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Thermo King SGCO 3000 - User Manual

Thermo King SGCO 3000
144 pages
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SGCO 3000 (233) 2011
MAEG302598 - MAEG302830
TK 55076-4-MM (Rev. 0, 04/11)
Copyright© 2011 Thermo King Corp., Minneapolis, MN, USA.
Printed in USA.

Table of Contents

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Summary

SGCO 3000 Genset Addendum

Fuel Strainer Option Details

Notes about the fuel strainer option for specific units.

Genset Model Features

Genset Model Feature List

Table detailing standard (S) and optional (O) features for the SGCO model.

Safety Precautions

General Safety Practices

Basic safety rules for unit operation and handling.

Battery Safety Precautions

Covers hazards, precautions, and first aid for battery handling.

Electrical Safety Precautions

Covers general electrical hazards, high voltage, and low voltage safety.

Safety Precautions for Microprocessor Controllers

Controller Repair Safety

Procedures to prevent electrostatic discharge when servicing the controller.

Welding Safety Precautions

Safety measures to prevent damage during welding operations.

Safety Dos and Donts

Guidelines for safe operational practices.

Serial Number Locations

Component Serial Number Locations

Specifies where to find serial numbers for generator, engine, SGCO units, and controller.

Unit Decals

SGCO 3000 Decal Overview

Describes the location and purpose of various decals on the unit.

Service Guide

Maintenance Schedule and Tasks

Outlines inspection and service tasks based on operating hours.

Specifications

Engine Specifications

Details about the engine's model, fuel, oil, and performance.

Generator Specifications

Details about the generator's type, output, and RPM.

Electrical Control System Specifications

Details of the controller, voltage, and electrical components.

Controller Default Settings

Default configurations for various controller parameters.

Physical Specifications

Unit Dimensions and Weight

Physical characteristics including weight and overall size.

Metric Hardware Torque Charts

Torque Specifications for Metric Fasteners

Tables for torque values based on bolt size and class.

Unit Description, Features & Options

General Unit Description

Overview of the generator set's self-contained, diesel-powered nature.

EMI 3000 Package Details

Features of the extended maintenance interval package.

SG+ Microprocessor Controller

Functionality and control capabilities of the SG+ controller.

Unit Instruments and Gauges

Description of indicator LEDs and fuel gauge.

Unit Protection Devices

Safety features that monitor and shut down the unit.

EcoPower Option Features

Description of the fuel-saving EcoPower option.

Fuel Level Sensor Option

Functionality of the optional fuel level sensor.

Other Unit Options

Mentions header pin mounting as an additional option.

Controller Description

SG+ Controller Functionality

Details the controller's automatic operation and protection features.

Controller Interface and Navigation

Explains the display, keypad, and basic navigation.

Controller Miscellaneous Features

Lists controller inputs, outputs, and self-diagnostic capabilities.

Navigating the Controller Menus

Controller Display Menu Structure

Outlines the organization of menus like Data, Alarm, Commands.

Controller Keypad Navigation

Explains how to use keys (Enter, Esc, Up, Down, Alarm, Language) to navigate menus.

Menu Overview and Navigation Flow

Provides a visual representation of the menu hierarchy and navigation paths.

Main Controller Menus

Details of primary menus like Data, Alarm, Message, Commands, Misc. Functions, Configuration, Event Log.

Controller Display Modes

Describes Standard, Pause Mode, and Network Down displays.

Operating Instructions

Pretrip and Visual Inspections

Procedures for pre-operation checks.

Unit Start-up and Functional Testing

Steps for starting the unit and performing PTI.

Data Menu and Input;Output Status

How to view unit operating information through Data Menu submenus.

Alarm and Message List Management

Procedures for viewing and acknowledging alarms and messages.

Commands Menu Functions

Accessing tests and system setup.

Misc. Functions Menu Options

Accessing settings like C/F mode, SW/HW version.

Configuration Menu Settings

Setting parameters like hour meter thresholds.

Event Log Menu Access

Reviewing recorded events and fuel events.

Viewing SG+ Event Logs

How to interpret and use LogView software to view event logs.

