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Thermo King 002008, Manual

The Thermo King 002008 user manual is an essential resource for operating and maintaining your Thermo King device. This comprehensive manual, available for free download on our website, provides step-by-step instructions, troubleshooting tips, and important safety information. Maximize the performance and longevity of your Thermo King with this invaluable manual. Download it today from manualshive.com.

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Table of Contents

6

Operating Instructions (continued)
Loading Procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Single Temperature Loading Procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Post Trip Checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Electrical Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Australian Bosch Alternator - Model 30  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

120 Amp Charging System Diagnostic Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Field Current Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Prestolite Alternator - Model 50  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

105 Amp Charging System Diagnostic Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Battery  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuse Link  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Air Heater   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Smart Reefer Multi-Temp µP-IV Microprocessor Controller   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Unit Wiring  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
AC Components (Model 50 Units Only)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Electrical Contactors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Evaporator Heaters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Auto Phase System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Engine Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
EMI 3000  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Engine Lubrication System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Engine Oil Change   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Oil Filter Change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Engine Cooling System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

ELC (Extended Life Coolant)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Bleeding Air from the Cooling System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine Thermostat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Engine Fuel System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Operation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Bleeding the Fuel System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Draining Water from Fuel Tank  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel Filter/Water Separator Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Injection Pump Timing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Injection Pump Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Injection Pump Reinstallation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fuel Solenoid System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Engine Valve Clearance Adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
EMI 3000 Air Cleaner   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Air Restriction Indicator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Model 30 Belt Adjustments  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Model 30 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Model 50 Belt Adjustments  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Model 50 Compressor Belt Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Model 50 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Clutch (Model 50)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Summary of Contents for 002008

Page 1: ...Spectrum SB TK 51296 2 MM Rev 3 07 04 Copyright 2001 Thermo King Corp Minneapolis MN U S A Printed in U S A ...

Page 2: ...egligence 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 Spectrum SB 30 2 002008 System Spectrum SB 30 2 918596 Spectrum SB 30 3 002009 System Spectrum SB 30 3 918597 Spectrum SB 50 2 00...

Page 3: ...nformation on regulations and technician certification programs contact your local Thermo King dealer R 404A WARNING Use only Polyol Ester based refrigeration compressor oil in R 404A See Thermo King Parts Manual for part number Do not mix Polyol Ester and standard synthetic compressor oils Keep Polyol Ester compressor oil in tightly sealed containers If Polyol Ester oil becomes contaminated with ...

Page 4: ...4 ...

Page 5: ...cessor 20 CYCLE SENTRY Start Stop Controls 20 DAS Optional 21 Remote Control Box Optional 21 Sequence of Operation 21 Defrost 21 System Operation 22 Refrigeration System Diagrams 23 Zone 1 Cool Zone 2 Cool and Zone 3 Cool 24 Zone 1 Cool Zone 2 Cool and Zone 3 Heat 26 Design Features 28 Serial Number Locations 29 Operating Instructions 35 Control Panel 35 Zone 1 Host On Off Switch 35 Zone 2 On Off ...

Page 6: ...stem 53 Engine Oil Change 53 Oil Filter Change 53 Low Oil Pressure 53 Engine Cooling System 55 ELC Extended Life Coolant 55 Antifreeze Maintenance Procedure 56 Bleeding Air from the Cooling System 57 Engine Thermostat 58 Engine Fuel System 58 Operation 58 Maintenance 58 Bleeding the Fuel System 60 Draining Water from Fuel Tank 60 Fuel Filter Water Separator 60 Fuel Filter Water Separator Replaceme...

Page 7: ...ischarge Vibrasorber 91 In Line Check Valves 91 Receiver Tank 92 Filter Drier 92 Expansion Valve Assembly 92 Heat Exchanger 93 Evaporator Coil 93 Accumulator 94 Suction Vibrasorber 94 High Pressure Cutout Switch and High Pressure Switch 94 Discharge Pressure Sensor 95 High Pressure Relief Valve 95 Throttling Valve 95 Removal 95 Disassembly 97 Reassembly 97 Installation 98 Liquid Line Solenoid Valv...

Page 8: ...rical 119 Remote Evaporator Maintenance Inspection Schedule 121 Remote Evaporator Unit Description 123 Unit Operation 125 Defrost 125 Operating Modes 125 Unit Features 125 Unit Protection Devices 126 Serial Number Location 126 Remote Evaporator Electrical Maintenance 127 Smart Reefer Multi Temp µP IV Microprocessor Controlled Components 127 Unit Wiring 127 Remote Evaporator Refrigeration Service O...

Page 9: ...gure 23 ELC Nameplate Located On Expansion Tank 55 Figure 24 Engine Cooling System 56 Figure 25 Engine Fuel System 59 Figure 26 Fuel Tank 60 Figure 27 Injection Pump 60 Figure 28 Filling Fuel Filter Water Separator 61 Figure 29 Engine Speed Adjustments 61 Figure 30 Component Location 62 Figure 31 Top Dead Center One and Four 62 Figure 32 Timing Mark Alignment 63 Figure 33 Correct Injection Timing ...

Page 10: ...ocation of Expansion Valve Bulb 93 Figure 63 Throttling Valve Assembly 96 Figure 64 Inspect the Parts 97 Figure 65 Inspect for Wear 97 Figure 66 Inspect for Damage 97 Figure 67 Throttling Valve Reassembly 98 Figure 68 Suction Line Check Valve 100 Figure 69 Check Valve with Cap Nut 100 Figure 70 Compressor Oil Filter 103 Figure 71 Unit and Engine Mounting Bolts 105 Figure 72 Defrost Damper Adjustme...

Page 11: ...lthough fluorocarbon refrigerants are classified as safe refrigerants certain precautions must be observed when handling them or servicing a unit in which they are used When exposed to the atmosphere in the liquid state fluorocarbon refrigerants evaporate rapidly freezing anything they contact First Aid In the event of frost bite the objectives of First Aid are to protect the frozen area from furt...

Page 12: ... the wire should be cut with either an insulated instrument e g a wooden handled axe or cable cutters with heavy insulated handles or by a rescuer wearing electrically insulated gloves and safety glasses Whichever method is used do not look at the wire while it is being cut The ensuing flash can cause burns and blindness If the victim has to be removed from a live circuit pull the victim off with ...

