Carrier RG2059 Series Operation And Service

Diesel Generator Set

OPERATIONS AND SERVICE

For

69RG15

Generator Set Units

RG2059 to RG2100 Series

T-361 Rev F 09/19

OPERATIONS AND SERVICE

For

69RG15

Generator Set Units

RG2059 to RG2100 Series

i T-361

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.2 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.3 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.4 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.5 UNIT HAZARD LABEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.6 SPECIFIC HAZARD STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2.2 CONFIGURATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2.3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

2.3.1 Electronic Governor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

2.3.2 Engine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

2.3.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

2.3.4 Lube Oil Filter Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.4 ENGINE SCREW THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.5 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.6 BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.7 VOLTAGE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.8 OPERATING CONTROLS & INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.8.2 Control Panel and Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.9 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10

2.10 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11

2.11 ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3.1 GENERATOR SET INSTALL AND REMOVE - PIN TYPE WITH LOCKING BRACKET . . . . . . . 3–1

3.1.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3.1.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

3.2 GENERATOR SET INSTALL AND REMOVE - CLAMP TYPE WITH LOCKING BRACKET . . . . 3–2

3.2.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

3.2.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

3.3 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

3.3.1 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

3.3.2 Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

3.3.3 Post-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

3.3.4 Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

3.4 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

4.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

4.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

4.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

4.1.3 Engine Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

4.1.4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

4.1.5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

4.1.6 Miscellaneous Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

T-361 ii

4.2 BATTERY CHARGER (SOLID STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

4.3 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5

4.4 AUTO RE-START OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6

4.5 ELECTRONIC GOVERNOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7

4.6 VOLTAGE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7

SERVICE AND PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5.2 PREVENTATIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5.3 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5.4 BATTERY CHARGER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

5.5 ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

5.5.1 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

5.5.2 Servicing Fuel Pump Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

5.5.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

5.5.4 In-Line Fuel Strainer (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

5.5.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

5.5.6 Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

5.5.7 Servicing Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

5.5.8 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

5.5.9 Replacing the Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

5.5.10 Servicing Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

5.5.11 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

5.5.12 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7

5.5.13 Intake Heater Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

5.5.14 Intake Heater Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

5.5.15 Intake Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9

5.6 SERVICING THE ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9

5.6.1 Generator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9

5.7 GENERAL GENERATOR SET MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13

5.7.1 Maintenance of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13

5.7.2 Checking and Replacing Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13

5.8 UNIDRIVE TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15

SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

SCHEMATICS PAGE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

SCHEMATICS PAGE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

SCHEMATICS PAGE 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4

SCHEMATICS PAGE 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5

SCHEMATICS PAGE 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6

SCHEMATICS PAGE 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX–1

iii T-361

LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

Figure 2.1 Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

Figure 2.2 Generator Set - Top Cover Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

Figure 2.3 Electronic Governor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Figure 2.4 Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Figure 2.5 Lube Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

Figure 2.6 Control Box Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6

Figure 2.7 Control Box and Panel With Auto Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

Figure 3.1 Generator Set Mounting - Pin Type with Locking Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

Figure 3.2 Generator Set Mounting - Clamp Type with Locking Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

Figure 5.1 Battery Cable Routing - Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

Figure 5.2 Battery Cable Routing - Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

Figure 5.3 Battery Cable / Harness Clamp (PIDs prior to RG2059) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

Figure 5.4 Battery Harness (PIDs prior to RG2059) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

Figure 5.5 Mechanical fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

Figure 5.6 Air Cleaner, Dry Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

Figure 5.7 Air Cleaner, Oil Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7

Figure 5.8 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

Figure 5.9 Intake Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

Figure 5.10 Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10

Figure 5.11 Generator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11

Figure 5.12 Battery Charger (PIDs Prior to RG2059) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13

Figure 5.13 Battery Charger (PIDs RG2059 and Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13

Figure 5.14 Snubber Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14

Figure 5.15 Engine Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15

Figure 5.16 Generator Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16

Figure 5.17 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17

Figure 6.1 Schematic Legend (PIDs prior to RG2059) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

Figure 6.2 Schematic 12VDC Control Circuit (PIDs prior to RG2059) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

Figure 6.3 Schematic 460 Volt Alternating Current Generator (PIDs prior to RG2059) . . . . . . . . . . . . . . . . . 6–3

Figure 6.4 Schematic Legend (PIDs RG2059 and Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4

Figure 6.5 Schematic 12VDC Control Circuit (PIDs RG2059 and Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5

Figure 6.6 Schematic High Voltage Circuitry - 7 Wire Generator (PID RG2059) . . . . . . . . . . . . . . . . . . . . . . 6–6

