Carrier MCI J4500 COACH Operation & Service Manual Download

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T-312 Rev-

Carrier

Transicold

Transport

Air Conditioning

Operation

& Service

68G5-105 SERIES

MCI J4500 COACH

Summary of Contents for MCI J4500 COACH

Page 1: ...T 312 Rev Carrier Transicold Transport Air Conditioning Operation Service 68G5 105 SERIES MCI J4500 COACH...

Page 2: ...PMENT Carrier Transport Refrigeration and Air Conditioning A member of the United Technologies Corporation family Stock symbol UTX Carrier Transicold Carrier Corporation P O Box 4805 Syracuse N Y 1322...

Page 3: ...f and power supply is disconnected Always work in pairs Never work on the equipment alone In case of severe vibration or unusual noise stop the unit and investigate MAINTENANCE PRECAUTIONS Beware of u...

Page 4: ...THE COMPRESSOR CRANKCASE OR THE RESULTANT PRESSURE WILL FORCIBLY DISCHARGE COMPRESSOR OIL WARNING WHEN MOVING THE COIL CARE MUST BE TAKEN TO AVOID PERSONAL INJURY BE CAUSE OF THE WEIGHT OF THE COIL C...

Page 5: ...OMATIC CONTROL DATA FLOW 1 14 OPERATION 2 1 2 1 STARTING STOPPING AND OPERATING INSTRUCTIONS 2 1 2 1 1 Operating Controls 2 1 2 1 2 HVAC Power to Controller 2 2 2 1 3 Starting 2 2 2 1 4 Activating Def...

Page 6: ...2 4 4 1 System Pumpdown 4 2 4 4 2 Removing the Refrigerant Charge 4 3 4 4 3 Refrigerant Removal From An Inoperative Compressor 4 3 4 4 4 Pump Down An Operable Compressor For Repair 4 3 4 5 REFRIGERAN...

Page 7: ...21 REMOVING THE CONDENSER ASSEMBLY 4 13 4 22 SERVICING THE CONDENSER COIL 4 13 4 23 SERVICING THE CONDENSER MOTOR 4 13 4 24 SERVICING THE DRIVER CONTROL BOX 4 13 4 25 SERVICING THE DRIVER EVAPORATOR...

Page 8: ...iver Control Box 4 13 5 1 Electrical Schematic Diagram Legend and Symbols 5 2 5 2 Electrical Schematic Diagram 5 3 5 3 Electrical Schematic Diagram 5 4 5 4 Electrical Schematic Diagram 5 5 LIST OF TAB...

Page 9: ...al cabling a parcel rack evaporator thermostat kit refrigerant piping engine coolant piping ductwork and other components furnished by the coach manufacturer to complete the system Table 1 1 Part Mode...

Page 10: ...o 2 CM1 and CM2 The control box also includes condenser speed relay no 1 CSR1 which controls the speed of both condenser fan motors CM1 and CM2 The main evaporator liquid line solenoid valve and the p...

Page 11: ...lve Charging Port 8 O Ring 9 Oil Drain Plug 10 Solenoid Unloader Electric Connectors 11 High Pressure Switch 12 Discharge Pressure Transducer 13 Capscrew 14 Lockwasher 15 Special Washer 16 Lock Nut 17...

Page 12: ...aporator heat valve EHV two fan and motor assemblies an air filter and two condensate drain connections The evaporator heat valve EHV for the driver evaporator is installed in the piping outside the e...

Page 13: ...ain Connections 14 Air Filter 15 Evaporator Coil Assembly 16 Heater Coil Assembly 2 11 14 9 13 4 16 15 12 10 8 7 6 5 3 1 13 Figure 1 4 Driver Evaporator Assembly 1 Suction Outlet Connection 2 Liquid I...

Page 14: ...ator Fan Relay High Speed EFRH 10 Evaporator Fan Relay Low Speed EFRL 11 Elastomeric Motor Mounts 12 2 Speed Motor 13 Blower Wheel Left 14 Blower Housing Left 15 Service Port 16 Coolant Drain valve 17...

Page 15: ...ecks of the program memory data memory and analog It has a self test feature which is executed when the system is first powered up The expansion board drives six discrete outputs in addition to the st...

