Morse GCRS-40-40 T4F Bedienungsanleitung

311822

1/13/20 DJH

http://www.morseindustrial.ca

P M

GCRS-40-40 T4F

Generator/Compressor

40 KW/40 CFM

This manual must be read carefully before using your MORSE Industrial Equipment GCRS-40-40 T4F.

Store in a safe and convenient location for future reference.

PHONE: 647-393-1212

311822

Engine Radiator ............................................24

Recommended Spare Parts...........................25

Replacement Parts.........................................26

Compressor Replacement Parts ....................27

Troubleshooting ................................28

Overview .......................................................28

Machine Will Not Crank..................................28

Machine Cranks But Will Not Start.................28

Machine Shuts Down With Air Demand

Present...........................................................28

Machine Will Not Build Pressure....................28

With No Demand, Machine Builds Excessive

Pressure ........................................................28

Insuﬃcient Air Delivery...................................28

Engine Fan.....................................................29

Radiator Pressure Cap..................................29

Unplanned Shutdown.....................................29

Improper Discharge Pressure .......................29

Engine Overheating ......................................29

Compressor....................................................29

Insuﬃcient Air Delivery ..................................30

High Compressor Discharge Temp................30

Separator Plugging .......................................30

Generator Troubleshooting..............31

Generator Not Working .................................31

Generator Shuts Down..................................31

Generator Overheats ....................................31

Generator Blowing Fuses..............................31

Generator Has Low Voltage at No Load........31

Generator Has High Voltage at No Load.......31

Generator Is Noisy ........................................32

Generator Has Low Voltage at Full Load ......32

Generator Unstable Voltage..........................32

Generator Has Dirty Windings ......................32

Generator - Improper Speed..........................32

Warranties..........................................33

Welcome

............................................................4

General information................................................4

Safety

...................................................................5

Safety Precautions .................................................5

Safety Rules...........................................................6

Installation ...............................................7

General Description ...............................10

Hazards and Warnings ...........................11

Electrical Shock Hazards .....................................11

Fire Hazards.........................................................11

Explosion Hazards ..............................................11

Warnings ..............................................................11

Operation.................................................12

Initial Startup Preparation ...................................12

Pre-Start-up Inspection Checks ...........................12

Operation Procedure...........................................12

Shutdown Procedure ..........................................12

Operating Conditions ...........................................12

Display Panel ..........................................13

Speciﬁcations .........................................16

Compressor Lubrication and

Maintenance............................................18

Draining Water From Compressor Oil.................19

Lubrication Recommendations............................19

Application Guide................................................20

Compressor Oil Level .........................................20

Maintenance...........................................21

Compressor Oil Sump Fill, Level, Drain ..............22

Air/Oil Coalescer .................................................22

Oil Filter ..............................................................23

Belt Tensioning Procedure ..................................23

Belt Replacement Procedure ..............................23

Engine Cooling System........................................24

Engine Coolant.....................................................24

Coolant Level .......................................................24

Table of Contents

311822

RADIATOR

DOC WITH MUFFLER

COMPRESSOR

CONTROL PANEL

BATTERY

GENERATOR

ENGINE

Welcome

General Information

Thank you for choosing the Morse Industrial

Equipment GCRS-40-40 T4F Generator/Air

Compressor package. Before operating, carefully

read this manual and become well acquainted with

your new machine. Doing this will increase your

safety and maximize the life of the machine.

Every eﬀort has been expended to make sure that the

information in this manual is both accurate and

current. However, Morse Industrial Inc. reserves the

right to change, alter or otherwise improve the

product at any time without prior notice.

Bold printed CAUTION boxes point out important

safety instructions, which if not followed, could

endanger personal safety and/or property.

Read this manual, the engine manual, and the

generator manual thoroughly prior to operating this

unit. Follow all instructions in all three manuals. If

you do not understand any portion of the manuals,

contact your Morse Generator authorized dealer.

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Safety

NOTICE

IF THIS UNIT IS USED FOR BACK-UP

POWER IN THE EVENT OF A UTILITY

POWER FAILURE, THE FOLLOWING STEP

MUST BE TAKEN BEFORE CONNECTING

THE GENERATOR TO AN ELECTRICAL

SYSTEM. OPEN THE MAIN CIRCUIT

BREAKER OR MAIN SWITCH SERVING

THE SYSTEM TO ISOLATE THE

GENERATOR SYSTEM FROM THE

ELECTRIC UTILITY. FAILURE TO

ISOLATE THE GENERATOR AND

UTILITY SYSTEMS WILL RESULT IN

DAMAGE TO THE GENERATOR AND MAY

ALSO RESULT IN INJURY OR DEATH TO

ELECTRIC UTILITY WORKERS, DUE TO A

BACKFEED OF ELECTRICAL ENERGY.

