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Electrical Maintenance

AUSTRALIAN BOSCH ALTERNATOR

NOTE: Units manufactured with CYCLE-SENTRY and

alternators with integral regulators MUST use replace-

ment alternators with integral regulators.

CAUTION: Full-fielding alternators with the

integral regulator is accomplished by installing a

jumper from terminal F2 to ground. Attempting to

full-field the alternator by applying battery voltage

to terminal F2 will cause voltage regulator failure.

CAUTION: The F15 fuse must be removed from the

relay board on units equipped with the Australian

Bosch alternator. The voltage regulator will be dam-

aged if the unit is turned ON with the F15 fuse in

place on the relay board.

Check Point for 2A Amperage

Check Point for Sense Circuit and

Excitation Circuit Voltages

Check Point for B+ Voltage

Position for Full Fielding Jumper

Содержание SB-190 30

Страница 2: ...on is required Thermo King Corporation should be consulted Sale of product shown in this manual is subject to Thermo King s terms and conditions including but not limited to the Thermo King Limited Ex...

Страница 3: ...o the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regula tions co...

Страница 4: ......

Страница 5: ...25 Unit Protection Devices 25 Unit Operation 25 Manual Pretrip Inspection Before Starting Unit 26 Starting Unit with Electronic Full Pretrip 26 Selection of Operating Modes 27 Restarting Unit Diesel O...

Страница 6: ...52 Belts 53 Model 30 Belt Adjustments 53 Model 30 Fan Belt Replacement 53 Refrigeration Maintenance 57 Refrigerant Charge 57 Refrigerant Leaks 59 Checking Compressor Oil 59 High Pressure Cutout Switch...

Страница 7: ...hange 80 Hot Gas Solenoid Valve Optional 81 Structural Maintenance 83 Unit and Engine Mounting Bolts 83 Unit Inspection 83 Condenser Evaporator and Radiator Coils 83 Defrost Drains 83 Unit installatio...

Страница 8: ......

Страница 9: ...ds to displace air and can cause oxygen depletion resulting in suffocation 11 EPA Section 608 Certification is needed to work on refrigeration systems REFRIGERANT Although fluorocarbon refrigerants ar...

Страница 10: ...lable The source of shock must be immediately removed by either shutting down the power or removing the victim from the source If it is not possible to shut off the power the wire should be cut with e...

Страница 11: ...0 30 to 30 C 22 to 86 F SAE 5W 30 Engine rpm Low Speed Operation 1425 to 1475 rpm High Speed Operation 2175 to 2225 rpm Engine Oil Pressure 276 to 448 kPa 40 to 65 psi 2 76 to 4 48 bar 2 814 to 4 568...

Страница 12: ...be noted or the oil removed from the compressor should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit ELECTRICAL CONTROL SYSTEM Voltage 1...

Страница 13: ...RT REEFER P VI MICROPROCESSOR TEMPERATURE CONTROLLER Temperature Controller Type Electronic THERMOGUARD P VI Microprocessor with digital thermostat thermometer and fault indicator monitor Setpoint Ran...

Страница 14: ...4...

Страница 15: ...ours Inspect Service These Items Engine Check fuel supply and engine oil level Inspect belts for condition and proper tension belt tension tool No 204 427 Check engine oil pressure hot on high speed s...

Страница 16: ...r from fuel tank and check vent Inspect clean fuel transfer pump inlet strainer pre filter Replace standard silver fuel filter water separator Replace EMI 3000 black fuel filter water separator Check...

Страница 17: ...00 oil filter and oil with API Rating CG 4 or better EMI 3000 filters are black with gold lettering Change green or blue green engine coolant every 2 years Change ELC red engine coolant every 5 years...

Страница 18: ...Check refrigerant level Check compressor oil level Check throttling valve regulating pressure on defrost Check compressor efficiency and pump down refrigeration system Replace dehydrator and check dis...

Страница 19: ...e microprocessor CYCLE SENTRY Start Stop Controls A CYCLE SENTRY Start Stop fuel saving system provides optimum operating economy Selecting Continuous or CYCLE SENTRY operation on units equipped with...

Страница 20: ...ernal DAS sensors and inputs The DAS features up to six directly con nected sensors The DAS is also connected through a serial port to the unit microprocessor This allows unit operating information op...

Страница 21: ...ol The engine horsepower control algorithm is the primary control used to obtain maximum capacity This allows the refrigeration sys tem to fully utilize the power capabilities of the engine under vary...

