Ingersoll-Rand Thermo King SGCM 4000 Maintenance Manual
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Ingersoll-Rand Thermo King SGCM 4000 Maintenance Manual

Ingersoll-Rand Thermo King SGCM 4000 Maintenance Manual

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Maintenance Manual
SB-210+
SB-210+
SB-210+
SGSM 4000, SGCM 4000
& SGCO 4000
Additional text information
Additional text information
Additional text information
TK 61010-4-MM (Rev. 0, 02/13)
to be placed here
to be placed here
to be placed here
TK 5XXXX-X-PL
TK 5XXXX-X-PL
TK 5XXXX-X-PL

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Summary of Contents for Ingersoll-Rand Thermo King SGCM 4000

  • Page 1 Maintenance Manual SB-210+ SB-210+ SB-210+ SGSM 4000, SGCM 4000 & SGCO 4000 Additional text information Additional text information Additional text information to be placed here to be placed here to be placed here TK 61010-4-MM (Rev. 0, 02/13) TK 5XXXX-X-PL TK 5XXXX-X-PL TK 5XXXX-X-PL...
  • Page 2 SGSM 4000, SGCM 4000 & SGCO 4000 TK 61010-4-MM (Rev. 0, 02/13) Copyright© 2013 Thermo King, Ingersoll Rand. Printed in EMEIA.
  • Page 3 The maintenance information in this manual covers unit models: SGCO (718208M): Model with SG+ controls and clip-on unit frame SGUM (718207M): Model with SG+ controls and side-mount or centre mount arms For further information, refer to: SGUM 4000 Parts Manual TK 55682 SGCO 4000 Parts Manual TK 55683...
  • Page 4 ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Return to: NORTH AMERICA EMEIA THERMO KING CORPORATION THERMO KING CORPORATION 314 West 90th Street Ingersoll Rand Climate Solutions Mail Stop 38 Monivea Road Minneapolis, MN 55420 Mervue, Galway, Ireland Attn: Service Department Attn: Service Department...

  • Page 6: Table Of Contents

    Table of Contents List of Figures ................9 Safety Precautions .
  • Page 7 Table of Contents Event Log Menu ..............57 Standard Display .
  • Page 8 Table of Contents Engine Maintenance ..............120 DV6NR Diesel Engine .
  • Page 9 Table of Contents Unit Inspection ................157 Mounting Bolts .

  • Page 10: List Of Figures

    List of Figures Figure 1: Model SGUM 4000 Decals ............18 Figure 2: Model SGCO 4000 Decals .
  • Page 11 List of Figures Figure 59: Electric Fuel Pump ............. . 138 Figure 60: Air Circuit Diagram .

  • Page 12: Safety Precautions

    Safety Precautions Thermo King recommends that all service be performed by a Thermo King dealer. However, you should be aware of several general safety practices: symbol appears next to a point that is particularly important DANGER: Denotes the possibility of serious injury or death. WARNING: Denotes the possibility of serious equipment damage or serious personal injury.

  • Page 13: First Aid

    Safety Precautions 3. Make sure the On/Off switch is in the OFF position when disconnecting or connecting the generator set battery. This will prevent an electrical arc which could cause the battery to explode. Disconnect the ground cable first, preferably at a point AWAY FROM THE BATTERY. Connect the ground cable last, again away from the battery if possible.

  • Page 14: Low Voltage

    Safety Precautions Low Voltage Control circuits are low voltage (12 Vdc). This voltage potential is not considered dangerous, but the large amount of current available (over 30 amperes) can cause severe burns if shorted to ground. Disconnect the negative terminal of the battery if possible when working on the generator set. Disconnect the cable end that is away from the battery.

  • Page 15: Welding Of Units Or Containers

    Safety Precautions 6. Leave the circuit boards in their static proof packing materials until ready for installation. 7. If a defective controller is to be returned for repair, it should be returned in the same static protective packing materials from which the replacement component was removed. 8.

  • Page 16: Battery Installation And Cable Routing

    Safety Precautions • Don’t wear loose clothing or jewelry in the vicinity of moving parts. These can get in machinery, with disastrous results. Don’t wear jewelry while working on electrical equipment. If your hair is long, wear a head covering. Hair caught in a drill press, fan belt or other moving parts can cause serious injury.
  • Page 17 Safety Precautions...

  • Page 18: Serial Number Locations

    Serial Number Locations The generator nameplate is attached to the generator housing. The serial number is located on Generator: this nameplate. The engine serial number is stamped on the back side of the engine block near the flywheel end. Engine: The unit serial number nameplate is attached to the unit frame near the rear mounting SGUM Units: bracket or on the air cleaner bracket.

  • Page 19: Unit Decals

    Unit Decals Serial number decals, installation decals and warning decals appear on all Thermo King generator sets. These decals provide information that may be needed to service or repair the unit. Service technicians should read and follow the instructions on all warning decals. Thermo King Symbol Operating Instructions EN/ES Auto Stop/Start...

  • Page 20: Figure 2: Model Sgco 4000 Decals

    AXA0313 Thermo King Symbol Operating Instructions EN/ES Auto Stop/Start Radiator Fill CA Proposition Warning - Ether Use Battery 925 CCA Universal Fan Decal Unit ID Caution, Lowering Bolts must be installed Figure 2: Model SGCO 4000 Decals...

  • Page 22: Specifications

    Specifications Engine Model DV6NR (Tier 4) Number of Cylinders Cylinder Arrangement In-line vertical, number 1 on flywheel end Firing Order 1-3-4-2 Direction of Rotation Counterclockwise viewed from flywheel end Emissions Compliance EPA Tier 4 Final - TRU Test Mode ONLY (4 Mode) Displacement 1.6L Combustion Chamber...

  • Page 23: Generator

    Specifications Engine (Continued) CAUTION: Do not add “GREEN” or “BLUE-GREEN” conventional coolant to cooling systems using “RED” Extended Life Coolant, except in an emergency. If conventional coolant is added to Extended Life Coolant, the coolant must be changed after 2 years instead of 5 years.

  • Page 24: Electrical Control System

    Specifications Electrical Control System Controls SG+ microprocessor controller Voltage 12.5 Vdc (nominal) Battery 12 volts, group C31, 925/950 Cold Cranking Amps at -18 C (0 F) Fuse SI1 30 Amp Fuse SI2 30 Amp Fuse SI3 10 Amp Electrical Components NOTE: Disconnect components from unit circuit to check resistance.

  • Page 25: Physical Specifications

    Specifications Physical Specifications Weight (net): SGUM 4000 (SGCM and SGSM 4000 - 678 Kg (1495 lbs) including oil, coolant, battery and the only difference is an added Bracket) 195 liter (50 gal.) fuel tank (excluding fuel) Unit Dimensions...

