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GENESIS R70/R80/R90OPERATOR’S MANUAL

4

This guide has been prepared for the operator of Carrier TransicoldGENESIS R70/R80/R90 refrigeration units. It contains basicinstructions for the daily operation of the refrigeration unit as well assafety information, trouble shooting tips, and other information thatwill help you to deliver the load in the best possible condition. Pleasetake the time to read the information contained in this booklet andrefer to it when ever you have a question about the operation of yourCarrier Transicold GENESIS R70/R80/R90 units.

Your refrigeration unit has been engineered to provide long,trouble--free performance when it is properly operated andmaintained. The checks outlined in this guide will help minimizeproblems.

Maintenance program will also help to control operating costs,increase the unit’s working life, and improve performance.

Carrier Transicold has an on--going product quality upgrade policy.As a result, specifications are liable to change without notice.

CONTENTS

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Page

UNIT IDENTIFICATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRETRIP INSPECTION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT OPERATION 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the unit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing the setpoint 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stop the unit 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation with auxiliary control panel (option) 26. . . . . . . . .Change setpoint 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lock the control panel 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unlock the control panel 28. . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT LOADING 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOMMENDED TRANSPORT TEMPERATURES 33. . . . . .

PROBLEMS 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT MAINTENANCE 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit maintenance schedules 42. . . . . . . . . . . . . . . . . . . . . . . .Description of maintenance operations 43. . . . . . . . . . . . . . .Belts 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filters 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDBY OPERATION GUIDELINES 49. . . . . . . . . . . . . . . . . .

MANUFACTURER INFORMATION 50. . . . . . . . . . . . . . . . . . . . .

“A.T.P. EUROPE” REGULATION EXTRACT 54. . . . . . . . . . . . .

EMERGENCY ROAD SERVICE 56. . . . . . . . . . . . . . . . . . . . . . . .

UNIT IDENTIFICATION

6

CONDENSER

The nameplate identifies:

: serial number: refrigerant charge and quantity: date in service

* gives you all the information when calling 24 hour Assistance.

UNIT IDENTIFICATION

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EVAPORATORS

MTS 700 model (single discharge)

MTD 2200 model (dual discharge)

SAFETY

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Your Carrier Transicold refrigeration unit has been designed with thesafety of the operator in mind. During normal operation, all movingparts are fully enclosed to help prevent injury. During all pre--tripinspections, daily inspections, and problem troubleshooting, youmay be exposed to moving parts; please stay clear of these movingparts when the unit is in operation and when the main power switchis in the Run (On) position.The evaporator and condenser are made of finned tubes. The finscan cause injury on contact with skin. It is recommended to wearprotective gloves during all handling operations.During operation, certain components such as the exhaust pipe,discharge outlet, and cooling circuit radiator can become extremelyhot. During routine service operations, wear protective gloves.

AUTO--START/STOP

Your refrigeration unit is equipped with Auto-Start/Stop, a valuablefuel saving feature. When the unit is set for Auto-Start/Stopoperation it may start at any time. When performing any check ofthe refrigeration unit (e.g., checking the belts, checking the oil),make certain that the main power switch is in the OFF (0) position.

ENGINE COOLANT

The engine, as with all diesel engines, is equipped with apressurized cooling system. Under normal operating conditions, thecoolant in the engine and radiator is under high pressure and is veryhot. Contact with hot coolant can cause severe burns. Do notremove the cap from a hot radiator; if the cap must be removed, doso very slowly in order to release the pressure without spraying.

REFRIGERANTS

The refrigerant contained in the refrigeration system of your unit cancause frostbite, severe burns, or blindness when in direct contactwith the skin or eyes. For this reason, and because of legislationregarding the handling of refrigerants during system service,whenever your unit requires service of the refrigeration system, werecommend that you contact your nearest Carrier Transicoldauthorized repair facility for service.

SAFETY

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BATTERY

This unit is equipped with a lead--acid type battery. The batterynormally vents small amounts of flammable hydrogen gas. Keepany flame, any lighted object (cigarette etc.) or any source of sparksaway from the battery elements. A battery explosion can causeserious physical harm and/or blindness.

AUTOMATIC START UP IN DIESELWHEN LOSS OF STANDBY

FROM EPROM 4.05

To activate this function: TIME STRT set up in functionnalparameters.

When the unit is started in standby, the “ROAD” light is flashingand the “STANDBY” light is lit.

After 5 minutes of loss of power, the unit automaticallystarts in diesel. 5 minutes after the power comes back, the unitstarts again automatically in electric mode. The “STANDBYMOTOR” alarm appears, alarm that you would have to clear.

* This function will be active even after a stop (OFF) of the unit.To deactivate it: set up TEMP STRT in functionnal parameters.

DEACTIVATE THIS FUNCTION WHEN UNIT ISRUNNING IN A CLOSED AREA !

FEATURES

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This refrigeration unit is equipped with a wide range of features thatare designed to improve reliability and temperature control withinthe body.

The group can be delivered fitted with a microprocessor controller.

MICROPROCESSOR CONTROLS

1. Display2. Up and down arrow keys3. Function change key4. Run/Stop switch5. Road key6. Comp. 1 ON/OFF switch7. City speed key8. Comp. 2 ON/OFF switch9. Manual defrost key

10. Comp. 3 ON/OFF switch

11. Buzzer off key

12. Standby key

13. Pretrip key

14. Auto-start/Stop key

15. Unit data key

16. Fault alarm led

17. Enter key

1.

