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Thermo King SB-210, Manual

The Thermo King SB-210 is a powerful and reliable refrigeration unit designed for trucks and trailers. With our user-friendly manual, you can easily operate and maintain this product to ensure optimal performance. Download the free manual from manualshive.com to get started on maximizing the efficiency and longevity of your Thermo King SB-210.

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Table of Contents

8

Refrigeration Service Operations (continued)
Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Suction Vibrasorber  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
High Pressure Relief Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Discharge Pressure Transducer  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Suction Pressure Transducer   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Electronic Throttling Valve (ETV)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Mechanical Throttling Valve   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Reassembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Hot Gas Solenoid Valve   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Compressor Oil Filter Change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Checking Compressor Oil Pressure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Priming New Compressor Installations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Unit and Engine Mounting Bolts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Condenser, Evaporator, and Radiator Coils  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Defrost Drains  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Unit Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Defrost Damper  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Condenser and Evaporator Fan Location  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Condenser Fan Blower  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Evaporator Fan Blower  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Fan Shaft Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Fan Shaft Assembly Overhaul   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Idler Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Idler Assembly Overhaul  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Mechanical Diagnosis  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Electric Standby Diagnosis   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Refrigeration Diagnosis   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Refrigeration Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Cool Cycle With Mechanical Throttling Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Heat/Defrost Cycle With Mechanical Throttling Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Cool Cycle With Electronic Throttling Valve   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Heat/Defrost Cycle With Electronic Throttling Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Index  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Wiring Diagram Index  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Summary of Contents for SB-210

Page 1: ...SB 210 SB 310 TK 51586 2 MM Rev 0 01 04 Copyright 2004 Thermo King Corp Minneapolis MN U S A Printed in U S A ...

Page 2: ...ll not be held liable in contract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles contents or persons by reason of the installation of any Thermo King product or its mechanical failure The maintenance information in this manual covers unit models System SB 210 30 Base 920190 SB 210 30 Base 002158 System SB 210 30 ETV 9...

Page 3: ...into the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians For additional information on regulations and technician certification programs contact your local Thermo King dealer ...

Page 4: ...4 ...

Page 5: ...ts 20 Maintenance Inspection Schedule 21 Unit Description 23 Unit Overview 23 Design Features 24 Diesel Engine 24 Thermo King X430L Reciprocating Compressor 24 Electronic Throttling Valve 25 SMART REEFER 2 SR 2 Control System 25 CYCLE SENTRY Start Stop Controls 25 Data Logging 26 Standard and Optional Temperature Data Management Systems 26 Sequence of Operation 26 Operating Modes 27 Engine Compart...

Page 6: ...ding Procedure 64 Post Load Procedure 64 Post Trip Checks 64 Electrical Maintenance 65 Alternator Australian Bosch Model 30 65 Charging System Diagnostic Procedures 65 Alternator Prestolite Model 50 69 Charging System Diagnostic Procedures 69 Battery 70 Unit Wiring 70 Fuses 71 Fuse Link 72 Air Heater 72 Smart Reefer 2 Microprocessor Controller 72 AC Components 72 Electrical Contactors 72 Auto Phas...

Page 7: ...t Charge With An Empty Trailer 101 Testing the Refrigerant Charge with a Loaded Trailer 101 Testing for an Overcharge 101 Moisture Indicating Sight Glass 102 Refrigerant Leaks 102 Checking Compressor Oil 103 High Pressure Cutout Switch HPCO 103 Three Way Valve Condenser Pressure Bypass Check Valve 104 Electronic Throttling Valve ETV 105 Pressure Transducers 105 Hot Gas Solenoid 106 Refrigeration S...

Page 8: ...enance 127 Unit and Engine Mounting Bolts 127 Unit Inspection 127 Condenser Evaporator and Radiator Coils 127 Defrost Drains 127 Unit Installation 127 Defrost Damper 128 Condenser and Evaporator Fan Location 129 Condenser Fan Blower 129 Evaporator Fan Blower 129 Fan Shaft Assembly 130 Fan Shaft Assembly Overhaul 130 Idler Assembly 131 Idler Assembly Overhaul 131 Mechanical Diagnosis 133 Electric S...

Page 9: ...ng Mode 44 Figure 24 Screen Sequence for Changing from CYCLE SENTRY Mode to Continuous Mode 44 Figure 25 Screen Sequence for Changing from Continuous Mode to CYCLE SENTRY Mode 44 Figure 26 Initiating a Manual Defrost Cycle 46 Figure 27 Initiating Manual Defrost Screen Sequence 46 Figure 28 Viewing Gauges 47 Figure 29 Viewing Gauges Screen Sequence 47 Figure 30 Viewing Sensors 48 Figure 31 Soft Key...

Page 10: ...n Timing Mark Alignment for SB 210 86 Figure 75 Correct Injection Timing Mark Alignment for SB 310 86 Figure 76 Injection Pump Gear Tool 88 Figure 77 Fuel Solenoid Location 88 Figure 78 Fuel Solenoid Connector Pin Identification 89 Figure 79 Fuel Solenoid Components 90 Figure 80 Top Dead Center One and Four 91 Figure 81 Adjusting the Valve Clearance 92 Figure 82 Crankcase Breather 92 Figure 83 EMI...

Page 11: ... Throttling Valve 120 Figure 109 Stepper Motor and Piston Assembly with Piston in Fully Open Position 121 Figure 110 Mechanical Throttling Valve Assembly 122 Figure 111 Inspect Parts 123 Figure 112 Inspect for Wear 123 Figure 113 Inspect for Damage 123 Figure 114 Throttling Valve Reassembly 124 Figure 115 Compressor Oil Filter 125 Figure 116 Unit and Engine Mounting Bolts 127 Figure 117 Defrost Da...