Страница 22: ...Range defrost intervals are determined by the Defrost Interval Not In Range timer DEFN This timer can be set for 2 4 6 8 or 12 hours The standard setting is 4 hours This feature allows a shorter defro...

Страница 23: ...ler Premium Drive Belts Heavy Duty Dry Element Air Cleaner Inside Unit Frame SMART REEFER P VI Microprocessor Controller Fuel Filter with Water Separator Spin On Full Flow Bypass Dual Element Oil Filt...

Страница 24: ...witch Engine Low Oil Level Switch Evaporator Coil Temperature Sensor Refrigerant High Pressure Cutout Switch High Refrigerant Pressure Relief Valve 12 Volt Fuse Link Fuse in Main Power Circuit Fuse in...

Страница 25: ...unit on the top evaporator back cover and on the curbside of the unit frame below the curbside door upper hinge bracket Engine See the engine identification plate located on the engine block Compress...

Страница 26: ...Unit Description Rev 12 03 16 Front View AJA890...

Страница 27: ...Unit Description Rev 12 03 17 1 Defrost Damper 2 X430L Compressor 3 se 2 2 Engine Back View 1 2 3 AJA894...

Страница 28: ...Description Rev 12 03 18 1 Condenser Fan 5 X430L Compressor 2 Condenser Coil 6 Fuel Filter Water Separator 3 Expansion Tank 7 Air Cleaner 4 SE 2 2 Engine Front View with Doors Open Model 30 1 2 3 4 5...

Страница 29: ...Battery Tray 3 Throttle Solenoid 12 Hand Primer Pump 4 Air Restriction Indicator 13 Dipstick 5 Fuel Solenoid 14 Oil Filter 6 Fuel Bleed Screw 15 Starter 7 Alternator 16 Compressor Sight Glass 8 Filte...

Страница 30: ...Unit Description Rev 12 03 20 ARA158 1 DAS Optional 2 Relay Board 3 Microprocessor Control Box Components 1 2 3...

Страница 31: ...er Diagnosis Manual TK 50566 for more complete operating information On Off Switch This switch turns the unit on and off When the switch is in the Off position the display will be off and the display...

Страница 32: ...display back light will turn on and the Standard Display will appear When the switch is in the Sleep position the unit will enter the Sleep Mode the display backlight will turn on and the display will...

Страница 33: ...n Icon Appears when the unit is operating in modulation mode In Range Icon Appears when the box temperature is within a few degrees of setpoint Discharge Air Icon Arrow pointing from unit Dis charge a...

Страница 34: ...ng Select Key Pressing this key displays temperature sensor reading and Sleep Mode Wakeup Time if pro grammed See the following list DIS A Discharge Air Temp TPDF Temp Differential COIL Coil Temp AMB...

Страница 35: ...to the throttle solenoid Fuse F21 25 amp protects the circuit that provides power to the On Off switch A number of 2 and 5 amp fuses protect microprocessor circuits control relay circuits remote ligh...

Страница 36: ...ATTERY The terminals must be clean and tight 5 BELTS The belts must be in good condition and adjusted to the proper tensions 6 ELECTRICAL The electrical connections should be securely fastened The wir...

Страница 37: ...Operation and Diagnosis Manual for detailed information about alarms c Repeat the PRE TRIP test until PASS appears the unit passes the Pretrip 6 Recheck the setpoint 7 Complete the After Start Inspec...

Страница 38: ...long period of time is first started it should be started and put through a full pretrip 1 Place the Diesel Electric switch in the DIESEL posi tion 2 Place the On Off switch in the ON position 3 After...

Страница 39: ...ng when loading the trailer from a warehouse with door seals 2 Spot check and record load temperature while loading Especially note any off temperature product 3 Load the product so that there is adeq...

Страница 40: ...Operating Instructions Rev 12 03 30...

Страница 41: ...2 to ground Attempting to full field the alternator by applying battery voltage to terminal F2 will cause voltage regulator failure CAUTION The F15 fuse must be removed from the relay board on units e...

Страница 42: ...Place the On Off switch in the ON position and enter Service Test Mode HSC before the unit starts Refer to the appropriate Operation and Diagnosis Manual for specific information about the Service Tes...

Страница 43: ...ition 1 Attach a clamp on ammeter to the 2A wire near the B terminal on the alternator 2 Connect a jumper wire between the F2 terminal on the alternator and a chassis ground and note the ammeter readi...

Страница 44: ...Electrical Maintenance Rev 12 03 34 1 Check Point for 2A Amperage 2 Position for Full Fielding Jumper Full Field Test...