3.

2.

17.

4.

5.

7. 9.

11.

12.

13.

14.

15.

16.

6. 8. 10.

FEATURES

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The microprocessor controls incorporated into this unit are the mostreliable control system available. It is also designed to be theeasiestto use, offering great flexibility in control, yet minimal user input fornormal operation: a true “set it and forget it” design.

1. Display window: shows set--point, box temperature, operatingmode, alarm displays, as well as data on the unit itself (batteryvoltage, water temperature etc.).

Function Change key

The function change key is used to display theoperating parameters. Each time this key is pressedthe display will advance to the next parameter. Thiskey, in conjunction with the up/down arrow and enterkeys, will allow the user to change the parameters.

Arrows key

The UP ARROW and DOWN ARROW keys areused to alter the set--point. Press the up or downarrow keys until the desired setpoint is displayed onthe left--hand side of the display window. When thecorrect set--point is displayed, press the ENTER keyto confirm the setting.The UP ARROW and DOWN ARROW keys are alsoused to change the unit functions and scroll throughthe FUNCTION and UNIT DATA screens.

Enter key

The ENTER key confirms changes made to unitoperation. It must be pressed to change the setpointafter using the arrow keys to adjust it. If the ENTERkey is not pressed, the setpoint will revert to thepreviously entered setting.The ENTER key must also be pressed whenever aFUNCTION setting is being altered. If this key is notpressed, the function will revert to its previoussetting.

FEATURES

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RUN/STOP switch

The main unit RUN/STOP switch controls the unitoperation. When switched to the Run (I) position, theunit will start in the operating mode last entered(Road or Standby). The set--point will be at the lastset--point entered on the keypad.

Road key

The ROAD key puts the unit into Road (or engine)operation when the unit has been previouslyoperated in the Standby mode.

City Speed key

The CITY SPEED key toggles the unit between highspeed and low speed (diesel mode). When CitySpeed is selected, the unit will run only in low speedexcept during defrost cycles. This feature is useful inareas where noise is restricted.

Manual defrost key

The MANUAL DEFROST key places the unit in adefrost cycle. Under most conditions it is notnecessary to defrost the unit manually as this is doneautomatically with the air switch or the defrost timer.Manual defrost may become necessary due to iceaccumulated on the evaporator coil during frequentdoor openings in humid environments.

Buzzer Off key

The BUZZER OFF key temporarily turns off theFAULT ALARM buzzer. The red light “Fault alarm”remains illuminated on the command cab.

FEATURES

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Standby key

The STANDBY key places the unit in Standby (orelectric) mode when the previous mode of operationhas been Road.

Pretrip Check key

The PRETRIP key initiates a check of all normaloperating modes. The temperature inside the boxmust be below 5ECp 1EC (35EFp 2EF) to start thischeck. Upon initiation, the unit will cycle through alloperating modes at 30 second intervals. The displaywill show “PPPP” at the beginning and will showvarious unit data during the pre--trip cycle. Uponcompletion of the pre--trip cycle the unit will beplaced into the defrost mode.

Auto Start/Stop Continuous key

The AUTO--START/STOP key toggles the unitoperating mode between Auto--Start/Stop andcontinuous run. When the unit is set forAuto--Start/Stop operation, the unit will run until thebox temperature reaches set--point and then cycleoff (after the minimum run time has been met) untilfurther cooling or heating is necessary. When in thecontinuous mode, the unit will cycle between heatand cool as required to maintain the set temperaturein the body. If the setpoint is below -12EC (10EF) theunit will not heat, it will run continuously in low speedcool.

FEATURES

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Unit Data key

iThis key scrolls the display through the variousoperating condition displays, engine temperature orbattery voltage, for example. A more completedescription of the function is found later in thischapter.

Compartment 1 ON/OFF switch

When switched to (I) the unit and compartment 1will start in the operating mode last entered(cooling or heating).





16. Fault Alarm led: illuminates when an alarm is detected.

FEATURES

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OPTION

Important: If the cab control displays nothing, check the positionof the RUN switch located on the microprocessor box.

1. Main unit operation switch (RS)Turn the switch to (1) “RUN” in order to control the unit fromthe cab control.

2. Turn the Glow and Manual start switch of the unit to“ROAD” -- diesel engine start--up (MGC) -- Optionnal.

GLOW: preheat

CRANK: start--up

1

2

i

FEATURES

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TO DISPLAY UNIT DATA

The unit data list can be scrolled through by pressing the UNITDATA key. The list will advance by one with each key press; or, pressthe UNIT DATA key once and use the UP or DOWN ARROW keysto scroll through the list more quickly. Press the ENTER key todisplay the data for 30 seconds.