Page 13: ...t Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Valve Setting Temperature 70 F 21 C Fuel Injection Timing 10 Degrees BTDC timed on No 1 cylinder Low Oil Pressure Switch Normally Closed 17 3 psi 117 21 kPa Engine Coolant Thermostat 180 F 82 C Coolant System Capacity 7 5 qt 7 1 liters Radiator Cap Pressure 7 psi 48 kPa Engine Coolant Type ELC Extended Life Coolant which is RED Use a 50 50 concen...

Page 14: ...rottling Valve Setting Model 30 27 to 29 psi 186 to 200 kPa Model 50 23 to 25 psi 159 to 172 kPa Heat Defrost Method Engine Operation Hot gas Electric Operation Hot gas and electric heater strips host only High Pressure Cutout 470 7 psi 3241 48 kPa Automatic reset 375 38 psi 2586 262 kPa High Pressure Control Switch Opens 300 25 0 psi 2068 172 0 kPa Closes 200 20 psi 1379 138 kPa See Compressor Su...

Page 15: ...ge Regulator Setting 13 8 to 14 3 volts 77 F 25 C NOTE Fuse F7 Bypass resistor for Prestolite Alternator must be removed for the Bosch Alternator The Bosch alternator has the word BOSCH on the end opposite the pulley see Figure 17 on page 43 Electrical Components NOTE Disconnect components from unit circuit to check resistance Current Draw Amps at 12 5 Vdc Resistance Cold Ohms Fuel Solenoid Pull i...

Page 16: ...tion Coil must be below 45 F 7 2 C Defrost Termination Terminates defrost with coil temperature above 57 F 14 C Defrost Interval Timer Terminates defrost 30 to 45 minutes programmable after initiation if coil sensor has not terminated defrost Electric Standby Model 50 Units Only Electric Motor and Overload Relay Voltage Phase Frequency Horsepower Kilowatts rpm Full Load amps Overload Relay Setting...

Page 17: ...pump inlet strainer prefilter Check and adjust engine speeds high and low speed Check condition of drive coupling bushings per Service Bulletin T T 171 Check condition of engine mounts Replace standard silver fuel filter water separator Replace EMI 3000 black fuel filter water separator Engine Oil Change Intervals see below NOTE The engine oil change interval is extended to 3 000 hours when equipp...

Page 18: ...aged loose or broken parts includes air ducts and bulkheads Inspect tapered roller bearing fanshaft and idlers for leakage and bearing wear noise Clean entire unit including condenser and evaporator coils and defrost drains Check all unit and fuel tank mounting bolts brackets lines hoses etc Check evaporator damper door adjustment and operation Host Unit Continued Pretrip Every 1 500 Hours Every 3...

Page 19: ...tor and the control box The Model 50 host unit also contains an electric motor The unit is equipped with a Smart Reefer Multi Temp µP IV Microprocessor which controls the operation of the host unit and any remote evaporators Refrigeration lines and wire harness connect the host unit to the remote evaporators The host unit mounts on the front of the trailer with the unit evaporator portion extendin...

Page 20: ...ard features DAS and a remote control box are optional features The microprocessor mounts inside a weather tight control box The display is clearly visible through a transparent cover Opening the keypad door provides quick access to the microprocessor keypad The keypad is used to control the operation of the microprocessor CYCLE SENTRY Start Stop Controls A CYCLE SENTRY Start Stop fuel saving syst...

Page 21: ...ht illuminates the display and the operating icons appear The unit will start automatically in both Continuous Run and CYCLE SENTRY modes The microprocessor uses a complex program to determine which operating mode each zone should be in Therefore it is difficult to predict which operating mode an evaporator should be in by comparing its setpoint to the compartment temperature Also the different ve...

Page 22: ...the check valves If the condenser inlet solenoid is energized closed because a zone is in heat or defrost and if the discharge pressure exceeds 400 psi 2758 kPa the condenser inlet solenoid is de energized until the discharge pressure drops below 250 psi 1724 kPa The receiver tank pressure solenoid and the purge valve are energized open when any zone is in heat or defrost If the discharge pressure...

Page 23: ...tion 23 Refrigeration System Diagrams The following pages show examples of the refrigerant flow through a three zone system The two zone system is similar except the Zone 3 evaporator and its components are removed ...

Page 24: ...e Zone 3 expansion valve into the Zone 3 evaporator There the liquid refrigerant cools the Zone 3 evaporator as it evaporates into low pressure vapor The refrigerant returns to the compressor through the SLS3 the suction line the SLCV3 and the accumulator Host Unit and Zone 1 Evaporator 1 Liquid Line Solenoid LLS Open 2 Liquid Return Check Valve LRCV Closed 3 Suction Line Check Valve SLCV Open 4 S...

Page 25: ...Unit Description 25 Figure 3 Zone 1 Cool Zone 2 Cool and Zone 3 Cool Zone 3 Zone 2 Zone 1 AGA168 ...

Page 26: ...rant returns to the compressor through the SLS2 the suction line the SLCV2 and the accumulator Host Unit and Zone 1 Evaporator 1 Liquid Line Solenoid LLS Open 2 Liquid Return Check Valve LRCV Closed 3 Suction Line Check Valve SLCV Open 4 Suction Line Solenoid SLS Open 5 Hot Gas Solenoid HGS Closed 6 Condenser Inlet Solenoid CIS Closed 7 Condenser Inlet Check Valve CICV Closed 8 Receiver Tank Press...

Page 27: ...Unit Description 27 Figure 4 Zone 1 Cool Zone 2 Cool and Zone 3 Heat Zone 3 Zone 2 Zone 1 AGA169 ...

Page 28: ...elts 3000 Hour Cyclonic Air Cleaner 3000 Hour Fuel Filter Water Separator 3000 Hour Dual Lube Oil Filter 5 Year 12 000 Hour Service Interval Extended Life Coolant ELC Smart Reefer Multi Temp µP IV Microprocessor Controller CYCLE SENTRY System Refrigerant 404A 120 Amp Alternator Model 30 105 Amp Alternator Model 50 Spectrum Remote Evaporator s Silicone Coolant Hoses Auto Phase Communications Data L...

Page 29: ...ed on an nameplate on the valve cover Compressor Stamped on the end above the oil pump Figure 8 Laminated Serial Number Plate Located Where Shown Above 1 Serial Number Location Figure 5 Compressor Serial Number Location 1 Serial Number Location Figure 6 Engine Serial Number Location 1 SP2001 1 AEA686 1 Serial Number Location Figure 7 Unit Serial Number Locations AJA920 1 1 AEA1398 ...