Страница 45: ...uses located on the relay board protect vari ous circuits and components The relay board is located inside the control box Refer to the THERMOGUARD P VI Microprocessor Controller Diagnosis Manual TK 5...

Страница 46: ...rge rate drops below 28 amps on PREHEAT at least one glow plug is bad To isolate an open glow plug remove the jumper bar and test each glow plug individually with an ohmmeter or a jumper wire and amme...

Страница 47: ...mbly The oil filter assembly con tains the oil pressure relief valve the bypass valve and the oil filter The oil is forced through the oil filter into the main oil gallery The main oil gallery supplie...

Страница 48: ...mostat The cool ant is circulated through the system by a belt driven centrif ugal pump The pump draws the coolant from the side of the radiator circulates it through the cylinder block and head and t...

Страница 49: ...ometer or a refractometer P N 204 754 designed for testing antifreeze Maintain a mini mum of 50 permanent type antifreeze concentrate and 50 water solution to provide protection to 34 C 30 F Do not mi...

Страница 50: ...stem as needed Bleeding Air from the Cooling System Jiggle pin thermostats are original equipment on units that have se 2 2 engines Jiggle pin thermostats make it unnec essary to bleed the air out of...

Страница 51: ...pressure in the fuel system by allowing a certain amount of fuel to return to the tank Filtered fuel passes through a line from the outlet fitting on the filter base to the injection pump Fuel enters...

Страница 52: ...Maintenance Rev 02 03 42 Engine Fuel System 1 Fuel Filter 6 Bleed Screw 2 Water Separator 7 Injection Pump 3 Transfer Pump 8 Injection Line 4 Prefilter 9 Return Fuel Line 5 Hand Pump AJA897 1 9 2 8 6...

Страница 53: ...system 1 Cap all fuel lines 2 Work in a relatively clean area whenever possible 3 Complete the work in the shortest possible time Any major injection pump or nozzle repairs should be done by a quality...

Страница 54: ...ks have a check valve in the drain plug fitting Push the check valve open with a small screw driver to drain the tank 3 Let the water and fuel drain into the container until no water is visible in the...

Страница 55: ...ex opening in the face of the plunger will keep the plunger from turning Turn the plunger eye bolt clockwise to increase the speed and counterclockwise to decrease the speed 6 Replace the control rod...

Страница 56: ...ing removed and replaced on the engine If the pump has not been removed only the last portion of the proce dure is used for timing Injection Pump Removal 1 Remove the fuel injection lines Cover all in...

Страница 57: ...access cover from the tim ing gear cover ditdc Injection Timing Mark NOTE The injection timing mark is a line scribed in the flywheel approximately 35 mm 1 3 8 in from the TC mark The injection timing...

Страница 58: ...13 mm 0 5 in The dial indicator should stay at zero 9 Rotate the engine forward clockwise from the front to the injection timing mark NOTE The injection timing mark is a line scribed in the flywheel...

Страница 59: ...and abnormal wear of the valves and rocker arms The intake and exhaust valves are adjusted with the valves closed 2 The valves are adjusted to 0 4 mm 0 016 in When the right gap is obtained MAKE SURE...

Страница 60: ...oth No 1 push rods should be loose and the No 1 piston is at TDC of the compression stroke An alternate method is to remove the camshaft gear access cover and rotate the engine until the O on the cam...

Страница 61: ...w would increase in the crossover line lowering the crankcase pres sure To prevent this the PCV diaphragm Figures 2 3 expands into the passageway restricting the flow to main tain a constant slightly...

Страница 62: ...avoid kinks and bends in the hose to prevent icing during cold weather operation ENGINE AIR CLEANER Filter A heavy duty dry air cleaner filters all of the air entering the engine Excessive restriction...

Страница 63: ...ting arm bolt 2 Move the alternator on the adjusting arm slots to adjust the belt to 35 on the belt tension gauge 3 Tighten the adjusting arm bolt and alternator pivot bolt Upper and Lower Fan Belt Ad...

Страница 64: ...709 1 2 3 5 4 6 7 8 9 8 10 1 Upper Fan Belt 2 Condenser Fan Pulley 3 Condenser Fan 4 Condenser Inlet Ring 5 Idler Assembly 6 Belt Guide 7 Lower Fan Belt 8 Engine Pulley 9 Idler Adjusting Arm 10 Altern...

Страница 65: ...n clearance between the blower wheel and the inlet ring NOTE If the condenser fan does not slide on the fan shaft with light tapping remove the small access panel located on the condenser coil header...

