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Ingersoll-Rand 070008, Maintenance Manual

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Ingersoll-Rand 070008 Maintenance Manual Download Page 112

Engine Maintenance

111

Injection Pump Removal

The injection pump drive gear will not fit through 
the gear housing when removing the pump, the 
gear must be separated from the pump. Using tool 
P/N 204-1011, it will not be necessary to remove 
the belts, crankshaft pulley, crankshaft seal or 
front plate. See Figure 185 “Injection Pump Gear 
Tool” on page 112. 

1. Note the alignment of the index marks on the 

injection pump and the gear case. The index 
mark on the injection pump is usually aligned 
with the single index mark on the gear case. If 
not, mark it so the injection pump can be 
returned to the same position when it is 
reinstalled. 

2. Remove the starter for clearance, remove 

throttle linkage, fuel lines, harness and 
mounting hardware from injection pump.

3. Remove the cover plate from the gear case. 

Remove the nut and lock washer which secure 
the gear to the injection pump shaft. Use a 
shop rag to prevent the lock washer or nut 
from falling into the gear case. 

NOTE: The injection pump gear assembly is 
made of three pieces; the flange, the gear, 
and the transfer pump cam. Do not loosen or 
remove the four bolts that fasten the gear to 
the flange because that changes the timing. 

4. Use the hardware from the cover plate to 

attach the tool plate (with the marked side 
pointing up and out) to the gear case.

5. Align the threaded holes in the injection pump 

gear with the two holes in the tool plate by 
rotating the engine crankshaft. Attach the gear 
to the tool plate with the screws provided with 
the tool plate.

6. Thread the long screw supplied with the tool 

plate into the small end of the adapter, also 
supplied with the tool plate. Insert the adapter 
into the tool plate and rotate to provide a solid 
position to force the injection pump shaft from 
the gear. Caution should be made to align the 
screw over the center of the injection pump 
shaft.

7. Remove the screw and adapter leaving the tool 

plate in place. This holds the gear in proper 
tooth alignment until the injection pump is 
re-installed.

1.

Index Marks

Figure 183: Index Mark Location

1.

Index Mark on Injection Pump

2.

Index Mark on Gear Case

Figure 184: Index Mark Alignment

1

1

2

Summary of Contents for 070008

Page 1: ...ere TK 5XXXX X PL TK 55494 2 MM 2013 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text information to be placed here TK 5XXXX X PL 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate SB 210 Additional text information to be placed here TK 5XXXX X PL Distri...

Page 2: ...Precedent C 600 TK 55494 2 MM Rev 0 06 13 Copyright 2013 Thermo King Corp Minneapolis MN U S A Printed in U S A ...

Page 3: ...nufacturer is not responsible and will not be held liable in contract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles contents or persons by reason of the installation of any Thermo King product or its mechanical failure The maintenance information in this manual covers unit models System Precedent C 600 901819 Precede...

Page 4: ...into the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians For additional information on regulations and technician certification programs contact your local Thermo King dealer ...

Page 5: ...__________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ _________________________________________________________________...

Page 6: ...lectric Heater Strips 18 Standby Power Cord Requirements 18 Electric Fuel Heater Optional 18 Maintenance Inspection Schedule 19 Unit Description 21 Unit Overview 21 Features and Options 21 Diesel Engine 22 AC Generator 22 Condenser Fans 22 Evaporator Fans 22 Refrigeration Cluster 23 Thermo King X430L Reciprocating Compressor 23 Electronic Throttling Valve 23 SMART REEFER 4 SR 4 Control System 24 C...

Page 7: ...ontinuous Mode 46 Using the Gauges Key 48 Using The Sensors Key 49 Using the Main Menu 49 Pretrip 50 Performing a Pretrip Test 51 Flash Drive 53 Languages If Enabled 54 Alarms 56 Gauges 59 Sensors 60 Data Logger CargoWatch 60 Hourmeters 62 Mode 63 SmartPower Electric Standby Option 66 Adjust Brightness 68 Time 69 Clear All ECU Faults 69 Manual Pretrip Inspection Before Starting Unit 69 Loading Pro...

Page 8: ... 2 FB2 89 Auto Phase System 89 Evaporator Heaters 90 Transformer 460 Vac Units Only 90 Ultrasonic Fuel Level Sensor 91 Important USFLS Replacement Information 92 Electric Fuel Heater Optional 93 Operation 93 Components 93 Diagnosis 94 Engine Maintenance 96 TK486V25 Diesel Engine 96 EMI 3000 96 Engine Lubrication System 96 Engine Oil Change 96 Oil Filter Change 96 Low Oil Pressure 97 Engine Cooling...

Page 9: ...gh Pressure Cutout Switch HPCO 131 Three Way Valve Condenser Pressure Bypass Check Valve 132 Electronic Throttling Valve ETV 133 Pressure Transducers 133 Hot Gas Bypass Valve 133 Refrigeration Service Operations 134 Refrigeration System Component Locations 134 Compressor 136 Compressor Coupling Removal Standard Units 137 Compressor Coupling Installation Standard Units 137 Curbside Condenser Coil 1...

Page 10: ...ction 155 Condenser Evaporator and Radiator Coils 155 Micro Channel Coil Cleaning Recommendations 155 Defrost Drains 157 Unit Installation 157 Condenser Fan Alignment 157 Evaporator Fan Blower Alignment 158 Mechanical Diagnosis 159 Electric Standby Diagnosis 162 Refrigeration Diagnosis 163 Refrigeration Diagrams 165 Cool Cycle With Electronic Throttling Valve 165 Heat Defrost Cycle With Electronic...

Page 11: ...letion resulting in suffocation and possible death DANGER Avoid engine operation in confined spaces and areas or circumstances where fumes from the engine could become trapped and cause serious injury or death WARNING Make sure your gauge manifold hoses are in good condition before using them Never let them come in contact with moving belts fans pulleys or hot surfaces Defective gauge equipment ca...

Page 12: ...ult in severe damage to equipment and void the warranty CAUTION Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury CAUTION Always wear protective clothing gloves and eye wear when handling and installing batteries Battery acid can cause serious burns when exposed to eyes or skin...

Page 13: ...n times and possible system contamination CAUTION Wipe up spills immediately Refrigerant oil can damage paints and rubber materials DANGER Lethal amounts of voltage are present in some electrical circuits Use extreme care when working on an operating refrigeration unit WARNING Do not make rapid moves when working on high voltage circuits in refrigeration units Do not grab for falling tools because...

Page 14: ...ts on any microprocessor based equipment Welding Precautions Take precautions before electrically welding any portion of the unit or the vehicle to which it is attached Ensure that welding currents are not allowed to flow through the unit s electronic circuits Observe the following precautions when welding to avoid damaging electronic components If the microprocessor has a power switch turn it OFF...

Page 15: ... assistance if possible The source of the shock must be quickly stopped by either shutting off the power or removing the victim If the power cannot be shut off the wire should be cut with an non conductive tool such as a wood handle axe or thickly insulated cable cutters Rescuers should wear insulated gloves and safety glasses and avoid looking at wires being cut The ensuing flash can cause burns ...

Page 16: ...2200 25 rpm Engine Oil Pressure 18 psig 127 kPa minimum in low speed 45 to 57 psig 310 to 390 kPa in high speed Intake Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Exhaust Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Valve Setting Temperature 70 F 21 C Low Oil Pressure Switch Normally Closed 17 3 psig 117 21 kPa Engine Coolant Thermostat 160 F 71 C Engine Coolant Type ELC Extended Life C...

Page 17: ...z 75 lbs 187 Hz 56 lbs Refrigeration System Compressor Thermo King X430LSC5 Refrigerant Charge Type 14 5 lb 6 6 kg R404A Compressor Oil Charge 4 3 qt 4 1 liters Compressor Oil Type Polyol Ester type P N 203 513 Heat Defrost Method Engine Operation Electric Operation Hot gas Hot gas and optional electric heater strips High Pressure Cutout 470 7 35 psig 3241 48 241 kPa Automatic reset 375 38 psig 25...

Page 18: ...d High Speed Current Draw at Low Engine Speed Low Speed Current Draw at High Engine Speed Low Speed Current Draw at Low Engine Speed 1 20 hp 0 90 kW 1 75 hp 1 31 kW 1770 rpm at low engine speed 1450 rpm 1800 rpm at high engine speed 2200 rpm 1180 rpm at low engine speed 1450 rpm 3 8 amps at low engine speed 1450 rpm 3 1 amps at high engine speed 2200 rpm 2 6 amps at low engine speed 1450 rpm Conde...

