Thermo King 088669 Manual Download Page 59

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Engine Maintenance (Rev. 04/03)

ENGINE FUEL SYSTEM

The fuel system used on the Thermo King TK 3.95 diesel is

a high pressure system used in conjunction with a

prechamber.

The components of the fuel system are:

Fuel tank (may be the truck fuel tank).

Electric Fuel pump.

RD-II SR Fuel System

Fuel filter.

Injection pump.

Injection nozzles.

A 10 psig (69 kPa) electric fuel pump pulls fuel from the

fuel tank through a prefilter, then pushes it to the fuel filter,

and to the injection pump. The prefilter is designed for die-

sel fuel and is the only type that should be used.

Summary of Contents for 088669

Page 2: ...tional purposes only and the information so provided should not be considered as all inclusive or covering all contingencies If further information is required Thermo King Corporation should be consul...

Page 3: ...o 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 con...

Page 4: ......

Page 5: ...Switch 20 Optional Electric Standby Model 50 Units Only 20 Optional Model 50 Features 21 Standard Model 50 Features 21 Remote Control Panel Features 23 p T Alarms 32 P T Unit Self Check Test 32 Electr...

Page 6: ...Screw 51 Engine Mounts for RD II SR Unit 52 RD II Idler Assembly 53 Auto Start Stop 53 TK 3 95 Engine 58 Fuel Solenoid Diagnostic and Replacement 58 Engine Speed Adjustments 59 Integral Fuel Solenoid...

Page 7: ...81 Equipment Recommendations for use with R 134a and R 404A 82 Refrigerant Recovery System THE COLLECTOR 85 Throttling Valve 86 Hilliard Clutch Maintenance 89 Structural Maintenance 93 Unit and Engin...

Page 8: ......

Page 9: ...xample a truck box or garage Refrigerant tends to displace air and can cause oxygen depletion resulting in suffocation and possible death AUTO START STOP CAUTION The unit may start automatically and a...

Page 10: ...al tools in your hand if exposed high voltage conductors are within reach 3 Treat all wires and connections as high voltage until a meter and wiring diagram show otherwise 4 Never work alone on high v...

Page 11: ...vicing the microprocessor and related components A potential difference less than that required to produce a small spark between a finger and a doorknob can cause severe damage to solid state com pone...

Page 12: ...Safety Precautions Rev 04 03 iv PUB126...

Page 13: ...Safety Precautions Rev 04 03 v aea105...

Page 14: ......

Page 15: ...w Oil Pressure Sensor 10 2 psig 69 21 kPa shutdown High Coolant Temperature Sensor 220 5 F 100 4 2 8 C shutdown Engine Thermostat 180 F 82 2 C Coolant System Capacity 4 8 quarts 4 5 liters with overfl...

Page 16: ...20 psig 124 to 138 kPa Heat Defrost Method Engine Operation Electric Operation Hot gas Hot gas and optional electric heater strips Model 50 High Pressure Cutout 470 7 psig 3241 48 kPa Automatically r...

Page 17: ...andby Model 50 Unit Only Electric Motor Voltage Phase Frequency Horsepower Kilowatts rpm Full Load amps Locked Rotor Amps 230 3 60 7 5 5 6 1765 21 2 70 1 460 3 60 7 5 5 6 1765 10 6 35 0 200 3 50 6 25...

Page 18: ...se for damage Change fuel filter Drain water from fuel tank and check vent Inspect clean electric fuel pump filter Change engine coolant every two years Maintain year around anti freeze protection at...

Page 19: ...akage and bearing wear noisy Clean entire unit including condenser and evaporator coils and defrost drains Check all unit fuel tank and electric motor mounting bolts brackets lines hoses etc Check dam...

Page 20: ...of the P T micropro cessor optimizes the Thermo King unit s performance thereby reducing fuel consumption and unit down time The unit s self check can be run before the daily distribution route to ide...

Page 21: ...e receiver tank sight glass is used to check the amount of refrigerant in the system and the moisture content of the refrigerant 4 COMPRESSOR OIL SIGHT GLASS The compressor oil sight glass is used to...

