Manual SG 3000 Thermo King

SGSM 3000, SGCM
3000 & SGCO 3000

TK 53414-4-MM (Rev. 6, 09/17)
Copyright© 2007-2017 Thermo King Corp., Minneapolis, MN, USA.

Printed in USA.
The maintenance information in this manual covers unit models:
SGCO (062007): Model with SG+ controls and clip-on unit frame
SGSM (062008): Model with SG+ controls and side-mount unit frame
SGCO (062009) Model with SG+ controls and clip-on unit frame
SGCM (062010): Model with SG+ controls and center-mount unit frame
For further information, refer to:
SGCO 3000 Parts Manual TK 53717
SGSM 3000 Parts Manual TK 53706
SGCM 3000 Parts Manual TK 53725
TK482 and TK486 Engine Overhaul Manual TK 50136
Electrostatic Discharge (ESD) Training Guide TK 40282
Tool Catalog TK 5955
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
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.
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits

the loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations

concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local Thermo King dealer.
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Genset Model Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Safety Precautions for Servicing Units (or Containers) Equipped with a Microprocessor Controller . . 17
Controller Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Welding of Units or Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Do’s and Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DO: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DO NOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unit Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Controller Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Metric Hardware Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Unit Description, Features & Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
EMI 3000 Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SG+ Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Unit Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dual Voltage Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
EcoPower Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel Level Sensor Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Additional Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SG+ Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Controller Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Miscellaneous Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Navigating the Controller Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Controller Display Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Navigating Controller Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Alarm List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Message List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Commands Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Misc. Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5
Table of Contents
Event Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pause Mode Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Network Down Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Pretrip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Functional Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Engine Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Internal States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Alarm List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Displaying and Acknowledging Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Alarm Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Message List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Displaying and Acknowledging Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Message Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Commands Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
PTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Manual Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Date/Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Misc. Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
C/F Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
SW/HW Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Timers/Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Setting Hour Meter Thresholds and Resetting Hour Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Event Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Fuel Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
LogView and Viewing SG+ Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Configuring a unit after Flashload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fuel Pull Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fuel Hold Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Speed (Throttle) Solenoid Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Quad Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Preheat Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
12 Vdc Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Coolant Level Detector Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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Flywheel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Testing the Flywheel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Cyclonic Dry Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Checking the Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Changing the Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Water in the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Single Element Fuel Filter/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Adjustment Procedure for Standard Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Adjustment Procedure for Units with EcoPower Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Integral Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
DIagnosing the Integral Fuel Solenoid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Fuel Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Injection Pump Service and Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Adjusting Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Belt Tension Adjustment and Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Alternator Operation and Diagnosis (prior to December 2016) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Dual Voltage Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Alternator Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Starting Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Running Excitation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Overload Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Alternator Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Test Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Alternator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Test 1 - Determine if Problem is in Controller or Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Test 2 - Controller Excitation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Test 3 - Testing Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Test 4 - Alternator Exciter Field Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Test 5 - Alternator Stator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Megohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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Field Coils, Stator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Generator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Generator Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Impeller Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Rewiring Procedures for Changing the Generator Set Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Rewiring Procedure for Changing the Output Voltage from 460 Vac to 230 Vac . . . . . . . . . . . . . . . . . . . . 170
Alternator Operation and Diagnosis (from December 2016) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Alternator Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Starting Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Running Excitation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Overload Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Alternator Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Test Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Alternator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Test 2- Alternator Exciter Field Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Test 3- Alternator Stator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Megohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Field Coils, Stator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Generator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Generator Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Impeller Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Alternator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Structural/Accessory Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Radiator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
SGSM 3000 Typical Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
SGSM 3000 Keener Arm Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
SGCM 3000 Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
SGCO 3000 Clip-on Corner Clamp Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
SGCO 3000 Clip-on Header Pin Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Radiator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Electrical and SG+ Menu Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
CONTROLLER MENU GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
CONTROLLER MENU GUIDE (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8
List of Figures
Figure 1: Model SGSM 3000 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 2: Model SGCM 3000 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 3: Model SGCO 3000 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 4: SGSM 3000 Side Mount Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 5: SGCM 3000 Center Mount Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 6: SGCO 3000 Clip On Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 7: SG+ Controller Versions G01 and G02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 8: SG+ Controller Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 9: EcoPower Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 10: SGSM 3000 — Unit Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 11: SGCM 3000 — Unit Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 12: SGCO 3000 — Unit Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 13: Powerpack (All Models) — Unit Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 14: SG+ Controller Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 15: SG+ Microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 16: Control Box Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 17: Controller Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 18: Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 19: Standard Display and Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 20: Typical Pause Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 21: Network Down Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 22: Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 23: Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 24: Engine Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 25: Generator submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 26: Internal States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 27: Alarm List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 28: Message List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 29: Commands Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 30: PTI Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 31: Manual Function Test Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 32: System Setup Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 33: Date/Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 34: Misc. Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 35: C/F Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 36: SW/HW Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 37: Timers/Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 38: Configuration Menu (Page 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 39: Configuration Menu (Page 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 40: Event Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 41: Event Log Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 42: Fuel Events Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 43: Example of SG+ Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 44: Components Inside Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 45: Relay Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 46: Alternator Exciter Field Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 47: Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 48: Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 49: Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 50: Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 51: Coolant Level Detector Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 52: Flywheel Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 53: Flywheel Sensor with Wiring and Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 54: Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 55: Cyclonic Dry Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 56: Cyclonic Dry Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 57: Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Figure 58: ELC Nameplate Located On Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9
List of Figures
Figure 59: SGCM and SGSM Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Figure 60: SGCO Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 61: Remove Plug from Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 62: Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 63: Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 64: Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 65: Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 66: Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 67: Engine Speed Adjustment for Standard Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 68: Engine Speed Adjustment for Units with EcoPower Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Figure 69: Integral Fuel Solenoid Harness Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 70: Integral Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 71: Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 72: Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 73: Injection Pump Gear Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 74: Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 75: Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 76: Marking Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 77: Place Injection Angle Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 78: Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 79: Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Figure 80: Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Figure 81: Injection Angle Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 82: Injection Pump Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 83: Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . . . 147
Figure 84: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 85: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . . 148
Figure 86: Trochoid Feed Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 87: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 88: Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 89: Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Figure 90: Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 91: Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 92: Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 93: Adjusting the Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 94: Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 95: Valve Adjustment and Cylinder Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Figure 96: Water Pump Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Figure 97: 460/230 Vac Alternator Component Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Figure 98: Remove Blue Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Figure 99: Check Voltage Between J15 and J16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Figure 100: DATA MENU/ANALOG INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Figure 101: Alternator Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Figure 102: Rectifying Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Figure 103: Exciter Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Figure 104: Main Field Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Figure 105: Alternator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Figure 106: Changing Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Figure 107: 460/230 Vac Alternator Component Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Figure 108: Alternator Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Figure 109: Rectifying Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Figure 110: Exciter Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Figure 111: Main Field Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Figure 112: Alternator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Figure 113: Radiator Fan Blade Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Figure 114: SGSM 3000 Side Mount Installation — Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Figure 115: SGSM 3000 Side Mount Installation — Keener Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Figure 116: SGCM 3000 C-Section Chassis Centermount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Figure 117: SGCM 3000 I-Beam Centermount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Figure 118: SGCO 3000 Clip-on Corner Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
10
List of Figures
Figure 119: SGCO 3000 Clip-on Corner Clamp Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Figure 120: SGCO Clip-on Header Pin Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
11
List of Figures
12
Genset Model Features
MODEL
SGCM
SGSM
SGCO
S S S TK486VG Tier 2 EPA 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
— O — 230 Vac and 460 Vac Dual Receptacle for 15 KW, 18.75 KVA, 3 Phase, 60 Hz, 4 Wire Generator
S S S SG+ Control System
S S S Battery with Threaded Terminals
S S S Battery Charging System, Solid-state
S — — Side-mount Unit Frame
— S — Center-mount Unit Frame
— — S Clip-on Unit Frame
S S S Combination Fuel Filter/Water Separator
S S S Dry Air Cleaner
S S S Silicone Coolant Hoses
S S S Stainless Steel Muffler
S S S Battery, Post Style
O O O Fuel Heater Electric
— — O Header Pin, Mounting
— O — Pre-cleaner for Air Cleaner
S S S EMI 3000 Extended Maintenance Interval Package
S — — 75 Gallon (284 Liter) Steel Fuel Tank
— S — Integral 80 Gallon (303 Liter) Aluminum Fuel Tank
— — S Integral 125 Gallon (473 Liter) Steel Fuel Tank
— O — Integral 50 Gallon (190 Liter) Aluminum Fuel Tank
— O — Integral 50 Gallon (190 Liter) Steel Fuel Tank
S = STD
O = Optional
— = N/A
13
14
Safety Precautions
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.
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.
15
Safety Precautions
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.
16
Safety Precautions
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.
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.
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.
17
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.
18
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.
19
Safety Precautions
20
Serial Number Locations
Generator: The generator nameplate is attached to the generator housing. The serial number is stamped on
the shell.
Engine: The engine serial number is stamped on the back side of the engine block.
SGSM Units: The unit serial number nameplate is attached to the bottom frame member inside the engine
compartment access door.
SGCM Units: The unit serial number nameplate is attached to the unit frame below the engine
compartment access door.
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.
21
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.
AXA0265 AXA0265
AXA0266
AJA1947
AXA0265
Unit Nameplate Location
AXA0263
AXA0312
AXA0264
Figure 1: Model SGSM 3000 Decals
22
AXA0265 AXA0265
AXA0266
AXA0312
AXA0265
AXA0267
AJA1947
AXA0264
Figure 2: Model SGCM 3000 Decals
23
AXA0265
AXA0266
AXA0313
AXA0268
AXA0312
AXA0314
AXA0264
AXA0265
AJA1947
Figure 3: Model SGCO 3000 Decals
24
Service Guide
This table is for Models SGSM 3000, SGCM 3000 and SGCO 3000.
Pre-Trip Every 3,000

2501 Hour2/
Hours Annual Inspect/Service These Items
Electrical
• Perform a controller Pretrip (PTI) check.
• • • Inspect battery terminals and electrolyte level.
• Inspect wire harness for damaged wires or connections.
• Inspect AC generator and alternator wire connections for tightness.
Engine
• Check fuel supply and fill.
• • • Check engine oil level and fill as needed.
Check engine coolant level. (CAUTION: Do not remove radiator cap while coolant
• • • is hot.)
• • • Inspect belt for condition and proper tension.
Check engine oil pressure hot, on high speed. Minimum 276 kPa,
• • • 2.76 bar, 40 psi.
• • • Listen for unusual noises, vibrations, etc.
• • • Inspect/clean fuel transfer pump inlet strainer.
Check air cleaner restriction indicator (change filter when indicator reaches 25 in.).
• Replace air cleaner element at two years if indicator has not reached 25 in.
Drain water from fuel tank and check vent. Clean fuel strainer in transfer pump
• • inlet.
Check and adjust engine speed. See “Engine Speed Adjustment” on pages 134
• • and 135.
• Change engine oil2 (hot) and oil filter.
• Change engine oil (hot) and oil filter.3
• Change fuel filter/water separator.3
• Check condition of engine mounts.
• Test fuel injection nozzles at least every 3,000 hours.4
Change ELC (red) engine coolant every 5 years or 12,000 hours. Maintain
— antifreeze protection at -34 C (-30 F).
— Replace fuel return lines between fuel injection nozzles every 10,000 hours.
Structural
• • • Visually inspect unit for fluid leaks (coolant and oil).
• • • Visually inspect unit for damaged, loose or broken parts.
1Inspect/service every 250 operating hours in extreme (dirt yard) operating conditions.
23,000 hours or 2 years, whichever occurs first.
3More frequent intervals may be necessary in extreme operating conditions.
4Based on EPA 40 CFR Part 89.
25
Service Guide
26
Specifications
Engine
Diesel Engine Model TK486VG Tier 2 EPA
Fuel Type No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Oil Capacity
Crankcase and Oil Filter: 12.3 litre (13 qt)
Fill to full mark on dipstick
Oil Type: Multi-grade Petroleum Oil (Standard)
Synthetic Oil (Optional) after first 500 hours
Classification: API Type CI-4 or better
ACEA Type E3 or better
Oil Viscosity:
Below -30 C (-22 F): SAE 0W-30 (Synthetic)
-30 C to +50 C (-22 F to +122 F): SAE 5W-40 (Synthetic)
-25 C to +30 C (-13 F to +86 F): SAE 10W-30
-25 C to +40 C (-13 F to +104 F): SAE 10W-40
-15 C to +40 C (+5 F to +104 F): SAE 15W-40
-10 C to +50 C (+14 F to +122 F): SAE 15W-40 (Synthetic)
Engine Oil Pressure 120 to 320 kPa (1.2 to 3.2 bar) (18 to 47psi)
Engine RPM:
No Load: 1890 ± 10 RPM (High Speed)
1560 ± 5 RPM (Low Speed EcoPower Option only)
Valve Clearance 0.15 to 0.25 mm (0.006 to 0.010 in.)
Valve Setting Temperature 21 C (70 F) (Room Temperature)
Low Oil Pressure Switch (Normally Closed) 117 ± 21 kPa (1.17 ± 0.21 bar) (17 ± 3 psi)
High Coolant Temperature Switch* Sensor*
Engine Thermostat 71 C (160 F)
Coolant System Capacity 9.5 liter (10 qt) with overflow tank
Engine Coolant Type Texaco ELC (Extended Life Coolant) or equivalent: ELC red
coolant, 50/50 antifreeze and water mixture, not to exceed 60/40
Radiator Cap Pressure 90 kPa (0.90 bar) (13 psi)
Fan/Water Pump Belt Tension
New or Field Reset: 15 to 35 tension number on belt tension gauge,
TK P/N 204-427; or 19 to 25 mm (0.75 to 1.0 in.) deflection with 3 to
4 Kg (6 to 9 lb) of force
* 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
27
Specifications
Electrical Control System

Controls SG+ microprocessor controller
Voltage 12.5 Vdc (nominal)
Battery 12 volts, group C31, 925/950 Cold Cranking Amps at
-18 C (0 F)
Fuse SI1 30 Amp
Fuse SI2 30 Amp
Fuse SI3 10 Amp
NOTE: Please note that there are 2 versions of the SG+ Controller - G01 and G02. Please refer to your
specific Parts Manual to ensure you are using the correct version for your unit.
Electrical Components
NOTE: Disconnect components from unit circuit to check resistance.
Current Draw (Amperes) at 12.5 Vdc Resistance (Ohms)
Air Heater 89 0.14
Fuel Solenoid:
Pull-in 35 to 45 0.2 to 0.3
Hold-in 0.5 to 1.0 24 to 29
Speed Solenoid (EcoPower Option only) 2.9 4.3
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
LOP (Low Oil Pressure) Restart – Configuration Off
DEL (Delayed) Coldstart – Configuration On
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
28
Specifications
Controller Default Settings

NOTE: The controller returns the Date/Time to the default setting when the battery is disconnected.
29
Specifications
Physical Specifications
Weight (net): SGSM 3000 678 Kg (1495 lbs) including oil, coolant, battery and
284 liter (75 gal.) fuel tank (excluding fuel)
Unit Dimensions
AXA0269
30
Specifications
Weight (net): SGCM 3000 671 Kg (1480 lbs) including oil, coolant, battery and
Unit Dimensions
AXA0270
31
Specifications
Weight (net): SGCO 3000 818 Kg (1804 lbs) including oil, coolant, battery and
Unit Dimensions:
AXA0271
32
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.
33
Specifications
34
Unit Description, Features & Options
General Description
Thermo King generator sets (clip-on, center mount and side-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.
An exclusive TK486VG (EPA Tier 2) direct injection diesel engine drives a brushless generator to
produce 15 KW of output power at 49 C (120 F) ambient temperature. A weatherproof box fastened
inside the unit contains the unit controls.
Each unit features a welded, heavy-gauge steel frame with special sea-going finish; non-corrosive
fittings, all stainless steel external hardware, copper tube aluminum fin 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.) on SGCM center mount models; and 284 liter
(75 gal.) on 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.
35
AXA0272
Figure 4: SGSM 3000 Side Mount Generator
AXA0273
Figure 5: SGCM 3000 Center Mount Generator
AXA0274
Figure 6: SGCO 3000 Clip On Generator
36
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 11-9182 (identified by black and gold colors)
• EMI 3000 API Rating CI-4 Mineral Oil
• EMI 3000 Fuel Filter, P/N 11-9342 (identified by black and gold colors)
EMI 3000 equipped units are identified by a “ELC” decal tag on the coolant expansion tank, and gold and
black colored oil and fuel 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 Service Guide chapter in this manual).
SG+ Microprocessor Controller

