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Container Edition SG 5000 Series

- i Preface For None
- ii Introduction
Chapter 1: Safety Precautions
- 1.1: Danger, Warning, Caution, and Notice
- 1.2: General Practices
- 1.3: Electrical Hazards
  - High Voltage
  - Low Voltage
- 1.4: Battery Installation and Cable Routing
- 1.5: Battery Removal
- 1.6: Electrostatic Discharge Precautions
  - Electrostatic Discharge and the Controller
- 1.7: Controller/Microprocessor Service Precautions
- 1.8: Welding on Refrigeration Units or Containers
- 1.9: High Pressure Fuel Hazards
- 1.10: First Aid
Chapter 2: Specifications
- 2.1: Generator
- 2.2: Electrical Control System
- 2.3: Engine
- 2.4: Controller Default Settings
- 2.5: SG 5000 Series Unit Weight
Chapter 3: Maintenance Inspection Schedule
Chapter 4: Unit Description
- 4.1: General Description
- 4.2: EMI 3000
- 4.3: SG Microprocessor Controller
- 4.4: Unit Instruments
  - Indicator LEDs
- 4.5: Unit Protection Devices
- 4.6: Voltage Option
- 4.7: EcoPower
- 4.8: Fuel Level Sensor Option
Chapter 5: SG 5000 Photos, Illustrations, and Measurements
Chapter 6: Genset Model Features
Chapter 7: SG+ 1.5 Controller and Operating Instructions
- 7.1: SG+ 1.5 Controller Description
- 7.2: SG+ 1.5 - Navigating the Controller Menus
- 7.3: SG+ 1.5 New Controller Set Up
- 7.4: SG+ 1.5 Operating Instructions
  - 7.4.1: Pretrip Inspection
  - 7.4.2: Starting the Unit
  - 7.4.3: After Start Inspection
  - 7.4.4: Pretrip Inspection Test (PTI)
  - 7.4.5: Main Menu
  - 7.4.6: Data Menu
    - 7.4.6.1: Engine Menu
    - 7.4.6.2: Engine Lamps
    - 7.4.6.3: Generator
    - 7.4.6.4: Unit
    - 7.4.6.5: Internal States
  - 7.4.7: Alarm List Menu SG+ 1.5
  - 7.4.8: Message List Menu SG+ 1.5
    - Message Diagnosis
  - 7.4.9: Commands Menu
    - 7.4.9.1: Pretrip Inspection Test (PTI)
    - 7.4.9.2: Manual Function Test
    - 7.4.9.3: Speed Control
    - 7.4.9.4: ECU Service Menu
    - 7.4.9.5: Oil Priming
    - 7.4.9.6: Fuel Priming
    - 7.4.9.7: Clear P Codes
  - 7.4.10: Misc. Functions Menu
    - 7.4.10.1: C/F Temperature and Language Mode
    - 7.4.10.2: SW/HW Version (Software / Hardware)
    - 7.4.10.3: Timers
    - 7.4.10.4: Counters
    - 7.4.10.5: Date and Time
  - 7.4.11: Configuration Menu
    - 7.4.11.1: Controls
    - 7.4.11.2: Unit Configuration
    - 7.4.11.3: Option Configuration
    - 7.4.11.4: System Configuration
    - 7.4.11.5: MISCH Configuration
  - 7.4.12: Event Log Menu
    - 7.4.12.1: Events
    - 7.4.12.2: Fuel Events
    - 7.4.12.3: USB Copy Event Log
  - 7.4.13: LogView and Viewing SG+ Logs
  - 7.4.14: Setting Hour Meter Thresholds and Resetting Hour Meters
Chapter 8: Electrical Maintenance
- 8.1: Battery
- 8.2: 12 Vdc Charging System
- 8.3: Controller Battery Charger Test
- 8.4: Fuses
  - ECU Fuses
- 8.5: Relays
- 8.6: Unit Wiring
- 8.7: Wire Harness Routing
- 8.8: Glow Plugs
- 8.9: Engine Oil Sensors
  - Engine Low Oil Pressure Switch
  - Engine Oil Level Sensor
Chapter 9: Engine Maintenance
- 9.1: TK488CR/CRH Diesel Engine
  - 9.1.1: TK488CR/CRH Engine Service
- 9.2: Engine Lubrication System
  - 9.2.1: Engine Oil Change
  - 9.2.2: Oil Filter Change
  - 9.2.3: Low Oil Pressure
- 9.3: Engine Cooling System
  - 9.3.1: Extended Life Coolant (ELC)
  - 9.3.2: Antifreeze Maintenance Procedure
  - 9.3.3: Bleeding Air from the Cooling System
  - 9.3.4: Engine Thermostat
  - 9.3.5: Coolant Level Switch
    - 9.3.5.1: Testing the Coolant Level Switch
    - 9.3.5.2: Checking the Float
    - 9.3.5.3: Replacing the Coolant Level Switch
- 9.4: Engine Fuel System
  - 9.4.1: Operation
  - 9.4.2: Fuel Line Routing
  - 9.4.3: Fuel System Fittings
  - 9.4.4: Maintenance
  - 9.4.5: Draining Water from Fuel Tank
  - 9.4.6: Fuel System Diagrams
    - SGCO 5000 Unit Fuel System
    - SGUM 5000 Unit Fuel System
  - 9.4.7: Fuel Filter/Water Separator
  - 9.4.8: Fuel Filter and Water Separator Service
  - 9.4.9: Electric Fuel Pump
- 9.5: Bleeding the Fuel System
- 9.6: Exhaust Gas Recirculation (EGR) System
  - 9.6.1: Cleaning EGR Valve
  - 9.6.2: Cleaning EGR Cooler
- 9.7: Diesel Oxidation Catalyst (DOC) System
  - 9.7.1: Diesel Oxidation Catalyst (DOC) Installation
- 9.8: Engine Valve Clearance Adjustment
- 9.9: Crankcase Breather
- 9.10: EMI 3000 Air Cleaner
- 9.11: Water Pump Belt Service
- 9.12: Radiator and Fan Service
Chapter 10: Yanmar YSAD Diagnostic Engine Service
Chapter 11: Alternator Operation and Diagnosis
Chapter 12: Structural/Accessory Maintenance
- 12.1: Unit Inspection
- 12.2: Mounting Bolts
- 12.3: SGCM Unit Installation
- 12.4: SGCO Clip-on Corner Clamp Unit Installation
- 12.5: SGCO Clip-on Corner Header Pin Unit Installation
Chapter 13: Telematics Information
Chapter 14: Mechanical Diagnosis
Chapter 15: Diagram Index
Chapter 16: Controller Menu Guide

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Engine Maintenance

In this section:

TK488CR/CRH Diesel Engine
Engine Lubrication System
Engine Cooling System
Engine Fuel System
Bleeding the Fuel System
Exhaust Gas Recirculation (EGR) System
Diesel Oxidation Catalyst (DOC) System
Engine Valve Clearance Adjustment
Crankcase Breather
EMI 3000 Air Cleaner
Water Pump Belt Service
Radiator and Fan Service

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