Page 22: ...F403 3A Heater Contactor help the valve reseat and SEAL PROPERLY The valve is non repairable and requires no adjustment If the valve fails to reseat properly remove the refrigerant charge and unscrew...

Page 23: ...out the Unit Self Check This procedure is automatic and can be performed on the way to the loading area or while waiting to load a Press the On button b Clear any alarms c Press and hold the T K key f...

Page 24: ...procedures are used when starting units that have been shut off for short periods of time When a unit has been shut off for a long period of time is first started it should be started and put through...

Page 25: ...ening 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 and record...

Page 26: ...Unit Description Rev 04 03 12 Front Curbside View RD II SR Front Roadside View RD II SR aea104 aea096...

Page 27: ...Unit Description Rev 04 03 13 Access Panel Open Curbside RD II SR Throttle Solenoid Fuel Filter Engine Air Filter Oil Filter aea099...

Page 28: ...Unit Description Rev 04 03 14 Rear View Curbside RD II SR Evaporator aea105...

Page 29: ...Unit Description Rev 04 03 15 Side View Roadside Return Air Sensor Microprocessor Switch Coil Sensor Location aea106...

Page 30: ...n Rev 04 03 16 Top View Fuel Filter Expansion Tank Three Way Valve Condenser Coil Filter Drier Air Defrost Switch Muffler Evaporator Compressor Alternator Nameplate High Pressure Relief Valve Throttli...

Page 31: ...tage Module Motor Contactor B K4 Relay K6 Relay K5 Relay Overload Reset Solenoid K2 Relay K3 Relay K1 Relay K9 Relay K7 Relay K8 Relay Preheat Buzzer Remote Control Cab Box Harness Connector Motor Con...

Page 32: ...Unit Description Rev 04 03 18 Power Receptacle Box RD II SR 50 aea102...

Page 33: ...Unit Description Rev 04 03 19 Thermoguard Remote Control Panel Remote Light Display aea43 Keypad LED Display aea103...

Page 34: ...ontrols Engine Controls High Voltage Tray Model 50 Units Microprocessor Power Switch The microprocessor power switch applies 12 volts DC con trol power to the microprocessor It is located just below t...

Page 35: ...witch to electric operation when a power cord is connected and the standby power is switched ON Phase Lockout Three Phase Units Only If the motor rotation is reversed as a result of incorrect phase ro...

Page 36: ...P T System Description Rev 04 03 22 High Voltage Tray No Options High Voltage Tray with Phase Correction High Voltage Tray with Electric Heat High Voltage Tray with Phase Correction and Electric Heat...

Page 37: ...anel on the truck box KEYPAD KEYS ON KEY Turns the unit ON OFF KEY Turns the unit OFF SELECT KEY Scrolls through the prompt and display screens UP ARROW KEY Chooses prompt screen actions or increases...

Page 38: ...and setpoint In addition the icons located at the sides of the display indicate the operating mode of the unit and shows if any alarm codes are present Pressing the SELECT key will show the prompt an...

Page 39: ...tpoint is being shown in the lower display WHISPER ICON Appears when Whisper mode has been selected These icons appear during a remote control panel test but are not used on truck units READING A TYPI...

Page 40: ...tpoint appears in the lower display This display shows a box temperature of 35 8 F and a setpoint of 35 F The Standard Display is the starting point used to reach all other prompts and displays To ret...

Page 41: ...10 seconds if the Enter key is not pressed SELECTING CYCLE SENTRY or CONTINUOUS MODE 1 Press the ON key to turn the unit ON 2 Press the Select key to display CYCLS and YES or no 3 Press the or Arrow...

Page 42: ...r example to change the setpoint or view display screens the engine will automatically preheat and start about 10 seconds after the last key is pressed INITIATING A MANUAL DEFROST CYCLE 1 The unit mus...

Page 43: ...1 Press the ON key to turn the unit ON 2 Press and hold the TK Logo key to display USC 3 Press the Select key to display rEU and the software revision The software revision shown here is Revision 1520...

