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Ingersoll-Rand Thermo King SGCM 4000, Maintenance Manual, Page: 8 / 181

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Ingersoll-Rand Thermo King SGCM 4000 Maintenance Manual Download Page 8

Table of Contents

7

Engine Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

DV6NR Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Engine Lubrication System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Engine Oil Change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Low Oil Pressure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

ELC (Extended Life Coolant)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Antifreeze Maintenance Procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Bleeding Air from the Cooling System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Engine Thermostat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Coolant Level Switch   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Engine Fuel System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fuel Line Routing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fuel System Fittings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Draining Water from Fuel Tank   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Fuel Filter/Water Separator   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Fuel Filter/Water Separator Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Electric Fuel Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Air Supply System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

EMI 3000 Air Cleaner  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Air Flow meter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Turbo Charge   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Intercooler  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
EGR (Exhaust Gas Recirculation) System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
DOC (Diesel Oxidation Catalyst) System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Belts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Timing Belt Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

DV6NR Engine Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Alternator Operation and Diagnosis  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

General Description   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Alternator Function  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Starting Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Running Excitation and Control   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Overload  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Overload Shutdown   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Alternator Diagnosis  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Test Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Alternator Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Test 2- Alternator Exciter Field Testing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Test 3- Alternator Stator Testing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Megohmmeter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Maintenance Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

General Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Insulation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Field Coils, Stator Windings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Generator Housing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Generator Bearing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Impeller Fan  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Coupling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Alternator Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Alternator Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Structural/Accessory Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Summary of Contents for Thermo King SGCM 4000

Page 1: ...XXXX X PL TK 61010 4 MM 2013 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text informati...

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: ...ract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles contents or persons by reason of the installation of any Thermo Kin...

Page 4: ..._____________________________________________________ ________________________________________________________________________ ________________________________________________________________________...

Page 5: ...4...

Page 6: ...Control System 23 Electrical Components 23 Controller Default Settings 23 Physical Specifications 24 Physical Specifications 25 Metric Hardware Torque Charts 26 Maintenance Inspection Schedule 27 Unit...

Page 7: ...rvice Menu 89 System Setup 90 Misc Functions Menu 93 C F Mode 94 SW HW Version 96 Timers Counters 98 Date Time 100 Configuration Menu 102 Setting Hour Meter Thresholds and Resetting Hour Meters 105 Ev...

Page 8: ...Air Flow meter 141 Turbo Charge 142 Intercooler 142 EGR Exhaust Gas Recirculation System 142 DOC Diesel Oxidation Catalyst System 142 Belts 142 Timing Belt Replacement 142 DV6NR Engine Service Tool 14...

Page 9: ...it Installation 161 SGCO 4000 Clip on Header Pin Unit Installation 164 Unit Inspection 165 Radiator and After Cooler 165 Mechanical Diagnosis 167 Index 171 Electrical and SG Menu Flow Diagrams 173 SGU...

Page 10: ...ion Test example 87 Figure 29 Manual Function Test Submenu 88 Figure 30 System Setup Submenu 92 Figure 31 Misc Functions Menu 93 Figure 32 C F Mode 95 Figure 33 SW HW Version 97 Figure 34 Timers Count...

Page 11: ...68 Alternator Stator 149 Figure 69 Rectifying Diodes 149 Figure 70 Exciter Armature 150 Figure 71 Main Field Winding 151 Figure 72 Alternator Assembly 153 Figure 73 Under View of Engine Showing Oil Pa...

Page 12: ...very dangerous under certain conditions Battery Hazards Few people realize just how dangerous a battery can be The electrolyte in a lead acid battery is dilute sulfuric acid H2SO4 During charge or dis...

Page 13: ...to OFF before connecting or disconnecting a power plug to the generator set receptacle Never attempt to stop a refrigeration unit by disconnecting the power plug from an operating generator set 2 Be...

Page 14: ...e is present respiration may be restored by using mouth to mouth resuscitation but call for emergency medical assistance General Safety Precautions for Servicing Units or Containers Equipped with a Mi...

Page 15: ...OFF position 4 Weld unit and or container per normal welding procedures Keep ground return electrode as close to the area to be welded as practical This will reduce stray welding currents passing thr...

Page 16: ...alled and properly secured to the battery tray WARNING Improperly installed battery cables could result in fire or explosion Battery cables must be installed routed and secured properly to prevent the...

Page 17: ...Safety Precautions 16...

Page 18: ...the engine block near the flywheel end SGUM Units The unit serial number nameplate is attached to the unit frame near the rear mounting bracket or on the air cleaner bracket SGCO Units The unit seria...