  • Page 26: Physical Specifications

    Specifications Physical Specifications Weight (net): SGCO 4000 818 Kg (1804 lbs) including oil, coolant, battery and 473 liter (125 gal.) fuel tank (excluding fuel) Unit Dimensions:...

  • Page 27: Metric Hardware Torque Charts

    Specifications Metric Hardware Torque Charts Bolt Size Bolt Type and Class* N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) HH – CL 5.8 6-9 (4-7) 12-16 (9-12) 27-34 (20-25) 48-61 (35-40) HH – CL 8.8 10-13 (7-10) 20-27 (15-20) 41-47 (30-35) 75-88 (55-65) HH –...

  • Page 28: Maintenance Inspection Schedule

    Maintenance Inspection Schedule Pretrip Every Annual/ Inspect/Service These Items 1,500 3,000 Hours Hours* Microprocessor • Run Pretrip Test Engine • Check fuel supply. • Check engine oil level. • • • Listen for unusual noises, vibrations, etc. • • • Check engine coolant level and antifreeze protection (-30 F [-40 C]).
  • Page 29 Maintenance Inspection Schedule...
  • Page 30 Maintenance Inspection Schedule...
  • Page 31 Maintenance Inspection Schedule...
  • Page 32 Maintenance Inspection Schedule...
  • Page 33 Maintenance Inspection Schedule...
  • Page 34 Maintenance Inspection Schedule...
  • Page 35 Maintenance Inspection Schedule...
  • Page 36 Maintenance Inspection Schedule...
  • Page 37 Maintenance Inspection Schedule...

  • Page 38: Unit Description, Features & Options

    Unit Description, Features & Options General Description Thermo King generator sets (clip-on and under-mount) are self-contained fully-automatic, diesel powered units. The generator sets supply 230 or 460 Vac electrical power for container refrigeration units. Enclosed within the unit frame are the engine, dual voltage alternator, generator battery compartment, battery charging regulator and control panel.

  • Page 39: Figure 4: Sgco 4000 Clip On Generator

    Unit Description, Features & Options Figure 4: SGCO 4000 Clip On Generator...

  • Page 40: Emi 3000 Package

    Unit Description, Features & Options EMI 3000 Package These units are equipped with an EMI 3000 Extended Maintenance Interval package. The EMI 3000 package will result in lower total unit life cycle cost, because maintenance intervals have an important impact on unit operating costs. The EMI 3000 package includes: •...

  • Page 41: Unit Instruments

    Unit Description, Features & Options Unit Instruments INDICATOR LEDs. a. POWER LED: A green Power LED lights up while the Unit On/Off Switch is in the ON position. It is located on the controller display. b. ALARM LED: A red Alarm LED illuminates when a shutdown condition has occurred. It is located on the controller display.

  • Page 42: Fuel Level Sensor Option

    Unit Description, Features & Options Fuel Level Sensor Option The fuel level sensor option allows the controller to monitor and log fuel events. Units equipped with the fuel level sensor option must have the Fuel Sensor turned on in the Configuration Menu, and the fuel tank size set in the System Setup submenu.

  • Page 43: Figure 6: Sgum 4000 - Unit Front View

    Unit Description, Features & Options BEN115 Fuel Tank Control Box Cover Fuel Tank Fill Neck and Cap Engine Compartment Access Door Unit Mounting Arms 460 or 230 Vac Power Receptacle Location Alternator and Control Box Radiator Location Compartment Access Door Figure 6: SGUM 4000 —...

  • Page 44: Figure 7: Sgco 4000 - Unit Front View

    Unit Description, Features & Options BEN121 Battery Lower Mounting Screw and Washer (each side) Unit Nameplate Location Fuel Gauge (each side) Fuel Tank Control Box Location Alternator and Engine Compartment Fuel Tank Fill Neck and Cap (each side) Access Door 460 or 230 Vac Power Receptacle Bracket-Clip on (One each side) Location...

  • Page 45: Figure 8: Engine (All Models) - Unit Front View

    Unit Description, Features & Options Flow meter Oil Fill and Electric gauge attachment TurboCharger Oil Drain Feed Return Oil Assembly ECU Connectors Oil Filter Warm up ECU Connector Water Inlet Assembly Air duct Spigot Exhaust Figure 8: Engine (All Models) — Unit Front View...

  • Page 46: Genset Model Features

    Genset Model Features Genset Model Features DV6NR Diesel Engine 460 Vac Output for 15 KW, 18.75 KVA, 3 Phase, 60 Hz, 4 Wire Generator 230 Vac Output for 15 KW, 18.75 KVA, 3 Phase, 60 Hz, 4 Wire Generator SG+ Control System Battery with Post Battery Charging System, Solid-state —...
  • Page 47 Genset Model Features...

  • Page 48: Controller Description

    Controller Description SG+ Controller Description The SG+ controller is a two-piece, self contained microprocessor for diesel generator sets. The SG+ display is mounted on the control box cover. The SG+ microprocessor is mounted inside the control box (see Figure 10 on page 48). Three external relays - two ECU Relays and the Start Relay are also mounted inside the control box near the microprocessor.

  • Page 49: Figure 10: Sg+ Microprocessor

    Controller Description J6 Connector – To AC Circuits Fuse SI1 – 30 Amp Fuse Power Relay Fuse SI2 – 30 Amp Protects Battery Charger Output Circuit 2A Circuit Connection CH Circuit Connection GND Circuit Connection Serial Port – For Flash Loading Software J2 Connector –...

  • Page 50: Controller Overview

    Controller Description Controller Overview A vacuum lucent display on the front panel shows operating information including output Display: voltage, current test state during a Pretrip test and the controller menu. Normally it shows the Output Voltage (this is called the Standard Display). It will be blank when the unit On/Off switch is OFF. Contains the following six keys.

  • Page 51: Figure 11: Control Box Cover

    Controller Description Display Down Key Enter Key Keypad Language Key Power LED Unit On/Off Switch Download Port Alarm LED 10. Alarm Key Escape Key 12. Up Key Figure 11: Control Box Cover...

  • Page 52: Miscellaneous Features

    Controller Description Miscellaneous Features • Internal self-checking/diagnostic capability • Pretrip test capability (see “PTI” on page 85) • Hourmeter: The controller has a built-in run hourmeter that can be accessed through the Timers/Counters Submenu under the Misc. Functions Menu. • The application software version is displayed by selecting the Program Version Submenu under the Misc.
  • Page 53 Controller Description...

  • Page 54: Navigating The Controller Menus

    Navigating the Controller Menus Controller Display Menus The SG+ controller contains extensive display menus that can be navigated via the keypad. The display menus are organized into the following menus (or groups) in the Main Menu: • Data Menu • Alarm List Menu •...

  • Page 55: Figure 12: Controller Display

    Navigating the Controller Menus Press the key to change the language used on the display. Language Key: ANGUAGE Down Key Enter Key Language Key Alarm Key Escape Key Up Key Figure 12: Controller Display...