Page 30: ...Unit Description 30 Figure 9 Front View AJA920 ...

Page 31: ...Unit Description 31 1 Access Panels 2 Defrost Damper Figure 10 Back View 1 2 ARA104 ...

Page 32: ... Suction Service Valve 10 Receiver Tank Sight Glass 3 Throttling Valve 11 Hand Primer Pump 4 Throttle Solenoid 12 Dipstick 5 Fuel Solenoid 13 Oil Filter 6 Air Restriction Indicator 14 Starter 7 Fuel Bleed Screw 15 Compressor Sight Glass 8 Alternator 16 Compressor Oil Filter Figure 11 Engine Compartment ...

Page 33: ...Unit Description 33 1 Microprocessor Control Panel 2 Display 3 Keypad 4 Switch Panel 3 Temp Unit Shown 5 Computer Port Optional 6 Printer Port Optional Figure 12 Control Panel 2 3 4 1 AJA919 5 6 ...

Page 34: ...Unit Description 34 1 DAS Module Optional 2 Fan Relays FR33 FR32 FR23 and FR22 3 Fuel Solenoid Relay 4 Relay Board 5 Microprocessor Figure 13 Typical Components Inside Control Box 1 2 3 4 5 ARA015 ...

Page 35: ...he display will be off and the display backlight will be off The switch should always be placed in the Off position before servicing the unit When the switch is in the On position the display backlight will turn on and the Standard Display will appear WARNING The unit may start and run automatically any time the Zone 1 Host On Off switch is in the On position 1 Display 5 Zone 3 On Off Switch Three...

Page 36: ...gments and operating icons are shown in Figure 14 on page 35 Icons An icon will appear next to the appropriate description when the unit is operating in that mode or if an alarm condition exists The Zone Icons indicate which zone is currently displayed Cool Icon Appears when the indicated zone is operating in Cool mode Heat Icon Appears when the indicated zone is operating in Heat mode Defrost Ico...

Page 37: ...r filter is not restricted Service the air filter when the yellow diaphragm indicates 25 in of water column Press the button on the top of the restriction indicator after servicing the air filter Replace the EMI 3000 air cleaner element see EMI 3000 Air Cleaner on page 70 at 3 000 hours or two years whichever occurs first if air clean indicator has not reached 25 in Remote Status Light Optional Th...

Page 38: ... relay opens the circuit to the electric motor if the motor overloads for any reason e g low line voltage or improper power supply while the unit is on electric standby operation Unit Operation Manual Pretrip Inspection Before Starting Unit The following Manual Pretrip Inspection should be completed before starting the unit and loading the trailer While the pretrip inspection is not a substitute f...

Page 39: ...d the pretrip has started The amps check will continue for several minutes then the unit will start automatically and the operational tests will be performed 4 When the Pretrip Test is complete PASS CHECK or FAIL will appear on the display until a function key e g SELECT or ENTER is pressed Continue as follows PASS The unit is running and no alarms have been recorded The unit has passed the pretri...

Page 40: ...d in the Diesel position 2 Place the Zone 1 Host On Off switch in the On position 3 After a 10 second delay the unit should preheat and start automatically NOTE When the CYCLE SENTRY icon is active the unit may not start if the compartment temperatures are near their respective setpoints the engine is warm and the battery is fully charged 4 Place the Zone 2 On Off switch in the On position to oper...

Page 41: ...mation about Manual Defrost The Defrost cycle should end automatically NOTE An evaporator will not defrost unless its coil temperature is below 45 F 7 C Loading Procedure 1 Make sure the unit is Off before opening the doors to minimize frost accumulation on the evaporator coil and heat gain in the trailer Unit may be running when loading the trailer from a warehouse with door seals 2 Spot check an...

Page 42: ...t the unit if it was shut off to load see Restarting Unit 3 Make sure the setpoints are at the desired settings 4 One half hour after loading manually initiate defrost cycles in each compartment If the evaporator coil sensor temperature is below 45 F 7 C the evaporator will defrost The microprocessor will terminate defrost automatically when the evaporator coil temperature reaches 58 F 14 C or the...

Page 43: ...p clamp or an equivalent CAUTION Full fielding alternators with the integral regulator is accomplished by installing a jumper from terminal F2 to ground Attempting to full field the alternator by applying battery voltage to terminal F2 will cause voltage regulator failure CAUTION The F7 fuse must be removed from the relay board on units equipped with the Australian Bosch alternator The voltage reg...

Page 44: ...olts or higher If not check the excitation circuit EXC or equivalent in the alternator harness and in the main wire harness 8 If battery voltage is present on the sense and excitation circuits connect the alternator harness to the voltage regulator and check the voltage on the B pin in the two pin connector on alternator harness The voltage should be 1 to 3 volts a No voltage or a voltage reading ...

Page 45: ...rent indicates an open circuit or excessive resistance in the field circuit Replace the voltage regulator and brush assembly inspect the slip rings and repeat the test If the brushes are not the problem replace the rotor or the alternator b High field current indicates a short in the field circuit Repair or replace the alternator Alternator Rating Field Current 12 Volts 120 Amp 2 0 to 5 0 Amps Dia...

Page 46: ...dure before replacing the voltage regulator or the alternator When testing alternators use accurate equipment such as a Thermo King P N 204 615 FLUKE 23 digital multimeter and a Thermo King P N 204 613 amp clamp or an equivalent CAUTION Full fielding alternators with the integral regulator is accomplished by installing a jumper from terminal F2 to ground Attempting to full field the alternator by ...

Page 47: ...the alternator Battery voltage must be present If not check the 2 circuit 6 Set the unit for continuous run operation and place the Zone 1 Host On Off switch in the On position 7 Check the voltage at the EXC terminal on the alternator Battery voltage must be present If not check the EXC circuit 8 Attach a clamp on ammeter to the 2A wire connected to the B terminal on the alternator 9 Connect a vol...

Page 48: ...ds protects the 7K1 circuit which supplies power to solenoids and components in the host unit A 25 amp fuse Fuse F12 Zone 3 Fan Motors protects the FMR3 circuit which supplies power to the Zone 3 evaporator fan motors and relays A 15 amp fuse Fuse F13 Zone 3 Solenoids protects the 8 3 circuit which supplies power to solenoids and components in the Zone 3 evaporator A 25 amp fuse Fuse F15 Zone 2 Fa...

