Maintenance Manual

SB-210+
SGSM 4000, SGCM 4000
& SGCO 4000
Additional text information
to be placed here
TK 61010-4-MM (Rev. 1, 02/16)
TK 5XXXX-X-PL
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and air
conditioning systems, building and contracting services, parts support and advanced controls
for commercial buildings and homes.

Distributed by:

Thermo King Corporate

314 West 90th Street
Minneapolis, MN 55420
Direct (952) 887-2200

TK 61010-4-MM

©2013 Ingersoll Rand Company

Printed in U.S.A.
 SGSM 4000, SGCM
4000 & SGCO 4000
TK 61010-4-MM (Rev. 1, 02/16)

Copyright© 2013 Thermo King, Ingersoll Rand.

Printed in EMEIA.
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
Electrostatic Discharge (ESD) Training Guide TK 40282
Tool Catalog TK 5955
TKDV6 Engine Repair Manual TK 55810
The information in this manual is provided to assist owners, operators and service people in the proper
upkeep and maintenance of Thermo King units. The Thermo King family of generator sets includes three
models: SGSM, SGCM and SGCO. When maintenance information differs between models, this manual
uses the model nomenclature (e.g. SGSM) to indicate that the information applies to specific units only. In
addition, the model nomenclature indicates the following:
Model Nomenclature Unit Feature
SM............................................ Side-mount unit frame
CM.........................................Center-mount unit frame
CO................................................... Clip-on unit frame

Revision History
Rev. 1 – TK 61010-4-MM (Rev. 1, 02/16) Update with 6,000 hour engine timing belt
replacement procedure, other latest engine information, new radiator fan motor, and
other general updates.

This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.

Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”

No warranties, express or implied, including warranties of fitness for a particular

purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
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 King product or its mechanical failure.

2
 CHANGES, COMMENTS and SUGGESTIONS
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needs. Any corrections, comments or suggestions are welcome. Please complete the following
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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

3
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Safety Precautions for Servicing Units (or Containers) Equipped with a Microprocessor Controller . . . 10
Controller Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Welding of Units or Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Do’s and Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DO: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DO NOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unit Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Controller Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Metric Hardware Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit Description, Features & Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
EMI 3000 Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SG+ Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Unit Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Voltage Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
EcoPower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel Level Sensor Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Genset Model Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SG+ Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Controller Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Miscellaneous Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Navigating the Controller Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Controller Display Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Navigating Controller Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alarm List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Message List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Commands Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Misc. Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4
 Table of Contents

Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Event Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pause Mode Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Controller Link Down Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pretrip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Functional Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Engine Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Internal States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Alarm List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Displaying and Acknowledging Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Alarm Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Message List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Displaying and Acknowledging Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Message Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Commands Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
PTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Manual Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ECU Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Oil Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Misc. Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
C/F Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SW/HW Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Timers/Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Date/Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Setting Hour Meter Thresholds and Resetting Hour Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Event Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fuel Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LogView and Viewing SG+ Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Ignition Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Run Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
The Run relay (RL2) is located on the PC board. It supplies power to the ECU. The RL2 LED on the PC board
will light up when the Run relay is energized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Preheat Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ECU Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
12 Vdc Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Engine Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5
Table of Contents

Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
DV6NR Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
DV6NR Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Using EXXODiag to Connect to ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Fuel Line Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Fuel System Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Fuel Filter/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Air Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Air Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
EGR (Exhaust Gas Recirculation) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
DOC (Diesel Oxidation Catalyst) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Timing Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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

6
 Table of Contents

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

Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Alternator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Structural/Accessory Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
SGSM 4000 Typical Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
SGSM 4000 Keener Arm Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
SGCM 4000 Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
SGCO 4000 Clip-on Corner Clamp Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
SGCO 4000 Clip-on Header Pin Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Radiator and Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Fan Installation for Separate Fan and Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Electrical and SG+ Menu Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Wiring Diagram SG+ Units with One Piece Fan and Motor (Before 6/15) — Page 1 of 2 . . . . . . . . . . . . . 173
Wiring Diagram SG+ Units with One Piece Fan and Motor (Before 6/15) — Page 2 of 2 . . . . . . . . . . . . . 174
Schematic Diagram SG+ Units with One Piece Fan and Motor (Before 6/15) — Page 1 of 1 . . . . . . . . . . 175
Wiring Diagram SG+ Units with Separate Fan and Fan Motor (6/15 and After) — Page 1 of 2 . . . . . . . . . 176
Wiring Diagram SG+ Units with Separate Fan and Fan Motor (6/15 and After) — Page 2 of 2 . . . . . . . . . 177
Schematic Diagram SG+ Units with Separate Fan and Fan Motor (6/15 and After) — Page 1 of 1 . . . . . 178
CONTROLLER MENU GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

7
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:

The 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.

CAUTION: Denotes the possibility of minor to severe equipment damage or personal injury.

General Practices
1. Always Wear Goggles Or Safety Glasses. Battery acid can permanently damage the eyes (see First
Aid under Battery Hazards).
2. Keep your hands, clothing and tools clear of all fans, pulleys and belts when the unit is running. Be
very careful with tools or meters to avoid contacting the rotor, if it is necessary to run the alternator
with the end cover removed.
3. Be sure all mounting bolts are tight and the correct length for their particular application.
4. Use extreme caution when drilling holes in the unit. The holes may weaken structural components.
Holes drilled into electrical wiring can cause fire, explosion or shock hazard.
5. Use caution when working around exposed coil fins. The fins can cause painful lacerations.
6. Do not work on a generator set in a confined area. Diesel exhaust can become 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 discharge functions of a battery, a chemical change takes place
within the individual cells. This causes the gas bubbling we see through the filler hole. The bubbling
gases are hydrogen and oxygen. They are EXPLOSIVE. An explosion could occur if a means of ignition
is present during this gassing action. A defective battery may suddenly explode even while standing idle.
Added to this danger, is the fall-out of highly corrosive sulfuric acid caused by the explosion. A rubber
blanket or other cover can be used to reduce the risk of injury from a possible explosion.

Precautions
1. Always wear eye protection when servicing a battery. If electrolyte is splashed on the skin or in the
eyes, flush immediately under running water. Obtain medical help as soon as possible.
2. Do not remove the vent caps when charging a battery.

8
 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.
4. Do not check a battery by shorting (sparking) across the battery posts. Eye injury may result from the
electrical arc or from an explosion.

First Aid
• EYES: Immediately flush eyes with large amounts of water while holding the eyelids open for at least
15 minutes. Get prompt medical attention.
• SKIN: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if
irritation persists.

Electrical Hazards
High Voltage
The possibility of serious or even fatal injury from electrical shock exists, when servicing or repairing a
generator set, Extreme care must be used when working with an operating generator set. Lethal voltage
potentials can exist at the unit power cord, inside the exciter control box, inside any high voltage junction
box and within the wiring harnesses.

Precautions
1. Turn the generator set On/Off switch 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 certain a unit power plug is clean and dry before connecting it to the generator set receptacle.
3. Use tools with insulated handles that are in good condition. Never hold metal tools in your hand if
exposed, energized conductors are within reach.
4. Stand on a solid work platform with rubber mats or dry wood if possible. If you slip, you can
instinctively grab for support. This can be lethal when working on a generator set.
5. Do not make any rapid moves when working on high voltage circuits. If a tool or other object falls, do
not attempt to grab it. People do not contact high voltage wires on purpose. It occurs from an
unplanned movement.
6. Treat all wires and connections as high voltage until a meter and wiring diagram show otherwise.
7. Never work alone on high voltage circuits on the generator set. Another person should always be
standing by in the event of an accident to shut off the generator set and to aid a victim.
8. Have electrically insulated gloves, cable cutters and safety glasses available in the immediate vicinity
in the event of an accident.

First Aid
IMMEDIATE action must be initiated after a person has received an electrical shock. Obtain immediate
medical assistance if available.

9
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.
Do not wear jewelry, watches or rings. These items can short out and cause severe bums to the wearer.
The source of shock must be immediately removed by either shutting down the power or removing the
victim from the source. If it is not possible to shut off the power, the wire should be cut with either an
insulated instrument (e.g., a wooden handled axe or cable cutters with heavy insulated handles) or by a
rescuer wearing electrically insulated gloves and safety glasses. Whichever method is used, do not look at
the wire while it is being cut. The ensuing flash can cause burns and blindness.
If the victim has to be removed from a live circuit, pull the victim off with a non-conductive material. Use
the victim’s coat, a rope, wood, or loop your belt around the victim’s leg or arm and pull the victim off.
DO NOT TOUCH the victim. You can receive a shock from current flowing through the victim’s body.
After separating the victim from the power source, check immediately for the presence of a pulse and
respiration. If a pulse is not present, start CPR (Cardio Pulmonary Resuscitation) and call for emergency
medical assistance. If a pulse 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 Microprocessor Controller
Precautions must be taken to prevent electrostatic discharge during service of the SG+ microprocessor
controller and related components. The risk of significant damage to the electronic components of the unit
is possible If these precautionary measures are not followed.
The primary risk potential results are as follows:
• The failure to wear adequate electrostatic discharge preventive equipment when handling and
servicing the controller.
• Electric welding on the unit and/or container chassis without taking precautionary steps.

Controller Repair
It’s necessary to ensure that electrostatic discharges are avoided when servicing the controller. Potential
differences considerably lower than those which produce a small spark from a finger to a door knob can
severely damage or destroy solid-state integrated circuit components. The following procedures must be
rigidly adhered to when servicing these units to avoid controller damage or destruction.
1. Turn the generator set OFF.
2. Disconnect the negative terminal of the battery. Disconnect the cable end that is away from the
battery.
3. Avoid wearing clothing that generates static electricity (wool, nylon, polyester, etc.).
4. Wear a static discharge wrist strap (TK P/N 204-622) with the lead end connected to the controller's
ground terminal. These straps are available at most electronic equipment distributors. DO NOT wear
these straps with power applied to the unit.
5. Avoid contacting the electronic components on the unit circuit boards.

10
 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. After servicing the circuit board and any other circuits, the wiring should be checked for possible
errors before restoring power.

Welding of Units or Containers

It is necessary to ensure that welding currents are NOT allowed to flow through the electronic circuits of
the unit. This includes whenever electric welding is to be performed on any portion of the generator set,
container or container chassis with the generator set attached. These procedures must be rigidly adhered
to when servicing these units to avoid damage or destruction.
1. Disconnect all power to the generator set.
2. Disconnect all wire harnesses from the microprocessor.
3. Switch all of the electrical circuit breakers in the control box to the 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 through any
electrical or electronic circuits.
5. When the welding operation is completed, the unit power cables, wiring and circuit breakers must be
restored to their normal condition.

Safety Do’s and Don’ts

DO:
• Do perform your tasks carefully, without undue haste.
• Do provide a fire extinguisher (rated ABC).
• Do provide a First Aid kit (for bums and abrasions). Obtain medical attention.
• Do use the correct tools for the job you are doing.
• Do make sure that all fasteners are secure.
• Do use extreme care while making adjustments on the generator set while it is running.
• Do keep your hands away from moving parts.
• Do disconnect the battery before starting work on a generator set.
• Do use screwdrivers, pliers, diagonal pliers. etc. with insulated handles.
• Do obtain CPR (Cardio Pulmonary Resuscitation) and mouth-to-mouth resuscitation knowledge.
• Do Practice Safety, The Life You Save May Be Your Own.

DO NOT
• Don’t allow inexperienced personnel to work on the generator or electrical equipment.
• Don’t remove guards or protective devices.

11
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.
• Don’t stand on a wet floor while working on electrical equipment. Use rubber insulated mats placed
on dry wood platforms.
• Don’t lunge after a dropped tool. To do so may place you in a position of extreme danger.
• Don’t commence any operation until you have taken all the necessary steps to ensure that you are in
complete safety.

Battery Installation and Cable Routing

WARNING: Improperly installed battery could result in a fire or explosion! A Thermo King
approved battery must be installed 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 them from rubbing, chaffing or
making contact with hot, sharp or rotating components.

WARNING: Do not attach fuel lines or any additional wiring harnesses to the battery cables as
this could cause an electrical fire!

CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King
unit. This could result in severe damage to equipment and void the warranty!

CAUTION: Set all unit electrical controls to the OFF position before connecting battery cables
to the battery to prevent unit from starting unexpectedly and causing personal injury.

CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing
batteries. Battery acid can cause serious burns when exposed to eyes or skin. If battery acid
contacts skin or clothing, wash immediately with soap and water. If acid enters your eye,
immediately flood it with running cold water for at least twenty minutes and get medical
attention immediately.

CAUTION: Always cover battery terminals to prevent them from making contact with metal
components during battery installation. Battery terminals grounding against metal could cause
the battery to explode.

Battery Removal
DANGER: Disconnect the negative battery terminal (-) first when removing a battery. Connect
the positive terminal (+) first when installing a battery.

This order is important because the frame is grounded to the negative battery terminal. If the negative
terminal is still connected, a complete circuit exists from the positive terminal of the battery to the frame.
Metal objects contacting the positive side and the frame simultaneously will cause sparks or arcing. If
there are sufficient hydrogen gases emitted from the battery, an explosion might occur, causing equipment
damage, serious injury, even death.

12
Serial Number Locations
Generator: The generator nameplate is attached to the generator housing. The serial number is located on
this nameplate.
Engine: The engine serial number is stamped on the back side of 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 serial number nameplate is attached to the unit battery box beside the engine
compartment.
SG+ Controller: The controller serial number nameplate is on the end of the controller and on mounting
flange of controller.

13
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.

10

3 6

7
5

1. Thermo King Symbol

2. Operating Instructions 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, 460V

Figure 1: Model SGUM 4000 Decals

14
 Unit Decals

10

5
AXA0313

4
8

1
9

3 2

1. Thermo King Symbol

2. Operating Instructions 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 4000 Decals

15
Specifications

Engine
Model DV6NR (Tier 4)
Number of Cylinders 4
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 Direct Injection
Speed Control Electronic Isochronous speed control
Electronically Controlled common rail system multiple
Fuel System
injection
Fuel Type No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Noise Less than 71 dBA under any condition
Diesel fuel Ultra low sulfur (ULSD) CFR 1065.703; Max
Fuel Requirements
15ppm Sulfur. ASTM D 975 No 2 diesel
ECU Electronic Control Unit
EGR Cooled Electric EGR value
Turbocharger Fixed geometry type, waste gate
Oil Capacity 12.4 quarts (11.7 liters) crankcase and oil filter
Fill to full mark on dipstick
Oil Type API Classification CJ-4 or better
Oil Viscosity: Recommended 10W-30 Delo XLE Syntheblend for -13 to 100 F (-25 C to
38 C)
5W-40 Delo 400LE Full Synthetic for Cold Climates -22 to
122 F (-30 C to 50 C)
For Other Climates 14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic)
5 to 104 F (-15 to 40 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 100 F (-25 to 38 C): SAE 10W-30
-22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic)
Below -22 F (-30 C): SAE 0W-30 (Synthetic)
Engine rpm: Low Speed Operation 1500 ± 25 rpm
High Speed Operation 1800 ± 25 rpm
Intake Valve Clearance Hydraulic
Exhaust Valve Clearance Hydraulic
Engine Coolant Thermostat 160 F (71 C)

16
 Specifications

Engine (Continued)
Engine Coolant Type Chevron/Delo XLC - a nitrite-free Extended Life Coolant
(ELC)
Use a 50/50 concentration
CAUTION: Do not add other types of coolant to cooling
systems using Chevron/Delo XLC except in an
emergency. If another type of coolant is added, the
coolant must be changed to Chevron/Delo XLC when
available.
Coolant System Capacity 7.5 quarts (7.1 liters)
Radiator Cap Pressure 21 psig (145 kPa)

* SG+ controller uses a sensor to provide engine high coolant temperature protection.

Generator
Type 460/230 Vac, 3 Phase, 60 Hz
Output Power 15 kw
Kilovolt-Amperes 18.75 kVA
RPM 1800 RPM

Radiator Fan Motor

One Piece Fan and Motor (Before 6/15)
Voltage/Phase/Frequency 460 Vac/3 Phase/60 Hz
Amperes 4.5 to 4.6 amps
RPM 2890 to 3430 RPM
Separate Fan and Fan Motor (6/15 and After)
Voltage/Phase/Frequency 460 Vac/3 Phase/60 Hz
Amperes 1.3 amps
RPM 3499 RPM

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

17
Specifications

Electrical Components
NOTE: Disconnect components from unit circuit to check resistance.
Current Draw (Amperes) at 12.5 Vdc Resistance (Ohms)
Glow Plugs 35 AMP Max
Starter 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 – Commands/System Setup 00000000
C/F Mode – Misc. Functions F
HM1 (Hour Meter 1) Threshold – Configuration 0
HM2 (Hour Meter 2) Threshold – Configuration 0
ENG (Engine) Off Hours – Configuration 0
Factory Reset – Configuration Off
APU Connected – Configuration Off
Output Voltage – Configuration 460
Fuel Sensor – Configuration Off
Fuel Level – Configuration 0
Crank Restarts – Configuration 3
Telematic – Configuration Off

18
 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

19
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:

RELEASED 18/Jul/2013
1

20
 Specifications

Metric Hardware Torque Charts

Bolt Size
Bolt Type
M6 M8 M10 M12
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 – CL 10.9 14-17 (10-13) 27-34 (20-25) 54-68 (40-50) 102-122 (75-90)
HH – CL 12.9 17-21 (12-16) 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 Size
Bolt Type and
M14 M16 M18 M22
Class*
N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.)
HH – CL 5.8 75-88 (55-65) 115-135 (85-100) 177-216 (130-160) 339-406 (250-300)
HH – CL 8.8 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)
HH – CL 10.9 136-176 (100-130) 224-298 (180-220) 393-474 (290-350) 678-813 (500-600)
HH – CL 12.9 177-216 (130-160) 285-352 (210-260) 448-542 (330-400) 881-1016 (650-750)
HH – SS (2) 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)

*HH = Hex Head, CL = Class.

21
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]).
• • Drain water from fuel tank and check vent.
• • Inspect/clean electric fuel pump filter.
Check engine mounts for wear.
• Replace EMI 3000 air cleaner element (see “EMI 3000 Air Cleaner” on
page 123) at 3,000 hours or one year (whichever occurs first).
• Replace EMI 3000 fuel filter/water separator.
• Change engine oil and oil filter (hot). Requires oil with API Rating CJ-4 or
better.
NOTE: For high biodiesel use (B20) the engine oil and oil filter should be
changed every 1,500 hours.
— Change Timing Belt, Water Pump, Belt Tensioner, and Idler Pulley with
Timing Belt Kit every 6,000 hours. When replacing the Timing Belt,
inspect the High Pressure Fuel Pump and replace as necessary.
— Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank.
Electrical
• • Inspect battery terminals and electrolyte level.
• • Inspect wire harness for damaged wires or connections.
Inspect AC generator and alternator wire connections for tightness.
Inspect electric motors.
Structural
• • • Visually inspect unit for fluid leaks.
• • • Visually inspect unit for damaged, loose or broken parts.
• • Clean entire unit including radiator coil.
• • Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.
*3,000 hours or one year, whichever occurs first.

