Ingersoll Rand Thermo King SGCO 4000 Manuals

Manuals and User Guides for Ingersoll Rand Thermo King SGCO 4000. We have 1 Ingersoll Rand Thermo King SGCO 4000 manual available for free PDF download: Maintenance Manual

Ingersoll Rand Thermo King SGCO 4000 Maintenance Manual

Ingersoll Rand Thermo King SGCO 4000 Maintenance Manual (181 pages)

Brand: Ingersoll Rand | Category: Portable Generator | Size: 7 MB

Table of Contents

Table of Contents
6
List of Figures

10
Safety Precautions

12
- General Practices
  12
- Battery Hazards
  12
  - Precautions
    12
  - First Aid
    13
- Electrical Hazards
  13
  - High Voltage
    13
  - Precautions
    13
  - Low Voltage
    14
- General Safety Precautions for Servicing Units (or Containers) Equipped with a Microprocessor Controller
  14
  - Controller Repair
    14
  - Welding of Units or Containers
    15
- Safety Do's and Don'ts
  15
  - Do Not
    15
- Battery Installation and Cable Routing
  16
- Battery Removal
  16
- Serial Number Locations
  18
- Unit Decals
  19
- Figure 1: Model SGUM 4000 Decals
  19
- Figure 2: Model SGCO 4000 Decals
  20
Specifications

22
- Engine
  22
- Generator
  23
- Electrical Control System
  24
- Electrical Components
  24
- Controller Default Settings
  24
- Physical Specifications
  25
- Physical Specifications
  26
- Metric Hardware Torque Charts
  27
Maintenance Inspection Schedule

28
Unit Description, Features & Options

38
- General Description
  38
- Figure 3: SGUM 4000 under Mount Generator
  38
- Figure 4: SGCO 4000 Clip on Generator
  39
- EMI 3000 Package
  40
- SG+ Microprocessor Controller
  40
- Figure 5: SG+ Controller Display
  40
- Unit Instruments
  41
- Unit Protection Devices
  41
- Voltage Option
  41
- Ecopower
  41
- Fuel Level Sensor Option
  42
- Figure 6: SGUM 4000 - Unit Front View
  43
- Figure 7: SGCO 4000 - Unit Front View
  44
- Figure 8: Engine (All Models) - Unit Front View
  45
Genset Model Features

46
Controller Description

48
- SG+ Controller Description
  48
- Figure 9: SG+ Controller Display
  48
- Figure 10: SG+ Microprocessor
  49
- Controller Overview
  50
- Figure 11: Control Box Cover
  51
- Miscellaneous Features
  52
Navigating the Controller Menus

54
- Controller Display Menus
  54
- Navigating Controller Menus
  54
  - Figure 12: Controller Display
    55
  - Figure 13: Menu Structure
    56
  - Menu Overview
    56
  - Alarm List Menu
    57
  - Commands Menu
    57
  - Configuration Menu
    57
  - Data Menu
    57
  - Message List Menu
    57
  - Misc. Functions Menu
    57
Table of Contents

58
Operating Instructions

60
- Pretrip Inspection
  60
  - Visual Inspection
    60
- Starting the Unit
  61
- After Start Inspection
  62
- Functional Inspection
  63
- Main Menu
  65
- Figure 17: Main Menu
  66
- Data Menu
  67
  - Figure 18: Data Menu
    68
  - Engine Menu
    69
  - Figure 19: Engine Submenu
    69
  - Engine Lamps
    70
  - Figure 20: Engine Lamps Submenu
    70
  - Figure 21: Generator Submenu
    71
  - Generator
    71
  - Figure 22: Unit Submenu
    72
  - Unit
    72
  - Figure 23: Internal States
    73
  - Internal States
    73
- Alarm List Menu
  74
  - Alarm Types
    74
  - Displaying and Acknowledging Alarms
    74
  - Alarm Diagnosis
    75
  - Figure 24: Alarm List Menu
    75
- Message List Menu
  78
- Commands Menu
  84
  - Figure 26: Commands Menu
    85
  - Pti
    86
  - Figure 27: PTI Submenu
    87
  - Figure 28: Manual Function Test Example
    88
  - Manual Function Test
    88
  - Figure 29: Manual Function Test Submenu
    89
  - ECU Service Menu
    90
  - System Setup
    91
  - Figure 30: System Setup Submenu
    93
- Misc. Functions Menu
  94
  - Figure 31: Misc. Functions Menu
    94
  - C/F Mode
    95
  - Figure 32: C/F Mode
    96
  - SW/HW Version
    97
  - Figure 33: SW/HW Version
    98
  - Timers/Counters
    99
  - Figure 34: Timers/Counters
    100
  - Date/Time
    101
  - Figure 35: Date/Time
    102
- Configuration Menu
  103
- Event Log Menu
  107
  - Figure 38: Event Log Menu
    107
  - Event Log
    108
  - Figure 39: Event Log Submenu
    109
  - Fuel Events
    110
  - Figure 40: Fuel Events Submenu
    111
  - Logview and Viewing SG+ Logs
    112
  - Figure 41: Example of SG+ Log
    113
Electrical Maintenance