Page 49: ...iate Microprocessor Controller Diagnosis Manual for complete service information about the microprocessor controller and the related components Unit Wiring Inspect the unit wiring and the wire harnesses during scheduled maintenance inspections for loose chaffed or broken wires to protect against unit malfunctions due to open or short circuits AC Components Model 50 Units Only Electrical Contactors...

Page 50: ...nected respectively to terminals L1 L2 and L3 on the heater contactor and both motor contactors c Wires T1A T2A and T3A should be connected respectively to terminals T1 T2 and T3 on MC1 d Wires T1A T2A and T3A should be connected respectively to terminals T3 T2 and T1 on MC2 e Wires T1A T2A and T3A should be connected respectively to terminals L1 L2 and L3 on the overload relay f Wires 1 2 and 3 s...

Page 51: ...s ground If there is no continuity to the CH circuit check the CH wire for continuity 3 Check for battery voltage 12 volts at the 7EA and 8 terminals on the PSM Battery voltage should be present If not check the 7EH circuit the overload relay the 7EHA circuit the Electric HPCO the 7EA circuit the F2 fuse the 7E circuit the Diesel Electric switch the 7K1 circuit the F6 fuse the run 7K relay the F22...

Page 52: ... at the 7EC terminal on MC2 Battery voltage should be present at one of these terminals If not check the continuity of the 7EB and 7EC wires 6 Check the continuity of the RED wires on the motor contactors The RED wires must have continuity 7 Check the CH circuit at MC1 and MC2 for continuity to a chassis ground If the CH circuits do not have continuity to a chassis ground check the CH wires 8 Chec...

Page 53: ...uld be changed according to the Maintenance Inspection Schedule Drain the oil only when the engine is hot to ensure that all the oil drains out When changing oil keep unit and trailer level so all the oil can flow from the oil pan It is important to get as much of the oil out as possible because most of the dirt particles are contained in the last few quarts of oil that drain out of the pan Refill...

Page 54: ...Known Good Oil Pressure Gauge Check Oil Pressure Oil Pressure OK Oil Pressure Low Remove Oil Pump Access the oil pump by removing the crankshaft pulley the sound shield and the timing gear cover Check Oil Pump Tolerances Check Oil Pressure Control Valve for Broken Spring or Sticking Piston Reinstall Oil Pump Check Oil Pressure Oil Pressure OK Oil Pressure Low Pull Engine Remove Oil Pan Check Inlet...

Page 55: ...s 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 has been phased into all trailer units equipped with TK 486 engines A nameplate on the coolant expansion tank identifies units with ELC NOTE The new engine coolant Texaco Extended Life Coolant is RED in color instead of the current GRE...

Page 56: ...itors become worn out and must be replaced by changing the antifreeze Change ELC red engine coolant every five years or 12 000 hours whichever occurs first Do not mix green or blue green engine coolant with ELC red engine coolant See ELC Extended Life Coolant on page 55 for more information about ELC The factory recommends the use of a 50 50 antifreeze mixture in all units even if they are not exp...

Page 57: ...make a 50 50 mixture Do not add antifreeze and then add water to the unit This procedure may not give a true 50 50 mixture because the exact cooling system capacity may not always be known 8 Refill the radiator with the 50 50 antifreeze mixture and make sure to bleed the air from the cooling system as needed Bleeding Air from the Cooling System Jiggle pin thermostats are original equipment on unit...

Page 58: ... cover The injection pump raises the pressure of the fuel and meters the correct amount of fuel to the nozzle at the correct time The increased fuel pressure will lift the spring loaded nozzle to admit fuel into the combustion chamber Injection pump leakage injection nozzle overflow and excess fuel from the fuel filter orifice are then all sent back to the fuel tank in the return line Maintenance ...

Page 59: ...air 5 Injection line replacement 6 Injection pump and governor adjustments 7 Injection pump timing 8 Nozzle spray pattern testing and adjustment 9 Minor rebuilding of nozzles 3 2 1 4 5 6 7 8 1 Check Valve Keeps air from entering fuel system when engine is not running 5 Fuel Transfer Pump 2 Filter Head 6 Inlet Strainer Prefilter 3 Injection Pump 7 Priming Pump 4 Bleed Screw 8 Fuel Filter Water Sepa...

Page 60: ...or nozzles Damage to the fuel system will subsequently cause more expensive damage to the engine A large accumulation of water in the bottom of the fuel tank will stop a diesel engine Water should be drained off during scheduled maintenance inspections to prevent breakdowns Drain the water off after the fuel tank and unit have remained idle for an hour 1 Place a container under the fuel tank to ca...

Page 61: ...Shut the unit off 3 Remove the ball joint from the eye bolt in the high speed solenoid 4 Remove the boot from the high speed solenoid 5 Pull the plunger out of the solenoid enough to loosen the jam nut An Allen wrench placed in the hex opening in the face of the plunger will keep the plunger from turning Turn the plunger eye bolt clockwise to increase the speed and counterclockwise to decrease the...

Page 62: ... mark on the flywheel lines up with the index mark in the timing mark access hole b Check the rocker arms on the number one cylinder to see if they are loose c If the rocker arms are loose the engine is at top dead center of the compression stroke for the number one cylinder d If the rocker arms are tight the engine is at top dead center of the exhaust stroke for the number one cylinder Rotate the...

Page 63: ... to recheck the timing 15 If the timing is off by more than 1 degree 0 1 in 2 5 mm loosen the mounting nuts on the studs that fasten the injection pump to the engine and rotate the injection pump to change the timing a Pull the top of the injection pump away from the engine to advance the timing b Push the top of the injection pump toward the engine to retard the timing 16 Tighten the injection pu...

Page 64: ...gear Caution should be made to align the screw over the center of the injection pump shaft 6 Remove the screw and adapter leaving the tool plate in place This holds the gear in proper tooth alignment until the injection pump is re installed Injection Pump Reinstallation 1 Position injection pump shaft into gear rotating shaft to mate key with keyway in gear 2 Secure injection pump to gear case wit...

Page 65: ...connected to the 8D circuit The fuel solenoid relay coil is also connected to the 8D circuit and it is grounded through the fuel solenoid timer The fuel solenoid pull in coil is connected to the 2A circuit through the normally open contacts of the fuel solenoid relay when the fuel solenoid relay is energized When the 8D circuit is energized it supplies power to the fuel solenoid hold in coil and t...

