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conditioning systems, building and contracting services, parts support and advanced controls
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TK 5XXXX-X-PL

TK 55635-1-MM

©2013 Ingersoll Rand Company
Printed in U.S.A.

314 West 90th Street
Minneapolis, MN 55420

Direct (952) 887-2200

Thermo King Corporate

Distributed by:

SB-210+

Additional text information

to be placed here

TK 5XXXX-X-PL

314 West 90th Street
Minneapolis, MN 55420

Direct (952) 887-2200

Thermo King Corporate

Distributed by:

T-680S, T-880S,

T-1080S Series

with SR-3

TK 55635-1-MM (Rev. 5, 11/16)

314 West 90th Street
Minneapolis, MN 55420

Direct (952) 887-2200

Thermo King Corporate

Maintenance Manual

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Summary of Contents for T-1080S

Page 1: ...X X PL TK 55635 1 MM 2013 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text information to be placed here TK 5XXXX X PL 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate SB 210 Additional text information to be placed here TK 5XXXX X PL Distributed by 31...

Page 2: ...T 680S T 880S T 1080S Series with SR 3 TK 55635 1 MM Rev 5 11 16 Copyright 2013 Thermo King Corp Minneapolis MN U S A Printed in U S A ...

Page 3: ...30 SR 902385 SYSTEM T 680S 50 SR 230 3 60 902386 SYSTEM T 680S 50 SR 460 3 60 902387 SYSTEM T 880S 30 SR 902388 SYSTEM T 880S 50 SR 230 3 60 902389 SYSTEM T 880S 50 SR 460 3 60 902391 SYSTEM T 1080S 30 SR 902392 SYSTEM T 1080S 50 SR 230 3 60 902393 SYSTEM T 1080S 50 SR 460 3 60 902394 For further information refer to T 680R T 880R T 1080R T 680S T 880S T 1080S with Standard Display Operator s Manu...

Page 4: ...ure 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 ...

Page 5: ...feedback will help improve our manuals The survey is accessible through any internet connected device with a web browser Scan the Quick Response QR code or click or type the web address http irco az1 qualtrics com SE SID SV_2octfSHoUJxsk6x to complete the survey ...

Page 6: ...ric Motor and Overload Relay 19 T 1080S Electric Motor and Overload Relay 19 Electric Heater Strips Optional 19 Standby Power Requirements 19 Maintenance Inspection Schedule 20 Unit Description 22 General Description 22 Design Features 22 Unit Options 23 Engine 23 ELC Extended Life Coolant 23 Clutch 23 Scroll Compressor 23 Standard HMI Control Panel 23 Mechanics HMI Control Panel 24 Premium HMI Co...

Page 7: ... Test 44 Starting a Pretrip Test 44 Pretrip Test Results 45 Display Brightness 45 Checking Truck HMI Control Panel Software Revision and Serial Number 46 Operating Instructions for Premium HMI Control Panel 47 SR 3 Truck Premium HMI Controller Description 47 Premium HMI Control Panel 47 Display 47 Keys 48 Hard Keys 48 Soft Keys 48 Turning the Unit On and Off 48 If More Than One Language is Enabled...

Page 8: ...Sensor 84 Engine Oil Change 84 Oil Filter Change 85 Engine Air Cleaner EMI 2000 85 Crankcase Breather System 86 Engine Cooling System 87 General Description 87 ELC Extended Life Coolant 89 Antifreeze Maintenance Procedures 89 Bleeding Air from the Cooling System for Units with Coolant Expansion Tank Only Ending 10 16 90 Bleeding Air from the Cooling System for Units with Coolant Expansion Tank and...

Page 9: ...se With R404A 129 Refrigerant Recovery 130 Refrigeration System Component Locations 131 Accumulator Replacement 133 Removal 133 Installation 133 Compressor Test 133 Compressor Replacement 133 Removal 133 Installation 133 Compressor Shaft Seal Change Procedure 136 Compressor Oil Filter Replacement 138 Compressor Oil Change 138 Compressor Temperature Sensor Testing 139 Compressor Temperature Sensor ...

Page 10: ...val 152 Installation 152 Liquid Injection Solenoid LIS Test 152 Liquid Injection Solenoid LIS Replacement 152 Removal 152 Installation 153 Purge Valve PV Test 153 Receiver Tank Pressure Check Valve Test 153 Receiver Tank Replacement 154 Removal 154 Installation 154 Solenoid Valve Replacement 154 Removal 154 Installation 154 Suction Pressure Transducer Testing 155 Suction Pressure Transducer Replac...

Page 11: ...mbly 166 Disassembly 166 Reassembly 168 Jackshaft Assembly 169 Disassembly 169 Reassembly 170 Mechanical Diagnosis 171 Electric Standby Optional Diagnosis 175 Refrigeration Diagnosis 177 Index 179 Wiring and Schematic Diagrams Index 182 ...

Page 12: ...letion resulting in suffocation and possible death DANGER Avoid engine operation in confined spaces and areas or circumstances where fumes from the engine could become trapped and cause serious injury or death WARNING Make sure your gauge manifold hoses are in good condition before using them Never let them come in contact with moving belts fans pulleys or hot surfaces Defective gauge equipment ca...

Page 13: ...or rotating components WARNING Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire CAUTION Do not connect other manufacturer s equipment or accessories to the Thermo King unit This could result in severe damage to equipment and void the warranty CAUTION Set all unit electrical controls to the OFF position before connecting batter...

Page 14: ...N Store refrigerant oil in an approved sealed container to avoid moisture contamination CAUTION Do not expose the refrigerant oil to the air any longer than necessary The oil will absorb moisture which results in much longer evacuation times and possible system contamination CAUTION Wipe up spills immediately Refrigerant oil can damage paints and rubber materials DANGER When servicing or repairing...

Page 15: ...autions Take precautions before electrically welding any portion of the unit or the vehicle to which it is attached Ensure that welding currents are not allowed to flow through the unit s electronic circuits Observe the following precautions when welding to avoid damaging electronic components If the microprocessor has a power switch turn it OFF before connecting or disconnecting the battery Disco...

Page 16: ...ontact local poison control center or physician First Aid Engine Coolant EYES Immediately flush with water for at least 15 minutes CALL A PHYSICIAN Wash skin with soap and water INGESTION Do not induce vomiting Immediately contact local poison control center or physician First Aid Electrical Shock Take IMMEDIATE action after a person has received an electrical shock Get quick medical assistance if...

Page 17: ...High Speed Operation 1625 25 rpm 2200 25 rpm Engine Oil Pressure 20 to 50 psig 138 to 345 kPa in low speed 40 to 60 psig 276 to 414 kPa 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 16 1 degrees BTDC Injection Nozzle Pressure 1784 to 1929 psig 12 300 to 13 30...

Page 18: ...ment 600 100 RPM Dynamic Torque 66 ft lb 89 5 N m minimum 1600 RPM Refrigeration System Compressor Model T 680S and T 880S T 1080S TK04 Scroll 4 HP TK06 Scroll 6 HP Refrigerant Charge T 680S and T 880S T 1080S 7 0 lb 3 2 kg R 404A 7 5 lb 3 4 kg R 404A Compressor Oil Charge 2 0 quarts 1 9 liters Compressor Oil Type Ester base P N 203 516 required for Scroll compressor Discharge Pressure Regulator V...

Page 19: ... F4 for units with Australian Bosch or Thermo King Alternators Install fuse F4 for units with Prestolite Alternator F10 When fuse F10 is installed in the right position the On Off keys on the HMI turn the unit on and off When fuse F10 is installed in the left position the unit will start and run without the HMI control panel Electrical Components Component Current Draw Amps at 12 5 Vdc Resistance ...

Page 20: ...c Motor and Overload Relay Voltage Phase Frequency Horsepower Kilowatts rpm Full Load amps Overload Relay Setting amps 230 3 50 10 0 7 5 1460 22 5 25 208 230 3 60 12 0 8 9 1765 28 8 32 400 3 50 10 0 7 5 1460 17 0 16 460 3 60 12 0 8 9 1765 14 4 16 Electric Heater Strips Optional Number 3 Watts 750 watts each Resistance 71 ohms each Standby Power Requirements Supply Circuit Breaker T 680S and T 880S...

