Thermo King 920000 Manual Download

Page: 138 / 190

Mechanical Diagnosis

138

Engine Emits Excessive Smoke

White Smoke

Black Smoke

Blue Smoke

Fuel is not burning

Excessive Fuel to Air Ratio

Oil Consumption

• Air or water in fuel

• Incorrect timing

• Poor compression

• Faulty injectors

• Type of fuel used

• Cold engine

• Excessive load

• Clogged air intake system

• Faulty nozzles

• Poor compression

• Restricted exhaust

• Faulty injection pump

• Poor compression

• Defective valve seals

Summary of Contents for 920000

Page 2: ...cturer 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 conten...

Page 3: ...ormation 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 Pa...

Page 4: ......

Page 5: ...6 Unit Operation 27 Reading Mode of Operation Charts 28 Mode of Operation Charts 29 Zone 1 Cool and Zone 2 Cool 33 Zone 1 Cool and Zone 2 Heat 34 Operating Modes 35 Engine Continuous Run Two Compartme...

Page 6: ...tor Defrost Cycle Diesel Operation 61 Zone 1 Evaporator Defrost Cycle Electric Operation 61 Zone 1 Evaporator Defrost Cycle Checkout Procedure 61 Zone 2 Evaporator Defrost Cycle Diesel Operation 63 Zo...

Page 7: ...02 Refrigeration Maintenance 103 Refrigerant Charge 106 Testing the Refrigerant Charge with an Empty Truck 106 Testing the Refrigerant Charge with a Loaded Truck 106 Testing for an Overcharge 106 Adju...

Page 8: ...alve RTPS 122 Removal 122 Installation 122 Purge Valve PV 123 Removal 123 Installation 123 Throttling Valve 123 Removal 123 Disassembly 123 Reassembly 124 Throttling Valve Installation 125 Compressor...

Page 9: ...ator Refrigeration Service Operations 155 Expansion Valve Assembly 155 Removal 155 Installation 155 Evaporator Coil 155 Removal 155 Installation 155 Solenoid Valves 156 Removal 156 Installation 156 Li...

Page 10: ...Table of Contents 10...

Page 11: ...elay Board 70 Figure 25 Multi Temperature In Cab TG V Controller 71 Figure 26 Connecting Tester to Controller 72 Figure 27 Connector on Back of Multi Temperature In Cab TG V 73 Figure 28 Door Sentry I...

Page 12: ...68 Inspect Pilot Hole for Damage 124 Figure 69 Throttling Valve Assembly 125 Figure 70 Compressor Oil Filter 126 Figure 71 Front View and Cross Section 127 Figure 72 Housing Removal 129 Figure 73 Bea...

Page 13: ...uck body or garage Refrigerant tends to displace air and can cause oxygen depletion resulting in suffocation and possible death 12 When using ladder or scaffolding use caution and follow manufacturer...

Page 14: ...e a small spark from a finger to a door knob can severely damage or destroy solid state integrated circuit components The following procedures must be rigidly adhered to when servicing units to avoid...

Page 15: ...h is turned Off before connecting or disconnecting the standby power plug Never attempt to stop the unit by disconnecting the power plug 2 Be certain the unit power plug is clean and dry before connec...

Page 16: ...spiration If a pulse is not present start CPR Cardiopulmonary Resuscitation and call for emergency medical assistance If a pulse is present respiration may be restored by using mouth to mouth resuscit...

Page 17: ...86 F SAE 5W 30 Engine RPM Low Speed Operation High Speed Operation 1625 25 RPM 2425 25 RPM Engine Oil Pressure 35 to 60 psig 241 to 414 kPa Intake Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Exh...

Page 18: ...eral Motors Dex Cool Caterpillar ELC Detroit Diesel POWERCOOL Plus Coolant System Capacity 4 quarts 3 8 liters with overflow tank Radiator Cap Pressure 10 psig 69 kPa Drive Belts to compressor fans 12...

Page 19: ...200 7 psig 1379 48 kPa 160 7 psig 1103 48 kPa Electronic Defrost Termination Timer Opens Closes 52 F 11 C 42 F 6 C Timer Part of TG V Microprocessor Programmable 2 to 16 hours in 2 hour increments th...

Page 20: ...tensioned cold and again tensioned cold after 10 hours of unit running Electrical Control System Control System Voltage 12 5 Vdc Control Circuit Fuse F1 2 Circuit 60 amps Main Circuit Breaker 50 amp...

