SB 210+ 30 - Grease Monkey Road Squad llc

SB 210+ 30 - Grease Monkey Road Squad llc
SB-210+ 30 DRC
(Domestic Refrigerated Container)
TK 54679-2-MM (Rev. 0, 12/10)
Copyright© 2010 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in
U.S.A.
The maintenance information in this manual covers unit models:
System SB-210+ 30 DRC (901494)
For further information, refer to:
SB-210+ 30 DRC Operator’s Manual
TK 54734
SB-210+ 30 DRC Parts Manual
TK 54788
SB-210+ 30 DRC Installation Manual
TK 54654
SR-2 Microprocessor Control System Diagnostic Manual
TK 51727
OptiSet Plus User’s Guide
TK 54045
i-Box Diagnostic Manual
TK 53242
TK482 and TK486 Engine Overhaul Manual
TK 50136
X214, X418, X426 and X430 Compressor Overhaul Manual
TK 6875
Diagnosing TK Refrigeration System
TK 5984
Tool Catalog
TK 5955
Evacuation Station Operation and Field Application
TK 40612
The information in this manual is provided to assist owners, operators and service people in the proper upkeep
and maintenance of Thermo King units.
This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular
purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.
2
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
concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local Thermo King dealer.
3
4
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Microprocessor Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
First Aid, Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
First Aid, Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electric Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thermo King X430L Reciprocating Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SMART REEFER 2 (SR-2) Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FreshSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Opening the Secondary Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Closing the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine Compartment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SMART REEFER 2 (SR-2) Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Microprocessor On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Manual Pretrip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Turning Unit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Turning Unit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Standard Display Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5
Table of Contents
Selection of Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting CYCLE-SENTRY or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Terminating a Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Viewing Gauge Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Viewing Sensor Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Navigating the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Language Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Datalogger Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Hourmeters Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pretrip Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Adjust Brightness Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Alternator Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Interface Board Fuse F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Test Equipment for Checking Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Alternator Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
General Diagnostic and Warranty Evaluation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Field Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Interface Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Smart FETs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SMART REEFER 2 (SR-2) Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Fuse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Electric Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Fuel Line Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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Table of Contents
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Draining Water from Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Fuel Filter/Water Separator Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fuel Filter/Water Separator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Injection Pump Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cold Start Device Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Electric Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Engine Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Testing The Refrigerant Charge With An Empty Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Testing the Refrigerant Charge with a Loaded Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Testing for an Overcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Oil Collection Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Three-Way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Hot Gas Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Compressor Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Discharge Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
In-Line Condenser Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Condenser Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Three-Way Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
End Cap Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Three-Way Valve Condenser Pressure Bypass Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Suction Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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Table of Contents
Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Hot Gas Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Checking Compressor Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Priming New Compressor Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Condenser, Evaporator, and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Condenser and Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Condenser Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Evaporator Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Fan Shaft Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Idler Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Refrigeration Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Cool Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Heat/Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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List of Figures
Figure 1: Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 2: TK486V (TK486VH is Similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 3: HMI Controller and Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 4: Door Latch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 5: Opening Secondary Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 6: Engine Compartment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 7: Compressor Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 8: Engine Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 9: Unit Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 10: Laminated Serial Number Plate (Located Where Shown Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 11: Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 12: Control Box With Service Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 13: SR-2 HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 14: Dedicated and Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 15: Press On Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 16: Turning Unit On Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 17: Press Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 18: Turning Unit Off Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 19: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 20: Standard Display Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 21: Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 22: Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 23: Changing Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 24: Changing the Setpoint Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 25: Changing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 26: Screen Sequence for Changing from CYCLE-SENTRY Mode to Continuous Mode . . . . . . . . . . . . . 42
Figure 27: Screen Sequence for Changing from Continuous Mode to CYCLE-SENTRY Mode . . . . . . . . . . . . . 42
Figure 28: Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 29: Initiating Manual Defrost Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 30: Viewing Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 31: Viewing Gauges Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 32: Viewing Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 33: Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 34: Viewing Sensors Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 35: Accessing Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 36: Main Menu Choices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 37: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 38: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 39: Change Language Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 40: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 41: Viewing and Clearing Alarms Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 42: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 43: Start of Trip Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 44: Printer Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 45: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 46: Print Report Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 47: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 48: Viewing Hourmeters Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 49: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 50: Selecting Mode Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 51: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 52: Mode Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 53: Keypad Lockout Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 54: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 55: Selecting Sleep Mode Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 56: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 57: No Pretrip Alarm Active Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 58: Pretrip Test Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9
List of Figures
Figure 59: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 60: Adjusting Display Brightness Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 61: Time and Date Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 62: Standard Display with Product Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 63: Standard Display with Product/Setpoint Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 64: Selecting Named Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 65: Selecting or Changing Named Product Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 66: Selecting Setpoint for Named Product Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 67: Changing Setpoint for Named Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 68: Changing Setpoint for Named Product Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 69: Selecting or Changing Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 70: Selecting or Changing Numeric Setpoint Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 71: Thermo King Alternator Terminal and Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 72: Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 73: Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 74: Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 75: Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 76: Electric Fuel Heater Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 77: Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 78: Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 79: Electrical Components In Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 80: Wire Connection to Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 81: Electric (Power) Filter Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 82: Electric (Power) Filter Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 83: Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 84: 2A/2FH Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 85: ELC Nameplate Located On Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 86: Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 87: Remove Plug from Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 88: Plastic Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 89: Removing Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 90: Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 91: Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 92: Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 93: Air/Fuel Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 94: Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 95: Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 96: Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 97: Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 98: Low Fuel Level - New Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 99: Intermediate Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 100: High Fuel Level - Replace Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 101: Fuel Filter/Water Separator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 102: Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 103: Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 104: Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 105: Marking Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 106: Place Injection Angle Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 107: Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 108: Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 109: Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 110: Injection Angle Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 111: Injection Pump Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 112: Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . . 103
Figure 113: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 114: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . 103
Figure 115: Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 116: Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 117: Injection Pump Gear Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 118: Fuel Solenoid Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10
List of Figures
Figure 119: Fuel Solenoid Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 120: Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 121: Trochoid Feed Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 122: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 123: Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 124: Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 125: Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 126: Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 127: Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 128: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 129: Adjusting the Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 130: Crankcase Breather Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 131: EMI 3000 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 132: EMI 3000 Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 133: EMI 3000 Air Cleaner System Model 30 Shown Model 50 Similar . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 134: Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 135: Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 136: Condenser Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 137: Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 138: Oil Collection Container Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Figure 139: Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Figure 140: High Pressure Cutout Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 141: Three-way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 142: Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 143: Compressor Coupling Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 144: Keyway Tool P/N 204-972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 145: Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 146: Cross Section of In-line Condenser Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 147: Location of Expansion Valve Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 148: Three-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 149: Gasket Tool P/N 204-424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 150: Piston and Stem Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 151: Check Bleed Hole Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 152: Check Piston Bleed Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 153: Check Seat Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 154: Seal Installation with Tool P/N 204-1008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 155: Teflon Check Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 156: Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 157: Removing Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 158: Stepper Motor and Piston Assembly with Piston in Fully Open Position . . . . . . . . . . . . . . . . . . . . 139
Figure 159: Stepper Motor and Piston Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 160: Insert Piston into Piston Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 161: Push Piston into Piston Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 162: Installing Complete ETV Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 163: Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 164: Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Figure 165: Defrost Damper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 166: Condenser Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 167: Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 168: Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 169: Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
11
List of Figures
12
Safety Precautions
Thermo King recommends that all service be
performed by a Thermo King dealer. However,
you should be aware of several general safety
practices:
The
symbol appears next to a point that is
particularly important
DANGER: Denotes the possibility of
serious injury or death.
WARNING: Denotes the possibility of
serious equipment damage or serious
personal injury.
CAUTION: Denotes the possibility of
minor to severe equipment damage or
personal injury.
General Practices
DANGER: Avoid engine operation in
confined spaces and areas or
circumstances where fumes from the
engine could become trapped and cause
serious injury or death.
WARNING: Make sure your gauge
manifold hoses are in good condition
before using them. Never let them come in
contact with moving belts, fans, pulleys or
hot surfaces. Defective gauge equipment
can damage components or cause serious
injury.
WARNING: Always wear goggles or safety
glasses when working on a unit.
Refrigerant liquid, oil and battery acid can
permanently damage your eyes. See “First
Aid” on page 16.
DANGER: Do not operate the compressor
with the discharge service valve closed.
This condition increases internal pressure,
which can cause an explosion.
WARNING: Use extreme caution when
drilling holes in a unit. Holes might
weaken structural components. Holes
drilled into electrical wiring can cause a
fire or explosion.
DANGER: Never apply heat to a sealed
refrigeration system or container. Heat
increases internal pressure, which might
cause an explosion.
WARNING: Exposed coil fins can cause
lacerations. Service work on the
evaporator or condenser coils is best left to
a certified Thermo King technician.
DANGER: Refrigerant in the presence of
an open flame, spark or electrical short
produces toxic gases that are severe
respiratory irritants.
WARNING: Do not apply heat to a closed
cooling system. Before applying heat to a
cooling system, drain it. Then flush it with
water and drain the water. Antifreeze
contains water and ethylene glycol. The
ethylene glycol is flammable and can
ignite if the antifreeze is heated enough to
boil off the water.
DANGER: Keep your hands, clothing and
tools clear of fans when working on a unit
that is running. Loose clothing might
entangle moving pulleys or belts, causing
serious injury or possible death.
DANGER: Do not inhale refrigerant. Use
caution when working with refrigerant or
a refrigeration system in any confined
area with a limited air supply, such as a
cargo area or garage. Refrigerant
displaces air and can cause oxygen
depletion, resulting in suffocation and
possible death.
WARNING: Be careful when using
ladders or scaffolding to install or service
a unit. Observe the manufacture’s safety
labels and warnings.
CAUTION: Make sure all mounting bolts
are tight and are the correct length for
their applications. Improper torque and
incorrect bolt lengths can damage
equipment.
13
Safety Precautions
NOTE: In the USA, EPA Section 608
Certification is required to work on refrigeration
systems.
Battery Removal
DANGER: Disconnect the negative
battery terminal (-) first when removing a
battery. Connect the positive terminal (+)
first when installing a battery.
This order is important because the frame is
grounded to the negative battery terminal. If the
negative terminal is still connected, a complete
circuit exists from the positive terminal of the
battery to the frame. Metal objects contacting the
positive side and the frame simultaneously will
cause sparks or arcing. If there are sufficient
hydrogen gases emitted from the battery, an
explosion might occur, causing equipment
damage, serious injury, even death.
Refrigerant Hazards
DANGER: Do not use a Halide torch.
When a flame comes in contact with
refrigerant, toxic gases are produced.
These gases can cause suffocation, even
death.
DANGER: Store refrigerant in proper
containers, out of direct sunlight and away
from intense heat. Heat increases pressure
inside storage containers, which can cause
them to burst.
DANGER: Do not use oxygen (O2 ) or
compressed air for leak testing. Oxygen
mixed with refrigerant is combustible.
WARNING: Wear butyl lined gloves when
handling refrigerant to help prevent
frostbite.
CAUTION: Refrigerant in a liquid state
evaporates rapidly when exposed to the
atmosphere, freezing anything it contacts.
Be careful when handling refrigerant to
protect your skin from frostbite.
14
CAUTION: When being transferred,
refrigerant must be in liquid state to avoid
possible equipment damage.
CAUTION: When transferring
refrigerant, use a process that prevents or
greatly restricts refrigerant from escaping
into the atmosphere. Refrigerant damages
the earth’s upper ozone layer.
Refrigerant Oil Hazards
WARNING: Protect your eyes from
contact with refrigerant oil. The oil can
cause serious eye injuries. Avoid
prolonged or repeated contact with
refrigerant oil. To prevent irritation, wash
your hands and clothing thoroughly after
handling the oil.
CAUTION: Use the correct oil in Thermo
King systems to avoid damaging
equipment and invalidating its warranty.
CAUTION: Do not mix refrigerant oils
because that can cause system damage.
CAUTION: Use dedicated equipment to
prevent contaminating systems with the
wrong type of oil.
CAUTION: Store refrigerant oil in an
approved sealed container to avoid
moisture contamination.
CAUTION: Do not expose the refrigerant
oil to the air any longer than necessary.
The oil will absorb moisture, which results
in much longer evacuation times and
possible system contamination.
CAUTION: Wipe up spills immediately.
Refrigerant oil can damage paints and
rubber materials.
Safety Precautions
Electrical Hazards
•
Avoid unnecessary contact with the electronic
components.
Low Voltage
•
Store and ship electronic components in
antistatic bags and protective packaging.
•
Leave electronic components in their antistatic
packing materials until you’re ready to use
them.
•
After servicing any electronic components,
check the wiring for possible errors before
restoring power to the unit.
•
Never use a battery and a light bulb to test
circuits on any microprocessor-based
equipment.
WARNING: Control circuits used in
refrigeration units are low voltage (12 to
24 volts dc). This voltage is not dangerous,
but the large amount of amperage
available from the alternator can cause
severe burns if accidentally shorted to
ground with metal objects, such as tools.
WARNING: Do not wear jewelry, watches
or rings because they increase the risk of
shorting out electrical circuits and
damaging equipment or causing severe
burns.
Microprocessor Service
Precautions
Take precautions to prevent electrostatic
discharge when servicing the microprocessor and
its related components. Even tiny amounts of
current can severely damage or destroy electronic
components.
Observe the following precautions when servicing
a microprocessor control system to avoid
damaging electronic components. Refer to the
appropriate microprocessor diagnosis manual and
the Electrostatic Discharge Training Guide (TK
40282) for more information.
Welding Precautions
Take precautions before electrically welding any
portion of the unit or the vehicle to which it is
attached. Ensure that welding currents are not
allowed to flow through the unit’s electronic
circuits.
Observe the following precautions when welding
to avoid damaging electronic components.
•
If the microprocessor has a power switch, turn
it OFF before connecting or disconnecting the
battery.
•
Disconnect power to the unit.
•
Disconnect all wire harnesses from the
microprocessor.
•
If the microprocessor has a power switch, turn
it OFF before connecting or disconnecting the
battery.
•
If there are any electrical circuit breakers in
the control box, switch them OFF.
•
Disconnect power to the unit.
•
Close the control box.
•
Avoid wearing clothing that generates static
electricity (wool, nylon, polyester, etc.).
•
Components that could be damaged by
welding sparks should be removed from the
unit.
•
Wear a wrist strap (P/N 204-622 or its
equivalent) with the lead end connected to the
microprocessor’s ground terminal. These
straps are available from most electronic
equipment distributors. DO NOT wear these
straps with power applied to the unit.
•
Use normal welding procedures, but keep the
ground return electrode as close to the area
being welded as practical. This will reduce the
likelihood of stray welding currents passing
through any electronic circuits.
15
Safety Precautions
First Aid
First Aid, Refrigerant
In the event of frostbite, protect the frozen area
from further injury, warm the area rapidly and
maintain respiration.
EYES : For contact with liquid, immediately flush
eyes with large amounts of water. CALL A
PHYSICIAN.
SKIN: Flush
area with large amounts of warm
water. Do not apply heat. Remove contaminated
clothing and shoes. Wrap burns with dry, sterile,
bulky dressing to protect from infection. CALL A
PHYSICIAN. Wash contaminated clothing before
reuse.
INHALATION: Move
victim to fresh air and use
CPR (cardio pulmonary resuscitation) or
mouth-to-mouth resuscitation to restore breathing,
if necessary. Stay with victim until emergency
personnel arrive.
First Aid, Refrigerant Oil
EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce
vomiting.
Immediately contact local poison control center or
physician.
First Aid, Engine Coolant
EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce
vomiting.
Immediately contact local poison control center or
physician.
16
Specifications
Engine
Model
TK486V (Tier 2)
Number of Cylinders
4
Cylinder Arrangement
In-line vertical, number 1 on flywheel end
Firing Order
1-3-4-2
Direction of Rotation
Counterclockwise viewed from flywheel end
Fuel Type
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity
13 quarts (12.3 liters) crankcase and oil filter
Fill to full mark on dipstick
Oil Type
API Classification CI-4 or better
(ACEA Rating E3 or better for Europe)
Oil Viscosity
14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic)
5 to 104 F (-15 to 40 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic)
Below -22 F (-30 C): SAE 0W-30 (Synthetic)
Engine rpm:
Low Speed Operation
High Speed Operation
1450 ± 25 rpm
2200 ± 25 rpm
Engine Oil Pressure
18 psi (127 kPa) minimum in low speed
45 to 57 psi (310 to 390 kPa) in high speed
Intake Valve Clearance
0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance
0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature
70 F (21 C)
Fuel Injection Timing:
See “Injection Pump Timing” on page 101.
Fuel Injection Nozzle Opening Pressure:
2,800-3,000 psi (19,300 to 20,700 kPa)
Low Oil Pressure Switch (Normally Closed)
17 ± 3 psi (117 ± 21 kPa)
Engine Coolant Thermostat
160 F (71 C)
17
Specifications
Engine
Engine Coolant Type
ELC (Extended Life Coolant), which is “RED”
Use a 50/50 concentration of any of the following
equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
CAUTION: Do not add “GREEN” or “BLUE-GREEN”
conventional coolant to cooling systems using “RED”
Extended Life Coolant, except in an emergency. If
conventional coolant is added to Extended Life
Coolant, the coolant must be changed after 2 years
instead of 5 years.
Coolant System Capacity
7.5 quarts (7.1 liters)
Radiator Cap Pressure
7 psi (48 kPa)
Drive
Direct to compressor; belts to fans, alternator, and water
pump
Belt Tension
Model 30
Tension No. on TK Gauge P/N 204-427
Alternator Belt
61
Lower Fan Belt (Engine to Idler)
67
Upper Fan Belt (Fan to Idler)
74
Refrigeration System
Compressor
Thermo King X430L
Refrigerant Charge—Type
13 lb (5.9 kg)—R404A
Compressor Oil Charge
4.3 qt (4.1 liters)*
Compressor Oil Type
Polyol Ester type P/N 203-513
Heat/Defrost Method
Hot gas
High Pressure Cutout
470 +7/-35 psi (3241 + 48/-241 kPa)
Automatic reset @ 375 ± 38 psi (2586 ± 262 kPa)
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured so that the same amount of oil can be added before placing the
replacement compressor in the unit.
18
Specifications
Electrical Control System
Voltage
12.5 Vdc
Battery
One, group C31, 12 volt, 1150 CCA
Fuses
See “Fuses” on page 76.
Battery Charging
12 volt, 65 amp, brush type, Thermo King Alternator
Voltage Regulator Setting
13.8 to 14.2 volts @ 77 F (25 C)
NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King
Alternator. Thermo King Alternators are painted black (see Figure 71 on page 73).
Electrical Components
NOTE: Disconnect components from unit circuit to check resistance.
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance—Cold
(Ohms)
35 to 45
0.5
0.2 to 0.3
24 to 29
Damper Solenoid
5.7
2.2
High Speed (Throttle) Solenoid
2.9
4.3
Air Heater
89
0.14
Pilot Solenoid
0.7
17.0
Electronic Throttling Valve:
Coil A (Red [EVA] and Blue [EVB] Wires)
Coil B (Black [EVC] and White [EVD] Wires)
—
—
20 to 35
20 to 35
Hot Gas Bypass Valve
1.1
11.1
Fuel Solenoid:
Pull-in Coil
Hold-in Coil
Starter Motor
350-475*
* On-the-engine cranking check. Bench test is approximately 140 amps.
Electric Fuel Heater
Electric Fuel Heater:
Resistance
Current Draw at 12.5 Vdc
Internal Thermostat Minimum Closing Temp.
Internal Thermostat Maximum Opening Temp.
W Fuse
0.8 to 1.1 ohms
11.4 to 15.5 amps
44 F (7 C)
62 F (17 C)
3 amps
2A/2FH Circuit Breaker
20 amps, manual reset
19
Specifications
20
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Microprocessor
•
Run Pretrip Test (see “Pretrip Tests” on page 60).
Engine
•
Check fuel supply.
•
Check engine oil level.
•
Drain water from fuel filter/water separator.
•
•
•
•
Inspect belts for condition and proper tension (belt tension tool
No. 204-427).
•
•
•
•
Check engine oil pressure hot, on high speed (should display “OK”).
•
•
•
•
Listen for unusual noises, vibrations, etc.
•
•
•
•
Check engine coolant level and antifreeze protection (-30 F [-40 C]).
•
Check air cleaner restriction indicator (change filter when indicator
reaches 25 in.). Replace EMI 3000 air cleaner element (see “EMI 3000
Air Cleaner” on page 114) at 3,000 hours or two years (whichever occurs
first) if indicator has not reached 25 in.
•
•
Check fuel level visible through the clear cover on fuel filter/water
separator. Replace filter element when fuel level rises to the top of filter
element.
•
•
•
Drain water from fuel tank and check vent.
•
•
•
Inspect/clean fuel transfer pump inlet strainer.
•
•
•
Check and adjust engine speeds (high and low speed).
•
•
•
Check condition of drive coupling bushings per Service Bulletin T&T 171.
•
Check engine mounts for wear.
•
Change engine oil and oil filter (hot). Requires oil with API Rating CI-4 or
better (ACEA Rating E3 for Europe).
—
•
Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank (see
page 87).
Test fuel injection nozzles at least every 3,000 hours. **
—
Replace fuel return lines between fuel injection nozzles every 10,000
hours.
Electrical
•
•
•
•
Inspect battery terminals and electrolyte level.
•
•
•
Inspect wire harness for damaged wires or connections.
•
•
•
Check operation of damper door (closes on defrost initiation and opens
on defrost termination).
•
Inspect alternator wire connections for tightness.
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.
21
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Refrigeration
•
•
•
•
Check refrigerant level.
•
•
•
Check for proper suction pressure.
•
•
•
Check compressor oil level and condition.
•
Check compressor efficiency and pump down refrigeration system.
•
Empty oil collection container mounted on compressor.
—
Replace dehydrator and check discharge and suction pressure every two
(2) years.
Structural
•
•
•
•
Visually inspect unit for fluid leaks.
•
•
•
•
Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads).
•
•
•
Inspect tapered roller bearing fanshaft and idlers for leakage and bearing
wear (noise).
•
•
•
Clean entire unit including condenser and evaporator coils and defrost
drains.
•
•
•
Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.
•
•
•
Check evaporator damper door adjustment and operation.
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.
22
Unit Description
Unit Overview
Design Features
The Thermo King SB-210+ 30 DRC (Domestic
Refrigerated Container) is a one piece,
self-contained, diesel powered, air
cooling/heating unit operating under the control of
a SMART REEFER 2 (SR-2) programmable
microprocessor controller. The unit mounts on the
front of the container with the evaporator
extending through an opening in the front wall.
•
SMART REEFER SR-2 Controller
•
OptiSet Plus™ with FreshSet™
Programmable Modes
•
ETV (Electronic Throttling Valve)
•
ServiceWatch™ Data Logger
•
CargoWatch™ Data Logger
The unit features cooling and heating using a quiet
running engine from the Thermo King TK486
engine family.
•
EMI-3000
•
High-Capacity Condenser Coil
•
Easy-Access Door Design
•
Composite Exterior Panels
•
Long-Life Coolant/Silicone Hoses
•
Standard Unit Color White
•
Standard Grille Color Black
•
Directional Air Delivery
•
Vibration Isolation System
•
Fuel Level Sensor
•
Fuel Filter/Water Separator with Electric Fuel
Heater
•
Alternator, 65 Amp, 12V dc
•
i-Box™ Interface with PAR Telematics
System
•
EON Battery, 12 Volt, Dry Cell
Figure 1: Front View
23
Unit Description
Diesel Engine
The unit uses a TK486V (Tier 2), which is a
4-cylinder, water cooled, direct injection diesel
engines.The engine is coupled directly to the
compressor. Belts transmit power to the unit fans,
alternator, and water pump.
The ETV system provides enhanced control of the
refrigeration system as follows:
Suction Pressure Control: The suction pressure
control algorithm is the primary control used to
obtain maximum capacity. This allows the
refrigeration system to fully utilize the power
capabilities of the engine under varying
conditions.
Discharge Pressure Protection: This protection
algorithm provides an additional measure of
protection against high discharge pressures and
possible compressor damage. It will prevent
shutdowns in high ambient temperatures by
allowing continued operation of the unit at a
temporarily reduced refrigeration capacity.
Engine Coolant Temperature Protection: This
Figure 2: TK486V (TK486VH is Similar)
protection algorithm protects the engine from high
coolant temperature shutdowns and possible
engine damage. It will reduce the load on the
engine by temporarily reducing refrigeration
capacity. This lowers the engine temperature
while still allowing continued unit operation.
The ETV system replaces the
modulation valve. The modulation control
algorithm operates much the same as modulation
on other units.
Modulation Control:
Thermo King X430L Reciprocating
Compressor
The unit is equipped with a Thermo King X430L
reciprocating compressor with 30.0 cu. in.
(492 cm3) displacement.
SMART REEFER 2 (SR-2) Control
System
Electronic Throttling Valve
WARNING: Do not operate the unit until
you are completely familiar with the
location and function of each control.
The Electronic Throttling Valve (ETV) is standard
on this unit.
The Electronic Throttling Valve (ETV) is a
variable position valve operated by a stepper
motor. The ETV is located in the suction line
between the evaporator and the heat exchanger.
Discharge and suction pressure transducers supply
pressure information to the microprocessor
control system. The microprocessor controls the
electronic throttling valve directly. The ETV
replaces both the throttling valve and the
modulation valve used in other units. The ETV
system also uses a hot gas bypass valve like the
one used with the modulation valve in other units.
24
The SR-2 is a microprocessor control system
designed for a transport refrigeration system. The
SR-2 integrates the following functions:
•
Changing setpoint and operating mode
•
Viewing gauge, sensor and hourmeter
readings
•
Initiating Defrost cycles
•
Viewing and clearing alarms.
Unit Description
The microprocessor components are located
inside the control box, which is located inside the
lower roadside service door. The microprocessor
is connected to an HMI (Human Machine
Interface) Control Panel. It is used to operate the
unit. The HMI control panel is mounted on the
face of the control box. It is clearly visible
through an opening in the lower roadside service
door.
See the Operating Instructions Chapter for more
information about the SR-2 controller.
Features of the CYCLE-SENTRY system are:
•
Offers either CYCLE-SENTRY or
Continuous Run operation.
•
Controller regulated all season temperature
control.
•
Maintains minimum engine temperature in
low ambient conditions.
•
Battery Sentry keeps batteries fully charged
during unit operation.
•
Variable preheat time.
CYCLE-SENTRY Start-Stop Controls
•
Preheat indicator buzzer.
The CYCLE-SENTRY Start-Stop fuel saving
system provides optimum operating economy.
Data Logging
WARNING: The unit can start at any time
without warning. Press the OFF key on the
HMI control panel and place the
microprocessor On/Off switch in the Off
position before inspecting or servicing any
part of the unit.
There are two separate data loggers. The data is
downloaded through the data ports on the front of
the control box using an IBM® PC compatible
laptop or desktop computer and Thermo King
WinTrac 4.4 (or higher) software.
1
2
The CYCLE-SENTRY system automatically
starts the unit on microprocessor demand, and
shuts down the unit after those conditions are
satisfied.
NOTE: The SR-2 controller provides a wide
range of control and programming flexibility.
However, pre-programming of the unit
controller may prohibit operation in certain
temperature ranges within some modes and may
also prohibit certain modes of operation. Refer
to TK 51727 the SR-2 Microprocessor Control
System Diagnostic Manual for information
about controller programming.
The system automatically monitors and maintains
the compartment temperature, engine block
temperature, and battery charge levels at a
condition where quick, easy starts are possible.
If the block temperature falls below 30 F (-1 C),
the engine will start and run until the block
temperature is above 90 F (32 C). If the battery
voltage falls to the programmed limit selected by
CYCLE-SENTRY Battery Voltage (typically 12.2
volts) and Diesel CYCLE-SENTRY mode is
selected, the engine will start and run until the
charge rate falls below that programmed by
CYCLE-SENTRY Amps (typically 5 amperes).
1.
CargoWatch Port
2.
ServiceWatch Port
Figure 3: HMI Controller and Data Ports
ServiceWatch™: ServiceWatch™
is standard
equipment. It records operating events, alarm
codes and compartment temperatures as they
occur and at preset intervals. This information is
typically used to analyze unit performance. Use
the ServiceWatch Port to downloaded the
ServiceWatch data.
25
Unit Description
CargoWatch™: CargoWatch™ data logging
requires the installation of optional sensors. Up to
six temperature sensor/probes and four door
switches can be installed. CargoWatch also logs
the setpoint. Use the CargoWatch Port to
downloaded the CargoWatch data. If optional
temperature sensors are installed, their readings
are displayed as Datalogger Sensor (1-6)
Temperature in the sensor readings. See “Viewing
Sensor Readings” on page 45.
Operating Modes
The microprocessor uses a complex program to
determine which operating mode the unit should
be in. Therefore, it is difficult to predict which
operating mode the unit should be in by
comparing the setpoint to the box temperature.
A printer can also be used to print a report of the
optional sensor readings. See “Printing a Trip
Report” on page 53.
The diesel engine operates at either low speed or
high speed as determined by the microprocessor.
The unit will Cool or Heat in either high or low
speed. The unit will Defrost in low speed only.
Heat and Defrost consists of hot gas delivered to
the evaporator coil distributor.
OptiSet Plus
The microprocessor will select the operating
mode from the following:
OptiSet Plus™ is a group of programmable
functions that control how the unit will operate
with specific setpoints or named products. This
assures that when a particular setpoint named
product is selected, the unit will always operate
the same way. This allows an entire fleet to be
configured to match customers’ needs. Refer to
TK 51727 the SR-2 Microprocessor Control
System Diagnostic Manual and TK 54045 the
OptiSet Plus User’s Guide for configuration
instructions.
FreshSet
FreshSet™ is included in OptiSet Plus. FreshSet
is a demand base temperature control for fresh
products. FreshSet modifies and adjusts unit
airflow operation to control temperature and to
maximize protection of cargo, while keeping
operating costs to a minimum. Refer to TK 51727
the SR-2 Microprocessor Control System
Diagnostic Manual for configuration instructions.
Sequence of Operation
When the Microprocessor On/Off switch is turned
on and Controller ON key is pressed, the LCD
display is illuminated and shows the setpoint and
the return air temperature. If the
CYCLE-SENTRY mode has been selected, the
unit will start and stop automatically. If the
Continuous mode has been selected, the unit will
start and run automatically.
26
•
High Speed Cool
•
Low Speed Cool
•
Low Speed Modulated Cool
•
Null (CYCLE-SENTRY operation only)
•
Low Speed Modulated Heat
•
Low Speed Heat
•
High Speed Heat
•
Defrost
Defrost
Frost gradually builds-up on evaporator coils as a
result of normal operation. The unit uses hot
refrigerant to defrost the evaporator coils. Hot
refrigerant gas passes through the evaporator coil
and melts the frost. The water flows through
collection drain tubes onto the ground. The
methods of Defrost initiation are Automatic, and
Manual.
Automatic Defrost: The controller is programmed
to automatically initiate timed or demand defrost
cycles. The controller can be programmed to
initiate timed defrost cycles at intervals of 2, 4, 6,
8, or 12 hours. Demand defrost cycles occur if the
differences between the return air temperature,
discharge air temperature, and coil temperature
exceed certain limits. The unit can enter defrost
cycles as often as every 30 minutes if required.
Manual Defrost: In Manual Defrost Mode, the
operator initiates a defrost cycle. See “Initiating a
Manual Defrost Cycle” on page 43.
Unit Description
NOTE: The unit will not perform a Manual
Defrost cycle unless the unit has been turned on
with the ON key, the unit is running in
Continuous or CYCLE-SENTRY mode (or shut
down in CYCLE-SENTRY Null mode), and the
coil temperature is below 45 F (7 C).
The evaporator coil temperature must be below
45 F (7 C) to allow defrost.
The following four defrost timers are used. These
timers can be set for intervals of 2, 4, 6, 8 or 12
hours.
•
•
Defrost Interval In Range with Fresh Setpoint
(standard setting 6 hours)
Defrost Interval Not In Range with Fresh
Setpoint (standard setting 4 hours)
•
Defrost Interval In Range with Frozen
Setpoint (standard setting 6 hours)
•
Defrost Interval Not In Range with Frozen
Setpoint (standard setting is 6 hours)
This feature allows a shorter Defrost interval to be
used when the unit is out of range during a
pull-down and more frequent Defrost cycles may
be beneficial.
1
2
1.
Door Latch
2.
Secondary Door Latch Nameplate
Figure 4: Door Latch Location
Opening the Secondary Door Latch
Later model units are equipped with a secondary
door latch. These units also have a secondary door
latch nameplate located below the front doors.
After opening the door latch, reach between the
front doors and lift the spring latch over the spring
catch while opening the door.