Page 44: ...rs if this hourmeter is set to Type 1 2 or 3 Hr5 Total accumulated hours on hourmeter 5 only appears if this hourmeter is set to Type 1 2 or 3 Hr6 Total accumulated hours on hourmeter 6 only appears i...

Page 45: ...how the Alarm display screen If more than one alarm code exists each will be displayed for several seconds The alarm code shown here is alarm code 66 Low Engine Oil Level To Clear Alarm Codes 1 Correc...

Page 46: ...at does not affect unit operation but that should be investi gated The Alarm icon will appear for 30 seconds when the unit On Off switch is turned ON and then disap pear Check Alarm Notice to take cor...

Page 47: ...eck the check results will appear on the display They will remain until any key on the controller is pressed Check results are shown as either PASS CHEC or FAIL PASS The unit has passed the Unit Self...

Page 48: ...lete the following checkout procedure before replac ing the voltage regulator or the alternator 1 With the unit switch OFF attach a voltmeter to termi nal SENSE and the alternator chassis Voltmeter sh...

Page 49: ...d the wire harnesses during sched uled maintenance inspections for loose chafed or broken wires to protect against unit malfunctions due to open or short circuits ELECTRICAL CONTACTS Inspect all relay...

Page 50: ...owever an automotive type meter may not give an accurate read ing because the meter may load the circuit heavily and cause the voltage level to appear lower than it actually is a The output voltage sh...

Page 51: ...fan grille on the front of the unit Correct rotation will hold the cloth or paper against the grille Improper rotation will blow the cloth or paper away from the grille To correct improper condenser f...

Page 52: ...sate traps If too much frost continues to accumulate before defrost decrease the pressure setting Turn the adjustment screw counterclockwise If defrost action occurs with too little frost accumulatio...

Page 53: ...round to the TherMax solenoid The pressure difference between the high pressure liquid in the condenser and the low pressure accumulator drives much of the refrigerant out of the condenser and receive...

Page 54: ...s hot to ensure that all the oil drains out When changing oil try to make sure that the trailer is not tipped away from the direction that the oil is supposed to flow from the oil pan It is important...

Page 55: ...can pass freely If the oil has absorbed the maximum amount of dirt it allows the dirt to enter the engine Remove the oil cup wash thoroughly and dry every 1000 operating hours 500 hours under dusty co...

Page 56: ...the radiator A thermostat mounted in the water outlet from the cylinder head to the radiator automatically maintains coolant temperature within the specified temperature range Engine Cooling Component...

Page 57: ...k and accumulator until it is clear 4 Inspect all the hoses for deterioration and the hose clamp tightness Replace if necessary 5 Loosen the water pump belt Check the water pump bearing for looseness...

Page 58: ...ing the radiator run the unit up to operating tem perature to check for overheating and coolant level and allow the air to be purged for a few minutes CAUTION Do not remove the radiator cap while the...

Page 59: ...of the fuel system are 1 Fuel tank may be the truck fuel tank 2 Electric Fuel pump RD II SR Fuel System 3 Fuel filter 4 Injection pump 5 Injection nozzles A 10 psig 69 kPa electric fuel pump pulls fue...

Page 60: ...st repair shops The following procedures can be done under field condi tions 1 Bleeding air from the fuel system 2 Maintenance involving the fuel tank and filter system 3 Speed and governor adjustment...

Page 61: ...The pump is self priming as long as it is not higher than 30 in 762 mm from the fuel in the fuel tank Maintenance Field service is limited to cleaning the bottom cover and fil ter The filter and cover...

Page 62: ...ocedure for timing the pump to the engine will be covered first The procedure for individual cylinder timing is very similar to timing the injection pump so it will be covered last CAUTION The cylinde...

Page 63: ...the injection timing mark until fuel flows from the drip tube 7 Slowly rotate the engine in the direction of rotation while watching the drip tube When the fuel flow slows to approximately one drip e...

Page 64: ...f number 2 and number 3 injector to the engine after checking number 1 The cylinders should time on their respective flywheel timing marks If the injection pump plungers are not correctly timed to eac...

Page 65: ...of rotation clockwise as viewed next to the flywheel from the water pump end CAUTION Make sure the fuel rack is off to prevent the engine from starting a Turn the engine so number 1 cylinder is on com...