Page 21: ...Suction Line Solenoids 18 watts 1 44 8 68 Starter Motor 90 to 105 cranking Thermostat Type Solid state THERMOGUARD V Thermostat Range 20 to 80 F 29 to 27 C Heat Lockout Continuous Run Operation CYCLE...

Page 22: ...Specifications 22...

Page 23: ...ir cleaner element when indicator reaches 25 in Replace air cleaner element at 2 000 hours or 1 year whichever occurs first if air restriction indicator has not reached 25 in If not equipped with an a...

Page 24: ...Check compressor efficiency and pump down refrigeration system Replace dehydrator and compressor oil filter Check discharge and suction pressures Structural Visually inspect unit for fluid leaks cool...

Page 25: ...ure of each of the compartments can be controlled separately There are two RD MT models RD MT 30 Cooling and heating on diesel engine operation RD MT 50 Cooling and heating on diesel engine operation...

Page 26: ...rmostat Provides temperature control from 20 to 80 F 28 to 28 C in 0 5 degree increments Defrost Control If the evaporator coil temperature is below 42 F 6 C Defrost is automatically initiated every 4...

Page 27: ...hen energized The flow of refrigerant through the system is controlled by the solenoid valves and the check valves The solenoid circuits are switched by the thermostat and defrost relays The receiver...

Page 28: ...C Normally Closed LLS Zone 1 Liquid Line Solenoid NC HGS Zone 1 Hot Gas Solenoid NC SLS Zone 1 Suction Line Solenoid NO F COOL Zone 1 Cool Lamp F HEAT Zone 1 Heat Lamp F DEF Zone 1 Defrost Lamp 1K Con...

Page 29: ...D D D E E D E LSH LSH R HEAT E D D E D D F HEAT CLOSED OPEN ON OFF LOW E E D D D D E LSH LSH R HEAT E D D E D D F HEAT OPEN OPEN ON OFF LOW E E D D D D E LSH LSH R HEAT E E D D E D F HEAT OPEN CLOSED...

Page 30: ...FF ON LOW D D D E E D E LSH LSH R HEAT E D D E D D F HEAT CLOSED OPEN ON OFF LOW E E D D D D E LSH LSH R HEAT E D D E D D F HEAT OPEN OPEN ON OFF LOW E E D D D D E LSH LSH R HEAT E E D D E D F HEAT OP...

Page 31: ...E E D D E D F HEAT OPEN CLOSED OFF ON ON D D E E D D D HEAT COOL R COOL D D D E D D F COOL OPEN CLOSED OFF OFF OFF D D D E E D E COOL NULL R HEAT D D D D E E F COOL CLOSED OPEN ON OFF ON E D D D D D...

Page 32: ...D D D E NULL NULL R HEAT E E D D E D F HEAT OPEN CLOSED OFF ON ON D D E E D D D HEAT COOL R COOL D D D E D D F COOL OPEN CLOSED OFF OFF OFF D D D E E D E COOL NULL R HEAT D D D D E E F COOL CLOSED OPE...

Page 33: ...tor as it evaporates into low pressure vapor The refrigerant returns to the compressor through the RSLS the Zone 2 suction line the RSLCV and the accumulator Zone 1 Evaporator 1F Zone 1 Liquid Line So...

Page 34: ...sor through the SLCV and the accumulator Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS Open 2F Zone 1 Liquid Return Check Valve LRCV Closed 3F Zone 1 Suction Line Check Valve SLCV Open 4F Zone...

Page 35: ...Heat Defrost At setpoints below 15 F 9 4 C the Zone 2 evaporator operates in the following modes Cool Null Defrost 0 Setpoint 1 Temperature Drop 2 Temperature Rise 3 Cool Force Condensing Unit to Hig...

Page 36: ...Zone 1 thermostat At setpoints below 15 F 9 4 C the Zone 2 evaporator operates in the following modes Cool Null Defrost 0 Setpoint 1 Temperature Drop 2 Temperature Rise 3 Cool Force Condensing Unit t...

Page 37: ...e CYCLE SENTRY system automatically maintains engine temperature in cold weather conditions by restarting the unit if the engine block temperature drops below 30 F 1 C Once the unit is started it will...

