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Engine Maintenance

82

ELC (Extended Life Coolant)

ELC has been phased into these units as of the
first quarter of 2001. The maintenance interval for
ELC is 5 years or 12,000 hours. A nameplate on
the coolant expansion tank identifies units with
ELC.

NOTE: The new engine coolant, Texaco
Extended Life Coolant, is Red in color instead of
the current Green or Blue-Green colored
coolants.

Figure 35: ELC Nameplate—Located On Expansion

Tank

The following are the Extended Life Coolants
currently approved by Thermo King for use in
ELC units for five years or 12,000 hours:

•

Texaco ELC #16445 (nitrite free) 100%
concentrate.

•

Texaco ELC #16447 premixed 50/50%
concentrate.

•

Havoline Dex-Cool #7994 (nitrite free) 100%
concentrate, or #7997 (with nitrites) 100%
concentrate.

•

Havoline Dex-Cool #7995 (nitrite free)
premixed 50/50% concentrate.

•

Shell Dexcool #94040.

•

Shell Rotella #94041.

•

Havoline XLC #30379 (Europe) 100%
concentrate.

•

Havoline XLC #33013 (Europe) premixed
50/50% concentrate.

•

Saturn/General Motors Dex-Cool.

•

Caterpillar ELC.

•

Detroit Diesel POWERCOOL Plus.

NOTE: The use of 50/50% pre-mixed Extended
Life Coolant (ELC) is recommended to assure
that de-ionized water is being used. If 100% full
strength concentrate is used, de-ionized or
distilled water is recommended over tap water to
insure the integrity of the cooling system is
maintained.

ELC cannot be used in all older units. The water
pump seal bellows and o-rings used on older units
are not compatible with ELC.

To upgrade new production engines for ELC use,
all water pump seal bellows were changed from
NBR to HNBR elastomer, and the o-rings
upgraded from NBR to EPDM elastomer. These
changes were made as of TK 3.95 engine serial
number K19855.

Units with engine serial numbers K19855 and
after can be changed over to ELC coolant. The
cooling system must be flushed until all traces of
green or blue-green coolant dye are gone, and the
discharge fluid (water) is clear. The system can
then be filled with extended life coolant (ELC).

Units with engine serial numbers before K19855
must have the water pump replaced to change
over to ELC coolant. See Service Bulletin
T&T 275 for information about retrofitting the
new water pump.

CAUTION: NEVER add Red Extended
Life Coolants to cooling systems using
Green or Blue-Green coolants. NEVER
add Green or Blue-Green coolants to
cooling systems using Red Extended Life
Coolants.

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Содержание 920000

Страница 1: ...RD MT w TK 3 95 TK 51730 1 MM Rev 0 08 02 Copyright 1999 Thermo King Corp Minneapolis MN USA Printed in USA...

Страница 2: ...cturer is not responsible and will not be held liable in contract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles conten...

Страница 3: ...ormation on regulations and technician certification programs contact your local Thermo King dealer R 404A WARNING Use only Polyol Ester based refrigeration compressor oil in R 404A See Thermo King Pa...

Страница 4: ......

Страница 5: ...6 Unit Operation 27 Reading Mode of Operation Charts 28 Mode of Operation Charts 29 Zone 1 Cool and Zone 2 Cool 33 Zone 1 Cool and Zone 2 Heat 34 Operating Modes 35 Engine Continuous Run Two Compartme...

Страница 6: ...tor Defrost Cycle Diesel Operation 61 Zone 1 Evaporator Defrost Cycle Electric Operation 61 Zone 1 Evaporator Defrost Cycle Checkout Procedure 61 Zone 2 Evaporator Defrost Cycle Diesel Operation 63 Zo...

Страница 7: ...02 Refrigeration Maintenance 103 Refrigerant Charge 106 Testing the Refrigerant Charge with an Empty Truck 106 Testing the Refrigerant Charge with a Loaded Truck 106 Testing for an Overcharge 106 Adju...

Страница 8: ...alve RTPS 122 Removal 122 Installation 122 Purge Valve PV 123 Removal 123 Installation 123 Throttling Valve 123 Removal 123 Disassembly 123 Reassembly 124 Throttling Valve Installation 125 Compressor...

Страница 9: ...ator Refrigeration Service Operations 155 Expansion Valve Assembly 155 Removal 155 Installation 155 Evaporator Coil 155 Removal 155 Installation 155 Solenoid Valves 156 Removal 156 Installation 156 Li...

Страница 10: ...Table of Contents 10...

Страница 11: ...elay Board 70 Figure 25 Multi Temperature In Cab TG V Controller 71 Figure 26 Connecting Tester to Controller 72 Figure 27 Connector on Back of Multi Temperature In Cab TG V 73 Figure 28 Door Sentry I...