Page 19: ...or 2000V Type W Power Cable 25 to 50 foot length 12 HP Motor 230 3 60 6 AWG Power Cable 4 Conductor 2000V Type W Power Cable 75 foot length 12 HP Motor 460 3 60 10 AWG Power Cable 4 Conductor 2000V Type W Power Cable up to 75 foot length 19 HP Motor 460 3 60 8 AWG 4 Conductor 2000V Type W Power Cable up to 75 foot length Electric Fuel Heater Optional Electric Fuel Heater Resistance Current Draw at...

Page 20: ...ter hot Requires oil with API Rating CI 4 or better ACEA Rating E3 for Europe Adjust engine valve clearance Change ELC red engine coolant every 5 years or 12 000 hours Units equipped with ELC have an ELC nameplate on the expansion tank see page 98 Test fuel injection nozzles at least every 3 000 hours Replace fuel return lines between fuel injection nozzles every 10 000 hours Electrical Inspect ba...

Page 21: ...e and suction pressure every two 2 years Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts includes air ducts and bulkheads Inspect idlers for bearing wear noise Clean entire unit including condenser and evaporator coils and defrost drains Check all unit and fuel tank mounting bolts brackets lines hoses etc 3 000 hours or two years whichever o...

Page 22: ...alled Option Dealer Installed Precedent C 600 Key Features Options SMART REEFER SR 4 Controller SmartPower Electric Standby SmartPower High Output SmartPower Prep Package OptiSet Plus ETV Electronic Throttling Valve ServiceWatch Data Logger CargoWatch Data Logger CargoLink Sensor Kits CargoLink Wireless Sensors EMI 3000 High Capacity Condenser Coils Easy access door design Composite Exterior Panel...

Page 23: ...ates counterclockwise when viewed from the top It draws air through the roadside condenser coil and the radiator coil It also draws air up through a cooling channel to cool the battery and battery charger if used The curbside condenser fan rotates clockwise when viewed from the top It draws air through the curbside condenser coil During engine operation the condenser fan speed varies with the engi...

Page 24: ...he ETV replaces the mechanical throttling valve used in other units The ETV system provides enhanced control of the refrigeration system as follows Suction Pressure Control The suction pressure control algorithm is the primary control used to obtain maximum capacity This allows the refrigeration system to fully utilize the power capabilities of the engine under varying conditions Discharge Pressur...

Page 25: ...to maintain setpoint and provide constant airflow NOTE The SR 4 controller provides a wide range of control and programming flexibility However pre programming of the unit controller may prohibit operation in certain temperature ranges within some modes and may also prohibit certain modes of operation Refer to TK 55533 the SR 4 Microprocessor Control System Diagnostic Manual for information about ...

Page 26: ...an SR 4 Controller Therefore it is recommended that a ServiceWatch download be preformed to help diagnose a problem A ServiceWatch download must be preformed before contacting the Thermo King Service Department for assistance in diagnosing a problem Refer to the SR 4 Microprocessor Control System Diagnostic Manual TK 55533 for information about downloading the ServiceWatch Data Logger and viewing ...

Page 27: ...erating mode the unit should be in by comparing the setpoint to the box temperature In diesel operation the diesel engine operates at either low speed or high speed as determined by the microprocessor The unit will Cool or Heat in either high or low speed The unit will Defrost in low speed only Heat and Defrost consists of hot gas delivered to the evaporator coil distributor In electric operation ...

Page 28: ...Range with Fresh Setpoint standard setting 4 hours Defrost Interval In Range with Frozen Setpoint standard setting 6 hours Defrost Interval Not In Range with Frozen Setpoint standard setting is 4 hours This feature allows a shorter Defrost interval to be used when the unit is out of range during a pull down and more frequent Defrost cycles may be beneficial Normally longer defrost timer intervals ...

Page 29: ...to check the level of refrigerant in the receiver tank See the Refrigeration Maintenance Chapter for the correct procedure WARNING The unit can start at any time without warning Press the Off key on the HMI control panel and place the microprocessor On Off switch in the Off position before inspecting any part of the unit CAUTION Make sure the engine is turned off before attempting to check the eng...

Page 30: ...er tank The valve is a spring loaded piston that lifts off its seat when refrigerant pressure exceeds 500 psig 3447 kPa The valve will reseat when the pressure drops to 400 psig 2758 kPa The valve could possibly leak refrigerant after it has relieved excess pressure Tapping the valve lightly may help the valve reseat and seal properly The valve is non repairable and requires no adjustment If the v...

Page 31: ...the cylinders on the front end above the oil pump 1 Serial Number Location Figure 9 Compressor Serial Number Location 1 Serial Number Location Figure 10 Engine Serial Number Location 1 ARA1956 1 1 On Evaporator Housing 2 On Frame In Engine Compartment Figure 11 Unit Serial Number Locations 1 Unit Serial Number 2 Unit Model 3 Bill of Material Number Figure 12 Laminated Serial Number Plate Located W...

Page 32: ...Unit Description 31 1 Fan Control Box High Voltage 2 High Voltage Box SmartPower Units Only 3 Control Box Low Voltage 4 HMI Figure 13 Electrical Control Boxes ARA2121 1 2 3 4 ...

Page 33: ...Unit Description 32 1 Evaporator Discharge Air Outlet Figure 14 Back View 1 ...

Page 34: ...panel to operate the unit Refer to the Precedent C 600 Operator s Manual TK 55538 and the SR 4 Microprocessor Control System Diagnostic Manual TK 55533 for more information The HMI control panel has a display and eight touch sensitive keys The display is capable of showing both text and graphics The four keys on the left and right sides of the display are hard dedicated keys The four keys under th...

Page 35: ... will briefly show the Thermo King Logo and then the statement Configuring System Please Wait When the power up sequence is complete the display shows the Standard Display of box temperature and setpoint Off Key Used to turn the unit off First the display will briefly show System is Powering Down Please Wait Press On to Resume and then Off will appear momentarily When the power down sequence is co...

Page 36: ...19 will briefly show FLASH DRIVE Figure 19 Flash Drive Then FLASH DRIVE DETECTED and the Flash Drive Menu will appear on the display Figure 20 The display will be shown for about 30 seconds and then the Standard Display will appear To go to the Standard Display immediately press the EXIT Soft Key Figure 20 Flash Drive Menu IMPORTANT The engine start is not delayed by the Flash Drive Menu shown abo...

Page 37: ...eeded to make the display visible in very cold ambient temperatures The HMI has its own internal temperature sensor for the display heater The heater is energized when the unit is turned on and the ambient temperature is below 29 4 F 2 C The heater turns off when the temperature sensed by the internal sensor rises above 37 4 F 3 C The heater draws from 1 4 to 1 7 amps when energized The colder the...

Page 38: ...ime outs are log alarms The TemperatureWatch screen is not disabled if only log alarm s are active If log alarm s are present the Log Alarm notice shown in Figure 27 will appear on the display for 60 seconds The remote indicator alarm light if installed will also be on during this period After 60 seconds the Standard Display will appear and the remote indicator alarm light will go off Pressing the...

Page 39: ...of the GAUGES and SENSORS soft keys may be re assigned to better suit customer requirements The GAUGES and SENSORS functions are always available from the Maintenance Menu The TemperatureWatch Display The TemperatureWatch Display appears 2 minutes after the Standard Display appears so long as there is no key activity and no check prevent or shutdown alarms are present The TemperatureWatch Display ...

Page 40: ...the specific named product A numerical setpoint range may be allowed for the specific named product Figure 34 Left Soft Key Labeled Product Both Numerical Setpoints and Named Products OptiSet Plus can allow the use of both Numerical Setpoints and Named Products If both numerical setpoints and named products are enabled the left soft key will be labeled PRODUCT SETPOINT Figure 35 Figure 35 Left Sof...

Page 41: ...show the old setpoint The display then returns to the Standard Display showing the new setpoint Notice in Figure 41 that the arrow now points up to indicate that the unit is heating Figure 41 Up Arrow IMPORTANT If the setpoint is changed using the or Keys the change must be confirmed or rejected by pressing the YES or NO Key within 10 seconds of changing the setpoint If the YES Key is pressed the ...

Page 42: ... the or Keys the change must be confirmed or rejected by pressing the YES or NO Key within 10 seconds of changing the product A warning beep will sound for 5 seconds as a reminder Failure to confirm the new product by pressing Yes or No within 10 seconds of changing the product will result in no product change In addition Alarm Code 127 Setpoint Not Entered is set to indicate that the product chan...