Page 19: ...needed to service or repair the unit Service technicians should read and follow the instructions on all warning decals Figure 1 Model SGUM 4000 Decals 1 Thermo King Symbol 2 Operating Instructions EN...

Page 20: ...ructions EN ES 3 Auto Stop Start 4 Radiator Fill 5 CA Proposition 6 Warning Ether Use 7 Battery 925 CCA 8 Universal Fan 9 Decal Unit ID 10 Caution Lowering Bolts must be installed Figure 2 Model SGCO...

Page 21: ...20...

Page 22: ...065 703 Distilled fuel Ultra Low Sulphur 15ppm ASTM D 975 No 2 diesel ECU Electronic Control Unit EGR Cooled Electric EGR value Turbo Fixed geometry type waste gate Oil Capacity 12 quarts 11 4 liters...

Page 23: ...s 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 Coolant System Capacity...

Page 24: ...Motor 400 cranking 140 bench test Controller Default Settings Setting Menu Location Default Setting Tank Size Commands System Setup 125 Date Time Commands System Setup Software Date ID Number Command...

Page 25: ...24 Physical Specifications Weight net SGUM 4000 SGCM and SGSM 4000 the only difference is an added Bracket 678 Kg 1495 lbs including oil coolant battery and 195 liter 50 gal fuel tank excluding fuel U...

Page 26: ...Specifications 25 Physical Specifications Weight net SGCO 4000 818 Kg 1804 lbs including oil coolant battery and 473 liter 125 gal fuel tank excluding fuel 1 Unit Dimensions...

Page 27: ...6 41 47 30 35 68 81 50 60 122 149 90 110 HH SS 2 10 13 7 10 20 27 15 20 41 47 30 35 75 88 55 65 Bolt Type and Class Bolt Size M14 M16 M18 M22 N m Ft lb N m Ft lb N m Ft lb N m Ft lb HH CL 5 8 75 88 55...

Page 28: ...CJ 4 or better Inspect clean EGR system valve piping and cooler Change ELC red engine coolant every 5 years or 12 000 hours Units equipped with ELC have an ELC nameplate on the expansion tank Change T...

Page 29: ...Maintenance Inspection Schedule 28...

Page 30: ...Maintenance Inspection Schedule 29...

Page 31: ...Maintenance Inspection Schedule 30...

Page 32: ...Maintenance Inspection Schedule 31...

Page 33: ...Maintenance Inspection Schedule 32 S 8 Ju 0 3...

Page 34: ...Maintenance Inspection Schedule 33 1...

Page 35: ...Maintenance Inspection Schedule 34 RELEASED 18 Jul 2013 1...

Page 36: ...Maintenance Inspection Schedule 35 RELEASED 18 Jul 2013 1...

Page 37: ...Maintenance Inspection Schedule 36...

Page 38: ...non corrosive fittings all stainless steel external hardware brazed aluminum radiator and poly vinyl coating on the engine and generator Fuel tanks are provided as an integral part of each unit Fuel...

Page 39: ...Unit Description Features Options 38 Figure 4 SGCO 4000 Clip On Generator...

Page 40: ...e allows standard genset maintenance intervals to be extended to 3000 hours However please note that units equipped with the EMI 3000 package still require regular inspection in accordance with Thermo...

Page 41: ...107 C 225 F for more than 30 seconds The controller also records an alarm The unit will restart when the coolant temperature drops to 88 C 190 F Voltage Option A power cable and receptacle wired for...

Page 42: ...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...

Page 43: ...Cover 2 Fuel Tank Fill Neck and Cap 6 Engine Compartment Access Door 3 Unit Mounting Arms 7 460 or 230 Vac Power Receptacle Location 4 Alternator and Control Box Compartment Access Door 8 Radiator Loc...

Page 44: ...eplate Location 7 Fuel Gauge each side 3 Fuel Tank 8 Control Box Location 4 Alternator and Engine Compartment Access Door 9 Fuel Tank Fill Neck and Cap each side 5 460 or 230 Vac Power Receptacle Loca...

Page 45: ...l and Electric gauge attachment 2 TurboCharger 8 Oil Drain 3 Feed Return Oil Assembly 9 ECU Connectors 4 Oil Filter 10 Warm up ECU Connector 5 Water Inlet Assembly 11 Air duct Spigot 6 Exhaust Figure...

Page 46: ...nit mounting bracket S Center mount Unit mounting arms S Clip on Unit Frame S S S Combination Fuel Filter Water Separator S S S Dry Air Cleaner S S S Stainless Steel Exhaust System O O O Fuel Heater E...