Страница 12: ...68 Inspect Pilot Hole for Damage 124 Figure 69 Throttling Valve Assembly 125 Figure 70 Compressor Oil Filter 126 Figure 71 Front View and Cross Section 127 Figure 72 Housing Removal 129 Figure 73 Bea...

Страница 13: ...uck body or garage Refrigerant tends to displace air and can cause oxygen depletion resulting in suffocation and possible death 12 When using ladder or scaffolding use caution and follow manufacturer...

Страница 14: ...e a small spark from a finger to a door knob can severely damage or destroy solid state integrated circuit components The following procedures must be rigidly adhered to when servicing units to avoid...

Страница 15: ...h is turned Off before connecting or disconnecting the standby power plug Never attempt to stop the unit by disconnecting the power plug 2 Be certain the unit power plug is clean and dry before connec...

Страница 16: ...spiration If a pulse is not present start CPR Cardiopulmonary Resuscitation and call for emergency medical assistance If a pulse is present respiration may be restored by using mouth to mouth resuscit...

Страница 17: ...86 F SAE 5W 30 Engine RPM Low Speed Operation High Speed Operation 1625 25 RPM 2425 25 RPM Engine Oil Pressure 35 to 60 psig 241 to 414 kPa Intake Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Exh...

Страница 18: ...eral Motors Dex Cool Caterpillar ELC Detroit Diesel POWERCOOL Plus Coolant System Capacity 4 quarts 3 8 liters with overflow tank Radiator Cap Pressure 10 psig 69 kPa Drive Belts to compressor fans 12...

Страница 19: ...200 7 psig 1379 48 kPa 160 7 psig 1103 48 kPa Electronic Defrost Termination Timer Opens Closes 52 F 11 C 42 F 6 C Timer Part of TG V Microprocessor Programmable 2 to 16 hours in 2 hour increments th...

Страница 20: ...tensioned cold and again tensioned cold after 10 hours of unit running Electrical Control System Control System Voltage 12 5 Vdc Control Circuit Fuse F1 2 Circuit 60 amps Main Circuit Breaker 50 amp...

Страница 21: ...Suction Line Solenoids 18 watts 1 44 8 68 Starter Motor 90 to 105 cranking Thermostat Type Solid state THERMOGUARD V Thermostat Range 20 to 80 F 29 to 27 C Heat Lockout Continuous Run Operation CYCLE...

Страница 22: ...Specifications 22...

Страница 23: ...ir cleaner element when indicator reaches 25 in Replace air cleaner element at 2 000 hours or 1 year whichever occurs first if air restriction indicator has not reached 25 in If not equipped with an a...

Страница 24: ...Check compressor efficiency and pump down refrigeration system Replace dehydrator and compressor oil filter Check discharge and suction pressures Structural Visually inspect unit for fluid leaks cool...

Страница 25: ...ure of each of the compartments can be controlled separately There are two RD MT models RD MT 30 Cooling and heating on diesel engine operation RD MT 50 Cooling and heating on diesel engine operation...

Страница 26: ...rmostat Provides temperature control from 20 to 80 F 28 to 28 C in 0 5 degree increments Defrost Control If the evaporator coil temperature is below 42 F 6 C Defrost is automatically initiated every 4...

Страница 27: ...hen energized The flow of refrigerant through the system is controlled by the solenoid valves and the check valves The solenoid circuits are switched by the thermostat and defrost relays The receiver...

Страница 28: ...C Normally Closed LLS Zone 1 Liquid Line Solenoid NC HGS Zone 1 Hot Gas Solenoid NC SLS Zone 1 Suction Line Solenoid NO F COOL Zone 1 Cool Lamp F HEAT Zone 1 Heat Lamp F DEF Zone 1 Defrost Lamp 1K Con...

Страница 29: ...D D D E E D E LSH LSH R HEAT E D D E D D F HEAT CLOSED OPEN ON OFF LOW E E D D D D E LSH LSH R HEAT E D D E D D F HEAT OPEN OPEN ON OFF LOW E E D D D D E LSH LSH R HEAT E E D D E D F HEAT OPEN CLOSED...

Страница 30: ...FF ON LOW D D D E E D E LSH LSH R HEAT E D D E D D F HEAT CLOSED OPEN ON OFF LOW E E D D D D E LSH LSH R HEAT E D D E D D F HEAT OPEN OPEN ON OFF LOW E E D D D D E LSH LSH R HEAT E E D D E D F HEAT OP...

Страница 31: ...E E D D E D F HEAT OPEN CLOSED OFF ON ON D D E E D D D HEAT COOL R COOL D D D E D D F COOL OPEN CLOSED OFF OFF OFF D D D E E D E COOL NULL R HEAT D D D D E E F COOL CLOSED OPEN ON OFF ON E D D D D D...

