Figure 5 6 Schematic Diagram 460 Volt A...

Page 6: ...usual noise stop the unit and investigate MAINTENANCE PRECAUTIONS Be sure power is turned off and the negative battery cable is disconnected before working on generator set Do not bypass any electrical safety devices e g bridging an overload or using any sort of jumper wires Problems with the system should be diagnosed and any necessary repairs performed by qualified service personnel In case of e...

Page 7: ... or connecting a battery charger the negative battery terminal must be grounded Reverse polarity may damage the charging system When charging the battery in unit isolate the battery by discon necting the negative battery terminal first then the positive Once the battery has been charged connect the positive battery termi nal first then the negative CAUTION Never pour cold water into a hot engine C...

Page 8: ...ard 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 Carrier Transicold s Ecodriven dual speed option provides an energy saving alternati...

Page 9: ...G15 080S 05 UG1465 5 10 5 11 5 12 Standard w Circuit Breaker Standard 69UG15 080Q 05 UG1466 5 10 5 11 5 12 Quick w Circuit Breaker Standard UG1467 5 1 5 2 5 3 Quick w Circuit Breaker Standard 69UG15 068S 06 UG1468 5 7 5 8 5 9 Standard w Circuit Breaker Auto Restart 1500 Series Dual Speed W Fuel Warmer 69UG15 050S 05 UG1550 5 10 5 11 5 12 Standard w Circuit Breaker 2 Speed 69UG15 050S 08 UG1558 5 1...

Page 10: ...Radiator 6 Controls See Figure 1 9 7 Engine Oil Filter 8 Engine Shockmount Typical 9 Lube Oil Dipstick Fill Cap 10 Starter 11 Air Cleaner 12 Generator Shockmount 13 Receptacle Box 14 Receptacle 15 Circuit Breaker 16 Air Filter Indicator if equipped 17 Air Filter Pre Cleaner if equipped 18 Intake Heater IH 19 Fuel Warmer if equipped Figure 1 1 Generator Set ...

Page 11: ...oolant Sensor If Equipped 5 Water Temperature Sensor 6 Water Temperature Switch 7 Engine 8 Fuel Heater If Equipped 9 Fuel Filter 10 Coolant Overflow Bottle 11 Alternating Current Generator 12 AC Generator Connection Box Access 13 Battery Figure 1 2 Generator Set Top View Top Frame Members Removed for Clarity ...

Page 12: ...gine and causing excessive wear on all operating parts In order for the air filter to operate properly the operator must regularly maintain the air cleaner equipment in accordance with the instructions provided within this document 1 3 3 Fuel System The fuel system is fitted with an in line fuel strainer and a fuel filter which also acts as a water separator The fuel system is shown in Figure 1 4 ...

Page 13: ...or no load voltage Another portion of exciter stator windings is connected in series with the output of the generator and provides a compounding excitation characteristic 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 rectifie...

Page 14: ... 7 Figure 1 8 Figure 1 9 is an indicator of the charging system and unit electrical draw It indicates the rate of discharge or charge of the battery During start up the intake heater draws approximately 42 amps 2 Total Time Meter TT The total time meter see Figure 1 7 Figure 1 8 Figure 1 9 calculates the total hours and provides an accurate readout of accumulated engine running time This data can ...

Page 15: ... Equipped 15 Intake Heater Timer Figure 1 7 Standard Control Panel and Box With Dual Speed Option CONTROL BOX CONTROL PANEL 12 10 14 13 15 9 11 1 8 7 6 5 4 3 2 1 Total Time Meter 2 Water Temperature Gauge 3 Oil Pressure Gauge 4 Ammeter 5 Intake Heater Switch 6 Ignition Switch 7 Dual Speed Switch If Equipped 8 Battery Charger Fuse or Circuit Breaker CB5 9 Ground Studs 10 Safety Relay 11 Intake Heat...

Page 16: ...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 post heat The dela...

Page 17: ... two seconds and repeat e Unit will rest 30 minutes and proceed to the next series 2 30 X Up To 15 25 If the engine starts a Run sequence begins b Intake heater remains energized for 3 minutes 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 twice Wait two seconds and repeat e Unit will rest 30...

Page 18: ...l rest five hours and proceed to the next series 5 30 X Up To 15 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 five times Wait two seconds and repeat e Unit will rest five hours and proceed to the next series 6 30 X Up To 15 25 If the engine star...