  • Page 56: Menu Overview

    Navigating the Controller Menus Menu Overview Press the keys to scroll through the Main Menu or a Submenu. Press the key to enter a NTER Submenu or Event. Press the key to return to the parent menu. SCAPE Main Menu Submenu Event ENGINE OUTPUTS...

  • Page 57: Data Menu

    Navigating the Controller Menus Data Menu The Data Menu contains the following submenus. See “Data Menu” on page 66 for more information. • Engine, which displays engine operating information such as oil pressure and RPM. • Engine Lamps, which displays the status of the different Engine Lamps - i.e protect, amber and stop lamp.

  • Page 58: Event Log Menu

    Navigating the Controller Menus Event Log Menu The Event Log Menu contains the following submenus: • Event Log, which shows a list of events, warnings, and alarms recorded in the controller memory. • Fuel Events, which shows a list of fuel events recorded in the controller memory. Standard Display The Standard Display shows the output voltage.

  • Page 59: Pause Mode Displays

    Navigating the Controller Menus Pause Mode Displays WARNING: The engine may start at any time without notice when the unit is in a PAUSE mode. A Pause mode display appears when normal unit operation has been interrupted because of a warning or alarm.

  • Page 60: Operating Instructions

    Operating Instructions Pretrip Inspection The pretrip inspection is an important part of the preventive maintenance program. It’s designed to head off operating problems and breakdowns before they happen.The Pretrip Inspection is not a substitute for a regularly scheduled maintenance. Visual Inspection The following inspections should be made before loading the container or trailer: The diesel fuel supply must be sufficient to guarantee engine operation to the next check point.

  • Page 61: Starting The Unit

    Operating Instructions Starting the Unit Generator sets are designed to provide power for a refrigeration unit. Before starting the generator set, make sure the refrigeration unit power cord is connected to the generator set electric power receptacle. To operate the refrigeration unit on shore power, disconnect the power cord from the generator set and plug it into the proper power supply.

  • Page 62: After Start Inspection

    Operating Instructions CAUTION: Never use starting fluid. After Start Inspection After the engine has started: 1. Listen for abnormal noises. 2. Check for any alarms or messages using the Alarm List Menu and the Message List Menu. NOTE: The engine must operate for approximately 2 minutes before the exciter circuit and battery charging circuits are energized.

  • Page 63: Functional Inspection

    Operating Instructions Functional Inspection To properly perform a PTI (Pretrip Inspection Test) on units equipped with a SG+ controller, do not apply a load to the alternator. 1. Start the unit (see “Starting the Unit” on page 60). 2. Initiate an automatic PTI. NOTE: Correct all existing alarm conditions and clear the alarm codes before performing a PTI.
  • Page 64 Operating Instructions NOTE: Acknowledge the alarms or messages ONLY after the alarm codes are documented and problems repaired.

  • Page 65: Main Menu

    Operating Instructions Main Menu The Main Menu contains the following menus: • Data Menu • Alarm List Menu • Message List Menu • Commands Menu • Misc. Functions Menu • Configuration Menu • Event Log Menu To enter the Main Menu complete the following steps: 1.

  • Page 66: Figure 17: Main Menu

    Operating Instructions MAIN MENU DATA From "DATA" menu VOLTAGE: 460 V To "DATA" menu MAIN MENU ALARM LIST From "ALARM LIST" menu VOLTAGE: 460 V To "ALARM LIST" menu MAIN MENU MESSAGE LIST From "MESSAGE LIST" menu VOLTAGE: 460 V To "MESSAGE LIST"...

  • Page 67: Data Menu

    Operating Instructions Data Menu NOTE: The Data Menu only displays information, items can NOT be changed. The Data Menu displays general unit operating information including electrical data, temperatures, etc. It contains the following submenus: • Engine • Engine Lamps • Generator •...

  • Page 68: Figure 18: Data Menu

    Operating Instructions To "DATA" prompt of From "DATA" prompt "MAIN" menu. of "MAIN" menu. DATA ENGINE From "ENGINE" menu VOLTAGE: 460 V To "ENGINE" menu DATA ENGINE LAMPS From "ENGINE LAMPS" menu VOLTAGE: 460 V To "ENGINE LAMPS" menu DATA GENERATOR From "GENERATOR"...

  • Page 69: Engine Menu

    Operating Instructions Engine Menu The Engine display the following unit operating information: • Water Temp. (Engine Coolant Temperature) • Load (shows percentage engine load) • Current RPM • Requested RPM • Fuel Rate • Ignition Relay • Run Relay To enter the Engine Submenu complete the following steps: 1.

  • Page 70: Engine Lamps

    Operating Instructions Engine Lamps The Engine Lamps submenu displays the the following information: • Amber Lamp on/off • Stop Lamp on/off 1. DTC Code 2. DTC Code 3. DTC Code 4. DTC Code To enter the Engine Lamps submenu complete the following steps: 1.

  • Page 71: Generator

    Operating Instructions Generator The Generator submenu display the status of the following outputs: • Voltage Measurement • Running Frequency • Quad closed on/off • Battery Voltage • Battery Charger on/off To enter the Generator submenusubmenu complete the following steps: 1. Place the On/Off switch in the “ON” position. 2.

  • Page 72: Unit

    Operating Instructions Unit The Unit submenu display the status of the following outputs: • Fuel Level Average • Fuel Level Low on/off • Fuel Pump on/off • Coolant Fan on/off To enter the Unit submenu complete the following steps: 1. Place the On/Off switch in the “ON” position. 2.

  • Page 73: Internal States

    Operating Instructions Internal States The Internal States displays which of the following states the unit is in as it prepares to start, and after it starts or if it shuts down: • INIT (Initiation Checks) • Fuel Relay On • Preheat On •...

  • Page 74: Alarm List Menu

    Operating Instructions Alarm List Menu The Alarm List Menu displays alarms. Alarms are recorded in the controller memory to simplify unit diagnostic procedures. The alarms are listed in the reverse order of their occurrence. The Alarm LED flashes if a shutdown alarm is present. Enter the Alarm List Menu to view the and acknowledge the alarms.

  • Page 75: Alarm Diagnosis

    Operating Instructions 3. The Alarm List Menu will appear on the display. It shows the most recent alarm and the following information: • The alarm code (A101 through A111) • The position of the alarm in the list of recorded alarms. For example, 1/2 means alarm one of two. •...
  • Page 76 Operating Instructions Alarm List Alarm Code and Text Alarm Type–Cause Diagnostics A101. Delayed Restart Alarm–Engine is 1. Check for cause of engine WATER TEMPERATURE running and water temperature is above overheating: HIGH 107 C (225 F) for 5 seconds. • Check engine coolant level. •...
  • Page 77 Operating Instructions Alarm List (Continued) Alarm Code and Text Alarm Type–Cause Diagnostics A113. Coolant level low after message 113. 1. Check coolant level. COOLANT LEVEL LOW 2. Check Coolant Level Sensor. 3. Check circuits to Coolant Level Sensor. A116. The engine is restarted if communication 1.