Page 38: ...initiated in ether compartment by pressing the appropriate Manual Defrost switch or automatically by an air switch or a defrost timer any time the corresponding evaporator coil temperature is below 4...

Page 39: ...The Manual Defrost Switch allows the operator to initiate the Defrost cycle For more information see the Controls and Instruments portion of this manual At in range temperatures If the setpoint is at...

Page 40: ...ilter Spin On Bypass Oil Filter Opt Opt Opt Spin On Fuel Filter EPDM Coolant Hoses Coolant Expansion Tank Hourmeter Engine Hours Hourmeter Electric Standby Hours Opt Opt Multi Temp In Cab TG V Control...

Page 41: ...Unit Description 41 Unit Photographs Figure 12 Front View Figure 13 Top View ARD026 AGA267...

Page 42: ...Unit Description 42 Figure 14 Engine Side Door Open ARD041...

Page 43: ...Preheat Start Switch 2 Auto Start Stop Continuous Run Switch 7 Run Hourmeter Optional on Model 50 3 Stop Start Light Optional 8 Electric Operation Hourmeter Optional on Model 50 4 Engine Reset 9 Engi...

Page 44: ...play Zone 1 7 UP Key 2 Temperature Display Zone 2 8 DOWN Key 3 Power Cord Indicator Light Model 50 9 ZONE 2 DEFROST Key 4 OFF Key 10 ZONE 1 DEFROST Key 5 ON Key 11 ENTER Key 6 SELECT Key 12 WHISPER MO...

Page 45: ...frost initiated Engine block temperature drops below 30F 1 C Once started the engine will run until Microprocessor Controller demands are satisfied The block temperature reaches 90 F 32 C The Defrost...

Page 46: ...n in operation This meter can be used to determine proper maintenance intervals TG V In Cab Controller for Multi Compartment Units The programmable TG V displays temperature and alarm conditions It al...

Page 47: ...be displayed for about 10 seconds Make sure that all display segments are operational Standard display is set to Return Air Temperature at the factory Each controller can be programmed to show return...

Page 48: ...es Engine Reset Switch A thermal type manual reset switch protects the engine The reset switch contains a heater coil that is attached to a sensor switch in the engine oil system engine coolant system...

Page 49: ...ing suggested pretrip inspection should be performed before every trip involving refrigerated cargo Fuel The diesel fuel supply must be adequate to guarantee the operation of the engine to at least th...

Page 50: ...wer receptacle On Off switch in the On position 2 Hold the Preheat Start switch in the Preheat position for the required time 3 Place the control box On Off switch in the On position 4 Press the ON ke...

Page 51: ...it start ups may also be initiated by Defrost cycle initiation or engine block temperature switch demand If Defrost is initiated either manually or automatically by the defrost timer the unit will sta...

Page 52: ...ing the thermostat setpoint does not make the unit cool faster 6 If a thermostat calls for Cool or Heat the glow plugs will automatically heat for the required amount of time depending on the engine t...

Page 53: ...at the mode of operation changes with the change in setpoint Pre Cooling With the thermostats set at the required temperatures allow the unit to run for one half to one hour longer if possible before...

Page 54: ...Operating Instructions 54 Post Trip Checks 1 Wash the unit 2 Check for leaks 3 Check for loose or missing hardware 4 Check for physical damage to the unit...

Page 55: ...od condition and are adjusted properly before testing the alternator Worn belts and pulleys or loose belts will lower the output of the alternator The battery must be well charged the battery cable co...

Page 56: ...nal and a chassis ground 12 Replace the CYCLE SENTRY module and connect the 20 wire to the engine reset switch 13 Start the unit and run it in high speed 14 Connect a jumper wire between the F2 termin...

Page 57: ...circuit breaker tripping or the control circuit burning out Check each glow plug a shorted glow plug will have very low resistance Engine Reset Switch The engine is protected by a manual reset switch...

Page 58: ...l and ground Repair consists of replacing the LOP Circuit Breakers Main Circuit Breaker This 50 amp auto reset circuit breaker protects 2A the main power circuit If the circuit breaker opens 1 Check f...

Page 59: ...the electric motor Testing the Unloading Timer 1 Remove the CYCLE SENTRY module from the option board to prevent the Auto Start system from preheating and cranking the engine 2 Disconnect the 20 wire...