Page 19: ...ill also de energize the fuel solenoid interrupt the fuel flow to the engine and stop the engine De energizing the fuel solenoid shuts off the fuel supply to the engine thus stopping the engine Safety device specifications are provided in Table 1 4 Table 1 4 Safety Devices Unsafe Condition Safety Switch Switch Setting ENGINE Low engine lubricating oil pressure Low oil pressure switch LOP Automatic...

Page 20: ...afety Switch Setting Opens 18 psig 1 27 kg cm2 Capacity Engine 16 0 US quarts 15 1 liters includes standard filter Oil Level Indicator 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 cap back onto the oil fill tube then remove to check level It is not necessary to screw the cap back i...

Page 21: ... mix is recommended Anti Freeze Extended Life The cooling system may be factory charged with a 50 50 mix of extended life coolant ELC and deionized water This mix ture provides protection to 34 F 37 C For replacement with extended life coolant ELC meeting GM specification GM6277M and deionized water Again a 50 50 mix is recom mended Extended life coolant is red or orange in color DO NOT mix with c...

Page 22: ... 11 1 12 4 mkg Upon completion remove safety chain before re moving forks of fork lift truck from unit b Quick Mount 1 Loosen mounting bolts see Figure 2 2 sufficient to bring clamp to open position To orient in open position lift nut end of bolt out of slot Clamp will fall open 2 Place forks into fork lift pockets of generator At tach safety chain between unit and fork truck 3 Center the generato...

Page 23: ...2 2 Generator Set Mounting Quick Mount 2 2 GENERATOR SET REMOVAL a Standard Mount 1 Disconnect power cable to generator if con nected 2 With fork lift in position and safety chain attached slide mounting plates back sufficiently to clear chassis 3 Lower and remove generator b Quick Mount 1 Disconnect power cable to unit if connected 2 With fork lift in position and safety chain attached loosen mou...

Page 24: ...nce over voltage alarms on refrigerated units that are sensitive to electrical spikes or transients 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 conjunction with the air intake heater NOTE Piston rings in engines that have operated less than 100 hours may not be ...

Page 25: ... is released 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 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 simul...

Page 26: ...harness and Electronic Governor Module EG Sections 1 9 1 10 g Section 4 4 1 Drain Sump Replace Section 4 4 15 Section 4 4 8 Section 4 4 16 Engine Manual Engine Manual Check replace Check correct Starter cranks and engages but dies after a few seconds Engine lube oil too heavy Voltage drop in starter cable s Section 1 10 f Check 3 1 2 Engine Starts Then Stops Engine stops after a few rotations No f...

Page 27: ...nual Starter motor does not disengage after switch has been released Ignition switch is bad Starter motor solenoid is bad Check Replace Engine Manual Pinion does not disengage after engine is running Starter is bad Engine Manual 3 1 5 Malfunction In The Engine Starting Circuit No power to starter motor solenoid Battery defective Loose electrical connections Correct Tighten Fuel solenoid does not e...

Page 28: ...pipe restriction Restriction in water jacket Restriction in radiator Coolant level too low Loose water pump alternator poly V belt Thermostat is bad Water pump is bad Section 4 4 12 Remove Engine Manual Section 4 4 5 Section 1 10 k Section 4 4 11 Engine Manual Engine Manual Excessive crankcase pressure Plugged crankcase breather line Section 4 4 13 3 2 BATTERY CHARGER SOLID STATE Circuit breaker t...

Page 29: ...charging Internal DC fuse blown and possible damage to current carrying components Replace 3 3 ALTERNATING CURRENT GENERATOR No voltage Loss of residual magnetism in exciter field Circuit breaker tripped Open in stator windings Open or short in rotating rectifiers Short circuited Open in alternator field Shorted exciter armature Section 4 5 2 a Check Section 4 5 4 Replace Section 4 5 1 c Section 4...

Page 30: ...5 4 Replace 3 4 AUTO RE START OPTION When the Ignition switch is placed in the RUN position nothing happens no lights illuminate Wait 30 seconds for intake heater to be activated Coolant level below the low coolant sensor Relay defective Ignition switch defective 3 amp Fuse is bad Loose connector on module Auto restart module is bad Miswired connectors Wait 1 10 k Check Replace Check Replace Switc...

Page 31: ...Timer DT is bad 12v is not available to the Dual Speed Timer DT 12v is not available to the Operating Mode switch Wait Check for 12 volts at Pin 15 Replace module Check Replace Switch Check Correct wiring 3 6 ELECTRONIC GOVERNOR MODULE Fault LED flash code Possible Cause Engine Over Speed more than 2 530 RPM One Long One Short ESS or mechan ical engine prob lem Actuator Wiring Disconnection No sig...

