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Thermo King Super II SR+, Manual, Page: 3 / 145

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Recover Refrigerant

At Thermo King, we recognize the need to preserve
the environment and limit the potential harm to the
ozone layer that can result from allowing refrigerant
to escape 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 refriger-
ants and the certification of technicians. For addi-
tional information on regulations and technician
certification programs, contact your local THERMO
KING dealer.

Summary of Contents for Super II SR+

Page 1: ...Super II SR with µP IV TK 50234 0 2 MM 6 98 Copyright 1998 Thermo King Corp Minneapolis MN U S A Printed in U S A ...

Page 2: ...encies If further information is required Thermo King Corporation should be consulted Sale of product shown in the 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 been so repaired or altered outside the m...

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 regulations concerning the use of refriger ants and the certification of technicians For addi tional information on regulations and technician certification programs contact your local THERMO KING dealer ...

Page 4: ......

Page 5: ... SENTRY Equipped Units 21 After Start Inspection 22 Pre Load Operation 23 Loading Procedure 23 Post Load Procedure 23 Post Trip Checks 23 Electronic Controls 25 SR Control Panel 25 Control Panel switches 25 On Off Switch 25 Preheat Start Switch 25 Manual Defrost Switch 26 Unit Controls 26 uP IV Microprocessor Display 26 Microprocessor Keypad 28 Select Key Prompts and Displays 29 uP IV Microprocess...

Page 6: ...rost System 45 Defrost Components 45 Air Switch Testing and Adjustment 47 Oil level switch 48 Switch Removal and Installation 48 Bench Test 48 Sensor Tests 49 Sensor Replacement 50 Return Air Sensor 50 Discharge Air Sensor 50 Coil Temperature Sensor 50 Engine Maintenance 51 Engine Lubrication System 51 Engine Oil Change 52 Oil Filter Change 52 Engine Cooling System 52 Antifreeze Maintenance Proced...

Page 7: ...ystem TF Only 79 Thermax V Operation 79 Refrigeration Service Operations 81 Condenser Coil 81 Discharge Vibrasorber 82 In line Condenser Check Valve 82 Condenser Check Valve Replacement 82 Bypass Check Valve 83 Receiver Tank 83 Filter Drier 84 Expansion Valve Assembly 84 Heat Exchanger 85 Evaporator Coil 85 Accumulator 86 Suction Vibrasorber 86 Three way Valve Repair 87 Three way Valve Condenser P...

Page 8: ... Fan Positioning 103 Evaporator Blower Alignment 104 Electrical Diagnosis 107 Condition 107 Possible Cause 107 Remedy 107 Fault Indication Diagnosis 111 Shutdown Alarms 111 Check Alarms 111 Stored Alarms 111 Alarm Code Legend 111 Alarm Code Diagnosis 111 Mechanical Diagnosis 121 Condition 121 Possible Cause 121 Remedy 121 Refrigeration Diagnosis 125 Symptom 125 Possible Causes 125 Refrigeration Cy...

Page 9: ...ir supply for example a bus or garage Refrigerant tends to displace air and can cause oxygen depletion resulting in suffocation and possible death 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 from the liquid state fluo rocarbon refr...

Page 10: ...ii ...

Page 11: ...st Valve Clearance 016 in 0 40 mm Valve Setting Temperature 70 F 21 C Fuel Injection Timing 02 in 0 5 mm at 14 BTDC timed on No 1 cylinder Engine Coolant Thermostat 180 F 82 C Coolant System Capacity 10 quarts 9 5 liters Radiator Cap Pressure 7 psi 48 kPa Drive Direct to compressor belts to fans alternator and water pump Thermo King synthetic oil is compatible with petroleum lubricants so there is...

Page 12: ...ic 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 AIR SWITCH SETTING 1 40 0 08 in 35 6 2 0 mm H2O ELECTRICAL CONTROL SYSTEM Voltage 12 5 Vdc Battery One group C31 12 volt battery Unit Fuse 4...

Page 13: ... gear reduction starter Test at 12 5 Vdc THERMOGUARD MICROPROCESSOR TEMPERATURE CONTROLLER Temperature Controller Type Electronic THERMOGUARD 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 DigitalTemp Display 40 to 99 9 F 40 to 40 C Internal Defrost Timer Temp Pulldown 4 hrs std can be set...

Page 14: ...4 ...

Page 15: ...an crankcase breather 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 engine mounts Change engine coolant Replace fuel filter replace water separator every 3000 hours Test fuel injection nozzles at least every 10000 hours ELECTRICAL Check ammeter for charge and discharge glow plug operati...

Page 16: ...d suction pressure STRUCTURAL Visually inspect unit for 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 evap...

Page 17: ...icroprocessor mounts inside a weather tight control box The LCD display and alarm light are clearly visible through a transparent door Opening the control box door provides quick access to the microprocessor keypad The keypad is used to control the operation of the microproces sor See the Operation and Diagnosis Manual TK 40893 for details The CYCLE SENTRY system and an integral defrost timer are ...

Page 18: ...rased from the microprocessor memory using the THERMOGUARD Data Pac Mini Pac portable microcomputer The microcomputer is connected to the Data Pac interface on the front of the control box A brief graphical or tabular report can then be printed on the Data Pac microprinter More detailed reports may be printed in either a graphical or tabular format on a high speed printer external to the portable ...

