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Thermo King SB-III 30 SR+, Manual

The Thermo King SB-III 30 SR+ is a high-performance refrigeration unit designed for commercial trucks. With our user-friendly manual, you can easily operate and maintain the system. Download the free manual from our website, ensuring hassle-free access to all the information you need to maximize the functionality of your Thermo King unit.

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Table of Contents

Safety Precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Maintenance Inspection Schedule   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Unit Description   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Sequence Of Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Operating Modes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Design Features  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Protection Devices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Serial Number Locations   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Unit Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Operating Instructions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Microprocessor Control Panel   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Microprocessor On-Off Switch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Unit Instruments  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Unit Protection Devices   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Unit Operation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Manual Pretrip Inspection (Before Starting Unit)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Starting Unit With Electronic Full Pretrip   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Selection of Operating Modes   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Restarting Unit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
After Start Inspection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Loading Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Post Load Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Post Trip Checks   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Electrical Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Alternator (Australian Bosch)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Battery   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Unit Wiring  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Fuse Link   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Air Heater  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Thermoguard 

µ

p v Microprocessor Controller  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Engine Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

EMI 3000   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Engine Oil Change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Oil Filter Change   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Engine Cooling System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
ELC (Extended Life Coolant)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Antifreeze Maintenance Procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Summary of Contents for SB-III 30 SR+

Page 1: ...Whisper TK 50200 2 MM Rev 4 04 02 For units with and without EMI 3000 Copyright 1998 Thermo King Corp Minneapolis MN U S A Printed in U S A ...

Page 2: ...as all inclusive or covering all contingencies If further information is required Thermo King Corporation should be consulted Sale of product shown in this manual is subject to Thermo King s terms and conditions including but not limited to the Thermo King Limited Express Warranty Such terms and conditions are available upon request Thermo King s warranty will not apply to any equipment which has ...

Page 3: ...to 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 regula tions concerning the use of refrigerants and the certification of technicians For additional information on regulations and tech nician certification programs contact your local THERMO KING dealer ...

Page 4: ......

Page 5: ...Pretrip Inspection Before Starting Unit 21 Starting Unit With Electronic Full Pretrip 21 Selection of Operating Modes 22 Restarting Unit 23 After Start Inspection 23 Loading Procedure 24 Post Load Procedure 24 Post Trip Checks 24 Electrical Maintenance 25 Alternator Australian Bosch 25 Charging System Diagnostic Procedures 25 Battery 29 Unit Wiring 29 Fuses 29 Fuse Link 29 Air Heater 30 Thermoguar...

Page 6: ...and Installation 54 Refrigeration Maintenance 57 Refrigerant Charge 57 Refrigerant Leaks 59 Checking Compressor Oil 59 High Pressure Cutout Switch HPCO 60 Three way Valve Condenser Pressure Bypass Check Valve 60 Modulation Valve Optional 62 Hot Gas Solenoid Optional 62 Refrigeration Service Operations 63 Compressor 63 Compressor Coupling Removal 63 Compressor Coupling Installation 64 Condenser Coi...

Page 7: ...alve Optional 79 Structural Maintenance 81 Unit And Engine Mounting Bolts 81 Unit Inspection 81 Condenser Evaporator And Radiator Coils 81 Defrost Drains 81 unit installation 81 Defrost Damper 82 Condenser And Evaporator Fan Location 83 Fan Shaft Assembly Overhaul 84 Idler assembly 86 Idler Assembly Overhaul 86 Mechanical Diagnosis 89 Refrigeration Diagnosis 93 Refrigeration Diagrams 95 Wiring Dia...

Page 8: ......

Page 9: ...nds to displace air and can cause oxygen depletion resulting in suffocation 11 EPA Section 608 Certification is needed to work on refrigeration systems REFRIGERANT Although fluorocarbon refrigerants are classified as safe refrigerants certain precautions must be observed when handling them or servicing a unit in which they are used When exposed to the atmosphere in the liquid state fluoro carbon r...

Page 10: ...ii ...

Page 11: ... in high speed Intake Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Exhaust Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Valve Setting Temperature 70 F 21 C Fuel Injection Timing 11 to 13 BTDC timed on No 1 cylinder Low Oil Pressure Switch Normally Closed 17 3 psi 117 21 kPa Engine Coolant Thermostat 180 F 82 C Engine Coolant Type Conventional Conventional coolant antifreeze is green or b...