Страница 66: ...hub clamping bolts to 24 N m 18 ft lb 6 Seat the upper belt in the blower wheel pulley groove 7 Push inward on the idler adjusting arm and slip the belt into the idler pulley groove 8 Pull the idler a...

Страница 67: ...thermometer to monitor the return air temperature 5 Run the unit on high speed cool until the air in the box is at 0 F 18 C By allowing the box to leak a small amount you will be able to maintain 0 F...

Страница 68: ...rop the unit most likely has an overcharge of refrigerant The refrigerant level should be adjusted To adjust the refrigerant level 1 Stop the unit and remove some refrigerant with an approved refriger...

Страница 69: ...stem have been removed for service or replacement To check compressor oil level with an ambient air temperature above 50 F 10 C Install a gauge manifold on the compressor Operate the unit on Cool with...

Страница 70: ...pressure of the compressor first by blocking the condenser coil air flow by covering the condenser grille with a piece of cardboard If this does not raise the discharge pressure to the cutout level of...

Страница 71: ...r and suction pressures should remain stable indicating no leaks 7 Shift the three way valve to the heat position Low side gauge will raise slightly High side gauge will drop to approximately zero Gau...

Страница 72: ...est Mode Service Procedure A34A in TK 50566 Use the GAUGE key to check the operation of the ETV dur ing the ETV test The valve position ETV P should be 0 at the start of the test when the valve is ful...

Страница 73: ...is located in the refrigeration line that connects the discharge line to the hot gas line The hot gas solenoid is energized opened at full modulation The hot gas solenoid is de energized closed when m...

Страница 74: ...64...

Страница 75: ...event dust dirt etc from falling into the compressor NOTE When the compressor is removed from the unit the oil level should be noted or the oil removed from the compressor should be measured so that t...

Страница 76: ...ol to the flange If a nut is used to prevent the bolt from falling out the nut should not be tightened 4 Use torque wrench and the appropriate Allen tool to unscrew the coupling mounting screw Apply a...

Страница 77: ...ricants set the coupling on the crankshaft and align the keyways using the Keyway Tool P N 204 972 Insert the tapered end of the tool into the keyway and gently move the coupling on the shaft while pr...

Страница 78: ...pansion tank from the condenser coil frame 4 Remove the condenser coil mounting bolts Remove the mounting clamps from the condenser inlet line 5 Unsolder the inlet line and liquid line connections Lif...

Страница 79: ...is not repairable and must be replaced if it fails A heat sink must be used on the in line check valve when it is being soldered in place to prevent damage to the neoprene seal CONDENSER CHECK VALVE R...

Страница 80: ...the bypass check valve from the receiver tank Use a heat sink on the bypass check valve 4 Remove the high pressure relief valve from the receiver tank 5 Unbolt the mounting brackets and remove the rec...

Страница 81: ...6 Remove the expansion valve mounting bolt and remove the expansion valve from the unit Installation 1 Install and bolt the expansion valve assembly in the unit 2 Connect the inlet liquid line and sol...

Страница 82: ...pansion valve 6 Pressurize the low side and test for leaks If no leaks are found evacuate the low side 7 Tighten the heat exchanger mounting hardware securely 8 Clean the suction tube to a brightly po...

Страница 83: ...nbolt and remove the accumulator from the unit Installation 1 Place the accumulator in the unit and tighten the mounting bolts and nuts 2 Solder the inlet and outlet suction lines to the accumu lator...

Страница 84: ...e discarded a Stem assembly b All gaskets c Piston seal 10 Remove the screen If any particles drop from the screen into the discharge line the discharge line must be removed at the compressor NOTE The...

Страница 85: ...h the spring side facing away from the piston d Use the pipe to hand press the seal onto the piston 5 Place the piston slot on the stem and secure with spring clip The open part of the clip should be...

Страница 86: ...seat in the three way valve 7 If replacement parts are needed a P N 60 163 kit must be used which includes the Teflon check valve spring O ring valve stem and snap ring Installation 1 Coat the O ring...

Страница 87: ...ulator and remove from the unit Installation 1 Prepare the suction hose and tube fittings for soldering by cleaning thoroughly 2 Solder the vibrasorber to the suction service valve CAUTION Use a heat...

Страница 88: ...tem 4 Recharge the unit with the proper refrigerant and check the compressor oil SUCTION PRESSURE TRANSDUCER OPTIONAL Removal 1 Pump down the low side and equalize pressure to slightly positive 2 Disc...

Страница 89: ...he same position The new ETV could interfere with the evaporator access panel if it is not placed in the same position as the old one Installation 1 If an ETV service kit stepper motor and piston asse...

