carrier genset manual

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carrier genset manual

PowerLINE generator sets offer the ideal combination of horsepower, torque, and motor-starting capability and provide power to start any ISO reefer, anywhere it’s necessary. Attaching and disconnecting the generator set can take just minutes.Up-front analog instrumentation is easy to read and allows immediate access to key operating parameters. The control system is uncomplicated, easy to access and troubleshoot. The powerful, reliable; low- maintenance field wound generator produces 460 volts of continuous power and features an internally excited, self-regulated design. All electrical components are enclosed within the generator package and provide superior resistance to moisture and salt. Clamp mounting to the corner casting of the container is available as an option. In either case, when mounted, the 69RG15 envelope allows access to the refrigeration unit control box. This applies to all Carrier and most competitive units as well. Additionally the design of the equipment considered a deep footprint to avoid tipping due to rough handling by yard forklifts, and fork pockets are extended and reinforced to eliminate fork tine damage. This directly translates to a reduction of the unit’s carbon footprint by up to 28%. See Exhibit B for additional information. For easy attachment and detachment from container box. The clear bowl allows visual inspection of the screen for clogging. Dry element, “cartridge”-style air filter with filter-minder allows for quick visual check of filter condition and signals when cartridge must be replaced. Optimum tension provided by the belt helps assure maximum life of the water pump bearing. The powerful, reliable; low- maintenance field wound generator produces 460 volts of continuous power and features an internally excited, self-regulated design. See Exhibit B for additional information. For easy attachment and detachment from container box. The clear bowl allows visual inspection of the screen for clogging.

Dry element, “cartridge”-style air filter with filter-minder allows for quick visual check of filter condition and signals when cartridge must be replaced. Optimum tension provided by the belt helps assure maximum life of the water pump bearing. PID UG1450 and Higher. T--343 Rev --PageThe 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 cautionsAlways obtain first aid or medical attention immediately.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 theAlways work in pairs. Never work on the equipment alone. In case of severe vibration or unusual noise, stop the unit and investigate.Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems withIn case of electrical fire, open circuit switch and extinguish with CO2 (never use water). Fuel Tanks present explosion, fire and rupture hazards even if liquid fuel has been drained. Do not attempt any repairs,Safety--iThese recommended precautions must be understood and applied during operation and maintenance of the equipment coveredBeware of moving poly V-belt, belt drivenUse of glycol by itselfUnder no circumstances should ether orBeware of moving poly V-Belt and belt driven components.Always cover the engine inlet tube while theOverfilling of cups causes loss of capacity;Do not allow any soap andUse an insulated 12 gaugeCut off all but a fewHigh voltage (dielectric) testing must not beThe insulation of thisObserve proper polarity when installing theSafety--iiCoolant Sensor.

The Auto Restart option automaticallyRestart also offers built--in indicators that signal low oilThe generator set (see Figure 1-1 and Figure 1-2)The engine is a vertical in--line,The generator provides aElectrical controls are mounted in a control box withAuxiliary engine equipment consists of the battery, solidThe label providesThe model numberSeparately bound manuals covering the diesel engineForm No.CoveredManual. Engine Parts List. WorkshopElectrical Wiring. Schematic andDiagram FiguresUnit. Mounting. Receptacle. Box. Control BoxInjector Pump. Engine Speed Sensor. Poly V--Belt. Radiator. Controls (See Figure 1-6 or Figure 1-8). Engine Oil Filter. Engine Shockmount (Typical)Air Cleaner. Generator Shockmount. Receptacle Box. Circuit Breaker. Air Filter Indicator (if equipped). Figure 1-1 Generator SetExhaust Muffler. Solid State Battery Charger. Low Coolant Sensor (If Equipped). Water Temperature Sensor. Water Temperature SwitchCoolant Overflow Bottle. Alternating Current Generator. AC Generator Connection Box Access. Battery. Figure 1-2 Generator Set -- Top View (Top Frame Members Removed for Clarity)The Marathon Alternator Company (Lima) brushless. AC generator (see Figure 1-2, item 9) is aAll connections between the exciter stator windings andFigure 1-5 shows the internal schematic diagram of theThe generator is aA portion of the exciterThis exciter shunt windingAnother portion of theAll threads used on the engine are metric.Fuel Supply Line. Inline Fuel Filter. Mechanical. Fuel Pump (Engine). Oil Filter (Primary). Oil Pressure Sender. Oil Pressure Switch. Oil Pan. Figure 1-4 Lube OilThe electronic governor module is a solid state controlThe electronicThe air cleaner (Item 11, Figure 1-1) is designed toIn order for the air filter toThe engine lubricating oil filter is mounted in a horizontalThe fuel system is fitted with an in--line pre--filter and aThe fuel system is shown in. Figure 1-3.