Страница 32: ...D D D E NULL NULL R HEAT E E D D E D F HEAT OPEN CLOSED OFF ON ON D D E E D D D HEAT COOL R COOL D D D E D D F COOL OPEN CLOSED OFF OFF OFF D D D E E D E COOL NULL R HEAT D D D D E E F COOL CLOSED OPE...

Страница 33: ...tor as it evaporates into low pressure vapor The refrigerant returns to the compressor through the RSLS the Zone 2 suction line the RSLCV and the accumulator Zone 1 Evaporator 1F Zone 1 Liquid Line So...

Страница 34: ...sor through the SLCV and the accumulator Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS Open 2F Zone 1 Liquid Return Check Valve LRCV Closed 3F Zone 1 Suction Line Check Valve SLCV Open 4F Zone...

Страница 35: ...Heat Defrost At setpoints below 15 F 9 4 C the Zone 2 evaporator operates in the following modes Cool Null Defrost 0 Setpoint 1 Temperature Drop 2 Temperature Rise 3 Cool Force Condensing Unit to Hig...

Страница 36: ...Zone 1 thermostat At setpoints below 15 F 9 4 C the Zone 2 evaporator operates in the following modes Cool Null Defrost 0 Setpoint 1 Temperature Drop 2 Temperature Rise 3 Cool Force Condensing Unit t...

Страница 37: ...e CYCLE SENTRY system automatically maintains engine temperature in cold weather conditions by restarting the unit if the engine block temperature drops below 30 F 1 C Once the unit is started it will...

Страница 38: ...initiated in ether compartment by pressing the appropriate Manual Defrost switch or automatically by an air switch or a defrost timer any time the corresponding evaporator coil temperature is below 4...

Страница 39: ...The Manual Defrost Switch allows the operator to initiate the Defrost cycle For more information see the Controls and Instruments portion of this manual At in range temperatures If the setpoint is at...

Страница 40: ...ilter Spin On Bypass Oil Filter Opt Opt Opt Spin On Fuel Filter EPDM Coolant Hoses Coolant Expansion Tank Hourmeter Engine Hours Hourmeter Electric Standby Hours Opt Opt Multi Temp In Cab TG V Control...

Страница 41: ...Unit Description 41 Unit Photographs Figure 12 Front View Figure 13 Top View ARD026 AGA267...

Страница 42: ...Unit Description 42 Figure 14 Engine Side Door Open ARD041...

Страница 43: ...Preheat Start Switch 2 Auto Start Stop Continuous Run Switch 7 Run Hourmeter Optional on Model 50 3 Stop Start Light Optional 8 Electric Operation Hourmeter Optional on Model 50 4 Engine Reset 9 Engi...

Страница 44: ...play Zone 1 7 UP Key 2 Temperature Display Zone 2 8 DOWN Key 3 Power Cord Indicator Light Model 50 9 ZONE 2 DEFROST Key 4 OFF Key 10 ZONE 1 DEFROST Key 5 ON Key 11 ENTER Key 6 SELECT Key 12 WHISPER MO...

Страница 45: ...frost initiated Engine block temperature drops below 30F 1 C Once started the engine will run until Microprocessor Controller demands are satisfied The block temperature reaches 90 F 32 C The Defrost...

Страница 46: ...n in operation This meter can be used to determine proper maintenance intervals TG V In Cab Controller for Multi Compartment Units The programmable TG V displays temperature and alarm conditions It al...

Страница 47: ...be displayed for about 10 seconds Make sure that all display segments are operational Standard display is set to Return Air Temperature at the factory Each controller can be programmed to show return...

Страница 48: ...es Engine Reset Switch A thermal type manual reset switch protects the engine The reset switch contains a heater coil that is attached to a sensor switch in the engine oil system engine coolant system...

Страница 49: ...ing suggested pretrip inspection should be performed before every trip involving refrigerated cargo Fuel The diesel fuel supply must be adequate to guarantee the operation of the engine to at least th...

Страница 50: ...wer receptacle On Off switch in the On position 2 Hold the Preheat Start switch in the Preheat position for the required time 3 Place the control box On Off switch in the On position 4 Press the ON ke...

Страница 51: ...it start ups may also be initiated by Defrost cycle initiation or engine block temperature switch demand If Defrost is initiated either manually or automatically by the defrost timer the unit will sta...

Страница 52: ...ing the thermostat setpoint does not make the unit cool faster 6 If a thermostat calls for Cool or Heat the glow plugs will automatically heat for the required amount of time depending on the engine t...

Страница 53: ...at the mode of operation changes with the change in setpoint Pre Cooling With the thermostats set at the required temperatures allow the unit to run for one half to one hour longer if possible before...

Страница 54: ...Operating Instructions 54 Post Trip Checks 1 Wash the unit 2 Check for leaks 3 Check for loose or missing hardware 4 Check for physical damage to the unit...

Страница 55: ...od condition and are adjusted properly before testing the alternator Worn belts and pulleys or loose belts will lower the output of the alternator The battery must be well charged the battery cable co...

