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Diesel Generator Set
r
OPERATION AND SERVICE
for
69UG15
Generator Set Units
PID UG1450 and Higher
T--343Rev --
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OPERATIONANDSERVICE MANUAL DIESELDRIVENGENERATORSET MODEL 69UG15
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TABLEOF CONTENTS PARAGRAPHNUMBER Page SAFETYSUMMARY .................................................................... Safety--i GENERALSAFETY NOTICES............................................................ Safety--i FIRST AID ............................................................................. Safety--i OPERATING PRECAUTIONS ............................................................ Safety--i MAINTENANCE PRECAUTIONS.......................................................... Safe
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TABLEOF CONTENTS -- Continued PARAGRAPHNUMBER Page 3.2 BATTERY CHARGER (SOLID STATE) .................................................. 3--3 3.3 ALTERNATING CURRENT GENERATOR ............................................... 3--4 3.4 AUTO RE-START OPTION ............................................................ 3--5 SERVICE ANDPREVENTIVE MAINTENANCE ................................................... 4--1 4.1 INTRODUCTION ..................................................................... 4--
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LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 1-1 Generator Set ...................................................................... 1--3 Figure 1-2 Generator Set -- Top View............................................................ 1--4 Figure 1-3 Fuel System Diagram ............................................................... 1--5 Figure 1-4 Lube Oil ........................................................................... 1--5 Figure 1-5 A--C Generator Circuit Diagram..............
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SAFETYSUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual.Theyarerecommendedprecautionsthatmustbeunderstoodandappliedduringoperationandmaintenance 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 cautions appearing elsewhere in the manu
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SPECIFICWARNING ANDCAUTIONSTATEMENTS 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 CAUTION Neverpourcold waterinto ahotengine. Beware of moving poly V-belt, belt driven componentsandhotexhaustcomponents. CAUTION WARNING Use only ethylene glycol, anti-freeze (with Under no circumstances should ether or inhibi
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SECTION1 DESCRIPTION 1.1 INTRODUCTION The 69UG15 is available as a standard configuration, withanAutoRestartoptionorwithAutoRestartandLow TheCarrierTransicoldmodel69UG15under--mounted CoolantSensor.TheAutoRestartoptionautomatically diesel--driven generator sets provide electrical power restarts the unit in the event of a unit shutdown. Auto for all--electric refrigeration units. Restart also offers built--in indicators that signal lowoil pressure, high water temperature, overspeed, and The gener
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Table1-1Model Chart LEGEND A1 -- Standard Mount -- (See Figure 2-1) B4 -- Receptacle Box -- Interlock A2 -- Quick Mount -- (See Figure 2-2) C1 -- 460 Volt -- Standard B1 -- Receptacle Box -- with Circuit Breaker C2 -- 460 Volt -- with Auto--Restart B2 -- Receptacle Box -- with Circuit Breaker C3 -- 460 Volt -- Customer Specific B3 -- Receptacle Box -- Customer Specific Electrical Wiring Unit Receptacle Schematicand Model PID Control Box Mounting Box DiagramFigures UG1450 5-1, 5-2, 5-3, 5-4 A1 B1
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5 14 2 3 16 15 14 13 12 11 10 9 87 6 15 15 15 230VOLT 460VOLT 14 14 14 1. Mechanical Fuel Pump 9. Lube Oil Dipstick/Fill Cap 2. Injector Pump 10. Starter 3. Engine Speed Sensor 11. Air Cleaner 4. Poly V--Belt 12. Generator Shockmount 5. Radiator 13. Receptacle Box 6. Controls (See Figure 1-6 or Figure 1-8) 14. Receptacle 7. Engine Oil Filter 15. Circuit Breaker 8. Engine Shockmount (Typical) 16. Air Filter Indicator (if equipped) Figure1-1GeneratorSet 1--3 T-343
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1 2 3 11 4 10 5 6 9 7 8 1. Fuel Tank 7. Engine 2. Exhaust Muffler 8. Coolant Overflow Bottle 3. Solid State Battery Charger 9. Alternating Current Generator 4. Low Coolant Sensor (If Equipped) 10. AC Generator Connection Box Access 5. Water Temperature Sensor 11. Battery 6. Water Temperature Switch Figure1-2GeneratorSet -- Top View (Top FrameMembersRemoved forClarity) T-343 1--4