22
Maintenance Inspection Schedule

23
Maintenance Inspection Schedule

24
Maintenance Inspection Schedule

25
Maintenance Inspection Schedule

26
Maintenance Inspection Schedule

RELEASED 18/Jul/2013
1

27
Maintenance Inspection Schedule

RELEASED 18/Jul/2013
1

28
Maintenance Inspection Schedule

RELEASED 18/Jul/2013
1

29
Maintenance Inspection Schedule

30
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.

CAUTION: DO NOT attempt to operate or maintain the generator until you have completely
familiarized yourself with the equipment.

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 also reduce emissions 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.
Each unit features a welded, heavy-gauge steel frame with special sea-going finish; 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 capacities are: 473 liter (125 gal.) on SGCO
clip-on models; 303 liter (80 gal.), or 210L (50 gal.) on SGCM center mount or SGSM side mount
models.
The alternator is a brushless, rotating field ac generator. A rectified exciter armature output provides dc
power for the field. The exciter field obtains its power from the full wave rectified output of the main
generator. The alternator supplies 230 or 460 Vac, 3 phase, 4 wire, 60 Hz power at 1800 RPM.
This equipment develops normal output voltages (below 600 volts) whenever the engine is running. All
output voltages normally reach 460 volts. Under malfunction conditions, 575 volts may be produced. Any
electric potential more than 50 volts is hazardous. Exercise caution and discretion in the operation and
maintenance of the equipment.

Figure 3: SGUM 4000 Under Mount Generator

31
Unit Description, Features & Options

Figure 4: SGCO 4000 Clip On Generator

32
 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:
• 5 Year or 12,000 Hour Extended Life Coolant (ELC)
• EMI 3000 Dual Element Oil Filter, P/N 11-9960 (identified by blue and white colors)
• EMI 3000 API Rating CI-4 Mineral Oil
• EMI 3000 Fuel Filter, P/N 11-9957
EMI 3000 equipped units are identified by a “ELC” decal tag on the coolant expansion tank, and blue and
white colored oil filters. The EMI 3000 package 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 King pretrip inspection and maintenance recommendations
(see the Maintenance Inspection Schedule chapter in this manual).

SG+ Microprocessor Controller

The SG+ Microprocessor controller controls and monitors unit operation, records system faults and
performs an automatic pre-trip check. The controller monitors all unit protection shutdown functions and
the exciter system.The controller shuts down unit operation due to low engine oil pressure, low engine oil
level, high coolant temperature, or alternator overload. The module also delays excitation power supply
for 2 minutes after unit start-up. The SG+ Microprocessor controller is designed with the capability to
have the software flash loaded.

Figure 5: SG+ Controller Display

33
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.
FUEL GAUGE. A gauge mounted in the fuel tank indicates the level of diesel fuel in the tank.

Unit Protection Devices

WARNING: the unit may start at any time without warning when the unit On/Off switch in the
On position.
Units equipped with a SG+ controller feature a Delayed Restart mode. The controller will make
up to three (3) attempts every 20 minutes to restart the unit after a Delay Alarm has occurred.
The Delayed Restart mode continues until the unit has been successfully restarted, or until a
Shutdown Alarm is generated. Protection shutdown devices that cause an Delayed Restart
shutdown condition include:
• Low Oil Pressure
• Low Oil Level
• High Water Temperature
Low Oil Pressure Switch: Engine oil pressure should rise immediately on starting. The controller will stop
the engine if oil pressure drops below 117 ± 21 kPa, (1.17 ± 0.21 bar), (17 ± 3 psig) for more than 30
seconds, and the oil level drops below 8 qt (7.6 litres) (Also see oil level sensor below). The controller
then records an alarm.
Oil Level Sensor: An oil level switch closes if the oil level drops below 8 qts. (7.6 liters) and the oil
pressure drops below 117 ± 21 kPa (Also see low oil pressure switch above). The controller will stop the
engine if the switch stays closed for more than 30 seconds. The controller then records an alarm.
Water Temperature Sensor: The controller will stop theengine if the engine coolant temperature rises to
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 230 Vac or 460 Vac is supplied as standard equipment with each
generator. Genset models can be wired for either receptacles: 230 Vac or 460 Vac.

EcoPower
EcoPowerTM is an standard feature on all SG 4000 units - designed to save fuel and meet emissions
regulations. The controller monitors the load from the refrigeration unit and determines if the engine
should run in high speed (1890 ± 10 RPM), or low speed (1560 ± 5 RPM). The output frequency is 60 Hz
in high speed and 50 hz in low speed. The engine runs in high speed for at least fifteen minutes when it is
started, and whenever it shifts from low speed to high speed.

34
 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.

3
1

BEN115 6

1. Fuel Tank 5. Control Box 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 8. Radiator Location
Compartment Access Door

Figure 6: SGUM 4000 — Unit Front View

35
Unit Description, Features & Options

10

8
9
4

6
7

BEN121

1. Battery 6. Lower Mounting Screw and Washer (each side)

2. Unit Nameplate Location 7. Fuel Gauge (each side)
3. Fuel Tank 8. Control Box Location
4. Alternator and Engine Compartment 9. Fuel Tank Fill Neck and Cap (each side)
Access Door
5. 460 or 230 Vac Power Receptacle 10. Bracket-Clip on (One each side)
Location

Figure 7: SGCO 4000 — Unit Front View

36
 Unit Description, Features & Options

10

4
9

5
7

1. Mass Air Flow Sensor 6. Exhaust

2. Turbocharger 7. Oil Fill and Electric gauge attachment
3. Feed Return Oil Assembly 8. Oil Drain
4. Oil Filter 9. ECU Connectors
5. Water Inlet Assembly 10. Preheat Relay Socket

Figure 8: Engine (All Models) — Unit Front View

37
Genset Model Features

Genset Model Features

MODEL
SGCM
SGSM

SGCO

S S S DV6NR Diesel Engine

S S S 460 Vac Output for 15 KW, 18.75 KVA, 3 Phase, 60 Hz, 4 Wire Generator
O O O 230 Vac Output for 15 KW, 18.75 KVA, 3 Phase, 60 Hz, 4 Wire Generator
S S S SG+ Control System
S S S Battery with Post
S S S Battery Charging System, Solid-state
S — — Side-mount Unit 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 Electric
— — O Header Pin, Mounting
S S S EMI 3000 Extended Maintenance Interval Package
O O — Integral 80 Gallon (303 Liter) Aluminum Fuel Tank
— — S Integral 125 Gallon (473 Liter) Steel Fuel Tank
S S — Integral 50 Gallon (190 Liter) Aluminum Fuel Tank
O O O Fuel Monitoring - Monitoring and Recording of fuel level events.
O O O Telematic’s
S = STD
O = Optional
— = N/A

38
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 40). Three external relays - two ECU Relays and the Start Relay are also mounted
inside the control box near the microprocessor. Another Relay - the Preheat Relay, is located in the
Engine Compartment.
This system automatically controls generator 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 excitation for 2 minutes
• Unit shutdown protection for the engine and alternator. The controller stops the unit due to low engine
oil pressure, low engine oil level, high coolant temperature, or alternator overload.
• Automatic unit restart 20 minutes after unit shutdown due to an unknown condition, high engine
water temperature, engine failure to start, check fuel alarm, or alternator overload (also low engine oil
pressure if enabled). It will attempt three (3) restarts and then stop.

Figure 9: SG+ Controller Display

39
Controller Description

1 2 3 4 5 6

16
7
15

14
8

17
9

13 10

12

11

1. J6 Connector – To AC Circuits
2. Fuse SI1 – 30 Amp Fuse Power Relay
3. Fuse SI2 – 30 Amp Protects Battery Charger Output Circuit
4. 2A Circuit Connection
5. CH Circuit Connection
6. GND Circuit Connection
7. Serial Port – 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 External Relay Circuits
13. RL1 – Ignition Relay
14. RL2 – Run Relay
15. RL3 - Fuel Pump Relay
16 J1 Connector – To Sensor and Fuel Solenoid Circuits
17. J20 - Connector to CAN
Figure 10: SG+ Microprocessor

40
 Controller Description

Controller Overview
Display: A vacuum lucent display on the front panel shows operating information including output
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.
Keypad: Contains the following six keys.
Escape Key: Press this key to escape a new setting or jump to the parent menu.
Up Key: Press this key to scroll UP through the menu display, or increase the value of a setting.
Down Key: Press this key to scroll DOWN through the menu display, or decrease the value of a setting.
Enter Key: Press 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 key to change the language used on the display. English and Spanish are the
languages that are currently available.
Alarm LED: Flashes when the controller has detected an alarm condition. It is off when there are no
alarms.
Power LED: Lights up while the Unit On/Off Switch is in the ON position. It is off when the Unit On/Off
Switch is in the OFF position.
Unit On/Off Switch: In the ON position, the electrical control system energizes for unit operation. In the
OFF position, the electrical control system including the fuel solenoid de-energizes to stop the engine.
The unit will not operate.
Download Port: Is used to download the event logger and flash load new software.

41
Controller Description

12 2

11 3

10 5

9 6

8 7

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

42
 Controller Description

Miscellaneous Features
• Internal self-checking/diagnostic capability
• Pretrip test capability (see “PTI” on page 71)
• 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. 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 Menu, Alarm List Menu,
Warning List Menu, Commands Menu, Misc. Functions Menu, Configuration Menu, and Event Log
Menu.
• Microprocessor Inputs:
• Alternator Voltage
• Battery Voltage
• Coolant Level Sensor
• Ignition Relay Feedback
• Run Relay Feedback
• Fuel Sender (Optional)
• Microprocessor Outputs:
• Start Relay
• Ignition Relay
• Run Relay
• On Light
• Alarm Light.
• Fuel Pump
• Quad Relay

43
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
• Message List Menu
• Commands Menu
• Misc. Functions Menu
• Configuration Menu
• Event Log Menu
The display also has some displays in addition to the Main Menus.
• Standard Display
• Pause Mode Display
• Composite Menu (if Telematics have been added to the unit)
Each menu listed above will be described later in this chapter.
An overview of the menu structure is shown in Figure 13 on page 46.
A complete listing of the controller menus is located on the 11 x 17 in. fold outs in the Diagrams section
in the back of the manual (see last two 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 leave it folded out until you become familiar with the controller menus.

Navigating Controller Menus

Moving through the menus and their submenus and entering commands requires the use of the following
keys:
Escape Key: Press the ESCAPE key to escape a new setting or jump to the parent menu.

Up Key: Press the UPkey each time you want to scroll up to view another item in a menu or
submenu), or increase the value of a setting.

Down Key: Press the DOWN key each time you want to scroll down to view another item in a menu
(or submenu), or decrease the value of a setting.

Enter Key: Press the ENTER key each time you want to enter or execute controller menu tasks or
commands.
Alarm Key: Press the ALARM key to go directly to the Alarm List Menu and view the alarm
information in the display.

44
 Navigating the Controller Menus

Language Key: Press the LANGUAGE key to change the language used on the display.

6 1

5 2

4 3

1. Down Key
2. Enter Key
3. Language Key
4. Alarm Key
5. Escape Key
6. Up Key

Figure 12: Controller Display

45
Navigating the Controller Menus

Menu Overview
Press the UP or DOWN keys to scroll through the Main Menu or a Submenu. Press the ENTER key to enter a
Submenu or Event. Press the ESCAPE key to return to the parent menu.

Main Menu Submenu Event

ENGINE OUTPUTS SHOW OUTPUTS

ENGINE LAMPS SHOW STATES

DATA

GENERATOR SHOW OUTPUTS

UNIT SHOW STATES

ALARM LIST SHOW ALARMS

MESSAGE LIST SHOW MESSAGES

PTI PERFORM PTI

MANUAL FUNCTION
PERFORM TESTS
TEST

COMMANDS ECU SERVICE MENU PERFORM SETUP

OIL PRIMING PERFORM SETUP

PERFORM SETUP/
SYSTEM SETUP
TESTS

°C/°F MODE CHANGE UNIT

MISC. FUNCTIONS SW/HW VERSION SHOW VERSION

SHOW TIMERS/
TIMERS/COUNTERS
COUNTERS

DATE/TIME SHOW DATE/TIME

CONFIGURABLE
CONFIGURATION VALUES

EVENT LOG SHOW EVENTS

EVENT LOG
SHOW FUEL
FUEL EVENTS EVENTS

ARA1103
Figure 13: Menu Structure

46
 Navigating the Controller Menus

Data Menu
The Data Menu contains the following submenus. See “Data Menu” on page 55 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.
• Generator, which displays generator operating information such as output voltage and the main
battery voltage.
• Unit, which displays unit operating information such as the status of components, if the unit is
running, and the engine RPM.

Alarm List Menu

The Alarm List Menu shows a list of the alarms recorded in the controller memory.

Message List Menu

The Message List Menu shows a list of the messages recorded in the controller memory.

Commands Menu
The Commands Menu contains the following submenus:
• PTI, which is the Pretrip Inspection Test. The PTI is a functional test of the unit.
• Manual Function Test, which is used to perform the individual PTI Test.
• ECU Service Menu, Used when the ECU 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
from high or low speed operation, set units Generator and Genset type, set the unit fuel tank size, set
the date and time, and set an ID number to identify the unit.

Misc. Functions Menu

The Misc. Functions Menu contains the following submenus:
• C/F Mode, which is used to select whether Celsius or Fahrenheit units are used to display temperature
readings. See “C/F Mode” on page 79 for more information. This function can also be used to change
your Pressure reading unit of measure - i.e. Bars or PSI
• SW/HW Version, which displays information about the controller software and hardware. See
“SW/HW Version” on page 80 for more information.
• Timers/Counters, which displays information about the hourmeters and restart counters. See
“Timers/Counters” on page 81 for more information.
• Date/Time, displays current date and time.

Configuration Menu
The Configuration Menu is used to configure some of the controller functions such as Engine type, and
hourmeter thresholds, factory reset, and output voltage system selection 230/460.

47
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. It appears approximately one minute after the last key is
pressed while the unit is running. The Standard Display floats within the display to prevent burn in.
Press the ENTER key or the ESCAPE key at the Standard Display to enter the Main Menu.

Standard Display

OUTPUT 460 V

Main Menu
DATA \

ALARM LIST

MESSAGE LIST

COMMANDS

MISC. FUNCTIONS

CONFIGURATION

EVENT LOG

Figure 14: Standard Display and Main Menu

48
 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. The display will show the cause and controller action. For example, the following display appears
if the engine fails to start.

ENGINE FAILED
TO START

RESTART IN 20 MIN.

Figure 15: Typical Pause Mode Display

Controller Link Down Display

The Controller 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 bad connection on the cable between the SG+ controller and the display.
The Controller Link Down display also appears when software is be flash loaded into the controller.

CONTROLLER LINK
DOWN!

Figure 16: Controller Link Down Display

49
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:
Fuel: The diesel fuel supply must be sufficient to guarantee engine operation to the next check point.
Engine Oil: Engine oil level should be at the FULL mark. Never overfill. The dipstick is attached to the
filler cap.
Coolant: Engine coolant must be above the ADD mark with antifreeze protection of -34 C (-30 F). Check
and add coolant in the expansion tank.
WARNING: DO NOT remove the radiator cap from the radiator fill neck when the engine
coolant is hot.

CAUTION: With both Extended Life Coolant (EMI 3000) and Conventional Coolant (non-EMI
3000) equipped units operating in the field, there are several important rules to remember:
• Extended Life Coolant (ELC) is RED in color while conventional coolant is GREEN or
BLUE-GREEN.
• 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.
Battery: Terminals must be clean. Electrolyte should be at the full mark.
Electrical: Electrical
connections should be securely fastened. Check wires and terminals 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 of debris. Clean if necessary. Use an air or water spray jet directed against the
coil from the air discharge side.

CAUTION: Air or water spray jet pressure should not be high enough to damage (bend) coil.

Mounting Bolts: Check the mounting bolts on the unit and engine. Tighten if necessary.

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.
WARNING: With the unit On/Off switch in the “ON” position, the unit may start at any time
without prior warning.

1. Turn unit ON/OFF switch to On.

50
 Operating Instructions

2. A series of displays called the Start Sequence appears on the display as follows:
a. DISPLAY UNIT
REV 1.0.0
b. SG+
X.X.X.X YYMMDD
HARDWARE REV. X
c. MAIN MENU
DATA
DELAY 30 (or 30, 29, 28, etc. to 01)
The delay screen counts down from 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 period. Preheat time ranges from 5 to 120 seconds, depending on the engine
temperature. Preheat may continue until after the engine starts.
e. MAIN MENU
DATA
FUEL RELAY ON
The controller energizes the fuel relay.
f. MAIN MENU
DATA
GLOW PLUG ON
The glow plugs are energized.
g. MAIN MENU
DATA
STARTER
The engine begins cranking. The glow plug and pre-heat buzzer may remain energized during the
cranking period.
h. MAIN MENU
DATA
DELAYED OUTPUT
This display appears while the controller delays energizing the alternator output for approximately
2 minutes.

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.

51
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 50).
2. Initiate an automatic PTI.
NOTE: Correct all existing alarm conditions and clear the alarm codes before performing a PTI.
a. Press the ENTER key or the ESCAPE key to enter the Main Menu, if necessary.
b. Press the UP or DOWN key to scroll up or down through the Main Menu to the Commands Menu.
c. Press the ENTER key to enter the Commands Menu.
d. The PTI submenu will be displayed.
e. Press the ENTER key to start the PTI.
3. The controller then performs the PTI. Observe the unit for proper operation and functions during the
PTI. The display shows which component is being tested, and the test result (PASSED of FAILED).
a. “Please Wait”
b. The engine stops.
c. A display test is performed. Watch the display to verify 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 Start is tested. The engine starts, The display says
“START ENGINE TEST (beep on, then off, then start appears briefly)
(the result of the test - i.e. RUNNING 1491)
RESULT: PASS” if the result is acceptable.
j. Low/High speed is tested. (Engine still running - similar results screen and test sequence to point
i. above)
k. The output voltage is tested, (Engine still running - similar results screen and test sequence to
point i. above)
NOTE: If a component fails its test, the PTI will stop at that point and display “FAILED -
REBOOT”. Correct the problem and repeat the PTI by pressing the ENTER Key.
4. 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.
5. 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.

52
 Operating Instructions

NOTE: Acknowledge the alarms or messages ONLY after the alarm codes are documented and
problems repaired.

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. 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. The Data Menu is typically the first menu displayed in the Main Menu.
• Press the ENTER key to enter the Data Menu.
• Press the UP or DOWN key to scroll up or down through the Main Menu.