Страница 56: ...nal and a chassis ground 12 Replace the CYCLE SENTRY module and connect the 20 wire to the engine reset switch 13 Start the unit and run it in high speed 14 Connect a jumper wire between the F2 termin...

Страница 57: ...circuit breaker tripping or the control circuit burning out Check each glow plug a shorted glow plug will have very low resistance Engine Reset Switch The engine is protected by a manual reset switch...

Страница 58: ...l and ground Repair consists of replacing the LOP Circuit Breakers Main Circuit Breaker This 50 amp auto reset circuit breaker protects 2A the main power circuit If the circuit breaker opens 1 Check f...

Страница 59: ...the electric motor Testing the Unloading Timer 1 Remove the CYCLE SENTRY module from the option board to prevent the Auto Start system from preheating and cranking the engine 2 Disconnect the 20 wire...

Страница 60: ...ck for a grounded 2 wire or for any of the conditions that would cause one of the circuit breakers to open Replace the defective circuit breaker and replace the fuse The fuse is located between the ba...

Страница 61: ...termines the mode of operation Zone 1 Evaporator Defrost Cycle Electric Operation The Defrost cycle on electric standby operation is similar to the Defrost cycle on diesel operation Zone 1 Evaporator...

Страница 62: ...l record alarm code 14 if the 11 circuit stays grounded and the Defrost termination on time limit is unsuccessful Zone 1 Evaporator Sticks In Defrost Indefinitely If the unit remains stuck in Defrost...

Страница 63: ...e MANUAL DEFROST key by the air switch or by the defrost timer in the TG V controller when the defrost termination switch is closed Initiating the Defrost cycle energizes the Zone 2 defrost relays RD...

Страница 64: ...between the defrost termination switch and the TG V controller If the 12 circuit is not open move to step 4 4 Check for an open in R11 circuit between the TG V Controller and the defrost relay If the...

Страница 65: ...ure for Multi Temperature In Cab TG V Controllers on page 72 Zone 2 Evaporator Continuously Fails to Terminate Defrost In Less than 45 Minutes If the unit continually fails to complete the Defrost cyc...

Страница 66: ...ads 2 Connect the negative lead of the switch to the negative battery terminal 3 Raise the temperature of the defrost termination switch above 52 F 11 C The light should be off indicating an open swit...

Страница 67: ...justment screw until the switch closes and the continuity tester indicates a completed circuit with the correct reading Release the pressure 6 Repeat the test procedure several times to be sure the se...

Страница 68: ...de of the evaporator coil goes on the hose fitting on the side of the air switch stamped BLACK The CLEAR hose from the low pressure or air outlet side of the evaporator coil goes on the hose fitting o...

Страница 69: ...are used as jumpers to configure the board for different applications If these jumpers are not in the correct positions the unit may not function properly The correct jumper positions for the unit are...

Страница 70: ...lays are located on the multi temp relay board The component locations are shown in the following illustration AEA623 1 Zone 2 Heat Cool Relay R1K 6 7X CH Fuse 2 Zone 2 Speed Relay R2K 7 Hot Gas Locko...

Страница 71: ...The operating manuals and the setup and operating manuals contain information about the control functions and how to customize the display screens Manuals for the Multi Temp In Cab TG V Controller Ope...

Страница 72: ...80 F 27 C to properly test the multi temperature controller NOTE The controller must be set to display temperatures in the Fahrenheit scale The test WILL NOT work if the controller is displaying tempe...

Страница 73: ...ion 11 PC WHT BLK VOIL Power Cord Electric Standby 12 R7T WHT BLK BLU Zone 2 Unit High Speed Latching Circuit 13 10T VIOLET Zone 1 Unit High Speed Relay 14 38 WHT BLK BRN Not Used 15 R12 WHT GRN Zone...

Страница 74: ...ermostat demand is satisfied When the Zone 2 unit thermostat is satisfied the condensing unit may shut down Opening Zone 2 Door Opening the Zone 2 door closes its door switch and grounds the control c...

Страница 75: ...ne 2 unit control circuits is interrupted Zone 1 unit ERC is disabled Zone 1 unit heats normally HS Cool Heat Damper solenoid energizes closes damper or stops fan motors LLS de energizes and closes Zo...

Страница 76: ...Electrical Maintenance 76...

Страница 77: ...If the filter element becomes clogged a bypass valve built into the oil filter allows the oil to bypass the filter element This keeps the engine components from being starved for oil if the filter ele...

Страница 78: ...lter 3 Tighten the filter until the rubber ring makes contact and then tighten it 1 2 turn more Crankcase Breather The crankcase breather system ducts crankcase gases formed in the crankcase directly...