Page 66: ...Engine Maintenance Rev 04 03 52 Engine Mounts for RD II SR Unit The engine mounting system contains three vibration mounts and two snubber mounts Engine Mounting Components...

Page 67: ...ally and at any time when the unit On Off switch is in the ON position Units with the CYCLE SENTRY option start automati cally in both CYCLE SENTRY mode and Continuous mode Be sure to turn the On Off...

Page 68: ...a 7 8 in crow s foot attached to a 3 8 in torque wrench to turn the sprocket and obtain a reading of 40 in lb 4 5 N m on the torque wrench for used belts and 45 in lb 5 0 N m for new belts Tighten the...

Page 69: ...e center of the longest span The engine compressor belt tension should be set at a read ing of 70 to 80 on the Thermo King Belt Tension Gauge P N 204 427 Belt Layout The compressor jackshaft electric...

Page 70: ...enough to obtain 1 2 inch 13 mm deflection at the center of the long est span of the Compressor Evaporator Fan Alternator belts and 1 2 inch 13 mm deflection at the center of the span on the Alternato...

Page 71: ...Engine Maintenance Rev 04 03 57 Integral Fuel Solenoid The fuel stop solenoid is located on the end of the fuel injec tion pump Integral Fuel Solenoid Components...

Page 72: ...noid is energized current is applied to the coil creating an electro magnetic field which pulls the plunger in When the solenoid is in the pulled in position the plunger releases tension on the govern...

Page 73: ...gine speed 5 Set the engine speed at 1625 25 rpm and tighten the jam nut Integral Fuel Solenoid Parts List Part Description Part Number Quantity Fuel Stop Solenoid 41 1386 1 O ring 33 2770 1 Throttle...

Page 74: ...60 Refrigeration Maintenance SYSTEM EVACUATION V 4 Thermistor Sensor V 3 V 2 V 1 Evacuation Quality Hoses Micron Gauge Calibration Standard Two Stage Vacuum Pump Evacuation Station TK No 204 725...

Page 75: ...eak Never attempt evacuation without a micron or vacuum gauge The micron gauge will help determine a If the pump is capable of pulling a deep vacuum b When the vacuum pump oil is contaminated c If the...

Page 76: ...Refrigeration Maintenance Rev 04 03 62...

Page 77: ...Refrigeration Maintenance Rev 04 03 63...

Page 78: ...hat a leak exists in the unit or the connect ing line The leak must then be located and eliminated NOTE If the vacuum pump is okay and there are no leaks between V 1 and V 3 the micron gauge should sh...

Page 79: ...e valves fully back seated turn the evac uation pump ON Open valve V 1 at the pump The micron gauge should move to a deep vacuum 5 Open valve V 4 The micron reading will rise If the micron gauge retur...

Page 80: ...harge liquid refriger ant until the system has the proper charge or until the system will take no more liquid The remainder of the charge will be added as a vapor through the suction ser vice valve if...

Page 81: ...Refrigeration Maintenance Rev 04 03 67...

Page 82: ...receiver tank sight glass with the following conditions established 1 Place a test box over the evaporator 2 Place a thermometer TK No 204 135 test lead in the box near the evaporator return air openi...

Page 83: ...ion pressure and 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...

Page 84: ...44 hose with a 900 psig 6204 kPa working pressure rating 2 Set the thermostat well below the box temperature so that the unit will be in High Speed Cool 3 Raise the discharge pressure of the compresso...

Page 85: ...Indicating 20 in Vacuum THREE WAY VALVE CONDENSER PRESSURE BYPASS CHECK VALVE The condenser pressure bypass check valve is built into the three way valve This check valve controls the bypass flow of...

Page 86: ...tely zero Gauges will equalize 8 Gauges will remain in this position approximately zero if the three way valve seals properly toward the condenser and the condenser pressure bypass check valve seals p...

Page 87: ...per ation Check refrigerant charge and compressor oil and add as required COMPRESSOR Removal 1 Pump down the compressor and equalize the pressure to slightly positive 2 Loosen and remove the compresso...

