3.1Generator Set Install and Remove - Pin Type with Locking Bracket
Figure 3.1 Generator Set Mounting - Pin Type with Locking Bracket
To prevent injury, the procedures provided for installation and removal of the generator set must be followed carefully.
This generator set is equipped with special pins and mounting bolts and can be installed only on containers with matching installation points.
1.Place forks into fork pockets of generator set. Attach safety chain (A) between fork pockets on generator set and fork truck. Be sure chain (A) is short enough to retain the generator set on the forks.
2.Line up generator set with refrigeration unit and container. Raise generator set until the top is several inches above the top edge of the container. Move generator set against container and lower into position. Ensure the two pins (B) are fully engaged in mating holes in container.
3.Keep forks in pockets on generator set and tighten mounting bolt (C) on each side of generator set into container frame. Torque mounting bolts to 125 + 25 ft. lbs (17.3 + 3.5 mkg). Ensure locking brackets (D) are locked into position so as to capture bolt heads (C) and prevent turning.
4.Remove safety chain (A) before removing forks.
Disconnect power plug before removing generator set.
1.Move forks into fork pockets on generator set. Attach safety chain (A) between fork pockets on generator set and fork truck.
2.Release locking brackets (D) on each side of generator set.
3.Remove mounting bolt (C) on each side of generator set and tighten into threaded hole (E).
4.Raise generator set several inches to disengage pins (B) from mating holes and remove from container.
3.2Generator Set Install and Remove - Clamp Type with Locking Bracket
Figure 3.2 Generator Set Mounting - Clamp Type with Locking Bracket
To prevent injury, the procedures provided for installation and removal of the generator set must be followed carefully.
This generator set is equipped with clamps and mounting bolts and can be installed only on containers with matching installation points for the mounting bolts.
1.Place forks into fork pockets of generator set. Attach safety chain (A) between fork pockets on generator set and fork truck. Be sure chain (A) is short enough to retain generator set on forks. Ensure that generator set clamps (B) are in the unlocked position and actuating handle (C) in the horizontal position.
2.Move generator set against container and fully engage clamps into mating holes in container castings. On both clamps, turn the actuating hand lever (C) into the vertical down position (locked). Using the ratchet handle (D), tighten the hand nut. Tightening should continue until the face of the clamp is hard against the corner casting and the actuating hand lever is moved over the locking tabs. Leave the ratchet handle (D) engaged in the tightening direction with the ratchet handle in the vertical down position.
Double-check that the generator set clamp (B) is securely tightened against the face of the corner casting and that the generator set clamp hand nut is tight before transporting the container. A loose fit could cause damage to both the generator set and the generator set clamp, and cause serious injury during transport.
3.Keeping forks in pockets on the generator set, tighten bolt (E) into container frame on each side of the generator set. Torque mounting bolts to 125 + 25 ft. lbs (17.3 + 3.5 mkg). Ensure locking brackets (F) are locked into position so as to capture bolt heads (E) and prevent turning.
4.Remove safety chain (A) before removing forks.
Disconnect power plug before removing generator set.
1.Place forks into fork pockets on generator set. Attach safety chain (A) between fork pockets on generator set and fork truck.
2.Release retaining plate from locking bracket on each side of generator set.
3.Remove mounting bolt (E) on each side of generator set and tighten into threaded hole (G).
4.Disengage clamps (B) by setting ratchet handle (D) in the loosening position. Loosen the hand nut until the actuating hand lever is clear of the locking tabs.
5.Turn actuating hand lever (C) upward into the horizontal position.
6.Carefully remove the generator set from the container.
3.3Starting and Stopping Instructions
1.Check engine lubrication and fuel filters, oil lines, and connections for leaks. If required, tighten connections and/or replace gaskets.
2.Check engine lubricating oil level. (Refer to Section 2.11, Lubrication System.)
3.Check poly V-belt for fraying or cracks and proper tension. (Refer to Section 5.5.10.)
4.Check radiator hoses for leaks and check radiator coolant level. (Refer to Section 2.11, Cooling System.)
5.Check radiator coil and generator air intake screen for cleanliness. If required, clean using compressed air, reversing the normal air flow.
6.Check air cleaner for cleanliness and clean if necessary. (Refer to Section 5.5.11).
7.Check in-line fuel strainer and clean if necessary. (Refer to Section 5.5.4)
8.Drain water from fuel filter bowl.
9.Fill fuel tank with diesel fuel. (Refer to Section 2.11, Fuel and Fuel Heater Thermostat (FHT).)
10.Check intake heater amperage. (Refer to Section 2.11, Intake Heater.)
11.Check battery terminals for cleanliness and secureness. If required, clean, then coat with a battery terminal sealant.
12.Check and if required, tighten all electrical connections.
13.Check and if required, tighten all hardware (brackets, etc.).