Page 16: ...l In the vent mode the evaporator fans are operated to circulate air in the bus interior In the heat mode the heat valve and the OEM supplied floor blower and or boost pump are energized The evaporato...

Page 17: ...vaporator and Parcel Rack Evaporator Superheat Setting Nonadjustable 5 to 12_F 6 7 to 10 1_C MOP Setting None d High Pressure Switch HPS Opens at 385 10 psig 26 2 68 BAR Closes at 285 10 psig 19 39 68...

Page 18: ...1 3 d During the A C mode HVAC system operation will automatically stop if the HPS switch contacts open due to an unsafe operating condition Opening HPS contacts de energizes through the main controll...

Page 19: ...uired temperatures inside the coach Engine coolant glycol solution is circulated through the heating circuit by the engine and auxiliary water pumps When the evaporator heat valve solenoid is de energ...

Page 20: ...liquid line solenoid valve to the main evaporator and thermal expansion valve and to the parcel rack evaporator solenoid valve if this option is active the parcel rack thermal expansion valve and thr...

Page 21: ...ER EVAPORATOR ASSEMBLY DRIVER SOLENOID VALVE MAIN LIQUID LINE SOLENOID VALVE DISCHARGE LINE SERVICE VALVE DISCHARGE LINE SUCTION LINE CONDENSER SUBCOOLER SIGHT GLASS FUSIBLE PLUG SERVICE PORT SERVICE...

Page 22: ...main controller and the rest of the system The following block diagram Figure 1 13 indicates data flow through the system Refer to section 2 for more detailed information on the theory of operation of...

Page 23: ...the passenger area and cooling to the driver area The panel has 10 keys whose functions are described as follows 1 On Off Pressing this key will change the display state from inactive to active If the...

Page 24: ...aporators will function only after the main evaporator is operating Figure 2 3 Driver A C e The Driver A C Switch Figure 2 3 allows the driver to control cooling with the driver s evaporator When the...

Page 25: ...ey When showing parameters the display will first flash out the parameter identifier Pxx for one second and then show the parameter value To return to normal operation press the On Off key see Figure...

Page 26: ...he Driver s A C switch on the left side console is turned on when cooling is desired in the driver area The driver area conditions are controlled by manually adjusting the Defrost and Heat slide switc...

Page 27: ...when staging is required a Suction Pressure In addition to temperature control the electric unloaders will be used to prevent coil frosting Staging is ignored for energizing the unloader solenoid due...

Page 28: ...a 2 3 11 RAM Air Control The RAM air control regulates admission of outside air into the system a Display Override The RAM air can be automatically controlled or set to open or closed by the display b...

Page 29: ...f the display does not receive data from the microprocessor Er5 Data Memory If memory on the display is not verified on power up Er6 Program Memory If program memory on the display is not verified on...

Page 30: ...ransducer Failure Sensor is unplugged wiring defective or humidity transducer failure Ensure sensor is plugged in Check transducer voltage or wiring Replace sen sor or repair wiring Refer to section 4...

Page 31: ...been activated three times in 30 minutes it de en ergizes the clutch for the minimum off time and until the alarm is de ac tivated Energizes the second con denser fan at high speed De ener gizes the r...

Page 32: ...will display CL If it is open circuited it will display OP NOTE This value is not updated it is the value at the time that the code is accessed P6 Discharge Pressure This value is the discharge pressu...

Page 33: ...erant overcharge Noncondensable in system Condenser fan rotation incorrect Condenser coil dirty 4 4 4 8 Check Clean Low discharge pressure Compressor valve s worn or broken Low refrigerant charge See...

Page 34: ...Valve Malfunction Low suction pressure with high superheat Low refrigerant charge Wax oil or dirt plugging valve orifice Ice formation at valve seat Power assembly failure Loss of bulb charge Broken...

Page 35: ...D DISCHARGE SERVICE VALVES The suction and discharge service valves See Figure 4 1 used on the compressor are equipped with mating flanges for connection to flanges on the compressor These valves are...

Page 36: ...t To connect the manifold gauge hose set for reading pressures do the following 1 Remove service valve stem cap and check to make sure it is backseated Remove access valve cap 2 Connect the field serv...

Page 37: ...ible it will be necessary to recover refrigerant through the suction service valve port only c Service or replace components as required and leak check the compressor d Using refrigerant hoses designe...