Page 47: ...Genset Model Features 46...

Page 48: ...rator operation by providing Automatic unit preheat and engine startup during initial startup or delayed restart Variable glow plug preheat time Automatic Pretrip Test capability Delayed alternator ex...

Page 49: ...rt For Flash Loading Software 8 J2 Connector To SG Controller Display 9 2C Circuit Connection 10 8 Circuit Connection 11 Fuse SI3 10 Amp Protects Microprocessor Power Input Circuit 12 J4 Connector To...

Page 50: ...ess this key to enter or execute controller menu tasks or commands Alarm Key Press this key to go directly to the Alarm List Menu and view the alarm information in the display Language Key Press this...

Page 51: ...tion 50 1 Display 2 Down Key 3 Enter Key 4 Keypad 5 Language Key 6 Power LED 7 Unit On Off Switch 8 Download Port 9 Alarm LED 10 Alarm Key 11 Escape Key 12 Up Key Figure 11 Control Box Cover 1 2 3 4 5...

Page 52: ...n Submenu under the Misc Functions Menu Display menus The SG controller contains extensive display menus that can be navigated via the keypad The display menus are organized into seven Main Menus Data...

Page 53: ...Controller Description 52...

Page 54: ...wo pages in the manual It is designed to be folded out so you can continuously view it as you are learning how to navigate the SG Controller Menus It is recommended to fold this flow diagram out and l...

Page 55: ...e Controller Menus 54 Language Key Press the LANGUAGE key to change the language used on the display Figure 12 Controller Display 1 Down Key 2 Enter Key 3 Language Key 4 Alarm Key 5 Escape Key 6 Up Ke...

Page 56: ...ENGINE LAMPS GENERATOR UNIT PTI MANUAL FUNCTION TEST SHOW OUTPUTS SHOW STATES SHOW OUTPUTS SHOW STATES PERFORM PTI PERFORM TESTS SHOW ALARMS SHOW MESSAGES Event Submenu Main Menu ECU SERVICE MENU PERF...

Page 57: ...service tool is connected Oil Priming allows engine to be cranked without starting to prime oil galleries System Setup which is used to check the engine speed Speed Solenoid can ask the ECU to switch...

Page 58: ...mory Standard Display The Standard Display shows the output voltage It appears approximately one minute after the last key is pressed while the unit is running The Standard Display floats within the d...

Page 59: ...troller Link Down display indicates there is no communication between the SG controller and the display This is typically caused by a defective SG controller a defective display a defective cable or a...

Page 60: ...inals for corrosion cracks or moisture Repair or replace if necessary Structural Visually inspect the unit for leaks loose or broken parts and other damage The radiator coil should be clean and free o...

Page 61: ...m 30 to 01 while the controller performs some self checks d MAIN MENU DATA INIT The controller energizes the glow plugs for preheat if necessary The preheat buzzer is energized during the preheat peri...

Page 62: ...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...

Page 63: ...fy it is operating properly d The controller beeps to test the buzzer e The ECU ignition is tested f The ECU run relay is tested g The ECU fuel relay is tested h The ECU CAN connect is tested i Engine...

Page 64: ...Operating Instructions 63 NOTE Acknowledge the alarms or messages ONLY after the alarm codes are documented and problems repaired...

Page 65: ...ent Log Menu To enter the Main Menu complete the following steps 1 Place the On Off switch in the ON position 2 Press the ENTER key or the ESCAPE key to enter the Main Menu if it is not displayed 3 Th...

Page 66: ...MISC FUNCTIONS VOLTAGE 460 V MAIN MENU CONFIGURATION VOLTAGE 460 V MAIN MENU EVENT LOG VOLTAGE 460 V From DATA menu To DATA menu From ALARM LIST menu To ALARM LIST menu From MESSAGE LIST menu To MESS...

Page 67: ...ps 1 Place the On Off switch in the ON position 2 Press the ENTER key or the ESCAPE key to enter the Main Menu if necessary 3 The Data Menu is typically the first menu displayed in the Main Menu NOTE...

Page 68: ...GE 460 V DATA UNIT VOLTAGE 460 V To DATA prompt of MAIN menu From ENGINE menu To ENGINE menu From ENGINE LAMPS menu To ENGINE LAMPS menu From GENERATOR menu To DIGITAL OUTPUTS menu From UNIT menu To U...

Page 69: ...Data Menu is typically the first menu displayed in the Main Menu NOTE Press the UP or DOWN key to scroll up or down through the Main Menu to the Data Menu if necessary 4 Press the ENTER key to enter t...