Page 21: ...hever occurs first Dry air cleaner Replace air cleaner element at 2 000 hours or 1 year whichever occurs first Change EMI 2000 black fuel filter Change engine oil and oil filters hot Requires oil with API Rating CI 4 or better ACEA Rating E3 for Europe and EMI 2000 bypass oil filter Check restraining mount snubber pre load adjustment Drain water from fuel tank and check vent Check and adjust engin...

Page 22: ...ficiency Replace dehydrator and compressor oil filter every two 2 years Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts includes air ducts and bulkheads Inspect clutch for shoe and anchor bushing wear with a mirror Check bearings Inspect idlers fan shafts and jackshaft if so equipped for leakage and bearing wear Clean entire unit including c...

Page 23: ...as a self check feature that can be run before the daily distribution route to identify possible malfunctions The built in CYCLE SENTRY an exclusive Thermo King feature automatically starts and stops the unit according to temperature demands Design Features Microprocessor Controller SR 3 Truck Alarm Code Display Battery Voltage Display Continuous System Monitoring Coolant Temperature Display CYCLE...

Page 24: ...ameplate on the coolant expansion tank identifies units with ELC see Safety Decals and Locations The new engine coolant Texaco Extended Life Coolant is Red instead of the previous Green or Blue Green coolants NOTE The use of 50 50 pre mixed ELC is recommended to ensure that deionized water is being used If 100 full strength concentrate is used deionized or distilled water is recommended instead of...

Page 25: ...ls as a result of normal operation Periodically this frost must be melted to prevent a loss of cooling and airflow Defrost is accomplished by passing hot refrigerant gas through the evaporator coil thus melting the frost or ice Melted frost drains out of the unit onto the ground through the drain tubes The defrost damper closes during defrost to prevent warm air from entering the cargo area The op...

Page 26: ...oolant level and temperature are monitored by the base controller If the coolant temperature becomes too high or the level becomes too low an alarm will occur The engine must have antifreeze protection to 30 F 34 C Check and add coolant in the expansion tank as needed Engine Oil Dipstick Use the engine oil dipstick to check the engine oil level Receiver Tank Sight Glass The receiver tank sight gla...

Page 27: ...essor If the engine coolant temperature is too high the controller stops the unit and records an alarm Electric Motor Overload Relay Model 50 The overload relay protects the electric standby motor The overload relay opens the circuit from the contactor to the electric motor if the motor overloads for any reason and an alarm will occur The relay resets when the alarm code is cleared Fuses Sizes and...

Page 28: ...ain Components 2 4 6 3 5 7 1 8 AMA828 1 Engine Oil Dipstick on side of engine 5 Alternator 2 Engine 6 Scroll Compressor 3 Coolant Expansion Tank 7 Dehydrator Filter Drier 4 Electric Motor 8 On Off Switch Main Components in Figure 5 ...

Page 29: ...ssure based on the actual system pressure Electronic Throttling Valve ETV This is an electronic valve that the microprocessor uses to control the suction pressure to the compressor The ETV is a variable position valve operated by a stepper motor The ETV system also uses discharge and suction pressure transducers Condenser Check Valve This check valve prevents refrigerant from migrating from the re...

Page 30: ...lass 18 Evaporator Coil 4 Liquid Injection Solenoid LIS 19 Drain Pan Heater 5 High Pressure Cutout Switch HPCO 20 Suction Access Port 6 Discharge Strainer 21 Accumulator 7 Discharge Pressure Transducer 22 Electronic Throttling Valve ETV 8 Discharge Service Port 23 Suction Service Valve 9 Condenser Inlet Solenoid CIS 24 Suction Pressure Transducer 10 Condenser Coil 25 Discharge Pressure Regulator D...

Page 31: ...o the evaporator There liquid refrigerant absorbs heat as it evaporates into low pressure vapor The refrigerant returns to the compressor through the heat exchanger accumulator and ETV Solenoid and Check Valves 1 Condenser Inlet Solenoid CIS Open De energized 2 Liquid Injection Solenoid LIS Closed De energized but the microprocessor will open it if necessary to control compressor temperature 3 Con...

Page 32: ... open so most of the refrigerant flows from the condenser through the PV and the purge check valve to the accumulator Some of the refrigerant flows through the condenser check valve receiver tank drier heat exchanger expansion valve and evaporator to the accumulator From the accumulator the refrigerant returns to the compressor through the ETV Solenoid and Check Valves 1 Condenser Inlet Solenoid C...

Page 33: ...ator and ETV Some of the refrigerant flows through the receiver tank pressure check valve and forces any liquid refrigerant out of receiver tank through the drier heat exchanger and expansion valve to the evaporator From which it returns to the compressor through the heat exchanger accumulator and ETV Solenoid and Check Valves 1 Condenser Inlet Solenoid CIS Closed Energized 2 Liquid Injection Sole...

Page 34: ... the display The LED will light when that function is active A red indicator LED is located between the ON Key and OFF Key This indicator will glow if Alarm Code 91 Check Electric Ready Input occurs It will also glow if a 15 pin Thermo King data cable is connected to the serial port on the back of the controller DPD Controller Features Displays Box Temperature and Setpoint in Fahrenheit or Celsius...

Page 35: ...setpoint When this icon is present the upper display is showing the diesel engine run time When this icon is present the lower display is showing the electric motor run time if the unit equipped with optional ELECTRIC STANDBY When this Alarm Icon is present one or more alarm conditions have occurred If the display is not flashing any alarms are Check Alarms If the display is flashing on and off a ...

Page 36: ...ey to increase or decrease the display brightness Secondary Use When the unit is on pressing this key will return to the Standard Display of box temperature and setpoint POWER OFF Key Pressing the OFF Key will turn the unit off UP ARROW Key When the unit is turned on and the Standard Display is shown pressing the UP ARROW Key will increase the setpoint Secondary Use When alarms are being displayed...

Page 37: ...ycle will terminate automatically and the amber LED will turn off when the evaporator coil temperature is greater than 52 F 11 C To manually terminate a defrost cycle turn the unit off and back on PRETRIP TEST Key Pressing and holding the PRETRIP TEST Key for 5 seconds will initiate either a Full Pretrip Test or Engine Running Pretrip Test so long as no alarm conditions exist If the Alarm Icon is ...

Page 38: ...r in the lower display as shown in Figure 14 A Full Pretrip Test is initiated from this display by pressing and holding the Pretrip Key as shown later in this section Figure 14 Electric Motor Run Time Hours and Electric Icon When the unit is ready to run the Standard Display of box temperature and setpoint appears The box temperature and Box Temp Icon are shown in the upper display The setpoint an...

Page 39: ... Figure 20 Alarm Icon and Setpoint Notice that the setpoint has returned to the old setpoint of 35 F 1 6 C and the Alarm Icon has lighted indicating that Alarm Code 127 Setpoint Not Entered is set IMPORTANT If the setpoint is changed using the UP ARROW Key or DOWN ARROW Key the change must be confirmed by pressing the ENTER Key within 20 seconds of changing the setpoint If the ENTER Key is pressed...

Page 40: ... details The Diesel to Electric Auto Switch Enabled feature should be set YES on units equipped with the Standard Truck HMI Control panel Diesel to Electric Auto Switch Enabled set YES Default If this feature is set YES the unit will switch automatically from Diesel Mode to Electric Mode when standby power is connected and present Diesel to Electric Auto Switch Enabled set NO The Diesel to Electri...

Page 41: ...t off Press the Standard Truck HMI Control Panel ON Key again to clear Alarm Code 91 Check Electric Ready Input and turn the unit back on in Diesel Mode If the Standard Truck HMI Control Panel OFF Key is pressed when the display shown in Figure 25 is present the unit will turn off and the display will be blank To restart the unit in Diesel Mode proceed as follows Press the Standard Truck HMI Contr...

Page 42: ...w No further high speed operation is allowed until this feature is turned off or the High Speed Lockout Timer is exceeded IMPORTANT HIGH SPEED LOCKOUT TIMER If High Speed Lockout Mode is selected the High Speed Inhibit Timeout feature may be enabled to return the unit to normal operation after a set time period has expired This prevents unintended extended operation with high speed operation locke...

Page 43: ...s a Shutdown Alarm the Alarm Icon and the display will flash on and off and the unit will shut down Figure 30 Alarm Icon Displaying Alarm Codes Alarms are displayed by simultaneously pressing and holding the ON Key and PRETRIP TEST Key The alarm display will appear as shown below The upper display shown in Figure 31 indicates that Alarm Code 127 Setpoint Not Entered has been set The lower display ...