  • Page 78: Message List Menu

    Operating Instructions Message List Menu The Message List Menu displays messages. Messages are recorded in the controller memory to simplify unit diagnostic procedures. The messages are listed in the reverse order of their occurrence. Enter the Message List Menu to view the and acknowledge the messages. Acknowledging a message clears it from the list.

  • Page 79: Message Diagnosis

    Operating Instructions To "MESSAGE LIST" prompt From "MESSAGE LIST" prompt of "MAIN" menu of "MAIN" menu 101. WATER TEMPERATURE SENSOR FAILURE STATUS: ACTIVE Jump to previous warning text Jump to next warning text Acknowledges warning ARA754 Figure 25: Message List Menu Message Diagnosis The Message List on the following pages lists the messages, their causes, and possible diagnosis.
  • Page 80 Operating Instructions Message List Message Code and Text Cause Diagnostics M101. 1. Check battery The battery voltage is reported to be BAT. VOLTAGE LOW below 12 voltages for 3 minutes. 2. Check battery cables. If the air heater is activated the battery voltage should be below 9 voltage for 3 seconds.
  • Page 81 Operating Instructions Message List (Continued) Message Code and Text Cause Diagnostics M114. Engine is running and input from Low Oil 1. Check oil level. LOW OIL PRESSURE Pressure Switch is low (grounded) for 60 2. Check oil pressure using the Engine seconds.
  • Page 82 Operating Instructions Message List (Continued) Message Code and Text Cause Diagnostics M124. RPM less than 1520 after startup. 1. Check engine speed. NO LOAD RPM LESS 2. Check RPM sensor. THEN 1530 M125. RL3 No feedback when relay is energized, or 1.
  • Page 83 Operating Instructions Message List (Continued) Message Code and Text Cause Diagnostics M141. Output is short-circuited 1. See “Alternator Diagnosis” on page DSR CHECKSUM 147. WARNING M142. Exciter current exceeds the damage 1. See “Alternator Diagnosis” on page DSR EXCITATION threshold 147.

  • Page 84: Commands Menu

    Operating Instructions Commands Menu The Commands Menu contains the following submenus that are used to test the operation or the unit and controller: • PTI (Pretrip Inspection Test) • Manual Function Test • ECU Service Menu • Oil Priming • System Setup To enter the Commands Menu complete the following steps: 1.

  • Page 85: Figure 26: Commands Menu

    Operating Instructions To "COMMANDS" From "COMMANDS" prompt of "MAIN" prompt of "MAIN" menu. menu. COMMANDS From PTI test VOLTAGE: 460 V To PTI test COMMANDS MANUAL FUNCTION TEST From "MANUAL FUNCTION TEST" menu VOLTAGE: 460 V To "MANUAL FUNCTION TEST" menu COMMANDS ECU SERVICE MENU From "ECU SERVICE"...

  • Page 86: Pti

    Operating Instructions The PTI (Pretrip Inspection Test) initiates a test of the unit’s electrical, engine, and alternator system components. To perform a PTI complete the following steps: NOTE: The unit will not start a PTI until all active messages have been acknowledged. The display will show “ACKNOWLEDGE MESSAGE”...

  • Page 87: Figure 27: Pti Submenu

    Operating Instructions 8. When the PTI is complete, the test ends automatically and the controller display shows “PTI PASSED (or FAILED) - REBOOT”. Turn the On/Off Switch Off and back On to reboot and return the unit to normal operation. 9.

  • Page 88: Manual Function Test

    Operating Instructions Manual Function Test The Manual Function Test submenu contains the following component tests: • Display Test • ECU Ignition Test • ECU Run Relay Test • ECU Run Relay Test • DSR Quad Relay Test The test result (PASSED of FAILED) is displayed after a test is performed. To enter the Manual Function Test complete the following steps: 1.

  • Page 89: Figure 29: Manual Function Test Submenu

    Operating Instructions To "MANUAL FUNCTION TEST" From "MANUAL FUNCTION TEST" prompt of "COMMANDS" menu. prompt of "COMMANDS" menu. DISPLAY TEST PERFORM ECU IGNITION TEST TEST ECU RUN RELAY TEST ECU FUEL RELAY TEST DISPLAY TEST PERFORM ECU IGNITION TEST TEST ECU RUN RELAY TEST ECU FUEL RELAY TEST DISPLAY TEST...

  • Page 90: Ecu Service Menu

    Operating Instructions ECU Service Menu The ECU Service Menu is used when the ECU Service Tool needs to be used to communicate with the Engine ECU for troubleshooting First enter the ECU Service Menu on the SG+ Controller. You will get the following messages: ECU SERVICE MODE ENGINE OFF CONTROLLER ON...

  • Page 91: System Setup

    Operating Instructions System Setup The System Setup submenu contains the following: • Current RPM, which is used to check the engine speed. • Speed Solenoid , which is used to request a speed change to the ECU. • Tank Size (50/75/80/125), which is used to set the unit fuel tank size. •...
  • Page 92 Operating Instructions 4. Press the key to enter the Commands Menu. NTER 5. The PTI submenu will be displayed. 6. Press the key to scroll up or down through the Commands Menu to the System Setup submenu. 7. Press the key to enter the System Setup submenu.

  • Page 93: Figure 30: System Setup Submenu

    Operating Instructions To "SYSTEM SETUP" From "SYSTEM SETUP" prompt prompt of "COMMANDS" menu. of "COMMANDS" menu. CURRENT RPM 1890 SPEED SOLENOID LOAD ENGINE TYPE CURRENT RPM 1890 ENTER CHANGE SPEED SOLENOID FUNCTION SPEED LOAD ENGINE TYPE CURRENT RPM 1890 ENTER CHANGE FUNCTION SETTING...

  • Page 94: Misc. Functions Menu

    Operating Instructions Misc. Functions Menu The Misc. Functions Menu contains the following submenus: • C/F Mode • SW/HW (Software/Hardware) Version • Timers/Counters • Date/ Time To enter the Misc. Functions complete the following steps: 1. Place the On/Off switch in the “ON” position. 2.

  • Page 95: C/F Mode

    Operating Instructions C/F Mode The C/F Mode submenu is used to select whether Celsius or Fahrenheit units are used to display temperature readings. To enter the C/F Mode submenu and change the units displayed complete the following steps: 1. Place the On/Off switch in the “ON” position. 2.

  • Page 96: Figure 32: C/F Mode

    Operating Instructions From "C/F MODE" prompt of "MISC. FUNCTIONS" menu. Save changes and return to "C/F MODE" prompt of "MISC. FUNCTIONS" menu C/F MODE: ELSIUS Toggles between ºC / ºF ARA737 Figure 32: C/F Mode...