53
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" menu

MAIN MENU
COMMANDS From "COMMANDS" menu

VOLTAGE: 460 V

To "COMMANDS" menu

MAIN MENU
MISC. FUNCTIONS From "MISC. FUNCTIONS" menu

VOLTAGE: 460 V

To "MISC. FUNCTIONS" menu

MAIN MENU
CONFIGURATION From "CONFIGURATION" menu

VOLTAGE: 460 V

To "CONFIGURATION" menu

MAIN MENU
EVENT LOG From "EVENT LOG" menu

VOLTAGE: 460 V

To "EVENT LOG" menu

ARA981
Figure 17: Main Menu

54
 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
• Unit
• Internal States
To enter the Data 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 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 through the Main Menu to the Data Menu, if
necessary.
4. Press the ENTER key to enter the Data Menu.
5. The Engine submenu will be displayed.
• Press the ENTER key to enter Engine Submenu.
• Press the UP or DOWN key to scroll up or down through the Data Menu.
• Press the ESCAPE key to return to the Main Menu.

55
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" menu

VOLTAGE: 460 V
To "DIGITAL OUTPUTS" menu

DATA
UNIT From "UNIT" menu

VOLTAGE: 460 V
To "UNIT" menu

DATA
INTERNAL STATES From "INTERNAL STATES" menu

VOLTAGE: 460 V
To "INTERNAL STATES" menu

Figure 18: Data Menu

56
 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. 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: 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. The Engine submenu will be displayed.
6. Press the ENTER key to enter the Engine submenu.
• Press the UP or DOWN key to scroll up or down through the Engine submenu.
• Press the ESCAPE key to return to the Data Menu.

To "ENGINE" prompt of From "ENGINE" prompt of

"DATA" menu. "DATA" menu.

WATER TEMP. 25ºC

LOAD 24
CURRNT RPM. 1498
REQUESTED RPM. 60Hz

FUEL RATE 1.2Lh

IGNITION RELAY ON
RUN RELAY ON
----------------------

Figure 19: Engine Submenu

57
Operating Instructions

Engine Lamps
The Engine Lamps submenu displays the following information:
• Amber Lamp on/off
• Stop Lamp on/off
1. DTC Code - DTC codes are the same has the P-codes out of the ECU. The EXXODiag Diagnostic
Tool is needed to clear these codes.
2. DTC Code
3. DTC Code
4. DTC Code
To enter the Engine Lamps submenu 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 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 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 through the Data Menu to the Engine Lamps submenu.
6. Press the ENTER key to enter the Engine Lamps Submenu.
• Press the UP or DOWN key to scroll up or down through the Engine Lamps submenu.
• Press the ESCAPE key to return to the Data Menu.

To "ENGINE LAMPS" From "ENGINE LAMPS" prompt

prompt of "DATA" menu. of "DATA" menu.

AMBER LAMP OFF

STOP LAMP OFF
1. DTC CODE
2. DTC CODE

3. DTC CODE
4. DTC CODE
----------------------
AMBER LAMP OFF

ARA1068

Figure 20: Engine Lamps submenu

58
 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 submenu 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 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 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 through the Data Menu to the Generator submenu.
6. Press the ENTER key to enter the Generator submenu.
• Press the UP or DOWN key to scroll up or down through the Generator submenu.
• Press the ESCAPE key to return to the Data Menu.

To "GENERATOR" prompt From "GENERATOR" prompt of

of "DATA" menu. "DATA" menu.

VOLTAGE MEAS. 14V

RUNNING FREQ 50Hz
QUAD CLOSED OFF
BAT. VOLTAGE 12.1V

QUAD CLOSED OFF

BAT. VOLTAGE 12.1V
BAT. CHARGER OFF
----------------------

ARA1069

Figure 21: Generator submenu

59
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. 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 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 through the Data Menu to the Unit submenu.
6. Press the ENTER key to enter the Unit submenu.
• Press the UP or DOWN key to scroll up or down through the Unit submenu.
• Press the ESCAPE key to return to the Data Menu.

To "UNIT" prompt of From "UNIT" prompt of "DATA"

"DATA" menu. menu.

FUEL LEV. MEAN

COOLANT LEV. LOW OFF
FUEL PUMP ON
COOLANT FAN OFF

COOLANT LEV. LOW OFF

FUEL PUMP ON
COOLANT FAN OFF
----------------------

BEN114

Figure 22: Unit submenu

60
 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
• Preheat Off
• Restart 20 MI (Minutes)
• Running
• Shutdown
• HW Error
• Delay
• PTI
• RPM (Displayed Below the State)
To enter the Internal States 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 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 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 through the Data Menu to the Internal States submenu.
6. Press the ENTER key to enter the Internal States.
7. Press the ESCAPE key to return to the Data Menu.

To "INTERNAL STATES" From "INTERNAL STATES"

prompt of "DATA" menu. prompt of "DATA" menu.

STATE: INIT
RPM: 1900

ARA729
Figure 23: Internal States

61
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.

Alarm Types
There are two types of alarms:
Delayed Restart Alarm: Delayed restart alarms indicate the unit has stopped temporarily because of a
problem or to prevent damage to the unit. The unit will attempt to restart in 20 minutes. The display will
show information about the unit in the message 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. Shutdown alarms indicate the unit has been
stopped to prevent damage to the unit. The condition must be corrected before restarting the unit.

Displaying and Acknowledging Alarms

Enter the Alarm List Menu to view and acknowledge the alarms as follows:
1. Place the On/Off switch in the “ON” position.
2. Press the ALARM key to enter the Alarm List Menu directly.
Or
Enter the Alarm List Menu through the Main Menu as follows:
a. Press the ENTER key or the ESCAPE key to enter the Main Menu, if necessary.
b. Press the UP or DOWN key to scroll up or down through the Main Menu to the Alarm List Menu.
c. Press the ENTER key to enter the Alarm List Menu.
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.
• The alarm text
• The alarm status (Active or Acknowledged).
4. Write down the alarm code and the alarm text.
5. Press the ENTER key to acknowledge the alarm. The Alarm LED will continue flashing until the active
alarms (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 alarm.
9. Repeat steps 6 through 8 until all active alarms have been written down and acknowledged.
10. Press the ESCAPE key to return to the Main Menu.

62
 Operating Instructions

To "ALARM LIST" prompt From "ALARM LIST" prompt

of "MAIN" menu of "MAIN" menu

102. 1/2
WATER TEMPERATURE
HIGH
STATUS: ACTIVE

Jump to previous alarm text

Jump to next alarm text

Acknowledges alarm
ARA753
Figure 24: Alarm List Menu

Alarm Diagnosis
The Alarm List on the following pages lists the alarms, their causes, and possible diagnosis.
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.
• Engine then stops and then attempts • Check water pump belt.
to restart.
• Check radiator for airflow and
coolant flow restrictions.
2. Check for faulty water temperature
sensor.
A103. Delayed Restart Alarm–Engine failed to 1. Check fuel level.
FAILED TO START crank. 2. Check fuel pump, and fuel system
Becomes a Shutdown Alarm when both electrically and mechanically.
number of restart attempts is greater
3. In cold ambient temperatures check
than number of “Crank Restarts” set in
for fuel gelling.
Configuration Menu.
4. Check for restricted air cleaner or air
intake system.
5. Check intake air heater.
A104. Shutdown Alarm–No feedback when 1. Check RL2 (Fuel Hold) relay.
RL2 (FUEL H) FEEDBACK relay is energized, or feedback when
FAILURE relay is not energized.
A107. Shutdown Alarm–Engine restart if output 1. Unplug load and attempt restart.
EXTERNAL OVERLOAD voltage is short-circuited.
2. Check alternator field circuit.
3. Check alternator output circuit.
4. Check external generator controller
electrical system.

63
Operating Instructions

Alarm List (Continued)

Alarm Code and Text Alarm Type–Cause Diagnostics
A108. Delayed Restart Alarm–Genset stops for 1. Check fuel level.
ENGINE NOT RUNNING restart without any reason with oil 2. Check oil level
REASON UNKNOWN pressure but zero RPM when engine
3. Check RPM Sensor
should be running.

• Engine will attempt to restart in 20

minutes.
A109. If low oil level for 60 seconds. 1. Check oil level.
LOW OIL LEVEL
2. Check Oil Level Switch.
3. Check circuits to Oil Level Switch.
A110. Shutdown Alarm–Engine stops for 1. Check engine speed.
RPM BELOW LIMIT restart if speed is below limit i.e, Engine 2. Check RPM sensor.
speed is below 1350 RPM.
A111. The controller is resetting 3 times during 1. Defective battery, load test battery.
FAILED TO START LOW crank caused by low voltage on the 2. Check Battery Charger.
BATTERY battery. The low voltage could be
3. Check ground connections at block.
controller not charging the battery,
defective battery or cables.
A113. Coolant level is low. 1. Check coolant level.
COOLANT LEVEL LOW
2. Check Coolant Level Sensor.
3. Check circuits to Coolant Level
Sensor.
A115. External controller has not responded 1. Check wiring to exciter controller.
EXCITER CONTROL within 5 seconds.
2. See “Alternator Diagnosis” on page
UNIT SHUTDOWN 147.
A116. The engine is restarted if communication 1. Check wiring to engine controller.
ENGINE CONTROL UNIT has been lost with the engine controller.
SHUTDOWN
• External controller has not
responded within 5 seconds.
A118. Engine stop lamp activated 1. Connect ECU Test Tool to read codes.
ENGINE STOP LAMP
A119. Low oil pressure message active. 1. Connect ECU Test Tool to read codes.
LOW OIL PRESSURE
A120. Output voltage above 500 volts over 15 1. See “Alternator Diagnosis” on page
OUTPUT VOLTAGE HIGH seconds 147.
A121. Engine degraded mode (speed 1. Connect ECU Test Tool to read codes.
ENGINE PROTECT LAMP limitation) or starter relay defect.
A122. Over excitation or short circuit 1. See “Alternator Diagnosis” on page
GENERATOR UNIT 147.
ERROR
A123. Coolant fan klixon is open and coolant 1. Check coolant fan klixon.
COOLANT FAN ERROR temperature is above limit.
2. Check circuits to coolant fan klixon.
A124. Monitoring the engine P-code for low fuel 1. Check fuel level.
FUEL TANK EMPTY delivery pressure will activate the alarm
when the engine is about to shut down
due to out of fuel condition.

64
 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.
NOTE: The unit will not start a PTI until all active messages have been acknowledged. The display will
show “ACKNOWLEDGE MESSAGE” if there are messages that have not been acknowledged when
trying to start a PTI.

Displaying and Acknowledging Messages

Enter the Message List Menu to view and acknowledge the messages as follows:
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 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 recent message and the
following information:
• The message code (M101 through M131)
• The position of the message in the list of recorded messages. For example, 1/1 means message one
of one.
• The message text
• The message status (Active or Acknowledged).
6. Write down the message code and the message text.
7. Press the ENTER key to acknowledge the message. The Alarm LED will continue flashing until the
active messages (and alarms) have been acknowledged.
8. Press the DOWN key to scroll down to the next message, if necessary.
9. Write down the message code and the message text.
10. Press the ENTER key to acknowledge the message.
11. Repeat steps 8 through 10 until all active messages have been written down and acknowledged.
12. Press the ESCAPE key to return to the Main Menu.
13. The unit will then enter the Start Sequence and start the engine.

65
Operating Instructions

To "MESSAGE LIST" prompt From "MESSAGE LIST" prompt

of "MAIN" menu of "MAIN" menu

101. 1/1
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.
Message List
Message Code and Text Cause Diagnostics
M101. The battery voltage is reported to be 1. Check battery
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.
M102. Digital inputs have been changing once This condition indicates noise on the line,
DIGITAL INPUT FAILURE a second for the last 100 seconds. a loose connection, or a bad sensor.
M103. Exciter field regulation is turned on and Check alternator for low output.
OUTPUT VOLTAGE voltage measurement is below 360 volts
< 180 V for 30 seconds.
M104. Not used.
AIR FILTER BLOCKED
M105. Coolant Level Sensor indicates low 1. Check coolant level.
COOLANT LEVEL LOW coolant level for 30 seconds.
2. Check Coolant Level Sensor.
3. Check circuits to Coolant Level
Sensor.
M106. Output frequency is below 45 Hz for 30 Check and adjust engine speed.
OUTPUT FREQUENCY seconds (engine RPM below 1350).
LOW
M107. Output frequency is above 70 Hz for 30 Check and adjust engine speed.
OUTPUT FREQUENCY seconds (engine RPM above 2100).
HIGH
M108. Oil Level Switch indicates low oil level for 1. Check oil level.
LOW OIL LEVEL 3 minutes.
2. Check Oil Level Switch.
3. Check circuits to Oil Level Switch.
M109. Hour Meter 1 (HM1) has exceeded the Acknowledge message to reset timer.
HOUR METER 1 HAS threshold set in the Configuration Menu.
EXCEEDED THRESHOLD

66
 Operating Instructions

Message List (Continued)

Message Code and Text Cause Diagnostics
M110. Hour Meter 2 (HM2) has exceeded the Acknowledge message to reset timer.
HOUR METER 2 HAS threshold set in the Configuration Menu.
EXCEEDED THRESHOLD
M111. Fuel Level is below “Fuel Level” set in 1. Check fuel level.
FUEL LEVEL LOW Configuration Menu.
2. Check Fuel Level Sensor.
3. Check circuits to Fuel Level Sensor.
M114. No oil pressure. 1. Check oil level.
LOW OIL PRESSURE
2. Check oil pressure using the Engine
submenu of the Data Menu.
3. Check Oil Pressure Switch.
4. Check Oil Pressure Switch circuit.
M116. If hour counter exceeds user setup. 1. Acknowledge message and reset
COUNTDOWN TIMER timer.
HAS EXPIRED
M119. If water temp. >107 C for 5 sec. - 1. Check water temperature sensor.
WATER TEMPERATURE restarting.
2. Check WTP/WTN circuit.
HIGH
M121. No oil pressure and did not reach 800 1. Check fuel level.
ENGINE FAILED TO RPM - restarting.
2. Check fuel pump, and fuel system
START
both electrically and mechanically.
3. In cold ambient temperatures check
for fuel gelling.
4. Check for restricted air cleaner or air
intake system.
5. Check glow plugs.
M122. If output is short-circuited - restarting. 1. Unplug load and attempt restart.
EXTERNAL OVERLOAD
2. Check alternator field circuit.
3. Check alternator output circuit.
M123. Oil pressure good and no RPM - 1. Check fuel level.
ENGINE STOPPED restarting.
2. Check fuel pump, and fuel system
REASON UNKNOWN
both electrically and mechanically.
3. In cold ambient temperatures check
for fuel gelling.
4. Check for seized engine or alternator.
M126. Fuel level reading is 90 Gallons above 1. Check fuel level sensor.
FUEL LEVEL SENSOR then maximum tank size.
2. Check FPOS, FNEG, and FOUT
OUT OF RANGE circuits.
3. Check fuel tank size setting in System
Setup submenu.
M127. Fuel level reading decreased faster than 1. Check for leak in fuel tank.
FUEL LEVEL CHANGE normally expected.
2. Check to see if fuel has been removed
TO FAST
NOTE: Must use password (0007) to from fuel tank.
clear this message.

67
Operating Instructions

Message List (Continued)

Message Code and Text Cause Diagnostics
M129. RPM is below 1350 for 5 sec. 1. Check engine speed.
RPM BELOW LIMIT
2. Check RPM sensor.
M130. Water temperature sensor is below 32 C 1. Check water temperature sensor.
DELAYED OUTPUT (90 F) for 5 minutes.
2. Check WTS circuit.
TIMED OUT
M133. External controller has not responded 1. See “Alternator Diagnosis” on page
EXCITER CONTROL within 5 sec 147.
SHUTDOWN
M135. Exciter voltage below 20V. 1. See “Alternator Diagnosis” on page
ENGINE CONTROL UNIT 147.
SHUTDOWN
M137. On for defects that could lead to 1. Connect ECU Test Tool to read codes.
ENGINE AMBER LAMP degraded mode (speed limitation), and
for Starter relay defect (because
impacting safety)
M138. On for defects that could lead to engine 1. Connect ECU Test Tool to read codes.
ENGINE STOP LAMP stop mode.
M140. Regulator running with default 1. See “Alternator Diagnosis” on page
DSR CHECKSUM parameters 147.
WARNING
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.
OVERCURRENT
WARNING
M143. Speed is below or above threshold. 1. See “Alternator Diagnosis” on page
DSR UNDER OR OVER 147.
SPEED WARNING
M144. Current and speed above limits. 1. See “Alternator Diagnosis” on page
DSR OVER CURRENT 147.
AND SPEED WARNING
M146. Output voltage above 500 volts over 15 1. See “Alternator Diagnosis” on page
OUTPUT VOLTAGE HIGH seconds 147.
M148. HRG exciter protection gizmo has been 1. See “Alternator Diagnosis” on page
EXCITER PROTECTION activated 147.
ACTIVATED
M149. Coolant fan klixon open for 5 seconds 1. Check coolant fan klixon.
COOLANT FAN FAILURE
2. Check circuits to coolant fan klixon.
M150. Generated for engine P-codes that do 1. Connect ECU Test Tool to read codes.
ENGINE P-CODE INFO not activate any engine lamps.

68
 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. 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 Menu to the Commands Menu.
4. Press the ENTER key to enter the Commands Menu.
5. The PTI submenu will be displayed.
• Press the ENTER key to start the PTI.
• Press the UP or DOWN key to scroll up or down through the Commands Menu.
• Press the ESCAPE key to return to the Main Menu.

69
Operating Instructions

To "COMMANDS" From "COMMANDS"

prompt of "MAIN" prompt of "MAIN"
menu. menu.

COMMANDS
PTI 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" menu

VOLTAGE: 460 V
To "ECU SERVICE" menu

COMMANDS
OIL PRIMING From "OIL PRIMING" menu

ARA1070
VOLTAGE: 460 V
To "OIL PRIMING" menu

COMMANDS
SYSTEM SETUP From "SYSTEM SETUP" menu

VOLTAGE: 460 V
To "SYSTEM SETUP" menu

Figure 26: Commands Menu

70
 Operating Instructions

PTI
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” if there are messages that have not been acknowledged when
trying to perform a PTI. See “Displaying and Acknowledging Messages” on page 65.
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 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 ENTER key to start the PTI.
7. The controller then performs the PTI. Observe the unit for proper operation and functions during the
PTI. The display shows which component is being tested, and the test result (PASSED of FAILED).
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 Ignition Test
• ECU Run Relay Test
• ECU Fuel Relay Test
• ECU CAN Connect Test
• Start Engine Test
• Low High Speed Test
• Output Voltage Test
e. When it comes to the “Start Engine Test, the display shows BEEP ON (and you can hear the beep)
and then BEEP OFF and the Engine starts. The Engine remains on for the rest of the PTI.
f. For the last three tests, the display shows the results readings as well as the PASS or FAIL. i.e.
• For “START ENGINE TEST”, the display shows “RUNNING 1491” for example above the
RESULT: PASS (or fail if applicable).
• For “LOW SPEED HIGH SPEED TEST” the display shows “1508 1802” for example to
signify the low and high speed in RPMs. The display says “RESULT: PASS” if the speeds are
acceptable.
• For “OUTPUT VOLTAGE TEST” the display shows “0429 0476” in the middle. The display
says “RESULT: PASS” if the output voltage is acceptable.
NOTE: If a component fails its test, the PTI will stop at that point and display “FAILED -
REBOOT”. Correct the problem and repeat the PTI by pressing the ENTER Key.