Page 44: ...a Pretrip Test if these features are enabled and the auto switch conditions occur Conditions where Pretrip Tests are not allowed Pretrip Tests are not allowed if any shutdown alarms are present Pretrip tests are allowed with some Check and Log alarms present Pretrip Test Sequence Pretrip tests proceed in the order shown below Full Pretrip Test Full Pretrip Tests include all of the tests shown belo...

Page 45: ...Test The Full Pretrip Test must be started with the unit not running Turn the unit on and clear all alarm codes Turn the unit off Turn the unit on and wait for the unit running time hourmeters to be shown on the display When the unit running time hourmeters are shown on the display press and hold the PRETRIP Key for 5 seconds Figure 35 Pretrip Test A flashing Pretrip LED indicates that the Pretrip...

Page 46: ... Pretrip Test will continue to run unless a Shutdown Alarm occurs The amber Pretrip Test LED will turn off at the completion of the test but the Alarm Icon will remain lit This indicates that one or more Check Alarm conditions occurred during the Pretrip Test More than one alarm may be present View and record the alarm s correct as necessary clear the alarm s and repeat the Pretrip Test Fail Pretr...

Page 47: ...ary To display the serial number and software revision press and hold the PRETRIP key for 5 seconds when the unit is turned off Figure 38 PRETRIP Key The serial number is shown at the top of the display and the software revision is shown at the bottom of the display The HMI Control Panel Serial Number shown in Figure 39 is 00212 The software revision shown below is Revision 2200 Figure 39 Software...

Page 48: ...eatures Displays Box Temperature and Setpoint in Fahrenheit or Celsius Displays Engine Running and Motor Running Hourmeters Changes Setpoint Indicates Alarm Condition Exists Displays and Clears Alarms Selects and Indicates CYCLE SENTRY or Continuous Mode Operation Selects and Indicates High Speed Lock Out Operation Initiates and Indicates a Defrost Cycle Initiates and Indicates a Pretrip Test Send...

Page 49: ... display will briefly show the Thermo King Logo and then the statement Configuring System Please Wait When the power up sequence is complete the display shows the Standard Display of box temperature and setpoint For more information see Turning the Unit On and Off later in this section This key is used to turn the unit off First the display will briefly show System is Powering Down Please Wait Pre...

Page 50: ... the NO key as shown in Figure 46 Figure 46 NO key The Language menu will appear as shown in Figure 47 Press the or keys to select the desired language When the desired language is shown press the YES key to confirm the choice Figure 47 YES Key The display will briefly show PROGRAMMING LANGUAGE PLEASE WAIT in the new language as shown in Figure 48 Figure 48 Programming Language The new language is...

Page 51: ...ature in Figure 55 is 35 8 F with a 35 F setpoint Figure 55 Standard Display The CYCLE SENTRY Icon in the upper right corner of the display shows that the unit is operating in CYCLE SENTRY Mode If the CYCLE SENTRY Icon is not present the unit is operating in Continuous Mode The down pointing arrow indicates that the unit is cooling If the unit was heating the arrow would be pointing upward Pressin...

Page 52: ...ng the or keys the change must be confirmed or rejected by pressing the YES or NO soft key within 10 seconds of changing the setpoint If the YES key is pressed the setpoint change made with the or key is accepted the setpoint changes and the display returns to the Standard Display If the NO key is pressed the setpoint change made with the or key is not accepted the setpoint is not changed and the ...

Page 53: ...paring to start the HMI control panel will display the motor start screen as shown in Figure 64 The preheat buzzer sounds for 20 seconds before the electric motor starts Figure 64 Motor Start Screen After the motor is running the display returns to the Standard Display of temperature and setpoint Figure 65 Standard Display of Temperature and Setpoint Switching from Diesel to Electric Units equippe...

Page 54: ...ill appear Figure 69 Prompt Screen after OFF and ON If YES is selected then the display will briefly show the screen in Figure 70 Then Diesel Mode operation will briefly be confirmed Figure 70 Display is YES is selected If unit operation is required the diesel engine will start as shown previously in STARTING THE DIESEL ENGINE Initiating a Manual Defrost Cycle Defrost cycles are usually initiated ...

Page 55: ...d the unit will return to normal operation with high speed operation allowed If this occurs the message HIGH SPEED LOCKOUT ACTIVE at the top of the display will disappear If necessary to return to High Speed Lockout Mode press the High Speed Lockout Key again The High Speed Lockout Key is a toggle If high speed is currently allowed then pressing the High Speed Lockout Key will disable high speed o...

Page 56: ...tates will appear dependent upon unit type and configuration Coolant Temperature Displays the temperature of the engine coolant Coolant Level Displays the coolant level in the overflow tank as OK or LOW Oil Pressure Displays the engine oil pressure as OK or LOW Oil Level Displays the engine oil level as OK or LOW Amps Displays the current flow in amps to or from the unit battery Battery Voltage Di...

Page 57: ...ator coil sensor Ambient Air Temperature Displays the temperature of the ambient air sensor Data Logger Sensor 1 Temperature Display the temperature of Data Logger Sensor 1 Data Logger Sensor 2 Temperature Display the temperature of Data Logger Sensor 2 Data Logger Sensor 3 Temperature Display the temperature of Data Logger Sensor 3 Data Logger Sensor 4 Temperature Display the temperature of Data ...

Page 58: ...erator is prompted to clear the alarm s ELECTRIC STANDBY If the Electric Standby option is present and the Diesel to Electric Auto switch feature is set NO this feature allows the operator to manually select electric mode operation This feature does not appear if the unit does not feature optional Electric Standby or if the Diesel to Electric Auto switch feature is set YES DIESEL MODE If a unit eq...

Page 59: ...ppear in the new language as shown in Figure 88 The unit is ready to run Figure 88 Standard Display in New Language Repeat the process to select a different language To select a different Main Menu item press the NEXT key To return to the Standard Display press the EXIT key IMPORTANT If necessary English and all other languages in the installed HMI Control Panel software revision may be accessed f...

Page 60: ...e set if continued operation could cause damage to the unit or the load Shutdown Alarms are indicated by the following The Alarm Icon will appear in the display The display and backlight will flash on and off The display will switch from normal video to reverse video and back to normal video Light areas become dark and dark areas become light The remote indicator alarm light if installed will disp...

Page 61: ...at affects only electric mode operation and the unit is switched to diesel the electric mode shutdown alarm becomes a diesel mode log alarm to allow diesel mode operation If the unit is switched back to electric mode the alarm reverts to an electric mode shutdown alarm and prevents unit operation If the unit is configured for electric to diesel autoswitch it automatically starts and runs in diesel...

Page 62: ... alarms are present the quantity of alarms if more than one and the most recent alarm code number will be shown In the example in Figure 96 there are two alarms present The most recent is Alarm Code 5 Figure 97 It indicates a problem with the ambient temperature sensor Figure 96 Alarm Code 6 After the alarm situation is resolved press the CLEAR key to clear the alarm For additional information reg...

Page 63: ... The ServiceWatch Data Logger and DAS Data Logger if equipped are accessed using the Data Logger Menu From the Standard Display press the MENU key Figure 99 Menu Key The Language Menu or Alarm Menu will appear Press the NEXT key as required to display the Data Logger Menu When the Data Logger Menu is shown press the SELECT key Figure 100 Select Key The first feature that appears is the Start of Tr...

Page 64: ...r On Total hours the controller and HMI control panel have been turned on Pretrip Reminder User Programmable number of hours before a Pretrip Reminder occurs Engine Reminder 1 User Programmable The number of hours before an Engine Run Time Maintenance Reminder 1 occurs Engine Reminder 2 User Programmable The number of hours before an Engine Run Time Maintenance Reminder 2 occurs Electric Reminder ...

Page 65: ...e up to be specified Minute to Wake Up This feature allows the minute the unit is to wake up to be specified Run Pretrip on Wakeup This feature allows a Pretrip Test to be automatically run when the unit wakes up Mode changes are made using the Mode Menu From the Standard Display press the MENU key Figure 106 Menu Key The Language Menu or Alarm Menu will appear Press the NEXT key as required to sh...

Page 66: ...Sleep Mode Normal CYCLE SENTRY mode starts and stops the unit as required to maintain the desired setpoint temperature maintain the unit battery in a charged condition and keep the unit engine warm in cold ambient conditions Sleep mode does not consider setpoint or maintain cargo temperatures it only keeps the engine warm and the unit battery charged This is useful in extremely cold weather or whe...