  • Page 97: Sw/Hw Version

    Operating Instructions SW/HW Version The SW/HW Version submenu displays the following information about the controller: • SW (Software Version) • HARDWARE REV. (Hardware Revision) To enter the Program Version submenu complete the following steps: 1. Place the On/Off switch in the “ON” position. 2.

  • Page 98: Figure 33: Sw/Hw Version

    Operating Instructions To "PROGRAM VERSION" From "PROGRAM VERSION" prompt of "MISC. prompt of "MISC. FUNCTIONS" menu FUNCTIONS" menu SW xxxxxx xx HARDWARE REV. y ARA738 Figure 33: SW/HW Version...

  • Page 99: Timers/Counters

    Operating Instructions Timers/Counters The Timers/Counters submenu displays the following information about the hourmeters and restart counters: • Run Hours – The number of hours the unit has been running. • Hour Meter 1 – The number of hours the unit has been running since Hour Meter 1 was cleared. A message is generated when the reading reaches the threshold set in the Configuration Menu.

  • Page 100: Figure 34: Timers/Counters

    Operating Instructions From "TIMERS/COUNTERS" To "TIMERS/COUNTERS" prompt of prompt of "MISC. FUNCTIONS" menu. "MISC. FUNCTIONS" menu. RUN HOURS HOUR METER 1 HOUR METER 2 ENGINE OFF HOURS RUN HOURS HOUR METER 1 HOUR METER 2 ENGINE OFF HOURS RUN HOURS HOUR METER 1 HOUR METER 2 ENGINE OFF HOURS...

  • Page 101: Date/Time

    Operating Instructions Date/Time The Date/Time submenu is used to set the clock in the controller. To enter the Date/Time submenu and set the clock complete the following steps: 1. Place the On/Off switch in the “ON” position. 2. Press the key or the key to enter the Main Menu, if necessary.

  • Page 102: Figure 35: Date/Time

    Operating Instructions From "DATE/TIME" prompt of Save changes and return to "MISC. FUNCTIONS" menu. "DATE/TIME" prompt of "MISC. FUNCTIONS" menu YEAR: MONTH: DATE: TIME: 14.08 Scrolls values up/down Moves cursor right ARA736 Figure 35: Date/Time...

  • Page 103: Configuration Menu

    Operating Instructions Configuration Menu The Configuration Menu is used to configure the following controller functions (also see the flowcharts on the following pages): NOTE: The Configuration Menu requires that a password (0007) be used change a setting. See “Setting Hour Meter Thresholds and Resetting Hour Meters” on page 105 for an example of how change a setting.

  • Page 104: Figure 36: Configuration Menu

    Operating Instructions To "CONFIGURATION" From "CONFIGURATION" prompt of "MAIN" menu. prompt of "MAIN" menu. ENGINE TYPE ENGINE TYPE Toggle between PCM/YANMAR LOP RESTART LOP RESTART HM1 THRESHOLD 00000 HM1 THRESHOLD 00000 PASS- Toggle between PCM/YANMAR HM2 THRESHOLD 00000 HM2 THRESHOLD 00000 WORD ENGINE TYPE...

  • Page 105: Figure 37: Configuration Menu

    Operating Instructions To/From Page 1 of Configuration Menu FUEL LEVEL 00000 FUEL LEVEL 00000 CRANK RESTARTS 00003 CRANK RESTARTS 00003 Toggle between YES/NO COMPOSIT COMPOSIT PASS- Toggle between YES/NO RMM MASTER RMM MASTER WORD FUEL LEVEL 00000 FUEL LEVEL 00000 Toggle between YES/NO CRANK RESTARTS 00003...

  • Page 106: Setting Hour Meter Thresholds And Resetting Hour Meters

    Operating Instructions Setting Hour Meter Thresholds and Resetting Hour Meters The Hour Meter Threshold feature sets the controller to alert the user that the unit has operated for a defined number of hours. The number of operating hours are entered in the controller in the Hour Meter Threshold display.

  • Page 107: Event Log Menu

    Operating Instructions Event Log Menu The Event Log Menu contains the following submenus that show events that are recorded in the controller memory: • Event Log • Fuel Events To enter the Event Log Menu complete the following steps: 1. Place the On/Off switch in the “ON” position. 2.

  • Page 108: Event Log

    Operating Instructions Event Log The Event Log is a list of events that are recorded in the controller memory. Examples of recorded events are a system power up, alarms, and messages. Events are listed in the reverse order of their occurrence. Viewing the event log can be helpful when diagnosing a problem.

  • Page 109: Figure 39: Event Log Submenu

    Operating Instructions To "EVENT LOG" prompt From "EVENT LOG" prompt of "EVENT LOG" menu of "EVENT LOG" menu 20YY.MM.DD-HH.MM SYSTEM POWERED UP Jump to previous log event Jump to next log event ARA1076 Figure 39: Event Log Submenu...

  • Page 110: Fuel Events

    Operating Instructions Fuel Events The Fuel Events is a list of fuel events that are recorded in the controller memory on units equipped with the fuel level sensor option. An example of a recorded event is when fuel is added to the fuel tank. Fuel Events are listed in the reverse order of their occurrence.

  • Page 111: Figure 40: Fuel Events Submenu

    Operating Instructions To "FUEL EVENTS" prompt From "FUEL EVENTS" prompt of "EVENT LOG" menu of "EVENT LOG" menu 20YY.MM.DD-HH.MM FUEL CHANGE +0025Ga Jump to previous log event Jump to next log event ARA1077 Figure 40: Fuel Events Submenu...

  • Page 112: Logview And Viewing Sg+ Logs

    Operating Instructions LogView and Viewing SG+ Logs With the release of LogView software version 5.9.2.0 (or later), you can now view SG+ Event logs. The following will outline how to interpret the SG+ log. To understand now to use LogView refer to the Help file found within LogView.

  • Page 113: Figure 41: Example Of Sg+ Log

    Operating Instructions Event Log Report Container ID: APZJ007063 LogView: 5.9.2.0 SGPlus2LogView.dll: Rev. : 1.1.1.9 Thermo King SG+ Event Log Time for transfer : 080826 16:13 Retriever ID : LogMan II PC v. 2.0.2 SG+ software version : 080423 revision 00 SG+ boot loader version : 040108 Thermo King SG+ Event Log Latest DLL file revision...

  • Page 114: Electrical Maintenance

    Electrical Maintenance Battery CAUTION: Place the Unit On/Off switch in the “OFF” position, Before connecting or disconnecting the unit battery. Inspect and clean the battery terminals, check the electrolyte level during scheduled maintenance inspections. The minimum specific gravity should be 1.235. Add distilled water as necessary to maintain the proper water level.
  • Page 115 Electrical Maintenance Fuel Pump Relay Spare Relay (If Installed) Figure 42: Components Inside Control Box...

