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Carrier Transicold X4 7300, Operation & Service Manual

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Carrier Transicold X4 7300 Operation & Service Manual Download Page 9

vii

62-11637

00246

EEPROM WRITE FAILURE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–74

00248

CONFIG MODE / HP2 ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–75

00250

LOSS OF COMMUNICATION WITH ALL MODULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–75

00251

LOSS OF COMMUNICATION WITH INPUT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–75

00252

LOSS OF COMMUNICATION WITH OUTPUT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–75

00253

LOSS OF COMMUNICATION WITH SUCTION MODULATION VALVE MODULE (SVM)       7–75

00254

LOSS OF COMMUNICATION WITH DISPLAY MODULE  . . . . . . . . . . . . . . . . . . . . . . . . .      7–76

00255

MICROPROCESSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–76

02000

UPDATE SOFTWARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–76

03001

ENGINE LOAD CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–77

05012

CHECK ENCU POWER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–78

05013

CHECK CLUTCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–79

05014

CHECK STARTER SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–80

05016

CHECK REMOTE AMBER LIGHT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–80

05017

CHECK GLOW PLUG RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–81

20100

NO COMM FROM MICRO TO DISPLAY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–82

21100

NO COMM FROM ANY BOARD TO MAIN MICRO  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–83

22100

NO COMM FROM MICRO TO INPBD1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–83

22101

SENSOR INPUT VOLTAGE LOW INP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–84

22102

SENSOR INPUT VOLTAGE HIGH INP1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–85

23100

NO COMM FROM MICRO TO OUTPBD1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–85

25100

NO COMM FROM MICRO TO STP1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–86

26100

NO COMM FROM MICRO TO ENCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      7–87

SERVICE    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–1

8.1

SECTION LAYOUT     . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–1

8.2

SCHEDULED MAINTENANCE     . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–1

8.3

PRE-TRIP INSPECTION    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–2

8.4

EXTERNAL SURFACE SERVICE    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–4

8.4.1

AutoFresh Fresh Air Exchange    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–4

8.4.2

Grille Insert Removal    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–4

8.4.3

Surround Removal    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–5

8.4.4

Door Latch Maintenance and Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–5

8.4.5

Display Module     . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–5

8.5

ENGINE AND ENGINE RELATED SYSTEMS SERVICE    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–6

8.5.1

Fuel System    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–6

8.5.2

Priming the Fuel System    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–7

8.5.3

Mechanical Fuel Pump Screen     . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–7

8.5.4

Electric Fuel Pump Screen     . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–8

8.5.5

Spin–On Fuel Filter Replacement    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–8

8.5.6

Suction Side Fuel Filter Replacement    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–8

8.5.7

Fuel Level Sensor (FLS)     . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–9

8.5.8

Fuel Heater     . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–10

8.5.9

Engine Oil And Oil Filter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–10

8.5.10 Air Cleaner    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–11
8.5.11 Engine Preheater    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–11
8.5.12 Engine Control System     . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–12
8.5.13 Rack Position Sensor (RPS) Calibration    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–12
8.5.14 Cooling System    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    8–12

Summary of Contents for Transicold X4 7300

Page 1: ...iler Rail Refrigeration BYPASS CHECK VALVE RECEIVER FUSIBLE PLUG FIL TER DRIER SV1 N O SV4 CONDENSER N C OPERATION SERVICE MANUAL For The X4 7300 X4 7500 Trailer and Rail Refrigeration Units 62 11637 Rev B ...

Page 2: ...OPERATION SERVICE MANUAL For The X4 7300 X4 7500 Trailer and Rail Refrigeration Units Carrier Corporation 2014 Printed in U S A September 2014 ...

Page 3: ...ator Operation 2 6 2 3 5 Power Train 2 6 2 3 6 Compressor 2 6 2 3 7 Unloaders 2 6 a Major Working Parts 2 6 b Unloaded Operation 2 7 c Loaded Operation 2 8 2 3 8 Compressor Switches Transducers and Sensors 2 8 a Compressor Discharge Pressure Transducer CDP 2 8 b Compressor Suction Pressure Transducer CSP 2 8 c High Pressure Switch HPS 2 8 d Compressor Discharge Temperature Sensor CDT 2 8 e Compres...

Page 4: ...Keys 2 13 2 6 OPTIONS 2 13 2 6 1 Light Bar 2 13 2 6 2 Remote Switch es 2 13 2 6 3 Remote Temperature Sensors 2 14 2 6 4 Fuel Level Sensor 2 14 2 6 5 Fuel Heater 2 14 2 6 6 Electric Fuel Pump 2 14 2 6 7 Remote Panel 2 14 2 7 ENGINE DATA 2 15 2 8 COMPRESSOR DATA 2 15 2 9 REFRIGERATION SYSTEM DATA 2 16 2 10 COMPONENT RESISTANCE CURRENT DRAW 2 16 2 11 SAFETY DEVICES 2 16 2 12 REFRIGERATION CIRCUIT DUR...

Page 5: ...e Temperature Control 4 4 4 4 6 Defrost 4 4 4 4 7 Overrides 4 4 4 5 TEMPERATURE CONTROL 4 5 4 5 1 Temperature Determination 4 5 4 5 2 Perishable And Frozen Setpoint Ranges 4 5 4 6 START STOP OPERATION 4 5 4 6 1 Start Stop Configuration 4 5 4 6 2 Stop Parameters 4 5 4 6 3 Re Start Parameters 4 6 4 6 4 Start Stop Operating Sequence 4 7 4 7 CONTINUOUS OPERATION 4 7 4 8 AUTOFRESH AIR EXCHANGE 4 8 4 9 ...

Page 6: ...cting Computer and Control System 5 14 5 5 MAIN MICROPROCESSOR REPLACEMENT 5 14 5 5 1 Pre Replacement Steps 5 15 5 5 2 Main Microprocessor Replacement 5 15 5 5 3 Main Microprocessor Setup 5 15 5 5 4 Configurations Via Display Mounted Keys 5 16 5 5 5 Functional Parameters Via Display Mounted Keys 5 16 5 5 6 DataLink Data recorder Via TRU Tech 5 16 5 5 7 System Final Checkout 5 17 MESSAGECENTER MESS...

Page 7: ...32 00060 DATALOGGER DataLink data recorder TIME WRONG 7 32 00061 DOOR OPEN DS1 7 33 00067 SENSOR 1 INPUT VOLTAGE LOW 7 34 00072 CHECK ENCU POWER CIRCUIT 7 34 00078 CHECK SV1 CIRCUIT 7 34 00079 CHECK SV4 CIRCUIT 7 35 00080 CHECK CLUTCH CIRCUIT 7 35 00081 CHECK FHR CIRCUIT 7 36 00082 CHECK STARTER SOLENOID CIRCUIT 7 36 00084 CHECK REMOTE ALARM LIGHT 7 36 00085 CHECK UL1 CIRCUIT 7 37 00086 CHECK UL2 ...

Page 8: ...ECK EXV EVXV SUPERHEAT 7 56 P00178 CHECK UL1 7 57 P00180 CHECK SUCTION MOD VALVE 7 58 P00181 CHECK SV4 VALVE 7 59 P00182 CHECK SV1 VALVE 7 59 P00186 CHECK EVAP OUTLET TEMP 7 59 P00191 CHECK UL2 7 60 P00192 CHECK SV2 CIRCUIT 7 60 P00194 HIGH SUCTION PRESSURE 7 61 P00196 HIGH DISCHARGE PRESSURE 7 62 P00198 LOW DISCHARGE PRESSURE 7 63 P00200 CHECK UL1 CYLINDERS 7 64 P00201 CHECK UL2 CYLINDERS 7 64 P0...

Page 9: ...INP1 7 84 22102 SENSOR INPUT VOLTAGE HIGH INP1 7 85 23100 NO COMM FROM MICRO TO OUTPBD1 7 85 25100 NO COMM FROM MICRO TO STP1 7 86 26100 NO COMM FROM MICRO TO ENCU 7 87 SERVICE 8 1 8 1 SECTION LAYOUT 8 1 8 2 SCHEDULED MAINTENANCE 8 1 8 3 PRE TRIP INSPECTION 8 2 8 4 EXTERNAL SURFACE SERVICE 8 4 8 4 1 AutoFresh Fresh Air Exchange 8 4 8 4 2 Grille Insert Removal 8 4 8 4 3 Surround Removal 8 5 8 4 4 D...

Page 10: ... Bearing Head 8 31 8 8 5 Compressor Oil Level 8 32 8 8 6 Unloaders 8 33 8 9 REFRIGERANT SYSTEM COMPONENT SERVICE 8 34 8 9 1 Evaporator Coil 8 34 8 9 2 Condenser Coil 8 35 8 9 3 Filter Drier 8 36 8 9 4 Replacing Receiver Sight Glass Or Fusible Plug 8 36 8 9 5 Condenser Pressure Control Solenoid Valve SV1 8 37 8 9 6 Liquid Line SV2 Hot Gas SV4 Solenoid Valves 8 38 8 9 7 Stepper Test Harness 8 39 8 9...

Page 11: ...mp Down 9 4 9 3 4 Unit Operates Long Or Continuously In Cooling 9 4 9 3 5 Unit Will Not Terminate Cooling 9 5 9 3 6 Unit Will Not Heat Or Has Insufficient Heating 9 5 9 3 7 Unit Will Not Terminate Heating 9 5 9 3 8 Defrost Cycle Malfunction 9 5 9 3 9 Abnormal Pressure Cooling 9 6 9 3 10 Abnormal Pressure Heating 9 6 9 3 11 Abnormal Noise 9 7 9 3 12 No Evaporator Air Flow Or Restricted Air Flow 9 7...

Page 12: ...5 1 Technician Mode 5 1 Figure 5 2 Technician Hour Meters 5 2 Figure 5 3 Inactive Alarms 5 3 Figure 5 4 Setting Configurations 5 4 Figure 5 5 Component Test Mode 5 6 Figure 5 6 Creating a Data Transfer USB Memory Device 5 8 Figure 5 7 PC Mode 5 9 Figure 5 8 Downloading Data Files 5 10 Figure 5 9 Installing Software 5 11 Figure 5 10 Transferring Configuration Files 5 12 Figure 5 11 TRU Tech TRU Vie...

Page 13: ...p 8 31 Figure 8 28 Oil Level in Sight Glass 8 32 Figure 8 29 Unloader Coil 8 33 Figure 8 30 Condenser Radiator Assembly 8 36 Figure 8 31 Condenser Pressure Control Solenoid Valve SV1 8 37 Figure 8 32 SV 2 and SV 4 8 38 Figure 8 33 Stepper Test Harness 8 39 Figure 8 34 Suction Modulation Valve CSMV 8 39 Figure 8 35 CSMV Coil 8 39 Figure 8 36 Evaporator Expansion Valve 8 40 Figure 8 37 Evaporator Ex...

Page 14: ...nctional Parameters 3 20 Table 4 1 Engine Preheat Time 4 2 Table 4 2 Continuous Operation Modes 4 8 Table 5 1 Configuration Settings 5 17 Table 6 1 MessageCenter Messages 6 1 Table 8 1 Maintenance Schedule 8 2 Table 8 2 EVXV Connections 8 41 Table 8 3 Sensor Resistance 8 47 Table 8 4 Sensor Resistance CDT 8 48 Table 8 5 Temperature Pressure Chart 8 49 ...

Page 15: ...62 11637 SECTION 1 SAFETY PRECAUTIONS PARAGRAPH NUMBER Page 1 1 SAFETY PRECAUTIONS 1 1 1 2 SPECIFIC WARNING CAUTION AND NOTICE STATEMENTS 1 2 1 3 SAFETY DECALS 1 6 ...

Page 16: ...ld a techni cian electrically probe the modules at any point other than the connector terminals where the harness attaches Module com ponents operate at different voltage lev els and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could per manently damage the module Automatic Start Stop Your refrigeration unit is equipped with auto start in both Star...

Page 17: ...enance procedures ensure any two way commu nication is disabled in accordance with the manufacturer s instruction ensure the START RUN OFF switch is in OFF position and whenever practical discon nect the negative battery connection WARNING Under no circumstances should ether or any other starting aids be used to start the engine WARNING Do not toggle the START RUN OFF switch out of the OFF positio...

Page 18: ...ing bolts all the way before break ing seal Entrapped pressure could result in injury WARNING Only a refrigerant cylinder containing R404A should be connected to this refrig eration unit in order to pressurize the system However dry nitrogen may be used to increase pressure Any other gas or vapor will contaminate the system and require additional removal and evacua tion CAUTION Observe proper pola...

Page 19: ...ime enter that time If you don t enter the current time at your location NOTICE DO NOT leave the air intake circuit ener gized for the full 5 minutes if full amper age is shown as the intake air heater element life will be greatly shortened NOTICE Unit uses R404A and POE oil The use of inert gas brazing procedures is manda tory for all Carrier Transicold refrigera tion units otherwise compressor f...

Page 20: ...ion will occur NOTICE Extreme care must be taken to ensure the hose is immersed in the oil at all times Otherwise air and moisture will be drawn into the compressor NOTICE Unit uses R404A and POE oil The use of inert gas brazing procedures is manda tory for all Carrier Transicold refrigera tion units otherwise compressor failure will occur For more information Refer to Technical Procedure 98 50553...

Page 21: ...62 11637 1 6 1 3 SAFETY DECALS ...

Page 22: ...1 7 62 11637 62 03958 ...

Page 23: ...62 11637 1 8 ...

Page 24: ...1 9 62 11637 ...

Page 25: ... 9 2 4 2 Evaporator Expansion Valve EVXV 2 9 2 4 3 Compressor Suction Modulation Valve CSMV 2 10 2 4 4 Evaporator Switches Transducers and Sensors 2 10 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 2 10 2 5 1 Multiple Languages 2 10 2 5 2 Automatic Start Stop 2 10 2 5 3 Special Features 2 10 2 5 4 Component Description And Location 2 10 2 6 OPTIONS 2 13 2 6 1 Light Bar 2 13 2 6 2 Remote Switch es 2...

Page 26: ...hich mounts separately on the front outside corner of the compartment Temperature control is provided by the Carrier Transi cold APXTM control system Refer to Section 2 5 Once the system is set at the desired temperature the unit will operate automatically to maintain the desired temperature within very close limits The control sys tem automatically selects high and low speed cooling or high and l...