1
Normally, longer defrost timer intervals are used
for colder loads. The defrost interval may need to
be changed if the unit will not hold the
compartment temperature at setpoint.
Use a longer defrost interval if defrost is not being
initiated on demand.
Use a shorter defrost interval if defrost is
frequently being initiated on demand.
If the unit is in CYCLE-SENTRY Null mode, the
engine will start when defrost is initiated. The unit
will stay in defrost until the evaporator coil
temperature rises to 58 F (14 C).
2
1.
Spring Latch
2.
Spring Catch
Figure 5: Opening Secondary Door Latch
Opening the Front Doors
Closing the Front Doors
Pull the door latch handle to open the doors and
access the engine compartment. Slam the door to
close it. Do not push the door closed while
holding the door latch handle open or the door
will not close properly.
Slam the door to close it. Do not push the door
closed while holding the door latch handle open
or the door will not close properly.
27
Unit Description
Engine Compartment
Components
The following maintenance items can be checked
visually.
WARNING: The unit can start at any time
without warning. Press the Off key on the
HMI control panel and place the
microprocessor On/Off switch in the Off
position before inspecting any part of the
unit.
Air Filter Restriction Indicator: The air filter
restriction indicator is attached to the engine
intake manifold. When the diaphragm indicates
25, service the air filter. Press the button on the
bottom of the restriction indicator to reset after
servicing the air cleaner.
Compressor Oil Sight Glass: Use
this sight glass
to check the compressor oil level. See the
Refrigeration Maintenance Chapter for the correct
procedure.
Engine Oil Dipstick: Use the engine oil dipstick to
check the engine oil level.
CAUTION: Make sure the engine is
turned off before attempting to check the
engine oil.
Receiver Tank Sight Glass: Use this sight glass to
check the level of refrigerant in the receiver tank.
See the Refrigeration Maintenance Chapter for the
correct procedure.
9
1
10
2
11
3
12
4
5
6
13
7
14
15
8
16
1.
Air Filter Restriction Indicator
9.
Alternator
2.
Suction Service Valve
10.
Three-Way Valve
3.
Discharge Service Valve
11.
Throttle Solenoid
4.
Engine Starter Motor
12.
Receiver Tank Sight Glass
5.
Engine RPM Sensor
13.
Hand Primer Pump
6.
Compressor Sight Glass
14.
Low Engine Oil Pressure Switch
7.
Compressor Oil Filter
15.
Engine Oil Dipstick
8.
Engine Oil Filter
16.
Battery Tray
Figure 6: Engine Compartment Components
28
Unit Description
Unit Protection Devices
Coolant Level Switch: The coolant level switch
closes if the coolant level drops below an
acceptable level. If it stays closed for a specified
time, the microprocessor records alarm code 37.
Engine Coolant Temperature Sensor: The
microprocessor uses the engine coolant
temperature sensor to monitor the engine coolant
temperature. If the engine coolant temperature
rises above an acceptable level, the
microprocessor records alarm code 41 and
possibly 18. The the microprocessor might also
shut the unit down.
Fuse Link (Current Limiter): The fuse link is
Low Oil Level Switch: The low oil level switch
closes if the oil drops below an acceptable level. If
it stays closed for a specified time, the
microprocessor shuts the unit down and records
alarm code 66.
Low Oil Pressure Switch: The low oil pressure
switch closes if the oil pressure drops below an
acceptable level. If it stays closed for a specified
time, the microprocessor shuts the unit down and
records alarm code 19.
Preheat Buzzer: The
preheat buzzer sounds when
the controller energizes the preheat relay. This
warns anyone near the unit that the controller is
about to start the engine.
located in the positive battery cable. The fuse link
protects the electric system from a short. If the
fuse link burns out, replace it by replacing the
positive battery cable.
Fuses: Various fuses are located on the controller
interface board to protect circuits and
components. See “Fuses” on page 76 for more
information.
Smart FETs: Smart FETs
in the controller
interface board and expansion module protect
circuits and components. See “Smart FETs” on
page 78 for more information.
High Pressure Cutout Switch: The high pressure
cutout switch is located on the compressor
discharge manifold. If the compressor discharge
pressure becomes excessive, the switch opens the
circuit to the run relay to stop the unit. The
microprocessor will record Alarm Code 10.
High Pressure Relief Valve: This valve is designed
to relieve excessive pressure in the refrigeration
system. It is located on the receiver tank. The
valve is a spring-loaded piston that lifts off its seat
when refrigerant pressure exceeds 500 psi (3447
kPa). The valve will reseat when the pressure
drops to 400 psi (2758 kPa). The valve could
possibly leak refrigerant after it has relieved
excess pressure. Tapping the valve lightly may
help the valve reseat and seal properly. The valve
is non-repairable and requires no adjustment. If
the valve fails to reseat properly, recover the
refrigerant charge and replace the valve.
29
Unit Description
Serial Number Locations
Unit: Nameplates
on the bulkhead above the
compressor inside the curbside door, and on the
roadside of the evaporator.
1
Engine: See the engine identification plate located
on the engine valve cover.
Compressor: Stamped
between the cylinders on
the front end above the oil pump.
1
1
1.
Serial Number Location
Figure 9: Unit Serial Number Locations
1
2
3
4
1.
Serial Number Location
Figure 7: Compressor Serial Number Location
1
ARA793
1.
2.
3.
4.
Unit Serial Number
Bill of Material Number
Unit Model
Unit ID
Figure 10: Laminated Serial Number Plate
(Located Where Shown Above)
1.
Serial Number Location
Figure 8: Engine Serial Number Location
30
Unit Description
1
2
3
1.
Defrost Damper
2.
X430L Compressor
3.
TK486V Engine
Figure 11: Back View
31
Unit Description
32
Operating Instructions
SMART REEFER 2 (SR-2)
Control System
The microprocessor components are located
inside the control box, which is located inside the
lower roadside service door. The microprocessor
is connected to an HMI (Human Machine
Interface) Control Panel. It is used to operate the
unit. The CargoWatch and ServiceWatch ports are
used to retrieve data from the data logging system.
1
2
3
HMI Control Panel
Use the HMI control panel to operate the unit.
Refer to the SB-210+ 30 DRC Operator’s Manual
TK 54734 and the SR-2 Microprocessor Control
System Diagnostic Manual TK 51727 for more
information.
The HMI control panel has a display and eight
touch sensitive keys. The display is capable of
showing both text and graphics. The four keys on
the left and right sides of the display are dedicated
keys. The four keys under the display are “soft”
keys. The function of “soft” keys change
depending on the operation being performed. If a
soft key is active, its function will be shown in the
display directly above the key.
4
5
1.
Control Box
4.
CargoWatch Port
2.
Microprocessor
On/Off Switch
5.
HMI Control Panel
3.
ServiceWatch Port
Figure 12: Control Box With Service Door Open
Figure 13: SR-2 HMI Control Panel
Microprocessor On/Off Switch
This switch supplies or removes electrical power
to the microprocessor. It is located on the left side
of the control box.
CAUTION: The unit can start at any time
without warning. Press the OFF key on the
HMI control panel and place the
microprocessor On/Off switch in the Off
position before inspecting or servicing any
part of the unit.
33
Operating Instructions
Mode Key: Press this key to switch
Control Panel Display
The display is used to supply unit information to
the operator. This information includes setpoint,
current box temperature operating information,
unit gauge readings, system temperatures and
other information as selected by the operator.
The default display is called the Standard Display.
It is shown in Figure 14 and is described in detail
later in this chapter.
3
2
4
1
5
back and forth between the
CYCLE-SENTRY mode and the
Continuous Run mode.
The four “soft” keys under the display
are multi-purpose keys (see Figure 14).
Their function changes depending on
the operation being performed. If a soft
key is active, it’s function will be
shown in the display directly above the
key.
Typical soft key applications:
• Set Point
• Gauges
• Sensors
• Menu
6
• Yes/No
1.
Off Key (Dedicated Key)
2.
On Key (Dedicated Key)
• +/–
3.
Display
• Up/Down
4.
Defrost Key (Dedicated Key)
• Select/Exit
5.
Continuous/CYCLE-SENTRY Mode Key
(Dedicated Key)
6.
Soft Keys
Figure 14: Dedicated and Soft Keys
Control Panel Keys
The four keys on the left and right sides of the
display screen are “dedicated keys” (see Figure
14). Their functions are listed below.
On Key: Press this key to
turn the unit
on. The Thermo King Logo screen will
appear briefly. The display will then
show the Standard Display of box
temperature and setpoint when the unit
is ready to run.
Off Key: Press
this key to turn the unit
off. The engine will stop immediately.
Then the HMI control panel will enter
the power-down sequence.
Defrost Key: Press this key to initiate a
Manual Defrost cycle.
34
• Next/Back
• Clear/Help
Operating Instructions
Unit Operation
Manual Pretrip Inspection (Before
Starting Unit)
The following Manual Pretrip Inspection should
be completed before starting the unit and loading
the container. While the pretrip inspection is not a
substitute for regularly scheduled maintenance
inspections, it is an important part of the
preventive maintenance program designed to head
off operating problems and breakdowns before
they happen.
Fuel: The
diesel fuel supply must be adequate to
guarantee engine operation to the next check
point.
Engine Oil: The engine oil level should be at the
FULL mark with the dipstick turned (threaded)
into oil pan. Never overfill.
Coolant: The
engine coolant must have antifreeze
protection to -30 F (-34 C). Alarm Code 37
indicates low coolant. Add coolant in the
expansion tank.
Turning Unit On
Complete the following steps to turn on the unit:
1. Press the ON key.
2
1
1.
On Key
2.
Display
Figure 15: Press On Key
2. The display briefly shows a Thermo King
Logo.
NOTE: With extremely cold ambient
temperatures it may take up to 15 seconds for
the first display to appear.
CAUTION: Do not remove expansion
tank cap while coolant is hot.
CAUTION: Do not add “GREEN” or
“BLUE-GREEN” conventional coolant to
cooling systems using “RED” Extended
Life Coolant, except in an emergency. If
conventional coolant is added to Extended
Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
Battery: The
terminals must be clean and tight.
Belts: The
belts must be in good condition and
adjusted to the proper tensions.
Electrical: The
electrical connections should be
securely fastened. The wires and terminals should
be free of corrosion, cracks or moisture.
Structural: Visually inspect the unit for leaks,
loose or broken parts and other damage. The
condenser and evaporator coils should be clean
and free of debris. Check the defrost drain hoses
and fittings to make sure they are open. Make sure
all the doors are latched securely.
Figure 16: Turning Unit On Screen Sequence
35
Operating Instructions
3. The “Configuring System” Screen briefly
appears while communications are established
between the microprocessor and the HMI
control panel.
Turning Unit Off
Complete the following steps to turn unit off:
1. Press the OFF key.
4. The Standard Display showing box
temperature and setpoint briefly appears.
5. The “Diesel Engine Starting” Screen briefly
appears as the engine preheats and starts.
2
1
6. The Standard Display showing box
temperature and setpoint reappears when the
unit is running.
1.
Off Key
2.
Display
Figure 17: Press Off Key
2. The engine will immediately shut off.
3. The “System is Powering Down” Screen will
briefly appear.
Figure 18: Turning Unit Off Screen Sequence
4. The Off Screen will briefly appear.
5. The screen goes blank when the unit power is
off.
36
Operating Instructions
Standard Display
Standard Display Variations
The Standard Display is the default display. It
appears if no other display function is selected.
The Standard Display shows the box temperature
and setpoint. The box temperature is measured by
the controlling sensor. The return air sensor is the
controlling sensor except when the controller is
programmed to use the discharge air sensor as the
controlling sensor during modulation. The box
temperature shown below in Figure 19 is 35.5 F.
The setpoint shown is 35 F. The CYCLESENTRY Icon in the upper right corner shows the
unit is operating in the CYCLE-SENTRY mode.
The arrow pointing down indicates the unit is
cooling.
The Standard Display has variations. A display
showing any of the following variations is still
considered a Standard Display (see Figure 20).
NOTE: The CYCLE-SENTRY Icon will appears
when the unit is operating in CYCLE-SENTRY
mode as shown below. If the CYCLE-SENTRY
Icon is not present the unit is operating in
Continuous mode.
1
3
4
2
The top of the display may show a named product
if the controller has been programmed with
OptiSet Plus temperature profiles. The far left soft
key may display PRODUCT or PRODUCT/SETPOINT if
the controller has been programmed with OptiSet
Plus temperature profiles. See “OptiSet Plus” on
page 65 for information about selecting or
changing the named product or the setpoint if the
controller has been programmed with OptiSet
Plus temperature profiles. Refer to TK 54045 the
OptiSet Plus User’s Guide and TK 51727 the
SR-2 Microprocessor Control System Diagnostic
Manual for information about programming the
controller with OptiSet Plus temperature profiles.
The temperature can be displayed in degrees
Fahrenheit (F) or degrees Celsius (C). An arrow
pointing upwards indicates the unit is heating. An
arrow pointing downwards indicates the unit is
cooling.
1
4
2
3
1.
Box Temperature
3.
CYCLE-SENTRY
Icon
2.
Cooling
4.
Setpoint
5
6
Figure 19: Standard Display
1.
Named Product
2.
Heating
3.
PRODUCT or PRODUCT/SETPOINT Soft Key
4.
Degrees Celsius
5.
Cooling
6.
Degrees Fahrenheit
Figure 20: Standard Display Variations
37
Operating Instructions
Temperature Watch Display
Alarm Display
The Standard Display defaults to the Temperature
Watch Display after about 2-1/2 minutes of
non-use (when no keys are pressed). The
Temperature Watch Display shows the same box
temperature and setpoint but in larger fonts. This
creates easy operator viewing from a distance. To
return to the Standard Display press the MENU soft
key (or any of the other three soft keys that are not
assigned).
If a unit alarm condition occurs the large Alarm
Icon will appear on the Standard Display as
shown below in Figure 22.
NOTE: A named product may appear above the
temperature reading if the controller has been
programmed with OptiSet Plus temperature
profiles and a named product has been selected.
NOTE: A shutdown alarm will also cause the
display and backlight to flash on and off, and the
display will switch from normal video to reverse
video and back to normal video (light areas
become dark and dark areas become light).
See “Alarms Menu” on page 50 for information
about displaying and clearing alarms.
1
2
NOTE: The CYCLE-SENTRY Icon will appear
in the Temperature Watch display when the unit
is operating in CYCLE-SENTRY mode as shown
below. If the CYCLE-SENTRY Icon is not
present the unit is operating in Continuous
mode.
2
1
1.
Alarm Icon
2.
Named Product (If Selected)
Figure 22: Alarm Display
3
1.
Named Product (If Selected)
2.
CYCLE-SENTRY Icon
3.
Menu Soft Key
Figure 21: Temperature Watch Display
38
Operating Instructions
Starting the Diesel Engine
After Start Inspection
Diesel engine preheats and starts automatically in
both Continuous Mode and CYCLE-SENTRY
mode. The engine will preheat and start if
necessary when the unit is turned on. The engine
preheat and start will be delayed in
CYCLE-SENTRY mode if there is no current
need for the engine to run. If a key or sequence of
keys are pressed on the controller before the
engine starts, the engine will preheat and start
approximately 10 seconds after pressing the last
key.
After the unit is running, check the following
items to confirm that the unit is running properly.
See “Turning Unit On” on page 35.
CAUTION: The engine may start
automatically any time the unit is turned
on.
WARNING: Never use starting fluid.
Oil Pressure: Check the engine oil pressure by
pressing the GAUGES soft key. See “Viewing Gauge
Readings” on page 44. The Engine Oil Pressure
Display should indicate OK not LOW.
Ammeter: Check the ammeter reading by pressing
the GAUGES soft key. See “Viewing Gauge
Readings” on page 44. The Amps Display should
indicate a positive charge amperage rate to the
battery. A negative (-) number indicates a
discharge condition.
Compressor Oil: The compressor oil level should
be visible in the compressor sight glass after 15
minutes of operation. If not, check the compressor
oil level using the procedure in the Refrigeration
Maintenance Chapter.
Pre-Cooling: Make
NOTE: Run a pretrip test if the unit has not been
used recently. See “Pretrip Tests” on page 60.
Unit Fails To Start
If the engine does not start and the Alarm Icon
appears on the display, take the following steps.
1. Check for and correct any alarm conditions.
See “Viewing and Clearing Alarms Screen
Sequence” on page 51.
2. Clear all alarms. See “Viewing and Clearing
Alarms Screen Sequence” on page 51.
3. Press the OFF key to turn the unit off.
sure that the setpoint is at the
desired temperature. See “Changing the Setpoint”
on page 40. Allow the unit to run for a minimum
of 30 minutes (longer if possible) before loading
the container.
This provides a good test of the refrigeration
system while removing residual heat and the
moisture from the container interior to prepare it
for a refrigerated load.
Defrost: When the unit has finished pre-cooling
the container interior, manually initiate a Defrost
cycle. See “Initiating a Manual Defrost Cycle” on
page 43. This will remove the frost that builds up
while running the unit to pre-cool the container.
4. Press the ON key to turn the unit on.
5. The controller will go through the start up
screens and then after a 10 second delay the
unit will start automatically.
6. If the engine will still not start, turn the unit
off. Determine and correct the cause for not
starting.
7. Repeat the procedure.
39
Operating Instructions
Changing the Setpoint
To change the setpoint complete the following
steps.
NOTE: If the SETPOINT soft key (far left) displays
PRODUCT or PRODUCT/SETPOINT, the controller has
been programmed with OptiSet Plus temperature
profiles. See “OptiSet Plus” on page 65 for
information about selecting or changing the
named product or the setpoint.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the SETPOINT soft key on the Standard
Display. See Figure 23. The “Setpoint” Screen
briefly appears, then the “Current Setpoint”
Screen appears. See Figure 24.
3. Press the + or - soft keys to change the setpoint
reading. See Figure 24.
4. Press the YES OR NO soft key accordingly as
described below. See Figure 24.
•
If the NO key is pressed the setpoint change
made with the “+” or “-” soft keys will not be
accepted, the setpoint will not be changed and
the display will return to the Standard Display.
•
If the YES soft key is pressed, the setpoint
change made with the “+” or “-” soft keys will
be accepted, and the following screens will
appear.
NOTE: Alarm Code 127 “Setpoint Not
Entered” may be generated if the + or - soft
keys are used to change the setpoint, but the
YES or NO soft keys are not used to accept or
decline the new setpoint.
5. The “Programming New Setpoint” Screen will
appear. See Figure 24.
1
6. The “New Setpoint Is XX” Screen briefly
appears. See Figure 24.
2
7. The Standard Display appears with setpoint
changed to the new setpoint. See Figure 24.
1.
Standard Display
2.
Setpoint Soft Key
Figure 23: Changing Setpoint
If YES Key was pressed
SETPOINT Key
+ or – Key
YES or NO Key
Figure 24: Changing the Setpoint Screen Sequence
40
If NO Key was pressed
Operating Instructions
Selection of Operating Modes
The Thermo King CYCLE-SENTRY system is
designed to save refrigeration fuel costs. The
savings vary with the commodity, ambient
temperatures and container insulation. However,
not all temperature controlled products can be
properly transported using CYCLE-SENTRY
operation. Certain highly sensitive products
normally require continuous air circulation.Use
the following guidelines to select the proper
operating mode to protect the commodity you are
transporting.
Examples of products normally acceptable for
CYCLE-SENTRY Operation:
•
Frozen foods (in adequately insulated
containers)
•
Boxed or processed meats Poultry
•
Fish
•
Dairy products
•
Candy
•
Chemicals
•
Film
•
All non-edible products.
Examples of products normally requiring
Continuous Run Operation for air flow:
•
Fresh fruits and vegetables, especially
asparagus, bananas, broccoli, carrots,
citrus, green peas, lettuce, peaches,
spinach, strawberries, sweet corn, etc.
•
Non-processed meat products (unless
pre-cooled to recommended temperature).
•
Fresh flowers and foliage.
The above listings are not all inclusive. Consult
your grower or shipper if you have any questions
about the operating mode selection of your type of
load.
41
Operating Instructions
Selecting CYCLE-SENTRY or
Continuous Mode
When CYCLE-SENTRY mode is selected the unit
will start and stop automatically to maintain the
setpoint, keep the engine warm, and the battery
charged. When Continuous mode is selected, the
unit will start automatically and run continuously
to maintain setpoint and provide constant airflow.
CYCLE-SENTRY or Continuous may not be
available if OptiSet Plus is in use.
If allowed by OptiSet Plus, complete the
following steps to change modes:
NOTE: The mode can also be changed using the
Mode Menu Screen in the Main Menu. See
“Turning CYCLE-SENTRY On or Off” on page
56.
1. Press the MODE key. See Figure 25.
1
Figure 26: Screen Sequence for Changing from
CYCLE-SENTRY Mode to Continuous Mode
2
1.
CYCLE-SENTRY Icon Shows Mode Selected
Displayed for CYCLE-SENTRY Mode
Not Displayed for Continuous Mode
2.
Mode Key
Figure 25: Changing Mode
2. The “Programming Continuous Mode” or
“Programming CYCLE-SENTRY Mode”
Screen briefly appears. See Figure 26 and
Figure 27.
3. The “New System Mode is Continuous”
Screen or the “New System Mode
CYCLE-SENTRY” Screen briefly appears.
See Figure 26 and Figure 27.
4. The Standard Display appears showing the
new mode. See Figure 26 and Figure 27.
5. Press the MODE key again to change the unit
back to the previous mode.
42
Figure 27: Screen Sequence for Changing from
Continuous Mode to CYCLE-SENTRY Mode
Operating Instructions
Initiating a Manual Defrost Cycle
Defrost cycles are usually initiated automatically
based on time or temperature. Manual Defrost is
also available if the unit is running and the coil
temperature is less than 45 F (7 C). Other features
such as door switch settings may not allow
Manual Defrost to be initiated.
Use the following steps to initiate a Manual
Defrost:
1. Press the DEFROST key. See Figure 28.
or
1
2
Figure 29: Initiating Manual Defrost Screen
Sequence
1.
Standard Display
2.
Defrost Key
Figure 28: Initiating a Manual Defrost Cycle
2. The “Defrost” Screen briefly appears. See
Figure 29.
3. The “Programming Defrost” Screen briefly
appears. See Figure 29.
4. The “Defrost Started” Screen briefly appears.
See Figure 29.
5. A modified Standard Display appears. The bar
indicator will fill in showing time remaining
to complete the Defrost cycle. The bar
indicator in the figure shows that the Defrost
cycle is 50% complete. When the Defrost
cycle is complete the display returns to the
Standard Display. See Figure 29.
Terminating a Defrost Cycle
The Defrost cycle will terminate automatically
when the coil temperature reaches 58 F (14 C) or
when the defrost timer expires. The defrost timer
is normally set for 45 minutes, but can be set for
30 minutes. Defrost can also be terminated by
turning the unit off.
NOTE: If the defrost timer consistently
terminates Defrost because the evaporator coil
temperature fails to reach 58 F (14 C), check the
unit to see if it is working properly.
If the unit is prevented from going into a
Manual Defrost (IE: Coil temperature more
than 45 F (7 C) or on economy mode etc.). A
“Defrost Unavailable” Screen briefly appears.
The display returns to the Standard Display.
See Figure 29.
43
Operating Instructions
Viewing Gauge Readings
Use the following steps to view the gauge
readings:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the GAUGES soft key to enter the Gauges
Menu. See Figure 30.
1
3. Press BACK or NEXT soft keys to scroll through
following gauges: Coolant Temperature,
Coolant Level, Oil Pressure, Oil Level, Amps,
Battery Voltage, Engine RPM, Fuel Level
Sensor, Discharge Pressure, Suction Pressure,
ETV Position, and I/O. Selecting I/O enters a
group of screens that show the status (On or
Off if applicable) of the High Speed Relay,
Run Relay, Run Relay Feedback, Alternator
Excite Output, Defrost Damper, Heat Output,
Alternator Frequency, Diesel/Electric Relay,
Electric Ready Input, Electric Overload, and
Hot Gas Bypass. See Figure 31. If no keys are
pressed within 30 seconds, the screen will
return to the standard display.
4. Press the LOCK soft key to display any Gauge
Screen for an indefinite period. Press the key
again to unlock the screen.
2
1.
Standard Display Screen
2.
Gauges Soft Key
5. Press the EXIT soft key to return to the Standard
Display.
Figure 30: Viewing Gauges
BACK Key
BACK Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
NEXT Key
NEXT Key
Figure 31: Viewing Gauges Screen Sequence
44
Operating Instructions
Viewing Sensor Readings
•
Optional Datalogger Sensor 1-6
Temperatures – The Datalogger Sensor
Temperature screens display dashes (– – –)
unless optional sensors are installed.
•
Board Temperature Sensor – The Board
Temperature Sensor displays the
temperature of the PC board inside the
HMI control panel. The controller will
turn the HMI display heater on if this
temperature goes below a certain point in
extremely cold ambient temperatures.
Use the following steps to view the sensor
readings.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the SENSOR soft key to enter the Sensor
Menu. See Figure 32.
1
See Figure 33 and Figure 34. If no keys are
pressed within 30 seconds, the screen will
return to the Standard Display.
2
1.
Standard Display
2.
Sensors Soft Key
Figure 32: Viewing Sensors
3. Press the BACK or NEXT soft keys to scroll
through the following sensor screens:
•
Control Return Air Temperature
•
Display Return Air Temperature
•
Control Discharge Air Temperature
•
Display Discharge Air Temperature
•
Temperature Differential – The
Temperature Differential is the difference
between the Control Return Air
Temperature and the Control Discharge
Air Temperature.
•
Evaporator Coil Temperature
•
Ambient Air Temperature
•
Spare 1 Temperature
1
2
3
4
1.
Exit Soft Key
3.
Back Soft Key
2.
Lock Soft Key
4.
Next Soft Key
Figure 33: Soft Keys
4. Press the LOCK soft key to display any sensor
screen for an indefinite period. Press the key
again to unlock the screen.
5. Press the EXIT soft key to return to the Standard
Display.
45
Operating Instructions
BACK Key
SENSORS Key
BACK Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
NEXT Key
NEXT Key
Figure 34: Viewing Sensors Screen Sequence
46
Operating Instructions
Navigating the Main Menu
LANGUAGE
The Main Menu contains individual menu areas
that allow the operator to view information and
modify unit operation. Use the following steps to
access these menu areas:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
3. Press NEXT and BACK soft keys to scroll up or
down through the main menu areas. See
Figure 35 and Figure 36.
4. Press the SELECT soft key to access a specific
menu area when shown on the display screen.
See Figure 35.
5. Press the EXIT soft key. To return to the
Standard Display. The Main Menu choices are
shown in Figure 36. For detailed information
on each menu area, see the individual
explanations of each menu item on the
following pages of this manual.
1
4
3
2
1.
Menu Soft Key
4.
Select Soft Key
2.
Next Soft Key
5.
Exit Soft Key
3.
Back Soft Key
ALARMS
DATALOGGER
HOURMETERS
MODE
PRETRIP
2. Press the MENU soft key. See Figure 35.
5
Does not appear unless more than
one language activated.
ADJUST BRIGHTNESS
TIME
Figure 36: Main Menu Choices
Main Menu Choices
1. Language Menu: This menu only appears if the
controller is programmed to activate more than
one language. It allows the operator to select
which language is used. All other subsequent
displays are shown in the selected language.
English is the default language. See page 48.
2. Alarms Menu: Shows any active alarms and
allows alarms to be cleared. See page 50.
3. Datalogger Menu: Allows the operator to view
the datalogger displays. See page 52.
4. Hourmeters Menu: If enabled, allows the
operator to view the hourmeter displays. See
page 54.
5. Mode Menu: Allows the operator to change unit
operating modes between CYCLE-SENTRY
mode and Continuous Run mode, select Keypad
Lockout, and start Sleep mode. See page 55.
6. Pretrip: Allows the operator to run a Pretrip.
See page 60.
7. Adjust Brightness: Allows the operator to
adjust the display intensity as required by
conditions. See page 63.
8. Time: Allows the operator to view the Time and
Date. The Time is displayed in 24 hour military
time. See page 64.
Figure 35: Accessing Main Menu
47
Operating Instructions
Language Menu
If the Language feature is activated in the
controller programming, an alternate language
can be selected from the Language Menu. After a
new language is chosen all displays will appear in
that language. If the language feature is not
enabled this menu does not appear.
The languages available are dependant on the
HMI control panel software revision. Languages
currently supported by software revision 65xx are
English, Spanish, French, German, Italian, Dutch,
Portuguese, Greek, Turkish, Arabic and Hebrew.
Languages currently supported by software
revision 66xx are English, Russian, Polish,
Hungarian, Romanian, Bulgarian, Czech, Danish,
Swedish, Norwegian and Finnish. Other than
languages supported, software revisions 65xx and
66xx are identical.
The default language is English. Only languages
that have been activated in the controller
programming will appear on this menu. Refer to
the SR-2 Microprocessor Control System
Diagnostic Manual TK 51727 for information
about programming the controller.
To select an alternate language:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the MENU soft key on the Standard
Display.
3. If enabled, the Language Menu Screen
appears. Press the SELECT soft key to choose
the Language Menu Screen. See Figure 39.
4. The “NEW LANGUAGE WILL BE” Screen
will appear. See Figure 39.
5. Press the + or - soft keys to select the desired
language. German is shown in Figure 39.
6. When the desired language is shown, press the
YES soft key to confirm the choice.
7. The “PROGRAMMING LANGUAGE
PLEASE WAIT” Screen briefly appears.
8. The “LANGUAGE SELECTED IS XXX”
Screen briefly appears.
9. The display will then return to the Language
Menu, but will show the new language.
German is shown in Figure 39.
NOTE: Exercise care when changing
languages, as once changed all HMI Control
panel displays will be in the new language. If
the user is not familiar with the new
language, problems may be experienced
returning to the default language.
10. Repeat the process to select a different
language. Press the NEXT soft key to select a
different main menu item. Press the EXIT soft
key to return to the Standard Display.
NOTE: English and all other enabled languages
may be accessed from the Standard Display.
When the Standard Display is shown press and
hold the first and last soft key for 5 seconds as
shown below in Figure 38.
1
1.
Menu Soft Key
1
Figure 37: Standard Display
1.
Press These Soft Keys
Figure 38: Standard Display
48
Operating Instructions
SELECT Key
HAUPTMENU
SPRACHE
BEENDEN
AUSWHAL
WEITER
ARA820
+ or - Key
NEW LANGUAGE WILL BE
DEUTSCH
YES Key
USE +/- TO CHANGE
-
+
OK?
YES
NO
ARA819
Figure 39: Change Language Screen Sequence
49
Operating Instructions
Alarms Menu
If an alarm condition occurs the large Alarm Icon
will appear on the Standard Display. See “Alarm
Display” on page 38.
7. After the alarm situation is resolved press the
CLEAR key to clear the alarm. To display the
next alarm, press the NEXT key (see Figure 41).
NOTE: For additional information
regarding the alarm shown on the display
press the HELP soft key. A help message will
appear.
Alarms are viewed and cleared using the Alarm
Menu as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the MENU soft key on the Standard
Display.
Important Alarm Notes
•
If an alarm will not clear, it may still exist. If
the alarm is not corrected, it will not clear.
•
If an alarm cannot be cleared from the Main
menu, the Clear key will not appear. These
alarms must be cleared from the Guarded
Access Menus.
•
All alarms must be viewed before any of the
alarms can be cleared.
•
Check Alarm Code 96 (Low Fuel Level) is set
when the fuel level falls below 15% of tank
capacity. Alarm Code 96 automatically resets
when the fuel tank is refilled above 25% of
tank capacity.
•
Alarm Code 44 (Out of Fuel) – The controller
can be programmed to set a Alarm Code 44
(Out of Fuel) when the fuel level falls below
5% of tank capacity. How Alarm Code 44
functions depends on which Base Controller is
used in the unit. Identify the Base Controller
from the last three digits of the serial number
on the Base Controller Label or on the Base
Controller/Interface Board Assembly Label as
shown in the following table. See Service
Bulletins TT492 and TT493 for more
information.
1
1.
Menu Soft Key
Figure 40: Standard Display
3. The Language Menu or Alarm Menu will
appear. If the Language Menu appears, press
the NEXT soft key until the Alarm Menu
appears.
4. Press the SELECT soft key. The Alarm Display
will appear. See Figure 41.
5. If no alarms are present, the “No Alarm”
Screen is shown. Press the EXIT soft key to
return to the Standard Display.