Page 12: ...h Pressure Cutout 470 7 psi 3241 48 kPa Automatic reset 375 38 psi 2586 262 kPa When the compressor 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 2 Circuit Fu...

Page 13: ... 5 Vdc THERMOGUARD µP V MICROPROCESSOR TEMPERATURE CONTROLLER Temperature Controller Type Electronic THERMOGUARD µP V Microprocessor with digital thermostat thermometer and fault indicator monitor Setpoint Range 20 to 80 F 29 to 27 C Programmable setpoint range to 90 F 32 C Digital Temperature Display 40 to 99 9 F 40 to 40 C Internal Defrost Timer Temperature Pulldown 2 4 6 8 or 12 hours selectabl...

Page 14: ...4 ...

Page 15: ...r has not reached 25 in Drain water from fuel tank and check vent Inspect clean fuel transfer pump inlet strainer Check and adjust engine speeds high and low speed Check condition of drive coupling bushings per Service Bulletin T T 171 Check condition of engine mounts Replace standard silver fuel filter water separator Replace EMI 3000 black fuel filter water separator ENGINE OIL CHANGE INTERVALS ...

Page 16: ...ction pressure Check compressor oil level and condition Check throttling valve regulating pressure Check compressor efficiency and pump down refrigeration system Replace dehydrator and check discharge and suction pressure every 2 years Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts includes air ducts and bulkheads Inspect tapered roller bea...

Page 17: ...Controls A CYCLE SENTRY Start Stop fuel saving system provides optimum operating economy Selecting Continuous or CYCLE SENTRY operation on units equipped with CYCLE SENTRY is accomplished using the microproces sor keypad WARNING With the unit On Off switch in the ON position the unit may start at anytime without prior warning NOTE A buzzer sounds when the unit is automatically preheating NOTE The ...

Page 18: ...ng The Tracker trans mits data at preset intervals or on demand depending on the type of SCS Data can also be transmitted through a Tracker to the microprocessor with some systems Thermo King X430 Compressor The unit is equipped with a Thermo King X430 four cylinder compressor with 30 cu in 492 cm3 displacement Refrigeration Modulation System Optional The refrigeration modulation system provides p...

Page 19: ...he temperature is within a few degrees of setpoint the tem perature is considered to be in range and the in range icon will turn on The microprocessor will select the operating mode from the list of possible modes below High Speed Cool Low Speed Cool Low Speed Modulated Cool Optional Low Speed Modulated Heat Optional Low Speed Heat High Speed Heat Defrost CYCLE SENTRY Mode Setpoint at or Above Fre...

Page 20: ...cur if the difference between the return air temperature discharge air temperature and coil temperature becomes excessive Two defrost timers are used When the unit is In Range within a few degrees of setpoint defrost intervals are con trolled by the Defrost Interval In range timer DEFI This timer can be set for 4 6 8 or 12 hours When the unit is not in range defrost intervals are determined by the...

Page 21: ...lts Heavy Duty Dry Element Air Cleaner Inside Unit Frame THERMOGUARD Microprocessor Controller Fuel Filter with Water Separator Spin On Full Flow Bypass Dual Element Oil Filter Dealer Installed Synthetic Engine Oil Opt Side Mount Coolant Expansion Tank Defrost Timer CYCLE SENTRY System 37 Amp Alternator Refrigerant R 404A Silicone Coolant Hoses Opt Fuel Heater Opt Fresh Air Exchange Opt Condenser ...

Page 22: ...ssure Switch Engine Low Oil Level Switch Evaporator Temperature Sensor Refrigerant High Pressure Cutout Switch High Refrigerant Pressure Relief Valve 12 Volt Fuse Link Fuse in Main Power Circuit Fuse in Control Circuit Fuse in Modulation Valve Circuit Opt Fuse in Microprocessor Power Circuit Relay Fuses Remote Status Light Fuse ...

Page 23: ... Nameplate on the curbside of the unit inside the top service access grille and on the roadside of the unit frame below control panel Engine Nameplate on rocker arm cover Compressor Stamped on the end above the oil pump 1 Serial Number Location 1 AGA231 1 1 1 ...

Page 24: ...Unit Description Rev 04 02 14 Unit Photos Front View AGA231 ...