71
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. 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 the alarm codes are documented and
problems repaired.

To "COMMANDS" prompt of From "COMMANDS" prompt of

"MAIN" menu "MAIN" menu

COMMANDS
PTI

VOLTAGE: 460 V

To MANUAL FUNCTION TEST

To MANUAL FUNCTION TEST

Starts PTI
ARA984
Figure 27: PTI Submenu

72
 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 Fuel 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. 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 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 the Manual Function
Test submenu.
7. Press the ENTER key to enter the Manual Function Test.
• The engine will stop if it is running.
• The Display Test is the first to appear. Press the ENTER key to perform the Display Test.
• Press the UP or DOWN key to scroll up or down through the Manual Function Test submenu. Press
the ENTER key to perform the selected test.
• Press the ESCAPE key to return to the Commands Menu.

ECU IGNITION TEST ECU IGNITION TEST

On: IS ON Off: IS OFF
RESULT: RESULT: PASS

Figure 28: Manual Function Test example

73
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 PERFORM

TEST
ECU IGNITION TEST
ECU RUN RELAY TEST
ECU FUEL RELAY TEST

ARA1071

DISPLAY TEST PERFORM

TEST
ECU IGNITION TEST
ECU RUN RELAY TEST
ECU FUEL RELAY TEST

ECU IGNITION TEST PERFORM

ECU RUN RELAY TEST TEST

ECU FUEL RELAY TEST

DSR QUAD RELAY TEST

Figure 29: Manual Function Test Submenu

74
 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
ECU ON

The ECU Service Tool is software that is independent of the SG+ Controller and is a program with is
opened on your PC. This software tool comes in a Diagnostic kit which is called EXXODiag Diagnostic
Tool. See the EXXODiag Diagnostic Tool Manual (which you can find on the help link within the tool
itself - see arrow below) on how to install and operate this tool, and “Using EXXODiag to Connect to
ECU” on page 102.

Figure 30: EXXODIAG Main Screen

Oil Priming
Oil Priming is used to crank the engine without starting to prime oil galleries. It is typically used when
changing the engine oil and oil filter.

75
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.
• Fuel Sensor (Yes/No), which is used to setup units with a fuel sensor. Unit with fuel sensor Yes, unit
without fuel sensor No.
• Date, which is used to set the date. See “Misc. Functions Menu” on page 78 for information about
setting the date.
• Time, which is used to set the time. See “Misc. Functions Menu” on page 78 for information about
setting the time.
• ID Number, which is used to set an ID number to identify the unit when downloading the event
logger.
• Serial Number, which is used to set the unit serial number in the controller menu.
To enter the System Setup submenu 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 necessary.
3. Press the UP or DOWN key to scroll up or down through 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 the System Setup
submenu.
7. Press the ENTER key to enter the System Setup submenu.
8. Press the UP or DOWN key to scroll up or down through the System 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 78 for information about setting the date and time.
NOTE: The engine speed will change when the UP or DOWN key is pressed.
• Press the ESCAPE key and the ENTER key at the same time to save the new Tank Size setting.
NOTE: Press the ESCAPE key to return to the System Setup submenu without saving the new
settings.
• Press the ESCAPE key to return to the System Setup submenu.

76
 Operating Instructions

To "SYSTEM SETUP"
From "SYSTEM SETUP" prompt
prompt
of "COMMANDS" menu.
of "COMMANDS" menu.

CURRENT RPM 1890

SPEED SOLENOID OFF
LOAD 18
ENGINE TYPE PCM

CURRENT RPM 1890 ENTER CHANGE

SPEED SOLENOID ON FUNCTION
or
SPEED
LOAD 18
ENGINE TYPE PCM

CURRENT RPM 1890 ENTER CHANGE

FUNCTION SETTING
SPEED SOLENOID ON or
LOAD 18
ENGINE TYPE PCM and
DISCARD SAVE SETTING
CHANGE

TANK SIZE 50 ENTER CHANGE

FUEL SENSOR OFF FUNCTION SETTING
CLD ON PIN 5 NO
DATE 2013-10-08
and
DISCARD SAVE SETTING
CHANGE

TIME ENTER CHANGE

ID 00000000 FUNCTION
or
SETTING
SER. NO. 00000000
---------------------
and
DISCARD SAVE SETTING
CHANGE

ARA1678

Figure 31: System Setup Submenu

77
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. 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 ENTER key to enter the Misc. Functions Menu.
5. 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 Misc. Functions Menu.
• Press the ESCAPE key to return to the Main Menu.

To "MISC. FUNCTIONS" From "MISC. FUNCTIONS"

prompt of "MAIN" menu. prompt of "MAIN" menu.

MISC. FUNCTIONS
C/F MODE From select ºC/ºF

VOLTAGE: 460 V
From select ºC/ºF

MISC. FUNCTIONS
SW/HW VERSION From SW/HW Version

VOLTAGE: 460 V
To SW/HW Version

MISC. FUNCTIONS
TIMERS/COUNTERS From "TIMERS/COUNTERS" menu

VOLTAGE: 460 V
To "TIMERS/COUNTERS" menu

MISC. FUNCTIONS
DATE/TIME From "DATE/TIME" menu

VOLTAGE: 460 V

To "DATE/TIME" menu

ARA1105
Figure 32: Misc. Functions Menu

78
 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. 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 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 or DOWN key to toggle between the Celsius and Fahrenheit settings.
8. Press the ESCAPE key and the ENTER key at the same time to save the new setting and return to the Misc.
Functions Menu.
NOTE: Press the ESCAPE key to return to the Misc. Functions Menu without saving the new setting.
NOTE: If you select C (Celsius) C for temperature and bars for pressure. If F (Fahrenheit) is selected
then you'll get F for temperature and PSI for pressure reading.

From "C/F MODE" prompt of

Save changes and return to "MISC. FUNCTIONS" menu.
"C/F MODE" prompt of
"MISC. FUNCTIONS" menu

C/F MODE: CELSIUS

ESC

Toggles between ºC / ºF
ARA737
Figure 33: C/F Mode

79
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. 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 ENTER key to enter the Misc. Functions Menu.
5. Press the UP or DOWN key to scroll up or down through the Misc. Functions Menu to the Program
Version submenu.
6. Press the ENTER key to enter the Program Version submenu.
7. Press the ESCAPE key to return to the Misc. Functions Menu.

To "PROGRAM VERSION" From "PROGRAM VERSION"

prompt of "MISC. prompt of "MISC.
FUNCTIONS" menu FUNCTIONS" menu

SW xxxxxx xx
HARDWARE REV. y

ARA738
Figure 34: SW/HW Version

80
 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.
• Hour Meter 2 – The number of hours the unit has been running since Hour Meter 2 was cleared. A
message is generated when the reading reaches the threshold set in the Configuration Menu.
• Engine Off Hours – The number of hours the unit has been running since Engine Off Hours was
cleared. An alarm is generated when the reading reaches the threshold set in the Configuration Menu.
• Restarts – The number of restarts the controller has made since the 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 running at 60 Hz (high speed).
NOTE: The readings for Run Hours, Run Hours 50 Hz, and Run Hours 60 Hz can be adjusted. See
“Setting Hour Meter Thresholds and Resetting Hour Meters” on page 87.
To enter the Timers/Counters submenu 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 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 ENTER key to enter the Misc. Functions Menu.
5. Press the UP or DOWN key to scroll up or down through the Misc. Functions Menu to the
Timers/Counters submenu.
6. Press the ENTER key to enter the Timers/Counters submenu.
• Press the UP or DOWN key to scroll up or down through the Timers/Counters.
• Press the ESCAPE key to return to the Misc. Functions Menu.

81
Operating Instructions

To "TIMERS/COUNTERS" From "TIMERS/COUNTERS"

prompt of prompt of
"MISC. FUNCTIONS" menu. "MISC. FUNCTIONS" menu.

RUN HOURS 0
HOUR METER 1 0
HOUR METER 2 0
ENGINE OFF HOURS 0

RUN HOURS 0
HOUR METER 1 0
HOUR METER 2 0
ENGINE OFF HOURS 0

RUN HOURS 0
HOUR METER 1 0
HOUR METER 2 0
ENGINE OFF HOURS 0

RUN HOURS 0
HOUR METER 1 0
HOUR METER 2 0
ENGINE OFF HOURS 0

HOUR METER 1 0
HOUR METER 2 0
ENGINE OFF HOURS 0
RESTARTS 0

3x 3x

RESTARTS 0
RESTARTS TOTAL 0
RUN HOURS 50 HZ 0
RUN HOURS 60 HZ 0

ARA1073
Figure 35: Timers/Counters

82
 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 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 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 the System Setup
submenu.
7. Press the ENTER key to enter the System Setup submenu.
8. Press 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 move the cursor (to the right or down at the end of a row) to select the value
you want to change.
NOTE: The ENTER key does not move the cursor to the right in the Time value. You must use the UP
or DOWN keys to scroll the total Time value up or down.
11. Press the UP or DOWN key to scroll the selected value up or down to the new setting.
12. Repeat steps 10 and 11 until you have changed all the values to the new settings.
13. Press the ESCAPE key and the ENTER key at the same time to save the new settings and return to the
System Setup submenu.
NOTE: Press the ESCAPE key to return to the Misc. Functions submenu without saving the new
settings.

From "DATE/TIME" prompt of

Save changes and return to "MISC. FUNCTIONS" menu.
"DATE/TIME" prompt of
"MISC. FUNCTIONS" menu

YEAR: 2006
MONTH: 03
ESC DATE: 22
TIME: 14.08

Scrolls values up/down

Moves cursor right

ARA736
Figure 36: Date/Time

83
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 87 for an example of how
change a setting.
• ENGINE TYPE - Yanmar or PCM
• HM1 (Hour Meter 1) Threshold – The default setting is 0. When this is set to anything other than 0, it
sets the threshold that generates the message “113. HOUR METER 1 HAS EXCEEDED
THRESHOLD”.
• HM2 (Hour Meter 2) Threshold – The default setting is 0. When this is set to anything other than 0, it
sets the threshold that generates the message “114. HOUR METER 2 HAS EXCEEDED
THRESHOLD”.
• ENG (Engine) Off Hours – The default setting is 0. When this is set to anything other than 0, it sets
the threshold that generates the alarm “110. ENGINE STOPPED DUE TO USER SETUP”.
• Factory Reset – The default setting 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 VOLTAGE - The default setting is 460. The other selection is 230, which is used is the
alternator is configured for an output voltage of 230 Vac.
• FUEL LEVEL - The default setting is 0. Possible settings are 1 to 400 gallons. This sets the threshold
that generates the alarm “115. FUEL LEVEL LOW”.
• CRANK RESTARTS - The default setting is 3. Possible settings are 0 to 15, and 0 equals infinite.
This sets the number of restart attempts that are allowed.
• COMPOSIT - Yes or No (Telematics)
• RMM MASTER - Yes or No
• FUEL PUMP TIME - Fuel pump enabled delay (0 = disabled / always on).

To enter the Configuration 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 necessary.
3. Press the UP or DOWN key to scroll up or down through the Main Menu to the Configuration Menu.
4. Press the ENTER key to enter the Configuration Menu.
5. See “Setting Hour Meter Thresholds and Resetting Hour Meters” on page 87 for an example of how
change a setting.

84
 Operating Instructions

To "CONFIGURATION" From "CONFIGURATION"

prompt of "MAIN" menu. prompt of "MAIN" menu.

ENGINE TYPE PCM ENGINE TYPE PCM

LOP RESTART OFF LOP RESTART OFF Toggle between PCM/YANMAR
HM1 THRESHOLD 00000 PASS- HM1 THRESHOLD 00000 Toggle between PCM/YANMAR
HM2 THRESHOLD 00000 WORD HM2 THRESHOLD 00000

ENGINE TYPE PCM ENGINE TYPE PCM

LOP RESTART OFF LOP RESTART OFF Toggle between ON/OFF
HM1 THRESHOLD 00000 PASS- HM1 THRESHOLD 00000 Toggle between ON/OFF
HM2 THRESHOLD 00000 WORD HM2 THRESHOLD 00000

LOP RESTART OFF LOP RESTART OFF Scrolls cursor right

HM1 THRESHOLD 00000 HM1 THRESHOLD 00000
HM2 THRESHOLD 00000 PASS- HM2 THRESHOLD 00000 Roll the active figure up
ENG. OFF HOURS 00000 WORD ENG. OFF HOURS 00000
Roll the active figure down

FACTORY RESET OFF FACTORY RESET OFF

GERERATOR M.ALTE GERERATOR M.ALTE Toggle between ON/OFF
GENSET CLIP-ON PASS- GENSET CLIP-ON Toggle between ON/OFF
OUTPUT VOLTAGE 460 WORD OUTPUT VOLTAGE 460

FACTORY RESET OFF FACTORY RESET OFF

GERERATOR M.ALTE GERERATOR M.ALTE Toggle between M.ALTE/STAMFRD
GENSET CLIP-ON PASS- GENSET CLIP-ON
Toggle between M.ALTE/STAMFRD
OUTPUT VOLTAGE 460 WORD OUTPUT VOLTAGE 460

FACTORY RESET OFF FACTORY RESET OFF Toggle between Clip-on, side,
GERERATOR M.ALTE GERERATOR M.ALTE centre
GENSET CLIP-ON PASS- GENSET CLIP-ON Toggle between Clip-on/side/
OUTPUT VOLTAGE 460 WORD OUTPUT VOLTAGE 460 centre

FACTORY RESET OFF FACTORY RESET OFF

GERERATOR M.ALTE GERERATOR M.ALTE Toggle between 460/230
GENSET CLIP-ON PASS- GENSET CLIP-ON
Toggle between 460/230
OUTPUT VOLTAGE 460 WORD OUTPUT VOLTAGE 460

FUEL LEVEL 00000 FUEL LEVEL 00000 Scrolls cursor right

CRANK RESTARTS 00003 CRANK RESTARTS 00003
Roll the active figure up
COMPOSIT OFF PASS- COMPOSIT OFF
RMM MASTER 460 WORD RMM MASTER 460 Roll the active figure down

To/From Page 2 of Configuration Menu

ARA1080
Figure 37: Configuration Menu (Page 1)

85
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 OFF PASS- COMPOSIT OFF
Toggle between YES/NO
RMM MASTER NO WORD RMM MASTER NO

FUEL LEVEL 00000 FUEL LEVEL 00000

Toggle between YES/NO
CRANK RESTARTS 00003 CRANK RESTARTS 00003
COMPOSIT OFF PASS- COMPOSIT OFF Toggle between YES/NO
RMM MASTER NO WORD RMM MASTER NO

FUEL PUMP TIME 00000 FUEL PUMP TIME 00000 Scrolls cursor right
LOAD 50/60 HZ 00065 LOAD 50/60 HZ 00003
LOAD 60/50 HZ 00040 PASS- LOAD 60/50 HZ 00000 Roll the active figure up
CLD ON PIN 5 NO WORD CLD ON PIN 5 NO
Roll the active figure down

FUEL PUMP TIME 00000 FUEL PUMP TIME 00000

LOAD 50/60 HZ 00065 LOAD 50/60 HZ 00065 Toggle between YES/NO
LOAD 60/50 HZ 00040 PASS- LOAD 60/50 HZ 00040
CLD ON PIN 5 NO WORD CLD ON PIN 5 NO Toggle between YES/NO

ARA1106
Figure 38: Configuration Menu (Page 2)

86
 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. The controller then generates a message when the hour meter reaches the threshold
setting.
NOTE: If the user does not desire to use the Hour Meter Threshold feature to measure maintenance
intervals, etc., leave the settings at “00000” to avoid nuisance messages.
The readings for Run Hours, Run Hours 50 Hz, and Run Hours 60 Hz can be adjusted.
To set the HM1 Threshold or the HM2 Threshold, or to reset Run Hours, Run Hours 50 Hz, or Run Hours
60 Hz, 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 necessary.
3. Press the UP or DOWN key to scroll up or down through the Main Menu to the Configuration Menu.
4. Press the ENTER key to enter the Configuration Menu.
5. The Configuration Menu will be displayed. with 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 key to display the Password screen.
8. Enter the password, which is 0007. To enter the password press the ENTER key to move the cursor to
the last value and press the UP or DOWN key to scroll the value to 7. Press the ESCAPE key and the ENTER
key at the same time to enter the password.
9. The cursor will be under the H of the HM1 or HM2 Threshold selection, or under the R of the Run
Hours, Run Hours 50 Hz or Run Hours 60 Hz selection.
10. Press the ENTER key to move the cursor to select the value you want to change.
NOTE: For example, to change the setting for the HM1 Threshold to 400 hours, press the ENTER
key until the cursor is under the third digit from the right. Then press the UP key until that value
reads 4.
11. Press the UP or DOWN key to scroll the selected value up or down to the new setting.
12. Repeat steps 10 and 11 until you have changed all the values to the new settings.
13. Press the ESCAPE key and the ENTER key at the same time to save the new settings and return to the
Configuration Menu.
NOTE: Press the ESCAPE key to return to the Configuration Menu without saving the new settings.

87
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. 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 ENTER key to enter the Event Log Menu.
5. The Event Log submenu will be displayed.
• Press the ENTER key to enter the Event Log submenu.
• Press the UP or DOWN key to scroll up or down to the Fuel Events submenu.
• Press the ESCAPE key to return to the Main Menu.

To "EVENT LOG" From "EVENT LOG"

prompt of "MAIN" prompt of "MAIN"
menu. menu.

EVENT LOG
From "EVENT LOG" submenu

To "EVENT LOG" submenu

EVENT LOG
FUEL EVENTS From "FUEL EVENTS" submenu

To "FUEL EVENTS" submenu

ARA1075
Figure 39: Event Log Menu

88
 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.
NOTE: The Event Log will log 128 events. When full, the controller uses a first in first out overwriting
of events.
To enter the Event Log submenu 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 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 ENTER key to enter the Event Log Menu.
5. The Event Log submenu will be displayed.
6. Press the ENTER key to enter the Event Log submenu.
7. The Event Log will appear on the display. It shows the most recent event and the date and time of that
event.
8. Press the DOWN key to scroll down to the next event.
9. Press the UP or DOWN key to scroll up or down through the event log.
10. Press the ESCAPE key to return to the Event Log Menu.