Page 12: ...List of Figures 12 ...

Page 13: ...se caution when working with refrigerant or a refrigeration system in any confined area with a limited air supply such as a cargo area or garage Refrigerant displaces air and can cause oxygen depletion resulting in suffocation and possible death DANGER Avoid engine operation in confined spaces and areas or circumstances where fumes from the engine could become trapped and cause serious injury or d...

Page 14: ...event frostbite CAUTION Refrigerant in a liquid state evaporates rapidly when exposed to the atmosphere freezing anything it contacts Be careful when handling refrigerant to protect your skin from frostbite CAUTION When being transferred refrigerant must be in liquid state to avoid possible equipment damage CAUTION When transferring refrigerant use a process that prevents or greatly restricts refr...

Page 15: ...circuits on any microprocessor based equipment DANGER Lethal amounts of voltage are present in some electrical circuits Use extreme care when working on an operating refrigeration unit WARNING Do not make rapid moves when working on high voltage circuits in refrigeration units Do not grab for falling tools because you might accidentally touch a high voltage source WARNING Use tools with well insul...

Page 16: ...on or mouth to mouth resuscitation to restore breathing if necessary Stay with victim until emergency personnel arrive First Aid Refrigerant Oil EYES Immediately flush with water for at least 15 minutes CALL A PHYSICIAN Wash skin with soap and water INGESTION Do not induce vomiting Immediately contact local poison control center or physician First Aid Engine Coolant EYES Immediately flush with wat...

Page 17: ...0W 40 13 to 86 F 25 to 30 C SAE 10W 30 22 to 32 F 30 to 0 C SAE 5W 30 Engine rpm SB 210 Low Speed Operation SB 210 High Speed Operation 1450 25 rpm 2200 25 rpm SB 310 Low Speed Operation SB 310 High Speed Operation 1450 25 rpm 1720 25 rpm with High Capacity Fresh Option 2600 25 rpm Engine Oil Pressure 18 psi 127 kPa minimum in low speed 45 to 57 psi 310 to 390 kPa in high speed Intake Valve Cleara...

Page 18: ...an emergency If conventional coolant is added to Extended Life Coolant the coolant must be changed after 2 years instead of 5 years Coolant System Capacity 7 5 quarts 7 1 liters Radiator Cap Pressure 7 psi 48 kPa Drive Model 30 Direct to compressor belts to fans alternator and water pump Model 50 Centrifugal clutch to compressor belts to electric standby motor fans alternator and water pump Engine...

Page 19: ...ompressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit Electrical Control System Voltage 12 5 Vdc Battery One group C31 12 volt battery Fuses See Unit Description and Electrical Maintenance Chapters Battery Charging Model 30 12 volt 37 am...

Page 20: ...Starter Motor Gear Reduction Type 250 375 On the engine cranking check Bench test is approximately 80 amps on the gear reduction starter Electrical Standby Model 50 Units Only Electric Motor and Overload Relay Voltage Phase Frequency Horsepower Kilowatts rpm Full Load amps Overload Relay Setting amps 230 3 60 14 0 10 4 1755 37 8 40 460 3 60 14 0 10 4 1755 18 9 20 Electric Heater Strips Number 3 Wa...

Page 21: ...Inspect clean fuel transfer 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 engine mounts for wear Replace fuel filter water separator Change engine oil and oil filter hot Requires oil with API Rating CG 4 or better ACEA Rating E2 96 for Europe Change ELC red engine coolant every 5 years o...

Page 22: ... fluid leaks Visually inspect unit for damaged 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 Pretrip Eve...

Page 23: ...h an opening in the front wall The SB 210 SB 310 features air cooling and heating using a quiet running Thermo King TK 486 4 cylinder water cooled direct injection diesel engine The SB 210 and SB 310 are available in the following three models SB 210 30 Cooling and heating on diesel engine operation SB 210 50 Cooling and heating on diesel engine operations and electric standby operation SB 310 30 ...

Page 24: ...l 30 SMART REEFER SR 2 Controller OptiSet with FreshSet Programmable Modes ETV Electronic Throttling Valve ServiceWatch CargoWatch EMI 3000 High Capacity Condenser Coil Whisper Quiet Technology Easy access door design Composite Exterior Panels Long Life Coolant SIlicone Hoses Remote Status Light Standard Unit Color White Standard Grille Color Black Directional Air Delivery Vibration Isolation Syst...

Page 25: ... load on the engine by temporarily reducing refrigeration capacity This lowers the engine temperature while still allowing continued unit operation Modulation Control The ETV system replaces the modulation valve The modulation control algorithm operates much the same as modulation on other units SMART REEFER 2 SR 2 Control System The SR 2 is a microprocessor control system designed for a transport...

Page 26: ...he Cargo Watch Port on the front of the control box Detailed graph or table trip reports can then be created If optional temperature sensors are installed a directly connected printer can be used to print a report of the sensor readings The printer is connected to the Service Watch Port Standard and Optional Temperature Data Management Systems OptiSet Optiset allows an entire fleet to be configure...

Page 27: ...ils Hot refrigerant gas passes through the evaporator coil and melts the frost The water flows through collection drain tubes onto the ground The methods of Defrost initiation are Automatic and Manual Automatic Defrost The controller is programmed to automatically initiate timed or demand defrost cycles The unit can enter defrost cycles as often as every 30 minutes if required Manual Defrost In Ma...

Page 28: ... the restriction indicator to reset after servicing the air cleaner Compressor Oil Sight Glass Use this sight glass to check the compressor oil level See the Refrigeration Maintenance Chapter for the correct procedure Engine Oil Dipstick Use the engine oil dipstick to check the engine oil level Receiver Tank Sight Glass Use this sight glass to check the level of refrigerant in the receiver tank Se...