Page 19: ...nits that are equipped with modulation and have modula tion enabled use the following operating modes High Speed Cool Low Speed Cool Low Speed Modulated Cool Low Speed Modulated Heat Low Speed Heat High Speed Heat Defrost Defrost Defrost mode can be initiated by the manual defrost switch air switch or by the microprocessor defrost timer any time the evaporator coil temperature is below 7 2 C 45 F ...

Page 20: ...eavy Duty Dry Element Air Cleaner Inside Unit Frame THERMOGUARD uP IV Microprocessor Controller Defrost Timer Built into THERMOGUARD uP IV Fuel Filter with Water Separator Spin On Full Flow Bypass Dual Element Oil Filter Dealer Installed Synthetic Engine Oil Opt Compressor Oil Filter Opt CYCLE SENTRY System 37 Amp Alternator Refrigerant 404A Silicone Coolant Hoses Opt Fuel Heater Opt Frost Plug He...

Page 21: ...ngine Low Level Switch Evaporator High 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 Fuse in Microprocessor Power Circuit Microprocessor Relay Fuses Remote Indicator Light Fuses ...

Page 22: ...Unit Description Rev 6 98 12 Front View AEA1350 ...

Page 23: ...Unit Description Rev 6 98 13 Right Side Door Open AEA1351 ...

Page 24: ...Unit Description Rev 6 98 14 Left Side Doors Open AEA1352 ...

Page 25: ...en the engine is extremely cold 2 MANUAL DEFROST Switch Pressing this switch causes the unit to initiate a defrost cycle if the evapora tor coil temperature is below 7 C 45 F If the evapo rator coil temperature is above 7 C 45 F pressing this switch will not affect the operation of the unit 3 AIR SWITCH The air switch senses the air pressure difference between the evaporator coil inlet and outlet ...

Page 26: ...Operating Instructions Rev 6 98 16 Control Box Cover AEA1354 ...

Page 27: ...SENTRY Continuous Run switch while the unit is operating or the engine will stop Manual Start Continuous Run Operation With the selector switch in the CONTINUOUS position the unit will operate in its regular cooling and heating modes 1 Hold the Preheat Start switch in the PREHEAT posi tion for the required time 2 Place the On Off switch in the ON position 3 Hold the Preheat Start switch in the STA...

Page 28: ...Off switch in the ON position the unit may start at any time without warning NOTE A buzzer sounds when the unit is automatically preheating Fully charged batteries in good condition are essential for reliable unit operation This is especially true on CYCLE SENTRY units in cold weather UNIT INSTRUMENTS 1 AMMETER The ammeter is built into the micropro cessor It indicates the battery charge and disch...

Page 29: ...s below 18 C 0 F the suction pressure should be 34 90 kPa 5 13 psi UNIT PROTECTION DEVICES 1 FUSIBLE LINK Current Limiter The fusible link is located electrically between the 2 wire and the battery At a current draw of approximately 50 to 55 amps the fusible link will melt cutting all power to the unit 2 FUSES A number of fuses located on the relay board protect various circuits and components A 4...

Page 30: ... ENGINE OIL The engine oil level should be at the FULL mark with the dipstick NOT turned threaded into oil pan Never overfill 3 COOLANT The engine coolant must have antifreeze protection to 34 C 30 F Check and add coolant in the expansion tank CAUTION Do not remove expansion tank cap while coolant is hot 4 BATTERY The terminals must be clean and tight 5 BELTS The belts must be in good condition an...

Page 31: ... etc Non processed meat products unless pre cooled to rec ommended temperature Fresh flowers and foliage The above listings are not all inclusive Consult your grower or shipper if you have any questions about the operating mode selection of your type of load Continuous Run Operation With the selector switch in the Continuous Run position the CYCLE SENTRY unit will operate in its regular cooling an...

Page 32: ...Y symbol should appear 3 If the microprocessor calls for cooling or heating the cool or heat icon will appear and the glow plugs will automatically preheat 4 At the end of the preheat period the engine will begin cranking and should start and run The glow plugs remain energized during the cranking period NOTE If the engine fails to start the unit reset switch will open interrupting current to the ...

Page 33: ...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 the load DO NOT block the evaporator inlet or outlet 4 Products should be pre cooled before loading Thermo King units are designed to maintain loads at the temper ature at which they w...

Page 34: ...24 ...

Page 35: ...NEL The switches on the switch panel are used to turn the unit on and off select the operating modes and initiate a manual defrost cycle CONTROL PANEL SWITCHES On Off Switch The On Off switch is used to turn the unit on and off When the switch is in the OFF position the unit is shut down The switch should always be placed in the OFF position before servicing the unit When the switch is in the ON p...

Page 36: ... If CYCLE SENTRY is selected the unit will automatically start and stop as required to maintain the set point and keep the engine warm and battery charged UNIT CONTROLS Two sets of controls are used to operate a unit that is equipped with a THERMOGUARD uP IV microprocessor controller The switch panel contains the switches that con trol the basic operation of the unit The microprocessor con trol pa...

Page 37: ...Electronic Controls Rev 6 98 27 uP IV Microprocessor Display 1 Display 2 Mode Description 3 Icons AEA1356 3 1 2 ...

Page 38: ...ressure 4 WATER TEMPERATURE Pressing this key displays the diesel engine coolant temperature 5 AMPS KEY Pressing this key displays the amount of current flow to or from the unit battery 6 CLEAR KEY Pressing this key clears alarm codes shown on the display 7 CODE KEY Pressing this key displays any alarm codes that may be present 00 means no alarm codes are present 8 ENTER KEY Pressing this key load...