UNIT DATA

CODE ENGLISH DATA

CD1 SUCT Suction pressure

CD2 ENG Engine hours

CD3 WT Engine temperature

CD4 1 RA Compartment 1 -- Return air temperature

CD6 2 DT Compartment 2 -- Defrost thermistor sensor

CD7 3 DT Compartment 3 -- Defrost thermistor sensor

CD8 1 DTS Compartment 1 -- Defrost thermistor sensor

CD9 CDT Compressor discharge temperature

CD10 BATT Battery voltage

CD11 SBY Standby hours

CD12 MOD V Future expansion

CD13 REV Software revision

CD14 SERL Serial number low

CD15 SERU Serial number upper

CD16 2RA Compartment 2 -- Return air temperature

CD17 3RA Compartment 3 -- Return air temperature

CD18 MHR1 Maintenance hour meter 1

CD19 MHR2 Maintenance hour meter 2

CD20 SON Switch on hour meter

FEATURES

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TO CHANGE A FUNCTION

1. Press the FUNCTION CHANGE key until the function youwant to change appears on the display.

2. Press ENTER.

3. Press the UP or DOWN ARROW key until the functionsetting you want appear on the display.

4. Press ENTER.

FUNCTION PARAMETERS

CODE ENGLISH AVAILABLE SELECTIONS

FN0 DEFR Defrost interval 1.5, 3, 6, or 12 hr

FN1 ON CITY SPEED Low speed only

FN1 OFF HIGH SPEED Low and High speed

FN2 OFF T Minimum off-time 10,20, 30, 45 or 90 mn

FN3 ON T On-time 4 or 7 min.

FN4 DegreesEC or EF

Temperature Unit (EC or EF)

FN5 ON TIME STRT Maximum Off-time 30 min*

Desactivate FN2

FN5 OFF TEMP STRT Minimum time 10, 20, 30, 45, 90 min

Reactivate FN2

FN6 MOP STD Future expansion

FN7 ON AUTO OP Auto start operation

FN7 OFF MAN OP Manual start operation

FN8 T RANGE Out of range (A=2EC / B= 3EC/ C=4EC)

CODES or ENGLISH Code or English display format

NORMAL GLOWOVERRIDE

Normal of add 30 seconds

ALARM CLR No alarm active

ALARM RST Alarm reset required

* From EPROM 4.05 version -- see WARNING here after

FEATURES

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AUTOMATIC START UP IN DIESELWHEN LOSS OF STANDBY

FROM EPROM 4.05

To activate this function: TIME STRT set up in functionnalparameters.

When the unit is started in standby, the “ROAD” light is flashingand the “STANDBY” light is lit.

After 5 minutes of loss of power, the unit automaticallystarts in diesel. 5 minutes after the power comes back, the unitstarts again automatically in electric mode. The “STANDBYMOTOR” alarm appears, alarm that you would have to clear.

* This function will be active even after a stop (OFF) of the unit.To deactivate it: set up TEMP STRT in functionnal parameters.

DEACTIVATE THIS FUNCTION WHEN UNIT ISRUNNING IN A CLOSED AREA !

FEATURES

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CONTROL PANEL (OPTION)

User-friendly indicator and operator control panels clearly showindividual compartment temperatures with easy-to-read displays.

These compact panels can be mounted to suit the individualoperator’s preferences.

(Example: on the front bulkhead, in the cab or in the refrigeratedcompartment -- including mounting in the truck wall itself.)

Control panel

1.Compartment ON/OFF key2.Control panel power on3.Unit ON/OFF key4.Manual defrost key5.Control panel locking6.Up and down arrow keys

7.Heating operating mode light ofa compartment

8.Cooling operating mode light ofa compartment

9.Temperature indicated in EC orEF

3. 4.

1.

6.

8.

7.

2.

9.

5.

FEATURES

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From this control panel (option) you can:

� switch on the unit;

� check compartement 1, 2 or 3 temperatures;

� change setpoints;

� energize a manual defrost.

PRETRIP INSPECTION

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The pre--trip inspection should be performed before picking up anyload. This inspection is essential to anticipate and help minimize thepossibility of “over--the--road” problems. These checks take only afew minutes.

1. Place the unit’s main switch in the STOP (0) position.

2. Fuel -- Drain any water and impurities from the sump of therefrigeration unit fuel tank by opening the drain--cock locatedon the bottom of the tank (if so equipped). Close the valvewhen only pure fuel emerges. Check the fuel level in thetank, ensuring that the fuel supply is adequate for unitoperation. Refuel if necessary.

3. Belts -- Check the belt tension by depressing the belt withyour thumb, near the center of the longest free run of eachbelt. Under moderate pressure each belt should deflectapproximately 6 mm to 13 mm (1/4 inch to 1/2 inch). If thebelts deflect more than this they should be tightened (loosebelts may slip, generating heat and reducing belt life). If thebelts are too tight they should be loosened; tight belts canreduce bearing life.

4. Battery -- On unit equipped with serviceable batteries, thelevel of the electrolyte in each of the cells should bechecked. If the level is low, distilled water should be addedto the correct level. Most units, however, are equipped withlow or no--maintenance batteries. Check batteryconnections and battery supports.

PRETRIP INSPECTION

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5. Engine Oil -- The engine oil should be checked last since itis necessary for oil to drain out of the block and into the oilpan to obtain a correct reading. Remove the plug/dip--stick(1), wipe it off and re--insert it fully into the engine block.Once again, remove the dip--stick and observe the oil level;it should be somewhere between the full and add marks. If itis below the add mark, add oil until the level is correct.

1

6. Over--all Unit inspection -- Visually inspect the entire unit forleaks, loose bolts, frayed, loose, or broken wires, etc. Theradiator and condenser coils of the unit should be free ofdirt, bugs, cardboard, or any other debris that may obstructairflow across the coils. The evaporator (located inside thebody) should be free of debris also, especially shrink--wrap,which is often used during transport to prevent cargoshifting.

