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T-360

4–4

4.1.6

Miscellaneous Engine Troubleshooting

4.2

BATTERY CHARGER (SOLID STATE)

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

Incorrect fuel injection pump timing

Engine Manual

Incorrect valve timing

Engine Manual

Poor compression

Engine Manual

Vibration

Engine shockmounts are bad

Replace

Poor compression

Engine Manual

Overheating

Restriction in air 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 poly V-belt

Section 5.4.11

Thermostat is bad

Engine Manual

Water pump is bad

Engine Manual

Excessive crankcase pressure Plugged crankcase breather line

Section 5.4.13

Table 4–7 Battery Charger (Solid State)

Condition

Possible Cause

Remedy/Reference Section

CB4 trips when charger is
turned on

Short in 12-volt wiring causing overload of
charger

Locate and remove short or re-
place charger

Circuit breaker trips repeated-
ly, even when not connected

Internal short

Replace charger

Charger does not taper back
after charging for a few min-
utes

Bad cell in battery

Test battery for defect according to
battery manufacturer’s instructions

Charger is bad

Replace

Содержание Carrier Transicold 69UG15

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

Страница 2: ......

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

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 12: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 36: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 64: ......

Страница 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...

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

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

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

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

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

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

Страница 72: ...T 360 6 8...

Страница 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...

Страница 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...

Страница 75: ......

Страница 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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