United Technologies Carrier Transicold 69UG15 Operation And Service Download Page 1

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PID UG2001-2050 SERIES

Diesel Generator Set

OPERATIONS AND SERVICE

For

69UG15

Generator Set Units

T-360 Rev G

Summary of Contents for Carrier Transicold 69UG15

Page 1: ...PID UG2001 2050 SERIES Diesel Generator Set OPERATIONS AND SERVICE For 69UG15 Generator Set Units T 360 Rev G...

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Page 3: ...OPERATIONS AND SERVICE For 69UG15 Generator Set Units Carrier Corporation 2018 Printed in U S A February 2018 PID UG2001 2050 SERIES...

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Page 5: ...NSTRUMENTS 2 9 2 7 1 Introduction 2 9 2 7 2 Control Panel and Related Components 2 9 2 8 SAFETY DEVICES 2 15 2 9 UNIT SPECIFICATIONS 2 16 2 10 ENGINE DATA 2 17 OPERATION 3 1 3 1 GENERATOR SET INSTALLA...

Page 6: ...3 5 4 7 Servicing the Low Coolant Sensor 5 3 5 4 8 Servicing Low Oil Pressure Switch 5 3 5 4 9 Engine Speed 5 4 5 4 10 Replacing the Engine Speed Sensor 5 4 5 4 11 Servicing Poly V belt 5 4 5 4 12 Eng...

Page 7: ...2 Low Coolant Sensor 5 3 Figure 5 3 Air Cleaner Dry Element 5 5 Figure 5 4 Air Cleaner Oil Bath 5 6 Figure 5 5 Engine Crankcase Breather 5 6 Figure 5 6 Intake Heater 5 7 Figure 5 7 Drive Gear 5 9 Figu...

Page 8: ...Engine Will Not Shut Off 4 2 Table 4 4 Starter Motor Malfunction 4 3 Table 4 5 Malfunction In The Engine Starting Circuit 4 3 Table 4 6 Miscellaneous Engine Troubleshooting 4 4 Table 4 7 Battery Char...

Page 9: ...rformed on the unit until all circuit breakers and start stop switches are turned off and the negative battery terminal has been disconnected Always work in pairs Never work on the equipment alone In...

Page 10: ...rts WARNING Do not direct water or steam into the generator openings Do not allow any soap and water solutions to enter the alternator WARNING High voltage dielectric testing must not be performed to...

Page 11: ...iator 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 Overfilling of cups causes l...

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Page 13: ...n on lube oil filter fuel filter and other necessary components for proper unit operation The water pump and the radiator cooling fan are belt driven from the engine crankshaft All references to engin...

Page 14: ...Battery Charger Battery Intake Air Heater Oil Pressure Sender Oil Pressure Switch Oil Filter Engine Shockmount V Belt Engine Speed Sensor Injector Pump Lube Oil Dipstick Fuel Cap Mechanical Fuel Pump...

Page 15: ...attery Charger Battery Intake Air Heater Oil Pressure Switch Oil Filter Engine Shockmount V Belt Engine Speed Sensor Injector Pump Lube Oil Dipstick Fuel Cap Mechanical Fuel Pump Starter Flywheel Acce...

Page 16: ...or to UG2019 Fuel Tank Intake Air Heater Water Temperature Switch Water Temperature Sensor Radiator Controls Fuel Filter Fuel Heater Coolant Overflow Bottle Air Cleaner Circuit Breaker Receptacle Rece...

Page 17: ...2019 and Up Fuel Tank Intake Air Heater Water Temperature Switch Water Temperature Sensor Radiator Controls Fuel Filter Fuel Heater Coolant Overflow Bottle Air Cleaner Receptacle Receptacle Box Genera...

Page 18: ...op PIDs prior to UG2019 Fuel Tank Battery Battery Charger Generator Receptacle Box Air Cleaner Intake Air Heater Coolant Overflow Bottle Fuel Filter Fuel Heater Radiator Low Coolant Senor Water Temp S...

Page 19: ...Top PIDs UG2019 and Up Fuel Tank Battery Battery Charger Generator Receptacle Box Air Cleaner Intake Air Heater Coolant Overflow Bottle Fuel Filter Fuel Heater Radiator Low Coolant Sensor Water Temp S...

Page 20: ...ong engine life and performance by preventing dirt and grit from enter ing the engine and causing excessive wear on all operating parts In order for the air filter to operate properly the operator mus...

Page 21: ...y disconnecting the negative battery ter minal first then the positive Once the battery has been charged connect the positive battery terminal first then the negative 2 6 VOLTAGE CONTROLLER Voltage Co...

Page 22: ...approxi mately 42 amps b Total Time Meter TT The total time meter see Figure 2 10 calculates the total hours and provides an accurate readout of accumulated engine running time This data can be used t...

Page 23: ...nic Governor Module EG Mounted to back of box Water Temperature Gauge CONTROL PANEL CONTROL BOX Starter Solenoid Timer SST Intake Heater Timer IHT Engine Start Alarm Buzzer Total Time Meter Auto Resta...