SeparatorFigure 1-3 Fuel System DiagramThe exciterAn increase in loadThe inherentThe charger is poweredThe batteryComponents required for monitoring and controlling theFigure 1-1).Figure 1-8). The purpose of this gauge is to observe normalNormal oil pressure is 35This device senses engine lube oil pressure andFigure 1-7, Figure 1-8). The function of this gauge is to observe water operatingThis device senses engine water temperature andThis device senses the coolant level inside the radiatorWhen the coolantThe auto restart function will perform a series of sixOnce the battery hasThe ignition switch is of the maintained contact type to. When switched toThe AC generator, solid state battery charger, fuelIn units with auto restart, the engine, engine controlThese safety devicesDe--energizing the fuel solenoid shuts off the fuel supplySafety deviceThe ammeter (see Figure 1-6, Figure 1-7, Figure 1-8) isThe total time meter (see Figure 1-6, Figure 1-7. Figure 1-8) calculates the total hours and provides anThis data can be used to establish the proper periodicFigure 1-7). The intake heater switch is of the momentary type. When held in the PREHEAT position, the switch allowsAfter starting theThe ignition switch is of the momentary type to be used. When held in the. START (ignition) position, it energizes the starter motorWater Temperature Gauge. Oil Pressure Gauge. Ammeter. Intake Air Heater Switch. Ignition Switch. Battery Charger Circuit Breaker (CB5)Circuit Breaker (CB2). Circuit Breaker (CB3). Intake Heater Relay. Safety Relay. Intake Heater Timer. Figure 1-6 Standard Control Panel and BoxWater Temperature Gauge. Battery Charger FuseGround Studs. Circuit Breaker (CB2). Figure 1-7 Customer Specific Control Panel and BoxTotal Time MeterEngine Start Alarm (Buzzer)Water Temperature GaugeAuto Restart ModuleOil Pressure GaugeAmmeterEnergized LightFigure 1-8 Auto Restart Control Box and PanelIndicator. Preset Value. Description. OverspeedCrank DisconnectShutdown Lockout.

DelayThe oil pressure and water temperature inputs are ignored duringIntake Heater DelayThe delay is used during start up. The intake heater delay beginsWhen the delayCrank AttemptsA series of six attempts with three attempts in each seriesTable 1-3 Auto Restart Sequencing. Series. Attempt. NumberHeater. EnergizedSecondsSolenoid. EngagedEngine. Crank. Rest. Duration. DurationUp To 15. Up To 15. Engine StatusIf the engine fails to start:If the engine fails to start:If the engine fails to start:Wait two seconds and repeat.Series. Engine StatusIf the engine fails to start:If the engine fails to start:If the engine fails to start:Unsafe Condition. Low engine lubricating oil pressure. High engine cooling water temperature. Low coolant. Excessive current draw by the safety relay, fuel heater, water temperature gauge,Excessive current draw by the electronicSafety SwitchWater temperature switch (HWT) -Automatic reset. Low coolant sensor. Automatic reset. Switch Setting. Opens below 18 psig. Opens at 230F (110C). Opens with a loss of 32Circuit breaker (CB--2) -Automatic reset. Trips at 30 amps. Fuse 1, 2, 3. Trips at 10 amps. Excessive current draw on intake heaterExcessive current draw on 230 volt feedCircuit breaker (CB--5) -- Manual reset. Opens at 3 ampsCircuit breaker (CB--4, 230 volt) -Manual reset. Trips at 26 ampsFill CapacityDraw CapacityBattery. Generator (A--C). Engine (Dry) -- without Accessories. Unit (with 50 gal steel tank, dry). Unit (with 50 gal aluminum tank, dry). Unit (with 65 gal steel tank, dry). Unit (with 80 gal aluminum tank, dry)Oil Pressure Safety. Opens. Capacity. Engine -- 16.0 US quarts (15.1 liters), includes standard filter. Dipstick in oil pan or fill capOil Level Indicator cap back onto the oil fill tube, then remove to check level. It isScrew cap fully into fill tube after checking level. Use a heavy duty lubricating oil conforming to American PeLube OilSpecification. Base Number 10 or above. Outdoor Temperature. Fahrenheit.

CentigradeWinter. Summer. Diesel No. 1. Diesel No. 2CapacityThis mixture provides protection. Anti--Freeze:This mixture provides protection to --34F (--37C). For replacement. Anti--Freeze:Extended LifeGM6277M and deionized water. Extended life coolant is red or orange in color. DO NOT mix with conventional coolant. Water Temperature. Safety Switch. ResetsSetting. Starts to openThermostat. Fully openOpens. Loss of 32 ounces of coolant or more. Sensor. Closes. Refilling of radiator to proper levelThe fork lift pocketsAttach safety chain between unit and fork truck.To orient in open position, lift nut end of bolt out of slot. Clamp will fall open.Washer, Spherical, Male. Mounting Plate. Generator FrameWasher, Spherical, Female. Tee Nut. Roll Pin. Figure 2-1 Typical Generator Set Mounting - Standard MountWasher, Spherical, Male. Washer, Spherical, Female. BoltRoll Pin. Frame Assembly. Figure 2-2 Typical Generator Set Mounting - Quick MountPREHEAT position. Suggested hold times for a coldTimeAfter the 30 second delay, the unit will attempt to start.If required, clean, then coat with a battery terminal sealant.Connect power cable to refrigeration unit and proceed to paragraph 2.3.2.Place generator setStart refrigeration unit.Place the ignition switch in the OFF position.The intake airSTART switch is released, the starter will beWith the engine running, the battery charger provides.