Electrical Maintenance

Battery Service and Inspection

How to inspect, clean, and maintain the unit's battery.

Relay Functions and Locations

Describes fuel pull, hold, speed, start, and preheat relays.

Unit Wiring and Charging System

Inspection of wiring and the 12 Vdc charging system.

Air Heater and Oil Pressure Switch

Describes the air heater and testing the low oil pressure switch.

Oil Level Sensor Testing and Replacement

Procedures for testing, removing, installing, and bench testing the oil level sensor.

Coolant Temperature Sensor Testing

How to test the coolant temperature sensor and interpret readings.

Coolant Level Detector Sensor Testing

How to test the coolant level sensor and troubleshoot related messages.

Flywheel Sensor Testing

Procedures for testing the flywheel sensor's resistance and voltage output.

Engine Maintenance

EMI 3000 Maintenance Package

Description of the extended maintenance interval package.

Engine Lubrication System Overview

Information on the TK486 engine's lubrication system.

Engine Oil and Filter Maintenance

Procedures for changing engine oil and oil filters.

Low Oil Pressure Diagnosis

Guidance on diagnosing low oil pressure issues using a flow chart.

Crankcase Breather System

Description and inspection of the crankcase breather.

Air Cleaner System Maintenance

Information on the cyclonic dry air cleaner and air restriction indicator.

Engine Cooling System and ELC

Describes the cooling system and approved Extended Life Coolants.

Antifreeze Maintenance and Replacement

Procedures for checking and changing antifreeze.

Bleeding Air from Cooling System

Procedure to remove trapped air from the engine cooling system.

Engine Thermostat and Fuel System

Details on the engine thermostat and components of the fuel system.

Fuel Return Line Replacement and Bleeding

Procedures for replacing fuel lines and bleeding the fuel system.

Fuel Filter, Water, and Strainer Maintenance

Procedures for handling water in fuel, replacing filters, and cleaning the fuel strainer.

Engine Speed Adjustment Procedures

How to adjust engine speed for standard and EcoPower units.

Integral Fuel Solenoid System

Description and diagnosis of the fuel solenoid system.

Fuel Solenoid Replacement

Steps for replacing the integral fuel solenoid.

Trochoid Feed Pump Service

Description, leaks, and replacement of the trochoid feed pump.

Cold Start Device Testing and Replacement

How to check and replace the cold start device.

Engine Valve Clearance Adjustment

Procedure for checking and adjusting engine valve clearance.

Belt Tension Adjustment and Replacement

How to adjust belt tension and replace belts.

Injection Pump Service and Timing

Injection Pump Removal Procedure

Steps for removing the injection pump using specialized tools.

Injection Pump Installation Procedure

Steps for installing the injection pump, including timing gear alignment.

Injection Pump Timing Adjustment

Procedure for setting injection pump timing using angle stickers.

Alternator Operation and Diagnosis

Alternator General Description

Overview of the alternator system and its components.

Dual Voltage Alternator Configuration

Information on changing the generator output voltage.

Alternator Function and Control

Explains excitation, running control, battery charging, and overload shutdown.

Alternator Diagnosis and Troubleshooting

Steps for diagnosing alternator issues, including preliminary checks and specific tests.

Alternator Maintenance Procedures

General inspection, insulation, windings, housing, bearing, fan, and coupling checks.

Changing Generator Output Voltage

Procedures for rewiring the alternator to change output voltage from 460 Vac to 230 Vac.

Structural;Accessory Maintenance

Unit Inspection and Mounting Bolt Checks

Inspecting for damage and checking mounting bolt tightness.

Radiator Fan Location and Alignment

How to position the radiator fan for optimal performance.

SGCO 3000 Corner Clamp Installation

Procedure for installing the clip-on corner clamp unit.

SGCO 3000 Header Pin Installation

Procedure for installing the clip-on header pin unit.

Radiator Coil Cleaning

Procedure for cleaning the radiator coil.

Mechanical Diagnosis

Diagnosing Unit Conditions

Troubleshooting guide for common unit conditions and their remedies.