Page 66: ...o the following illustrations to identify the pins in the wire connectors a If battery voltage is not present on the 8D circuit check the 8D circuit and the related circuits and components for a fault b If battery voltage is present on the 8D circuit go to step 5 Figure 38 Main Wire Harness Connector Pin Identification 5 Check the CH circuit pin C in the main wire harness connector for continuity ...

Page 67: ...ut should not click when the pull in coil is de energized c De energize the hold in coil by removing the jumper from the red wire 8D pin A and the positive battery terminal The fuel solenoid should make a definite click when the hold in coil is de energized d If the hold in coil does not function properly check the resistance of the hold in coil by placing an ohmmeter between the red wire 8D pin A...

Page 68: ... the fuel solenoid by energizing the run relay RUNR with the Relay Board Test mode NOTE The fuel solenoid must be energized when it is being installed If it is not the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly 6 Place the o ring in the groove in the end of the fuel injection pump Make sure that the o ring is positioned correctly during insta...

Page 69: ...ndition and is positioned squarely on the top of the valve stem Replace the valve stem cap if it shows significant wear 5 Adjust the valves if necessary by loosening the locknut and turning the adjustment screw until the valve clearance is correct 6 Hold the adjustment screw in place and tighten the locknut Figure 43 Adjusting the Valve Clearance 7 Recheck the valve clearance 8 Rotate the engine o...

Page 70: ...old This prevents condensation from collecting in the breather hose The condensation can plug the breather hose if it collects and freezes in the hose Air Cleaner Before the first quarter of 2001 a heavy duty dry element air cleaner was used on this unit Replace this air cleaner when the air restriction indicator reads 25 in of vacuum EMI 3000 Air Cleaner The EMI 3000 air cleaner is a dry element ...

Page 71: ...he belt fibers and bearings Using belt tension gauge P N 204 427 is the best method of checking belts for tightness Install the belt gauge in the center of the longest belt span Press the plunger so the hook will engage the belt Make sure the hook is on the face of the belt not in a notch Release the plunger with a quick motion and without pulling on the belt Then read the dial Use an average of t...

Page 72: ...n belts are adjusted at the same time in one procedure NOTE If a fan belt is loose or damaged replace the belt see Model 30 Fan Belt Replacement on page 73 1 Loosen the idler assembly pivot bolts and the idler adjusting arm bolts 2 Push in or pull out on the idler adjusting arm to center the idler assembly between the belts and balance the tension equally between the upper and lower belts 1 2 3 6 ...

Page 73: ...ull the idler adjusting arm OUT The upper fan belt should slip off the idler pulley as the idler pulley hub clears the curbside idler mounting bracket 4 Loosen the two condenser fan hub to the shaft clamping bolts 5 Tap the blower wheel with a soft hammer to drive the blower wheel up the fan shaft to provide 1 2 in 13 mm clearance between the blower wheel and the inlet ring NOTE If the condenser f...

Page 74: ...h the proper belt tension adjustment tighten the back up hex nut to the adjustment hex nut on the compression spring adjustment screw Water Pump Belt Adjustment The water pump belt tension should be 35 on the belt tension gauge 1 Remove the bolts from the water pump pulley 2 Remove the pulley sliding section and add or remove shims to adjusting the belt tension gauge 3 Reinstall the belt on the pu...

Page 75: ...e flywheel Installation 1 Install the belts on the clutch pulley through the gap between the clutch and the flywheel 2 Place the compressor in position and install the mounting bolts 3 Adjust the hex nuts on the compression spring adjustment to tighten the belts to 79 on the belt tension gauge 4 Tighten the back up hex nut on the belt tension compression spring adjustment screw 1 Condenser Fan Pul...

Page 76: ...ring using a soft hammer 3 Position the blower wheel so the edge of the inlet ring lines up with the alignment mark on the blower wheel see Figure 50 on page 74 4 Check the radial clearance between the blower wheel and inlet ring with a gauge wire Check around the entire circumference to the inlet ring and blower wheel see Condenser and Evaporator Fan Location on page 107 5 Torque the blower hub c...

Page 77: ...olts and the lock nuts Torque the lock nuts to 30 to 35 ft lb 41 to 47 N m 11 To replace the bearing a Remove the snap ring and press the bearing out of the hub b Press the new bearing into the hub and install the snap ring 12 To assemble the clutch press the pulley into the bearing 13 Place the key in the compressor crankshaft 14 Place the clutch on the compressor crankshaft and align the keyway ...

Page 78: ...e 78 11 10 9 8 7 6 5 4 3 2 1 AGA338 1 Clutch Mounting Bolt 7 Spring 2 Special Washer 8 Friction Shoe 3 Snap Ring 9 Mounting Bolt Plate 4 Bearing 10 Friction Shoe Mounting Bolt 5 Lock Nut 11 Pulley 6 Hub Figure 52 Clutch ...

Page 79: ...onditions the ball should be floating 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 NOTE This test determines if there is enough refrigerant for the current temperatures not if there is a full charge of refrigerant 1 Install a gauge manifold 2 Run all the evaporator...

Page 80: ...the liquid flow so the suction pressure increases approximately 20 psig 138 kPa g Maintain a discharge pressure of at least 325 to 400 psig 2241 to 2758 kPa while adding refrigerant h Close the hand valve on the refrigerant tank when liquid appears in the receiver sight glass 4 Repeat the overcharge test 5 Remove the gauge manifold set and cap all service ports and valve stems when the refrigerant...

Page 81: ...the top of its gasket surface Compressor Oil Level The recommended compressor oil level is the same for both compressors The sight glass should be 1 4 to 1 2 full See Checking Compressor Oil on page 82 See the Specifications Chapter for the total quantity of compressor oil Compatibility The 7 quart sump compressor and the 4 quart sump compressor are interchangeable However the increased oil capaci...

Page 82: ...imum suction pressure and a 185 psig 1275 kPa minimum discharge pressure for 15 minutes or more After the unit has maintained the above conditions for 15 minutes observe the oil level The oil should be 1 4 to 1 2 up in the sight glass To check compressor oil level with an ambient air temperature below 50 F 10 C Run all the evaporators through a complete defrost cycle After completing the defrost c...

Page 83: ...s below 200 psig 1379 kPa Use the following procedure to test the HPSW 1 Install a gauge manifold on the compressor 2 Disconnect the HPSW from the 7K1 and HP wires in the main wire harness 3 Check the HPSW for continuity It should be closed when the unit is not running 4 Use the Service Test mode to run the host unit in High Speed Cool Refer to the appropriate Diagnosis Manual for specific informa...