Page 27: ... Exchanger 14 Compressor Suction Temperature Sensor CST 15 Discharge Service Valve Strainer 16 High Pressure Switch HPS Located in the tee 17 Compressor Discharge Pressure Transducer CDP Located in the elbow 18 Front Unloader Valve UL1 on front head 19 Rear Unloader Valve UL2 on back head 20 Compressor 21 Compressor Sight Glass 22 Compressor Discharge Temperature Sensor CDT 23 Suction Service Valv...

Page 28: ... 17 Engine Oil Filter 18 Mechanical Fuel Pump 19 Engine Oil Fill Dipstick 20 Rack Position Sensor RPS 21 Engine Oil Drain 22 Starter SS SSC SM 23 Engine Preheater EPH 24 Engine Coolant Temperature Sensor ENCT Behind Engine Preheater 25 Intake Air Temperature Sensor IAT If Equipped 26 Battery BTY 27 Power Control Module PCM See Figure 2 7 28 Main Microprocessor Module MM 29 Air Cleaner Air Cleaner ...

Page 29: ...l 7 High Pressure Air Switch Fitting 8 Low Pressure Air Switch Fitting Location 9 Compressor Suction Modulation Valve CSMV 10 Defrost Termination Temperature Sensor DTT 11 Return Air Temperature Sensor RAT 12 EVXV Inlet Strainer Location 13 Evaporator Outlet Pressure Transducer EVOP and Evaporator Outlet Temperature Sensor EVOT 14 Hot Gas Line 15 Evaporator Expansion Valve EVXV TUBE SHEET MOUNT DT...

Page 30: ...n is to indicate when the air cleaner filter element requires replacement Refer to Section 8 5 10 The system may be fitted with an intake air tempera ture sensor IAT and a manifold absolute pressure transducer MAP These sensors are installed when Carrier Transicold factory monitoring of the air system is required 2 3 3 Engine Controls a Fuel Speed Actuator FSA The FSA combines the fuel shutoff sol...

Page 31: ...lements used have proved reliable enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures 2 3 5 Power Train The power train see Figure 2 4 is a belt drive system that transfers power from the engine to the condenser and evaporator fans The system consists an upper and lower belt gear box fan shaft and clutch 2 3 6 Compressor The c...

Page 32: ...e gas bypass port is greater than the rate of bleed through the bleed orifice When the pressure behind the piston has been reduced sufficiently the valve spring will force the pis ton back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the discharge manifold will close the discharge piston check valve assembly isolating the compressor discharge man...

Page 33: ... compressor cylinders The reading is displayed recorded in the DataLink data recorder and used to control the refrigeration system It is located in the suction line just above the suction ser vice valve c High Pressure Switch HPS The HPS is normally closed and opens on pressure rise to signal to the control system to shutdown the engine if the discharge pressure rises above the switch setting It i...

Page 34: ...adversely affect the shelf life of some sensitive perishable products When transporting these products it may be desirable to maintain normal atmo spheric conditions prevent the build up of CO2 and the depletion of O2 by using fresh air exchange in addi tion to accurate temperature control The AutoFresh Air Exchange item 32 Figure 2 2 controls the amount of fresh air entering the refrigerated comp...

Page 35: ...tem It is located in the supply air outlet housing 2 5 SYSTEM OPERATING CONTROLS AND COM PONENTS Temperature control is provided by the Carrier Transi cold APXTM control system Once the system is set at the desired temperature the unit will operate automati cally to maintain the desired temperature within very close limits 2 5 1 Multiple Languages Messages in the MessageCenter can be displayed in ...

Page 36: ...ain microprocessor at terminal 2MM12 see schematic dia gram Section 10 b Main Microprocessor Module The main microprocessor module MM houses the main system microprocessor is totally self contained and does not contain any serviceable components c SVM Module The stepper valve module SVM houses the CSMV EVXV operating microprocessor The SVM communi cates with the control system through the CAN netw...

Page 37: ...em may be configured to display the setpoint in either whole num bers or with tenths of a degree The temperature description will be followed by a letter indicating the information is in degrees Fahrenheit F or degrees Centigrade C Message Center Messages generated by the control system are dis played in the MessageCenter Details of the messages are described in Section 6 START RUN OFF Switch SROS...

Page 38: ...or a remote switch REMS1 directly to the control system at the SVM Two types of switches may be used 1 A switch with contacts that are open when the door is open or the remote switch is activated 2 A switch with contacts that are closed when the when the door is open or the remote switch is activated Four Configurations are available 1 Activate an alarm only while the switch is acti vated 2 Activa...

Page 39: ... and to prevent the filter from plugging with wax and or ice crystals When the ambient air sensor is reading 68 F 20 C or lower the control system will enable this circuit The circuit is disabled when the ambient air sensor reading rises to 77 F 25 C Also the heater is fitted with an internal temperature switch which will close on a tem perature fall to energize the heater element at tem peratures...

Page 40: ...ature rise 75 F 24 C Firing Order 1 3 4 2 Engine Preheater EPH 42 amps at 12 VDC resistance approximately 0 3 Ohms Lubrication System Engine Oil Pressure 40 to 62 psig 2 8 To 4 2 Bar Engine in high speed Engine Oil Pressure Safety Switch ENOPS Closes on pressure rise at 18 psig 1 22 Bar Opens on pressure fall at 12 psig 0 82 Bar Oil Capacity with Filter 15 quarts 14 2 liters Engine Oil Viscosity A...

Page 41: ...0 pounds 735 KG Battery 50 pounds 23 KG Fan Clutch Air Gap 0 011 to 0 085 inch 0 28 to 2 2 mm Refrigerant Charge Refer to Table 2 1 Gearbox Oil Mobil Delvac 75 90W 15oz 0 44 liters Fanshaft Oil Mobil SHC 630 2 8oz 0 08 liters Component Ohms Amps AutoFresh Air Exchange Relay AFAR 97 Ohms between pins 1 2 AutoFresh Air Exchange AFAS Pull in 0 36 Ohms 10 Hold 14 4 Ohms 10 Pull in 29 Amps Hold 0 83 Am...

Page 42: ...er drier where a screen and absorbent keep the refrigerant clean and dry The refrigerant then flows through the liquid line sole noid valve SV2 to the suction line heat exchanger Here the liquid is further reduced in temperature by giv ing off some of its heat to the suction gas The liquid then flows to the evaporator expansion valve which reduces the pressure of the liquid and meters the flow of ...

Page 43: ...E RECEIVER FUSIBLE PLUG FILTER DRIER HEAT EXCHANGER VIBRASORBER DISCHARGE CHECK VALVE SUBCOOLER LIQUID LINE SERVICE VALVE SV1 SV2 N O N C HPS CDP COMPRESSOR CSMV CSP EVAPORATOR CDT CST EVOP EVOT VIBRASORBER N C SV4 EVXV DISTRIBUTOR 6 5 2 48 2 68 7 21 2 CONDENSER DRAIN PAN MM ...

Page 44: ...red to the air circulated over the evaporator This warm air is circulated throughout the refrigerated compartment to maintain the cargo at the desired temperature When additional heating capacity is required the nor mally closed Liquid Line Solenoid valve SV2 is ener gized opened to allow additional refrigerant to be metered into the hot gas cycle through the evaporator expansion valve Refrigerant...

Page 45: ...DATA RECORDER 3 10 3 9 1 Control System Information 3 11 3 9 2 Data Recording 3 11 3 9 3 Data Downloading 3 11 3 9 4 DataLink Data Recorder Power Up 3 11 3 10 MANUAL DEFROST 3 13 3 11 LANGUAGE SELECTION 3 14 3 12 ADVANCED USER 3 15 3 13 UNIT DATA 3 16 3 14 VIEW ACTIVE ALARMS 3 18 3 15 VIEW HOUR METERS 3 19 3 16 FUNCTIONAL PARAMETERS 3 19 3 17 SLEEP MODE 3 23 3 18 STOPPING UNIT 3 25 3 19 OPTION DAT...

Page 46: ...en performing service or maintenance procedures ensure any two way communication is disabled in accordance with the manufacturer s instructions ensure the START RUN OFF switch is in the OFF position and whenever practical disconnect the negative battery connec tion OFF START RUN O I CONTINUOUS START STOP MENU ALARM DEFROST DIESEL START STOP STATUS OK 36 36 2 BOX TEMPERATURE F SETPOINT F LCD Displa...

Page 47: ...t is displayed in the status bar Up to 5 items may be displayed at one time Press the key to view additional items or the key to scroll back up the list END OF LIST will be displayed after the last item in the list DIESEL START STOP STATUS OK 36 36 2 BOX TEMPERATURE F SETPOINT F DIESEL START STOP INTELLISET Viewing Menu Soft Key Selections Press Menu Key to Scroll HOUR METERS UNIT DATA DEFAULT SCR...

Page 48: ...the display module and all other module con nectors are securely attached 3 4 INTELLISET Products carried or stored in a refrigerated compart ment require a multitude of refrigeration unit settings that must be checked and if required reset each time a new product is loaded The APX control system offers the settings necessary to meet these require ments IntelliSet is a feature that allows pre sele...

Page 49: ...ceed to step 2 2 Press the MENU key until INTELLISET is displayed Then press the INTELLISET soft key to display the IntelliSet screen 3 The IntelliSet screen will display with a 10 second timeout and five of the available IntelliSets listed There may be more than five IntelliSets available This information is provided in parenthesis on the first line For example in the preceding illustration there...

Page 50: ... for example Low Fuel Warning Check Engine Oil Level Check Coolant Temperature Pretrip will display FAILED indicating that the unit is not ready to be sent out for a load but that the alarm list should be checked and all present alarm situations corrected 1 With the system powered up START RUN OFF switch in the START RUN position press the MENU key until PRETRIP is displayed 2 Press the PRETRIP so...

Page 51: ...cycle Pretrip will continue regardless of the outcome of this test Test 2 12VDC Electrical Component Amperage Check Test 2 will check the amperage current draw of the following components Battery Amp Draw All Components Turned Off AutoFresh Air Exchange Relay AFAR if equipped Clutch CLH Font Unloader Solenoid UL1 Rear Unloader Solenoid UL2 SV1 SV2 SV4 Preheat Circuit EPH Fuel Solenoid FSA Each com...

Page 52: ...f the EVXV If evaporator outlet pressure doesn t change as expected with the EVXV closed then the P00177 CHECK EVAP SUPERHEAT alarm will be displayed Test 12 SV1 The test continues with the unit running in two cylinder low speed cool SV1 is energized and de energized If the valve does not operate correctly the P00182 CHECK SV1 VALVE alarm will be displayed This test may last up to three minutes Te...

Page 53: ...ter when either of these conditions is reached Setpoint may be changed any time the START RUN OFF switch is in the START RUN position or when the unit is in PC Mode EXCEPT when Viewing the Alarm List Data List or Functional Parameters OR When the unit is in Pretrip OR When the unit is in Sleep Mode Pressing the key will cause the new displayed setpoint value to become active and SETPOINT CHANGED w...

Page 54: ...RT STOP LOCKED displays in the MessageCen ter when the key is pressed and the unit is in Start Stop Operation or CONTINUOUS LOCKED displays in the MessageCenter when the key is pressed and the unit is in Continuous Run Operation Refer to Section 5 2 3 for Configuration information If the unit fails to start after three start attempts the A000 31 FAILED TO START AUTO alarm will be activated While r...

Page 55: ...ive times without running a minimum of 15 minutes between shutdowns the A00030 FAILED TO RUN MINIMUM TIME alarm will be activated The shutdown counter is cleared when the unit has run for 15 min utes 3 9 DATA RECORDER The APX control system contains a built in DataLink data recorder with 3 megabytes of memory The recorded data can be downloaded from the DataLink data recorder using either the TRU ...

Page 56: ...that is recorded on a when it occurs basis Events are recorded by the recorder as they occur An Event is defined as something that happens and may include Setpoint change Defrost cycle start Defrost Cycle End START RUN OFF switch on START RUN position Pretrip start Pretrip end Unit Mode Control Mode Door and Remote switch activations Hour Meter readings Hour meters are recorded at midnight or the ...

Page 57: ...displays a graphical representation of the recorded data To display the data with PRINT TO SCREEN highlighted press the Key NOTE If configured to do so the system will prompt for entry of the data protect PIN code refer to PROTECT DATA WITH PIN Table 5 1 Once the graphical display is presented press the or keys to move through the recorded data day by day The data is presented with the left horizo...

Page 58: ...is in PC Mode OR The unit is in Pretrip OR There is an active shutdown Alarm Defrost may also be initiated automatically at preset intervals by the system defrost timer or by the defrost air switch The Defrost Mode terminates when both the defrost termination temperature DTT and supply air temperature SAT rise higher than 55 F 12 8 C Should the defrost cycle not end after a maximum of 45 minutes t...

Page 59: ...ith a 10 second timeout Press the or key to scroll through the avail able selections 4 With the desired language highlighted press the key The highlighted language will become active and LANGUAGE CHANGED will be displayed CONTINUOUS START STOP MENU ALARM COOL DIESEL START STOP INTELLISET Viewing Menu Soft Key Selections Press Menu Key to Scroll PRETRIP HOUR METERS UNIT DATA DEFROST COOL DIESEL STA...

Page 60: ...ssage 3 The Advanced User menus will be available for 60 minutes or until the START RUN OFF switch is placed in the OFF position 4 The system can be toggled between Driver Mode and Advanced User Mode by pressing and then releasing the two outside soft keys simultaneously and then pressing the key When toggling from Advance User Mode to Driver Mode DRIVERS MODE ENABLED will display for 5 seconds Wh...

Page 61: ...NU ALARM COOL DIESEL START STOP INTELLISET Viewing Menu Soft Key Selections Press Menu Key to Scroll PRETRIP HOUR METERS UNIT DATA DEFROST 2 1 BACK EXIT Unit Data Listing UNIT DATA END OF LIST ENGINE REFRIGERATION SENSORS REMOTE SENSORS REFRIGERATION SYSTEM MENU SYSTEM INFORMATION INSTALLED OPTIONS REFRIGERATION SENSORS 1 of 5 BACK EXIT Ambient Air Temp Return Air Temp Supply Air Temp Delta T Defr...