Page 25: ...Unit Description Rev 04 02 15 1 Defrost Damper 2 X430 Compressor 3 TK 486 Engine Back View AEA698 2 3 1 ...

Page 26: ...alve 12 Battery Tray 4 Throttle Solenoid 13 Hand Primer Pump 5 Fuel Solenoid 14 Dipstick 6 Air Restriction Indicator 15 Oil Filter Standard Blue Filter Shown 7 Fuel Bleed Screw 16 Starter 8 Alternator 17 Compressor Sight Glass 9 Three way Valve 18 Compressor Oil Filter Engine Compartment 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ara193 ...

Page 27: ...Unit Description Rev 04 02 17 1 Display 3 Keypad 2 Microprocessor Control Panel 4 Switch Panel Control Panel AEA737 1 2 3 4 ...

Page 28: ...18 ...

Page 29: ...sor also continu ously monitors discharge and return air sensor temperatures and unit operational information The Microprocessor Control Panel contains the display screen and the keypad The display shows various informa tion The keypad controls the operation of the microproces sor Refer to the appropriate Operation Manual or Operation and Diagnosis Manual for detailed information about oper ating ...

Page 30: ...rt in the 2 circuit 2 FUSES A number of fuses located on the relay board protect various circuits and components A 40 amp fuse F9 2 Circuit protects the 2AA cir cuit which is the main power circuit A 15 amp fuse F3 Damper protects the 29F circuit which supplies power to the damper solenoid A 15 amp fuse F18 High Speed Solenoid protects the 7D circuit which supplies power to the high speed solenoid...

Page 31: ...p while coolant is hot CAUTION Do not add RED Extended Life Coolants to cooling systems using GREEN or BLUE GREEN coolants Do not add GREEN or BLUE GREEN coolants to cooling systems using RED Extended Life Coolants See ELC Extended Life Coolant on page 32 for more information 4 BATTERY The terminals must be clean and tight 5 BELTS The belts must be in good condition and adjusted to the proper tens...

Page 32: ...e Alarms with the CODE key refer to the appropriate Operation and Diagnosis Manual for detailed information about alarms a Correct the alarm conditions b Clear the alarms with the CLEAR key refer to the appropriate Operation and Diagnosis Manual for detailed information about alarms c Repeat the PRE TRIP test until PASS appears the unit passes the PRETRIP 6 Recheck the setpoint 7 Complete the Afte...

Page 33: ...ay the unit should preheat and start automatically NOTE When the CYCLE SENTRY Icon is active the unit may not start if the compartment temperature is near the setpoint the engine is warm and the battery is fully charged If cooling or heating is required and the engine temperature is below approximately 90 F 32 C but the engine fails to start automatically Turn the On Off switch to the OFF position...

Page 34: ...ke sure the unit is OFF before opening the doors to minimize frost accumulation on the evaporator coil and heat gain in the trailer Unit may be running when loading the trailer from a warehouse with door seals 2 Spot check and record load temperature while loading Especially note any off temperature product 3 Load the product so that there is adequate space for air circulation completely around th...

Page 35: ...UTION The F15 fuse must be removed from the relay board on units equipped with the Australian Bosch alternator The voltage regulator will be dam aged if the unit is turned ON with the F15 fuse in place on the relay board Complete the following checkout procedure before replac ing the voltage regulator or the alternator When testing alternators use accurate equipment such as a Thermo King P N 204 6...

Page 36: ...hould be at battery voltage If not check 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 cir cuit 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 altern...

Page 37: ...ulator defective Replace volt age regulator and brush assembly Approximately 60 of rated output Approximately equal to battery voltage and does not change or rises slightly Receiver diode defective Repair or replace alternator Low or no output Less than or equal to battery voltage and decreasing Stator windings field windings brush or diode defective Perform Field Current Test to check brushes and...

Page 38: ...Electrical Maintenance Rev 04 02 28 1 Check Point for 2A Amperage 2 Position for Full Fielding Jumper Full Field Test AEA694 ...

Page 39: ...mponents The relay board is located inside the control box Refer to the appropriate THERMO GUARD Microprocessor Controller Operation Diagnosis Manual for a complete list of the size and function of the fuses A 40 amp fuse F9 2 Circuit protects the 2AA cir cuit which is the main power circuit A 15 amp fuse F3 Damper protects the 29F circuit which supplies power to the damper solenoid A 15 amp fuse ...