Page 67: ...p mode does not consider setpoint or maintain cargo temperatures To exit Sleep Mode press the EXIT key or turn the unit off and back on The unit will resume normal operation and control to setpoint Figure 121 Sleep Mode Display To enter a Wake up Time verify the unit clock is set properly Then press the YES key at the Sleep Mode menu Figure 122 Yes Key The display will prompt the operator for the ...

Page 68: ...vice amp checks will be performed If the Pretrip Test is entered with the unit running in either diesel or electric mode a Running Pretrip Test is performed but the device amps checks are not performed Test results are reported as PASS CHECK or FAIL when the Pretrip Test is completed If an alarm occurs during a Pretrip Test the alarm code will be displayed as Pretrip Alarm XX where XX is the alarm...

Page 69: ... load temperature during the test as normal temperature control is suspended during a Pretrip Test Always perform Pretrip Tests with the truck or trailer cargo doors closed to prevent false test failures Performing a Pretrip Test If a Pretrip Test is initiated with the engine shut down a Full Pretrip Test will be performed If a Pretrip Test is initiated with the engine or motor running a Running P...

Page 70: ...he technician to the cause of the problem Figure 134 Pass Check or Fail If the Pretrip Test results are CHECK or FAIL the problem should be diagnosed and corrected before the unit is released for service Diesel Electric Menu The Diesel Mode Electric Standby menu allows the operator to manually select diesel or electric mode operation The unit can also be programmed to automatically select electric...

Page 71: ...R Soft Key will not clear these two alarms Then the prompt screen shown in Figure 138 will appear Figure 138 Prompt for Switch to Diesel If YES is selected then the display will briefly show the screen in Figure 139 Then Diesel Mode operation will briefly be confirmed Figure 139 Display when YES is selected If unit operation is required the diesel engine will start as shown previously in STARTING ...

Page 72: ...ew setting Time The system time and date is viewed using the Main Menu Time and Date cannot be changed from the Main Menu From the Standard Display press the MENU key Figure 144 Menu Key The Language Menu or Alarm Menu will appear Press the NEXT key as required to display the Time Menu When the Time Menu is shown press the SELECT key Figure 145 Select Key The current time and date will appear Figu...

Page 73: ...lt is not properly adjusted Be sure the belt is not loose or cracked and the pulleys are the correct size and in good condition The excitation circuit EXC circuit must supply voltage to the excite terminal of the alternator The sense circuit SENSE circuit must supply voltage to the sense terminal of the alternator The alternator must be properly grounded The unit control circuits or installed acce...

Page 74: ... alternator under load Thermo King recommends the use of a clamp on ammeter to monitor output current both on initial startup and under full unit load conditions For example on multi temp units all remote evaporators should be turned on General Diagnostic and Warranty Evaluation Procedure Complete the following diagnostic procedures before replacing an alternator or the voltage regulator 1 When te...

Page 75: ...us charge current to the unit battery typically 5 10 amps A reading on the clamp on ammeter at or near 0 amps indicates the alternator is not charging Checking the unit ammeter will show a discharge condition The alternator is defective if there are no problems in the wiring Recheck the wiring before assuming the alternator is defective 15 Check the voltage at the B terminal The voltage should inc...

Page 76: ...ing alternator by connecting a jumper wire between the F2 terminal and the B terminal Do not connect the F2 terminal to ground or the alternator will be damaged 3 Note the ammeter reading The ammeter reading indicates the field current which should be 2 0 to 6 0 amps at 12 volts No field current or a low field current indicates an open circuit or excessive resistance in the field circuit Remove th...

Page 77: ... F20 2A Alternator Sense F25 7 5A HPCO Run Circuit F26 5A Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators Install fuse F4 for units with Prestolite Alternator F10 There are three in line fuse clips that allow for two configurations of the F10 fuse The right position is the normal position This position has a white bar below it on the circuit ...

Page 78: ...e engine speed and precisely control the timing of the starter disengagement If the flywheel sensor fails the starter may not disengage or engage properly and a fault code will be generated Interface Board LED Functions LED Function LED 3 K2 Preheat Circuit LED 4 K4 Damper Circuit LED 5 K3 High Speed Circuit LED 6 K1 Run Relay Circuit LED 7 K5 Diesel Electric Relay LED 8 Condenser Inlet Solenoid C...

Page 79: ...re and the voltage may be lowered by turning the sensor out more 5 Reconnect the FS1 and FS2 wires to the sensor If the flywheel sensor passes the above test the sensor may be considered good If the engine will not start an alternate less reliable test may be performed as follows Disconnect the sensor from all wires and measure the resistance across the terminals and from each terminal to the alum...

Page 80: ...ng it from the circuit and checking it with an ohmmeter The resistance of each evaporator heater should be approximately 71 ohms Condenser Fan Rotation The condenser fan is belt driven On electric standby operation check for correct fan rotation by placing a small cloth or sheet of paper against the condenser fan grille on the front of the unit Correct rotation will hold the cloth or paper against...

Page 81: ...12 volt DC power to the phase select module CH Chassis ground Inputs Input Description L1 This Brown wire supplies standby power L1 to the phase select module L2 This Gray wire supplies standby power L2 to the phase select module L3 This Black wire supplies standby power L3 to the phase select module 7EA If 12 volts DC is supplied then output 7EB or 7EC will be at 12 volts DC SP If this wire is co...

Page 82: ... 2 Using a Fluke Meter test the L1 L2 and L3 circuits at the input to the terminals where the Brown Blue and Black wires are connected The voltage should be between 200 480 VAC between the circuits If not repair as necessary to supply the needed voltage to the unit 3 Check the 8 circuit to the phase select module for 12 Vdc If voltage is not present check the phase select module connector and the ...

Page 83: ...ement When the overload relay is replaced the new overload relay must be set up to open at the correct amperage and reset automatically See the following procedure to set up a new overload relay 1 Open the clear plastic cover 2 Use a small screwdriver to set the opening amperage See Electric Motor and Overload Relay in the Specifications chapter for the correct overload relay setting 3 Use a small...

Page 84: ...as removed This sets the overload relay to reset automatically The new overload relay is now set up correctly Note which wires go to which terminals when removing the old overload relay so the wires are connected correctly when the new overload relay is installed 1 Switch Clicks into Place at Bottom of Slot Figure 156 Move Switch Down 1 ...

Page 85: ... or worn bearings Low oil pressure is not normally caused by a faulty oil pump The use of improper viscosity oil will also produce low oil pressure shutdowns Engine Oil Pressure Switch Sensor The engine oil pressure switch sensor is located on the filter head above the bypass oil filter Engine oil pressure should rise immediately on starting If engine oil pressure drops below 10 2 psig 69 14 kPa t...

Page 86: ... 4 Start the unit and check for leaks Engine Air Cleaner EMI 2000 The EMI 2000 air cleaner used with this unit is a dry element air cleaner The air cleaner filters all of the air entering the engine Excessive restriction of the air intake system affects horsepower fuel consumption and engine life Inspect the element at every oil change Replace the EMI 2000 air cleaner filter element at 2 000 hours...

Page 87: ...gets dirty and becomes more restrictive Remove the breather cover and the baffle plate and check to make sure nothing is plugged or damaged See the TK270 TK370 TK374F TK376 and TK380F Engine Overhaul Manual TK 53163 for the procedure to check the crankcase pressure If your readings are significantly more positive than 0 to 11 in 0 to 279 mm H2O of vacuum you may have excess blowby past the rings A...

Page 88: ...oolant temperature within the specified temperature range All water cooled engines are shipped from the factory with a mixture of 50 percent permanent type antifreeze concentrate and 50 percent water in the engine cooling system This provides the following 1 Prevents freezing down to 30 F 34 C 2 Retards rust and mineral scale that can cause engine overheating 3 Retards corrosion acid that can atta...

Page 89: ...5 Overflow Bottle 2 Coolant Level Switch 6 Coolant Temperature Sensor 3 Expansion Tank Cap 7 Radiator 4 Expansion Tank 8 Drain Cock Figure 162 Engine Cooling System Components for Units with Coolant Expansion Tank and Overflow Bottle Starting 10 16 ...

Page 90: ... regular basis is required to verify the condition of the antifreeze Inhibitors become worn out and must be replaced by changing the antifreeze Change green or blue green engine coolant every two years Change ELC red engine coolant every five years or 12 000 hours whichever occurs first Do not mix green or blue green engine coolant with ELC red engine coolant See ELC Extended Life Coolant for more...