Page 38: ...paragraph 4 5 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump with a minimum of 6 cfm 10 2 m3 hr volume displacement CTD P N 07 00176 11 and a good digital...

Page 39: ...E LINE SERVICE VALVE PARCEL RACK LIQUID LINE SOLENOID VALVE DISCHARGE LINE SUCTION LINE CONDENSER SUBCOOLER SIGHT GLASS FUSIBLE PLUG SERVICE PORT SERVICE PORT SERVICE PORT D S 1 Reclaimer 2 Manifold G...

Page 40: ...ge the system may be under charged 3 If the actual discharge pressure is in the discharge pressure range the system charge is adequate NOTE Many system related problems will effect system pressures Us...

Page 41: ...e Slowly open the regulator valve to increase the pressure until it reaches cutout point The switch should open which is indicated by an infinity reading on an ohmmeter no continuity f Close cylinder...

Page 42: ...ed clamp making sure both bulbs are firmly secured to suction line See Figure 4 7 Reinstall insulation around the bulb e Connect an accurate low pressure gauge or install a manifold gauge set to the s...

Page 43: ...n c Install compressor in unit by performing steps c through g in reverse sequence It is recommended that new locknuts be used when replacing compressor Install new gaskets on service valves and tight...

Page 44: ...hose at the oil pump Add oil as necessary NOTE Allow time at least 60 seconds for the oil to flow thru to the crankcase and show on the sightglass 4 12 5 2 Closed System Method a Install manifold gaug...

Page 45: ...inside the coach the third sensor is located in the condenser section The two inside sensors are wired in parallel and together send an averaged signal to the controller If one of these sensors fails...

Page 46: ...orator motor mounting plate motor and blower housing assembly to the bottom panel f Remove motor and blower wheel assembly by sliding out of evaporator housing g Repair or replace any defective compon...

Page 47: ...t refrigerant lines to the module f Remove the door latch stud to the right side of the condenser compartment g Remove the front panel and the eight screws fastening the condenser to the coach h Remov...

Page 48: ...center and turn right corner past edge b Slide left hand side filter to the right and repeat as above c Clean replace filter and re install 4 25 4 Removal of Evaporator Heater Coil Assembly a Clamp o...

Page 49: ...1 1 20 1 18 20 7 18 5 1 30 1 28 22 6 19 9 1 40 1 37 24 4 21 4 1 50 1 48 26 3 22 9 1 61 1 58 Temperature Pressure F C Psig Kg cm Bar 28 2 24 5 1 72 1 69 30 1 26 1 1 84 1 80 32 0 27 8 1 95 1 92 34 1 29...

Page 50: ...TRODUCTION This section contains Electrical Schematic Diagrams covering the Models listed in Table 1 1 Contact your Carrier Transicold service representative or call the technical hot line at 800 450...

Page 51: ...T 312 5 2 COACH INTERFACE CONNECTOR A THRU K 1 2 3 L THRU Y PACKARD CONNECTOR Figure 5 1 Electrical Schematic Diagram Legend and Symbols Based On Drawing No 62 10907 Rev...

Page 52: ...IVER EVAPORATOR CONDENSER NOTE In 2003 early production units were retrofitted with diodes If servicing a unit that is not wired as shown above the unit should be retrofitted Contact Carrier Service E...

Page 53: ...T 312 5 4 Figure 5 3 Electrical Schematic Diagram Sheet 2 of 2 Drawing No 62 10907 Rev...

Page 54: ...T 312 5 5 Figure 5 4 Electrical Schematic Diagram Contact vehicle manufacturer for a specific diagram...

Page 55: ...Flow 1 14 Evacuation And Dehydration 4 4 Evaporator Assemblies 1 4 Evaporator Coils 1 12 F Filter Drier 4 7 H Heating Flow Cycle 1 11 Humidity Control 2 5 Humidity Sensor 4 11 4 12 I Installing Manif...

Page 56: ...5 4 5 5 Servicing Motor Brushes 4 12 Suction and Discharge Service Valves 4 1 Superheat Check Measure 4 8 System Pumpdown 4 2 System Service 4 1 T Temperature Pressure Chart 4 15 Temperature Sensor 4...

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