Page 40: ...with an ohm meter between the M6 terminal on the front of the heater and the screw on the back of the heater or the heater case The resistance should be 0 1 to 0 2 ohms 1 Fuse Link 2 Bracket 3 Battery Fuse Link Location Early Models Only 1 3 2 aea823 Check the current draw of the heater with a clamp on ammeter at the H1 wire near the M6 terminal on the front of the heater Hold the Preheat Start sw...

Page 41: ...picking up any of the residue that tends to settle on the bottom of the pan The oil then passes through the intake pipe to the oil pump The oil pump forces the oil through an oil gallery to the dual element full flow bypass oil filter Dirt and other particles are trapped in the filter element as the oil passes through the oil filter If the filter element becomes clogged a bypass valve built into t...

Page 42: ...Use a genuine Thermo King oil filter 1 Remove the filter 2 Apply oil to the rubber ring of the new filter and install the filter 3 Tighten the filter until the rubber ring makes contact then tighten 1 2 turn more 4 Start the unit and check for leaks ENGINE COOLING SYSTEM The engine employs a closed circulating type pressurized cooling system Correct engine temperatures are controlled and maintaine...

Page 43: ...e of 50 50 pre mixed Extended Life Cool ant 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 of the cooling system is main tained ELC cannot be used in older units The water pump seal bel lows and O rings used on older units are not compatible with ELC To upg...

Page 44: ...ars or 12 000 hours whichever occurs first ARA114 1 Expansion Tank 5 Water Pump 2 Radiator Cap 6 Thermostat 3 Coolant Level Sensor 7 Thermostat Housing 4 Radiator Engine Cooling System 1 2 3 4 5 6 7 Do not mix green or blue green engine coolant with ELC red engine coolant See ELC Extended Life Coolant on page 32 for more information about ELC The factory recommends the use of a 50 50 antifreeze mi...

Page 45: ...cessary 5 Loosen the water pump belt Check the water pump bearing for looseness 6 Inspect the radiator cap Replace the cap if the gasket shows any signs of deterioration 7 Determine which type of antifreeze to use Conven tional coolants are green or blue green ELC is red Do not mix conventional coolants and ELC See ELC Extended Life Coolant on page 32 to help determine which type of antifreeze to ...

Page 46: ...el 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 Filtered fuel passes throug...

Page 47: ...Engine Maintenance Rev 04 02 37 2 3 5 6 7 4 1 Check Valve 5 Fuel Transfer Pump 2 Filter Head 6 Priming Pump 3 Injection Pump 7 Fuel Filter Water Separator 4 Bleed Screw Engine Fuel System 1 ARA014 ...

Page 48: ...leeding air from the fuel system 2 Fuel tank and filter system maintenance 3 Priming pump hand replacement or repair 4 Fuel pump replacement or repair 5 Injection line replacement 6 Injection pump and governor adjustments 7 Injection pump timing 8 Nozzle spray pattern testing and adjustment 9 Minor rebuilding of nozzles Bleeding the Fuel System If the engine runs out of fuel repairs are made to th...

Page 49: ...e open with a small screw driver to drain the tank 1 Bleed Screw Injection Pump aea759 1 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 Separator The fuel filter water separator removes water fro...

Page 50: ...e high speed solenoid 5 Pull the plunger out of the solenoid enough to loosen the jam nut An Allen wrench placed in the hex opening in the face of the plunger will keep the plunger from turning Turn the plunger eye bolt clockwise to increase the speed and counterclockwise to decrease the speed 6 Replace the ball joint start the unit and check the speed When the speed is correct tighten the jam nut...

Page 51: ...s to prevent the possibility of the engine firing while it is being rotated a Rotate the engine in the normal direction of rota tion clockwise viewed from the water pump end until the 1 4 timing mark on the flywheel lines up with the index mark in the timing mark access hole b Check the rocker arms on the number one cylinder to see if they are loose c If the rocker arms are loose the engine is at ...

Page 52: ...e in the end of the delivery valve holder Stop as soon as you see the fuel rise 1 Index Mark 2 Injection Mark Timing Mark Alignment aea702 1 2 15 Check position of the timing marks The injection tim ing mark on the flywheel should be aligned with the index mark on the side of the timing mark access hole Repeat steps 11 through 15 to recheck the timing 16 If the timing is off by more than 1 degree ...