Page 91: ...not add antifreeze and then add water to the unit This procedure may not give a true 50 50 mixture because the exact cooling system capacity may not always be known 8 Refill the radiator with the 50 50 mixture Bleeding Air from the Cooling System for Units with Coolant Expansion Tank Only Ending 10 16 Often when a self powered truck unit cooling system is refilled air is trapped in the engine bloc...

Page 92: ...uum is better If the vacuum is unsteady or sputtering continue to apply the vacuum until it becomes steady and then hold it for an additional 60 seconds 6 Isolate the cooling system from the vacuum pump with a shut off valve and check for vacuum decay an indication of cooling system leak Fix any leaks or connections before filling the system 7 Fully prime the coolant fill hose tube with coolant an...

Page 93: ...F 74 C it passes the test and there is no need to continue heating the engine or continuing to run the test If the cooling system pressure does not achieve full system pressure of 14 psig 97 kPa the system is not full and you should First check for cooling system leaks Next use the Spill Free Funnel Procedure to purge any air bubbles out of the system 13 When the system is completely cool replace ...

Page 94: ...m use a Spill Free Funnel This coolant fill tool can be procured locally We recommend the Lisle 24680 or similar tool Figure 172 Spill Free Funnel Tool a Attach a Spill Free Funnel assembly to the expansion tank as shown in the following images Figure 173 Attach Spill Free Funnel Tool 1 Bring coolant up to this level Figure 170 Fill Expansion Tank 1 Bleed Valve Figure 171 Open Bleed Valve 1 1 CAUT...

Page 95: ...ssure and exceed the desired 185F coolant temperature Figure 175 Cover Condenser Coil If Necessary e Squeeze the upper radiator hose closed and open to vary the flow of coolant through the radiator and help push air out of the radiator Be careful to keep hands rags or tools away from the water pump pulley and belt CAUTION The radiator tube is hot f As air escapes from the cooling system the coolan...

Page 96: ...ssure is at 14 psig or higher the system is full of coolant and all the trapped air has been removed Proceed to Step 9 otherwise continue to Step 8 8 If the pressure is below 14 psig the system still has air trapped Repeat the coolant fill process Steps 4 thru 7 until the pressure is above 15 psig 9 With the system completely cool remove the pressure test tool and replace the expansion cap 10 The ...

Page 97: ...heck the coolant level in the overflow bottle It should be above the Full Cold line If necessary add coolant to the overflow bottle During Service check the coolant level in the expansion tank It should be at the bottom of the filler neck Standard Fill Procedure 1 Visually inspect upper radiator hose to verify the engine side of the hose is higher than or level with the radiator inlet end of the h...

Page 98: ...ondenser to make sure the engine temperature gets above 162 F 72 C Check the engine temperature with the Gauges Menu screen on the premium HMI or with a laser thermometer This will ensure that the thermostat is open and any air trapped in the cylinder head will be purged by the water pump circulation 10 Check for bubbles coming from the bottom of the dip tube in the overflow bottle If bubbles pass...

Page 99: ...the coolant level is above the switch and check the continuity of the switch The switch should be closed If you removed the switch from the tank do this check with the float in the upper position 4 Drain coolant from the expansion tank until the coolant level is well below the switch and check continuity of the switch The switch should be open If you removed the switch from the tank do this check ...

Page 100: ...ith the tank upside down 4 Drain coolant from the expansion tank until the coolant level is well below the switch level and check continuity of the switch The switch should be open If you removed the tank from the unit do this check with the tank right side up 5 Replace the switch if it is does not close in step 3 and does not open in step 4 Checking the Float The float is made of polypropylene fo...

Page 101: ...nough that the fuel must be clean fuel tanks must be free from contaminants and the fuel filter must be changed regularly Any time that the fuel system is opened up all possible precautions must be taken to keep dirt from entering the system This means all fuel lines should be capped when open The work should be done in a relatively clean area if possible and the work should be completed in the sh...

Page 102: ...Engine Maintenance 101 Figure 182 Fuel and Oil System Components ...

Page 103: ...21 Tee with restrictor 7 Nut 1 4 22 Switch oil pressure 8 Elbow hose fitting 1 4 23 Bushing 9 Hose 1 4 od 24 Valve Schrader 10 Tee 25 Pump fuel 12V 11 Tee with restrictor Kit filter 12 Elbow 45 degree Kit bowl gasket 13 Filter fuel EMI 2000 Gasket bowl to body 14 Adapter fuel pickup 26 Bracket fuel pump 15 Bracket fuel filter Screw bracket Screw Flatwasher Flatwasher Nut Nut 27 Tube fuel pickup Fu...

Page 104: ...l subsequently cause more expensive damage to the engine A large accumulation of water in the bottom of the fuel tank will stop a diesel engine Water should be drained off during scheduled maintenance inspections to prevent breakdowns Drain the water off after the fuel tank and unit have remained idle for an hour 1 Place a container under the fuel tank to catch the draining water and fuel 2 Remove...

Page 105: ...to the pump housing finger tight 2 Place the fuel filter bowl gasket in place and hand tighten or 100 in lb 11 3 N m the fuel filter bowl If the pump does not operate check for A good ground on the black wire pin of the pump harness More than 9 Vdc on the red wire pin of the pump harness Clean and tighten the electrical connections The pump voltage and polarity must be the same as the unit system ...

Page 106: ...ression stroke for the number one cylinder d 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 degrees to place the engine at top dead center of the compression stroke for the number one cylinder 5 Disconnect the 8S wire from the starter solenoid to prevent the engine from cranking when the unit is turned On 6 Ener...

Page 107: ...p mounting nuts and recheck the timing Repeat steps 7 through 12 until the timing is correct 13 Install the delivery valve spring for the number one cylinder by removing the delivery valve holder installing the delivery valve spring and then reinstalling the delivery valve holder 14 Install the injection line for the number one cylinder the cylinder head cover tighten the other injection lines and...

Page 108: ... gear case you will have to remove the gear case cover to realign the timing marks on the injection pump gear and the idler gear Injection Pump Installation 1 Place a new O ring on the injection pump and lubricate it with engine oil 2 Place the injection pump in the gear case Rotate the injection pump shaft to mate the key in the shaft with the keyway in the injection pump gear Take care to make s...

Page 109: ...n the end of the injection pump It contains two coils the pull in coil and the hold in coil The pull in coil draws approximately 35 to 45 amps at 12 volts The hold in coil draws approximately 0 5 amps at 12 volts The pull in coil must be momentarily energized to move the fuel rack to the on position Once the fuel rack has been moved to the on position the hold in coil will then hold the fuel rack ...

Page 110: ... operation The fuel solenoid must be energized when it is re installed in the injection pump If it is not the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly 5 If the fuel solenoid is not operating properly check the run relay K1 the fuel solenoid pull in relay K6 their fuses and the associated circuits If the relays fuses and circuits are accepta...

Page 111: ...is not in this range replace the fuel solenoid Fuel Solenoid Replacement 1 Disconnect the fuel solenoid wire connector from the main wire harness and remove the old fuel solenoid 2 Connect the new fuel solenoid wire connector to the main wire harness 3 Press the ON key to turn the unit on 4 Use the Mechanics Premium HMI Control Panel to enter the Interface Board Test Mode Refer to the appropriate ...

Page 112: ...d tighten both jam nuts 6 Recheck the engine speed Adjust Engine Valve Clearance The valve clearance should be checked after every 1 000 operating hours maximum It is important that valves be adjusted to the correct specifications for satisfactory engine operation Insufficient valve clearance will result in compression loss and misfiring of cylinders resulting in burned valves and seats Excessive ...

Page 113: ...ker arms on the number 1 cylinder to see if they are loose c If the rocker arms are loose the engine is at top dead center of the compression stroke for the number 1 cylinder d If the rocker arms are tight the engine is at top dead center of the exhaust stroke for the number 1 cylinder Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number 1 c...

Page 114: ... center of the compression stroke for the number 3 cylinder 8 Check and adjust both valves for the number 3 cylinder 9 Place the engine at top dead center of the compression stroke for the number 2 cylinder a Rotate the engine in the normal direction of rotation counterclockwise viewed from the flywheel end until the top dead center timing mark for the number 2 cylinder on the flywheel lines up wi...

Page 115: ...Engine Maintenance 114 Engine Mounts The engine mounting system contains three vibration mounts and a chain restraining mount snubber Figure 201 Engine Mounting Components ...