Page 29: ...scharge manifold If the compressor discharge pressure becomes excessive the switch opens the circuit to the fuel solenoid to stop the engine High Pressure Relief Valve This valve is designed to relieve excessive pressure in the refrigeration system Low Oil Level Switch The low oil level switch closes if the oil drops below an acceptable level If it stays closed for a specified time the microproces...

Page 30: ...tor Engine See the engine identification plate located on the engine valve cover Compressor Stamped between the cylinders on the front end above the oil pump 1 Serial Number Location Figure 3 Compressor Serial Number Location 1 1 Serial Number Location Figure 4 Unit Serial Number Locations 1 Serial Number Location Figure 5 Engine Serial Number Location AJA1617 1 1 1 ...

Page 31: ...Unit Description 31 Unit Photos Figure 6 Front View AJA1617 ...

Page 32: ...Unit Description 32 1 Defrost Damper 2 X430L Compressor 3 TK 486 Engine Figure 7 Back View 2 3 1 AJA1930 ...

Page 33: ...scription 33 1 Condenser Fan 5 X430L Compressor 2 Condenser Coil 6 Fuel Filter Water Separator 3 Expansion Tank 7 Air Cleaner 4 TK 486 Engine Figure 8 Front View with Doors Open Model 30 4 1 AJA1931 2 3 5 6 7 ...

Page 34: ...tion 34 1 Condenser Fan 5 Electric Motor 2 Condenser Coil 6 X430L Compressor 3 Expansion Tank 7 Fuel Filter Water Separator 4 TK 486 Engine 8 Air Cleaner Figure 9 Front View with Doors Open Model 50 5 1 2 3 6 7 8 4 ...

Page 35: ...Unit Description 35 1 Overload Relay 2 Heaters Contactor 3 Phase Selector 4 Drive Motor Contactors Figure 10 High Voltage Tray Model 50 Only AJA1932 1 2 3 4 ...

Page 36: ...Unit Description 36 ...

Page 37: ...play and eight touch sensitive keys The display is capable of showing both text and graphics The four keys on the left and right sides of the display are dedicated keys The four keys under the display are soft keys The function of soft keys change depending on the operation being performed If a soft key is active its function will be shown in the display directly above the key Figure 12 SR 2 HMI C...

Page 38: ... temperature and setpoint when the unit is ready to run Off Key Press this key to turn the unit off The engine will stop immediately Then the HMI control panel will enter the power down sequence Defrost Key Press this key to initiate a Manual Defrost cycle Mode Key Press this key to switch back and forth between the CYCLE SENTRY mode and the Continuous Run mode The four soft keys under the display...

Page 39: ...and tight Belts The belts must be in good condition and adjusted to the proper tensions Electrical The electrical connections should be securely fastened The wires and terminals should be free of corrosion cracks or moisture Structural Visually inspect the unit for leaks loose or broken parts and other damage The condenser and evaporator coils should be clean and free of debris Check the defrost d...

Page 40: ...rting Screen briefly appears as the engine preheats and starts 7 The Standard Display showing box temperature and setpoint reappears when the unit is running Turning Unit Off Complete the following steps to turn unit off 1 Press the OFF key 2 The engine will immediately shut off 3 The System is Powering Down Screen will briefly appear Figure 17 Turning Unit Off Screen Sequence 4 The Off Screen wil...

Page 41: ... viewing from a distance To return to the Standard Display press the MENU soft key or any of the other three soft keys that are not assigned Standard Display Variations The Standard Display has variations A display showing any of the following variations is still considered a Standard Display The top of the display will show that the unit is operating in either CYCLE SENTRY or Continuous Mode It m...

Page 42: ...r not starting 7 Repeat the procedure After Start Inspection After the unit is running check the following items to confirm that the unit is running properly Oil Pressure Check the engine oil pressure by pressing the GAUGES soft key See Viewing Gauge Readings on page 47 The Engine Oil Pressure Display should indicate OK not LOW Ammeter Check the ammeter reading by pressing the GAUGES soft key See ...

Page 43: ...oint change made with the or soft keys will not be accepted the setpoint will not be changed and the display will return to the Standard Display NOTE This generates an Alarm Code 127 Setpoint Not Entered See Figure 22 If the YES soft key was pressed the setpoint change made with the or soft keys will be accepted and the following screens will appear 5 The Programming New Setpoint Screen will appea...

Page 44: ... Continuous Mode on page 56 1 Press the MODE key See Figure 23 2 The Programming Continuous Mode or Programming CYCLE SENTRY Mode Screen briefly appears See Figure 24 and Figure 25 3 The New System Mode is Continuous Screen or the New System Mode CYCLE SENTRY Screen briefly appears See Figure 24 and Figure 25 4 The Standard Display appears and the bar on top of screen reads the new mode See Figure...

Page 45: ...transporting Examples of products normally acceptable for CYCLE SENTRY Operation Frozen foods in adequately insulated trailers Boxed or processed meats Poultry Fish Dairy products Candy Chemicals Film All non edible products Examples of products normally requiring Continuous Run Operation for air flow Fresh fruits and vegetables especially asparagus bananas broccoli carrots citrus green peas lettu...

Page 46: ...ars The bar indicator will fill in showing time remaining to complete the Defrost cycle The bar indicator in the figure shows that the Defrost cycle is 50 complete When the Defrost cycle is complete the display returns to the Standard Display See Figure 27 If the unit is prevented from going into a Manual Defrost IE Coil temperature more than 45 F 7 C or on economy mode etc A Defrost Unavailable S...

Page 47: ...essure ETV Position and I O Selecting I O enters a group of screens that show the status On or Off of the High Speed Relay Run Relay Defrost Damper Heat Output and Hot Gas Bypass See Figure 29 If no keys are pressed within 30 seconds the screen will return to the standard display NOTE Units without an ETV will not display the Discharge Pressure Suction Pressure and ETV Position 4 Press the LOCK so...