Page 24: ...sed during start up The intake heater delay begins timing after the auto restart module signal is re ceived During the entire delay the intake heater circuit will be energized an indicator light will...

Page 25: ...ze 2 Fuel solenoid will de energize 3 Crank output will de energize 4 Overcrank LED will flash once Wait two seconds and repeat 5 Unit will rest 30 minutes and proceed to the next series Intake Heater...

Page 26: ...art 1 Intake heater will de energize 2 Fuel solenoid will de energize 3 Crank output will de energize 4 Overcrank LED will flash four times Wait two seconds and repeat 5 Unit will rest five hours and...

Page 27: ...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 2 3 Table 2 3 Safety Devices ENGINE Unsafe Co...

Page 28: ...lons 189 liters Nominal Tank Sizes 50 Gallon Aluminum Fill Capacity 52 Gallons 197 liters Draw Capacity 50 Gallons 189 liters Nominal Tank Sizes 65 Gallon Steel Fill Capacity 67 5 Gallons 256 liters D...

Page 29: ...vy duty lubricating oil conforming to American Petroleum Institute API Service Classification CF or bet ter Lube Oil Viscosity Outdoor Temperature Fahrenheit 0 F to 45 F Centigrade 18 C to 7 C SAE 10W...

Page 30: ...vides protection to 34 F 37 C For replace ment with extended life coolant ELC meeting ASTM D4656 specification and deionized water A 50 50 mix is recommended Extended life coolant is red or orange in...

Page 31: ...unting bolts to 80 90 ft lbs 11 1 12 4 m kg Upon completion remove safety chain before removing forks of fork lift truck from unit 2 Quick Mount a Loosen mounting bolts see Figure 3 2 sufficient to br...

Page 32: ...nd remove generator 3 3 STARTING AND STOPPING INSTRUCTIONS 3 3 1 Pre Start Inspection 1 Check engine lubrication and fuel filters oil lines and connections for leaks If required tighten connections an...

Page 33: ...lying power to the refrigerated unit This will eliminate the potential of any cold start transient spikes from reaching the refrigerated unit Cold start transient spikes can potentially cause nuisance...

Page 34: ...e the ignition switch in the OFF position 3 4 SEQUENCE OF OPERATION WARNING Beware of moving poly V Belt and belt driven components 1 Standard Units With the intake heater switch HS held in the ON pos...

Page 35: ...ter the self test is complete the auto restart module will energize the intake heater and sound the audible alarm warning indicating that the unit has been powered on and will start The 30 second dela...

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Page 37: ...2 10 Fuse F5 is bad Replace Starter motor cranks but fails to start No fuel in tank Section 2 9 Section 2 10 Air inside the fuel system Section 5 4 1 Water inside the fuel system Drain Sump Plugged fu...

Page 38: ...13 Safety device open Section 2 8 Open wiring circuit to fuel solenoid Check Fuel solenoid defective Replace Fuel supply restricted Section 2 10 Section 5 4 2 and Section 5 4 3 Mechanical lift fuel p...

Page 39: ...en re leased Ignition switch is bad Check Replace Starter motor solenoid is bad Engine Manual Pinion does not disengage af ter engine is running Starter is bad Engine Manual Table 4 5 Malfunction In T...

Page 40: ...cleaner Section 5 4 12 Exhaust pipe restriction Remove Restriction in water jacket Engine Manual Restriction in radiator Section 5 4 5 Coolant level too low Section 2 10 Loose water pump alternator po...

Page 41: ...e blown and possible dam age to current carrying components Replace Table 4 8 Alternating Current Generator Condition Possible Cause Remedy Reference Section No voltage Loss of rotor magnetism Replace...

Page 42: ...nate Wait 30 seconds for intake heater to be ac tivated Wait Coolant level below the low coolant sensor 1 10 j Relay defective Check Replace Ignition switch defective Check Replace Switch 3 amp Fuse i...

Page 43: ...le Cause Engine Over Speed more than 2 530 RPM One Long One Short ESS or mechanical engine problem Actuator Wiring Disconnection No signal from ESS for 2 seconds after RPM is greater than 1 000 RPM fo...

Page 44: ...Test the input power to the Circuit Breaker CB 11 12 12 13 11 13 High Voltage Wires from Pri mary and Boost Contactors to Circuit Breaker Voltage Con troller Fuse Blocks Genera tor and Battery Charge...

Page 45: ...7 Fuse Loose con nections Faulty Generator Re place and tighten Verify Voltage Controller has green light il luminated and yellow light flashing at 1 Hz Yellow light flashing sequence other than at 1...

Page 46: ...t 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 Test the input voltage to Primary P or Boost B Contactor T1 T2 T2 T3 T1 T3 300 600 VAC...

Page 47: ...rn fuel bleed valve Red see Figure 2 8 counterclockwise until fully opened 2 Turn the top of the manual priming pump see Figure 5 1 counter clockwise to unlock it and then hand pump the manual plunger...