Figure 6.7 Schematic High Voltage Circuitry - 8 Wire Generator (PIDs RG2060 and Up) . . . . . . . . . . . . . . . 6–7

T-361 iv

LIST OF TABLES

TABLE NUMBER Page

Table 2–1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

Table 2–2 Auto Restart Preset Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8

Table 2–3 Auto Restart Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8

Table 2–4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10

Table 2–5 Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11

Table 2–6 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11

Table 3–1 Cold Engine Preheat Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

Table 4–1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

Table 4–2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

Table 4–3 Engine Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

Table 4–4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

Table 4–5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

Table 4–6 Miscellaneous Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

Table 4–7 Battery Charger (Solid State) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

Table 4–8 Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5

Table 4–9 Auto Re-Start Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6

Table 4–10 Electronic Governor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7

Table 4–11 Voltage Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7

Table 5–1 Preventative Maintenance Actions and Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18

1–1 T-361

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. A listing of the specific warnings and cau-

tions appearing elsewhere in the manual follows the general safety notices.

1.2 FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

1.3 OPERATING PRECAUTIONS

Always wear safety glasses and hearing protection.

Keep hands, clothing and tools clear of the radiator fan and rotating belts.

No work should be performed 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 case of severe vibration or unusual noise, stop the unit and investigate.

1.4 MAINTENANCE PRECAUTIONS

Installation and servicing of refrigeration equipment can be hazardous due to system pressures and electrical com-

ponents. Only trained and qualified service personnel should install, repair, or service refrigeration equipment.

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 electrical fire, open circuit switch and extinguish with CO

2

(never use water).

Fuel Tanks present explosion, fire and rupture hazards even if liquid fuel has been drained. Do not attempt any

repairs, especially repairs using flame, welder or torch, unless you have been properly trained and the tank has

been emptied of liquid fuel and fuel vapors and the tank is properly ventilated.

1.5 UNIT HAZARD LABEL IDENTIFICATION

To help identify the hazard labels on the Unit and explain the level of awareness each one carries, explanations

with appropriate consequences are provided below:

DANGER

!

Indicates an immediate hazard which WILL result in severe personal injury or death.

WARNING

!

Indicates hazards or unsafe conditions which COULD result in severe personal injury or death.

CAUTION

!

Indicates potential hazards or unsafe practices which COULD result in minor personal injury,

product or property damage.

T-361 1–2

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

!

To prevent injury, the procedures provided for installation and removal of the generator set

must be followed carefully.

WARNING

!

Disconnect power plug before removing generator set.

WARNING

!

To prevent injury, the procedures provided for installation and removal of the generator set

must be followed carefully.

WARNING

!

Double-check that the generator set clamp (B) is securely tightened against the face of the cor-

ner casting and that the generator set clamp hand nut is tight before transporting the con-

tainer. A loose fit could cause damage to both the generator set and the generator set clamp,

and cause serious injury during transport.

WARNING

!

Disconnect power plug before removing generator set.

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.

WARNING

!

Beware of pinch points.

WARNING

!

Do not use gasoline to clean air cleaner parts.

WARNING

!

Do not direct water or steam into the generator openings. Do not allow any soap and water

solutions to enter the alternator.

1–3 T-361

WARNING

!

High voltage (dielectric) testing must not be performed to the machine without first observing

NEMA rules. The insulation of this generator winding may be safely checked by using a meg-

ger. A high megger reading indicates good insulation.

CAUTION

!

Observe proper polarity when installing the battery or connecting a battery charger, the nega-

tive battery terminal must be grounded. Reverse polarity may damage the charging system.

When charging the battery in unit, isolate the battery by 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.

CAUTION

!

Never pour cold water into a hot engine.

CAUTION

!

Use only ethylene glycol (anti-freeze with inhibitors) in system. Use of glycol by itself will dam-

age the cooling system. Always cover the engine inlet tube while the air cleaner is being ser-

viced.

CAUTION

!

Do not underfill or overfill the oil bath cups. Overfilling of cups causes loss of capacity; under-

filling cups causes lack of filtering efficiency.

CAUTION

!

Continued operation with failed shockmounts may result in engine or generator damage.

NOTICE

If the generator set is equipped with the fuel filter bowl assembly, when replacing the fuel filter,

a new fuel filter O-ring should be oiled and replaced, and then the clear bowl should also be

tightened to 18 ft-lbs.

NOTICE

Do not attempt to adjust engine speed.

