morse GCRS-40-40 T4F Product Manual Download Page 15 | Manualshive

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Summary of Contents for GCRS-40-40 T4F

Page 1: ...ustrial ca P M GCRS 40 40 T4F Generator Compressor 40 KW 40 CFM This manual must be read carefully before using your MORSE Industrial Equipment GCRS 40 40 T4F Store in a safe and convenient location for future reference PHONE 647 393 1212 ...

Page 2: ...311822 2 ...

Page 3: ...age at No Load 31 Generator Is Noisy 32 Generator Has Low Voltage at Full Load 32 Generator Unstable Voltage 32 Generator Has Dirty Windings 32 Generator Improper Speed 32 Warranties 33 Welcome 4 General information 4 Safety 5 Safety Precautions 5 Safety Rules 6 Installation 7 General Description 10 Hazards and Warnings 11 Electrical Shock Hazards 11 Fire Hazards 11 Explosion Hazards 11 Warnings 1...

Page 4: ...een expended to make sure that the information in this manual is both accurate and current However Morse Industrial Inc reserves the right to change alter or otherwise improve the product at any time without prior notice Bold printed CAUTION boxes point out important safety instructions which if not followed could endanger personal safety and or property Read this manual the engine manual and the ...

Page 5: ...ES WHILE STANDING IN WATER BAREFOOT OR HANDS AND FEET ARE WET HARMFUL OR FATAL ELECTRICAL SHOCK WILL RESULT LOCAL ELECTRICAL CODES MAY REQUIRE THE USE OF AN APPROVED EARTH GROUND TO THE FRAME OF THE GENERATOR THE GENERATOR IS EQUIPPED WITH A MOUNTING GROUND BOLT AND NUT FOR PROPER CONNECTION CONSULT WITH A LOCAL ELECTRICIAN FOR GROUNDING REQUIREMENTS IN YOURAREA NEVER ADD FUEL WHILE UNIT IS RUNNIN...

Page 6: ...ENERATOR REMAIN ALERT AT ALL TIMES WEAR PROTECTIVE CLOTHING INCLUDING SAFETY GLASSES NEVER WORK ON THIS EQUIPMENT WHEN YOU ARE MENTALLY OR PHYSICALLY FATIGUED BEFORE PERFORMING MAINTENANCE ON THIS EQUIPMENT DISCONNECT THE BATTERY CABLES TO PREVENT ACCIDENTAL START UP TAKE CARE NOT TO ARC THE BATTERY POSTS DO NOT TOUCH POSITIVE TO NEGATIVE WITH THE ENDS OF THE CABLE OR TOOLS USED TO REMOVE THE CABL...

Page 7: ...311822 7 Installation 1 PHASE REMOTE METER PANELWIRING 3 PHASE REMOTE METER PANELWIRING ...

Page 8: ...311822 8 Installation Three Phase Single Phase Volts 208V 220V 240V 230V 240V 140A 130A 120A 130A 125A Breaker RECOMMENDED BREAKER SIZE CUSTOMER SUPPLIED INTERNAL GENERATOR WIRING ...

Page 9: ... louvers should be at least double the size and performance of the exhaust louvers Installation Louvers DO NOT move the DOC muﬄer or adjust its position Tampering with the DOC will void the warranty For exhaust routing use 3 exhaust pipe A combination of straight pipe flex pipe and elbows is allowed A section of flex piping is REQUIRED if the exhaust is hard mounted to the trailer DOC Muﬄer ...

Page 10: ...al for details Follow all local electrical codes that may require proper grounding of the generator and its electrical system In case of an accident caused by electric shock immediately shut down the generator Press the Emergency stop button located on the side of the control panel Then turn the main ON OFF rotary switch to the OFF position Do not try to free the victim with the generator running ...

Page 11: ...s and recommendations Do not alter the construction of the generator or engine or change controls which might create an unsafe operating condition Keep a fire extinguisher near the generator at all times Make sure the extinguisher is rated ABC by the National Fire ProtectionAssociation Keep the extinguisher properly charged and be informed on instructions for use Explosion Hazards Do not smoke aro...

Page 12: ...ove all tools rags and installation equipment from the area IV Check compressor oil level and check valves to ensure they re in the correct position V Check belt tension Proper belt tensioning is 1 4 deflection 2 89 lbf to 4 29 lbf per strand For banded belts like the one supplied with the unit the belt tensioning should be 1 4 deflection 5 78 lbf to 8 58 lbf total Operating Procedure I Read this ...

Page 13: ...any faults The user will not have to interact with the panel during normal operation Startup and shutdown is controlled through the ignition switch while the panel s function is to display parameters and faults If there is an engine fault at any time you will need to acknowledge the fault by pressing the Enter Key If the fault is still active the panel will still show the warning or shutdown icon ...

Page 14: ...311822 14 DISPLAY PANEL ...

Page 15: ...311822 15 DISPLAY PANEL ...

Page 16: ...degrees Fahrenheit Ambient Operating Temp Range 0ºF to 120ºF 18ºC to 49ºC GENERATOR Model 40 KW Alternator Output kw 40 kw Prime 44 5 kw Stand by Voltage 208 240 3 ph 60 hz Amps 142 208v 134 220v 123 240v COMPRESSOR Model Integrated Air Compressor Type Oil Flooded Rotary Screw Delivery 40 cfm 1 13 m min Operating Pressure Range 80 to 130 PSIG 5 5 to 9 bar Oil Sump Capacity 75 gal 2 83 L Total Syst...

Page 17: ...311822 17 Specifications ...