Page 70: ...enu NOTE Press the UP or DOWN key to scroll up or down through the Main Menu to the Data Menu if necessary 4 Press the ENTER key to enter the Data Menu 5 Press the UP or DOWN key to scroll up or down...

Page 71: ...n Menu NOTE Press the UP or DOWN key to scroll up or down through the Main Menu to the Data Menu if necessary 4 Press the ENTER key to enter the Data Menu 5 Press the UP or DOWN key to scroll up or do...

Page 72: ...Menu NOTE Press the UP or DOWN key to scroll up or down through the Main Menu to the Data Menu if necessary 4 Press the ENTER key to enter the Data Menu 5 Press the UP or DOWN key to scroll up or dow...

Page 73: ...2 Press the ENTER key or the ESCAPE key to enter the Main Menu if necessary 3 The Data Menu is typically the first menu displayed in the Main Menu NOTE Press the UP or DOWN key to scroll up or down t...

Page 74: ...e screen and the time left to the restart attempt A delayed restart alarm becomes a shutdown alarm after the third failed restart attempt in an hour Shutdown Alarm The Alarm LED flashes and unit stops...

Page 75: ...arms and messages have been acknowledged 6 Press the DOWN key to scroll down to the next alarm if necessary 7 Write down the alarm code and the alarm text 8 Press the ENTER key to acknowledge the alar...

Page 76: ...gized 1 Check RL2 Fuel Hold relay A107 EXTERNAL OVERLOAD Shutdown Alarm Engine restart if output voltage is short circuited 1 Unplug load and attempt restart 2 Check alternator field circuit 3 Check a...

Page 77: ...A118 ENGINE STOP LAMP Engine stop lamp activated 1 Connect ECU Test Tool to read codes A119 LOW OIL PRESSURE Low oil pressure message active 1 Connect ECU Test Tool to read codes A120 OUTPUT VOLTAGE...

Page 78: ...key to scroll up or down through the Main Menu to the Message List Menu 4 Press the ENTER key to enter the Message List Menu 5 The Message List Menu will appear on the display It shows the most recen...

Page 79: ...n the following pages lists the messages their causes and possible diagnosis 101 1 1 WATER TEMPERATURE SENSOR FAILURE STATUS ACTIVE To MESSAGE LIST prompt of MAIN menu From MESSAGE LIST prompt of MAIN...

Page 80: ...engine RPM below 1350 Check and adjust engine speed M107 OUTPUT FREQUENCY HIGH Output frequency is above 70 Hz for 30 seconds engine RPM above 2100 Check and adjust engine speed M108 LOW OIL LEVEL Oi...

Page 81: ...C for 5 sec restarting 1 Check water temperature sensor 2 Check WTP WTN circuit M120 ENGINE FAILED TO CRANK Engine failed to crank and did not reach 40 RPM 1 Check battery battery cables and starter...

Page 82: ...k RPM sensor M130 DELAYED OUTPUT TIMED OUT Water temperature sensor is below 32 C 90 F for 5 minutes 1 Check water temperature sensor 2 Check WTS circuit M131 RL5 STARTER FEEDBACK FAILURE No feedback...

Page 83: ...Speed is below or above threshold 1 See Alternator Diagnosis on page 147 M144 DSR OVER CURRENT AND SPEED WARNING Current and speed above limits 1 See Alternator Diagnosis on page 147 M146 OUTPUT VOLTA...

Page 84: ...te the following steps 1 Place the On Off switch in the ON position 2 Press the ENTER key or the ESCAPE key to enter the Main Menu if necessary 3 Press the UP or DOWN key to scroll up or down through...

Page 85: ...PTI test COMMANDS MANUAL FUNCTION TEST VOLTAGE 460 V To MANUAL FUNCTION TEST menu From MANUAL FUNCTION TEST menu COMMANDS ECU SERVICE MENU VOLTAGE 460 V To ECU SERVICE menu From ECU SERVICE menu COMMA...

Page 86: ...ILED a The engine stops b The controller beeps to test the buzzer c A display test is performed Watch the display to verify it is operating properly d The PTI test is run in the following order ECU Ig...

Page 87: ...9 If an operating problem occurs during the PTI view and correct any alarms or messages Then acknowledge the alarms or messages and repeat the PTI NOTE Acknowledge the alarms or messages ONLY after th...

Page 88: ...gh the Main Menu to the Commands Menu 4 Press the ENTER key to enter the Commands Menu 5 The PTI submenu will be displayed 6 Press the UP or DOWN key to scroll up or down through the Commands Menu to...