Page 62: ...SSURE Refrigerant pressure entering the compressor SUCTION LINE TEMP Refrigerant temperature entering the compressor EVAPORATOR PRESSURE Refrigerant pressure leaving the evaporator EVAPORATOR OUTLET TEMP Refrigerant temperature leaving the evaporator SUCTION MOD VALVE open of CSMV EXPANSION VALVE open of EVXV SYSTEM INFORMATION DATE This is the current Date and Time that the system is using This m...

Page 63: ...r key to scroll through the list of alarms 4 To clear the alarms press the CLEAR ALARMS soft key The LCD Display will provide an ACTIVE ALARMS CLEARED message to confirm the alarms have cleared 5 If there are no active alarms the LCD Display will provide a NO ACTIVE ALARMS message and then return to the default display after 5 seconds Alarms are stored in the Alarm List in the main microprocessor ...

Page 64: ...Press the DOWN ARROW key until the desired sub menu is highlighted as in Sample Screen B Then press the key to enter the sub menu The highlight will move to the present setting as in Sample Screen C CONTINUOUS START STOP MENU ALARM COOL DIESEL START STOP INTELLISET Viewing Menu Soft Key Selections Press Menu Key to Scroll PRETRIP HOUR METERS UNIT DATA DEFROST 1 2 STANDARD HOUR METERS 2 of 3 BACK E...

Page 65: ... ly occurs with produce The HIGH selection is used for these loads if continuous high air flow is required to keep the entire load at a constant temperature The engine will remain in High Speed when High is selected NOTE HIGH AIR FLOW is not active with setpoints below 10 4 F 12 0 C DEFROST TIMER SET FOR 1 5 HRS 3 HRS 6 HRS 12 HRS The defrost timer will automatically put the unit into the defrost ...

Page 66: ...trol Assembly will be cycled open and closed over a 20 minute time period The length of time the assembly is opened or closed is based on the Auto Fresh Air Control Functional Parameter The CFM CONTROL will only be active if the engine is run ning and the setpoint is greater than 28 0 F 2 22 C AUTOFRESH AIR CONTROL 5 To 50 CFM in 5 CFM increments 25 CFM When CFM Control is selected this setting is...

Page 67: ...he unit will run before cycling off This will allow for a lower aver age compartment temperature when considering temperature rises during off cycles SLEEP MODE For complete instructions on entering and setting parameters for Sleep Mode refer to Section 3 17 OVERRIDES OVERRIDE REMOTE SWITCH 1 SHUTDOWN REMS1 AND OVERRIDE DOOR SWITCH SHUTDOWN DS NO YES If the switches are all configured Switch Not I...

Page 68: ...ll wake up at the designated time and control to setpoint b When PRETRIP TEST AT WAKE is set to YES the unit will wake up at the designated time automatically run Pretrip and then control to setpoint PRETRIP PASS FAIL will remain in the MessageCenter until it is manually cleared by pressing any key If Sleep Mode is selected when the unit is not running during a Start Stop Off Cycle any remaining M...

Page 69: ...er the UP or DOWN ARROW key until ON is highlighted Press the key to save the setting to memory the unit is now in Sleep Mode 5 Additional Functional Parameter sub menu selections for wake up time and run pretrip at wake will now be available and may be saved to memory following the key stroke sequence in the preceding step Refer to the following for information on these settings TO EXIT SLEEP MOD...

Page 70: ... option USB memory device into the USB interface port and following the on screen instructions The DataTrak Option installation can be confirmed by scrolling through the Advanced User Unit Data refer to Sec tion 3 13 DataTrak will be listed under the Installed Options heading if it is installed Once DataTrak is installed the control system must be configured for the provider that will be connectin...

Page 71: ...st Check mode of operation Initiate Pre trip The Remote Panel cannot be used to Enter Advance User and Technician modes Access any USB Functions USB menus PC Mode Print The Remote Panel does not have the following features There is no USB port on the remote panel There is no SROS Start Run Off switch at the remote panel Remote Panel unit ON Off is controlled by the UNIT ON OFF softkey replaces the...

Page 72: ...er 30 minutes of inactivity To turn the remote panel back on simply press any but ton on the remote panel The remote panel will turn off again after 30 minutes of inactivity 1 On the remote panel press and release the MENU key until the UNIT ON OFF soft key is displayed NOTE The UNIT ON OFF soft key on the remote panel takes the place of the ENGINE HOURS softkey in the main dis play 2 To turn the ...

Page 73: ...OPERATION 4 5 4 6 1 Start Stop Configuration 4 5 4 6 2 Stop Parameters 4 5 4 6 3 Re Start Parameters 4 6 4 6 4 Start Stop Operating Sequence 4 7 4 7 CONTINUOUS OPERATION 4 7 4 8 AUTOFRESH AIR EXCHANGE 4 8 4 9 DEFROST 4 9 4 9 1 Defrost Initiation And Start 4 9 4 9 2 Normal Defrost Operation Ambient Air Temperature less than 80 F 26 7 C 4 9 4 9 3 Normal Defrost Termination 4 9 4 9 4 Normal Defrost T...

Page 74: ...splay module DM 2 The connectivity also continues from SP 1 to the engine control unit ENCU 23 The LO CAN connectivity is established from the main microprocessor 1MM 4 through SP 4 to the stepper valve module 1SVM 7 and from the stepper valve module 1SVM 4 to the display module DM 6 The connectivity also continues from SP 4 to the engine control unit ENCU 24 To start the unit SROS is placed in th...

Page 75: ... speed drops below 50 rpm for three seconds the starter solenoid contactor will be de energized and the A00035 CHECK STARTER CIRCUIT alarm will be activated If the unit fails to start after three start attempts the A00031 FAILED TO START AUTO alarm will be activated If the unit is equipped with a fuel heater the control system will monitor ambient temperature If ambient is below 77 F 25 C the fuel...

Page 76: ... control system will operate the unit controls as follows NOTE 1 The selected temperature control sensor deter mines if the unit is running high or low speed 2 The control system monitors the suction pres sure ambient temperature and calculates the system load If required the system will unload cylinders and modulate the CSMV to keep the load within required limits Refer to Section 4 11 3 and Sect...

Page 77: ...h will modify the length of each mode in 10 second cycles That is if the unit is in Cool Pulse Mode the unit may run in cool for up to nine seconds then null for one second if the Control Temperature is away from setpoint As the Control Temperature comes closer to setpoint the length of cool pulse time will decrease and the amount of null time will increase However the combination of the two will ...

Page 78: ...ion Start Stop Operation is dependent on both Configura tion and Functional Parameter settings The first set ting to be considered is the START STOP PARAMETERS Configuration This setting determines control actions when in the Perishable Range or Fro zen Range The available settings are TOGETHER and SEPARATE When SEPARATE is chosen the control action will be different depending on whether the set p...

Page 79: ...START STOP RESTART Configuration value the engine will be started The value may be set from 12 0 to 12 8 volts The factory default setting is 12 2 volts If this is the only reason operation is required the unit will operate as if it is in Continuous Operation until the requirement has been met 3 The Maximum Off Time has expired In some ambient conditions there are times when the unit may remain in...

Page 80: ... Range Lock Section 4 10 2 for additional information In Continuous Operation Pulldown or Pull up will con tinue until the control system has calculated it is to end The calculation determines the average temperature using the formula SAT RAT 2 Calculated Average Temperature When the Control Temperature is within the calculated average temperature of set point Pulldown or Pull up ends Once Pulldow...

Page 81: ...SETPOINT control will begin when the control temperature is 1 5 F 0 8 C away from setpoint If a time value is entered it will become active after the time has expired and the system is no longer in Pulldown or Pull up even if the control temperature has not reached 1 5 F 0 8 C away from setpoint Table 4 2 Continuous Operation Modes SETPOINT ALLOWED OPERATION 32 F 0 0 C and above UltraFresh with Fr...

Page 82: ...evapo rator coil or the return air grille can also cause the DAS contacts to close b Defrost based on time Time interval between defrosts is selected in the Func tional Parameters The parameter value may be set to 1 5 3 6 or 12 hours factory default setting is 6 hours NOTE The defrost timer will not count when the unit is in defrost the unit is in a Start Stop off cycle or the DTT is greater than ...

Page 83: ...e data recorder will record a Defrost Termination Event 4 10 USER SELECTED OVERRIDE OPERATION Four optional software override programs are available to the user These programs include Temperature Range Lock ProductShield FreshProtect and Air Flow Information on how the unit operates under these pro grams is provided in the following sub paragraphs 4 10 1 FreshProtectTM Supply Air Control FreshProt...

Page 84: ...f 28 F 2 2 C and a Maximum Tem perature of 55 F 12 8 C Should Continuous Opera tion ALWAYS also be required with setpoints between 22 and 0 F 30 and 17 8 C then Range 2 will be set for Continuous with a Minimum Temperature of 22 F 30 C and a Maximum Temperature of 0 F 17 8 C Any setpoint outside of Range 1 or 2 will allow changes between Start Stop and Continuous Range Lock 1 2 Range 2 is set for ...

Page 85: ... must be lower than the value selected in order to enter Start Stop Once the control system detects that the above criteria have been met the unit will switch from Continuous Operation to a Start Stop Off Cycle for the MINIMUM OFF TIME Functional Parameter setting During the Minimum Off Time the RESTART OVERRIDE TEM PERATURE Functional Parameter setting can cause the unit to restart to protect the...

Page 86: ...r is not required Operation in High Air is controlled by four Configura tions PRODUCTSHIELD HIGH AIR HIGH AIR MINI MUM TEMPERATURE HIGH AIR MAXIMUM TEMPERATURE and HIGH AIR DELTA T The PRODUCT SHIELD HIGH AIR Configura tion may be set to OFF or ON ProductShield High Air is only active when the Configuration is set to ON The High Air ambient air temperature range is defined by the HIGH AIR MAXIMUM ...

Page 87: ...r HIGH The factory default setting is NOR MAL Some products generate a considerable amount of heat heat of respiration during transportation This frequently occurs with produce The HIGH selection can be used for these loads since continuous high air flow may be required to keep the entire load at a con stant temperature The engine will remain in high speed when HIGH is selected unless a low speed ...

Page 88: ... above 120 F 48 9 C when the engine starts UL1 and UL2 will both be unloaded for the first 2 minutes of unit operation 2 Discharge Pressure If discharge pressure is greater than 414 7 PSIG 22 22 bar UL1 and UL2 will unload 3 Engine Power Unloading If the actual engine RPM is less than the desired RPM this is defined as engine RPM droop When the system is running in heating or cooling with the CSMV...

Page 89: ... maximum position the CSMV will move toward the closed position as required to lower the engine load and thereby the rack position 2 Engine RPM When the engine throttle position has been more than 90 for three seconds the control system will monitor actual engine RPM verses desired engine RPM if the actual RPM is less than the desired RPM this is defined as engine RPM droop If the droop is above 3...

Page 90: ...nloading Data Files 5 10 5 3 4 Installing Software 5 11 5 3 5 Transferring Configuration Files 5 12 5 4 TRU TECH TRU VIEW 5 13 5 4 1 TRU Tech 5 13 5 4 2 TRU View 5 13 5 4 3 Connecting Computer and Control System 5 14 5 5 MAIN MICROPROCESSOR REPLACEMENT 5 14 5 5 1 Pre Replacement Steps 5 15 5 5 2 Main Microprocessor Replacement 5 15 5 5 3 Main Microprocessor Setup 5 15 5 5 4 Configurations Via Disp...

Page 91: ... for entering the Technician Mode are provided in Figure 5 1 while information on these operations is provided in the following sub paragraphs Figure 5 1 Technician Mode 1 With the system powered up START RUN OFF switch in the START RUN position or in PC Mode press the MENU key until TECH MODE is displayed If TECH MODE does not display place the system in Advanced User Mode refer to Section 3 12 2...

Page 92: ...tem will not respond and then press the key The system will return to Driver Mode 5 2 1 Technician Hour Meters Hour meters other than the standard hour meters are available for viewing when the control system is in the Tech nician Mode Instructions for viewing these hour meters are provided in Figure 5 2 Figure 5 2 Technician Hour Meters 1 Enter the Technician Mode as described in Figure 5 1 While...

Page 93: ...n s List Only qualified refrigeration technicians should access the inactive list It is not intended for the use of drivers or Advanced Users Figure 5 3 Inactive Alarms STANDARD HOUR METERS BACK EXIT Engine Hours Switch On Hours Total Run Hours 1060 Hours 1400 Hours 1182 Hours END OF LIST MAINTENANCE METERS BACK EXIT Time Left to Meter Name END OF LIST OTHER METERS COUNTERS BACK EXIT Meter Counter...

Page 94: ...ck in the RUN STOP position 8 Once activity requiring use of Technician Mode is complete Technician Mode should be manually canceled refer to Figure 5 1 5 2 3 Configuration Settings Configuration settings match the control system to the unit and define control system action under various opera tional conditions Instructions for working with Configurations are provided in Figure 5 4 Figure 5 4 Sett...

Page 95: ... key to scroll through the individual Configurations The individual Configurations will highlight as the list is scrolled a With the desired individual Configuration highlighted press the key The highlight will move to the pres ent setting As in Sample Screen C Press the or key to scroll through the available settings With the desired setting highlighted press the key to select Refer to Table 5 1 ...

Page 96: ...eturn to the test selection screen 4 To extend the test time press the RESET TIMER soft key The time will reset to 5 minutes To stop the test press the CANCEL STOP soft key 5 Continue as above to test additional components as required NOTICE Technician Mode should be canceled when work is complete If Technician Mode is not can celed Technician Mode will be available for 60 minutes after the last k...

Page 97: ...During evacuation the control system will monitor the pressure transducer readings The System will remain in RECOVER LEAKCHK EVAC MODE as evacuation is started As the refrigeration system is evacuated the system pressure will go into a deep vacuum Once the CSP is less than 20 inhg and the CDP is less than 5 psig the operator message panel will change to EVAC CHARGE MODE The position of the CSMV EV...

Page 98: ...s from the DataLink data recorder may be transferred from the control system to the DATAEXT folder Software files may be transferred to the PROGRAM folder and then transferred to the control system IntelliSet Configuration files may be transferred to the CONFIG folder and then transferred to the control system Figure 5 6 Creating a Data Transfer USB Memory Device 1 Using a standard computer file c...