Page 116: ...e upper rear 9 Washer belleville 2 Bracket engine compressor side 10 Flatwasher 3 Bracket engine door side 11 Nut Screw plate bracket socket head 12 Chain 3 links Washer belleville 13 Bolt eye 1 2 in Sealer thread 14 Bracket snubber 4 Screw mount 15 Spacer spring 5 Washer special 16 Washer special 6 Mount vibration set of two 17 Nut 7 Nut 18 Plate bearing 8 Screw chain Rivet plate Engine Mounting ...

Page 117: ...10 Compressor Pulley 2 Clutch 11 Scroll Compressor 3 Engine Electric Motor Jackshaft Belt 12 Evaporator Fan Pulley Compressor Side 4 Evaporator Fan Pulley Engine Side 13 Electric Motor Jackshaft Pulley 5 Belt Tensioner Pulley 14 Alternator 6 Fan Shaft 15 Jackshaft 7 Evaporator Fans 16 Electric Motor 8 Alternator Pulley 17 Condenser Fan 9 Electric Motor Jackshaft Compressor Belt 18 Water Pump Belt ...

Page 118: ...nstall the new belt Make sure it fits on the pulleys correctly 7 Take a straight edge place it against the side of the muffler can and mark the frame as shown below This is the unloaded engine position Figure 204 Mark Frame 8 Turn the adjusting bolt clockwise to make the pulley descend and tighten the belt until it is at approximately 10 Hz lower than the correct belt tension setting using the fre...

Page 119: ... prevent tension from building up in the belt NOTE The washer on the restraining mount snubber should not go below the bracket side wall height If it does the restraining mount snubber will be over compressed 13 Check the belt tension frequency using the frequency gauge P N 204 1903 and adjust to the correct tension if necessary 14 Reinstall the electric motor jackshaft compressor belt if it was r...

Page 120: ...ng bolt until the top of the belt tension setting tool contacts the top of the alternator adjusting bracket 7 Tighten the alternator mounting bolt see Figure 209 8 Tighten the alternator pivot bolt Water Pump Belt The water pump pulley is a split type Adjust the tension by adding or removing shims between the pulley sheaves See Specifications for the correct water pump belt tension setting 1 Remov...

Page 121: ...he micron gauge will help determine a If the pump is capable of pulling a deep vacuum b When the vacuum pump oil is contaminated c If the vacuum hoses and valves are leak free d If the unit is leak free e How long you should evacuate the unit f That the unit is still in a deep vacuum before any lines are disconnected or refrigerant is added NOTE The attached evacuation procedures have been written...

Page 122: ...dures 121 2 4 5 3 1 6 8 9 10 AGA654 7 11 1 V 1 7 Iso Valve 2 V 2 8 To 110 Vac Power 3 V 3 9 Calibration Standard 4 V 4 10 Vacuum or Micron Gauge 5 Thermistor 11 Charging Port 6 Two Stage Vacuum Pump Figure 210 Evacuation Station ...

Page 123: ...2 500 Microns 3 1000 Microns 4 2500 Microns 5 5000 Microns 6 20 000 Microns 7 Atmospheric Pressure 8 Calibration Adjustment Screw 9 Example Meter needle shown at calibration position when Calibration Standard specifies 0 15 mm Hg Figure 211 Vacuum Gauge ...

Page 124: ...reached close valve V 1 to the pump Turn the vacuum pump Off 9 Observe the micron gauge reading The vacuum rise should not exceed 2000 microns in 5 minutes 10 If the rise is above 2000 microns in 5 minutes check all hoses and connections for leaks Hoses with moisture present will require additional evacuation time to achieve satisfactory results NOTE Dirty vacuum pump oil or a defective vacuum pum...

Page 125: ...Start the vacuum pump and open valves V 1 V 2 V 3 V 4 7 Evacuate the refrigeration system to 500 microns or the lowest achievable level between 500 and 1000 microns NOTE The presence of refrigerant in the compressor oil may prevent a low micron reading from being achieved The oil can continue to outgas for long periods of time If the micron level appears to stall after 1 2 hour or 45 minutes betwe...

Page 126: ...eiver tank outlet valve 5 If the unit is not fully charged attach the gauge manifold set to the suction service valve and the discharge service port and open the suction service valve one turn A low loss fitting must be used on the hose connected to the discharge service port 6 Open the refrigerant supply valve for liquid 7 Start the unit and use the Service Test mode to run the unit in high speed...

Page 127: ...or compressor shaft seals to have a slightly oily film Refrigerant Charge Testing the Refrigerant Charge with an Empty Box Controlled Check If the unit has an insufficient charge of refrigerant the evaporator will be starved and the box temperature will rise even though the unit is operating The suction pressure will drop as the refrigerant charge decreases The charge may be determined by inspecti...

Page 128: ...the box is empty you can run the unit on the Heat cycle instead of the Defrost cycle NOTE Use refrigeration compressor oil ONLY R 404A systems use a special Ester oil P N 203 516 Required for Scroll compressors Oil can be added to the compressor through the Schrader valve on the suction adapter while the unit is running Take precautions to prevent contaminants from entering the system while adding...

Page 129: ...idual component tests for more information 11 Back seat the suction service valve and then the receiver tank outlet valve Perform a Refrigerant Gauge Removal procedure Low Side Pump Down NOTE Operate the unit in cool for 2 to 5 minutes before performing the low side pump down 1 Attach a gauge manifold to the suction service valve and the discharge service port Attach another low pressure gauge to ...

Page 130: ...uld be added as the last step in system repair Rubber gloves are recommended when handling Polyol Ester because it may cause skin irritation Equipment Recommendations For Use With R404A Dedicated Equipment Vacuum Pumps When evacuating a two stage five to seven CFM pump is recommended It is also recommended that dry nitrogen be used first Ideally a new vacuum pump should be used and dedicated for u...

Page 131: ...d but extreme care should be taken to prevent contamination of the R404A systems with other refrigerants Purge manifold and hoses with dry nitrogen before using Never use equipment that may be contaminated with automotive type Polyalkylene Glycol PAG oils Refrigerant Recovery Systems used for the recovery of R404A should be dedicated to the recovery of this refrigerant Consult the manufacturer of ...

Page 132: ...frigeration System Component Locations The following drawings show the locations of various refrigeration system components Figure 219 Condenser Refrigeration Component Locations 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 21 22 23 24 ...

Page 133: ...harge Strainer 19 Condenser Check Valve 8 Discharge Pressure Transducer with ETV 20 Condenser Inlet Solenoid CIS 9 Discharge Service Port 21 Liquid Injection Solenoid LIS 10 Discharge Pressure Regulator DPR 22 Condenser Radiator Coil 11 Hot Gas Solenoid HGS 23 Purge Check Valve 12 Receiver Tank Pressure Check Valve 24 Accumulator Components for Condenser Refrigeration Component Locations on page 1...

Page 134: ... service port A low loss fitting must be used on the hose connected to the discharge service port 2 Run the unit in high speed cool until the system pressures stabilize 3 Note the discharge pressure on the high pressure gauge 4 Cover the condenser and check the discharge pressure The compressor should be able to increase the discharge pressure by at least 100 psig 689 kPa or to 375 psig 2586 kPa T...

Page 135: ...d line drier then evacuate the system 7 Replace the compressor electric motor belt and adjust the tension 8 Recharge the unit with the proper refrigerant 9 Operate the unit at least 30 minutes and then inspect the oil level in the compressor Add or remove oil if necessary 10 Check the refrigerant charge and add refrigerant if needed ...

Page 136: ...t lb 24 to 30 N m 10 Baffle 2 Pulley 11 Compressor Temperature Sensor 3 Shaft Seal Cover 12 Oil Drain Plug 4 Shaft Seal Assembly 13 Sight Glass 5 Oil Filter 14 Screen Cover 6 Oil Filter Spring 15 Screen 7 Oil Filter Cover Plate 16 Spring 8 Suction Adapter 17 Oil Drain Cap 9 Screen Figure 221 Compressor Components ...

Page 137: ... seal cover 8 Loosen the set screws that secure the bellows to the shaft These set screws typically use an 1 8 inch Allen wrench which is provided with the new seal 9 Remove the old bellows from the shaft Use a small prybar or screwdriver on each side of the bellows but do not scratch the shaft when removing the bellows Be careful not to lose the spacer that is on the shaft 10 Ensure the spacer is...