Page 60: ...ck for a grounded 2 wire or for any of the conditions that would cause one of the circuit breakers to open Replace the defective circuit breaker and replace the fuse The fuse is located between the ba...

Page 61: ...termines the mode of operation Zone 1 Evaporator Defrost Cycle Electric Operation The Defrost cycle on electric standby operation is similar to the Defrost cycle on diesel operation Zone 1 Evaporator...

Page 62: ...l record alarm code 14 if the 11 circuit stays grounded and the Defrost termination on time limit is unsuccessful Zone 1 Evaporator Sticks In Defrost Indefinitely If the unit remains stuck in Defrost...

Page 63: ...e MANUAL DEFROST key by the air switch or by the defrost timer in the TG V controller when the defrost termination switch is closed Initiating the Defrost cycle energizes the Zone 2 defrost relays RD...

Page 64: ...between the defrost termination switch and the TG V controller If the 12 circuit is not open move to step 4 4 Check for an open in R11 circuit between the TG V Controller and the defrost relay If the...

Page 65: ...ure for Multi Temperature In Cab TG V Controllers on page 72 Zone 2 Evaporator Continuously Fails to Terminate Defrost In Less than 45 Minutes If the unit continually fails to complete the Defrost cyc...

Page 66: ...ads 2 Connect the negative lead of the switch to the negative battery terminal 3 Raise the temperature of the defrost termination switch above 52 F 11 C The light should be off indicating an open swit...

Page 67: ...justment screw until the switch closes and the continuity tester indicates a completed circuit with the correct reading Release the pressure 6 Repeat the test procedure several times to be sure the se...

Page 68: ...de of the evaporator coil goes on the hose fitting on the side of the air switch stamped BLACK The CLEAR hose from the low pressure or air outlet side of the evaporator coil goes on the hose fitting o...

Page 69: ...are used as jumpers to configure the board for different applications If these jumpers are not in the correct positions the unit may not function properly The correct jumper positions for the unit are...

Page 70: ...lays are located on the multi temp relay board The component locations are shown in the following illustration AEA623 1 Zone 2 Heat Cool Relay R1K 6 7X CH Fuse 2 Zone 2 Speed Relay R2K 7 Hot Gas Locko...

Page 71: ...The operating manuals and the setup and operating manuals contain information about the control functions and how to customize the display screens Manuals for the Multi Temp In Cab TG V Controller Ope...

Page 72: ...80 F 27 C to properly test the multi temperature controller NOTE The controller must be set to display temperatures in the Fahrenheit scale The test WILL NOT work if the controller is displaying tempe...

Page 73: ...ion 11 PC WHT BLK VOIL Power Cord Electric Standby 12 R7T WHT BLK BLU Zone 2 Unit High Speed Latching Circuit 13 10T VIOLET Zone 1 Unit High Speed Relay 14 38 WHT BLK BRN Not Used 15 R12 WHT GRN Zone...

Page 74: ...ermostat demand is satisfied When the Zone 2 unit thermostat is satisfied the condensing unit may shut down Opening Zone 2 Door Opening the Zone 2 door closes its door switch and grounds the control c...

Page 75: ...ne 2 unit control circuits is interrupted Zone 1 unit ERC is disabled Zone 1 unit heats normally HS Cool Heat Damper solenoid energizes closes damper or stops fan motors LLS de energizes and closes Zo...

Page 76: ...Electrical Maintenance 76...

Page 77: ...If the filter element becomes clogged a bypass valve built into the oil filter allows the oil to bypass the filter element This keeps the engine components from being starved for oil if the filter ele...

Page 78: ...lter 3 Tighten the filter until the rubber ring makes contact and then tighten it 1 2 turn more Crankcase Breather The crankcase breather system ducts crankcase gases formed in the crankcase directly...

Page 79: ...lows the dirt to enter the engine Remove the oil cup wash thoroughly and dry every 1000 operating hours 500 hours under dusty conditions Refill using the same weight oil used in the engine crankcase I...

Page 80: ...to assure the air filter is not restricted Service the air filter when the yellow diaphragm indicates 22 in 559 mm of vacuum Press the reset button on the bottom of the restriction indicator after se...

Page 81: ...ins the coolant temperature within the specified temperature range All water cooled engines are shipped from the factory with a 50 permanent type antifreeze concentrate and 50 water mixture in the eng...