Страница 79: ...lows the dirt to enter the engine Remove the oil cup wash thoroughly and dry every 1000 operating hours 500 hours under dusty conditions Refill using the same weight oil used in the engine crankcase I...

Страница 80: ...to assure the air filter is not restricted Service the air filter when the yellow diaphragm indicates 22 in 559 mm of vacuum Press the reset button on the bottom of the restriction indicator after se...

Страница 81: ...ins the coolant temperature within the specified temperature range All water cooled engines are shipped from the factory with a 50 permanent type antifreeze concentrate and 50 water mixture in the eng...

Страница 82: ...e Coolant ELC is recommended to assure that de ionized water is being used If 100 full strength concentrate is used de ionized or distilled water is recommended over tap water to insure the integrity...

Страница 83: ...is up to operating temperature Stop the unit 2 Open the engine block drain and accumulator tank drain and completely drain coolant Observe coolant color If the coolant is dirty proceed with a b and c...

Страница 84: ...aft The governor s speed requirements are relayed to the injection pump through a linkage arrangement located in the rear cover The injection pump raises the pressure of the fuel and meters the correc...

Страница 85: ...Engine Maintenance 85 AEA628 1 Fuel Injection Pump 3 Fuel Pickup Tube 2 Fuel Filter 4 Electric Fuel Pump Figure 38 Fuel System...

Страница 86: ...mp 3 Energize the electric fuel pump by placing the On Off switches in the On position and pressing the ON key Tighten the air bleed screw and press the OFF key when a clear flow of fuel appears NOTE...

Страница 87: ...in cleaning solvent and blow out the dirt and cleaning solvent with compressed air Check the cover gasket and replace if damaged Clean the cover Reassembly Place the cover gasket on the bottom cover...

Страница 88: ...l on position the hold in coil will keep it in fuel on position until the 8D circuit is de energized The pull in coil must be de energized after a few seconds to keep it from being damaged A fuel sole...

Страница 89: ...D The fuel solenoid relay is energized momentarily by the fuel solenoid timer when the 8D circuit is first energized After approximately 2 5 seconds the fuel solenoid timer de energizes the fuel solen...

Страница 90: ...o step 7 7 Check the CH circuit pin C in the main wire harness at the fuel solenoid connector for continuity to a good chassis ground a If there is no continuity between the CH circuit and a good chas...

Страница 91: ...ove the fuel solenoid relay from its socket and make sure the On Off switch is in the On position 13 Check the voltage on the 8D circuit at the 85 terminal in the fuel solenoid relay socket Refer to t...

Страница 92: ...gine fails to maintain the correct engine speeds check the following before adjusting the speed 1 Bleed air out of the fuel system Recheck the speed 2 Bleed air out of the nozzles Recheck the speed 3...

Страница 93: ...el injection lines and the fuel lines Remove the four nuts holding the pump to the timing cover and the fuel supply line 2 Remove the inspection plate on the side of the timing cover 3 Remove the clip...

Страница 94: ...cylinder timing is so minimal the procedure for timing the pump to the engine will be covered first The procedure for individual cylinder timing is very similar to timing the injection pump so it will...

Страница 95: ...did not line up a shim or shims will have to be added or subtracted from the injection pump Adding shims will retard the injection timing subtracting shims will advance the timing Increasing or decre...

Страница 96: ...rew The fuel limit screw and the maximum speed stop screw are both covered with anti tamper caps and are not adjustable Engine Valve Clearance Adjustment The valve clearance should be checked after th...

Страница 97: ...er is at top dead center of the compression stroke c If the rocker arms and push rods are tight the number 3 cylinder is at top dead center of the exhaust stroke Rotate the engine 360 degrees to place...

Страница 98: ...98 Engine Mounts The engine mounting system contains three vibration mounts and two snubber mounts Figure 51 Engine Mounting Components 0 20 Air Gap Between Lower Snubber and Engine Bracket When Assem...

Страница 99: ...99 9449 6 Engine Mount curbside 91 2278 Wear Plate Rivet 55 3044 7 Engine Mount upper 91 2279 17 Engine Screw 55 5888 Screw socket head 10 x 1 5 25 mm lg 55 5957 18 Belleville Washer 55 7122 Screw so...

Страница 100: ...t is at the proper tension Use one of the following methods to check or set the belt tension a The belt tension should be set at a reading of 70 3 on the Thermo King Belt Tension Gauge b The belt shou...

Страница 101: ...Engine Maintenance 101 AEA638 1 Engine Compressor Belt 3 Compressor Jackshaft Electric Motor Belt 2 Compressor Alternator Belt 4 Water Pump Belt Figure 53 Belt Arrangement...

Страница 102: ...bolt and the alternator bracket mounting bolts Compressor Electric Motor Belt Adjustment 1 Loosen the electric motor mounting bolts 2 Position the electric motor to obtain a tension of 67 3 on the The...