Page 99: ...cable at this time 2 The MessageCenter will display PC MODE The System is now in PC Mode The purpose of PC Mode is to allow demonstration of the System features and allow changes to the System while the engine is not actually running It is important to note that any changes saved to memory while in PC Mode will remain after leaving PC Mode NOTICE Technician Mode should be canceled when work is com...

Page 100: ...Y Press any key to return to the USB soft keys 4 The MessageCenter will return to the USB soft key display and the USB may be removed 5 The downloaded data will now be in a folder inside the Data Transfer USB memory device DATAEXT folder Each day data is extracted to the USB a folder will be created The folder naming convention will begin with the letters DX followed by the last two digits of the ...

Page 101: ...d to do so the System will prompt for entry of the data protect PIN code refer to PROTECT DATA WITH PIN Table 5 1 3 In less than two minutes time the MessageCenter will display the USB soft keys NOTE The INSTALL SETTINGS soft key will not display if files are not loaded In the CONFIG folder and DOWNLOAD DATA does not display if the DATAEXT folder is not present 4 Press the INSTALL SOFTWARE soft ke...

Page 102: ...erial number trailer ID hour meter readings date and time These configurations must be set using the display mounted keys or TRU Tech and a service cable Figure 5 10 Transferring Configuration Files 1 Ensure the desired setting file s are loaded to the CONFIG folder on a Data Transfer USB memory device 2 With the System powered or off remove protective cover from the USB interface port and Insert ...

Page 103: ...s Record sensor data to a file for diagnostic pur poses Display edit and send unit model number unit serial number and trailer ID to the main micro processor Display edit and send Functional Parameters and Configuration settings to the System includ ing the DataLink data recorder or to a Data Transfer USB memory device Write hour meter values to a replacement main microprocessors during the first ...

Page 104: ...ation from electrical static dis charge ESD contamination or abuse Before touching a module touch your body and or conductive tool being used to the frame to discharge ESD safely All electronics should be handled carefully and only held by edges of any exposed board Care should be taken when insert ing extracting connectors and compo nents to avoid exerting excessive stress on the board which coul...

Page 105: ...prior to beginning work 5 5 2 Main Microprocessor Replacement 1 Ensure the unit will not start automatically by disabling any two way communication placing the STOP RUN OFF switch in the OFF position and removing the negative battery cable 2 Release the tabs on and remove the two 35 pin connectors and 8 pin connector from the front of the module 3 Replace module Tighten mounting hardware to 96 inc...

Page 106: ...unit switch is on and the unit is operating and no further manual changes will be allowed NOTES 1 If a Data Transfer USB memory device will be used to setup the remainder of the main micro processor settings proceed to Section 5 5 7 after the settings are entered 2 After the unit specific and time sensitive configu ration settings are complete use the UP or DOWN ARROW keys until CONFIGS COM PLETE ...

Page 107: ...modified if the UNIT OPERATION Configuration in the Rail Settings group is set to RAIL If this Configuration is set to RAIL then ASSET ID or CAR ID may display rather than the TRAILER ID default Refer to the UNIT OPERATION Configuration later in this table UNIT SERIAL NUMBER The unit S N may be entered Numbers Letters and a space are available by scrolling through the avail able list Refer to Sect...

Page 108: ...ver the setpoint is between the minimum maximum temperatures for that range refer to the following sub configurations RANGE 1 or 2 MINIMUM TEMPERATURE 22 F TO 90 F 30C to 32 C in 0 1 F or C increments Select the lowest temperature desired for this range RANGE 1 or 2 MAXI MUM TEMPERATURE 22 F TO 90 F 30C to 32 C in 0 1 F or C increments Select the highest temperature desired for this range START ST...

Page 109: ...uous Run This provides continuous air flow and good product protection for extreme ambi ent temperatures Unit will return to START STOP when ambient comes back inside range ECONO MIN TEMP OFF or 20 F to 119 0 F 28 9 C to 48 4 C in 0 5 increments Default 119 0 F 48 4 C OFF There is no lower limit for this parameter Select the lowest ambient temperature desired to ac tivate ProductShield Econo If Pr...

Page 110: ...r to Section 4 10 3 for more information on High Air Delta T PRODUCTSHIELD WIN TER OFF 20 F to 32 F 28 9 C to 0 C in 0 5 C or F increments Select the desired ambient temperature below which ProductShield Winter will operate forced Continu ous Run operation PRODUCTSHIELD FRESH NO YES OFF ProductShield Fresh is turned off ON The FreshProtect value in the system will be overridden when operating unde...

Page 111: ...hni cian Reset Required alarm will be activated NO When the A00012 High Coolant Tempera ture alarm has been activated three times in the last two hours of engine operation the A00021 Techni cian Reset Required alarm will not be activated ENGINE OIL PRESS SHUTDOWN YES NO YES When the A00011 Low Engine Oil Pres sure alarm has been activated three times in the last two hours of engine operation the A...

Page 112: ...the unit will continue to run LP SHUTDOWN DELAY 0 255 seconds in 1 second increments 120 SECS If the Low Pressure Shutdown Configuration is set to YES shutdown is to be delayed for this amount of time after the Low Pressure Shutdown signal is re ceived HIGH SUCT PRESS SHUT DOWN YES NO YES When the A00027 HIGH SUCTION PRES SURE alarm is activated the alarm light will illumi nate and the unit will s...

Page 113: ...orough PM 5 OFF HIGH SPEED HOURS START CYCLES CLUTCH CYCLES SWITCH ON HOURS ENGINE HOURS OFF This selection will turn this meter OFF will not display ENGINE HOURS this meter will count the engine hours until the next reset interval SWITCH ON HOURS this meter will count the switch on hours until the next reset interval START CYCLES this meter will count how many times the engine has started until t...

Page 114: ... here is the desired number of hours or cycles between PM Maintenance Alarms for this meter When the meter is reset the value selected here will be added to the to the present meter reading to indi cate to the main microprocessor when the next ser vice interval alarm is to be activated REMOTE SENSORS REMOTE TEMP SENSOR 1 or 2 ON OFF ON A remote sensor has been added to the unit and connected into ...

Page 115: ...hen ambi ent temperature is above the entered value the unit will not shutdown RUN LOW SPEED BE LOW ambient air temperature OFF 120 to 20 F 49 to 29 C If Door Switch Low Engine Speed is selected OFF the unit will transition to low speed at any am bient temperature Value when ambient temperature is below the en tered value transition to low speed will be allowed When ambient temperature is above th...

Page 116: ...ntrol system YES The data protect PIN code will override the master technician PIN code and the data protect code must be entered to use the USB Interface port or data recorder print functions NO The data protect PIN code if entered will not override the master technician PIN code when using the USB Interface port or data recorder print functions PARAMETERS LOCKOUT YES NO YES All Functional Parame...

Page 117: ...45 CAR will display CAR 12345 RAIL SHUTDOWN OVER RIDE NO YES NO When the A00030 FAILED TO RUN MIN TIME or A00031 FAILED TO START AUTO alarm is activated the system will not override the alarm s and the unit will not restart until the alarms are cleared manually YES When either an A00030 FAILED TO RUN MIN TIME or A00031 FAILED TO START AUTO alarm is activated the unit will automatically override an...

Page 118: ...POINT Once the compartment temperature has reached setpoint 1 5 F 0 8 C the Auto Fresh Air Exchange will start to operate based on the se lected Functional Parameters 0 to 48 Hours After this length of time AutoFresh Air Exchange will begin if the unit is no longer run ning in Pulldown even though the compartment tem perature may not have reached setpoint Table 5 1 Configuration Settings Configura...

Page 119: ...62 11637 SECTION 6 MESSAGECENTER PARAGRAPH NUMBER Page 6 1 MESSAGECENTER MESSAGES 6 1 ...

Page 120: ... CANNOT START DEFROST CYCLE Due to current unit conditions the defrost cycle cannot be started Refer to Defrost Section 3 10 and Section 8 9 13 CANNOT START PRETRIP Due to current unit conditions a Pretrip test cannot be started Re fer to Pretrip Section 3 5 CHANGE INTELLISET TO EXIT The IntelliSleep IntelliSet is active Alternates with INTELLI SLEEP MODE at 5 second interval whether unit is runni...

Page 121: ... the name of the module will also be indicated MAX SETPOINT HAS BEEN REACHED Maximum setpoint allowed by configuration settings has been reached MICRO WILL RESET RESTART NOW The microprocessor program software has just been changed or a new configuration has been programmed into the microprocessor The micro processor will turn itself off then on again similar to a computer reboot in order for the ...

Page 122: ...w setpoint has been entered saved into microprocessor memo ry the new setpoint will be used SETPOINT NOT CHANGED The new setpoint has NOT been entered NOT saved into micro proces sor memory the old setpoint will be used SETTING SMV XXX The START RUN OFF switch has been toggled out of the OFF position and the CSMV is opening SLEEP MODE OFF ON TO WAKE The unit is cycled off in Sleep Mode Place the S...

Page 123: ...s open UNIT SHUTDOWN SEE ALARM LIST An active shutdown alarm has shut the unit down UNIT SHUTDOWN RMS1 The unit has shutdown because switch is open May be connected to a door or a remote control switch USE UP DOWN KEY TO SCROLL USE KEY TO SELECT ITEM TO CHANGE Items available are being displayed or additional items are available for selection Use the up or down arrow key to highlight or display an...

Page 124: ...ODE 7 16 00034 ENGINE FAILED TO STOP 7 17 00035 CHECK STARTER CIRCUIT 7 18 00036 CHECK COOLANT TEMPERATURE 7 19 00037 CHECK LOW SPEED RPM 7 19 00038 CHECK HIGH SPEED RPM 7 20 00039 CHECK ENGINE RPM 7 21 00040 CHECK ENGINE PREHEAT CIRCUIT 7 22 00041 ENGINE STALLED 7 23 00051 ALTERNATOR NOT CHARGING 7 25 00053 BOX TEMP OUT OF RANGE 7 26 00054 DEFROST NOT COMPLETE 7 28 00055 CHECK DEFROST AIR SWITCH ...

Page 125: ...CHECK SV4 CIRCUIT 7 50 P00151 CHECK GLOW CIRCUIT This applies to the engine preheater EPH 7 50 P00152 CHECK FUEL SOLENOID CIRCUIT 7 51 P00153 CHECK RETURN AIR SENSOR 7 51 P00154 CHECK SUPPLY AIR SENSOR 7 51 P00155 CHECK COOLANT TEMP SENSOR 7 52 P00157 CHECK BATTERY CURRENT 7 52 P00158 CHECK AMBIENT AIR SENSOR 7 53 P00160 CHECK DISCHARGE TEMP SENSOR 7 53 P00161 CHECK SUCTION TEMP SENSOR 7 53 P00162...

Page 126: ...N WITH ALL MODULES 7 75 00251 LOSS OF COMMUNICATION WITH INPUT BOARD 7 75 00252 LOSS OF COMMUNICATION WITH OUTPUT BOARD 7 75 00253 LOSS OF COMMUNICATION WITH SUCTION MODULATION VALVE MODULE SVM 7 75 00254 LOSS OF COMMUNICATION WITH DISPLAY MODULE 7 76 00255 MICROPROCESSOR ERROR 7 76 02000 UPDATE SOFTWARE 7 76 03001 ENGINE LOAD CALIBRATION 7 77 05012 CHECK ENCU POWER CIRCUIT 7 78 05013 CHECK CLUTCH...

Page 127: ...e of assistance Troubleshooting should begin with the first alarm that appears in the active alarm list The first alarm that appears is the last alarm that was recorded Other alarms in the list may have contributed to the occur rence of the first alarm The check items in the troubleshooting guide are listed in order of their likeliness of occurrence and ease of test ing We recommend that you follo...

Page 128: ...fore using Component Test Mode Refer to Section 5 3 2 NOTE Note 3 Sensors may be tested by taking a resistance measurement at the sensor side of the harness connector at the sensor loca tion To do this being careful not to damage the connector pins disconnect the sensor from the harness and measure resistance Refer to Section 8 10 7 for chart of resis tances for different sensors The interconnecti...

Page 129: ...sing the display mounted keys or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself refer to reset condition above Operate the unit through the appropriate modes to see if any ac tive alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check For Low F...

Page 130: ...PS Power Wiring a Inspect switch connector pins terminals Verify that there is no physical damage to the switch Check the connections for damage and corrosion b Using Component Test Mode energize the ENCU Power Circuit Check for power at the switch con nector Must have minimum 11 VDC If not check the connectors and wiring between terminals for damage moisture or corrosion c Check for continuity fr...

Page 131: ...oolant system If the cap must be removed do so very slowly in order to release the pressure without spray a Check coolant level in overflow bottle Level must be in the normal range b Inspect connecting tube between overflow bottle and radiator Connections must be airtight No leakage or holes in tube 2 Check Engine Coolant Temperature Sensor ENCT a Refer to procedure for alarm 00129 CHECK ENG COOLA...

Page 132: ...t Must operate correctly c Check water pump operation Verify no seepage at weep hole bearings tight and quiet and Impel ler firmly attached to shaft d Check cooling system for scale sludge rust etc Coolant must be clean clear with no foreign par ticles or substances in it Flush clean the coolant system as necessary e Check water pump bypass hose to thermostat housing for internal blockage Must be ...

Page 133: ...r Coil a Inspect condenser radiator Ninety percent or more of the coil surface must be undamaged Con denser Radiator coil must be clean b Check airflow with unit running Verify even airflow through the entire coil and no dead spots c Check upper and lower fan belt tension condition Verify no glazing cracking or slipping Replace if required Refer to Section 8 6 4 Check Refrigerant Charge Refer to S...

Page 134: ...00016 BATTERY VOLTAGE TOO LOW ACTIVATION Voltage at the main microprocessor is less than 10 VDC except when the engine starter is engaged UNIT CONTROL Shutdown and alarm Alarm condition only if activated while starting unit RESET CONDITION Auto reset after 15 minutes when the voltage at the main microprocessor is between 11 14 VDC or alarm may be manually reset using the display mounted keys or by...