There are two versions of the SG+ Controller. G01 and G02. The G02 controller now has J20 connector
for the ECU. This is used for CAN communication to the new PCM engine.
1. RTC Battery
2. ECU J20 Connection
Figure 7: SG+ Controller Versions G01 and G02
The SG-3000 is compatible with both G01 and G02 versions, however, there are also two different
software versions.
The separation of software was released with the following software versions:
37
1. SG+ 4.1.5.00 or greater 140425 G01

2. SG+ 4.1.6.00 or greater 140625 G02
NOTE: The technician will now need to match the version of software to the type of controller. The
G02 controller can be used in a SG3000 or SG4000 genset, but must have the G02 software. The G01
controller can be used in the SG3000 genset ONLY, but must have the G01 software.
NOTE: Please refer to your specific Parts Manual to ensure you are using the correct version for your
unit.
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, fuel relay feedback failure, or alternator overload. The module also
delays excitation power supply for 15 seconds after unit start-up or until the engine water temperature
reaches 32 C (90 F).
The SG+ Microprocessor controller is designed with the capability to have the software flash loaded.
Figure 8: SG+ Controller Display
38
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 the engine 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).
Dual Voltage Option

A power cable and receptacle wired for 230 Vac or 460 Vac is supplied as standard equipment with each
generator. SGCM center mount models can be wired for dual receptacles: 230 Vac or 460 Vac.
39
EcoPower Option
EcoPowerTM is an option designed to save fuel. A speed solenoid is mounted on the engine and controlled
by the controller. 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 one hour when it is
started, and whenever it shifts from low speed to high speed. Units equipped with the EcoPower option
have the following decal.
92-6384
ARA1066
Figure 9: EcoPower Decal
Fuel Level Sensor Option

The fuel level sensor option allows the controller to log fuel events (see “Fuel Events” on page 100).
Units equipped with the fuel level sensor option must have the Fuel Sensor turned on in the Configuration
Menu (see “Configuration Menu” on page 94), and the fuel tank size set in the System Setup submenu
(“System Setup” on page 86).
40
Additional Options
Header pin mounting (SGCO clip-on models only).
1
9
AXA0272 5
3
4
1. Unit Mounting Arms 6. Unit Nameplate Location

2. Fuel Tank 7. Fuel Tank Fill Neck and Cap
3. Control Box Cover 8. Coolant Expansion Tank Location
4. Alternator and Control Box 9. 460 or 230 Vac Power Receptacle Location
Compartment Access Door
5. Engine Compartment Access Door
Figure 10: SGSM 3000 — Unit Front View
41
1
10
9
2
3
7
5
AXA0273
4
1. Fuel Tank 6. Control Box Cover

2. Fuel Tank Fill Neck and Cap 7. Engine Compartment Access Door
3. Unit Mounting Arms 8. Coolant Expansion Tank Location
4. Unit Nameplate Location 9. 460 or 230 Vac Power Receptacle Location
5. Alternator and Control Box 10. Radiator Location
Compartment Access Door
Figure 11: SGCM 3000 — Unit Front View
42
1 12
11
10
4
8
7
6
AXA0274
1. Battery 7. Lower Mounting Screw and Washer (each side)

2. Unit Nameplate Location 8. Fuel Gauge (each side)
3. Fuel Tank 9. Control Box Location
4. Alternator and Engine Compartment 10. Fuel Tank Fill Neck and Cap (each side)
Access Doors
5. Coolant Expansion Tank Location 11. Upper Unit Mounting Clamps (Corner Clamp
Equipped Units Only)
6. 460 or 230 Vac Power Receptacle 12. Header Pin Mounting Flange (Header Pin Equipped
Location Units Only)
Figure 12: SGCO 3000 — Unit Front View
43
13
12
11
3
10
6
9
7
8
1. Air Inlet Adapter 8. Oil Fill and Dipstick

2. Alternator 9. Oil Level Sensor
3. Starter 10. Oil Drain
4. Timing Mark Location 11. Engine Speed Adjustment Screw
5. Flywheel Sensor 12. Water Pump Pulley
6. Oil Filter 13. Water Temperature Sensor
7. Low Oil Pressure Switch
Figure 13: Powerpack (All Models) — Unit Front View
44
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 15 on page 46). Two external relays, the Start Relay and the Preheat Relay, are also mounted
inside the control box near the microprocessor.
This system automatically controls generator operation by providing:
• Automatic unit preheat and engine startup during initial startup or delayed restart
• Variable air heater preheat time
• Automatic Pretrip Test capability
• Delayed alternator excitation for 15 seconds or until engine coolant temperature increases to 32 C (90
F)
• 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, fuel relay feedback failure, or alternator
overload.
• Automatic unit restart 20 minutes after unit shutdown due to an unknown condition, high engine
water temperature, engine failure to start, fuel relay feedback failure, check fuel alarm, or alternator
overload (also low engine oil pressure if enabled). It will attempt three (3) restarts and then stop.
Figure 14: SG+ Controller Display
45
1 2 3 4 5 6
17
7
16
15
8
10
14
11
13
12
1. J6 Connector – To AC Circuits
2. Fuse SI1 – 30 Amp Protects 8D and 8DP Circuits
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. J20 Connector - To ECU
10. 2C Circuit Connection
11. 8 Circuit Connection
12. Fuse SI3 – 10 Amp Protects Microprocessor Power Input Circuit
13. J4 Connector – To External Relay Circuits
14. RL1 – Fuel Pull Relay
15. RL2 – Fuel Hold Relay
16. J1 Connector – To Sensor and Fuel Solenoid Circuits
17. RL4 - Quad Relay (new 401132 alternator and software 4.2.1.0 or
higher in SG+ controller from January 2017)
Figure 15: SG+ Microprocessor
NOTE: G02 Control board version shown here for illustration purposes. Please refer to “SG+
Microprocessor Controller” on page 37 for more information on controller versions.
46
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.
47
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 16: Control Box Cover
48
Miscellaneous Features
• Internal self-checking/diagnostic capability
• Pretrip test capability (see “PTI” on page 82)
• 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:
• Engine Oil Pressure
• Alternator Voltage
• Battery Voltage
• Water (Engine Coolant) Temperature
• Air Filter Switch
• Coolant Level Sensor
• Engine Oil Pressure Switch
• Engine Oil Level Sensor
• Air Heater (Preheat) Feedback
• Fuel Pull Relay Feedback
• Fuel Hold Relay Feedback
• Excitation Feedback
• Flywheel Sensor
• Microprocessor Outputs:
• Start Relay
• Preheat Relay
• Fuel Pull Relay
• Fuel Hold Relay
• Speed Solenoid Relay (EcoPower Option only)
• Quad Relay
• On Light
• Alarm Light.
49
50
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
Each menu listed above will be described later in this chapter.
An overview of the menu structure is shown in Figure 18 on page 53.
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.
Language Key: Press the LANGUAGE key to change the language used on the display.
51
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 17: Controller Display
52
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.
Figure 18: Menu Structure
53
Data Menu
The Data Menu contains the following submenus. See “Data Menu” on page 64 for more information.
Alarm List Menu

The Alarm List Menu shows a list of the alarms recorded in the controller memory. See “Alarm List
Menu” on page 70 for more information.
Message List Menu

The Message List Menu shows a list of the messages recorded in the controller memory. See “Message
List Menu” on page 75 for more information.
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. See “PTI” on page 82
for more information.
• Manual Function Test, which is used to test some components such as the display and relays. See
“Manual Function Test” on page 84 for more information.
• System Setup, which is used to check the engine speed, energize and de-energize the Speed Solenoid,
set the unit fuel tank size, set the date and time, and set an ID number to identify the unit. See “System
Setup” on page 86 for more information.
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 90 for more information.
• SW/HW Version, which displays information about the controller software and hardware. See
“SW/HW Version” on page 91 for more information.
• Timers/Counters, which displays information about the hourmeters and restart counters. See
“Timers/Counters” on page 92 for more information.
• Date/Time
Configuration Menu
The Configuration Menu is used to configure some of the controller functions such as low oil pressure
restart and hourmeter thresholds. See “Configuration Menu” on page 94 for more information.
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. See
“Event Log” on page 99 for more information.
• Fuel Events, which shows a list of fuel events recorded in the controller memory. See “Fuel Events”
on page 100 for more information.
54
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 19: Standard Display and Main Menu
55
Pause Mode Displays

WARNING: The AC alternator output or 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 20: Typical Pause Mode Display
Network Down Display

The Network 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 Network Down display also appears when software is be flash loaded into the controller.
NETWORK DOWN
Figure 21: Network Down Display
56
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.
Belt: The water pump belt must be in good condition and adjusted to proper tension.
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
fins.
Mounting Bolts: Check the mounting bolts on the unit and engine. Tighten if necessary.
57
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 standby 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.

2. A series of displays called the Start Sequence appears on the display as follows:
NOTE: If the Display shows the following: DELAY 30, DELAY 29, DELAY 30, DELAY 29, then see
“Configuring a unit after Flashload” on page 103. Your unit needs to have the Engine and Alternator
configured.
a. HMI
REV 1.0
b. HMI
SUM: XXX
c. MAIN MENU
DATA
DELAY 11 (or 10, 09, 08, etc. to 01)
The delay screen counts down from 11 to 01 while the controller performs some self checks.
d. MAIN MENU
DATA
INIT
The controller energizes the air heater 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.
NOTE: For software version 4.2.1.0 or higher and with the introduction of the new alternator, the
Genset will run in LOW speed and output power will be delayed for 2 minutes. After 2 minutes will
shift to HIGH then Quad relay will energize apply power to the DSR and output power will be present.
e. MAIN MENU
DATA
FUEL RELAY ON
The controller energizes the fuel relay.
f. MAIN MENU
DATA
ALTERNATOR OFF
The controller verifies that the alternator output is off.
g. MAIN MENU
DATA
AIR HEATER ON
This display appears only if the controller determines that the engine coolant temperature is low
enough to require that the air heater be energized.
58
h. MAIN MENU
DATA
STARTER
The engine begins cranking. The air heater and pre-heat buzzer may remain energized during the
cranking period. The air heater may also remain energized for 30 seconds after the engine starts.
i. MAIN MENU
DATA
RPM CHECK
If the engine RPM does not exceed 50 RPM during the first 4 seconds of cranking, or if the engine
does not start after 30 seconds of cranking, the cranking cycle terminates.
j. MAIN MENU
DATA
SPEED MEAS
This display appears only on units equipped with the EcoPower option while the controller checks
the low engine speed. The engine runs in low speed until the engine temperature reaches 32 C
(90 F).
k. MAIN MENU
DATA
DELAYED OUTPUT
This display appears while the controller delays energizing the alternator output for approximately
15 seconds. If the DEL COLDSTART feature in the Configuration Menu is set to ON, the
alternator output remains off until the engine temperature reaches 32 C (90 F).
l. MAIN MENU
DATA
SPEED MEAS
This display appears only on units equipped with the EcoPower option while the controller checks
the high engine speed. The engine switches to high speed when the engine temperature reaches 32
C (90 F).
m. MAIN MENU
DATA
VOLTAGE:
This display shows the alternator output, indicating the alternator is functioning.
3. If the engine fails to start, place the unit switch in the OFF position. Determine and correct the cause of
the starting failure. Then repeat the starting procedure.
CAUTION: Never use starting fluid.
59
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 15 seconds before the exciter circuit and battery
charging circuits are energized. When DEL COLDSTART feature in the Configuration Menu is set to
ON, the alternator output remains off until the engine temperature increases to 32 C (90 F).
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 58).
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. 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 oil level switch is tested.
e. The oil pressure switch is tested.
f. The coolant temperature sensor is tested.
g. The coolant level is tested.
h. Test speed solenoid relay, if detected.
i. The preheat relay is tested.
j. The fuel hold relay is tested.
k. The fuel pull relay is tested.
l. Test fuel level, if selected.
m. The start relay is tested.
n. The output voltage is tested.
o. The engine starts.
60
p. The display says “PASSED OUTPUT VOLTAGE TEST” if the output voltage is acceptable.
q. The oil pressure switch is tested.
r. Preheat is tested.
s. Test speed solenoid high and low, if detected.
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.
NOTE: Acknowledge the alarms or messages ONLY after the alarm codes are documented and
problems repaired.
61
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.
62
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 22: Main Menu
63
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
• Generator
• Unit
• Internal States
To enter the Data Menu complete the following steps:
2. Press the ENTER key or the ESCAPE key to enter the Main Menu, if necessary.
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 Analog Inputs submenu will be displayed.
• Press the ENTER key to enter Analog Inputs.
• 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.
64
Figure 23: Data Menu
65
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:
necessary.
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.
Figure 24: Engine Submenu
66
Generator
The Generator submenu display the status of the following outputs:
• Voltage Measurement
• Field Current
• Running Frequency
• HRG Gizmo
• Quard closed on/off
• Battery Voltage
• Battery Charger on/off
• Event Code
To enter the Generator submenu complete the following steps:
necessary.
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.
Figure 25: Generator submenu
67
Unit
The Unit submenu display the status of the following outputs:
• Fuel Level Average
• Fuel Level Low on/off
• Air Heater on/off
• Fuel Pull Relay activated
• Fuel Hold Relay activated
• Throttle solenoid activated (low or high speed).
To enter the Unit submenu complete the following steps:
necessary.
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.
68
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
• Air Heater On
• Air Heater 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:
necessary.
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 26: Internal States
69
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:
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 (101 through 111)
• 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.
70
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 27: Alarm List Menu
Alarm Diagnosis
The Alarm List on the following pages lists the alarms, their causes, and possible diagnosis.
71
Alarm List
Alarm Code and Text Alarm Type–Cause Diagnostics
101. 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 25 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.
102. Delayed Restart Alarm–Engine failed to 1. Check battery, battery cables, and
FAILED TO CRANK crank. starter.
Becomes a Shutdown Alarm when 2. Check 8S circuit.
number of restart attempts is greater 3. Check Start Relay.
than number of “Crank Restarts” set in
Configuration Menu. 4. Check for seized engine or alternator.
103. Delayed Restart Alarm–Engine failed to 1. Check fuel level.

FAILED TO START crank. 2. Check fuel solenoid, fuel pump, and
Becomes a Shutdown Alarm when fuel system both electrically and
number of restart attempts is greater mechanically.
than number of “Crank Restarts” set in
3. In cold ambient temperatures check
Configuration Menu. for fuel gelling.
4. Check for restricted air cleaner or air
intake system.
5. Check intake air heater.
104. Shutdown Alarm–No feedback when 1. Check RL2 (Fuel Hold) relay.
RL2 (FUEL H) FEEDBACK relay is energized, or feedback when
2. Check 8D circuit.
FAILURE relay is not energized.
105. Shutdown Alarm–No feedback when 1. Check RL1 (Fuel Pull) relay.
RL1 (FUEL P) FEEDBACK relay is energized, or feedback when
2. Check 8DP circuit.
FAILURE relay is not energized.
106. Shutdown Alarm–No feedback when 1. Check RL5 (Start) relay.
RL5 (STARTER) relay is energized, or feedback when
2. Check SR, PSR, and FSR circuits.
FEEDBACK FAILURE relay is not energized.
107. Shutdown Alarm–Message 122 has 1. Unplug load and attempt restart.
EXTERNAL OVERLOAD occurred 3 times.
2. Check alternator field circuit.
3. Check alternator output circuit.
108. Delayed Restart Alarm–Input from Low 1. Check fuel level.
ENGINE NOT RUNNING Oil Pressure Switch is low (grounded)
2. Check fuel solenoid, fuel pump, and
REASON UNKNOWN and RPM equals 0 when engine should
fuel system both electrically and
be running.
mechanically.
• Engine will attempt to restart in 20 3. In cold ambient temperatures check
minutes. for fuel gelling.
4. Check for seized engine or alternator.
72
Alarm List (Continued)