  • Page 116: Start Relay

    Electrical Maintenance Start Relay The start relay is mounted on the inside of the control box. It is energized by the controller after proper preheat time has occurred. When this relay energizes, the starter solenoid receives power and the engine cranks.

  • Page 117: Figure 43: Engine Oil Pressure Switch

    Electrical Maintenance Figure 43: Engine Oil Pressure Switch...

  • Page 118: Oil Level Sensor

    Electrical Maintenance Oil Level Sensor If the engine oil level drops below the actuation level, the low oil level sensor (OLS) switch will close. This will cause the ECU to signal to shutdown to stop the engine. The oil level switch is located in the oil pan on the front side of the engine near the oil filter.

  • Page 119: Bench Test

    Electrical Maintenance Bench Test 1. Disconnect the switch wires from the main wire harness. Remove the switch from the oil pan. 2. Use a small container partially filled with engine oil to check the float. Make sure that it floats in engine oil and that it slides freely between the upper and lower stops.

  • Page 120: Coolant Temperature Sensor

    Electrical Maintenance Coolant Temperature Sensor The coolant temperature sensor is connected to the engine coolant system near the water pump. It uses coolant temperature to present a variable resistance to the ECU. Test the coolant temperature sensor if the controller records Alarm Code 18 or 41 and the coolant temperature appears to be normal. Figure 45: Coolant Temperature Sensor Sensor Test 1.

  • Page 121: Engine Maintenance

    Engine Maintenance DV6NR Diesel Engine This unit uses a new engine called the DV6NR. Common Rail fuel injection system, which used electronically controlled fuel injectors to reduce emissions. An EGR (Exhaust Gas Recirculation) system and DOC (Diesel Oxidation Catalyst) exhaust after-treatment system and turbo charger also reduce emissions so the engine is EPA Tier 4 compliant.

  • Page 122: Figure 47: Dv6Nr Sensors & Actuators For The Non-Service View, Or Exhaust Side

    Engine Maintenance Injector Cylinder 4 Crankshaft Speed Sensor Oxygen Sensor Oil Pressure Switch Figure 47: DV6NR Sensors & Actuators for the non-service view, or exhaust side...

  • Page 123: Figure 48: Dv6Nr Sensors & Actuators Rear View

    Engine Maintenance Glow Plugs Oil Breather Heater Camshaft Position Sensor Figure 48: DV6NR Sensors & Actuators Rear View...

  • Page 124: Figure 49: Dv6Nr Under Engine View

    Engine Maintenance CAUTION: Anytime engine power pack is removed from the frame, DO NOT sit engine on ground without supporting engine on green highlight areas. If engine is sat on the ground without support, damage will occur to the pan and oil pump.  ...

  • Page 125: Emi 3000

    Engine Maintenance EMI 3000 EMI 3000 is an extended maintenance interval package. The EMI 3000 package consists of the following key components: • EMI 3000-Hour Cyclonic Air Cleaner Assembly and Air Cleaner Element • EMI 3000-Hour 5-Micron Fuel Filter • EMI 3000-Hour Dual Element Oil Filter (blue with white lettering) •...

  • Page 126: Engine Oil Change

    Engine Maintenance Engine Oil Change The engine oil should be changed according to the Maintenance Inspection Schedule. Drain the oil only when the engine is hot to ensure that all the oil drains out. When changing oil, keep unit and Genset level so all the oil can flow from the oil pan.
  • Page 127 Engine Maintenance Low Oil Pressure Flow Chart Low Oil Pressure Check for oil dilution. Add oil until full. Is it just thin or does it Full Check Oil Level Re-check oil pressure in smell like fuel? low and high speed. Verify the unit switch, Repair and sensor, or gauge...

  • Page 128: Engine Cooling System

    Engine Maintenance Engine Cooling System The engine employs a closed, circulating type, pressurized cooling system. Correct engine temperatures are controlled and maintained by a radiator, fan and thermostat. The coolant is circulated through the system by a belt driven centrifugal pump. The pump draws the coolant from the side of the radiator, circulates it through the cylinder block and head and returns it to the radiator.

  • Page 129: Elc (Extended Life Coolant)

    Engine Maintenance ELC (Extended Life Coolant) ELC is used in this unit. A nameplate near the coolant expansion tank identifies units with ELC. NOTE: The new engine coolant, Texaco Extended Life Coolant, is RED in color instead of the current GREEN or BLUE-GREEN colored coolants.

  • Page 130: Antifreeze Maintenance Procedure

    Engine Maintenance NOTE: The use of 50/50 percent pre-mixed Extended Life Coolant (ELC) is recommended to assure that de-ionized water is being used. If 100 percent full strength concentrate is used, de-ionized or distilled water is recommended over tap water to insure the integrity of the cooling system is maintained.

  • Page 131: Bleeding Air From The Cooling System

    Engine Maintenance 8. Refill the radiator with the 50/50 antifreeze mixture and make sure to bleed the air from the cooling system as needed. Bleeding Air from the Cooling System Normally, all but about 1.5 qt (1.4 liters) of coolant drain out of the cooling system when it is drained. If approximately half of the Cooling System Capacity (see Specifications Chapter) seems to fill the cooling system after it has been drained, air has been trapped in the block.

  • Page 132: Figure 54: Expansion Tank

    Engine Maintenance The expansion tank uses a float type coolant level switch. The coolant level switch senses the position of the magnetic float inside the expansion tank. When the coolant level is above the switch, the float is in the upper position and the switch is closed.

  • Page 133: Engine Fuel System

    Engine Maintenance 4. Flip the expansion tank upside down and right side up to see if the float moves inside the expansion tank. Replace the expansion tank with a new one if the float is stuck or does not move with the coolant level.

  • Page 134: Operation

    Engine Maintenance Operation Fuel is drawn from the fuel tank by the electric fuel pump, which pushes fuel to the fuel filter/water separator. Filtered fuel passes through a line from the outlet fitting on the filter base to the high pressure fuel pump.

  • Page 135: Maintenance

    Engine Maintenance Maintenance Contamination is the most common cause of fuel system problems. Therefore, to ensure best operating results, the fuel must be clean and fuel tanks must be free of contaminants. Change the fuel filter/water separator regularly and inspect/clean the electric fuel pump filter. IMPORTANT: Do not open the fuel system unless required.

  • Page 136: Figure 57: Fuel Tank

    Engine Maintenance NOTE: MAKE SURE the fuel tank vent is kept open. If the vent becomes clogged, a partial vacuum develops in the tank, and this increases the tendency for air to enter the system. Vent Fuel Gauge Drain Plug Cap Tank Figure 57: Fuel Tank...

  • Page 137: Draining Water From Fuel Tank

    Engine Maintenance Draining Water from Fuel Tank Water run through the system may damage the fuel injection system components. Damage to the fuel injection system will subsequently cause more expensive damage to the engine. A large accumulation of water in the bottom of the fuel tank will stop a diesel engine. Water should be drained off during scheduled maintenance inspections to prevent breakdowns.