Page 53: ...e gear case Remove the nut and lockwasher which secure the gear to the injec tion pump shaft Use a shop rag to prevent the lock washer or nut from falling into the 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 ...

Page 54: ...kwasher and nut use a shop rag as before to prevent the lock washer or nut from falling into the gear case Torque the nut to 84 to 90 ft lb 113 to 122 N m 5 Fasten cover plate to gear case and reinstall all compo nents removed previously to facilitate injection pump removal Fuel Solenoid System The fuel solenoid is located on the end of the injection pump It contains two coils the pull in coil and...

Page 55: ...zed it supplies power to the fuel solenoid hold in coil and to the fuel solenoid relay coil The hold in coil is energized and remains energized as long as there is power on 8D 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 solenoid relay by open ing the ...

Page 56: ...ge is not present on the 8D circuit check the 8D circuit and the related circuits and components for a fault b If battery voltage is present on the 8D circuit go to step 5 Main Wire Harness Connector Pin Identification aea704 5 Check the CH circuit pin C in the main wire harness connector for continuity to a good chassis ground a If there is no continuity between the CH circuit a good chassis grou...

Page 57: ...k when the hold in coil is de energized d If the hold in coil does not function properly check the resistance of the hold in coil by placing an ohmmeter between the red wire 8D pin A and the black wire CH pin C in the fuel sole noid connector The resistance of the hold in coil should be 24 to 29 ohms If the resistance of the hold in coil is not in this range replace the fuel solenoid e If the hold...

Page 58: ...uel solenoid must be energized when it is being installed If it is not the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly 5 Place the O ring in the groove in the end of the fuel injection pump Make sure that the O ring is positioned correctly during installation to avoid damage and leaks 6 Install the new fuel solenoid 7 Place the On Off switch i...

Page 59: ...If the rocker arms are tight the engine is at top dead center of the exhaust stroke for the number one cylinder Rotate the engine 360 to place the engine at top dead center of the compression stroke for the number one cylinder 5 Check the valve clearance of both valves for the num ber one cylinder with a feeler gauge The valve clear ance for both the intake valve and the exhaust valve should be 0 ...

Page 60: ...ccess hole and tighten the fuel injection lines when finished aea705 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 back into the engine and...

Page 61: ...essive 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 man ifold Visually inspect the restriction indicator periodically to assure the air filter is not restricted Service the air filter when the yellow diaphragm indicates 22 in of vacuum Press the res...

Page 62: ...sing belt tension gauge P N 204 427 is the best method of checking belts for tightness Install the belt gauge in the center of the longest belt span Press the plunger so the hook will engage the belt Make sure the hook is on the face of the belt not in a notch Release the plunger with a quick motion and without pulling on the belt Then read the dial Use an average of three readings NOTE Do not att...

Page 63: ... Upper Fan Belt 2 Condenser Fan Pulley 3 Condenser Fan Blower 4 Condenser Inlet Ring 5 Idler Assembly 6 Belt Guide 7 Lower Fan Belt 8 Engine Pulley 9 Idler Adjusting Arm 10 Alternator Belt Belt Arrangement aea709 1 2 3 5 4 6 7 8 9 8 10 ...

Page 64: ...me off the engine pulley Move the arm OUT far enough to clear the roadside idler mounting bracket Installation 1 Slip the belt into the groove of the idler pulley 2 Push the idler adjusting arm back in toward the unit 3 Slip the belt onto the pulley groove on the engine 4 Pull the idler adjusting arm back OUT and adjust the belts to the proper tension 5 Tighten the idler assembly pivot bolts and t...

Page 65: ...wheel 4 Check the radial clearance between the blower wheel and inlet ring with a gauge wire Check around the entire circumference to the inlet ring and blower wheel see Condenser and Evaporator Fan Location under Structural Maintenance 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...

Page 66: ...56 ...

Page 67: ...sor thermometer to monitor the return air temperature 5 Run the unit on high speed cool until the air in the box is at 0 F 18 C By allowing the box to leak a small amount you will be able to maintain 0 F 18 C 6 The suction pressure should be 13 to 18 psi 90 to 124 kPa 7 The discharge pressure should be at least 275 psi 1896 kPa If the pressure is below this it can be raised by cover ing a portion ...