Page 84: ...he SELECT key If OFF and PRNT appear on the display press the SELECT key again The letters REV should appear in the lower display and the revision number should appear in the upper display 8 With the revision screen on the display press both the TK key and the CLEAR key and hold them down for 3 to 5 seconds until TEST and VAC appears on the display 9 Press the ENTER key to load the Evacuation mode...

Page 85: ...e remains below 2000 microns for 5 minutes restart the pump open the Evacuation Station valve nearest the pump and back seat the suction service valve while the evacuation pump is still operating Replace the valve cap re close the Evacuation Station valve nearest the pump V1 and stop the evacuation pump Do not exercise the service valves with the unit in a deep vacuum unless the evacuation pump is...

Page 86: ...nsure that all zones run in Cool mode Allow the unit to start 9 Cover the condenser as required to maintain discharge pressure from 325 to 400 psig 2241 to 2758 kPa and add the remaining charge by weight as liquid through the suction service valve 10 If necessary continue to add refrigerant until the ball in the receiver tank sight glass is floating but is no higher than 1 2 way up the glass If th...

Page 87: ...ow into the accumulator undoing the low side pump down b Place the unit in the Evacuation mode Refer to the Service Test mode in the appropriate Microprocessor Diagnosis Manual The high and low side pressures should equalize in the Evacuation mode NOTE Repeat the pump down procedure if the pressures equalize above 20 psi 138 kPa If suitably low pressures cannot be achieved after the third pump dow...

Page 88: ...s on Model 50 units and install the mounting bolts 4 Install the service valves using new gaskets soaked in compressor oil Connect the HPCO wires the HPSW wires and install the compressor oil filter 5 Pressurize the compressor and test for refrigerant leaks 6 If no leaks are found evacuate the compressor 7 Back seat the suction and discharge service valves 8 Tighten the compressor belts on Model 5...

Page 89: ... with 20 ft lb 27 N m torque This insures that the key cannot hold the tapers apart when the final bolt torque is applied Use the following procedure to install a compressor coupling on the compressor crankshaft 1 Clean the compressor shaft taper and coupling bore taper with a solvent that leaves no oily residue such as naphtha lacquer thinner brake cleaner or the like 2 Inspect both mating surfac...

Page 90: ...ed in farther it may cause the coupling to move off center on the shaft 9 Re install the bolt and heavy flat washer and snug the bolt down by hand Torque the bolt to 90 ft lb 122 N m 10 Spray a corrosion inhibitor such as spray paint on the exposed part of the shaft and the joint between the shaft and the coupling This prevents moisture from wicking into the joint and causing corrosion Condenser C...

Page 91: ... the compressor oil level In Line Check Valves This unit uses some in line check valves An 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 Removal 1 Recover the refrigerant charge 2 Place a heat sink on the check valve 3 Unsolder the lines and remove ...

Page 92: ... the mounting screws and nuts 3 Install and tighten the inlet ORS nut Hold the drier with a back up wrench on the hex behind the ORS fitting 4 Release a small amount of refrigerant to purge the air through the drier Then tighten the outlet ORS nut 5 Pressurize the system and inspect for leaks If no leaks are found open the refrigeration valves and place the unit in operation Expansion Valve Assemb...

Page 93: ...er the liquid inlet and the suction outlet line connections on the condenser side of the bulkhead Seal the openings through the bulkhead with putty when the refrigerant lines have cooled off 4 Solder the suction inlet line connection 5 Solder the liquid outlet line connection 6 Pressurize the low side and test for leaks If no leaks are found evacuate the low side 7 Tighten the heat exchanger mount...

Page 94: ...nd place the unit in operation Check the refrigerant charge and the compressor oil and add as required Suction Vibrasorber Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Unsolder the suction vibrasorber from the suction service valve 3 Unsolder the connection to the accumulator and remove the vibrasorber from the unit Installation 1 Prepare the suction vibrasorbe...

Page 95: ...Screw the discharge pressure sensor into the adapter on the end of the tube Use a backup wrench to hold the adapter 3 Install the mounting clamp if used for the discharge pressure sensor 4 Recharge the unit with the proper refrigerant and check the compressor oil High Pressure Relief Valve Removal 1 Recover the refrigerant charge 2 Unscrew and remove the high pressure relief valve It is located ne...

Page 96: ...g 2 Flatwasher 11 Piston 3 Plate bellows end 12 Spring piston 4 Gasket end plate 13 Nut adjusting 5 Washer adjusting 14 Pin cotter 6 Spring bellows 15 Housing piston 7 Bellows Shaft assy 16 O ring valve to compressor 8 O ring 17 Cap rubber 9 Housing Figure 63 Throttling Valve Assembly ...

Page 97: ...llows is normally replaced 9 Clean the parts that will be reused Reassembly 1 Install the bellows with the O ring in the housing 2 Center the spring on the bellows shoulder 3 Oil the gasket install it on the housing and place the shims in the end cap use same number as removed Tighten the end cap in place with the vent hole closest to the outlet opening of the valve housing 4 Install the piston sp...

Page 98: ...sembled before soldering Removal 1 Pump down the low side and equalize pressure to slightly positive 2 Remove the evaporator access panels 3 Remove the coil and disassemble the valve 4 Unsolder the liquid lines from the valve and remove the valve from the unit Installation 1 Clean the tubes for soldering 2 Remove the coil disassemble the valve and place the valve in position 3 Solder the inlet and...

Page 99: ...gerant charge and compressor oil Suction Line Solenoid Valve SLS NOTE Valves that have nylon seats must be disassembled before soldering Removal 1 Pump down the low side and equalize the pressure in the high side to slightly positive 2 Remove the evaporator access panels 3 Remove the coil and disassemble the valve 4 Unsolder the suction lines from the valve and remove the valve from the unit Insta...

Page 100: ...at might adhere to the seat and damage the new seat If the body is damaged replace the check valve 2 Install the new seat and spring Place a new gasket on the cap and tighten the cap 3 Pressurize the low side and test for leaks 4 If no leaks are found evacuate the system 5 Install the evaporator access panels 6 Open the refrigeration valves and run the unit Check the refrigerant charge and compres...

Page 101: ... the unit Installation 1 Clean the tubes for soldering 2 Remove the coil disassemble the valve and place the valve in position 3 Solder the inlet and outlet connections After the valve cools assemble the valve and install the coil 4 Pressurize the refrigeration system and test for leaks 5 If no leaks are found evacuate the system 6 Recharge the unit with proper refrigerant and check the compressor...

