Carrier TRANSICOLD PowerLINE 69RG15 Series Operation manual

Diesel Generator Set
OPERATIONS AND SERVICE
MANUAL
For
69RG15
PowerLINE® Series 22 Generator Set Units
PID RG2200 to 2299
Tier 4 Compliant
T-376

OPERATIONS AND SERVICE
MANUAL
For
69RG15
PowerLINE® Series 22 Generator Set Units
PID RG2200 to 2299 Tier 4 Compliant
© Carrier Corporation, 2023 Printed in U. S. A. January 2023

i T-376
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 SPECIFIC HAZARD STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.2 CONFIGURATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.3 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.3.1 Voltage Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.4.1 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4.2 Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.3 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.4 Engine Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.4.5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.5 BATTERY AND BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6 CONTROL PANEL AND CONTROL BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.1 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.2 Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.3 Total Time Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.4 Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.5 Intake Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.6 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.7 Intake Heater Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.6.8 Starter Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.7 RECEPTACLE BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.8 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.9 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.1 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.2 Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.3 Post-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.4 Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.2 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1.3 Engine Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

T-376 ii
5.1.4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5.1.5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5.1.6 Miscellaneous Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.2 BATTERY CHARGER (SOLID STATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.3 ALTERNATING CURRENT GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4 ELECTRONIC GOVERNOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.5 VOLTAGE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.6 HIGH VOLTAGE CIRCUIT, ELECTRICAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5–6
SERVICE AND PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.2 PREVENTATIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.3 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.4 ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.4.1 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.4.2 Servicing the Fuel Pump Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.4.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.4.4 In-Line Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.4.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.4.6 Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.4.7 Servicing Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.4.8 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.4.9 Replacing the Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.4.10 Servicing the Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.4.11 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
6.4.12 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.4.13 Intake Heater Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.4.14 Intake Heater Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.4.15 Intake Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.5 SERVICING THE AC GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.5.1 Remove and Replace Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.6 GENERAL GENERATOR SET MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.6.1 Maintenance of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.6.2 Checking and Replacing Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.7 UNIDRIVE TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
SCHEMATICS PAGE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
SCHEMATICS PAGE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX–1

iii T-376
List of Figures
FIGURE NUMBER Page
Figure 2.1 Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Figure 2.2 Generator Set Components - Covers Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Figure 2.3 Unit Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Figure 2.4 Generator and Engine - Unidrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Figure 2.5 Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
Figure 2.6 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Figure 2.7 Electronic Governor Module (EG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Figure 2.8 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Figure 2.9 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Figure 2.10 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Figure 2.11 Control Panel and Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
Figure 2.12 Receptacle Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Figure 3.1 Generator Set Mounting - Pin Type with Locking Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Figure 6.1 Battery Cable Routing - Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Figure 6.2 Air Cleaner, Dry Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Figure 6.3 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Figure 6.4 Intake Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Figure 6.5 Generator Shaft Keyway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Figure 6.6 Generator Coupler Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Figure 6.7 Generator Alignment Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Figure 6.8 Generator Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Figure 6.9 Generator Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
Figure 6.10 Engine Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Figure 6.11 Truss and Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Figure 6.12 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
Figure 7.1 Schematic Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Figure 7.2 Schematic 12VDC Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Figure 7.3 Schematic High Voltage Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

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List of Tables
TABLE NUMBER Page
Table 2–1 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
Table 2–2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Table 2–3 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Table 2–4 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Table 4–1 Cold Engine Preheat Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Table 6–1 Preventative Maintenance Actions and Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

1–1 T-376
Section 1
Safety Summary
1.1 General Safety Notices
Installation and servicing of generator set equipment can be hazardous due to system belts, radiator fan, and
electrical components. Only trained and qualified service personnel should install, repair, or service generator set
equipment. When working on generator set equipment, observe all potential Danger, Warning and Caution
hazards, including those shown below and on hazard labels attached to the unit.
The following general safety notices supplement specific warnings and cautions appearing elsewhere in this
manual. They are recommended precautions that must be understood and applied during operation and
maintenance 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 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
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 CO2 (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 Specific Hazard Statements
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.
The statements that follow are applicable to the generator set and appear elsewhere in this manual. These
recommended precautions must be understood and applied during operation and maintenance of the equipment
covered herein.