Page 43: ...de with the or Key is not accepted the product is not changed and the display returns to the Standard Display If the YES or NO Key is not pressed within 10 seconds of making a change with the or Key the product is not changed and the display returns to the Standard Display The display briefly shows SETPOINT NOT CHANGED and Alarm Code 127 Setpoint Not Entered is set to indicate that the product cha...

Page 44: ...ional prompts before the engine will start See STARTING THE ELECTRIC MOTOR on the following pages for details CAUTION The engine may start automatically any time the unit is turned on WARNING Never use starting fluid When the engine is preparing to start the HMI Control Panel will display the engine start screen Figure 52 The preheat buzzer sounds during the engine preheat and crank sequence Figur...

Page 45: ... to Electric Auto Switch Enabled feature in Guarded Access is set NO then the unit can also be switched from Diesel mode to Electric mode operation using the Electric Standby Selection from the Main Menu as shown later in this section Switching from Electric to Diesel Units equipped with the SmartPower option only If the Electric to Diesel Auto Switch Enabled feature in Guarded Access is set YES t...

Page 46: ...h an evaporator coil temperature less than or equal to 55 F 13 C Other features such as door switch settings may not allow manual defrost under some conditions To initiate a manual defrost cycle press the Defrost Key Figure 59 Figure 59 Press Defrost Key The display briefly shows DEFROST PROGRAMMING DEFROST PLEASE WAIT and then DEFROST STARTED Figure 60 Figure 60 Defrost Started The display then s...

Page 47: ...re 69 for an overview of the Selecting Cycle Sentry or Continuous Mode procedure If the unit is operating in Cycle Sentry Mode the Cycle Sentry Icon will be present in the upper right corner of the display as shown below If the Cycle Sentry Icon Figure 64 is not present the unit is operating in Continuous Mode Figure 64 Cycle Sentry Icon If allowed by OptiSet Plus Cycle Sentry Mode or Continuous M...

Page 48: ...ntry Mode operation IMPORTANT If the unit is in Cycle Sentry Null and the mode is switched to Continuous Mode the unit will start automatically IMPORTANT Cycle Sentry or Continuous Mode may not be selectable if OptiSet Plus is in use Figure 69 Selecting Cycle Sentry or Continuous Mode ON OFF PROGRAMMING CONT MODE PLEASE WAIT ON OFF NEW SYSTEM MODE IS CONTINUOUS ON OFF MENU 35 F 35 SET SENSORS GAUG...

Page 49: ...Voltage Displays the voltage of the unit battery Accessory Battery Voltage Displays the voltage at the alternator Engine RPM Displays the engine speed in RPMs Fuel Level Sensor Displays the fuel level if a fuel level sensor is installed Discharge Pressure Displays the unit discharge pressure ETV units only Suction Pressure Displays the unit suction pressure ETV units only ETV Position Displays the...

Page 50: ...ture of the ambient air sensor Spare 1 Temperature Displays the temperature of the spare 1 temperature sensor Log Sensor 1 Displays the temperature of the CargoWatch Data Logger temperature sensor 1 Log Sensor 2 Displays the temperature of the CargoWatch Data Logger temperature sensor 2 Log Sensor 3 Displays the temperature of the CargoWatch Data Logger temperature sensor 3 Log Sensor 4 Displays t...

Page 51: ... Standby selection from the Main Menu allows the operator to manually select diesel or electric mode operation on units equipped with the electric standby SmartPower option Adjust Brightness The brightness of the HMI Control Panel display can be adjusted to allow for changing ambient light conditions Time The Time and Date held by the HMI Control Panel can be checked Time and Date cannot be change...

Page 52: ...gh refrigeration capacity which results in rapid temperature changes Sensitive dry cargo may be damaged as a result If running a Pretrip Test on a trailer that has just been washed down the extremely high humidity inside the trailer may result in false test results If running a Pretrip Test on a trailer loaded with sensitive cargo monitor the load temperature during the test as normal temperature ...

Page 53: ...d before completion When the non running tests are complete the unit will start automatically and continue with the Running Pretrip Test In the example shown in Figure 81 the unit is in the Running Pretrip and is performing Test 21 of 26 Cool Test Figure 81 Cool Test When all tests are complete the results are reported as PASS CHECK or FAIL Figure 82 If the results are CHECK or FAIL the accompanyi...

Page 54: ...sh Drive Icon The USB Icon Figure 84 will appear in the upper left corner of the display as shown below when a USB Flash Drive is inserted into the Flash Drive Only USB Port on the Unit Control Panel The USB Icon will also appear if a computer is connected to the PC Only USB Port inside the control box Figure 84 Flash Drive Icon Selecting the Flash Drive Menu from the Main Menu If Already Connecte...

Page 55: ...oft Key Pressed Languages If Enabled If more than one language is enabled from the Guarded Access Language Menu this menu item will appear If only one language is enabled this menu will not appear The Language Menu allows the operator to select a language from the enabled languages All subsequent displays are shown in the selected language English is the default language See the Guarded Access Lan...

Page 56: ...SE WAIT in the new language The display will then return to the Language Menu but will show the new language Español Spanish is shown in Figure 93 Figure 93 New Language Example Español Repeat the process to select a different language To select a different Main Menu item press the NEXT SIGUIENTE Key To return to the Standard Display press the EXIT SALIDA Key All displays will now be in the new la...

Page 57: ...em Diagnostic Manual TK 55533 for more information about alarm codes and their diagnosis Log Alarms If only Log Alarms exist the display shown in Figure 98 will appear and the optional remote alarm light will light for 30 seconds when the unit is turned on Figure 98 Log Alarms Exist Check Alarms If a Check Alarm condition occurs while the unit is running the alarm icon will appear in the display a...

Page 58: ...sor Alarm Code 203 Check Display Return Air Sensor Alarm Code 204 Check Display Discharge Air Sensor The following alarm codes clear automatically Alarm Code 64 Pretrip Reminder Clears when a Pretrip Test is performed Alarm Code 84 Restart Null Clears when the unit is no longer in a restart null due to a Prevent Alarm Alarm Code 85 Forced Unit Operation Clears when the unit is no longer running in...

Page 59: ...y will display the Shutdown Alarm Code For additional information regarding the alarm shown on the display press the HELP Key Figure 108 Figure 108 Help Key A help message will appear Press the EXIT Key to return to the Alarms Menu Figure 109 Check the oil level and add oil as required clear the alarm and restart the engine Figure 109 Exit Key To return to the Main Menu press the EXIT Key To retur...

Page 60: ... Keys to scroll through the gauges and I O conditions Pressing the LOCK Key will lock the current gauge on the display Figure 113 Figure 113 Next Back Lock Keys ON OFF LOG ALARMS ACTIVE GO TO MENU TO VIEW EXIT MENU 35 35 SET SENSORS GAUGES POINT ON OFF MENU 35 35 SET SENSORS GAUGES POINT ON OFF MENU 35 35 SET SENSORS GAUGES POINT ON OFF ON OFF MAIN MENU DOWN EXIT SELECT UP PRETRIP LANGUAGE ALARMS ...

Page 61: ...ors available are described in Sensors Available on page 49 To return to the Main Menu press the EXIT Key To return to the Standard display press the EXIT Key again Data Logger CargoWatch The CargoWatch Data Logger is physically located in the HMI Control Panel It can support up to 6 optional temperature sensors When shipped from the factory CargoWatch sensors 1 and 2 are turned on to be logged an...

Page 62: ...the SELECT Key will print the ticket Figure 121 The Delivery Ticket is a short ticket that shows delivery specific details including the current temperature A sample Delivery Ticket is shown in Figure 122 Figure 121 Select Key Print Delivery Ticket Figure 122 Sample Delivery Ticket Pressing the DOWN Key allows the operator to print a Trip Ticket using a hand held printer Press the SELECT Key to pr...

Page 63: ...XT or PREVIOUS Key to scroll through the hourmeters Figure 127 Figure 127 Up Down Keys Hourmeter names and definitions are shown in the table on the next page in the order they appear Only hourmeters enabled in the Guarded Access Menu will be shown To return to the Standard Display press the EXIT Key When shipped from the factory only these hourmeters are enabled for viewing from the Main Menu Tot...