Page 138: ...substitute installation tool should have a diameter approximately the same size as the I D of the polished surface NOTE The following illustration shows the seal installation tool being used on a reciprocating compressor seal cover The same procedure applies to the scroll compressor seal cover 18 Remove the orange protective cap Clean the hard ring and the primary ring bronze ring with the alcohol...

Page 139: ...y positive 2 Clean oil drain cap area bottom and bottom rear of compressor of excess dirt 3 Remove oil drain plug from bottom rear of compressor to drain oil Measure amount of oil drained from compressor 4 Remove two screws and oil drain cap from compressor 5 Scrape gasket from oil drain cap and body 6 Remove spring screen and screen cover from body 7 Clean screen and cover 8 Replace screen cover ...

Page 140: ...n heat A unit with a leaking condenser check valve or purge check valve will have good heating capacity when it first goes into the heat mode But it will gradually lose heating capacity as refrigerant moves into the condenser This problem is more noticeable at lower ambient temperatures Use the following procedure to test the condenser check valve and the purge check valve 1 Attach a gauge manifol...

Page 141: ...st 1 Attach a gauge manifold to the suction service valve and the discharge service port Attach another low pressure gauge to the suction access port located in the suction line near the accumulator inlet Low loss fittings must be used on the hoses connected to the discharge service port and the suction access port 2 Operate the unit in low speed cool 3 Front seat the receiver tank outlet valve an...

Page 142: ...ent damage to the heat shrink tubing and brazed connections and the aluminum that attach the copper stub tubes to the aluminum micro channel coil The heat shrink tubing is used to prevent corrosion between the copper and aluminum 5 Unbolt and remove the condenser radiator coil Installation 1 Clean the tubes for soldering 2 Place the coil in the unit and install the mounting hardware 3 Solder the h...

Page 143: ...alve and the discharge service port A low loss fitting must be used on the hose connected to the discharge service port 2 Operate the unit in high speed heat until the system pressures stabilize 3 Check the discharge pressure on the gauge attached to the discharge service port It should be within the range shown for the DPR setting in the Specifications chapter If the setting is incorrect remove t...

Page 144: ...ts to run and will record Alarm Code 10 High Discharge Pressure This can also be caused by a faulty HPCO It can be difficult to determine whether the discharge strainer of the HPCO is causing this problem See the following procedure and guidelines 1 Connect a high pressure gauge to the discharge service port to monitor the discharge pressure 2 Start the unit while watching the discharge pressure I...

Page 145: ...ure to slightly positive Make sure to front seat the suction service valve to isolate the low side and use the suction access port to access the low side 2 The ETV must be open to remove the stepper motor and piston assembly Open the ETV by placing the unit in the Evacuation Mode Test and then turning the unit off Refer to the appropriate Microprocessor Diagnostic Manual for information about the ...

Page 146: ...erant begin to flow through the valve when the stepper motor and piston assembly are loosened unscrew the Old Style ETV stepper motor and piston assembly no more than four turns or unscrew the four screws on the New Style ETV stepper motor no more than four turns each and check the suction low side pressure on the gauge manifold If the suction pressure has increased from the pressure to which it w...

Page 147: ... to 18 mm from the bottom edge of the brass nut piston housing The piston retracts to open and extends to close 2 Old Style ETV Only a Lubricate the piston and threads on the new stepper motor and piston assembly with refrigeration oil b Screw the new stepper motor and piston assembly into the valve body c Torque the nut to approximately 118 ft lb 160 N m Hold the valve body with backup wrench to ...

Page 148: ...ston to be inserted into the piston nut 3 Push the piston into the piston nut until the end of the rectangular shaft is about even with the top of the piston nut 4 Make sure the copper washer is in place in the top of the piston nut 5 Place the threaded shaft of the stepper motor into the rectangular shaft of the piston and turn the piston and piston nut onto the threaded shaft of the stepper moto...

Page 149: ...aporator top panel 3 Unsolder the hot gas line and the line to the expansion valve from the distributor 4 Unsolder the suction line from the evaporator coil 5 Remove the mounting bolts and slide the coil from the evaporator housing Installation 1 Place the evaporator coil in the housing 2 Install and tighten the mounting bolts 3 Clean the tubes for soldering 4 Solder the suction line to the evapor...

Page 150: ...acement procedure should only be attempted by qualified technicians Removal 1 Recover the refrigerant charge 2 Remove the evaporator top panel 3 Remove the mounting hardware that holds the heat exchanger on the bulkhead 4 Unsolder the equalizer line from the suction line 5 Unsolder the liquid line to the expansion valve 6 Note the position of the feeler bulb on the side of the suction line Remove ...

Page 151: ...ig 3241 48 kPa the switch opens the HPCO circuit the to run relay and stops the unit To test the switch rework a gauge manifold per the following illustration 1 Connect the gauge manifold to the discharge service port with a heavy duty black jacketed thick wall HCA 144 hose with a 900 psig 6204 kPa working pressure rating 2 Set the thermostat well below the box temperature so that the unit will be...

Page 152: ...5 in Hg vacuum 0 to 17 kPa 4 Turn the unit Off 5 Front seat the suction service valve to isolate the low side while it is still in a vacuum 6 Watch the low pressure gauge attached to the suction access port The low side pressure should not rise It it does there could be a leak through one or more of following components hot gas solenoid liquid injection solenoid purge valve or receiver tank pressu...

Page 153: ... the unit Off 5 Monitor the suction pressure It will rise very slowly as the discharge pressure leaks back through the discharge device into the compressor If the suction pressure is rising steadily the LIS might be leaking 6 Check the temperatures of the refrigeration lines on each side of the LIS by hand A temperature difference between the two sides of the LIS indicates it is leaking 7 Use the ...

Page 154: ...f the PV by hand A temperature difference between the two sides of the PV indicates it is leaking 8 Use the Mechanics Premium HMI Control Panel to enter the Interface Board Test Mode Refer to the appropriate Microprocessor Diagnostic Manual for specific information about the Interface Board Test Mode 9 From the Interface Board Test Mode select Purge Valve 10 Momentarily for approximately 1 second ...

Page 155: ...ube lines up 2 Solder the inlet tube from condenser check valve tube to the receiver tank 3 Solder the filter drier line to the receiver tank outlet valve 4 Tighten the receiver tank mounting hardware securely 5 Pressurize the system and test for leaks 6 If no leaks are found replace the liquid line drier then evacuate the system 7 Recharge the unit with refrigerant and check the compressor oil So...

Page 156: ...ttached to the suction service valve port Refer to the appropriate Microprocessor Diagnostic Manual for more information about the testing and operation of the suction pressure transducer Suction Pressure Transducer Replacement Removal 1 Pump down the low side and equalize the pressure to slightly positive Make sure to front seat the suction service valve to isolate the low side 2 Disconnect the w...

Page 157: ...156 Clutch Maintenance Centrifugal Clutch The centrifugal clutch has three belt grooves and its engagement speed is 600 100 RPM Figure 243 Front View and Cross Section AGA127 ...

Page 158: ...ooves 1 Screw 10 Grease Seal 2 Washer 11 Roller Bearing Inner Race 3 Snap Ring 12 Pulley Housing 4 Ball Bearing 13 Elastic Stop Nuts 6 5 Large Small Spacers 14 Connector Link 6 6 Rolling Bearing 15 Spring 6 7 Lockwasher 12 16 Shoe Assembly 3 8 Bushing 6 17 Screws 6 9 Hub Figure 244 Centrifugal Clutch ...

Page 159: ...ollows 1 Check and adjust the Engine Electric Motor Belt Tension 2 Check and adjust the Electric Motor Compressor Belt Tension 3 Check and adjust the Engine Restraining Mount Snubber 4 Check the Condition of Belts They must be TK recommended or the equivalent and in good condition see Check Condition of Belts below 5 Check the Clutch see Check the Clutch below Check Condition of Belts 1 Check to m...

Page 160: ...p rate to protect against rust bonding If there is slip detected of more than 4 5 revolutions per minute it might be an indication that there is a problem starting depending on how fast the slip rate is If the unit can be run in electric mode Have the unit run in electric mode to see if the clutch turns over freely After a short run time in electric mode have them check the heat in the clutch If t...

Page 161: ...e retaining ring 2 Remove the 3 8 16 flat head cap screw and washer NOTE This screw was installed using Loctite see Tool Catalog and will require the use of an impact tool for removal NOTE A small amount of heat propane or acetylene torch with small heating tip applied to the cap screw head may be required to help loosen the screw 3 Remove housing from hub by supporting hub in a minimum of three p...