Electrical and SG+ Menu Flow Diagrams

Diagram Index

Lists available wiring, schematic, and menu flow diagrams.

Summary

SGCO 3000 Genset Addendum

Fuel Strainer Option Details

Notes about the fuel strainer option for specific units.

Genset Model Features

Genset Model Feature List

Table detailing standard (S) and optional (O) features for the SGCO model.

Safety Precautions

General Safety Practices

Basic safety rules for unit operation and handling.

Battery Safety Precautions

Covers hazards, precautions, and first aid for battery handling.

Electrical Safety Precautions

Covers general electrical hazards, high voltage, and low voltage safety.

Safety Precautions for Microprocessor Controllers

Controller Repair Safety

Procedures to prevent electrostatic discharge when servicing the controller.

Welding Safety Precautions

Safety measures to prevent damage during welding operations.

Safety Dos and Donts

Guidelines for safe operational practices.

Serial Number Locations

Component Serial Number Locations

Specifies where to find serial numbers for generator, engine, SGCO units, and controller.

Unit Decals

SGCO 3000 Decal Overview

Describes the location and purpose of various decals on the unit.

Service Guide

Maintenance Schedule and Tasks

Outlines inspection and service tasks based on operating hours.

Specifications

Engine Specifications

Details about the engine's model, fuel, oil, and performance.

Generator Specifications

Details about the generator's type, output, and RPM.

Electrical Control System Specifications

Details of the controller, voltage, and electrical components.

Controller Default Settings

Default configurations for various controller parameters.

Physical Specifications

Unit Dimensions and Weight

Physical characteristics including weight and overall size.

Metric Hardware Torque Charts

Torque Specifications for Metric Fasteners

Tables for torque values based on bolt size and class.

Unit Description, Features & Options

General Unit Description

Overview of the generator set's self-contained, diesel-powered nature.

EMI 3000 Package Details

Features of the extended maintenance interval package.

SG+ Microprocessor Controller

Functionality and control capabilities of the SG+ controller.

Unit Instruments and Gauges

Description of indicator LEDs and fuel gauge.

Unit Protection Devices

Safety features that monitor and shut down the unit.

EcoPower Option Features

Description of the fuel-saving EcoPower option.

Fuel Level Sensor Option

Functionality of the optional fuel level sensor.

Other Unit Options

Mentions header pin mounting as an additional option.

Controller Description

SG+ Controller Functionality

Details the controller's automatic operation and protection features.

Controller Interface and Navigation

Explains the display, keypad, and basic navigation.

Controller Miscellaneous Features

Lists controller inputs, outputs, and self-diagnostic capabilities.

Navigating the Controller Menus

Controller Display Menu Structure

Outlines the organization of menus like Data, Alarm, Commands.

Controller Keypad Navigation

Explains how to use keys (Enter, Esc, Up, Down, Alarm, Language) to navigate menus.

Menu Overview and Navigation Flow

Provides a visual representation of the menu hierarchy and navigation paths.

Main Controller Menus

Details of primary menus like Data, Alarm, Message, Commands, Misc. Functions, Configuration, Event Log.

Controller Display Modes

Describes Standard, Pause Mode, and Network Down displays.

Operating Instructions

Pretrip and Visual Inspections

Procedures for pre-operation checks.

Unit Start-up and Functional Testing

Steps for starting the unit and performing PTI.

Data Menu and Input;Output Status

How to view unit operating information through Data Menu submenus.

Alarm and Message List Management

Procedures for viewing and acknowledging alarms and messages.

Commands Menu Functions

Accessing tests and system setup.

Misc. Functions Menu Options

Accessing settings like C/F mode, SW/HW version.

Configuration Menu Settings

Setting parameters like hour meter thresholds.

Event Log Menu Access

Reviewing recorded events and fuel events.

Viewing SG+ Event Logs

How to interpret and use LogView software to view event logs.

Electrical Maintenance

Battery Service and Inspection

How to inspect, clean, and maintain the unit's battery.

Relay Functions and Locations

Describes fuel pull, hold, speed, start, and preheat relays.

Unit Wiring and Charging System

Inspection of wiring and the 12 Vdc charging system.