Page 64: ... to the Standard display press the EXIT Key again Using the Change Mode Menu Mode changes are made using the Mode Menu From the Standard Display press the MENU Key Figure 128 Figure 128 Menu Key The Main Menu will appear Press the UP or DOWN Key as required to choose the Mode Menu When the Mode Menu is selected press the SELECT Key to choose the Mode Menu Figure 129 Hourmeter Name Definition Total...

Page 65: ...Sentry Mode press the SELECT Soft Key Figure 132 to turn off Cycle Sentry Mode as shown below Figure 132 Select Key Confirmation screens will appear briefly the unit will switch to Continuous Mode operation and the Cycle Sentry Icon will disappear To turn Cycle Sentry back on press the SELECT Key again To leave this menu without changing the setting press the EXIT Soft Key To return to the Standar...

Page 66: ...e 136 Select Key The Fresh Air Exchange door will open To close the Fresh Air Exchange door press the SELECT Key again IMPORTANT The Fresh Air Exchange feature should be used exactly as specified by the customer The Fresh Air Exchange door will only be open when the unit engine is running The door will close when the engine shuts down to preserve unit battery life The setting of the Fresh Air Exch...

Page 67: ...a wakeup time to be specified When the selected time is reached the unit will start and resume normal operation If a Wakeup Time is selected the following features are available Day to Wake Up This feature allows the day the unit is to wake up to be specified Hour to Wake Up This feature allows the hour the unit is to wake up to be specified Minute to Wake Up This feature allows the minute the uni...

Page 68: ...ed feature in Guarded Access is set NO the unit can be switched to Electric Mode using the Electric Standby selection from the Main Menu From the Standard Display press the MENU Key Figure 140 Figure 140 Menu Key From the Main Menu choose Electric Standby and press the SELECT Soft Key Figure 141 Figure 141 Select Key If the unit has standby power available and is turned on the electric standby run...

Page 69: ...wn Alarms Adjust Brightness The brightness of the HMI Control Panel display can be adjusted to allow for changing ambient light conditions The choices available to the operator are HIGH MEDIUM LOW and OFF OFF actually results in a very dim screen suitable for low light conditions Display brightness is adjusted using the Adjust Brightness Menu From the Standard Display press the MENU Key Figure 145...

Page 70: ... not a substitute for regularly scheduled maintenance inspections it is an important part of the preventive maintenance program designed to head off operating problems and breakdowns before they happen Fuel The diesel fuel supply must be adequate to guarantee engine operation to the next check point Engine Oil The engine oil level should be at the FULL mark with the dipstick turned threaded into o...

Page 71: ...T block the evaporator inlet or outlet 4 Products should be pre cooled before loading Thermo King transport refrigeration units are designed to maintain loads at the temperature at which they were loaded Transport refrigeration units are not designed to pull hot loads down to temperature Post Load Procedure 1 Make sure all the doors are closed and locked 2 Start the unit if it was shut off to load...

Page 72: ...ually monitor load temperature Report alarm at end of day 17 Engine Failed to Crank If unit is shut down repair immediately Otherwise report alarm at end of day 18 High Engine Coolant Temperature If unit is shut down repair immediately Otherwise report alarm at end of day 19 Low Engine Oil Pressure If unit is shut down repair immediately Otherwise report alarm at end of day 20 Engine Failed to Sta...

Page 73: ...eport alarm at end of day 49 Check Spare Sensor 1 Report alarm at end of day 50 Reset Clock Report alarm at end of day 52 Check Heat Circuit If unit is shut down repair immediately Otherwise report alarm at end of day 53 Check Liquid Line Solenoid Circuit If unit is shut down repair immediately Otherwise report alarm at end of day 54 Test Mode Timeout Service Test or Output Test timed out after 15...

Page 74: ...se report alarm at end of day 106 Check Purge Valve Circuit If unit is shut down repair immediately Otherwise report alarm at end of day 107 Check Condenser Inlet Solenoid Circuit If unit is shut down repair immediately Otherwise report alarm at end of day 108 Door Open Time out Close doors Report alarm at end of day 110 Check Suction Line Solenoid Circuit If unit is shut down repair immediately O...

Page 75: ...ch Sensor Out of Range Low Report alarm at end of day 151 CargoWatch Sensor Out of Range High Report alarm at end of day 152 CargoWatch Sensor Failed Report alarm at end of day 153 Expansion Module Flash Load Failure Report alarm at end of day 157 OptiSet File Mismatch Report alarm at end of day 158 Primary Software failed to load Report alarm at end of day 159 Check Battery Condition Report alarm...

Page 76: ...t alarm at end of day 521 Battery Charger Overheat Shutdown Report alarm at end of day 522 Battery Temperature Sensor Alarm Report alarm at end of day 523 Battery Charger Exceeded High Temperature Limit Report alarm at end of day 528 Failed CAN Communication Controller and Battery Charger Report alarm at end of day 529 Check Fuel Pump Circuit If unit is shut down repair immediately Otherwise repor...

Page 77: ...rt alarm at end of the day 551 Battery Charger Internal Temp Sensor Fault Report alarm at end of day 552 Battery Charger Charging Low Battery Report alarm at end of day 553 Battery Charger Operating Derated Due To High Temp Condition Report alarm at end of day 599 Engine Service Tool Connected Maintenance information only Report alarm at end of the day COLOR CODE DEFINITIONS OK TO RUN CHECK AS SPE...

Page 78: ...e Bulletin T T 388 for more information A problem may exist in the 2A output circuit from the alternator to the base controller or in the 2 circuit from the base controller to the battery Check for an open 2 or 2A circuits fuse FS8 loose connections defective battery cables or dirty battery terminals The battery must be in good condition and capable of accepting a charge Check for a damaged batter...

Page 79: ...ccurate test equipment such as the Fluke 23 Digital Multi Meter and the Fluke Clamp On Ammeter accessory when checking alternator circuit voltage and amperage See the table below for Thermo King service parts numbers Be sure voltages are measured from the designated terminal to the alternator chassis ground All voltages are DC voltages unless otherwise noted Alternator Load Test Thermo King no lon...

Page 80: ...en removed Units with Thermo King alternators must have the resistor bypass fuse F4 removed 5 Check and note the battery voltage at the battery with the unit turned off 6 With the unit off check the voltage at the B terminal on the alternator Battery voltage must be present If not check the 2 and 2A circuits and fuse FS8 7 Disconnect the alternator harness from the voltage regulator On Thermo King...

Page 81: ...0 Vdc higher than the voltage between the battery terminals continue with Step 17 If the voltage at the B POS terminal is more than 1 0 Vdc higher than the voltage between the battery terminals clean and check the wires and connections in the 2A and 2 circuits and repeat this check 17 Increase the charging system load as much as possible by running the unit in high speed heat 18 Monitor the altern...

Page 82: ...ode 2 Use the GAUGES key to check the Amps Display and the Battery Voltage Display The Amps reading should show a positive value The Battery Voltage reading should increase slowly until it stabilizes at approximately 14 Vdc If not go to the next step 3 Check for DC voltage Between the BATT and GND terminals at the battery charger The voltage should be within 1 Vdc of the Battery Voltage reading in...

Page 83: ...orrect but the fan still runs backwards switch the T1 and T2 wire connections on the fan harness side of the contactor for the fan being tested If the fan now runs correctly it is probably wired incorrectly Evaporator Fans The evaporator fans are axial blower type fans mounted on both ends of a single evaporator fan motor The evaporator fans and motor are mounted in the evaporator but are accessed...

Page 84: ...f and check the resistance on the three pairs of wires ET11 ET12 ET12 ET13 and ET11 ET13 at the fan side of the contactor for fan being tested The resistance should be approximately 5 8 ohms on each pair If not go to the next step 9 Check the continuity of the ET11 ET12 and ET13 wires from the EFHC contactor to the fan If all three wires have good continuity the fan motor is probably faulty 10 Che...

Page 85: ... J33 J12 J13 J9 J10 J8 J6 12 1 23 13 35 24 J1 12 1 23 13 35 24 J3 12 1 23 13 35 24 J4 J27 1 1 1 1 1 1 1 1 1 J102 J101 J29 J11 F4 LED45 2935 Rev H Watlow RoHS J21 LED09 LED48 LED44 LED05 LED04 LED07 LED08 LED 02 LED01 LED27 LED29 LED30 LED32 LED24 LED25 LED26 LED39 LED40 LED41 LED42 LED06 LED43 LED50 LED47 LED46 LED49 LED35 LED36 LED37 LED38 LED23 STATUS LED11 LED12 LED13 LED10 LED16 LED17 LED14 1 ...