Page 48: ...ature Display Discharge Air Temperature Temperature Differential Evaporator Coil Temperature Ambient Air Temperature Spare 1 Temperature optional Datalogger Temperature Sensors 1 6 and Board Temperature Sensor See Figure 31 and Figure 32 If no keys are pressed within 30 seconds the screen will return to the Standard Display 4 Press the LOCK soft key to display any sensor screen for an indefinite p...

Page 49: ...Operating Instructions 49 Figure 32 Viewing Sensors Screen Sequence ...

Page 50: ...Menu Choices 1 Language Menu If enabled allows the operator to select a language from a list of 11 languages All other subsequent displays are shown in the selected language English is the default language See page 51 2 Alarms Menu Shows any active alarms and allows alarms to be cleared See page 52 3 Datalogger Menu Allows the operator to view the datalogger displays See page 53 4 Hourmeters Menu ...

Page 51: ...ress the MENU soft key on the Standard Display 3 The Language Menu Screen appears Press the SELECT soft key to choose the Language Menu Screen See Figure 36 4 The NEW LANGUAGE WILL BE Screen will appear See Figure 36 5 Press the or soft keys to select the desired language See Figure 36 6 When the desired language is shown press the YES soft key to confirm the choice 7 The PROGRAMMING LANGUAGE PLEA...

Page 52: ...re is more than one alarm press the NEXT soft key to view each alarm 7 If a serious alarm occurs the unit will be shut down to prevent damage to the unit or the load If this occurs the display will show that the unit is shut down and display the alarm code that caused the shutdown 8 To clear an alarm press the CLEAR soft key NOTE Some sensor alarms cannot be cleared in the Alarms Menu They must be...

Page 53: ...e Standard Display 3 Press the NEXT soft key until the Datalogger Menu appears See Figure 40 4 Press the SELECT soft key on the Datalogger Menu The Start Trip Screen will appear 5 Press the SELECT soft key The Start Of Trip Screen will appear 6 Press the SELECT soft key to initiate a start of trip 7 A Start Of Trip Marker has been inserted into the datalogger memory Printing a Trip Report This pro...

Page 54: ...Operating Instructions 54 Figure 40 Datalogger Screen Sequence ...

Page 55: ... Hourmeters can be viewed in the Hourmeters Menu as follows 1 Start at the Standard Display If the Temperature Watch Display is showing press the MENU soft key once to return to the Standard Display 2 Press the MENU soft key on the Standard Display 3 Press the NEXT soft key until the Hourmeters Menu appears See Figure 42 4 Press the SELECT soft key to enter the Hourmeters Menu 5 Press the NEXT and...

Page 56: ...U soft key on the Standard Display 3 Press the NEXT soft key until the Mode Menu appears 4 Press SELECT soft key to enter the Mode Menu See Figure 44 5 Press the SELECT soft key to switch between modes 6 The new mode is then confirmed for 10 seconds 7 The display then returns to the Mode Menu Press the SELECT soft key again to change the mode again Figure 44 Selecting Mode Screen Sequence 1 Shows ...

Page 57: ...h Display is showing press the MENU soft key once to return to the Standard Display 2 Press the MENU soft key on the Standard Display 3 Press the NEXT soft key until the Mode Menu appears 4 Press SELECT soft key to enter the Mode Menu See Figure 46 and Figure 47 5 Press the NEXT soft key as required to display Economy mode The current state of Economy mode either enabled or disabled will appear in...

Page 58: ...ply enter Sleep mode immediately Press the NO soft key to immediately enter Sleep mode a The display will show SLEEP and the unit will start and stop as required to keep engine warm and or the battery charged Sleep mode does not maintain the compartment temperature b Press the EXIT soft key to exit Sleep mode or turn the unit off and back on The unit will resume normal operation and control to set...

Page 59: ... 59 15 To exit Sleep mode before the selected Wake up time press the EXIT soft key or turn the unit off and back on The unit will resume normal operation and control to setpoint Figure 49 Selecting Sleep Mode Screen Sequence ...

Page 60: ...ow speed is checked RPM Check The engine RPM in high and low speed is checked during the Cool Check Heat Check The ability of the unit to heat in low speed is checked Report Test Results The test results are reported as PASS CHECK or FAILED when the Pretrip is completed If test results are Check or Failed alarm codes will exist to direct the technician to the source of the problem If a Pretrip is ...

Page 61: ...mpletion 8 When all tests are complete the results are reported as PASS CHECK or FAILED If FAILED appears the unit will shut down If the results are Check or Failed the accompanying alarm codes will direct the technician to the cause of the problem 9 When the non running test are complete the unit will start automatically and continue with the Running Pretrip Test 10 If the Pretrip Test results ar...

Page 62: ...manually If the unit has standby power available and is turned on the electric standby run screen will appear after the standard screen The new mode is then confirmed for 10 seconds If the unit was switched on in Electric mode and electric standby power is not available the operator will receive a prompt to return to Diesel mode operation If enabled select Electric Standby Diesel Mode as follows 1...

Page 63: ...ey until the Adjust Brightness Menu appears See Figure 56 4 Press the or soft keys to select the desired brightness See Figure 56 This example shows changing screen brightness from low to medium 5 Press the YES soft key to enter the new brightness level 6 The selected level appears on the screen 7 The Adjust Brightness Main Menu Screen reappears and if no keys are pressed the Standard Display appe...

Page 64: ...NOT block the evaporator inlet or outlet 4 Products should be pre cooled before loading Thermo King transport refrigeration units are designed to maintain loads at the temperature at which they were loaded Transport refrigeration units are not designed to pull hot loads down to temperature Post Load Procedure 1 Make sure all the doors are closed and locked 2 Start the unit if it was shut off to lo...