109. If low oil level and low oil pressure is 1. Check oil level.
LOW OIL LEVEL present at the same time.
2. Check Oil Level Switch.
3. Check circuits to Oil Level Switch.
4. Check oil pressure using the Analog
Inputs submenu of the Data Menu.
5. Check Low Oil Pressure Switch.
6. Check OPS circuit.
110. Shutdown Alarm–Unit attempted 3 1. Check engine speed.
RPM BELOW LIMIT restarts that failed.
2. Check RPM sensor.
111. Controller is reset 3 times during 1. Defective battery, load test battery.
FAILED TO START LOW cranking. 2. Controller not charging battery.
BATTERY
3. Check ground connections at block.
112. Message 113 has occurred 3 times. 1. Check sensor circuits and wiring
WATER TEMPERATURE connections.
SENSOR FAILURE
2. Check for faulty sensor.
113. Coolant level low after message 113. 1. Check coolant level.
COOLANT LEVEL LOW 2. Check Coolant Level Sensor.
3. Check circuits to Coolant Level
Sensor.
114. Message 132 has occurred 3 times. 1. See “Alternator Diagnosis” on
INTERNAL OVERLOAD page 162. For old Alternator.
1. See “Alternator Diagnosis” on
page 175. For new Alternator.
115. External controller has not responded 1. Check Relays. See “Relays” on
EXCITER CONTROL within 5 seconds. page 105.
UNIT SHUTDOWN
116. External controller has not responded 1. Check Relays. See “Relays” on
ENGINE CONTROL UNIT within 30 seconds. page 105.
SHUTDOWN
The controller constantly monitoring the
communication when the engine is
running and will activate alarm 116 if
there has not been communication
(response from the ECU on requested
telegrams) over 30 seconds.
117. Exciter voltage below 20V. 1. See “Alternator Diagnosis” on
LOW EXCITATION page 162. For old Alternator.
VOLTAGE
119. Low oil pressure message active. 1. Check oil level.
LOW OIL PRESSURE 2. Check oil pressure using the Analog
73
Alarm List (Continued)

120. Output voltage above 500 volts for over 1. See “Alternator Diagnosis” on
OUTPUT VOLTAGE HIGH 15 seconds. page 162.
122 Over excitation or short circuit. 1. See “Alternator Diagnosis” on
GENERATOR UNIT page 162. For old Alternator.
ERROR
123. Generated if the coolant klixon is open 1. .Coolant klixon open circuit.
COOLANT FAN FAILURE and coolant temperature is above limit.
124. 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.
125. Timing belt expired caused by years of 1. .Change Timing belt. See “Service
TIMING BELT EXPIRED operation or hours actuated. Guide” on page 25 for more
information.
126. Output frequency above 99 Hz for 5 1. Check for short on L2 to L3.
OUTPUT FREQUENCY seconds.
FAILURE
74
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:
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 (101 through 131)
• 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.
75
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 28: Message List Menu
Message Diagnosis
The Message List on the following pages lists the messages, their causes, and possible diagnosis.
76
Message List
Message Code and Text Cause Diagnostics
101. Battery Voltage is below 9 volts. 1. Check battery
BAT. VOLTAGE LOW
2. Check battery cables.
102. Digital inputs have been changing once This condition indicates noise on the line,
DIGITAL INPUT FAILURE a second for the last 10 seconds. a loose connection, or a bad sensor.
103. The engine is running and the exciter Check alternator for low output.
OUTPUT VOLTAGE field is energized, but the output voltage
< 180 V is below 360 volts for 30 seconds.
104. Not used.
AIR FILTER BLOCKED
105. 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.
106. Output frequency is below 45 Hz for 30 Check and adjust engine speed.
OUTPUT FREQUENCY seconds (engine RPM below 1350).
LOW
107. Output frequency is above 70 Hz for 30 Check and adjust engine speed.
OUTPUT FREQUENCY seconds (engine RPM above 2100).
HIGH
108. 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.
109. Hour Meter 1 (HM1) has exceeded the Acknowledge message to reset timer.
HOUR METER 1 HAS threshold set in the Configuration Menu.
EXCEEDED THRESHOLD
110. Hour Meter 2 (HM2) has exceeded the Acknowledge message to reset timer.
HOUR METER 2 HAS threshold set in the Configuration Menu.
EXCEEDED THRESHOLD
111. 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.
112. Engine is running and input from Low Oil 1. Check RPM Sensor.
ENGINE RPM SENSOR Pressure Switch is high (grounded), but
2. Check circuits to RPM Sensor.
FAILURE RPM is below 800.
113. Water temperature sensor reading is 1. Check sensor circuits and wiring
WATER TEMPERATURE below -40 C (-40 F) or above 115 C connections.
SENSOR FAILURE (240 F).
2. Check for faulty sensor.
114. Engine is running and input from Low Oil 1. Check oil level.
LOW OIL PRESSURE Pressure Switch is low (grounded) for 60
2. Check oil pressure using the Analog
seconds.
77
Message List (Continued)

115. No feedback when relay is energized, or 1. Check RL6 (Preheat) relay.
RL6 (AIRHEAT) feedback when relay is not energized.
2. Check PHR, PPHR, and FPHR
FEEDBACK FAILURE
circuits.
116. If hour counter exceeds user setup. 1. Acknowledge message and reset
COUNTDOWN TIMER timer.
HAS EXPIRED
117. During PTI input from Low Oil Pressure 1. Check Low Oil Pressure Switch.
OIL PRESSURE HIGH Switch is high (not grounded) when the
WHILE ENG. IS NOT engine was not running.
RUNNING
118. Input from Low Oil Pressure Switch is 1. Check Low Oil Pressure Switch.
OIL PRESSURE SWITCH high (not grounded) before engine starts.
FAILURE
119. If water temp. >107 C for 5 sec. - 1. Check water temperature sensor.
WATER TEMPERATURE restarting.
2. Check WTP/WTN circuit.
HIGH
120. Engine failed to crank. 1. Check battery, battery cables, and
ENGINE FAILED TO starter.
CRANK
2. Check 8S circuit.
3. Check Start Relay.
121. No oil pressure and did not reach 800 1. Check fuel level.
ENGINE FAILED TO RPM - restarting.
START
mechanically.
for fuel gelling.
4. Check for restricted air cleaner or air
intake system.
5. Check intake air heater.
122. If output is short-circuited - restarting. 1. Unplug load and attempt restart.
EXTERNAL OVERLOAD
2. Check alternator field circuit.
3. Check alternator output circuit.
123. If oil pressure low and no RPM, while 1. Check fuel level.
ENGINE STOPPED running - restarting.
REASON UNKNOWN
mechanically.
for fuel gelling.
124. RPM less than 1530 after startup. 1. Check engine speed.
NO LOAD RPM LESS
THEN 1530
78

125. RL3 No feedback when relay is energized, or 1. Check RL3 (Speed [Throttle]
(SPEED SOLENOID) feedback when relay is not energized. Solenoid) relay.
FEEDBACK FAILURE
2. Check 7D circuit.
126. Fuel level reading is above the maximum 1. Check fuel level sensor.
FUEL LEVEL SENSOR tank value.
2. Check FPOS, FNEG, and FOUT
OUT OF RANGE
circuits.
3. Check fuel tank size setting in System
Setup submenu.
127. Fuel level reading decreased faster than 1. Check for leak in fuel tank.
FUEL LEVEL normally expected. 2. Check to see if fuel has been removed
DECREASED TO FAST
NOTE: Must use password (0007) to from fuel tank.
clear this message.
128. During PTI if HIGH speed is same as 1. Check throttle solenoid.
SPEED SOLENOID LOW speed.
1. Check TS circuit.
FAILURE
129. RPM is below 1350 for 5 sec. 1. Check engine speed.
RPM BELOW LIMIT
130. 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
131. No feedback when RL5 relay is 1. Check RL5 (Starter Solenoid) relay.
RL5 (STARTER) energized. 2. Check 2A and 8S circuits.
FEEDBACK FAILURE
132. Field current (F1 – F2) is more than 1.75 1. See “Alternator Diagnosis” on
INTERNAL OVERLOAD amps. page 162. For old Alternator.
133. External controller has not responded 1. See “Relays” on page 105.
EXCITER CONTROL within 5 sec.
UNIT SHUTDOWN
134. Exciter voltage below 20V. 1. See “Alternator Diagnosis” on
LOW EXCITATION page 162. For old Alternator.
VOLTAGE
ENGINE CONTROL UNIT within 5 sec.
SHUTDOWN
ENGINE MAILFUNCTION within 5 sec.
INDICATOR LAMP
140. Regulator running with default 1. See “Alternator Diagnosis” on
DSR CHECKSUM parameters. page 162. For old Alternator.
WARNING
79

141. Output is short-circuited. 1. See “Alternator Diagnosis” on
DSR SHORT CIRCUIT page 162. For old Alternator.
WARNING
142. Exciter current exceeds the damage 1. See “Alternator Diagnosis” on
DSR EXCITATION threshold. page 162. For old Alternator.
OVERCURRENT
WARNING
143. Other conditions than short over current 1. See “Alternator Diagnosis” on
DSR EVENT such as speed is below or above page 162. For old Alternator.
threshold.
144. Speed is above or below limits. 1. See “Alternator Diagnosis” on
DSR SPEED WARNING page 162. For old Alternator.
146. Output voltage above 500 voltage over 1. See “Alternator Diagnosis” on
OUTPUT VOLTAGE HIGH 15 seconds. page 162. For old Alternator.
148. HRG exciter protection gizmo has been 1. See “Alternator Diagnosis” on
EXCITER PROTECTION activated. page 162. For old Alternator.
ACTIVATED
149. Coolant fan klixon open. 1. Fan open circuit for 5 seconds
COOLANT FAN FAILURE activates the message.
150. New engine P-code generated. 1. Generated for engine P-codes not
ENGINE P-CODE INFO activating any engine lamps.
151. Timing belt expired caused by years of 1. See “Service Guide” on page 25
TIMING BELT EXPIRED operation or hours actuated.
80
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
• System Setup
To enter the Commands Menu complete the following steps:
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.
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
SYSTEM SETUP From "SYSTEM SETUP" menu
VOLTAGE: 460 V
To "SYSTEM SETUP" menu
ARA1070
Figure 29: Commands Menu
81
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 75.
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 oil level switch is tested.
e. The oil pressure switch is tested.
f. The coolant temperature sensor is tested.
g. The coolant level is tested.
h. Test speed solenoid relay, if detected.
i. The preheat relay is tested.
j. The fuel hold relay is tested.
k. The fuel pull relay is tested.
l. Test fuel level, if selected.
m. The start relay is tested.
n. The output voltage is tested.
o. The engine starts.
p. The display says “PASSED OUTPUT VOLTAGE TEST” if the output voltage is acceptable.
q. The oil pressure switch is tested.
r. Test speed solenoid high and low, if detected.
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.
82
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 30: PTI Submenu
83
Manual Function Test

The Manual Function Test submenu contains the following component tests:
• Display Test
• Preheat Relay Test
• Fuel Hold Relay Test
• Fuel Pull Relay Test
• Start Relay Test
• Force Speed (Energizes or de-energizes the speed solenoid to change the engine speed.)
• 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:
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.
84
Figure 31: Manual Function Test Submenu
85
System Setup
The System Setup submenu contains the following:
• Current RPM, which is used to check the engine speed.
• Speed Solenoid (On/Off), which is used to energize and de-energize the speed solenoid when
checking or adjusting the engine speeds.
• Engine Type
• Generator
• Genset
NOTE: If your ENGINE, GENERATOR or GENSET states “NOT DEF”, please refer to
“Configuring a unit after Flashload” on page 103. These need to be configured. Please refer to your
Parts Manual to ensure that you have the correct software for your particular options.
• 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.
• Throttle Solenoid (Yes/No), which is used to setup units with EcoPower. Unit with solenoid Yes, unit
without solenoid No.
• Date, which is used to set the date. See “Date/Time” on page 88 for information about setting the date.
• Time, which is used to set the time. See “Date/Time” on page 88 for information about setting the
time.
• HRG GIZMO (Yes/No), Exciter protection circuit mounted.
• 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.
NOTE: The controller returns the Date/Time to the default setting when the battery is disconnected.
To enter the System Setup submenu complete the following steps:
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 “Date/Time” on
page 88 for information about setting the date and time.
86
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.
Figure 32: System Setup Submenu
87
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:
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 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 System Setup 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 33: Date/Time
88
Misc. Functions Menu

The Misc. Functions Menu contains the following submenus:
• C/F Mode
• SW/HW (Software/Hardware) Version
• Timers/Counters
To enter the Misc. Functions complete the following steps:
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.
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
ARA1105
Figure 34: Misc. Functions Menu
89
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:
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.
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 35: C/F Mode
90
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:
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 36: SW/HW Version
91
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 97.
To enter the Timers/Counters submenu complete the following steps:
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.
92
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 37: Timers/Counters
93
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 97 for an example of how
change a setting.
• LOP (Low Oil Pressure) Restart – The default setting is OFF.
• DEL (Delayed) Coldstart – The default setting is ON. When this is set to ON, the controller will delay
energizing the exciter field until the Water Temperature reaches 32 C (90 F).
• 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.
• APU Connected – The default setting is OFF. This is not used.
• 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 Sensor – The default setting is OFF. This is set to ON if the unit is equipped with a fuel level
sensor.
• 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 – ComPosIT module connected.
• RMM Master – RMM master module connected.
• HRG GIZMO – Exciter protection circuit mounted.
• Start Delay – Engine start delay (INIT state). Default 30 seconds.
• Free Text – Text send to ComPosIt
To enter the Configuration Menu complete the following steps:
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” on page 73 for an example of how change a setting.
94
Figure 38: Configuration Menu (Page 1)
95
Figure 39: Configuration Menu (Page 2)
96
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.
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.
97
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:
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.
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 40: Event Log Menu
98
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:
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 41: Event Log Submenu
99
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:
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 42: Fuel Events Submenu
100
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.
With the release of SG+ software 08042300, some changes were made to the description so the log may
have different wording based on the software that was in the controller at the time of the logging. The
following shows the latest release descriptions.
The latest LogView files can be found on our Web site under Global Marine Solutions Info Central.
NOTE: Logman II PC Rev. 2.4.1 (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 Αλαρμ Λιστ ον
παγε 72 for alarm descriptions
Message Message code A message is activated, see Μεσσαγε Λιστ ον
παγε 77 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
101
Event Description (Continued)

Data ID / Code Description
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
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 43: Example of SG+ Log
102
Configuring a unit after Flashload

When updating your software, you will need to re-configure your alternator type:
SG3000 genset can use either G01 or the G02 controllers. After flash loading the software the controller
will default to ENGINE type NOT DEF and GENERATOR type NOT DEF. When the genset is turned
ON the display will show DELAY 30, DELAY 29, DELAY 30, DELAY 29, … until the Generator type is
defined.
The process for configuring the unit is the same for both controllers:
1. Scroll to COMMANDS/SYSTEM SETUP.
2. Scroll to ENGINE NOT DEF and change to YANMAR.
3. Press the ENTER key, curser will move to the right, scroll to YANMAR, press the ESC and the
ENTER keys at the same time, curser will move to the left and YANMAR will be saved.
4. Scroll to GENERATOR NOT DEF and change to STAMFRD or M.ALTE.
5. Press the ENTER key, curser will move to the right, scroll to STAMFRD or M.ALTE, press the ESC
and the ENTER keys at the same time to select your choice, curser will move to the left and your
choice will be saved.
6. Scroll to GENSET NOT DEF and select CILP-ON, SIDE, CENTER.
Press the ENTER key, curser will move to the right, scroll to either CILP-ON, SIDE, CENTER, press the
ESC and the ENTER keys at the same time, curser will move to the left and genset type will be saved.
103
104
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.
Fuel Pull Relay

The fuel pull relay (RL1) is located on the PC board. It supplies power to the fuel solenoid pull-in coil
through the 8DP circuit. If the fuel pull relay fails in the closed position, the fuel solenoid pull-in coil will
be damaged. If the relay fails in the open position, the fuel solenoid will not energize. The RL1 LED on
the PC board will light up when the fuel pull relay is energized.
Fuel Hold Relay

The fuel hold relay (RL2) is located on the PC board. It supplies power to the fuel solenoid hold-in coil
through the 8D circuit. If the fuel hold relay fails in the closed position, the unit would operate
continuously and not stop for a protection shutdown. If the relay fails in the open position, the fuel
solenoid will energize momentarily but will not stay energized. The RL2 LED on the PC board will light
up when the fuel hold relay is energized.
Speed (Throttle) Solenoid Relay