Page 39: ...tration is 35 F NOTE The icons show that the unit is in Diesel CYCLE SENTRY mode and is operating in high speed cool Return Air Temperature and Setpoint Changing The Setpoint To change the setpoint the standard display must be shown In the illustration the setpoint is 35 F 1 Press the UP or DOWN arrows on the keypad to select the new setpoint 2 When the desired setpoint appears in the display pres...

Page 40: ...NOTE Each display screen will be shown in the display for 10 seconds if no other key is pressed DIS A Discharge air temperature TPDF Temperature differential COIL Coil Temperature AMB T Ambient temperature SPR 1 Spare sensor 1 SPR 2 Spare sensor 2 BATV Battery voltage RPM Diesel engine rpm DEFI Defrost interval when not in range DEFN Defrost interval when in range DDUR Defrost duration MVST Modula...

Page 41: ...more than one alarm at a time NOTE Alarm codes are displayed in the order that they occurred with the most recent alarm appearing first NOTE If the condition that caused the alarm code has not been corrected the alarm code will continue to appear NOTE ALWAYS record ALL alarm codes that are present NOTE For additional information on alarm codes con sult the appropriate microprocessor manual Viewing...

Page 42: ...Electronic Controls Rev 6 98 32 SOFTWARE REVISION 04XX ALARMS AEA1358 ...

Page 43: ...Electronic Controls Rev 6 98 33 SOFTWARE REVISION 04XX ALARMS CONTINUED Cleared through guarded access only Note A dash before an alarm indicates it was generated during a pretrip AEA1359 ...

Page 44: ...LAYING THE SOFTWARE REVISION Turn the unit On Off switch to ON Press and hold the TK key logo key for at least 3 seconds The pretrip prompt screen PrETRIP will appear in the dis play Press the SELECT key as required to display REV and the software revision number will appear on the display OPERATING SERVICE TEST MODE NOTE Read and understand the Service Test Mode Notes and the Service Test Mode Fu...

Page 45: ...st mode as required If the CYCLE SENTRY Continuous switch is set to CYCLE SENTRY and the engine is running when entering service test mode it will remain running If the engine is not running it will automatically start after entering service test mode The hours oil press water temp amps SELECT CODE and CLEAR keys function normally when in service test mode The protection circuits such as low oil p...

Page 46: ...ew function and then pressing the ENTER key The unit will remain in any service test mode function for 15 minutes if no other test mode function is selected At the end of 15 minutes if no other test mode is selected the unit will shut down and record alarm code 54 service test shut down Pressing the up or down arrow keys allows the operator to continue to scroll forward or backward through the tes...

Page 47: ...and HSH The unit is forced to high speed heat mode The run relay heat output and high speed relay are energized The heat and high speed icons are ON Press the up arrow key again to display DEF Press ENTER to activate this mode The display will show tESt and DEF The unit is forced to defrost mode The run relay heat output and damper relay are energized The defrost icon is ON If the unit is not equi...

Page 48: ...and modulation icons are ON Press the up arrow key again to display MH0 5 Press ENTER to activate this mode The display will show tESt and MH0 5 The unit is forced to modulation heat mode modulation valve set for 50 modulation The run relay and heat output are energized The heat and modulation icons are ON Press the up arrow key again to display MH1 0 Press ENTER to activate this mode The display ...

Page 49: ...ulator failure CAUTION The F15 fuse must be removed from the relay board on units equipped with the Australian Bosch alternator The voltage regulator will be damaged 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 Therm...

Page 50: ...ould 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 alterna...

Page 51: ...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 52: ...Electrical Maintenance Rev 6 98 42 1 Check Point for 2A Amperage 2 Position for Full Fielding Jumper Full Field Test aea694 ...

Page 53: ...ion If the ammeter shows a discharge after start up check the alternator belt tension and all charg ing circuit connections including the battery GLOW PLUGS Glow plugs heat the combustion chamber to aid in quick starting The glow plugs are energized when the Preheat Start switch is held in the PREHEAT or START position or when the microprocessor initiates unit start up An open glow plug burned out...

Page 54: ...ch 1 Remove the 20A wire from the switch 2 The continuity tester should indicate a complete circuit between each terminal and ground 3 Start the engine The tester should show an open circuit between each terminal and ground NOTE The engine low oil pressure switch cannot be repaired It must be replaced THERMOGUARD µP IV MICROPROCESSOR CONTROLLER Refer to the appropriate THERMOGUARD Microprocessor C...

Page 55: ...tervals are every 4 hours when the trailer temperature is not in range and every 6 hours when the temperature is in range NOTE If the return air sensor temperature goes out of range during unit operation defrost cycles again are initi ated on the 4 hour interval Even if the return air sensor temperature returns to in range in just 2 3 minutes the next defrost cycle will be initiated based on the 4...

Page 56: ...TION Remove jumper wires from the unit after checking or testing unit components 3 EVAPORATOR COIL SENSOR If the evaporator coil sensor fails the alarm light will flash and the micropro cessor will not initiate a defrost cycle A faulty evapo rator coil sensor is reported on the fault indication readout display as code 02 evaporator coil sensor when the CODE key is depressed If the unit fails to de...