Page 65: ...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 F4 fuse must be removed from the interface board on units equipped with the Australian Bosch alternator The voltage regulat...

Page 66: ...ck the sense circuit 2 or equivalent in the alternator harness and in the main wire harness b The B pin is the excitation circuit and should be at 10 volts or higher If not check the excitation circuit 7K 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 a...

Page 67: ...for each alternator with 12 volts applied to the field a No field current or a low field current 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...

Page 68: ...Electrical Maintenance 68 1 Check Point for 2A Amperage 2 Position for Full Fielding Jumper Figure 59 Full Field Test ...

Page 69: ...re 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 ap...

Page 70: ...oltage 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 voltmeter between the B terminal and a chassis ground 10 Start the unit and run it in high speed 11 Connect a jumper wire between the F2 terminal and a chassis ground This will full field the alternator a Full alternator output the alternators rat...

Page 71: ...h Speed Circuits F7 2A 8FP Circuit CAN bus F8 3A CAN Connector J12 F9 3A CAN Connector J14 F10 7 5A 8X Power Install fuse in upper position F11 10A Electric Clutch Not Used F12 3A CAN Connector J13 F13 2A 8FC Circuit Remote Lights F15 P S On Off Relay F20 2A Alternator Sense F4 Remove fuse F4 for Model 30 units with Australian Bosch Alternator Install fuse F4 for Model 50 units with Prestolite Alt...

Page 72: ...he Microprocessor Controller and the related components AC Components Electrical Contactors Periodically inspect all contactor points for pitting or corrosion and repair or replace as necessary Test the contactor points by checking the voltage drop across each set of points when the contactor is energized and the system is operating If the voltage drop across a set of points is more than 15 Vac re...

Page 73: ...If the electric motor does not run at all 1 Make sure that the unit is turned On that Electric Standby has been selected in the Operator Menu and that the power supply is connected and turned On 2 Check the CH wire to the PSM for continuity to the CH circuit chassis 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 w...

Page 74: ...Electrical Maintenance 74 1 Overload Relay 2 HC Heaters Contactor 3 PSM Phase Selection Module 4 MC2 Motor Contactor 5 MC1 Motor Contactor Figure 63 High Voltage Tray 2 3 1 4 ARD077 5 ...

Page 75: ...fer to the TK 482 and TK 486 Engine Overhaul Manual TK 50136 for a detailed description of the engine lubrication system Engine Oil Change The engine oil should be changed according to the Maintenance Inspection Schedule Drain the oil only when the engine is hot to ensure that all the oil drains out When changing oil keep unit and trailer level so all the oil can flow from the oil pan It is import...

Page 76: ...dd Oil Check Oil Pressure Oil May Be Diluted Change Oil and Filter Check Oil Pressure Oil Pressure OK Oil Pressure OK Check Oil Level Oil Level Low Oil Pressure Low Install 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 ...

Page 77: ...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 486L 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 GR...

Page 78: ...nent type coolant concentrate and 32 percent water for use in extreme temperatures Changing the Antifreeze 1 Run the engine until it is up to its normal operating temperature Stop the unit 2 Open the engine block drain located behind the starter and completely drain the coolant Observe the coolant color If the coolant is dirty proceed with a b and c Otherwise go to 3 a Run clear water into the rad...

Page 79: ...r out of the block using the following procedure NOTE If an engine runs with air trapped in the block the engine may be damaged The high water temperature switch may not protect an engine that has air trapped in the block because the high water temperature switch is designed to protect an engine from overheating due to failures in the cooling system 1 Loosen the plug on the back of the water pump ...

Page 80: ...he prefilter by the fuel transfer pump The fuel transfer pump delivers fuel to the fuel filter water separator Two orifices in the filter head control the pressure in the fuel system by allowing a certain amount of fuel to return to the tank One orifice is located in the center of the filter head It bleeds off water The other orifice is located off center on the filter head It bleeds off air Filte...

Page 81: ...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 Separator Figure 66 Engine Fuel System ...

Page 82: ...an area whenever possible 3 Complete the work in the shortest possible time Any major injection pump or nozzle repairs should be done by a quality diesel injection service shop The necessary service equipment and facilities are not found in most engine rebuild shops because of the large investment required The following procedures can be done under field conditions 1 Bleeding air from the fuel sys...

Page 83: ...e fuel tank NOTE Some fuel tanks have a check valve in the drain plug fitting Push the check valve open with a small screw driver to drain the tank 3 Let the water and fuel drain into the container until no water is visible in the fuel draining from the tank If the water and fuel do not drain freely the vent may be plugged If so clean or replace the vent 4 Install the drain plug Fuel Filter Water ...

Page 84: ...t start the unit and check the speed When the speed is correct tighten the jam nut and replace the solenoid boot NOTE If the correct speed cannot be set close enough with half turns of the eye bolt use the Allen wrench to turn the plunger in smaller increments Low Speed 1 Loosen the jam nut on the low speed adjustment screw 2 Use the Service Test Mode to run the unit in low speed Adjust the screw ...

Page 85: ...ad center of the compression stroke for the number one cylinder 6 Disconnect the 8S wire from the starter solenoid to prevent the engine from cranking when the unit is turned On 7 Press the ON key to turn the unit on 8 Use the keypad to enter the Interface Board Test Mode Refer to the appropriate Microprocessor Diagnostic Manual for detailed information about the Service Test Mode 9 Energize the f...

Page 86: ...ng mark on the flywheel should be aligned with the index mark on the side of the timing mark access hole b On the SB 310 the index mark should align with the midpoint between the two timing marks on the flywheel 15 Repeat steps 10 through 14 to recheck the timing 16 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 ...