Page 86: ...14 Spare 1 LED 15 Spare 4 LED 16 Spare 3 LED 17 Spare 2 LED 23 Liquid Line Solenoid Circuit MT LED 24 CIS LV Digital Scroll Circuits LED 25 Suction Line Solenoid Liquid Line Economizer Valve Circuits LED 26 Alternator Excite Circuit LED 27 EFL Evaporator Fan Low Circuit LED 29 EFH Evaporator Fan High Circuit LED 30 CFR Condenser Fan Roadside Circuit LED 32 CFC Condenser Fan Curbside Circuit LED 35...

Page 87: ...col for use with third party telematics systems NOTE REBs that have iBox and Cellular capabilities can be configured to either use the iBox protocol or communicate with TracKing They cannot be configured to do both The REB is a daughter board that mounts on the base controller as shown in Figure 154 The REB communicates with the base controller through the CAN connector J98 on the base controller ...

Page 88: ... wiring and the wire harnesses during scheduled maintenance inspections for loose chaffed or broken wires to protect against unit malfunctions due to open or short circuits Wire Harness Routing Do not change the factory routing of the wire harnesses inside the unit Electric Standby AC Components for SmartPower Units Electrical Contactors Periodically inspect all contactor points for pitting or cor...

Page 89: ...BC2 This contactor is energized while running in diesel operation and provides 3 phase Vac from the generator to the optional battery charger This contactor is mechanically interlocked with BC1 and electrically interlocked with TRC and BC1 Phase Contactor 1 PC1 Provides non corrected 3 phase power to the system This is controlled by the Phase Select Module 7EC This is mechanically interlocked with...

Page 90: ...tric motor The main components of the system are the phase selection module PSM and the two phase contactors PC1 and PC1 Contactor PC1 is wired to retain the phase sequence Contactor PC2 is wired to change the phase sequence The PSM senses the phase sequence at PC2 and energizes the appropriate phase contactor Troubleshooting the Auto Phase System If the electric motor runs backwards 1 Turn the el...

Page 91: ...PC2 and on the 7EC 01 terminal at PC1 Battery voltage should be present at one of these terminals If not check the continuity of the 7EB 01 and 7EC 01 wires 6 Check the continuity of the RED wires on the phase contactors The RED wires must have continuity 7 Check the CH circuits at PC1 and PC2 for continuity to a chassis ground If the CH circuits do not have continuity to a chassis ground check th...

Page 92: ...pty tank to 4 0 Vdc for a full tank Check the operation of the fuel level sensor as follows 1 Use the GAUGES soft key to display the Fuel Level Sensor reading and compare it to the reading of the fuel gauge on the end of the fuel tank The Fuel Level Sensor reading should be approximately 50 when the fuel gauge reads 1 2 full 2 Check to make sure that the Fuel Sensor Type is set to Solid State in U...

Page 93: ...king of the plastic sensor DO NOT apply any type of gasket sealer USE ONLY new gaskets Make sure to order new gaskets when ordering the replacement sensor DO NOT use power tools to tighten the mounting hardware or damage to the plastic sensor will result DO NOT overtighten the mounting hardware or damage to the plastic sensor will result 1 Remove and discard the sensor and the gaskets DO NOT reuse...

Page 94: ...sing solder connectors P N 41 5210 and heat shrink tubing P N 92 846 as follows IMPORTANT DO NOT burn the heat shrink If the heat shrink is burnt charred or has bubbles from overheating the wire connections must be removed and redone correctly Electric Fuel Heater Optional An electric fuel heater is optional equipment on these units Operation The electric fuel heater has an internal thermostat tha...

Page 95: ...e temperature of the electric fuel heater must be below 30 F 1 C to close the internal thermostat If the temperature of the electric fuel heater is below 30 F 1 C and high resistance indicates an open circuit the electric fuel heater is probably defective and should be replaced If the resistance is significantly less than 0 9 ohms the heating element is probably defective and the electric fuel hea...

Page 96: ...ion at the 2A J25 screw terminal is clean and tight 8 If battery voltage is present on the 2A 03 wire at the Fuel Heater Relay check for battery voltage on the 8FH 02 wire at the Fuel Heater Relay If battery voltage is not present check the continuity of 8FH 02 and 8FH 01 wires between the Fuel Heater Relay and pin 7 in the J16 connector on the base controller Also check to make sure the wire conn...

Page 97: ...ion System The TK486 family of engines use a pressure lubrication system Refer to the TK482 and TK486 Engine Overhaul Manual TK 50136 for a detailed description of the engine lubrication system Engine Oil Change The engine oil should be changed according to the Maintenance Inspection Schedule Drain the oil only when the engine is hot to ensure that all the oil drains out When changing oil keep uni...

Page 98: ... thin or does it smell like fuel OK Verify the unit switch sensor or gauge accuracy using a test gauge Accurate Not Accurate Repair and re check oil pressure in low and high speed Diluted with Fuel Check for excessive radial end play at the flywheel with a dial indicator Maximum 0 007 in 4 cylinder Excessive OK Drain oil through a clean coffee filter and check for wear metal contamination No Wear ...

Page 99: ... overheating 3 Retards corrosion acid that can attack accumulator tanks water tubes radiators and core plugs 4 Provides lubrication for the water pump seal ELC Extended Life Coolant ELC is used in this unit A nameplate near the coolant expansion tank identifies units with ELC NOTE The new engine coolant Texaco Extended Life Coolant is RED in color instead of the current GREEN or BLUE GREEN colored...

Page 100: ... permanent type coolant concentrate and 32 percent water for use in extreme temperatures Changing the Antifreeze 1 Run the engine until it is up to its normal operating temperature Stop the unit 2 Open the engine block drain located behind the starter and completely drain the coolant Observe the coolant color If the coolant is dirty proceed with a b and c Otherwise go to 3 a Run clear water into t...

Page 101: ...62 2 Slowly pour the coolant into the system until you see coolant at the plug fitting 3 Reinstall the plug 4 Pour coolant into the system until it appears to be full 5 Make sure that the amount of coolant that goes back into the system is approximately equal to the amount of coolant that came out of the system 6 Start the engine Monitor the coolant temperature with the unit engine coolant tempera...

Page 102: ...k upside down 4 Drain coolant from the expansion tank until the coolant level is well below the switch level and check continuity of the switch The switch should be open If you removed the tank from the unit do this check with the tank right side up 5 Replace the switch if it is does not close in step 3 and does not open in step 4 Checking the Float The float is made of polypropylene foam It is un...

Page 103: ...st operating results the fuel must be clean and fuel tanks must be free of contaminants Change the fuel filter water separator regularly and inspect clean the electric fuel pump filter IMPORTANT Do not open the fuel system unless required NOTE The injection nozzles must be cleaned and tested and repaired if necessary at least every 3 000 hours in accordance with EPA 40 CFR Part 89 Normal condition...

Page 104: ...l Filter 2 Feed Line From Fuel Filter to Injection Pump 7 Electric Fuel Pump With Prefilter 3 Injection Pump Return Line Fitting Bleed Screw 8 Inlet Line From Fuel Tank 4 Mono plunger and Distributor Injection Pump 9 Return Line To Fuel Tank 5 Return Line From Injection Pump to Fuel Filter Figure 164 Fuel System ...

Page 105: ...6 Write the date and engine hours on the decal Bleeding the Fuel System If the engine runs out of fuel repairs are made to the fuel system or if air gets into the system for any other reason the air must be bled out of the fuel system To bleed air from the fuel system 1 Turn the unit on and use the Output Test Mode to energize the Run Relay which energizes the electric fuel pump Refer to the appro...

Page 106: ... to drain the tank 3 Let the water and fuel drain into the container until no water is visible in the fuel draining from the tank If the water and fuel do not drain freely the vent may be plugged If so clean or replace the vent 4 Install the drain plug Fuel Filter Water Separator The fuel filter water separator filters the fuel and removes water from the fuel and returns it to the fuel tank Fuel F...

Page 107: ...ure steps 7 through 12 Electric Fuel Pump The electric fuel pump should be mounted behind the fuel tank to protect it from road debris The electric fuel pump should be located far enough back to allow fuel filter bowl removal and service Operation The electric fuel pump must be mounted next to the fuel tank This pump is designed to push fuel rather than pull fuel Make sure the CHFP black wire comp...

Page 108: ... in High Speed engine operation it is important to ensure the engine high speed throttle is set properly 1 Shut the unit off 2 Remove the ball socket from the throttle bracket ball see Figure 170 3 Energize the throttle solenoid by using the Output Test Mode to energize the high speed solenoid while the engine is not running 4 Adjust the ball socket on the end of the linkage rod as necessary to ma...