T-376 1–2
WARNING
!
To prevent injury, the procedures provided for installation and removal of the generator set
must be followed carefully.
WARNING
!
Disconnect the power plug before removing the 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
conjunction with the air intake heater.
WARNING
!
Beware of pinch points.
WARNING
!
Do not use gasoline to clean air cleaner parts.
CAUTION
!
Observe proper polarity when installing the battery or connecting a battery charger. The
negative 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 terminal 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
damage the cooling system.
CAUTION
!
Always cover the engine inlet tube while the air cleaner is being serviced.

1–3 T-376
CAUTION
!
When reassembling the air cleaner, make sure the clamp bolt faces out, away from the fuel filter. If
the clamp bolt is assembled facing in, it can contact the fuel filter and cause excessive wear.
CAUTION
!
Continued operation with failed shockmounts may result in engine or generator damage. When
a shockmount has been cut, split, abraded or has flared due to normal deterioration, it must be
replaced. Damage to the mounts may not be visible when installed and under load from the
component. To correctly inspect shockmounts, they must be removed.
NOTICE
This generator set is equipped with special pins and mounting bolts and can be installed only
on containers with matching installation points.
NOTICE
Piston rings in engines that have operated less than 100 hours may not be fully seated. This may
lead to the possibility of oil seepage from the exhaust pipe. To properly seat the rings, operate
the engine under full load for a period of 24 hours. If the condition persists, check valve
clearance when the engine is cold. (Refer to engine workshop manual listed in Section 2.4).
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.
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 torsional dampener and flywheel 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.

T-376 1–4
NOTICE
Inspect the generator torsional dampener, bolt, and key as they are removed from the old generator
and installed onto the new generator. Replace any components that are worn or damaged.
NOTICE
Align the torsional dampener and aluminum housing by rotating either one to seat correctly.
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 6.12.

2–1 T-376
Section 2
Description
2.1 Introduction
The Carrier Transicold model 69RG15 Series 22 diesel-driven generator set provides a constant electrical power
supply for all-electric refrigeration units. The 69RG15 is a a clip-on unit (see Figure 2.1, Figure 2.2) mounted to the
front of the container either by pin mounts located on the top channel or by optional clamp mounts located on either
side of the generator set.
The generator set 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 manufactured by Kubota. The
generator is a 15 kW, permanent, single winding, dual bearing type that supplies nominal 50/60Hz power.
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
and control box door.
Figure 2.1 Generator Set
1) Clamp Mounts (Optional)
2) Pin Mounts
3) Unit Nameplate (Model, Serial, PID)
4) Fuel Cap
5) Access Door
6) Control Box / Control Panel
7) Fuel Gauge
- - - - -
1
2
4
6
7
5
2
1
3
4

T-376 2–2
Figure 2.2 Generator Set Components - Covers Removed
1) AC Generator
2) Receptacle Box
3) Battery Charger
4) Voltage Controller
5) Engine
6) Exhaust Muffler
7) Battery
8) Radiator
9) Oil Filter
10) Coolant Recovery Bottle
11) Fuel Tank
12) Fuel Filter / Water Separator
13) Engine Air Cleaner
14) Control Panel and Control Box
- - - - -
2.2 Configuration Identification
Generator set identification information is provided on a unit nameplate located on the side of the unit. 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.
Figure 2.3 Unit Nameplate
1
3
4
2
56
7
8
9
10
11
12
13
14