Page 89: ...LAY TEST DISPLAY TEST ECU IGNITION TEST ECU RUN RELAY TEST ECU FUEL RELAY TEST To MANUAL FUNCTION TEST prompt of COMMANDS menu From MANUAL FUNCTION TEST prompt of COMMANDS menu DISPLAY TEST ECU IGNITI...

Page 90: ...oller You will get the following messages ECU SERVICE MODE ENGINE OFF CONTROLLER ON ECU ON The ECU Service Tool is software that is independant of the SG Controller and is a program with is opened on...

Page 91: ...Misc Functions Menu on page 93 for information about setting the date Time which is used to set the time See Misc Functions Menu on page 93 for information about setting the time ID Number which is us...

Page 92: ...Setup submenu 9 Press the ENTER key to enter the selected function Press the UP or DOWN key to change the value of the selected function See Misc Functions Menu on page 93 for information about setti...

Page 93: ...SYSTEM SETUP prompt of COMMANDS menu ENTER FUNCTION CHANGE SETTING or CURRENT RPM 1890 SPEED SOLENOID ON LOAD 18 ENGINE TYPE PCM ENTER FUNCTION CHANGE SPEED or and SAVE SETTING DISCARD CHANGE TANK SIZ...

Page 94: ...The C F Mode submenu will be displayed Press the ENTER key to enter C F Mode submenu to set the controller for Celsius or Fahrenheit units Press the UP or DOWN key to scroll up or down through the Mis...

Page 95: ...isc Functions Menu 4 Press the ENTER key to enter the Misc Functions Menu 5 The C F Mode submenu will be displayed 6 Press the ENTER key to enter C F Mode to change the units displayed 7 Press the UP...

Page 96: ...perating Instructions 95 Figure 32 C F Mode C F MODE CELSIUS ESC Save changes and return to C F MODE prompt of MISC FUNCTIONS menu From C F MODE prompt of MISC FUNCTIONS menu Toggles between C F ARA73...

Page 97: ...ON position 2 Press the ENTER key or the ESCAPE key to enter the Main Menu if necessary 3 Press the UP or DOWN key to scroll up or down through the Main Menu to the Misc Functions Menu 4 Press the EN...

Page 98: ...Operating Instructions 97 Figure 33 SW HW Version SW xxxxxx xx HARDWARE REV y To PROGRAM VERSION prompt of MISC FUNCTIONS menu From PROGRAM VERSION prompt of MISC FUNCTIONS menu ARA738...

Page 99: ...e last power up Total Restarts The total number of restarts Run Hours 50 Hz The number of hours the unit has been running at 50 Hz low speed Run Hours 60 Hz The number of hours the unit has been runni...

Page 100: ...OURS 0 RUN HOURS 0 HOUR METER 1 0 HOUR METER 2 0 ENGINE OFF HOURS 0 To TIMERS COUNTERS prompt of MISC FUNCTIONS menu From TIMERS COUNTERS prompt of MISC FUNCTIONS menu HOUR METER 1 0 HOUR METER 2 0 EN...

Page 101: ...ress the UP or DOWN key to scroll up or down through the MISC FUNCTIONS submenu to the Date Time submenu 9 Press the ENTER key to enter the Date Time submenu to set the clock 10 Press the ENTER key to...

Page 102: ...1 Figure 35 Date Time YEAR 2006 MONTH 03 DATE 22 TIME 14 08 Save changes and return to DATE TIME prompt of MISC FUNCTIONS menu ESC From DATE TIME prompt of MISC FUNCTIONS menu Scrolls values up down M...

Page 103: ...is OFF When this is set to ON the controller will reset all run timers to 0 when the unit is turned Off and then back On GENERATOR generator type M ALTE or STAMFRD GENSET Clip ON Side or centre OUTPUT...

Page 104: ...ASS WORD FACTORY RESET OFF GERERATOR M ALTE GENSET CLIP ON OUTPUT VOLTAGE 460 Toggle between PCM YANMAR Toggle between PCM YANMAR Toggle between ON OFF Toggle between ON OFF Scrolls cursor right Roll...

Page 105: ...00 CRANK RESTARTS 00003 COMPOSIT OFF RMM MASTER NO PASS WORD PASS WORD FUEL LEVEL 00000 CRANK RESTARTS 00003 COMPOSIT OFF RMM MASTER NO FUEL PUMP TIME 00000 LOAD 50 60 HZ 00003 LOAD 60 50 HZ 00000 CLD...

Page 106: ...the cursor on LOP Restart 6 Press the UP or DOWN key to scroll up or down through the Configuration Menu to HM1 Threshold HM2 Threshold Run Hours Run Hours 50 Hz or Run Hours 60 Hz 7 Press the ENTER k...