Page 109: ...on the injection pump see Figure 173 2 Clean the area with brake cleaner or something similar Place an injection angle sticker on the gear case so the center line on the sticker is aligned with the index mark on the injection pump An injection angle sticker is provided with the new injection pump 1 Index Marks Figure 171 Index Mark Location 1 Index Mark on Injection Pump 2 Index Mark on Gear Case ...

Page 110: ... is located on the side of the pump facing the engine The injection angle mark on the pump does not use a decimal point Add a decimal point before the last digit of the injection angle mark to get the injection angle The injection angle mark in the following photographs is 67 That equals an injection angle of 6 7 degrees NOTE If you cannot read the injection angle mark contact the Thermo King Serv...

Page 111: ...elps to install the idler gear last when aligning the timing marks NOTE The oil pump is located in the timing gear cover on TK486V25 engines The inner rotor of the oil pump fits around the crankshaft gear Make sure that the flat sides of the inner rotor are aligned with the flat sides on the crankshaft gear when installing the timing gear cover Examples Injection Angle of New Injection Pump Degree...

Page 112: ...The injection pump gear assembly is made of three pieces the flange the gear and the transfer pump cam Do not loosen or remove the four bolts that fasten the gear to the flange because that changes the timing 4 Use the hardware from the cover plate to attach the tool plate with the marked side pointing up and out to the gear case 5 Align the threaded holes in the injection pump gear with the two h...

Page 113: ... to gear case and reinstall all components removed previously to facilitate injection pump removal Fuel Solenoid The fuel solenoid is located on the end of the injection pump It contains two coils the pull in coil and the hold in coil The pull in coil draws approximately 35 to 45 amps at 12 volts The hold in coil draws approximately 0 5 amps at 12 volts The pull in coil must be energized to move t...

Page 114: ...d when it is re installed in the injection pump If it is not the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly 5 If the fuel solenoid is not operating properly check the run relay K8 the fuel solenoid pull in relay K2 their fuses and the associated circuits If the relays fuses and circuits are acceptable use steps 6 through 9 to isolate and chec...

Page 115: ...nect the new fuel solenoid wire connector to the main wire harness 3 Press the ON key to turn the unit on 4 Use the microprocessor keypad to enter the Output Test Mode Refer to the appropriate Microprocessor Diagnostic Manual for specific information about the Output Test Mode 5 Energize the fuel solenoid by energizing the run relay with the Output Test Mode NOTE The fuel solenoid must be energize...

Page 116: ...he following procedure to replace the trochoid feed pump 1 Remove the four hex head screws that attach the trochoid feed pump to the injection pump see Figure 190 Do not remove the two Allen head screws 2 Remove the trochoid feed pump from the injection pump NOTE The gear on the trochoid feed pump is lubricated with engine oil Some engine oil might leak out of the injection pump when the trochoid ...

Page 117: ...eck the operation of the cold start device The engine coolant temperature must be below 32 F 0 C to start the procedure 1 Press the ON key to turn the unit on 2 Press the GAUGES key before the engine starts to enter the Gauges Menu and check the coolant temperature to make sure it is below 32 F 0 C 3 Let the engine start then check the engine rpm in the Gauges Menu The engine rpm should be approxi...

Page 118: ... the timing mark access hole on the front of the bell housing 3 Place the engine at top dead center of the compression stroke for the number one cylinder See steps a through d a Rotate the engine in the normal direction of rotation clockwise viewed from the water pump end until the 1 4 timing mark on the flywheel lines up with the index mark in the timing mark access hole b Check the rocker arms o...

Page 119: ...ustment screw until the valve clearance is correct 6 Hold the adjustment screw in place and tighten the locknut Figure 197 Adjusting the Valve Clearance 7 Recheck the valve clearance 8 Rotate the engine one full turn 360 degrees in the normal direction of rotation clockwise viewed from the water pump end and align the 1 4 timing mark on the flywheel with the index mark in the timing mark access ho...

Page 120: ...e air restriction indicator exceeds 20 in 508 mm H2O of vacuum A dirty air cleaner may cause excessive vacuum leading to oil carry over and high oil consumption The crankcase breather and the breather hose should be inspected when the air cleaner element is replaced to make sure they are not plugged or damaged Inspect the insulation to make sure it is in place and undamaged The insulation is used ...

Page 121: ...ey The procedure to adjust the belt is the same for units with and without the alternator on the AC generator belt AC Generator Belt Adjustment See Belt Tension on page 16 in the Specifications chapter for the correct AC generator belt tension settings 1 Loosen the idler mounting bolt 2 Turn the idler adjuster as needed to adjust the belt to the correct belt tension setting 3 Tighten the idler mou...

Page 122: ...e water pump pulley 5 Check the belt tension setting and readjust if necessary Compressor Drive Belt SmartPower Units Only Compressor Drive Belt Adjustment See Belt Tension on page 16 in the Specifications chapter for the correct compressor drive belt tension settings 1 Loosen the idler mounting bolt 2 Turn the idler adjuster as needed to adjust the belt to the correct belt tension setting 3 Tight...

Page 123: ... Check the belt tension setting and readjust if necessary Alternator Belt Replacement NOTE Do not attempt to remove or install the belts without loosening the adjustments Belts that are installed by prying over pulleys will fail prematurely due to internal cord damage 1 Loosen the compressor drive belt idler mounting bolt 2 Turn the compressor drive belt idler adjuster as needed to loosen the belt...

Page 124: ...OTE The refrigeration lines may be removed from the compressor to allow more movement of the compressor for better access to the clutch 5 Remove the compressor drive belt 6 Remove the clutch mounting bolt and special washer Use the Spanner Wrench and the appropriate hex driver or an air impact driver with the appropriate hex driver 7 Using the Clutch Puller to remove the clutch by threading the pu...

Page 125: ...tall the special washer and the clutch mounting bolt Torque the clutch mounting bolt to 90 ft lb 122 N m Use the Clutch Restraint Tool or an impact wrench 16 Reinstall the compressor drive belt on the clutch pulley 17 Slide the compressor back into position and install the mounting hardware 18 Place the belt on the electric motor and idler pulleys Make sure the belt fits on the pulleys correctly 1...

Page 126: ... bushing in the clutch hub coupling about 1 8 in 3 mm to make sure it fits in the hole and does not hang up on something Start fit the bushing in the side of the hub coupling that faces the flywheel NOTE The Loctite adhesive has a working time of 2 minutes so the bushing must be installed within 2 minutes of when the adhesive was applied Apply the adhesive and install the bushings one at a time to...

Page 127: ...einstall the compressor drive belt on the clutch pulley 22 Slide the compressor back into position and install the mounting hardware NOTE Do not place any kind of lubricant on the outside of the dowel pins or on the inside of the drive bushings Lubricant between the dowel pins and drive bushings will cause premature wear 23 Place the belt on the electric motor and idler pulleys Make sure the belt ...

Page 128: ...aft 5 Install the flywheel mounting bolts Torque the flywheel mounting bolts to 65 ft lb 88 N m 6 Install the compressor and adjust the drive belts 1 Drive Dowel Pin In Until Tool Hits Flywheel 2 Dowel Pin 3 Outer Face Of Flywheel Figure 208 Driving New Dowel Pin Into Flywheel with Impact Pin Tool 1 2 3 ...

Page 129: ...96 kPa If the pressure is below this it can be raised by covering a portion of the condenser grille with a piece of cardboard to block condenser airflow 8 Under these conditions refrigerant should be visible in the receiver tank sight glass If refrigerant is not visible in the receiver tank sight glass the unit is low on refrigerant Testing the Refrigerant Charge with a Loaded Trailer 1 Install a ...

Page 130: ...low liquid refrigerant to flow into the compressor suction service valve f Control the liquid flow so the suction pressure increases approximately 20 psig 138 kPa g Maintain a discharge pressure of at least 275 psig 1896 kPa while adding refrigerant h Close the hand valve on the refrigerant tank when the liquid level approaches the top of the receiver sight glass 4 Repeat the overcharge test Moist...

Page 131: ...r If maintenance in the area requires removal of the oil collection container or the tube caution should be observed to prevent damage to the check valve Although the check valve was glued to the tube at production pulling the check valve back through the grommet may cause the Valve to fall off or be damaged Several options are available 1 If possible disconnect the tube at the seal cover drain ba...