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 40: Event Log Submenu

89
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.
NOTE: The Fuel Events will log 128 events. When full, the controller uses a first in first out
overwriting of events.
To enter the Fuel Events submenu 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 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 ENTER key to enter the Event Log Menu.
5. The Event Log submenu will be displayed.
6. Press the UP or DOWN key to scroll up or down to the Fuel Events submenu.
7. Press the ENTER key to enter the Fuel Events submenu.
8. The Fuel Events will appear on the display. It shows the most recent fuel event and the date and time
of that event.
9. Press the DOWN key to scroll down to the next fuel event.
10. Press the UP or DOWN key to scroll up or down through the fuel events.
11. Press the ESCAPE key to return to the Event Log Menu.

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 41: Fuel Events Submenu

90
 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.
The SG+ log can store up to 128 Event logs. The oldest events will be over written in the log
automatically.
The latest LogView files can be found on our Web site under Global Marine Solutions Info Central.
NOTE: Logman II PC Rev. 2.5.0 (or later) is required to flashload software or to download the data
logger.
Event Description
Data ID / Code Description
Alarm Alarm Code An alarm is activated, see “Alarm List” on
page 63 for alarm descriptions
Message Message code A message is activated, see “Message List” on
page 66 for message descriptions
Engine Shutdown alarm If an alarm is active and entering shutdown state
Engine running The engine is running
Restart engine Restart sequence started
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 date for controller power off
Power on Time and date for controller power on
Log retrieved Log retrieved The event log is retrieved from the unit
Speed High to low speed - was XXX RPM RPM above shift point
Low to high speed - was XXX RPM RPM below shift point
Low to high speed RPM below limit RPM below 1500 RPM
High to low speed MAGNUM unit detected A TK MAGNUM unit is detected
Low to high speed compressor start detected Reefer unit controller is resetting
Low to high speed water temperature to high If water temperature is above 5 C below alarm
Water temperature XXX high limit
Failed to detect speed solenoid This event is set in the state “LOAD MEAS” if it
fails to detect the speed change
Fuel Positive change from X.X to X.X Ga Change Positive fuel change detected
in level; +X.X Ga
Negative change from X.X to X.X Ga Change Negative fuel change detected
in level; - X.X Ga
System Flashload completed OLD: XXX to NEW: A new version of the application is loaded
XXX

91
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

DATE TIME DATA
2008/07/21 20:28 POWER..........: Power ON Old fuel event description
2008/07/23 14:26 ENGINE.........: Engine running prior to 080423 software
2008/07/23 15:26 SPEED..........: High to low speed
2008/07/23 16:12 SPEED..........: Low to high speed Software update
Compressor start detected
2008/07/23 21:51 POWER..........: Power OFF New fuel event description
2008/07/23 21:51 POWER..........: Power ON
2008/07/24 20:43 ENGINE.........: Engine running
2008/07/25 13:18 FUEL..............: Change 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 speed - was 1849 rpm
2008/08/12 15:13 SPEED..........: Low to high speed - was 1505 rpm
2008/08/16 14:30 SPEED..........: Low to high speed - water temperature too high
Water temperature 102.6 C
2008/08/16 14:31 MESSAGE........: Water temperature sensor failure (#113)
2008/08/20 15:18 SPEED..........: Low to high speed - was 1538 rpm
Compressor start detected
2008/08/21 04:18 FUEL...........: Positive change from 41.3 to 54.3 Ga
Change in level: +13.0 Ga
2008/08/24 05:18 FUEL...........: Negative change from 54.2 to 35.2 Ga
Change in level: -19.0 Ga
2008/08/26 16:13 LOG RETRIEVED..: Log retrieved
ARA1663
Figure 42: Example of SG+ Log

92
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.
A dead or low battery can be the cause of an ammeter indicating discharge due to lack of initial excitation
of the alternator.
NOTE: If the battery was discharged enough that a boost was needed, the alternator may not recharge
the battery. This is because there may not be adequate current to excite the alternator field.

Relays
All the relays are 12 Vdc relays. The relays on the microprocessor PC board are interchangeable. The
relays mounted on the inside of the control 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 relay.

Ignition Relay
The Ignition relay (RL1) is located on the PC board. It supplies power to the ECU. The RL1 LED on the
PC board will light up when the Ignition relay is energized.

Run Relay
The Run relay (RL2) is located on the PC board. It supplies power to the ECU. The RL2 LED on the PC
board will light up when the Run relay is energized.

Fuel Pump Relay

The Fuel Pump relay (RL3) is located on the PC board. It supplies power to the fuel pump. The RL3 LED
on the PC board will light up when the fuel pump relay is energized.

1 2 3 4 5



1. PC Board 4. Fuel Pump Relay

2. Ignition Relay (RL1) 5. Spare Relay (If Installed)
3. Run Relay (RL2) 6. ECU Fuses

Figure 43: Components Inside Control Box

93
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. If the start relay fails in the open position, the engine would not crank. If the relay failed in the
closed position, the starter would continue to crank after the unit started.

Preheat Relay
The preheat relay is mounted on the inside of the engine compartment. It supplies power to the glow
plugs. If the preheat relay fails a P code will be generated in the ECU and the controller will display a
message.

ECU Fuses
Several ECU fuses are located inside of the control box. See the unit wiring and schematic diagrams for
the size and function of these fuses.

Unit Wiring
Inspect the unit wiring and wire harnesses during scheduled maintenance inspections for loose, chaffed or
broken wires. This will protect against unit malfunctions due to open or short circuits.

12 Vdc Charging 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 exciter field is controlled by the DSR. This initiates battery charging approximately 15
seconds after unit has output voltage.
NOTE: The engine must run for approximately 120 seconds before the battery charging circuit is
energized.

Engine Low Oil Pressure Switch

Engine oil pressure should rise immediately on starting. This causes the oil pressure switch to open. If the
oil pressure drops below 117 ± 21 kPa (1.17 ± 0.21 bar) (17 ± 3 psi), the switch will close. This causes the
ECU to signal a shutdown to stop the engine. A continuity tester is needed to check the oil pressure
switch. To check switch continuity complete the following steps:
1. Remove wire OPS from the switch.
2. Continuity tester should indicate a complete circuit between the terminal and ground.
3. Start the engine. Tester should show an open circuit between each terminal and ground. Repair
consists of replacing the switch.

94
 Electrical Maintenance

Figure 44: Engine Oil Pressure Switch

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.

Figure 45: Oil Level Sensor

95
Electrical Maintenance

Switch Test
1. Turn the unit ON/OFF switch to the “OFF” position.
2. Disconnect the switch wires from the main wire harness.
3. Connect a continuity tester to the two sockets in the low oil level switch wire connector.
4. Check the oil level with the dipstick. 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 between the low mark and the full mark on the dipstick).
Bench test the switch if there is continuity between the OLS and CH wires and there are no short circuits
in the wires.

Switch Removal and Installation

1. Disconnect the switch wires from the main wire harness before removing the switch.
2. Remove the screw-in style switch by carefully turning it out of the oil pan with a wrench.
3. To install the screw-in style switch, first lubricate the O-ring on the switch with engine oil. Then
screw the switch into the oil pan.
4. Connect the switch wires to the main wire harness after installing it.

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.
3. Slide the float up to the upper stop. Check the continuity through the switch (between OLS and CH
wires). The switch should be open.
4. Slide the float down to the lower stop. Check the continuity through the switch. The switch should be
closed.
5. Replace the switch if the float sinks or does not slide freely, or if the switch does not open and close
properly.

96
 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 46: Coolant Temperature Sensor

Sensor Test
1. Turn 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 sensors. If a sensor is connected
backwards, the display will show a reading below -40 C (-40 F) or above 130 C (266 F) and record
Alarm Code 101. Consult the unit wiring diagram or schematic for correct connections.
4. Enter the Engine submenu of the Data Menu and scroll to the engine temperature screen. If the display
shows a reading below -40 C (-40 F) or above 130 C (266 F) check the sensor wiring, the sensor
polarity.

97
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 turbocharger also reduce
emissions 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.
K1 K2 K3
F

B&C

G I

E
A

A. Crankshaft Speed Sensor

B&C Ambient Air Temperature Sensor & Flowmeter
D Fuel rail pressure sensor
E Oil Level Sensor
F Air Boost Temperature Sensor
G Coolant Temperature Sensor
H Fuel Temperature Sensor
I Fuel Metering Unit
J EGR Valve actuator
K Injector Cylinders 1, 2 & 3
Figure 47: DV6NR Sensors and Actuators

98
 Engine Maintenance

1. Injector Cylinder 4
2. Crankshaft Speed Sensor
3. Oxygen Sensor
4. Oil Pressure Switch
Figure 48: DV6NR Sensors & Actuators for the non-service view, or exhaust side

99
Engine Maintenance

3
2

1. Glow Plugs
2. Oil Breather Heater
3. Camshaft Position Sensor
Figure 49: DV6NR Sensors & Actuators Rear View

100
 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.

Figure 50: DV6NR Under Engine View

DV6NR Engine Service

Refer to the TKDV6 Repair Manual TK 55810 for engine service information not included in this
manual. Use the following procedure to connect a PC with the Peugeot EXXODiag Diagnostic Software
to the ECU to view the DV6NR engine DTCs (Diagnostic Trouble Codes) and troubleshoot engine
problems. Thermo King alarm codes A118 or A121 indicate DTCs are recorded in the ECU.

Figure 51: ECU Interfaces (except Power)

101
Engine Maintenance

Using EXXODiag to Connect to ECU

The EXXODiag Diagnostic Tool is used to connect the PC Computer USB Port to the ECU. An
EXXODiag Diagnostic Tool connector is located in the unit Control Box. Peugeot EXXODiag Diagnostic
Software installed on the PC Computer is used to communicate with the ECU. This allows ECU
information to be retrieved, DTCs to be read, operational data to be examined and updated, and other
diagnostic functions to be performed. The EXXODiag Diagnostic Tool (P/N 204-1993 or P/N 204-1996)
consists of the EXXODiag Interface Module, a standard Micro USB to USB cable, a storage box and
instructions.

Figure 52: EXXODiag Diagnostic Tool (P/N 204-1993 or P/N 204-1996)

Procedure
1. The unit battery must be connected and the Unit On/Off Switch must be turned on.
2. Turn the unit on and enter the Commands Menu.
3. In the Maintenance Menu, scroll down to and enter the ECU Service Menu.

Figure 53: EXXODiag Diagnostic Tool Interface Module and Micro USB to USB Cable

4. Open the control box and locate the EXXODiag Diagnostic Harness and Connector (OBD Port). It is
an open 16-pin connector on the ECU harness, which is black.

102
 Engine Maintenance

Figure 54: EXXODiag Connector

5. Remove the connector dust cover and connect the EXXODiag Diagnostic Tool Interface Module to
the EXXODiag Connector in the unit Control Box as shown below.

Figure 55: Connect EXXODiag Diagnostic Tool Interface Module to EXXODiag Connector

6. Connect the EXXODiag Diagnostic Tool Interface Module to the PC Computer using the supplied
standard Micro USB to USB cable.
7. Start the EXXODiag software.
8. The EXXODiag Main Menu will appear. Click on DIAGNOSTIC as shown below.
NOTE: If an update version of EXXODiag software is available a notification will be shown at the
bottom of the display as shown below.

Figure 56: EXXODiag Main Menu

103
Engine Maintenance

9. The Diagnostic Validation screen will appear. Complete the required fields. When all fields have been
completed, the VALIDATE Button will become active. Click VALIDATE to continue.

Figure 57: EXXODiag Diagnostic Validation Screen

10. The Diagnostic Menu will appear. To display the DTCs, click READING OF TROUBLE CODES.

Figure 58: EXXODiag Diagnostic Menu

11. You can now use the EXXODiag to view the DTCs and diagnose the problem.

Creating and Sending Repair Reports

Use the following procedure to create and send a repair report whenever new DTCs are recorded.
1. Use the above procedure to connect EXXODiag to the unit and enter the Diagnostic Menu.
2. Click READING OF TROUBLE CODES on the Diagnostic Menu.

Figure 59: Click Reading of Trouble Codes

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 Engine Maintenance

3. The screen will display the DTCs in the memory (if any).
4. Click HOME.



Figure 60: Click Home

5. The following pop-up screen will appear. Click YES.



Figure 61: Click Yes

6. The following screen will appear. Fill out the form and click CLOSE THE REPORT.



Figure 62: Fill Out Form and Click Close the Report

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Engine Maintenance

7. The following pop-up screen will appear. Click YES.



Figure 63: Click Yes

8. If the lap top is connected to the web, it will automatically send the report.

Otherwise, once the lap top is connected to the web; (no need to be connected to the unit anymore)
click SYNCHRONIZATION from the Main Menu.

Figure 64: Click Synchronization

9. The following screen will appear. Click SYNCHRONIZE.



Figure 65: Click Synchronize

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 Engine Maintenance

10. Check that the Synchronization is successful. If not, check the connection and the tools settings.



Figure 66: Synchronization Successful

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)
• API Rating CJ-4 Mineral Oil.
• Five Year or 12,000 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 do require regular inspection in accordance with
Thermo King's maintenance recommendations.
NOTE: The new EMI 3000 oil filters and new EMI 3000 air cleaners are NOT interchangeable with
the oil filters and air cleaners previously used in Genset units.

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Engine Maintenance

Engine Lubrication System

The DV6NR engine use a pressure lubrication system.

Figure 67: Oil Circuit Diagram

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. It is important to get as much of the oil out as possible because
most of the dirt particles are contained in the last few quarts of oil that drain out of the pan. Refill the pan
with oil and check the dipstick level. Because the new oil filter must also be filled with oil before it is
installed, use a total of approximately 12.4 quarts (11.7 liters) to fill the oil filter and refill the pan. Run
the unit, and then recheck the oil level. The engine oil level should be at the FULL mark with the dipstick
turned (threaded) into the oil pan. Never overfill.
NOTE: If filling or adding oil from the valve 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. Use a genuine Thermo King extended
maintenance oil filter.
1. Remove the filter.
2. Apply oil to the two inner O-rings of the new filter
3. Fill filter with clean engine oil before installing filter.
4. Install the filter.

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 Engine Maintenance

5. Hand tighten the filter until it seats firmly. The exposed dust seal ring, if equipped, does not need to be
compressed.
6. Turn on the controller and go the Commands Menu and perform OIL PRIMING. Start genset and
check for leaks.

Low Oil Pressure

Oil pressure is affected by oil temperature, oil viscosity, and engine speed. Low oil pressure can usually
be traced to the lack of oil, a faulty oil pressure regulating valve, or worn bearings. Low oil pressure is not
normally caused by a faulty oil pump. Use the “Low Oil Pressure Flow Chart” on the following page to
help diagnose low oil pressure.

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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 Low Re-check oil pressure in
smell like fuel? low and high speed.

Verify the unit switch,

Repair and
sensor, or gauge Not
Thin OK re-check oil pressure in
accuracy using a test Accurate
low and high speed.
gauge.

Diluted
Accurate
with Fuel

Find cause
of fuel in oil Check for excessive
and repair. radial end play at the
flywheel with a dial Excessive
indicator. Maximum;
0.007 in. 4-cylinder.

OK

Drain oil through a clean

coffee filter and check Wear Metal Repair or
for wear metal Present replace engine.
contamination.

No Wear
Metal

Check oil pressure regulator or

oil pressure control valve and
Change oil and filter. Re- repair or replace as necessary.
check oil pressure in low Low Re-check oil pressure in
and high speed. low and high speed. If oil
pressure is still low, repair or
replace engine.

ARA2441
OK

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 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. A thermostat 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 the factory with a 50 percent permanent type antifreeze
concentrate and 50 percent water mixture in the engine cooling system.
This provides the following:
1. Prevents freezing down to -30 F (-34 C).
2. Retards rust and mineral scale that can cause engine overheating.
3. Retards corrosion (acid) that can attack accumulator tanks, water tubes, radiators and core plugs.
4. Provides lubrication for the water pump seal.

Figure 68: Cooling Circuit Diagram

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Engine Maintenance

ELC (Extended Life Coolant)

Chevron/Delo XLC is currently the only Extended Life Coolant approved by Thermo King for use in
these units for five years or 12,000 hours.
CAUTION: Do not add other types of coolant to cooling systems using Chevron/Delo XLC
except in an emergency. If another type of coolant is added, the coolant must be changed to
Chevron/Delo XLC when available.
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.

Antifreeze Maintenance Procedure

As with all equipment containing antifreeze, periodic inspection on a regular basis is required to verify
the condition of the antifreeze. Inhibitors become worn out and must be replaced by changing the
antifreeze. Change ELC (red) engine coolant every five years or 12,000 hours (whichever occurs first).
Do not mix green or blue-green engine coolant with ELC (red) engine coolant. See “ELC (Extended Life
Coolant)” on page 112 for more information about ELC.
The factory recommends the use of a 50/50 antifreeze mixture in all units even if they are not exposed to
freezing temperatures. This antifreeze mixture will provide the required corrosion protection and
lubrication for the water pump.

Checking the Antifreeze

Check the solution concentration by using a temperature compensated antifreeze hydrometer or a
refractometer (P/N 204-754) designed for testing antifreeze. Maintain a minimum of 50 percent
permanent type antifreeze concentrate and 50 percent water solution to provide protection 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 up to its normal operating temperature. Stop the unit.
2. Open the engine block drain (located off water intake tube) and completely drain the coolant. Observe
the coolant color. If the coolant is dirty, proceed with a, b, and c. Otherwise go to 3.
CAUTION: Avoid direct contact with hot coolant.

a. Run clear water into the radiator and allow it to drain out of the block until it is clear.
b. Close the block drain and install a commercially available radiator and block flushing agent, and
operate the unit in accordance with instructions of the flushing agent manufacturer.
c. Open the engine block drain to drain the water and flushing solution.
CAUTION: Avoid direct contact with hot coolant.

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 Engine Maintenance

3. Run clear water into the radiator, and allow it to drain out of the block until it is clear.
4. Inspect all hoses for deterioration and hose clamp tightness. Replace if necessary.
5. Inspect the radiator cap. Replace the cap if the gasket shows any signs of deterioration.
6. If using ELC concentrate, mix one gallon of ELC concentrate and one gallon of de-ionized or distilled
water in a container to make a 50/50 mixture. (Do not add antifreeze and then add water to the unit.
This procedure may not give a true 50/50 mixture because the exact cooling system capacity may not
always be known.)
7. 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. Bleed the air out of the block using the
following procedure:
CAUTION: Do not start the engine without bleeding the air out of the block.