Страница 103: ...densables Always leave service valve caps on during evacuation and do not exercise the valve stems while the unit is in a deep vacuum Packing glands on older valves are prone to leak Never attempt eva...

Страница 104: ...eration Maintenance 104 1 2 3 4 5 6 7 8 9 AGA654 1 V 4 6 Two Stage Vacuum Pump 2 Thermistor 7 To 110 Vac Power 3 V 3 8 Calibration Standard 4 V 2 9 Vacuum or Micron Gauge 5 V 1 Figure 55 Evacuation St...

Страница 105: ...0 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 Stan...

Страница 106: ...d Truck 1 Install a gauge manifold 2 Run both evaporators in Cool 3 Build up and maintain a head pressure of 275 psi 1896 kPa If the pressure is below this it can be raised by covering the condenser g...

Страница 107: ...rant to flow into the compressor suction service valve f Control the liquid flow so the suction pressure increases approximately 20 psi 138 kPa g Maintain a discharge pressure of at least 275 psi 1896...

Страница 108: ...re for 15 minutes or more After the unit has maintained the above conditions for 15 minutes observe the oil level The oil should be 1 4 to 1 2 up in the sight glass To check compressor oil level with...

Страница 109: ...h evaporators run in Cool and the condensing unit runs in high speed 3 Raise the discharge pressure of the compressor first by blocking the condenser coil air flow by covering the condenser grille wit...

Страница 110: ...gized Set up and Test Evacuation Equipment NOTE The use of the Thermo King Evacuation Station P N 204 725 is recommended NOTE Do not attempt to evacuate the unit until the evacuation equipment has bee...

Страница 111: ...Refrigeration Maintenance 111 1 2 3 5 AEA647 4 1 Vacuum Gauge 4 Vacuum Valve 2 Thermistor 5 Back Seated 3 Isolation Valve Open Figure 60 Set up and Test Evacuation Equipment...

Страница 112: ...5 minutes between 1000 and 1500 microns back seat the suction service valve and observe the micron gauge A sharp drop in the micron reading 300 to 500 microns indicates that refrigerant is in the oil...

Страница 113: ...Refrigeration Maintenance 113 2 3 AEA647 4 1 1 Vacuum Gauge 3 Isolation Valve Leave Closed for First 5 Minutes of Evacuation 2 Thermistor 4 Vacuum Valve Figure 61 Unit Evacuation...

Страница 114: ...HGS wires and the RHGS wires to the relay board Connect the condenser inlet solenoid wires 2 pin connector to the main wire harness Connect the 20A wire to the low oil pressure switch Replace the CYC...

Страница 115: ...Refrigeration Maintenance 115 AEA647 2 3 1 5 4 1 Isolation Valve Closed 4 Scale 2 Vacuum Valve Closed 5 Refrigerant 3 Evacuate or Purge Figure 62 Unit Charging...

Страница 116: ...to 34 kPa Stop the unit Remove the hose from the suction service valve service port Immediately install the cap on the suction service port and tighten it 3 Back seat the suction service valve 4 Remo...

Страница 117: ...ng the high side and low side pressures a Disconnect the purge valve solenoid wires from the main wire harness b Remove the CYCLE SENTRY module from the option board to prevent the Auto Start system f...

Страница 118: ...gerant leaks 4 If no leaks are found evacuate the compressor Replace the belts and adjust the tensions 5 Back seat the suction and discharge service valves 6 Operate the unit at least 30 minutes and t...

Страница 119: ...sure 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...

Страница 120: ...ly Position the receiver tank so the sight glass is clearly visible and the outlet tube lines up with the drier line 2 Solder the inlet tube to the receiver tank 3 Solder the drier line to the receive...

Страница 121: ...body for damage or foreign particles which might adhere to the seat and damage the new seat If the body is damaged replace the check valve 2 Install the new seat and spring Place a new gasket on the c...

Страница 122: ...ration system and test for leaks 6 If no leaks are found evacuate the system 7 Recharge the unit with the proper refrigerant and check the compressor oil if pumped down open the refrigeration valves i...

Страница 123: ...ling Valve Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Front seat the discharge and suction service valves Release the remaining pressure 3 Remove the suction ser...

Страница 124: ...hole closest to the outlet opening of the valve housing 4 Install the piston spring and tighten the castle nut until it is firmly seated against the bottom of the piston 5 Back off the castle nut one...

Страница 125: ...k for leaks If no leaks are found evacuate the low side 4 Open the refrigeration valves and place the unit in operation AEA652 1 Screw mtg plate 9 Gasket piston housing 2 Plate bellows end 10 Piston 3...

Страница 126: ...th back up wrench on the hex behind the ORS fitting 4 Remove the clamp and the compressor oil filter 5 Coat the new O rings with clean compressor oil and place them in the ORS fittings on the ends of...