Page 132: ...tach the oil filter return line to the compressor Evacuate the compressor before opening the service valves High Pressure Cutout Switch HPCO The HPCO is located on the compressor discharge manifold If the discharge pressure rises above 470 psig 3241 kPa the HPCO opens the HPCO circuit to the run relay and stops the unit To test the HPCO rework a gauge manifold as shown in Figure 212 High Pressure ...

Page 133: ...s check valve cap from the three way valve 2 Using a screwdriver gently turn the check valve stem in until the valve is front seated 3 Install a gauge manifold set on the compressor 4 Close front seat the receiver tank outlet valve 5 Operate the unit on cool and pump down the low side to 20 in Hg 68 kPa of vacuum 6 Stop the unit The condenser and suction pressures should remain stable indicating n...

Page 134: ... decrease when the valve position decreases and increase when the valve position increases Refer to the SR 4 Microprocessor Control System Diagnostic Manual TK 55533 for complete information about the testing and operation of the ETV See Electronic Throttling Valve in the Refrigeration Service Operations chapter of this manual for removal and installation procedures Pressure Transducers The discha...

Page 135: ...s of various refrigeration system components Most of the refrigeration system components are located in the refrigeration cluster on the lower curbside of the unit This allows good access from the front and side for maintenance diagnosis and repair ARA1974 7 8 2 3 4 6 5 10 12 1 9 13 14 15 11 1 Suction Pressure Transducer 9 Suction Vibrasorber 2 Discharge Pressure Transducer 10 Discharge Vibrasorbe...

Page 136: ...16 Curbsibe View of Refrigeration Cluster ARA1985 1 Curbsibe Condenser Coil 2 Road Condenser Radiator Coil Figure 217 Condenser Coils 1 Curbsibe Condenser Coil 2 Radiator Coil 3 Road Condenser Coil Figure 218 Condenser and Radiator Coils 1 2 1 2 3 ...

Page 137: ...ure cutout switch the pilot solenoid line if used and remove the compressor oil filter 7 Support the compressor and unbolt the compressor mounting flange from the engine 8 Lift the service valves out of the way 9 Slide the compressor to the left until the coupling pins are clear and remove the compressor belt from SmartPower units 10 Remove the compressor from the front of the unit Keep the compre...

Page 138: ...pacers with shallow compressor mounting flanges and the longer set for deeper flanges The side with the countersunk holes should be toward the coupling 3 To prevent the tool and crankshaft from rotating use an appropriately sized bolt to pin the tool to the flange If a nut is used to prevent the bolt from falling out the nut should not be tightened 4 Use the appropriate Allen tool to loosen the co...

Page 139: ...ays and key for burrs or other problems Recheck the fit as shown above 5 When the key fits properly remove the coupling and key from the shaft AGA1059 1 3 4 8 5 6 7 2 1 Coupling 5 10 mm Allen Tool for large shaft compressor 2 Long Spacers supplied with tool 6 5 16 Allen Tool for small shaft compressors 3 Short Spacers supplied with tool 7 Coupling Removal Tool P N 204 991 4 Socket Head Bolts suppl...

Page 140: ...MPORTANT This unit uses micro channel condenser coils Micro channel coils are make of aluminum but have copper stub tubes at the inlet and outlet connections Make sure to use a heat sink on the copper stub tubes to prevent damage to the heat shrink tubing and brazed connections and the aluminum that attached the copper stub tubes to the aluminum micro channel coil The heat shrink tubing is used to...

Page 141: ...is used to prevent corrosion between the copper and aluminum 4 Remove the condenser coil mounting bolts and lift the coil from the unit Installation 1 Clean the fittings for soldering 2 Place the coil in the unit and install the mounting bolts 3 Solder the inlet and outlet refrigeration line connections to the copper stub tubes on the micro channel condenser coil Make sure to use a heat sink on th...

Page 142: ...ompressor oil level In Line Condenser Check Valve This unit uses an in line condenser check valve The in line check valve is not repairable and must be replaced if it fails A heat sink must be used on the in line check valve when it is being soldered in place to prevent damage to the neoprene seal Condenser Check Valve Replacement Removal 1 Recover the refrigerant charge 2 Place a heat sink on the...

Page 143: ... check valve 4 Remove the high pressure relief valve from the receiver tank 5 Unbolt the mounting brackets and remove the receiver tank from the unit Installation 1 Install the high pressure relief valve in the receiver tank 2 Solder the bypass check valve onto the receiver tank Use a heat sink on the bypass check valve 3 Place the receiver tank in the unit and install the mounting bolts and nuts ...

Page 144: ...n 7 Test the unit to see that the expansion valve is properly installed Heat Exchanger Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Remove the evaporator access panels 3 Remove the mounting bolts that hold the heat exchanger on the bulkhead 4 Unsolder the equalizer line from the suction line 5 Unsolder the liquid outlet line from the expansion valve 6 Note the ...

Page 145: ...rom the unit Installation 1 Place the evaporator coil assembly in position and install the mounting bolts 2 Solder the liquid line hot gas line and suction line connections on the curbside of the evaporator Seal the openings through the bulkhead with putty when the refrigerant lines have cooled off 3 Replace and reconnect connect the sensors and reconnect defrost drain hoses 4 Pressurize the low s...

Page 146: ...from the valve 6 Remove the end cap and spring 7 Remove the spring clip which secures the stem to the piston Slide piston off the stem 8 Remove the seat and stem assembly 9 Inspect the following parts for wear or damage a Bottom cap sealing and support area b Seat sealing surface c End cap sealing and support surface The following parts will be discarded a Stem assembly b All gaskets c Piston seal...

Page 147: ...check the orifice in the bleed hole from the gasket surface to the groove in the bottom of the piston bore 2 Carefully check to see that the drill projects down into the groove and that there are no burrs at the end of the hole in the groove Do not enlarge this hole Check Valve Piston Check 1 Reassemble the end cap using a new check valve piston spring stem and snap ring Kit P N 60 163 2 Leave the...

Page 148: ...in 0 84 mm Whenever you disassemble a three way valve you should check that all three of the holes are drilled cleanly Assembly Installation After cleaning and inspecting all parts reassemble the valve 1 Install the screen in the bottom cap 2 Install the new stem in the bottom cap 3 Install new gaskets on both sides of the seat Oil the gaskets in compressor oil before installing 4 Use the three wa...

Page 149: ...into the hole in the check valve stem and then install the piston on the other end of the spring with the hole in the piston towards the spring 3 Coat the entire assembly with compressor oil and install the assembly into the check valve seat in the three way valve 4 Screw the check valve stem into the three way valve until the snap ring can be installed 5 Install the snap ring 6 Unscrew back seat ...

Page 150: ...h Pressure Cutout Switch Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Front seat the discharge and suction service valves Recover the refrigerant remaining in the compressor 3 Disconnect the wires and remove the high pressure cutout switch from the compressor discharge manifold Installation 1 A new high pressure cutout switch does not have a connector installed...

Page 151: ...n the ETV by placing the unit in the Evacuation Mode Test and then disconnecting the ETV harness from the four pin connector on the main unified harness before turning the unit off The microprocessor closes the ETV when the unit is turned off Refer to the appropriate Microprocessor Diagnostic Manual for information about the Evacuation Mode Test 3 Unscrew the large nut that attaches the stepper mo...

Page 152: ...arness connected to main wire harness the controller will attempt to close the ETV This will cause the piston to be turned screwed off the threaded shaft of the stepper motor because the valve body is not present to stop it Further disassembly is required to reassemble the piston and stepper motor See Reassembly of Piston and Stepper Motor 1 The new stepper motor and piston assembly is supplied wi...

Page 153: ...ft on the piston with the rectangular hole in the piston nut to allow the piston to be inserted into the piston nut 3 Push the piston into the piston nut until the end of the rectangular shaft is about even with the top of the piston nut 4 Make sure the copper washer is in place in the top of the piston nut 5 Place the threaded shaft of the stepper motor into the rectangular shaft of the piston an...

Page 154: ...he refrigerant charge 2 Disconnect the wires and remove the coil for the valve 3 Unsolder the refrigeration lines 4 Remove the mounting bolts and remove the valve Installation 1 Clean the tubes for soldering 2 Remove the coil from the valve 3 Place the valve in the unit and install the mounting bolts The arrow on the valve indicates the direction of flow through the valve Make sure that the arrow ...