NOTICE

A frayed, cracked or worn poly V-belt must be replaced. After installing a new belt, check the

adjustment after running the unit for three or four hours. This will allow for the initial stretch,

which is common on new belts. Once this initial stretch has taken place, the belt should be

checked at regular intervals.

T-361 1–4

NOTICE

The generator/engine must be slightly lifted off of the unit frame in order to provide enough

clearance for the generator support plate to slide back, away from the engine.

NOTICE

Although the generator drive gear and fly wheel adapter plate will normally keep the generator

coupled to the engine, even without the bolts, it is safest to remove the lower generator bolts

first, in case the generator shifts and falls during bolt removal.

NOTICE

Inspect the generator drive gear, bolt, and key as they will have to be removed from the old

generator and installed onto the new generator; replace these components if they are worn or

damaged.

NOTICE

In order to match up the teeth of the generator drive gear with the teeth of the fly wheel adaptor

plate, the fly wheel will need to be rotated by hand.

NOTICE

Although the drive gear and mating surface of the generator will generally keep the generator

coupled to the engine, even with all of the bolts removed, it is safest to start installation of the

top generator bolts first, just in case the generator shifts and falls.

NOTICE

SST is an abbreviation for 300 Series Corrosion Resistant Steel.

Loctite #242 or an equivalent product should be used on ALL hardware shown in Figure 5.17.

2–1 T-361

SECTION 2

DESCRIPTION

2.1 INTRODUCTION

The Carrier Transicold model 69RG15 clip-on diesel driven generator sets provide electrical power for all-electric

refrigeration units.

The generator set (see Figure 2.1 and Figure 2.2) consists of a diesel engine directly connected to an alternating

current generator and mounted in a structural steel frame. The engine is a vertical in-line, four cylinder diesel man-

ufactured by Kubota. The generator is a 15 kW, permanent, dual bearing type. Generator sets will start at 50Hz.

Once the unit is running, the voltage controller will read the voltage output of the generator and adjust accordingly

to keep the voltage within ISO limits. As the Container becomes loaded, voltage drops and current increases, caus-

ing the generator set to switch windings or speed based on power demand and ambient conditions. The unit will

typically run at 50Hz and will vary generator output via winding selection. The speed change to 60 Hz will typically

occur when the ambient temperature is high and the unit is heavily loaded.

Electrical controls are mounted in a control box with operating controls and gauges mounted on a control panel

(which also serves as the control box cover). The control panel components are protected by a deflector assembly.

Auxiliary engine equipment consists of the battery, solid state battery charging system, “spin-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 engine are as viewed from the fly wheel end.

The 69RG15 is available as a standard configuration, with an Auto Restart option. The Auto Restart option auto-

matically restarts the unit in the event of specific unit shutdowns.

Carrier Transicold’s Ecodriven dual speed option provides an energy saving alternative to the practice of continu-

ously running the generator at full speed. This speed reduction results in increased fuel economy, reduced carbon

footprint, and lowers operating costs.

2.2 CONFIGURATION IDENTIFICATION

Generator set identification information is provided on a label located below the right mounting clamp (front facing).

The label provides the generator set model number, serial number and parts identification number (PID). The

model number identifies the overall configuration while the PID provides information on specific optional equipment

and differences in detailed parts.

The model number, serial number and PID number must be included when ordering parts and inquiring about your

unit.

Separately bound manuals covering the diesel engine are also available. (See Table 2–1).

Table 2–1 Model Chart

Manual / Form Number Equipment Covered Type of Manual

62-11335 V2203-DI Engine Part List

62-11362 V2203-DI Workshop

T-361 2–2

Figure 2.1 Generator Set

Figure 2.2 Generator Set - Top Cover Removed

Fuel Cap

Mounting Clamp

(Optional)

Radiator Cap

Unit Model,

Serial &PID

Plate

Control Box

Fuel Gauge

(Either Side)

Access Door

Mounting Pin

Fuel Cap

Mounting Clamp

(Optional)

Battery Charger

Intake Heater (IH)

Engine

Exhaust Muffler

Inject Pump

Water Temp Sender

Battery

Engine Oil Filter

Coolant Recovery Bottle

Lube Oil Dip Stick/Fill Cap

Mechanical Fuel Pump

Starter Motor

Fuel Filter

**Fuel Heater

Air Cleaner

Control Box

& Panel

AC Generator

Circuit Breaker

(CB1)

Receptacle

** If equipped

2–3 T-361

2.3 ENGINE

The engine is a vertical, in-line four cylinder diesel engine that is directly connected to the alternating current gen-

erator. Information on the major engine systems is provided in the remainder of this chapter.