Страница 127: ...gal clutch P N 104 272 which supersedes P N 104 257 Centrifugal clutch P N 104 272 has three belt grooves and its engagement speed is 600 100 RPM When this clutch is installed on a unit equipped with...

Страница 128: ...3 belt grooves 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 Bea...

Страница 129: ...8 16 flat head cap screw and washer NOTE This screw was installed using Loctite 680 and will require the use of an impact tool for removal NOTE A small amount of heat propane or acetylene torch with...

Страница 130: ...3 Apply Loctite 270 to O D of oil seal then press seal in end of hub opposite the flange to a depth of approximately 1 16 in below the surface 4 Apply a small amount of Loctite 270 to O D of roller b...

Страница 131: ...s 41 to 48 m 1 Roller Bearing Pack with Mobil 28 Grease 2 Pack These Areas with Mobil 28 Grease at Assembly 3 HEX HD Cap Screw 6X 1 4 28 UNF X 1 75 Long Torque to 110 5 in lbs 12 5 0 6 N m NOTE Shoes...

Страница 132: ...Hilliard Clutch Maintenance 132...

Страница 133: ...flow Repair bent fins and any other noticeable damage Fan Location When mounting the fan and hub assembly on the shaft position the assembly in the orifice with 30 to 35 percent of the blade width to...

Страница 134: ...Structural Maintenance 134...

Страница 135: ...lace relay Corroded battery connections Clean and tighten Defective starter Repair starter Water in cylinders Check for hydrostatic lock Remove glow plugs and turn engine slowly Starter motor turns bu...

Страница 136: ...dirty filter or air in system Defective electric fuel pump Check fuel pump Injection pump timing off Adjust timing Nozzles defective Repair or replace nozzles Compression low or unbalanced Overhaul e...

Страница 137: ...Worn oil pump camshaft main or connecting rod bearings loose oil gallery plug Repair engine High oil consumption Oil leakage Check and eliminate possible causes at cylinder head cover oil lines oil f...

Страница 138: ...ning Excessive Fuel to Air Ratio Oil Consumption Air or water in fuel Incorrect timing Poor compression Faulty injectors Type of fuel used Cold engine Excessive load Clogged air intake system Faulty n...

Страница 139: ...SM Unit will not automatically preheat but run relay does energize Defective preheat relay Test or replace preheat relay Defective CSM Test or replace CSM Open H circuit from preheat relay to glow plu...

Страница 140: ...e CSM Replace CSM with known good one Do not rely on bench test of CSM Low battery voltage or condition Test battery Poor connection or excessive voltage drop from battery positive post to 7A circuit...

Страница 141: ...tactor hot side 4 Motor contactor load side contactor closed 5 Overload relay 6 Motor terminals Defective motor contactor Repair or replace motor contactor Defective low oil pressure switch Replace lo...

Страница 142: ...f current Check for grounds shorts or excessive motor load current Low voltage Correct voltage condition Check momentary voltage dip during starting Foreign matter prevents contacts from closing Clean...

Страница 143: ...vercharge 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 sy...

Страница 144: ...faulty Compound pressure gauge out of calibration Leaky receiver tank outlet valve Leaky check valve Faulty check valve Leaky receiver tank pressure solenoid RTPS Closed receiver tank pressure solenoi...

Страница 145: ...S Leaky Zone 2 liquid return check valve RLRCV Leaky Zone 2 suction line solenoid RSLS Leaky Zone 2 suction line check valve RSLCV Leaky purge valve PV Rapid cycling between Cool and Heat Unit cools i...

Страница 146: ...Refrigeration Diagnosis 146...

Страница 147: ...Vdc Spectrum Evaporator Fan Motor Horsepower 0 13 hp Fan Voltage 8 to 16 Vdc RPM 1900 Full Load Amps 8 7 amps per motor Fuse F1 1 F1 2 F2 1 F2 2 30 amp Remote Liquid Line Solenoid 15 watt Current Draw...

Страница 148: ...Remote Evaporator Specifications 148...

Страница 149: ...s Electrical Inspect wire harness for damaged wires or connections Inspect replace fan motor brushes Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken...

Страница 150: ...Remote Evaporator Maintenance Inspection Schedule 150...

Страница 151: ...ensor Ungraded 5 Discharge Return Air Sensor Graded 9 Terminal Board Bracket 2 Hot Gas Solenoid 6 Variable Blower 12 V 10 Terminal Board 3 Liquid Line Solenoid 7 Blower Housing 11 Terminal Board Marks...

Страница 152: ...Remote Evaporator Unit Description 152 Figure 80 Spectrum Evaporator Front View Figure 81 Spectrum Evaporator Back View AJA984 AJA985...

Страница 153: ...evaporator coil temperature is below 45 F 7 C Defrost is initiated automatically by the controller or manually by selecting the Manual Defrost The evaporator fan stops during Defrost The Defrost mode...