6. If alarms are present, the quantity of alarms (if
more than one), the alarm code number and
alarm description will be shown on the
display. In the example below (see Figure 41),
there are two alarms present. The most recent
is Alarm Code 6. This alarm code indicates a
problem with the coolant temperature sensor.
NOTE: If a serious alarm occurs, the unit
will be shut down to prevent damage to the
unit or the load. If this occurs, the display
will show that the unit is shut down and
display the alarm code that caused the
shutdown.
50
Last Three Digits
of Serial Number
Base Controller
000
SR-2/A
0T2
SR-2/B
0T3
SR-2/C
0T4
SR-2/D
Operating Instructions
SR-2/D (0T4) Base Controller with
B030 Software – Alarm Code 44 is set as
a Shutdown Alarm with either the float
fuel level sensor or the solid state fuel
level sensor. Shutdown Alarm Code 44
can be manually cleared with the Clear
key. In that case it becomes a check alarm
and the unit will continue to run until it
runs out of fuel (if it is not refilled). Alarm
Code 44 automatically resets when the
fuel tank is refilled.
SR-2/A (000), SR-2/B (0T2), or SR-2/C
(0T3) Base Controllers with B020 or
B030 Software – If the float fuel level
sensor is used, then Alarm Code 44 is set
as a Check Alarm, never as a Shutdown
Alarm. If the solid state fuel level sensor is
used, then Alarm Code 44 is set as a a
Shutdown Alarm. Shutdown Alarm Code
44 can be manually cleared with the Clear
key. In that case it becomes a check alarm
and the unit will continue to run until it
runs out of fuel (if it is not refilled). Alarm
Code 44 automatically resets when the
fuel tank is refilled.
NOTE: Shutdown Alarm Code 44 reappears
when it is manually cleared from the Alarms
Menu. However, it changes to a check alarm
so the unit will now start after you exit the
Alarms Menu.
Refer to the SR-2 Microprocessor Control System
Diagnostic Manual TK 51727 for more
information about alarm codes and their
diagnosis.
ALARM 6
2 OF 2 ALARMS
COOLANT TEMP SENSOR
EXIT
CLEAR
HELP
NEXT
ARA823
NEXT Key
MENU Key
ALARM 5
1 OF 2 ALARMS
AMBIENT TEMP SENSOR
SELECT Key
EXIT
CLEAR
HELP
NEXT
ARA824
SELECT Key
CLEAR Key
Figure 41: Viewing and Clearing Alarms Screen Sequence
51
Operating Instructions
Datalogger Menu
The Datalogger Menu is used to initiate a start of
trip, or to print a trip report.
1
Initiating a Start of Trip
A “Start Of Trip” places a marker in the
datalogger memory. It is typically initiated when
the cargo is being loaded. The Start Of Trip
marker then shows when the trip started in the
data that is downloaded or printed from the
datalogger. A Start Of Trip can be initiated
through the use of WinTrac datalogging software,
or manually in the field. The following procedure
covers manual initiation. For more information on
datalogging, see the WinTrac User Manual
included with the WinTrac software.
3. Press the NEXT soft key until the Datalogger
Menu appears. See Figure 43.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display. See Figure 42.
6. Press the SELECT soft key to initiate a start of
trip.
2. Press the MENU soft key on the Standard
Display.
SELECT Key
1.
Figure 42: Standard Display
4. Press the SELECT soft key on the Datalogger
Menu. The “Start Trip” Screen will appear.
5. Press the SELECT soft key. The “Start Of Trip”
Screen will appear.
7. A Start Of Trip Marker has been inserted into
the datalogger memory.
SELECT Key
SELECT Key
Figure 43: Start of Trip Screen Sequence
52
Menu Soft Key
Operating Instructions
Printing a Trip Report
This procedure prints the CargoWatch datalogger
record directly to a handheld printer. The printed
record shows things such as the unit and
controller identification numbers, dates and times,
the setpoint, and data from the optional sensors
connected to the CargoWatch data logger. If no
sensors are connected, the printed record shows
the same things without the sensor data.
NOTE: The printer port can be mounted so it
is accessible without opening the control box.
It is typically mounted between the
CargoWatch Port and the ServiceWatch Port.
2. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display. See Figure 45.
1
1
1.
Menu Soft Key
Figure 45: Standard Display
2
3
3. Press the MENU soft key on the Standard
Display.
4. Press the NEXT soft key until the Datalogger
Menu appears. See Figure 46.
1.
CargoWatch Port
2.
ServiceWatch Port
3.
Printer Port
Figure 44: Printer Port Location
1. Connect the printer to the 6-pin printer port
located inside the control box.
5. Press the SELECT soft key on the Datalogger
Menu. The “Start Trip” Screen will appear.
6. Press the NEXT soft key. The “Print/View”
Screen will appear.
7. Press the SELECT soft key. The “Delivery
Ticket” Screen will appear. Press the SELECT
soft key to print a delivery report.
8. Press the NEXT soft key to go to the “Trip
Ticket” Screen. Press the SELECT soft key to
print a trip report.
SELECT Key
SELECT Key
SELECT Key
NEXT Key
NEXT Key
SELECT Key
Figure 46: Print Report Screen Sequence
53
Operating Instructions
Hourmeters Menu
The Hourmeters are programmable to be visible
or hidden in Guarded Access. Hourmeters that are
visible are displayed. Hourmeters that are hidden
are not displayed, but they do count hours. The
default setting for Model 30 units is to display
only the Engine Hours. The default setting for
Model 50 units is to display Total Run Time
Hours, Engine Hours, and Electric Run Hours.
The Hourmeters Menu will not appear if all
hourmeters are hidden. Refer to the SR-2
Microprocessor Control System Diagnostic
Manual TK 51727 for information about
programming the controller.
2. Press the MENU soft key on the Standard
Display.
1
1.
Menu Soft Key
Figure 47: Standard Display
3. Press the NEXT soft key until the Hourmeters
Menu appears. See Figure 48.
Hourmeters can be viewed in the Hourmeters
Menu as follows:
4. Press the SELECT soft key to enter the
Hourmeters Menu.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
5. Press the NEXT and BACK soft keys to view the
hourmeter displays.
BACK Key
BACK Key
SELECT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
BACK Key
NEXT Key
NEXT Key
NEXT Key
Figure 48: Viewing Hourmeters Screen Sequence
54
Operating Instructions
Mode Menu
Sleep Mode
Various operating modes can be selected using the
Mode menu. Not all modes may be available,
depending on OptiSet Plus usage and settings of
other programmable features. The following
modes may be available.
If enabled in Guarded Access, Sleep Mode is used
to keep the engine warm and the battery charged
when the unit is not in use. When the unit is in
Sleep Mode the display will show “SLEEP” and
the current time. See “Selecting Sleep Mode” on
page 58.
Turn CYCLE-SENTRY On or Off
The CYCLE-SENTRY Mode can be turned On or
Off. If CYCLE-SENTRY is turned off the unit
runs in Continuous mode. Either
CYCLE-SENTRY or Continuous operation may
be disabled via OptiSet Plus. See “Turning
CYCLE-SENTRY On or Off” on page 56.
Keypad Lockout
If enabled in Guarded Access, the keypad can be
locked to prevent unauthorized use. If the keypad
is locked only the On and Off keys function. The
keypad will remain locked even if the unit is
turned off and back on. If Keypad Lockout is
active, press and hold any soft key for 5 seconds
to deactivate the feature. See “Selecting Keypad
Lockout” on page 57.
•
Program Wakeup Time: This feature allows a
wakeup time to be specified. When the
selected time is reached the unit will start and
resume normal operation.
If Wakeup Time is selected:
•
Day to Wake Up: This feature allows the
day the unit is to wake up to be specified.
•
Hour to Wake Up: This feature allows the
hour the unit is to wake up to be specified.
•
Minute to Wake Up: This feature allows
the minute the unit is to wake up to be
specified.
•
Run Pretrip on Wake Up: This feature
allows a Pretrip Test to be automatically
run when the unit wakes up.
55
Operating Instructions
Turning CYCLE-SENTRY On or Off
The easiest way to switch between
CYCLE-SENTRY and Continuous Run is to press
the Mode key (see page 42). But, you can also
switch modes in the Mode Menu as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
1
2
3
1.
CYCLE-SENTRY Icon Shows Current Mode
Displayed for CYCLE-SENTRY Mode
Not Displayed for Continuous Mode
2.
Mode Key
3.
Menu Soft Key
2. Press the MENU soft key on the Standard
Display.
3. Press the NEXT soft key until the Mode Menu
appears.
4. Press SELECT soft key to enter the Mode Menu.
See Figure 50.
5. Press the SELECT soft key, to switch between
modes.
6. The new mode is then confirmed for 10
seconds.
7. The display then returns to the Mode Menu.
Press the SELECT soft key again to change the
mode again.
CAUTION: If the unit is in
CYCLE-SENTRY null and the mode is
switched to Continuous mode, the unit will
start automatically.
Figure 49: Standard Display
SELECT Key
SELECT Key
SELECT Key
Figure 50: Selecting Mode Screen Sequence
56
Operating Instructions
Selecting Keypad Lockout
This feature must be enabled in Guarded Access
to be available. See “Keypad Lockout” on page 55
for more information about Keypad Lockout. Use
the following steps to select Keypad Lockout:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press any soft key to return to the Standard
Display.
5. Press the NEXT soft key until the Keypad
Lockout Display appears.
6. Press the SELECT soft key to select Keypad
Lockout.
CHANGE MODE
ON
KEYPAD LOCKOUT
OFF
EXIT
1
SELECT
BACK
NEXT
2. Press the MENU soft key on the Standard
Display.
ARA834
1.
Press Select Soft Key
Figure 53: Keypad Lockout Display
1
7. The new mode is then confirmed for 10
seconds.
8. The display then returns to the Mode Menu.
1.
Press Menu Soft Key
Figure 51: Standard Display
3. Press the NEXT soft key until the Mode Menu
appears.
4. Press the SELECT soft key to enter the Mode
Menu. The Turn CYCLE-SENTRY On/Off
Screen will appear.
9. Press the Exit soft key to return to the
Standard Display. If no keys are pressed
within 30 seconds, the screen will return to the
Standard Display.
NOTE: If Keypad Lockout is active, press and
hold any soft key for 5 seconds to deactivate the
feature.
MAIN MENU
ON
MODE
OFF
EXIT
SELECT
BACK
NEXT
1
ARA832
1.
Press Select Soft Key
Figure 52: Mode Menu Display
57
Operating Instructions
Selecting Sleep Mode
This feature must be enabled in Guarded Access
to be available. Sleep mode starts and stops the
unit as required to keep the unit battery in a
charged condition and keep the unit engine warm
in cold ambient conditions. Sleep mode does not
maintain setpoint, it keeps the compartment
temperature near the ambient temperature when
the unit is running. This is useful in extremely
cold weather or when the unit is to be out of
service for an extended time.
Sleep mode operates in both Diesel mode and
Electric mode. In Diesel mode the unit will start
and stop as required to maintain engine
temperature and battery charge. In Electric mode
the unit starts and stops as necessary to maintain
battery charge only.
When Sleep mode is entered, the operator can
program an automatic Wake-up Time up to a week
away. Using this feature, the unit will
automatically restart and run normally at the
determined time. If a Wake-up Time is
programmed, the operator can also program an
automatic Pretrip Test when the unit restarts.
Select Sleep Mode as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
1
Menu Soft Key
Figure 54: Standard Display
3. Press the NEXT soft key until the Mode Menu
appears. See Figure 55.
4. Press SELECT soft key to enter the Mode Menu.
5. Press the NEXT soft key as required to display
the Sleep Mode Screen.
58
7. You now choose to program a Sleep mode
Wake-up Time or simply enter Sleep mode
immediately. Press the NO soft key to
immediately enter Sleep mode.
a. The display will show “SLEEP” and the
unit will start and stop as required to keep
engine warm and/or the battery charged.
Sleep mode does not maintain the
compartment temperature.
b. Press the EXIT soft key to exit Sleep mode
or turn the unit off and back on. The unit
will resume normal operation and control
to setpoint.
8. To enter a Wake-up Time verify that the unit
clock is set properly (see “Time Display” on
page 64). Then press the YES soft key at the
“Program A Wake-Up Time?” Screen.
9. Press the + or - soft keys to select the day the
unit is to restart in normal operation. In this
example Monday has been chosen. Press the
YES soft key to confirm the day.
10. The display will now prompt you for the hour
the unit is to restart in normal operation. In
this example 18:00 hours has been chosen.
Note that 24 hour “military time” is used.
Press the YES soft key to confirm the hour.
11. The display will now prompt you for the
minute the unit is to restart in normal
operation. In this example 18:37 hours has
been chosen. Press the YES soft key to confirm
the minute.
2. Press the MENU soft key on the Standard
Display.
1.
6. Press the SELECT soft key to start the Sleep
mode.
12. The display will now prompt you to “Run A
Pretrip On Wake-Up?” Press YES soft key or
the NO soft key accordingly and the display
will show the unit is programming the Sleep
mode.
13. The display will show “SLEEP” and the unit
will start and stop as required to keep the
engine warm and/or the battery charged. Sleep
mode does not maintain setpoint.
Operating Instructions
14. The unit will restart at the programmed time
(in this example 18:37 hours) and perform a
Pretrip (if selected). After the Pretrip is
complete the test results will be displayed and
the unit will resume normal operation and
control to setpoint.
SELECT Key then NEXT Key
YES Key
SELECT Key
YES Key
YES Key
15. To exit Sleep mode before the selected
Wake-up time press the EXIT soft key or turn
the unit off and back on. The unit will resume
normal operation and control to setpoint.
YES Key or NO Key
YES Key
Figure 55: Selecting Sleep Mode Screen Sequence
59
Operating Instructions
Pretrip Tests
A Pretrip test verifies unit operation. The Pretrip
Menu allows the operator to select and initiate a
Pretrip Test. There are two different Pretrip Tests,
the Full Pretrip and the Running Pretrip.
are Check or Failed, alarm codes will exist to
direct the technician to the source of the
problem.
Running Pretrip
Pretrip Tests are not allowed if:
A Running Pretrip occurs when Pretrip is initiated
after the engine or electric motor is running. The
Running Pretrip test proceeds in the order shown
below:
•
Any alarms are present
•
•
The unit is in Sleep mode.
Defrost – If the coil temperature is below 45 F
(7 C), a Defrost cycle is initiated.
•
Unit is in Service Test Mode, Interface Board
Test Mode, or Evacuation Mode.
•
Cool Check – The ability of the unit to cool in
low speed is checked.
•
RPM Check (Diesel Mode only) – If the unit
is running in the Diesel Mode, the engine
RPM in high and low speed is checked during
the Cool Check.
•
Heat Check - The ability of the unit to heat in
low speed is checked.
•
Report Test Results – The test results are
reported as “PASS”, “CHECK” or “FAILED”
when the Pretrip is completed. If test results
are Check or Failed, alarm codes will exist to
direct the technician to the source of the
problem.
The Pretrip Tests can be run in either Diesel or
Electric mode.
CAUTION: Monitor the return air
temperature when performing a Pretrip
Test on a loaded container. The controller
may not maintain setpoint during the
Pretrip Test.
Full Pretrip
A Full Pretrip occurs when Pretrip is initiated
before the engine or electric motor starts running.
The Full Pretrip test proceeds in the order shown
below:
•
Amp Checks – Each electrical control
component is energized and the current drawn
is confirmed to be within specification.
•
Engine or Electric Motor Start – The engine or
electric will start automatically.
•
Defrost – If the coil temperature is below 45 F
(7 C), a Defrost cycle is initiated.
•
Cool Check – The ability of the unit to cool in
low speed is checked.
•
RPM Check (Diesel Mode only) – If the unit
is running in the Diesel Mode, the engine
RPM in high and low speed is checked during
the Cool Check.
•
Heat Check - The ability of the unit to heat in
low speed is checked.
•
Report Test Results – The test results are
reported as “PASS”, “CHECK” or “FAILED”
when the Pretrip is completed. If test results
60
Pretrip Test Issues
When performing a Pretrip Test, the following
issues should be considered.
•
If running a Pretrip Test on a container loaded
with dry cargo, insure that proper airflow can
occur around the load. If the load restricts
airflow, false test results may occur. Also,
SR-2 units have high refrigeration capacity
which results in rapid temperature changes.
Sensitive dry cargo may be damaged as a
result.
•
If running a Pretrip Test on a container that
has just been washed down, the extremely
high humidity inside the container may result
in false test results.
•
If running a Pretrip Test on a container loaded
with sensitive cargo, monitor the load
temperature during the test as normal
temperature control is suspended during
pre-trip operation.
Operating Instructions
•
Always perform Pretrip Tests with the
container cargo doors closed to prevent false
test failures.
ON
NO PRETRIP -- ALARM ACTIVE
OFF
EXIT
Initiating a Pretrip Test
1
Before initiating a Pretrip Test, clear all alarm
codes.
ARA835
1.
To stop a Pretrip Test at any time, turn the unit off.
Press Exit Soft Key
Figure 57: No Pretrip Alarm Active Display
Use the following procedure to initiate a Full
Pretrip or a Running Pretrip. A Running Pretrip
can also be initiated by starting at step 3 with the
unit running.
1. If the unit is running, press the OFF key to stop
the unit.
6. The Pretrip display appears. See Figure 58.
•
The top line of the display indicates which
test the unit is performing.
•
The second line shows Test 1 of 49 is
being performed. Note that the tests may
not be performed in numerical order.
•
The soft keys may be used during the
Pretrip Test to select the Hourmeter,
Gauge or Sensor menus.
2. Press the ON key to turn the unit on.
3. To initiate a Full Pretrip press the MENU soft
key as soon as the Standard Display appears
and before the unit starts.
To initiate a Running Pretrip let the unit start
before pressing the MENU soft key on the
Standard Display.
1
1.
Menu Soft Key
Figure 56: Standard Display
4. Press the NEXT soft key until the Pretrip Screen
appears. See Figure 58.
5. Press the SELECT soft key to start a Pretrip.
NOTE: If all alarms were not cleared, a
prompt appears as shown below. Press the
EXIT key to exit the Pretrip Test, clear all
alarms and repeat the Pretrip Test.
In a Full Pretrip, when the non-running tests
are complete the unit will start automatically
and continue with the running tests.
7. When all tests are complete, the results are
reported as “PASS”, “CHECK” or “FAILED”.
If “FAILED” appears, the unit will shut down.
If the results are Check or Failed, the
accompanying alarm codes will direct the
technician to the cause of the problem.
8. If the Pretrip Test results are Check or Failed,
the problem should be diagnosed and
corrected and the Pretrip Test repeated and
passed before the unit is released for service.
The Pretrip Test result screen will exit to the
Main Menu Alarm Submenu for convenient
access to any alarms generated during the
Pretrip Test.
Stopping a Pretrip Test
Turn the unit off to stop a Pretrip Test at any time.
This will generate Alarm Code 28–Pretrip Abort.
Other alarm codes may also be generated. This is
normal when the Pretrip test is stopped before
completion.
61
Operating Instructions
SELECT Key
Figure 58: Pretrip Test Screen Sequence
62
Operating Instructions
Adjust Brightness Menu
The brightness of the HMI Control Panel display
backlight can be adjusted to allow for changing
ambient light conditions. The choices available to
the operator are HIGH, MEDIUM, LOW, and
OFF. OFF actually results in a very dim backlight
suitable for low light conditions.
IMPORTANT: Before replacing an HMI with no
backlight, check the Adjust Backlight feature to
be sure the backlight is turned on.
10. Press the Exit soft key to return to the
Standard Display. If no keys are pressed
within 30 seconds, the screen will return to the
Standard Display.
SELECT Key
Adjust the display brightness as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
+ Key
2. Press the MENU soft key on the Standard
Display.
YES Key
1
1.
Menu Soft Key
Figure 59: Standard Display
3. Press the NEXT soft key until the Adjust
Brightness Menu appears. See Figure 60.
4. Press the SELECT soft key to enter the Adjust
Brightness Menu. See Figure 60.
5. Press the + or - soft keys to select the desired
brightness. See Figure 60. This example
shows changing screen brightness from low to
medium.
6. Press the YES soft key to enter the new
brightness level.
7. The “ADJUSTING BRIGHTNESS - PLEASE
WAIT” Screen briefly appears.
Figure 60: Adjusting Display Brightness
Screen Sequence
8. The selected level appears on the screen.
9. The Adjust Brightness Main Menu Screen
reappears and if no keys are pressed the
Standard Display appears.
63
Operating Instructions
Time Display
The time and date held by the HMI Control Panel
real time clock can be checked. Time and Date
cannot be changed from the Main Menu. The time
and date are changed by programming the
controller. Refer to the SR-2 Microprocessor
Control System Diagnostic Manual TK 51727 for
information about programming the controller.
View the time and date as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the MENU soft key on the Standard
Display.
3. Press the NEXT soft key until the Time Display
appears.
4. Press the SELECT soft key to view the time and
date.
1
2
MENU Key then NEXT Key
SELECT Key
1.
Standard Display
2.
Menu Soft Key
Figure 61: Time and Date Screens
64
Operating Instructions
OptiSet Plus
The controller can be programmed with OptiSet
Plus temperature profiles that allow the user to
select named products. Refer to TK 54045 the
OptiSet Plus User’s Guide and TK 51727 the
SR-2 Microprocessor Control System Diagnostic
Manual for information about programming the
controller with OptiSet Plus temperature profiles.
•
Named products can have a single setpoint, or
they can have a setpoint range that allows the
user to select a setpoint within that range.
•
The controller can be programmed to allow
only named products to be selected. In which
case the far left soft key will display PRODUCT.
See Figure 62.
•
The controller can be programmed to allow
named products or numeric setpoints to be
selected. In which case the far left soft key
will display PRODUCT/SETPOINT. See Figure 63.
1
1.
Product Soft Key
Figure 62: Standard Display with Product Soft Key
1
1.
Product/Setpoint Soft Key
Figure 63: Standard Display with
Product/Setpoint Soft Key
NOTE: In OptiSet Plus the terms “numeric
setpoint” and “setpoint” mean the same
thing and are displayed as numbers. The
terms “named product” and “product” mean
the same thing and are displayed as words.
See “Selecting a Named Product” on page 66 for
information about selecting or changing the
named product.
See “Changing the Setpoint for a Named Product”
on page 69 for information about changing the
setpoint for a named product.
See “Selecting a Setpoint” on page 71 for
information about selecting or changing the
setpoint.
65
Operating Instructions
Selecting a Named Product
To select or change a named product complete the
following steps. This example shows the Standard
Display with the PRODUCT/SETPOINT soft key. Using
the Standard Display with the PRODUCT soft key is
basically the same but some of the screens differ
slightly.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the PRODUCT/SETPOINT (or PRODUCT) soft
key on the Standard Display. See Figure 64.
1
7. Press the YES or NO soft key accordingly as
described below. See Figure 65.
•
If the NO key is pressed the named product
change made with the “+” or “-” soft keys will
not be accepted, the named product will not be
changed and the display will return to the
Standard Display.
•
If the YES soft key is pressed, the named
product change made with the “+” or “-” soft
keys will be accepted, and the following
screens will appear.
NOTE: Alarm Code 127 may be generated if
the + or - soft keys are used to change the
named product, but the YES or NO soft keys
are not used to accept or decline the new
named product.
8. The “Programming Named Product” Screen
will briefly appear. See Figure 65.
2
1.
Standard Display
2.
Product/Setpoint Soft Key
Figure 64: Selecting Named Product
3. The “Named Product / Numeric Setpoint?” (or
Named Product) Screen briefly appears, then
the “Named Product or Numeric Setpoint?”
(or Named Product) Screen will appear. See
Figure 65.
NOTE: If the “Change Setpoint for
XXXXX” Screen appears, the named product
has been programmed with a setpoint range.
See “Selecting the Setpoint for a Named
Product” on page 68.
9. The “New Named Product Is XXXXX”
Screen briefly appears. See Figure 65.
10. The Standard Display appears with the new
named product. See Figure 65.
4. Press the NAMED soft key. See Figure 65.
NOTE: Pressing the EXIT soft key at any point
will return to the Standard Display.
5. The “Product” Screen briefly appears, then the
“Current Product Is” Screen will appear. See
Figure 65.
NOTE: If no keys are pressed for 30 seconds
while in the Named Product Changer Screens,
the HMI will return to the Standard Display.
6. Press the + or - soft keys to change the named
product. See Figure 65.
66
Operating Instructions
NOTE: If “Change Setpoint
for XXXXX” Screen appears
instead, see “Selecting the
Setpoint for a Named
Product” on page 68
PRODUCT/SETPOINT Key
+ or – Key
NAMED Key
YES Key
Figure 65: Selecting or Changing Named Product Screen Sequence
67
Operating Instructions
Selecting the Setpoint for a Named Product
If the “Change Setpoint for XXXXX” Screen
appears after pressing the YES soft key to select a
named product, the named product has been
programmed with a setpoint range. Complete the
following steps to select a setpoint for the named
product.
1. The “Change Setpoint for XXXXX” Screen
briefly appears, then the “Current Setpoint of
XXXXX & Setpoint Range Is XX to XX”
Screen will appear. See Figure 66.
2. Press the + /- or EXIT soft keys accordingly as
described below. See Figure 66.
•
•
Press the + or - soft keys to change the current
setpoint for the named product and then go to
step 3.
Press the EXIT soft key to accept the current
setpoint for the named product. The Standard
Display will appear with the named product
and setpoint. See Figure 66.
+ or – Key
3. If the + or - soft keys were pressed to change
the current setpoint for the named product, the
“New Setpoint for XXXXX Will Be” Screen
will appear. See Figure 66.
4. Press the YES soft key to accept the new
setpoint for the named product.
NOTE: If the NO key is pressed, the setpoint
will not be changed and the display will
return to the Standard Display.
5. The “Programming New Setpoint for
XXXXX” Screen will briefly appear. See
Figure 66.
6. The “New Setpoint Is XX” Screen briefly
appears. See Figure 66.
7. The Standard Display appears with the named
product and new setpoint. See Figure 66.
NOTE: Pressing the EXIT soft key at any point
will return to the Standard Display.
NOTE: If no keys are pressed for 30 seconds
while in the Named Product Changer Screens,
the HMI will return to the Standard Display.
EXIT Key
YES Key
Figure 66: Selecting Setpoint for Named Product Screen Sequence
68
Operating Instructions
Changing the Setpoint for a Named
Product
7. Press the YES or NO soft keys accordingly as
described below. See Figure 68.
If the named product has been programmed with a
setpoint range, the setpoint for the named product
can be changed. Complete the following steps to
change the setpoint for a named product. This
example shows the Standard Display with the
PRODUCT/SETPOINT soft key. Using the Standard
Display with the PRODUCT soft key is basically the
same but some of the screens differ slightly.
•
If the NO key is pressed the named product
setpoint change made with the “+” or “-” soft
keys will not be accepted, the named product
setpoint will not be changed and the display
will return to the Standard Display.
•
If the YES soft key is pressed, the named
product setpoint change made with the “+” or
“-” soft keys will be accepted, and the
following screens will appear.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the PRODUCT/SETPOINT (or PRODUCT) soft
key on the Standard Display. See Figure 67.
1
8. The “Programming New Setpoint for
XXXXX” Screen will briefly appear. See
Figure 68.
9. The “New Setpoint Is XX” Screen briefly
appears. See Figure 68.
10. The Standard Display appears with the new
setpoint. See Figure 66.
NOTE: Pressing the EXIT soft key at any point
will return to the Standard Display.
2
1.
Standard Display
2.
Product/Setpoint Soft Key
NOTE: If no keys are pressed for 30 seconds
while in the Named Product Changer Screens,
the HMI will return to the Standard Display.
Figure 67: Changing Setpoint for Named Product
3. The “Named Product, Numeric Setpoint or
Change Setpoint?” (or Named Product or
Change Setpoint?) Screen will appear. See
Figure 68.
4. Press the CHANGE SP soft key. See Figure 68.
5. The “Change Setpoint for XXXXX” Screen
briefly appears, then the “Current Setpoint for
XXXXX & Setpoint Range Is XX to XX”
Screen will appear. See Figure 68.
6. Press the + or - soft keys to change the setpoint
reading. See Figure 68.
69
Operating Instructions
PRODUCT/SETPOINT Key
CHANGE SP Key
+ or – Key
YES Key
Figure 68: Changing Setpoint for Named Product Screen Sequence
70
Operating Instructions
Selecting a Setpoint
5. The “Setpoint” Screen briefly appears, then
the “Current Setpoint Is” Screen will appear.
See Figure 70.
To select or change a setpoint complete the
following steps.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the PRODUCT/SETPOINT soft key on the
Standard Display. See Figure 69.
6. Press the + or - soft keys to change the
setpoint. See Figure 70.
7. Press the YES or NO soft key accordingly as
described below. See Figure 70.
•
If the NO key is pressed the setpoint change
made with the “+” or “-” soft keys will not be
accepted, the setpoint will not be changed and
the display will return to the Standard Display.
•
If the YES soft key is pressed, the setpoint
change made with the “+” or “-” soft keys will
be accepted, and the following screens will
appear.
1
2
1.
Standard Display
2.
Product/Setpoint Soft Key
8. The “Programming New Setpoint” Screen will
appear. See Figure 70.
9. The “New Setpoint Is XX” Screen briefly
appears. See Figure 70.
Figure 69: Selecting or Changing Setpoint
3. The “Named Product / Numeric Setpoint?”
Screen briefly appears, then the “Named
Product or Numeric Setpoint?” Screen will
appear. See Figure 70.
10. The Standard Display appears with setpoint
changed to the new setpoint. See Figure 70.
4. Press the NUMERIC soft key. See Figure 70.
NOTE: If no keys are pressed for 30 seconds
while in the Named Product Changer Screens,
the HMI will return to the Standard Display.
NOTE: Pressing the EXIT soft key at any point
will return to the Standard Display.
PRODUCT/SETPOINT Key
+ or – Key
NUMERIC Key
YES Key
Figure 70: Selecting or Changing Numeric Setpoint Screen Sequence
71
Operating Instructions
Loading Procedure
1. Make sure the unit is turned off before
opening the doors to minimize frost
accumulation on the evaporator coil and heat
gain in the container. (Unit may be running
when loading the container from a warehouse
with door seals.)
2. Spot check and record load temperature while
loading. Especially note any off-temperature
product.
3. Load the product so that there is adequate
space for air circulation completely around the
load. DO NOT block the evaporator inlet or
outlet.
4. Products should be pre-cooled before loading.
Thermo King transport refrigeration units are
designed to maintain loads at the temperature
at which they were loaded. Transport
refrigeration units are not designed to pull hot
loads down to temperature.
Post Load Procedure
1. Make sure all the doors are closed and locked.
2. Start the unit if it was shut off to load (see
“Turning Unit On”).
3. Make sure the setpoint is at the desired setting.
4. One-half hour after loading, manually initiate
a Defrost cycle. If the evaporator coil sensor
temperature is below 45 F (7 C), the unit will
Defrost. The microprocessor will terminate
Defrost automatically when the evaporator
coil temperature reaches 58 F (14 C) or the
unit has been in the Defrost mode for 30 or 45
minutes (depending on setting).
Post Trip Checks
1. Wash the unit.
2. Check for leaks.
3. Check for loose or missing hardware.
4. Check for physical damage to the unit.
72
Electrical Maintenance
Alternator Charging System
Diagnostic Procedures
•
The alternator charging output will be low if
the alternator belt or pulleys are defective or
the belt is not properly adjusted. Be sure the
belt is not loose or cracked and the pulleys are
the correct size and in good condition.
•
The excitation circuit (EXC circuit) must
supply voltage to the excite terminal of the
alternator.
•
The sense circuit (2 circuit) must supply
voltage to the sense terminal of the alternator.
•
The alternator must be properly grounded.
•
The unit control circuits or installed
accessories may be drawing excessive current.
•
An overcharged battery is usually caused by a
defective voltage regulator.
General Information
Poor charging performance may not be caused by
a bad alternator. The following conditions can
cause improper battery charging, even with a
good alternator. (See Service Bulletin T&T 388
for more information.)
•
•
A problem may exist in the 2A output circuit
from the alternator to the battery. Check for an
open 2A circuit, loose connections, defective
battery cables or dirty battery terminals.
The battery must be in good condition and
capable of accepting a charge. Check for a
damaged battery, correct electrolyte level, and
loose or corroded connections.
Alternator Identification
•
These units use Thermo King Alternators (see
Figure 71), which are painted black.
1
2
3
4
5
7
6
1.
B+ Terminal (Positive Output - 2A Wire)
5.
F2 Terminal (Do Not Ground)
2.