DC power to operate the control system and charge theWhen the ignition switch is placed in the RUN position,After the self test is complete, the module will energizeWhen the engine starts, the intake heater will remainWith the intake heater switch (IH) held in the ONA second set of contacts also energizes the safety relayTo start the engine, the ignition switch (IGN) is held inCurrent thenThe starter motor turns over the engine resulting inOnce the engine has started, the intake heater willStarter motor will not crank or lowStarter motor cranks, but fails toStarter cranks and engages, butBattery insufficiently charged. Battery terminal post or battery defective. Electrical connections at starter are bad. Starter motor malfunctions. Starter motor solenoid defective. Open starting circuit. Incorrect grade of lubricating oil. Charge. Check. Correct. See 3.1.4. Engine Manual. See 3.1.5. Section 1.10.f. No fuel in tank. Sections. Section 4.4.1. Drain Sump. Replace. Section 4.4.15. Section 4.4.7. Section 4.4.8. Air inside the fuel system. Water inside the fuel system. Plugged fuel filters. Air intake heater is bad. Faulty heater switch. Plugged fuel lines to injector(s). Mechanical lift fuel pump malfunction. Fuses F1, F2, F3, F4 are bad. Loose or no connection between wire harness andEngine lube oil too heavy. Voltage drop in starter cable(s). Hold switch. Section 4.4.13. Section 4.4.14. Section 1.8. Sections 1.10.g,Engine Manual. Table 1-4Engine stops after a few rotations. Fuel heater switch not held long enough. Fuel filter restricted. Air cleaner or hose restricted. Engine crankcase breather or hose restricted. Safety device open. Open wiring circuit to fuel solenoid. Fuel solenoid defective. Fuel supply restricted. Leak in fuel system. Injector nozzle(s) defective. Injection pump defective. Generator internal overloads openLoose ground connection. Improperly seated fuel solenoid. Starter motor will not crank or turnsBattery insufficiently charged.

Battery cable connections loose or oxidized. Battery cables defective. Starter brushes shorted out. Starter brushes hang up, defective or have no contact. Starter solenoid damaged. Ignition switch defective. Engine lube oil too heavy. Starter motor turns, but pinion doesPinion or ring gear obstructed or worn. Starter motor does not disengageIgnition switch is bad. Starter motor solenoid is bad. Pinion does not disengage afterStarter is bad. Engine will not shut offNo power to starter motor solenoid. Fuel solenoid does not energize orIntake heater does not energizeLoose electrical connections. Tighten. Battery defective. Loose electrical connections. Oil pressure switch defective. Water temperature safety switch open. Intake heater switch is bad. Electronic governor module is bad. CheckReplaceIntake heater switch is bad. Timer is bad. Heater element is bad. Heater relay is bad. Section 4.4.15Loss of power. Restriction in air cleaner. Air in fuel system. Air vent restricted. Restricted fuel lines. Fuel injection pump is bad. Injector(s) bad or incorrect type used. Incorrect fuel injection pump timing. Incorrect valve timing. Poor compression. Clean. Vibration. Engine shockmounts are bad. Overheating. Exhaust pipe restriction. Restriction in water jacket. Restriction in radiator. Coolant level too low. Thermostat is bad. Water pump is bad. Remove. Section 4.4.5. Section 1.10.j. Section 4.4.9. Excessive crankcase pressure. Plugged crankcase breather line. Section 4.4.14Short in 12-volt wiring causing overload of charger. Locate andCircuit breaker trips repeatedly,Internal short. Replace charger. Bad cell in battery. Test battery forReplace. Charger does not taper back afterCharger is badCharger is not receiving AC input. Reset. Using a voltmeter, confirmAC voltage. If not,Charger output is not connected to 12 volt battery. Check outputCharger is bad. Low output voltage measuredBattery not connected to charger.

It is normal toCheck chargingReverse polarity connection toInternal DC fuse blown and possible damage toReplace. Charger does not chargeCircuit breaker tripped. Open in stator windings. No voltage. Open or short in rotating rectifiers. Short circuited. Open in alternator field. Shorted exciter armature. Section 4.5.2.a. Section 4.5.1.c. Low engine speed. Excessive load. High resistance connections - connections areShorted field. Section 4.4.11. Fluctuating voltage (May be indicated by flickering lights). Fluctuating speed. Irregular speed of engine. Loose terminal or load connections. Bad bearing causing uneven air gap. TightenExcessive engine speed. Low voltageGenerator overloaded. Clogged ventilating screens. High temperature surrounding generator. Insufficient air circulation. Unbalanced load. Dry bearing. Section 4.5.1. BalanceSection 4.5.4. Rotor scrubbing on stator. Mechanical Noise. Loose laminations. Loose or misaligned coupling. Generator frame produces shockStatic charge. Grounded armature of field coil. Check ground toReplaceCoolant level below the low coolant sensor. Relay defective. When the Ignition switch is placed in 3 amp Fuse is badLoose connector on module.