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Ingersoll-Rand Thermo King SGCM 4000, Руководство по обслуживанию

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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.

SB-210+

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TK 5XXXX-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 information 

to be placed here

TK 5XXXX-X-PL

314 West 90th Street
Minneapolis, MN 55420

Direct  (952) 887-2200

Thermo King Corporate

Distributed by:

SGSM 4000, SGCM 4000 

& SGCO 4000

TK 61010-4-MM (Rev. 0, 02/13)

314 West 90th Street
Minneapolis, MN 55420

Direct  (952) 887-2200

Thermo King Corporate

Maintenance Manual

Содержание Thermo King SGCM 4000

Страница 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...

Страница 2: ...SGSM 4000 SGCM 4000 SGCO 4000 TK 61010 4 MM Rev 0 02 13 Copyright 2013 Thermo King Ingersoll Rand Printed in EMEIA...

Страница 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...

Страница 4: ..._____________________________________________________ ________________________________________________________________________ ________________________________________________________________________...

Страница 5: ...4...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 17: ...Safety Precautions 16...

Страница 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...

Страница 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...

Страница 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...

Страница 21: ...20...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 29: ...Maintenance Inspection Schedule 28...

Страница 30: ...Maintenance Inspection Schedule 29...

Страница 31: ...Maintenance Inspection Schedule 30...

Страница 32: ...Maintenance Inspection Schedule 31...

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

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

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

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

Страница 37: ...Maintenance Inspection Schedule 36...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 47: ...Genset Model Features 46...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 53: ...Controller Description 52...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 145: ...Engine Maintenance 144...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 167: ...Structural Accessory Maintenance 166...

Страница 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...

Страница 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...

Страница 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...

Страница 171: ...Mechanical Diagnosis 170...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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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