Страница 90: ...y 100 ft lb 136 N m Hold the valve body with backup wrench to prevent damage to the refrigeration tubing CAUTION Tighten the large nut Do not tighten the small nut 6 Connect the ETV harness connector...

Страница 91: ...trapped air 9 Open the service valves operate the system and check the compressor oil filter for leaks HOT GAS SOLENOID VALVE OPTIONAL Removal 1 Recover the refrigerant charge 2 Disconnect the wires a...

Страница 92: ...82...

Страница 93: ...eduled maintenance inspections Remove any debris e g leaves or plastic wrap that reduces the air flow Clean dirty coils with compressed air or a pressure washer Be careful not to bend the fins when cl...

Страница 94: ...at air flow is stopped on the top and bottom edges with the solenoid plunger bottomed out To adjust the damper 1 Remove the damper assembly from the evaporator 2 Disconnect the damper link from the ey...

Страница 95: ...that the damper operates correctly and seals properly 9 Make sure the damper blade rests on the round stops when the damper is open Adjust the round stops if nec essary 10 Install the damper assembly...

Страница 96: ...If there is any sign of leakage the fan shaft assembly should be removed and repaired NOTE The fan shaft assembly requires a special lubri cant Thermo King P N 203 278 Fan Shaft Assembly Overhaul Dis...

Страница 97: ...the assembly in a vise and set up a dial indicator to read end play To measure the end play rotate the shaft while pushing in one direction and set the dial indicator to 0 Now rotate the shaft and pu...

Страница 98: ...nd of the assem bly 3 To remove the shaft from the assembly tap the opposite end of the shaft with a soft hammer After the shaft has been removed clean all the parts in clean solvent 4 Using a punch r...

Страница 99: ...top plug until it runs out of the side hole Check the condition of the O ring used on the plugs and replace if necessary Install the top and side plugs Clean up any spillage 8 Place the assembly on t...

Страница 100: ...90...

Страница 101: ...nd Diagnosis Manual Fuel solenoid defective or stuck Replace Fuel injection pump defective Replace pump Air heater defective Replace No fuel or wrong fuel Fill with proper fuel Fuel pump defective Rep...

Страница 102: ...ve injection rate too low gum formations Repair or replace pump Engine speed too high Misadjusted high speed solenoid Adjust high speed solenoid Defective injection pump Repair injection pump Engine f...

Страница 103: ...oil pressure switch Replace if necessary Oil control valve defective Check oil pressure control valve Worn oil pump camshaft main or connecting rod bearings loose oil gallery plug Repair engine High o...

Страница 104: ...t burning Excessive Fuel to Air Ratio Oil Consumption Air or water in fuel Type of fuel used Poor compression Incorrect timing Cold engine Defective valve seals Poor compression Excessive load Faulty...

Страница 105: ...of refrigerant Shortage of refrigerant No refrigerant Air through condenser too hot ambient Air flow through condenser restricted Air through condenser too cold ambient Air in refrigerant system Cond...

Страница 106: ...mpound pressure gauge out of calibration Leaky receiver tank outlet valve Leaky bypass check valve Leaky condenser check valve Faulty three way condenser pressure bypass check valve Faulty ETV Hot gas...

Страница 107: ...ressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator...

Страница 108: ...ressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator...

Страница 109: ...r Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumu...

Страница 110: ...ceiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 A...

Страница 111: ...acement 69 Draining Water Fuel Tank 44 E Electrical Hazards ii Electrical Maintenance 31 Electronic 11 Electronic Throttling Valve ETV 11 Electronic Throttling Valve Optional 62 Electronic Throttling...

Страница 112: ...Refrigerant Charge 57 Refrigerant Leaks 59 Refrigeration Cycle Flow Chart 97 Refrigeration Diagnosis 95 Refrigeration Maintenance 57 Refrigeration Service Operations 65 Remote Status Light 25 Restart...

Страница 113: ...103 SB 100 190 Schematic Diagram Page 1 of 2...

Страница 114: ...104 SB 100 190 Schematic Diagram Page 2 of 2...

Страница 115: ...105 SB 100 190 Wiring Diagram Page 1 of 5...

Страница 116: ...106 SB 100 190 Wiring Diagram Page 2 of 5...

Страница 117: ...107 SB 100 190 Wiring Diagram Page 3 of 5...

Страница 118: ...108 SB 100 190 Wiring Diagram Page 4 of 5...

Страница 119: ...109 SB 100 190 Wiring Diagram Page 5 of 5...

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