7. Truck body -- The body should be inspected prior to loading.Check the door and vent seals for damage and wear.Inspect the entire interior and exterior of the body to detectany damage including in the inner and outer skins of thebody. Damage to the insulation may compromise the unit’sability to maintain the product temperature by increasing theamount of heat gain across the truck body.

UNIT OPERATION

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STARTING THE UNIT

Complete the pre-trip inspection described in the previous section.

: Road operation

1.

2.

3.

1. Place the RUN/STOP switch (O/I) to the RUN position (I).

2. Press the ROAD operation key (only if the unit has beenpreviously used in standby mode).

3. Place either one, two or three compartments OFF/ONswitches to ON (I).

4. Then, the unit will:

� perform a complete diagnostic check on themicroprocessor controller;

� pre-heat for the required amount of time based on theengine temperature;

� starts automatically.

UNIT OPERATION

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: On Standby

1.

2.

3.

Be certain that the unit is connected to anappropriate power source.

1. Place the RUN/STOP switch (O/I) to the RUN position (I).

2. Press the STANDBY operation key.

3. Place either one, two or three compartments OFF/ONswitches to ON (I).

4. Then, the unit will begin to run on electric power.

UNIT OPERATION

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CHANGING THE SETPOINT

The sequence is the same for each compartment.

2.

1. Start the unit.

2. When the setpoint box temperature is displayed, press theUP or DOWN ARROW key to change the temperature setpoint.

STOP THE UNIT

1.

2.

1. Place C1, C2 and C3 switches to the OFF position (O).

2. Place the RUN/STOP switch (O/I) to the OFF (O) position.

To shut down the unit, ALWAYS use the cab commandor the general switch (RS) located on the control box.

UNIT OPERATION

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OPERATION WITH AUXILIARY CONTROL PANEL(OPTION)

1. Start the unit as mentioned before.

2.

3.

2. Press the SYSTEM ON/OFF key. Power light will go ON.

3. Press the ON/OFF key to energize selected compartment.

4. DISPLAY

waiting for communication with unit

compartment temperature display

setpoint temperature display

evaporator status (heat or cool or null)

compartment shut-down via remotecontrol

defrost compartment

temperature sensor malfunction

UNIT OPERATION

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CHANGE SETPOINT

Setpoint change can be made from control panel or cab control.

1.

1. Press the UP or DOWN ARROW key to increase ordecrease setpoint. This is the same operation for eachcompartment.

LOCK THE CONTROL PANEL

1.

2.

1. Press the CARRIER logo 1 s.

2. The indicator comes on.

UNIT OPERATION

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UNLOCK THE CONTROL PANEL

1.

2.

1. Press the CARRIER logo for about 10 s.

2. The indicator goes off.

REMARK

It is not necessary for the compartment to be running in orderto modify or see the setpoint value and the temperature of thecompartment.

The unit can be shut down both with the cab command and thegeneral switch.

PRODUCT LOADING

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Proper air circulation in the truck body, air that can move around andthrough the load, is a critical element in maintaining product qualityduring transport. If air cannot circulate completely around the load,hot spots or top--freeze can occur.

The use of pallets is highly recommended. Pallets, when loaded soair can flow freely through the pallets to return to the evaporator,help protect the product from heat passing through the floor of thetruck. When using pallets, it is important to refrain from stackingextra boxes on the floor at the rear of the truck, because this will cutoff the airflow.

Product stacking is another important factor in protecting theproduct. Products that generate heat, fruits and vegetables forexample, should be stacked so the air can flow through the productto remove the heat; this is called “air stacking” the product. Productsthat do not create heat, meats and frozen products, should bestacked tightly in the center of the truck. All products should be keptaway from the sidewalls of the body, allowing air to flow between thebody and the load; this prevents heat filtering through the walls fromaffecting the product.

It is important to check the temperature of the product being loadedto ensure that it is at the correct temperature for transport. Therefrigeration unit is designed to maintain the temperature of theproduct at the temperature at which it was loaded; it was notdesigned to cool a warm product.

PRODUCT LOADING

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OPTIONS FOR INSULATED BODIES

- Mobile partition

The mobile partition must be placed at a minimum distance from theevaporator of 1 m for: MTS700 / MTS1100 / MTS1450 / MTS2200.

- Ducting of evaporator air outlet

Ventilation ducts must never be covered.

SOME ADVICE

Before loading

- Pre--cool the inside of the insulated body by lowering thetemperature for about 15 minutes.

- Evacuate the humidity existing inside the box by carrying out amanual defrost. This can only take place when enabled by thedefrost thermostat (box temperature lower than 3EC duringpulldown and 8EC during heating).

- Evaporator fans are protected by safety grills. In the event ofheavy duty use of the unit, ice can accumulate on the grills. It istherefore recommended to clean them regularly by means of asmall brush. The operation MUST be done when the unit has beenSHUT DOWN.

PRODUCT LOADING

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When loading

- To be carried out with the unit stopped.

- It is recommended to open doors as little as possible to avoid theintake of hot air and humidity.

- Select the temperature by means of the thermostat, according tothe transported goods.

- Check the internal temperature of the goods being loaded (usinga probe thermometer).