2.3.1 Electronic Governor Module

The electronic governor module (EG) is a solid state control module preprogrammed for 1800 RPM high speed and

1500 RPM low speed operation.

The unit has an LED which may be used to diagnose failures within the electronic speed control system, refer to

Section 4.5 for additional troubleshooting information on diagnosing failures.

Figure 2.3 Electronic Governor Module

2.3.2 Engine Air System

The air cleaner (Figure 2.2) is designed to prolong engine life and performance by preventing dirt and grit from

entering the engine 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.

2.3.3 Fuel System

The fuel system is fitted with an optional in-line fuel strainer and a fuel filter, which also acts as a water separator.

The fuel system is shown in Figure 2.4.

The fuel heater system is located in the fuel filter, and uses a 12 volt heater to heat fuel as it passes through the

fuel filter.

Figure 2.4 Fuel System Diagram

p

LED

Fuel Tank

In-Line Fuel S trai ner

(optional)

Mechanical Lift Pump

Fuel Filter/Heater

Bleed Valve

Injector Nozzle

I n j e c t i o n

Pump

T-361 2–4

2.3.4 Lube Oil Filter Arrangement

The engine lubricating oil filter is mounted in a horizontal arrangement and is shown in Figure 2.5.

Figure 2.5 Lube Oil

2.4 ENGINE SCREW THREADS

All threads on the engine are metric, except for the oil drain plug which is American Standard Pipe Thread (NPT).

2.5 ALTERNATING CURRENT GENERATOR

The generator bolts directly to the engine and supplies nominal 50/60Hz power depending on the load requirement.

2.6 BATTERY CHARGING SYSTEM

The solid state battery charger (see Figure 2.2) is located on top of the generator. The battery charger is powered

by the generator, and this input is protected by fuses located in the receptacle box. The battery charger produces a

tapered charge (40 amps maximum) and is designed not to overcharge the battery.

CAUTION

!

Observe proper polarity when installing the battery or connecting a battery charger. The nega-

tive battery terminal must be grounded. Reverse polarity may damage the charging system.

When charging the battery in unit, isolate the battery by 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.

2.7 VOLTAGE CONTROLLER

Voltage Controller maintains ISO voltage via two-speed and dual winding control. It regulates voltage in order to

keep the generator output within ISO limits:

• 50Hz: 1500 RPM, 360-460 VAC

• 60Hz: 1800 RPM, 400-500 VAC

2.8 OPERATING CONTROLS & INSTRUMENTS

2.8.1 Introduction

Components required for monitoring and controlling the unit are located in the control box, on the control panel

(seeFigure 2.1) and on the receptacle box (see Figure 2.1).

2.8.2 Control Panel and Related Components

1. Gauges and Senders

a. Oil Pressure Gauge (see Figure 2.6 or Figure 2.7)

The purpose of this gauge is to observe normal operating engine oil pressure. Normal oil pressure is 35

to 60 psig (3.3 to 5.2 kg/cm

2

).

Oil Pan

Oil Pressure Switch

Oil Filter (Primary)

Oil Pressure Sender

2–5 T-361

b. Oil Pressure Sender (see Figure 2.5)

This device senses engine lube oil pressure and transmits a signal to the oil pressure gauge. The oil

pressure sender is located on the oil filter housing.

c. Water Temperature Gauge (see Figure 2.6 or Figure 2.7)

The function of this gauge is to observe water operating temperature. The gauge is connected to the

water temperature sender.

d. Water Temperature Sender

This device (see Figure 2.2) senses engine water temperature and transmits a signal to the water tem-

perature gauge. The water temperature sender is located on the top, left-hand side of the engine below

the high water temperature switch.

e. Auto Restart Module (If Equipped) (see Figure 2.7)

Auto start/restart is provided to simplify the start-up process and provide an automatic restart feature that

will automatically attempt to restart the unit in the event of some shutdowns. Four LEDs are used to indi-

cate shutdown from overcrank, overspeed, low oil pressure, and high water temperature. A fifth LED is

used to indicate the unit is running. Refer to Table 2–2 for system preset values.

The auto restart function will perform a series of six attempts to restart the unit and make three attempts

within each series. Once the function has completed all 18 attempts the unit will automatically lock out

future crank attempts. Refer to Table 2–3 for detailed information on auto restart sequencing.

2. Meters

a. Ammeter (A) (see Figure 2.6 or Figure 2.7)

The ammeter is an indicator of the charging system and unit electrical draw. It indicates the rate of dis-

charge or charge of the battery. During start up, the intake heater draws approximately 42 amps.

b. Total Time Meter (TT) (see Figure 2.6 or Figure 2.7)

This meter designates the total hours and provides an accurate readout of accumulated engine running

time. This data can be used to establish the proper periodic maintenance schedule. (Refer to Table 5–1.)