Page 32: ...uel is used or untreated fuel is used in cold weather contaminating the fuel If the internal filter is plugged the engine will lose power Therefore the filter must be cleaned on a regular basis The quality of the fuel will affect the filter cleaning schedule refer to section 4 2 a Turn nut item 1 counter clockwise to loosen and re move b Remove banjo fitting item 2 and let it hang loose making sur...

Page 33: ...ensor as de scribed in Section 4 4 7 b steps 1 and 2 below 6 With the sensor removed from the radiator and 12 VDC applied to terminal B the circuit between termi nals A and C should be open Figure 4 2 Low Coolant Sensor CAUTION Never open the radiator cap when the cool ant is hot b Replacing the Low Coolant Sensor LCS 1 Loosen the radiator drain pet cock and drain coolant to a point below the sens...

Page 34: ...air its operation Therefore a service schedule must be set up and followed 1 Check all connections for mechanical tightness Be sure the air cleaner outlet pipe is not fractured 2 In case of leakage if adjustment does not correct the problem replace necessary parts or gaskets Swollen or distorted gaskets must always be re placed a Air Filter Indicator The air filter indicator used with the dry elem...

Page 35: ...the cylinder head cover see Figure 4 5 It is not necessary to disassemble valve style elements for cleaning However the bleed hole should be checked to ensure it is free of obstruction Check once a year or at every 3 000 hours maintenance interval whichever comes first 1 5 4 3 2 1 Screw 2 Breather Cover 3 Bleed Hole 4 Breather Valve 5 Breather Tube Figure 4 5 Engine Crankcase Breather 4 4 14 Intak...

Page 36: ...rage for any period of time a P D George 11127 type air dry fungus resistant varnish should be applied The finest insulation job can be very quickly broken down by carelessly applying high voltage to windings in a moisture saturated condition Failure to follow these guidelines could easily cause a breakdown making it necessary to return the generator to the factory for repair c Rotor Damage If a r...

Page 37: ...tor Rectifier Assembly 3 Remove the two cap screws that secure each diode assembly to the exiter Once this procedure is com plete 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 ro tor lead connection anode and the to the diode bridge cathode and a high resistance when the po larity of the ohmmeter is rev...

Page 38: ...holes CAUTION The rotor should not be pulled out from the alternator more than 0 75 inches Damage to the bearing and windings may result 3 Start the 8mm bolts by hand through the disc plate and into the flywheel Once alignment is made torque the six bolts 4 Secure two of the housing bolts 3 8 inch on the top and bottom of the generator housing to draw the mating flanges together 5 Secure the remai...

Page 39: ...lues refer to paragraph 4 7 6 Lower the engine enough to assemble hardware as shown and torque per paragraph 4 7 7 Remove chains from the lift eyes ENGINE FRAME 1 3 4 5 2 3 1 Bolt 2 Lock Washer 3 Snubbing Washer 4 Shockmount 5 Flat Washer Figure 4 10 Engine Shockmounts c Generator Shockmount Replacement 1 Use the two lift eyes to lift and support the engine 2 Remove shockmount hardware 3 Raise the...

Page 40: ...ld be used on ALL hardware shown in Figure 4 12 UNIDRIVE SECTIONAL VIEW ENGINE GENERATOR SHOCKMOUNTS ISOLATORS TOP VIEW ENGINE MOUNT RIGHT SIDE VIEW Engine Flywheel Generator Disc Drive 3 8 16 x 1 1 2 lg SST 12 Req d 25 ft lb 3 46 mkg 1 2 13 x 3 1 2 lg SST 2 Req d 75 ft lb 10 37 mkg 5 8 18 x 2 00 lg SST 4 Req d 91 95 ft lb 1 58 13 13 mkg 3 8 16 x 1 lg SST 4 Req d 25 ft lb 3 46 mkg M8 x 15 MM lg SS...

Page 41: ... Check air cleaner 7a Oil bath air filter Check for cleanliness and clean filter body and internal mesh Change oil every 250 hours 4 4 12 X X X 7b Dry element air filter with indicator Check for cleanliness and clean replace as air filter indicator indicates 4 4 12 X X X 8 Drain water from fuel tank sump and fuel filter bowl X X X 9 Fill fuel tank with diesel fuel check fuel gauge operation 1 10 g...

Page 42: ...ondition See Engine Manual X X 27 Check engine compression See Engine Manual X X 28 Check and adjust injector nozzles See Engine Manual X X 29 Perform generator maintenance 4 5 1 X X After Starting Generator Set perform the following 30 Check total time meter operation Allow engine to run for 10 minutes X 31 Listen for abnormal bearing noise X 32 Check fuel lines lube oil lines and filters for lea...