Page 48: ...il by reversing the normal air flow Compressed air or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dishwasher detergent If a detergent is...

Page 49: ...nt sensor and remove the sensor as described in Section 4 4 7 2 steps a and b below f With the sensor removed from the radiator and 12 VDC applied to terminal B the circuit between termi nals A and C...

Page 50: ...ocket 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 Be careful not to damage grooves on the pulley 2...

Page 51: ...ir Cleaner Oil Bath Service 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 resu...

Page 52: ...he air outlet with sufficient force and volume to produce a hard even stream out of the bottom of the body assembly Reverse flush until all foreign material is removed 5 4 13 Engine Crankcase Breather...

Page 53: ...ble transition to heater and torque mounting hardware refer to engine manual for torque values 7 Reconnect harness to heater connection point 8 Coat stud on heater with protective coating 5 4 16 Intak...

Page 54: ...erator support plate to the two generator shock mounts 11 Remove the bolts washers 3 that secure the lower radiator access panel on the other side of the unit in order to access the engine shock mount...

Page 55: ...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 8 Generator R R PIDs prior to UG2019 Key Drive Gear Washer Bolt...

Page 56: ...t 25 Remove the cover of the fly wheel inspection port Using a long flat head screwdriver inserted into the fly wheel inspection port you will be able to slowly rotate the teeth of the fly wheel 26 Wi...

Page 57: ...for alignment and install the bolts and large washers from the bottom of the shock mounts through the generator support plate Secure the bolts 2 with nuts torque to 75 ft lbs 34 Tighten the engine sho...

Page 58: ...panel covers 5 6 GENERAL GENERATOR SET MAINTENANCE 5 6 1 Maintenance of Painted Surfaces The unit is protected against the corrosive atmosphere in which it normally operates by a special paint system...

Page 59: ...ure 5 12 d Install new shockmounts e Lower the engine enough to assemble hardware as shown and torque Refer to Section 5 7 for torque values f Remove chains from the lift eyes Figure 5 12 Generator Sh...

Page 60: ...hockmounts Figure 5 14 Truss and Isolator FRAME Bolt FRAME Lock Washer Snubbing Washer Shockmount Flat Washer Shockmount Snubbing Washer FRAME TRUSS UNIDRIVE TRUSS Bolt Lock Washer Heat Shield Isolato...

Page 61: ...equivalent product should be used on ALL hardware shown in Figure 5 15 Figure 5 15 Unidrive Torque Requirements 5 8 11 x 4 00 lg SST 2 Req d 90 ft lb 122 02Nm M8 X 1 1 4 lg STL 4 Req d 11 ft lb 14 91...

Page 62: ...h Change oil every 250 hours Section 5 4 12 X X X For Dry element air cleaner Check for cleanliness and clean replace as filter indicator indicates Section 5 4 12 X X X 9 Drain Water from fuel tank su...

Page 63: ...eck crankcase breather Section 5 4 13 X X 25 Remove and check engine generator shock mounts for cracks cuts abrasion or flaring Section 5 6 2 X X 26 Clean and flush coolant system Section 5 4 5 X X 27...

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Page 65: ...SECTION 6 SCHEMATICS 6 1 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...

Page 66: ...T 360 6 2 Figure 6 2 Schematic Diagram PIDs prior to UG2019 62 11725 0...

Page 67: ...6 3 T 360 Figure 6 3 Schematic High Voltage Circuitry PIDs prior to UG2019...

Page 68: ...T 360 6 4 Figure 6 4 Schematic Diagram Legend PIDs UG2019 and Up 62 04233 00...

Page 69: ...6 5 T 360 Figure 6 5 Schematic Diagram PIDs UG2019 and Up 62 04233 00...

Page 70: ...T 360 6 6 Figure 6 6 Schematic High Voltage Circuitry 7 Wire Generator PID UG2019 62 04232 00...

Page 71: ...6 7 T 360 Figure 6 7 Schematic High Voltage Circuitry 8 Wire Generator PIDs UG2020 and Up 62 04235 00...

Page 72: ...T 360 6 8...

Page 73: ...Filter 5 2 G General Generator Set Maintenance 5 12 General Safety Notices 1 1 2 1 Generator Set Installation 3 1 Generator Set Removal 3 2 H Heater Test 5 7 High Voltage Circuit 4 8 I In Line Fuel St...

Page 74: ...tion 4 3 Starting and Stopping Instructions 3 2 Starting Instructions 3 3 Stopping Instructions 3 4 T Troubleshooting 4 1 Truss and Isolator 5 14 U UniDrive 2 3 UniDrive Torque Requirements 5 15 Unit...

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Page 76: ...g Industrial Systems a business unit of United Technologies Corporation Stock symbol UTX Carrier Transicold Division Carrier Corporation P O Box 4805 Syracuse NY 13221 USA www carrier transicold com O...

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