NOTE: If an engine runs with air trapped in the block, the engine may be damaged. The high water
temperature switch may not protect an engine that has air trapped in the block, because the high water
temperature switch is designed to protect an engine from overheating due to failures in the cooling
system.
1. Slowly pour the coolant into the expansion tank until it appears to be full.
2. Make sure that the amount of coolant that 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, or
by using a non-contact thermometer pointed at the thermostat housing in the location of the high
water temperature switch or sensor. When the temperature reaches 150 F (66 C), shut the engine off
for 2 minutes. This allows time for the thermostat to heat soak and open fully, ensuring that any
remaining air will be purged out of the engine block when the engine is restarted.
4. Restart the engine and run it in low speed. Remove the cap from the expansion tank and slowly pour
coolant into expansion tank until it is full, then reinstall the expansion tank cap.
5. Repeat steps 3 and 4 until the coolant level stabilizes.

Engine Thermostat
Thermostat is molded in the water outlet box.

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Engine Maintenance

Coolant Level Switch

The coolant level switch is a float and needs to be positioned correctly. The notch needs to be in the 6
o’clock position when mounted in the tank.

Figure 69: Notch Position

The expansion tank uses a magnetic 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. When the coolant level is below the switch, the float
is in the lower position and the switch is open.

1. Cap-Rad
2. Expansion Tank
3. Coolant Level Switch
Figure 70: Expansion Tank

1. Float in Upper Position - Switch Closed

2. Float in Lower Position - Switch Open
Figure 71: Coolant Level Switch

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 Engine Maintenance

Testing the Coolant Level Switch

You can test the switch in the unit by adjusting the coolant level. You can also remove the coolant level
switch from the expansion tank and test the switch by moving the float up and down.
1. Remove the wire harness connector from the coolant level switch.
2. Use an ohmmeter to check the continuity of the switch at the connection pins.
3. Make sure the coolant level is above the switch and check the continuity of the switch. The switch
should be closed. If you removed the switch from the tank, do this check with the float in the upper
position.
4. Drain coolant from the expansion tank until the coolant level is well below the switch level and check
continuity of the switch. The switch should be open. If you removed the switch from the tank, do this
check with the float in the lower position.
5. Replace the switch if it is does not close in step 3 and does not open in step 4.

Replacing the Coolant Level Switch

1. Disconnect the wire harness connector from the coolant level switch.
2. Turn the coolant level switch 1/4 turn to loosen it and remove it from the tank.
3. Place the new 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.

NOTE: For checking the remaining components of the PCM Engine - i.e. RPM sensor, oil sensor, air
flow meter, etc. Refer to the EXXODiag Diagnostic Tool or check continuity of the harness.

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Engine Maintenance

Engine Fuel System

DV6NR engine uses a common rail fuel injection system.
The components of the fuel system are:
• Fuel tank
• Electric fuel pump
• Fuel filter/water separator
• High pressure fuel pump
• Common (high pressure fuel) rail
• Electronic injection nozzles

Figure 72: Fuel System

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 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.
The high pressure fuel pump supplies high pressure fuel to the common rail. The common rail acts as a
reservoir for the high pressure fuel and supplies the high pressure fuel to the electronic injection nozzles,
which inject fuel when energized by the ECU. The ECU monitors multiple sensors to determine the
timing and duration of the fuel injection pulses.

5 1 2

4 3

1. Electronic Injection Nozzles

2. Return Fuel Port
3. Supply Fuel Port
4. High Pressure Fuel Pump (Fuel Supply Pump)
5. Common Rail

Figure 73: Fuel Injection Components on Engine

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 filter to the high pressure fuel pump.

Fuel System Fittings

IMPORTANT: Using the wrong fuel system fittings may void your engine warranty! All Thermo King
supplied fuel line fittings (except fuel line connector) are nickel plated brass for Gensets with Common
Rail Engines.

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Engine Maintenance

DO NOT use fuel fittings (main body) made of brass, copper, zinc, zinc plated or galvanized steel where
it would make direct contact with flowing diesel fuel. Diesel fuel flowing through these types of fittings
allows those metals to leach into the fuel forming deposits on the injector tips which fouls them
prematurely.
Fuel fitting nuts, compression sleeves, and fuel line connectors made of brass are acceptable because
diesel fuel does not flow across their surfaces.
Do not use PTFE (Polytetrafluoroethylene) thread sealing tape on the fuel fittings in a Precedent unit.
PTFE tape may allow strands into the fuel system that could plug up the tight clearance fuel injectors
causing failures.

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.
Whenever the fuel system is opened, take the following precautions to prevent dirt from entering the
system:
1. Cap all fuel lines.
2. Work in a relatively clean area whenever possible.
3. Complete the work in the shortest possible time.
The following procedures 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 replacement or repair.
5. Injection line replacement.
6. Common (high pressure fuel) rail replacement.
7. Electronic injection nozzles replacement.

Bleeding the Fuel System

If the engine runs out of fuel, repairs are made to the fuel system, or if air gets into the system for any
other reason, the air must be bled out of the fuel system to prevent interrupted unit operation or possibly
severe damage to the high pressure fuel pump. Never attempt to purge air and prime the high pressure fuel
pump by cranking the engine with the starter.
To bleed air from the fuel system:
1. Turn the unit on and go to Manual Function Test and select ECU Fuel Relay Test. Run the fuel pump
for 1-2 minutes.
2. Start the engine and observe the engine run for a few minutes. If the engine fails to start, or starts but
stops in a few minutes, repeat the procedure.

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 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.

2
4

1. Vent
2. Fuel Gauge
3. Drain Plug
4. Cap Tank
Figure 74: Fuel Tank

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. Drain the water off after the fuel tank and unit
have remained idle for an hour.
1. Place a container under the fuel tank to catch the draining water and fuel.
2. Remove the drain plug from the bottom of the fuel tank.
NOTE: Some fuel tanks have a check valve in the drain plug fitting. Push the check 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 drain freely, the vent may be plugged. If so, clean or replace the vent.
4. Install the drain plug.

Fuel Filter/Water Separator

The fuel filter/water separator filters the fuel, and removes water from the fuel and returns it to the fuel
tank.

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Engine Maintenance

Fuel Filter/Water Separator Replacement

Replace the fuel filter/water separator at intervals according to the Maintenance Inspection Schedule.
1. Unscrew the filter bowl 1/4 turn and remove it and the filter element. Drain the fuel from the filter
bowl and dispose of the filter element properly.
2. Clean the filter bowl and the filter head.
3. Lubricate the top inside edge of the filter bowl with oil.
4. Lubricate the O-ring in the top of the filter element with oil.

ARA1912

1. Filter Head 3. Filter Element

2. Filter Element Tab 4. Filter Bowl
Figure 75: 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.
6. Install and tighten the filter bowl about 1/4 turn until you hear and/or feel it click.
NOTE: Do not fill the filter bowl with fuel before installing it.
7. Loosen the bleed screw on the filter head about one turn.
8. Turn the unit on and go to Manual Function Test and select ECU Fuel Relay Test.

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 Engine Maintenance

9. Run the electric fuel pump until air bubbles are no longer visible in the fuel coming out of the bleed
screw.
10. Tighten the bleed screw and check to make sure there are no leaks.
11. Exit the ECU Fuel Relay Test to de-energize the electric fuel pump.
12. Start the engine and observe the engine run for a few minutes. If the engine fails to start, or starts but
stops in a few minutes, repeat the procedure steps 7 through 12.

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 GND wire completes a good ground with the battery. Check the voltage at the FP wire in
the harness. The pump will not operate at less than 9 Vdc. The pump is self priming.

Maintenance
The fuel pump filter should be cleaned whenever the oil is changed. The filter and gasket are replaceable
but the pump cannot be repaired. It must be replaced if it is defective.

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 the fuel filter bowl.
5. Check the fuel filter bowl gasket and replace if necessary.

1
4

2
ARA2000

3
AMA704

1. Fuel Inlet
2. Fuel Filter
3. Fuel Filter Bowl
4. Fuel Filter Bowl Gasket
Figure 76: Electric Fuel Pump

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Engine Maintenance

Assembly
1. Screw the fuel filter back into the pump housing (finger tight).
2. Place the fuel filter bowl gasket in place and hand tighten (or 100 in-lb [11.3 N•m]) the fuel filter
bowl.

If the pump does not operate, check for:

• A good ground on the black wire pin of the pump harness
• More than 9 Vdc on the red wire pin of the pump harness
• 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
• Kinks or other restrictions in the fuel lines
• A leaking or distorted fuel bowl gasket
• A clogged or dirty filter.

Air Supply System

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

Figure 77: Air Circuit Diagram

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 Engine Maintenance

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 78: EMI 3000 Air Cleaner Assembly

ARA1915
Figure 79: EMI 3000 Air Filter Element

Air Flow Meter

Measures air supplied to the engine and communicate the reading to the ECU.

Turbocharger
Delivers improved fuel economy, more power and fewer particulate emissions.

Intercooler
The air after the turbocharger 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.
The EGR tube can be removed and replaced if it is dirty. Do not try to clean the EGR tube.
1. Remove the EGR tube from between the EGR cooler and the exhaust manifold.
2. Clean the carbon deposits from inside the EGR tube.
3. Reinstall EGR tube and make sure to use a new O-ring and gasket.

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Engine Maintenance

1 2

1. EGR Valve 3. EGR Cooler

2. EGR Tube
Figure 80: EGR Components

DOC (Diesel Oxidation Catalyst) System

The DOC (Diesel Oxidation Catalyst) is an exhaust after-treatment system similar to a catalytic converter
used on a gasoline engine in a car. It is located on the back of the engine.

1. DOC
Figure 81: Back View of Engine

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 Engine Maintenance

Timing Belt Replacement

The timing belt, water pump, belt tensioner, and idler pulley should be replaced every 6,000 hours. These
components are all included in the Timing Belt Kit. The first 6,000 hour timing belt replacement is
typically covered under the unit's basic warranty. See the following procedure to replace the timing belt
and related components. The procedure requires the use of the following tools:
• Flywheel Locking Tool P/N 204-2971
• Timing Belt Tool Kit P/N 204-2979 (includes the following)
• Locator Pin 5 mm P/N 204-2977
• Locator Pin 8 mm P/N 204-2978
1. Disconnect the battery from the unit.
2. Drain the engine cooling system.
3. Support the engine and remove the front engine mount bracket and other components as necessary to
access the timing covers on the front of the engine.
4. Remove the top timing cover (four bolts).

Figure 82: Remove Top Timing Cover

5. Mark the old crankshaft bolt so it does not get mistaken for the new crankshaft bolt.



Figure 83: Mark Old Crankshaft Bolt

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Engine Maintenance

6. Rotate the crankshaft clockwise using an 18 mm socket to align the camshaft pulley to the pegging
position. The pegging position is reached when the hole in the camshaft pulley is aligned with the
corresponding hole in the cylinder head. This position is located to the upper right of the axis of the
pulley.
NOTE: Do not turn the engine counter clockwise. If the position is exceeded, do not turn back,
turn two crankshaft revolutions, always clockwise until you reach the correct position.

Figure 84: Rotate Crankshaft Clockwise

Figure 85: Align Hole in Camshaft Pulley with Corresponding Hole in Cylinder Head

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 Engine Maintenance

7. Peg the camshaft pulley using an 8 mm Locator Pin from Timing Belt Tool Kit P/N 204-2979.

Figure 86: Place Peg in Camshaft and Cylinder Head

NOTE: The 8 mm Locator Pin from Timing Belt Tool Kit P/N 204-2979 may need to be trimmed so
it will fit between the unit frame and the engine. See the picture below. If needed, trim the knurled
end of peg.

Figure 87: Trim Knurled End if Necessary

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Engine Maintenance

8. Peg the crankshaft pulley using a 5 mm Locator Pin from Timing Belt Tool Kit P/N 204-2979.



Figure 88: Place Peg in Crankshaft Pulley

9. Remove shield below starter and install a flywheel locking tool P/N 204-2971.

Figure 89: Flywheel Locking Tool

Figure 90: Install Flywheel Locking Tool

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 Engine Maintenance

10. Remove peg from the crankshaft pulley.



Figure 91: Remove Peg from Crankshaft Pulley

11. Remove the crankshaft bolt and pulley, and set aside.

Figure 92: Remove Crankshaft Bolt

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Engine Maintenance

12. Remove the five bolts, disconnect the wiring harness, and remove the lower timing cover.

Figure 93: Remove The Lower Timing Cover

13. Peg the injection pump gear using a 5 mm Locator Pin from Timing Belt Tool Kit P/N 204-2979.
14. Remove bolt (8) and the engine speed sensor.

5 mm Pin

Figure 94: Peg Injection Pump Gear and Remove Engine Speed Sensor

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 Engine Maintenance

15. Remove the top engine bracket.

Figure 95: Remove Top Engine Bracket

16. Loosen bolt (13) and remove the belt tensioner.

Figure 96: Remove Belt Tensioner

17. Keep the camshaft and injection pump pegs in place and remove the timing belt.

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Engine Maintenance

18. Loosen and remove the timing belt guide roller.

Figure 97: Remove Belt Guide Roller

19. Set aside and DO NOT REUSE the following removed parts.
a. Belt guide roller
b. Tensioner roller
c. Timing belt
20. Install the new belt guide roller. Torque to 27.3 ft-lb (37 N•m).

Figure 98: Install New Belt Guide Roller

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 Engine Maintenance

21. Replace the coolant (water) pump.

a. Remove the seven bolts that fasten the water pump to the engine.

Figure 99: Remove Water Pump Bolts

b. Remove the water pump and gasket.

c. Install a new gasket and water pump. Torque the bolts in two stages in the order shown below.
The initial torque should be 3.7 ft-lb (5 N•m).
The final torque should be 6.6 ft-lb (9 N•m).

Figure 100: Install New Water Pump

22. Before installing the new timing belt, check for play in the injection pump shaft (high pressure fuel
pump). If injection pump shaft has play, replace the injection pump. Refer to the TKDV6 Repair
Manual TK 55810.

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Engine Maintenance

23. Install the new timing belt. Position the belt, the reference number on the belt should be between the
injection pump pulley (iii) and the camshaft pulley (ii).
a. Start at the crankshaft pulley (0).
b. From (0) work the belt up and around pulley (i).
c. Keep Strand C tight and wrap belt around the camshaft pulley (ii).
d. Next bring the belt down to the injection pump pulley (iii). Keep all slack in the belt between the
injection pump pulley (iii) and the water pump (iv).

Figure 101: Install New Timing Belt

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 Engine Maintenance

24. Install the new belt tensioner and finger tighten the bolt.
25. Remove the shipping key from the belt tensioner.

Figure 102: Remove Shipping Key from Belt Tensioner

26. Install the engine speed sensor and tighten the bolt to 5.9 ft-lb (8 N•m).

Figure 103: Install Engine Speed Sensor

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Engine Maintenance

27. Remove the camshaft and injection pump pin tools.

Figure 104: Remove Camshaft and Injection Pump Pin Tools

28. Use an Allen wrench to rotate the tensioner roller counter clockwise until Pin A is centered with Area
B.

Figure 105: Rotate Tensioner Roller Counter Clockwise until Pin A Is Centered with Area B

29. While holding Allen wrench with Pin A centered in Area B. Tighten the bolt to secure the tensioner to
engine block. Torque the tensioner bolt to 22.1 ft-lb (30 N•m).

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 Engine Maintenance

30. Place the crankshaft pulley onto the crankshaft.

NOTE: Be sure to align the input print on the back of the crankshaft pulley with the key in the
crankshaft.

Figure 106: Input Print on Crankshaft Pulley

Figure 107: Key in Crankshaft

31. Install the old crankshaft bolt. DO NOT tighten at this time.

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Engine Maintenance

32. Remove the flywheel locking tool.

Figure 108: Remove Flywheel Locking Tool

33. Rotate the crankshaft six turns clockwise.

Figure 109: Rotate Crankshaft Six Turns Clockwise

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 Engine Maintenance

34. Put the engine into the pegging position. Peg the crankshaft with a 5 mm Locator Pin from Timing
Belt Tool Kit P/N 204-2979.

Figure 110: Peg Crankshaft with 5 mm Locator Pin from Timing Belt Tool Kit P/N 204-2979

35. Once crankshaft is in pegging position, remove the 5 mm Locator Pin from Timing Belt Tool Kit P/N
204-2979 and install the at the injection pump pulley. The peg tool should fit into hole in block at the
gap in the pulley.

Figure 111: Install 5 mm Locator Pin from Timing Belt Tool Kit P/N 204-2979 at Injection Pump Pulley

139
Engine Maintenance

36. Use the 8 mm Locator Pin from Timing Belt Tool Kit P/N 204-2979 to check the position of the
camshaft pulley.

Figure 112: Use 8 mm Locator Pin from Timing Belt Tool Kit P/N 204-2979 to Check Camshaft Pulley Position

37. If the camshaft peg hole does not line up, check to make sure the pin is not misaligned by more than
0.04 in. (1 mm).
NOTE: If the camshaft or injection pump pins do not fit properly go back to step 7 and repeat
timing belt procedure. If the camshaft and injection pump are timed correctly remove all pins and
proceed to step 38.
38. Check that the timing belt tension is set correctly. The control pin A must be between these two
extreme positions.

Between These
Positions

Figure 113: Control Pin A Should Be Between These Positions

140
 Engine Maintenance

39. If the tensioner needs to be adjusted, place an Allen wrench in the tensioner, loosen the bolt, and
adjust it to center control pin A as shown below. Re-torque the tensioner bolt if adjustment was
necessary to 22.1 ft-lb (30 N•m).

Figure 114: Control Pin A in Center Position

40. Install the engine bracket. Tighten the four bolts to 33.2 ft-lb (45 N•m).

Figure 115: Install Engine Bracket

41. Reinstall the flywheel locking tool.

Figure 116: Reinstall Flywheel Locking Tool

141
Engine Maintenance

42. Remove the crankshaft bolt and pulley.

43. Install the lower timing cover Torque the bolts to 3 ft-lb (4 N•m).
44. Install the upper timing cover. Torque the bolts to 3 ft-lb (4 N•m).
45. Install the crankshaft pulley. Make sure to align the input print on the back of the crankshaft pulley
with the key in the crankshaft when installing the pulley onto the crankshaft.
46. Install a NEW crankshaft bolt.
a. Torque the bolt to 25.8 ft-lb (35 N•m).

Figure 117: Torque to 25.8 ft-lb (35 N•m)

b. Tighten the bolt an additional 190 degrees.