B- Terminal (Negative Ground - CH Wire)
6.
Voltage Regulator and Brush Assembly
3.
S Terminal (Regulator Sense - 2 Wire)
7.
W Terminal (AC Output)
4.
L Terminal (Regulator Excite - 7K Wire)
Figure 71: Thermo King Alternator Terminal and Component Locations
73
Electrical Maintenance
Interface Board Fuse F4
The interface board has a 300 ohm resistor and a
resistor bypass fuse (F4) in the alternator
excitation circuit. The fuse and resistor are
connected in parallel and are located on the
interface board. Removing the resistor bypass
fuse places the 300 ohm resistor in the excitation
circuit as required for Thermo King alternators
(and Australian Bosch alternators). Installing the
resistor bypass fuse removes the 300 ohm resistor
from the excitation circuit as required for
Prestolite alternators. See the specific unit wiring
diagram for exact details.
NOTE: The F4 fuse must be removed from the
interface board on units equipped with Thermo
King alternators. The voltage regulator on the
Thermo King alternators will be damaged if the
unit is turned On with the F4 fuse in place on
the interface board.
Test Equipment for Checking
Voltage and Current
Always use accurate test equipment such as the
Fluke 23 Digital Multi-Meter and the Fluke
Clamp-On Ammeter accessory when checking
alternator circuit voltage and amperage. See the
table below for Thermo King service parts
numbers. Be sure voltages are measured from the
designated terminal to the alternator chassis
ground. All voltages are DC voltages unless
otherwise noted.
Meter
Service
Part
Number
Fluke 23 Digital Multi-Meter
204-1079
Clamp-On Ammeter for above Meter
204-947
Alternator Load Test
Thermo King no longer recommends a full field
test for determining the alternator current output.
Full fielding an alternator can cause increases in
alternator output voltage that may damage internal
alternator or unit components. This damage may
not be readily apparent.
To test the alternator under load, Thermo King
recommends the use of a clamp-on ammeter to
monitor output current, both on initial startup and
74
under full unit load conditions. For example, on
multi-temp units, all remote evaporators should be
turned on.
General Diagnostic and Warranty
Evaluation Procedure
Complete the following diagnostic procedures
before replacing an alternator or the voltage
regulator.
1. When testing an alternator, use accurate
equipment such as a Thermo King P/N
204-1079 digital multimeter and a Thermo
King P/N 204-947 amp clamp or an
equivalent.
2. Make sure the drive belts and pulleys of the
charging system are in good condition and are
adjusted properly before testing the alternator.
Be sure the pulleys are the correct size. Worn
belts, loose belts and worn or improperly sized
pulleys will lower the output of the alternator.
3. The battery must be charged and in good
condition, the battery cable connections must
be clean and tight, and the 2A, 2 (sense), and
EXC (excitation) circuits must be connected
properly. All charging circuit connections
must be clean and secure. If the unit battery is
questionable, a known good jumper battery
should be substituted for alternator testing.
NOTE: If the unit battery is questionable, a
known good jumper battery should be
substituted for alternator testing.
NOTE: Do not perform this test with a
battery charger connected to the unit battery.
NOTE: All voltage readings should be taken
between the chassis ground on the alternator
and the terminals indicated, unless stated
otherwise.
4. Check that the resistor bypass fuse (F4) has
been removed. Units with Thermo King
alternators must have the resistor bypass fuse
(F4) removed.
CAUTION: Energizing the circuit with
the resistor bypass fuse installed will
damage Thermo King alternators. Be sure
the resistor bypass fuse is removed for
Thermo King alternators.
Electrical Maintenance
5. Check and note the battery voltage at the
battery with the unit turned off.
6. With the unit off, check the voltage at the B+
terminal on the alternator. Battery voltage
must be present. If not, check the 2A circuit.
7. Disconnect the alternator harness from the
voltage regulator. On Thermo King
alternators, carefully push on the spring clip to
release the plug lock.
8. Turn the unit on and enter Non-Running
Service Test Mode. Place the unit in High
Speed Cool. Refer to the appropriate
Diagnostic Manual for information about the
Service Test Mode.
9. Check the voltage at the sense circuit (2
circuit). Battery voltage should be present. If
not, check the sense circuit (2 circuit) in the
alternator harness and in the main wire
harness.
10. Check the voltage at the excitation circuit
(EXC circuit). 10 Vdc or more should be
present. If not, check the excitation circuit
(EXC circuit) in the alternator harness and in
the main wire harness.
11. Turn the unit off and reconnect the alternator
harness.
12. Attach a clamp-on ammeter around the 2A
wire connected to the B+ terminal on the
alternator. All wires connected to the B+
terminal must pass through the clamp-on
ammeter.
13. Connect a digital multi-meter between the B+
terminal at the alternator and chassis ground.
14. Turn the unit on and allow it to start. Using the
clamp-on ammeter, check the current flow in
the 2A wire.
A positive reading indicates the alternator is
charging. On unit startup, the current flow
should momentarily increase to allow for
battery current used during preheat and
cranking. Within a short time the current
should fall to normal unit load plus charge
current to the unit battery (typically 5-10
amps).
A reading on the clamp-on ammeter at or near
0 amps indicates the alternator is not charging.
Checking the unit ammeter will show a
discharge condition. The alternator is
defective if there are no problems in the
wiring. Recheck the wiring before assuming
the alternator is defective.
15. Check the voltage at the B+ terminal. The
voltage should increase until it reaches the
anticipated voltage regulator setting as shown
in the table below. Record the voltage.
The voltage regulator setting varies inversely
with the temperature as shown below.
Regulator voltage can vary from
approximately 15.2 Vdc at -40 F (-40 C) to
approximately 13.2 Vdc at 176 F (80 C).
Temperature
Anticipated Regulator Voltage
-40 F (-40 C)
From 15.2 Vdc to 14.0 Vdc
77 F (25 C)
From 14.4 Vdc to 13.6 Vdc
176 F (80 C)
From 14.2 Vdc to 13.2 Vdc
If the voltage does not increase to the
anticipated voltage regulator setting, the
alternator is defective if there are no problems
in the wiring. Recheck the wiring before
replacing the alternator.
16. If the voltage does increase until it reaches the
anticipated voltage regulator setting, compare
the voltage at the B+ terminal to the voltage
between the battery terminals. The voltage at
the B+ terminal should be no more than 1.0
Vdc higher than the voltage between the
battery terminals.
If the voltage at the B+ terminal is no more
than 1.0 Vdc higher than the voltage between
the battery terminals, continue with Step 17.
If the voltage at the B+ (POS) terminal is
more than 1.0 Vdc higher than the voltage
between the battery terminals, clean and check
the wires and connections in the 2A and 2
circuits and repeat this check.
17. Increase the charging system load as much as
possible by running the unit in high speed or
defrost.
75
Electrical Maintenance
18. Monitor the alternator output voltage.
With the increased load, the alternator output
voltage should decrease no more than 0.5 Vdc.
The voltage may increase as much as 1.0 Vdc.
If the alternator output voltage decreases no
more than 0.5 Vdc the alternator is good.
If the alternator output voltage decreases more
than 0.5 Vdc, the alternator is defective if
there are no problems in the wiring. Recheck
the wiring before replacing the alternator.
Alternator Diode Quick Check:
This check confirms proper diode function.
19. With the unit still running, set the digital
multi-meter connected from the alternator B+
output to chassis ground for AC volts. No
more than 1.0 Vac should be present. A
reading of more than 1.0 Vac indicates
damaged alternator diodes.
20. Turn the unit off.
Field Current Test
Use this test to determine if the alternator can be
repaired. Perform this test with the unit turned off.
1. Attach a clamp-on ammeter to the 2A wire
near the B+ terminal on the alternator.
2. Energize the field on the Thermo King
alternator by connecting a jumper wire
between the F2 terminal and the B+ terminal.
Do not connect the F2 terminal to ground or
the alternator will be damaged.
3. Note the ammeter reading. The ammeter
reading indicates the field current, which
should be 2.0 to 6.0 amps at 12 volts.
•
•
76
No field current or a low field current
indicates an open circuit or excessive
resistance in the field circuit. Remove the
voltage regulator and brush assembly and
inspect the slip rings. If the slip rings and
are acceptable, install a new voltage
regulator and brush assembly and repeat
the test. If the brushes are not the problem,
replace the alternator.
High field current indicates a short in the
field circuit. Replace the rotor or the
alternator.
Battery
Inspect/clean the battery terminals and check the
electrolyte level during scheduled maintenance
inspections. A dead or low battery can be the
cause of an ammeter indicating discharge due to
lack of initial excitation of the alternator even
after the unit has been boosted for starting. The
minimum specific gravity should be 1.235. Add
distilled water as necessary to maintain the proper
water level.
Battery Cables
Units with Tier 2 engines use 0-gauge battery
cables to ensure reliable starting in extremely cold
weather. Make sure to use the 0-gauge battery
cables when replacing the battery cables for a Tier
2 engine. Refer to the unit Parts Manual for the
correct part numbers.
Fuses
A number of fuses, located on the interface board,
protect various circuits and components. The
interface board is located inside the control box.
Refer to the SR-2 Microprocessor Control System
Diagnostic Manual TK 51727 for a complete list
of the size and function of the fuses.
Fuses
Fuse
Size
Function
F2
15A
Power to On/Off Switch
F3
40A
Fuel Sol Pull-In/Starter Circuit
F4
None No Fuse - All Bosch and Thermo
King Alternators
2A 2A Fuse - All Prestolite Alternators
F5
60A
Preheat Circuit
F6
15A
Damper and High Speed Circuits
F7
2A
8XP Circuit - Controller On Feedback
to HMI
F8
5A
CAN Connector J12
F9
5A
CAN Connector J14
F10
10A
8X Power (Install fuse in upper
position)
F11
10A
Zone 1 LLS
F12
5A
CAN Connector J13
F13
2A
8FC Circuit (Remote Lights)
F15
P/S
On/Off Relay
F20
2A
Alternator Sense
Electrical Maintenance
Fuse
Size
Fuses (Continued)
Interface Board LEDs
Function
The interface board has LEDs that indicate which
outputs are energized. The LED is illuminated
when the associated circuit output is energized.
F22
Not Used
F23
Not Used
F25
7.5A
HPCO/Run Circuit
F4 Remove fuse F4 for units with Australian Bosch or
Thermo King Alternators. Install fuse F4 for units with
Prestolite Alternator.
F5 The F5 preheat fuse is a “slow blow” type. It is
designed for use with the Yanmar engine air heater.
Always replace the fuse with the TK specified fuse.
F10 When fuse F10 is installed in the upper position
the On/Off keys on the HMI turn the unit on and off.
When fuse F10 is installed in the lower position the
unit will start and run without the HMI control panel.
F15 The device identified as F15 is a poly switch.
These over-current devices reset automatically and
are not replaceable.
Figure 72: Interface Board
Interface Board LED Functions
LED #
Function
LED 3
K2 Preheat Circuit
LED 4
K4 Damper Circuit
LED 5
K3 High Speed Circuit
LED 6
K1 Run Relay Circuit
LED 7
K5 Diesel/Electric Relay
LED 8
Pilot Solenoid Circuit
LED 9
Liquid Line Solenoid Circuit (Not Used)
LED 10
Hot Gas Bypass Valve Circuit
LED 11
Purge Valve Solenoid Circuit (Not Used)
LED 17
Loader Valve 1 (Not Used)
LED 18
Alternator Excite
LED 19
Liquid Injection Valve Circuit (Not Used)
LED 20
Water Valve (Not Used)
LED 21
Status – Flashes once per second when
the base controller is powered and
operating normally. Flashes several times
per second when flash loading. Is on
without flashing during reboot and when
under test. Flashes twice within 1 second
followed by 1 second off if a CAN
communication error is present.
LED 22
K8 LLS1 Circuit (Not Used)
LED 23
K9 On/Off Circuit
LED 24
K6 Fuel Solenoid Pull-In Circuit
LED 25
K7 Starter Circuit
LED 26
Future Use
LED 27
ETV*
LED 28
ETV*
LED 29
ETV*
LED 30
ETV*
* May be illuminated even if the ETV outputs are not
used.
77
Electrical Maintenance
Smart FETs
Air Heater
A Smart FET (Field Effect Transistor) is a self
protecting device. Smart FETs halt current flow if
an overcurrent condition exists, and resume
normal operation when current flow is within
limits. Smart FETs are not field repairable. Refer
to the SR-2 Microprocessor Control System
Diagnostic Manual TK 51727 for more
information about the Smart FETs.
The air heater is mounted on the open end of the
intake manifold. It heats the intake air to help the
engine start in cold weather. The air heater is
energized by the microprocessor during preheat,
just before the engine is started.
Interface Board Outputs With Smart FETs
Output
Function
Run Relay Coil
High Speed Relay Coil
EVA, EVB, EVC, EVD
ETV Outputs
26
Pilot Solenoid
HG
Hot Gas Solenoid
ALPC
Alarm Light
ALM
Alarm Light
EXC
Alternator Excite
The heater is probably defective if the resistance
is more than 0.2 ohms and the current draw is less
than 60 amps, or if the current draw is more than
100 amps.
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 0.14 ± 0.02 ohms.
Check the current draw of the heater with a
clamp-on ammeter at the H1 wire near the M6
terminal on the front of the heater. During preheat
the current draw should be approximately 70
amps.
SMART REEFER 2 (SR-2)
Microprocessor Controller
Refer to the SR-2 Microprocessor Control System
Diagnostic Manual TK 51727 for complete
service information about the Microprocessor
Controller and the related components.
Fuse Link
The fuse link is located in the positive battery
cable. The fuse link protects the electric system
from a short in the 2 circuit. If the fuse link burns
out, check for a grounded 2 wire before replacing
the fuse link. Replace the fuse link by replacing
the positive battery cable.
78
1
AEA693
1.
M6 Terminal
Figure 73: Air Heater
Unit Wiring
Inspect the unit wiring and the wire harnesses
during scheduled maintenance inspections for
loose, chaffed or broken wires to protect against
unit malfunctions due to open or short circuits.
Electrical Maintenance
Wire Harness Routing
The wire harness is routed in front of the starter
on the TK486V (Tier 2) engine. The wire harness
is attached to a harness routing bracket, which is
attached to the starter.
1
2
3. If the resistance of the fuel level sensor is
acceptable, turn the unit on and check the
voltage between the FUEL and FUELN wires
in the sensor harness going to the interface
board. The voltage between the FUEL and
FUELN wires should be approximately 7.4
Vdc with the fuel level sensor disconnected.
4. If the voltage is incorrect, check the continuity
of the FUEL and FUELN wires in the sensor
harness going to the interface board. The
FUEL wire goes to the J3-23 pin. The FUELN
wire goes to J3-35 pin.
5. If the FUEL and FUELN wires have good
continuity, check the microprocessor.
1
1.
Wire Harness In Front Of Starter
2.
Harness Routing Bracket
Figure 74: Wire Harness Routing
Fuel Level Sensor
A resistive (float) fuel level sensor is standard
equipment on these units. The fuel level sensor is
mounted in the end of the fuel tank.
Check the operation of the fuel level sensor as
follows:
1. Disconnect the three pin connector that
connects the harness from the fuel level sensor
to the sensor harness from the J3 connector on
the interface board. This three pin connector is
located either in the control box or under the
unit near the control box.
2. Check the resistance between the two wires
that go to the fuel level sensor. The resistance
should be approximately 30 ohms with the
float in the full position. The resistance should
be approximately 240 ohms with the float in
the empty position.
2
1.
Float in Full Position
2.
Float in Empty Position
Figure 75: Fuel Level Sensor
NOTE: If the resistance of the fuel level
sensor is incorrect, check the continuity of
the wires between the three pin connector
and the fuel level sensor before assuming the
fuel level sensor is bad.
79
Electrical Maintenance
Electric Fuel Heater
An electric fuel heater is standard equipment on
these units.
The electric fuel heater is mounted in base of fuel
filter/water separator as shown in Figure 77.
Operation
The electric fuel heater has an internal thermostat
that closes at 44 F (7 C) minimum, and opens at
62 F (17 C) maximum.
After the unit is turned On and the engine starts
running, the alternator will output AC power to
the W/WF circuit. The electric (power) filter
converts this to DC power, which energizes the
Unit Run Relay and closes its contacts.
1
With the relay contacts closed, the 2A circuit
provides power to the fuel heater, which will heat
up if its internal thermostat is closed. The current
through the fuel heater is 11.4 to 15.5 amps at 12.5
Vdc.
NOTE: The electric fuel heater does not
function when the unit is in the Null Mode, or
during the non-running portion of the Pretrip
Test.
1.
Electric Fuel Heater
Figure 77: Fuel Filter/Water Separator
The relay, fuse, electric (power) filter, and circuit
breaker are mounted inside the control box as
shown in Figure 78 and Figure 79.
1
Figure 76: Electric Fuel Heater Schematic
Components
The main components of the electric fuel heater
option are listed below.
•
Electric Fuel Heater (mounted in base of fuel
filter/water separator)
•
Fuel Heater Harness (includes the following)
80
2
ARA1641
•
W Fuse (3 amp)
1.
Electrical Connection to Interface Board
•
Electric (Power) Filter
2.
Electrical Components In Control Box
•
Unit Run Relay
•
2A/2FH Circuit Breaker (20 amp manual
reset)
Figure 78: Control Box
Electrical Maintenance
1
2
1
3
ARA1643
1.
2A Wire Attached to 2A Screw Terminal,
which is also marked J25
Figure 80: Wire Connection to Interface Board
1.
Unit Run Relay
2.
Electric (Power) Filter
3.
2A/2FH Circuit Breaker
Figure 79: Electrical Components In Control Box
The wires in the fuel heater harness are connected
to the unit as follows.
•
The WF wire is attached to the W terminal
(AC output) on the alternator.
NOTE: The end of the WF wire that is
attached to the W terminal is a red wire about
8 in. (203 mm) long with yellow fuse holder
in the middle. This red wire with the fuse
holder is connected with a splice to the WF
wire.
•
•
The 2A wire is attached to the 2A screw
terminal on the interface board.
Diagnosis
Use the following procedure to diagnose the
electric fuel heater.
1. Disconnect the electric fuel heater from the
fuel heater harness at the 2-pin connector
located near the electric fuel heater.
2. Check the resistance of the electric fuel heater
by checking the resistance between the two
terminals in the 2-pin connector on the wires
to the electric fuel heater. The resistance
should be 0.8 to 1.1 ohms.
NOTE: The temperature of the electric fuel
heater must be below 44 F (7 C) to verify the
internal thermostat closes.
•
If the resistance is acceptable, go to Step 3.
•
If the resistance is very high, indicating an
open circuit, check the temperature of the
electric fuel heater using a non-contact
thermometer. The temperature of the
electric fuel heater must be below 44 F
(7 C) to close the internal thermostat. If
the temperature of the electric fuel heater
is below 44 F (7 C) and high resistance
indicates an open circuit, the electric fuel
heater is probably defective and should be
replaced.
•
If the resistance is significantly less than
0.8 ohms, the heating element is probably
defective and the electric fuel heater
should be replaced.
The CH wires are connected to the CH ground
plate behind the battery.
81
Electrical Maintenance
NOTE: The unit must be turned on and running
for the rest of the procedure.
3. If the resistance of the electric fuel heater is
acceptable, turn the unit on and let the engine
start. Check the voltage between the 2HP and
CH wires in the fuel heater harness at the
2-pin connector that was disconnected from
the electric fuel heater in Step 1. Battery
voltage should be present between the 2HP
and CH wires.
1
3
4. If battery voltage is not present, check for AC
voltage at the W terminal on the alternator. At
least 8 Vac should be present at the W
terminal on the alternator. If not, check the
alternator.
5. If the AC voltage at the W terminal is
acceptable, check for AC voltage at the WF
wire where it connects to the screw (8)
terminal on the electric (power) filter in the
control box. At least 8 Vac should be present
on the WF wire at electric (power) filter. If
not, check the W fuse and the continuity of the
WF wire. The W fuse holder is located in the
Red wire that is spliced to the end of the WF
wire and attached to the W terminal on the
alternator.
1.
WF Wire Connected to Screw Terminal
(Marked 8 on Side)
2.
Black Wire Spliced to CH Wire
3.
Red Wire Spliced to 7R2 Wire
Figure 82: Electric (Power) Filter Side View
1
2
3
1.
Red Wire
2.
Fuse Holder
3.
WF Wire
Figure 83: Fuse Holder
2
1
3
1.
WF Wire Connected to Screw Terminal
(Marked 8 on Side)
2.
Black Wire Spliced to CH Wire
3.
Red Wire Spliced to 7R2 Wire
Figure 81: Electric (Power) Filter Top View
82
2
6. If the AC voltage on the WF wire at electric
(power) filter is acceptable, check for DC
voltage on the 7R2 wire (pin 85) at the Unit
Run Relay in the control box. At least 8 Vdc
should be present on the 7R2 wire (pin 85) at
the Unit Run Relay. If not, check the
continuity between the 7R2 wire (pin 85) at
the Unit Run Relay and the Red wire at the
electric (power) filter. Also check the
continuity between the Black wire at the
electric (power) filter and the CH wire where
it attaches to the CH ground plate. If these
wires have good continuity, replace electric
(power) filter.
7. If the voltage on the 7R2 wire (pin 85) at the
Unit Run Relay is acceptable, check for
continuity on the CH wire between the Unit
Run Relay (pin 86) and the CH ground plate.
Electrical Maintenance
8. Check for battery voltage on the 2A wire
where it is attached to the 2A screw terminal
on the interface board. If battery voltage is not
present, check to make sure the 2A wire
connection is clean and tight.
9. If battery voltage is present on the 2A wire at
the 2A terminal, check for battery voltage on
the 2FH wire (pin 30) at the Unit Run Relay. If
battery voltage is not present, press the reset
button on the side of the 2A/2FH circuit
breaker and check the continuity of the 2A and
2FH wires.
1
1.
Reset Button, Press to Reset
Figure 84: 2A/2FH Circuit Breaker
10. If battery voltage is present on the 2FH wire
(pin 30) at the Unit Run Relay, check for
battery voltage on the 2HP wire at the 2-pin
connector that was disconnected from the
electric fuel heater in Step 1. If battery voltage
is not present, check the continuity of the 2HP
wire and check for a defective Unit Run
Relay.
11. If battery voltage is present on the 2HP wire at
the 2-pin connector, check for continuity on
the CH wire between the 2-pin connector and
the CH ground plate.
83
Electrical Maintenance
84
Engine Maintenance
EMI 3000
Oil Filter Change
EMI 3000 is an extended maintenance interval
package. The EMI 3000 package consists of the
following key components:
The oil filter should be changed along with the
engine oil. Use a genuine Thermo King extended
maintenance oil filter.
•
1. Remove the filter.
EMI 3000-Hour Cyclonic Air Cleaner
Assembly and Air Cleaner Element
•
EMI 3000-Hour Dual Element Oil Filter
(black with gold lettering)
•
API Rating CI-4 Mineral Oil (ACEA Rating
E3 for Europe)
•
Five Year or 12,000 Hour ELC (Extended Life
Coolant).
The EMI package allows standard maintenance
intervals to be extended to 3,000 hours, or 2 years,
whichever occurs first.
NOTE: Units equipped with the EMI 3000
package do require regular inspection in
accordance with Thermo King's maintenance
recommendations.
2. Apply oil to the rubber ring of the new filter
and install the filter.
3. Tighten the filter until the rubber ring makes
contact, then tighten 1/2 turn more.
4. Start the unit and check for leaks.
Low Oil Pressure
Oil pressure is affected by oil temperature, oil
viscosity, and engine speed. Low oil pressure can
usually be traced to the lack of oil, a faulty oil
pressure regulating valve, or worn bearings. Low
oil pressure is not normally caused by a faulty oil
pump. Use the “Low Oil Pressure Flow Chart” on
the following page to help diagnose low oil
pressure.
Engine Lubrication System
The TK486 family of engines use a pressure
lubrication system. Refer to the TK482 and
TK486 Engine Overhaul Manual TK 50136 for a
detailed description of the engine lubrication
system.
Engine Oil Change
The engine oil should be changed according to the
Maintenance Inspection Schedule. Drain the oil
only when the engine is hot to ensure that all the
oil drains out. When changing oil, keep unit and
container level so all the oil can flow from the oil
pan. It is important to get as much of the oil out as
possible because most of the dirt particles are
contained in the last few quarts of oil that drain
out of the pan. Refill the pan with 13 quarts
(12.3 liters) and check the dipstick level. Run the
unit, and then recheck the oil level. The engine oil
level should be at the FULL mark with the
dipstick turned (threaded) into the oil pan. Never
overfill. See Specifications Chapter for correct
type of oil.
85
Engine Maintenance
Low Oil Pressure Flow Chart
Low Oil Pressure
Check for oil dilution.
Is it just thin or does it
smell like fuel?
Thin
Diluted
with Fuel
See
EDP08
Fuel in Oil
Full
Check Oil Level
Low
Add oil until full.
Re-check oil pressure in
low and high speed.
OK
Verify the unit switch,
sensor, or gauge
accuracy using a test
gauge.
Not
Accurate
Repair and
re-check oil pressure in
low and high speed.
Accurate
Check for excessive
radial end play at the
flywheel with a dial
indicator. Maximum;
0.007 in. 4-cylinder.
Excessive
OK
Drain oil through a
clean coffee filter and
check for wear metal
contamination.
Wear Metal
Present
Repair or
replace engine.
No Wear
Metal
Change oil and filter.
Re-check oil pressure
in low and high speed.
OK
86
Low
Check oil pressure regulator
or oil pressure control valve
and repair or replace as
necessary. Re-check oil
pressure in
low and high speed. If oil
pressure is still low, repair or
replace engine.
ARA1368
Engine Maintenance
Engine Cooling System
The engine employs a closed, circulating type,
pressurized cooling system. Correct engine
temperatures are controlled and maintained by a
radiator, fan and thermostat. The coolant is
circulated through the system by a belt driven
centrifugal pump. The pump draws the coolant
from the side of the radiator, circulates it through
the cylinder block and head and returns it to the
radiator. A thermostat mounted in the coolant
outlet line 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 percent permanent type
antifreeze concentrate and 50 percent water
mixture in the engine cooling system.
This provides the following:
1. Prevents freezing down to -30 F (-34 C).
2. Retards rust and mineral scale that can cause
engine overheating.
AJA1947
Figure 85: ELC Nameplate
Located On Expansion Tank
The following are the Extended Life Coolants
currently approved by Thermo King for use in
ELC units for five years or 12,000 hours:
•
Chevron Dex-Cool
3. Retards corrosion (acid) that can attack
accumulator tanks, water tubes, radiators and
core plugs.
•
Texaco ELC (nitrite free)
•
Havoline Dex-Cool (with nitrates)
4. Provides lubrication for the water pump seal.
•
Havoline Dex-Cool (nitrite free)
•
Shell Dexcool
•
Shell Rotella
•
Havoline XLC (Europe)
•
Saturn/General Motors Dex-Cool
•
Caterpillar ELC
•
Detroit Diesel POWERCOOL Plus.
ELC (Extended Life Coolant)
ELC has been phased into all trailer units
equipped with engines from the TK486 engine
family. A nameplate on the coolant expansion
tank identifies units with ELC.
NOTE: The new engine coolant, Texaco
Extended Life Coolant, is RED in color instead
of the current GREEN or BLUE-GREEN
colored coolants.
CAUTION: Do not add “GREEN” or
“BLUE-GREEN” conventional coolant to
cooling systems using “RED” Extended
Life Coolant, except in an emergency. If
conventional coolant is added to Extended
Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
87
Engine Maintenance
NOTE: The use of 50/50 percent pre-mixed
Extended Life Coolant (ELC) is recommended to
assure that de-ionized water is being used. If 100
percent full strength concentrate is used,
de-ionized or distilled water is recommended
over tap water to insure the integrity of the
cooling system is maintained.
changing the antifreeze. Change ELC (red) engine
coolant every five years or 12,000 hours
(whichever occurs first).
Antifreeze Maintenance Procedure
The factory recommends the use of a 50/50
antifreeze mixture in all units even if they are not
exposed to freezing temperatures. This antifreeze
mixture will provide the required corrosion
protection and lubrication for the water pump.
Do not mix green or blue-green engine coolant
with ELC (red) engine coolant. See “ELC
(Extended Life Coolant)” on page 87 for more
information about ELC.
As with all equipment containing antifreeze,
periodic inspection on a regular basis is required
to verify the condition of the antifreeze. Inhibitors
become worn out and must be replaced by
1
2
4
3
8
6
7
5
1.
Expansion Tank
5.
Water Pump
2.
Expansion Tank Cap
6.
Coolant Hoses to Cold Start Device on Injection Pump
3.
Coolant Level Switch
7.
Thermostat
4.
Radiator
8.
Thermostat Housing
Figure 86: Engine Cooling System
88
Engine Maintenance
Checking the Antifreeze
Check the solution concentration by using a
temperature compensated antifreeze hydrometer
or a refractometer (P/N 204-754) designed for
testing antifreeze. Maintain a minimum of
50 percent permanent type antifreeze concentrate
and 50 percent water solution to provide
protection to -30 F (-34 C). Do not mix antifreeze
stronger than 68 percent permanent type coolant
concentrate and 32 percent water for use in
extreme temperatures.
Changing the Antifreeze
1. Run the engine until it is up to its normal
operating temperature. Stop the unit.
2. Open the engine block drain (located behind
the starter) and completely drain the coolant.
Observe the coolant color. If the coolant is
dirty, proceed with a, b, and c. Otherwise go
to 3.
CAUTION: Avoid direct contact with hot
coolant.
a. Run clear water into the 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, and operate the unit in
accordance with instructions of the
flushing agent manufacturer.
c. Open the engine block drain to drain the
water and flushing solution.
CAUTION: Avoid direct contact with hot
coolant.
3. Run clear water into the radiator, and allow it
to drain out of the block until it is clear.
4. Inspect all hoses for deterioration and hose
clamp tightness. Replace if necessary.
5. Loosen the water pump belt. Check the water
pump bearing for looseness.
7. If using ELC concentrate, mix one gallon of
ELC concentrate and one gallon of de-ionized
or distilled water in a container to make a
50/50 mixture. (Do not add antifreeze and
then add water to the unit. This procedure may
not give a true 50/50 mixture because the
exact cooling system capacity may not always
be known.)
8. Refill the radiator with the 50/50 antifreeze
mixture and make sure to bleed the air from
the cooling system as needed.
Bleeding Air from the Cooling
System
Jiggle pin thermostats are original equipment on
units that have engines from the TK486 engine
family. Jiggle pin thermostats make it unnecessary
to bleed the air out of the engine block because
they keep air from being trapped in the engine
block. Normally, all but about 1.5 qt (1.4 liters) of
coolant drain out of the cooling system when it is
drained. If approximately half of the Cooling
System Capacity (see Specifications Chapter)
seems 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: Do not start the engine
without bleeding the air out of the block.
NOTE: If an engine runs 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, because
the high water temperature switch is designed to
protect an engine from overheating due to
failures in the cooling system.
1. Remove the plug from the front end of the
water pump below the thermostat housing as
shown in Figure 87.
2. Slowly pour the coolant into the system until
you see coolant at the plug fitting.
3. Reinstall the plug.
6. Inspect the radiator cap. Replace the cap if the
gasket shows any signs of deterioration.
89
Engine Maintenance
Coolant Level Switch
1
1.
The plastic expansion tank uses a reed type
coolant level switch. The coolant level switch
senses the position of the magnetic float inside the
expansion tank. When the coolant level is above
the switch, the float is in the upper position and
the switch is closed. When the coolant level is
below the switch, the float is in the lower position
and the switch is open.
Plug
Figure 87: Remove Plug from 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 came out
of the system.
6. Start the engine. Monitor the coolant
temperature with the unit engine coolant
temperature gauge, or by using a non-contact
thermometer pointed at the thermostat housing
in the location of the high water temperature
switch or sensor. When the temperature
reaches 150 F (66 C), shut the engine off for 2
minutes. This allows time for the thermostat to
heat soak and open fully, ensuring that any
remaining air will be purged out of the engine
block when the engine is restarted.
1
2
1.
Coolant Level Switch
2.
Float
Figure 88: Plastic Expansion Tank
7. Restart the engine and run it in low speed.
Remove the cap from the expansion tank and
slowly pour coolant into expansion tank until
it is full, then reinstall the expansion tank cap.
NOTE: Figure 88 shows the expansion tank in
two pieces. The two pieces are bonded together
when the tank is assembled, so it cannot be
disassembled, but the coolant level switch can be
replaced.