Page 43: ...e 12 volt DC control circuit schematics and the 460 volt alternating current generator schematics To identify the schematics applicable to your PID number refer to Table 1 1 Based On Drawing 62 11411 00 Rev Figure 5 1 Schematic Diagram Legend Applies to Figures 5 2 thru 5 3 ...

Page 44: ...5 2 T 343 Based On Drawing 62 11411 00 Rev IH Figure 5 2 Schematic Diagram For Applicability Refer to Table 1 1 ...

Page 45: ... FITTED OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMI NAL STRIP TERMINAL T10 Based On Drawing 62 11411 00 Rev Figure 5 3 Schematic Diagram 460 Volt Alternating Current Generator For Applicability Refer to Table 1 1 ...

Page 46: ...5 4 T 343 Based On Drawing 62 11413 00 Rev A Figure 5 4 Schematic Diagram Legend Applies to Figures 5 5 thru 5 6 ...

Page 47: ...5 5 T 343 Based On Drawing 62 11413 00 Rev A Figure 5 5 Schematic Diagram For Applicability Refer to Table 1 1 ...

Page 48: ...5 6 T 343 Based On Drawing 62 11413 00 Rev A Figure 5 6 Schematic Diagram 460 Volt Alternating Current Generator For Applicability Refer to Table 1 1 ...

Page 49: ...5 7 T 343 Based On Drawing 62 11466 00 Rev B Figure 5 7 Schematic Diagram Legend Applies to Figures 5 8 thru 5 9 ...

Page 50: ...5 8 T 343 Based On Drawing 62 11466 00 Rev B Figure 5 8 Schematic Diagram For Applicability Refer to Table 1 1 ...

Page 51: ...FITTED OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMINAL STRIP TERMINAL T10 Based On Drawings 62 11466 00 Rev B Figure 5 9 Schematic Diagram 460 Volt Alternating Current Generator For Applicability Refer to Table 1 1 ...

Page 52: ...5 10 T 343 Based On Drawing 62 11438 00 Rev D Figure 5 10 Schematic Diagram Legend Applies to Figures 5 11 thru 5 12 ...

Page 53: ...5 11 T 343 Based On Drawing 62 11438 00 Rev D Figure 5 11 Schematic Diagram For Applicability Refer to Table 1 1 ...

Page 54: ...T FITTED OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMINAL STRIP TERMINAL T10 Based On Drawing 62 11438 Rev D Figure 5 12 Schematic Diagram 460 Volt Alternating Current Generator For Applicability Refer to Table 1 1 ...

Page 55: ...5 13 T 343 Based On Drawing 62 11441 00 Rev D Figure 5 13 Schematic Diagram Legend Applies to Figures 5 14 thru 5 15 ...

Page 56: ...5 14 T 343 Based On Drawing 62 11441 00 Rev D Figure 5 14 Schematic Diagram For Applicability Refer to Table 1 1 ...

Page 57: ...T FITTED OUTPUT GROUND WIRES ARE CONNECTED DIRECTLY AT GENERATOR TERMINAL STRIP TERMINAL T10 Based On Drawing 62 11441 Rev D Figure 5 15 Schematic Diagram 460 Volt Alternating Current Generator For Applicability Refer to Table 1 1 ...

Page 58: ...n 1 5 Engine Isolator Shockmount Replacement 4 8 Engine Screw Threads 1 6 Engine Service 4 1 Engine Speed 4 2 Engine Speed Sensor Replacement 4 2 F First Aid Safety i Fuel Filter 4 1 Fuel Pump Filter Service 4 1 Fuel System 1 5 G Gauges and Senders 1 7 Generator Principle of Operation 1 6 Generator Removal and Installation 4 7 Generator Repair 4 5 Generator Service 4 5 Generator Set Installation 2...

Page 59: ...spection 2 3 Pre Start Inspection 2 3 Preventative Maintenance and Operating Precautions 4 5 Preventative Maintenance Schedule 4 1 4 10 S Safety Devices 1 12 Safety Notices Safety i Safety Summary Safety i Schematics 5 1 SEQUENCE OF OPERATION 2 4 Starting Instructions 2 3 Stopping Instructions 2 3 T Timers 1 7 Torque Requirements 4 9 Total Time Meter 1 7 Troubleshooting 3 1 U Unit Introduction 1 1...

Page 60: ...rinted in U S A 11 11 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 Technologies Corporation family Stock symbol UTX ...

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