- Take care not to obstruct the air intakes on the evaporator sectionand the ventilation ducts.

Load spacers

Load on pallets

- Leave a free space of about:� 6 to 8 cm between load and frontwall,� 20 cm between the top of the load and the roof,� between the floor and the load (gratings, pallets).

- Do not forget to close the doors.

- Before closing the doors, check your load once more and see thatnobody is shut inside the box.

PRODUCT LOADING

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NOTE:

For stationnary utilization, we recommend to place the body in theshade.

IMPORTANT

Never leave your unit more than a month without running.

RECOMMENDED TRANSPORTTEMPERATURES

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Below are some general recommendations on product transporttemperatures and operating modes for the unit. These are includedfor reference only and should not be considered pre--emptive of theset--point required by the shipper or receiver.

More detailed information can be obtained from your CarrierTransicold dealer.

Product Set--point Range Operatingmode*

Bananas 15EC 60EF Continuous

Fresh fruits andvegetables

��EC to+6EC

��EF to+43EF

Continuous

Fresh meatsand seefood

��EC ��EF Auto--Start/Stopor continuous

Dairy Products +2EC to+6EC

+36EF to+43EF

Auto--Start/Stopor continuous

Ice --20EC 15EF to20EF

Auto--Start/Stop

Frozen fruitsand vegetables

--18EC 0EF Auto--Start/Stop

Frozen meatsand seafood

--20EC --10EF to0EF

Auto--Start/Stop

Ice cream --25EC --20EF Auto--Start/Stop

* During delivery cycles that include frequent stops and dooropenings, it is recommended that the unit always be operated in thecontinuous run mode to help insure product quality.

It is essential to shut down the compartment during the periodswhen the doors are open, in order to maintain the temperature of thecargo in the other compartments and keep the unit operatingcorrectly. To do so, the main O/I switch (O: stop/I: start) should beswitched to O).

PROBLEMS

34

Everything possible has been done to ensure that your unit is themost reliable, trouble--free equipment available on the markettoday. If, however, you run into problems, the following section maybe of assistance.

If you do not find the trouble that you have experienced listed below,please call your Carrier Transicold dealer for assistance.

General Problems

UNIT WON’T CRANK, BY THE STARTER CHECK BATTERY CONDITION.

CHECK BATTERY CONNECTIONS.

CHECK ALL FUSES.

UNIT WON’T START CHECK FUEL LEVEL.

CHECK ALL FUSES.

UNIT WON’T RUN CHECK FUEL LEVEL.

CHECK ENGINE OIL LEVEL.

CHECK ALL FUSES.

UNIT DIES CHECK BELTS.

CHECK ENGINE OIL LEVEL.

CHECK COOLANT LEVEL.

CHECK FUEL LEVEL.

CHECK ALL FUSES.

UNIT NOT COOLING PROPERLY DEFROST UNIT.

CHECK EVAPORATOR FOR AIRFLOW

RESTRICTION.

CHECK CONDENSER FOR AIRFLOW

RESTRICTION.

CHECK BODY FOR DAMAGE OR AIR

LEAKS.

PROBLEMS

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FAULT ALARM DISPLAY AND SAFETY FEATURES

Display will alternate between an alarm message and the normaldisplay whenever any of the failures listed below occur.

NOTE: Whenever the fault light is on, check display for faultmessage.

-- Reset the micro to start the unit.

-- Press FUNCTION CHANGE key.

-- Press the UP/DOWN ARROW keys until ALARM RST isdisplayed.

-- Press enter to clear alarm. Alarm CLR will now be displayed andunit will restart.

Other method to reset: move RUN/STOP switch to STOP. Unitresets and will start when RUN/STOP switch is moved to runposition.

ALARM DISPLAY °= FAULT LIGHT ON

CODE ENGLISH DESCRIPTION

AL0 ENG OIL ° Low Oil Pressure

AL1 ENG HOT ° High coolant Temperature

AL2 HI PRESS ° High Discharge Pressure

AL3 START FAIL ° Start failure

AL4 LOW BATT ° Low battery voltage

AL5 HI BATT ° High battery voltage

AL6 DEFRFAIL Defrost Override

AL7 ALT AUX (°) No Alternator Auxiliary Output

AL8 STARTER ° Starter Motor Fault

AL9 1RA SENSOR ° Return Air Sensor Compartment 1Fault


AL11 WT SENSOR Coolant temperature sensor

PROBLEMS

36

ALARM DISPLAY °= FAULT LIGHT ON

CODE ENGLISH DESCRIPTION

AL12 HIGH CDT ° High discharge temperature

AL13 CD SENSOR Discharge temperature sensor

AL14 SBY MOTOR ° Standby motor overload

AL15 FUSE BAD ° Fuse open


AL17 DISPLAY Display

AL18 SERVICE 1 Maintenance Hour meter 1

AL19 SERVICE 2 Maintenance Hour meter 2

AL20 1RA OUT ° Compartment 1 Out-of-Range



AL23 NO POWER No power supply

° = fault light ON

WARNING : AL0 (ENG OIL) could come up if alternator is badlyconnected.

PROBLEMS

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FUSES

The fuses which protect the circuits of the control system arelocated in the box on the left-hand side of the unit.

The fuses are accessed by loosening the screws that hold thecontrol panel closed.