Safety Precautions

DANGER

●THIS UNIT PRODUCES DANGEROUS HIGH

VOLTAGE THAT CAN CAUSE EXTREMELY

HAZARDOUS ELECTRICAL SHOCK. AVOID

CONTACT WITH BARE WIRES, TERMINALS,

ETC. NEVER PERMIT AN UNQUALIFIED

PERSON TO OPERATE OR SERVICE THIS UNIT.

●NEVER HANDLE ANY ELECTRICAL CORDS OR

DEVICES WHILE STANDING IN WATER,

BAREFOOT, OR HANDS AND FEET ARE WET.

HARMFUL OR FATAL ELECTRICAL SHOCK

WILL RESULT.

●LOCAL ELECTRICAL CODES MAY REQUIRE

THE USE OF AN APPROVED EARTH GROUND

TO THE FRAME OF THE GENERATOR. THE

GENERATOR IS EQUIPPED WITH A

MOUNTING GROUND BOLT AND NUT FOR

PROPER CONNECTION. CONSULT WITH A

LOCAL ELECTRICIAN FOR GROUNDING

REQUIREMENTS IN YOUR AREA.

●NEVER ADD FUEL WHILE UNIT IS RUNNING.

●DO NOT SMOKE WHEN PUTTING FUEL IN

THE TANK.

●DIESEL ENGINE EXHAUST CONTAINS

DEADLY CARBON MONOXIDE GAS. IF

BREATHED IN SUFFICIENT

CONCENTRATIONS, IT WILL CAUSE

UNCONSCIOUSNESS OR DEATH. MAKE

SURE THE GENERATOR HAS ADEQUATE

VENTILATION FOR THE EXHAUST.

●KEEP HANDS,

FEET, CLOTHING, ETC. AWAY

FROM DRIVE BELTS, FANS, AND OTHER

MOVING PARTS. NEVER REMOVE DRIVE

BELTS OR FAN GUARDS WHILE THE UNIT IS

RUNNING.

NOTICE

●DO NOT OVERFILL THE FUEL TANK.

●BOTH THE DIESEL ENGINE AND THE

GENERATOR REQUIRE FRESH AIR FOR

COOLING. MAKE SURE SUFFICIENT

VENTILATION IS AVAILABLE FOR BOTH THE

GENERATOR AND ENGINE FANS.

311822

Safety

●DO NOT OPERATE GENERATOR WHERE IT

WILL BE EXPOSED TO EXCESSIVE

MOISTURE, DIRT, DUST OR CORROSIVE

VAPORS.

●NEVER START OR STOP THE GENERATOR

WITH ELECTRICAL LOADS CONNECTED

AND THE CONNECTED DEVICES TURNED

ON! START THE ENGINE FIRST AND LET IT

STABILIZE BEFORE TURNING ON THE

ELECTRICAL LOADS. TURN OFF ALL

ELECTRICAL LOADS BEFORE SHUTTING

DOWN THE ENGINE.

●OPERATE GENERATOR ON LEVEL

SURFACES UP TO + OR - 10° GRADE.

Safety Precautions

(

Continued

)

NOTICE

Safety Rules

●MORSE INDUSTRIAL EQUIPMENT INC.

RECOMMENDS THAT THE INSTALLATION,

INITIAL START-UP AND MAINTENANCE OF

THIS GENERATOR IS CARRIED OUT BY A

MORSE GENERATOR DEALER. DO NOT

ATTEMPT TO INSTALL, START, WIRE OR

PERFORM MAINTENANCE ON THIS

GENERATOR UNLESS YOU ARE TRAINED

AND QUALIFIED TO DO SO. PERSONAL

INJURY OR DEATH MAY OCCUR.

●KEEP HANDS AND ALL BODY PARTS AWAY

FROM THE HOT ENGINE EXHAUST. THIS

INCLUDES THE MUFFLER, TURBO

CHARGER, AND ALL EXHAUST PIPES.