Page 135: ...surface must be undamaged Con denser Radiator coil must be clean b Check airflow with unit running Even airflow through the entire coil No dead spots c Check upper and lower fan belt tension condition Verify no Glazing no cracking and no slipping Refer to Section 8 6 Replace if required 4 Check System Pressures Install Manifold Gauge Set and check and compare compressor discharge suction pressures...

Page 136: ... engaged e Check upper and lower fan belt tension condition Verify no glazing cracking or slipping Refer to Section 8 6 Replace if required 2 Check Refrigerant Charge Refer to Section 8 7 2 for correct charge 3 Check System Pressures Install manifold gauge set and check and compare compressor discharge suction and evaporator out let pressure to the Unit Data readings Suction pressure must be above...

Page 137: ...n must be cor rected and the alarm cleared to continue 00020 MAXIMUM COMPRESSOR ALARMS ACTIVATION This option must be installed and alarm must be enabled by configuring the Compressor Alarm Shutdown to YES Alarms 00013 00017 00018 00027 00028 00029 or 00056 individually occur 3 times within the last 2 hours UNIT CONTROL Shutdown and alarm RESET CONDITION Clear the alarm from inactive alarm list Th...

Page 138: ...2 LOW SUCTION SUPERHEAT ACTIVATION Check Suction Temperature Sensor and or Check Evaporator Temperature Sensor alarms are not active refer to Alarm 000127 and or 000131 first and Compressor Suction Superheat Compressor Suction Temperature CST minus saturated tempera ture for Compressor Suction Pressure CSP is less than 5 C 9 F for more than 2 minutes UNIT CONTROL Shutdown and alarm RESET CONDITION...

Page 139: ...d compare compressor discharge suction pressures with those shown in Unit Data Suction pressure must be above 3 psig 0 2 bar and should be in the nor mal range for ambient refrigerated compartment conditions Refer to Section 8 9 12 2 Check Compressor Drive Coupling Verify that compressor coupling is intact and the compressor crankshaft is turning Repair as required 3 Check Refrigerant Charge Refer...

Page 140: ...y mounted keys or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself refer to reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Compressor Drive Coupling...

Page 141: ...er to Section 9 3 6 00030 FAILED TO RUN MINIMUM TIME ACTIVATION If Configured STANDARD The unit has shutdown on an alarm 3 times without having run for at least 15 minutes between each shutdown not including door switch shutdowns If Configured RAIL The unit has shutdown on an alarm and attempted to restart for the configured number of times without having run for at least 15 minutes between each s...

Page 142: ...ngine Control Unit ENCU and Fuel Speed Actuator FSA a Check voltage from fuse F3 through PCM 34 and SP 6 to ENCU 22 Verify correct fuse see Fig ure 2 7 Must have minimum 11 VDC with the battery connected and SROS in the OFF position b Check voltage from 3MM 9 to ENCU 44 Must have minimum 11 VDC with SROS in the START RUN position If not energize the run relay output using component test mode refer...

Page 143: ...ith the steps below as necessary CORRECTIVE ACTIONS 1 Check to Ensure Engine is Running Verify that engine is still running Engine should not be running 2 Check Start Run Off Switch Circuit a Check SROS It must be in the OFF position b Check two way communication equipment It must not be wired so unit can start with SROS in the OFF position Correct wiring as needed c Check voltage to 2MM 35 0 VDC ...

Page 144: ... no damage or corro sion Wiring and battery cable must be clean and tight b Check voltage to starter motor Must be above 10 VDC while cranking c Check resistance of starter motor Refer to Section 2 10 for specifications d Check amperage draw of starter Refer to Section 2 10 for specifications 5 Check Battery Voltage a Inspect cable ends and posts Must be clean and tight with no corrosion b Test vo...

Page 145: ...TION Auto reset if control system is calling for low engine speed operation and signal is within 1220 and 1480 rpm for 60 seconds or alarm may be manually reset using the display mounted keys or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself refer to reset condition above...

Page 146: ...ee if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Force High Speed Operation Place unit in continuous run adjust setpoint above 11 F 12 C and set the Air Flow Functional Parameter to HIGH Reset following testing System should run in high speed If not check speed overrides Section 4 11 2 Ensure System is calling for high speed when performing steps 3 4 2 ...

Page 147: ...ator Flag must not be visible b Inspect air intake system Verify hoses tubes in good condition with no kinks or restrictions 3 Force Low Speed Operation Set the High Speed Delay Functional Parameter to 10 minutes and restart unit Reset following test ing System should run in low speed If not check speed overrides Section 4 11 2 Ensure System is calling for low speed when performing step 4 4 Check ...

Page 148: ...priate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check for Alarm 05017 CHECK GLOW PLUG RELAY Check for Alarm 05017 CHECK GLOW PLUG RELAY Alarm conditions must be corrected and the alarm cleared to continue 2 Check Engine Preheater Circuit a Using Component Test Mode refer to Section 5 2 4 energize engine preheat circuit Check dis played...

Page 149: ...l lines between the fuel tank and the fuel pump inlet for air leakage 2 Check Start Run Off Switch Circuit a Check SROS Must be in the START RUN position b Check two way communication equipment Must be set to allow operation and calling for operation 3 Check Fuel System a Check for Alarm 00001 LOW FUEL LEVEL WARNING Fill tank as needed b Check fuel flow Unrestricted fuel flow through system Pump s...

Page 150: ...be visible b Inspect air intake system Verify hoses tubes in good condition with no kinks or restrictions 7 Check Engine Exhaust System Inspect the exhaust system Must be clear and unobstructed 8 Check Engine a Check Injection pump timing Timing must be correct b Check engine valve adjustment Rocker arm clearance must be correct c Check engine compression Compression must be above 400 psig 27 2 ba...

Page 151: ... Current Transformer CT a Check current value Power up control system in PC Mode Refer to Section 5 3 2 Check Unit Data Must be 2 0 to 1 5A with no load b Check CT power from main microprocessor Must have 5 VDC from terminal 2MM 29 to PCM 31 c Check CT ground to main microprocessor Check wiring from terminal 2MM 23 to PCM 30 d Check CT signal to main microprocessor Check wiring from terminal 2MM 1...

Page 152: ... only If the alarm is Configured for shutdown the unit will shutdown and alarm RESET CONDITION Condition 1 Auto reset If the unit is running in Pulldown and the SAT is greater than 1 F 0 56 C below the RAT or if the unit is running in Pull Up and the SAT is greater than the RAT Condition 2 3 Auto reset when the temperature is within 2 7 F 1 5 C for perishable setpoints or 2 7 F 1 5 C for frozen se...

Page 153: ...cleared to continue 5 Check Refrigerant Charge Refer to Section 8 7 2 Charge must be correct 6 Check System Pressures Install manifold gauge set and check and compare compressor discharge suction pressures with those shown in Unit Data Refer to Section 8 9 12 for instruction on comparison 7 Check for Alarm 00056 Low Evaporator Airflow Check for Alarm 00056 CHECK EVAPORATOR AIR FLOW Alarm condition...

Page 154: ... Evaporator Fan Clutch Check fan clutch operation in defrost Must completely disengage fan 2 Check Refrigerant Charge Refer to Section 8 7 2 Charge must be correct 3 Check for Alarm 00018 Low Refrigerant Pressure Check for Alarm 00018 LOW REFRIGERANT PRESSURE Alarm conditions must be corrected and the alarm cleared to continue 4 Check DTT a Using a service test thermometer check temperature of eva...

Page 155: ... 1 Check Condition of Refrigerated Compartment Load a Check condition of refrigerated compartment doors seals Doors must be closed and door seals must seal and prevent entrance of outside air b Check condition of evaporator Check for blockage sufficient to cause an air pressure differential across the coil great enough to close the contacts of the defrost air switch Coil must be free of ice follow...

Page 156: ...ith the steps below as necessary CORRECTIVE ACTIONS 1 Check Airflow Through Evaporator Coil Section a Inspect coil Ninety percent or more of the coil surface must be undamaged Coil must be clean b Check airflow with unit running Even airflow through the entire coil No dead spots c Check return air bulkhead air chute Verify good air flow and Return Air not restricted Air chute in good condition d C...

Page 157: ...1 Verify that Configuration is set for the type of switch being used i e when switch is activated switch contacts are closed etc Configuration must agree with switch type Refer to Section 5 2 3 4 Check Wiring a Visually inspect wiring to REMS1 Wiring must be connected b Visually inspect condition of switch Must not be damaged wet corroded etc c Check circuit See wiring schematic Section 10 With th...

Page 158: ...TIME WRONG ACTIVATION The real time clock in the DataLink data recorder does not contain a valid date UNIT CONTROL Alarm only RESET CONDITION Auto reset when the DataLink data recorder real time clock is reset or alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm shou...

Page 159: ...d etc Configuration must agree with switch type Refer to Section 5 2 3 4 Check Wiring a Visually inspect wiring to DS1 to make sure it is connected b Visually inspect condition of switch It must not be damaged wet corroded etc c Check circuit See wiring schematic Section 10 With the switch contacts closed check for mini mum 11 VDC from 2SVM 14 through the wiring and switch back to 2SVM 25 5 Tempor...

Page 160: ...ection has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check for Additional Alarms If this alarm is activated in conjunction with other alarms 00031 00072 00079 00080 00085 or 000 86 check F5 F10 Fuses must be good Replace fus...

Page 161: ...TIONS 1 Check for Additional Alarms If this alarm is activated in conjunction with other alarms 00031 00041 00072 00078 00080 00085 or 00086 check F5 F10 Fuses must be good Replace fuse s as required clear alarms restart and check for repeat alarm s 2 Check Coil a Inspect coil connector pins terminals No damage to coil No damaged or corroded pins b Check resistance of coil Refer to Section 2 10 fo...

Page 162: ...r specifications 2 Check Power and Wiring a Check for power at fuse F10 terminal A inside PCM Minimum 11 VDC If not check PER circuit and fuse F5 NOTE FLS SATPWR and LB will also be without power b Check fuses F5 F10 Verify correct fuse see Figure 2 7 c Check for power at FHR terminal Replace PCM d If the ambient temperature is below 77 F 25 C the fuel heater relay FHR will be grounded by the main...

Page 163: ...onal Alarms If this alarm is activated in conjunction with other alarms 00031 00041 00072 00078 00079 00080 or 00086 check F5 F10 Fuses must be good Replace fuse s as required clear alarms restart and check for repeat alarm s 2 Check Coil a Inspect coil connector pins terminals Verify no damage to coil Verify no damaged or corroded pins b Check resistance of coil Refer to Section 2 10 for specific...

Page 164: ...l Alarms If this alarm is activated in conjunction with other alarms 00031 00041 00071 00072 00078 00079 00080 or 00085 check F5 F10 Fuses must be good Replace fuse s as required clear alarms restart and check for repeat alarm s 2 Check Coil a Inspect coil connector pins terminals Verify no damage to coil Verify no damaged or corroded pins b Check resistance of coil Refer to Section 2 10 for speci...

Page 165: ...tinue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Relay a Inspect relay socket and connection pins inside PCM Verify there is no damage to relay and no damaged or corroded connections b Check resistance of coil terminals 1 2 Refer to Section 2 10 for specifications 2 Check Power and Wiring a Check for power at fuse F10 terminal A inside PCM Must have minimum 11 VDC If not check PC...

Page 166: ...mage or corrosion b Check resistance of buzzer Cannot be opened infinite ohms or shorted Zero Ohms c Use Component Test Mode Refer to Section 5 2 4 to test actual current draw of the circuit Buzzer provides audible signal View current draw in Component Test Mode screen Verify the actual cur rent is within the specifications 2 Check Buzzer Wiring Inspect PCM sub harness connector pins terminals See...

Page 167: ...osion b Check for ground at SV2 terminal B including SP 3 to GND RING1 Good ground If not check con nectors and wiring between terminals Verify no damage moisture or corrosion 00121 CHECK AMBIENT AIR SENSOR ACTIVATION Ambient Air Temperature Sensor ATA is not within range of 53 to 158 F 47 to 70 C UNIT CONTROL Alarm and a value of 122 F 50 C will be used for any calculations RESET CONDITION Auto r...

Page 168: ... pins This verifies microprocessor output and wiring connections to the sensor 00123 CHECK SUPPLY AIR SENSOR ACTIVATION Supply Air Temperature Sensor SAT is not within range of 53 to 158 F 47 to 70 C UNIT CONTROL If Alarm 00122 is not active Functional Parameter Temperature Control is set for Supply Air and the setpoint is in the perishable range Alarm and switch to return air control If Alarm 001...

Page 169: ...o physical damage to harness and no damage moisture or corrosion in connectors b Place the system in PC Mode Refer to Note 2 in Notes Section page 7 2 Disconnect sensor from harness Check for 3 0 0 1 VDC volts at harness plug between pins This verifies microprocessor output and wiring connections to the sensor 00126 CHECK FUEL SENSOR CIRCUIT ACTIVATION The fuel level sensor is configured YES and t...

Page 170: ...k for 3 0 0 1 VDC volts at harness plug between pins This verifies microprocessor output and wiring connections to the sensor 00129 CHECK ENG COOLANT SENSOR ACTIVATION Engine Coolant Temperature Sensor ENCT is not within the range of 58 to 266 F 50 to 130 C UNIT CONTROL Alarm Only RESET CONDITION Auto reset when sensor is in range or alarm may be manually reset using the display mounted keys or by...

Page 171: ...occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check for Alarm 00041 Engine Stalled Check for Alarm 00041 ENGINE STALLED When alarms 00041 and 00130 occur at the same time generally the engine has run out or is running out of fuel This causes the engine to surge Check fuel in tank and add fuel as necessary Check fuel lines between the fuel tank and the fuel pump inlet to en...

Page 172: ...iate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Sensor a Inspect sensor connector Verify there is no damage to sensor and no damage moisture or cor rosion in connector b Check Evap Temp Sensor resistance Refer to Note 3 in Notes Section page 7 2 10 000 Ohms 77 F 25 C See Table 8 3 for complete table of temperatures and resistance v...

Page 173: ...g the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself refer to reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Sensor a Inspect sensor connector Verify there is no...

Page 174: ...25 C Refer to Section 8 10 7 for chart of resistances for different sensors 2 Check Sensor Wiring a Inspect connector pins terminals at sensor REM connector and 2CCB See wiring schematic Section 10 Verify there is no physical damage to harness and no damage moisture or corrosion in connectors b Place the system in PC Mode Refer to Note 2 in Notes Section page 7 2 Disconnect sensor from harness Che...