Page 155: ...ressure in the compressor Therefore we need to calculate the net oil pressure to determine the actual compressor oil pressure The net oil pressure is the pressure at the oil pressure access port minus the suction pressure below the throttling valve Use the following procedure to check the compressor oil pressure 1 Attach a suitable oil pressure gauge to the oil pressure access port on the compress...

Page 156: ...water through the coil in the direction opposite the normal airflow Repair bent fins and any other noticeable damage Micro Channel Coil Cleaning Recommendations Cleaning Intervals The coils should be cleaned a Minimum of once a year It is recommended that any time the unit is in for service or maintenance that the coils be inspected and cleaned if needed The coil should be cleaned if there are vis...

Page 157: ...er sprayer may be used in pressures under 600 psi Water will work best when blown thru the coil from the non air side when possible Spraying thru from the airside may imbed debris in the coil that was only on the surface It is recommended to start with one of the first three options before using water if the non air side is not accessible The angle at which the water should be directed at the coil...

Page 158: ...or mounting the unit should be elastic stop nuts Nylock type Condenser Fan Alignment When mounting a condenser fan and hub assembly on the fan motor the fan and orifice must be properly aligned for proper air flow and to prevent damage to the fan 1 Place the fan assembly on the condenser motor shaft so the taper lock bushing is resting on condenser motor shaft shoulder See Figure 247 2 Finger tigh...

Page 159: ...mounting bolts securely 4 Slide the blower away from the orifice 5 Position the blower so the edge of the orifice lines up with the alignment mark on the blower as shown in Figure 250 and tighten the blower hub bolts 6 Spin the blower by hand to check for blower distortion 7 Pass a 0 09 in 2 3 mm diameter gauge wire completely around the circumference of the orifice and the blower wheel to check f...

Page 160: ...gnostic Manual Fuel solenoid defective or stuck Replace fuel solenoid Fuel injection pump defective Replace injection pump Air heater defective Replace air heater No fuel or wrong fuel Fill with proper fuel Electric fuel pump not energized Check 8DF and CHFP circuits Electric fuel pump defective Replace electric fuel pump Air in fuel system Bleed air Compression low Overhaul engine Injection nozzl...

Page 161: ...crew Defective injection pump Repair injection pump Engine fails to stop when unit is OFF Fuel solenoid defective Replace Injection pump defective Replace pump Engine knocks heavily Air in system Bleed fuel system Wrong fuel Change fuel Injection pump not timed Retime injection pump Injection nozzles fouled or opening pressure too low Clean repair or replace injection nozzles Delivery valve spring...

Page 162: ... possible causes at rocker arm cover oil lines oil filter front timing cover or crankshaft seals Damaged valve seals Replace seals on valve stem Worn valve stem Replace valves Broken piston rings or cylinder bore worn or scored Have engine repaired and rebored Replace broken piston rings Clogged air cleaner system Unclog air cleaner Condition Possible Cause Remedy Engine Emits Excessive Smoke Whit...

Page 163: ...ed Select ELECTRIC Unit in NULL Check setpoint and box temperature Fuse F25 blown Check for short circuit and replace fuse Faulty HPCO Check HPCO Open or faulty overload relay Determine cause and rest or replace overload relay Faulty PSM Check PSM Faulty motor contactor Check motor contactors Open circuit Check 8 ER EOL 7E 7EB 7EC CH L1 L2 and L3 circuits Faulty drive motor Check drive motor Fault...

Page 164: ...r fan blades bent or broken Air short cycling around evaporator coil Air through evaporator restricted Evaporator needs defrosting Compressor discharge valves leaking Compressor suction valves leaking Too much compressor oil in system Faulty oil pump in compressor Faulty compressor drive coupling Compressor bearing loose or burned out Broken valve plate in compressor Expansion valve power element ...

Page 165: ...valve stuck open or leaking Rapid cycling between cool and heat Unit cools in heat and defrost cycle Unit heats in refrigeration cycle High head pressure Low head pressure High suction pressure Low suction pressure No suction pressure Unit operating in a vacuum Receiver sight glass empty Suction line frosting back Unable to pump down system Unable to pull vacuum in low side Unable to hold vacuum i...

Page 166: ...Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Hot Gas Bypass Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Service Valve 31 E...

Page 167: ...ief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Hot Gas Bypass Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Service Valve ...

Page 168: ... test 81 90 control panel 33 display 34 keys 34 coolant level switch 29 101 checking the float 101 replacing 101 testing 101 cooling system engine 98 bleeding air from 100 crankcase breather 119 curbside condenser coil replacement 139 CYCLE SENTRY Operation 24 CYCLE SENTRY Start Stop Controls 24 D data logging 24 30 defrost 26 30 defrost drains 157 Defrost key 34 38 diagnosis electric standby 162 ...

Page 169: ... engine 96 M maintenance inspection schedule 19 manual pretrip inspection 69 microprocessor On Off switch 33 Mode key 34 moisture indicating sight glass 129 mounting bolts unit and engine 155 O Off key 34 38 oil change engine 96 oil collection container 130 oil filter change engine 96 On key 34 38 operating modes 26 OptiSet Plus 26 overload relay 29 89 P phase contactor 1 PC1 88 phase contactor MC...

Page 170: ...100 three way valve condenser pressure bypass check valve 132 three way valve condenser pressure bypass check valve repair 148 three way valve repair 145 transducers pressure 133 transformer 90 transformer contactor 88 trochoid feed pump 114 U unit description 21 unit wiring 87 V valve clearance adjustment engine 117 W water pump belt 121 wire harness routing 87 X X430L compressor 23 ...

Page 171: ...170 Diagram Index Drawing No Drawing Title Page 1H81406 Schematic Diagram 171 176 1H81407 Wiring Diagram 177 183 1H75892 Fuel Line Routing Diagram 184 185 ...

Page 172: ... M M M M M M M M M M I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I N N N A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R...

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Page 174: ... A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A R R R Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y...

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Page 179: ...P 02 S3P 02 S4P 02 S5P 02 S6P 02 S6N 02 S5N 02 S3N 02 S2N 02 S1N 02 BLU BRN SENSOR OPTIONAL TYPICAL 1 OF 6 CHFP 01 CHFP 02 GSN 02 GT1 01 GT1 01 GT2 01 GT2 01 GT3 01 GT3 01 FAN BOX COMMON TO ALL 30 50 UNITS CW 01 12 11 10 9 8 7 6 5 4 3 2 1 CH26 01 CH26 01 CHCL 01 DPN 01 OLS 01 CHOLS 01 CHOLS 01 20B 01 FWS FLYWHEEL SENSOR FS1 01 FS2 01 HS HIGH SPEED SOLENOID 7D 01 CHHS 01 8S 01 8D 01 CHF 01 CHF 01 8...

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Page 181: ...1 T1 T2 T2 T3 T3 T5 01 19 HP 12 HP UNIT ONLY CH G Y 20 J5 POWER IN X Y Z GND FAN BOX SEE SHEET 2 UNIT ONLY 8D 02 GENERATOR 3 ALTERNATOR 50 Pg1 4 E 2Y 02 EXC 02 2A 02 CH CH WRPM 02 Pg2 3 B CHER 02 Pg2 3 B WRPM 02 Pg2 3 B CHER 02 Pg2 3 B GSI 02 GSN 02 GSP 02 7E 01 BC2 CL CC RL L1 L3 L2 T1 T2 T3 A1 A2 21 22 BATTERY CHARGER CONTACTOR 2 BC1 CL CC RL L1 L3 L2 T1 T2 T3 A1 A2 21 22 BATTERY CHARGER CONTACT...

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Page 184: ...R CONTACTOR H2A 01 EVAPORATOR HEATERS H3 01 HEATER OVERLOAD TO HEATER CONTACTOR H3A 01 EVAPORATOR HEATERS HGB 01 HOT GAS BYPASS HPCO 01 HIGH PRESSURE CUTOUT HRGC 01 HIGH RESISTANCE GROUND HRGN 01 HIGH RESISTANCE GROUND NEGATIVE JCANH 01 J33 1 TO BAT CHARGER 3 JCANL 01 J33 2 TO BAT CHARGER 4 JCH 01 J33 4 TO BAT CHARGER 1 JSH 01 J33 3 JSH 02 J33 2 L1 POWER PLUG TO PC1 PC2 L1A 03 COMP CONT TO FUSE FB...

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Page 187: ...ere TK 5XXXX X PL TK 55494 2 MM 2013 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text information to be placed here TK 5XXXX X PL 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate SB 210 Additional text information to be placed here TK 5XXXX X PL Distri...

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