8. Repeat steps 6 and 7 until the coolant level
stabilizes.
Testing the Coolant Level Switch
Engine Thermostat
For the best engine operation, use a 160 F (71 C)
thermostat year-round.
You can test the switch in the unit by adjusting the
coolant level. You can also remove the expansion
tank from the unit and test the switch by flipping
the expansion tank upside down and right side up.
1. Remove the wire harness connector from the
coolant level switch.
90
Engine Maintenance
2. Use an ohmmeter to check the continuity of
the switch at the connection pins.
3. Make sure the coolant level is above the
switch and check the continuity of the switch.
The switch should be closed. If you removed
the tank from the unit, do this check with the
tank upside down.
4. Drain coolant from the expansion tank until
the coolant level is well below the switch and
check continuity of the switch. The switch
should be open. If you removed the tank from
the unit, do this check with the tank right side
up.
2. Use a wide, flat screwdriver to pry the switch
out of the expansion tank.
1
2
5. Replace the switch if it is does not closed in
step 3 and does not open in step 4.
Checking the Float
The float is made of polypropylene foam. It is
unlikely that the float would fail unless it sticks
inside the tank so it cannot move.
1. Make sure the coolant level is above the float.
2. Slowly drain coolant from the expansion tank
and watch the float. The float should drop
with the coolant level.
3. If the float did not drop with the coolant level,
remove the expansion tank from the unit.
1.
Warm Here
2.
Pry Here
Figure 89: Removing Coolant Level Switch
3. Look at the new coolant level switch. Notice
that the switch has a raised ring around it. This
ring snaps into a grove in the expansion tank.
Also, notice that there is a slot in the top of the
switch. This slot fits around a tab in the
expansion tank.
1
2
4. Flip the expansion tank upside down and right
side up to see if the float moves inside the
expansion tank. Replace the expansion tank
with a new one if the float is stuck or does not
move with the coolant level.
Replacing the Coolant Level Switch
It makes it easier to remove and install the switch
if you use a blow drier or heat gun to warm the
expansion tank in the area around the switch. Do
not overheat the expansion tank. Warm it to about
the temperature of hot bath water.
1.
Raised Ring
2.
Slot
Figure 90: Coolant Level Switch
1. Warm the area around the coolant level
switch, but do not overheat it.
91
Engine Maintenance
4. Look at the hole in the expansion tank from
which the coolant level switch was removed.
Notice that there is a tab in the top of the hole.
The slot in the switch must fit around this tab
when the switch is installed.
7. Press the coolant level switch into the
expansion tank. It should click when it snaps
into place. It may be helpful to use a wide
bladed screwdriver to press on the switch
where shown in the following photograph.
1
1
1.
Tab
Figure 91: Expansion Tank
1.
Tab
Figure 92: Expansion Tank
5. Warm the expansion tank in the area around
the hole for the coolant level switch, but do
not overheat it.
8. Refill the expansion tank with coolant (after
installing the expansion tank if it was
removed).
6. Place the coolant level switch in the expansion
tank. Make sure that the slot in the switch is
aligned with the tab in the expansion tank.
9. Connect the wire harness connector to the
coolant level switch.
92
Engine Maintenance
Engine Fuel System
TK486V engines use a mono-plunger and
distributor injection pump.
The components of the fuel system are:
•
Fuel tank
•
Fuel filter/water separator
•
Inlet strainer (in fuel transfer pump)
•
Priming pump
•
Fuel transfer pump
•
Air/fuel separator (sometimes called Pro
Check)
•
Injection pump
•
Trochoid feed pump
•
Injection nozzles
The priming pump is used to manually draw fuel
from the tank up to the fuel pump if the unit
should run out of fuel.
The fuel transfer pump delivers fuel to the air/fuel
separator. The air/fuel separator prevents any air
in the system from entering the injection pump by
returning the air back to the fuel tank.
The air/fuel separator does this by first separating
any air in the fuel using gravity. After fuel enters
the “IN” port, air bubbles float to the top of the
cylinder while the fuel sinks to the bottom of the
cylinder.
Next it provides a path of least resistance for the
air to return to the fuel tank through the
“RETURN FUEL” port. Any excess fuel also
returns to the fuel tank through this port, which
contains a small orifice that restricts fuel flow to
maintain fuel pressure.
This ensures that the “OUT” port always has
air-free fuel to push into the injection pump and
that any air in the system gets returned to the fuel
tank rather than passed to the injection pump.
2
Operation
Fuel is drawn from the fuel tank through the fuel
filter/water separator and the inlet strainer by the
fuel transfer pump.
The inlet side of the fuel transfer pump can be
thought of as the “suction” side because the fuel
transfer pump can create a vacuum of up to
approximately 10 in. Hg (-34 kPa) to draw fuel
into its inlet. The components on the “suction”
side of the fuel transfer pump are the inlet line
from the fuel tank to the filter/water separator, the
filter/water separator, and the fuel line from the
filter/water separator to the inlet of the fuel
transfer pump.
The outlet side of the fuel transfer pump can be
thought of as the “pressurized” side because the
fuel transfer pump can create a pressure of
approximately 7 psi (48 kPa) at its outlet. The
components on the “pressurized” side of the fuel
transfer pump are the line from the fuel transfer
pump to the air/fuel separator, the air/fuel
separator, and the fuel line from the air/fuel
separator to the inlet of the injection pump.
3
4
1
5
1.
IN Port - Fuel from Fuel Transfer Pump
2.
Air
3.
Fuel
4.
OUT Port - Fuel to Injection Pump
5.
RETURN FUEL Port - Air and Excess Fuel to
Fuel Tank
Figure 93: Air/Fuel Separator
93
Engine Maintenance
Fuel passes through a line from the outlet fitting
on the “OUT” port of the air/fuel separator to the
injection pump.
the injection nozzles. The injection nozzles
atomize the fuel as it is injected directly into the
combustion chambers.
At the injection pump the trochoid feed pump
boosts the fuel pressure. Then the injection pump
forces the fuel, at a very high pressure, through
Injection pump leakage, injection nozzle
overflow, air and excess fuel from the air/fuel
separator are then all sent back to the fuel tank in
the return line.
2
1
4
3
5
8
6
7
10
ARA1646
9
1.
Air/Fuel Separator (On Pressurized Side of Transfer Pump)
6.
Fuel Transfer Pump
2.
Vent Cap
7.
Priming Pump
3.
Fuel Filter/Water Separator (On Suction Side of Transfer Pump) 8.
Drain Valve
4.
Bleed Screw
9.
Inlet Line (From Fuel Tank)
5.
Injection Pump
10.
Return Line (To Fuel Tank)
Figure 94: Fuel System
94
Engine Maintenance
Fuel Line Routing
The fuel lines inside the unit are installed and
routed at the factory. Do not change the factory
routing of the fuel lines inside the unit. See the
fuel line routing diagrams in the Diagrams
Chapter.
Maintenance
The injection pump and fuel transfer pump are
relatively trouble-free and if properly maintained
will usually not require major service repairs
between engine overhauls.
Contamination is the most common cause of fuel
system problems. Therefore, to ensure best
operating results, the fuel must be clean and fuel
tanks must be free of contaminants. Regularly
drain the water, change the filter element, and
clean the inlet strainer on the inlet side of the fuel
transfer pump.
NOTE: The injection nozzles must be tested (and
repaired if necessary) at least every 3,000 hours
in accordance with EPA 40 CFR Part 89.
Normal conditions are considered to be the use
of clean high quality fuel, no used oil blending,
and regular maintenance of the fuel system
according to the Maintenance Inspection
Schedule. Refer to the TK482 and TK486
Overhaul Manual TK 50136 for injection nozzle
testing and repair procedures.
The following procedures can be done under field
conditions:
1. Bleeding air from the fuel system.
2. Fuel tank and filter system maintenance.
3. Priming pump (hand) replacement or repair.
4. Fuel transfer pump replacement or repair.
5. Injection line replacement.
6. Engine speed adjustments.
7. Injection pump timing.
8. Nozzle spray pattern testing and adjustment.
9. Injection nozzle testing, adjustment, and
minor repair.
10. Trochoid feed pump replacement.
Fuel Return Line Replacement
The fuel return lines (hoses) and end cap on the
fuel injection nozzles should be changed every
10,000 engine operating hours. The return line kit
(P/N 10-373) contains new return lines, clamps,
an end cap, and a decal like the one shown below.
The decal is located near the unit serial plate. The
date and engine hours must be entered on the
decal when the fuel return lines are changed.
Whenever the fuel system is opened, take the
following precautions to prevent dirt from
entering the system:
1. Cap all fuel lines.
Figure 95: Fuel Return Line Replacement Decal
2. Work in a relatively clean area whenever
possible.
Use the following procedure to replace the fuel
return lines and end cap.
3. Complete the work in the shortest possible
time.
1. Remove the clamps, the end cap, the short fuel
return lines between the injection nozzles, and
the long fuel return line from the injection
nozzle to the banjo fitting on the injection
pump.
Any major injection pump or nozzle repairs
should be done by a quality diesel injection
service shop. The necessary service equipment
and facilities are not found in most engine rebuild
shops because of the large investment required.
95
Engine Maintenance
To bleed air from the fuel system:
1
1. Remove the vent cap from the top of the clear
cover on the fuel filter/water separator (see
Figure 101). Fill the fuel filter with clean fuel.
Reinstall the vent cap and tighten by hand
only.
3
2
3
2. Loosen the bleed screw about one turn.
4
1
3
5
3
1.
End Cap
4.
Short Fuel Return Lines
2.
Larger Clamp
5.
Long Fuel Return Lines
3.
Smaller Clamps
Figure 96: Fuel Return Line Replacement
2. Discard the old clamps, end cap, and fuel
return lines.
3. Install the end cap and clamp. Note that the
end cap has a larger OD than the other hoses
and requires the larger clamp.
4. Install the fuel return lines and clamps. It may
be necessary to adjust the banjo fitting slightly
to obtain the straightest routing for the long
return line.
2
1.
Bleed Screw
2.
Priming Pump
Figure 97: Injection Pump
3. Unscrew the priming pump handle and
manually prime the fuel system until air
bubbles are no longer visible in the fuel
coming out of the bleed screw.
4. Tighten the bleed screw and screw the priming
pump handle back in.
5. Be sure all the fittings are tight and check for
leaks.
5. Loosen the injection lines at the injection
nozzles.
6. Write the date and engine hours on the decal.
6. Crank the engine until fuel appears at the
nozzles.
Bleeding the Fuel System
If the engine runs out of fuel, repairs are made to
the fuel system, or if air gets into the system for
any other reason, the air must be bled out of the
fuel system.
NOTE: MAKE SURE the fuel tank vent is kept
open. If the vent becomes clogged, a partial
vacuum develops in the tank, and this increases
the tendency for air to enter the system.
96
7. Tighten the injection lines.
8. Start the engine and observe the engine run for
a few minutes. If the engine fails to start, or
starts but stops in a few minutes, repeat the
procedure.
9. After the engine runs well for a few minutes,
loosen the vent cap on top of the fuel
filter/water separator until the fuel level drops
to the middle of the clear cover. Then tighten
the vent cap by hand only.
Engine Maintenance
Draining Water from Fuel Tank
Water run through the system may damage the
injection pump or nozzles. Damage to the fuel
system will subsequently cause more expensive
damage to the engine. A large accumulation of
water in the bottom of the fuel tank will stop a
diesel engine. Water should be drained off during
scheduled maintenance inspections to prevent
breakdowns. Drain the water off after the fuel
tank and unit have remained idle for an hour.
1. Place a container under the fuel tank to catch
the draining water and fuel.
2. Remove the drain plug from the bottom of the
fuel tank.
NOTE: Some fuel tanks have a check valve in
the drain plug fitting. Push the check valve open
with a small screw driver to drain the tank.
1
ARA1648
1.
Fuel Level
Figure 99: Intermediate Fuel Level
The fuel level continues to rise until it completely
covers the filter element. At this point, all of the
surface area on the filter element is used.
Restriction is increasing and the filter element
should be changed at the next scheduled
maintenance interval.
3. Let the water and fuel drain into the container
until no water is visible in the fuel draining
from the tank. If the water and fuel do not
drain freely, the vent may be plugged. If so,
clean or replace the vent.
1
4. Install the drain plug.
Fuel Filter/Water Separator
ARA1649
The fuel filter/water separator removes
contaminants and water from the fuel as it is
drawn from the fuel tank by the transfer pump.
When the filter element is new the fuel level
visible through the clear cover will be very low.
1.
Fuel Level
Figure 100: High Fuel Level Replace Filter Element
Draining Water from Fuel
Filter/Water Separator
Drain the water from the fuel filter/water
separator during the pretrip inspection.
1. Open the vent cap.
1
ARA1647
1.
Fuel Level
Figure 98: Low Fuel Level - New Filter Element
As contaminants collect on the filter element, the
fuel level rises to a non-contaminated section of
the filter element, providing optimal filtration
while maintaining lowest restriction.
2. Place a suitable eight ounce, plastic or metal
container under the drain valve at the base of
the fuel filter/water separator and open the
drain valve.
3. Water will flow into the container. When fuel
begins to flow out the drain, close the drain
valve. Drain the least amount of fuel as
possible.
4. Hand-tighten the vent cap.
5. Start the engine. Raise the RPM for one
minute to purge the air from the system.
97
Engine Maintenance
Fuel Filter/Water Separator Filter
Element Replacement
Replace the filter element in the fuel filter/water
separator at intervals according to the
Maintenance Inspection Schedule, or when the
fuel level rises to near the top of the filter element
as shown in Figure 100.
14. Close the vent cap. Hand tighten only. It is
normal for the fuel level to vary after the
initial start-up and during engine operation.
Filter performance is not affected.
1
2
1. Remove the vent cap.
3
2. Open the drain valve and drain the fuel to a
level below the collar.
3. Remove the collar using a collar wrench
(P/N 204-1932) and then remove the clear
cover.
4
4. Remove the filter element, and the O-rings for
the clear cover and vent cap.
5
6
5. Use a clean shop rag to clean the clear cover,
collar, and threads on the filter body.
7
6. Install a new filter element, and new O-rings
for the clear cover and vent cap.
7. Reinstall the clear cover and collar. Hand
tighten the collar.
8
8. Prime the filter by filling the clear cover
through the opening for the vent cap with
clean diesel fuel until it reaches the top of the
filter element.
9
10
9. Unscrew the priming pump handle and pump
it by hand until the fuel level drops to the
bottom of the clear cover.
ARA1650
11
10. Fill the clear cover with clean diesel fuel again
and pump the priming pump by hand until the
the fuel level drops to the bottom of the clear
cover. Tighten the priming pump handle back
in.
11. Fill the clear cover with clean diesel fuel again
and install the vent cap. Hand tighten only.
12. Start the engine, run it for at least one minute
and check for leaks.
13. Slowly open the vent cap and allow the fuel
level to drop to just above the collar.
NOTE: Make sure that the fuel level is
lowered to just above the collar before
releasing the unit back into service
operation.
98
1.
2.
3.
4.
5.
6.
Collar
Vent Cap
O-Ring
Clear Cover
O-Ring
Spring
7.
8.
9.
10
11.
Filter Element
Check Valve Assembly
Filter Body
Electric Fuel Heater
Drain Valve
Figure 101: Fuel Filter/Water
Separator Components
Engine Maintenance
Fuel Filter/Water Separator
Troubleshooting
Most field issues associated with leaks are related
to loose fittings. These leaks are easily eliminated
by checking and torquing the fuel fittings in the
area of the leak. Some fittings may also require
the application of sealer.
NOTE: All suction side fuel filters experience
bubbles. It is normal to see champagne size
bubbles in the fuel filter/water separator outlet
or at the transfer pump.
Air Leaks
Air bubbles will be visible in the clear cover of
the fuel filter/water separator if the leak originates
from the fuel tank up to the fuel filter/water
separator. The following is a quick test to isolate
the air leak source.
Bubbles Visible: Remove
the fuel filter/water
separator inlet hose.
1. Install a jumper hose from the fuel filter/water
separator to the fuel tank (through the fill cap)
or to a container of fuel.
2. Start the engine. If this eliminates the air
bubbles, the air source is at the fuel tank
fittings or hose connections.
a. Tighten all fittings and connectors
b. Retest.
3. If air bubbles persist, the air source is on the
fuel filter/water separator side of the system:
a. Tighten all fittings on the fuel filter/water
separator.
b. Hand tighten the collar.
c. If the drain valve is suspected, install a
plug in place of the drain valve (for test
purposes only).
4. If air bubbles continue to persist, test as
follows:
c. Apply 5 psig (34 kPa) of air pressure at the
fuel inlet. Immerse the fuel filter/water
separator in a tank of water and look for
air bubbles.
d. Correct the source of the air leak and
retest.
Bubbles Not Visible: If there are symptoms of
sucking air (indicated by engine loping/rough
running performance/power loss, etc.)and there
are no bubbles in the clear cover, the air leak is
either at the fuel filter/water separator outlet
fitting, vent cap o-ring, the transfer pump inlet
connection, or the fuel hose/connections to the
transfer pump. Inspect and tighten fittings as
needed.
Excessive Restriction
If the fuel level is at the top of the filter element,
replace the fuel filter. The fuel filter/water
separator will not cause excess system restriction
if the fuel level is below the top of the filter
element. The only exception is if the grommet is
not installed in the bottom of the filter element.
Loss of Prime
When air is introduced into the fuel system,
(i.e.draining water from the fuel filter/water
separator or when replacing the filter element) the
check valve assembly keeps the fuel inlet line
primed from the fuel filter/water separator back to
the fuel tank.
1. To test for proper check valve operation,
remove the fuel inlet hose and open the vent
cap. Fuel should not flow out of the fuel
filter/water separator, although a slight
seepage of fuel is normal.
2. If fuel drains back to the fuel tank, remove the
check valve assembly from the filter body.
Disassemble the check valve assembly. Clean
and inspect. Replace the assembly if any cuts,
grooves or nicks are evident in the ball or
body seat. Reinstall the check valve assembly.
a. Remove the fuel filter/water separator
from the chassis.
b. Plug the fuel outlet port. Do not remove
filter, cover/collar, vent cap, drain valve,
or electric fuel heater.
99
Engine Maintenance
Engine Speed Adjustments
Low Speed
When the diesel engine fails to maintain the
correct engine speed, check the following before
adjusting the speed:
1. Loosen the jam nut on the low speed
adjustment screw.
1. Check the fuel inlet strainer. Check the speed.
2. Bleed the air out of the fuel system. Check the
speed.
3. Bleed the air out of the nozzles. Check the
speed.
2. Use the Service Test Mode to run the unit in
low speed. Adjust the screw to obtain the
correct speed. It should be 1450 ± 25 rpm.
3. Tighten the jam nut and recheck the speed.
1
2
3
4
5
Make the engine speed adjustments with the
engine fully warmed up.
High Speed
1. Use the Service Test Mode to run the unit in
high speed and check the high speed rpm. It
should be 2200 ± 25 rpm.
2. Shut the unit off.
3. Remove the ball joint from the eye bolt in the
high speed solenoid.
4. Remove the boot from the high speed
solenoid.
5. Pull the plunger out of the solenoid enough to
loosen the jam nut. An Allen wrench placed in
the hex opening in the face of the plunger will
keep the plunger from turning. Turn the
plunger eye bolt clockwise to increase the
speed and counterclockwise to decrease the
speed.
6. Replace the ball joint, start the unit and check
the speed. When the speed is correct, tighten
the jam nut and replace the solenoid boot.
NOTE: If the correct speed cannot be set close
enough with half turns of the eye bolt, use the
Allen wrench to turn the plunger in smaller
increments.
100
1.
High Speed Solenoid
2.
Boot
3.
Ball Joint
4.
Speed Control Rod
5.
Low Speed Adjustment Screw
Figure 102: Engine Speed Adjustments
Engine Maintenance
Injection Pump Timing
Use this timing procedure when installing a new
injection pump. It is not necessary to use this
timing procedure when removing and reinstalling
the original injection pump. In that case, align the
index marks on the injection pump and the gear
case as they were before removing the injection
pump.
1. Before removing the old injection pump, note
the alignment of the index marks on the
injection pump and the gear case. The index
mark on the injection pump is usually aligned
with the index mark on the gear case. If not,
make a mark on gear case in line with the
index mark on the injection pump (see Figure
105).
2
1
3
1.
Index Mark on Injection Pump
2.
Existing Index Mark on Gear Case
3.
Make New Mark on Gear Case If Needed
Figure 105: Marking Gear Case
2. Clean the area with brake cleaner or
something similar. Place an injection angle
sticker on the gear case so the center line on
the sticker is aligned with the index mark on
the injection pump. An injection angle sticker
is provided with the new injection pump.
1
2
1
1.
Index Marks
1.
Index Mark on Injection Pump
2.
Injection Angle Sticker
Figure 103: Index Mark Location
Figure 106: Place Injection
Angle Sticker on Gear Case
0.5 Degrees
1
2
3
1
2
1.
–1.0 Degrees Mark
1.
Index Mark on Injection Pump
2.
Center Line (0 Degrees Mark)
2.
Index Mark on Gear Case
3.
+1.0 Degrees Mark
Figure 104: Index Mark Alignment
Figure 107: Injection Angle Sticker
101
Engine Maintenance
3. Remove the old injection pump. Use the
injection pump gear tool P/N 204-1011 to
remove the injection pump gear without
removing the timing gear cover (see “Injection
Pump Removal” on page 104).
NOTE: Remove the injection pump gear by
removing the nut and lock washer that
secure the injection pump gear assembly to
the injection pump shaft. The injection pump
gear assembly is made of three pieces; the
flange, the gear, and the transfer pump cam.
Do not loosen or remove the four bolts that
fasten the gear to the flange because that
changes the factory-set timing. The EPA
certification is based on the factory-set
timing. If the factory-set timing is changed,
the EPA certification is void.
1
1.
Injection Angle Mark
Figure 109: Injection Angle Mark Location
1
1
2
1
1
1
1.
Injection Angle Mark
Figure 110: Injection Angle Mark
1.
Do Not Loosen or Remove These Four Bolts
2.
Remove Nut and Lock Washer
Figure 108: Removing Injection Pump Gear
4. Record the injection angle marked on the old
injection pump (see the following
photographs). The injection angle mark is
located on the side of the pump facing the
engine. The injection angle mark on the pump
does not use a decimal point. Add a decimal
point before the last digit of the injection
angle mark to get the injection angle. The
injection angle mark in the following
photographs is 67. That equals an injection
angle of 6.7 degrees.
NOTE: If you cannot read the injection angle
mark, contact the Thermo King Service
Department with the injection pump serial
number or the engine serial number and they
will provide the injection angle. The injection
pump serial number is located on the bottom of
the sticker on the injection pump.
1
Examples
102
Injection Angle Mark
Injection Angle
67
6.7 Degrees
85
8.5 Degrees
1.
Injection Pump Serial Number
Figure 111: Injection Pump Serial Number Location
Engine Maintenance
5. Record the injection angle marked on the side
of the new injection pump.
3
1
2
6. Calculate the injection angle difference by
subtracting the injection angle of the old
injection pump from the injection angle of the
new injection pump.
Examples
Injection Angle of New
Injection Pump (Degrees)
8.5
6.1
– Injection Angle of Old
Injection Pump (Degrees)
– 6.7
– 6.7
= Injection Angle Difference
= +1.8
(Degrees)
4
= –0.6
7. Install the new injection pump on the gear
case and position it so the index mark on the
injection pump is aligned with the mark equal
to the injection angle difference on the
injection angle sticker (see the following
examples). Tighten the injection pump
mounting nuts when the index mark is aligned
as necessary with the injection angle sticker.
1.
Fuel Injection Pump Gear
2.
Idler Gear
3.
Camshaft Gear
4.
Crankshaft Gear
Figure 113: Timing Mark Alignment
NOTE: The oil pump is located in the timing
gear cover on TK486V engines. The inner rotor
of the oil pump fits around the crankshaft gear.
Make sure that the flat sides of the inner rotor
are aligned with the flat sides on the crankshaft
gear when installing the timing gear cover.
1
1
2
5
3
4
7
2
6
1.
Injection Pump Index Mark at –0.6 Degrees
2.
Injection Pump Index Mark at +1.8 Degrees
Figure 112: Examples of Injection Pump Index
Mark Alignment with Injection Angle Sticker
1.
Crankshaft Gear
8. Install the injection pump gear, lock washer,
and nut. Torque the nut to 58 to 65 ft-lb (78 to
88 N•m).
2.
Oil Pump Cover
3.
Outer Rotor
4.
Inner Rotor
NOTE: If the timing gear cover was removed to
remove the injection pump gear, make sure the
timing marks on the timing gears are aligned as
shown below. It helps to install the idler gear last
when aligning the timing marks.
5.
Timing Gear Cover
6.
Flat Sides on Inner Rotor
7.
Flat Side on Crankshaft Gear
Figure 114: Align Flat Sides of Crankshaft Gear
with Flat Sides of Inner Rotor in Timing Gear Cover
103
Engine Maintenance
Injection Pump Removal
The injection pump drive gear will not fit through
the gear housing when removing the pump, the
gear must be separated from the pump. Using tool
P/N 204-1011, it will not be necessary to remove
the belts, fuel pump, crankshaft pulley, crankshaft
seal or front plate. See Figure 117 “Injection
Pump Gear Tool” on page 105.
1. Note the alignment of the index marks on the
injection pump and the gear case. The index
mark on the injection pump is usually aligned
with the single index mark on the gear case. If
not, mark it so the injection pump can be
returned to the same position when it is
reinstalled.
2. Remove the starter for clearance, remove
throttle linkage, fuel lines, harness and
mounting hardware from injection pump.
3. Remove the cover plate from the gear case.
Remove the nut and lock washer which secure
the gear to the injection pump shaft. Use a
shop rag to prevent the lock washer or nut
from falling into the gear case.
NOTE: The injection pump gear assembly is
made of three pieces; the flange, the gear,
and the transfer pump cam. Do not loosen or
remove the four bolts that fasten the gear to
the flange because that changes the timing.
4. Use the hardware from the cover plate to
attach the tool plate (with the marked side
pointing up and out) to the gear case.
5. Align the threaded holes in the injection pump
gear with the two holes in the tool plate by
rotating the engine crankshaft. Attach the gear
to the tool plate with the screws provided with
the tool plate.
1
1.
Index Marks
Figure 115: Index Mark Location
6. Thread the long screw supplied with the tool
plate into the small end of the adapter, also
supplied with the tool plate. Insert the adapter
into the tool plate and rotate to provide a solid
position to force the injection pump shaft from
the gear. Caution should be made to align the
screw over the center of the injection pump
shaft.
7. Remove the screw and adapter leaving the tool
plate in place. This holds the gear in proper
tooth alignment until the injection pump is
re-installed.
Injection Pump Reinstallation
1. Position injection pump shaft into gear,
rotating shaft to mate key with keyway in
gear. Take care to make sure the key mates
with the keyway.
1
2
1.
Index Mark on Injection Pump
2.
Index Mark on Gear Case
Figure 116: Index Mark Alignment
104
2. Secure injection pump to gear case with
previously removed hardware. Make sure to
align the index marks on the injection pump
and the gear case like they were in step 1 of
“Injection Pump Removal”.
NOTE: If a different injection pump is being
installed, see “Injection Pump Timing” on
page 101 to set the timing.
Engine Maintenance
3. Remove hardware holding gear to tool plate,
then remove tool plate.
5. Fasten cover plate to gear case and reinstall all
components removed previously to facilitate
injection pump removal.
4. Secure the gear to the injection pump shaft
with the lock washer and nut. Use a shop rag,
as before, to prevent the lock washer or nut
from falling into the gear case. Torque the nut
to 58 to 65 ft-lb (78 to 88 N•m).
1
2
3
4
5
8
7
1.
Injection Pump
5.
Adapter (Tool)
2.
Gear Case
6.
Tool Long Screw (Tool)
3.
Cover Plate
7.
Tool Short Screw (Tool)
4.
Cover Plate Bolt
8.
Tool Plate (Tool)
6
Figure 117: Injection Pump Gear Tool
105
Engine Maintenance
Fuel Solenoid
The fuel solenoid is located on the end of the
injection pump. It contains two coils: the pull-in
coil, and the hold-in coil. The pull-in coil draws
approximately 35 to 45 amps at 12 volts. The
hold-in coil draws approximately 0.5 amps at
12 volts.
The pull-in coil must be energized to move the
injection pump governor linkage to the fuel on
position. Once the injection pump governor
linkage has been moved to the fuel on position,
the hold-in coil will keep it in 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. The pull-in coil is
controlled by the microprocessor through the fuel
solenoid pull in relay (K6).
2. Energize the run relay with the Interface
Board Test Mode. The fuel solenoid relay is
momentarily energized when the run relay is
energized with the Interface Board Test Mode.
This energizes the fuel solenoid, which makes
a definite click when energized.
3. De-energize the run relay with the Interface
Board Test Mode. This de-energizes the fuel
solenoid, which makes a definite click when
de-energized.
4. Repeat steps 2 and 3 a few times to check the
operation of the fuel solenoid.
NOTE: The fuel solenoid may be removed
from the injection pump to visually check its
operation. The fuel solenoid must be
energized when it is re-installed in the
injection pump. If it is not, the plunger and
the linkage may not line up correctly and the
fuel solenoid will not function properly.
5. If the fuel solenoid is not operating properly,
check the run relay (K1), the fuel solenoid pull
in relay (K6), their fuses, and the associated
circuits. If the relays, fuses and circuits are
acceptable, use steps 6 through 9 to isolate and
check the fuel solenoid.
6. Disconnect the fuel solenoid wire connector
from the main wire harness.
1
1.
Fuel Solenoid
Figure 118: Fuel Solenoid Location
Testing the Fuel Solenoid
NOTE: The fuel solenoid pull-in coil will
require 35 to 45 amps to turn on the fuel. The
unit’s battery must be in good condition. If the
battery 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 run
because the fuel solenoid is not operating
correctly, use the following procedure:
1. Use the microprocessor keypad to enter the
Interface Board Test Mode. Refer to the
appropriate Microprocessor Diagnostic
Manual for specific information about the
Interface Board Test Mode.
106
AEA633
1.
Red (8D)
2.
White (8DP)
3.
Black (CH)
Figure 119: Fuel Solenoid
Connector Pin Identification
7. Place a jumper wire between the black wire
(CH—pin C) in the fuel solenoid connector
and a good chassis ground.
8. Test the pull-in coil by momentarily placing a
jumper between the white wire (8DP—pin B)
in the fuel solenoid connector and the positive
Engine Maintenance
battery terminal. The fuel solenoid should
make a definite click when the pull-in coil is
energized and should click again when the
pull-in coil is de-energized.
NOTE: The pull-in coil will draw 35 to 45
amps so do not leave the jumper connected to
the white wire (8DP—pin B) for more than a
few seconds.
a. If the pull-in coil does not energize, check
the resistance of the pull-in coil by placing
an ohmmeter between the white wire
(8DP—pin B) and the black wire (CH—
pin C) in the fuel solenoid connector. 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
solenoid.
b. If the pull-in coil does energize, go to
step 9.
9. Test the hold-in coil.
a. Energize the hold-in coil by placing a
jumper between the red wire (8D—pin A)
in the fuel solenoid connector and the
positive battery terminal.
Fuel Solenoid Replacement
1. Disconnect the fuel solenoid wire connector
from the main wire harness and remove the
old fuel solenoid.
2. Connect the new fuel solenoid wire connector
to the main wire harness.
3. Press the ON key to turn the unit on.
4. Use the microprocessor keypad to enter the
Interface Board Test Mode. Refer to the
appropriate Microprocessor Diagnostic
Manual for specific information about the
Relay Test Mode.
5. Energize the fuel solenoid by energizing the
run relay with the Interface Board Test Mode.
NOTE: The fuel solenoid must be energized
when it is installed. If not, the plunger and
the linkage may not line up correctly and the
fuel solenoid will not function properly.
6. Place the O-ring in the groove in the end of
the fuel injection pump. Make sure that the
O-ring is positioned correctly during
installation to avoid damage and leaks.
b. Momentarily energize the pull-in coil by
placing a jumper between the white wire
(8DP—pin B) in the fuel solenoid
connector and the positive battery
terminal. 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.
c. De-energize the hold-in coil by removing
the jumper from the red wire (8D—pin A)
and the positive battery terminal. 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 ohmmeter
between the red wire (8D—pin A) and the
black wire (CH—pin C) in the fuel
solenoid connector. The resistance of the
hold-in coil should be 24 to 29 ohms. If
the resistance of the hold-in coil is not in
this range, replace the fuel solenoid.