Page 107: ...or DOWN key to scroll up or down through the Main Menu to the Event Log Menu 4 Press the ENTER key to enter the Event Log Menu 5 The Event Log submenu will be displayed Press the ENTER key to enter t...

Page 108: ...ollowing steps 1 Place the On Off switch in the ON position 2 Press the ENTER key or the ESCAPE key to enter the Main Menu if necessary 3 Press the UP or DOWN key to scroll up or down through the Main...

Page 109: ...tructions 108 Figure 39 Event Log Submenu 20YY MM DD HH MM SYSTEM POWERED UP To EVENT LOG prompt of EVENT LOG menu From EVENT LOG prompt of EVENT LOG menu Jump to previous log event Jump to next log e...

Page 110: ...n the ON position 2 Press the ENTER key or the ESCAPE key to enter the Main Menu if necessary 3 Press the UP or DOWN key to scroll up or down through the Main Menu to the Event Log Menu 4 Press the EN...

Page 111: ...ctions 110 Figure 40 Fuel Events Submenu 20YY MM DD HH MM FUEL CHANGE 0025Ga To FUEL EVENTS prompt of EVENT LOG menu From FUEL EVENTS prompt of EVENT LOG menu Jump to previous log event Jump to next l...

Page 112: ...Pre trip PTI started PTI start event PTI failed PTI failed PTI OK PTI completed Configuration Factory reset Factory reset initiated by user Clock set Time and date adjusted Power Power off Time and d...

Page 113: ...hange in level 7 Ga 2008 08 10 18 39 SYSTEM Flash load completed Old 000000 00 New 080423 00 2008 08 10 18 39 POWER Power ON 2008 08 10 18 39 CONFIGURATION Clock set 2008 08 12 14 06 SPEED High to low...

Page 114: ...box are interchangeable The relays on the microprocessor PC board are not interchangeable with the relays mounted on the inside of the control box Test a relay by interchanging it with a known good re...

Page 115: ...Electrical Maintenance 114 4 Fuel Pump Relay 5 Spare Relay If Installed Figure 42 Components Inside Control Box...

Page 116: ...g System Battery charging current is supplied by SG Controller The battery charging circuit provides current to the battery until the proper charge level is attained 13 1 to 14 6 volts The alternator...

Page 117: ...Electrical Maintenance 116 Figure 43 Engine Oil Pressure Switch...

Page 118: ...tick Make sure that it is between the low mark and the full mark Add oil if necessary 5 The switch should be open and there should be no continuity between the switch wires When the oil level is betwe...

Page 119: ...s in engine oil and that it slides freely between the upper and lower stops 3 Slide the float up to the upper stop Check the continuity through the switch between OLS and CH wires The switch should be...

Page 120: ...urn the unit On Off switch to the OFF position 2 Disconnect the sensor at the plug next to the sensor 3 Turn the unit On Off switch ON NOTE Polarity must be considered when connecting temperature sens...

Page 121: ...issions so the engine is EPA Tier 4 compliant An ECU Engine Control Unit monitors and controls engine operation The unit controller indirectly monitors and controls the engine through the ECU Figure 4...

Page 122: ...Engine Maintenance 121 Figure 47 DV6NR Sensors Actuators for the non service view or exhaust side 1 Injector Cylinder 4 2 Crankshaft Speed Sensor 3 Oxygen Sensor 4 Oil Pressure Switch 1 2 3 4...

Page 123: ...Engine Maintenance 122 Figure 48 DV6NR Sensors Actuators Rear View 1 Glow Plugs 2 Oil Breather Heater 3 Camshaft Position Sensor 1 2 3...

Page 124: ...ine 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...

Page 125: ...2 000 Hour ELC Extended Life Coolant The EMI package allows standard maintenance intervals to be extended to 3 000 hours or 2 years whichever occurs first NOTE Units equipped with the EMI 3000 package...

Page 126: ...ve cover allow time for oil to migrate down to pan before checking level See Specifications Chapter for correct type of oil Oil Filter Change The oil filter should be changed along with the engine oil...

Page 127: ...Diluted with Fuel Check for excessive radial end play at the flywheel with a dial indicator Maximum 0 007 in 4 cylinder Excessive OK Drain oil through a clean coffee filter and check for wear metal co...

Page 128: ...at mounted in the water outlet box from the cylinder head to the radiator automatically maintains coolant temperature within the specified temperature range All water cooled engines are shipped from t...

