Thermo King 920000, Manual

Page: 86 / 190

Engine Maintenance
86
Thermo King recommends that any major
injection pump or nozzle repairs be done by a
quality diesel injection service specialty shop. The
investment in equipment and facilities to service
these components is quite high. Therefore, this
equipment is not found in most repair shops.
The following procedures can be done under field
conditions.
• Bleeding air from the fuel system
• Maintenance involving the fuel tank and filter
system
• Speed and governor adjustments
• Electric fuel pump replacement or repair (9.5
to 11.5 psi [66 to 79 kPa] pump with diesel
filter)
• Injection line replacement
• Pump timing
• Nozzle spray pattern testing and adjustment
• Minor rebuilding of nozzles.
Bleeding the Fuel System
If the engine runs out of fuel, if repairs are made
to the fuel system, or if air gets into the system for
any other reason, the air must be bled out of the
fuel system.
NOTE: MAKE SURE to keep the fuel tank vent
open. If the vent becomes clogged, a partial
vacuum develops in the tank, this may cause air
to enter the system.
Proceed as follows:
1. Remove the CYCLE-SENTRY module from
the option board to prevent the Auto Start
system from preheating and cranking the
engine.
2. Loosen the air bleed screw in the inlet fuel
fitting on the injection pump.
3. Energize the electric fuel pump by placing the
On/Off switches in the On position and
pressing the
O
N
key. Tighten the air bleed
screw and press the
O
FF
key when a clear flow
of fuel appears.
NOTE: For the initial start-up, crack the air
bleed screw at the injection pump and bleed
fuel until a clear flow of fuel is noted.
4. Loosen the injector lines at the injection
nozzles.
5. Crank the engine until fuel appears at the
nozzles. Tighten the injector lines, replace the
CYCLE-SENTRY module and start the
engine.
NOTE: Fuel will not appear at the nozzles by
merely running the electric pump. The
engine must be cranked.
Water in the Fuel System
Water in the fuel system can damage the injection
pump and nozzles. This damage 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 periodically to avoid breakdowns.
This should be done after the tank has set idle for
an hour. Do not steam clean fuel tank caps.
Fuel Filter Replacement
1. Remove the filter and discard it.
2. Lubricate the rubber ring on the new filter
with fuel.
3. Install the filter and tighten it until the filter is
slightly loose (rubber ring not making
contact).
4. Bleed the air from the filter by operating the
electric fuel pump until fuel bubbles appear at
the top of the filter.
5. Tighten the filter until the rubber ring makes
contact, and then tighten it 1/2 turn more.