Page 57: ...e spastic sensing tubing from both sides of the air switch 2 Disconnect one wire at the switch terminal Connect a test light or continuity tester to the two terminals used on the switch 3 Connect the test equipment TK 204 442 and TK 204 494 to the hose fitting on the side of the air switch stamped BLACK Air Switch Test 4 Pressurize the hose until the continuity tester indicates a completed circuit...

Page 58: ... at the relay board 3 Check the oil level with the dipstick and make sure that it is between the low mark and the full mark Add oil if necessary 4 The switch should open and there should be no continu ity between the OLS and the 8F circuits with the oil level between the low mark and the full mark on the dipstick Bench test the oil level switch if there is continuity between the OLS and the 8F cir...

Page 59: ...open circuit indicates that the sensor has failed by becoming an open circuit A very low reading 9below 1 Vdc indicates that the sensor has failed by becoming a short circuit This is the normal polarity used on the sensor in the circuit With the black lead of the multimeter connected to the red wire of the sensor and the red lead of the multimeter con nected to the black wire of the sensor the vol...

Page 60: ...TP and RTN wires NOTE If the return air sensor is replaced the micropro cessor must be programmed to match the grade of the new sensor being installed The grade number is stamped on the new sensor Refer to Guarded Access for calibration procedures The sensor grade decal on the control box must also be remarked with the new return air sensor grade Discharge Air Sensor Access the discharge air senso...

Page 61: ...il filter The oil is forced through the oil filter into the main oil gallery The main oil gallery supplies oil to the main bearings camshaft and camshaft idler gear support Oil passes from the main bearings through drilled passages in the crankshaft to the connecting rod bearings The tap pets and cylinder walls are lubricated by oil thrown from connecting rod bearings as the crankshaft rotates Fro...

Page 62: ...fied temperature range All water cooled engines are shipped from the factory with a 50 permanent type antifreeze concentrate and 50 water mixture in the engine cooling system This provides the following 1 Prevents freezing down to 34 C 30 F 2 Retards rust and mineral scale that can cause engine overheating 3 Retards corrosion acid that can attack accumulator tanks water tubes radiators and core pl...

Page 63: ...f the coolant is dirty proceed with a b and c Otherwise go to 3 1 Radiator 4 Expansion Tank 2 Radiator Cap 5 Thermostat Housing 3 Coolant Level Sensor 6 Accumulator Tank AEA1361 1 4 5 6 CAUTION Avoid direct contact with hot cool ant a Run clear water into the radiator and allow it to drain out of the block until it is clear b Close the block drain and install a commercially available radiator and ...

Page 64: ...8 qt of coolant drains out If approxi mately 3 8 liters 4 qt of coolant seems to fill the cooling system after it has been drained air has been trapped in the block Bleed the air out of the block using the following procedure CAUTION IF YOU SUSPECT THAT AIR IS TRAPPED IN THE BLOCK DO NOT START THE ENGINE WITHOUT BLEEDING THE AIR OUT OF THE BLOCK NOTE If an engine runs with air trapped in the block...

Page 65: ...Engine Maintenance Rev 6 98 55 Engine Compartment 1 Air Cleaner 5 Starter 2 Throttle Solenoid 6 Flywheel Sensor 3 Alternator 7 Fuse Link 4 Oil Filter 1 2 3 4 5 6 AEA1362 7 ...

Page 66: ... the fuel system by allowing a certain amount of fuel to return to the tank Filtered fuel passes through a line from the outlet fitting on the filter base to the injection pump Fuel enters the injection pump and then a fuel supply pump Pressure in the injection pump is set by a relief valve located in the output of the fuel supply pump and a small drilled orifice in the outlet banjo bolt on the to...

Page 67: ...Engine Maintenance Rev 6 98 57 Engine Fuel System 1 Injection Line 6 Injection Pump 2 Injection Nozzle 7 Transfer Pump 3 Return Fuel Line 8 Hand Pump 4 Fuel Filter 9 Bleed Screw 5 Water Separator ...

Page 68: ...vered in the di 2 2 and se 2 2 Overhaul Manual TK 8009 Bleeding the Fuel System If the engine runs out of fuel repairs are made to the fuel system or if air gets into the system for any other reason the air must be bled out of the fuel system NOTE MAKE SURE the fuel tank vent is kept open If the vent becomes clogged a partial vacuum develops in the tank and this increases the tendency for air to e...

Page 69: ...res it When the stored water reaches the level of the bleed port it returns to the fuel tank through the fuel return hose Replace the water separator every 3 000 hours Replace the fuel filter every 1 500 hours If the engine does not come up to full speed or loses speed under full load conditions it may be caused by fuel starva tion The fuel line that goes from the outlet fitting on the fil ter bas...

Page 70: ...ead the retaining clips 2 Pull the separator or filter away from the base 3 Place the new separator or filter on the base and secure with the retaining clips 1 Retaining Clips 2 Filter Base 3 Fuel Filter 4 Water Separator Water Separator Fuel Filter Installation 1 2 3 4 AEA1365 ...

Page 71: ...oot 3 Control Rod 4 Injection Pump High Speed Adjustment 1 2 3 4 AEA1366 1 Pull the plunger out of the solenoid enough to loosen the jam nut Turn the plunger eye bolt clockwise to increase the speed and counterclockwise to decrease the speed NOTE An Allen wrench placed in the hex opening in the face of the plunger will keep the plunger from turning 2 Replace the control rod start the unit and chec...