Page 129: ...urrently approved by Thermo King for use in ELC units for five years or 12 000 hours Chevron Dex Cool Texaco ELC nitrite free Havoline Dex Cool with nitrates Havoline Dex Cool nitrite free Shell Dexco...

Page 130: ...to 30 F 34 C Do not mix antifreeze stronger than 68 percent permanent type coolant concentrate and 32 percent water for use in extreme temperatures Changing the Antifreeze 1 Run the engine until it is...

Page 131: ...goes back into the system is approximately equal to the amount of coolant that came out of the system 3 Start the engine Monitor the coolant temperature with the unit engine coolant temperature gauge...

Page 132: ...ant level is above the switch and check the continuity of the switch The switch should be closed If you removed the tank from the unit do this check with the tank upside down 4 Drain coolant from the...

Page 133: ...coolant level switch in the tank Align the tabs on the switch with the slots in the tank and turn the switch 1 4 turn to tighten it 4 Connect the wire harness connector to the coolant level switch NOT...

Page 134: ...uration of the fuel injection pulses Fuel Line Routing The fuel lines from the fuel tank connect to the fittings on the fuel filter Do not change the factory routing of the fuel lines from the fuel fi...

Page 135: ...rocedures can be done under field conditions 1 Bleeding air from the fuel system 2 Fuel tank and filter system maintenance 3 Electric fuel pump replacement or repair 4 High pressure fuel pump replacem...

Page 136: ...URE 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 1 Vent 2 Fuel Gauge 3 Drain Plug 4 Cap...

Page 137: ...eck valve open with a small screw driver to drain the tank 3 Let the water and fuel drain into the container until no water is visible in the fuel draining from the tank If the water and fuel do not d...

Page 138: ...ce Test Mode to energize the electric fuel pump Refer to the appropriate Diagnostic Manual for specific information about the Service Test Mode 9 Run the electric fuel pump until air bubbles are no lo...

Page 139: ...ective Disassembly 1 Unscrew and remove the fuel filter bowl 2 Unscrew the fuel filter 3 Wash the fuel filter in cleaning solvent and blow out the dirt and cleaning solvent with compressed air 4 Clean...

Page 140: ...ump 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 Kinks or other restrictions in the fuel...

Page 141: ...e 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...

Page 142: ...the EMI 3000 air cleaner element at 3 000 hours or 2 years whichever occurs first Figure 62 EMI 3000 Air Cleaner Assembly Figure 63 EMI 3000 Air Filter Element Air Flow meter Measures air supplied to...

Page 143: ...d the EGR valve 2 Inspect the EGR pipe and other components for carbon deposits and clean as necessary 3 Reinstall EGR pipe and other components if removed and make sure to use new gaskets DOC Diesel...

Page 144: ...CM 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 informatio...

Page 145: ...Engine Maintenance 144...

Page 146: ...R Excitation power is derived from a separate 2 lead stator winding Positive voltage build up from residual levels is provided through the semiconductor power circuitry of the DSR The rotor contains a...

Page 147: ...oltage fed to the exciter field and therefore the main field to maintain the alternator output voltage within specified limits Overload For temporary overloads such as refrigeration unit start up the...

Page 148: ...igeration unit 3 Check all push in plugs on control circuits for loose pins or sockets Make sure all wire terminals are tight Test Instruments If the preceding checks did not uncover the cause of the...

Page 149: ...output voltage Output voltage should be 400 VAC NOTE If output voltage is not 400 VAC go to Test 2 5 If the output is 400 VAC a Stop genset and check the resistance on the Quad winding b Disconnect t...

Page 150: ...megger meter check for insulation break down between each pair of leads to the stator case 500 Volts must be more than 1 M ohm c Remove the end bell for the remaining checks 2 Rotating Rectifier Each...

Page 151: ...er Armature a With the armature leads still disconnected from the diodes test between the following pairs of leads CR6 CR4 CR3 CR1 CR3 CR2 CR6 CR5 CR5 CR4 CR2 CR1 The resistance between any of the pai...

Page 152: ...ure content of the insulation resistance decreases with increase in temperature or moisture They can be quite different for a generator tested three days in a row yet not mean bad insulation What real...

Page 153: ...ion loose connections foreign matter etc Generator Housing Feel the alternator housing cautiously for abnormal temperatures as determined by previous experience with the unit If the generator is overh...

Page 154: ...sembly 9 Rear Bearing 2 Gasket cover 10 Rectifier 3 Terminal Board 11 Armature 4 DSR Regulator 12 Rotor 5 Rear Grille 13 Blower Generator 6 End Bracket 14 Alternator Frame 7 O Ring 15 Dowel Pin 8 Stra...