The speed solenoid relay (RL3) is used on units equipped with the EcoPower option and is located on the
PC board. It supplies power to the speed solenoid through the 7D circuit. If the speed solenoid relay fails
in the closed position, the engine would only run in high speed. If the relay fails in the open position, the
engine would only run in low speed. The RL3 LED on the PC board will light up when the speed solenoid
relay is energized.
Quad Relay
The Quad Relay (RL4) is used on units fitted with the new 401132 alternator and software 4.2.1.0 or
higher in SG+ controller from January 2017. During controller start up, Genset will run in LOW speed
and output power will be delayed for 2 minutes. After 2 minutes will shift to HIGH then Quad relay will
energize, apply power to the DSR and output power will be present.
105
1 2 3 4 5
6
7
1. PC Board
2. Fuel Pull Relay (RL1)
3. Fuel Hold Relay (RL2)
4. Speed Solenoid Relay (RL3) (EcoPower Option
Only)
Spare Relay (If Installed On Units Without
EcoPower Option)
5. Spare
Quad Relay (RL4) (fitted with the new 401132
alternator and software 4.2.1.0 or higher in SG+
controller from January 2017)
6. Terminal Boards
7. Start and Preheat Relays (RL5 and RL6)
Figure 44: Components Inside Control Box
106
Start Relay
The start relay (RL5) 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. The RL5 LED on the PC
board will light up when the fuel pull relay is energized.
Preheat Relay
The preheat relay (PHR) is mounted on the inside of the control box. It supplies power to the air heater. If
the preheat relay fails in the open position, the air heater would not preheat and the engine may not start,
resulting in the cranking time limit being exceeded. If the preheat relay fails in the closed position, the air
heater will remain energized. The RL6 LED on the PC board will light up when the fuel pull relay is
energized.
1 2
1. Start Relay (RL5)

2. Preheat Relay (RL6)
Figure 45: Relay Locations
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 a transformer and rectifier utilizing current from the ac alternator.
The battery charging circuit provides current to the battery until the proper charge level is attained (13.1
to 14.6 volts).
107
The alternator exciter field is energized by the SG+ controller. This initiates battery charging
approximately 15 seconds after engine start-up.
NOTE: The engine must run for approximately 15 seconds before the battery charging circuit is
energized. When the Delayed Cold Start feature is set to ON, the controller shows “dELAY / AC”
screen and the alternator output remains off until the engine temperature increases to 32 C (90 F).
NOTE: The alternator exciter field coil (F1/F2) for the SG+ and the µPG are different. The SG+
resistance reading is 13.9 ohms and the µPG is 2.3 ohms. In the photo below the µPG is on the left and
SG+ is on the right. The µPG will have the external lead shown on the top of the coils. See Service
Bulletin C087 for more information.
1. External Lead on Top of µPG Coil
Figure 46: Alternator Exciter Field Coils
Air Heater
The air heater heats the intake air to help the engine start in cold weather. The air heater is energized when
the controller initiates a unit start-up (unit On/Off switch in the “ON” position).
The air heater is mounted on the open end of the intake manifold. Check the resistance of the air intake
heater with an ohmmeter. Place the ohmmeter leads between the M6 terminal on the front of the heater
and the screw on the back of the heater (or the heater case). The resistance should be 0.1 to 0.2 ohms.
Check the current draw of the heater with a clamp-on ammeter while the engine is cranking. Connect
ammeter at the H wire near the M6 terminal on the front of the heater. The current draw should be
approximately 89 amps at 12.5 volts. The heater is probably defective if the current draw is less than 60
amps or more than 100 amps.
AXA0336
1. M6 Terminal
Figure 47: Air Heater
108
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
controller 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.
Figure 48: Engine Oil Pressure Switch
109
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 controller 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.
AJA2064
Figure 49: Oil Level Sensor
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.
110
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.
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 controller. Test the coolant temperature sensor
if the controller records Alarm Code 18 or 41 and the coolant temperature appears to be normal.
AJA2063
AJA2061
Figure 50: Coolant Temperature Sensor
111
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 Analog Inputs 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, and test the controller.
5. Using a digital voltmeter, check the voltage at the sensor plug connected to the controller. The voltage
must be from 2.33 to 3.98 Vdc.
a. If the voltage is correct, disassemble and inspect the coolant sensor plug. Replace the sensor if
there are no broken wires or pushed pins in the plug.
b. If the voltage is incorrect, recheck the voltage at the same circuit at pins 13 (positive) and 14
(negative) of the J1 connector on the microprocessor PC board. The voltage must be from 2.33 to
3.98 Vdc. If the voltage is correct at the controller, the problem is in the wiring. Continuity test the
wire harness circuits. If the voltage is incorrect again, the controller is defective. Test the
controller.
Coolant Level Detector Sensor

The coolant level detector sensor is a stainless steel probe immersed in the coolant. It is located on the
side of the radiator. It does not fail or wear out, but may fail to conduct current if it is dirty.
The sensor will no longer conduct current to return a signal to the controller if the coolant level drops too
low in the radiator. After 30 seconds, the controller will record Message Code 108. Test the coolant level
sensor if the controller records Message Code 108 and the radiator is full of coolant.
WARNING: DO NOT remove the radiator cap from the radiator fill neck when the engine
coolant is hot.
112
AJA2062
Figure 51: Coolant Level Detector Sensor
Sensor Test
1. Ground the sensor to chassis ground with a jumper wire.
2. Attempt to clear Message Code 108 from the controller by acknowledging it.
• Check to see if Message Code 108 clears by turning the On/Off switch OFF and then back ON.
Wait 30 seconds to see if Message Code 108 reappears.
• If Message Code 108 reappears, test the wire harness for continuity. Also test the controller.
113
Flywheel Sensor
The flywheel sensor is in the engine bell housing adjacent to, but not touching, the flywheel (backed off
1/2 turn).
1. Flywheel Sensor
Figure 52: Flywheel Sensor Location
The flywheel sensor is a device containing an inductance coil and magnet. When the magnetic field is
distorted by the passing ring gear teeth, the inductance coil generates an ac electrical signal. The signal
has a voltage and frequency variation proportional to the engine rpm.
The timing of the starter disengagement can be precisely controlled by monitoring the frequency of this
signal with the starter disconnect module.
The starter may not disengage or engage properly, if the flywheel sensor fails.
Testing the Flywheel Sensor

Equipment required:
• AC voltmeter capable of reading up to 10 volts
• Ohmmeter
• SG unit for installing the sensor in the threaded hole in the flywheel housing.
To test the flywheel sensor:
1. Install the flywheel sensor into the threaded hole in the flywheel housing of an SG unit until it
contacts the ring gear.
2. Back out the sensor 1/2 turn and tighten the locknut.
3. Disconnect wires FS1 and FS2 from the sensor.
4. Start and operate the unit.
5. Check the ac voltage output across the sensor terminals. Use a meter with a high ohms per volt
internal resistance. A Simpson 260, Fluke digital or any good VOM will work. However, an
automotive type meter may not give an accurate reading because the meter may load the circuit
heavily and cause the voltage level to appear lower than actual. The output voltage should be 1.5 to
2.0 Vac.
NOTE: If the voltage is slightly off, the voltage may be increased by turning the sensor in more.
The voltage may be lowered by turning the sensor out more.
6. Reconnect FS1 and FS2 wires on flywheel sensor.
114
The sensor may be considered good if the flywheel sensor passes the above test. If a unit is not available,
an alternate but less reliable test may be performed as follows:
1. Disconnect the sensor from all wires.
2. Measure the resistance across the terminals. The resistance should be 250 to 300 ohms across the
terminals.
3. Measure the resistance from each terminal to the aluminum case. There should be no continuity from
each terminal to the case.
AXA0288
Figure 53: Flywheel Sensor with Wiring and Schematic Symbols
115
116
Engine Maintenance
EMI 3000
EMI 3000 is an extended maintenance interval package. It is standard equipment on these units. The EMI
3000 package consists of the following key components:
• New EMI 3000-Hour Fuel Filter (black with gold lettering)
• New EMI 3000-Hour Dual Element Oil Filter (black with gold lettering)
• API Rating CI-4 Mineral Oil (ACEA Rating E3 for Europe)
• 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 cyclonic dry air cleaners are NOT interchangeable with
the oil filters and air cleaners previously used in these units.
Engine Lubrication System

The TK486 family of engines use a pressure lubrication system. Refer to the TK482 and TK486 Engine
Overhaul Manual TK 50136 for a detailed description of the engine lubrication system.
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 trailer 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 12.3 litres (13 quarts) and check the dipstick level. 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. See Specifications Chapter for the 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 rubber ring of the new filter and install the filter.
3. Tighten the filter until the rubber ring makes contact, then tighten 1/2 turn more.
4. Start the unit and check for leaks.
117
Engine Maintenance
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 following “Low Oil Pressure Flow Chart” to help diagnose
low oil pressure.
Low Oil Pressure Flow Chart
Oil Pressure Low
Check Oil Level
Oil Level Low Oil Level OK or High
Add Oil Oil May Be Diluted

Check Oil Pressure Change Oil and Filter
Check Oil Pressure
Oil Pressure OK Oil Pressure Low Oil Pressure OK
Install Known Good Oil Pressure Gauge

Check Oil Pressure
Oil Pressure OK Oil Pressure Low
Remove Oil Pump (Access the oil pump by removing the

crankshaft pulley, the sound shield and the timing gear cover.)
Check Oil Pump Tolerances
Check Oil Pressure Control Valve for Broken Spring or Sticking Piston
Reinstall Oil Pump

Check Oil Pressure
Oil Pressure OK Oil Pressure Low
Pull Engine
Remove Oil Pan
Check Inlet Screen and Intake Pipe
Pressure Check Engine for Internal Leaks
118
Engine Maintenance
Crankcase Breather
Gases formed in the crankcase are directed to the intake manifold. Harmful vapors that would otherwise
collect in the crankcase and contaminate the oil, or escape to the outside, are drawn back into the engine
and burned.
The crankcase breather is located in the valve cover. A restrictor is cast into the fitting for the breather
hose on the intake manifold. The restrictor limits the flow of gases from the crankcase to the intake
manifold and keeps the crankcase pressure from getting too low in vacuum. A breather hose connects the
crankcase breather to the intake manifold.
3
1 2
4
7
6 5
1. Breather Hose 5. Baffle Breather

2. Insulation 6. Baffle Plate
3. Breather Cover 7. Intake Manifold
4. O-Ring 8. Restrictor Location
Figure 54: Crankcase Breather
Normal crankcase pressures with a new air cleaner are 2 to 12 in. (50 to 300 mm) H2O of vacuum. The
vacuum will increase as the air cleaner gets dirty and becomes more restrictive. Check the air restriction
indicator before checking the crankcase pressure. Replace the air cleaner if the reading on the air
restriction indicator exceeds 20 in. (508 mm) H2O of vacuum. A dirty air cleaner may cause excessive
vacuum, leading to oil carry over and high oil consumption.
The crankcase breather and the breather hose should be inspected when the air cleaner element is replaced
to make sure they are not plugged or damaged. Inspect the insulation to make sure it is in place and
undamaged. The insulation is used to prevent freezing in cold weather.
The following items can effect the crankcase pressure readings.
Crankcase
Pressure Typical Cause
Effect
Increase Piston Rings Stuck or Worn
Breather Hose or Restrictor
Increase
Plugged with Dirt or Ice
Decrease Air Cleaner Dirty or Plugged
119
Engine Maintenance
Cyclonic Dry Air Cleaner

The cyclonic dry air cleaner is a dry element air cleaner used on units manufactured after 11/15/02. It
filters all of the air entering the engine. Replace the dry air cleaner element when the air restriction
indicator reads 25 in. of vacuum, or at 2 years, whichever comes first.
NOTE: The dust ejector must point down when installed.
5
4
3
2
6
7
8
1
10 9
AJA2072
1. Air Cleaner Clamp

2. Dry Air Cleaner
3. Air Cleaner Element
4. Hose Clamp
5. Air Cleaner Hose
6. Air Restriction Indicator
7. Indicator Fitting
8. Breather Hose
9. Band wrap
10. Insulation Hose
Figure 55: Cyclonic Dry Air Cleaner
ARA189
1. Dust Ejector Must Point Down When Installed

Figure 56: Cyclonic Dry Air Cleaner
120
Engine Maintenance
Air Restriction Indicator

An air restriction indicator is installed in the air intake manifold on units with a dry air cleaner. Excessive
restriction of the air intake system reduces the flow of air to the engine. This affects horsepower output,
fuel consumption and engine life.
Periodically inspect the restriction indicator to assure the air filter is not restricted. Service the air filter
when the yellow diaphragm indicates 25 in. of vacuum. Press the reset button on the bottom of the
restriction indicator after servicing the air filter.
AEA710
Figure 57: Air Restriction Indicator
121
Engine Maintenance
Engine Cooling System

The engine uses 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. It circulates
the coolant through the cylinder block and head and back to the radiator. A thermostat is mounted in the
water outlet from the cylinder head to the radiator. It automatically maintains coolant temperature within
the specified temperature range.
All water-cooled engines are shipped from the factory with a 50% permanent type antifreeze concentrate
and 50% water mixture in the engine cooling system. Benefits include:
1. Prevents freezing down to -34 C (-30 F).
2. Retards rust and mineral scale that can cause the engine to overheat.
3. Retards corrosion (acid) that can an attack accumulator tank, water tubes, radiator and engine block
plug.
4. Provides lubrication for the water pump seal.
ELC (Extended Life Coolant)

ELC has been phased into all container units equipped with engines from the TK486 engine family. A
nameplate on the coolant expansion tank identifies units with ELC.
NOTE: The new engine coolant, Texaco Extended Life Coolant, is RED in color instead of the current
GREEN or BLUE-GREEN colored coolants.
AJA1947
Figure 58: ELC Nameplate Located On Expansion Tank
The following are the Extended Life Coolants currently approved by Thermo King for use in ELC units
for five years or 12,000 hours:
• Chevron Dex-Cool
• Texaco ELC (nitrite free)
• Havoline Dex-Cool (with nitrates)
• Havoline Dex-Cool (nitrite free)
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Engine Maintenance
• Shell Dexcool
• Shell Rotella
• Havoline XLC (Europe)
• Saturn/General Motors Dex-Cool
• Caterpillar ELC
• Detroit Diesel POWERCOOL Plus.
CAUTION: Do not add “GREEN” or
“BLUE-GREEN” conventional coolant to
cooling systems using “RED” Extended
Life Coolant, except in an emergency. If
conventional coolant is added to Extended
Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
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.
123
Engine Maintenance
7
6
5
8
3
4
2 9
1 10
11
12
AJA2075
1. Water Pump 7. Overflow Tank

2. Water Temperature Sensor 8. Radiator Cap
3. Engine Thermostat Housing 9. Vent Fitting for Bleeding Air from Radiator (recently
built models)
4. Engine Thermostat 10. Water Level Sensor
5. Vent Hose 11. Radiator
6. Expansion Tank 12. Drain Cock, Radiator
Figure 59: SGCM and SGSM Engine Cooling System
124
Engine Maintenance
6
7
5
3
8
4
2 9
1
10
11
12
AJA2076
1. Water Pump 7. Expansion Tank

2. Water Temperature Sensor 8. Vent Fitting for Bleeding Air from
Radiator (recently built models)
3. Engine Thermostat Housing 9. Water Level Sensor
4. Engine Thermostat 10. Radiator
5. Vent Hose 11. Drain Cock, Radiator
6. Radiator Cap 12. Overflow Tank
Figure 60: SGCO Engine Cooling System
125
Engine Maintenance
Antifreeze Maintenance Procedure

Regular inspection is required to verify the condition of the antifreeze. Inhibitors become worn out and
must be replaced by changing the antifreeze. The inhibitors in Extended Life Coolant (ELC) antifreeze
(red color) extend change intervals to 5 years or 12,000 hours.
Do not mix green or blue-green engine coolant with ELC (red) engine coolant. See “ELC (Extended Life
Coolant)” on page 122 for more information about ELC.
ELC coolants are available in 100 percent full strength concentrate or (pre-mixed) 50/50 percent mixture.
Thermo King recommends the use of 50/50 percent pre-mixed ELC antifreeze to assure that de-ionized
water is used. 100 percent concentrate extended life coolant must be mixed with de-ionized or distilled
water (NOT tap water) to ensure cooling system integrity.
NOTE: See Specifications chapter for coolant capacity and correct type of antifreeze for your unit.
When changing antifreeze, drain, flush and replace the total antifreeze mixture to maintain total cooling
system protection. To prevent mineral scale, use water with a total hardness under 170 ppm. If the total
water hardness is over 170 ppm, soften the water or use distilled water. The water must also be
de-mineralized, de-ionized or distilled if it does not meet the following requirements: chlorides
concentration under 40 ppm, sulfates concentration under 100 ppm and total dissolved solids under 340
ppm.
The factory recommends the use of a 50/50 antifreeze/water mixture in all units. Even if they are not
exposed to freezing temperatures. A 50/50 antifreeze mixture will provide the required corrosion
protection and lubrication for the water pump.
Checking the Antifreeze

