Maintenance Manual

SGCO 2000-151
for Maersk Sealand
TK 51291-4-MM (Rev. 1, 7/01)

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 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 concern-

ing 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

Unit Protection Devices 3-2

Introduction iii
Pretrip Inspection 3-2
About This Manual iii Visual Inspection 3-2
Other Reference Manuals iii Functional Inspection 3-3
Genset Model Features iv Starting the Unit 3-3
After Start Inspection 3-4
Safety Precautions v
Microprocessor Controller 4-1
General Practices v
Battery Hazards v µP-G Microprocessor Description 4-1
Electrical Hazards v Status Indicator LEDs 4-2
General Safety Practices for Servicing Units Controller Display Menus 4-2
(or Containers) Equipped with a Navigating the Controller Menu 4-2
Microprocessor Controller vi Software Version Display 4-3
Safety Do’s and Don’ts vii Pause Mode Displays 4-3
Serial Number Locations viii Alarm List Menu 4-3
Unit Decals viii View Menu (from Main Menu) 4-3
Pretrip Menu (from Main Menu) 4-3
Test Menu (from Main Menu) 4-3
Service Guide ix
Guard Menu (from Main Menu) 4-3
Program Menu (from Main Menu) 4-3
Menu Display Definitions 4-3
Specifications 1-1
Alarm List Menu 4-4
Engine 1-1 Alarm Types 4-4
Generator 1-2 Displaying and Clearing Alarm Codes 4-5
Electrical Control System 1-2 Alarm List 4-5
Electrical Components 1-2 View Menu 4-6
Physical Specifications 1-3 Pretrip Menu 4-6
Metric Hardware Torque Charts 1-4 Test Menu 4-7
Guard Menu 4-8
Navigating Menu Guard Screens 4-8
Unit Description 2-1
Setting the User Hourmeter Thresholds
General Description 2-1 and User Hours 4-9
Unit Illustrations 2-2 Setting Unit Restarts 4-9
Unit Front View 2-2 Setting Low Oil Pressure Restart 4-10
Powerpack — Front View 2-3 Setting Delayed Cold Start 4-10
Selecting Engine Type 4-10
Selecting Regulator Type 4-10
Operating Instructions 3-1
Voltmeter Calibration 4-10
Unit Controls 3-1 Program Menu 4-11
Unit Instruments 3-1 µP-G Alarm Codes, Type and Description 4-12 to 4-17

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ii 05A71*"B*!"4)14)8

Electrical Maintenance 5-1 Alternator Operation and Diagnosis 7-1

Battery 5-1 General Description 7-1
Unit Wiring 5-1 Alternator Function 7-2
Fuse Link 5-1 Starting Excitation 7-2
Fuse 5-1 Running Excitation and Control 7-2
12 Vdc Charging System 5-1 Overload 7-2
Air Heater 5-2 Overload Shutdown 7-2
Engine Low Oil Pressure Switch 5-2 Alternator Diagnosis 7-3
Oil Pressure Sensor 5-2 Preliminary Checks 7-3
Oil Level Switch 5-3 Test Instruments 7-3
Coolant Temperature Sensor 5-4 Generator Diagnosis Procedure 7-4
Coolant Level Detector 5-4 Alternator Tests 7-10
Flywheel Sensor 5-4 AVR Replacement and Adjustment 7-12
Field, Preheat, Start and Run Relays 5-5 Maintenance Procedures 7-13
Buzzer 5-5
Structural/Accessory Maintenance 8-1
Engine Maintenance 6-1
Unit Inspection 8-1
Engine Lubrication System 6-1
Mounting Bolts 8-1
Engine Oil Change 6-1
Radiator Coil 8-1
Oil Filter Change 6-1
Radiator Fan Location 8-1
Crankcase Breather 6-1
Clip-on Header Pin Unit Installation 8-2
Engine Air Cleaner 6-2
Engine Cooling System 6-2
Antifreeze Maintenance Procedure 6-2 Mechanical Diagnosis 9-1
Checking the Antifreeze 6-3
Changing the Antifreeze 6-3
Bleeding Air from the Cooling System 6-4 Electrical and µP-G Menu Flow Diagrams 10-1
Engine Thermostat 6-4
SGCO 2000-151 Wiring Diagram 10-3
Engine Fuel System 6-5
SGCO 2000-151 Wiring Schematic 10-4
Maintenance 6-5
µP-G Menu Flow Diagram 10-5
Bleeding the Fuel System 6-6
Water in the Fuel System 6-6
Single Element Fuel Filter/Water
Separator Replacement 6-6
Engine Speed Adjustment 6-7
Adjustment Procedure 6-7
Integral Fuel Solenoid 6-7
Diagnosing the Integral Fuel Solenoid System 6-7
Fuel Solenoid Replacement 6-9
Injection Pump Service and Timing 6-9
Injection Pump Removal 6-9
Injection Pump Installation 6-10
Injection Pump Timing 6-11
Adjusting Engine Valve Clearance 6-12
Belt Tension Adjustment and Belt Replacement 6-13

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 Introduction

About This Manual Other Reference Manuals

The information in this manual is provided to assist owners, For detailed descriptions of Thermo King engines, see the
operators and service people in the proper upkeep and mainte- appropriate overhaul manual. For further information refer to:
nance of Thermo King units. The maintenance information in
this manual covers model: Parts Manual
SGCO 2000-151 Parts Manual TK 51292
SGCO Model System Number
SGCO 2000-151 718151 Diagnosis and Overhaul Manuals
TK 482 and TK 486 Engine Overhaul Manual TK 50136
Electrostatic Discharge (ESD) Training Guide TK 40282
Tool Catalog TK 5955

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iv Genset Model Features F4)%"?@D)&"4*

SGCO Genset Model Features

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MODEL

FEATURES
S = Standard

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 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, pul-
leys and belts when the unit is running. If it is necessary to
run the alternator with the end cover removed, be very
careful with tools or meters to avoid contacting the rotor.
3. Be sure all mounting bolts are tight and are 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. Under
certain conditions diesel exhaust can become very danger-
ous.
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 that
causes the gas bubbling we see through the filler hole. The
bubbling gases are hydrogen and oxygen, and they are
EXPLOSIVE. If a means of ignition is present during this
gassing action, an explosion could occur. A defective battery
may suddenly explode even while standing idle. Added to this
danger, consider a 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. When charging a battery, do not remove the vent caps.
3. When disconnecting or connecting the generator set bat-
tery, make sure the On-Off switch is in the OFF position
to 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 for at least 15 minutes while holding the eyelids
open. Get prompt medical attention.
• SKIN: Remove contaminated clothing. Wash thoroughly
with soap and water. Get medical attention if irritation
persists.
Electrical Hazards
High Voltage
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.
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vi General Safety Precautions for Servicing Controllers
Precautions
1. Be certain the generator set On/Off switch is turned OFF
before connecting or disconnecting a power plug to the
generator set receptacle. Never attempt to stop a refriger-
ation unit by disconnecting the power plug from an oper-
ating generator set.
2. Be certain a unit power plug is clean and dry before con-
necting it to the generator set receptacle.
3. Use tools with insulated handles that are in good condi-
tion. 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 genera-
tor set.
5. Do not make any rapid moves when working on high volt-
age 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 genera-
tor 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 assis-
tance if available.
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 wood-
en 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 vic-
tim’s body.
<5B1)$*>%1D5@)&"48
After separating the victim from 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 assis-
tance.
Low Voltage
Control circuits are low voltage (12 Vdc). This voltage poten-
tial is not considered dangerous, but the large amount of cur-
rent available (over 30 amperes) can cause severe burns if
shorted to ground.
Do not wear jewelry, watch or rings. These items can short
out electrical circuits and cause severe burns to the wearer.
1. 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.
2. 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 µP-G microprocessor controller and relat-
ed components. If these precautionary measures are not fol-
lowed, the risk of significant damage to the electronic compo-
nents of the unit is possible.
The primary risk potential results from the failure to wear
adequate electrostatic discharge preventive equipment when
handling and servicing the controller. The second cause
results from electric welding on the unit and/or container chas-
sis without taking precautionary steps.
Controller Repair
When servicing the controller, it is necessary to ensure that
electrostatic discharges are avoided. Potential differences con-
siderably 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.
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<5B1)$*>%1D5@)&"48
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. Do wear a static discharge wrist strap (TK P/N 204-622)
with the lead end connected to the controller's ground ter-
minal. These straps are available at most electronic equip-
ment distributors. DO NOT wear these straps with power
applied to the unit.
5. Avoid contacting the electronic components on the circuit
boards of the unit being serviced.
6. Leave the circuit boards in their static proof packing mate-
rials 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 restor-
ing power.
Welding of Units or Containers
Whenever electric welding is to be performed on any portion
of the generator set, container or container chassis with the
generator set attached, it is necessary to ensure that welding
currents are NOT allowed to flow through the electronic cir-
cuits of the unit. 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 quick-disconnect wire harnesses from the
back of the controller.
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 proce-
dures. Keep ground return electrode as close to the area to
be welded as practical. This will reduce the likelihood of
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 vii
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 gener-
ator set while it is running.
• Do keep your hands away from moving parts.
• Do remember that horseplay is for horses! It has no place
around machinery.
• Do disconnect the battery before starting work on a generator
set.
• Do use screwdrivers, pliers, diagonal pliers. etc. with insulat-
ed handles.
• Do remember to keep one hand in your pocket if it is neces-
sary to work on live circuits. This will prevent passage of
electricity into one hand, across the heart, and out the other
hand.
• 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 genera-
tor or electrical equipment.
• Don’t remove guards or protective devices.
• Don’t wear loose clothing or jewelry in the vicinity of mov-
ing 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 equip-
ment. Use rubber insulated mats placed on dry wood plat-
forms.
• 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.
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viii Serial Number Locations <5B1)$*>%1D5@)&"48

Serial Number Locations Unit Decals

Unit: Nameplate attached to the unit battery box beside the
engine compartment.
Generator: Nameplate attached to the generator housing.
Engine: Stamped on the engine block above the oil filter.
µP-G Controller: Nameplate on back of controller.
Serial number decals, installation decals and warning decals
appear on all Thermo King generator sets. These decals pro-
vide information that may be needed to service or repair the
unit. Service technicians should read and follow the instruc-
tions on all warning decals.

:4&)*9521#75)1*d"D5)&"4

This ELC decal tag appears

on the coolant expansion
tank to identify units with
an EMI 3000 package and
Extended Life Coolant.

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 Service Guide

Every Every
2501 3,0002
Pre-Trip Hours Hours Inspect/Service These Items
Electrical
• Perform a controller Pretrip (PrE) check.
• • • Inspect battery terminals and electrolyte level.
• Inspect wire harness for damaged wires or connections.
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.
• • Remove and clean air cleaner (and pre-cleaner). Install new oil in oil bath air cleaner
assembly. Check air cleaner hose and breather hose for damage.
• • Remove and clean crankcase breather.
• • Drain water from fuel tank and check vent. Clean fuel strainer in transfer pump inlet.
• • Check and adjust engine speed at full load (60 Hz alternator output).
•3 Change engine oil (hot) and oil filter.
•3 Change fuel filter/water separator.
• Check condition of engine mounts.
— Change ELC (red) engine coolant every 5 years or 12,000 hours. Maintain anti-freeze pro-
tection at -34 C (-30 F).
Structural
• • • Visually inspect unit for fluid leaks (coolant and oil).
• • • Visually inspect unit for damaged, loose or broken parts.
• • Clean entire unit including radiator coil.
• Check all unit, fuel tank, engine and alternator mounting bolts, brackets, lines, hoses, etc.

1Inspect/serviceevery 250 operating hours in extreme (dirt yard) operating conditions.

23,000hours or 2 years, whichever occurs first.
3More frequent intervals may be necessary in extreme operating conditions.

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1 Specifications

Engine
Diesel Engine Model TK 486
Fuel Type No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Oil Capacity: Crankcase: 12.3 litre (13 qt)
Crankcase and Oil Filter: 13.3 litre (14 qt)
Fill to full mark on dipstick
Oil: Type: Multi-grade Petroleum Oil (Standard)
Synthetic Oil (Optional) after first 500 hours
Classification: API Type CG-4, CH-4 or better
ACEA Type E2, E3 or better
Oil Viscosity: -30 C to +0 C (-22 F to +32 F) SAE 5W-30
-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 +50 C (+5 F to +122 F) SAE 15W-40
Engine Oil Pressure 100 to 380 kPa, 1.0 to 3.8 bar, 15 to 55 psi
Engine RPM Full Load (60 Hz Alternator) 1800 +/- 10 RPM (High Speed)
No Load 1890 +/- 10 RPM (High Speed)
Valve Clearance: 0.15 to 0.25 mm (0.006 to 0.010 in.) on intake valve
0.15 to 0.25 mm (0.006 to 0.010 in.) on intake valve
Valve Setting Temperature 21 C (70 F) (Room temperature)
Timing Injection Pump 12o +/- 1o BTDC (timed on No. 1 cylinder)
Low Oil Pressure Switch (Normally Closed): 117 +/- 21 kPa, 1.17 +/- 0.21 bar, 17 +/- 3 psi
High Coolant Temperature Switch* Sensor*
Engine Thermostat 82 C (180 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

*µP-G controller uses a sensor to provide engine high coolant temperature protection.

SGCO 2000-151, July 2001

1-2 Generator Specifications

Generator
Type 460/230 Vac, 3 Phase, 60 Hz
Output Power 15 KW
Kilovolt-Amperes 18.75 kVA
RPM 1800
Automatic Voltage Regulator: Power Input 170 -250 Vac, 50-60 Hz, 1 Phase, 2-wire
Maximum Power Output: Voltage 90 Vdc at 207 Vac input
Maximum Power Output: Current Continuous 4 Amp dc; transient 6 Amp dc for 10 seconds

Electrical Control System

Controls: µP-G microprocessor controller
Voltage 12.5 V dc (nominal)
Battery 12 volt, group C31, 625 Cold Cranking Amps at -18 C (0 F)
Battery Charging 12 Vdc solid-state battery charger with 20 ampere output
Fusible Link 18 gauge wire (50 to 55 amperes)
Fuse, Battery Charger 25 amp

Electrical Components
NOTE: Disconnect components from unit circuit
to check resistance.
Current Draw (Amperes) Resistance
at 12.5 V dc (Ohms)
Air Heater: One 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
Starter Motor 250 to 375 (cranking)
80 no load (bench test)

SGCO 2000-151, July 2001

Specifications Physical Specifications 1-3

Physical Specifications
Weight (net): SGCO 2000-151 843 Kg (1860 lbs) including oil, coolant, battery and 473 liter (125
gal.) fuel tank (excluding fuel)
Unit Dimensions:

SGCO 2000-151, July 2001

1-4 Metric Hardware Torque Charts 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 M14 M16 M18 M22
and 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.

SGCO 2000-151, July 2001

2 Unit Description

CAUTION: DO NOT attempt to operate or maintain
the generator until you have familiarized yourself
completely with the equipment by reading the
instructions in this manual.
Stop the engine before connecting or disconnecting instru-
ments or power cables. Stop the machine immediately if there
is any doubt regarding an electrical operating condition or
maintenance procedure. Take no unnecessary chances. Lethal
potentials may suddenly develop on output terminals whenever
a unit is being serviced with the engine running.

General Description EMI 3000 Package

The genset includes an EMI 3000 Extended Maintenance
Thermo King SGCO 2000-151 generator set is a self-con- Interval package, allowing standard genset maintenance inter-
tained, fully-automatic, clip-on, diesel powered unit that sup- vals to be extended to 3000 hours. However, units do require
plies 460 Volt ac electrical power for container refrigeration regular inspection in accordance with Thermo King pretrip
units. inspection and maintenance recommendations (see Service
Enclosed within the unit frame are the engine, dual volt- Guide in the introduction of this manual).
age alternator, generator battery compartment, battery charger,
regulator and control panel. An exclusive TK 486, direct
injection diesel engine drives a brushless alternator 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. The frame
also supports an integral, 473 liter (125 gal.) fuel tank.
The alternator is a brushless, rotating field ac generator.
An automatic voltage regulator provides dc power for the
field. At 1800 rpm, the alternator supplies 460 Vac, 3 phase, 3
wire, 60 Hz power.
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 oper-
ation and maintenance of the equipment. Avoid contacting
terminals, binding posts and other exposed connections. Use
extra care when the control box is open.

SGCO 2000-151, July 2001

2-2 Illustrations Unit Description

1 11

10

8
4

5 7

Unit Front View

1. Battery
2. Unit Nameplate Location
3. Fuel Tank
4. Alternator and Engine Compartment Access Doors
5. Coolant Expansion Tank Location
6. 460 Vac Power Receptacle Location
7. Lower Mounting Screw and Washer (each side)
8. Fuel Gauge (each side)
9. Control Box Location
10. Fuel Tank Fill Neck and Cap (each side)
11. Header Pin Mounting Flange (each side)

SGCO 2000-151, July 2001

Unit Description Illustrations 2-3

14

1 13

12
4

5 11

6 10

7 9

Powerpack — Front View

1. Air Inlet Adapter
2. Alternator
3. Starter
4. Timing Mark Location
5. Flywheel Sensor
6. Oil Filter
7. Low Oil Pressure Switch
8. Oil Pressure Sensor
9. Oil Fill and Dipstick
10. Oil Level Sensor
11. Oil Drain Hose
12. Engine Speed Adjustment Screw
13. Water Pump Pulley
14. Water Temperature Sensor

SGCO 2000-151, July 2001

3 Operating Instructions

Unit Controls Unit Instruments

1. UNIT ON/OFF SWITCH. 1. INDICATOR LEDs.
a. ON position. Electrical control system energizes for a. UNIT ON LED: A green Unit On indicator LED
unit operation. FLASHES while the air heater and starter motor are
b. OFF position. Electrical control system including the energized. The Unit On light then remains ON to
fuel solenoid de-energizes to stop the engine. The indicate normal unit operation.
unit will not operate. b. ALARM LED: A red ALARM LED turns ON when a
2. µP-G CONTROLLER. The controller controls and moni- shutdown condition has occurred.
tors unit operation, records system faults and performs an 2. FUEL GAUGE. A gauge mounted in the fuel tank indi-
automatic pre-trip check. The controller monitors all unit cates the level of diesel fuel in the tank.
protection shutdown functions and the exciter system. If a
low oil level, low oil pressure, high water temperature or
alternator overload condition exists for more than 30 sec-
onds, the controller shuts down unit operation. The mod-
ule also delays excitation power supply for 15 seconds
after unit start-up.
a. DISPLAY. A digital display on the front panel
shows operating information including output volt-
age, current test state during a Pretrip test and the
controller menu. An alarm icon appears to signal an
alarm condition.
b. ALARM KEY: Press this key to view the fault code
readout in the digital display.
c. ENTER KEY: Press this key to enter or execute con-
troller menu tasks or commands.
d. DOWN ARROW KEY: Press this key to scroll
DOWN through the menu display.
e. UP ARROW KEY: Press this key to scroll UP
through the menu display.
f. SELECT KEY: Press this key to enter and display
screens from the controller menu.