AEA635
1.
Fuel Solenoid
2.
O-ring
3.
Groove in Fuel Injection Pump
Figure 120: Fuel Solenoid Components
7. Install the new fuel solenoid.
8. Press the OFF key to turn the unit off after
installing the fuel solenoid.
107
Engine Maintenance
Trochoid Feed Pump
Trochoid Feed Pump Replacement
The TK486V engine has a trochoid feed pump on
the fuel injection pump. The trochoid feed pump
supplies fuel to the injection pump at a pressure of
65 to 87 psi (450 to 600 kPa). Check the outlet
pressure of the trochoid feed pump by removing
the plug and attaching a pressure gauge to the port
shown below. The plug has M12x1.25 threads.
You will have to make an adaptor to attach a
pressure gauge. Replace the trochoid feed pump if
the outlet pressure is below the pressure
specifications in the following table.
Use the following procedure to replace the
trochoid feed pump.
1. Remove the four hex head screws that attach
the trochoid feed pump to the injection pump.
Do not remove the two Allen head screws.
Trochoid Feed Pump Outlet Pressure
Cranking
15-30 psi (103-206 kPa)
Low Speed
30-50 psi (206-345 kPa)
High Speed
65-87 psi (450-600 kPa)
1
1
2
1
1.
Allen Head Screws (Do Not Remove)
2.
Hex Head Screws
Figure 122: Trochoid Feed Pump Removal
2
1.
Trochoid Feed Pump Outlet Pressure Port
2.
Trochoid Feed Pump
Figure 121: Trochoid Feed Pump Location
Trochoid Feed Pump Leaks
Internal – If the seal in the trochoid feed pump
fails, it could allow some fuel to leak into the
engine oil. A faulty injection nozzle or fuel
transfer pump can also dilute the engine oil with
fuel. Replace the trochoid feed pump if the engine
oil is being diluted with fuel and a faulty injection
nozzle or fuel transfer pump is not the cause.
External – Replace the O-ring seal between the
trochoid feed pump and the injection pump if oil
is leaking. Torque the bolts to prevent leaks (6 to 7
ft-lb [8 to 10 N•m]).
Replace all O-rings if fuel is leaking. Torque the
Allen head screws and Hex head bolts to prevent
leaks (6 to 7 ft-lb [8 to 10 N•m]).
108
2. Remove the trochoid feed pump from the
injection pump.
NOTE: The gear on the trochoid feed pump
is lubricated with engine oil. Some engine oil
might leak out of the injection pump when
the trochoid feed pump is removed. The
trochoid feed pump does not need to be timed
when it is installed. Clean the area on the
injection pump from which the trochoid feed
pump was removed.
3. Clean the area on the injection pump from
which the trochoid feed pump was removed.
Engine Maintenance
4. Place new O-rings on the new trochoid feed
pump and make sure it is clean.
1
1.
Plunger (Extended)
Figure 124: Cold Start Device
1
1
1.
O-Rings
Figure 123: Trochoid Feed Pump
5. Place the new trochoid feed pump on the
injection pump.
6. Install and tighten four hex head screws that
attach the trochoid feed pump to the injection
pump. Torque the hex head screws to 6 to
7 ft-lb (8 to 10 N•m).
Cold Start Device Tier 2 Engine
The TK486V engine has a cold start device
located on the fuel injection pump. The cold start
device has a plunger that retracts at engine coolant
temperatures below 41 F (5 C) to advance the
injection timing approximately 2 degrees. The
plunger controls the position of a piston in the
injection pump to change the timing. The plunger
is extended and the injection timing is normal at
engine coolant temperatures above 41 F (5 C).
Check the operation of the cold start device if it is
difficult to start the engine in cold weather.
Checking Cold Start Device Operation
Use the following procedure to check the
operation of the cold start device. The engine
coolant temperature must be below 32 F (0 C) to
start the procedure.
1. Press the ON key to turn the unit on.
2. Press the GAUGES key before the engine starts
(to enter the Gauges Menu) and check the
coolant temperature to make sure it is below
32 F (0 C).
3. Let the engine start, then check the engine rpm
in the Gauges Menu. The engine rpm should
be approximately 100 rpm higher than normal
(see Specifications).
4. Let the engine run to warm up and use the
Gauges Menu to check the coolant
temperature and engine rpm. When the
coolant temperature rises above 41 F (5 C),
the engine rpm should drop back to normal.
Replace the cold start device if the engine rpm
does not drop approximately 100 rpm when
the engine warms up.
NOTE: Do not pull the plunger out of a cold
start device because that will damage it.
109
Engine Maintenance
Cold Start Device Replacement
4. Make sure the piston inside the injection
pump fitting is clean.
1. Drain the engine coolant.
2. Remove the banjo bolt that fastens the engine
coolant fitting to the cold start device. Use a
backup wrench on the cold start device if
necessary.
1
1
2
3
1.
Piston
Figure 127: Clean Piston
1.
Banjo Bolt
2.
Engine Coolant Fitting
3.
Coolant Hoses to Cold Start Device
5. Install the new cold start device with a new
O-ring in the injection pump fitting. Torque
the cold start device to 22 to 26 ft-lb (30 to 35
N•m).
Figure 125: Remove Engine Coolant Fitting
3. Remove the cold start device from the
injection pump fitting. Use a backup wrench
on the injection pump fitting if necessary.
6. Install the coolant fitting and banjo bolt on the
cold start device. Torque the banjo bolt to 16
to 18 ft-lb (22 to 25 N•m).
7. Refill the engine cooling system and make
sure to bleed the air from the cooling system.
Electric Fuel Heater
See “Electric Fuel Heater” on page 80 for
information about the electric fuel heater.
1
2
1.
Cold Start Device
2.
Injection Pump Fitting
Figure 126: Remove Cold Start Device
110
Engine Maintenance
Engine Valve Clearance
Adjustment
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.
CAUTION: 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. See steps a through d.
1
2
4. Use a feeler gauge to check the valve
clearance on both valves for the number one
cylinder, the intake valve for the number two
cylinder, and the exhaust valve for the number
three cylinder. The valve clearance for both
the intake valve and the exhaust valve should
be 0.006 to 0.010 in. (0.15 to 0.25 mm).
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. Adjust the valves if necessary by loosening
the locknut and turning the adjustment screw
until the valve clearance is correct.
6. Hold the adjustment screw in place and
tighten the locknut.
AEA701
1.
Index Mark
2.
Top Dead Center Mark for 1 and 4
Figure 128: Top Dead Center One and Four
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.
d. If the rocker arms are tight, the engine is at
top dead center of the exhaust stroke for
the number one cylinder. Rotate the engine
360 degrees to place the engine at top dead
center of the compression stroke for the
number one cylinder.
AEA705
Figure 129: Adjusting the Valve Clearance
7. Recheck the valve clearance.
8. Rotate the engine one full turn (360 degrees)
in the normal direction of rotation (clockwise
viewed from the water pump end), and align
the 1-4 timing mark on the flywheel with the
index mark in the timing mark access hole.
This is top dead center of the compression
stroke for the number four cylinder.
9. Check and adjust the exhaust valve for the
number two cylinder, the intake valve for the
number three cylinder, and both valves for the
number four cylinder.
10. Replace the rocker arm cover, the cover for
the timing mark access hole, and tighten the
fuel injection lines when finished.
111
Engine Maintenance
Valve Adjustments and Cylinder Configurations
Rear
Flywheel End
Cylinder Number
Valve arrangement
Piston in No. 1 cylinder is at
TDC on compression stroke
Piston in No. 4 cylinder is at
TDC on compression stroke
112
Front
Pulley End
1
E
2
I
E
3
I
E
4
I
E
I
Engine Maintenance
Crankcase Breather
Gases formed in the crankcase are directed to the
intake manifold. Harmful vapors that would
otherwise collect in the crankcase and
contaminate the oil, or escape to the outside, are
drawn back into the engine and burned.
The crankcase breather is located in the valve
cover. A restrictor is cast into the fitting for the
breather hose on the intake manifold. The
restrictor limits the flow of gases from the
crankcase to the intake manifold and keeps the
crankcase pressure from getting too low in
vacuum. A breather hose connects the crankcase
breather to the intake manifold.
3
The crankcase breather and the breather hose
should be inspected when the air cleaner element
is replaced to make sure they are not plugged or
damaged. Inspect the insulation to make sure it is
in place and undamaged. The insulation is used to
prevent freezing in cold weather.
4
The following items can effect the crankcase
pressure readings.
2
1
8
7
1.
6
Breather Hose
5.
Baffle Breather
2.
Insulation
6.
Baffle Plate
3.
Breather Cover
7.
Intake Manifold
4.
O-Ring
8.
Restrictor Location
Normal crankcase pressures with a new air
cleaner are 0 to 12 in. (0 to 300 mm) H2O of
vacuum. The vacuum will increase as the air
cleaner gets dirty and becomes more restrictive.
Check the air restriction indicator before checking
the crankcase pressure. Replace the air cleaner if
the reading on the air restriction indicator exceeds
20 in. (508 mm) H2O of vacuum. A dirty air
cleaner may cause excessive vacuum, leading to
oil carry over and high oil consumption.
Crankcase
Pressure
Effect
Typical Cause
Increase
Piston Rings Stuck or Worn
Increase
Breather Hose or Restrictor
Plugged with Dirt or Ice
Decrease
Air Cleaner Dirty or Plugged
5
Figure 130: Crankcase Breather Tier 2 Engine
113
Engine Maintenance
EMI 3000 Air Cleaner
The EMI 3000 air cleaner is a dry element air
cleaner. Replace the EMI 3000 air cleaner element
when the air restriction indicator reads 25 in. of
vacuum, or at 3,000 hours or 2 years, whichever
occurs first. The EMI 3000 air cleaner element
has a nameplate that reads “EMI 3000.” It cannot
be interchanged with air cleaners used on previous
units, however it can be retrofit on previous units
by using the EMI 3000 Air Cleaner Assembly and
the related components.
1
2
3
ARA189
1
ARA190
Dust Ejector Must Point Down When Installed
Figure 132: EMI 3000 Air Filter Element
114
EMI 3000 Air Cleaner Assembly
2.
EMI 3000 Air Filter Element
3.
Air Restriction Indicator
Figure 133: EMI 3000 Air Cleaner System
Model 30 Shown Model 50 Similar
Figure 131: EMI 3000 Air Cleaner Assembly
1.
1.
Engine Maintenance
Air Restriction Indicator
Belts
Excessive restriction of the air intake system
reduces the flow of air to the engine affecting
horsepower output, fuel consumption and engine
life.
Belts should be regularly inspected during unit
pretrip inspections for wear, scuffing or cracking.
Belt tension should also be checked during
scheduled maintenance inspections. Belts that are
too loose will whip and belts that are too tight put
too much strain on the belt fibers and bearings.
An air restriction indicator is installed on the air
intake manifold. Visually inspect the restriction
indicator periodically to assure the air filter is not
restricted. Service the air filter when the yellow
diaphragm indicates 25 in. of vacuum. Press the
reset button on the top of the air restriction
indicator after servicing the air filter.
Using belt tension gauge, P/N 204-427, is the best
method of checking belts for tightness. Install the
belt gauge in the center of the longest belt span.
Press the plunger so the hook will engage the belt.
Make sure the hook is on the face of the belt, not
in a notch. Release the plunger with a quick
motion and without pulling on the belt. Then read
the dial. Use an average of three readings.
NOTE: Do not attempt to remove or install belts
without loosening adjustments. Belts that are
installed by prying over pulleys will fail
prematurely due to internal cord damage.
CAUTION: Do not attempt to adjust belts
with the unit running.
AEA710
Figure 134: Air Restriction Indicator
CAUTION: Turn the unit off before
performing maintenance or repair
procedures. When the unit is turned on, it
can start at any time without warning.
115
Engine Maintenance
Belt Adjustments
Upper and Lower Fan Belt Adjustment
Alternator Belt Adjustment
The upper fan belt should read 74, and the lower
fan belt should read 67 on the belt tension gauge.
The alternator belt tension should read 61 on the
belt tension gauge.
NOTE: Both the upper and lower fan belts are
adjusted at the same time in one procedure.
1. Loosen the alternator pivot bolt and the
adjusting arm bolt.
NOTE: If a fan belt is loose or damaged, replace
the belt (see “Fan Belt Replacement” on page
117).
2. Move the alternator on the adjusting arm slots
to adjust the belt to 61 on the belt tension
gauge.
1. Loosen the idler assembly pivot bolts and the
idler adjusting arm bolts.
3. Tighten the adjusting arm bolt and alternator
pivot bolt.
2. Push in or pull out on the idler adjusting arm
to “center” the idler assembly between the
belts and balance the tension equally between
the upper and lower belts.
2
3
4
1
13
5
6
7
12
8
9
9
11
10
1.
Upper Fan Belt
8.
Lower Fan Belt
2.
Condenser Fan Pulley
9.
Engine Pulley
3.
Condenser Fan
10.
Idler Adjusting Arm Bolt
4.
Condenser Inlet Ring
11.
Idler Adjusting Arm
5.
Idler Assembly Pivot Bolt
12.
Alternator Belt
6.
Idler Assembly
13
Idler Adjusting Arm Pivot Bolt
7.
Belt Guide
Figure 135: Belt Arrangement
116
Engine Maintenance
3. Tighten both idler adjusting arm bolts and
both idler assembly pivot bolts.
NOTE: If the idler assembly binds when
moving for belt adjustment, loosen the upper
idler support bracket mounting bolts to free
up the assembly. Check the main idler
retainer nut assembly for proper alignment
between the nut and the support bracket
slots.
Fan Belt Replacement
NOTE: Do not attempt to remove or install the
belts without loosening the adjustments. Belts
that are installed by prying over pulleys will fail
prematurely due to internal cord damage.
Lower Fan Belt
Removal
1. Loosen both idler adjusting arm bolts and both
idler pulley assembly bolts.
2. Push the idler adjusting arm IN. The lower fan
belt will come off the engine pulley. Move the
arm OUT far enough to clear the roadside
idler mounting bracket.
Installation
1. Slip the belt into the groove of the idler pulley.
2. Push the idler adjusting arm back in toward
the unit.
3. Slip the belt onto the pulley groove on the
engine.
4. Pull the idler adjusting arm back OUT and
adjust the belts to the proper tension.
5. Tighten the idler assembly pivot bolts and the
idler adjusting arm bolts.
Upper Fan Belt
Removal
1. Loosen the idler adjusting arm bolts and
remove the lower fan belt (see “Lower Fan
Belt” above).
2. Push the idler adjusting arm in and the idler
assembly up. The upper belt should become
slack and slip down out of the idler pulley
groove.
3. Pull the idler adjusting arm OUT. The upper
fan belt should slip off the idler pulley as the
idler pulley hub clears the curbside idler
mounting bracket.
4. Loosen the two condenser fan hub to the shaft
clamping bolts.
5. Tap the blower wheel with a soft hammer to
drive the blower wheel up the fan shaft to
provide 1/2 in. (13 mm) clearance between the
blower wheel and the inlet ring.
NOTE: If the condenser fan does not slide
on the fan shaft with light tapping, remove
the small access panel located on the
condenser coil header above the radiator
tank. Thread a 1/4-20 x 1 in. diameter bolt
into the end of the fan shaft. Tighten the bolt
and washer down on the condenser fan hub
to loosen the blower wheel. Drive the blower
wheel back to provide 1/2 in. (13 mm)
clearance between the blower wheel and
condenser fan inlet ring.
6. Lift the belt up over the condenser blower
wheel and remove it from the unit.
Installation
1. Slip the belt over the condenser blower wheel
and place it in the condenser fan pulley.
2. Drive the condenser blower wheel out toward
the condenser fan inlet ring using a soft
hammer.
3. Position the blower wheel so the edge of the
inlet ring lines up with the alignment mark on
the blower wheel.
4. Check the radial clearance between the blower
wheel and inlet ring with a gauge wire. Check
around the entire circumference to the inlet
ring and blower wheel (see “Condenser and
Evaporator Fan Location” on page 147).
5. Torque the blower hub clamping bolts to
18 ft-lb (24 N•m).
6. Seat the upper belt in the blower wheel pulley
groove.
7. Push inward on the idler adjusting arm and
slip the belt into the idler pulley groove.
117
Engine Maintenance
8. Pull the idler adjusting arm forward and install
the lower fan belt.
1
2
3
4
AEA749
1.
Blower Wheel
2.
Inlet Ring
3.
Alignment Mark
4.
Edge of Inlet Ring
Figure 136: Condenser Blower Alignment
118
Refrigeration Maintenance
NOTE: The following procedures involve
servicing the refrigeration system. Some of these
service procedures are regulated by Federal, and
in some cases, by State and Local laws.
In the USA all regulated refrigeration service
procedures must be performed by an EPA
certified technician, using approved equipment
and complying with all Federal, State and Local
laws.
Refrigerant Charge
Testing The Refrigerant Charge With
An Empty Container
If the unit has an insufficient charge of refrigerant,
the evaporator will be “starved” and the box
temperatures will rise even though the unit is
operating. The suction pressure will drop as the
refrigerant charge decreases. If the unit has an
overcharge of refrigerant, the unit may not cool
properly and the suction and discharge pressure
may be high. The charge may be determined by
inspection of the refrigerant through the receiver
tank sight glasses with the following conditions
established:
1. Place a test box over the evaporator.
2. Install a gauge manifold.
3. Use the Service Test Mode to run the unit in
high speed cool. Refer to the appropriate
Diagnostic Manual for specific information
about the Service Test Mode.
4. Use the microprocessor thermometer to
monitor the return air temperature.
5. Run the unit on high speed cool until the air in
the box is at 0 F (-18 C). By allowing the box
to leak a small amount, you will be able to
maintain 0 F (-18 C).
8. Under these conditions, refrigerant should be
visible in the receiver tank sight glass. If
refrigerant is not visible in the receiver tank
sight glass, the unit is low on refrigerant.
Testing the Refrigerant Charge with
a Loaded Container
1. Install a gauge manifold.
2. Use the Service Test Mode to run the unit in
high speed cool. Refer to the appropriate
Diagnostic Manual for specific information
about the Service Test Mode.
3. Build up and maintain 275 psi (1896 kPa) of
head pressure. If the pressure is below this, it
can be raised by covering the roadside
condenser grille with a piece of cardboard to
block condenser air flow.
4. Cool the compartment to the lowest
temperature required.
5. Check suction pressure. It should be 13 to 25
psi (90 to 165 kPa).
6. Under these conditions, refrigerant should be
visible in the receiver tank sight glass. If
refrigerant is not visible in the receiver tank
sight glass, the unit is low on refrigerant.
Testing for an Overcharge
Use the following procedure to identify a Thermo
King unit with an excessive refrigerant charge:
1. Install a calibrated gauge manifold on the
compressor.
2. Use the Service Test Mode to run the unit in
high speed cool. Refer to the appropriate
Diagnostic Manual for specific information
about the Service Test Mode.
6. The suction pressure should be 13 to 18 psi
(90 to 124 kPa).
3. Operate the unit in high speed cool long
enough to stabilize system pressures and
reduce the box temperature to approximately
60 F (16 C) or colder.
7. The discharge pressure should be at least 275
sag (1896 kPa). If the pressure is below this, it
can be raised by covering a portion of the
condenser grille with a piece of cardboard to
block condenser airflow.
4. Observe discharge pressure and cover the
condenser to increase the discharge pressure
approximately 75 to 100 psi (500 to 690 kPa)
above observed pressure.
119
Refrigeration Maintenance
NOTE: If the liquid level in the receiver sight
glass drops during step 4, the unit is not
overcharged and it is not necessary to
complete the procedure.
5. Remove the condenser cover to rapidly reduce
discharge pressure.
6. Observe the receiver tank sight glass and the
unit discharge pressure.
7. By the time the discharge pressure drops
approximately 50 psi (345 kPa), the liquid
level in the receiver tank should drop.
a. When the discharge pressure stabilizes,
the liquid level will rise.
b. If the liquid level will not drop, the unit
most likely has an overcharge of
refrigerant. The refrigerant level should be
adjusted.
h. Close the hand valve on the refrigerant
tank when the liquid level approaches the
top of the receiver sight glass.
4. Repeat the overcharge test.
Moisture Indicating Sight Glass
The receiver tank is equipped with a moisture
indicating sight glass. The outer edge of the sight
glass has a colored ring approximately 0.1 in.
(2.5 mm) thick. The color of the ring indicates the
moisture content of the refrigerant, but it is not
completely reliable.
•
Green = Dry
•
Chartreuse = Caution
•
Yellow = Wet
1
To adjust the refrigerant level:
1. Stop the unit and remove some refrigerant
with an approved refrigerant recovery device.
2
2. Perform a refrigerant level check and repeat
the overcharge test.
3. If the liquid level is low, add refrigerant as
follows:
AEA672
1.
Floating Ball
2.
Colored Ring
Figure 137: Moisture Indicating Sight Glass
a. Connect a refrigerant tank to the gauge
manifold service line and purge the line.
b. Mid seat the compressor suction service
valve.
c. Set the refrigerant tank for liquid removal
and open the hand valve.
d. Operate the unit in high speed cool.
e. Observe the suction pressure and slowly
open the gauge manifold low pressure
hand valve to allow liquid refrigerant to
flow into the compressor suction service
valve.
f. Control the liquid flow so the suction
pressure increases approximately 20 psi
(138 kPa).
g. Maintain a discharge pressure of at least
275 psi (1896 kPa) while adding
refrigerant.
120
A system has to run for at least 15 minutes to
change the color of the indicator ring after the
moisture content of the system has been changed.
For example, evacuating a system to remove the
moisture will not change the color of the indicator
ring until the system has been recharged and then
operated for at least 15 minutes.
Refrigerant Leaks
Use a reliable leak detector that is suitable for
R-404A to leak test the refrigeration system.
Inspect for signs of oil leakage, which is the first
sign of a leak in the refrigeration system.
NOTE: It is normal for compressor shaft seals to
have a slightly oily film.
Refrigeration Maintenance
Oil Collection Container
The oil collection container collects the
compressor shaft seal seepage to keep the unit
clean. This seepage is normal and is necessary for
shaft seal durability.
The oil collection container is mounted on the
body of the compressor. A tube connects the oil
collection container to the compressor shaft seal
cover. The oil that seeps from the seal will travel
through the tube and collect in the container.
Empty the container once per year during oil
changes, or during annual services. The container
has a drain spout with a cap. Remove cap and
drain the oil into a cup (not provided) and discard
the oil properly. Retighten the cap snugly by hand.
1
1.
Sight Glass
Figure 139: Checking Compressor Oil
To check compressor oil level with an
ambient air temperature above 50 F (10 C):
Install a gauge manifold on the compressor.
Operate the unit on cool with a 20 psi (138 kPa)
minimum suction pressure and a 185 psi
(1275 kPa) minimum discharge pressure for 15
minutes or more.
1
2
3
4
1.
Tube to Compressor Shaft Seal Cover
2.
Compressor Mounting Flange
(Sectioned to Show Detail)
3.
Oil Collection Container
4.
Cap (Remove to Drain Oil)
Figure 138: Oil Collection Container Components
Checking Compressor Oil
The compressor oil should be checked when there
is evidence of oil loss (oil leaks) or when
components in the refrigeration system have been
removed for service or replacement.
After the unit has maintained the above conditions
for 15 minutes, observe the oil level. The oil
should be 1/4 to 1/2 up in the sight glass.
To check compressor oil level with an
ambient air temperature below 50 F (10 C):
Run the unit through a complete defrost cycle.
After completing the defrost cycle, run the unit on
cool for ten minutes. Observe the oil level. The oil
should be 1/4 to 1/2 up in the sight glass.
If the box is empty, you can run the unit on the
heat cycle instead of the defrost cycle.
NOTE: Use refrigeration compressor oil ONLY.
Polyol Ester P/N 203-513 is required for
R-404A.
To add compressor oil pump down the compressor
and equalize the pressure to slightly positive.
Disconnect the compressor oil filter return line
from the top of the compressor and add the oil.
Reattach the oil filter return line to the
compressor. Evacuate the compressor before
opening the service valves.
121
Refrigeration Maintenance
High Pressure Cutout Switch
(HPCO)
The HPCO is located on the compressor discharge
manifold. If the discharge pressure rises above
470 psi (3241 kPa), the HPCO opens the HPCO
circuit to the run relay and stops the unit. To test
the HPCO, rework a gauge manifold as shown in
Figure 140 “High Pressure Cutout Manifold” and
use the following procedure.
1. Connect the gauge manifold to the compressor
discharge service valve with a heavy duty,
black jacketed thick wall #HCA 144 hose with
a 900 psi (6204 kPa) working pressure rating.
overriding the throttle solenoid. This should
increase the discharge pressure enough to
cause the HPCO to cut out.
CAUTION: If the discharge pressure
reaches 477 psi (3289 kPa), shut the unit
off immediately. Do not allow the
discharge pressure to exceed 477 psi (3289
kPa).
4. If the HPCO does not open to de-energize the
run relay and stop the unit, it must be
replaced.
Three-Way Valve Condenser
Pressure Bypass Check Valve
A three-way valve condenser pressure bypass
check valve is used in this unit. This check valve
controls the bypass flow of refrigerant gas
between the condenser inlet line and the
compressor discharge line.
The check valve is closed when the unit is running
on cool, or whenever the discharge pressure is
higher than the condenser pressure.
When the unit is running on defrost or heat, if the
condenser pressure is higher than the discharge
pressure, the check valve opens and the condenser
pressure is bled off until it drops to the level of the
discharge pressure. The purpose of the valve is to
improve the three-way valve response time when
shifting from heat to cool.
1.
Relief Valve (66-6543)
2.
O-Ring (33-1015)
3.
Adapter Tee Weather Head No. 552X3
Figure 140: High Pressure Cutout Manifold
2. Use the Service Test Mode to run the unit in
high speed cool.
3. Raise the discharge pressure of the
compressor first by blocking the condenser
coil air flow by covering the condenser grille
with a piece of cardboard. If this does not raise
the discharge pressure to the cutout level of
the HPCO, increase the engine speed by
122
If a three-way valve does not shift back to cool
immediately after the pilot solenoid closes, and
finally shifts to cool when the temperature rise
puts the unit into high speed, the three-way valve
end cap should be checked. See “End Cap
Checks” in the Refrigeration Service Operations
Chapter.
To check the operation of the condenser pressure
bypass check valve:
1. Remove the condenser pressure bypass check
valve cap from the three-way valve.
2. Using a screwdriver, gently turn the check
valve stem in until the valve is front seated.
3. Install a gauge manifold set on the
compressor.
Refrigeration Maintenance
4. Close (front seat) the receiver tank outlet
valve.
bypass check valve is properly releasing
condenser pressure into the discharge tube and
evaporator.
10. Replace the cap on the condenser pressure
bypass check valve.
NOTE: Valve stem MUST be back seated
during normal unit operation.
11. Open the receiver tank return outlet valve,
remove the gauges and return the unit to
normal operation.
Electronic Throttling Valve
(ETV)
The Electronic Throttling Valve (ETV) is
standard on this unit.
The Electronic Throttling Valve (ETV) is a
variable position valve operated by a stepper
motor. The ETV is located in the suction line
between the evaporator and the heat exchanger.
The ETV system also uses discharge and suction
pressure transducers, and a hot gas bypass valve.
1.
Check Valve
2.
Heating/Defrost Position
3.
Cooling Position
Figure 141: Three-way Valve Condenser
Pressure Bypass Check Valve
5. Operate the unit on cool and pump down the
low side to 20 in. Hg (-68 kPa) of vacuum.
6. Stop the unit. The condenser and suction
pressures should remain stable, indicating no
leaks.
7. Shift the three-way valve to the heat position.
The low side gauge will raise slightly. The
high side gauge will drop to approximately
zero. The gauges will equalize.
8. The gauges will remain in this position,
approximately zero, if the three-way valve
seals properly toward the condenser and the
condenser pressure bypass check valve seals
properly.
9. Back seat condenser pressure bypass check
valve stem against the snap ring. Both gauges
should rise indicating the condenser pressure
The ETV has two internal coils. The
microprocessor operates the valve by energizing
the coils with a variable frequency ac signal. The
valve position can be monitored with the
GAUGES key. Zero (0) indicates the valve is fully
closed and 800 indicates the valve is fully open.
The microprocessor tests the ETV if required
when the unit is started. Alarm Code 89 indicates
the refrigeration system pressures did not respond
as expected during the test. This may be caused by
a malfunction of the ETV or by a refrigeration
system problem such as low refrigerant level, a
frozen expansion valve, or a restriction in suction
line. The microprocessor ignores the test results if
the box temperature or the ambient temperature is
below 10 F (-12 C). The ETV test can also be
performed using the Service Test Mode.
Use the GAUGES key to check the operation of the
ETV during the ETV test. The valve position
should be 0 at the start of the test when the valve
is fully closed, and should go to a higher value
when the valve is opened. The suction pressure
should decrease while the valve is fully closed,
and should begin to increase when the valve is
opened.
123
Refrigeration Maintenance
Refer to the SR-2 Microprocessor Control System
Diagnostic Manual TK 51727 for complete
information about the testing and operation of the
ETV.
See “Electronic Throttling Valve” in the
Refrigeration Service Operations chapter of this
manual for removal and installation procedures.
3
The hot gas solenoid (or hot gas bypass valve) is
used in conjunction with the electronic throttling
valve to reduce the capacity of the unit during
modulation. This normally closed solenoid valve
is located in the refrigeration line that connects the
discharge line to the hot gas line. The hot gas
solenoid is energized (opened) at full modulation.
The hot gas solenoid is de-energized (closed)
when modulation is discontinued.
Refer to the SR-2 Microprocessor Control System
Diagnostic Manual TK 51727 for information
about testing the hot gas solenoid. See the
Refrigeration Service Operations chapter of this
manual for removal and installation procedures.
2
1
4
1.
Inlet
2.
Valve Body
3.
Stepper Motor
4.
Outlet
Figure 142: Electronic Throttling Valve
Pressure Transducers
The discharge pressure transducer and the suction
pressure transducer supply pressure information
to the microprocessor. These pressures can be
monitored with the GAUGES key. Check the
readings by comparing them to the readings on a
gauge manifold set attached to the compressor.
Refer to the SR-2 Microprocessor Control System
Diagnostic Manual TK 51727 for more
information about the testing and operation of the
pressure transducers.
124
Hot Gas Solenoid
Refrigeration Service Operations
NOTE: The following procedures involve
servicing the refrigeration system. Some of these
service procedures are regulated by Federal, and
in some cases, by State and Local laws.
In the USA all regulated refrigeration service
procedures must be performed by an EPA
certified technician, using approved equipment
and complying with all Federal, State and Local
laws.
Compressor
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Front seat the discharge and suction service
valves.
3. Recover the refrigerant remaining in the
compressor.
Installation
1. Slide the compressor into the unit.
2. Place the compressor in position and install
the mounting bolts.
NOTE: The compressor drive coupling will
only slide onto the coupling pins in either of
two positions, which are 180 degrees apart.
3. Install the service valves using new gaskets
soaked in compressor oil. Connect the high
pressure cutout switch, the pilot solenoid
valve line, and install the compressor oil filter.
4. Pressurize the compressor and test for
refrigerant leaks.
5. If no leaks are found, evacuate the
compressor.
6. Back seat the suction and discharge service
valves.
4. Unbolt the discharge and suction service
valves from the compressor.
7. Operate the unit at least 30 minutes and then
inspect the oil level in the compressor. Add or
remove oil if necessary.
5. Disconnect the high pressure cutout switch,
the pilot solenoid line, and remove the
compressor oil filter.
8. Check the refrigerant charge and add
refrigerant if needed.
6. Support the compressor and remove the
compressor mounting bolts from the flywheel
housing.
Compressor Coupling Removal
7. Lift the service valves out of the way.
8. Slide the compressor to the left until the
coupling pins are clear.
9. Remove the compressor from the front of the
unit. Keep the compressor ports covered to
prevent dust, dirt, etc., from falling into the
compressor.
NOTE: When the compressor is removed
from the unit, the oil level should be noted,
or the oil removed from the compressor
should be measured so that the same amount
of oil can be added before placing the
replacement compressor in the unit.
1. After the compressor has been removed from
the unit, use the appropriate Allen tool
provided with removal tool P/N 204-991 to
loosen the center bolt which holds the
coupling to the compressor shaft.