WARNING: Avoid direct contact with hot
coolant.
Check the solution concentration by using a temperature compensated antifreeze hydrometer or a

refractometer designed for testing antifreeze. A refractometer works with both ELC and conventional
antifreeze. Maintain a minimum of 50 percent permanent type antifreeze concentrate and 50 percent
water solution to provide protection to -34 C (-30 F). 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. Operate the engine until it is up to operating temperature. Then stop the unit.
2. Open the engine block drain and completely drain coolant. Observe coolant color. If the coolant is
dirty, proceed with a, b, and c. Otherwise go to step 3.
a. Pour clear water into 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.
Operate the unit in accordance with instructions of the flushing agent manufacturer.
c. Open the engine block drain to drain water and flushing solution.
3. Pour clear water into the radiator. Allow it to drain out of the block until it is clear.
4. Inspect all the hoses for deterioration and the hose clamps for tightness. Replace if necessary.
5. Loosen the water pump belt. Check the water pump bearing for looseness and retighten the belt (See
“Belt Tension Adjustment and Belt Replacement” in this chapter).
126
Engine Maintenance
6. Inspect the radiator cap. Replace the cap if the gasket shows any signs of deterioration.
7. Prepare 8 liters (2 gallons) of 50/50 percent antifreeze/water mixture. Do not add antifreeze and then
water to the unit. This procedure may not give a true 50/50 mixture because the exact cooling system
capacity may not be known.
NOTE: Thermo King recommends the use of 50/50 percent pre-mixed ELC antifreeze to assure
that de-ionized water is used. 100 percent concentrate extended life coolant must be mixed with
de-ionized or distilled water (NOT tap water) to ensure cooling system integrity.
8. Close all drains. On recently built units, also open vent fitting on top of the inlet header on the
radiator. Refill the radiator with the 50/50 antifreeze mixture. Make sure all air is bled from the
cooling system.
NOTE: Make certain all air is purged from the cooling system, especially on centermount and
sidemount units. Recently built units include a special vent fitting on the top of the inlet header on the
radiator. Open this fitting to bleed air from the cooling system when refilling the radiator with coolant.
Bleeding Air from the Cooling System

A jiggle pin thermostat prevents air from being trapped in the engine block. This should make it
unnecessary to bleed the air out of the engine. Normally approximately 8.5 liters (9 quarts) of coolant will
drain from the cooling system. If only 4 liters (4 quarts) of coolant 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: If you suspect that air is

trapped in block, do not start the engine
without bleeding the air out of the block.
NOTE: If an engine operates with air trapped in the block, engine damage could occur. The high water
temperature switch may not protect an engine that has air trapped in the block.
1. Remove the plug from the front end of the water pump before pouring coolant into the cooling
system. Recently built units also include a special vent fitting on the top of the inlet header on the
radiator. Also open this fitting to bleed air from the radiator.
1. Plug
Figure 61: Remove Plug from Water Pump
2. Slowly pour coolant into the system until coolant comes out of the plug fitting.
3. Reinstall the plug on the water pump.
127
Engine Maintenance
4. Pour coolant into the system until it appears to be full.

5. Make sure that the amount of coolant that goes back into the system is approximately equal to the
amount of coolant that was drained from the system.
6. Start the engine. Monitor the engine coolant temperature with the controller. When the temperature
reaches 66 C (150 F), 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.
7. Restart the engine and run it for a minute. Then stop the unit.
8. Check the coolant level and add coolant if necessary.
9. Repeat steps 7 and 8 until the coolant level stabilizes.
10. Close the vent fitting on the top of the inlet header on the radiator (recently built units only).
Engine Thermostat
TK486VG engines use a 71 C (160 F) thermostat.
1
2
3 AJA2067
AJA2061
1. Thermostat
2. Jiggle Pin
3. Install This End Toward Engine
Figure 62: Engine Thermostat
128
Engine Maintenance
Engine Fuel System

TK486VG engines use a mono-plunger and distributor injection pump.
The components of a typical fuel system include:
1. Fuel tank
2. Fuel strainer (inlet to transfer pump)
3. Fuel filter
4. Water separator
5. Hand fuel pump
6. Transfer pump
7. Injection pump
8. Injection nozzles
The hand fuel pump is used to manually draw fuel from the tank up to the transfer pump if the unit should
run out of fuel.
The transfer pump draws fuel from the fuel tank through a fuel inlet strainer at the inlet to the transfer
pump. The transfer pump then delivers fuel through the fuel heater to the fuel filter/water separator.
Filtered fuel passes through a line from the outlet fitting on the filter base to the injection pump.
The injection pump forces the fuel, at a very high pressure, through the injection nozzles. The injection
nozzles atomize the fuel as it is injected directly into the combustion chambers.
Injection pump leakage, injection nozzle overflow and excess fuel from the fuel filter assembly return to
the fuel tank through the return lines.
Maintenance
The fuel system is relatively trouble-free and if correctly maintained will usually not require major
service repairs between engine overhauls.
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. The single element fuel
filter/water separator must be changed according to the Service Guide in the Introduction of this manual
or the Maintenance Inspection Schedule on the unit.
NOTE: The injection nozzles must be tested (and repaired if necessary) at least every 3,000 hours in
accordance with EPA 40 CFR Part 89. Normal conditions are considered to be the use of clean high
quality fuel, no used oil blending, and regular maintenance of the fuel system according to the
Maintenance Inspection Schedule. Refer to the TK482 and TK486 Overhaul Manual TK 50136 for
injection nozzle testing and repair procedures.
Whenever the fuel system is opened, take the following precautions to prevent dirt from entering the
system:
• Cap all fuel lines.
• Work in as clean of an area as possible.
• Complete the work in the shortest possible time.
129
Engine Maintenance
Any major injection pump or nozzle repairs should be done by a quality diesel injection service shop. The
necessary service equipment and facilities are not found in most engine rebuild shops because of the large
investment required.
The following procedures can be done under field conditions:
• Bleeding air from the fuel system
• Fuel tank and filter system maintenance
• Prime pump (hand) replacement or repair*
• Transfer pump replacement or repair*
• Injection line replacement*
• Engine speed adjustments
• Pump timing
• Nozzle spray pattern testing and adjustment*
• Minor rebuilding of nozzles*
• Trochoid feed pump replacement
*These procedures are covered in the TK482 and TK486 Overhaul Manual, TK 50136.
130
Engine Maintenance
1 2
1. Relief Valve (Keeps air from entering fuel

5. Fuel Transfer Pump
system when engine is not running.)
2. Filter Head 6. Priming Pump
3. Bleed Screw 7. Fuel Filter/Water Separator
4. Mono-plunger and Distributor Injection Pump
Figure 63: Fuel System
131
Engine Maintenance
Fuel Return Line Replacement

The fuel return lines (hoses) and end cap on the fuel injection nozzles should be changed every 10,000
engine operating hours. The return line kit (P/N 10-373) contains new return lines, clamps, an end cap,
and a decal like the one shown below. This decal is was added to production units in January of 2005. The
decal is located near the unit serial plate. The date and engine hours must be entered on the decal when the
fuel return lines are changed.
Figure 64: Fuel Return Line Replacement Decal
Use the following procedure to replace the fuel return lines and end cap.
1. Remove the clamps, the end cap, the short fuel return lines between the injection nozzles, and the long
fuel return line from the injection nozzle to the banjo fitting on the injection pump.
1
2 3
1. End Cap 4. Short Fuel Return Lines

2. Larger Clamp 5. Long Fuel Return Lines
3. Smaller Clamps
Figure 65: Fuel Return Line Replacement
2. Discard the old clamps, end cap, and fuel return lines.
3. Install the end cap and clamp. Note that the end cap has a larger OD than the other hoses and requires
the larger clamp.
4. Install the fuel return lines and clamps. It may be necessary to adjust the banjo fitting slightly to
obtain the straightest routing for the long return line.
5. Be sure all the fittings are tight and check for leaks.
6. Write the date and engine hours on the decal.
132
Engine Maintenance
Bleeding the Fuel System

The fuel system must have the air bled out if any of the following circumstances occur:
• If the fuel tank becomes empty
• If repairs are made to the fuel system
• If air gets into the system for any other reason.
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.
To bleed air from the fuel system:
1. Loosen the bleed screw on the injection pump about one turn.
1
1. Bleed Screw 2. Priming Pump

Figure 66: Injection Pump
2. Unscrew the priming pump handle and manually prime the fuel system until air bubbles are no longer
visible in the fuel coming out of the bleed screw.
3. Tighten the bleed screw and screw the priming pump handle back in.
4. Loosen the injection lines at the injection nozzles.
5. Crank the engine until fuel appears at the nozzles.
6. Tighten the injection lines.
7. 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.
Water in the Fuel System

Water in the fuel system can damage the injection pump and nozzles. This damage 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. Let the
tank set idle for an hour before removing the drain plug from fuel tank. Let water and fuel drain into a
container until only fuel is draining from tank. Replace drain plug. DO NOT steam clean fuel tank caps.
133
Engine Maintenance
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 water and fuel.
Single Element Fuel Filter/Water Separator Replacement

A single element fuel filter/water separator removes contaminates and water from the fuel. Two orifices
in the filter head control the pressure in the fuel system by allowing a certain amount of fuel to return to
the tank. One orifice is located in the center of the filter head. It bleeds off water and returns it to the fuel
tank. The other orifice is located off-center on the filter head and bleeds off air.
1. Unscrew the filter using a strap wrench. Drain filter. Properly dispose of fuel and filter.
2. Fill the new filter with clean fuel through one of the small openings in the top of the filter body. Do
not use the center hole to add fuel to the filter or unfiltered fuel may reach the injection pump. Filling
the filter with fuel purges air from the filter.
3. Clean the filter head seal surface. Lubricate filter seal with clean fuel.
4. Hand tighten the filter.
Draining Water from Fuel Tank

Water run through the system may damage the injection pump or nozzles. Damage to the fuel 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.
Engine Speed Adjustment

When the diesel engine fails to maintain the correct engine speed, check the following before adjusting
the speed:
1. Bleed the air out of the fuel system. Check the speed.
2. Bleed the air out of the nozzles. Check the speed.
Adjustment Procedure for Standard Units

Make the engine speed adjustments with the engine fully warmed up.
1. Turn the refrigeration unit off so there is no load on the engine.
2. Start the unit and use the Data Menu and the Internal States submenu (or the Commands Menu and the
System Setup submenu) to check the engine speed. The engine speed should be 1890 ± 10 RPM with
No Load.
3. Loosen the jam nut on the speed adjustment screw.
134
Engine Maintenance
4. Adjust the screw to change engine RPM.

5. Tighten the jam nut, when the speed is correct.
1
1. Fuel Solenoid
2. Speed Adjustment Screw
Figure 67: Engine Speed Adjustment for Standard Unit
Adjustment Procedure for Units with EcoPower Option

Make the engine speed adjustments with the engine fully warmed up.
1. Turn the refrigeration unit off so there is no load on the engine.
2. Start the unit.
3. Enter the Commands Menu and then enter the System Setup submenu. See “System Setup” on
page 86.
4. Set the Speed Solenoid to Off in the System Setup submenu.
5. Check the engine speed. The engine speed should be 1560 ± 5 RPM with No Load and the Speed
Solenoid Off.
a. If necessary, loosen the jam nut on the low speed adjustment screw.
b. Adjust the low speed adjustment screw to change engine RPM.
c. Tighten the jam nut on the low speed adjustment screw when the speed is correct.
6. Set the Speed Solenoid to On in the System Setup submenu.
7. Check the engine speed. The engine speed should be 1890 ± 10 RPM with No Load and the Speed
Solenoid On.
a. If necessary, loosen the jam nut on the high speed adjustment screw.
b. Adjust high speed adjustment screw to change engine RPM.
c. Tighten the jam nut on the high speed adjustment screw when the speed is correct.
8. Exit the System Setup submenu by pressing the ESCAPE key as necessary to return to the Main Menu.
135
Engine Maintenance
3 2
1. Speed Solenoid
2. Low Speed Adjustment Screw
3. High Speed Adjustment Screw
Figure 68: Engine Speed Adjustment for Units with EcoPower Option
136
Engine Maintenance
Integral Fuel Solenoid

The fuel solenoid contains 2 coils: the pull-in coil, and the hold-in coil. The pull-in coil draws
approximately 35 to 45 amperes at 12 volts. The hold-in coil draws approximately 1 ampere at 12 volts.
The pull-in coil must be energized to move the injection pump governor linkage to the fuel “ON”
position. Once the governor linkage is in the fuel “ON” position, the hold-in coil will keep the linkage in
the fuel on position until the 8D circuit is de-energized. The pull-in coil must be de-energized after a few
seconds to keep it from being damaged.
DIagnosing the Integral Fuel Solenoid System

NOTE: The fuel solenoid pull-in coil may require 35 to 45 amperes to pull the solenoid plunger in. The
unit’s battery must be in good condition. If the battery has enough power to crank the engine over, it
has enough power to energize the fuel solenoid pull-in coil.
1 2
3 8DP
8D
4
5
CH
AJA2080
1. Pin B: White (8DP) Wire

2. Pin A: Red (8D) Wire
3. Pin C: Black (CH) Wire
4. Fuel Solenoid and Connector
5. Main Wire Harness Connector and Pins:
Pin A = 8D
Pin B = 8DP
Pin C = CH
Figure 69: Integral Fuel Solenoid Harness Connections
If you suspect that the engine does not operate because the fuel solenoid is not operating correctly, use the
following procedure:
1. Check the operation of the fuel hold relay and the fuel pull relay.
a. Go to the Commands Menu and use the PTI submenu or the Manual Function Test submenu to
test the relays. See “Commands Menu” on page 81, “PTI” on page 82, and “Manual Function
Test” on page 84.
b. If a relay fail the test, replace the relay.
c. If the relays pass the tests, go to step 2.
2. Disconnect wire 8S from the starter solenoid.
3. Disconnect the fuel solenoid wire connector from the main wire harness.
137
Engine Maintenance
4. Place the Unit On/Off switch in the “ON” position.

5. Check the voltage on 8D circuit in the main wire harness connector for the fuel solenoid. Refer to
Figure 69 or the unit wiring diagram to identify the pins in the wire harness and fuel solenoid
connectors.
a. If battery voltage is not present on the 8D circuit, check the 8D circuit and related components for
a fault.
b. If battery voltage is present on the 8D circuit, go to step 6.
6. Check CH circuit in the main wire harness at the fuel solenoid connector for continuity to a good
chassis ground.
a. If there is no continuity between CH circuit and a good chassis ground, check the CH wire for an
open circuit.
b. If there is continuity between CH circuit and a good chassis ground, go to step 7.
7. Turn the unit off.
8. Place a jumper wire between the CH circuit in the connector on the fuel solenoid and a good chassis
ground.
9. Test the pull-in coil by momentarily placing a jumper between the 8DP circuit pin in the connector on
the fuel solenoid and the positive battery terminal. The fuel solenoid should make a definite click
when the pull-in coil is energized. It should click again when the pull-in coil is de-energized.
NOTE: The pull-in coil may draw 35 to 45 amperes so do not leave the jumper connected to pin
8DP for more than a few seconds.
a. If the pull-in coil does not energize, check the resistance of the pull-in coil by placing an
ohmmeter between 8DP circuit and the CH circuit in the connector on the fuel solenoid. The
resistance of the pull-in coil should be 0.2 to 0.3 ohms. Replace the fuel solenoid if the resistance
of the pull-in coil is not in this range.
b. If the pull-in coil does energize, go to step 10.
10. Test the hold-in coil.
a. Energize the hold-in coil by placing a jumper between the 8D circuit in the connector to the fuel
solenoid and the positive battery terminal.
b. Momentarily energize the pull-in coil by placing a jumper between the 8DP circuit in the
connector to the fuel solenoid and the positive battery terminal. The fuel solenoid should make a
definite click when the pull-in coil is energized, but should not click when the pull-in coil is
de-energized.
c. De-energize the hold-in coil by removing the jumper from the 8D circuit and the positive battery
terminal. The fuel solenoid should make a definite click when the hold-in coil is de-energized.
d. If the hold-in coil does not function properly, check the resistance of the hold-in coil by placing an
ohm-meter between the 8D circuit and the CH circuit in the connector to the fuel solenoid. The
resistance of the hold-in coil should be 24 to 29 ohms. If the resistance of the hold-in coil is not in
this range, replace the fuel solenoid.
11. Reconnect the main wire harness connector to the fuel solenoid connector.
12. Connect wire 8S to the starter solenoid.
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Engine Maintenance
Fuel Solenoid Replacement