Page 82: ...e Coolant ELC is recommended to assure that de ionized water is being used If 100 full strength concentrate is used de ionized or distilled water is recommended over tap water to insure the integrity...

Page 83: ...is up to operating temperature Stop the unit 2 Open the engine block drain and accumulator tank drain and completely drain coolant Observe coolant color If the coolant is dirty proceed with a b and c...

Page 84: ...aft The governor s speed requirements are relayed to the injection pump through a linkage arrangement located in the rear cover The injection pump raises the pressure of the fuel and meters the correc...

Page 85: ...Engine Maintenance 85 AEA628 1 Fuel Injection Pump 3 Fuel Pickup Tube 2 Fuel Filter 4 Electric Fuel Pump Figure 38 Fuel System...

Page 86: ...mp 3 Energize the electric fuel pump by placing the On Off switches in the On position and pressing the ON key Tighten the air bleed screw and press the OFF key when a clear flow of fuel appears NOTE...

Page 87: ...in cleaning solvent and blow out the dirt and cleaning solvent with compressed air Check the cover gasket and replace if damaged Clean the cover Reassembly Place the cover gasket on the bottom cover...

Page 88: ...l on position the hold in coil will keep it in fuel on position until the 8D circuit is de energized The pull in coil must be de energized after a few seconds to keep it from being damaged A fuel sole...

Page 89: ...D The fuel solenoid relay is energized momentarily by the fuel solenoid timer when the 8D circuit is first energized After approximately 2 5 seconds the fuel solenoid timer de energizes the fuel solen...

Page 90: ...o step 7 7 Check the CH circuit pin C in the main wire harness at the fuel solenoid connector for continuity to a good chassis ground a If there is no continuity between the CH circuit and a good chas...

Page 91: ...ove the fuel solenoid relay from its socket and make sure the On Off switch is in the On position 13 Check the voltage on the 8D circuit at the 85 terminal in the fuel solenoid relay socket Refer to t...

Page 92: ...gine fails to maintain the correct engine speeds check the following before adjusting the speed 1 Bleed air out of the fuel system Recheck the speed 2 Bleed air out of the nozzles Recheck the speed 3...

Page 93: ...el injection lines and the fuel lines Remove the four nuts holding the pump to the timing cover and the fuel supply line 2 Remove the inspection plate on the side of the timing cover 3 Remove the clip...

Page 94: ...cylinder timing is so minimal the procedure 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...

Page 95: ...did not line up a shim or shims will have to be added or subtracted from the injection pump Adding shims will retard the injection timing subtracting shims will advance the timing Increasing or decre...

Page 96: ...rew The fuel limit screw and the maximum speed stop screw are both covered with anti tamper caps and are not adjustable Engine Valve Clearance Adjustment The valve clearance should be checked after th...

Page 97: ...er is at top dead center of the compression stroke c If the rocker arms and push rods are tight the number 3 cylinder is at top dead center of the exhaust stroke Rotate the engine 360 degrees to place...

Page 98: ...98 Engine Mounts The engine mounting system contains three vibration mounts and two snubber mounts Figure 51 Engine Mounting Components 0 20 Air Gap Between Lower Snubber and Engine Bracket When Assem...

Page 99: ...99 9449 6 Engine Mount curbside 91 2278 Wear Plate Rivet 55 3044 7 Engine Mount upper 91 2279 17 Engine Screw 55 5888 Screw socket head 10 x 1 5 25 mm lg 55 5957 18 Belleville Washer 55 7122 Screw so...

Page 100: ...t is at the proper tension Use one of the following methods to check or set the belt tension a The belt tension should be set at a reading of 70 3 on the Thermo King Belt Tension Gauge b The belt shou...

Page 101: ...Engine Maintenance 101 AEA638 1 Engine Compressor Belt 3 Compressor Jackshaft Electric Motor Belt 2 Compressor Alternator Belt 4 Water Pump Belt Figure 53 Belt Arrangement...

Page 102: ...bolt and the alternator bracket mounting bolts Compressor Electric Motor Belt Adjustment 1 Loosen the electric motor mounting bolts 2 Position the electric motor to obtain a tension of 67 3 on the The...

Page 103: ...densables Always leave service valve caps on during evacuation and do not exercise the valve stems while the unit is in a deep vacuum Packing glands on older valves are prone to leak Never attempt eva...