Страница 154: ...Remote Evaporator Unit Description 154...

Страница 155: ...Install the access panels 7 Open the refrigeration valves and place the unit in operation 8 Test the unit to see that the expansion valve is properly installed Evaporator Coil Removal 1 Remove refrige...

Страница 156: ...ne 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 th...

Страница 157: ...equire repair or replacement of parts Defrost Drains Clean the defrost drains during scheduled maintenance inspections to make sure the lines remain open Evaporator Coil Clean the evaporator coil duri...

Страница 158: ...Remote Evaporator Structural Maintenance 158...

Страница 159: ...Defrost or clean evaporator coil Expansion valve open too much Replace or adjust valve Poor fitting trailer door Repair or replace doors Liquid line solenoid partially closed or defective Repair or r...

Страница 160: ...Remote Evaporator System Diagnosis 160...

Страница 161: ...st system components 66 defrost termination switches 66 design features 40 Door Sentry II 74 drier 118 E ELC extended life coolant 82 electric fuel pump 87 electric operation 52 electric standby diagn...

Страница 162: ...47 evaporator coil 155 157 expansion valve assembly 155 liquid return check valve 156 maintenance inspection schedule 149 operating modes 153 refrigeration service operations 155 refrigeration system...

Страница 163: ...1E07391 MD RD MT Model 30 w In Cab CYCLE SENTRY Wiring Diagram 172 174 1E07778 MD RD MT Model 30 CYCLE SENTRY Wiring Diagram 175 177 1E05455 MD RD MT Model 50 w In Cab Schematic Diagram 178 179 1E0545...

Страница 164: ...Wiring and Schematic Diagrams Index 164...

Страница 165: ...165 MD RD MT Model 30 w In Cab Schematic Diagram Page 1 of 2...

Страница 166: ...166 MD RD MT Model 30 w In Cab Schematic Diagram Page 2 of 2...

Страница 167: ...167 MD RD MT Model 30 w In Cab Wiring Diagram Page 1 of 3...

Страница 168: ...168 MD RD MT Model 30 w In Cab Wiring Diagram Page 2 of 3...

Страница 169: ...169 MD RD MT Model 30 w In Cab Wiring Diagram Page 3 of 3...

Страница 170: ...170 MD RD MT Model 30 w In Cab CYCLE SENTRY Schematic Diagram Page 1 of 2...

Страница 171: ...171 MD RD MT Model 30 w In Cab CYCLE SENTRY Schematic Diagram Page 2 of 2...

Страница 172: ...172 MD RD MT Model 30 w In Cab CYCLE SENTRY Wiring Diagram Page 1 of 3...

Страница 173: ...173 MD RD MT Model 30 w In Cab CYCLE SENTRY Wiring Diagram Page 2 of 3...

Страница 174: ...174 MD RD MT Model 30 w In Cab CYCLE SENTRY Wiring Diagram Page 3 of 3...

Страница 175: ...175 MD RD MT Model 30 CYCLE SENTRY Wiring Diagram Page 1 of 3...

Страница 176: ...176 MD RD MT Model 30 CYCLE SENTRY Wiring Diagram Page 2 of 3...

Страница 177: ...177 MD RD MT Model 30 CYCLE SENTRY Wiring Diagram Page 3 of 3...

Страница 178: ...178 MD RD MT Model 50 w In Cab Schematic Diagram Page 1 of 2...

Страница 179: ...179 MD RD MT Model 50 w In Cab Schematic Diagram Page 2 of 2...

Страница 180: ...180 MD RD MT Model 50 w In Cab Wiring Diagram Page 1 of 3...

Страница 181: ...181 MD RD MT Model 50 w In Cab Wiring Diagram Page 2 of 3...

Страница 182: ...182 MD RD MT Model 50 w In Cab Wiring Diagram Page 3 of 3...

Страница 183: ...183 MD RD MT Model 50 w In Cab CYCLE SENTRY Schematic Diagram Page 1 of 2...

Страница 184: ...184 MD RD MT Model 50 w In Cab CYCLE SENTRY Schematic Diagram Page 2 of 2...

Страница 185: ...185 MD RD MT Model 50 w In Cab CYCLE SENTRY Wiring Diagram Page 1 of 3...

Страница 186: ...186 MD RD MT Model 50 w In Cab CYCLE SENTRY Wiring Diagram Page 2 of 3...

Страница 187: ...187 MD RD MT Model 50 w In Cab CYCLE SENTRY Wiring Diagram Page 3 of 3...

Страница 188: ...188 MD RD MT Model 50 CYCLE SENTRY Wiring Diagram Page 1 of 3...

Страница 189: ...189 MD RD MT Model 50 CYCLE SENTRY Wiring Diagram Page 2 of 3...

Страница 190: ...190 MD RD MT Model 50 CYCLE SENTRY Wiring Diagram Page 3 of 3...

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