1. Disconnect wire 8S from the starter solenoid.
2. Disconnect the fuel solenoid wire connector.
3. Remove the old fuel solenoid.
4. Connect the main harness connector to the new fuel solenoid.
5. Place the Unit On/Off switch in the “ON” position to energize the fuel solenoid.
NOTE: The fuel solenoid must be energized when it is being installed. If it is not, the plunger and the
linkage may not line up correctly.
6. Place the O-ring in the groove in the end of the fuel injection pump. Make sure that the O-ring is
positioned correctly during installation to avoid damage and leaks.
7. Install the new fuel solenoid.
8. Turn the unit Off.
9. Connect wire 8S to the starter solenoid.
AXA0298
1. Integral Fuel Solenoid

2. O-ring
3. Fuel Injection Pump Groove
Figure 70: Integral Fuel Solenoid Components
139
Engine Maintenance
Injection Pump Service and Timing

Injection Pump Removal
The injection pump drive gear will not fit through the gear housing when removing the pump. The gear
must be separated from the pump using tool P/N 204-1011. When this tool is used, it is not necessary to
remove the water pump belt, fuel pump, crankshaft pulley, crankshaft seal or front plate. See Figure 73
“Injection Pump Gear Tool” on page 142.
1. Note the alignment of the index marks on the injection pump and the gear case. The index mark on the
injection pump is usually aligned with the single index mark on the gear case. If not, mark it so the
injection pump can be returned to the same position when it is reinstalled.
1. Index Marks
Figure 71: Index Mark Location
1 2
1. Index Mark on Injection Pump

2. Index Mark on Gear Case
Figure 72: Index Mark Alignment
2. Remove the starter for clearance. Also remove the fuel lines, harness and mounting hardware from the
injection pump. Cover all injection lines and fuel lines with plastic covers or tape. The smallest
amount of dirt can damage the fuel system.
3. Remove the cover plate from the gear case. Remove the nut and lockwasher that secure the gear to the
injection pump shaft. Use a shop rag to prevent the lock washer or nut from falling into the gear case.
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Engine Maintenance
NOTE: The injection pump gear assembly is made of three pieces; the flange, the gear, and the
transfer pump cam. Do not loosen or remove the four bolts that fasten the gear to the flange
because that changes the timing.
4. Use the hardware from the cover plate to attach the tool plate (P/N 204-1011) to the gear case. Attach
the plate with the marked side pointing up and out away from the case.
5. Align the threaded holes in the injection pump gear with the two holes in the tool plate by rotating the
engine crankshaft. Attach the gear to the tool plate with the screws provided with the tool plate.
6. Thread the long screw into the small end of the adapter (both parts are supplied with the tool plate).
Insert the adapter into the tool plate. Carefully align the screw over the center of the injection pump
shaft. Then rotate the screw to force the injection pump shaft from the gear.
7. Remove the screw and adapter, leaving the tool plate in position. This holds the gear in the proper
tooth alignment until the injection pump is re-installed.
Injection Pump Installation

1. Rotate the injection pump shaft to align the key with the keyway in the gear. Take care to make sure
the key mates with the keyway. Then insert the injection pump shaft into the gear.
2. Fasten the injection pump to the gear case using the correct hardware. Make sure to align the index
marks on the injection pump and the gear case like they were in step 1 of “Injection Pump Removal”.
NOTE: If a different injection pump is being installed, see “Injection Pump Timing” on page 143
to set the timing.
3. Remove the screws that hold the gear to the tool plate and remove the tool plate.
4. Fasten gear to injection pump shaft with a lock washer and nut. Use a shop rag to prevent the lock
washer or nut from falling into the gear case. Torque the nut to 58 to 65 ft-lb (78 to 88 N•m).
5. Fasten the cover plate to the gear case. Install the fuel lines, harness and mounting hardware from the
injection pump. Also install the starter.
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Engine Maintenance
8 7 6
1. Injection Pump 5. Adapter (Tool)

2. Gear Case 6. Tool Long Screw (Tool)
3. Cover Plate 7. Tool Short Screw (Tool)
4. Cover Plate Bolt 8. Tool Plate (Tool)
Figure 73: Injection Pump Gear Tool
142
Engine Maintenance
Injection Pump Timing

Use this timing procedure when installing a new injection pump. It is not necessary to use this timing
procedure when removing and reinstalling the original injection pump. In that case, align the index marks
on the injection pump and the gear case as they were before removing the injection pump.
1. Before removing the old injection pump, note the alignment of the index marks on the injection pump
and the gear case. The index mark on the injection pump is usually aligned with the index mark on the
gear case. If not, make a mark on gear case in line with the index mark on the injection pump (see
Figure 76).
1. Index Marks
Figure 74: Index Mark Location
1 2

2. Index Mark on Gear Case
Figure 75: Index Mark Alignment
143
Engine Maintenance
2
1

2. Existing Index Mark on Gear Case
3. Make New Mark on Gear Case If Needed
Figure 76: Marking Gear Case
2. Clean the area with brake cleaner or something similar. Place an injection angle sticker on the gear
case so the center line on the sticker is aligned with the index mark on the injection pump. An
injection angle sticker is provided with the new injection pump.
1 2

2. Injection Angle Sticker
Figure 77: Place Injection Angle Sticker on Gear Case
0.5 Degrees
1
2
1. –1.0 Degrees Mark

2. Center Line (0 Degrees Mark)
3. +1.0 Degrees Mark
Figure 78: Injection Angle Sticker
3. Remove the old injection pump. Use the injection pump gear tool P/N 204-1011 to remove the
injection pump gear without removing the timing gear cover (see “Injection Pump Removal” on
page 140).
144
Engine Maintenance
NOTE: Remove the injection pump gear by removing the nut and lock washer that secure the
injection pump gear assembly to the injection pump shaft. The injection pump gear assembly is
made of three pieces; the flange, the gear, and the transfer pump cam. Do not loosen or remove the
four bolts that fasten the gear to the flange because that changes the factory-set timing. The EPA
certification is based on the factory-set timing. If the factory-set timing is changed, the EPA
certification is void.
1
1
2
1
1
1. Do Not Loosen or Remove These Four Bolts

2. Remove Nut and Lock Washer
Figure 79: Removing Injection Pump Gear
4. Record the injection angle marked on the old injection pump (see the following photographs). The
injection angle mark is located on the side of the pump facing the engine. The injection angle mark on
the pump does not use a decimal point. Add a decimal point before the last digit of the injection angle
mark to get the injection angle. The injection angle mark in the following photographs is 67. That
equals an injection angle of 6.7 degrees.
Examples
Injection Angle Mark Injection Angle
67 6.7 Degrees
85 8.5 Degrees
1. Injection Angle Mark

Figure 80: Injection Angle Mark Location
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Engine Maintenance
1. Injection Angle Mark

Figure 81: Injection Angle Mark
NOTE: If you cannot read the injection angle mark, contact the Thermo King Service Department with
the injection pump serial number or the engine serial number and they will provide the injection angle.
The injection pump serial number is located on the bottom of the sticker on the injection pump.
1. Injection Pump Serial Number

Figure 82: Injection Pump Serial Number Location
5. Record the injection angle marked on the side of the new injection pump.
6. Calculate the injection angle difference by subtracting the injection angle of the old injection pump
from the injection angle of the new injection pump.
Examples
Injection Angle of New
8.5 6.1
Injection Pump (Degrees)
– Injection Angle of Old
– 6.7 – 6.7
Injection Pump (Degrees)
= Injection Angle Difference
= +1.8 = –0.6
(Degrees)
146
Engine Maintenance
7. Install the new injection pump on the gear case and position it so the index mark on the injection
pump is aligned with the mark equal to the injection angle difference on the injection angle sticker
(see the following examples). Tighten the injection pump mounting nuts when the index mark is
aligned as necessary with the injection angle sticker.
1. Injection Pump Index Mark at –0.6 Degrees

2. Injection Pump Index Mark at +1.8 Degrees
Figure 83: Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker
8. Install the injection pump gear, lock washer, and nut. Torque the nut to 58 to 65 ft-lb (78 to 88 N•m).
NOTE: If the timing gear cover was removed to remove the injection pump gear, make sure the timing
marks on the timing gears are aligned as shown below. It helps to install the idler gear last when
aligning the timing marks.
1 3
2
1. Fuel Injection Pump Gear

2. Idler Gear
3. Camshaft Gear
4. Crankshaft Gear
Figure 84: Timing Mark Alignment
NOTE: The oil pump is located in the timing gear cover on TK486VG engines. The inner rotor of the
oil pump fits around the crankshaft gear. Make sure that the flat sides of the inner rotor are aligned
with the flat sides on the crankshaft gear when installing the timing gear cover.
147
Engine Maintenance
1
2
5
3
4
1. Crankshaft Gear
2. Oil Pump Cover
3. Outer Rotor
4. Inner Rotor
5. Timing Gear Cover
6. Flat Sides on Inner Rotor
7. Flat Side on Crankshaft Gear
Figure 85: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover
Trochoid Feed Pump

The TK486VG engine has a trochoid feed pump on the fuel injection pump. The trochoid feed pump
supplies fuel to the injection pump at a pressure of 450 to 600 kPa (65 to 87 psi) in high speed. Check the
outlet pressure of the trochoid feed pump by removing the plug and attaching a pressure gauge to the port
shown below. The plug has M12x1.25 threads. You will have to make an adaptor to attach a pressure
gauge. Replace the trochoid feed pump if the outlet pressure is below the pressure specifications in the
following table.
Trochoid Feed Pump Outlet Pressure

Cranking 103-206 kPa (15-30 psi)
Low Speed 206-345 kPa (30-50 psi)
High Speed 450-600 kPa (65-87 psi)
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Engine Maintenance
1. Trochoid Feed Pump Outlet Pressure Port

2. Trochoid Feed Pump
Figure 86: Trochoid Feed Pump Location
Trochoid Feed Pump Leaks

Internal – If the seal in the trochoid feed pump fails, it could allow some fuel to leak into the engine oil. A
faulty injection nozzle or fuel transfer pump can also dilute the engine oil with fuel. Replace the trochoid
feed pump if the engine oil is being diluted with fuel and a faulty injection nozzle or fuel transfer pump is
not the cause.
External – Replace the O-ring seal between the trochoid feed pump and the injection pump if oil is
leaking. Torque the bolts to prevent leaks (8 to 10 N•m [6 to 7 ft-lb]).
Replace all O-rings if fuel is leaking. Torque the Allen head screws and Hex head bolts to prevent leaks (8
to 10 N•m [6 to 7 ft-lb]).
Trochoid Feed Pump Replacement

Use the following procedure to replace the trochoid feed pump.
1. Remove the four hex head screws that attach the trochoid feed pump to the injection pump. Do not
remove the two Allen head screws.
1 2 1
1. Allen Head Screws (Do Not Remove)

2. Hex Head Screws
Figure 87: Trochoid Feed Pump Removal
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Engine Maintenance
2. Remove the trochoid feed pump from the injection pump.

NOTE: The gear on the trochoid feed pump is lubricated with engine oil. Some engine oil might
leak out of the injection pump when the trochoid feed pump is removed. The trochoid feed pump
does not need to be timed when it is installed.
3. Clean the area on the injection pump from which the trochoid feed pump was removed.
4. Place new O-rings on the new trochoid feed pump and make sure it is clean.
1
1
1. O-Rings
Figure 88: Trochoid Feed Pump
5. Place the new trochoid feed pump on the injection pump.

6. Install and tighten four hex head screws that attach the trochoid feed pump to the injection pump.
Torque the hex head screws to 8 to 10 N•m (6 to 7 ft-lb).
Cold Start Device

The TK486VG engine has a cold start device located on the fuel injection pump. The cold start device has
a plunger that retracts at engine coolant temperatures below 5 C (41 F) to advance the injection timing
approximately 2 degrees. The plunger controls the position of a piston in the injection pump to change the
timing. The plunger is extended and the injection timing is normal at engine coolant temperatures above
5 C (41 F). Check the operation of the cold start device if it is difficult to start the engine in cold weather.
NOTE: Do not pull the plunger out of a cold start device because that will damage it.
150
Engine Maintenance
1. Plunger (Extended)
Figure 89: Cold Start Device
Checking Cold Start Device Operation

Use the following procedure to check the operation of the cold start device. The engine coolant
temperature must be below 0 C (32 F) to start the procedure.
1. Place the On/Off switch in the On position.
2. Enter the Analog Inputs submenu in the Data Menu before the engine starts and check the coolant
temperature to make sure it is below 0 C (32 F).
3. Let the engine start, then enter the Internal States submenu in the Data Menu to check the engine rpm.
The engine rpm should be approximately 100 rpm higher than normal (see Specifications).
4. Let the engine run to warm up and use Analog Inputs and Internal States submenus to check the
coolant temperature and engine rpm. When the coolant temperature rises above 5 C (41 F), the engine
rpm should drop back to normal. Replace the cold start device if the engine rpm does not drop
approximately 100 rpm when the engine warms up.
Cold Start Device Replacement

1. Drain the engine coolant.
2. Remove the banjo bolt that fastens the engine coolant fitting to the cold start device. Use a backup
wrench on the cold start device if necessary.
151
Engine Maintenance
1. Banjo Bolt
2. Engine Coolant Fitting
3. Coolant Hoses to Cold Start Device
Figure 90: Remove Engine Coolant Fitting
3. Remove the cold start device from the injection pump fitting. Use a backup wrench on the injection
pump fitting if necessary.
1. Cold Start Device

2. Injection Pump Fitting
Figure 91: Remove Cold Start Device
152
Engine Maintenance
4. Make sure the piston inside the injection pump fitting is clean.
1. Piston
Figure 92: Clean Piston
5. Install the new cold start device with a new O-ring in the injection pump fitting. Torque the cold start
device to 30 to 35 N•m (22 to 26 ft-lb).
6. Install the coolant fitting and banjo bolt on the cold start device. Torque the banjo bolt to 22 to 25 N•m
(16 to 18 ft-lb).
7. Refill the engine cooling system and make sure to bleed the air from the cooling system.
Adjusting Engine Valve Clearance

Valve clearance should be checked as required. It is very important that valves be adjusted to the correct
specifications for satisfactory engine operation. Insufficient valve clearance will result in compression
loss and misfiring of cylinders. This will result in burned valves and seats. Excessive valve clearance will
result in noisy valve operation and abnormal wear of the valves and rocker arms. The intake and exhaust
valves are adjusted with the valve in the closed position.
AXA0304
Figure 93: Adjusting the Valve Clearance
Complete the following steps to adjust the engine value clearance.