Page 68: ...nt The refrigerant level should be adjusted To adjust the refrigerant level 1 Stop the unit and remove some refrigerant with an approved refrigerant recovery device such as the COLLECTOR P N 204 884 2 Perform a refrigerant level check and repeat the over charge test 3 If the liquid level is low add refrigerant as follows a Connect a refrigerant tank to the gauge manifold service line and purge the...

Page 69: ...e been removed for service or replacement 1 Floating Ball 2 Colored Ring Moisture Indicating Sight Glass AEA672 1 2 To check compressor oil level with an ambient air temperature above 50 F 10 C Install a gauge manifold on the compressor Operate the unit on Cool with a 20 psi 138 kPa minimum suction pressure and a 185 psi 1275 kPa minimum dis charge pressure for 15 minutes or more After the unit ha...

Page 70: ...pressure of the compressor first by blocking the condenser coil air flow by covering the condenser grille with a piece of cardboard If this does not raise the discharge pressure to the cutout level of the HPCO increase the engine speed by overriding the throttle solenoid This should increase the discharge pressure enough to cause the HPCO to cut out NOTE The discharge pressure should never be allo...

Page 71: ...lve 5 Operate the unit on cool and pump down the low side to 20 in Hg 68 kPa of vacuum 6 Stop the unit The condenser and suction pressures should remain stable indicating no leaks 7 Shift the three way valve to the heat position Low side gauge will raise slightly High side gauge will drop to approximately zero Gauges will equalize 8 Gauges will remain in this position approximately zero if the thr...

Page 72: ... modulation valve is not repairable but the electric coil can be replaced 1 Outlet 2 Electric Coil 3 Armature 4 Inlet 5 Opening Spring 6 Seats Modulation Valve AEA712 1 2 3 4 5 6 Refer to the appropriate Microprocessor Operation and Diagnosis Manual for information about testing the modula tion valve See the Refrigeration Service Operations section of this manual for removal and installation proce...

Page 73: ... replacement compressor in the unit Installation 1 Slide the compressor into the unit 2 Place the compressor in position and install the mount ing bolts NOTE The compressor drive coupling 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 and th...

Page 74: ... the flange If a nut is used to prevent the bolt from falling out the nut should not be tightened 3 Use torque wrench and the appropriate Allen tool to unscrew the coupling mounting screw Apply a maxi mum of 90 ft lb 122 N m of torque to the screw 4 Once the center screw has been loosened back the head against the tool and it should push the coupling off the crankshaft as you continuing turning th...

Page 75: ...key will not fit and it will hold the taper in the coupler off the taper on the shaft Check both keyways for burrs or corrosion A key can be coated with fine lapping compound and used as a lapping tool to clean the keyways AGA333 4 Remove the Keyway Tool and check the fit of the new key P N 55 9024 It should fit into the keyway with a light press fit requiring only a minimum of light tap ping If t...

Page 76: ...or Coupling Installation 1 2 3 4 5 AGA335 4 Remove the condenser coil mounting bolts Remove the mounting clamps from the condenser inlet line 5 Unsolder the inlet line and liquid line connections Lift the coil from the unit Installation 1 Clean the fittings for soldering 2 Place the coil in the unit and install the mounting bolts 3 Solder the inlet line and liquid line connections 4 Pressurize the...

Page 77: ...eck valve Installation NOTE 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 1 Clean the tubes for soldering 2 Place the check valve in position The arrow on the valve body indicates the direction of refrigerant flow through the valve 3 Place a heat sink on the check valve 4 Solder the inlet and outlet connections 5 Press...

Page 78: ...valve line to the receiver tank 4 Connect the bypass check valve and filter drier inlet lines 5 Tighten the receiver tank mounting hardware securely 6 Pressurize the refrigeration system and check for leaks If no leaks are found evacuate the system 7 Recharge the unit with proper refrigerant FILTER DRIER Removal 1 Pump down the refrigeration system and equalize the pressure to slightly positive 2 ...

Page 79: ...ss panels 7 Open the refrigeration valves and place the unit in oper ation 8 Test the unit to see that the expansion valve is properly installed HEAT EXCHANGER 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 mounting bolts that hold the heat exchanger on the bulkhead 4 Disconnect the equalizer line f...