Page 155: ...1 Remove the grill from around the alternator Remove all but one of the bolts holding the alternator to the flywheel housing 2 Remove the bolts holding the flex plate to the flywheel Notice that one o...

Page 156: ...o the flywheel housing Align the 2 dowel pins in the flywheel to the holes in the flex plate Start to install the bolt through the alternator outer ring to the flywheel housing Install bolts at the 10...

Page 157: ...Alternator Operation and Diagnosis 156...

Page 158: ...rating conditions Mounting Bolts Check and tighten all engine and control box mounting bolts every 1 000 operating hours Unit mounting hardware should be inspected for tightness during every pretrip M...

Page 159: ...of the unit frame members 2 Move the unit under container or trailer chassis Place each mounting channel on top of a chassis frame member Locate each channel as close to the vertical web of the chass...

Page 160: ...d gripper channels Move each slider channel forward over the back edge of the chassis I beam 6 Place the eye bolts over the slider pins by adjusting the bolt length as necessary 7 Insert quick release...

Page 161: ...the chassis member as possible 3 Torque the mounting bolts Mounting Arm to Unit Frame 88 to 115 N m 65 to 85 ft lb Chassis Clip Bolt 162 to 176 N m 120 to 130 ft lb 1 Fasten Chassis Clips on the Outs...

Page 162: ...d fit into mounting hole on each side of the container CAUTION Take adequate precautions when lifting and mounting the generator set to prevent personal injury or unit damage 1 Lock Pawl 7 Washer Asse...

Page 163: ...t on the head of the clamp shaft CAUTION Watch the clamp flat on threaded end of the mounting shaft when rotating the handle The clamp flat should turn as the clamp handle rotates With the mounting cl...

Page 164: ...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 Tighten the lower mounting bolts to 300 to 380 N m 220 to...

Page 165: ...be sure the generator set frame fits tightly against the container Figure 79 SGCO Clip on Header Pin Mounting Installation CAUTION Take adequate precautions when lifting and mounting the generator se...

Page 166: ...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...

Page 167: ...Structural Accessory Maintenance 166...

Page 168: ...open circuit Replace relay check 2A 8S SR and PSR circuits Defective starter solenoid Replace solenoid Defective starter Repair starter Water in cylinders Check for hydrostatic lock Remove injectors...

Page 169: ...ine plugged Remove return line restriction Injection nozzles fouled or opening pressure too low Clean repair or replace injection nozzles Valve out of adjustment Adjust valves Compression too low Over...

Page 170: ...tem Battery defective Replace battery Controller defective Replace controller White Smoke fuel is not burning Cold engine Allow engine to warm up Air or water in fuel Bleed system Replace filters clea...

Page 171: ...Mechanical Diagnosis 170...

Page 172: ...uts 69 Digital Outputs 70 Displaying and Acknowledging Alarms 73 Displaying and Acknowledging Messages 77 DOC Diesel Oxidation Catalyst system 142 E EcoPower Option 40 EGR Exhaust Gas Recirculation sy...

Page 173: ...tions Battery Hazards 11 Controller Repair 13 Electrical Hazards 12 First Aid 12 High Voltage 12 Precautions 12 Safety Do s and Don ts 14 Welding 14 Safety Precautions 11 safety precautions battery in...

Page 174: ...173 Electrical and SG Menu Flow Diagrams Drawing Title Page Wiring Diagram Genset SG 175 Schematic Diagram Genset SG 176 ECU Wiring Diagram 177 SG Menu Flow Diagram 178 179...

Page 175: ...Electrical and SG Menu Flow Diagrams 174...

Page 176: ...175 SGUM 4000 and SGCO 4000 Wiring Diagram Page 1 of 1 RELEASED 16 Sep 2013...

Page 177: ...176 SGUM 4000 and SGCO 4000 Schematic Diagram Page 1 of 1...

Page 178: ...177 ECU Wiring Diagram Page 1 of 1...

Page 179: ...om Next Page CONTROLLER MENU GUIDE PAUSE MODE DISPLAYS deLAY AC1 RESTART IN XX MIN 2 STANDARD DISPLAY Top line shows Alarm Code and the position of the alarm and number of alarms stored in memory e g...

Page 180: ...r Meter 1 Hour Meter 2 Engine Off Hours Restarts Total Restarts Run Hours 50 Hz Run Hours 60 Hz SW XXXXXX XX Hardware Rev Y MISC FUNCTIONS MENU C F Mode Celsius Press or key to toggle between Celsius...

Page 181: ...XXXX X PL TK 61010 4 MM 2013 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text informati...

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