Air Heater and Oil Pressure Switch

Describes the air heater and testing the low oil pressure switch.

Oil Level Sensor Testing and Replacement

Procedures for testing, removing, installing, and bench testing the oil level sensor.

Coolant Temperature Sensor Testing

How to test the coolant temperature sensor and interpret readings.

Coolant Level Detector Sensor Testing

How to test the coolant level sensor and troubleshoot related messages.

Flywheel Sensor Testing

Procedures for testing the flywheel sensor's resistance and voltage output.

Engine Maintenance

EMI 3000 Maintenance Package

Description of the extended maintenance interval package.

Engine Lubrication System Overview

Information on the TK486 engine's lubrication system.

Engine Oil and Filter Maintenance

Procedures for changing engine oil and oil filters.

Low Oil Pressure Diagnosis

Guidance on diagnosing low oil pressure issues using a flow chart.

Crankcase Breather System

Description and inspection of the crankcase breather.

Air Cleaner System Maintenance

Information on the cyclonic dry air cleaner and air restriction indicator.

Engine Cooling System and ELC

Describes the cooling system and approved Extended Life Coolants.

Antifreeze Maintenance and Replacement

Procedures for checking and changing antifreeze.

Bleeding Air from Cooling System

Procedure to remove trapped air from the engine cooling system.

Engine Thermostat and Fuel System

Details on the engine thermostat and components of the fuel system.

Fuel Return Line Replacement and Bleeding

Procedures for replacing fuel lines and bleeding the fuel system.

Fuel Filter, Water, and Strainer Maintenance

Procedures for handling water in fuel, replacing filters, and cleaning the fuel strainer.

Engine Speed Adjustment Procedures

How to adjust engine speed for standard and EcoPower units.

Integral Fuel Solenoid System

Description and diagnosis of the fuel solenoid system.

Fuel Solenoid Replacement

Steps for replacing the integral fuel solenoid.

Trochoid Feed Pump Service

Description, leaks, and replacement of the trochoid feed pump.

Cold Start Device Testing and Replacement

How to check and replace the cold start device.

Engine Valve Clearance Adjustment

Procedure for checking and adjusting engine valve clearance.

Belt Tension Adjustment and Replacement

How to adjust belt tension and replace belts.

Injection Pump Service and Timing

Injection Pump Removal Procedure

Steps for removing the injection pump using specialized tools.

Injection Pump Installation Procedure

Steps for installing the injection pump, including timing gear alignment.

Injection Pump Timing Adjustment

Procedure for setting injection pump timing using angle stickers.

Alternator Operation and Diagnosis

Alternator General Description

Overview of the alternator system and its components.

Dual Voltage Alternator Configuration

Information on changing the generator output voltage.

Alternator Function and Control

Explains excitation, running control, battery charging, and overload shutdown.

Alternator Diagnosis and Troubleshooting

Steps for diagnosing alternator issues, including preliminary checks and specific tests.

Alternator Maintenance Procedures

General inspection, insulation, windings, housing, bearing, fan, and coupling checks.

Changing Generator Output Voltage

Procedures for rewiring the alternator to change output voltage from 460 Vac to 230 Vac.

Structural;Accessory Maintenance

Unit Inspection and Mounting Bolt Checks

Inspecting for damage and checking mounting bolt tightness.

Radiator Fan Location and Alignment

How to position the radiator fan for optimal performance.

SGCO 3000 Corner Clamp Installation

Procedure for installing the clip-on corner clamp unit.

SGCO 3000 Header Pin Installation

Procedure for installing the clip-on header pin unit.

Radiator Coil Cleaning

Procedure for cleaning the radiator coil.

Mechanical Diagnosis

Diagnosing Unit Conditions

Troubleshooting guide for common unit conditions and their remedies.

Electrical and SG+ Menu Flow Diagrams

Diagram Index

Lists available wiring, schematic, and menu flow diagrams.

Thermo King SGCO 3000 Specifications

General IconGeneral
BrandThermo King
ModelSGCO 3000
CategoryPortable Generator
LanguageEnglish

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