Page 80: ...ounting channels 4 Disconnect the sensors 5 Remove the feeler bulb from the suction line clamp Note the position of the feeler bulb on the suction line 6 Unsolder the distributor from the expansion valve 7 Unsolder the hot gas line and the suction line from the evaporator coil 8 Remove the mounting bolts lift and slide the coil from the housing Installation 1 Place the evaporator coil in the evapo...

Page 81: ...refrigerant charge and the compressor oil and 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 Removal Disassembly 1 Remove the refrigerant charge 2 Clean the exterior surface of ...

Page 82: ...e must be removed at the compressor NOTE The valve body cannot be reconditioned Seat positions change and improper sealing will result 1 Seal Groove in Piston 2 Connecting Notch in Piston 3 Internal Spring in Seal 4 Connecting Groove in Stem 5 Retaining Clip Piston Stem Parts 2 5 4 3 1 1 Cap 7 Clip 2 Top Cap 8 Seat 3 Check Valve 9 Gaskets 4 Spring 10 Stem Assembly 5 Piston 11 Screen 6 Seal 12 Bott...

Page 83: ...the piston 5 Place the piston slot on the stem and secure with spring clip The open part of the clip should be on the opposite side of the piston slot 6 Install the spring and top cap 7 Line up the passageways 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 9 Install the pilot line and pressurize t...

Page 84: ...flon Check Valve Assembly AEA715 4 Screw the check valve stem into the three way valve until the snap ring can be installed 5 Install the snap ring 6 Unscrew back seat the check valve stem against the snap ring NOTE The valve stem must be back seated during normal unit operation 7 Coat sealing area in the cap with compressor oil install and tighten the cap on the three way valve 8 Pressurize the r...

Page 85: ...ualize the pressure to slightly positive 2 Front seat the discharge and suction service valves Release the remaining pressure 3 Disconnect the wires and remove the high pressure cut out switch from the compressor discharge manifold Installation 1 Apply a refrigerant locktite to the threads of the high pressure cutout switch 2 Install and tighten the high pressure cutout switch and reconnect the wi...

Page 86: ...NG piston 4 GASKET end plate 13 NUT adjusting 5 WASHER adjusting 14 PIN cotter 6 SPRING bellows 15 HOUSING piston 7 BELLOWS SHAFT assy 16 O RING valve to compressor 8 O RING 17 CAP rubber 9 HOUSING Throttling Valve Assembly AEA717 2 Front seat the discharge and suction service valves Release the remaining pressure 3 Remove the suction service valve and line from the compound gauge 4 Unbolt and rem...

Page 87: ...p is under slight spring pressure 5 Break the gasket free and remove the end cap 6 Note the number of shims next to the cap These can be reused 7 Remove the bellows 1 Inspect Cap 2 Inspect Spring 3 Shims 8 Inspect all the parts a Piston and cap for wear scuff marks b Body for stripped threads c Bellows end cap for damage in the pilot hole NOTE The bellows is normally replaced 9 Clean the parts tha...

Page 88: ... pressor 2 Install the suction valve and the line from the com pound gauge 3 Pressurize the low side and check for leaks If no leaks are found evacuate the low side 4 Open the refrigeration valves and place the unit in oper ation COMPRESSOR OIL FILTER CHANGE This unit is equipped with a compressor oil filter The com pressor oil filter should be changed when the drier is replaced 1 Pump down the lo...

Page 89: ...the valve Installation 1 Clean the tubes and elbow for soldering 2 Properly position the modulation valve the tube and the elbow between the evaporator outlet and the heat exchanger inlet 3 Solder the connections CAUTION Use a heat sink or wrap the valve with wet rags to prevent damaging the valve 4 Pressurize the low side and test for leaks If no leaks are found evacuate the low side 5 Install th...

Page 90: ...older the inlet and outlet connections After the valve cools install the coil 4 Pressurize the refrigeration system and test for leaks 5 If no leaks are found evacuate the system 6 Recharge the unit with proper refrigerant and check the compressor oil ...

Page 91: ...heduled 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 ...

Page 92: ...hat air flow is stopped on the top and bottom edges with the solenoid plunger bottomed out AEA719 1 Stop 6 Eye Bolt 2 Mounting Bolts 7 Round Stop 3 Closed Position 8 Distance A 2 75 in 69 85 mm 4 Open Position 9 Solenoid 5 Damper Link Defrost Damper Adjustment 1 2 9 8 1 7 4 3 5 6 To adjust the damper 1 Remove the damper assembly from the evaporator 2 Disconnect the damper link from the eye bolt ...