Page 102: ...il from the valve and place the valve in position 3 Solder the inlet and outlet connections After the valve cools install the coil on the valve 4 Pressurize the refrigeration system and test for leaks 5 If no leaks are found evacuate the system 6 Recharge the unit with proper refrigerant and check the compressor oil Purge Valve PV Removal 1 Recover the refrigerant charge 2 Remove the coil from the...

Page 103: ...ing 4 Remove the clamp and the compressor oil filter 5 Coat the new O rings with clean compressor oil and place them in the ORS fittings on the ends of the new compressor oil filter 6 Fasten the new compressor oil filter in place with the clamp 7 Attach and tighten the oil lines to the compressor oil filter Hold the oil filter with a back up wrench on the hex behind the ORS fitting 8 Evacuate the ...

Page 104: ...compressor below the throttling valve 3 Disconnect the wires to the fuel solenoid 4 Disconnect the wires to the high speed solenoid NOTE The microprocessor will probably record some alarm codes because the solenoids are disconnected and the engine does not start Clear these alarm codes as necessary 5 Turn the unit on and let the engine crank or crank the engine for 30 seconds but do not crank the ...

Page 105: ... maintenance inspections Remove any debris e g leaves or plastic wrap that reduces the air flow Clean dirty coils with compressed air or a pressure washer Be careful not to bend the fins when cleaning a coil If possible blow the air or water through the coil in the direction opposite the normal airflow Repair bent fins and any other noticeable damage Defrost Drains Clean the defrost drains during ...

Page 106: ...dimension by loosening the locknut on the end of the solenoid plunger and turning the eye bolt Tighten the locknut when Distance A is correct 5 Connect the damper link to the eye bolt 6 Energize the solenoid apply 12 volts dc and check the damper blade to make sure that both edges contact the damper housing If necessary adjust this by loosening the solenoid mounting bolts and moving the solenoid T...

Page 107: ...rifice to check for uniform clearance 6 Spin the blower by hand to check for blower distortion 7 Position the blower so the edge of the inlet ring lines up with the alignment mark on the blower 8 Torque blower hub bolts to 18 ft lb 24 N m Evaporator Fan Blower 1 Loosen the inlet rings on the sides of the blower housing 2 Center the blower wheel in the blower housing with equal overlap on both inle...

Page 108: ... the oil from the housing remove the four retaining bolts from the condenser end of the assembly 3 To remove the shaft from the assembly tap the opposite end of the shaft with a soft hammer After the shaft has been removed clean all parts in clean solvent 4 Using a punch remove the oil seal from the evaporator end of the assembly With the seal removed clean the housing in clean solvent 5 Check the...

Page 109: ... There is a level plug and a fill plug but they are not normally used except after removal and repair of the idler assembly The roadside end oil seal and the curbside end oil seal should be checked during the pretrip inspection for oil leakage If there is any sign of leakage the idler assembly should be removed and repaired Idler Assembly Overhaul Disassembly 1 Remove the idler assembly from the u...

Page 110: ...t end play is obtained add approximately 1 5 oz 44 ml of oil for the bearings 8 Lock the assembly in a vise with the vent facing up Pour the oil through the top plug until it runs out of the side hole Check the condition of the O ring used on the plugs and replace if necessary Install the top and side plugs Clean up any spillage 9 Place the assembly on the workbench with the vent up Rotate the sha...

Page 111: ... Replace nozzles Incorrect timing Adjust timing Air cleaner clogged Replace air filter Exhaust plugged Clean exhaust Defective HPCO Replace HPCO Engine stops after starting Air in injection pump Bleed fuel system Fuel filter obstructed Replace filter element High head pressure Eliminate cause of high head pressure Vent of fuel tank obstructed Unclog vent Clogged fuel tank or fuel lines Clean fuel ...

Page 112: ...or Wash radiator Coolant level is low Add coolant Cooling system heavily scaled Cleaning cooling system Cylinder head gasket leaks Replace cylinder head gasket Use correct gasket Faulty thermostat Check or replace thermostat Loose or worn water pump belt Replace belt Oil pressure low Insufficient oil in pan Add oil Faulty oil pressure switch Check oil pressure switch Replace if necessary Oil contr...

Page 113: ...rning Excessive Fuel to Air Ratio Oil Consumption Air or water in fuel Type of fuel used Poor compression Incorrect timing Cold engine Defective valve seals Poor compression Excessive load Faulty injectors Clogged air intake system Faulty nozzles Poor compression Restricted exhaust Faulty injection pump ...

Page 114: ...Mechanical Diagnosis 114 ...

Page 115: ...sel Electric switch on Diesel Place switch on Electric Unit in NULL Check setpoint and box temperature Faulty Diesel Electric switch Check switch Faulty K7 relay Check K7 relay Fuse F6 or F2 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 co...

Page 116: ...Electric Standby Diagnosis 116 ...

Page 117: ...ambient Air in refrigerant system Condenser fan blades bent or broken Air short cycling around evaporator coil Air through evaporator restricted Evaporator needs defrosting Compressor discharge valves leaking Compressor suction valves leaking 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...

Page 118: ...losed Zone 2 or 3 hot gas solenoid HGS2 or 3 Leaky Zone 2 or 3 liquid line solenoid LLS2 or 3 Closed Zone 2 or 3 liquid line solenoid LLS2 or 3 Leaky Zone 2 or 3 liquid return check valve LRCV2 or 3 Leaky Zone 2 or 3 suction line solenoid SLS2 or 3 Leaky Zone 2 or 3 suction line check valve SLCV2 or 3 Leaky purge valve PV Rapid cycling between Cool and Heat Unit cools in Heat and Defrost cycle Uni...

Page 119: ...2 Zone 3 Fan Motors 30 amp auto reset Fuse F12 Zone 3 Fan Motors 25 amp Fuse F13 Zone 3 Solenoids 15 amp Fuse F15 Zone 2 Fan Motors 25 amp Fuse F16 Zone 2 Solenoids 15 amp Fan Motors each Power Rating 0 13 hp 100 Watts rpm 2390 Full Load Amps 7 amps per motor Remote Liquid Line Solenoid Current Draw 1 3 amps Resistance 9 6 ohms Remote Hot Gas Solenoid Current Draw 1 5 amps Resistance 8 3 ohms Remo...

Page 120: ...Remote Evaporator Specifications 120 ...