Control Box Cover

1. Display
2. Mode Description
3. Keypad
4. Unit On/Off Switch
5. Unit On Light
6. Alarm Light
SGCO 2000-151, July 2001
3-2 Unit Protection Devices
Unit Protection Devices
WARNING: With the Unit On/Off switch in the ON
position, the unit may start at any time without warn-
ing.
Units equipped with a µP-G controller feature
AUTO-RESTART. The controller will make up to
three attempts every 20 minutes to restart the unit
after a shutdown has occurred. This restart mode
continues until the unit has been successfully
restarted or until a code 61 is generated due to low
battery. Protection shutdown devices that cause an
AUTO-RESTART shutdown condition include:
• Low Oil Pressure
• Low Oil Level
• High Water Temperature
• Alternator Output Overload
1. LOW OIL PRESSURE SWITCH. Engine oil pressure
should rise immediately on starting. If oil pressure drops
below 117 +/- 21 kPa, 1.17 +/- 0.21 bar, 17 ± 3 psig for
more than 30 seconds, the controller will stop the engine.
The controller then turns ON the Alarm light and activates
the Alarm icon in the display.
2. OIL LEVEL SENSOR. An oil level switch closes if the
oil drops below a level that is approximately 8 qt (7.6
liters) low. If the switch stays closed for more than 30
seconds, the controller will stop the engine. The con-
troller then turns ON the Alarm light and activates the
Alarm icon in the display.
3. WATER TEMPERATURE SENSOR. If the engine
coolant temperature rises to 215 to 225 F (101.7 to 107.2
C) for more than 30 seconds, the controller will stop the
engine. The controller also turns ON the Alarm light and
activates the Alarm icon in the display. The unit will
restart when the coolant temperature drops to 88 C (190 F).
4. CURRENT LIMITER. The current limiter is a fusible
link acting as a connection between the battery and the 12
Vdc unit controls. At approximately 50 to 55 amps, the
fusible link will melt, cutting power to the fuel heater, air
heater and the rest of the unit.
5. FUSE. A 25 ampere fuse protects the battery charger cir-
cuit. The fuse is located in the battery charger cable.
6. ALTERNATOR FIELD CURRENT MONITORED. The
alternator field input is continuously monitored to indicate
an output power overload. The controller will shut down
the generator set in response to excessive exciter field cur-
rent.
Operating Instructions
Pretrip Inspection
While the Pre-trip Inspection is not a substitute for regularly
scheduled maintenance, it is an important part of the preven-
tive maintenance program designed to head off operating prob-
lems and breakdowns before they happen.
Visual Inspection
The following inspections should be made before loading the
container or trailer:
1. FUEL. The diesel fuel supply must be sufficient to guar-
antee engine operation to the next check point.
2. ENGINE OIL. Engine oil level should be at the FULL
mark. Never overfill. The dipstick is attached to the filler
cap.
3. COOLANT. Engine coolant must be above the ADD
mark with anti-freeze 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 “RED” coolant to cooling systems
using “GREEN” or “BLUE-GREEN” coolant.
• Do NOT add “GREEN” or “BLUE-GREEN”
coolant to cooling systems using “RED”
coolant.
4. BATTERY. Terminals must be clean. Electrolyte should
be at the full mark.
5. BELT. The water pump belt must be in good condition
and adjusted to proper tension.
6. ELECTRICAL. Electrical connections should be securely
fastened. Check wires and terminals for corrosion, cracks
or moisture. Repair or replace if necessary.
7. STRUCTURAL. Visually inspect the unit for leaks, loose
or broken parts and other damage. 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 dis-
charge side.
CAUTION: Air or water spray jet pressure should
not be high enough to damage (bend) coil fins.
8. MOUNTING BOLTS. Check the mounting bolts on the
unit and engine. Tighten if necessary.
SGCO 2000-151, July 2001
Operating Instructions Starting the Unit 3-3

Functional Inspection e. If an operating problem occurs during the Pretrip

To properly perform a Pretrip Test on units equipped with a Test, the Alarm icon will turn ON and FLASH. View
µP-G controller, do not apply a load to the alternator. and correct any alarm conditions. Then clear the
1. Start the unit (see “Starting the Unit” on this page). Alarms and repeat the Pretrip Test.
2. Initiate an automatic Pretrip Test.
NOTE: Clear the Alarm codes ONLY after the
NOTE: Correct all existing alarm conditions and alarm codes are documented and problems
clear the alarm codes before performing a Pretrip repaired.
test.
4. Press the ENTER key on the controller to return the unit
a. Press the SELECT key to enter Main Menu. to normal operation.
b. Press the UP or DOWN key to scroll up or down in
menu to “PtrlP”.
c. Press the SELECT key to activate the Pretrip Test
function. Flashing display will show “EntEr / PrE”. Starting the Unit
d. Press the ENTER key to start the Pretrip Test.
Flashing display will show “LOAd / PrE”. Generator sets are designed to provide power for a refrigera-
3. The controller then performs the Pretrip Test. Observe the tion unit. Before starting the generator set, make sure the
unit for proper operation and functions during pretrip test. refrigeration unit power cord is connected to the generator set
a. Controller LED display turns On and then Off. electric power receptacle. To operate the refrigeration unit on
b. LED display shows the controller input or output cir- standby power, disconnect the power cord from the generator
cuit being tested. set and plug it into the proper power supply.
c. When the controller display reaches “Phr” (preheat
relay test), the controller preheats and restarts the WARNING: With the Unit On/Off switch in the ON
engine. position, the unit may start at any time without prior
warning.
Display
Message Pretrip Test Performed 1. Turn Unit On-Off switch to ON.
88888 / 88 Display Test 2. The controller will automatically energize the air heater
OLS / PrE Oil Level Switch Test for preheat (if necessary). The preheat buzzer is energized
OPS / PrE Oil Pressure Sensor Test during the preheat period. Preheat time ranges from 5 to
LOP / PrE Oil Pressure Switch Test 120 seconds, depending on the engine temperature.
UtS / PrE Coolant Temperature Test 3. The engine then begins cranking. The air heater and pre-
FUS / PrE RPM Sensor Test heat buzzer remain energized during the cranking period.
Phr / PrE Preheat Relay Test The air heater also remains energized for 30 seconds after
rr / PrE Run Relay Test the engine starts.
Sr / PrE Start Relay Test • If the engine rpm does not exceed 50 rpm during the first
Fr / PrE Field Relay Test 4 seconds of cranking, or if the engine does not start
OPS / PrE Oil Pressure Sensor Test after 30 seconds of cranking, the cranking cycle termi-
LOP / PrE Oil Pressure Switch Test nates.
rPN / PrE RPM Sensor Test 4. If the engine fails to start, place the unit switch in the OFF
AC / PrE Output Volts Test position. Determine and correct the cause of the starting
failure. Then repeat the starting procedure.
d. When the Pretrip Test is complete, the test ends auto-
matically and the controller display shows “PASS” or CAUTION: Never use starting fluid.
“FAIL”.

SGCO 2000-151, July 2001

3-4 After Start Inspection Operating Instructions

After Start Inspection

After the engine has started:
1. Listen for abnormal noises.
2. Check engine oil pressure using the View menu of the
controller display. Engine oil pressure should read 100 to
380 kPa, 1.00 to 3.80 bar, 15 to 55 psig; or more.

NOTE: The engine must operate for approximately 15

seconds before the exciter circuit and battery charg-
ing circuits are energized. When Delayed Cold Start
feature is set to YES, controller shows “dELAY / AC”
screen and the alternator output remains off until the
engine temperature increases to 32 C (90 F).

SGCO 2000-151, July 2001

4 Microprocessor Controller

engine oil level, high coolant temperature, run relay circuit

µP-G Microprocessor Description failure or alternator overload.
• Automatic unit restart 20 minutes after unit shutdown due to
The µP-G controller is a one-piece, self contained micro-
an unknown condition, high engine water temperature, low
processor for diesel generator sets. This system automatically
engine oil pressure, engine failure to start, check fuel alarm,
control generator set operation by providing:
or alternator overload.
• Automatic unit preheat and engine startup during initial
startup or delayed restart
The controller contains the following basic features:
• Variable air heater preheat time
1. Two digital displays on front panel:
• Automatic Pre-trip Test capability
• LARGE DISPLAY: Five digits (numerical hundreds,
• Delayed alternator excitation for 15 seconds or until engine
tens, ones, tenths and hundredth position).
coolant temperature increases to 32 C (90 F) (optional).
• SMALL DISPLAY: Three digits (numerical tens, ones
• Unit shutdown protection for the engine and alternator.
and tenths position).
Controller stops unit due to low engine oil pressure, low

µP-G Microprocessor Controller

Display
Normally shows the Output Voltage. All segments and
icons are shown in the illustration. It will be blank
when the unit On/Off switch is OFF.

Mode Description
The Alarm description indicates alarms.

Icon
An alarm icon appears next to the Alarm description if
an alarm condition occurs.

Keypad
Alarm Key: Displays fault code readout.
Enter Key: Enters/initiates new settings.
Down Arrow Key: Scrolls down through MENU dis-
play.
Up Arrow Key: Scrolls up through MENU display.
Select Key: Places you in (enters) the MENU list and
selects items for display or change.

Indicator LEDs
Unit On (Green) LED: LED FLASHES while the glow
plugs and starter motor are energized; remains ON to
indicate normal unit operation.
Alarm (Red) LED: LED turns ON when a shutdown
condition has occurred.

SGCO 2000-151, July 2001

4-2 Status Indicator LEDs Microprocessor Controller

2. Alarm icon appears when the Microprocessor has detected

an alarm condition. Status Indicator LEDs
3. Keypad:
The indicator LEDs located on the control box cover stay ON
a. ALARM Key: Press to display the fault code list in
continuously to indicate a unit operating mode or condition.
the controller display.
• Unit ON LED: This LED FLASHES ON and OFF during
b. ENTER KEY: Press to load settings and execute
engine preheat and cranking; and stays ON continuously dur-
other controller commands.
ing unit operation.
c. DOWN Key: Press to scroll DOWN through the con-
• Alarm LED: This LED stays ON continuously when a
troller MENU.
Shutdown Alarm occurs.
d. UP Key: Press to scroll UP through the controller
MENU.
e. SELECT Key: Press to enter the controller MENU
and select items for display or change. Controller Display Menus
4. Internal self-checking/diagnostic capability.
5. Pre-trip test capability (see “Pretrip Test” under Pretrip The µP-G controller contains an extensive display menu that
Menu in this chapter). can be navigated via keypad. The display shows several infor-
6. Hourmeter: The µP-G controller has a built-in run mation displays in addition to the Main Menu. The Main
Menu is organized into five menus (or groups).
hourmeter that can be accessed through the View Menu.
7. Application software version display when ENTER key is
NOTE: See page 10-5 to view a diagram of the com-
pressed and held for 3 seconds.
plete µP-G menu.
8. Microprocessor Inputs:
Run Relay Enabled
Engine Oil Level Sensor
Engine Oil Pressure Switch Navigating the Controller Menu:
Preheat Feedback The µP-G Main Menu is divided into 5 major menus: View,
Coolant Level Sensor Pretrip, Test, Guard and Program. Moving through these
Air Filter Switch menus and their submenus and entering commands requires
Excitation Feedback the use of 4 keys:
Voltage Regulator
Flywheel Sensor SELECT key: Press the SELECT key to enter or exit
9. Microprocessor Outputs: the Main menu or a submenu; or to enter a command
Run Relay or value.
Field Relay
Start Relay DOWN or UP key: Press the DOWN or UP
Preheat Relay or key each time you want to scroll up or down
On Light to view another item in a menu or submenu.
Alarm Light
10. Display menus: The µP-G controller contains an exten- ENTER key: Press the ENTER key each time you
sive display menu that can be navigated via keypad. The want to enter a value or load a command.
display menu is organized into 6 Main Menus: Alarm List
Menu, View Menu, Pretrip Menu, Test Menu, Guard
Menu and Program Menu.

SGCO 2000-151, July 2001

Microprocessor Controller Controller Display Menus 4-3

Software Version Display View Menu (from Main Menu)

The software version is stored in the controller memory. With
the unit On/Off switch ON and the LCD display showing the
standard display (voltage output):
• Press ENTER key for 3 seconds. The display shows the soft-
ware version for 3 seconds (e.g. “ 0200 / rEv”).
Menu screens in this group are used to display unit operating
information including output frequency, engine temperature,
oil pressure, engine speed, battery voltage and operating hour
information. No changes can be made to the data from the
View menu.

Pretrip Menu (from Main Menu)

Pause Mode Displays Menu screens in this group are used to activate pretrip tests.

WARNING: When the unit is in a PAUSE mode, the Test Menu (from Main Menu)
AC alternator output or engine may start at any time
without notice. Menu screens in this group are used to set the unit to activate
manual function tests.
A Pause mode display appears when the controller interrupts
normal unit operation to perform a check or test. Guard Menu (from Main Menu)
Menu screens in this group are used to set hourmeters, auto-
Pause Condition Display/Description restart and engine features; and calibrate the controller volt-
AC Output Delay “dELAy / AC” screen indicates that 460V meter. An access code (0007) is required to enter this menu.
output is off. Controller activates exciter
circuit when engine temperature increases Program Menu (from Main Menu)
to 32 C (90F). The Delayed Cold Start fea-
Menu screens in this group are used to set values including
ture is set to yES or nO from the Guard
temperature display units (F or C) and oil pressure units (kPa,
menu.
bar or psi).
Alarm Shutdown “PAUSE / run” screen indicates the con-
troller has stopped unit operation due to a
shutdown alarm condition. The controller Menu Display Definitions
restarts the unit if the alarm condition is Acronym Definition
corrected. The Pause mode display contin- AC Alternating current or Volts A.C. (typically)
ues until the shutdown condition has been AL Alarm light
corrected. AL_01 Alarm 01
bArS Bars
Alarm List Menu bAt Battery volts D.C.
C Celsius
Menu screens in this group display a list of alarm code(s)
CHECh Check alarm after pretrip
recorded in the controller memory. Alarm codes are used to
CntrL Control test menu or submenu
simplify unit diagnosis procedures.
dEG Degree
dELAY Delay
dLYSt Delayed field relay energize option
Ent Engine temperature
EntEr Prompt for key stroke
EOH Engine off hours (while rHr is running)
Standard Display F Fahrenheit
FAIL Fail result during pretrip
Fr Field relay
FUS Flywheel sensor
GUArd Guard menu or submenu prompt
HM1 Programmable hourmeter #1 hours

Review Software Version

• Depress ENTER key for 3 sec-
onds.
• Display shows software ver-
sion for 3 seconds.

Software Version Display

SGCO 2000-151, July 2001

4-4 Alarm List Menu Microprocessor Controller

HM2 Programmable hourmeter #2 hours

Ht1 Programmable hourmeter #1 threshold Alarm List Menu
Ht2 Programmable hourmeter #2 threshold
The Alarm List menu displays alarm codes. Alarm codes are
HZ Hertz
recorded in the controller memory to simplify unit diagnosis
kPa Kilo Pascals
procedures. The first 16 fault codes including the most recent
LOAd Load of data into micro controller
fault code are retained by the controller in a non-volatile mem-
LOP Low oil pressure switch
ory in order of their occurrence (see codes, alarm type and
LOPrS Low oil pressure restart option
alarm description below). If the Alarm LED is ON or flashing
MEnU Menu menu or submenu prompt
ON and OFF, enter the ALARM LIST to view the alarm
nUrEG Newage AVR Regulator
code(s).
OIL Oil pressure
Some alarm codes are only recorded during a Pretrip Test.
OL On light
Alarm codes that are recorded during an automatic Pretrip Test
OLS Oil level switch
are recorded in the controller memory and displayed with a
OPS Oil pressure sensor
hyphen (-) preceding the alarm code.
PASS Pass result after pretrip
PAUSE Pause
Phr Preheat relay Alarm Types
PrE Pretrip mode There are three types of alarms:
PrGrM Program menu or submenu prompt • Shutdown Alarm: Alarm LED flashes and unit stops.
PSI Pounds per square inch Shutdown alarms indicate the unit has been stopped to pre-
PtrIP Pretrip menu or submenu prompt vent damage to the unit. The condition must be corrected
rEv Revision, software (typically) before restarting the unit. Alarm codes 17-20, 25, 44, 51, 61,
rHr Run hourmeter 66 and 74 are shutdown alarms.
rPM Revolutions per minute • Check Alarm: Alarm LED remains ON until alarm is
rr Run relay cleared. Check alarms indicate corrective action should be
rSL Restarts since last power up taken before a problem becomes severe. Alarm codes 06, 07,
Sr Start relay 15 to 17, 19-31, 37-43, 45, 46, 61-63, 69-72 and 99 are
St Restarts total for unit Check alarms.
tESt Test menu or submenu prompt • Log Alarm: Alarm is recorded in controller memory only.
UtS Water temperature sensor Alarm LED does not flash or turn on. Alarm codes 15, 61,
vIEW View menu or submenu prompt and 88 are Log alarms.
vr Voltage regulator
YAnEn Yanmar (TK 486) Engine

Standard Display

Alarms List
• View and write down all alarm
codes.
• Press DOWN key to view the
next alarm code.
• Correct problem.
• To clear alarm code(s) from dis-
play, press ENTER key with last
alarm code (“AL 1”) in display.