Page 162: ...in nut Thread nut onto screw approximately 3 4 to 1 in Insert threaded end of screw into bushing Lubricate bushing by dipping in clean water only Then press into place Figure 252 Bushing Insertion DO NOT USE SOAP OR OIL TO LUBRICATE BUSHING PRIOR TO ASSEMBLY 2 Remove the inner race from the roller bearing apply a small amount of Loctite see Tool Catalog to race I D and press onto the housing shaft...

Page 163: ... 6 N m NOTE Shoes MUST be held tightly against hub while nuts are tightened 14 Place the hub and shoe assembly into the housing and place flatwasher over the bearing 15 Apply Loctite see Tool Catalog to 3 8 16 x 1 in screw and install through washer into housing shaft The housing and hub will be drawn together to the proper relative position as the screw is tightened Tighten the screw to 30 to 35 ...

Page 164: ...s listed in order of recommended method Take a cloth or towel and wipe the air side of the coil going with the fins across the tubes Results shown in Figure 255 The coil will clean in a manner similar to the way lint cleans from the lint trap of a household clothes dryer Use a soft bristled brush DO NOT USE A WIRE BRUSH and brush the coil going with the fins across the tubes The coil will clean in...

Page 165: ... assembly in the orifice as follows for proper fan performance For the ten blade condenser fan position the fan with 50 percent of the blade width to the air discharge side NOTE One evaporator fan rotates clockwise CW and one evaporator fan rotates counterclockwise CCW on engine side of unit viewed from inside the box Figure 257 Fan Blade Position in Orifice for Ten Blade Fan ORIFICE AIR FLOW 50 P...

Page 166: ... be adjusted if necessary by adjusting the position of the eye bolt in the damper solenoid Check the damper during scheduled maintenance inspections for wear and sealing the air flow 1 2 3 5 4 6 2 1 1 Blade Pivots 4 Damper Solenoid 2 Springs 5 Damper Solenoid Rod 3 Plastic Damper Blade 6 Center Damper Blade Clamp Figure 258 Plastic Defrost Damper Blade Components ...

Page 167: ...oil seal and the evaporator end oil seal should be checked during the pretrip inspection for oil leakage If there is any sign of leakage the fanshaft assembly should be removed and repaired NOTE The fanshaft assembly requires a special lubricant P N 203 278 Disassembly 1 Remove the fanshaft assembly from the unit Remove both oil plugs and drain the oil from the housing 1 Blade Pivot Figure 259 Bla...

Page 168: ...ure 265 Removing Oil Seal 5 Check the condition of the vent If it is loose or damaged 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 Figure 266 Removing Roll Pin 8 With the roll pin removed place a pipe over the shaft and drive one bear...

Page 169: ...acing the bearing race Figure 268 Installing Splash Guard 3 Install a new oil seal after replacing the bearing race and splash guard NOTE Tape shaft holes or keyway to prevent seal damage Figure 269 Installing Oil Seal 4 Place the shaft in the housing Install a new seal in the retainer cap Use the original shims and replace the o ring if necessary NOTE Tape shaft holes or keyway to prevent seal da...

Page 170: ...s special sealed bearings The jackshaft bearings should be checked when the belts are replaced Spin the jackshaft with the belts removed and listen Unusually loud bearing noise indicates the jackshaft bearings should be replaced NOTE The jackshaft assembly can be disassembled and reassembled without removing the brackets from the ends of the housing Disassembly 1 Remove the jackshaft assembly from...

Page 171: ...e shaft and bearing in the housing from the belt side bracket end 4 Place the wave washer in the condenser side bracket end of the housing 5 Install the bearing on the small end of the shaft and in the condenser side bracket end of the housing 6 Install the snap ring on the small end of the shaft 7 Reinstall the jackshaft assembly in the unit CAUTION To prevent damage to the bearings use bearing d...

Page 172: ...ace No fuel or wrong fuel Fill with proper fuel Electric fuel pump not operating Check fuel pump is running and 8 to 10 psig 55 to 69 kPa Repair or replace fuel pump Air in fuel system Bleed air Compression low Overhaul engine Injection nozzles defective Replace nozzles Incorrect timing Adjust timing Air cleaner clogged Replace air filter Exhaust plugged Clean exhaust Engine stops after starting A...

Page 173: ...gasket leaking Replace gasket Compression low or unbalanced Overhaul engine Restricted exhaust system Clean or replace restricted parts Engine is sooting heavily emits thick black clouds of smoke excessive fuel to air ratio Wrong fuel Drain and refill with correct fuel Clogged air intake system Clean air cleaner Restricted exhaust system Clean or replace Opening pressure of nozzle is too low or ne...

Page 174: ...ure sensor Replace if necessary Worn oil pump camshaft main or connecting rod bearings loose oil gallery plug oil in water through crack Repair engine High oil consumption Oil leakage Check and eliminate possible causes Clogged air cleaner Clean air cleaner Damaged valve seals Replace seals on valve stem Worn valve stem or valve guides Replace valves and valve guides Broken piston rings or cylinde...

Page 175: ...connections in electrical system Check all electrical connections and charging system Worn brushes in alternator Repair Voltage regulator faulty Replace Battery defective Replace Alternator defective Repair or replace Dirty battery terminals Clean and retighten Condition Possible Cause Remedy ...

Page 176: ...ECTRIC Unit in NULL Check setpoint and box temperature Fuse F25 blown Check for short circuit and replace fuse Faulty HPCO Check HPCO Open or faulty overload relay Determine cause and reset or replace overload relay Faulty run relay K1 Check run relay K1 Faulty diesel electric relay K5 Check diesel electric relay K5 Faulty phase select module Check phase select module Faulty motor contactor Check ...

Page 177: ...shorts or excessive motor load current Low voltage Correct voltage condition Check momentary voltage dip during starting Foreign matter prevents contacts from closing Clean contacts Rapid cycling Check for cause of short cycling such as thermostat Short circuit Correct fault Battery is not recharging Loose alternator belt Tighten belt Loose connections in electrical system Check all electrical con...

Page 178: ...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 check valve leaking Scroll compressor seals leaking Too much compressor oil in system Faulty oil pump in compressor Loose compressor pulley Compre...

Page 179: ... Valve ETV Faulty Liquid Injection Solenoid LIS Faulty Purge Valve PV Faulty Condenser Check Valve Faulty Receiver Tank Pressure Check Valve Rapid cycling between Cool and Heat Unit cools in Heat and Defrost cycle Unit heats in Refrigeration Cool cycle High head pressure Low head pressure No head pressure High suction pressure Low suction pressure No suction pressure Unit operating in a vacuum Rec...

Page 180: ...em engine 87 crankcase breather system 86 D Defrost 24 defrost damper plastic 165 defrost mode 32 dehydrator filter drier 142 Design Features 22 diagnosis mechanical 171 diagnosis refrigeration 177 discharge pressure regulator DPR replacement 142 test 142 discharge pressure transducer replacement 143 testing 143 discharge strainer test 143 draining water from fuel tank 103 E ELC Extended Life Cool...

Page 181: ...se select module 79 Preheat Buzzer 26 purge check valve test 139 purge mode 31 purge valve PV test 153 R R 404A 3 R404A refrigerant 129 radiator coil 141 163 receiver tank replacement 154 receiver tank pressure check valve test 153 Receiver Tank Sight Glass 25 refrigerant charge 126 refrigerant gauge removal 126 refrigerant leaks 126 refrigeration diagnosis 177 refrigeration system checks 127 comp...

Page 182: ...Index 181 Unit Options 23 W wiring 79 wiring diagrams index 182 ...

Page 183: ...182 Wiring and Schematic Diagrams Index Dwg No Drawing Title Page 2E24812 Schematic Diagram 183 184 2E24811 Wiring Diagram 185 189 ...

Page 184: ...183 Schematic Diagram Page 1 of 2 RELEASED 06 Jul 2015 13 52 47 GMT 7 ...

Page 185: ...184 Schematic Diagram Page 2 of 2 RELEASED 06 Jul 2015 13 52 47 GMT 7 ...

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Page 191: ...X X PL TK 55635 1 MM 2013 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text information to be placed here TK 5XXXX X PL 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate SB 210 Additional text information to be placed here TK 5XXXX X PL Distributed by 31...

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