Page 104: ...eration Maintenance 104 1 2 3 4 5 6 7 8 9 AGA654 1 V 4 6 Two Stage Vacuum Pump 2 Thermistor 7 To 110 Vac Power 3 V 3 8 Calibration Standard 4 V 2 9 Vacuum or Micron Gauge 5 V 1 Figure 55 Evacuation St...

Page 105: ...0 Microns 3 1000 Microns 4 2500 Microns 5 5000 Microns 6 20 000 Microns 7 Atmospheric Pressure 8 Calibration Adjustment Screw 9 Example Meter needle shown at calibration position when Calibration Stan...

Page 106: ...d Truck 1 Install a gauge manifold 2 Run both evaporators in Cool 3 Build up and maintain a head pressure of 275 psi 1896 kPa If the pressure is below this it can be raised by covering the condenser g...

Page 107: ...rant to flow into the compressor suction service valve f Control the liquid flow so the suction pressure increases approximately 20 psi 138 kPa g Maintain a discharge pressure of at least 275 psi 1896...

Page 108: ...re 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...

Page 109: ...h evaporators run in Cool and the condensing unit runs in high speed 3 Raise the discharge pressure of the compressor first by blocking the condenser coil air flow by covering the condenser grille wit...

Page 110: ...gized Set up and Test Evacuation Equipment NOTE The use of the Thermo King Evacuation Station P N 204 725 is recommended NOTE Do not attempt to evacuate the unit until the evacuation equipment has bee...

Page 111: ...Refrigeration Maintenance 111 1 2 3 5 AEA647 4 1 Vacuum Gauge 4 Vacuum Valve 2 Thermistor 5 Back Seated 3 Isolation Valve Open Figure 60 Set up and Test Evacuation Equipment...

Page 112: ...5 minutes between 1000 and 1500 microns back seat the suction service valve and observe the micron gauge A sharp drop in the micron reading 300 to 500 microns indicates that refrigerant is in the oil...

Page 113: ...Refrigeration Maintenance 113 2 3 AEA647 4 1 1 Vacuum Gauge 3 Isolation Valve Leave Closed for First 5 Minutes of Evacuation 2 Thermistor 4 Vacuum Valve Figure 61 Unit Evacuation...

Page 114: ...HGS wires and the RHGS wires to the relay board Connect the condenser inlet solenoid wires 2 pin connector to the main wire harness Connect the 20A wire to the low oil pressure switch Replace the CYC...

Page 115: ...Refrigeration Maintenance 115 AEA647 2 3 1 5 4 1 Isolation Valve Closed 4 Scale 2 Vacuum Valve Closed 5 Refrigerant 3 Evacuate or Purge Figure 62 Unit Charging...

Page 116: ...to 34 kPa Stop the unit Remove the hose from the suction service valve service port Immediately install the cap on the suction service port and tighten it 3 Back seat the suction service valve 4 Remo...

Page 117: ...ng the high side and low side pressures a Disconnect the purge valve solenoid wires from the main wire harness b Remove the CYCLE SENTRY module from the option board to prevent the Auto Start system f...

Page 118: ...gerant leaks 4 If no leaks are found evacuate the compressor Replace the belts and adjust the tensions 5 Back seat the suction and discharge service valves 6 Operate the unit at least 30 minutes and t...

Page 119: ...sure cutout switch 2 Install and tighten the high pressure cutout switch and reconnect the wires 3 Pressurize the refrigeration system and test for leaks 4 If no leaks are found open the refrigeration...

Page 120: ...ly Position the receiver tank so the sight glass is clearly visible and the outlet tube lines up with the drier line 2 Solder the inlet tube to the receiver tank 3 Solder the drier line to the receive...

Page 121: ...body for damage or foreign particles which 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 c...

Page 122: ...ration system and test for leaks 6 If no leaks are found evacuate the system 7 Recharge the unit with the proper refrigerant and check the compressor oil if pumped down open the refrigeration valves i...

Page 123: ...ling Valve Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Front seat the discharge and suction service valves Release the remaining pressure 3 Remove the suction ser...

Page 124: ...hole closest to the outlet opening of the valve housing 4 Install the piston spring and tighten the castle nut until it is firmly seated against the bottom of the piston 5 Back off the castle nut one...