2. Attach the tool to the coupling with the
provided socket head screws and spacers. Two
sets of spacers are provided with the tool, use
the short spacers with shallow compressor
mounting flanges and the longer set for deeper
flanges. The side with the countersunk holes
should be toward the coupling.
3. To prevent the tool and crankshaft from
rotating, use one of the compressor to engine
mounting screws to pin the tool to the flange.
If a nut is used to prevent the bolt from falling
out, the nut should not be tightened.
4. Use the appropriate Allen tool to loosen the
coupling mounting screw.
125
Refrigeration Service Operations
5. Once the center screw has been loosened,
back the head against the tool and it should
push the coupling off the crankshaft as you
continuing turning the center screw in a
counter-clockwise direction. Using this tool
will prevent the coupling from popping off
because the center bolt and flatwasher will
hold it in place.
The following procedure requires the key to be
fitted after the tapers are pulled together with
20 ft-lb (27 N•m) torque. This insures that the key
cannot hold the tapers apart when the final bolt
torque is applied.
Compressor Coupling Installation
1. Clean the compressor shaft taper and coupling
bore taper with a solvent that leaves no oily
residue (such as naphtha, lacquer thinner,
brake cleaner or the like).
Use the following procedure to install a
compressor coupling on the compressor
crankshaft.
In a tapered fit joint the entire twisting load
should be handled by the friction fit between the
two tapered parts. The key is only a backup and is
used to index the parts correctly. When a taper fit
is machined and assembled properly a key is not
needed. In fact, if the key is not installed correctly
it may be worse than no key at all! If the key does
not fit easily into the keyway, it will push the
tapered components apart and the reduced friction
could lead to slippage and premature failure.
2. Inspect both mating surfaces for burrs,
oxidation and other surface imperfections.
Dress with crocus cloth if necessary and
re-clean as required.
1
2
3
8
4
5
7
6
AGA1059
1.
Coupling
5.
10 mm Allen Tool (for large shaft compressor)
2.
Long Spacers (supplied with tool)
6.
5/16 Allen Tool (for small shaft compressors)
3.
Short Spacers (supplied with tool)
7.
Coupling Removal Tool (P/N 204-991)
4.
Socket Head Bolts (supplied with tool)
8.
Engine Mounting Flange
Figure 143: Compressor Coupling Removal Tool
126
Refrigeration Service Operations
3. Using no lubricants, set the coupling on the
crankshaft and align the keyways using the
Keyway Tool (P/N 204-972). Insert the
tapered end of the tool into the keyway and
gently move the coupling on the shaft while
pressing the tool into the keyway. This will
align the keyway in the crankshaft with the
keyway in the coupler.
8. Install the key in the keyway. As above, it
should fit with a light press fit requiring only a
minimum of light tapping. Do not install the
key into the keyway beyond the front face
of the coupling. If tapped in farther it may
cause the coupling to move off center on the
shaft.
1
2
3
AGA333
Figure 144: Keyway Tool P/N 204-972
CAUTION: If you are assembling a used
coupler or crankshaft and the tool does
not fit easily there is a problem with one of
the keyways! Do not remove the coupler
and place the key in the crankshaft
keyway and then drop the coupler on. If
the tool does not fit, the key will not fit,
and it will hold the taper in the coupler off
the taper on the shaft. Check both keyways
for burrs or corrosion. A key can be
coated with fine lapping compound and
used as a lapping tool to clean the
keyways.
4. Remove the Keyway Tool and check the fit of
the key (P/N 55-9024). It should fit into the
keyway with a light press fit requiring only a
minimum of light tapping. If the key does not
fit properly, remove the coupler and inspect
the keyways and key for burrs or other
problems. Recheck the fit as shown above.
5. When the key fits properly, remove the
coupling and key from the shaft.
6. Re-install the coupling and align the keyways
with the Keyway Tool.
7. Do not install the key at this time. Install the
flat washer and bolt and pre-torque to 20 ft-lb
(27 N•m). Remove the bolt and washer.
5
AGA1254
4
1.
Compressor Coupling or Clutch
2.
Key tapped flush with outside face of coupling.
Do not tap key any farther into keyway.
3.
Torque bolt to 90 ft-lb (122 N•m)
4.
Washer
5.
Spray this area with corrosion inhibitor after
assembling.
Figure 145: Compressor Coupling Installation
9. Re-install the bolt and heavy flat washer and
snug the bolt down by hand. Torque the bolt to
90 ft-lb (122 N•m).
10. Spray a corrosion inhibitor (such as spray
paint) on the exposed part of the shaft and the
joint between the shaft and the coupling. This
prevents moisture from wicking into the joint
and causing corrosion.
Condenser Coil
Removal
1. Recover the refrigerant charge.
2. Open the roadside condenser fan grille.
3. Drain engine coolant from the expansion tank.
Unbolt and remove the expansion tank from
the condenser coil frame.
127
Refrigeration Service Operations
4. Remove the condenser coil mounting bolts.
Remove the mounting clamps from the
condenser inlet line.
4. Charge the unit with the proper refrigerant and
check the compressor oil level.
5. Unsolder the inlet line and liquid line
connections. Lift the coil from the unit.
In-Line Condenser Check Valve
Installation
1. Clean the fittings for soldering.
2. Place the coil in the unit and install the
mounting bolts.
This unit uses an in-line condenser check valve.
The in-line check valve is not repairable and must
be replaced if it fails. A heat sink must be used on
the in-line check valve when it is being soldered
in place to prevent damage to the neoprene seal.
3. Solder the inlet line and liquid line
connections.
4. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
AEA648
5. Install the clamps on the condenser inlet line.
6. Install the engine coolant expansion tank and
refill half way with engine coolant.
1.
Valve
7. Close the roadside condenser fan grille.
2.
Neoprene Seal
8. Recharge the unit with proper refrigerant and
check the compressor oil.
3.
Valve Seat
4.
Spring
Discharge Vibrasorber
Removal
1. Recover the refrigerant charge.
2. Heat the connections on the vibrasorber until
the vibrasorber can be removed.
CAUTION: Use a heat sink, P/N 204-584
or wrap the vibrasorber with wet rags to
prevent damaging the vibrasorber.
Figure 146: Cross Section of In-line
Condenser Check Valve
Condenser Check Valve
Replacement
Removal
1. Recover the refrigerant charge.
2. Place a heat sink on the check valve.
3. Unsolder the lines and remove the check
valve.
Installation
1. Prepare the vibrasorber and tubing fittings by
cleaning thoroughly.
2. Solder the vibrasorber connections.
CAUTION: Use a heat sink, P/N 204-584
or wrap the vibrasorber with wet rags to
prevent damaging the vibrasorber.
3. Pressurize the system and test for leaks. If no
leaks are found, evacuate the system.
128
Installation
NOTE: A heat sink must be used on the in-line
check valve when it is being soldered in place to
prevent damage to the neoprene seal.
1. Clean the tubes for soldering.
2. Place the check valve in position. The arrow
on the valve body indicates the direction of
refrigerant flow through the valve.
3. Place a heat sink on the check valve.
Refrigeration Service Operations
4. Solder the inlet and outlet connections.
5. Pressurize the refrigeration system and test for
leaks.
6. If no leaks are found, evacuate the system.
7. Recharge the unit with proper refrigerant and
check the compressor oil.
Bypass Check Valve
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Close the bypass service valve.
3. Unsolder the bypass check valve line from the
bypass check valve. Use a heat sink on the
bypass check valve.
4. Unsolder and remove the bypass check valve
from the receiver tank. Use a heat sink on the
bypass check valve.
Installation
1. Solder the bypass check valve onto the
receiver tank. Use a heat sink on the bypass
check valve.
2. Solder the bypass check valve line to the
bypass check valve. Use a heat sink on the
bypass check valve.
3. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the system.
4. Open the bypass service valve and place the
unit in operation.
Receiver Tank
Removal
1. Recover the refrigerant charge.
2. Unsolder the inlet, outlet, and bypass check
valve lines from the receiver tank. Use a heat
sink on the bypass check valve.
3. Unsolder and remove the bypass check valve
from the receiver tank. Use a heat sink on the
bypass check valve.
4. Remove the high pressure relief valve from
the receiver tank.
5. Unbolt the mounting brackets and remove the
receiver tank from the unit.
Installation
1. Install the high pressure relief valve in the
receiver tank.
2. Solder the bypass check valve onto the
receiver tank. Use a heat sink on the bypass
check valve.
3. Place the receiver tank in the unit and install
the mounting bolts and nuts loosely. Position
the receiver tank so that the sight glass is
clearly visible through the viewing hole in the
mounting bracket.
4. Solder the inlet, outlet, and bypass check
valve lines to the receiver tank. Use a heat
sink on the bypass check valve.
5. Tighten the receiver tank mounting hardware
securely.
6. Pressurize the refrigeration system and check
for leaks. If no leaks are found, evacuate the
system.
7. Recharge the unit with proper refrigerant.
Filter Drier
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Disconnect the nuts at the ends of the drier.
3. Loosen the mounting hardware and remove
the drier.
Installation
1. Place the new O-rings in the ORS fittings on
the ends of the drier.
2. Install the new drier and tighten the mounting
hardware.
3. Install and tighten the ORS nuts. Hold the
drier with a back-up wrench on the hex behind
the ORS fitting.
129
Refrigeration Service Operations
4. Pressurize the low side and inspect for leaks.
If no leaks are found, evacuate the low side.
5. Open the refrigeration valves and place the
unit in operation.
Expansion Valve Assembly
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Remove the evaporator access panels.
AEA713
3. Remove the feeler bulb from the clamp. Note
the position of the feeler bulb on the suction
line.
4. Disconnect the equalizer line from the suction
line.
5. Disconnect the inlet liquid line and unsolder
the distributor from the expansion valve.
1.
End View
2.
Side View
Figure 147: Location of Expansion Valve Bulb
5. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
6. Replace the access panels.
6. Remove the expansion valve mounting bolt
and remove the expansion valve from the unit.
7. Open the refrigeration valves and place the
unit in operation.
Installation
8. Test the unit to see that the expansion valve is
properly installed.
1. Install and bolt the expansion valve assembly
in the unit.
Heat Exchanger
2. Connect the inlet liquid line and solder the
distributor to the expansion valve.
Removal
3. Connect the equalizer line to the suction line.
1. Pump down the low side and equalize the
pressure to slightly positive.
4. Clean the suction line to a bright polished
condition. Install the feeler bulb clamps and
the feeler bulb on the side of the suction line
in its former position. The feeler bulb must
make good contact with the suction line or
operation will be faulty. Wrap with insulating
tape.
2. Remove the upper and lower evaporator
access panels.
3. Remove the mounting bolts that hold the heat
exchanger on the bulkhead.
4. Disconnect the equalizer line from the suction
line.
5. Disconnect the liquid outlet line from the
expansion valve.
6. Note the position of the feeler bulb on the side
of the suction line. Remove the expansion
valve feeler bulb from the suction tube.
130
Refrigeration Service Operations
7. Unsolder the suction line at the evaporator coil
end.
Evaporator Coil
8. Unsolder the remaining outlet suction line and
inlet liquid line connections from the
condenser side of the bulkhead. Remove any
putty from around the lines before unsoldering
the connections.
Removal
9. Slide the heat exchanger assembly out of the
evaporator housing.
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Remove the upper and lower evaporator
access panels.
3. Remove the roadside and curbside evaporator
access panel mounting channels.
Installation
4. Disconnect the sensors.
1. Clean the tubes for soldering.
5. Remove the feeler bulb from the suction line
clamp. Note the position of the feeler bulb on
the suction line.
2. Place the heat exchanger assembly in the
evaporator housing and install the mounting
hardware loosely.
3. Solder the liquid inlet and the suction outlet
line connections on the condenser side of the
bulkhead. Seal the openings through the
bulkhead with putty when the refrigerant lines
have cooled off.
4. Solder the suction line connection to the
evaporator coil.
5. Connect the equalizer line to the suction line
and the liquid outlet line to the expansion
valve.
6. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
7. Tighten the heat exchanger mounting
hardware securely.
8. Clean the suction tube to a brightly polished
condition. Install the feeler bulb clamps and
the feeler bulb on the side of the suction line
in its former position. The feeler bulb must
make good contact with the suction line or the
operation will be faulty. Wrap with insulating
tape.
9. Replace the upper and lower evaporator
access panels.
10. Open the refrigeration valves and place the
unit in operation.
6. Unsolder the distributor from the expansion
valve.
7. Unsolder the hot gas line and the suction line
from the evaporator coil.
8. Remove the mounting bolts, lift and slide the
coil from the housing.
Installation
1. Place the evaporator coil in the evaporator
housing and install the mounting bolts.
2. Solder the hot gas line and suction line
connections to the evaporator coil.
3. Connect the distributor to the expansion valve.
4. Replace and connect the sensors.
5. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
6. Clean the suction line to a bright polished
condition. Install the feeler bulb on the side of
the suction line in its former position. The
feeler bulb must make good contact with the
suction line or its operation will be faulty.
Wrap with insulating tape.
7. Replace the roadside and curbside evaporator
access panel mounting channels.
8. Replace the evaporator access panels.
9. Open the refrigeration valves and place the
unit in operation. Check the refrigerant charge
and the compressor oil. Add as required.
131
Refrigeration Service Operations
Accumulator
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Unsolder the inlet and outlet suction lines
from the accumulator.
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent
damaging the vibrasorber.
3. Disconnect the tee fitting from the
accumulator tank.
4. Unbolt and remove the accumulator from the
unit.
Installation
1. Place the accumulator in the unit and tighten
the mounting bolts and nuts.
2. Solder the inlet and outlet suction lines to the
accumulator.
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent
damaging the vibrasorber.
3. Connect the tee fitting and lines to the
accumulator.
AEA714
4. Pressurize the low side and test for refrigerant
leaks. If no leaks are found, evacuate the low
side.
5. Open the refrigeration valves and place the
unit in operation. Check the refrigerant charge
and the compressor oil. Add as required.
Three-Way Valve Repair
NOTE: The three-way valve can be repaired in
the unit if leakage or damage to the Teflon seals
should occur. There is usually enough give in
the copper tubing to separate the three sections
of the valve without unsoldering any tubes.
1.
Cap
7.
Clip
2.
End Cap
8.
Seat
3.
Check Valve
9.
Gaskets
4.
Spring
10.
Stem Assembly
5.
Piston
11.
Screen
6.
Seal
12.
Bottom Cap
Figure 148: Three-Way Valve
Removal/Disassembly
1. Recover the refrigerant charge.
2. Clean the exterior surface of the valve.
3. Remove the line from the three-way valve to
the pilot solenoid.
132
Refrigeration Service Operations
4. Loosen the four 1/4 in. Allen head screws (DO
NOT REMOVE OR CAP MAY POP OFF);
use tool P/N 204-424 to break the gasket at
each side of the center section.
1
CAUTION: Do not force the tool into the
brass or against the bolts.
5
2
4
3
AGA1069
Figure 149: Gasket Tool P/N 204-424
AGA1066
5. Remove the four bolts from the valve.
1.
Seal Groove in Piston
2.
Connecting Notch in Piston
7. Remove the spring clip which secures the
stem to the piston. Slide piston off the stem.
3.
Internal Spring in Seal
4.
Connecting Groove in Stem
8. Remove the seat and stem assembly.
5.
Retaining Clip
6. Remove the end cap and spring.
9. Inspect the following parts for wear or
damage:
a. Bottom cap, sealing and support area.
b. Seat, sealing surface.
c. End cap, sealing and support surface.
Figure 150: Piston and Stem Parts
End Cap Checks
All end caps, even new ones, should be checked
as follows. See Service Bulletin T&T 260 for
more information.
The following parts will be discarded:
Check Valve Bleed Hole Diameter
a. Stem assembly.
1. Remove the condenser pressure bypass check
valve snap ring, stem, spring, and piston from
the end cap.
b. All gaskets.
c. Piston seal.
10. Remove the screen. If any particles drop from
the screen into the discharge line, the
discharge line must be removed at the
compressor.
NOTE: The valve body cannot be
reconditioned. Seat positions change and
improper sealing will result.
2. Use a number 43 (0.089 in. [2.26 mm]) drill
bit to check the size of the hole from the end
cap gasket face to the check valve piston bore
as shown.
3. If the drill does not go all the way into the
bore, drill the hole completely through.
4. Deburr the hole in the check valve piston bore.
A used drill bit can be modified to use as a
deburring tool.
133
Refrigeration Service Operations
3. With the piston pushed all the way back in its
bore, use a strong light to look down the
0.089 in. (2.26 mm) hole towards the back of
the piston and determine how much of the end
of the hole is covered by the piston. If the
piston covers more than three-quarters of the
hole replace the end cap.
1
NOTE: When front seating a condenser bypass
check valve DO NOT over-tighten the stem!
Excessive torque will deform the piston and the
deformed piston can increase the hole blockage.
1.
Number 43 Drill
Seat (Center Section) Orifice Check
Figure 151: Check Bleed Hole Diameter
Piston Bleed Orifice Check
1. Use a number 66 (0.033 in. [0.84 mm]) drill
bit to check the orifice in the bleed hole from
the gasket surface to the groove in the bottom
of the piston bore.
2. Carefully check to see that the drill projects
down into the groove and that there are no
burrs at the end of the hole in the groove. Do
not enlarge this hole.
1
2
1.
Number 66 Drill
2.
Check for Burr Here
There are three 0.033 in. (0.84 mm) holes located
in the three-way valve seat (center section). Only
one is used depending on how the valve is configured. If the hole is too large the valve will be slow
to shift from heat to cool when the condenser
pressure is higher than discharge pressure because
gas will flow to the discharge line instead of
behind the piston. If the hole is too small the valve
will be slow to shift from heat to cool when discharge pressure is higher than condenser pressure
because the flow is restricted. Do not enlarge this
hole larger than 0.033 in. (0.84 mm)! Whenever
you disassemble a three-way valve you should
check that all three of the holes are drilled cleanly.
1
Figure 152: Check Piston Bleed Orifice
Check Valve Piston Check
1. Reassemble the end cap using a new check
valve piston, spring, stem, and snap ring (Kit
P/N 60-163).
2. Leave the stem back seated against the snap
ring. Use a paper clip bent into a 90 degree
angle to push the check valve piston back in
its bore. Make sure you can feel the piston
working against the spring.
134
1.
Number 66 Drill
Figure 153: Check Seat Orifice
Assembly/Installation
After cleaning and inspecting all parts, reassemble
the valve.
1. Install the screen in the bottom cap.
2. Install the new stem in the bottom cap.
Refrigeration Service Operations
3. Install new gaskets on both sides of the seat.
Oil the gaskets in compressor oil before
installing.
4. Use the three-way valve seal installation tool
P/N 204-1008 to install a new seal on the
piston. This prevents the seal from being
stretched and damaged.
a. Place the tapered tool over the piston.
b. Lubricate the seal with refrigeration oil.
c. Slide the seal onto the tapered tool with
the spring side facing away from the
piston.
d. Use the pipe to hand press the seal onto
the piston.
1
9. Install the pilot solenoid line and pressurize
the system with refrigerant to check for leaks.
10. If there are no leaks, evacuate the system and
recharge with the proper refrigerant.
11. Run the unit to check for proper three-way
valve operation.
Three-Way Valve Condenser
Pressure Bypass Check Valve
Repair
Removal
1. Recover the refrigerant charge.
2. Unscrew the condenser pressure bypass check
valve cap from the three-way valve.
3. Remove the snap ring.
2
3
4
AEA715
5
ARA166
1.
Press by Hand
4.
Tapered Tool
2.
Pipe
5.
Piston
3.
Seal
Figure 154: Seal Installation with Tool P/N 204-1008
5. Place the piston slot on the stem and secure
with spring clip. The open part of the clip
should be on the opposite side of the piston
slot.
6. Install the spring and end cap.
7. Line up the passageways in the cap and body.
Failure to line up the holes will result in
improper operation of the valve.
8. Install the bolts and tighten in rotating
sequence. Torque to 160 in-lb (18 N•m).
1.
Piston
4.
Stem
2.
Snap Ring
5.
O-ring
3.
Cap
6.
Spring
Figure 155: Teflon Check Valve Assembly
4. Unscrew the check valve stem by using a
screwdriver in the slot provided.
NOTE: The spring and piston are held in by
the stem. While removing the stem, use care
so the spring and piston are not lost.
5. Remove the spring and piston.
6. Inspect the check valve seat in the three-way
valve.
7. If replacement parts are needed, a kit
P/N 60-163 must be used which includes the
piston, spring, O-ring, valve stem, and snap
ring.
135
Refrigeration Service Operations
Installation
1. Coat the O-ring with compressor oil and
install it on the check valve stem.
2. Insert the spring into the hole in the check
valve stem and then install the piston on the
other end of the spring with the hole in the
piston towards the spring.
3. Coat the entire assembly with compressor oil
and install the assembly into the check valve
seat in the three-way valve.
CAUTION: The piston must be inserted
with the flat side against the valve seat to
ensure proper sealing.
4. Screw the check valve stem into the three-way
valve until the snap ring can be installed.
5. Install the snap ring.
6. Unscrew (back seat) the check valve stem
against the snap ring.
NOTE: The valve stem must be back seated
during normal unit operation.
7. Coat the sealing area in the cap with
compressor oil, install and tighten the cap on
the three-way valve.
8. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
9. Recharge the unit with the proper refrigerant.
Pilot Solenoid
Removal
1. Recover the refrigerant charge.
2. Disconnect the wires and remove the coil from
the valve.
3. Unsolder the refrigeration lines.
4. Remove the mounting bolts and remove the
valve.
Installation
1. Remove the coil from the valve.
136
2. Place the valve in the unit and install the
mounting bolts. The arrow on the valve
indicates the direction of flow through the
valve. Make sure that the arrow points in the
proper direction.
3. Solder the refrigeration lines to the valve.
4. Install the coil and connect the wires.
5. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
6. Recharge the unit with the proper refrigerant
and check the compressor oil.
Suction Vibrasorber
Removal
1. Pump down the low side and equalize pressure
to slightly positive.
2. Unsolder the suction vibrasorber from the
suction service valve. Unsolder the connection
to the accumulator and remove the vibrasorber
from the unit.
Installation
1. Prepare the suction vibrasorber and tube
fittings for soldering by cleaning the
thoroughly.
2. Solder the vibrasorber to the suction service
valve.
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent
damaging the vibrasorber.
3. Solder the suction vibrasorber connection to
the accumulator.
4. Pressurize the low side and check for leaks. If
no leaks are found, evacuate the system.
5. Open the refrigeration valves and place the
unit in operation.
Refrigeration Service Operations
High Pressure Cutout Switch
4. Recharge the unit with the proper refrigerant
and check the compressor oil.
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Front seat the discharge and suction service
valves. Recover the refrigerant remaining in
the compressor.
3. Disconnect the wires and remove the high
pressure cutout switch from the compressor
discharge manifold.
Installation
Discharge Pressure Transducer
Removal
1. Recover the refrigerant charge.
2. Disconnect the wires and remove the
discharge pressure transducer.
Installation
1. Apply a refrigerant Loctite to the threads of
the discharge pressure transducer.
1. A new high pressure cutout switch does not
have a connector installed. Use the old
connector and just install new wire terminals,
or install a new connector and wire terminals.
See the appropriate Parts Manual for the
correct connector and terminal part numbers.
2. Install and tighten the discharge pressure
transducer and reconnect the wires.
2. Place a new copper sealing washer on the high
pressure cutout switch.
4. Recharge the unit with the proper refrigerant
and check the compressor oil.
3. Install the high pressure cutout switch and
torque it to 20 ± 2 ft-lb (27 ± 3 N•m).
Suction Pressure Transducer
4. Connect the wires.
Removal
5. Pressurize the compressor and test for leaks.
1. Pump down the low side and equalize pressure
to slightly positive.
6. If no leaks are found, open the refrigeration
service valves and place the unit in operation.
High Pressure Relief Valve
Removal
3. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
2. Disconnect the wires and remove the suction
pressure transducer.
Installation
1. Recover the refrigerant charge.
1. Apply a refrigerant Loctite to the threads of
the suction pressure transducer.
2. Unscrew and remove the high pressure relief
valve.
2. Install and tighten the suction pressure
transducer and reconnect the wires.
Installation
3. Pressurize the low side and check for leaks. If
no leaks are found, evacuate the low side.
1. Apply a refrigerant oil to the O-ring of the
high pressure relief valve.
4. Open the refrigeration valves and place the
unit in operation.
2. Install and tighten the high pressure relief
valve.
3. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
137
Refrigeration Service Operations
Electronic Throttling Valve
(ETV)
Removal
1
2
1. Pump down the low side and equalize the
pressure to slightly positive.
3
2. The ETV must be open to remove the stepper
motor and piston assembly. Open the ETV by
placing the unit in the Evacuation Mode/Test,
and then turning the unit off. Refer to the
appropriate Microprocessor Diagnostic
Manual for information about the Evacuation
Mode/Test.
3. Remove the evaporator access panels.
4. Disconnect the ETV harness from the four-pin
connector on the main wire harness.
1.
Small Hex on Stepper Motor
2.
Large Nut
3.
Valve Body
Figure 156: Electronic Throttling Valve
5. Unscrew the large nut that attaches the stepper
motor and piston assembly to the valve body.
The torque on the nut is approximately 118
ft-lb (160 N•m). Hold the valve body with
backup wrench to prevent damage to the
refrigeration tubing.
1
CAUTION: Unscrew the large nut. Do not
unscrew the small hex on the stepper
motor.
WARNING: If the ETV is stuck in the
closed position, much of the refrigerant
charge may be trapped in the evaporator.
If you hear refrigerant begin to flow
through the valve when the stepper motor
and piston assembly are loosened,
unscrew the stepper motor and piston
assembly no more than four turns and
check the suction (low side) pressure on
the gauge manifold. If the suction
pressure has increased from the pressure
to which it was equalized after the low side
pump down, refrigerant is trapped and
must be recovered. Screw the stepper
motor and piston assembly back into the
valve body. Attach a refrigerant recovery
device to the service port on the receiver
tank outlet valve. Midseat the receiver tank
outlet valve, and recover the refrigerant
charge. The stepper motor and piston
assembly may then be removed.
138
1.
Unscrew Large Nut
Figure 157: Removing Electronic Throttling Valve
6. If the complete ETV assembly is being
replaced, unsolder and remove the valve body.
It may be necessary to unsolder the tubes
above or below the valve body to obtain
enough clearance to remove the valve body.
Note the position of the valve body so the new
one will be placed in the same position. The
new ETV could interfere with the evaporator
access panel if it is not placed in the same
position as the old one.
Refrigeration Service Operations
Installation of Service Kit
NOTE: Do not connect the ETV harness to main
wire harness and turn the unit on before the
stepper motor and piston assembly is installed in
the valve body. The controller is programmed to
close the ETV when the unit is turned on. If the
unit is turned on with the ETV harness
connected to main wire harness, the controller
will attempt to close the ETV. This will cause the
piston to be turned (screwed) off the threaded
shaft of the stepper motor because the valve body
is not present to stop it. Further disassembly is
required to reassemble the piston and stepper
motor. See “Reassembly of Piston and Stepper
Motor”.
1. The new stepper motor and piston assembly is
supplied with the piston in the open position.
In the open position the bottom edge of the
piston is 0.3 to 0.7 in. (8 to 18 mm) from the
bottom edge of the brass nut. The piston
retracts to open and extends to close.
2. Lubricate the piston and threads on the new
stepper motor and piston assembly with
refrigeration oil.
3. Screw the new stepper motor and piston
assembly into the valve body.
4. Torque the nut to approximately 118 ft-lb
(160 N•m). Hold the valve body with backup
wrench to prevent damage to the refrigeration
tubing.
5. Connect the ETV harness to the main wire
harness at the four-pin connector.
6. Pressurize the low side and test for leaks.
7. If no leaks are found, evacuate the low side.
8. Install the evaporator access panels.
9. Open the refrigeration valves and place the
unit in operation.
Reassembly of Piston and Stepper Motor
Use the following procedure to reassemble the
piston and stepper motor if the piston has
accidentally been turned off of the threaded shaft
of the stepper motor.
1. Disassemble the stepper motor and piston
assembly by unscrewing the stepper motor
(small hex) from the piston nut (large nut).
1
2
3
4
5
6
0.3 in.
(8 mm)
1
2
1.
Piston
2.
Rectangular Shaft on Piston
3.
Piston Nut
4.
Copper Washer
1.
Bottom Edge of Brass Nut
5.
Threaded Shaft of Stepper Motor
2.
Bottom Edge of Piston
6.
Stepper Motor
Figure 158: Stepper Motor and Piston Assembly
with Piston in Fully Open Position
Figure 159: Stepper Motor and
Piston Assembly Components
139
Refrigeration Service Operations
2. Insert the piston into the piston nut. You must
align the rectangular shaft on the piston with
the rectangular hole in the piston nut to allow
the piston to be inserted into the piston nut.
7. Continue to turn the piston and piston nut onto
the stepper motor until they are tight. Torque
the piston nut and stepper motor to 37 ft-lb (50
N•m).
Installation of Complete ETV Assembly
1
1.
Align Rectangular Shaft on Piston
with Rectangular Hole in Piston Nut
Figure 160: Insert Piston into Piston Nut
3. Push the piston into the piston nut until the
end of the rectangular shaft is about even with
the top of the piston nut.
1. Clean the tubes for soldering.
2. Place the new complete ETV assembly (and
any tubes that were removed) in the same
position from which the old one was removed.
The new ETV could interfere with other
components if it is not placed in the same
position as the old one. The ETV assembly
must be installed as shown below relative to
the direction of refrigerant flow from the
evaporator to the heat exchanger.
NOTE: Do not disassemble the new ETV to
solder it in place.
1
2
1
1.
Position End of Rectangular Shaft
about Even with Top of Piston Nut
Figure 161: Push Piston into Piston Nut
4. Make sure the copper washer is in place in the
top of the piston nut.
5. Place the threaded shaft of the stepper motor
into the rectangular shaft of the piston and
turn the piston and piston nut onto the
threaded shaft of the stepper motor.
6. When the threads in the top of piston nut reach
the threads on the bottom of the stepper motor,
carefully continue to turn the piston and piston
nut onto the stepper motor. Make sure that the
copper washer is in place and take care to
avoid cross threading the fine threads on the
stepper motor and in the top of the piston nut.
140
1.
Use Heat Sink
2.
Direction of Refrigerant Flow
Figure 162: Installing Complete ETV Assembly
3. Use a heat sink or wrap the valve body with a
wet rag to prevent damage and solder the
tubing connections with 95-5 soft solder.
4. Connect the ETV harness to the main wire
harness at the four-pin connector.
5. Pressurize the low side and test for leaks.
6. If no leaks are found, evacuate the low side.
7. Install the components that were removed to
access the ETV.
8. Open the refrigeration valves and place the
unit in operation.
Refrigeration Service Operations
Hot Gas Solenoid Valve
4. Remove the clamp and the compressor oil
filter.
Removal
5. Coat the new O-rings with clean compressor
oil and place them in the ORS fittings on the
ends of the new compressor oil filter.
1. Recover the refrigerant charge.
2. Disconnect the wires and remove the coil for
the valve.
3. Unsolder the lines and remove the valve.
Installation
1. Clean the tubes for soldering.
2. Remove the coil and place the valve in
position.
3. Solder the inlet and outlet connections. After
the valve cools, install the coil.
4. Pressurize the refrigeration system and test for
leaks.
6. Fasten the new compressor oil filter in place
with the clamp.
7. Attach and tighten the oil lines to the
compressor oil filter. Hold the oil filter with a
back-up wrench on the hex behind the ORS
fitting.
8. Evacuate the compressor and filter to a
maximum of 500 microns to remove trapped
air.
9. Open the service valves, operate the system,
and check the compressor oil filter for leaks.
5. If no leaks are found, evacuate the system.
6. Recharge the unit with proper refrigerant and
check the compressor oil.
Compressor Oil Filter
This unit is equipped with a compressor oil filter.
The compressor oil filter should be changed when
the drier is replaced.
The outlet fitting is larger than the inlet fitting, so
the compressor oil filter cannot be put on
backwards. There are two fittings on the inlet end
of the compressor oil filter. The inlet fitting
contains a check valve that prevents reverse flow
through the compressor oil filter. The capped
fitting is called the oil pressure access port and is
used to check the compressor oil pressure (see
“Checking Compressor Oil Pressure”).
1
3
Use the following procedure to change the
compressor oil filter.
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Front seat the discharge and suction service
valves. Recover the remaining refrigerant
from the compressor.