Page 175: ...splay PRETRIP FAIL AND COMPLETED RESET CONDITION Auto reset if Pretrip is started again or Alarm may be manually reset using the dis play mounted keys or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s Refer to Note 1 in Notes Section page 7 2 Operate the unit through the appropriate modes t...

Page 176: ...V1 CIRCUIT Alarm condition must be corrected and the alarm cleared to continue P00150 CHECK SV4 CIRCUIT ACTIVATION The circuit current draw is outside the normal range UNIT CONTROL Pretrip will fail in test 2 and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto reset if Pretrip is started again or Alarm may be manually reset using the dis play mounted keys or by turning the unit off then ba...

Page 177: ...SOR ACTIVATION Return Air Temperature Sensor RAT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto reset if Pretrip is started again or alarm may be manually reset using the dis play mounted keys or by turning the unit off then back on again CORRECTIVE ACTIONS 1 Check Sensor Operation Refer to procedure for ...

Page 178: ...rning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s Refer to Note 1 in Notes Section page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check DC Current Draw and Sensor a Observe current draw readin...

Page 179: ...and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto reset if Pretrip is started again or alarm may be manually reset using the dis play mounted keys or by turning the unit off then back on again CORRECTIVE ACTIONS 1 Check Sensor Operation Refer to procedure for alarm 00125 CHECK COMP DISCHARGE SENSOR Alarm condition must be corrected and the alarm cleared to continue P00161 CHECK SUCTION T...

Page 180: ...ocedure for alarm 00090 CHK AFA SOLENOID CIRCUIT Alarm condition must be cor rected and the alarm cleared to continue P00164 CHECK UL2 CIRCUIT ACTIVATION The circuit current draw is outside the normal range UNIT CONTROL Pretrip will fail in test 2 and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto reset if Pretrip is started again or alarm may be manually reset using the dis play mounted ...

Page 181: ...at least 0 psig If this check does not pass continue to Check Compressor Pumpdown 4 Manually Test Refrigeration System See Refrigeration Troubleshooting Section 9 3 3 for System Will Not Pump Down Must pass all tests P00174 CHECK LOW SPEED RPM ACTIVATION in Test 7 With the CAN calling for low speed engine speed is NOT between 1200 and 1500 rpm in Test 9 15 seconds after the high speed test engine ...

Page 182: ...g the dis play mounted keys or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s Refer to Note 1 in Notes Section page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Refrigerant Level Ch...

Page 183: ...SP a Verify that correct wires are connected to each transducer Plugs to transducers are the same The cor rect wire plug must be connected to the proper transducer The CDP connector is identified with a red tape band while the CSP connector is identified with a blue band b Verify that correct transducer is being used in each position Mechanical connections to transducers are the same The discharge...

Page 184: ...er Plugs to transducers are the same The cor rect wire plug must be connected to the proper transducer The CDP connector is identified with a red tape band while the CSP connector is identified with a blue band b Verify that correct transducer is being used in each position Mechanical connections to transducers are the same The Discharge Transducer should have a RED marking dot on it The Suction T...

Page 185: ...increase as expected when SV1 was energized closed in Cool Pretrip UNIT CONTROL Alarm only RESET CONDITION Auto reset if Pretrip is started again or alarm may be manually reset using the dis play mounted keys or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s Refer to Note 1 in Notes Section...

Page 186: ... is identified with a red tape band while the CSP connector is identified with a blue band b Verify that correct transducer is being used in each position Mechanical connections to transducers are the same The Discharge Transducer should have a RED marking dot on it The Suction Trans ducer should have a BLUE marking dot on it 2 Check Alarms Check for alarm 00086 CHECK UL2 CIRCUIT or P00164 CHECK U...

Page 187: ...ame The cor rect wire plug must be connected to the proper transducer The CDP connector is identified with a red tape band while the CSP connector is identified with a blue band b Verify that correct transducer is being used in each position Mechanical connections to transducers are the same The Discharge Transducer should have a RED marking dot on it The Suction Trans ducer should have a BLUE mar...

Page 188: ...ion page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Wiring to CDP CSP a Verify that correct wires are connected to each transducer Plugs to transducers are the same The cor rect wire plug must be connected to the proper transducer The CDP connector is identified with a red tape band whil...

Page 189: ...oper transducer The CDP connector is identified with a red tape band while the CSP connector is identified with a blue band b Verify that correct transducer is installed in each position Mechanical connections are the same The CDT should have a red dot on it while the CST has a blue dot 2 Check for Alarms a Check for alarm 00121 CHECK AMBIENT AIR SENSOR or P00158 CHECK AMBIENT AIR SENSOR Alarm con...

Page 190: ...ves Gaskets Remove compressor front head inspect condition of cylinder suction valves cylinder discharge valves gaskets Must be in good condition P00201 CHECK UL2 CYLINDERS ACTIVATION A problem has been detected inside the rear cylinder head of the compressor with a cylinder suction valve cylinder discharge valve head gasket or valve plate gasket UNIT CONTROL Alarm Only RESET CONDITION Auto reset ...

Page 191: ...Down Test Refer to Section 8 8 1 Must hold a vacuum and not equalize in a short period of time b Cover condenser and build up discharge pressure Must be able to raise pressure to 400 psig 27 2 bar c Disassemble and inspect compressor valve plates cylinder suction valves cylinder discharge valves and pistons etc Must be intact clean and in good working order P00203 CHK DISCHARGE CHECK VALVE ACTIVAT...

Page 192: ...6 Replace if required 2 Check System Pressures Install manifold gauge set and check and compare compressor discharge suction pressures with those shown in Unit Data Refer to Section 8 9 12 for instruction on comparison 3 Manually Defrost Unit Defrost unit and terminate automatically Typical defrost cycle time is 5 20 minutes Suction pressure should rise gradually during cycle 4 Check Airflow Throu...

Page 193: ...tly to microprocessor No wires are pushed back through plug b Check Defrost Termination Temperature Sensor 2 resistance 10 000 Ohms 77 F 25 C Refer to Section 8 10 7 for chart of resistances for different sensors 2 Check Defrost Termination Temperature Sensor 2 Wiring Inspect harness control box connector pins terminals See wiring schematic Section 10 No physi cal damage to harness No damaged or c...

Page 194: ... Meter for the next service interval Hour Meter reset is a Func tional Parameter Follow maintenance interval recommendations 00226 SERVICE SOON PM 1 DUE ACTIVATION The Maintenance Hour Meter 1 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad CORRECTIVE ACTIONS 1 Check Unit Maintenance Records Schedule unit into servic...

Page 195: ...erval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 00228 SERVICE SOON PM 3 DUE ACTIVATION The Maintenance Hour Meter 3 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset using the display mounted keys CORRECTIVE ACTIONS 1 Check Unit Maintenance Records Schedule unit into ser...

Page 196: ...erval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 00230 SERVICE SOON PM 5 DUE ACTIVATION The Maintenance Hour Meter 4 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad CORRECTIVE ACTIONS 1 Check Unit Maintenance Records Schedule unit into service facility for ma...

Page 197: ... 5 00233 MODEL ERROR ACTIVATION There is an error in the Model Number that is stored in the main microprocessor memory UNIT CONTROL Shutdown and alarm RESET CONDITION Auto reset only when a valid Model number is entered NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself refer to reset condition above Operate the unit ...

Page 198: ...ional Parameters Check Functional Parameters All must be set for selectable values 2 Check Software Version Check microprocessor Software version Upgrade to the latest version of software Newer versions may contain functional parameters that were not present in older versions of microprocessor software Refer to Section 5 3 4 3 Reset Microprocessor a Place the START RUN OFF switch in the OFF positi...

Page 199: ...tem software 3 Reconfigure Microprocessor Send settings to microprocessor Using the latest version of TRU Tech and a Data Transfer USB Memory Device write the desired Configuration file to the device then load the file into the micropro cessor Allow the microprocessor to reboot itself 4 Reset Microprocessor a Place the START RUN OFF switch in the OFF position Disconnect positive battery cable remo...

Page 200: ... Alarm 00245 remains active Unit will operate but changes to the settings will not be retained in the microprocessor memory Download data and replace the main microprocessor module MM Refer to Section 5 5 00246 EEPROM WRITE FAILURE ACTIVATION There is an error in the ability to write information to be stored in the main microprocessor memory UNIT CONTROL Alarm only RESET CONDITION Alarm may be man...

Page 201: ...d Send desired settings to microprocessor using the latest version of TRU Tech a USB data transfer device Do NOT use the display mounted keys 3 Reset Microprocessor a Place the START RUN OFF switch in the OFF position Disconnect positive battery cable remove F7 fuse or unplug 1MM connector wait 20 seconds and reinstall Then place the START RUN OFF back in the START RUN position The microprocessor ...

Page 202: ...croprocessor a Place the START RUN OFF switch in the OFF position Disconnect positive battery cable remove F7 fuse or unplug 1MM connector wait 20 seconds and reinstall Then place the START RUN OFF back in the START RUN position The microprocessor powers up OK and the latest setpoint appears in the display b Alarm 00255 remains active Download data and replace the main microprocessor module MM Ref...

Page 203: ... unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Rack Position Sensor RPS Power And Wiring a Inspect sensor connector pins terminals No physical damage to sensor No damaged or corro sion in connections b If required power sensor by placing the unit in PC Mode check for power Voltage reading between connector...

Page 204: ...on has been made the active alarm should clear itself refer to reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Wiring a Inspect main microprocessor 3MM ENCU connectors Verify there is no damage to module and no damage moisture or corrosion in connector b Use Component Test M...

Page 205: ...es to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Fuses Check F5 F10 Fuses must be good Replace fuse s as required clear alarms restart and check for repeat alarms 2 Check Coil a Inspect coil connector pins terminals Verify no damage to coil Verify no damaged or corroded pins b Check resistance of coil Refer to Section 2 10 for specification...

Page 206: ...zzer check for power at SS terminal and 3MM 12 Must have minimum 11 VDC If not check connectors and wiring between terminals for damage moisture or corrosion b Check starter Refer to engine workshop manual 05016 CHECK REMOTE AMBER LIGHT ACTIVATION A problem has been detected in the alarm amber light circuit LB If this alarm is activated while the circuit is energized the circuit is detected shorte...

Page 207: ...5 2 4 energize engine preheat circuit Verify the cir cuit is energized and amp draw is displayed NOTICE DO NOT leave the air intake circuit energized for the full 5 minutes if full amperage is shown as the intake air heater element life will be greatly shortened b Check for power at 3MM 14 Must have minimum 11 VDC If not download data and replace main microprocessor For complete Main Microprocesso...

Page 208: ...lem is found Once a repair or correction has been made clear the alarm s Refer to Note 1 in Notes Section page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check CAN bus a Inspect connector pins terminals on 1MM 1SVM DM and ENCU Verify no damage or corrosion in connections b Check display LOSS O...

Page 209: ... If not check connectors and wiring between terminals Verify no damage moisture or corrosion 2 Check for other CAN Bus Alarms This alarm may accompany by other alarms complete troubleshooting steps for alarms found If repairs have been made and the other alarms have cleared further troubleshooting may not be required If this alarm reoccurs check CAN bus as described in the proceeding step 3 Perfor...

Page 210: ...tive alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check System Pressures Install manifold gauge set and check and compare compressor discharge evaporator outlet suction pressures with those shown in Unit Data Refer to Section 8 9 12 for instruction on comparison 2 Check Wiring If a transducer reading is not within a reasonable range of gauge reading check wires to s...

Page 211: ...Wiring Check wires to sensor for short from another circuit Check wiring from 2MM 29 2MM 12 and 2MM 23 to PCM 3 Replace Main Microprocessor Download data and replace main microprocessor For complete Main Microprocessor Module replace ment instructions refer to Section 5 5 2 23100 NO COMM FROM MICRO TO OUTPBD1 ACTIVATION Main microprocessor cannot communicate internally UNIT CONTROL Shutdown all mo...

Page 212: ...o Note 1 in Notes Section page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Both Active and Inactive Alarms for other NO COMM Alarms a If more than one alarm record all and proceed to step 2 b If this is the only NO COMM alarm replace module 2 Check CAN Bus a Inspect connector pins termina...

Page 213: ...rm occurs Continue with the steps below as necessary CORRECTIVE ACTIONS 1 Check Both Active and Inactive Alarms for other NO COMM Alarms a If more than one alarm record all and proceed to step 2 b If this is the only alarm check for continuity CAN Hi 1MM 2 through SP 1 to ENCU 23 CAN Lo 1MM 4 through SP 4 to ENCU 24 c Replace ENCU 2 Check CAN Bus a Inspect connector pins terminals on 1MM and1SVM N...

Page 214: ... 8 3 PRE TRIP INSPECTION 8 2 8 4 EXTERNAL SURFACE SERVICE 8 4 8 5 ENGINE AND ENGINE RELATED SYSTEMS SERVICE 8 6 8 6 POWER TRAIN SERVICE 8 15 8 7 REFRIGERANT SYSTEM SERVICE 8 21 8 8 COMPRESSOR AND UNLOADER SERVICE 8 28 8 9 REFRIGERANT SYSTEM COMPONENT SERVICE 8 34 8 10 ELECTRICAL SYSTEM COMPONENTS 8 44 ...

Page 215: ...is attached trailer container rail car metal building etc NOTICE Unit uses R404A and POE oil The use of inert gas brazing procedures is manda tory for all Carrier Transicold refrigera tion units otherwise compressor failure will occur For more information Refer to Technical Procedure 98 50553 00 Inert Gas Brazing 8 1 SECTION LAYOUT Service procedures are presented herein under the fol lowing major...

Page 216: ...Engine Manual Engine Manual Engine Manual Fuel System 1 Clean mechanical and electric if equipped fuel pump screens 2 Change fuel filter 3 Check fuel heater if equipped Section 8 5 3 Section 8 5 4 Section 8 5 5 Section 8 5 8 Cooling System 1 Check coolant change interval refer to Section e of this table If replacement is not required check antifreeze con centration using a refractometer Carrier Tr...