Page 125: ...k for leaks If no leaks are found evacuate the low side 4 Open the refrigeration valves and place the unit in operation AEA652 1 Screw mtg plate 9 Gasket piston housing 2 Plate bellows end 10 Piston 3...

Page 126: ...th back up wrench on the hex behind the ORS fitting 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...

Page 127: ...gal clutch P N 104 272 which supersedes P N 104 257 Centrifugal clutch P N 104 272 has three belt grooves and its engagement speed is 600 100 RPM When this clutch is installed on a unit equipped with...

Page 128: ...3 belt grooves 1 Screw 10 Grease Seal 2 Washer 11 Roller Bearing Inner Race 3 Snap Ring 12 Pulley Housing 4 Ball Bearing 13 Elastic Stop Nuts 6 5 Large Small Spacers 14 Connector Link 6 6 Rolling Bea...

Page 129: ...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 small amount of heat propane or acetylene torch with...

Page 130: ...3 Apply Loctite 270 to O D of oil seal then press seal in end of hub opposite the flange to a depth of approximately 1 16 in below the surface 4 Apply a small amount of Loctite 270 to O D of roller b...

Page 131: ...s 41 to 48 m 1 Roller Bearing Pack with Mobil 28 Grease 2 Pack These Areas with Mobil 28 Grease at Assembly 3 HEX HD Cap Screw 6X 1 4 28 UNF X 1 75 Long Torque to 110 5 in lbs 12 5 0 6 N m NOTE Shoes...

Page 132: ...Hilliard Clutch Maintenance 132...

Page 133: ...flow Repair bent fins and any other noticeable damage Fan Location When mounting the fan and hub assembly on the shaft position the assembly in the orifice with 30 to 35 percent of the blade width to...

Page 134: ...Structural Maintenance 134...

Page 135: ...lace relay Corroded battery connections Clean and tighten Defective starter Repair starter Water in cylinders Check for hydrostatic lock Remove glow plugs and turn engine slowly Starter motor turns bu...

Page 136: ...dirty filter or air in system Defective electric fuel pump Check fuel pump Injection pump timing off Adjust timing Nozzles defective Repair or replace nozzles Compression low or unbalanced Overhaul e...

Page 137: ...Worn oil pump camshaft main or connecting rod bearings loose oil gallery plug Repair engine High oil consumption Oil leakage Check and eliminate possible causes at cylinder head cover oil lines oil f...

Page 138: ...ning Excessive Fuel to Air Ratio Oil Consumption Air or water in fuel Incorrect timing Poor compression Faulty injectors Type of fuel used Cold engine Excessive load Clogged air intake system Faulty n...

Page 139: ...SM Unit will not automatically preheat but run relay does energize Defective preheat relay Test or replace preheat relay Defective CSM Test or replace CSM Open H circuit from preheat relay to glow plu...

Page 140: ...e CSM Replace CSM with known good one Do not rely on bench test of CSM Low battery voltage or condition Test battery Poor connection or excessive voltage drop from battery positive post to 7A circuit...

Page 141: ...tactor hot side 4 Motor contactor load side contactor closed 5 Overload relay 6 Motor terminals Defective motor contactor Repair or replace motor contactor Defective low oil pressure switch Replace lo...

Page 142: ...f current Check for grounds shorts or excessive motor load current Low voltage Correct voltage condition Check momentary voltage dip during starting Foreign matter prevents contacts from closing Clean...

Page 143: ...vercharge of refrigerant Shortage of refrigerant No refrigerant Air through condenser too hot ambient Air flow through condenser restricted Air through condenser too cold ambient Air in refrigerant sy...

Page 144: ...faulty Compound pressure gauge out of calibration Leaky receiver tank outlet valve Leaky check valve Faulty check valve Leaky receiver tank pressure solenoid RTPS Closed receiver tank pressure solenoi...

Page 145: ...S Leaky Zone 2 liquid return check valve RLRCV Leaky Zone 2 suction line solenoid RSLS Leaky Zone 2 suction line check valve RSLCV Leaky purge valve PV Rapid cycling between Cool and Heat Unit cools i...

Page 146: ...Refrigeration Diagnosis 146...

Page 147: ...Vdc Spectrum Evaporator Fan Motor Horsepower 0 13 hp Fan Voltage 8 to 16 Vdc RPM 1900 Full Load Amps 8 7 amps per motor Fuse F1 1 F1 2 F2 1 F2 2 30 amp Remote Liquid Line Solenoid 15 watt Current Draw...