14.Ensure the main generator set circuit breaker (CB1) is in the OFF position. Connect power cable to refrigeration unit and proceed to Section 3.3.2.
Before start up, both the genset circuit breaker (CB1) and the refrigerated unit should be OFF. After start up, the genset unit should be run for at least two minutes to allow the power source to stabilize before supplying power to the refrigerated unit. This will eliminate the potential of any cold start transient spikes from reaching the refrigerated unit. Cold start transient spikes can potentially cause nuisance over voltage alarms on refrigerated units that are sensitive to electrical spikes or transients.
Beware of moving poly V-belt, belt driven components and hot exhaust components.
Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the intake heater.
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 condition persists, check valve clearance when engine is cold. (Refer to engine workshop manual)
Standard Units
1.Make sure that CB-1 is in the OFF position.
2.Hook up the 460 volt cable from the refrigerated unit to the Genset receptacle.
3.Hold intake heater switch (see Figure 2.6) in the PREHEAT position. Suggested hold times for a cold engine are as follows:
Ambient Temperature |
Time |
|---|---|
78°F / 26°C |
5 seconds |
32°F to 78°F (0°C to 26°C) |
10 seconds |
18°F to 32°F (-8°C to 26°C) |
20 seconds |
Below 18°F / -8°C |
30 seconds |
4.With the intake heater switch held in the PREHEAT position, place the ignition switch in the START position.
5.After the engine has started, continue to hold the intake heater switch in the PREHEAT position until the engine develops sufficient oil pressure to close the oil pressure safety switch (approximately 5 seconds). When released, the intake heater switch will automatically return to the OFF position and the heater will remain energized for 3 minutes.
Units with Auto Restart
1.Make sure that CB-1 is in the OFF position.
2.Hook up the 460 volt cable from the refrigerated unit to the Genset receptacle.
3.Place the Ignition switch (IGN) (See Figure 2.6) in the Run position.
4.The auto restart module will energize the heater for 30 seconds and the safety buzzer will sound. After the 30 second delay, the unit will attempt to start.
1.Allow the Genset unit to run for at least 2 minutes.
2.Turn on CB-1.
3.Check generator output with a volt meter, voltage output at start up with no load at 50Hz operation should be 1500 RPM, 360-460 VAC. Voltage output may vary and fall with ISO specifications based on ambient (Refer to Section 2.7).
4.Start the refrigeration unit.
5.Run engine 10 minutes and check total time meter operation.
6.Listen for abnormal bearing noise from the AC generator.
7.Check fuel lines, lube oil lines, and filters for leaks.
8.Check exhaust system for leaks.
1.Place CB-1 in the OFF position.
2.Place the ignition switch in the OFF position.
Beware of moving V-Belt and belt driven components.
Standard Units
With the intake heater switch (HS) held in the ON position, current flows through the ammeter to the intake heater. While heater is on, the ammeter will show an approximate 42-amp draw.
A second set of contacts also energizes the safety relay (S).
If the high water temperature switch (HWT) opens to break the safety relay ground connection, the safety relay will not energize, and the engine will not start, To start the engine, the ignition switch (IGN) is held in the START position. With the switch in the START position, current flows to the start solenoid (SS), through the SS contacts to the starter motor (SM). Current then flows to the intake heater timer, intake heater relay (HR) and to the heater, while simultaneously powering the electronic governor module (EG), fuel solenoid (FS), and engine speed sensor (ESS).
The starter motor turns over the engine resulting in pumping of fuel to the engine cylinders by the injection pump. This fuel is ignited by heat of compression; thus starting the engine. When the engine has developed sufficient oil pressure, the low oil pressure (LOP) switch contacts close to maintain power to the safety relay (S).
Once the engine has started and the start switch has been released, the starter motor will stop cranking and the intake heater will remain energized for 3 minutes. With the engine running, the battery charger provides DC power to operate the control system and charge the battery.
Units with Auto Restart
When the ignition switch is placed in the RUN position, 12-volt DC power is applied to the auto restart module. The auto restart module will maintain power and all lights on the module will illuminate. As the auto restart module performs its self test, the lights will go out individually.
After the self test is complete, the auto restart module will energize the intake heater and sound the audible alarm warning, indicating that the unit has been powered on and will start. The 30 second delay starts at this time. When the 30 second delay expires, power will be applied to the electronic governor and the engine attempts to crank for 15 seconds.
When the engine starts, the intake heater will remain energized for 3 minutes; during this time, the engine/intake heater light and alarm will be energized, the shutdown/lockout time delay of 15 seconds will begin counting, and the starter will be disengaged. During the shutdown/lockout time delay at start up, the auto restart module will disregard the signals to the oil pressure and engine temperature inputs, and the Run sequence will begin. If engine does not start, refer to Table 2–3 for auto restart sequencing.