Page 88: ...he refrigeration system and test for leaks If no leaks are found evacuate the system 5 Connect the coolant hoses to the radiator and refill the expansion tank with 50 50 ethylene glycol water solu tio...

Page 89: ...he evaporator coil in the housing 2 Install the mounting bolts and tighten 3 Clean the tubes for soldering 4 Solder the suction line and drain pan hot gas line con nections to the evaporator coil 5 Co...

Page 90: ...e fitting 3 A small tool with a slight hook may be needed to pull screen from the expansion valve 4 Clean the screen and reinstall NOTE Outlet screen points toward the distributor RD II SR Expansion V...

Page 91: ...frigerant charge 10 Test the unit to see that the expansion valve is properly installed HIGH PRESSURE CUTOUT SWITCH Removal 1 Pump down the compressor and equalize pressure to slightly positive 2 Fron...

Page 92: ...s 4 If no leaks are found evacuate the low side 5 Open the refrigeration valves and place the unit in operation Check the refrigerant charge and add refrig erant as required RECEIVER TANK Removal 1 Re...

Page 93: ...lat side against the valve seat to ensure proper sealing 4 Screw the check valve stem into the three way valve until the snap ring can be installed 5 Install the snap ring 6 Unscrew back seat the chec...

Page 94: ...1 Install the screen into the bottom cap 2 Install new stem into the center section 3 Install new gaskets on both sides of the valve body Dip gaskets in compressor oil use same type of oil that is use...

Page 95: ...s of these new refrigerants are similar for box temperatures above 0 F 18 C At temperatures below 0 F 18 C H F C refriger ant capacities are slightly less than CFC refrigerants Unit Identification Uni...

Page 96: ...ion EQUIPMENT RECOMMENDATIONS FOR USE WITH R 134a AND R 404A Dedicated Equipment CAUTION Equipment that has been used with other refrigerants MUST NOT be used with R 134a and R 404A refrigerants Mixin...

Page 97: ...ils must be removed from clean up devices to prevent contamination of R 134a and R 404A systems Dangerous contamination will result if other refrigerants or standard oils are introduced to R 134a or R...

Page 98: ...nance X426 compressors using R 134a and R 404A are equipped with a bypass oil filter To ensure the system stays clean the oil filter and filter drier MUST be changed every two 2 years or whenever a ma...

Page 99: ...and vapor refrigerant from the system through the same hose connections The COLLECTOR Is equipped with a low pressure shutoff switch which automatically stops the recovery process once the sys tem ex...

Page 100: ...nd cap round end 2 Remove the cotter pin from the castle nut and remove the nut 3 Remove the spring and piston 4 Loosen all the bolts on bellows end cap CAUTION This end cap is under slight spring pre...

Page 101: ...nly 6 Insert the cotter pin 7 Oil the gasket and install the end cap 8 Throttling valve will have to be recalibrated on operat ing unit Refer to Specification chapter for setting 9 Adjust by adding or...

Page 102: ...WASHER 11 GASKET piston housing 3 PLATE bellows end 12 PISTON 4 GASKET end plate 13 SPRING piston 5 WASHER adjusting 14 NUT adjusting 6 SPRING bellows 15 PIN cotter 7 BELLOWS SHAFT assembly 16 HOUSING...

Page 103: ...89 Hilliard Clutch Maintenance Clutch Assembly...

Page 104: ...Remove retaining ring from hub bore 2 Remove the 3 8 16 flat head cap screw and washer NOTE This screw was installed using Loctite 680 and will require the use of an impact tool for removal NOTE A sm...

Page 105: ...be on flange side of hub See drawing for correct position 9 Install remaining links and 1 4 28 locknuts torquing them to 85 to 90 in lb 9 9 to 10 5 N m NOTE Shoes must be held tightly against hub whil...

Page 106: ...Hilliard Clutch Maintenance Rev 04 03 92 12 Install retaining ring Clutch Torque Values...

Page 107: ...n the evaporator coil during scheduled maintenance inspections by blowing compressed air opposite normal air flow Inspect the coil and fins for damage and repair if nec essary CAUTION Air pressure sho...