1. Remove the rocker arm cover.
2. Remove the round cover (plug) from the timing mark access hole on the front of the bell housing.
153
Engine Maintenance
WARNING: Loosen all of the injection lines at the injection nozzles to prevent the possibility of
the engine firing while it is being rotated.
3. Place the engine at top dead center of the compression stroke for the number one cylinder.
a. Rotate the engine in the normal direction of rotation (clockwise viewed from the water pump end).
Rotate the engine until the 1-4 timing mark on the flywheel lines up with the index mark in access
hole.
b. Check the rocker arms on the number one cylinder.
c. If the rocker arms are loose, the engine is at top dead center of the compression stroke for the
number one cylinder.
d. If the rocker arms are tight, the engine is at top dead center of the exhaust stroke for the number
one cylinder. Rotate the engine 360 degrees to place the engine at top dead center of the
compression stroke for the number one cylinder.
1
1 2 3
AJA2085
1. Timing Mark
2. Top Dead Center Mark for Cylinders 1 and 4
3. Top Dead Center Mark for Cylinders 2 and 3
Figure 94: Timing Marks
4. Check the valve clearance of both valves for the number one cylinder with a feeler gauge. Also check
the valve clearance for the intake valve for the number two cylinder, and the exhaust valve for the
number three cylinder. The clearance for both the intake and exhaust valves should be 0.15 to 0.25
mm (0.006 to 0.010 in.).
NOTE: Check to make sure that the valve stem cap is in good condition and is positioned squarely
on the top of the valve stem. Replace the valve stem cap if it shows significant wear.
5. Loosen the locknut and adjust the valves as required by turning the adjustment screw.
6. Hold the adjustment screw while tightening the locknut.
7. Recheck the valve clearance.
154
Engine Maintenance
8. Rotate the engine one full turn (360 degrees) to place the engine at top dead center of the compression
stroke for the number four cylinder. Rotate the engine clockwise as viewed from the water pump end.
Align the 1-4 timing mark on the flywheel with the index mark in the access hole. This places the
engine at top dead center of the compression stroke for the number four cylinder.
9. Check and adjust both valves for the number four cylinder. Also check the valve clearance for the
intake valve for the number three cylinder, and the exhaust valve for the number two cylinder. The
clearance for both the intake and exhaust valves should be 0.15 to 0.25 mm (0.006 to 0.010 in.).
10. Replace the rocker arm cover and the timing mark access hole cover. Tighten the fuel injection lines
when finished.
Engine Rear Front

Flywheel Pulley
End End
Cylinder No. 1 2 3 4
Valve Arrangement E I E I E I E I
Piston in No. 1 cylinder is at TDC on O O O O
compression stroke
Piston in No. 4 cylinder is at TDC on Θ Θ Θ Θ
compression stroke
Figure 95: Valve Adjustment and Cylinder Configurations
155
Engine Maintenance
Belt Tension Adjustment and Belt Replacement

NOTE: Belt tension specifications are measured using Thermo King belt gauge tool, P/N 204-427.
Belts should be regularly inspected during unit pretrip for wear, scuffing or cracking and correct tension.
Correct belt tension is critical for correct unit operation. Belts that are too loose will slip, squeal or whip
causing excessive vibration levels and poor unit performance. Belts that are too tight will put too much
strain on the belt fibers and bearings, causing premature belt and bearing failures. New belts should be
tensioned cold.
NOTE: DO NOT attempt to remove or install belts without loosening adjustments. Belts that are
installed by prying will fail prematurely due to internal cord damage.
WARNING: DO NOT jump belts on by cranking the engine. Personal injury may result.
WARNING: DO NOT attempt to adjust belts with the unit operating.
WARNING: With the unit On/Off switch in the “ON” position, the unit may start operation at
any time without prior warning. Switch unit On/Off switch to “OFF” position before
performing maintenance or repair procedures.
The water pump belt tension should read 15 to 35 on the belt tension gauge.
1. Remove the nuts from the water pump pulley.
2. Remove the pulley sliding section and add or remove shims to adjust the belt tension.
156
Engine Maintenance
1 2 3 4 5
AJA2086
6
Water Pump Pulley (Items 1 - 5)

1. Fixed Pulley Section
2. Spacer
3. Shims (4)
4. Sliding Pulley Section
5. Nut (4)
6. Belt
7. Crankshaft Pulley
Figure 96: Water Pump Fan Belt
3. Reinstall the belt on the pulley and replace the sliding pulley section on the pulley.
4. Tighten the mounting nuts on the water pump pulley.
5. The belt tension should read 15-35 on the belt tension gauge.
NOTE: When adjusting the belt tension using shims and adjustable pulleys, the belt may still feel loose
when the belt tension gauge indicates the correct tension. Allow 18 to 25 mm (0.75 to 1.0 inch)
deflection with 3 to 4 kg (6 to 9 lb) of force.
157
Engine Maintenance
158
Alternator Operation and Diagnosis (prior to
December 2016)
General Description
The 460/230 Vac alternator system consists of two principal components: the main alternator, and the
SG+ Controller.
The main alternator may be subdivided into the 4-pole main rotating field and the main stator winding.
The main rotating 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. This provides excitation to
the main alternator rotating field.
The SG+ Controller energizes (and controls) the exciter field. The output from the main winding builds
up until the voltage and amperage reaches the rated amount. The controller then decreases field current,
and the alternator maintains the proper output voltage.
Dual Voltage Alternator

The generator set is factory wired for 460V power output. The alternator output can be changed to 230V
by changing the jumper wire connections at the terminal strips in the control box. See “Rewiring
Procedures for Changing the Generator Set Output Voltage” on page 170.
Figure 97: 460/230 Vac Alternator Component Function
159
Alternator Operation and Diagnosis (prior to December 2016)
Alternator Function
Starting Excitation
The initial excitation for the alternator is supplied by the SG+ Controller approximately 15 seconds after
the engine starts. The controller energizes wire F1, which sends the current through the exciter field to
build voltage in the stator windings. The current then travels through wire F2 where the circuit is
completed to chassis ground.
NOTE: When the Delayed Cold Start feature is set to ON, the exciter field is not energized until the
engine temperature rises to 32 C (90 F).
Running Excitation and Control

The magnetic field that was formed in the exciter field stator winding by current from the controller
induces a current in the exciter rotating winding. This current is changed from three-phase ac to dc by the
rotating rectifier. The dc current is transferred to the main alternator field winding. The main alternator
field now becomes magnetic.
The magnetic field formed in the main field winding now induces a voltage in the alternator stator
windings. This voltage is either 230 Vac or 460 Vac, 3-phase, depending on stator connections.
It is sent out of the alternator stator leads to the power plug and then to the load. The controller is tapped
into the alternator stator leads. The controller reads the alternator output voltage and steps this voltage
down to around 12 Vac (1/20th of output voltage). This current is rectified to dc current and is used to
charge the battery and energize the exciter field. The controller monitors the alternator output voltage and
adjusts the output to the exciter field as necessary to maintain the alternator output at the correct voltage.
160
Battery Charging
The unit battery is recharged by the alternator through the controller, which performs the functions of a
voltage regulator and rectifier. Fuse SI2 (30 amps) protects the battery charger output circuit.
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 controller to increase field current through wire F2. The controller senses the
overload current and then de-energizes the fuel solenoid to stop the engine.
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.
161
Alternator Diagnosis
Preliminary Checks
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.
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
Listed below are the categories in which most generator malfunctions will fall. Following each category
are a number of possible component failures that may cause the malfunction. Listed with each component
is the test used to check the component.
NOTE: Always use Test 1 first to determine if the alternator or the controller is at fault.
1. Generator set has low or no output voltage (system overload).
a. Controller is not exciting alternator (Test 1).
b. Exciter field circuit in alternator is open circuit (Test 4).
162
c. Alternator stator, main rotating field, rotating rectifier or rotating exciter armature is defective
(Test 5).
2. Generator set tries to pick up the load but engine labors excessively, eventually causing a system
overload condition.
a. Mechanical problems with engine (see preliminary check 1).
b. Excessive load from refrigeration unit malfunction (see preliminary check 2).
c. Defect in controller, rotating field, rotating bridge, alternator main field or alternator stator (Test 1
and Test 5).
3. Unit battery undercharged.
a. Battery defective.
b. Fuse SI2 bad.
c. Controller fault (Test 2).
Test 1 - Determine if Problem is in Controller or Alternator

1. Need to put the genset in a non-excitation condition. Unplug the water temperature sensor and
connect a spare sensor with a temperature of 29 C (85 F) or below. If no spare sensor is available
connect a 1500 - 1550 ohm resistor across the WTS and WTN wires.
NOTE: NOTE: Units with Eco Power will run in Low speed 400 V 50 Hz operation.
2. Disconnect the J6 (green) connector from controller
3. Start the genset and let run for 1-2 minutes. Check for residual AC voltage at T1-T2, T1-T3, and
T2-T3. Reading should be 50 to 120 VAC.
a. If residual voltage is present problem is in controller. Go to Test 2.
b. If low or no residual AC voltage is present, magnet in exciter stator may have lost its magnetism
and the field needs to be flashed. Disconnect F1 and F2 wires from J6 connector in control box.
Using a jumper wire connect F2 to GRD stud. Start genset. Using a jumper wire connect the F1
wire to J9 terminal or 12 Vdc. Check for AC voltage output on T1-T2, T1-T3, T2-T3, should be
400 VAC or higher. If AC voltage is present problem is in controller. Go to Test 2. If still no AC
voltage problem is in alternator, go to Test 3 and Test 4.
c. If the unit has add on F1/F2 circuit board, remove the board and repeat step b. If AC voltage is
now present replace the F1/F2 circuit board. If still no AC voltage problem is in alternator, go to
Test 3 and Test 4.
163
Test 2 - Controller Excitation Test

1. Make sure unit is in the excite condition, J6 is connected and water temperature is above 32 C (90 F).
Measure the voltage across the battery and record (12.5 Vdc).
2. Remove and check the 30 amp battery charger fuse S12. With the fuse removed from the controller
start the unit and measure voltage at terminals J15 and J16 located under blue cap. See photos below.
If the voltage is 16.1 to 16.8 Vdc, the controller is good. If voltage is the same has battery voltage,
replace controller. Reinstall the battery fuse S12 and take the same readings at J15 and J16. If voltage
reading is 16.1 to 16.8 Vdc, check the CH (10 ga) wire from J11 to the engine frame.
1
1. Blue Cap
Figure 98: Remove Blue Cap
Figure 99: Check Voltage Between J15 and J16
Test 3 - Testing Alternator

1. Make sure software is 3.8.1 100325 or higher.
2. Connect J6 connector and water temperature sensor. Start unit, no load and water temperature >90? F.
3. Go to DATA MENU/ANALOG INPUTS and read the FIELD CURRENT. If higher than 0.5 Amps
problem is in the alternator. Go to Test 4 and Test 5.
164
VOLTAGE MEAS. 460 V

FIELD CURRENT 1.1 A
WATER TEMP. 92ºC
RUNNING FREQ. 60Hz
Figure 100: DATA MENU/ANALOG INPUTS
Test 4 - Alternator Exciter Field Testing

1. Disconnect the field wire F1 and F2 from the J6 or at the plug in the control box. Measure the
resistance of the field circuit (F1 to F2). The standard value is 13.9 (±10%) ohms at 77 F (25C). If
field is open or resistance value is low replace exciter field 45-2301.
2. Measure F1 or F2 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.
Test 5 - Alternator Stator Testing

Test 5 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 control box. Check for
continuity between the following pairs. T1-T4, T2-T5, T3-T6, T7-T10, T8-T11, T9-T12. The
resistance between any of the pairs should be 0.114 (±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
AJA2089
1. Disconnect all 12 stator leads to test

the stator.
Figure 101: Alternator Stator
2. Rotating Rectifier
165
Six rectifying diodes are mounted on the rotating exciter field, three are positive and three are negative.
AJA2090
1. Disconnect the main alternator field leads to

test the diodes.
Figure 102: 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. With the armature leads still disconnected from the diodes, test between the following pairs of
leads. CR6-CR4, CR3-CR1, CR3-CR2, CR6-CR5, CR5-CR4, CR2-CR1. The resistance between
any of the pairs should be 0.645 (±10%) ohms at 25 C (77 F).
b. Using a megger meter, check for insulation break down between each pair of leads to the rotor
shaft. @ 500 Volts must be more than 1 M ohm.
Figure 103: Exciter Armature
4. Rotating Field Armature
166
a. Measure the resistance of the main field armature leads. The resistance should be 2.5 (±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.
AXA0324
1. Main Field
2. Exciter Rotor
3. Exciter Field
4. Ohmmeter
Figure 104: 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.
167
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.
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.
168
AXA0325
1. Rotor Assembly 14. Stator and End Bell Assembly

2. Disc, Rotor Drive 15. Stator, Wound
3. Blower, Generator 16. Exciter, Field
4. Rotor 17. Bell, End
5. Key 18. Stud, Bell
6. Spacer, Bearing 19. Cover, End Bell
7. Bearing/Seal, Rotor 20. Screw, Mounting End Bell Cover
8. Exciter Assembly, Rotor 21. Gasket, End Bell Cover
9. Rectifier, Positive Assembly 22. O-ring
10 Rectifier, Negative Assembly 23. Screw, Retainer
11. Nut, Rectifier Assembly 24. Retainer, Exciter
12. Screw, Mounting Rectifier 25. Rotor
13. Screw, Mounting Bearing
Figure 105: Alternator Assembly
169
Rewiring Procedures for Changing the Generator Set Output

Voltage
The alternator stator features a 12 lead design that contains two separate windings for each of the three
output phases. The 12 leads are numbered T1 through T12. All rewiring is performed inside the control
box.
All generator sets are factory wired for 460 Vac power output. 460 Vac operation requires that the two
individual windings in each of the three phases be connected in series: T4 tied to T7, T5 tied to T8, and
T6 tied to T9. The three output phases are:
Phase Wires
A (Black) T1
B (White) T2
C (Red) T3
230 Vac operation requires that one of the two windings in each of the three phases be connected in
parallel: T4, T5, and T6 are tied together. The three output phases are:
Phase Wires
A (Black) T1, T7 (tied together)
B (White) T2, T8 (tied together)
C (Red) T3, T9 (tied together)
Figure 106: Changing Output Voltage
Rewiring Procedure for Changing the Output Voltage from 460 Vac to 230
Vac
WARNING: Disconnect the unit battery to prevent the unit from accidentally starting during
rewiring.
1. Refer to the unit wiring diagram for illustrations of the proper wire connections.
2. Disconnect Wires:
a. Remove wire T7 from T4 connection, wire T8 from T5 connection and wire T9 from T6
connection on the main output terminal block.
b. Remove jumper wires on the terminal block from the T4 connection and T5 connection.
170
3. Reconnect Wires:
a. Install wire T7 lead on L1 (Black Wire) terminal, wire T8 on L2 (White Wire) terminal and wire
T9 lead on L3 (Red Wire) terminal.
b. Connect T4 jumper wire lead to J5 wire terminal. Connect T5 jumper wire lead to J6 wire
terminal.
4. Change output receptacle to 230 Vac.
5. Change voltage decal and nameplate markings from 460 Vac to 230 Vac.
6. Use the Configuration Menu to change the Output Voltage setting from 460 to 230. See
“Configuration Menu” on page 94.
171
172
Alternator Operation and Diagnosis (from Decem-
ber 2016)
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 107: 460/230 Vac Alternator Component Function
173
Alternator Operation and Diagnosis (from December 2016)
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.
174
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.
175
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 negative post of the battery 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,
c. Stop genset and check the resistance on the Quad winding.
d. Disconnect the Red wire on Pin 3 and Red wire to DSR wire,
e. Check resistance between the Red wires, should be 1.6 ohms.
f. 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.
176
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 108: Alternator Stator
177
2. Rotating Rectifier
Each plate one positive and one negative diode mounted to it.
AJA2090
1. Disconnect the main alternator field leads to test the diodes.
Figure 109: 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 110: Exciter Rotor
178
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.
AXA0324
1. Main Field
2. Exciter Rotor
3. Exciter Field
4. Ohmmeter
Figure 111: 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.
179
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.
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.
180
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 112: Alternator Assembly
181
Alternator Replacement
Alternator Removal
When removing the alternator from the engine do not separate the stator and rotor, remove as one
assembly.
1. Unwire old alternator harness (T1-T12, F1-F2) from control box.
2. Remove the grill from around the alternator. Remove all but one of the bolts holding the alternator to
the flywheel housing.
3. Remove the bolts holding the flex plate to the flywheel.
4. 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.
5. Save stator flange mounting bolts.
6. From the control box, remove the L1-L3 harness to the receptacle, discard. Remove exciter harness
F1 and F2, discard. Remove T7, T8, T9, discard. Save green connector
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.
For units built prior to January 2017 you will need to change to the new alternator and this also
requires a retrofit kit - see Bulletin C-127 or you parts manual for more information.
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.
NOTE: DO NOT separate the rotor from the stator on Mecc Alte alternator, rotor and stator can be
secured to the flywheel and housing through the front access holes.
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 20—27 nm (15-20 ft.lbs.)
NOTE: If changing from old type to new type alternator, use the new Allen head 8 mm bolts in kit to
secure rotor to flywheel. The original bolts are too long and hex head might interfere with the fan
blades. Fan blade CANNOT be rotated on the shaft.
182
3. Install the new liquid tight connector to the junction box on the alternator. Route the new harness thru
the connector into the junction box. Install cap plugs from kit in spare hole in junction box. Connect
wires per drawing. Connect new resistor assemble from N2 to ground stud. Connect receptacle wires
W1 wire to W1, V1 wire V1, U1 wire to U1. Connect the sense wires W2 wire to W2, V2 wire to V2,
U2 wire to U2. Disconnect RED wire from DSR pin 8. Connect DSR wire to RED, Quad wire to pin
8 on DSR. Connect ORANGE/PIN15 wire to pin 15 on DSR.
4. Install harness tie down bracket at the 2 O’clock position on flywheel housing using a alternator
mounting bolt. Route and secure harness to control box and receptacle. Wire harness to receptacle,
W1 wire to 3, V1 wire to 2, U1 wire to 1. See drawing above. Secure harness using ty-band and
existing clamps.
183
5. Install grills.
6. Inside control box remove terminal strip and decal, save mounting hardware. Install Quad relay and
Opto coupler to mounting bracket using hardware supplied in kit. Mount bracket assemble using the
saved hardware. Refer to drawing below. G01 CM, G02 SM, G03 CO
7. Wire control box harness per drawing below
184
8. Install new relay supplied in kit in RL4 socket on SG+ controller, ref item 9 in drawing above. Place
new wiring placard supplied in kit in control box.
9. CO and SM type gensets, mount new air filter bracket and install new hose supplied in kit between
intake and air filter.
10. Install 4.2.1.0 or higher software in SG+ controller. If control does not have the J20 connector use
G01 software. If the controller has the J20 connector use G02 software.
11. Generator type has to be changed in the controller. Turn genset ON and scroll to COMMANDS, then
SYSTEM SETUP, then GENERATOR. Press the ENTER key cursor will shift to the right, then scroll
to M. ALTE. To load press the ENTER and ECS key at the same time, cursor will shift back to the left
and M. ALTE will be displayed.
12. Run test genset. Genset will run in LOW speed and output power will be delayed for 2 minutes. After
2 minutes will shift to HIGH then Quad relay will energize apply power to the DSR and output power
will be present.
13. Release unit to service.
185
186
Structural/Accessory Maintenance
Unit Inspection
Inspect the unit during unit pre-trip inspection and scheduled maintenance intervals. Look for loose or
broken wires or hardware, and other physical damage which might affect unit performance. Repair if
required.
NOTE: See Service Guide chapter in this manual for the correct service interval for your unit. 250 or
500 hour inspection/service intervals are required in extreme operating conditions.
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:
TK486 Engine 203 N.m (150 ft-lb)
Exciter Control Box 20 to 27 N.m (15 to
20 ft-lb)
Power Cord Receptacle 20 to 27 N.m (15 to
20 ft-lb)
Fuel Tank 81 to 88 N.m (60 to
65 ft-lb)
187
Radiator Fan Location