3. Manual Switches

a. Intake Heater Switch (HS)

The intake heater switch is of the momentary type. When held in the PREHEAT position, the switch

allows approximately 42 amps of battery current to flow into the intake heater. This, in turn preheats the

air within the intake manifold and allows the engine to start. After starting the engine, the intake heater

switch should continue to be held in the ON position for approximately 5 seconds until the engine has

developed enough oil pressure to close the oil pressure safety switch.

b. Ignition Switch (IGN) (see Figure 2.6)

The ignition switch is of the momentary type to be used in the OFF/ON/START positions. When held in

the START (ignition) position, it energizes the starter motor solenoid, which in turn allows the starter

motor to crank the engine. The switch is released to the RUN position once the engine has started.

c. Ignition Switch (IGN) (Auto Restart) (see Figure 2.7)

The ignition switch is of the maintained contact type to be used in the RUN/OFF positions. When

switched to the RUN position, it energizes the control module, which in turn controls all functions of the

generator set.

4. Timers

a. Intake Heater Timer (IHT) (If Equipped)

The intake heater timer continues to supply power to the intake heater for 3 minutes after initial start- up.

b. Starter Timer

The Starter Timer limits the amount of time that the starter can be engaged to 15 seconds. If the starter is

manually engaged for more than 15 seconds, power will be cut to the starter. Once power has been

removed, the starter can again be engaged for up to 15 seconds.

T-361 2–6

Figure 2.6 Control Box Standard

Control Panel

Control Box (Front View with Cover Removed)

Intake Heater Switch

Ignition Switch

Total Time Meter

Water Temp Gauge Oil Pressure Gauge

Ammeter

I n t a k e He a t e r

Timer (IHT)

Starter S olenoid

Relay (SSR)

Circuit Breaker (CB4)

Circuit Breaker (CB3)

Circuit Breaker (CB2)

S t a r t e r S o le n o i d

Timer (SST)

Gr o u n d S t r a p

Assembly

Safety Relay

Intake Heater Relay

2–7 T-361

Figure 2.7 Control Box and Panel With Auto Restart

Control Panel

Control Box (Front View with Cover Removed)

Engine Start/

Intake Heater

Energized Light

Ignition Switch

Total Time Meter

Water Temp Gauge

Oil Pressure Gauge

Ammeter

Intake Heater

Relay (HR)

Circuit Breaker (CB4)

Circuit Breaker (CB3)

Circuit Breaker (CB2)

Grou n d S tr a p

Assembly

Starter Relay

Safety Relay

Engine Star t Alarm

(Buzzer)

Auto Restart Module

T-361 2–8

Table 2–2 Auto Restart Preset Values

Indicator Preset Value Description

Overspeed 2100 RPM Overspeed is the 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 De-

lay

15 seconds The oil pressure and water temperature inputs are ignored

during this 15 second delay (during startup).

Intake Heater Delay 30 seconds preheat

3 minutes post heat

The delay is used during start up. The intake heater delay begins

timing after the auto restart module signal is received. During the

entire delay, the intake heater circuit will be energized, an indi-

cator light will be illuminated, and an alarm will sound. When the

delay expires, the unit will crank.

Crank Attempts 18 attempts A series of six attempts with three attempts in each series for a

total of 18 attempts, refer to Table 2–3, Auto Restart Sequenc-

ing.

Table 2–3 Auto Restart Sequencing

Series Attempt Number 1 Engine Status:

If the engine starts:

1. Run sequence begins

2. Intake heater remains energized for 3 minutes

If the engine fails to start:

1. Intake heater will de-energize.

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 Energized

in Seconds

30

Fuel Solenoid Engaged X

Engine Crank Duration

(Seconds)

Up to 15

Engine Rest Duration

(Seconds)

25

Series Attempt Number 2 Engine Status:

If the engine starts:

1. Run sequence begins

2. Intake heater remains energized for 3 minutes

If the engine fails to start:

1. Intake heater will de-energize.

2. Fuel solenoid will de-energize.

3. Crank output will de-energize.

4. Overcrank LED will flash twice. Wait two seconds and repeat.

5. Unit will rest 30 minutes and proceed to the next series.

Intake Heater Energized

in Seconds

30

Fuel Solenoid Engaged X

Engine Crank Duration

(Seconds)

Up to 15

Engine Rest Duration

(Seconds)

25

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