: Old model

PROBLEMS

38

FUSE IDENTIFICATIONRep. Item AmpsF1 General 80 AF2 Controller MP 5 A

F3 Run fuse 25 AF4 Speed control solenoid 15 AF5 Hot gas valve 7.5 AF6 Fuel heater (option) 25 AF7 Compartment 1 10 AF8 Compartment 2 10 AF9 Compartment 3 10 AF11 Flashing relay 5 A

PROBLEMS

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: New model

FUSE IDENTIFICATIONRep. Item AmpsF1 General fuse 60 AF2 Controller microprocessor fuse 5 AF3 Run fuse 15 AF4 Main heat valve fuse 5 AF5 Speed control solenoid fuse 10 AF6 Unloader fuse 3 AF7 Liquid solenoid valve fuse (comp. 1) 3 A

F8 Liquid solenoid valve fuse (comp. 2) 3 AF9 Liquid solenoid valve fuse (comp. 3) 3 A

F10 Fuel pump fuse 5 AF11 Hot gas valve fuse (comp. 1) 10 AF12 Hot gas valve fuse (comp. 2) 10 AF13 Hot gas valve fuse (comp. 3) 10 A

UNIT MAINTENANCE

40

Engine oil -- the oils recommended for use in your refrigeration unitmust comply with the American Petroleum Institute’s (API) SG/CDrating. The use of any oil that does not meet this rating may affectthe warranty on the engine in the unit. The use of oil of the properweight (viscosity) is also essential. The following chart indicates theSAE Weight Rating of the oil to be used in various climates:

10 W or 10W30

20 W or 15W40

30 W or15W40

EF

EC

UNIT MAINTENANCE

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GB

The following oils are accepted for use in Europe with these units.

RECOMMENDED OILS

CARRIERAGIPANTARBP

ELF

FIATFINA

HAFA

IGOL

IMPERATORLABOMOBIL

OPALORLYPOLAROILRENAULT

TEXACOTOTALSHELL

UNIL

YACCO

CARRIER TD+15W--40

SIGMA TURBO SHPD 15W--40

GRAPHITE R 15W--40

VANELLUS C3 EXTRA 15W--40

VANELLUS FE 15W30

MULTIPERFORMANCE4D 15W--40

PERFORMANCE TROPHY 15W--40

URANIA TURBO 15W--40

KAPPA LDO 15W--40

KAPPA TD PLUS 15W--40

KAPPA EXTRA 15W--40

DETERGENTE 4DM 15W--40

STRADEX 900 ECO 15W--40

SYNTHIDEX ECO 15W--40

RALLYE TURBO 4E 15W--40

RALLYE TURBO 4E LD 15W--40

RAFF SUPER HPDO 15W--40

MEGAMAXI 15W--40

DELVAC SHC 15W--40

DELVAC 1400 SUPEROPALGET D 500 15W--40

TURBO 2002 15W--40

POLATRUCK 15W--40

KMX 2 PLUS 15W--30

KMX 2 PLUS 15W--40

MV5 “EUROPE”

URSA SUPER TD 15W--40

RUBIA TIR MAX 15W40

MYRINA TX 15W--40

MYRINA T 15W--30

SUPER ROC 3D 15W--40

TURBO DX 15W--40

SM 4D + 15W--40

The above oil equivalents are based on the recommendationscontained in the suppliers’s technical literature.

UNIT MAINTENANCE

42

UNIT MAINTENANCE SCHEDULES

For the most reliable operation and for maximum life, your unitrequires regular maintenance. This includes oil and filter changes,fuel and air filter replacement, coolant replacement, belts etc.

Genesis R70/R80 Genesis R90

Withoutbypassoil filter

Hours

Withbypassoil filter(option)

HoursRemoteoil filter

Hours

A 250 A 250 A 250

AB 1000 AB 1250 AB 1250

R i dA 1750 ABC 2250 ABC 2250

Requiredservice ABC 2500 AB 3250 AB 3250service

A 3250 ABD 4250 ABD 4250

ABD 4000 ABC 5250 ABC 5250

A 4750 AB 6250 AB 6250

ABC 5500 AB 7250 AB 7250

A 6250 ABCD 8250 ABCD 8250

AB 7000 AB 9250 AB 9250

AD 7750 AB 10250 AB 10250

In addition to the above service requirements, please adhere to thefollowing:

The engine oil should be changed at least once per year, even if theengine has not run the necessary number of hours.The coolant(anti-freeze) should be replaced after a maximum of two years.

UNIT MAINTENANCE

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GB

DESCRIPTION OF MAINTENANCE OPERATIONS

Service Operations

SERVICE A

: Drain the engine oil, replace oil filter

: Check engine cooling system

: Clean the cartridge of the dry air filter

: Check air cleaner and change air cleaner oil

: Check all bolts, screws and unit mounting bolts fortightness. Tighten as required (1st service only)

: Check all belts

: Check engine speed under load

SERVICE B

: Replace fuel filter

: Check fuel pump filter

: Replace the cartridge of the dry air filter

: Check the battery terminals and fluid level

: Check compressor oil level

: Check alternator brushes

: Check engine thermostat for proper operation

: Check defrost:

� Check timer setting and function

� Check refrigerant control valves for proper operation

� Fans stop

� Defrost ends automatically

� Water drains from evaporator: Check and adjust rocker arms

: Replace belts as necessary

SERVICE C

: Clean radiator and condenser

: Check refrigerant level

: Check and rebuild the alternator

: Clean and adjust fuel injectors (140 kg/cm2)

SERVICE D: Check all belt tension pulleys

: Change anti--freeze in diesel engine

: Check bearings in clutch(es) and electric motors

UNIT MAINTENANCE

44

BELTS

GENESIS R70

Quantity

1. Engine to compressor v-belt 2

2. Alternator v-belt 1

3. Electric motor to compressor v-belt 1

4. Engine to water pump 1

5. Electric motor to generator 1

CompressorDiesel engine

Water pump

Alternator12VDC

Electric motor

Generator

1.