Alarms List Screen Flow Diagram

SGCO 2000-151, July 2001

Microprocessor Controller Alarm List Menu 4-5

Displaying and Clearing Alarm Codes Alarm List

If the Alarm LED is ON or flashing ON and OFF, use the Alarm
ALARM key to view the alarm code(s). With the unit On/Off Code Type Description
switch ON and the LCD display showing the standard display 06 Check Water Temperature Sensor Failure
(output voltage): 07 Check Engine RPM Sensor
1. Press the ALARM key. 15 Check Preheat Circuit Check
• The top display shows the number of alarms stored in 16 Check Digital Input Failure
memory (e.g. “AL 2”). 17 Check or
• The bottom display shows a two digit code for the most Shutdown Engine Failed to Crank
recent alarm (e.g. “31”). 18 Check High Engine Water Temperature
2. Write down the first alarm code. Then press the DOWN 19 Check or
key to view the next alarm code. Shutdown Low Engine Oil Pressure
3. Repeat step 2 until all alarm codes have been recorded. 20 Check Engine Failed to Start
4. After the last alarm code (“AL 1”) has been viewed and 25 Check or
recorded, the top display flashes “ENTER” (the code Shutdown Low Output Volts
number of the last alarm still appears in the bottom dis- 31 Check or
play). Shutdown Oil Pressure Sensor
35 Shutdown Run Relay Circuit
NOTE: Clear the Alarm codes ONLY after the 37 Check Coolant Level Alarm
alarm codes are documented and problems 41 Check Engine Water Temperature Check
repaired. Clearing the codes erases them from 43 Check Frequency Out of Range — Low
the controller Alarm display memory. 44 Check Fuel System Check
45 Check Frequency Out of Range — High
NOTE: If the ENTER key is not pressed within 10 46 Check Check Air Filter
seconds, the controller will default (return) to the 51 Check Alternator Overload Alarm
Standard Display. 61 Check or Low Battery or Low Battery during
Shutdown Cranking
5. To clear all alarm codes from the current display memory, 63 Check Engine Stopped — Reason Unknown
press the ENTER key. The display briefly shows 65 Check Battery Charger Check
“ALARM CLR”. 66 Check or
Shutdown Low Engine Oil Level
WARNING: Some unit malfunctions will cause an 69 Check Field Relay Check
Alarm and unit shutdown condition. When the 70 Check Any Hourmeter or Counter Exceeds
alarm codes are cleared, the unit will start auto- Limit
matically. 71 Check Hourmeter 1 Exceeds Threshold
72 Check Hourmeter 2 Exceeds Threshold
6. The controller then returns to the Standard Display. 74 Shutdown Control Revert to Default Settings
88 Log Microprocessor Internal Error
99 Check Restart Null

SGCO 2000-151, July 2001

4-6 View Menu Microprocessor Controller

View Menu Pretrip Menu

NOTE: Information can ONLY be displayed using the
View menu. Items can NOT be changed.
The View menu displays general unit operating information
including electrical data, temperatures, etc. With the unit
On/Off switch ON and the LCD display showing the standard
display (voltage output):
1. Press SELECT key to enter the menu list. Display shows
“MEnU / ---”.
2. Press DOWN key to scroll to “VIEW” in display.
3. Press SELECT key to access the View menu. Display
shows “VIEW / ---”.
4. Press DOWN key to view items in the View menu list.
The display shows the value for the following functions:
• Output Frequency (HZ)
• Engine Temperature (Ent)
• Oil Pressure (OIL)
• Engine Speed (rPM)
• Battery Volts (bAT)
• Run Hours (rHr)
NOTE: Press the ENTER key to lock a View
screen in the LCD display. A decimal point flash-
es in the bottom display to indicate the screen is
locked. The screen remains locked for 15 min-
utes. Press any key to unlock the display.
NOTE: The controller returns to the Standard
Display from a View Menu screen after about 10
seconds, or when the SELECT key is pressed
and held for 3 seconds.
NOTE: The controller will not perform an automatic
pre-trip test until all alarms have been corrected and
cleared.
The Pretrip menu initiates a test of the unit’s electrical, engine
and alternator system components. With the unit On/Off
switch ON and the LCD display showing the standard display
(voltage output):
1. Press SELECT key to enter the menu list. Display shows
“MEnU / ---”.
2. Press DOWN key to scroll to “PtrlP” in display.
3. Press SELECT key to access the Pretrip menu. Flashing
display shows “EntEr / PrE”.
4. Press ENTER key to start an automatic Pretrip test.
Display briefly shows “LOAd / PrE”. The controller then
displays the following screens as the Pretrip test is per-
formed:
Display Screen Pretrip Test
88888 / 88 Display Test
OLS / PrE Oil Level Switch Test
OPS / PrE Oil Pressure Sensor Test
LOP / PrE Oil Pressure Switch Test
UtS / PrE Coolant Temperature Test
FUS / PrE RPM Sensor Test
Phr / PrE Preheat Relay Test
rr / PrE Run Relay Test
Sr / PrE Start Relay Test
Fr / PrE Field Relay Test
OPS / PrE Oil Pressure Sensor Test

Standard Display Standard Display

MAIN MENU MAIN MENU

View Menu
— VIEW — VIEW
— VIEW / --- Pretrip Menu
— PRETRIP — PRETRIP
— XX / HZ • Display flashes “EntEr / PrE”.
— TEST — XXX.XX / Ent — TEST • Press ENTER to start Pretrip
— GUARD — XX / OlL test. Display shows “LOAd
— GUARD
— XXXX / rPM /PrE”.
— PROGRAM — XX.X / bAT — PROGRAM • Display shows current Pretrip
— XXXXX / rHr Test function as controller con-
ducts Pretrip test.

View Menu Screen Flow Diagram Pretrip Menu Screen Flow Diagram

SGCO 2000-151, July 2001

Microprocessor Controller Test Menu 4-7

LOP / PrE Oil Pressure Switch Test 4. Press DOWN key to scroll to “CntrL” in the display.
rPN / PrE RPM Sensor Test 5. Press SELECT key to access the Control Test submenu.
AC / PrE Output Volts Test Display shows “CntrL / ---”.
5. When pretrip test is complete, displays shows PASS or 6. Press DOWN key to scroll to desired test. The controller
FAIL. Press the ENTER key to clear the pretrip message displays the following test functions:
display and return to standard screen. View and correct Display Screen Test
any alarm codes recorded before placing unit in service. AL / 0 l Alarm Light Test
OL / 0 l On Light Test
PHr / 0 l Preheat Relay Test
rr / 0 l Run Relay Test
Test Menu Sr / 0 l Start Relay Test
Fr / 0 l Field Relay Test
The Test menu allows technicians to perform specific diagnos-
tic tests on the unit. With the unit On/Off switch ON and the NOTE: A flashing “l” in the display indicates the
LCD display showing the standard display (voltage output): test output is OFF. A flashing “0” in the display
indicates the test output is ON.
NOTE: The controller STOPS the unit when the Test
Menu is entered. A technician can then select the 7. When the desired test appears in the display, press the
control circuit or component to be tested/checked SELECT key to activate the test. The flashing “l” in the
from the Test submenu. lower display changes to a flashing “0” when the test out-
put is turned ON.
WARNING: If no key is pressed for 30 seconds and 8. When the check/diagnosis of the selected circuit is com-
all test outputs are OFF in the Test submenu, the plete, press the SELECT key to stop the test. The flashing
unit may restart at any time without prior warning. “0” in the lower display changes to a flashing “1” when
the test output is turned OFF.
1. Press SELECT key to enter the menu list. Display shows 9. When all desired tests are complete, wait 30 seconds for
“MEnU / ---”. the controller to exit the Test submenu and return to the
2. Press DOWN key to scroll to “tESt” in the display. standard display. The controller then automatically
3. Press SELECT key to access the Test menu. Display restarts the unit.
shows “tESt / ---”.
WARNING: With the Unit On/Off switch in the ON
position, the unit may start at any time without
prior warning if a controller key has not been
pressed for 30 seconds.
Standard Display

WARNING: With the Unit On/Off

switch in the ON position, the
unit may start at any time with-
out prior warning if a controller
key has not been pressed for 30
seconds.

MAIN MENU

— VIEW
— PRETRIP
Test Menu
— TEST
• Display shows “tESt / ---”.
— GUARD • Press DOWN to show “CntrL /
— PROGRAM tSt” in display.
• Press SELECT. Display
shows “Cntrl / --”.
• Press DOWN until display
shows the desired Test func-
tion.
• Press SELECT to start Test
function.
• Press SELECT again to stop
Test function.

Test Menu Screen Flow Diagram

SGCO 2000-151, July 2001

4-8 Guard Menu Microprocessor Controller

• Regulator Selection
Guard Menu • Voltmeter Calibration

NOTE: An access code is required to enter the Navigating Menu Guard Screens
Guard menu to prevent unauthorized personnel from With the unit On/Off switch ON and the controller showing
tampering with the programmable features. the Standard Display:
1. Press SELECT key to enter the menu list. Display shows
The Guard menu is used to view and set programmable fea- “MEnU / ---”.
tures including: 2. Press DOWN key to scroll to “GUArd” in the display.
• Run Hourmeter (View Only) 3. Press SELECT key to access the Guard menu. Display
• Hourmeter 1 shows “0000 / GUA” with left “0” flashing. A flashing
• Hourmeter 2 digit indicates the digit that can be changed.
• Engine Off Hourmeter (View Only) 4. Enter the current access code “0007”.
• Restarts after Powerup (View Only) a. Press and release the SELECT key three times to
• Unit Restarts scroll the flashing digit (“0”) to the right digit.
• Low Oil Pressure Restart b. Press and release the DOWN key three times to scroll
• Delayed Cold Start the flashing digit to “7” (display now shows “0007 /
• Engine Selection GUA”).

Standard Display

Guard Menu
— 0 0 0 0 / GUA

MAIN MENU Enter access code 7.

Press to scroll cursor to
— VIEW next digit to right.
— PRETRIP Press or to select
— TEST number.

— GUARD Press to enter access

code. Display shows
— PROGRAM GUArd / l- - -l.

Press to enter load

Guard Submenu
value display. Top display
— GUArd / l- - -l flashes value to be
— XXXXX / rHr (Run Hours) changed.
— XXXXX / Ht1 (HM 1 Threshold)
Footnotes: — XXXXX / Hn1 (HM 1 Hours) Press or to select
1When Delayed Cold Start is set to yES, controller — XXXXX / Ht2 (HM 2 Threshold) new number.
shows “dELAy / AC” screen and alternator output — XXXXX / Hn2 (HM 2 Hours)
remains off until engine temperature increases to — XXXXX / EOH (Engine Off Hours) Press to load new
32 C (90 F). — XXXXX / rSl (Restarts after number.
2The Engine Select screen MUST be set to “yES”
Powerup)
on units equipped with a TK 486 (Yanmar) engine.
Set this screen to “nO” on units equipped with a di — XXXXX / rSt (Unit Restarts)
2.2 or se 2.2 engine. Default setting is “nO” on — LOPrS / n0 (Low Oil Press. Restart)
Press to enter load
version 0100 software and “yES” on version 0200 — dLYSt / yES1 (Delayed Cold Start)
value display.
software. — YAnEn / yES2 (Engine Select)
3The Regulator Select screen MUST be set to — nUrEG / YES3 (Regulator Select) Press or to
“yES” on units equipped with a Newage regulator. — XXXXX / CAL (Voltmeter Calib.) select new value.
Set this screen to “nO” on units equipped with a
Thermo King excitor. Default setting is “nO”. Press to load new
value.

Guard Menu Screen Flow Diagram

SGCO 2000-151, July 2001

Microprocessor Controller
c. Press the ENTER key to load the code and access the
Guard menu. The display will show “GUArd / ---”.
NOTE: If the correct code is not entered, the dis-
play returns to “GUArd”.
5. Press the DOWN or UP key to scroll through the menu list.
NOTE: If a new controller or new software has
been installed, proceed immediately to
“Calibrating the Voltmeter” below.
NOTE: If no key is pressed, the controller returns
to the “GUArd / ---” display from a Guard Menu
screen after 30 seconds.
Setting the User Hourmeter Thresholds and
User Hours
NOTE: The procedure for setting the threshold and
countdown hours for Hourmeter 1 and Hourmeter 2
are the same.
The User Hourmeter feature sets the controller to alert the user
that unit has operated for a defined number of hours. The
number of operating hours are entered in the controller in the
Hourmeter Threshold display. The controller then generates
an Check alarm when the user hourmeter reaches the threshold
setting.
NOTE: If the user does not desire to use the User
Hourmeter feature to measure maintenance inter-
vals, etc., leave the settings at “0000” to avoid nui-
sance alarms. On units equipped with version
“0200” software, the controller will reset the User
Hourmeters automatically when an hourmeter
threshold alarm is cleared.
1. From “GUArd / ---” in the Guard menu, press the DOWN
key until the display shows “XXXXX / Ht1” (where
“XXXXX” is the threshold setting and “Ht1” is
Hourmeter Threshold 1).
a. Press the SELECT key to enter the load User
Hourmeter Threshold display. Bottom display flashes
“Ht1”.
b. Press the UP or DOWN key to choose the desired
threshold setting.
c. When the desired threshold hours show in the top dis-
play, press the ENTER key. The display flashes
“LOAd” and then shows “XXXXX / Ht1” (where
“XXXXX” is the new threshold hours).
Guard Menu 4-9
2. From “XXXXX / Ht1” in the controller display, press the
DOWN key until the display shows “XXXXX / Hn1”
(where “XXXXX” is the number of accumulated user
hours and “Hn1” is Hourmeter 1).
NOTE: If a new controller is being installed in
the unit and the number of accumulated run
hours can not be determined, leave this setting
“00000”.
a. Press the SELECT key to enter the load User
Hourmeter display. Bottom display flashes “Hn1”.
b. Press the UP or DOWN key to choose the desired
hour setting.
c. When the desired hours show in the top display, press
the ENTER key. The display flashes “LOAd” and
then shows “XXXXX / Hn1” (where “XXXXX” is
the new accumulated user hours).
Setting Unit Restarts
The Unit Restart feature sets the number of times the con-
troller will attempt to restart the unit after unit operation stops
due to an an auto-shutdown condition.
NOTE: Leave this setting “00000” to have the con-
troller attempt to restart the unit until the unit has
been successfully restarted or until a code 61 is gen-
erated due to a low battery.
1. From “GUArd / ---” in the Guard menu, press the DOWN
key until the display shows “XXXXX / rSt” (where
“XXXXX” is the number of restart attempts).
2. Press the SELECT key to enter the load Unit Restart dis-
play. Bottom display flashes “rSt”.
3. Press the UP or DOWN key to choose the desired restart
attempt setting.
4. When the desired restart attempt setting shows in the top
display, press the ENTER key. The display flashes
“LOAd” and then shows “XXXXX / rSt” (where
“XXXXX” is the new restart attempt setting).
SGCO 2000-151, July 2001
4-10 Guard Menu
Setting Low Oil Pressure Restart
The Low Oil Pressure Restart feature sets the controller to
restart the unit after unit operation stops due to a low oil pres-
sure condition. Factory default setting is “n0”.
1. From “GUArd / ---” in the Guard menu, press the DOWN
key until the display shows “LOPrS / n0” (where “n0”
means the feature is off).
2. Press the SELECT key to enter the load Low Oil Pressure
Restart display. Bottom display flashes “n0”.
3. Press the UP or DOWN key to choose the desired restart
attempt setting:
• n0 = inactive or off.
• yES = active or on.
4. When the desired restart attempt setting shows in the bot-
tom display, press the ENTER key. The display flashes
“LOAd” and then shows “LOPrS / XXX” (where “XXX”
is the new low oil pressure restart attempt setting).
Setting Delayed Cold Start
The Delayed Cold Start feature sets the controller to delay
alternator excitation until the engine water temperature
increases to 32 C (90 F). Factory default setting is “yES”.
1. From “GUArd / ---” in the Guard menu, press the DOWN
key until the display shows “dLYSt / n0” (where “n0”
means the feature is off).
2. Press the SELECT key to enter the load Delayed Cold
Start display. Bottom display flashes “n0”.
3. Press the UP or DOWN key to choose the desired restart
attempt setting:
• n0 = inactive or off.
• yES = active or on.
4. When the desired restart attempt setting shows in the bot-
tom display, press the ENTER key. The display flashes
“LOAd” and then shows “dLYSt / XXX” (where “XXX”
is the new delayed cold start setting).
Selecting Engine Type
The Engine Select feature sets the controller to the Yanmar
(TK 486) engine. The Engine Select screen must be set to
“YES” on units equipped with a TK 486 engine. Default set-
ting is “YES” on version 0200 software and “nO” and version
0100 software.
1. From “GUArd / ---” in the Guard menu, press the DOWN
key until the display shows “YAnEN / YES” (where
“YES” means the feature is set for a TK 486 engine).
2. Press the SELECT key to enter the load Engine Select dis-
play. Bottom display flashes “YES”.
Microprocessor Controller
3. Press the UP or DOWN key to choose the desired engine
type setting:
• n0 = di 2.2 or se 2.2 engine.
• YES = TK 486 (Yanmar) engine.
4. When the desired engine setting shows in the bottom dis-
play, press the ENTER key. The display flashes “LOAd”
and then shows “YAnEN / XXX” (where “XXX” is the
new setting).
Selecting Regulator Type
The Regulator Select feature sets the controller to the Newage
AVR regulator. The Engine Select screen must be set to
“YES” on units equipped with an AVR regulator. Factory
default setting is “YES” units with AVR regulator. However,
default setting on replacement software is “nO”.
1. From “GUArd / ---” in the Guard menu, press the DOWN
key until the display shows “nUrEG / YES” (where
“YES” means the feature is set for a AVR regulator).
2. Press the SELECT key to enter the load Engine Select dis-
play. Bottom display flashes “YES”.
3. Press the UP or DOWN key to choose the desired engine
type setting:
• n0 = Standard Thermo King exciter.
• YES = Newage AVR regulator.
4. When the desired engine setting shows in the bottom dis-
play, press the ENTER key. The display flashes “LOAd”
and then shows “YAnEN / XXX” (where “XXX” is the
new setting).
Voltmeter Calibration
The Voltmeter Calibration feature calibrates the controller to
the alternator output. The controller voltmeter should be cali-
brated whenever a new controller is installed in the unit or
when the controller is suspected of displaying inaccurate read-
ings.
1. Turn the unit On/Off switch OFF to stop the unit.
2. Disconnect the refrigeration unit from the generator.
3. Turn the unit On/Off switch ON to restart the unit.
4. Check the output voltage at the genset plug. Check the
voltage between the three phases. All three phases should
be within 3% of each other. Determine the average volt-
age reading between the three phases.
5. From “GUArd / ---” in the Guard menu, press the DOWN
key until the display shows “XXXXX / CAL” (where
“XXXXX” is the current voltage reading).
6. Press the SELECT key to enter the load Voltmeter
Calibration display. Bottom display flashes “CAL”.
SGCO 2000-151, July 2001
Microprocessor Controller Program Menu 4-11

7. Press the UP or DOWN key to adjust the top display read- 5. When the desired function appears in the display, press
ing to the average voltage reading determined in step 1. the SELECT key to activate the program function. The
8. When the correct voltage reading shows in the top display, upper display begins flashing (e.g. “F” flashes).
press the ENTER key. The display flashes “LOAd” and 6. Press DOWN key to scroll to the desired value.
then shows “XXX / CAL” (where “XXX” is the new volt- 7. With the new value in the display, press the ENTER key
age reading). to load the value in the controller memory. Display will
show “LOAd” and then return to display the new value
and function (e.g. “C / dEG”).
8. When all new values s are set, wait 30 seconds for the
Program Menu controller to exit the Program submenu and return to the
standard display.
The Program menu is used to set display values for tempera-
ture and oil pressure units. With the unit On/Off switch ON
and the LCD display showing the standard display (voltage
output):
1. Press SELECT key to enter the menu list. Display shows
“MEnU / ---”.
2. Press DOWN key to scroll to “PrGm” in display.
3. Press SELECT key to access the Program menu. Display
shows “PrGm / ---”.
4. Press DOWN key to scroll to the desired function:
Display Screen Program Function
X / dEG Set degrees F or C
XXXX / OIL Set oil pressure units in PSI, BARS or
kPA

Standard Display

MAIN MENU

— VIEW
— PRETRIP
— TEST
— GUARD
Test Menu
— PROGRAM
• Display shows “PrGm / ---”.
• Press DOWN until display
shows the desired Program
function.
• Press SELECT to activate the
Program function.
• Press DOWN to scroll to
desired value.
• Press ENTER to load the new
value in the controller memory.

