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Thermo King SG 3500 Series User Manual

Thermo King SG 3500 Series
164 pages
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Revision A
April 2022
TTKK 6611991144--44--MMMM--EENN
Container Edition
SG 3500 Series
Maintenance Manual

Table of Contents

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Thermo King SG 3500 Series Specifications

General IconGeneral
BrandThermo King
ModelSG 3500 Series
CategoryLaboratory Equipment
LanguageEnglish

Summary

Safety Precautions

Understanding Safety Advisories and Practices

Defines safety advisories and outlines general practices like PPE.

Electrical and Component Safety

Covers high/low voltage risks, battery handling, and ESD prevention.

System Hazards and First Aid

Warns about fuel pressure, welding hazards, and provides first aid instructions.

Specifications

Generator Specifications

Technical specifications for the generator unit.

Electrical System Specifications

Details on controls, voltage, battery, fuses, and components.

Engine Specifications

Engine model, fuel, oil capacity, viscosity, RPM, and coolant details.

Belt Tension Specifications

Guidelines and specifications for checking and adjusting belt tension.

Maintenance Inspection Schedule

Periodic Maintenance Tasks

Outlines maintenance tasks for microprocessor, engine, electrical, and structural systems.

Unit Description

General Unit Overview

Overview of Thermo King generator sets, their components, and operation.

EMI 3000 Package Details

Details the EMI 3000 Extended Maintenance Interval package and its components.

Controller and Operating Instructions

Controller Overview and Features

Describes the controller interface, its features, and navigation.

Operating Procedures and Inspections

Details pretrip inspection, visual checks, and safety warnings during operation.

Controller Software Management

Step-by-step guide for flashloading software to the controller.

Controller Menu Navigation and Diagnostics

Explains controller menus, alarms, DTCs, and event logs.

Genset Start-up and Operation

Covers genset start-up, runtime, engine speed control, and stall procedures.

Genset Service and Testing

Outlines pre-trip testing, manual speed control, and service mode functions.

Engine Maintenance

EMI 3000 Package and Lubrication

Details EMI 3000 components, lubrication system, and oil pump types.

Engine Oil and Filter Service

Step-by-step instructions for changing engine oil and filter.

Low Oil Pressure Diagnosis

Discusses factors affecting low oil pressure and diagnostic methods.

Cooling System and Antifreeze Management

Covers cooling system, ELC, and antifreeze procedures.

Fuel System Maintenance and Bleeding

Overview of fuel system, fittings, line replacement, and bleeding procedures.

Injection Pump Service

Detailed steps for removing, reinstalling, and downloading procedures for the injection pump.

Valve Clearance and Crankcase Breather

Covers engine valve clearance adjustment and crankcase breather inspection.

Belt and Fan Maintenance

Guides on belt tension, water pump belt service, and fan/shroud adjustment.

Yanmar YSAD Diagnostic Engine Service

YSAD Tool Overview and Setup

Overview of the YSAD tool, DTC correlation, and connection procedures.

ECU Software Management

Procedures for software download, ECU replacement, and updates.

ECU Recovery Procedures

Procedures for recovering ECU from failures during flash load.

Alternator Operation and Diagnosis

Alternator Maintenance and Inspection

Explains megohmmeter use, general inspection, and component checks.

Alternator Troubleshooting and Testing

Lists instruments, preliminary checks, and diagnostic tests for the alternator.

Alternator Removal and Installation

Steps for removing and installing the alternator from the engine.

Structural/Accessory Maintenance

Unit Inspection and Mounting Bolt Torque

Inspects unit for damage and tightens mounting bolts with torque specs.

SGCO Unit Mounting Procedures

Step-by-step guide for installing SGCO clip-on clamp and header pin units.

Telematics Information

Telematics System Overview and Components

Overview of the telematics system and component locations.

Telematics Module Diagnostics

Explains LED flashing sequences and diagnostic procedures for the telematics module.

Telematics Fuel Level Sensor and Antenna

Troubleshooting and maintenance for fuel level sensor and antenna.

Pairing Telematics Module to SG Unit

Instructions for installing the Globe Tracker App for pairing the telematics module.

Mechanical Diagnosis

Diagnosing Unit Mechanical Conditions

Table listing unit conditions, causes, and remedies for mechanical issues.

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