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1.3 ENGINE 2 1 The engine is a vertical, in--line four cylinder diesel engine, which is direct--connected to the alternating current generator. Information on the major engine systems is provided in the following subparagraphs. 1.3.1 ElectronicGovernorModule The electronic governor module is a solid state control module preprogrammed for 1800 RPM. The electronic governor module, along with the engine speedsensor, 3 replaced the manual governor in order to provide a constant engine speed. 1.3.2 E
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Therotoris,ineffect,thesecondaryofarotatingcurrent 1.6 BATTERY CHARGER transformer induction frequencyconverter. Theexciter The solid state battery charger (see Figure 1-2) is rotor output voltage is applied to the generator field locatedtotheleftoftheradiator.Thechargerispowered windings by a three--phase, full wave rotating silicon bythegenerator,andthisinputisprotectedbyacircuit rectifierunit.Theresponsetimeoftheexcitationsystem breaker located on the control panel. The battery is very fast a
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b. Meters 3. IgnitionSwitch(IGN)(AutoRestart)(seeFigure 1-8) 1. Ammeter (A) The ignition switch is of the maintainedcontact typeto be used in the RUN/OFF positions. When switched to Theammeter(seeFigure 1-6,Figure 1-7,Figure 1-8)is theRUNposition,itenergizesthecontrolmodule,which an indicator of the charging system and unit electrical in turn controls all functions of the genset. draw. It indicatestherateof dischargeorchargeof the battery. During start up, the intake heater draws 1.8 SAFETY DEVI
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CONTROL CONTROL PANEL BOX 3 2 11 10 1 4 5 12 9 6 7 8 13 1. Total Time Meter 8. Ground Studs 2. Water Temperature Gauge 9. Safety Relay 3. Oil Pressure Gauge 10. Intake Heater Relay 4. Ammeter 11. Intake Heater Timer 5. Intake Air Heater Switch 12. Circuit Breaker (CB2) 6. Ignition Switch 13. Circuit Breaker (CB3) 7. Battery Charger Fuse or Circuit Breaker (CB5) Figure1-7CustomerSpecificControl Panel and Box CONTROL CONTROL PANEL BOX 4 3 5 13 14 2 6 1 12 15 7 16 11 8 10 9 1. Total Time Meter 9. B
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Table1-2Auto Restart Preset Values Indicator Preset Value Description Overspeed 2100 RPM Overspeed is the point at which the unit will signal for shutdown Crank Disconnect is the point at which the auto restart module Crank Disconnect 700 RPM senses the engine has started and will disengage the starter Shutdown Lockout The oil pressure and water temperature inputs are ignored during 15 seconds Delay this 15 second delay (after start up) The delay is used during start up. The intake heater delay
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Table1-3Auto RestartSequencing (Continued) Intake Engine Engine Series Heater Fuel Crank Rest Attempt Energized Solenoid EngineStatus Duration Duration Number in Engaged (Seconds) (Seconds) Seconds If the engine starts: a. Run sequence begins. If the engine fails to start: a. Intake heater will de--energize. 4 30 X Up To 15 25 b. Fuel solenoid will de--energize. c. Crank output will de--energize. d. Overcrank LED will flash four times. Wait two seconds and repeat. e. Unit will rest five hours an
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Table1-4SafetyDevices UnsafeCondition SafetySwitch Switch Setting ENGINE Low oil pressure switch (LOP) -- Opens below 18 psig Low engine lubricating oil pressure 2 Automatic reset (1.27 kg/cm ) Water temperature switch (HWT) -- High engine cooling water temperature Opens at 230F (110C) Automatic reset Low coolant sensor Opens with a loss of 32 Low coolant Automatic reset ounces of coolant Excessive current draw by the safety re- Circuit breaker (CB--2) -- lay, fuel heater, water temperature gaug
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1.10 ENGINE DATA (Continued) Oil Pressure Safety 2 Switch Setting 18 psig (1.27 kg/cm ) Opens Capacity Engine -- 16.0 US quarts (15.1 liters), includes standard filter. Dipstick in oil pan or fill cap NOTE To check oil level on engines with the dipstick mounted in the fill cap, remove the cap and wipe the dipstick clean. Insert the Oil Level Indicator cap back onto the oil fill tube, then remove to check level. It is not necessary to screw the cap back into the fill tube when f. Lubrication Syst
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SECTION2 OPERATION 2.1 GENERATORSET INSTALLATION completion, remove safety chain before removing forks of fork lift truck from unit. The generator set is mounted under the center of the b. Quick Mount trailerchassisandiseasilyhandledwithaforklifttruck capableofhandling2,000pounds. Theforkliftpockets 1. Loosenmountingbolts(seeFigure 2-2)sufficientto provided are accessible from either side. Mounting bringclamptoopenposition.Toorientinopenposi- clamps are designed to be attached to outside I-beam