Page 87: ...he gear case 3 Use the hardware from the cover plate to attach the tool plate with the marked side pointing up and out to the gear case 4 Align the threaded holes in the injection pump gear with the two holes in the tool plate by rotating the engine crankshaft Attach the gear to the tool plate with the screws provided with the tool plate 5 Thread the long screw supplied with the tool plate into th...

Page 88: ...e the injection pump governor linkage has been moved to the fuel 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 The pull in coil is controlled by the microprocessor through the fuel solenoid pull in relay K6 1 Injection Pump 5 Adapter 2 Gear Case 6 Tool Long S...

Page 89: ...d will not function properly 5 If the fuel solenoid is not operating properly check the run relay K1 the fuel solenoid pull in relay K6 their fuses and the associated circuits If the relays fuses and circuits are acceptable use steps 6 through 9 to isolate and check the fuel solenoid 6 Disconnect the fuel solenoid wire connector from the main wire harness 7 Place a jumper wire between the black wi...

Page 90: ... Refer to the appropriate Microprocessor Diagnostic Manual for specific information about the Relay Test Mode 5 Energize the fuel solenoid by energizing the run relay with the Interface Board Test Mode NOTE The fuel solenoid must be energized when it is installed If 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 ...

Page 91: ... exhaust stroke for the number one cylinder Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number one cylinder 1 Index Mark 2 Top Dead Center Mark for 1 and 4 Figure 80 Top Dead Center One and Four 1 2 AEA701 Valve Adjustments and Cylinder Configurations Front Rear Cylinder No 1 2 3 4 Valve arrangement E I E I E I E I Piston in No 1 cylinder ...

Page 92: ... the cover for the timing mark access hole and tighten the fuel injection lines when finished Crankcase Breather The crankcase breather is located on top of the rocker arm cover The crankcase breather system ducts crankcase gases formed in the crankcase directly to the air intake Harmful vapors that would otherwise collect in the crankcase and contaminate the oil or escape to the outside are drawn...

Page 93: ...r Assembly Figure 83 EMI 3000 Air Cleaner Assembly Air Restriction Indicator Excessive restriction of the air intake system reduces the flow of air to the engine affecting horsepower output fuel consumption and engine life An air restriction indicator is installed in the air intake manifold Visually inspect the restriction indicator periodically to assure the air filter is not restricted Service t...

Page 94: ...k motion and without pulling on the belt Then read the dial Use an average of three readings NOTE Do not attempt to remove or install belts without loosening adjustments Belts that are installed by prying over pulleys will fail prematurely due to internal cord damage CAUTION Do not attempt to adjust belts with the unit running CAUTION Turn the unit off before performing maintenance or repair proce...

Page 95: ...lots Model 30 Fan Belt Replacement NOTE Do not attempt to remove or install the belts without loosening the adjustments Belts that are installed by prying over pulleys will fail prematurely due to internal cord damage Lower Fan Belt Removal 1 Loosen both idler adjusting arm bolts and both idler assembly pivot bolts 2 Push the idler adjusting arm IN The lower fan belt will come off the engine pulle...

Page 96: ... 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 in the Structural Maintenance chapter 5 Torque the blower hub clamping bolts to 18 ft lb 24 N m 6 Seat the upper belt in the blower wheel pulley groove 7 Push inward on the idler adjusting arm and slip the belt into the idler pulley groove 8 Pull the ...

Page 97: ...n the pulley and replace the sliding pulley section on the pulley 4 Tighten the mounting belts on the water pump pulley 5 The belt tension should read 35 on the belt tension gauge Fan Belt Adjustment The fan belt tension should read 74 on the belt tension gauge 1 Loosen the idler pulley mounting bolts 2 Move the idler pulley assembly to adjust the belt tension to 74 on the belt tension gauge 3 Tig...

Page 98: ...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 fan does not slide on the fan shaft with light tapping remove the small access panel located on the condenser coil header above the expansion tank Thread a 1 4 20 x 1 in diameter bolt into the end of the fan shaft Tighten the bolt and washer down on the con...

Page 99: ...s to the clutch NOTE The refrigeration lines may be removed from the compressor to allow more movement of the compressor for better access to the clutch 4 Remove the compressor belts 5 Remove the clutch mounting bolt and special washer 6 Remove the clutch with a clutch puller 7 Remove the key from the compressor crankshaft and inspect the key and the crankshaft for wear burrs or damage 8 To disass...

Page 100: ...e 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 with the key 15 Install the spec...

Page 101: ...Engine Maintenance 101 ...

Page 102: ...Engine Maintenance 102 ...

Page 103: ...896 kPa If the pressure is below this it can be raised by covering a portion of the condenser grille with a piece of cardboard to block condenser airflow 8 Under these conditions refrigerant should be visible in the receiver tank sight glass If refrigerant is not visible in the receiver tank sight glass the unit is low on refrigerant Testing the Refrigerant Charge with a Loaded Trailer 1 Install a...

Page 104: ...llow liquid refrigerant 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 kPa while adding refrigerant h Close the hand valve on the refrigerant tank when the liquid level approaches the top of the receiver sight glass 4 Repeat the overcharge test Moistu...

Page 105: ...n the unit on the heat cycle instead of the defrost cycle NOTE Use refrigeration compressor oil ONLY Polyol Ester P N 203 513 is required for R 404A To add compressor oil pump down the compressor and equalize the pressure to slightly positive Disconnect the compressor oil filter return line from the top of the compressor and add the oil Reattach the oil filter return line to the compressor Evacuat...

Page 106: ...scharge pressure The purpose of the valve is to improve the three way valve response time when shifting from heat to cool If a three way valve does not shift back to cool immediately after the pilot solenoid closes and finally shifts to cool when the temperature rise puts the unit into high speed the three way valve end cap should be checked See End Cap Checks in the Refrigeration Service Operatio...