Program Menu Screen Flow Diagram

SGCO 2000-151, July 2001

4-12 Alarm Codes, Type and Description Microprocessor Controller

µP-G Alarm Codes, Type and Description

• Shutdown Alarm (Level 1 Alarm): Alarm icon appears in controller display, Alarm LED turns ON and the unit stops.
Correct alarm condition and acknowledge alarm before restarting the unit.
• Check Alarm (Level 2 Alarm): Alarm icon appears in display until alarm is acknowledged and cleared.

Note: The phrase “restart after 20 minutes” refers to the auto-restart mode where the unit will make up to three
attempts every 20 minutes to restart the unit after a shutdown has occurred. This restart mode contin-
ues until the unit has been successfully restarted or until a code 61 is generated due to low battery.

Alarm
Code Type Cause or Explanation

*06 Check Water Temperature Sensor Failure

• Check alarm is generated if:
- Water temperature is out of range for 2 seconds: Below -40 C (-40 F) or above
130 C (266 F)
- Sensor or circuit is open or shorted

*Pretrip:
• Check alarm is generated if the fault conditions above occur during a pretrip test.

*07 Check Engine RPM Sensor

• Check alarm is generated if:
- Engine cranks; RPM is below 40 during cranking, but oil pressure was above 35
kPa, 0.35 bar, 5 psig for 7 seconds after the starter de-energized
- Engine cranks; RPM is above 40 but below 800, and oil pressure is above 35
kPa, 0.35 bar, 5 psig for 37 seconds
- Engine has started but RPM is below 800 for 60 seconds

*Pretrip:
• During Pretrip test, a Check alarm is generated if:
- RPM sensor showed RPMs when the engine was not running
- RPM sensor did NOT show RPMs when the engine should have been running

15 Check Preheat Circuit Check

• Check alarm is generated if:
- Preheat relay output is energized during cranking, but the preheat digital input is
low for 2 seconds, log alarm is recorded.
- Preheat output is energized during cranking and the battery volts are less than
9.0 V for 3 seconds, a log alarm is recorded. The unit will attempt to start without
the preheat if this occurs.

16 Check Digital Input Failure

• Check alarm is generated if:
- Digital inputs have been changing once a second for the last 10 seconds. This
condition indicates noise on the line, a loose connection, or a bad sensor.

SGCO 2000-151, July 2001

Microprocessor Controller Alarm Codes, Type and Description 4-13

Alarm
Code Type Cause or Explanation

17 Check/Shutdown Engine Failed to Crank

• Check alarm is generated if:
- Engine does not crank: RPM is below 40 for 3 seconds after starter is energized
and oil pressure is below 35 kPa, 0.35 bar, 5 psig for 7 seconds after starter is
de-energized
- The unit will try to start 2 more times.

• Shutdown alarm is generated if:

- Engine fails to start after the 3rd attempt

18 Check High Engine Water Temperature

• Check alarm is generated if:
- Engine is ON and water temperature is above 107 C (225 F) for 25 seconds
- Engine then stops until water temperature decreases to 88 C (190 F). Engine
then attempts to restart

*19 Check/Shutdown Low Engine Oil Pressure

• Check alarm is generated if:
- Engine is ON; oil level indicates normal; and oil pressure is below 104 kPa, 1.04
bar, 15 psig at water temperatures above 10 C (50 F) for 30 seconds, or oil pres-
sure does NOT increase 35 kPa, 0.35 bar, 5 psig at water temperatures below
10 C (50 F) for 30 seconds
- Unit will attempt to restart after 20 minutes if programmable Low Oil Pressure
Restart feature is set to Yes (ON)

• Shutdown alarm is generated if:

- The fault conditions above occur and the programmable Low Oil Pressure
Restart feature is set to nO (OFF)

*Pretrip: Alarms are generated during the pretrip test if the fault conditions above
occur.

20 Check Engine Failed To Start

• Check alarm is generated if:
- Engine cranks; RPM is above 40, but below 800 for 30 seconds and oil pressure
was not above 35 kPa, 0.35 bar, 5 psig for 7 seconds after starter de-energized
- The unit will try to start 2 more times
- If engine fails to start after the 3rd attempt, it will try to restart after 20 minutes

SGCO 2000-151, July 2001

4-14 Alarm Codes, Type and Description Microprocessor Controller

Alarm
Code Type Cause or Explanation

*25 Check/Shutdown Low Output Voltage

• Check alarm is generated if:
- Engine is ON; field relay is energized but the output voltage is below 180 VAC for
30 seconds

*Pretrip:
• Shutdown alarm is generated if:
- The field relay is energized during the pretrip test and the output voltage is below
200 VAC

*31 Check/Shutdown Oil Pressure Sensor

• A Check alarm is generated if:
- Engine is OFF and oil pressure is above 69 kPa, 0.69 bar, 10 psig for 2 seconds;
or the low oil pressure switch indicates oil pressure (opens) for 10 seconds
- Engine is ON and oil pressure is above 2070 kPa, 20.70 bar, 300 psig
- Engine is ON; the low oil pressure switch indicates oil pressure (opens); the oil
level switch indicates normal (open); but the oil pressure is below 15 psig at
water temperatures above 100 C (212 F), or the oil pressure has not increased
by 35 kPa, 0.35 bar, 5 psig at water temperatures below 100 C (212 F)

*Pretrip:
• During Pretrip test, a Check alarm is generated if:
- Engine is OFF and oil pressure is above 69 kPa, 0.69 bar, 10 psig
- Engine is ON and oil pressure is below 35 kPa, 0.35 bar, 5 psig
- Engine is ON; the low oil pressure switch indicates no oil pressure (closed); and
the controller has not recorded a previous Oil Pressure Sensor Check alarm
• A Shutdown alarm is generated if:
- Engine is OFF; the low oil pressure switch indicates oil pressure (open); and the
controller has already generated a Oil Pressure Sensor Check alarm
- Engine is ON; the low oil pressure switch indicates no oil pressure (closed); and
the controller has already generated a Oil Pressure Sensor Check alarm

*35 Shutdown Run Relay Circuit

• A Shutdown alarm is generated if:
- During cranking: Run relay digital feedback is low after energizing during crank-
ing. Controller attempts to energize run relay and obtain high digital feedback 3
times before generating alarm
- During running: The run relay output does not match the run relay digital feed-
back input for 4 seconds

*Pretrip:
• A Shutdown alarm is generated if:
- Run relay digital feedback input is low after 3 seconds during the pretrip test

SGCO 2000-151, July 2001

Microprocessor Controller Alarm Codes, Type and Description 4-15

Alarm
Code Type Cause or Explanation

*37 Check Coolant Level Alarm

• Check alarm is generated if:
- Engine is OFF and the coolant level sensor indicates low coolant for 30 seconds

*Pretrip:
• Check alarm is generated if:
- During the Engine OFF portion of the pretrip test, the coolant level sensor indi-
cates low coolant for 3 seconds

41 Check Engine Water Temperature Check

• Check alarm is generated if:
- Engine is ON and water temperature is above 102 C (215 F) for 2 minutes

43 Check Frequency Out of Range-Low

• Check alarm is generated if:
- Engine is ON and engine RPMs are above 800 but below 1350 for 10 seconds

44 Check Fuel System Check

• Check alarm is generated if:
- Engine is ON and engine RPMs are below 1050 and have stayed below 1075 for
80 seconds
- The engine stops and will then attempt to restart after 20 minutes

45 Check Frequency Out of Range-High

• Check alarm is generated if:
- Engine is ON and engine RPMs are above 2100 for 10 seconds

46 Check Check Air Filter

• Check alarm is generated if:
- Engine is ON and the air filter digital input is low for 10 seconds

51 Check Alternator Overload Alarm

• Check alarm is generated if:
- Engine is ON and field current exceeds 1.7 amperes for 15 seconds, or exceeds
2.4 amperes for 5 seconds
- The engine stops and will then attempt to restart after 20 minutes

SGCO 2000-151, July 2001

4-16 Alarm Codes, Type and Description Microprocessor Controller

Alarm
Code Type Cause or Explanation

61 Check/Shutdown Low or High Battery Alarm

• A Check alarm is generated if:
- During engine preheating: The battery voltage is below 9.0 V for 3 seconds.
Controller will attempt to start engine without preheat
- Engine is OFF: The battery voltage is below 12.2 V for 3 minutes. If this occurs
when the unit is in a restart null mode, the engine immediately attempts to start
- Engine is ON: The battery voltage is above 16.0 V for 3 minutes

• A Shutdown alarm is generated if:

- The unit has attempted a start and a controller reset occurs before the unit start
is completed

63 Check Engine Stopped - Reason Unknown

• A Check alarm is generated if:
- Engine is OFF: The engine has stopped when it should be running
- The engine will attempt to restart after 20 minutes

65 Check Battery Charger Check

• A Check alarm is generated if:
- Engine is ON: The battery voltage is below 12.2 V for 3 minutes
- Engine is ON: The battery voltage is above 16.0 V for 3 minutes

*66 Check/Shutdown Low Engine Oil Level

• A Check alarm is generated if:
- Engine is OFF and the oil level switch indicates low oil level (closed) for 3 min-
utes
- Engine is ON, oil pressure sensor is high, but low oil level switch indicates low oil
level (closed) for 3 minutes

• A Shutdown alarm is generated if:

- Engine is ON, the oil level switch indicates low oil level (closed) for 3 minutes,
and the low oil pressure switch indicates no oil pressure (closed)

*Pretrip:
• A Shutdown alarm is generated if:
- During the Engine OFF portion of the pretrip test, the oil level switch indicates
low oil level (closed) for 3 seconds

SGCO 2000-151, July 2001

Microprocessor Controller Alarm Codes, Type and Description 4-17

Alarm
Code Type Cause or Explanation

*69 Check Field Relay Check

• A Check alarm is generated if:
- Field relay is energized and the field current is less than 0.3 amperes for 10 sec-
onds

*Pretrip:
• A Check alarm is generated if the fault conditions above occur during a pretrip
test

70 Check Hour Meter Exceeds Limits

• A Check alarm is generated if:
- One or more hourmeters exceeds 99,999
- Restart counter has exceeded 9999

71 Check Hour Meter Exceeds Limits

• A Check alarm is generated if:
- Programmable hourmeter 1 has exceeded the set limit. Clearing this code will
also reset the hourmeter 1.

72 Check Hour Meter Exceeds Limits

• A Check alarm is generated if:
- Programmable hourmeter 2 has exceeded the set limit. Clearing this code will
also reset the hourmeter 2.

74 Shutdown Control Reverted to Default Settings

• A Shutdown alarm is generated if:
- Controller reverts to factory programmable settings due to a chip change in the
controller or due to performing a controller cold start

88 Check Shutdown Microprocessor Fault Alarm

• A Check alarm is generated if:
- Controller has found a fault condition with either its RAM or Eprom. If this alarm
occurs twice the controller should be returned for repair

99 Check Restart Null

• The controller will try to restart unit after 20 minute null (off) period.

SGCO 2000-151, July 2001

5 Electrical Maintenance
Battery
CAUTION: Before connecting or disconnecting the
unit battery, place the Unit On/Off switch in OFF
position.
Inspect and clean the battery terminals and check the elec-
trolyte 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
Unit Wiring
Inspect the unit wiring and wire harnesses during scheduled
maintenance inspections for loose, chaffed or broken wires to
protect against unit malfunctions due to open or short circuits.
Fuse Link
The fuse link is located inside the unit control box on the back
of the µP-G microprocessor. The fuse link protects the electric
system from a short in the 2A or 2A1 circuit. If the fuse link
burns out, check for a grounded 2A or 2A1 wire or a short in
the fuel heater.
Fuse
A 25 amp fuse protects the battery charger circuit. The fuse is
located in the battery charger cable.
12 V dc Charging System
Battery charging current is supplied by a solid-state battery
charger using current from the ac alternator. The battery
charging circuit provides a 12 Vdc, 20 amp output to maintain
the battery at the proper charge level (13.8 to 14.3 volts).
The alternator exciter field is energized by the µP-G Field
Conversion Module to initiate battery charging approximately
15 seconds after engine start-up.
NOTE: The engine must run for approximately 15
seconds before the before the exciter field is ener-
gized to start alternator output. When Delayed Cold
Start feature is set to YES, controller shows “dELAY
/ AC” screen and the alternator output remains off
until the engine temperature increases to 32 C (90 F).
Battery Charger Diagnosis
The battery charger contains a red and green LEDs. These
LEDs provide the following indications:
• Green LED on: Ready — Battery is fully charged.
• Red and Green LED on: Charging — Battery charge level is
between 13.8 to 14.2 Vdc.
• Red LED on: Charging — Battery charge level is below 13.
• No LED on: No power output from battery charger.
Disconnect output leads and check for 14 Vdc voltage out-
put. If no output, check for 230 Vac input to battery charger
on Brown and Blue wires. If 230 Vac input to battery charg-
er and connections are good, replace the battery charger.
Battery Charger
1. LED Display
SGCO 2000-151, July 2001
5-2 Air Heater
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 posi-
tion).
The air heater is mounted on the open end of the intake
manifold. Check the resistance of the air intake heater with an
ohmmeter 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.
Air Heater
1. M6 Terminal
Oil Pressure Switch
1. Oil Pressure Switch
Electrical Maintenance
Engine Low Oil Pressure Switch
Engine oil pressure should rise immediately on starting, caus-
ing 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 and cause the controller to stop the engine. A
continuity tester is needed to check the oil pressure switch.
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.
Oil Pressure Sensor
The oil pressure sensor is connected to the engine oil system
and uses oil pressure to present a variable resistance to the
controller. If the controller records Alarm Code 31 and the oil
pressure appears to be normal, test the oil pressure sensor.
NOTE: Polarity must be considered when connect-
ing pressure sensors. If a sensor is connected back-
wards, the display will show four dashes (----).
Consult the unit wiring diagram or schematic for cor-
rect connections.
Sensor Test
1. Turn the unit On/Off switch OFF.
2. Disconnect the OSP and OSN wires from the oil pressure
sensor.
3. Turn the unit On/Off switch ON.
4. Enter the controller View menu and scroll to the oil pres-
sure screen. The display should show “---- / OiL”. If all
sensors show “----” in the top display, the controller may
be defective or the sensor polarity may be reversed. Test
the controller and check the sensor wiring for correct
polarity.
Oil Pressure Sensor
SGCO 2000-151, July 2001
Electrical Maintenance Oil Level Switch 5-3

5. Using a digital voltmeter, check the voltage from the OSP
wire to OSN. The voltage must be +7 volts or more.
a. If the top display showed “----” and the voltage is +7
volts or more, the sensor is defective. Replace the
sensor. Be sure to reconnect the OSP wire after ser-
vice is complete.
b. If the top display showed something other than “----”
or the voltage is less than +7 volts, the wire harness
or the controller is defective, not the sensor.
Continuity test the wire harness OSP circuit. Test the
controller.
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 push-in style switch by carefully prying it out
of the oil pan with a pry bar. The neoprene seal may stay
in the oil pan.
3. To install the push-in style switch, first remove the neo-
prene seal from the switch. Lubricate the neoprene seal
and install it in the oil pan. Then press the switch into the
neoprene seal. No tools are required.

Oil Level Switch 4. Connect the switch wires to the main wire harness after
installing it.
The low oil level sensor (OLS) switch will close and cause the
controller to stop the engine if the engine oil level drops below
NOTE: The low oil level switch must have a drip
the actuation level. The oil level switch is located in the oil
loop formed in wire leads as shown in the illus-
pan on the front side of the engine near the oil filter.
tration. The drip loop prevents water from enter-
ing the switch through the end of the sleeving
Switch Test
that protects the switch wires.
1. Make sure that the unit is turned OFF.
2. Disconnect the switch wires from the main wire harness.
Bench Test
3. Connect a continuity tester to the two sockets in the low
1. Disconnect the switch wires from the main wire harness.
oil level switch wire connector.
Remove the switch from the oil pan.
4. Check the oil level with the dipstick and make sure that it
2. Use a small container partially filled with engine oil to
is between the low mark and the full mark. Add oil if nec-
check the float. Make sure that it floats in engine oil and
essary.
that it slides freely between the upper and lower stops.
5. The switch should be open and there should be no conti-
3. Slide the float up to the upper stop and check the continu-
nuity between the switch wires with the oil level between
ity through the switch (between OLS and CH wires). The
the low mark and the full mark on the dipstick.
switch should be open.
4. Slide the float down to the lower stop and check the conti-
nuity 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.