3.

2.

4.5.

UNIT MAINTENANCE

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GB

GENESIS R80


Water pump

Alternator12VDC

Electric motor

Generator

Quantity






1.

3.

4.

5.

UNIT MAINTENANCE

46

GENESIS R90


Water pump

Alternator12VDC

Electric motor

Generator

Quantity






1.

3.

4.5.

UNIT MAINTENANCE

47

GB

Too little belt tension cause slippage and excessive belt wear. Toomuch tension shortens belt and bearing life. Belt deflection shouldbe equal to belt thickness.

Properly adjusted belts give long lasting and efficient service (referto maintenance schedule).

Important: During intervention on twin mounted belts, replaceIMPERATIVELY both belts and make sure they are both in thesame package.

UNIT MAINTENANCE

48

FILTERS

1. Diesel fuel filter

2. Oil filter

3. Air filter, dry type

1. 2.3.

For code numbers consult the corresponding spare parts manual.

STANDBY OPERATION GUIDELINES

49

GB

For safe, reliable operation in Standby mode, it is important toconsider the following guidelines:

- Never plug the unit in to the power source with the main switch inthe RUN position. The main switch should always be in the STOPposition when connecting the unit to the power source.

- The fusing and extension cable used for Standby operationshould conform to the following:

UnitFuse

200/240/3/50 Hz220/256/3/60 Hz

Fuse350/415/3/50 Hz380/460/3/60 Hz

Standardized extensioncable

H.07.RNF220/256/3/60 Hz 380/460/3/60 Hz

220 volts 380 volts

GenesisR70 23 A 13 A 4 x 6 mm2 4 x 6 mm2



- The unit connection cable must be fitted with a ground connection.The cable must be connected to earth.

- On the 380 V supply, it is recommended to use a differentialprotection on each plug.

- When performing service and/or maintenance procedures on arefrigeration unit, make certain that the unit is disconnected fromthe power source and that the main unit switch is turned OFF.

- Operations on the 380 V supply for the unit must only be carriedout by authorized personnel.

- Warning: changing the operation of a unit from 380 V to 220 Vimplies a change in the electrical coupling, adjustment of theoverload relay and for certain unit models, the replacement ofsome components. Please consult our technical service.

MANUFACTURER INFORMATION

50

WARRANTY

As soon as you receive your warranty card, please keep it in a safeplace.

The card will be requested for any intervention under warrantywhich needs to be performed on your equipment. Always update theservice chart which is to be found inside the front cover.

This manual refers to the standard model.

Some options may not appear in it, and in such cases you arerequested to consult our Technical Services.

Carrier Transicold constantly seeks to improve the quality of itsproducts and therefore reserve the right to modify them without priornotice.

INSTALLATION

During assembly and routine service operations, access to theunit may involve certain risks.

TAKE EVERY SAFETY MEASURE TO ACCESS THE UNIT (e.g.:standard ladders, running board with railing, safety belt etc.)

Installation of this unit requires no special knowledge ofrefrigeration. To fit the nosemount unit to the vehicle body, it isnecessary only to slide the evaporator section into the opening inthe front panel and secure using the bolts provided.

Advice

When handling, use suitable lifting gear attached to the lifting pointsprovided for this purpose on the unit.

Note: The unit should not protude out of the body.

BATTERY

Maintenance:

Never leave a unit more than a month without running. In case oflong standstill, charge the battery independently.


51

GB

Before performing any welding on the chassis, take care todisconnect the battery of the vehicle and the 12VDC and 3 phasealternator, and any other electronic system.

Never try to start the vehicle with a booster because this coulddamage the electronic components in the unit or on the vehicle.

1. Check that all mounting bolts are well tightened and suitablefor use.

2. When you drill holes in the unit or in the body of the vehicle, becareful not to pierce the refrigeration tubes or the electricalwiring.

3. When you are working next to the unit (condenser andevaporator) be careful not to cut yourself on the sharp edges.

4. When the unit is running, keep your hands away from belts andfan motors.

5. Never close the discharge valves of the compressor whenthe unit is running.

6. In case of repair, only use manometer by--pass hoses whichare in a good condition and avoid their contact with belts, pulleyand fan motor.

7. The refrigerant liquid must be handled with great care.

8. Next to a flame the refrigerant liquid gives off a phosgene gaswhich has an unpleasant smell and irritates the lungs.

9. Never heat up a closed cooling circuit with a flame, the coolingsystem must be handled with great care.

10. When liquid refrigerant is in contact with the atmosphere, itevaporates and freezes everything it makes contact with.