Page 18: ...d become a routine The LUBRICATION AND MAINTENANCE CHART lists serviceable items on this compressor package The items are listed according to their frequency of maintenance followed by those items which need only As Required maintenance The maintenance time intervals are expressed in hours Use the display panel hour readings for determining your maintenance schedules To find machine hours simply u...

Page 19: ...t up it is recommended to drain water from the compressor sump Compressor must be shut oﬀ for at least 4 6 hours First verify there is no pressure in the system Then slowly crack the oil drain cap When opening the oil drain port any water will drain out before the oil if fully separated Catch all fluids in a container and dispose of properly When no water is present retighten the compressor oil dr...

Page 20: ...ance in the compressor over a broad range of environmental influences the responsibility for recommending and consistently furnishing a suitable heavy duty lubricant must rest with the individual supplier The lubricant supplier s recommendation must therefore be based upon not only the following general characteristics but also upon his own knowledge of the suitability of the recommended lubricant...

Page 21: ...r piping fittings and clamps 3 Install new air filter element Shorter interval may be necessary under dusty conditions 4 Check for excessive wear on drive belts Replace if necessary 5 Ensure coolant voltage is below 300mV EVERY 1000 HOURS OR 1 YEAR 1 Check safety circuit switches 2 Clean battery terminals 3 Check compressor shaft seal for leakage 4 Install new air filter element Shorter interval m...

Page 22: ...IN THE AIR OR OIL SYSTEM WITHOUT SHUTTING OFF COMPRESSOR AND RELIEVING PRESSURE FROM THE SUMP FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM Compressor Oil Sump Fill Level Drain Air Oil Coalescer This is a single piece unit that requires replacement when it fails to remove the oil from the discharge air To replace element P N 5013 proceed as follows 1 Shut...

Page 23: ...f to 4 29 lbf per strand For banded belts like the one supplied with the unit the belt tensioning should be 1 4 deflection 5 78 lbf to 8 58 lbf total DO NOT SUBSTITUTE ELEMENT USE ONLY A GENUINE MORSE INDUSTRIAL REPLACEMENT ELEMENT THIS ELEMENT IS RATED AT 200 PSI WORKING PRESSURE USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULD IMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR POSSIBLY ...

Page 24: ...LIZED WATER IS RECOMMENEDED WARNING NOTE Engine Coolant Before each start up when radiator is cold the coolant level should be checked When needed refill with EC 1 The proper level for coolant in the system is to the bottom of the radiator fill neck RADIATOR IS FACTORY FILLED WITH EC 1 COOLANT USE OF ANY OTHER COOLANT COULD CAUSE DAMAGE TO THE RADIATOR NOTE Coolant Level CAT EC 1 pre mix Freeze Pr...

Page 25: ... 40 T4F Recommended Spare Parts FOR ENGINE MAINTENANCE DETAILS PLEASE REFER TO THE ENGINE MANUAL DESCRIPTION PART NUMBER MORSE SCO 1000 LUBRICANT 1G 5050 OIL FILTER ELEMENT 5012 COALESCER ELEMENT 5013 AIR FILTER ELEMENT 5014 DRIVE BELTS 5015 SHAFT SEAL REPAIR KIT SCA8D 5016 ENGINE AIR FILTER ELEMENT 5017 ...

Page 26: ...311822 26 Replacement Parts ...

Page 27: ...311822 27 Compressor Replacement Parts ...

Page 28: ...oid or starter Machine Cranks But Will Not Start If machine cranks but doesn t start check for the following 1 No fuel 2 Air in fuel system 3 Fuel solenoid inoperative Machine Shuts Down With Air Demand Present If the machine is shutting down when there is an air demand check for the following 1 Out of fuel 2 Fuel filter restricted 3 Safety shutdown activated 4 Thermostatic valve malfunctioning Ma...

Page 29: ...e stopped and in a level position If the oil level is low remove the oil filler cap and fill to the upper limit mark on the dipstick with the recommended oil Unplanned Shutdown 1 If discharge pressure is too low check the following Too much air demand Service valves open blowing to atmosphere Improper Discharge Pressure Leaks in service line Restricted compressor inlet air filter Faulty control sy...

Page 30: ... oil filter Change element 6 Plugged oil return line clean orifice and check valve High Compressor Discharge Temp If the separator element has to be replaced frequently because it is plugging up it is an indication that foreign material may be entering the compressor inlet or the compressor oil is breaking down or excessive moisture is not being drawn from the unit Compressor oil can break down pr...

Page 31: ...heck the following Faulty voltage regulator Faulty rectifier bridge Exciter stator down to earth Sensing wires has wrong connection Short circuit between aux and main winding Generator Has Low Voltage at No Load If the generator has a low no load voltage check the following Reduce the generator speed The voltage regulator is out of calibration The sensing wires has wrong connection The voltage reg...

Page 32: ...s down Intervention of under frequency device Generator Unstable Voltage If the generator has unstable voltage check the following Loose connections The voltage regulator is out of calibration Irregular rotation Generator Has Dirty Windings Can cause smoke Demagnetization of the generator Could burn the windings Excessive heat Generator Improper Speed If the generator is running at a improper spee...

Page 33: ...usive remedy hereunder is limited to such repair replacement or repayment of the purchase price Parts not of Morse manufacture are warranted only to the extent that they are warranted by the original manufacture Morse shall have no responsibility for any cost or expense incurred by Buyer from inability of Morse to repair under said warranty when such inability is beyond the control of Morse or cau...

Page 34: ...311822 34 Warranty Mail to PO BOX 1519 Antigonish Nova Scotia Canada B2G 2L8 Phone 647 393 1212 ...

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