2–3 T-376
2.3 Alternating Current Generator
The alternating current (AC) generator (see Figure 2.4) bolts directly to the engine and supplies nominal 50/60Hz
power depending on the load requirement.
Generator sets will start at 50Hz. Once the unit is running, the voltage controller (see Section 2.3.1) 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, causing the generator set to adjust speed based on power
demand and ambient conditions. The unit will typically run at 50Hz and vary generator output via winding selection.
The speed change to 60Hz will typically occur when the ambient temperature is high and the unit is heavily loaded.
2.3.1 Voltage Controller
The voltage controller (VC) maintains ISO voltage via two-speed and single winding control. It regulates voltage in
order to keep the generator output within ISO limits (see Table 2–3). The voltage controller and voltage controller
fuses (VCF1 and VCF2) are located in the receptacle box (see Figure 2.12).
2.4 Engine
The engine (see Figure 2.4) is a vertical, in-line four cylinder diesel engine, model V2203-DI, that is directly
connected to the AC generator. The diesel engine takes air, compresses it and then injects fuel into the
compressed air. The heat of the compressed air ignites the fuel spontaneously.
Separately bound manuals covering the diesel engine are available:
•62-10865, V2203-DI Engine Workshop
•62-11695, V2203-DI Engine Parts List
Figure 2.4 Generator and Engine - Unidrive Assembly
1) Generator
2) Generator Shockmount
3) Engine
4) Engine Shockmount
5) Starter
6) Poly V-Belt
- - - - -
1
2
3
4
5
6

T-376 2–4
2.4.1 Engine Fuel System
The engine fuel system (see Figure 2.5) is a closed circuit that injects a precise amount of atomized fuel into the
engine cylinders. A mechanical lift pump initially transfers fuel at low pressure from the fuel tank and through the
fuel shutoff valve. An optional in-line fuel strainer can be used prior to the fuel filter / water separator to trap large
particles. The fuel filter / water separator removes water and finer particles and includes a 12-volt baldwin fuel
heater. Low pressure fuel then enters the injection pump, where it is compressed to higher pressures and
distributed to individual fuel lines that supply each cylinder’s injector nozzle. The nozzles spray atomized fuel into
the combustion chamber based on the timing of the injector pump. Any excess fuel in the nozzles not used for
combustion is sent back to the fuel tank.
Figure 2.5 Fuel System Diagram
1) Fuel Tank
2) Fuel Tank Supply with Shutoff Valve
3) In-Line Fuel Strainer (option)
4) Mechanical Lift Pump
5) Fuel Filter / Water Separator
6) Injection Pump
7) Injector Nozzles (4)
8) Manual Fuel Bleed Valve
9) Fuel Tank Return
- - - - -
12
4
8
9
3
5
6
7
1
2
3
4
6
8
5
7
9

2–5 T-376
The engine requires all air to be removed the system in order to run at optimal performance. The fuel system
contains a fuel pump primer on the mechanical lift pump and an air bleed screw after the injection pump, if bleeding
air from the system is required.
The engine fuel tank (see Figure 2.6) is available in 120 gallon capacity.
Figure 2.6 Fuel Tank
2.4.2 Electronic Governor
The electronic governor controls the speed of the engine by using an electronic governor (EG) module, fuel
solenoid (FS) and engine speed sensor (ESS).
The electronic governor (EG) module (see Figure 2.7) is a solid state control module pre-programmed for 1800
RPM high speed operation and 1500 RPM low speed operation. It receives an input signal from the engine speed
sensor (ESS) of the current RPM and compares this to a preset value. The electronic governor (EG) module sends
a correction signal to the fuel solenoid (FS) to maintain the proper RPMs.
The electronic governor (EG) module is mounted in the control box and has an LED which may assist in
diagnosing failures within the electronic speed control system. See Section 5.4 for additional troubleshooting
information.
Figure 2.7 Electronic Governor Module (EG)
p
LED

T-376 2–6
2.4.3 Engine Lubrication System
The engine lubrication system (see Figure 2.8) supplies lubricating oil to the various moving parts in the engine.
The main function is to enable the formation of a film of oil between moving parts, to reduce friction and wear.
The engine lubricating oil filter is mounted in a horizontal arrangement. The Oil Pressure Sender (OPS), located at
the oil filter housing, senses lube oil pressure and transmits a signal to the Oil Pressure Gauge (OPG) located on
the control panel (see Figure 2.11). The Low Oil Pressure (LOP) switch opens when engine lubricating oil pressure
is observed below 1.27 kg/cm.
Figure 2.8 Engine Lubrication System
1) Oil Filter
2) Oil Pressure Sender (OPS)
3) Low Oil Pressure (LOP) Switch
4) Oil Dipstick / Fill Cap
- - - - -
1
2
3
4
4
2
3
1