Page 108: ...ss b If damper blade closes proceed to step 2 If not proceed to step 1 c c Remove the jumper wire loosen the evaporator outlet adjustment angle and move so when ener gized the damper will close d Reti...

Page 109: ...d the housing These should be saved for possible reuse during reassembly 4 Remove the shaft and bearings 5 Remove the end cap from level plug end of assembly 6 Use a punch and hammer to remove the sea...

Page 110: ...leakage If there is any sign of leakage the fanshaft assem bly should be removed and repaired NOTE The fanshaft assembly requires a special lubri cant TK P N 203 278 Fanshaft Assembly Overhaul Disasse...

Page 111: ...oving one bearing and the bearing spacer turn the shaft upside down and drive the other bearing off using the pipe 10 The bearing races can now be driven out with a punch and replaced in the same mann...

Page 112: ...uing Retainer Plate Bolts 7 Lock the assembly in a vise and set up a dial indicator to read the end play To measure the end play rotate the shaft while pushing in one direction and set the dial indica...

Page 113: ...ion of the O ring used on the plugs and replace if necessary Install top and side plugs Clean up any spillage 9 Place the assembly on the workbench with the vent up Rotate the shaft by hand The shaft...

Page 114: ...ngs are deleted and to prevent pressure build up in the pulley assembly the seals are installed with the seal lip facing outward See diagram below Installation Procedure To perform a seal change the f...

Page 115: ...seal assembly P N 33 1924 with seal lip facing outward Press pulley side seal until it bottoms on pulley shoulder Press the opposite seal until it is flush with the pulley edge 5 Install snap ring 6 I...

Page 116: ...ace relay Corroded battery connections Clean and tighten Starter clutch defective Replace Starter defective Repair or replace Starter switch defective Replace Engine cranks but FAILS to start Misadjus...

Page 117: ...mp not operating Check pump for running and 8 to 10 psig 55 to 69 kPa Repair or replace fuel pump Dry air cleaner optional plugged Change filter element Fuel solenoid not energized Check run circuit H...

Page 118: ...el system Bleed fuel system Air is drawn into fuel pump Check all fuel lines and fittings Loose governor assembly Check and repair governor assembly Restricted exhaust system Clean or replace restrict...

Page 119: ...eavily scaled Clean cooling system Water pump leaks Repair or replace water pump Worn or loose belt Replace belt or adjust Cylinder head gasket leaks bubbles appear in radiator if cylinder gasket is l...

Page 120: ...eather Blue Smoke oil consumption Excessive oil consumption Refer to High Oil Consumption Repair as necessary White Smoke fuel is not burning Cold engine Allow engine to warm up Low compression Check...

Page 121: ...ower source 2 Power plug 3 Motor contactor hot side 4 Motor contactor load side contactor closed 5 Overload relay 6 Motor terminals Defective motor contactor Repair or replace motor contactor Defectiv...

Page 122: ...Foreign matter prevents contacts from closing Clean contacts Rapid cycling Check for cause of short cycling such as thermostat Short circuit Correct fault Electric heaters do not heat optional indicat...

Page 123: ...ing SYMPTOM POSSIBLE CAUSES Overcharge of refrigerant Shortage of refrigerant No refrigerant Air through condenser too hot ambient Air flow through condenser restricted Air through condenser too cold...

Page 124: ...lot solenoid Loose or broken electrical connections Thermostat or thermometer out of calibration Suction pressure gauge out of calibration Leaky receiver tank outlet valve Leaky bypass check valve Lea...

Page 125: ...111 Cool Cycle RD II SR with TherMax Heating...

Page 126: ...112 Condenser Cycle RD II SR with TherMax Heating...

Page 127: ...113 Heat and Defrost Cycle RD II SR with TherMax Heating...

Page 128: ...114 Index Drawing Title Dwg No Rev Page Wiring Diagram RD II 30 5D45077 B 115 Schematic Diagram RD II 30 5D45075 C 117 Wiring Diagram RD II 50 5D45960 B 119 Schematic Diagram RD II 50 5D45076 C 121...

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