Page 121: ...e These Items Electrical Inspect wire harness for damaged wires or connections Inspect replace DC fan motors Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts Clean entire unit including evaporator coils and defrost drains Check all unit mounting bolts brackets lines hoses etc ...

Page 122: ...Remote Evaporator Maintenance Inspection Schedule 122 ...

Page 123: ... Return Air Sensor Graded 9 Terminal Board Bracket 2 Hot Gas Solenoid 6 Variable Blower 12 V 10 Terminal Board 3 Liquid Solenoid 7 Blower Housing 11 Terminal Board Markstrip 4 Suction Line Solenoid 8 Blower Cover 12 Resistance Wire Figure 77 Spectrum S 3 Evaporator Components ...

Page 124: ...Remote Evaporator Unit Description 124 Figure 78 Spectrum S 3 Evaporator Front View Figure 79 Spectrum S 3 Evaporator Back View AJA984 AJA985 ...

Page 125: ...µP IV microprocessor energizes the remote liquid line solenoid valve Refrigerant flows through the evaporator coil to provide cooling When the compartment temperature is near setpoint the Smart Reefer Multi Temp µP IV microprocessor de energizes the remote liquid line solenoid valve and switches the remote evaporator to null The Smart Reefer Multi Temp µP IV microprocessor energizes the remote hot...

Page 126: ...s Circuit Breakers in Host Unit located inside the control box Fuses in Host Unit located on the relay board Serial Number Location Unit Nameplate on the right end of the unit frame Figure 80 Serial Number Location 1 Nameplate on Right End of Unit Frame 1 AJA985 ...

Page 127: ... to the appropriate Microprocessor Diagnosis Manual for information about maintenance of the microprocessor controlled components Unit Wiring Inspect the unit wiring and wire harnesses during scheduled maintenance inspections for loose chaffed or broken wires to protect against unit malfunction due to opens or shorts ...

Page 128: ...Remote Evaporator Electrical Maintenance 128 ...

Page 129: ...tion valves and place the unit in operation 8 Test the unit to see that the expansion valve is properly installed Evaporator Coil Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Disconnect the distributor from the expansion valve 3 Remove the insulating tape and feeler bulb from the suction line Note the position of the feeler bulb on the suction line Disconnect t...

Page 130: ...anels 6 Open the refrigeration valves and run the unit Check the refrigerant charge and compressor oil Add as required For the hot gas valve recharge the unit with proper refrigerant Liquid Return Check Valve Repair Removal 1 Pump down the low side and equalize pressure to slightly positive 2 Remove the access panels 3 Remove the cap nut from the check valve and remove the spring and seat Installa...

Page 131: ...gerant charge and compressor oil Heat Exchanger Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Remove the access panels 3 Remove the mounting hardware used to mount heat exchanger to the panel 4 Unsolder the refrigeration lines from the heat exchanger ports and remove it from the unit Installation 1 Clean the tubes for soldering 2 Position the tubes in the proper...

Page 132: ...Remote Evaporator Refrigeration Service Operations 132 ...

Page 133: ... repair or replacement of parts Defrost Drains Clean the defrost drains during scheduled maintenance inspections to make sure the lines remain open Evaporator Coil Clean the evaporator coil during scheduled maintenance inspections by blowing compressed air from the top side of the coil down toward the bottom the direction opposite the normal air flow Inspect the coil and fins for damage and repair...

Page 134: ...Remote Evaporator Structural Maintenance 134 ...

Page 135: ...ty evaporator coil Defrost or clean evaporator coil Expansion valve open too much Replace or adjust valve Poor fitting trailer door Repair or replace doors Liquid line solenoid partially closed or defective Repair or replace Evaporator fan not operating Check and correct evaporator fan Evaporator fan motor does not run Fuse F12 or F15 blown Check for short circuit in unit wiring and replace fuse O...

Page 136: ...Remote Evaporator System Diagnosis 136 ...

Page 137: ...03 compressor oil sight glass 37 computer port 37 condenser coil replacement 90 condenser inlet check valve repair 101 replacement 102 condenser inlet solenoid valve replacement 101 control panel 35 cooling system engine 55 bleeding air from 57 crankcase breather 70 D DAS Data Acquisition System 21 defrost 21 remote evaporator 125 defrost damper adjustment 106 defrost drains 105 defrost drains rem...

Page 138: ...eplacement 102 receiver tank sight glass 37 receiver tank replacement 92 refrigerant charge 79 adjusting refrigerant level 80 testing for an overcharge 79 testing with a loaded trailer 79 testing with an empty trailer 79 refrigerant leaks 80 remote control box 21 remote evaporator coil cleaning 133 replacement 129 remote evaporators 19 remote expansion valve replacement 129 remote heat exchanger r...

Page 139: ...nspection remote evaporator 133 unit operation 38 remote evaporator 125 unit protection devices 37 remote evaporator 126 unit wiring 49 V valve clearance adjustment engine 68 Z Zone 1 Host On Off Switch 35 Zone 2 On Off Switch 36 Zone 3 On Off Switch 36 ...

Page 140: ...Index 140 ...

Page 141: ... Diagrams Index Drawing No Drawing Title Page 5D55924 Model 30 Schematic Diagram 143 144 5D55923 Model 30 Wiring Diagram 145 148 5D56152 Model 50 Schematic Diagram 149 150 5D56153 Model 50 Wiring Diagram 151 155 ...

Page 142: ......

Page 143: ...143 Model 30 Schematic Diagram Page 1 of 2 ...

Page 144: ...144 Model 30 Schematic Diagram Page 2 of 2 ...

Page 145: ...145 Model 30 Wiring Diagram Page 1 of 4 ...

Page 146: ...146 Model 30 Wiring Diagram Page 2 of 4 ...

Page 147: ...147 Model 30 Wiring Diagram Page 3 of 4 ...

Page 148: ...148 Model 30 Wiring Diagram Page 4 of 4 ...

Page 149: ...149 Model 50 Schematic Diagram Page 1 of 2 ...

Page 150: ...150 Model 50 Schematic Diagram Page 2 of 2 ...

Page 151: ...151 Model 50 Wiring Diagram Page 1 of 5 ...

Page 152: ...152 Model 50 Wiring Diagram Page 2 of 5 ...

Page 153: ...153 Model 50 Wiring Diagram Page 3 of 5 ...

Page 154: ...154 Model 50 Wiring Diagram Page 4 of 5 ...

Page 155: ...155 Model 50 Wiring Diagram Page 5 of 5 ...

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