The radiator fan and hub assembly mounts on the water pump pulley. When installed, the fan blade
should be in the orifice with 65 to 70 percent of the blade width to the air discharge side for proper fan
performance.
3
AJA2092
1. Radiator Coil Orifice

2. Airflow Direction
3. 65 to 70 Percent of Fan Blade Depth to Air
Discharge Side of Orifice
Figure 113: Radiator Fan Blade Placement
188
SGSM 3000 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: 88 to
115 N.m (65 to 85 ft-lb)
AXA0327
1. Mounting Arm Tube and Channel Assembly

2. Unit Mounting Bracket Assembly
Figure 114: SGSM 3000 Side Mount Installation — Typical
189
SGSM 3000 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 115: SGSM 3000 Side Mount Installation — Keener Arm
190
SGCM 3000 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. Use the top set of holes when mounting the unit on a container or
trailer chassis with 254 mm (10 in.) beams. Use the bottom set of holes when mounting the unit on a
container or trailer chassis with 305 mm (12 in.) beams.
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.
AXA0329
1. Fasten Chassis Clips on the Inside Edge of each C-Beam and TIghten Bolts
2. Tighten Mounting Arm to Unit Bolts
Figure 116: SGCM 3000 C-Section Chassis Centermount Installation
AXA0330
1. Fasten Chassis Clips on the Outside Edge of each I-Beam and TIghten Bolts
2. Tighten Mounting Arm to Unit Bolts
Figure 117: SGCM 3000 I-Beam Centermount Installation
191
2. Mount the power receptacle on the front mounting plate.

3. 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.
4. 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)
• Power Cord Receptacle: 20 to 27 N.m
(15 to 20 ft-lb)
SGCO 3000 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.
192
AXA0331
1. Lock Pawl 6. Mounting Bolt Retainer Assembly

2. Mounting Clamp Flat 7. Mounting Bolt
3. Handle 8. Retainer Door with Latch
4. Shoulder Screw 9. Bolt Holder Tube
5. Mounting Clamp Foot
Figure 118: SGCO 3000 Clip-on Corner Clamp Installation
193
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 119: SGCO 3000 Clip-on Corner Clamp Installation Procedure
194
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.
195
SGCO 3000 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.
AXA0333
1. Header Pin 4. Retainer Door with Latch

2. Mounting Bolt Retainer Assembly 5. Bolt Holder Tube
3. Mounting Bolt
Figure 120: SGCO Clip-on Header Pin Mounting Installation
196
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 Service Guide chapter in this manual for the correct service interval for your unit. 250 or
500 hour inspection/service intervals are required in extreme operating conditions.
Radiator Coil
Clean the radiator 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 fins.
197
198
Mechanical Diagnosis
NOTE: This diagnosis guide applies to units equipped with TK486 engines. For major repair of TK486
engines, refer to Overhaul Manual, TK 50136.
Diagnosing Unit Conditions
Condition Possible Cause Remedy

Unit switch On; controller Corroded battery cable connections Clean and tighten
display does not come on
Batteries discharged Charge or replace batteries
Fuse SI3 open (blown) Check for short circuit and replace fuse
Defective On/Off switch Check switch
Open circuit 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 Fuel solenoid not energized Check fuse SI1, 8D and 8DP circuits,
start fuel pull relay (RL1), and fuel hold relay
(RL2).
Fuel solenoid valve defective or stuck Replace
No fuel or wrong fuel Fill with proper fuel
Air cleaner clogged Clean and refill oil reservoir on oil bath
air cleaner; or replace dry air cleaner
filter
Exhaust plugged Clear exhaust system
Air heater defective Replace defective air heater
Air in fuel system Bleed air
Fuel pump defective Replace pump
Incorrect timing Adjust timing
Injection nozzles defective Repair or replace nozzles
Injection pump defective Replace pump
Compression low Overhaul engine
199

Engine stops after starting Alarm LED flashing Check alarm code and repair fault (see
Αλαρμ Λιστ ον παγε 72)
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
Engine does not develop Air cleaner or intake system clogged Clean air intake system; clean and refill
full power oil reservoir on oil bath air cleaner; or
replace dry air cleaner filter
Fuel tank vent clogged Unclog vent
Clogged fuel tank or fuel lines Clean fuel tank and fuel lines
Speed adjustment wrong Adjust speed
Insufficient fuel volume leaving filter(s) Check for dirty filter or air in system
Injection pump timing off Adjust timing
Nozzles defective Repair or replace nozzles
Delivery of fuel pump insufficient Repair pump
Worn injection pump plungers, delivery Repair or replace pump
valve defective, injection rate too low,
gum formations
Compression low or unbalanced Overhaul engine
Engine knocks heavily Wrong fuel Change fuel
Air in system Bleed fuel system
Fuel return line plugged Remove return line restriction
Injection nozzles fouled or opening Clean, repair or replace injection nozzles
pressure too low
Valve out of adjustment Adjust valves
Delivery valve spring broken Replace spring or repair injection pump
Injection pump not timed Retime injection pump
Compression too low Overhaul engine
Rod or main bearing worn Replace rod or main bearings
Engine speed too high Mis-adjusted speed screw Adjust speed screw
Control rod sticks Repair injection pump
Engine fails to stop when Fuel solenoid defective Replace solenoid
unit is Off
Injection pump defective Replace pump
200

Engine runs hot Coolant level is low Add coolant
Loose or worn water pump belt Replace belt
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 sensor Check oil line to oil pressure sensor to
oil pressure for a hot
see if it is blocked. Check oil pressure
engine is 117 kPa, 1.17
sensor. Replace if necessary
bar, 17 psi (low oil
pressure switch setting) Oil relief valve sticking Disassemble and clean oil pressure
regulator valve
Worn oil pump, camshaft, main or Repair engine
connecting rod bearings, loose oil gallery
plug
High oil consumption Oil leakage Check and eliminate possible causes at
cylinder head cover, oil lines, oil filter,
front timing cover or crankshaft seals
Clogged air cleaner system Clean air intake system; clean and refill
oil reservoir on oil bath air cleaner; or
replace dry air cleaner filter
Clogged crankcase breather Clean breather system
Damaged valve seals Replace seals on valve stem
Worn valve stem Replace valves
Poor compression Check and eliminate possible causes.
Repair as necessary
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
Air heater does not shut off Check preheat relay and preheat circuit
Controller defective Replace controller
201

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 air heater
Low compression Check and eliminate possible causes.
Repair as necessary
Timing incorrect Readjust timing
Injection pump defective Replace or repair pump
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,
Clogged air intake system Clean or replace air cleaner
emits thick black clouds of
smoke Restricted exhaust system Clean or replace
Oil being drawn in Check oil level in oil bath air filter
Excessive load Check drive system and engine oil
pressure
Injection pump not timed Check timing of injection pump
Opening pressure of nozzle is too low or Repair nozzle. Replace if necessary
needle sticks
Injection amount too great Have pump repaired
Poor compression Check and eliminate possible causes.
Repair as necessary
202
Electrical and SG+ Menu Flow Diagrams
Drawing Title Page

Wiring Diagram Genset SG+ (from December 2016) 205
Schematic Diagram Genset SG+ (from December 2016) 206
Wiring Diagram Genset SG+ (prior to December 2016) 207
Schematic Diagram Genset SG+ (prior to December 2016) 208
SG+ Menu Flow Diagram 209-210
203
Electrical and SG+ Menu Flow Diagrams
204
SGSM 3000, SGCM 3000 and SGCO 3000 Wiring Diagram (from December 2016) — Page 1 of 1
RELEASED 15/Dec/2016
2 01:33:45 GMT
205
SGSM 3000, SGCM 3000 and SGCO 3000 Schematic Diagram (from December 2016) — Page 1 of 1
RELEASED 15/Dec/2016 01:33:52 GMT
206
SGSM 3000, SGCM 3000 and SGCO 3000 Wiring Diagram (prior to December 2016)— Page 1 of 1
207
SGSM 3000, SGCM 3000 and SGCO 3000 Schematic Diagram (prior to December 2016) — Page 1 of 1
208
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 the ENTER key to scroll the cursor to the right. and number of alarms stored in memory (e.g. “1/2”).
• Press key to view additional alarms.
• 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.

• Press the ENTER key or the ESCAPE key to enter the Main Water Temp.
Menu. RPM
Coolant Level
• Press ENTER key to enter a menu from the Main Menu, or a MAIN MENU Oil Pressure Low Volatge Meas.
Oil Level Low Field Current
submenu from its parent menu. Submenus Running FREQ
Engine
• Press ESCAPE key to return to the Main Menu from a menu, or Generator
HRG GIZMO
Quard Closed
a menu from a submenu. DATA MENU DATA MENU
Unit Fuel Lev. Mean Bat. Voltage
Internal States Low Coolant Level Bat. Charger
Airheater Relay Event Code
To Scroll in a menu: Fuel Relay Pull
Fuel Relay Hold
• Press UP key to scroll up. State Speed Solenoid
RPM
• 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
System Setup Output Voltage
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
Force Speed and repeat test.
DSR Quad Relay Test
Submenus • Press or key to toggle between Speed

Current RPM Solenoid On and Off (High Speed and Low Speed).
Speed Solenoid Speed Solenoid: On • Press key to return to System Setup Submenu.
Tank Size
Fuel Sensor
Throttle Solenoid
Date/Time
ID No. • Press or key to scroll value.
Ser. No. • Press and keys at same time to save new
Engine Type Tank Size: XX setting and return to System Setup Submenu.
Generator • Press key to return to System Setup Submenu
Footnotes: Genset
HRG GIZMO
without saving new setting.
1When Delayed Cold Start is set to ON, controller shows “dELAy • Press or key to toggle between Fuel
/ AC” screen and alternator output remains off until engine Fuel Sensor: No
Sensor Yes and No.
• Press key to return to System Setup
temperature increases to 32 C (90 F). Submenu.
• Press or key to toggle between Throttle

2 “RESTART IN XX MIN.” screen indicates controller has Solenoid Yes and No.
Throttle Solenoid: No
stopped unit operation due to an alarm. Controller will attempt to • Press key to return to System Setup
Submenu.
restart unit in the time shown.
To/From To Next Page
Next Page
209
To/From CONTROLLER MENU GUIDE (Continued)
Previous Page
From Previous Page
• Press key to move cursor.
Year: XXXX • Press or key to scroll value.
Month: XX
• Press and keys at same time to save new
Date: XX
settings and return to Misc. Functions Menu.
Time: XX.XX
• Press key to return to Misc. Functions Menu without
saving new settings.
• Press or key to scroll value.

ID: XXXXXXXX setting and return to System Setup Submenu.
• Press key to return to System Setup Submenu
• Press or key to scroll value.

Ser. No: XXXXXXXXXX setting and return to System Setup Submenu.
• Press key to return to System Setup Submenu
• Press or key to toggle between options.

NOT DEFINED • Press and keys at same time to save new settings
YANMAR and return to Misc. Functions Menu.
PCM • Press key to return to Misc. Functions Menu without
saving new settings.

NOT DEFINED • Press and keys at same time to save new
M.ALTE setting and return to System Setup Submenu.
STAMFD • Press key to return to System Setup Submenu

NOT DEFINED
CLIP-ON • Press and keys at same time to save new
SIDE setting and return to System Setup Submenu.
CENTRE • Press key to return to System Setup Submenu
• Press or key to toggle between Celsius

and Fahrenheit.
Submenus
MISC. C/F Mode C/F Mode: Celsius • Press and keys at same time to save
new setting and return to Misc. Functions Menu.
MISC. FUNCTIONS MENU FUNCTIONS SW/HW Version
MENU Timers/Counters • Press key to return to Misc. Functions Menu
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
LOP Restart • Press key to display the Password screen.

DEL Coldstart • Enter password 0007 by pressing key to move cursor to the last
HM1 Threshold value and press or key to scroll the value to 7.
HM2 Threshold
ENG. Off Hours • Press key to display selection.
Factory Reset • Press key to move cursor to right (if needed).
CONFIGURATION MENU CONFIGURATION MENU
APU Connected
Output Voltage • Press or key to scroll or toggle value.
Fuel Sensor • Press and keys at same time to save new setting and return
Fuel Level to Configuration Menu.
Crank Restarts
Telematics • Press key to return to Configuration Menu without saving new
settings.
• Press key to view earlier events.

210 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.

Manual SG 3000 Thermo King

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Manual SG 3000 Thermo King

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Manual SG 3000 Thermo King

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SGSM 3000, SGCM

3000 & SGCO 3000

Copyright© 2007-2017 Thermo King Corp., Minneapolis, MN, USA.

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

We strictly adhere to a policy that promotes the recovery and limits

In addition, service personnel must be aware of Federal regulations

Event Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Flywheel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Field Coils, Stator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Figure 59: SGCM and SGSM Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Genset Model Features

S S S TK486VG Tier 2 EPA Diesel Engine

General Safety Precautions for Servicing Units (or Containers)

Welding of Units or Containers

Safety Do’s and Don’ts

Unit Nameplate Location

Figure 1: Model SGSM 3000 Decals

Unit Nameplate Location

Figure 2: Model SGCM 3000 Decals

Figure 3: Model SGCO 3000 Decals

Pre-Trip Every 3,000

4Based on EPA 40 CFR Part 89.

Electrical Control System

Controller Default Settings

Controller Default Settings

Metric Hardware Torque Charts

*HH = Hex Head, CL = Class.

Figure 4: SGSM 3000 Side Mount Generator

Figure 5: SGCM 3000 Center Mount Generator

Figure 6: SGCO 3000 Clip On Generator

EMI 3000 Package

SG+ Microprocessor Controller

Figure 7: SG+ Controller Versions G01 and G02

1. SG+ 4.1.5.00 or greater 140425 G01

Figure 8: SG+ Controller Display

Unit Protection Devices

Dual Voltage Option

Figure 9: EcoPower Decal

Fuel Level Sensor Option

1. Unit Mounting Arms 6. Unit Nameplate Location

Figure 10: SGSM 3000 — Unit Front View

1. Fuel Tank 6. Control Box Cover

Figure 11: SGCM 3000 — Unit Front View

1. Battery 7. Lower Mounting Screw and Washer (each side)

Figure 12: SGCO 3000 — Unit Front View

1. Air Inlet Adapter 8. Oil Fill and Dipstick

Figure 13: Powerpack (All Models) — Unit Front View

SG+ Controller Description

Figure 14: SG+ Controller Display

Controller Display Menus

Navigating Controller Menus

Figure 17: Controller Display

Figure 18: Menu Structure

Alarm List Menu

Message List Menu

Misc. Functions Menu

Event Log Menu

Figure 19: Standard Display and Main Menu

Pause Mode Displays