Page 217: ...ate as necessary 3 Check clean the evaporator coil and all defrost drain hoses 4 Install manifold gauge set and check refrigerant pressure 5 Run APX Control System Pretrip 6 Check manual defrost operation Section 8 6 Section 8 9 13 Section 8 9 1 Check Section 3 5 Section 3 10 Electrical System 1 Check unit switches and electrical connections 2 Check condition of all modules Check c 5 year or 12 00...

Page 218: ...enoid 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the STOP RUN OFF switch in the OFF position 2 Remove cover in accordance with preceding step Loosen innermost cover mounting nut to unlock and remove remaining cover hardware 3 Disconnect the solenoid connector remove hardware 7 attaching old solenoid and bring new solenoid in place Torque moun...

Page 219: ... for smooth operation of the latch assemblies and the latch pins that are mounted on the unit s frame See Figure 8 2 In order to keep the movable parts clean and lubricated CTD recommends the use of a de greasing cleaner and LPS 2 lubricant This lubricant should be available at any local automobile and truck parts suppliers b Cable Replacement 1 Remove circular clip that secures the cable to the p...

Page 220: ...ric pump and or optional electric fuel heater Two fuel system configurations are available the stan dard extended life spin on filter system and the extra heavy duty suction side filter system see Figure 8 5 Figure 8 5 Fuel System Diagram 1 Fuel Tank 2 Supply Line 3 Electric Pump 4 Mechanical Pump 5 Water Drain Valve 6 Heater 7 Filter 8 Filter or Fuel Head Leak Off Line 9 Injection Pump 10 Injecto...

Page 221: ... be necessary to continue to pump until the engine starts NOTICE Running the engine for an extended period of time with the manual plunger up can cause a priming pump failure 6 Depress and turn the top of the manual plunger clockwise to lock in place 7 When engine is running smoothly turn bleed valve clockwise until fully closed If bleeding a suction side filter system loosen the vent on the cover...

Page 222: ...element using new O ring or heater bowl on new element using new gasket 5 Fill new element with clean diesel fuel lubricate the seal and install Tighten firmly by hand 6 Start unit and check for leaks Figure 8 9 Suction Side Fuel Filter 8 5 6 Suction Side Fuel Filter Replacement To replace filter 1 Ensure unit will not start automatically by dis abling any two way communication and placing the STO...

Page 223: ...gine operation Check power approximately 12 VDC from PCM 22 9 Figure 8 10 through to connector 13 Check ground from 2MM 24 8 through connector 12 Check signal greater than 0 24 VDC and less than 5VDC at 2MM 13 5 If checks in the preceding step are OK remove the fuel level sensor focus tube gaskets With the trailer level verify that the fuel level sensor flange is within one half bubble of level us...

Page 224: ...gh PCM 14 3 through SP8 to the fuel heater connector at terminal A Check also for ground from the fuel heater connector terminal B through SP 3 to GND1RING1 3 If the wiring is good and the fuel heater tempera ture is below the cut in temperature replace the fuel heater If the wiring is good but the fuel heater temperature is above the cut out tem perature the internal temperature switch may be ope...

Page 225: ...c ing the STOP RUN OFF switch in the OFF posi tion 2 Check all connections for mechanical tightness Be sure filter outlet pipe is not fractured 3 Release 2 clips on air cleaner housing and remove the cover 4 Remove filter element wipe inside of air cleaner housing clean inspect filter element and replace if required 5 Wipe inside of the cover and re install 6 Re secure 2 clips on air cleaner housi...

Page 226: ...ut the system into Technician Mode refer to Section 5 2 2 Select Component Calibration Mode Soft key 3 Press to start the Rack Position Sensor cali bration During the calibration process the display will show the Engine Load RPMs current calibration offset the offset in the Engine ECU and calibration status The Rack Position Sensor is calibrated at an engine speed of 1700 1780 RPM In order to reac...

Page 227: ...adiator Replacement 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the START RUN OFF switch in the OFF position 2 To facilitate the removal process remove the surround with grill attached refer to Section 8 4 3 and then remove the condenser fan sup port bracket at the top of the frame 3 Drain coolant into a suitable container by remov ing coolant...

Page 228: ...mp sheaves to ensure proper alignment Pulley misalignment will cre ate excess belt wear and shorten alternator bearing life The center line of all three sheaves must be in line 4 Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure Check belt tension using belt tension tool Carrier Transi cold part number 07 00203 00 ...

Page 229: ...n see Figure 2 4 is a belt drive system that transfers power from the engine to the condenser and evaporator fans The system consists an upper and lower belt gear box fanshaft and clutch Service instructions for the power train system are provided in the following sub paragraphs NOTE Coverage of the water pump alternator belt is provided in Section 8 5 15 while coverage of the alternator is provid...

Page 230: ...r use 5 16 18 x 2 1 2 lg bolts in every other hole of adapter and take up evenly on the bolts until the original 5 16 18 x 1 lg bolts engage flywheel Apply thread sealer Loctite 262 to the bolts Take up on all bolts evenly and then torque bolts 26 to 30 ft lbs 35 3 to 40 7 Nm 7 Fit new belt in grooves and check the center alignment of the drive adapter upper idler and gearbox sheaves to ensure pro...

Page 231: ...mpression Ring 11 Clamp 12 Bushing 13 Bushing Bolts Washers 14 Nozzle Cover 15 Armature Retaining Bolts Washers 16 Key Round End 17 Armature 18 Rotor Retaining Nut 19 Rotor 20 Rotor Spacer 21 Coil 22 Key Square End 23 Fanshaft bolts and washers 24 Shims 25 Vent Fitting 26 Vent Tube 27 Fan Clutch Bolts Washers 1 2 3 4 5 6 7 8 9 10 11 7 12 13 14 1 15 16 17 18 19 20 21 2 22 23 24 25 26 27 3 ...

Page 232: ...e tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure Using inch drive ratchet in adjustment position 8 to pivot idler set belt tension Use belt tension tool Carrier Transicold part number 07 00203 00 or 07 00253 00 in accordance with the following chart Tighten upper idler pivot bolt 13 Reinstall upper fan shroud and upper frame support 14 R...

Page 233: ...rt number 07 00432 00 check gap Refer to Technical Instruction 98 50180 for air gap tool usage instructions The gap should be between 0 015 and 0 095 inch 0 38 and 2 3 mm 11 If the gap is less than 0 015 remove enough shims to increase the gap to approximately 0 020 inch 0 25 mm Shims Carrier Transicold part number 50 00232 30 are 0 010 inch 0 25 mm each If the gap is more than 0 090 inch add enou...

Page 234: ...g seal ring bolts 45 to 50 inch lbs 5 1 to 5 7 Nm Sug gested torque for the clamp is 38 inch lbs 4 3 Nm maximum torque is 50 inch lbs 5 7 Nm 10 Reinstall the upper belt condenser fan clutch and evaporator fan Refer to Section 8 6 2 through 8 6 5 8 6 7 Gearbox To remove and reinstall the gearbox right angle drive Item 6 Figure 8 19 do the following 1 Ensure the unit will not start automatically by ...

Page 235: ...ding of discharge pressure See Figure 8 22 2 Start unit in Continuous Operation Adjust set point so that unit is running in high speed fully loaded and operating in cooling Run approxi mately ten minutes until the refrigeration system is warmed up and the refrigerated compartment temperature is approaching setpoint 3 Partially block off air flow to condenser coil so discharge pressure rises to 230...

Page 236: ... check evacuate and recharge the system d Pumping Down The Low Side Components on the low side of the refrigeration system the filter drier EVXV evaporator coil CSMV heat exchanger suction line etc may be serviced or replaced without having to completely remove the refrigerant charge from the system by pumping down the low side and temporarily storing the refrigerant in the condenser and receiver ...

Page 237: ... backseat the liquid line service valve when the ball in the upper sight glass drops to the bottom of the glass It the unit is not operat ing when approximately 5 lbs 2 3 kg have been removed close the cylinder valve and backseat the liquid line service valve Proceed to step 7 3 If charge is to be added place cylinder of refrig erant on a scale and connect a charging line and gauge from cylinder t...

Page 238: ...rant system equipment if not already connected Refer to Figure 8 22 WARNING Only a refrigerant cylinder containing R404A should be connected to this refrig eration unit in order to pressurize the system However dry nitrogen may be used to increase pressure Any other gas or vapor will contaminate the system and require additional removal and evacua tion NOTICE Do not vapor charge R404A Only liquid ...

Page 239: ...psig 1 4 to 10 2 bar to detect the leak The larger the leak the less pressure is required The smaller the leak the greater the pressure required 6 The recommended procedure for finding leaks from a system is with an electronic leak detector Checking joints with soapsuds is satisfactory only for locating large leaks or pinpointing small leaks once a general area has been located 7 Once leak checkin...

Page 240: ...ocess is completed because of its inherent inaccuracy Standard service hoses are not recommended for evacuation purposes Evacuation hoses are recommended for this procedure a Evacuation of the Complete System 1 Evacuate only after leak check Refer to Sec tion 8 7 3 2 If possible keep the temperature of the major components condenser evaporator compres sor and receiver above 60 F 15 6 C to speed ev...

Page 241: ... service valve Raise system pressure to approximately 2 psig 0 1 bar Ensure that the control system does not switch to the Charge Mode If this occurs switch it back to the RECOVER LEAK CHK EVAC MODE Refer to Section 5 2 5 8 Purge nitrogen from the low side of the system at the suction service valve 9 Open the vacuum pump valve and start the pump Evacuate unit to 500 microns Close the vacuum pump v...

Page 242: ...o not unscrew service valve mounting capscrews all the way before breaking seal Entrapped pressure could result in injury 5 Loosen the suction and discharge service valve mounting bolts Tap the valve bodies to break the seal and then remove bolts 6 Disconnect all low voltage connectors UL1 UL2 CDT CDP HPS 7 Loosen lower belt idler and remove belt from gearbox Belt may be removed with and rein stal...

Page 243: ... evacuate dehydrate and charge system as required Refer to Section 8 7 2 8 7 3 8 7 4 8 8 3 Cylinder Head and Valve Plate Service 1 Pumpdown the compressor Refer to Section 8 7 2 2 Ensure the unit will not start automatically by disabling any two way communication and plac ing the STOP RUN OFF switch in the OFF posi tion WARNING Do not unscrew cylinder head mounting capscrews all the way before bre...

Page 244: ... piston for damage Check for debris burned and carbonized oil sludge or mechanical failure i Inspect cylinder bores for excessive wear Excessive wear for cylinder bores is defined as heavy and uneven scratches gouges or chip ping of the internal wall of the cylinder with a depth greater than 0 025 inch which are caused by foreign objects other than a normal reciprocating movement of the pistons an...

Page 245: ...cover plate O ring However in the event the pump requires inspection or cleaning refer to Figure 8 27 for disassembly and reassembly Clean all parts coat all moving parts with com pressor oil before proceeding with reassembly 5 Install the pump end thrust washer on the two dowel pins located on the bearing head See Figure 8 26 Figure 8 26 Oil Pump Bearing Head Assembly Figure 8 27 Oil Pump NOTICE ...

Page 246: ... System CAUTION Use only Carrier Transicold approved Polyol Ester Oil POE Buy quantities of one gallon or less When using this hygroscopic oil immediately reseal Do not leave container of oil open or contam ination will occur Two methods for adding oil are the oil pump method and closed system method Oil Pump Method One compressor oil pump that may be purchased is a Robinair part no 14388 This oil...

Page 247: ... on the suction pressure gauge Discharge pressure should drop approxi mately 5 to 15 psig 0 4 to 1 0 bar 4 De energize UL1 and note pressures Suction pressure should drop and discharge pressure should rise by same amount as in step 3 above 5 Repeat steps 3 4 for the rear unloader UL2 At the end of the test reconnect both unloaders NOTE If pressures do not change as indicated check the unloader coi...

Page 248: ...ng bolts 12 to16 ft lbs 1 3 to 1 8 Nm 7 Leak check evacuate dehydrate and charge system as required Refer to Section 8 7 2 8 7 3 8 7 4 8 Check operation refer to preceding step a 8 9 REFRIGERANT SYSTEM COMPONENT SER VICE 8 9 1 Evaporator Coil The use of recycled cardboard cartons is increasing across the country The recycled cardboard cartons create much more fiber dust during transport than new c...

Page 249: ...reen sufficient to reach the ambient sensor 2 Figure 8 30 and wiring Remove sensor and wiring from Front Condenser Frame 3 7 Remove the captive washer screws 11 secur ing the condenser radiator assembly to the unit 8 Remove the condenser radiator assembly from the unit 9 Remove the eight bolts 10 securing the rear condenser frame to the front condenser frame 2 and set rear frame aside 10 Separate ...

Page 250: ...mp down the low side Refer to Section 8 7 2 2 Remove bracket loosen the inlet connection to relieve any remaining pressure then remove drier 3 Procure new O rings Lubricate the O rings back side of sleeves and coupling nuts Using a backup wrench at each connection torque 30 to 38 ft lbs 40 7 to 51 5 Nm 4 Leak check evacuate dehydrate and charge system as required Refer to Section 8 7 2 8 7 3 8 7 4...

Page 251: ...e discharge and receiver pressures If the valve is closing properly compressor dis charge pressure will begin to rise and the receiver pressure will remain the same or begin to drop slowly If the valve is not seating prop erly both discharge and receiver pressure will rise slowly or remain the same 5 Operate the unit until discharge pressure reaches 200 PSIG 13 61 Bars and disconnect the coil Disc...

Page 252: ...tainer Figure 8 32 3 Disconnect wiring and remove coil 4 Replace coil by reversing the preceding steps b Replacing Internal Components CAUTION Service Mode MUST be used whenever removing refrigerant charge refrigerant leak checking or evacuating 1 To service the liquid line solenoid valve pump the unit down Refer to Section 8 7 2 step d To service the hot gas solenoid valve remove the refrigerant ...

Page 253: ...witch in the START RUN position DO NOT ALLOW THE UNIT TO START When the MessageCenter displays SMV CLOSING measure the AC volt age on the harness side of the connector between pins A B and then between C D A voltage 10 to 16 VAC should be read by the digital voltmeter for each pair of wires If the reading is present on all of the wire pairs there is a good signal coming from the control system 3 I...

