Carrier TRANSICOLD PowerLINE Series Operation manual

Diesel Generator Set
OPERATIONS AND SERVICE
MANUAL
For
69UG15
PowerLINE® Series 55 Generator Set Units
PID UG5500 to 5599
EU Stage V Compliant
T-375

OPERATIONS AND SERVICE
MANUAL
For
69UG15
PowerLINE® Series 55 Generator Set Units
PID UG5500 to 5599
EU Stage V Compliant
© Carrier Corporation, 2021 Printed in U. S. A. March 2021

i T-375
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.3.1 Voltage Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4.1 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.2 Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.3 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.4.4 Engine Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.4.5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.5 BATTERY AND BATTERY CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6 CONTROL PANEL AND CONTROL BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.1 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.2 Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.3 Total Time Meter (TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.4 Ammeter (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.5 Intake Heater Switch (HS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.6 Ignition Switch (IGN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.7 Intake Heater Timer (IHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6.8 Starter Solenoid Timer (SST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.7 RECEPTACLE BOX COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
2.8 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
2.9 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1 GENERATOR SET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2 GENERATOR SET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.3 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3.1 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3.2 Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3.3 Post-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.3.4 Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.4 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

T-375 ii
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.2 BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.3 ALTERNATING CURRENT (AC) GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.4 ELECTRONIC GOVERNOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.5 VOLTAGE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.6 HIGH VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
SERVICE AND PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.2 PREVENTATIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.3 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.4 ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.4.1 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.4.2 Servicing Fuel Pump Internal Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.4.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.4 In-Line Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.6 Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.7 Servicing Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4.8 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.4.9 Replacing the Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.4.10 Servicing Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.4.11 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.4.12 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.4.13 Intake Heater Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.4.14 Intake Heater Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.4.15 Intake Heater Switch (HS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
5.5 SERVICING THE AC GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
5.5.1 Remove and Replace Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
5.6 GENERAL GENERATOR SET MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.6.1 Maintenance of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.6.2 Check and Replace Isolators / Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
5.7 UNIDRIVE TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX–1

iii T-375
LIST OF ILLUSTRATIONS
FIGURE NUMBER Page
Figure 2.1 Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Figure 2.2 Generator Set Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Figure 2.3 Generator Set Components - Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Figure 2.4 Generator and Engine - Unidrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
Figure 2.5 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Figure 2.6 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Figure 2.7 Electronic Governor Module (EG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Figure 2.8 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Figure 2.9 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Figure 2.10 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
Figure 2.11 Control Panel and Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Figure 2.12 Receptacle Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
Figure 3.1 Generator Set Mounting - Standard Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Figure 5.1 Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Figure 5.2 Air Cleaner, Dry Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Figure 5.3 Air Cleaner, Oil Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
Figure 5.4 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Figure 5.5 Intake Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Figure 5.6 Generator Shaft Keyway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
Figure 5.7 Generator Coupler Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
Figure 5.8 Generator Alignment Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
Figure 5.9 Generator Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
Figure 5.10 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
Figure 5.11 Generator Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15
Figure 5.12 Engine Shockmounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Figure 5.13 Truss and Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Figure 5.14 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17
Figure 6.1 Schematic Legend for 12VDC Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Figure 6.2 Schematic for 12 VDC Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Figure 6.3 Schematic High Voltage Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

T-375 iv
LIST OF TABLES
TABLE NUMBER Page
Table 2–1 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Table 2–2 Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
Table 2–3 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
Table 2–4 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
Table 3–1 Cold Engine Preheat Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
Table 4–7 Battery Charger (Solid State) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Table 4–8 Alternating Current Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
Table 4–9 Electronic Governor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Table 4–10 Voltage Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Table 5–1 Preventative Maintenance Actions and Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

1–1 T-375
SECTION 1
SAFETY SUMMARY
1.1 General Safety Notices
Installation and servicing of Genset equipment can be hazardous due to system belts, radiator fan, and electrical
components. Only trained and qualified service personnel should install, repair, or service Genset equipment.
When working on Genset 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 man-
ual. 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.
Wear appropriate personal protective equipment for the work being undertaken.
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 recom-
mended precautions must be understood and applied during operation and maintenance of the equipment covered
herein.

T-375 1–2
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.
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.
CAUTION
!
Never open the radiator cap when the coolant is hot.

1–3 T-375
CAUTION
!
Always cover the engine inlet tube while the air cleaner is being serviced.
CAUTION
!
Do not underfill or overfill the oil bath cups. Overfilling of cups causes loss of capacity; under-
filling cups causes lack of filtering efficiency.
CAUTION
!
Continued operation with failed shockmounts may result in engine or generator damage.