Page 148: ...Remote Evaporator Specifications 148...

Page 149: ...s Electrical Inspect wire harness for damaged wires or connections Inspect replace fan motor brushes Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken...

Page 150: ...Remote Evaporator Maintenance Inspection Schedule 150...

Page 151: ...ensor Ungraded 5 Discharge Return Air Sensor Graded 9 Terminal Board Bracket 2 Hot Gas Solenoid 6 Variable Blower 12 V 10 Terminal Board 3 Liquid Line Solenoid 7 Blower Housing 11 Terminal Board Marks...

Page 152: ...Remote Evaporator Unit Description 152 Figure 80 Spectrum Evaporator Front View Figure 81 Spectrum Evaporator Back View AJA984 AJA985...

Page 153: ...evaporator coil temperature is below 45 F 7 C Defrost is initiated automatically by the controller or manually by selecting the Manual Defrost The evaporator fan stops during Defrost The Defrost mode...

Page 154: ...Remote Evaporator Unit Description 154...

Page 155: ...Install the access panels 7 Open the refrigeration valves and place the unit in operation 8 Test the unit to see that the expansion valve is properly installed Evaporator Coil Removal 1 Remove refrige...

Page 156: ...ne 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 th...

Page 157: ...equire 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 duri...

Page 158: ...Remote Evaporator Structural Maintenance 158...

Page 159: ...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 r...

Page 160: ...Remote Evaporator System Diagnosis 160...

Page 161: ...st system components 66 defrost termination switches 66 design features 40 Door Sentry II 74 drier 118 E ELC extended life coolant 82 electric fuel pump 87 electric operation 52 electric standby diagn...

Page 162: ...47 evaporator coil 155 157 expansion valve assembly 155 liquid return check valve 156 maintenance inspection schedule 149 operating modes 153 refrigeration service operations 155 refrigeration system...

Page 163: ...1E07391 MD RD MT Model 30 w In Cab CYCLE SENTRY Wiring Diagram 172 174 1E07778 MD RD MT Model 30 CYCLE SENTRY Wiring Diagram 175 177 1E05455 MD RD MT Model 50 w In Cab Schematic Diagram 178 179 1E0545...

Page 164: ...Wiring and Schematic Diagrams Index 164...

Page 165: ...165 MD RD MT Model 30 w In Cab Schematic Diagram Page 1 of 2...

Page 166: ...166 MD RD MT Model 30 w In Cab Schematic Diagram Page 2 of 2...

Page 167: ...167 MD RD MT Model 30 w In Cab Wiring Diagram Page 1 of 3...

Page 168: ...168 MD RD MT Model 30 w In Cab Wiring Diagram Page 2 of 3...

Page 169: ...169 MD RD MT Model 30 w In Cab Wiring Diagram Page 3 of 3...

Page 170: ...170 MD RD MT Model 30 w In Cab CYCLE SENTRY Schematic Diagram Page 1 of 2...

Page 171: ...171 MD RD MT Model 30 w In Cab CYCLE SENTRY Schematic Diagram Page 2 of 2...

Page 172: ...172 MD RD MT Model 30 w In Cab CYCLE SENTRY Wiring Diagram Page 1 of 3...

Page 173: ...173 MD RD MT Model 30 w In Cab CYCLE SENTRY Wiring Diagram Page 2 of 3...

Page 174: ...174 MD RD MT Model 30 w In Cab CYCLE SENTRY Wiring Diagram Page 3 of 3...

Page 175: ...175 MD RD MT Model 30 CYCLE SENTRY Wiring Diagram Page 1 of 3...

Page 176: ...176 MD RD MT Model 30 CYCLE SENTRY Wiring Diagram Page 2 of 3...

Page 177: ...177 MD RD MT Model 30 CYCLE SENTRY Wiring Diagram Page 3 of 3...

Page 178: ...178 MD RD MT Model 50 w In Cab Schematic Diagram Page 1 of 2...

Page 179: ...179 MD RD MT Model 50 w In Cab Schematic Diagram Page 2 of 2...

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Page 183: ...183 MD RD MT Model 50 w In Cab CYCLE SENTRY Schematic Diagram Page 1 of 2...

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Thermo King 920000, Manual

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