Page 254: ...in an emergency a LIMP HOME procedure can be done as follows 1 Install a manifold gauge set 2 Pump down the low side Refer to Section 8 7 2 3 Remove the internal motor piston assembly 4 Loosening the Allen screw and remove the pis ton and screw 5 Install the motor piston assembly without pis ton Torque the nut 35 to 40 ft lb 47 5 to 54 2 Nm or body screws 80 to 97 inch lbs 9 to 11 Nm as applicable...

Page 255: ...nd either open or close the valve Each red LED should light sequentially until all four are illumi nated Any LED failing to illuminate indicates an open on that leg and a need to replace the drive 3 To test with an ohmmeter check the winding resistance between connector pin A E B E C E and then between D E In normal ambi ent the resistance between the pins should be 46 ohms If an infinite or zero ...

Page 256: ...aze the remaining stub out from the con necting copper 3 Clean tube stubs so new valve fits easily Posi tion new valve 4 Wrap valve with wet rags to keep cool when brazing 5 Braze valve in place and cool connections with wet rag 6 Leak check evacuate dehydrate and charge system as required Refer to Section 8 7 2 8 7 3 8 7 4 8 9 11 High Pressure Switch a Replacing High Pressure Switch 1 Pump down t...

Page 257: ...gher than 100 psig even if actual pressure is higher 4 If the compressor suction pressure or evapora tor pressure transducer has lost power or the signal is not returning to the module the reading in Unit Data will default to 55 to 60 psig 3 74 to 4 08 bar Comparisons in this pressure range are not conclusive To test the transducer wiring do the following 1 Verify that the wiring to the transducer...

Page 258: ...itch An ohmmeter will indicate continuity when switch actuates The switch contacts should close and the ohm meter needle move rapidly to 0 Any hesitation in the ohmmeter indicates a possible problem with the switch and it should be replaced 9 Refer to Section 2 9 for switch setting If switch fails to actuate at correct gauge reading adjust switch by turning adjusting screw clockwise to increase se...

Page 259: ...two 35 pin connectors and 8 pin connector from the front of the module 3 Replace module Tighten mounting hardware to 96 inch lbs 10 8 Nm 4 Reinstall connectors ensuring tabs are fully locked in place 5 Make sure the latest software has been loaded to ensure all modules are compatible refer to Section 5 3 4 NOTICE When a module is replaced software should be upgraded before switching the unit on Th...

Page 260: ...0 to 60 ft lbs 68 to 88 Nm while holding shaft using a six point Torx T50 wrench For instruction on tightening alternator mounting hardware and checking belt refer to Section 8 5 15 Figure 8 43 Light Bar Connections 8 10 6 Light Bar The light bar may be tested using a 12 VDC source To test the light bar 1 Connect the ground from the power source to pin G on the light bar side of the connector 2 Th...

Page 261: ...6 099 165 73 9 1 537 16 26 7 144 200 42 5 5 24 700 100 37 8 5 828 170 76 7 1 402 14 25 6 134 800 44 6 6 23 390 102 38 9 5 571 175 79 4 1 281 12 24 4 126 100 46 7 7 22 160 104 40 0 5 327 180 82 2 1 171 10 23 3 118 100 48 8 9 20 990 106 41 1 5 095 185 85 0 1 072 8 22 2 110 500 50 10 19 900 108 42 2 4 874 190 87 8 983 6 21 1 103 600 52 11 1 18 870 110 43 3 4 665 195 90 6 902 4 20 97 070 54 12 2 17 90...

Page 262: ...320 1 480 23 3 10 1 177 150 16 6 62 145 340 56 7 134 28 160 165 5 330 1 310 22 2 8 1 102 240 17 7 64 138 120 57 8 136 27 040 171 1 340 1 160 21 1 6 1 032 600 18 9 66 131 310 58 9 138 25 970 176 7 350 1 040 20 4 967 830 20 0 68 124 870 60 0 140 24 960 182 2 360 920 18 9 2 907 560 21 1 70 118 790 61 1 142 23 980 187 8 370 830 17 8 0 851 450 22 2 72 113 040 62 2 144 23 050 193 3 380 740 16 7 2 799 18...

Page 263: ... 6 13 55 8 0 115 4 21 6 1 88 27 3 16 60 8 7 126 1 20 4 2 0 29 1 18 65 9 5 137 4 19 2 2 1 30 9 21 70 10 3 149 4 18 0 2 3 32 8 24 75 11 2 162 1 17 2 2 4 34 8 27 80 12 1 175 5 16 4 2 5 36 8 29 85 13 1 189 6 14 6 2 7 38 9 32 90 14 1 204 5 13 8 2 8 41 1 35 95 15 2 220 2 12 10 3 0 43 3 38 100 16 3 236 8 11 12 3 1 45 6 41 105 17 5 254 2 10 14 3 3 48 0 43 110 18 8 272 4 9 16 3 5 50 4 46 115 20 1 291 6 8 1...

Page 264: ...Unit Runs But Has Insufficient Cooling 9 4 9 3 3 System Will Not Pump Down 9 4 9 3 4 Unit Operates Long Or Continuously In Cooling 9 4 9 3 5 Unit Will Not Terminate Cooling 9 5 9 3 6 Unit Will Not Heat Or Has Insufficient Heating 9 5 9 3 7 Unit Will Not Terminate Heating 9 5 9 3 8 Defrost Cycle Malfunction 9 5 9 3 9 Abnormal Pressure Cooling 9 6 9 3 10 Abnormal Pressure Heating 9 6 9 3 11 Abnormal...

Page 265: ...t starter Check Repair Starter motor malfunction 9 1 4 Starter motor solenoid defective Engine Manual Open starting circuit 9 1 5 Incorrect grade of lubricating oil 2 7 Compressor not unloaded 8 8 6 High suction pressure 8 9 8 Starter motor cranks but engine fails to start No fuel in tank Check Air in fuel system 8 5 2 Water in fuel system Drain Sump 8 5 5 Plugged fuel filter 8 5 5 Plugged inlet s...

Page 266: ...NCU operation defective Replace 9 1 4 Starter Motor Malfunction Starter motor will not crank or turns slowly Battery insufficiently charged 9 2 Battery cable connections loose or corroded Check Battery cables defective Replace Excessively worn open or defective starter brushes Engine Manual Starter motor solenoid defective Engine Manual Incorrect grade of lubricating oil 2 7 Starter motor turns bu...

Page 267: ...ngine Manual Restriction in radiator 8 5 14 Coolant level too low 8 5 14 Loose water pump Engine Manual Defective thermostat Engine Manual Alternator Water pump belt loose broken 8 5 16 Excessive crankcase pressure Plugged crankcase breather 8 5 16 Indication Trouble Possible Causes Action Reference Alternator fails to charge Limited charging system operating time Check Battery condition Load Test...

Page 268: ...or internal damage 8 8 1 Unloader malfunction 8 8 6 Refrigeration system Abnormal pressure 9 3 9 Unloader malfunction 8 8 6 Expansion valve malfunction 9 3 13 No or restricted evaporator airflow 9 3 12 Suction Modulation Valve malfunction 8 9 8 Check system for noncondensibles 8 7 2 Clutch failure 8 6 4 9 3 3 System Will Not Pump Down Valve malfunction SV2 or SV4 not closing 8 9 6 Check valve not ...

Page 269: ... sor is set for C or F Check 9 3 8 Defrost Cycle Malfunction Will not initiate defrost automati cally Defrost timer has not expired Check Reset Defrost air switch DAS malfunction 8 9 13 DTT is above 40 F 4 4 C Cool Down Damaged or corroded electrical connections at DTT Check Repair Will not initiate defrost manually Display key defective 8 10 4 DTT is above 40 F 4 4 C Cool Down Unit has been runni...

Page 270: ... or restricted air flow 9 3 12 Excessive frost on evaporator coil 9 3 8 SV2 defective 8 9 6 Suction modulation valve malfunction 8 9 8 Liquid or suction line service valve partially closed Open Clutch failure 8 6 4 High suction pressure SV4 leaking 8 9 6 Compressor valves s worn or broken 8 8 1 Compressor gasket s defective 8 8 1 Suction and discharge pressures tend to equalize when unit is oper a...

Page 271: ...correctly Low refrigerant charge 8 7 2 EVOT defective 8 10 7 Coil not seated properly on valve 8 9 12 EVOP defective Check EVXV inlet screen plugged Check Replace Damaged or corroded electrical connections at valve or SVM Check Repair 9 3 14 Compressor Suction Modulation Valve CSMV Malfunction CSMV not controlling correctly Coil not seated properly Check Coil defective 8 9 8 CSP defective 8 9 12 C...

Page 272: ...62 11637 SECTION 10 WIRING PARAGRAPH NUMBER Page 10 1 HARNESS CONNECTOR WIRING 10 1 10 2 SPLICE POINTS 10 5 10 3 WIRING SCHEMATIC 10 5 ...

Page 273: ...ponent Terminal SPï8 3 14 SATPWRïB 6 LBïB 7 3MMï34 8 3MMï23 9 PCMï35 13 35 SPï8 14 3 SPï5 15 3MMï18 16 3MMï17 17 2SVMï11 18 1MMï1 19 FLSïA 22 3MMï15 23 AFASïA F6ïA 24 3MMï13 26 3MMï14 27 3MMï28 28 2MMï12 29 2MMï23 30 2MMï29 31 1MMï6 32 SPï6 34 PCMï13 35 13 Unused terminals 1 2 4 5 10 11 12 20 21 25 1MM ï BLACK 1 3 6 8 Component Terminal PCMï19 1 SPï1 2 1SVMï1 3 SPï4 4 PCMï32 6 1SVMï6 8 Unused term...

Page 274: ...SPï1 20 CDPï1 21 DTTïA 22 PCMï30 23 FLSïB 24 REMïF 25 IATïB If equipped 26 REMïG If Not CSTïB 27 EVOPï1 28 PCMï31 29 SPï7 30 SPï9 35 Unused terminals 31 32 33 34 3MM ï GRAY 1 12 24 35 Component Terminal SV1ïA 1 SV2ïA 2 SV4ïA 3 UL1ïA 6 LBïH 7 UL2ïA 8 ENCUï44 9 FPï 10 CLHïA 11 SSïA 12 PCMï26 13 PCMï27 14 PCMï23 15 SPï5 16 PCMï17 17 PCMï16 18 DASï 19 PCMï9 23 PCMï28 28 DAS negative 29 PCMï8 34 Unused...

Page 275: ...ïD 5 EVXVïE 6 EVXVïA 7 EVXVïB 8 EVXVïC 9 EVXVïD 10 PCMï18 11 Units With DS Connector DSïA 14 Units Without DS Connector REMïA Units With DS Connector REMïA 15 Units Without DS Connector REMïC SPï6 22 Units With DS Connector DSïB 25 Units Without DS Connector REBïB Units With DS Connector REMïB 26 Units Without DS Connector REMïD Unused terminals 1 12 13 16 to 21 23 24 27 to 35 Units With DS Connec...

Page 276: ...13 14 ENCU 1 22 23 44 Component Terminal ENCTïB 1 ENSSNï2 2 ENCTïA 6 RPSï3 7 ENOPSïA 15 ENOPSïB 18 ENCU GND A 19 ENSSNï1 20 SM 21 SPï6 22 SPï1 23 SPï4 24 SPï27 If equipped with MAP 27 RPSï2 If not MAPï3 If equipped with MAP 28 SPï28 If equipped with MAP 29 RPSï1 If not FSAï1 36 FSAï2 41 ENSSNï3 43 3MMï9 44 Unused Terminals 3ï5 8ï14 16 17 25 26 30ï35 37ï40 42 ...

Page 277: ...VMï26 D REMS1 2MMï14 E REMSN1 2MMï25 F REMSN1 Unused Terminals G H J K Splice Point No Component SPï1 CAN high 1MMï2 1SVMï5 ENCUï23 SPï2 Ground SATPWRïA UL1ï negative UL2ï negative FPï negative GND1ïRING1 LBïG SPï3 Ground AFASïB negative CLHï B negative GND1ïRING1 SV1ïB negative SV2ïB negative SV4ïB negative FH1ïB FH to FHTS to FH1ïA FH2ïB FH to FHTS to FH2ïA SPï4 CAN low 1MMï4 1SVMï7 ENCUï24 SPï5...

Page 278: ......

Page 279: ... Data Refrigeration System 2 16 DataLink Data Recorder Power Up 3 11 DataLink Data recorder Via TRU Tech 5 16 Defrost 4 4 4 9 Defrost Air Switch 8 43 Defrost Initiation And Start 4 9 Display 3 1 Display Module 8 5 Display Module DM 8 45 Display Module Keys 2 13 Display Screens 3 2 Door Latch Maintenance and Replacement 8 5 Downloading Data Files 5 10 E Electric Fuel Pump 2 14 Electric Fuel Pump Sc...

Page 280: ... Steps 5 15 Pressure Transducers 8 43 Pre Trip Inspection 8 2 Priming the Fuel System 8 7 ProductShield 4 12 Pull Down Pull Up 4 3 R Rack Position Sensor RPS Calibration 8 12 Receiver 2 9 Refrigerant System Component Service 8 34 Refrigerant System Service 8 21 Refrigerant System Service Connections 8 21 Refrigeration Circuit During Cooling 2 17 Remote Panel 2 14 3 26 Remote Switches 2 13 Remote T...

Page 281: ...t 9 2 Troubleshooting Misc Engine Troubleshooting 9 3 Troubleshooting Refrig Temp Control 9 4 Troubleshooting Restricted Evaporator Air Flow 9 7 Troubleshooting Solenoid Valve Malfunction 9 7 Troubleshooting Starter Motor Malfunction 9 2 Troubleshooting System Will Not Pump Down 9 4 Troubleshooting Unit Operates Too Long In Cooling 9 4 Troubleshooting Unit Runs But Insufficient Cooling 9 4 Trouble...

Page 282: ...oration P O Box 4805 Syracuse NY 13221 USA www carrier transicold com North America Carrier Transicold 700 Olympic Drive Athens GA 30601 USA Tel 1 706 357 7223 Fax 1 706 355 5435 Central America and Mexico Ejercito Nacional 253 A Piso 5700 Colonia Anahuac 11320 Mexico D F Tel 55315010 Fax 55315010 ext 1005 ...

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