2–7 T-376
2.4.4 Engine Air Cleaner System
The engine air cleaner system (see Figure 2.9) utilizes a filter element to filter the engine intake air. The air cleaner
effectively removes contaminants from the air stream, resulting in prolonged engine life and reduced wear on all
operating engine parts. When a dry element air filter is utilized, an air filter indicator is mounted on the air filter body
to indicate when the filter element needs to be replaced.
As air exits the air cleaner, it passes through the air intake heater (IH) and then enters the engine cylinder. This is
done to help the engine start in cold temperatures.
Figure 2.9 Engine Air Cleaner
1) Air Cleaner, Dry Element
2) Air Filter Indicator
3) Air Inlet Hose
4) Air Intake Heater
- - - - -
1
2
34
24

T-376 2–8
2.4.5 Engine Cooling System
The engine cooling system (see Figure 2.10) uses extended life coolant and a radiator to keep the engine from
overheating. The radiator transfers the heat from the engine coolant to the surrounding air. The water pump and
the radiator cooling fan are belt-driven from the engine crankshaft. The High Water Temperature Switch (HWT) and
Water Temperature Sender (WTS) monitor and regulate cooling water temperature.
Figure 2.10 Engine Cooling System
1) Radiator assembly
2) Radiator fill cap
3) Coolant recovery bottle
4) High Water Temperature Switch (HWT)
5) Water Temperature Sender (WTS)
- - - - -
3
4
3
1
5
5
4

2–9 T-376
2.5 Battery and Battery Charging System
The battery provides 12 VDC power to the starter motor. It also provides the initial voltage for the intake heater (IH)
until the unit starts. The solid state 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. See Figure 2.2 for location of components.
2.6 Control Panel and Control Box Components
The control panel and control box (see Figure 2.11) contain components required for monitoring and controlling the
generator set unit.
2.6.1 Water Temperature Gauge
The water temperature gauge (WTG) observes water operating temperature. Once the unit has achieved normal
running temperature, the coolant temperature is between 82 - 96°C. The high water temperature (HWT) switch
senses engine water temperature and transmits a signal to the water temperature gauge (WTG).
2.6.2 Oil Pressure Gauge
The oil pressure gauge (OPG) observes normal operating engine oil pressure. Normal oil pressure is 3.3 to 5.2 kg/
cm2. The oil pressure sender (OPS) (see Figure 2.8), located at the oil filter housing, senses lube oil pressure and
transmits a signal to the oil pressure gauge (OPG).
2.6.3 Total Time Meter
The total time meter (TT) calculates the total hours the unit has been running, which provides an accurate readout
of accumulated engine running time. This data can be used to establish proper maintenance schedules (refer to
Table 6–1).
2.6.4 Ammeter
The ammeter (A) indicates the rate of charge or discharge of the battery charging system. The battery charging
system is composed of the battery and the battery charger, either solid state or alternator. During start up, the
intake heater (IH) draws approximately 42 amps.
2.6.5 Intake Heater Switch
The intake heater switch (HS) is a momentary switch. When held in the PREHEAT position, the switch allows
approximately 42 amps of battery current to flow into the intake heater, which 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.
2.6.6 Ignition Switch
The ignition switch (IGN) is a momentary switch that has 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.
2.6.7 Intake Heater Timer
The intake heater timer (IHT) continues to supply power to the intake heater (IH) for 3 minutes after initial start-up.
2.6.8 Starter Solenoid Timer
The starter solenoid timer (SST) 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-376 2–10
Figure 2.11 Control Panel and Control Box
1) Water Temperature Gauge (WTG)
2) Oil Pressure Gauge (OPG)
3) Total Time Meter (TT)
4) Ammeter (A)
5) Intake Heater Switch (HS)
6) Ignition Switch (IGN)
7) Starter Solenoid Relay (SSR)
8) Safety Relay (S)
9) Intake Heater Relay (HR)
10) Circuit Breaker (CB2)
11) Circuit Breaker (CB3)
12) Circuit Breaker (CB4)
13) Starter Solenoid Timer (SST)
14) Intake Heater Timer (IHT)
15) Ground Studs
16) Electronic Governor Module (EG)
- - - - -
3
2
4
5
15
10
12
7
9
8
11
16
Mounted to
back of box
1
Control Panel Control Box
13
14
6