3. Disconnect the oil lines from the compressor
oil filter. Hold the oil filter with back-up
wrench on the hex behind the ORS fitting.
2
AEA718
1.
Oil Pressure Access Port
2.
Inlet Fitting
3.
Outlet Fitting
Figure 163: Compressor Oil Filter
141
Refrigeration Service Operations
Checking Compressor Oil
Pressure
1. Attach a suitable oil pressure gauge to the oil
pressure access port on the compressor oil
filter.
The oil pressure at the oil pressure access port
varies with the suction pressure in the compressor.
Therefore, we need to calculate the “net oil
pressure” to determine the actual compressor oil
pressure. The net oil pressure is the pressure at the
oil pressure access port minus the suction pressure
below the throttling valve. Use the following
procedure to check the compressor oil pressure.
2. Attach the low pressure gauge of a gauge
manifold to the fitting on the side of the
throttling valve (or suction valve adapter).
This fitting allows you to monitor the suction
pressure in the compressor below the
throttling valve.
1. Attach a suitable oil pressure gauge to the oil
pressure access port on the compressor oil
filter.
4. Disconnect the wires to the high speed
solenoid.
2. Attach the low pressure gauge of a gauge
manifold to the fitting on the side of the
throttling valve (or suction valve adapter).
This fitting allows you to monitor the suction
pressure in the compressor below the
throttling valve.
3. Start the unit and note the pressure at the oil
pressure access port and the suction pressure
below the throttling valve.
4. Subtract the suction pressure below the
throttling valve from the pressure at the oil
pressure access port to get the net oil pressure.
Pressure at Oil Pressure Access Port
– Suction Pressure Below Throttling Valve
= Net Oil Pressure
5. The net oil pressure should be at least 20 psi
(138 kPa). If the net oil pressure is low, first
check the compressor oil level, then check the
compressor oil pump and relief valve.
Priming New Compressor
Installations
Thermo King remanufactured compressors have
had a special break in process to assure that the oil
pump is primed, functioning, and broken in. The
following procedure is recommended, but not
required for factory-remanufactured compressors.
This procedure must be followed to prevent
premature pump failure in any compressor that
has had an oil pump installed, especially a
compressor that has been stored for any length of
time.
142
3. Disconnect the wires to the fuel solenoid.
NOTE: The microprocessor will probably
record some alarm codes because the
solenoids are disconnected and the engine
does not start. Clear these alarm codes as
necessary.
5. Turn the unit on and let the engine crank (or
crank the engine) for 30 seconds, but do not
crank the engine for more than 30 seconds.
a. Note the pressure at the oil pressure access
port and the suction pressure below the
throttling valve while the engine is
cranking. Subtract the suction pressure
below the throttling valve from the
pressure at the oil pressure access port to
get the net oil pressure.
b. If the compressor does not develop at least
10 psi (96 kPa) of net oil pressure in the
first 30 seconds, allow the starter to cool
for a few minutes and the crank the engine
again for 30 seconds. If 10 psi (96 kPa) of
net oil pressure still does not develop, first
check the compressor oil level, then check
the compressor oil pump and relief valve.
6. As soon as the compressor develops 10 psi
(96 kPa) of net oil pressure, re-connected the
fuel solenoid wires, but do not re-connect the
high speed solenoid wires.
7. Start unit and run the engine on low speed for
at least five minutes. If the net oil pressure is
above 20 psi (138 kPa) for this period, stop the
unit and re-connect the high speed solenoid
wires.
Refrigeration Service Operations
8. Run the engine on high speed for at least five
more minutes. The compressor oil pump is
now primed and broken in.
143
Refrigeration Service Operations
144
Structural Maintenance
Unit and Engine Mounting Bolts
Check and tighten all unit and engine mounting
bolts during scheduled maintenance inspections.
Torque the unit mounting bolts to 60 ft-lb
(81 N•m). Torque the engine mounting bolts to
150 ft-lb (203 N•m).
Unit Inspection
Inspect the unit during pretrip inspection and
scheduled maintenance inspections for loose or
broken wires or hardware, compressor oil leaks,
or other physical damage which might affect unit
performance and require repair or replacement of
parts.
Condenser, Evaporator, and
Radiator Coils
Clean the coils during scheduled maintenance
inspections. Remove any debris (e.g., leaves or
plastic wrap) that reduces the air flow. Clean dirty
coils with compressed air or a pressure washer. Be
careful not to bend the fins when cleaning a coil.
If possible, blow the air or water through the coil
in the direction opposite the normal airflow.
Repair bent fins and any other noticeable damage.
1
Defrost Drains
Clean the defrost drains during scheduled
maintenance inspections to be sure the lines
remain open.
Unit Installation
All nuts that hold the unit to the container are
accessible using an impact wrench with a 10 in.
extension, ball-type swivel and a deep-well
socket.
1.
Check Bolts for Tightness
Figure 164: Unit and Engine Mounting Bolts
NOTE: The nuts for mounting the unit should
be elastic stop nuts (Nylock type).
145
Structural Maintenance
Defrost Damper
4. If necessary, adjust Distance A to the proper
dimension by loosening the locknut on the end
of the solenoid plunger and turning the eye
bolt. Tighten the locknut when Distance A is
correct.
Check the damper during scheduled maintenance
inspections for shaft wear, end play, and the
ability to stop the air flow.
Position the damper so that air flow is stopped on
the top and bottom edges with the solenoid
plunger bottomed out.
5. Connect the damper link to the eye bolt.
6. Energize the solenoid (apply 12 volts dc) and
check the damper blade to make sure that both
edges contact the damper housing. If
necessary, adjust this by loosening the
solenoid mounting bolts and moving the
solenoid. Tighten the solenoid mounting bolts
when both edges of the damper blade contact
the damper housing.
To adjust the damper:
1. Remove the damper assembly from the
evaporator.
2. Disconnect the damper link from the eye bolt.
3. Check Distance A, the distance from the
shoulder on the solenoid to the center of the
hole in the eye bolt. Distance A should be
2.75 in. (69.85 mm) with the solenoid
de-energized.
7. Adjust the damper blade stops so they contact
the edges of the damper blade. This keeps the
damper from sticking closed.
2
1
3
6
5
4
7
9
AEA719
8
1
1.
Stop
6.
Eye Bolt
2.
Mounting Bolts
7.
Round Stop
3.
Closed Position
8.
Distance A 2.75 in. (69.85 mm)
4.
Open Position
9.
Solenoid
5.
Damper Link
Figure 165: Defrost Damper Adjustment
146
Structural Maintenance
8. De-energize and energize the damper several
times to make sure that the damper operates
correctly and seals properly.
9. Make sure the damper blade rests on the round
stops when the damper is open. Adjust the
round stops if necessary.
10. Install the damper assembly in the evaporator.
Condenser and Evaporator Fan
Location
When mounting the condenser or evaporator fan
and hub assembly on the fanshaft, the blowers and
inlet orifices must be properly aligned for proper
air flow and to prevent damage to the blower.
Condenser Fan Blower Alignment
1. Loosen the condenser inlet ring (spinning) on
the condenser coil bulkhead.
2. Slide the blower towards the inlet ring until it
contacts the inlet ring. This centers the inlet
ring in the blower orifice.
3. Tighten the inlet ring securely.
4. Slide the blower away from the inlet ring.
1
5. Pass a gauge wire completely around the
blower orifice to check for uniform clearance.
6. Spin the blower by hand to check for blower
distortion.
7. Position the blower so the edge of the inlet
ring lines up with the alignment mark on the
blower.
8. Torque blower hub bolts to 18 ft-lb (24 N•m).
Evaporator Fan Blower Alignment
1. Loosen the inlet rings on the sides of the
blower housing.
2. Center the blower wheel in the blower housing
with equal overlap on both inlet rings. The
overlap on each ring should be approximately
0.15 in. (3.8 mm).
3. Tighten the hub bolts that hold the blower
wheel on the fanshaft.
4. Center the inlet rings in the blower orifices.
Tighten the inlet rings securely.
5. Check the radial clearance by passing a wire
completely around the circumference of the
inlet rings and the blower wheel.
6. Torque the blower hub bolts to 18 ft-lb
(24 N•m).
2
3
4
AEA720
AEA749
1.
Blower Wheel
3.
Alignment Mark
2.
Inlet Ring
4.
Edge of Inlet Ring
Figure 166: Condenser Blower Alignment
1.
Check Clearance with a Wire
2.
Blower Housing Sides
3.
Inlet Rings
4.
Evaporator Blower
5.
Radial Clearance
6.
Equalize Blower Inlet Overlap
Figure 167: Evaporator Fan Location
147
Structural Maintenance
Fan Shaft Assembly
2. After draining the oil from the housing,
remove the four retaining bolts from the
condenser end of the assembly.
The unit is equipped with a one-piece fan shaft
assembly that contains tapered roller bearings in a
sealed oil reservoir.
3. To remove the shaft from the assembly, tap the
opposite end of the shaft with a soft hammer.
After the shaft has been removed, clean all
parts in clean solvent.
This assembly does not require any maintenance.
There is a level plug and a fill plug, but they are
not normally used except after removal and repair
of the fan shaft assembly. The condenser and
evaporator end oil seals should be checked during
the pretrip inspection for oil leakage. If there is
any sign of leakage, the fan shaft assembly should
be removed and repaired.
4. Using a punch, remove the oil seal from the
evaporator end of the assembly. With the seal
removed, clean the housing in clean solvent.
5. Check the condition of the vent. If it is loose
or damaged, it must be repaired or replaced.
NOTE: The fan shaft assembly requires a
special lubricant, Thermo King P/N 203-278.
6. After all the parts are cleaned, inspect the
bearings and bearing races for wear or
damage.
Fan Shaft Assembly Overhaul
7. If necessary, remove the bearings by tapping
them off the shaft with a hammer and a punch.
Be careful not to damage the shaft with the
punch.
Disassembly
1. Remove the fan shaft assembly from the unit.
Remove both oil plugs and drain the oil from
the housing.
8. The bearing races can now be driven out with
a punch and replaced in the same manner.
AEA721
1.
Cap and Shims
6.
Oil Seal
2.
Oil Plug Screw (Use Oil P/N 203-278)
7.
Shaft
3.
Breather Vent
8.
Sleeve
4.
Housing
9.
Pin
5.
Roller Bearing
10.
O-ring
Figure 168: Fan Shaft Assembly
148
Structural Maintenance
Reassembly
Idler Assembly
1. Tap the new bearings on the shaft with a pipe.
The unit is equipped with a one-piece idler
assembly that contains tapered roller bearings in a
sealed oil reservoir. This assembly does not
require any maintenance. There is a level plug and
a fill plug, but they are not normally used except
after removal and repair of the idler assembly. The
roadside end oil seal and the curbside end oil seal
should be checked during the pretrip inspection
for oil leakage. If there is any sign of leakage, the
idler assembly should be removed and repaired.
2. Install new oil seals after replacing the bearing
races.
3. Replace the shaft in the housing. Install a new
seal in the retainer cap. Use the original shims
and replace the O-ring if needed.
4. Install the retainer cap assembly over the
shaft, then install the bolts.
5. Torque the bolts in a criss-cross pattern in
equal steps to 80 in-lb (9.04 N•m).
6. Lock the assembly in a vise and set up a dial
indicator to read end-play. To measure the
end-play, rotate the shaft while pushing in one
direction and set the dial indicator to ‘0’. Now
rotate the shaft and pull in the opposite
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025
to 0.127 mm). If end-play is incorrect, use
different shims to obtain correct end-play.
Shims available from the Service Parts
Department
0.020 in. (0.500 mm) Thermo King P/N 99-4231
0.007 in. (0.177 mm) Thermo King P/N 99-2902
0.005 in. (0.127 mm) Thermo King P/N 99-2901
7. After correct end-play is obtained, add oil for
the bearings.
8. Lock the assembly in a vise with the vent
facing up. Pour the oil (P/N 203-278) through
the top plug until it runs out of the side hole.
The assembly holds approximately 2.5 oz
(74 ml). Check the condition of the O-ring
used on the plugs and replace if necessary.
Install the top and side plugs. Clean up any
spillage.
9. Place the assembly on the workbench with the
vent up. Rotate the shaft by hand. The shaft
should be free enough to rotate without having
to hold the housing.
CAUTION: When installing the fan shaft
assembly, make sure that the vent is
mounted facing up.
Idler Assembly Overhaul
Disassembly
1. Remove the idler assembly from the unit.
Remove both oil plugs and drain the oil from
the housing.
2. After draining the oil from the housing,
remove the four retaining bolts from the
curbside end of the assembly.
3. To remove the shaft from the assembly, tap
the opposite end of the shaft with a soft
hammer. After the shaft has been removed,
clean all the parts in clean solvent.
4. Using a punch, remove the oil seal from the
curbside end of the assembly. With the seal
removed, clean the housing in solvent.
5. Check the condition of the vent. If it is loose
or damaged, it must be repaired or replaced.
6. After all the parts are cleaned, inspect the
bearings and bearing races for wear or
damage.
7. To replace the bearings, first drive bearing off
shaft with a punch at notch in the base of the
shaft.
Reassembly
1. Install the new bearings on the shaft with a
pipe. Place the pipe over the shaft and drive
bearing down. Turn the shaft upside down,
and use the pipe to drive the other bearing
down.
2. Install a new oil seal on the curbside end of
the assembly after replacing the bearing race
and splash guard.
149
Structural Maintenance
3. Replace the shaft in the housing. Install a new
seal in the retainer cap. Use the original shims
and replace the O-ring if needed.
7. After the correct end-play is obtained, add
approximately 1.1 oz (33 ml) of oil
(P/N 203-278) for the bearings.
4. Install the retainer cap assembly over the
shaft, then install the bolts.
8. Lock the assembly in a vise with the vent
facing up. Pour the oil through the top plug
until it runs out of the side hole. Check the
condition of the O-ring used on the plugs and
replace if necessary. Install the top and side
plugs. Clean up any spillage.
5. Torque the bolts in a criss-cross pattern in
equal steps to 80 in-lb (9.04 N•m).
6. Lock the assembly in a vise and set up a dial
indicator to read end-play. To measure the
end-play, rotate the shaft while pushing in one
direction, and set the dial indicator to ‘0’.
Now rotate the shaft and pull in the opposite
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025
to 0.127 mm). If end-play is incorrect, use
different shims to obtain correct end-play.
9. Place the assembly on the workbench with the
vent up. Rotate the shaft by hand. The shaft
should be free enough to rotate without having
to hold the housing.
CAUTION: Reinstall the assembly into
the unit, making sure the vent is mounted
facing up.
Shims available from the Service Parts
Department
0.020 in. (0.500 mm) Thermo King P/N 99-4231
0.007 in. (0.177 mm) Thermo King P/N 99-2902
0.005 in. (0.127 mm) Thermo King P/N 99-2901
AEA722
1.
Oil Seal
6.
Shaft
2.
Cap and Shims
7.
Housing
3.
O-ring
8.
Breather Vent
4.
Roller Bearing
9.
Oil Plug Screw (Use Oil P/N 203-278)
5.
Splash Guard Tube
Figure 169: Idler Assembly
150
Mechanical Diagnosis
Condition
Possible Cause
Remedy
Engine will not crank
Electrical problem
Check and repair electrical system
Defective starter solenoid
Replace solenoid
Defective starter
Repair starter
Water in cylinders
Check for hydrostatic lock. Remove
injectors and turn engine slowly
Starter motor turns but engine
does not crank
Starter clutch defective
Replace
Engine cranks but fails to start
Fuel solenoid not energized
Check 8D and 8DP and CH circuits
and fuel solenoid pull-in relay.
Check that controller is configured
for Yanmar engine. Refer to
appropriate Microprocessor
Diagnostic Manual.
Fuel solenoid defective or stuck
Replace
Fuel injection pump defective
Replace pump
Air heater defective
Replace
No fuel or wrong fuel
Fill with proper fuel
Fuel transfer pump defective
Replace transfer pump
Air in fuel system
Bleed air
Compression low
Overhaul engine
Injection nozzles defective
Replace nozzles
Incorrect timing
Adjust timing
Air cleaner clogged
Replace air filter
Exhaust plugged
Clean exhaust
Air in injection pump
Bleed fuel system
Fuel filter obstructed
Replace filter element
High head pressure
Eliminate cause of high head
pressure
Vent of fuel tank obstructed
Unclog vent
Clogged fuel tank or fuel lines
Clean fuel tank and fuel lines
Engine stops after starting
151
Mechanical Diagnosis
Condition
Possible Cause
Remedy
Engine does not develop full
power
Air intake system clogged
Clean air intake system
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 filter
Check for dirty filter or air in system
Air cleaner clogged
Replace air filter
Delivery of fuel pump insufficient
Repair pump
Injection pump timing off
Adjusting timing
Injection nozzles defective
Repair or replace nozzles
Compression low or unbalanced
Overhaul engine
Worn injection pump plungers,
delivery valve defective, injection
rate too low, gum formations
Repair or replace pump
Misadjusted high speed solenoid
Adjust high speed solenoid
Defective injection pump
Repair injection pump
Engine fails to stop when unit is
OFF
Fuel solenoid defective
Replace
Injection pump defective
Replace pump
Engine knocks heavily
Air in system
Bleed fuel system
Injection pump not timed
Retime injection pump
Wrong fuel
Change fuel
Compression too low
Overhaul engine
Injection nozzles fouled or opening
pressure too low
Clean, repair or replace injection
nozzles
Delivery valve spring broken
Replace spring or repair injection
pump
Valve out of adjustment
Adjust valves
Fuel return line plugged
Remove return line restriction
Rod or main bearing worn
Replace rod or main bearings
Engine speed too high
152
Mechanical Diagnosis
Condition
Possible Cause
Remedy
Engine runs hot
Dirty radiator
Wash radiator
Coolant level is low
Add coolant
Cooling system heavily scaled
Cleaning cooling system
Cylinder head gasket leaks
Replace cylinder head gasket. Use
correct gasket
Faulty thermostat
Check or replace thermostat
Loose or worn water pump belt
Replace belt
Insufficient oil in pan
Add oil
Faulty oil pressure switch
Check oil pressure switch. Replace
if necessary
Oil control valve defective
Check oil pressure control valve
Worn oil pump, camshaft, main or
connecting rod bearings, loose oil
gallery plug
Repair engine
Oil leakage
Check and eliminate possible
causes at rocker arm cover, oil lines,
oil filter, front timing cover or
crankshaft seals
Damaged valve seals
Replace seals on valve stem
Worn valve stem
Replace valves
Broken piston rings or cylinder bore
worn or scored
Have engine repaired and rebored.
Replace broken piston rings
Clogged air cleaner system
Unclog air cleaner
Oil pressure low
High oil consumption
153
Mechanical Diagnosis
Engine Emits Excessive Smoke
White Smoke
Black Smoke
Blue Smoke
Fuel is not burning
Excessive Fuel to Air Ratio
Oil Consumption
• Air or water in fuel
• Type of fuel used
• Poor compression
• Incorrect timing
• Cold engine
• Defective valve seals
• Poor compression
• Excessive load
• Faulty injectors
• Clogged air intake system
• Faulty nozzles
• Poor compression
• Restricted exhaust
• Faulty injection pump
154
•
•
•
•
•
•
•
•
•
•
•
• Shortage of refrigerant
•
• No refrigerant
Air through condenser too hot (ambient)
Air flow through condenser restricted
•
•
•
Air through condenser too cold (ambient)
•
•
•
•
Air in refrigerant system
Condenser fan blades bent or broken
Air short cycling around evaporator coil
•
•
Air through evaporator restricted
•
•
•
•
•
Evaporator needs defrosting
•
•
Compressor discharge valves leaking
Compressor suction valves leaking
•
•
•
•
•
•
Faulty oil pump in compressor
•
Faulty compressor drive coupling
•
•
Compressor bearing loose or burned out
Broken valve plate in compressor
•
•
•
•
•
•
•
•
Expansion valve feeler bulb making poor contact
Expansion valve open too much
•
Expansion valve closed too much
•
•
Expansion valve needle eroded or leaking
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Expansion valve partially closed by ice, dirt or wax
Liquid refrigerant entering compressor
Restricted line on the low side
•
•
Expansion valve power element lost its charge
Expansion valve feeler bulb improperly mounted
•
•
Too much compressor oil in system
•
•
•
•
Possible Causes
Overcharge of refrigerant
•
•
•
•
•
Symptom
Rapid cycling between cool and heat
Unit cools in heat and defrost cycle
Unit heats in refrigeration cycle
High head pressure
Low head pressure
High suction pressure
Low suction pressure
No suction pressure
Unit operating in a vacuum
Receiver sight glass empty
Suction line frosting back
Unable to pump down system
Unable to pull vacuum in low side
Unable to hold vacuum in low side
Noisy compressor
Unit not refrigerating
Unit not heating or defrosting
Refrigeration Diagnosis
Restricted line on the high side
Restricted drier
• Defrost damper stays open
Defrost damper stuck closed
Suction service valve back seated
•
•
•
•
•
• Faulty three-way valve
• Faulty pilot solenoid
155
•
•
•
156
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Symptom
Rapid cycling between cool and heat
Unit cools in heat and defrost cycle
Unit heats in refrigeration cycle
High head pressure
Low head pressure
High suction pressure
Low suction pressure
No suction pressure
Unit operating in a vacuum
Receiver sight glass empty
Suction line frosting back
Unable to pump down system
Unable to pull vacuum in low side
Unable to hold vacuum in low side
Noisy compressor
Unit not refrigerating
Unit not heating or defrosting
Refrigeration Diagnosis
Possible Causes
• Loose or broken electrical connections
Sensor out of calibration
Compound pressure gauge out of calibration
Leaky receiver tank outlet valve
Leaky bypass check valve
• Leaky condenser check valve
• Faulty three-way condenser pressure bypass check valve
•
• Faulty ETV
•
• Hot gas bypass valve stuck open or leaking
Refrigeration Diagrams
Cool Cycle
1.
Compressor
2.
Discharge Service Valve
3.
Discharge Vibrasorber
4.
Discharge Line
5.
Three-way Valve
6.
Three-way Valve Bypass
Check Valve
7.
Condenser Coil
8.
Condenser Check Valve
9.
High Pressure Relief Valve
10.
Receiver Tank
11.
Sight Glass
12.
Receiver Outlet Valve
13.
Liquid Line
14.
Drier
15.
Heat Exchanger
16.
Expansion Valve
17.
Feeler Bulb
18.
Equalizer Line
19.
Distributor
20.
Evaporator Coil
21.
Suction Line
22.
Accumulator
23.
Suction Vibrasorber
24.
Suction Service Valve
25.
Hot Gas Bypass Valve
26.
Pilot Solenoid
27.
Hot Gas Line
28.
Defrost Pan Heater
29.
Bypass Check Valve
30.
Bypass Service Valve
31.
Electronic Throttling Valve
32.
Suction Transducer
33.
Discharge Transducer
ARA161
AEA724
157
Refrigeration Diagrams
Heat/Defrost Cycle
1.
Compressor
2.
Discharge Service Valve
3.
Discharge Vibrasorber
4.
Discharge Line
5.
Three-way Valve
6.
Three-way Valve Bypass
Check Valve
7.
Condenser Coil
8.
Condenser Check Valve
9.
High Pressure Relief Valve
10.
Receiver Tank
11.
Sight Glass
12.
Receiver Outlet Valve
13.
Liquid Line
14.
Drier
15.
Heat Exchanger
16.
Expansion Valve
17.
Feeler Bulb
18.
Equalizer Line
19.
Distributor
20.
Evaporator Coil
21.
Suction Line
22.
Accumulator
23.
Suction Vibrasorber
24.
Suction Service Valve
25.
Hot Gas Bypass Valve
26.
Pilot Solenoid
27.
Hot Gas Line
28.
Defrost Pan Heater
29.
Bypass Check Valve
30.
Bypass Service Valve
31.
Electronic Throttling Valve
32.
Suction Transducer
33.
Discharge Transducer
158
ARA162
aea725
Index
A
accumulator, replacement 132
adjust brightness menu 63
air cleaner, EMI 3000 114
air heater 78
air restriction indicator 28, 115
alarms menu 50
alternator 73
field current test 76
general diagnostic and warranty evaluation
procedure 74
identification 73
load test 74
antifreeze
changing 89
checking 89
maintenance procedure 88
B
battery 76
battery cables 76
belt adjustments 116
alternator belt 116
upper and lower fan belts 116
belt replacement
lower fan belt 117
upper fan belt 117
belt tension, specifications 18
belts 115
bypass check valve, replacement 129
C
charging system diagnostic procedures 73
cold start device 109
compressor
priming new compressor installations 142
compressor coupling
installation 126
removal 125
compressor oil
checking 121
compressor oil filter, replacement 141
compressor oil pressure, checking 142
compressor oil sight glass 28
compressor, replacement 125
condenser check valve, replacement 128
condenser coil, replacement 127
continuous mode
selecting 42
control panel 33
display 34
keys 34
coolant level switch 29, 90
checking the float 91
replacing 91
testing 90
cooling system, engine 87
bleeding air from 89
crankcase breather 113
CYCLE-SENTRY
selecting 42
CYCLE-SENTRY Operation 25
CYCLE-SENTRY Start-Stop Controls 25
D
data logging 25, 30
datalogger menu 52
defrost 26, 30
defrost damper, adjustment 146
defrost drains 145
Defrost key 34
diagnosis, mechanical 151
diagnosis, refrigeration 155
diagrams
fuel line routing 163
refrigeration 157
wiring 163
discharge pressure transducer, replacement 137
discharge vibrasorber, replacement 128
E
ELC (Extended Life Coolant) 87
electric fuel heater 80
electrical components, specifications 19
electrical control system, specifications 19
electronic throttling valve (ETV) 24, 30, 123
replacement 138
EMI 3000 85
engine compartment components 28
engine coolant temperature sensor 29
engine speed adjustments 100
high speed 100
low speed 100
engine, specifications 17
evaporator coil, replacement 131
expansion valve assembly, replacement 130
F
fan alignment
condenser blower 147
evaporator blower 147
fan shaft assembly 148
overhaul 148
filter drier, replacement 129
first aid 16
engine coolant 16
refrigerant 16
refrigerant oil 16
FreshSet 26
front doors
closing 27
opening 27
fuel filter/water separator 97
draining water 97
filter element replacement 98
troubleshooting 99
159
Index
fuel level sensor 79
fuel line routing 95
fuel return line replacement 95
fuel solenoid 106
replacement 107
testing 106
fuel system 93
bleeding 96
maintenance 95
fuel tank, draining water from 97
fuse link 29, 78
fuses 29, 76
G
mode menu 55
moisture indicating sight glass 120
mounting bolts, unit and engine 145
O
Off key 34
oil change, engine 85
oil collection container 121
oil filter change, engine 85
On key 34
operating modes 26
operator menu
navigating 47
OptiSet Plus 26, 65
gauge readings, viewing 44
P
H
heat exchanger, replacement 130
high pressure cutout switch (HPCO) 29, 122
replacement 137
high pressure relief valve 29
HMI control panel 33
hot gas solenoid valve 124
hot gas solenoid valve, replacement 141
hourmeters menu 54
I
idler assembly 149
overhaul 149
injection pump
reinstallation 104
removal 104
timing 101
in-line condenser check valve 128
inspection, unit 145
installation, unit 145
interface board LEDs 77
K
keypad lockout 55
selecting 57
L
language menu 48
leaks, refrigerant 120
loading procedure 72
low oil level switch 29
low oil pressure 85
low oil pressure switch 29
lubrication system, engine 85
M
main menu
choices 47
maintenance inspection schedule 21
manual defrost cycle, initiating 43
manual pretrip inspection 35
microprocessor On/Off switch 33
Mode key 34
160
pilot solenoid, replacement 136
post trip checks 72
preheat buzzer 29
pretrip tests 60
priming new compressor installations 142
protection devices 28
R
receiver tank sight glass 28
receiver tank, replacement 129
refrigerant charge
testing for an overcharge 119
testing with a loaded container 119
testing with an empty container 119
refrigerant leaks 120
refrigeration system, specifications 18
routing
fuel line 95
wire harness 79
S
safety precautions 13
battery removal 14
electrical hazards 15
general practices 13
microprocessor service precautions 15
refrigerant hazards 14
refrigerant oil hazards 14
welding precautions 15
selection of operating modes 41
sensor readings, viewing 45
serial number locations 30
setpoint, changing 40
sight glass, moisture indicating 120
sleep mode 55
sleep mode, selecting 58
Smart FETs 29, 78
SMART REEFER 2 (SR-2) Control System 33
soft keys 34
specifications
electric fuel heater 19
SR-2 Control System 33
standard display 37
Index
start of trip, initiating 52
suction pressure transducer, replacement 137
suction vibrasorber, replacement 136
T
temperature watch display 38
thermostat, engine 90
three-way valve condenser pressure bypass check
valve 122
three-way valve condenser pressure bypass check
valve, repair 135
three-way valve, repair 132
time display 64
transducers, pressure 124
trip report, printing 53
trochoid feed pump 108
U
unit description 23
unit wiring 78
V
valve clearance adjustment, engine 111
W
wire harness routing 79
X
X430L compressor 24
161
Index
162
Diagram Index
Drawing No.
Drawing Title
Page
1E63906
Schematic Diagram
165-167
1E63905
Wiring Diagram
168-171
Fuel Line Routing Diagram
172-175
163
Diagram Index
164
Schematic Diagram - Page 1 of 3
165
Schematic Diagram - Page 2 of 3
166
Schematic Diagram - Page 3 of 3
167
Wiring Diagram - Page 1 of 4
168
Wiring Diagram - Page 2 of 4
169
Wiring Diagram - Page 3 of 4
170
Wiring Diagram - Page 4 of 4
171
Fuel Line Routing Diagram - Page 1 of 4
1.
Screw 1/4-20 X 0.75 in. 55-145
2.
Flatwasher 1/4 in. (2) 55-411
3.
Nylock Nut 1/4 in. 55-4118
4.
Clamp 5/8 in. Diameter 55-3026
5.
Band Wrap 1.75 Diameter (2) 56-2330
FUEL LINE ROUTING DIAGRAM
1E63248MAP1
172
SHEET 1 OF 4
Fuel Line Routing Diagram - Page 2 of 4
1.
Grommet 33-316
2.
Flatwasher M8 55-7069
3.
Lockwasher M8 55-7727
4.
Screw M8 X 110 55-5424
5.
Clamp 1.0 in. Diameter 55-3644
6.
Band Wrap 1.75 Diameter (3) 56-2330
7.
Clamp 5/8 in. Diameter 55-3026
8.
Screw 1/4-20 X 0.75 in. 55-145
9.
Flatwasher 1/4 in. 55-411
10.
Lockwasher 1/4 in. 55-366
11.
Clamp 5/8 in. Diameter 55-4203
FUEL LINE ROUTING DIAGRAM
1E63248MAP2
173
SHEET 2 OF 4
Fuel Line Routing Diagram - Page 3 of 4
1.
3/8 in. Line from Fuel Filter Outlet to Transfer Pump Inlet
8.
Nylock Nut 5/16 in. 55-4967
2.
3/8 in. Line from Transfer Pump Outlet to Pro Check Inlet
9.
Flatwasher 3/8 in. 55-402
3.
1/4 in. Line from Injector Pump Outlet to Pro Check “T”
10.
Nylock Nut 3/8 in. 55-5078
4.
1/4 in. Line from Pro Check Outlet to Injector Pump Inlet
11.
Filter Bracket Assembly
5.
3/8 in. Inlet Line from Fuel Tank
12.
Fuel Filter-Heater Assembly
6.
Pro Check (Air/Fuel Separator)
13.
1/4 in. Return Line to Fuel Tank
7.
Flatwasher 5/16 in. 55-371
14.
Band Wrap 1.75 Diameter 56-2330
174
FUEL LINE ROUTING DIAGRAM
1E63248MAP3
SHEET 3 OF 4
Fuel Line Routing Diagram - Page 4 of 4
1.
Screw 1/4-20 X 0.75 in. 55-145
2.
Flatwasher 1/4 in. 55-411
3.
Nylock Nut 1/4 in. 55-4118
4.
3/8 in. Inlet Line from Fuel Tank
5.
Band Wrap 1.75 Diameter (5) 56-2330
6.
1/4 in. Return Line to Fuel Tank
7.
Clamp 5/8 in. Diameter 55-3026
8.
Cap for 1/4 in. Fuel Line
9.
Cap for 3/8 in. Fuel Line
FUEL LINE ROUTING DIAGRAM
1E63248MAP4
175
SHEET 4 OF 4
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