Push-in Style Oil Level Switch

1. 19 mm (0.75 in.)
2. Secure with Tie Band
3. Drip Loop with Open End of Sleeving Pointed Down
4. Upper Stop
5. Float
6. Lower Stop

SGCO 2000-151, July 2001

5-4 Coolant Temperature Sensor
Coolant Temperature Sensor
The coolant temperature sensor is connected to the engine
coolant system near the water pump and uses coolant tempera-
ture to present a variable resistance to the controller. If the
controller records Alarm Code 18 or 41 and the coolant tem-
perature appears to be normal, test the coolant temperature
sensor.
NOTE: Polarity must be considered when connect-
ing temperature sensors. If a sensor is connected
backwards, the display will show four dashes (----)
and record Alarm Code 06. Consult the unit wiring
diagram or schematic for correct connections.
Sensor Test
1. Turn the unit On/Off switch OFF.
2. Disconnect the sensor at the plug next to the sensor.
3. Turn the unit On/Off switch ON.
4. Enter the controller View menu and scroll to the engine
temperature screen. The display should show “---- / Ent”.
If all sensors show “----” in the top display, the controller
may be defective or the sensor polarity may be reversed.
Test the controller and check the sensor wiring for correct
polarity.
5. Using a digital voltmeter, check the voltage at the sensor
plug connected to the controller. The voltage must be
from 4.90 to 5.10 volts dc.
a. If the voltage is correct, disassemble and inspect the
coolant sensor plug. If there are no broken wires or
pushed pins in the plug, replace the sensor.
Flywheel Sensor with Wiring and Schematic
Symbols
Electrical Maintenance
b. If the voltage is incorrect, recheck the voltage at the
same circuit at pins 1 and 2 of the CN7 connector on
the back of the controller. The voltage must be from
4.90 to 5.10 volts dc. If the voltage is correct at the
controller, the problem is in the wiring. Continuity
test the wire harness circuits. If the voltage is incor-
rect again, the controller is defective. Test the con-
troller.
Coolant Level Detector
The coolant level detector (sensor) is a stainless steel probe
immersed in the coolant. It does not fail or wear out, but may
fail to conduct current if it is dirty.
If the coolant level drops too low in the radiator, the sen-
sor will no longer conduct current to return a signal to the con-
troller. After 30 seconds, the controller will record Alarm
Code 37. If the controller records alarm code 37 and the radia-
tor is full of coolant, test the coolant level sensor.
WARNING: DO NOT remove the radiator cap from
the radiator fill neck when the engine coolant is hot.
Sensor Test
1. Ground the sensor to chassis ground with a jumper wire.
2. Attempt to clear Alarm Code 37 from the controller.
• If Alarm Code 37 clears, clean the sensor.
• If Alarm Code 37 does not clear, test the wire harness
for continuity. Also test the controller.
Flywheel Sensor
The flywheel sensor is in the engine bell housing adjacent to,
but not touching, the flywheel (backed off 1/2 turn).
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 that has a voltage and frequency variation pro-
portional to the engine rpm.
By monitoring the frequency of this signal with the starter
disconnect module, the timing of the starter disengagement can
be precisely controlled.
If the flywheel sensor fails, the starter may not disengage
or engage properly.
SGCO 2000-151, July 2001
Electrical Maintenance Relays 5-5

Testing the Flywheel Sensor

Equipment required: Field, Preheat, Start and Run Relays
• AC voltmeter capable of reading up to 10 volts
These are 12 Vdc relays. These relays are identical and inter-
• Ohmmeter
changeable. Test a relay by interchanging it with a known
• SG unit for installing the sensor in the threaded hole in the
good relay.
flywheel housing.
To test the flywheel sensor:
Field Relay A
1. Install the flywheel sensor into the threaded hole in the
Field Relay A grounds the exciter field circuit 15 -20 seconds
flywheel housing of an SG unit until it contacts the ring
after unit startup. Field Relay A must be grounded to supply
gear. Back out the sensor 1/2 turn and tighten the lock
alternator output to the battery charger. If the field relay fails
nut.
in the open position, the exciter field will not energize. If the
2. Disconnect wires (FS1 and FS2) from the sensor.
field relay fails in the closed position, the exciter field will
3. Start and operate the unit. Check the ac voltage output
remained energized.
across the sensor terminals. Use a meter with a high ohms
per volt internal resistance. A Simpson 260, Fluke digital
Preheat Relay
or any good VOM will work. However, an automotive
The preheat relay supplies power to the air heater relay
type meter may not give an accurate reading because the
and the buzzer. If the preheat relay fails in the open position,
meter may load the circuit heavily and cause the voltage
the air heater would not preheat and the engine may not start,
level to appear lower than actual. The output voltage
resulting in the cranking time limit being exceeded. If the pre-
should be 1.5 to 2.0 Vac.
heat relay fails in the closed position, the air heater will remain
energized.
NOTE: If the voltage is slightly off, the voltage
may be increased by turning the sensor in more. Start Relay
The voltage may be lowered by turning the sen- The start relay is energized by the controller after proper pre-
sor out more. heat time has occurred. When this relay energizes, the starter
solenoid receives power and the engine cranks. If the start
4. Reconnect FS1 and FS2 wires on flywheel sensor. relay fails in the open position, the engine would not crank. If
the relay failed in the closed position, the starter would contin-
If the flywheel sensor passes the above test, the sensor may be ue to crank after the unit started.
considered good. If a unit is not available, an alternate but less
reliable test may be performed as follows: Run Relay
1. Disconnect the sensor from all wires. The run relay supplies power to the fuel solenoid. If the run
2. Measure the resistance across the terminals. The resis- relay fails in the closed position, the unit would operate contin-
tance should be 250 to 300 ohms across the terminals. uously and not stop for a protection shutdown. If the relay
3. Measure the resistance from each terminal to the alu- fails in the open position, the fuel solenoid would not stay in.
minum case. There should be no continuity from each
terminal to the case.

Buzzer
The buzzer module on the circuit board is sounds off when the
air heater relay is energized for preheat and starting.

SGCO 2000-151, July 2001

6 Engine Maintenance

Oil Filter Change

Engine Lubrication System
The TK 486 diesel engine has a pressure lubrication system.
Oil is circulated by a trochoid type oil pump driven by the
crankshaft timing gear. The pumping capacity of the trochoid
type pump is several times greater than the capacity required
by the engine. Oil is picked up through a suction tube with a
screened inlet.
Engine Oil Change
The engine oil should be changed according to the Service
Guide in the Introduction of this manual or the Maintenance
Inspection Schedule on the unit. Drain the oil only when the
engine is hot to ensure that all the oil drains out. When chang-
ing oil, keep the unit and trailer level so all the oil can flow
from the oil pan.
1. Drain out as much of the oil as possible. Most of the dirt
particles are found in the last few quarts of oil that drain
out.
2. Refill the pan with oil and check the dipstick level.
• TK 486 Engine: Add 12.3 liters (13 qt.) of oil.
The oil filter should be changed when you change engine oil.
Spin-on Filter:
1. Remove the filter.
2. Apply oil to rubber ring of new filter and install filter.
3. Tighten the filter by hand until the rubber ring makes con-
tact. Then tighten 1/2 turn more.
4. Start the unit and check for leaks.
NOTE: Do not use a tool to tighten the filter.
Crankcase Breather
The crankcase breather includes a baffle, screen and cover
located in the rocker arm cover. The crankcase pressure
should be between 0 and 50 mm (0 to 2 in.) H2O. Inspect the
breather assembly and hose during scheduled maintenance
inspections to make sure they are not plugged or damaged.

NOTE: See Specifications chapter for unit oil

capacity and correct type of oil to use.

3. Operate the unit. Then recheck the oil level. Add oil as
necessary to reach the full mark.

Crankcase Breather System

1. Air Heater
2. Intake Manifold
3. Restrictor in Breather Hose
4. Crankcase Breather

SGCO 2000-151, July 2001

6-2 Engine Air Cleaner Engine Maintenance

Engine Air Cleaner Engine Cooling System

A heavy duty oil bath air cleaner filters all of the air entering
the engine. Excessive restriction of the air intake system
reduces the flow of air to the engine. This in turn affects
horsepower output, fuel consumption and engine life.
The speed that dirt and foreign particles accumulate at the
bottom of the air cleaner sump determines the frequency of
cleaning.
1. Remove the reservoir under the filter.
2. Remove the dirty oil and sludge. Remove air cleaner
body and clean in a parts washer.
3. Refill the reservoir to the oil level mark with clean engine
oil, but DO NOT OVERFILL. Use the same weight oil
used in the engine crankcase.
The engine uses a closed, circulating type, pressurized cooling
system. Correct engine temperatures are controlled and main-
tained by a radiator, fan and thermostat. The coolant is circu-
lated through the system by a belt-driven centrifugal pump.
The pump draws the coolant from the side of the radiator, cir-
culates it through the cylinder block and head, then back to the
radiator. A thermostat mounted in the water outlet from the
cylinder head to the radiator automatically maintains coolant
temperature within the specified temperature range.
All water-cooled engines are shipped from the factory
with a 50% 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.

Antifreeze Maintenance Procedure

Regular inspection is required to verify the condition of the
antifreeze. The inhibitors in Extended Life Coolant (ELC)
antifreeze (red color) extend change intervals to 5 years or
12,000 hours. A decal tag on the coolant expansion tank will
identify units with ELC antifreeze.
ELC coolants are available in 100% full strength concen-
trate or (pre-mixed) 50/50% mixture. Thermo King recom-
mends the use of 50/50% pre-mixed ELC antifreeze to assure
that de-ionized water is used. 100% 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 capac-

ity and correct type of antifreeze for your unit.

CAUTION: There are several important rules:

• Extended Life Coolant (ELC) is RED in color while
conventional coolant is GREEN or BLUE-GREEN.
• Do NOT add “RED” coolant to cooling systems
using “GREEN” or “BLUE-GREEN” coolant.
• Do NOT add “GREEN” or “BLUE-GREEN” coolant
to cooling systems using “RED” coolant.

When changing antifreeze, drain, flush and replace the

total antifreeze mixture to maintain total cooling system pro-
tection. To prevent mineral scale, use water with a total hard-
Air Cleaner System ness under 170 ppm. If the total water hardness is over 170
ppm, soften the water or use distilled water. The water must
1. Air Cleaner also be de-mineralized, de-ionized or distilled if it does not
2. Air Cleaner Hose meet the following requirements: chlorides concentration
3. Air Intake Adapter under 40 ppm, sulfates concentration under 100 ppm and total
4. Oil Cup Clamp dissolved solids under 340 ppm.
5. Oil Cup

SGCO 2000-151, July 2001

Engine Maintenance Engine Cooling System 6-3

The factory recommends the use of a 50/50 antifreeze/water
mixture in all units even if they are not exposed to freezing tem-
peratures. This antifreeze mixture will provide the required cor-
rosion protection and lubrication for the water pump.
Checking the Antifreeze
Check the solution concentration by using a temperature com-
pensated 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 con-
centrate and 32 percent water for use in extreme temperatures.
Changing the Antifreeze
WARNING: Avoid direct contact with hot coolant.
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 flush-
ing agent manufacturer.
c. Open the engine block drain to drain water and flush-
ing solution.

Engine Cooling System

1. Water Pump 12. Overflow Tank
2. Water Temperature Sensor
3. Engine Thermostat Housing
4. Engine Thermostat
5. Vent Hose
6. Radiator Cap
7. Expansion Tank
8. Vent Fitting for Bleeding Air from Radiator (recently built models)
9. Water Level Sensor
10. Radiator
11. Drain Cock, Radiator
SGCO 2000-151, July 2001
6-4 Engine Cooling System
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 bear-
ing for looseness and retighten the belt (see “Belt Tension
Adjustment and Replacement” on page 6-13).
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% 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% pre-mixed ELC antifreeze to assure that
de-ionized water is used. 100% concentrate
extended life coolant must be mixed with de-ion-
ized or distilled water (NOT tap water) to ensure
cooling system integrity.
8. Close all drains. On recently built units, also open vent fit-
ting 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. 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 radia-
tor with coolant.
Engine Maintenance
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 seem to fill the cooling system after it has
been drained, air has been trapped in the block. Bleed the air
out of the block using the following procedure:
CAUTION: IF YOU SUSPECT THAT AIR IS TRAPPED
IN THE BLOCK, DO NOT START THE ENGINE WITH-
OUT BLEEDING THE AIR OUT OF THE BLOCK.
NOTE: If an engine operates with air trapped in the
block, the engine may be damaged. The high water
temperature switch may not protect an engine that
has air trapped in the block.
1. Before pouring coolant into the cooling system, loosen the
plug on the back of the water pump. 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.
2. Slowly pour coolant into the system until coolant comes
out of the bypass hose (or plug) fitting.
3. Tighten the plug on the water pump.
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 and operate the unit for a minute. Then stop the unit.
7. Check the coolant level and add coolant if necessary.
8. Repeat steps 6 and 7 until the coolant level stabilizes.
9. Close the vent fitting on the top of the inlet header on the
radiator (recently built units only).
Engine Thermostat
For best engine operation, always use a 82.0 C (180 F) ther-
mostat.
Engine Thermostat
1. Jiggle Pin
2. Install This End Toward Engine
SGCO 2000-151, July 2001
Engine Maintenance Engine Fuel System 6-5

The TK 486 diesel engine uses an in-line injection pump.

Engine Fuel System The injection pump camshaft is driven at one end by the
engine timing gears. The cam lobes actuate the plungers, forc-
The components of a typical fuel system include:
ing fuel through the injection nozzles. A governor assembly is
1. Fuel tank
connected to the other end of the injection pump camshaft.
2. Fuel strainer (inlet to transfer pump)
The governor meters the amount of fuel delivered to the injec-
3. Fuel filter
tion nozzles by controlling the position of the plungers.
4. Water separator
Injection pump leakage, injection nozzle overflow and
5. Hand fuel pump
excess fuel from the fuel filter assembly return to the fuel tank
6. Transfer pump
through the return lines.
7. Injection pump
8. Injection nozzles
Maintenance
The hand fuel pump is used to manually draw fuel from The fuel system is relatively trouble-free and if correctly main-
the tank up to the transfer pump if the unit should run out of tained will usually not require major service repairs between
fuel. engine overhauls.
The transfer pump draws fuel from the fuel tank through a Contamination is the most common cause of fuel system
fuel inlet strainer at the inlet to the transfer pump. The transfer problems. Therefore, to ensure best operating results, the fuel
pump then delivers fuel through the fuel heater (option) to the must be clean and fuel tanks must be free of contaminants.
water separator and fuel filter. Filtered fuel passes through a The single element fuel filter/water separator must be changed
line from the outlet fitting on the filter base to the injection according to the Service Guide in the Introduction of this man-
pump. ual or the Maintenance Inspection Schedule on the unit.

Fuel System
1. Fuel Return Line 7. Fuel strainer
2. Fuel Supply Line to Injection Pump 8. Hand Pump
3. Fuel Bleed Screw 9. Fuel Supply Line
4. Injection Pump 10. Electric Fuel Heater
5. Fuel Supply Line to Fuel Filter 11. Fuel Filter/Water Separator
6. Transfer Pump 12. Fuel Return Line

SGCO 2000-151, July 2001

6-6 Engine Fuel System Engine Maintenance

NOTE: The injection nozzles should be tested every 4. Loosen the injection lines at the injection nozzles.
10,000 hours when only clean fuel is used and the 5. Crank the engine until fuel appears at the nozzles.
fuel system is maintained according to the 6. Tighten the injection lines.
Maintenance Inspection Schedule. Refer to the TK 7. Start the engine and observe engine operation for a few
482 and TK 486 Engine Overhaul Manual for injection minutes. If the engine fails to start, or starts but stops in a
nozzle testing and repair. few minutes, repeat the procedure.

Whenever the fuel system is opened, take the following Water in the Fuel System
precautions to prevent dirt from entering the system:
Water in the fuel system can damage the injection pump and
• Cap all fuel lines.
nozzles. This damage will subsequently cause more expensive
• Work in a relatively clean area whenever possible.
damage to the engine. A large accumulation of water in the
• Complete the work in the shortest possible time.
bottom of the fuel tank will stop a diesel engine. Water should
Any major injection pump or nozzle repairs should be
be drained off during scheduled maintenance inspections. Let
done by a quality diesel injection service shop. The necessary
the tank set idle for an hour before removing the drain plug
service equipment and facilities are not found in most engine
from fuel tank. Let water and fuel drain into a container until
rebuild shops because of the large investment required.
only fuel is draining from tank. Replace drain plug. DO NOT
The following procedures can be done under field condi-
steam clean fuel tank caps.
tions:
• Bleeding air from the fuel system
NOTE: Some fuel tanks have a check valve in the
• Fuel tank and filter system maintenance
drain plug fitting. Push the check valve open with a
• Prime pump (hand) replacement or repair*
small screw driver to drain water and fuel.
• Transfer pump replacement or repair*
• Injection line replacement*
• Pump and governor adjustments*
• Pump timing
Single Element Fuel Filter/Water Separator
• Nozzle spray pattern testing and adjustment*
Replacement
• Minor rebuilding of nozzles* A single element fuel filter/water separator removes contami-
nates and water from the fuel. Two orifices in the filter head
*These procedures are covered in the TK 482 and TK 486 control the pressure in the fuel system by allowing a certain
Overhaul Manual, TK 50136. amount of fuel to return to the tank. One orifice is located in
the center of the filter head bleeds off water and returns it to
the fuel tank. The other orifice is located off-center on the fil-
Bleeding the Fuel System ter head and bleeds off air.
The fuel system must have the air bled out if the fuel tank 1. Unscrew the filter using a strap wrench. Drain filter and
becomes empty, if repairs are made to the fuel system, or if air properly dispose of fuel and filter.
gets into the system for any other reason. 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 cen-
NOTE: Keep the fuel tank vent open. If the vent ter hole to add fuel to the filter or unfiltered fuel may
becomes clogged, a partial vacuum develops in the reach the injection pump. Filling the filter with fuel
tank. This increases the tendency for air to enter the purges air from the filter.
system. 3. Clean the filter head seal surface. Lubricate filter seal
with clean fuel.
1. Loosen the bleed screw at the injection pump about one 4. Install and tighten the filter until it is hand-tight. Then
turn. tighten 1/4 turn more using a strap wrench.
2. Unscrew the hand 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 hand pump handle
back in.