52

First aid in case of frost--bite:

a) Cover up the frost--bitten part.

b) Warm up quickly the frost--bitten part by dipping it into lukewarmwater (not hot).

c) In case you do not have water wrap the wounded place in a cleancloth.

d) If refrigerant fluid has been splashed into your eyes, rinse themimmediately with clean water; as a precaution, you arerecommended to have a medical examination as well.

11. Cooling oil

Synthetic or derived from fuel

- Avoid contact with skin.

- Wash carefully after handling.

REMARKS ABOUT SAFETY:

Diesel engine

NEVER START THE ENGINE IN A CLOSED ROOM, THEEXHAUST GAS IS POISONOUS.

It is colourless and adourless and created by incompletecombustion of hydrocarbons.

Exhaust gas is poisonous; breathing it in induces drowsiness andmay lead to loss of consciousness.

The following symptons indicate an exhaust gas inhalation:

- Blackout

- Intense headache

- Sudden weakness and sleepiness

- Vomiting

- Muscular contractions

- Beating temples


53

GB

If you feel one of the above mentioned symptoms, go out andbreathe fresh air.

The maintenance operation should be done at the recommendedintervals on your equipment. Check the exhaust gas system toavoid gas inhalation.

If you notice a noise or modification of the exhaust system stopimmediately the engine and call sales service center for checkingand repair.

Standby and start/stop:

The unit will start automatically, keep away from belts, pulleys andfans.

“A.T.P. EUROPE” REGULATION EXTRACT

54

(Date: March 1974)

Approval of vehicles intended for the carriage of perishable goods.

Before putting a refrigerated vehicle into service, it is necessary tohave it approved by the Regional Health Department.

CHARACTERISTICS OF VEHICLES USED FOR CARRYINGPERISHABLE GOODS; REFRIGERATION UNIT.

The refrigeration unit is an insulated unit with a cooling systemwhich makes it possible, with a mean outside temperature of+30EC, to lower the temperature inside the empty body and tomaintain this low temperature in the following way:

CLASS A

Refrigeration unit furnished with a cooling system whereby atemperature between +12EC and 0EC inclusive can be chosen.

CLASS B

Refrigeration unit furnished with a cooling system whereby atemperature between +12EC and --10EC inclusive can be chosen.

CLASS C

Refrigeration unit furnished with a cooling system whereby atemperature between +12EC and --20EC inclusive can be chosen.

The cooling capacity of a unit is determined by a test carried out inone of the approved testing stations and ratified by an official report.

Note: The “K“ factor of bodies intended to be classified as C mustbe equal to or lower than 0.4 W/m2 EC.

“A.T.P. EUROPE” REGULATION EXTRACT

55

GB

SIGNS, IDENTIFICATION MARKS AND PLATES TO BEATTACHED TO REFRIGERATION UNITS

Refrigeration Plate

This reference must be followed by identification marks accordingto the following list:

Standard refrigeration unit Class A FNA

Reinforced refrigeration unit Class A FRA

Reinforced refrigeration unit Class B FRB

Reinforced refrigeration unit Class C FRC

In addition to the above identification marks, the date (month andyear) of expiry of the approval certificate must be indicated.

Example:

FRC

6--2000

(6 = month (June) 2000 = year)

Very important

Regularly check the expiry date of the approval certificate. Duringtransport, the approval certificate or provisional certificate should beshown on request of qualified agents. To have an insulated unitapproved as a refrigeration unit, an application to modify theapproval certificate should be sent to the regional health office.

EMERGENCY ROAD SERVICE

56

At Carrier Transicold we’re working hard to give you completeservice when and where you need it. That implies a worldwidenetwork of dealers and available an emergency service. Theseservice centers are manned by factory--trained service personneland backed by extensive parts inventories that will assure you ofprompt repair.

Should you encounter a unit problem with your refrigeration unitduring transit, follow your company’s emergency procedure orcontact the nearest Carrier Transicold service center. Consult thedirectory to locate the service center nearest you. This directorymay be obtained from your Carrier Transicold dealer.

If you are unable to reach a service center, call Carrier Transicold’s24 Hour Assistance:

In Europe, please use the following free phone numbers from:

A AUSTRIA 0800 291039B BELGIUM 0800 99310

CH SWITZERLAND 0800 838839D GERMANY 0800 1808180

DK DENMARK 808 81832E SPAIN 900 993213F FRANCE 0800 913148

FIN FINLAND 0800 113221GB GREAT BRITAIN 0800 9179067GR GREECE 00800 3222523H HUNGARY 00800 13526I ITALY 800 791033

IRL IRELAND 1800 553286L LUXEMBURG 0800 3581

RUS RUSSIA 810 800 200 31032N NORWAY 800 11435NL THE NETHERLANDS 0800 0224894P PORTUGAL 8008 32283PL POLAND 00800 3211238S SWEDEN 020 790470

EMERGENCY ROAD SERVICE

57

GB

From other countries: +32 9 255 67 89

Direct: +32 9 255 67 89

In Canada or United States, call 1 -- 800 -- 448 -- 1661.

When calling, please have the following information ready forfastest service:

- Your name, the name of your company, and your location.

- A telephone number where you can be called back.

- Refrigeration unit model number and serial number.

- Box temperature, set--point and product.

- Brief description of the problem you are having, and what youhave already done to correct the problem.

We will do everything we can to get your problem taken care of andget you back on the road.

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