Page 72: ...ine If the pump has not been removed only the last portion of the proce dure is used for timing Injection Pump Removal 1 Remove the fuel injection lines Cover all injection lines and fuel lines with plastic covers or tape The smallest amount of dirt can damage the fuel system 2 Remove inlet and outlet fuel lines from the transfer pump Cap all lines 3 Remove the high speed linkage 4 Remove the five...

Page 73: ...lywheel approximately 1 3 8 in 35 mm from the TC mark The injection timing mark has no identifi cation markings TC Mark on Flywheel The engine now has the No 1 cylinder at the fuel injec tion mark of its compression stroke 1 Access Cover 2 Pump Gear Access Hole 3 Cam Gear Access Hole Timing Marks 1 2 3 AEA1368 ...

Page 74: ...To check this 1 Timing Mark 1 AEA1369 rotate the engine back and forth no more than 13 mm 0 5 in The dial indicator should stay at zero Dial Indicator Installation 4 Rotate the engine forward clockwise from the front to the injection timing mark NOTE The injection timing mark is a line scribed in the flywheel approximately 35 mm 1 3 8 in from the TC mark The injection timing mark has no identifi c...

Page 75: ...learance will result in noisy valve operation and abnormal wear of the valves and rocker arms The intake and exhaust valves are adjusted with the valves closed 2 The valves are adjusted to 0 4 mm 0 016 in When the right gap is obtained MAKE SURE to tighten the lock nut while holding the adjusting screw in position Turn the engine using a wrench on the front crankshaft bolt Front Rear Cylinder No 1...

Page 76: ...he cam gear lines up with the pointer and the TC mark on the flywheel lines up with the pointer on the bellhousing Adjust both valves on the No 1 cylinder the intake valve on the No 2 cylinder and the exhaust valve on the No 3 cylinder c Turn the crankshaft one full turn clockwise from the front and align the TC mark This is TDC of the No 4 cylinder compression stroke Adjust the No 2 exhaust valve...

Page 77: ...engine and burned To prevent the crankcase from drawing into a deep vacuum fresh air is drawn into the engine through an air inlet mounted on the engine block Crankcase Breather System 1 Air Inlet 1 AEA1370 ENGINE AIR CLEANER Filter Dry Type A heavy duty dry air cleaner filters all of the air entering the engine Excessive restriction of the air intake system reduces the flow of air to the engine a...

Page 78: ...Engine Maintenance Rev 6 98 68 1 Air Cleaner 2 Intake Manifold 3 Air Restriction Indicator Dry Air Cleaner System 1 2 3 AEA1371 ...

Page 79: ... BELTS Belts should be regularly inspected during unit pre trip for wear scuffing or cracking Belt tension should also be checked during scheduled maintenance inspections Belts that are too loose will whip and belts that are too tight put too much strain on the belt fibers and bearings Using belt tension gauge P N 204 427 is the best method of checking belts for tightness Install the belt gauge in...

Page 80: ...nsion should read 72 on the belt tension gauge 1 Remove the lower belt guard 2 Loosen the lower idler assembly 3 To increase the belt tension pry upward on the idler pulley Hold the tension on the pulley and torque the bolt to 54 N m 40 ft lb NOTE Make sure to position the belt guide properly when tightening the lower idler 4 Install the lower belt guard Proper Belt Guide Position Fan Belt Replace...

Page 81: ...Engine Maintenance Rev 6 98 71 1 Engine Pulley 2 Lower Belt Guard 3 Lower Idler 4 Grille and Orifice Assembly 5 Belt Guide 6 Control Box Fan Belt Replacement 1 2 3 4 5 6 AEA1374 ...

Page 82: ...72 ...

Page 83: ...ser grille with a piece of cardboard to block condenser airfoil 8 Under these conditions the ball should be floating in the receiver tank sight glass Testing the Refrigerant Charge with a Loaded Trailer 1 Install a gauge manifold 2 Use the Service Test Mode to run the unit in high speed cool Refer to the appropriate Operation and Diagnosis Manual for specific information abut the Service Test Mode...

Page 84: ...iquid level is less than a full sight glass adjust by adding vapor through the suction service valve With the unit running in high speed cool add vapor until the ball is near the top of the sight glass Allow to stabilize 1 to 2 minutes NOTE When adding refrigerant maintain a dis charge pressure of at least 1896 kPa 275 psi 4 Repeat overcharge test Moisture Indicating Sight Glass The receiver tank ...

Page 85: ... C 50 F Run the unit through a complete defrost cycle After com pleting the defrost cycle run the unit on Cool for ten min utes Observe the oil level The oil should be 1 4 to 1 2 up in the sight glass If the box is empty you can run the unit on the heat cycle instead of the defrost cycle NOTE Use refrigeration compressor oil ONLY Polyol Ester type P N 203 413 is required for R 402B R 404A and R 13...

Page 86: ...uld be investigated first by checking the control cir cuit operation and secondly by HPCO switch replace ment THREE WAY VALVE CONDENSER PRESSURE BYPASS CHECK VALVE A three way valve condenser pressure bypass check valve is used in this unit This check valve controls the bypass flow of refrigerant gas between the condenser inlet line and the compressor discharge line The check valve is closed when ...

Page 87: ...d rise indicating the condenser pressure bypass check valve is properly releasing condenser pressure into the discharge tube and evaporator 10 Replace the cap on the condenser pressure bypass check valve NOTE Valve stem MUST be back seated during nor mal unit operation 11 Open the receiver tank return outlet valve remove the gauges and return the unit to normal operation MODULATION VALVE The modul...