  • Page 138: Figure 58: Fuel Filter/Water Separator Assembly

    Engine Maintenance ARA1912 Filter Head Filter Element Filter Element Tab Filter Bowl Figure 58: Fuel Filter/Water Separator Assembly 5. Place the filter element in the filter head with the tabs (and the arrows) on the filter element aligned with the slots (and the arrows) in the filter bowl. Make sure that filter element is fully seated in the filter bowl.

  • Page 139: Electric Fuel Pump

    Engine Maintenance Electric Fuel Pump Operation The electric fuel pump must be mounted in the engine compartment. This pump is designed to push fuel rather than pull fuel. Make sure the CH wire completes a good ground with the battery. Check the voltage at the 8H wire in the harness.
  • Page 140 Engine Maintenance • Clean and tighten the electrical connections • The pump voltage and polarity must be the same as the unit system. If the pump operates but does not deliver fuel, check for: • Air leaks in the fuel lines or connections •...

  • Page 141: Air Supply System

    Engine Maintenance Air Supply System Air is supplied to the engine through the air filter to the Air flow meter to the turbo to the Intercooler to the intake manifold. It is then exhausted through the manifold to the turbo to the DOC. Some exhaust gas is recirculated through the EGR valve to engine intake.

  • Page 142: Emi 3000 Air Cleaner

    Engine Maintenance Figure 61: Back View of Engine EMI 3000 Air Cleaner The EMI 3000 air cleaner is a dry element air cleaner. Replace the EMI 3000 air cleaner element at 3,000 hours or 2 years, whichever occurs first. ARA1914 Figure 62: EMI 3000 Air Cleaner Assembly ARA1915 Figure 63: EMI 3000 Air Filter Element...

  • Page 143: Turbo Charge

    Engine Maintenance Turbo Charge Delivers improved fuel economy, more power and fewer particulate emissions. Intercooler The air after the turbo charger is cooled by the intercooler. It is mounted above the radiator EGR (Exhaust Gas Recirculation) System The EGR (Exhaust Gas Recirculation) system recirculates cooled exhaust gas to engine intake to reduce NOx emissions.

  • Page 144: Dv6Nr Engine Service Tool

    Engine Maintenance DV6NR Engine Service Tool The engine service tool Exxotest is a diagnostics tool to communicate with the ECU to view the PCM engine DTC’s (Diagnostics Trouble Code) and troubleshoot engine problems. Thermo King alarm codes A118 or A121 indicate DTCs are recorded in the ECU. Refer to section of this manual for more information about using Exxotest to connect to the ECU.
  • Page 145 Engine Maintenance...

  • Page 146: Alternator Operation And Diagnosis

    Alternator Operation and Diagnosis General Description The 460/230 Vac alternator consists of three principal components: the main alternator, the integral direct-connected exciter, and an externally mounted excitation control system. The main alternator may be subdivided into the 4-pole rotating main field and the alternator stator (ALT). The rotating main field, the rotating rectifier and the exciter armature are all mounted on a common shaft.

  • Page 147: Alternator Function

    Alternator Operation and Diagnosis Alternator Function Starting Excitation The initial excitation for the alternator is supplied by residual magnetism in the main field. Residual main stator voltage provides initial excitation power to the digital simplified regulator (DSR) from a separate 2-lead stator winding.

  • Page 148: Alternator Diagnosis

    Alternator Operation and Diagnosis Alternator Diagnosis Preliminary Checks WARNING: Extreme care must be used when working with an operating generator set. Lethal voltage potentials exist inside the control box, at terminals on the DSR and at the power receptacle. Before attempting the more complicated diagnosis procedures, check the following items to ensure a superficial problem is not overlooked.

  • Page 149: Test 2- Alternator Exciter Field Testing

    Alternator Operation and Diagnosis tests listed below to identify the component that may be causing a generator malfunction. • Symptom: Low Output Voltage—0 to 100 Vac NOTE: The DSR has a glass fuse (5AF 250 Volt) on the board. Check fuse if this fuse is blown disconnect fan and replace fuse check output voltage.

  • Page 150: Figure 68: Alternator Stator

    Alternator Operation and Diagnosis a. Disconnect the stator leads from the terminal board and ground stud in the terminal box. Check for continuity between the following pairs. 1-2, 3-4, 5-6, 7-8, 9-10, 11-12. The resistance between any of the pairs should be 0.239 (±10%) ohms at 25 C (77 F). b.

  • Page 151: Figure 70: Exciter Armature

    Alternator Operation and Diagnosis b. Unbolt the main field armature leads. Along with the main field armature leads are leads to a MOV. The MOV is a high voltage suppression device. When measured it will show open, it closes with peak voltage more than 600V cannot test. c.

  • Page 152: Megohmmeter

    Alternator Operation and Diagnosis AXA0324 Main Field Exciter Rotor Exciter Field Ohmmeter Figure 71: Main Field Winding Megohmmeter The use of a megohmmeter can be a valuable addition to the repair and maintenance of the generator set. The megohmmeter is essentially a high-range resistance meter (ohmmeter) with a built-in direct-current generator.

  • Page 153: General Inspection

    Alternator Operation and Diagnosis General Inspection Inspect the entire unit to see that controls are in order and that there are no loose nuts, bolts, electrical connections or fittings. Inspect for secure engine to generator mountings. Remove any waste material from area around the unit.

  • Page 154: Figure 72: Alternator Assembly

    Alternator Operation and Diagnosis BEN126 Rotor Assembly Rear Bearing Gasket - cover Rectifier Terminal Board Armature DSR Regulator Rotor Rear Grille Blower, Generator End Bracket Alternator Frame O-Ring Dowel Pin Strator Bracket Figure 72: Alternator Assembly...

  • Page 155: Alternator Replacement

    Alternator Operation and Diagnosis Alternator Replacement Alternator Removal When removing the alternator from the engine do not separate the stator and rotor, remove as one assembly. NOTE: If powerpack is removed from the frame, be sure to support the engine at the block area and do not sit it up on the oil pan(1).

  • Page 156: Alternator Installation

    Alternator Operation and Diagnosis Alternator Installation NOTE: A bad allignment may cause vibrations and bearing danages. It is advisable to verify the compatibility of the generator torsional characteristic’s and the Engine. 1. Position the alternator assembly up to the flywheel housing. Align the 2 dowel pins in the flywheel to the holes in the flex plate.
  • Page 157 Alternator Operation and Diagnosis...

  • Page 158: Structural/Accessory Maintenance

    Structural/Accessory Maintenance Unit Inspection Inspect the unit during unit pre-trip inspection and scheduled maintenance intervals. Look for loose or broken wires or hardware, and other physical damage which might affect unit performance. Repair if required. NOTE: See Service Guide chapter in this manual for the correct service interval for your unit. 250 or 500 hour inspection/service intervals are required in extreme operating conditions.