Page 107: ...started Alarm Code 89 indicates the refrigeration system pressures did not respond as expected during the test This may be caused by a malfunction of the ETV or by a refrigeration system problem such as low refrigerant level a frozen expansion valve or a restriction in suction line The microprocessor ignores the test results if the box temperature or the ambient temperature is below 10 F 12 C The ...

Page 108: ...ated in the refrigeration line that connects the discharge line to the hot gas line The hot gas solenoid is energized opened at full modulation The hot gas solenoid is de energized closed when modulation is discontinued Refer to the SR 2 Microprocessor Control System Diagnostic Manual TK 51587 for information about testing the hot gas solenoid See the Refrigeration Service Operations chapter of th...

Page 109: ... install the compressor belts on Model 50 units and install the mounting bolts NOTE The compressor drive coupling or clutch will only slide onto the coupling pins in either of two positions which are 180 degrees apart 3 Install the service valves using new gaskets soaked in compressor oil Connect the high pressure cutout switch the pilot solenoid valve line and install the compressor oil filter 4 ...

Page 110: ... will push the tapered components apart and the reduced friction could lead to slippage and premature failure The following procedure requires the key to be fitted after the tapers are pulled together 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...

Page 111: ...f 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 Coil Removal 1 Recover the refrigerant charge 2 Ope...

Page 112: ...per refrigerant and check the compressor oil level In Line Condenser Check Valve This unit uses an in line condenser check valve The in line check valve is not repairable and must be replaced if it fails A heat sink must be used on the in line check valve when it is being soldered in place to prevent damage to the neoprene seal Condenser Check Valve Replacement Removal 1 Recover the refrigerant ch...

Page 113: ...e bypass check valve 4 Remove the high pressure relief valve from the receiver tank 5 Unbolt the mounting brackets and remove the receiver tank from the unit Installation 1 Install the high pressure relief valve in the receiver tank 2 Solder the bypass check valve onto the receiver tank Use a heat sink on the bypass check valve 3 Place the receiver tank in the unit and install the mounting bolts a...

Page 114: ...ished condition Install the feeler bulb clamps and the feeler bulb on the side of the suction line in its former position The feeler bulb must make good contact with the suction line or operation will be faulty Wrap with insulating tape 5 Pressurize the low side and test for leaks If no leaks are found evacuate the low side 6 Replace the access panels 7 Open the refrigeration valves and place the ...

Page 115: ...panels 10 Open the refrigeration valves and place the unit in operation Evaporator Coil Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Remove the upper and lower evaporator access panels 3 Remove the roadside and curbside evaporator access panel mounting channels 4 Disconnect the sensors 5 Remove the feeler bulb from the suction line clamp Note the position of th...

Page 116: ...e the low side 5 Open the refrigeration valves and place the unit in operation Check the refrigerant charge and the compressor oil Add as required Three Way Valve Repair NOTE The three way valve can be repaired in the unit if leakage or damage to the Teflon seals should occur There is usually enough give in the copper tubing to separate the three sections of the valve without unsoldering any tubes...

Page 117: ...move the screen If any particles drop from the screen into the discharge line the discharge line must be removed at the compressor NOTE The valve body cannot be reconditioned Seat positions change and improper sealing will result End Cap Checks All end caps even new ones should be checked as follows See Service Bulletin T T 260 for more information Check Valve Bleed Hole Diameter 1 Remove the cond...

Page 118: ...he hole is covered by the piston If the piston covers more than three quarters of the hole replace the end cap NOTE When front seating a condenser bypass check valve DO NOT over tighten the stem Excessive torque will deform the piston and the deformed piston can increase the hole blockage Seat Center Section Orifice Check There are three 0 033 in 0 84 mm holes located in the three way valve seat c...

Page 119: ...ays in the cap and body Failure to line up the holes will result in improper operation of the valve 8 Install the bolts and tighten in rotating sequence Torque to 160 in lb 18 N m 9 Install the pilot solenoid line and pressurize the system with refrigerant to check for leaks 10 If there are no leaks evacuate the system and recharge with the proper refrigerant 11 Run the unit to check for proper th...

Page 120: ...Recharge the unit with the proper refrigerant Pilot Solenoid Removal 1 Recover the refrigerant charge 2 Disconnect the wires and remove the coil from the valve 3 Unsolder the refrigeration lines 4 Remove the mounting bolts and remove the valve Installation 1 Remove the coil from the valve 2 Place the valve in the unit and install the mounting bolts The arrow on the valve indicates the direction of...

Page 121: ...l and tighten the high pressure relief valve 3 Pressurize the refrigeration system and test for leaks If no leaks are found evacuate the system 4 Recharge the unit with the proper refrigerant and check the compressor oil Discharge Pressure Transducer Removal 1 Recover the refrigerant charge 2 Disconnect the wires and remove the discharge pressure transducer Installation 1 Apply a refrigerant Locti...

Page 122: ...nstalled go to step 2 If a complete ETV assembly is being installed proceed as follows a Remove the stepper motor and piston assembly from the valve body on the new ETV assembly b Clean the tubes for soldering CAUTION Unscrew the large nut Do not unscrew the small nut WARNING If the ETV is stuck in the closed position much of the refrigerant charge may be trapped in the evaporator If you hear refr...

Page 123: ...frigeration tubing 6 Connect the ETV harness connector to the stepper motor Take care when making the connection The connector attaches to the ETV in only one position 7 Install the clip and secure it with a band wrap 8 Pressurize the low side and test for leaks 9 If no leaks are found evacuate the low side 10 Install the evaporator access panels 11 Open the refrigeration valves and place the unit...