Page 88: ... Mode with modula tion valve set for 100 modulation 2 3 4 5 6 1 1 Outlet 4 Inlet 2 Armature 5 Opening Spring 3 Electric Coil 6 Seats 3 Check the suction pressure while the unit is in modula tion The suction pressure should be 0 to 69 kPa 0 to 10 psi 4 Remove fuse F31 from the relay board The suction pressure should rise 69 to 138 kPa 10 to 20 psi If the suction pressure does not rise check the mod...

Page 89: ...G wire If the pressure in the low side rises the HG is opening If the pressure in the low side does not rise the HG is not opening Perform further diagnosis using the procedures in Diagnosing Thermo King Refrigeration Systems TK 5984 7 4 Reconnect the HGS and HGG wires to the main wire harness before returning the unit to service See the Refrigeration Service Operations chapter of this manual for ...

Page 90: ...80 ...

Page 91: ... the compressor should be measured so that the same amount of oil can be added before placing the 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 3 Install the service valves using new gaskets soaked in compressor oil Connect the high pressure cutout switch and the pilot solenoid valve line 4 Pr...

Page 92: ... 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 charge 2 Place a heat...

Page 93: ...found evacuate the system 4 Open the bypass service valve and place the unit in operation RECEIVER TANK Removal 1 Recover the refrigerant charge 2 Unsolder the condenser check valve line from the receiver tank Disconnect the filter drier inlet and the bypass check valve lines Remove the check valve from the receiver tank 3 Unbolt the mounting brackets and remove the receiver tank from the unit Ins...

Page 94: ...rs 3 Remove the feeler bulb from the clamp Note the posi tion of the feeler bulb on the suction line 4 Disconnect the equalizer line from the suction line 5 Disconnect the inlet liquid line and unsolder the distrib utor from the expansion valve 6 Remove the expansion valve mounting bolt and remove the expansion valve from the unit Installation 1 Install and bolt the expansion valve assembly in the...

Page 95: ...positive 2 Remove the rear panel from the evaporator housing 3 Disconnect and remove the sensors 4 Remove the feeler bulb from the suction line clamp Note the position of the feeler bulb on the suction line 5 Disconnect the distributor from the expansion valve 6 Unsolder the hot gas line and suction line from the evaporator coil 7 Remove the mounting bolts lift and remove the evapo rator coil from...

Page 96: ...erant leaks If no leaks are found evacuate the low side 5 Open the refrigeration valves and place the unit in oper ation Check the refrigerant charge and the compressor oil and add as required SUCTION VIBRASORBER Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Unsolder the suction hose from the suction service valve Unsolder the connection to the accumulator and r...

Page 97: ...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 Assembly Installation NOTE Three way valve Kit P N 60 156 is supplied to repair the three way valves After cleaning inspecting all parts reassemble the valve 1 Install the screen in the bot...

Page 98: ...ations Rev 6 98 88 Three way Valve 1 2 3 4 5 6 8 7 9 10 11 13 8 12 AEA1375 Three Way Valve 1 Cap 2 Check Valve Assembly 3 Top Cap 4 Spring 5 Piston 6 O ring 7 Teflon seal 8 Gasket 2 9 Clip 10 Seat 11 Stem 12 Screen 13 Bottom Cap ...

Page 99: ... Installation 1 Coat the O ring with compressor oil and install it on the check valve stem 2 Insert the spring into the hole in the check valve stem and then install the Teflon check valve on the other end of the spring with the hole in the valve towards the spring 3 Coat the entire assembly with compressor oil and install the assembly into the Teflon check valve seat in the three way valve CAUTIO...

Page 100: ...ischarge 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 wires 3 Pressurize the refrigeration system and test for leaks 4 If no leaks are found open the refrigeration service valves and place the unit in operation HIGH PRESSURE RELIEF VALVE Removal 1 Recover the refrigeran...

Page 101: ...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 compressor 8 O RING 17 CAP rubber 9 HOUSING Throttling Valve Assembly ...

Page 102: ...t free and remove the end cap 6 Note the number of shims next to the cap These can be reused 7 Remove the bellows 8 Inspect all the parts Piston and cap for wear scuff marks Body for stripped threads 1 Inspect Cap 2 Inspect Spring 3 Shims Bellows end cap for damage in the pilot hole NOTE The bellows is normally replaced 9 Clean the parts that will be reused Reassembly 1 Install the bellows with th...

Page 103: ...ked in compressor oil Bolt the throttling valve to the com 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 MODULATION VALVE Removal 1 Pump down the low side and equalize pressure to slightly positive 2 Remove the grille...

Page 104: ...contact with the suction line or operation will be faulty Wrap with insulating tape 9 Install the coil on the modulation valve and connect the wires 10 Install the fan module the fan belt and both idler pul leys Tighten the fan belt to the proper tension and install the grille 11 Open the refrigeration valves and place the unit in oper ation HOT GAS SOLENOID VALVE Removal 1 Recover the refrigerant...

Page 105: ... charge and compressor oil LIQUID LINE CHECK VALVE REPLACEMENT Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Remove the grille both idler pulleys the fan belt and the fan module 3 Unsolder the lines and remove the check valve NOTE Disassemble the valve before unsoldering Installation 1 Clean the tubes for soldering 2 Place the disassembled check valve in positio...