2–1 T-375
SECTION 2
DESCRIPTION
2.1 Introduction
The Carrier Transicold model 69UG15 diesel-driven generator set (see Figure 2.1) provides a constant electrical
power supply for all-electric refrigeration units. The 69UG15 is an under-mounted unit secured to the frame rails of
the container trailer chassis.
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 a windowed control box door.
Figure 2.1 Generator Set
1) Standard Mounts
2) Power Cord Receptacle Cover
3) Unit Nameplate
4) Access Door
5) Control Panel / Control Box
6) Fuel Tank
- - - - -
1
6
34
2
5

T-375 2–2
2.2 Configuration Identification
Generator set identification information is provided on a unit nameplate located next to the access service door
(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.
Figure 2.2 Generator Set Components
1) Fuel Tank
2) Battery
3) Battery Charger
4) AC Generator
5) Engine
6) Exhaust Muffler
7) Engine Air Cleaner
8) Fuel Filter / Water Separator
9) Oil Filter
10) Receptacle Box
11) Control Panel and Control Box
- - - - -
4
1
3
2
5
6
7
8
9
10
11

2–3 T-375
Figure 2.3 Generator Set Components - Top View
1) Fuel Tank
2) Battery
3) Battery Charger
4) AC Generator
5) Engine
6) Exhaust Muffler
7) Air Cleaner
8) Fuel Filter / Water Separator
9) Oil Filter
10) Receptacle Box
11) Control Panel and Control Box
12) Radiator
- - - - -
1
2
3
4
5
6
789
10
11
12

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 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
60 Hz 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 is used to regulate
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 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
4
3
5
2
6

2–5 T-375
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.
Fuel exits the lift pump and is pushed into the fuel filter / water separator to remove water and finer particles. 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 also contains a 12-volt fuel heater to heat the fuel. Low pressure fuel then enters the injection
pump, where it is compressed to higher pressures and distributed to individual fuel lines that supply an injector
nozzle for each cylinder. The injector nozzles spray atomized fuel into the combustion chamber based on the tim-
ing of the injector pump. Any excess fuel in the nozzles not used for combustion is sent back to the fuel tank.
Figure 2.5 Engine Fuel System
1) Fuel Tank
2) In-Line Fuel Strainer (option)
3) Mechanical Lift Pump
4) Fuel Filter / Water Separator
5) Injection Pump
6) Injector Nozzles (4)
7) Manual Fuel Bleed Valve
- - - - -
Fuel Tank Supply / Return
6
234
5
7
1
3
2
47
5
6
Fuel Tank Supply / Return

T-375 2–6
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 50 and 65 gallon capacity, with 50 gallon standard.
Figure 2.6 Fuel Tank
1) Cap
2) Gauge
3) Vent
4) Fuel Lines
- - - - -
2.4.2 Electronic Governor
The electronic governor controls the speed of the engine by using an Electronic Governor Module (EG), Fuel
Solenoid (FS) and an Engine Speed Sensor (ESS).
The EG (see Figure 2.7) is a solid state control module pre-programmed for 1800 RPM high speed and 1500 RPM
low speed operation. The EG receives an input signal from the ESS of the current RPM and compares this to a
preset value. The EG sends a correction signal to the FS to maintain the proper RPMs.
The EG is mounted in the control box and has an LED which may assist in diagnosing failures within the electronic
speed control system. See Section 4.4 for additional troubleshooting information.
Figure 2.7 Electronic Governor Module (EG)
1
2 3
4
LED

2–7 T-375
2.4.3 Engine Lubrication System
The engine lubrication system (see Figure 2.8) keeps the engine running smoothly, providing a supply of lubricat-
ing 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 located on the con-
trol 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
- - - - -
3
1
2
4
3
1
2

T-375 2–8
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
is designed to effectively remove contaminants from the air stream, resulting in prolonged engine life and reduced
wear on all engine operating 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.
Air exits the air cleaner and then enters the air intake heater (IH), which heats the air before it enters the engine cyl-
inder. This is done to help engine starting in cold temperatures.
Figure 2.9 Engine Air Cleaner
1) Air Cleaner, Dry Element
2) Air Cleaner, Oil Bath
3) Air Filter Indicator
4) Air Inlet Hose
5) Air Intake Heater (IH)
- - - - -
4
5
1
3
2
4
5Oil Bath
Dry Element
35