114
- Battery
  114
- Relays
  114
  - Run Relay
    114
  - Will Light up When the Run Relay Is Energized
    114
  - Ignition Relay
    114
  - Fuel Pump Relay
    114
  - Figure 42: Components Inside Control Box
    114
  - Start Relay
    116
  - Preheat Relay
    116
- Unit Wiring
  116
- 12 VDC Charging System
  116
  - Engine Low Oil Pressure Switch
    116
  - Figure 43: Engine Oil Pressure Switch
    117
- Oil Level Sensor
  118
  - Switch Test
    118
  - Switch Removal and Installation
    118
  - Figure 44: Oil Level Sensor
    118
  - Bench Test
    119
- Coolant Temperature Sensor
  120
  - Sensor Test
    120
  - Figure 45: Coolant Temperature Sensor
    120
Engine Maintenance

121
- DV6NR Diesel Engine
  121
- Figure 46: DV6NR Sensors and Actuators
  121
- Figure 47: DV6NR Sensors & Actuators for the Non-Service View, or Exhaust Side
  122
- Figure 48: DV6NR Sensors & Actuators Rear View
  123
- Figure 49: DV6NR under Engine View
  124
- Emi 3000
  125
- Engine Lubrication System
  125
  - Figure 50: Oil Circuit Diagram
    125
  - Engine Oil Change
    126
  - Low Oil Pressure
    126
  - Oil Filter Change
    126
- Engine Cooling System
  128
- Bleeding Air from the Cooling System
  131
  - Engine Thermostat
    131
  - Coolant Level Switch
    131
  - Figure 53: Notch Position
    131
  - Figure 54: Expansion Tank
    132
- Engine Fuel System
  133
  - Figure 55: Fuel System
    133
  - Figure 56: Fuel Injection Components on Engine
    134
  - Fuel Line Routing
    134
  - Fuel System Fittings
    134
  - Operation
    134
  - Bleeding the Fuel System
    135
  - Maintenance
    135
  - Figure 57: Fuel Tank
    136
  - Draining Water from Fuel Tank
    137
  - Fuel Filter/Water Separator
    137
  - Fuel Filter/Water Separator Replacement
    137
  - Figure 58: Fuel Filter/Water Separator Assembly
    138
  - Electric Fuel Pump
    139
  - Figure 59: Electric Fuel Pump
    139
  - Air Supply System
    141
  - Figure 60: Air Circuit Diagram
    141
- List of Figures
  
  139
- Air Flow Meter
  142
- EMI 3000 Air Cleaner
  142
- Figure 61: Back View of Engine
  142
- Figure 62: EMI 3000 Air Cleaner Assembly
  142
- Figure 63: EMI 3000 Air Filter Element
  142
- Belts
  143
  - Timing Belt Replacement
    143
  - Figure 64: EGR Components
    143
- DOC (Diesel Oxidation Catalyst) System
  143
- EGR (Exhaust Gas Recirculation) System
  143
- Intercooler
  143
- Turbo Charge
  143
- DV6NR Engine Service Tool
  144
- Figure 65: ECU Interfaces (Except Power)
  144
- Figure 66: PCM ECU
  144
Alternator Operation and Diagnosis

146
- General Description
  146
- Figure 67: 460/230 Vac Alternator Component Function
  146
- Alternator Function
  147
  - Starting Excitation
    147
  - Running Excitation and Control
    147
  - Overload
    147
  - Overload Shutdown
    147
- Alternator Diagnosis
  148
  - Preliminary Checks
    148
  - Test Instruments
    148
  - Alternator Troubleshooting
    148
  - Test 2- Alternator Exciter Field Testing
    149
  - Test 3- Alternator Stator Testing
    149
  - Figure 68: Alternator Stator
    150
  - Figure 69: Rectifying Diodes
    150
  - Figure 70: Exciter Armature
    151
- Megohmmeter
  152
- Maintenance Procedures
  152
  - Figure 71: Main Field Winding
    152
  - Coupling
    153
  - Field Coils, Stator Windings
    153
  - General Inspection
    153
  - Generator Bearing
    153
  - Generator Housing
    153
  - Impeller Fan
    153
  - Insulation
    153
  - Figure 72: Alternator Assembly
    154
- Alternator Replacement
  155
  - Alternator Removal
    155
  - Figure 73: under View of Engine Showing Oil Pan
    155
  - Alternator Installation
    156
Table of Contents

158
Structural/Accessory Maintenance

158
Mechanical Diagnosis

168
Index

172
Electrical and SG+ Menu Flow Diagrams

174

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