Page 106: ...valve in position and fasten it in place with the U bolt 2 Solder the inlet and outlet connections 3 Clean the suction line to a bright polished 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 4 Pressurize the low sid...

Page 107: ...t and Engine Mounting Bolts Washer Plate Installation UNIT INSPECTION During the unit pre trip inspections and during scheduled maintenance inspections check the unit for loose or broken wires or hardware compressor oil leaks or other physical damage which might affect unit performance and require repair or replacement of parts AEA1377 1 Thick Washer Plate 2 Standard Washer 3 Nyloc Hex Locking Nut...

Page 108: ...ible 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 scheduled maintenance inspections to be sure the lines remain open DEFROST DAMPER Check the defrost damper during scheduled maintenance inspections for shaft wear and to make sure that the damper blade seals properl...

Page 109: ... loosely install all of the mount bolts 2 Tighten the fan module mount bolts 3 Install the upper idler 4 Install the lower idler but do not tighten the idler 5 Install the fan belt adjust the belt to the proper tension and tighten the lower idler 6 Install the condenser orifice and frame loosely install the mount bolts and center the fan module in the orifice opening 7 Check the radial clearance b...

Page 110: ... Rev 6 98 100 Fan Module Assembly 1 2 3 4 5 6 7 8 9 1 Condenser Grille 2 Condenser Screen 3 Condenser Frame 4 Condenser Orifice 5 Condenser Fan 6 Fanshaft Assembly 7 Bulkhead 8 Evaporator Blower 9 Evap Inlet Orifice AEA1380 ...

Page 111: ... seals removed clean the housing and cap in clean solvent 5 Check the condition of the vent If it is loose or dam aged it must be repaired or replaced 6 After all the parts are cleaned inspect the bearings and bearing races for wear or damage 7 To replace the bearings first remove the roll pin that is in the center of the shaft 8 With the roll pin removed place a pipe over the shaft and drive one ...

Page 112: ... 6 98 102 Fanshaft Assembly 1 Seal 9 Plug 2 Retainer Cap 10 Seal 3 O ring 11 Plug 4 Bearing 12 Spacer 5 Shims 13 Roll Pin 6 Splash Guard 14 Key 7 Bearing 15 Shaft 8 Air Vent 16 Key 1 2 3 4 5 6 9 7 8 10 11 12 13 16 14 15 AEA1381 ...

Page 113: ...oz Check the condition of the O ring used on the plugs and replace if necessary Install top and side plugs Clean up any spill age 9 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 When installing the fan shaft assembly make sure that the vent is mounted facing up Condenser Fan Positio...

Page 114: ... the blower onto the fan shaft 2 Shim the inlet orifice to position it 198 1 1 3 mm 7 8 0 05 in from the bulkhead panel 3 Center the inlet orifice in the blower orifice Check the radial clearance with a 2 3 mm 0 09 in gauge wire and tighten the inlet orifice in position 4 Position the blower on the fan shaft so the blower over laps the inlet orifice by 2 5 to 3 8 mm 0 10 to 0 15 in Snug the blower...

Page 115: ... 5 6 7 AEA1383 Evaporator Blower Alignment 1 Bulkhead Panel 2 Check Clearance with 2 3 mm 0 09 in gauge wire 3 198 1 1 3 mm 7 8 0 05 in 4 Shim as needed 5 Blower to inlet orifice overlap 2 5 3 8 mm 0 10 0 15 in 6 Blower Assembly 7 Inlet Orifice ...

Page 116: ...106 ...

Page 117: ... circuit Faulty microprocessor Replace microprocessor Faulty relay logic board Replace relay logic board Start relay will not energize Defective K5 relay Remove and test K5 relay Fault in 8P circuit Test 8P circuit Fault in SRP circuit Test SRP circuit Faulty microprocessor Replace microprocessor Faulty relay logic board Replace relay logic board Starter will not engage K5 relay not energizing See...

Page 118: ...essor Replace microprocessor Defective relay logic board Replace relay logic board Damper door will not close Damper relay not energizing See Damper relay will not energize Faulty damper solenoid Test damper solenoid Fault in 29 circuit Test 29 circuit Fault in damper solenoid ground Test CH ground to solenoid Hot gas solenoid will not energize Fault in 8F circuit Test 8F circuit Fault in HGR circ...

Page 119: ...lty modulation valve coil Test modulation valve coil defective microprocessor Replace microprocessor Microprocessor Dead Fuse open Test fuse 12 Fault in 2P circuit Test 2P circuit Fault in CHP circuit Test CHP circuit Battery dead Test battery CONDITION POSSIBLE CAUSE REMEDY ...

Page 120: ...110 ...

Page 121: ...ndicated by a steady alarm symbol that is displayed for 30 seconds after the On Off switch is turned ON After 30 seconds the Stored Alarm will disappear from the display View and write down each fault code as it is displayed When all codes have been viewed and correct serviced or repaired press the CLEAR key to clear each alarm from the display Alarm Code Legend ST Stored Alarm CH Check Alarm SH S...

Page 122: ...replace microprocessor NOTE Control changes to return air sensor If both sen sors are faulty the unit will shut down 05 ST Ambient Air Sensor Possible cause open sensor lead Test procedure test for continuity Possible cause shorted sensor lead Test procedure test for ground Possible cause defective sensor Test procedure test sensor voltage Possible cause defective microprocessor Test procedure rep...