Figure 118: Tighten Bolt 190 Degrees

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 Engine Maintenance

47. Remove the flywheel locking tool and reinstall the bolt.

Figure 119: Remove Flywheel Locking Tool

a. Torque the bolt to 40.6 ft-lb (55 N•m).

Figure 120: Torque to 40.6 ft-lb (55 N•m)

143
Engine Maintenance

48. Plug the harness into the crankshaft position sensor and clip the harness onto the lower timing cover.

Figure 121: Install Crankshaft Position Sensor Harness

49. Reinstall the front engine mount bracket and other components that were removed to access the
timing covers on the front of the engine.
50. Refill the engine cooling system.
51. Connect the battery and verify proper unit operation.

144
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.
Output of the exciter is rectified by the shaft mounted rotating bridge rectifier to provide the rotating main
field excitation.
The externally mounted excitation control system is energized from the alternator output through an digital
simplified regulator (DSR). 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 magnetism to maintain a residual voltage level.
The residual voltage supplies initial excitation power to the DSR. The initial excitation power increases
alternator output until steady state output voltage is reached. The DSR derives a sample voltage from the
output windings for voltage control purposes. In response to this sample voltage, the DSR controls the
power fed to the exciter field (FLD) and thereby the rotating main field. The DSR provides closed loop
control of the output voltage within the specified limits, compensating for load, speed, temperature and
power factor of the generator.

NOTE: The generator set is factory wired for 460V power output.

Figure 122: 460/230 Vac Alternator Component Function

145
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. The SG+ controller energizes Quad Relay 2 minutes after the engine starts.
Energizing the Quad Relay starts current flow from the DSR to yellow wire. The yellow wire sends the
current through the exciter field to build voltage in the stator windings. The exciter field current then
returns through the blue wire to chassis ground.

Running Excitation and Control

When the alternator output reaches the rated voltage, excitation is provided by the alternator excitation
winding. The magnetic field that was formed in the exciter field winding by the DSR induces voltage in
the exciter rotating winding. This voltage is changed from three-phase ac to dc by the rotating rectifier.
The dc current is transferred to the rotating main field winding. The rotating main field now becomes
magnetized. The magnetic field formed in the rotating main field winding induces a voltage in the
alternator stator windings. This voltage is sent out of the alternator stator leads to the power plug and
load. 460 Vac, 3-phase output can be measured at the power plug. In addition to being powered from the
stator excitation winding, the DSR monitors the stator output for voltage control purposes. The DSR
controls the voltage 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 DSR controls the voltage fed to the
exciter field to maintain the alternator output voltage. Over voltages caused by open circuit sensing
terminals are avoided by loss detection sensing circuitry that reduces the alternator terminal voltage to a
safe fixed level.

Overload Shutdown
The overload shutdown is provided by the controller.
If an overload condition becomes more than temporary, the reduction in alternator output voltage due to
the overload causes the DSR to increase field current through yellow wire. The DSR senses the overload
current and sends a signal out through the Open Collect circuit. The controller reads this signal and shuts
down the engine. A 20 minute restart is initiated.
If the controller shuts down unit operation, it indicates one of the following:
1. There is a malfunction in the load causing the load to fail to start or to draw single phase current.
2. The engine speed or power is low due to improper speed adjustment, fuel supply problems or other
mechanical conditions while the generator is supplying motor starting current to the load.
3. Internal component failure in the excitation control system, resulting in excessive field current. This
includes possible malfunction of protective elements in the excitation control.
4. Failure in the alternator rotating elements (exciter armature, rotating diode assemblies or main field)
can cause the regulator to supply excessive exciter field current.
5. Engine shutdown on low engine oil level, low oil pressure or high water temperature.

146
 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.
NOTE: Further diagnosis is a waste of time until these items are checked, since a problem in one of
these areas will influence test results.
1. If the generator malfunction is accompanied by excessive black exhaust smoke and engine lugging,
double check all possible engine problems such as fuel supply, injection timing, engine speed,
restricted air cleaner, etc.
2. Disconnect the refrigeration unit from the generator and check the output voltage at the plug. Voltage
between the three phases should be between 230 to 250 Vac or 400 to 500 Vac depending on engine
speed and whether the alternator stator is wired for 230 or 460 Volt operation. All three phases should
be within 3% of each other. If the voltages appear normal, make sure the refrigeration unit is not at
fault. Reconnect refrigeration unit and run in Cool mode. Check the amperage draw with an induction
type ammeter (amprobe), and compare it with the load plate on the refrigeration unit.
3. Check all push-in plugs on control circuits for loose pins or sockets. Make sure all wire terminals are
tight. Be sure J6 connector is plugged in to controller, if disconnected can cause a Message 122.

Test Instruments
If the preceding checks did not uncover the cause of the malfunction, more extensive diagnosis
procedures will be required. The following tests will require various electrical test instruments, and the
technician performing the tests should have a good working knowledge of their basic electrical principles.
The tests are intended to determine whether the source of difficulty lies in the generator itself or in the
excitation control system. Following the procedures carefully will, in many cases, avoid unnecessary
dismantling and reassembly of the generator when easily corrected problems may exist in the external
circuitry.
The test instruments required:
1. AC-DC voltmeter 2.5 Volts to 500 V ranges (± 2% max. error).
2. AC induction ammeter (amprobe).
3. DC ammeter (preferably induction type TK No. 204-947).
4. Ohmmeter.
5. Megohmmeter (Megger®)

Alternator Troubleshooting
WARNING: When servicing or repairing a generator set, the possibility of serious or even fatal injury
from electrical shock exists. Extreme care must be used when working with an operating generator set.
Lethal voltage potentials can exist at the unit power cord, inside the exciter control box, inside any
high voltage junction box and within the wiring harnesses.

147
Alternator Operation and Diagnosis

Normal alternator output voltage is 460 +/- 10 VAC with engine rpm 1800 +/- 25 rpm and no load
applied. If the generator produces no or low voltage output at the plug, perform the 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.
NOTE: Using a flashlight visually inspect exciter rotor for signs of being burnt, if burnt replace
alternator.

Test 1 - Determine if problem is with the DSR or the Alternator

During the 2 minute delayed output, perform the following steps
1. Disconnect the radiator fan at the connector. This connector is found in the harness or at the terminal
block located in the junction box on the alternator (L1, L2, L3).
2. Open the junction box on the alternator and disconnect the Blue and Yellow wires from the DSR pins
1 and 2. Connect jumper wire from 12 VDC positive to the Yellow wire. Connect another jumper wire
to the Blue wire.
NOTE: Do not connect to ground yet.
3. Connect an AC volt meter to the output terminals U1 and V1.
• Start genset - engine will be in low speed.
4. Momentarily connect the jumper wire from the Blue wire to ground and monitor the 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,
b. Stop genset and check the resistance on the Quad winding.
c. Disconnect the Red wire on Pin 3 and Red wire to DSR wire,
d. Check resistance between the Red wires, should be 1.6 ohms.
e. If resistance is correct go to step 6.
6. Check the Quad relay circuit. Connect the ohm meter to the DSR wire and Quad wire. Turn genset on
and go to Commands/Manual Function Test, select Quad relay test. Observe if ohm meter turns relay
ON and OFF. If relay is working replace DSR.

Test 2- Alternator Exciter Field Testing

1. Disconnect the Blue and Yellow wires from pin 1 and 2 on the DSR field wire. Measure the resistance
of the field circuit (Blue to Yellow). The standard value is 9.7 (±10%) ohms at 77 F (25C). If field is
open or resistance value is low replace exciter field.
2. Measure Blue or yellow wires to GND for possible shorted to ground coils. Megger F1 to stator case
to check for insulation break down, @ 500 Volts must be more than 1 M ohm. If exciter field is OK,
go to test 3.

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 Alternator Operation and Diagnosis

Test 3- Alternator Stator Testing

Test 3 covers testing the main alternator stator, the rotating rectifier, the rotating exciter field, and the
rotating field armature.
1. Main alternator stator windings
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. Using a 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

1
BEN124

1. Disconnect all 12 stator leads to test

the stator.

Figure 123: Alternator Stator

2. Rotating Rectifier
Each plate one positive and one negative diode mounted to it.

AJA2090

149
Alternator Operation and Diagnosis

1. Disconnect the main alternator field

leads to test the diodes.

Figure 124: Rectifying Diodes

a. Unbolt each of the exciter armature leads.

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. Check each diode in the forward and reverse direction. Good diode will have a high resistance
reading in one direction and no reading when ohmmeter leads are reversed.
3. Rotating Exciter Armature
a. Disconnect wires from diode blocks to check ohms and diodes.
b. Measure ohms from A to A on the main field. Should be 1.3 ohms ±10%.
c. Measure ohms from B to B, B to B, and B to B. Should be 0.420 ohms ±10%.

Measure Ohms from A to A Main Field 1.3 Ohms

Measure Ohms from B to B, B to B, and B to B, 0.420 Ohms

 

Figure 125: Exciter Rotor

4. Rotating Field Armature

a. Measure the resistance of the main field armature leads. The resistance should be 1.33 (±10%)
ohms.
b. Using a megger meter, check for insulation break down between the leads to the rotor shaft. @
500 Volts must be more than 1 M ohm.

150
 Alternator Operation and Diagnosis

AXA0324

1. Main Field
2. Exciter Rotor
3. Exciter Field
4. Ohmmeter
Figure 126: 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. This meter is of special construction with both current and voltage coils-enabling true ohms to
be read directly, independently of the actual voltage applied.
The meter gives you a direct reading of insulation resistance in “ohms” or “megohms” (1 megohm =
1,000,000 ohms). For good insulation, the resistance usually reads in the megohm range.
Normally, good insulation has high resistance; poor insulation, relatively low resistance. The actual
resistance values can be higher or lower, depending upon such factors as the temperature or moisture
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 really matters
is the trend in readings over a time period, showing lessening resistance and warning of coming problems.
Periodic testing is, therefore, your best approach to preventive maintenance.

Maintenance Procedures
The following paragraphs cover detailed maintenance procedures, including disassembly and assembly of
equipment for necessary component removal and replacement. Many repair or replacement operations
can be performed without extensive disassembly of the generator.
WARNING: DO NOT attempt adjustments or changes in wiring while a unit is in operation.
The unit generates sufficient voltage to cause severe and possible fatal shock. Use extreme
caution when operating in wet or damp locations.

151
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. Check battery connections.

Insulation
Inspect insulation on wires, coils and control components. See that insulation is not frayed, broken or
deteriorated. Replace wire having damaged insulation.

Field Coils, Stator Windings

Visually inspect the field coils and stator windings, their leads and connections to determine if they are
electrically and mechanically satisfactory. Look for any evidence of overheating, burned or frayed
insulation, 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 overheated, check the winding temperature with thermometer, locate the
cause such as lack of ventilation, overload, etc., and correct the condition or shut down the generator.
Inspect the generator housing for obstruction of air passages.

Generator Bearing
All alternators covered in this manual are fitted with a permanently lubricated bearing which requires no
maintenance in normal service.

Impeller Fan
Visually inspect the impeller fan to ascertain that no vanes are missing. Visually inspect the fan is not
encrusted with dirt or other foreign matter to the point where it will not function properly.

Coupling
Disc type coupling. Inspect to see that coupling bolts are tight and that the generator is solidly secured to
the engine.

152
 Alternator Operation and Diagnosis

BEN126

1. Rotor Assembly 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. Stator Bracket

Figure 127: Alternator Assembly

153
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).

1
Figure 128: Under View of Engine Showing Oil Pan

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 of the vanes of the blower fan
is cut away and can be used to remove a bolt if it aligned with a vane. Using a 6 mm Allen wrench
loosen the fan and rotate. Be sure to retighten fan bolt.

3. Once all flex plate bolts are removed, be sure to support engine and alternator, remove the last bolt
holding the alternator to flywheel housing and remove alternator from engine.

154
 Alternator Operation and Diagnosis

Alternator Installation
NOTE: A bad alignment may cause vibrations and bearing damage. 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. Start to install the bolt through the alternator outer ring to the flywheel
housing. Install bolts at the 10 and 4 o’clock position.

2. Start to install the bolts through the flex plate to the flywheel. Rotate engine to install all the bolts.
Loosen fan and rotate if needed. Torque bolts to 2—27 nm (15-20.
3. Install the outer ring bolt and toque to 41047 nm (30-35).
4. Install grills.

155
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 Maintenance Inspection Schedule 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.

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.

Mounting Bolt Torque

SGSM Units:
Tubular Mounting Arm to 203 N.m (150 ft-lb)
Unit Frame
I-Beam Clamp Screw 203 N.m (150 ft-lb)
SGCM Units:
Mounting Arm to Unit 88 to 115 N.m (65 to
Frame 85 ft-lb)
Chassis Clip Bolt 162 to 176 N.m (120 to
130 ft-lb)
SGCO Units:
Upper Clamp Lock clamp with lock
pawl
Lower Mounting Bolts 300 to 380 N.m (220 to
280 ft-lb)
All Units:
PCM Engine 203 N.m (150 ft-lb)
Exciter Control Box 20 to 27 N.m (15 to
20 ft-lb)

156
 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. The stainless steel plate should be placed on the outside 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 chassis member as possible.

CAUTION: Keep all container or trailer electrical lines and air lines away from the channel to
prevent damage during unit installation and operation.

3. Torque the mounting bolts:

• Mounting Arm to Unit Frame:
203 N.m (150 ft-lb)

AXA0327

1. Mounting Arm Tube and Channel Assembly

2. Unit Mounting Bracket Assembly

Figure 129: SGSM 4000 Side Mount Installation — Typical

157
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. Place mounting arm clamp screw assemblies in open (down) position.
3. Open each slider channel at least 200 mm
(8 in.).
4. Move the unit under container or trailer chassis. Place fixed gripper channels on unit over edge of
chassis I-beam.
5. Seat the chassis I-beam against the back of both fixed 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 pins in eye bolt handles to lock the eye bolts in the closed (lock) position.
8. Place the clamp screw assemblies on the rear edge of the second chassis I-beam.
9. Seat each clamp firmly against the edge of the I-beam and tighten clamp screw. Torque each clamp
screw to 203 N.m (150 ft-lb).

AXA0328

1. Clamp Channel 7. Unit

2. Clamp Screw 8. Unit Mounting Bracket Assembly
3. Mounting Arm Clamp 9. Chain and Quick Release Pin
4. Mounting Arm Tube 10. Eye Bolt
5. Slider Channel 11. Slider Pin
6. Fixed Gripper Channel

Figure 130: SGSM 4000 Side Mount Installation — Keener Arm

158
 Structural/Accessory Maintenance

SGCM 4000 Unit Installation

1. Attach the mounting arm assemblies on each end of the unit.

BEN128

1. Fasten Chassis Clips on the Outside Edge of each I-Beam and TIghten Bolts
2. Tighten Mounting Arm to Unit Bolts
Figure 131: SGUM 4000 I-Beam Centermount Installation

2. Move the unit under container or trailer chassis. Place each mounting clip on top of a chassis frame
member. Locate each clip as close to the vertical web of the chassis member as possible.
CAUTION: Keep all container or trailer electrical lines and air lines away from the clips to
prevent damage during unit installation and operation.

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)

159
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.

CAUTION: Take adequate precautions when lifting and mounting the generator set to prevent
personal injury or unit damage.

1
2

3
4
5

12

11

10

BEN122

8
7

9 6

1. Lock Pawl 7. Washer Assembly

2. Mounting Clamp Flat 8. Lower Mounting Bolt Assembly
3. Handle 9. Cotter Hair Spring 2LOOP
4. Shoulder Screw 10. Screw
5. Mounting Clamp Foot 11. Lanyard (other end mounted onto #9)
6. Stopper Plate 12. Nut hexstop

Figure 132: SGCO 4000 Clip-on Corner Clamp Installation

160
 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. The clamp flat should turn as the clamp handle rotates. With the mounting clamp in the
locked position (handle down), the clamp flat must be horizontal. If the flat is not horizontal,
check the clamp handle for a broken shoulder screw.
4. Release the lock pawl to hold the clamp handle in the locked (down) position.

CAUTION: Excessive vibration or unit malfunction can occur if mounting clamps are not
properly secured. The generator set MUST be tight against the container.

5. Check to be sure the generator set frame fits tightly against the container. Turning the mounting clamp
handle should pull the generator set frame tight against the container front wall. If necessary, tighten
the mounting clamp. The mounting clamp can be tightened or loosened by turning the nut on the head
of the clamp shaft.

AXA0332

1. Lift (Unlock) Lock Pawl 5. Lift (Unlock) Lock Pawl

2. Rotate Clamp Handle Up 90 degrees 6. Rotate Clamp Handle Down 90 degrees
3. Release (Lower) Lock Pawl 7. Release (Lower) Lock Pawl
4. Insert Mounting Clamp Foot in 8.
Container Mounting Hole

Figure 133: SGCO 4000 Clip-on Corner Clamp Installation Procedure

161
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. Tighten the lower mounting bolts to 300 to 380 N.m (220 to 280 ft-lb).
d. Install the retaining pin and hair pin key to prevent accidental loss of the mounting bolt and
backup plate during unit operation.

162
 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.

2. Check to be sure the generator set frame fits tightly against the container.
CAUTION: Excessive vibration or unit malfunction can occur if mounting clamps are not
properly secured. The generator set MUST be tight against the container.

2 BEN123

1. Header Pin 3. Lower Mounting Bolt Assembly

2. Stopper Plate

Figure 134: SGCO Clip-on Header Pin Mounting Installation

163
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. Tighten the lower mounting bolts to 203 N.m (150 ft-lb).
d. Install the retaining pin and hair pin key to prevent accidental loss of the mounting bolt and
backup plate during unit operation.

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 Maintenance Inspection Schedule 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.

Radiator and Intercooler

Clean the radiator and intercooler every 1,000 operating hours. Blow compressed air from the outside of
the coil in toward the condenser fan to clean coil (the direction opposite the normal air flow). Inspect the
coil and fins for damage and repair if necessary.

CAUTION: Air pressure should not be high enough to damage coil.

Radiator Fan Motor

Starting in June of 2015 the radiator fan motor changed from a one piece fan and motor to a separate fan
and fan motor.

Figure 135: One Piece Fan and Motor Figure 136: Separate Fan and Fan Motor

164
 Structural/Accessory Maintenance

Fan Installation for Separate Fan and Fan Motor

When installing the fan on the fan motor, the fan and fan shroud must be properly aligned for proper air
flow.
1. Place the fan assembly on the fan motor shaft so and position it so the inside fan blade tip is 7.0 to 9.0
mm (0.28 to 0.35 in.) from the fan shroud as shown below.
7.0 to 9.0 mm
(0.28 to 0.35 in.)

