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SG 3500 Series
Thermo King SG 3500 Series User Manual
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April
2022
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SG
3500
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Maintenance
Manual
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Table of Contents
P P H H O O T T O O S S , , I I L L L L U U S S T T R R a a T T I I O O N N S S , , a a N N D D M M E E a a S S U U R R E E M M E E N N T T S
2
Table of Contents
4
S S T T R R U U C C T T U U R R a a L L / / a a C C C C E E S S S S O O R R y y M M a a I I N N T T E E N N a a N N C C E
6
Danger, Warning, Caution, and Notice
9
General Practices
9
Electrical Hazards
10
High Voltage
10
Low Voltage
11
Battery Installation and Cable Routing
11
Battery Removal
12
Electrostatic Discharge Precautions
12
Electrostatic Discharge and the Controller
12
Controller / Microprocessor Service Precautions
13
Welding on Refrigeration Units or Containers
13
High Pressure Fuel Hazards
13
First Aid
13
Generator
15
Electrical Control System
15
Engine
16
Belt Tension
17
SG 3500 Series Unit Weight
17
General Description
19
Emi 3000
20
Microprocessor Controller
21
Unit Protection Devices
21
Voltage Option
21
SGCO 3500 Front View
22
SGCO 3500 Front View (Covers Removed)
23
SGCO 3500 Control Box (External)
24
SGCO 3500 Pins and Clamps (Option)
24
SGCO 3500 Telematics Fuel Sensor
25
SGCO 3500 Customer Asset ID Decal
25
SGCO 3500 Mechanical Fuel Gauge (Option)
26
Control Box SGCO Inside View
27
SGUM 3500 Front View
28
SGUM 3500 Front View (Covers Removed)
29
SGUM 3500 Arms Mounting
30
SGUM 3500 Telematics Fuel Sensor
30
SGCO 3500 Control Box (External)
31
Control Box SGUM Inside View
32
SGUM 3500 Installation Decal
33
Controller Description
35
Controller Overview
35
Miscellaneous Controller Features
35
Navigating the Controller Menus
36
Hot Keys
36
Directional and Confirmation Keys
36
Operating Instructions
37
Pretrip Inspection
37
Controller Interaction and Display
38
Unit Power Toggle Switch
38
Controller Display
38
Flashloading the Controller
39
Controller Display Menu
41
Status
41
Engine
41
Generator
41
Alarms
42
Active ECU Dtc's Menu
42
Event Log
42
Serial Port Menu
42
Genset Data Menu and Config Details
42
PLC Instrumentation
42
About
42
Genset Start-Up and Initial Runtime
44
Unit Start Sequence
44
Countdown Timer
44
Buzzer
44
Engine Start Sequence
44
Engine Restart Sequence
44
Post Start
45
Pre and Post Heat
45
Engine Operation and Speed Control
45
Engine Stall
46
Unit Alarm Monitoring
46
Genset Service and Pre-Trip Testing
46
Pre-Trip Testing
46
Manual Speed Control
46
Service Mode
46
Event Logging
47
Alarms List
47
Warning Alarms
47
Shutdown Alarms
48
Alarm Codes
48
Battery
50
Genset Battery Charger Specification
50
I/O Descriptions
50
AC Input
50
Battery Charge Current
50
Battery Charge Voltage
50
Battery Charger
51
Battery Charge
51
Microprocessor Controller
52
Fuses
52
Unit Wiring
53
Wire Harness Routing
53
Engine Oil Sensors
53
Engine Low Oil Pressure Switch
53
Engine Oil Level Sensor
54
Emi 3000
55
Engine Lubrication System
55
Engine Oil Change
55
Oil Filter Change
56
Low Oil Pressure
56
Engine Cooling System
58
Extended Life Coolant (ELC)
58
Antifreeze Maintenance Procedure
59
Checking the Antifreeze
59
Changing the Antifreeze
59
Bleeding Air from the Cooling System
59
Engine Thermostat
60
Coolant Level Switch
60
Testing the Coolant Level Switch
60
Checking the Float
60
Replacing the Coolant Level Switch
60
Engine Fuel System
62
Operation
62
Fuel Line Routing
62
Fuel System Fittings
62
Maintenance
62
Fuel Return Line Replacement
63
Bleeding the Fuel System
64
SG 3500 Series
64
Draining Water from Fuel Tank
64
Fuel Filter/Water Separator
64
Fuel Filter and Water Separator Service
64
Filter Icon Identification
65
Injection Pump and Engine Speed Control
65
Injection Pump Removal
66
Injection Pump Reinstallation
67
Download Procedure for Injection Pump Replacement
68
Engine Valve Clearance Adjustment
84
Crankcase Breather
86
EMI 3000 Air Cleaner
87
Belts
87
Water Pump Belt
88
Radiator and Fan Service
89
Radiator
89
Radiator Cooling Fan
90
Fan and Shroud Adjustment
90
Yanmar Diagnostic Trouble Codes (DTC) and Associated Thermo King Alarm Codes
91
Clearing Yanmar DTC Codes and Associated Thermo King Alarm Codes
91
Connecting and Using the Yanmar Engine Diagnostic Tool
91
Software Download for Flash to Replacement ECU
95
Uploading Information to Yanmar
99
Updating ECU Software from Yanmar Core Database
100
ECU Recovery/Failures During Flash Load Procedures
105
ECU Programming or ECU Updating of Software Failure During Flash
105
Communication Interruption During Flashing Process
108
Abnormality Occurrence During Flashing Process
108
Accessing and Downloading YSAD Troubleshooting Manual
109
Megohmmeter
112
Maintenance Procedures
112
General Inspection
112
Insulation
112
Field Coils, Stator Windings
112
Generator Housing
112
Generator Bearing
112
Impeller Fan
113
Coupling
113
General Description
115
Alternator Function
116
Starting Excitation
116
Running Excitation and Control
116
Overload
116
Overload Shutdown
116
Alternator Diagnosis
117
Preliminary Checks
117
Test Instruments
117
Alternator Troubleshooting
117
Test 1 - Determine if Problem Is with the DSR or the Alternator
118
Test 2 - Alternator Exciter Field Testing
118
Test 3 - Alternator Stator Testing
118
Test 4- Exciter and Diode Test
120
Alternator Replacement
123
Alternator Removal
123
Alternator Installation
124
Unit Inspection
126
Mounting Bolts
126
SGCO Clip-On Corner Clamp Unit Installation
127
SGCO Clip-On Corner Header Pin Unit Installation
130
Telematics General Description
131
Telematics Component Locations
132
Telematics Module Cycle Identification (LED Flash)
132
Telematics Diagnostic Information
135
Telematics Fuel Level Sensor (Optional)
138
Telematics Antenna
140
Pairing Telematics Module to SG Unit
142
Install of Telematics in the SGUM-3500
149
M M E E C C H H a a N N I I C C a a L L D D I I a a G G N N O O S S I I S
152
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Thermo King SG 3500 Series Specifications
General
Brand
Thermo King
Model
SG 3500 Series
Category
Laboratory Equipment
Language
English
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