SGCO 2000-151, July 2001

Engine Maintenance
Engine Speed Adjustment
NOTE: The speed of the engine should be checked
with a hand tachometer, TK P/N 204-220, on the
crankshaft pulley bolt or by the use of a stroboscope
tachometer, TK P/N 204-436.
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.
Make the engine speed adjustments with the engine fully
warmed up.
Adjustment Procedure
1. Start the unit and check the speed rpm. The engine speed
should be 1800 +/- 10 rpm at Full Load (60 Hz alternator
output); 1890 +/- 10 rpm at No Load.
2. Loosen the jam nut on the speed adjustment screw.
3. Adjust the screw to change engine rpm.
4. When the speed is correct, tighten the jam nut.
Engine Speed Adjustment
1. Fuel Solenoid
2. Low Speed Adjustment Screw
Engine Speed Adjustment 6-7
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 posi-
tion. 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.
A fuel solenoid timer printed circuit board contains the
timer and relay that control the pull-in coil in the fuel solenoid.
Refer to a parts manual for the correct printed circuit board for
your unit.
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 bat-
tery has enough power to crank the engine over, it
has enough power to energize the fuel solenoid pull-
in coil.
If you suspect that the engine does not operate because the fuel
solenoid is not operating correctly, use the following proce-
dure:
1. Disconnect wire 8S from the starter solenoid.
Integral Fuel Solenoid Harness Connections
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
SGCO 2000-151, July 2001
6-8 Integral Fuel Solenoid
2. Disconnect the fuel solenoid wire connector from the
main wire harness.
3. Place the Unit On/Off switch in the ON position.
4. Check the voltage on 8D circuit in the main wire harness
connector for the fuel solenoid. Refer to the illustration
on page 6-7 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 5.
5. Check CH circuit in the main wire harness at the fuel sole-
noid 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 6.
6. Place a jumper wire between the CH circuit in the connec-
tor on the fuel solenoid and a good chassis ground.
7. Test the pull-in coil by momentarily placing a jumper
between the 8DP circuit pin in the connector on the fuel
solenoid and terminal 2 at the fuse link. The fuel solenoid
should make a definite click when the pull-in coil is ener-
gized and 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 resis-
tance of the pull-in coil by placing an ohmmeter
between 8DP circuit and the CH circuit in the connec-
tor on the fuel solenoid. The resistance of the pull-in
coil should be 0.2 to 0.3 ohms. If the resistance of the
pull-in coil is not in this range, replace the fuel sole-
noid.
NOTE: If the pull-in coil fails, make sure to
replace the fuel solenoid relay with the cor-
rect relay. Refer to unit parts manual.
b. If the pull-in coil does energize, go to step 8.
8. 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 terminal 2 at the fuse link.
b. Momentarily energize the pull-in coil by placing a
jumper between the 8DP circuit in the connector to
the fuel solenoid and terminal 2 at the fuse link. 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.
Engine Maintenance
c. De-energize the hold-in coil by removing the jumper
from the 8D circuit and terminal 2. 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 resis-
tance of the hold-in coil is not in this range, replace
the fuel solenoid.
e. If the hold-in coil does function properly, go to step
9.
9. Reconnect the main wire harness connector to the fuel
solenoid connector.
10. Remove the fuel solenoid relay from its socket and make
sure the unit On-Off switch is in the ON position.
11. Check the voltage on the 8D circuit at terminal 85 in the
fuel solenoid relay socket. Refer to the illustration below
to identify the terminals in the relay socket.
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 12.
12. Check the voltage on the 2A or 2B circuit at terminal 30
in the fuel solenoid relay socket.
a. If battery voltage is not present on the 2A or 2B cir-
cuit, check circuit 2A or 2B for an open or a short.
b. If battery voltage is present on circuit 2A or 2B, go to
step 13.
Relay Socket Terminal Identification — Integral Fuel
Solenoid
1. 87 Terminal/8DP Wire
2. 85 Terminal/8D Wire
3. 86 Terminal/8DC Wire
4. 30 Terminal/2A or 2B Wire
SGCO 2000-151, July 2001
Engine Maintenance Injection Pump Service 6-9

13. Test the relay.

a. Use a jumper to connect the 85 terminal on the relay Injection Pump Service and Timing
to terminal 2 at the fuse link.
b. Use another jumper to connect the 86 terminal on the
NOTE: The procedure outlined will assume the
relay to a CH circuit.
pump is being removed and replaced on the engine.
c. If the relay does not energize, it is defective. Replace
If the pump has not been removed, only the last por-
the relay.
tion of the procedure is used for timing.
d. If the fuel solenoid does energize, the timer is defec-
tive. Replace the fuel solenoid timer PC board.
14. Turn the unit OFF.
15. Connect wire 8S to the starter solenoid.
Injection Pump Removal
The injection pump drive gear will not fit through the gear
Fuel Solenoid Replacement housing when removing the pump. The gear must be separat-
ed from the pump using tool P/N 204-1011. When this tool is
1. Disconnect wire 8S from the starter solenoid.
used, it is not necessary to remove the water pump belt, fuel
2. Disconnect the fuel solenoid wire connector and remove
pump, crankshaft pulley, crankshaft seal or front plate.
the old fuel solenoid.
1. Remove the starter for clearance. Also remove the fuel
3. Connect the main harness connector to the new fuel sole-
lines, harness and mounting hardware from the injection
noid.
pump. Cover all injection lines and fuel lines with plastic
4. Place the Unit On/Off switch in the ON position to to
covers or tape. The smallest amount of dirt can damage
energize the fuel solenoid.
the fuel system.
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. Then
the fuel solenoid will not function properly.

5. Place the O-ring in the groove in the end of the fuel injec-
tion pump. Make sure that the O-ring is positioned cor-
rectly during installation to avoid damage and leaks.
6. Install the new fuel solenoid.
7. Turn the unit OFF.
8. Connect wire 8S to the starter solenoid.

Integral Fuel Solenoid Components Align Timing Marks

1. Integral Fuel Solenoid 1. Timing Mark Access Hole
2. O-ring 2. Number One Cylinder Injection Line
3. Fuel Injection Pump Groove 3. Number One Cylinder Delivery Valve Holder

SGCO 2000-151, July 2001

6-10 Injection Pump Service Engine Maintenance

2. Remove the cover plate from the gear case. Remove the Injection Pump Installation
nut and lockwasher that secure the gear to the injection
pump shaft. Use a shop rag to prevent the lockwasher or 1.
nut from falling into the gear case.
3. Use the hardware from the cover plate to attach the tool
plate (P/N 204-1011) to the gear case. Attach the plate 2.
with the marked side pointing up and out away from the
case. 3.
4. Align the threaded holes in the injection pump gear with
the two holes in the tool plate by rotating the engine 4.
crankshaft. Attach the gear to the tool plate with the
screws provided with the tool plate.
5. Thread the long screw into the small end of the adapter
(both parts are supplied with the tool plate). Insert the 5.
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. 6.
6. Remove the screw and adapter, leaving the tool plate in
position. This holds the gear in the proper tooth align-
ment until the injection pump is re-installed.
Rotate the injection pump shaft to align the key with the
keyway in the gear. Then insert the injection pump shaft
into the gear.
Fasten the injection pump to the gear case using the cor-
rect hardware.
Remove the screws that hold the gear to the tool plate and
remove the tool plate.
Fasten gear to injection pump shaft with a lockwasher and
nut. Use a shop rag to prevent the lockwasher or nut from
falling into the gear case. Torque the nut to 60 to 68 N.m
(44 to 50 ft-lb).
Fasten the cover plate to the gear case. Install the fuel
lines, harness and mounting hardware from the injection
pump. Also install the starter.
Check the injection pump timing.

Injection Pump Gear Tool (P/N 204-1011)

1. Injection Pump 5. Adapter (Tool)
2. Gear Case 6. Long Screw (Tool)
3. Cover Plate 7. Short Screw (Tool)
4. Cover Plate Bolt 8. Plate (Tool)

SGCO 2000-151, July 2001

Engine Maintenance
Injection Pump Timing
This timing procedure requires fuel pressure at the injection
pump inlet. This can be accomplished by pumping the priming
pump by hand, or by using an electric fuel pump to supply fuel
to the fuel pump inlet.
1. Place the Unit On/Off switch in the OFF position.
2. Remove the round cover (plug) from the timing mark
access hole on the front of the bell housing. The index
marks on either side of this hole and the timing marks on
the flywheel are used to check the injection pump timing.
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. Remove the injection line for the number one cylinder
from the injection nozzle and from the delivery valve on
the injection pump.
NOTE: The number one cylinder is the cylinder at
the flywheel end of the engine.
4. Remove the rocker arm cover.
5. 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) until
the 1-4 timing mark on the flywheel lines up with the
index mark in the timing mark access hole.
b. Check the rocker arms on the number one cylinder to
see if they are loose.
c. If the rocker arms are loose, the engine is at top dead
center of the compression stroke for the number one
cylinder.
Top Dead Center Marks
1. Index Mark
2. Top Dead Center Mark for Cylinders 1 and 4
Injection Pump Service 6-11
d. If the rocker arms are tight, the engine is at top dead
center of the exhaust stroke for the number one cylin-
der. Rotate the engine 360 degrees to place the engine
at top dead center of the compression stroke for the
number one cylinder.
6. Energize the fuel solenoid:
WARNING: Disconnect the 8S wire from the
starter solenoid to prevent the engine from
cranking. Otherwise, the µP-G controller may
start the unit at any time when the unit On/Off
switch is ON.
a. Disconnect the 8S wire from the starter solenoid to
prevent the controller from cranking the engine.
Then place the On-Off switch in the ON position.
b. If the engine is not in the unit, use jumper wires to
energize the fuel solenoid at the three pin fuel sole-
noid connector. Place a jumper between the black
wire (CH wire, pin C) and the negative terminal of a
12 Vdc power source. Place a jumper between the
red wire (8D wire, pin A) and the positive terminal of
a 12 Vdc power source. Then momentarily place a
jumper between the white wire (8DP wire, pin B) and
the positive terminal of a 12 Vdc power source.
CAUTION: Do not leave the jumper on the white
wire (8DP wire, pin B) more than a few seconds
or the fuel solenoid will be damaged.
Timing Mark Alignment
1. Position Timing Mark in Bottom of Access Hole
2. Correct Timing Mark Alignment as Fuel Rises in
Delivery Valve Holder
3. Injection Timing Mark
SGCO 2000-151, July 2001
6-12 Adjusting Engine Valve Clearance
7. Rotate the engine backwards (counterclockwise viewed
from the water pump end) until the injection timing mark
is positioned in the bottom of the timing mark access hole.
The injection timing mark is a horizontal line stamped on
the flywheel approximately 30 mm (1.2 in.) before the top
dead center mark.
8. Pump the priming pump by hand a few times, or energize
the electric fuel pump if an electric fuel is being used.
9. Use a clean towel to remove the fuel from the top end of
the delivery valve holder.
10. Slowly turn the engine in the normal direction of rotation
until you see the fuel rise in the end of the delivery valve
holder. Stop as soon as you see the fuel rise.
11. Check position of the timing marks. The injection timing
mark on the flywheel should be aligned with the index
mark on the side of the timing mark access hole. Repeat
steps 8 through 11 to recheck the timing.
12. If the timing is off by more than 1 degree (2.5 mm),
loosen the mounting nuts on the studs that fasten the injec-
tion pump to the engine and rotate the injection pump to
change the timing.
a. Pull the top of the injection pump away from the
engine to advance the timing.
b. Push the top of the injection pump toward the engine
to retard the timing.
13. Tighten the injection pump mounting nuts and recheck the
timing. Repeat steps 8 through 12 until the timing is cor-
rect.
14. Install the cover in the timing mark access hole, install the
injection line for the number one cylinder, install the rock-
er arm cover, tighten the other injection lines, and recon-
nect the 8S wire when finished with the procedure.
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
resulting in burned valves and seats. Excessive valve clear-
ance 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.
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.
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 cylin-
der. Rotate the engine 360 degrees to place the engine
at top dead center of the compression stroke for the
number one cylinder.
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 lock nut and adjust the valves as required by
turning the adjustment screw.
Timing Marks
1. Timing Mark
2. Top Dead Center Mark for Cylinders 1 and 4
3. Top Dead Center Mark for Cylinders 2 and 3
SGCO 2000-151, July 2001
Engine Maintenance Belt Tension Adjustment 6-13

6. Hold the adjustment screw while tightening the lock nut.

7. Recheck the valve clearance. Belt Tension Adjustment and Belt
8. Rotate the engine one full turn (360 degrees) to place the Replacement
engine at top dead center of the compression stroke for the
number four cylinder. Rotate the engine clockwise as
NOTE: Belt tension specifications are measured
viewed from the water pump end. Align the 1-4 timing
using Thermo King belt gauge tool, P/N 204-427.
mark on the flywheel with the index mark in the access
hole. This places the engine at top dead center of the
Belts should be regularly inspected during unit pre-trip for
compression stroke for the number four cylinder.
wear, scuffing or cracking and correct tension.
9. Check and adjust both valves for the number four cylin-
Correct belt tension is critical for correct unit operation.
der.
Belts that are too loose will slip, squeal or whip causing exces-
10. Place the engine at top dead center of the compression
sive vibration levels and poor unit performance. Belts that are
stroke for the number four cylinder. Also check the valve
too tight will put too much strain on the belt fibers and bear-
clearance for the intake valve for the number three cylin-
ings, causing premature belt and bearing failures. New belts
der, and the exhaust valve for the number two cylinder.
should be tensioned cold.
The clearance for both the intake and exhaust valves
should be 0.15 to 0.25 mm (0.006 to 0.010 in.).
NOTE: DO NOT attempt to remove or install belts
11. Replace the rocker arm cover and the timing mark access
without loosening adjustments. Belts that are
hole cover. Tighten the fuel injection lines when finished.
installed by prying will fail prematurely due to inter-
nal cord damage.

Valve Adjustments
Water Pump Fan Belt

Engine Water Pump Pulley (Items 1- 6):

Cylinder No. 1 2 3 4 1. Fixed Pulley Section
2. Spacer
Valve arrangement E I E I E I E I
3. Shims*
Piston in No. 1 cylinder is at O O O O 4. Sliding Pulley Section
TDC on compression stroke 5. Store Extra Shims Here*
Piston in No. 4 cylinder is at Θ Θ ΘΘ 6. Nut (4)
TDC on compression stroke 7. Belt
8. Crankshaft Pulley

Valve Adjustments and Cylinder Configurations * NOTE: The entire pulley assembly requires a minimum
of 4 shims for correct radiator fan alignment.

SGCO 2000-151, July 2001

6-14 Belt Tension Adjustment Engine Maintenance

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. If shims are removed to
tighten the belt, the shims that are removed must be
installed on the front of the pulley (see “Water Pump Fan
Belt” illustration on page 6-13).
3. Reinstall the belt on the pulley and replace the sliding pul-
ley section on the pulley.
4. Place any extra shims on the outside of the sliding pulley.

NOTE: The entire pulley assembly requires a

minimum of 4 shims for correct radiator fan
alignment.

5. Tighten the mounting nuts on the water pump pulley.

6. 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) deflec-
tion with 3 to 4 kg ( 6 to 9 lb) of force.

SGCO 2000-151, July 2001

7 Alternator Operation
and Diagnosis
The residual voltage supplies initial excitation power to
General Description the AVR. The initial excitation power increases alternator out-
put until steady state output voltage is reached. The AVR
The 460/230 Vac alternator consists of three principal compo-
derives a sample voltage from the output windings for voltage
nents: the main alternator, the integral direct-connected
control purposes. In response to this sample voltage, the AVR
exciter, and an externally mounted excitation control system.
controls the power fed to the exciter field (FLD) and thereby
The main alternator may be subdivided into the 4-pole
the rotating main field. The AVR provides closed loop control
rotating main field and the alternator stator (ALT).
of the output voltage within the specified limits, compensating
The rotating main field, the rotating rectifier and the
for load, speed, temperature and power factor of the generator.
exciter armature are all mounted on a common shaft. Output
A frequency measuring circuit continually monitors the
of the exciter is rectified by the shaft mounted rotating bridge
generator output and provides output under speed protection of
rectifier to provide the rotating main field excitation.
the excitation system. AVR provides under-speed protection
The externally mounted excitation control system is ener-
by reducing the output voltage proportionally with speed below
gized from the alternator output through an automatic voltage
a preset threshold. This threshold, called the under frequency
regulator (AVR). Excitation power is derived from a separate
roll off point (UFRO), is factory set at 95%. The UFRO adjust-
2-lead stator winding. Positive voltage build up from residual
ment is factory sealed to prevent field adjustment.
levels is provided through the semiconductor power circuitry
A solid-state battery charger is also tapped into the alter-
of the AVR. The exciter field contains a permanent magnet to
nator stator leads. The battery charger converts the alternator
maintain a residual voltage level.
output voltage to 14 Vdc. The voltage regulator RED lead is
connected to the 2 circuit.