Page 93: ...re that the damper operates correctly and seals properly 9 Make sure the damper blade rests on the round stops when the damper is open Adjust the round stops if nec essary 10 Install the damper assembly in the evaporator CONDENSER AND EVAPORATOR FAN LOCATION When mounting the condenser or evaporator fan and hub assembly on the fanshaft the blowers and inlet orifices must be properly aligned for pr...

Page 94: ...used except after removal and repair of the fan shaft assembly The condenser and evaporator end oil seals should be checked during the pre trip inspection for oil leakage If there is any sign of leakage the fan shaft assembly should be removed and repaired NOTE The fan shaft assembly requires a special lubri cant Thermo King P N 203 278 Fan Shaft Assembly Overhaul Disassembly 1 Remove the fan shaf...

Page 95: ...k the assembly in a vise and set up a dial indicator to read end play To measure the end play rotate the shaft while pushing in one direction and set the dial indicator to 0 Now rotate the shaft and pull in the opposite direction while reading the dial indicator End play should be 0 001 to 0 005 in 0 025 to 0 127 mm If end play is incorrect use different shims to obtain correct end play Shims avai...

Page 96: ...nd of the assem bly 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 the parts in clean solvent 4 Using a punch remove the oil seal from the curbside end of the assembly With the seal removed clean the housing in solvent 5 Check the condition of the vent If it is loose or dam aged it must be repaired or replaced...

Page 97: ...e 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 8 Place the assembly on the workbench with the vent up Rotate the shaft by hand The shaft should be free enough to rotate without having to hold the housing CAUTION Reinstall the assembly into the unit making sure the vent i...

Page 98: ...88 ...

Page 99: ...opriate Microprocessor Operation and Diagnosis 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 clogged ...

Page 100: ...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 101: ... oil 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 val...

Page 102: ...ot burning 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 103: ...efrigerant 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 system Condenser fan blades bent or broken Air short cycling around evaporator coil Air through evaporator restricted Evaporator needs defrosting Compressor discharge valves leaking Compressor suction valves leaking ...

Page 104: ...e gauge out of calibration Leaky receiver tank outlet valve Leaky bypass check valve Leaky condenser check valve Faulty three way condenser pressure bypass check valve Modulation valve stuck closed Hot gas bypass 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 No head pressur...

Page 105: ...igh 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 Valve 30 Bypass Se...

Page 106: ...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 Valve 30 Bypass Servic...

Page 107: ...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 Valve 30 Bypass Service Valve 31 Modulation ...

Page 108: ...f 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 Valve 30 Bypass Service Valve 31 Mod...

Page 109: ...314 Early Model Coiled Wire Fuse Link Wiring Schematic 101 5D49313 Early Model Coiled Wire Fuse Link Wiring Diagram 102 105 5D52378 Late Model Fuse Link in Battery Cable Wiring Schematic 106 5D54669 Late Model Fuse Link in Battery Cable Wiring Diagram 107 110 ...

Page 110: ...100 ...

Page 111: ...101 Early Model Coiled Wire Fuse Link Wiring Schematic ...

Page 112: ...102 Early Model Coiled Wire Fuse Link Wiring Diagram Page 1 of 4 ...

Page 113: ...103 Early Model Coiled Wire Fuse Link Wiring Diagram Page 2 of 4 ...

Page 114: ...104 Early Model Coiled Wire Fuse Link Wiring Diagram Page 3 of 4 ...

Page 115: ...105 Early Model Coiled Wire Fuse Link Wiring Diagram Page 4 of 4 ...

Page 116: ...106 Late Model Fuse Link in Battery Cable Wiring Schematic ...

Page 117: ...107 Late Model Fuse Link in Battery Cable Wiring Diagram Page 1 of 4 ...

Page 118: ...108 Late Model Fuse Link in Battery Cable Wiring Diagram Page 2 of 4 ...

Page 119: ...109 Late Model Fuse Link in Battery Cable Wiring Diagram Page 3 of 4 ...

Page 120: ...110 Late Model Fuse Link in Battery Cable Wiring Diagram Page 4 of 4 ...

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