OTHER PARTS OF THE ENGINE AND

RADIATOR ARE ALSO HOT.

●WHEN WORKING ON THIS GENERATOR,

REMAIN ALERT AT ALL TIMES. WEAR

PROTECTIVE CLOTHING INCLUDING

SAFETY GLASSES. NEVER WORK ON THIS

EQUIPMENT WHEN YOU ARE MENTALLY

OR PHYSICALLY FATIGUED,

●BEFORE PERFORMING MAINTENANCE ON

THIS EQUIPMENT, DISCONNECT THE

BATTERY CABLES TO PREVENT

ACCIDENTAL START-UP. TAKE CARE NOT

TO “ARC” THE BATTERY POSTS (DO NOT

TOUCH POSITIVE (+) TO NEGATIVE (-))

WITH THE ENDS OF THE CABLE OR TOOLS

USED TO REMOVE THE CABLES.

DISCONNECT THE POSITIVE (+) CABLE

FIRST. RECONNECT THE POSITIVE (+)

CABLE LAST.

●NEVER WEAR JEWELRY WHEN WORKING

ON THIS GENERATOR. JEWELRY CAN

CONDUCT ELECTRICITY RESULTING IN

ELECTRIC SHOCK, OR MAY GET CAUGHT

IN MOVING COMPONENTS SUCH AS FANS

OR BELTS CAUSING INJURY.

●STUDY THE DANGER WARNINGS AND

SAFETY RULES CAREFULLY. BECOME

FAMILIAR WITH BOTH THE ENGINE AND

GENERATOR SAFETY RULES AND

WARNINGS FOUND IN THEIR RESPECTIVE

MANUALS.

●MORSE INDUSTRIAL EQUIPMENT INC.

CANNOT ANTICIPATE EVERY POSSIBLE

CIRCUMSTANCE THAT MIGHT INVOLVE A

SAFETY HAZARD. THE WARNINGS IN THIS

MANUAL, THE ENGINE, AND THE

GENERATOR MANUALS ARE NOT ALL

INCLUSIVE AND ONE MUST USE COMMON

SENSE.

●MORSE INDUSTRIAL EQUIPMENT INC.

REQUIRES THE INSTALLATION OF AN

ELECTRICAL DISCONNECT BOX THAT

ADHERES TO ALL LOCAL ELECTRICAL

CODES.

311822

Installation

1-PHASE REMOTE METER PANEL WIRING

3-PHASE REMOTE METER PANEL WIRING

311822

Installation

Three Phase Single Phase

Volts

208V 220V 240V 230V 240V

140A 130A 120A 130A 125A

Breaker

RECOMMENDED BREAKER SIZE (CUSTOMER SUPPLIED)

INTERNAL GENERATOR WIRING

311822

●

To avoid potential overheating issues, the exhaust

louvers should be sized to a minimum of 6000

CFM @ 1” H2O and at least 27” H x 23 3/4” W.

●

To ensure adequate fresh air ﬂow, the air intake

louvers should be at least double the size and

performance of the exhaust louvers.

Installation

Louvers

●

DO NOT move the DOC mu

ﬄ

er or adjust its

position. Tampering with the DOC will void the

warranty!

●

For exhaust routing use 3” exhaust pipe. A

combination of straight pipe, ﬂex pipe, and

elbows is allowed.

●

A section of ﬂex piping is REQUIRED if the

exhaust is hard mounted to the trailer.

DOC Muﬄer

311822

General Description

This generator is a frame mounted, diesel engine driven, revolving ﬁeld, alternating current (AC)

generator. The generators revolving ﬁeld is driven at 1800 rpm by the diesel engine.

●

This generator can be used for prime or stand by power and can be wired 3 phase or 1 phase at a frequency of 60

hertz. Voltage can be 120/240 1-PH; and 416 to 480 volt 3-PH. Please refer to the Generator Manual for details.

●

Follow all local electrical codes that may require proper grounding of the generator and its electrical system.

●

In case of an accident caused by electric shock, immediately shut down the generator. Press the Emergency stop

button located on the side of the control panel. Then turn the main ON/OFF rotary switch to the “OFF” position.

Do not try to free the victim with the generator running; the electric shock could pass from the victim to anyone

in contact with the victim. Make sure the generator is o

ﬀ

and the electric system is de-energized. Seek medical

attention immediately.

EMERGENCY STOP MAIN ON/OFF

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