Page 123: ...ocedure Replace microprocessor 10 SH High Discharge Pressure Possible cause condenser fan belt broken or slipping Test procedure tighten or replace belt Possible cause dirty condenser coil Test procedure clean condenser coil 11 CH Unit Controlling On Discharge Air Possible cause faulty return air sensor Test procedure check return air sensor Possible cause defective microprocessor Test procedure r...

Page 124: ... engine oil Test procedure check engine oil level Possible cause engine reset tripped Test procedure push in engine reset button 21 CH Cooling Cycle Check Possible cause low on refrigerant Test procedure check refrigerant level Possible cause defective three way valve Test procedure check three way valve operation Possible cause defective pilot solenoid Test procedure check pilot solenoid operatio...

Page 125: ...ossible cause defective microprocessor Test procedure replace microprocessor 23 SH Cooling Cycle Fault Possible cause low on refrigerant Test procedure check refrigerant level Possible cause defective three way valve Test procedure check operation of three way valve Possible cause defective pilot solenoid Test procedure check pilot solenoid operation Possible cause defective K1 relay Test procedur...

Page 126: ...cessor 25 CH SH Alternator Check Possible cause loose or broken alternator belt Test procedure check tighten belt Possible cause faulty alternator Test procedure test alternator 26 CH Check Refrigeration Capacity Possible cause low on refrigerant Test procedure check refrigerant level Possible cause compressor inefficient Test procedure check compressor capacity Possible cause partial obstruction ...

Page 127: ...le cause low on refrigerant Test procedure check refrigerant level Possible cause defective three way valve Test procedure check operation of three way valve Possible cause defective pilot solenoid Test procedure check pilot solenoid operation Possible cause defective K1 relay Test procedure test K1 relay Possible cause compressor inefficient Test procedure check compressor capacity Possible cause...

Page 128: ...lay 36 SH Electric Motor Failed To Run Possible cause faulty electric motor Test procedure check motor 37 CH Check Engine Water Level Possible cause engine coolant level low Test procedure check coolant level 40 CH High Speed Circuit Possible cause defective K2 relay Test procedure test K2 relay Possible cause open 7DD and 7D circuit Test procedure check fuse Possible cause faulty throttle solenoi...

Page 129: ...vel Possible cause engine oil level low Test procedure check oil level 71 ST Maintenance Interval Hourmeter 4 Exceeds Set Limit Possible cause hourmeter 4 has exceeded its limit 72 ST Maintenance Interval Hourmeter 5 Exceeds Set Limit Possible cause hourmeter 5 has exceeded its limit 73 ST Maintenance Interval Hourmeter 6 Exceeds Set Limit Possible cause hourmeter 6 has exceeded its limit 74 SH uP...

Page 130: ...120 ...

Page 131: ...ck Remove glow plugs and turn engine slowly Starter motor turns but engine does not crank Starter clutch defective Replace Engine cranks but fails to start Fuel solenoid valve defective or stuck Replace Fuel injection pump defective Replace pump Glow plugs defective Replace defective glow plugs No fuel or wrong fuel Fill with proper fuel Fuel pump defective Replace pump Air in fuel system Bleed ai...

Page 132: ... dirty filters or air in system Delivery of fuel pump insufficient Repair pump Injection pump timing off Adjust timing Nozzles defective Repair or replace nozzles Compression low or unbalanced Overhaul engine Worn injection pump plungers delivery valve defective injection rate too low gum formations Repair or replace pump Engine speed too high Misadjusted high speed solenoid Adjust high speed sole...

Page 133: ...ooling system Cylinder head gasket leaks Replace cylinder head gasket Use correct gasket Faulty thermostat Check or replace thermostat Loose or worn water pump belt Replace belt Condenser shutters do not open Adjust shutters or check power element Oil pressure too low or drops suddenly Minimum oil pressure for a hot engine is 17 psi 107 kPa the setting on the low oil pressure switch Insufficient o...

Page 134: ... connections in electrical system Check all electrical connections and charging system Alternator defective Repair alternator Voltage regulator faulty Replace regulator Battery defective Replace battery Voltage regulator wire harness defective Replace wire harness Loose alternator belt Replace alternator belt ENGINE EMITS EXCESSIVE SMOKE WHITE SMOKE BLACK SMOKE BLUE SMOKE Fuel Is Not Burning Exces...

Page 135: ...Overcharge of refrigerant Shortage of refrigerant No refrigerant Air through condenser too hot ambient Air flow through condenser restricted Air through condenser too cold ambient Air in refrigerant 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 ...

Page 136: ...ation Suction pressure 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 pre...

Page 137: ...r Check Valve 9 High Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Dehydrator 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 Throttle Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Chec...

Page 138: ...essure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Dehydrator 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 Throttle Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Servi...

Page 139: ...nser Check Valve 9 High Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Dehydrator 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 Throttle Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass C...

Page 140: ... Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Dehydrator 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 Throttle Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Se...

Page 141: ...131 Schematic Diagram SBIII SII RMNII 30 SR MPIV ...

Page 142: ...132 Wiring Diagram SII SBIII RMN30 SR MPIV Page 1 of 4 ...

Page 143: ...133 Wiring Diagram SII SBIII RMN30 SR MPIV Page 2 of 4 ...

Page 144: ...134 Wiring Diagram SII SBIII RMN30 SR MPIV Page 3 of 4 ...

Page 145: ...135 Wiring Diagram SII SBIII RMN30 SR MPIV page 4 of 4 ...

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