  • Page 159: Sgsm 4000 Typical Unit Installation

    Structural/Accessory Maintenance SGSM 4000 Typical Unit Installation 1. Attach the mounting arm assemblies on each end of the unit. Two sets of mounting bolt holes are provided on the mounting arms. NOTE: The clear insulator pad should be located between the steel mounting arms and the inside of the unit frame members.

  • Page 160: Sgsm 4000 Keener Arm Unit Installation

    Structural/Accessory Maintenance SGSM 4000 Keener Arm Unit Installation 1. Attach mounting arm assemblies to unit with clamp screw end of the channel facing the rear side of the unit. Torque mounting bolts that fasten mounting arms to the unit to 203 N.m (150 ft-lb). 2.

  • Page 161: Sgcm 4000 Unit Installation

    Structural/Accessory Maintenance SGCM 4000 Unit Installation 1. Attach the mounting arm assemblies on each end of the unit. BEN128 Fasten Chassis Clips on the Outside Edge of each I-Beam and TIghten Bolts Tighten Mounting Arm to Unit Bolts Figure 76: SGUM 4000 I-Beam Centermount Installation 2.

  • Page 162: Sgco 4000 Clip-On Corner Clamp Unit Installation

    Structural/Accessory Maintenance SGCO 4000 Clip-on Corner Clamp Unit Installation 1. Pull the lock pawl handle forward. Lift the clamp handle to rotate the clamp shaft 90 Degrees. 2. Lift the unit into mounting position on front wall of the container. The foot of generator set mounting clamp should fit into mounting hole on each side of the container.

  • Page 163: Figure 78: Sgco 4000 Clip-On Corner Clamp Installation Procedure

    Structural/Accessory Maintenance 3. Insert the foot of the mounting clamp fully into the container mounting hole. Pull lock pawl handle forward. Pull the clamp handle down to rotate the clamp shaft bolt 90° and clamp generator set to container. CAUTION: Watch the clamp flat on threaded end of the mounting shaft when rotating the handle.
  • Page 164 Structural/Accessory Maintenance 6. Install the lower mounting bolts: a. Remove the retaining pin from the lower mounting bracket. b. Remove the mounting bolt and backup plate from the keeper nut. Put the mounting bolt through the backup plate and install the bolt in the mounting hole. c.

  • Page 165: Sgco 4000 Clip-On Header Pin Unit Installation

    Structural/Accessory Maintenance SGCO 4000 Clip-on Header Pin Unit Installation 1. Lift the unit into mounting position on front wall of the container. Both header pins of generator set mounting channel should fit into mounting holes on top of the container. CAUTION: Take adequate precautions when lifting and mounting the generator set to prevent personal injury or unit damage.

  • Page 166: Unit Inspection

    Structural/Accessory Maintenance 3. Install the lower mounting bolts: a. Remove the retaining pin from the lower mounting bracket. b. Remove the mounting bolt and backup plate from the keeper nut. Put the mounting bolt through the backup plate and install the bolt in the mounting hole. c.
  • Page 167 Structural/Accessory Maintenance...

  • Page 168: Mechanical Diagnosis

    Mechanical Diagnosis Diagnosing Unit Conditions Condition Possible Cause Remedy Unit switch On; controller Corroded battery cable connections Clean and tighten display does not come on Batteries discharged Charge or replace batteries Fuse SI3 open (blown) Check for short circuit and replace fuse Defective On/Off switch Check switch Open circuit...
  • Page 169 Mechanical Diagnosis Diagnosing Unit Conditions Condition Possible Cause Remedy Engine stops after starting Alarm LED flashing Check alarm code and repair fault Vent of fuel tank obstructed Unclog vent Fuel filter obstructed Replace filter element Clogged fuel tank or fuel lines Clean fuel tank and fuel lines Air in injection pump Bleed fuel system...
  • Page 170 Mechanical Diagnosis Diagnosing Unit Conditions Condition Possible Cause Remedy High oil consumption Oil leakage Check and eliminate possible causes at cylinder head cover, oil lines, oil filter, front timing cover or crankshaft seals Clogged air cleaner system Clean air intake system; clean and refill oil reservoir on oil bath air cleaner;...
  • Page 171 Mechanical Diagnosis...

  • Page 172: Index

    Index Displaying and Acknowledging Messages 77 DOC (Diesel Oxidation Catalyst) system 142 Additional Options 42 After Start Inspection 61 air cleaner, EMI 3000 140 Alarm Diagnosis 74 EcoPower Option 40 Alarm List Menu 56, 73 EGR (Exhaust Gas Recirculation) system 141 Alarm Types 73 ELC (Extended Life Coolant) 128 Alarms, Displaying and Acknowledging 73...
  • Page 173 Index Installation, SGCO 3000 Clip-on Header Pin Unit 164 Controller Repair 13 Installation, SGSM 3000 158 Electrical Hazards 12 Installation, SGSM 3000 Keener Arm Unit 159 First Aid 12 Internal States 71 High Voltage 12 Precautions 12 Safety Do’s and Don’ts 14 Welding 14 LogView 111 Safety Precautions 11...

  • Page 174: Electrical And Sg+ Menu Flow Diagrams

    Electrical and SG+ Menu Flow Diagrams Drawing Title Page Wiring Diagram Genset SG+ Schematic Diagram Genset SG+ ECU Wiring Diagram SG+ Menu Flow Diagram 178-179...
  • Page 175 Electrical and SG+ Menu Flow Diagrams...

  • Page 176: Sgum 4000 And Sgco 4000 Wiring Diagram - Page 1 Of 1

    SGUM 4000 and SGCO 4000 Wiring Diagram — Page 1 of 1 RELEASED 16/Sep/2013...

  • Page 177: Sgum 4000 And Sgco 4000 Schematic Diagram - Page 1 Of 1

    SGUM 4000 and SGCO 4000 Schematic Diagram — Page 1 of 1...

  • Page 178: Ecu Wiring Diagram

    ECU Wiring Diagram (Page 1 of 1)

  • Page 179: Controller Menu Guide

    STANDARD DISPLAY CONTROLLER MENU GUIDE Keypad Operating Tips Text Input: PAUSE MODE DISPLAYS deLAY / AC RESTART IN XX MIN. • To enter a number: Press the U or D key to increase or decrease the value of a digit in the display. ALARM LIST MENU •...

  • Page 180: Controller Menu Guide (Continued)

    CONTROLLER MENU GUIDE (Continued) To/From Previous Page From Previous Page • Press key to toggle between Fuel Sensor Yes and No. Fuel Sensor: No • Press key to return to System Setup Submenu. • Press key to toggle between CLD on pin 5 Yes and No.
  • Page 181 Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

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