460/230 Vac Alternator Component Function

SGCO 2000-151, July 2001

7-2 Alternator Function Alternator Operation and Diagnosis

Alternator Function
Starting Excitation
The initial excitation for the alternator is supplied by a perma-
nent magnet in the exciter field and residual magnetism in the
main field. Residual main stator voltage provides initial exci-
tation power to the automatic voltage regulator (AVR) from a
separate 2-lead stator winding. The generator set controller
energizes Field Relay A 15 seconds after the engine starts.
Energizing the Field Relay A connects K1 and K2 on the AVR
to start current flow from the AVR to wire F1. Wire F1 sends
the current through the exciter field to build voltage in the sta-
tor windings. The exciter field current then returns through
wire F2 to the Field Amps Conversion Module where the cir-
cuit is completed to chassis ground. The Field Amps
Conversion Module is on the µP-G relay board.
Running Excitation and Control
When the alternator output reaches the rated voltage, excita-
tion is provided by the alternator excitation winding. The
magnetic field that was formed in the exciter field winding by
the AVR 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 magne-
tized.
The magnetic field formed in the rotating main field wind-
ing 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 AVR monitors the stator output for voltage con-
trol purposes. The AVR controls the power fed to the exciter
field, and therefore, the main field, to maintain the alternator
output voltage within specified limits.
Overload Shutdown
Overload shutdown is provided by the Field Amps Conversion
Module. If an overload condition becomes more than tempo-
rary, the increase in exciter field current due to the overload
causes the AVR to increase field current to the Field Amps
Conversion Module. This module converts the field current to
an analog voltage that is sent to the microprocessor controller.
When an overload occurs, the controller de-energizes the fuel
solenoid to stop the engine.
If the Generator set 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 AVR, resulting in exces-
sive field current. This includes possible malfunction of
protective elements in the excitation control.
4. Failure in the alternator rotating elements (exciter arma-
ture, 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.

Overload
For temporary overloads (such as refrigeration unit start up),
the AVR controls the power 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.

SGCO 2000-151, July 2001

Alternator Operation and Diagnosis
Alternator Diagnosis
Preliminary Checks
WARNING: Extreme care must be used when work-
ing with an operating generator set. Lethal voltage
potentials exist inside the control box, at terminals
on the AVR and at the power receptacle.
Before attempting more specific diagnosis procedures, check
the following items to ensure a superficial problem is not over-
looked.
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 fails to provide voltage output to the plug,
perform a controller Pretrip Test. The controller must pass
the Pretrip test to verify the field relay circuit is operating
correctly. Field Relay A (K1 to K2) circuit must be ener-
gized before the automatic voltage regulator (AVR) can
supply current to the exciter field of the alternator.
2. 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.
3. Disconnect the refrigeration unit from the generator and
check the output voltage at the plug. Voltage between the
three phases should be 450 to 470 Vac, depending on
engine speed. All three phases should be within 1% of
each other.
If the voltages appear normal, make sure the refriger-
ation unit is not at fault. Reconnect refrigeration unit and
run in Cool mode. Check the amperage draw with an
induction ammeter (amprobe), and compare it with the
refrigeration unit nameplate.
4. Stop the generator set. Check all push-in plugs on control
circuit for loose pins or sockets. Make sure all wire termi-
nals are tight.
Alternator Diagnosis 7-3
Test Instruments
If the preceding checks did not uncover the cause of the mal-
function, more extensive diagnostic procedures will be
required. The following tests will require various electrical test
instruments. 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 most
cases, avoid unnecessary dismantling and reassembly of the
generator when easily corrected problems may exist in the
external circuitry.
The test instruments required include:
• AC-DC voltmeter 2.5 V to 500 V ranges (+/- 2% max. error).
• AC induction ammeter (amprobe).
• DC ammeter (preferably induction type TK P/N 204-449).
• Ohmmeter.
• Megohmmeter (Megger®). A megohmmeter is essentially a
high-range resistance meter (ohmmeter) with a built-in
direct-current generator. This meter is constructed with both
current and voltage coils-enabling true ohms to be read
directly and 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 should read in the megohm
range.
Normally, good insulation has high resistance; poor insu-
lation, 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).
A popular megohmmeter used in the field today is the
“Megger®” manufactured by:
AVO Biddle Instruments
Bluebell, Pennsylvania 19422
Phone: (215) 646-9200
• Milli-ohmmeter.
SGCO 2000-151, July 2001
7-4 Alternator Diagnosis Alternator Operation and Diagnosis

Generator Diagnosis Procedure 3. Start the engine. Alternator output voltage should
rise to 470 to 550 Vac while the jumper wire is con-
nected to the F1 lead. If the voltage does not reach
WARNING: When servicing or repairing a generator
the 470 to 550 Vac, check for an internal alternator
set, the possibility of serious or even fatal injury
problem. See Alternator Tests on pages 7-10 to 7-11.
from electrical shock exists. Extreme care must be
4. Stop the engine and disconnect the jumper wire.
used when working with an operating generator set.
Connect F1 lead to X terminal of the AVR.
Lethal voltage potentials can exist at the unit power
5. Restart the engine to verify normal 460 Vac output.
cord, inside the exciter control box, inside any high
• If the Alternator output voltage returns to 0 to 100
voltage junction box and within the wiring harness-
Vac, repeat steps 1 through 5 to flash the exciter field
es.
again. Normal output AC voltage after field flashing
due to residual magnetism is 120 +/- 20 Vac. If the
Normal alternator output voltage is 460 +/- 10 VAC with
AC voltage output is less than 120 +/- 20 Vac,
engine rpm 1890 +/- 10 rpm and no load applied. If the gener-
replace the exciter field.
ator produces no or low voltage output at the plug, perform the
tests listed below to identify the component that may be caus-
NOTE: A new exciter field is not magnetized.
ing a generator malfunction.
Install the new exciter field and then follow the
Flash Exciter Field procedure to magnetize it.
• Symptom: Low Output Voltage—0 to 100 Vac
A. Flash Exciter Field (see illustration below).
• If the output voltage is now greater than 120 Vac
1. With the unit off, open the control box and disconnect
but less than 420 Vac, and all three output voltages
the F1 lead from the AVR.
are equal, go to step B on page 7-5.
2. Connect a jumper wire from the positive (+) post of
• If the output voltage is now greater than 120 Vac
the 12 Vdc battery to the F1 lead.
but less than 420 Vac, and unequal line to line volt-
ages, go to “Symptom: Unequal Line to Line
Voltage” on page 7-9.

Flashing the Exciter Field

SGCO 2000-151, July 2001

Alternator Operation and Diagnosis
B. Check AVR Excitation and Sense Voltage Inputs (see
illustration below).
Both the Excitation voltage and Sense voltage should be
one half the generator output voltage with 460 VAC alter-
nator connections.
1. With the engine running, measure the voltage on the
excitation winding, Q1 to Q2 at AVR terminals P2 to
P3.
2. Also measure the sense voltage on the T7 to T8 wires
at AVR terminals 2 to 3.
3. With 120 to 420 Vac output voltage, the excitation
voltage and sense voltage should each be one-half of
the output voltage due to the permanent magnet in
exciter field and residual magnetism in the main field.
4. If AVR excitation voltage or sense voltage is outside
the value in step 3 above, disconnect the wires from
the AVR and recheck the voltage across the wire
leads.
• If the excitation voltage and sense voltage remain
outside the above readings, check for an alternator
problem. See Alternator Tests on pages 7-10 to 7-11.
• If the measured voltage recovers to one-half of the
output voltage, the AVR input may be shorted. Go
to Step E on page 7-9.
Measuring the Excitation and Sense Voltage Inputs to AVR
Alternator Diagnosis 7-5
C. Check Exciter Field Circuit Resistance (see illustrations
on pages 7-6 and 7-7). If the excitation and sense voltage
are one-half the output voltage, but alternator output does
not reach 460 +/- 10 VAC, check the resistance of the
exciter field circuit.
1. With the engine stopped, disconnect the F1 wire from
AVR terminal X and the CH wire from AVR terminal
XX.
2. Measure the field wire resistance across wires F1 to
CH. The resistance should be 13.9 +/- 10% Ohms at
25 C (77 F) field temperature. If the alternator has
been operated recently, the resistance could be
approximately one ohm higher.
• If the resistance is correct, go to step D on page 7-8.
• If the resistance is incorrect, measure the resistance
from F1 to F2 at controller relay board connector
plug CN1. The resistance should still be 13.9 +/-
10% Ohms at 25 C (77 F) field temperature.
- If the resistance is still incorrect, replace the alter-
nator exciter field.
- If the resistance is now correct, check the F2 cir-
cuit from the controller relay board to CH for a
problem. Resistance should be 0 ohms to indicate
a good circuit.
SGCO 2000-151, July 2001
7-6 Alternator Diagnosis Alternator Operation and Diagnosis

Check Exciter Field Circuit Resistance: F1 to CH

Check Exciter Field Circuit Resistance: F1 to F2

SGCO 2000-151, July 2001

Alternator Operation and Diagnosis Alternator Diagnosis 7-7

Check Exciter Field Circuit Resistance: F2 to CH

SGCO 2000-151, July 2001

7-8 Alternator Diagnosis
D. Check Field Relay A Circuit (see illustration below).
AVR terminals K1 to K2 must be connected together thru
the Field Relay A (FRA) contacts 30 and 87 before the
AVR will start voltage output across exciter field wires F1
and CH.
1. Insulate the ammeter connections in the following
procedure to prevent shock hazard. With the engine
stopped, connect a 10 amp DC ammeter in series with
AVR terminal X and the field lead F1 (normally con-
nected to AVR terminal X).
2. Disconnect the K1 and K2 wires from AVR terminals
K1 and K2. Connect a jumper wire between termi-
nals K1 and K2.
3. Start the engine and check the exciter field output
current on the ammeter. Exciter circuit current draw
should be 0.5 to 0.60 amps at no load or 1.0 to 1.5
amps at full load with 460 Vac output and with
engine rpm at 1890 +/- 10 rpm.
4. Stop the engine. If there was no current output from
AVR terminal X to F1 lead, go to step E on page 7-9.
Otherwise go to the next step.
5. Remove the jumper from the K1 to K2 terminals.
Reconnect the K1 and K2 wires to AVR terminals K1
and K2.
Checking Field Relay A Circuit K1 to K2
Alternator Operation and Diagnosis
6. Start the engine and repeat the exciter field output
current test in step 3 above.
• If there is now no current output from AVR terminal
X to the F1 lead, check for a defective Field Relay
A (FRA) or K1 to K2 circuit.
• If there is measurable field current but the field cur-
rent is low and the output voltage is low, or the field
current is high and the output voltage is high; go to
“Setting the Volts and Stability Controls on the
AVR” on page 7-12.
• If there is measurable field current but the field cur-
rent is high and the output voltage is low, check for
low engine rpm. Adjust engine to 1890 +/- 10 rpm
and then go to “Setting the Volts and Stability
Controls on the AVR” on page 7-12.
• If there is measurable field current but the field cur-
rent is low and the output voltage is high, check for
high engine rpm. Adjust engine to 1890 +/- 10 rpm
and then go to “Setting the Volts and Stability
Controls on the AVR” on page 7-12.
NOTE: Correct engine rpm provides 60 Hertz
output with 15 KW electrical load connected
to the generator set.
SGCO 2000-151, July 2001
Alternator Operation and Diagnosis
7. If adjusting the voltage and stability controls on the
AVR (page 7-12) does not result in correct output of
460 Vac with the correct field excitation current, go
to step E.
E. Replace the AVR. If the alternator output voltage contin-
ues to be incorrect with correct excitation voltage, correct
sense voltage, correct exciter field resistance, correct con-
nection across AVR terminals K1 to K2, and 1890 +/- 10
rpm at no load; stop the engine and replace the AVR.
F. If step E does not correct the voltage output and excitation
current readings, reinstall the original AVR in the control
box and check for an alternator problem. Go to Alternator
Tests on pages 7-10 to 7-11.
• Symptom: Low Output Voltage—100 to 440 Vac;
Equal Line to Line Voltage
Follow alternator check procedures in paragraphs B through F
on page 7-5 to 7-9.
• Symptom: Unequal Line to Line Voltage
Verify the unequal line to line voltage condition with no load
applied to the alternator. If the unequal voltage condition is
present with no load applied, check the alternator lead connec-
tions against the unit wiring diagram. If the connections are
correct, check for an internal alternator fault with the stator
windings.
7-9
• Symptom: Poor Motor Starting Performance
1. Check for poor engine performance or low engine rpm.
2. Check the motor starting exciter field current draw. The
ammeter connections for this check are the same as the
ammeter connections for the “Checking Field Relay A
Circuit K1 to K2” illustration below but do not remove
wires K1 and K2.
a. With the unit off, open the control box and disconnect
the F1 lead from the AVR.
b. Insulate the ammeter connections in the following
procedure to prevent shock hazard. With the engine
stopped, connect a 10 amp DC ammeter in series with
AVR terminal X and the field lead F1 (normally con-
nected to AVR terminal X).
c. Start the engine and check the exciter field output
current from the AVR terminal X. Exciter circuit
current draw should reach 6 amps. If the current
draw is less than 5 amps, stop the engine. Follow
alternator check procedures in paragraphs B through
F on pages 7-5 to 7-9.
3. If the engine performance is correct and the motor starting
performance is poor, check the exciter armature diodes for
an open or short. See “Alternator Test C: Rotating
Rectifier” on page 7-10.
SGCO 2000-151, July 2001
7-10 Alternator Diagnosis Alternator Operation and Diagnosis

Alternator Tests Alternator Test C: Rotating Rectifier (See Illustration

The Alternator Test includes testing the main alternator-stator,
rotating main field, rotating rectifier, rotating exciter and
exciter field. All tests must be made with reliable equipment.
• Standard ohmmeter can be used to check winding continuity.
• Milliohmmeter must be used to check winding resistance of
the main stator windings.
• Megohmmeter must be used to check for insulation break-
down.
Below)
Six rectifying diodes are mounted on the rotating rectifier.
Three are positive and three are negative. When testing
diodes, use the diode test on a digital multimeter.
1. Unbolt each of the diode leads.
NOTE: The diodes must be disconnected for
testing, or false test readings may occur.

Alternator Test A: Main Alternator Stator Windings 2.
(See Illustration Below)
Disconnect all 12 stator leads to test the stator windings. 3.
1. Disconnect the stator leads from the excitation control
package. Check for continuity between the following pairs:
T1-T4, T2-T5, T3-T6, T7-T10, T8-T11, T9-T12. Using a 4.
milliohmmeter, the resistance between any of the above
pairs should be 0.1236 to 0.1366 ohms at 77 F (25 C).
2. Using a megohmmeter, check for insulation breakdown
between each pair of leads. Insulation resistance should be
greater than a 1megohm.
3. Remove the stator end bell for the remaining alternator
tests.
Disconnect main alternator field leads which connect to
exciter diode heat sinks.
Check the forward voltage drop of each diode. Forward
voltage drop should be 0.5 to 0.7 V. Forward voltage drop
on all diodes should be equal.
Check reverse continuity of each diode. Meter display
should show open circuit (OL) on reverse continuity
check.

Alternator Test B: Excitation Stator Winding (See

Illustration Below)
1. Disconnect the Q1 and Q2 stator leads to test the excita-
tion stator winding for continuity. The resistance of the
excitation winding should be 2.28 to 2.52 ohms at 77 F
(25 C).
2. Using a megohmmeter, check for insulation breakdown
between each pair of leads. Insulation resistance should be
greater than a 1megohm.
3. Remove the stator end bell for the remaining alternator
tests.

Alternator Test C: Rotating Rectifier Diodes

Alternator Tests A and B: Alternator Stator Windings
A. Disconnect all 14 stator leads to test the stator.
Check the continuity, resistance and insulation of
each set of leads.
A. Disconnect the main alternator field lead to test the
diodes.
B. Test each diode separately using the diode test on a
digital multimeter.

SGCO 2000-151, July 2001

Alternator Operation and Diagnosis
Alternator Test D: Rotating Exciter (See Illustration
Below)
All rectifier leads must remain disconnected from previous
tests.
1. Check the resistance between the following combinations
of leads: (CR6-CR4), (CR3-CR1), (CR3-CR2), (CR6-
CR5), (CR5-CR4) and (CR2-CR1). The resistance should
be 0.580 to 0.710 ohms at 77 F (25 C) for each lead com-
bination.
2. Using a megohmmeter, check for insulation breakdown
between each pair of leads and the rotor case.
Alternator Test E: Main Alternator Field (See
Illustration Below)
1. Measure the resistance of the main alternator field. The
resistance should be 2.475 to 3.025 ohms at 77 F (25 C).
2. Using a megohmmeter, check for insulation breakdown
between the main field and the rotor or ground.
Alternator Test D: Rotating Exciter Armature
Resistance of each lead combination should be 0.580 to
0.710 ohms at 25 C (77 F).
Alternator Diagnosis 7-11
Alternator Test F: Exciter Field (See Illustrations on
Pages 7-6 and 7-7)
Refer to the results from the Exciter Field Circuit Test or
check the resistance of the exciter field again. Also check the
exciter field for a short to ground.
1. Disconnect the field wires F1 and F2 from the control box
circuitry.
2. Measure the resistance of the field circuit (F1 to chassis
ground). The resistance should be 13.9 (+/- 10%) ohms at
77 F (25 C).
3. Using a megohmmeter, check for insulation breakdown
between the exciter field and the stator or ground.
NOTE: A new exciter field is not magnetized. If
you install a new exciter field, follow the proce-
dure, “A. Flash Exciter Field” on page 7-4 to
magnetize it.
Alternator Test E: Main Alternator Field
Resistance of the main field should be 2.475 to 3.025
ohms at 25 C (77 F).
SGCO 2000-151, July 2001
7-12 AVR Replacement and Adjustment
AVR Replacement and Adjustment
The generator output voltage is set at the factory, but can be
altered by careful adjustment of the Volts control on the AVR
board. If the generator set voltage output is unstable, a separate
Stability control includes a damping circuit to provide good
steady state and transient performance of the generator.
The Volts and Stability controls must be reset when an
AVR Test has been performed on a good AVR or when a
replacement AVR is installed. When a replacement AVR is
installed in the generator set, the Frequency Selection and
Optimum Response Selection must also be set to match the
generator set.
AVR Board
1. Stability Selection: Jumper must be set between A
and C terminals.
2. Stability Control: Adjust to prevent voltage hunting.
3. Frequency Selection: Jumper must be set between C
and 60 terminals.
4. Do not adjust. UFRO under speed control is preset at
95% and sealed at the factory.
5. Voltage Control: Adjust to set alternator output volt-
age.
6. Droop Control: Not used.
7. Trim Control: Not used.
Alternator Operation and Diagnosis
Setting the Frequency Selection and Optimum
Response Selection on a Replacement AVR
NOTE: Set the Frequency and Optimum Response
selections before installing the AVR board in the
control box.
The Frequency Selection determines the frequency of the alter-
nator output. Set the “jumper” selector lead for 60 Hz by con-
necting the jumper between the C and 60 terminals on the
AVR board.
The Optimum Response Selection matches the AVR to
the size of the alternator. Set the “jumper” selector lead
between the C and A terminals on the AVR board.
Setting the Volts and Stability Controls on the AVR
WARNING: Do not increase the voltage above the
rated generator voltage. If in doubt, refer to the rat-
ing plate mounted on generator case.
1. Before running generator, turn VOLTS control fully anti-
clockwise.
2. Turn the STABILITY control to midway position.
3. Connect a suitable voltmeter (O-600 Vac) across the line
output of the generator.
4. Start generator set, and run on no load at nominal frequen-
cy (60-63Hz).
NOTE: If the red Light Emitting Diode (LED) is
illuminated, the Under Frequency Roll Off (UFRO)
adjustment circuit is operating. The UFRO
adjustment is preset and sealed at the factory.
Make sure the Frequency Selection jumper link is
set to 60 Hz and engine speed is 1890 +/- 10 rpm
at no load.
5. Carefully turn VOLTS control clockwise until 460 Vac is
reached.
6. Voltage and stability adjustment is now complete.
NOTE: The DROOP and TRIM controls on the AVR
board are not used on this generator set.
SGCO 2000-151, July 2001
Alternator Operation and Diagnosis
Maintenance Procedures
The following paragraphs cover detailed maintenance proce-
dures, 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. See “Alternator Assembly”
illustration on page 7-14.
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 overheat-
ing, burned or frayed insulation, loose connections, foreign
matter, etc.
Maintenance Procedures 7-13
Generator Housing
Feel the alternator housing cautiously for abnormally high
temperatures as determined by previous experience with the
unit. If the generator is overheated, check the winding temper-
ature with thermometer, locate the cause such as lack of venti-
lation, overload, etc., and correct the condition or shut down
the generator. Inspect the generator housing for obstruction of
air passages.
Generator Bearing
The alternator is fitted with a permanently lubricated, sealed
bearing that requires no maintenance in normal service.
Impeller Fan (Blower)
Visually inspect the impeller fan to confirm that no vanes are
missing and that the fan is not encrusted with dirt or other for-
eign 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.
SGCO 2000-151, July 2001
7-14 Maintenance Procedures Alternator Operation and Diagnosis