Page 124: ...ver the refrigerant remaining in the compressor 3 Remove the suction service valve 4 Unbolt and remove the throttling valve from the unit AEA717 1 Screw Mtg Plate 10 Gasket Piston Housing 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 Compress...

Page 125: ...ellows 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 s...

Page 126: ...g by adding or removing shims under the spring Installation 1 Install the throttling valve using a new O ring soaked in compressor oil Bolt the throttling valve to the compressor 2 Install the suction valve 3 Pressurize the compressor and check for leaks If no leaks are found evacuate the compressor 4 Open the refrigeration valves and place the unit in operation 1 Tighten castle nut to bottom then...

Page 127: ...ack 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 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 th...

Page 128: ...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 129: ... 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 130: ...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 131: ...ifice 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 inlet...

Page 132: ... 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 133: ... 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 pre trip 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 ...

Page 134: ...lay is obtained add approximately 1 5 oz 44 ml of oil P N 203 278 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 th...

Page 135: ...ne Refer to appropriate Microprocessor Diagnostic Manual Fuel solenoid defective or stuck Replace Fuel injection pump defective Replace pump Air heater defective Replace No fuel or wrong fuel Fill with proper fuel Fuel pump defective Replace pump Air in fuel system Bleed air Compression low Overhaul engine Injection nozzles defective Replace nozzles Incorrect timing Adjust timing Air cleaner clogg...

Page 136: ...ive injection rate too low gum formations Repair or replace pump Engine speed too high Misadjusted high speed solenoid Adjust high speed solenoid Defective injection pump Repair injection pump Engine fails to stop when unit is OFF Fuel solenoid defective Replace Injection pump defective Replace pump Engine knocks heavily Air in system Bleed fuel system Injection pump not timed Retime injection pum...

Page 137: ...pressure switch Replace if necessary Oil control valve defective Check oil pressure control valve 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 rocker arm cover oil lines oil filter front timing cover or crankshaft seals Damaged valve seals Replace seals on valve stem Worn valve st...

Page 138: ...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 139: ... Select ELECTRIC Unit in NULL Check setpoint and box temperature Fuse F1 blown Check for short circuit and replace fuse Faulty HPCO Check HPCO Open or faulty overload relay Determine cause and rest or replace overload relay Faulty PSM Check PSM Faulty motor contactor Check motor contactors Open circuit Check 8 ER EOL 7E 7EB 7EC CH L1 L2 and L3 circuits Faulty drive motor Check drive motor Faulty e...

Page 140: ...Electric Standby Diagnosis 140 ...

Page 141: ...er fan blades bent or broken Air short cycling around evaporator coil Air through evaporator restricted Evaporator needs defrosting Compressor discharge valves leaking Compressor suction valves leaking Too much compressor oil in system Faulty oil pump in compressor Faulty compressor drive coupling Compressor bearing loose or burned out Broken valve plate in compressor Expansion valve power element...

Page 142: ...valve stuck open or leaking Rapid cycling between cool and heat Unit cools in heat and defrost cycle Unit heats in refrigeration cycle High head pressure Low head pressure High suction pressure Low suction pressure No suction pressure Unit operating in a vacuum Receiver sight glass empty Suction line frosting back Unable to pump down system Unable to pull vacuum in low side Unable to hold vacuum i...

Page 143: ...r Check Valve 9 High Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Throttling Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check V...

Page 144: ...enser Check Valve 9 High Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Throttling Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Che...

Page 145: ...0 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Hot Gas Bypass Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Service Valve 31 Electron...

Page 146: ...ve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Hot Gas Bypass Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Service Valve 31 Elec...

Page 147: ... switch 29 cooling system 77 cooling system engine 77 bleeding air from 79 crankcase breather 92 CYCLE SENTRY selecting 44 CYCLE SENTRY Operation 25 CYCLE SENTRY Start Stop Controls 25 D data logging 26 30 datalogger menu 53 defrost 27 30 defrost damper adjustment 128 defrost drains 127 Defrost key 38 diagnosis electric standby 137 diagnosis mechanical 133 diagnosis refrigeration 139 diagrams refr...

Page 148: ...roprocessor On Off switch 37 Mode key 38 mode menu 56 moisture indicating sight glass 102 mounting bolts unit and engine 127 O Off key 38 oil change engine 75 oil filter change compressor 125 oil filter change engine 75 On key 38 operating modes 27 operator menu choices 50 navigating 50 overload relay 29 P pilot solenoid replacement 118 post trip checks 64 preheat buzzer 29 pretrip tests 60 primin...

Page 149: ...04 three way valve condenser pressure bypass check valve repair 117 three way valve repair 114 throttling valve mechanical See mechanical throttling valve time display 64 transducers pressure 105 trip report printing 53 U unit description 23 V valve clearance adjustment engine 90 W wiring unit 70 X X430L compressor 24 ...

Page 150: ...Index 150 ...

Page 151: ...151 Wiring Diagram Index Drawing No Drawing Title Page 1E07692 Model 30 and 50 Schematic Diagram 153 155 1E07693 Model 30 and 50 Wiring Diagram 156 159 ...

Page 152: ...Wiring Diagram Index 152 ...

Page 153: ...153 Model 30 and 50 Schematic Diagram Page 1 of 3 ...

Page 154: ...154 Model 30 and 50 Schematic Diagram Page 2 of 3 ...

Page 155: ...155 Model 30 and 50 Schematic Diagram Page 3of 3 ...

Page 156: ...156 Model 30 and 50 Wiring Diagram Page 1 of 4 ...

Page 157: ...157 Model 30 and 50 Wiring Diagram Page 2 of 4 ...

Page 158: ...158 Model 30 and 50 Wiring Diagram Page 3 of 4 ...

Page 159: ...159 Model 30 and 50 Wiring Diagram Page 4 of 4 ...

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