Figure 137: Fan Position

2. Finger tighten the hub bolts till the bolt heads are flush with the hub face.
3. Using a wrench, do a full turn on each bolt alternatively. Repeat this step until some torque builds.
4. Use a torque wrench set at 7.0 to 9.0 N.m (5.2 to 6.6 ft-lb) to complete the tightening sequence on
each hub bolt alternatively.
5. Tighten the set screw to a torque of 2.5 to 2.9 N.m (1.8 to 2.1 ft-lb).

1. Hub Bolts 2. Set Screw

Figure 138: Fan Hub Bolts and Set Screw

165
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 S13 open (blown) Check for short circuit and replace fuse
Defective On/Off switch Check switch
Open circuit Check 2, 2B, 2C and 8 circuits
Unit switch On (controller Batteries discharged Charge or replace battery
display is On) but engine
Corroded battery connections Clean and tighten
does not crank
Defective starter relay or 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 and turn engine slowly
Starter motor turns but Starter clutch defective Replace
engine does not crank
Engine cranks but fails to No fuel or wrong fuel Fill with proper fuel
start
Air cleaner clogged Replace dry air cleaner filter
Exhaust plugged Clear exhaust system
Glow Plug defective Replace defective air heater
Air in fuel system Bleed air
Electric fuel pump not energized Check FP+ and GND circuits
Electric Fuel pump defective Replace pump
Voltage falls below 6 Vdc at ECU while Repair cause of low voltage at ECU while
starter cranking starter cranking
Problem with ECU controlled engine Use EXXODiag diagnostic tool to
function diagnose problem
Compression low Overhaul engine
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

166
 Mechanical Diagnosis

Diagnosing Unit Conditions (Continued)

Condition Possible Cause Remedy

Engine does not develop Air cleaner or intake system clogged Clean air intake system, or replace dry
full power air cleaner filter
Fuel tank vent clogged Unclog vent
Clogged fuel tank or fuel lines Clean fuel tank and fuel lines
Insufficient fuel volume leaving filter(s) Check for dirty filter or air in system
Air cleaner clogged Replace air filter
Delivery of electric fuel pump insufficient Repair pump
Problem with ECU controlled engine Use EXXODiag diagnostic tool to
function diagnose problem
Compression low or unbalanced Overhaul engine
Engine speed too high Problem with ECU controlled engine Use EXXODiag diagnostic tool to
function diagnose problem
Engine fails to stop when Problem with ECU controlled engine Use EXXODiag diagnostic tool to
unit is OFF function diagnose problem
Engine knocks heavily Wrong fuel Change fuel
Air in system Bleed fuel system
Fuel return line plugged Remove return line restriction
Valve out of adjustment Adjust valves
Compression too low Overhaul engine
Rod or main bearing worn Replace rod or main bearings
Engine runs hot Coolant level is low Add coolant
Generator overloaded Check load
Dirty radiator Wash radiator
Defective thermostat Check or replace thermostat
Cooling system heavily scaled Clean cooling system
Cylinder head gasket leaks Replace cylinder head gasket. Use
correct gasket
Oil pressure too low or Insufficient oil in pan Add oil
drops suddenly. Minimum
Defective oil pressure switch Check oil pressure switch. Replace if
oil pressure for a hot
necessary
engine is 117 kPa, 1.17
bar, 17 psi (low oil Oil pressure control valve defective Check oil pressure control valve
pressure switch setting)
Worn oil pump, camshaft, main or Repair engine
connecting rod bearings, loose oil gallery
plug

167
Mechanical Diagnosis

Diagnosing Unit Conditions (Continued)

Condition Possible Cause Remedy

High oil consumption 10 hour engine break in running was not Run unit continuously for 10 hours in
successfully completed high speed with varying load
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, or replace dry
air cleaner filter
Damaged valve seals Replace seals on valve stem
Worn valve stem Replace valves
Broken piston rings or cylinder bore worn Have engine repaired and re-bored.
or scored Replace broken piston rings
Battery is not recharging Loose connections in electrical system Check all electrical connections and
system charging system charging system
Battery defective Replace battery
Controller defective Replace controller
White Smoke (fuel is not Cold engine Allow engine to warm up
burning)
Air or water in fuel Bleed system. Replace filters, clean fuel
system, drain and clean tank and check
supply tank for water. Use known good
fuel
Insufficient preheat Check glow plugs
Low compression Check and eliminate possible causes.
Repair as necessary
Blue Smoke (oil Excessive oil consumption Refer to High Oil Consumption. Repair
consumption) as necessary
Black Smoke Cold engine Allow engine to warm up
(excessive fuel to air ratio)
Wrong fuel Drain and refill with correct fuel
• Engine is sooting heavily,
emits thick black clouds of Clogged air intake system
Clean or replace air cleaner
smoke Restricted exhaust system Clean or replace
Excessive load Check drive system and engine oil
pressure
Poor compression Check and eliminate possible causes.
Repair as necessary
Air leak in intercooler or piping Repair or replace

168
Index
A ELC (Extended Life Coolant) 112
Additional Options 35 Elecrical Maintenance 93
After Start Inspection 51 electric fuel pump 121
Alarm Diagnosis 63 Electrical Diagrams 171
Alarm List Menu 47, 62 Electrical Hazards 9
Alarm Types 62 EMI 3000 107
Alarms, Displaying and Acknowledging 62 EMI 3000 Package 33
Alternator Assembly Drawings 153 Engine Lamps 58
Alternator Tests Engine Low Oil Pressure Switch 94
Test 4 148 Engine, Serial Number Locations 13
Test 5 149 engine, specifications 16
Alternator, Diagnosis 147 Event Log 89
Alternator, Function of 146 Event Log Menu 48, 88
Alternator, General Description 145
antifreeze F
changing 112 Fan Location, Radiator 157
checking 112 Features, Genset Model 38
maintenance procedure 112 First Aid 9
Front View
B Powerpack 37
Battery 93 SGCM 35
Battery Hazards 8 SGCO 36
Fuel Events 90
C fuel filter/water separator, replacement 120
C/F Mode 79 fuel line routing 117
Charging System, Battery 12 vdc 94 fuel system 116
Coil, Radiator 164 bleeding 118
Commands Menu 47, 69 fittings 117
Configuration Menu 47, 84 maintenance 118
Controller Display Menus 44 fuel tank, draining water from 119
Controller Overview 41 Functional Inspection 52
Controller Repair 10
coolant level switch 114 G
replacing 115 Generator Submenu 59
testing 115 Generator, Serial Number Locations 13
Coolant Temperature Sensor 97 Genset
Sensor Test 97 Model Features 38
cooling system, engine 111 Genset Model Features 38
bleeding air from 113
H
D High Voltage 9
Data Menu 47, 55 HM1 Threshold 87
Date/Time Submenu 83 HM2 Threshold 87
Decals Hour Meter Thresholds, Setting 87
SGCM 14 Hour Meters, Resetting 87
SGCO 15
SGSM 14 I
Decals, Units 14 Inspection of Unit 156, 164
Description, General 31 Inspection, After Start 51
Diagnosis, Mechanical 166 Installation, SGCM 3000 Unit 159
Displaying and Acknowledging Alarms 62 Installation, SGCO 3000 Clip-on Corner Clamp Unit
Displaying and Acknowledging Messages 65 160
DOC (Diesel Oxidation Catalyst) system 124 Installation, SGCO 3000 Clip-on Header Pin Unit 163
DV6NR Engine Service 101 Installation, SGSM 3000 157
Installation, SGSM 3000 Keener Arm Unit 158
E
EcoPower Option 34 L
ECU Service Menu 75 LogView 91

169
Index

low oil pressure 109 Safety Do’s and Don’ts 11

Low Oil Pressure Switch, Description 34 Welding 11
lubrication system, engine 108 Safety Precautions 8
safety precautions
M battery installation and cable routing 12
Main Menu 53 battery removal 12
maintenance inspection schedule 22 Schematic Diagrams 171
Maintenance Procedures 151 Serial Number Locations 13
Manual Function Test 73 Engine 13
Mechanical Diagnosis 166 Generator 13
Megohmmeter 151 SGCO Units 13
Menu Flow Diagrams 171 SGSM Units 13
Menu Overview 46 Setting Hour Meter Thresholds 87
Menus 44 SG+ Controller Description 39
Navigating 44 SGCM 3000 Unit Installation 159
Message Diagnosis 66 SGCO 3000 Clip-on Corner Clamp Unit Installation 160
Message List Menu 47, 65 SGCO 3000 Clip-on Header Pin Unit Installation 163
Microprocessor, Description 39 SGCO Units, Serial Number Locations 13
Misc. Functions Menu 47, 78 SGSM 3000 Installation 157
Model Features, Genset 38 SGSM 3000 Keener Arm Unit Installation 158
Mounting Bolts, Torque Values 156 SGSM Units, Serial Number Locations 13
Specifications
N Controller Default Settings 18
Navigating Controller Menus 44 Electrical Components 18
Electrical Control System 17
Generator 17
O
Metric Hardware Torque Charts 21
oil change, engine 108
Physical Specifications 19
oil filter change, engine 108
Radiator Fan Motor 17
Oil Level Sensor 95
Standard Display 48
Switch Test 96
Starting the Unit 50
Oil Level Sensor, Description 34
SW/HW Version 80
Oil Priming 75
System Setup Submenu 76
P
T
Precautions 9
thermostat, engine 113
Pretrip Inspection 50
Timers/Counters 81
Pretrip Inspection Test 52, 71
timing belt replacement 125
Protection Devices, Descriptions 34
Torque Values, Mounting Bolts 156
PTI (Pretrip Inspection Test) 52, 71
U
R
Unit Controls, Descriptions 41
Radiator Coil 164
Unit Decals 14
Radiator Fan Location 157
Unit Inspection 156, 164
Radiator Fan Motor 164
Unit Instruments, Descriptions 34
Relays 93
Unit Submenu 60
Resetting Hour Meters 87
routing
fuel line 117 V
Viewing SG+ Logs 91
S
Safety 11 W
Safety Do’s and Don’ts 11 Water Temperature Sensor, Description 34
Safety Instructions Welding 11
Battery Hazards 8 Wiring Diagrams 171
Controller Repair 10
Electrical Hazards 9
First Aid 9
High Voltage 9
Precautions 9

170
Electrical and SG+ Menu Flow Diagrams

Drawing Title Page

Wiring Diagram Genset SG+ Units with One Piece Fan and Motor (Before 6/15) 173-174
Schematic Diagram Genset SG+ Units with One Piece Fan and Motor (Before 6/15) 175
Wiring Diagram Genset SG+ Units with Separate Fan and Fan Motor (6/15 and After) 176-177
Schematic Diagram Genset SG+ Units with Separate Fan and Fan Motor (6/15 and After) 178
SG+ Menu Flow Diagram 179-180

171
Electrical and SG+ Menu Flow Diagrams

172
Wiring Diagram SG+ Units with One Piece Fan and Motor (Before 6/15) — Page 1 of 2
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173
Wiring Diagram SG+ Units with One Piece Fan and Motor (Before 6/15) — Page 2 of 2
RELEASED 04/Jun/2014
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174
Schematic Diagram SG+ Units with One Piece Fan and Motor (Before 6/15) — Page 1 of 1
RELEASED 04/Jun/2014
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175
Wiring Diagram SG+ Units with Separate Fan and Fan Motor (6/15 and After) — Page 1 of 2
RELEASED 08/Sep/2015
2 12:48:36 GMT

176
Wiring Diagram SG+ Units with Separate Fan and Fan Motor (6/15 and After) — Page 2 of 2
2

177
Schematic Diagram SG+ Units with Separate Fan and Fan Motor (6/15 and After) — Page 1 of 1
RELEASED 08/Sep/2015
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178
 STANDARD DISPLAY
CONTROLLER MENU GUIDE
Keypad Operating Tips
Text Input: PAUSE MODE DISPLAYS deLAY / AC1 RESTART IN XX MIN.2
• To enter a number: Press the UP or DOWN key to increase or
decrease the value of a digit in the display. ALARM LIST MENU
• Top line shows Alarm Code, and the position of the alarm • Press key to view additional alarms.
• Press the ENTER key to scroll the cursor to the right. and number of alarms stored in memory (e.g. “1/2”).
• Middle lines show alarm text. • Press key to acknowledge the alarm being displayed.
• Bottom line shows alarm status. • Correct all problems before returning the unit to service.
To Enter a Controller Menu or Submenu: • View and write down all alarms before acknowledging.

• Press ALARM key to directly enter the Alarm List Menu. Water Temp.
Load
• Press the ENTER key or the ESCAPE key to enter the Main RPM
RPM Requested
Menu. Fuel Rate
Ignition Relay
• Press ENTER key to enter a menu from the Main Menu, or a MAIN MENU Submenus Run Relay Protect Lamp
submenu from its parent menu. Engine Amber Lamp
Engine Lamps Stop Lamp
• Press ESCAPE key to return to the Main Menu from a menu, or DATA MENU Generator Voltage Meas Malfunction Lamp
a menu from a submenu. DATA MENU Unit Field Current Wait to start
Internal States Running Freq.
Quad Closed
Bat. Voltage
To Scroll in a menu: Bat. Charger Fuel Lev. Mean
Low Coolant Level
• Press UP key to scroll up. State Fuel Pump
RPM Coolant Fan
• Press DOWN key to scroll down.

To Enter a Command or execute a task: ALARM LIST MENU

• Press ENTER key.
MESSAGE LIST MENU
• Top line shows Message Code, and the position of the message • Press key to view additional messages.
and number of messages stored in memory (e.g. “1/2”).
To Enter a New Value in a Screen: MESSAGE LIST MENU • Middle lines show message text. • Press key to acknowledge the message being displayed.
• Correct all problems before returning the unit to service.
• Press ENTER key and ESCAPE key at the same time. • Bottom line shows message status.
• View and write down all messages before acknowledging.

To change language Oil Level Switch • When PTI is complete,

• Press LANGUAGE key. Coolant Temperature Sensor display shows test result:
RPM Sensor “PASSED” or “FAILED”.
Preheat Relay • If “FAILED”, correct any
Fuel Hold Relay problems and repeat PTI.
Fuel Pull Relay
Submenus Start Relay
PTI (Pretrip Inspection Test) Oil Pressure Switch
COMMANDS
COMMANDS MENU MENU
Manual Function Test RPM Sensor
ECU Service Menu Output Voltage
System Setup
Display Test • Press key to start test.
Preheat Relay Test When test complete, display
Fuel Hold Relay Test shows test result: “PASSED” or
Fuel Pull Relay Test “FAILED”.
Start Relay Test • If “FAILED”, correct problem
and repeat test.

Submenus • Press or key to toggle between Speed

Current RPM Solenoid On and Off (High Speed and Low
Speed Solenoid Speed Solenoid: On Speed).
Load • Press key to return to System Setup
Engine Type Submenu.
Generator
Genset • Press or key to toggle between PCM and
Tank Size Engine Type: Yanmar.
Fuel Sensor
PCM • Press key to return to System Setup
CLD on pin 5
Submenu.
Date
Footnotes: Time
ID No.
• Press or key to toggle M.ALTE AND
1“dELAy/ AC.” screen indicates controller has a 2 minute delay. Ser. No.
STAMFRD.
Generator:
2“RESTART IN XX MIN.” screen indicates controller has
M.ALTE • Press key to return to System Setup
Submenu.
stopped unit operation due to an alarm. Controller will attempt to
restart unit in the time shown. • Press or key to toggle between Clip on,
centre and side (the 3 different Genset units).
Genset: Clip on
• Press key to return to System Setup
Submenu.

• Press or key to scroll value.

To/From • Press and keys at same time to save new
Next Page Tank Size: XX setting and return to System Setup Submenu.
• Press key to return to System Setup Submenu
without saving new setting.

To Next Page
179
 To/From CONTROLLER MENU GUIDE (Continued)
Previous Page
From Previous Page

• Press or key to toggle between Fuel

Sensor Yes and No.
Fuel Sensor: No
• Press key to return to System Setup
Submenu.

• Press or key to toggle between CLD on

pin 5 Yes and No.
CLD on pin 5: No
• Press key to return to System Setup
Submenu.

• Press or key to scroll value.

• Press and keys at same time to save new
ID: XXXXXXXX setting and return to System Setup Submenu.
• Press key to return to System Setup Submenu
without saving new setting.

• Press or key to scroll value.

• Press and keys at same time to save new
Ser. No: XXXXXXXXXX setting and return to System Setup Submenu.
• Press key to return to System Setup Submenu
without saving new setting.

• Press or key to toggle between Celsius

and Fahrenheit.
Submenus
C/F Mode C/F Mode: Celsius • Press and keys at same time to save
MISC.
SW/HW Version new setting and return to Misc. Functions Menu.
MISC. FUNCTIONS MENU FUNCTIONS
MENU Timers/Counters • Press key to return to Misc. Functions Menu
Date/Time without saving new setting.

SW XXXXXX XX
Hardware Rev. Y

Run Hours
Hour Meter 1
Hour Meter 2
Engine Off Hours
Restarts
Total Restarts
Run Hours 50 Hz
Run Hours 60 Hz

• Press key to move cursor.

Year: XXXX • Press or key to scroll value.
Month: XX
• Press and keys at same time to save new settings
Date: XX
and return to Misc. Functions Menu.
Time: XX.XX
• Press key to return to Misc. Functions Menu without
saving new settings.

Engine Type
LOP Restart
HM1 Threshold
HM2 Threshold • Press key to display the Password screen.
ENG. Off Hours • Enter password 0007 by pressing key to move cursor to the last
Factory Reset
CONFIGURATION MENU CONFIGURATION MENU
Generator value and press or key to scroll the value to 7.
Genset • Press key to display selection.
Output Voltage
• Press key to move cursor to right (if needed).
Fuel Level
Crank Restarts • Press or key to scroll or toggle value.
Composit
• Press and keys at same time to save new setting and return
RMM MASTER to Configuration Menu.
Fuel Pump Time
• Press key to return to Configuration Menu without saving new
50 TO 60 HZ settings.
60 TO 50 HZ
CLD on Pin 5
Start Delay

• Press key to view earlier events.

Submenus • Press key to scroll back from earlier events to later events.
EVENT LOG Event Log • Top line shows date and time of the event.
EVENT LOG MENU MENU Fuel Events
• Lower lines show the event message text.
• The most recent event appears first.
• Events are listed in reverse order of occurrence.

180
 Maintenance Manual

SB-210+
SGSM 4000, SGCM 4000
& SGCO 4000
Additional text information
to be placed here
TK 61010-4-MM (Rev. 1, 02/16)
TK 5XXXX-X-PL
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and air
conditioning systems, building and contracting services, parts support and advanced controls
for commercial buildings and homes.

Distributed by:

Thermo King Corporate

314 West 90th Street
Minneapolis, MN 55420
Direct (952) 887-2200

TK 61010-4-MM

©2013 Ingersoll Rand Company

Printed in U.S.A.