Alternator Assembly
1. Rotor Assembly
2. Disc, Rotor Drive
3. Impeller Fan (Blower), Generator
4. Rotor (Includes items 1, 2, 3 and 5 through 12)
5. Key
6. Spacer, Bearing
7. Bearing/Seal, Rotor
8. Exciter Assembly, Rotor
9. Rectifier, Positive Assembly
10. Rectifier, Negative Assembly
11. Nut, Rectifier Assembly
12. Screw, Mounting Rectifier
13. Screw, Mounting Bearing
14. Stator and End Bell Assembly
15. Stator, Wound
16. Exciter, Field
17. Bell, End
18. Stud, Bell
19. Cover, End Bell
20. Screw, Mounting End Bell Cover
21. Gasket, End Bell Cover
22. O-ring
23. Screw, Retainer
24. Retainer, Exciter
25. Rotor
SGCO 2000-151, July 2001
8 Structural/Accessory
Maintenance

Unit Inspection Radiator Coil

Inspect the unit during unit pre-trip inspection and scheduled Clean the radiator during scheduled maintenance intervals by
maintenance intervals for loose or broken wires or hardware, blowing compressed air from the outside of the coil in toward
and other physical damage which might affect unit perfor- the condenser fan (the direction opposite the normal air flow).
mance and require repair or replacement of parts. Inspect the coil and fins for damage and repair if necessary.

NOTE: See Service Guide in the Introduction of this CAUTION: Air pressure should not be high enough
manual for correct service interval for your unit. 250 to damage coil fins.
or 500 hour inspection/service intervals are required
in extreme operating conditions.

Radiator Fan Location

Mounting Bolts
Check and tighten all engine and control box mounting bolts
during scheduled maintenance intervals. Unit mounting hard-
ware should be inspected for tightness during every pre-trip.
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.

Mounting Bolt Torque

Lower Mounting Bolts 203 N.m (150 ft-lb)
TK 486 Engine 203 N.m (150 ft-lb)
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)

Radiator Fan Blade Placement

1. Radiator Coil Orifice
2. Airflow Direction
3. 65 to 70% of Fan Blade Depth to Air Discharge Side
of Orifice

SGCO 2000-151, July 2001

8-2 Clip-on Header Pin Unit Installation Structural/Accessory Maintenance

3. Install two lower mounting bolts:

Clip-on Header Pin Unit Installation a. Open the retainer door covering each mounting bolt
hole.
1. Lift the unit into mounting position on front wall of the
b. Remove the mounting bolt from the bolt holder tube
container. Both header pins of generator set mounting
and install the bolt in the mounting hole.
channel should fit into mounting holes on top of the con-
c. Tighten each lower mounting bolt to 203 N.m (150 ft-
tainer.
lb).
d. Close and latch the retainer door over each mounting
CAUTION: Take adequate precautions when lift-
bolt to prevent accidental loosening or loss of the
ing and mounting the generator set to prevent
mounting bolt during unit operation.
personal injury or unit damage.

2. Check to be sure the generator set frame fits tightly

against the container.

CAUTION: Excessive vibration or unit malfunc-

tion can occur if mounting clamps are not prop-
erly secured. The generator set MUST be tight
against the container.

Clip-on Header Pin Mounting Installation

1. Header Pin
2. Mounting Bolt Retainer Assembly
3. Mounting Bolt
4. Retainer Door with Latch
5. Bolt Holder Tube

SGCO 2000-151, July 2001

A B+45-#%4-*,:%-<#"(%(

NOTE: This diagnosis guide applies to units equipped with TK 486 engines. For major repair of TK 486
engines, refer to Overhaul Manual, TK 50136.

!"#$%&%"# '"((%)*+,!-.(+ /+0+$1

2#%&,(3%&45,678,9!: Corroded battery cable connections Clean and tighten

)-4;*%<5&,$"+(,#"&
4"0+,"# Batteries discharged Charge or replace batteries

Fuse link open (blown) Check for short circuit and replace
fuse link

Defective On/Off switch Check switch

Open circuit Check 2, 2A and 8 circuits

2#%&,(3%&45,67,=4"#&>"**+>, Batteries discharged Charge or replace battery

9!:,)-4;*%<5&,%(,67?,).&
+#<%#+,$"+(,#"&,4>-#; Corroded battery connections Clean and tighten

Defective starter relay or open circuit Replace relay; check 8 and 52 circuits

Defective starter solenoid Replace solenoid

Defective starter Repair starter

Water in cylinders Check for hydrostatic lock. Remove

injectors and turn engine slowly

@&->&+>,0"&">,&.>#(,).& Starter clutch defective Replace

+#<%#+,$"+(,#"&,4>-#;

SGCO 2000-151, July 2001

ACD
!67:EFE67 '6@@EG9H,!I2@H
H#<%#+,4>-#;(,).&,K-%*( Fuel solenoid not energized
&",(&->&
Fuel solenoid valve defective
or stuck
No fuel or wrong fuel
Air cleaner clogged
Exhaust plugged
Air heater defective
Air in fuel system
Fuel pump defective
Incorrect timing
Injection nozzles defective
Injection pump defective
Compression low
H#<%#+,(&"L(,-K&+>,(&->&%#< Alarm symbol in controller display
Vent of fuel tank obstructed
Fuel filter obstructed
Clogged fuel tank or fuel lines
Air in injection pump
Fuse link open (blown)
Mechanical Diagnosis
/HBH:J
Check 8D, 8DP circuits and fuel relay.
Check the Engine Select screen in the
Guard submenu of the controller: YanEn
must be set to yES. See “Guard Menu” in
the Microprocessor Controller chapter of
this manual
Replace
Fill with proper fuel
Clean and refill oil reservoir on oil bath air
cleaner
Clear exhaust system
Replace defective air heater
Bleed air
Replace pump
Adjust timing
Repair or replace nozzles
Replace pump
Overhaul engine
Check alarm code and repair fault (see
“Alarm Codes Descriptions and Corrective
Actions” in Electrical Maintenance chapter)
Unclog vent
Replace filter element
Clean fuel tank and fuel lines
Bleed fuel system
Check for short circuit and replace
fuse link
SGCO 2000-151, July 2001
Mechanical Diagnosis ACM

!67:EFE67 '6@@EG9H,!I2@H /HBH:J

H#<%#+,$"+(,#"&,$+N+*"L Air cleaner or intake Clean air intake system; clean and refill oil
K.**,L"3+> system clogged reservoir on oil bath air cleaner

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 Check for dirty filter or air in system
filter(s)

Injection pump timing off Adjust timing

Nozzles defective Repair or replace nozzles

Delivery of fuel pump insufficient Repair pump

Worn injection pump plungers, Repair or replace pump

delivery valve defective, injection
rate too low, gum formations

Compression low or unbalanced Overhaul engine

H#<%#+,;#"4;(,5+-N%*1 Wrong fuel Change fuel

Air in system Bleed fuel system

Fuel return line plugged Remove return line restriction

Injection nozzles fouled or Clean, repair or replace injection

opening pressure too low nozzles

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

SGCO 2000-151, July 2001

ACO Mechanical Diagnosis

!67:EFE67 '6@@EG9H,!I2@H /HBH:J

H#<%#+,(L++$,&"",5%<5 Mis-adjusted speed screw Adjust speed screw

Control rod sticks Repair injection pump

H#<%#+,K-%*(,&",(&"L,35+# Fuel solenoid defective Replace solenoid

.#%&,%(,6KK
Injection pump defective Replace pump

H#<%#+,>.#(,5"& 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

6%*,L>+((.>+,&"",*"3,">, Insufficient oil in pan Add oil

$>"L(,(.$$+#*1P,B%#%0.0
"%*,L>+((.>+,K">,-,5"& Defective oil pressure sensor Check oil line to oil pressure sensor to
+#<%#+,%(,QQR,;'-S see if it is blocked. Check oil pressure
QPQR,)->S,QR,L(%,=*"3,"%* sensor. Replace if necessary
L>+((.>+,(3%&45,(+&&%#<?
Oil relief valve sticking Disassemble and clean oil pressure
regulator valve

Worn oil pump, camshaft, main Repair engine

or connecting rod bearings,
loose oil gallery plug

SGCO 2000-151, July 2001

Mechanical Diagnosis ACT

!67:EFE67 '6@@EG9H,!I2@H /HBH:J

U%<5,"%*,4"#(.0L&%"# 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

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 Have engine repaired and rebored.

bore worn or scored Replace broken piston rings

G-&&+>1,%(,#"&,>+45-><%#< Loose connections in electrical Check all electrical connections and

">,%(,"N+>45-><%#< system charging system

Battery defective Replace battery

Battery charger wire harness Replace wire harness

defective

Air heater does not shut off Check preheat relay and preheat circuit

Battery charger defective Replace battery charger

V5%&+,@0";+, Cold engine Allow engine to warm up

=K.+*,%(,#"&,).>#%#<?
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

SGCO 2000-151, July 2001

ACW Mechanical Diagnosis

!67:EFE67 '6@@EG9H,!I2@H /HBH:J

G*.+,@0";+ Excessive oil consumption Refer to High Oil Consumption. Repair

="%*,4"#(.0L&%"#? as necessary

G*-4;,@0";+ Cold engine Allow engine to warm up

=+X4+((%N+,K.+*,&",-%>,>-&%"?
Y,H#<%#+,%(,(""&%#<,5+-N%*1S Wrong fuel Drain and refill with correct fuel
+0%&(,&5%4;,)*-4;,4*".$(
"K,(0";+ Clogged air intake system Clean or replace air cleaner

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 Repair nozzle. Replace if necessary

too low or needle sticks

Injection amount too great Have pump repaired

Poor compression Check and eliminate possible causes.

Repair as necessary

SGCO 2000-151, July 2001

10 Electrical and µP-G
Menu Flow Diagrams

Electrical and µP-G Menu Flow Diagrams 10-1

SGCO 2000-151 Wiring Diagram 10-3
SGCO 2000-151 Wiring Schematic 10-4
µP-G Menu Flow Diagram 10-5

SGCO 2000-151, July 2001

10-2 Electrical and µP-G Menu Flow Diagrams

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SGCO 2000-151, July 2001

Electrical and µP-G Menu Flow Diagrams SGCO 2000-151 Wiring Diagram 10-3

SGCO 2000-151, July 2001

Electrical and µP-G Menu Flow Diagrams SGCO 2000-151 Wiring Schematic 10-4

SGCO 2000-151, July 2001

 Standard Display

Keypad Operating Tips

Text Input:
• To enter a number: Press the UP or DOWN key to
increase or decrease the value of a digit in the display.
Pause Mode Displays
To Enter a Controller Menu or Submenu:
— dELAY / AC1 • Press ALARM key to directly enter the Alarms menu.
— PAUSE / run2 • Press ENTER key to view the Software Version display.
• Press SELECT key to directly enter the Main Menu; or a
submenu from the Main Menu.
• Press and hold SELECT key down for 3 seconds to return
Software Display
directly to the Standard Display.
— Version “XX.XX / rEu”
To Enter a Command or a New Value in a Screen:
• Press ENTER key.
Electrical and µP-G Menu Flow Diagrams

Alarms Menu To Scroll in a Menu:

• Top display shows the number • Press UP key to scroll up.
of alarms stored in memory • Press DOWN key to scroll down.
(e.g. “AL 3”). To Lock a View Screen on the Display:
• Bottom display shows a 2 digit • Press ENTER key to increase the display time of the cur-
MAIN MENU code for the most recent rent screen to 15 minutes. Press any key to unlock/exit
alarm. screen.
• View and write down all alarm
— nEnU / l- - -l codes.

• Press key to view addi-

tional alarm codes.
• After the last alarm code (AL
1) has been viewed and
View Menu recorded, the top display flash-
— vIEU es “ENTER”.
— XX / HZ (Output Frequency) • Press key to clear all
— XXX / Ent (Engine Temp.) alarm codes from the current
— XX / OiL (Oil Pressure) display memory.
— XXXX / rPn (Engine Speed) • Correct all problems before
— XX.X / bAt (Battery Volts) returning the unit to service.
— XXXX / rHr (Run Hours)

Pretrip Menu
— PtrIP
• The display flashes “EntEr / PrE”.

• Press key to to start an auto-

matic Pretrip test.
• Display shows “LOAd / PrE”.
Test Menu • Display then shows the current
— tESt test. Pretrip tests include:
— tESt / l- - -l Controller Test Submenu
— CntrL / tSt - Display “88888 / 888”
— CntrL / l- - -l - Oil Level Switch “OLS / PrE”
— AL / O “l” (Alarm Light Test) - Oil Press. Sensor “OPS / PrE”
— OL / O “l” (On Light Test) - Oil Press. Switch “LOP / PrE”
— PHr / O “l” (Preheat Relay Test) Press to start test. - Coolant Level “CLS / PrE”
— rr / O “l” (Run Relay Test) Display shows: (TEST) / “O” l. - Water Temp. Sensor “UtS / PrE”
— Sr / O “l” (Start Relay Test) - RPM Sensor “FUS / PrE”
— Fr / O “l” (Field Relay Test) Press again to stop test. - Preheat Relay “PHr / PrE”
- Run Relay “rr / PrE”
- Start Relay “Sr / PrE”
- Field Relay “Fr / PrE”
Guard Menu - Oil Press. Sensor “OPS / PrE”
— GUArd - Oil Press. Switch “LOP / PrE”
— 0 0 0 0 / GUA - RPM Sensor “rPN / PrE”
Enter access code 7. Guard Submenu - Output Voltage “AC / PrE”
• When test is complete, display
Press to scroll cursor to — GUArd / l- - -l shows test result: “PASS”, “FAIL”
next digit to right. — XXXXX / rHr (Run Hours) or CHECK”.
Press or to select — XXXXX / Ht1 (HM 1 Threshold)
— XXXXX / Hn1 (HM 1 Hours) • If “FAIL” or “CHECK” appear,
number.
— XXXXX / Ht2 (HM 2 Threshold) press the key to view and
Press to enter access Press to enter load
— XXXXX / Hn2 (HM 2 Hours) correct any alarms that occur.
code. Display shows value display. Top display
— XXXXX / EOH (Engine Off Hours)
GUArd / l- - -l. flashes value to be • If “PASS” appears, press the
— XXXXX / rSl (Restarts after
changed. key to return to the Main Menu
Powerup)
— XXXXX / rSt (Unit Restarts) Press or to select
— LOPrS / n0 (Low Oil Press. Restart) new number.
— dLYSt / YES1 (Delayed Cold Start)
— YAnEn / YES3 (Engine Select) Press to load new
— nUrEG / YES4 (Regulator Select) number.
— XXXXX / CAL (Voltmeter Calib.)

Press to enter load

value display.

Press or to select
new value.
Press to load new value.
Program Menu
— PrGrn
— PrGrn / l- - -l
— F (or C) / dEG(Temperature Units)
— PSI (or bArS or kPA) / OlL (Pressure Units) Footnotes:
Press to enter load
1When Delayed Cold Start is set to yES, controller shows “dELAy /
value display.
AC” screen and alternator output remains off until engine tempera-
ture increases to 32 C (90 F).
Top display flashes unit 2”PAUSE / run” screen indicates controller has stopped unit opera-
to be changed. tion due to a shutdown alarm. Controller restarts unit if alarm con-
dition is corrected.
µP-G Menu Flow Diagram

Press or to 3The Engine Select screen MUST be set to “yES” on units equipped
select new value. with a TK 486 (Yanmar) engine. Set this screen to “nO” on units
equipped with a di 2.2 or se 2.2 engine. Default setting is “nO” on
Press to load new
version 0100 software and “yES” on version 0200 software.
value. 4The Regualtor Select screen MUST be set to “yES” on units
equipped with a Newage regulator. Set this screen to “nO” on
units equipped with a Thermo King excitor. Default setting is “nO”.
10-5

SGCO 2000-151, July 2001